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SERVICE MANUAL 5

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INSTALLAZIONE GRU - INTERVENTI TECNICI


CRANE INSTALLATION AND TECHNICAL OPERATIONS
INSTALLATION GRUE ET OPERATIONES TECHNIQUES
INSTALLATION DES KRANES UND TECHNISCHE
OPERATIONEN

BMI00026GB_0-29092008
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A
INSTALLAZIONE GRU E INTERVENTI TECNICI
CRANE INSTALLATION AND TECHNICAL OPERATIONS
INSTALLATION GRUE ET OPERATIONES TECHNIQUES
INSTALLATION DES KRANES UND TECHNISCHE
OPERATIONEN

A1 - INSTALLATION INSTRUCTIONS OF CRANES ON TRUCKS


A2 - TECHNICAL OPERATIONS

B
PARTE IDRAULICA
HYDRAULIC SECTION
PARTIE HYDRAULIQUE
HYDRAULIK

C
PARTE ELETTRICA
ELECTRICAL SECTION
PARTIE ELECTRIQUE
ELEKTRIK

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INDEX A
A1 INSTALLATION INSTRUCTIONS OF CRANES ON TRUCKS
1 Presentation............................................................................................................................................................................ 4
2 Identification of installation parts.................................................................................................................................24
3 Handling instructions of parts to be installed on the truck ...............................................................................25
4 Identification of the serial number of the crane......................................................................................................29
5 Parts and installation information................................................................................................................................31
6 Installation calculations....................................................................................................................................................52
7 Constructional information for the counter-chassis..............................................................................................62
8 Fitting the components on the truck..........................................................................................................................84
9 Hydraulic connections of the crane.......................................................................................................................... 119
10 Electrical connections.................................................................................................................................................. 128
11Additional outriggers.................................................................................................................................................... 132
12 Installing and commissioning some accessories............................................................................................... 136
13 Running-in the crane................................................................................................................................................... 141
14 Stability tests................................................................................................................................................................... 142
15 Crane conversions......................................................................................................................................................... 150
16 Crane consignment...................................................................................................................................................... 152
17 Measurement conversion table............................................................................................................................... 157

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


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INDEX A


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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

2 - Identication of installation parts


2.1 Foreword

3 - Handling instructions of parts to be installed on the truck


3.1 - Instructions supplied by the manufacturer
3.2 - Storage - Disassembly - Disposal

4 - Identication of the serial number of the crane

5 - Parts and installation information


5.1 Instructions on requested oil ow rates and pressures
5.2 Sizing of the power take-off and hydraulic pump
5.2.1 Operating the crane with an alternative power unit
5.2.2 Checking the power of the host vehicle’s engine
5.3 Crane bracketing material
5.4 Counter-chassis
5.5 Truck board
5.6 Spaces required to install the crane correctly
5.7 Identifying the rotation dead centre point
5.8 Changing the rotation dead centre point

6 Installation calculations
6.1 Purpose of the calculation

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6.2 Useful information on calculating the theoretic weight test on the axles
6.3 Information on calculating the theoretic stability test

7 - Constructional information for the counter-chassis


7.1 Cross section of the counter-chassis
7.2 Assembling the counter-chassis
7.3 Built-in counter-chassis

8- Fitting the components on the truck


8.1 Fitting the hydraulic power take-off
8.2 Fitting the hydraulic pump
8.3 Fitting the counter-chassis
8.4 Securing the crane
8.5 Fitting the outrigger cylinders on the crane and any vertical extensions envisaged
8.6 Attachment/adjustments for feasible raised control station
8.7 Manoeuvring station

9 Hydraulic connections of the crane


9.1 Choosing the components
9.2 Sizing the pipes
9.3 Characteristics of the hydraulic oil

10 Electrical connections

11 Additional outriggers
11.1 Fitting “feasible” additional outriggers
11.2 Free space under the outrigger jack

12 Installing and commissioning some accessories


12.1 Additional hydraulic y-jib
12.2 Mechanical extensions
12.3 Winch
12.4 Radio controller

13 Running-in the crane

14 Stability tests
14.1 Static test
14.2 Dynamic test

15 Crane conversions

16 Crane consignment

17 Measurement conversion table

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1 - PRESENTATION
EFFER hydraulic cranes can be qualied 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 efcient “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 modications 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 modications 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 efciency 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!!

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1.2 - General warnings

1.2.1 - Safety instructions

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 specic 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.

- Do not start the truck indoors unless the


workshop has an adequate extractor and
discharge system for the lethal combustion
fumes.
- In extreme and particularly harsh working
conditions, always guarantee that there is an
extra operator at hand who is ready to act in
the case of danger or hazard.

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- 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.)

1.2.2 - Welding instructions

The installation of the crane also envisages some


welding points, in particular on the counter-chassis
when the crane is positioned on the truck.
Before you start any welding jobs, you are reminded
to protect the electronic equipment of the truck
following the instructions of the individual manu-
facturers. We remind you that the electronic
equipment of the crane, such as the electronic
load restrictor, the radio controller, the winch
pull restrictor etc. must also be protected when
welding on the counter-chassis or on the truck
board.
Proceed as follows to protect the various electronic
components from serious damages:
- strictly follow the indications given by the truck
manufacturer;
- isolate all the electrical cables of the crane, of
the batteries and any other electrical connection
points on the vehicles.

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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.

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1.2.3 - Truck information

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.

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1.2.4 Welding tips

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.

Parts involved in welding jobs must be:


• cleaned with grinder
• perfectly dry
Hypothetically speaking, the following materials will be used to construct the counter-chassis:
S 355 - Fe 510 - Fe 52 - Gr 50 - S 420 - Fe E420 /St E420 - Fe E420 /St E490

We recommend the use of the following electrode:


- AWS A5.1 / SFA 5.1: E 7018-1 H4R, recommended diameter 2.5 - 3.25 mm.

Or in the case of wire welding:


- full wire AWS A5.18 ER 70S-6 EN420G42, recommended diameter 1-1.2 mm
- gas classied EN439 type M21: ARGON (85% - 75%) + C02 (15% - 25%)
HELIUM (85% - 75%) + C02 (15% - 25%)
- quantity of gas regulated on the outlet of the cylinder: 12 I / min. indoors, 18 I / min.
outdoors.
- welding current: 160-180 A for wire diameter 1 mm.
190-230 A for wire diameter 1.2 mm.
The workshop shall be rigged-out to be able to turn the counter-chassis:
this is indispensable to perform the bottom joining welds and to avoid welding vertically.

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1.2.5 Welding notes:

1) Welding is correct when it is free from marginal


incisions.
Marginal incisions shall be eliminated by grinding (if
small, max. 0.3 mm) or by means of an additional
welding bead.

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

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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

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1.3 - Responsibilities of the tter

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

Suitable truck/vehicle, crane position: Calculate/test the weights on the axles.


Calculate the stability in advance, as
imposed by DIN 15019-EN12999

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.

Counter-chassis design: Calculate the counter-chassis section (see


standard EN 12999-CUNA NC034-05)

Choice of additional outriggers: Check suitability following the instructions


given by the manufacturer.

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.

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Practical stability tests:

Testing with rated capacities and overload


Refer to standards DIN 15019, EN12999, DIN 15018,
directive 96/37/EC. (table E)

Write the nal documents:


Certicate of suitability for work.
EC certicate for the European Community.

Consignment to user:

The tter shall provide all the instructions on


how to operate the crane correctly and must
consign all the documentation requested.

Testing and auto-certication of the tter: According


to current laws and standards (*)

On request the manufacturer supplies more


detailed instructions.

NOTE: The tter who rigs out the vehicle actually creates a new machine. He
therefore becomes the manufacturer of such machine and shall full 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
certicate of CONFORMITY. The work carried out shall be documented in the
Technical Folder.

(*): in UE-SEE countries, EC conformity to directive 96/37/EC of the whole machine/assembly


in which the hydraulic crane is tted shall be guaranteed by the tter/who ever commissions
the crane and who must issue the EC declaration subject to appendix II-A of the same
directive.

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1.3.1 - Technical folder

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 congurations (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 coefcients 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

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outriggers of the crane).


Once these stability tests have been completed, the dedicated form is to be filled-in with
the date, the signature of the operator and the stamp of the company (see chapter 14 for
further information). A copy of this document is to be enclosed with the control register
of the specic crane.
7- EC declaration of conformity of the crane and any other EC product declarations of conformity
relative to accessories installed self-sufciently by the workshop.
8- Copy of the EC declaration and of the certicate of conformity relative to the
new machine, signed by the legal representative of the company that carried
out the installation: this document is obligatory for countries belonging to
the European Community.
9- Risk analysis: if accessories complete with an EC certicate are installed on the crane (buckets,
winches, radio and remote controllers.) or in any event if the crane has been modied or
customised, the technical folder must include a copy of the instructions of the same and a
declaration stating that all the operating risks that may derive following the conversion have
been analysed and at the time of consignment are non-existent.
We advise you to include any other documents in the technical folder that may prove useful
to prove what you have done :
10- Certicate of the material related to crane bracketing tie-rods if they are not purchased
from EFFER.
11- Certicate of the material relative to the construction of the counter-chassis.
12- Copy of the certicate relative to the welding wire and the welding gas used to construct
the counter-chassis.
13- For countries belonging to the European Com-
munity: Photocopy of the EC label that you apply
relative to the marking of the new “Machine”.
An example of what is requested on this subject
is included in the “production information” docu-
ments that can be consulted on the internet site:
www.effer.it
14- Indication relative to the calculation made to
determine the power take-off and the hydraulic
pump, with copy of the technical characteristics
of the same.
15- Copy of the Delivery Documents to the customer,
which must state that the customer has been
informed on how to use the crane and that you
have given the customer a copy of the operator
manual, spare parts catalogue etc.

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1.4 Where to nd technical data

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

installation calcula- with CR19 Highline


with CR19 Topline
3.608
3.976 LH unloading 610 890
tions are those rela- with CR19 Comfortline with lowered roof and CR16 Steeline 3.168 Vertical unloading 920 1.100
Height of rear chassis edge from ground (when empty) V 1.015
tive to the dimen-
Measurements that depend on the pitch, in mm
sions and weights.
As an example, a *Practicable spaces with CR19 Comfortline and Highline

truck with pitch P


(distance between
the axles) of A =
3.900 m.

* Practicable spaces with CR19 Topline

* Practicable spaces with CR16 Steeline L

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

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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.

Truck pitch of 3.900 m. with 340.11 / 4 extensions

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.

The technical data of the crane necessary are the following:

a) dimensions, weights and centres of gravity page 18


b) Load chart page 18
c) Hydraulic diagram page 19
d) Model of additional outriggers (if any) page 20
e) Type of truck board requested and length of the same page 25

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a) Dimensions, weights and centres of gravity


You will find the dimensions, weights and centres of gravity of the crane in the technical
data sheets that follow.

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

CARATTERISTICHE TECNICHE GRU BASE

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

Caratteristiche elettriche 10090 (20°)


C=1540 C=1540
Tensione di alimentazione (std / opzionale) V 24 / 12 c.c. 3S
1700 kg
Max corrente assorbita A
Height of fastening bracket
Altezza staffa di fissaggio

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

Coordinate del baricentro della gru in posizione di mm


trasporto, della parte fissa e mossa
4210
Valori di 0,1A [DIN 15019-2] [EN12999] Vedi schede "dati per la stabilità"
16950 (20°)
DIMENSIONI
295

6S
Ingombri mm Vedi schede "dimensioni d'ingombro" 2250 kg
STAFFAGGIO
220

max 995
80

90

min 870

Numero dei tiranti fra gru e controtelaio 8


130

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

2320 1540 7377


NOTE
(2040) 5400 (2040) 249
The load chart indicates the technical 147data relative to the maximum lifting performance of the
(*1) [EN12999] Mst = (P R + Gb Xb)
(6400)
(*2) [EN12999] Mdyn = (ϕ2 P R + ϕ1 Gb Xb)

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

teorici e non considerano le flessioni 211,5


(± 2% in orizzontale).
Ext. brackets

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

kgA 3993 4193 4543 4848

le
A 1428 1907 2880 3887
62

B 52 71 100 122
E
76
62

C 1869 1967 2085 2161


354 354 D
E
219 211,5 [mm] X 734 832 978 1088

[mm]

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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

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Manuale installatore

d) Additional outriggers for the truck


After consulting the table that follows or after initially testing the stability calculations, you may
notice that the chosen crane/truck combination needs additional outriggers to guarantee
stability during operation.

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.

