work shop manual urv work shop manual.pdf · of boom3. insert pin after the pin has been inserted,...
TRANSCRIPT
UNIC HYDRAULIC CRANE
MODEL
WMURVseries200107APRINTED IN JAPAN
HEAD OFFICE : Center Bldg., 3-12, Higashishinagawa 2-chome,Shinagawa-ku, Tokyo 140-0002, JAPAN
WORK SHOPMANUAL
INTRODUCTION
This technical instruction manual describes the construction of the UNIC URV SERIES crane and mainte-nance procedures for those who engage in its maintenance.Please carefully read the manual to acquire the proper maintenance skills and provide efficient, speedy, cor-rect service that are essential to customer trust. In this way, UNIC truck crane will be able to deliver theirsuperb performance and be kept in satisfactory operating condition.It is recommended that separate parts list be referred to together with this manual.
Technical Section, Service DepartmentFURUKAWA UNIC CORPORATION
CONTENTS
1. GENERAL VIEW......................................................................................................................... 1
2. BOOM2. 1. 2-Section Boom .......................................................................................................................... 2(1) Construction of boom and operation......................................................................................... 2(2) Boom 1, 2 front side section in detail ........................................................................................ 3
2. 2. 3-Section Boom .......................................................................................................................... 4(1) Construction, operation, and disassembling procedures ....................................................... 4(2) Boom 2, 3 front side section in detail ........................................................................................ 5(3) Boom disassembly procedures ................................................................................................. 6
2. 3. 4-Section Boom .......................................................................................................................... 8(1) Construction of boom and operation......................................................................................... 8(2) How boom-top sheave is mounted ............................................................................................ 9(3) Installation procedures for slide plate and guide..................................................................... 10(4) Boom 3, 4 front side section in detail ........................................................................................ 11(5) Boom 2, 3 rear side section in detail ......................................................................................... 12(6) Boom 3, 4 rear side section in detail ......................................................................................... 13(7) How to disassemble 4-section boom of URV-series ................................................................ 14
2. 4. 5-Section Boom .......................................................................................................................... 18(1) Simultaneous telescoping boom 4 and boom 5 ....................................................................... 18(2) Boom 4, 5 front side section in detail ........................................................................................ 19(3) Boom 3, 4 rear side section in detail ......................................................................................... 20
3. TELESCOPING CYLINDER3. 1 2-section boom (Single cylinder) operation.............................................................................. 21(1) When telescoping cylinder extends........................................................................................... 21(2) When telescoping cylinder retracts ........................................................................................... 22
3. 2 3-section boom (Dual cylinder) operation................................................................................. 23(1) When telescoping cylinder extends........................................................................................... 23(2) When telescoping cylinder retracts ........................................................................................... 24(3) When telescoping cylinder 2 extends........................................................................................ 25(4) When telescoping cylinder 2 retracts ........................................................................................ 26
3. 3 4-section boom (Dual cylinder) operation................................................................................. 27(1) When telescoping cylinder 1 extends........................................................................................ 27(2) When telescoping cylinder 1 retracts ........................................................................................ 28(3) When telescoping cylinder 2 extends........................................................................................ 29(4) When telescoping cylinder 2 retracts ........................................................................................ 30
3. 4 5-section boom (Triple cylinder) operation............................................................................... 31(1) When telescoping cylinder 1 extends........................................................................................ 31(2) When telescoping cylinder 1 retracts ........................................................................................ 32(3) When telescoping cylinder 2 extends........................................................................................ 33(4) When telescoping cylinder 2 retracts ........................................................................................ 34(5) When telescoping cylinder 3 extends........................................................................................ 35(6) When telescoping cylinder 3 retracts ........................................................................................ 36
3. 5 3-section boom (Dual telescoping cylinder) disassembly procedures.................................. 37(1) Disassembly procedures for telescoping cylinder 1................................................................ 38(2) Disassembly procedures for telescoping cylinder 2................................................................ 40(3) Inspection..................................................................................................................................... 41(4) Adjusting procedures for selector valve with adjusting bolt .................................................. 41
3. 6 Function and working of cushion seal ...................................................................................... 42(1) Flow of pressure oil when retracting ......................................................................................... 42(2) Flow of pressure oil when extending......................................................................................... 43
3. 7 Cause of troubles and measures to be taken ........................................................................... 44
4. DERRICK CYLINDER4. 1 Flow of oil when raising.............................................................................................................. 474. 2 Flow of oil when lowering........................................................................................................... 48
5. OUTRIGGER5. 1 Outrigger cylinder (URV230, V260, V290, V300, V340)............................................................. 49(1) Flow of oil when extending ......................................................................................................... 49(2) Flow of oil when retracting.......................................................................................................... 50
5. 2 Construction of outrigger cylinder (URV370) ........................................................................... 515. 3 Construction of outrigger cylinder (URV500) ........................................................................... 525. 4 Construction of inner box........................................................................................................... 53
6. HOIST WINCH6. 1 Construction of hoist winch and brake shoe adjusting procedures ...................................... 546. 2 Caution to be taken when reassembling hoist winch .............................................................. 556. 3 Cause of troubles and measures to be taken ........................................................................... 56
7. HOOK ............................................................................................................................................. 57
8. SLEWING8. 1 Slewing reduction gear ............................................................................................................... 58(1) Construction of slewing reduction gear .................................................................................... 58(2) Caution to be taken when reassembling slewing reduction gear ........................................... 59(3) Slewing reduction gear disassembling procedures ................................................................. 608. 2 Turn table mounting procedures ............................................................................................... 63(1) Turn table mounting procedures................................................................................................ 63(2) Position of soft zone, tightening sequence of bolts and tightening torque........................... 64
9. COLUMN9. 1 Tightening torque for bolts fastening column and tightening order...................................... 65
10. SWIVEL JOINT10. 1 Construction of swivel joint and position of hoses ............................................................... 6610. 2 Swivel joint assembling procedures ....................................................................................... 68
11. SLIP RING11. 1 Construction of slip ring and its fitting position .................................................................... 69
12. CONTROL................................................................................................................................... 70
13. HYDRAULIC CIRCUIT DIAGRAM13. 1 Hydraulic Circuit Diagram (URV230, URV260, URV290, URV340, URV370) ......................... 7113. 2 Hydraulic Circuit Diagram (URV500) ....................................................................................... 72
14. CONYROL VALVE14. 1 General view and specifications .............................................................................................. 7314. 2 How oil flows in control valve .................................................................................................. 7414. 3 Relief valve................................................................................................................................. 75
15. OVERWINDING ALARM15. 1 Function of overwinding alarm and procedures for operation ............................................. 7715. 2 General view .............................................................................................................................. 7815. 3 Illustrated wiring diagram, overwinding alarm ....................................................................... 8015. 4 Electric circuit diagram............................................................................................................. 81
16. FILTERS (Suction Filter and Return Filter)................................................................... 82
17. CYLINDERS, HOW TO PUNCH .......................................................................................... 83
18. TELESCOPING/DERRICK CYLINDER ASS’Y, MEASURES TOPREVENT FROM BEING LOOSENED.............. 84
19. INSPECTION PROCEDURES WHEN CYLINDER SINKS19. 1 Inspection of telescoping cylinder (3-section or 4-section boom) ....................................... 8619. 2 Inspection of derrick cylinder .................................................................................................. 8719. 3 Inspection of outrigger cylinder............................................................................................... 88
20. MAINTENANCE AND INSPECTION20. 1 Inspection................................................................................................................................... 90(1) Inspection before operation........................................................................................................ 90(2) Inspection of the slewing bearing mounting bolts ................................................................... 9120. 2 Replacement .............................................................................................................................. 91(1) Replacement of return filter ........................................................................................................ 91(2) Replacement of wire rope (for winding up) ............................................................................... 92(3) Replacement of expendable parts.............................................................................................. 96
21. LUBRICATION21. 1 Precaution on lubrication ......................................................................................................... 97(1) List of recommended lubricants................................................................................................. 98(2) Lubrication chart.......................................................................................................................... 9921. 2 Lubrication ................................................................................................................................. 100(1) Replacement of hydraulic oil ...................................................................................................... 100(2) Replacement of gear oil............................................................................................................... 101(3) Lubrication to slewing bearings ................................................................................................. 102(3) Lubrication to wire rope for boom extension............................................................................ 102
- 1 -
1. GENERAL VIEW
HOOK
HOIST WINCH
TERESCOPING CYLINDER
DRUM
COLUMN
LOAD GAUGE
SLIP RING
SLEWING REDUCTION GEAR
SLEWING MOTOR
OUTRIGGER CYLINDER
BASETURNTABLE
PTO(POWER TAKE OUT)
DERRICK CYLINDER
PUMP
Hook on standardspecification
- 3 -
(2) Boom 1, 2 front side section in detail
Boom1
Boom2
Tele-cylinder Rod
Boom2Conecting Pin
Tele Rod
- 5 -
(2) Boom 2, 3 front side section in detail
Tele1
Tele2
Tele2 Rod Boom3Conecting Pin
Boom3
Boom2
When assembling,
apply grease.
When assembling,
apply grease.
- 6 -
(3) Boom Disassembly Procedures
(1) 3-Section Boom
Pull out the booms (2) and (3) from the boom (1).
PIN (1)
JOINT BOOM (2)
BOOM (1) BOLT FOR GUIDE
BOLT FOR SLIDE PLATE
BOOM (3)
1. Remove the joint (for piping) of the telescoping cylinder.2. Remove the slide plates (side and lower plates), and the guide.3. Remove the pin (1) from the boom (1), and pull the booms (2) and (3) out of the boom (1).
Pull out the boom (3) from the boom (2).
PIN (2)
BOOM (2) BOLT FOR GUIDE
BOLT FOR SLIDE PLATEBOOM (3)
1. Remove the slide plates (side and lower plates) and the guide.2. Remove the pin (2) from the boom (2), and pull out the boom (3).
- 7 -
Pull out the telescoping cylinder (1) and (2) from the boom(3).
PIN (1)
TELESCOPING CYLINDER (1)
TELESCOPING CYLINDER (2) PIN (3)
BOOM (3)
1. Pull out the telescoping cylinder (2) and the pin (3) from the boom (3).2. From the boom (3), pull out the telescoping cylinder ass’y (1) and the telescoping cylinder ass’y (2) in the
direction towards the rear.
TELESCOPING CYLINDER (1) ASS’Y
TELESCOPING CYLINDER (2) ASS’Y
SELECTOR VALVE
Reassembling shall be made in reverse order of the disassembly procedures.
Notes : 1. When assembling the pin, apply grease to the inside of its boss for rustproofpurpose.
2. Apply grease (Chassis Grease No.1) to the inner surface of the bushing.3. Apply “THREE BOND #1102” to the slide plate to prevent it from falling. Apply the
disulfide molybdenum grease to the slide surface.4. Do not apply grease to the slide sheave pin.
- 10 -
(3) Installation procedures for slide plate and guide
It has similar construction irrespective of number of boom section
Clearance 1mm
Clearance 2mm
When assembling,
apply"Lock tight #242".
Slide plate
Guide
- 11 -
(4) Boom 3, 4 front side section in detail
Boom4
Boom3
Pass the wire cord on the cord reel through the round bar at the top of tele2
- 12 -
(5) Boom 2, 3 rear side section in detail
Tele2
Tele1
Boom3 RetractingWIre rope
Tele2 tube
Boom3Connecting Pin
Apply
molybdenumgrease here.
Apply "Three Bond#1102"
to the slide plate to prevent it from falling.
Boom2
- 13 -
(6) Boom 3, 4 rear side section in detail
Retracting wire rope
Extending wire rope
Boom4
Boom3
- 14 -
(7) How to disassemble 4-section boom of URV-series
Extend the boom by approx. 500mm (release pressure with the engine stopped).
Remove the wire and the cord reel.
Remove the slide base mounting for boom up/down and the bolts for the stopper.
Remove the slide plate on the boom side.
“Lock Tight #242” has been applied here.
Slide plate (Put some shims if a gap exists).
Remove the plate (Rotate the slide plate by 90°).
Remove piping to telescoping cylinder, extract the rod-end pin for telescoping cylinder, and extract booms 2, 3,and 4 out of boom1.
With the booms (2 4) assembled (as in step ), remove the slide base at the top of boom2, the stopper, thebolts, and the slide plate, and extract the pin at the base of boom2 to extract booms 3 and 4 out of boom2.
With the booms 3 and 4 assembled (as in step ), remove the bolts fitting the sheave for pulling-out wirelocated at the bottom of rear end of the boom.
Remove bolts to which “Lock Tight #242” has been applied.
With the booms 3 and 4 assembled (as in step ), measure and record the position of adjusting bolt forpulling-in wire located at the boom top then remove it.
★ Record measured distance here
Unfasten the catch for the sheave for pulling-out wire located at the rear end of the boom.
Raise the sheave with a screw-driver.
- 15 -
Pull out boom4 by approx. 150mm.
Approx. 150mm
Remove the pin mounting tele2 at the rear end of boom3.
Remove the pin
Extract the cylinder out of boom.(When hanging the cylinder, pull it out to the slinging implement, and the pulling-in wire should not to be slung.)
Pulling-in wire
Pulling-out wire
(8) When fitting the cylinder to the boom.
Adjusting bolt for pulling-out wire
Approx. 20mm
Double nut6mm (Bolt length to be jutted out)
Sheave for pulling-out wire
- 16 -
With the boom4 extended by approx. 150mm, pass a string or the like as illustrated so that the pulling-in wireequalizer sheave can be pulled in the boom.
Insert the cylinder while pulling the string when it is being fitted. ★ Allow both the pulling-out wire and the pulling-in wire to be free
(do not hitch them in a slinging implement) when suspending the cylinder.
★ Check the contact between the change over bolt and the spool before putting the cylinder in the boom.
Dealing with the wire on rear end of boom when the telescoping cylinder is inserted.
Pulling-in wire Pulling-out wire
Rear end of boom
After the telescoping cylinder has been inserted, insert the pin for fixing cylinders on both sides at the rear endof boom3.
Insert pin
After the pin has been inserted, push in the boom4 until both booms 3 and 4 hit their ends.Secure the sheave for pulling-out wire by tightening the bolts.
Apply screw lock agent #262.
Illustration shows that the sheave for pulling-out wire has been fitted in the boom4.
- 17 -
Insert the booms 3 and 4 into the boom4.
Insert the pin for fixing cylinder at the rear end of boom2.
After they have been inserted, fit the slide base at the top of boom2, the slide plate, and the bolts for stopper.★ Apply screw lock agent #262.
Slide base mounting bolt.★ Apply screw lock agent #262.
Insert the booms 2 through 4 into the boom1 and fit the slide base at the top of boom etc. in the same manner asin the step .Insert the rod-end pin for telescoping cylinder 1 at the base of boom1.
Although this reaches the state in which the booms can be tested for telescoping, operate the booms with therelease switch turned ON because the reel cord has not been fitted yet.After testing the booms for telescoping, check the pulling-out wire for tension at the opening on the side ofboom3 with the booms fully extended.If it is found too weak, retract the booms to their minimum to tighten the adjusting bolt at the boom top.
Tension adjusting bolt for pulling-out wire
Remove bolt stopper
★ Note that a piece of plain washer is inserted on each side under the bottom of slide base at the top of boom1. ★ While the booms are being retracted from the position fully extended, hunting might occur when the retraction switches from the booms 3 and 4 to the boom2. In this case, remove the plain washer on the side of stopper and add a piece of washer to each side under the bottom of slide base.
Pay attention to the items marked with ★, and this completes the procedures after fitting the cord reel and the hook.
