unic urw295cp2a operation manual

SERIES

MINI-CRAWLER CRANE

MODEL

OPERATION&

MAINTENANCEMANUAL

OMURW295CP2A201311APRINTED IN JAPAN

0-1

INTRODUCTION

Crane model

Specification

Serial number

Code number

MODEL

SPEC.

CODE NO.

SERIAL NO.

CAPACITYFURUKAWA UNIC

CORPORATIONTOKYO JAPAN

MADE IN JAPAN

t

Request to those who operate the craneThe operators manual describes correct operation methods, simple inspection, and ser-vice for the UNIC crane.Be sure to read this manual carefully to carry out correct and safe operation of the crane.Operate the crane after you have understood the contents of this manual.

Although we take all possible measures to ensure quality of the crane, you are requestedto contact our business offices, UNIC sales agents, or authorized service stations when-ever you have anything you do not understand.

For making inquiriesWhen making inquiries, ordering spare parts, and requesting repairs, be sure to informus of the crane model, specification, serial number, and date of manufacture which areindicated on the name plate.

Name plate of the machine is located at the rear side of column.

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TABLE OF CONTENTS

8.HOW TO REFER TO WORK-ING RANGE CHART ANDNET RATED LOAD CHART

q Working range chart ..................................8- 1

w Net rated load chart....................................8- 2

9.DESCRIPTION OF EACHCONTROL DEVICE

q Overwinding alarm ...................................9- 1

w Automatic stop for over-winding .............9- 2

e Load indicator ...........................................9- 3

r Load meter ................................................9- 6

t Digital load meter (option) .......................9- 8

y Warning horn ............................................9-12

u Hook safety latch .......................................9-13

i Automatic stop for leaving

minimum wire rope ........9-13

o Specifications on

turnover prevention device ........................9-14

!0 U-AOL system...........................................9-26

10. HOW TO OPERATECARRIER

q Designation of each control lever

and its location ..10- 1

w Preparation before operation .................10- 2

e How to operate .......................................10- 3

r How to crawl .........................................10- 6

SETUP OF THIS MANUAL .....0- 4

1. FOR SAFETY OPERATION q Request to operators .................................1- 1

2. SAFETY PRECAUTIONS ONCARRIER OPERATION

q Before operation .......................................2- 1

w During operation .......................................2- 2

e When loading and unloading ....................2- 3

r After operation ..........................................2- 4

3. SAFETY PRECAUTIONS ONCRANE OPERATION

q Before operation .......................................3- 1

w During operation .......................................3- 2

e After operation ..........................................3- 3

4. DESCRIPTION OF CARRIEREQUIPMENT ................................4- 1

5. DESCRIPTION OF CRANEEQUIPMENT ................................5- 1

6. NAME PLATESq Description of name plates (Stickers) ......6- 1

w Stickers in detail .......................................6- 2

7. DEFINITION OF TERMSq Extension and spread of outriggers .........7- 1

w How boom-sections are extended ............7- 3

e Net rated load ...........................................7- 4

r Rated load ................................................7- 4

t Lifting capacity ........................................7- 4

y Working radius ........................................7- 4

u Boom length ............................................7- 4

i Boom angle ..............................................7- 4

o Lift above ground ....................................7- 4

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11. HOW TO OPERATE CRANE q Designation of each control lever

and its location ....11- 1

w Preparation before operation .................11- 2

e Procedures to set up outriggers ..............11- 3

r How to operate boom for derricking .....11- 7

t How to wind up/down hook ..................11- 8

y How to telescope boom .........................11-10

u How to slew boom .................................11-11

i How to store crane .................................11-13

o Procedures for storing hook ...................11-14

!0 How to store outriggers .........................11-15

!1 How to operate outriggers

when in an emergency .........11-17

12. U-WAVE, RADIO REMOTOCONTROL DEVICE

q Request to those who operate the crane ....12- 1

w Safety precautions ..................................12- 2

e Designation of each equipment .............12- 5

r Inspection before crane operation ..........12- 8

t How to switch crane operation mode ....12-10

y How to operate the crane through radio control operation ....12-12

u How to replace batteries of transmitter ...12-34

i Daily checks, trouble inspection ............12-37

13. MAINTENANCE ANDINSPECTION OF CARRIER

q Inspection before operation ....................13- 2

w InspectionMaintenance which is to be carried

out every 250 hours or 3 months ............13- 9

e Storage ....................................................13-11

r Fitting safety covers ................................13-12

t Maintenance and inspection of engine .........13-12

14. MAINTENANCE ANDINSPECTION OF CRANE

q Inspection before operation ....................14- 2

w Cleaning ..................................................14- 3

e Inspection of bolts mounting

slewing bearings ........14- 3

r Replacement of wire rope .......................14- 4

t Replacement of expendable parts ...........14- 8

15. WATER SUPPLY/LUBRICA-TION TO CARRIER

q Precaution when carrying

out lubrication ..........15- 1

w List of recommended lubricant ...............15- 2

e Filling waterlubrication chart ................15- 4

16. LUBRICATION TO CRANEq Precaution when carrying out

lubrication .........16- 1

w List of recommended lubricant ..............16- 2

e Lubrication chart.....................................16- 3

r Lubrication..............................................16- 4

17. MAJOR SPECIFICATIONSq URW295CP2A (5-section boom) ..........17- 1

w Turnover prevention device ...................17- 6

e Dismounted weight ................................17- 6

r Major specification (Radio remote

control device) .....17- 7

18. MODE INDICATOR LAMP(Control box)...............................18- 1

19. MEASURES TO BE TAKENIN AN EMERGENCY ..........19- 1

TABLE OF CONTENTS

0-4

URW295CP2A

URW295CP2A

RS

ModelSpec.

URW295CP2A series

Designation (example)

Specifications with overturn preventiondevice

Manual specification

URW295CP2AWith cable remote controller

With radio remote controller

R

SETUP OF THIS MANUAL

SETUP OF THIS MANUAL

Crane covered in this manual have some difference in operation in accordance with thespecifications of with or without radio remote controller.Difference in operation due to crane specifications is separately illustrated in this manualfor each specification.Refer to separate Instruction manual of radio controller for operation and/or mainte-nance of the radio remote controller.

1. Designation of specificationsCrane specifications covered in this manual is the type with overturn prevention device. This is divided into two kinds according to the type with or without radio remote con-troller.

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1. FOR SAFETY OPERATION

Never failed to observe and described in the manual asthey are of great importance in safety and the crane operation.

. .Failure to observe this may invite an accident resulting in injury or death.

. .Failure to observe this may cause damage to the crane.

Store this manual where it is easily accessible to read it over and over again. Failure to observe the right operation and maintenance/inspection illustrated in this manual

may cause trouble in the crane and may invite an accident, and this will not only shorten itsservice 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 withinvalid warranty period.

In order to prevent injury or death to crane operators and to those who stand close to craneoperating area due to operational mistake, caution plates are stuck on the crane. You are requested to read them carefully.

Do not alter the crane. If you want to make an alteration, contact with UNIC sales agent or an authorized service

shop. UNIC does not bear any responsibility for troubles and/or accidents due to unauthorized

alteration.

qRequest to customers

Read preventive measuresagainst danger and cautionsstated in this manual for properunderstanding.

Most accidents related to thecrane occur due to operation,maintenance, and inspectionwhich have failed in observingbasic safety regulations.

Observe all the safety regulations !

CAUTIONWARNING

WARNING

CAUTION

2-1

1 Dress neatly and wear protectors such ashelmet, safety shoes, and gloves withoutfail.Do not wear baggy clothes and accessorieswhich can be caught by control levers andfittings, and oil-stained working clotheswhich may catch fire.

2 Be sure to make inspection before oper-ation and periodical voluntary inspec-tion.If found something wrong, repair it immedi-ately.

3 The crane is prohibited to crawl on apublic road by the road traffic law.4 Check that no safety covers have beenleft removed.It is very dangerous to start the engine, tooperate the crane with the safety coverremoved as the driving mechanism is directlyexposed.

5 Be sure to stop the engine before refuel-ing or supplying and changing lubricant.A fire source such as smoking cigarette inmouth is strictly prohibited.Failure to observe this may cause a fire.

6 When starting the engine in a small lim-ited area or indoors, open the windowsand doors for well ventilation.Poor ventilation may invite an exhaust gaspoisoning.

7 Shift the crane-crawl lever to Crawlwhen crawling the crane.

qBefore operation

TRAVEL LEVER STAND

LOCK LEVER

STAND LEVER

TRAVEL LEVER

CRANE OPERATION POSITION TRAVEL POSITION STOWAGE POSITION

Crane will not work unless the crane-crawllever is shifted to Crane position.

2. SAFETY PRECAUTIONS ON CARRIER OPERATION

Observe the cautions for securing safety.Failure to observe the cautions may invite trouble or serious acci-dent.

WARNING

2-2

SAFETY PRECAUTIONS ON CARRIER OPERATION

1 The machine employs particularly smalltruck to facilitate working in a restrictedspace.Since high performance crane is mounted onthe small truck, it has been built with a highercenter of gravity.Take special care not to overturn the cranewhen crawling on a unleveled ground.

