UNIC Crane Maintenance Manual PDF

UNIC CRANE
　MAINTENANCE
　 MANUAL
CONTENTS
DESCRIPTION OF MAJOR EQUIPMENT 1
Inspection before operation 2
Replacement of expendable parts/Welding precautions 3
List of recommended lubricants 4
Lubrication chart 5
Annual self-inspection record 6
PTO／Hydraulic pump 8
Propeller shaft／Hydraulic pump 9
Hydraulic oil tank 10
　　　　Replacement of hydraulic oil／Draining hydraulic tank 11
　　　　Replacement of return filter／Replacement of line filter element 12
Control valve 13
Outrigger 14
Hoist winch 15
Slewing device 16
　　　　　Inspection of the slewing bearing mounting bolts 17
　　　　　Replacement of gear oil／Lubrication to slewing bearings 18
Telescoping cylinder／Boom 19
Swiveljoint／Derrick cylinder／Column／Piping 20
Wire rope 21
　　　　　　Easy inspection of the wire rope 22
　　　　　　How to replace the wire rope 24
　　　　　　How to fix the wire rope end 25
　　　　　　How to correct the twisted wire ropes 26
Hook 27
Load meter 28
Load indicator 29
Automatic stop for overwinding／Over-winding alarm／Level 30
Worning horn／Name plate 31
Base／Chassis frame 32
INSUPECTION PROCEDURES WHEN CYLINDER SINKE 33
　　　　　　Inspection of derrick cylinder 34
　　　　　　Inspection of telescoping cylinder 35
　　　　　　Inspection of outrigger cylinder 36
DESCRIPTION OF MAJOR EQUIPMENT
11
5 10 8
21 13
18
19 7,16
9
14
1
22,23
23
3
17
24
15 20
1 12
4 2
6
1 P. T.O.lever 7 Swivel joint 13 Column 19 Load indicator

2 Propeller shaft 8 Hoist winch 14 Boom 20 Overwinding stop
3 Differential oil tank 9 Slewing device 15 Wire rope 21 Level
4 Oil hydraulic pump 10 Derrick cylinder 16 Pipeing 22 Warning horn
5 Control Valve 11 Telescoping cylinder 17 Hook 23 Name plate
6 Outrigger 12 Base 18 Load meter 24 Chassis frame
- 1 -
Inspection before operation
In order to secure safe operation and improve working efficiency, be sure to inspect each part of the crane according
to the table as follows;
Device Inspection for: Check Device Inspection for: Check
Oil leakage, Damage, Condition of

P.T.O. Wire rope
Unusual noise rope-end
Hydraulic oil Overwinding
Oil level, Oil leakage Operation, Buzzer sound
tank alarm
Operation, Deformation,
Outriggers Load meter Oil leakage, Operation
Damage, Oil leakage, Cracks
Operation, Braking func-

Hoisting winch Warning horn Operation
tion, Irregular winding
Slewing device Operation, Oil leakage Piping(hydraulic) Oil leakage
Boom(derrick- Operation, Oil leakage, Fastening tightness of

ing) Mounting of foot-pin Base crane body mounting
bolts
Operation, Oil leakage,
Boom(telescop-
Deformation, Cracks, Slinging imple-
ing) Missing necessary items
Mounting of fixing pin ments
Rotation of hook, Function of Operation of automatic stop
Hook Uni-hook
hook safety latch and storing function
CAUTION
Always keep the machine in good condition so that it is ready for normal
operation.
Cleaning
Keep the machine clean at any time.
Sand and fine dust may cause an abnormal wear of the
machine.
Do not wash the machine by splashing water with high-pres-
sure to prevent the water from entering into the electric sys-
tem which may cause malfunction of the machine.
-2-
Replacement of expendable parts
1. Replacement of gaskets and seals for each

cylinder
Although timing of replacing a part varies according to how
frequently the crane has been operated, replace gaskets and
seals used in each cylinder after every 3 years of operation
(period during which crane is not operated is included) in
order to operate the crane safely.
Ask a local UNIC authorized service shop for replacement of
gaskets and/or seals.
2. Replacement of sliding plate of boom

Sliding plate Replace it every 3 years.
3. Replacement of brake shoe in hoisting

winch
Replace it every 3 years.
Brake shoe
No grounding Welding precautions

When welding is needed for some reason, do not use outrig-
ger cylinder for welding ground as the cylinder rod and/or the
Outrigger cylinder piston may be damaged by electric sparks due to current
flown in the inner part of cylinder.
-3-
◆1. List of recommended lubricants
★RECOMMENDED GREASE
(a) Chassis grease
Use NLGI No. 1 grade.
Petroleum Maker Brand
ESSO Chassis grease L
MOBIL HP221
CALTEX Multifak EPI
SHELL RETINAX-CD
(b) Molybdenum grease

Use NLGI No. 2 grade.
ESSO Beacon Q2
MOBIL Mobilplex Special
CALTEX Molytex Grease EP2
SHELL Retinax AM
★RECOMMENDED GEAR OIL

