Cobra Maxilift 5500 Use And Maintenance Manual Download

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SERVICE CRANE

Mod.

5500

USE AND MAINTENANCE MANUAL

Code

MD.0.176

Rev

Edition

07/09

Summary of Contents for Maxilift 5500

Page 1: ...SERVICE CRANE Mod 5500 USE AND MAINTENANCE MANUAL Code MD 0 176 Rev 0 Edition 07 09...

Page 2: ...editerraneo 6 I 42022 BORETTO Reggio Emilia 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 ma...

Page 3: ...n 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 Operator safety tips 11 5 5 3 General rules when o...

Page 4: ...ne operator 34 8 2 Daily check list 34 8 3 Safety tips for crane starting in cold climates 34 8 4 Crane protection and storage 34 8 4 1 Short shutdowns 34 8 4 2 Long shutdowns 35 9 MAINTENANCE 36 9 1...

Page 5: ...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...

Page 6: ...led 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 t...

Page 7: ...oportional mono function Fed by a punp driven by a P T O truck 12 24V 5500 RKP E Radio Proportional mono function Fed by a DC electro hydr power pack 12 24V 5500 RKPD H Radio Proportional dual mode Fe...

Page 8: ...difications 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 improp...

Page 9: ...equired 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 s...

Page 10: ...lment 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 manuf...

Page 11: ...rigger 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...

Page 12: ...n 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 1...

Page 13: ...nd 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 linka...

Page 14: ...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...

Page 15: ...e 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...

Page 16: ...ort 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 ra...

Page 17: ...7 Second hydraulic boom section 8 First telescope cylinder 9 Second telescope cylinder 10 Hydraulic unit 11 Electronic Power unit 12 Cable or radio remote control box 13 Winch 14 Travelling block 15...

Page 18: ...nd hydraulic boom section 8 First telescope cylinder 9 Second telescope cylinder 10 Hydraulic unit 11 Electronic Power unit 12 Cable or radio remote control box 13 Winch 14 Travelling block 15 Elettro...

Page 19: ...ter or manipulate the safety devices Before operating the crane make sure that all the safety devices are in perfect working conditions 6 3 2Load limiting device The load limiting device system locks...

Page 20: ...e 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 saf...

Page 21: ...m is consisting of the following main components Pict 7 1 Control and safety devices managing con trol unit 2 Remote control keyboard 3 Directional and flow regulating hydraulic unit 4 Electrical conn...

Page 22: ...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 su...

Page 23: ...rcular magnet located on the rear that allows placing the keyboard on metallic surfaces WARNING Verify the emergency button correct operation 5 before using the radio control The radio control must be...

Page 24: ...nsisting of two separate aluminium blocks The upper section includes the proportional adjusting valve VR and the manual bypass control valve OM of the proportional regulator The lower section includes...

Page 25: ...manual override of the valve coupled to the desired movement extension re entry boom lowering etc c Finally Fully turn counter clockwise the manual override of the valve EV9 in order to activate the...

Page 26: ...TTENTION Do not operate the proportional button before selecting the movement it will not work Do not pull immediately the proportional button to its maximum limit you will not get the right gradualne...

Page 27: ...onal 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 use...

Page 28: ...ing out whichever movement by selecting the function it must appear When the overload condition is almost reached the display shows When the crane goes gets locked by the LLD overload the display show...

Page 29: ...4 O_r open circuit VR proportional valve 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 These menus...

Page 30: ...pressure transducer When no operation is activated the electronic control unit automatically switches to the Normal Display Menu after 60 seconds otherwise a new power on is required in order to get...

Page 31: ...ovements activated simultaneously only the state of the first received command is displayed Example indication without any active movement Example indication when the contact 1A is closed on the remot...

Page 32: ...ulic 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 select...

Page 33: ...nned joints and the hook pin are safely locked by their retainers Lifting tackles chains or ropes must be applied to the hook in such a way that will not damage the hook safety latch Whilst swinging t...