2 When crawling the crane, all personnelexcept for the operator are strictly for-bidden to stand within 2m of it.

3 When crawling the crane, be sure to putoutriggers in a condition of being storedand store the hook.

4 Do not run the crane with a cargo hoist-ed or without the crane being stored.5 Special care must be taken to run thecrane slowly when making a sharp turnand crawling on a rough road.

6 When going over uneven ground andgoing up and down hills, do so straight-on. Be careful not to unbalance or expose thecrane to sharp impact.

7 Be sure to use a foot-board to run over aramp of more than 15cm.8 Crawl the crane with low (1st) speedgear on a slope.9 Be sure to use a pallet against the rubbercrawler when parking the crane on aslope.

10 Do not make an abrupt stop and start,and change a course on a slope.11 When crawling up and down a slope,operate the crane by standing at ahigher position than the crane body.

12 Do not use the crane on a steep slopeof more than 10 degrees.Pay attention that the crane will not lean bymore than 10 degrees due to jolting whenoperating/crawling on a unleveled road.

Less than 10 degrees

13 Do not run the crane over bumpyarea, lying rocks with sharp edges,rough solid rock, small broken stones, edgesof steel plate, steel bars for reinforcement,scrap metals, and waste materials and on aroad such as in riverside where covered withmany stones which may remarkably shortenservice life of rubber crawler.

14 Do not turn the crane body in suchway that the rubber crawler makes asimultaneous rotation by turns as this causesremarkable wear of rubber crawler due toquick movement.

wDuring operation

2-3


1 When loading and unloading the crane,use a non-slip foot-board with a enoughcapacity of strength, width, and length andrun the crane straight up and down veryslowly.In addition, operate it by standing at a higherposition than the crane body.Changing direction of the crane on the foot-board may cause the crane to fall off.

2 Stop the engine, apply parking brake,and put drags to wheels to secure themounting vehicle when loading and unload-ing the crane.Failure to observe this may cause the craneto fall off because the vehicle shift while it isbeing loaded and unloaded.

eWhen loading and unloading15 Do not take an article or an animal onthe crane.

It may invite critical situation due toabrupt swing or shift of center of gravity.

16 Do not park the crane over a placewhere withered grass or straw arebeing spread.It may cause a fire by heat of exhaust pipeor exhaust gas.

( )

( )

( )

Be sure to drive both sides of crawler in the same direction for making a turn.

Do not drive both sides of crawler in the opposite direction each other.

Do not drive only one side of the crawler.

For the white (or gray) crawler, observe the driving strictly in terms of its characteristics.

17 To avoid rubber crawler damage.

2-4


1 Return the crawling lever and run theengine at a low speed.2 Shift the crawling lever to Crane posi-tion.3 Stop the engine and remove dirt anddust stuck on the crane body.Since dust stuck on the battery, electricwiring, and engine related components suchas muffler may cause a fire in particular, besure to remove it.

4 Cover the crane or store it in a storagehouse to prevent it from being accessedby unrelated persons such as children.Cover the crane after heated sections havebeen cooled off.Putting a cover on while the crane body isstill hot may cause a fire.

5 Remove the starter switch key to keep itsecurely.6 Disconnect a battery cable before thecrane is to be stored for a long period oftime.Failure to disconnect it may cause a fire ascables short-circuited by gnawing animalssuch as rat.

rAfter operation

Cable (-) Disconnect

3-1

3. SAFETY PRECAUTIONS ON CRANE OPERATION

qBefore operation

1 Be sure to make inspection before opera-tion and periodical inspection for sling-ing implements.If a defective slinging implement is used,fall of lifted cargo may result.

2 Shift the crawling lever to Crane posi-tion.

TRAVEL LEVER STAND

LOCK LEVER

STAND LEVER

TRAVEL LEVER


3 Turn ON the over-winding alarm switch.

4 Make sure that each safety device isalways functioning properly.Be sure to turn ON the over-winding alarmswitch before starting crane operation.

5 Keep a safety distance away from thehigh-voltage power line to avoid anelectric shock.The crane is not electrically insulated.

6 Do not operate the crane when windvelocity exceeds 10m/sec. and/or whilethundering.Crane operation while strong wind isblowing can cause fall of a lifted cargo oroverturn of the crane as the boom and/or alifted cargo are hit by a gust of wind.

7 Pay attention that anyone except personsconcerned will not enter within a work-ing radius of the crane.Take good care to carry out safety opera-tion by keeping a close watch around theworking area.

8 Make sure that the ground on which out-riggers are to be set up is solid and firm.When setting up the outriggers on anunleveled ground or on a slope, be sure toplace a support (such as plank, steel plateetc.) under the outrigger foot flanges to keepthe crane level.In addition, when the crane is to be operatedon a soft ground, take the same measures toprevent the outrigger foot flanges from sink-ing into the ground when a cargo is lifted up.

9 Lift up the crawler by approx. 50mmfrom the ground.

10 Operation with the crane kept leaningmakes it unstable when a cargo islifted up.Such operation can cause the crane to beoverturned.

11 In normal crane operation, be sure toset up the crane level with the outrig-gers fully extended.

12 Do not stand under or in front of thehook when unhooking as it swings.13 Do not try adjusting hydraulic equip-ment.14 If the crane is equipped with theturnover prevention device, confirmthat the crane makes an automatic stop whenoverloaded.

DANGERBEFORE OPERATING THE CRANEIT IS MANDATORY TO

OUTRIGGERSSET UP ALL THE

3-2

SAFETY PRECAUTIONS ON CRANE OPERATION

wDuring operation

1 Pay attention that the hook will not beover-wound.Be sure to turn ON the over-winding alarmswitch.Remember that the hook is wound upwhen boom is extending.If the hook hits against the boom top dueto being over-wound of the hook, it maycause damage to wire rope and the sheaves atthe boom top and may cause the fall of liftedcargo.

2 Operate each lever slowly and smoothly.An abrupt lever operation with a cargo lift-ed gives an excessive shock to the cranewhich may cause damage to the crane and/oroverturn due to swing of a lifted cargo. If a control lever will not make a smoothreturn to its neutral position, carry out lubri-cation and repair as soon as possible.

3 Slew the crane at low speed.Swing of a lifted cargo increases workingradius of the crane which may cause it to beoverloaded.

4 If the engine speed is too slow whenoperating the crane, control the accelera-tor lever to increase it. Crane operation with the engine (andpump) running at low speed may cause acargo hoisted up to swing due to pulsation ofthe engine.This is not a malfunction but impairs smoothcontrol of the crane.

5 Overloaded operation is strictly prohib-ited.Crane operation with a load exceeding therated load hoisted may cause damage or over-turn to the crane.

For the crane equipped with turnover pre-vention device (be sure to check if it ismounted):Do not put too much confidence on thedevice even if the crane is equipped with thedevice with warning and automatic stop.It functions just as an auxiliary device.It is the principle that you should persistentlyobserve the operation within rated load.If an alarm sounds due to decrease of groundreaction, lower the operating speed immedi-ately to shift the crane to safer side.If ground reaction decreases further, thecrane stops following functions automaticallywhen you should pay special attention to thecrane because it may roll over due to swingof a lifted cargo.

Winding-up hook extension of boom

lowering boom Slewing

6 Pulling a cargo sideways, straight, orobliquely is strictly prohibited.These operation may cause slewing mem-bers, booms, columns, and derrick cylinder tobe damaged.

7 When a cargo to be lifted is detachedfrom the ground, stop lifting it up tem-porarily to confirm safety.When a cargo is lifted off the ground, stoplifting it up temporarily to make sure that thecargo is kept horizontally, the crane main-tains its stability, and the rope slinging up thecargo is positioned properly.Then lift it up again after making sure of thesafety.For lowering a cargo, stop lowering itimmediately before it touches the groundthen lower it again gradually.

8 Do not leave from operating positionwith a cargo hoisted.Lower a hoisted cargo onto the groundbefore leaving the operation site.

3-3

SAFETY PRECAUTIONS ON CRANE OPERATION

9 Do not get up on a cargo being hoisted.This may cause a fall from the cargo beinghoisted.

10 Do not stay under a hoisted cargo.

11 Pay attention that wire ropes will notbe paid out unnecessarily to preventropes from being wound around the drumirregularly.Operation such as paying out wire ropesfurther with a cargo placed on the ground,retraction and/or lowering boom whichloosen the ropes to cause them irregularwinding which results in remarkable shorten-ing service life of the ropes.Wind the first layer of rope firmly and reg-ularly around the drum.Correct kinks of rope immediately with amallet.

12 Pay extra attention to undergroundcrane work in which the hook mustbe lowered further than the work on theground. When paying out wire ropes, be sure thatmore than 3 turns of rope must always be lefton the drum.

13 Stop the crane operation when tem-perature of hydraulic oil exceeds80C.Oil temperature is apt to rise easily ifrepeated operation of winding up and downthe hook, especially in a high lift, is required.Excessive high temperature of hydraulicoil damages high-pressure hoses and gasketsbeing employed to cause the oil to spout outso that a scald may result.

