Ing. BONFIGLIOLI S.p.A.

CRANE ON TRUCK

USE AND MAINTENANCE

MANUAL
 Mod.

ING. BONFIGLIOLI S.P.A.

BOLOGNA - ITALIA

CAUTION !
Do not use the crane before reading this manual

Most accidents, happening during the work are due to the not-observance of safety rules or to
the lack of elementary precautions. Lots of accidents can be avoided by knowing causes and
taking beforehand suitable measures.

Premise
These service rules and loading diagrams are integral part of the crane supply. First of all they
are designed to the operator and include all information about the recommended possibility of
safe use of the crane.
These service rules are not a teaching guide for the inexperienced operator. In all descriptions
we suppose that anyone who operates with the crane must be well trained and have experience
of the crane and its operation.

The operator is the sole direct responsible of the crane itself and the work done
with it.
Hurried and incomplete operations force to the improvisation, which is the main
cause of lots accidents.
Respect always the following basic instructions:

1. Before working get experienced with crane manoeuvres in any position.

Read all service rules and carry out on testing all activities on the crane described on this guide

2. Bring always the service manual and the load charts in the cabin.

3. Plan carefully every manoeuvre and operation.

4. Make sure to have all the necessary information on to the working place: distance, itinerary,
height of passages, bridges capacity etc..

5. Study where and how the crane use is expected: soil capacity, loads, their dimensions, lift
height and necessary range, limitation movements because of buildings, electrical and
telephonic lines, etc...

6. Do not utilise the crane with environmental conditions of poor visibility (inadequate lighting,
fog, etc.)

7. Make sure to have the necessary equipment always available: certified and in a good
condition breeches and ropes, stabilizer blocking plates, personal protective devices, etc.

8. Before starting any work make sure that safety devices work correctly: never use the crane
when there are doubts about the correct functioning of one of those.

9. Respect all rules and relevant prescriptions which have been established by the laws in force
on prevention of accidents and of road circulation during the road transport and the crane work.

10. The safety precautions must be read and followed by anyone involved at any title with the
work of the loader.

11. Keep always high level of the safety service of the crane through one preventive, constant
and careful maintenance. Never postpone due reparations which must be done by authorised
staff only. Use original spare parts only.
.
TABLE OF CONTENTS
1 INTRODUCTION
1.1 INSTRUCTIONS OF USE
2 GENERAL SPECIFICATIONS
2.1 MACHINE DESCRIPTION
2.2 NORMAL USE CONDITION
2.3 ABNORMAL FORESEEABLE USE CONDITION
2.4 REQUIRED OPERATOR'S TRAINING
2.5 CLASSIFICATION OF CRANE
2.6 RATING PLATES
3 SAFETY INSTRUCTIONS
3.1 SAFETY ON THE ROAD
3.2 SAFETY AT WORKS
3.3 SAFETY OF ON USE
3.4 GENERAL SAFETY RULES
3.5 MANOEUVRING ERRORS
3.6 LOAD LIMITER
4 GENERAL INSTRUCTIONS
5 SETTING AT WORK
5.1 CHECKS BEFORE THE SETTING AT WORK
5.2 CHECKS BEFORE EVERY WORKING DAY
5.3 PRECAUTIONS BEFORE STARTING IN COLD CLIMATE
5.4 ACCESSORIES
5.5 TRAVELLING ON THE ROAD
5.6 PROTECTION AND STORAGE
6 CONTROLS
6.1 CONTROLS DESCRIPTION
7 MANOEUVRES
7.1 GENERAL INFORMATION ABOUT STABILIZATION
7.2 MANUAL STABILIZER EXTENSIONS
7.3 HYDRAULIC STABILIZER EXTENSIONS
7.4 CRANE WORK POSITION
7.5 INSTRUCTIONS FOR THE USE OF THE CRANE
7.6 CRANE STOWED POSITION
7.7 HYDRAULIC FLYING JIB
8 CRANE MAINTENANCE
8.1 TIGHTENING CHECK
8.2 LONG INACTIVITY
8.3 LUBRICATION
8.4 DEMOLITION AND ELIMINATION
9 FINDING FAILURES
10 SAFETY DEVICES
10.1 EMERGENCY PUSH BUTTONS
10.2 LOCK VALVES AND CONTROL LOWERING
10.3 LOAD LIMITER
10.4 WEDGES FOR STOWED CRANE
11 NOISE
TECHNICAL SPECIFICATIONS
1. INTRODUCTION
The present general service rules are good enough for any size of crane: or model and it will be
duly noted when peculiar diagrams, or rules are requested for a special model.

1.1. INSTRUCTIONS OF USE

Read all the instructions of this manual before working with the crane.
The following remarks are noted in the service manual and they mean:

DANGER: It refers to activities which imply real danger for people.

WARNING: It refers to danger that involves objects only, like the crane itself or the load.

Instructions: Here there are some integrations and advices for the crane use.
2. GENERAL SPECIFICATIONS
2.1. MACHINE DESCRIPTION
The machine in subject is a hydraulic crane with a knuckle boom fitted with a suitable subframe,
on the frame of a commercial vehicle and destined for loading and unloading stuff.
The crane components are the following:

1) Base with supports for stabilizer extensions

2) Stabilizer extensions
3) Stabilizer extension rams (for hydraulic stabilizer extensions only)
4) Outrigger rams
5) Column slewing with pinion and rack (fig.1) or with slewing ring with hydraulic motor and gear (fig.2)
6) Column ram (main lifting ram)
7) First boom on the top of the column
8) Second boom ram
9) Second boom
10) Hydraulic extensions with a telescopic shift
11) Hydraulic extensions rams
12) Valve block with control levers
13) Control levers on opposite side
14) Load limiter
15) Lock emergency push button with light signals

The crane can be equipped with extra options like the flying jib ( for description, see Chapter 7)
2.2. NORMAL USE CONDITIONS
The crane must be used for lifting vertically only the stuff, with side movements only when loads
are suspended.

