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: 4400W -.............................................................................................................................................. “ 13

6.2 Safety devices ................................................................................................................................................. “ 14

6.2.1 Safety devices installed .................................................................................................................................. “ 14

6.2.2 Load limiting device ........................................................................................................................................ “ 14

6.2.3 Relief valve ...................................................................................................................................................... “ 15

6.2.4 Pilot operated holding valves ......................................................................................................................... “ 15

6.2.5 Safety devices’sealing .................................................................................................................................... “ 15

6.3 Controls description ....................................................................................................................................... “ 16

6.3.1 Electronic power unit ...................................................................................................................................... “ 16

6.3.2 Remote Control Box ....................................................................................................................................... “ 17

6.4 WIRING ........................................................................................................................................................... “ 17

7 OPERATING INSTRUCTIONS......................................................................PAGE 18

7.1 General attentions .................................................................................................................................... “ 18

7.2 Stabilizing the truck ................................................................................................................................... “ 19

7.3 Opening the crane .................................................................................................................................... “ 21

7.4 Closing the crane ..................................................................................................................................... “ 21

7.5 Winch system operation ........................................................................................................................... “ 21

7.6 Before starting traveling on road .............................................................................................................. “ 21

7.7 Main errors occurring when operating the crane ..................................................................................... “ 21

7.8 Standard hand signals ............................................................................................................................. “ 22

8 PUTTING THE CRANE INTO SERVICE ........................................................... “ 23

8.1 Ten rules for the perfect crane operator ................................................................................................... “ 23

8.2 Daily check list .......................................................................................................................................... “ 23

8.3 Crane protection and storage .................................................................................................................. “ 23

8.3.1 Short shutdowns ...................................................................................................................................... “ 23

8.3.2 Long shutdowns ....................................................................................................................................... “ 24

9 MAINTENANCE ............................................................................................... “ 25

9.1 Warnings .................................................................................................................................................. “ 25

9.2 Maintenance prescriptions ....................................................................................................................... “ 25

9.3 Maintenance schedule ............................................................................................................................. “ 26

9.3.1 Daily checking ........................................................................................................................................... “ 26

9.3.2 Monthly checking ...................................................................................................................................... “ 27

9.3.3 Checking every six months....................................................................................................................... “ 27

9.3.4 Others ....................................................................................................................................................... “ 27

9.4 Crane servicing.........................................................................................................................................“ 28

9.4.1 Oil level checking ...................................................................................................................................... “ 28

9.4.2 Oil change ................................................................................................................................................. “ 28

9.4.3 Wormgear assembly control ............................................................................................................... “ 29

9.4.4 Greasing the hydraulic boom sections .................................................................................................... “ 29

9.4.5 Wear pads check and replacement ......................................................................................................... “ 29

9.5 Greases and oils reference table ............................................................................................................ “ 30

9.6 Wire rope .................................................................................................................................................. “ 31

9.6.1 Wire rope inspection ................................................................................................................................ “ 31

9.6.2 Rope replacement .................................................................................................................................... “ 31

9.6.3 Wire rope lubrication ................................................................................................................................ “ 31

9.7 Possible faults and relevant remedies .................................................................................................... “ 33

10 TECHNICAL DATA .......................................................................................... “ 35

Overall dimension .................................................................................................................................... Performances ........................................................................................................................................... Load chart table ........................................................................................................................................

11 WIRING AND HYDRAULIC DIAGRAMS...........................................................“ 37

11.1 Pendant wiring .......................................................................................................................................... “ 37

11.2 Power unit and control wiring ................................................................................................................... “ 38

11.2.2 4400W -wiring diagram ......................................................................................................................... “ 39

11.3 Hydraulic diagrams .................................................................................................................................. “ 40

11.3.1 Hydraulic diagram for E 12V version ........................................................................................................ “ 40

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.

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.

to be taken and tips to be followed.

3 CRANE IDENTIFICATION

3.1 VERSIONS AND OPTIONS AVAILABLE

The service instructions written on this manual are referred to the CRANE MAXILIFT COBRA 4400W. This model is supplied in one only version, the hydraulic circuit is fed by a DC hydraulic power pack connected to the truck battery.

4400W 12V DC single boom hydraulic section, electro-hydr.version

The crane can be supplied with the following option:

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

• 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

5.2 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.

6 63 1L

7
1R
						7
8
2
4	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 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.