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Fitter’s manual

Tables of “Technical characteristics of additional outriggers”

fac
-si
mi
le

9260026

The tables indicate the various models/types


of outriggers available.
These vary based on:
- the side outlet amplitude
- the minimum distance from the axle of the
crane for which they are installed
- the type of the same, to be able to t them
under the chassis (obviously if they are
installed at the back of the truck), or to be
tted within the counter-chassis.

In our example, the model with code 9260026


is chosen, just to explain better:
outriggers with side outlet of 600 mm.

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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.

The data relative to the additional outriggers


are indispensable to be able to make the
theoretic calculations on the distribution of
the weights on the axles and the stability.

This is done to approve the correct combination


of crane/additional outriggers from a structural
point of view.

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Fitter’s manual

e) Type of truck board requested


The type of truck board is also to be considered when making the installation calculations.
The user will choose the type of truck board based on his specic requirements.

- Fixed truck board

- Fixed with sides

- 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.

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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

Pump/Power take-off Counter-chassis

Extensions Additional outriggers

Bracketing
material

Additional y-jib

Pompa /Presa di forza


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Fitter’s manual

3 - HANDLING INSTRUCTIONS OF PARTS


TO BE INSTALLED ON THE TRUCK

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.

3.1 - Instructions supplied by the manufacturer

Never underestimate risks that may derive from


the crane movements!
The centre of gravity of the crane almost never
coincides with the centre of the surface on
which it rests: the second boom is always a
side weight and the points in which the bed
rests on the ground may be an odd number
and close to each other.
Consequently all movements must be made in
full respect of the indications given by the
manufacturer.
The weight of the crane is written inside the
operator manual and is also indicated in the
product information pages on the internet
site.
When there are supports under the crane base,
i.e. wooden wedges, metal girders used for
shipment, the crane rests on a surface and
there is no risk of it tipping: the crane will
not fall.
It is on the other hand very dangerous to move
the crane using forks of a front-loading forklift
truck. In this case, the crane must be strapped
to the supports of the forks, lifting the crane as
little as possible off the ground to ensure its
stability, moving at very slow speed.

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Manuale installatore

It is always preferable to lift and handle the crane


using an overhead travelling crane.

NB: it may be handy to rest the crane on


the counter-chassis while installing it to
check the spaces available and to dene
the bracketing of the crane.

This specic type of handling must be done without


fail by applying ropes/chains in the bracket on the
top of the crane and the same must be born by
the lifting equipment until at least one tie-rod has
been tted for each bracket present.

Failing to observe this, the crane could tip.

The y-jib is equipped with supports used to rest


it on the ground without damaging it and so that it
rests solidly. The actual weight of the jib is printed
and pointed out on one side of the main boom and
the centre of gravity is indicated by an adhesive
plate with relative symbol.

Use ropes, cables or straps with greater load-bearing


capacity than the weight of the y-jib to lift the
latter. The length must be suitable so that their join
corresponds with the lifting point for the vertical
line passing through the centre of gravity. If you
use straps or ropes made of synthetic bre, they
must not be able to slip: if you use metal chains or
cables, apply them on the y-jib without damaging
the paint or other parts of the same. You are
advised to secure the end sections of the ropes,
chains or whatever other system used for lifting,
to the two ends of the y-jib, using on one end
the attachment pin of the hook or the actual lifting
hook from the pointed part in the dedicated
brackets at the end of the last extension, and on
the other end, the pin that secures the y-jib to
the base crane, if present.
kg....

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Fitter’s manual

To handle the extensions you must use ropes,


chains or straps having a greater load-bearing
capacity than the weight of the actual exten-
sions. If the single extension weighs more than
30 kg, its real weight will be punched at the
front of the same.

kg kg

The length must be suitable, so that their join,


corresponding to the lifting point, is on the
vertical line passing through the centre of
gravity, bearing in mind that the centre of gravity
is roughly halfway along the total length of the
extension. Particular attention is to be given to
the attachment of whatever lifting system used
on the extensions: whatever system used must
never be able to slip.

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.

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Manuale installatore

3.2 - Storage - dismantling - disposal

Temporary positioning or storage


Store the crane in a safe place where it cannot be damaged and where it is sheltered
from atmospheric agents. Position the crane on a flat supporting base and make sure
it rests solidly.
If it is to be stored away for a few months, you are recommended to protect the chrome-plated
parts of the stem of the cylinders, which remain exposed, plus all the other galvanised
parts with special rust-inhibitor solution. This protective method is obligatory if the crane
is stored in salty environments.

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.

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Fitter’s manual

4 - IDENTIFICATION OF THE SERIAL


NUMBER OF THE CRANE

Standard crane
The essential crane identication 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.

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Manuale installatore

Additional y-jib

The essential y-jib identication 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 identication 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.

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Fitter’s manual

5 - PARTS AND INSTALLATION


INFORMATION

5.1 - Instructions on requested oil ow rates and pressures

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.

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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

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Fitter’s manual

5.2 - Sizing of the power take-off and the hydraulic pump 800 rpm

The hydraulic pump may be the gear type or


piston type: whatever the case, you must
choose a pump that respects the maximum
pressure requested by the hydraulic system
of the crane.
Even if the use of the crane is considered to 800 rpm
be non-continuative, but intermittent, you are
recommended to ensure a reasonable tolerance
between the maximum pressure indicated by the
pump manufacturer and the maximum pressure
requested by the crane.
When operating the crane, you are recommended
to keep the truck engine running at between
700 and 900 rpm to avoid either a drop in the
rpm when the crane is manoeuvred at high
pressure or a wasteful overheating of the engine
accompanied by an excessive consumption
of fuel.
The choice of the correct type of power take-off to be installed on the gearbox of the truck is
sometimes bound to the type of gearbox itself or to its dimensions: you are in any event
recommended to install a power take-off of the “de-multiplied” type (power take-off with
transmission value less than 1) because it is easier to nd on the market and therefore more
economic compared to those called “multiplied”.
It is up to the tter to choose the right combination of power take-off, hydraulic pump and
gearbox of the truck, so that the crane receives the correct quantity of oil, as indicated in
the table given in the previous chapter.
To determine the model of pump to be installed, you must rst calculate the rpm that will be
output from the power take-off: supposing that the truck engine is regulated at 800 rpm
while the crane is in use, and having chosen a power take-off with internal transmission
ratio of 0.93 for example, the hydraulic pump will be subjected to the rpm shown in the
following calculation:
- truck engine rpm = 800
- internal transmission ratio of power take-off = 0.93
- rpm to which the pump is subjected =

800 x 0.93 = 744 rpm

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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.

PUMP LITRES - Litres/min. PUMP DISPLACEMENT - cm3 / rev.

PUMP RPM - Rpm.

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:

Q = Quantity of oil sent to crane

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 specic 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.

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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.

We are providing a table with the indicative weights


of the pump/power take-off, based on the power
of the crane expressed in tons per meter. Lifting Pump and power
(i.e. crane model 115 = 11,5 txm 115 KN.m torque take-off
crane model 370 = 37 txm 370 KN.m txm KN.m kg
crane model 850 = 85 txm 850 KN.m
0÷3 0÷30 18
3,1÷5 31÷50 18
5,1÷10 51÷100 28
10,1÷20 101÷200 35
20,1÷30 201÷300 37
30,1÷50 301÷500 37
>50,1 >501 37

NB: The weights are merely indicative

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.

Q = Oil ow rate requested to operate the crane, expressed in l/min


P = Maximum working pressure of the crane, expressed in bar
R = Uprating coefcient that bears in mind performance; value recommended by EFFER
= 0.93

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

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Manuale installatore

Example calculation of the power input by the pump


To operate a pump that must output an oil ow rate of Q=60 l/min at a pressure of P=320
bar, supposing a performance of R= 0,93, an available power Kw of more than or equal
to the following is required:

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:

HP = Kw x 1.36 = 34.4 x 1.36 = 46.78 HP

Calculation of the input torque


The torque input by the pump while the crane is in use must be lower than or equal to the
torque available on the truck gearbox and on the power take-off, which is obtained by
processing the following formulae:
M = value of the minimum torque requested by the crane
N = rpm of the pump (i.e. 700 rpm)
P = maximum working pressure of the crane expressed in bar
Q = oil ow rate sent to the crane expressed in l/min

PXQ
M= x 1.59 = daNxm
N

Example of the calculation of the input torque


To verify the previous example, the torque input by the pump indicated above must be lower than
that available on the power take-off and supplied by the manufacturer of the same and logically
also lower than the maximum admitted value of the vehicle gearbox.

320x60
M= x 1.59 = 43.6 daNxm

700

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Fitter’s manual

5.2.1 Operating the crane with an alternative power unit

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.

Kw = power requested by the motor, expressed in Kilowatt Kw


P = maximum working pressure of the crane expressed in bar
Q = oil ow rate requested to operate the crane, expressed in l/min
R = uprating coefcient that bears in mind the various performance capacities and the overload
tests to be carried out: value recommended by EFFER = 10.8

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.

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Manuale installatore

In the case of power units combined with auxiliary


diesel engines, you must make sure that such
power is supplied by the same at the operating
rpm recommended by the manufacturer (gene-
rally 1400 - 1600 rpm), making sure that the
maximum power of the engine is generally
obtained at the maximum rpm.

The sizing of the hydraulic pump must be calculated


considering the rpm at which the diesel engine will
run, paying particular attention to the maximum
rpm admitted for the pump: it is a good rule to
apply pumps that do not exceed 80% of the
value admitted by the manufacturer of the pump
during operation when they are subjected to a
maximum rpm. This is to avoid straining them,
which certainly affects their life.

In the case of electric motors, the Horse Power


obtained from the above-mentioned formula
corresponds to the rated power value - minimum
value - that the motor itself must have, since
the electric motor has a constant rpm. The rpm
of the electric motor derives from the number
of poles:

Motor with 2 poles: 3000 rpm


Motor with 4 poles: 1500 rpm *
Motor with 6 poles: 1000 rpm
Motor with 8 poles: 750 rpm

* type of motor recommended

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

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Fitter’s manual

5.2.2 Checking the power of the host vehicle’s engine

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

R = 0.93 is a multiplication coefficient related to the performance of the power take-off


and the pump.

As an example, we are providing a power test related 345 x 140


to a crane that works with a pressure of 345 bar, KW = = 86.6 KW
and that is powered by two pumps of 70 l / min.
each.
600 x 0.93

While the crane is working, supposing the truck engine runs at 900 rpm.
We are providing two power diagrams related to two diesel engines:

Diagram of an engine with maximum Diagram of an engine with maximum


power of 154 KW power of 202 KW.

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Manuale installatore

Considerations made based on the tests carried


out:

150 KW ENGINE

This engine outputs a power of 60 KW when it runs at


900 rpm (line A).
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 1250


rpm (line B), which is a rather high rpm, therefore in
this crane/truck combination it is better to request a
slightly lower power by reducing the oil ow rate to
be sent to the crane.

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.

Note: in the examples given above, we have


intentionally considered a high oil ow rate.

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.

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5.3 Crane bracketing material

The technical data of the bracketing material are


supplied by EFFER and can be consulted on
the internet site www.effer.it.

The internet site also offers tables that indicate


the codes of the kits of bracketing material
available.

EFFER may supply the kits of bracketing material


upon specic request.

The diameter of the bracketing tie-rods of the crane


must be equal to that indicated in the drawings and documents issued by EFFER.

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

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Manuale installatore

We are providing the type of material advised if you


build your own crane bracketing tie-rods:
- 39NiCrMo3 hardened and tempered UNI 7845-78/
EN10083-1
- 42NiCrMo4 hardened and tempered UNI 7845-78/
EN10083-1
- AISI 9840
- 39CrNiMo4 -DIN 17200

If the crane bracketing tie-rod is used just to join


the crane and counter-chassis, which requires the
use of another tie-rod or another system to anchor
the counter-chassis to the chassis of the truck,
the tie-rod must have a minimum free length L
equal to at least ve (5) times the diameter of
the tie-rod.

Only in this case can you exploit the exibility of


the tie-rod, which is indispensable to prevent it
from breaking. d
We are providing a table that indicates the
tightening torques to be adopted based on
L ≥5xd
the diameter/threads of the tie-rods for the
correct and safe bracketing of the crane. TIGHTENING TORQUES OF
CRANE BRACKETING TIE-RODS
Diameter Min. Max.
of tie-rod torque torque
mm (Nm) (Nm)
M18X1,5 85 136
M24X2 201 322
M27X2 294 470
M30X2 411 658
M33X2 451 724
M39X3 533 856
M42X3 574 922
M20 116 193
M36 480 800
M45 900 1500
M48 900 1500

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Fitter’s manual

5.4 Counter-chassis

We are providing a table to help you to preventively


establish a weight per meter of the counter-
chassis to be constructed to install the crane
on the truck.
The application of a counter-chassis is always
necessary to increase the resistance of the truck
chassis especially in the zone under the crane
but also to increase the rigidity of the same,
which is indispensable while the crane is in
use: truck manufacturers design their structure
supposing the loads to be evenly distributed,
while the crane generates a localised load.

