Unic 376c1am R546c1amr Work Shop Manual

URW376C1AMR
URW546C1AMR
Contents
General view
Major Specifications (URW376C1A)
Major specifications (URW546C1A)
Outrigger operation
How to extend outriggers
How to store outriggers
How to store outriggers when in an emergency

When failed storage by normal operation
When failed extension by normal operation
Mode indicator lamp (control box)
Mode indication when crane is in normal operation

Mode indication when crane is mistakenly operated
Indication ofeachoperation
Error indication
List of voice messages
How to switch operation mode
Switching of mode(Manual mode Radio control mode)

How to operate outriggers by manual lever
How to operate outriggers by radio control transmitter
Switching of mode indicator(State Operation)
Restting of interlocking balance control
Switching of "Shockless"function(Carry it out when it is not over-wound)
Switching of low-temperature operation mode
Method of engine start and stop that radio controller
Radio control cannot be operated
Emergency measures
Hydraulic circuit diagram (carrier
Control valve for carrier

Manifold
Pump
Crawling motor
Hydraulic circuit diagram (control valve for crane)
Swivel joint
Column
winch
Outrigger
Hydraulic circuit diagram
Outrigger
Verticaloutrigger
outrigger
errickingcylinder
elescopingcylinder
Boom
Installation procedures for slide plate and guide
How to punch
Telescoping/derrick cylinder ass'y,

Measures toprevent piston from being loosened
Earth position
Earth for engine start relay and engine stop relay
Earth of the main harness
Eleectric Wiring Diagram

Electric wiring in control seat part turnover prevention divice (degital type)
Power supply fuse
Solenoid valves for operating outrigger
Connector of Emergency stop
Wiring for operation switch panel
Switch panel(key switch type) (turnover prevention device)
Interlock for crane-crawl lever
The other side of accelerator pedal
Accelerator cable
Electric wiring in control valve part turnover prevention device(degital type)
Reay box
Buzzer
Position of hose
Engine
All view of engine
Wiring for warning lamp
Water separatoroil fillter element
Air cleaner elementAlternator
Electric Wiring diagram (engine part)
Electric Wiring diagram

Control box for power unit
Converter
Power unit37W0117
Power unit37W0120
Inspection for sinking of cylinder

Inspection of derrick cylinder
Inspection of telescoping cylinder
Inspection of outrigger cylinder
Replacement of wire rope (for winding-up)
Replacement ofexpendable parts
List of recommended lubricant

Lubrication to carrier
Lubrication to crane
Filling water and lubrication chart
Lubrication chart
Lubrication
Inspection records
Before starting crane operation
Monthly self-inspection records
Annual self-inspection records
Periodically replacing components and expedable parts
Digital Load MeterDL-100)

Initial setting up
Error code
DL
DL
Momet LemitterKM-100)
Initial setting up
Control box modulation mode list
Error code
U-AOL system ( Anti overloading system )
KM
KM
KM
KM
1.GENERAL VIEW
1190
1800
URW376C
1750
3530
300
1300
4340
1215
2035
URW546C
1750
220
3970
4870
1-1
300
1300
MAJOR SPECIFICATIONS
URW376C1A(6-section boom)
(Speed indicated in the table below is at oil temperature range of 45~55C, operating with noload, and at rated pump discharge.)
Major specifications
Crane capacity
(Net rated load)
3.0t 2.5m
(With outriggers, extended fully)
Maximum lift above ground (Hook)
14.9m
Boom to be extended to:
3.63m~5.85m~8.04m~10.23m~12.42m~14.61m
Maximum working radius
14.45m
Speed of winding-up (Rope speed)
Extending speed of boom
68m/min (At 4th layer on the drum)

17m/min
(At 4th layer on the drum, with 4-part line hooking)
10.98m/23sec
Raising speed of boom
0 ~ 80/10sec
Slewing speed
2.5rpm
Slewing range
360(continuous)
IWRC6 WS(26) calss B[Breaking load:42.4kN
(4320kgf)]
8mm 85m
Hoisting speed of hook
Hoisting rope
Construction
Diameterlength
Horizontal
Outrigger
Rated discharge
Direct pushing by double acting hydraulic cylinder

(directly connected to hydraulic automatic locking
device)
Crane: 20.6MPa(210kgf/cm2)
Crawl: 21.6MPa(220kgf/cm2)
Approx. 60 /min
Rated rotation
Approx. 2100rpm
Vertical
Rated pressure
Hydraulic pump

device)
Hydraulic oil tank Capacity
70 liters
2-1
Equipment and construction
Boom:6-section, Hexagonal box beam
Boom telescoping
Boom derricking
Hoisting
Telescoped by direct pushing of double acting hydraulic cylinder

together with by wire rope
(With hydraulic automatic locking device)
(2nd section : sequential actuation, 3rd, 4th, 5th & 6th sections: simultaneous actuation)
Direct pushing by hydraulic cylinder
Hydraulic motor: Axial plunger type
Reduction gears: Spur-gear reduction
Brake: Automatic mechanical brake
Slewing

Reduction gears: Worm-gear+Spur-gear reduction
(Supported by ball bearings)
Brake: Worm self-lock
Hydraulic pump
Variable delivery piston pump
Hooking capacity
3.0t Number of slinging rope: 4

Safety valve for hydraulic circuit
Hydraulic automatic lock
Automatic stop for overwinding
Overwinding alarm
Slewing automatic lock
Automatic stop for leaving minimum wire rope
Load indicator (With angle meter)
Safety devices
Alarm buzzer
Retaining mechanism to prevent wire rope from disengagement
Interlock for crane-crawl operation
Crane/outrigger interlocking device
Checker for outrigger rotary set pin insertion
Digital load meter
Emergency stop button
U-AOL system
Level
Weight
Approx. 3860kg
2-2
Crawling device
Crawling
Endless rubber crawler
Crawler
30052.588
Length of ground contact
1750mm
Pressure of ground contact
36.3kPa (0.37kgf/cm2)
Crawling speed
Forward/Backward: 0~3km/h
Hill-climbing ability
23
Engine
Rated output15.17kW/2500rpm (20.6PS/2500rpm)
Crawling
Independently driven by hydraulic power
Parking brake
Disc brake with hydraulic motor built-in
Starting engine
Electric starter
Fuel tank
Capacity: 40 liters
2-3
Chart of net rated load
Net rated loads chart

BOOM SECTION
WORKING RADIUS(m)
OUTRIGGERS
NET RATED MAX EXT
OUTRIGGERS
LOAD(t)
NOT MAX EXT
BOOM SECTION
WORKING RADIUS(m)
OUTRIGGERS
NET RATED MAX EXT
OUTRIGGERS
LOAD(t)
NOT MAX EXT
BOOM SECTION
WORKING RADIUS(m)
OUTRIGGERS
NET RATED MAX EXT
OUTRIGGERS
LOAD(t)
NOT MAX EXT
BOOM SECTION
WORKING RADIUS(m)
NET RATED
LOAD(t)
OUTRIGGERS
MAX EXT
OUTRIGGERS
NOT MAX EXT
BOOM SECTION
WORKING RADIUS(m)
NET RATED
LOAD(t)
OUTRIGGERS
MAX EXT
OUTRIGGERS
NOT MAX EXT
1
1+2
2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.69
3.0 3.0 2.35 1.95 1.67 1.45 1.3 1.07
3.0 3.0 2.17 1.5 1.12 0.9 0.72 0.47
1+2+3
2.7 3.0 3.5 4.0 4.5 5.0 5.5 6.0 7.0 7.88
2.24 2.09 1.65 1.4 1.22 1.07 0.95 0.84 0.69 0.59
2.24 2.06 1.57 1.22 1.02 0.83 0.65 0.51 0.3 0.19
1+2+3+4
4.0 4.5 5.0 6.0 7.0 8.0 9.0 10.07
1.04 0.93 0.84 0.73 0.62 0.52 0.47 0.38
1.03 0.82 0.64 0.47 0.31 0.22 0.13 0.09
1+2+3+4+5
4.5 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.26
0.75 0.62 0.48 0.39 0.34 0.3 0.27 0.24 0.23
0.75 0.62 0.4 0.25 0.18 0.13 0.09 0.06 0.01
1+2+3+4+5+6
4.9 5.5 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.45
0.3 0.27 0.25 0.22 0.2 0.18 0.16 0.14 0.13 0.11 0.1
0.3 0.27 0.25 0.22 0.17 0.11 0.08 0.05 0.03 0.02 0.01
2-4
Points to notice, Rated load
The net rated load is performance when the crane is placed level and is based on
actual working radius including boom deflection under loaded. The net rated load is
also based on strength and stability of the crane.
Outriggers max ext means the state that the inner box is extended to the position
where the 2nd mark is visible.
Outriggers not max ext means the state that the inner box is extended to the position
where the 2nd mark is invisible.
When each of 4 outriggers has been set to different extension,operate the crane by
using the worst extended capacity.
When each of boom sections being extended is exceeded even slightly,operate it by
application of the capacity for the next boom section.
Boom 1+2+3+4 means that the boom is extended to the position where the 1st
mark on the 4th boom-section is visible.
Boom 1+2+3+4+5 means that the boom is extended to the position where the 2nd
Operate the crane using the rated load capacity data under the boom extension of:
1+2+3+4 when the
mark on the 3rd boom-section goes beyond the 2nd boom
section, regardless of the displacement, 1+2+3+4+5 when the 1st
mark on the
side plate of the 4th boom-section goes beyond the 3rd boom-section, regardless of
the displacement, 1+2+3+4+5+6 when the 2nd
mark on the side plate of the 4th
boom-section goes beyond the 3rd boom-section, regardless of the displacement.
2-5
Operating condition of booms;
Boom 2
Boom 1
Boom 1 :
All booms are completely retracted.
Boom 4
Boom 5
Boom 6
Boom 3
Boom 1
Boom 2
Boom 4
Boom 4
Boom 2
Boom 2
Boom 6
Boom 3
Boom 5
Boom 4
Boom
or
1+2+3+4
Boom 6
Boom is extended to where 2nd mark

Boom 1
Boom 2
on the side plate of Boom
Boom 3
Boom 1+2+3+4+5 or 5 :
Boom is extended to where 3rd mark
Boom 2
Boom
1+2+3+4+5+6
2
or
5
and
on the side plate of Boom
is visible.
Boom 5
Boom 3
Boom 6
:
6
is visible.
Boom 6
Boom 4
Boom
Boom 5
Boom 4
Boom 1
or 2 :
is extended.
Boom 1+2+3 or 3 :
Boom is extended to the mark
the side plate of Boom 3 .
Boom 5
Boom 3
Boom 1
1+2
Boom 6
Boom 3
Boom 1
Boom
Boom
Boom 5
are all extended to their extremes.
2-6
on
1 URW506C
W506C (6-section boom)
(Speed indicated in the table below is at oil temperature range of 45~55C, operating with noload, and at rated pump discharge.)
Major specifications
Crane capacity
(Net rated load)
3.0t3.4m
(With outriggers, extended fully)
Maximum lift above ground (Hook)
16.0m
Boom to be extended to:
3.93m6.33m8.72m11.05m13.38m15.71m
Maximum working radius
15.52m
Speed of winding-up (Rope speed)
68m/min (At 4th layer on the drum)
Hoisting speed of hook
17m/min
(At 4th layer on the drum, with 4-part line hooking)
Extending speed of boom
11.78m/35sec
Raising speed of boom
080/18sec
Slewing speed
2.5r.p.m.
Slewing range
360 (Continuous)
Hoisting rope Construction

Diameter length
IWRC6WS (26) class B [Breaking load: 42.4kN (4320 kgf)]
Horizontal

device)
V ertical

device)
Rated pressure
Crane:20.6MPa(210kgf/cm2 )
Crawl:21.6MPa(220kgf/cm 2)
Rated discharge
Approx. 60/min
Rated rotation
Approx. 2100rpm
Outrigger
Hydraulic
pump
8mm91.5m
Hydraulic oil tank capacity
70 liters
3-1
Equipment and construction
Boom: 6-section, Hexagonal box beam
T elescoped by direct pushing of double acting hydraulic cylinder

Boom telescoping
Boom derricking
together with by wire rope

(2nd section: sequential actuation, 3rd, 4th, 5th & 6th sections: simultaneous actuation)
Direct pushing by hydraulic cylinder
Hoisting
Reduction gears: Spur-gear reduction

Brake: Automatic mechanical brake
Slewing
Reduction gears: Worm-gear+Spur-gear reduction

(Supported by ball bearings)
Brake: Worm self-lock
Hydraulic pump
V ariable delivery piston pump
Hooking capacity
3.0 t Number of slinging rope: 4
Safety device
Safety valve for hydraulic circuit

Hydraulic automatic lock
Automatic stop for overwinding
Overwinding alarm
Slewing automatic lock
Automatic stop for leaving minimum wire rope
Load indicator (With angle meter)
Alarm buzzer
Retaining mechanism to prevent wire rope from disengagement
Interlock for crane-crawl operation
Crane/outrigger interlocking device
Checker for outrigger rotary set pin insertion
Level
Weight
Approx. 4880kg
3-2
Crawling device
Crawling
Endless rubber crawler
Crawler
30052.588
Length of ground contact
1750mm
Pressure of ground contact
45.1kPa (0.46kgf/cm 2
Crawling speed
Forward/Backward: 03km/h
Hill-climbing ability
23
Engine
Rated output18.0kW/2100r.p.m (24.5PS/2100r.p.m)
Crawling
Independently driven by hydraulic power
Parking brake
Disc brake with hydraulic motor built-in
Starting engine
Electric starter
Fuel tank
Capacity: 40 liters
3-3
Chart of net rated load
Net rated loads chart

BOOM SECTION
WORKING RADIUS(m)
OUTRIGGERS
NET RATED MAX EXT
OUTRIGGERS
LOAD(t)
NOT MAX EXT
BOOM SECTION
WORKING RADIUS(m)
OUTRIGGERS
NET RATED MAX EXT
OUTRIGGERS
LOAD(t)
NOT MAX EXT
BOOM SECTION
WORKING RADIUS(m)
OUTRIGGERS
NET RATED MAX EXT
OUTRIGGERS
LOAD(t)
NOT MAX EXT
BOOM SECTION
WORKING RADIUS(m)
NET RATED
LOAD(t)
OUTRIGGERS
MAX EXT
OUTRIGGERS
NOT MAX EXT
BOOM SECTION
WORKING RADIUS(m)
NET RATED
LOAD(t)
OUTRIGGERS
MAX EXT
OUTRIGGERS
NOT MAX EXT
1
1+2
2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.69
3.0 3.0 2.35 1.95 1.67 1.45 1.3 1.07
3.0 3.0 2.17 1.5 1.12 0.9 0.72 0.47
1+2+3
2.7 3.0 3.5 4.0 4.5 5.0 5.5 6.0 7.0 7.88
2.24 2.09 1.65 1.4 1.22 1.07 0.95 0.84 0.69 0.59
2.24 2.06 1.57 1.22 1.02 0.83 0.65 0.51 0.3 0.19
1+2+3+4
4.0 4.5 5.0 6.0 7.0 8.0 9.0 10.07
1.04 0.93 0.84 0.73 0.62 0.52 0.47 0.38
1.03 0.82 0.64 0.47 0.31 0.22 0.13 0.09
1+2+3+4+5
4.5 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.26
0.75 0.62 0.48 0.39 0.34 0.3 0.27 0.24 0.23
0.75 0.62 0.4 0.25 0.18 0.13 0.09 0.06 0.01
1+2+3+4+5+6
4.9 5.5 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.45
0.3 0.27 0.25 0.22 0.2 0.18 0.16 0.14 0.13 0.11 0.1
0.3 0.27 0.25 0.22 0.17 0.11 0.08 0.05 0.03 0.02 0.01
URW376C1A
2-4
Points to notice, Rated load
The net rated load is performance when the crane is placed level and is based on
actual working radius including boom deflection under loaded. The net rated load is
also based on strength and stability of the crane.
Outriggers extended to maximum means the state that the inner box is extended
to the position where the 2nd mark is visible.
Outriggers extended to halfway means the state that the inner box is extended to
the position where the 1st mark is visible.
Outriggers extended to minimum means the state that the inner box is extended to
the position where the 1st mark is invisible.
When each of 4 outriggers has been set to different extension, operate the crane
by using the worst extended capacity.
When each of boom sections being extended is exceeded even slightly, operate it
by application of the capacity for the next boom section.
Boom 1 + 2 + 3 + 4 means that the boom is extended to the position where the 1st
Boom 1 + 2 + 3 + 4 + 5 means that the boom is extended to the position where the
2nd
Operate the crane using the rated load capacity data under the boom extension
of: 1 + 2 + 3 + 4 when the
mark on the 3rd boom-section goes beyond the 2nd
boom section, regardless of the displacement, 1 + 2 + 3 + 4 + 5 when the 1st
mark
on the side plate of the 4th boom-section goes beyond the 3rd boom-section,
regardless of the displacement, 1 + 2 + 3 + 4 + 5 + 6 when the 2nd
mark on the
side plate of the 4th boom-section goes beyond the 3rd boom-section, regard less
of the displacement.
3-5
How boom-sections a
aree extended
Boom 1
Boom 2
Boom
Boom 1
Boom
Boom
Boom
Boom : 1
All boom sections are retracted.
Boom 2
Boom
Boom
Boom : 1 + 2 or 2
Boom section(2) only is extended.
Boom
Boom 1
Boom
Boom
Boom 2
Boom
Boom : 1 + 2 + 3 or 3
Boom sections(2) and (3) extended to

a position where the mark
on the
boom section (3) is visible.
Boom
Boom 1
Boom 2
Boom
Boom
Boom
Boom
Boom
Boom : 1 + 2 + 3 + 4 or 4
Boom sections are extended to a position where 1st mark
Boom 1
Boom 2
Boom
Boom
Boom
on the boom section (4) is visible.
Boom
Boom : 1 + 2 + 3 + 4 + 5 or 5
Boom sections are extended to a position where 2rd mark
Boom 1
Boom 2
Boom
Boom
Boom
on the boom section(4) is visible.
Boom
Boom : 1 + 2 + 3 + 4 + 5 + 6 or 6
Boom sections(2), (3), (4), (5), and (6) are fully extended.
3-6
4.OUTRIGGER OPERATION
HOW TO EXTEND OUTRIGGERS
Traveling
Crane
Outrigger extension detector

Extract the pins to rotate outriggers,
then insert the pins.
1. Throw the interlock of cranetraveling lever to crane side.

2. Rotate the outriggers and insert the set pins securely to light up the extension lamp.
Outriggers
cannot
be
operated unless all 4 pieces of set pin have been inserted.

