Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
12000
Code MD.0.187
Rev
Edition
0
07/09
USE AND MAINTENANCE MANUAL
OPTIONALS SUPPLIED ALONG WITH THE CRANE
Description YES NO
Oil tank
Outrigger beam - (hydraulic jack)
The table has to be filled carefully with the above option when purchased
PRELIMINARY INFORMATION
SERIAL NO:..............................................................
YEAR OF MANUFACTURING:.................................
ATTENTION
Always carefully read this manual before operating the crane. Most of the accidents occurred during opera-
tions are caused by the omission of elementary precautions and non fulfillment of the safety instructions.
Many accidents can be avoided when their causes are well known and the relevant adequate counter mea-
sures are previously taken.
INDEX
1 FOREWORD .................................................................................................. PAGE 1
1.1 Summary ........................................................................................................................................................ “ 1
1.2 Remarks ......................................................................................................................................................... “ 1
1.3 Manual revision ............................................................................................................................................... “ 2
I
6.6 Signal and diagnostic ............................................................................................................................ Page 23
6.6.1 Keyboard diagnostic signal ............................................................................................................................ “ 23
6.6.2 Display messages ......................................................................................................................................... “ 24
6.6.3 Normal display menu ..................................................................................................................................... “ 24
6.6.4 Micro-switches and pressure switch display menu ...................................................................................... “ 26
6.6.5 Current display menu ..................................................................................................................................... “ 26
6.6.6 Remote control keyboard display menu ........................................................................................................ “ 27
6.6.7 Work pressure display menu ......................................................................................................................... “ 28
9 MAINTENANCE ................................................................................................................ “ 36
9.1 Warnings ........................................................................................................................................................ “ 36
9.2 Maintenance prescriptions ............................................................................................................................. “ 36
9.3 Maintenance schedule ................................................................................................................................... “ 37
9.3.1 Daily checking ................................................................................................................................................. “ 37
9.3.2 Monthly checking ............................................................................................................................................ “ 38
9.3.3 Checking every six months ............................................................................................................................. “ 38
9.3.4 Others ............................................................................................................................................................. “ 38
9.4 Crane servicing ............................................................................................................................................... “ 39
9.4.1 Oil level checking ............................................................................................................................................ “ 39
9.4.2 Oil change ....................................................................................................................................................... “ 39
9.4.3 Oil filter cartridge maintenance ...................................................................................................................... “ 39
9.4.4 Slewing mechanism maintenance ................................................................................................................ “ 40
9.4.5 Greasing the hydraulic boom sections .......................................................................................................... “ 40
9.4.6 Wear pads check and replacement ............................................................................................................... “ 40
9.5 Greases and oils reference table .................................................................................................................. “ 41
9.6 Wire rope ........................................................................................................................................................ “ 42
9.6.1 Wire rope inspection ...................................................................................................................................... “ 42
9.6.2 Rope replacement .......................................................................................................................................... “ 42
9.6.3 Wire rope lubrication ...................................................................................................................................... “ 43
9.7 Possible faults and relevant remedies .......................................................................................................... “ 44
II
1 FOREWORD
1.1 SUMMARY
This manual is divided into chapters to make its consultation easier.
ATTENTION
As far as safety is concerned it is strongly recommended to carefully read the safety tips of the
chapter, SAFETY RULES.
ATTENTION
Should some or any part of this manual be not clear, please contact the Manufacturer.
IMPORTANT
When receiving this manual, check if all the data are correct. Inform the Manufacturer if so-
mething is found wrong.
1
NOTE
The table on the back of the front page has to be filled at customer’s care. It contains all the ne-
cessary 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.
1.3 MANUAL REVISION
Should be necessary to carry some modification on the crane, they must be authorized by the Manufacturer
which also takes the commitment of manual updating. Revised or added pages will be mailed to the Custo-
mer and shall be inserted in the manual at his care and cost.
! DANGER
Referred to dangers related to the described activity, when the safety of people is concerned.
ATTENTION
Referred to dangers related to the described activity, mainly when the safety of things is concer-
ned (for instance, damage of the load or of the crane).
IMPORTANT
Referred to information or integration on crane operation.
NOTE
Used to draw your attention on information or suggestions to make easier the crane 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.
! DANGER
In this manual the crane is shown in many pictures with its panels or covers removed for a better evidence.
It is forbidden to use and operate the crane with panels, covers and other safety devices removed.
2
3 CRANE IDENTIFICATION
3.1 VERSIONS AND OPTIONS AVAILABLE
The service instructions written on this manual are referred to the CRANE MAXILIFT COBRA 12000. This
model is supplied in four version. When ordering, are to be specified:
Pict. 1
3
4 CRANE USAGE AND LIMITS OF APPLICATIONS
4.1 CRANE CLASSIFICATION AND PROPER USAGE
The machine is an hydraulic truck crane for hook service. It can also be used for the same purpose from a
static mounting. The lifting capacity is 9,2 ton-meter (66,500 ft. lbs.), making it especially suitable for instal-
lation 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
It is forbidden:
• To use the crane in different operations from those it has been designed and built for. (see above
point 4.1).
• To use the crane with attachment like: grabs, clamshells, magnets and so on.
