cobra 4400w product manual md.0.123
Contents
1. Remarks Manual REVISION nmm HOW TO CONSULT THE MANUAL 2 CRANE IDENTIFICATION utuntur uda Versions optional available sssrinin EEEE euge AE i CRANE identification data RE A eee CRANE USAGE AND LIMITS CRANE classification and proper usage UI o M CRANE operators tralning ciere rhe LUE SAFETY RULES ON EM Md Gf R les concerning people aa e Rules concenning the Crane oH ioc sia scu ai un c de Rules for the correct positioning of the uiii nitent necs c teo i Choice of the crane operating place pressure on the Safety distance from trenches and Slopes 2 12 0 eec oe aes Safety distance from electric2. 6 2 SAFETY DEVICES 6 2 1 Safety devices installed Allthe safety devices installed on MAXILIFT COBRA 4400W crane are listed and described in the following pages description of safety functions The crane is fitted with 4 standard electro hydraulic safety limitations 1 The load 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 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 wraps of rope and locks the lowering of the winch rope A 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 2 Load 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
3. Controls description E Electronic power UMi reima C ania NT Remote Control BOX EE E ES X l3 l3 l3 l3 YNNNSSSSOOPONNNGPD FRR A NN Nece maxiliff 7 OPERATNOGI INSISUCIRNS 0332299235 4 99015490894940894080 0128 92095 PAGE 18 7 1 General attentloris x 5 aient Ce ED eee a ee side eee aes 18 7 2 Stabilizing Me ANU CK c ow deca 19 429 the ct 21 7 4 CIOSING the Grane d 21 7 5 Winch system sae 21 7 6 Before Starting traveling oni fOad drerit Er pe etse 21 T Main errors occurring when operating the crane 21 7 8 standard hand 22 8 PUTTING THE CRANE INTO 5 1 EA CEA uas 23 8 1 Ten rules for the perfect crane Mea 23 8 2 Daily check i 23 8 3 Crane protection and Storage iss sorge vet etae cnet 23 8 3 1 Short SNUTAOWMS
4. i 23 8 3 2 Long sSh tdOWFRs iei Eat eie hr on eta a aie 24 9 MAIN TENAN OE 25 9 1 M ris m 25 9 2 Maintenance prescriptions sisisi 25 9 3 Maintenance 5 x 26 9 32 Daily checking ETE 26 9 3 2 Monthly CHECKING nr iri ttr tme E PEU t eR EE Eee eo Hi PE Aes 27 9 3 3 CHECKING every SIX MOMS Oh 27 9 3 4 9111131 T E 27 9 4 Crane SENVICING x eee ns aie es ee a A a ee ee 28 9 4 1 Oil MSV CHECKING 2 28 9 4 2 Oil CRNA Caine eased c 28 9 4 3 Wormgear assembly control E i 29 9 4 4 Greasing the hydraulic Sections sassis ede anise et eite ru rece 29 9 4 5 Wear pads check and replacement eren nier tenet 29 9 5 Greases and oils reference table ciiin icone aco esce 30 9 6 WIRE TODO 31 9 6 1 cce eee ien te c e
5. SERVICE CRANE Mod 4400W USE AND MAINTENANCE MANUAL MD 0 123 1 07 09 Code Rev Edition OPTIONALS SUPPLIED ALONG WITH THE CRANE Description YES NO Oil tank Outrigger beam mechanical jack 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 4400W SERVICE CRANE Manual code MD 0 123 This manual is valid starting from serial no 9649 Manufacturer NEXT HYDRAULICS S r l Via Mediterraneo 6 42022 BORETTO 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 Spare part manual SERIALNO Mer YEAR OF 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 5 3 5 3 1 5 3 2 5 3 3 5 3 4 5 3 5 5 4 5 5 5 5 1 5 5 2 5 5 3 5 6 5 6 1 5 6 2 6 1 6 2 6 2 1 6 2 2 6 2 3 6 2 4 6 2 5 6 3 6 3 1 6 3 2 6 4 FOREWORD 2
6. BRAND TOTAL MOBIL ESSO AGIP IP BP GREASE MULTIS MOBILGREASE BEACON GR MU ATHESIA ENEGREASE 2 2 2 EP2 LR MP t3 GREASE MULTIS MOBILGREASE BEACOM GR MU ATHESIA ENERGREASE LR MP MP EP2 EP2 EP2 EP2 V HYDRAULIC AZOLLA DTE NUTO OSO HYDRUS HENERGOL OIL ZS 46 25 H 46 46 46 HL 80 ZS 48 H68 68 GREASE WINN S GS 80 fortemperate and cold climate for hot climate Pict 18 maxiliff 9 6 WIRE ROPE 9 6 1 WIREROPE 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 AN DANGER Do Not open the rope for inspection Inspect 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 ROPEREPLACEMENT 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 j
7. 5 6 2 Wire rope precautions 1 Avoid the formation of kinks Kinks will cause severe weak ness in the rope No corrections are available for kinked rope 2 Do not drag wire rope over a non rotating 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 crushing 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 appro priate wire rope 7 Do not expose the rope to corrosive chemicals 8 Lubricate the rope frequently to reduce friction and help pre vent corrosion 6 DESCRIPTION OF THE CRANE 6 1 MODEL 4400W Item Description gt Slewing system Slewing motor Column Main boom Boom hoist cylinder First hydraulic boom section Second mechanical boom section Telescope cylinder Control valve Electric shunt board Remote control box Winch Travelling block Elettro hydraulic power pack Outrigger beam mechanical jack OPTIONAL maxiliff 42 4 s 2 294 NS Y a is
8. 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 until crane moment becomes lower than that marked on the loading diagramm or intervent on winch lowering by putting the load on the ground AN DANGER The load limiting device even when in perfect working condition cannot avoid accidents due to operator s maneuvering mistakes N 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 order 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 electro hydraulic unit 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 remai
