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UNIC CRANE
MAINTENANCE
MANUAL
CONTENTS DESCRIPTION OF MAJOR EQUIPMENT Inspection before operation Replacement of expendable parts/Welding precautions List of recommended lubricants Lubrication chart Annual self-inspection record PTO／Hydraulic pump Propeller shaft／Hydraulic pump Hydraulic oil tank
1 2 3 4 5 6 8 9 10
Replacement of hydraulic oil／Draining hydraulic tank
11
Replacement of return filter／Replacement of line filter element
12
Control valve Outrigger Hoist winch Slewing device
13
Inspection of the slewing bearing mounting bolts
17
Replacement of gear oil／Lubrication to slewing bearings
18
Telescoping cylinder／Boom Swiveljoint／Derrick cylinder／Column／Piping Wire rope
19
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 Load meter Load indicator Automatic stop for overwinding／Over-winding alarm／Level Worning horn／Name plate Base／Chassis frame INSUPECTION PROCEDURES WHEN CYLINDER SINKE
27
Inspection of derrick cylinder
34
Inspection of telescoping cylinder
35
Inspection of outrigger cylinder
36
14 15 16
20 21
28 29 30 31 32 33
DESCRIPTION OF MAJOR EQUIPMENT 11 8
5 10 18
21
13
19
7,16 9
14 1
22,23
23 3 17 24 15
20
1 2
4
12 6
1 P. T.O.lever 2 Propeller shaft 3 Differential oil tank 4 Oil hydraulic pump 5 Control Valve 6 Outrigger
7 Swivel joint 8 Hoist winch 9 Slewing device 10 Derrick cylinder 11 Telescoping cylinder 12 Base
13 Column 14 Boom 15 Wire rope 16 Pipeing 17 Hook 18 Load meter
- 1 -
19 Load indicator 20 Overwinding stop 21 Level 22 Warning horn 23 Name plate 24 Chassis frame
Inspection before operation In order to secure safe operation and improve working efficiency, be sure to inspect each part of the crane according to the table as follows;
Device
Inspection for:
Check
Device
Inspection for:
P.T.O.
Oil leakage, Unusual noise
Wire rope
Damage, Condition of rope-end
Hydraulic oil tank
Oil level, Oil leakage
Overwinding alarm
Operation, Buzzer sound
Outriggers
Operation, Deformation, Damage, Oil leakage, Cracks
Load meter
Oil leakage, Operation
Hoisting winch
Operation, Braking function, Irregular winding
Warning horn
Operation
Slewing device
Operation, Oil leakage
Piping(hydraulic)
Oil leakage
Boom(derricking)
Operation, Oil leakage, Mounting of foot-pin
Base
Boom(telescoping)
Operation, Oil leakage, Deformation, Cracks, Mounting of fixing pin
Fastening tightness of crane body mounting bolts
Slinging implements
Missing necessary items
Hook
Rotation of hook, Function of hook safety latch
Uni-hook
Operation of automatic stop and storing function
CAUTION Always keep the machine in good condition so that it is ready for normal operation.
Cleaning Keep the machine clean at any time. Sand and fine dust may cause an abnormal wear of the machine. Do not wash the machine by splashing water with high-pressure to prevent the water from entering into the electric system which may cause malfunction of the machine.
-2-
Check
Replacement of expendable parts 1. Replacement of gaskets and seals for each cylinder Although timing of replacing 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 is not operated is included) in order to operate the crane safely. Ask a local UNIC authorized service shop for replacement of gaskets and/or seals.
2. Replacement of sliding plate of boom Sliding plate
Replace it every 3 years.
3. Replacement of brake shoe in hoisting winch Replace it every 3 years.
Brake shoe
No grounding
Outrigger cylinder
Welding precautions When welding is needed for some reason, do not use outrigger cylinder for welding ground as the cylinder rod and/or the piston may be damaged by electric sparks due to current flown in the inner part of cylinder.
