Академический Документы
Профессиональный Документы
Культура Документы
SERVICE MANUAL 5
A B C Home
BMI00026GB_0-29092008
THE POWER OF PERFORMANCE
THE POWER OF PERFORMANCE
A
INSTALLAZIONE GRU E INTERVENTI TECNICI
CRANE INSTALLATION AND TECHNICAL OPERATIONS
INSTALLATION GRUE ET OPERATIONES TECHNIQUES
INSTALLATION DES KRANES UND TECHNISCHE
OPERATIONEN
B
PARTE IDRAULICA
HYDRAULIC SECTION
PARTIE HYDRAULIQUE
HYDRAULIK
C
PARTE ELETTRICA
ELECTRICAL SECTION
PARTIE ELECTRIQUE
ELEKTRIK
A2 TECHNICAL OPERATIONS
1 Tightening torque of the mechanical components................................................................................................. 3
2 Crane slewing transversal clearance.............................................................................................................................. 5
3 Reducing clearances in extension cylinders............................................................................................................19
4 Maximum wear point allowed for extension bushings........................................................................................22
5 Pipe fastening......................................................................................................................................................................23
5.1 Flex hose protective sheath..................................................................................................................................25
6 Unintentional exit of extension cylinders..................................................................................................................27
7 Visual check - Structural Intactness..............................................................................................................................31
8 Structural repairs.................................................................................................................................................................33
THE POWER OF PERFORMANCE
INDEX A
THE POWER OF PERFORMANCE
THE POWER OF PERFORMANCE
Installation instructions of
cranes on trucks
A1
Manuale installatore
CONTENTS
1 - Presentation
General information
1.1 Responsibilities
1.2 General warnings
1.2.1 Safety instructions
1.2.2 Welding instructions
1.2.3 Truck information
1.2.4 Welding tips
1.2.5 Welding notes
1.3 Responsibilities of the tter
1.3.1 Technical folder
1.4 Where to nd technical data
6 Installation calculations
6.1 Purpose of the calculation
2/158
Fitter’s manual
6.2 Useful information on calculating the theoretic weight test on the axles
6.3 Information on calculating the theoretic stability test
10 Electrical connections
11 Additional outriggers
11.1 Fitting “feasible” additional outriggers
11.2 Free space under the outrigger jack
14 Stability tests
14.1 Static test
14.2 Dynamic test
15 Crane conversions
16 Crane consignment
3/158
Manuale installatore
1 - PRESENTATION
EFFER hydraulic cranes can be qualied as Loader Cranes, as they are usually installed on
a truck (with trailer or semi-trailer) and are designed to handle loads non-continuously; in
other words they are designed to load-unload the truck and possible trailer or semi-trailer
and envisage IDLE times when they are driven on the road on the truck, hypothetically
for a maximum of 1000 hours per year, under intermittent service with medium/light duty
work cycles.
If they are to be used for different purposes, contact the After Sales service of the manufacturer to
receive information on the shorter life of the crane and on which inspections the customer/user
shall perform more frequently.
The manufacturer has written this document to facilitate the work of tters, with regard to the
installation of the crane on the truck and everything deriving from such activities, such as the
preparation of an efcient “Technical Folder” that the customer shall keep in his les.
This document provides all the technical information required to install the crane perfectly, including
the description of the tests to be carried out at the end of the installation jobs. If you should
encounter any problems that are not contemplated in this document, contact the manufacturer’s
After Sales staff, who will provide you with instructions following written requests.
This manual has been written for specialists. Contact the After Sales service of EFFER if
you should have any doubts or questions.
The contents of this manual do not exempt you from studying and observing all the
standards currently in force with regard to design, manufacture and safety.
1.1 Responsibilities
The responsibility of the design, manufacture and assembly of upper structures on trucks, likewise
for any modications to the chassis of the truck is always and exclusively and totally to the
charge of the manufacturer and/or the tter of the upper structure. Road safety and operational
safety are regulated by standards currently in force in the country of use.
Damages caused by the incorrect assembly and installation of the crane or by the failed
observance of the design and safety standards and operating instructions are to the
charge of the tters.
Upper structures or modications shall be approved by
the truck manufacturer.
When installing the crane, tters must bear in mind the
provisions, suggestions and instructions issued by the
truck manufacturer, in order to guarantee the perfect
operating efciency of the vehicle and all the safety and
driving conditions of the same, together with any local
standards of which we are not informed: we remind you
that the observance of the instructions issued by the
truck manufacturer and of local provisions have priority
over our instructions.
ALL THE BEST!!
4/158
Fitter’s manual
When installing the crane, the tter must not only refer to the directives currently in force
in the country of use but also all the Health & Safety provisions related to workshops
and load handling.
- Always make sure you have read and fully understood the Fitter’s manual before you start to
install the crane. The failed observance of the instructions therein relieves EFFER from all forms
of liability with regard to personal injuries and/or material damages.
- Make sure that crane/truck installation accessories (pumps, power take-offs etc.) have
their own instructions and EC declaration of conformity for countries belonging to the
European Community.
- Mark off the operating areas, leaving enough space to be able to install and move the crane
installation parts around, in full respect of all the Health & Safety provisions currently in force
with regard to workshops and load handling.
- Loads are to be handled in conditions of total safety (counter-chassis, cranes, truck boards etc.),
also following the instructions enhanced in the pages that follow.
- Operators shall be skilled and psycho-physically t to install and rig-out the crane/truck.
- Do not work if you are not dressed suitably (i.e. do not wear ties, baggy clothing, unbuttoned
shirts/jackets and/or dangling items. Do not wear personal jewellery such as bracelets,
watches etc.).
- Make sure all components have been tted perfectly before starting the crane.
- Read this manual carefully and also the specic manual of the crane before you start, use,
service or do anything else with the crane.
- We remind you that the employer and/or directors are obliged to inform workers on the risks of
injury and shall provide suitable personal protection equipment.
- Do not allow unauthorised personnel to work on the machine.
- Stabilise and level the crane-truck adequately so that you always work on a at surface.
5/158
Manuale installatore
- Never use petrol, solvents or other ammable liquids instead of detergents: Always use
authorised commercial non-ammable and non-toxic solvents.
- Use lifting tackle and suitable lifting equipment to lift or transport heavy parts. Make sure
the lifting tackle is perfectly intact. Use the lifting eyebolts, if envisaged, and make sure
nobody stands near the operating area.
- Take appropriate precautions in the case of damaged or bent chains or cables: always wear
suitably thick work gloves. Chains or ropes are to be secured rmly: make sure the attachment
is of suitable load-bearing capacity to be able to take the weight of the load to be lifted. Always
make sure nobody stands in the work area.
- Make sure all parts of the hydraulic circuit are secured adequately. Make sure there are
no pressurised uids before dismantling unions or pipes: pressurised oil could spurt out of
the circuits and cause serious injuries.
- Never service or disassemble accessories without using suitable tools and personal protection
equipment, in compliance with Health & Safety standards currently in force (gloves,
helmet, goggles etc.)
6/158
Fitter’s manual
ATTENTION!!!
The crane mainly consists of parts in highly exible special steel: therefore
never weld any part of the crane without authorisation and instructions on
behalf of the manufacturer.
ATTENTION!!!
Before you start any welding jobs, always disconnect the electrical cables
from the battery to avoid damages to the electrical and electronic
equipment.
7/158
Manuale installatore
When choosing the truck, you need to carefully evaluate if the technical characteristics of the
same are compatible with the characteristics of the crane to be installed, in particular 1)
theoretic evaluation concerning weight distribution and stability of the truck while the crane
is working; 2) check the characteristics of the engine/gear box of the truck with regard to
the power required for crane operation.
Together with the instructions and safety warnings indicated in the instruction manual of the
truck, the following is also important:
- Make sure the equipment of the truck can be freely accessed to carry out periodic inspections,
maintenance, tests etc. and make sure enclosed upper structures are equipped with
appropriate compartments and hatches.
- Make sure tipping cabs are able to move freely; in the case of upper structures that involve the
upper part of the cab, make sure the air extracted is able to circulate freely.
- Do not modify the cooling and extraction conditions of the engine air.
- If the position of the spare wheel, the chucks and the fuel tank is changed, make sure their new
position and attachment is accessible and safe, in compliance with national and international
standards and with the instructions of the truck manufacturer.
- Make sure the various units can be dismantled. For example: you must be able to work on
the gear box and clutch without having to disassemble major elements of the additional
structure.
- Make sure the battery casing is adequately ventilated.
8/158
Fitter’s manual
We believe that a short chapter on welding should not go amiss: welding jobs that must be done
obligatory to construct the counter-chassis, to secure feasible casing/mudguards or truck
boards, to attach the base rotation blocking devices and so on.
Good welding rules impose the execution of the same in areas sheltered from wind and where
the temperature is higher than 10°C.
9/158
Manuale installatore
2) It is absolutely forbidden to cool welded pieces with forced cooling sources (water,
compressed air.)
3) The minimum welding section - S - shall be equal to or greater than the minimum thickness
welded; it must never exceed 20% of the minimum thickness welded whatever the case.
The most common types of welding used to assemble the counter-chassis are the
following:
55°÷ 60°
S S
B 1÷2 mm
A
A
B> A 1
S A
S A
10/158
Fitter’s manual
Welding beads:
Welding beads: with S>6 mm, are to be welded
with a number of applications.
Filled welding:
To speed-up welding jobs, with the lling method (i.e.: union point between the side members
and the cross members) you can place metal wedges in-between: the formula s> a must
be respected in any event.
S A
S A
11/158
Manuale installatore
The tter shall proceed following the instructions supplied by the manufacturer, as he has full
responsibility of the correct execution.
The fitter shall define the suitable crane/truck combination and is responsible for the
design/manufacture of the parts required for installation and also their perfect assembly.
Always observe laws and indications supplied by the truck manufacturer and standards currently
in force in the country of use.
The fundamental points to be analysed to complete the job correctly are given hereafter:
Installation
Choice of power take-off/hydraulic pump: Calculations according to the oil ow rate
requested by the crane and the maximum
requested pressure.
Check the power of the engine for the
power requested to operate the crane.
Choice of electrical and hydraulic systems: the material applied must have superior
or the same characteristics as the crane
and must respect current standards in
terms of safety whatever the case.
12/158
Fitter’s manual
Consignment to user:
NOTE: The tter who rigs out the vehicle actually creates a new machine. He
therefore becomes the manufacturer of such machine and shall full the provisions
of all laws currently in force. For countries in the European Community, the
job is completed with the issue of a new EC certificate and the fitters own
certicate of CONFORMITY. The work carried out shall be documented in the
Technical Folder.
13/158
Manuale installatore
The tter shall keep a technical folder with all the work carried out on le. Fitters in the European
Community shall keep this folder on le for at least 10 years, available for relative authorities
to consult it. It is simply a le of all the work phases carried out.
This folder shall contain the following:
1- Technical characteristics of the truck and of the crane: for
the truck, it is a copy of the logbook or of the data sheets
concerning the technical characteristics; for the crane it
is a copy of the technical characteristics taken from the
“production information” documents, which can be consulted
on the internet site: www.effer.it
2- If additional outriggers are tted, add a copy of the table
issued by EFFER concerning the outriggers, enhancing the
minimum distance from the crane to which they can be installed: this distance obviously must
be the same or further away. The table involved is kept in the documents of the crane or it can
be consulted on the internet site: www.effer.it.
3- Theoretic calculation of the distribution test of weights on the truck axles, in the two different
transport congurations (empty and fully loaded): you are recommended to use the tables
issued by EFFER relative to the weights of the crane including, oil, crane bracketing rods,
weights of the pump and power take-off, kept in the “production information” documents or
consultable on the internet site: www.effer.it.
4- Theoretic calculation of the stability test carried out subject to standard DIN 15019 - EN12999:
to determine the correct value of the tipping torque, in other words the test load, adopt
the load up-rating coefcients found in the “product information” documents or consultable
on the internet site: www.effer.it
5- Theoretic calculation of the section of the counter-chassis, carried out subject to standard EN
12999-CUNA NC034-05. The values of the various dynamic torques required to complete
the calculation are found in the “production information” documents or consultable on the
internet site: www.effer.it
6- Stability tests: once the crane has been installed and the practicable part of the truck has been
completed, the practical stability tests are to be carried out: these tests are to be carried out in
the operating area of the crane and involve two types: dynamic test and static test.
• For the dynamic test, you need to put loads equal to those indicated in the load-bearing
capacity graph table on the lifting hook, if the performance has been downrated due to
the non theoretic stability of the truck, plus 10%, then make all the movements possible
with the crane.
• For the static test, the loads to be put on the hook of the crane are those uprated and obtained
from the theoretic stability calculation; the only movement to be made is that of rotating
around the whole operating area, keeping the load very near the ground. Throughout
these two tests, the truck must remain stable, in other words at least three points must
rest rmly on the ground without moving (three points found between the tyres and the
14/158
Fitter’s manual
15/158
Manuale installatore
The pages that follow inform you on how to nd the technical data relative to the
truck, to the crane and to the components that may be installed; furthermore, as an
example, we are enclosing a specimen of the technical data sheets to identify the
technical data relative to the components to be installed.
We advise you to write down all the data that you may need to be able to
calculate the theoretic distribution of the weights on the axles and the
stability (see chapter 6).
Truck:
All truck manufac-
turers provide the
technical data of
their products, either
on technical data
sheets or on their
internet sites. The
technical data requi- General measurements in mm
red to make the Maximum height “O”
with CR19 Comfortline 3.408
Distance “D min.” CR16 CR19
Weights and dimensions refer to vehicles with standard equipment. Weights may vary by ±3%
Key
Weights of cab truck, Kg W: Maximum practicable space
Weight on front axle, max. w: minimum practicable space
Weight on 2nd axle, max. Z: Maximum overhang for testing
Weight on 3rd axle, max. z: Minimum overhang for testing
Overall weight Zs: Maximum overhang for Scania
Towable weight L: Maximum length of vehicle
Total weight of truck and trailer T: ton (kg)
S: Free space behind cab
16/158
Fitter’s manual
Crane:
Note: the documents that follow mainly aim at explaining how to install the crane
behind the cab, because this is the position that is most frequently requested.
The technical data sheets do however include all the technical elements to face
other types of installation (rear, on tractor for semi-trailer etc.).
An example crane model 340.11 / 4 extensions is chosen, being a standard machine with
uprated outriggers that extend from the side.
The information necessary relative to the technical data of the crane can
be consulted in the technical data sheets supplied by EFFER on its internet
site: www.effer.it
EFFER provides all its dealers and importers with a password to access the “TEC
INFO” section of the site to be able to consult and print the required technical
data sheets relative to the crane.
17/158
Manuale installatore
N. DT6K001I
DATI TECNICI Pag. 1/3
Rev. 0
340.11 Data 12.09.02
Date
Dati tecnici generali per l'installazione Prep. (MKT) T. Ceccardi
fac
VERSIONE DI SFILI 2S (*6) 3S 4S 6S 8S
Momento max di sollevamento (*1) kNm 319,8 316,6 309,1 298 293,1
-si
kgm 32600 32270 31510 30380 29880
Angolo di max potenza I° braccio 20°
mi
Classificazione EN 12999 (DIN 15018) H1-B3 (sollevamento con gancio)
le
Momento dinamico max (*2) kNm 418 415 411 418 417
Momento rotazione kNm 68,7
Inclinazione max piano apparecchio a gru orizzontale 5°
(capacità di rotazione)
Angolo di rotazione std 407°
Punto morto std lato stabilizzatori (tipo S)
fac
Estensione stabilizzatori mm std: 5400
N. DT6K009 N. DT6K030
DATI TECNICI TECHNICAL DATA
mm opzionali:Pag.
