SHOP MANUAL RK250-3 APPLICABLE : EZ-5003~ Book Code No. SSEZO005E Read and understand these instructions. Faillure to do so will increase risk of injury.1, GENERAL TERMINOLOGY 1.1 TERMINOLOGY OF OUTSIDE VIEW REAR TIRE ‘TOOL BOX REAR COMBINATION LAMPS Figure 1-1. ‘Terminology ana1.2 ‘TERMINOLOGY OF INSIDE OF OPERATOR'S ROOM SWING LOCK LEVER SHIFT SELECT LEVER EMERGENCY STEERING SWITCH SWING CONTROL LEVER STEERING WHEEL TOP PANEL, HORN SWITCH TEI ‘TELESCOPE SELECT LEVER DRUM LOCK KNOBS COPE LEVER INTERCEPTIVE LEVER FOR ON AND OFF ‘TRAVEL SERVICE BRAKE PEDAL WINCH DRUM BRAKE PEDALS L CRANE CONTROL LEVERS AUXILIARY SEAT Lain WINCH PEDAL “srep LAMP swiTcH BOOM HOIST (OR TELESCOPE) PEDAL HOTICOOL BOX. OPERATOR'S SE. JUICE PLACE SWING BRAKELEVER! LcLuTcHLEVERS TOP PANEL| OPTIONAL SWITCHES AIR CONDITIONER SWITCH AM RADIO ‘TOP (SKYLIGHT) WIPER SWITCH 1 ROOM LIGHT Figure 1-2 1-21.3. TERMINOLOGY OF UPPER / LOWER OPERATOR'S ROOM (CAB) SWING MOTOR AUXILIARY WINCH MAIN WINCH ‘TELESCOPE CYLINDER SLEWING RING HYDRAULIC OIL TANK TORQUE CONVERTER STEERING CYLINDER WORKING LIGHT TRANSMISSION REAR AXLE Figure 1-3 1-3 MAIN HOOK AUXILIARY HOOK 100M WORKING LIGHT DOOM LENGTH DETECTOR1.4 FRONT PANEL KEY SWITCH Hee a) TRAVEL METERPANEL) HIGH BEAMINDICATOR LAMP TACHOMETER TURN SIGNAL INDICATOR LAMP ‘TURN SIGNAL INDICATOR LAMP (RIGHT) (LEFT) TORQUE CONVERTE} AIR oI PRESSURE TEMPERATURE GAUGE GAUGE WATER FUEL GAUGE TEMPERATURE GAUGE GLow SENSOR InpicaTor fer =9][es = =} rrounte LAMP WARNING CHARGING WARNING LAMP RADIATOR WATER LAMP ENGINE OIL PRESSURE WARNING LEVEL WARNING LAMP LAMP HOUR METER ODOMETER (TOTAL DISTANCE) eve A TOROUE CONVERTER ON PROS, LOW BRAKE FLUID LEVEL WARNING LAME WARNING LAMP HYDRAULIC OIL WARNING LAMP ‘TRIP METER (SECTIONAL DISTANCE) | _ REAR STEERING NEUTRAL INDICATOR LAMP LOW AIR PRESSURE WARNING LAMP [TRAVEL CONTROL PANEL MONITOR TELEVISION REVERSE STEI SELECTOR SWITCH ‘TRAVEL SELECTOR SWITCR, (MODE SELECTOR SwITcH) —~~f- TTT) PARKING BRAKE, HIGH/LOW SPE SWITCH JRESET SWITCH INDICATOR LAMP AUXILIARY BRAKE Ss INDICATOR LAMP PARKING BRAKE SWITCH (AUX. BRAKE DEVICE SWITCH) ‘SUSPENSION LOCK/FREE SELECTOR SWITCH PARKING LIGHT SWITCH LOCK PIN PULLING OUT SWITCH MONITOR TELEVISION ‘CONTROL SWITCH 2/4 DRIVE SELECTOR SWITCH CPU DOWN INDICATION BACK MIRROR EXTENSION /STOWING SWITCH D SELECTOR 1-4WW MOMENT LIMITER (LOAD SAFETY DEVICE) PANEL, ML (AUTOMATIC STOP) RELEASE SWITCH [MOMENT LIMITER PANEL] 00M LENGTHILIFTING } = INDICATION SELECTOR SW! MOMENT LIMITER BOOMLENGTH MOMENT RATIO INDICATOR CPU ABNORMALITY ILIFTING HEIGHT 2 INDICATOR LAMP INDICATOR See eT RCNG HOE OVERLOAD WARNING Farag oa |-SELECTOR SWITCH OVERLOAD PRENOTICE LaMP|Bg—ty {wae OO) eee HOOK OVERHOIST 11Sa—a, }— WORKING AREA INDICATOR LAMP, 2 LIMITING DEVI TELESCOPE MISTAKE “[{Qaam OPERATION INDICATOR LAMP--[( nites) {a ‘SWING STOP WARNING LAMP. WINCH/CLUTCH LOW’ PRESSURE WARNING LAMP SWING AREA INDICATOR + be |_ML FUNCTION LI CHECK SWITCH OPERATING RADIUSINDICATOR TrTING LOAD INDICATOR BOOMANGLEINDICATOR LIMITSD(RATED) LOAD INDICATOR (OUTRIGGER CONTROL INDICATOR] ONTROL SWITCHES) (TT OUTRIGGER SETTING swircHES r P.T.0.SWITCH 1— WORKING LIGHT ourricorn c SWITCH \UTRIGGER CONTROL. 