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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7
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)
SOIL ADMITTABLE PRESSURE
(daN/cm2) (lbs./sq.in.)
Dumped, non compacted soi 0.0/1.0 0,0/14
natural, virgin soil:
-mud, marshland, peat 0.0 0,0
incoherent artificially compacted soils:
-fine and medium size sand 1.5 21
-large size sand, gravel 2.0 28
natural coherent terrain:
-doughy 0.0 0,0
-soft. 0.4 6
-stiff 1.0 14
-demi-solid 2.0 28
-solid 4.0 56
rock, not altered by athmospheric agents, well stratified and slightly cracked:
-closed stratified 15.0 213
-solid stratified, pillar-like 30.0 426
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8
Pict. 3
!
• 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.
5.3.3Safety distance from electrical power lines
Always keep a sufficient safety distance when you cannot avoid having electric power lines in the working
area of the crane. Special care must be taken when the power lines have not been disconnected by expe-
rienced people, or when the lines status is unknown.
Voltage (V) minimum distance
(m) (ft)
up to 1000 v 1 4
from 1 kV to 110 kV 3 10
from 110 kV to 220 kV 4 13
from 220 kV to 380 kV 5 16
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
!
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9
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
Crane ground connection
DANGER
electrocution hazard
While grounding the crane, carefully follow the below mentioned instructions, in order to avoid
electrocution hazard
In order to avoid electrocution hazard the following tips must be followed:
• drive a metal rod, roughly 1.5 meter long, (5 ft.) in the ground, at least 1 meter (4 ft.) deep
• connect a power cable of minimum 16 mm2(0,025 sq. in.) cross section to the former rod. This linkage
must be made with a hose clamp or a vice.
• moisten the ground all around the rod to improve conductivity.
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. Moisten 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.
!
!
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10
!
!
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:
Force of the wind wind speed wind effects
Beaufort Denom. m/sec(ft./sec.) km/h (mile/h)
0 calm 0 - 0.2 0-0.65 1 0.6 calm,the smoke goes straight upwards
1 light 0.3 - 1.5 1-5 1-5 0.6-3 wind direction can only be seen looking at the
smoke. Wind indicators are idle
2 light 1.6 - 3.3 5-11 6-11 3-7 leaves are moving,the wind can be on the face.
3 light 3.4 - 5.4 11-18 12-19 7-12 leaves and small brances are moving breeze
4 slow 5.5 - 7.9 18-26 20-28 12-17 dust and paper sheets are lifted up, breeze
slender, rods are moved
5 strong 8 - 10.7 26-35 29-38 17-24 small waves on water surfaces breeze
6 strong 10.8 - 13.8 35-45 39-49 24-30 rods are bent,it is difficult to use wind umbrella
7 tight 13.9 - 17.1 45-56 50-61 30-38 the trees are moved it is difficult to wind walk
against wind
8 stormy 17.2 - 20.7 56-68 62 - 74 38-46 trees’branches break.it is very difficult to walk in
open areas
9 tempest 20.8 - 24.4 68-80 75 - 88 46-55 small damages to buidings (roofing tiles wind fall
down)
10 violent 24.5 - 28.4 80-93 89 - 102 55-63 big damages to the buildings, trees uprooted
tempest
5.4 RULES CONCERNING SAFETY IN THE TRAFFIC
- The machine is an hidraulic crane for lorries and light trucks.The installation on the vehicle must be made
in compliance with the relevant national laws and regulations.
- When traveling on roads and public sites always respect the relevant national laws and regulations.
DANGER
Before traveling on roads,make sure that the crane is folded in rest position. If the crane is open
or lying on vehicle’s body exceeding the overall dimensions allowwed by the highway code,it can
hit bridges,electric power lines or other obstructions.
-Always disconnect the battery isolator before driving away
-Before driving away, make sure that the lever of the pin securing the outrigger’s beam is fully
locked.Accidental slipping out of the outrigger during traveling can result in serious damages.
Special care must be taken when driving nearby crossroads, lever-crossing and subways.
!