6400 1/1 DATI TECNICI TECHNICAL DATA Pag. 1/1
340.11 Rev. 0 340.11 Rev. 0
-si
Reazione sullo stabilizzatore daN std: 16000
Data 12.09.2002
Dimensioni
daN d'ingombro opzionali:Data
1350012.09.2002 Pesi e baricentri Date
Date
Weight - center of gravity
mi
Pressione acustica nel posto di comando (*3) Overall
dB dimensions
(A) Prep. (MKT) T. Ceccardi
< 70 Prep. (MKT) T. Ceccardi
Vibrazioni nel posto di comando (*4) Stabilizzatori standard - Standard stabilizer
le
Versione 6S (3S, 4S)
fac
Errore max del blocco momento (D) [EN12999] 8 + 0,5 R (max 20%)
6S version (3S, 4S)
Caratteristiche oleodinamiche PESO PARTE
-si
Portata max olio al distributore 2500 l/min 1230
60 ÷ 100 380 FISSA
PESO PARTE MOSSA WEIGHT OF
Pressione max al distributore MPa 31 WEIGHT OF THE MOVING PART THE FIX PART
mi
380 530 2293 kg
Potenza richiesta min / max kW 31 / 52
20 453,5
le
Capacità serbatoio olio l 140 C
20
PESI E BARICENTRI
Peso gru base senza carica olio - stabilizzatori std kg (*5) 3653 3863 4063 4413 4718 3355
2700 2700
Peso gru base senza carica olio - stabiliz. opzionali kg (*5) 3718 3928 4128 4478 4783 12350 (20°)
2450
5400
Peso carica olio kg (*5) 130 4S
Peso parte fissa e mossa kg (*5) Vedi schede "pesi e baricentri" 1900 kg
6S
Ingombri mm Vedi schede "dimensioni d'ingombro" 2250 kg
STAFFAGGIO
220
max 995
80
90
min 870
5816
Diametro dei tiranti mm M33 x 2
21640 (20°)
Materiale dei tiranti [UNI 7845 / UNI EN 10083-1] 39NiCrMo3 Bonificato / 42CrMo4
Coppia di serraggio 800 700 Nm 600 8S
2555 kg
b) Load
1540 chart
780
500
crane: these values are indispensable to be able to calculate the stability of the crane.
1210
(*3) E' possibile che sia > 70 dB (A) a gru installata; cio' dipende dal rumore della pompa e dal motore del veicolo. X
(*4) Dipende dal tipo di veicolo. (*5) Pesi ± 2%. (*6) Versione base disponibile a richiesta
I dati relativi ai carichi sollevabili e sbracci, sono rilevabili dai diagrammi di carico. Gli sbracci indicati sui diagrammi di carico sono PESO GRU CON OLIO NEL SERBATOIO
kgA WEIGHT OF THE CRANE WITH OIL IN THE TANK
8 tiranti M33x2
Esterno staffe
8 tie-rods M33x2
In seguito ad aggiornamenti tecnici i dati indicati possono211,5 subire modifiche. BARICENTRO COMPLESSIVO
A TOTAL CENTRE OF GRAVITY
347 347
fac
500,5
-si
D B
528
719
975
mi
3S 4S 6S 8S
419
le
A 1428 1907 2880 3887
62
B 52 71 100 122
E
76
62
[mm]
18/158
Fitter’s manual
c) Hydraulic diagram
The hydraulic diagram is indispensable to be able to perform the nal/functional test once
the crane has been installed; it is the only document that indicates the times of the various
movements of the crane and the design pressures of all the hydraulic components on the
crane. The hydraulic diagram of the crane is to be kept in the technical folder relative
to the installation completed.
facf
-asci-
msim
le ile
19/158
Manuale installatore
fac
-si
mi
le
From the table and taking the example of a crane Mod. 340 you can see that it is to be installed
on a truck of which the overall weight is minimum 26t and that additional outriggers must
be installed on the truck.
The choice of the type of outriggers and their characteristics mainly derives from the
technical/commercial experience gained.
Table with the characteristics of the additional outriggers are distributed by EFFER to the sales
area and its collaborators or, as indicated previously, you can consult them on the internet site:
www.effer.it in the “accessories” section.
Once you have chosen the additional outriggers, follow the requested suitability tests, with regard
to the mechanical strength and the stability of the truck.
20/158
Fitter’s manual
fac
-si
mi
le
9260026
21/158
Manuale installatore
We are providing other tables with further indications that prove useful for installing and
choosing additional outriggers:
fac
-si
mi
le
9260026
The outrigger chosen can be installed under the chassis of the truck because its foot jack
can be adjusted vertically.
fac
-si
mi
le
9260026
The outrigger chosen can be positioned at a minimum distance from the rotation axle of
the crane of 4797 mm.
22/158
Fitter’s manual
- Tipper
The user may request a truck board with customised length based on his own requirements
but his request can only be accepted or refused after making the calculations relative to
the weight on the axles.
?
NB: The length of the truck board in
the back part compared to the last
axle of the truck is called “overhang”.
You are obliged to make sure that this
parameter does not contrast with road
regulations in force in the country ?
where the truck will be driven.
23/158
Manuale installatore
2 - IDENTIFICATION OF INSTALLATION
COMPONENTS
We are indicating some visual macro-subjects that must be considered from a technical point of
view to be able to install the crane correctly.
We also remind you that the presence of other additional accessories such as manual/mechanical
extensions or additional hydraulic y-jib certainly modify the value of the weights on the
axles and in the case of the additional y-jib, also the parameter relative to the space
required for installation. Again, these technical parameters can be consulted on the
internet site: www.effer.it
Bracketing
material
Additional y-jib
The person in charge of such jobs shall follow the safety instructions
accordingly:
- Never pass or stand under the load while it is lifted.
- Lifting equipment shall be of suitable load-bearing capacity and be perfectly
intact to be able to lift the crane.
- The choice of lifting equipment to be used is of the responsibility of the
operator and depends on the weight of the load to be lifted.
- Make sure the components are balanced when moving them around.
- Do not stand on the crane; use suitable means (stepladders etc.) subject to
Health & Safety standards in force in the country of use.
25/158
Manuale installatore
26/158
Fitter’s manual
kg kg
kg....
NB: For the handling instructions and the weights of the accessories
required for installation but that are not supplied by the manufacturer,
such as power take-off, pump etc, you are recommended to follow the
instructions of the manufacturer of the accessory.
27/158
Manuale installatore
Dismantling
The crane is to be dismantled from the truck (or other vehicle) with the same precautions and
warnings observed to install it. Be very careful therefore not to disconnect the crane from the
truck without rst having applied lifting equipment to keep it balanced; observe the handling
instructions given in the previous pages.
Disposal
This device contains materials that can be recycled and reused.
Specialised companies are able to recycle this product to exploit all the reusable
materials and to minimise waste disposal.
Special attention is to be given to the disposal of pollutants such as oil
and plastic.
Observe local laws when scrapping the device.
28/158
Fitter’s manual
Standard crane
The essential crane identication data (model, serial number, year of manufacture) are written
on the metal nameplate tted on the outer side of the column.
The serial number of the crane is also punched on the female crane outrigger or on the top
cylindrical part of the base and is highlighted with different colours.
We are providing a specimen of the nameplates that may be tted on the crane.
29/158
Manuale installatore
Additional y-jib
The essential y-jib identication data (model, serial number, year of manufacture) are written on
the nameplate tted on the outer side of the shank.
The serial number of the y-jib and the year of manufacture are punched on the end of the female
tubular piece and are highlighted with different colours.
We are providing a specimen of the nameplates that may be tted on the y-jib.
Mechanical extensions
The essential extension identication data (code, year of manufacture) are punched on the
end of the extension.
The extension is also complete with the maximum admitted weight that it can lift; this value is based
on the mechanical strength of the extensions and the lifting capacity of the crane.
30/158
Fitter’s manual
The hydraulic systems of the crane are designed and sized for oil ow rates that are established
by EFFER during the project phase of the crane.
The operating speed of the crane derives from the oil ow rate: the application of a pump sized in
such a way that it is unable to send enough oil compared to that envisaged means that crane
movements will be slower, with dissatisfaction on behalf of the user, whereas if too much oil
is sent, the oil will overheat with consequent rapid deterioration of the hydraulic components
of the crane, plus the operating speeds would be higher than those envisaged in the project
calculations, which would be dangerous in terms of structural damages. A lower ow rate
of the oil compared to the minimum ow rate indicated could lead to vibrations of the crane
during the movements.
The application of proportional distributors (distributors tted with compensator on the inlet), only
allows the requested amount of hydraulic oil into the distributor based on the crane control
levers operated by the crane driver.
Excess oil compared to that requested by the movement made is sent to the tank and is always
available for other movements.
NB: the proportional distributors have elements with gauged cursors so that
they do not send more oil to the individual cylinders than that envisaged in
the design phase.
The installation of a proportional distributor as optional unit, on cranes that do not envisage them in
the standard version, enables the installation of pumps with displacement that is able to send a
higher amount of oil to the distributor inlet, of even 30% compared to the data written in the data
sheets relative to the hydraulic characteristics of the single models of crane.
This oil ow rate enables the operator to make a number of movements simultaneously even
when the load is hooked on the crane.
For cranes without proportional distributor, it is extremely important to respect the design data
relative to the amount of oil to be sent to the crane control distributor.
31/158
Manuale installatore
The table indicates the recommended oil ow rate for each crane model, - in other words it
indicates the same oil quantities given in the data sheets relative to the hydraulic characteristics
of the crane - and the maximum pressure that the crane requires to be able to work: these
parameters are required to determine the displacement of the hydraulic pump and to determine
the maximum working pressure characteristics that the pump to be installed on the truck must
have, as indicated more in detail in the chapter that follows.
NB: Oil ow rates expressed in l/min. (1 l/min corresponds to 0.016 dm3/s)
Pressures expressed in bar (10 bar corresponds to 1Mpa)
NB: the same values indicated in the table, relative to the oil ow rates to be sent to
the crane to be installed, are given in the hydraulic diagram enclosed in the operator
manual and are published on the internet site of EFFER. In the case of doubts, do
not hesitate to contact the After Sales service of EFFER.
Crane Requested oil Admitted Maximum Crane Requested oil Admitted Maximum
Model ow rate tolerance pressure Model ow rate tolerance pressure
l/min l/min bar l/min l/min bar
20 7÷8 ±2 175 305 60÷100 ±4 325
30 10 ±2 200 310 50÷100 ±4 305
40 12 ±2 300 325 50÷100 ±4 325
42 12 ±2 300 340 60÷100 ±4 310
360 45 ±5 315
45 12 ±2 315
370 60÷100 ±5 330
62 20 ±2 285
75 20 ±2 315 430 45 ±5 335
95 25 ±3 320 44N 50 ±5 290
110E 35 ±3 315 500 70÷100 ±5 325
520 70 ±5 290
115 35÷60 ±3 335
120 30 ±3 300 550 70÷100 ±5 340
130 40 ±3 315 750 70÷110 ±5 330
140 30 ±3 325 80N 70 ±7 280
145 70 ±3 335 850 70÷110 ±5 370
150 35 ±4 315 860 70 ±5 290
155 40 ±4 335 950 70÷110 ±5 335
165 40÷70 ±4 350 1050 80÷110 ±5 380
170 35 ±4 320 1250 80÷110 ±5 355
210 40 ±4 295 1350 110÷200 ±5 355
250 40 ±4 325 1550 110÷200 ±5 360
275 60÷100 ±4 305 1750 130÷200 ±5 365
32/158
Fitter’s manual
5.2 - Sizing of the power take-off and the hydraulic pump 800 rpm
33/158
Manuale installatore
The technical characteristics of the pump mainly show the oil ow rate of the same when it is
subjected to 1000 rpm and pump manufacturers provide some diagrams in which you can see
the oil ow rate of the same when it is subjected to a certain rpm. By reading these diagrams
you can establish the suitability of the pump chosen.
Another way of checking is that of calculating: by knowing that the pump chosen has a
displacement of 80 cm3/rev. for example and knowing that the power take-off will output 744
rpm, (rpm of pump) you will obtain the following:
1000 : 80 = 744 : Q
Q = ( 80 x 744 ) : 1000
Q = 59.52 l / min.
If you wish to make a very precise calculation, you should also consider the pump performance:
supposing it has an average performance of 0.95, the actual oil flow rate of the crane
will be:
Q = 59.5 x 0.95 = 56.5 l / min.
All you need to do now is check if this ow rate is within the tolerance indicated by EFFER for
the specic model of crane involved.
If this is not the case, you need to change some parameters: the rpm of the truck engine, the
reduction ratio of the power take-off or the displacement of the hydraulic pump.
34/158
Fitter’s manual
The additional weights of the truck; pump and power take-off are to be considered
when making the theoretic calculations on the distribution of the weights on
the axles and the stability.
Using the formula that follow you can calculate the power requested on the attachment on the
gearbox of the truck to operate the crane. The sizing of the power take-off must obviously
also guarantee the transmission of the power indicated.
PxQ
Input power calculation Kw =
of the crane expressed in 600 x R
Kilowatt
If you wish to nd out the power required and expressed in - HP - you can use the following
formula:
HP = Kw x 1.36
35/158
Manuale installatore
320 x 60
Kw = = 34.4 Kw
600 x 0.93
If you wish to nd out the power needed and expressed in - HP - you can use the following
formula:
PXQ
M= x 1.59 = daNxm
N
320x60
M= x 1.59 = 43.6 daNxm
700
36/158
Fitter’s manual
Note: The crane can be operated without using the truck engine, using an
alternative power unit such as an electric motor or an explosion engine, obviously
combined with a hydraulic pump.
We are providing a simple calculation formula that you can use to establish the power requested to
operate the crane, at the operating rpm supposed for the alternative power unit.
PxQ
Kw =
600 x R
Another test that the tter must carry out relates to the power that the power unit outputs from
the attachment pre-arranged for the application of the pump when the motor is regulated
at the rpm for working with the crane.
This parameter is given in the technical characteristics of the power unit and must be equal to or
higher than the power value obtained from the above-mentioned formula.
NB: The value obtained from the above-mentioned formula does not indicate the
rated power that the alternative power unit must ensure but the power necessary
to operate the crane, at the operating rpm of the engine.
37/158
Manuale installatore
If you wish to nd out the power necessary and expressed in kilowatt - Kw - you can use
the following formula:
Kw = HP x 0.736
38/158
Fitter’s manual
All explosion engines have variable powers based on the rpm of the engine.
While the crane is in use, it is a good rule for the engine not to exceed 1000 rpm, to prevent
overheating, excessive noise and excessive fuel consumption.
The maximum power of explosion engines is always output at an rpm that generally ranges
between 1600 and 2400 rpm - approximately-. Consequently the power of the engine must be
tested while the crane is working to prevent the engine from stalling.
All truck manufacturers, likewise for explosion engine manufacturers related to independent
power units, provide the diagrams related to the power of the engine.
