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cobra 8000 - Pride Bodies

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1. MAX 1700 kg gt lt Kg 2100 gt Om 2 3 4 5 6 7 1 LOAD CAPACITIES COBRA 8000 Pict 22 maxiliff TECHNICAL DATA 8000 Crane rating ft lbs 50 000 Standard outreach ft 218 Slewing angle CONTINUOUS Slewind torque ft Ibs 5 000 Boom elevation 6 75 Lifting height from base of crane ft 214 Remote control Proportional Pump capacity hydraul H pto GPM 474 5 Working pressure psi 2 970 Crane weight lbs 1 450 WINCH SPECIFICATION 8000 Winch pull line lbs 4 120 Pull line speed 3 layer ft min 39 Rope diameter inch 3 8 Wire rope length ft 98 5 Cable breaking strength lbs minimum 20 700 Technical data not binding 151 20 9 16 130 7 16 01 5 32 18 1 8 18 lbs 15 12 LOAD CAPACITIES COBRA 8000 5 310 3 2315 i Aso ea j 3 bd x x 4630 2930 2090 Oft 12 15 18 21 24 Pict 23 E maxiliff 11 WIRING AND HYDRAULIC DIAGRAMS 11 1 ELECTRICAL DIAGRAMS MONO FUNCTION DUAL MODE d
2. GAME WITH NET HYDRAULICS BO THAT YOU CAM BE kmat a BREAST OF IMPORTANT THE OF RATION I CAUTION n IT AN DPENATIONAL DECALE DA CHARTS ONTHIS Cogne AME PEMOUED OF DEFACED CONSULT THE UWN EHS MANUAL FOR IMMEDIATE REPLACEMENT OUTRIGGERS WILL CAUSE SERIOUS CRUSHING INJURY STAND CLEAR 5 3 RULES FOR THE CORRECT POSITIONING OF THE CRANE 5 3 1Choice of crane operating place pressure on the ground Carefully choose the place where lowering and put into action the stabilizers of the crane outriggers The most important thing is the capacity of the ground to bear the pressure produced by the outriggers Make sure that the outriggers working area is free from underground piping tunnels holes The positioning must be carried out so as to operate the crane with the shortest outreach possible and without any obstacle in the working area Never move the crane from its rest position without stabilizing the truck The outriggers reaction is transmitted to the ground by steel pads When this pressure exceed the maximum admittable pressure value of the ground the surface of their bearing area must be increased by means of additional plates of firm material i e wooden plates The outriggers pads must work in the middle of the additional plates The required bearing surface can be easily calculated as follows when the outrigger s reaction and the admittable pressure on the ground are known Outrigger s rea
3. 2 1 INSTUCHON c ER 3 CRANE IDENTIFICATION cosas 3 1 V rsions and optional avallable inttr Rite aaa i 3 2 CRANE identification data cit li 4 CRANE USAGE AND LIMITS OF APPLICATIONS essen 4 1 CRANE classification and proper sage oce a er e p A E 4 2 IMproper usage t Lada ail ch nants dare ii aa 4 3 CRANE operators training niiia aria 5 SAFETY RULES mE T i 5 1 R le concerning People e bi 5 2 Rules concerning the crane 1a ta cd 5 3 Rules for the correct positioning of the crane eene et 9 31 Choice of the crane operating place pressure on the Ground ii 5 3 2 Safety distance from trenches and slopes uu iii i 5 3 3 Safety distance from electrical power lines asian 5 3 4 Grane and load ground connection iii dilo ie 5 3 5 Influence of the wind on the crane operationi ua E 5 4 Rules concerning safety in the traffic eee eee a a di 5 5 General rules on Winch Operations cauca nati 5 5 1 WINCH ECCE a aa 5 5 2 Operator Safety PS iio 5 5 3 General rules when operating WINch 4 Gia sia ian li 5 6 WIRE ROPE in heces A e A Rs ete 5 6 1 iuc PE 5 6 2 WIG FOE PRECAUTIONS EE l 6 DESCRIPTION OF THE CRANE sessi 6 1 Model 80
4. maxilift SERVICE CRANE Mod 8000 Code MD 0 180 USE AND MAINTENANCE MANUAL Rev 0 Edition 09 09 maxiliff OPTIONALS SUPPLIED ALONG WITH THE CRANE Description YES NO Oil tank Outrigger beam hydraulic jack The table has to be filled carefully with the above option when purchased PRELIMINARY INFORMATION Operator s and maintenance manual of MAXILIFT COBRA 8000 SERVICE CRANE Manual code MD 0 180 This manual is valid starting from serial no Manufacturer NEXT HYDRAULICS S r l Via Mediterraneo 6 42022 BORETTO Reggio Emilia In this booklet the word Manufacturer is referred to NEXT HYDRAULICS S r l List of documentation supplied along with the CRANE Operator s and maintenance manual for the end user SERIAL B naaa aii YEAR OF MANUFACTURING ATTENTION Always carefully read this manual before operating the crane Most of the accidents occurred during opera tions are caused by the omission of elementary precautions and non fulfillment of the safety instructions Many accidents can be avoided when their causes are well known and the relevant adequate counter mea sures are previously taken maxiliff INDEX 1 FOREWORD 9 O HO QA PAGE 1 1 SUMMA Sorrento li 1 2 ECL CMT 1 3 Manual revisionaias alia aci aie aaa 2 HOW TO CONSULT THE MANUAL iii
5. N DANGER electrocution hazard Always ground the crane perfectly Load ground connection In order to avoid the electrostatic charging of the load it is necessary to use a metal rod having a good conductivity with a length of 1 5 meters 5 ft roughly to be driven into the ground at least 1 meter 4 ft deep a power cable with a minimum cross section of 16 mm 0 025 sq in a second metal rod having good conductivity and an insulating handle complying to the relevant safety Regulations This rod has to be used to touch the load Then connect this cable to the ground rod on one side Moinsten the ground all around the rod to improve conductivity Then connect the other side of the cable to the insulated rod Both connections must be made using the relevant vices or metal clamps as an alternative EN maxiliff N DANGER electrocution hazard Always connect in a perfect way the load and the ground Before touching the load with your hands always ground the load by touching it with the insulated rod N DANGER electrocution hazard Always hold the rod by its insulated handle 5 3 5 Influence of the wind on the crane operation A strong wind can overload the crane so during operations keep under control the wind speed When working with full load the maximum admittable wind speed is 45 km h 28 mile h When this value is exceeded any crane operation must be stopped and the crane must be brought to the rest
6. If itis necessary to liftthe crane and or other parts make sure that they are locked as requested from current safety regulations Always use approved protective clothing safety gloves and protective glasses when using steel ropes as they produce steel splinters Never use the tools in a way different from the one they are meant i e pliers instead of wrenches The maintenance area is to be kept clean and dry Remove immediately any trace of water or oil Leakage of fluid from a very small hole may be almost invisible and yet strong enough to penetrate the skin Before starting looking for the leaks it is important to wear protective glasses with side shields Do not use your hands use a piece of cardboard or wood to locate the source of the leak Injuries caused by pressure fluid may result in serious infections so it is recomended to contact immediately a doctor Do not heap dirty rags with oil or grease they may be a danger of fire Instead put them in a metallic closed case Immediately replace any missing sticker or plate carrying a notice of danger attention or other in structions IMPORTANT Various part of the crane are manufactured with high tensile steel Never perform any operation welding drilling etc without authorization and instructions from the manufacturer A ATTENTION The crane is supplied with electrical and electronic devices installed Always disconnect the connections of these devices before carrying out welding
7. VM EV9 VR 5 OM OM phe 1 NC VM o EAR EV9 a V4 ge OC FAO EV4A EV4A 0 OH EV4B O EV3A EV3A EV3B EV2A EV2A HO OH EV2B EV1A EVIA EV1B GA y RADIO VERSION USE ONLY SOLO SU VERSIONE RADIO N PANEL COMPONENTS LAYOUT REAR SIDE VIEW DISPOSIZIONE COMPONENTI VISTA INTERNA sw6 nb us RADIO VERSION VERSIONE RADIO 7 8 MALE CONNECTOR CABLE VERSION VERSIONE TELE M12 FLAT CABLE PIATTINA M12 P as 20 rt VBATT I I ch me E E y J2F BEBE SERVICE CABLE CAVD DI SERVIZIO RADIO VERSION USE ONLY a M FEMALE CONNECTOR SOLO SU VERSIONE RADIO 778 MALE CONECTOR LI Sw5 Y ES amp Lu SW4 SW3 ES a HEB SW2 SW1 PANEL COMPONENTS LAYOUT FRONT SIDE VIEW DISPOSIZIONE COMPONENTI VISTA ESTERNA RADIO VERSION USE ONLY SOLO SU VERSIONE RADIO E eebra 1 6 463 Jh Jes Je6 J67 8 169 6 10 4881012141818 ES Jem i ta To ma 3 4 lg 2 Gn BL 111 i y El yee cm GND EI 2 ra PROPORTIONAL TRIGGER PULS
8. Wire rope is lubricated during manufacturing so the strands and individual wires in strands may move and adjust as the rope moves and bends A wire rope cannot be lubrificated sifficiently during manufacture to last its entire life Therefore new lubricant must be added periodically throughout the life of a rope to replace factory lubricant which is used or lost The surface of some ropes may become covered with dirt rock dust or other material during their operation This covering can prevent field applied lubricants from properly penetrating into the rope Therefore these ropes should be cleaned before being lubricated The lubricant applied should be light bodied enough to penetrate to the core of the rope Lubricant may be applied effictively by various methods It may be dripped on sprayed on or put on by brushing but in any case it should be applied at a place where the rope is being bent such as at a sheave It shold be applied at the top of the bend because at that point the strands are spread by bending and are more easily penetrated The service life of rope will be directly proportional to the effectiveness of the method used and amount of lubricant reaching the working parts of the rope A proper lubrificant must reduce friction protect against corrosion adhere to every wire and be pliable and not crack or separate when cold and yet not drip when warm manilift 9 7 POSSIBLE FAULTS AND RELEVANT REMEDIES Fault Cause Reme
9. a3 maxiliff for brought back or crumbling terrain safety distance a must be double of the slopes depth that is a 2 b for compacted not crumbling terrain safety distance a must be equal to the slopes depth that is a 1 b Distance to be measured from point Max reaction on the ground varies according to the vehicle where the crane is installed IMPORTANT The installer must calculate this max reaction on the ground and applied the value on the ou trigger jacks Pict 3 5 3 3Safety distance from electrical power lines Always keep a sufficient safety distance when you cannot avoid having electric power lines in the working area of the crane Special care must be taken when the power lines have not been disconnected by expe rienced people or when the lines status is unknown Voltage V minimum distance m ft upto 1000 v 1 4 from 1 kV to 110 kV 3 10 from 110 kV to 220 kV 4 13 from 220 kV to 380 kV 5 16 N DANGER Always keep a sufficient safety distance from electric power lines Follow present law regula tions When the voltage of the lines is unknown keep a minimum safety distance of at least 5m 20 ft 5 3 4Crane and load ground connection The crane can be electrostatically charged especially when the additional bearing plates are made of insu lating materials wood plastics It has to be noted that even when the crane has been connected to groun