Plain washer
Boom4
Boom3
While booms 3 and 4 have been retracting, this portion must be closely touched.★ Note that it will not be touched if tension of pulling-out wire is too tight.
Boom1
Boom2
- 19 -
(2) Boom 4, 5 front side section in detail
Retractingwire rope
Extendingwire rope
Adjusting boltfor extending wire rope
Boom5
Boom4
Guide
Pipe
Connect the cord which cameout of the pipe to the overwinding detector by passing it throughinside of the guide.
- 20 -
(3) Boom 3, 4 rear side section in detail
Tele1
Tele2
Tele3
Tere3 Tube
Boom4Connecting Pin
Retractingwire rope
to the slide plate surface.
Apply the disulfidemolybudenum grease
Apply "Three Bond #1102"to the slide plate
to prevent it from falling.
Boom3
Boom4
- 2 -
2. B
OO
M
2. 1
2-S
ecti
on
Bo
om
(1)
Co
nst
ruct
ion
of
bo
om
an
d o
per
atio
n
Ret
ract
ion
of te
le a
llow
s bo
om2
to r
etra
ct.
Rep
lace
the
slid
e pl
ate
with
a n
ew o
new
hen
it is
wor
n ou
t by
2mm
or
mor
e.
Op
erat
ion
Exi
ten
din
g
Ext
ensi
on o
f tel
e al
low
s bo
om2
to e
xten
d.
Ret
ract
ing
Cor
d re
el
Boo
m2
Boo
m1
Tele
Pin
1P
in2
to th
e sl
ide
shea
ve p
in.
Do
not a
pply
gre
ase
Insp
ecti
on
o
f P
late
-Slid
e
- 4 -
Rep
lace
the
slid
e pl
ate
with
a n
ew o
new
hen
it is
wor
n ou
t by
2mm
or
mor
e.
Boo
m3
Boo
m2
Boo
m1
Tele
1
Tele
2
Cor
d re
el
Ext
ensi
on o
f tel
e1 a
llow
s bo
om2
to e
xten
d.E
xten
d
Ret
ract
Dis
asse
mbl
ing
Pro
cedu
res
4.R
emov
e th
e pi
n1 fr
om th
e bo
om1,
and
extr
act t
he b
oom
s2,3
out
of t
he b
oom
1.
2.R
emov
e w
ire r
ope,
cor
d-re
el, a
nd th
e jo
int
(fo
r pi
ping
)of t
he te
lesc
opin
g cy
linde
r.
1. S
tore
the
boom
to r
elea
se p
ress
ure
rem
aine
d in
the
tele
scop
ing
cylin
der.
3.R
emov
e th
e sl
ide
plat
es(s
ide
and
low
er p
late
s) a
nd th
e gu
ide
from
boo
m1.
6.R
emov
e th
e pi
n2 fr
om th
e bo
om2,
and
pull
out t
he b
oom
3.7.
Pul
l out
the
pin3
from
the
boom
3.
To th
e sl
ide
shea
ve p
in
do n
ot a
pply
gre
ase.
Pin
1
Pin
2
Pin
3
Slid
e pl
ate
Insp
ectio
n of
Slid
e pl
ate
Gui
de
Ope
ratio
n
5.R
emov
e th
e sl
ide
plat
es(s
ide
and
low
er p
late
s) a
nd th
e gu
ide
from
boo
m2.
8.P
ull o
ut th
e te
le1,
2 as
sem
blie
s in
the
dire
ctio
n t
owar
ds th
e re
ar.
Ext
ensi
on o
f tel
e2 a
llow
s bo
om3
to e
xten
d.
Ret
raci
on o
f tel
e1 a
llow
s bo
om2
to r
etra
ct.
Ret
raci
on o
f tel
e2 a
llow
s bo
om3
to r
etra
ct.
�
2. 2
3-S
ecti
on
Bo
om
(1)
Co
nst
ruct
ion
, op
erat
ion
, an
d d
isas
sem
blin
g p
roce
du
res
- 8 -
Boo
m1
Boo
m2
Boo
m3
Tele
1
Tele
2
Rep
lace
the
slid
e pl
ate
with
a ne
w o
ne w
hen
it is
wor
n ou
t by
2mm
or m
ore.
Ope
ratio
n
Boo
m4
Ext
endi
ng w
ire r
ope
She
ave1
Cor
d re
el
Aju
stin
g bo
ltfo
r ex
tend
ing
wire
rop
e
Aju
stin
g bo
ltfo
r re
trac
ting
wire
rop
e
Ret
ract
ing
wire
rop
e
She
ave2
the
slid
e sh
eave
pin
.
Do
not a
pply
gre
ase
to
Insp
ectio
nof
Slid
e pl
ate
Ext
end Ext
ensi
on o
f tel
e1 a
llow
s bo
om2
to e
xten
d.E
xten
sion
of t
ele2
allo
ws
boom
3 to
ext
end.
Ext
ensi
on o
f tel
e2 a
llow
s sh
eave
1 to
shi
ft an
d bo
om4
is to
be
e
xten
ded
as it
is p
ulle
d by
ext
endi
ng w
ire.
Ret
ract
ing
wire
follo
ws
acco
rdin
gly.
Ret
ract Ret
ract
ion
of te
le1
allo
ws
boom
2 to
ret
ract
.R
etra
ctio
n of
tele
2 al
low
s bo
om3
to r
etra
ct.
Ret
ract
ion
of te
le2
allo
ws
shea
ve 2
to s
hift
and
boom
4 is
ret
ract
ed a
s
it is
pul
led
by r
etra
ctin
g w
ire.
Ext
endi
ng w
ire fo
llow
s ac
cord
ingl
y.
2. 3
4-S
ecti
on
Bo
om
(1)
Co
nst
ruct
ion
of
bo
om
an
d o
per
atio
n
Sim
ult
aneo
us
tele
sco
pin
g o
f b
oo
m 3
an
d b
oo
m4
- 9 -
She
ave
Wire
soc
ket
(2)
Ho
w b
oo
m-t
op
sh
eave
is m
ou
nte
d
- 18 -
Boo
m1
Boo
m2
Tere
1
Tere
2
Boo
m3
Boo
m4
Boo
m5
Tere
3 Exi
ten
din
g
Ret
ract
ing
Rep
lace
the
slid
e pl
ate
with
a ne
w o
ne w
hen
it is
wor
n ou
t by
2mm
or m
ore.
Op
erat
ion
Cor
d re
el
Exi
tend
ing
wire
rop
e
She
ave2
She
ave1
Ret
ract
ing
wire
rop
e
To th
e sl
ide
shea
ve p
indo
not
app
ly g
reas
e.
Insp
ecti
on
of
slid
e p
late
Ext
ensi
on o
f tel
e1 a
llow
s bo
om2
to e
xten
d.E
xten
sion
of t
ele2
allo
ws
boom
3 to
ext
end.
Ext
ensi
on o
f tel
e3 a
llow
s bo
om4
to e
xten
d.E
xten
sion
of t
ele3
allo
ws
shea
ve 1
to s
hift
and
boom
5 is
to b
e e
xten
ded
as it
is p
ulle
d by
ext
endi
ng w
ire.
Ret
ract
ing
wire
follo
ws
acco
rdin
gly.
Ret
ract
ion
of te
le1
allo
ws
boom
2 to
ret
ract
.R
etra
ctio
n of
tele
2 al
low
s bo
om3
to r
etra
ct.
Ret
ract
ion
of te
le3
allo
ws
boom
4 to
ret
ract
.R
etra
ctio
n of
tele
3 al
low
s sh
eave
2 to
shi
ft an
d bo
om5
is to
be
ret
ract
ed a
s it
is p
ulle
d by
ret
ract
ing
wire
.E
xten
ding
wire
follo
ws
acco
rdin
gly.
2. 4
5-S
ecti
on
Bo
om
(1)
Sim
ult
aneo
us
tele
sco
pin
g o
f b
oo
m4
and
bo
om
5
- 21 -
3. T
EL
ES
CO
PIN
G C
YL
IND
ER
3. 1
2-S
ecti
on
Bo
om
(S
ing
le C
ylin
der
) O
per
atio
n(1
) W
hen
Tel
esco
pin
g C
ylin
der
ext
end
s
Rod
Pip
e
Pis
ton
Pre
ssur
eO
ilTo
Tan
k
Che
ck v
alve
Cou
nter
-bal
ance
Val
ve
Pip
e-C
ord
Pre
ssur
e oi
l ope
ns th
e ch
eck
valv
e in
the
coun
ter-
bala
nce
valv
e to
en
ter
the
tube
to a
llow
tele
scop
ing
cylin
der
to e
xten
d.A
t the
sam
e tim
e, o
il in
the
cylin
der
on r
etra
ctio
n si
de fl
ows
thro
ugh
the
pipe
to r
etur
n to
the
tank
.
- 22 -
(2)
Wh
en T
eles
cop
ing
Cyl
ind
er r
etra
cts
Cou
nter
-bal
ance
Val
ve
Pip
e-C
ord
Rod
Pis
ton
Pip
e
Pre
ssur
eO
il
To T
ank
Che
ck v
alve
Pilo
tP
ress
ure
Spo
ol
Pre
ssur
e oi
l flo
ws
thro
ugh
the
pipe
to e
nter
the
cylin
der
on
retr
actio
n si
de a
nd o
il fo
r re
trac
ting
tele
scop
ing
cylin
der
is le
d to
the
coun
ter-
bala
nce
valv
e.A
lthou
gh th
e ch
eck
valv
e in
the
coun
ter-
bala
nce
valv
e is
clo
sed
at
the
time,
the
spoo
l is
open
ed b
y pi
lot p
ress
ure
on th
e re
trac
tion
side
al
low
ing
oil o
n th
e ex
tens
ion
side
to r
etur
n to
the
tank
.T
his
allo
ws
the
tele
scop
ing
cylin
der
to r
etra
ct.
- 23 -
3. 2
3-S
ecti
on
Bo
om
(D
ual
Cyl
ind
er)
Op
erat
ion
(1)
Wh
en T
eles
cop
ing
Cyl
ind
er1
exte
nd
s
Pre
ssur
eO
ilTo
Tan
k
App
ly"L
ockt
ight
#638
".R
od
Che
ck v
alve
Che
ck v
alve
1
Che
ck v
alve
2
Spo
ol
Bol
t
Pis
ton
Slid
e pi
peS
elec
tor
valv
e as
s’y
Tele
1
Tele
2C
ount
er-b
alan
ce v
alve
Pip
e fo
r co
rd r
eel Sel
ecto
rva
lve
ass’
y
Afte
r th
e se
t-sc
rew
is ti
ghte
ned
with
Loc
k Ti
ght #
2701
app
lied、
hit w
ith a
pun
ch a
t 2 p
lace
s on
the
circ
umfe
renc
ean
d le
ave
it as
it is
for
1 ho
ur.
How
oil
flow
s w
hen
tele
1 is
ext
ende
dP
ress
ure
oil o
pens
the
chec
k va
lve
in th
e co
unte
r-ba
lanc
e va
lve
to
ente
r th
e cy
linde
r ro
d of
tele
1 an
d flo
ws
thro
ugh
the
slid
e pi
pe to
rea
ch th
e ch
eck
valv
e 1
of s
elec
tor
valv
e as
s’y.
The
tele
2 ha
s be
en fu
lly r
etra
cted
at t
he ti
me
and
the
bolt
open
s th
e ch
eck
valv
e 1
of s
elec
tor
valv
e as
s’y
via
spoo
l whi
ch le
ads
the
pres
sure
oil
to
the
exte
nsio
n si
de.
Sim
ulta
neou
sly,
oil
in th
e ex
tens
ion
side
of t
ele1
flow
s th
roug
h th
e du
al c
ylin
der
in th
e ro
d to
ret
urn
to th
e ta
nk.
Thi
s al
low
s th
e te
le1
to e
xten
d.S
ince
the
chec
k va
lve
2 of
sel
ecto
r va
lve
ass’
y is
clo
sed
at th
e tim
e,
pres
sure
oil
will
not
flow
in th
e te
le2.
Als
o, th
e te
le2
will
not
be
actu
ated
bec
ause
no
oil i
s re
mai
ned
in th
e re
trac
tion
side
as
the
tele
2 ha
s be
en fu
lly r
etra
cted
.
- 24 -
(2)
Wh
en T
eles
cop
ing
1 C
ylin
der
1 re
trac
ts
App
ly"L
ockt
ight
#638
".
Pis
ton
Rod
Che
ck v
alve
Slid
e pi
pe
Che
ck v
alve
1
Pre
ssur
eO
il
To T
ank
Che
ck v
alve
2
Spo
ol
Bol
t
Pilo
tP
ress
ure
Spo
ol
Sel
ecto
rva
lve
ass’
y
Tele
1
Tele
2
Pip
e fo
r C
ord
reel
Cou
nter
-bal
ance
val
ve
Sel
ecto
rV
alve
Ass
’y
Afte
r th
e se
t-sc
rew
is ti
ghte
ned
with
Loc
k Ti
ght #
2701
app
lied、
hit w
ith a
pun
ch a
t 2 p
lace
s on
the
circ
umfe
renc
ean
d le
ave
it as
it is
for
1 ho
ur.
How
oil
flow
s w
hen
tele
1 is
ret
ract
edP
ress
ure
oil f
low
s th
roug
h th
e du
al c
ylin
der
of c
ylin
der
rod
of te
le1
to e
nter
the
retr
actio
n si
de o
f tel
e1.
Sin
ce th
e te
le2
has
been
fully
ret
ract
ed, t
he b
olt o
pens
the
chec
k va
lve
1 of
sel
ecto
r va
lve
ass’
y vi
a sp
ool t
o le
ad th
e oi
l in
the
exte
nsio
n si
de to
th
e co
unte
r-ba
lanc
e va
lve
by w
ay o
f slid
e va
lve.
Alth
ough
the
chec
k va
lve
in th
e co
unte
r-ba
lanc
e va
lve
is c
lose
d at
th
e tim
e, th
e sp
ool i
s op
ened
by
pilo
t pre
ssur
e in
the
retr
actio
n si
de w
hich
al
low
s oi
l in
the
exte
nsio
n si
de to
ret
urn
to th
e ta
nk.
Thi
s al
low
s th
e te
le1
to r
etra
ct.
Alth
ough
pre
ssur
e is
app
lied
to th
e te
le2
on r
etra
ctio
n si
de a
t thi
s tim
e, th
e te
le2
will
not
be
actu
ated
bec
ause
the
chec
k va
lve
2 of
sel
ecto
r va
lve
ass’
y is
clo
sed
and
the
tele
2 is
fully
ret
ract
ed w
hich
pre
vent
s oi
l in
the
exte
nsio
n si
de o
f tel
e2 fr
om fl
owin
g in
the
tele
1.
- 25 -
(3)
Wh
en T
eles
cop
ing
Cyl
ind
er2
exte
nd
s
Che
ck v
alve
1
Che
ck v
alve
2
Spo
ol
Pis
ton
Rod
Pip
e
Pre
ssur
eO
ilTo
Tan
k
Rod
Che
ck v
alve
Pis
ton
Slid
e pi
pe
App
ly"L
ock
Tigh
t#63
8".
Bol
t
Sel
ecto
rva
lve
ass’
y
App
ly"L
ock
Tigh
t#63
8".
Tele
1
Tele
2C
ount
er-b
alan
ce v
alve
Pip
e fo
r co
rd r
eel Sel
ecto
rva
lve
ass’
y
Afte
r th
e se
t-sc
rew
is ti
ghte
ned
with
Loc
k Ti
ght #
2701
app
lied、
hit w
ith a
pun
ch a
t 2 p
lace
s on
the
circ
umfe
renc
ean
d le
ave
it as
it is
for
1 ho
ur.
