SERVICE CRANE Mod.14000

Code MD.0.184 Rev 0

USE AND MAINTENANCE MANUAL

Edition 07/09

OPTIONALS SUPPLIED ALONG WITH THE CRANE

Description

YES

NO Oil tank Outrigger beam - (hydraulic jack)

The table has to be filled carefully with the above option when purchased

PRELIMINARY INFORMATION

Operator’s and maintenance manual of MAXILIFT COBRA 14000 SERVICE CRANE Manual code: MD.0.184 This manual is valid starting from serial no: ...... Manufacturer: NEXT HYDRAULICS S.r.l. Via Mediterraneo, 6 - I 42022 BORETTO In this booklet the word “Manufacturer” is referred to “NEXT HYDRAULICS S.r.l.” List of documentation supplied along with the CRANE:

• Operator’s and maintenance manual (for the end user)

SERIAL NO:.............................................................. YEAR OF MANUFACTURING:.................................

ATTENTION

Always carefully read this manual before operating the crane. Most of the accidents occurred during operations 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 measures are previously taken.

INDEX

1 FOREWORD ..................................................................................................PAGE 1

1.1 Summary ........................................................................................................................................................ “ 1

1.2 Remarks ......................................................................................................................................................... “ 1

1.3 Manual revision............................................................................................................................................... “ 2

2 HOW TO CONSULT THE MANUAL ...................................................................... “ 2

2.1 Instructions ..................................................................................................................................................... “ 2

3 CRANE IDENTIFICATION ..................................................................................... “ 3

3.1 Versions and optional available ..................................................................................................................... “ 3

3.2 CRANE identification data .............................................................................................................................. “ 3

4 CRANE USAGE AND LIMITS OF APPLICATIONS................................................“ 4

4.1 CRANE classification and proper usage ....................................................................................................... “ 4

4.2 Improper usage .............................................................................................................................................. “ 4

4.3 CRANE operator’s training ............................................................................................................................. “ 4

5 SAFETY RULES ................................................................................................... “ 6

5.1 Rules concerning people ............................................................................................................................... “ 6

5.2 Rules concerning the crane ........................................................................................................................... “ 6

5.3 Rules for the correct positioning of the crane ................................................................................................ “ 7

5.3.1 Choice of the crane operating place pressure on the ground....................................................................... “ 7

5.3.2 Safety distance from trenches and slopes .................................................................................................... “ 7

5.3.3 Safety distance from electrical power lines ................................................................................................... “ 8

5.3.4 Crane and load ground connection ............................................................................................................... “ 8

5.3.5 Influence of the wind on the crane operation ................................................................................................. “ 10

5.4 Rules concerning safety in the traffic ............................................................................................................. “ 10

5.5 General rules on winch operations ................................................................................................................ “ 11

5.5.1 Winch system operation ................................................................................................................................. “ 11

5.5.2 Operator safety tips......................................................................................................................................... “ 11

5.5.3 General rules when operating winch ............................................................................................................. “ 11

5.6 WIRE ROPE .................................................................................................................................................... “ 12

5.6.1 General ........................................................................................................................................................... “ 12

5.6.2 Wire rope precautions .................................................................................................................................... “ 12

6 DESCRIPTION OF THE CRANE .......................................................................... “ 13

6.1 Model: 14000.2L ............................................................................................................................................. “ 13

6.2 Model: 14000.3L ............................................................................................................................................. “ 14

6.3 Safety devices ................................................................................................................................................. “ 15

6.3.1 Safety devices installed .................................................................................................................................. “ 15

6.3.2 Load limiting device ........................................................................................................................................ “ 15

6.3.3 Relief valve ...................................................................................................................................................... “ 16

6.3.4 Pilot operated holding valves ......................................................................................................................... “ 16

6.3.5 Safety devices’sealing .................................................................................................................................... “ 16

6.4 Microprocessor remote control system ......................................................................................................... “ 17

6.4.1 Available control version ................................................................................................................................. “ 17

6.4.2 Electronic power unit ...................................................................................................................................... “ 17

6.4.3 The radio receiver unit .................................................................................................................................... “ 18

6.4.4 The cable keyboard ........................................................................................................................................ “ 18

6.4.5 The keyboard radio trasmitter ........................................................................................................................ “ 19

6.4.5.1 Radio system protection device ..................................................................................................................... “ 20

6.4.6 Proportional mono-function regulation hydraulic unit .................................................................................... “ 20

6.4.7 Proportional dual-mode regulation hydraulic unit ......................................................................................... “ 21

6.4.8 Wiring .............................................................................................................................................................. “ 21

6.5 Remote control use ........................................................................................................................................“ 22

6.5.1 Use of the mono-function proportional remote control .................................................................................. “ 22

6.5.2 Use of the dual-mode proportional remote control ....................................................................................... “ 22

6.6 Signal and diagnostic ............................................................................................................................ Page 23

6.6.1 Keyboard diagnostic signal ............................................................................................................................ “ 23

6.6.2 Display messages ......................................................................................................................................... “ 24

6.6.3 Normal display menu ..................................................................................................................................... “ 24

6.6.4 Micro-switches and pressure switch display menu ...................................................................................... “ 26

6.6.5 Current display menu ..................................................................................................................................... “ 26

6.6.6 Remote control keyboard display menu ........................................................................................................ “ 27

6.6.7 Work pressure display menu ......................................................................................................................... “ 28

7 OPERATING INSTRUCTIONS ......................................................................................... “ 29

7.1 General attentions .......................................................................................................................................... “ 29