Crane ground connection

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:

DANGER

Before traveling on roads,make sure that the crane is folded in rest position. If the crane is open or lying on vehicle’s body exceeding the overall dimensions allowwed by the highway code,it can hit bridges,electric power lines or other obstructions. -Always disconnect the battery isolator before driving away -Before driving away, make sure that the lever of the pin securing the outrigger’s beam is fully locked.Accidental slipping out of the outrigger during traveling can result in serious damages. Special care must be taken when driving nearby crossroads, lever-crossing and subways.

5.5 GENERAL RULES ON WINCH OPERATIONS

5.5.1 Winch system operation

The Winch is mounted at the rear of the first section boom.It has capacities totally indipendent of the rest of the crane 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

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

5 -When lifting a load approaching the rated winch load, raise the load a few inches and return the control to neutral to determine if the brake is working properly.

6 -Do not drag loads 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.

DESCRIPTION OF THE CRANE

6.1 MODEL 4400W

Item Description

1 Slewing system 2 Slewing motor 3 Column 4 Main boom 5 Boom hoist cylinder 6 First hydraulic boom section 7 Second mechanical boom section 8 Telescope cylinder 9 10 Control valve 11 Electric shunt board 12 Remote control box 13 Winch 14 Travelling block 15 Elettro-hydraulic power pack 16 Outrigger beam (mechanical jack) OPTIONAL

7 6 8

4

2

16 5 15

	11
12
	10
	3			Pict. 5

SAFETY DEVICES

6.2.1 Safety devices installed

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

description of safety functions

The crane is fitted with 4 standard electro-hydraulic safety limitations:

service or faulty.

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

6.2.3 Relief valve

The main relief valve is on the electro-hydraulic unit and limits the maximum working pressure.

6.2.4 Pilot operated holding valves

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

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

6.3 CONTROLS DESCRIPTION

This crane is fitted with a standard cable remote control. The remote control system includes a directional electro-hydraulic unit (manifold) (A) and a electronic power unit (B), placed inside the casing behind the column, a remote control box and a wiring system. The electrohydraulic manifold includes an aluminium block equipped with directional electrovalves (EV..A-EV..B) (two each mouvements), a main relief valve (5). The electrovalves (EV3B-EV2B-EV1B-EV1A) are fitted with manual controls, to be used only in case of emergency (remote control box or electronic power unit breakdown). For emergency manoeuvres, fully turn counter-clockwise the manual control of the electrovalve coupled to the desired mouvement and let the electric power pack motor run temporaly, supplying directly relevant relais by the prepared cable from the positive power terminal to the positive solenoid connection, momentarly replacing the existing cable. This way, the motor run until the emergency cable is connected . Keep the motor running only for the short periods required to carry out the emergency manoeuvres. Afterwards, restore the original connection.

6.3.1 Electronic power unit

The electronic control unit, placed inside the near column casing, is a fully sealed component containing the electronic parts with microprocessor logic, due to handle all crane movements and safety device. Two connector for the guide connection to the solenoids and safety device cables jut out of it.

Manifold

A

5

EV3B
B	EV3A	EV2B
	EV2A	EV1B
	EV1A

Pict. 6

16 16

6.3.2 Remote Control Box

The remote control box for single-hand use was designed to give the operator an ergonomic, practical remote control device, and to optimize the several crane functions. It is essentially consisting of a plastic container with protected control panel completely connected to an ergonomic handgrip. On the panel are located the crane operating selectors

(S) in radial arrangement. The pendant panel is fitted with an essential symbology S for the different functions on a green background, which is very agreeable and intuitive for the operator. On the cable end, which can keep its flexibility and handling even under extreme conditions, is applied the connector to the control unit. All moving operations are carried out by the remote control box. The pendant controller is supplied by plugging the connector on the socket placed by the side on the control casing, (see pict 7).

