INDEX

1 FOREWORD --------------------------------------------------------------------------------------------Page --1

1.1 Remarks ------------------------------------------------------------------------------------------------“-----1

2 HOW TO CONSULT THE MANUAL-------------------------------------------------------------------“ -----1

2.1 Instructions ------------------------------------------------------------------------------------------------“-----1

3 CRANE IDENTIFICATION--------------------------------------------------------------------------------“ -----2

3.1 Identification data--------------------------------------------------------------------------------------------“-----2

3.3.1 Name plate description ------------------------------------------------------------------------------------“-----2

3.2 Main crane components identification------------------------------------------------------------------“-----2

3.3 Crane composition------------------------------------------------------------------------------------------“-----3

3.4 Accessories ------------------------------------------------------------------------------------------------“-----4

3.4.1 Winch ------------------------------------------------------------------------------------------------“-----4

3.4.2 Stabilizers ------------------------------------------------------------------------------------------------“-----4

4 COMMISSIONING -----------------------------------------------------------------------------------------“ -----5

4.1 Check list before the first commissioning-------------------------------------------------------------“-----5

4.2 Daily check list --------------------------------------------------------------------------------------------------5

4.3 CE Certification ---------------------------------------------------------------------------------------------------5

5 GENERAL SAFETY RULES -----------------------------------------------------------------------------“ -----5

5.1 Rules concerning persons---------------------------------------------------------------------------------“-----5

5.2 Rules concerning the crane-------------------------------------------------------------------------------“-----5

5.3 Rules concerning safety in the traffic-------------------------------------------------------------------“-----6

6 OPERATING INSTRUCTIONS --------------------------------------------------------------------------“ -----7

6.1 Daily check list----------------------------------------------------------------------------------------------“-----7

6.2 Loader classification and proper usage----------------------------------------------------------------“-----7

6.3 Improper usage----------------------------------------------------------------------------------------------“-----7

6.4 General attentions ------------------------------------------------------------------------------------------“-----7

6.5 Ten basic rules for the safe loader operator-----------------------------------------------------------“-----9

6.6 Instructions for use -----------------------------------------------------------------------------------------“-----9

6.6.1 Thrust slewing system-------------------------------------------------------------------------------------“----10

6.6.2 Crank slewing system -------------------------------------------------------------------------------------“----10

6.6.3 Hydraulic slewing system ---------------------------------------------------------------------------------“ ----11

6.6.4 Boom lifting system by mechanic strut ----------------------------------------------------------------“ ----11

6.6.5 Boom lifting system by hydraulic cylinder ------------------------------------------------------------“ ----12

6.6.6 Two manual extensions boom system -----------------------------------------------------------------“ ----13

6.6.7 Boom system with 1^st hydraulic and 2^nd manual extensions --------------------------------------“ ----14

6.6.8 Hydraulic operating system by hand pump for lifting cylinder------------------------------------“----15

6.6.9 Hydraulic operating system by hand pump for lifting and extension cylinders ---------------“ ----16

6.6.10 Hydraulic operating system by hand pump for extension cylinder ------------------------------“----17

6.6.11 Electro-hydraulic operating system by power unit with one function for lifting cylinder--------------------------------------------------------------------------------------------“----17

6.6.12 Electro-hydraulic operating system by power unit with two functions for lifting and extension cylinders -----------------------------------------------------------------------------------“----18

6.6.13 Electro-hydraulic operating system by power unit with two functions for slewing and lifting cylinder -------------------------------------------------------------------------------------------“ ----19

6.6.14 Electro-hydraulic operating system by power unit with three functions for slewing, lifting and extension cylinders----------------------------------------------------------------------------“----20

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6.7 Accessories --------------------------------------------------------------------------------------------Page -21

6.7.1 Electrical winch----------------------------------------------------------------------------------------------“----21

6.7.2 Manual winch ------------------------------------------------------------------------------------------------“----23

6.7.3 Stabilizer kit ------------------------------------------------------------------------------------------------“ ----24

6.7.4 Back load attachment--------------------------------------------------------------------------------------“----24

6.7.5 Quick fitting kit-----------------------------------------------------------------------------------------------“ ----25

6.8 Main operating errors---------------------------------------------------------------------------------------“----26

7 MAINTENANCE AND CHECKING ---------------------------------------------------------------------“ ----27

7.1 Protection and storage-------------------------------------------------------------------------------------“----27

7.1.1 Short shutdowns --------------------------------------------------------------------------------------------“ ----27