-3-
◆1. List of recommended lubricants ★RECOMMENDED GREASE (a) Chassis grease Use NLGI No. 1 grade. Petroleum Maker
Brand
ESSO
Chassis grease L
MOBIL
HP221
CALTEX
Multifak EPI
SHELL
RETINAX-CD
(b) Molybdenum grease Use NLGI No. 2 grade. Petroleum Maker
Brand
ESSO
Beacon Q2
MOBIL
Mobilplex Special
CALTEX
Molytex Grease EP2
SHELL
Retinax AM
★RECOMMENDED GEAR OIL Use API Service GL-4 gear oils. Petroleum Maker
Brand
ESSO
Standard gear oil 90
MOBIL
Mobilube SAE 90
CALTEX
Universal Thuban SAE 90
SHELL
Shel Spirax EP 90
★RECOMMENDED HYDRAULIC OIL Use industrial-type hydraulic oil; ISO VG 46 for most temperatures ISO VG 32 extremely low temperatures Petroleum Maker
Brand ISO VG 32
ISO VG 46
ESSO
UNVICE J32
Teresso 46
MOBIL
Mobil DTE 13
Mobil DTE 25
CALTEX
Rando Oil HD AZ32
Rando Oil 46
SHELL
Shell Tellus Oil 32
Shell Tellus Oil 46
-4-
Lubrication chart 3-section boom
4-section boom 5-section boom
6-section boom
Service interval
Daily
Weekly
Monthly
Do not apply grease to the slide-sheave pin.
Part to be lubricate 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 pin Upper support pin of derrick cylinder Lower support pin of derrick cylinder Oil tank(59l) Winch drum gear Slewing gear(to gear-teeth) Propeller shaft Winch reduction gear(approx.1.0l) Slewing reduction gear(approx.1.2l) Wire rope Slewing bearings Wire rope for boom extension -5-
No. of Lubricant Tool part 2 Molybdenum grease Manual application 3
Molybdenum grease Manual application
4
Molybdenum grease Manual application
5
Molybdenum grease Manual application
2 1 1 1 1
Molybdenum grease Grease pump Chassis grease Grease pump Chassis grease Grease pump Chassis grease Grease pump Hydraulic oil(up to middle of level gauge)
1 1 3
Chassis grease Chassis grease Chassis grease
Grease pump Manual application Grease pump
1 1 1 2
Gear oil Gear oil Rope grease Chassis grease Rope grease
Spray gun Grease pump Spray gun
When you perform the annual inspection, copy this sheet and use it. Annual self-inspection record Store the inspection results for 3 years.
Propeller
2 shaft
Hydraulic
3 pump
Hydraulic
4 oil tank
Control
5 valve
6 Outrigger
Swivel
7 joint
Hoist
8 winch
Slewing
9 device
レ 〇
Replacement
Repair
× △
Adjustment
Tightening
A T
Cleaning Lubrication
Result of check
Contents of check
Check point 1 PTO
Check Disassembly
Good
C L Remedial
No good measure
Operation of “ON” and “OFF”, abnormal noise and oil leakag Operation of the PTO check lamp Looseness/falling off of the bolts and nuts in the mounting unit Play of the universal joint/spline and lubricatio Looseness/falling off of the bolts and nuts in the mounting unit Operating condition, abnormal noise and oil leakag Setting of the rated rotation Looseness/falling off of the bolts and nuts in the mounting unit Oil leakage and crack Quantity, contamination and deterioration of the hydraulic o Stain and damage of the air breather and suction filte Operating status, deformation and crack of the lever Falling off of knob and exfoliation/deterioration of stick Oil leakage Looseness/falling off of the bolts, nuts, pins, etc. in the mounting unit Set pressure of the relief valve Operating condition and effect of the horizontal setting stoppe Effect of the stopper pin when loaded or set and deformation of pi Deformation and crack of the inner box Damage of the lock lever Oil leakage/natural sinking of the outrigger cylinde Operation of the one-touch lever and condition of the cable termina Looseness/falling off of the bolts, nuts, pins, etc. in the mounting unit Oil leakage Looseness of the stopper mounting bolts and deformation of the plat Looseness/falling off of the bolts and nuts in the mounting unit Continuity of the slip ring, damage of wiring and mounting conditio Operating condition, abnormal noise and oil leakag Damage of the air breather Quantity and deterioration of the gear oi Crack of the drum and lubrication to the gear Looseness/falling off of the bolts and nuts in the mounting unit
Operating condition, abnormal noise and oil leakag Damage of the air breather Quantity and deterioration of the gear oi Operating condition, abnormal noise and lubrication of the turntabl Looseness/falling off of the bolts and nuts in the mounting unit