2.3. ABNORMAL FORESEEABLE USE CONDITIONS

The crane cannot be used for:
. dragging or pushing materials still laying on ground
. hoisting materials or constrained objects (tree uprooting, pole drawing , etc.)
. hosting people if the crane is not equipped and tested for this purpose.
. working in explosive or corrosive atmospheres
. working in difficult environmental and climatic conditions ( see Chapter 3 )
2.4. REQUIRED OPERATOR'S TRAINING
The dealer, responsible of installation, gives suitable instructions to the operator for the use of
the crane. The customer receives, with the crane, the use and also spare parts book.
The crane must be used by skilled operators only, who:
. have suitable physical and psychical requirements
. well trained with the crane after having studied the necessary theoretical and practice
information given by the installer, and the operator instructions for working with this type of
device

2.5. CLASSIFICATION OF THE CRANE

2.5.1. Below reference rules have been used for the project of this crane

DIN 15018/1
DIN 15018/3
DIN 4114/1-2
DAST-RICHTLINIE 011
DIN 15019/2
EN 12999

2.5.2. Expected working life hoisting with the hook

200000 ÷ 600000 working cycles

In case of crane usage with terminal fixtures like grabs, buckets, magnet, grapples for tree
trunks, etc. the usage is more difficult. In this case the operator must communicate it to the ING.
BONFIGLIOLI S.P.A.. which will supply him with a suitable diagram with reduced loads so as to
take into consideration the most difficult employment conditions, and relevant dynamic effects.
2.5.3. Class
H1-B2/B3 standard classification of lifting crane
H3-B4 standard classification of scrap or timber cranes
2.6. RATING PLATES
2.6.1. WARNING PLATES AND LOADING DIAGRAMS
The following stickers are located on the crane; they must be always shown and replaced when
damaged

The stickers, which are shown below (one on both side of the crane), and they can be located on
different places according to the model of crane and truck fitting (rear of cabin or rear of truck);
they must be always located near the levers for being in front of the operator when manoeuvring

2.6.2. CE plates
On the crane are visible located the following CE plates.
3. SAFETY INSTRUCTIONS
The crane has been projected and manufactured on the basis of the actual state of the art and of up
to dated rules concerning the crane for loading and unloading. All laws, dispositions, instructions,
orders, directive in force today for making truck cranes have been followed. Used materials,
equipment, parts and production procedures, quality assurance and control satisfy the maximum
requirements of safety and crane reliability. Using the crane for forecast purposes only according to
services rules, right manoeuvring, carrying out an accurate maintenance and proper revisions it is
possible to have high performances and long life of the crane.

3.1. SAFETY ON THE ROAD

The crane in most cases is mounted on a commercial truck. This installation must be done
according to the regulations in force in the respective countries, and engineering requirements.
Travelling on the road with the crane, all the regulations in force have to be respected.

3.2. SAFETY AT WORK

The manufacture is not responsible for any accident happened during the use of the crane,
caused by operator's mistake or not observance of laws, or rules of use of the crane.
The crane has been projected for the use with temperature from -10°C to 60°C. It should work
inside this range of temperature only.
The manufacturer is not responsible for accidents which are caused by the use of crane outside
above limit temperature.

3.3. SAFETY ON USE

The manufacturer is not responsible in case of anomalous functioning or damages, if the crane is:
- used for other aims and not for those ones for which it was destined;
- not manoeuvred in accordance with its services rules;
- not properly maintained and/or the maintenance is not done as prescribed or not original spare
parts are used
- modified or changed the equipment without manufacturer's permission;
- when the safety system efficiency has been reduced or intentionally out of order;
- used over the approved limit of temperature.

3.4. GENERAL SAFETY RULES

3.4.1. Cares and maintenance

Maintenance mistakes are the cause of lots damages and accidents :
- lack of oil or antifreeze grease ;
- dirt;
- breaking of ropes;
- emergency limit switch, rotation limit switch or load limiter out of order;
- hydraulic deficiency, i.e. damaging of hoses and low tightening of bolts and nuts.

WARNING: Maintenance works are to be done carefully, for the own safety too.
Never postpone reparations works. Qualified personnel only is allowed to repair the crane.

3.4.2. Before working with the crane

Also when a good knowledge of crane manoeuvres is acquired, never forget the observance of
the following safety rules:
- Adequate the speed of vehicle to the conditions of the road. Pay attention to the height of
underpass under bridges, roofs, electric lines and similar.
- Maintain always clean the glass of the cabin.
- Before starting the work check if all movements, load limiter, protection devices work well.
- Do not let anybody get in to the container or in to the truck cabin.
- Do not use the crane to lift people.
- Continuously assure that people are in the range of the crane. Warn people with electric horn or
personally, and stop working if people do not go away.

