UNIC HYDRAULIC CRANE MODEL URV500 sERIES OPERATION MAINTENANCE MANUAL FURUKAWA UNIC conroraron HEAD OFFICE : Center Bldg., 3-12, Higashishinagawa 2-chome, Shinagawa-ku, Tokyo 140-0002, JAPAN OMURV500200011A PRINTED IN JAPAN__ INTRODUCTION. Ae Set AEN ER WY IN I ER AY I ee ae Request to those who operate UNIC crane The instruction manual describes correct operation methods, easy inspection and service for the UNIC crane. Be sure to read this manual carefully to carry out correct and safe operation of the machine. Operate the machine after you have understood the contents of this manual Although we take all possible measures to ensure quality of the machine, you are requested to contact our business offices, UNIC sales agents, or authorized service sta- tions whenever you have anything you do not understand @When making inquiries When making inquiries, ordering spare parts, and requesting repairs, be sure to give us the crane model. specification, serial number, date of manufacture, and the vehicle type. Name plate of the machine is located at the side of column. cron Rood od Code number 0-1TABLE OF CONTENTS MCA el AGE AEE ND EI I MR NN ENN A ND I YN a OD SETUP OF THIS MANUAL....0- 4 1. FOR SAFETY OPERATION (4] Request to customers ...... al 2, SAFETY PRECAUTIONS ON CRANE OPERATION Before operation . 2-1 During operation . 2 5 After operation... 2-10 3. DESCRIPTION OF ae EQUIPMENT ............. 2 4, NAME PLATES Description of name plates {2] Caution plates in detail .... 5. DEFINITION OF TERMS Behind-cabin mounting (2] Over-front hoisting [3] Over-side hoisting . (4) Over-rear hoisting coe 5 (5) Net rated load (6) Rated load (7) Lifting capacity . [8] Working radius ... [3] Boom length [19 Boom angle (77) Lift above the ground. (72) Outrigger extension .. (13) Booms employed 6.HOW TO REFER TO "WORK- ING RANGE CHART" (7) Working range chart....cssssussensnsennO- I RURNRNNDNNHKE HE 0-2 7.DESCRIPTION OF EACH CONTROL DEVICE (1) Designation of control levers and their arrangements . [2] Automatic accelerator mechanism (3) Accelerator lever ... (4) Warning horn ...... [5] Overwinding alarm ...... [8] Automatic stop for overwinding . [7] Load indicator [2] Load meter [9] Hook safety latch {70] Wire rope arranger ......... 8 HOW TO OPERATE THE CRANE [4] How to start hydraulic pump .. (2) Procedures to set up outriggers [3] How to operate for derricking boom .... (4 How to hoist and lower the hook (5) How to telescope the boom ... [2] How to make the boom slewing ... [7] How to store outriggers .......-. (8) Preparation before traveling vehicle 9. UNI-HOOK TYPE (K TYPE) (4) Preparation for crane operation... 9 {2] Procedures for storing hook .. 10. MAINTENANCE AND INSPECTION [7] Inspection before operation ... (2) Cleaning .. @ Inspection o of the mounting bolt the slewing bearin; ] Replacement of return filter [5] Replacement of wire rope . [&] Replacement of expendable parts .. (2) Caution when weldingTABLE OF CONTENTS AA A AH AE ES A A CORN MR ON I OT IN REIN RN DA EE EE SI 11. LUBRICATION (7) Precautions on lubrication (2) Lubrication........ 12. MAJOR SPECIFICATIONS LF) URVS03(3-section boom) .... 12-1 (2) URVS04(4-sect [3] URVS05(5 (4) URV506(6-section boom) .......eer ee 12-16 0-3TABLE OF CONTENTS eee SO a A A A A A A ES MN NN IRE RH 11. LUBRICATION (1) Precautions on lubrication Fe 2] Lubrication... cssssteenstensesnaeutenead be 4 12. MAJOR SPECIFICATIONS (1) URV503(3-section boom) [2] URV504(4-section boom) . [3] URV505(5-section boom) [4] URV506(6-section boom) .....SETUP OF THIS MANUAL ee SETUP OF THIS MANUAL Cranes covered in this manual are somewhat different in operation of the cranes in accor- dance with how to store hook and specifications with or without the cable or the radio remote control Difference in operation due to crane specifications is separately illustrated in the manual for each specification. Refer to separate "Radio remote control instruction manual" or “Cable remote control instruction manual" for operation and maintenance of the cable or the radio remote con- trol. 1. Designation of specification Crane specifications covered in this manual are divided broadly into two categories according to how to store hook. And each specification is sub-divided into two according to operation with or without the cable or the radio remote control. Model Spec. designation (example) (Difference in how to store hook) Standard types Without remote contro! With remote control a UBYEOS. URV500 series Automatic hook storage types| (Uni-hook types) Without remote control H UE EOS With remote control H 2. Designation of model URVS00 series of crane model is to be designated according to the number of sections of telescoping boom. URV503_ RK (Model) (Number of boom-sections) URVS03 3 URV504 4 URV505 5 URV506 6 0-41. FOR SAFETY OPERATION I IS AY I ERS RD NE AC I EN AY A MENS EY EN NY EN A Observe all the safety regulations ! y%& Read preventive measures against danger and cautions in this manual for proper under- standing. * Most accidents of crane occur due to operation, maintenance, and inspection