SERVICE CRANE Mod. 5500

6.4.1 AVAILABLE CONTROL VERSIONS

· Single function cable proportional control

17

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,

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.

6.6.1 KEYBOARD DIAGNOSTIC SIGNALS

The following signal devices are found on the radio keyboard: -a beeper -a green led

6.6.2 DISPLAY MESSAGES

As previously explained, the electronic control unit is fitted with a 3 digits display showing messages which help the operator understanding if everything is working properly, the operating state and the functioning of its electrical components. The operator, when led by an expert or following basic operations, can actually read on such display different messages helping him locating possible electrical anomalies on the system. This is a great help for searching and identifying possible faults, preventing useless and unsuitable interventions by the after-sales service. Against possible displays of error messages, the operator is requested to contact the Technical After-Sales Service.

6.6.3 NORMAL DISPLAY MENU

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

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

When the overload condition is almost reached the display shows:

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

In this case you have to carry out the manoeuvres allowing the overload reduction, i.e.: extension re-entry or winch lowering. The boom might be blocked on maximum lift position on some crane models, even without load. To be able to descend with the lifting cylinder, it is necessary to select the extension insertion or the winch descent and immediately afterwards the boom descent followed by the proportional button.

In case of pressure gauge (pressure transducer) signal absence

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

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

Examples: Open circuit alarm on solenoid valve EV3B.

The following table shows all the displayed alarm codes.

The system, through simple operations, allows to enter other menus, which can be helpful for the operatoror a technician from the After-Sales Service.

These menus are:

- -CURRENT DISPLAY MENU (for proportional valve adjustment) -

-WORK PRESSURE DISPLAY MENU

-MOMENTUM LIMITER TYPE SETTING MENU

-RFID (Radio Frequency Identifier) CODE LEARNING MENU

6.6.4 MICRO-SWITCHES AND PRESSURE SWITCH DISPLAY MENU

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

push the proportional button to its maximum level, then operate the 1A and 3B movements simultaneously for at least 5 seconds (the maneuver can be performed in radio mode or through serial cable). . In this menu the state of FA, FB, FV, PM micro-switches are displayed cyclically, with a 2.5 seconds interval; each micro-switch can be in one of the following conditions:

O open C closed

Example: display of the state “FB micro-switch open”

5A 4A

Example: display of the state

3A

“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) ^1B Fb.O Fb.C micro-switch FB (stopped boom limit switch) Fu.O Fu.C micro-switch FV (limit switch on cable diverting pulley / cable lift) Pr.O Pr.C micro-switch PM (digital pressure gauge or analog pressure transducer)

When no operation is activated the electronic control unit automatically switches to the Normal Display Menu after 60 seconds; otherwise a new power-on is required in order to get out of this menu.

6.6.5 CURRENT DISPLAY MENU (proportional regulation)

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

-push the proportional button to its maximum level, then operate the 1A and 4B movements simultaneously for at least 5 seconds (the maneuver can be performed in radio mode or through serial cable). -In this menu, when no operation is active, the indication “Cur” is displayed. When a movement is active the value of the current (in mA) that is driving the proportional solenoid valve is displayed.

Example: indication without any active movement

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

When no operation is activated the electronic control unit automatically switches to the Normal Display Menu after 60 seconds; otherwise a new power-on is required in order to get out of this menu.

6.6.6 REMOTE CONTROL KEYBOARD DISPLAY MENU

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

push the proportional button to its maximum level, then operate the 1A and 2B movements simultaneously for at least 5 seconds (the maneuver can be performed in radio mode or through serial cable). In this menu, when no operation is active, the indication “_ _ _” is displayed. When a movement is active the

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

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.

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

• 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
• Extend the outriggers beams, acting separately on each side of the truck. Their release is made turning 180° upwards the locking handle (2) on picture 15. Pull the beam (1) on picture 15 out for a length of approx. 20 cm (8 in.), then turn again the locking handle 180° downwards in its previous position. Pull again out the outrigger beam, and the locking pin of the handle will automatically engage and lock the beam when its working position is reached. Always extend fully the outrigger beams to their working position (i.e.: maximum opening position) to grant the maximum stability of the vehicle and safety. Always pull and push the outrigger beams acting on the handle (3) on picture 15 foreseen for this purpose, never pull the hoses or piping.

ATTENTION

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

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

Hydraulic jack (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 (hidraulic jack), operate the corresponding lever of the control valve and lower the pad to the ground as described before. When duly positioned, close the valve (1) as described.