7.2 Stabilizing the truck ......................................................................................................................................... “ 30

7.3 Opening the crane .......................................................................................................................................... “ 32

7.4 Closing the crane ........................................................................................................................................... “ 32

7.5 Winch system operation ................................................................................................................................. “ 32

7.6 Before starting traveling on road .................................................................................................................... “ 32

7.7 Main errors occurring when operating the crane ........................................................................................... “ 32

7.8 Standard hand signals ................................................................................................................................... “ 33

8 PUTTING THE CRANE INTO SERVICE .......................................................................... “ 34

8.1 Ten rules for the perfect crane operator ......................................................................................................... “ 34

8.2 Daily check list ................................................................................................................................................ “ 34

8.3 Safety tips for crane starting in cold climates ................................................................................................ “ 34

8.4 Crane protection and storage ........................................................................................................................ “ 34

8.4.1 Short shutdowns ............................................................................................................................................ “ 34

8.4.2 Long shutdowns ............................................................................................................................................. “ 35

9 MAINTENANCE ................................................................................................................ “ 36

9.1 Warnings ........................................................................................................................................................ “ 36

9.2 Maintenance prescriptions ............................................................................................................................. “ 36

9.3 Maintenance schedule ................................................................................................................................... “ 37

9.3.1 Daily checking ................................................................................................................................................. “ 37

9.3.2 Monthly checking ............................................................................................................................................ “ 38

9.3.3 Checking every six months............................................................................................................................. “ 38

9.3.4 Others ............................................................................................................................................................. “ 38

9.4 Crane servicing............................................................................................................................................... “ 39

9.4.1 Oil level checking ............................................................................................................................................ “ 39

9.4.2 Oil change ....................................................................................................................................................... “ 39

9.4.3 Oil filter cartridge maintenance ...................................................................................................................... “ 39

9.4.4 Slewing mechanism maintenance ................................................................................................................ “ 40

9.4.5 Greasing the hydraulic boom sections .......................................................................................................... “ 40

9.4.6 Wear pads check and replacement ............................................................................................................... “ 40

9.5 Greases and oils reference table .................................................................................................................. “ 41

9.6 Wire rope ........................................................................................................................................................ “ 42

9.6.1 Wire rope inspection ...................................................................................................................................... “ 42

9.6.2 Rope replacement .......................................................................................................................................... “ 42

9.6.3 Wire rope lubrication ...................................................................................................................................... “ 43

9.7 Possible faults and relevant remedies .......................................................................................................... “ 44

10 TECHNICAL DATA............................................................................................................ “ 46

10.1 Overall dimension 14000.2L .......................................................................................................................... “ 46 Performances Load chart table

10.2 Overall dimension 14000.3L .......................................................................................................................... “ 48 Performances .................................................................................................................................................. Load chart table ...............................................................................................................................................

11 WIRING AND HYDRAULIC DIAGRAMS ........................................................................... “ 50

11.1 Electrical diagrams......................................................................................................................................... “ 50

11.2 Hydraulic diagrams ........................................................................................................................................ “ 52

11.2.1 Hydraulic diagram 14000.2L ......................................................................................................................... “ 52

11.2.2 Hydraulic diagram 14000.3L ......................................................................................................................... “ 53

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:

truck maintenance manual.

Chapter 11: Wiring and hydraulic diagrams

1.2 REMARKS

Many thanks for the preference kindly given to our product. Please remember that the servicing instructions and the load charts hereby reported and applied on the crane are an essential part of the crane supply itself. They are mainly intended for the crane operator and include all necessary information on the admittable and permissible field of usage for a safe operation. Anyway, these instructions are not a training manual for beginners or unskilled operators, it must be stressed that as a fundamental presupposition only skilled and professional crane operators are allowed to work with the crane. The crane operator is directly responsible for the state of the crane and for every crane operation. When the training is hurried and full of gaps, this is the origin of many accidents. This manual gives the guidelines for a correct, safe usage of the crane and its rational maintenance. When daily and constantly applied, these guidelines ensure long service life with minimum maintenance costs, high performance of the crane and good commercial value after years. Moreover, most of the frequent accidents during operation and servicing are avoided. Once this manual has been read carefully, keep it in good conditions and quickly available close to the crane.

ATTENTION

As far as safety is concerned it is strongly recommended to carefully read the safety tips of the chapter, SAFETY RULES.

ATTENTION

Should some or any part of this manual be not clear, please contact the Manufacturer.

IMPORTANT

When receiving this manual, check if all the data are correct. Inform the Manufacturer if something is found wrong.

NOTE

The table on the back of the front page has to be filled at customer’s care. It contains all the necessary data required when calling our Technical Service.

A copy of this manual is supplied along with every crane. Data, descriptions and pictures of this manual are not binding. The Manufacturer reserves the right to change at any time all the items, components and parts deemed to be necessary for product improvement or commercial or production needs. This right is kept without obligeance of quick updating of this manual. Fundamental data, performances and characteristics of the product will be maintained.

The symbols and marks are completed with notices stating the dangers, their nature, the avoidance actions to be taken and tips to be followed.

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.