14 Do not touch the engine and the hoodin the side with a bare finger as theybecome too hot.

eAfter operation

1 Make sure that the booms, the outrig-gers, and the hook have been storedbefore crawling the crane.

2 Do not carry out maintenance andinspection while temperature of eitherhydraulic oil or gear oil is still high.Temperature of both hydraulic and gear oilis high immediately after crane operation sothat accumulated high pressure still remains.Removing filling cap, draining oil, or replac-ing oil filter while temperature is still highallows hydraulic and/or gear oil to spout outand a scald may result.

3 Since temperature on the engine and thehood in the side is too high immediatelyafter crane work, touch them after they havebeen cooled down.

4-1

4. DESCRIPTION OF CARRIER EQUIPMENT

10 9

6

3

8

11 14 7 13

1 4 5 2

12

4-2

DESCRIPTION OF CARRIER EQUIPMENT

1. Rubber crawlerCored bar and steel fabric (cords) are inte-grally molded in the rubber which is of thesame quality as automobile tire.

2. Wheel sprocketIt transmits driving power to the rubbercrawler to allow the crane to crawl.

3. Idle rollerThis is a roller which gives a proper tensionto the rubber crawler.

4. Truck rollerThis supports the weight of crane and rolls onthe rubber crawler.

5. Crawling motorHydraulic motor with reduction gears whichtransmits driving power to the wheel sprocketis built inside.

6. Crawling leverThis is to change crawling speed and direc-tion.

7. Accelerator leverThis is to control engine speed.

8. Horn switch

9. Fuel tankFuel to be used is leadless gasoline.

10. Hydraulic oil tankThis is filled with hydraulic oil which com-monly supplies both to the carrier and to thecrane.

11. Starter switchThis is a switch to start and stop the engine.

12. Hour meterThis indicates total engine running time.

13. Choke knobThis is pulled when starting the engine incold weather.

14. Lock lever

5-1

5. DESCRIPTION OF CRANE EQUIPMENT

2 4 6 16 8 7 1 18 9 12

15

11

10

19

20

17 Option

3

5

14

13

5-2

DESCRIPTION OF CRANE EQUIPMENT

1. BoomIt extends and retracts by hydraulic cylinderand the hook is suspended from its top.

2. ColumnThis is a vertically mounted member on thecrane in which boom, winch, and derrickcylinders are installed.The column can be turned by slewing device.

3. FrameThis is fixed on the vehicle to support the col-umn and outriggers.

4. Hoist winchThis is a device which rotates the wire drumby hydraulic motor to hoist up and down acargo via wire ropes.

5. Slewing deviceThis turns the column by hydraulic motor.

6. Derrick cylinderThis raises and lowers the boom.

7. Telescoping cylinderThis extends and retracts sections of boom.

8. OutriggerThis supports the crane to maintain its stabili-ty while it is operated.

9. Crane operating leversRespective levers control raising and lower-ing boom, hoisting a cargo up and down, tele-scoping boom, and slewing boom.

10. Outrigger control leversRespective levers control raising/loweringand extending/retracting outriggers.

11. Hook

12. Over-winding alarmWhen the hook comes close to the boom top,this makes an alarm to warn that wire ropesare to be over-wound.

13. Load meterThis reads weight of a cargo being hoisted.

14. Warning hornDepression of warning switch sounds thehorn for warning.This is to warn co-workers and others in theoperation site.

15. Wire rope

16. Load indicatorThis can read the net rated load value corre-sponding to extended length of the boom andits raised angle.

17. Automatic stop for leaving minimumwire rope (with wire rope retainingroller) (Option)

This is a devise to restrict slackening of wirerope on the drum which allows to stopunwinding automatically when remainingwire rope on the drum comes close to 3 turns.

18. LevelThis is an instrument for checking horizontalplane of the crane body.

19. Turnover prevention device (onlycrane equipped with device)

This detects load against ground from outrig-gers.

20. Outrigger selection switchThis selects active outrigger and operatingdirection.

6-1

6. NAME PLATES

The machine is provided with stickers indicating caution (framed in box ) and specificationsas shown in the figure below, and in addition to that there are stickers showing control levers,switches, and instructions for lubrication.

qDescription of name plates (Stickers)

Machine identification

CautionCaution, Battery

Caution , Watch-your-foot

Caution, Travelling

Net Rated Road Chart

Caution, Radio-controlled operation Caution , Mode Indicator Lamp

Caution, Travel Lever Stand Caution, OUTRIGGERS

PROHIBITED AREA OF CRANE OPERATIONS

OUTRIGGER OPERATION FOR EMERGENCY

6-2

NAME PLATES

qStickers in detail

Sticker [BATTERY]

CAUTION, HIGH TEMPERATURE

094383140

CAUTION, BATTERYWrong handling of battery may cause to catch fire leading to explosion.Do not make it short-circuiting, spark-ing, and bring close to a fire. In addition, you may be blinded or burned by battery electrolytic solution.When your eye, skin, or clothes was stained with the solution, wash it away with plenty of water immediately.In case where the solution entered into someones eye accidentally, see a doc-tor to receive treatment after washing it with water.

Sticker [WATCH-YOUR-FOOT]

Mind yourfeet

Pay attention to yourfeet when extendingoutriggers. 094383110

Sticker [HIGH TEMPERATURE]

Always keep the stickers clean so that they can be read easily. If any of the stickers has come off, stick it again or replace it with

new sticker.When ordering stickers, specify the part number shown at the bot-

tom-right of the sticker concerned.

CAUTION

6-3

NAME PLATES

Sticker [OUTRIGGERS]

For extension of the outriggers, be sure to support the outriggers on the ground with the outrigger cylinders after the inner boxes are extended.For stowage of the outriggers, be sure to stow the inner boxes after the outriggers are fully retracted, and swing the outriggers to the stowage position after the outer boxes are folded.

If either of the inner box or outer box is positioned at other than maximum extension, operate with performance of other than maximum extension.In case of swing with a load lifted, fore-and-aft stability of the main body is different from right-and-left stability. Shorten an operating radius as much as possible and perform operations using caution in turnover.

If placement of each outrigger is changed from the above illustration, operate according to a different plate "Prohibited area of crane operation."

Place the crane on a firm and level surface and use the outriggers in principle in a fully extended condition.

When operating the crane, be sure to keep the crane level using the outriggers.

When extending and retracting the outriggers, be sure to insert swing lock pins to prevent the outriggers from swinging.

39

10

39

35

3885

55

5550

50

INNER BOX

OUTER BOXARMCENTER OF SLEWING

Condition in which the inner box is fully extended and the outer box securing pin is placed in the "fully extended" position.

CAUTION OUTRIGGERS

09R886080-W295CR

Do not extend the outrigger cylinders with the outriggers stowed.Swing the outriggers with the outrigger cylinders retracted.

When travelling, be sure to stow the outriggers.

FULLY EXTENDED CONDITION OF OUTRIGGERS

6-4

NAME PLATES

Sticker [CAUTION, CRAWLING]

094383160

CAUTION, TRAVELING

The truck might fall off or fall down dur-ing traveling.Slow down the vehi-cle and direct your mind to traveling when passing close to road shoulder or on the soft ground.

Sticker [CAUTION]

If the engine oil decreases, the sensor may be activated, causing the engine to stop automatically.

Note:The chart shows the data when the crane is operated with no-load and shift due to deflection of boom is not considered.

High-speed slewing may cause the crane to turn over by slewing of load. Slewing at such a speed as does not cause slewing of load.

A load indicator shows performance of the crane placed on a firm and level surface.Never perform overload operation by combined use with a load meter.

Never allow travel with a load lifted and crane operation with no outriggers extended.Doing so is very dangerous.Extend the outriggers and float the carriage by approx. 50 mm for crane operations.The carriage, if not floated, may be damaged. Never perform operations with the carriage floated high, which is very dangerous.

The weight of a lifted load can be measured with a load meter only during hoisting of the hook. Adjust the engine speed so that the needle points to 0 while operating hoist work under no load and measure the weight of the lifted load at the engine speed.

Be sure to reinstall covers removed for inspection and maintenance.

09R886030-W295CR

Read the instruction manual carefully before use.When operating this crane, check the surrounding area for safety.

Perform inspection and maintenance of the engine after the motor cools down.

Be sure to perform inspection and maintenance before starting operation.

As the engine heats up, pay attention to prevent fire, always checking the surrounding area.

Place the crane level using a level.

Be sure to stop power (engine, power source) before inspection and maintenance.

When extending the boom, allow room between the boom top and the hook.

When travelling, be sure to store the hook completely.

43 61 7 8 92

CAUTION

0

5

6

7

8

9

4

3

2

5

1

0

0

10

20

30

40

50

607078

WORKING RANGE CHART

BOOM LENGTH 2.53m 4.075m 5.61m 7.13m 8.65m

Lift of hook

Lift of hook

Lift of hook

Lift of hook

Lift of hook

1 2 3 4 5

WORKING RADIUS (m)

HE

IGH

T (

m)

Boom angle

After completing the work, be sure to turn OFF the key switch.

If hoisting the load exceeding the rated load, the crane may turn over. Observe the rated load for operation.