3.4.3. Working with the crane

- Never leave the manoeuvring place with the suspended load
- Keep under eye control the load and the hook especially during crane movements.
- Use only slings with known and certified capacity.
- Fix mechanic extensions with security pins only.
- Introduce always pins from the outside towards the inside. Pins do not have to protrude.
- Make sure that each pin has got safety peg.

3.4.4. Manual signals for the authorized staff to give instructions

When it is not possible to see clearly the load, it is better to put a person in charge of giving
instructions with signals: by arms or radio.

3.4.5. Ground capacity and stabilization

Choose carefully the ground for the outriggers. The most important thing is that the ground is
able to support pressures caused by them. Verify the presence of hidden lines and check that
there are not channels or sewers. Choose the place so that the working area remains reduced
and there are not obstacles in the slewing reach. Never unfold the crane from the travelling
position without having stabilized the truck. Increase the supporting area of the stabilizers
whenever the pressure on the ground exceeds the earth strength, with large wooden or steel
plates. The supporting surface can be calculated according to the outriggers reaction and to the
ground capacity:
Approximate value for the ground capacity:
CAPACITY
TYPE OF GROUND (kg/cm²)

Embankment ground, not artificially tamped from 0,0 to 1,0

Embankment ground, apparently virgin:

- Mud, peat, marshy ground 0,0
Not coherent grounds, but sufficiently compact :
- fine sand and medium 1,5
- coarse sand and pebble gravel 2,0
Coherent ground:
- pasty 0,0
- soft 0,4
- stiff 1,0
- half-solid 2,0
-solid 4,0
Rock with minimum leak, not changed by atmospheric agents and with
a favourable stratification:
- closed stratification 15,0
- back or pillar make-up 30,0

Calculation of the pressure bearing.

D = reaction on the ground (daN) defined for each single crane in the chapter 8 of the installation manual.
A = area of supporting plate (cm²)
p = D/A = pressure bearing in (daN/cm²)

WARNING: If there are doubts about the ground capacity it is better to carry out a soil
test. Level always the truck with the stabilizers.

DANGER: When the vehicle on which the crane is mounted is inclined, there is the
danger that it overturns. Work always with vehicle in horizontal position.

3.4.6. Safety distance from slope and ditches

Park the truck-crane at a safe distance from road slopes or ditches.
Practical rule:
In case of land subject to landslides or embankment, the
safety distance (a) must be the double of the ditch depth
(b). a = 2xb
In case of compact ground, not subject to landslides, the
safety distance (a) must be the same as the ditch depth
(b). a = 1xb
The safety distance is calculated from the foot ditch (c).

3.4.7. Safety distance from electric lines

Keep always a sufficient safety distance when in the crane working area there are electric
lines, overall in case there are overhead lines which have not been switched off or whose
state is unknown.
In Italy the D.P.R. 164 provides for a distance of 5 metres, for any value of tension. This value is
absolutely minimum, so during the manoeuvres no parts of the crane and of the fittings have to
overcome this limit.

DANGER: During strong wind, the lines can swing according to their length. Keep
always a distance of 5 meters increased of the eventual swinging. Observe in any case
the specific national rules.

3.4.8. Connect the crane and load on earth

The crane can charge electrostatic by itself. It can happen especially when the crane is on bearing
plates, which are made of plastic, or elements put between bearing plates and ground are made of
insulating material (for example tables of wood).
In some cases the load can be charged electrostatic by itself even if the crane has been put on the
ground.
DANGER: Before starting any work with the crane, connect it with the load on the earth
- nearby a strong transmitters (radio transmitter, station and so on...)
- nearby a high frequency transformer
- during storms.

3.4.9. Wind influence on the crane work

Strong wind can overload the crane. Check always the wind speed during the work.
The allowable wind speed with all the load on the crane is : Max. 50 km/h ( 35 MPH )
When the allowable wind speed is exceeded, stop working and set the crane in stowed position.
As a helpful thing refer to the following table to evaluate the wind effects

WIND FORCE WIND SPEED

WIND EFFECT INLAND
Beaufort n° Name m/s km/h

0 calm from 0 a 0,2 1 Calm, smoke rises vertically

Direction of wind shown only by smoke, not by winds

1 light air from 0,3 to 1,5 from 1 to 5
vanes
Wind felt on face, leaves rustle; ordinary vane moved by
2 light breeze from 1,6 to 3,3 from 6 to 11
wind
Leaves and small twigs in constant motion; wind
3 gentle breeze from 3,4 to 5,4 from 12 to 19
extends light flag
Raises dust and loose paper, small branches are
4 moderate breeze from 5,5 to 7,9 from 20 to 28
moved

5 fresh breeze from 8,0 to 10,7 from 29 to 38 Small trees in leaf begin to sway;

Large branches in motion; telegraph wires whistle;

6 strong breeze from 10,8 to 13,8 from 39 to 49
difficulties to used umbrellas
All trees in motion; inconvenience in walking against
7 moderate gale from 13,9 to 17,1 from 50 to 61
wind

8 fresh gale from 17,2 to 20,7 from 62 to 74 Breaks twigs off trees; generally impedes progress
 Slight structural damages occur (chimney pots and
9 strong gale from 20,8 to 24,4 from 75 to 88
slates removed)

10 whole gale from 24,5 to 28,4 from 89 to 102 Trees uprooted; considerable structural damages occur

3.4.10 Equipment weight

The weight of the load equipment (winch, grab, etc.) has to be deducted from the useful load.

