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Summary of Contents for Cobra Maxilift 5500
- Page 1 SERVICE CRANE 5500 Mod. Code MD.0.176 USE AND MAINTENANCE MANUAL Edition 07/09...
- Page 2 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: ..
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Page 3: Table Of Contents
INDEX FOREWORD ....................P Summary ................................ “ Remarks ................................. “ Manual revision ............................... “ HOW TO CONSULT THE MANUAL ..............“ Instructions ..............................“ CRANE IDENTIFICATION ..................“ Versions and optional available ........................“ Crane identification data ..........................“ CRANE USAGE AND LIMITS OF APPLICATIONS..........“ Crane classification and proper usage ...................... - Page 4 Remote control use ..........................Page 6.5.1 Use of the mono-function proportional remote control .................. “ 6.5.2 Use of the dual-mode proportional remote control ..................“ Signal and diagnostic ............................. “ 6.6.1 Keyboard diagnostic signal ..........................“ 6.6.2 Display messages ............................“ 6.6.3 Normal display menu .............................
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Page 5: Age
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. -
Page 6: Manual Revision
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. -
Page 7: 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:... -
Page 8: Crane Usage And Limits Of Applications
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 instal- lation on light truck. - Page 9 • 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; •...
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Page 10: Safety Rules
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. •... -
Page 11: Rules For The Correct Positioning Of The Crane
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. •... -
Page 12: Safety Distance From Electrical Power Lines
• 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 •... - Page 13 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...
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Page 14: Influence Of The Wind On The Crane Operation
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. -
Page 15: General Rules On Winch Operations
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. -
Page 16: Wire Rope
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. -
Page 17: Description Of The Crane
DESCRIPTION OF THE CRANE 6.1 MODEL 5500 H Item Description Slewing system Slewing motor Column Main boom Boom hoist cylinder First hydraulic boom section Second hydraulic boom section First telescope cylinder Second telescope cylinder 10 Hydraulic unit 11 Electronic Power unit 12 Cable or radio remote control box 13 Winch 14 Travelling block... -
Page 18: Model: 5500 E - 12/24
6.2 Model 5500 E 12/24 Item Description Slewing system Slewing motor Column Main boom Boom hoist cylinder First hydraulic boom section Second hydraulic boom section First telescope cylinder 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... -
Page 19: Safety Devices
6.3 SAFETY DEVICES 6.3.1Safety devices installed All the safety devices,installed on MAXILIFT COBRA 5500 crane, are listed and described in the following pages. description of safety functions The crane is fitted with 4 standard electrohydraulic safety limitations: 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. -
Page 20: Relief Valve
6.3.3 Relief valve The main relief valve is on the control valve 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. -
Page 21: Microprocessor Remote Control System
6.4 MICROPROCESSOR REMOTE CONTROL SYSTEM COBRA cranes are equipped with an advanced microprocessor remote control system that correctly manages the crane operations as well as its safety devices and provides indications to help the operator performing rapid troubleshooting or adjustments when necessary. -
Page 22: The Radio Receiver Unit
6.4.3 THE RADIO RECEIVER UNIT (Pict.10) The radio control version unit (3) is externally equal to the remote control version, internally, it includes the electronic system that manages machine logic and radio module and works as a receiver; a safety system prevents other transmitters from entering the system since it only recognizes its matched keyboard (transmitter) through the RFID code (radio frequency identifier). -
Page 23: The Keyboard Radio Trasmitter
6.4.5 THE KEYBOARD – RADIO TRANSMITTER (Pict.10) The operator interface is identical to the abovementioned one. The differences are: The absence of the integral cable, replaced by a connector at the base of the handgrip to connect the battery supply serial cable (1). -
Page 24: Radio System Protection Device