10. and safe place The radio keyboard batteries last from 12 to 24 hours depending on their use It is suggested to let the batteries discharge until they are completely flat before starting a new recharge cycle maxiliff 6 3 5 1 RADIO SYSTEM PROTECTION DEVICES The radio control system is provided with some protection systems that are automatically started in case of radio interference on the crane working area that influences the radio control frequency range transmitter capacity field exceeded keyboard On these cases the system locks all the functions Press and release the emergency button to restore the functions In addition when the battery charge is too low for safety operations the system is blocked the green LED turns off and the radio module interrupts transmissions with the unit The keyboard is provided with battery energy saving system to reduce battery consumption When the keyboard remains unused for at least 15 minutes the radio system is set to energy save the green led turns off and the radio module interrupts the transmission with the unit receiver Press and release the emergency button to unblock 6 3 6 PROPORTIONAL MONO FUNCTION REGULATION HYDRAULIC UNIT Pict 11 The unit is consisting of two separate aluminium blocks The upper section includes the proportional adjusting valve VR and the manual bypass control valve OM of the proportional regulator The lower section includes the main relief
11. control When the boom is roughly horizontal or in any case higher than vehicle sides or other existing obstacles Then operate the switch crane swing to direct the boom in the desired direction Then operate the switch boom section extend until the hook has reached the required position 7 4 CLOSING THE CRANE Closing the crane into rest position is performed by carrying out the opposite movements to those made to open it taking special care at the end of the operation there are no parts protruding from the truck size Push the emergency button on the control board disconnect the control board connection and save it in the driver s cab 7 5 WINCH SYSTEM OPERATION The Winch is mounted at the rear of the first section boom It has capacities totally independent of the rest of the crane and can normally pull more than the crane itself can withstand Therefore care must be taken to insure that the load being lifted is within boom rating To lift some of the heavier loads on the capacity chart it will be necessary to multiple part reeve the winch block to increase the lifting capacity of the winch the speed is proportionately slower and remain in the strength limitations of the winch and wire rope The winch load rating chart on each machine provides the information for pull limitations on the winch with various applicable part reevings These ratings are based on providing the proper operating safety factor on the wire rope supplied w
12. in compliance with the relevant national laws and regulations When traveling on roads and public sites always respect the relevant national laws and regulations N DANGER Before traveling on roads make sure that the crane is folded in rest position If the crane is open or lying on vehicle s body exceeding the overall dimensions allowwed by the highway code it can hit bridges electric power lines or other obstructions Before driving away make sure that the lever of the pin securing the outrigger s beam is fully locked Accidental slipping out of the outrigger during traveling can result in serious damages Special care must be taken when driving nearby crossroads lever crossing and subways 5 5 GENERAL RULES ON WINCH OPERATIONS 5 5 1 Winch system operation The Winch is mounted at the rear of the first section boom It has capacities totally indipendent of the rest of the crane and can normally pull more than the crane itself can withstand Therefore care must be taken to insure that the load being lifted is within boom rating To lift some of the heavier loads on the capacity chart it will be necessary to multiple part reeve the winch block to increase the lifting capacity of the winch the speed is proportionately slower and remain in the strenght limitations of the winch and wire rope The winch load rating chart on each machine provides the information for pull limitations on the winch with various applicable part reevings These ratings a
13. movements will be jerking and dangerous Always release first the proportional but ton and then the selector of the movement chosen Pict 14 6 4 2 USE OF THE DUAL MODE PROPORTIONAL REMOTE CONTROL The dual mode remote control can be normally used as a mono function remote control when following the instructions of previous paragraph The remote control in object allows the combination of two movements at the same time by coupling the winch function raising or lowering to one of the remaining movements You always have to select first the two functions chosen and then to operate the proportional button metering the speed in order to achieve the desired speed even allowing at the same time the winch rope raising or lowering By releasing one of the movements the speed of the other one does not increase until the function is stopped By this way of operating the two speeds are nearly halved in comparison to the use of a single function omo f maxililff b 6 5 SIGNALS AND DIAGNOSTIC 6 5 1 KEYBOARD DIAGNOSTIC SIGNALS The following signal devices are found on the radio keyboard a beeper a green led Beeper signals Radio connection keyboard a brief signal beep indicates that the keyboard is powered through the emergency button along signal beep indicates that the RFID code radio frequency identifier exclusively used by authorized workshops self learning procedure has been activated four brie
14. or other operations with electric to ols on the crane or on any part of the truck When repair or maintenance operation is over before putting again the machine into service make sure that any tool or other piece has not been forgotten in places containing moving parts or close to them The machine and its accessories has to be kept in good conditions Replace failed or worn components with genuine spare parts or other approved by the Manufacturer 9 3 MAINTENANCE SCHEDULE 9 3 1 Daily checking e Check the level of hydraulic oil in the tank Check the hoses the fittings and all the other components of the hydraulic system in order to elimi nate any possible source of oil leak Check that all the crane is in good condition Immediately repair the item or the component found to be faulty maxiliff 9 3 2 Monthly checking Checkthe setting of the pressures in the hydraulic system and integrity of the seals e Check the absence of oil leaks Check integrity and tightening of crane tie rods and bolts Check integrity and tightening of hoses piping and their fittings Check fastenings and safety devices Check readability of symbols on the remote control Check integrity of hooks ropes chain and all the other lifting ancillary equipment e Check that all the identification and warning plates are still applied and readable Visually check all the structural components for any deformation backlash o
15. the panel 4 for crane movements 1 for engine START STOP The P L start stop safety stop emergency button P is located over the maneuver selectors it must also be used as keyboard on off button The green indication Led L is found aside the emergency button and the diesel engine START STOP selector if these two functions are activated The system foresees the possibility to supply and control these two external functions The keyboard panel is provided with the essential function guiding symbols with green background it results pleasant and intuitive for the operator The movement speed that has been pre established through the maneuver selectors S can be controlled through the potentiometric button that is housed on the bottom of the handgrip The control unit connector is applied at the end of the cable such cable remains flexible and easy to handle even if exposed to extreme conditions 6 3 5 THE KEYBOARD RADIO TRANSMITTER Pict 10 The operator interface is identical to the abovementioned one The differences are The absence of the integral cable replaced by a connector at the base of the handgrip to connect the battery supply serial cable 1 This 2 m cable is included in the standard supply and it charges the keyboard batteries it can also be used to control the crane through cable system A 10 m cable is available upon request it can be used to work on areas where the radio con
16. the tires Pull the outrigger s beams out of their housing till the yellow line painted on it is completely visible and make sure that the safety pins on the box are perfectly hooked on the beams Lower the outriggers pads down to the ground Be sure of not entirely lifting up the truck suspensions It is important for the truck stability that a part of the truck weight still burdens on the tires When swinging outrigger jacks are supplied check that it is in vertical position and with its safety pin inserted in its housing and well secured see picture 16 When lowering the outrigger jacks stay away from them to avoid crushing of feet and legs Never operate the crane without having checked that the outriggers are well positioned on firm ground If necessary their bearing area must be increased with additional pads The truck stability relies very much on the working conditions When the ground under the outrigger pads is sinking their bearing area must be increased The crane Manufacturer can supply additional plates with increased area Be sure that the lifted loads are for every outreach not higher than those stated on the load chart Before operating the crane be sure that all the pinned joints and the hook pin are safely locked by their retainers Lifting tackles chains or ropes must be applied to the hook in such a way that will not damage the hook safety latch While swinging the boom always keep the load suspended from the ground Dr
17. until crane moment becomes lower than that marked on the loading diagramm or intervent on winch lowering by putting the load on the ground A DANGER The load limiting device even when in perfect working condition cannot avoid accidents due to operator s maneuvering mistakes A DANGER It is strictly forbidden to operate the crane with its load limiting device switched off or put out of service or faulty NOTE The load limiting device can lock at the max main boom angle even without load In such case in orer to unlock the machine it is necessary to act simultaneosly both on the ex tension re entry and boom lowering levers maxiliff 6 2 3 Relief valve The main relief valve is on the control valve and limits the maximum working pressure 6 2 4 Pilot operated holding valves These valves are installed on every cylinder and will stop and lock every motion of the cylinder should any pressure loss occur Before starting operations it is necessary to check that these valves are perfectly working as follows lift a load and raise the boom up to an angle of 45 upwards with the boom sections partially extended Switch the truck engine off push and pull repeatedly all the control switches the load must remain still 6 2 5 Safety devices sealing Some safety devices or crane components can be sealed after setting during testing operations Such sealing can be only removed by the manufacturer or by an authorized workshop who w
18. valve VM the dump valve EV9 and the control solenoid valves EV A EV B two for each movement The solenoid valves EV9 EV3B EV2B EV1B EV1A are equipped with a manual override to be used only for emergency failure of the electronic control unit or the button strip lack of power supply In such cases it is necessary to proceed as follows a fully turn counter clockwise the valve handwheel OM in order to bypass the proportional valve VR b fully turn counter clockwise the manual override of the valve coupled to the desired movement extension re entry boom lowering etc c finally fully turn counter clockwise the manual override of the valve EV9 in order to activate the desired movement d once the standard working conditions of the crane are restored always remember to close completely the manual overrides by turning them clockwise e finally close completely the bypass valve OM by turning the handwheel clockwise maxilift 6 3 7 PROPORTIONAL DUAL MODE REGULATION HYDRAULIC UNIT Pict 12 The unit is consisting of two separate aluminium blocks The upper section includes the proportional adjusting valve VR the manual bypass control valve OM of the proportional regulator the main relief valve VM the winch operating solenoid valves EV4A EV4B the dump valve EV9 and the solenoid valves EV3 EV4 required to operate the win