Use API Service GL-4 gear oils.
ESSO Standard gear oil 90
MOBIL Mobilube SAE 90
CALTEX Universal Thuban SAE 90
SHELL Shel Spirax EP 90
★RECOMMENDED HYDRAULIC OIL

Use industrial-type hydraulic oil;
ISO VG 46 for most temperatures
ISO VG 32 extremely low temperatures
Brand
Petroleum Maker
ISO VG 32 ISO VG 46
ESSO UNVICE J32 Teresso 46
MOBIL Mobil DTE 13 Mobil DTE 25
CALTEX Rando Oil HD AZ32 Rando Oil 46
SHELL Shell Tellus Oil 32 Shell Tellus Oil 46
-4-
Lubrication chart
3-section boom
4-section boom
5-section boom
6-section boom
Do not apply grease to the slide-sheave pin.
Service No. of
Part to be lubricate Lubricant Tool
interval part
Boom slide plate(Underside/sides of 2 Molybdenum grease Manual application
boom sections , ) 3-section boom
boom sections , , ) 4-section boom
boom sections , , , ) 5-section boom
Daily
boom sections , , , , ) 6-section boom
Boom slide plate(Upper side of boom section ) 2 Molybdenum grease Grease pump
Boom foot pin 1 Chassis grease Grease pump
Upper support pin of derrick cylinder 1 Chassis grease Grease pump
Lower support pin of derrick cylinder 1 Chassis grease Grease pump
Oil tank(59l) 1 Hydraulic oil(up to
middle of level gauge)
Winch drum gear 1 Chassis grease Grease pump
Weekly Slewing gear(to gear-teeth) 1 Chassis grease Manual application
Propeller shaft 3 Chassis grease Grease pump
Winch reduction gear(approx.1.0l) 1 Gear oil
Slewing reduction gear(approx.1.2l) 1 Gear oil
Monthly Wire rope 1 Rope grease Spray gun
Slewing bearings 2 Chassis grease Grease pump
Wire rope for boom extension Rope grease Spray gun
-5-
When you perform the annual inspection, copy this sheet and use it.
Check レ Replacement
× Adjustment A Cleaning C
Annual self-inspection record Store the inspection results for 3 years. Disassembly
〇 Repair △ Tightening T Lubrication
L
Result of check Remedial
Check point Contents of check Good No good measure
Operation of “ON” and “OFF”, abnormal noise and oil leakag

1 PTO Operation of the PTO check lamp
Looseness/falling off of the bolts and nuts in the mounting unit
Propeller
2 shaft Play of the universal joint/spline and lubricatio
Hydraulic
Operating condition, abnormal noise and oil leakag
3 pump Setting of the rated rotation
Hydraulic
Oil leakage and crack
4 oil tank Quantity, contamination and deterioration of the hydraulic o
Stain and damage of the air breather and suction filte
Operating status, deformation and crack of the lever
Falling off of knob and exfoliation/deterioration of stick
Control
5 valve Oil leakage
Looseness/falling off of the bolts, nuts, pins, etc. in the mounting unit
Set pressure of the relief valve
Operating condition and effect of the horizontal setting stoppe
Effect of the stopper pin when loaded or set and deformation of pi
Deformation and crack of the inner box
6 Outrigger Damage of the lock lever
Oil leakage/natural sinking of the outrigger cylinde
Operation of the one-touch lever and condition of the cable termina
Looseness/falling off of the bolts, nuts, pins, etc. in the mounting unit
Oil leakage
Swivel
7 joint Looseness of the stopper mounting bolts and deformation of the plat
Continuity of the slip ring, damage of wiring and mounting conditio
Damage of the air breather
Hoist
Quantity and deterioration of the gear oi
8 winch Crack of the drum and lubrication to the gear