9. 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 pecial care 10 The safety during the crane service must be kept to the highest level carrying out a regular constant and accurate preventive maintenance Repairs if necessary should never be delayed and must be made by specialized authorized people using only genuine spare parts 82 DAILY CHECKLIST Check the existence of oil leaks Check the correct working of the load limiting device Checkoil level and fill up if necessary e Check the good conditions of hoses and piping Checkthe good conditions of painting and chrome plating Checkthe correct working of safety valves Check winch brake s functioning 8 3 CRANEPROTECTION AND STORAGE 8 3 1 Short shutdowns Wash and clean the crane lubricate all the parts provided with grease nipples and the slewing system N 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 3 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 connect
10. 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 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 NOTE The table on the back of the front page has to be filled at customer s care It contains all 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
11. air Replace or clean the suction hose Check that the relevant fittings are well tightened Crane rotation not regular The truck is not correctly levelled Worn slewing motor Level the truck Replace slewing motor 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 valves 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 DC electric motor does not run Truck battery discharged Electric connections are damaged Burned fuses Motor windings are burnt Charge battery Check electrical wirings terminals con nections and their integrity Replace fuses Replace the electric motor DC electric motor overheating Too long running time Running periods are to be shortened and their intervals to be elongated The crane locks with boom lifted at end course Pressure transducer not set Setting of general
12. 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 full 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 Do not drag loads any direction with the winch 7 Never attempt to lift loads wich not loose and free 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 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
13. cul ticae dre Pict 14 E 8 PUTTING THE CRANE INTO SERVICE 81 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 always be carried in the driver s cab along with a copy of the load chart 3 Every operation has 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 increased 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
14. motor run until the emergency cable is connected Keep the motor running only for the short periods required to carry out the emergency manoeuvres Afterwards restore the original connection 6 3 1 Electronic power unit The electronic control unit placed inside the near column casing is a fully sealed component containing the electronic parts with microprocessor logic due to handle all crane movements and safety device Two connector for the guide connection to the solenoids and safety device cables jut out of it Manifold EV3B EV2B maxiliff 6 3 2 Remote Control Box The remote control box for single hand use was designed to give the operator an ergonomic practical remote control device and to optimize the several crane functions It is essentially consisting of a plastic container with protected control panel completely connected to an ergonomic handgrip On the panel are located the crane operating selectors S in radial arrangement The pendant panelis fitted with an essential symbology for the different functions on a green background which is very agreeable and intuitive for the operator On the cable end which can keep its flexibility and handling even under extreme conditions is applied the connector to the control unit All moving operations are carried out by the remote control box The pendant controller is supplied by plugging the connector on the socket placed by the
15. of optional Outrigger beam mechanical Jack 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 Data plate description a Crane model b Serial number c Year of manufacturing d Lifting class e max SWL f Approval number Z ATTENTION It is strictly forbidden to change erase modify the data written on the plate 4 CRANE USAGE AND LIMITS OF APPLICATIONS 4 1 CRANE CLASSIFICATION 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 2 2 ton meter 16 000 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 It is 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 N
16. 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 levelled in order to have a good stability Maximum allowed angle is 3 A IMPORTANT Proper leveling has to be checked by means of a leveled instrument fitted on the truck Pict 11 Pict 12 Pict 10 Pict 13 7 3 OPENING THE CRANE Starting from the crane in rest position operate the switch of boom hoist up on remote 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 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 wi