CRANE IDENTIFICATION

3.1 VERSIONS AND OPTIONS AVAILABLE

The service instructions written on this manual are referred to the CRANE MAXILIFT COBRA 14000. This model is supplied in four version. When ordering, are to be specified:

Version Remote control Hydraulic supply Hydraulic

Power extension

supply 14000.2L KPD - H

Cable -Proportional

Fed by a punp, driven by dual-mode

a P.T.O. on the truck gearbox

Two 12 - 24V

14000.2L RKPD - H

Radio -Proportional

Fed by a punp, driven by dual-mode

a P.T.O. on the truck gearbox

Two 12 - 24V

14000.3L KPD - H

Cable -Proportional

Fed by a punp, driven by dual-mode

a P.T.O. on the truck gearbox

Three 12 - 24V

14000.3L RKPD - H

Radio -Proportional

Fed by a punp, driven by dual-mode

a P.T.O. on the truck gearbox

Three 12 - 24V

The following options are available for the above versions:

Type of optional Available on models

Oil tank

All Outrigger beam - (hydraulic jach)

All

3.2 CRANE IDENTIFICATION DATA

Every crane is identified by its serial number and name of the model written on the plate riveted on the crane. The same data are also punched on the crane column.

Data plate description Colum punching

a) Crane model g) Crane model b) Serial number h) Serial number c) Year of manufacturing d) Lifting class e) max SWL f) Approval number

ATTENTION

It is strictly forbidden to change, erase, modify the data written on the plate and punched on the column.

Pict. 1

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 9,2 ton-meter (66,500 ft. lbs.), making it especially suitable for installation on light truck. The crane is classified in class H2-B3 according to DIN 15018 standards, and must be used accordingly, that is: trucks loading/unloading, hook service.

truck stability against tipping over;

practical knowledge of slings usage and precautions when moving the loads;
complete knowledge of all the operations and motions to be executed with the crane; competent and qualified personnel of the authorized workshop which has installed the crane will take care of this;
complete reading and understanding of this manual;
complete knowledge and understanding of safety and risk avoidance regulations;

Vision of at least 20/30 Snellen in one eye and 20/50 in the other, with or without the aid of corrective lenses;

normal depth perception and field of vision (peripheral);
ability to distinguish colors if color recognition or differentiation is, required for safe operation;
adequate hearing, with or without a hearing aid;
sufficient strength, endurance, agility and coordination to meet equipment operation demands;
emotionally stable;
not subject to seizures, loss of physical control, dizziness or have physical limitations which could impair the ability to safety operate the crane.

SAFETY RULES

5.1 RULES CONCERNING PEOPLE

Always wear the prescribed personal safety devices
Always wear approved accident-prevention clothing such as: protective helmets, anti-slip shoes, protec tive gloves, antinoise headphones, protective glasses, reflective jackets with breathing apparatus. Con sult your employer regarding current safety regulations and accident-prevention equipment.
Do not wear ring, wristwatches, jewelry, loose-fitting or hanging clothing such as ties, torn garments, scarves, unbuttoned ja-ckets or unzipped overalls, which could get caught up in the moving parts of the crane.
Keep quickly and readily available on the truck a first-aid box and a fire extinguisher. The fire extin guisher must always be kept charged and has to be used according to current regulations.

5.2 RULES CONCERNING THE CRANE

The Manufacturer is not liable for accidents occurred during the usage of the crane caused by non fulfillment from the opera tor’s side of current rules, laws and regulations.
The crane is designed to be used within the -30°/+50° (-22 °F/ +122 °F) temperature range and has to be operated only in this range. The manufacturer is not liable for accidents occurred during the usage of the crane outside this temperature range.
Carefully read the Operator’s and maintenance manual before starting up, using, servicing or doing any thing on the crane.
Read and follow all the safety instruction plates applied on the crane before starting up, using, servicing or doing anything on the crane.
Do not use controls and hoses as handholds: these parts move and cannot provide stable support. Furthermore, a control mistakenly moving can accidentally set the crane in motion.
The operator’s control desk must always be kept clean from oil, grease, mud, snow to avoid accidents due to slippery surface.
The safety 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.

7 2

5 Pict. 2

5.3 RULES FOR THE CORRECT POSITIONING OF THE CRANE

5.3.1Choice of crane operating place pressure on the ground

Carefully choose the place where lowering and put into action the stabilizers of the crane outriggers. The most important thing is the capacity of the ground to bear the pressure produced by the outriggers.
Make sure that the outriggers working area is free from underground piping, tunnels, holes.
The positioning must be carried out so as to operate the crane with the shortest outreach possible and without any obstacle in the working area.
Never move the crane from its rest position without stabilizing the truck.
• The outriggers reaction is transmitted to the ground by steel pads. When this pressure exceed the

• for brought-back or crumbling terrain safety distance (a) must be double of the slopes’ depth that is:

a = 2 • b

• for compacted, not crumbling terrain safety distance (a) must be equal to the slopes’ depth, that is:

a = 1 • b

Distance to be measured from point © Max. reaction on the ground varies according to the vehicle where the crane is installed.

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

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 insulating materials (wood, plastics) It has to be noted that, even when the crane has been connected to ground, the load can be loaded electrostatically charged, because the rope pulleys or the slings and ropes used to lift the load are made of insulating materials.

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

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 mm²(0,025 sq. in.).
a second metal rod, having good conductivity and an insulating handle complying to the relevant safety Regulations. This rod has to be used to touch the load.
Then connect this cable to the ground rod on one side. Moinsten the ground all around the rod to improve conductivity.
Then connect the other side of the cable to the insulated rod. Both connections must be made using the relevant vices or metal clamps as an alternative.

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.

DANGER

electrocution hazard Always hold the rod by its insulated handle.

