SERVICE CRANE Mod. 4400

Code MD.0.141 Rev 0

USE AND MAINTENANCE MANUAL

Edition 07/09

OPTIONALS SUPPLIED ALONG WITH THE CRANE

Description

YES

NO Oil tank Outrigger beam - (mechanical jack) Outrigger beam - (hydraulic jack)

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

PRELIMINARY INFORMATION

Operator’s and maintenance manual of MAXILIFT COBRA 4400 SERVICE CRANE Manual code: MD.0.141 This manual is valid starting from serial no: .......... Manufacturer: NEXT HYDRAULICS S.r.l. Via Mediterraneo 6, I 42022 BORETTO Reggio Emilia In this booklet the word “Manufacturer” is referred to “NEXT HYDRAULICS S.r.l.” List of documentation supplied along with the CRANE:

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

SERIAL NO:.............................................................. 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: 4400 H ................................................................................................................................................. “ 13

6.2 Model: 4400 E - 12V/24V ................................................................................................................................ “ 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 ................................................................................................................................ Page 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 ..................................................................................................................................... “ 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 replacement ...................................................................................................................................... “ 39

9.4.4 Wormgear assembly control .......................................................................................................................... “ 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 Overall dimension ........................................................................................................................................... Performances .................................................................................................................................................. Load chart table ...............................................................................................................................................

11 WIRING AND HYDRAULIC DIAGRAMS................................................................“ 48

11.1 Electrical diagrams......................................................................................................................................... “ 48

11.2 Hydraulic diagrams ........................................................................................................................................ “ 50

11.2.1 Hydraulic diagram mono-function proportional ............................................................................................. “ 50

11.2.2 Hydraulic diagram dual-mode proportional ................................................................................................... “ 51

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: Chapter 9:

Chapter 11: Wiring and hydraulic diagrams

1.2 REMARKS

close to the crane.

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.

3 CRANE IDENTIFICATION

3.1 VERSIONS AND OPTIONS AVAILABLE

The service instructions written on this manual are referred to the CRANE MAXILIFT COBRA 4400. This model is supplied in 6 versions. When ordering, one or more of the following versions are to be specified:

Version	Remote control	Hydraulic supply	Power supply
4400 KP - H	Cable - Proportional mono-function	Fed by a punp, driven by a P.T.O. truck	12 - 24V
4400 KP - E	Cable - Proportional mono-function	Fed by a DC electro-hydr. power pack	12 - 24V
4400 KPD - H	Cable - Proportional dual-mode	Fed by a punp, driven by a P.T.O. truck	12 - 24V
4400 RKP - H	Radio - Proportional mono-function	Fed by a punp, driven by a P.T.O. truck	12 - 24V
4400 RKP - E	Radio - Proportional mono-function	Fed by a DC electro-hydr. power pack	12 - 24V
4400 RKPD - H	Radio - Proportional dual-mode	Fed by a punp, driven by a P.T.O. truck	12 - 24V

4 CRANE USAGE AND LIMITS OF APPLICATIONS

4.1 CRANE CLASSIFICATION AND PROPER USAGE

The machine is an hydraulic truck crane for hook service. It can also be used for the same purpose from a static mounting. The lifting capacity is 2.2 ton-meter (16,000 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.

4.2 IMPROPER USAGE

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 jackets or unzipped overalls, which could get caught up in the moving parts of the crane.
Keep quickly and readily available on the truck a first-aid box and a fire extinguisher. The fire extin guisher must always be kept charged and has to be used according to current regulations.

5.2 RULES CONCERNING THE CRANE

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

31R 4

7 15

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 maximum admittable pressure value of the ground, the surface of their bearing area must be increased by means of additional plates of firm material (i.e. wooden plates). The outriggers pads must work in the

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

a = 2 • b

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

a = 1 • b Distance to be measured from point © Max. reaction on the ground varies according to the vehicle where the crane is installed.

IMPORTANT

The installer must calculate this max. reaction on the ground and applied the value on the outrigger jacks.

Always keep a sufficient safety distance when you cannot avoid having electric power lines in the working area of the crane. Special care must be taken when the power lines have not been disconnected by experienced people, or when the lines status is unknown.

DANGER

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

DANGER

electrocution hazard

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. Moisten the ground all around the rod to improve conductivity.
Then connect the other side of the cable to the insulated rod. Both connections must be made using the relevant vices or metal clamps as an alternative.

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.
Payout loadline before or during boom extension to avoid two-blocking.