3. As a general rule, extend the lateral members of outrigger to their full extents.
4. Touch the vertical members of outrigger to the ground and raise the crawler by approximately 50mm to
Extension
Touching
ground
Detector for ground contact of outrigger
Boom storage detector
5. Unwind the hook until it is off the weight for over-winding alarm, then raise the boom.
Crane can now be operated when the storage lamps have gone out.
4-1
HOW TO STORE OUTRIGGERS

1. Store the hook and lower the boom until the
storage
2. Retract vertical members of outrigger to make
outriggers
horizontal.
Check that all 4 lamps indicating the outriggers touched
Boom storage detector
3. Retract the lateral members of outrigger.

4. Extract the pins to rotate the outriggers then insert the pins.
5. Throw the interlock of cranetraveling lever to traveling side.
Storage
Storage
Outrigger extension detector
Detector for ground contact of outrigger
Extract the pins to rotate outriggers,

then insert the pins.
Traveling
4-2
Crane
5.HOW TO STORE OUTRIGGERS WHEN IN AN EMERGENCY

HOW TO STORE OUTRIGGERS WHEN FAILED STORAGE BY NORMAL OPERATION
1. Remove the label stuck cover located in the arrow direction.
2. Return the boom to the position where it is to be stored.

3. Turn the retraction button on the valve for extension/retraction by 90with the button depressed to
secure it.
4. Depress, with a screwdriver, button on the solenoid valve for which is intended to be actuated located
on the outrigger valve for vertical/lateral members.
Outrigger
Outrigger
Outrigger
Outrigger
Vertical
Operation
Depressing 1 to operate lever
Horizontal
Vertical
Horizontal
Vertical
Horizontal
Vertical
Horizontal
7
3
1
Vertical
Horizontal
Vertical
Horizontal
Vertical
Horizontal
Vertical
Horizontal
6
8
4
2
Operators seat side
Outrigger to be actuated
Outrigger valve for vertical/Horizontal members
Throw outrigger
lever to your side.
5
6
7
8
3
4
Depress retraction button

to turn it to secure it.
1
2
5. Throw the outrigger lever to your side with the solenoid valve button depressed.
Sticker showing instructions on how to operate

outriggers when in an emergency is stuck here.
5-1
Push the button at the center of

solenoid valve with a screwdriver.
HOW TO EXTEND OUTRIGGERS WHEN FAILED EXTENSION BY NORMAL OPERATION

1. Remove the label stuck cover located in the arrow direction.
2. Return the boom to the position where it is to be stored.

3. Turn the retraction button on the valve for extension/retraction by 90with the button depressed to
secure it.
4. Depress, with a screwdriver, button on the solenoid valve for which is intended to be actuated located
on the outrigger valve for vertical/Horizontal members.
Outrigger
Outrigger
Outrigger
Outrigger
Vertical
Operation
Horizontal
Vertical
Horizontal
Vertical
Horizontal
Vertical
Horizontal
7
3
1
Vertical
Horizontal
Vertical
Horizontal
Vertical
Horizontal
Vertical
Horizontal
6
8
4
2
Operators seat side
Outrigger to be actuated
Outrigger valve for vertical/Horizontal members
Throw outrigger
lever to your side.
5
6
7
8
3
Remove cover on arrow

mark side and depress
extension button to turn
it to secure it.
4
1
2
5. Throw the outrigger lever to your side with the solenoid valve button depressed.
Sticker showing instructions on how to operate

outriggers when in an emergency is stuck here.
5-2
Push the button at the center of

solenoid valve with a screwdriver.
. MODE INDICATOR LAMP (Control Box)

1 Mode indicator lamp (Control box)
The mode indicator lamp is mounted in the control box indicating conditions of crane operation and troubles in detail.
When the mode indicator lamp lights, the
crane system is working normally.
When the mode indicator lamp blinks, the
crane system is in a trouble or prohibited
operation is being carried out.
Mode indicator
lamp
1.Mode indication when crane is in normal operation

It indicates each operation mode and condition of the crane when it is normal.
Description of mode indication when it is in normal is as follows:
Mode indication when crane is in normal condition (lighting indication)

Mode
Mode description
Radio Manual
control operation
operation mode Priority
mode
Current control is on traveling mode.

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

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

Operation can only be carried out manually but not
through radio remote control device.
Current operation is in outrigger radio control mode.

Extension and retraction of outriggers can only be possible by manual control when in manual control mode
or by radio remote control when in radio remote control mode.
Operation other than the above is impossible either by
manual or by radio remote control.
Current control is on low temperature operation mode.
Operation can be carried either by manual control or
by radio remote control device.
()
()
MODE INDICATOR LAMP (Control Box)
Mode
Mode description
Radio
Manual
control
operation Priority
operation
mode
mode
Current control is on low temperature operation mode.

Operation can be carried by manual control but not
through radio remote control.
Hook hits against weight for over-winding alarm

(over-wound condition).
During operation of storing hook.
Automatic stop for over-winding reset switch is being

controlled
Boom store or Automatic stop for overloading

is actuated .
Automatic stop for overloading alarm

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

2.Mode indication when crane is mistakenly operated
When prohibited operation or combination of operation which may invites dangerous situations
has been carried out, the mode indicator lamp will blink corresponding numbers (operation
error indication).
When the operation error is indicated, the mode indicator lamp blinks showing corresponding
numbers accordingly.
Confirm and follow the mode description concerned on the table illustrated below:
Remarks
The operation error indication is not to indicate that the crane system is in trouble.
The error indication is to be reset when stopping the operation concerned.
Mode description when crane is mistakenly operated (Blinking indication)
Mode
Description of wrong operation
Measures to be taken
Radio remote control operation is

carried out in manual control
mode.
Radio remote control cannot be carried out in

manual control mode.
When operating with radio remote controller,
turn the selector switch located on the top of
cover to radio remote control mode.
Mode indicator lamp located in

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

control levers will be lit when in radio remote
control mode.
Crane is being operated when in

outrigger mode.
Crane cannot be operated when in outrigger

control mode.
When operating crane, turn the mode selector
switch to crane to select crane mode.
Crane and outriggers are operated

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

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

Mode
Description of wrong operation
Either one of operation such as

boom Up, hook Up, or
boom Extend (when operated
on para-hook mode) is being
carried out while hook has hit
against weight for over-winding
alarm.
Detach hook from weight for over-winding

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

remote control device is pressed.
Release the Emergency stop switch when operating crane.
Operating one of boom lowering,

wind-up, boom extending or slewing
while the boom is at stowed
position and fully lowered.
Operate boom raising to release the

automatic stop system then operate others.
Operation of winding down hook

is carried out while the sensor
detecting minimum wire rope is
being activated.
Stop winding down hook and wind it up so that

the sensor detecting minimum wire rope will
not be activated.
In the boom/outrigger interlocking

device, outrigger operation is
being carried out without boom
being stored.
Stop outrigger operation without boom being

stored.
Operate outriggers after boom has been stored.
Mode indication of each operation

Mode
indication
Operation
Fastest speed
mode
Medium speed
mode
Slow speed
mode
interlocking
operation
interlocking
operation
interlocking
operation
interlocking
operation
interlocking
operation
interlocking
operation
Mode
indication
Operation
Mode
indication
Operation
Raising boom
Storing hook
Lowering boom
Modeselect
Hoisting-up
Horn
Hoisting-down
Retracting boom
Extending boom
Slewing C.W.
Slewing C.C.W
Speed: 0
100%
When wind-up switch of transmitter and radio control selector switch

are pushed at the same time,it is change to the operation display.
It returns to the state display when wind-up switch of transmitter
and radio control selector switch are pushed at the same time again.
6-4
Error indication
When an error is detected, the mode indicator goes off or blinks and the voice message Service remote control sounds.
Mode
Available
Measures
Trouble
indication
operation
Check all load cell wirings on outrigger and Digital
No operation Amplipier wirings.
Turnover prevention error
is possible. Zero-Point Adjust Digital Amplipier.

Replace Digital Amplipier.
None
System error
No operation
is possible.
Replace fuse in control box.

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

Failure in radio controller receiver Transmitter lever

has been pulled before indication on indicator
8.8 goes off.
Transmitter switch has be depressed before
indication on indicator "8.8" goes off.Signal from
receiver failed to be received
Hook storing/releasing switchon crane side has

been controlled before indicator "8.8" goes off.
Radio controller selector switchin control box has
been controlled before indicator "8.8" goes off.
Radio
controller Check transmitter and receiver.
cannot be
operated. After turning power ON again,
wait untilmode on "8.8" indicator goes off to
operateradio controller.
Check connection of cable to receiver.
Operation is After turning power ON again,

possible. wait until mode on "8.8" indicator goes off to
operate radio controller.
No operation
is possible.
System error
Unloading error
Radio controllercannot be operated. Replace control box.

No operation After turning power ON again,
is possible. wait until 8.8on mode indicator goes off to
operate radio controller.
Spool neutral error

Derrick
Manual lever (spool) fails
to be returned to neutral Hoisting
within 2 seconds after
power has been turned
Telescoping
ON.
Check that manual lever has not been caught.
Slewing
If lever has no problem, replace proportional

solenoid valve.
Outrigger
Acceleration
When an error is detected, the mode indicator goes off or blinks and the voice message Service remote control sounds.
Mode
Available
Measures
Trouble
indication
operation
Outrigger selection switch Front right RET/EXT
Front left RET/EXT
Rear left
Derrick
Hoisting
Spool deviation error.

Manual lever (spool) fails
to be controlled as
intended while radio
controller is operated.
ET/EXT
Acceleration
Hoisting
Telescoping
Slewing
Derrick
Slewing
Outrigger
Acceleration
Operation is
possible.
Replace broken transmitter switch.
Radio
controller
cannot be
operated.
No operation
is possible.
Check connector of differential transformerfor
connection.
Feed-back signal wire is

broken.
Hoisting
Differential transformer is
not functioning normally. Telescoping
If lever has no problem,

replace proportional solenoid valve.
Derrick
Check that manual lever has not been caught.
Slewing
High outrigger
Transmitter switch is
broken.
No operation
Check if oil pressure is applied.
is possible.
Telescoping
It is possible to operate it excluding the damaged switch.
Rear right RET/EXT
Damaged switch exchange
If there is no problem,
replace differentialtransformer.
The voltage of the battery is nine volts or less.
No operation Battery exchange

is possible. 98 blinking when the engine starts is not
abnormal.
Transmitter batteries are dead.When batteries have

Replace batteries of transmitter to turn it ON
Operation is
run out, voice message requesting replacement of
again.Radio controller is wrong unless power indi
possible.
batteries is to be issued.
cator lamp on transmitter lights or blinksquickly.
7.LIST OF VOICE MESSAGES

Remote control ready.
When power to the crane is supplied with key switch turn on.
When it is turned to normal mode by depression of radio control selector switch.
When emergency stop is released by depression of emergency stop switch.
When switch is not depressed.

Emergency stop is released
Stop winch up.

Scure lifting hook.
When switch is depressed.

Emergency stop is functioning.
When "raising boom","winding-up hook",or "extending boom" operation is

carried out on over-wound condition.
When hook storing switch is controlled.
Chenge control mode.
When it has been selected to outrigger radio control mode.

When outrigger radio control mode has been released.
When it has been selected to low temperature operation mode.
When low temperature operation mode has been released.
Service remote control.
When mode indicator is blinking any of figures, [4258] and [6087].
Low transmitter battery.
When battery in the transmitter has run down.
Outrigger operation switch

Operation mode
switch
Outrigger monitor
Outrigger selector switch
Voice switch
Switches in detail
7-1
5YKVEJKPIQHOQFG
/CPWCNOQFG4CFKQEQPVTQNOQFG
#NNVJGOQPKVQTNCORUCTGNKV
2WUJVJGOQFGUGNGEVQTUYKVEJVQUYKVEJKVVQVJGTCFKQTGOQVGEQPVTQNOQFG
6JG/QFGKPFKECVQTNCOR
/CPWCNOQFG4CFKQEQPVTQNOQFG
6JG/QFGKPFKECVQTNCORNKIJVUQHH6JG/QFGKPFKECVQTNCORNKIJVUQP
/CPWCNNGXGTQPN[4CFKQEQPVTQNQPN[
*QYVQQRGTCVGQWVTKIIGTUD[OCPWCNNGXGT
1RGTCVKQPOQFGUYKVEJKUEJCPIGFVQVJGQWVTKIIGTUKFG
1WVTKIIGTOQFGKPFKECVQTNCORNKIJVUQP
6JGTGCTGHQWT
QWVTKIIGTEQPVTQNUYKVEJGUCPFGCEJUYKVEJKUPWODGTGF
5GNGEVCPQWVTKIIGTEQPVTQNUYKVEJVQVJTQYKVVQ FGUKTGF HWPEVKQP CPF
QRGTCVG VJG QWVTKIIGTNGXGTCEEQTFKPIN[
*QYVQQRGTCVGQWVTKIIGTUD[TCFKQEQPVTQNVTCPUOKVVGT
1RGTCVKQPOQFGUYKVEJKUEJCPIGFVQVJGQWVTKIIGTUKFG

QFGUGNGEVQTUYKVEJKUEJCPIGF
/QFGKPFKECVQTNCORNKIJVUQP
1WVTKIIGTOQFGKPFKECVQTNCORNKIJVUQP
#NNVJGOQPKVQTNCORUCTGNKV
6JGMG[UYKVEJQHVJGVTCPUOKVVGTKUVWTPGFQP
2QYGTNCORKUNKVRWUJKPIUVCTVUYKVEJQHVJGVTCPUOKVVGT
6JGUGNGEVKQPUYKVEJKUEJCPIGFCPFVJGURGGFNGXGTKURWNNGF
5GNGEVQT
UYKVEJGU
8.4 Switching of mode indicator (State Operation)

Depress both winding-up and mode selector switch
simultaneously.
Operation indication
State indication
(normal case
Depress both winding-up and mode selector switches
at the same time or turn OFF power to crane and turn
it ON again.
Radio control operation
8.5 Resetting of interlocking balance control
Depress the switch for storing hook with the switch

for boom-up turned ON.
Retaining function of
dividing operation ON
(normal case
Depress the switch for storing hook with the switch
for boom-down turned ON.
(8-4)
Retaining function of
dividing operation OFF
Mode indicator shows [oF].
Voice message, change control modeis issued
8.6 Switching of "shockless"function(Carry it out when it is not over-wound
Turn ON winding-down switch with para-hook switch

depressed.
"shockless"
(normal case
No"shockless"
[-] appears on the left side of mode indicator.
Turn ON winding-up switch with para-hook switch
depressed.
8.7 Switching oflow-temperature operation mode
Depress the switch for storing hook with the switch for
slewing C.C.W.turned ON.
Low-temperature
operation mode
OFF(normal case
Low-temperature
operation mode ON
Depress the switch for storing hook with the switch for
Mode indicator shows [06].
slewing C.W.turned ON.
Voice message, change control modeis issued.
(8-5)
/GVJQFQHGPIKPGUVCTVCPFUVQRVJCVWUGUTCFKQEQPVTQNNGT
2WUJVJGOQFGUGNGEVQTUYKVEJVQUYKVEJKVVQVJGTCFKQTGOQVGEQPVTQNOQFG
6JG/QFGKPFKECVQTNCORNKIJVUQP
9.RADIO CONTROL CANNOT BE OPERATED

(In case where it is due to electrical failure)
Turn "ON" the voice switch and start engine to check it.
YES
Power indicator lamp lights.
No
Radio control selector switch

has been depressed.
.(dot)
is
shown
at
bottom-right side of mode
Depress radio control

selector switch again.
"54" is shown on mode indicator.
Check receiver cable

for connection.
"51" is shown on mode indicator.
Repair transmitter and

receiver.
Moisture is stuck on inspection

window of receiver.
Repair receiver.
Replace batteries.
Battery life is approximately 20 hours
when new 4 pieces of alkaline battery
have been replaced.
Batteries have run down.

"99" is blinking on mode indicator.
Voice message requesting battery
replacement is heard.
Power indicator lamp blinks when
batteries come close to be dead.
Repair transmitter and receiver.