To test this situation, you need to know the hydraulic characteristics of the crane:
1- the maximum working pressure P ( bar )
2- the effective oil ow rate sent to the crane by the pump Q (l / min.)
PxQ
Using the formula, you can determine the minimum KW =
power required to operate the crane:
600 x R
While the crane is working, supposing the truck engine runs at 900 rpm.
We are providing two power diagrams related to two diesel engines:
39/158
Manuale installatore
150 KW ENGINE
202 KW ENGINE
This engine outputs a power of slightly more than 70 Kw
when it runs at 900 rpm (Line C).
The crane needs 86.6 KW to operate.
Consequently the engine is not powerful enough and
will certainly stall.
This engine has a power of 86.6 KW when it runs at
1000 rpm (line D), which is an acceptable rpm to
operate the crane.
A crane that works, for example, with an oil ow rate of 80 l/min, at a constant pressure of 345
bar, would require a power of 50 KW.
If you analyse the diagrams given related to the power of the two engines, you will see that the
curves of the diesel engines of the latest generation are quite “vertical”, in other words they
have a very high increase in power as the engine rpm varies.
From this trend you can understand the importance of carrying out the test mentioned, despite
the model of crane or the type of truck, to avoid the engine stalling while the crane is working
at its maximum performance.
40/158
Fitter’s manual
The crane must be secured with two tie-rods for each bracket on the base.
The weights of the “bracketing material” are to be considered when making the
theoretic calculations of the distribution of weights on the axles and the stability.
The table indicates the rough weights of the crane INDICATIVE WEIGHT
bracketing material, including the weight of
Lifting Bracketing/hydr.
the hydraulic material required to connect the
pump to the crane, based on the power of Torque conn. material
the crane (lifting torque) expressed in tons txm KN.m kg
per meter.
example: crane mod. 115 = 11,5 txm 115 KN.m 0÷3 0÷30 15
crane mod. 370 = 37 txm 370 KN.m 3,1÷5 31÷50 20
crane mod. 850 = 85 txm 850 KN.m 5,1÷10 51÷100 25
10,1÷20 101÷200 30
20,1÷30 201÷300 50
30,1÷50 301÷500 70
>50,1 >501 80
41/158
Manuale installatore
42/158
Fitter’s manual
5.4 Counter-chassis
We are providing a table with the indicative weights of the counter-chassis, based on the power
of the crane expressed in tons per meter.
example: crane mod. 115 = 11,5 txm 115 KN.m
crane mod. 370 = 37 txm 370 KN.m
crane mod. 850 = 85 txm 850 KN.m
43/158
Manuale installatore
A question that our customers often ask us right from the sales negotiation phase is that of the
value of additional weights following the installation of a crane on a truck. We are providing a
table that indicates the weight per meter of some types of truck boards: these parameters are
obviously indicative but will help you in your evaluations.
44/158
Fitter’s manual
?
the second boom takes up more space compared
to the standard version.
ø3
h2
h1
45/158
Manuale installatore
The crane with column rotation by means of hydraulic cylinders and rack has its rotation dead
centre point in a preset position.
NB: by dead centre point - or zero point - we mean the centre line of the small zone
restricted by the two rotation limit switches.
The dead centre point is indicated by an adhesive plate on the base of the crane and by a zero
punched on the same base, near the adhesive plate.
The rotation angle varies based on the various models of crane: this parameter is written in
the table that follows but can also be consulted in the sales price list and on the internet
site: www.effer.it.
A crane installed behind the cab of the truck must have the rotation dead centre point facing the
front of the truck, the same applies to a crane installed at the back of the truck board.
Up until a few years ago, the standard dead centre point was on the side of the cross member
of the outriggers but this is no longer valid because the rule that envisaged the installation
of the outriggers always facing the cab no longer applies (rule relative to cranes installed
between the cab and truck board).
For particular installation requirements - installation on semi-trailers, rear installations - you
can request the manufacturer to supply the crane with the dead centre point turned by 180°
compared to the standard version.
2
=
0
=
Punto zero
Dead point 2
Null punkt
Point zero
=
0
=
46/158
Fitter’s manual
380° a 45 X X
=
380° a 45/40 X X 1
370° b 55 X X
370° b 62 X X 2 OS
380° b 75 X
=
380° b 95 X 0
400° b 110 X X
=
400° b 110E X X
1
400° b 115 X X
400° c 120 X X
400° b 130 X X
400° c 140 X X ASSEMBLY OF STANDARD VERSION
400° b 145 X X
400° c 150 X X
400° b 155 X X
400° b 165 X X
400° c 170 X X a b c
400° c 210 X X
400° c 250 X X
407° c 310 X X
407° c 325 X X
420° c 335 X X
407° c 340 X X
407° c 370 X X
47/158
Manuale installatore
275 600°
305 600°
360 650°
400 650°
460 650°
44N 650°
500 580°
520 650°
550 580°
600 650°
680 650°
720 650°
80N 650°
860 640°
950 640°
1050 R.C.
100N 650°
1250 R.C.
1350 R.C.
1550 R.C.
1750 R.C.
Note: C.R.= Continuous rotation
48/158
Fitter’s manual
49/158
Manuale installatore
50/158
Fitter’s manual
Some cranes of the EC version have some electric proximity/micro switches in the top
part of the base, which automatically restrict the working angle of 180° in relation to the
maximum lifting capacity of the crane.
When the rotation dead centre point of a crane needs to be changed, the electric proximity/micro
switches installed must be positioned on the opposite side of the base.
51/158
Manuale installatore
6 INSTALLATION CALCULATIONS
Another fundamental element for choosing the crane to be installed on a certain type of truck is
that the stability of the rig-out is guaranteed when the crane is in use.
Note: the tter shall in any event respect the technical specications supplied by
the manufacturer of the vehicle and of the crane.
This report will become part of the technical folder that each tter must keep and that must be
handed over to control authorities if requested.
NB: Before you approve and confirm the customer’s/user’s installation, you
therefore need to make the theoretic calculations of the distribution of weights
on the axles and the stability.
52/158
Fitter’s manual
We are providing an illustration of the graphic calculation processed with the “TRAILERWIN”
program relative to the installation of a crane model 340.11 4S on a truck.
2220 4700
22/02/06 13.45 C:\TRAILERW\DATA\Manuale installatore _ ITA 2
1330
340.11-4S
940 1230 Manuale dell'installatore
SCANIA R 000 LB6X2*4MNA 3900 CR19 Comfortline
EX
50 50
Passo base mm 3900
10400 kg Sbalzo anteriore mm 1455
AM
DOPPIO ASSALE POSTERIORE
Distanza tra gli assali posteriori mm 1355
-135 Posizione dell'asse ideale dietro al primo assale p. mm 535
Distanza assale anteriore - filo posteriore cabina mm 890
E
+ Peso del telaio 5135 3505 8640
+ Numero delle persone 2 x 75 kg 0 150 0 150
1 3 2 + Peso proprio del cassone 200 kg/m 4570 -29 969 940
4 + Peso controtelaio 207 kg/m 3100 376 874 1250
1 EFFER 340.11 / 4S 1535 2784 1474 4258
2 STAFFAGGIO E COLLEGAMENTO IDRAULICO 1470 47 23 70
3 PTO+POMPA 1200 27 10 37
4 EFFER 9260026 6270 -106 361 255
= Peso allestimento a vuoto 8385 7215 15600
3900 1355 + Portata residua 4570 -317 10717 10400
= Peso allestimento a pieno carico 8068 17932 26000
:: Carico massimo ammesso (PTT) 8500 19000 26000
1455
Optimum MISURE DEL CASSONE consigliate: ( x1 = 2220 mm )
8375 Lunghezza del cassone mm 5535 ... 4362
Sbalzo mm 3178 ... 2005
Scaricato 8385 { 54%} 7215 = 15600 kg
Sporgenza % % 69 ... 44
Caricato 8068 { 31%} 17932 = 26000 kg Lunghezza totale dell'allestimento mm 9211 ... 8038
Punto di applicazione del carico mm -410 ... 177
53/158
Manuale installatore
6.2 - Useful information on calculating the theoretic weight test on the axles
The calculation used for the theoretic testing of the weights on the axles are done to test the
weights on the front axle, denominated RA, and on the rear axle, denominated RB.
From this calculation, you will realise that the truck is considered to have just two points on
which it rests on the ground.
This is obviously true in trucks with two axles type 4x2 or 4x4.
4x2 4x4
There are also trucks on the market with more than two axles. The manufacturers almost
always provide the position of the two reaction points of the weights on the ground, in
other words the position of RA and of RB, with the relative tare and maximum admitted
weight values.
In the case of trucks with more than two axles, of which the values of the single axles is known,
the position of RA and of RB is to be calculated.
6x2 6x4
= =
6x6 6x2/4
= =
8x2 8x4
= =
54/158
Fitter’s manual
Here’s the calculation to be made with regard to the different types of trucks:
1st case: truck with three axles, with two rear axles: the rear axles have different tare and
maximum admitted weight values.
Parameters known:
6x2 6x2/4
I = distance between 1st and 2nd axle
Z = distance between 2nd and 3rd axle
M1 = Maximum admitted weight on 1st axle Z
I
M2 = Maximum admitted weight on 2nd axle
dx dy
M3 = Maximum admitted weight on 3rd axle
m1 = Tare of 1st axle
RA RB
m2 = Tare of 2nd axle 2nd axle 3rd axle
1st axle
m3 = Tare of 3rd axle M1 / m1 M2 / m2 M3 / m3
EI
Parameter to be calculated: distance EI
Distance EI is the distance between points RA and RB
M3x Z
dx = dy = Z - dx
M2 + M3
EI= I + dx
2nd case: truck with four axles, with two front axles and two rear axles.
55/158
Manuale installatore
As for the calculation to be carried out to nd the distance of EI, proceed in the same way
as described for the previous case:
Parameter to be calculated: distance EI
Distance EI is the distance between points RA and RB
NB: Weights M3 + M4 and m3 + m4 are concentrated
in point RB.
I Z
M4x Z
dx dy
dx = dy = Z - dx
M3 + M4
RA RB
EI
EI = I + dx
1 2
EI µ EI µ
3 4
EI µ EI µ
NB. In countries of the European Community, a percentage has been dened for
the maximum length of the overhangs of vehicles ( µ ), which is calculated over
the distance of EI, distance between the two reaction points on the ground, also
dened as “technical pitch”.
Below is the different percentage based on the number of axles of the truck:
type 1; 2 axles µ max = 65% EI type 3; 3 axles µ max = 70% EI
type 2; 3 axles µ max = 70% EI type 4; 4 axles µ max = 70% EI
56/158
Fitter’s manual
NB: - European standards indicate 1450 mm as the maximum height of the ring off the
ground - you can generally prepare a lower mimic chassis under the ring than that needed
under or near the crane. This depends on the maximum dynamic torque of the crane,
which decreases as you move away from the rotation axle.
57/158
Manuale installatore
Truck data:
..................
F = Rear chassis overhang of
original truck
EI µ = Maximum rear overhang ..................
admitted by road regula-
I Z tions
The minimum ratio when empty with load between the weights of the front axle (RA)
and the weights of the rear axle (RB) is a parameter supplied by the manufacturer of
the truck. It is important to respect it: otherwise the steering and braking efciency
of the truck could be compromised.
58/158
Fitter’s manual
Crane data:
.................. d d d
a = Overall dimensions of the crane
c c c
b = Space needed for installation ..................
c = Distance of crane rotation axle
from beginning of space needed ..................
for installation e e e
d = Distance of centre of gravity
from beginning of space needed ..................
for installation
e = Weight of crane with oil in tank ..................
a a a
b b b
59/158
Manuale installatore
Each crane installation must be preceded by a calculation of the theoretic stability test. This
calculation shall be kept in the technical folder of the crane and the theoretic data shall be
practically tested at the end of the job. The calculation involved can be carried out:
1) Using an electronic calculation program on computer, supplied by EFFER. This program is called
“trailerwin” and is used to theoretically test the stability and to print out the result.
In both cases the data required to make the calculation are the same.
We are providing a specimen of what can be found for each single crane model by consulting
the internet site of EFFER: the table also shows the distances of the centres of gravity of the
crane, measured from the rotation axle and the values relative to the weight of the xed part
(base/column unit) and of the mobile part (booms).
Similar tables can also be prepared for cranes with additional hydraulic y-jibs.
BARICENTRO COMPLESSIVO
A TOTAL CENTRE OF GRAVITY
fac
-si
mi
D B le
3S 4S 6S 8S
kgA 3993 4193 4543 4848
A 1428 1907 2880 3887
B 52 71 100 122
E
60/158
Fitter’s manual
Here’s an illustration of the graphic calculation carried out using the “TRAILERWIN” program
relative to the installation of crane model 340.11 4S on the truck.
ex
am
0°
ple 340.11-4S
SCANIA R 000 LB6X2*4MNA Manuale dell'installatore
EFFER 340.11 / 4S
1470
CALCOLO DI STABILITA' (Distanze dalla linea di ribaltamento)
90° Laterale destra
kg x m= kgm
3200 3200
Peso asse anteriore 5556 x 3.417 = 18987
6400 Peso asse posteriore 5381 x 2.074 = 11161
Peso stabilizzatori 0x 3.081 = 0
Peso degli stabilizzatori supplementari 255 x 1.577 = 402
Peso del basamento 2358 x 3.005 = 7086
n = 1.20 n = 1.23
Laterale sinistra Laterale destra Momento stabilizzante Totale = 37637
Peso del braccio 1900 x 1.205 = 2289
Portata al massimo sbraccio 3040 x 9.345 = 28408
Momento ribaltante Totale = 30698
Coefficiente di sicurezza n 37637 / 30698 = 1.23
Carico max. 3040 kg
Anteriore destra
kg x m= kgm
3300
n = 2.46 Posteriore
Peso asse posteriore 5381 x 3.356 = 18059
Peso stabilizzatori 0x 0.073 = 0
Peso degli stabilizzatori supplementari 255 x 5.049 = 1287
Peso del basamento 2358 x 0.249 = 587
340.11-4S 180°
Momento stabilizzante Totale = 19933
SCANIA R 000 LB6X2*4MNA
EFFER 340.11 / 4S Peso asse anteriore 5556 x 1.221 = 6784
3040 kg x 12350 mm Peso del braccio 1900 x 3.961 = 7526
Portata al massimo sbraccio 3040 x 12.101 = 36787
n= Carico max.
Momento ribaltante Totale = 51097
Laterale destra 1.23 3040 kg
Anteriore destra 0.39 386 kg n< 1.05 ø = -72° ... 73° Coefficiente di sicurezza n 19933 / 51097 = 0.39
Laterale sinistra 1.20 3040 kg
Anteriore sinistra 0.41 481 kg n< 1.05 ø = 291° ....... Carico max. 386 kg
EFFER HOLDING S.P.A. - VIA BONAZZI 12 - 40013 CASTEL MAGGIORE (BO) ITALY
Manuale installatore_ITA 2
EFFER HOLDING S.P.A. - VIA BONAZZI 12 - 40013 CASTEL MAGGIORE (BO) ITALY
Manuale installatore_ITA 2
___CraneWIN 2004-01____ 22/02/06 13.47
61/158
Manuale installatore
7 - CONSTRUCTIONAL INFORMATION
FOR THE COUNTER-CHASSIS
The counter-chassis must have an absolutely specic cross section, which derives from a test
calculation that is to be carried out before starting to install the crane. The purpose of this
theoretic calculation is that of proving that the maximum dynamic torque of the crane is
completely absorbed by the resistance of the chassis of the truck added to the resistance of
the counter-chassis that will be constructed.
