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cobra 3300he product manual md.0.140

1. Ni TE T 47 al A LD ama e amp B Part A i CL PTO VERSION dE VERSIONE PTO L 3 im m QEON LLL TOR pio m e D Lu e eb gd e M Gs uj I y O i VU B oH dA A 1 SZ y Y e B O IN jg DA DA A Pict 27 ER 11 2 2 Hydraulic diagram dual mode proportional Pump Electrohydraulic unit Rotation motor Lifting cylinder Overcenter valve Pressure trasducer Extension cylinder Overcenter valve OO JO Om P GO A 10 11 Oil filter 12 Oil tank 13 14 Winch motor maxiliff ft 0M Hu H al d 509 3C RG L Bd E RID ef yg 5020 TE iu AL ZEN GD vi CUL V4B Ba LO P de 1 14
2. Pict 28 EN manilift NOTES Name of the installer person Name of the authorized installer workshop Address 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 maxilift NH Next Hydraulics Via MEDITERRANEO 6 42022 BORETTO REGGIO Emilia Italy Tel 0522 96 30 08 Fax 0522 96 30 39 info maxiliftcrane com MD 0 140
3. TECHNICAL DATA 3300H E Crane rating KNm 16 Standard outreach m 4 5 Slewing angle 400 Boom elevation 5 80 Lifting height from base of crane m 45 Remote control Proportional Pump for electrical E 12V 24V l min 5 9 Pump capacity hydraulic H pto l min 10 Working pressure bar 160 Crane weight Kg 240 WINCH SPECIFICATION 3300H E Winch pull line daN 730 Pull line speed without load E E12V 24V m min 5 5 10 Pull line speed without load H E 12V 24V m min 11 Rope diameter rm 6 Wire rope length m 25 Cable breaking strength Kg minimum 2650 Technical data not binding 2525 350 2175 Q E DE eun DA 2 LOAD CAPACITIES COBRA 3300H E 365 E a d 395 H MAX 500 725 o kg S S S E a 400 un p 0 360 00 a o 8o 340 Pict 24 S 46 maxiliff TECHNICAL DATA3300H E Crane rating ft lbs 11 500 Standard outreach ft 15 Slewing angle 400 Boom elevation 5 80 Lifting height from base of crane ft 15 Remote control Proportional Pump for electrical E 12V 24V GPM 1 3 2 4 Pump capacity hydraulic H pto GPM 2 7 Working pressure psi 2300 Crane weight lbs 530 WINCH SPECIFICATION 3300H E Winch pull line lbs 1600 Pull line speed without load E E12V 24V ft min 18 33 Pull line speed without load H E 12V 24V ft min 36 Rope diameter inch 1 4 Wire rope length
4. maxilift SERVICE CRANE Mod 3300H E Code MD 0 140 USE AND MAINTENANCE MANUAL Rev 1 Edition 07 09 maxilift 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 3300H E SERVICE CRANE Manual code MD 0 140 This manual is valid starting from serial no 13471 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 NO Me RR YEAR OF MANUEACTURING 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 index 1 FOREWORD silicio PAGE 1 1 Summary E EE B 1 2 Remarks E S n 1 3 Manual TOVISIOM 2 ala 2 HOW TO CONSULT THE MANUAL cca 2 1 INSTrUGtIONS cuidan aaa sd
5. 3 CRANE IDENTIFICATION Tr 3 1 Versions and optional available iaia iaia i 3 2 CRANE identification data tcc apra al dE 4 CRANE USAGE AND LIMITS OF APPLICATIONS sees 4 1 CRANE classification and proper usage i 4 2 IMProperiisage s R 4 3 CRANE operators tral mcr ar aa R 5 SAFETY ET 5 1 Rules concerning PCOPI e ME EM 5 2 Ne le Bar EE di 5 3 Rules for the correct positioning of the crane i 5 3 1 Choice of the crane operating place pressure on the oround ii 5 3 2 Safety distance from trenches and slopes A 5 3 3 Safety distance from electrical power lines iii S 5 3 4 Crane and load ground connection oiii iaia ado 5 3 5 Influence of the Wind on the crane operation iaia 5 4 Rules concerning safety in the traffic asia 5 5 General rules On Winch Operations oen aaa a satan ER Era EE 5 5 1 Winch Erie er p N li 5 5 2 Crane ain Single pull INS command 5 5 3 Crane In double pull JD eet ek cai terio reto reae air R 5 5 4 Operator safety 5 5 5 General rules when operating Winch alain Si 5 6 WIRE ROPE 5 6 1 EE 5 6 2 Wire rope PRECAUTIONS mM 6 DESCRIPTION OF THE ORANE 5 51 22
6. 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 loa ds 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 5 6 2 Wire rope precautions 1 Avoid the formation of kinks Kinks will cause severe weakness 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 distor tion will result 4 Do not use nicked or othe
7. 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 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 Operations to be carried out only by authorised installer workshop maxilift 10 TECHNICAL DATA WINCH SPECIFICATIONS SERIES 3300H E STANDARD EQUIPMENT Winch with planetary gear reducer Remote control with connection and 10 m 33 ft of cable Negativ brake for winch or radio remote control Load limiting device Solenoid valve with manual functions only for emergency Rotation with worm gear Stop end system for winch up and down