Slewing
Quantity and deterioration of the gear oi
9 device Operating condition, abnormal noise and lubrication of the turntabl
Operating condition
10
Derrick Play of the derrick cylinder upper/lower pin
cylinder Oil leakage/natural sinking of the derrick cylinde
Operating condition
Telescopin
11 g Oil leakage/natural sinking of the telescoping cylinde
cylinder Mounting condition of the support pin and falling off of the snap rin
Looseness/falling off of the bolts and nuts in the mounting bolt
12 Base Deformation and crack of the base main body and the mounting bas
Looseness/falling off of the mounting bolts and nut
13 Column Crack and deformation
Looseness of the turntable mounting bolts
Operating condition (extension/retraction) and lubricatio
Deformation/crack of the boom and wear of the slide plat
14 Boom Looseness/falling off of the slide plate mounting bolt
Damage, wear and rotation of the sheave
Mounting condition of the support pin and sheave pin
User
Crane model Company name that has performed the inspection
Serial No.
Date of delivery
. . . Person in charge of inspection
Signature
Date of practice
. . .
-6-
When you perform the annual inspection, copy this sheet and use it.
Check レ Replacement
× Adjustment A Cleaning C
Annual self-inspection record Store the inspection results for 3 years. Disassembly
〇 Repair △ Tightening T Lubrication
L
Looseness/falling off of the bolts, nuts, pins, etc. in the mounting units
14 Boom Looseness and wear of the extending wire, cutting of its strand and corrosion (4- to 6-section)
Looseness of the retracting wire (4- to 6-section)
Specification (length and thickness)
Wear, cutting of the strand, deformation, kink, corrosion and lubrication
Tight connection to the wire socket and clipping of the terminal
15 Wire rope
Deformation and crack of the wire socket
Tight connection to the drum, confused winding and kink
Mounting condition of the support pin and looseness/falling off of the bolts
Oil leakage
16 Piping Supporting condition of the pipes
Damage, aging, crack, twist and crushed status
Wear, deformation, rotation and lubrication of the hook
Aim point distance of the hook
Damage, wear, rotation and lubrication of the sheave
17 Hook Operation, deformation and damage of the stopper
Play of the hook screw unit and thrust bearing (worn condition)
Rotating status of the hook loading roller and deformation of the roller mounting bracket
Looseness and falling off of the bolts, nuts, pins, etc. in the mounting units
18 Load detector Operating condition, oil leakage and damage
19 Load indication Falling off of the pointer, damage of the name plate and operating condition
Over-winding
Operating condition, over-winding detection switch and alarm sound
20 alarm/automatic Winding status of the cord reel and damage/disconnection of the cord
stop
Damage of the weight and sling wire
21 Level Mounting condition
22 Alarm Operating condition and alarm sound
23 Name plate Mounting condition, damage and deterioration of the name plate
Chassis Bend, deformation and crack
24 frame Mounting condition and deformation of the stopper
Sling the rated load and check the hoisting and braking abilities.
Load test/ Sling the rated load and check the natural sinking of the derrick cylinder.
25 Test load Sling the rated load and check the natural sinking of the outrigger cylinder.
( ton) Sling the rated load with the boom in the longest status and check the natural lowering of the boom.
Sling the rated load and check the slewing ability.
Operating condition
Mounting condition of the reception antenna
Radio Condition of the transmitter case
control Connection, looseness, stain and corrosion of the cables
(Remote Damage, deterioration and twist of the wires and cables
control) Corrosion, deterioration and looseness of the contact terminal
Option
Oil leakage from the accelerator cylinder/piping unit

Operating condition and oil leakage of the solenoid valves
Operating condition of the indicator units
ＭＬ Operating condition of the alarm buzzer at the alarm point
Operating condition of the crane at the alarm point (Stop type)
Turnover
Operating condition of the alarm buzzer at the alarm point
preventive
device Operating condition of the crane at the alarm point
Other special mention
User
Crane model Company name that has performed the inspection
Serial No.
Date of delivery
. . . Person in charge of inspection
Signature
Date of practice
. . .
-7-
PTO / Hydraulic pump
Check PTO for the ON/OFF operation.
Depress the clutch pedal fully to disen-

gage the clutch. Set PTO to "OFF". (The lamp is lit.) The
Pull the PTO lever to its extreme. crane operation is finished.
Release the clutch pedal gradually.
Check that the PTO indicator lamp lights.
Truck engine
Transmission
Hydraulic pump
PTO（Power Take Off） Check the bolts, nuts, and pins.
Check the parts for oil leakage.
Disulfide molybdenum grease No.2
Greasing the shaft and spline of the directly-

connected pump
To prevent rust and wear, apply the disulfide molybde-
num grease No. 2 to the pump shaft and the PTO spline
unit.
Result of
Check check
point Contents of check Good No good
Remedial
measure
Operation of “ON” and “OFF”, abnormal noise and oil leakage

PTO Operation of the PTO check lamp
Looseness/falling off of the bolts and nuts in the mounting units
Hydraulic Operating condition, abnormal noise and oil leakage
pump Setting of the rated rotation
-8-
Propeller shaft／Hydraulic pump
Spline yoke
Check of play Pump mounting side
Weld yoke Grease nipple
Spline shaft
Spline yoke
Check the bolt for looseness.
Sway of shaft
PTO mounting side Apply grease.
Check the bolt for looseness.
Chassis grease No. 1
Disulfide molybdenum grease No. 2
Greasing the universal joint of the propeller shaft

Greasing the pump shaft spline of the propeller shaft
To prevent rust and wear, apply the chassis

grease No. 1 to the universal joint.
Apply the disulfide molybdenum grease No. 2 to
the pump shaft spline.
Result of
Check check Remedial
point Contents of check Good No good measure
Propeller Play of the universal joint/spline and lubrication
shaft Looseness/falling off of the bolts and nuts in the mounting units
Operating condition, abnormal noise and oil leakage
Hydraulic
Setting of the rated rotation
pump
-9-
Hydraulic oil tank
Filler port of hydraulic oil

Check the oil level.
Check the air breather for stain.
Return filter
Hydraulic oil tank
Suction filter
Check the suction filter for stain,
deterioration and oil leakage.
Drain plug
Result of
Check point Contents of check check
Good No good
Remedial
measure
Oil leakage and crack