Operating condition Play of the derrick cylinder upper/lower pin 10 Oil leakage/natural sinking of the derrick cylinde Looseness/falling off of the bolts and nuts in the mounting unit Operating condition Telescopin Oil leakage/natural sinking of the telescoping cylinde 11 g Mounting condition of the support pin and falling off of the snap rin cylinder Looseness/falling off of the bolts and nuts in the mounting bolt Deformation and crack of the base main body and the mounting bas 12 Base Looseness/falling off of the mounting bolts and nut 13 Column Crack and deformation Looseness of the turntable mounting bolts Operating condition (extension/retraction) and lubricatio Deformation/crack of the boom and wear of the slide plat 14 Boom Looseness/falling off of the slide plate mounting bolt Damage, wear and rotation of the sheave Mounting condition of the support pin and sheave pin Derrick cylinder
User Company name that has performed the inspection
Crane model Serial No. Date of delivery
.
.
.
Date of practice
.
.
.
Person in charge of inspection Signature
-6-
When you perform the annual inspection, copy this sheet and use it. Annual self-inspection record Store the inspection results for 3 years.
Check Disassembly
Replacement
Repair
× △
Adjustment
Tightening
A T
Cleaning Lubrication
Result of check
Contents of check
Check point
レ 〇
Good
C L Remedial
No good measure
Looseness/falling off of the bolts, nuts, pins, etc. in the mounting units Looseness 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 lubrication Tight connection to the wire socket and clipping of the terminal Wire rope 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 Oil leakage Piping Supporting condition of the pipes Damage, aging, crack, twist and crushed status Wear, deformation, rotation and lubrication of the hook Aim point distance of the hook Damage, wear, rotation and lubrication of the sheave Hook Operation, deformation and damage of the stopper Play of the hook screw unit and thrust bearing (worn condition) Rotating status of the hook loading roller and deformation of the roller mounting bracket Looseness and falling off of the bolts, nuts, pins, etc. in the mounting units Load detector Operating condition, oil leakage and damage Load indication Falling off of the pointer, damage of the name plate and operating condition Operating condition, over-winding detection switch and alarm sound Over-winding alarm/automatic Winding status of the cord reel and damage/disconnection of the cord stop Damage of the weight and sling wire Level Mounting condition Alarm Operating condition and alarm sound Name plate Mounting condition, damage and deterioration of the name plate Bend, deformation and crack Chassis frame Mounting condition and deformation of the stopper Sling the rated load and check the hoisting and braking abilities. Load test/ Sling the rated load and check the natural sinking of the derrick cylinder. Test load Sling the rated load and check the natural sinking of the outrigger cylinder. ( ton) 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 condition Mounting condition of the reception antenna Condition of the transmitter case Radio Connection, looseness, stain and corrosion of the cables control (Remote Damage, deterioration and twist of the wires and cables control) Corrosion, deterioration and looseness of the contact terminal Oil leakage from the accelerator cylinder/piping unit Operating condition and oil leakage of the solenoid valves Operating condition of the indicator units ＭＬ Operating condition of the alarm buzzer at the alarm point Operating condition of the crane at the alarm point (Stop type) Turnover Operating condition of the alarm buzzer at the alarm point preventive device Operating condition of the crane at the alarm point
14 Boom
15
16
17
18 19 20 21 22 23 24
25
Option
Other special mention
User Company name that has performed the inspection
Crane model Serial No. Date of delivery Date of practice
.