Afte
r th
e se
t-sc
rew
is ti
ghte
ned
with
Loc
k Ti
ght #
2701
app
lied、
hit w
ith a
pun
ch a
t 2 p
lace
s on
the
circ
umfe
renc
ean
d le
ave
it as
it is
for
1 ho
ur.
Ho
w o
il fl
ow
s w
hen
tel
e2 is
ext
end
edP
ress
ure
oil o
pens
the
chec
k va
lve
in th
e co
unte
r-ba
lanc
e va
lve
to
ente
r th
e cy
linde
r ro
d of
tele
1 an
d flo
ws
thro
ugh
the
slid
e pi
pe to
rea
ch th
e ch
eck
valv
e 2
of s
elec
tor
valv
e as
s’y.
Sin
ce th
e sl
ide
pipe
is p
ushe
d up
by
pist
on im
med
iate
ly b
efor
e th
e te
le1
is fu
lly e
xten
ded
whi
ch in
turn
ope
ns th
e ch
eck
valv
e 2
of s
elec
tor
valv
e as
s’y
to le
ad th
e pr
essu
re o
il in
the
exte
nsio
n si
de o
f tel
e2.
Sim
ulta
neou
sly,
oil
in th
e re
trac
tion
side
of t
ele2
flow
s th
roug
h th
e pi
pe o
f tel
e2 a
nd th
roug
h th
e du
al c
ylin
der
of th
e cy
linde
r ro
d of
the
tele
1 to
re
turn
to th
e ta
nk.
Thi
s al
low
s th
e te
le2
to e
xten
d.T
he te
le1
will
not
be
actu
ated
as
the
chec
k va
lve
1 of
sel
ecto
r va
lve
ass’
y is
clo
sed
and
the
exte
nsio
n ci
rcui
t for
tele
1 is
shu
t off.
- 26 -
(4)
Wh
en T
eles
cop
ing
Cyl
ind
er2
retr
acts
To T
ankR
od
Che
ck v
alve
1
Spo
ol
Pilo
tP
ress
ure
Spo
ol
Rod
Pis
ton
Pip
e
App
ly"L
ock
Tigh
t#63
8".Pis
ton
Pip
e-S
lide
Sel
ecto
rva
lve
ass’
yC
heck
val
ve 2
Bol
t
App
ly"L
ockt
ight
#638
".
Che
ck v
alve
Pre
ssur
eO
il
Tele
1
Tele
2C
ount
er-b
alan
ce v
alve
Pip
e fo
r co
rd r
eel
Sel
ecto
rva
lve
ass’
y
Afte
r th
e se
t-sc
rew
is ti
ghte
ned
with
Loc
k Ti
ght #
2701
app
lied、
hit w
ith a
pun
ch a
t 2 p
lace
s on
the
circ
umfe
renc
ean
d le
ave
it as
it is
for
1 ho
ur.
Afte
r th
e se
t-sc
rew
is ti
ghte
ned
with
Loc
k Ti
ght #
2701
app
lied、
hit w
ith a
pun
ch a
t 2 p
lace
s on
the
circ
umfe
renc
ean
d le
ave
it as
it is
for
1 ho
ur.
Ho
w o
il fl
ow
s w
hen
tel
e2 is
ret
ract
edP
ress
ure
oil f
low
s th
roug
h th
e du
al c
ylin
der
of c
ylin
der
rod
of te
le1
to e
nter
the
retr
actio
n si
de o
f tel
e2.
Sin
ce th
e te
le1
has
been
fully
ext
ende
d an
d th
e sl
ide
pipe
is p
ushe
d up
by
pist
on w
hich
in tu
rn o
pens
the
chec
k va
lve
2 of
sel
ecto
r va
lve
ass’
y to
le
ad th
e oi
l in
the
exte
nsio
n si
de o
f tel
e2 to
the
coun
ter-
bala
nce
valv
e by
way
of
slid
e pi
pe.
Alth
ough
the
chec
k va
lve
in th
e co
unte
r-ba
lanc
e va
lve
is c
lose
d at
th
e tim
e, th
e sp
ool i
s op
ened
by
pilo
t pre
ssur
e fr
om th
e re
trac
tion
side
w
hich
allo
ws
oil i
n th
e ex
tens
ion
side
to r
etur
n to
the
tank
.T
his
allo
ws
the
tele
2 to
ret
ract
.T
he te
le1
will
not
be
actu
ated
as
the
chec
k va
lve
1 of
sel
ecto
r va
lve
ass’
y is
clo
sed
and
the
exte
nsio
n ci
rcui
t for
tele
1 is
shu
t off.
- 27 -
3. 3
4-S
ecti
on
Bo
om
(D
ual
Cyl
ind
er)
Op
erat
ion
(1)
Wh
en T
eles
cop
ing
Cyl
ind
er1
exte
nd
s
Pre
ssur
e O
ilTo
Tan
k
Rod
Che
ck v
alve
App
ly"L
ock
Tigh
t#63
8"
Pis
ton
Slid
e pi
pe
Che
ck v
alve
1S
pool
Bol
t
Sel
ecto
rva
lve
ass’
yC
heck
val
ve 2
App
ly"L
ockt
ight
#638
"
Cou
nter
-bal
ance
val
ve
Tele
1
Tele
2
Pip
e fo
r co
rd r
eel
Sel
ecto
r va
lve
ass’
y
Afte
r th
e se
t-sc
rew
is ti
ghte
ned
with
Loc
k Ti
ght #
2701
app
lied、
hit w
ith a
pun
ch a
t 2 p
lace
s on
the
circ
umfe
renc
ean
d le
ave
it as
it is
for
1 ho
ur.
Afte
r th
e se
t-sc
rew
is ti
ghte
ned
with
Loc
k Ti
ght #
2701
app
lied、
hit w
ith a
pun
ch a
t 2 p
lace
s on
the
circ
umfe
renc
ean
d le
ave
it as
it is
for
1 ho
ur.
Ho
w o
il fl
ow
s w
hen
tel
e1 is
ext
end
edP
ress
ure
oil o
pens
the
chec
k va
lve
in th
e co
unte
r-ba
lanc
e va
lve
to
ente
r th
e cy
linde
r ro
d of
tele
1 an
d flo
ws
thro
ugh
the
slid
e pi
pe to
rea
ch th
e ch
eck
valv
e 1
of s
elec
tor
valv
e as
s’y.
The
tele
2 ha
s be
en fu
lly r
etra
cted
at t
he ti
me
and
the
bolt
open
s th
e ch
eck
valv
e 1
of s
elec
tor
valv
e as
s’y
via
spoo
l whi
ch le
ads
the
pres
sure
oil
to
the
exte
nsio
n si
de.
Sim
ulta
neou
sly,
oil
in th
e re
trac
tion
side
of t
ele1
flow
s th
roug
h th
e du
al c
ylin
der
in th
e ro
d to
ret
urn
to th
e ta
nk.
Thi
s, a
s a
resu
lt, a
llow
s th
e te
le1
to e
xten
d.S
ince
the
chec
k va
lve
2 of
sel
ecto
r va
lve
ass’
y is
stil
l clo
sed
at th
is
stag
e, p
ress
ure
oil w
ill n
ot fl
ows
in th
e te
le2.
Als
o, s
ince
the
tele
2 ha
s be
en fu
lly r
etra
cted
, oil
in th
e re
trac
tion
side
of t
ele2
will
not
flow
in th
e te
le1
so th
at th
e te
le2
will
not
be
actu
ated
.
- 28 -
(2)
Wh
en T
eles
cop
ing
1 C
ylin
der
1 re
trac
ts
App
ly"L
ock
Tigh
t#63
8"
Pis
ton
Rod
Che
ck v
alve
Slid
e pi
pe
Che
ck v
alve
1
Pre
ssur
e O
ilTo
Tan
k
Che
ck v
alve
2
Spo
ol
Bol
t
Pilo
tP
ress
ure
Spo
ol
Sel
ecto
rva
lve
ass’
y
App
ly"L
ock
Tigh
t#63
8"
Tele
1
Tele
2
Pip
e fo
r co
rd r
eel
Cou
nter
-bal
ance
val
ve
Sel
ecto
r va
lve
ass’
y
Afte
r th
e se
t-sc
rew
is ti
ghte
ned
with
Loc
k Ti
ght #
2701
app
lied、
hit w
ith a
pun
ch a
t 2 p
lace
s on
the
circ
umfe
renc
ean
d le
ave
it as
it is
for
1 ho
ur.
Afte
r th
e se
t-sc
rew
is ti
ghte
ned
with
Loc
k Ti
ght #
2701
app
lied、
hit w
ith a
pun
ch a
t 2 p
lace
s on
the
circ
umfe
renc
ean
d le
ave
it as
it is
for
1 ho
ur.
Ho
w o
il fl
ow
s w
hen
tel
e1 is
ret
ract
edP
ress
ure
oil f
low
s th
roug
h th
e du
al c
ylin
der
of c
ylin
der
rod
of te
le1
to e
nter
the
retr
actio
n si
de o
f tel
e1.
Sin
ce th
e te
le2
has
been
fully
ret
ract
ed a
t the
tim
e, th
e bo
lt op
ens
the
chec
k va
lve
1 of
sel
ecto
r va
lve
ass’
y vi
a sp
ool w
hich
lead
s th
e oi
l in
the
exte
nsio
n si
de to
the
coun
ter-
bala
nce
valv
e by
way
of s
lide
pipe
.A
lthou
gh th
e ch
eck
valv
e in
the
coun
ter-
bala
nce
valv
e is
clo
sed
at
this
tim
e, th
e sp
ool i
s op
ened
by
pilo
t pre
ssur
e fr
om th
e re
trac
tion
side
al
low
ing
the
oil i
n th
e ex
tens
ion
side
to r
etur
n to
the
tank
.T
his
allo
ws
the
tele
1 to
ret
ract
.A
lthou
gh p
ress
ure
is a
pplie
d to
the
retr
actio
n si
de o
f tel
e2 a
t thi
s st
age,
the
tele
2 w
ill n
ot b
e ac
tuat
ed b
ecau
se th
e ch
eck
valv
e 2
of s
elec
tor
valv
e as
s’y
is c
lose
d an
d th
e te
le2
is fu
lly r
etra
cted
whi
ch p
reve
nts
oil i
n th
e ex
tens
ion
side
of t
ele2
from
flow
ing
in th
e te
le1.
- 29 -
(3)
Wh
en T
eles
cop
ing
Cyl
ind
er2
exte
nd
s
Pre
ssur
e O
ilTo
Tan
k
Rod
Che
ck v
alve
Pis
ton
Slid
e pi
peC
heck
val
ve 2
Sel
ecto
rva
lve
ass’
yBol
t
Spo
olC
heck
val
ve 1
App
ly"L
ock
Tigh
t#63
8"
App
ly"L
ock
Tigh
t#63
8"
Cou
nter
-bal
ance
val
veTe
le2
Tele
1
Pip
e fo
r co
rd r
eel
Sel
ecto
r va
lve
ass’
y
Afte
r th
e se
t-sc
rew
is ti
ghte
ned
with
Loc
k Ti
ght #
2701
app
lied、
hit w
ith a
pun
ch a
t 2 p
lace
s on
the
circ
umfe
renc
ean
d le
ave
it as
it is
for
1 ho
ur.
Afte
r th
e se
t-sc
rew
is ti
ghte
ned
with
Loc
k Ti
ght #
2701
app
lied、
hit w
ith a
pun
ch a
t 2 p
lace
s on
the
circ
umfe
renc
ean
d le
ave
it as
it is
for
1 ho
ur.
Ho
w o
il fl
ow
s w
hen
tel
e2 is
ext
end
edP
ress
ure
oil o
pens
the
chec
k va
lve
in th
e co
unte
r-ba
lanc
e va
lve
to
ente
r th
e cy
linde
r ro
d of
tele
1 an
d flo
ws
thro
ugh
the
slid
e pi
pe to
rea
ch th
e ch
eck
valv
e 2
of s
elec
tor
valv
e as
s’y.
Sin
ce th
e sl
ide
pipe
is p
ushe
d up
by
pist
on im
med
iate
ly b
efor
e th
e te
le1
is fu
lly e
xten
ded
whi
ch in
turn
ope
ns th
e ch
eck
valv
e 2
of s
elec
tor
valv
e as
s’y
to le
ad th
e pr
essu
re o
il in
the
exte
nsio
n si
de o
f tel
e2.
Sim
ulta
neou
sly,
oil
in th
e re
trac
tion
side
of t
ele2
flow
s th
roug
h th
e du
al c
ylin
der
in th
e cy
linde
r ro
d of
tele
2 an
d th
roug
h th
e du
al c
ylin
der
in
the
cylin
der
rod
of th
e te
le1
to r
etur
n to
the
tank
.T
his,
as
a re
sult,
allo
ws
the
tele
2 to
ext
end.
Sin
ce th
e ch
eck
valv
e 1
of s
elec
tor
valv
e as
s’y
is c
lose
d at
this
sta
ge
and
the
exte
nsio
n ci
rcui
t for
tele
1 is
shu
t off,
the
tele
1 w
ill n
ot b
e ac
tuat
ed.
- 30 -
(4)
Wh
en T
eles
cop
ing
Cyl
ind
er2
retr
acts Pre
ssur
e O
ilTo
Tan
kRod
Pilo
tP
ress
ure
Spo
ol
Che
ck v
alve
Pis
ton
Slid
e pi
pe
App
ly"L
ock
Tigh
t#63
8"
App
ly"L
ock
Tigh
t#63
8"
Bol
t
Sel
ecto
rva
lve
ass’
y
Spo
olC
heck
val
ve 1
Che
ck v
alve
2
Cou
nter
-bal
ance
val
veTe
le2
Tele
1
Pip
e fo
r co
rd r
eel
Sel
ecto
r va
lve
ass’
y
Afte
r th
e se
t-sc
rew
is ti
ghte
ned
with
Loc
k Ti
ght #
2701
app
lied、
hit w
ith a
pun
ch a
t 2 p
lace
s on
the
circ
umfe
renc
ean
d le
ave
it as
it is
for
1 ho
ur.
Afte
r th
e se
t-sc
rew
is ti
ghte
ned
with
Loc
k Ti
ght #
2701
app
lied、
hit w
ith a
pun
ch a
t 2 p
lace
s on
the
circ
umfe
renc
ean
d le
ave
it as
it is
for
1 ho
ur.
Ho
w o
il fl
ow
s w
hen
tel
e2 is
ret
ract
edP
ress
ure
oil f
low
s th
roug
h th
e du
al c
ylin
der
of c
ylin
der
rod
of te
le1
to e
nter
the
retr
actio
n si
de o
f tel
e2.
Sin
ce th
e te
le1
has
been
fully
ext
ende
d an
d th
e sl
ide
pipe
is p
ushe
d up
by
pist
on w
hich
in tu
rn o
pens
the
chec
k va
lve
2 of
sel
ecto
r va
lve
ass’
y to
le
ad th
e oi
l in
the
exte
nsio
n si
de o
f tel
e2 to
the
coun
ter-
bala
nce
valv
e by
way
of
slid
e pi
pe.
Alth
ough
the
chec
k va
lve
in th
e co
unte
r-ba
lanc
e va
lve
is c
lose
d at
th
e tim
e, th
e sp
ool i
s op
ened
by
pilo
t pre
ssur
e fr
om th
e re
trac
tion
side
w
hich
allo
ws
oil i
n th
e ex
tens
ion
side
to r
etur
n to
the
tank
.T
his
allo
ws
the
tele
2 to
ret
ract
.A
t thi
s st
age,
the
tele
1 w
ill n
ot b
e ac
tuat
ed a
s th
e ch
eck
valv
e 1
of
sele
ctor
val
ve a
ss’y
is c
lose
d an
d th
e ex
tens
ion
circ
uit f
or te
le1
is s
hut o
ff.