1 : R |-|—SWING WARNING SWITCHES (INDIVIDUAL) RT ASHRR STITCH f=) fH SWING FREE SELECTOR SWITCH OUTRIGGER CONTROL SWITCII (ALL) MOVEMENT SELECTOR: SWITCHES2, GENERAL SPECIFICATIONS 2.1. SPECIFICATIONS (1) PERFORMANCE OF CRANE ‘Boom ‘9. im (90, aft) Boom X 25, 065, 115 Ibs) (6 parts) Boom fength 16, 4m (63. ft) Boom % 18. 0 (39, 683 Ibs) (6 parts) X lifting capacity 23, 5m (77. 10ft) Boom ¥ 1. 5t (25, 353 ba) (4 parts) (No.of reeving parts) __| 30.6m (100.4ft) Boom % 7. 0¢ (15, 432 Ths) (4 parts) 7.5m (24. 61ft) Jib (*) X 3. Ot (6 614 Ibs) (1 part) Maximum ‘i Jib Jib (25") % 2. 1t 4, 690 Ibs) 1 part) Rated Gopacsty Jib US") % 1. 5¢ (2,756 Ibs) (1 part) - “ib length (otfset angle) m (89.371) Jib (©) % 2.0 (6 409 Ibs) (part) X lifting capacity 12, Om (88, 37) Jb (25°) X 1.2 (2,646 Ibs) (part) (No.of reeving parts) __| 12. 0m (89, 374) Jib 45°) % 1. O& (2, 208 ibs) (I part) ‘Auxiliary Sheave ‘3. 2t (7, 055 Ibs) (I part) _ Lifting Capacity at Max. Operating Radius with Boom | 0. 95t (2, 094ft) at 28. 0m (91. B6fi) Maximum Boom Length ~ 0.6m (100. dt) “Fb Lenath Tim G4. 614) Tm GO. 3TED Maximum Lifting Height Main hook /Jib hook | 31. im 104. 31)/43. 7m (143. 40, ‘Main Winch Line Speed High speed/ Low speed | 124m (406.8) / 60m (196. 85) / min th layer) ‘Aux. Winch Line Speed High speed /Low speed | 107m (351. 1ft) /52m (170. 6ft)/ min @2nd layer) Boom Extending Speed 95. 2600/21.3m (9, 68ft) “Boom Raising Speed | Ar bec 70" 1082" - Slewing Speed 3.06pm Swing Radius to Rear End 3.03m 9.9470 (2) MAIN STRUCTURE OF CRANE Box type, 4 section, Bnd independent, Srd/ th synchronows? Type of Boom independent telescope selection type. Side stowing and down extending type, new lift up twist jib Type of Jib (power tilt twist jib as an option). (Offset angle) Basic truss / tip box type drawing out form, variable inclining type (5°, 25° and 45° at offset angle). “Boom Telescoping Device ‘Two hydraulic cylinders together with use of wire ropes. ‘Boom Raising / Lowering Device (Boom angle) | One directly pushing hydraulic eylinder type (0° to82"). | Hydraulic motor drive (2 units), spur gear reduction type, |_with free fall device and automatic brake attached. | Hydraulic motor drive, planetary gear reduction type, Winch System ‘Swing System Free / lock selector type with hand brake attached, ‘Type Full hydraulic type, and type H / type X selector type. Outrigger 6. 3m (20. 674t)/5. 1m (16.7344) /3. 8m (12.4740) / 2. 1m (6. 69 Extended Width £1) (E-type outrigger only) () WIRE ROPE — IWRC 6 X Fi (22-7) c/o, special class 2, hard to twist type. ‘Main Winch Wire Rope 16an dia. X 170meters. (5/ 8° X558') “ IWRC 6 X Fi @2++7)/ o, special clase, hard to bist type, Anuiliary Winch Wire Rove ‘160 dia. X YOmeters.(5/ 8295") (@ HYDRAULICSYSTEM “Hydraulic Pump Type [_2tandem (variable plunger) + tandem gear “Hydraulic Oi tank capacity 358. (04. S7gals) (4208 110. 95eals))(©) TRAVELING PERFORMANCE ‘Maximum Traveling Speed ‘Minimum Turning Radius Zhe steer /4 wheel steer. “Gradability in tan@ (degree) Steering Mode. (6) ENGINE 49ka Th (30. Amp) 9.3m (90.51f¢)/5. 35m (17. 554) 0.661) “4 modes (normal, crab, crampand rear) Model Type “Total Displacement “Maximum Output ‘Maximum Torque (7) MAIN STRUCTURE OF CARRIER Mitsubishi DI6T. Water cooled, 4 cycle, direct injection type, with turbo charger. 