CAUTION SLEWING BOOM

6-5

Sticker [NET RATED LOAD CHART]

NAME PLATES

Sticker [MODE INDICATION LAMP]

RADIO CONTROLSELECTOR SWITCH

POSSIBLE OPERATION

OUTRIGGER RADIO CONTROLED MODE

When radio control is OFF, radio-controlled operation cannot be performed (except for outrigger radio-controlled operation).

CANCELLATION OF AUTO-STOP

MANUAL AND RADIO CONTROL

INDICATOR (LIT)

OPERATION MODE (STATUS)

MANUAL AND RADIO CONTROL

Flashing of the mode indicator shows abnormality of operation or the equipment. Follow instructions of the instruction manual.

RADIO CONTROL ONRADIO CONTROL OFF

TRAVEL MODE

09R886160-W295CR

The radio control selector switch opposite to the mode indicator lamp allows selection of ON and OFF of radio-controlled operation.

MODE INDICATOR LAMP

The above table shows the main mode indication. For details, see the instructions.

CRANE MODE

OVERWINDINGSTORAGE OF HOOK

RADIO CONTROL ON

RADIO CONTROL OFF

CAUTION MODE INDICATOR LAMP

MANUAL

When radio control is ON, both manual and radio-controlled operation can be performed.

DIRECTION OF INDICATORAUTOMATIC STOP

6-6

NAME PLATES

Sticker [OUTRIGGEROPERATION FOREMERGENCY]

PUSH THE BUTTON

PUSH THEBUTTON

Note: When removing the cover or pushing the solenoid valve switch, be careful not to damage the wiring.

RET.EXT.

EXT.RET.EXT.RET.

OUTRIGGER

OUTRIGGER

OUTRIGGER

OUTRIGGER

RET. Push 2 and operate the lever.Push 5 and operate the lever.Push 6 and operate the lever.Push 7 and operate the lever.Push 8 and operate the lever.Push 3 and operate the lever.Push 4 and operate the lever.

EXT

EXT

RET

VALVES FOR OPERATING OUTRIGGERS

EXT

EXT

RET

RET

RET

When the outriggers do not operate normally with normal operation methods, operate them in a make-shift manner in the following procedures. When the specific work is complete, have the out-riggers inspected and repaired at your nearest service shop of our products as soon as possible.

1. Remove this cover of the outrigger valves.2. Push the solenoid valve button of the following outriggers to be operated with a narrow rod such as a screwdriver.3. Operate the outrigger control lever while pushing the solenoid valve button.

1

4

3

2

1

2

3

4

OUTRIGGER OPERATION FOR EMERGENCY

09R886190-W295CR

EXT.OPERATION OPERATION METHOD

Push 1 and operate the lever.

12

3

5

7

4

6

8

Sticker [Radio-controlledoperation]

For approx. two seconds after the key is switched ON, the system is analyzed. Do not operate the crane during this period. If the crane is operated during system analysis, a voice urging "inspe-ction and maintenance" is announced. In this case, switch the key ON again.When the emergency stop switch in the switch panel is turned to "STOP", all crane movements make an emergency stop.

If the manual operating lever is moved during radio-controlled operation, the crane stops automatically.Operation with a radio control transmi-tter cannot be performed during crane operation with the manual lever.

If the crane does not operate in spite of an announced voice saying "Remote control ready." after the key is switched ON, it is possible that the emergency stop switch is turned to "STOP." In this case, the crane can be operated if the emergency stop switch is turned to "RESET."Be careful that in case of performing hook storage operation with the switch panel of the crane, the manual operat-ing lever also moves with the switch turned to "STORE."Be careful that in case of operating the crane with a radio control trans-mitter, the manual operating lever moves simultaneously.

09R886150-W295CR

CAUTION Radio-controlled operation

6-7

NAME PLATES

Sticker [TRAVEL LEVER STAND]

STOWAGE POSITION

TRAVEL POSITION

CRANE OPERATION POSITION

09R886220-W295CR

CAUTION TRAVEL LEVER STAND

When operating a crane, pull up the lock lever and tilt the travel lever stand toward you.

When the travel lever stand is set to the travel position, the crane does not operate at all except for travelling.

When transporting a crane, pull up the lock lever and tilt the travel lever stand toward the column.

Tilt the travel lever stand until it contacts the stopper. If the crane is operated without the travel lever stand tilted to the end, the travel lever may contact the main body of the crane while the crane is swung, resulting in breakage.Be careful not to contact the travel lever while operating the crane. The contact activates the crawler, which is dangerous.

When travelling, set the travel lever stand to the travel position. Be sure to secure the stand with the lock lever.

When changing to the travel position, be sure to stow the boom and outriggers and position the crane to the travel position. Travelling without positioning the crane to the travel position may cause a serious accident such as turnover.

When changing the position of the travel lever stand, be sure to change the position by holding the stand lever instead of the travel lever.

Even when the travel lever stand is in the stowage position, operation of the travel lever actuates the carriage if the hydraulic pump operates. Use due care when changing the position.

TRAVEL LEVER STAND

LOCK LEVER

STAND LEVER

TRAVEL LEVER


Sticker [PROHIBITED AREA OF CRANE OPERATIONS]

Perform operations with outriggers extended in each illustration so that the position of a lifted load does not go beyond white areas.

Be sure to set any two adjacent outriggers of the four outriggers to normal extension (front 55 degrees, rear 50 degrees) as shown in the above illustrations. If any one of the four outriggers is not fully extended, operate with performance of not maximum extension.

CENTER OF SLEWING

NORMAL EXTENDED CONDITION

Never perform operations in orange areas, because the crane may turn over.

50

50

55

55

09R886070-W295CR

PROHIBITED AREA OF CRANE OPERATIONSOrange areas in each outrigger placement shows prohibited areas of crane operations.

Be sure to insert the swing lock pins to prevent the outriggers from rotating.

50

50

50

50

55

55

55

55

55 50 50 55

55 50 50 55

7-1

qExtension and spread of outriggers

7. DEFINITION OF TERMS

3910

3935

388555

5550

50

50mm

Slewing center

Position of pin

Outrigger setting with inner box extended to its extreme

The figure above shows that outriggers are extended to their extremes.Carry out operation by making the crane level on a flat and solid ground with the outriggersextended to their extremes, and with the crane body raised by approx. 50mm above the ground.

7-2

DEFINITION OF TERMS

Net rated load is expressed when the outriggers are extended to maximum and to a distancebelow maximum with their spread angle set the same.As a rule, set the outriggers extended to their extremes and with the spread angle of each 55and 50.When any one of 4 outriggers has not been set to the maximum extension, the net rated loadother than maximum extension is to be applied which must be observed.

Since prohibited range of crane operation is specified according to spread angle of outriggers,confirm it on the sticker.If it is failed to observe, the crane may be overturned.

3935

5555

50

50 3

910

3885

2570

2240

2310

5555

50

50

Example: Outrigger setting to a distance below maximum (Figure shows they are set to minimum extension).

Position of pin

Outriggers extended to maximum

Outrigger setting with inner box extended to its maximum

Position of pin

Outrigger setting with inner box pushed in to its minimum

7-3

DEFINITION OF TERMS

wHow boom-sections are extended

Boom Boom BoomBoom

Boom

Boom Boom

Boom :

All boom sections are retracted.

1

Boom : or

Boom section(2) only is extended.

21+2

How boom-sections are extended

Boom

Boom

Boom

Boom : or

Boom section(4) is extended to the mark .

41+2+3+4

Boom : or

Boom-sections(2), (3), (4), and (5) are fullyextended.

51+2+3+4+5

Boom

Boom

Boom

Boom

Boom

Boom : or

Boom sections(2) and (3) are extended.

31+2+3

Boom

Boom

Boom

Boom

Boom

5-section boom

7-4

eNet rated loadNet load which can be lifted by hook deter-mined on the basis of stability of crane.

Net rated load Rated load

Weight of hooking implements such as hook

DEFINITION OF TERMS

rRated loadMaximum load including hook and hookingimplements which can be lifted according tothe boom angle and/or the boom length deter-mined on the basis of stability of crane.

tLifting capacityThis refers to maximum load of the ratedload described section r above.

yWorking radiusThis is horizontal distance from the slewingcenter to the hook center.

uBoom lengthThis is distance from the boom foot pin to thesheave pin on the boom top.

iBoom angleThis refers to an angle made by axis line ofboom and the horizontal line.

Lif

t ab

ove

gro

un

d

Working radius

Boom angle

Sheave pin

Boom foot pin

Slewing center

Boom

leng

th

oLift above groundThis refers to maximum vertical distancebetween bottom end of the hook to theground surface with the hook wound up totouch the over-winding alarm detector.

8-1

8. HOW TO REFER TO WORKING RANGE CHART AND NET RATED LOAD CHART

Note:The chart shows the data when the crane is operated with no-load and shift due to deflection of boom is not considered.

43 61 7 8 920

5

6

7

8

9

4

3

2

5

1

0

0

10

20

30

40

50

607078

WORKING RANGE CHART

BOOM LENGTH 2.53m 4.075m 5.61m 7.13m 8.65m

Lift of hook

Lift of hook

Lift of hook

Lift of hook

Lift of hook

1 2 3 4 5

WORKING RADIUS (m)

HE

IGH

T (

m)

Boom angle

qWorking range chartThe chart shows the relation among boomlength and working radius, boom angle, andlift above ground.