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11
5.5 GENERAL RULES ON WINCH OPERATIONS
5.5.1 Winch system operation
The Winch is mounted at the rear of the first section boom.It has capacities totally indipendent of the rest of
the crane and can normally pull more than the crane itself can withstand.Therefore,care must be taken to
insure that the load being lifted is within boom rating.To lift some of the heavier loads on the capacity chart,it
will be necessary to multiple-part reeve the winch block to increase the lifting capacity of the winch (the
speed is proportionately slower) and remain in the strenght limitations of the winch and wire rope.
The winch load rating chart on each machine provides the information for pull limitations on the winch with
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 specifications for size,construction and stregth as
outlined in specification sections of this manual.
ATTENTION
The extension and the re-entry of manual extension must be carried out only loadless. Always remember to
lock the extensions by the proper pins and lockpins, before lifting loads.
5.5.2 Crane in single pull line (Pict. 4)
Use the winch in single pull line with a max. load of 730 Kg. (1600lbs); with heavier loads set the winch in
double pull line by using the rope block kit on issue. For the use in single pull line it is necessary to leave the
balance weight 1 on the lifting hook in order to keep the rope tensioned. The balance weight is kept in slide
on the sleeved thimble terminal in correspondence of the hook, and is locked in position by the proper
retainer 2 locked by wing screw 3.
5.5.3 Crane in double pull line (Pict. 5)
Use the winch in double pull line when lifting loads heavier than 730 Kg (1600 lbs) up to max. 1450 Kg (3200
lbs). For the use in double pull line it is necessary to remove the balance weight 1 by unloosing the wing
screw, and to put it back in a safe place. Then mount the rope block on issue with the crane, letting the rope
reeve on the pulley, after unscrewing of the screws 4, and hitch the lifting hook on the back pivot of the
pulley-head.
5.5.4Operator safety tips
• Do not pull the load block into the boom tip.
• Payout loadline before or during boom extension to avoid two-blocking.
• Do not allow personnel to ride the load-line, hook or load, or any other device attached to loadline.
• Keep at least three full wraps of wire rope on the winch drum at all times.
• Check the winch brake for proper operation before handling the load.
• Use proper multi-part reeving for the load to be lifted.
• When using multi-part reeving, be sure cable is properly routed.
• Know the lifting capacity of both the winch and boom. They will have different capacities. The weight of
the load must not ex-ceed the lesser capacity.
• Do not drag loads with winch or boom.
• Always wind loadline.under tension to assist proper spooling
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5.5.5 General rules when operating winch
1 - Always operate the winch control to payout the loadline while extending the boom. This will maintain
clearance between the boom tip and loading hook.
2 - Do not pull load block into boom tip.
3 - Make certain the winch cable is not twisted or kinked and that cable is properly seated on the drum and
in the sheaves.
4 - Before lifting a load, always make certain that three full wraps of rope will remain on the drum at all
times throughout the lift.
5 - When lifting a load approaching the rated winch load, raise the load a few inches and return the con-
trol to neutral to determine if the brake is working properly.
6 - Do not drag loads in any direction with the winch.
7 - Never attempt to lift loads wich are not loose and free, i.e. frozen down material or poles out of ground.
8 - Maintain tension on the loadline at all times to prevent the cable from becoming twisted or improperly
seated on the winch drum or sheaves.
9 - Avoid rough boom lifting and lowering manoeuvres with suspended load, in order not to cause dan-
gerous swingings of the same.
10- Avoid boom extension manoeuvre under load. When moving loa-
ds near to max. rates it is rather advisable to extend the boom
without load in order to reach the vertical line of the same, and
then to proceed with lifting by using the winch.
5.6 WIRE ROPE
5.6.1 General
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.