Power indicator lamp
Voice switch
Receiver cable
Receiver
Check lamps
Interference (Lights)
When receiving noise from outside, it lights in red.
Receiving (Blinks)
When receiving signal from transmitter, it blinks in green.
Error (Blinks)
When receiver is in trouble or batteries are running down, it blinks in red.
Power (Blinks)
When key switch turn on, it blinks in green.
9-1
10.EMERGENCY MEASURES TO BE TAKEN WHEN CRANE CANNOT

BE OPERATED AT ALL
Procedure 1
Operate it while the safety device reset switch is being pushed up.
When outriggers are raised before storing boom and hook, overturn prevention device is actuated so that crane
cannot be operated.
Store the crane while the reset switch of safety device is pushed up.
If it is key switch type, operate it with the key turned to release side.
Procedure 2
(In case where the crane cannot be operated even if the safety device
reset switch is controlled.)
Store the crane with the control box reset switch pushed up.
Procedure 3
(In case where the crane cannot be operated even if control box reset switch
is operated.)
Unfasten the hexagon nut on the control valve to screw in the set bolt until it stops, then
store the crane by using control lever.
Set bolt
Safety device reset switch
ML auto stop switch
Control box reset switch
10 - 1
Hexagon nut
Hydraulic Circuit Diagram (Carrier

Control valve for crane
T
T2
It connects with drain pipe of

Slewing motor and hoisting motor.
PB2 DR
DR2 DR1
P1
URW370CDE
S/N
37W0062
Manufacturing2006/8
URW506CDE
S/N
50W0005
Manufacturing2006/8
Manifold block
High pressure line
LP
Tank line
T0
RP
PB
T1
DR3 DR4 P2
GP
Crawlingmotor left
Dr
Dr
Crawlingmotor right
Reduction gear
Reduction gear
PP
PP
B
A1
B1
A2
Forward
Forward
P1
P2
Backward
Backward

T
Return filter
B2
P1
P2
Engine
Pump

From the power unit
From the pump P2
To right B
To T1
To left A
From Manifold block P2
2
pump P
e
h
t
m
Fro
To motor (right side) A

To motor (right side) B
block PB
d
l
o
f
i
n
To ma
d block T1
To manifol
To motor (left side) B
To motor (left side) A
From manifold block P2
From the power unit P1
it P2
n
u
r
e
he pow
From t
Left
Right
Ground
Sky
Left
Right
The upper surface of manifold block
The upper surface of Manifold block
Ground
Side of manifold block
Sky
Ground
The front side of Manifold block
Sky
Ground
The front side of manifold block
Sky
Ground
The back side of Manifold block
Sky
Pump
Sky
Ground
Crawling motor
Sky
Ground
Sky
Ground
Crawling motor
Right
Crawling motor
Ground
Left
Sky
Hydraulic Circuit Diagram (control valve for crane

High pressure line
Tank line
Pilot pressure line
Tank
Feed-back line
Line filter
Gauge Port
Solenoid valve
for unloading
pump
Main relief valve

Emergency screw
Pilot pressure
Gauge Port
Solenoid valve
for storing hook
Set bolt
Back pressure valve
Pressure reducing
valve
Pressure regulator
valve
Outrigger side
Accelerator
Hydraulic Circuit
Ext.
Outrigger
C.C.W
C.C.W
Hydraulic motor
Slewing
C.W
C.W
Slewing
Telescope
Counter balance valve

Ext.
Ret.
Telescope
Down
Up
Hydraulic motor
Hoist
Load metor
Down
Up
Hoist
Counter balance valve
Lower
Raise
Derrick
Control valve (for crane)
Check valve
13.SWIVEL JOINT
Construction of swivel joint and where hoses are attached
Front of crane
Column foot pin side
Square ring
7
Seal ring
4
3
Rear of crane
Column derrick pin side
Section A in detail,STK seal fitting
Inner joint
Outer joint
Fill up greese
when mounting
6 DERRICK(RAISING)
4 DERRICK(LOWERING)
TELESCOPING(EXTENSION)
TELESCOPING(RETRACTION)
4
3
2 HOIST(DOWN)
3 HOIST(UP)
Fill up greese
when mounting
2
1
1 HOIST(DRAIN)
SWIVEL JOINT PIPING
Derrick(raising)
Derrick(lowering)
Hoist(down)
Telescoping
(extension)
Telescoping
(retraction)
Hoist(up)
Hoist(drain)
SWIVEL JOINT PIPING
Telescoping
(Extension)
Derrick
(raising)
Derrick
(Lowering)
Telescoping
(Retraction)
Hoist(up)
Hoist(Down)
Hoist(Drain)
SWIVEL JOINT PIPING
Telescoping
(Extension)
Derrick
(raising)
Derrick
(lowering)
Telescoping
(retraction)
Hoist(up)
Hoist(down)
Hoist(drain)
SWIVEL JOINT PIPING
Derrick
(lowering)
HOIST(DRAIN)
Derrick
(raising)
Hoist(up)
Hoist(down)
Telescoping
(Extension)
Telescoping
(retraction)
SWIVEL JOINT PIPING
Hoist(down)
Hoist(up)
Telescoping
(Extension)
Telescoping
(retraction)
Hoist(drain)
Derrick
(raising)
Derrick
(lowering)
14 COLUMN
14.1 Tightening torque for bolts fastening column and tightening order
Bolt for derrick pin

Torque 78N-m8kgf-m
Bolt for column

When assembling,apply LOCTITE #962T
Tighten the bolts in the numerical
order as illustrated in the figure.
Torque
URW376CDE 245N-m25kgf-m
URW506CDE 333N-m34kgf-m
5
11
10
9
8
2
Hoist(up)
Hoist(drain)
Hoist(down)
Derrick
(lowering)
Derrick
(raising)
Telescoping Telescoping
(retraction)
(extension)
WIRE ROPE RETAINIG MECHANISM
Inside width of drum

154.8
Limt switch (Electric wiring assy)

750306029 OMRON D4C1203
. HOIST WINCH
15. 1 Construction of Hoist Winch and brake shoe adjusting procedure
Gear4
Drum
Apply"LOCTITE #242"
Breather
Gear2
Ratchet Wheel
Brake Shoe
Split
Pin
After assembling,
apply grease to
engaging tooth
surfaces of the gear.
Castle
Nut
Rotate the gear shaft to
check that the pawl makes
a smooth movement.
Plain
Washer
Disk
Motor
Bearing
Pay attention
to its direction.
Gear1
Casing
Brake Shoe Ajusting procedures

1.Tighten the castle nut lightly with a spanner.
2.After tighning,loosen the castle nut for approx.1/6 turn
and within this range align the castle nut with the hole in the
gear shaft;and fix it with the split pin.
3.Replace the break shoe every 3years.
15. 2 Caution to be taken when reassembling hoist winch
Check that the spring is caught

in the drill hole on the pawl.
Dimensions on both sides

should beequally arranged
when fitting the ratchet wheel.
Set bolt position

3
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.
15. 3 Cause of Troubles and Measures to be Taken

(1) Hoist winch
Problems
Possible cause
Pump is faulty.
(Pressure does not rise at idling speed.)
(Total pressure required for operation is
insufficient.)
Replace.
Relief set of control valve is faulty.

(Pressure rises but not enough.)
Adjust or replace.
O-ring and other parts of relief valve of

control valve are faulty.
(Adjusting bolt of relief valve is tightened but unable to control pressure.)
Replace parts or replace relief

assy with new one.
Hoist motor is faulty.

(Quantity of drain is larger than the specified.)
Replace.
Pressure rises but hoisting

up impossible.
Drum or internal mechanism of reduction

gear is faulty.
Overhaul reduction gear.

Inspect the drum
Pressure rises but lowering

is impossible.
Brake shoe is over-tightened..
Adjust tightening of brake

shoe.
Overhaul reduction gear.
Check drum.
Pressure does not rise.
Drum or reduction gear is defective.

Unable to maintain suspended load.
Brake shoe is faulty.

Pawl is faulty.
Replace brake shoe.

Replace pawl.
When lowering, hunting

occurs.
Brake shoe is faulty.
Inspect brake shoe and check

quantity of oil.
Adjust tightening of nut.
Disassemble reduction gear.
Over-tightening of brake shoe.

Internal mechanism of reduction gear is
faulty.
When hoisting up, clattering
sound is heard.
Spring pressing the pawl against slide

plate is faulty.
Bushing the part of fitting pawl is worn
out.
Replace spring.
Replace bushing.
16. HOOK
Apply"LOCTITE#242"
Bearing-Thrust ball
Aplly grease
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
Nut
Spring pins
(both sides)
Hook
Enlarged portion
where sealing agent
is to be applied.
W376C 90 mm
W546C 130 mm
17. Turntable Mounting Procedures

(1) Turntable mounting procedures
1.Install the slewing reduction gear to the base.

2.Set the turntable on the base to screw-in the bolts for mounting turntable lightly.
3. Insert the thickness gauge(0.10.2mm)into the space between the turntable gear
and the pinion gear,and press strongly the turntable to the pinion gear.
10
18
15
7
11
14
Hydraulic motor
19
2
5
12
13
8
16
17
"S"Mark(Soft Zone)
Turntable mounting bolts (19-M20)
Slewing reduction gear

mounting bolt(4-M16)
Turntable
After assembling
,apply grease to
engaging tooth
surfaces of
the gears.
Note:
1. Tightening torque of bolts (4-M16) mounting slewing reduction gear is 25529N-m(263Kgf-m)
Tighten the mounting bolts in diagonal order.
2.Position the mark Son the inner part of turntable directed toward the truck front when mounting
turntable.
3.Tightnen the bolts in the numerical order as illustrated inthe figure above.
4.Tighten the turntable mounting bolts (19-M20) equally with a torque of 47139N-m(484Kgf-m)
Before mounting bolts are tightened,degrease the bolts and the tapped holes to apply
"LOCTITE #962T" to the bolts and tighten them with an equal torque.
5.The bolts for fastening the turntable(tempered bolts)must be UNIC genuine bolts, on which
mark "UNIC12" is inscribed on the head.
18.SLEWING REDUCTION GEAR

1)Construction
Gear shaft
Dust seal
Taper roller bearing
Breather
Filled with grease
Bearing housing
Nut
Casing
Warm wheel
Worm shaft
Snap ring
Taper roller bearing
Ball bearing
Crown nut
(2) Construction to be taken when reassembling slewing reduction gear
ApplyThreeBond
#1401to it.
Apply Grease to
the inside of
dust seal.
Dust Seal
Fill up with grease here.

Use Lithium soap radical grease
(such as Rizonix grease No.1 or Kyseki)
Nut:ApplyLOCTITE #262before tightening it.
Note:Tighten the nut to the extent that
the gear shaft can be rotated to either
Direction with your both hands.
Bearing housing
Assemble the worm
wheel with the markV
directed upward.
Flange bolt
Tightnig torque:
59N-m(6kgf-m)
(3) Slewing reduction gear disassembly procedures

Remove a snap ring (H-80) retaining the taper roller bearing which 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.
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.
Pull out the O-ring which is assembled in the nut.
With a pin spanner, remove the nut which retains the taper roller bearing.
Note: To the threaded part of the nut, LOCTITE was applied. Therefore,
when loosening, warm up lightly the threaded part with gas flame, and then
loosen. When reassembling, be sure to apply LOCTITE #262 to the
threaded part.
Ground
Pinping of Hydraulic Motor for Slewing
Sky
..
External pilot port
Pinping of Hydraulic Motor for Slewing
External pilot port
..
Drain port

Hydraulic Circuit Diagram
(Outrigger
High pressure side
Tank side
OutriggerVertical
Front, Right
Solenoid valve 740170008

to select Outrigger(Vertical)
and Outrigger(Horizontal)
OutriggerHorizontal
Front, Right
OutriggerVertical
Front, Left
OutriggerHorizontal
Front, Left
OutriggerVertical
Rear, Right
OutriggerHorizontal
Rear, Right
OutriggerVertical
Rear, Left
OutriggerHorizontal
Rear, Left
Outrigger cylinderHorizontal
Outrigger cylinderVertical
Double pilot check valve
740197040
Solenoid valve 740170009

to extend Outrigger cylinder, and to withdraw Outrigger cylinder
Pilot check valve601529000
19.HOW OUTRIGGERS ARE EXTENDED

Vertically extending cylinder
Stroke:700(URW376C)
Stroke:1020(URW546C)
Horizontally extending cylinder
19-2
19.OUTRIGGER CYLINDER
1)Construction of vertically extending cylinder
Pilot check valve

CD-02RA
In order to prevent moisture from entering the

cylider from the threads, apply liquid gasket,
solventless type #1101(fatty acid degenerated
phenolic resin family),supplied by ThreeBond
here (4 places on its circumference).
19-3
Apply grease here
(IDEMITSU DUFNEET grease,
model XCZ-1 or equivalent)
Split position of bushing
Construction of horizontally extending cylinder
Pilot check valve

CP-02F
19-4
20.DERRICKING CYLINDER
Bend this toward the gland aftter
the gland has been fightened.
(1 place)
Counterbalance valve
CB-03ED-W
Hydraulic driven
20-1
In order to prevent moisture from entering the
cylider from the threads, apply liquid gasket,
solventless type #1101(fatty acid degenerated
phenolic resin family),supplied by ThreeBond
here (4 places on its circumference).
Apply grease here

(IDEMITSU DUFNEET grease,
model XCZ-1 or equivalent)
20.2Flow of oil,when lowering
Rod
Apply"LOCTITE"638"here
Hexagon socket head screw
For grand Bush omission stop
Apply"LOCTITE #2701" With"Curing accelerator
#7649"If the addelerater is not used,
do not flow of the agent.After the screw is
tightened,hit with a pinch at 2 places on
its circumference.
The check valve shuts and the
amountof oil that returns to the
tank is limited.
Pressure oil
Tank
The spool opens

according to the
reduction side
pilot pressure
Counter-balance valve
Piston
For piston turn stop
its circumference.
20.3Flow of oil,when raising

Rod

for gland-bush turn stop
its circumference.
Pressure oil
Tank
Check Valve
opens.
Counter-Balance Valve
Check Valve opens.
Spool opens
Piston

For piston turn stop
its circumference.
When telescoping cylinder1 extends(URW376C)

Selector valve assy
Check valve2
Rod
Stopper
Check valve
Tube/Rod
Check valve1
Tube
Piston
Piston
Spool
Slide pipe
Pressure Oil
To Tank
How to extend the tele1 section

The pressure oil opens the check valve in the counterbalance valve, enters the rod,
goes through the slide pipe and reaches the check valve 1 of the selector valve assy.
The tele2 section is fully retracted at this time.
The tube end opens the check valve 1 of the selector valve assy via the spool to
lead the pressure oil to the extension side.
Simultaneously, the oil at the retraction side of the tele1 section flows through
the rod and returns to the tank to extend the tele1 section.
Since the check valve 2 of the selector valve assy is closed,
the pressure oil does not flow into the tele2 section.
Since the tele2 section is fully retracted, the oil does not remain at the retraction
side and so the tele2 section does not operate.
When telescoping cylinder1 retructs(URW376C)

Check valve 2
Rod
Seletor valve assy
Stopper
Check valve
Spool
Tube/Rod
Tube
Piston
Piston2
Check Valve1
Spool
Slide pipe
To Tank
Pressure Oil
Pilot Pressure
How to retract the tele1 section

The pressure oil goes through the rod and enters the retraction side of the tele1 section.
The tube end opens the check valve 1 of the selector valve assy via the spool and leads
the oil at the extension side of the tele1 section to the counterbalance valve via the slide pipe.
Although the check valve in the counterbalance valve is closed at this time, the spool is opened
by the pilot pressure supplied from the retraction side. Therefore, the oil at the extension side is
returned to the tank and the tele1 section is retracted.
Although pressure is applied to the retraction side of the tele2 section at the same time,
the check valve 2 of the selector valve assy is closed and the passage at the extension
side of the tele2 section is interrupted.
So, the oil does not remain at the extension side of the tele2 section and the tele2 section does not operate.
When telescoping cylinder2 extends(URW376C)

Check valve2
Rod
Selector valve assy
Stopper
Check valve
Tube/Rod
Piston1
Piston2
Tube
Check valve1
Slide pipe
Pressure Oil
To Tank
How to extend the tele2 section

The pressure oil opens the check valve in the counterbalance valve, enters the rod,
goes through the slide pipe and reaches the check valve 2 of the selector valve assy.
Right before the tele1 section is fully extended, the slide pipe is pushed up by the
stopper to open the check valve 2 of the selector valve assy.
Then, the pressure oil is led to the extension side of the tele2 section.
Simultaneously, the oil at the retraction side of the tele2 section goes
through the rod and returns to the tank. Then, the tele2 section is extended.
At this time, the check valve 1 of the selector valve assy is closed and the passage
at the extension side of the tele1 section is interrupted.
Since the tele1 section is fully extended, the oil does not remain
at the extension side and so the tele1 section does not operate.
Spool
6-Section Boom (Dual Cylinder) Operation(URW56C)

(1) When Telescoping Cylinder1 extends
After the set-screw is tightened

with LOCTITE #2701 applied
hit with a punch at 2 places on the
circumference and leave it as it is for 1 hour.
Rod
Check valve 1
Spool
Check valve
Bolt
Tele2
Piston
Apply"LOCTITE#638".
Seletor valve assy

Check valve 2
Slide pipe
Pressure Oil
To Tank
How oil flows when tele1 is extended

Pressure oil opens the check valve in the counter-balance valve to
enter the cylinder rod of tele1 and flows through the slide pipe to reach
the check valve 1 of selector valve assy.
The tele2 has been fully retracted at the time and the bolt opens the
check valve 1 of selector valve assy 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 assy
pressure oil will not flows in the tele2.
Also, oil in the retraction side of tele2 will not flows in the tele1 as
the tele2 has been fully retracted so that the tele2 will not be actuated.
And the tele3 also will not be actuated according to the same reasons as in the tele2.
Tele1
Tele2
Counter-balance
valve
Tele3

(2) When Telescoping Cylinder1 retracts
After the set-screw is tightened

with LOCTITE #2701 applied
hit with a punch at 2 places on the
circumference and leave it as it is for 1 hour.
Check valve 1
Spool
Rod
Check valve
Spool
Bolt
Tele2
Piston
Apply"LOCTITE #638".
Selector valve assy

Check valve 2
Slide pipe
Pressure
Oil
To tank
Counter balance Valve
Pilot
Pressure
How oil flows when tele1 is retracted
Pressure oil flows through the dual cylinder of cylinder rod of tele1
to enter the retraction side of tele1.
At this stage, the bolt opens the check valve 1 of selector valve ass
via spool which leads the oil in the extension side to the counter-balance
valve by way of slide pipe.
Although the check valve in the counter-balance valve is closed at
this time, the spool is opened by pilot pressure from the retraction side
allowing the oil in the extension side to return to the tank.
This allows the tele1 to retract.
Although pressure is also applied to the retraction side of tele2 at
this stage, the tele2 will not be actuated because the check valve 1 of selector
valve assy for tele1 is closed and the passage to the extension side of tele2 is
shut off so that no oil is to be remained in the extension side of tele2.
And the tele3 also will not be actuated according to the same
reasons as in the tele2.
Tele1
Tele2
counterbalance
valve
Tele3
6-Section Boom (Dual Cylinder) OperationURW56C)

Slide pipe
Rod
Check valve 1
Selector
valve assy
Check valve
Check valve 2
Piston
Pressure Oil
After the set-screw is tightened with LOCTITE #2701

hit with a punch at 2 places on the circumference
and leave it asit is for 1 hour.
To tank
Bolt
Tele2
Check valve 1
Spool
Counter balance
valve
Bolt
Tele3
Rod
enter the cylinder rod of tele1 and flows through the slide pipe to reach the
check valve 2 of selector valve ass
Since the slide pipe of tele1 is pulled by piston immediately before the
tele1 is fully extended which in turn opens the check valve 2 of selector valve
assy to lead the pressure oil to the extension side of tele2.
dual cylinder in the cylinder rod of tele2 and through the dual cylinder in
the cylinder rod of the tele1 to return to the tank.
Since the check valve 1 of selector valve ass
stage, the passage on extension side for tele1 is shut off.
The tele1 will not be actuated because no oil is remained in the
retraction side of tele1 as the tele1 is fully extended.
In addition, the tele3 will not be actuated because the check valve 2
of selector valve ass
to extension side of tele3.
Tele1
Tele2
Tele3
Piston
Apply "LOCTITE #638".
Selector
valve assy
Check valve 2
Slide pipe

Slide pipe
Rod
Check valve 1
Selector
valve assy
Check valve
Spool
Piston
To tank
Check valve 2
Tele3

applied,hit with a punch at 2 places on the circumference
and leave it asit is for 1 hour.
Pressure
Oil
Bolt
Tele2
Check valve 1
Spool
Counter balance valve Pilot

Pressure
Bolt
Tele3
Rod
to enter the retraction side of tele2.
Also, the bolt for tele3 opens the check valve 1 of selector valve ass
via spool which leads the oil in the extension side of tele2 to the counterbalance valve by way of the slide pipe of tele2, the check valve 2 of selector
valve assy for tele1, and the slide pipe of tele1.
allowing the oil in the extension side to return to the tank.
Although pressure is applied to the retraction side of tele1 at the
time, the tele1 will not be actuated because the check valve 1 of selector valve
assy is closed and the passage to the extension side of tele1 is shut off.
Piston
Slide pipe
Tele1
Tele2
Tele3
Selector valve
assy
Check valve 2
-Section Boom (Dual Cylinder) Operation(URW56C)