3.5. MANOEUVRING ERRORS

Lack of attention and of instruction to avoid, can cause dangers during the real work of the crane.
These manoeuvring errors are for example :
- sling too much heavy loads. At the beginning check the load amount and control that the crane
capacity does not exceed. Pay attention to disassembly works of heavy loads in order to not
cause damages and accidents ;
- sudden stop during the load on its way down; too exceed inertial forces overload the crane;
- an object bangs against the hosting rope on which there is a suspended load. The traction
force ascending in the rope overloads the crane;
- do not hoist loads slantwise or drag the load on the ground: there could be inadmissible
lateral forces on the boom;
- if the ground is soft, the crane can bend over or turns over;
- assembly mistakes into mechanic extensions;
- load slings error. Means of load slings (chain, rope and so on) has broken and the load falls
down. The boom under pressure overturns, because of the load and the crane itself;
- hoisting fixed loads (tree uprooting, drain hosting etc...): also when the capacity is not exceed by
the loads weight, the boom because of the pull can bound backward and the crane can turn over.
The force of pull exceeds in many situations the weight of the load. Speeding up or breaking
quickly the slewing movement, the load starts to swing. The boom can be broken by excessive
swinging.

3.6. LOAD LIMITER

All cranes, whose maximum load limiter is equal to 4000 daNxm or whose maximum load is 1000
Kg., have a load limiter as a protection against the overload or the turning over.
The load limiter excludes the overload of the crane (see chapter 10 par.3)

DANGER: Also a perfectly functioning load limiter cannot avoid accidents

caused by manoeuvring errors. It is forbidden to work with load limiter switched off, out
of duty or defective.
4. GENERAL INSTRUCTIONS
READ CAREFULLY THE FOLLOWING INSTRUCTIONS

- Before starting any operation, make sure that no-one is in the crane work area.
- Before starting the work, make sure that all safety devices are in perfect efficiency (see
Chapter 10).
- Do not use the crane if the splices of the valves and of the cable of the load limiter are not
present.
- Make sure that the visibility is enough to work in safety conditions, and that allows to see at
least the loading diagrams and the identification plates of levers.
- Locate the truck in the better working position, for manoeuvring without having possible
dangerous situation.
- The crane has got two control stations, drive it always from the side which permits to have a
good load visibility, also when the operator is out of the operating range of the crane.
- If the direct visibility of the working area is not enough from the manoeuvring place, the
operator should be helped by encharged personnel.
- Indicate the start of manoeuvring by proper signals.
- Avoid manoeuvres involving the lifting and carrying of loads over working and transit areas.
If it is not possible to avoid that, give warning, by proper signals, of both the manoeuvres, i.e.
the start and the passage of the load.
- Before leaving the manoeuvring position, turn all the controls to zero, never leave the load
suspended and turn off the main switch of the crane.
- The crane can be used on flat ground only.
- Before starting any operation with the crane, brake properly the truck and, if required, lock the
wheels by means of suitable wedges.
- Do not run on the crane before having checked that outriggers are placed on solid ground,
( if necessary increase it with a base support ).
- Check the grade of stability respecting the conditions in which you operate.
- If the ground, on which outriggers are located, it is not stable and solid enough, it is
necessary to increase the support surface of outriggers or, better, fit plates, supplied by
manufacturer, for increasing the support surface.
- Make sure the loads, hosted with regard to the reach, do not exceed the values indicated on
the load chart, under penalty of warranty forfeiture.
- Before starting any operation with the crane, make sure that the pins on connections, among
the crane, the equipment and the hook, are held back by the suitable split pins.
- Apply the hoisting ropes to the hook, in order to not damage the hook safety.
- Do not operate the crane with sudden movements. Operate the control levers softly and
gradually.
- Slew with suspended loads and not drag them on the ground.
- Keep clear of the suspended loads, and keep out of the crane working area.
- Do not work near telephonic or electric power lines.
- Do not stay between stabilizer booms and the truck when they are retracting, in order to
avoid a possible crushing of the body.
- When outriggers drop, go away from their work line, in order to avoid the injure your legs.
- There are warning stickers on the crane body which make safer the crane usage; if they
become unreadable, replace them. The truck engine must turn at a working rate minimum
(800+900 rpm).
- Disarm the power take-off before setting in motion the truck ( a high number of engine
revolutions can damage the PTO ).
- The crane operator must have experience with this type of machine
- After any accidental shock suffered by the crane an authorized workshop must carry out a
careful check.
- Check monthly the integrity and the functionality of most used parts (pins, valves, hoses
etc...): if it is necessary, carry out the replacement with original spare parts.
- Never tamper the hydraulic system and the safety devices, do not remove anyway seals
located on the valves because it is strictly forbidden under penalty of warranty forfeiture. An
excessive oil overheating damages seals of hydraulic circuit and a deterioration of the fluid.
The overheating can be caused by extended use of rams to the top of stroke, or by an
excessive flow of the pump.
- The pump must feed the control valve with flow rate of oil corresponding to the values
reported on the technical specifications.
5. SETTING AT WORK
5.1 CHECKS BEFORE THE SETTING AT WORK
Make sure that the machine has got:
- Manufacturer declaration 98/37/CE as for the crane and following updating
- declaration of conformity CE as for the installation
- tests and inspections handbook of the crane
- testing of the vehicle with crane for circulating on public roads (M.C.T.C.)