which have failed in observing basic safety regula- tions. (1) Request to customers @ Never fail to observe PUG Nal 2nd [A CAUTION] described in the manual as they are of great importance in safety and operation. PRENZNEN Ne). Failure to observe this may invite an accident resulting in injury or death. ACAUTION). . Failure to observe this may cause damage to the crane and the vehicle. @ Store the instruction manual where it is easily accessible to read it over and over again. @ Failure to observe the right operation and maintenance/inspection as illustrated in this manu- al may cause trouble in the crane and may invite an accident, and this will not only shorten. its service life but will impair safety in the crane operation. Please remember, in such cases, that no warranty will be given even if the crane is within warranty period. @ in order to prevent injury or death to crane operators and to those who stand close to crane operating area due to operational mistake, caution plates are stuck on the crane. Read them carefully. @ Do not alter the crane. & If you want to make an alteration, contact with UNIC sales agent or authorized service shop. +k UNIC does not bear any responsibility for troubles and accidents due to un-authorized alteration. i-12. SAFETY PRECAUTIONS ON CRANE OPERATION SO EY AD “ORD DD ca TE SH Vv ok Vhoisting/lowering lever To hoist — To lower hook Gal a> L » hook Boom telescoping lever To retract “1 \ To extend boom <<] > boom Slewing lever __\. Toslew Cy» counter- (ae clockwise Toslew “1 \ clockwise’ ‘Outrigger control lever Extension Retraction ~~ — Outrigger | Chey >> Outrigger . aN J eether side) — (other side) i WZ \ a Extension 7__ _\. Retraction Accelerator lever Guage q| &> ( > Suttigger (this side) \J~ — 1% (this side) Low speed eo High speed (Figure shows left-hand side view) 7-1DESCRIPTION OF EACH CONTROL DEVICE A ENE IPN MN SO A EN DN AO MN AN MT MS ME A I I @ Hook storage lever(for Uni- hook ee 7-2tom i ee I A SY ND ee RE — |+—~—— Control lever DESCRIPTION OF EACH CONTROL DEVICE [2} Automatic accelera- tor mechanism {fhe machine is equipped with an automatic accelerator mechanism for levers of boom derricking, hook winding up/down, boom telescoping, and slewing. \Operating speed of the crane can freely be \changed from low to high by controlling each control lever. How to operate the automatic accelerator mechanism I Position of lever before operation Each control lever is in the neutral posi- tion. 2 For low-speed crane operation When a control lever is shifted toward the desired operation, the crane starts func- tioning at a low speed. 3 For high-speed crane operation When the control lever is shifted further, the engine speed increases to allow the crane to operate at higher speed according to the movement of the lever as it is interlocked with the accelerator. For stopping crane operation Release of the control lever allow the lever to return to the neutral position automatically to stop the crane operation.DESCRIPTION OF EACH CONTROL DEVICE “Se pe AR a sen we te aon REI All ‘Accelerator lev ar ©=: se a I ER DERE ION VN AE mE NG ® Function of accelerator lever 1 Operating speed control Accelerator lever can control operating speed of both the crane and the outriggers. Adjustment of idling speed In some engines, it may vibrate because idling speed of the engines too low. In such cases, pull the accelerator lever slightly toward higher speed position to adjust the idling speed before starting opera- tion. ACAUTION ¥& When starting and stopping each crane function, be sure to the return accelerator lever to low speed position to avoid abrupt starts and stops. * Return the accelerator lever to low speed position before operating it by using automatic accelerator mechanism. ¥& Be sure to return the acceler- ator lever to low speed position where it come to a stop after crane operation. @Remarks It is convenient that the accelerator lever is used when making an adjustment for load meter calibration or when warming-up the engine in wintertime.DESCRIPTION OF EACH CONTROL DEVICE << cam SY wn AS A I NN EN EN AN eS I DY REY eR tr Warning horn Depress either of warning horn switches located on both sides of contro] panel to give arning sound to those who have entered vithin the slewing range during crane opera- ion, or to co-workers in charge of slinging work standing close to the cargo or in a course through which the cargo is to be lifted 4p before starting the crane operation. fehicle horn gives warning sound while the witch is depressed. ~ aDESCRIPTION OF EACH CONTROL DEVICE A SA A ARO EY MEE ED I EN ERY a NG YE RY ( Overwinding alarm 1.Function of overwinding alarm e The device automatically makes an alarm sound to warn that the wire rope is over- a ind wound when the hook comes close to the verwinding detector $ a { Weight for i hl i overwinding alarm | =< 2.Procedures for operation Turn ON the overwinding alarm switch before starting the crane operation. If the alarm sounds while the hook is being hoisted or the boom is being extended, stop the crane operation immediately and lower the hook or retract the boom. Turn the switch OFF after completion of the crane work. The evcraindiid) ‘alarm will not function even if the hook is under overwound condition with the overwinding alarm switch turned OFF. Be sure to turn the switch ON before starting crane work and check that the alarm sounds every time when the weight for overwinding alarm is lifted up. Jk Since the length of wire rope hanging the weight is specified by laws and regulations concerned, do not make it short at random. * The alarm will not sound if the wires(cords) connected to the over- winding detector at the boom top 'is broken. Pay attention to the wires(cords). 