Use proper multi-part reeving for the load to be lifted.
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

1 clearance between the boom tip and loading hook.

2 -Do not pull load block into boom tip.

3 and in the sheaves.

4 -Before lifting a load, always make certain that three full wraps of rope will remain on the drum at all

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 4400 H

Item Description

1 Slewing system 2 Slewing motor 3 Column 4 Main boom 5 Boom hoist cylinder 6 First hydraulic boom section

6.2 Model 4400 E 12V/24V Item Description
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17	Slewing system Slewing motor Column Main boom Boom hoist cylinder First hydraulic boom section Second mechanical boom section Telescope cylinder Hydraulic unit Electronic Power unit Cable or radio remote control box Winch Travelling block Electro-hydraulic power pack Outrigger beam (mechanical jack) OPTIONAL Outrigger beam (hydraulic jack) OPTIONAL
7			6		8
		14	16					15
				4				13		10
									11
17						3 5
						1
Pict. 6							2	12

6.3 SAFETY DEVICES

6.3.1Safety devices installed All the safety devices,installed on MAXILIFT COBRA 4400 crane, are listed and described in the following pages.

description of safety functions

The crane is fitted with 4 standard electro-hydraulic safety limitations: 1) The load limiting device, which intervent each time the load mentioned on loading diagram is excee

NOTE The load limiting device can lock at the max. main boom angle even without load. In such case, in order to unlock the machine it is necessary to act simultaneosly both on the extension re-entry and boom lowering levers.

6.3.3Relief valve

The main relief valve is on the control valve and limits the maximum working pressure.

6.3.4Pilot operated holding valves

These valves are installed on every cylinder and will stop and lock every motion of the cylinder should any pressure loss occur. Before starting operations it is necessary to check that these valves are perfectly working, as follows:

lift a load and raise the boom up to an angle of 45° upwards, with the boom sections partially extended
switch the truck engine off push and pull repeatedly all the control switches: the load must remain still.

6.4 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). A supplementary unit (7 function radio) is available upon request; it is similar to the main one and it activates

easy to handle even if exposed to extreme conditions.

6.4.5 THE KEYBOARD – RADIO TRANSMITTER (Pict.10)

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. When the keyboard remains unused for at least 15 minutes, the radio system is set to “energy save”, the

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. Cable connection keyboard (serial): --

- led OFF indicates that the keyboard does not recharge the batteries and that the emergency button is pressed.

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.

Display	Alarm Type	Valve on which the alarm is detected
O1A	open circuit	EV on/off 1A (CLOCKWISE ROTATION)
O1b	open circuit	EV on/off 1b (COUNTER-CLOCKWISE ROTATION)
O2A	open circuit	EV on/off 2A (BOOM UP)
O2b	open circuit	EV on/off 2b (BOOM DOWN)
O3A	open circuit	EV on/off 3A (TELESCOPIC BOOM OUT)
O3b	open circuit	EV on/off 3b (TELESCOPIC BOOM IN)
O4A	open circuit	EV on/off 4A (WINCH DOWN)
O4b	open circuit	EV on/off 4b (WINCH UP)
O_3	open circuit	E3
O_4	open circuit	E4
O_r	open circuit	VR (proportional valve)

-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.

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)

6.6.6 REMOTE CONTROL KEYBOARD DISPLAY MENU

This menu is accessed from the Normal Display Menu through the following procedure:

push the proportional button to its maximum level, then operate the 1A and 2B movements simultaneously for at least 5 seconds (the maneuver can be performed in radio mode or through serial cable).

In this menu, when no operation is active, the indication “_ _ _” is displayed. When a movement is active the state of the contact that activates the movement in the remote control pendant is displayed. For each of the contacts the following state is displayed:

C closed

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:

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.

valves are closed. Lack of doing this may result in serious danger if these parts come out whilst traveling on road.

The stickers and plates applied on the crane are necessary to enable a safe usage of the same. Should them be no longer readable, replace them as soon as possible with new ones.
Always disconnect the power take-off before driving away. If the truck engine turns at high revs, the PTO could be damaged.
The operator should be someone who is familiar with type of crane and has had some experience with it.
If the crane is accidentally hit, it has to be checked and tested from the closest authorized installer workshop.

Check every month the 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.

Pull the beam (1) on picture 15 out for a length ofapprox. 20 cm (8 in.), then turn again the locking handle 180° downwards in its previous position. Pull again out the outrigger beam, and the locking pin of the handle will automatically engage and lock the beam when its working position is reached. Always extend fully the outrigger beam to its working position (i.e.: maximum opening position) to grant the maximum stability of the vehicle and safety. Always pull and push the outrigger beam acting on the handle (3) on picture 15 foreseen for this purpose, never pull the hoses or piping.