8. 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 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 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 el WARNING STAY CLEAR OF BOOM AT ALL TIMES su ADANGER AN UNTRAINED OPERATOR SUBJECTS HIMSELF AND OTHERS TO ADANGER DEATH OR SERIOUS INJURY YOU MUST NOT OP
9. Replace fuses Replace the electric pump 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 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 maxiliff y Remedy dl lack in the control box green led out Discharged battery Disconnected electric coupling Emergency button pressed Recharge the battery Join correctly the connection Replace the electric coupling Restore emergency bulbe One of the function 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 boardor the remote control box The proportional valve does not meter Electric valve EV9 is not working The wigger on the remote hand held control box does not worck 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 lt is not possible to adjast the speed
10. pons gn plug Dr repa mah ing puyung mongn n depor gn t OL EVENVTHbaE Clip Fanos RON H Boi TRAWEL Ome Trechk Lock tw F ck on piy mac by minare Vat reet appese Mach i geg E AE Sci Ai A in anl A bey For er nta ey TRAVEL Beth Trocka Use pom Retain eon rd bests memng a cir cular bon gio mich Hhe indi atr direson oi rape Kn ien 0 baciami Vor land cranes om mhTmart BOOM Takeo Bonum Hamm ais n hon dl Body mik sms pg inan amc mire LOER A doe de ib groen ord foretege Gear UR pen utt wen quaamery Hoi Tap ninja wath gag hang n uim wn EXTEHU BOOM Tito ing para BO Aan vant ec med arih tft panig duad EXTRACTED FROM ANSI STAHDARD ADDENDUM ESO 1965 630541984 E THIS COMPLIES WITH OSHA STANDARDS Pict 19 ES maxilift 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 ofthe 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 Getall the necessary information for reaching the working site distance it
11. 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 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 maxilift 5 SAFETY RULES 5 1 RULES CONCERNING PEOPLE e 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 The fire extin guisher must always be kept charged and has to be used according to current regulations 5 2
12. regulations When traveling on roads and public sites always respect the relevant national laws and regulations A 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 are based on providing the proper operating safet
13. 0 maxilift 6 6 Signal and e Ee ura A ERRE aaa iaia NI IRE Page 23 6 6 1 K yboard diagnostic Signals iner aa aaa iaia aa 23 6 6 2 Display Messages isdn an iaia aA EEE iii 24 6 6 3 Normal display menu 24 6 6 4 Micro switches and pressure switch display menu ii 26 6 6 5 Current display AMI 26 6 6 6 Remote control keyboard display menu uu 27 6 6 7 Work pressure display men enisi netten tti iii 28 T OPERATINGINSTRUCTIONS ocn recia 29 CA EE EE IT 29 7 2 Stabilizing TS THICK MU ia 20 3 Opening stlie Crane sese terme ao homero ed aaa da 92 7 4 CIOSING ue 23 7 5 Wirich systemiuoperatiohi fa EE 32 7 6 Before starting traveling op TOA enean iii 32 7 7 Main errors occurring when operating the crane i 392 7 8 Standard hand signals iio Roi iie ce Pea eade des Ane baa vin apo ae 283 8 PUTTING THE CRANE INTO SERVICE 34 8 1 Ten rules for the perfect Crane operator iii 34 8 2 Daily checklist iaia aaa iaia lia iaia 34 8 3 Safety tips for crane starting cold climates ii 84 8 4 Crane protection arid storage teet itcrum eri PARLE LESE alain 24 8 4 1 lanes PP 24 8 4 2 Long SUI dae H P 985 9 MAINTENANCE cc PPP 36 9 1 MCI e REED 96 9 2 Maintenance prescripliOlis rece etn iii artes ail cae
14. 242221454 2 02000 c rtu cobalt d d ius 6 1 Model Oe He EE A S 6 2 Model 3300 NEE 6 3 Safety devices cuca 5 6 3 1 Safety devices installed rnit nere iaia eR d rli oet aad li 6 3 2 Load limiting device 6 3 3 Relief valve n R 6 3 4 Pilot operated holding valves cai ete teinte set AA Iaia iaia 6 3 5 Safety devices SEALING titan tai A in eae Eaa a ictericia si 6 4 Microprocessor remote Control System icc ocuicir ia AR 6 4 1 Available Control Vers maior iii 4 6 4 2 Electronic power Unit ii a 7 6 4 3 TING r dio recever UNE EE i 6 4 4 The cable keyboarde eet ar Ra ds 6 4 5 The Keyboard radio trasmitient aiea alii 6 4 5 1 Radio system protection device i 6 4 6 Proportional mono function regulation hydraulic unit enne J 6 4 7 Proportional dual mode regulation hydraulic unit sses i D E EVI ai 6 5 Remote controll Use oie e ec a tete eere eese aaa ste a aa a 6 5 1 Use of the mono function proportional remote Control S 6 5 2 Use of the dual mode proportional remote Control x ssiisssarsiiniinnisrinkiiranianin ianuarii nainii kanaatin li KW RBNo2a223223060000 4000 SASA WWW NN N A Ad A AA MA AA AA AA AA A A on S 0 o OO 4 0000101000 OD NNNNNNN NNN 0