• Pulling loads with crane in horizontal position.
• To operate the crane with procedures different from those described in this manual, or using componen
ts and attachments not approved when the crane was designed.
• Non observance of the established maintenance programs.
• Non observance of safety rules.
• To make modifications involving crane components or parameters related to the working cycle.
• The unauthorized use of captive spare parts and components not specifically approved by the Manufac
turer.
• To carry out modifications or structural interventions without the approval of the Manufacturer.
• To operate the crane out of the admittable range of temperatures:
• -30° C/ +50° C (-22 °F/ + 122 °F).
Any of the above mentioned improper usages or non observance will cause:
• immediate cancellation of the Manufacturer Warranty
• cancellation of Manufacturer liability for damage of people, animals, things.
ATTENTION
The improper usage can damage the crane and subsequently result in dangerous situations for
the staff entitled to its operation.
4.3 CRANE OPERATOR’S TRAINING
The crane must be operated only by skilled people trained for this purpose.
This people will be asked for:
• a basic technical education and a working experience in the mechanical, hydraulic and electrical field;
• a technical knowledge of cranes operation, covering all the points, especially the load charts and the
truck stability against tipping over;
• practical knowledge of slings usage and precautions when moving the loads;
• complete knowledge of all the operations and motions to be executed with the crane; competent and
qualified personnel of the authorized workshop which has installed the crane will take care of
this;
• complete reading and understanding of this manual;
• complete knowledge and understanding of safety and risk avoidance regulations;
• Vision of at least 20/30 Snellen in one eye and 20/50 in the other, with or without the aid of corrective
lenses;
4
• 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.
5
5 SAFETY RULES
5.1 RULES CONCERNING PEOPLE
• Always wear the prescribed personal safety devices
• Always wear approved accident-prevention clothing such as: protective helmets, anti-slip shoes, protec
tive gloves, antinoise headphones, protective glasses, reflective jackets with breathing apparatus. Con
sult your employer regarding current safety regulations and accident-prevention equipment.
• Do not wear ring, wristwatches, jewelry, loose-fitting or hanging clothing such as ties, torn garments,
scarves, unbuttoned ja-ckets or unzipped overalls, which could get caught up in the moving parts of the
crane.
• Keep quickly and readily available on the truck a first-aid box and a fire extinguisher. The fire extin
guisher must always be kept charged and has to be used according to current regulations.
5.2 RULES CONCERNING THE CRANE
• The Manufacturer is not liable for accidents occurred during the usage of the crane caused by non
fulfillment from the opera tor’s side of current rules, laws and regulations.
• The crane is designed to be used within the -30°/+50° (-22 °F/ +122 °F) temperature range and has to be
operated only in this range. The manufacturer is not liable for accidents occurred during the usage of
the crane outside this temperature range.
• Carefully read the Operator’s and maintenance manual before starting up, using, servicing or doing any
thing on the crane.
• Read and follow all the safety instruction plates applied on the crane before starting up, using, servicing
or doing anything on the crane.
• Do not use controls and hoses as handholds: these parts move and cannot provide stable support.
Furthermore, a control mistakenly moving can accidentally set the crane in motion.
• The operator’s control desk must always be kept clean from oil, grease, mud, snow to avoid accidents
due to slippery surface.
• The safety instruction plates, notices, load charts and any other sticker applied on The crane must be
kept readable and in good conditions. If necessary, replace them. The position of these plates is shown
in the following picture.
6 3
6
1R
7
2
2
7
1L
8
5
4
Pict. 2
6
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
middle of the additional plates. The required bearing surface can be easily calculated as follows
when the outrigger’s reaction and the admittable pressure on the ground are known. Outrigger’s
reaction: look at the plate applied on the outrigger jack. Admittable pressure on various types of soils:
look at the following table for indicative values.
Bearing pressure calculation
When: Then:
t = outrigger’s reaction (tons) (US ton) p = bearing pressure on ground (daN/cm2) (lbs./Sq.in.)
A = bearing plate surface (cm2) (sq. in.)
p = (1000 • t) : A (metric)
p = (2000 • t) : A (U.S.A.)
ATTENTION
In case of doubts on the ground carrying capacity, make a hardness test of the ground.
Always level the crane acting on outriggers with reference to the level indicator fitted on the truck. Maximum
admittable angle is 3°.
5.3.2Safety distance from trencher and slopes
The crane must be positioned sufficiently far away from trenches or slopes. The safety distance depends
also on the soil, if the slopes or trenches are not sustained. Rule of the thumb: (look at the following picture)
7
• for brought-back or crumbling terrain safety distance (a) must be double of the slopes’ depth that is:
a=2•b
• for compacted, not crumbling terrain safety distance (a) must be equal to the slopes’ depth, that is:
a=1•b
Distance to be measured from point ©
Max. reaction on the ground varies according to the vehicle where the crane is installed.
IMPORTANT
The installer must calculate this max. reaction on the ground and applied the value on the ou-
trigger jacks.
Pict. 3
! DANGER
Always keep a sufficient safety distance from electric power lines. Follow present law regula-
tions. When the voltage of the lines is unknown keep a minimum safety distance of at least
5m (20 ft.)