Hydraulic Quantity, contamination and deterioration of the hydraulic oil
oil tank Stain and damage of the air breather and suction filter
- 10 -
◆1. Replacement of hydraulic oil
★ The amount required for oil change is
32 liters when filled up to the middle
between upper and lower limits of the level
gauge.
Upper limit
★ The oil should be replaced at early
Lower limit autumn because there is possibility of
freezing moisture in the tank as well as in
Level gauge the hydraulic circuit when temperature
goes below the freezing point.(Depending
on the countries)
★ Air entering in the oil tank brings dirt
and moisture.
In addition, since hydraulic equipment
gradually wears to produce worn particles,
replace the oil 3 months after the start of
crane operation then once a year there-
after.
★ T ighten the cap securely with your
hand after oil has been refilled. Remember
that hydraulic oil may leak out if the cap is
loosely tightened.
CAUTION
★ Do not mix a different brand
of hydraulic oil as properties of
mixed oil deteriorates and dam-
age to hydraulic equipment
results.
◆2. Draining hydraulic tank

Remove moisture in the hydraulic tank.
Moisture may enter through the air-breather
and it is mixed with the hydraulic oil when
the crane has been operated for a long time.
Remove the drain plug located at lower part
on the tank to drain the water.
Drain plug
- 11 -
Replacement of
return filter
The replacement of the return filter is
depends on how often the crane has been
operated, however, as a general rule, replace
it after 3 months of initial operation and once
a year thereafter.
Return filter How to replace
● Give the gasket a thin coat of oil.
● Screw in the cartridge and tighten it with
your hand securely.
Line filter Replacement of line

filter element
Replace the inner element of line filter after 1
year from the start of operation.
Be sure to replace the element when the
hydraulic pump is replaced and replace it
after 1 year from the start of operation of the
Element pump.
(Showing left-hand side of control valve)
- 12 -
Boom derricking lever〔raise/lower〕
Control valve Hook lever〔hoisting/lower〕
Boom telescoping lever〔retract/extend〕
Slewing lever〔clockwise/counter clockwise〕
Load meter
Check these
parts for oil
leakage.
Check the sticker for exfoliation. Check the nut
for looseness.
Outrigger control lever[extension/retraction]
Check the levers for the operating status, deformation and crack.
Check if the pin or any other part has fallen off.
Result of
check Remedial
Check point Contents of check Good No good
measure
Operating status, deformation and crack of the levers

Falling off of knob and exfoliation/deterioration of sticker
Control
valve Oil leakage
Set pressure of the relief valve
- 13 -
Outrigger
Check if the snap ring
is properly mounted.
Check the connecting

unit for oil leakage.
Check the horizontal inner box

for deformation, crack, etc.
Check Valve
Outrigger cylinder
Shift the lock lever for lock.
● Remarks
Shift ing the lock levers for
lock pr events the horizontal
members of outrigger from
sticking out by car eless grip
of extension lever.
In addition, this pr events
a rattling noise rom the horiz- Check the vertical
ontal members of outrigger inner box for sticking
while the vehicle is traveling. and deformation.
● Remarks
Fully visible blue
mark indicates that
the lock pin for the Check if the snap ring
horizontal member is properly mounted.
of outrigger is inserted
into the hole.
After the outriggersare completely
stored, check the following.
① Release the grip of extension lever
.
② Blue mark on the top of extension lever is
fully visible.
③ The horizontal membersof outrigger are
securelylocked so that they will not stick
out sideways out of the vehicle.
Result of check
Remedial
measure
Operating condition and effect of the horizontal setting stopper

Effect of the stopper pin when loaded or set and deformation of pin
Deformation and crack of the inner box
Outrigger Damage of the lock lever
Oil leakage/natural sinking of the outrigger cylinder
Operation of the one-touch lever and condition of the cable terminal
- 14 -
Hoist winch
Crack of the drum
lubrication to the gears
Looseness
falling off of the bolts
Damage of
the air breather
Looseness falling off
of the bolts
Gear oil
filler port
Replacement of gear oil

(Winch reduction gear)
★Air enters in and out of the gear case so Hoist motor Winch reduction gear
that dirt and moisture are brought in the
gear case.
replace the oil 6 months after the start of
operation.
★After that replace gear oil; Quantity and
deterioration
Once a year for winch reduction gear, and. of the gear oil
Once every 2 years for slewing reduction gear.
★For gear oil to lubricate winch reduc- Drain plug
tion gears, fill it up to the middle of the oil Oil leakage
level gauge (approx. 1.0 liter).
CAUTION
★Replace gear oil after oil tem-
perature has dropped.
Result of check
Remedial
measure

Hoist Quantity and deterioration of the gear oil
winch
Crack of the drum and lubrication to the gears
- 15 -
Slewing device Slewing device （Turntable）
Slewing bearing
Grease nipple
Remove the cover,

and check the gear teeth
for crack.
Check the mounting

bolt for looseness.
Check this part

for damage.
Table-turn
Shaft-gear
Wheel-worm
Hydraulic motor(Slewing)
Check the gear oil for contamination and level.
Cover
Inspection
hole

Slewing
device Quantity and deterioration of the gear oil
Operating condition, abnormal noise and lubrication of the turntable
- 16 -
Mounting bolts
Inspection of the
Mounting bolts slewing bearing
mounting bolts
When the slewing device makes an unusual
noise while operating or traveling of the
crane, or when a gap is created on the mount-
ing surface, contact a UNIC authorized ser-
vice shop for inspection and/or repair.
Slewing bearing
◆ Inspection of mounting bolts located