Slide pipe
Rod
Check valve 1
Bolt
Tele3
Check valve
Selector valve assy
Piston
Check valve 2
Slide pipe
Pressure Oil
Counter
balance
valve
To tank
Check valve 1
Spool
Rod
Bolt
Tele3

enter the cylinder rod of tele1 and flows through the slide pipe to reach
the check valve 2 of selector valve assy.
Pressure oil entered the extension side of tele2 flows through the
slide pipe to reach the check valve 2 of selector valve assy
dual cylinder in the cylinder rod of tele3 to enter the extension side of tele2,
then it flows through the dual cylinder and further through the dual
cylinder in the cylinder rod of the tele1 to return to the tank.
Since the check valves 1 of selector valve assy of tele1 and tele2 are
closed at this stage, the passages of extension side for tele1 and tele2 are shut off.
Both tele1 and 2 will not be actuated because no oil is remained in
the retraction side of tele1 and 2 as the tele1 and 2 are fully extended.
Selector valve assy
Piston
Check valve 2
applied hit with a punch at 2 places on the
circumference and leave it asit is for 1 hour.
Piston
Apply "LOCTITE#638".
Tele1
Rod
Tele2
Tele3

Slide pipe
Rod
Check valve 1
Check valve
Spool
Bolt
Tele3
Selector Valve
Piston
Check valve 2
Slide pipe
To tank
Counterbalance
valve
Pressure
Oil
Check valve 1
Spool
Rod
Pilot
Pressure
Bolt
Tele3
Piston
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.
allowing the oil to return to the tank.
Although pressure is applied to the retraction side of tele1 at the
time, the tele1 will not be actuated because the check valve 1 of selector valve
assy of tele1 is closed and the passage to the extension side of tele1 is shut
off.
Selector Valve
Check valve 2
applied,hit with a punch at 2 places on the
circumference and leave it asit is for 1 hour.
Tele1
Rod
Tele2
Tele3
Piston
(7) Adjusting Procedures for Selector Valve with Adjusting Bolt
Adjusting Procedures with Adjusting Bolt

Retract telescoping cylinders (1) and (2) to their minimum.
Apply LOCTITE #242 to 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.
Function and Working of Cushion Seal

For the purpose of absorbing a piston shock to the stroke end, the 6-section boom have the cushion seal
in the part of piston of the telescoping cylinder (2) and (3).
(1) Flow of Pressure Oil When Retracting

1. Cushion mechanism of the telescoping cylinder (3) for 6-section booms.
In the retracting process, before the piston gets in the plunger, the pressure oil in the chamber A flows
through the central part of the piston as shown in the illustration and returns to the tank without being
squeezed.
CUSHION SEAL
TUBE
PISTON
CHAMBER A
PLUNGER
At the same time when the piston gets in the plunger, the chamber A is closed with the cushion seal.
As a result, the pressure oil in the chamber A is forced to return only through a drilled hole in the
state of being squeezed. Thus the piston shock at the stroke end is absorbed.
CUSHION SEAL
. Cushion mechanism of the telescoping cylinder (2) for 6-section boom.

SQUEEZING PART
PISTON
CUSHION SEAL
PLUNGER
(2) Flow of Pressure Oil When Extending

When extending, the pressure oil flows into the chamber A as shown in the illustration.
In this way, the telescoping cylinder extends.
CUSHION SEAL
CHAMBER A
PLUNGER
Cushion mechanism of the telescoping cylinder for 6-section booms is to squeeze the
return pressure oil at the position just before the end of extension and absorb the piston shock to the
stroke end.
SQUEEZING PART
GLAND
ROD
Cause of
Troubles and Measures to be Taken
(1) 6-section boom

When retraction of the boom (3) becomes impossible at the position just before full retraction of the booms (4), (5)
and (6), inspect the plunger which is assembled in the telescoping cylinder (3).
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 plungerof the telescoping cylinder (2).
of the plunger of the telescoping cylinder (2).
(2) Cause of Troubles and Remedy
NUT
SPOOL(1)
C
ADJUSTING BOLT
STICK
URW546C 6-section boom (Triple cylinders)

Troubles
Possible cause
Retraction is normal, but when

extending, booms (2) and (3)
extend at the same time, in
other words disorderly.
Some foreign substances are

clogging the part? of selector valve of telescoping cylinder (1).
Disassemble selector valve for

cleaning, or replace it with a
new one.
Extension is normal, but when

retracting, booms (3) (4) and
(5) retract at the same time, in
other words disorderly.

clogging the part? of selector valve of telescoping cylinder (2).
Extension is normal, but

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

clogging the part of selector valve of telescoping cylinder (2).
Snap ring at the part? of
selector valve of telescoping
cylinder (2) got out of place.
Extension is normal, but

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

clogging the part of selector valve of telescoping cylinder (1).
Snap ring at the part? of
selector valve of telescoping
cylinder (2) got out of place.
Boom (2) extends but boom

(3) does not extend.
Nut at slide pipe of telescoping cylinder (1) was loosened.
Disassemble telescoping
cylinder (1) and tighten the
nut.
Boom (2) and (3) extend,

but boom (4) and (5) does
not extend.
Nut at slide pipe of telescoping cylinder (2) loosened.
Disassemble telescoping
cylinder (2) and tighten the
nut.
After full extension, booms

(5) retracts but boom (3)
does not retract.
Adjusting bolt pushing the

spool of selector valve of
telescoping cylinder (2) was
loosened.
Selector valve spool of telescoping cylinder (2) was bent.
Adjust the bolt.
Boom (3), (4) and (5)

retracts but boom (2) does
not retract.
Adjusting bolt pushing the

spool of selector valve of
telescoping cylinder (1) was
loosened.
Selector valve spool of telescoping cylinder (1) was bent.
Disassemble selector valve for

cleaning, or replace it with a
new one.
Rearrange snap ring.
Replace selector valve ass'y

with a new one.
Note: During operation test after disassembling and repairing, the reason why the booms (4), (5)
and (6) stop extending halfway is presumed that the left and the right wire ropes for
extension were crossed when reassembling.
-section boom
Boom 4 front side section in detail
How sheave2 is mounted
Wire rope with role to extend boom 5

and role to retract boom 4
Boom 5 front side section in detail

Wire rope with role to extend boom 6

and role to retract boom 5
Sheave
Boom
Boom
Boom
Sheave
Boom
-section boom
Boom 3 rear side section in detail
Boom 4 rear side section in detail

Boom
Wire rope of role

to retract boom 6
Sheave
Sheave
Boom
Wire rope of role to
retract boom 4
Wire rope of role

to extend boom 4
Telescoping cylinder1
Boom5
Boom1
Boom2
Boom3
Boom4
Boom6
Installation procedures for slide plate and guide

It has similar construction irrespective of number of boom section
Bolt
Clearance 2mm
Clearance 1mm
When assembling,
apply"LOKTITE #242".
Slide plate
HOW TO PUNCH
(1) Purpose
Troubles injuring the inside surface of cylinder tube due to screws mounting piston being loosened have been
happened.
Therefore, we not only upgraded the screw lock agent LOCTITE #262 to #2701 to strengthen adhesion but
also added punching process (partly carried out for derrick cylinder). The section defines how to punch.
(2) Punching procedures
1. Use a punch whose tip is hard and sharp enough.
Closeup
2. Hit the punch head hard enough with a hammer with the punch put at a distance of 1 1.5mm from the screw end.
3. Hit the punch head so hard that the diameter of punch mark will be more than 1.5mm
4. Punch 2 places around the screw thread in diagonal position.

Tighten each hexagon socket
screw with "LOCTITE #2701"
applied to the threads to
punch specified places close
to screw threads.
Fig.1 Piston
Points to 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 LOCTITE has been applied.
(Try not to give shock to the area where LOCTITE has been applied as it starts curing.)
TELESCOPING/DERRICK CYLINDER ASSY, MEASURES TO

PREVENT PISTON FROM BEING LOOSENED
(Description)
In order to ensure preventing the pistons of telescoping and derrick cylinders from becoming loose, fix the screw
threads on the rods and the pistons with the adhesive LOCTITE #638 (excepting for W376C telescopic cylinders).
Besides, securing piston with screws and punching after application of LOCTITE #2701 are also
to be carried outas before
(Rods and pistons are to be fixed perfectly by application of adhesive LOCTITE #638.)
(Main points)
Rods and pistons are fixed by tightening after application of LOCTITE to the threads on the
rods and on the pistons.
Apply LOCTITE to the entire circumference of 2nd to 3rd threads from the thread end.
Apply the primer as the gap in the effective diameter of threads exceeds 0.1mm.
Use type #7474 (primer T) for the primer.
(Although type #7469 is being used currently, type #7474 is more
effective as the target adhesion is to be at between metal components.)
Note : Pay special attention to observing the points to notice illustrated below while working
as curing itself and curing time of LOCTITE depends largely on how the adhesion
procedureshave been carried out.
Points to notice on procedures to apply LOCTITE
Procedures
1. Degreasing and cleaning 2. Priming coating 3. Application of LOCTITE 4. Assembly 5. Curing
(1) Degreasing and cleaning
Separate the oil well enough which has been applied to the threads (of rod/piston) to wipe it off with a
rag or blowit off with compressed air.
When blowing it off with air, remember that the unclean oil will not be blown off but will just escape along
thethreads.
In case of spray cleaning as well, target oil will not be removed but return if doing nothing but just spraying.
After carrying out degreasing and cleaning, wait until cleaning fluid is dried up completely.
(2) Priming coating
After primer #7471 has been applied, do not wipe it off but allow as it is for 5 10 minutes to dry naturally.
(Application of LOCTITE without complete drying may result in reduction of adhesive strength by half.)
Although a component primed is effective for 7 days, store it by preventing dust and/or oil from being stuck
before use.
When LOCTITE is applied to a component and it is shut off air, curing will start after 5 minutes from
application and will reach approx. 70% of curing in about 2 hours.
(Curing time will be shortened by priming, but theoretical adhesive strength will be 85% against a component
without priming.)
Do not dip a primed component in LOCTITE agent directly.
Carry out priming at a place where well ventilated because priming agent escapes into air as vapor.
TELESCOPING/DERRICK CYLINDER ASSY, MEASURES TO

PREVENT PISTON FROM BEING LOOSENED
(3) Application of LOCTITE
Apply LOCTITE sufficiently to the threads to fill them.
Apply LOCTITE to the component mounting o-ring (piston) at the 2nd to 3rd threads from the thread end.
(Refer to Estimated adhesive consumption illustrated below.)
LOCTITE #638 is an anaerobic adhesive so that the part forced out will not cure because it is
in contact with air.In addition, sticking of #638 to o-rings and packings may cause the rubber to be
(When it is possible to be stuck on the rubber such as o-rings and packing, apply LOCTITE to
the threads on piston side to avoid sticking to them.)
Try shortening the working period from the time when application of the LOCTITE to a primed
component to completion of fitting the component.
(4) Assembly
Tighten the component after application so that applied LOCTITE may spread entirely to the
threads of the component.
Since LOCTITE forced out of the threads will not be cured, take care not the LOCTITE
to be out during application as hydraulic oil is to be contaminated with it.
Work quickly as the LOCTITET in the treads starts curing.
Curing speed differs according to temperature(ambient temperature included) of target component.
Since curing time becomes excessively longer at a temperature below 10C, work with the component
temperature raised to 15C or over.
Chart of breakdown torque vs. curing
Bolt:M10P1.5- L2S
timeWhen using "Lock Tight #638with

primer #7471 (primer T)
Nut: M10P1.5
Material:Soft steel (raw)
Breakdown torque (kgf/cm)
Ambient temperature 35
(5) Curing
This is a period while an adhesive is being joined.

Store the components still during the period.
(Recommended conditions is at an component
temperature of 15C min. for more than 1 hour.)
Reference:
Estimated adhesive consumption when it is applied to 3 spirals of thread entirely.
15
Curing time (Hr)
Threading diameter
Amount to be applied
Which primer of #7649 and #7471 should be used together with L OCTITE #638.
Curing speed of #7469 is faster than that of #7471 but adhesion strength is lower.
If adhesion is to be carried out between metal articles, #7471 gives better result.
Type #7471 is to be used in normal case (refer to manufacturers comment and catalog specifications).
25
Ground
Earth for engine start relay and engine stop relay
Sky
Earth of the main harness
Sky
Ground
Slip ring
26.1 ELECTRIC WIRING DIAGRAM ( CRANE )
SLOW DOWN(0V)
ML STOP(12V)
SUB BATTERY
BL
Or
BL/Wh
Or
G
ML POWER(12V) Re
Ye
Gr
to Degital load display device
B
SPEAKER Wh
MODE SELECTOR(TRAVEL/CRANE)
CONTOROL BOX
MRV-500
CONTROL VALVES
Ye
Wh
BL
B
Gr
Ye
Wh
BL
B
Gr
Ye
Wh
BL
B
Gr
Ye
Wh
BL
B
Gr
Ye
Wh
BL
B
Gr
Ye
Wh
BL
B
Gr
LVDT
(DERRICK)
LVDT
(WINCH)
LVDT
(TELESCOPIC)
LVDT
(SLEWING)
LVDT
(OUTRIGGER)
LVDT
(ACCELERATOR)
RAISE
LOWER
UP
DOWN
RETRACT
EXTEND
RIGHT
LEFT
B/Pi
Gr/BL
Br/Wh
B/Pi
UNLOAD
ACCELERATOR
Gr/Ye
G/B
B/Pi
OUTRIGGER
INTER LOCK
LVDT 2 WINCH 1
LVDT 2 WINCH 2
LEAVING MINIMAM
WIRE ROPE DETECTOR
LVDT 2 TELESCOPIC 1
LVDT 2 TELESCOPIC 2
Re/BL
Wh/Vi
B/Re
Ye/B
B/Pi
Re/BL
Wh/Vi
Gr/Re
Vi/B
B/Pi
Re/BL
Wh/Vi
Gr/Vi
Pi/Wh
B/Pi
Pi
Re/B
Re/B
BL
B
Pi
Re/B
B
Pi
Re/B
Re/B
B
Pi
Re/B
B
Pi
Re/B
B
Pi
B
Gr/Pi
B
Pi
B
Re/B
LVDT 2 SLEWING 1
LVDT 2 SLEWING 2 OUTRRIGER MODE
CRANE MODE
LVDT 2 OUTRRIGER RIGHT SIDE 1
LVDT 2 OUTRRIGER RIGHT SIDE 2 OUTRRIGER MODE
OUTRRIGER(2)RETRACT
Ye
WINCH UP
OUTRRIGER(3)EXTEND
Br
WINCH DOWN
OUTRRIGER(3)RETRACT
Or
BOOM RETRACT
OUTRRIGER(4)EXTEND
Pi
BOOM EXTEND
OUTRRIGER(4)RETRACT
Sk
SLEWING C.W
ENGINE START
SLEWING C.C.W
Wh/B
HOOK RELIEF
Gr/Pi
UNLOADING
ENGINE STOP
POWER SUPPLY(RSERVE)
STOP SINAL 2
B/Re
ACCELERATOR
Wh/Re
OUTRRIGER
Re/B
Gr
G/Re
OUTRRIGER(2)EXTEND
OUTRRIGER(2)RETRACT
Ye/BL
Br/Re
OUTRRIGER(3)EXTEND
OUTRRIGER(3)RETRACT
OUTRRIGER(4)EXTEND
OUTRRIGER(4)RETRACT
MAIN CONTACT
RELAY N.O.
B
Re
Or/Gr
Re/B
STORE HOOK
AUTOMATIC STOP RESET
BL/Wh
Vi/Or
Re/Gr
Vi/Gr
Re
Vi/Ye
BL
Vi/Re
Br
BL/Pi
Ye
B/Or
Gr
Vi/BL
Ye
Wh
Re
B
Wh
B
Vi/Re
Gr/Or
B
B
Br/Gr
B
BZ
RADIO CONTROL SWITCH
Or
Re
Br
OUTRRIGER(HORIZONTAL)
SELECT SWITCH
OUTRRIGER(VERTICAL)
Or
Re
Br
CRANE
OPERATION MODE SW
OUTRRIGER
Re
Or
Re
Br
EXTEND
OUTRRIGER(1)SW
RETRACT
Re
Or
Re
Br
EXTEND
OUTRRIGER(2)SW
RETRACT
Re
Or
Re
Br
EXTEND
OUTRRIGER(3)SW
RETRACT
Re
Or
Re
Br
Br/B
Ye/Gr
Re
Wh
Gr/Or
Wh/Or
Ye/Re
Pi/BL
Ye/Wh
Wh/Br
B/BL
B/BL
Wh/Ye
Sk
Gr/Or
Wh/Ye
Re
Gr/Wh
Wh/Ye
B/Ye
BL/Vi
Ye/Vi
BL/Vi
B/Br
HORN
Pin1
VOICE
AUTOMATIC STOP RESET
Re
SPARE POWER SUPPLLY
Pin2
Re
Wh
B
Re
Wh
Pin3 B
Pin4
Wh/B
Gr
B
B
Pi/Gr
Re/Gr
Vi/Gr
B
Ye/B
Gr/B
Re
BL/Pi
Vi/Or
Or/Wh
Wh
BL/Pi
Vi/Or
Or
Wh
Sk
G/B
Or/B
Wh
BL/Vi
BL/Vi
BL/B
Pi/B
Pi/B
Lg
Head light
Head light
Or
Re
Re
Re/Wh
Re/Wh
B
B
Wh/Gr
Re
Wh
B
Pi/Gr
Or/Re
Wh/Gr
Or/Gr
Re
Wh/Gr
Br/Gr
Re
Pi/Gr
Or/BL
Re
Wh
B
Re
Re
Re
Re
Re
Re
Re
Gr
B
Gr
B
Gr
B
Pi/Gr
Gr/Br
Re
Re
B
B
Or/Ye
Gr
B
Pi/Gr
G/Gr
LED1
(1)HORIZONTAL
(1)VERTICAL
LED2
LED3
LED4
(2)HORIZONTAL
(2)VERTICAL
(3)HORIZONTAL
(3)VERTICAL
(4)HORIZONTAL
(4)VERTICAL
Stored boom detection