5.6.2 Wire rope precautions
1 - Avoid the formation of kinks. Kinks will cause severe weakness in
the rope. No corrections are available 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 distor-
tion 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 crushing
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 cor-
rosion. Pict. 5
Pict. 4
1
2
3
4
5
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6 DESCRIPTION OF THE CRANE
6.1 MODEL 3300W
Item Description
1 Slewing system
2 Slewing motor
3 Column
4 Main boom
5 Boom hoist cylinder
6 First boom section (hydraulic)
7 Second boom section (mechanical)
8 Telescope cylinder (inside the boom)
9
10 Control valve
11 Electric shunt board
12 Remote control box
13 Winch
14 Travelling block
15 Electro-hydraulic power pack
16 Outrigger beam (mechanical jack) OPTIONAL
Pict. 6
1
2
3
5
7
6
8
10
11
12
13
14
16
15
4
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6.3 SAFETY DEVICES
6.3.1 Safety devices installed
All the safety devices,installed on MAXILIFT COBRA 3300 crane, are listed and described in the following
pages.
description of safety functions
The crane is fitted with 4 standard electro-hydraulic safety limitations:
1) The load limiting device, which intervent each time the load mentioned on loading diagram is excee
ded and locks the crane, stopping all mouvements, except re-entry of boom extension and lowering
the load.
2) 0° working placing of the boom. The crane is fitted with a stop-end system allowing only boom lifting
manoeuvre when the position is lower than 0° (rest position)
3) Stop-end system for winch raising, which intervent in order to avoid the travelling block to hit against
the pulley. It stops the raising of the winch rope, boom lowering and boom extension.
4) Stop-end system for winch lowering, which intervent when in the winch drum remaining only 3 wraps
of rope and locks the lowering of the winch rope.
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
6.3.2 Load limiting device
The load limiting device system locks crane functioning when pressure in the main cylinder reachs the
setting level, corresponding to the nominal crane moment.
The load limiting is used in order to avoid crane overload.
In lock position it is not possible to carry out any manoeuvre, except re-entry of boom extension and lowering
the load (only possible manoeuvres).
In order to unlock the crane, re-entry with the boom extension until crane moment becomes lower than that
marked on the loading diagramm, or intervent on winch lowering by putting the load on the ground.
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 order to unlock the machine it is necessary to act simultaneosly both on the ex-
tension re-entry and boom lowering levers.
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6.3.3 Relief valve
The main relief valve is on the electro-hydraulic unit and limits the maximum working pressure.
6.3.4 Pilot operated holding valves
These valves are installed on every cylinder and will stop and lock every motion of the cylinder should any
pressure loss occur. Before starting operations it is necessary to check that these valves are perfectly
working, as follows:
• lift a load and raise the boom up to an angle of 45° upwards, with the boom sections partially extended
• switch the truck engine off push and pull repeatedly all the control switches: the load must remain still.
6.3.5 Safety devices’ sealing
Some safety devices or crane components can be sealed after setting during testing operations.
Such sealing can be only removed by the manufacturer or by an authorized workshop who will carry out a
new sealing after repairing according to Manufacturer’s specifications.
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.
!
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6.4 CONTROLS DESCRIPTION
This crane is fitted with a standard cable remote control.
The remote control system includes a directional electro-hydraulic unit (manifold) (A) and a electronic power
unit (B), placed inside the casing behind the column, a remote control box and a wiring system.The electro-
hydraulic manifold includes an aluminium block equipped with directional electrovalves (EV..A-EV..B) (two
each mouvements), a main relief valve (5).
The electrovalves (EV3B-EV2B-EV1B-EV1A) are fitted with manual controls, to be used only in case of
emergency (remote control box or electronic power unit breakdown).
Model 3300W - E
For emergency manoeuvres, fully turn counter-clockwise the manual control of the electrovalve coupled to
the desired mouvement and let the electric power pack motor run temporaly, supplying directly relevant
relais by the prepared cable from the positive power terminal to the positive solenoid connection, momen-
tarly replacing the existing cable. This way, the motor run until the emergency cable is connected . Keep the
motor running only for the short periods required to carry out the emergency manoeuvres. Afterwards,
restore the original connection.
6.4.1 Electronic power unit
The electronic control unit, placed inside the near column casing, is a fully sealed component containing the
electronic parts with microprocessor logic, due to handle all crane movements and safety device. Two
connector for the guide connection to the solenoids and safety device cables jut out of it.
Pict. 7
B
A
5
EV3A
EV2A
EV1A
EV2B
EV1B
EV3B
Manifold
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