.
.
Person in charge of inspection Signature
.
.
.
-7-
PTO / Hydraulic pump Check PTO for the ON/OFF operation.
Depress the clutch pedal fully to disengage the clutch. Pull the PTO lever to its extreme. Release the clutch pedal gradually. Check that the PTO indicator lamp lights.
Set PTO to "OFF". (The lamp is lit.) The crane operation is finished.
Truck engine Transmission
Hydraulic pump
PTO（Power Take Off）
Check the bolts, nuts, and pins. Check the parts for oil leakage.
Disulfide molybdenum grease No.2 Greasing the shaft and spline of the directlyconnected pump To prevent rust and wear, apply the disulfide molybdenum grease No. 2 to the pump shaft and the PTO spline unit.
Check point
Contents of check Operation of “ON” and “OFF”, abnormal noise and oil leakage
PTO
Operation of the PTO check lamp Looseness/falling off of the bolts and nuts in the mounting units
Hydraulic Operating condition, abnormal noise and oil leakage Setting of the rated rotation pump -8-
Result of
check
Good No good
Remedial
measure
Propeller shaft／Hydraulic pump Spline yoke
Check of play Weld yoke Spline shaft
Pump mounting side
Grease nipple
Spline yoke
Check the bolt for looseness. Sway of shaft PTO mounting side Apply grease. Check the bolt for looseness.
Chassis grease No. 1
Disulfide molybdenum grease No. 2
Greasing the universal joint of the propeller shaft Greasing the pump shaft spline of the propeller shaft 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 point
Contents of check
Propeller shaft
Play of the universal joint/spline and lubrication
Hydraulic pump
Operating condition, abnormal noise and oil leakage Setting of the rated rotation
Looseness/falling off of the bolts and nuts in the mounting units
Looseness/falling off of the bolts and nuts in the mounting units
-9-
Result of Remedial check Good No good measure
Hydraulic oil tank
Filler port of hydraulic oil
Check the oil level.
Check the air breather for stain.
Return filter
Hydraulic oil tank
Suction filter Check the suction filter for stain, deterioration and oil leakage.
Drain plug
Check point
Contents of check Oil leakage and crack
Hydraulic Quantity, contamination and deterioration of the hydraulic oil oil tank Stain and damage of the air breather and suction filter
- 10 -
Result of Remedial check measure Good No good
◆1. Replacement of hydraulic oil ★ The amount required for oil change is 32 liters when filled up to the middle between upper and lower limits of the level gauge. ★ The oil should be replaced at early autumn because there is possibility of freezing moisture in the tank as well as in the hydraulic circuit when temperature goes below the freezing point.(Depending on the countries)
Upper limit Lower limit Level gauge
★ Air entering in the oil tank brings dirt and moisture. In addition, since hydraulic equipment gradually wears to produce worn particles, replace the oil 3 months after the start of crane operation then once a year thereafter.
★ T ighten the cap securely with your hand after oil has been refilled. Remember that hydraulic oil may leak out if the cap is loosely tightened.
CAUTION ★ Do not mix a different brand of hydraulic oil as properties of mixed oil deteriorates and damage to hydraulic equipment results.
◆2. Draining hydraulic tank Remove moisture in the hydraulic tank. Moisture may enter through the air-breather and it is mixed with the hydraulic oil when the crane has been operated for a long time. Remove the drain plug located at lower part on the tank to drain the water.
Drain plug
- 11 -
Replacement of return filter The replacement of the return filter is depends on how often the crane has been operated, however, as a general rule, replace it after 3 months of initial operation and once a year thereafter. Return filter
How to replace ● Give the gasket a thin coat of oil. ● Screw in the cartridge and tighten it with your hand securely.