19. 0 Snellen in one eye and 20 50 in the other with or without the aid of corrective lenses e e e e e maxiliff normal depth perception and field of vision peripheral ability to distinguish colors if color recognition or differentiation is required for safe operation adequate hearing with or without a hearing aid sufficient strength endurance agility and coordination to meet equipment operation demands emotionally stable not subject to seizures loss of physical control dizziness or have physical limitations which could impair the ability to safety operate the crane maxiliff 5 SAFETY RULES 5 1 RULES CONCERNING PEOPLE Always wear the prescribed personal safety devices Always wear approved accident prevention clothing such as protective helmets anti slip shoes protec tive gloves antinoise headphones protective glasses reflective jackets with breathing apparatus Con sult your employer regarding current safety regulations and accident prevention equipment Do not wear ring wristwatches jewelry loose fitting or hanging clothing such as ties torn garments scarves unbuttoned ja ckets or unzipped overalls which could get caught up in the moving parts of the crane Keep quickly and readily available on the truck a first aid box and a fire extinguisher The fire extin guisher must always be kept charged and has to be used according to current regulations 5 2 RULES CONCERNING THE CRANE The Ma
20. 00 H alia 6 2 Safety Devices sica ais 6 2 1 Safety devices installed oe dialer 6 2 2 Load lMIINO ASVICE EU tea ia ei E 6 2 3 Rellano 6 2 4 Pilot operated holding ValveS 1 2 Ascii dian en riter a aa 6 2 5 Safety devices seallng ii erint ott la Aia 6 3 Microprocessor remote Control System ecu ia M 6 3 1 Available control VOTO sis 2ate li 6 3 2 Electronic power Unit naaa des 6 3 3 The radio receiverunit c M r e 6 3 4 The cable keyboard m Nia 6 3 5 The keyboard radio trasmmitter eiecit Iaia 6 3 5 1 Radio system protection device 6 3 6 Proportional mono function regulation hydraulic unit essen mee 6 3 7 Proportional dual mode regulation hydraulic unit emen 60 93 80 WI O si A ae aaa e 6 4 Remote Control USE ui aa ad i 6 4 1 Use of the mono function proportional remote control mmn 6 4 2 Use of the dual mode proportional remote control isisisi esiosan naaa aa aipa eaaa eikai AE si NE c 0 4 00 TV FARA A WWW N N N S maxiliff 6 5 Signal and diagrmnostle OE OP ior t exer ptr au ne eu fas feet paid hs elu rait ues Page 22 6 5 1 Keyboard iGlagnOStie Signal e A 6 5 2 Display Messages M ita 23 6 5 3 Normal displa
21. 15 Overcenter valve 16 One way restrictor OMONDOARWHND WI cera XE 7 BE RG M LT p it P P1 d L e Fa TR DS 7 M K t ll i n i I Pm E d A qu yA Pat A E evs B a PTO VERSION VERSIONE PTO dn N iP o 4 N AF EH ng FA EA vas L B S o Gus 4 gt pi 7 UI En ec L NU A mS 4 a EV2A Eg B el ea A es B EVA EVB Lel Al n Pict 25 maxiliff 11 2 2 Hydraulic diagram Dual mode proportional Pump Electrohydraulic unit Rotation motor Lifting cylinder Overcenter valve Pressure switch 1st extension cylinder 2st extension cylinder Overcenter valve 10 Sequence valve 11 Oil filter 12 Oil tank 13 Swivel hydraulic coupling only PTO version 14 Winch motor 15 Overcenter valve 16 One way restrictor OMONDOABRWHND n Dna ft d 2 GA T t 8T gt RG T Bat
22. ANTE PROPORZIONALE RADIO VERSION USE ONLY MEER EIE SOLO SU VERSIONE RADIO Pict 24 maxiliff 11 1 SW1 SW2 SW3 SW4 SW5 SW6 L1 ES V3 V4 EVIA EV1B EV2A EV2B EV3A EV3B EV4A EV4B FA FV FB PM PT VR SC EV9 DESCRIPTION Crane rotation selector Boom movement selector Extension selector Winch selector Engine start stop selector Optinal function selector opt Green led Emergency push button Circuit board Proportional trigger button Winch electro valve solenoid Winch electro valve solenoid Clockw rotation electrov solenoid Counter clockw rotation electrov solenoid Boom lifting electro valve solenoid Boom lowering electro valve solenoid Extensions electro valve solenoid Extensions re entry electro valve solenoid Winch lowering electro valve solenoid Winch raising electro valve solenoid Winch lowering stop end Winch raising stop end Boom lowering stop end Pressure switch Pressure tansducer Proportional electro valve solenoid Setting connector Safety valve solenoid maxiliff 11 2 HYDRAULIC DIAGRAMS 11 2 1 Hydraulic diagram mono function proportional Pump Electrohydraulic unit Rotation motor Lifting cylinder Overcenter valve Pressure switch 1st extension cylinder 2st extension cylinder Overcenter valve 10 Sequence valve 11 Oil filter 12 Oil tank 13 Swivel hydraulic coupling only PTO version 14 Winch motor
23. ED eU Eve LUE d YS LEER Ha dX EROR He EUR IR e ug 85 9 3 Maintenance schedule en onere t Per oe neci et RE DRE qu ien ertet ede 96 9 3 1 Daily Checkiig nen 36 9 3 2 Monthlycheckingi ac sila aLaaa s E 537 9 3 3 Checkingevery SDCImonths insere re iret oft cei re cis eti ei dee Prec nde 37 9 3 4 Gul c Me rre 37 9 4 Crane Sec me ats 88 9 4 1 Oil level CHECKING me 988 9 4 2 Ie Ee yip EI INIRE 88 9 4 3 Oil filter cartridge Maintenance eo een eto Ee etn ETERNI en ER c ERE Eas UI HIE siste EE 988 9 4 4 Slewing mechanism Maintenance ccoo nr eunte onere mit dee 839 9 4 5 Greasing the hydraulic boom sections iiinn nennen enne nnne trennen nennen 89 9 4 6 Wear pads check and replacement cuina daa iia 39 9 5 Greases and ollS reference Table cota ib 40 9 6 WIG TODO somo 41 9 6 1 Wire ROPE IMSPOCHON eiii le ad a cinc a eddie 41 9 6 2 Rope replacement isi cete rio e tease cien ae dec Er Ebr aid 41 9 6 3 Wire rope lUbmcation assisi EL ORE ERE D er eie R eh RO EAE Ric E oL Lea eiu eres Ead dU RR E REESE na 42 9 7 Possible faults and relevant remedies eire ai teens 43 10 TECHNICAL DATA nd A A ce ati iota ees esas 45 erui A acacia Performance cavas ida aaa AL meee Load chart table cedere na
24. LIST Check the existence of oil leaks Check the correct working of the load limiting device Check oil level and fill up if necessary e Check the good conditions of hoses and piping Checkthe good conditions of painting and chrome plating Check the correct working of safety valves 8 3 SAFETY TIPS FOR CRANE STARTING IN COLD CLIMATES In the crane with PTO driven wait for some minutes with the pump running at no load before operate any crane movement 8 4 CRANE PROTECTION AND STORAGE 8 4 1 Shortshutdowns Wash and clean the crane lubricate all the parts provided with grease nipples and the slewing system maxiliff ATTENTION Never wash the crane with chemical products or high pressure water jets as they can cause the detaching of the stickers water entering inside the electrical components and the slewing case 8 4 2 Long shutdowns Same precautions as above and moreover apply protective oil on the entire crane surface cover the crane using a plastic curtain against rain etc store in a dry place under roof disconnect the connections to the truck battery maxiliff 9 MAINTENANCE 9 1 WARNINGS Do not wear rings wristwatches jewelry loose fitting or hanging clothing such as ties torn garments ordinary shoes unbut toned jackets or un zipped overalls which could get caught up in the moving parts of the crane Instead always wear approved accident prevention clothing such as protective
25. M OUT open circuit EV on off 3b TELESCOPIC BOOM IN open circuit EV on off 4A WINCH DOWN open circuit EV on off 4b WINCH UP open circuit E3 open circuit E4 open circuit VR proportional valve The system through simple operations allows to enter other menus which can be helpful for the operator or a technician from the After Sales Service These menus are MICRO SWITCHES AND PRESSURE SWITCH DISPLAY MENU CURRENT DISPLAY MENU for proportional valve adjustment REMOTE CONTROL KEYBOARD DISPLAY MENU WORK PRESSURE DISPLAY MENU The following calibration and regulation menus need specific qualification and are exclusively used by authorized workshops RAMPAND CURRENT CALIBRATION MENU MOMENTUM LIMITER THRESHOLD VALUE SELF LEARNING MENU SYSTEM TYPE SETTING MENU SINGLE FUNCTION DUAL MODE MOMENTUM LIMITER TYPE SETTING MENU RFID Radio Frequency Identifier CODE LEARNING MENU maxiliff 6 5 4 MICRO SWITCHES AND PRESSURE SWITCH DISPLAY MENU This menu is accessed from the Normal Display Menu through the following procedure push the proportional button to its maximum level then operate the 1A and 3B movements simultaneously for atleast 5 seconds the maneuver can be performed in radio mode or through serial cable In this menu the state of FA FB FV PM micro switches are displayed cyclically with a 2 5 seconds interval each micro switch can be in one of the follo
26. PIC BOOM OUT C3b contact 3B closed TELESCOPIC BOOM IN C4A contact 4A closed WINCH DOWN C4b contact 4B closed WINCH UP C5A contact 5A closed START C5b contact 5B closed STOP When no operation is activated the electronic control unit automatically switches to the Normal Display Menu after 60 seconds otherwise a new power on is required in order to get out of this menu maxiliff 6 5 7 WORK PRESSURE DISPLAY MENU This menu is only available on the momentum limiter system with analog pressure transducer and it displays the real time oil hydraulic pressure in bar This menu can be accessed from the normal display menu through the following procedure Fully press the proportional button and simultaneously start maneuver 1A and the STOP selector for 5 seconds the maneuver can be performed in radio mode or through serial cable 80 bar work pressure display example i I i 1 nm don Turn the system off and on to exit this menu 7 OPERATING INSTRUCTIONS 7 1 GENERALATTENTIONS The crane must be used exclusively by qualified and skilled operators They must know location and func tion of every control instruments indicators lights plate and sticker N DANGER Before starting operations make sure that nobody is in the working area of the crane e e e e e e e The crane must work only on flat ground Make sure that the truck is well braked and if necessary apply blocks to
27. Switch on the hydraulic power pack A IMPORTANT In cold weather and in winter it is advisable to wait a few minutes with the pump running at no load before starting to operate the crane Extend the outriggers beams acting separately on each side of the truck Their release is made turning 180 upwards the locking handle 2 on picture 14 Pull the beam 1 on picture 14 out for a length of approx 20 cm 8 in then turn again the locking handle 180 downwards in its previous position Pull again out the outrigger beam and the locking pin of the handle will automatically engage and lock the beam when its working position is reached Always extend fully the outrigger beams to their working position i e maximum opening position to grant the maximum stability of the vehicle and safety Always pull and push the outrigger beams acting on the handle 3 on picture 14 foreseen for this purpose never pull the hoses or piping maxilift maxilift ATTENTION The outrigger beams are in their working position when the yellow band existing on every beam can be entirely seen Lower to the ground the bearing pads of the outriggers jacks one at a time acting as follows Hydraulic jack Fig 15 Open the shut off valve 1 to allow the lowering to ground of the cylinder s pad and rod 2 The valve is open when its lever is on position A Operate the corresponding lever of the control valve until the pad reaches the ground Avoid to lift th