5.3.4Crane and load ground connection
The crane can be electrostatically charged, especially when the additional bearing plates are made of insu-
lating materials (wood, plastics) It has to be noted that, even when the crane has been connected to ground,
the load can be loaded electrostatically charged, because the rope pulleys or the slings and ropes used to
lift the load are made of insulating materials.
! DANGER
Always connect to ground both the crane and its load before starting operations
8
Grounding is especially required when:
• working close to electric power lines;
• working nearby powerful broadcasting plants such as radio, T.V., an so on
• working nearby electricity plants where high frequency is involved
• when a storm is approaching
! DANGER
electrocution hazard
While grounding the crane, carefully follow the below mentioned instructions, in order to avoid
electrocution hazard
NOTE
Arrange the linkage for ground connection and the relevant symbol
• connect the remaining end of the cable with the point of connection indicated en on the crane base.
DANGER
electrocution hazard
The ground cable must be connected only on the indicated point on the crane base. Avoid any
linkage to screwed on parts of the crane, such as valves, cover plates, gearboxes, etc.
! DANGER
electrocution hazard
Always ground the crane perfectly.
Load ground connection
In order to avoid the electrostatic charging of the load it is necessary to use:
• a metal rod having a good conductivity, with a length of 1.5 meters (5 ft.) roughly, to be driven into the
ground, at least 1 meter (4 ft.) deep.
• a power cable with a minimum cross section of 16 mm2 (0,025 sq. in.).
• a second metal rod, having good conductivity and an insulating handle complying to the relevant safety
Regulations. This rod has to be used to touch the load.
• Then connect this cable to the ground rod on one side. Moinsten the ground all around the rod to
improve conductivity.
• Then connect the other side of the cable to the insulated rod. Both connections must be made using the
relevant vices or metal clamps as an alternative.
9
! DANGER
electrocution hazard
Always connect in a perfect way the load and the ground
Before touching the load with your hands, always ground the load by touching it with the insulated rod.
! DANGER
electrocution hazard
Always hold the rod by its insulated handle.
5.3.5 Influence of the wind on the crane operation
A strong wind can overload the crane, so during operations keep under control the wind speed. When
working with full load, the maximum admittable wind speed is 45 km/h (28 mile/h).
When this value is exceeded, any crane operation must be stopped and the crane must be brought to the
rest position. Since the maximum working height of the crane is reasonable, refer to the following table to
evaluate the possible wind effect:
! DANGER
Before traveling on roads,make sure that the crane is folded in rest position. If the crane is open
or lying on vehicle’s body exceeding the overall dimensions allowwed by the highway code,it can
hit bridges,electric power lines or other obstructions.
-Before driving away,make sure that the lever of the pin securing the outrigger’s beam is fully locked.Accidental
slipping out of the outrigger during traveling can result in serious damages. Special care must be taken
when driving nearby crossroads, lever-crossing and subways.
10
5.5 GENERAL RULES ON WINCH OPERATIONS
11
5.6 WIRE ROPE
5.6.1General
Wire rope can be the weak link in crane safety. It is subjected to heavy loads, abrasion, kinking, extreme
weather conditions, chemical attack and other forces which can reduce its reliability. The inspection and
care of wire rope is essential in the effort to provide for safe working conditions.
5.6.2Wire rope precautions
1 - Avoid the formation of kinks. Kinks will cause severe weakness in the rope. No corrections are availa
ble for kinked rope.
2 - Do not drag wire rope over a non-rotating support such as a non-functioning sheave. Severe abrasion
caused to outer wire strands will result from friction.
3 - Do not use worn sheaves or flat grooved sheaves. They do not provide support to the full radius of the
rope. Flattening and distortion will result.
4 - Do not use nicked or otherwise broken sheaves. Necks and cracks in sheaves will cut the wire rope.
5 - Evenly wrap wire rope onto the drum. Uneveness will cause crusking and/or crimping of the rope.
6 - Select replacement wire rope to match the capacity and use of the crane. The crane was originally
equipped with appropriate wire rope.
7 - Do not expose the rope to corrosive chemicals.
8 - Lubricate the rope frequently to reduce friction and help prevent corrosion.
6.7.1 REMOTE CONTROL USE
Pict. 4
12
6 DESCRIPTION OF THE CRANE
6.1 MODEL 12000.2L H
Item Description
7
9
6 8
4
14
13
5
2 11
18
12
15 3
17
16 10
Pict. 5
13
6.2 MODEL 12000.3L H
Item Description
19
9
20
14 7 8
6
4
13
5
2 11
18
12
15
3
17 16
Pict. 6 10
14
6.3 SAFETY DEVICES
6.3.1Safety devices installed
All the safety devices,installed on MAXILIFT COBRA 12000 crane, are listed and described in the following
pages.
ATTENTION
It is strictly forbidden to alter or manipulate the safety devices
Before operating the crane make sure that all the safety devices are in perfect working conditions
! DANGER
The load limiting device, even when in perfect working condition, cannot avoid accidents due to
operator’s maneuvering mistakes.
! DANGER
It is strictly forbidden to operate the crane with its load limiting device switched off or put out of
service or faulty.