5.2 CHECKS BEFORE EVERY WORKING DAY

- general survey of the crane for any possible leak;
- control of the functioning of the load limiter device;
- oil level
- check the state of rubber hoses
- check the state of steel pipes;
- check the painting, mainly for marine crane;
- check chromed rods, mainly for marine crane.

5.3 PRECAUTIONS BEFORE STARTING IN COLD CLIMATES

Before starting work, let the pump run idle for 10 minutes. Do not operate the crane with sudden
movements.

5.4 ACCESSORIES
Make sure that all accessories which are going to be used have got the proper documentation of
European Conformity and are marked with the symbol

DANGER: When accessories have been installed, the crane load capacities change.
Consult the manufacturer for being informed about new performances of the crane.
The weight of each accessory has to be deducted from the net lifting loads.

5.4.1 ADDITIONAL OUTRIGGERS

When the stabilization of the crane is not sufficient to ensure vehicle stability, it is installed on the
vehicle an additional stabilizer beam (for the use see Chapter 7).

5.4.2 WINCH
This type of attachment is extremely useful for having the purpose of lifting loads which otherwise
cannot be attained with a hook. The winch is made with a rotating drum driven by hydraulic
motor; a rope is wound around the above mentioned drum and the load is applied to such rope.
The weight of the accessories of hoisting have to be deducted from the useful load.

DANGER: Do not swing the hanging load in order to avoid the fall of the rope out of
idler and an excessive side effort on the rotation of the crane.
INSTRUCTIONS: for the use and maintenance of the winch, follow instructions shown on the
manual supplied by the winch manufacturer.
5.4.3. Grabs, buckets, etc:
They are accessories used by cranes which have been conceived to host woods, scraps, solid
waste and other bulk material.
These accessories are fitted, by a suitable connection, to the crane extension and are essentially
made up with a certain number of clams, driven by rams. Some models have an hydraulic
rotation.
The weight of the accessories have to be deducted from the lifting load.

5.4.4. Ropes and slings

This type of accessories are used to hang solidly load to the hook of the crane; they must be
always in a good condition and of allowed type with permissible lifting capacity printed on top and
certified by the manufacturer and with EEC documents..

5.4.5. Hooks and shackles

This type of accessories is used to hang the binding of the load to the crane. Only the standard
ones have to be used, with permissible carrying capacity marked by the manufacturer and the
European documentation.

5.4.6. Aerial Basket

The crane can be equipped with an aerial basket, naturally introducing changes in conformity
with all safety rules requested by the different use of the machine.
The group crane+basket has to be certified CE by notified body.

5.5 TRAVELLING ON THE ROAD

Instructions for road circulation:
- The boom has to be settled in folded position between the truck body and the cabin or placed
along the truck body with all extensions retracted;
- stabilizers retracted and locked by suitable mechanical locks

5.6 PROTECTION AND STORAGE

5.6.1. Inactive for a short period
Do general cleanings and grease all items provided with a greaser.

5.6.2. Inactive for a long period

Proceed as above and moreover:
- spray the whole crane with preservative oil;
- protect the crane with a waterproof sheet against bad weather;
- store it in a dry place.
6. CONTROLS

6.1. CONTROLS DESCRIPTION

Crane operations must be carried out moving levers joined to a valve block. The levers can be
mounted horizontally or vertically, and are placed on both crane sides. In some cranes, like those
ones of series G, there are two valve blocks: first one for levers which move stabilizer booms and
ram; the second one for all the others movements. The cranes have not the same controls
arrangement: it depends on many elements, as the manufacturing differences of various models,
the presence of flying jib, the assembly of different accessories, etc..
DANGER: Check (working carefully and without load) when the crane has just been
delivered, the correspondence of symbology with levers, and if necessary, point out
anomalies to the dealer. Do not use two levers with different movements at the same
time, especially with the crane loading: this could cause sudden accelerations to one of
the movements, with dangerous instability of the load.

Before starting any work with the crane, get familiar with the levers so as that the use of
controls becomes easy and spontaneous.

You will find, here below, the functioning explanation of the various levers in correspondence of
the symbol which marks them. Each symbol is divided into two sections: the sketch of a crane
with the moving items in red colour, and the evidence of the direction movement by black/white
arrows.
The following symbols indicate the arrangement and the way of movement of the levers: they are
used as a guide for understanding symbols and arrows printed on the own crane

main boom lever

lever to right the boom rises
lever to left the boom drops

column slew lever

lever to right the column turns left
lever to left the column turns right

second boom lever

lever to right the little boom opens
lever to left the little boom closes

extensions lever
lever to right extensions enter
lever to left extensions go out
 outrigger rams lever
lever to right outriggers drop
lever to left outriggers rise

The following levers can be placed with the other control levers or connected to a separate valve
block.

stabilizer lever
lever to right stabilizer out
lever to left stabilizer in.

Warning: At the receipt of the crane, check the correspondence of any various
selector lever position with real movements of stabilization system, getting familiar with
different functions.

Warning: In the crane P 2300 L and P 3500 L only there is an extra lever
with the knob of red colour with the stop function, and it is indicated by this
symbol:

See in chapter 10 par. 1 and following

7. MANOEUVRES
7.1..GENERAL INFORMATION ABOUT STABILIZATION
At work place, park the vehicle braking or locking it by wedges under the wheels. For choosing
the best place to park, read chapter 3 paragraph 4. Make sure that the inclination of the vehicle
does not exceed 5°. Extensions of stabilizers have to go out and lower ram rods, until the
stabilizer plates touch the ground. If plates drive into the earth, it is necessary to increase their
bearing surface as pare chapter 3 paragraph 4.