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

Lifting Weight/m counter-chassis Lifting Weight/m counter-chassis


Torque (for two side members) Torque (for two side members)
txm KN.m kg txm KN.m kg
0÷2 0÷20 38 11,1÷12 111÷120 135
2,1÷3 21÷30 46 12,1÷13 121÷130 145
3,1÷4 31÷40 58 13,1÷15 131÷150 170
4,1÷5 41÷50 70 15,1÷17 151÷170 200
5,1÷6 51÷60 74 17,1÷20 171÷200 220
6,1÷7 61÷70 80 20,1÷25 201÷250 240
7,1÷8 71÷80 85 25,1÷35 251÷350 275
8,1÷9 81÷90 105 35,1÷50 351÷500 300
9,1÷10 91÷100 115 50,1÷75 501÷750 325
10,1÷11 101÷110 125 >75,1 >751 350

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Manuale installatore

5.5 Truck board

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.

Type of truck board Weight in kg


(Height of sides: 600 mm) per 1 m in
length

Aluminium sides 180


Wooden board (xed)

Aluminium sides 200


Sheet plate board (xed)

Aluminium sides 300


Iron board (tipper

NB: the weights are merely indicative

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Fitter’s manual

5.6 - Spaces required to install the crane correctly

Each model of crane has specic overall dimensions,


which are written in the technical data sheets that
make up the production information issued by the
manufacturer.
The overall dimensions of the crane also depend on
the presence of accessories, such as:
- A hydraulic output, when it is an optional unit,
may take up more space compared to a standard
crane.
- The presence of an y-jib may take up more space
compared to a standard version.
- The application of a hose-carrying jib at the side of

?
the second boom takes up more space compared
to the standard version.

The dimensions indicated in the technical data sheets


relate to the real overall dimensions of the crane, to
which you must add a few centimetres at the side
where the second boom folds down to make such
movement easier, especially if the truck board is
positioned on this side.

To establish the correct overall dimensions of the


crane you also need make sure that the top part
of the column does not interfere with the truck
cab during the rotation movements, in particular ø1
when the truck cab is particularly tall and upright.
To check this situation you can use the technical
drawings enclosed with the documents written for
each single model of crane. ø2
h4
h3

ø3
h2
h1

NB: We advise you always to consult


updated technical sheets on the internet x
site www.effer.it; you can also nd the
overall dimensions related to y-jibs and
jibs in the data sheets. y

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Manuale installatore

5.7 - Identifying the rotation dead centre point

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
=

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Fitter’s manual

The table that follows shows the standard dead centre


points of the current production of EFFER.
It is important that you notice that it is particularly difcult
(impossible) to modify the position of the rotation dead
centre in some models of cranes.
Version S: Female tubular unit on cab side

Version 0S: Female tubular unit on truck board side

Std. assembly Crane Standard Optional


Rotation model version version
angle S OS S OS
360° a 18 X X
360° a 20 X X
360° a 28 X X S
2
360° a 30 X X
380° a 40 X X
380° b 42 X X =
0

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

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Manuale installatore

In Cranes with rotation by means of ring and gear


motor, since these have a much greater angle
of rotation compared to cranes with rotation by
means of pinion and rack, the dead centre point
cannot be changed.
The dead centre point related to the angle of
rotation, in other words the centre line of the
smaller zone restricted by the two rotation limit
switches is always on the outriggers.

Crane Angle of rotation


Model dead centre

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

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Fitter’s manual

5.8 Changing the rotation dead centre

Here are the instructions needed to change the


rotation dead centre if such modification is
to be carried out after the crane has already
been consigned:

1- Install the crane on the truck, or block the


base temporarily on a solid support: it must be
impossible for it to tip.

2- Hydraulically connect the crane to the pump of


the truck or to an independent controller.

3- Position the rst boom of the crane horizontally,


the second boom slightly facing downwards
and the extensions in a completely retracted
position.

4- Rotate to position the crane booms halfway


along the rotation angle: this point coincides
with the opposite part compared to the original
rotation dead centre point.

5- Some mechanical locking devices are tted at


the bottom to prevent the column of the crane
from slipping out of the base: Snap rings or
ring nut secured with screws. Free the column
from the attachment system.

6- If the rotation play adjustment device is installed,


the latter needs to be completely loosened.

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Manuale installatore

7- Raise the crane column and all the booms keeping


them balanced to release the rotation pinion
from the rack.
By lifting the column this is 100÷130 mm. If you
try to turn the end of the crane while lifting the
column by pulling it manually using a rope, the
end of the crane will turn as soon as the rotation
pinion is released from the rack.
Stop lifting the crane immediately to prevent the
column from coming out of the vertical guides.

NOTE: In crane models 310, 325, 340,


370 the column only raises just a few
centimetres, after which it is stopped
mechanically.

To modify the rotation dead centre point in these


cranes, you need to dismantle the two rotation
barrels and move the rack outwards after
having completely unscrewed the rotation
adjustment device. In this way you can turn
the crane since the pinion of the column is
released from the rack.

8- Turn the raised part by 180°.


9- Lower the column very slowly and as vertically
as possible, making slight rotation movements
of the boom of the crane manually using the
rope applied on the end of the crane: only in this
way can you insert the pinion in the rack again.
Otherwise you need to dismantle a barrel of the
rotation jack and position the rack vertically,
which can be moved from its vertical position after
knocking it in the attempt to insert the column.
10- Fit the bottom locking device of the column.
11- Tighten the relative rotation play, if there is
any.

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Fitter’s manual

12- The pipes fed through the hole of the column


are now rather twisted: they cannot be turned
further without irreparably damaging them.
Loosen the hydraulic connection of these pipes
as near as possible to the bottom part of the
column and untwist the pipes.
Be very careful in this phase because if it is not
done correctly, the flexible hoses will wear
rapidly and the electrical cables inserted in the
column could possibly break.

Crane with electric rotation restrictor

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.

Crane with ring gear motor

This requirement does not occur in cranes


where the rotation movement is performed
by means of a ring and a gearmotor, because foto gru ralla
their rotation angle is much greater compa-
red to cranes that are rotated by means of
pinion and rack.

It is in any event important to check the


suitability of the rotation dead centre point
with the installation to be carried out,
because a feasible modication beforehand
could mean that you will have to dismantle
the column and work on the base, which is
highly discouraged!

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Manuale installatore

6 INSTALLATION CALCULATIONS

6.1 - Purpose of the test calculation

Once a crane has been installed on a truck,


the tare values, capacity, dimensions, weight
distribution on the axles etc. must be calculated
and tested.
Before you start to install a crane, you must
prepare a technical report concerning the kg ? kg ? kg ? kg ?
theoretic testing of the weights on the axles
of the truck.
The purpose of this report is that of ensuring that
the maximum admitted weights envisaged by
the manufacturer of the truck are not exceeded
after putting additional weights on the truck
following the installation of the crane, counter- kg ? kg ? kg ? kg ?
chassis, additional outriggers, etc. and of
testing the weight ratios between the axles
of the truck in the various driving conditions:
when empty and when fully loaded.

When assembling upper structures, manufacturers of industrial vehicles set a series of


limit values, whatever the type of equipment involved, which must be strictly respected
because they are bound to the specific characteristics of each vehicle (resistance to
strain, braking etc.).

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 specications 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.

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Fitter’s manual

The weights on the axles can be tested in the


following manners:
1) Using an electronic calculation program on
computer, supplied by EFFER. This program is
called “trailerwin” and is used to test the weights
on the axles and to print out the drawing of the
truck rigged out with the crane.
2) Using a manual mathematical calculation.

NB: If you do not avail of the com-


puterised calculation program, you
can request EFFER for the manual
procedure or you can even ask EFFER
to make the calculation.

In both cases the data required to make the


calculation are the same.

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

PL Posizione ant. post. Totale

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

Techn. 4435 2485 =56%


340.11-4S ! Il punto, nella posizione posteriore, è troppo lontano
Manuale dell'installatore
SCANIA R 000 LB6X2*4MNA 3900 CR19 Comfortline
I risultati di questo studio (preliminare) sono basati su dati teorici e sono soggetti a verifica e
correzione, a montaggio avvenuto, considerando gru ed autotelaio nelle loro configurazioni
definitive
I risultati di questo studio (preliminare) sono basati su dati teorici e sono soggetti a e reali.
verifica e correzione, a montaggio avvenuto, considerando gru ed autotelaio Va nelle loro
segnalato che in particolare i dati dell’autotelaio potrebbero variare in funzione
configurazioni definitive e reali.
dell’Omologazione ottenuta dal costruttore e delle Norme in Materia di Circolazione Stradale di
Va segnalato che in particolare i dati dell’autotelaio potrebbero variare in funzione
Autoveicoli
dell’Omologazione ottenuta dal costruttore e delle Norme in Materia di Circolazione e di Trasporto in vigore nel paese di immatricolazione finale del veicolo.
Stradale
di Autoveicoli e di Trasporto in vigore nel paese di immatricolazione finale delEffer
veicolo.
ed i suoi concessionari-rivenditori dichiarano che nessuna responsabilità potrà loro essere
Effer ed i suoi concessionari-rivenditori dichiarano che nessuna responsabilità potrà loro
essere addebitata per eventuali danni, diretti o indiretti, derivanti da errori odaddebitata per eventuali danni, diretti o indiretti, derivanti da errori od omissioni nell’impiego del
omissioni nell’impiego del software TrailerWin e/o dalla divulgazione dei calcoli software TrailerWin e/o dalla divulgazione dei calcoli realizzati.
EFFER HOLDING S.P.A. - VIA BONAZZI 12 - 40013 CASTEL MAGGIORE (BO) ITALY
realizzati.

22/02/06 13.45 C:\TRAILERW\DATA\Manuale installatore _ ITA 2 TrailerWIN 2004-12

Graphic representation of the calculation concer-


ning the weight test on the axles.
EFFER HOLDING S.P.A. - VIA BONAZZI 12 - 40013 CASTEL MAGGIORE (BO) ITALY
22/02/06 13.45 C:\TRAILERW\DATA\Manuale installatore _ ITA 2 TrailerWIN 2004-12

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

= =

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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

NB: Weights M2 + M3 and m2 + m3 are concentrated in point 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.

With regard to the position of RA, unless indicated


otherwise by the truck manufacturer, it is suppo-
sed to coincide with the distance between centre
lines I1 (distance between 1st and 2nd axle). In
this point, consider that the value of mA (sum of
the weight of the 1st axle + the weight of the 2nd
axle) and the value of MA (sum of the maximum
I1 M3 / m3 M4 / m4

weight admitted on the 1st axle + the maximum


weight admitted on the 2nd axle) converge. RA RB
M1 / m1 M2 / m2
M1 / m1
MA / mA

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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

Rear overhang of truck µ


The length of the rear overhang µ is subject to the observance of the weights admitted on the axles
of the truck; the weight transportable on the truck board, evenly distributed along the same,
must not exceed the single maximum weights admitted on the single axle.

1 2

EI µ EI µ

2 axles µ max = 65% EI 3 axles µ max = 70% EI

3 4

EI µ EI µ

3 axles µ max = 70% EI 4 axles µ max = 70% EI

NB. In countries of the European Community, a percentage has been dened 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
dened 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

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Fitter’s manual

Crane rig-out on tractor


We are indicating the main problems to be faced when installing the crane on a tractor:

1) Max front radius of semi-trailer (Xmax)


In this case it is impossible to hook a standard semi-trailer; the difference lies in the front
“beak” that must have a limited length and possibly shaped to avoid interference with the
crane when steering.
2) Overall radius in the tractor tail (Ymin)
In the case of additional outriggers, you need to bear in mind their overall dimensions; the
supporting feet of the semi-trailer must be positioned at a minimum distance so that they do
not interfere with the additional outriggers when steering.
3) Ring height of semi-trailer (H)
You need to arrange a mimic chassis
under the crane or an extension of
the integrated mimic chassis under
the ring that reaches the additional
outriggers, ensuring that the sum of
the heights of the chassis + mimic
chassis + ring does not exceed
the maximum height admitted for
coupling the ring with the semi-
trailer.