ATTENTION

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

• Repeat this sequence of operations for the outrigger jack on the other side of the truck and for every

other jack fitted on the truck. Make sure that the vehicle is level, in order to have a good stability. Maximum allowed angle is 3°.

IMPORTANT

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

7									4
1
									5
2					A	5
3			1	C			6			1 6
			2				4			2
										3
		Pict. 15			Pict. 16			Pict. 17		Pict. 18

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

NOTE Always remember that if the crane is left open on the body and it overcomes the maximum height allowed by the law, it could hit bridges and other obstructions

7.7 MAIN ERRORS OCCURRING WHEN OPERATING THE CRANE

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

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

• 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

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

8.3 SAFETY TIPS FOR CRANE STARTING IN COLD CLIMATES

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

safe way.

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

DANGER

of fire or scald It is forbidden to use naked flame as lighting device when carrying out checks or looking for leaks in the machine.

• Do not lubricate, repair or carry out settings on the crane when it is working, unless this is expressly required in the instructions of the Operator’s/Maintenance manual.
• If it is necessary to lift the crane and/or other parts, make sure that they are locked as requested from current safety regulations
• Always use approved protective clothing, safety gloves and protective glasses when using steel

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 the oil level and lubricate accordingly to the lubricating and greasing chart.
• Replace the filter of the hydraulic oil.
• Make a working test of the crane, with and without the load, take care of listening to strange noises coming from the crane parts.

9.3.4 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)

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

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

Do Not open the rope for inspection. Inspect the rope daily or before use each day and also inspect the rope eye for abrasion, corrosion and broken wires.

Inspect the wire rope monthly as follows:

1 -The entire length of the rope

2 -The wire rope eye

9.6.2 ROPE REPLACEMENT

It is extremely difficult to determine the exact time for replacement of wire rope since many variable factors are involved. Proper determination of the condition of a wire rope depends upon the good judgement of an experienced person in evaluating the remaining strength in a used rope after allowance for deterioration disclosed by inspection. The following reasons are sufficient justification for consideration of rope replacement: 1-Six randomly distributed broken wires in one rope lay or three broken wires in one strand in one rope lay.

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

9.6.3 WIRE ROPE LUBRICATION

Wire rope is lubricated during manufacturing so the strands, and individual wires in strands, may move and adjust as the rope 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

Fault	Cause	Remedy
Vibrations in hydraulic cylinder and jerkings at the first manoeuvres.	The temperature of the hydraulic oil is too low.	Perform manoeuvres without loads for some minutes to warm the oil up.
Vibrations with every functions when the oil is hot.	Lacking of oil in the tank. Air in the hydraulic system.	Add hydraulic oil to the tank. Operate the control lever carrying the cylinders to stroke end for some times in both directions.
All the crane movements are very slow, even when unloaded.	Suction hose from oiltank crushed or obstructed. The pump is drawing in air.	Replace or clean the suction hose. Check that the relevant fittings are well tightened.
The hydraulic extension are not extending in the right sequence.	Bad lubrication. Sliding pads are worn. Sequence valve on extension cylinder has to be adjusted.	Grease the extensions. Replace sliding pads.* Adjust the sequence valve.*
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 pump.
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 (EV2B). Reduce the general max. pressure valve (pict.11)

10 TECHNICAL DATA - WINCH SPECIFICATIONS SERIES 5500 STANDARD EQUIPMENT

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

TECHNICAL DATA5500
Crane rating		KNm	35
Standard outreach		m	5.65
Slewing angle			CONTINUOUS
Boom elevation			(-5° +72°)
Lifting height from base of crane		m	5.65
Remote control			PROPORTIONAL
Pump capacity hydraul. “H” (pto)		l/min	12
Working pressure		bar	175
Crane weight		Kg	480 (E) - 455 (H)
Slewing torque		KNm	3.5
WINCH SPECIFICATION 5500
Winch pull line		daN	1200
Pull line speed	H	m/min	10
	24V	m/min	5 - 9.5
Rope diameter		mm	8
Wire rope length		m	30
Cable breaking strength		Kg	minimum 6050

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 VR -Proportional electro-valve solenoid 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

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	1st. extension cylinder
8	2st. extension cylinder
9	Overcenter valve

10 Sequence valve

NOTES

NEXT HYDRAULICS S.r.l.

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

COPYRIGHT BY NEXT HYDRAULICS S.r.l.

Layout and pubblication by “ Studio Tecnico Pinotti”

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

NEXT HYDRAULICS s.r.l.

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