7-6 ee JDESCRIPTION OF EACH CONTROL DEVICE ‘Se SER A NI AIH SRS MO SN ENP MN I MEN A DY a a A (6) Automatic stop for overwinding (for Uni-hook type) Stop (extend) Restore (retract) Restore (_, (wind-downy" Weight for overwinding alarm pestore (ower) (This sh i\ ows panel on the right) ~ $1 Functions of automatic stop for overwinding If hook comes close to the boom top and it hits against the weight for overwinding alarm, the buzzer sounds and winding-up of. hook, extension and raising-up of boom auto- matically stop functioning. When the alarm is activated, lower the hook, retract or lower the boom until the buzzer stops sounding. This recovers the automatic stop being acti- vated into normal @ Remarks Since viscosity of hydraulic oil increases dur- ing winter or in low temperature environ- ment, functions of winding-up of hook, or boom extension may not make a perfect stop but it allows to make a slight movement even if the hook hits against the weight when the oil is cold. | Since this is not a disorder, warm-up the engine. The automatic stop recovers func- tioning when temperature of hydraulic oil rises to a certain level. 2 How to reset when automatic stop for overwinding is found abnormal If crane operation can not be carried out due to malfunction of the automatic stop for over- winding alarm, reset the automatic stop and store the crane, @ Step 1 Put the switch (for automatic stop for over- winding) located on the panel on the right to "Reset" to reset the automatic stop. Then wind-up the hook, extend the boom, or raise the boom by operating each control lever. 7-7DESCRIPTION OF EACH CONTROL DEVICE wEH Load meter The meter shows weight of a cargo being hoisted. Read the scale corresponding to the wire- rope hooking systera(number of wire ropes being hooked). @ Remarks Since the load meter is designed to be rotated, rotate it to where the dial can eas- ily be read from the operating position. @ Dial of the load meter has: @ Scale bands corresponding to A and B of the “load indicator" for 4-rope hook- ing system, and @ Scale band for single-rope hooking sys- tem. * “Load meter” indicates the weight of a hoisted cargo only while the hook is being lifted up .DESCRIPTION OF EACH CONTROL DEVICE Ae A ASIA i IN DS NS EN I MI TE DY NN A EY ED NY AERO cs aS @ Follow the steps illustrated below when measuring the weight of hoist- ed cargo with the load meter. Compare the reading on the load meter with the reading on the load indicator. Load meter has two hands. Read weight of a cargo where each hand indicates, i.e. the scale band [A] for red hand and the scale band [B] for white hand. @ Lower the engine speed ® Adjust engine speed so that the needle i gine sp points at 0 (zero) on the load meter scale while the hook is lifting up with no-load @ As an example, let us take the case where (ea = a cargo is hoisted using 4-rope hooking pL system and extended boom configuration of [1243] as shown in the figures; The load meter shows that the crane can lift up the load up to [1.74] on the scale band [A] at the point (a) on the load indi- cator as shown in Fig.1 @ Read the load meter for the point (b) on the scale band [A] while a cargo hooked is being lifted up to approximately 30cm. The meter shows [0.8t] as the actual weight of the cargo. This means that the crane can be operated with a margin of [0.91] in this example. B Redhand — White hand Fig. 1 Load indicator Fig. 2 Load meter (The chart is an example showing for URV503)DESCRIPTION OF EACH CONTROL DEVICE om SO eR NR EY ORD ME MERI MC OS MEI UN RY aN NI RN @ Check for safety operation @ If a crane is loaded so much that readings on the load meter exceeds the rated load, the crane may be damaged or overturned. In such case, move the vehicle toward the cargo to be hoisted to decrease the working radius then operate the crane again within the rated load. @® When the load meter reads less than the specified in chart of the rated load, the cargo can be lifted up safely. 