15. A Sw5 B H E B 2 SW6 SW4 SW3 SW2 SW1 NO Connected NC In normal operation PANEL COMPONENTS LAYOUT FRONT SIDE VIEW DISPOSIZIONE COMPONENTI VISTA ESTERNA RADIO VERSION USE ONLY SO SU VERSIONE RADIO a r BERB 2233 Si BEBE mr 2e 6T aut M12 MALE CONNECTOR CONNETTORE NASCHO M12 M12 FEMALE CONNECTOR M12 FEMALE CONNECTOR SERVICE CABLE E CABL CAVO DI SERVIZIO RADIO VERSION USE ONLY SOLO SU VERSIONE RADIO CONNETTORE MASCHO 7 8 33 ga 23 qa an x 1 7911131917 J6 da alal alal alal dd ala ELE slo sus sel e 2 2 2 2 2 2 p ES Jou Te P s ye gt 42 ei 7 8 MALE CONNECTOR cm MEL Tra vec GNA 2 Sei PROPORTIONAL TRIGGER PULSANTE PROPORZIONALE BATTERY PACK CONNECTOR CONNETTORE PER LE BATTERIE RADIO VERSION USE ONLY SOLO SU VERSIONE RADIO Pict 26 maxilift 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 E
16. DRAULIC 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 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 4 7 PROPORTIONAL DUAL MODE REGULATION HYDRAULIC UNIT Pict 12 The unit is consisting of two separate aluminium blocks The upper section includes th
17. ERATE ADANGER STAY CLEAR OF LOAD ZAT ALL TIMES 1 PART UNE 2200 le max PULL LBS Al CAUTION n OUTRIGGERS WILL CAUSE SERIOUS CRUSHING INJURY STAND CLEAR 5 3 RULES FOR THE CORRECT POSITIONING OF THE CRANE 5 3 1 Choice of crane operating place pressure on the ground e 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 Admitt
18. Insert the filter group in its housing and tighten the relevant screws After a filter replacement bleed the air off the circuit as explained on point 9 4 2 Pict 20 ES maxilift 9 4 4 Wormgear assembly control Pict 21 It is 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 5 Greasing the hydraulic boom sections Pict 22 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 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 6 Wear pads check and replacement Wear pads need to be replaced when their thickness drops under 5 5 mm 0 22 inch A 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 Pict 21 maxili
19. ONAL O OO JO Om P Gabi A Pict 6a EN 6 3 SAFETY DEVICES 6 3 1 Safety devices installed All the safety devices installed on MAXILIFT COBRA 3300 crane are listed and described in the following pages description of safety functions The crane is fitted with 4 standard electrohydraulic 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 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 thr winch drum remaining only 3 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 3 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 lim
20. able pressure on various types 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 p 1000 t A metric p 2000 t A U S 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 W i maxilift e for brought back or crumbling te
21. arged 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 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 ZN DANGER electrocution hazard Always ground
22. ayed 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 BOOM 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 maxilift 6 6 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 op
23. 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 seconds 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 a 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 off maxilift 6 6 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 message
24. board 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 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 maxilift 6 4 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 4 6 PROPORTIONAL MONO FUNCTION REGULATION HY
25. ckthe good conditions of painting and chrome plating Check the correct working of safety valves 8 3 SAFETY TIPS FOR CRANE STARTING IN COLD CLIMATES Only ifthe crane is 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 Short shutdowns Wash and clean the crane lubricate all the parts provided with grease nipples and the slewing system maxiliff A 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 unbuttoned 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
26. control switches the load must remain still 6 3 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 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 4 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 4 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 switch board 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 4 2 ELECTRONIC POWER UNIT Pict 8 The elec