- 31 -
3. 4
5-S
ecti
on
Bo
om
(D
ual
Cyl
ind
er)
Op
erat
ion
(1)
Wh
en T
eles
cop
ing
Cyl
ind
er1
exte
nd
s
Pis
ton
App
ly"L
ockt
ight
#638
".
Slid
e pi
pe
Pre
ssur
e O
ilTo
Tan
k
Sel
etor
val
ve a
ss’y
Che
ck v
alve
2
Rod
Che
ckva
lve
Bol
tTe
le2
Che
ck v
alve
1
Spo
ol
Tele
1Te
le2 Te
le3
Pip
e fo
r co
rd r
eel
Cou
nter
-bal
ance
valv
e
Ho
w o
il fl
ow
s w
hen
tel
e1 is
ext
end
edP
ress
ure
oil o
pens
the
chec
k va
lve
in th
e co
unte
r-ba
lanc
e va
lve
to
ente
r th
e cy
linde
r ro
d of
tele
1 an
d flo
ws
thro
ugh
the
slid
e pi
pe to
rea
ch th
e ch
eck
valv
e 1
of s
elec
tor
valv
e as
s’y.
The
tele
2 ha
s be
en fu
lly r
etra
cted
at t
he ti
me
and
the
bolt
open
s th
e ch
eck
valv
e 1
of s
elec
tor
valv
e as
s’y
via
spoo
l whi
ch le
ads
the
pres
sure
oil
to
the
exte
nsio
n si
de.
Sim
ulta
neou
sly,
oil
in th
e re
trac
tion
side
of t
ele1
flow
s th
roug
h th
e du
al c
ylin
der
in th
e ro
d to
ret
urn
to th
e ta
nk.
Thi
s al
low
s th
e te
le1
to e
xten
d.S
ince
the
chec
k va
lve
2 of
sel
ecto
r va
lve
ass’
y is
clo
sed
at th
e tim
e,
pres
sure
oil
will
not
flow
s in
the
tele
2.A
lso,
oil
in th
e re
trac
tion
side
of t
ele2
will
not
flow
s in
the
tele
1 as
th
e te
le2
has
been
fully
ret
ract
ed s
o th
at th
e te
le2
will
not
be
actu
ated
.A
nd th
e te
le3
also
will
not
be
actu
ated
acc
ordi
ng to
the
sam
e re
ason
s as
in th
e te
le2.
Afte
r th
e se
t-sc
rew
is ti
ghte
ned
with
Loc
k Ti
ght #
2701
app
lied、
hit
with
a p
unch
at 2
pla
ces
on th
e ci
rcum
fere
nce
and
leav
e it
as
it is
for
1 ho
ur.
- 32 -
(2)
Wh
en T
eles
cop
ing
1 C
ylin
der
1 re
trac
ts
Pis
ton
App
ly"L
ock
Tigh
t#63
8".
Slid
e pi
pe
Pre
ssur
eO
il
To ta
nk
Sel
ecto
r va
lve
ass’
y
Che
ck v
alve
2
Spo
ol
Cou
nter
bal
ance
Val
veP
ilot
Pre
ssur
e
Rod
Che
ckva
lve
Bol
tTe
le2
Che
ck v
alve
1
Spo
ol
Tele
1
Tele
2 Tele
3
Pip
e fo
r co
rd r
eel
coun
terb
alan
ceva
lve
Afte
r th
e se
t-sc
rew
is ti
ghte
nedw
ith L
ock
Tigh
t #27
01 a
pplie
d、hi
t with
a p
unch
at 2
pla
ces
on th
e ci
rcum
fere
nce
and
leav
e it
asit
is fo
r 1
hour
.
Ho
w o
il fl
ow
s w
hen
tel
e1 is
ret
ract
ed P
ress
ure
oil f
low
s th
roug
h th
e du
al c
ylin
der
of c
ylin
der
rod
of te
le1
to e
nter
the
retr
actio
n si
de o
f tel
e1.
At t
his
stag
e, th
e bo
lt op
ens
the
chec
k va
lve
1 of
sel
ecto
r va
lve
ass’
y vi
a sp
ool w
hich
lead
s th
e oi
l in
the
exte
nsio
n si
de to
the
coun
ter-
bala
nce
valv
e by
way
of s
lide
pipe
. A
lthou
gh th
e ch
eck
valv
e in
the
coun
ter-
bala
nce
valv
e is
clo
sed
at
this
tim
e, th
e sp
ool i
s op
ened
by
pilo
t pre
ssur
e fr
om th
e re
trac
tion
side
al
low
ing
the
oil i
n th
e ex
tens
ion
side
to r
etur
n to
the
tank
. T
his
allo
ws
the
tele
1 to
ret
ract
. A
lthou
gh p
ress
ure
is a
lso
appl
ied
to th
e re
trac
tion
side
of t
ele2
at
this
sta
ge, t
he te
le2
will
not
be
actu
ated
bec
ause
the
chec
k va
lve
1 of
sel
ecto
r va
lve
ass’
y fo
r te
le1
is c
lose
d an
d th
e pa
ssag
e to
the
exte
nsio
n si
de o
f tel
e2 is
sh
ut o
ff so
that
no
oil i
s to
be
rem
aine
d in
the
exte
nsio
n si
de o
f tel
e2.
And
the
tele
3 al
so w
ill n
ot b
e ac
tuat
ed a
ccor
ding
to th
e sa
me
reas
ons
as in
the
tele
2.
- 33 -
(3)
Wh
en T
eles
cop
ing
Cyl
ind
er2
exte
nd
s
Pis
ton
App
ly "
Lock
Tig
ht#6
38".
Slid
e pi
pe
Pre
ssur
e O
ilTo
tank
Sel
ecto
rva
lve
ass’
y
Che
ck v
alve
2
Che
ck v
alve
2
Slid
e pi
pe
Sel
ecto
r va
lve
ass’
yP
isto
n
Rod
Rod
Che
ckva
lve
Bol
tTe
le3
Che
ck v
alve
1
Spo
ol
Che
ck v
alve
1
Bol
tTe
le2
Tele
1
Tele
2
Tele
3
Pip
e fo
r co
rd r
eel
Cou
nter
bala
nce
valv
e
Afte
r th
e se
t-sc
rew
is ti
ghte
nedw
ith L
ock
Tigh
t #27
01 a
pplie
d、hi
t with
a p
unch
at 2
pla
ces
on th
e ci
rcum
fere
nce
and
leav
e it
asit
is fo
r 1
hour
.
Ho
w o
il fl
ow
s w
hen
tel
e2 is
ext
end
ed P
ress
ure
oil o
pens
the
chec
k va
lve
in th
e co
unte
r-ba
lanc
e va
lve
to
ente
r th
e cy
linde
r ro
d of
tele
1 an
d flo
ws
thro
ugh
the
slid
e pi
pe to
rea
ch th
e ch
eck
valv
e 2
of s
elec
tor
valv
e as
s’y.
Sin
ce th
e sl
ide
pipe
of t
ele1
is p
ulle
d by
pis
ton
imm
edia
tely
bef
ore
the
tele
1 is
fully
ext
ende
d w
hich
in tu
rn o
pens
the
chec
k va
lve
2 of
sel
ecto
r va
lve
ass’
y to
lead
the
pres
sure
oil
to th
e ex
tens
ion
side
of t
ele2
. S
imul
tane
ousl
y, o
il in
the
retr
actio
n si
de o
f tel
e2 fl
ows
thro
ugh
the
dual
cyl
inde
r in
the
cylin
der
rod
of te
le2
and
thro
ugh
the
dual
cyl
inde
r in
th
e cy
linde
r ro
d of
the
tele
1 to
ret
urn
to th
e ta
nk.
Thi
s al
low
s th
e te
le2
to e
xten
d. S
ince
the
chec
k va
lve
1 of
sel
ecto
r va
lve
ass’
y of
tele
1 is
clo
sed
at th
is
stag
e, th
e pa
ssag
e on
ext
ensi
on s
ide
for
tele
1 is
shu
t off.
The
tele
1 w
ill n
ot b
e ac
tuat
ed b
ecau
se n
o oi
l is
rem
aine
d in
the
retr
actio
n si
de o
f tel
e1 a
s th
e te
le1
is fu
lly e
xten
ded.
In
addi
tion,
the
tele
3 w
ill n
ot b
e ac
tuat
ed b
ecau
se th
e ch
eck
valv
e 2
of s
elec
tor
valv
e as
s’y
for
tele
2 is
clo
sed
whi
ch in
turn
shu
ts o
ff th
e pa
ssag
e to
ext
ensi
on s
ide
of te
le3.
- 34 -
(4)
Wh
en T
eles
cop
ing
Cyl
ind
er2
retr
acts
Slid
e pi
pe
Che
ck v
alve
2
Slid
e pi
pe
Pis
ton
Rod
Spo
ol
Pre
ssur
eO
il
To ta
nk
Pilo
tP
ress
ure
Cou
nter
bal
ance
Val
ve
Pis
ton
App
ly"L
ock
Tigh
t#63
8".
Sel
ecto
r va
lve
ass’
y
Che
ck v
alve
2
Sel
ecto
r va
lve
ass’
y
Rod
Che
ck v
alve
1
Che
ckva
lve
Bol
tTe
le2 S
pool
Che
ck v
alve
1
Bol
tTe
le3
Tele
1
Tele
2
Tele
3
Pip
e fo
r co
rd r
eel
Cou
nte
rbal
ance
valv
e
Afte
r th
e se
t-sc
rew
is ti
ghte
nedw
ith L
ock
Tigh
t #27
01 a
pplie
d、hi
t with
a p
unch
at 2
pla
ces
on th
e ci
rcum
fere
nce
and
leav
e it
asit
is fo
r 1
hour
.
Ho
w o
il fl
ow
s w
hen
tel
e2 is
ret
ract
ed P
ress
ure
oil f
low
s th
roug
h th
e du
al c
ylin
der
of c
ylin
der
rod
of te
le1
to e
nter
the
retr
actio
n si
de o
f tel
e2.
Als
o, th
e bo
lt fo
r te
le3
open
s th
e ch
eck
valv
e 1
of s
elec
tor
valv
e as
s’y
via
spoo
l whi
ch le
ads
the
oil i
n th
e ex
tens
ion
side
of t
ele2
to th
e co
unte
r-ba
lanc
e va
lve
by w
ay o
f the
slid
e pi
pe o
f tel
e2, t
he c
heck
val
ve 2
of s
elec
tor
valv
e as
s’y
for
tele
1, a
nd th
e sl
ide
pipe
of t
ele1
. A
lthou
gh th
e ch
eck
valv
e in
the
coun
ter-
bala
nce
valv
e is
clo
sed
at
this
tim
e, th
e sp
ool i
s op
ened
by
pilo
t pre
ssur
e fr
om th
e re
trac
tion
side
al
low
ing
the
oil i
n th
e ex
tens
ion
side
to r
etur
n to
the
tank
. T
his
allo
ws
the
tele
2 to
ret
ract
. A
lthou
gh p
ress
ure
is a
pplie
d to
the
retr
actio
n si
de o
f tel
e1 a
t the
tim
e, th
e te
le1
will
not
be
actu
ated
bec
ause
the
chec
k va
lve
1 of
sel
ecto
r va
lve
ass’
y is
clo
sed
and
the
pass
age
to th
e ex
tens
ion
side
of t
ele1
is s
hut o
ff. A
nd th
e te
le3
also
will
not
be
actu
ated
acc
ordi
ng to
the
sam
e re
ason
s as
in th
e te
le1.
- 35 -
(5)
Wh
en T
eles
cop
ing
Cyl
ind
er3
exte
nd
s
Pis
ton
App
ly "
Lock
Tig
ht#6
38".
Slid
e pi
pe
Pre
ssur
e O
il
Sel
ecto
r va
lve
ass’
y
Che
ck v
alve
2
Che
ck v
alve
2
Slid
e pi
pe
Sel
ecto
r va
lve
ass’
yP
isto
n
Pis
ton
Rod
Rod
To ta
nk
Rod
Che
ckva
lve
Bol
tTe
le3
Che
ck v
alve
1
Spo
ol
Che
ck v
alve
1
Bol
tTe
le2
Tele
1Te
le2
Tele
3
Pip
e fo
r co
rd r
eel
Cou
nter
bal
ance
valv
e
Afte
r th
e se
t-sc
rew
is ti
ghte
nedw
ith L
ock
Tigh
t #27
01 a
pplie
d、hi
t with
a p
unch
at 2
pla
ces
on th
e ci
rcum
fere
nce
and
leav
e it
asit
is fo
r 1
hour
.
Ho
w o
il fl
ow
s w
hen
tel
e3 is
ext
end
ed P
ress
ure
oil o
pens
the
chec
k va
lve
in th
e co
unte
r-ba
lanc
e va
lve
to
ente
r th
e cy
linde
r ro
d of
tele
1 an
d flo
ws
thro
ugh
the
slid
e pi
pe to
rea
chth
e ch
eck
valv
e 2
of s
elec
tor
valv
e as
s’y.
Sin
ce th
e sl
ide
pipe
of t
ele1
is p
ulle
d by
pis
ton
imm
edia
tely
bef
ore
the
tele
1 is
fully
ext
ende
d w
hich
in tu
rn o
pens
the
chec
k va
lve
2 of
sel
ecto
r va
lve
ass’
y to
lead
the
pres
sure
oil
to th
e ex
tens
ion
side
of t
ele2
. P
ress
ure
oil e
nter
ed th
e ex
tens
ion
side
of t
ele2
flow
s th
roug
h th
e sl
ide
pipe
to r
each
the
chec
k va
lve
2 of
sel
ecto
r va
lve
ass’
y. S
ince
the
slid
e pi
pe o
f tel
e2 is
pul
led
by p
isto
n im
med
iate
ly b
efor
e th
e te
le2
is fu
lly e
xten
ded
whi
ch in
turn
ope
ns th
e ch
eck
valv
e 2
of s
elec
tor
valv
e as
s’y
to le
ad th
e pr
essu
re o
il to
the
exte
nsio
n si
de o
f tel
e3.
Sim
ulta
neou
sly,
oil
in th
e re
trac
tion
side
of t
ele3
flow
s th
roug
h th
e du
al c
ylin
der
in th
e cy
linde
r ro
d of
tele
3 to
ent
er th
e ex
tens
ion
side
of t
ele2
, th
en it
flow
s th
roug
h th
e du
al c
ylin
der
and
furt
her
thro
ugh
the
dual
cy
linde
r in
the
cylin
der
rod
of th
e te
le1
to r
etur
n to
the
tank
. T
his
allo
ws
the
tele
3 to
ext
end.
Sin
ce th
e ch
eck
valv
es 1
of s
elec
tor
valv
e as
s’y
of te
le1
and
tele
2 ar
e cl
osed
at t
his
stag
e, th
e pa
ssag
es o
f ext
ensi
on s
ide
for
tele
1 an
d te
le2
are
shut
off.
Bot
h te
le1
and
2 w
ill n
ot b
e ac
tuat
ed b
ecau
se n
o oi
l is
rem
aine
d in
th
e re
trac
tion
side
of t
ele1
and
2 a
s th
e te
le1
and
2 ar
e fu
lly e
xten
ded.
- 36 -
(6)
Wh
en T
eles
cop
ing
Cyl
ind
er3
retr
acts
Pis
ton
App
ly"L
ockt
ight
#638
".
