maxilift 3300W User manual

SERVICE CRANE Mod. 3300W
USE AND MAINTENANCE MANUAL
Code MD.0.121
Rev 2
Edition 07/09
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OPTIONALS SUPPLIED ALONG WITH THE CRANE
Description YES NO
Outrigger beam - (mechanical jack)
The table has to be filled carefully with the above option when purchased
PRELIMINARY INFORMATION
Operator’s and maintenance manual of MAXILIFT COBRA 3300W SERVICE CRANE
Manual code: MD.0.121
This manual is valid starting from serial no: 9310
Manufacturer: NEXT HYDRAULICS S.r.l.
Via Mediterraneo 6, I 42022 BORETTO
In this booklet the word “Manufacturer” is referred to “NEXT HYDRAULICS S.r.l.”
List of documentation supplied along with the CRANE:
• Operator’s and maintenance manual (for the end user)
• Spare part manual
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.
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INDEX
1 FOREWORD ..................................................................................................PAGE 1
1.1 Summary ........................................................................................................................................................ “ 1
1.2 Remarks ......................................................................................................................................................... “ 1
1.3 Manual revision ............................................................................................................................................... “ 2
2 HOW TO CONSULT THE MANUAL ...................................................................... “ 2
2.1 Instructions ..................................................................................................................................................... “ 2
3 CRANE IDENTIFICATION ..................................................................................... “ 3
3.1 Versions and optional available ..................................................................................................................... “ 3
3.2 CRANE identification data .............................................................................................................................. “ 3
4 CRANE USAGE AND LIMITS OF APPLICATIONS................................................ “ 4
4.1 CRANE classification and proper usage ....................................................................................................... “ 4
4.2 Improper usage .............................................................................................................................................. “ 4
4.3 CRANE operator’s training ............................................................................................................................. “ 4
5 SAFETY RULES ................................................................................................... “ 6
5.1 Rules concerning people ............................................................................................................................... “ 6
5.2 Rules concerning the crane ........................................................................................................................... “ 6
5.3 Rules for the correct positioning of the crane ................................................................................................ “ 7
5.3.1 Choice of the crane operating place pressure on the ground ....................................................................... “ 7
5.3.2 Safety distance from trenches and slopes .................................................................................................... “ 7
5.3.3 Safety distance from electrical power lines ................................................................................................... “ 8
5.3.4 Crane and load ground connection ............................................................................................................... “ 8
5.3.5 Influence of the wind on the crane operation ................................................................................................. “ 10
5.4 Rules concerning safety in the traffic ............................................................................................................. “ 10
5.5 General rules on winch operations ................................................................................................................ “ 11
5.5.1 Winch system operation ................................................................................................................................. “ 11
5.5.2 Crane in single pull line ................................................................................................................................. “ 11
5.5.3 Crane in double pull line ................................................................................................................................ “ 11
5.5.4 Operator safety tips ......................................................................................................................................... “ 11
5.5.5 General rules when operating winch ............................................................................................................. “ 12
5.6 WIRE ROPE .................................................................................................................................................... “ 12
5.6.1 General ........................................................................................................................................................... “ 12
5.6.2 Wire rope precautions .................................................................................................................................... “ 12
6 DESCRIPTION OF THE CRANE .......................................................................... “ 13
6.1 Model: 3303W - .............................................................................................................................................. “ 13
6.2
6.3 Controls description ....................................................................................................................................... “ 14
6.3.1 Description of shunt board ............................................................................................................................. “ 14
6.3.2 Description of control box ............................................................................................................................... “ 14
6.3.3 Relief valve ...................................................................................................................................................... “ 15
6.3.4 Pilot operated holding valves ......................................................................................................................... “ 15
6.3.5 Safety devices’sealing .................................................................................................................................... “ 15
6.4 Controls description ....................................................................................................................................... “ 16
6.4.1 Electronic power unit ...................................................................................................................................... “ 16
6.4.2 Remote control box ......................................................................................................................................... “ 17
6.5 Wiring .............................................................................................................................................................. “ 17
I
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II
7 OPERATING INSTRUCTIONS ......................................................................... PAGE 18
7.1 General attentions .......................................................................................................................................... “ 18
7.2 Stabilizing the truck ......................................................................................................................................... “ 19
7.3 Opening the crane .......................................................................................................................................... “ 21
7.4 Closing the crane ........................................................................................................................................... “ 21
7.5 Winch system operation ................................................................................................................................. “ 21
7.6 Before starting traveling on road .................................................................................................................... “ 21
7.7 Main errors occurring when operating the crane ........................................................................................... “ 21
7.8 Standard hand signals ................................................................................................................................... “ 22
8 PUTTING THE CRANE INTO SERVICE ................................................................ “ 23
8.1 Ten rules for the perfect crane operator ......................................................................................................... “ 23
8.2 Daily check list ................................................................................................................................................ “ 23
8.3 Crane protection and storage ........................................................................................................................ “ 23
8.3.1 Short shutdowns ............................................................................................................................................ “ 23
8.3.2 Long shutdowns ............................................................................................................................................. “ 24
9 MAINTENANCE .................................................................................................... “ 25
9.1 Warnings ........................................................................................................................................................ “ 25
9.2 Maintenance prescriptions ............................................................................................................................. “ 25
9.3 Maintenance schedule ................................................................................................................................... “ 26
9.3.1 Daily checking ................................................................................................................................................. “ 26
9.3.2 Monthly checking ............................................................................................................................................ “ 27
9.3.3 Checking every six months ............................................................................................................................. “ 27
9.3.4 Others ............................................................................................................................................................. “ 27
9.4 Crane servicing ............................................................................................................................................... “ 28
9.4.1 Oil level checking ............................................................................................................................................ “ 28
9.4.2 Oil change ....................................................................................................................................................... “ 28
9.4.3 Wormgear assembly control .......................................................................................................................... “ 29
9.4.4 Greasing the hydraulic boom sections .......................................................................................................... “ 29
9.4.5 Wear pads check and replacement ............................................................................................................... “ 29
9.5 Greases and oils reference table .................................................................................................................. “ 30
9.6 Wire rope ........................................................................................................................................................ “ 31
9.6.1 Wire rope inspection ...................................................................................................................................... “ 31
9.6.2 Rope replacement .......................................................................................................................................... “ 31
9.6.3 Wire rope lubrication ...................................................................................................................................... “ 31
9.7 Possible faults and relevant remedies .......................................................................................................... “ 33
10 TECHNICAL DATA ............................................................................................... “ 36
Overall dimension ...........................................................................................................................................