B
Wh
Pi/B
B
Re
EXTEND
RETRUCT
Br
Re
HORN
Release switch for safety device
(EARTH)
(EARTH)
B
Or/Ye
Wh
B
B
Ye
B
Wh
B
Br/B
Br/BL
Gr
G
Gr
G/Re
BL
Or
BL/Gr
Or/Gr
Ye
Br
Ye/BL
Br/Re
Pi
Wh/B
Pi/Ye
Wh/BL
Re/B
Vi/Re
STOP
Re/B
Re
G
Wh
B
Gr
G
Ye
B
Or
G
Pi
B
BL
G
BL
B
Wh/B
Gr/B
Ye/B
Or/B
Pi
BL/B
Br/B
Gr/Wh
B
B
Wh
B
Wh
B
Wh
B
Wh
B
Wh
B
Wh
B
Wh
B
Wh
B
Re
B
G
Lg
G
Re
HORN RELAY(N.O.)
BL
Sk
Or
BOOM STORAGE
Br
Re
HORN
Re/Wh
HOOK STORING
B
Re
Re
Pi/B
BL/Vi
Ye/Br
Re
EMAGENCY STOP
CONTROL BOX
RESET SW
Re
Or
POWER SUPPLY(MAIN)
POWER SUPPLY(RADIO CONTROL)
Valve for carrier
BL/Vi
G/BL
Br
Re
G
B
Br
Or
Or
Re
B
B
Br/Ye
B
B/Ye
Re/B
Gr/Pi
Or/Gr
C.O.
Outrigger monitor
Limit Switch
Gr/B
Pi
EXTEND
OUTRRIGER(4)SW
RETRACT
ENGINE
Gr/B
Vi
Wh
Re
N.O.
OUTRRIGER MODE
BUZZER
OUTRRIGER MODE
LAMP
Or
Re
Re
Or
B
Re
Gr
B
Br/Gr
Wh
MODE LAMP
Re
Wh
Gr
B
Re/Wh
Gr
B
Re
GND
GND
POWER SUPPLY(SOLENOID)
Re
G
Or/Ye
B
Or/Wh
OUTRRIGER(1)EXTEND
OUTRRIGER(1)RETRACT
BL/Gr
Or/Gr
Pi/Ye
Wh/BL
MAINCONTACT
Speare power supplly

Re
B
BL/Wh
BL/Or
OUTRRIGER(2)EXTEND
BOOM LOWER
Re
Re
B
BL/Wh
G/Ye
MODE LAMP
Lg
LVDT 2 ACCELERATOR 1 OUTRRIGER(1)EXTEND

LVDT 2 ACCELERATOR 2
OUTRRIGER(1)RETRACT
BOOM RAISE
Vi
Pi
RADIO CONTROL MODE
Re/B
B
Pi
B
Pi
1+
122 DERRICK 1
2 DERRICK 2
Re/BL
Wh/Vi
HOOK RELIEF
LVDT
LVDT
LVDT
LVDT
LVDT
Re/BL
Wh/Vi
B
Pi
B
Pi
Re/BL
Wh/Vi
B/Pi
Vi/Wh
G/Wh
Re/BL
Wh/Vi
Or/Wh
BL/B
Re
Re/Wh
Re
DIGITAL SIGNAL(-)
SPEAKER(+)
DIGITAL SIGNAL(+)
OVERWINDING DETECTOR
POWER SUPPLY (TRANSMITTER)
SAFTY DEVICE RESET SW
GND
OPERATION SIGNAL
Re
B
a b
Wh/Pi
BL/Ye
Re/Ye
B/Gr
Or/Gr
REMOTE CONTROL
(TRANSMITTER)
Br/Ye
Re
B
G/B
Br
Ye
Wh
Gr
RELAY BOX
control box
STOP
ALARM
OVERWINDING SIGNAL
Re
BZ
Or
Or
ALARM
+5V
BOOM LENGTH
BL/Re
0V
BL/Re
B
B
B
Re
Re
Re
Re
Re
Re
Re
Ye
Gr
Gr
Ye
Ye
Gr
Gr/B
Wh
B/Wh
B/Wh
Gr
Gr
B/Wh
Ye/B
Ye
Wh
Wh
Re
BL
G
Wh/Ye
Wh/Ye
Gr
Wh/Gr
Lg
Lg
LOAD DISPLAY UNIT
SLIP RING
Lg
OVER FRONT HOISTING
OVER FRONT HOISTING
BL/Wh
LEAVING MINIMUM WIRE ROPE
POWER SUPPLY
(+)DEGITAL SIGNAL
(-)DEGITAL SIGNAL
Re/Wh
OVERWINDING SIGNAL
ALARM
STOP
+5V
D-IN
CLK
LOAD
GND
BL
BL
Re/B
Gr
Pi
Re/B
Re/B
Re
Wh/B
Wh/B
Wh
BOOM
LENGTH
SENSOR
Gr
GND
Re
POWER SUPPLY
RS485(+)
BOOM ANGLE
Br
Br
OVER FRONT HOISTING

STOP
OVERWINDING SIGNAL
(+) Ye
DEGITAL SIGNAL
Ye
Ye
(-) Wh
DEGITAL SIGNAL
Wh
Wh
CORD REEL
Ye
Ye
(+)
DEGITAL SIGNAL
Wh
Wh
(-)
DEGITAL SIGNAL
GND
THREE COLOURED LAMP
Re
Re
Ye
Ye
BL
BL
Br
Br
Wh
Wh
12
B
Wh
Re/Wh
Ye/B
Wh
Gr
STOP
ALARM
To relay box
BL
Re/Wh
Wh/Ye
Or
BL/Wh
Power supply
B/Ye
Relay for alarm signal

BL/Wh
B/Gr
Wh/Gr
B/Gr
Rest switch for safety device
Re
Or/Ye
Or/Ye
Re
B
Or/Ye
B
Or/Ye
Rest switch for ML device
BL
Wh
B
Ye
Re
Ye
Re
Br
Or
Or
Gr
Wh/Ye
Wh/Ye
Wh
Gr/Re
Gr
Br
BL/Wh
Sky
Pi
G
Or
Re
B
Outrigger
Horizontal Length max.
Pi
Wh
Or
Br
Re
B
Outrigger4
Wh
Pi
Br
Or
Re
B
Outrigger2
Pi
B
Or
B
Re
B
Outrigger3
(EARTH)
Limit switch
Wh/Ye
Power supply for ML
Re
Re
Re
Re/Wh
Relay for stop signal

Br
Or
Re
stop
Wh/Gr
Re
Re
N.C.
B/BL
Sky
G
B/Ye
Relay for stop signal
Re
Wh
B
Re
Re/Wh
BL/Wh
Re
Re/Wh
OVERWINDINGDETECTOR
OVERWINDING
DETECTOR
Limit switch
for leaving minimum wire rope
To relay box
LOAD CELL
+5V
SIGNAL
0V
SIGNAL
POWER SUPPLY
BOOM
ANGLE
SENSOR
Wh
RS485(-)
LOAD CELL AMP

Re
Re
B
Power supply
To stored boom detection
Or/Ye
To relay box
26.1 ELECTRIC WIRING DIAGRAM ( CRANE )
Electric wiring in control seat part
Operation switch panel

left side

under side
Operation switch panelleft side

Operation switch panelright side
Crane
Vertical
Horizontal
Retruct
Outrigger
Outrigger
AUTOSTOP
RELEASE
2
On
Head light
Radio contoller selector switch

Radio control Manual
To earth
To earth
To outrigger buzzer or to radio control
To control valve
HorizontalOutriggerVertical
Solenoid selector valve
To Relay
ON
ON
To relay or to diode
Hook
To outrigger
mode indicator
lamp
To slip ring
To Relay box
Rest switch for control box
Store
SAFTY DEVICE
RELEASE 1
SAFTY DEVICE
RELEASE 2
reset
Horn
Off
reset
ML STOP
RELEASE
Rest switch for safety device
Relay
AUTO STOP
INTERLOCK
AUTOSTOP
RELEASE
1
Voice switch
Off
Outrigger
Extend
On
LED
Automatic stop for over windiding reset switch
Outrigger
Extend
Retruct
reset
ML STOP
RELEASE
AUTO STOP
INTERLOCK
Control box
Stored boom
Outrigger operation
LED
Extend
Retruct
reset
Outrigger pin 1
Outrigger pin 2
Outrigger pin 3
Outrigger pin 4
Extend
Retruct
V/H
OutriggerVertical
Operation mode switch
Outrigger
Operation switch panelunder side
Relay
OutriggerHorizontal

right side
To outrigger monitor
limit switch
Power supply
( Carrier side )
To Key switch box

( Carrier side )
To limit switch to detect

boom not being stored
To speaker
TO interlock
Relay
for crane-crawl opration
2
C/O
TO solenoid of
carrier side
Emergency stop
Emergency stop(Head light side)
To earth
To relay box
Power supply fuse

Control box
Ground
Solenoid valves for operating outrigger
Sky
Connector of Emergency stop
Switch panel
Switch panel( Key switch type )

( Turnover prevention device)

Crawl position
Crane position
Ground
Sky
Sky
Ground
Sky
It connects with the accelerator

cylinder of the control valve.
Ground
It connects with the accelerator pedal.
Electric wiring in control valve part
Relay
RB
RB 3COLOR
LAMP
RB
RB
To slipring
OD
POWER
SUPPLY
ML STOP
1
OD
EARTH
EARTH
To degital load metor
To 3 Color lamp
POWER
SUPPLY
To
To
AC
POWER
SUPPLY
To
AC
UL
HR
ML STOP
2
To
3COLOR
LAMP
DL
INDICATOR
RB
Diode
OUT EXT
DETECTION
ML STOP
2
Sky
Ground
Sky
Ground
Relay box
Sky
Ground
Sky
Ground
Horn
Buzzer
for Outrigger
Position of hose
Telescoping
Slewing
Derrick
Hoist
Engine
Air cleaner element
Fuse box
Solenoid
to stop engine
Sky
Muffler
Filling
port
Ground
Oil fillter element
Water separator
Warning lamp and Fuse box

Warning lamp
Hour meter
Starter switch
FUSE BOX
Wiring for warning lamp
BOX
EARTH
4 5
7 8
FUSE BOX
10
20
20
15
10
20
10
1 2
15
3
10
30
It connects with
the accelerator pedal.
Water separator
Oil fillter element

Drain plug
Air cleaner element
Alternator
b
b
Re
a
a
Re
Re/Wh
TERMINAL B
PREHEAT
ELECTRIC WIRING DIAGRAM ( Engine part )

b
Re
Re
a
a
Re/Wh
W370CD
Carrier side
Re
b
b
Re
B/BL
Gr/B
B/BL
Crane sideGr/B
B R Acc
R1 R2 C
OFF
ON
START
Engine start relay

N.O.
N.C.
Wh/Re
Wh/Re
Re/Wh
A CC
Or
BR
R2
1 2 3 4
3 4 5 6
S R L P E
Wh/BL
Wh/Gr
Ye
Wh/Ye
B
B
Re/Gr
Gr/Wh
BL/B
Wh
Re
R1
BL
Re
Ye/Gr
Warning lamp
for air cleaner clogging
Re
Oil pressure
switch
c
BL/Wh
d
Re
Re/Ye
Warning lamp
for alternator(for charging)
Pilot lamp
indicating preheating engine
Glow lamp
BL/Re
Ye/Gr
c
Wh
d
Fuse
e G
f B
Re/BL
B
B
Battery
Air cleaner switch
Wh/Ye
Ye/Gr
Oil temperature
switch
Oil tank
Water temperature
switch
Br/Wh
B/BL
Re
a
BL/Re
b
B/Ye
Switch
Engine
Fuse
Warning lamp
for hydraulinc oil temperature
Alternator
Solenid
to stop engine
e
Re/BL
f
Starter
BL/Re
Re
BL/Wh
Warning lamp
for circulating water temperature
Re
a
BL
b
Re
Br
B/Wh
B
BL
Warning lamp
for engine lubricating oil pressure
Wh
Fuse
B
Hour meter
b B
1 2 3 4
Fuel pump
Re/Ye
Solnoid
Safety relay
Or
BL BL
Glow timer
Starter switch
BL
L
Re/B
Glow relay
Power supply on crane side Glow
20A
Wh/Ye
15A
Or/Gr
Re/BL
15A
Wh
Br
Wh
Wh/BL
Re
Wh
Wh
Gr/Wh
BL
Gr/Wh
20A
Re
B/YeG
BL/B
Re/Gr
Re
B/Wh
Gr
20A
b a
b a
B/Wh
Ye
30A
B/Wh
B/Wh
Gr
Wh/BL
Gr/Wh
Emagency stop switch
Wh/Re
10A
B/Ye
B/Wh
3A
Br/Wh
Wh/Re
Gr
Wh/Re
Re
Re
Re
Wh/B
Engine stop relay
Wh/Re
Wh/B
Re
Re/Wh
Carrier side
a
Or
Re
b
b
Re/Ye
Re
a
a
a
a
Re/Wh
Re
Re
Gr/B
B/BL
a
a
Re
b
b
Gr/Re
b
b
Re
Gr/B
B/BL
ELECTRIC WIRING DIAGRAM

Power unit option
Engine start relay

N.O.
N.C.
Wh/Re
b a
b a
BL
L
Re
3 4 5 6
S R L P E
Wh/BL
Wh/Gr
Ye
Wh/Ye
B
1 2 3 4
B
Re/Gr
Gr/Wh
BL/B
B
Fuel pump
Or
Safety relay
Glow timer
Wh
Re/BL
Wh
Re
Br
Glow relay
1 2 3 4
Wh/B
Starter switch
R 2 R1
Glow
Wh/Ye
Wh/BL
Wh
Gr/Wh
Re
Gr/Wh
20A 15A 15A 20A
Wh
Gr
Gr/Wh
20A
Wh
B/Wh
Ye
10A 30A
BL
B/Wh
Gr
3A
Br/Wh
Wh/Re
Re
B/YeG
BL/B
Re/Gr
ACC C
Wh/Re
B/Wh
B/Wh
Wh/BL
Emagency
stop switch
Re/Wh
B/Wh
Re
Re
Re
Power supply on crane side
Or
B/Ye
Engine stop relay
Wh/B
Or/Gr
Wh/Re
BR
BL BL
BL
c
d
TERMINAL B
PREHEAT
B R Acc
R1 R2 C
e
f
Starter
Oil pressure switch
BL/Wh
Re
Re/BL
Ye/Gr
Wh
Engine
Fuse
BL/Re
Re/BL
Switch
Re/Ye
Re/B
B
Power unit
Air cleaner
Switch
33W
S
T
50/60Hz
X
Y
Z
X
Y
Z
Gr
BL
Gr
BL
Wh/Ye
Water tempernature
switch(105
G
B
Oil temperature
switch
Oil tank
Glow lamp
a
Solenid
Solenid to stop engine

BATTERY
BL/Re
ON
START
Alternator
Re
Pilot lamp
indicating preheating engine
OFF
BL/Wh
Warning lamp
for alternator(for charging)
R
B
a
b
Re
Br
B/Wh
B
Re
BL
Warning lamp
for hydraulinc oil temperature
Re
BL/Re
e
f
Br/Wh
B/BL
c
d
Fuse
BL
BL/Re
Warning lamp
for circulating water temperature
Re
Re/Ye
a
b
Re
Warning lamp
for engine lubricating oil pressure
Warning lamp
for air cleaner clogging
Wh
Fuse
B
Hour meter
Ye/Gr
Ye/Gr
B/Ye
Re
Re/Ye
Gr
BL
BL
B
(2.0)
Wh
EM
U Re
V Wh
W B
V
W
Power unit
(7.5kw 15/14A)
Controlbox
for Power unit
50/60Hz
R
S
T
E
X
Y
Z
Electric diagram of control box
E
U
V
W
R1
R
S
T
X
Y
Z
T1
ELB
Power unit
EM
THP(Set15A)
Converter
F1
F2
Earth
U
V
W
B
6
QER
4
3
S1
MCP
RC
400 R0
SC
0
Converter
P +
N -
SC
Earth
PBL
00
RC
PBS
QER
01
(1)
MCP
04
FUSE
BREAKER
THP
03
MCP
GL
EM Ry
Wh
(5)
02
FUSE

Converter
R1
R
S
T
X
Y
Z
T1
ELB
THP(Set15A)
F2
MCP
RC
400 R0
SC
0
Converter
P +
N -
SC
Earth
PBL
00
RC
PBS
QER
01
(1)
MCP
Wh
F1
Earth
U
V
W
B
6
QER
4
3
S1
04
EM Ry
(5)
02
THP
03
MCP
GL

Converter
R1
R
S
T
X
Y
Z
T1
ELB
THP(Set15A)
F2
MCP
RC
400 R0
SC
0
Converter
P +
N -
SC
Earth
PBL
00
RC
PBS
QER
01
(1)
MCP
Wh
F1
Earth
U
V
W
B
6
QER
4
3
S1
04
EM Ry
Converter
(5)
02
THP
03
MCP
GL
Power Unit (400V type )

S/N 37W0117
Earth
Harness
(Carrier side)
Harness
Harness
(Carrier side)
Emergency
stop button
Re/B
Re/Ye
Re/Ye
Switch for speed select

RelayDiode
Power Supply
for Crane
V1
W2
Relay
W1
V2
Motor
P
EM
DC12V
EMARGENCY
TH
U1
DC12V
DC12V
Emergency
stop button
Harness
V2
KEYSW
Harness
Earth
EARTH
EARTH
Contorol box
for power unit
KEYSW
EARTH
EAR
FUSE
2NDSW
EARTH
Diode
Harness
Power Unit (400V type )

S/N 37W0120
Harness
(Carrier side)
Emergency
stop button
Re/B
Re/Ye
Re/Ye
Switch for speed select

RelayDiode
Power Supply
for Crane
Harness
TH
EARTH
EARTH
Contorol box
for power unit
DC12V
EM
DC12V
EMARGENCY
DC12V
Relay
Harness
KEYSW
Tag block of Motor
Emergency
stop button
KEYSW
EARTH
EAR
FUSE
2NDSW
EARTH
Diode
Harness
30.1 Inspection for sinking of cylinder

The load is lowered.
Set the conditions for
sinking in the crane.
Stop the engine,
change the lever and
remove the pressure.
Then, start the test.
The outrigger
cylinder sinks.
Does the oil come out

when removing the
pipe at retracting
side?
YES
Inside leakage occurs.

The packing is
damaged.
The tube is scratched.
NO
The derrick
cylinder sinks.

when removing the
hose at lowering side?
YES

when removing the
hose at retracting
side?
YES

when removing the
hose at raising side?
The counterbalance
YES valve malfunctions.
The seat surface is
damaged.
Foreign matter is caught
by the seat surface.

when removing the
hose at extending
side?
The counterbalance
YES valve malfunctions.
The seat surface is
damaged.

The packing is
damaged.
NO
YES Check the pilot.

The seat surface is
damaged.