28. TIONS i n EMERY ETOM Pole pref gd Ihi tears A re arm Bah E OS f oma hueh genmemn doen bach aa ko Paige iy quad onda irrig mo hard wT Maii ua E LHE Ml HART Tap lar co nia Ti ndaj TRAVEL qllo Tomapt sm Lun DI pitti pari Por ace Jim um E h e r uu rr WM m Irge ol boot making A la tiaras mH gp n lhm yy ing Peg neben in Lo CA ul das alaa nali ip a lA nnam ralng diraclion aisi ae reerd ac al Ei ler pigna nly if xd mermiuT BOUM iTimacuphg CATCHO BOOM Teh coping Boarsay Bem fei Boami Pun ie chi marii Pah wang pard ach aci ers peor auream moran comer EXTRACTED FROM ANSI STANDARD ABDbEMOUM 930 55 1985 A 130 5d 1484 THIS COMPLIES WITH Ciria TANDA ADS MOYE LOL Uu cre hend sa brp inp malnm egal cmd chee TEE LOAD Mih aam piaba THE LORD Wih arm mire Cr hand menor an nre al Harm ai vp PRG angu n dem DATA Doh Ha lin Fawn ume np aux pal Anm aur as keng aa load merda det as ng ia homed masa Pi ict 17 33 maxiliff 8 PUTTING THE CRANE INTO SERVICE 8 1 TEN RULES FOR THE PERFECT CRANE OPERATOR Always comply with the following ten basic rules 1 When approaching the crane for the first time become on familiar terms with it executing all the manoeuvres the crane can perform during working Carefully read all the prescriptions of this manual and execute step by step the activities hereby described to be sure of the correct under standing 2 This manual must al
29. agging of the load is forbidden Never stay or walk under hanging loads or within the operating radius of the crane Do not use the crane near electric power or telephone lines Never start the crane operation without signaling it in a proper way The load should never be lifted or carried on areas where people are passing or working If this cannot be avoided in any way hese operations must be properly signaled Before leaving the controls make sure that the control switches are in neutral position the main switch is turned off and the load is resting on the ground When the working area of the crane cannot be clearly seen from the operator control deck a second operator charged with signaling is required see pag 30 Stay away from the outrigger beams when they are pulled in to avoid crushing hazard between them and the truck parts When the work is over make sure that the outriggers beam are locked in rest position and the shut off valves are closed Lack of doing this may result in serious danger if these parts come out whilst traveling on road The stickers and plates applied on the crane are necessary to enable a safe usage of the same Should them be no longer readable replace them as soon as possible with new ones Always disconnect the power take off before driving away If the truck engine turns at high revs the PTO could be damaged The operator should be someone who is familiar with type of crane and has had some experience
30. are completed with notices stating the dangers their nature the avoidance actions to be taken and tips to be followed N DANGER In this manual the crane is shown in many pictures with its panels or covers removed for a better evidence It is forbidden to use and operate the crane with panels covers and other safety devices removed maxiliff 3 CRANE IDENTIFICATION 3 1 VERSIONS AND OPTIONS AVAILABLE The service instructions written on this manual are referred to the CRANE MAXILIFT COBRA 8000 This model is supplied in two version When ordering are to be specified Version Remote control Hydraulic supply Power supply 8000 KP H Cable Proportional mono function Fed by a punp driven by a P T O truck 12 24V 8000 KPD H Cable Proportional dual mode Fed by a punp driven by a P T O truck 12 24V 8000 RKP H Cable Proportional mono function Fed by a punp driven by a P T O truck 12 24V 8000 RKPD H Cable Proportional dual mode Fed by a punp driven by a P T O truck 12 24V The following options are available for the above versions Type of optional Available on models Oil tank All Outrigger beam hydraulic jach All 3 2 CRANE IDENTIFICATION DATA Every crane is identified by its serial number and name of the model written on the plate riveted on the crane The same data are also punched on the crane column Data plate description Colum punc
31. are parts and components not specifically approved by the Manufac turer To carry out modifications or structural interventions without the approval of the Manufacturer To operate the crane out of the admittable range of temperatures e 30 C 50 C 22 F 122 F Any of the above mentioned improper usages or non observance will cause immediate cancellation of the Manufacturer Warranty cancellation of Manufacturer liability for damage of people animals things ATTENTION The improper usage can damage the crane and subsequently result in dangerous situations for the staff entitled to its operation 4 3 CRANE OPERATOR S TRAINING The crane must be operated only by skilled people trained for this purpose This people will be asked for a basic technical education and a working experience in the mechanical hydraulic and electrical field a technical knowledge of cranes operation covering all the points especially the load charts and the truck stability against tipping over practical knowledge of slings usage and precautions when moving the loads complete knowledge of all the operations and motions to be executed with the crane competent and qualified personnel of the authorized workshop which has installed the crane will take care of this complete reading and understanding of this manual complete knowledge and understanding of safety and risk avoidance regulations Vision of at least 20 3
32. ch and another function at the same time The lower section includes the control solenoid valves EV A EV B two for each movement The solenoid valves EV9 EV3B EV2B EV1B EV1A are equipped with a manual override to be used only for emergency failure of the electronic control unit or the button strip lack of power supply In such cases it is necessary to proceed as follows a Fully turn counter clockwise the valve handwheel OM in order to bypass the proportional valve VR b Fully turn counter clockwise the manual override of the valve coupled to the desired movement extension re entry boom lowering etc c Finally Fully turn counter clockwise the manual override of the valve EV9 in order to activate the desired movement d Once the standard working conditions of the crane are restored always remember to close completely the manual overrides by turning them clockwise e Finally close completely the bypass valve OM by turning the handwheel clockwise m Bs LE 3 2 e W E B DI U 6 3 8 WIRING pict 13 Made up of a single wiring unit that is connected to the electronic unit through two sealed multipolar connectors 1 provided with quick hooking system The wiring includes the solenoids to connect the solenoid valves located on the hydraulic unit it also connects the unit to the safety limit switches FA FB FV to the pressure gauge or to the
33. city always check their actual weight not to overload the crane or the winch Special care has to be taken when handling big loads when free they can remain hanging on the crane and result in damages and accidents maxiliff Asudden stop when lowering a load This creates high forces of inertia on the crane structure with relevant dangerous overload Hitting the rope where the load is suspended overload is generated Side pull dragging the load on the ground All these operations originate strong overloading forces on the crane The outriggers are badly positioned or the ground is not firm in both cases the truck tilts and could tip over Working with strong wind or wind gusts The manual boom sections are not correctly installed The load is not correctly slinged So the lifting accessory used chain rope etc breaks or flips out and the load falls down to earth The boom suddenly unloaded springs back and this could result in tipping over Trying to lift fixed load up rooting of trees raising of culverts etc Even if their load is smaller than the capacity of the crane the dynamic force created when it is suddenly stripped may easily exceed the capacity and make the truck tip over Swinging movements of the load When acting on the slewing control too suddenly the load starts swinging Danger of overload And boom s breaking 7 8 STANDARD HAND SIGNALS STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERA
34. ction look at the plate applied on the outrigger jack Admittable pressure on various types of soils look at the following table for indicative values e Bearing pressure calculation When Then t outrigger s reaction tons US ton p bearing pressure on ground daN cm Ibs Sq in A bearing plate surface cm sq in p 1000 t A metric p 2000 t A U S A ZN ATTENTION In case of doubts on the ground carrying capacity make a hardness test of the ground Always level the crane acting on outriggers with reference to the level indicator fitted on the truck Maximum admittable angle is 3 5 3 2Safety distance from trencher and slopes The crane must be positioned sufficiently far away from trenches or slopes The safety distance depends also on the soil if the slopes or trenches are not sustained Rule of the thumb look at the following picture SOIL ADMITTABLE PRESSURE daN cm Ibs sq in Dumped non compacted soi 0 0 1 0 0 0 14 natural virgin soil mud marshland peat 0 0 0 0 incoherent artificially compacted soils fine and medium size sand 1 5 21 large size sand gravel 2 0 28 natural coherent terrain doughy 0 0 0 0 soft 0 4 6 stiff 1 0 14 demi solid 2 0 28 solid 4 0 56 rock not altered by athmospheric agents well stratified and slightly cracked closed stratified 15 0 213 solid stratified pillar like 30 0 426
35. d the load can be loaded electrostatically charged because the rope pulleys or the slings and ropes used to lift the load are made of insulating materials N DANGER Always connect to ground both the crane and its load before starting operations Grounding is especially required when working close to electric power lines working nearby powerful broadcasting plants such as radio T V an so on working nearby electricity plants where high frequency is involved when a storm is approaching Crane ground connection N DANGER electrocution hazard While grounding the crane carefully follow the below mentioned instructions in order to avoid electrocution hazard In order to avoid electrocution hazard the following tips must be followed drive a metal rod roughly 1 5 meter long 5 ft in the ground at least 1 meter 4 ft deep connect a power cable of minimum 16 mm 0 025 sq in cross section to the former rod This linkage must be made with a hose clamp or a vice moisten the ground all around the rod to improve conductivity NOTE Arrange the linkage for ground connection and the relevant symbol connect the remaining end of the cable with the point of connection indicated en on the crane base N DANGER electrocution hazard The ground cable must be connected only on the indicated point on the crane base Avoid any linkage to screwed on parts of the crane such as valves cover plates gearboxes etc
36. d only to qualified skilled people The recommended procedures of repair and maintenance must always be followed carefully If ne cessary ask for a preventive authorization Before taking any part away of the crane always switch the motor off and be sure that the pressure in all the circuits has been discharged See relevant manual Do not put the head or fingers or feet or arms or any other part of the human body into an area where the danger of shearing or crushing exists if the parts of the machine have not previously locked in a safe way Do not use your fingers to align holes or slots always use appropriate centering tools Wear protective glasses with side shields to protect your eyes when using compressed air for clea ning the machine parts Do not allow the pressure of the air to exceed 2 bar 29 psi The access steps or platforms in the workshop or where the crane is operated must be built accor ding to current hazard avoiding regulations Never use petrol or thinners or other flammable liquids or detergents Use instead authorized com mercially sold cleaning products which are granted to be non flammable and non toxic N DANGER of fire or scald It is forbidden to use naked flame as lighting device when carrying out checks or looking for le aks in the machine Do not lubricate repair or carry out settings on the crane when it is working unless this is expressly required in the instructions of the Operator s Maintenance manual
