outrigger stabilizers - bigmax by · pdf fileby technocrane outrigger stabilizers...

by TECHNOCRANE

OUTRIGGER STABILIZERSINSTALLATION, USE AND MAINTENANCE MANUAL

Technocrane Inc.4165 Packalen Blvd., Garden Bay, BC Canada V0N 1S1

Offi ce: 604-575-2103 | Toll free: 877-531-8644 | Fax: 604-648-9852 | [email protected]

www.bigmaxcranes.com

BIGMAX by Technocrane Outriggers and Stabilizers | 2

INTRODUCTORY NOTE 3

1 MAIN FEATURES OF BIGMAX STABILIZERS 4

1.1 IDENTIFICATION AND EC MARKING 4

1.2 GENERAL DESCRIPTION AND USE 4

1.3 MAIN COMPONENTS 5

2 SAFETY 7

2.1 GENERAL INSTRUCTIONS 7

2.2 SAFETY DEVICES 7

3 USE OF STABILIZERS 8

3.1 HANDLING 8

3.2 WEIGHTS AND DIMENSIONS 9

3.3 INSTALLATION 10

3.4 HYDRAULIC CONNECTION 12

3.5 OPERATING INSTRUCTIONS 13

4 MAINTENANCE OF BIGMAX STABILIZERS 14

4.1 MAINTENANCE 14

4.2 TECHNICAL ASSISTANCE 14

5 MAXIMUM REACTION CALCULATION 15

TABLE OF CONTENTS

Outriggers and Stabilizers | 3BIGMAX by Technocrane

This handbook contains instructions for the installation, use, handling and maintenance of BIGMAX stabilizers.

The information given in this manual is to be used for reference only. The manufacturer is entitled to bring modifi cations to its products and to this handbook at any time without giving prior notice and without the obligation to revise previous editions.

This manual is the property of TECHNOCRANE INC. Consequently, its reproduction and communication to third parties, even partly and through any whatsoever mechanical and/or electronic means, is prohibited without obtaining written consent.

The manufacturer is released from responsibility under the following circumstances:

INTRODUCTORY NOTE

USER AND MANUFACTURER’S LIABILITY

WARNING!

THE INSTALLER AND USER ARE REQUIRED TO FOLLOW THE INSTRUCTIONS IN THIS MANUAL. FAILURE TO DO SO WILL RELIEVE THE SUPPLIER FROM ALL RESPONSIBILITY INCLUDING INJURY TO PERSONNEL AND DAMAGE TO EQUIPMENT AND PROPERTY.

• Installation of stabilizers not suitable to the type of crane mounted and/or to the mounting position.

• Incorrect mounting of crossbeams (installation error).

• Improper use of additional stabilizers or usage error by personnel not specifi cally familiar with their use and possible risks deriving therefrom.

• Failure to perform recommended maintenance.

• Any changes and/or modifi cations whatsoever, carried out by unskilled labour and/or without the manufacturer’s prior consent.

• Use of unsuitable and/or non original spare parts.


An identifying plate (see fi g 1) permanently attached to the left or right side of each stabilizer beam shows the following information:

Identifying data of the stabilizer and manufacturer

Main technical data of the stabilizer

EC marking of the crossbeam if applicable

BIGMAX stabilizers are intended for use as the main stabilizers for smaller corner mounted cranes or specialty equipment that requires stabilizers to operate safely and eff ectively.

BIGMAX stabilizers can also be used as auxiliary stabilizers on vehicles already equipped with cranes or other equipment to supplement the main stabilizer if that vehicle does not meet stability requirements.

In case of damage to the identifying plate, a duplicate must be requested from the manufacturer, who will supply an identical plate upon return of the original one.

1 MAIN FEATURES OF BIGMAX STABILIZERS

1.1 IDENTIFICATION AND EC MARKING

1.2 GENERAL DESCRIPTION AND USE

WARNING!