This calculation must be kept in the technical folder of the crane.
The calculation involved can be carried out:
1) Using an electronic calculation program on computer, supplied by EFFER. This program
is called “trailerwin”.
2) Using a manual mathematical calculation.
NB: If you do not avail of the computerised calculation program, you can request
EFFER for the manual procedure or you can even request EFFER to do the
calculation for you.
The position of the maximum dynamic torque of the crane coincides with the position
of the crane’s rotation axle; it is supposed to decrease in a linear manner along the
axis of the truck, further away you move from the rotation axle of the crane, through to
becoming null by the rear additional outriggers - if present - or by the rear axle of the
truck if there are no additional outriggers.
The dynamic torque of the crane is also supposed to be distributed in equal parts on each
of the two side members of the counter-chassis/chassis of the truck, even if the rotation
axle of the crane is not positioned on the centre line.
The above only applies if the two side members of the counter-chassis are suitably
connected together, especially under and near the base of the crane.
62/158
Fitter’s manual
R=5
63/158
Manuale installatore
64/158
Fitter’s manual
All parts of the vehicle involved in the conversion or application shall be protected against
corrosion and rust.
All parts involved shall be treated and painted efciently. The nished counter-chassis in
particular shall be treated with a cycle that envisages the following, once it has been
completely assembled:
- degreasing of the surfaces using adequate solvents that are not harmful to humans.
- electrophoresis, or rust inhibitor treatment in alternative.
- painting with suitably thick products (approx. 60 µ m).
Note 1: all parts involved in welding shall be cleaned before painting them, if
necessary.
Note 2: the counter-chassis shall be closed at the end with some welded and sealed
plates or open or semi-open boxed parts of the counter-chassis shall be treated with
oil-wax products. Seal joints and overlapped parts and protect zones exposed to
abrasive action using specic products.
Painting precautions
Due precautions shall be taken to protect parts where paint could compromise their conservation
or operation, such as:
- Flexible hoses for pneumatic and hydraulic systems in rubber or plastic.
- Gaskets, parts in rubber or plastic.
- Stems of shock absorbers, of hydraulic or pneumatic cylinders.
- Nameplates, initials etc.
65/158
Manuale installatore
As already mentioned, the section of the counter-chassis can be gradually reduced after a
length of three times the width of the crane base.
The most usual way is that of leaving the internal closure of the side member of the counter-
chassis and of creating a reduction of the resistant torque as indicated below:
h h
h
3x
h
3x
Sufcient Perfect
If the section of the counter-chassis envisages some internal horizontal spacer plates, these too
can be limited in length, again gradually.
30°
66/158
Fitter’s manual
The material and the outer dimensions of such connection cross members shall correspond to
those used to construct the side members of the counter-chassis.
67/158
Manuale installatore
With the same crane and same truck, installation number 2) takes more work and more material,
because the counter-chassis must be more rigid in order to limit twisting while the crane is
working and to avoid problems of stability deriving from twisting.
The rear part of the truck is not as rigid and twists if it is strained by the use of a crane, therefore
the boxed parts that are appropriately prepared in the zone next to the crane to make the
counter-chassis rigid (cross members of the counter-chassis) in this specic type of installation
must be increased both in terms of number and section.
For the sake of evaluation, let’s say that the solutions used to prevent twisting in trucks with crane
installation type 1) must be increased by 30-40% compared to installation type 2).
68/158
Fitter’s manual
We are providing some useful tips on installing a crane correctly behind the cab, with regard to
the construction of the counter-chassis:
There are three types of crane bases:
1) Bases with 3 anchoring brackets
1
With this base, the constructional nature of which
does not contribute in reducing truck twisting,
you need to apply an initial cross member on the
counter-chassis under the base of the crane.
This cross member must obviously and theoretically be as high as the side member of the
counter-chassis: sometimes however this is not possible due to the shapes and sizes of
the truck, which stick out from the top edge of the chassis, or due to the shapes and sizes
under the base of the crane.
You are recommended to make as high a section as possible whatever the case to contrast
truck twisting while the crane is working.
The technical data sheets of the individual cranes related to information on the product provide
further information concerning the construction of this initial cross member.
69/158
Manuale installatore
The structure of the base contributes in making the part under the crane rigid therefore the
application of cross members can start after the rear crane bracketing tie-rods: with this we
do not mean that it is not useful but almost superuous.
70/158
Fitter’s manual
71/158
Manuale installatore
72/158
Fitter’s manual
As mentioned previously, another important aspect to be observed strictly in order to obtain a good
result is the height of the cross member: a cross member that is even only just a few centimetres
lower than the height of the side member looses up to 50% of its effectiveness.
73/158
Manuale installatore
When constructing a counter-chassis, it may occur that some cross members are to be applied in
zones where the counter-chassis consists of a simple C prole.
The application of a cross member that must be a boxed one (otherwise it would be almost
useless), envisages the closure of the prole in the joining zone of the cross member by means
of a wedge almost as thick as the prole and appropriately welded.
100
The profile is to be closed so that there are two free protrusions at the side of roughly
100 mm.
74/158
Fitter’s manual
If the crane is installed at the back of the truck, the instructions just mentioned for the stiffening
triangles must be observed.
A part of the counter-chassis is to be closed with some sheet plates (as can be seen in the
illustrations): this will form a box that is very unlikely to deform through twisting.
Md. A A
M= B
B x
Md
If there are no additional outriggers, distances
A and B must refer to the rear wheel axle. M
Counter-chassis
controtelaio
telaio veicolo
vehicle chassis
A
B
x
75/158
Manuale installatore
Md
mic torque of the crane is contra-
M1
sted by the additional outriggers
or by the rear axles of the truck,
and is annulled. x
76/158
Fitter’s manual
Some models of crane are offered in the lowered version, in other words they already have an
initial part of counter-chassis supplied by EFFER. In these crane versions, the rotation ring is
applied on the structure that acts as the crane base and also the counter-chassis.
The part of counter-chassis supplied may be considered load-bearing, in other words this part
alone is able to withstand the maximum dynamic torque of the crane.
The work related to the installation of a crane equipped with integral counter-chassis consists
in constructing the follow-on of the counter-chassis through to the back end of the truck:
together with the crane, EFFER supplies some plates that are to be tted in the joining
point between the two parts.
77/158
Manuale installatore
Below is a table related to the dimensions of the sections of the side members supplied
by EFFER.
Crane Mod. A B C D
Generally speaking, or in most cases, if a counter-chassis is constructed at the back with the
side members of the section indicated in the table above, using material type S355J2G3C UNI
EN 10025 (EX Fe 510 D UNI 7070) - or similar - the dynamic torque of the crane, in the point in
which the constructed section begins, is overcome by the resistance of the section made, also
considering the contribution given by the section of the truck chassis.
However, this is always to be checked with a test calculation, which we advise you to carry out
following the indications relative to a rigid bracket.
Find the positions where the bracket of the counter-chassis/crane can be applied on the truck
chassis: we point out that, since this is a section in which the dynamic torque of the crane
is completely absorbed by the structure supplied, you can use some joining tie-rods with
diameter of 24 mm for the brackets (see chapter 5.3 for the material specications), starting
from the front end and positioning them at a distance of 800-1200 mm. This type of bracketing
is considered “exible”.
If you wish to make the brackets using side plates, observe the indications given
in the chapter concerning the rigid bracket.
78/158
Fitter’s manual
The function of the tie-rods is that of securing the counter-chassis/crane to the chassis
of the truck.
It is obviously important and fundamental to install at least four side blocking devices, two
on each side, that stop any side movement of the counter-chassis/crane compared to
the truck chassis.
Once you have found the position of the brackets and of the side blocking devices,
raise the counter-chassis/crane and position it so that you are able to remove the
paint from the zone to be welded.
NB: the section of the counter-chassis/crane is much wider than the section of
the truck chassis: the recommended type of brackets is that indicated in the
drawing that follows. In this way you also block the counter-chassis on the truck
to stop it moving sideways.
No 2. stiffening ribs ≠ 10 at
the side of the bracket
Anti-squashing plates of
Threaded block
the truck chassis (≠ min
(60x40 ≠ 40) 10 mm)
79/158
Manuale installatore
The crane is to be taken off the truck again to be able to weld perfectly.
Once you have nished welding and cleaning, protect the welded zones with special paint.
80/158
Fitter’s manual
The side members made must coincide perfectly with the end part of the counter-chassis supplied
by the manufacturer: the joining points are to be prepared for welding as follows:
90°
gru controtelaio
2mm
90°
90°
300
Top metal plate of the exten-
sion:
it must be shorter to create the
room required to weld internally 90°
and to apply the reinforcement
in the joining point between
the two bottom horizontal sheet crane counter-chassis
metal plates.
81/158
Manuale installatore
You can then weld the bracketing material and pound the zones left free from the joining cross
members of the side members using 10-mm thick sheet metal.
You will then weld and paint the counter-chassis. The counter-chassis thus prepared is to be
tted on the truck and bracketed to it nally.
Once you have bracketed the counter-chassis, join the same to the chassis of the crane by
welding them together.
82/158
Fitter’s manual
Two reinforcement plates are supplied with the crane, which are to be welded inside the side
members to join the two bottom plates.
90°
Finally, apply the top metal plate to
close the opening between the
counter-chassis and the chassis
of the crane.
This will create a counter-chassis as
illustrated in the photo above. crane counter-chassis
2 mm
83/158
Manuale installatore
When installing the power take-off on the gearbox you need to work with maximum caution
to ensure you assemble the power take-off correctly, which would otherwise damage the
truck’s gearbox.
Proceed as follows:
2) Screw the stud bolts in the holes where the screws of the hatch were tted and tighten rmly.
If the threaded holes go right through the gearbox, make sure the stud bolts do not interfere
with the gears inside the box. In this case, we remind you to apply a sealing product on the
thread of the stud bolts to avoid the possible leakage of oil.
3) Fit the power take-off on the gearbox using a gasket in-between (supplied with the
power take-off).
To assemble correctly, there should be a play of between 0.15 and 0.3 mm between the teeth of
the gears of the gearbox and those of the power take-off. Fit a number of gaskets between
the power take-off and the gearbox to obtain an empty rotation movement on the output shaft
of the power take-off with a play of between 0.5 and 1 mm.
Gearbox
Power take-off
84/158
Fitter’s manual
To check, leave the truck engine turned off and operate the power take-off and manually
turn its output shaft.
In some power take-offs there is an opening through which you can check the play between
the gears.
NB: The output shaft turns and engages the power take-off. Connect the drive of the
power take-off to check the play. The truck engine must be turned off.
4) The correct attachment of the power take-off requires the application of safety washers that
cannot come loose or even better the application of Loctite on the threads.
Recommended tightening torques for the attachment screws of the power take-off:
5) Once you have tted the power take-off, you need to check the noise of the gears by activating
the power take-off and starting the engine just shortly and at roughly 700 rpm, bearing in mind
that the gearbox and the power take-off work without oil in this phase. A “creaking” noise
means that they are installed too tight: there’s no play between the teeth. A “beating” noise
means that there is too much play between the teeth.
6) Once you have checked the perfect completion of the job, ll the gearbox back up with oil.
NB: The power take-off is always to be engaged and disengaged with your foot
pressed right down on the clutch pedal.
NB: check the tightness of the power take-off after a few hours of work.
85/158
Manuale installatore
on the branch to prevent a defect in the power take-off or in the system created from
compromising the operation of the truck too. Furthermore to avoid air leaks, the pneumatic
connections must be made very carefully and using pipes with pipe fittings. You are
recommended not to complete pneumatic connections with welded pipes.
It is absolutely forbidden to move the truck while the power take-off is engaged; for this
purpose you are advised to install a luminous red LED in a clearly visible position (this is
actually obligatory in EC countries), so that the truck driver can always check the condition
of the power take-off.
If you move the truck while the power take-off is engaged you will damage the power take-off
irreparably.
Earth
+
Truck utility air tank
Power take-off
86/158
Fitter’s manual
Engaging lever
Engaging lever
Earth
Power take-off
+ Flexible cable
Power take-off
Electric contact
on command
87/158
Manuale installatore
Operation with the hydraulic control unit is usually used for smaller cranes, for random
work and for cranes with lower lifting capacities, due to the considerable input and electric
power available that the normal system of the vehicle is not always able to output, which
compromises its use and leads to frequent maintenance jobs such as the replacement of
starter switches and electric motors.
88/158
Fitter’s manual
There are two possible ways of installing the hydraulic pump based on your own requirements:
NB: To avoid cavitation, the pump must always be installed under the minimum
level of the hydraulic oil of the tank.
89/158
Manuale installatore
α α α
α
Angles not the same
Angles the same
and joints timed
and joints timed
90/158
Fitter’s manual
To use the Cardan shaft correctly, the angles of the two end joints must be the same and
must not exceed the maximum angle admitted by the manufacturer and that the joints at
the ends are timed with each other.
Practically speaking:
- t the pump on the counter-chassis, tilting at the same angle as the gearbox compared
to the chassis;
- make sure the end anges of the Cardan shaft are on the same level.
If the Cardan shaft is installed incorrectly it could not only compromise the life of the Cardan shaft
itself but also that of the power take-off and of the pump.
Note: for the operator’s safety you are recommended to use Cardan shafts complete
with protection devices on the joints.
Note: If the two circuits (tipper/crane) are integrated or they are operated by just
one pump, if the tipper is already on the truck, you need to drain the oil of the
tipper in the cylinder so that it does not pollute that of the crane tank with particles
or other suspended bodies, which would consequently damage the hydraulic
components of the crane circuit.
91/158
Manuale installatore
Note: when installing the counter-chassis, do not move the truck until the counter-
chassis has been completely bracketed.
If you need to move the truck you will have to repeat all just explained.
NB: before you start any jobs, disconnect the truck’s battery as explained in
section 1.2.2.
92/158
Fitter’s manual
93/158
Manuale installatore
Let’s analyse the case of a crane installed behind the truck cab, in other words a crane that has
a reduced lifting capacity in the work zone over the cab. The crane base is secured by four
tie-rods on each side of the counter-chassis. The counter-chassis is joined to the chassis of
the truck with plate and screws. Here’s a table with the minimum number of screws that are
to be applied on one side of the chassis of the truck.
Note: you are advised to use screws in material type 10.9 to reduce their number.
94/158
Fitter’s manual
A exible type attachment, excluding the part under the crane, is also done using brackets
joined with large screws or tie-rods:
Counter-chassis
Chassis
Counter-chassis
Chassis
The brackets are tted on the outer rib of the side members of the truck chassis using bolts
or nails, while can be done by welding on the counter-chassis. The brackets shall be
appropriately distributed along the counter-chassis (as an indicative value, centre line
between brackets: 750 / 1000 mm).
If you need to make additional holes in the chassis, do so bearing in mind the specic directives of
the truck manufacturer (see also indications given in section that follows).
To ensure the exibility of the connection, during assembly, make sure the distance between the
brackets of the chassis and of the counter-chassis is 1-2 mm before tightening the attachment
bolts; greater distances are reduced using appropriate spacers.