37. dy Vibrations in hydraulic cylinder and jerkin gs at the first manoeuvres The temperature of the hydraulic oil is too low Perform manoeuvres without loads for some minutes to warm the oil up Vibrations with every functions when the oil is hot Lacking of oil in the tank Air in the hydrau lic system Add hydraulic oil to the tank Operate the control lever carrying the cylinders to stroke end for some times in both directions All the crane movements are very slow even when unloaded Suction hose from oiltank crushed or obstructed The pump is drawing in air Replace or clean the suction hose Check that the relevant fittings are well tightened The hydraulic extension are not exten ding in the right sequence Bad lubrication Sliding pads are worn Sequence valve on extension cylinder has to be adjusted Grease the extensions Replace sliding pads Adjust the sequence valve Slewing is not regular or with insufficient power Ground slope too great Domaged slewing motor Lucking of lubrication Level the truck Replace slewing motor Grease show chapfer 9 44 The crane does not lift the loads of the load chart table Defective pump Uncorrect settings of the valves Hydraulic cylinder sealings are worn Replace the pump Adjust valve settings Replace worn sealings The crane lift the load but cannot hold it Uncorrect settings of the valve
38. e hand held control box does not work Check relevant fuzes and indicator LEDS Check tension with a tester Check the solenoid of the valve Check and clean the valve cartridge As above Check the control box All the functions work at full speed It is not possible to adjast the speed Multi function operation are not possible The proportional valve is not working The trigger on the hand held control box is not working Electric valves EV3 and EV4 does not work Pict 12 Check and clean the valve cartridge on an authorized workshop Check the relevant potentiometer and electric board on an authorized workshop Check the relevant solenoid Check and clean the relevant valve car tridges One or more movemente keep on func tioning while selecting another function Solenoid valve jammed in open position dirt working shaving long inactivity pe riods Manual operator where foreseen acti vated Unlock clean or in case replace the so lenoid valve cartridge Close down the manual operator The winch does not work when single operated Solenoid valve V4 jammed in closed position dirt working shaving long inactivity periods pict 12 Unlock clean or in case replace the solenoid valve cartridge The winch does not work when operated together with other functions Solenoid valve V3 jammed in closed dirt working shaving long inactivity periods pict 12 Flow divider 1 wrongly set or n
39. e hydraulic oil Make a working test of the crane with and without the load take care of listening to strange noises coming from the crane parts 9 3 4 Others e Stability of unit throughout working area Check stability procedure annualy or when any change is made to crane or truck maxilift 9 4 CRANE SERVICING 9 4 1 Oil level checking Check the hydraulic oil level monthly with the truck on level flat ground 1 minimum oil level with the crane booms raised at full elevation and fully extended and hydraulic outrigger completely out the oil level must NOT be lower than the indicator 3 2 maximum oil level when the crane is in travelling position the oil level must be two inches below the plug cap of the dipstick 9 4 2 Oil change The oil deteriorates during daily usage The oil change every year is necessary to avoid damages to the hydraulic system Take a container with a capacity of 40 liters 10 gal and having suitable dimensions to be positioned under the oil drain plug 2 AN ATTENTION Itis forbidden to pollute the environment with exhausted oil After the replacement it is important to carry out a bleeding of the circuit otherwise the air introduced in the system with this operation may damage the sealing parts To do that operate every function of the control valve driving it smoothly to stroke end Use only the oils stated in the greasing lubricating table or equivalent ones chap 9 5 9 4 3 Oil fil
40. e truck off the ground unloading the vehicle suspension this reduces greatly the stability of the truck Then turn again the valve lever to its previous C closed position Swinging hydraulic jack Fig 16 When swinging jack are fitted before operating the shut off valve 1 make sure that the jack 2 is in vertical position with its pad 3 oriented downward its pin 4 secured with the retainer spring 5 If not take off the pin turn the jack downward and then lock in the working position in the aforesaid way Then open the valve 1 as already explained hidraulic jack operate the corresponding lever of the control valve and lower the pad to the ground as described before When duly positioned close the valve 1 as described Z ATTENTION When turning the swinging jack and removing its pin be careful and hold it up to prevent it from falling down because of gravity resulting in damage or injuries Repeat this sequence of operations for the outrigger jack on the other side of the truck and for every other jack fitted on the truck Make sure that the vehicle is level in order to have a good stability Maximum allowed angle is 3 AN IMPORTANT Proper leveling has to be checked by means of a level instrument fitted on the truck Pict 14 maxiliff maxiliff 7 3 OPENING THE CRANE Starting from the crane in rest position operate the switch of boom hoist up on remote
41. econds afterwards the recharge procedure is automatically started if no errors are found The following signal devices are found on the remote keyboard a beeper a green led Beeper signals 4 brief signal beep indicates that the keyboard is powered connected cable and emergency button switched off Led signals led ON indicates that the keyboard is supplied the emergency button is released led OFF indicates that the keyboard is out of service the emergency button is switched maxiliff 6 5 2 DISPLAY MESSAGES As previously explained the electronic control unit is fitted with a 3 digits display showing messages which help the operator understanding if everything is working properly the operating state and the functioning of its electrical components The operator when led by an expert or following basic operations can actually read on such display different messages helping him locating possible electrical anomalies on the system This is a great help for searching and identifying possible faults preventing useless and unsuitable interventions by the after sales service Against possible displays of error messages the operator is requested to contact the Technical After Sales Service 6 5 3 NORMAL DISPLAY MENU ao When switching on after a sequence of messages on the display this must show c D c3 AL DJ When carrying out whichever movement by selecting the function it must appear W
42. ension idling operations in order to allow the distribution of the grease 9 4 6 Wear pads check and replacement Wear pads need to be replaced when their thickness drops under 5 5 mm 0 22 inch ATTENTION Failure to replace the wear pads when they have reached the above stated wear limit can prejudi ce to the good and safe operation of the crane Pos B Pict 19 Pict 20 EN maxilift 9 5 Greases and oils reference table BRAND TOTAL MOBIL ESSO AGIP IP BP GREASE MULTIS MOBILGREASE BEACON GR MU ATHESIA ENEGREASE 9 EP2 MP EP2 EP2 EP2 LRMP GREASE y MULTIS MOBILGREASE BEACOM GR MU ATHESIA ENERGREASE LR MP MP EP2 EP2 EP2 EP2 Y HYDRAULIC AZOLLA DTE NUTO OSO HYDRUS HENERGOL OIL I ZS 32 15 H 32 32 32 HL 80 ZS 46 25 H46 46 46 OIL GEAR CARTER GEAR SPARTAN BLASIA PONTIAX ENERGOL 2 EP 100 627 EP 100 100 HDS GR XP100 e EP 150 629 EP 150 150 GR XP150 fortemperate and cold climate forhot climate Pict 21 EN maxiliff 9 6 WIRE ROPE 9 6 1 WIRE ROPE INSPECTION Each day and before use inspect the wire rope for the following conditions 1 Kinking Sharp bends 6 Rope diameter loss 2 Crushing 7 Rope strand uneveness 3 Unstranding 8 General corrosion 4 Birdcaging 9 Broken strands 5 Core protrusion 10 Cut strands N DANGER Do Not open the rope for inspection In
43. f signals indicate that the keyboard has switched to energy save mode or that battery charge is not enough Cable connection keyboard serial a brief signal beep indicates that the serial cable has been connected Led signals Radio connection keyboard led ON indicates that the keyboard is supplied the emergency button is released and the battery level is enough to work Slow continuous blinking led indicates that the keyboard is supplied and the battery charge level is too low to work led off indicates that the keyboard is in energy save mode or out of service due to insufficient battery charge level or that the proportional button is switched on a continuous and fast blinking signal indicates that the keyboard is tuned to the auxiliary channel for example when the RFID code radio frequency identifier exclusively used by authorized workshops self learning function is used Cable connection keyboard serial led with intermittent blink two blinks followed by a pause indicates battery recharge mode led ON indicates that the keyboard is supplied for example that the serial cable is connected and is ready to be used during battery recharge it indicates that a function has been activated led OFF indicates that the keyboard does not recharge the batteries and that the emergency button is pressed NOTE every time that the serial cable is connected the keyboard performs the battery status control for about 3 s
44. helmets anti slip shoes anti noise headphones protective glasses and reflective jackets with bre athing apparatus Consult your employer concerning current safety regulations and accident pre vention equipment Apply a clearly visible plate on the cab door or on the control valve with the notice crane under maintenance Do not start Do not get under any raised part of the crane unless a safety lock support has been applied to it Before starting any maintenance or repair operation always install safety locking supports on any raised part of the crane especially the boom system Do not jump into or out of the machine always use adequate steps and handrails The truck engine should be started in closed rooms only if well aired Before operating the crane make sure that nobody stays or walks in the working area 9 2 MAINTENANCE PRESCRIPTIONS Many damages and accidents are caused by a bad maintenance or by mistakes in the maintenance itself Common causes are recognized to be leacking of oil grease or anti freeze liquid dirt on crane components or assemblies breaking of ropes or slings safety valves load limiting device or other safety devices out of service or not in good working conditions hydraulic plant in bad conditions for instances hoses damaged loose hydraulic fittings etc Every maintenance work has to be carried out with care Do not delay repair or maintenance works on the crane Repair works must be assigne