NOTE
The load limiting device can lock at the max. main boom angle even without load.
In such case, in orer to unlock the machine it is necessary to act simultaneosly both on the ex-
tension re-entry and boom lowering levers.
15
6.3.3 Relief valve
The main relief valve is on the control valve and limits the maximum working pressure.
! DANGER
The removal of sealing by non authorized personnel, or a sealing not complying to manufacturer
specifications results in an improper usage of the crane.
16
6.4 MICROPROCESSOR REMOTE CONTROL SYSTEM
COBRA cranes are equipped with an advanced microprocessor remote control system that correctly manages
the crane operations as well as its safety devices and provides indications to help the operator performing rapid
troubleshooting or adjustments when necessary.
4
Pict.7
2
Pict.8
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,
it enhances the medium/large range reception field (considering the 868 MHz transmitter reduced power).
A supplementary unit (7 function radio) is available upon request; it is similar to the main one and it activates
two auxiliary functions (on the OPT1 – OPT2 radio button) that control the diesel engine acceleration or turns
on-off a motor-compressor (generator).
The keyboard, which can be used with a single hand, has been studied to provide the operator with an
ergonomic and practical remote control device to optimize the different crane functions.
It is mainly made up of a plastic container with a protected control panel integrally connected to a supporting
ergonomic handgrip.
Five radial selectors (S) that control machine
maneuvers are found on the panel (4 for crane
movements, 1 for engine START/STOP). The P L start-stop
safety stop emergency button (P) is located over
the maneuver selectors; it must also be used
as keyboard on/off button.
The green indication Led (L) is found aside the
emergency button and the diesel engine START/
S
STOP selector, if these two functions are
activated.
The system foresees the possibility to
supply and control these two external functions.
The keyboard panel is provided with the
essential function-guiding symbols with green
background; it results pleasant and intuitive for
the operator.
The movement speed that has been pre-
established through the maneuver selectors, (S)
can be controlled through the potentiometric
button that is housed on the bottom of the
handgrip.
The control unit connector is applied at the end
of the cable; such cable remains flexible and Pict.9
easy to handle even if exposed to extreme
conditions.
18
6.4.5 THE KEYBOARD – RADIO TRANSMITTER (Pict.10)
WARNING
Verify the emergency button correct operation (5) before using the radio control.
The radio control must be turned off when operations are suspended by pressing the
emergency button (5).
The keyboard box must only be opened in case of repair or anomaly.
N.B. Never let the crane work with disabled emergency button.
WARNING
When the cable keyboard is not being used, it must be disconnected from the connector
located on the guard aside the unit where the protection cover will be screwed.
Press the mushroom button of the cable and radio keyboards after their use and before storing
them on a protected and safe place.
The radio keyboard batteries last from 12 to 24 hours depending on their use.
It is suggested to let the batteries discharge until they are completely flat before starting a new
recharge cycle.
19
6.4.5.1 RADIO SYSTEM PROTECTION DEVICES
The radio control system is provided with some protection systems that are automatically started in case of:
- radio interference on the crane working area that influences the radio control frequency range
- transmitter capacity field exceeded (keyboard)
On these cases the system locks all the functions.
Press and release the emergency button to restore the functions
In addition, when the battery charge is too low for safety operations the system is blocked, the green LED
turns off and the radio module interrupts transmissions with the unit.
The keyboard is provided with battery energy saving system to reduce battery consumption.
When the keyboard remains unused for at least 15 minutes, the radio system is set to “energy save”, the
green led turns off and the radio module interrupts the transmission with the unit (receiver).
Press and release the emergency button to unblock.
EV2A EV1B
EV1A
20 Pict.11
6.4.7 PROPORTIONAL DUAL-MODE REGULATION HYDRAULIC UNIT (Pict.12)
EV1A Pict.12
ATTENTION
Do not operate the proportional button
before selecting the movement: it will not
work.
Do not pull immediately the proportional P
button to its maximum limit: you will not get
the right gradualness and the movements
will be jerking and dangerous.
Pict.14
Always release first the proportional but-
ton, and then the selector of the movement
chosen.
The dual-mode remote control can be normally used as a mono-function remote control when following the
instructions of previous paragraph.
The remote control in object allows the combination of two movements at the same time by coupling the winch
function (raising or lowering) to one of the remaining movements.
You always have to select first the two functions chosen, and then to operate the proportional button metering the speed,
in order to achieve the desired speed, even allowing at the same time the winch rope raising or lowering.
By releasing one of the movements the speed of the other one does not increase until the function is stopped.
By this way of operating the two speeds are nearly halved in comparison to the use of a single function.
22
6.6 SIGNALS AND DIAGNOSTIC
6.6.1 KEYBOARD DIAGNOSTIC SIGNALS
Beeper signals:
Radio connection keyboard:
- a brief signal (beep) indicates that the keyboard is powered (through the emergency button)
- a long signal (beep) indicates that the RFID code (radio frequency identifier, exclusively used by
authorized workshops) self-learning procedure has been activated.
- four brief signals indicate that the keyboard has switched to energy save mode or that battery charge is
not enough.