THE PLATE IS TO BE KEPT ALWAYS CLEARLY READABLE AND NEVER TO BE REMOVED FROM STABILIZERS.

WARNING!

THE INSTALLATION OF BIGMAX STABILIZERS AS MAIN STABILIZERS FOR CRANES OR FOR SIMILAR USES REQUIRES ACCURATE PLANNING AND CHECKS OF THE WHOLE SYSTEM, TO BE CARRIED OUT BY THE CRANE INSTALLER, WHO TAKES COMPLETE RESPONSIBILITY FOR THE INSTALLATION.

Fig. 1


1.3 MAIN COMPONENTS

Fig. 2

Type E

CR Version

Optional PDA

CGR Version

Standard Version

Optional PRS


Fig. 3 – LIST OF COMPONENTS

Num Description

1 Bearing crossbeam

2 Extending beams

3 Hydraulic stabilizing cylinder

4 Footplate

5 Safety lock valve

6 Hydraulic lateral (side) extension cylinder

7 Safety lock pin

8 Rigid connecting pipes

9 Cylinder fastener (only CR version)

10 Screws/nuts to cylinder fastener (only CR version)

11 Supplementary positioning rings to cylinder fastener (only CR version)

12 Tilting block (only CGR version)

13 Leg lock-pin (only CGR version)

14 Stabilizer pads (optional)

15 Leg extension (optional)

16 Identifi cation plate


• Stay out of the working range of the crane and vehicle equipped with stabilizers, maintaining a minimum safe distance.

• Stabilizers may only be operated by skilled personnel duly instructed in their operation, and in the operation of crane and vehicle on which they are mounted.

• Ensure that the vehicle is safely braked; if necessary, blocked with wheel chocks or blocks.

• Pay careful attention while extending beams and lowering cylinders to avoid crushing danger.

• Stabilizers increase the stability of the vehicle while operating the crane only if helped by the support of the wheels of the vehicle itself. NEVER LIFT THE TRUCK WHEELS OFF THE GROUND USING THE STABILIZER CYLINDERS.

• ALWAYS USE STABILIZERS WITH BEAM(S) FULLY EXTENDED, to ensure maximum vehicle stability.

• Check the maintenance handbooks of both the crane and vehicle carefully to ensure full knowledge of required safety measures.

• Installation, service and repair operation of the stabilizers must only be carried out by skilled personnel duly trained in mechanical and hydraulic fi elds.

1. SAFETY LOCK VALVES (see Fig 3); all BIGMAX stabilizers are equipped with lock valves to prevent sudden loss of vehicle stability due to cylinder leak or hose failure.

a) Pilot operated lock valves with manual release. (Code M)ORb) Pilot operated lock valves with hydraulic release. (Code P)

2. SAFETY LOCK PINS (see Fig.3): two safety lock pins prevent the accidental sliding of extending beams, by locking them in a fully closed position during transport or fully open while working. These pins, compulsory on crossbeams with manual extensions are also available on crossbeams with hydraulic extensions.

3. LEG LOCK PIN (see Fig.3): locks the cylinders in the required position; available only on stabilizers equipped with tilting legs (CGR version).

The operating safety of stabilizers is linked to the eff ectiveness of the safety devices of the vehicle on which they are mounted. The vehicle is required to be equipped with visual and acoustic devices to warn about crane and stabilizer operation.

2 SAFETY

2.1 GENERAL INSTRUCTIONS

2.2 SAFETY DEVICES

WARNING!

IT IS STRICTLY FORBIDDEN TO TAMPER WITH SAFETY DEVICES, TO REMOVE THEM, OR TO ADJUST THE STABILIZER LEGS WHILE WORKING.

It is the responsibility of the installer to test the stability of the assembled vehicle in accordance with procedures required by local laws and safety organizations, and if necessary to provide the crane owner with updated load diagrams showing new lifting capacities.