The height of the mimic chassis pre-


pared under the ring depends on Ymin
the maximum height off the ground
of the ring:
Xmax
(H) max. height of ring off ground Xmax = X1 - ~100
2550

(H1) ring height


(H2) chassis height ~100
X1
(H3) max. height of counter chassis
H2 H3 H1
H

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.

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Manuale installatore

We are summarising the parameters needed to be able to make the


theoretic calculations of the distribution of the axles and the stability
of the truck/crane assembly.

• a crane model 340.11 / 4 extensions.


• combined with the truck as per the technical data sheet given in chapter 1.4.
• with the crane installed between the cab of the truck and the truck board
• truck with pitch between the rst and second axle of 3900 mm
• remaining truck board, length 4700 mm, xed type requested.

Truck data:

.................. m 2 = Tare of 2nd axle, truck


I = Distance between 1st and ..................
without rig-out, including a
2nd axle
.................. driver
Z = Distance between 2nd and
m 3 = Tare of 3rd axle, truck ..................
3rd axle
without rig-out, including a
..................
EI = Distance between the two driver
supporting points M = Maximum weight of truck ..................
T = Tare of truck without rig-out, .................. in driving position
including a driver M1 = Maximum weight admit-
m1 = Tare of 1st axle, truck ted by manufacturer on 1st ..................
.................. axle
without rig-out, including a
driver M2 = Maximum weight admit- ..................
ted by manufacturer on 2nd
axle
D F M3 = Maximum weight admit- ..................
ted by manufacturer on 3rd
axle
..................
D = Cab overall dimensions

..................
F = Rear chassis overhang of
original truck
EI µ = Maximum rear overhang ..................
admitted by road regula-
I Z tions

m1 / M1 m2 / M2 m3 / M3 K = Minimum ratio when empty


and when loaded, front axle ..................
RA µ
RB weight/rear axle weight

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 efciency
of the truck could be compromised.

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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

Theoretic data of components to be installed

1. Weight of hydraulic pump, power take-off


Consult the table given in chapter 5.1.
..................
We remind you that the crane taken for the example calculation is a 34 txm and
as such is within the range of 30.1 and 50 txm.

2. Weight of bracketing material ..................


Consult the table given in chapter 5.3.

3. Weight per meter of the counter chassis


The truck involved has a practicable space of roughly 6 meters (space between
..................
the rear part of the cab and the rear edge of the original chassis). Consult the
table given in chapter 5.4. We may suppose that the counter chassis is as long
as the practicable space, in other words 6 meters.

4. Weight of truck board


Consult the table given in chapter 5.5. Fixed truck board (4.7 m in length) with ..................
wooden board and aluminium sides.

5. Weight of additional outriggers


..................
Consult the table given in chapter 1.4.
The outriggers suitable for our installation have code 9260026.

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6.3 - Information on calculating the theoretic stability test

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.

2) Using a manual mathematical calculation.


NB: If you do not avail of the computerised calculation program, you can request
the crane manufacturer for the manual procedure or you can even ask the latter
to do the calculation for you.

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.

PESO GRU CON OLIO NEL SERBATOIO


kgA WEIGHT OF THE CRANE WITH OIL IN THE TANK

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

C 1869 1967 2085 2161


D
E
[mm] X 734 832 978 1088

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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.

Graphic representation of the stability test calculation.

ex
am

ple 340.11-4S
SCANIA R 000 LB6X2*4MNA Manuale dell'installatore
EFFER 340.11 / 4S

Distanza centro di rotazione della gru - Asse anteriore mm 1470


Peso della gru kg 4258
Peso del basamento kg 2358
Peso del braccio kg 1900
2.0 nn==0.39
0.41 Distanza centro di rotaz della gru - CDG dei bracci max sbraccio mm 4210
Anteriore
Anterioredestra
sinistra Massimo sbraccio mm 12350
1.8 Portata al massimo sbraccio kg 3040
360° Peso asse anteriore kg 5556
1.6 Peso asse posteriore kg 5381
Distanza centro di rotazione della gru - Mezzeria del camion mm -20
1.4
Dist. centro rotaz. gru - asse stabilizzatori mm < = -396 > = -249
Apertura stabilizzatori mm 6400
1.2
Peso stabilizzatori kg 0
Distanza degli stabilizzatori supplementari - Asse anteriore mm 6270
1.0
Apertura degli stabilizzatori supplementari mm 3300
-20 Peso degli stabilizzatori supplementari kg 255
Distanza primo asse anteriore - punto ribaltante dell'asse anteriore mm 0
Distanza fra asse anteriore - Punto d'appoggio dell'asse posteriore mm 4577
-72°
291° 73° Carreggiata asse anteriore TIR mm 2000
Carreggiata asse posteriore TIR mm 1800

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

Posteriore 2.46 3040 kg

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

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

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7 - CONSTRUCTIONAL INFORMATION
FOR THE COUNTER-CHASSIS

7.1 Cross section of the counter-chassis

The counter-chassis must have an absolutely specic 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.

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7.2 Assembling the counter-chassis

Warning! The counter-chassis is to be assembled by resting the side members


and the cross members on one single surface or on special adjustable supports
so that the side members are perfectly at and parallel with each other (to be
tested using spirit level).

It is forbidden to use the chassis of


the truck for the assembly phase of
the counter-chassis.

You must check the atness and the parallelism of


the side members especially when welding; if
necessary straighten using dedicated tools.

The previous chapter mentioned the section of


the counter-chassis, which is to be installed
between the crane and the chassis of the truck;
this section is to be built for a minimum length
of 3 times the width of the crane base, then it
can be reduced gradually through to the rear
part of the truck.
a
From the point in which the section starts to reduce, 3a
further resistance tests must obviously be carried
out.

The most commonly encountered installations


involve the application of a truck board on the
counter-chassis: it is therefore advisable to build
the counter-chassis with a constant height for the
full length, reducing the thickness as you move Counter-chassis
away from the rotation axle of the crane. R=5

The front part is to be extended as far as possible Truck chassis


under the cab and must end so that it ensures a
gradual ow from one section to the other.

R=5

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The easiest way that most truck manufacturers


agree with is that of making a bevel at the
front end with an angle of between 15 and 45
degrees.

We remind you that this is indispensable to avoid


damaging the truck chassis when working
with the crane, especially when the crane is
approved to work in front of the cab. This is
because variations in the resistant sections
must always occur gradually.

The bottom edge of the front end is very important;


it must be rounded with a minimum radius of
R= 5 mm., to avoid the risk of cutting and/or
breaking the truck side member.

The side members of the additional structure


shall be seamless, extending as far as possible
towards the front of the vehicle and shall
possibly reach the front supporting zone of
the rear leaf spring and rest on the chassis
of the vehicle. Wedge
The previously mentioned counter-chassis shall
be in direct contact with the chassis of the truck, Counter-chassis
ensuring supporting continuity.
If anything should stick out such as heads of nails,
you need to put wedges or spacers in-between,
made of steel or other light alloy provided they
are suitable for such purpose.
The surfaces in contact between the wedge and
the counter-chassis shall be pre-treated with
rust inhibitor.
Using the additional outriggers, the lengths of the
counter-chassis shall be extended up to such
cross member.
Truck chassis

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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 efciently. 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 specic 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.

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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
Sufcient Perfect

If the section of the counter-chassis envisages some internal horizontal spacer plates, these too
can be limited in length, again gradually.

30°

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The two side members thus made shall be


connected together by cross members
to ensure the rigidity of the truck. This
rigidity is indispensable to be able to
distribute the weight of the single axles
of the truck when the crane is working
and therefore ensuring the stability of
the truck.

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.

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There are basically two types of installation:

1) Installation behind the cab


Advantages:
- The weight of the truck that is mainly concentrated
at the front strongly contributes in gaining
stability while the crane is in use.
- The cost of installation of the crane is relatively
economic.
- You can load material longer than the truck
board.

2) Installation behind the truck board


Advantages:
- The crane can be used even on a trailer.
- Weights can be lifted very close to the crane,
exploiting its maximum power.
- The crane has a wide operating area without
obstacles.
- Thanks to the crane/truck combination, the
operating stability of the crane is ensured
over 360°.

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 specic 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).

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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.

2) Bases with 4 anchoring brackets with mobile equalizer


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.
The outer dimensions of this cross member must be as similar
as possible to those of the side member. Sometimes a slight
reduction in height is required due to any shapes and sizes
2
under the crane or due to some part sticking out from the top
edge of the truck chassis.

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3) Bases with 4 xed anchoring brackets with xed equalizer

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 superuous.

A small cross member under the base of


the crane or even better at the front of
the counter-chassis may be of use in
the constructional phase of the counter-
chassis to keep the two side members
parallel during the assembly phases and
installation of the truck.
This cross member is on the other hand
very useful when installing cranes at the
back.
In this case it is to be arranged in the centre
line of the base, it must have a closed
section that is twice as wide as the width
of a single side member and it must be as
high as the side members of the counter-
chassis.

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Cross members of the counter-chassis


The cross members of a counter-chassis,
as explained in the previous pages, are
elements that determine the rigidity of the
counter-chassis. There are no specic
regulations for their dimensions and the
number of them to be applied, neither
on behalf of truck manufacturers nor
inspection authorities; they can still not
be avoided however because, as already
explained, there would be too much
twisting when the crane is working, which
would could problems of stability.
Experience certainly helps in realising their
importance.
Various factors are to be considered when
determining the type of stiffening system
to be carried out, such as the pitch of
the truck, the presence of additional
outriggers and the weight of the truck
in relation to the minimum tare weight
envisaged for installing the specic type
of crane model.

Positioning the cross members


If the additional outriggers are not envisaged x max. = 800 ÷ 900 mm.
for the specic type of installation to be
carried out, it goes without saying that X X
the truck is “big” in relation to the model
of crane; therefore simply apply some
cross members up to near the rear axle,
making sure to apply them at equal
distances apart.

Note: Bearing in mind all mentioned


in the previous pages, an initial cross
member is always to be installed next
to the crane bracketing tie-rods outside
the base area even if the upper structure
of the truck is a tipper.

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If xed additional outriggers are to be installed,


x max. = 800 ÷ 900 mm.
the cross members shall be distributed in
the free length between the rear bracketing x1 max. = 1100 ÷1200 mm.
tie-rods of the crane and the cross member
of the outriggers, applying them at equal X X X1 X1 X1
distances and not exceeding an empty
length of 800/900 mm.
The cross members can be applied slightly
further apart near the rear axle.
If the application of a certain model of crane
on a certain model of truck envisages
the installation of additional outriggers
that extend out to the side, we explained
previously that the counter-chassis must be Foto stabilizzatori uscita
made even more rigid to avoid excessive
laterale
twisting, which could penalise stability
enormously during operation.

Sections of the cross members


An ideal rigidity is created with a large section:
cross members that are narrow but very
thick do not create sufcient rigidity but just
increase the weight!
Many installers use the same section to
construct the cross members as that used
for the counter-chassis: this is wrong. If
you think of a box of shoes, you think of
something rigid that is not easy to deform
even though it is made of thin cardboard.
The same concept is to be applied to deter-
mine the section of the cross members.
A economic, handy and very functional solution
consists in doubling the outer section of the
counter-chassis, as indicated at the side.
Indicative thickness of cross members:
Crane up to 15 txm: thickness 6 mm
Crane from 15 txm to 30 txm: thickness 8 mm
Crane of over 30 txm: thickness 10 mm
Higher thicknesses just lead to a superuous
increase in the weight of the counter-
chassis.

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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.

Stiffening the counter-chassis


The zone next to the crane is obviously that most
subject to twisting during operation; to further
reduce twisting, you are suggested to apply some
sheet metal triangles between the side members
and the cross members using the indications
given below; these indications apply for an ideal
crane/truck combination and can be reduced in
the case of small cranes tted on large trucks but
they can also be increased in the case of large
cranes installed on medium sized trucks or even
large trucks but very long.
These stiffening triangles must be fitted “flush”
with the counter-chassis: otherwise they loose
effectiveness.
The ideal dimensions of the triangles is such to
have two sides with the same length of 150/200
mm.

Note: there is no use in applying triangles


that are thicker than the cross member:
this would just increase the weight without
need.

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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 prole.

The application of a cross member that must be a boxed one (otherwise it would be almost
useless), envisages the closure of the prole in the joining zone of the cross member by means
of a wedge almost as thick as the prole and appropriately welded.

100

The profile is to be closed so that there are two free protrusions at the side of roughly
100 mm.

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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.