Line filter
Element
Replacement of line filter element Replace the inner element of line filter after 1 year from the start of operation. Be sure to replace the element when the hydraulic pump is replaced and replace it after 1 year from the start of operation of the pump.
(Showing left-hand side of control valve)
- 12 -
Boom derricking lever〔raise/lower〕 Hook lever〔hoisting/lower〕 Boom telescoping lever〔retract/extend〕
Control valve
Slewing lever〔clockwise/counter clockwise〕
Load meter
Check these parts for oil leakage. Check the nut for looseness.
Check the sticker for exfoliation.
Outrigger control lever[extension/retraction]
Check the levers for the operating status, deformation and crack. Check if the pin or any other part has fallen off.
Contents of check
Check point
Control valve
Operating status, deformation and crack of the levers Falling off of knob and exfoliation/deterioration of sticker
Oil leakage Looseness/falling off of the bolts, nuts, pins, etc. in the mounting units
Set pressure of the relief valve
- 13 -
Result of Remedial check measure Good No good
Outrigger 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 Valve
Shift the lock lever for lock.
Outrigger cylinder
● Remarks Shift ing the lock levers for lock pr events the horizontal members of outrigger from sticking out by car eless grip of extension lever. In addition, this pr events a rattling noise rom the horizontal members of outrigger while the vehicle is traveling.
Check the vertical inner box for sticking and deformation.
● Remarks Fully visible blue mark indicates that the lock pin for the horizontal member of outrigger is inserted into the hole. After the outriggersare completely stored, check the following. ① Release the grip of extension lever . ② Blue mark on the top of extension lever is fully visible. ③ The horizontal membersof outrigger are securelylocked so that they will not stick out sideways out of the vehicle.
Check point
Check if the snap ring is properly mounted.
Contents of check Operating condition and effect of the horizontal setting stopper Effect of the stopper pin when loaded or set and deformation of pin
Outrigger
Deformation and crack of the inner box Damage of the lock lever Oil leakage/natural sinking of the outrigger cylinder Operation of the one-touch lever and condition of the cable terminal
Looseness/falling off of the bolts, nuts, pins, etc. in the mounting units - 14 -
Result of check Good No good
Remedial measure
Hoist winch Crack of the drum
lubrication to the gears Looseness falling off of the bolts
Damage of the air breather Looseness falling off of the bolts Gear oil filler port
Replacement of gear oil (Winch reduction gear) Winch reduction gear
Hoist motor
★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 the oil 6 months after the start of operation. ★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 reduction gears, fill it up to the middle of the oil level gauge (approx. 1.0 liter).
Quantity and deterioration of the gear oil Drain plug
Oil leakage
CAUTION ★Replace gear oil after oil temperature has dropped.
Check point
Contents of check Operating condition, abnormal noise and oil leakage
Hoist winch
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
- 15 -
Result of check
Good No good
Remedial measure
Slewing device （Turntable）
Slewing device
Slewing bearing Grease nipple
Remove the cover, and check the gear teeth for crack.
Check the mounting bolt for looseness. Check this part for damage.
Table-turn Shaft-gear Wheel-worm Hydraulic motor(Slewing) Check the gear oil for contamination and level. Cover
Inspection hole
Check point
Slewing device
Contents of check Operating condition, abnormal noise and oil leakage Damage of the air breather
Quantity and deterioration of the gear oil Operating condition, abnormal noise and lubrication of the turntable
Looseness/falling off of the bolts and nuts in the mounting units
- 16 -
Result of check Good No good
Remedial measure
Mounting bolts Mounting bolts
Inspection of the slewing bearing mounting bolts When the slewing device makes an unusual noise while operating or traveling of the crane, or when a gap is created on the mounting surface, contact a UNIC authorized service shop for inspection and/or repair.
Slewing bearing
◆ Inspection of mounting bolts located inner race 1. Remove the cover to inspection hole. 2. Slew the boom so that each mounting bolt comes to the center of inspection hole for inspection. 3. Fit the cover as it was after inspection.