Cable connection keyboard (serial):
- a brief signal (beep) indicates that the serial cable has been connected
Led signals:
Radio connection keyboard:
- led ON indicates that the keyboard is supplied, the emergency button is released and the battery level is
enough to work.
- slow continuous blinking led indicates that the keyboard is supplied and the battery charge level is too
low to work.
- led off indicates that the keyboard is in energy save mode or out of service due to insufficient battery
charge level or that the proportional button is switched on
- a continuous and fast blinking signal indicates that the keyboard is tuned to the auxiliary channel, for
example when the RFID code (radio frequency identifier, exclusively used by authorized workshops) self-
learning function is used.
Cable connection keyboard (serial):
- led with intermittent blink (two blinks followed by a pause), indicates battery recharge mode
- led ON indicates that the keyboard is supplied (for example that the serial cable is connected) and is
ready to be used; during battery recharge it indicates that a function has been activated;
- led OFF indicates that the keyboard does not recharge the batteries and that the emergency button is
pressed.
NOTE: every time that the serial cable is connected, the keyboard performs the battery status control for
about 3 seconds, afterwards, the recharge procedure is automatically started if no errors are found.
Beeper signals:
- a brief signal (beep) indicates that the keyboard is powered (connected cable and emergency button
switched off)
Led signals:
- led ON indicates that the keyboard is supplied, the emergency button is released
- led OFF indicates that the keyboard is out of service, the emergency button is switched 23
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.
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 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.
Moreover, the system can show the following error messages, which can be displayed when operating or trying
unsuccessfully to operate.
Examples:
Open circuit alarm on solenoid valve EV3B.
24
The following table shows all the displayed alarm codes.
The system, through simple operations, allows to enter other menus, which can be helpful for the operator
or a technician from the After-Sales Service.
The following calibration and regulation menus need specific qualification and are exclusively
used by authorized workshops:
25
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
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.
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.
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.
26
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
In case of multiple command (two or more movements activated simultaneously) only the state of the first
received command is displayed.
Display Indication
C1A contact 1A closed (CLOCKWISE ROTATION)
C1b contact 1B closed (COUNTER-CLOCKWISE ROTATION)
C2A contact 2A closed (BOOM UP)
C2b contact 2B closed (BOOM DOWN)
C3A contact 3A closed (TELESCOPIC BOOM OUT)
C3b contact 3B closed (TELESCOPIC BOOM IN)
C4A contact 4A closed (WINCH DOWN)
C4b contact 4B closed (WINCH UP)
C5A contact 5A closed (START)
C5b contact 5B closed (STOP)
When no operation is activated the electronic control unit automatically switches to the Normal Display Menu
after 60 seconds; otherwise a new power-on is required in order to get out of this menu.
27
6.6.7 WORK PRESSURE DISPLAY MENU
This menu is only available on the momentum limiter system with analog pressure transducer and it
displays the real time oil hydraulic pressure (in bar).
This menu can be accessed from the normal display menu through the following procedure:
Fully press the proportional button and simultaneously start maneuver 1A and the STOP selector for 5
seconds (the maneuver can be performed in radio mode or through serial cable).
28
7 OPERATING INSTRUCTIONS
7.1 GENERAL ATTENTIONS
The crane must be used exclusively by qualified and skilled operators. They must know location and func-
tion 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.
IMPORTANT
In cold weather and in winter it is advisable to wait a few minutes with the pump running at no
load before starting to operate the crane.
• Extend the outriggers beams, acting separately on each side of the truck. Their release is made turning
180° upwards the locking handle (2) on picture 15. Pull the beam (1) on picture 15 out for a length of
approx. 20 cm (8 in.), then turn again the locking handle 180° downwards in its previous position. Pull
again out the outrigger beam, and the locking pin of the handle will automatically engage and lock the
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.
30
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:
ATTENTION
When turning the swinging jack and removing its pin, be careful and hold it up, to prevent it from
falling down because of gravity , resulting in damage or injuries.
• Repeat this sequence of operations for the outrigger jack on the other side of the truck and for every
other jack fitted on the truck. Make sure that the vehicle is level, in order to have a good stability.
Maximum allowed angle is 3°.
IMPORTANT
Proper leveling has to be checked by means of a level instrument fitted on the truck.
4
1
5
2 A
3 1
1 6
C
2 2
3
Pict. 15 Pict. 16 Pict. 17
31
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.
Push the emergency button on the control board, disconnect the control board connection and save it in the
driver’s cab.
7.5 WINCH SYSTEM OPERATION
The Winch is mounted at the rear of the first section boom. It has capacities totally independent 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 strength limitations of the winch and wire rope.
The winch load rating chart on each machine provides the information for pull limitations on the winch with
various applicable part reevings. These ratings are based on providing the proper operating safety factor on
the wire rope supplied with the machine. Therefore, any replacement rope must meet the rope specifica-
tions for size, construction and strength as outlined in specification sections of this manual.
7.6 BEFORE STARTING TRAVELING ON ROAD
Make sure that:
• The crane is in rest position as specified on chapter 7.4.
• The emergency button must be pushed.
• The control board connection has been taken off the remote control and put in its box in the driver’s cab.
• The outriggers jacks are fully retracted, their stop pins are in their housing and secured with relevant
retainers.