5.3.5 Influence of the wind on the crane operation

A strong wind can overload the crane, so during operations keep under control the wind speed. When working with full load, the maximum admittable wind speed is 45 km/h (28 mile/h). When this value is exceeded, any crane operation must be stopped and the crane must be brought to the rest position. Since the maximum working height of the crane is reasonable, refer to the 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 - 0.2	0-0.65	1	0.6	calm,the smoke goes straight upwards
1 light	0.3 - 1.5	1-5	1-5	0.6-3	wind direction can only be seen looking at the smoke. Wind indicators are idle
2 light	1.6 - 3.3	5-11	6-11	3-7	leaves are moving,the wind can be on the face.
3 light	3.4 - 5.4	11-18	12-19	7-12	leaves and small brances are moving breeze
4 slow	5.5 - 7.9	18-26	20-28	12-17	dust and paper sheets are lifted up, breeze slender, rods are moved
5 strong	8 -10.7	26-35	29-38	17-24	small waves on water surfaces breeze
6 strong	10.8 - 13.8	35-45	39-49	24-30	rods are bent,it is difficult to use wind umbrella
7 tight	13.9 - 17.1	45-56	50-61	30-38	the trees are moved it is difficult to wind walk against wind
8 stormy	17.2 - 20.7	56-68	62 - 74	38-46	trees’branches break.it is very difficult to walk in open areas
9 tempest	20.8 - 24.4	68-80	75 - 88	46-55	small damages to buidings (roofing tiles wind fall down)
10 violent	24.5 - 28.4	80-93	89 - 102	55-63	big damages to the buildings, trees uprooted tempest

5.4 RULES CONCERNING SAFETY IN THE TRAFFIC

-The machine is an hidraulic crane for lorries and light trucks.The installation on the vehicle must be made in compliance with the relevant national laws and regulations.

-When traveling on roads and public sites always respect the relevant national laws and regulations.

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 safety factor on the wire rope supplied with the machine. Therefore,any replacement rope must meet the rope specifications for size,construction and stregth as outlined in specification sections of this manual.

5.5.2Operator safety tips

Do not pull the load block into the boom tip.
Use proper multi-part reeving for the load to be lifted.

When using multi-part reeving, be sure cable is properly routed.
the load must not ex-ceed the lesser capacity.

Do not drag loads with winch or boom.
Always wind loadline.under tension to assist proper spooling

5.5.3General rules when operating winch

clearance between the boom tip and loading hook. 2 3

control to neutral to determine if the brake is working properly. 6 -Do not drag loads in any direction with the winch. 7 -Never attempt to lift loads wich are not loose and free, i.e. frozen down material or poles out of

ground. 8 -Maintain tension on the loadline at all times to prevent the cable from becoming twisted or improperly seated on the winch drum or sheaves. 9 -Avoid rough boom lifting and lowering manoeuvres with suspended load, in order not to cause dangerous swingings of the same.

10-Avoid boom extension manoeuvre under load. When moving loads near to max. rates it is rather advisable to extend the boom without load in order to reach the vertical line of the same, and then to proceed with lifting by using the winch.

5.6 WIRE ROPE

5.6.1General

Wire rope can be the weak link in crane safety. It is subjected to heavy loads, abrasion, kinking, extreme weather conditions, chemical attack and other forces which can reduce its reliability. The inspection and care of wire rope is essential in the effort to provide for safe working conditions.

5.6.2Wire rope precautions

1 -Avoid the formation of kinks. Kinks will cause severe weakness in the rope. No corrections are availa

6 DESCRIPTION OF THE CRANE

6.1 MODEL 14000.2L H

Item Description

1 Slewing ring 16 Swivel coupling 2 Planetary gear reducer 17 Base plate 3 Column 18 Outrigger beam - (hydraulic jack) OPTIONAL 4 Main boom 5 Boom hoist cylinder 6 First hydraulic boom section

6.2 MODEL 14000.3L H
Item		Description
1 2 3 4 5	Slewing ring Planetary gear reducer Column Main boom Boom hoist cylinder		17 18 19 20	Base plate Outrigger beam - (hydraulic jack) OPTIONAL Third hydraulic boom section Third telescope cylinder

6.3 SAFETY DEVICES 6.3.1Safety devices installed

All the safety devices,installed on MAXILIFT COBRA 14000 crane, are listed and described in the following pages.

description of safety functions

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 extension re-entry and boom lowering levers.

6.3.3 Relief valve

The main relief valve is on the control valve 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:

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 2 ³main components (Pict. 7):

1) Control and safety devices managing con

trol unit 2) Remote control keyboard 3) Directional and flow regulating hydraulic unit 4) Electrical connection wiring from the unit to

the solenoid valves, the micro-switches, the

power supply and the keypad.

Pict.7

6.4.2 ELECTRONIC POWER UNIT (Pict.8)

The electronic unit, located aside the revolving column’s guard, is made up of a sealed plastic compact container (ip 67), that includes a

microprocessor electronic device to manage crane operation controls and safety systems. A three digit display (1) used as regulation or control interface is found on the front of the unit. Two electrical wiring connectors (2) are found on the unit.

Pict.8

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).

easy to handle even if exposed to extreme conditions.

6.4.5 THE KEYBOARD – RADIO TRANSMITTER (Pict.10)

N.B. Never let the crane work with disabled emergency button.

WARNING When the cable keyboard is not being used, it must be disconnected from the connector located on the guard aside the unit where the protection cover will be screwed. Press the mushroom button of the cable and radio keyboards after their use and before storing them on a protected 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.

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.

