MAINTENANCE MANUAL

UNIC CRANE

　

CONTENTSDESCRIPTION OF MAJOR EQUIPMENT 1

Inspection before operation 2

Replacement of expendable parts/Welding precautions 3

List of recommended lubricants 4

Lubrication chart 5

Annual self-inspection record 6

PTO／Hydraulic pump 8

Propeller shaft／Hydraulic pump 9

Hydraulic oil tank 10

　　　　Replacement of hydraulic oil／Draining hydraulic tank 11

12

Control valve 13

Outrigger 14

Hoist winch 15

Slewing device 16

　　　　　Inspection of the slewing bearing mounting bolts 17

　　　　　Replacement of gear oil／Lubrication to slewing bearings 18

Telescoping cylinder／Boom 19

Swiveljoint／Derrick cylinder／Column／Piping 20

Wire rope 21

　　　　　　Easy inspection of the wire rope 22

　　　　　　How to replace the wire rope 24

　　　　　　How to fix the wire rope end 25

　　　　　　How to correct the twisted wire ropes 26

Hook 27

Load meter 28

Load indicator 29

Automatic stop for overwinding／Over-winding alarm／Level 30

Worning horn／Name plate 31

Base／Chassis frame 32

INSUPECTION PROCEDURES WHEN CYLINDER SINKE 33

　　　　　　Inspection of derrick cylinder 34

　　　　　　Inspection of telescoping cylinder 35

　　　　　　Inspection of outrigger cylinder 36

　　　　Replacement of return filter／Replacement of line filter element

DESCRIPTION OF MAJOR EQUIPMENT

1 P. T.O.lever 7 Swivel joint 13 Column 19 Load indicator2 Propeller shaft 8 Hoist winch 14 Boom 20 Overwinding stop3 Differential oil tank 9 Slewing device 15 Wire rope 21 Level4 Oil hydraulic pump 10 Derrick cylinder 16 Pipeing 22 Warning horn5 Control Valve 11 Telescoping cylinder 17 Hook 23 Name plate6 Outrigger 12 Base 18 Load meter 24 Chassis frame

15 20

17

23

14

21

19

518

10

118

13

7,16

9

1

22,23

6

12124

24

3

- 1 -

- 2 -

Inspection before operationIn order to secure safe operation and improve working efficiency, be sure to inspect each part of the crane accordingto the table as follows;

Device Inspection for:

P.T.O.Oil leakage, Unusual noise

Hydraulic oiltank

Oil level, Oil leakage

OutriggersOperation, Deformation,Damage, Oil leakage, Cracks

Hoisting winchOperation, Braking func-tion, Irregular winding

Slewing device Operation, Oil leakage

Boom(derrick-ing)

Operation, Oil leakage,Mounting of foot-pin

Boom(telescop-ing)

Operation, Oil leakage,Deformation, Cracks,Mounting of fixing pin

HookRotation of hook, Function ofhook safety latch

DeviceCheck Inspection for:

Wire ropeDamage, Condition ofrope-end

Overwindingalarm

Operation, Buzzer sound

Load meter Oil leakage, Operation

Warning horn Operation

Piping(hydraulic) Oil leakage

BaseFastening tightness ofcrane body mountingbolts

Slinging imple-ments

Missing necessary items

Uni-hookOperation of automatic stopand storing function

Check

CleaningKeep the machine clean at any time.Sand and fine dust may cause an abnormal wear of themachine.Do not wash the machine by splashing water with high-pres-sure to prevent the water from entering into the electric sys-tem which may cause malfunction of the machine.

Always keep the machine in good condition so that it is ready for normaloperation.

CAUTION

- 3 -

1. Replacement of gaskets and seals for eachcylinder

Although timing of replacing a part varies according to howfrequently the crane has been operated, replace gaskets andseals used in each cylinder after every 3 years of operation(period during which crane is not operated is included) inorder to operate the crane safely. Ask a local UNIC authorized service shop for replacement ofgaskets and/or seals.

Welding precautionsWhen welding is needed for some reason, do not use outrig-ger cylinder for welding ground as the cylinder rod and/or thepiston may be damaged by electric sparks due to currentflown in the inner part of cylinder.

Replacement of expendable parts

2. Replacement of sliding plate of boom

Replace it every 3 years.

3. Replacement of brake shoe in hoistingwinch

Replace it every 3 years.

Brake shoe

No grounding

Outrigger cylinder

Sliding plate

◆1. List of recommended lubricants

★RECOMMENDED GREASE

(a) Chassis greaseUse NLGI No. 1 grade.

(b) Molybdenum greaseUse NLGI No. 2 grade.

★RECOMMENDED GEAR OIL

Use API Service GL-4 gear oils.

