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MD0136 GB.pmd - MAXILIFT and COBRA Truck Cranes. North

1. 9 2 9 2 22 2222 2 anne n nana os 9 6 6 1 Thrust slewing system 10 6 6 2 Crank slewing system 10 6 6 3 Hydraulic slewing system 11 6 6 4 Boom lifting system by mechanic strut a 11 6 6 5 Boom lifting system by hydraulic cylinder 12 6 6 6 Two manual extensions boom system 13 6 6 7 Boom system with 1 hydraulic and 2 manual extensions 14 6 6 8 Hydraulic operating system by hand pump for lifting cylinder 15 6 6 9 Hydraulic operating system by hand pump for lifting and extension cylinders 16 6 6 10 Hydraulic operating system by hand pump for extension cylinder 17 6 6 11 Electro hydraulic operating system by power unit with one function for lifting cylinder 17 6 6 12 Electro hydraulic operating system by power unit with two functions for lifting and exte
2. gt vehicle stability loss gt boom descent triggering in case the boom lifting lever is operated again this is caused by the intervention of the overpressure valve on the valve bank CORRELATED SAFETY DEVICES The pump overpressure valve calibrated at 170 bar prevents lifting weights exceeding the allowed ones The sink rate control valve on the lifting cylinder controls load s lowering in case of hose breaking Double acting pilot operated lock valve on the extension cylinder Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy 16 Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 info maxilifterane com VVV maxilift 6 6 10 Hydraulic operating system by hand pump for extension cylinder Operation The system pict 15 is consisting of manually operated hydraulic pump and a two functions control valve bank with one lever equipped with automatic return into neutral position The valve bank controls the boom extension This operating system is necessarily associated to the following unit combination gt boom system with 1 hydraulic and 2 manual extensions gt boom lifting system by mechanical strut gt winch manual or electrical Use gt Lead the boom to the working position See paragraph 6 6 4 gt To operate the extension boom out or boom in movements push or pull the lever on the valve bank with one hand and operate the pump lever with the other hand Pump s
3. 3688 Max lifting height from crane base m 3 40 ft 11 15 Max working slope 4 Max working pressure bar 170 p s i 2465 6 Electro hydraulic power unit supply voltage V 12 Max absorption electro hydraulic power unit A 100 Hydraulic oil tank capacity I 1 6 Max absorption electrical winch A 30 EI Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Tel 39 0522 96 30 08 info maxilifterane com Fax 39 0522 96 30 39 9 4 2 Table of weights for foreseen crane versions maxilift VERSION Basic crane weight Crane weight with winch kg Ibs kg Ibs M50 2M MSF VE VM 63 138 6 M50 2M MLF VE VM 71 156 2 M50 2H PSF VE VM 82 180 4 M50 2H PLF VE VM 90 198 M50 2M PSH 65 143 76 167 2 M50 2M PLH 74 162 8 85 187 M50 2M ESH 61 134 2 72 158 4 M50 2M ELH 70 154 81 178 2 M50 2H PSH 74 162 8 85 187 M50 2H PLH 83 182 6 94 206 8 M50 2H ELH 81 178 2 92 202 4 M50 2M ERH 78 171 6 89 195 8 M50 2H ERH 85 187 96 211 2 9 4 3 Accessories weights table ACCESSORY Weight kg Ibs Stabilizer kit 20 44 Counter flange 6 13 2 Quick fitting kit 20 44 Back load attachment kit 1 7 3 74 10 WIRING AND HYDRAULIC DIAGRAMS 10 1 Hydraulic diagram hand pump for lifting cylinder Hand pump Pump Lifting cylinder Compensated throttle Sink rate control valve Oil t
4. hoses damaged loose hydraulic fittings etc damaged lifting ropes snub pulleys hooks Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 oF a info maxiliftcrane com VVVVVV maxilift VVVV VV 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 gualified skilled people The recommended procedures of repair and maintenance must always be followed carefully If necessary ask for a preventive authorization Before taking any part away of the crane always be sure that the pressure in all the circuits has been discharged Do not put the head or fingers or feet or arms or any other part of the human body into an area where the danger of shearing or crushing exists if the parts of the machine have not previously locked in a safe way Do not use your fingers to align holes or slots always use appropriate centering tools Wear protective glasses with side shields to protect your eyes when using compressed air for cleaning 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 according to current hazard avoiding regulations Never use petrol or thinners or other flammable liquids or detergents Use instead authorized commercially sold cleaning products which
5. slewing Pict 19 6 7 Accessories 6 7 1 Electrical winch Operation The electrical winch pict 20 is a cable lifting device applied on the crane boom by proper brackets which along with the transmission hooking and safety devices becomes an integral part of it Its lifting capacity is indicated on the labels stuck on the crane near the operating place Press the upper part of the button for the rise and vice versa for the lowering Use To start the system it is necessary to gt Apply the pulley attachment pict 21 to the end of the 2 extension making sure the lock pin is perfectly inserted as for manual extensions unwind the cable so that it can reeve on the pulley loosen the wing nut of the anti fleeting system to allow the cable entering between the pulley holding sides fit the rope in the pulley race restore the anti fleeting safety device inserting the spacer plug the button strip connector in its socket on the connector block after lifting the cover lead the lifting hook over the load using extension boom out and boom angle Front Connector block Electrical motor Drum Button strip Connector Pict 20 Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 info maxiliftcrane com a maxilift IMPORTANT Always keep the rope tensioned avoiding leaning the counter weight
6. when foreseen to grant the maximum stability of the vehicle and safety ATTENTION The outrigger beams are in their working position when the yellow band existing on every beam can be entirely seen 6 5 Ten basic rules for the safe loader operator Always comply with the following ten basic rules gt gt gt VVV When approaching the crane for the first time become on familiar terms with it executing all the manoeuvres the loader 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 understanding This manual must always be carried in the driver s cab along with a copy ofthe load chart Study and plan the best way to operate the crane soil consistence weight and dimensions ofthe loads to be lifted height to be raised and necessary booms outreach Check available room or limitations due to the presence of buildings obstacles electricity power lines etc Make sure of availability of all the necessary eguipment accident prevention clothing additional bearing plates with increased surface area slings hooks ropes and chains ofcertified origin and in perfect conditions Before starting loader operations check the efficiency of the safety control devices Never use the loader if the correct functioning of a device is not sure Traffic and safety laws in force must be strictly observed both when travelling on road
7. when hooking the load This prevents turns loosening on the winch drum and consequently the rope damaging gt liftthe load of a few centimetres using the winch and immediately release the lifting button to check the winch brake correct functioning gt complete the load handling operation paying attention to the correct and regular cable winding After use Put the crane back into the min overall volume position to do this the pulley attachment must be removed otherwise the crane stays more open The following operations must be carried out with the boom set horizontally to remove the Pulley holding side Anti fleeting system Hook Counterweight Pict 21 pulley attachment gt loosen the wing nut of the anti fleeting system to allow cable extraction from the pulley attachment gt restore the anti fleeting safety device to prevent loosing its components gt pull out the pulley attachment from the extension end and put it back in a safe place gt hook the cable winding it carefully until the counterweight stops against the winch front protection gt disconnect the button strip from its connector block socket putting it back in a safe and protected place gt cover the connector block socket with its lid AN DANGERS gt Since the machine does not include a rope raising stop end it is essential to check that the anti fleeting system is correctly assembled Without t
8. The sink rate control valve on the lifting cylinder controls load s lowering in case of hose breaking Load descent control throttle ZN LE 27 E a A SW Z Buttonstrip LA 27 9 EE N Raisin FAME bution e et de Z E 4 _ Pl ae Pa E M i Lowering Lifting cylinder button Hose Tank Connector Sink rate 2 control valve T Motor pump Pict 16 6 6 12 Electro hydraulic operating system by power unit with two functions for lifting and extension cylinders Operation The operating system pict 17 is consisting of an electro hydraulic power unit operated by the button and controlled by a two functions valve bank with levers equipped with automatic return into neutral position The valve bank controls are gt boom lifting lever gt boom extension lever This system is necessarily Use gt The battery disconnector key must be inserted and turned clockwise to start the system To operate the extensions boom out or boom in push or pull relevant lever on the valve bank and keep the motor starting button pressed To operate boom lifting or lowering pull or push relevant lever on the valve bank always keeping the motor starting button pressed Hoses Motor start button Battery TT disconnector J SoK Extension vi Valve bank h ofi ril Boom lowering levers Levers Protection Pict 17 mn Via Mediterraneo 6 4
