UNIC HYDRAULIC CRANE INSTALLATION MANUAL UR1500
Contents
1. Bn d APREN EXTEND fas EXTEND S 8 8 VIEW LN 5 HORZ N N 4L 4 16 ELECTRIC WIRING 1 Wiring boom and column Part A 4 four wiring connectors are provided for the boom and the column respectively Connect each connector as illustrated in the figure shown below 2 Wiring base and chassis Part B Connect 5 five lead wires coming from the crane body to the chassis side by referring to the following illustration 1 Connect the white conductor to horn switch on chassis 2 Connect the brown conductor to engine start solenoid on chassis 3 Connect the orange and red white conductors to relay for engine shut down sole noid 4 Connect the red conductor to power cable of chassis via a 10 A fuse a 1 Jj f 9999 cw 1 CON LE INN Yoggg r c c c z 9999 a W WS WN z 1 ee ea ee M c F L us amp Ue E n f EESTI X LL 7777 Vehicle Fuse box H 5A 20A 74 Cigarette lighter gt ENGINE SHUTDOWN gt SOLENOID v D C 12V Fuse box on the vehicle BA 20A Orange K Lm 2 gt ENGINE START Vehicle horn switch SOLENOID Vehicle horn Brown White VV 26 ELECTRIC WIRING DIAGRAM m gt ENGINE SHUTDOWN P SOLENOID Orange fg Pi Brown p ENGINE STA2. 14 For Base ass y 15 For Swing Device ass y Stopper Weight ass y Return filter ass y Placard Hydraulic Oil Placard Filter Placard Up Placard PTO caution Placard Electrocaution Hazard 098321480 760280001 098396810 h 740580029 1 080581020 1 089181070 1 098381060 1 088F81110 3 Placard Name Plate Placard Danger Ride Load line Clip wire Tool ass y Sliding plate Placard Danger Hoisting Personnel 08A481130 1 602104431 2 08A481120 760160066 760990346 08VB21160 Breather 16 For Platform ass y E 3 Accelerator cable ass y 013841120 1 1 4 1 098349050 2 760260164 1 Sub assembly Boeing 72050 8 Band hose Joint hose Hose rubber 77H112000 3m Band hose 760000867 2 Joint hose 080062030 1 For Oil Tank ass y Bonded seal 728510800 Bracke 18 For Rear Outrigger assy Bokrelnng 71974600 8 Nt 7zme 8 Washer spring 722211160 Hanger for hose 602109220 023163100 2 Bolt 711108020 Nut 721111080 Washer spring 722211080 Band wire 750516005 4 Hose high pressure 772502180 4 Clamp 602211051 24 Plate 089T65030 11 Bolt SW 714206012 18 Hose high pressure 792502503 3 H
3. the accelerator pedal for travelling vehicle Connect both accelerator pedals attached to each platform on the right and on the left with the accelerator cable 19 4 12 MOUNTING THE OIL TANK 4 14 MOUNTING THE REAR OUTRIGGER 1 Fix the bracket on the chassis frame with bolts Spring washer i 1160 Nut 21111160 Bol 1 1716040 2 Adjust height of rear outriggers to be 10 250mm in dimension and weld rear out riggers to the brackets rj E cud 250 mm B AA 21 3 Weld plates to each bracket and rear outrigger 22 4 15 CONNECTING THE HIGH PRESSURE HOSE FOR REAR OUTRIGGER EXTEND EXTEND S S VERT S S HORZ EXTEND RETRACT C S VERT High pressure hose 792503547 Clamp 602211071 Bolt SW 714206012 Seat 090365170 Sr is T dH 1 High pressure hose 792502547 High pressure hose 792502503 1 lt High pressure hose 792502503 Plate 089T65030 Bolt SW 714206012 Clamp 602211051 23 RETRACT oe ee Bf eee os aac e ES ue 1 l f 3b e Lem B Re Me de l Ru Hunger for hose 602109220 7 Spring 023163100 Bolt 711108020 721111080 I Washer spring d 822211080 S S VERT EXTEND CS VERT High pressure hose 772502180 Band wire 750516005