7.1.2 Long shutdowns---------------------------------------------------------------------------------------------“----27

8 MAINTENANCE --------------------------------------------------------------------------------------------“ ----27

8.1 Warnings ------------------------------------------------------------------------------------------------“ ----27

8.1.1 Environmental protection----------------------------------------------------------------------------------“----27

8.2 Maintenance prescriptions--------------------------------------------------------------------------------“----27

8.3 Maintenance schedule-------------------------------------------------------------------------------------“----29

8.3.1 Check list before a working session --------------------------------------------------------------------“ ----29

8.3.2 Quarterly checking------------------------------------------------------------------------------------------“----29

8.3.3 Yearly checking----------------------------------------------------------------------------------------------“ ----29

8.4 Loader servicing---------------------------------------------------------------------------------------------“----29

8.4.1 Oil level checking--------------------------------------------------------------------------------------------“----30

8.4.2 Oil change ------------------------------------------------------------------------------------------------“ ----30

8.4.3 Wear pads checks and replacement -------------------------------------------------------------------“ ----30

8.4.4 Worm gear assembly control-----------------------------------------------------------------------------“ ----31

8.4.5 Thrust rotation brake control ------------------------------------------------------------------------------“----31

8.5 Electric winch maintenance------------------------------------------------------------------------------“----31

8.6 Greases and oils reference table------------------------------------------------------------------------“----32

9 TECHNICAL DATA ----------------------------------------------------------------------------------------“ ----33

9.1 Crane overall dimensions----------------------------------------------------------------------------------“----33

9.2 Stabilizer overall dimensions -----------------------------------------------------------------------------“----33

9.3 Load chart tables--------------------------------------------------------------------------------------------“----34

9.4 Technical specifications -----------------------------------------------------------------------------------“ ----34

9.4.1 Technical data table ----------------------------------------------------------------------------------------“----34

9.4.2 Table of weights for foreseen crane versions ----------------------------------------------------------“----35

9.4.3 Accessories weights table --------------------------------------------------------------------------------“ ----35

10 WIRING AND HYDRAULIC DIAGRAMS -------------------------------------------------------------“ ----35

10.1 Hydraulic diagram hand pump for lifting cylinder-----------------------------------------------------“----35

10.2 Hydraulic diagram hand pump + valve bank for lifting and extension cylinders -----------------------------------------------------------------------------------“----36

10.3 Hydraulic diagram hand pump + valve bank for extension cylinder ------------------------------“----36

10.4 Electro-hydraulic diagram motor pump for lifting cylinder ------------------------------------------“----37

10.5 Electro-hydraulic diagram motor pump for lifting and extension cylinders---------------------“----37

10.6 Electro-hydraulic diagram motor pump for slewing and extension cylinder-------------------“----38

10.7 Electro-hydraulic diagram motor pump for slewing, lifting and extension cylinders----------------------------------------------------------------------------“----38

10.8 Electrical winch wiring diagram--------------------------------------------------------------------------“----39

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1.1 Remarks

This manual gives the guidelines for a correct, safe usage of the loader and its rational maintenance. When daily and constantly applied, these guidelines ensure long service life with minimum maintenance costs, high performance of the

IMPORTANT Referred to information or integration on loader operation.

NOTE Used to draw your attention on information or suggestions to make easier the loader usage for the operator.

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

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CRANE IDENTIFICATION

3.2 Main crane components identification

The main components of a telescopic boom crane are (pict. 2): Button strip

Motor pump

• Slewing support Boom

• Column
• Boom assembly Extension
• cylinder 1^st extension The full crane structure is positioned 2^nd extension
• Operating system

and slews over the rotation support, which is consequently the slewing Liftingsystem housing.

Control valve

cylinderbank SlewingThe column is the slewing component

support

on which the most important Mechanicalarticulation fulcrums allowing boom strutlifting are located. The boom can be

lifted in two ways: Hook

• hydraulically, by means of a attachment
• lifting cylinder;
• manually, by keeping it in fixed position by means of a Hand pump mechanical support strut. ^Crank

slewing The boom assembly is the element ^device allowing load recovering and hooking.

BrakingHydraulic device forIt is consisting of: slewing thrust

• boom, on which the articulation device rotationfulcrums are located;

• extensions, allowing its in & out movements (manual or hydraulic by means of a cylinder); Pict. 2
• hook attachment.

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Finally, the operating system is the hydraulic or electro-hydraulic system transmitting the movement to the actuators (cylinders). It is consisting of a pump (electric or manual) and control system (button strip or hydraulic valve bank). In this type of crane the slewing support and column assembly make up the slewing system, which can be of three types:

• thrust rotation;
• crank rotation (operating a worm screw – worm wheel gear);
• hydraulic (hydraulic motor operating a worm screw – worm wheel gear).