95/158
Manuale installatore
You must nd the number of screws to be applied under the crane instead of the tie-rods.
These screws must ensure the perfect connection between the side plates tted and the
original chassis of the truck and must be tightened so that they are able to withstand
the cutting force.
NB: Unless specifically specified, based on the calculations carried out, the
connection plates must be made of the same material and with the same or greater
thickness as that used to construct
the counter-chassis. We are providing Max. crane torque Thickness of sheet plat
a table of some indicative thicknesses, txm KN.m recommended “S”
obviously using material with mecha-
nical characteristics of at least type S < 10 < 100 8 mm
355 J2G3C UNI EN 10025 (ex Fe 510D 10 ÷30 100 ÷300 10 mm
UNI 7070).
> 30 > 300 12 mm
Consider the following to find the minimum number of screws to be fitted instead of the
tie-rods:
96/158
Fitter’s manual
1) crane installed behind the cab, in other words a crane with reduced lifting capacity over the
cab. The four crane attachment tie-rods, on each side, secure the crane to the counter-chassis.
The counter-chassis is joined to the truck chassis by a plate and a number of screws - again
on each side - as per table below.
NUMBER OF SCREWS ON EACH SIDE OF CHASSIS
Diameter of Screw M12 Screw M14 Screw M16
crane
bracketing Class of resistance Class of resistance Class of resistance
8.8 (8G) 10.9 (10K) 8.8 (8G) 10.9 (10K) 8.8 (8G) 10.9 (10K)
M16X1,5 12 10 11 9 10 8
M18X1,5 15 12 12 10 11 9
M20X2 17 14 15 12 12 10
M24X2 20 16 17 14 15 12
M27X2 22 18 20 16 17 14
M30X2 24 20 21 17 18 15
M33X2 26 22 23 19 21 17
M36X2 29 24 24 20 22 18
M39X3 32 26 26 24 24 22
M42X3 26 24
M45X3 28 26
M48X3 32 30
2) crane installed at the back of truck, in other words a crane with maximum lifting capacity
in the work zone. The four tie-rods secure the crane to the counter-chassis. The counter-
chassis is joined to the truck chassis by a plate and a number of screws - again on each
side - as per table below.
NUMBER OF SCREWS ON EACH SIDE OF CHASSIS
Diameter of Screw M12 Screw M14 Screw M16
crane
bracketing Class of resistance Class of resistance Class of resistance
8.8 (8G) 10.9 (10K) 8.8 (8G) 10.9 (10K) 8.8 (8G) 10.9 (10K)
M16X1,5 16 14 15 12 14 12
M18X1,5 20 16 17 14 16 13
M20X2 24 20 21 17 17 14
M24X2 28 22 24 20 21 17
M27X2 30 25 28 23 24 20
M30X2 34 28 30 24 26 21
M33X2 36 30 33 27 30 24
M36X2 40 34 34 28 31 26
M39X3 45 37 36 32 34 30
M42X3 34 32
M45X3 37 36
M48X3 40 38
Note: you are advised to use screws in material type 10.9 to reduce their number.
97/158
Manuale installatore
The holes (through holes) where the screws are screwed must be
larger in diameter than the diameter of the screw, by max 0.5 mm
(example: for a screw type M14 the hole must be 14.5 mm).
The remaining screws are to be arranged as near as possible to the above-mentioned zone.
Rigid attachments in the zone that is not under the crane is also done using brackets joined
with screws.
Counter-chassis
Chassis
Counter-chassis
Chassis
98/158
Fitter’s manual
The brackets are applied on the outer rib of the side members of the truck chassis using bolts or
nails, while the counter-chassis can be applied by welding it.
The brackets are to be appropriately distributed along the counter-chassis.
If you need to make additional holes in the chassis, do so bearing in mind the specic directives
of the truck manufacturer.
To ensure the exibility of the connection, during assembly, make sure the distance between the
brackets of the chassis and of the counter-chassis is 1-2 mm before tightening the attachment
bolts; greater distances are reduced using appropriate spacers.
99/158
Manuale installatore
3) Mixed attachment
This type of attachment is a mix between the exible and rigid types. The test calculation shall
identify the point where the rigid attachment is to end, in other words the point from where you
can continue with the exible attachment due to lower strain conditions.
It enables the construction of very short counter-frames and is constructionally more economic
compared to the completely rigid attachment. It offers a contribution towards twisting slightly
lower than the rigid type but superior compared to the exible type.
It is to be pointed out that it can also be done by applying single tie-rods to attach the
crane/counter-chassis/truck chassis, but plates need to be arranged between the counter-
chassis and the chassis in the rigid section to prevent any running between the two
elements.
Force
Mixed deformation
For indications on the bracketing next to the crane, observe the instructions given in section
2 “rigid bracketing” while you can observe all indicated in section 1 “exible attachment”
for the remaining part.
100/158
Fitter’s manual
Generally speaking and unless instructed otherwise by the truck manufacturer, you can use the
diagram given below if you need to drill holes in the truck chassis.
C
Note: the counter-chassis constructed must rest constantly on the truck chassis
for its whole length.
No type of material is requested to be placed between the two structures, neither rubber
and not even wood.
If there are any nails in the top wing of the truck chassis, a plate is to be tted over it that is
as large as the chassis, as thick as how far the nails stick out and with holes by the heads
of the nails, as stated in section 7.
We remind you that this plate must as long as the counter-chassis and must be joined to the
counter-chassis: remember it cannot be welded to the truck chassis.
101/158
Manuale installatore
102/158
Fitter’s manual
B Z B
1 1
3 3
4
2
4
s s
A C A
The plate that joins the counter-chassis / truck chassis is bolted to the truck chassis and welded
to the counter-chassis. If the counter-chassis and the chassis have the same width, the plate
is vertical. If the counter-chassis is wider than the truck chassis, the width is recovered using
the base plate in the shape of a bracket.
Prepare the width of the joining plate so that the corner welding has a thickness of Z = S and
can be placed without hindrance.
The reinforcement plates - re. 2 - must be tted every 200÷300 mm.
The recommended thickness of sheet plate “S” of the side plate depends on the lifting torque of
the crane: If there are no dimensional restrictions deriving from the theoretic calculations, we
recommend you not to use wedges smaller than that indicated in the table:
103/158
Manuale installatore
Front side of
truck
A A
L1 L2
104/158
Fitter’s manual
A A
L1 L2
Note: Plates A must be at least 1.2 times as thick as the diameter of the tie-rod.
L3 L3
L4 L4
L3 ≥ L4
L4 L3
L3 L4
105/158
Manuale installatore
10 mm 10 mm
90° 90°
106/158
Fitter’s manual
In the case of counter-chassis built with very thin vertical sheet plates, or in other words thinner
than or equal to 6 mm, there is the risk of the side members of the counter chassis getting
squashed when the crane is at work, whatever the type of crane installed.
You are advised to apply some localised reinforcements on the counter-chassis, by the
tie-rod itself.
The minimum recommended width L is of 0.8÷1 times the height of the counter-chassis, the
minimum thickness of the reinforcement plate is indicated as 6 mm.
h
L min = (0,8 ÷1) x h
You are recommended to weld continuously in the top and bottom zone, while the welding
on the vertical sides is to be concentrated just in the central zone, with indicative length
of 1/3 the length of the plate.
1/3 di L
107/158
Manuale installatore
108/158
Fitter’s manual
Use some tie-rods to secure the crane to the truck or just to the counter-chassis. The
securing nuts must be tightened using a dynamometric spanner. All this is explained and
illustrated in section 5.3.
Not only is the crane to be blocked vertically, but you must also prevent the base from moving
compared to the counter-chassis especially after the crane rotates or if the truck brakes
suddenly. For this reason you need to install some suitable blocking devices, at the top part
of the counter-chassis, to prevent the crane base from slipping.
The presence of such blocking devices is indispensable to guarantee the tightness of the
tie-rods in time.
These blocking devices must be in quantities of four: their position is very important based
on the type of crane base.
in alternative
109/158
Manuale installatore
2) Base with four brackets for securing the crane with mobile equalisers:
3) Base with four brackets for securing the crane and with xed equaliser:
in alternative
110/158
Fitter’s manual
2) the blocking device that is not applied on the top side of the counter-chassis is replaced with a
plate that is welded on the outer side of the counter-chassis.
You need to create an interference between the blocking device and the crane of at least 40
mm (part of blocking device that sticks out of the top edge of the counter-chassis) and use a
minimum thickness of 15 mm for cranes up to 30 txm, whereas for cranes with greater lifting
capacities, the minimum thickness must be 20 mm.
111/158
Manuale installatore
8.5 Fitting the outrigger cylinders on the crane and any vertical extensions
envisaged
Read the use and maintenance manual of the crane where you will find the
instructions on the correct hydraulic handling of the outrigger jacks.
112/158
Fitter’s manual
We remind you that the jack must be lled with hydraulic oil, after completing any hydraulic
connection jobs on the outrigger jack.
Start the crane and operate the levers of the distributor corresponding to the jacks of the
outriggers and raise and lower the stem a few times at minimum speed.
Key:
113/158
Manuale installatore
For some crane models, the plates on which the outriggers rest are secured with exible plugs,
while other models are delivered with two extensions.
These are to be welded to the stem of the foot jack after having decided the length necessary
(based on the height of the truck chassis).
It is a good rule to make an extension that enables the crane to work without the outrigger jack
having to reach its end-of-hydraulic-stroke position.
We remind you that is absolutely forbidden to apply extensions on the stems of the outrigger
feet that are longer than that envisaged and delivered, unless the manufacturer authorises
you to do so in advance.
The structural calculation of the outrigger jack has a ratio between lining length and stem length; if
this ratio is not respected, the jack could break and the truck could consequently tip.
114/158
Fitter’s manual
Position the plate on the ground, in line with the stem of the
jack, position the previously sized extension on the plate and
slowly slide out the jack stem until it rests hydraulically on the
extension and on the plate.
Weld some points in the two joins then position the cylinder
and weld.
WARNING: Before you start welding, protect the chrome-plated parts of the stem
with rubber paper or rags. Once you nished welding, protect the end that is not
chrome-plated with paint.
115/158
Manuale installatore
Before you tighten the support make sure the control station does not interfere with
parts of the crane while the crane rotates.
The attachment screws of the support must be tightened using a dynamometric spanner, in
compliance with the tightening torque indicated below.
116/158
Fitter’s manual
3- in the case of particular installations, you may have to prepare simple footboards for the operator
to stand on to be able to reach and operate the controls of the crane. These must not be
positioned higher than 600 mm , plus they must not be smaller than 350 x 350 mm.
4- The overhanging footboard structure attached to the crane or the truck must be able to
withstand a load of 120 kg at its end.
5- If you have to prepare structures to access the raised control station, the operator must be able
to use them with natural movements so that he feels completely safe.
6- The control station must not be accessed if there is the risk of colliding with the structure
or against parts of the truck itself, worse still if there is the risk of getting clothing caught
up in parts.
117/158
Manuale installatore
LADDERS
R
min max
A --- 600
B 220 300
C 300* 400
E D 150 ---
B
E 20 ---
R 300
* 150, per foot
C A D
A RAILINGS
min max
A 16 40
B B 150 ---
C 75 ---
118/158
Fitter’s manual
It is up to the tter to make the hydraulic connection of the hydraulic pump and of any additional
outriggers to the crane.
To guarantee the correct operating efciency of the crane and its just reliability, it is very important
for the tter to observe the following instructions: incorrect connections can cause the oil to
overheat, pipes to burst, vibrations in movements and so on.
All the hydraulic material used must have the same safety factor as the material on the crane:
we remind you that rigid pipes must have a safety factor of 2.5 times on bursting and 2.2
times on the non-destructive overpressure test compared to the maximum pressure value
envisaged by the hydraulic circuit of the crane.
For exible hoses that will be subjected to pressure, the minimum requested safety coefcient is
4 with regard to bursting and 2.2 times for the non-destructive overpressure test compared to
maximum pressure envisaged by the hydraulic circuit of the crane.
The exible hose that connects the oil tank to the pump is not a pressure hose: the most common
types of hoses are those made of reinforced rubber or rubber in which there is a steel coil
inside. This hose must be able to withstand a pressure of 10 without being damaged so that
it cannot deform under the oil drawing effect of the pump.
119/158
Manuale installatore
If necessary, rigid pipes are to be bent using special tools so that the bend is even, not
squashed in certain points and with bending radius that is at least three times the outer
diameter of the pipe. In the case of doubt, the tter shall request further information from
the material supplier.
Flexible hoses shall not be installed too tight. We remind you that a exible hose tends to pull
straight when subjected to pressure and shortens and increases in diameter: this must be
possible without the hose interfering with edges or any other elements present.
All exible hoses that are less than one meter from the operator and subjected to pressure values
above 50 shall be protected with a sturdy sheath or with metal guards, as imposed by operator
health & safety standards with regard to bursting.
Flexible hoses are to be secured without damaging them at least every 1000- 1200 mm.
120/158
Fitter’s manual
Before you install the hydraulic components needed to complete the hydraulic connection of the
crane, clean them internally using compressed air. Do not let the open ends of the piping
rest on the ground, nor any other parts used to make hydraulic connections, in order to stop
any impurities that certainly settle on the material from
penetrating the hydraulic circuit of the crane if they are
not cleaned properly.
The exible hosing that connects the oil tank to the pump is
called the “oil in-take hose”.
Attention: The maximum pressure in the hosing is
0.3-0.5 bar.
Apply the gate and relative unions on the in-take hole
in the tank. To apply the unions on the oil in-take
hole correctly you need to add a hydraulic sealant
and tighten them with little force.
IT IS USELESS AND HARMFUL TO tighten with force;
this could damage the structure of the tank with
consequent oil leaks.
It is important to secure the in-take hosing to the
structure at roughly 500 mm from the oil tank so that
any vibrations of the pump are eliminated, which
would be dangerous for the hydraulic seal of the
oil tank.
The minimum characteristics of this hosing are given in the previous chapter. You need to dene
the minimum diameter to be used to ensure the ow of oil in the quantity requested by the
pump, especially during the initial work phases at low temperatures. Oil does indeed reduce in
viscosity as the temperature drops (index that measures uidity).
All manufacturers of hydraulic pumps recommend the application of oil in-take hosing with
rather abundant internal openings.
For this purpose, we are providing a table that most pump manufacturers distribute, which
indicates the minimum inside diameter to be used in relation to the real oil ow rate that the
pump will send to the crane when it is working.
121/158
Manuale installatore
This table applies for hoses that are not longer than 2 meters and that are particularly twisted.
For other hoses, you must guarantee a minimum oil velocity of:
Here’s a diagram related to the oil velocity inside the in-take hosing.
0,4
150 Line b
3"
0,5
70
21⁄2" 60
100 Line a
2" 50
90
80 40
70
11⁄2" 1
11⁄4" 30
60
1" 25
50 1,5
40 20
3⁄4"
2
30 15
2,5
Quantity of oil sent 1⁄2" 3
Oil velocity
from oil tank to
pump Inside diameter of
hoses
The diagram shows that an opening with cross section equal to 1 1⁄4” (line a) is needed for
an oil ow rate of 50 I/min.
In this way the oil velocity obtained is approximately 0.8 m/s.
Obviously, because the oil velocity has to be between a maximum value and a minimum
value, if the hosing is longer than 2 meters, the cross section of the hose must be as near
as possible to the minimum value. The same diagram shows the case in which the cross
section is 1 1/2” (line b).
