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SERVICE CRANE Mod. 4400USE AND MAINTENANCE MANUALCode MD.0.141Rev 0Edition 07/09

65 SAFETY RULES5.1 RULES CONCERNING PEOPLE• Always wear the prescribed personal safety devices• Always wear approved accident-prevention clothing such

75.3 RULES FOR THE CORRECT POSITIONING OF THE CRANE5.3.1Choice of crane operating place pressure on the ground• Carefully choose the place where lower

8Pict. 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 crumbli

9Grounding is especially required when:• working close to electric power lines;• working nearby powerful broadcasting plants such as radio, T.V., an s

10!!DANGERelectrocution hazardAlways connect in a perfect way the load and the groundBefore touching the load with your hands, always ground the load

115.5 GENERAL RULES ON WINCH OPERATIONS5.5.1 Winch system operationThe Winch is mounted at the rear of the first section boom.It has capacities tota

125.6 WIRE ROPE5.6.1GeneralWire rope can be the weak link in crane safety. It is subjected to heavy loads, abrasion, kinking, extremeweather condition

136 DESCRIPTION OF THE CRANE6.1 MODEL 4400 HItem Description1 Slewing system2 Slewing motor3 Column4 Main boom5 Boom hoist cylinder6 First hydraulic b

146.2 Model 4400 E 12V/24VItem Description1 Slewing system2 Slewing motor3 Column4 Main boom5 Boom hoist cylinder6 First hydraulic boom section7 Secon

156.3 SAFETY DEVICES6.3.1Safety devices installedAll the safety devices,installed on MAXILIFT COBRA 4400 crane, are listed and described in the follow

OPTIONALS SUPPLIED ALONG WITH THE CRANEDescription YES NOOil tankOutrigger beam - (mechanical jack)Outrigger beam - (hydraulic jack)The table has to b

166.3.3Relief valveThe main relief valve is on the control valve and limits the maximum working pressure.6.3.4Pilot operated holding valvesThese valve

176.4 MICROPROCESSOR REMOTE CONTROL SYSTEMCOBRA cranes are equipped with an advanced microprocessor remote control system that correctly managesthe cr

186.4.3 THE RADIO RECEIVER UNIT (Pict.10)The radio control version unit (3) is externally equal to the remote control version, internally, it includes

196.4.5 THE KEYBOARD – RADIO TRANSMITTER (Pict.10)The operator interface is identical to theabovementioned one.The differences are:- The absence of th

206.4.5.1 RADIO SYSTEM PROTECTION DEVICESThe radio control system is provided with some protection systems that are automatically started in case of:-

216.4.7 PROPORTIONAL DUAL-MODE REGULATION HYDRAULIC UNIT (Pict.12)The unit is consisting of two separate aluminium blocks.The upper section includes t

226.5 REMOTE CONTROL USEAfter the preliminary operations concerning:- PTO engaging- extension and lowering of stabilizer legs and their levelling- con

236.6 SIGNALS AND DIAGNOSTIC6.6.1 KEYBOARD DIAGNOSTIC SIGNALSThe following signal devices are found on the radio keyboard:- a beeper- a green ledBeepe

246.6.2 DISPLAY MESSAGESAs previously explained, the electronic control unit is fitted with a 3 digits display showing messages which helpthe operator

25The following table shows all the displayed alarm codes.Display Alarm Type Valve on which the alarm is detectedO1A open circuit EV on/off 1A (CLOCKW

INDEX1 FOREWORD ...PAGE 11.1 Summary ...

266.6.4 MICRO-SWITCHES AND PRESSURE SWITCH DISPLAY MENUThis menu is accessed from the Normal Display Menu through the following procedure:push the pro

276.6.6 REMOTE CONTROL KEYBOARD DISPLAY MENUThis menu is accessed from the Normal Display Menu through the following procedure:push the proportional b

286.6.7 WORK PRESSURE DISPLAY MENUThis menu is only available on the momentum limiter system with analog pressure transducer and itdisplays the real t

297 OPERATING INSTRUCTIONS7.1 GENERAL ATTENTIONSThe crane must be used exclusively by qualified and skilled operators. They must know location and fun

30• Check every month the state and correct functioning of all the parts subject to wear: pins, valves, hoses,sliding pads and bushings, etc. If neces

31ATTENTIONThe outrigger beam is in its working position when the yellow band existing on the beam can beentirely seen.• Lower to the ground the beari

327.3 OPENING THE CRANE• Starting from the crane in rest position, operate the switch of „boom hoist up“ on remote control. Whenthe boom is roughly ho

33• Hitting the rope where the load is suspended, overload is generated.• Side pull, dragging the load on the ground. All these operations originate s

348 PUTTING THE CRANE INTO SERVICE8.1 TEN RULES FOR THE PERFECT CRANE OPERATORAlways comply with the following ten basic rules:1 - When approaching

35ATTENTIONNever wash the crane with chemical products or high pressure water jets, as they can causethe detaching of the stickers water entering insi

II6.5 Remote control use ...