9. and when operating the loader The warnings of these manual referred to special dangers are to be read and observed with special care The safety during the loader service must be kept to the highest level carrying out a regular constant and accurate preventive maintenance Repairs if necessary should never be delayed and must be made by specialized authorized people using only genuine spare parts 6 6 Instructions for use The crane instructions for use are based on the analysis of the different functioning units Find your own version in the following table that are combining each other according to The sub paragraphs that must be compulsorily read for using the crane the versions are indicated beside of it The main units are VVVVV VVVV V V VVV VV Thrust slewing system VERSION Paragraphs Crank slewing system M50 2M MSF VE VM 6 6 1 6 6 4 6 6 6 6 7 1 6 7 2 Hydraulic slewing system M50 2M MLF VE VM 6 6 2 6 6 4 6 6 6 6 7 1 6 7 2 Boom lifting system by mechanical strut M50 2H PSF VE VM 6 6 1 6 6 4 6 6 5 6 6 10 6 7 1 6 7 2 Boom lifting system by hydraulic M50 2H PLF VE VM 6 6 2 6 6 4 6 6 5 6 6 10 6 7 1 6 7 2 cylinder M50 2M PSH 6 6 1 6 6 5 6 6 6 6 6 8 Lifting system by electrical winch M50 2M PLH 6 6 2 6 6 5 6 6 6 6 6 8 Lifting system by manual winch M50 2M ESH 6 6 1 6 6 5 6 6 6 6 6 11 Two manual extension boom sy
10. are granted to be non flammable and non toxic DANGER It is forbidden to use naked flame as lighting device when carrying out checks or looking for leaks in the machine gt Donotlubricate repair or carry out settings on the loader when it is working unless this is expressly required in the instructions of the Operator s Maintenance manual gt If it is necessary to lift the loader and or other parts make sure that they are locked as requested from current safety regulations gt Always use approved protective clothing safety gloves and protective glasses when using steel ropes as they produce steel splinters gt Never use the tools in a way different from the one they are meant i e pliers instead of wrenches gt The maintenance area is to be kept clean and dry Remove immediately any trace of water or oil gt Leakage of fluid from a very small hole may be almost invisible and yet strong enough to penetrate the skin Before starting looking for the leaks it is important to wear protective glasses with side shields Do not use your hands use a piece of cardboard or wood to locate the source of the leak Injuries caused by pressure fluid may result in serious infections so it is recommended to contact immediately a doctor Before disconnecting or loosing the piping and components belonging to the hydraulics make sure any residual pressure in the circuit has been discharged gt Donotheap dirty rags with oil or grease the
11. extract the key from the battery disconnector and put it back in a safe and protected place A ATTENTION If you wish to extend the boom hydraulically once the max allowed load is lifted to a specific outreach the overcenter valve on the lifting cylinder intervenes making the boom lower slowly This is to prevent risks of gt crane structure overloading A DANGERS gt vehicle stability loss gt Make sure thatthe rotation stop prevents excessive tractive forces on hydraulic hoses CORRELATED SAFETY DEVICES gt The control valve overpressure valve calibrated at 170 bar prevents lifting weights exceeding the allowed ones gt The overcenter valve on the lifting cylinder controls load s lifting and lowering in case the slewing function is operated simultaneously to the lifting function Moreover it makes the boom lower slowly in case the hydraulic extension is operated with the max allowed loads The functions are only operated by keeping the power unit starting button pressed Therefore all functions are stopped when the button is released Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy 22 05 Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 info maxilifterane com maxilift Motor start button Valve bank levers Levers Protection Casing Battery disconnector Extension boom in Boom raising Extension P boom out Boom SL Left slewing lowering Right
12. hoses piping and their fittings Make a safety test of the hydraulic system 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 etc Check the oil level and lubricate according to the lubricating and greasing chart Make a working test of the crane with and without the load Check good fastening and good conditions of the power cables from and to the battery Grease the terminals and protect with relevant boots 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 A ATTENTION All grease and hydraulic oils can cause skin damages and irritations Always protect the hands with suitable gloves before carrying out any operation involving the above VVVVVVVVVV VV 8 4 Loader servicing Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 ON info maxiliftcrane com maxilift 8 4 1 Oijillevel checking The oil level must be checked periodically by the fill up cover of the hand pump and visually through the transparent tank of electro hydraulic power unit with the crane in rest position and the truck on fl
13. its safety latch VVV Loader driven by DC power pack The DC power pack is connected with the truck battery The electric pump will start or will have to be started each time a lever of the control valve is moved The loader can work for short periods even when the engine of the truck is off but it is strongly recommended to keep the engine idling so the alternator can continuously charge the battery of the vehicle AN aaa 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 manoeuvres but should never exceed 5 minutes in any case with intervals of 20 min to enable a sufficient cooling AN ATTENTION It is advisable to start the vehicle engine to avoid running down the battery when operating in a ventilated area without any fire or explosion risks Stabilizing the truck gt 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 gt The truck engine shall be kept idling to allow batteries recharging gt Extend the outriggers beams Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy af se Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 info maxiliftcrane com maxilift Always extend fully the outrigger beams to their working position i e maximum opening position
14. lifting lever gt boom extension lever Hoses IN Extension gt gt boom Boom This system is necessarily associated to the following units gt Boom lifting system by hydraulic cylinder gt Boom system with 1 hydraulic and 2 manual extensions Valve bank Use gt Operate boom lifting by pulling relevant lever on the valve bank with one hand and pumping by the pump lever with the other hand gt Operate the extensions boom lever Hand pump out or boom in by pushing or Pict 14 pulling relevant lever on the valve bank with one hand and operating the pump lever with the other hand gt Tooperate boom lowering simply push relevant lever forward without pumping It is convenient to operate as follows to minimize the stress of the operator on the pump lever when handling a load gt lift the load from the surface it lies on gt afterwards hydraulically pull the extension in as much as possible to reduce the stress gt lift up to the necessary height to place the load in the new position gt carry out the extension if required After use gt put the crane back within its min overall volume position gt remove the lever from the pump and put it back into the support lever holder A DANGERS If the max allowed load is lifted with the extensions retracted avoid pushing the extensions out afterwards This is to prevent risks of gt crane structure overloading
15. s A TI 2 EI ee A AN ip O 8 2 i ca lt 7 Calibration overpr valve 170bar gf S l aaa NS 1 Motor pump 8 Overpressure valve 2 Pump 9 Check valve 3 Lifting cylinder 10 Boom raising button 4 Compensated throttle 11 Boomlowering button 5 Sink rate control valve 12 Relay 6 Oil tank 13 Dump solenoid valve 7 Filter 14 Unipolar battery disconnector Pict 35 10 5 Electro hydraulic diagram motor pump for lifting and extension cylinders Motor pump Valve bank Lifting cylinder Overcenter valve Double acting lock valve Extension cylinder Oil tank Filter O OSI 0 VI KON 10 Button 11 Relay Unipolar battery disconnector n Li V I L 8 Lo ke f 7 _ Calibration overpr valve 170bar Pict 36 Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 a 37a info maxilifterane com maxilift 10 6 Electro hydraulic diagram motor pump for slewing and lifting cylinder 1 Motor pump 2 Valve bank 3 Lifting cylinder 4 Overcenter valve 5 Hydraulic motor 6 Oil tank 7 Filter 8 Unipolar battery disconnecto 9 Button 10 Relay 0 Pict 37 10 7 Electro hydraulic diagram motor p
16. the crank would not turn and it would interfere with the rod when pulled out On the contrary in case of right side installation pict 24 B the main beam must remain on the opposite side to the cabin for the same reason explained above 6 7 4 Back load attachment This accessory pict 25 brings the hook attachment to a rear position compared to the one allowed by the standard boom assembly Its application is suggested to gt handle a particularly bulky load through doors or narrow areas gt position or lift a load at a very short distance from crane axle which would be otherwise impossible to achieve with the standard boom assembly Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy 24 Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 info maxilifterane com This accessory cannot be used gt when the electrical or manual winch kits are used because the device is applied on an hexagonal tube which is to be slipped into the end of the 2 extension fixing it by its safety lock pin in place of the pulley attachment required for the winch kit gt on cranes provided with boom lifting system by mechanical strut The biggest advantages by this system are achieved on cranes equipped with lifting and extension cylinders The back load attachment can make up for the winch function if the load is to be placed within the working area drawn by the boom assembly in horizontal position with fully retracted