27. d grease the worm and the worm gear replace the grease brush spreader if worn e 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 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 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 the 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 Ot
28. e 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 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 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 AN 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 a
29. e 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 winch 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 lt lt A bb EEE EV4B EV3B EV2B EV1B Pict 12 6 4 8 WIRING pict 13 Made up of a single wiring unit that is connected
30. 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 e 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 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 par
31. erate the 1A and 3B movements simultaneously for at least 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 following conditions O open C closed Example display of the state E 5 1 FB micro switch open C LI du Example display of the state H PM micro switch closed f L The following table shows all displayed codes Fa O Fa C micro switch FA micro on winch drum cable descent Fb O Fb C micro switch FB stopped boom limit switch Vv Pict 14A Fu O Fu C micro switch FV limit switch on cable diverting 1B pulley cable lift PrO PC micro switch PM digital pressure gauge or analog pressure transducer 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 6 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 d
32. ff maxiliff 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 LR MP GREASE Y MULTIS MOBILGREASE BEACOM GR MU ATHESIA ENERGREASE LR MP MP EP2 EP2 EP2 EP2 Y HYDRAULIC AZOLLA DTE NUTO OSO HYDRUS HENERGOL ZS 46 25 H 46 46 46 HL 80 ZS 48 H68 68 t GREASE WINN S GS 80 j fortemperate and cold climate forhot climate maxilift 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 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 d
33. ft 82 Cable breaking strength lbs minimum 5850 Technical data not binding B 3 4 29 1 2 14 11 32 400 Pict 25 LOAD CAPACITIES COBRA 3300H E 18 2750 15 12 1540 3200 AN 1100 100 o 880 3200 2400 1200 6 00 000 100 si 1720 3 A x i Lbs 1860 1050 750 ito e FJ 12 15 E maxiliff 11 WIRING AND HYDRAULIC DIAGRAMS 11 1 ELECTRICAL DIAGRAMS MONO FUNCTION DUAL MODE V3 VM EV9 NO Connected VR i H O FA NC In normal operation OM lt OM 1 7 VM V4 EV9 E a VR Om EVAA EV48 EVAA EV4B EV3A EV3B EV3A OH v38 re FV EV2A 0 EV2B EVZA 40O GE EV28 EVIA EVIB EVIA EV1B NC 7 87 MALE CONECTOR 7 8 MALE CONNECTOR CABLE VERSION VERSIONE TELE 7 8 MALE CONNECTOR CONNETTORE NASCHIO 7 8 RADIO VERSION VERSIONE RADIO MZ FLAT CABLE PIATTINA M12 RADIO VERSION USE ONLY SOLO SU VERSIONE RADIO PANEL COMPONENTS LAYOUT REAR SIDE VIEW DISPOSIZIONE COMPONENTI VISTA INTERN
34. h it If the crane is accidentally hit it has to be checked and tested from the closest authorized installer workshop maxilift 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 e 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 Swi
35. he 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 e 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 e Always wind loadline under tension to assist proper spooling maxiliff 5 5 5 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 Donot pull load block into boom tip 3 Makecertain 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 con trol to neutral to determine if the brake is working properly 6 Do not drag loads in any direction with the winch
36. hers 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 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 25 liters 6 gal and having suitable dimensions to be positioned under the oil drain plug 2 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 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 filter replacement oil tank optional Only H version e Unscrew the screws 5 holding the filter case Pull the case out without damaging the OR Loosen the nut 5 and take the cartridge 4 off Replace it with a new one of the same type and tighten the nut 5 again Check the seal for satisfactory condition if not replace by new one
37. ial 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 control 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 A WARNING When the cable key
38. icker A DANGER Before starting operations make sure that nobody is in the working area of the crane e e The crane must work only on flat ground Make 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 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 loc
39. inerary 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 ifthe 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 2 DAILY CHECK 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 Che