45. hen the overload condition is almost reached the display shows LI a 99 When the crane goes gets locked by the LLD overload the display shows O In this case you have to carry out the manoeuvres allowing the overload reduction i e extension re entry or winch lowering The boom might be blocked on maximum lift position on some crane models even without load To be able to descend with the lifting cylinder it is necessary to select the extension insertion or the winch descent and immediately afterwards the boom descent followed by the proportional button In case of pressure gauge pressure transducer signal absence O jc PI E Moreover the system can show the following error messages which can be displayed when operating or trying unsuccessfully to operate gt The messages and relevant meanings are the following i O xx followed by the solenoid valve abbreviation LI It means open circuit detected on the solenoid valve in object Examples Open circuit alarm on solenoid valve EV3B CI MW o The following table shows all the displayed alarm codes Alarm Type Valve on which the alarm is detected open circuit EV on off 1A CLOCKWISE ROTATION open circuit EV on off 1b COUNTER CLOCKWISE ROTATION open circuit EV on off 2A BOOM UP open circuit EV on off 2b BOOM DOWN open circuit EV on off 3A TELESCOPIC BOO
46. hing a Crane model g Crane model b Serial number h Serial number C Year of manufacturing d Lifting class e max SWL f Approval number ATTENTION It is strictly forbidden to change erase modify the data written on the plate and punched on the column g h maxiliff 4 CRANE USAGE AND LIMITS OF APPLICATIONS 4 1 CRANECLASSIFICATION AND PROPER USAGE The machine is an hydraulic truck crane for hook service It can also be used for the same purpose from a static mounting The lifting capacity is 6 9 ton meter 50 000 ft Ibs making it especially suitable for instal lation on light truck The crane is classified in class H2 B3 according to DIN 15018 standards and must be used accordingly that is trucks loading unloading hook service 4 2 IMPROPER USAGE Itis forbidden To use the crane in different operations from those it has been designed and built for see above point 4 1 To use the crane with attachment like grabs clamshells magnets and so on Pulling loads with crane in horizontal position To operate the crane with procedures different from those described in this manual or using componen ts and attachments not approved when the crane was designed Non observance of the established maintenance programs Non observance of safety rules To make modifications involving crane components or parameters related to the working cycle The unauthorized use of captive sp
47. ill carry out a new sealing after repairing according to Manufacturer s specifications A DANGER The removal of sealing by non authorized personnel or a sealing not complying to manufacturer specifications results in an improper usage of the crane maxilift 6 3 MICROPROCESSOR REMOTE CONTROL SYSTEM COBRA cranes are equipped with an advanced microprocessor remote control system that correctly manages the crane operations as well as its safety devices and provides indications to help the operator performing rapid troubleshooting or adjustments when necessary 6 3 1 AVAILABLE CONTROL VERSIONS Single function cable proportional control Dual mode multi function cable proportional control Single function radio proportional control Dual mode multi function radio proportional control The system is consisting of the following main components Pict 7 1 Control and safety devices managing con trol unit 2 Remote control keyboard 3 Directional and flow regulating hydraulic unit 4 Electrical connection wiring from the unit to the solenoid valves the micro switches the power supply and the keypad Pict 7 6 3 2 ELECTRONIC POWER UNIT Pict 8 The electronic unit located aside the revolving column s guard is made up of a sealed plastic compact container ip 67 that includes a microprocessor electronic device to manage crane operation controls and safety systems A three digit display 1 used as regulation
48. ing support such as a non functioning sheave Severe abrasion caused to outer wire strands will result from friction 3 Do not use worn sheaves or flat grooved sheaves They do not provide support to the full radius of the rope Flattening and distortion will result 4 Do not use nicked or otherwise broken sheaves Necks and cracks in sheaves will cut the wire rope 5 Evenly wrap wire rope onto the drum Uneveness will cause crusking and or crimping of the rope 6 Select replacement wire rope to match the capacity and use of the crane The crane was originally equipped with appropriate wire rope 7 Do not expose the rope to corrosive chemicals 8 Lubricate the rope frequently to reduce friction and help prevent corrosion Pict 4 6 maxiliff DESCRIPTION OF THE CRANE 6 1 MODEL 8000 H Item Description OONODABRWDNDY Slewing ring drive 16 Swivel coupling 17 Base plate Column 18 Outrigger beam hydraulic jack OPTIONAL Main boom Boom hoist cylinder First hydraulic boom section Second hydraulic boom section First telescope cylinder Second telescope cylinder Hydraulic unit Electronic Power unit Cable or radio remote control box Winch Travelling block Oil tank OPTIONAL 6 2 SAFETY DEVICES 6 2 1Safety devices installed All the safety devices installed on MAXILIFT COBRA 8000 crane are listed and described in the following pages de
49. ith the machine Therefore any replacement rope must meet the rope specifica tions for size construction and strength as outlined in specification sections of this manual 7 6 BEFORE STARTING TRAVELING ON ROAD Make sure that The crane is in rest position as specified on chapter 7 4 The emergency button is turned off The control board connection has been taken off the remote control and put in its box in the driver s cab The outriggers jacks are fully retracted their stop pins are in their housing and secured with relevant retainers The manual boom sections if installed are secured with stop pins and safety retainers The locking handle of the outrigger beams 2 on pict 14 is safely locked in place Unexpected sliding out of the outriggers beams when the truck is traveling could result in serious accidents e The lever of the shut off valve on hydraulic jacks see 1 in pict 15 is in the CLOSED position c The PTO is disconnected The overall dimensions of the crane in rest position are complying to regulations standard NOTE Always remember that if the crane is left open on the body and it overcomes the maximum height allowed by the law it could hit bridges and other obstructions 7 7 MAIN ERRORS OCCURRING WHEN OPERATING THE CRANE Because of lacking of care or of adequate instructions some dangers may occur during crane operation Most common errors are Slinging of loads exceeding the crane capa
50. l the ne cessary data required when calling our Technical Service A copy of this manual is supplied along with every crane Data descriptions and pictures of this manual are not binding The Manufacturer reserves the right to change at any time all the items components and parts deemed to be necessary for product improvement or commercial or production needs This right is kept without obligeance of quick updating of this manual Fundamental data performances and characteristics of the product will be maintained 1 3 MANUAL REVISION Should be necessary to carry some modification on the crane they must be authorized by the Manufacturer which also takes the commitment of manual updating Revised or added pages will be mailed to the Custo mer and shall be inserted in the manual at his care and cost 2 HOW TO CONSULT THE MANUAL 2 1 INSTRUCTIONS Always carefully read this manual before operating the crane In this manual the following symbols are used A DANGER Referred to dangers related to the described activity when the safety of people is concerned Z ATTENTION Referred to dangers related to the described activity mainly when the safety of things is concer ned for instance damage of the load or of the crane N IMPORTANT Referred to information or integration on crane operation NOTE Used to draw your attention on information or suggestions to make easier the crane usage for the operator The symbols and marks
51. l valve driven at 523 m EN When no operation is activated the electronic control unit automatically switches to the Normal Display Menu after 60 seconds otherwise a new power on is required in order to get out of this menu 6 5 6 REMOTE CONTROL KEYBOARD DISPLAY MENU This menu is accessed from the Normal Display Menu through the following procedure push the proportional button to its maximum level then operate the 1A and 2B movements simultaneously for at least 5 seconds the maneuver can be performed in radio mode or through serial cable In this menu when no operation is active the indication _ _ is displayed When a movement is active the state of the contact that activates the movement in the remote control pendant is displayed For each of the contacts the following state is displayed C closed In case of multiple command two or more movements activated simultaneously only the state of the first received command is displayed Example indication without any active movement is closed on the remote control uni 4m Example indication when the contact 1A N L H ep The following table shows all displayed codes Display Indication C1A contact 1A closed CLOCKWISE ROTATION C1b contact 1B closed COUNTER CLOCKWISE ROTATION C2A contact 2A closed BOOM UP C2b contact 2B closed BOOM DOWN C3A contact 3A closed TELESCO
52. nufacturer is not liable for accidents occurred during the usage of the crane caused by non fulfillment from the opera tor s side of current rules laws and regulations The crane is designed to be used within the 30 50 22 F 122 F temperature range and has to be operated only in this range The manufacturer is not liable for accidents occurred during the usage of the crane outside this temperature range Carefully read the Operator s and maintenance manual before starting up using servicing or doing any thing on the crane Read and follow all the safety instruction plates applied on the crane before starting up using servicing or doing anything on the crane Do not use controls and hoses as handholds these parts move and cannot provide stable support Furthermore a control mistakenly moving can accidentally set the crane in motion The operator s control desk must always be kept clean from oil grease mud snow to avoid accidents due to slippery surface The safety ADANGER ELECTROCUTION HAZARD THIS CRANE IS NOT INSULATED DE ADANGER AN UNTRAINEO OPERATOR SUBJECTS HIMSELF AND OTHERS TO DEATH OR SERIOUS INJURY OU MUST NOT OPERATE LESS WARNING STAY CLEAR OF BOOM AT ALL TIMES A DANGER STAY CLEAR OF LOAD 2 AT ALL TIMES sum IMPORTANT AUBSEGUENT DAYNER PLEASE REGISTER YOUR NAME AS THE HEW OWNER OF THIA Hi ADANGER
53. operation Anyway these instructions are not a training manual for beginners or unskilled operators it must be stressed that as a fundamental presupposition only skilled and professional crane operators are allowed to work with the crane The crane operator is directly responsible for the state of the crane and for every crane operation When the training is hurried and full of gaps this is the origin of many accidents This manual gives the guidelines for a correct safe usage of the crane and its rational maintenance When daily and constantly applied these guidelines ensure long service life with minimum maintenance costs high performance of the crane and good commercial value after years Moreover most of the frequent accidents during operation and servicing are avoided Once this manual has been read carefully keep it in good conditions and quickly available close to the crane If a technical assistance is required please apply to the nearest authorized installer ATTENTION As far as safety is concerned it is strongly recommended to carefully read the safety tips of the chapter SAFETY RULES A ATTENTION Should some or any part of this manual be not clear please contact the Manufacturer IMPORTANT When receiving this manual check if all the data are correct Inform the Manufacturer if so mething is found wrong maxiliff NOTE The table on the back of the front page has to be filled at customer s care It contains al