Note: the hydraulic connection on the oil tank for the in-take hose may be smaller
in diameter than the diameter of the hose to be installed.
This fact does not compromise the perfect completion of the system, because it is in any event a
localised restriction. The correct sizing of the in-take hosing is important to avoid load losses
that could be encountered along the oil’s path inside the hose.
122/158
Fitter’s manual
The exible hosing that connects the hydraulic system of the crane - in the specic case or the
control distributor or the delivery lter if present - to the pump is called the “oil delivery hosing”.
The previous chapter gives the minimum characteristics of this hosing. You need to dene the
minimum diameter to be used to guarantee the ow of oil in the quantity requested by the crane
without encountering excessive and harmful overheating of the hydraulic oil.
When a certain amount of oil passes inside a hose, the oil gets faster the smaller the cross
section in which it ows: the oil delivery hosing must have an inside cross section such to
obtain a velocity of the oil between the values given below:
V= 5-7m/s (meters/second)
Here’s a diagram of the velocity of the oil inside the oil delivery hose. The diagram shows
that an oil ow rate of 50 I/min requires a cross section opening of 1/2 “. In this way the
oil velocity is approximately 6 m/s.
100 2" 50
90
80 40
70
11⁄2" 1
11⁄4" 30
60
1" 25
50 1,5
40 20
3⁄4"
2
30 15
2,5
1⁄2" 3
20
10
9
8
4
15
7 5
1⁄4" 6 6
10 5 7
4
8
Oil velocity
Inside diameter of
5 hoses
4
123/158
Manuale installatore
From our experience on this subject we are providing a table split-up per size of crane:
If observed correctly, there will be no anomalies in the operation of the additional outriggers.
NB: It is not advisable to use hoses with diameter smaller than 12 mm even for
smaller cranes, to avoid load losses inside the hoses which, for example, could
cause a rather reduced operating speed of the additional outriggers.
124/158
Fitter’s manual
The hydraulic oil in the system of the crane is the means with
which the power is transmitted from the hydraulic pump to
the various driving cylinders of the crane booms. Together
with this function, the hydraulic oil must also be a perfect
lubricant, must protect the various components from rust
and must be a perfect coolant: the power output by the
hydraulic pump emits heat and this must be dissipated
again by the oil itself.
125/158
Manuale installatore
For the correct choice of oil you need to bear in mind the parameters that follow, which identify
the constructional characteristics of the oil itself:
1) viscosity: choose an oil with viscosity value suitable for use both during the initial minutes
of work, when the environmental temperature prevails and after a few hours of work, when
the temperature reached by the oil prevails. The viscosity index of the hydraulic oil is
measured in mm2/s, or in cSt.
2) temperature: we have already said that the viscosity index of the oil changes as the temperature
varies: when choosing the right type of oil you must bear well in mind the minimum temperature
- ambient temperature - at which the hydraulic oil will work.
Here’s a diagram that shows the viscosity trend of some hydraulic oils based on the working
temperature.
We point out that the recommended values are obtained between 12 and 100 cSt.
In extreme cases, you can use a range of between 10 and 12 cSt.
The diagram shows that an oil classied as ISO VG15 is suitable to work at initial working
temperatures of below 0° C, up to full working temperatures of 45 °C, max. 52 °C.
An oil classied as ISO VG68 is suitable to work at initial working temperatures of 32° C, up to a
maximum working temperature of 85 °C.
Once you have chosen the type of oil to be used you can ll the oil tank.
126/158
Fitter’s manual
To ll the tank correctly, you need to follow the recommendations listed below:
1. The correct level of the hydraulic oil is to be checked with the crane completely folded
down in stand-by.
2. Operators must avoid extended contact of the skin with the uid and must immediately clean
and rinse any parts of the body or clothing that come into contact with it.
3. All equipment used to ll the tank (hoses, barrels, funnels, lters etc.) must be cleaned
thoroughly and pickled before use.
4. If you are unable to get hold of pre-ltered oil or generally speaking to be absolutely certain that
the oil to be put in the tank is clean, you can lter it yourselves before pouring it into the tank by
feeding it through a mobile and appropriately sized uxing station.
5. Fill the tank and top-up again, through the lling cap with built-in metal mesh lter.
6. Check the minimum level and maximum level indicators on the tank with regard to the
quantity of oil poured in the tank.
Max
Min
Note: It is absolutely forbidden to use recycled spent oil in the hydraulic system.
Spent oil (old oil) is not to be thrown away just anywhere but is to be collected and
handed over to someone authorised to collect and dispose of spent oil in order to
a avoid polluting the environment.
Note: Many believe that hydraulic oil cannot be compressed. This is wrong,
because hydraulic oil reduces in volume as the pressure increases and increases
in volume as the temperature rises.
This explains why the stems of the crane booms retract by a few millimetres when a load is
lifted on the lifting hook and also the difculties encountered in connecting the quick-release
couplings of a hydraulic device after it has been left in the sun.
127/158
Manuale installatore
10 ELECTRICAL CONNECTIONS
Cranes are equipped with electrically-operated devices, which may be either accessories (heat
exchangers, radio controller etc.) or built-in parts of the crane (load restrictor, sensors,
pressure transducers etc.).
To operate these devices, the fitter must connect them to the vehicle when installing the
crane on the truck.
These connections are to be done by qualied experts who are able to carry the job out according
to the tting instructions provided by the manufacturer of the vehicle itself.
The electrical voltage required to operate the electrical devices of a standard crane is 24
Volt dc.
On request, the crane can also be rigged out to operate at 12 Volt, dc.
Here are the voltage tolerances admitted for the correct operation of the electrical system:
If the voltage is lower than the values given above, some electrical components will
not work and consequently the crane will not work either.
If the voltage is higher than the values given above, the electrical components will
overheat and possibly become defective, plus the crane will stop.
128/158
Fitter’s manual
The connection cables to the battery on the crane are normally long
enough to make the connections.
If this is not the case, you need to install an electrical box; it must
be installed and attached solidly to the structure of the crane or
the truck and must have cable feeders for electrical cables at the
bottom to prevent water inltrations.
We are providing the instructions related to the minimum cross sections of the electrical cables
to be used if the existent cables are not long enough.
The cross section of the cable depends on the cross section of the copper
winding.
You are advised to install cables approved for “mobile laying”.
For extensions up to 10-12 meters = increase the cross section of the cable by 0.5 mm.
It is advisable to use boxes built with material that is resistant to solvents and the ozone and
that have a good degree of resistance to water inltrations: the recommended waterproong
rating is at least IP 55.
The various poles are indicated at the ends of the electrical cables on the crane: these must be
strictly observed because you could damage the electrical/electronic components installed
if the poles are inverted.
129/158
Manuale installatore
On the electrical system of the crane there is always a safety fuse for each positive wire that
is to be connected to the batteries.
Individual
Ampere
Table with values of the ampere ratings of the fuses envisaged by the
ampere
ratings
ratings
manufacturer of the crane to protect the electrical system.
Total
1- Standard crane, EC, without radio control and without load restrictor
2- Electro-hydraulic load restrictor 15 A --
3- Electronic load restrictor
4- Radio controller
5- Heat exchanger 20 A --
Fuse
Relay Voltage picked-up
for crane
87A 87
Fuse 86 85
Electrical system 30
of truck
Connection of
negative
cable for crane
130/158
Fitter’s manual
The cables must be connected directly to the terminals of the batteries only is there is no
battery disconnector on the truck (device that isolates the major input part of the electrical
system of the truck from the batteries).
If the truck has a battery disconnector, you must observe the diagram given below: different
congurations could lead to putting the whole ampere rating requested by the engine of the truck
through the electrical system of the crane with consequent and irreparable damages.
It is absolutely forbidden to install devices built to be powered at 12 Volt on trucks with 24 Volt,
connecting them to just one battery: such battery would deteriorate very quickly.
Attention: if you need to weld the crane structure, the truck board, the counter-
chassis or the truck you must disconnect the electrical system from the batteries.
131/158 131/158
Manuale installatore
11 ADDITIONAL OUTRIGGERS
The tipping torque reaches its maximum value by the rotation column of the crane and a part
of this force reaches the additional outriggers via the structure of the truck chassis and the
counter-chassis. This is why, when the additional outriggers are installed, the counter-chassis
must be long enough to end by the same outriggers and must be built so that it neutralises the
twisting effect created by the rotation axle of the crane as far as possible.
Since the counter-chassis consists of a structure that is always more sturdy than the
original chassis of the truck, the additional outriggers must always be solidly joined to
the counter-chassis.
An instruction manual is supplied with the additional outriggers that provides useful information
on how to install them: everything written in this chapter does not mean that you do not need
to read and observe all the instructions given in such manual.
1- inserted in the especially built counter-chassis: in this case, they are connected to the same
by welding and reinforcement brackets.
132/158
Fitter’s manual
2- inserted under the truck chassis: in this case they are still to be connected to the truck
chassis by special plates and brackets.
If an additional outrigger is installed under the truck chassis, you must be careful not to squash
the original chassis of the truck: this squashing is partly contrasted by the very large plate that
is applied externally to join the outrigger to the counter-chassis and must partly be contrasted
by internally applying anti-squashing bumpers in the truck chassis, just like what is done in the
crane bracketing zone and indicated in chapter 5.
133/158
Manuale installatore
When rear outriggers are installed, you need to make sure a free space is left between the
back part of the outrigger jack and the ground - height h - in order to create an angle -
angle α -, denominated outlet angle, which enables the truck to drive over rough ground
without interfering with the ground.
α h
Most additional outriggers are adjustable and enable the adjustment in height of the outrigger
jack.
From a functional point of view, these should be as near as possible to the wheel, because the
rear part of the truck is always quite exible and would reduce the stabilising effect of the
outriggers, plus in this way the alpha angle is greater.
α α
134/158
Fitter’s manual
Note: Additional and more detailed instructions are given in the manual supplied
by the manufacturer of the additional outriggers.
Note: If you do not have a dynamometric spanner, you can block the outrigger jack
in the desired position by following the instructions that follow:
b) make three welding sections, at equal distances apart and 15 mm in length approximately,
between the bottom part of the ring that blocks the outrigger jack and the actual outrigger; this
welding, which must be approximately 6x6 mm, is to be done after removing the paint from the
surfaces of the outrigger jack and the surface treatment from the blocking ring.
135/158
Manuale installatore
It is important to inform the user on the importance of respecting the position of the quick-release
couplings to avoid damages that are obviously not covered by guarantee.
When the jib is not used, it must be positioned on at ground with the shank completely folded
down; it is also advisable to protect it against direct sunlight, which would heat the oil inside
the cylinders, consequently increasing the oil volume and making it very difcult to insert
the quick-release couplings.
It is important to inform the user on the instructions given above. Often when
the user has difculty in inserting the quick-release couplings, he depressurises
them by knocking them with sharp tools on their ends. This would obviously
lead to oil leaks from the couplings and even more obviously these will not be
replaced under guarantee!!!!!
136/158
Fitter’s manual
In hydraulic jibs combined with cranes with electro-hydraulic load restrictor, to be able to connect
and disconnect the quick-release couplings without difculty, you need to strictly observe a
certain procedure, otherwise the job will be almost impossible.
Assembly:
- the jib is to be on the ground at a suitable distance from
the axle of the crane. Bring the last extension up to
the shank so that they are on the same level.
- Close the jib using the jib control lever.
- Disengage the hydraulic pump.
- Insert the quick-release coupling marked with one
red clip.
- Using the jib movement control lever, open/close
the jib.
- Insert the other quick-release couplings.
- Engage the hydraulic pump.
- Move the shank of the jib to position it so that the axle
of the tubular part of the crane is aligned with that
of the actual shank.
- Extend the extension of the base crane to match-up
the securing holes of the extension with the shank.
Insert the pins (pin) and block them in place.
137/158
Manuale installatore
Disassembly:
138/158
Fitter’s manual
12.3 Winch
Winches tted on EC approved cranes have an electronic load restrictor: The load restrictor is
not calibrated by the manufacturer because it has to be done with practical lifting tests. The
tter must carry out the electronic calibration and must carry out load tests. All the information
on how to calibrate the load restrictor correctly is given in the service-manual, which you can
consult on the internet site: www.effer.it.
139/158
Manuale installatore
The crane may be equipped with a radio controller to use the crane remotely.
When the crane leaves the manufacturer’s factory, the radio controller is already calibrated in-
house: we remind you that some settings, especially those related to slower operating speeds,
can be customised following specic request on behalf of the customer/user.
Information on how to customise the unit are given in the service manual, which you can consult
on the internet site of the manufacturer.
It is however up to the tter to install the battery charger inside the truck cab: this charger shall be
secured properly and shall only be electrically powered when the truck is running: it is a serious
mistake to leave the battery charger powered even when the truck is not in use.
140/158
Fitter’s manual
Once the crane has been installed, you must therefore carry out an initial running-in phase
that envisages the execution of at least 10 complete manoeuvres of all the movements
possible without any load applied.
Upon completion of this initial phase, a load is to be put on the end of the crane, which must be
roughly 50% of the maximum lifting capacity right at the end of the crane, performing at least
15 complete manoeuvres of all the movements possible.
After running-in, the joints of the crane are ready and the bushes of the extensions have adapted
to the running surfaces and therefore the crane will work perfectly. You need to grease the
crane if the joints scrape or the hydraulic extensions are without grease.
141/158
Manuale installatore
14 STABILITY TEST
In European countries, stability tests are regulated by standard EN 12999/2005, which replaces
standard DIN 15019.
To declare the installation suitable for work, you MUST carry out a stability test before declaring it
suitable for use; we advise you to follow the instructions that follow also for countries in which
the above-mentioned standards are not obligatory.
The standard imposes the execution of at least one test with lower load P applied on the
crane boom when fully extended and with greater load P applied on the crane boom
when fully extended.
In the case of cranes equipped with additional hydraulic y-jib, the tests are obviously intended
as carried out in the base crane configuration and crane configuration with additional
y-jib tted.
6.2.5.4 The stability test must be carried out in compliance with the less favourable
boom/extension conguration within the entire rotation sector. If, you have had to
reduce the value of the rated load in a part of the rotation sector, in such parts the test
load must be determined accordingly. The restrictors and indicators can be temporarily
disabled while the test is carried out.
Load P is the load indicated in the load charts, plus 20%, to which you need to add a load
value of 0.2 A, where A is the weight of the horizontal booms of the crane, which is found
in the technical documents of the crane, applied in the extreme point (on the crane hook).
Whatever the case, the increased load applied must not be lower than 25% of the rated
load given in the table.
Note: the weight of the horizontal booms of the crane is also called “Driven
part” and is indicated in the technical data of the crane where the weights and
centres of gravity are given.
6.2.5.5 Stability test approval criteria
The test is considered to be passed successfully if the test load is held in the static position
without any sign of tipping.
142/158
Fitter’s manual
The stability test consists in making the rotation movement at minimum operating speed
without the truck tipping.
NB: the pressure will obviously rise in the hydraulic cylinders that bear the load.
This may lead to the automatic opening of some blocking valves, with consequent closure
of the cylinder and the load lowering to the ground. To overcome this problem, tighten
the register of the blocking valves on the cylinder that opens, by retracting the stem of the
jack and remembering to turn the adjustment screw back to its initial position at the end
of the test and to apply new lead seals on the registers.