17. side on the control casing see pict 7 Operation is as follows 1 push and hold the button P 2 operate the toggle switch selector of the choosen function 3 the green led lights up and the crane starts moving On the pendant control box the following controls are available as shown in pict 8 gt crane slewing boom raising lowering boom extension in out winch raising lowering power button ED green showing that one or more function are activated 0 6 4 WIRING pict 9 The system is consisting of two fully independent wiring systems which are connected to the electronic control unit through tight multipolar connectors 1 fitted with a quick coupling system The first wiring 2 includes the solenoids for the connection of the operation valves which are located on the hydraulic unit to the electronic control unit The second wiring 3 connects the control unit to the safety stop ends FB FV to the pressure switch PM and to the power supply 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 AN DANGER Before starting operations make sure that nobody is in the working area of the crane The crane must work only on flat ground Mak
18. 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 N DANGER Referred to dangers related to the described activity when the safety of people is concerned A 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 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 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 4400W This model is supplied in one only version the hydraulic circuit is fed by a DC hydraulic power pack connected to the truck battery 4400W 12V DC single boom hydraulic section electro hydr version The crane can be supplied with the following option Type
19. ED WIRING AND HYDRAULIC DIAGRAMS 11 WIRING AND HYDRAULIC DIAGRAMS 11 1 WIRING DIAGRAMS 11 1 1 Pendant and control wirings NO Connected NC In normal operation NO Connected NC In normal operation Pict 21 ES Remote control box 1A Clockwise rotation magnet B Electronic power unit 1B Counter clockwise rotation magnet Limit switch wiring 2A Boom raising magnet D Solenoid wiring 2B Boom lowering magnet SW1 Crane rotation selector 3A Boom extension magnet 5 2 Boom movement selector 3B Boom re entry magnet SW3 Extension selector FA Winch lowering stop end system SW4 Winch selector FB Boom lowering stop end system L1 Green led FV Snatch block stop end system J1 24 poles female connector PM Pressure switch solenoid J2 24 poles female connector P1 Emergency push button J5 10 poles male connector J6 10 poles female connector Max pressure valve UJ N J1J2 24 POLES SICMA FEMALE CONNECTORS Pict 22 38 Rev 1 38 04 06 11 2 2 4400W wiring diagram Battery Starting Key Fuse protection Electronic power unit Electro hydraulic power pack Power pack switch Electric winch s contactor pack Electric winch Battery switch OMONDARWHND Pict 23 Rev 2 02 08 39 11 2 H
20. T ALL TIMES ADANGER STAY CLEAR OF LOAD T TIMES sum ADANGER OUTRIGGERS WILL CAUSE SERIOUS CRUSHING INJURY Pict 2 STAND CLEAR 5 3 RULES FOR THE CORRECT POSITIONING OF THE CRANE 5 3 1 Choice 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 reaction look at the plate applied on the outrigger jack Admittable pressure on various typ
21. YDRAULIC DIAGRAMS 11 2 1 HYDRAULIC DIAGRAM FOR E 12V VERSION Pump Electrohydraulic unit Rotation motor Lifting cylinder Overcenter valve Pressure switch Cylinder Overcenter valve 10 11 Oil filter 12 Oil tank 13 1 a LT d I T 4 9 m BA IN 0 s V2B V2A 2 12 IM UN VB I P di 1B Pict 24 EN NOTES Name of the installer person Name of the authorized installer workshop Address ci NEXT HYDRAULICS S r l Via della Costituzione 25 Poviglio RE ITALY Tel 0522 960707 Fax 0522 967197 Tel number COPYRIGHT BY NEXT HYDRAULICS S r l Layout and pubblication by STM Studio Tecnico Associato Reproduction and distribution are forbidden according to law without written permission in writing from Next Hydraulics S r l NEXT HYDRAULIC S r l Via Mediterraneo 6 42022 BORETTO Reggio E Italy Tel 0522 96 30 08 Fax 0522 96 30 39 info maxiliftcrane com
22. al power 1 Crane and load ground connection centena retener t 2 Influence of the wind on the crane operation nnnm ken tese nemen Rules concerning Safety in the oec ect ceci e De faa Let eo renda General rules on winch Winch system ODS RAUIOM EE EE OE E TEE DD LTD Operator c General rules when operating WINCH WIRE ROPE ULL MAIL E General M M Wire TOPs PhECAUTIONS cscs DESCRIPTION OF THE CRANE HP NONON A A eee eee Safety deviCes eimi ein DAT LL i Bera Load limiting Relief valve MEE Pilot operated holding valves ret beads piste cause eer pae er Ihe Satety devices a
23. ate 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 It is 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 hydraulic circuit of the crane shall be activated as follows Cranes driven by DC power pack The DC power pack is connected with the truck battery The electric pump will start every time a switch of the remote control is moved The crane can work even when the engine of the truck is off but it is strongly recommended of keeping the engine idling so the alternator can continuously charge the battery of the vehicle A battery switch as shown in pict 23 fully dedicated to the crane electrical system must be present This battery switch must be tu