Performances ..................................................................................................................................................
Load chart table ...............................................................................................................................................
11 WIRING AND HYDRAULIC DIAGRAMS ................................................................ “ 38
11.1 Wiring diagrams ............................................................................................................................................. “ 38
11.1.1 Pendant and control wirings .......................................................................................................................... “ 38
11.1.2 3300 Wiring diagram ...................................................................................................................................... “ 40
11.2 Hydraulic diagrams ........................................................................................................................................ “ 41
11.2.1 Hydraulic diagram 3300W .............................................................................................................................. “ 41
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1
1 FOREWORD
1.1 SUMMARY
This manual is divided into chapters to make its consultation easier.
Chapter 1: Includes summary and a short introduction.
Chapter 2: Explains how to consult the manual.
Chapter 3: Crane identification data.
Chapter 4: Limits of crane operation and usage.
Chapter 5: Safety rules.
Chapter 6: Description of the crane, safety devices and controls.
Chapter 7: Description of operation and usage tips.
Chapter 8: Crane starting up and storage.
Chapter 9: Essential crane maintenance instructions. Additional instructions can be included in the
truck maintenance manual.
Chapter 10: Includes the crane technical data, load charts and diagrams, list of main characteristics.
Chapter 11: Wiring and hydraulic diagrams
1.2 REMARKS
Many thanks for the preference kindly given to our product. Please remember that the servicing instructions
and the load charts hereby reported and applied on the crane are an essential part of the crane supply itself.
They are mainly intended for the crane operator and include all necessary information on the admittable and
permissible field of usage for a safe operation. Anyway, these instructions are not a training manual for
beginners or unskilled operators, it must be stressed that as a fundamental presupposition only skilled and
professional crane operators are allowed to work with the crane.
The crane operator is directly responsible for the state of the crane and for every crane operation. When the
training is hurried and full of gaps, this is the origin of many accidents. This manual gives the guidelines for
a correct, safe usage of the crane and its rational maintenance. When daily and constantly applied, these
guidelines ensure long service life with minimum maintenance costs, high performance of the crane and
good commercial value after years. Moreover, most of the frequent accidents during operation and servicing
are avoided. Once this manual has been read carefully, keep it in good conditions and quickly available
close to the crane.
If a technical assistance is required please apply to the nearest authorized installer.
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.
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2
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.
2 HOW TO CONSULT THE MANUAL
2.1 INSTRUCTIONS
Always carefully read this manual before operating the crane. In this manual the following symbols are used:
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.
!
!
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3
3 CRANE IDENTIFICATION
3.1 VERSIONS AND OPTIONS AVAILABLE
The service instructions written on this manual are referred to the CRANE MAXILIFT COBRA 3300W. This
model is supplied in one only version, the hydraulic circuit is fed by a DC hydraulic power pack connected to
the truck battery.
3300W 12V DC single boom hydraulic section, electro-hydr.version
The crane can be supplied with the following option:
Type of optional
Outrigger beam - (mechanical Jack)
3.2 CRANE IDENTIFICATION DATA
Every crane is identified by its serial number and name of the model written on the plate riveted on the crane.
The same data are also punched on the crane column.
Data plate description Colum punching
a) Crane model g) Crane model
b) Serial number h) Serial number
c) Year of manufacturing
d) Lifting class
e) max SWL
f) Approval number
ATTENTION
It is strictly forbidden to change, erase, modify the data written on the plate and punched on the
column.
Pict. 1
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4
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 1.6 ton-meter (11,500 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;
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5
• 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.
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6
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 jackets or unzipped overalls, which could get caught up in the moving parts of the
crane.
• Keep quickly and readily available on the truck a first-aid box and a fire extinguisher. The fire extin
guisher must always be kept charged and has to be used according to current regulations.
5.2 RULES CONCERNING THE CRANE
• The Manufacturer is not liable for accidents occurred during the usage of the crane caused by non
fulfillment from the operator’s side of current rules, laws and regulations.
• The crane is designed to be used within the -30°/+50° (-22 °F/ +122 °F) temperature range and has to be
operated only in this range. The manufacturer is not liable for accidents occurred during the usage of
the crane outside this temperature range.
• Carefully read the Operator’s and maintenance manual before starting up, using, servicing or doing any
thing on the crane.
• Read and follow all the safety instruction plates applied on the crane before starting up, using, servicing
or doing anything on the crane.
• Do not use controls and hoses as handholds: these parts move and cannot provide stable support.
Furthermore, a control mistakenly moving can accidentally set the crane in motion.
• The operator’s control desk must always be kept clean from oil, grease, mud, snow to avoid accidents
due to slippery surface.
• The safety instruction plates, notices, load charts and any other sticker applied on The crane must be
kept readable and in good conditions. If necessary, replace them. The position of these plates is shown
in the following picture.
1R
1L
2
3
4
8
7
66
2
Pict. 2
7
5
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