• The manual boom sections, if installed, are secured with stop pins and safety retainers.
• The locking handle of the outrigger beams, (2) on pict. 15, is safely locked in place. Unexpected
sliding out of the outriggers beams when the truck is traveling could result in serious accidents.
• The lever of the shut-off valve on hydraulic jacks, see (1) in pict. 16, is in the CLOSED position. (c)
• The PTO is disconnected.
• The overall dimensions of the crane in rest position are complying to regulations standard.
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.
32
• A sudden stop when lowering a load. This creates high forces of inertia on the crane structure with
relevant dangerous overload.
• Hitting the rope where the load is suspended, overload is generated.
• Side pull, dragging the load on the ground. All these operations originate strong overloading forces on
the crane.
• The outriggers are badly positioned or the ground is not firm: in both cases the truck tilts and could tip
over.
• Working with strong wind or wind gusts
• The manual boom sections are not correctly installed.
• The load is not correctly slinged. So the lifting accessory used (chain, rope, etc) breaks or flips out and
the load falls down to earth. The boom, suddenly unloaded, springs back and this could result in tipping
over.
• Trying to lift fixed load up(rooting of trees, raising of culverts, etc). Even if their load is smaller than the
capacity of the crane, the dynamic force created when it is suddenly stripped, may easily exceed the
capacity, and make the truck tip over.
• Swinging movements of the load. When acting on the slewing control too suddenly, the load starts
swinging. Danger of overload. And boom’s breaking.
7.8 STANDARD HAND SIGNALS
Pict. 18
33
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.
2 - This manual must always be carried in the driver’s cab along with a copy of the load chart.
3 - Every operationhas to be planned with care.
4 - Get all the necessary information for reaching the working site: distance, itinerary, heigth of exi
sting tunnels, capacity of the bridges to be crossed, etc.
5 - Study and plan the best way to operate the crane: soil consistence, weight and dimensions of the
loads to be lifted, heigth to be raised and necessary booms outreach. Check available room or
limitations due to the presence of buildings, obstacles, electricity power lines, etc.
6 - Make sure of availability of all the necessary equipment: accident-prevention clothings, additional
bearing plates with increa sed surface area, slings, hooks, ropes and chains of certified origin and
in perfect conditions.
7 - Before starting crane operations check the efficiency of the safety control devices. Never use the
crane if the correct functioning of a device is not sure.
8 - Traffic and safety laws in force must be strictly observed both when travelling on road and when
operating the crane.
9 - The warnings of these manual referred to special dangers are to be read and observed with
special care.
10 - The safety during the crane service must be kept to the highest level carrying out a regular,
constant and accurate preven tive maintenance. Repairs if necessary should never be delayed,
and must be made by specialized, authorized people using only genuine spare parts.
34
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:
35
9 MAINTENANCE
9.1 WARNINGS
• Do not wear rings, wristwatches, jewelry, loose-fitting or hanging clothing such as ties, torn garments,
ordinary shoes, unbut toned jackets or un-zipped overalls, which could get caught up in the moving
parts of the crane. Instead, always wear approved accident-prevention clothing such as protective
helmets, anti-slip shoes, anti-noise headphones, protective glasses, and reflective jackets with bre
athing apparatus. Consult your employer concerning current safety regulations and accident-pre
vention equipment.
• Apply a clearly visible plate on the cab door or on the control valve with the notice: “crane under
maintenance. Do not start”
• Do not get under any raised part of the crane, unless a safety lock support has been applied to it.
• Before starting any maintenance or repair operation always install safety locking supports on any
raised part of the crane, especially the boom system.
• Do not jump into or out of the machine, always use adequate steps and handrails.
• The truck engine should be started in closed rooms only if well aired.
• Before operating the crane make sure that nobody stays or walks in the working area.
36
! DANGER
of fire or scald
It is forbidden to use naked flame as lighting device when carrying out checks or looking for le-
aks in the machine.
• Do not lubricate, repair or carry out settings on the crane when it is working, unless this is expressly
required in the instructions of the Operator’s/Maintenance manual.
• If it is necessary to lift the crane and/or other parts, make sure that they are locked as requested from
current safety regulations
• Always use approved protective clothing, safety gloves and protective glasses when using steel
ropes, as they produce steel splinters.
• Never use the tools in a way different from the one they are meant, i. e.: pliers instead of wrenches.
• The maintenance area is to be kept clean and dry. Remove immediately any trace of water or oil.
• Leakage of fluid from a very small hole may be almost invisible and yet strong enough to penetrate
the skin. Before starting looking for the leaks, it is important to wear protective glasses with side
shields. Do not use your hands, use a piece of cardboard or wood to locate the source of the leak.
Injuries caused by pressure fluid may result in serious infections, so it is recomended to contact
immediately a doctor.
• Do not heap dirty rags with oil or grease, they may be a danger of fire. Instead, put them in a metallic
closed case.
• Immediately replace any missing sticker or plate carrying a notice of danger, attention or other in
structions.
IMPORTANT
Various part of the crane are manufactured with high tensile steel. Never perform any operation
(welding, drilling, etc) without authorization and instructions from the manufacturer.