★RECOMMENDED HYDRAULIC OIL

Use industrial-type hydraulic oil;ISO VG 46 for most temperaturesISO VG 32 extremely low temperatures

Petroleum Maker Brand

ESSO Chassis grease L

MOBIL HP221

CALTEX Multifak EPI

SHELL RETINAX-CD

Petroleum Maker Brand

ESSO Beacon Q2

MOBIL Mobilplex Special

CALTEX Molytex Grease EP2

SHELL Retinax AM

Petroleum Maker Brand

ESSO Standard gear oil 90

MOBIL Mobilube SAE 90

CALTEX Universal Thuban SAE 90

SHELL Shel Spirax EP 90

Petroleum MakerBrand

Shell Tellus Oil 46

Rando Oil 46

ESSO UNVICE J32

Mobil DTE 25

Teresso 46

MOBIL Mobil DTE 13

ISO VG 32

CALTEX Rando Oil HD AZ32

ISO VG 46

SHELL Shell Tellus Oil 32

- 4 -

Lubrication chart

3-section boom

4-section boom

5-section boom

6-section boomDo not apply grease to the slide-sheave pin.

S e r v i c einterval Part to be lubricate No. of

part Lubricant Tool

Daily

Boom slide plate(Underside/sides of boom sections , ) 3-section boom Boom slide plate(Underside/sides of boom sections , , ) 4-section boom Boom slide plate(Underside/sides of boom sections , , , ) 5-section boom Boom slide plate(Underside/sides of boom sections , , , , ) 6-section boom Boom slide plate(Upper side of boom section ) Boom foot pinUpper support pin of derrick cylinderLower support pin of derrick cylinderOil tank(59l)

2

3

4

5

21111

Molybdenum grease

Molybdenum grease

Molybdenum grease

Molybdenum grease

Molybdenum greaseChassis greaseChassis greaseChassis greaseHydraulic oil(up tomiddle of level gauge)

Manual application

Manual application

Manual application

Manual application

Grease pumpGrease pumpGrease pumpGrease pump

WeeklyWinch drum gearSlewing gear(to gear-teeth)Propeller shaft

113

Chassis greaseChassis greaseChassis grease

Grease pump

Manual application

Grease pump

Monthly

Winch reduction gear(approx.1.0l)Slewing reduction gear(approx.1.2l) Wire ropeSlewing bearings Wire rope for boom extension

1112

Gear oilGear oilRope greaseChassis greaseRope grease

Spray gun

Grease pump

Spray gun

- 5 -

Good No good

Operation of “ON” and “OFF”, abnormal noise and oil leakagOperation of the PTO check lampLooseness/falling off of the bolts and nuts in the mounting unitPlay of the universal joint/spline and lubricatioLooseness/falling off of the bolts and nuts in the mounting unitOperating condition, abnormal noise and oil leakagSetting of the rated rotationLooseness/falling off of the bolts and nuts in the mounting unitOil leakage and crackQuantity, contamination and deterioration of the hydraulic oStain and damage of the air breather and suction filteOperating status, deformation and crack of the leverFalling off of knob and exfoliation/deterioration of stickOil leakageLooseness/falling off of the bolts, nuts, pins, etc. in the mounting unitSet pressure of the relief valveOperating condition and effect of the horizontal setting stoppeEffect of the stopper pin when loaded or set and deformation of piDeformation and crack of the inner boxDamage of the lock leverOil leakage/natural sinking of the outrigger cylindeOperation of the one-touch lever and condition of the cable terminaLooseness/falling off of the bolts, nuts, pins, etc. in the mounting unitOil leakageLooseness of the stopper mounting bolts and deformation of the platLooseness/falling off of the bolts and nuts in the mounting unitContinuity of the slip ring, damage of wiring and mounting conditioOperating condition, abnormal noise and oil leakagDamage of the air breatherQuantity and deterioration of the gear oiCrack of the drum and lubrication to the gearLooseness/falling off of the bolts and nuts in the mounting unit

Operating condition, abnormal noise and oil leakagDamage of the air breatherQuantity and deterioration of the gear oiOperating condition, abnormal noise and lubrication of the turntablLooseness/falling off of the bolts and nuts in the mounting unit

Operating conditionPlay of the derrick cylinder upper/lower pinOil leakage/natural sinking of the derrick cylindeLooseness/falling off of the bolts and nuts in the mounting unitOperating conditionOil leakage/natural sinking of the telescoping cylindeMounting condition of the support pin and falling off of the snap rinLooseness/falling off of the bolts and nuts in the mounting boltDeformation and crack of the base main body and the mounting basLooseness/falling off of the mounting bolts and nutCrack and deformationLooseness of the turntable mounting boltsOperating condition (extension/retraction) and lubricatioDeformation/crack of the boom and wear of the slide platLooseness/falling off of the slide plate mounting boltDamage, wear and rotation of the sheaveMounting condition of the support pin and sheave pin

Company name that has performed the inspection

User

Date of delivery

Slewingdevice9

10 Derrickcylinder

Crane model

Serial No.