Cover inner race
1. Remove the cover to inspection hole.
2. Slew the boom so that each mounting bolt
comes to the center of inspection hole for
inspection.
3. Fit the cover as it was after inspection.
Inspection
hole
- 17 -
◆3. Replacement of gear oil
Slewing reduction gear (Winch reduction gear ･ Slewing reduc-
(Draining oil) tion gear)
★ Air enters in and out of the gear case so
that dirt and moisture are brought in the
gear case.
r eplace the oil 6 months after the start of
operation.
★ After that replace gear oil;
･Once every 2 years for slewing reduc-
Drain plug
tion gear.
★ For gear oil to lubricate slewing reduc-
Level gauge tion gears, fill it up to a level between
upper and lower limit marks of the oil
Gear oil level gauge (approx. 0.7 liters).
filler port Check oil level not by tighten up the oil
level gauge cap but by just inserting the
gauge in the filler port.
Upper limit
Lower limit (Supplying oil)

Oil surface
4. Lubrication to slewing bear-

Grease nipple
ings
The machine uses ball bearing as the slewing
bearing.
Be sure to lubricate the bearing as insuf fi-
cient lubrication may cause it to make unusu-
al noise.
Grease in the nipples while slewing the boom
once a month for moderate operation, and
once a week for heavy-duty operation.
- 18 -
Telescoping cylinder／Boom
Apply grease when retracted to the utmost.

(Grease nipple) Boom(1) Bppm(2) Boom(3) Boom(4)
Remove the cover and

check the inside.
Check the bolt for looseness. Rope-wire(Boom Ret) Rope-wire(Boom Ext)

Check this part
for oil leakage.
Check the slide sheave Telescoping cylinder(1) Telescoping cylinder(2) Check the bolt Check the bolt
Apply grease to the for operation. for looseness. for looseness.
support pin. Check the sheave for rotation,
damage and wear.
Check each boom for deformation, etc.
Apply grease to the side surface and lower surface
on the 2-section boom and other booms.
Replacement of brake shoe in hoisting winch

Replace it every 3 years.
Slide plate
Result of
check Remedial
Operating condition
Telescoping Oil leakage/natural sinking of the telescoping cylinder
cylinder Mounting condition of the support pin and falling off of the snap ring
Looseness/falling off of the bolts and nuts in the mounting bolts
Operating condition (extension/retraction) and lubrication
Deformation/crack of the boom and wear of the slide plate
Looseness/falling off of the slide plate mounting bolts
Damage, wear and rotation of the sheave
Boom
Mounting condition of the support pin and sheave pin
Looseness and wear of the extending wire, cutting of its strand and corrosion (4- to 6-section)
Looseness of the retracting wire (4- to 6-section)
- 19 -
Swiveljoint／Derrick cylinder／Column／Piping
Column
Derrick
cylinder Swivel
joint

Oil leakage
Swivel Looseness of the stopper mounting bolts and deformation of the plate
joint Looseness/falling off of the bolts and nuts in the mounting units
Continuity of the slip ring, damage of wiring and mounting condition
Operating condition
Derrick Play of the derrick cylinder upper/lower pins
cylinder Oil leakage/natural sinking of the derrick cylinder
Crack and deformation
Column
Looseness of the turntable mounting bolts
Oil leakage
Piping Supporting condition of the pipes
Damage, aging, crack, twist and crushed status
- 20 -
Wire rope
Wire rope is an expendable article and it will be damaged orWire rope is an expendable article and it will be damaged or
broken in its strand wires through a long period of use.
Replace the rope according to following criteria.
◆1. Replacement criteria

1. A rope in which amount of broken strand wires (except
1 filler wires) comes to more than 10% within a pitch of strand.
Replace the wire ropes intended for use with this crane if 13
pieces of strand wire have been broken within a pitch of
strand.
2. A rope being kinked.
2
3.A rope from which its diameter has decreased by more
than 7% of the nominal diameter.
For example, if wire rope with a nominal diameter of 8mm is
used, replace it when the diameter becomes 7.5mm.
For length and construction of the wire rope for winding-up.
4. A rope which has been deformed and/or corroded exces-