17. 2022 Boretto Reggio Emilia Italy Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 info maxilifterane com maxilift After use gt Fully retract the extensions and lock the 2 one correctly gt put the crane back within its min overall volume position gt extract the key from the battery disconnector and put it back in a safe and protected place A ATTENTION If you wish to extend the boom hydraulically once the max allowed load is lifted to a specific outreach the overcenter valve on the lifting cylinder intervenes making the boom lower slowly This is to prevent risks of gt crane structure overloading gt vehicle stability loss CORRELATED SAFETY DEVICES gt The control valve overpressure valve calibrated at 170 bar prevents lifting weights exceeding the allowed ones gt The overcenter valve on the lifting cylinder makes the boom lower slowly if the hydraulic extension is operated with the max allowed loads gt The functions are only operated by keeping the power unit starting button pressed Therefore all functions are stopped when the button is released 6 6 13 Electro hydraulic operating system by power unit with two functions for slewing and lifting cylinder Operation This operating system pict 18 is consisting of an electro hydraulic power unit operated by the button and controlled through a two functions valve bank with levers equipped with automatic return into neutral position The valv
18. 5 4 1 Check list before the first commissioning ES IO 5 4 2 Daily check list peace cece nn nnn Mn 5 4 3 CE Certification 1 ie 5 5 GENERAL SAFETY RULES 2no22nmmmcsesanezezenezezaze eee nno ene nenezanezezzezezzzoninenanenea f amene 5 5 1 Rules concerning persons 6 nanan 5 5 2 Rules concerning the crane n mene 5 5 3 Rules concerning safety in the traffic fl 6 6 OPERATING INSTRUCTIONS nnnnnnnnnnnnnnnnnnnnnnnenneennnnnnennee f amen 7 6 1 Daily check list oo 7 6 2 Loader classification and proper usage nanan 7 6 3 Improper USAGE nanan 7 6 4 General attentions meene 7 6 5 Ten basic rules for the safe loader operator emme enn 9 6 6 Instructions for use
19. 96 30 08 info maxiliftcrane com Fax 39 0522 96 30 39 maxilift Antitheft device When the crane is locked we suggest to apply the two padlocks supplied with the kit to the proper holes of the mobile hooking pivots In order to apply the padlocks to such holes it is essential that both nuts are fully screwed Checking before fixing the crane Check he main structural parts involved by the fixing operation hooking profiles of the slewing support mobile hooking fixed hooking do not show any deformation or welding with flaws Checking before operating with the crane gt Make sure that the hooking nut is correctly tightened gt Check that the clearance left to allow the rotation of the mobile hooking is as much reduced as possible in case tighten the nut periodically on the knuckle pin gt Make sure periodically that the nuts on the fixing tie bolts M16x2 of the plate on the platform are correctly tightened The driving torque must be 12 daNm To remove the crane To release the crane before unscrewing the hooking nut the crane is to be put back into transport position also it is necessary to use proper equipments to lift or to move gt Loosen the hooking nut releasing it from its seat by using an Allen wrench CH 24 gt Open the device releasing the mobile hooking from its pivot gt Slip the crane out releasing it from the fixed hooking After the crane has been removed gt Engage back the mobile ho
20. HYDRAULICS S r l Via Mediterraneo 6 Boretto RE ITALY Tel 0522 963008 Fax 0522 963039 info maxiliftcrane com
21. ack to horizontal position gt fully retract the extensions and lock the 2 one correctly gt put the crane back within its the min overall volume position Double acting valve ac 2 Extension cylinder 1 extension HI Pict 12 Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy 14 Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 info maxilifterane com maxilift AN DANGERS gt Exclusively use the lock pin and not the fingers to align the profiles slots gt Before lifting a load make sure the lock pin is correctly inserted a wrong lock pin insertion may cause its breaking gt The lock pin extraction with the boom assembly in leaning position increases shearing risk gt The lock pin non insertion or breaking cause an uncontrolled sliding of the 2 extension CORRELATED SAFETY DEVICES gt Double acting pilot operated lock valve on the extension cylinder gt The safety hook on the 1 extension prevents lock pin sliding out once it has been fully inserted and turned with handle facing downwards gt The manual extension is equipped with a pull out preventing device 6 6 8 Hydraulic operating system by hand pump for lifting cylinder Operation This operating system pict 13 is necessarily associated to the following units gt Boom lifting system by hydraulic cylinder gt Two manual extensions boom system The manually operated h
22. al safety devices Always wear approved accident prevention clothing such as protective helmets anti slip shoes protective gloves reflective jackets breathing apparatus and protective glasses Consult your employer regarding current safety regulations and accident prevention equipment Do not wear rings wristwatches jewellery loose fitting or hanging clothing such as ties torn garments scarves unbuttoned jackets or unzipped overalls which could get caught up by parts in motion Keep quickly and readily available on the truck a first aid box and a fire extinguisher The fire extinguisher must always be kept charged and has to be used according to current regulations 5 2 Rules concerning the crane gt gt The Manufacturer is not liable for accidents occurred when using the crane caused by non fulfilment from the operator s side of current rules laws and regulations The regular crane functioning is guaranteed within a temperature range between 0 C and 40 C If temperature drops under 0 C it is essential to replace the oil in the whole circuit by a less viscous one as indicated in the suggested oil table Carefully read the Operator s and maintenance manual before commissioning using servicing or doing any thing on the loader Read and follow all safety instruction plates applied on the loader before starting up using servicing or doing any thing on the loader If the crane is provided with electrical devices befor
23. ank Filter Overpressure valve Dump valve 0 Check valve gt OONODURON Il BHE HJ 0 J Calibration overpr valve 170bar 3 Pict 32 Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Fax 39 0522 96 30 39 Tel 39 0522 96 30 08 info maxiliftcrane com 3 maxilift 10 2 Hydraulic diagram hand pump valve bank for lifting and extension cylinders Hand pump Pump Valve bank m2 Lifting cylinder Compensated throttle Sink rate control valve P Double acting lock valve 7 Extension dna L110 Calibration overpr valve 170 bar Check valve 10 Oil tank 11 Filter Pict 33 ND O OO SNI 0 VN RON 10 3 Hydraulic diagram hand pump valve bank for extension cylinder 4 5 Haid pump Calibration overpr valve 170bar Pump Valve bank Double acting lock valve Extension cylinder Check valve Oil tank Pict 34 Filter Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy 36 Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 info maxilifterane com OO NI 0 HG RON maxilift 10 4 Electro hydraulic diagram motor pump for lifting cylinder 11 T 14 oo 12V DC i E Ilio 07010 LiL Lia
24. at ground If necessary top up with hydraulic oil filling up through the cover 8 4 2 Oil change The oil deteriorates during daily usage this can damage the hydraulic system The hydraulic oil does not have to be changed in versions equipped with hand pump in this case it is only necessary to fill up in case of need For the cranes with power unit fill up the oil in case of need and replace it if contamination can be visually detected check the oil colour through the transparent tank For the oil change on cranes with power unit the tank must be disassembled by loosening the four cheese headed screws The screws can be accessed by removing the electrical motor protection cover As an alternative it is possible to extract the oil by a syringe avoiding to remove the tank A ATTENTION It is forbidden to pollute the environment with exhausted oil After the replacement it is important to carry out a bleeding of the circuit otherwise the air introduced in the system with this operation may damage the sealing parts To do that operate every function of the control valve driving it smoothly to stroke end Use only the oils stated in the greasing lubricating table or equivalent ones 8 4 3 Wear pads check and replacement Wear pads pict 24 need to be replaced when the thickness drops under 4 mm for the front ones and under 3mm for the rear ones AN ATTENTION Failure to replace the wear pads when they have reached the above stated w
25. boom assembly in leaning position increases shearing risk Before lifting a load make sure the lock pin is correctly inserted a wrong lock pin insertion may cause its breaking The lock pin non insertion or breaking cause an uncontrolled sliding of the extensions VVV CORRELATED SAFETY DEVICES gt The safety hooks on the boom and on the 1 extension prevent the lock pins slipping out once they have been completely inserted and turned with the handles facing downwards gt Both manual extensions are provided with a pull out prevention device gt The 2 extension is dimensioned to lift the load related to the 1 extension 6 6 7 Boom system with 15 hydraulic and 2 manual extensions Operation This system pict 12 permits to adjust the outreach of boom assembly even with the load hanging allowing the 1 extension hydraulic boom out and boom in movements by pushing or pulling relevant lever on the control valve bank Use The 2 extension is manually pulled out by proceeding as follows gt pull out the pin that locks the 2 extension on the 1 one holding it by the handle and turning it to release it from relevant safety hook gt pull out the 2 extension until the slot on its profile is aligned with the hole on the 1 extension gt putbackthe lock pin into its housing with the handle parallel to the boom and facing backwards making sure that it falls downwards for gravity After use gt Put the boom b