Column

14

Date of practice

.

.

.

. .

Person in charge of inspection.

Signature

LRemedialmeasure

Result of checkContents of checkLubrication△ TTightening

8

Hydraulicoil tank

Controlvalve

6

Hoistwinch

Outrigger

7

Boom

Telescopingcylinder

11

Base12

13

Check point

When you perform the annual inspection, copy this sheet and use it.

4

5

Replacement

RepairAnnual self-inspection record 〇Store the inspection results for 3 years.

Disassembly

Hydraulicpump

2

3

1

C

Swiveljoint

A Cleaning× AdjustmentCheck レ

PTO

Propellershaft

- 6 -

Good No good

Looseness/falling off of the bolts, nuts, pins, etc. in the mounting unitsLooseness and wear of the extending wire, cutting of its strand and corrosion (4- to 6-section)Looseness of the retracting wire (4- to 6-section)Specification (length and thickness)Wear, cutting of the strand, deformation, kink, corrosion and lubricationTight connection to the wire socket and clipping of the terminalDeformation and crack of the wire socketTight connection to the drum, confused winding and kinkMounting condition of the support pin and looseness/falling off of the boltsOil leakageSupporting condition of the pipesDamage, aging, crack, twist and crushed statusWear, deformation, rotation and lubrication of the hookAim point distance of the hookDamage, wear, rotation and lubrication of the sheaveOperation, deformation and damage of the stopperPlay of the hook screw unit and thrust bearing (worn condition)Rotating status of the hook loading roller and deformation of the roller mounting bracketLooseness and falling off of the bolts, nuts, pins, etc. in the mounting units

18 Operating condition, oil leakage and damage19 Falling off of the pointer, damage of the name plate and operating condition

Operating condition, over-winding detection switch and alarm soundWinding status of the cord reel and damage/disconnection of the cordDamage of the weight and sling wire

21 Mounting condition22 Operating condition and alarm sound23 Mounting condition, damage and deterioration of the name plate

Bend, deformation and crackMounting condition and deformation of the stopperSling the rated load and check the hoisting and braking abilities.Sling the rated load and check the natural sinking of the derrick cylinder.Sling the rated load and check the natural sinking of the outrigger cylinder.Sling the rated load with the boom in the longest status and check the natural lowering of the boom.Sling the rated load and check the slewing ability.Operating conditionMounting condition of the reception antennaCondition of the transmitter caseConnection, looseness, stain and corrosion of the cablesDamage, deterioration and twist of the wires and cablesCorrosion, deterioration and looseness of the contact terminalOil leakage from the accelerator cylinder/piping unitOperating condition and oil leakage of the solenoid valvesOperating condition of the indicator unitsOperating condition of the alarm buzzer at the alarm pointOperating condition of the crane at the alarm point (Stop type)Operating condition of the alarm buzzer at the alarm pointOperating condition of the crane at the alarm point

Other special mention

Company name that has performed the inspection

When you perform the annual inspection, copy this sheet and use it.Replacement CA Cleaning× Adjustment

〇Store the inspection results for 3 years.

Disassembly

Check レLRemedialmeasure

Result of checkCheck point

Lubrication△ TTighteningRepairAnnual self-inspection record

.

Person in charge of inspection.

SignatureDate of practice

.

.

.

.

User

Date of delivery

Crane model

Serial No.

17 Hook

Option

20Over-windingalarm/automaticstop

Alarm

ＭＬ

Turnoverpreventivedevice

24

Wire rope

Contents of check

16 Piping

14

15

Boom

Chassisframe

25Load test/Test load( ton)

Radiocontrol(Remotecontrol)

Load detector

Load indication

Level

Name plate

- 7 -

PTO / Hydraulic pump

Depress the clutch pedal fully to disen-gage the clutch.Pull the PTO lever to its extreme. Release the clutch pedal gradually.Check that the PTO indicator lamp lights.

Truck engine

Transmission

PTO（Power Take Off）Hydraulic pump

Good No good

Operation of “ON” and “OFF”, abnormal noise and oil leakage

Looseness/falling off of the bolts and nuts in the mounting units

Operating condition, abnormal noise and oil leakage

PTO

Hydraulicpump

Contents of checkpointCheck Remedialcheck

Result of

Disulfide molybdenum grease No.2

- 8 -

Operation of the PTO check lamp

measure

Setting of the rated rotation

Check PTO for the ON/OFF operation.

Set PTO to "OFF". (The lamp is lit.) The crane operation is finished.

Check the bolts, nuts, and pins. Check the parts for oil leakage.

Greasing the shaft and spline of the directly-connected pumpTo prevent rust and wear, apply the disulfide molybde-num grease No. 2 to the pump shaft and the PTO spline unit.