4. above the ground Lower the boom slowly Confirm the working radius when it has been made an automatic stop that it is at approx 75 feet 23 m 75 feet 23m 38 FURUKAWA UNIC Corporation
5. 12 Square Washer 17 16 2 3 4 Square Washer 13 16 Adjust to Frame Width 10 4 2 MOUNTING THE HYDRAULIC PUMP REFERENCE Hydraulic Pump 2850 psi 200 kg cm 1 26 4 GPM 100L min 2 26 4 GPM 100L min 3 12 7 GPM 48L min Hydraulic pump Pump bracket Mounting bolt for securing pump bracket Pump flange Chassis frame Propeller shaft Hydraulic pump Pump bracket NOTES I Attach pump bracket to chassis frame with bolts 11 4 3 MOUNTING THE PROPELLER SHAFT Hydraulic pump Spline yoke Normal mounting PTO Weld york mounts twisted as against spline yoke Ubnormal mountin Grease nipple Supply grease after mounting Vehicle transmission Both axes of PTO and hydrautic pump are on the straight line as viewed from the top Flange yoke Axis of PTO Axis of h i 5 F Axis of PTO Propeller shaft ae roe A ZG N B2 1 4 7 E oct tas PRS i p i un i e m Mount propeller shaft so that angles at both joints 2 P B1 and 2 defined below equal i Pd 4 7 B1 Angle made by both axes of PTO and propeller shaft Ps gt B2 Angle made by both axes of hydraulic pump and propeller shaft Ideal angles of both joints are less than 5 1 In order to prevent moisture from entering in the spline yoke attach spline shaft directed upward 2 After shaft has been welded ch
6. G SYSTEM Use API Service GL 4 gear oils b WINCH SYSTEM Use API GL 2 3 gear oils or equivalent TEXACO MEROPA 150 7 TESTING 1 Engage PTO and check that abnormal noise is not produced from around it 2 Check control levers that they move as indicated on stickers glued to knobs 3 Operate each control lever and check the operation of topping cylinder telescoping cylinder and outrigger cylinder Cylinder operation test Operate full stroke twice or more Apply rated pressure for 5 seconds or more at each stroke end Check pipes and glands for oil leaks Winch operation test Raise boom to 45 or more Extend boom Operate winch lower and raise for twice or more check gear box and pipes for oil leaks Swing operation test e Swing to right and left twice or more Check pipes for oil leaks 4 Check Anti tow block device Check that winch winding boom extension stops when Anti tow block device is closed b Check that horn sounds while outrigger are being extended or retracted 6 Check that horn sounds when push button switch is depressed 7 Wire rope twist check Fully extend boom Raise boom to 45 or more Weight 900 Ibs 410 kg Hoist about 1 feet 0 3 m high Hook twist angle 1 4 or less Check that drum winds in order 37 8 Check capacity alert system Fully extend boom Raise boom to 30 or more Lift up a cargo with 390 Ibs 180 kg in weight to 6 feet 1 8 m
7. HECK 1 Hydraulic oil tank level check Check that hydraulic oil level is between the marks indicating upper and lower limits on the oil level gauge which is attached on the side of the oil tank Conditions of checking Return the crane to its original position to set the vehicle in a state ready for running Insert level gauge until cap contacts oil filler pull out level gauge and check oil level Check oil level on the oil level gauge attached on the side of oil tank Upper limit Level gauge Lower limit RECOMMENDED HYDRAULIC OIL Use industrial type hydraulic oil ISO VG 46 for temperatures above 32 F 0 C ISO VG 22 for temperatures below 32 F 0 C Brand Mobil DTE 22 Spindura oil 22 Shell Tellus Oil 