26. close to the loader A ATTENTION Should some or any part of this manual be not clear please contact the Manufacturer NOTE The table on the back of the front page has to be filled at customer s care It contains all the necessary data required when calling our Technical Service A copy of this manual is supplied along with every loader 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 2 HOW TO CONSULT THE MANUAL 2 1 Instructions Always carefully read this manual before operating the loader The manual must be entirely read except for chapter 6 whose paragraphs must be compulsorily read up to 6 5 inclusive Paragraph 6 6 contains the instructions for use for all those units that may constitute the machine and which are represented in the picture of paragraph 3 3 To simplify reading this last one it is necessary to determine all the units making up one s machine and to read only the concerning sub paragraphs Actually relevant legend includes the corresponding sub paragraph beside the name of every single unit Paragraph 6 7 contains the instructions for use for accessories among which it is necessary to single out those provided with one s machine in order to read relevant the sub paragraphs We suggest to cross all the parts o
27. crank in the proper housing made in the worm screw gt turn in either sense After use After the crane has been used or before re starting off pull out the crank and put it back in the lever holder of the hand pump support If the crane is not provided with hand pump put the crank inside the boom assembly or in the tools compartment A DANGERS Make sure that the slewing stop prevents excessive traction stresses on the hydraulic hoses Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy 10 Tel 39 0522 96 30 08 info maxilifterane com Pict 7 Fax 39 0522 96 30 39 maxilift 6 6 3 Hydraulic slewing system Operation This system is fulfilled with a worm crown gearing protected by a casing and operated by an hydraulic motor pict 8 Such motor is energized by the operating system consisting of an electro hydraulic power unit and a control valve bank Use To start the system you have to gt plugin the battery disconnector of the operating system gt operate the corresponding lever on the valve bank while pushing the motor ignition switch After use Shelter the crane in the min overall volume position so that it does not protrude from vehicle s profile A DANGERS Make sure that the rotation stop prevents excessive tractive forces on hydraulic hoses 6 6 4 Boom lifting system by mechanical strut Operation The boom is manually posi
28. dental slipping out of the outrigger beam during travelling can result in serious accidents gt Special care must be taken when driving nearby crossroads level crossings and subways Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy 65 Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 info maxiliftcrane com maxilift 6 OPERATING INSTRUCTIONS 6 1 Daily check list Check the existence of oil leaks Check the correct working of the load limiting device if installed see on relevant paragraph Check oil level and fill up if necessary Check the good conditions of hoses and piping Check the good conditions of the winch rope Check the efficiency of thrust rotation brake VVVVVV 6 2 Loader classification and proper usage The machine is an hydraulic truck loader for hook service It can also be used for the same purpose from a static mounting The lifting capacity is 5 kNm making it especially suitable for installation on light truck The crane is classified in class H1 B1 according to DIN 15018 standards and must be used accordingly that is trucks loading unloading hook service 6 3 Improper usages It is forbidden To use the loader in different operations from those it has been designed and built for see above point 6 2 To use the loader with attachment like grabs clamshells magnets and so on Pulling loads with loader in horizontal position Crane operation with procedures not s
29. e bank controls are gt boom lifting lever gt slewing lever This system is necessarily associated to the boom system with manual extensions Use The battery disconnector key must be inserted and turned clockwise to start the system gt To operate the right or left slewing push or pull relevant lever on the valve bank keeping the motor starting button pressed gt Tooperate boom lifting or lowering pull Motor Hoses or push relevant lever start on the valve bank button Battery always keeping the disconnector motor starting button pressed After use a bank slewing Boom gt Fully retract the oe DA lowering extensions and lock Left N them correctly slewing gt put the crane back gt S within its min overall Levers _ CS volume position Protection Boom gt extract the key from raising the battery disconnector and put it back in a safe and rotected place P i Pict 18 Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 NOTE info maxiliftcrane com maxilift AN DANGERS gt Make sure thatthe rotation stop prevents excessive tractive forces on hydraulic hoses CORRELATED SAFETY DEVICES gt The control valve overpressure valve calibrated at 170 bar prevents lifting weights exceeding the allowed ones gt The overcenter valve on the lifting cylinder controls load s lifting and loweri
30. e operating the loader make sure that its voltage 12V is same as the vehicle one Do not use controls and hoses as handholds these parts move and cannot provide stable support The operator s control desk must always be kept clean from oil grease mud and snow to avoid accidents due to slippery surfaces The safety instruction plates notices load charts and any other sticker applied on the loader must be kept readable and in good conditions If necessary replace them The position of these plates is shown in pict 5 Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 ISTE info maxiliftcrane com maxilift MAX Kg200 Pict 5 5 3 Rules concerning safety in the traffic The machine is an hydraulic loader for lorries and light trucks The installation on the vehicle must be made in compliance with the relevant national laws and regulations gt When travelling on roads and public sites always respect the relevant national laws and regulations DANGER Before travelling on roads make sure that the loader is folded in rest position If the loader is open or lying on vehicle s body exceeding the overall dimensions allowed by the highway code it can hit bridges electric power lines or other obstructions gt Before driving away make sure that the levers and the pins securing the outrigger s beam are fully locked Acci
31. e safety instructions Many accidents can be avoided when their causes are well known and relevant adequate countermeasures are previously taken maxilift INDEX FOREWORD _ nnn nn nnn nnn ene nnn nnn enn nen en nnn enennennnnnnene Page 1 1 1 Remarks 2000 men 1 2 HOW TO CONSULT THE MANUAL __ _____ nn 1 2 1 Instructions n n ne nn nnn nn nn nnn nnn nnn nnn nnn nnn nn nnn enna nnn nnnnn os 1 3 CRANE IDENTIFICATION 2 nz n neon nn nn nn nn nn nnen nen en enenenes f amm 2 3 1 Identification data mene 2 3 3 1 Name plate description eee 2 3 2 Main crane components identification meem 2 3 3 Crane composition _ 3 3 4 Accessories n nanan nnn nn nnn nnn nnn ______________ nanan 4 3 4 1 Winch _r ________ oo 4 3 4 2 Stabilizers _ 4 4 COMMISSIONING 0 0 02 nnn ne ne sence nen nen n en enn enenenenens of imm
32. ear assembly control Thrust rotation brake control Electric winch maintenance nni Greases and oils reference table TECHNICAL DATA n2 nnn 2mmmane nane zena zizi eee eee eee mn Crane overall dimensions Stabilizer overall dimensions ee Load chart tables o Technical specifications Technical data table Table of weights for foreseen crane versions Accessories weights table WIRING AND HYDRAULIC DIAGRAMS x2 2 2xxx x2xmsnnnnszazenzzzane genes Hydraulic diagram hand pump for lifting cylinder Hydraulic diagram hand pump valve bank for li
33. ear limit can result in prejudice to the good and safe operation of the loader 1 extension rear sliding blocks Front sliding l blocks a Pict 27 Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy 30 Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 info maxilifterane com maxilift 8 4 4 Worm gear assembly control It is important to check that the worm gear reducer has a correct axial backlash This can be made with the crane at standstill and the boom in horizontal position Pushing the boom aside on the left and on the right by hand you can notice ifthe axial backlash between the worm screw and the worm gear is too great In this case it has to be reduced by tightening the nut accordingly Grease the gear with the suggested product and replace the lubricator if worn out Worm wheel Worm screw 8 45 Thrust rotation brake genni control Check that the plastic ring on the column is in good conditions If broken or cracked it must be replaced Check the correct tightening force of the lever and the braking block Adjust it if necessary Pict 28 ict 8 5 Electric winch maintenance General norms The lifting rope is one of the most delicate components for crane safety It is subject to abrasions twisting extreme environmental conditions corrosion and other problems that may reduce its reliability The periodical rope inspection and maintenance a
34. eration and integrity Check good conditions and charging of battery Check good conditions of lifting hooks and ropes VVV 8 3 2 Quarterly 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 loader tie rods and bolts Check integrity and tightening of hoses piping and their fittings Check fastenings and safety devices 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 etc Check the oil level and lubricate accordingly to the lubricating and greasing chart Check the good conditions of the slewing system a ifitis a worm gear type grease the gear through the specific greaser b ifit is a thrust type check the correct operation of the slewing braking block Make a working test of the loader with and without the load Check the good condition of the lock pin hooking plate If they are worn or deformed due to negligence restore or replace them in a qualified workshop VVVVVVVV VV VV 8 3 3 Yearly checking Wash and clean the crane Check the pressure settings in the hydraulic system Check the absence of oil leaks Check integrity and tightening of screwed assemblies Check integrity and tightening of