Check of playWeld yoke

Spline shaftGrease nipple

PTO mounting side

Pump mounting side

Check the bolt for looseness.Apply grease.

Sway of shaft

Check the bolt for looseness.

Spline yoke

Spline yoke

Good No goodPlay of the universal joint/spline and lubricationLooseness/falling off of the bolts and nuts in the mounting unitsOperating condition, abnormal noise and oil leakage

Looseness/falling off of the bolts and nuts in the mounting units

Contents of checkpointCheck Remedial

measurecheckResult of

Propellershaft

Hydraulicpump Setting of the rated rotation

Propeller shaft／Hydraulic pump

Chassis grease No. 1

Disulfide molybdenum grease No. 2

Greasing the universal joint of the propeller shaftGreasing the pump shaft spline of the propeller shaft

- 9 -

To prevent rust and wear, apply the chassis grease No. 1 to the universal joint.Apply the disulfide molybdenum grease No. 2 to the pump shaft spline.

Check the oil level. Filler port of hydraulic oil

Return filter

Hydraulic oil tank

Suction filter

Drain plug

Check the air breather for stain.

Check the suction filter for stain,deterioration and oil leakage.

No good

Quantity, contamination and deterioration of the hydraulic oilStain and damage of the air breather and suction filter

Contents of checkCheck point RemedialcheckResult of

Hydraulicoil tank

- 10 -

Hydraulic oil tank

Oil leakage and crack

Goodmeasure

◆1. Replacement of hydraulic oil

★ The amount required for oil change is32 liters when filled up to the middlebetween upper and lower limits of the levelgauge.★ The oil should be replaced at earlyautumn because there is possibility offreezing moisture in the tank as well as inthe hydraulic circuit when temperaturegoes below the freezing point.(Dependingon the countries)

★ Air entering in the oil tank brings dirtand moisture. In addition, since hydraulic equipmentgradually wears to produce worn particles,replace the oil 3 months after the start ofcrane operation then once a year there-after.

★ T ighten the cap securely with yourhand after oil has been refilled. Rememberthat hydraulic oil may leak out if the cap isloosely tightened.

CAUTION★ Do not mix a different brandof hydraulic oil as properties ofmixed oil deteriorates and dam-age to hydraulic equipmentresults.

Upper limit

Lower limit

Level gauge

- 11 -

◆2. Draining hydraulic tankRemove moisture in the hydraulic tank. Moisture may enter through the air-breatherand it is mixed with the hydraulic oil whenthe crane has been operated for a long time.Remove the drain plug located at lower parton the tank to drain the water.

Drain plug

The replacement of the return filter isdepends on how often the crane has beenoperated, however, as a general rule, replaceit after 3 months of initial operation and oncea year thereafter.

How to replace● Give the gasket a thin coat of oil.● Screw in the cartridge and tighten it with

your hand securely.

Return filter

Replacement of line filter element

Replacement of return filter

Replace the inner element of line filter after 1year from the start of operation.Be sure to replace the element when thehydraulic pump is replaced and replace itafter 1 year from the start of operation of thepump.

Line filter

Element

(Showing left-hand side of control valve)

- 12 -

Load meter

Slewing lever〔clockwise/counter clockwise〕Boom telescoping lever〔retract/extend〕Hook lever〔hoisting/lower〕Boom derricking lever〔raise/lower〕

Check the sticker for exfoliation.

Outrigger control lever[extension/retraction]

Check the nutfor looseness.

Check theseparts for oilleakage.

Check the levers for the operating status, deformation and crack.Check if the pin or any other part has fallen off.

Control valve

- 13 -

Good No good

Operating status, deformation and crack of the leversFalling off of knob and exfoliation/deterioration of stickerOil leakageLooseness/falling off of the bolts, nuts, pins, etc. in the mounting unitsSet pressure of the relief valve

Controlvalve

Contents of checkCheck point measureRemedialcheck

Result of

Shift the lock lever for lock.● Remarks

Shift ing the lock levers forlock prevents the horizontalmembersof outrigger fromsticking out by car eless gripof extension lever.In addition, this preventsa rattling noise rom the horiz-ontal membersof outriggerwhile the vehicle is traveling.

Check ValveOutrigger cylinder

Outrigger

- 14 -

Good No good

Operating condition and effect of the horizontal setting stopperEffect of the stopper pin when loaded or set and deformation of pinDeformation and crack of the inner boxDamage of the lock leverOil leakage/natural sinking of the outrigger cylinderOperation of the one-touch lever and condition of the cable terminalLooseness/falling off of the bolts, nuts, pins, etc. in the mounting units

Outrigger

Contents of checkCheck point measureRemedialResult of check

After the outriggersare completelystored, check the following.

① Release the grip of extension lever.② Blue markon the top of extension lever is

fully visible.③The horizontalmembersof outriggerare

securelylockedso that they will not stickout sideways out of the vehicle.