54. or control interface is found on the front of the unit Two electrical wiring connectors 2 are found on the unit maxilift 6 3 3 THE RADIO RECEIVER UNIT Pict 10 The radio control version unit 3 is externally equal to the remote control version internally it includes the electronic system that manages machine logic and radio module and works as a receiver a safety system prevents other transmitters from entering the system since it only recognizes its matched keyboard transmitter through the RFID code radio frequency identifier The European version 868 MHz includes an antenna that is applied to the electronic units through a connector it enhances the medium large range reception field considering the 868 MHz transmitter reduced power A supplementary unit 7 function radio is available upon request it is similar to the main one and it activates two auxiliary functions on the OPT1 OPT2 radio button that control the diesel engine acceleration or turns on off a motor compressor generator 6 3 4 THE CABLE KEYBOARD Pict 9 The keyboard which can be used with a single hand has been studied to provide the operator with an ergonomic and practical remote control device to optimize the different crane functions It is mainly made up of a plastic container with a protected control panel integrally connected to a supporting ergonomic handgrip Five radial selectors S that control machine maneuvers are found on
55. ot working pict 12 Unlock clean or in case replace the solenoid valve cartridge or the flow di vider Operations to be carried out only by authorised installer workshop maxiliff 10 TECHNICAL DATA WINCH SPECIFICATIONS SERIES 8000 STANDARD EQUIPMENT High speed winch with planetary gears reducer Continuous rotation with slewing ring drive Negativ brake for winch Remote control with connection and 10 m 33 ft of cable Hydraulic swivel coupling for continuous rotation or radio remote control Proportional monofunction multifunction hydraulic system Load limiting device Solenoid valve with manual functions only for emergency Two hydraulic extensions Stop end system for winch up and down TECHNICAL DATA 8000 Crane rating KNm 67 8 Standard outreach m 6 6 Slewing angle CONTINUOUS Boom elevation 6 75 Slewing torque KNm 6 8 Lifting height from base of crane m 6 5 Remote control Proportional Pump capacity hydraul H pto l min ism Working pressure bar 205 Crane weight Kg 670 WINCH SPECIFICATION 8000 Winch pull line daN 1870 Pull line speed 3 layer H m min 12 Rope diameter mn 10 Wire rope length m 30 Cable breaking strength Kg minimum 9 400 Technical data not binding 3835
56. position Since the maximum working height of the crane is reasonable refer to the following table to evaluate the possible wind effect Force of the wind wind speed wind effects Beaufort Denom m sec ft sec km h mile h 0 calm 0 02 0 0 65 1 0 6 calm the smoke goes straight upwards 1 light 0 3 1 5 1 5 1 5 0 6 3 wind direction can only be seen looking at the smoke Wind indicators are idle 2 light 1 6 3 3 5 11 6 11 3 7 leaves are moving the wind can be on the face 3 light 3 4 5 4 11 18 12 19 7 12 leaves and small brances are moving breeze 4 slow 5 5 7 9 18 26 20 28 12 17 dust and paper sheets are lifted up breeze slender rods are moved 5 strong 8 10 7 26 35 29 38 17 24 small waves on water surfaces breeze 6 strong 10 8 13 8 35 45 39 49 24 30 rods are bent it is difficult to use wind umbrella 7 tight 13 9 17 1 45 56 50 61 30 38 the trees are moved it is difficult to wind walk against wind 8 stormy 17 2 20 7 56 68 62 74 38 46 trees branches break it is very difficult to walk in open areas 9 tempest 20 8 24 4 68 80 75 88 46 55 small damages to buidings roofing tiles wind fall down 10 violent 24 5 28 4 80 93 89 102 55 63 big damages to the buildings trees uprooted tempest 5 4 RULES CONCERNING SAFETY IN THE TRAFFIC The machine is an hidraulic crane for lorries and light trucks The installation on the vehicle must be made
57. pressure transducer PM to the diesel engine start stop and to the power supply The wiring also includes the keyboard connection female connector 3 that is placed aside the electronic unit on the crane s cover maxiliff 6 4 REMOTE CONTROL USE After the preliminary operations concerning PTO engaging extension and lowering of stabilizer legs and their levelling control system supply by switching on the proper switch inside the cabin power supply by turning the battery disconnecting lever in case of electro hydraulic crane you can go on working with the remote control 6 4 1 USE OF THE MONO FUNCTION PROPORTIONAL REMOTE CONTROL First release the emergency button E It is necessary to select the desired movement by pushing the selector S upwards or down wards check carefully the symbols on the panel the opposite movements are carried out by in verting the movement While keeping the selector pushed act gradu ally with your forefinger on the proportional but ton P in order to get a gradual speed increase Proportionally to the stroke of the button you will get a movement of the selected function which will be quicker and quicker until you achieve the maximum speed A ATTENTION Do not operate the proportional button before selecting the movement it will not work Do not pull immediately the proportional button to its maximum limit you will not get the right gradualness and the
58. r crack out e Clean oil filter Check the oil level and lubricate accordingly to the lubricating and greasing chart e Check the regular working of the slewing system grease with the suggested grease the pinion and slewing ring teeth Make a working test of the crane with and without the load paying attention to possible unusual noises coming from the crane parts Grease the hydraulic boom sections 9 3 3 Checking every six moths Wash and clean the crane A ATTENTION Never wash the crane with chemical products or high pressure water jets as they can cause the detaching of the stickers and water entering inside the electrical components and the slewing case Check the pressure settings in the hydraulic system e Check the absence of oil leaks Check integrity and tightening of crane tie rods and bolts Check integrity and tightening of hoses piping and their fittings Check fastenings and safety devices e Make a safety test of the hydraulic system Check correct working of remote control and readability of relevant symbols Check integrity of hooks ropes chain and all the other lifting ancillary equipment Check that the all the identification and warning plates are still applied and readable Visually check all the structural components to find any deformation backlash or crack out Check the oil level and lubricate accordingly to the lubricating and greasing chart Replace the filter of th
59. re based on providing the proper operating safety factor on the wire rope supplied with the machine Therefore any replacement rope must meet the rope specifications for size construction and stregth as outlined in specification sections of this manual 5 5 2Operator safety tips Do not pull the load block into the boom tip Payout loadline before or during boom extension to avoid two blocking Do not allow personnel to ride the load line hook or load or any other device attached to loadline Keep at least three full wraps of wire rope on the winch drum at all times Check the winch brake for proper operation before handling the load Use proper multi part reeving for the load to be lifted When using multi part reeving be sure cable is properly routed Know the lifting capacity of both the winch and boom They will have different capacities The weight of the load must not ex ceed the lesser capacity Do not drag loads with winch or boom Always wind loadline under tension to assist proper spooling 5 5 3 General rules when operating winch 1 Always operate the winch control to payout the loadline while extending the boom This will maintain clearance between the boom tip and loading hook 2 Do not pull load block into boom tip 3 Make certain the winch cable is not twisted or kinked and that cable is properly seated on the drum and in the sheaves 4 Before lifting a load always make certain that three f
60. s Hydraulic cylinder sealings are worn Adjust valve settings Replace worn sealings Noise coming from articulation points Lacking of lubrication Grease articulation points The hydraulic legs does not hold under load Defective holding valves Worn sealings in the stabilizer cylinder Clean or replace holding valves Replace worn sealings The crane locks with boom lifted at end course Pressure transducer not set Setting of general max pressure valve too high Disassemble the casing and move ma nually the boom descent valve EV2B pict 11 12 Check the general max pressure valve ll lack in the control box green led out Discharged battery Disconnected electric coupling Emergency push button engaged Recharge the battery Join correctly the connection Replace the electric coupling Release the emergency push button Fault Cause maxiliff y Remedy One of the tunctions does not work Defective switch Burned solenoid Locked valve cartridge Damaged electric connection Replace the switch Replace the solenoid Disassemble and clean the valve cartri dge Check continuity of the circuit All the functions do not work No power or insufficient to the shunt boarder the remote control box The proportional valve does not meter pict 11 12 Electric valve EV9 pict 11 12 is not working The trigger on the remot
61. sali 11 WIRING AND HYDRAULIC DIAGRAMS crisis 4T 11 1 Electrical diaga Missean terrai 47 11 2 Hydraulic diagrams cai 49 11 2 1 Hydraulic diagram mono function proportional nennen nne enne 49 11 2 2 Hydraulic diagram dual mode proportional essen emen nennen nnne 50 1 FOREWORD 1 1 SUMMARY This manual is divided into chapters to make its consultation easier Chapter 1 Includes summary and a short introduction Chapter 2 Explains how to consult the manual Chapter 3 Crane identification data Chapter 4 Limits of crane operation and usage Chapter 5 Safety rules Chapter 6 Description of the crane safety devices and controls Chapter 7 Description of operation and usage tips Chapter 8 Crane starting up and storage Chapter 9 Essential crane maintenance instructions Additional instructions can be included in the truck maintenance manual Chapter 10 Includes the crane technical data load charts and diagrams list of main characteristics Chapter 11 Wiring and hydraulic diagrams 1 2 REMARKS Many thanks for the preference kindly given to our product Please remember that the servicing instructions and the load charts hereby reported and applied on the crane are an essential part of the crane supply itself They are mainly intended for the crane operator and include all necessary information on the admittable and permissible field of usage for a safe
62. scription of safety functions The crane is fitted with 4 standard electrohydraulic safety limitations 1 Theload limiting device which intervent each time the load mentioned on loading diagram is excee ded and locks the crane stopping all mouvements except re entry of boom extension and lowering the load 2 0 working placing of the boom The crane is fitted with a stop end system allowing only boom lifting manoeuvre when the position is lower than 0 rest position 3 Stop end system for winch raising which intervent in order to avoid the travelling block to hit against the pulley It stops the raising of the winch rope boom lowering and boom extension 4 Stop end system for winch lowering which intervent when in the winch drum remaining only 3 wraps of rope and locks the lowering of the winch rope AN ATTENTION It is strictly forbidden to alter or manipulate the safety devices Before operating the crane make sure that all the safety devices are in perfect working conditions 6 2 2Load limiting device The load limiting device system locks crane functioning when pressure in the main cylinder reachs the setting level corresponding to the nominal crane moment The load limiting is used in order to avoid crane overload In lock position it is not possible to carry out any manoeuvre except re entry of boom extension and lowering the load only possible manoeuvres In order to unlock the crane re entry with the boom extension