Slid
e pi
pe
Che
ck v
alve
2
Che
ck v
alve
2
Sel
ecto
r V
alve
Ass
’yP
isto
n
Pis
ton
Rod
Rod
Spo
ol
To ta
nk
Pre
ssur
eO
ilP
ilot
Pre
ssur
e
Slid
e pi
pe
Sel
ecto
rva
lve
ass’
y
Bol
tTe
le3
Che
ck v
alve
1
Spo
ol
Che
ck v
alve
1
Bol
tTe
le2
Che
ckva
lve
Rod
Tele
1
Tele
2
Tele
3
Pip
e fo
r co
rd r
eel
Cou
nter
bala
nce
valv
e
Afte
r th
e se
t-sc
rew
is ti
ghte
nedw
ith L
ock
Tigh
t #27
01 a
pplie
d、hi
t with
a p
unch
at 2
pla
ces
on th
e ci
rcum
fere
nce
and
leav
e it
asit
is fo
r 1
hour
.
Ho
w o
il fl
ow
s w
hen
tel
e3 is
ret
ract
ed P
ress
ure
oil f
low
s th
roug
h th
e du
al c
ylin
der
of c
ylin
der
rod
of te
le1
and
thro
ugh
the
dual
cyl
inde
r of
tele
2 to
ent
er th
e re
trac
tion
side
of t
ele3
. A
lso,
oil
in th
e ex
tens
ion
side
of t
ele3
flow
s by
way
of t
he s
elec
tor
valv
e of
tele
2, th
e sl
ide
pipe
, the
sel
ecto
r va
lve
of te
le1,
and
the
slid
e pi
pein
that
ord
er to
rea
ch th
e co
unte
r-ba
lanc
e va
lve.
Alth
ough
the
chec
k va
lve
in th
e co
unte
r-ba
lanc
e va
lve
is c
lose
d at
th
is ti
me,
the
spoo
l is
open
ed b
y pi
lot p
ress
ure
from
the
retr
actio
n si
de
allo
win
g th
e oi
l to
retu
rn to
the
tank
. T
his
allo
ws
the
tele
3 to
ret
ract
. A
lthou
gh p
ress
ure
is a
pplie
d to
the
retr
actio
n si
de o
f tel
e1 a
t the
tim
e, th
e te
le1
will
not
be
actu
ated
bec
ause
the
chec
k va
lve
1 of
sel
ecto
r va
lve
ass’
y of
tele
1 is
clo
sed
and
the
pass
age
to th
e ex
tens
ion
side
of t
ele1
is s
hut
off.
And
the
tele
2 al
so w
ill n
ot b
e ac
tuat
ed a
ccor
ding
to th
e sa
me
reas
ons
as in
the
tele
1.
- 37 -
3. 5 3-Section Boom (Dual Telescoping Cylinder) Disassembly ProceduresRemove the bolt which connects the telescoping cylinder (1) with the telescoping cylinder (2) and separate the onefrom the other.
Remove 3 pcs. of hexagon socket head bolt from the part A .
Next, remove 4 pcs. of hexagon socket head bolt from the part B .
- 38 -
(1) Disassembly Procedures for Telescoping Cylinder 1
Remove 3 pcs. of hexagon socket head bolt which fasten the selector valve.
Remove a lock screw for nut of the slide pipe.
When assembling, apply“LOCK TIGHT #2701” to the screw.
From the slide pipe remove the nut, the check valve, and the spring.
- 39 -
Compensate the revolution stopper of the gland, remove the gland from the tube with a hook-spanner, and pullout the rod ass’y from the tube (1).
Pull out the rod ass’y from the tube (1).
Loosen the screw which stops revolution of the piston, and take out the piston from the rod ass’y.
From the rod ass’y, pull out the piston and the slide pipe at the same time.
- 40 -
(2) Disassembly Procedures for Telescoping Cylinder 2
Remove the lock screw for the cylinder cover.When assembling, apply “LOCK TIGHT#2701”.
Loosen the cylinder cover with a lock-spanner.
Pull out the rod ass’y from the tube (2). Remove the lock screw securing the piston.When assembling, apply “LOCK TIGHT#2701”.
Loosen the piston with the hook-spanner.
- 41 -
(3) Inspection
Check all the parts that they are free pf harmful defects for operation such as flaw, crack, deformation, rust, burr, etc.
Check that every part is free of attachments of metal powder, foreign substances, etc.
Check to see if the piston rod sliding surface is free of damages harmful for operation.
In principle, packings and seals shall be replaced with new ones when disassembled. However, if these parts areforced to be reused, check them very carefully and confirm that they are free of damage and foreign substances.Reassembling shall be made in reverse order of the disassembly procedures.
• Check that every part is free of metal powder attachment and then sock the parts in hydraulic oil.
(4) Adjusting Procedures for Selector Valve with Adjusting Bolt
Adjusting Procedures with Adjusting BoltRetract telescoping cylinders (1) and (2) to their minimum.
Apply“LOCK TIGHT 242” to the threads of the adjusting bolt.
Put a board with a thickness of 3mm to the part marked with*.and tighten the adjusting bolt.
After adjusting, lock with the lock nut.
- 42 -
3. 6 Function and Working of Cushion SealFor the purpose of absorbing a piston shock to the stroke end, the 4-section boom and 6-section boom have thecushion seal in the part of piston of the telescoping cylinder (2), while the 5-section boom has the cushion seal in itstelescoping cylinder of (2) and (3).
(1) Flow of Pressure Oil When Retracting
Cushion mechanism of the telescoping cylinder (2) for 4-section boom and that of the telescoping cylinder (3) for 5-section and 6-section booms.
In the retracting process, before the piston gets in the plunger, the pressure oil in the chamber A flows through thecentral part of the piston as shown in the illustration and returns to the tank without being squeezed.
At the same time when the piston gets in the plunger, the chamber A is closed with the cushion seal a .As a result, the pressure oil in the chamber A is forced to return only through a drilled 1 hole in the state of beingsqueezed. Thus the piston shock at the stroke end is absorbed.
- 43 -
Cushion mechanism of the telescoping cylinder (2) for 5-section and 5-section boom.
(2) Flow of Pressure Oil When Extending
When extending the cushion seal a is pushed to ward the snap ring, and the pressure oil flows into the chamber Awithout being shut as shown in the illustration. In this way, the telescoping cylinder extends.
Cushion mechanism of the telescoping cylinder for 5-section and 6-section booms is to squeeze the return pressure oilat the position just before the end of extension and absorb the piston shock to the stroke end.
- 44 -
3. 7 Cause of Troubles and Measures to be Taken(1) 4-section boom
Immediately before the full retraction of the booms (3) and (4), and before changing over to the boom (2) , i.e. 3040mm before changing over to the boom (2), retracting operation may suddenly be stopped. In such a case, it is
presumed that a drill hole is clogged with foreign substances at the position A of the plunger of the telescopingcylinder (2).
(2) 5-section, 6-section boom
When retraction of the boom (3) becomes impossible at the position just before full retraction of the booms (4), (5)and (6), inspect the plunger which is assembled in the telescoping cylinder (3).
When the boom (3) does not change over to the boom (2), and retraction becomes impossible at the position justbefore full retraction, inspect the drilled hole at the position B of the plunger of the telescoping cylinder (2).
- 45 -
(3) Cause of Troubles and Remedy
SPOOL(1)
NUTA
B
C
ADJUSTING BOLT
STICK
3-section boom(Dual cylinders)
Troubles Possible cause Measures to be taken
Retractions is normal, butextending operation andsequence are not in a goodorder
Take part A of the selectorvalve is clogged with foreignsubstances.
Disassemble selector valve forcleaning or replace it with newone.
Extension is normal, butretracting operation andsequence are not in a goodorder.
Take part B of the selectorvalve is clogged with foreignsubstances.
Snap ring of the part C gotout of place.
Disassemble selector valve forcleaning or replace it with newone.Rearrange the snap ring.
Boom (2) extend but boom(3) does not extend.
Nut at the slide pipe of tele-scoping cylinder (1) is loos-ened.
Disassemble telescopingcylinder (1) and tighten thenut.
After full extension ofbooms, boom (3) retracts orextends but boom (2) doesnot retract.
Adjusting bolt pushing thespool of selector valve is loos-ened or the stick is bent.Selector valve spool (1) isbent.
Adjust the bolt. Straighten the bent stick.
Replace selector valve ass’ywith a new one.
- 46 -
5-section boom (Triple cylinders)
Troubles Possible cause Measures to be taken
Retraction is normal, but whenextending, booms (2) and (3)extend at the same time, inother words “disorderly”.
Some foreign substances are
clogging the part A of selec-tor valve of telescoping cylin-der (1).
Disassemble selector valve forcleaning, or replace it with anew one.
Extension is normal, but whenretracting, booms (3) (4) and(5) retract at the same time, inother words “disorderly”.
Some foreign substances are
clogging the part A of selec-tor valve of telescoping cylin-der (2).
Extension is normal, butwhen retracting, booms (3),(4) and (5) retract at thesame time, in other words“disorderly”.
Some foreign substances are
clogging the part B of selec-tor valve of telescoping cylin-der (2).
Snap ring at the part C ofselector valve of telescopingcylinder (2) got out of place.
Disassemble selector valve forcleaning, or replace it with anew one..Rearrange snap ring.
Extension is normal, butwhen retracting, booms (2)and (3) retract at the sametime, in other words “disor-derly”.
Some foreign substances are
clogging the part B of selec-tor valve of telescoping cylin-der (1).
Snap ring at the part C ofselector valve of telescopingcylinder (2) got out of place.
Boom (2) extends but boom(3) does not extend.
Nut at slide pipe of telescop-ing cylinder (1) was loosened.
Disassemble telescopingcylinder (1) and tighten thenut.
Boom (2) and (3) extend,but boom (4) and (5) doesnot extend.
Nut at slide pipe of telescop-ing cylinder (2) loosened.
Disassemble telescopingcylinder (2) and tighten thenut.
After full extension, booms(5) retracts but boom (3)does not retract.
Adjusting bolt pushing thespool of selector valve oftelescoping cylinder (2) wasloosened.Selector valve spool of tele-scoping cylinder (2) was bent.
Adjust the bolt.
Replace selector valve ass'ywith a new one.
Boom (3), (4) and (5)retracts but boom (2) doesnot retract.
Adjusting bolt pushing thespool of selector valve oftelescoping cylinder (1) wasloosened.Selector valve spool of tele-scoping cylinder (1) was bent.
Note: During operation test after disassembling and repairing, the reason why the booms (4), (5)and (6) stop extending halfway is presumed that the left and the right wire ropes forextension were crossed when reassembling.
As to the 4-section boom and 6-section boom, check the cause of troubles by following the proceduresfor 5-section boom.
- 47 -
4. D
ER
RIC
K C
YL
IND
ER
4. 1
Flo
w o
f o
il, w
hen
rai
sin
g
Rai
sin
gLo
wer
ing
P
T
Mar
k"W
"sta
mpe
d
6060
2200
0C
heck
val
ve o
pens
.
CO
UN
TE
R-B
ALA
NC
E V
ALV
E
Hex
agon
soc
ket h
ead
scre
wA
pply
"Lo
ck ti
ght #
2701
" w
ith "
Cur
ing
acce
lera
tor
#764
9".
If th
e ac
cele
rato
r is
not
use
d,do
not
flow
oil
for
at le
ast 1
hou
r af
ter
appl
icat
ion
of th
e ag
ent.
App
lyA
pply
"Lo
ck T
ight
"63
8" h
ere.
Hex
agon
soc
ket h
ead
scre
wA
pply
"Lo
ck ti
ght #
2701
"w
ith "
Cur
ing
acce
lera
tor
#764
9".
If th
e ac
cele
rato
r is
not
use
d,
do n
ot fl
ow o
il fo
r at
leas
t 1 h
our
afte
r ap
plic
atio
n of
the
agen
t.A
fter
the
scre
w is
tigh
tene
d、hi
t with
a p
unch
at 2
pla
ces
on it
s ci
rcum
fere
nce.
- 48 -
4. 2
Flo
w o
f o
il, w
hen
low
erin
g
1.RemovetheCounter-balanceValve.
2.Compensate
rotationstopperofthegland
andthenloosentheglandandremoveit
from
thecylindertube.
3.Removethehexagonsocketheadscrew
(cuppoint,M10×20L)whichstopsrotation
of the piston.
Tube
Gland
RodAss'y
Piston
Pulloutthepistonrod.
Pulloutthepistonfrom
therodass'y.
P T
Lowering
Raising
Mark"W
"stamped
Pilot
Pressure
COUNTER-BALANCEVALVE
606022000
Checkvalveopens.
Spoolopens.
Spoolopens.
Hexagonsocketheadscrew
Apply"Locktight#2701"
with"Curingaccelerator#7649".
Iftheacceleratorisnotused,
donotflowoilforatleast1hourafter
applicationoftheagent.
Apply
Apply"LockTight
"638"here.
Hexagonsocketheadscrew
Apply"Locktight#2701"
with"Curingaccelerator#7649".
Iftheacceleratorisnotused,
donotflowoilforatleast1hourafter
applicationoftheagent.
Afterthescrewistightened、
hitwithapunchat2placesonits
circumference.
DisassmblingPocedure
- 49 -
5. OUTRIGGER
5.1 Outrigger Cylinder (URV230, V260, V290, V300, V340)(1) Flow of oil when extending
Aplly
Grease
Spool
ExtentionRetraction
Before fastenig
Hexagon socket head screw,apply"Lock Tight#2701"
Pilot Check Valve
601681000Check valve
Pressure Oil
Tank
The spool is shifted upward by pilot pressure applied fromretraction side which in turn opens the check valve to allow the oil in theextension side of cylinder to return to the tank.
- 50 -
(2) Flow of oil when retracting
Pilot Check Valve
601681000
Apply
Grease
Before fastenig
Hexagon socket head screw,apply"Lock Tight#2701"
Check valve
Spool
Pilot Pressure
RetractionExtention
Pressure
Oil
Tank
The spool is shifted upward by pilot pressure applied fromretraction side which in turn opens the check valve to allow the oil in theextension side of cylinder to return to the tank.
- 51 -
5.2 Construction of outrigger cylinder (URV370)
For extention
For retraction
Joint
Bfore fastening
Hexagon socket head screw,Apply "Lock Tight#2701".
Apply
grease
Pilot check valve601681000
- 52 -
5.3 Construction of outrigger cylinder (URV500)URV500 Series Standard
Before fastening hexagon socket screw for the cylinder cover and piston, apply “LOCK TIGHT#2701”.
Construction of the Part where Pilot Check Valve is Fitted
- 53 -
5. 4
Co
nst
ruct
ion
of
inn
er b
ox
Aplly"LockTight#262" Aplly"LockTight#262".
Base
Innerbox
Stopper
Cushion
Hoseband
Stopperpin
CableAss'y
Boots
Wire band
Wire
20
Aplly"LockTight#262".
アウトリガ最大張出位置�
Lever
Stopper
16
Positionwhere
outriggers
are
extendedto
theirextremes
Proceduresforadjustingloosenessofoutriggers.
(1)Withtheinnerboxstored,adjusttheboltforthegapto
the
baseto
be1.5mm
thensecure
theboltwithanut.
(2)Withtheinnerboxextendedto
itsextreme,tightenin
the
hexagonsocketheadscrewuntilithitsagainsttheinnerbox,
thenloosenitby1/2
turnsto
secure
itwithanut.
(3)Checkthattheinnerboxmakesasmooth
extensionand
retraction.