sively.
3
Diameter of
rope
4
★Be sure to replace a wire rope when it comes under the
criteria, item 1 through 4, illustrated above.
Result of Remedial
Check point Contents of check check
Good No good measure
Specification (length and thickness)
Wire Wear, cutting of the strand, deformation, kink, corrosion and lubrication
rope Tight connection to the wire socket and clipping of the terminal
Deformation and crack of the wire socket
Tight connection to the drum, confused winding and kink
Mounting condition of the support pin and looseness/falling off of the bolts
- 21 -
Easy inspection of the
wire rope used in crane, Visually check the wire rope parts passing through the sheave frequently and others
for damage. Compare the damage status with the damaged wire rope in the photos.
etc.
Inspect the wire rope by the following steps.
Step 1: Deformation Step 2: Wear and corrosion Step 3: Breakage
If the wire rope meets one of the standards
STEP1
● Deformation
Compare the deformed part with the similar
for disposal, dispose of the rope.
damaged part in the photos.
The strand wire is The core wire is The strand wire is The strand wire is Flattened. Kinked. Kinked. Twisted. Basket status
protruded. protruded. sunk. exposed.
- 22 -
The wire rope is pressed The strand wire is The strand wire is Spiral status The wire rope is swollen
locally to be flattened. locally tightened. locally loosened. to be like a basket.
Easy inspection of the wire rope used in crane, etc. Standard of disposal
(1) When crown breakage (broken thread) has occurred
Count the broken wires in the following two ranges:
one range is six times larger (approx. 1 pitch) than
the rope diameter (d) and, the other, thirty times
● Wear and corrosion ● Breakage larger (approx. 5 pitches). Then, check the wire rope
STEP2 STEP3
composition. If the broken wires are beyond the
When the rope is worn and so its Visually check the wire quantity shown in the following table, dispose of the
surface glistens or when you see rope. If you have found the wire rope.
red rust on the rope surface, breakage part, wipe its (2) When nip breakage (broken root) has occurred
wipe the trouble part well to vicinity well to remove oil or If nip breakage has occurred in one wire, dispose of
remove oil or stain. Then, com- stain and then inspect the the wire rope at once.
pare the part with the damaged part. After the inspection,
Visible broken
wire rope in the photos. apply the rope grease to it.
wires
Wire rope
Inspection range
composition
Wear Corrosion Crown breakage Nip breakage
(broken thread) (broken root) 6d 30d
18×7 19×7 4 8
- 23 -
6×Fi(25) 5 10
6×WS(26) 5 10
6×P･WS(26) 5 10
34×7 35×7 5 10
6×Fi(29) 6 11
6×WS(31) 6 13
6×WS(36) 7 14
6×P･WS(36) 7 14
6×SeS(37) 8 16
6×P･WS(41) 9 18
6×37 10 19
6×F(40) 2 4
3×F(40) 2 4
There is no clearance between the Pitching has occurred and so the wire ･ Handle the wire rope of IWRC in
strand wires. rope surface is pitted. the same way.
How to r eplace wir e rope
1. Refer to the figure in the left for how to hook the wire
ropes for hoisting and for where to mount the weight for
overwinding alarm.
For Uni-hook type

Boom top Refer to the figure in the left for how to install hook.
Front of boom
Guide
Higher side
is to the front
- 24 -
2. How to fix the wire rope end
Winch drum
Wedge When 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 of
the winding-up area of winch drum.
In order to avoid irregular winding, wind up a wire rope
slowly on the drum along its groove with a proper tension
applied to the rope to form the 1st layer.
From the 2nd layer on, wind up the rope over the wound-
up layer so that it is fit in each gutter formed between
ropes wound side by side of the layer below.
Wire rope end

Wire socket
When passing a wire rope end through the wire socket, be
40mm Where cut out sure to pass it as indicated by the arrows on the socket.
Leave the wire rope end more than 40 mm as “a” illustrat-
Wire clip ed in the figure in the left.
(pay attention to If it is passed from the opposite direction, service life of
mounting direction) the wire rope shrinks as the wire rope is kept bent all the
time.
50mm Do not forget to mount the wedge and the wire clip as
illustrated in the figure in the left.
Arrow mark
Wedge
(Diameter of wire rope=8mm)
Pass the pin through with the wire socket held with your
hand and tighten it with the bolt securely.
Projection on upper part
of wire socket
Stopper
If rope end is left by more than 40mm

(as “a” illustrated-above), rope
end is visible through this hole, if
not, adjust length of rope end.
Pass the pin through and

tighten it securely with bolt.
- 25 -
3. How to correct the twisted wire ropes
Wire ropes tend to turn in the untwisting direction when they
are under tension.
If two or more wire ropes are hooked together, they tend to
be twisted particularly while they are new.
The twist will decrease as the ropes are getting fit to the
crane.
If wire ropes are twisted, correct them as follows;
Unload the hook.
Extend the boom fully.
Set the boom to an angle of approximately 65°.
Unwind the hook until it comes close to the ground.
Check how many turns the wire rope has been twisted.
Hoist the hook and retract the boom to be on a stored
condition.
Remove the wire socket and turn the socket in the
4 wire ropes Wire socket untwisting direction by as many turns as the wire ropes have
been twisted multiplied by the number of wire ropes hooked.
Remember, however, that the wire socket may be turned up
to 4 turns at a time.
Attach the wire socket and repeat hoisting and lowering
Untwisting the rope 2 or 3 times between extremes of lift.
direction Then check if twist of the wire ropes is corrected.
If they remain twisted, repeat the procedures shown above.
Wire rope’s twisting

direction
Note : Turn the wire socket in the direction

opposite to wire rope twisting.
- 26 -
Hook
Check the worn status of the thrust bearing.
Measure the gap between the hook and trunnion. If it is the specified value or more, replace the
thrust bearing.
* If the measured value is beneath the specified value and the bearing does not
rotate well, it is worn in a great degree. Replace the bearing as early as pos
sible.
* If the bearing is worn, the nut thread part is increasingly burdened. If you keep
using the bearing, the nut thread part will also be worn.
* When checking the bearing, check if play occurs in the nut thread part.
If play occurs, replace the hook and nut.
The nut thread part is worn.
The thrust bearing is worn.
Play of trunnion
Gap
Reference value = 1mm
Specified value
for replacement = 2mm
Hook