40. ion 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 15 foreseen for this purpose never pull the hoses or piping A ATTENTION The outrigger beam is in its working position when the yellow band existing on the 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 16 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 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 17 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 18 When swinging jack are fitted before
41. ips to be followed A 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 3 CRANE IDENTIFICATION 3 1 VERSIONS AND OPTIONS AVAILABLE The service instructions written on this manual are referred to the CRANE MAXILIFT COBRA 3300H E This model is supplied in 6 versions When ordering one or more of the following versions are to be speci maxiliff fied Version Remote control Hydraulic supply Power supply 3300 KP H Cable Proportional mono function Fed by a punp driven by a P T O truck 12 24V 3300 KP E Cable Proportional mono function Fed by a DC electro hydr power pack 12 24V 3300 KPD H Cable Proportional dual mode Fed by a punp driven by a P T O truck 12 24V 3300 RKP H Radio Proportional mono function Fed by a punp driven by aP T O truck 12 24V 3300 RKP E Radio Proportional mono function Fed by a DC electro hydr power pack 12 24V 3300 RKPD H Radio 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 only for H version Outrigger beam mechanical Jack All Outrigger beam hydraulic jach All 3 2 CRANE IDENTIFICATION DATA Every crane is ide
42. isclosed 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 Wire rope is lubricated during manufacturing so the strands and individual wires in strands may move and adjust as the rope 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
43. isplayed When a movement is active the value of the current in mA that is driving the proportional solenoid valve is displayed Example indication without any active movement f f LD Example indication with an active movement and ck with the proportional valve driven at 523 m 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 6 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 Example indication when the contact 1A Te is closed on the remote control unit um H vc The following table shows all di
44. iting 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 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 3 3 Relief valve The main relief valve is on the hydraulic unit and limits the maximum working pressure 6 3 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
45. ked 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 Whilst 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 33 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 wit
46. ngine 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 trasducer Extension cylinder Overcenter valve GO OO JO Om P GO A 10 11 Oil filter 12 Oil tank 13 14 Winch motor VR y RG T x CP 3 IG P 1 n Ill FRI ul z b
47. ntified 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 ATTENTION It is strictly forbidden to change erase modify the data written on the plate maxilift 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 1 6 ton meter 11 500 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 thatis 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 e 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 c
48. ny 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 maxilift 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 and their fittings Check fastenings and safety devices e 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 Clean oil filter Check the oil level and lubricate accordingly to the lubricating and greasing chart Check the regular working of the slewing system grease with the suggeste
49. 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 hydraulic 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 4 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 for every other jack fitted on the truck Make sure that the vehicle is leveled 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 15 Pict 18 EN Pict 16 s Pict 17 maxilift 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
50. ote 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 the panel 4 for crane movements 1 for engine START STOP The 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 P L start stop 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 4 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 ser
51. perators 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 A 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 maxilift 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 s