Gapbetweenbaseandinnerbox
should
be1.5mm
withinnerboxstored.
Secure
wirewithbolt.
Lever
Openedto
itsmaxim
um.
How
tofitcable
ass'y
1.Afterthecable
ass'yhasbeenattachedto
thestopperpin
atthe
rearendofinnerbox,fitthehosebandsecurelyinto
therecess(φ
15.5)ofthepin.
2.Proceduresforconnectingtheleverwiththecable
ass'y.
(1)Allowthewirethroughthelever.
(2)Pullthewirewiththeleveropenedto
itsmaxim
um.
(3)Secure
thewirewithabolt(M
5×8)withthestopperpin
protrudedby20mm
from
thebottom
ofinnerbox.
3.Attachtheboots
tothecollarandfixitattherearendto
thenut
withthewireband,thencutoffanexcesspartofwireband.
- 54 -
6. HOIST WINCH
6. 1 Construction of Hoist Winch and brake shoe adjusting procedure
Motor
Brake Shoe Ajusting procedures1.Tighten the castle nut lightly with a spanner.2.After tighning,loosen the castle nut for approx.1/6 turnand within this range align the castle nut with the hole in thegear shaft;and fix it with the split pin.
3.Replace the break shoe every 3years.
After assembling,
apply grease toengaging toothsurfaces of thegear.
Gear4
Drum
Gear2
Gear1
Disk
Ratchet Wheel
Brake Shoe
Casing
Breather
PlainWasher
CastleNut
Split
Pin
Apply"Lock Tight#242"
Pay attentionto its direction.
Bearing
Rotate the gear shaft tocheck that the pawl makesa smooth movement.
- 55 -
6. 2 Caution to be taken when reassembling hoist winch
Ratchet Wheel
2 2
2
1
2
3
4
Check that the spring is caughtin the drill hole on the pawl.
Dimensions on both sidesshould beequally arrangedwhen fitting the ratchet wheel.
Set bolt position
Tightening order of bolts for mounting reduction gearTighten the hexagon socket head screws in diagonal orderafter the set bolt has been fastened first to align each screw hole.
- 56 -
6. 3 Cause of Troubles and Measures to be Taken(1) Hoist winch
Problems Possible cause Measures to be taken
Pressure does not rise. • Pump is faulty.(Pressure does not rise at idling speed.)(Total pressure required for operation isinsufficient.)
• Replace.
• Relief set of control valve is faulty.(Pressure rises but not enough.)
• Adjust or replace.
• O-ring and other parts of relief valve ofcontrol valve are faulty.(Adjusting bolt of relief valve is tight-ened but unable to control pressure.)
• Replace parts or replace reliefass’y with new one.
• Hoist motor is faulty.(Quantity of drain is larger than the spec-ified.)
• Replace.
Pressure rises but hoistingup impossible.
• Drum or internal mechanism of reductiongear is faulty.
• Overhaul reduction gear.• Inspect the drum
Pressure rises but loweringis impossible.
•Brake shoe is over-tightened..
•Drum or reduction gear is defective.
• Adjust tightening of brakeshoe.
• Overhaul reduction gear.• Check drum.
Unable to maintain suspend-ed load.
• Brake shoe is faulty.• Pawl is faulty.
• Replace brake shoe.• Replace pawl.
When lowering, huntingoccurs.
• Brake shoe is faulty.
• Over-tightening of brake shoe.• Internal mechanism of reduction gear is
faulty.
• Inspect brake shoe and checkquantity of oil.
• Adjust tightening of nut.• Disassemble reduction gear.
When hoisting up, clatteringsound is heard.
• Spring pressing the pawl against slideplate is faulty.
• Bushing the part of fitting pawl is wornout.
•Replace spring.
• Replace bushing.
- 57 -
7. H
OO
K
Nut
Aplly
"LockTight#242"
Aplly
grease
Hook
Bearing-Thrustball
90
Aplly
grease
Ifthegapofmore
than2mm
isconfirm
ed,
checkthehook,thethrustbearings,
andthenuts
andreplace
adeform
ed(w
orn
out)component.
Entire
screwthread
(both
sides)
Enlargedportion
where
sealingagent
isto
beapplied.
Springpins
- 58 -
8. SLEWING
8. 1 Slewing reduction gear(1) Construction of slewing reduction gear
Casing
Worm wheel
Breather
Gear shaft
Bearing
housing
Crown nut
Snap ring
Teper roller bearing
Worm shaft
Taper roller bearing
Ball bearing
Crown nut
Dust seal
Flange
bolt
Nut
- 59 -
(2) Construction to be taken when reassembling slewing reduction gear
Assemble the worm
wheel with the mark"V"directed upward.
Bearing housing
Flange bolt
Tightnig torque:167±20N-m(17±2kgf-m)
Nut:Apply "Lock Tight#262"before tightening it.
Fill up with grease here.
Use Lithium soap radical grease
(such as Rizonix grease No.1 or Kyseki)
Note: Tighten the nut to the extent thatthe gear shaft can be rotated to eitherdirection with your both hands.
Apply Grease to
the inside ofdust seal.
ReferenceTightening torque:20N-m(2kgf-m)
Apply "ThreeBond
#1401"to it.
Dust Seal
- 60 -
(3) Slewing reduction gear disassembly procedures
Remove a snap ring (H-80) retaining the taper roller bearing which sustains the worm shaft.
Turn the gear shaft counterclockwise, and pull out the worm shaft from the casing. (Use of special tool forremoving worm shaft is recommended.)
Remove 8 pcs. of bolt (M10 X 25 ) which fasten the bearing housing and pull out the housing, utilizing 3 pcs.of bolt for 3 through holes in the housing.
- 61 -
This figure shows the pulled out housing with gear shaft and worm wheel.
Grip the housing with a vice and pull out the worm wheel with a gear puller.
Pull out the collar which is assembled in the nut.
- 62 -
Pull out the O-ring which is assembled in the nut.
With a pin spanner, remove the nut which retains the taper roller bearing.
Note: To the threaded part of the nut, “LOCK TIGHT” was applied. Therefore,when loosening, warm up lightly the threaded part with gas flame, and thenloosen. When reassembling, be sure to apply “LOCK TIGHT #262” to thethreaded part.
- 63 -
8. 2 Turntable Mounting Procedures(1) Turntable mounting procedures
1
212
19 614
8
16
4
18
3
10
17 15
9
11
7
513
After assembling,apply grease to
engaging tooth
surfaces of the gears.
Base
Pinion gear
Turntable
Bolt
Tempered bolt
1.Install the slewing reduction gear to the base.
2.Set the turntable on the base to screw-in the bolts formounting turntable lightly.
Position the Soft zone Mark "S" on innerside of turntable to the rear (Bed side)
when mounting the turntable.
Rear(Bed side)
Front
"S"Mark(Soft Zone)
Slewing reductiongear ass'y
3.Insert the thickness gauge(0.1～0.2mm)into the space between
the turntable gear and the pinion gear,and press strongly
the turntable to the pinion gear.
Ｓ
- 64 -
(2) Position of soft zone, tightening sequence of bolts and tightening torque
1
212
19 614
8
16
4
18
3
10
17 15
9
11
7
513
"S"Mark(Soft Zone)
Rear(Bed side)
Front
Position the Soft zone Mark "S" on innerside of turntable to the rear (Bed side)when mounting the turntable.
Tightnen the bolts in the numerical order as illustrated inthe figure above.
Tightning sequence of bolt formounting turntable
Parts Name Torque
BoltM14X40L716114D40
167±20N-m(17±2Kgf-m)
Model
V23*,V26*V29*
V34*,V37*V50*
BoltM16X50L716116050
Tempered BoltM20X80L(12T)093T41020
255±29N-m(26±3Kgf-m)
471±39N-m(48±4Kgf-m)
Tempered BoltM20X95L(12T)088541040
471±39N-m(48±4Kgf-m)
V23*,V26*V29*
V34*,V37*V50*
Tightning torque for boltsfastening slewing reduction gear ass'y
Tightning torque for boltsfastening turntable
Model Parts Name Torque
Slewing reduction
gear ass'y
Turntable
Tempered bolt
Ｓ
12
UNIC Note:The bolts for fastening the turntable(tempered bolts)must
be UNIC genuine bolts,on which mark "UNIC12"is inscribed on the head.
Tighten the mounting bolts in diagonal order.
Before mounting bolts are tightened,degrease the bolts and the tapped holesto apply "Lock Tight #262" to the bolts andtighten them with an equal torque.
- 65 -
9. C
OL
UM
N
9. 1
Tig
hte
nin
g t
orq
ue
for
bo
lts
fast
enin
g c
olu
mn
an
d t
igh
ten
ing
ord
er
811
10
23
9
75
64
1
MJ12×50(12T)08H651060
Tightentheboltsinthenumericalorder
asillustratedinthefigure.
Whenassembling,apply"LockTight#262T"
TightningTorque:8Kgf・
m
Turntable
InspectionHole
forbolts
mounting
turntable
BoltsforColumn
BoltM12×30(10T)
711912D30
BoltsM12×30(10T)
711912D30
Whenassembling,
apply"LockTight#262T"
TightningTorque:8Kgf・
m
Whenassembling,apply"LockTight#962T"
TightningTorque:25Kgf・
m
Column
Stopper
SwivelJoint
- 66 -
10. SWIVEL JOINT
10. 1 Construction of swivel joint and position of hoses
Detail of STKSeal fitting to A
SealRing
Square
Ring
A
To hexagon socket head plug,apply
"Lock Tight#202"before tightening.(Don't use a sealing tape.)
When assem-
bling,fill up
with grease.
Telescoping
Extension
Telescoping
Retraction
HoistDown
DerrickRaising
DerrickLowering
HoistUp
HoistDrain
Hoist
UpDerrickRaising
DerrickLowering
Telescoping
Retraction
HoistDrain
Telescoping
Extension
HoistDown
When assem-
bling,fill upwith chassisgrease.
Inner Joint
Outer Joint
- 67 -
Figure shows swivel joint is installed.
Figure shows outer joint is taken out.
INNER JOINT
OUTER JOINT
- 68 -
10. 2 Swivel joint assembling procedures
Illustration of STK Seal fitting
SQUARE RING
CLINCHED PART
100mm
140mm
CLINCHED PART
SEAL RING
ROUND BAR2φ�
φ2 PIPE
20φ�
• After fitting the square ring, check to see if it is twisted,then fit the seal ring.
When fitting seal ring, it is recommended to usethe jib as shown below.
INNER JOINT
A
B
• The upper most A and the lower most B of the innerjoint must be filled up with grease. To prevent the mix ofwater or others and the corrosion).
• To the part where STK seal is to be fitted, apply chassisgrease sparingly.
• Put the outer joint over the inner joint while taking carethat the STK seal fitted to the inner joint will not be bit.
- 69 -
11. SLIP RING
11. 1 Construction of slip ring and its fitting position
Black
White
Yellow
Red
Green
WhiteBlack
Red
Yellow
White
Black
White
Red
GreenYellow
Green
Apply sealing agent, "Three Bond #1220C", to the mounting surface(over entire circumference).Degrease sealing surface thoroughly.
- 70 -
12. C
ON
TR
OL
Operation
ControlValve
Derrick
Hoist
TeleScoping
Slewing
Outrigger
Roller1
LeverAss'y
Stopper
Turn
buckle
Pipe1
Accelerator
CableAss'y
Rod
Roller2
Plate2
Pipe2
Plate1
Derrick
Hoist
TeleScoping
Slewing
Outrigger
9mm
11mm
Motorforslewing
AB
P T
Connections"P"to
"A",and"B"to
"T"are
establishedbymovingthe
spoolto
therightallowstheslewingmotorto
bedriven.
Ifitmeasures1.5mm,
tightenthenutin
by1turn.
1
2
①Throwtheleverdown.
②Rodisshiftedto
theright.
③Leverontherightpushesthepipe1.(Enginecannotbe
raceduntilithitsthepipe1.)
④Plate
1pushesroller1.
⑤Enginespeedincreasesasacceleratorcable
ispulled.
Nut
(left-handthread)
Nut(right-handthread)
5
2
Ifspeeddifferenceistoolargeaccordingto
operatingdirection
whenin
manualoperation:Loosenthenutto
adjusttheturnbuckle
tothe
distancespecifiedaboveasayardstick.
1
4
3
Bolt
Forsettingupperlim
itto
enginespeed.
6mm
4.5mm
- 71 -
Telescoping
Up
Right
Left
Outrigger
Left
Right
URV23*,26*,29*
URV34*
Hydraulic
motor
(Slewing)
740360027
Hydraulic
motor(Hoist)
URV23*,26*,29*→
740320029
URV34*,37*→
740320026
Down
URV37*
Derrick
Pilotcheckvalve
601681000
Jointblock(Orifice¿1.8)
090B65010
Pilotcheckvalve
601681000
770290159
Counter-balancevalve
CB-03ED-W
606022000
Counter-balancevalve
CB-03ET601473000
Cartridge
filter
740580204
Gaugeport
770290147
Fusevalve
Loadmeter
770363331
Reliefvalve
606042000
740290148
Left
Right
740290148
Slewing
Hoist
Hydraulic
pump
PartsNo.
740240028
531700rpm
20.6MPa
Rateddelivery
Ratedrevolution
Pressure
relief
valvesetting
(210Kgf/cm)2
/min
Model
URV23*,26*,29*
740240067
601700rpm
20.6MPa
(210Kgf/cm)2
/min
URV34*,37*
Elbow(withfilter)
Adapter(withfilter)
Adapter(withfilter)
45°elbow(withfilter)
13. H
YD
RA
UL
ICC
IRC
UIT
DIA
GR
AM
13. 1
Hyd
rau
lic C
ircu
it D
iag
ram
(U
RV
230,
UR
V26
0, U
RV
290,
UR
V34
0, U
RV
370)
- 72 -
13. 2
Hyd
rau
lic C
ircu
it D
iag
ram
(U
RV
500)
Right
Left
740290148
Hydraulic
motor
(Hoist)
740320026
770290159
Counter-balancevalve
CB-03JT606004000
Checkvalve
606006000
Gaugeport
Gaugeport
Reliefvalve
606042000
Cartridge
filter
740580204
Fusevalve
Loadmeter
770363331
Derrick
Counter-balancevalve
CB-03ED-W
606022000
Down
Up
Hoist
Telescoping
770290147
Hydraulic
motor
(Slewing)
740360025
Pilotcheckvalve
601529000
Outrigger
Left
Right
Hydraulic
pump
PartsNo.
740240036
601400rpm
20.6MPa
Rateddelivery
Ratedrevolution
Pressure
relief
valvesetting
(210Kgf/cm)2
/min
Model
URV50*
Slewing
Adapter(withfilter)
Elbow(withfilter)
45°elbow(withfilter)
- 73 -
14. C
ON
TR
OL
VALV
E
14. 1
Gen
eral
vie
w a
nd
sp
ecif
icat
ion
s
Tankport
Pumpport
Reliefbody
605133010
Tierod
25.5
Valvebody
601625010
Valveend
605134010
Nut
Nut
Reliefvalve
606042000
Tightningtorque:
8820±980N・cm
(900±100kg・cm)
Gaugeport
Slewing
Outrigger
Outrigger
Derrick
Hoist
Telescoping
Rateddelivery
Ratedpressure
Tightningtorque
oftierod
Maxmum
perm
issible
pressure
of
tankport
60
/min
20.6MPa
(210kg/cm
)
0.3MPa
(3kg/cm
)
Specifications
2450±245N・cm
(250±25kg・cm)
2
2
- 74 -
14. 2 How oil flows in control valve
Spool strokeHoist,Slewing→6.5mmDerrick,Tele,Out→7.5mm
Neutralposition
B A
P
T
P
P
T
T
B A
B A
- 75 -
14. 3 Relief valveThe relief valve is a preventive valve to control the pressure in the hydraulic circuit.