● RemarksFully visible bluemark indicates thatthe lock pin for thehorizontal memberof outrigger is inserted into the hole.

Check if the snap ring is properly mounted.

Check the connecting unit for oil leakage.

Check the horizontal inner box for deformation, crack, etc.

Check the vertical inner box for sticking and deformation.

Check if the snap ring is properly mounted.

Crack of the drum

lubrication to the gears

Loosenessfalling off of the bolts

the air breatherDamage of

filler portGear oil

deteriorationof the gear oil

Quantity and

Oil leakage

Hoist motor Winch reduction gear

Hoist winch

Replacement of gear oil

★Air enters in and out of the gear case sothat dirt and moisture are brought in thegear case.In addition, since hydraulic equipmentgradually wears to produce worn particles,replace the oil 6 months after the start ofoperation.

★After that replace gear oil; Once a year for winch reduction gear, and. Once every 2 years for slewing reduction gear.

★For gear oil to lubricate winch reduc-tion gears, fill it up to the middle of the oillevel gauge (approx. 1.0 liter).

Drain plug

- 15 -

Good No good

Operating condition, abnormal noise and oil leakage

Damage of the air breather

Quantity and deterioration of the gear oil

Crack of the drum and lubrication to the gears

Looseness/falling off of the bolts and nuts in the mounting units

Hoistwinch

Contents of checkCheck point measureRemedialResult of check

CAUTION★Replace gear oil after oil tem-perature has dropped.

(Winch reduction gear)

of the boltsLooseness falling off

Slewing device Slewing device （Turntable）

Slewing bearing

Table-turn

Shaft-gear

Wheel-worm

Hydraulic motor(Slewing)

Grease nipple

Check the gear oil for contamination and level.

Check this partfor damage.

Check the mountingbolt for looseness.

Remove the cover,and check the gear teethfor crack.

- 16 -

Good No good

Operating condition, abnormal noise and oil leakageDamage of the air breatherQuantity and deterioration of the gear oilOperating condition, abnormal noise and lubrication of the turntableLooseness/falling off of the bolts and nuts in the mounting units

Contents of checkCheck point Remedialmeasure

Result of check

Slewingdevice

Cover

Inspectionhole

When the slewing device makes an unusualnoise while operating or traveling of thecrane, or when a gap is created on the mount-ing surface, contact a UNIC authorized ser-vice shop for inspection and/or repair.

Slewing bearing

Mounting bolts

Mounting bolts

Cover

Inspectionhole

◆ Inspection of mounting bolts locatedinner race

1. Remove the cover to inspection hole.2. Slew the boom so that each mounting bolt

comes to the center of inspection hole forinspection.

3. Fit the cover as it was after inspection.

Inspection of the slewing bearingmounting bolts

- 17 -

4. Lubrication to slewing bear-ings

The machine uses ball bearing as the slewingbearing.Be sure to lubricate the bearing as insuf fi-cient lubrication may cause it to make unusu-al noise. Grease in the nipples while slewing the boomonce a month for moderate operation, andonce a week for heavy-duty operation.

Grease nipple

◆3. Replacement of gear oil(Winch reduction gear ･ Slewing reduc-tion gear)

★ Air enters in and out of the gear case sothat dirt and moisture are brought in thegear case.In addition, since hydraulic equipmentgradually wears to produce worn particles,replace the oil 6 months after the start ofoperation.★After that replace gear oil;

･Once every 2 years for slewing reduc-tion gear.

★ For gear oil to lubricate slewing reduc-tion gears, fill it up to a level betweenupper and lower limit marks of the oillevel gauge (approx. 0.7 liters).

Check oil level not by tighten up the oillevel gauge cap but by just inserting thegauge in the filler port.

- 18 -

Slewing reduction gear(Draining oil)

Drain plug

Level gauge

(Supplying oil)

Gear oil filler port

Upper limit

Lower limitOil surface

Replacement of brake shoe in hoisting winch

Telescoping cylinder／Boom

Replace it every 3 years.

Slide plate

Apply grease to thesupport pin.

Check this partfor oil leakage. Telescoping cylinder(1) Telescoping cylinder(2)

Rope-wire(Boom Ret) Rope-wire(Boom Ext)

Apply grease when retracted to the utmost.(Grease nipple) Boom(1) Bppm(2) Boom(3) Boom(4)

Remove the cover andcheck the inside.

Check the sheave for rotation,damage and wear.

Check the slide sheavefor operation.

Check the bolt for looseness.

Check the boltfor looseness.

Check the boltfor looseness.

Check each boom for deformation, etc.Apply grease to the side surface and lower surfaceon the 2-section boom and other booms.