Reduction of the height of the counter-


chassis Md
If you wish to reduce the height of the section
of the counter-chassis or to install a ring M
for the semi-trailer or to construct a special
truck board, you need to check the new
section, in the reduction point, but adopting
value M of the torque induced by the crane Counter-chassis
controtelaio
on that certain section.
telaio veicolo
Md = dynamic torque of the crane vehicle chassis

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

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The position of the maximum dynamic torque


of the crane coincides with the position
of the rotation axle of the crane and
decreases slightly the more you move
away from the rotation axle.
If you wish to construct a very light counter-
chassis, you can create various sections
of the side members, which must be
tested with regard to the torque value in
a
that specic point.
b
Note: in point X (position of the
outriggers in this case) the dyna-

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

Md = maximum dynamic torque


a = distance of additional outriggers/crane rotation axle
M1 = maximum dynamic torque in the test point
b = distance of the point in which the section of the counter-chassis of the crane rotation
axle reduces

Note: The cross members of the counter-chassis must be positioned without


considering the brackets in the case of an installation with a tipper truck board.
These brackets are generally of smaller section and thickness compared to what the
structure of the counter-chassis requires, therefore they cannot be considered to
replace the cross members requested by a job done correctly.

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7.3 INTEGRAL COUNTER-CHASSIS

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.

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Below is a table related to the dimensions of the sections of the side members supplied
by EFFER.

Crane Mod. A B C D

D 750 200 8 300 8


C
850 200 8 300 8
D
1050 200 10 300 10
1250 200 10 300 10
B B 1550 200 10 330 10
1750 270 10 370 10
A
NB: measurements expressed in millimetres

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.

Tips on preparing the rear part of the counter-chassis


The crane and its counter-chassis are supplied already installed.

We advise you to position the counter-


chassis/crane on the truck, respecting
the position obtained from the test
calculations relative to the weights on
the axles described previously.

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 specications), 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.

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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.

Position the counter-chassis/crane back


on the truck; weld the brackets prepared
previously in the positions envisaged.

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

Bracket (60x40 ≠ 40)


welded on the counter-
chassis

Anti-squashing plates of
Threaded block
the truck chassis (≠ min
(60x40 ≠ 40) 10 mm)

No. 2 tie-rods M24


Block ≠ 40x60

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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.

Put the crane back on the truck and complete


the nal brackets.

NB: in this phase it is important for the


truck chassis to be perfectly at and
supported on four rigid points.

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The part of counter-chassis that is to be tted on the crane


is to be constructed separately, on sturdy supports and
perfectly at: the structure thus constructed must be
free from twisting or misalignments.

Apply the structure constructed on the truck,


by the crane. Dene the bracketing points,
setting them at roughly 1000÷1400 mm
apart and find the position of the side
blocking points that guarantee that the
structure cannot move compared to the truck
chassis.

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°

Bottom metal plates

gru controtelaio
2mm
90°

side metal plates


crane counter-chassis
2mm

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.

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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.

~ 500 ~ 1000 ~ 1000

200 * 200 * 200 *


* Cross members of the counter- X: Joining sheet metal of the side members: Recom-
chassis: recommended section mended thickness 10 mm for the rst two zones to
same as the section of the con- be closed near the crane. The other zones can be
structed side member. closed with 8-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.

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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

Note: follow the instructions given in


chapter 11 for the application of the
additional outriggers.

Note: Welding instructions required


to construct the counter-chassis
are given in chapter 1.2.4. of this
manual.

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8- FITTING THE COMPONENTS ON


THE TRUCK

8.1 - Fitting the hydraulic power take-off

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:

1) Drain the oil from the gearbox of the truck and


remove the cover of the hatch where the power
take-off will be applied (hatch, re. A).

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

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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:

Screw M 8 = 2.4 kgm (22-25 Nm)


Screw M 8.5 = 2.4 kgm (22-25 Nm)
Screw M 10 = 5 kgm (44-49 Nm)
Screw M12 = 8 kgm (70-75 Nm)

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.

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Pneumatically operated power take-off


This type of drive is only suitable for trucks with air
for the brakes circuit.
The pneumatic deviator is to be placed in the cab
near the dashboard or under the driver’s seat.
The compressed air drawn from the truck’s circuit
shall reach the pneumatic deviator installed in
the cab via a pipe and from here it must reach
the power take-off.

You are recommended to t a pneumatic lock valve

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.

Luminous red LED

Earth

Pressure switch or electric


contact on the command

+
Truck utility air tank

Power take-off

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Mechanically operated power take-off

This type of drive is installed in small and medium


trucks that do not have air for the brakes
circuit.
The lever and relative support used to operate
the power take-off are generally installed in a
handy position next to the driver’s seat. Using
a exible cable, connect the operating lever to
the power take-off.
Be careful where you position the exible cable so
that it is as short as possible, that it does not
suddenly change direction (to avoid compromi-
sing the free run of the cable) and that it is not
in contact with sources of heat.

It is strictly forbidden to move the vehicle while the


power take-of 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.

Luminous red LED


Cable

Engaging lever
Engaging lever
Earth
Power take-off

+ Flexible cable
Power take-off
Electric contact
on command

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Power take-off on the torque distributor


In 4x4 or 6x6 drive vehicles, you can t the power take-off on the torque distributor. The rpm for
the utility is correlated to the gear engaged.
Consult the truck manufacturer’s manuals to check the output power available on the torque
distributor.
Other possible types of power take-off
In some vehicles with hatch on the gearbox for the power take-off, the supply of the hydraulic
system can be prepared as follows:
- with the hydraulic control unit connected directly to the truck battery;
- with the power take-off from the engine, via pulley.

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.

An alternative to such application is with power


take-off from the engine via belt transmissions
(usually geared and trapeze) with suitable
electro-magnetic joints controlled from inside
the cab.

These applications are very specic and involve


costly work in the engine bay, plus very much
attention must be paid to the following points
in particular:
• check the temperature of the engine coolant
and of the oil if the crane is used for long hours
and possibly t additional heat exchangers;
• make sure the drive transmission on the engine
shaft is done with exible systems so as not to
cause vibrations on the actual shaft;
• the protrusion of the transmission pulley com-
pared to the bed support shall be minimal.

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8.2 - Fitting the hydraulic pump

There are two possible ways of installing the hydraulic pump based on your own requirements:

1. Direct application: pump coupled and anged


on the power take-off.

2. Indirect application: pump fitted by


means of a cardan shaft.

1. Direct application: pump coupled and anged on the power take-off.


This type of application is done when the following conditions exist:
- there is enough space near the gearbox, in order to prevent oscillations of the gearbox from
damaging the pump by making it interfere with other parts of the truck;
- the manufacturer of the power take-off knows the characteristics of the hydraulic pump and
the hydraulic operating specifications of the crane and must guarantee that the gearbox
of the truck is suitable to withstand the vibrations produced by the power take-off and the
hydraulic pump tted overhanging;
- the pipes that connect the hydraulic pump to the crane must not be tightly bent or squashed;
- these pipes must not rest on structural edges: vibrations would cut the pipes;
- the oil in-take hose - connection between the pump and the oil tank of the crane - must not have
siphon sacks but must run continuously
downwards and its cross section must be
such to minimise load losses, therefore
it must be much larger than the pipes
normally installed on the crane;
- the exible hoses must be secured using
rigid supports every 30-35 mm.

NB: To avoid cavitation, the pump must always be installed under the minimum
level of the hydraulic oil of the tank.

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2 Indirect application: pump applied by means of a Cardan shaft

In this case the application consists in anging the


pump to the counter-chassis using a bracket and
in connecting it by means of a Cardan shaft with
coupling ange to the power take-off.
Cardan shaft manufacturers impose maximum
inclination angles that generally range between 8°
and 10° (deviation between the axes of the power
take-off and the pump).
The Cardan shaft must be sized to transmit the
maximum “rotation torque” requested by the pump
when the crane is working.
Another parameter to check when choosing the
Cardan shaft is the maximum rpm at which it
can be used.
Considering that this installation is to be used when
there is not enough room to apply the pump
directly, it is quite easy to forget to observe
all the rules mentioned above and therefore to
compromise not only the life of the Cardan shaft
itself but also that of the power take-off and the
pump.
There are lubricators on the coupling anges of the
Cardan shaft, which are used to service the Cardan shaft periodically to obtain correct
operation and lasting wear in time.

Correct assemblies Incorrect assemblies

Angles the same Angles the same but


joints not timed
and joints timed
α
α
α

α α α

α
Angles not the same
Angles the same
and joints timed
and joints timed

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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.

Starting the hydraulic gear pump


There are no special precautions involved in starting a gear pump: all the instructions supplied
by the manufacturer of the pump must be strictly observed.
It is in any event useful to engage the power take-off while the truck engine is just turning over
and to release the clutch with caution and gradually so that you are ready to interrupt the
starting phase if something goes wrong.

Starting the hydraulic piston pump


A piston pump is to be started much more carefully and cautiously.
All the instructions supplied by the manufacturer of the pump must be strictly observed.
For some types of piston pumps, the pump must be lled with oil to evacuate the air with operating
methods that are not always the same.
We would like to point out the importance of this operation, which if requested and not done,
could lead to the breakage of the pump.
It is advisable to engage the power take-off while the truck engine is just turning over and to
release the clutch with caution and gradually so that you are ready to interrupt the starting
phase if something goes wrong.
We advise you to run the hydraulic piston pump for a few minutes before pressurising the hydraulic
circuit of the crane to be certain that there is no air in the oil in-take circuit.

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.

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8.3 Fitting the counter-chassis

Positioning it on the truck

The truck is to be parked on at ground so that the


truck chassis cannot be twisted.
Make sure the two side members of the truck are on
the same level, in other words that the chassis
is not distorted. You are also recommended to
put at least four adjustable supports between the
ground and the bottom part of the chassis (two on
each side member) so that the chassis level does
not change by the weight of the counter-chassis
when it is put on top of it.
This is indispensable to ensure the lasting quality of
the installation and not to alter the functional life
of the original chassis of the truck.

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.

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Securing the counter-chassis


When the counter-chassis is calculated, the type
of attachment to be adopted to join the truck
and counter-chassis must already have been
dened.
Based on the type of attachment, the chassis of the
truck gives a different contribution in creating,
together with the counter-chassis, sufficient
resistance to the strain induced by the crane
when it is working.
When calculating the counter-chassis, one assu-
mes that the twisting and exing of the structure Dynamic torque of the crane
created are the same on both sides of the truck,
both when working and when driving the truck
on the road: from this you can realise how Counter-chassis
controtelaio
important the function of the cross members
applied between the two side members of the telaio veicolo
Truck chassis
counter-chassis is.

The following types of attachment are possible:

1) Flexible attachment Force


The chassis of the truck and the counter-chassis are
connected in a way that is not totally restricted,
therefore you can exploit a maximum total resi-
stance bound to the resistance of the weakest
element in the calculation. This type of attachment
means that the chassis and the counter-chassis
can run between each other, therefore they must
be joined with so-called “flexible” connections, Released deformation
such as long tie-rods or side plates with the screws (double section)
that secure them to the chassis tightened with
low tightening torque and with plenty of play in
the holes.

If the attachment is done using side plates and joining


screws, you must nd the number of screws to
apply instead of the crane tie-rod. These screws
are subject to a cutting force and therefore are
much less resistant compared to screws subject
to traction.

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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.

NUMBER OF SCREWS IN THE PLACE OF 2 TIE-RODS


Diameter of Screw M12 Screw M14 Screw M16
crane
bracketing Class of resistance Class of resistance Class of resistance
tie-rod 8.8 (8G) 10.9 (10K) 8.8 (8G) 10.9 (10K) 8.8 (8G) 10.9 (10K)
M16X1,5 9 7 8 7 6 6
M18X1,5 11 9 9 7 8 7
M20X2 12 10 11 9 9 8
M24X2 14 12 12 10 11 9
M27X2 16 13 14 12 12 10
M30X2 17 14 15 12 13 11
M33X2 19 16 16 14 15 12
M36X2 20 17 17 15 16 13
M39X3 23 20 19 17 18 16
M42X3 18 17
M45X3 20 19
M48X3 24 22

Note: you are advised to use screws in material type 10.9 to reduce their number.

At least 70% of the screws are to be arranged under the


crane base in two or more rows.
The remaining screws are to be applied as near as possible
to the above-indicated zone.
The holes (through holes) where the screws are screwed
must be 0.5 ÷ 1 mm larger in diameter than the diameter
of the screw (example: for a screw type M14 the hole
must be 14.5 to 15 mm).