6.4.7 PROPORTIONAL DUAL-MODE REGULATION HYDRAULIC UNIT (Pict.12)

The unit is consisting of two separate aluminium blocks. The upper section includes the proportional adjusting valve (VR), the manual bypass control valve (OM) of the proportional regulator, the main relief valve (VM), the winch operating solenoid valves (EV4A – EV4B), the dump valve (EV9) and the solenoid valves (EV3 – EV4) required to operate the 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
b)	proportional valve (VR) Fully turn counter-clockwise the manual override of the valve coupled to the	EV3	EV9 VM
	desired movement (extension re-entry,		1
	boom lowering, etc.).
c)	Finally Fully turn counter-clockwise the
	manual override of the valve (EV9), in order to activate the desired movement	OM	VR
d)	Once the standard working conditions of	EV4	EV4B
	the crane are restored, always remember to close completely the manual overrides,	EV4A	EV3B
e)	by turning them clockwise. Finally close completely the bypass valve	EV3A	EV2B
	(OM) by turning the handwheel clockwise.		EV1B
		EV2A

EV1A

Pict.12

6.4.8 WIRING (pict.13)

Made up of a single wiring unit that is connected to the electronic unit through two sealed multipolar connectors (1) provided with quick hooking system.

The wiring includes the solenoids to connect the solenoid valves located on the hydraulic unit, it also connects the unit to the safety limit switches (FA – FB – FV), to the pressure gauge or to the pressure transducer (PM), to the diesel engine start/stop and to the power supply. The wiring also includes the keyboard

connection female connector (3) that is

Pict.13

placed aside the electronic unit on the crane’s cover.

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.

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.

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 signals:

Radio connection keyboard: -a brief signal (beep) indicates that the keyboard is powered (through the emergency button) -a long 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: -enough to work. -low to work. -charge level or that the proportional button is switched on -

learning function is used. --

-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

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 messages, the operator is requested to contact the Technical After-Sales Service.

6.6.3 NORMAL DISPLAY MENU

When switching on, after a sequence of messages on the display this must show:

When carrying out whichever movement by selecting the function it must appear:

When the overload condition is almost reached the display shows:

When the crane goes gets locked by the LLD (overload) the display shows:

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

Moreover, the system can show the following error messages, which can be displayed when operating or trying unsuccessfully to operate.

The messages and relevant meanings are the following: “O”xx followed by the solenoid valve abbreviation. It means open circuit detected on the solenoid valve in object.

Examples: Open circuit alarm on solenoid valve EV3B.

The following table shows all the displayed alarm codes.

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

-SYSTEM TYPE SETTING MENU (SINGLE-FUNCTION – DUAL MODE) -MOMENTUM LIMITER TYPE SETTING MENU -RFID (Radio Frequency Identifier) CODE LEARNING MENU

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 operate 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 “FB micro-switch open”

5A 4A

Example: display of the state

“PM micro-switch closed”

2A 1A 5B

The following table shows all displayed codes:

4B 3B 2B

Fa.O Fa.C micro-switch FA (micro on winch drum/cable

Pict. 14A

descent) ^1BFb.O Fb.C micro-switch FB (stopped boom limit switch) Fu.O Fu.C micro-switch FV (limit switch on cable diverting pulley / cable lift) Pr.O Pr.C 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 displayed. 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

Example: indication with an active movement and with the proportional valve driven at 523 m^A

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 contacts the following state is displayed: C closed

received command is displayed. Example: indication without any active movement

Example: indication when the contact 1A is closed on the remote control uni

The following table shows all displayed codes:

Display	Indication
C1A	contact 1A closed (CLOCKWISE ROTATION)
C1b	contact 1B closed (COUNTER-CLOCKWISE ROTATION)
C2A	contact 2A closed (BOOM UP)
C2b	contact 2B closed (BOOM DOWN)
C3A	contact 3A closed (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.

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).

7 OPERATING INSTRUCTIONS

7.1 GENERAL ATTENTIONS

The crane must be used exclusively by qualified and skilled operators. They must know location and function of every control, instruments, indicators, lights, plate and sticker.

DANGER

Before starting operations make sure that nobody is in the working area of the crane.

Stay away from the outrigger beams when they are pulled in, to avoid crushing hazard between them and the truck parts.
When the work is over make sure that the outriggers beam are locked in rest position and the shut-off valves are closed. Lack of doing this may result in serious danger if these parts come out whilst traveling on road.
The stickers and plates applied on the crane are necessary to enable a safe usage of the same. Should them be no longer readable, replace them as soon as possible with new ones.
Always disconnect the power take-off before driving away. If the truck engine turns at high revs, the PTO would be damaged.
The operator should be someone who is familiar with type of crane and has had some experience with it.
• If the crane is accidentally hit, it has to be checked and tested from the closest authorized installer workshop.

If the crane is accidentally hit, it has to be checked and tested from the closest authorized installer workshop.
Check every month the state and correct functioning of all the parts subject to wear: pins, valves, hoses, sliding pads and bushings, etc. If necessary replace with genuine spare parts.
It is absolutely forbidden to alterate the hydraulic circuit and open the safety seals. Failure to comply will cause automatically the voiding of any warranty on the product. Valves adjustments or setting must be done only by authorized installer workshops.
Overheating of hydraulic oil may burn the sealing parts and alterate the oil itself. This can be caused by an excessive oil flow of the pump or by repeated stroke ends of the cylinders.
• Check that the pump supplies the control valve with the oil flow suggested in our technical specifica tions.

7.2 STABILIZING THE TRUCK

Bearing in mind the job to be done, the vehicle has to be positioned in the most convenient position, stopped with the parking brake and the tires blocked.
The 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

the clutch pedal.

Cranes on stationary mounting

Switch-on the hydraulic power pack.

load before starting to operate the crane.