DANGER: The incomplete extension of stabilizer extensions or the foundering of

plates can cause the vehicle overturning.

DANGER: Outriggers have to balance the risk of the crane overturning, and not to lift
the whole vehicle: in fact, this event could cause a not correct stabilization and a
dangerous overload on stabilizers. It is necessary to change the stabilization each time
that the vehicle must be charged or discharged with a weight bigger than the capacity of the
crane at 4 meters: during this operation keep the crane closed.

ALL CRANES CAN BE SUPPLIED WITH MANUAL OR HYDRAULIC EXTENSIONS OF

STABILIZERS. THE FOLLOWING PROCEDURE GIVES THE CORRECT USE OF BOTH
VERSIONS.

DANGER: Watch carefully any movement of stabilizers by operating only with the
levers of the moving side.

7.2. MANUAL STABILIZER EXTENSIONS

Remove the pin A slewing the lever in position 1, take carefully the segment out for 10
centimetres, fully close the pin A slewing the lever in position 2 and pull again the extensions
carefully out, until the pin releases
(pushed by suitable spring) which
locks the extension.

Do not try to take the extension out

beyond the area of hooking to
avoid the risk of its fall down.
Before lowering the outrigger, open
the valve B, putting the lever in
position 2.
At this point, carry on to the
outrigger lowering, operating on the
suitable lever described at the
chapter 6, and following the other instructions written in this paragraph.
Whenever lowered correctly the stabilizers, close the valve with lever B in position 1.
At the end of the work and with the crane in folded position, for taking off the stabilization:
- open the valve B with the lever in position 2
- raise outriggers and disarm the ram by the valve B with lever in position 1
- release the pin A putting it in position 1, retract for 10 centimetres the extension, put the
lever A in position 2 and retract the extension until notice the hooking pin release.

7.3. HYDRAULIC STABILIZER EXTENSIONS

Put the selector (see Chapter 6) on the position of outrigger extension. Pull out the extension
until the ram limit. Put the selector on outrigger position and the lever of valve B on position 2 for
opening the ram circuit.
At this point, drop the outrigger working on the suitable lever (described in the Chapter 6) and
follow the other instructions contained in this Chapter. After having correctly dropped, close the
ram putting the valve lever B in position 1.
Carried out this operation, go to the other side of the vehicle and repeat operations which have
been just described with the extension and with ram of its side.
At this point, drops the outrigger working on the suitable lever described in the Chapter 6 and
follow other instructions contained in this Chapter.
After having correctly dropped deactivate the ram with the valve lever B in position 1.
At the end of the work and with the crane in folded position , for taking off the stabilization,
operate in this way from both sides:
- reactivate the ram by the valve B with lever in position 2
- raise the outrigger and deactivate the ram by the valve B in position 1
- put the selector (see Chapter 6) on position of stabilizer extension on the side in which you are.
- retract the extension until the ram limit switch.

N.B. IF THE VEHICLE IS EQUIPPED WITH SUPPLEMENTARY OUTRIGGERS,

OPERATE IN THE SAME WAY AS JUST EXPLAINED.

DANGER: Also supplementary outriggers have to balance the risk of the crane
overturning, not to lift the whole vehicle; this possibility would cause a not correct
stabilization and a dangerous overload on stabilizers. It is necessary to change the
stabilization each time that the vehicle must be charged or discharged with a weight bigger than
the capacity of the crane at 4 meters: during this operation keep the crane closed.

DANGER: Check that, during the work, that nobody is in the range of the crane.
POSSIBILITY OF DROP IMPACT, BUCKLING AND CUTTING RISKS.
7.4. CRANE WORK POSITION
Setting the crane from the stowed position (with the folded boom between the truck body and the
cabin) to the working position, proceed as follows:
1) check that the boom ram is fully closed
2) open the column ram for lifting the first boom, taking it out from its bearing base, and set it
in a high inclined position (see Chapter 6)
3) open the boom ram to align main boom and second boom in horizontal position.
At the end of these operations, the crane is ready to work.

7.5. INSTRUCTIONS FOR THE USE OF THE CRANE

DANGER: Check the functioning of safety devices (as from Chapter 10)
DANGER: Always operating on control levers to avoid sudden movements, injurious
both for crane life and efficiency and for the load, which can fall or slide (see Chapter 6)

WARNING: Stop the control lever work when the ram switch has been joined to avoid
an excessive oil overheating.

DANGER: The operator must always have the view of the whole working area of the
crane and not drive the boom over the control area; moreover, he cannot hoist loads
when manoeuvring in dangerous positions from himself and the appointed personnel. At the end,
during a work break, the operator shall drop the boom, switch off the pump and make sure that
nobody could manoeuvre the crane.

DANGER: Never exceed maximum lifting loads reported on loading diagram (see
Chapter 2 paragraph 6)

7.6. CRANE STOWED POSITION

To set the crane from the working position to the stowed one (with folded boom between truck
body and cabin), no load has to be applied during the above mentioned manoeuvres.
(see chapter 6):
1) Raise the boom until it is in vertical position
2) Retract all the hydraulic extensions, fold up the second boom closing the boom ram and close
the boom ram totally
3) Slew the crane in a perpendicular direction to the vehicle axle
4) Close carefully the column ram and check the boom lowers on the suitable support: so that, it
avoids any crane slewings and lowering movements, during the road circulation.
5) Each type of crane has got a different support; turn to the dealer for having detailed
explanations about position and function of your model.
DANGER: Control during the work that nobody is in the range of the crane. BUCKLING
RISKS.
If, on the road, the booms are not folded up behind the cabin, but placed along the truck body,
they have to be fixed in a proper way to avoid side movements.