- 19 -

Good No good

Operating conditionOil leakage/natural sinking of the telescoping cylinderMounting condition of the support pin and falling off of the snap ringLooseness/falling off of the bolts and nuts in the mounting boltsOperating condition (extension/retraction) and lubricationDeformation/crack of the boom and wear of the slide plateLooseness/falling off of the slide plate mounting bolts

Mounting condition of the support pin and sheave pinLooseness/falling off of the bolts, nuts, pins, etc. in the mounting unitsLooseness and wear of the extending wire, cutting of its strand and corrosion (4- to 6-section)Looseness of the retracting wire (4- to 6-section)

Boom

cylinderTelescoping

Contents of checkCheck point Remedial measure

checkResult of

Damage, wear and rotation of the sheave

Swiveljoint／Derrick cylinder／Column／Piping

- 20 -

Derrickcylinder

Column

Swiveljoint

Good No good

Looseness/falling off of the bolts and nuts in the mounting unitsLooseness of the stopper mounting bolts and deformation of the plate

Continuity of the slip ring, damage of wiring and mounting conditionOperating conditionPlay of the derrick cylinder upper/lower pinsOil leakage/natural sinking of the derrick cylinderLooseness/falling off of the bolts and nuts in the mounting unitsCrack and deformationLooseness of the turntable mounting boltsOil leakage

Oil leakage

Supporting condition of the pipesDamage, aging, crack, twist and crushed status

Swiveljoint

Contents of checkCheck pointRemedialmeasure

Result of check

Piping

Derrickcylinder

Column

Wire ropeWire rope is an expendable article and it will be damaged orWire rope is an expendable article and it will be damaged orbroken in its strand wires through a long period of use. Replace the rope according to following criteria.

◆1. Replacement criteria1. A rope in which amount of broken strand wires (exceptfiller wires) comes to more than 10% within a pitch of strand. Replace the wire ropes intended for use with this crane if 13pieces of strand wire have been broken within a pitch ofstrand.

2. A rope being kinked.

3.A rope from which its diameter has decreased by morethan 7% of the nominal diameter. For example, if wire rope with a nominal diameter of 8mm isused, replace it when the diameter becomes 7.5mm. For length and construction of the wire rope for winding-up.

4. A rope which has been deformed and/or corroded exces-sively.

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

1

2

3

4

Diameter ofrope

- 21 -

Wear, cutting of the strand, deformation, kink, corrosion and lubrication

Specification (length and thickness)

Check point

Wirerope Tight connection to the wire socket and clipping of the terminal

Deformation and crack of the wire socket

Tight connection to the drum, confused winding and kink

Mounting condition of the support pin and looseness/falling off of the bolts

Good No good

Remedialmeasure

Result ofcheckContents of check

-22

-

Visually check the wire rope parts passing through the sheave frequently and others for damage. Compare the damage status with the damaged wire rope in the photos. Inspect the wire rope by the following steps.

Step 1: Deformation Step 2: Wear and corrosion Step 3: BreakageStep 1: Deformation Step 2: Wear and corrosion Step 3: BreakageStep 1: Deformation Step 2: Wear and corrosion Step 3: Breakage

If the wire rope meets one of the standards for disposal, dispose of the rope.STEP1

The strand wire is protruded.

The core wire is protruded.

The strand wire is sunk.

The strand wire is exposed.

Flattened.

The wire rope is pressed locally to be flattened.

Kinked.

The strand wire is locally tightened.

Twisted.Kinked.

The strand wire is locally loosened.

Spiral status

Basket status

The wire rope is swollen to be like a basket.

● DeformationCompare the deformed part with the similar damaged part in the photos.

Easy inspection of the wire rope used in crane, etc.

Easy inspection of the wire rope used in crane, etc.(1) When crown breakage (broken thread) has occurred Count the broken wires in the following two ranges:

one range is six times larger (approx. 1 pitch) than the rope diameter (d) and, the other, thirty times larger (approx. 5 pitches). Then, check the wire rope composition. If the broken wires are beyond the quantity shown in the following table, dispose of the wire rope.

(2) When nip breakage (broken root) has occurred If nip breakage has occurred in one wire, dispose of

the wire rope at once.

Standard of disposal

STEP2● Wear and corrosionWhen the rope is worn and so its surface glistens or when you see red rust on the rope surface, wipe the trouble part well to remove oil or stain. Then, com-pare the part with the damaged wire rope in the photos.

● BreakageVisually check the wire rope. If you have found the breakage part, wipe its vicinity well to remove oil or stain and then inspect the part. After the inspection, apply the rope grease to it.

STEP3

Wear

There is no clearance between the strand wires.

Corrosion

Pitching has occurred and so the wire rope surface is pitted.

Crown breakage (broken thread)

Nip breakage(broken root) 6d 30d

18×7 19×7 4 8

6×Fi(25) 5 10

6×WS(26) 5 10

6×P･WS(26) 5 10

34×7 35×7 5 10

6×Fi(29) 6 11

6×WS(31) 6 13

6×WS(36) 7 14

6×P･WS(36) 7 14

6×SeS(37) 8 16

6×P･WS(41) 9 18

6×37 10 19

6×F(40) 2 4

3×F(40) 2 4

Wire rope composition

Visible broken wires

Inspection range

･ Handle the wire rope of IWRC in the same way.