• Extend the outriggers beams, acting separately on each side of the truck. Their release is made turning 180° upwards the locking handle (2) on picture 15. Pull the beam (1) on picture 15 out for a length of

approx. 20 cm (8 in.), then turn again the locking handle 180° downwards in its previous position. Pull again out the outrigger beam, and the locking pin of the handle will automatically engage and lock the

ATTENTION

The outrigger beams are in their working position when the yellow band existing on every beam can be entirely seen.

• Lower to the ground the bearing pads of the outriggers jacks, one at a time, acting as follows:

Hydraulic jack (Pict. 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.

Swinging hydraulic jack (Pict. 17) When swinging jack are fitted, before operating the shut-off valve (1) make sure that the jack (2) is in vertical position, with its pad (3) oriented downward, its pin (4) secured with the retainer spring (5). If not, take off the pin, turn the jack downward and then lock in the working position in the aforesaid way. Then open the valve

(1) as already explained (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.

ATTENTION

When turning the swinging jack and removing its pin, be careful and hold it up, to prevent it from falling down because of gravity , resulting in damage or injuries.

• Repeat this sequence of operations for the outrigger jack on the other side of the truck and for every other jack fitted on the truck. Make sure that the vehicle is level, in order to have a good stability. Maximum allowed angle is 3°.

IMPORTANT

Proper leveling has to be checked by means of a level instrument fitted on the truck.

4
1
5
2				A
3		1	C		1 6
		2			2
	Pict. 15			Pict. 16	3	Pict. 17

7.3 OPENING THE CRANE

Starting from the crane in rest position, operate the switch of „boom hoist up“ on remote control. When the boom is roughly horizontal or in any case, higher than vehicle sides or other existing obstacles.
Then operate the switch “crane swing”, to direct the boom in the desired direction.
Then operate the switch “boom section extend” until the hook has reached the required position.

7.4 CLOSING THE CRANE

Closing the crane into rest position is performed by carrying out the opposite movements to those made to

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.

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 crane.
The outriggers are badly positioned or the ground is not firm: in both cases the truck tilts and could tip over.
Working with strong wind or wind gusts
The manual boom sections are not correctly installed.

8 PUTTING THE CRANE INTO SERVICE

8.1 TEN RULES FOR THE PERFECT CRANE OPERATOR

Always comply with the following ten basic rules:

1 -When approaching the crane for the first time, become on familiar terms with it, executing all the manoeuvres the crane can perform during working. Carefully read all the prescriptions of this manual and execute step by step the activities hereby described to be sure of the correct under

8.3 SAFETY TIPS FOR CRANE STARTING IN COLD CLIMATES

In the crane with PTO-driven: wait for some minutes with the pump running at no load before operate any crane movement.

8.4 CRANE PROTECTION AND STORAGE

8.4.1 Short shutdowns

Wash and clean the crane, lubricate all the parts provided with grease nipples and the slewing system.

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.

9 MAINTENANCE

9.1 WARNINGS

Do not wear rings, wristwatches, jewelry, loose-fitting or hanging clothing such as ties, torn garments, ordinary shoes, unbut toned jackets or un-zipped overalls, which could get caught up in the moving parts of the crane. Instead, always wear approved accident-prevention clothing such as protective helmets, anti-slip shoes, anti-noise headphones, protective glasses, and reflective jackets with bre athing apparatus. Consult your employer concerning current safety regulations and accident-pre vention equipment.
Apply a clearly visible plate on the cab door or on the control valve with the notice: “crane under maintenance. Do not start”
Do not get under any raised part of the crane, unless a safety lock support has been applied to it.
Before starting any maintenance or repair operation always install safety locking supports on any raised part of the crane, especially the boom system.
The truck engine should be started in closed rooms only if well aired.

9.2 MAINTENANCE PRESCRIPTIONS

Many damages and accidents are caused by a bad maintenance or by mistakes in the maintenance itself. Common causes are recognized to be: leacking of oil, grease or anti-freeze liquid. dirt on crane components or assemblies. breaking of ropes or slings.
conditions.

• 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 danger of shearing or crushing exists, if the parts of the machine have not previously locked in a safe way. • Do not use your fingers to align holes or slots: always use appropriate centering tools.

Wear protective glasses with side shields to protect your eyes when using compressed air for clea ning the machine parts. Do not allow the pressure of the air to exceed 2 bar (29 psi).
The access steps or platforms in the workshop or where the crane is operated must be built accor ding to current hazard avoiding regulations.
Never use petrol or thinners or other flammable liquids or detergents. Use instead authorized com mercially sold cleaning products which are granted to be non-flammable and non toxic.

DANGER

of fire or scald It is forbidden to use naked flame as lighting device when carrying out checks or looking for leaks 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 it is necessary to lift the crane and/or other parts, make sure that they are locked as requested from current safety regulations

9.3MAINTENANCE SCHEDULE

9.3.1Daily checking

Check the level of hydraulic oil in the tank.
Check the hoses, the fittings and all the other components of the hydraulic system, in order to elimi nate any possible source of oil leak.
Check that all the crane is in good condition.
Immediately repair the item or the component found to be faulty.

9.3.2Monthly 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.
Check readability of symbols on the remote control.
Check integrity of hooks, ropes, chain and all the other lifting ancillary equipment.
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 Others

• Stability of unit throughout working area. Check stability procedure annualy or when any change is made to crane or truck.

9.4CRANE SERVICING

9.4.1 Oil level checking

Check the hydraulic oil level monthly,with the truck on level,flat ground.