7-13DESCRIPTION OF EACH CONTROL DEVICE ere a MEH EIN WAIN ES le AE I IE A NN MR EP ED EE (9) Hook safety latch — —__—__——,_ The mechanism is to prevent slinging wire 7 ropes from being disengaged out of the hook. Hook safety latch Wire rope arranger (Mounted on both 5-section and 6-sec- tion booms as standard) The assembly is to keep wire rope wound around winch drum from slackening. ‘This prevents wire rope wound around winch drum from slackening possibly be occurring when the hook is wound up and down in high-speed, made an abrupt stop, and low- ered onto the ground. Wire rope arranger | |8. HOW TO OPERATE THE CRANE SSS Wh an eS EN REI EIN AE I IN ME AG BRN nS eS IN low to start hydraulic How to start hydrauli pump Procedure for operation 1 Confirm a condition of the ground where crane is to be set up. Make sure that the ground on which the vehi- cle is to be parked to set up the crane is solid and firm. Secure crane-mounted-vehicle immovable. © Pull the parking brake lever to allow the vehicle to check motion ® Be sure to use a drag when operating the crane at slanted areas such as on a slope or on aroad in a mountain. 3 Confirm where each control lever is positioned. @ Check that the accelerator lever in the crane is returned to low speed position. @® Check that each control lever is in its neu- tral position. 4 Confirm position of gearshift lever. Move the gearshift lever on the vehicle to its neutral position. 5 Start engine. Start the engine running. (Figure shows left-hand side view)HOW TO OPERATE THE CRANE “AE A AI SAT AH I CN A A SE EN A GE Ne 6 Pull the PTO lever. ® Depress the clutch pedal fully to disen- oe gage the clutch. @® Pull the PTO lever to its extreme. @ Release the clutch pedal gradually. @® Check that che PTO indicator lamp lights. CAUTION %& The PTO fails to engage smoothly unless the clutch is completely disengaged. 7 Start hydraulic pump. This starts the hydraulic pump running. _ACAUTION — ein wintertime, try not to oper- ate the crane immediately but run the hydraulic pump for a while to warm it up even if the crane is ready for operation. * Viscosity of hydraulic oil is high when the oil temperature is low. For that reason, if the hydraulic pump is operated in high speed with the hydraulic oil at low temperature, the pump may be damaged due to seizure because the oil will not be suffi- ciently circulated, 8-2HOW TO OPERATE THE CRANE tn A MD i eR BIN A I EN RE NE II YE EN AER I EI (2) Procedures to set up outriggers WARNING ¥* Crane operation without set- ting up outriggers is strictly pro- hibited. %* When setting up the outriggers on a unleveled ground or ona slope, be sure to place a support (such as plank, steel plate) under the outrigger foot plates to keep the vehicle level. in addition, when the crane is to be operated on a soft ground, take the same measures to pre- vent the outrigger foot flanges from sinking into the ground when a cargo is lifted up. Setting up the crane on the ground where it is not solid and firm enough may cause the crane to be overturned. %&* Putting your foot under the outrigger foot plate while vertical members of outrigger are extend- ing may invite an accident such as crush of foot. %* Crane operation with the vehi- cle kept leaning makes the vehicle unstable when a cargo is lifted up. This may cause the vertical mem- bers of outrigger to break or the crane to be overturned. 8-3HOW TO OPERATE THE CRANE IL Extension lever NN Sy 8-4 Follow the procedures when setting up outriggers; 1 Release the lock lever. _ACAUTION ~ * Be sure to release the lock lever even when operating the crane with the minimum exten- sion of outrigger. Hold the extension Jever to pull out the outrigger.HOW TO OPERATE THE CRANE aR eS A i A EN NPS NS AR EN MEN RN A TE EI EN I eE Extension lever S QY QZ’ B mark (white) \. Extension lever Position of the first stop is where the out- rigger is extended to halfway. Grip the extension lever again and pull out the outrigger to extend to its extreme. When the outriggers are fully extended, the second “I” mark appears on each side of horizontal member of outriggers. After the outriggers are completely extended fully, be sure to check that the blue mark at the top of extension lever is fully visible. ACAUTION ¥& Extend the outriggers to the maximum in normal crane opera- tion.HOW TO OPERATE THE CRANE oe ne MI En EDD OY IN AE A ERNE EN a ON a I WY Extension Outrigger (other side) Extension Outrigger (this side) / Outrigger control lever Retraction LAG) = aioe (other side) Retraction g SS ‘Outrigger (this side) (Figure shows left-hand side view) D =| -— ———+ Extended to maximum 8-6 Front wheels touch lightly to the ground Shift the outrigger control lever to [Extension]. The control levers(each on both sides) can be shifted either simultaneously or independent- ly. To extend ---- Shift the lever to "EXT" to extend the vertical members of outrigger. To retract Shift the lever to "RET" to retract the vertical mem- bers of outrigger. To stop Return the lever to neutral Position to stop extension and retraction of outrig- gers. @ Automatic accelerator When the control lever is shifted further to “EXT” or "RET", the engine speed increases according to the movement of the lever which in turn increases extending and retract- ing speed of outriggers as the lever is inter- locked with the accelerator. @Use of accelerator lever together with automatic accelerator Although engine speed increases from idling to the highest, how it increases varies from vehicle to