Cover
Inspection hole
- 17 -
◆3. Replacement of gear oil (Winch reduction gear ･ Slewing reduction gear)
Slewing reduction gear (Draining oil)
★ Air enters in and out of the gear case so
Drain plug Level gauge
Gear oil filler port
that dirt and moisture are brought in the gear case. In addition, since hydraulic equipment gradually wears to produce worn particles, r eplace the oil 6 months after the start of operation. ★ After that replace gear oil; ･Once every 2 years for slewing reduction gear. ★ For gear oil to lubricate slewing reduction gears, fill it up to a level between upper and lower limit marks of the oil level gauge (approx. 0.7 liters). Check oil level not by tighten up the oil level gauge cap but by just inserting the gauge in the filler port.
Upper limit
Oil surface
Lower limit
(Supplying oil)
4. Lubrication to slewing bearings
Grease nipple
The machine uses ball bearing as the slewing bearing. Be sure to lubricate the bearing as insuf ficient lubrication may cause it to make unusual noise. Grease in the nipples while slewing the boom once a month for moderate operation, and once a week for heavy-duty operation.
- 18 -
Telescoping cylinder／Boom Apply grease when retracted to the utmost. (Grease nipple)
Boom(1)
Bppm(2)
Boom(3)
Boom(4)
Remove the cover and check the inside.
Check the slide sheave for operation.
Apply grease to the support pin.
Rope-wire(Boom Ret) Rope-wire(Boom Ext)
Check the bolt for looseness.
Check this part for oil leakage.
Telescoping cylinder(1)
Telescoping cylinder(2)
Check the bolt for looseness.
Check the bolt for looseness.
Check the sheave for rotation, damage and wear.
Check each boom for deformation, etc. Apply grease to the side surface and lower surface on the 2-section boom and other booms.
Replacement of brake shoe in hoisting winch Replace it every 3 years.
Slide plate
Check point
Contents of check Operating condition
Telescoping Oil leakage/natural sinking of the telescoping cylinder cylinder Mounting condition of the support pin and falling off of the snap ring Looseness/falling off of the bolts and nuts in the mounting bolts Operating condition (extension/retraction) and lubrication Deformation/crack of the boom and wear of the slide plate
Looseness/falling off of the slide plate mounting bolts
Boom
Damage, wear and rotation of the sheave Mounting condition of the support pin and sheave pin Looseness/falling off of the bolts, nuts, pins, etc. in the mounting units Looseness 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)
- 19 -
Result of Remedial check Good No good measure
Swiveljoint／Derrick cylinder／Column／Piping
Column
Derrick cylinder
Check point
Swivel joint Derrick cylinder Column
Piping
Swivel joint
Contents of check Oil leakage Looseness of the stopper mounting bolts and deformation of the plate Looseness/falling off of the bolts and nuts in the mounting units Continuity of the slip ring, damage of wiring and mounting condition Operating condition Play of the derrick cylinder upper/lower pins Oil leakage/natural sinking of the derrick cylinder Looseness/falling off of the bolts and nuts in the mounting units Crack and deformation Looseness of the turntable mounting bolts Oil leakage Supporting condition of the pipes Damage, aging, crack, twist and crushed status
- 20 -
Result of check Remedial
Good No good measure
Wire rope Wire rope is an expendable article and it will be damaged orWire rope is an expendable article and it will be damaged or broken in its strand wires through a long period of use. 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 strand. Replace the wire ropes intended for use with this crane if 13 pieces of strand wire have been broken within a pitch of strand.
1
2. A rope being kinked.
2
3.A rope from which its diameter has decreased by more than 7% of the nominal diameter. For example, if wire rope with a nominal diameter of 8mm is used, 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 excessively.
3 Diameter of rope
4 ★Be sure to replace a wire rope when it comes under the criteria, item 1 through 4, illustrated above.