A3	Hydraulic slewing system (6.6.3)
B1	Boom lifting system by mechanical strut (6.6.4)
B2	Boom lifting system by hydraulic cylinder (6.6.5)
C1	Two manual extensions boom system (6.6.6)
C2	Boom system with 1st hydraulic and 2nd manual extensions (6.6.7)
D1	Hydraulic operating system with hand pump for lifting cylinder (6.6.8)
D2	Hydraulic operating system with hand pump for lifting and extension cylinders (6.6.9)
D3	Hydraulic operating system with hand pump for extension cylinder (6.6.10)
D4	Electro-hydraulic operating system by power unit with single function for lifting cylinder (6.6.11)
D5	Electro-hydraulic operating system by power unit with two functions for lifting and extension cylinders (6.6.12) or
	for slewing and lifting cylinder (6.6.13)
D6	Electro-hydraulic operating system by power unit with three functions for slewing, lifting and extension cylinders
	(6.6.14)

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3.4 Accessories

According to crane use, there are accessories whose application is not compulsory, but which are essential in some cases. These are:

Manual winch Electrical winch Back load attachment

Stabilizer Quick fitting system

Pict. 4

• Winch (see chap. 6.7.1 for electrical winch and 6.7.2. for the manual winch);
• Stabilizers (see chap. 6.7.3). The merely optional accessories are:
• Back load attachment (see chap. 6.7.4).
• Quick fitting kit (see chap. 6.7.5).

3.4.1 Winch

The winch is a rope lifting device, which is installed on the crane boom, through proper fastening, and which together with the transmission, coupling and safety devices, becomes an integral part of it The winch is an accessory allowing the vertical load handling. On cranes equipped with mechanic strut, the winch is no longer an accessory, rather an essential component, as it is the only available lifting device. On this crane, the winch can be either mechanical or electrical, and relevant instructions are reported respectively in sub-paragraphs 6.7.1 and 6.7.2.

3.4.2 Stabilizers

The stabilizers are installed on the vehicle to increase stability and prevent overturning. The stabilizers are consisting of rods to whose end a stabilizer leg is applied; such leg is an extendable telescopic tube which lowers and leans on the ground by a plate. Such rods can be either fixed or extendable from a tube fixed on the vehicle, called main beam; the rod locking in this case is made by means of an automatic hooking device. The stabilizer’s instructions for use are listed in sub-paragraph 6.7.3.

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4.1 Check list before the first commissioning

Check that the crane is complete of:

• CE declaration of conformity of the crane manufacturer;
• CE declaration of conformity of the crane installing workshop or self-certification of installation performed according

drops under 0°C, it is essential to replace the oil in the whole circuit by a less viscous one, as indicated in the suggested oil table.

• Carefully read the Operator’s and maintenance manual before commissioning, using, servicing or doing any thing on the loader.
• Read and follow all safety instruction plates applied on the loader before starting up, using, servicing or doing any thing on the loader.
• If the crane is provided with electrical devices, before operating the loader make sure that its voltage (12V) is same as the vehicle one.
• Do not use controls and hoses as handholds: these parts move and cannot provide stable support.
• The operator’s control desk must always be kept clean from oil, grease, mud and snow to avoid accidents due to slippery surfaces.
• The safety instruction plates, notices, load charts and any other sticker applied on the loader must be kept readable and in good conditions. If necessary, replace them. The position of these plates is shown in pict. 5.

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MAX Kg200

12V

Pict. 5

5.3 Rules concerning safety in the traffic

• The machine is an hydraulic loader for lorries and light trucks. The installation on the vehicle must be made in compliance with the relevant national laws and regulations.
• When travelling on roads and public sites always respect the relevant national laws and regulations.

^! DANGER

Before travelling on roads, make sure that the loader is folded in rest position. If the loader is open or lying on vehicle’s body exceeding the overall dimensions allowed by the highway code, it can hit bridges, electric power lines or other obstructions.

• Before driving away, make sure that the levers and the pins securing the outrigger’s beam are fully locked. Accidental slipping out of the outrigger beam during travelling can result in serious accidents.
• Special care must be taken when driving nearby crossroads, level-crossings and subways.

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6.1 Daily check list

• Check the existence of oil leaks;
• Check the correct working of the load limiting device, if installed (see on relevant paragraph);
• Check oil level and fill up if necessary;
• Check the good conditions of hoses and piping;
• Check the good conditions of the winch rope;
• Check the efficiency of thrust rotation brake

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

Preliminary prescriptions:

• The crane must work only if stabilized on flat and thick ground.
• Make sure that the truck is well braked and, if necessary, apply chocks to the tires.

If mechanical stabilizers are used:

• Pull the outrigger’s beams out of their housing till the yellow line painted on it is completely visible, and make sure that the safety pins on the box are perfectly hooked on the beams.
• Lower the outriggers pads down to the ground. Be sure of not entirely lifting up the truck suspensions. It is important for the truck stability that a part of the truck weight still burdens on the tires.