ATTENTION
The crane is supplied with electrical and electronic devices installed. Always disconnect the
connections of these devices before carrying out welding or other operations with electric to-
ols on the crane or on any part of the truck .
• 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.
9.3 MAINTENANCE SCHEDULE
37
9.3.2 Monthly 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.
• Clean oil filter.
• 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 pinion and
slewing ring teeth.
• 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.
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.
• Check the pressure settings in the hydraulic system.
• 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.
• Make a safety test of the hydraulic system.
• Check correct working of remote control and readability of relevant symbols.
• Check integrity of hooks, ropes, chain and all the other lifting ancillary equipment.
• Check that the all the identification and warning plates are still applied and readable.
• Visually check all the structural components to find any deformation, backlash or crack out.
• 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.
38
9.4 CRANE SERVICING
ATTENTION
It is forbidden to pollute the environment with exhausted oil.
After the replacement, it is important to carry out a bleeding of the circuit, otherwise the air introduced in the
system with this operation may damage the sealing parts. To do that, operate every function of the control
valve, driving it smoothly to stroke end.
Use only the oils stated in the greasing/lubricating table, or equivalent ones. (chap. 9.5)
7
ATTENTION
AFTER EVERY OPERATION ON THE
OIL CARTRIDGE IS NECESSARY TO
TAKE THE AIR OFF THE HYDRAULIC
CIRCUIT. THIS CAN BE MADE
OPERATING ONE OF THE
3
CYLINDERS OF THE CRANE AND
PULLING IT TO STROKE END IN
BOTH DIRECTIONS SOME TIMES.
Pict. 19
39
9.4.4 Slewing mechanism maintenance (Pict. 20)
It is recommended to periodically lubricate ( see relevant chapter 9.3) the teeth of pinion and slewing ring.This
to be made with a greased brush, through the large hole existing in the column base plate.
Also with the same interval lubricate the bearing of the ring,with a greaser through the grease nipple existing
outside the outer ring. Grease to be according the reference table on chapter 9.5.
ATTENTION :for safety reasons always switch the engine off and disconnect the control box before
attending the slewing mechanism lubrication.
ATTENTION
Failure to replace the wear pads when they have
reached the above stated wear limit, can prejudi-
ce to the good and safe operation of the crane.
1
Pos. “B” 3
Pict. 20
Pos. “A”
Pict. 21
40
9.5 Greases and oils reference table
Pict. 22
41
9.6 WIRE ROPE
9.6.1 WIRE ROPE INSPECTION
Each day and before use, inspect the wire rope for the following conditions:
! DANGER
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.
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
7 - If a broken wire protrudes or lops out from the core of the rope
42
9.6.3 WIRE ROPE LUBRICATION
Wire rope is lubricated during manufacturing so the strands, and individual wires in strands, may move and
adjust as the rope meves and bends. A wire rope cannot be lubrificated sifficiently during manufacture to last
its entire life. Therefore, new lubricant must be added periodically throughout the life of a rope to replace
factory lubricant which is used or lost.
The surface of some ropes may become covered with dirt, rock dust, or other material during their operation.
This covering can prevent field applied lubricants from properly penetrating into the rope. Therefore, these
ropes should be cleaned before being lubricated.
The lubricant applied should be light bodied enough to penetrate to the core of the rope. Lubricant may be
applied effictively by various methods. It may be dripped on, sprayed on, or put on by brushing, but in any
case it should be applied at a place where the rope is being bent, such as at a sheave. It shold be applied at
the top of the bend, because at that point the strands are spread by bending and are more easily penetrated.
The service life of rope will be directly proportional to the effectiveness of the method used and amount of
lubricant reaching the working parts of the rope.
A proper lubrificant must reduce friction, protect against corrosion, adhere to every wire and be pliable and
not crack or separate when cold and yet not drip when warm.
43
9.7 POSSIBLE FAULTS AND RELEVANT REMEDIES
Fault Cause Remedy
Vibrations in hydraulic cylinder and jerkin- The temperature of the hydraulic oil is Perform manoeuvres without loads for
gs at the first manoeuvres. too low. some minutes to warm the oil up.
Vibrations with every functions when the Lacking of oil in the tank. Air in the hydrau- Add hydraulic oil to the tank.
oil is hot. lic system.
Operate the control lever carrying the
cylinders to stroke end for some times in
both directions.
All the crane movements are very slow, Suction hose from oiltank crushed or Replace or clean the suction hose.
even when unloaded. obstructed.
Check that the relevant fittings are well
The pump is drawing in air. tightened.
The hydraulic extension are not exten- Bad lubrication. Grease the extensions.
ding in the right sequence.
Sliding pads are worn. Replace sliding pads.*
Slewing is not regular or with insufficient Ground slope too great Level the truck.
power
Domaged slewing motor Replace slewing motor. *
The crane does not lift the loads of the Defective pump. Replace the pump.*
load chart table.
Uncorrect settings of the valves. Adjust valve settings.*
The crane lift the load, but cannot hold it. Uncorrect settings of the valves. Adjust valve settings.*
Noise coming from articulation points. Lacking of lubrication. Grease articulation points.