22 Quantity of hydraulic oil 50 2 gallons 190 Liters Petroleum Maker ESSO MOBIL CALTEX SHELL 34 2 Winch gear box and swing gear box oil level check WINCH SYSTEM 1 Remove the oil level plug 2 Fill oil up to the standard level 3 Install the oil level plug Oil level plug SWING SYSTEM 1 Remove the vent plug for filler port 1 Remove the oil level plug 2 Fill oil up to the standard level 3 Install the oil level plug and the vent plug Oil filler l n aj Oil level plug Remove the cover standard level about 1 4 liter I 35 RECOMMENDED GEAR OIL a SWIN
8. NG THE VENT PLUG aq s e e 18 4 10 MOUNTING THE PLATFORM ASS Y 6 6n 18 4 11 CONNECTING THE ACCELERATOR CABLE 19 4 1 2 MOUNTING THE OIL TANK e c9 6972020 709 6 29 256 79 22 0 099 20 4 13 CONNECTING THE RETURN FILTER ASS Y 20 4 14 MOUNTING THE REAR OUTRIGGER 666 21 4 15 CONNECTING THE HIGH PRESSURE HOSE FOR REAR OUTRIGGER 23 4 16 ELECTRIC WIRING se o sa o o s s e m 26 4 17 MOUNTING THE HOOK eec 952 er 9 30 4 18 PLACARD LOCATION CHART s eee 32 5 TEARING OFF MASKING USED WHEN PAINTING 33 6 START UP CHECK sow W Role a a rcm Rim in WS cA cm Je WI Ua e 8 34 TABLE OF CONTENTS 7 TESTING V records uoa ved aca deu eiu UE ROI e eon Os MIS Br b uA upside 37 1 SHIPPING PARTS LIST Sub assembly 1 Base and column ass y 2 Boom ass y 3 Rear outrigger ass y Outrigger inner box ass y 2 ay jen N oa 4 part line hook ass y optional optional Single line hook ass y Oil tank Platform ass y 5 6 7 8 9 Ext jib optional 10 For Boom ass y Wedge IN 1 For Safety device ass y 12 For Hydraulic driving device ass y 13 For Equipment
9. RT Vehicle hom switch SOLENOID Ol veniae hom w I White exa E I Cigarette lighter 7 D C 12V Fuse box on the vehicle SA 20A 28 4 17 MOUNTING THE HOOK 1 Pull out wire slowly from drum Pass wire rope under the boom and turn it around the right sheave of boom tip as view from the base em 30 2 Pass wire through wire socket in the direction shown in the figure Note Pay also attention to the position of weight ass y 1 PART LINE 2 PART LINE 3 PART LINE 4 PART LINE 3 Pass wire through wire socket in the direction shown in the figure 9 16 in wire rope wire clip wedge wire socket 4 Fit the wire socket either to the hook or to the boom tip 31 4 18 PLACARD LOCATION CHART To be stuck on the right and on the left sides 2 1 2 1 3 Part No o Famam 2 Danger Ride Load obadert20 3 Placard Name Plate 32 5 TEARING OFF MASKING USED WHEN PAINTING Masking used when painting are sticked to the crane as they were After assembling be sure to tear off the maskings If you fail to tear off the maskings from the following parts they can cause operational troubles or hydraulic leakage 1 Topping cylinder rod 2 Sliding part of the limit switch for the swing warning system mI 33 6 START UP C
10. T JIB optional 2 Insert pin in pin stow bracket and jib end 1 It has been retracted fully 4 MOUNTING PROCEDURES Before mounting Carefuily refer to the contents of these drawings and general cautions for mounting 4 1 MOUNTING THE CRANE BODY Main body of crane Sub frame Chassis frame 37 4 Front of truck 950mm Main body of crane foot Washer Details of Washer Welding SpotYrof above drawing NOTES 1 In tightening system using install bolts as illustrated above attach a suitable article to prevent the chassis frame from being deformed Do not attach the unti deformation article to the chassis frame by welding 2 Weld the square