!

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• Never operate the crane without having checked that the outriggers are well positioned on firm ground. If necessary, their bearing area must be increased with additional pads. The truck stability relies very much on the working conditions! When the ground under the outrigger pads is sinking, their bearing area must be increased. The crane Manufacturer can supply additional plates on request with increased area.

Before starting operations:

• Make sure that lifted loads do not exceed the allowed ones for every outreach.
• Make sure that the extension lock pins are correctly inserted and safely locked by their retainers (see pictures 9, 11, 12, 21, 25).

While operating:

•

latch.

• Avoid sudden movements especially during descent. •
• Never stay or walk under hanging loads. • •

any way, these operations must be properly signalled.

•

ground.

•

charged with signalling is required.

General instructions:

•

• •

•

authorized installer workshops.

•

• • Carefully check conditions and wear of the rope and its couplings.
• Check the conditions of the hook and its safety latch.

vehicle.

DANGER DC electric motor overheating. Keep the electric pump running for short periods to avoid its over heating. The maximum working period of the pump depends on the pressure requested by the manoeuvres, but should never exceed 5 minutes in any case, with intervals of 20 min. to enable a sufficient cooling.

ATTENTION It is advisable to start the vehicle engine to avoid running down the battery when operating in a ventilated area without any fire or explosion risks.

Stabilizing the truck:

• Bearing in mind the job to be done, the vehicle has to be positioned in the most convenient position, stopped with the parking brake and the tires blocked.
• The truck engine shall be kept idling to allow batteries’ recharging.
• Extend the outriggers’ beams.

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Always extend fully the outrigger beams to their working position (i.e.: maximum opening position), when foreseen, to grant the maximum stability of the vehicle and safety.

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

6.5 Ten basic rules for the safe loader operator

Always comply with the following ten basic rules:

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6.6.1 Thrust rotation system

Operation:

The thrust rotation system is so called because the operator performs column rotation by pushing on BrakingScrewcrane arm. The system is supported by a friction block

braking device (pict. 6). It is consisting of a block which is locked by a lever on a plastic ring fixed on Ring

lever the slewing column.

Use:

• Before lifting a load, check braking system efficiency by tightening the lever and trying to push the boom without load.
• The operator has to push the crane boom in one

Pict. 6

sense or the other to perform the slewing.

• After the slewing and before performing the vertical load translation with the winch, or lifting by the cylinder, tighten further the brake lever to prevent any slewing caused by load swinging or hunting.

After use:

• Shelter the crane in the min. overall volume position;
• Tighten the brake lever to lock the slewing, in order to prevent it from triggering spontaneously when the vehicle is on the road due to the forces of inertia.

! DANGERS

To perform the thrust slewing, the brake lever must be tightened; the crane must rotate only if pushed by the operator. Keep as far from the load as possible while it is being handled, always making sure that no part of the body is below of it, especially in case of load hunting. We advise against choosing this slewing system in all situations where the crane base may be leaning compared with the horizontal line. Do not lubricate or grease either the block or the plastic ring; this causes a braking reduction.

6.6.2 Crank rotation system

Operation:

This system is consisting of a worm screw/worm wheel gearing protected by a casing and driven by a crank (pict. 7).

Use:

To operate the system, it is necessary to:

• insert the crank in the proper housing made in the worm screw;
• turn in either sense.

Casing

After use:

After the crane has been used, or before re-starting off, pull out the crank and put it back in the lever holder of the hand pump support. If the crane is not provided with hand pump, put the crank inside the boom assembly or in the tools

Crank

compartment.

! DANGERS

Make sure that the slewing stop prevents excessive traction stresses on the hydraulic hoses .

Pict. 7

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6.6.3 Hydraulic slewing system

Use:

To lead the boom to working position the operator has to:

• set the boom almost horizontally;
• pull out the manual extensions (if necessary, and in case of manual extension boom system);
• lift the boom assembly to the desired angle, choosing among those allowed by the mechanic strut holes. To adjust the mechanic strut length you have to:
• support the boom without any load hanging;
• hold the lock pin by its handle and turn it to pull it out of the safety hook;
• lift the boom up to the desired angle, and put the lock pin in until the handle hits against the safety hook, making sure that the handle faces downwards.

After use:

Shelter the crane in the min. overall volume position in correspondence of the specific hole of the strut, by correctly inserting the lock pin into it.

^! DANGERS

• Avoid holding the mechanical strut for any reason; holes may cause shearing in case fingers are trapped into them.
• If the lock pin is not correctly inserted, it can slip out and the boom may fall causing crushing or shearing.
• Exclusively use the lock pin (and not the fingers!) to align the strut profiles’ holes.
• Before lifting a load, make sure the lock pin is correctly inserted; a wrong lock pin insertion may cause its breaking, with consequent load falling.