52. r ed End Feb ne aspe ta stola eme ile ti 96 9 3 Maintenance schedule iini rear ette aicut seen ieri Of 9 3 1 Daily CheckiNg rm S37 9 3 2 Monthly Checking NES 88 9 3 3 Checking every Six MONOS eurer ei a eei edited dene id oci ent AA eR dax 88 9 3 4 Gu ERES 38 9 4 Crane Sed ee 39 9 4 1 Oil level check tedio 89 9 4 2 Oil CAN eE 89 9 4 3 Oil Filter replacement m E 89 9 4 4 Wormgear assembly COntrol iii iaia tertie titre Fe Len Ere alii iii 40 9 4 5 Greasing the hydraulic boom Sectors sissid id rn 40 9 4 6 Wear pads check and replacement icons ai eno ae 40 9 5 Greases and oils reference table ooo io io Ai 9 6 Wire rope m alas 42 9 6 1 WIFE NOPE Inspecllol 285 israeliana 42 9 6 2 Rope A etre exero otra Re ve chc edge RA ERA NE Exe RE Ga XE sansa Sea vend Lx ada Een LER Ra eae sii atri 42 9 6 3 Wire rope lUDMCatioh EEUU UU DEEST DU 43 9 7 Possible faults and relevant remedies enne nennen enne nnne neret 44 10 TECHNICAL DATA WINCH SPECIFICATIONS essseeeeeeeeeene 46 Series 3300 H E Standard equipment is eee cec eie LER ene cele ned eee P rOnmanCeS asiH NP METER Eo rEej mmt E 11 WIRING AND HYDRAULIC DIAGRAMS 22222 rk retis ada ba ttc 48 11 1 Electricals diagram ii AL Ania iaia 48 11 1 pr
53. r me 49 11 2 Hydraulic diagram S seins Ii 50 11 2 1 Hydraulic diagram mono function proportional mener nnns 50 11 2 2 Hydraulic diagram dual mode proportional Di 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 operation Anyway these instructions are not a training manual for beginners or unskilled o
54. rane 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 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 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 in compliance with the relevant national laws and
55. rest position as specified on chapter 7 4 The emergency button must be pushed 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 15 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 16 is in the CLOSED position 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 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 e A sudden stop when lowering a load Thi
56. 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 lt 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 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 obs
57. rrain 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 3 Safety 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 ch
58. rwise 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 appropriate wire rope 7 Do not expose the rope to corrosive chemicals 8 Lubricate the rope frequently to reduce friction and help prevent cor rosion Pict 4 maxiliff 6 DESCRIPTION OF THE CRANE 6 1 MODEL 3300H Item Description Slewing system Slewing motor Column Main boom Boom hoist cylinder First boom section hydraulic Second boom section mechanical Telescope cylinder inside the boom Oil tank OPTIONAL 10 Control valve 11 Electronic power unit 12 Remote control box 13 Winch 14 Travelling block 15 Outrigger beam hydraulic jack OPTIONAL 16 Outrigger beam mechanical jack OPTIONAL O DONDQDUIDSDWNWN Pict 6 maxiliff 6 2 MODEL 3300E Item Description Slewing system Slewing motor Column Main boom Boom hoist cylinder First boom section hydraulic Second boom section mechanical Telescope cylinder inside the boom Electro hydraulic power pack 10 Control valve 11 Electronic power unit 12 Remote control box 13 Winch 14 Travelling block 15 Outrigger beam hydraulic jack OPTIONAL 16 Outrigger beam mechanical jack OPTI
59. s the operator is requested to contact the Technical After Sales Service 6 6 3 NORMAL DISPLAY MENU When the crane goes gets locked by the LLD overload the display shows When switching on after a sequence of messages on the display this must show LIA i When carrying out whichever movement by selecting the function it must appear i H au LJ CD uu When the overload condition is almost reached the display shows LJ LI H 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 H E Moreover the system can show the following error messages which can be displayed when operating or trying unsuccessfully to operate f1 The messages and relevant meanings are the following LI O xx followed by the solenoid valve abbreviation It means open circuit detected on the solenoid valve in object c3 UN ND Examples Open circuit alarm on solenoid valve EV3B The following table shows all the displ
60. s creates high forces of inertia on the crane structure with relevant dangerous overload maxiliff 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 e 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 OPERATIONS SWING dem eslanded pone mih lingar in decana oF seeing ol noc USE MAIA CHET Tap Sar zen tao IM Lcd reor ba geer amy moon gr end placa Dinge hang are n pe DI hand peng va monon HU rine mbr mn Ba dT TRL Sum actended forward Free