7, 545ce (460. feu. 220psat 2, 800rpm 65kg + m (47Oft - Tbs) at 1, 600rpm ) Tie Fe — sre (Hw ie EH son GS Seems, 1 stay 2 pases: ‘orgue Converter Tye Electron cote al soma with eck each Transton : Forward anges reverse? range [samara ue euermes een a “rypect Gear Rei 2atageredvction pe Typeof Axles Front axle/ Rear axle Type of Steering |All floating type//all floating type Fully hydraulic power steering. Eng. rpm sensitive travel, power loss reducing system. With emergency steering device and reverse steering correcting device attached. Main Brake Brake Parking Brake ‘Air over hydraulic type, dise type 4 wheel brakes, with electronic control exhaust brake linked with torque converter lock-up clutch Propeller shaft braking internal expanding type, auxiliary brake for work attached, ‘Suspension Form Capacity of Fuel Tank Tires (8) GENERAL DIMENSIONS AND WEIGHT Hydro-pneumatic suspension (with hydraulic lock eylinder) 3008 (79. 25gals) 16,00-25.28PR (OR) “Overall Length of Machine ‘Overall Length of Carrier 11, 10a 6.127) 7, 590m (24 908) Overall Width, 2,490an( 8.178) Overall Height 3, 450m (11. 324) Wheel Base 3, 7005 (12. 14ft) Tread Front Wheels / Rear Wheels 2, 020an (6. 63ft)/ 2, 020 __ Overall Weight of Machine 26, 500k (58, 420 Ibs)2.2 WORKING RANGE (1) H-TYPE OUTRIGGER 50m, 30,62m BOOM + 12m JIB (OFFSET) — 30,62m BOOM + 12m JIB @5° OFFSET) ms 30.62m BOOM + 12m JIB. (45° OFFSET) 30.62m BOOM + 7.5m JIB (© OFFSET) 062m BOOM + 7.5m JIB (@5° OFFSET) 40m— 30,62m BOOM + 7.5m JIB: (4S OFFSET) 35m} 30.62m BOOM. (100.4%) 30m} 23.52m BOOM .. (77-1080) 25mm} HEIGHT ABOVE GROUND (m) 1642m Boom 207 (asitt) 15m] 932m BOOM. (a0sart) v Sm Tom ism 20m 2m 30m ‘Sm OPERATING RADIUS (m) 2-3@) SKY TILT IIB 50m; 30.62m BOOM + 12m JIB (OFFSET) 30.62m BOOM +12m JIB. 8 OFFSET) 45mi= 30,62m BOOM + 12m JIB, 5" OFFSET) 30,62m BOOM + 7.5m JIB, & QFESET) 30,62m BOOM +7.5m JIB. (25° OFFSET) 40m} 30.62m BOOM + 75m JIB GS" OFFSET) 35m} 30.62m BOOM - | (100.4%) 30m} 2352m BOOM (774081) 25m) HEIGHT ABOVE, GROUND (m) (mn) 16.42m Boom 28 (asitty 15m) 932m BOOM (a0.52tty 0 om 10m 1m 20m 2m 30m om. OPERATING RADIUS (m)23 RATED LIFTING CAPACITY ()_ RATING CHART ON OUTRIGGERS IN TONS 20 Ly .0 7.0 7 aT ur0og EA. 3 T 1 Te 3 08 = | os 3 Ct O77 z t 1 ow < TT om g TT] ou a z= oer g z_| I o8t 2 z i out a3 *€ oor 53 °E ost ae ¥ 1 ov g 5 + Ore et g¢ OF? | 06 E | Ser a? or 027 | wer Zs Gtmssemieni eer va] 52 $60 T % 29 [58s | or 2 eT | $0T 6 0679 | $0 | oor 2¢ oot | OFT * or [soe | 06 BE Ore _| 06 T | OF" ists 0L'8_| 06 OF oe 33 #2 |oe ort [ss st6 | on Tt oh as sez _[09e | S07 Lore one | ost OL 23 se [se [0% T3979 06 | 082 | OO ro EE see [sre [srt [8% [ood cy “oF | ov er | oF aT £9 ge ose [see [s6% [ore | 007 od Ov | OFS oe 2 a 3076 os st | 08 at a 3s oes | O6F [ocr | es [ooe | ez or OF OF | 09 OF ‘OL 91 | OF '6T oe 23 Toss ost fooet | ov zt | oer | oat oF 38 can Of TT [ost | O: ST ‘00°81 | 00" oF Ze [086 (os -11 | 00st [00 "02. ost | 00'sz. oe 38 t ‘00°8T | 00°se 1 "1 "8a, OF BS coat woz | 1 $2 35 hea 08 eS TWEE 6 [ED OG RE TECH OT] WEG [LD ONES HEY OT 1aaa 0 Sawa) 5 | | ameeto | $l | |_pavoq moog | & wy PEER) reo PEER PRT ROT T ze PopoNS um eANG | (uigE) Mpg pUsEANNG | (uIS)medpRE wERNNG | Papua AMMEN | Bs stability.