24. complete reading and understanding of this manual complete knowledge and understanding of safety and risk avoidance regulations Vision of at least 20 30 Snellen in one eye and 20 50 in the other with or without the aid of corrective lenses 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 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 jackets 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 Th
25. d 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 Moisten 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 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 position Since the maximum working height of the crane is reasonable refer to the f
26. d 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 Check that all the identification and warning plates are still applied and readable Visually check all the structural components for any deformation backlash or crack out Check the oil level and lubricate accordingly to the lubricating and greasing chart Check the regular working of the slewing system grease with the suggested grease the worm and the worm gear replace the grease brush spreader if worn 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 ZN 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 Checkthe pressure settings in the hydraulic system Checkthe 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 Make a safety test of the hydraulic system Check correct working of remote control and readability of relevant symbols Check
27. e 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 up to 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 ground the load can be loaded electrostatically charged because the rope pulleys or th
28. e fire extin guisher must always be kept charged and has to be used according to current regulations 5 2 RULES CONCERNING THE CRANE The Manufacturer is not liable for accidents occurred during the usage of the crane caused by non fulfillment from the operator s side of current rules laws and regulations The crane is designed to be used within the 30 50 22 122 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 instruction plates notices load charts and any other sticker applied on The crane must be kept readable and in good conditions If necessary replace them The position of these plates is shown in the following picture ADANGER ADANGER ELECTROCUTION HAZARD D WARNING STAY CLEAR OF BOOM A
29. e 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 the 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 Mechanical jack Fig 12 Lower the pad 4 by pulling the locking pin 5 out of its housing The telescope and the pad will come down because of gravity When it is close to ground engage again the pin in the appropriate hole securing it with the relevant safety retainer 6 Turn the crank handle 7 until the ground is reached bearing in mind what was explained above regarding the vehicle suspension Swinging hydraulic jack Fig 13 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 explained in the previous page 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 AN 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
30. e 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 N DANGER electrocution hazard Always ground the crane perfectly Load groun
31. e speed without load E 12V m min RS Rope diameter nm 8 Wire rope length m 22 Cable breaking strength Kg minimum 6050 Technical data not binding 508 2140 0 2340 un 400 405 y MAX 1000 E N X V 4490 T S 450 0 Pict 19 LOAD CAPACITIES COBRA 4400W TECHNICAL DATA4400W Crane rating ft jbs 16 000 Standard outreach ft 15 8 Slewing angle 400 Boom elevation 5 80 Lifting height from base of crane ft 158 Remote control ON OFF Pump for electrical E 12V GM 0 5 1 2 Working pressure psi 2830 Crane weight jbs 700 WINCH SPECIFICATION 4400W Winch pull line jbs 2200 Pull line speed without load E12V ft min 25 Rope diameter inch 5 16 Wire rope length ft 72 Cable breaking strength jbs minimum 13300 Technical data not binding 20 3 4 107 3 4 121 2 8 174 15 3 4 927 LOAD CAPACITIES COBRA 4400W Pict 20
32. e sure that the truck is well braked and if necessary apply blocks to 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 13 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 Whi
33. ee A ie i 31 9 6 2 Rope replacement ete zie rer cect nets ri TE a BR rue tuere id ce cet ii 31 9 6 3 Wire rop lUbricatiOm ge 31 9 7 Possible faults and relevant remedies riii 33 10 DAS rrr 35 Overall difmiension se n a A E din aii teach LGad chart tablen nm 11 WIRING AND HYDRAULIC DIAGRAMS 1222222242 eda red ausa 37 11 1 Wing E SE 3T 11 2 Power unit and control wiring i 38 11 2 2 4400W Wiring diag aMi emer reme IRE O aaas 39 11 3 40 11 3 1 Hydraulic diagram for E 12V ce 40 1 FOREWORD 1 1 SUMMARY This manual is divided into chapters to make its consultation easier Chapter 1 Includes summary 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 Chapte
34. es of soils look at the following table for indicative values e 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 1000 6 A metric 2000 t A U S A A 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 T for brought back or crumbling terrain safety distance must b