Operation is as follows: Pict.7

1) push and hold the button P 2) operate the toggle switch selector of the

LED

choosen function

D

3) the green led lights up and the crane starts moving

C

On the pendant control box the following controls are available, as shown in pict.8

B
A B	--	crane slewing boom raising/lowering	P	A
C D	--	boom extension in/out winch raising/lowering			Pict. 8
P	-	power button
LED	-	(green) showing that one or more
		function are activated

6.4 WIRING (pict.9)

The system is consisting of two fully independent wiring systems, which are connected to the electronic control 2 unit through tight multipolar connectors (1) fitted with a quick coupling system. The first wiring (2) includes the solenoids for the connection, of the operation valves which are located 3 on the hydraulic unit, to the electronic control unit. The ¹ second wiring (3) connects the control unit to the safety Pict.9 stop ends (FA – FB – FV), to the pressure switch (PM), and to the power supply. Rev.1

17

04/06

7 OPERATING INSTRUCTIONS

7.2 STABILIZING THE TRUCK

• • Bearing in mind the job to be done, the vehicle has to be positioned in the most convenient position, stopped with the parking brake and the tires blocked.
• The hydraulic circuit of the crane shall be activated as follows:

Cranes driven by DC power pack

The DC power pack is connected with the truck battery. The electric pump will start every time a switch of the remote control is moved. The crane can work even when the engine of the truck is off, but it is strongly

vehicle.

This battery switch must be turned on (or off) every time the crane starts (or terminates) the working session.

to enable a sufficient cooling.

2) on picture 10. Pull the beam (1) on picture 10 out for a length of approx. 20 cm (8 in.), then turn again the locking handle 180° downwards in its previous position. Pull again out the outrigger beam, and the locking pin of the handle

for this purpose.

7.3 OPENING THE CRANE

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

7.4 CLOSING THE CRANE

Closing the crane into rest position is performed by carrying out the opposite movements to those made to open it, taking special care , at the end of the operation there are no parts protruding from the truck size. Disconnect the control board connection and save it in the driver’s cab.

7.7 MAIN ERRORS OCCURRING WHEN OPERATING THE CRANE

Because of lacking of care or of adequate instructions, some dangers may occur during crane operation. Most common errors are:

• Slinging of loads exceeding the crane capacity: always check their actual weight not to overload the crane or the winch. Special care has to be taken when handling big loads, when free they can remain hanging on the crane and result in damages and accidents.

Rev.1 04/06

• A sudden stop when lowering a load. This creates high forces of inertia on the crane structure with rele vant dangerous overload.
• Hitting the rope where the load is suspended, overload is generated.
• Side pull, dragging the load on the ground. All these operations originate strong overloading forces on the crane.
• The outriggers are badly positioned or the ground is not firm: in both cases the truck tilts and could tip over.
• Working with strong wind or wind gusts
• The manual boom sections are not correctly installed.
• The load is not correctly slinged. So the lifting accessory used (chain, rope, etc) breaks or flips out and the load falls down to earth. The boom, suddenly unloaded, springs back and this could result in tipping

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.

8.3.1 Short shutdowns

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

8.3.2 Long shutdowns

Same precautions as above and, moreover:

• apply protective oil on the entire crane surface
• cover the crane using a plastic curtain against rain etc.
• store in a dry place, under roof
• disconnect the connections to the truck battery.

9 MAINTENANCE

9.2 MAINTENANCE PRESCRIPTIONS

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.
• The recommended procedures of repair and maintenance must always be followed carefully. If ne
• 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.

9.3.1 Daily 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.
• • Visually check all the structural components for any deformation, backlash or crack out.
• 
• Check the oil level and lubricate accordingly to the lubricating and greasing chart.
• Check the regular working of the slewing system, grease with the suggested grease the worm and the worm gear, replace the grease brush spreader if worn.
• Make a working test of the crane, with and without the load, paying attention to possible unusual noises coming from the crane parts.
• Grease the hydraulic boom sections.

9.3.3 Checking every six moths

• Wash and clean the crane

Never wash the crane with chemical products or high pressure water jets, as they can cause the

case.

• Check the pressure settings in the hydraulic system.
• Check the absence of oil leaks.
• Check integrity and tightening of crane tie rods and bolts.
• Make a safety test of the hydraulic system.
• Make a working test of the crane, with and without the load, take care of listening to strange noises coming from the crane parts.

9.3.4 Others

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

9.4 CRANE SERVICING

9.4.1 Oil level checking

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

9.4.2 Oil change

The oil deteriorates during daily usage. The oil change every year is necessary to avoid damages to the

Pict. 15

9.4.3 Wormgear assembly control (Pict. 16)

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.

9.4.4 Greasing the hydraulic boom sections (Pict. 17)

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

the grease

9.4.5 Wear pads check and replacement

Wear pads need to be replaced when their thickness drops under 5.5 mm (0.22 inch.)