Boo

mle

ngth

A

B

Working radius

Boom angle

Lift above ground (H)

Working radius with a cargo hoisted

Working radius before hoisting cargo

These charts are stuck in front of crane operation levers and how to refer to charts is illustratedas follows:

Although the point-A and the point-B followthe tracks along the same working radius, thepoint-A refers to the boom angle and thepoint-B the lift above ground.

The working range chart does not incorporateany shift due to deflection of boom.Keep in mind that the actual working radiusis somewhat extended due to boom deflectionwhen a cargo is being hoisted.

8-2

wNet rated load chartThe chart shows maximum load which can be hoisted up for every combination of boom-sec-tions to be extended for each working radius.

HOW TO REFER TO WORKING RANGE CHART AND RATED LOAD CHART

The chart shows hoisting capacity when the crane is set up level withthe outriggers extended and the data are based on actual workingradius by incorporating shift due to deflection of the boom underloaded.

The net rated loads specified above are based on strength of thecrane and stability of the crane.Be sure to check the chart for the net rated load as it is to be changedaccording to how far the outriggers are extended.

CAUTION

9-1

9. DESCRIPTION OF EACH CONTROL DEVICE

qOverwinding alarm1. Function of overwinding alarmThe device automatically makes an alarmsound to warn that the wire ropes are beingover-wound when the hook comes close tothe boom top.

1 Turn ON the over-winding alarm switchbefore starting crane operation.If the alarm sounds while the hook is beinghoisted or the boom is being extended, stopthe crane operation immediately and lowerthe hook or retract the boom.

2 Turn the alarm switch OFF after thecrane work has been completed.

2. Operating procedures

When the over-winding alarm switch is turned OFF, over-windingalarm will not function even if the hook is being overwound.Be sure to turn the switch ON before starting crane work and check thatthe alarm sounds every time when the weight for over-winding alarm islifted up to the detector.

Since the length of wire rope hanging the weight is specified by lawsand regulations concerned, do not make it short at random.

The alarm sounds even if any of electric wires connected to the over-winding detector at the boom top is broken.Ask an authorized UNIC service station for repair.

Over-winding alarm switch

ON

OFF

Cord reel

Overwinding detector

Weight for over-winding alarm

CAUTION

9-2

Reset

Reset switch for automatic stop

wAutomatic stop for over-winding

2. How to reset when automatic stop forover-winding is found out of order

If crane can not be operated due to failure inthe automatic stop, reset the automatic stopand store the crane.

Step 1Turn the reset switch for the automatic stopto Reset to reset the automatic stop.Then wind up the hook, extend or raise theboom by controlling operation lever.

1. Function of automatic stop forover-winding

If the hook comes close to the boom top andit hits against the weight for over-windingalarm, buzzer sounds and functions of wind-ing-up hook, extending boom, and raisingboom stop automatically.When the automatic stop is activated, lowerthe hook, retract or lower the boom until thebuzzer stops sounding.This allows the activated automatic stop toreturn to normal.

RemarksSince viscosity of hydraulic oil increasesduring cold winter or in low temperatureenvironment, function of winding-up hookor extending boom may not stop perfectlybut it allows to make a slight movementeven if the hook hits against the weightwhich is not a disorder.Carry out warming-up and the automaticstop recovers functioning when tempera-ture of hydraulic oil rises to a certain level.

DESCRIPTION OF EACH CONTROL DEVICE

Stop(extending) Restore

(retraction)

Stop(raising)

Restore(lowering)

Restore(unwinding)

Stop(winding-up)

9-3

Pointer

(Side of boom)

Scale

eLoad indicator (With angle meter)

The indicator reads the net rated load corre-sponding to extended length of boom and itsangle to show the maximum weight of cargowhich can be hoisted at this point.1. Net rated loadThe value to which the needle points on thescale of meter is the net rated load in eachcombination of boom-sections being extend-ed.

2. Boom angleDeflection of the needle on the angle scalereads the boom angle.

The load indicator reads the net rated load when the outriggers arefully extended.

The load indicator can not be used when the outriggers are extendedto a halfway or to minimum.

Use a proper scale band according to boom-sections being extended.


CAUTION

9-4


(b)(a)

(c)

(d)

(f)

(e)

Working radius with a cargo hoisted

Working radius before hoisting cargo

[Example]How to read when the needle deflects asshown in the figure.(1) Boom angle reads 41 at the point (a) on

the boom angle scale.(2) Maximum load which can be hoisted (Net

rated load) reads:For boom (With all boom sections

retracted) : 2.2t at point (b).For boom (With boom section

extended) : 1.2t at point (c).For boom (With boom-section

extended) : 0.7t at point (d).For boom (With boom-

section extended) : 0.42t at point (e).For boom (With boom-

section extended) : 0.22t at point (f).51+2+3+4+5

4

1+2+3+4

3

1+2+3

21+2

1

When a boom is extended tohalfway, use the net rated loadwith the boom concerned fullyextended in order to secure safe-ty.When boom-section is

extended from boom-section, take the net rated load for

boom (1.2t in the exam-ple shown above).When boom-section is

extended from boom-section, take the net rated load for

boom (0.7t in the exam-ple shown above).

Since the working radiusincreases due to deflection of theboom when a cargo starts to belifted up , set the boom angle sothat the hook comes to some-what inner side.

1+2+3

2

3

1+2

1

2

CAUTION

9-5


How to refer to hoisting capacity when outriggers are extended to minimum or tohalfway.

As a general rule, the outriggers are to be extended to their extremes.If it is forced to operate the crane with the outriggers extended to minimum or to halfway, oper-ate the crane in accordance with instructions shown below.

1. Find the working radius.2. The net rated load is to be obtained from the data shown in the outriggers extended to mini-mum on the chart of net rated load according to how boom-sections are extended.

When operated with the working radius of 3.5m ,with the extended boom configuration of, and with outriggers extended to halfway or to minimum, take 0.35t.

When operated with the working radius of 3m, with the extended boom configuration of, and with outriggers extended to halfway or to minimum, take 0.5t.1+2+3

1+2

When the outriggers areextended to minimum or tohalfway, operate the craneaccording to capacity obtainedfrom the outriggers extended tominimum or to halfway accordinglyon the chart of net rated load.

The load indicator can not beused when the outriggers areextended to minimum or tohalfway.

CAUTION

9-6


Load meter

rLoad meter

2.9

2.3

2.6

2.3

770363335

0

5

10 15

20

250

1

2

0

0.5

1

2

4

4

1

0MPa

0.73

2.9

0.65

2.6

0.58A

B

Number of ropes being hooked

Dial of load meter has:Scale bands corresponding to A and Bfor 4-rope hooking system, Scale band for single-rope hookingsystem.

Load meter indicates theweight of a hoisted cargo onlywhile the hook is being lifted upand it will not show the weightwhile other operations, such aswhen stopping winding up andlowering a cargo, are beingcarried out.

Take the weight indicated onthe load meter as an approximatevalue.

The meter shows weight of a cargo beinghoisted.Read the scale band corresponding to thewire-rope hooking system (number of wireropes being hooked).

RemarksThe load meter is fixed on the panel.

CAUTION

9-7

Follow the steps illustrated below when measuring weight of a hoisted cargo with the load meter.Compare the reading on the load meter with the reading on the load indicator.

Allow the engine to run at a low speed.

Adjust the lifting-up speed of hook so that the needle may point at 0 (zero) on the load meterscale by lifting up hook with no-load.Measure the weight of a cargo at the lifting-up speed adjusted. Shift the lever for winding-up hook to the position just before the engine starts increasing its speed

by auto-acceleration.This will not be measured by a slight control of the lever for winding-up hook.

For radio remote control types, when it is measured by winding-up hook control using the manualcontrol lever after the speed mode has been switched to a very slow speed mode by the radioremote controller, the measurement can easily be done as the engine speed will not be increased.

Weight measurement through radio remote controller can only be done in the fastest speed mode.It cannot be measured in the mode of medium or slow speed.

Taking an example of the case where a cargo is hoisted up by using 4-rope hooking systemand with the extended boom configuration of .The load indicator shows at point (a) that the crane can lift up the load up to 0.7t (Fig. 1).

Read the load meter for the point (b) on the scale band of B while a cargo hooked is beinglifted up to approximately 30cm above the ground (Fig. 2).

The meter shows 0.5t for the actual weight of the cargo.

This means that the crane can be operated with a margin of 0.2t in the example.

1+2+3


Fig. 1. Load indicator

Point (a)

2.9

2.3

2.6

2.3

770363335

0

5

10 15

20

250

1

2

0

0.5

1

2

4

4

1

0MPa

0.73

2.9

0.65

2.6

0.58A

B

A

B

Point (b)

Fig. 2 Load meter

Long needle Short needle

9-8


Check for safety operation If a crane is loaded so much that readingson the load meter exceeds the net rated load,the crane can be damaged or overturned.In such case, move the crawler crane closerto the cargo to be hoisted to decrease theworking radius, then operate the crane againwithin the net rated load.