WARNING: Do not put the crane booms on the load in the truck body if the crane has
no special indicator. (Ask the installer)

7.7. HYDRAULIC FLYING JIB

The hydraulic flying jib allows to reach long distance with full hydraulic movements.
7.7.1. Description
The hydraulic flying jib consists of the following elements:
1) Connecting head
1a)Fixed joint
2) Flying jib boom
3) Small side rod (one for each side)
4) Long side rod (one for each side)
5) Flying jib ram
6) Hydraulic extensions
7) Hydraulic extension rams
(telescopic or single stroke)
7.7.2. Installation
For installing or taking off the hydraulic flying jib, address yourselves always to a dealer, who will
provide to carry out correctly all hydraulic connections and lock properly all mechanical connections.

Working position of hydraulic flying jib

To work with the hydraulic flying jib carry out the following operations (see Chapter 6):
1) Set the crane in working position with all extensions laid in horizontal position.
2) Unfold the articulation ram so that the boom of hydraulic flying jib coincides with the extension
of the crane in horizontal position.
3) From now onwards the hydraulic flying jib extensions can operate at the requested outreach
with shown load on lifting diagram.

WARNING: all operative recommended rules for the crane use are in force when the jib
is installed (see Chapter 6).

7.7.3. Hydraulic flying jib in stowed position

For folding the hydraulic flying jib in stowed position, carry out the opposite of the above operations.

WARNING: Independently from hydraulic extensions of the crane, maximum allowable

capacities for extension jib are those ones shown on the load chart (see Chapter 2 paragraph
6).
8. CRANE MAINTENANCE

WARNING: All servicing operations not included in this chapter shall be carried out by
workshops of an authorized dealer; besides we recommend that the setting pressure of the
crane valves be checked always by an authorized workshop, once a year at least.

8.1. TIGHTENING CHECK

Periodically, especially after the first loading cycles, check the tightening of all nuts and safety
nuts of anchor bolts. Verify also the tightening of hydraulic fittings, in order to prevent any oil
leaks.

8.2. LONG INACTIVITY

If the crane is inactive for a long period, it is recommended to set it in stowed position so that
rams are closed and prevent dirt and dusty on the rods.

8.3. LUBRICATION
8.3.1. Hydraulic oil
Check daily the oil level of the tank, especially if the crane continuously worked, and eventually
fill it up using oil with the same specifications only. The oil of the hydraulic system shall be
replaced every 1000 working hours, or at least once a year, changing the filter cartridges and
washing the tank with a suitable detergent. The operation of changing oil must be carried out,
after having placed the crane in folded position and with cold oil.
Use only IP HYDRUS OIL 46 or equivalent: ( Ex: ESSO Nuto H 46; MOBIL DTE oil 25 - 46;
SHELL Tellus oil 46; CASTROL Hyspin AWS 46; AGIP OSO 46).

INSTRUCTION: Avoid pouring and spreading oils in the environment; deliver the exhausted oil
to an authorized centre for exhausted oils collection.

8.3.2. Filter tank

The is situated as per drawing on oil tank. With the tank is
supplied the following filter FBO mod. FIOM75 (CR75)
We recommend the following actions:
Before acting on filter first empty the tank oil till the inside
level is lower than filter position

- after the first 70 working hours, take off the filter

cartridge and - replace it;
- every 30 afterwards working hours, clean the cartridges
with petrol or diesel oil and dry it with compressed air;
- the cartridge must be replaced at least once a year.
8.3.3. Greasing
All points marked in the picture must be greased every 30 hours. It is recommended a
multipurpose grease (i.e. type IP Athina) or, anyway, a good quality one.

z = MANUAL GREASING WITH BRUSH

{ = GREASING WITH PNEUMATIC OR MANUAL PISTOL

WARNING: All hydraulic surfaces of the extensions of the base crane and flying jib
must be always coated with grease by manual greasing.

DANGER: Never climb up the crane for reaching greasing points; use a ladder, after
having stabilized, or get up on the truck body.

8.4. DEMOLITION AND ELIMINATION

At the end of the life of the machine, you have to provide for the demolition and elimination of
the crane through authorized people, according to the rules in force.
For every changing of oil, batteries, rubber pipes and other parts, subjects to differentiated
disposal, refer to the national standards.
9. FINDING FAILURES
Here below are listed possible failures and anomalies which can happen in the crane:

INCONVENIENCE CAUSE SOLUTION

high oil temperature which causes a check the pump pressure and eventually
wear of the feed pump
serious decrease of crane efficiency replace it (:)
check the oil level, refill it up and
low oil level or high density
excessive noise of the hydraulic pump eventually change it
air suction by the pump Lock the pipes fittings
pump failure replace the pump (:)

damaged valve block replace the valve block (:)

the crane cannot lift the prescript load
clean the general pressure valve or
worn or dirty general pressure valve
replace it (:)
excessive wear of seals replace seals (:)
oil leakage from rams ruling on the piston rod or on cylinder Replacement of the piston rod or the
tube cylinder tube