6.4.5.1 RADIO SYSTEM PROTECTION DEVICES The radio control system is provided with some protection systems that are automatically started in case of: - radio interference on the crane working area that influences the radio control frequency range - transmitter capacity field exceeded (keyboard) On these cases the system locks all the functions. -
Page 25: Proportional Dual-Mode Regulation Hydraulic Unit
6.4.7 PROPORTIONAL DUAL-MODE REGULATION HYDRAULIC UNIT (Pict.12) The unit is consisting of two separate aluminium blocks. The upper section includes the proportional adjusting valve (VR), the manual bypass control valve (OM) of the proportional regulator, the main relief valve (VM), the winch operating solenoid valves (EV4A – EV4B), the dump valve (EV9) and the solenoid valves (EV3 –... -
Page 26: Remote Control Use
REMOTE CONTROL USE After the preliminary operations concerning: - PTO engaging - extension and lowering of stabilizer legs and their levelling - control system supply by switching on the proper switch inside the cabin - power supply by turning the battery-disconnecting lever in case of electro-hydraulic crane you can go on working with the remote control. -
Page 27: Signal And Diagnostic
6.6 SIGNALS AND DIAGNOSTIC 6.6.1 KEYBOARD DIAGNOSTIC SIGNALS The following signal devices are found on the radio keyboard: - a beeper - a green led Beeper signals: Radio connection keyboard: - a brief signal (beep) indicates that the keyboard is powered (through the emergency button) - a long signal (beep) indicates that the RFID code (radio frequency identifier, exclusively used by authorized workshops) self-learning procedure has been activated. -
Page 28: Display Messages
6.6.2 DISPLAY MESSAGES As previously explained, the electronic control unit is fitted with a 3 digits display showing messages which help the operator understanding if everything is working properly, the operating state and the functioning of its electrical components. The operator, when led by an expert or following basic operations, can actually read on such display different messages helping him locating possible electrical anomalies on the system. - Page 29 The following table shows all the displayed alarm codes. Display Alarm Type Valve on which the alarm is detected open circuit EV on/off 1A (CLOCKWISE ROTATION) open circuit EV on/off 1b (COUNTER-CLOCKWISE ROTATION) open circuit EV on/off 2A (BOOM UP) open circuit EV on/off 2b (BOOM DOWN) open circuit...
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Page 30: Micro-Switches And Pressure Switch Display Menu
6.6.4 MICRO-SWITCHES AND PRESSURE SWITCH DISPLAY MENU This menu is accessed from the Normal Display Menu through the following procedure: push the proportional button to its maximum level, then operate the 1A and 3B movements simultaneously for at least 5 seconds (the maneuver can be performed in radio mode or through serial cable). In this menu the state of FA, FB, FV, PM micro-switches are displayed cyclically, with a 2.5 seconds interval;... -
Page 31: Remote Control Keyboard Display Menu
6.6.6 REMOTE CONTROL KEYBOARD DISPLAY MENU This menu is accessed from the Normal Display Menu through the following procedure: push the proportional button to its maximum level, then operate the 1A and 2B movements simultaneously for at least 5 seconds (the maneuver can be performed in radio mode or through serial cable). In this menu, when no operation is active, the indication “_ _ _”... -
Page 32: Work Pressure Display Menu
6.6.7 WORK PRESSURE DISPLAY MENU This menu is only available on the momentum limiter system with analog pressure transducer and it displays the real time oil hydraulic 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 selector for 5 seconds (the maneuver can be performed in radio mode or through serial cable). -
Page 33: Operating Instructions
OPERATING INSTRUCTIONS 7.1 GENERAL ATTENTIONS The crane must be used exclusively by qualified and skilled operators. They must know location and func- tion of every control, instruments, indicators, lights, plate and sticker. DANGER Before starting operations make sure that nobody is in the working area of the crane. •... -
Page 34: Stabilizing The Truck
• Check every month the state and correct functioning of all the parts subject to wear: pins, valves, hoses, sliding pads and bushings, etc. If necessary replace with genuine spare parts. • It is absolutely forbidden to alterate the hydraulic circuit and open the safety seals. Failure to comply will cause automatically the voiding of any warranty on the product. - Page 35 ATTENTION The outrigger beams are in their working position when the yellow band existing on every beam can be entirely seen. • Lower to the ground the bearing pads of the outriggers jacks, one at a time, acting as follows: Hydraulic jack (Fig.