Wear, deformation, rotation and lubrication of the hook
Aim point distance of the hook
Damage, wear, rotation and lubrication of the sheave
Hook
Play of the hook screw unit and thrust bearing (worn condition)
Rotating status of the hook loading roller and deformation of the roller mounting bracket
Looseness and falling off of the bolts, nuts, pins, etc. in the mounting units
- 27 -
Load meter
3 Load meter
Number of ropes 29
being hooked 2 4-part lines

１０１５ 1-part line B
0 0
770363331
1
５２０
0 1
０２５
A MPa
0.5
4-part lines 0.73

2
３ 29
Load meter
Check the swivel elbow unit and the load meter

for oil leakage.
Load detector Operating condition, oil leakage and damage
- 28 -
Load indicator(with angle indicator)
(Side of boom)
Pointer
(t)
E
AN
A DS TH
E
CR
Y
LO ED
ON
AB
I LIT
0-
V3
44
E D BA
S
N
ST
86
01
AT
E A U
AR TH 0 91
R S
AD ATH
ER
LO R
D H
TE GT
RA N
RE
ST
Scale
(The chart is an example showing for URV344)
Result of
Check point Contents of check check Remedial
measure
Good No good
Load indication Falling off of the pointer, damage of the name plate and operating condition
- 29 -
Automatic stop for overwinding／Over-winding alarm
Overwinding
detector
Weight for
overwinding alarm

Over-winding Operating condition, over-winding detection switch and alarm sound
alarm/auto- Winding status of the cord reel and damage/disconnection of the cord
matic stop Damage of the weight and sling wire
Level

Level Mounting condition
- 30 -
Warning horn
Warning
arning horn swith
Check the warning horn for the following points:

operating condition, alarm sound, damage of wiring,
corrosion of the connecting terminal and mounting condition.
Alarm Operating condition and alarm sound
Name plate MODEL URV34 Crane model

SPEC.
Specifications
CAPACITY t
SERIAL NO. Serial number
TOKYO JAPAN
MADE IN JAPAN CODE NO. Code number
Check point Result of check Remedial

Contents of check Good No good measure
Name plate Mounting condition, damage and deterioration of the name plate
- 31 -
Base／Chassis frame
Base
Deformation of the stopper

Deformation and crack of the base main body and the mounting base
Base
Looseness/falling off of the mounting bolts and nuts
Chassis Bend, deformation and crack
frame Mounting condition and deformation of the stopper
- 32 -
Inspection for sinking of cylinder
The outrigger Does the oil come out YES

The load is lowered. when removing the Inside leakage occurs.
cylinder sinks. The packing is
pipe at retracting
side? damaged.
Set the conditions for The tube is scratched.
sinking in the crane. Does the oil come out
Stop the engine, when removing the YES Check the pilot.
The seat surface is
change the lever and pipe at extending
NO damaged.
remove the pressure. side?
Then, start the test. Foreign matter is caught
The derrick Does the oil come out YES
Inside leakage occurs. by the seat surface.
cylinder sinks. when removing the The packing is
hose at lowering side? damaged.
The tube is scratched.
Does the oil come out The counterbalance

- 33 -
YES valve malfunctions.

when removing the
NO hose at raising side? The seat surface is
damaged.
Does the oil come out YES
The telescoping Inside leakage occurs. Foreign matter is caught
when removing the by the seat surface.
cylinder sinks. The packing is
hose at retracting
damaged.
side?
The tube is scratched.
Does the oil come out The counterbalance
when removing the YES valve malfunctions.
NO hose at extending The seat surface is

side? damaged.
Foreign matter is caught
by the seat surface.
INSUPECTION PROCEDURES WHEN CYLINDER SINKE
Inspection of derrick cylinder
(1) Preparation before inspection
Raise booms to an angle of approx. 30°.
Put a mark on the rod with a felt pen (refer to Fig. 1).
In order to release pressure remained in the derrick system, stop the engine and shift the manual lever for
raising/lowering of booms.
(2) Starting inspection

Remove the lowering hose to check if oil overflows continuously out of the cylinder port of lowering side.
At he same time, check also that how far the rod shifts.
If no oil flows out of the port of lowering side, the cylinder is normal.
Next, remove the raising hose, and if oil overflows continuously out of counter-balance valve port of raising side,
there may be faulty on the seat surface of counter-balance valve (refer to Fig. 3).
In addition, check how far the cylinder sinks simultaneously.
Caution:
In order to release pilot pressure in the lowering side, be sure to remove the raising hose after the
lowering hose has been removed (refer to Fig. 2).
If oil overflows out of the port on lowering side, it suggests internal leakage in the cylinder.
Be sure to measure the how far each boom sinks as it is an important point for judging that it is
- 34 -
Inspection of telescoping cylinder (3-section or 4-section boom)
Allow booms to be horizontal and extend them fully to put a
mark on each boom section (refer to Fig. 1).
Raise booms to their maximum to sling a load.
In order to release pressure remained in the telescoping system,
stop the engine and shift the manual lever for telescoping
booms.