vehicle. Operate the outriggers smoothly by using the accelerator lever together with the automatic accelerator. Adjust each vertical member of outrigger with the levers so that the vehicle can be set up level ACAUTION — % Set up the outriggers so that the front wheels of the vehicle touch lightly to the ground. Return each control lever to neutral posi- tion after the outriggers have been set up.HOW TO OPERATE THE CRANE aes eT AND NN A AE I OY RY MS ee ION A (3] How to operate for derricking boom AWARNING % An abrupt crane operation while a cargo is being lifted gives an excessive shock to the crane which may cause damage to the crane or overturn of the vehicle. Be sure to move levers slowly. & The longer the boom is extended, the faster a cargo is lifted up and down by boom derricking operation. Move the control lever slowly. %& When lowering the boom with a cargo being lifted, the working radius increases and this decreases the capacity specified in the chart of "rated load". Check the readings of load indica- tor to confirm the safety before the boom is lowered. _, Raise | boom Lower Toraise ----- Shift the lever to "RAISE" to raise the boom. To lower ----- Shift the lever to "LOWER" to lower the boom.. To stop --Return the lever to neutral position to stop the boom derricking. @ Automatic accelerator When the control lever is shifted further to "RAISE" or "LOWER", the engine speed increases according to the movement of the lever which in turn increases derricking speed of the boom as the lever is interlocked with the accelerator. Use of accelerator lever together with automatic accelerator Although engine speed increases from idling to the highest, how it increases varies from vehicle to vehicle. Operate the derricking boom smoothly by using the accelerator lever together with the automatic accelerator. 8-7HOW TO OPERATE THE CRANE ie i eS I NE SN I ET NM AI SE RY A ER (4) How to hoist and lower the hook NINN % Pay attention that the hook will not be overwound. Be sure to turn the “overwinding alarm switch" ON. elf the hook hits against the boom top due to being over- wound of the hook, it may cause damage to the wire rope and the sheaves at the boom top and may cause the fall of the lifted cargo. = Lift DOWN Hook hoisting/lowering lever! Tohoist ----- Shift the lever to "UP" to hoist the hook. To lower - - - - - Shift the lever to "DOWN" to lower the hook. To stop ------ Return the lever to neutral position to stop winding up/down. @ Automatic accelerator When the control lever is shifted further to "UP" or to "DOWN", the engine speed increas- es according to the movement of the lever which in turn increases hoisting speed of the hook as the lever is interlocked with the accelerator. @Use of accelerator lever together with automatic accelerator Although engine speed increases from idling to the highest, how it increases varies from vehicle to vehicle. Operate the hoisting/lowering the hook smoothly by using the accelerator lever together with the automatic accelerator,HOW TO OPERATE THE CRANE (SSE LON Me AN A ADS ER IPS RY MERI YN ACAUTION ~ Oil tank %& Lowering operation of the hook with the hook or a cargo put on the ground loosens the ropes which causes the ropes to be wound irregularly and this results in remarkable shortening the ser- vice life of the rope. ye When paying out the wire rope such as in underground crane operation, make sure that more than 3 turns of wire rope are always left on the drum. ye When the first layer of wire rope fails to be wound around the drum firmly and regularly, ropes wound over the first layer may dig into the inner layers to cause an irregular winding. When the wire rope is unwound to or wound up from the first layer of rope, wind up/down the rope slowly so that the first layer of rope can be wound around the drum firmly and regularly. * Stop the crane operation when temperature of hydraulic oi) exceeds 80°C. Oj) temperature is apt to rise easily if repeated operation of hoisting/lowering of the hook, especially in a high lift, is required. ll To know approximate oil tem- perature by sense of touch: You can touch the oil tank (Lower 70T part) with the palm of your hand for 3~4 seconds, You can touch the oil tank (Lower 80T part) with your finger tip for 1~2 seconds, The moment you touch the oil 90°C | tank (Lower part), you will let the hand off by reflex action. | @—@§|_ [+ 8-9HOW TO OPERATE THE CRANE OS i I EIN He EY ED EES A. MO BED EN A I EID i on (5) How to telescope the boom % If the boom is extended with the hook come close to the boom top, the hook may hit against the boom top causing damage to the wire rope and to the sheaves at the boom top, and the fall of the lifted cargo may result. Be sure to turn the "overwind- ing alarm switch" ON. \ a AL aN h p Retract < © Cp extend (Figure shows lefi-hand side view) To extend Shift the lever to “EXT" to extend the boom. To retract Shift the lever to "RET" to retract the boom To stop -Return the lever to neutral position to stop telescoping of the boom. @ Automatic accelerator When the control lever is shifted