NB: a load heavier than the maximum weight indicated in the load charts is put on
the crane hook; it is therefore quite normal for the load restrictor to trip.
The operating area of the crane must be fenced off throughout the stability tests so that
other vehicles or persons cannot approach it.
The operator must stand in a safe position and must constantly keep his eye on the
stability of the truck.
143/158
Manuale installatore
We are providing a practical interpretation related to the concept of stability with obvious
reference to the contents of standard EN 12999/2005, illustrating the various cases:
Tip
p
Tipping axis
is
ing
g ax
axis
x
in
is
Tipp
Tipping axis
Tipping axis
Tipping axis
The most critical theoretic position in terms of the stability of the truck is that when the boom of
the crane is perpendicular to the tipping axis.
In practice, the torsional deformation of the truck moves the most critical position
by roughly 20-30° compared to the theoretic point, towards the zone with minor
stabilisation amplitude.
144/158
Fitter’s manual
B B
145/158
Manuale installatore
B B
146/158
Fitter’s manual
B B
147/158
Manuale installatore
C
The test is considered to be passed succes-
sfully if during these tests the truck shows
no sign of tipping (the truck with the weight
applied on the hook raised off the ground by
20-30 cm must remain in the static position;
the weight applied must not touch the ground).
If this is not the case, the crane needs to
be calibrated in order to limit the lifting perfor-
mance.
The After Sales ofce can provide you with the
instructions needed based on the specific
model of crane.
148/158
Fitter’s manual
We remind you that a feasible load restrictor may trip, especially if you make sudden movements.
During the tests you can disable the load restrictor; the After Sales ofce is at your disposal if
you should have difculties in disabling the load restrictor during the dynamic test.
To check the lowering speed (due to giving), the maximum rated load must be
applied on the maximum hydraulic boom extension (in other words without the
manual extensions).
The information given in this chapter does not exempt the tter from observing and
respecting all the provisions of standard EN 12999.
149/158
Manuale installatore
15 CRANE CONVERSIONS
A customer/user may request a conversion for a crane that he already owns or you may request
a conversion for a new crane that you have in your factory.
You need to forward us the serial number of the crane to order the conversion
kit.
By conversion we mean:
- modication of the number of extensions
- application of a winch
- application of a radio controller
- application of an additional hydraulic y-jib
- application of manual mechanical extensions
This conversion kit includes the instructions and is always dened by our engineering department
that customises it based on the real composition of the crane involved.
Together with the material, you are supplied with the following documents:
Note: In both cases, together with the above-mentioned documents, the dates in
which the material required to convert the crane are also indicated. The documents
indicate the number of the original production order and the number related to
the work order of the crane conversion for which we are requested. Note: this
type of documentation is also issued for manual mechanical extensions that do
not have EC marking.
150/158
Fitter’s manual
Responsibilities
The workshop that converts a crane is responsible for all the work done: the After Sales
ofce of the manufacturer is at your disposal for any further technical explanations possibly
needed.
The workshop shall carry the job out to perfection, possibly
consulting the documents available on the internet site:
www.effer.it
There are no justications for any work carried out incorrectly
if the instructions supplied by the manufacturer are not
observed.
151/158
Manuale installatore
Work related to the installation of a crane on a truck ends with the consignment to the
end customer.
To be correct, we are summarising the operating phases that precede the consignment of
the crane to the customer/user:
• the crane has been installed and all the safety devices have been tried out and tested
both when empty and when loaded;
• the level of oil in the tank has been checked;
• all the pins and the extensions are perfectly greased and the load charts of the crane
are tted on the dedicated supports;
• the truck board is equipped with any accessories supplied with the crane and not
installed;
The above information obviously concerns the specic crane: it is however up to the tter
to certicate the crane installation also with regard to driving aspects of the truck on the
road, in compliance with standards currently in force in the country in which the truck is
driven on the road.
When the crane is consigned it must be complete with all the documents involved, which also
strictly involves the consignment of the operator manual, the spare parts catalogue and the
guarantee certicate. We remind you that the vendor shall full all guarantee requests possibly
made by the end customer: the vendor will then forward them to whoever sold the crane to
him through to the manufacturer of the product.
We point out that a clause of the crane manufacturer concerning the acceptance of any requests
made under guarantee is that the guarantee certicate, duly lled-in in all parts is received
beforehand: no request under guarantee will be taken into consideration if the guarantee
certicate has not been lled-in and returned.
The consignment of the crane envisages a training phase for the customer/user, as imposed by
international health & safety standards.
Training is considered to be sufcient when the user is informed on how the crane works, which
can be summarised in the following points:
- use and positioning of outriggers
- manoeuvring the crane without a load
- manoeuvring the crane with a load
- explanation of the load restrictor (if present)
with practical demonstration of how it
works
- installation and use of all the accessories
present, both when empty and when loaded
- illustration of the contents of the operator
manual with special attention towards the chapter related to the risks involved in using
the crane and towards the chapter related to crane maintenance.
152/158
Fitter’s manual
Everything written up to here does not represent an operating obstacle for one of our
importers/dealers who installs the crane at his own workshop.
We would like to point out the responsibilities assumed when the crane is
installed by another workshop or when the crane is sold off the ground,
in other words not installed on the truck.
It is obviously up to whoever purchases the crane from the manufacturer
to provide his customer with all the technical documents needed to be
able to install the crane perfectly.
The technical folder shall be written and kept by the workshop that
installs the crane.
It is always advisable to make sure the customer is satised; for this
purpose we are providing a list of what we consider to be:
1 MAKE SURE THE INSTALLATION HAS BEEN COMPLETED FOLLOWING THE TECHNICAL
INSTRUCTIONS RECEIVED; IF NECESSARY GIVE A COPY OF THESE INSTRUCTIONS
TO THE FITTER WHO WILL INSTALL THE CRANE.
For your own interest: you are safeguarded towards the customer and the end tter
concerning the correct installation of the crane.
For your customer’s interest: he has the certainty of having
purchased an efcient machine because it has been installed to
perfection.
2 BE THERE WHEN THE CRANE IS CONSIGNED AND SHOW THE CUSTOMER THAT THE
CRANE DELIVERED MATCHES THE ORDER SIGNED.
For your own interest: together with the satisfaction of personally
presenting the outcome of your hard work, you can also clear up
any possible misunderstandings (often encountered) concerning who
should/should have supplied what.
For your customer’s interest: he is able to make sure you have
done everything requested straight away, consequently eliminating
any future claims.
153/158
Manuale installatore
3 MAKE SURE THE LOAD TESTS IMPOSED BY CURRENT LAWS HAVE BEEN CARRIED
OUT BY THE WORKSHOP THAT COMPLETED THE INSTALLATION AND EXPLAIN THEIR
RESULTS TO THE CUSTOMER.
For your own interest: you will be certain that the crane
supplied and fitted is installed safely and in compliance
with current laws.
4 MAKE SURE THE OPERATOR HAS BEEN TRAINED TO PRACTICALLY USE THE CRANE
BY THE WORKSHOP.
For your own interest: you will be certain that the operator is fully
aware of the machine that he will use every day.
154/158
Fitter’s manual
8 IF THE OPERATOR IS NOT PRESENT WHEN THE CRANE IS CONSIGNED, YOU MUST
MAKE SURE THAT THE CRANE IS NOT USED UNTIL ALL THE POINTS ABOVE HAVE
BEEN SATISFIED.
For your own interest: you will be certain that the operator only starts to use the machine
after becoming familiar with it and after having fully understood its conditions of use.
For your customer’s interest: it enables him to work in total safety right from the start,
saving mistakes or accidents that could become quite costly.
155/158
Manuale installatore
9 IF YOU HAVE SOLD THE CRANE WITHOUT INSTALLING IT YOU ARE STILL RESPON-
SIBLE FOR MAKING SURE THAT THE PREVIOUS POINTS ARE FULLY SATISFIED
ALL THE SAME
For your own interest: you will be certain that the operator starts to
use a machine that has been installed perfectly and after receiving
the instructions involved.
For your customer’s interest: he will know that he has purchased the
BEST and that he can rely on your help at any time.
156/158
Fitter’s manual
157/158
Sol. Ge. S.p.A. - Via Bonazzi, 12/14 – 40013 Castel Maggiore (BO) – Italy - tel. +39 051 4181211- fax +39 051 701492
C.F. / P..I.V.A / Reg. I. di TN 01943080224 - C.C.I.A.A. Trento 189370 - web: www.effer.it - e-mail: info@effer.it
Società soggetta a direzione e controllo da parte di CTE S.p.A.
MI00007GB_0-270406
TECHNICAL OPERATIONS
A2
THE POWER OF PERFORMANCE
Technical operations A2
It is only by applying the appropriate torque setting to the screws that you can obtain a perfect and reliable
coupling between two structural elements.
Screw
Screw material
diameter
Class 8.8 Class 10.9 Class 12.9
Metric
(8G) (10k) (12k)
thread
Nm Nm Nm
M5 6 8 9
M6 9 14 16
M8 23 34 38
M10 45 67 78
M 12 78 117 135
M 14 126 184 216
M 16 193 279 333
M 18 270 387 459
M 20 387 558 648
M 22 522 747 873
M 24 666 954 1116
M 27 990 1395 1665
M 30 1350 1890 2250
10 Nm ~ 1Kgm
The screws that can be removed, may have a superficial corrosion which is more or less marked, according to the
environment where the crane worked and how long the crane has been working.
To ensure the implementation of the right torque setting, the screw must be free from corrosion, and a grease
suitable for tightening like MOLYKOTE 1000, must be applied with a dynamometric key.
It is possible to REUSE THE SCREWS that connect “important” structural elements only if the surface of
screws is visually not corroded.
THE POWER OF PERFORMANCE
Technical operations A2
It is possible to remove any slight superficial corrosion, through the
use of a metal brush, manually.
THE POWER OF PERFORMANCE
Technical operations A2
2 - Crane slewing transversal clearance
Introduction
The slewing system in cranes, is a mechanical system, built according to the model of cranes, using a reduc-
tion gear/slewing ring or a pinion/rack system.
Below please find some useful information to determine the extent of the mechanical clearance and some techni-
cal solutions to be applied if an excessive clearance is found and you want to reduce it.
The presence of an excessive clearance on the slewing mechanical system implies that the crane end, especially
in horizontal configuration of booms, when the slewing manoeuvre is suddenly stopped, does not stop in a single
point, but bounces. This may result in an undesired displacement of the hook fitted to the crane end, for load at-
taching.
Please note that, as with all the mechanical couplings, in case of a crane slewing, you cannot have a “zero” clear-
ance, that is a small rebound of the hook is unavoidable.
Obviously broader is the rebound, the more the operator finds it difficult to carry out accurate slewing manoeuvres:
In the chapters below please find a description of the necessary steps to determine the extent of the mechanical
clearance on the crane, and how – in some cases – you can reduce this mechanical clearance.
Fig.1
THE POWER OF PERFORMANCE
Technical operations A2
The truck engine must be turned off, then the crane must not be operational: the crane end must be pushed to a
slewing direction and with the crane in this position, draw a line of the displacement of the slewing ring.
Repeat the moving operation end of the crane to the other slewing direction, as shown in fig. 2 and fig. 3.
Fig.2 Fig.3
N.B.: Manual action of one or two operators is usually sufficient to slew the crane in order to bring the
mechanical clearance on a crane pinion/rack unit to zero.
If we denote the misalignment found in one direction by “a”, and misalignment found in the other direction by “b”,
we will have that the mechanical clearance “G” is the sum of the two:
G=a+b
N.B: The value “G” measured must be communicated to EFFER after-sale service: In accordance with the
crane model and to the pinion diameter, you will be notified if this clearance is standard or excessive.
THE POWER OF PERFORMANCE
Technical operations A2
a’) Adjusting pinion-rack clearance
Almost all models of cranes currently in production are equipped with a slewing clearance adjusting system.
1 slewing screw is fitted to the lower part of the base as indicated in fig. 1.
The screw acts on a bronze bearing called rack-pressing bronze bearing, whose function is to create a sliding sur-
face for the rack: By changing the position of the rack-pressing bronze bearing through adjusting screw you can
adjust mechanical clearance between the pinion and the rack.
Fig.1
Examples of adjusting screw positioning
Fig. 2
Bronzina premicremagliera
Rack-pressing bronze bearing
ViteAdjusting
di regolazione
screw
THE POWER OF PERFORMANCE
Technical operations A2
Please find below the steps to be followed to adjust the slewing mechanical clearance:
1. Place the crane booms in the middle of slewing angle
2. Remove locking applied to the adjusting screw (ref.1)
3. Tighten the adjusting screw, by exerting a slight pressure on the key: approximately 10Kgm
4. Loosen the adjusting screw by 1/4 of turn
5. Tighten again the adjusting screw by 1/8 of turn
6. Lock the adjusting screw in this position, by fitting the lock previously removed.
N.B: Check the crane operation and remember to grease all the mechanical slewing system thoroughly.
THE POWER OF PERFORMANCE
Technical operations A2
b) Determining the extent of the mechanical clearance on
cranes with slewing through gearmotor/slewing ring
To determine the extent of the mechanical clearance on a crane gearmotor/slewing ring unit, place the crane,
reclining on truck, in horizontal configuration of booms, and remove the pulled-out hydraulic extensions, placing
the extreme tip of the crane at about 1.5 metres in height from the ground.
Clean an area of the slewing ring that is easily accessible for visual inspection, place two strips of adhesive tape (if
possible, paper) one on the slewing ring and therefore with the column, and other one on the crane base. Mark
with a pen a line of reference “n” on both stickers applied checking that there is a perfect alignment between the
two lines, as shown in fig.1. and fig. 2.
Fig.1 Fig.2
The truck engine must be turned off, then the crane must not be operational: the crane end shall be pushed to a
slewing direction and with the crane in this position, draw a line of the displacement of the slewing ring.
Repeat the moving operation of the crane end to the other slewing direction, as shown in fig. 3 and fig. 4.
NOTE: Manual action of one or two operators is usually sufficient to slew the crane in order to bring the
mechanical clearance on the gearmotor/slewing ring unit to zero.
Fig.3 Fig.4
THE POWER OF PERFORMANCE
Technical operations A2
If we denote the misalignment found in one direction by “a”, and the misalignment found in the other direction
by “b”, we will have that the mechanical clearance “G” is the sum of the two:
G=a+b
NOTE: The value “G” measured must be communicated to EFFER after-sale service: In accordance with the
crane model and to the slewing ring diameter, along with the number of mechanical reductions inside
the reduction gear, you will be notified if this clearance is standard or excessive.
10
THE POWER OF PERFORMANCE
Technical operations A2
b’) Reducing “Slewing ring clearance” with reduction gear
flanged to column
On the models of cranes equipped with a reduction gear to operate slewing fitted to the crane column using a
flange screwed (therefore a bell centering bell is not fitted). If you wish to reduce mechanical clearance in the
slewing unit, proceed as follows:
Bell centering
NOTE: If the centering bell is fitted the following setting cannot be made.
1) Unscrew the screws that fasten the reduction gear to the crane column and remove the reduction gear.
11
THE POWER OF PERFORMANCE
Technical operations A2
2) Increase the diameter of all the screw passing holes on the flange of the gearmotor by 2-3mm.
fig.2.