(2) RATING CHART WITHOUT USE OF OUTRIGGERS IN TONS Stationary lifting Pick and carry(overfront) | Pick and carry (alaround) - (over front) Lomax. Zha/h (124mph) | (max. 2ka/h 1.24mph)) Boom Length - Operating Radius inmeters_| 9.32m [16.42m|23.52m] 9.32m |16. 42m|23. 52m) $.32m [16.42m|23.52mn| 9. 32m 3.0 [14.00 10.10 5.90 35 [14.00 10.10 440 oe 10 3.30 45 11.25 8.10 2.60 5.0 8.90 7.10 2.10 5.5 6.55, 6.20 1.70 | 1. 60 7.20 5.20 1.30 | 85 6.15 440 1.00 5|a|a/s|a/3|3/5} 16.0 17.0 [Min.boom angle! O° | a | ae | a0" | sx | ae | 0" a | sr | oF(3) RATING CHART WITH BOOM AND JIB IN TONS © Outrigger Maximum Extended Boom + 75m ib oom + 120m i _ Outrigg (6.3m) extended (all around) Outrigger max. (6.3m) extended (all around) Boom Angle | 5° offset 25" offset | 45° offset 5 offset 25 offset ¢) | “Lead (ton) | ~Load (ton) | Load (on) | Load ton) | Load ton) | Load (ton) 30.0 3.0 7.10. 1.25 2.00 1.20 75.0 3.00. 1.25 113 73.5 3.00 1a 1.08 [Min, boom angle| © Outrigger Mi point Extended (1) Outrigger mid Boom + 7.5m jib oin (5.1m) extended (oer side) Boom Angle | 5° offset 25" offset ©) Load (ton) Load (ton) ~ 50.0 19.0 in. boom angle] Ei ie F © Outrigger Mid-point Extended (2) Boom + 7.5m ib Boom + 120m jib _ Outrigger mid-point (3.8m) extended (all around) | Outrigger mid-point (3.8m) extended (all around) | Boom Angle [__$° offset 25° offset | 45° offset 5! offset | 25° offset [45° offset ¢) Lead Gon) [Lead ton) {Land on) | Lend on) "Load on) [Load Gon] 2.10 1.25 2.00 | _ 1.20, 60.0 Nin, Boom angle|2.4 NOTES FOR RATED CAPACITY CHARTS [RATINGS WITH USE OF OUTRIGGERS] Load ratings do not exceed 78 percents of tipping load with the machine set horizontally on a firm and level ground, satisfy the specified stability over front, and include weight of hook block (s) and other load handling accessories. Rating in the area are based on the machine's structural strength, and others are determined by the machine's stability. Kind of hook ton 32ton 210k«s 7Okes ‘Weleht (463 Ibs) (154 1bs) @Since the operating radius given in the chart includes allowances for laden boom deflection, the machine must always be operated on the basis of actual operating radius. ©lib operation must be based on main boom angle. ©The outrigger maximum extended width is 6.3m (20.7ft), mid-point extended widths are 5.1m (16.7ft) and 3.8m (12.5¢t), and minimum extended width (H-type outrigger only) is 2.1m (6.89ft).. ORatings in “Over Side” vary according to the outrigger extended width condition, therefore, operation must be based on the rating chart corresponding to each outrigger extended condition. Operation in “Over Front” and “Over Rear” areas must be as per the ratings when the outrigger is extended to maximum. es ov REAR & ‘Outrigger | Mid-point | Mid-point | Minimum extended | width width, width condition | 5.1m 3.8m 2.4m _ asm) | aasty | asm, ‘Area a 28° 20" s ORatings with use of the auxiliary sheave are the same as the ratings with the boom less weight of 25ton hook (210kgs), but should not exceed 3,200 kgs (7,055 Ibs). ©When the boom length exceeds the specified length shown in the rating chart, operation must be performed basing on the smaller rating of the specified length or the rating