35. extensions Carefully avoid pulling the load sideways or dragging it on the ground 6 7 5 Quick fitting kit The device is consisting of a plate fixed in a permanent way to the vehicle platform by tie bolts nuts and lock nuts which is equipped with a system to lock quickly and safely the crane on the truck Crane fastening gt Open the device by releasing the mobile hooking from its pivot Pict 26A gt Position the crane making it slide on the plate and fit the hooking profiles of the slewing support in the proper slits of the fixed hooking gt Lock the opposite hooking profiles of the slewing support engaging again the mobile hooking on relevant pivot Pict 26 B gt Screw manually the hooking nut engaging it into its proper seat and tighten it thoroughly by using an Allen wrench CH 24 in order to prevent the possible unscrewing because of vibrations A DANGER The nut when not correctly tightened can allow the accidental opening of the mobile hooking causing crane overturning _ maxilift Hexagonal tube Spring catch Pin Load back Hook attachment Pict 25 AN vancer Hooking ixed plate Hooking profiles Hole for padlock Mobile hooking 7 Hole for _ Hooking nut A Hooking ___ profiles Tie bolts and nuts for plate ACE padlock Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Tel 39 0522
36. ezine enne n Protection and storage Short shutdowns fu Long shutdowns MAINTENANCE 2 2 2 2nnnnene nea n ene z ezine zena naz e zen genes Warnings Environmental protection Maintenance prescriptions Maintenance schedule e ncn Check list before a working session ed eesse Seas Quarterly checking Se eee Yearly checking rr mn Loader servicing Pt Oil level checking nnnnnnnnnn e ef Oil change Pf Wear pads checks and replacement Worm g
37. f the manual that do not apply to one s loader In this manual the following symbols are used AN 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 concerned for instance damage of the load or of the loader IMPORTANT Referred to information or integration on loader operation NOTE Used to draw your attention on information or suggestions to make easier the loader usage for the operator The symbols and marks are completed with notices stating the dangers their nature the avoidance actions to be taken and tips to be followed Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 I info maxiliftcrane com maxilift 3 CRANE IDENTIFICATION 3 1 Identification data Every loader is identified by its serial number and name of the model written on the plate riveted on the column Pict 1 3 1 1 Name plate description Crane model Serial number Year of manufacturing Lifting class Max SWL kg Max SWL lbs A ATTENTION VVVVVV It is strictly forbidden to change and or erase the data written on the name plate 3 2 The main components of a telescopic boom crane are pict 2 Slewing support Column Boom assembly Operating system VVVV The full crane structu
38. fting and extension cylinders Hydraulic diagram hand pump valve bank for extension cylinder Electro hydraulic diagram motor pump for lifting cylinder Electro hydraulic diagram motor pump for lifting and extension cylinders Electro hydraulic diagram motor pump for slewing and extension cylinder Electro hydraulic diagram motor pump for slewing lifting and extension cylinders Electrical winch wiring diagram Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy II Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 info maxiliftcrane com maxilift 1 FOREWORD 1 1 Remarks This manual gives the guidelines for a correct safe usage of the loader and its rational maintenance When daily and constantly applied these guidelines ensure long service life with minimum maintenance costs high performance of the loader 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
39. he anti fleeting system when you go on winding the rope the counterweight hits against the pulley attachment sliding on it without finding any resistance and causing the uncontrolled load falling gt Do not hold the rope or work with the hands near the winch drum if this is not disconnected from the power supply These operations may cause fingers crushing gt Do notoperate near the drum with loose hair or with frayed or loose clothes scarves or ties gt Do not stay near the winch while it is being used In case of rope tearing under load this can produce a strong counterstroke gt Avoid the button strip cable from coming into contact with parts in motion or being crushed by the load gt Prevent the complete rope unwinding gt The rope must be wound on the drum preventing its crushing or bending and the turns must be perfectly in contact one another gt Do not drag the cable with the snub pulley locked to prevent causing damages and abrasions to the external strands gt Donotuse worn pulleys or pulleys with a flat groove They do not guarantee a proper support to the rope and may cause its flattening and distortion gt Prevent the cable from coming into contact with corrosive chemical agents CORRELATED SAFETY DEVICES gt The winch negative brake lets the load lower slowly when a weight exceeding 240 kg is trying to be lifted This prevents the winch and the crane structure from being overloaded gt The anti fleet
40. he hydraulic or electro hydraulic system transmitting the movement to the actuators cylinders It is consisting of a pump electric or manual and control system button strip or hydraulic valve bank In this type of crane the slewing support and column assembly make up the slewing system which can be of three types gt thrust rotation gt crank rotation operating a worm screw worm wheel gear gt hydraulic hydraulic motor operating a worm screw worm wheel gear 3 3 Crane composition Al Thrust slewing system 6 6 1 A2 Crank slewing system 6 6 2 A3 Hydraulic slewing system 6 6 3 B1 Boom lifting system by mechanical strut 6 6 4 B2 Boom lifting system by hydraulic cylinder 6 6 5 C1 Two manual extensions boom system 6 6 6 C2 Boom system with 18 hydraulic and 2 manual extensions 6 6 7 D1 Hydraulic operating system with hand pump for lifting cylinder 6 6 8 D2 Hydraulic operating system with hand pump for lifting and extension cylinders 6 6 9 D3 Hydraulic operating system with hand pump for extension cylinder 6 6 10 D4 Electro hydraulic operating system by power unit with single function for lifting cylinder 6 6 11 D5 Electro hydraulic operating system by power unit with two functions for lifting and extension cylinders 6 6 12 or for slewing and lifting cylinder 6 6 13 D6 Electro hydraulic operating system by power unit with three func
41. ift 6 7 3 Stabilizer kit Hooking issioni Max Commissioning i A gt Pull out the stabilizer rod GENES extension from the base unlocking the hole automatic hooking device i and slip it in with the Mounting stabilizer leg downwards Plate lifting and immediately releasing the hooking device until it automatic locks into the hole which allows the maximum extension pict 23 check the locking of the automatic hooking device rod by pulling and pushing the Middle rod which must keep in R split ube place pin The stabilizing leg is adjusted y in two phases in 1 Pull the pin out holding the plate with one hand make the internal profile slide downwards as close as possible to the ground so that one of its holes lines up with the intermediate profile hole 2 slip the lock pin back in lock it by a split pin and turn the pin itself until the plate is completely leaning on the ground gt After the crane has been used or before starting off pull out the stabilizer rod and fully slip it into the base checking the perfect locking of the automatic locking device with the stabilizer leg completely retracted facing upwards Internal tube Right side board Pct 24 NOTE The stabilizer main beam in case of installation behind the cabin on the left pict 24 A has to remain on the side of the cabin otherwise
42. ing device works as stop end switch for the cable it stops it without causing any damage to it thanks to the negative brake Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Sopra Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 info maxilifterane com maxilift 6 7 2 Manual winch Operation To lift the load turn the crank clockwise To lower the load turn the crank counter clockwise Give a sharp counter clockwise blow to the crank handle to facilitate rope unwinding without load Use To start the system it is necessary to gt VVVVV Always keep the rope tensioned avoiding leaning the counter weight when hooking the load This prevents Casing turns loosening on the winch drum and consequently the rope damaging gt lift the load of a few centimetres and check that the winch can support it gt complete the load handling operation paying attention to the correct and regular cable winding After use Put the crane back into the min overall Dai Crank volume position to do this the pulley attachment must be removed otherwise the crane stays more open The following operations must be carried out with the boom set horizontally to remove the Pict 22 pulley attachment VVVV VV Apply the pulley attachment pict 21 to the end of the 2 extension making sure the lock pin is perfectly inserted as for manual extensions unwind the cable so that it can reeve on the pulle
