Cobra Maxilift 5500 Use And Maintenance Manual

SERVICE CRANE

Mod.

5500

USE AND MAINTENANCE MANUAL

Code MD.0.176
Rev 0
Edition 07/09

OPTIONALS SUPPLIED ALONG WITH THE CRANE

Description YES NO

Oil tank

Outrigger beam - (mechanical jack)

Outrigger beam - (hydraulic jack)

The table has to be filled carefully with the above option when purchased

PRELIMINARY INFORMATION

Operator’s and maintenance manual of MAXILIFT COBRA 5500 SERVICE CRANE

Manual code: MD.0.176

This manual is valid starting from serial no: .......

Manufacturer: NEXT HYDRAULICS S.r.l.

Via Mediterraneo 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 manual (for the end user)

SERIAL NO:..............................................................

YEAR OF MANUFACTURING:.................................

ATTENTION

Always carefully read this manual before operating the crane. Most of the accidents occurred during opera­tions 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 mea­sures are previously taken.

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 Operator safety tips......................................................................................................................................... “ 11

5.5.3 General rules when operating winch ............................................................................................................. “ 11

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: 5500 H ................................................................................................................................................. “ 13

6.2 Model: 5500 E - 12/24 ..................................................................................................................................... “ 14

6.3 Safety devices ................................................................................................................................................. “ 15

6.3.1 Safety devices installed .................................................................................................................................. “ 15

6.3.2 Load limiting device ........................................................................................................................................ “ 15

6.3.3 Relief valve ...................................................................................................................................................... “ 16

6.3.4 Pilot operated holding valves ......................................................................................................................... “ 16

6.3.5 Safety devices’sealing .................................................................................................................................... “ 16

6.4 Microprocessor remote control system ......................................................................................................... “ 1 7

6.4.1 Available control version ................................................................................................................................. “ 17

6.4.2 Electronic power unit ...................................................................................................................................... “ 17

6.4.3 The radio receiver unit .................................................................................................................................... “ 18

6.4.4 The cable keyboard ........................................................................................................................................ “ 18

6.4.5 The keyboard radio trasmitter ........................................................................................................................ “ 19

6.4.5.1 Radio system protection device ..................................................................................................................... “ 20

6.4.6 Proportional mono-function regulation hydraulic unit .................................................................................... “ 20

6.4.7 Proportional dual-mode regulation hydraulic unit ......................................................................................... “ 21

6.4.8 Wiring .............................................................................................................................................................. “ 21

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II

6.5 Remote control use ................................................................................................................................ Page 22

6.5.1 Use of the mono-function proportional remote control .................................................................................. “ 22

6.5.2 Use of the dual-mode proportional remote control ....................................................................................... “ 22

6.6 Signal and diagnostic ..................................................................................................................................... “ 23

6.6.1 Keyboard diagnostic signal ............................................................................................................................ “ 23

6.6.2 Display messages ......................................................................................................................................... “ 24

6.6.3 Normal display menu ..................................................................................................................................... “ 24

6.6.4 Micro-switches and pressure switch display menu ...................................................................................... “ 26

6.6.5 Current display menu ..................................................................................................................................... “ 26

6.6.6 Remote control keyboard display menu ........................................................................................................ “ 27

6.6.7 Work pressure display menu ......................................................................................................................... “ 28

7 OPERATING INSTRUCTIONS .........................................................................PAGE 29

7.1 General attentions .......................................................................................................................................... “ 29

7.2 Stabilizing the truck ......................................................................................................................................... “ 3 0

7.3 Opening the crane .......................................................................................................................................... “ 32

7.4 Closing the crane ........................................................................................................................................... “ 32

7.5 Winch system operation ................................................................................................................................. “ 32

7.6 Before starting traveling on road .................................................................................................................... “ 3 2

7.7 Main errors occurring when operating the crane ........................................................................................... “ 32

7.8 Standard hand signals ................................................................................................................................... “ 33