To tighten these screws, adopt the TIGHTENING TORQUE TABLE - Nm


tightening torque given in the table and Screw Class of resistance
diameter (8G) 10.9 (10K)
use self-locking nuts.
Screw M12 13 20
Screw M14 20 32
Screw M16 33 48

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NB: Unless specically specied,


Max. crane torque Thickness of sheet plate
based on the calculations carried
out, the connection plates must be txm KN.m recommended “S”
made of the same material or of superior < 10 < 100 8 mm
material as that used to construct the
counter-chassis. We are providing a 10 ÷30 100 ÷300 10 mm
table of some indicative thicknesses, > 30 > 300 12 mm
obviously using material with mechanical
characteristics of at least S 355 J2G3C
UNI EN 10025 (ex Fe 510D UNI 7070).

A exible type attachment, excluding the part under the crane, is also done using brackets
joined with large screws or tie-rods:

Leave 1-2 mm before the closure

Counter-chassis

Chassis

Leave 1-2 mm before the closure

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 specic 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.

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1) Rigid attachment (also called single section)


NB: This type of attachment is the most frequently used in the theoretic test
calculations, because it generally enables the construction of shorter counter-
chassis. Remember that it can also be done by applying single tie-rods to
secure the crane/counter-chassis/chassis of the truck, but some plates must be
tted all the same between the counter-chassis and the chassis to stop the two
elements from running.
The truck chassis and the counter-chassis are joined Force
together rigidly and there is no sliding movement
between the counter-chassis and the truck chassis,
therefore the test calculation is done considering
just one section. The two ends of the section can
reach the limit tension values envisaged for the two
individual materials. The joining plates between
chassis and counter-chassis shall be appropriately
distributed right along the length (as an indicative Restricted deformation
value, assume a centre line between the plates of (double section)
900/1200 mm).

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:

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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.

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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).

Use the standard tightening torque to tighten these screws, as


per table.

At least 80% of the screws are


to be arranged under the base TIGHTENING TORQUE TABLE - Nm
of the crane, on two or more Screw Class of resistance
rows. diameter 8.8 (8G) 10.9 (10K)
Screw M12 78 118
Screw M14 126 184
Screw M16 193 280

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

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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 specic 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.

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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.

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Useful information on the attachments of the counter-chassis

Note: It is not possible to weld the truck chassis, just


like it is never possible to drill holes in the wings of
the same: holes can only be drilled in the vertical side
of the chassis in compliance with the instructions
given in the manuals of the truck manufacturer.

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

D = hole diameter: max. 20 mm


A = distance between the centre of the top holes and the top edge of the chassis.
Minimum distance = 40 mm, or alternatively: Minimum distance = 3 x D
B = Minimum horizontal distance between holes = 4 x D
C = minimum vertical distance between holes = 3 x D

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.

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The whole surface of the plates are to be protected


against corrosion.
Bolts are to be tightened using a dynamometric
spanner, observing the values given in the previous
tables.
It is forbidden to use exible washers (type groover
etc.) but you are advised to use resilient flat
washers specic for bolts.

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Indications for side plates

B Z B

1 1

3 3

4
2

4
s s
A C A

A- width of truck chassis 1- counter-chassis


B- width of counter-chassis 2- reinforcement sheet plate
C- width of reinforcement plate 3- joining plate
S- thickness of joining plate 4- truck chassis

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:

Max. crane torque Thickness of sheet plate


txm KN.m recommended “S”
< 10 < 100 8 mm
10 ÷30 100 ÷300 10 mm
> 30 > 300 12 mm

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Securing the counter-chassis using tie-rods

The application of vertical tie-rods in two by two


for each bracket on the base, which joints
the crane/counter-chassis/truck chassis, is
certainly the quickest and cheapest way.
Any protrusions at the side of the truck chassis,
created by the mechanical components
present (i.e. cylinders, supports, exhaust etc.)
do not always make it possible to block the
counter-chassis with just one vertical tie-rod.
Remembering that it is forbidden to install
tie-rods that are not vertical compared to
the truck chassis, the execution of a “return”
enables the installation via tie-rods all the
same.
This “return” can be made in the following
methods:
a) Return bracket outside the counter-chassis

Front side of
truck
A A

L1 L2

When L1 exceeds 70 mm and L2 exceeds 100


mm, you need to apply some gusset plates
to back-up the welding of the bracket “A” on
the counter-chassis, as wide as the bracket
and twice as high as the minimum thickness
width of 8 mm.

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b) Through return bracket in the counter-chassis


Front side of
truck

A A

L1 L2

Likewise for the previous case, L1 and L2 again


cannot exceed certain lengths, which we indicate DIAMETER L1 L2
OF TIE-ROD mm mm
in the table. mm
The above can be applied to a pair of tie-rods or to 16 0 ÷ 70 0 ÷100
all four, based on the requirements of the specic 18 0 ÷ 120 0÷180
installation.
20 0 ÷ 120 0÷1730
In any case, it is important to make the “returns” so
24 0 ÷ 140 0÷210
that L3 is greater or the same as L4.
27 0 ÷ 200 0÷ 300
You are also recommended to weld the tie-rod return
30 0 ÷ 250 0÷350
brackets as near as possible to the central zone
of the counter-chassis, both whether they are 33 0 ÷ 300 0÷400
applied externally or embedded internally. 39 0 ÷ 300 0÷400

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

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Note: Be very careful if you make brackets with


through vertical tie-rods that block the crane,
counter-chassis and truck chassis, to avoid
squashing the truck chassis when tightening.

To avoid squashing, you need some sheet plates by each


internal tie-rod to stop them from squashing.

10 mm 10 mm

90° 90°

We remind you that the bracketing tie-rods are to


be tightened with the crane completely folded
down, or if this is not possible, with the boom
extensions as vertical as they can possibly go.

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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

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Blocking the counter-chassis at the side


Some of the systems mentioned above used to
join the counter-chassis to the truck chassis
are not sufcient to contrast the side movement
of the counter-chassis compared to the truck
chassis; this movement may occur either when
driving the truck on the road or when working
with the crane.

The counter-chassis must therefore have some


side stoppers compared to the top wings of the
truck chassis; these stoppers must be welded
to the counter-chassis.

These stoppers are obviously superuous in a


zone that has been bracketed using a side plate,
but are indispensable when a tie-rod bracketing
system is used.

If the bracket system is used, simply apply some


on the chassis so that they hang over the top
edge or to the counter-chassis so that they hang
over the bottom edge and that the container
prevents the side movement between the two
elements.

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8.4 Securing the crane

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.

These blocking devices must be applied by welding them to the counter-chassis.

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.

1) Base with three brackets to secure the crane:

in alternative

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2) Base with four brackets for securing the crane with mobile equalisers:

This solution compromises


the integrity of the attach-
ment of the equaliser
to the crane base

3) Base with four brackets for securing the crane and with xed equaliser:

in alternative

NB: the effectiveness of these blocking


devices strongly depends on their distance
from the crane. You are recommended to
keep them as near as possible to the crane
during welding.

NB: Having completed the testing phase of


the crane, phase during which maximum
lifting movements are made, it may occur
that when the various structures installed
settle (counter-chassis, crane) the bracketing
tie-rods may work loose.

Check the tightness of the bracketing tie-rods and provide


a system that stops the nut from coming loose: the
most popular system is the application of a second
securing nut.

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NOTE: on some models of crane, or in the case of particular types of installation,


the point where the blocking devices should be welded may not be easily accessible
and therefore it is impossible to weld them on the counter-chassis.

There are two alternatives:


1) the blocking device that is not applied on the top side of the counter-chassis is welded under
the female cross piece of the crane, as aligned as possible with the position that it should
have had on the counter-chassis.
In this case, you are recommended to apply blocking devices with minimum section of 40
x 40 mm.

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.

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8.5 Fitting the outrigger cylinders on the crane and any vertical extensions
envisaged

Be very careful when handling the outrigger jacks.


In the case of small cranes, the jacks can be handled manually (they
weigh less than 30 kg), otherwise lift with caution using suitable
lifting equipment.

Read the use and maintenance manual of the crane where you will find the
instructions on the correct hydraulic handling of the outrigger jacks.

The outrigger jacks may be:

1- already fitted on the crane and positioned


vertically facing upwards.

Turn them downwards to make them operative. They


are secured with pins: it is up to the tter to make
sure that the securing system is always complete
with a safety device that stops the pin from slipping
out. There must always be a safety split pin or
automatic spring retaining device of the pin.

2- delivered in a pack together with the crane.

The jacks may be tted:


- with pins: make sure they are blocked by split pins
or ring nuts

- with screws: secure the screws using a dynamometric


spanner.

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Hydraulic connection of the outriggers

Some clips of two different colours


are tted on the exible hoses and on
the fittings on the valve of the jack.
Work with caution to avoid inverting the
connections. You would definitely damage
the outrigger jack if you should invert the
pipes.
If you have any doubts on the connections,
consult the “service manual” that includes
a chapter on the hydraulic connection of the
outrigger jacks.

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.

Table of tightening torque to be used to secure the jacks.

Key:

Diameter of Hexagon Allen Tightening torque A


screw headed screw screw
type A type B daN.m
M16 24 mm 14 mm 130
B
M18 27 mm 180
M24 36 mm 19 mm 450
M30 22 mm 500

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Deciding the extensions

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.

How to weld the plate supplied

To stabilise the truck correctly, the jack stem must have an


excursion under the ground of roughly 130 mm. The
tter must decide the correct length of the extension
with regard to the space that the plate will have from
the ground while the truck is driving on the road.
130 mm

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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.

Note: If there is a ball joint at the end of the stem, it is


absolutely forbidden to apply xed extensions under the
plate that rests on the ground.
Contact the manufacturer if you need to change the lengths
of the outrigger jacks that have a ball joint.

Housing of the outrigger jacks


The housing of the outrigger jacks at the side of the truck in a vertical position facing downwards
while the truck is driving on the road may require some modications to the truck itself.
We remind you that any modication to the truck, if of a certain
entity, can only be carried out if authorised to do so by the
truck manufacturer.
The tted is liable for damages or anomalies deriving from
having made unauthorised modications: the air suction
system or the discharge system can only be modified
following authorisation on behalf of the truck manufacturer.
You can however move units such as the fuel tank, the spare
wheel or the whole battery compartment, provided that their
operating efciency is not altered.

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8.6 Attachments/adjustments for feasible raised control station

The support of the raised controls of EFFER cranes


is adjustable in height. In this way there are no
problems of interference with the truck cabs, which
have different heights based on the brand and
on the type.
The above-mentioned support can be attached in
different positions compared to the minimum height
position.
The support is to be attached to the column using the
number of screws consigned.
To contain overall dimensions, the support of the
raised controls is delivered completely lowered; if
this position coincides with that desired, you must
check if the screws are tight before delivering the
crane to the customer.

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.

Metric Class Class Class


Thread 8.8 (8G) 10.9 (10K) 12.9 (12K)
Nm Nm Nm
M5 6 8 9
M6 9 14 16
M8 23 34 38
M10 45 67 78
M12 78 117 135
M14 126 184 216
M16 193 279 333
M18 270 387 459
M20 387 558 648
M22 522 747 873
M24 666 654 1116
M27 990 1395 1665
M30 1350 1890 2250
Tightening torques for screw-nut bolted attachments

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8.7 Manoeuvring station

There is always a manoeuvring station on the crane:


this may be at the bottom on one side, on the bottom
on two sides, or at the top on a platform for the
operator while standing or sat on a seat. These
units are manufactured in compliance with European
standards, but when the crane is installed on the
truck, the tter is requested to check/prepare access
to the manoeuvring station.

Here are the obligatory requirements of the manoeuvring


stations:

1- in the case of controls operated from the ground, the


height of these must be checked compared to the
ground so that they can be operated easily with an
exact view of the indications on the controls, of all
the indications exposed, including the load charts
of the crane.

2- It is a good rule for the crane controls to be arranged


at a maximum height off the ground of 1500 mm.

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.

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7- Rests or handles prepared MUST be rounded, smooth and


easy to get hold of.

8- Support surfaces for feet MUST be made with non-slip material


and steps must not be rounded: the step must be big enough
for both feet.

9- Handles or safety railings must be such to withstand a minimum


force of 100 kg even if applied in all possible directions.

10 - As for the minimum dimensions of steps, please consult the


illustrations given hereafter.

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 ---

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9 HYDRAULIC CONNECTIONS OF THE


CRANE

9.1 Choosing the components

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 efciency 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 coefcient 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.

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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.

min. 1000- 1200 mm.

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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.

9.2 Sizing the hosing

A) Oil in-take hosing

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 dene
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.

Maximum ow rate


17 30 45 65 120
Litres/minute
Hosing 3/4” 1” 1 1/4” 1 1/2” 2”
Inside diameter in mm 19 25 32 33 50

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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:

V= 0,5÷1 m/s (meters/second)

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.