- 2

3 -

- 24 -

How to r eplace wire rope

1. Refer to the figure in the left for how to hook the wireropes for hoisting and for where to mount the weight foroverwinding alarm.

Boom top

Guide

Front of boom

Higher sideis to the front

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

For Uni-hook type

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Wire rope end40mm Where cut out

Wire clip(pay attention tomounting direction)

50mm

Arrow mark

Wedge(Diameter of wire rope=8mm)

Stopper

Projection on upper partof wire socket

Pass the pin through andtighten it securely with bolt.

If rope end is left by more than 40mm(as “a” illustrated-above), rope end is visible through this hole, if not, adjust length of rope end.

Wedge

2. How to fix the wire rope end

Winch drumWhen passing a wire rope end through the winch drum,pass it so that the rope end comes inside as illustrated inthe left.

Pay attention that wire rope end will not be jutted out ofthe winding-up area of winch drum.

In order to avoid irregular winding, wind up a wire ropeslowly on the drum along its groove with a proper tensionapplied to the rope to form the 1st layer.From the 2nd layer on, wind up the rope over the wound-up layer so that it is fit in each gutter formed betweenropes wound side by side of the layer below.

Wire socketWhen passing a wire rope end through the wire socket, besure to pass it as indicated by the arrows on the socket.Leave the wire rope end more than 40 mm as “a” illustrat-ed in the figure in the left.If it is passed from the opposite direction, service life ofthe wire rope shrinks as the wire rope is kept bent all thetime.

Do not forget to mount the wedge and the wire clip asillustrated in the figure in the left.

Pass the pin through with the wire socket held with yourhand and tighten it with the bolt securely.

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3. How to correct the twisted wire ropes Wire ropes tend to turn in the untwisting direction when theyare under tension.If two or more wire ropes are hooked together, they tend tobe twisted particularly while they are new.The twist will decrease as the ropes are getting fit to thecrane.

If wire ropes are twisted, correct them as follows; Unload the hook.

Extend the boom fully.

Set the boom to an angle of approximately 65°.

Unwind the hook until it comes close to the ground.

Check how many turns the wire rope has been twisted.

Hoist the hook and retract the boom to be on a storedcondition.

Remove the wire socket and turn the socket in theuntwisting direction by as many turns as the wire ropes havebeen twisted multiplied by the number of wire ropes hooked. Remember, however, that the wire socket may be turned upto 4 turns at a time.

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

Wire socket

Untwistingdirection

4 wire ropes

Wire rope’s twistingdirection

Note : Turn the wire socket in the direction opposite to wire rope twisting.

Good No good

Wear, deformation, rotation and lubrication of the hookAim point distance of the hookDamage, wear, rotation and lubrication of the sheavePlay of the hook screw unit and thrust bearing (worn condition)Rotating status of the hook loading roller and deformation of the roller mounting bracket

Check point Remedialmeasure

Result of checkContents of check

Hook

Looseness and falling off of the bolts, nuts, pins, etc. in the mounting units

The nut thread part is worn.

The thrust bearing is worn.

Play of trunnion

Hook

GapReference value = 1mmSpecified value for replacement = 2mm

Hook

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Check the worn status of the thrust bearing.Measure the gap between the hook and trunnion. If it is the specified value or more, replace the thrust bearing.* If the measured value is beneath the specified value and the bearing does not rotate well, it is worn in a great degree. Replace the bearing as early as pos sible.* If the bearing is worn, the nut thread part is increasingly burdened. If you keep using the bearing, the nut thread part will also be worn.* When checking the bearing, check if play occurs in the nut thread part. If play occurs, replace the hook and nut.

MPaA

B

770363331

Check the swivel elbow unit and the load meterfor oil leakage.

Load meter

Number of ropesbeing hooked

Load meter

１５

２０

２５

１０

５

０

29

2

1

0

0

1

2

29

3

0

0.5

0.73

３

Load meter

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Good No goodLoad detector Operating condition, oil leakage and damage

Check point measureRemedialResult of checkContents of check

4-part lines

1-part line

4-part lines

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Load indicator(with angle indicator)

Good No good

Falling off of the pointer, damage of the name plate and operating condition

measureRemedial

Result of checkContents of checkCheck point

Load indication

R ATE D L OADS A R E B AS E D ON T HE C R ANE

S TR E NGTH R ATHE R T HAN S TAB ILITY

(t)

RATED LOADS

091U86010-V344

(Side of boom)

Scale

(The chart is an example showing for URV344)

Pointer

Automatic stop for overwinding／Over-winding alarm

detectorOverwinding

overwinding alarmWeight for

Level

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Good No good

Damage of the weight and sling wire

Winding status of the cord reel and damage/disconnection of the cord

Operating condition, over-winding detection switch and alarm sound

Remedialmeasure

Result of check

Good No goodRemedialmeasure

Result of check

Contents of checkCheck point

Check point

Over-winding

Mounting conditionLevel

alarm/auto-

matic stop

Contents of check

Warning horn

Name plate

Warning horn switharning horn swith

Check the warning horn for the following points:operating condition, alarm sound, damage of wiring,corrosion of the connecting terminal and mounting condition.