CORRELATED SAFETY DEVICES

The safety hook prevents lock pin shifting out once it has been completely inserted and turned with handle facing downwards.

6.6.5 Boom lifting system by hydraulic cylinder

Operation:

This system (pict. 10) allows lifting the boom hydraulically by a cylinder fed with oil under pressure. The feeding can be supplied by:

• hand pump;
• electro-hydraulic power unit.

Use:

The use depends on the type of feeding and the operating system it is associated with. Therefore it is necessary to refer to the specific paragraphs.

After use:

Lifting cylinderAlso this phase depends on the type of feeding and the operating system it is associated with. Therefore it is necessary to refer to the specific paragraphs.

Hose

! DANGERS

Sink rate control Dangers depend on the type of valve feeding and the operating system the cylinder is associated with.

CORRELATED SAFETY DEVICES Pict. 10

The safety devices depend on the operating systems.

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6.6.6 Two manual extensions boom system

Operation:

With this system (pict. 11), the extensions can only be manually pulled out, fixing the boom assembly outreach by inserting the lock pins into the properly aligned holes.

Use:

• Place the boom horizontally. To pull out both extensions, proceed as follows:
• pull out the lock pin A holding it by the handle, and turn it to release it from relevant safety hook on the boom;
• pull out 1^st and 2^nd extensions together, until the slot of the 1^st extension is aligned with the hole on the boom;
• insert the lock pin A, locking it back into the safety hook on the boom;
• pull out the lock pin B holding it by the handle, and turn it to release it from relevant safety hook on the 1^st extension;
• pull out the 2^nd extension until the slot allowing to achieve the outreach as near as possible to the desired one is aligned with the hole on the 1^st extension;
• insert the lock pin B, locking it back into the safety hook on the 1^st extension. If you wish to pull out only one extension, it is convenient to extract only the 2^nd one. This allows:
• the same outreach of the 1^st extension;
• an intermediate length;
• a more rapid commissioning, since only one extension must be handled instead of two, and only one lock pin must
• be inserted instead of two. In such case proceed as follows:
• pull out the lock pin A holding it by the handle, and turn it to release it from relevant safety hook on the boom;
• pull out the lock pin B holding it by the handle, and turn it to release it from relevant safety hook on the 1^st extension;
• pull out the 2^nd extension until the slot allowing to achieve the outreach as near as possible to the desired one is aligned with the hole on the boom;
• insert the lock pin A, locking it back into the safety hook on the boom.

After use:

• Put the boom back to horizontal position;
• fully retract the extensions and lock them correctly;
• put the crane back within its min. overall volume position.

1° 2°3° Boom

1^st extension

2nd extension			Pin A
Hook attachment	Middle slot	Pin B

Pict. 11

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DANGERS

• If you wish to pull out only the 2^nd extension with the 1^st one completely retracted, it is necessary to lock the assembly by inserting the lock pin only in the hole on the boom, and not in the hole of the 1^st extension, otherwise the system would not be locked.
• The profiles’ holes may cause shearing if fingers are slipped into them.
• Lock pins extraction with the boom assembly in leaning position increases shearing risk.
• Before lifting a load, make sure the lock pin is correctly inserted; a wrong lock pin insertion may cause

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DANGERS

• Exclusively use the lock pin (and not the fingers!) to align the profiles’ slots.
• Before lifting a load, make sure the lock pin is correctly inserted; a wrong lock pin insertion may cause its breaking.
• The lock pin extraction with the boom assembly in leaning position increases shearing risk.
• The lock pin non-insertion or breaking cause an uncontrolled sliding of the 2^nd extension.

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6.6.9 Hydraulic operating system by hand pump for lifting and extension cylinders

Operation:

The system (pict. 14) is consisting of a manually operated hydraulic pump and a two functions control valve bank with levers equipped with automatic return into neutral position. The valve bank controls are:

• boom lifting lever;
• boom extension lever;

HosesThis system is necessarily Extensionassociated to the following units: Valve bank boom-Boom

• Boom lifting system by levers out loweringhydraulic cylinder; Levers Extension

₁st

• Boom system with protection boom-in

hydraulic and 2^nd manual Overpressureextensions.

valve Boom

Use:

raising

• Operate boom lifting by pulling Valve bank relevant lever on the valve bank (with one hand) and pumping by the pump lever (with the Tank Pump supportPump

other hand).