further to "EXT" or "RET", the engine speed increases according to the movement of the lever which in turn increases telescoping speed of the boom as the lever is interlocked with the accelerator. @Use of accelerator lever together with automatic accelerator Although engine speed increases from idling to the highest, how it increases varies from vehicle to vehicle. Operate the telescoping the boom smoothly by using the accelerator lever together with the automatic accelerator. ~ ACAUTION % The hook is hoisted as the boom extends and is lowered as it retracts. When telescoping the boom, pay attention to where the hook is. 8-10HOW TO OPERATE THE CRANE ye Make sure that the vertical members of outrigger on both sides have been retracted to their minimum and each lock lever has been released before pushing in the horizontal mem- bers of outrigger. 3 After the outriggers are completely stored, check the following. @ Release the grip of extension lever. @ Blue mark on the top of extension lever is fully visible. @ The horizontal members of outrigger are securely locked so that they will not stick out sideways out of the vehicle. @ Remarks Fully visible blue mark indicates that the lock pin for the horizontal member of out- rigger is inserted into the hole. 8-15HOW TO OPERATE THE CRANE om i in A aR ENO ND EN RS I a EN A MED Ne IY I a EN 4 Shift the lock lever for lock. @ Remarks Shifting the lock levers for lock prevents the horizontal members of outrigger from sticking out by careless grip of extension lever. In addition, this prevents a rattling noise from the horizontal members of outrigger while the vehicle is traveling,HOW TO OPERATE THE CRANE A Me A AEN AREY AION NN A EDS A ANS A SN A A EY AY A YN (8) Preparation before traveling vehicle WARNING yk Make sure that the boom, the outrigger, and the hook have been stored and fixed securely before traveling the vehicle. * Be sure to fully retract and store the outrigger members and check that the blue mark at the top of extension lever on either side is fully visible and any of out- rigger inner boxes is not protrud- ed. & Be sure to fasten the outrigger members with lock levers. * Traveling the vehicle with incom- plete storage of or fastening of the boom, the outrigger, and the hook allows them to be loose or to swing which may cause acci- dents such as of damage to each crane member or of bumping into vehicles running in the opposite direction. Retraction of Follow the procedures for traveling vehicle. 1 Retract the boom.HOW TO OPERATE THE CRANE core cS a MO MHL WEEE EW ARR IER ER EN Or AEE CE EN ON Traveling with the boom stored to the front Move the boom either to the front or to the rear. Stop the boom slewing at the position where both of yellow positioning stickers are met. ~—Sslewing positioning \ _ 3 Lower the boom to its lowest extreme. Pay attention that the hook will not strike! against: The driver's cabin when storing it to the front, or The cargo loading body when storing it to the| rear. 8-18HOW TO OPERATE THE CRANE ta Ae MY AEN RE AEM A EY I ET AS A A NY MS A I EIN I 4 Put the hooking wire rope on the hook. Hoist the hook gradually and stop it where the rope is pulled up with a mod- erate tension. “ AACAUTION ¥& Do not give an excessive ten- sion to the wire rope when stor- ing the hook to the front. Otherwise, this may cause to bend the frame of vehicle or to damage the bumper. ee : Store either side of vertical and horizon- tal member of outrigger securely. Then, store the front outriggers. Store them in accordance with section [7] “How to store outriggers”.HOW TO OPERATE THE CRANE 80h COI AO ean RE I ANY AED CS EY ENE I EN ON IN aN SN Check that the accelerator control lever is returned to the position of lowest speed. Turn OFF the "overwinding alarm switch". ( Overwinding j alarm switch Push in the P.T.O. lever fully with the clutch pedal in the driver's seat depressed, then release the pedal gradually. The P.T.O. indicator light turns off and the hydraulic pump stops running. The vehicle is now ready for traveling. CAUTIO! & Trav ling the vehicle without P.T.O turned off allows the hydraulic pump to keep running so that damage to the pump may result. 8-209, UNI-HOOK TYPE (K TYPE). eo en er on A MN A NN ME TE A A a A This is the type on which the hook can be stored under the boom and this section discusses the matters which is different from the standard type. (7) Preparation for crane operation AWARNING % In order to avoid an accident, do not stand under and/or in front of the auto-stored hook as it swings when it is released. Turn ON the “overwinding alarm" switch. The overwinding alarm sounds, Operate the hook hoisting/lowering lever to allow the hook lowering to loosen it from where it has been stored. 14 Hook ‘hoisting/lowering lever Do not stand under or in front of the hook when releasing the hook as the hook swings. Lower the hook until it detaches from the weight for overwinding alarm to stop the buzzer to sound. This crane is now operationalUNI-HOOK TYPE (K TYPE) Aten i ie i A AN EIN NS ED ie ER NIG A A RY OI EN EN in EI on (2) Procedures for storing hook AWARNING ¥& Never try to operate the crane by controlling the hook storing lever as this is dangerous. %& Store the hook after all sec- tions of boom have been retracted and the boom has been lowered fully. 