1) minimum oil level :with the crane booms raised at full elevation and fully extended,and hydraulic outrigger completely out,the oil level must NOT be lower than the indicator (3)

2) maximum oil level :when the crane is in travelling position,the oil level must be two inches below the

9.4.4 Slewing mechanism maintenance (Pict. 20)

It is recommended to periodically lubricate ( see relevant chapter 9.3) the teeth of pinion and slewing ring.This to be made with a greased brush, through the large hole existing in the column base plate. Also with the same interval lubricate the bearing of the ring,with a greaser through the grease nipple existing outside the outer ring. Grease to be according the reference table on chapter 9.5.

ATTENTION :for safety reasons always switch the engine off and disconnect the control box before attending the slewing mechanism lubrication.

9.4.5 Greasing the hydraulic boom sections (Pict. 21)

1 - Completely extend the telescopic boom 2 - Grease the lower part of the extensions by a brush 3 - Grease the upper part of 1st. extension by the two grease nipples (pos. A) 4 - Move the grease nipples to pos. B and go on greasing the upper part of 2nd. extension 5 - Take the grease nipples off and move them back to pos. A 6 - Carry out 2 or 3 boom re-entry and 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.)

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.

Pos. “B”

Pict. 20 Pos. “A”

Pict. 21

9.5 Greases and oils reference table

BRAND	TOTAL	MOBIL	ESSO	AGIP	IP	BP
GREASE	MULTIS	MOBILGREASE	BEACON	GR MU	ATHESIA	ENEGREASE
	EP2	MP	EP2	EP2	EP2	LR MP
GREASE	MULTIS	MOBILGREASE	BEACOM	GR MU	ATHESIA	ENERGREASE
	LR MP	MP	EP2	EP2	EP2	EP2
HYDRAULIC	AZOLLA	DTE	NUTO	OSO	HYDRUS	HENERGOL
OIL	ZS 32•	15	H 32•	32•	32•	HL 80
	ZS 46*	25*	H46*	46*	46*
OIL GEAR	CARTER	GEAR	SPARTAN	BLASIA	PONTIAX	ENERGOL
	EP 100•	627•	EP 100•	100•	HDS	GR XP100•
	EP 150*	629*	EP 150*	150*		GR XP150*
• for temperate and cold climate
* for hot climate

Pict. 22

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

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 ara 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

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 rope. Therefore, these ropes should be cleaned before being lubricated. The lubricant applied should be light bodied enough to penetrate to the core of the rope. Lubricant may be applied effictively by various methods. It may be dripped on, sprayed on, or put on by brushing, but in any case it should be applied at a place where the rope is being bent, such as at a sheave. It shold be applied at the top of the bend, because at that point the strands are spread by bending and are more easily penetrated. The service life of rope will be directly proportional to the effectiveness of the method used and amount of lubricant reaching the working parts of the rope. A proper lubrificant must reduce friction, protect against corrosion, adhere to every wire and be pliable and not crack or separate when cold and yet not drip when warm.

9.7 POSSIBLE FAULTS AND RELEVANT REMEDIES

Fault	Cause	Remedy
Vibrations in hydraulic cylinder and jerkings 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 hydraulic system.	Add hydraulic oil to the tank. Operate the control lever carrying the cylinders to stroke end for some times in both directions.
All the crane movements are very slow, even when unloaded.	Suction hose from oiltank crushed or obstructed. The pump is drawing in air.	Replace or clean the suction hose. Check that the relevant fittings are well tightened.
The hydraulic extension are not extending in the right sequence.	Bad lubrication. Sliding pads are worn. Sequence valve on extension cylinder has to be adjusted.	Grease the extensions. Replace sliding pads.* Adjust the sequence valve.*
Slewing is not regular or with insufficient power he crane does not lift the loads of the	Ground slope too great Domaged slewing motor Worn pinion Worn gear motor Worn slewing ring	Level the truck. Replace slewing motor. * Check and replace * Check and replace * Check
Tload 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.*
course. The crane locks with boom lifted at end	Pressure transducer not set. Setting of general max. pressure valve too high.	Disassemble the casing and move manually the boom descent valve (EV2B). Reduce the general max. pressure valve (Pict.12). *
44 One or more movements keep on functioning while selecting another function.	-Solenoid valve jammed in open posi tion (dirt, working shaving, long inacti vity periods) -Manual operator (where foreseen) activated	-Unlock, clean or in case replace the solenoid valve cartridge -Close down the manual operator

Fault ne of the function does not work.	Cause	Remedy
O	Defective switch Burned solenoid. Locked valve cartridge Damaged electric connection.	Replace the switch Replace the solenoid. * Disassemble and clean the valve cartridge Check continuity of the circuit
All the functions do not work	No power (or insufficient) to the shuntboarder the remote control box The proportional valve does not meter Electric valve (EV9 pict. 12) is not working The trigger on the remote hand-heldcontrol box does not work	Check relevant fuzes and indicator LEDS Check tension with a tester Check the solenoid of the valve Check and clean the valve cartridge As above Check the control box
AIt	The proportional valve is not working	Check and clean the valve cartridge on
ll the functions work at full speedis not possible to adjust the speed	The trigger on the hand-held control boxis not working	an authorized workshop Check the relevant potentiometer andelectric board on an authorized workshop
M	Electric valves (EV3 pict.12) and (EV4pict.12) does not worck	Check the relevant solenoid Check and clean the relevant valve cartridges
Oti	Solenoid valve jammed in open position	Unlock, clean or in case replace the so-
ne or more movemente keep on funconing while selecting another function ulti-function operation are not possible	(dirt, working shaving, long inactivity periods) Manual operator (where foreseen) activated	lenoid valve cartridge Close down the manual operator
operated The winch does not work when singlehe winch does not work when operatedtogether with other functions	Solenoid valve EV4 jammed in closedposition (dirt, working shaving, longinactivity periods) (pict.12)	Unlock, clean or in case replace thesolenoid valve cartridge
T	Solenoid valve EV3 jammed in closed(dirt, working shaving, long inactivityperiods) (pict.12) Flow divider 1 wrongly set or notworking (pict.12)	Unlock, clean or in case replace thesolenoid valve cartridge or the flow divider