• Operate the extensions boom-^lever Hand pump out or boom-in by pushing or Pict. 14 pulling relevant lever on the valve bank (with one hand) and operating the pump lever (with the other hand).
• To operate boom lowering, simply push relevant lever forward without pumping. It is convenient to operate as follows to minimize the stress of the operator on the pump lever when handling a load:
• lift the load from the surface it lies on;
• afterwards, hydraulically pull the extension in as much as possible to reduce the stress;
• lift up to the necessary height to place the load in the new position;
• carry out the extension if required.

After use:

• put the crane back within its min. overall volume position;
• remove the lever from the pump and put it back into the support lever holder.

! DANGERS

If the max. allowed load is lifted with the extensions retracted, avoid pushing the extensions out afterwards. This is to prevent risks of:

• crane structure overloading
• vehicle stability loss
• boom descent triggering in case the boom lifting lever is operated again; this is caused by the intervention of the overpressure valve on the valve bank.

CORRELATED SAFETY DEVICES

• The pump overpressure valve, calibrated at 170 bar, prevents lifting weights exceeding the allowed ones.
• The sink rate control valve on the lifting cylinder controls load’s lowering in case of hose breaking.
• Double-acting pilot-operated lock valve on the extension cylinder.

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6.6.10 Hydraulic operating system by hand pump for extension cylinder

This system is necessarily associated to the two manual extensions boom system.

Use:

The button strip connector must be plugged in the specific socket on the motor pump to start the system. Press the upward arrow button to lift the arm; press the downward arrow button to lower the boom.

After use:

• Fully retract the extensions and lock them correctly;
• put the crane back within its min. overall volume position;
• disconnect the button strip from the power unit socket, putting it back in a safe and protected place.

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CORRELATED SAFETY DEVICES

• The power unit overpressure valve, calibrated at 170 bar, prevents lifting Button strip weights exceeding Raising the allowed ones. button
• The sink rate control valve on the lifting

Casing

cylinder controls Cable load’s lowering in case of hose

Lowering

Lifting cylinder

breaking. button

• Load descent control throttle.

Hose

Tank

Connector

Sink rate control valve

Motor pump

Pict. 16

6.6.12 Electro-hydraulic operating system by power unit with two functions for lifting and extension cylinders

Operation:

The operating system (pict. 17) is consisting of an electro-hydraulic power unit operated by the button and controlled by a two functions valve bank with levers equipped with automatic return into neutral position. The valve bank controls are:

• boom lifting lever;
• boom extension lever. This system is necessarily

Use:

• The battery disconnector key must be inserted and turned clockwise to start the system. Hoses
• To operate the Motor start extensions boom-out or button

Batteryboom-in, push or pull

disconnector

relevant lever on the Extensionvalve bank, and keep Valve bank boom-out

Boom button pressed.

the motor starting levers lowering

• To operate boom lifting Extension or lowering, pull or

boom-in

push relevant lever on Leversthe valve bank, always Protection

keeping the motor Boom starting button pressed. raising

Casing Pict. 17

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After use:

• Fully retract the extensions and lock the 2^nd one correctly;
• put the crane back within its min. overall volume position;
• extract the key from the battery disconnector and put it back in a safe and protected place.

ATTENTION If you wish to extend the boom hydraulically once the max. allowed load is lifted to a specific outreach, the overcenter valve on the lifting cylinder intervenes, making the boom lower slowly. This is to prevent risks of:

• crane structure overloading
• vehicle stability loss. CORRELATED SAFETY DEVICES
• •
• The overcenter valve on the lifting cylinder makes the boom lower slowly if the hydraulic extension is operated with the max. allowed loads.
• • The functions are only operated by keeping the power unit starting button pressed. Therefore all functions are stopped when the button is released.

6.6.13 Electro-hydraulic operating system by power unit with two functions for slewing and lifting cylinder

Operation:

This operating system (pict. 18) is consisting of an electro-hydraulic power unit operated by the button and controlled through a two functions valve bank with levers equipped with automatic return into neutral position. The valve bank controls are:

DANGERS

• Make sure that the rotation stop prevents excessive tractive forces on hydraulic hoses.

CORRELATED SAFETY DEVICES

• •

•

After use:

• Fully retract the extensions and lock the 2^nd one correctly;
• put the crane back within its min. overall volume position;
• Make sure that the rotation stop prevents excessive tractive forces on hydraulic hoses.

CORRELATED SAFETY DEVICES

• The control valve overpressure valve, calibrated at 170 bar, prevents lifting weights exceeding the allowed ones.
• The overcenter valve on the lifting cylinder controls load’s lifting and lowering in case the slewing function is operated simultaneously to the lifting function. Moreover it makes the boom lower slowly in case the hydraulic extension is operated with the max. allowed loads.
• The functions are only operated by keeping the power unit starting button pressed. Therefore all functions are stopped when the button is released.

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in contact one another.

