Use and Maintenance Manual
Use and Maintenance Manual
Use and Maintenance Manual
CRANE ON TRUCK
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:
2. Bring always the service manual and the load charts in the cabin.
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.
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:
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.
DIN 15018/1
DIN 15018/3
DIN 4114/1-2
DAST-RICHTLINIE 011
DIN 15019/2
EN 12999
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.
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.
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.
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.
5 fresh breeze from 8,0 to 10,7 from 29 to 38 Small trees in leaf begin to sway;
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
- 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.)
5.4 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.
5.4.2 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.
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
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:
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.
DANGER: Watch carefully any movement of stabilizers by operating only with the
levers of the moving side.
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.
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)
WARNING: Do not put the crane booms on the load in the truck body if the crane has
no special indicator. (Ask the installer)
WARNING: all operative recommended rules for the crane use are in force when the jib
is installed (see Chapter 6).
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.
8.3. 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.
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.
Under load and no working pump the check the valves calibration and eventually
loss in the valves
boom drops down replace them (:)
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 (:)
(:):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.
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:
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.
10.2.1. Description
These valves, placed on boom rams, check the
descent speed and lock the descent in case of any
hose breaking.
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
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.
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).