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Operating condition and alarm sound

Mounting condition, damage and deterioration of the name plate

Contents of check

Contents of check

Check point

Alarm

Check point

Name plateGood No good

Remedialmeasure

Result of check

Good No goodRemedialmeasure

Result of check

URV34 Crane modelSpecifications Serial number Code number

Warning horn swith

MODEL

SPEC.

CODE NO.

SERIAL NO.

CAPACITY t

TOKYO JAPANMADE IN JAPAN

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Good No goodRemedialmeasure

Result of checkCheck point Contents of check

Base／Chassis frame

Base

Deformation of the stopper

Deformation and crack of the base main body and the mounting base

Looseness/falling off of the mounting bolts and nuts

Bend, deformation and crack

Mounting condition and deformation of the stopper

Base

Chassisframe

- 3

3 -

YES

YES

YES

YES

YES

YES

NO

NO

NO

Inspection for sinking of cylinder

The load is lowered.

Set the conditions for sinking in the crane. Stop the engine, change the lever and remove the pressure. Then, start the test.

The outrigger cylinder sinks.

The derrick cylinder sinks.

The telescoping cylinder sinks.

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

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

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

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

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

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

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

Check the pilot.The seat surface is damaged.

Foreign matter is caught by the seat surface.

Foreign matter is caught by the seat surface.

Foreign matter is caught by the seat surface.

The counterbalance valve malfunctions.The seat surface is damaged.

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

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

The counterbalance valve malfunctions.The seat surface is damaged.

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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 forraising/lowering of booms.

(2) Starting inspectionRemove 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 thelowering 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

INSUPECTION PROCEDURES WHEN CYLINDER SINKE

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INSUPECTION PROCEDURES WHEN CYLINDER SINKE Inspection of telescoping cylinder (3-section or 4-section boom)

(1) Preparation before inspectionAllow booms to be horizontal and extend them fully to put amark 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 telescopingbooms.

(2) Starting inspectionRemove the retraction hose to check if oil overflowscontinuously out of the cylinder port of retraction side.At he same time, also check that which boom section sinkshow far to grasp condition of booms as a whole.If no oil flows out of the port of retraction side, the cylinder isnormal.Next, remove the extension hose, and if oil overflowscontinuously out of counter-balance valve port of extensionside, there may be faulty on the seat surface of counter-balancevalve (refer to Fig. 3).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 theretraction hose has been removed (refer to Fig. 2).Since overflowing oil out of the port on retraction sidemeans internal leakage in the cylinder, check tele1 andtele2 separately.Be sure to measure the how far each boom sinks as it isan important point for judging that it is normal orabnormal.

(3) Inspection of tele1Extend booms to a position where it is a little bit shorter than2-section boom to put a mark on the boom (refer to Fig. 4).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 telescopingbooms.Remove the retraction hose.If oil overflows out of cylinder port of retraction side andboom2 sinks, there may be internal oil leakage in tele1.In addition, check how far boom2 sinks simultaneously.

(4) Inspection of tele2Allow booms to be horizontal and extend them fully to put amark 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 telescopingbooms.Remove the retraction hose.If oil overflows out of cylinder port of retraction side andboom3 sinks, there may be internal oil leakage in tele2.In addition, check how far boom3 sinks simultaneously.

The same procedures in checking boom sinkage are applied for5-section boomBe sure to check the boom sections one by one reliably.

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Inspection of outrigger cylinder(1) Preparation before inspection

Extend outrigger cylinders to their extremes.Put a mark on the rod with a felt pen (refer to Fig. 1).In order to release pressure remained in the outrigger system, stop the engine and shift the manual levers forextension/retraction of outriggers.

(2) Starting inspectionRemove the retraction pipe to check if oil overflows continuously out of the cylinder port of retraction 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 extension pipe, and if oil overflows continuously out of the pilot check valve port of raisingside, there may be faulty on the seat surface of pilot check valve (refer to Fig. 2).In addition, check how far the cylinder sinks simultaneously.

Caution:In order to release pilot pressure in the retraction side, be sure to remove the extension pipe afterthe retraction pipe has been removed (refer to Fig. 1).If oil overflows out of the port on retraction 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

INSUPECTION PROCEDURES WHEN CYLINDER SINKE