The pressure should not become higher than the specified.
(1) Construction of relief valve
(2) Adjusting procedures
The hydraulic pressure in the relief valve is decided by the movable allowance of its adjusting screw. For adjusting the pressure,loosen the cap nut and the nut to turn the screw clockwise with a screwdriver to increasethe pressure.Turn the screw counterclockwise to reduce the pressure.
Remove the cap nut and loosen the nut.Turn the screw clockwise with a screwdriver to increase the pressure.Turn the screw counterclockwise to reduce the pressure.
When setting up,be sure to watch the pressure meter while one of the cylinders (outrigger or telescoping orderrick)is being retracted.Engine speed at the time of setting up the hydraulic pressure should conform to the rated revolution of thepump.Never set up the hydraulic pressure when the engine is running at idling speed or higher speed.
When tightening the nut and the cap nut,the adjusting screw may be loosened.Therefore, hold the screw with a screwdriver and lock the nut with spanner when tightening the nut.
Cap nut
Nut
Cap
Valve seat
Pilot spring
Pilot valve
Pilot spring
Gauge port
Relief bodyTank
Adjustingscrew Pump port
Pilote valve
- 76 -
(3) Check points of relief valve
If the pressure it not increase, check the points of the relief valve as shown below.
D
E
CBA
. Foreign substance is caught in A section and the seat surface is damaged.
. The O-ring in B section is broken.
. The O-ring in C section is broken.
. Foreign substance is caught in the drill hole of the D main valve.
. Foreign substance is caught in E section and the seat surface is damaged.
Note : If the above-mentioned points have no trouble,the hydraulic pump is defective.
- 77 -
15. OVERWINDING ALARM
15. 1 Function of overwinding alarm and procedures for operation(1) Function of overwinding alarm
Cord reel
Overwinding detector
Weight for overwinding alarm
The device automatically makes an alarm sound to warnthat the wire rope is overwound when the hook comesclose to the boom top.
Overwindingalarm switch� ON
OFF
(This shows panel on the right)
1. Turn ON the overwinding alarm switch before startingthe crane operation.If the alarm sounds while the hook is being hoisted orthe boom is being extended, stop the crane operationimmediately and lower the hook or retract the boom.
2. Turn the switch OFF after completion of the crane work.
(2) Procedures for operation
The overwinding alarm will not function even if the hook is under overwound condition with theoverwinding alarm switch turned OFF.Be sure to turn the switch ON before starting crane work and check that the alarm sounds everytime when the weight for overwinding alarm is lifted up.
Since the length of wire rope hanging the weight is specified by laws and regulations con-cerned, do not make it short at random.
The alarm will not sound if the wires(cords) connected to the overwinding detector at the boomtop is broken.Pay attention to the wires(cords).
CAUTION
- 78 -
15. 2
Gen
eral
vie
w
Black
Earth
WhiteGreen
Red
Yellow
Black
Green
Vehiclefusebox
Red
Cigarettelighter
Red
Red
Red／Black
Slip
ring
Black
White
YellowG
reen
Thisshowspanel
ontheleft.
Thisshowspanel
ontheright.
Tobeconnectedtoslip
ring.
Overwinding
alearm
switch
Horn
Horn
Tobeconnectedtoterm
inal"S"
ofvehiclehorn
relay
Tovehiclehorn
switch
- 79 -
(1) Boom top in detail
Overwindig
detector
Earth Fit push-nut while paying attentionthat overwinding wire makes asmooth movement.
Fit the weight directed as illustrated.
- 80 -
15. 3
Illu
stra
ted
wir
ing
dia
gra
m, o
verw
ind
ing
ala
rm
Switchbox
(left)
Horn
Overwinding
relay
Overwinding
buzzer
Switchbox
(right)
Slip
ring
Black
Black
Red Red／Black
Red
Black
Green
Yellow
White
Green
Yellow
White
Black
Red
Green
Black
Green／WhiteEarth
Horn
Red
Green
Black
Black
Green
White
／Black
Red
／Black
Red
／Yellow
Overwinding
alarm
switch
Cord
reel
Overwinding
detector
Black
Black
Tobeconnectedtopowersupply
(+24V)
Tobeconnectedtochassisground
Horn
relaymountedonvehicle
Reservepowersupply
- 81 -
15. 4
Ele
ctri
c ci
rcu
it d
iag
ram
Overwinding
detetor
603218000 Black
Black
Cord
reel
Overwinding
buzzer
ＳＢ
Ｈ
Vehicle
fusebox
(10A～20A)
Vehicle
horn
Vehicle
horn
relay
Horn
button
switch
750303050
D.C24V
Green
Green
Black
Black
Back
lamp
switch
Back
lamp
Backlamp
switch
Horn
Green
Inside
cab
Crane
Cigarette
lighter
Red
Black
Red／Yellow Red
White
Black
White
Red
Green
Black
Black
Black
Red
Red
Red
Red／Black
Red
Green
／White
Green
／White
Red／Black
White／Black
Black
Black
Overwinding
alarm
switch
Overwinding
relay
Black
Black
Green
Yellow
Green
Yellow
Black
Slip
ring
V23*
750518031
V30*
V34*
V37*
750518031
750518031
750518027
750518032
V26*,29*
750518031
750518031
750518027
V50*
750518031
750518031
750518040
N.O
N.O
Horn
switch,vehicleside
Tableofcord
reelapplication
2ndsection
3ndsection
4ndsection
5ndsection
- 82 -
16. FILTERS (Suction Filter and Line Filter)(1) Suction filter and line filter
SUCTION FILTER LINE FILTER
(2) Suction filter
The suction filter is attached to the inside of thfe oil tank at the end of the pump suction pipe. It is a notch-wire type.When changing hydraulic oil, check the filter that it is not clogged up. If it is, clean it.Care must be taken against a clogged-up filter because it will adversely affect pump suction, possibly causingcavitation, abnormal noise, and pump failure.
(3) Line filter
The line filter is installed halfway between the control valve and oil tank. It is a filter paper type with a bypass valve.Filter replacing interval varies depending on the frequency of use. Generally, hpwever, replace it for the first timethree months after initial use of the crane, and once a year thereafter.
Return filter
- 83 -
17. CYLINDERS, HOW TO PUNCH
(1) Purpose
Troubles injuring the inside surface of cylinder tube due to screws mounting piston being loosened have beenhappened.Therefore, we not only upgraded the screw lock agent “LOCK TIGHT #262” to “#2701” to strengthen adhesion butalso added punching process (partly carried out for derrick cylinder). The section defines how to punch.
(2) Punching procedures
1. Use a punch whose tip is hard and sharp enough.
2. Hit the punch head hard enough with a hammer with the punch put at a distance of 1 1.5mm from the screw end.3. Hit the punch head so hard that the diameter of punch mark will be more than 1.5mm4. Punch 2 places around the screw thread in diagonal position.
Piston
Hexagon socket head screw
Tighten each hexagon socket
screw with "Lock Tight #2701"
applied to the threads to
punch specified places close
to screw threads.
Fig. 1
Points to remember1. Take care not to break the target piston while punching.2. Make the clear punch mark as illustrated in Fig. 1.3. Punch within 5 minutes after “LOCK TIGHT” has been applied.
(Try not to give shock to the area where “LOCK TIGHT” has been applied as it starts curing.)
- 84 -
18. TELESCOPING/DERRICK CYLINDER ASS’Y, MEASURES TOPREVENT PISTON FROM BEING LOOSENED
DescriptionIn order to ensure preventing the pistons of telescoping and derrick cylinders from becoming loose, fix the screwthreads on the rods and the pistons with the adhesive “LOCK TIGHT #638” (excepting for telescopic cylinders).Besides, securing piston with screws and punching after application of “LOCK TIGHT #2701” are also to be carried outas before(Rods and pistons are to be fixed perfectly by application of adhesive “LOCK TIGHT #638”.)
Main pointsRods and pistons are fixed by tightening after application of “LOCK TIGHT” to the threads on the rods and on thepistons.Apply “LOCK TIGHT” to the entire circumference of 2nd to 3rd threads from the thread end.Apply the primer as the gap in the effective diameter of threads exceeds 0.1mm.Use type #7474 (primer T) for the primer.(Although type #7469 is being used currently, type #7474 is more effective as the target adhesion is to be at between metal components.)
Note : Pay special attention to observing the points to notice illustrated below while working ascuring itself and curing time of “Lock Tight” depends largely on how the adhesion procedureshave been carried out.
Points to notice on procedures to apply “LOCK TIGHT”
Procedures1. Degreasing and cleaning 2. Priming coating 3. Application of “LOCK TIGHT” 4. Assembly 5. Curing
(1) Degreasing and cleaning• Separate the oil well enough which has been applied to the threads (of rod/piston) to wipe it off with a rag or blow
it off with compressed air.When blowing it off with air, remember that the unclean oil will not be blown off but will just escape along thethreads.
• In case of spray cleaning as well, target oil will not be removed but return if doing nothing but just spraying.• After carrying out degreasing and cleaning, wait until cleaning fluid is dried up completely.
(2) Priming coating• After primer #7471 has been applied, do not wipe it off but allow as it is for 5 10 minutes to dry naturally.
(Application of “LOCK TIGHT” without complete drying may result in reduction of adhesive strength by half.)• Although a component primed is effective for 7 days, store it by preventing dust and/or oil from being stuck
before use.• When “LOCK TIGHT” is applied to a component and it is shut off air, curing will start after 5 minutes from
application and will reach approx. 70% of curing in about 2 hours.(Curing time will be shortened by priming, but theoretical adhesive strength will be 85% against a componentwithout priming.)
• Do not dip a primed component in “LOCK TIGHT” agent directly.• Carry out priming at a place where well ventilated because priming agent escapes into air as vapor.
(3) Application of “Lock Tight”• Apply “LOCK TIGHT” sufficiently to the threads to fill them.
Apply “LOCK TIGHT” to the component mounting o-ring (piston) at the 2nd to 3rd threads from the thread end.(Refer to “Estimated adhesive consumption” illustrated below.)
• “LOCK TIGHT #638” is an anaerobic adhesive so that the part forced out will not cure because it is in contactwith air.In addition, sticking of “#638” to o-rings and packings may cause the rubber to be deteriorate (as incrack).(When it is possible to be stuck on the rubber such as o-rings and packing, apply “LOCK TIGHT” to the threadson piston side to avoid sticking to them.)
• Try shortening the working period from the time when application of the “LOCK TIGHT” to a primed componentto completion of fitting the component.
- 85 -
(4) Assembly
• Tighten the component after application so that applied “LOCK TIGHT” may spread entirely to the threads of thecomponent.
• Since “LOCK TIGHT” forced out of the threads will not be cured, take care not the “LOCK TIGHT” to be outduring application as hydraulic oil is to be contaminated with it.
• Work quickly as the “LOCK TIGHT” in the treads starts curing.• Curing speed differs according to temperature (ambient temperature included) of target component.
Since curing time becomes excessively longer at a temperature below 10°C, work with the component temperatureraised to 15°C or over.
Chart of breakdown torque vs. curing timeWhen using "Lock Tight #638"with primer #7471 (primer T)
Bolt:M10×P1.5- L2SNut: M10×P1.5Material:Soft steel (raw)
Ambient temperature 35℃
Ambient temperature 25℃
Ambient temperature 15℃
Ambient temperature 0℃
Breakdowntorque(kgf/cm)
Curing time (Hr)
0 1 3 6 24
300
200
100
(5) Curing
• This is a period while an adhesive is being joined.Store the components still during the period.(Recommended conditions is at an component temperature of 15°C min. for more than 1 hour.)
Reference:Estimated adhesive consumption when it is applied to 3 spirals of thread entirely.
Threading diameter Amount to be appliedM40 0.46 ccM60 0.69 ccM80 0.92 ccM100 1.15 ccM120 1.38 cc
Which primer of #7649 and #7471 should be used together with “Lock Tight #638”.Curing speed of #7469 is faster than that of #7471 but adhesion strength is lower.If adhesion is to be carried out between metal articles, #7471 gives better result.Type #7471 is to be used in normal case (refer to manufacturer’s comment and catalog specifications).
- 86 -
19. INSUPECTION PROCEDURES WHEN CYLINDER SINKE
19. 1 Inspection of telescoping cylinder (3-section or 4-section boom)
Load
100
100
100
Fig1
Boom2
Boom3
Boom4
Boom1
Load
100
Fig4
Boom2
Boom1
Fig2
Extention
hose
Retraction
hose
Fig3
Counterbalance
valve
Put a mark on each boom
Put a mark on each boom
Opening for hose piping of boom1
Fault in seat surface
(1) Preparation before inspectionAllow booms to be horizontal and extend them fully to put amark on each boom section (refer to Fig. 1).Raise booms to their maximum to sling a load.In order to release pressure remained in the telescoping system,stop the engine and shift the manual lever for telescopingbooms.
(2) Starting inspectionRemove the retraction hose to check if oil overflowscontinuously out of the cylinder port of retraction side.At he same time, also check that which boom section sinkshow far to grasp condition of booms as a whole.If no oil flows out of the port of retraction side, the cylinder isnormal.Next, remove the extension hose, and if oil overflowscontinuously out of counter-balance valve port of extensionside, there may be faulty on the seat surface of counter-balancevalve (refer to Fig. 3).In addition, check how far boom3 sinks simultaneously.
Caution:In order to release pilot pressure in the retraction side,be sure to remove the extension hose after theretraction hose has been removed (refer to Fig. 2).Since overflowing oil out of the port on retraction sidemeans internal leakage in the cylinder, check tele1 andtele2 separately.Be sure to measure the how far each boom sinks as it isan important point for judging that it is normal orabnormal.
(3) Inspection of tele1Extend booms to a position where it is a little bit shorter than2-section boom to put a mark on the boom (refer to Fig. 4).Raise booms to their maximum to sling a load.In order to release pressure remained in the telescoping system,stop the engine and shift the manual lever for telescopingbooms.Remove the retraction hose.If oil overflows out of cylinder port of retraction side andboom2 sinks, there may be internal oil leakage in tele1.In addition, check how far boom2 sinks simultaneously.
(4) Inspection of tele2Allow booms to be horizontal and extend them fully to put amark on each boom section (refer to Fig. 1).Raise booms to their maximum to sling a load.In order to release pressure remained in the telescoping system,stop the engine and shift the manual lever for telescopingbooms.Remove the retraction hose.If oil overflows out of cylinder port of retraction side andboom3 sinks, there may be internal oil leakage in tele2.In addition, check how far boom3 sinks simultaneously.
The same procedures in checking boom sinkage are applied for5-section boomBe sure to check the boom sections one by one reliably.
- 87 -
19. 2 Inspection of derrick cylinder(1) Preparation before inspection
Raise booms to an angle of approx. 30°.Put a mark on the rod with a felt pen (refer to Fig. 1).In order to release pressure remained in the derrick system, stop the engine and shift the manual lever forraising/lowering of booms.
(2) Starting inspection
Remove the lowering hose to check if oil overflows continuously out of the cylinder port of lowering side.At he same time, check also that how far the rod shifts.If no oil flows out of the port of lowering side, the cylinder is normal.
Next, remove the raising hose, and if oil overflows continuously out of counter-balance valve port of raising side,there may be faulty on the seat surface of counter-balance valve (refer to Fig. 3).In addition, check how far the cylinder sinks simultaneously.