washer on the crane foot to the crane foot after the install bolts have been tightened 3 Secure each install bolt by using double nut tightening system at its both ends 4 After the crane has been tightened with the install bolts put the stopper plates 4 pieces on the sides of crane foot and weld the plates to the sub frame to prevent the crane mounted vehicle from moving forward and backward SECTION A A Sub Frame eee Chassis frame L B Brace channel Drilled plate which prevents brace channel from getting out of chassis frame SECTION B B Recommended Install Bolts Grade Diameter 1 1 8 NF X 12 Proof load 120000PS Recommended Install Nuts 11 8 NF X
11. UNIC HYDRAULIC CRANE INSTALLATION MANUAL UR1500 SERIES FURUKAWA UNIC CORPORATION 1 SHIPPING PARTS LIST Gwen yp sup tuto e Sb ee 9l 9 4 E o 9 V a 1 2 PUNCHING POSITION OF DATE OF MANUFACTURE AND HOW TOREADIT s 666 3 3 SHIPPING FORMS 3 1 BASE AND COLUMN ASS Y Pe ee ee i 4 3 2 BOOM ASS Y nnn 5 3 3 OUTRIGGER INNER BOX ASS Y 1 1 6 3 4 PLATFORM ASS Y oru EXE 6 3 5 REAR OUTRIGGER ASS Y optional 666 7 3 6 SINGLE LINE HOOK eu we recess es e iei oe iether Wi W Sw U 7 3 7 4 PART LINE HOOK optional Qus ca ei ue We i e rw V 8 3 8 OIL TANK d e ves i 9 ie wie n S v v 8 3 9 EXT JIB optional rr rr er 9 9 9 4 MOUNTING PROCEDURES 4 1 MOUNTING THE CRANE BODY c eres 10 4 2 MOUNTING THE HYDRAULIV PUMP t 11 4 3 MOUNTING THE PROPELLER SHAFT 5 6668 12 4 4 MOUNTING THE PIPING AT LOWER PART 55 6666 13 4 5 MOUNTING THE BOOM ee er er ee 6 18 70 6 6 2 14 4 6 CONNECTING THE HIGH PRESSURE HOSE FOR TELESCOPING CYLINDER 14 4 7 CONNECTING THE HIGH PRESSURE FOR WINCH 15 4 8 ASSEMBLING THE OUTRIGGER INNER gt 16 4 9 MOUNTI
12. and cap 7 Insert outrigger cylinder mounting pin into base 8 Fit platform mounting bolt on base side 9 Stop connected port for rear outrigger with plugs 10 Fit slide base and shim into base Bind topping cylinder rod end boom 3 Insert boom mounting pin into column 1 Stop hose end with hose plug Hose plug 3 8 770280004 Hose plug 1 2 770280008 10 Fit slide base and shim into base Insert outrigger cylinder mounting pin into base 3 2 BOOM ASS Y 2 Fit hose plug into telescoping cylinder pipe Hose plug 1 2 770280009 Hose plug 3 8 770280006 1 Insert topping cylinder mounting pin 3 Stop hose end with hose plug Hose plug 3 4 77028001 1 1 Insert topping cylinder mounting pin into boom 2 Insert hose plug into hose joint for telescoping cylinder pipe 3 Insert hose plug into hose for winch 3 3 OUTRIGGER INNER BOX ASS Y Applies to both right and left ones 1 Stop pipe ends with plugs plug 728521200 1 Stop pipe ends for outrigger cylinder with plugs 3 4 PLATFORM ASS Y STREET side CURB side 3 5 REAR OUTRIGGER ASS Y optional 1 Stop connected port with hose plugs points hose plug 1 4 770280007 3 6 SINGLE LINE HOOK Hook for slinging single line 3 7 4 PART LINE HOOK optional Hook for slinging two or more lines 3 8 OIL TANK 1 No hydraulic oil is in the tank 3 9 EX