43. maxilift Mod M50 USE AND MAINTENANCE MANUAL Code MD 0 136 GB Rev 0 Edition 03 07 maxilift Fill in the space below with the required crane identification data Code filling example M50 2H ELH M 50 2 H E L H M 50 2 SERIAL NUMBER MANUFACTURING YEAR Mark the box regarding the accessories supplied with the crane ACCESSORIES SUPPLIED WITH THE CRANE Description YES NO Electrical winch Manual winch Stabilizer Back load attachment Quick fitting kit PRELIMINARY INFORMATION Operator s and Maintenance Manual of MAXILIFT M50 truck loader Manual code MD 0 136 GB This manual is valid starting from serial no Manufacturer NEXT HYDRAULICS S r l Via Mediterraneo 6 Boretto RE ITALY In this manual the word Manufacturer is referred to NEXT HYDRAULICS S r l List of documentation supplied along with the loader gt Operator s and Maintenance Manual for the end user gt Installation Manual for the installer and the end user ATTENTION Always carefully read this manual before operating the loader Most of the accidents occurred during operations are caused by omission of elementary precautions and non fulfilment of th
44. mediate length gt amore rapid commissioning since only one extension must be handled instead of two and only one lock pin must be inserted instead of two In such case proceed as follows gt pull out the lock pin A holding it by the handle and turn it to release it from relevant safety hook on the boom gt pull out the lock pin B holding it by the handle and turn it to release it from relevant safety hook on the 1 extension gt pull out the 2 extension until the slot allowing to achieve the outreach as near as possible to the desired one is aligned with the hole on the boom gt insert the lock pin A locking it back into the safety hook on the boom VVVVV After use gt Put the boom back to horizontal position gt fully retract the extensions and lock them correctly gt put the crane back within its min overall volume position Hook attachment Pict 11 Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 gt info maxiliftcrane com maxilift AN DANGERS gt Ifyou wish to pull out only the 2 extension with the 15 one completely retracted it is necessary to lock the assembly by inserting the lock pin only in the hole on the boom and not in the hole of the 1 extension otherwise the system would not be locked The profiles holes may cause shearing if fingers are slipped into them Lock pins extraction with the
45. ne in the min overall volume position in correspondence of the specific hole of the strut by correctly inserting the lock pin into it A DANGERS gt Avoid holding the mechanical strut for any reason holes may cause shearing in case fingers are trapped into them If the lock pin is not correctly inserted it can slip out and the boom may fall causing crushing or shearing Exclusively use the lock pin and not the fingers to align the strut profiles holes Before lifting a load make sure the lock pin is correctly inserted a wrong lock pin insertion may cause its breaking with consequent load falling VVV CORRELATED SAFETY DEVICES The safety hook prevents lock pin shifting out once it has been completely inserted and turned with handle facing downwards 6 6 5 Boom lifting system by hydraulic cylinder Operation This system pict 10 allows lifting the boom hydraulically by a cylinder fed with oil under pressure The feeding can be supplied by gt hand pump gt electro hydraulic power unit Use The use depends on the type of feeding and the operating system it is associated with Therefore it is necessary to refer to the specific paragraphs After use Also this phase depends on the type of feeding and the operating system it is associated with Therefore it is necessary to refer to the specific paragraphs AN DANGERS Sink rate control Dangers depend on the type of valve feeding and the operating sys
46. ng in case the slewing function is operated simultaneously to the lifting function The functions are only operated by keeping the power unit starting button pressed Therefore all functions are stopped when the button is released 6 6 14 Electro hydraulic operating system by power unit with three functions for slewing lifting and extension cylinders Operation This operating system pict 19 is consisting of an electro hydraulic power unit operated by the button and controlled through a three functions valve bank with levers equipped with automatic return into neutral position The valve bank controls are gt boom lifting lever gt boom extension lever gt slewing lever This system is necessarily associated to the boom system with 1 hydraulic and 2 manual extensions Use gt The battery disconnector key must be inserted and turned clockwise to start the system gt To operate the right or left slewing push or pull relevant lever on the valve bank keeping the motor starting button pressed gt To operate boom lifting or lowering pull or push relevant lever on the valve bank always keeping the motor starting button pressed gt To operate the extensions boom out or boom in push or pull relevant lever on the valve bank keeping the motor starting button pressed After use gt Fully retract the extensions and lock the 2 one correctly gt put the crane back within its min overall volume position gt
47. nsion cylinders 18 6 6 13 Electro hydraulic operating system by power unit with two functions for slewing and lifting cylinder 19 6 6 14 Electro hydraulic operating system by power unit with three functions for slewing lifting and extension cylinders 20 Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 ollie info maxiliftcrane com maxilift 6 7 6 7 1 6 7 2 6 7 3 6 7 4 6 7 5 6 8 7 1 7 1 1 7 1 2 10 2 10 3 10 4 10 5 10 6 10 7 10 8 Accessories 22 222 222 nn nnn nnn nnn nen nnn nnn Page Electrical winch 2 92 9229 9 n nnn nn nnn nnn nnn nnn nnn nn Sonne Manual winch ef Stabilizer Kit 2202 0 mene Back load attachment Ane Quick fitting kit 2 292 22 fa Main operating errors MAINTENANCE AND CHECKING 2 22 2 2un2nmoaneeneza zaini nana a
48. oking on its pivot locking it by the hooking nut 6 8 Main operating errors Because of lacking of care or adequate instructions some dangers may occur during loader operation Most common errors are gt Slinging of loads exceeding the loader capacity always check their actual weight not to overload the crane Special care has to be taken when handling big loads once lifted they can remain hanging on the crane and result in damages and accidents A sudden stop when lowering a load This creates high forces of inertia on the crane structure with relevant dangerous overload Hitting the rope where the load is suspended overload is generated Side pull dragging the load on the ground All these operations originate strong overloading forces on the loader The outriggers are badly positioned or the ground is not firm in both cases the truck tilts and could tip over The load is not correctly slung 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 of the truck 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 gt Swinging movements of the load When acting on the slewing control too suddenly the load star
49. ore lifting a load check braking system efficiency by tightening the lever and trying to push the boom without load gt The operator has to push the crane boom in one sense or the other to perform the slewing gt After the slewing and before performing the vertical load translation with the winch or lifting by the cylinder tighten further the brake lever to prevent any slewing caused by load swinging or hunting After use gt Shelter the crane in the min overall volume position gt Tighten the brake lever to lock the slewing in order to prevent it from triggering spontaneously when the vehicle is on the road due to the forces of inertia Ring Braking Pict 6 AN DANGERS To perform the thrust slewing the brake lever must be tightened the crane must rotate only if pushed by the operator Keep as far from the load as possible while it is being handled always making sure that no part of the body is below of it especially in case of load hunting We advise against choosing this slewing system in all situations where the crane base may be leaning compared with the horizontal line Do not lubricate or grease either the block or the plastic ring this causes a braking reduction 6 6 2 Crank rotation system Operation This system is consisting of a worm screw worm wheel gearing protected by a casing and driven by a crank pict 7 Use To operate the system it is necessary to gt insert the
50. pecified in this manual or using components not foreseen during the design phase Non observance of the established maintenance programs Non observance of safety rules Perform interventions on the machine that imply the modification of components or parameters that influence the working cycle The unauthorized use of captive spare parts and components not specifically approved by the Manufacturer To carry out modifications or structural interventions without the approval of the Manufacturer To operate the loader out of the admissible range of temperatures Any of the above mentioned improper usages or non observance will cause gt immediate cancellation of the Manufacturer Warranty gt cancellation of Manufacturer liability for damage of people animals things VVV VVV V VVV ATTENTION The improper usage can damage the loader and subseguently result in dangerous situations for the staff entitled to its operation 6 4 General attentions AN DANGER Before starting operations make sure that nobody is in the working area of the loader Preliminary prescriptions gt The crane must work only if stabilized on flat and thick ground gt Make sure that the truck is well braked and if necessary apply chocks to the tires If mechanical stabilizers are used gt 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 perfectl
51. r on the crane with the notice Loader under maintenance Do not start gt Do not get under any raised part of the loader unless a safety lock support has been applied to it gt Before starting any maintenance or repair operation always install safety locking supports on any raised part of the crane especially the boom system gt The truck engine should be started in closed rooms only if well aired Before operating the loader make sure that nobody stays or walks in the working area 8 1 1 Environmental protection Every operation involving maintenance cleaning parts replacements must be carried out in an environmental friendly way Exhausted oils and lubricants must be collected in suitable tanks and delivered to authorized specialized companies The same must be for every other part filters hoses seals contaminated by lubricants Plastic parts covers lids etc are recyclable and must be collected and treated separately Steel and metal parts when cleaned from grease and other contaminants can de delivered to authorized scrap yards VVVV 8 2 Maintenance prescriptions Many damages and accidents are caused by a bad maintenance or by mistakes in the maintenance itself Common causes are recognized to be lacking of oil or grease dirt on loader components or assemblies breaking of ropes or slings safety valves out of service or not in good working conditions hydraulic plant in bad conditions for instances