369 MAINTENANCE9.1 WARNINGS• Do not wear rings, wristwatches, jewelry, loose-fitting or hanging clothing such as ties, torn garments,ordinary shoes, u

37 DANGERof fire or scaldIt is forbidden to use naked flame as lighting device when carrying out checks or looking for le-aks in the machine.• Do not

389.3.2 Monthly checking• Check the setting of the pressures in the hydraulic system, and integrity of the seals.• Check the absence of oil leaks.• Ch

399.4 CRANE SERVICING9.4.1 Oil level checkingThe oil level must be checked daily, with the crane in rest position and the truck on flat ground If nece

409.4.4 Wormgear assembly control (Pict. 21)It is important to check that the worm gear reducer has a correct axial backlash. This can be made, with t

419.5 Greases and oils reference tableBRAND TOTAL MOBIL ESSO AGIP IP BP GREASE MULTIS MOBILGREASE BEACON GR MU ATHESIA ENEGREASEEP2 MP EP2 EP2 EP2

429.6 WIRE ROPE9.6.1 WIRE ROPE INSPECTIONEach day and before use, inspect the wire rope for the following conditions:1 - Kinking (Sharp bends) 6 - Rop

439.6.3 WIRE ROPE LUBRICATIONWire rope is lubricated during manufacturing so the strands, and individual wires in strands, may move andadjust as the r

449.7 POSSIBLE FAULTS AND RELEVANT REMEDIESFaultVibrations in hydraulic cylinder and jerkin-gs at the first manoeuvres.Vibrations with every functions

45* Operations to be carried out only by authorised installer workshopThe winch does not work when singleoperatedThe winch does not work when operated

11 FOREWORD1.1 SUMMARYThis manual is divided into chapters to make its consultation easier.Chapter 1: Includes summary and a short introduction.Chapte

4610 TECHNICAL DATA - WINCH SPECIFICATIONSSERIES 4400 STANDARD EQUIPMENT- High speed winch with planetary gears reducer - Remote control with connecti

47TECHNICAL DATA 4400Crane rating ft.lbs 16.000Standard outreach ft. 15’ 9”Slewing angle 400°Boom elevation (-5° +80°)Lifting height from base of cran

48Pict. 2611 WIRING AND HYDRAULIC DIAGRAMS11.1 ELECTRICAL DIAGRAMS

4911.1 DESCRIPTIONSW1 -Crane rotation selectorSW2 -Boom movement selectorSW3 -Extension selectorSW4 -Winch selectorSW5 -Engine start/stop selectorSW6

5011.2 HYDRAULIC DIAGRAMS11.2.1 Hydraulic diagram mono-function proportional1 Pump2 Electrohydraulic unit3 Rotation motor4 Lifting cylinder5 Overcente

5111.2.2 Hydraulic diagram dual-mode proportional1 Pump2 Electrohydraulic unit3 Rotation motor4 Lifting cylinder5 Overcenter valve6 Pressure switch78

NOTESNEXT HYDRAULICS S.r.l.Via Mediterraneo , 6 Boretto 42022 (RE) - ITALYTel. 0522/963008 - Fax 0522/963039e-mail: [email protected] of the i

NEXT HYDRAULICS s.r.l.Via Mediterraneo, 642022 Boretto (Reggio E.) -ItalyTel. 0522/963008 - Fax 0522/963039e-mail: [email protected]

2NOTEThe 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 Techn

33 CRANE IDENTIFICATION3.1 VERSIONS AND OPTIONS AVAILABLEThe service instructions written on this manual are referred to the CRANE MAXILIFT COBRA 4400

44 CRANE USAGE AND LIMITS OF APPLICATIONS4.1 CRANE CLASSIFICATION AND PROPER USAGEThe machine is an hydraulic truck crane for hook service. It can als

5• normal depth perception and field of vision (peripheral);• ability to distinguish colors if color recognition or differentiation is, required for s