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b) Oil delivery hosing

The exible hosing that connects the hydraulic system of the crane - in the specic 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 dene 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

Quantity of oil sent to


the crane by the pump

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c) Hoses for connecting additional outriggers

In the case of additional outriggers, it is up to


the tter to make the hydraulic connection
between the existent hydraulic system on
the outriggers and the hydraulic system of
the crane.
The outriggers are not operated constantly, plus
in cranes where the ow of oil to the control
distributor for the movement of the booms is
very high there are some valves that reduce
the quantity of oil to operate the outriggers. It
is useful to know this if you need to determine
the sizing of the supply hoses of the additional
outriggers, therefore touching the subject of
the real hydraulic system of the crane.

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.

Crane model series Diameter of Diameter of


lexible hose rigid hose
Up to 44 txm 3/8” 12x1.5
Over 44 txm 1⁄2” 16x2

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.

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9.3 Characteristics of the hydraulic oil

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.

The temperature of the oil must never exceed 80 °C: otherwise


all oils loose their main characteristics.
The hydraulic oil used in hydraulic systems of cranes must
have the following characteristics:
- it must be used within a temperature range of -20 °C +80°C,
based on the chosen viscosity value
- it must have a purity class of at least 18/14, subject to standard ISO 4406 (class 9 subject
to NAS 1638)
- it must provide ideal protection against rust and corrosion
- it must be a perfect coolant
- it must not emulsify easily in contact with air
- it must be compatible with the rubber of the gaskets and of the exible hoses
- its viscosity must not alter when the working temperature changes
- it must contain additives that retard its deterioration as far as possible in time
- it must have a contained formation of foam.

There are various types of hydraulic oil:


a) mineral oil: type of oil used by manufacturers during production, therefore inside the
hydraulic system of the crane when it is consigned. Oil easily available and suitable for
use in hydraulic cranes.
b) natural oil: biodegradable hydraulic oil that can be used in the crane system after having
eliminated the mineral oil present. This oil has a rather limited temperature range: the
choice is therefore very delicate based on the temperature of the environment in which
the crane works.
c) synthetic oil: this biodegradable oil is found more easily than natural oil but when choosing
the type to be used it is always important to pay utmost attention to the temperature of the
environment in which the crane works in relation to the maximum temperature reached while
the crane is in use. It cannot be mixed with mineral oil therefore the hydraulic system of the
crane MUST be completely emptied.

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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 classied 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 classied 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.

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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.

Volume = - 0.7 % with increase of 100 bar in pressure

Volume = +0.7 % with increase of 10° C in temperature

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 difculties encountered in connecting the quick-release
couplings of a hydraulic device after it has been left in the sun.

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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 qualied 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:

24 Volt = 22-28 Volt 12 Volt = 11-14 Volt

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.

Checking the correct voltage


Using an oscilloscope, check for any voltage peaks when the truck is started to avoid faults in the
electrical parts. The peak is caused by the abnormal operation of the alternator.
Using the tester, check the voltage of the electrical system of the actual truck; the value must
not exceed the admitted values.

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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 inltrations.

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 5 meters = same cross section as crane.

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 inltrations: the recommended waterproong
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.

How to identify the poles:


Positive cable: there is a mobile fuse on the cable or
the cable is marked with a symbol “+”.

Negative cable: the cable does not have a fuse or is


marked with the symbol “-”.

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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 --

The heat exchanger is to be connected independently to the batteries of the


truck.
It is absolutely forbidden to t fuses with lower or higher ampere ratings compared
to those envisaged by EFFER.

Main ON/OFF switch


All cranes have a main ON-OFF switch that is used to switch the whole electrical system
of the crane on and off.
If a customer/user requests it, the electrical system of the crane can be activated when the
power take-off is engaged.
This system envisages the installation of a relay that powers the crane only when it is activated
by a positive signal sent from the manual control of the power take-off. The contact of the relay
must be sized to provide the total ampere rating requested by the crane; between the relay and
the batteries of the truck you must install a single fuse that must have the same ampere rating
as the sum of the ampere ratings of the fuses installed originally.
Here’s the diagram related to this type of application:

Fuse
Relay Voltage picked-up
for crane
87A 87
Fuse 86 85
Electrical system 30
of truck

Connection of
negative
cable for crane

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Picking- up the voltage from the batteries:

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
congurations 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.

Electrical system of truck


Fuse
Voltage picked-up for crane
Connection of negative cable for crane

Original circuit breaker on truck

Electrical system of truck


Fusibile
Voltage picked-up for crane
Connection of negative cable for crane

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.

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11 ADDITIONAL OUTRIGGERS

11.1. Fitting “feasible” additional outriggers

To rig-out perfectly it is extremely important to mechanically install the additional outriggers


correctly. It is the additional outriggers that make the truck stable while the crane is working, in
other words they contrast the tipping torque produced by the crane while it lifts a load.

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.

The additional outriggers can be installed in two different ways:

1- inserted in the especially built counter-chassis: in this case, they are connected to the same
by welding and reinforcement brackets.

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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.

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11.2 FREE SPACE UNDER THE OUTRIGGER JACK

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

There are different types of height adjustments:

1) Position the jack at the desired height, apply


the stop ring so that it coincides with a foreseen
position, block the jack with some nuts to
prevent it from rotating inside the attachment
tube and weld the bottom ring that prevents
the jack from running vertically inside the
attachment tube.

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2) The outrigger jack is held in the desired position by a clamp, the


inner surface of which is grooved to wedge into the outrigger
jack.
The clamp has a screw, which is screwed to block the outrigger
jack in the desired position.

The clamp is to be tightened to block the outrigger jack using a


dynamometric spanner.
Clean the screw and the thread on the collar thoroughly before
tightening.

We are providing the tightening torque to be used based on the


different outside diameters of the outrigger cylinders.

Cylinder diameter Type of screw Tightening torque


(mm) (material type 12.9/12K) (dan/m) Nm
70 M 12 12 120
80 M 14 20 200
95 M 16 30 300

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:

a) manually tighten the screw that blocks the clamp

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.

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12 INSTALLING AND COMMISSIONING


SOME ACCESSORIES

12.1 Additional hydraulic y-jib

The additional hydraulic y-jib is delivered separately,


in other words it is not installed on the crane.
During in-house testing, the additional y-jib is
installed on the crane and is put through another
test, which involves various movements amongst
which also its efciency in folding back down.
The tter shall t the jib at the end of the hydraulic extensions of the crane and
must make sure that the jib opens out and closes back down correctly and also
that the jib and the hydraulic hoses to do not interfere with anything on the truck
or the truck board built on the chassis.

Make sure that the quick-release couplings are all


marked differently to avoid possible mistakes: we
are listing the colours applied by the manufacturer.
The jacks would bulge if the quick-release couplings
are inverted.

- 1 red clip = jib jack stem outlet


- 2 red clips = jib jack stem back-in
- 1 green clip = jib extensions jack stems outlet
- 2 green clips = jib extensions jack stems back-in
- 1 blue clip = winch cable up
- 2 blue clips = winch cable down

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 difcult to insert
the quick-release couplings.

It is important to inform the user on the instructions given above. Often when
the user has difculty 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!!!!!

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In hydraulic jibs combined with cranes with electro-hydraulic load restrictor, to be able to connect
and disconnect the quick-release couplings without difculty, you need to strictly observe a
certain procedure, otherwise the job will be almost impossible.

Here’s the procedure:

NB: there is a cock on these cranes on the jib jack,


which is operated using a handle.

This handle is to positioned parallel with the jack while


the crane is working and when it is left parked.

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.

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Disassembly:

- Rest the jib on at and solid ground.

- Take the securing pins out and then release


the jib by retracting the extensions of the
base crane.

- Using the jib lever, open/close it to position the


shank parallel with the jib.

- Disengage the hydraulic pump.

- Eliminate the residue pressure from the hydraulic


circuit of the jib jack by opening and closing
the cock again using the red handle on the
jack itself.

- Using the jib lever, open/close it.

- Disconnect the quick-release couplings, remem-


bering to protect them with the plastic caps
supplied.

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12.2 Mechanical extensions

There are no particular instructions involved for


the presence of mechanical extensions.
The only aspect that you are requested to
check when the crane is delivered to the end
customer is that all the plug-in pins are present
with their split pins to block the extensions
in the open and closed position and also on
the crane itself.
The material required to block the units as
explained above are supplied standard.

12.3 Winch

The crane may be equipped with a winch for lifting


loads. You need rather detailed instructions
to be able to use this accessory, otherwise
you could break either the cable or other
mechanical components. The fitter shall
instruct the customer/user appropriately. You
must carry out practical tests during which
you will explain how the cable is supposed
to run, together with the electrical connection
and how the automatic limit switches of the
cable work.

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.

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12.4 Radio controller

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 specic 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.

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13 RUNNING-IN THE CRANE


A phase that is not to be underestimated and that is to be carried out by the tter is that of
running-in the crane. All mechanical components need to be run-in so that the contact surfaces
adapt to each other without seizures.

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.

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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.

14.1 STATIC TEST


Point 6.2 of the standard: TESTS AND TEST PROCEDURES

6.2.5.2 The purpose of the test is to check the stability


of the truck crane fitted on an unloaded
vehicle. While the test is carried out, one or
more outrigger jacks or one wheel may leave
the ground. However, at least one of the
wheels blocked with handbrake must remain
in contact with the ground. The test load is
to be lifted with the vehicle unloaded and
without operator.

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 conguration 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.

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Before you apply the load related to the sta-


bility test, the crane must be positioned in
the maximum performance conguration:
the rst boom section must tilt upwards by
the amount stated in the load charts and
the other boom sections and extensions
must be horizontal.

The crane must be positioned with the lifting


hook that coincides with the distance
at which the test is to be carried out.
The load is to be put on the crane hook
statically using other lifting equipment and
must be held just a few meters off the ground.

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.

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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:

- crane with additional outriggers - crane without additional outriggers


Tipping a

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.

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1) Crane installed behind the cab with additional outriggers:

1.1 crane boom in sector A: during the test:


- one rear outrigger jack may leave the ground
- none of the rear wheels must leave the ground

1.2 crane boom in sector B: during the test


- 2 outrigger jacks at the most may leave the ground
- the wheels of the truck near the outrigger jacks that leave the ground may rise - on the
same side.

1.3 crane boom in sector C: during the test


- the 2 front outrigger jacks may leave the ground
- all front wheels may leave the ground: in the case of truck with two front axles, all the
wheels tted on the two axles.
- in the case of trucks with two rear axles, just one axle may leave the ground if the one remaining
on the ground is equipped with a parking brake.

B B

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2) Crane installed behind the truck board with additional outriggers:

2.1 crane boom in sector A: during the test


- one of the two rear outrigger jacks may leave the ground
- in the case of trucks with double rear axle, the axle further back may leave the ground.
- in the case of trucks with single rear axle, one rear wheel may leave the ground.

2.2 crane boom in sector B: during the test


- one of the two rear outrigger jacks may leave the ground
- the wheels of the truck positioned near the outrigger jack that leaves the ground may also
leave the ground - on the same side.

2.3 crane boom in sector C: during the test


- the front outriggers may leave the ground.
- all front wheels may leave the ground; in the case of trucks with two front axles, all the
wheels on the two axles.
- in the case of trucks with two rear axles, just one axle may leave the ground only if the one that
remains on the ground is equipped with parking brake.

B B

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3) Crane installed behind the cab without additional outriggers:

3.1 crane boom in sector A: during the test


- none of the rear wheels must leave the ground

3.2 crane boom in sector B: during the test


- one outrigger may leave the ground
- all the wheels of the truck on the opposite side of the crane boom position may leave
the ground.

3.3 crane boom in sector C: during the test


- all front wheels may leave the ground; in the case of trucks with two front axles, all the
wheels on the two axles.
- one outrigger may leave the ground.

B B

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4) Crane installed behind the truck board without additional outriggers:

4.1 crane boom in sector A: during the test


- one of the two rear outriggers may leave the ground
- in the case of trucks with double rear axle, the axle further back may leave the ground.
- in the case of trucks with single rear axle, one rear wheel may leave the ground.

4.2 crane boom in sector B: during the test


- one crane outrigger may leave the ground
- the wheels of the truck near the outrigger that leaves the ground may also leave the ground
- on the same side.

4.3 crane boom in sector C: during the A


test
- all front wheels may leave the ground; in
the case of trucks with two front axles, B B
all the wheels of the two axles.
- in the case of trucks with two rear axles,
one axle may leave the ground only if
the one that remains on the ground is
equipped with parking brake.

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 ofce can provide you with the
instructions needed based on the specific
model of crane.

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14.2 Dynamic test

The dynamic test is to be carried out after the


static test.