The hydraulic legs does not hold under Defective holding valves. Clean or replace holding valves.*
load.
Worn sealings in the stabilizer cylinder. Replace worn sealings.*
The crane locks with boom lifted at end Pressure transducer not set. Disassemble the casing and move ma-
course. nually the boom descent valve (EV2B).
Setting of general max. pressure valve Reduce the general max. pressure valve
too high. (Pict.12). *
One or more movements keep on func- - Solenoid valve jammed in open posi - Unlock, clean or in case replace the
tioning while selecting another function. tion (dirt, working shaving, long inacti solenoid valve cartridge
vity periods)
44
Fault Cause Remedy
One of the function does not work. Defective switch Replace the switch
Burned solenoid. Replace the solenoid. *
Locked valve cartridge Disassemble and clean the valve cartri-
dge
Damaged electric connection. Check continuity of the circuit
All the functions do not work No power (or insufficient) to the shunt Check relevant fuzes and indicator LEDS
boarder the remote control box Check tension with a tester
The proportional valve does not meter Check the solenoid of the valve
Check and clean the valve cartridge
Electric valve (EV9 pict. 12) is not working As above
The trigger on the remote hand-held
control box does not work Check the control box
All the functions work at full speed The proportional valve is not working Check and clean the valve cartridge on
It is not possible to adjust the speed an authorized workshop
The trigger on the hand-held control box Check the relevant potentiometer and
is not working electric board on an authorized workshop
Multi-function operation are not possible Electric valves (EV3 pict.12) and (EV4 Check the relevant solenoid
pict.12) does not worck Check and clean the relevant valve car-
tridges
One or more movemente keep on func- Solenoid valve jammed in open position Unlock, clean or in case replace the so-
tioning while selecting another function (dirt, working shaving, long inactivity pe- lenoid valve cartridge
riods)
Manual operator (where foreseen) acti- Close down the manual operator
vated
The winch does not work when single Solenoid valve EV4 jammed in closed Unlock, clean or in case replace the
operated position (dirt, working shaving, long solenoid valve cartridge
inactivity periods) (pict.12)
The winch does not work when operated Solenoid valve EV3 jammed in closed Unlock, clean or in case replace the
together with other functions (dirt, working shaving, long inactivity solenoid valve cartridge or the flow di
periods) (pict.12) vider
Flow divider 1 wrongly set or not
working (pict.12)
45
10 TECHNICAL DATA - WINCH SPECIFICATIONS
10.1 SERIES 12000.2L STANDARD EQUIPMENT
- High speed winch with planetary gears reducer - Continuous rotation with worm-gear
- Negativ brake for winch - Remote control with connection and 10 m. - 33' ft. of cable
- Hydraulic swivel coupling, for continuous rotation or radio remote control
- Proportional multifunction hydraulic system
- Load limiting device - Solenoid valve with manual functions (only for emergency)
- Two hydraulic extensions - Stop-end system for winch (up and down)
LOAD CAPACITIES
COBRA 12000.2L
Pict. 23
46
TECHNICAL DATA 12000.2L
LOAD CAPACITIES
COBRA 12000.2L
Pict. 24
47
10.2 SERIES 12000.3L STANDARD EQUIPMENT
- High speed winch with planetary gears reducer - Continuous rotation with worm-gear
- Negativ brake for winch - Remote control with connection and 10 m. - 33' ft. of cable
- Hydraulic swivel coupling, for continuous rotation or radio remote control
- Proportional multifunction hydraulic system
- Load limiting device - Solenoid valve with manual functions (only for emergency)
- Three hydraulic extensions - Stop-end system for winch (up and down)
LOAD CAPACITIES
COBRA 12000.3L
Pict. 25
48
TECHNICAL DATA 12000.3L
LOAD CAPACITIES
COBRA 12000.3L
Pict. 26
49
11 WIRING AND HYDRAULIC DIAGRAMS
11.1 ELECTRICAL DIAGRAMS
Pict. 27
50
11.1 DESCRIPTION
51
11.2 HYDRAULIC DIAGRAMS
Pict. 28
52
11.2.2 Hydraulic diagram 12000.3L
1 Pump 15 Winch motor
2 Electrohydraulic unit 16 Anti shock + owc. valves
3 Rotation motor 17 Spool
4 Overcenter valve 18 3rd. extension cylinder
5 Lifting cylinder
6 Overcenter valve
7 Pressure switch
8 1st. extension cylinder
9 2nd. extension cylinder
10 Overcenter valve
11 Sequence valve
12 Oil filter
13 Oil tank
14 Swivel hydraulic coupling
Pict. 29
53
NOTES
Address
NEXT HYDRAULICS S.r.l.
City Province State Via Mediterraneo , 6 Boretto 42022 (RE) - ITALY
Tel. 0522/963008 - Fax 0522/963039
Tel number. Date e-mail: nexthydraulics@tin.it
Reproduction and distribution are forbidden according to law without written permission in writing from
Next Hydraulics S.r.l.
NEXT HYDRAULICS s.r.l.
Via Mediterraneo, 6
42022 Boretto (Reggio E.) -Italy
Tel. 0522/963008 - Fax 0522/963039
e-mail: info@maxiliftcrane.com