Caution:In order to release pilot pressure in the lowering side, be sure to remove the raising hose after thelowering hose has been removed (refer to Fig. 2).If oil overflows out of the port on lowering side, it suggests internal leakage in the cylinder.Be sure to measure the how far each boom sinks as it is an important point for judging that it is
Fig2
Lowering
hose
Raising
hose
LoadFig1
Fig3
Counterbalance valve
Put a mark on the rodwith felt pen
Fault in seat surface
- 88 -
19. 3 Inspection of outrigger cylinder(1) Preparation before inspection
Extend outrigger cylinders to their extremes.Put a mark on the rod with a felt pen (refer to Fig. 1).In order to release pressure remained in the outrigger system, stop the engine and shift the manual levers forextension/retraction of outriggers.
(2) Starting inspection
Remove the retraction pipe to check if oil overflows continuously out of the cylinder port of retraction side.At he same time, check also that how far the rod shifts.If no oil flows out of the port of lowering side, the cylinder is normal.
Next, remove the extension pipe, and if oil overflows continuously out of the pilot check valve port of raisingside, there may be faulty on the seat surface of pilot check valve (refer to Fig. 2).In addition, check how far the cylinder sinks simultaneously.
Caution:In order to release pilot pressure in the retraction side, be sure to remove the extension pipe afterthe retraction pipe has been removed (refer to Fig. 1).If oil overflows out of the port on retraction side, it suggests internal leakage in the cylinder.Be sure to measure the how far each boom sinks as it is an important point for judging that it is
URV230,260,290
URV300,340
URV370,500Fig1
Retraction hose
Extension
hose
Extension
hose
Retraction hose
Extensionhose
Extensionpipe
Retraction hose
Retractionpipe
Joint
Joint
Fig2
Extention
Retraction
Put a markon the rod.
- 89 -
Inspection before operation and periodi-cal inspection.Preform the inspection before operation andindependent periodical (monthly and annu-al) inspection, and make repairs immediatelywhen anything abnormal is found.
Caution signboard Whenever carrying out maintenance andinspection, be sure to hang out a "cautionsignboard" and do not try operating thecrane.
Be sure to replace consumable itemsaccording to the replacement criteria.Failure to observe the replacement as speci-fied may cause a breakdown and warrantywill not be given even if it is within the peri-od to be applied.
When parts need to be replaced or anythingabnormal is found, ask an authorized UNICservice shop for inspection or repair assoon as possible.
WARNING
20. MAINTENANCE AND INSPECTION
- 90 -
20. 1 Inspection\(1) Inspection before operationIn order to secure safe operation and improve working efficiency, be sure to inspect each part of the crane accordingto the table as follows;
Device Inspection for:
P.T.O.Oil leakage, Unusual noise
Hydraulic oiltank
Oil level, Oil leakage
OutriggersOperation, Deformation,Damage, Oil leakage, Cracks
Hoisting winchOperation, Braking func-tion, Irregular winding
Slewing device Operation, Oil leakage
Boom(derrick-ing)
Operation, Oil leakage,Mounting of foot-pin
Boom(telescop-ing)
Operation, Oil leakage,Deformation, Cracks,Mounting of fixing pin
HookRotation of hook, Function ofhook safety latch
Device Inspection for:
Wire ropeDamage, Condition ofrope-end
Overwindingalarm
Operation, Buzzer sound
Load meter Oil leakage, Operation
Warning horn Operation
Piping(hydraulic) Oil leakage
BaseFastening tightness ofcrane body mountingbolts
Slinging imple-ments
Missing necessary items
Uni-hookOperation of automatic stopand storing function
CleaningKeep the machine clean at any time.Sand and fine dust may cause an abnormal wear of themachine.Do not wash the machine by splashing water with high-pres-sure to prevent the water from entering into the electric sys-tem which may cause malfunction of the machine.
Always keep the machine in good condition so that it is ready for normaloperation.
CAUTION
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When the slewing device makes an unusual noise while oper-ating or traveling of the crane, or when a gap is created onthe mounting surface, contact a UNIC authorized serviceshop for inspection and/or repair.
The replacement of the return filter is depends on howoften the crane has been operated, however, as a generalrule, replace it after 3 months of initial operation andonce a year thereafter.
How to replaceGive the gasket a thin coat of oil.Screw in the cartridge and tighten it with your handsecurely.
(2) Inspection of the slewing bearing mounting bolts
20. 2 Replacement(1) ReplacementReplacement of return filter
Slewing bearing
Mounting bolts
Mounting bolts
Return filter
Cover
Inspection hole
Inspection of mounting bolts located inner race1. Remove the cover to inspection hole.2. Slew the boom so that each mounting bolt comes to the
center of inspection hole for inspection.3. Fit the cover as it was after inspection.
- 92 -
Wire rope is an expendable article and it will be damaged orbroken in its strand wires through a long period of use. Replace the rope according to following criteria.
1. Replacement criteria1. A rope in which amount of broken strand wires (exceptfiller wires) comes to more than 10% within a pitch of strand. Replace the wire ropes intended for use with this crane if 13pieces of strand wire have been broken within a pitch of
strand.
2. A rope being kinked.
3. A rope from which its diameter has decreased by morethan 7% of the nominal diameter. For example, if wire rope with a nominal diameter of 8mm isused, replace it when the diameter becomes 7.5mm. For length and construction of the wire rope for winding-up.
4. A rope which has been deformed and/or corroded exces-sively.
Be sure to replace a wire rope when it comes under thecriteria, item 1 through 4, illustrated above.
(2) Replacement of wire rope (for winding-up)
1
2
3
4
Diameter ofrope
Wear leather gloves when replacingwire ropes.
CAUTION
- 93 -
2. How to replace wire rope
1. Refer to the figure in the left for how to hook the wireropes for hoisting and for where to mount the weight foroverwinding alarm.
Boom top
Guide
Front of boom
Higher sideis to the front
Refer to the figure in the left for how to install hook.
For Uni-hook type
- 94 -
a
Wire rope end
40mm Where cut out
Wire clip(pay attention tomounting direction)
50mm
Arrow mark
Wedge(Diameter of wire rope=8mm)
Stopper
Projection on upper partof wire socket
Pass the pin through andtighten it securely with bolt.
If rope end is left by more than 40mm(as “a” illustrated-above), rope end is visible through this hole, if not, adjust length of rope end.
Wedge
2. How to fix the wire rope end
Winch drumWhen passing a wire rope end through the winch drum,pass it so that the rope end comes inside as illustrated in
the left.
Pay attention that wire rope end will not be jutted out ofthe winding-up area of winch drum.
In order to avoid irregular winding, wind up a wire ropeslowly on the drum along its groove with a proper tensionapplied to the rope to form the 1st layer.From the 2nd layer on, wind up the rope over the wound-up layer so that it is fit in each gutter formed betweenropes wound side by side of the layer below.
Wire socketWhen passing a wire rope end through the wire socket, besure to pass it as indicated by the arrows on the socket.Leave the wire rope end more than 40 mm as “a” illustrat-ed in the figure in the left.If it is passed from the opposite direction, service life ofthe wire rope shrinks as the wire rope is kept bent all the
time.
Do not forget to mount the wedge and the wire clip asillustrated in the figure in the left.
Pass the pin through with the wire socket held with yourhand and tighten it with the bolt securely.
- 95 -
3. How to correct the twisted wire ropes
Wire ropes tend to turn in the untwisting direction when theyare under tension.If two or more wire ropes are hooked together, they tend tobe twisted particularly while they are new.The twist will decrease as the ropes are getting fit to the
crane.
If wire ropes are twisted, correct them as follows; Unload the hook.
Extend the boom fully.
Set the boom to an angle of approximately 65°.
Unwind the hook until it comes close to the ground.
Check how many turns the wire rope has been twisted.
Hoist the hook and retract the boom to be on a storedcondition.
Remove the wire socket and turn the socket in theuntwisting direction by as many turns as the wire ropes havebeen twisted multiplied by the number of wire ropes hooked. Remember, however, that the wire socket may be turned up
to 4 turns at a time.
Attach the wire socket and repeat hoisting and loweringthe rope 2 or 3 times between extremes of lift. Then check if twist of the wire ropes is corrected.If they remain twisted, repeat the procedures shown above.
Wire socket
Untwisting direction
4 wire ropes
Wire rope’s twistingdirection
Note : Turn the wire socket in the direction opposite to wire rope twisting.
- 96 -
1. Replacement of gaskets and seals for eachcylinder
Although timing of replacing a part varies according to howfrequently the crane has been operated, replace gaskets andseals used in each cylinder after every 3 years of operation(period during which crane is not operated is included) inorder to operate the crane safely. Ask a local UNIC authorized service shop for replacement ofgaskets and/or seals.
Welding precautionsWhen welding is needed for some reason, do not use outrig-ger cylinder for welding ground as the cylinder rod and/or thepiston may be damaged by electric sparks due to currentflown in the inner part of cylinder.
(3) Replacement of expendable parts
2. Replacement of sliding plate of boom
Replace it every 3 years.
3. Replacement of brake shoe in hoistingwinch
Replace it every 3 years.
Brake shoe
●No grounding
Outrigger cylinder
Sliding plate
- 97 -
21. LUBRICATION
1 Precautions on lubrication
Lubricate according to "Lubrication chart" and keep the fol-lowing instructions in mind when carrying out lubrication.
Thoroughly clean filler ports and grease nipples beforelubrication.
Always supply new lubricant and prevent dusts fromentering inside.
When supplying grease into each nipples, be sure toinject it until old grease is forced out of it.
Do not carry out maintenance and ser-vice while temperature of hydraulic oil isstill high.
Temperature of both hydraulic andgear oils is high immediately after craneoperation so that accumulated high pres-sure still remains inside.Uncapping the filler port, draining oil, andreplacing filter while oil temperature is highallow hydraulic and/or gear oils to spout outand a scald may result.
WARNING
CAUTIONIn order to ensure smooth operation
of each part of the crane, minimum wear,and longer service life, be sure to supplylubricant as well as hydraulic oil whichis necessary to drive hydraulic equip-ment.
Warranty will not be given, even if it iswithin the period to be applied, for failureto observe the replacement of lubricantas specified.
- 98 -
Petroleum MakerBrand
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
((1). List of recommended lubricants
★★RECOMMENDED GREASE
(a) Chassis greaseUse NLGI No. 1 grade.
Petroleum Maker Brand
ESSO Chassis grease L
MOBIL HP221
CALTEX Multifak EPI
SHELL RETINAX-CD
(b) Molybdenum greaseUse NLGI No. 2 grade.
Petroleum Maker Brand
ESSO Beacon Q2
MOBIL Mobilplex Special
CALTEX Molytex Grease EP2
SHELL Retinax AM
★★RECOMMENDED GEAR OIL
Use API Service GL-4 gear oils.
Petroleum Maker Brand
ESSO Standard gear oil 90
MOBIL Mobilube SAE 90
CALTEX Universal Thuban SAE 90
SHELL Shell Spirax EP 90
★★RECOMMENDED HYDRAULIC OIL
Use industrial-type hydraulic oil;ISO VG 46 for most temperaturesISO VG 32 extremely low temperatures
- 99 -
((2) Lubrication chart
⑰�⑧�
⑪�
③�
⑯�
④�
①�
⑫�
⑨�
⑩�⑥�⑤�
⑦�
⑬�
⑮�
②�
⑭�
3-section boom
4-section boom
5-section boom
6-section boomDo not apply grease to the slide-sheave pin.
Serv iceinterval Part to be lubricate No. of
part Lubricant Tool
Daily
①Boom slide plate(Underside/sides of boom sections②, ③) 3-section boom
②Boom slide plate(Underside/sides of boom sections②, ③, ④) 4-section boom
③Boom slide plate(Underside/sides of boom sections②, ③, ④, ⑤) 5-section boom
④Boom slide plate(Underside/sides of boom sections②, ③, ④, ⑤, ⑥) 6-section boom
⑤Boom slide plate(Upper side of boom section ①) ⑥Boom foot pin⑦Upper support pin of derrick cylinder⑧Lower support pin of derrick cylinder⑨Oil tank(59l)
2
3
4
5
21111
Molybdenum grease
Molybdenum grease
Molybdenum grease
Molybdenum grease
Molybdenum greaseChassis greaseChassis greaseChassis greaseHydraulic oil(up tomiddle of level gauge)
Manual application
Manual application
Manual application
Manual application
Grease pumpGrease pumpGrease pumpGrease pump
Weekly⑩Winch drum gear⑪Slewing gear(to gear-teeth)⑫Propeller shaft
113
Chassis greaseChassis greaseChassis grease
Grease pumpManual applicationGrease pump
Monthly
⑬Winch reduction gear(approx.1.0l)⑭Slewing reduction gear(approx.1.2l) ⑮Wire rope⑯Slewing bearings ⑰Wire rope for boom extension
1112
Gear oilGear oilRope greaseChassis greaseRope grease
Spray gunGrease pumpSpray gun
- 100 -
The amount required for oil change is 22 liters whenfilled up to the middle between upper and lower limits ofthe level gauge.
The oil should be replaced at early autumn becausethere is possibility of freezing moisture in the tank as wellas in the hydraulic circuit when temperature goes belowthe freezing point.(Depending on the countries)
Air entering in the oil tank brings dirt and moisture. In addition, since hydraulic equipment gradually wears toproduce worn particles, replace the oil 3 months after thestart of crane operation then once a year thereafter.
Tighten the cap securely with your hand after oil hasbeen refilled. Remember that hydraulic oil may leak outif the cap is loosely tightened.
Remove moisture in the hydraulic tank. Moisture may enter through the air-breather and it is mixedwith the hydraulic oil when the crane has been operated for along time. Remove the drain plug located at the bottom of thetank to drain the water.
21. 2 Lubrication(1) Replacement of hydraulic oil
Upper limit
Lower limit
Level gauge
Drain plug
CAUTIONDo not mix a different brand of
hydraulic oil as properties of mixed oildeteriorates and damage to hydraulicequipment results.
(2) Draining hydraulic tank
- 101 -
Air enters in and out of the gear case so that dirt andmoisture are brought in the gear case.In addition, since hydraulic equipment gradually wears toproduce worn particles, replace the oil 6 months after thestart of operation.
After that replace gear oil;Once a year for winch reduction gear, and.Once every 2 years for slewing reduction gear.
Winch reduction gear
Slewing reduction gear
(Draining oil)
Drain plug
Level gauge
(Supplying oil)
Gear oil filler port
For gear oil to lubricate winch reduction gears, fill itup to the middle of the oil level gauge (approx. 1.0 liter).
For gear oil to lubricate slewing reduction gears, fill itup to a level between upper and lower limit marks of theoil level gauge (approx. 1.2 liters).
Check oil level not by tighten up the oil level gauge capbut by just inserting the gauge in the filler port.
(Draining oil)
Drain plug
Level gauge
(Supplying oil)
Gear oil filler port
Upper limit
Lower limitOil surface
(2) Replacement of gear oil(Winch reduction gear-Slewing reduction gear)
CAUTIONReplace gear oil after oil temperature
has dropped.
- 102 -
The machine uses ball bearing as the slewing bearing.Be sure to lubricate the bearing as insufficient lubricationmay cause it to make unusual noise. Grease in the nipples while slewing the boom once a monthfor moderate operation, and once a week for heavy-dutyoperation.
Grease nipple
Spray the rope grease sufficiently once a month to the wireropes with the boom fully extended.
(3) Lubrication to slewing bearings
(4) Lubrication to wire rope for boom extension
HEAD OFFICE : Center Bldg., 3-12, Higashishinagawa 2-chome,Shinagawa-ku, Tokyo 140-0002, JAPAN