35. g 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 AN ATTENTION Always remember of turning the crane battery switch OFF before starting travelling on road 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 capacity 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 Rev 1 04 06 21 Asudden stop when lowering a load This creates high forces of inertia on the crane structure with rele vant 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 boo
36. hly to stroke end Use only the oils stated in the greasing lubricating table or equivalent ones chap 9 5 Pict 15 EN maxiliff 9 4 3 Wormgear assembly control Pict 16 Itis important to check that the worm gear reducer has a correct axial backlash This can be made with the crane at standstill the boom in horizontal position Pushing the boom aside on the left and on the right by hand you can notice if the axial backlash between the wormshaft 6 and the wormgear 8 is too great In this case it has to be reduced tighten the nut 7 accordingly Grease the gear with the suggested product and replace the grease spreader 9 if worn out 9 4 4 Greasing the hydraulic boom sections Pict 17 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 4 Grease the upper part of the 2nd extension by the brush 5 Carry out 2 or 3 boom re entry and extension idling operations in order to allow the distribution of the grease 9 4 5 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 prejudice to the good and safe operation of the crane 9 5 Greases and oils reference table
37. iding 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 extension and the re entry of manual extension must be carried out only loadless Always remember to lock the extensions by the proper pins and lockpins before lifting loads 5 5 2 Operator 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 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
38. 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 e Check the oil level and lubricate accordingly to the lubricating and greasing chart 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 Stability of unit throughout working area Check stability procedure annualy or when any change is made to crane or truck 9 4 CRANE SERVICING 9 4 1 Oil level checking The oil level must be checked daily with the crane in rest position and the truck on flat ground If necessary top up with hydraulic oil The level is checked by mean of the dipstick 1 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 2 gallons and having suitable dimensions to be posi tioned under the oil drain plug 2 A ATTENTION It is 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 box driving it smoot
39. ions to the truck battery 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 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
40. lst swinging the boom always keep the load suspended from the ground Dragging 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 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 22 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 battery isolator before driving away The operator should be someone who is familiar with type of crane and has had some experience with it If the crane is accidentally hit it has to be checked and tested from the closest authorized installer workshop Check every month the st
41. m 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 theirload 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 OPERATIONS n Malh peng Ihi tears ee Gee tery ee Mewt wng AE ANONG ab Marh SAM ehrn peni bach Peeper quad irrig myy hand UTA Maii unga gene BLAH TMAWEL her armed korearra EWS Teme hands TRAVEL dam Tomi gx opu 1 lim eh m done ni oeny Wu in irg ol body making 3 Lage par Ihm inn in AMECA nulh valium pagal nnam EATEHO BOOM Bona 1 1 ayes quiero ELTRACTES FROM 2H5I ETAMDARD AODENOVM 430 50 1985 0 54 1 THIS COMPLIES WITH ria MOYE LC Ul cr hend sa ek dn melan gal er ohe cir hand THER tore al iam
42. max pressure valve too high Disassemble the casing and move ma nually the boom descent valve VB2 Reduce the general max pressure valve Fault Cause Remedy Tension lack in the control box Discharged battery Disconnected electric coupling Burned fuses Recharge the battery Join correctly the connection Replace the electric coupling Replace fuses A manoeuvre does not work Defective switch Burned solenoid Locked valve cartridge Damaged electric connection Replace the switch Replace the solenoid Disable and clean the valve cartri ge Check continuity of the circuit Operations to be carried out only by authorised installer workshop maxiliff 10 TECHNICAL DATA WINCH SPECIFICATIONS SERIES 4400W STANDARD EQUIPMENT Electric winch Remote control with connection and 8 m 26 ft of cable Negativ brake for winch Load limiting device Solenoid valve with manual functions only for emergency Rotation with worm gear Stop end system for winch up and down TECHNICAL DATA 4400W Crane rating KNm 22 Standard outreach m 4 80 Slewing angle 400 Boom elevation 5 80 Lifting height from base of crane m 4 80 Remote control ON OFF Pump for electrical E 12V l min 2 4 5 Working pressure bar 195 Crane weight Kg 320 WINCH SPECIFICATION 4400W Winch pull line daN 1000 Pull lin