63. spect the rope daily or before use each day and also inspect the rope eye for abrasion corrosion and broken wires Inspect the wire rope monthly as follows 1 The entire length of the rope 2 The wire rope eye 9 6 2 ROPE REPLACEMENT It is extremely difficult to determine the exact time for replacement of wire rope since many variable factors are involved Proper determination of the condition of a wire rope depends upon the good judgement of an experienced person in evaluating the remaining strength in a used rope after allowance for deterioration disclosed by inspection The following reasons are sufficient justification for consideration of rope replacement 1 Six randomly distributed broken wires in one rope lay or three broken wires in one strand in one rope lay 1 When there are either 3 broken wires in one strand or a total of six broken wires in all strands in any one rope lay 2 When flat spots on the outer wires appear and those outside wires are less than 2 3 the thickness of the unworn 3 When there is a decrease of diameter indicating a core failure 4 When kinking crushing birdcaging or other distortion occurs 5 When there is noticeable heat damage discoloration of the rope by any means 6 When the diameter is reduced from nominal size by 0 8 mm 1 32 or more 7 If a broken wire protrudes or lops out from the core of the rope maxilift 9 6 3 WIRE ROPE LUBRICATION
64. ter cartridge maintenance Loose the screws 4 take the cover 5 off and extract the cartridge 6 Wash it with petrol and clean with compressed air or replace if damaged Before re assembling check the integrity of the seals 7 and replace them if needed A ATTENTION AFTER EVERY OPERATION ON THE OIL CARTRIDGE IS NECESSARY TO TAKE THE AIR OFF THE HYDRAULIC CIRCUIT THIS CAN BE MADE OPERATING ONE OF THE CYLINDERS OF THE CRANE AND PULLING IT TO STROKE END IN BOTH DIRECTIONS SOME TIMES maxiliff 9 4 4 Slewing mechanism maintenance Pict 19 It is recommended to periodically lubricate see relevant chapter 9 3 worm gear of the slewing ring drive This to be made with a grease nipple 1 Also with the same interval lubricate the bearing of the ring with a greaser through the grease nipple 2 For a correct lubrication of the slewing wheel use the grease cartridge supplied with the crane or another one with similar features making sure to carry out a complete slewing operation 9 4 5 Greasing the hydraulic boom sections Pict 20 1 Completely extend the telescopic boom 2 Grease the lower part of the extensions by a brush 3 Grease the upper part of 1st extension by the two grease nipples pos A 4 Move the grease nipples to pos B and go on greasing the upper part of 2nd extension 5 Take the grease nipples off and move them back to pos A 6 Carry out 2 or 3 boom re entry and ext
65. trol is forbidden an additional selector for optional functions OPT1 and OPT2 The rechargeable batteries that are housed on a specific compartment 2 protected by the keyboard and that can be easily extracted disconnecting a quick connector Battery recharge may last up to three hours if batteries are completely flat For this purpose a car battery charging cable that can be connected to the car lighter is also supplied The radio transmitter module A circular magnet located on the rear that allows placing the keyboard on metallic surfaces A WARNING Verify the emergency button correct operation 5 before using the radio control The radio control must be turned off when operations are suspended by pressing the emergency button 5 The keyboard box must only be opened in case of repair or anomaly Pict 10 Check the emergency button operation as follows Start a function ex boom lift checking if it is performed by the crane Press the emergency button and check if the previously performed action is immediately stopped otherwise stop the machine N B Never let the crane work with disabled emergency button AN WARNING When the cable keyboard is not being used it must be disconnected from the connector located on the guard aside the unit where the protection cover will be screwed Press the mushroom button of the cable and radio keyboards after their use and before storing them on a protected
66. ull wraps of rope will remain on the drum at all times throughout the lift 5 When lifting a load approaching the rated winch load raise the load a few inches and return the control to neutral to determine if the brake is working properly 6 Donot drag loads in any direction with the winch 7 Never attempt to lift loads wich are not loose and free i e frozen down material or poles out of ground 8 Maintain tension on the loadline at all times to prevent the cable from becoming twisted or improperly seated on the winch drum or sheaves 9 Avoid rough boom lifting and lowering manoeuvres with suspended load in order not to cause dan gerous swingings of the same 10 Avoid boom extension manoeuvre under load When moving loads near to max rates it is rather advisable to extend the boom without load in order to reach the vertical line of the same and then to proceed with lifting by using the winch maxiliff 5 6 WIRE ROPE 5 6 1 General Wire rope can be the weak link in crane safety It is subjected to heavy loads abrasion kinking extreme weather conditions chemical attack and other forces which can reduce its reliability The inspection and care of wire rope is essential in the effort to provide for safe working conditions 5 6 2Wire rope precautions 1 Avoid the formation of kinks Kinks will cause severe weakness in the rope No corrections are availa ble for kinked rope 2 Do not drag wire rope over a non rotat
67. ways be carried in the driver s cab along with a copy of the load chart 3 Everyoperationhas to be planned with care 4 Getallthe necessary information for reaching the working site distance itinerary heigth of exi sting tunnels capacity of the bridges to be crossed etc 5 Study and plan the best way to operate the crane soil consistence weight and dimensions of the loads to be lifted heigth to be raised and necessary booms outreach Check available room or limitations due to the presence of buildings obstacles electricity power lines etc 6 Make sure of availability of all the necessary equipment accident prevention clothings additional bearing plates with increa sed surface area slings hooks ropes and chains of certified origin and in perfect conditions 7 Before starting crane operations check the efficiency of the safety control devices Never use the crane if the correct functioning of a device is not sure 8 Traffic and safety laws in force must be strictly observed both when travelling on road and when operating the crane 9 The warnings of these manual referred to special dangers are to be read and observed with special care 10 The safety during the crane service must be kept to the highest level carrying out a regular constant and accurate preven tive maintenance Repairs if necessary should never be delayed and must be made by specialized authorized people using only genuine spare parts 8 2DAILY CHECK
68. wing conditions O open C closed f Example display of the state E 5 e LJ FB micro switch open a md Example display of the state P f l PM micro switch closed a The following table shows all displayed codes Fa O Fa C micro switch FA micro on winch drum cable Vv descent 1B Fb O Fb C micro switch FB stopped boom limit switch Fu O Fu C micro switch FV limit switch on cable diverting pulley cable lift PrO PrC micro switch PM digital pressure gauge or analog pressure transducer Pict 14A When no operation is activated the electronic control unit automatically switches to the Normal Display Menu after 60 seconds otherwise a new power on is required in order to get out of this menu 6 5 5 CURRENT DISPLAY MENU proportional regulation This menu is accessed from the Normal Display Menu through the following procedure push the proportional button to its maximum level then operate the 1A and 4B movements simultaneously for at least 5 seconds the maneuver can be performed in radio mode or through serial cable In this menu when no operation is active the indication Cur is displayed When a movement is active the value of the current in mA that is driving the proportional solenoid valve is displayed f Example indication without any active movement i LI Fr uu a am Example indication with an active movement and 5 e j with the proportiona
69. with it maxiliff If the crane is accidentally hit it has to be checked and tested from the closest authorized installer workshop Check every month the state and correct functioning of all the parts subject to wear pins valves hoses sliding pads and bushings etc If necessary replace with genuine spare parts Itis absolutely forbidden to alterate the hydraulic circuit and open the safety seals Failure to comply will cause automatically the voiding of any warranty on the product Valves adjustments or setting must be done only by authorized installer workshops Overheating of hydraulic oil may burn the sealing parts and alterate the oil itself This can be caused by an excessive oil flow of the pump or by repeated stroke ends of the cylinders Check that the pump supplies the control valve with the oil flow suggested in our technical specifica tions 7 2 STABILIZING THE TRUCK Bearing in mind the job to be done the vehicle has to be positioned in the most convenient position stopped with the parking brake and the tires blocked The truck engine shall be kept idling 800 900 rpm The hydraulic circuit of the crane shall be activated as follows Cranes with pump driven by a power take off Engage the PTO by means of the appropriate air switch normally located in the cab while depressing the clutch pedal If a mechanical coupling system is installed the lever is behind the driving seat Cranes on stationary mounting
70. y Me iuris a Gaiam 23 6 5 4 Micro switches and pressure switch display menu i 25 6 5 5 Gurrent display I II 25 6 5 6 Remote control keyboard display Menu eene nteen ettet ntn oaoa NETen a c 26 6 5 7 Work pressure display MENU uii t elia 27 T7 OPERATING INSTRUCTIONS siciliana aia ir 28 7 1 SOMO Kall ASM OMS s ee gto aa ee cancels o utere adi deret eim E heir Ier ELLEN 28 7 2 Stabilizing the THU CK ADDE ale 29 7 3 Opening th cfane i ARE a EC 7 4 Closing the crane E iaa dais 281 7 5 Winch system Operatii siii ii etd rire RE vans D re ERA aO Des hides 81 4 6 Before starting traveling On road i aerei iaia eee 4 7 7 Main errors occurring when operating the crane ii o 3 7 8 Standard hand Signal Sica iia a A hei 832 8 PUTTING THE CRANE INTO SERVICE 3 iii 33 8 1 Ten rules for the perfect crane operator 283 8 2 Priest 33 8 3 Safety tips for crane starting in cold climates e 2 199 8 4 Crane protection and Storage iaia AIAR a A 33 8 4 1 Short SMUT OWNS D nn e 8 42 LONG SMULAOWINS de X X 984 9 MAINTENANCE arcaica ici 35 9 1 lC ree 95 9 2 Maintenance prFeScrIDlHOons utili vo dr EUH eU
71. z v9 VM 1 STO yy lan A T CP cq m ur GU V4 16LT p E V4B B l ARGANO V4A n TL PL A SFILI VIA E 16 B V3B E HO i ni SOLLEVAMENTO V2B B VIA E ROTAZIONE VB E Pict 26 EN manilift NOTES Name of the installer person Name of the authorized installer workshop es NEXT HYDRAULICS S r l City Province Via Mediterraneo 6 Boretto 42022 RE ITALY Tel 0522 963008 Fax 0522 963039 e mail nexthydraulics tin it Tel number COPYRIGHT BY NEXT HYDRAULICS S r l Layout and pubblication by Studio tecnico Pinotti Reproduction and distribution are forbidden according to law without written permission in writing from Next Hydraulics S r l maxiliff NEXT HYDRAULICS s r l Via Mediterraneo 6 42022 Boretto Reggio E Italy Tel 0522 963008 Fax 0522 963039 e mail nexthydraulics tin it

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