52. re essential to keep safe working conditions gt Carefully inspect and rewind the rope after each use Cuts twisting bending corroded areas internal wires outlets diameter reductions and wires or strands tearing reduce the original rope resistance replace the cable if one of these damages is detected gt Frequently inspect the button strip cable for tears uncovered conductors or corrosion Controls Perform the following inspections monthly gt Check the full rope length looking for the above mentioned damages gt Check fixing trailing thimble eyelets etc Maintenance gt Check all locking screws and make sure they are correctly tightened gt Periodically check the electrical connections and make sure they are correctly tightened and free from corrosion gt Periodically check the brake for slipping which can be seen when the winch is loaded If the drum keeps turning after the lifting button has been released the winch must be replaced Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 ol info maxiliftcrane com maxilift 8 6 Greases and oils reference table BRAND TOTAL IP BP GREASE MULTIS ATHESIA ENEGREASE EP2 EP2 LR MP GREASE yy MULTIS ATHESIA ENERGREASE r LR MP EP2 EP2 HYDRAULIC OIL HYDRUS HENERGOL ZS 46 gt HL 80 ZS 48 ci GREASE WINN S GS 80 MOBIL MOBILTAC D ESSO EDL 501 e For mild and cold clima
53. re is positioned and slews over the rotation support which is consequently the slewing system housing The column is the slewing component on which the most important articulation fulcrums allowing boom lifting are located The boom can be lifted in two ways gt hydraulically by means of a lifting cylinder gt manually by keeping it in fixed position by means of a mechanical support strut The boom assembly is the element allowing load recovering and hooking It is consisting of gt boom on which the articulation fulcrums are located gt extensions allowing its in amp out movements manual or hydraulic by means of a cylinder gt hook attachment E mpaxilift Next Hydraulics 21225007 12 nur Gru Tipo Crane Type Classe class N fabbricazione Serial number Anno Year l Portata max Max lifting capacity Lbs Pict 1 Main crane components identification Extension NL 18 extension 2 extension Il Mechanical gt strut Hook attachment Uf ASE ENL 2 LI LA 4657 CZ E slewing device Braking device for thrust rotation Hydraulic slewing device Pict 2 Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 info maxilifterane com maxilift Finally the operating system is t
54. s applied such leg is an extendable telescopic tube which lowers and leans on the ground by a plate Such rods can be either fixed or extendable from a tube fixed on the vehicle called main beam the rod locking in this case is made by means of an automatic hooking device The stabilizer s instructions for use are listed in sub paragraph 6 7 3 Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy 4 Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 info maxilifterane com maxilift 4 COMMISSIONING 4 1 Check list before the first commissioning Check that the crane is complete of gt gt VV CE declaration of conformity of the crane manufacturer CE declaration of conformity of the crane installing workshop or self certification of installation performed according to Manufacturer s installation instructions Operator s and maintenance manual other testing certificates according to Safety Law in force 4 2 Daily check list VVVVV Check the existence of oil leaks Check the correct working of all crane safety devices as indicated in relevant paragraph Check oil level and fill up if necessary Check the good conditions of hoses and piping Check the good conditions of the rope 4 3 CE Certification Fillin the CE certification document with the required crane identification data 5 GENERAL SAFETY RULES 5 1 Rules concerning persons Always wear the prescribed person
55. signalling it in a proper way gt The load should never be lifted or carried on areas where people are passing or working If this cannot be avoided in any way these operations must be properly signalled Before leaving the controls make sure that the control levers are in neutral position and the load is resting on the ground gt When the working area of the crane cannot be clearly seen from the operator control deck a second operator charged with signalling is required General instructions gt The stickers and plates applied on the loader are necessary to enable a safe usage of the same Should them be no longer readable replace them as soon as possible by new ones gt Ifthe loader is accidentally hit it has to be checked and tested from the closest authorized installer workshop gt 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 by Original Spare Parts gt Itis absolutely forbidden to tamper with 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 It is absolutely forbidden to tamper with electrical parts winches lockpins and their housings Carefully check conditions and wear of the rope and its couplings Check the conditions of the hook and
56. stem M50 2M ELH 6 6 2 6 6 5 6 6 6 6 6 11 Boom system with 1 hydraulic and 2 M50 2H PSH 6 6 1 6 6 5 6 6 7 6 6 9 qual extensions M50 2H PLH 6 6 2 6 6 5 6 6 7 6 6 9 Hydraulic operating system by hand M50 2H ELH 6 6 2 6 6 5 6 6 7 6 6 12 pump for lifting cylinder M50 2M ERH 6 6 3 6 6 5 6 6 7 6 6 13 M50 2H ERH 6 6 3 6 6 5 6 6 7 6 6 14 Hydraulic operating system by hand pump for extension cylinder Hydraulic operating system by hand pump for lifting and extension cylinders Electro hydraulic operating system by power unit with single function for lifting cylinder Electro hydraulic operating system by power unit with two functions for lifting and extension cylinders Electro hydraulic operating system by power unit with two functions for slewing and lifting cylinder Electro hydraulic operating system by power unit with three functions for slewing lifting and extension cylinders Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 O info maxiliftcrane com maxilift 6 6 1 Thrustrotation system Operation The thrust rotation system is so called because the operator performs column rotation by pushing on crane arm The system is supported by a friction braking device pict 6 It is consisting of a block which is locked by a lever on a plastic ring fixed on the slewing column Use gt Bef
57. tem the cylinder is associated with Hose CORRELATED SAFETY DEVICES Pict 10 The safety devices depend on the operating systems Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy 12 Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 info maxilifterane com maxilift 6 6 6 Two manual extensions boom system Operation With this system pict 11 the extensions can only be manually pulled out fixing the boom assembly outreach by inserting the lock pins into the properly aligned holes Use gt Place the boom horizontally To pull out both extensions proceed as follows pull out the lock pin A holding it by the handle and turn it to release it from relevant safety hook on the boom pull out 1 and 2 extensions together until the slot of the 18 extension is aligned with the hole on the boom insert the lock pin A locking it back into the safety hook on the boom pull out the lock pin B holding it by the handle and turn it to release it from relevant safety hook on the 1 extension pull out the 2 extension until the slot allowing to achieve the outreach as near as possible to the desired one is aligned with the hole on the 1 extension gt insert the lock pin B locking it back into the safety hook on the 1 extension If you wish to pull out only one extension it is convenient to extract only the 2 one This allows gt the same outreach of the 1 extension gt an inter
58. tes For hot climates Pict 29 Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy 530 Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 info maxiliftcrane com maxilift 9 TECHNICAL DATA 9 1 Crane over all dimensions L 120 390 310 Winch overall dimensions Type A B C D E VE 110 160 1180 280 1340 VM 60 210 1160 265 1360 i Pict 30 9 2 Stabilizer overall dimensions Pict 31 700 MAX Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 39 info maxiliftcrane com maxilift 9 3 Load chart tables M DD 12 v v y 1 v v v Kg 500 Kg 300 Kg 200 Ibs 1100 Ibs 600 Ibs 440 m 0 98 m 1 70 m 2 47 ft 33 ft 5 7 ft 81 0 0 1 2 3 0 3 6 9 4 12 VERS VE VM VERS VE VM DI a NI 9 x Te ae N N LS POLE MAX LIFTING CAPACITY 200 kg 440 Ibs m 1 14 m183 m 263 A 39 ft 6 ft Fr A J 0 0 1 2 3 3 6 9 9 4 Technical specifications 9 4 1 Technical data table Lifting capacity kNm 5 0 ft Ibs
59. tioned by the operator and it is kept in place by a support strut with hole type adjustment pict 9 The lifting operation is helped by a gas spring By this system load lifting and its height positioning are allowed only by the winch The boom assembly working position must lead the cable along the vertical line over the load to be lifted Therefore it must be defined according to gt distance from the load to handle gt load lifting height gt any limitin height if the load must pass through openings or doors 2 3 Safety lock Pin Internal tube External tube Pict 9 Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 221 10 1 4 info maxiliftcrane com maxilift Use To lead the boom to working position the operator has to gt set the boom almost horizontally gt pull out the manual extensions if necessary and in case of manual extension boom system gt lift the boom assembly to the desired angle choosing among those allowed by the mechanic strut holes To adjust the mechanic strut length you have to gt support the boom without any load hanging gt hold the lock pin by its handle and turn it to pull it out of the safety hook gt lift the boom up to the desired angle and put the lock pin in until the handle hits against the safety hook making sure that the handle faces downwards After use Shelter the cra