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Page 36: Opening The Crane
7.3 OPENING THE CRANE • Starting from the crane in rest position, operate the switch of „boom hoist up“ on remote control. When the boom is roughly horizontal or in any case, higher than vehicle sides or other existing obstacles. •... -
Page 37: Standard Hand Signals
• A sudden stop when lowering a load. This creates high forces of inertia on the crane structure with relevant dangerous overload. • Hitting the rope where the load is suspended, overload is generated. • Side pull, dragging the load on the ground. All these operations originate strong overloading forces on the crane. -
Page 38: Putting The Crane Into Service
8 PUTTING THE CRANE INTO SERVICE 8.1 TEN RULES FOR THE PERFECT CRANE OPERATOR Always comply with the following ten basic rules: 1 - When approaching the crane for the first time, become on familiar terms with it, executing all the manoeuvres the crane can perform during working. -
Page 39: Long Shutdowns
ATTENTION Never wash the crane with chemical products or high pressure water jets, as they can cause the detaching of the stickers water entering inside the electrical components and the slewing case. 8.4.2 Long shutdowns Same precautions as above and, moreover: •... -
Page 40: Maintenance
9 MAINTENANCE 9.1 WARNINGS • Do not wear rings, wristwatches, jewelry, loose-fitting or hanging clothing such as ties, torn garments, ordinary shoes, unbut toned jackets or un-zipped overalls, which could get caught up in the moving parts of the crane. Instead, always wear approved accident-prevention clothing such as protective helmets, anti-slip shoes, anti-noise headphones, protective glasses, and reflective jackets with bre athing apparatus. -
Page 41: Maintenance Schedule
DANGER of fire or scald It is forbidden to use naked flame as lighting device when carrying out checks or looking for le- aks in the machine. • Do not lubricate, repair or carry out settings on the crane when it is working, unless this is expressly required in the instructions of the Operator’s/Maintenance manual. -
Page 42: Monthly Checking
9.3.2 Monthly checking • Check the setting of the pressures in the hydraulic system, and integrity of the seals. • Check the absence of oil leaks. • Check integrity and tightening of crane tie rods and bolts. • Check integrity and tightening of hoses, piping and their fittings. •... -
Page 43: Crane Servicing
9.4 CRANE SERVICING 9.4.1 Oil level checking The oil level must be checked daily, with the crane in rest position and the truck on flat ground If necessary top up with hydraulic oil. The level is checked by mean of the dipstick. (1) 9.4.2 Oil change The oil deteriorates during daily usage. -
Page 44: Wormgear Assembly Control
9.4.4 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 the crane at standstill, the boom in horizontal position. Pushing the boom aside on the left and on the right by hand, you can notice if the axial backlash between the wormshaft (6) and the wormgear (8) is too great. -
Page 45: Greases And Oils Reference Table
9.5 Greases and oils reference table BRAND TOTAL MOBIL ESSO AGIP GREASE MULTIS MOBILGREASE BEACON GR MU ATHESIA ENEGREASE LR MP GREASE MULTIS MOBILGREASE BEACOM GR MU ATHESIA ENERGREASE LR MP HYDRAULIC AZOLLA NUTO HYDRUS HENERGOL • • • ZS 46 H 46 HL 80 ZS 48... -
Page 46: Wire Rope
WIRE ROPE 9.6.1 WIRE ROPE INSPECTION Each day and before use, inspect the wire rope for the following conditions: 1 - Kinking (Sharp bends) 6 - Rope diameter loss 2 - Crushing 7 - Rope strand uneveness 3 - Unstranding 8 - General corrosion 4 - Birdcaging 9 - Broken strands... -
Page 47: Wire Rope Lubrication
9.6.3 WIRE ROPE LUBRICATION Wire rope is lubricated during manufacturing so the strands, and individual wires in strands, may move and adjust as the rope moves and bends. A wire rope cannot be lubrificated sifficiently during manufacture to last its entire life. Therefore, new lubricant must be added periodically throughout the life of a rope to replace factory lubricant which is used or lost. -
Page 48: Possible Faults And Relevant Remedies
9.7 POSSIBLE FAULTS AND RELEVANT REMEDIES Fault Cause Remedy Vibrations in hydraulic cylinder and jerkin- The temperature of the hydraulic oil is Perform manoeuvres without loads for gs at the first manoeuvres. too low. some minutes to warm the oil up. Vibrations with every functions when the Lacking of oil in the tank. - Page 49 Fault Cause Remedy One of the function does not work. Defective switch Replace the switch Burned solenoid. Replace the solenoid. Locked valve cartridge Disassemble and clean the valve cartri- Damaged electric connection. Check continuity of the circuit All the functions do not work No power (or insufficient) to the shunt Check relevant fuzes and indicator LEDS boarder the remote control box...