Check point
Wire rope
Contents of check Specification (length and thickness) Wear, cutting of the strand, deformation, kink, corrosion and lubrication 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
- 21 -
Result of Remedial check Good No good measure
Easy inspection of the wire rope used in crane, etc.
STEP1 The strand wire is protruded.
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: Breakage
If the wire rope meets one of the standards for disposal, dispose of the rope.
● Deformation Compare the deformed part with the similar damaged part in the photos.
The core wire is protruded.
The strand wire is sunk.
The strand wire is exposed.
Kinked.
Kinked.
Twisted.
Basket status
The wire rope is pressed locally to be flattened.
The strand wire is locally tightened.
The strand wire is locally loosened.
Spiral status
The wire rope is swollen to be like a basket.
- 22 -
Flattened.
Easy inspection of the wire rope used in crane, etc.
STEP2
● Wear and corrosion When 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, compare the part with the damaged wire rope in the photos.
Wear
STEP3 Corrosion
- 23 There is no clearance between the strand wires.
Pitching has occurred and so the wire rope surface is pitted.
● Breakage Visually 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. Crown breakage (broken thread)
Standard of disposal (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.
Nip breakage (broken root)
Wire rope composition
Visible broken wires Inspection range
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
･ Handle the wire rope of IWRC in the same way.
How to r eplace wir e rope 1. Refer to the figure in the left for how to hook the wire ropes for hoisting and for where to mount the weight for overwinding alarm.
For Uni-hook type Refer to the figure in the left for how to install hook.
Boom top Front of boom
Guide Higher side is to the front
- 24 -
2. How to fix the wire rope end Winch drum When passing a wire rope end through the winch drum, pass it so that the rope end comes inside as illustrated in the left.
Wedge
Pay attention that wire rope end will not be jutted out of the winding-up area of winch drum. In order to avoid irregular winding, wind up a wire rope slowly on the drum along its groove with a proper tension applied to the rope to form the 1st layer. From the 2nd layer on, wind up the rope over the woundup layer so that it is fit in each gutter formed between ropes wound side by side of the layer below.
Wire rope end 40mm
Where cut out Wire clip (pay attention to mounting direction)
50mm
Wire socket When passing a wire rope end through the wire socket, be sure to pass it as indicated by the arrows on the socket. Leave the wire rope end more than 40 mm as “a” illustrated in the figure in the left. If it is passed from the opposite direction, service life of the wire rope shrinks 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.
Arrow mark Wedge (Diameter of wire rope=8mm)
Projection on upper part of wire socket
Pass the pin through with the 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 length of rope end. Pass the pin through and tighten it securely with bolt.
- 25 -
3. How to correct the twisted wire ropes Wire ropes tend to turn in the 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 decrease as the ropes are getting fit to the crane. 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 stored condition. 4 wire ropes
Wire socket
Untwisting direction
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 hooked. Remember, however, that the wire socket may be turned up to 4 turns at a time. Attach the wire socket and repeat hoisting and lowering the 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 rope’s twisting direction
Note : Turn the wire socket in the direction opposite to wire rope twisting.
- 26 -
Hook 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.
The nut thread part is worn.
The thrust bearing is worn.