43. n 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 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 9 3 2 Monthly checking Check the setting of the pressures in the hydraulic system and integrity of the seals Check the absence of oil leaks Check integrity and tightening of crane tie rods and bolts Check integrity and tightening of hoses piping an
44. n 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 will carry out a new sealing after repairing according to Manufacturer s specifications AN 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 6 3 CONTROLS DESCRIPTION This crane is fitted with a standard cable remote control The remote control system includes a directional electro hydraulic unit manifold A and a electronic power unit B placed inside the casing behind the column a remote control box and a wiring system The electro hydraulic manifold includes an aluminium block equipped with directional electrovalves EV A EV B two each mouvements a main relief valve 5 The electrovalves EV3B EV2B EV1B EV1A are fitted with manual controls to be used only in case of emergency remote control box or electronic power unit breakdown For emergency manoeuvres fully turn counter clockwise the manual control of the electrovalve coupled to the desired mouvement and let the electric power pack motor run temporaly supplying directly relevant relais by the prepared cable from the positive power terminal to the positive solenoid connection momen tarly replacing the existing cable This way the
45. ollowing 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 8 5 11 6 11 9 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 dustand 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 in compliance with the relevant national laws and regulations When traveling on
46. on observance of safety rules To make modifications involving crane components or parameters related to the working cycle The unauthorized use of captive spare 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 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 AN 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 abasic 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
47. ore 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 9 7 POSSIBLE FAULTS AND RELEVANT REMEDIES Fault Cause wy axilift Remedy 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
48. r 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 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
49. re granted to be non flammable and non toxic AN 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 If itis necessary to lift the 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 itis 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 itis 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 i
50. rned on or off every time the crane starts or terminates the working session AN DANGER DC electric motor overheating Keep the electric pump running for short periods to avoid its over heating The maximum working period of the pump depends on the pressure requested by the maneuvers but should never exceed 5 6 minutes in any case with intervals of 20 min to enable a sufficient cooling Extend the outrigger beam Its release is made turning 180 upwards the locking handle 2 on picture 10 Pull the beam 1 on picture 10 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 beam to its working position i e maximum opening position to grant the maximum stability of the vehicle and safety Always pull and push the outrigger beam acting on the handle 3 on picture 10 foreseen for this purpose AN ATTENTION The outrigger beam is in its working position when the yellow band existing on the beam can be entirely seen Rev 1 04 06 19 Lower to the ground the bearing pads of the outriggers jacks at a time acting as follows Hydraulic jack Fig 11 Open the shut off valve 1 to allow the lowering to ground of the cylinder s pad and rod 2 The valv
51. roads and public sites always respect the relevant national laws and regulations AN 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 Always disconnect the battery isolator before driving away 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 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 are based on prov
52. 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 assigned 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 a
53. thin 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 with 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 control board connection has been taken off the remote control the control put in its box in the driver s cab and the plug on the crane has been well closed with its cover 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 10 is safely locked in place Unexpected sliding out of the outriggers beams when the truck is traveling could result in serious accidents The overall dimensions of the crane in rest position are complyin
54. ustification 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 9 6 3 WIRE ROPE LUBRICATION 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 Wire is lubricated during manufacturing so the strands individual wires in strands may move and adjust as the meves 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 bef
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