Remove the retraction hose to check if oil overflows
continuously out of the cylinder port of retraction side.
At he same time, also check that which boom section sinks
how far to grasp condition of booms as a whole.
If no oil flows out of the port of retraction side, the cylinder is
normal.
Next, remove the extension hose, and if oil overflows
continuously out of counter-balance valve port of extension
side, there may be faulty on the seat surface of counter-balance
valve (refer to Fig. 3).
In addition, check how far boom3 sinks simultaneously.
Caution:
In order to release pilot pressure in the retraction side,
be sure to remove the extension hose after the
retraction hose has been removed (refer to Fig. 2).
Since overflowing oil out of the port on retraction side
means internal leakage in the cylinder, check tele1 and
tele2 separately.
Be sure to measure the how far each boom sinks as it is
an important point for judging that it is normal or
abnormal.
(3) Inspection of tele1

Extend booms to a position where it is a little bit shorter than
2-section boom to put a mark on the boom (refer to Fig. 4).
booms.
Remove the retraction hose.
If oil overflows out of cylinder port of retraction side and
boom2 sinks, there may be internal oil leakage in tele1.
(4) Inspection of tele2

Allow booms to be horizontal and extend them fully to put a
mark on each boom section (refer to Fig. 1).
booms.
Remove the retraction hose.
If oil overflows out of cylinder port of retraction side and
boom3 sinks, there may be internal oil leakage in tele2.
The same procedures in checking boom sinkage are applied for

5-section boom
Be sure to check the boom sections one by one reliably.
- 35-
Inspection of outrigger cylinder
Extend outrigger cylinders to their extremes.
Put a mark on the rod with a felt pen (refer to Fig. 1).
In order to release pressure remained in the outrigger system, stop the engine and shift the manual levers for
extension/retraction of outriggers.

Remove the retraction pipe to check if oil overflows continuously out of the cylinder port of retraction side.
At he same time, check also that how far the rod shifts.
If no oil flows out of the port of lowering side, the cylinder is normal.
Next, remove the extension pipe, and if oil overflows continuously out of the pilot check valve port of raising
side, there may be faulty on the seat surface of pilot check valve (refer to Fig. 2).
In addition, check how far the cylinder sinks simultaneously.
Caution:
In order to release pilot pressure in the retraction side, be sure to remove the extension pipe after
the retraction pipe has been removed (refer to Fig. 1).
If oil overflows out of the port on retraction side, it suggests internal leakage in the cylinder.
Be sure to measure the how far each boom sinks as it is an important point for judging that it is
- 36-

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UNIC CRANE

1 P. T.O.lever 7 Swivel joint 13 Column 19 Load indicator

Device Inspection for: Check Device Inspection for: Check

Oil leakage, Damage, Condition of

Operation, Braking func-

Slewing device Operation, Oil leakage Piping(hydraulic) Oil leakage

Boom(derrick- Operation, Oil leakage, Fastening tightness of

1. Replacement of gaskets and seals for each

2. Replacement of sliding plate of boom

3. Replacement of brake shoe in hoisting

No grounding Welding precautions

(b) Molybdenum grease

★RECOMMENDED GEAR OIL

★RECOMMENDED HYDRAULIC OIL

Operation of “ON” and “OFF”, abnormal noise and oil leakag

Operating condition, abnormal noise and oil leakag

Crane model Company name that has performed the inspection

Oil leakage from the accelerator cylinder/piping unit

Crane model Company name that has performed the inspection

Depress the clutch pedal fully to disen-

Disulfide molybdenum grease No.2

Greasing the shaft and spline of the directly-

Operation of “ON” and “OFF”, abnormal noise and oil leakage

Check the bolt for looseness.

Chassis grease No. 1

Disulfide molybdenum grease No. 2

Greasing the universal joint of the propeller shaft

To prevent rust and wear, apply the chassis

Filler port of hydraulic oil

Hydraulic oil tank

Oil leakage and crack

◆2. Draining hydraulic tank

Line filter Replacement of line

Operating status, deformation and crack of the levers

Check the connecting

Check the horizontal inner box

Operating condition and effect of the horizontal setting stopper

lubrication to the gears

Replacement of gear oil

Operating condition, abnormal noise and oil leakage

Remove the cover,

Check the mounting

Check this part

Result of check Remedial

◆ Inspection of mounting bolts located

Lower limit (Supplying oil)

4. Lubrication to slewing bear-

Apply grease when retracted to the utmost.

Remove the cover and

Check the bolt for looseness. Rope-wire(Boom Ret) Rope-wire(Boom Ext)

Replacement of brake shoe in hoisting winch

Result of check Remedial

◆1. Replacement criteria

2. A rope being kinked.

4. A rope which has been deformed and/or corroded exces-

 If the wire rope meets one of the standards

For Uni-hook type

If the wire rope meets one of the standards