The packing is
damaged.
NO
The telescoping
cylinder sinks.

when removing the
pipe at extending
side?
. Inspection of derrick cylinder

(1) Preparation before inspection
Raise booms to an angle of approx. 30.
Put a mark on the rod with a felt pen (refer to Fig. 1).
In order to release pressure remained in the derrick system, stop the engine and shift the manual lever
for raising/lowering of booms.
(2) Starting inspection

Remove the lowering hose to check if oil overflows continuously out of the cylinder port of lowering side.
At he same time, check also that how far the rod shifts.
If no oil flows out of the port of lowering side, the cylinder is normal.
Next, remove the raising hose, and if oil overflows continuously out of counter-balance valve port of raising
side, there may be faulty on the seat surface of counter-balance valve (refer to Fig. 3).
In addition, check how far the cylinder sinks simultaneously.
Caution:
In order to release pilot pressure in the lowering side, be sure to remove the raising
hose after the lowering hose has been removed (refer to Fig. 2).
If oil overflows out of the port on lowering side, it suggests internal leakage in the cylinder.
Be sure to measure the how far each boom sinks as it is an important point for judging that it is
Put a mark on the rod with felt pen
hose
Lowerring
hose
Risinghose
Fig2
Counterbalancevalve
Fault in seat surface
Fig1
Load
Fig3
30.3 INSUPECTION PROCEDURES WHEN CYLINDER SINKE

Inspection of telescoping cylinder
(1) Preparation before inspection
Allow booms to be horizontal and extend them fully to put a
mark on each boom section (refer to Fig. 1).
Raise booms to their maximum to sling a load.
In order to release pressure remained in the telescoping system,
stop the engine and shift the manual lever for telescoping
booms.
Put a mark
on each boom
(2) Starting inspection

Remove the retraction hose to check if oil overflows
continuously out of the cylinder port of retraction side.
At he same time, also check that which boom section sinks
how far to grasp condition of booms as a whole.
If no oil flows out of the port of retraction side, the cylinder is
normal.
Next, remove the extension hose, and if oil overflows
continuously out of counter-balance valve port of extension
side, there may be faulty on the seat surface of counter-balance
valve (refer to Fig. 3).
In addition, check how far boom3 sinks simultaneously.
Caution:
In order to release pilot pressure in the retraction side,
be sure to remove the extension hose after the
retraction hose has been removed (refer to Fig. 2).
Since overflowing oil out of the port on retraction side
means internal leakage in the cylinder, check tele1 and
tele2 separately.
Be sure to measure the how far each boom sinks as it is
an important point for judging that it is normal or
abnormal.
Fig1
Counterbalancevalve
Fault in seat surface
Fig2
(3) Inspection of tele1

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).
booms.
Remove the retraction hose.
If oil overflows out of cylinder port of retraction side and
boom2 sinks, there may be internal oil leakage in tele1.
(4) Inspection of tele2

Allow booms to be horizontal and extend them fully to put a
mark on each boom section (refer to Fig. 1).
booms.
Remove the retraction hose.
If oil overflows out of cylinder port of retraction side and
boom3 sinks, there may be internal oil leakage in tele2.
The same procedures in checking boom sinkage are applied for
5-section boom
Be sure to check the boom sections one by one reliably.
30 - 3
Fig3
30.4Procedures for checking outriggers

for sinking
Raise vehicle by 50mm.
In case where outrigger sinks during crane operation

Test 1
Putting the crane on a solid level ground, extend the outriggers
to their extremes and raise the crane mounted vehicle
by 50mm from the ground to check the sinking condition.
1. Stop the engine to release pressure remaining
in the outrigger circuit.
2. Disconnect all 8 hoses connecting to the W.P. check valve.
3. Mark each rod of 4 outrigger cylinders.
4. Measure the movement of each rod.
Retract
Mark here .
Extend
Test 2
Exchange the W.P. check valve measuring maximum
sinking and the one measuring minimum sinking to
repeat the same procedures of Test 1 above.
W.P. check valve
Starter key
Judgment by comparison
When position of sinking is reversed in Test 1 and Test 2;
W.P. check valve is faulty.
If in failure, oil continuously comes out of the cylinder
for extension.
When position of sinking has not changed;
Cylinder is faulty.
Outrigger mode indicator lump
Caution
When a cylinder has been replaced of, re-adjustment of
the load cell amplifier is needed.
How to release pressure out of outrigger cylinder circuit

Be sure to operate by using the switch and the lever illustrated
in the picture.
Even if outriggers are controlled via radio controller, pressure in
the circuit will not be released as the engine has been shut off so
that oil pressure will not be generated and as a result the lever
controlling outrigger will not move.
1. Shift the lever to CRANE position to start the engine.
2. Put the control mode switch at OUTRIGGER position.
3. Extend outriggers to allow each cylinder to extend to its
stroke end and relief it.
4. Stop the engine.
5. Turn ON the starter key again to light the outrigger
mode indicator lamp.At this time, do not start the engine.
6. Turn outrigger control switches through to STORAGE
side to throw the outrigger control lever. Release of hydraulic
pressure can be felt . by holding the hose on extension side
7. Turn outrigger control switches through to
EXTENSION side to throw the outrigger control lever.
Release of hydraulic pressure can be felt by holding the hose
on retraction side.
30 - 4
Outrigger lever
Operation mode switch
Outrigger control switch
MAINTENANCE AND INSPECTION OF CRANE
31 Replacement of wire
rope (for winding-up)
Wire rope is an expendable article and it will
be damaged and its strand wires are broken to
allow it to be thinner through a long period of
operation.
Replace the rope according to following criteria.
1. Replacement criteria
1.
A rope in which amount of broken strand

wires (except filler wires) comes to more
than 10% within a pitch of twist.
Replace the wire ropes intended for use with
this crane if 13 pieces of strand wire have
been broken within a pitch of twist.
2.
A rope being kinked.
3.
A rope from which its diameter has

decreased by more than 7% of the nominal
3
Wire rope
diameter
diameter.
For example, if wire rope with a nominal
diameter of 8mm is used, replace it when the
diameter becomes 7.5mm.
Refer to the section 17. MAJOR SPECIFICATIONS, for length and construction of the
wire rope for winding-up.
4. A rope which has been deformed and/or

corroded excessively.
4
Be sure to replace a wire rope when it
comes under the criteria, item 1 through 4,
illustrated above.
CAUTION
Wear leather gloves when
replacing wire ropes.

2. How to replace wire ropes
1.
Refer to the figure in the left for how to

hook the wire ropes for winding -up and for
where the weight for overwinding alarm is to
be mounted.
Wire clip
Overwinding
alarm detector
Ring
Wedge
Wire rope for

overwinding alarm
Weight for
overwinding
alarm
Refer to the figure in the left for how to

attach the hook.
Boom top
Front of boom
Guide
Higher side is
to be in front

2. How to fix wire rope end
Wire rope end
40mm
a
Notch
Wire clip
(Pay attention to
mounting direction)
50mm
When passing the wire rope end through

the wire socket, be sure to pass it as indicated
by the arrow mark on the socket.
If it is passed from the opposite direction,
service life of wire rope shortens as the wire
rope is kept bent all the time.
Do not forget to mount the wedge and the
wire clip as illustrated in the figure in the left.
Leave the wire rope end to allow a distance
from the notch to the rope end by more than
40mm as illustrated in the figure as a.
Arrow mark
Wedge
(Wire rope diameter: 8mm)
Pass the pin through with the wire socket

Projection on upper part
of wire socket
held with your hand and tighten it with the

bolt securely.
Stopper
If rope end is left by
more than 40mm (as
a illustrated above),
rope end is visible
through this hole.
If not, adjust the
distance of rope end.
Pass the pin through and
tighten it with bolt securely.

3. How to correct twisted wire ropes
Wire ropes tend to turn in untwisting direction when they are under tension.
If two or more wire ropes are hooked together, they tend to be twisted particularly while
they are new.
The twist will decreases as the ropes are getting fit to the crane.
If wire ropes are twisted, correct them as follows:
1.
Unload the hook.
2.
Extend the boom fully.
3.
Raise the boom to an angle of approximately 65.
4.
Unwind the hook until it comes close to

the ground.
4-rope hooking
Wire socket
5. Check how many turns the wire rope has

been twisted.
6.
Direction that rope
is untwisted
Direction that
rope is twisted
Wind up the hook and retract the boom to

be on a stored condition.
7.
Remove the wire socket and turn the socket in the untwisting direction by as many
turns as the wire ropes have been twisted
multiplied by the number of wire ropes being
hooked.
However, remember that the wire socket may
be turned up to 4 turns at a time.
8.
(Note) Rotate wire socket to the direction opposite to wire ropes have
been twisted.
Attach the wire socket and repeat winding

up and down the rope 2 or 3 times between
both extremes.
Then, check if twist of the wire ropes is corrected.
If they remain twisted, repeat the procedures
shown above.
32 Replacement of
expendable parts
1. Replacement of gaskets and seals
for each cylinder
Although timing of replacement of a part
varies according to how frequently the crane
has been operated, replace gaskets and seals
used in each cylinder after every 3 years of
operation (period during which crane has not
been operated is included) in order to operate
the crane safely.
Ask a local UNIC authorized service shop for
replacement of gaskets and/or seals.
Sliding plate
2. Replacement of sliding plate of

boom
Replace it every 3 years.
3. Replacement of brake shoe of

hoisting winch
Replace it every 3 years.
Brake shoe
4. Cleaning and replacement of filter

in the control valve
If the filter built in the control valve is
clogged up, radio remote control operation
and acceleration interlocking operation cannot be carried out.
Clean it by blowing air once after one year of
use and replace it if it has been clogged up
remarkably or it has been damaged.
Filter
WATER SUPPLY AND LUBRICATION TO CARRIER
33 List of recommended lubricant

1. Use the engine oils as below:
Classification
Depending on atmospheric temperature
Rating to be applied
-30
-20
Engine oil
Diesel engine oil
of CD class
SAE5W
-10
10
20
30
SAE30
SAE10W
SAE10W -30
The selection of engine oil is very important to a diesel engine.

If an unsuitable oil is used, or oil change is neglected, it may result in damage, and a
shorter engine life.
Use oils that meet API Engine Service Classification CD.
2. Use the recommended grease for lubrication as below.

Chassis grease
Use NLGI No. 2 grade for most temperatures.
Use NLGI No. 1 grade for extremely low temperatures.
3. Use the fuel as specified below. (Diesel fuel oil)

Use ONLY clean, high-quality fuel.
Use Grade No. 2-D fuel above 4C.
Use Grade No. 1-D fuel below 4C.
4. Use an antifreezing solution for coolant

Antifreezing solution functions to prevent the water from freezing and the cooling system
from rusting.
Use an antifreezing solution if atmospheric temperature goes below the freezing point.
Use Long Life Coolant (LLC) as the antifreezing solution.
The Long Life Coolant can be used throughout the year.
Replace the Long Life Coolant once every other year (in the season of autumn or fall).
(Follow the instruction of the manufacturer on how much the antifreezing solution should
be mixed with water.)
CAUTION
Use the softened water with less impurity such as tap water for cooling water.
Do not use well water and river water as cooling water.
Use of coolant which too much of antifreezing solution mixed with

water allows the engine to be overheated earlier.

5. Hydraulic oil is the same as the oil used in the crane.
6. Use the gear oils for the reduction gears of crawling motor .
LUBRICATION TO CRANE
1. List of recommended lubricants

Use the UNIC genuine hydraulic oils listed below as hydraulic oil for the crane.
Use industrial-type hydraulic oil
ISO VG 46 for temperatures above 32F.
ISO VG 32 for temperatures below 32F.
Brand
Petroleum Maker
ISO VG 32
ISO VG 46
ESSO
Spinesso 32
T eresso 46
MOBIL
Mobil DTE 32
Mobil DTE Oil Medium
CALTEX
Spindura oil 32
Rando Oil 46
SHELL
Shell Tellus Oil 32
Shell Tellus Oil 46
Use the recommended lubricants listed below as gear oil for lubrication.
Aplication
Reducer for winch
Petroleum Maker
Shell
Brand
Shell Spirax EP 90
Use API service GL-4 gear oils.

(Refer to the followings)
Reducer for slewing
gear
ESSO
MOBIL
CALTEX
SHELL
Standard gear oil 90

Mobilube GX 90
Universal Thuban SEA 90
Shell Spirax EP 90
Use the recommended greases listed below as grease for lubrication.

(a) Chassis grease
Use NLGI No. 2 grade for most temperatures.
Use NLGI No. 1 grade for extremely low temperatures.
(b)Molybdenum grease
Use NLGI No. 2 grade.
Petroleum Maker
Brand
ESSO
Beacon G2
MOBIL
Mobilplex Special
CALTEX
Molytex Grease EP2
SHELL
Retinax AM
34 Filling water and lubrication chart(URW376C)
Fuel
Service interval
Where to lubricate
No. of
part
Lubricant
Initial: Replace after 100 hours

Engine (4.0 liters)
After : Replace every 250 hours
Engine oil
Initial : 30 hours, Whenever nec- Tension adjustment of

essary
rubber crawler
Chassis grease
Replace antifreezing solution

(LLC) every 2 years
Antifreezing
solution
Hydraulic oil
Initial: Replace after 3 months

After : Replace 2 years
Replace every 1000 hours
Radiator (5.5iters)
Hydraulic oil tank
(70 liters)
Tool
Grease pump
Reduction gears of crawl- 2 (Right/ Diesel engine oil
ing motor (0.7 liters)
Left)
or Gear oil
Refer to MAINTENANCE AND INSPECTION OF CARRIER for replacement procedures.

Fuel
Light oil
Fuel tank capacity
40 liters
34 Filling water and lubrication chart (URW546C)

4
Fuel
OUTRIGGER
NOT MAX EXT.
SELECT
SET
Service interval
Where to lubricate
Initial: Replace after 100 hours

After : Replace every 250 hours
Engine 4.0 liters
No. of
part
Lubricant
Tool
Engine oil
Initial : 30 hours, Whenever neces- Tension adjustment of

sary
rubber crawler
Chassis grease Grease pump
Replace antifreezing solution (LLC)

Radiator 5.5liters
every 2 years
Antifreezing
solution
Hydraulic oil
Initial: Replace after 3 months

After : Replace 2 years
Hydraulic oil tank

70 liters
Replace every 1000 hours
Reduction gears of crawl- 2 (Right/

Gear oil
Left)
ing motor 0.7 liters
Refer to "MAINTENANCE AND INSPECTION OF CARRIER" for replacement procedures.

Fuel
light oil
Fuel tank capacity
40 liters
34-2
35 1 Lubrication chart(URW376C)
6-section boom
Service
interval
Daily
Weekly
No. of
Lubricant
Tool
part
5 Molybdenum grease Manual appli Boom slide plate (Underside & side face of boom
cation
sections, , , and )For 6-section boom
Grease pump
Molybdenum
grease
Boom
slide
plate
(Upper
side
of
boom
section
)
2
Grease pump
1 Chassis grease
Boom foot pin
Grease pump
1 Chassis grease
Upper support pin of derrick cylinder
1 Chassis grease
Lower support pin of derrick cylinder
Grease pump
1 Hydraulic oil(up to mid Oil tank (70 liters)
dle of level gauge)
Where to lubricate
Winch drum gears

Slewing gears
Winch reduction gears (Approx. 1.0 liter)

Slewing reduction gears (Approx. 0.7 liters)
Wire rope
Slewing bearings
Monthly Wire rope for boom extension
Outrigger fulcrum pin
Outer box support
Outrigger vertical cylinder (Bracket side)
Outrigger vertical cylinder (Outer box side)
1
1
Chassis grease
Chassis grease
1
1
1
2
1
4
4
4
4
Gear oil
Gear oil
Rope grease
Chassis grease
Rope grease
Chassis grease
Chassis grease
Chassis grease
Chassis grease
Grease pump
Manual application
Spray gun
Grease pump
Spray gun
Grease pump
Grease pump
Grease pump
Grease pump
35 Lubrication chart (URW546C)

8
10
6-section boom
13
1
11
7 3
12
16 14
OUTRIGGER
NOT MAX EXT.
SELECT
SET
17
Service
interval
No. of
Lubricant
part
Molybdenum grease
6
Boom slide plate (Underside & side face of boom sections , , , , and ) For 7-section boom
Molybdenum grease
2
Boom slide plate (Upper side of boom section )
Chassis grease
1
Boom foot pin
Daily
Chassis grease
1
Upper support pin of derrick cylinder
Chassis grease
1
Lower support pin of derrick cylinder
1
Hydraulic oil (up to mid Oil tank (70 liters)
dle of level gauge)
1
Chassis grease
Winch drum gears
1
Chassis grease
Weekly Slewing gears
Where to lubricate
Winch reduction gears (Approx. 1.0 liter)

Slewing reduction gears (Approx. 0.7 liters)
Wire rope
Slewing bearings
Monthly Wire rope for boom extension
Outrigger fulcrum pin
Outer box support
Outrigger vertical cylinder (Bracket side)
Outrigger vertical cylinder (Outer box side)
35-2
1
1
1
2
1
4
4
4
4
Gear oil
Gear oil
Rope grease
Chassis grease
Rope grease
Chassis grease
Chassis grease
Chassis grease
Chassis grease
15
Tool
Manual application
Grease pump
Grease pump
Grease pump
Grease pump
Grease pump
Manual application
Spray gun
Grease pump
Spray gun
Grease pump
Grease pump
Grease pump
Grease pump
36 Lubrication
1. Replacement of gear oil
(Winch reduction gears and Slewing
reduction gears)
Winch reduction gears
Air enters in and out of the gear case so

that dirt and moisture are brought in the
gear case.
In addition, since hydraulic equipment
gradually wears to produce worn particles,
replace gear oil 6 months after the start of
operation.
(Draining oil)
After that, replace gear oil:

Once a year for winch reduction gears,
and
Once every 2 years for slewing reduction gears.
Drain plug
CAUTION
(Filling oil)
Gear oil
filling port
Replace gear oil after oil temperature has dropped.
Oil level gauge
Fill the gear oil for winch reduction gear

to a middle of oil level gauge (approx. 1.0
liter).
Slewing reduction gears

Oil level plug
Gear oil
filling port
Standard
level
range
Approx.
0.7 liters
(Draining oil)
Drain plug
(Filling oil)
When carrying out inspection before crane operation, use photocopy of this sheet.
CHART FOR INSPECTION BEFORE STARTING CRANE OPERATION

Date:
Weather: (Fine, Cloudy, Rain, Snow)
Place
Device
Operator
Inspect for:
Check
Device
Inspect for:
Hydraulic pump
Tightness of fitting,Oil leak,

unusual noise
Frame
Crack, tightness of bolts and missing
Hydraulic oil tank
Oil level, oil leak
Automatic stop for

leaving minimum
wire rope
It should make an automatic stop for

unwinding when remaining wire rope
on the drum come to 3 turns.
Outrigger
Gravity-descent, operating condition,