60. tions for slewing lifting and extension cylinders 6 6 14 Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 2g info maxiliftcrane com maxilift 3 4 Accessories According to crane use there are accessories whose application is not compulsory but which are essential in some cases These are Manual winch Electrical winch Back load attachment Pict 4 gt Winch see chap 6 7 1 for electrical winch and 6 7 2 for the manual winch gt Stabilizers see chap 6 7 3 The merely optional accessories are gt Back load attachment see chap 6 7 4 gt Quick fitting kit see chap 6 7 5 3 4 1 Winch The winch is a rope lifting device which is installed on the crane boom through proper fastening and which together with the transmission coupling and safety devices becomes an integral part of it The winch is an accessory allowing the vertical load handling On cranes equipped with mechanic strut the winch is no longer an accessory rather an essential component as it is the only available lifting device On this crane the winch can be either mechanical or electrical and relevant instructions are reported respectively in sub paragraphs 6 7 1 and 6 7 2 3 4 2 Stabilizers The stabilizers are installed on the vehicle to increase stability and prevent overturning The stabilizers are consisting of rods to whose end a stabilizer leg i
61. ts swinging Danger of overload and boom failure VVVV V v Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy 26 Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 info maxilifterane com maxilift 7 MAINTENANCE AND CHECKING 7 1 Protection and storage 7 1 1 Short shutdowns Wash and clean the loader lubricate all the parts provided with grease nipples and the worm screw gearing PAS ATTENTION Never wash the loader 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 7 1 2 Long shutdowns Same precautions as above and moreover gt cover the loader using a plastic curtain against rain etc gt store in a dry place under roof gt disconnect the connections to the truck battery 8 MAINTENANCE 8 1 Warnings gt Do not wear rings wristwatches jewellery 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 reflective jackets breathing apparatus Consult your employer concerning current safety regulations and accident prevention equipment gt Apply a clearly visible plate on the cab door o
62. ump for slewing lifting and extension cylinders Motor pump Valve bank Lifting cylinder Overcenter valve Double acting lock valve Extension cylinder Oil tank Filter O OSI O VI KON 5 Unipolar battery disconnector 7 10 Button 11 Relay He 12 Hydraulic motor p EI p L L 7 5 Calibration overpr valve 170bar Pict 38 EI Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 info maxilifterane com maxilift 10 8 Electrical winch wiring diagram 1 Raising button 2 Lowering button 3 Remote control reverser 4 Winch electric motor 5 Unipolar battery disconnector NE WY Pict 39 Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 39 info maxiliftcrane com maxilift COPYRIGHT BY NEXT HYDRAULICS S r l Ideazione e realizzazione by Studio Pinotti R E Layout and publication by Studio Pinotti R E Riproduzione e divulgazione vietati a termine di legge senza autorizzazione scritta della Next Hydraulics S r l Reproduction and distribution are forbidden according to law without written permission in writing from Next Hydraulics S r l maxilift NEXT
63. upport After use Hand pump gt putthe crane back within its min Fig 15 overall volume position gt remove the lever from the pump and put it back into the support lever holder CORRELATED SAFETY DEVICES Double acting pilot operated lock valve on the extension cylinder 6 6 11 Electro hydraulic operating system by power unit with one function for lifting cylinder Operation This operating system pict 16 is consisting of a motor pump controlling the lifting cylinder by means of a button strip including the following controls gt boom lifting button gt boom descent button This system is necessarily associated to the two manual extensions boom system Use The button strip connector must be plugged in the specific socket on the motor pump to start the system Press the upward arrow button to lift the arm press the downward arrow button to lower the boom After use gt Fully retract the extensions and lock them correctly gt put the crane back within its min overall volume position gt disconnect the button strip from the power unit socket putting it back in a safe and protected place Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 ofa info maxiliftcrane com maxilift CORRELATED SAFETY DEVICES gt The power unit overpressure valve calibrated at 170 bar prevents lifting weights exceeding the allowed ones
64. y loosen the wing nut of the anti fleeting system to allow the cable entering between the pulley holding sides fit the rope in the pulley race restore the anti fleeting safety device inserting the spacer lead the lifting hook over the load using extension boom out and boom angle IMPORTANT loosen the wing nut of the anti fleeting system to allow cable extraction from the pulley attachment restore the anti fleeting safety device to prevent loosing its components pull out the pulley attachment from the extension end and put it back in a safe place hook the cable AN DANGERS Do not wear frayed or loose clothes scarves or ties Do not stay near the winch while it is being used In case of rope tearing under load this can produce a strong counterstroke Prevent the complete rope unwinding The rope must be wound on the drum preventing its crushing or bending and the turns must be perfectly in contact one another Do not drag the cable with the snub pulley locked to prevent causing damages and abrasions to the external strands Do not use worn pulleys or pulleys with a flat groove They do not guarantee a proper support to the rope and may cause its flattening and distortion Prevent the cable from coming into contact with corrosive chemical agents Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 gt 23 info maxiliftcrane com maxil
65. y hooked on the beams gt 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 Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 J 2 info maxiliftcrane com maxilift gt 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 on request with increased area Before starting operations gt Make sure that lifted loads do not exceed the allowed ones for every outreach gt Make sure that the extension lock pins are correctly inserted and safely locked by their retainers see pictures 9 11 12 21 25 While operating gt Lifting tackles chains or ropes must be applied to the hook in such a way that will not damage the hook safety latch gt Avoid sudden movements especially during descent gt Whilst swinging the boom always keep the load suspended from the ground Dragging of the load is forbidden gt Never stay or walk under hanging loads gt Never start the loader operation without
66. y may be a danger of fire Instead put them in a metallic closed case gt Immediately replace any missing sticker or plate carrying a notice of danger attention or other instructions IMPORTANT Various part of the crane are manufactured with high tensile steel Never perform any operation welding drilling etc without authorization and instructions from the manufacturer A ATTENTION The loader is supplied with electrical devices installed Always disconnect the connections of these devices before carrying out welding or other operations with electric tools on the loader or on any part of the truck gt gt gt When repair or maintenance operation is over before putting again the machine into service make sure that any tool or other piece has not been forgotten in places containing moving parts or close to them The machine and its accessories has to be kept in good conditions Replace failed or worn components with genuine spare parts or other approved by the Manufacturer Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy SIS Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 info maxilifterane com maxilift 8 3 Maintenance schedule 8 3 1 Checklist before a working session gt 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 eliminate any possible source of oil leak General verification of crane op
67. ydraulic pump allows boom lifting or lowering The controls regarding load vertical translation are gt boom lifting lever gt boom lowering valve Use gt Slip the lever into the pump lever holder gt use the lever to lift the boom Slowly open the lowering valve to make the boom descend After use gt putthe crane back within its min overall volume position gt remove the lever and put it back into the support lever holder AN DANGERS Avoid sudden opening of the dump valve which would cause a guick load lowering with dynamic stress and conseguent load oscillations and hunting by the stop phase Lowering valve TEN Overpressure a valve Hand pump Pict 13 CORRELATED SAFETY DEVICES gt The pump overpressure valve calibrated at 170 bar prevents lifting weights exceeding the allowed ones gt The sink rate control valve on the lifting cylinder controls load s lowering in case of hose breaking Via Mediterraneo 6 42022 Boretto Reggio Emilia Italy Tel 39 0522 96 30 08 Fax 39 0522 96 30 39 IST info maxiliftcrane com maxilift 6 6 9 Hydraulic operating system by hand pump for lifting and extension cylinders Operation The system pict 14 is consisting of a manually operated hydraulic pump and a two functions control valve bank with levers equipped with automatic return into neutral position The valve bank controls are gt boom

MD0136 GB.pmd - MAXILIFT and COBRA Truck Cranes. North

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