When the load meter reads less than thespecified net rated load in the chart, the cargocan be lifted up safely.

tDigital load meter(option)

Load detector

Load display

How to measure the weight of hoistedcargo correctlyTo measure the hoisted cargo properly, liftit slowly off the ground, bring it to astandstill and then read the indicated value.

Pre-operation inspection

Check that the load display shows [ ]with no cargo hoisted.When there is a problem viewing the loaddisplay, have it inspected, repaired orrecalibrated at a designated Unic servicingdealer.

The load meter digitally displays (3-digits)the weight of the cargo being hoisted. Unlikeordinary hydraulic load meters, the digitalload meter displays the weight of the cargo atall times while it is being lifted. If the hook is overwound (automatic over-wind stop device or the overwind alarm is

activated), the load display blinks [ ]to catch the attention of the operators.

RemarksThe weight display can be rotated.Therefore, rotate it so that it can be readfrom where the crane is operated.

9-9

Checking safe operation exceeds the rated capacity, the crane couldbe damaged or overturn. In this case, operatethe crane within its rated capacity by movingthe vehicle closer to the cargo to reduce thecranes working radius.

It is safe to lift up cargo when the loadmeter shows a value less than the rated load.

Major specifications

The device does not provide the function as measurement equipmentbut is to find out hoisting load of the crane.Therefore, we take no responsibilities for any damage resulted from theuse for the purpose of measurement.

The device can apply when using 4-part line hooking system.

Although load indication may become unstable while the crane isbeing operated, it is not a trouble. Stop of the crane operation makes it back to normal.

If the hoisted load drastically exceeds the rated capacity, the auto-matic overwind stopping device (or overwind alarm) will activate.Immediately lower hoisted loads that are heavier than the rated capacitybecause they may damage the load detector and crane.

As the distance between the boom top and the hook is getting farapart, the load indicated is what the weight of the wire rope betweenthem is included. (When distance between the boom top and the hookis 10m, weight of the wire rope is approx. 11kg.)

Do not perform pressure washing at the load meter.

CAUTION

Rated load 3.00t

Resolution 0.02t

Indicating accuracy

(at room temperature of 25)

0.02t (For lifting load of less than 0.5t).

0.04t (For lifting load of more than 0.5t).

If rated load of the crane is smaller than the rated load, choose the rated load of the crane.


9-10

ZERO RESET SWITCH

2. Preparation before measurement1.Check for number of slinging wire ropesWith [ADD MODE] lamp lighted OFF;Depress the [HOOK WIRE] to confirm that[H4] appears on the load display. Indicatorreturns to wait indication in 3 seconds afterthe switch has been released.

2.Checking load indication and zero-pointadjustment

Check that load meter indicates [ ]with no load lifted up.If it is not, depress the ZERO RESETswitch for 1 second to make zero-pointadjustment of the load meter.

When the zero-point adjustment hassuccessfully been made, the indication blinksonce then the load meter shows [ ].

RemarksWhen in overwound condition ([ ]blinks), zero-point adjustment cannot bepossible.Carry out zero-point adjustment when theload meter indicates [---] or loadedweight.


9-11

ZERO RESET SWITCH

1 Switching to addition modeWhen the load is indicated on the load meter,depress the [ADD MODE] switch once toallow the [ADD MODE] indicator lamp to belit.

2 Addition of indicated load valueLift up a cargo slowly off the ground andallow it to be at a standstill then depress the[M+] ([ZERO RESET]) switch once.After the memorized load value is displayedfor 1 second, it returns to show the currentloaded value.Afterward, every time the [M+] ([ZERORESET]) switch is depressed, the value thatthe current loaded value is added to the mem-orized value is displayed for 1 second then itreturns to indicate the current loaded value.

3 Indication of added valueThe added total amount is displayed bydepression of the [MR] ([HOOK WIRE])switch.Current load is to be displayed after 3 sec-onds from the time when the switch has beenreleased.

4 Resetting added valueDepression of the [AC] ([ADD MODE])switch allows the [ADD MODE] lamp to gooff and the added total amount is to be reset.

3. How to use addition functionThe device equips with the function that adds indicated weight of lifted cargo to show the totalweight loaded.It can be used when total weight of cargos has to be known when more than two cargos havebeen loaded on the vehicle.

RemarksUse the total weight of cargos gained by the addition function just as a reference value.


9-12


4. How to refer to error indication

Error No. Error

Load detector is wrong(Overwinding stop, ML stop).

Turn OFF power then turn it ON again.If failed to restore, ask a UNIC service shopfor repair.

Load detector is wrong(ML stop).

Load meter is wrong(Overwinding stop, ML stop).

Communication with overwindingdetector was inter rupted (Overwindingstop, ML stop).

Turn OFF power then turn it ON again.If failed to restore, ask a UNIC service shopfor repair.

Measures to be taken

Warning horn switch

yWarning hornBefore lifting up the cargo, depress the warn-ing horn switch on the crawler panel to givewarning sound to those who have enteredwithin slewing range during crane operation,or to workers in charge of slinging work nearthe cargo or in a course where the cargo maypass along.Depress the switch button to give warningsound.

Warning horn switch

9-13

Automatic stop for leaving minimum wire rope (with wire rope retaining roller)

iAutomatic stop forleaving minimumwire rope (with wirerope retaining roller)(Option)

This is a devise to restrict slackening of wirerope on the drum.The device prevents the rope on the drumfrom slackening when winding up and downthe hook or making it an abrupt stop andwhen the hook is lowered to the ground.In addition, it allows to stop unwinding auto-matically when remaining wire ropes on thedrum come close to 3 turns so that the ropecan not be unwound further.


Hook safety latch

uHook safety latchThe mechanism is to prevent slinging wirerope from being disengaged out of the hook.

9-14


Beep

oSpecifications on turnover prevention device

Observe the caution to secure safety.Failure to observe the cautions may invite trouble or serious accident.Be sure to carry out the inspection in particular before starting opera-tion.

1 Carry out careful inspection before oper-ation, and daily and periodical inspectionto confirm that the turnover preventiondevice functions properly.

2 The turnover prevention device is a safe-ty device that allows to slow down oper-ating speed gradually while making an inter-mittent warning sound when the ground reac-tion against the outrigger located on oppositeside of the boom decreases to the specifiedlevel due to increase of crane moment.If the ground reaction against the outriggerdecreases further, the warning changes tocontinuous sound and the crane makes anautomatic stop.Crane functions to be stopped are : winding uphook, extending boom, and lowering boom.Check the turnover prevention device forproper operation before starting the craneoperation.

3 If the crane is operated via radio-con-troller, operate it within the range wherethe alarm sound can be heard.

4 Over-loaded operation is strictly prohib-ited.The turnover prevention device is not adevice for preventing overload. It is the principle that you should persistentlyobserve the operation within rated load.Do not put too much confidence on thedevice.Leaning of the crane due to swing of a liftedcargo or parking on unleveled ground mayallow the crane to be overturned.

WARNING

9-15


5 If an alarm sounds intermittently due todecrease of ground reaction against out-riggers, operating the crane to safer side.If the ground reaction against the outriggerdecreases further, the crane makes an auto-matic stop.In this case, faster operating speed can makethe crane to be overturned to which must payattention.

6 Observe that the crane shall not be oper-ated within the prohibited range inextending outriggers.The turnover prevention device will not func-tion safely when the crane is operated withinthe prohibited range.

7 Keep the ON-OFF switch for alarmbuzzer turning ON unless there is anyspecial reason.

8 As a rule, set up the crane on a flat andsolid ground to operate it with the out-riggers extended to their extremes, with thetruck kept level, and with the rubber crawlerlifted up by approx. 50mm above the ground.

9-16


1. Construction of turnover prevention device

Control box

Load sensor Alarm buzzer

Reset switch

2. Inspection before starting crane operation

Be sure to carry out inspection of turnover prevention device beforestarting the crane operation to check that the device functions normally.If found something wrong with the device, ask a UNIC authorized ser-vice shop for repair as soon as possible.

Turn ON the turnover prevention alarm buzzer switch while carryingout preparation of the crane operation to check that continuous alarmsound is heard until the outriggers are set up on the ground.If the alarm fails to sound, ask a UNIC authorized service shop forrepair immediately as something is wrong with the turnover preventiondevice.

The crane might be overturned even if the system has been actuatedwhen a lifted cargo is swinging and/or operation speed is too fastbecause the load is increased by inertia.Do not rely too much on the system but try always carrying out safeoperation of the crane carefully by observing that the load is kept withinthe rated load.

WARNING

9-17

Check the following before starting crane operation,.If found something wrong with the turnover prevention device, contact with a UNIC authorizedservice shop as soon as possible because it will not function as a safety device.

bee ee

ZERO RESET switch

1 Check that the continuous alarm sound(bee ee) of the turnover preventiondevice is issued before setting up outriggers.(Keep always the ON-OFF switch foralarm buzzer turning ON.)

2 By following procedures for setting upthe outriggers on the ground, rotate theoutriggers to secure them with the lock pinsat this time, allow the outriggers to be fullyretracted without setting them up on theground.

3 Through the hole on the side of opera-tion panel, depress the ZERO RESETswitch in the control box of turnover preven-tion device mounted inside for 1 second.