9-2 To store & Always keep the machine in good condition so that it is ready for normal operation. Cleaning Keep the machine clean at any time. Sands and fine dusts 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,MAINTENANCE AND INSPECTION A ER ee OE REY A REDS ENA ERS A A SD EY ID EY I (6) Replacement of expendable parts Sliding plate (7) Welding precautions @No grounding Outrigger cylinder__— a | 10-8 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 opera- tion (period during which crane is not operat- ed 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 Replace it every 3 years 3. Replacement of brake shoe in hoisting winch Replace it every 3 years. When welding is needed for some reason, do not use outrigger cylinder for welding ground as the cylinder red and/or the piston may be damaged by electric sparks due to current flown in the inner part of cylinder.11, LUBRICATION M2 RIDE GLE WIN ERIN SE URI AY RI A a A AR ER MLN I RO NEN LE NY AWARNING % Do not carry out maintenance and service while temperature of hydraulic oil is still high. %& Temperature of both hydraulic and gear oils is high immediately after crane operation so that accumulated high pressure still remains inside. Uncapping the filler port, draining oil, and replacing filter while oil tem- perature is high allow hydraulic and/or gear oils to spout out and a scald may result. (7) mee on lubrication Lubricate according to “Lubrication chart" and keep the following instructions in mind when carrying out lubrication, 1. Thoroughly clean filler ports and grease nipples before lubrication 2. Always supply new lubricant and prevent dusts from entering inside. 3. When supplying grease into each nipples, be sure to inject it until old grease is forced out of it. % In order to ensure smooth operation of each part of the crane, minimum wear, and longer service life, be sure to supply lubricant as well as hydraulic oil which is necessary to drive hydraulic equipment. ¥& Warranty will not be given, even if it is within the period to be applied, for failure to observe the replacement of lubricant as specified.LUBRICATION 1. List of recommended lubricants ye 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 — | SHELL Retinax AM AeRECOMMENDED GEAR OIL Use API Service GL-4 gear oi [~ Petroleum Maker Brand | ESSO Standard gear oi! 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 Brand Petroleum Maker 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LUBRICATION ‘xem sem eine ee ona ae EY SOUS ED NH ERR ER ED UR NEY NE le 2. Lubrication chart 3-section boom 2 i (a %» 5-section boom.“ Service [No. of Part to be lubricate Lubricant Tool interval part (Boom slide plate(Underside/sides of 2 [Molybdenum grease | Manual application -section boom Boom slide plate(Underside/sides of 3. | Molybdenum grease | Manual application boom sections@), @),@) 4-section boom @Boom slide plate(Underside/sides of 4 | Molybdenum grease | Manual application boom sections! ©) 5-section boom Daily @Boom slide plate(Underside/sides of 5 | Molybdenum grease | Manual application ‘boom sections. ®,®, ©) 6-section boom Boom slide plate(Upper side of boom section) | 2 | Molybdenum grease | Grease pump ©Boom foot pin 1 Chassis grease Grease pump @ Upper support pin of derrick cylinder 1 Chassis grease. Grease pump Lower support pin of derrick cylinder 1 | Chassis grease Grease pump Oil tank(S9) 1 | Hydraulic oil(up to middle of level gauge) 40 Winch drum gear 1 Chassis grease Grease pump Weekly | @Slewing gear(to gear-teeth) 1 Chassis grease Manual application ©Propeller shaft 3 | Chassis grease Grease pump @® Winch reduction gear(approx.1.01) Gert @Slewing reduction gear(approx.1.21) a Monthly | @5!Wire rope 1 |Rope grease Spray gun @Slewing bearings 2 Chassis grease Grease pump (Wire rope for boom extension Rope grease [Spray gunLUBRICATION a ANY Me AE ENN ON EN MT AR OM AEN ERIN AY EN A A A EN => Level gauge: Sele ~——— Drain plug 11-4 Lubrication 1. Replacement of hydraulic oil ¥& The amount required for oil change is 22 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) % 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 there- after. %& Tighten the cap securely with your hand after oil has been refilled. Remember that hydraulic oil may leak out if the cap i loosely tightened. AUTION %* Do not mix a different brand of hydraulic oil as properties of mixed oil deteriorates and dam- age 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,LUBRICATION