8 PUTTING THE CRANE INTO SERVICE ................................................................ “ 34

8.1 Ten rules for the perfect crane operator ......................................................................................................... “ 34

8.2 Daily check list ................................................................................................................................................ “ 3 4

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 Warnings ........................................................................................................................................................ “ 36

9.2 Maintenance prescriptions ............................................................................................................................. “ 36

9.3 Maintenance schedule ................................................................................................................................... “ 3 7

9.3.1 Daily checking ................................................................................................................................................. “ 3 7

9.3.2 Monthly checking ............................................................................................................................................ “ 3 8

9.3.3 Checking every six months ............................................................................................................................. “ 3 8

9.3.4 Others ............................................................................................................................................................. “ 38

9.4 Crane servicing ............................................................................................................................................... “ 39

9.4.1 Oil level checking ............................................................................................................................................ “ 39

9.4.2 Oil change ....................................................................................................................................................... “ 3 9

9.4.3 Oil filter replacement ...................................................................................................................................... “ 39

9.4.4 Wormgear assembly control .......................................................................................................................... “ 4 0

9.4.5 Greasing the hydraulic boom sections .......................................................................................................... “ 40

9.4.6 Wear pads check and replacement ............................................................................................................... “ 40

9.5 Greases and oils reference table .................................................................................................................. “ 41

9.6 Wire rope ........................................................................................................................................................ “ 42

9.6.1 Wire rope inspection ...................................................................................................................................... “ 4 2

9.6.2 Rope replacement .......................................................................................................................................... “ 42

9.6.3 Wire rope lubrication ...................................................................................................................................... “ 4 3

9.7 Possible faults and relevant remedies .......................................................................................................... “ 44

10 TECHNICAL DATA ............................................................................................... “ 46

11 WIRING AND HYDRAULIC DIAGRAMS ................................................................ “ 48

11.1 Electrical diagram ........................................................................................................................................... “ 48

11.2 Hydraulic diagrams ........................................................................................................................................ “ 50

11.2.1 Hydraulic diagram mono-function proportional ............................................................................................. “ 50

11.2.2 Hydraulic diagram dual-mode proportional ................................................................................................... “ 5 1

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 so­mething is found wrong.

2

NOTE

The table on the back of the front page has to be filled at customer’s care. It contains all the ne­cessary 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 Custo­mer 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 concer­ned (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 CRANE IDENTIFICATION

3.1 VERSIONS AND OPTIONS AVAILABLE

The service instructions written on this manual are referred to the CRANE MAXILIFT COBRA 5500. This
model is supplied in 8 versions. When ordering, one or more of the following versions are to be specified:

Version Remote control Hydraulic supply Power supply
5500 KP - H Cable - Proportional mono-function Fed by a punp, driven by a P.T.O. truck 12 - 24V
5500 KP - E Cable - Proportional mono-function Fed by a DC electro-hydr. power pack 12 - 24V
5500 KPD - H Cable - Proportional dual-mode Fed by a punp, driven by a P.T.O. truck 12 - 24V
5500 KPD - E Cable - Proportional dual-mode Fed by a DC electro-hydr. power pack 12 - 24V
5500 RKP - H Radio - Proportional 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 Fed by a punp, driven by a P.T.O. truck 12 - 24V
5500 RKPD - E Radio - Proportional dual-mode Fed by a DC electro-hydr. power pack 12 - 24V

The following options are available for the above versions:

Type of optional Available on models

Oil tank (only for H version)

Outrigger beam - (mechanical Jack) All

Outrigger beam - (hydraulic jach) All

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.

Data plate description

a) Crane model
b) 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.

Pict. 1

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 3,5 ton-meter (25,000 ft. lbs.), making it especially suitable for instal­lation 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;

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.

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 ja-ckets or unzipped overalls, which could get caught up in the moving parts of the
crane.