61. 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 brief 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
62. splayed codes Display Indication CIA 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 TELESCOPIC 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 6 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 do 80 bar work pressure display example l o I 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 st
63. t 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 ina 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 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 protectiv
64. tch on the hydraulic power pack Cranes driven by DC power pack The DC power pack is connected with the truck battery The connection is made turning on the emergen cy button Pict 9 P located on the remote control 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 fully dedicated to the crane electrical system must be present A 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 10 15 minutes in any case with intervals of 20 min to enable a sufficient cooling 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 only for PTO driven cranes Extend the outriggers beam Its release is made turning 180 upwards the locking handle 2 on picture 15 Pull the beam 1 on picture 15 out for a length ofapprox 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 posit
65. 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 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 maxilift ZN 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 c
66. 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 pressure transducer PM to the die sel 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 maxilift 6 5 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 5 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 f
67. tronic 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 or control interface is found on the front of the unit Two electrical wiring connectors 2 are found on the unit maxilift 6 4 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 4 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 rem
68. tructed 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 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
69. unction which will be quicker and quicker until you achieve the maximum speed 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 movements will be jerking and dangerous Always release first the proportional but ton and then the selector of the movement chosen 6 5 2 USE OF THE DUAL MODE PROPORTIONAL REMOTE CONTROL Pict 14 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 Gy 6 6 SIGNALS AND DIAGNOSTIC 6 6 1 KEYBOARD DIAGNOSTIC SIGNALS The following signal devices are found on the radio keyboard a beeper a green led Beeper
70. 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 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
71. upplied 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 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 A 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 t
72. y 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 A ATTENTION The 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 Crane in single pull line Pict 4 Use the winch in single pull line with a max load of 730 Kg 1600lbs with heavier loads set the winch in double pull line by using the rope block kit on issue For the use in single pull line it is necessary to leave the balance weight 1 on the lifting hook in order to keep the rope tensioned The balance weight is kept in slide on the sleeved thimble terminal in correspondence of the hook and is locked in position by the proper retainer 2 locked by wing screw 3 5 5 3 Crane in double pull line Pict 5 Use the winch in double pull line when lifting loads heavier than 730 Kg 1600 Ibs up to max 1450 Kg 3200 lbs For the use in double pull line it is necessary to remove the balance weight 1 by unloosing the wing screw and to put it back in a safe place Then mount the rope block on issue with the crane letting the rope reeve on the pulley after unscrewing of the screws 4 and hitch the lifting hook on the back pivot of the pulley head 5 5 4Operator safety tips Do not pull the load block into t
73. ycle 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 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

cobra 3300he product manual md.0.140

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