Deformation, damage, oil leak, crack
Radio controller
Operating condition,
Hoist winch
Operating condition, braking

performance, irregular winding
Overturn prevention
device
Alarm, automatic stop, damage in

wiring, tightness of detector
Swinging device
Operating condition, oil leak
Digital load meter
Load indication on no-load, damage

in wiring
Derricking boom
Operating condition, oil leak, fitting of

foot-pin
Overload prevention Power lamp should light, error lamp

device
should go off, damage in wiring
Telescoping boom
Operating condition, oil leak, deformation, crack, fitting of mounting pin
Hook
Rotation of hook, operating condition

of retainer
Wire rope
Damage, Fastening at rope end
Rubber crawler
Tension, damage, crack
Over-winding alarm
Operating condition, alarm sound
Wheel sprocket
Tightness of bolts
Load meter
Oil leak, operating condition
Track roller
Tightness of nuts, oil leak
Alarm device
Operating condition, alarm sound
Piping
High-pressure hose
Oil leak at each connection, damage
Engine
Automatic storing
hook device
Automatic stop and storing operation
Remaining fuel level, draining water,

engine oil level, cooling water level,
fan belt tension and adjustment,
battery liquid level, unusual vibration,
unusual noise, tightness and damage
in each bolt
Interlocking device
for cranetraveling
lever
Crane will not function when selected

on traveling side.
Traveling will not function when
selected on crane side.
Check
MONTHLY SELF-INSPECTION RECORDS

Check point
What to check for:

Condition of air cleaner element
Contamination of fuel strainer and ignition plug
1 Engine
When carrying out inspection, use photocopy of this sheet. Check

Keep the inspected results for 3 years.
Overhaul
Checked result Measures

Check point
taken
OK
NG
13 Column
3 Frame
Deformation, crack, wear of sliding plate
Hydraulic
oil tank
Hydraulic
5
pump
6 Control valve
8 Swivel joint
Fitting of support pin, sheave pin

Tightness of fitting bolts, nuts, pins, and missing
Tightness of take-up bolts, nuts, and missing
Tightness of telescoping wire, wear, broken strand wire, corrosion
Forwardbackward operation of traveling lever
Specifications: length, thickness
Operation of accelerator lever
Wear, broken strand wire, distortion, kink, corrosion, lubrication

15 Wire rope
Deformation, crack of wire socket
Oil leak from reduction gear in traveling motor
Tight connection to drum, irregular winding, twist
Crack in welded section
Fitting of support pin, tightness of bolts and missing
Oil leak
16 Piping
Damage, aging, crack, twist, dent
Contamination of air breather, return filter, suction filter
Wear, deformation, rotation of hook and lubrication
Operation, unusual noise, oil leak
Gauge mark distance of hook
Tightness of fitting bolts, nuts, and missing
17 Hook
Function, deformation, damage in retainer
Missing knob, peeled off and deteriorated sticker
Tightness of hook screws and looseness of thrust bearing (worn condition)
Oil leak
Tightness of fitting bolts, nuts, pins and missing
18 Load meter
Operation of cylinder, lamp, buzzer
19 Load indicator Missing pointer, damage in indication plate, function
Function, oil leak, damage
Automatic
stop for
20 over-wound
alarm
Function, condition of over-wound detection switch

and alarm sound
Winding-up condition of cord reel, damage in cord,
broken cord
Damage in weight and sling wire
21 Level
Setting condition
Oil leak
22 Alarm
Function, alarm spund
Tightness of stopper mounting bolts, deformation of plate
23 Name plate
Fitting, damage, deterioration
Deformation of outer box, inner box,

suspending bracket of outrigger body
Oil leak from outrigger cylinder, gravity-descent
Operation
Continuity of slip ring, damage in wiring, mounting
Condition of transmitter enclosure
Gear oil quantity, deterioration
Cable connections: tightness, contamination, corrosion

Radio remote
Damage, deterioration, twist of wiring and cables
24 control
Corrosion, deterioration, tightness of contact terminals
Crack in drum, lubrication to gears
Oil leak from accelerator cylinder
Function of each solenoid valve, oil leak
Alarm function when reaction force against outrigger drops
Damage in air breather
Crane operation when reaction force against outrigger drops
Operation of turn-table, unusual noise, lubrication
25
Overturn
prevention

Deformation, wear, damage in load cell
Operation
Telescoping
cylinder
Damage, wear, rotation of sheave and lubrication
Operation, deformation, crack in each lever
10 Swing device Gear oil quantity, deterioration
12
Support of piping
Quantity, contamination, and deterioration of hydraulic oil
11 Derrick cylinder
Tight connection to wire socket, fastening clip at rope end
Damage in stand lever and lock lever

9 Hoist winch
Damage, wear, rotaition sliding plate, missing bolts
Crack, wear, damage in rubber crawler
Effect of stopper pin when outriggers are stored

and extended, deformation of pins
7 Outriggers
Tightness of bolts mounting turntable, missing bolts

14 Boom
Oil leak, crack

taken
OK
NG
Tightness of bolts mounting turntable

Telescoping operation, lubrication
Braking performance
Adjustment A Cleaning C
Tightening T Oil supply L
Crack, deformation
Battery liquid level
Unusual vibration and noise
devices
What to check for:
Fuel leak
Engine oil level and deterioration
2 Traveling
Replacement
Repair
Function
Looseness in upper and lower pins of derrick cylinder
26 3-color light
Oil leak from derrick cylinder, gravity-descent

Automatic stop for Function

27 leaving minimum
wire rope
Mounting of detector switch
Operation
Remarks to be recorded
Oil leak from telescoping cylinder, gravity-descent

Fitting of support pins, missing snap ring
Operator
Crane model
Delivered date
Inspected date
Company in charge of inspection

Inspected by Signature
ANNUAL SELF-INSPECTION RECORDS

Check point
When carrying out inspection, use photocopy of this sheet. Check

Keep the inspected results for 3 years.
Overhaul

Check point
taken
OK
NG
What to check for:
Telescoping operation, lubrication
Contamination of fuel strainer and ignition plug
Deformation, crack, wear of sliding plate
devices
Hydraulic
oil tank
Fitting of support pin, sheave pin
Unusual vibration and noise
Tightness of telescoping wire, wear, broken strand wire, corrosion
Crack, wear, damage in rubber crawler
Specifications: length, thickness
Tightness of take-up bolts, nuts, and missing
Wear, broken strand wire, distortion, kink, corrosion, lubrication

15 Wire rope
Deformation, crack of wire socket
Braking performance
Tight connection to drum, irregular winding, twist
Damage in stand lever and lock lever
Fitting of support pin, tightness of bolts and missing

Oil leak
16 Piping
Crack in welded section
Damage, aging, crack, twist, dent
Oil leak, crack
Wear, deformation, rotation of hook and lubrication
Quantity, contamination, and deterioration of hydraulic oil
Gauge mark distance of hook

17 Hook
Function, deformation, damage in retainer
Tightness of hook screws and looseness of thrust bearing (worn condition)
Tightness of fitting bolts, nuts, pins and missing

18 Load meter
Operation of cylinder, lamp, buzzer
Automatic
stop for
20 over-wound
alarm
Effect of stopper pin when outriggers are stored

and extended, deformation of pins
Function, condition of over-wound detection switch

and alarm sound
Winding-up condition of cord reel, damage in cord,
broken cord
Damage in weight and sling wire
21 Level
Setting condition
22 Alarm
Function, alarm spund
23 Name plate
Fitting, damage, deterioration

Set pressure of relief valve
Deformation of outer box, inner box,

suspending bracket of outrigger body
Oil leak from outrigger cylinder, gravity-descent
Operation
Oil leak
Condition of transmitter enclosure
Tightness of stopper mounting bolts, deformation of plate

Continuity of slip ring, damage in wiring, mounting

Radio remote
24 control
Oil leak from accelerator cylinder
Function of each solenoid valve, oil leak
Gear oil quantity, deterioration
Alarm function when reaction force against outrigger drops
Crack in drum, lubrication to gears
Crane operation when reaction force against outrigger drops

25
Overturn
prevention
10 Swing device Gear oil quantity, deterioration
Function
26 3-color light
Operation
Automatic stop for Function

27 leaving minimum
wire rope
Mounting of detector switch
Looseness in upper and lower pins of derrick cylinder
Winding-up capacity, braking with rated load lifted up
Oil leak from derrick cylinder, gravity-descent
Operation
Oil leak from telescoping cylinder, gravity-descent
Load test
28 Test load
( ton)
Gravity descent of derrick cylinder with rated load lifted up

Gravity descent of outrigger cylinder with rated load lifted
Gravity descent with rated load lifted up when boom extended to its extreme
Swing capacity with rated load lifted up
Fitting of support pins, missing snap ring

13 Column
Zero-point adjustment and check for load cell
Telescoping
cylinder
Deformation, wear, damage in load cell
Operation of turn-table, unusual noise, lubrication
12
11 Derrick cylinder
Function, oil leak, damage
19 Load indicator Missing pointer, damage in indication plate, function
6 Control valve Oil leak
9 Hoist winch
Damage, wear, rotation of sheave and lubrication
Missing knob, peeled off and deteriorated sticker
8 Swivel joint
Support of piping
Operation, deformation, crack in each lever
7 Outriggers
Tight connection to wire socket, fastening clip at rope end
Operation of accelerator lever
Contamination of air breather, return filter, suction filter

Hydraulic
5
pump

taken
OK
NG
Damage, wear, rotaition sliding plate, missing bolts
Engine oil level and deterioration
Oil leak from reduction gear in traveling motor

3 Frame
Adjustment A Cleaning C
Tightening T Oil supply L
Tightness of bolts mounting turntable, missing bolts

14 Boom
Battery liquid level
Forwardbackward operation of traveling lever

2 Traveling
What to check for:
Condition of air cleaner element
Fuel leak
1 Engine
Replacement
Repair
Remarks to be recorded
Crack, deformation
Tightness of bolts mounting turntable
Operator
Crane model
Delivered date
Inspected date
Company in charge of inspection

Inspected by Signature
38. PERIODICALLY REPLACING COMPONENTS AND EXPEDABLE PARTS

In order to ensure safe operation of UNIC mini-crawler crane while maintaining its functions and performance,
replace components specified as periodical replacement regularly.
In addition, you are requested to replace the expendable components when you have noticed wear and damage as
there may be exhausted and/or deteriorated components due to frequency of use and aging deterioration.
In order to use the crane in good condition, we recommend regular replacement of the components as specified in
the table below.
Item
Components
Line filter
Once a year
Packing and seal for each cylinder
Every 3 years
Sliding plate of boom
Every 3 years
Brake shoe of hoist winch
Every 3 years
Expendable parts Wire rope
Crane
Replacement
Replace according to damage and wear
Rubber components, wiring, cables
Replace according to damage
Batteries, bulbs, switches, fuses
Replace according to damage and/or

consumption
Enclosure, switch, lever of transmitter Replace according to damage and wear
Lubrication
Traveling Expendable parts
Engine
Hydraulic oil
Every 2 years
Gear oil (hoist winch)
Once a year
Gear oil (swinging reduction gear)
Every 2 years
Other greases
Lubricate according to consumption
Diesel engine oil

(traveling motor reduction gear)
Every 1,000 hours according to hour meter
Rubber crawler
Replace according to crack/elongation
Engine oil
Every 100 hours according to hour meter

Replace according to consumption and
deterioration
Expendable parts Battery

Rubber components, wiring, cables
Replace according to damage
Note: It is to be charged for replacement of expendable components.
REPLACEMENT OF HYDRAULIC OIL

Air entering in oil tank brings dust and moisture.
Since contaminated and deteriorated hydraulic oil in pump and motor accelerates wear and seizure, replace
hydraulic oil periodically in 3 months after start of machine operation and once every 2 years thereafter.
If the periodical replacement has failed to be carried out, warranty repair will not be applied even if it is within
warranty period
ONE-YEAR WARRANTY COMPONENTS

In case where it will not impair quality remarkably, rust in sliding part, in fitting part, and that resulted from operation
and insufficient lubrication, warranty repair will not be applied.
DL-100
Initial Setting Up of Digital Load Meter
Appearance of Digital Load Meter

We explain below calling each three switches "L","C","R" on load indicator panel.
In normal mode load is indicated in unit of 0.02 t ("*.**"t).
DL-1
1
1
2
3
4
*
Confirming lines of wire

Normal Mode
Press "C" once
Indicated lighting for 3 seconds
Confirm lines of wire
Initial setting up is 4 lines.
H22 lines
H44 lines
H66 lines
Setting lines of wire
Press "C" long (3 seconds)

Indicated brinking lines of wire
Press "L" and select lines of wire.
Decide pressing "C"
After lines of wire set indicated lighting for
3seconds, digital load meter returns to normal
mode.
Note: If anti-overload system (below "AOL" )
"KM-100" is installed with digital load meter,
do the initial setting up of AOL.
1
2
3
4
5
3
1
2
3
4
Load detector0.0/Setting line value
Cranes remains without load and swinging load

Press "R" for 1 second.
Indication brinks once.
"0.00" t is indicated and memorized.
DL-2
4-1 Changing modulation mode and
load detector0.5/Setting line value

1 Press "C"and "R" long at a time (5 seconds)
* 1) In each item of modulation mode, after initial
indication for 1 second, it is replaced by norma
indication.
* 2) changing modulation mode to normal mode,
go once through items or put the power off.
* 3) In items that need setting up
selecting value with "L" doesn't lead to
memorization.
* 4) Press "R" and get value to memorize.
* 5) In case of not getting value to memorize,
go to the next item pressing "C".
*4
*5
4-2 Load detector0.5t/Setting line value
*
*
*
*
*
1 Lift the weight of clear weight as standard of

0.5t per one wire.
Standard
2 lines1t
4 lines2t
6 lines3t
2 Press "L" and adjust value to actual
weight value.
1) In case weight value is less than 10kg,
round up to the nearest whole number.
2) 2 linesPossible range to set is 0.5t 1.6t
5) Press "L" and load value is changed 0.01t lbs by
0.01t and Press "L" long and load value is
changed in the units of 0.1t.
6) Go once through value and get value to indicate
again in case of exceeding load value to set.
3 After adjusting to actual weight, press "R"
Indication brinks once and value is memorized.
4 Press "C" and go to next item.
DL-3
54321
5
1
2
* 1)
* 2)
* 3)
1
2
3
* 1)
* 2)
* 3)
* 4)
* 5)
Intial Setting up Completes

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

Function
Loadmeter can add and memorize Lifting load
value, and summon and indicate memorized
value.
In normal mode press "L". Then normal mode
is replaced by add mode.
Add mode lamp lights red in add mode.
Press "R" once and the detector memorizes
lifting load value. After indication disappears
for 0.5 second, memorized load meter is
indicated for one second
Then after indication disappears, loadmeter
returns to indication of lifting load value.
Loadmeter adds current load value to load valu
memorized whenever pressing "R" and
re-memorizes. After disappearing indication
for 0.5 second, memorized load meter is
indicated for one second.
Then after indication disappears, loadmeter
returns to indication of lifting load value.
In add mode and on pressing no switch, lifting
load value is digital-indicated by three digit "*.
**"t (in unit of 0.02t).
"8.8.8." indicates on overwinding.
"OL" indicates on overloading.
Impossible to add during brinking.
During pressing "C" and for 3 seconds after
releasing finger from "C", memorized load valu
is digital-indicated by three digit. Then it is
replaced back by current lifting load value.
When loadmeter indicates memorized load
of over 10t, it indicates "**.*"t (in unit of 0.1t)
On pressing "C", it resets memorized load
value and returns to normal mode.
DL-4
3, 4
Overwinding Signal Output

According to overwinding signal from load detector or "KM-100" control box,
put on/off "Overwinding Signal Output".
And loadmeter brinks " O L " as load indication during overwinding.
Function of Detecting Overload
When load signal from load detector or "KM-100" control box exceeds rated load of load cell,
put off "Overwinding Signal Output" and brink " O L " as load indication.
1
9 Zero Reset
1 When you press "R" long (for one second) ,
you can reset zero of load value.
When loadmeter puts zero reset into practice,
"0.00"t is indicated after indication disappears
for 0.5 second.
* 1) When "8.8.8."(overwinding) or " O L "(overloading)
brinks, it is impossible to reset zero.
1 second
10 Error Code
Error Code
E01
E02
E03
E04
E05
E06
E07
What Goes Wrong

Fault in load cell amplifier
Fault in load cell
Fault in load cell
Fault in load cell
Fault in digital loadmeter indicator
Fault in digital loadmeter indicator
The snapping between load cell amplifier
and digital load detector or fault in load cell
amplifier and digital load meter
DL-5
Measures
Exchange
Exchange
Exchange
Exchange
of
of
of
of
load
load
load
load
cell
cell
cell
cell
and
and
and
and
load
load
load
load
cell
cell
cell
cell
amplifier
amplifier
amplifier
amplifier
Exchange of digital loadmeter indicator

Exchange of digital loadmeter indicator
Confirm if wiring of digital loadmeter and
load cell amplifier is snapped.
If wiring is normal, exchange digital
loadmeter assembly.
KM-100
Setting Up Of ML Control Box
Appearance Of ML Control Box

We explain below calling each three switches "L","C","R" on ML control box panel.
In normal mode load is indicated in unit of 0.1t ("*.*").
KM-1
1
1
2
3
4
*
Confirming lines of wire

Normal Mode
Press "C" once
Indicated lighting for 3 seconds
Confirm lines of wire
Initial setting up is 4 lines.
H22 lines
H44 lines
H66 lines
H 4
MOMENT
2-1 Setting lines of wire

(In case of changing lines of wire)
1 Press "C" long (3 seconds)
2 "Pe" sounds
3 Indicated brinking lines of wire
H 4
Pe
MOMENT
2-2 Setting lines of wire

(In case of changing lines of wire)
1 Press "L" and change indication
2 Press "C" and decide
3 "Pe" sounds
4 Decision ("H2" or "H4" or "H6" )is indicated
for 3 seconds.
5 Back to normal mode
H2orH4orH6
H2orH4orH6
MOMENT
KM-2
Pe
MOMENT

1
* 1)
* 2)
* 3)
* 4)
Changing modulation mode and setting

up initially
Press "C"and "R" long at a time (5 seconds)
Wait for 1 second after changing item.
Item is not changed without waiting over
1 second.)
Returning modulation mode to normal mode,
mode
Go once through items or put the power off.
"L": Mainly cord selection switch
"C": Go next item.
"R": Memory switch
When "---" indicates brinking, it shows except
range possible to set up the detector in the
item.
Check if installing detector and detector itself
is abnormal.
4 Setting up model
1 Select model with "L".
(Go in turn by pressing "L" long)
2 Press "R".
3 Detector sounds "Pe", brinks, and memorize
model.
* 1) If model code to select goes over, go once
through model codes and indicate model code
to select again.
* 2) Take care that model code with "" right
under it is different from model code without it.
* 3) Sure to set up each detector when changing
model code.
Each detector is reset up.)
Pe
t
MOMENT
c o d
Pe
Model
MOMENT
MOMENT
Press "C" and go to next item.