Under load and no working pump the check the valves calibration and eventually
loss in the valves
boom drops down replace them (:)

fold and unfold completely rams many

air in the hydraulic circuit times, until the whole air is gone out
(without load)
slow or stick-slip crane motions

worn sliding pads of the boom replace them (:)

low oil quantity restore the oil level

the crane does not complete not correctly recorded valves calibrate valves (:)
movements
breakdown in the pump check and eventually replace it (:)

deteriorated elements of the hydraulic search worn elements and replace them
finding metal chips into the oil filter
circuit (:)
replace seals and make sure that the
delivery pump corresponds to that one
damaged seals overheated oil
advised by the manufacturer, and
eventually replace it (:)

lock owing to overload (load limiter) retract the extensions (:)

all crane movements are locked
deliver immediately the crane to a
load limiter parts out of work
workshop for reparation (:)
deliver immediately the crane to a
one crane movement is locked hydraulic hose breakdown
workshop for replacement (:)

(:):all reparations marked by this symbol must be carried out by an authorized workshop.
10. SAFETY DEVICES
The crane is equipped with devices which assure a safe machine use.

DANGER: The presence of safety devices, can not anyway avoid accidents
caused by: manoeuvring errors, operator inexperience or use in bad conditions.

DANGER: Before starting any operation, the operator must check the perfect working
of safety devices and the general crane conditions.

10.1. EMERGENCY PUSH BUTTONS

10.1.1. Description
Emergency push buttons, placed on the two sides of the crane, near the control levers, stop
suddenly the crane operations, if pushed.

N.B. For the crane mod. P 2300 L and P 3500 L the two emergency push buttons
are substituted by two levers on each side of the crane and directly link to the valve
block. These levers are different from the other ones as position (the first ones at
the top) and colour of the knob (red). They are marked by the symbol:

10.1.2. Working Check

Press the emergency push button checking that the crane stops all movements; slew the push
button in clockwise direction for releasing the crane. Before resetting the push button, make sure
that any dangerous situation has been solved.

N.B.: For the crane mod. P 2300 L and P 3500 L move the lever to the indicated position by the
arrow and verify both the stop movement of the crane and the movement of the other levers have
no effects. To restore the use of the crane, move the lever in the opposite direction of what
indicated by the arrow.
Before moving the crane, check there are no dangerous situations.

10.2. LOCK VALVES AND CONTROL LOWERING

10.2.1. Description
These valves, placed on boom rams, check the
descent speed and lock the descent in case of any
hose breaking.

10.2.2. Checking operation

Work as follows:

- put the cranes as per fig.1 and apply a medium size

load, according to the loading diagram
- switch off the vehicle engine
- turn pressure off the hydraulic system, by driving
valve block levers
- make sure that the extensions do not go down
- if the flying jib is mounted on the crane, carry out checks positioning the crane as per fig. 2
- turn pressure off the hydraulic system, by driving
valve block levers
- make sure that the extensions do not go down

10.3. LOAD LIMITER

10.3.1. Description

In the crane with a maximum load limiter equal or above 4000 daNxm, the load limiter circuit,
connected to the column ram, is designed to stop all the movements, except the return of the
extensions, if its maximum allowable moment is exceeded.
When the crane is locked, owing to load limiter, the only one allowed manoeuvre is the retraction
of hydraulic extensions, so as to reduce the total moment, i.e. the distance between load and
crane column.
The load limiter consists of:
- a box containing the electronic board unit, fitted on the base of the crane
- a pressure sensor, mounted on the column ram
- a electrovalve set on the valve block
- a microswitch fitted on the extensions lever for resetting the system
- two light signals mounted on each one of the two emergency buttons

10.3.2. Light signals

On each emergency button there are two light signals, with different colours, that mean:

YELLOW LIGHT: as warning signal when the lifted load exceeds the allowed one of a
percentage of 90%. In this stage the crane keeps every movements.

RED LIGHT: flashing together with the yellow one when the maximum moment allowed has been
exceeded. All crane movements are locked, but not that one of retraction of extensions.

10.3.3. Working
The pressure sensor on the column ram gives the value of the oil pressure to the control unit,
which is connected to the load limiter of the crane.
The control unit processes the signal of the sensor and compares it with memorized data during
the assembly and the initial setting. If the maximum load limiter of the crane is exceeded, the
solenoid valve locks the hydraulic system.
The lock is temporally suspended only acting the lever for the extension movements to the side
of retraction, on which the reset microswitch is present. The lock is removed when the retraction
of the extensions takes the load limiter within the safety limit.
10.3.4. Working check
Before starting the work, check that the lights on stop buttons are both switched off. The
operating crane confirms the correct working of the safety system because, in case of any
problem, the crane is automatically locked.
For a further test, hook at the crane, in horizontal position, a known load equal to these ones in
the capacity rating plate, gradually extract the crane till the maximum distance for that kind of
load. The yellow light will be on as a warning sign; at the attempt to exceed the maximum
distance, the red light will be on with the consequence lock of the machine.

10.4. WEDGES FOR STOWED CRANE

Cranes are equipped with suitable wedges which lock them in folded position not allowing
dangerous movements when the truck is running, like booms lowering, or extensions of
outriggers shifting out (mechanical ones only) and not desired slews (see chapter 7, paragraph 2
and 6).

11. NOISE
During the movement of the loads, the value of the continuous acoustics pressure is within
70db(A) and it never exceeds that one of the truck, where it is placed (equipped with road
circulation homologation).