13. eck that shaft rotates wothout run out 12 4 4 MOUNTING THE PIPING AT LOWER PART Hydraulic pump 1 Mount the high pressure hoses and the rubber hoses to avoid interference with rotating members and do not let the hoses come close to the high temperatur members such as exhaust pipe Besides do not give a sharp bend to the hoses 2 Connect the rubber hose with the hydraulic pump first then fill the hose wit hydraulic oil by pouring it into the hose from other end to connect the hose end with the hydraulic oil tank Tighten the hose band securely to prevent air from entering rubber hose connection 3 Check that no oil leakage is found after mounting of the piping has been completed 13 4 5 MOUNTING THE BOOM Plate Spring washer f Plate fJ Spring washer A Bolt 1 Remove pins form the column and boom 2 Fit the boom ass y and the column together by inserting pins 3 Raise or lower the boom to align holes and insert derrick cylinder upper pin 4 6 CONNECTING THE HIGH PRESSURE HOSE FOR TELESCOPING CYLINDER 1 Remove plugs from boom pipes and hoses 4 in total 2 Connect high pressure hoses to boom piping hose dimensions 1 2 3 8 14 4 7 CONNECTING THE HIGH PRESSURE HOSE FOR WINCH lt 1 Remove both plugs fitted in the col umn and in the winch 2 Connect high pressure hoses to the connector on column side Note Pay attention to the ports to be connected High
14. ose high pressure 792502547 1 Hose high pressure 792503547 1 Clamp 602211071 Seat 090365170 19 Piping for rear outrigger alo 2 PUNCHING POSITION OF DATE OF MANUFACTURE AND HOW TO READ IT To assemble sub assemblies of the same date of manufacture as crane model name plate on side of column Q 1 rear part Inner box upper part both left and right Punching 989 Hook Punching Reading example Ti represents month 1 9 X Y Z Oct ber November December represents year lower two digits of the year 1998 A D 3 3 SHIPPING FORMS 3 1 BASE AND COLUMN ASS Y 2 Stop connected port with plugs g Plug 3 4 08US65060 foot pin together securely with wire 4 Remove vent plugs and insert blind plugs in their places Blind plug 725260300 6 Stop pump port with plugs and cap Plug 3 4 08US65060 7 8 Fit platform mounting bolt Aj Cap 1 2 760400016 5 Stop pipe ends 9 ig port wilh with caps at 8 points Hose plugs 770280007 Cap 770310032 Hose plugs 770280006 1 Insert hose plug into telescoping pipe hose 2 Stop connected port for hoist winch with plugs 3 Insert boom mounting pin into column 4 Insert blind plugs in place of vent plugs for swing gear box 5 Insert plugs to outrigger pipes 8 plugs 6 Stop control valve pump port with plug
15. t pressu hose 2 7 7 Sar SS S 27 22 27 Ed NS 2 NS CZ 52 NS v 4 8 ASSEMBLING THE OUTRIGGER INNER BOX 16 1 Remove slide base shim and cap pin attached to the pipe end 2 Insert the outrigger inner box into the base 3 Fix the horizontal cylinder of outrigger inner box on the base with pins 4 Remove the plug attached to pipe end of outrigger inner box to connect the pipe 5 Fit the slide plate in the slide base to mount it on the base by putting it between the base and the inner box 17 4 9 MOUNTING THE VENT PLUG Vent plug 013841120 XT q The swing gear box hove a plug in their casings to prevent oil leakage during transit Remove these plugs and fasten vent wound sealing tape in their place Remove the cover and then attach the cover again 4 10 MOUNTING THE PLATFORM ASS Y Mount the platform with bolts being attached to the mounting bracket of platform 4 11 CONNECTING THE ACCELERATOR CABLE Wire stopper lt Engine side gt View A Determine the distance between the center of injection pump lever and the accelerator cable so that desired engine speed can be obtained by operating the control lever on the crane and the control lever can make a smooth movement NOTE Attach the accelerator cable not to obstruct
Download Pdf Manuals
Related Search