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Page 50: Technical Data
480 (E) - 455 (H) Slewing torque WINCH SPECIFICATION 5500 Winch pull line 1200 Pull line speed m/min m/min 5 - 9.5 Rope diameter Wire rope length Cable breaking strength minimum 6050 Technical data not binding Pict. 24 LOAD CAPACITIES COBRA 5500... - Page 51 Slewing torque ft.lbs 2.500 WINCH SPECIFICATION 5500 Winch pull line 2.700 Pull line speed ft/min ft/min 16 - 31 Rope diameter inch. 5/16” Wire rope length Cable breaking strength minimum 13.300 Technical data not binding Pict. 25 LOAD CAPACITIES COBRA 5500...
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Page 52: Wiring And Hydraulic Diagrams
11 WIRING AND HYDRAULIC DIAGRAMS 11.1 ELECTRICAL DIAGRAMS Pict. 26... - Page 53 11.1 DESCRIPTION -Crane rotation selector -Boom movement selector -Extension selector -Winch selector -Engine start/stop selector -Optinal function selector (opt) -Green led -Emergency push button -Circuit board -Proportional trigger button -Winch electro-valve solenoid -Winch electro-valve solenoid EV1A -Clockw. rotation electrov. solenoid EV1B -Counter clockw.
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Page 54: Hydraulic Diagrams
11.2 HYDRAULIC DIAGRAMS mono-function 11.2.1 Hydraulic diagram proportional 1 Pump 2 Electrohydraulic unit 3 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 hydraulic coupling (only PTO version) 14 Winch motor... -
Page 55: Hydraulic Diagram Dual-Mode Proportional
11.2.2 Hydraulic diagram Dual-mode proportional 1 Pump 2 Electrohydraulic unit 3 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 hydraulic coupling (only PTO version) 14 Winch motor 15 Overcenter valve... - Page 57 NOTES Name of the installer (person) Name of the authorized installer workshop NEXT HYDRAULICS S.r.l. Address Via Mediterraneo , 6 Boretto 42022 (RE) - ITALY City Province State Tel. 0522/963008 - Fax 0522/963039 Tel number. Date e-mail: nexthydraulics@tin.it COPYRIGHT BY NEXT HYDRAULICS S.r.l. Layout and pubblication by “...
- 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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Questions and answers
the remote for the crane only works with the cord, the crane was just bought used with the service truck ( crane is a 2014 cobra maxilift 5500) Have a new RX-DBX modual on it
The remote for the 2014 Cobra Maxilift 5500 crane may only work with the cord because the wireless system uses an RFID code to recognize its matched transmitter. If the transmitter is not correctly paired, damaged, or the antenna is missing or faulty (especially for the 868 MHz European version), the remote will not function wirelessly. Therefore, it defaults to corded operation.
This answer is automatically generated
J'AI BESOIN DU FIL QUI PLUG DAND L'ALLUME CIGARETTE POUR CHARGER LA BATTERIE DE LA MANETTE NUMERO DE PIECE ET PRIX SVP