5
Setting up minimum value in boom length

detector.
1 Retract boom at minimum.
2 Press "R".
3 "Pe" sounds and set up boom length is
indicated and memorized.
Pe
MOMENT
KM-3
6
1
2
3
* 1)
Setting up middle value in boom length

(Except 2 section boom)
Move boom by indicated section.
Press "R".
"Pe" sounds and boom section set up is
3 to 4 section boom is set up with boom
and .
5 to 6 section boom is set up with boom ,
, and .
Pe
(S
L
ti
MOMENT

7
1
2
3
4
Setting up maximum value in boom length

Indicate maximum boom section.
Extend boom at maximum.
Press "R".
"Pe" sounds and boom section set up is
(Section
Pe
MOMENT

1
8 Setting up boom angle detector at 5
1 Move boom angle at 5
2 Press "L" and adjust indication value to
actual value.
3 Press "R"
4 "Pe" sounds and indication blinks once and
"5"is memorized.
* 1) Possible range to modulate is 52.
(0, 1unit)
* 2) Go in order with pressing "L" long.
(Next 7, back to 3. 5,6,7,3,4,5)
A_5
A _ 5
Pe
MOMENT
MOMENT

9 Setting up boom angle detector at 70
1 Move boom angle at 5
2 Press "L" and adjust indication value to
actual value.
3 Press "R"
is memorized.
* 1) Possible range to modulate is 702.
(0, 1unit)
* 2) Go in order with pressing "L" long.
(Next 72, back to 68. 70,71,72,68,69,70)
A7 0
MOMENT
KM-4
A 7 0
Pe
MOMENT
10 Load detector0.0t/Setting line value

1 Press "R" with hook only keeping
is memorized.
* 1) Wire line is displayed on initial indication.
2or4or6
Pe
MOMENT
MOMENT

11 Load detector0.5t/Setting line value
1 Lift the weight of clear weight.
2 lines1t
4 lines2t
6 lines3t
2 Press "L" and indicate same weight value
as weight.
3 Press "R" without load swinging.
is memorized.
* 1) Range set on load detector
2 lines0.5t 1.6t
1t is best condition
4 lines1t 3.2t
6 lines1.5t 4.8t
* 2) Press "L" and load value is changed 0.01t by
0.01t.
* 3) Press "L" long and load value is changed in the
units of 0.1t.
Pe
Load Value
oror
MOMENT
MOMENT
12 Initial Setting up Completes

1 Press "C" repeatedly and go once through
items of modulation cord.
2 When items of modulation go once through,
"Pe" sounds. And after "8.8.8." is indicated for
1 second, detector returns to normal mode.
* 1) This operation has no relation to initial setting
up, so after this skip 11th item.
KM-5
MOMENT
Pe
13 Indication of Boom Length

1 Indicate current boom length ( **.* m ).
2 While only pressing "R", output voltage
(**.*V) from the detector is indicated.
Initial Indication
.m
Press "C" and go next item.

14 Indication of Boom Angle
1 Indicate current boom angle ("**.*"degrees).
2 While only pressing "R", output voltage
("**.*"V) from the detector is indicated.
Initial Indication
.V
Press "C" and go next item.
KM-6
Initial Indication
"Angle for detecting boom angle"

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

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

1 Indicate current lifting load ("*.**"t ).
2 While only pressing "R", indicate output voltage
of differential motion("*.**"V) from detector.
Initial Indication
KM-7
.t
17 Rated Load Indication

1 Indicate current rated load ("*.**"t).
2 While only pressing "R", indicate current load
rate ("***"%).
Initial Indication
.t
18 Setting up Intermission Alarm Output

Factor_K0
Set up factor ("*.**") for decision formula
of ML intermission alarm output.
Whenever pressing "L", revise value +0.05 by
+0.05.
When pressing "R", "Pe" sounds and indication
* Refer to "Model code list" about initial value
of ML alarm output factor_K1.
* Range of revisable factor is from 0.50 to
1.50.
When factor is over 1.50, it is back to 0.50.
Initial Indication
Factor
MOMENT
MOMENT
3
Mode only for Japan.
Set to the same value as K1.
Factor
KM-8
Pe
19 Setting up Continuous Alarm Output

Factor_K1
Set up factor ("*.**") for decision formula
of ML continuous alarm output.
Whenever pressing "L", revise value +0.05 by
+0.05.
When pressing "R", "Pe" sounds and indication
* Refer to "Model code list" about initial value
of ML alarm output factor_K1.
* Range of revisable factor is from 0.50 to
1.50.
Initial Indication
Factor
MOMENT
MOMENT
Factor
Pe
20 Setting up Stop Output Factor

_K2
1 Set up factor ("*.**") for decision formula
of ML stop output.
2 Whenever pressing "L", revise value +0.05 by
+0.05.
3 When pressing "R", "Pe" sounds and indication
* 1) Refer to "Model code list" about initial value
of ML stop output factor_K2.
* 2) Range of revisable factor is from 0.50 to
1.50.
Note: Factor for Taiwan is "1.00".
Factor for Australia and
Europe is "1.10".
Initial Indication
KM-9
Factor
Factor
Pe
21 Setting up Stop Return Factor _ K3

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

1 Set up if controling with front rated load chart
or with performance calculated from rear
performance.
2 Whenever pressing "L", change modes as
"F_ _r_ _r00r05r10...r95F_ _... "
*
*
3 Pressing "R", "Pe" sounds and indication

1) In front zone when selecting "F__",
control with front rated load chart.
2) In front zone when selecting "r__",
control with 100% performance of rear
performance.
3) In front zone when selecting "r**",
control with **% performance of rear
performance.
4) It is possible to set up within percentage 0%
to 100% in units of 5%.
Initial Indication
KM-10
Mode Value
Mode Value
t
Pe
MOMENT
23 Setting up ML Stop Output Mode

1 Setting up if output of KM-100 is alarm type
or autostop type.
2 Whenever pressing "L", alarm type changes
"off", autostop type changes "on".
3 Pressing "R", "Pe " sounds and indication
Initial Indication
Mode Value
Mode Value
Pe

24 Resetting set-up value
1 Reset set-up value and return the detector
to initial condition.
2 Pressing "L" and "R" long at a time (3
seconds), all set-up value is reset. And "Pe"
sounds and "000" is indicated.
3 Pressing "C", "Pe" sounds and "8.8.8." is
indicated for 1 second. Then modulation mode
is finished and returned to normal mode.
Initial Indication
Pe
KM-11
Pe
KM-100 ML Control Box Modulation Mode List
1
2
3
4
heading
first indication1sec
usual indication
left SW
Changing modulation mode
Setting up model
Model code
Select Model
Setting up minimum value
in boom length detector

Setting up middle value in
Section Section
boom length detector
Setting up maximum value
Section Section
in boom length detector
Adjust indication
value to actual
value
Adjust indication
value to actual
value
Setting up boom angle

detector at 5
Indication value
Setting up boom angle

detector at 70
Indication value
Wire line
Wire line
Load value
Adjust load value
7
8
Load detector
0lbssetting line value
Load detector
1100lbssetting line
Indication of boom length
Boom length
10
Indication of boom angle
Boom angle
Working radius
Warping boom
angle
Lifting load
Rated load
Factor
Revise factor
Factor
Revise factor
Factor
Revise factor
Factor
Revise factor
Mode value
Select Mode
Mode value
Select Mode
Press long at
once3sec
Indication of working
radius
Three digital indication of
12
lifting load
11
13
14
15
16
17
18
19
20
Rated load indication
Setting up Intermission
alarm output factor K0

Setting up continuous
alarm output factor K1

Setting up stop output
factor K2
Setting up stop return
output factor K3
Setting up "Outrugger
Mode value
not max mode"
Setting up ML stop output
Mode value
mode
Resetting set-up value
KM12
center SW
right SW
Press long at Press long at
once
once
5sec
5sec
Go to next
memorized
item
Go to next
memorized
item
Go to next
memorized
item
Go to next
memorized
item
remarks
Returning modulation mode to normal mode,go once through
items or put the power off.
Refer to Model code list0628
Set up boom length at minimum is indicated and memorized
ft
Set up boom length at 2or 3-section is indicated and memorized
ftExcept 2 section boom
Set up boom length at maximum is indicated and memorized
Go to next
item
memorized
Possible range to modulate is 3.07.0Initial value is 5.0
Go to next
item
memorized
Possible range to modulate is 6872Initial value is 70
memorized
2 lines,4 lines,6 lines
Go to next
item
Go to next
item
Go to next
item
Go to next
item
Go to next
item
Go to next
item
Go to next
item
Go to next
item
Go to next
item
Go to next
item
Go to next
item
Go to next
item
Go to next
item
Conpleted
memorized
indicate
voltage
indicate
voltage
memorized
indicate
voltage
Rated load
indication
memorized
2 lines,4 lines,6 lines

Possible range to modurate500lbs1800lbswire lines
Indication of boom lengthft
Indication of voltage
Indication of boom angle
Indication of voltage
Indication of working radiusft
Possible range to modulate is 0.03.0initial value 1.0
Indication of lifting loadX1000lbs
indicate voltage
Indication of rated loadX1000lbs
Indication of rated load ratio
Possible range to modulate is 0.501.50per 0.05
Mode only for Japan. Set to the same value as K1.
memorized
memorized
memorized
memorized
Outrigger not max ext. Outrigger max ext.100

of Outrigger max ext.per 5
memorized
Autostop typeAlarm type
Press long at once(3 seconds),all set-up value is reset and 000

Press long at
is indicated.When modulation mode is finished,888 is indicated
once3sec
for 1 second.
Mode(Error code) list of Moment limiter

Error code
Trouble
Defection of Load cell Amplifier
Load Signal(A) from Load cell to Amplifier of Load cell is disconnected..
Load Signal(B) from Load cell to Amplifier of Load cell is disconnected..
Load Signal(A),(B) from Load cell to Amplifier of Load cell is disconnected..
Moment limiter control box is broken.
Moment limiter control box is broken.
Signals from Amplifier of Load cell to Moment limiter control box is disconnected..
Signals from Boom Angle detector are disconnected.
Signals from Boom Length detector are detected.
KM-13
Reset (Try to turn on power.)

Check wiring and connector.
Reset (Try to turn on power.)
The setting change was done 100,000 times or more.
Model code list
KM-100-CA
Model code
Model
295
URW295C
Loading capacity
2.9
Division
for Japan
K1
1.00
K2
1.25
K3
1.15
Type
Alarm
375
376
URW375CD
URW376CD
2.9
2.9
for Japan
for Japan
1.00
1.00
1.25
1.25
1.15
1.15
Alarm
Alarm
506
305
URW506CD
URW295C
2.9
2.9
for Japan
for Japan
1.00
0.90
1.25
2.00
1.15
1.80
Alarm
Alarm
385
386
URW375CD
URW376CD
2.9
2.9
for Japan
for Japan
0.90
0.90
2.00
2.00
1.80
1.80
Alarm
Alarm
516
285
URW506CD
URW295CMR-A
2.9
2.9
for Japan
for Japan
0.90
0.90
2.00
1.00
1.80
0.95
Alarm
Auto stop
365
366
496
295.
375.
376.
546.
URW375CD-A
URW376CD-A
URW506CD-A
URW295C
URW375CDA
URW376CDA
URW546CDA
2.9
2.9
2.9
2.9
3.0
3.0
4.0t
for Japan
for Japan
for Japan
for Russia
for AUS
for AUS
for AUS
0.90
0.90
0.90
0.90
0.90
0.90
0.90
1.00
1.00
1.00
1.10
1.10
1.10
1.10
0.95
0.95
0.95
1.05
1.05
1.05
1.05
Auto
Auto
Auto
Auto
Auto
Auto
Auto
KM-14
stop
stop
stop
stop
stop
stop
stop
DESCRIPTION OF EACH CONTROL DEVICE
U-AOL system (Anti overloading system)

1. Function of U-AOL system
U-AOL system is a safety device that detects load applied to the crane to issue an alarm
automatically when the load reaches the rated total load.
* Rated total load
Rated total load is maximum load based on hoisting capacity of the crane as against
raised angle and/or extended length of the boom and this includes weight of hooking
implement.
WARNING
The system is not for preventing the crane from overturning.
Operate the crane by paying full attention to its stability.
Even if the system actuates, load applied to the crane may increase
due to inertia so that the crane might be damaged when a lifted cargo is swinging or working speed is too fast.
Do not put too much dependence on the system but try to operate it
carefully at all times for securing safety.
Do not carry out operation which increases lifting load, such as piling
up a cargo on the lifted pallet or pouring a liquid into the lifted container during lifting operation.
This may cause the crane to be damaged or overturned.
KM-15

2. Construction of U-AOL system
Boom length detector
Boom angle detector
3-color indictor lamp
Over-load alarm
control box
Capacity limit alarm buzzer
Load detector
3. Operation of U-AOL system

1.Over-load alarm
Capacity limit alarm
WARNING
If the capacity limit alarm is actuated, stop the crane operation immediately to move the lifted cargo toward safer side.
When the load applied to the crane comes
close to the rated total load (capacity limit),
the alarm buzzer sounds (Ping-pong, Pingpong) to issue an alarm.
When the load applied to the crane reaches
the capacity limit, crane functions listed
below stop automatically:
ong,
Ping-p Ping-pong
Extending boom Lowering boom

Winding-up hook Swinging CW.&C.C.W.
KM-16

4.
M e a s u re s t o b e t a k e n w h e n
U-AOL system is in trouble.
In case where the crane becomes impossible

to be operated due to system trouble, cancel
the U-AOL system to store the crane.
Step 1
Throwing the ML auto stop switch to OFF
position allows the ML device is to be
cancelled (for 5 seconds maximum).
Carry out winding-up hook, lowering boom, and
slewing operation with each control lever.
OFF
Step 2
If the crane cannot be operated by the
step 1 above, operate the crane by following
2. How to reset when automatic stop for
overwinding is found to be out of order section.
ML auto stop switch
CAUTION
Boom cannot be extended even when the safety device is being cancelled.
In case where the crane is operated with the safety device has been
cancelled once, it will take 30 seconds until it can be cancelled next
time.
5. Function of load indication
In normal operation, the load is to be
indicated in the weight of 0.1t on the digital
indicator in the over-load alarm control box.
OUTRIGGERS
NOT MAX EXT
SELECT
SET
MOMENT LIMITER
URW376C1A, URW540C1A
KM-17

Designation of each part of
Lamp indicating
Outriggers not max EXT
Capacity limit alarm
Indicator:
Indicator
It indicates weight of lifted cargo (t).
Lamp indicating outriggers not

max ext:
It indicates in green when outriggers are
not in maximum extension.
OUTRIGGERS
NOT MAX EXT
Check switch:
It is to confirm operation of each indication
and alarm.
SELECT
SET
MOMENT LIMITER
Check switch
Error indication of overload alarm device
When an error is detected, corresponding error code appears on the control box.
Error
code
Trouble
Trouble may be in load indicator.
Trouble may be in overload alarm control box.
Trouble may be in connection between load detector

Trouble may be in boom length detector.
Trouble may be in boom angle detector.
KM-18

Digital indicator
6. Checking U-AOL system

before starting crane operation
Before starting the crane operation, checks
follows:
Remarks
OUTRIGGERS
NOT MAX EXT
SELECT
SET
MOMENT LIMITER
The power to U-AOL system is supplied

through ON/OFF control of crane-crawl
lever.
Checking over-load alarm system
Check that [0.0] t is indicatetd on the digital
indicator when no-load is applied.
Depress the checking switch to confirm that
[8.8.8.] appears on the digital indicator.
Switch for setting

number of slinging
wire rope
Checking switch
Confirm that crane functions listed below

cannot be operated while the checking switch
is being depressed.
Extending boom Lowering boom
Winding-up hook Swinging C.W.&C.C.W.
Depress the switch for setting number of
slinging wire rope to confirm that [H4]
appears on the digital indicator.
Indicator returns to wait indication in 3
seconds after the switch has been released.
In case where anything unusual is found while inspection before starting work is being
carried out or the crane is being operated, ask a UNIC authorized service shop for inspection
immediately.
KM-19

Unic 376c1am R546c1amr Work Shop Manual

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Unic 376c1am R546c1amr Work Shop Manual

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URW376C1AMR

Major Specifications (URW376C1A)

Major specifications (URW546C1A)

How to store outriggers when in an emergency

Mode indicator lamp (control box)

Mode indication when crane is in normal operation

List of voice messages

How to switch operation mode

Switching of mode(Manual mode Radio control mode)

Radio control cannot be operated

Hydraulic circuit diagram (carrier

Control valve for carrier

Hydraulic circuit diagram (control valve for crane)

Installation procedures for slide plate and guide

Telescoping/derrick cylinder ass'y,

Eleectric Wiring Diagram

Electric Wiring diagram

Inspection for sinking of cylinder

Replacement of wire rope (for winding-up)

Replacement ofexpendable parts

List of recommended lubricant

Filling water and lubrication chart

Periodically replacing components and expedable parts

Digital Load MeterDL-100)

Maximum lift above ground (Hook)

Boom to be extended to:

Maximum working radius

Speed of winding-up (Rope speed)

Extending speed of boom

68m/min (At 4th layer on the drum)

Raising speed of boom

Hoisting speed of hook

Direct pushing by double acting hydraulic cylinder

Direct pushing by double acting hydraulic cylinder

Hydraulic oil tank Capacity

Telescoped by direct pushing of double acting hydraulic cylinder

Hydraulic motor: Axial plunger type

Variable delivery piston pump

3.0t Number of slinging rope: 4

Endless rubber crawler

Length of ground contact

Pressure of ground contact

Rated output15.17kW/2500rpm (20.6PS/2500rpm)

Independently driven by hydraulic power

Disc brake with hydraulic motor built-in

Net rated loads chart

Boom is extended to where 2nd mark

on the side plate of Boom

on the side plate of Boom

are all extended to their extremes.

Maximum lift above ground (Hook)

Boom to be extended to:

Maximum working radius

Speed of winding-up (Rope speed)

68m/min (At 4th layer on the drum)

Hoisting speed of hook

Extending speed of boom

Raising speed of boom

Hoisting rope Construction

IWRC6WS (26) class B [Breaking load: 42.4kN (4320 kgf)]

Direct pushing by double acting hydraulic cylinder

Direct pushing by double acting hydraulic cylinder

Hydraulic oil tank capacity