for the next longer boom length shown. When operating with the boom with the jib attached deduct 1,550kes (3417 Ibs) when one step jib is extended, and deduct 1,750k«s (3,858 Ibs) when two step jib is extended besides weight of lifting slings, etc. At this time, do not use the auxiliary sheave. ©Do not operate in a condition not shown in the rating chart. When the min, boom angle is indicated at the bottom of the rating chart, tipping may result if the boom is lowered beyond the stated angle. ©The minimum reeving is determined so that the single line load does not exceed 3,125kes (6,889 Ibs). ‘The standard reevings of the hook block are shown below. Boom length | 93m] 164m | 235m Used hook ~ 2ton hook Number of eeving 8 6 ‘ Boomlength | 806m | Jib/aux.sheave Used hook | 25tonhook | 32ton hook ‘Number of reeving ‘ : Free falling operation shall be, as a rule, be used. when lowering the hook block only. When it is required to free fall a load, the load should not exceed one fifth of the rated load, and sudden brake must be absolutely avoided.[RATING WITHOUT USE OF OUTRIGGERS] @Since the operating radius given in the chart includes allowances for laden boom deflection, the machine must always be operated on the basis of actual operating radius. ©Load ratings are the approved maximum lifting capacity with the specified air pressure of the tires and with the suspension lock cylinders fully retracted on a firm and level ground, and include weight of hook block (s) and other load handling accessories. Rating in the area are based on the machine's structural strength, and others are determined by the machine's stability. ind of hooks 25ton ‘Baton 2i0kes 70kes Weight (463 Ibs) (454 Tbs) Specified air pressure of tire :7.75ke / caf (110psi) When performing stationary lifting, be sure to engage the parking brake and the auxiliary brake for work. ‘When performing picking and carrying operation, be sure to place the high speed / low speed selector switch in the LOW range position. ©When picking and carrying a load, hold the load near the ground and travel within 2kn (124 miles) per hour of speed not to allow the load to be swung. Especially be careful for comering, sudden start and sudden stop. ©Do not perform crane operation while traveling with a load suspended. ©The minimum reeving is determined so that the single line load does not exceed 3,125kus (6,889 Ibs). ‘The standard reevings of the hook block are shown below. Ratings in “Over Front” and ratings in “Over Boom Ten 33m_|_I64m | 285m Side” are different. When swinging from “Over | Used hi Zinn hook. Front" to “Over Side” , sufficiently be carefull ae 8 4 4 not to exceed the rated load. (The capacity in “Over Front” is set with the swing lock pin amie ier inserted.) Usedhook | 32tonhook | = ‘Number of 1 — reeving LOCK | FREE eee = AXEBLOCK Lights up ¢o fLO EPI Liens uv _ orr AUX. OVER FRONT Grane operation [Stationary liting | Pick and carry rea ¢ ¢ wis ORatings with use of the auxiliary sheave are awoIlllltow ‘equal to the ratings with the boom less weight of the 25ton hook block (210kss) (463 Ibs), but 24WD HIGH/LOW should not exceed 3,200ks (7,055 Ibs). ws ©Do not perform free falling operation and a operation with the jib. Lights up