• Do not drag the cable with the snub pulley locked, to prevent causing damages and abrasions to the external strands.
• Do not use worn pulleys or pulleys with a flat groove. They do not guarantee a proper support to the rope and may cause its flattening and distortion.
• Prevent the cable from coming into contact with corrosive chemical agents.

CORRELATED SAFETY DEVICES

• The winch negative brake lets the load lower slowly when a weight exceeding 240 kg. is trying to be lifted. This prevents the winch and the crane structure from being overloaded.
• The anti-fleeting device works as stop end switch for the cable; it stops it without causing any damage to it thanks to the negative brake.

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6.7.2 Manual winch

Operation:

To lift the load, turn the crank clockwise. To lower the load turn the crank counter clockwise. Give a sharp counter clockwise blow to the crank handle to facilitate rope unwinding without load.

Use:

To start the system, it is necessary to:

• Do not wear frayed or loose clothes (scarves or ties).
• Do not stay near the winch while it is being used. In case of rope tearing under load, this can produce a strong counterstroke.
• Prevent the complete rope unwinding.
• The rope must be wound on the drum preventing its crushing or bending, and the turns must be perfectly in contact one another.
• Do not drag the cable with the snub pulley locked, to prevent causing damages and abrasions to the external strands.
• Do not use worn pulleys or pulleys with a flat groove. They do not guarantee a proper support to the rope and may cause its flattening and distortion.
• Prevent the cable from coming into contact with corrosive chemical agents.

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6.7.3 Stabilizer kit

cabin, otherwise the crank would not turn and it would interfere with the rod when pulled out. On the contrary, in case of right side installation (pict. 24 B), the main beam must remain on the opposite side to the cabin for the same reason explained above.

6.7.4 Back load attachment

This accessory (pict. 25) brings the hook attachment to a rear position compared to the one allowed by the standard boom assembly. Its application is suggested to:

• handle a particularly bulky load through doors or narrow areas;
• position or lift a load at a very short distance from crane axle, which would be otherwise impossible to achieve with the standard boom assembly.

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This accessory cannot be used:

• when the electrical or manual winch kits are used, because the device is Hexagonal applied on an hexagonal tube which is tube to be slipped into the end of the 2^nd extension, fixing it by its safety lock pin in place of the pulley attachment

Spring catch required for the winch kit; Pin

• on cranes provided with boom lifting system by mechanical strut.

The biggest advantages by this system are achieved on cranes equipped with lifting and extension cylinders. The back load attachment ^{Load back}

Hook attachment

can make up for the winch function if the load is to be placed within the working area drawn by the boom assembly in horizontal position with Pict. 25 fully retracted extensions.

! DANGER

Carefully avoid pulling the load sideways or dragging it on the ground.

6.7.5 Quick fitting kit

The device is consisting of a plate, fixed in Hookinga permanent way to the vehicle platform by profilestie bolts, nuts and lock nuts, which is equipped with a system to lock quickly and Fixed plate safely the crane on the truck.

Hooking Crane fastening: ^profiles

• Open the device by releasing the mobile hooking from its pivot (Pict. 26A);
• Position the crane making it slide on _{Hole for}

Hookingthe plate, and fit the hooking profiles of _padlock profiles

the slewing support in the proper slits of the fixed hooking;

• Lock the opposite hooking profiles of Tie bolts and

the slewing support, engaging again the nuts for platemobile hooking on relevant pivot (Pict.

fixing

26 B);

• Screw manually the hooking nut, engaging it into its proper seat, and tighten it thoroughly, by using an Allen wrench CH 24, in order to prevent the possible unscrewing because of vibrations.

! DANGER

Hole for

The nut, when not correctly tightened, Mobile hooking

padlock

can allow the accidental opening of the mobile hooking, causing crane Hooking nut Pict. 26overturning.

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Antitheft device

When the crane is locked, we suggest to apply the two padlocks supplied with the kit to the proper holes of the mobile hooking pivots. In order to apply the padlocks to such holes it is essential that both nuts are fully screwed.

Checking before fixing the crane:

Check he main structural parts involved by the fixing operation (hooking profiles of the slewing support, mobile hooking, fixed hooking) do not show any deformation or welding with flaws.

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7.1 Protection and storage

7.1.1 Short shutdowns

Wash and clean the loader, lubricate all the parts provided with grease nipples and the worm screw gearing.

• Steel and metal parts when cleaned from grease and other contaminants can de delivered to authorized scrap yards.

8.2 Maintenance prescriptions

Many damages and accidents are caused by a bad maintenance or by mistakes in the maintenance itself. Common causes are recognized to be:

• lacking of oil or grease;
• dirt on loader components or assemblies;
• breaking of ropes or slings;
• safety valves out of service or not in good working conditions;
• hydraulic plant in bad conditions, for instances: hoses damaged, loose hydraulic fittings, etc;
• damaged lifting ropes, snub pulleys, hooks.