• Keep quickly and readily available on the truck a first-aid box and a fire extinguisher. The fire extin

guisher must always be kept charged and has to be used according to current regulations.

5.2 RULES CONCERNING THE CRANE

• The Manufacturer is not liable for accidents occurred during the usage of the crane caused by non
fulfillment from the opera tor’s side of current rules, laws and regulations.

• The crane is designed to be used within the -30°/+50° (-22 °F/ +122 °F) temperature range and has to be
operated only in this range. The manufacturer is not liable for accidents occurred during the usage of
the crane outside this temperature range.

• Carefully read the Operator’s and maintenance manual before starting up, using, servicing or doing any
thing on the crane.

• Read and follow all the safety instruction plates applied on the crane before starting up, using, servicing
or doing anything on the crane.

• Do not use controls and hoses as handholds: these parts move and cannot provide stable support.
Furthermore, a control mistakenly moving can accidentally set the crane in motion.

• The operator’s control desk must always be kept clean from oil, grease, mud, snow to avoid accidents
due to slippery surface.

• The safety instruction plates, notices, load charts and any other sticker applied on The crane must be
kept readable and in good conditions. If necessary, replace them. The position of these plates is shown
in the following picture.

1R

1L

5

2

3

4

8

7

6

6

7

2

Pict. 2

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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/cm

2

) (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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Pict. 3

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• 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 ou­trigger 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 expe­rienced 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 regula­tions. 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 insu­lating 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. Moinsten the ground all around the rod to

improve conductivity.

• Then connect the other side of the cable to the insulated rod. Both connections must be made using the
relevant vices or metal clamps as an alternative.

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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 hydraulic 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.

-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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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.

5.5.2Operator 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

5.5.3General 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

control 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 loads 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.

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5.6 WIRE ROPE

5.6.1General

Wire rope can be the weak link in crane safety. It is subjected to heavy loads, abrasion, kinking, extreme
weather conditions, chemical attack and other forces which can reduce its reliability. The inspection and
care of wire rope is essential in the effort to provide for safe working conditions.

5.6.2Wire rope precautions

1 - Avoid the formation of kinks. Kinks will cause severe weakness in the rope. No corrections are availa

ble for kinked rope.

2 - Do not drag wire rope over a non-rotating support such as a non-functioning sheave. Severe abrasion

caused to outer wire strands will result from friction.

3 - Do not use worn sheaves or flat grooved sheaves. They do not provide support to the full radius of the

rope. Flattening and distortion will result.
4 - Do not use nicked or otherwise broken sheaves. Necks and cracks in sheaves will cut the wire rope.
5 - Evenly wrap wire rope onto the drum. Uneveness will cause crusking and/or crimping of the rope.
6 - Select replacement wire rope to match the capacity and use of the crane. The crane was originally

equipped with appropriate wire rope.
7 - Do not expose the rope to corrosive chemicals.
8 - Lubricate the rope frequently to reduce friction and help prevent corrosion.

Pict. 4

13

6 DESCRIPTION OF THE CRANE

6.1 MODEL 5500 H

Item Description

1 Slewing system
2 Slewing motor
3 Column
4 Main boom
5 Boom hoist cylinder
6 First hydraulic boom section
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 Oil tank - (only for H version ) OPTIONAL
16 Outrigger beam - (mechanical jack) OPTIONAL
17 Outrigger beam - (hydraulic jack) OPTIONAL

16

17

3

15

2

1

4

5

6

7

8

9

10

11

13

14

Pict. 5

12

14

6.2 Model 5500 E 12/24

Item Description

1 Slewing system
2 Slewing motor
3 Column
4 Main boom
5 Boom hoist cylinder
6 First hydraulic boom section
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 Elettro-hydraulic power pack
16 Outrigger beam (mechanical jack) OPTIONAL
17 Outrigger beam (hydraulic jack) OPTIONAL

16

17

3

2

1

4

5

7

10

11

14

Pict. 6

8

9

6

13

15

12