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 reduc- tion gear. : CAUTION | x Replace gear oil after oil tem- perature has dropped. % For gear oil to lubricate winch reduc- tion gears, fill it up to the middle of the oil level gauge (approx. 1.0 liter). %& For gear oil to lubricate slewing reduc- tion gears, fill it up to a level between upper and lower limit marks of the oil level gauge (approx. 1.2 liters). Check oil level not by tighten up the oil level gauge cap but by just inserting the gauge in the filler port. Lower limit —— Oil surfaceLUBRICATION A EY AE MER AON RN ER ER EY AD A A A A I a 4. Lubrication to slewing bear- ings The machine uses ball bearing as the slewing bearing, Be sure to lubricate the bearing as insuffi- cient lubrication may cause it to make unusu- al noise. Grease in the nipples while slewing the boom ‘once a month for moderate operation, and once a week for heavy-duty operation. Grease nipple 5. Lubrication to wire rope for boom extension Spray the rope grease sufficiently once a v ¥ month to the wire ropes with the boom fully _ extended. 11-6flow.) Major specifications 12, MAJOR SPECIFICATIONS AS IE AE IS NED AR I A EG RO A SI EG NEY EA A EE TD [7] URV503 (3-section boom) (Operating speeds are on condition that oil temperature at 45~55°C , no-load and rated oil Model URV503(3-section boom) Crane capacity (lifting capacity) 3.03 X4.1m (with outrigger extended to max.) Maximum hook height above ground 10.2m Boom length 3.51m~5.94m~8.34m Maximum working radius 8.1m Hoisting speed 19.0m/min.(at 4th layer on the drum) with 4-part line slinging Boom extending speed 4.83m/17.5s Boom raising speed 1° 7812s Slewing speed 2.5rpm Slewing range 360° (continuous) Wire rope Construction | TWRC 6 X WS(26) GRADE B Dia.XLength | 8mm X55m Outrigger span Halfway 3.0m Maximum. 3.8m Hydraulic pump | Rated pressure | 20.6MPa{210kg/cm’) Rated delivery | 60 L/min. Rated revolution | 1400rpm Hydraulic oil tank Capacity 59 L 12-1MAJOR SPECIFICATIONS (URV503) i A A A A EE EI EI IN EO I AN AE i OY Equipment and construction Model URV503(3-section boom) Boom telescoping Boom : 3-section, hexagonal box beam Direct actuation by hydraulic cylinder (with hydraulic automatic locking device) (2nd and 3rd section extends sequentially) Boom derricking Hydraulic cylinder, direct actuation (with hydraulic automatic locking device) Hoisting Hydraulic motor : Axial plunger type Reduction gear _: Spur-gear Brake : Automatic mechanical Slewing Hydraulic motor : Trochoid type Reduction gear: Worm-gear+Spur-gear (supported by ball bearing) Brake : Worm self-lock Outrigger (Horizontal) : Manual extension (Vertical); Hydraulic cylinder, direct actuation (with hydraulic automatic locking device) | Hydraulic pump Gear type | PTO With indicator lamp Safety devices Pressure relief valve for hydraulic circuit Counterbalance valves for boom raising and boom telescoping cylinders Pilot-operated cl k valves for vertical outrigger cylinders Boom angle indicator with load indicator Hook safety latch Automatic mechanical brake for winch Loadmeter Overwinding alarm With automatic lock mechanism for slewing Unichook type With automatic stop for overwinding ° (Automatic stops for:winding-up hook, raising boom, and extending boom) | 12-2MAJOR SPECIFICATIONS (URV503) oom I A I IN GY ED MY GR A DY MY CY ra a a Working range chart 8.34m Boom Teele 5.94m Boom elie 3.51m Boom. 40° Boom angle a 30° = = > 20°— : \\ 10° cc 8.1) 9 —— Ground fevel Distance from the center of rotation (m) Note: The above figures are based on no-load condition and do not include the deflection of the boom. 12-3MAJOR SPECIFICATIONS (URV503) non kee ey ea REE WN AED A A EE ERG NY CLI DY RW EY EO. Rated load Unit : kg Working | Boom length Radius, (m) 3.51m 5.94m 8.34m 28 3030 | 3030 3030 35 (320) 8080 3030 44 3030 3030 45 2580 2580 5.0 T2280 | 2280 55 2000 | 2000 | 60 3% 1730 65 7 | 4580 | To. al ] 1430 [i 1330 . a4 1230 | (_): Working radius CAUTION 1. Fully extend all outriggers on solid, level surface leveling vehicle. 2. Rated loads shown in the chart are based on the crane strength rather than stability. 3. Rated loads shown must be reduced in accordance with vehicle weight, loaded condition of truck, crane mounting position, wind, ground condition and operating speed. 4.The mass of hook(30kg), slings, and any accessories attached to the boom or loadline must be deducted from the above rated loads in the chart, 5. In accordance with our policy of constant product improvement, all specifications are subject to change without notice or obligations. 12-4MAJOR SPECIFICATIONS (URV503) | 7 S0c0 3030 2030 45. 2580 2580 | 2080 5.0 2280 2280 1830 55 1930 1930 1650 | 6.0 S75) 1730 1480 65 1530 1330 7.0 1400 4230 75 T4280 | 1180 8.0 (8.18) 1080 ao | 980 10.0 ; a) | 106 7 [830 (_): Working radius CAUTION 1. Fully extend all outriggers on solid, level surface leveling vehicle. 2. Rated loads shown in the chart are based on the crane strength rather than stability. 3. Rated loads shown must be reduced in accordance with vehicle weight, loaded condition of truck, crane mounting position, wind, ground condition and operating speed. 4. The mass of hook(30kg), slings, and any accessories attached to the boom or loadline must be deducted from the above rated loads in the chart. 5. In accordance with our policy of constant product improvement, all specifications are subject to change without notice or obligations. 12-9