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

9.6.3 WIRE ROPE LUBRICATION

1 -When there are either 3 broken wires in one strand or a total of six broken wires in all strands in any one rope lay.
2 -When flat spots on the outer wires appear and those outside wires are less than 2/3 the thickness of the unworn
3 -When there is a decrease of diameter indicating a core failure
4 -When kinking, crushing, birdcaging or other distortion occurs
5 -When there is noticeable heat damage (discoloration) of the rope by any means
6 -When the diameter is reduced from nominal size by 0.8 mm (1/32”) or more
7 -If a broken wire protrudes or lops out from the core of the rope

Wire 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.
Crane rotation not regular. he crane does not lift the loads of the	The truck is not correctly levelled. Worn slewing motor.	Level the truck. Replace slewing motor.
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. he DC electric motor does not run.	Defective holding valves. Worn sealings in the stabilizer cylinder.	Clean or replace holding valves.* Replace worn sealings.*
T	Truck battery discharged. Electric connections are damaged. Burned fuses Motor windings are burnt.	Charge battery. Check electrical wirings, terminals, connections and their integrity. Replace fuses Replace the electric motor.
DC electric motor overheating.	Too long running time.	Running periods are to be shortened and their intervals to be elongated.
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 (VB2). Reduce the general max. pressure valve

Fault ension lack in the control box	Cause	Remedy
T	Discharged battery. Disconnected electric coupling Burned fuses	Recharge the battery. Join correctly the connection.Replace the electric coupling.* Replace fuses
A manoeuvre does not work.	Defective switch Burned solenoid. Locked valve cartridge Damaged electric connection.	Replace the switch Replace the solenoid. Disassemble and clean the valve cartridge Check continuity of the circuit

10 TECHNICAL DATA - WINCH SPECIFICATIONS SERIES 4400W STANDARD EQUIPMENT

WIRING AND HYDRAULIC DIAGRAMS 11 WIRING AND HYDRAULIC DIAGRAMS

11.1 WIRING DIAGRAMS

11.1.1 Pendant and control wirings

Pict. 21

A	-Remote control box	1A	-Clockwise rotation magnet
B	-Electronic power unit	1B	-Counter clockwise rotation magnet
C	-Limit switch wiring	2A	-Boom raising magnet
D	-Solenoid wiring	2B	-Boom lowering magnet
SW1	-Crane rotation selector	3A	-Boom extension magnet
SW2	-Boom movement selector	3B	-Boom re-entry magnet
SW3	-Extension selector	FA	-Winch lowering stop end system
SW4	-Winch selector	FB	-Boom lowering stop end system
L1	-Green led	FV	-Snatch block stop end system
J1	-24 poles female connector	PM	-Pressure switch solenoid
J2	-24 poles female connector	P1	-Emergency push button
J5	-10 poles male connector
J6	-10 poles female connector
VM	-Max pressure valve

Pict. 22

Rev.1 04/06

11.2.2 4400W -wiring diagram

8
7
6							5		9
1 2 3 4 5 6 7 8 9	Battery Starting Key Fuse protection Electronic power unit Electro-hydraulic power pack Power pack switch Electric winch’s contactor pack Electric winch Battery switch		4		3	2		1		Pict. 23

Rev.2 02/08

11.2 HYDRAULIC DIAGRAMS

11.2.1 HYDRAULIC DIAGRAM FOR E 12V VERSION

1 Pump 2 Electrohydraulic unit 3 Rotation motor 4 Lifting cylinder 5 Overcenter valve 6 Pressure switch 7 8 Cylinder 9 Overcenter valve 10 11 Oil filter 12 Oil tank 13

NEXT HYDRAULICS S.r.l.

Via della Costituzione, 25 Poviglio (RE) - ITALY Tel. 0522/960707 - Fax 0522/967197

COPYRIGHT BY NEXT HYDRAULICS S.r.l.

Layout and pubblication by “STM Studio Tecnico Associato”

Reproduction and distribution are forbidden according to law without written permission in writing from Next Hydraulics S.r.l.

NEXT HYDRAULIC S.r.l.

Via Mediterraneo 6 42022 BORETTO (Reggio E.) -Italy Tel. 0522 / 96 30 08 - Fax 0522 / 96 30 39 - info@maxiliftcrane.com