Play of trunnion Gap Reference value = 1mm Specified value for replacement = 2mm Hook
Check point
Hook
Contents of check Wear, deformation, rotation and lubrication of the hook Aim point distance of the hook Damage, wear, rotation and lubrication of the sheave Play of the hook screw unit and thrust bearing (worn condition)
Rotating status of the hook loading roller and deformation of the roller mounting bracket Looseness and falling off of the bolts, nuts, pins, etc. in the mounting units - 27 -
Result of check Remedial Good No good measure
Load meter
3
Number of ropes being hooked
29
Load meter 4-part lines
2 １０
１５
1-part line 0
B 0
770363331
1
２０
５
0
1 ０
A
２５
MPa 0.5 0.73
4-part lines
３
2 29
Load meter
Check the swivel elbow unit and the load meter for oil leakage. Check point Load detector
Contents of check Operating condition, oil leakage and damage - 28 -
Result of check Remedial
Good No good measure
Load indicator(with angle indicator) (Side of boom) Pointer
(t)
DS
A
D
E AT
R
RA
TE
D
ST
LO
N RE
LO
E AR
BA
S
S ER AD ATH R H
ED
ON
A TH
N
TH
ST
E
AN
CR
I AB
E
Y
LIT
V3
0
U 91
86
01
44
0-
GT
Scale (The chart is an example showing for URV344)
Check point
Contents of check
Load indication Falling off of the pointer, damage of the name plate and operating condition
- 29 -
Result of Remedial check measure
Good No good
Automatic stop for overwinding／Over-winding alarm Overwinding detector
Weight for overwinding alarm
Check point
Contents of check
Result of check Remedial Good No good measure
Over-winding Operating condition, over-winding detection switch and alarm sound alarm/auto- Winding status of the cord reel and damage/disconnection of the cord matic stop Damage of the weight and sling wire
Level
Check point Level
Contents of check Mounting condition
- 30 -
Result of check Remedial Good No good measure
Warning horn Warning arning 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.
Alarm
Operating condition and alarm sound
Name plate
MODEL
URV34
SPEC.
t
CAPACITY TOKYO JAPAN MADE IN JAPAN
Check point Name plate
Result of check Remedial Good No good measure
Contents of check
Check point
Crane model Specifications
SERIAL NO.
Serial number
CODE NO.
Code number
Contents of check Mounting condition, damage and deterioration of the name plate - 31 -
Result of check Remedial Good No good measure
Base／Chassis frame
Base
Deformation of the stopper
Check point
Base Chassis frame
Contents of check 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
- 32 -
Result of check Remedial Good No good measure
Inspection for sinking of cylinder The load is lowered. Set the conditions for sinking in the crane. Stop the engine, change the lever and remove the pressure. Then, start the test.
The outrigger cylinder sinks.
Does the oil come out when removing the pipe at retracting side?
YES
Inside leakage occurs. The packing is damaged. The tube is scratched.
NO The derrick cylinder sinks.
Does the oil come out when removing the hose at lowering side?
YES
- 33 Does the oil come out when removing the hose at retracting side?
YES
Does the oil come out when removing the hose at raising side?
The counterbalance YES valve malfunctions. The seat surface is damaged. Foreign matter is caught by the seat surface.
Does the oil come out when removing the hose at extending side?
The counterbalance YES valve malfunctions. The seat surface is damaged. Foreign matter is caught by the seat surface.
Inside leakage occurs. The packing is damaged. The tube is scratched.
NO
YES Check the pilot. The seat surface is damaged. Foreign matter is caught by the seat surface.
Inside leakage occurs. The packing is damaged. The tube is scratched.
NO The telescoping cylinder sinks.
Does the oil come out when removing the pipe at extending side?
INSUPECTION PROCEDURES WHEN CYLINDER SINKE 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
- 34 -
INSUPECTION PROCEDURES WHEN CYLINDER SINKE Inspection of telescoping cylinder (3-section or 4-section boom) (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. (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. (3) Inspection of tele1 Extend booms to a position where it is a little bit shorter than 2-section boom to put a mark on the boom (refer to Fig. 4). Raise booms to their maximum to sling a load. In order to release pressure remained in the telescoping system, stop the engine and shift the manual lever for telescoping 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. In addition, check how far boom2 sinks simultaneously. (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). 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. 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. In addition, check how far boom3 sinks simultaneously. The same procedures in checking boom sinkage are applied for 5-section boom Be sure to check the boom sections one by one reliably. - 35-
INSUPECTION PROCEDURES WHEN CYLINDER SINKE 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 for extension/retraction of outriggers. (2) Starting inspection Remove 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 raising side, 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 after the 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
- 36-