* Operations to be carried out only by authorised installer workshop

10 TECHNICAL DATA - WINCH SPECIFICATIONS

10.1 SERIES 14000.2L STANDARD EQUIPMENT

-High speed winch with planetary gears reducer	-Continuous rotation with worm-gear
-Negativ brake for winch	-Remote control with connection and 10 m. - 33' ft. of cable
-Hydraulic swivel coupling, for continuous rotation	or radio remote control
	-Proportional multifunction hydraulic system
-Load limiting device	-Solenoid valve with manual functions (only for emergency)
-Two hydraulic extensions	-Stop-end system for winch (up and down)

TECHNICAL DATA14000.2L
Crane rating		ft.lbs	66.500
Standard outreach		ft.	22’4”
Slewing angle			CONTINUOUS
Slewind torque		ft.lbs	6.650
Boom elevation			(-10° +75°)
Lifting height from base of crane		ft.	22’
Remote control			PROPORTIONAL
Pump capacity hydraul. “H” (pto)		GPM	5.8 - 6.5
Working pressure		psi	3.045
Crane weight		lbs	2.000
WINCH SPECIFICATION 14000.2L
Winch pull line		lbs	5.400
Pull line speed	H	ft./min	36 -42.5
Rope diameter		inch.	1/2”
Wire rope length		ft.	115
Cable breaking strength		lbs	(minimum 30.700)

10.2 SERIES 14000.3L STANDARD EQUIPMENT

-High speed winch with planetary gears reducer	-Continuous rotation with worm-gear
-Negativ brake for winch	-Remote control with connection and 10 m. - 33' ft. of cable
-Hydraulic swivel coupling, for continuous rotation	or radio remote control
	-Proportional multifunction hydraulic system
-Load limiting device	-Solenoid valve with manual functions (only for emergency)
-Three hydraulic extensions	-Stop-end system for winch (up and down)

TECHNICAL DATA14000.3L
Crane rating		ft.lbs	66.500
Standard outreach		ft.	27’7”
Slewing angle			CONTINUOUS
Slewing torque		ft.lbs	6.650
Boom elevation			(-10° +75°)
Lifting height from base of crane		ft.	27’7”
Remote control			PROPORTIONAL
Pump capacity hydraul. “H” (pto)		GPM	5.8 - 6.5
Working pressure		psi	3.045
Crane weight		lbs	2.270
WINCH SPECIFICATION 14000.3L
Winch pull line		lbs	5.400
Pull line speed	H	ft./min	36 -42.5
Rope diameter		inch.	1/2”
Wire rope length		ft.	115
Cable breaking strength		lbs	(minimum 30.700)

11 WIRING AND HYDRAULIC DIAGRAMS

11.1 ELECTRICAL DIAGRAMS

Pict. 27

11.1 DESCRIPTION

SW1 -Crane rotation selector SW2 -Boom movement selector SW3 -Extension selector SW4 -Winch selector SW5 -Engine start/stop selector SW6 -Optinal function selector (opt) L1 -Green led ES -Emergency push button 1 -Circuit board 2 -Proportional trigger button V3 -Winch electro-valve solenoid V4 -Winch electro-valve solenoid EV1A -Clockw. rotation electrov. solenoid EV1B -Counter clockw. rotation electrov. solenoid EV2A -Boom lifting electro-valve solenoid EV2B -Boom lowering electro-valve solenoid EV3A -Extensions electro-valve solenoid EV3B EV4A -Winch lowering electro-valve solenoid EV4B -Winch raising electro-valve solenoid FA -Winch lowering stop end FV -Winch raising stop end FB -Boom lowering stop end PM -Pressure switch PT VR -Proportional electro-valve solenoid SC EV9

11.2 HYDRAULIC DIAGRAMS
11.2.1 Hydraulic diagram 14000.2L
1	Pump	15 Winch motor
2	Electrohydraulic unit	16 Anti shock + owc. valves
3	Rotation motor
4	Overcenter valve
5	Lifting cylinder
6	Overcenter valve

11.2.2 Hydraulic diagram 14000.3L

1	Pump	15 Winch motor
2	Electrohydraulic unit	16 Anti shock + owc. valves
3	Rotation motor	17 Spool
4	Overcenter valve	18 3rd. extension cylinder
5	Lifting cylinder
6	Overcenter valve
7	Pressure switch
8	1st. extension cylinder
9	2nd. extension cylinder

NOTES

NEXT HYDRAULICS S.r.l.

Via Mediterraneo , 6 Boretto 42022 (RE) - ITALY Tel. 0522/963008 - Fax 0522/963039 e-mail: nexthydraulics@tin.it

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.

NEXT HYDRAULICS s.r.l.

Via Mediterraneo, 6 42022 Boretto (Reggio E.) -Italy Tel. 0522/963008 - Fax 0522/963039 e-mail: info@maxiliftcrane.com

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