3) Grind the gearmotor housing on the column on semicircle facing the slewing ring with emery, and increase
the diameter by maximum 2mm.
2 mm
0 mm 0 mm
12
THE POWER OF PERFORMANCE
Technical operations A2
4) Using a polishing stone make two notches at 90°, of triangular shape, on the flange of the gearmotor.
5) Fit the gearmotor again, checking to push it toward the slewing ring according to the direction “d” and tighten
the screws respecting the correct torque setting.
In this way the slewing ring and the pinion will couple with a minimum mechanical clearance.
13
THE POWER OF PERFORMANCE
Technical operations A2
6) Place 2 retainers into the cuts previously done on the reduction gear flange and weld them only on the base
of the column (and not on the flange of the gearmotor).
NOTE: Check the crane operation and remember to grease all the mechanical slewing system thoroughly
and also check the lubricating oil level inside the reduction gear.
14
THE POWER OF PERFORMANCE
Technical operations A2
b’’) Adjusting gear motor – slewing ring clearance on cranes
mod. 275/305
The crane models 275 and 305 are equipped with a mechanical adjusting system that allows you to optimize
clearance between the slewing ring teeth and the gear motor pinion.
This adjusting system is made up of an eccentric: If you rotate it, you change the position of the reduction gear
with respect to the slewing ring.
If you wish to reduce mechanical clearance in the slewing unit, proceed as follows:
1) Remove the slewing ring guard
2) Three teeth of the slewing ring are marked, by its manufacturer, with green paint, to indicate the area of ma-
ximum ovalization of the slewing ring. During the adjustment of clearance, the three teeth should be taken with
the pinion of the gear motor, otherwise we risk damaging the slewing ring and gear motor irreparably.
NB. It is very likely that, with the use of the crane, it is difficult to identify the position of maximum ovaliza-
tion of the slewing ring. In this case run small slewing movements with the crane column, and measure
the mechanical clearance between the slewing ring teeth and the pinion of the gear motor: the area of
maximum ovalization is where mechanical clearance is smaller in the coupling specified above.
3) Loosen the three dowels “C” securing the eccentric “D”, using a 6 mm Allen wrench.
4) loosen the 7 nuts (ref. B) securing the reduction gear to crane base.
NOTE: It may be difficult to loosen details “B” and “C” and adjust the eccentric “D” as loctite was originally
applied .
15
THE POWER OF PERFORMANCE
Technical operations A2
5) The eccentric “D” has holes that are 10 mm in diameter on the outer surface: insert a tool with cylindrical tip
into one of these and turn the eccentric until a 0.1 – 0.3 mm clearance is obtained between the slewing ring
teeth and the pinion teeth.
N.B. Check the crane operation and remember to grease all the mechanical slewing system thoroughly and
also check the lubricating oil level inside the reduction gear.
16
THE POWER OF PERFORMANCE
Technical operations A2
b’’’) Adjusting gearmotor-slewing ring clearance on cranes mod.
440/470
On crane models 440/470 the gearmotor is secured to the column flange by means
of 8 screws, and the pinion is centered on a bronze bushing -see ref. A -.
It follows that the gearmotor has a fixed position, not changeable, with respect to
the slewing column.
A
The slewing column is fitted to the slewing ring by 32 screws, and between the column and the nut locking the
screw there are 8 bored rings, see ref. B-.
The holes for screw passage on the slewing column, have a diameter which is larger than those of screws, allowing
moving all column and reducing the distance between the pinion teeth and the slewing ring teeth, as pointed out
by the arrow ref. C. The new position of the column is secured by the friction originating by screwing the screws
fastening the slewing ring to the column.
17
THE POWER OF PERFORMANCE
Technical operations A2
Tightening of the screws that secure the slewing column to the slewing ring shall be obviously carried out using
a dynamometric key: please refer to chapter “torque settings” to identify the proper dynamometric key setting.
Note: before you start the clearance adjustment between gearmotor and slewing ring, it is appropriate to mea-
sure the clearance on the crane, and provide EFFER with it together with the crane serial number: our After Sales
Service will give you an indication of clearance reduction that you can obtain after you have performed the work
described above.
NOTE: Check the crane operation and remember to grease all the mechanical slewing system thoroughly
and also check the lubricating oil level inside the reduction gear.
NOTE: The above mentioned instructions refer to adjustments to be performed when assembling the crane
for the first time.
18
THE POWER OF PERFORMANCE
Technical operations A2
3 - Reducing clearances in extension cylinders
Extension cylinders of EFFER cranes, are fitted to the extension framework with different kinds of connection,
which are different for reasons of design or production.
The cylinder rods have always framework anchors with cylindrical section: this section is ideal to convey a force.
In case of cranes with several extension cylinders, they are hydraulically connected oen to the other by pipes. This
is necessary to comply with applicable regulations governing the construction of hydraulic cranes.
In particular, the hydraulic connection carried out with pipes is located between an extension cylinder rod and
the following cylinder rod, i.e. between components belonging to two different cylinders but fitted to the same
framework extension.
19
THE POWER OF PERFORMANCE
Technical operations A2
In the planning stages, pipes with different curves are designed.
The material pipes are built with, their section, that is wide to obtain quick extension movements, are elements
that make the pipe stiff.
The number of curves, the length of pipes, are designed to absorb the deformations that you have during the
work of the crane.
All this works well, and you have excellent results of reliability.
The above mentioned reliability can be easily jeopardized if you have mechanical clearance on the exten-
sion cylinder points, or if a cylinder rod has the possibility of moving, with respect to the rod of another
cylinder, more than what has been stated in the planning stage.
Corrosion, work in brackish environments, the use of accessories such as buckets or drills, are only some of the
reasons which lead to an increase in space between the structure and the connection of the extension cylinder.
20
THE POWER OF PERFORMANCE
Technical operations A2
Here are the instructions to reduce the clearance in the points referred to above:
1) Remove the cylinder complete with the extension on which you want to work
2) Clean, degrease and remove paint in the areas of the extension where the cylinder connection is located.
3) Carry out a facing weld inside the cylinder housing ***
4) Smooth the extension cylinder connection housing to adapt it to cylinder cylindrical connection while
checking to create a housing which is as more cylindrical as possible: the use of a cylindrical emery
wheel is recommended.
5) The extension cylinder, housed in the new housing, must be correctly aligned both lengthwise and
vertically with the others.
6) Grease the new housing created, in order to reduce wear.
***for data of welding to be carried out inside the cylinder rod housing, comply with the welding specifications
- INTERVENTION B – in chapter A8.
21
THE POWER OF PERFORMANCE
Technical operations A2
4 - Maximum wear point allowed for extension
bushings
- Used materials:
1) bronze SAE 430
2) resin T.S.D.
3) LAMIGAMID 510
4) ERTACETAL-C
876X
-Maximum wear point allowed for bushings: to be found on lower bushings of the basic crane first extension.
For Type 1 and 2 when they have a 3-mm thickness
For Type 3 and 4 when they have a 4-mm thickness
22
THE POWER OF PERFORMANCE
Technical operations A2
5 - Pipe fastening
Pipes shall be fastened to crane cylinders or frame by means of supports.
For cylinders with independent extensions, pipes shall be fastened according to the instructions below:
50 ÷ 60 cm 50 ÷ 60 cm
When servicing the crane, check the presence of the plastic supports.
23
THE POWER OF PERFORMANCE
Technical operations A2
The clamp fitted in the position shown in the picture, allows correct pipe movements, considering the play of the
extensions and the connected cylinders.
24
THE POWER OF PERFORMANCE
Technical operations A2
5.1 - Flex hose protective sheath
Operation steps:
2
25
THE POWER OF PERFORMANCE
Technical operations A2
Plastic sheath
Plastic sheath protects flex hoses against dangerous rubbing.
26
THE POWER OF PERFORMANCE
Technical operations A2
6 - Unintentional exit of extension cylinders
Unintentional exit that occurs when the truck engine is switched off and with the extensions turned up-
wards.
Cause: Oil leakage inside an extension cylinder.
Explanation of the event:
If a seal fitted inside an extension cylinder has been damaged, a passage in pressure between the two cylinder
chambers – one on the rod side and the other on the bottom side - will occur.
When performing the closing manoeuvre of a cylinder in the chamber on the rod side, a high pressure value is
read, if the extension return manoeuvre is not stopped immediately when the point of cylinder end-of-stroke is
reached, the pressure value can reach the valve value of the control bank that controls maximum pressure on that
specific hydraulic line: that value may exceed 300 bar according to crane model.
If the hydraulic sealing of gaskets on piston is not hermetic, the pressure passes from the chamber on the rod side
to the chamber on the bottom side: pressure will run along the chambers, until reaching the same pressure value
inside the two chambers.
The time necessary to match the pressure values into the two chambers depends on the wear state of the
seals: they may require an hour or a few minutes.
27
THE POWER OF PERFORMANCE
Technical operations A2
The same pressure value, inside the two rooms, acts however on two different areas:
According to the formula F = P x A (Force = pressure X Area), you will have that inside the same cylinder two
F F1
p = pressure (bar)
p = pressure (bar)
As the area of the bottom side is higher and �“F” is higher than “F1”��������������������������������������������������
, a higher force coming from the bottom side will
act on the piston, and the cylinder will open unintentionally.
Note: In case of the extension cylinders, they are all connected in series, that is all the rod side chambers,
and the bottom side chambers, are interconnected.
If a seal fitted inside an extension cylinder has been damaged, the cylinder will come out unintentionally
and will require a lower force to move the relating extension. This force depends on the mechanical friction
that is present between the single extensions.
This to say that when an extension cylinder comes out unintentionally, the trouble should NOT be searched
in the cylinder that has moved, but an investigation should be carried out to identify the cylinder that has
to be maintained.
- Place the crane with the extension unit horizontally and carry out 2 or 3 manoeuvres of full exit or full
retraction with the extension cylinders.
- Carry out a further closing manoeuvre with extension cylinders while keeping the control bank lever op-
erated for a few seconds: in this way you will be sure that the pressure value inside the rod side chambers will be
high.
- Wait: if the customer/user has given information about the time that passes since when the crane is folded
to when the extensions come out, this is the time that must pass before examining the crane. Otherwise, one hour
is more than enough to highlight the presence of the problem though limited .
28
THE POWER OF PERFORMANCE
Technical operations A2
- ONCE YOU HAVE ESTABLISHED THAT THERE IS A PROBLEM OF OIL LEAKAGE, PROCEED AS FOLLOWS:
u insulate the last half of extension cylinders hydraulically: if, for example extension cylinders are eight, insulate
the last four or transform the crane into a four hydraulic extension crane.
u Carry out some movements with the extensions to remove the possible presence of air that may have been
inserted in the hydraulic circuit due to the disassembly of pipes, carry out a complete closing manoeuvre of
extension cylinders and wait to see if they come out unintentionally.
- ONCE YOU HAVE IDENTIFIED THE EXTENSION CYLINDER UNIT WHERE THE CYLINDER TO BE MAINTAINED, IS
LOCATED, CONTINUE WITH THE INSULATION TEST OF ONE FURTHER CYLINDER AT A TIME: THE TEST WHOSE
RESULT IS NO LONGER THE UNINTENTIONAL EXIT OF CYLINDERS SHOWS THAT THE LAST INSULATED CYLINDER
IS THE ONE THAT HAS TO BE DISASSEMBLED AND SERVICED.
- leave only 1st, 2nd, 3rd, 4th extension cylinders connected hydraulically.
Actions to perform:
- leave only 1st, 2nd, 3rd, extension cylinders connected hydraulically.
- Perform a pressure test
- If you have a positive result, the problem is inside the 4th extension cylinder. Otherwise, leave only 1st, and
2nd extension cylinders connected hydraulically.
- Perform a pressure test until the cylinder that has a problem in the seals is identified.
Actions to perform:
- Connect only the 5th extension cylinder hydraulically.
- Perform a pressure test
- If you have the exit of extensions, the problem is in the 5th extension cylinder, otherwise if you have not the
exit of extensions the problem is not present.
- In case the latter hypothesis occurs, connect another extension cylinder hydraulically until the cylinder that
has a problem in the seals is identified.
29
THE POWER OF PERFORMANCE
Technical operations A2
4°
3°
2°
Ideal
Linea line ofdidivision
ideale of a hydraulic
suddivisione del circuito
circuit
idraulico onsfili
sugli extensions
1°
5°
6°
7°
Fig.3
30
THE POWER OF PERFORMANCE
Technical operations A2
31
THE POWER OF PERFORMANCE
Technical operations A2
u A crack on the painting near the welds, easily recognizable by rust coloured traces, shows that a break is
beginning in this area: therefore, immediate repairing is necessary!!
u After sending the necessary documentation, EFFER’s after-sales service, can give useful advice for the re-
pair.
32
THE POWER OF PERFORMANCE
Technical operations A2
8 - Structural repairs
Intervention a:
Crane structural part, to carry out some repairs and for the extension of the EFFER integral
subframe
(for ex.: Material S 690 and/or higher)
Intervention b:
Cylinders
Pins ears
Application of brackets
(for ex.: Material st 510 and/or lower)
N.B: Effer after sale dept. must be informed about the repair interventions that customers would carry out,
in order to supply with a comment concerning the better solution to be adopted.
Effer refuses any liability in case of interventions carried out without its authorization.
General notes
1- The welding interventions must be carried out in environments having a temperature higher than 10° C, and
windless.
2- the parts of structure to be welded must be:
Cleaned by grinding
Dry
3- The parts of structure to be welded must be:
Preheated at 80° - 100° C.
Intervention a:
Electrode classification: en 757/e69 4 zb - Aws a5.5 / e 11018 - m
Recommended electrodes diameters: 2,5 - 3,25 mm.
Nb: It is compulsory to carry out the electrode drying process before using,
according to the manufacturer’s instructions.
Welding current:
160 - 180 A for the wire diametre 1 mm
190 - 230 A for the wire diametre 1,2 mm
N.B: Employ lower currents only for weldings in vertical position.
(100÷130A).
33
THE POWER OF PERFORMANCE
Technical operations A2
Intervention B:
Electrode classification: iso 2560:2002/e46 a z b
Aws a5.1 / sfa 5.1:e 7018-1 h4
Recommended electrodes diameters: 2,5 - 3,25 mm.
N.b: It is compulsory to carry out the electrode drying process before using, according to
the manufacturer’s instructions.
Welding current:
160 - 180 A for the wire diametre 1 mm
190 - 230 A for the wire diametre 1,2 mm
N.B: Employ lower currents only for weldings
in vertical position (100÷130A).
34
THE POWER OF PERFORMANCE
Technical operations A2
General notes about welding procedure:
1 ) A correct welding is without marginal nicking. Some eventual marginal nicking must be removed by grinding
(if of little dimension, max. 0,3 mrn ) or removed by a further welding seam.
under cut
2) It is absolutely forbidden to cool the welded parts by some forced cold sources (water, compressed air...).
3) The minimum welding section must be similar or higher than the welded minimum, thickness.
However it must not be higher than 20% of the minimum welded thickness.
4) Welding operations.
5) It is forbidden to carry out some welding which are transversal to the line of longitudinal booms.
6) The welding operation causes some material stresses. It is very important that such stresses are removed in
blending the welding by grinding the extremity.
35
THE POWER OF PERFORMANCE
Technical operations A2
36
THE POWER OF PERFORMANCE