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• Every maintenance work has to be carried out with care.
• Do not delay repair or maintenance works on the crane.
• Repair works must be assigned only to qualified, skilled people.
• The recommended procedures of repair and maintenance must always be followed carefully. If necessary ask for a preventive authorization.
• Before taking any part away of the crane, always be sure that the pressure in all the circuits has been discharged.
• Do not put the head or fingers or feet or arms or any other part of the human body into an area where the danger of shearing or crushing exists, if the parts of the machine have not previously locked in a safe way.
• When repair or maintenance operation is over, before putting again the machine into service, make sure that any tool or other piece has not been forgotten in places containing moving parts, or close to them.
• The machine and its accessories has to be kept in good conditions.
• Replace failed or worn components with genuine spare parts or other approved by the Manufacturer.

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8.3 Maintenance schedule

8.3.2 Quarterly checking

•

• Check the absence of oil leaks.
• Check integrity and tightening of loader tie rods and bolts.
• Check integrity and tightening of hoses, piping and their fittings.
• Check fastenings and safety devices. • • • •
• Check the good conditions of the slewing system. a) b)

• •

replace them in a qualified workshop.

8.3.3 Yearly checking

• Wash and clean the crane.
• Check the pressure settings in the hydraulic system. • • • • • • • • • •

ATTENTION Never wash the crane with chemical products or high pressure water jets, as they can cause the detaching of the stickers and water entering inside the electrical components and the slewing case.

8.4 Loader servicing

ATTENTION All grease and hydraulic oils can cause skin damages and irritations. Always protect the hands with suitable gloves before carrying out any operation involving the above.

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8.4.2 Oil change

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8.5 Electric winch maintenance

8.6 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

BEACON

GR MU

ATHESIA

ENERGREASE

LR MP

MP

EP2

EP2

EP2

EP2

HYDRAULIC OIL

AZOLLA

DTE

NUTO

OSO

HYDRUS

HENERGOL

ZS 46•

25

H 46•

46•

46

HL 80

ZS 48*

H 68*

68*

GREASE

WINN'S (GS-80) MOBIL (MOBILTAC D) ESSO (EDL-501)

• For mild and cold climates

* For hot climates

Pict. 29

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9 TECHNICAL DATA

9.1 Crane overall dimensions

Winch overall dimensions

Type A

B

C

D

E

VE

110

160

1180

280

1340

VM

60

210

1160

265

1360

Pict. 30

9.2 Stabilizer overall dimensions

Pict. 31

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9.3 Load chart tables

9.4 Technical specifications
9.4.1 Technical data table
Lifting capacity Max. lifting height from crane base Max. working slope Max. working pressure Electro-hydraulic power unit supply voltage Max. absorption electro-hydraulic power unit Hydraulic oil tank capacity Max. absorption electrical winch		[kNm] [m] [°] [bar] [V] [A] [l] [A]	5.0 3.40 4 170 12 100 1.6 30	[ft*lbs] [ft] [p.s.i.]	3688 11.15 2465.6
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9.4.2 Table of weights for foreseen crane versions

VERSION	Basic crane weight [kg] [lbs]		Crane weight with winch [kg] [lbs]
M50.2M MSF VE (VM)	-	-	63	138.6
M50.2M MLF VE (VM)	-	-	71	156.2
M50.2H PSF VE (VM)	-	-	82	180.4
M50.2H PLF VE (VM)	-	-	90	198
M50.2M PSH	65	143	76	167.2
M50.2M PLH	74	162.8	85	187
M50.2M ESH	61	134.2	72	158.4
M50.2M ELH	70	154	81	178.2
M50.2H PSH	74	162.8	85	187
M50.2H PLH	83	182.6	94	206.8
M50.2H ELH	81	178.2	92	202.4
M50.2M ERH	78	171.6	89	195.8
M50.2H ERH	85	187	96	211.2

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10.2 Hydraulic diagram hand pump + valve bank for lifting and extension cylinders

10.4 Electro-hydraulic diagram motor pump for lifting cylinder

10.6 Electro-hydraulic diagram motor pump for slewing and lifting cylinder

10.8 Electrical winch wiring diagram

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© COPYRIGHT BY NEXT HYDRAULICS S.r.l.

© Ideazione e realizzazione by "Studio Pinotti" R.E.

© Layout and publication by "Studio Pinotti " R.E.

Riproduzione e divulgazione vietati a termine di legge senza autorizzazione scritta della Next Hydraulics S.r.l. Reproduction and distribution are forbidden according to law without written permission in writing from Next Hydraulics S.r.l.