Page 34: ...h the truck battery The connection is made turning on the emergen cy button pict 9 P located on the remote control The electric pump will start every time a switch of the remote control is moved The c...

Page 35: ...ng in mind what was explained above regarding the vehicle suspension Swinging hydraulic jack Fig 18 When swinging jack are fitted before operating the shut off valve 1 make sure that the jack 2 is in...

Page 36: ...roviding 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...

Page 37: ...om 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 s...

Page 38: ...lings 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 func...

Page 39: ...stickers water entering inside the electrical components and the slewing case 8 4 2Longshutdowns Same precautions as above and moreover apply protective oil on the entire crane surface cover the cran...

Page 40: ...id dirt on crane components or assemblies breaking of ropes or slings safety valves load limiting device or other safety devices out of service or not in good working conditions hydraulic plant in bad...

Page 41: ...tely 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 da...

Page 42: ...xmoths Wash and clean the crane 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 electric...

Page 43: ...ortant 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...

Page 44: ...ions Pict 22 1 Completely extend the telescopic boom 2 Grease the lower part of the extensions by a brush 3 Grease the upper part of 1st extension by the two grease nipples pos A 4 Move the grease nip...

Page 45: ...EACON GR MU ATHESIA ENEGREASE EP2 MP EP2 EP2 EP2 LR MP GREASE MULTIS MOBILGREASE BEACOM GR MU ATHESIA ENERGREASE LR MP MP EP2 EP2 EP2 EP2 HYDRAULIC AZOLLA DTE NUTO OSO HYDRUS HENERGOL OIL ZS 46 25 H 4...

Page 46: ...e depends upon the good judgement of an experienced person in evaluating the remaining strength in a used rope after allowance for deterioration disclosed by inspection The following reasons are suffi...

Page 47: ...ese 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...

Page 48: ...r Defective pump Uncorrect settings of the valves Hydraulic cylinder sealings are worn Uncorrect settings of the valves Hydraulic cylinder sealings are worn Lacking of lubrication Defective holding va...

Page 49: ...Solenoid valve jammed in open position dirt working shaving long inactivity pe riods Manual operator where foreseen acti vated Solenoid valve V4 jammed in closed position dirt working shaving long in...

Page 50: ...nual functions only for emergency Two hydraulic extensions Stop end system for winch up and down TECHNICALDATA5500 Crane rating KNm 35 Standard outreach m 5 65 Slewing angle CONTINUOUS Boomelevation 5...

Page 51: ...PORTIONAL Pump capacity hydraul H pto GPM 3 2 Working pressure psi 2 500 Crane weight lbs 1 000 H 1060 E Slewing torque ft lbs 2 500 WINCHSPECIFICATION5500 Winch pull line lbs 2 700 Pull line speed H...

Page 52: ...48 Pict 26 11 WIRINGAND HYDRAULIC DIAGRAMS 11 1 ELECTRICALDIAGRAMS...

Page 53: ...ckw rotation electrov solenoid EV1B Counter clockw rotation electrov solenoid EV2A Boom lifting electro valve solenoid EV2B Boom lowering electro valve solenoid EV3A Extensions electro valve solenoid...

Page 54: ...Rotation motor 4 Lifting cylinder 5 Overcenter valve 6 Pressure switch 7 1st extension cylinder 8 2st extension cylinder 9 Overcenter valve 10 Sequence valve 11 Oil filter 12 Oil tank 13 Swivel hydra...

Page 55: ...or 4 Lifting cylinder 5 Overcenter valve 6 Pressure switch 7 1st extension cylinder 8 2st extension cylinder 9 Overcenter valve 10 Sequence valve 11 Oil filter 12 Oil tank 13 Swivel hydraulic coupling...

Page 56: ......

Page 57: ...it Name of the installer person Name of the authorized installer workshop Address City Province State Tel number Date Reproduction and distribution are forbidden according to law without written permi...

Page 58: ...NEXT HYDRAULICS s r l Via Mediterraneo 6 42022 Boretto Reggio E Italy Tel 0522 963008 Fax 0522 963039 e mail nexthydraulics tin it...

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