During these tests, the load to be applied is


that indicated in the load charts plus 10%;
movements in the whole operating area of the
crane are to be carried out at normal working
speed conditions of the crane, especially in
congurations such to subject the installation
to maximum strain conditions, including
starting and stopping movements.

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 ofce is at your disposal if
you should have difculties in disabling the load restrictor during the dynamic test.

The test is considered to be passed successfully if no structural damages are enhanced.

The crane hook gives way


The expectations of many customers is that of having a crane that does not move for hours from
the point in which it is left, both when empty and when loaded.
EFFER has been using top quality hydraulic components for years to reduce the possibility
of the crane hook giving way.
Some hydraulic components, due indeed to their technical nature, envisage a slight ow of oil
that stops the hook from remaining perfectly still in time.
Standard EN 12999, in point 5.5.7, allows a maximum unintentional lowering movement
of the load equal to 0.5 % of the crane boom extension per minute with the maximum
rated load applied.

5.5.7 Lowering speed of the boom unit.


The lowering speed measured on the tip of the boom caused by a leak in the hydraulic components
must not be greater than 0.5 % of the boom extension per minute.

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.

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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:
- modication 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 dened 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:

Cranes with EC marking:


- new EC certicate that includes the equipment purchased
- new adhesive load chart plates, if necessary
- just for Italy: new certicate of origin but only if the modication requested envisages a variation
to the number of hydraulic extensions.

Cranes without EC marking:


- new declaration of the manufacturer
- new adhesive load chart plates, if necessary.

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.

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Making the conversion


To make the conversion job easier, some technical documents are also supplied that include
instructions, drawings, mechanical specications etc. based on the complexity of the work
to be carried out.
Information concerning possible modications to hydraulic settings and the hydraulic diagrams of
the crane can obviously be consulted on the internet site: www.effer.it.

Modication of electronic calibration values DMU (if the


conversion requests so)
1- The new parameters to be added to the program that is already
in your possession will be forwarded to you by E-mail or you
will be given the program on computerised support.

2- Send the DMU system to our company for the update.

Responsibilities
The workshop that converts a crane is responsible for all the work done: the After Sales
ofce 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 justications for any work carried out incorrectly
if the instructions supplied by the manufacturer are not
observed.

Technical folder / Operator manual


The workshop that carries out the conversion work shall:
- update the technical folder in his own files if the original
installation was carried out by the same.
- write and keep the technical folder related to just the conversion in his les.
- update the use and maintenance manual that was supplied with the crane.
- write a document that states that the customer/user has been informed on how to use
the modied crane.

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Manuale installatore

16 CRANE CONSIGNMENT TO THE CUSTOMER/USER

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 specic crane: it is however up to the tter
to certicate 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 certicate. We remind you that the vendor shall full 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 certicate, duly lled-in in all parts is received
beforehand: no request under guarantee will be taken into consideration if the guarantee
certicate 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 sufcient 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.

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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 satised; for this
purpose we are providing a list of what we consider to be:

the 10 rules to follow to ensure customer/user satisfaction

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 efcient 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.

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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.

For your customer’s interest: it enables him to check the


effective operating capacity of the crane straight away.

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.

For your customer’s interest: it enables him to work in total


safety right from the start, saving any mistakes that could be very
dangerous and expensive.

5 MAKE SURE THE OPERATOR MANUAL IS HANDED OVER; IT IS INDISPENSABLE TO


MAKE THE OPERATOR HIMSELF RESPONSIBLE FOR USING THE CRANE.
For your own interest: you will be certain that the operator will
always know how to use the crane in the best and safest way
possible, exploiting its full operating potentials.

For your customer’s interest: it enables him to work in total


safety right from the start, both for himself and for anyone
else nearby.

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Fitter’s manual

6 INFORM THE OPERATOR ON THE IMPORTANCE OF READING THE USE AND


MAINTENANCE MANUAL THOROUGHLY.
For your own interest: you will be certain that the operator will
always find the answer to his doubts in a document that he can
always consult.

For your customer’s interest: it enables him always to have solutions


to unusual operating situations ready at hand.

7 INFORM THE OPERATOR ON THE IMPORTANCE OF CRANE MAINTENANCE, ESPE-


CIALLY WITH REGARD TO THE REPLACEMENT OF FILTER CARTRIDGES AND
GREASING.
For your own interest:you will be certain that the operator
keeps the machine that he will use daily in an efcient
and safe state at all times and will constantly check
its state of use.
For your customer’s interest: it enables him to keep
the machine fully efficient, avoiding stoppages for
maintenance, or at least being able to plan them in
advance.

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.

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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 has a reliable machine and he knows


exactly how it works.

10 MAKE SURE THE CUSTOMER IS SATISFIED WITH WHAT HE HAS PURCHASED:


CONTACT HIM AFTER HE HAS USED THE CRANE FOR A FEW WEEKS AND DO
WHATEVER IS NECESSARY TO RESOLVE ANY PROBLEMS THAT HE MAY HAVE
ENCOUNTERED WHEN USING THE CRANE.
For your own interest: you will be certain that the customer is
really satisfied with the crane, which simplifies your work the
next time that he or his colleagues wish to purchase a crane
manufactured by EFFER.

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.

The manufacturer HOLDS THE DEALER RESPONSIBLE IF ANY PROBLEMS OR INCON-


VENIENCES SHOULD ARISE DERIVING FROM THE FAILED OBSERVANCE OF THE 10
POINTS JUST MENTIONED:
“WHAT’S BETTER PUBLICITY THAN A SATISFIED OPERATOR!”,
LET’S NOT WASTE THIS OPPORTUNITY !

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Fitter’s manual

17 CONVERSION TABLE OF UNITS OF


MEASUREMENT
This table is to be used to have an immediate comparison between
a known value and other more common and useful units of
measurement.

Parameter Unit of measurement Symbol Multiplication Parameter obtained


factor

Length meter m 3,28084 foot (‘)


millimetre mm 0,03937 inch (“)
meter m 1,09361 yard (yd)
3 3
Volume cubic decimetre dm 0,03531 cubic foot (cu. ft )

Pressure bar bar 100 kPa

Weight kilogram kg 2,2046 pound (lb)


3
Flow rate cubic centimetres per second cm /s 0,01319 g.p.m.

Torque kilogram force per meter kgf·m 7,233 ft.lbs


kilogram force per meter kgf·m 9,80665 Nm
kilogram force per meter kgf·m 0,980665 dan/m

Power kilowatt kW 1,34102 HP


Hourly steam horsepower CV 0,9863 HP

Kinematic viscosity - m2/s 1/ 106 cSt (centistokes)


- cSt 106 m2/s

Temperature degrees centigrade °C °C =(°F-32)·5/9 °F (Fahreneit)

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

Service Manual Rev. 2 07-2008 GB

THE POWER OF PERFORMANCE


Technical operations A2


THE POWER OF PERFORMANCE
Technical operations A2

1 - Tightening torque of the mechanical


components
“Important” structural elements, such as for instance::
- GEARMOTORS
- SLEWING RING
- SLEWING COLUMN
- SLEWING CYLINDERS
- STABILISER CYLINDERS
- WINCHES
should be fitted using a dynamometric key: otherwise you
may run the risk that the screw unlooses or, even worse, that
it breaks.

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 reuse of screws cleaned by corrosion using a metal brush strongly


affect crane safety .


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.

a) Determining the extent of the mechanical clearance on


cranes with slewing through pinion/rack
To determine the extent of the mechanical clearance on a crane pinion/rack 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 column that is easily accessible for visual inspection and next to the crane base, place two
strips of adhesive tape (if possible, paper) one on the column and other one on the 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.

Fig.1


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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

The design shown in Fig. 2 shows the explanation above.

Fig. 2

Bronzina premicremagliera
Rack-pressing bronze bearing
ViteAdjusting
di regolazione
screw


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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.

The position of cuts must be opposite to the slewing ring teeth.

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.

6) Tighten the 7 securing nuts (ref.


����������������������������������������������������
B) first
�������������������������������������������
and only after the 3 dowels (ref.
���������
C)�.

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.

There can be a maximum clearance of 0.5-mm on


the connection points of the extension cylinders.

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
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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

Plastic support: EFFER part # 8898477 Pipe clamp:

EFFER part # 8601000 from ø 24 to ø 36


EFFER part # 8601100 from ø 32 to ø 52
EFFER part # 8601500 from ø 47 to ø 67
EFFER part # 8601700 from ø 68 to ø 82
EFFER part # 8601800 from ø 77 to ø 97
EFFER part # 8604005 from ø 92 to ø 112
EFFER part # 8604006 from ø 107 to ø 127
EFFER part # 8604011 from ø 137 to ø 157
EFFER part # 8602900 from ø 248 to ø 263

When servicing the crane, check the presence of the plastic supports.

23
THE POWER OF PERFORMANCE
Technical operations A2

The plastic support can be fitted in two different positions:

Pipes with diameter 8 ÷ 12 Pipes with diameter 16 ÷ 20

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

Canvas sheath (to keep flex hoses together)

EFFER part # 8625567 width 65mm (1m)


EFFER part # 8625568 width 90mm (1m)
EFFER part # 8625569 width 150mm (1m)

EFFER part # 8625576 (4 items)

EFFER part # 8602250 L=260


EFFER part # 8602350 L=355

Operation steps:

2
25
THE POWER OF PERFORMANCE
Technical operations A2
Plastic sheath
Plastic sheath protects flex hoses against dangerous rubbing.

Each sheath protects one flex hose.

EFFER part # 9394702 (1 m)

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.

Rod side chamber


Bottom side
chamber

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.

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The same pressure value, inside the two rooms, acts however on two different areas:

area “ A ” which is on the bottom side - BOTTOM SIDE THRUST AREA -


area “ A1 ” which is on the rod side - ROD SIDE THRUST AREA –

According to the formula F = P x A (Force = pressure X Area), you will have that inside the same cylinder two

different forces will act at the same time “ F ” and “ F1 ” .

bottom rod side


fondello stelo
A A1

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.

How to identify the cylinder 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 .

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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.

u The result of this test shows as follows:


- The extensions connected to cylinders tested are in their original position: The problem is not in
the extension cylinder unit tested, the trouble is to be searched in the series of cylinders previously
insulated.
- The extensions connected to cylinders tested have come out only by a few centimetres: It is one
of the extension cylinders, that was tested hydraulically, which has inner seals that are damaged.

- 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.

Below is a hydraulic diagram concerning eight extension cylinders.

Here is a summary of the procedure above:

- leave only 1st, 2nd, 3rd, 4th extension cylinders connected hydraulically.

First hypothesis: Exit of extensions still occurs.

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.

Second hypothesis: Exit of extensions does not occur.

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.

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Ideal
Linea line ofdidivision
ideale of a hydraulic
suddivisione del circuito
circuit
idraulico onsfili
sugli extensions

Fig.3

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Technical operations A2

7 - Visual check - Structural Intactness


u The structural part of a crane is subject to wear, or better,
to ageing.

Such wear or ageing are proportional to the amount of work


that the crane has carried out, and also to the way it has worked:
it is obvious that a daily work at maximum performances will
require extraordinary maintenance a lot more in advance than
a discontinuous and light work.

That is why it is essential to recommend making visual checks


on the structural part of the crane, at the beginning, even every
six months only, then, with the passing of time, at increasingly
closer intervals.

u To carry out these checks in the best possible way, do as


follows:
√ Wash all the structure of the crane very carefully
√ Wait for the crane to dry out outdoors (one day is advisa-
ble)
√ Check visually that all the welds on the crane are intact
√ Check visually that the structural part next to the welds is
intact

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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.

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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.

Rod classification (type full): en 12534/g69 4 m Mn 3 Ni1Cr Mo


Aws a5.28 er 100s-1
Recommended rods diameters: 1 - 1,2 mm.
Gas classification: EN 439 TIPO m21
- Argon (85% - 75%) + co2 (15% - 25%)
- Elio (85% - 75%) + co2 (15% - 25%)
Quantity of gas adjusted to the exit from the gay cylinder:
12 lt/min in closed environment
18 it/min in open air

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).

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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.

Rod classification (Type full): en 440 g46 4mg4si1


Aws a5.18 er 70s
Recommended rods diameters: 1 - 1,2 mm.
Gas classification:: EN 439 TIPO m21
- Argon (85% - 75%) + co2 (15% - 25%)
- Elio (85% - 75%) + co2 (15% - 25%)
QQuantity of gas adjusted to the exit from the gas cylinder:
12 lt/min in closed environment
18 it/min in open air

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).

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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.

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THE POWER OF PERFORMANCE
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