ATTENTION

The outrigger beam is in its working position when the yellow band existing on the beam can be entirely seen.

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

Hydraulic jack (Fig. 16) Open the shut-off valve (1) to allow the lowering to ground of the cylinder’s pad and rod (2). The valve is open when its lever is on position “A”. Operate the corresponding lever of the control valve until the pad reaches the ground. Avoid to lift the truck off the ground unloading the vehicle suspension, this reduces greatly the stability of the truck. Then, turn again the valve lever to its previous “C”closed position.

Mechanical jack (Fig. 17) Lower the pad (4) by pulling the locking pin (5) out of its housing. The telescope and the pad will come down because of gravity. When it is close to ground, engage again the pin in the appropriate hole, securing it with the relevant safety retainer (6). Turn the crank handle (7) until the ground is reached, bearing in mind what was explained above regarding the vehicle suspension.

Swinging hydraulic jack (Fig. 18) When swinging jack are fitted, before 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 leveled, 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.

7								4
1
								5
2				A	5
3		1	C			6			1 6
		2				4			2
	Pict. 15			Pict. 16			Pict. 17		Pict. 183

7.3 OPENING THE CRANE

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

7.4 CLOSING THE CRANE

Closing the crane into rest position is performed by carrying out the opposite movements to those made to open it, taking special care , at the end of the operation there are no parts protruding from the truck size.

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.
The load is not correctly slinged. So the lifting accessory used (chain, rope, etc) breaks or flips out and the load falls down to earth. The boom, suddenly unloaded, springs back and this could result in tipping over.
Trying to lift fixed load up(rooting of trees, raising of culverts, etc). Even if their load is smaller than the

8 PUTTING THE CRANE INTO SERVICE

8.1 TEN RULES FOR THE PERFECT CRANE OPERATOR

Always comply with the following ten basic rules:

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

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

8.4 CRANE PROTECTION AND STORAGE

8.4.1 Short shutdowns

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

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

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
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
Always use approved protective clothing, safety gloves and protective glasses when using steel ropes, as they produce steel splinters.

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.
Check that all the identification and warning plates are still applied and readable.
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

The oil level must be checked daily, with the crane in rest position and the truck on flat ground If necessary top up with hydraulic oil. The level is checked by mean of the dipstick. (1)

9.4.2 Oil change

The oil deteriorates during daily usage. The oil change every year is necessary to avoid damages to the hydraulic system. Take a container with a capacity of 40 liters (10 gal.) and having suitable dimensions to be positioned under the oil drain plug. (2)

ATTENTION

It is forbidden to pollute the environment with exhausted oil.

After the replacement, it is important to carry out a bleeding of the circuit, otherwise the air introduced in the system with this operation may damage the sealing parts. To do that, operate every function of the control valve, driving it smoothly to stroke end. Use only the oils stated in the greasing/lubricating table, or equivalent ones. (chap. 9.5)

9.4.3 Oil filter replacement

Unscrew the screws (5) holding the filter case.
Pull the case out without damaging the OR.
Loosen the nut (5) and take the cartridge (4) off.
Replace it with a new one, of the same type, and tighten the nut (5) again.
Check the seal for satisfactory condition, if not replace by new one.
Insert the filter group in its housing and tighten the relevant screws.
After a filter replacement, bleed the air off the circuit as explained on point 9.4.2.

1 1 5

2 Pict. 20

9.4.4 Wormgear assembly control (Pict. 21)

It is important to check that the worm gear reducer has a correct axial backlash. This can be made, with the crane at standstill, the boom in horizontal position. Pushing the boom aside on the left and on the right by hand, you can notice if the axial backlash between the wormshaft (6) and the wormgear (8) is too great. In this case it has to be reduced, tighten the nut (7) accordingly. Grease the gear with the suggested product and replace the grease spreader (9), if worn out.

9.4.5 Greasing the hydraulic boom sections (Pict. 22)

1 - Completely extend the telescopic boom 2 - Grease the lower part of the extensions by a brush 3 - Grease the upper part of 1st. extension by the two grease nipples 4 -Grease the upper part of the 2nd. extension by the brush 5 - Carry out 2 or 3 boom re-entry and extension idling operations in order to allow the distribution of

the grease

9.4.6 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.