When the zero-point adjustment hassuccessfully been completed, all the lampsfor self-diagnosis light for 2 seconds and theoverturn alarm buzzer will stop sounding for2 seconds.

After that, RUN lamp (green) lights andlamps of ch. A through ch. D blink.

In addition, the overturn alarm buzzer makesa continuous sound.

4 Confirm that the alarm buzzer stopssounding when the outriggers have beenset up on a solid and level ground.(Set them up so that the crane body can bepositioned at 50mm off the ground.)Check at this time that lamps of RUN andch. A through ch. D among the self-diag-nosis lamps in the control box of turnoverprevention device lights or blinks.


9-18

5 After the outriggers have been set upproperly and the buzzer is making noalarm sound, check that the alarm buzzerstarts to make an intermittent sound (beep,beep) when the two adjacent outriggers areretracted gradually.

6 Check also that the alarm buzzer makesa continuous sound (bee ee) whenthe two adjacent outriggers are retracted fur-ther.

7 In the condition that the alarm buzzer ismaking a continuous sound (bee ee),following crane operation will becomeimpossible:

Extension of boom Lowering boom Winding-up hook Slewing boom

TS-100RUNERRch. Dch. Cch. Bch. A

ZERORESET

Control box of turnover prevention device

ZERO RESET switch

Lamps indicating self-diagnosis

50mm


9-19

Do not carry out zero point adjustment for turnover preventiondevice after the outriggers have been set up.Depression of ZERO RESET switch in this condition, the zero pointadjustment does not complete successfully which in turn the turnoverprevention device will be in failure so that crane operation of winding-up hook, extension of boom, lowering boom, and slewing boom cannotbe possible.

In this case, store the crane by following the step 1illustrated on page 9-19, "How to release when turnover prevention device" is found to be outof order, then store the outriggers to depress the ZERO RESET switchagain.

Although in case where the zero point adjustment has been com-pleted, the RUN lamp fails to be lit, or if lamps of ch. A through ch.D are blinking even after the outriggers have been set up right, ask aUNIC authorized service shop immediately for inspection and repair asthe reaction force detector may be out of order.

After the zero point adjustment has been completed right, if theERR lamp blinks for only 5 seconds and the alarm buzzer makes anintermittent sound (Beep, Beep) at the same time when the RUN lamplights, it indicates that the reaction force detector should be replaced.Although the reaction force detector can be used for some time, ask aUNIC authorized service shop as early as possible for repair.

In case where the ERR lamp in the control box of turnover preven-tion device is blinking, the alarm buzzer makes a brief intermittentsound (Pi, Pi, Pi ).Since this indicates that the turnover prevention device is in trouble,ask a UNIC authorized service shop immediately for inspection andrepair.

CAUTION


9-20

1 Advance alarm for overturnWhen the average of setting-up reaction forceof the ground against two (2) adjacent outrig-gers on the opposite side of the boomdecreases, the alarm buzzer makes an inter-mittent alarm sound (beep, beep) of advancealarm to give a warning.If the alarm is heard, slow down operationspeed of the crane to operate it for safer sideimmediately.

2 Threshold alarm for overturnWhen the average of setting-up reaction forceof the ground against two (2) adjacent outrig-gers on the opposite side of the boomdecreases further and it becomes dangerousconditions, the alarm buzzer makes an con-tinuous threshold alarm sound (bee ee)to give a warning and following functions ofthe crane are to be stopped automatically:

Hoisting hook Extending boom Lowering boom Slewing boom

The crane may be overturned due toswing of a lifted cargo such as by anabrupt stop when the crane is operated inhigh speed to which special attention mustbe paid.

If sound of alarm buzzer should beavoided such as in working at night orworking in residential areas, turn OFF thealarm buzzer switch to stop the buzzer.Turn it ON when in normal crane opera-tion.

Carry out normal crane operation after completion of inspection before starting crane operation.The turn over prevention device is a safety device that prevents the crane from being overturnedby stopping crane functions automatically while issuing alarm sound when the average setting-up reaction force of the ground against two (2) adjacent outriggers on the opposite side of theboom reaches the specified set value.The setting-up reaction force of the ground against each outrigger is always detected by load cell.

ON

OFF

Alarm buzzerON/OFF switch

beep

3. Function of turnover prevention device


9-21

Lamps indicating self-diagnosis are mount-ed in the control box of turnover preventiondevice to show such as operation, detailedfaults of the device.

RUN lamp (green)It lights when the turnover prevention deviceis functioning right.

ERR lamp (red)It lights when the reaction force detector is introuble.

ch. D lamp (orange)It lights or blinks according to outriggers onthe rear-right side of the crane body.

ch. C lamp (orange)It lights or blinks according to outriggers onthe front-right side of the crane body.

ch. B lamp (orange)It lights or blinks according to outriggers onthe front-left side of the crane body.

ch. A lamp (orange)It lights or blinks according to outriggers onthe rear-left side of the crane body.

TS-100RUNERRch. Dch. Cch. Bch. A

ZERORESET

Control box of turnover prevention device

ZERO RESET switch

Lamps indicating self-diagnosis

4. Self-diagnosis functions

The lamps of ch. A trough ch. D indicate condition of each outrigger separatelyhow it touches the ground and the alarm of the turnover prevention device is to be deter-mined by combination of two (2) adjacent outriggers with smaller reaction force againstcombination of outriggers than other combination.

All the self-diagnosis lamps light up for approximately 2 seconds after the crane travel-ing lever interlock has been switched to the crane.Self-diagnosis for the turnover prevention device is being carried out while the lamps forself-diagnosis are being lit.

In case of URW295CP2A type, remove the set pins out of outriggers to rotate them to theirspecified positions, the self-diagnosis lamps light up for approximately 2 seconds when 4pieces of set pins have fully been inserted.


9-22

Indication of lamps for self-diagnosis when turnover prevention devicefunctions normally

Indication of lamps for self-diagnosis when turnover prevention deviceis in trouble

When reaction force detector is in trouble

When control box of turnover prevention device is in troubleAll the lamps for self-diagnosis do not light.

Lamps Indication State

RUN LightingTurnover prevention device is functioning right.

ERR Lighting off

Lighting or slowblinking

ch.Dch.Cch.Bch.A

Quick blinkingIt is in condition of overturn threshold as ground reaction forceagainst outriggers has been decreased, or outriggers have beenstored.

Crane can be operated safely due to sufficient ground reactionforce against outriggers.

2 blinkins at a time

It is in condition of overturn prediction as ground reaction forceagainst outriggers has been decreased.

Lamps Indication State

RUN Lighting offReaction force detector is in trouble.

ERR Quick blinking

ch.Dch.Cch.Bch.A

Quick blinking Reaction force detector is in trouble.

Lighting Reaction force detector is working right.

In case where the crane cannot be operated because a trouble has been occurred tothe turnover prevention device while the crane is being operated, turn OFF the enginekey once then start the engine again.

If the trouble fails to be solved, store the crane by following the steps illustrated onpage 9-19, "How to release when turnover prevention device" is found to be out oforder, then ask a UNIC authorized service shop for repair.

CAUTION


9-23

If the crane cannot be operated due to trouble in the turnover prevention device, store the cranein accordance with steps as follows:

5. How to release when turnover prevention device is found to be out of order

Step 1

The release switch for turn over preventiondevice is located inside of the cover near therecoil of engine.Operate the crane while the release switch isbeing pushed up.If the crane is operated with the releaseswitch pushed up, the device loses thefunctions as the safety device.Operate the crane by paying special attentionthat the crane will not be overturned.If any of outriggers is raised before the boomand the hook have been stored, the turn overprevention device is to be actuated so that thecrane turns to be inoperable.Store the crane while the release switch isbeing pushed up.

Reset

Release switch


9-24

Since this is a temporary measures in an emergency, be sure torepair it at a UNIC service shop after the crane has been stored.

CAUTION

Step 2

If the crane cannot be operated (it will notfunction) by taking measures in step 1 above,operate the crane by following proceduresbelow.

Unfasten the hexagon nut on the side ofunload valve attached to underside of thecontrol valves to tighten up the set bolt beinglocked until it comes to a stop.Since this allows the crane to be operated,store the crane by controlling levers.

Set bolt Hexagon nut

(Underside of control valve)


9-25


6. Caution plates in detail

Always keep the stickers clean so that they can be read easily. If any of the stickers has come off, stick it again or replace it with

new sticker.When ordering stickers, specify the part number shown at the bot-

tom-right of the sticker concerned.

CAUTION

9-26


!0U-AOL system (Anti overloading system)(OPTION)

The system is not for preventing the crane from overturning.Operate the crane by paying full attention to its stability.

Even if the system actuates, load applied to the crane may increasedue to inertia so that the crane might be damaged when a lifted cargo isswinging or working speed is too fast.Do not put too much dependence on the system but try to operate itcarefully at all times for securing safety.

Do not carry out operation which increases lifting load, such as pilingup a cargo on the lifted pallet or pouring a liquid into the lifted containerduring lifting operation.This may cause the crane to be damaged or overturned.

WARNING

1. Function of U-AOL system

2. Construction of U-AOL system

U-AOL system is a safety device that detects load applied to the crane to issue an alarmautomatically when the load reaches the rated load.