6
	8
		Pict. 21

Pict. 22

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 46•	25	H 46•	46•	46	HL 80
	ZS 48*		H68*	68*
GREASE			WINN’S (GS-80)
• for temperate and cold climate
* for hot climate

Pict. 23

9.6 WIRE ROPE

9.6.1 WIRE ROPE INSPECTION

Each day and before use, inspect the wire rope for the following conditions:

1	-Kinking (Sharp bends)	6	-Rope diameter loss
2	-Crushing	7	-Rope strand	uneveness
3	-Unstranding	8	-General corrosion
4	-Birdcaging	9	-Broken strands
5	-Core protrusion	10	-Cut strands

DANGER

the rope eye for abrasion, corrosion and broken wires.

Inspect the wire rope monthly as follows: 1 -The entire length of the rope 2 -The wire rope eye

9.6.2 ROPE REPLACEMENT

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 moves and bends. A wire rope cannot be lubrificated sifficiently during manufacture to last its entire life. Therefore, new lubricant must be added periodically throughout the life of a rope to replace factory lubricant which is used or lost. The surface of some ropes may become covered with dirt, rock dust, or other material during their operation. This covering can prevent field applied lubricants from properly penetrating into the rope. Therefore, these ropes should be cleaned before being lubricated. The lubricant applied should be light bodied enough to penetrate to the core of the rope. Lubricant may be applied effictively by various methods. It may be dripped on, sprayed on, or put on by brushing, but in any case it should be applied at a place where the rope is being bent, such as at a sheave. It shold be applied at the top of the bend, because at that point the strands are spread by bending and are more easily penetrated. The service life of rope will be directly proportional to the effectiveness of the method used and amount of lubricant reaching the working parts of the rope. A proper lubrificant must reduce friction, protect against corrosion, adhere to every wire and be pliable and not crack or separate when cold and yet not drip when warm.

9.7 POSSIBLE FAULTS AND RELEVANT REMEDIES

10 TECHNICAL DATA - WINCH SPECIFICATIONS

SERIES 4400 STANDARD EQUIPMENT
-High speed winch with planetary gears reducer			-	Remote control with connection and 10 m. - 33’ ft. of cable
				or radio remote control
-Negativ brake for winch		-		Proportional monofunction-multifunction hydraulic system
-Load limiting device		-		Solenoid valve with manual functions (only for emergency)
-Rotation with worm-gear		-		Stop-end system for winch (up and down)
TECHNICAL DATA4400
Crane rating				KNm	22
Standard outreach				m	4,80
Slewing angle					400°
Boom elevation					(-5° +80°)
Lifting height from base of crane				m	4.80
Remote control					Proportional
Pump capacity hydraul. “H” (pto)				l/min	10
Working pressure				bar	195
Crane weight				Kg	320
WINCH SPECIFICATION 3304
Winch pull line				daN		1000
Pull line speed	H			m/min		12
	E 12V-24V			m/min		7 -11
Rope diameter				mm		8
Wire rope length				m		30
Cable breaking strength				Kg		minimum 5.155
Technical data not binding

Pict. 24

LOAD CAPACITIES COBRA 4400 LOAD CAPACITIES COBRA 4400

TECHNICAL DATA4400
Crane rating Standard outreach Slewing angle Boom elevation Lifting height from base of crane Remote control Pump capacity hydraul. “H” (pto) Working pressure Crane weight		ft.lbs ft. ft. GPM psi lbs	16.000 15’ 9” 400° (-5° +80°) 15’ 9” Proportional 2.7 2830 700
WINCH SPECIFICATION 3304
Winch pull line Pull line speed Rope diameter Wire rope length Cable breaking strength	H E 12V-24V	lbs ft./min ft./min inch. ft. lbs	2.200 40 23- 36 5/16” 98 minimum 11.365
Technical data not binding

Pict. 25

11 WIRING AND HYDRAULIC DIAGRAMS

11.1 ELECTRICAL DIAGRAMS

Pict. 26

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 -Pressure tansducer VR SC EV9

11.2 HYDRAULIC DIAGRAMS

11.2.1 Hydraulic diagram mono-function proportional

1	Pump
2	Electrohydraulic unit
3	Rotation motor
4	Lifting cylinder
5	Overcenter valve
6	Pressure switch
7

11.2.2 Hydraulic diagram dual-mode proportional

1 Pump 2 Electrohydraulic unit 3 Rotation motor 4 Lifting cylinder 5 Overcenter valve 6 Pressure switch 7 8 Extension cylinder 9 Overcenter valve 10

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: nexthydraulics@tin.it

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