* Rated loadRated load is maximum load based on hoisting capacity of the crane as against raised angleand/or extended length of the boom and this includes weight of hooking implement.

Capacity limit alarm buzzerBoom angle detector

Over-load alarmcontrol boxLoad detector

Boom length detector

3-color indicator lamp

The U-AOL system installation time, simultaneous mounting of the turnover prevention deviceis not possible.

9-27


If the capacity limit alarm is actuated, stop the crane operation imme-diately to move the lifted cargo toward safer side.

WARNING

3. Operation of U-AOL system1. Over-load alarmCapacity limit alarm

When the load applied to the crane comesclose to the rated load (capacity limit), thealarm buzzer sounds (Ping-pong, Ping-pong) to issue an alarm.

When the load applied to the crane reachesthe capacity limit, crane functions listedbelow stop automatically: Extending boom Lowering boom Winding-up hook Swinging CW.&C.C.W.

Ping-pong,

Ping-pong

Safety device switch

OFF

4. Measures to be taken when U-AOLsystem is in trouble.

In case where the crane becomes impossibleto be operated due to system trouble, cancelthe U-AOL system to store the crane.

Step 1Throwing the safety device switch to OFFposition allows the safety device is to becancelled (for 5 seconds maximum).Carry out winding-up hook, lowering boom,and slewing operation with each controllever.

Step 2If the crane cannot be operated by the step 1above, operate the crane by following w 2. How to reset when automatic stopfor overwinding is found to be out of ordersection.

9-28

Boom cannot be extended even when the safety device is beingcancelled.In case where the crane is operated with the safety device has beencancelled once, it will take 30 seconds until it can be cancelled nexttime.

CAUTION

5. Function of load indication

In normal operation, the load is to beindicated in the weight of 0.1t on the digitalindicator in the over-load alarm control box.

Designation of each part ofCapacity limit alarm

Indicator:It indicates weight of lifted cargo (t).

Lamp indicating outriggers not max ext:It indicates in green when outriggers arenot in maximum extension.

Check switch:

It is to confirm operation of each indicationand alarm.

Lamp indicating

Outriggers not max EXT

Indicator

Check switch


9-29

Error indication of overload alarm device

When an error is detected, corresponding error code appears on the control box.

In case where anything unusual is found while inspection before starting work is being carried outor the crane is being operated, ask a UNIC authorized service shop for inspection immediately.

6.Checking U-AOL systembefore starting crane operation

Before starting the crane operation, checksfollows:

RemarksThe power to U-AOL system is suppliedthrough ON/OFF control of crane-crawl lever.

Checking over-load alarm system

Check that [ ] t is indicated on thedigital indicator when no-load is applied.

Depress the checking switch to confirm that [ ] appears on the digital indicator.

Confirm that crane functions listed belowcannot be operated while the checking switchis being depressed.

Extending boom Lowering boom

Winding-up hook Swinging C.W.&C.C.W.

Depress the switch for setting number ofslinging wire rope to confirm that [H4]appears on the digital indicator.

Indicator returns to wait indication in 3seconds after the switch has been released.

Digital indicator

Checking switch Switch for setting

number of slinging

wire rope

Error code Trouble

Trouble may be in load indicator.

Trouble may be in overload alarm control box.

Trouble may be in connection between load detector

Trouble may be in boom length detector.

Trouble may be in boom angle detector.


10-1

10. HOW TO OPERATE CARRIER

qDesignation of each control lever and its location

Accelerator lever

Stand lever Crawling lever (Left) Crawling lever (Right)

Starter switch

Horn switchChoke knob

Lever stand Lock lever

10-2

HOW TO OPERATE CARRIER

1 Shift the crawling lever stand to Crawlposition.2 Make sure that both crawling levers (leftand right) are at their neutral positions3 Confirm that the machine is at crawlingposture. Boom is lowered to its extreme. Outriggers are stored. Hook is stored.

TRAVEL LEVER STAND

LOCK LEVER

STAND LEVER

TRAVEL LEVER


wPreparation before operation

Ventilate well when starting the engine in a small limited area orindoors.

Do not start the engine from the outside of the operators seat.

Confirm the safety around the crane working site before starting theengine.

Heavy-duty operation of the crane during an initial period after thestart of operation may deteriorate its performance in a shorter time.Take approximately 100 hours after the start of operation as a breaking-in period during which abrupt start and acceleration, and continuousoperation under heavy load must be avoided.

WARNING

CAUTION

Open

4 Open the fuel cock.

5 Raise engine speed to that somewhathigher than idling.

10-3


eHow to operate

Do not start the engine by using a auxiliary ignition fluid as it may bein danger of explosion.

Be sure to repair whenever found anything unusual.

Be sure to stop the engine before re-fueling.

1. Starting engineStarting in normal condition

1 Insert the key into the starter switch andturn it to ON position.2 Pull the accelerator lever a bit, and pullthe choke knob if the engine is cold.Return the choke knob fully to its originalposition after the engine has started.

3 Turn the switch key to START positionto start the engine.4 Release the key after the engine hasstarted running.The key returns to ON position by itself.

Continuous running of starter motor allows the battery to bedischarged and the starter motor itself to be damaged.Do not activate the motor for more than 5 seconds without a break.

If the engine failed to be started, wait 1 or 2 minutes to try it again.

WARNING

CAUTION

OFF ON

START

10-4

Starting in a cold weather

When it is hard to start the engine in loweroutside air temperature, take steps as follows:

1 Pull the choke knob and pull the acceler-ator lever a bit to get the engine speedsomewhat higher than idling.

2 Turn the switch key to START positionto start the engine.3 Release the key immediately after theengine has started running.The key returns to ON position by itself.

4 Return the choke knob to its originalposition after the engine speed hasincreased

5 Return the accelerator lever to idlingposition after the engine makes a steadyrunning.

Choke knob

Pull the choke knob

OFF ON

START


10-5


2. Steps to be taken after engine hasstarted

Do not make the engine to accelerate abruptly before it has beenwarmed up.

After the engine has started, do not rush intocrawling the crane but take the steps as fol-lows:

1 After the engine has started, check forunusual noise, vibration, heat, bad odor,and for fuel leakage.If found anything wrong, stop the engine tofind the cause.

2 The warming-up allows not only thelubricant to circulate well enoughthrough each operating section but alsoallows the engine to be warmed up graduallyto raise temperature of oil which in turn cre-ates the better operating conditions.

CAUTION

Warm upthe enginefor about 5minutes

10-6

rHow to Crawl

Start the crane crawling after the safety around the crawler has beenconfirmed and make a sign when starting the crane crawling.Carry out crawling operation by standing in front of the crawlinglever.Keep anyone away from the crane.Do not craw the crane with someone or an object mounted on thecrane.Arrange those who guide at a place where it may be unsafe and youhave a blind spot.Crawl the crane as slowly as possible while making a turn.If crawling backward, watch where it is to be crawl and restraincrawling speed.Run the crane slowly when making a sharp turn and crawling on arough road.Before leaving the crane, shift the crawling lever stand to storingposition and stop the engine.Avoid running over obstacles.If it is unavoidable, crawl at low speed and keep the crane to lean lessthan 10Kto the left.When parking the crane on the street is unavoidable, set up safetydevices such as a sign, a barricade, and a blinking light so that passingof other vehicles and pedestrians may not be disturbed.Put a pallet against the rubber crawler when parking the crane for along period of time.Do not park the crane over a place where withered grass or straw,which is flammable. This may cause a fire by heat of exhaust pipe or exhaust fume.When crawling the crane on a water filled area, observe to crawl itwithin allowable depth of water.Allowable depth: Up to the center of crawling motor or of sprocket.In case where the machine is forced to turn on the spot (spin turn),be sure to stop the movement of the machine first, allow the engine torun at a low speed to make it turn slowly and gently.An abrupt turning not only damages the rubber crawler badly but alsocauses the machine to bounce from which may invite a very dangeroussituation.

WARNING


10-7


1. Starting, crawling, stopping the crane

1 Make sure that the crawling lever standis shifted to Crawl position.2 Shift the crawling levers (left and right)simultaneously to the other side to makethe crane to crawl forward and shift thelevers to this side makes it to move back-ward..Shifting the levers to neutral together allowsthe brake to be applied automatically.

Crawling straight

Forward Forward

Neutral Neutral

Backward Backward

Crawling straight

2. Making a turn

Making a turn while movingWhen traveling forward: It turns to the left(right) by shifting the right (left) travelinglever much further than the left (right) travel-ing lever.When traveling backward: It turns to the left(right) by shifting the right (left) travelinglever much further than the left (right) travel-ing lever.

Pivot

Do not operate the right (left) traveling lever with the left (right) traveling leverput at its neutral position.Otherwise, the rubber crawler damages and the machine bounces from whichmay invite a very dangerous situation.In case where the machine is forced to operate this way, be sure to stop themovement of the machine first, allow the engine to run at a low speed to operateit slowly and gently.

WARNING

When riding over an obstacle orgoing up and down a hill, do sostraight-on. If you operate the craneat an angle, it may becomeunbalanced and tip over.

WARNING

10-8

HOW TO OPERATE CARRIE

unic urw295cp2a operation manual

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