BIGMAX stabilizers are delivered secured to wooden pallets. Lifting and handling of stabilizers on pallets can be done by forklift or with chains/ropes and a crane with suitable lifting capacity; pay attention to balancing the load while lifting.

Stabilizers no longer on pallets should be handled using slings as shown in fi g 4, keeping them equidistant from the centre of the crossbeam. Refer to the table of stabilizer weights on the following pages to determine the capacity of handling and lifting gear.

3 USE OF STABILIZERS

3.1 HANDLING

WARNING!

CARRIAGE AND HANDLING OF CROSSBEAMS MUST ONLY BE PERFORMED USING SUITABLE GEAR FOR THE LOAD TO BE LIFTED.

IT IS STRICTLY PROHIBITED TO HANDLE THE LOAD OVER PEOPLE OR WORK SPACES.

Fig. 4


3.2 GENERAL WEIGHTS AND DIMENSIONS OF STABILIZERS

WEIGHTS (Kg)* DIMENSIONS (mm)*

MODELS CONSTRUCTIVE SERIES L B H

0A 0 1 2 3 4 5 6 MIN MAX MIN MAX MIN MAX

FIX

ED

OU

TRIG

GER

S TD-F/C - - - 170 - - - - 2300 100 700

TD-F/S 65 85 125 185 - - - - 1960 2300 80 100 530 780

TD-F/L - - 130 190 - - - - 2160 2300 100 100 810 865

OU

TRIG

GER

S W

ITH

O

PPO

SED

RO

DS

TD-EML/C - - - 240 - - - - 2300 120 700

TD-EML/S 95 125 190 245 - - - - 1960 2300 80 120 530 780

TD-EML/L - - 195 250 - - - - 2260 2300 100 120 810 865

TD-EHL/C - - - 260 - - - - 2300 120 700

TD-EHL/S - - 210 265 - - - - 2260 2300 100 120 685 780

TD-EHL/L - - 215 270 - - - - 2260 2300 100 120 810 865

OU

TRIG

GER

S W

ITH

PA

RALL

EL R

OD

S

TD-EMP/C - - - 340 - - - - 2300 235 700

TD-EMP/S - - 300 350 - - - - 2260 2300 200 235 685 780

TD-EMP/L - - 305 355 - - - - 2260 2300 200 235 810 865

TD-EHP/C - - - 380 435 530 665 - 2300 2400 235 280 700 820

TD-EHP/S - - 340 390 445 545 - - 2260 2400 200 235 685 960

TD-EHP/L - - 345 395 460 - 675 - 2260 2400 200 280 810 970

TD-EHPL/C

- - - - - - 805 1065 2550 320 340 820 820

TD-EHPL/L

- - - - - - 815 1075 2550 320 340 815 970

* Data has to be considered approximate.


The installation of stabilizers can be done in two ways; over or under the chassis of the vehicle. The choice should take into account the height of the chassis from the ground, the dimensions of the stabilizer and of the other equipment already mounted on the vehicle, and the height of stabilizing cylinders.

The presence of additional stabilizers on the vehicle may require the need to strengthen the chassis by adding a subframe. Check with the vehicle manufacturer for further information about required modifi cations.

The crossbeam can be welded at the end of the subframe (see fi g.5), or in between by crossing it through a slot in the subframe (see fi g.6). The assembly formed by the stabilizer

and subframe should then be fi xed to the chassis of the vehicle by proper braces and plates to be welded to the subframe and bolted to the chassis.

3.3 INSTALLATION

Installation over chassis

WARNING!

THE INSTALLATION OF THE STABILIZERS MUST BE CARRIED OUT BY SKILLED PERSONNEL, DULY TRAINED IN MECHANICAL AND HYDRAULIC FIELDS.

Fig. 5

Fig. 6


The beam can be attached, always using brackets, plates and counter-plates, to the chassis alone, or to both the chassis and subframe (see fi g. 7 – 8). Bearings should ensure the lateral support of the stabilizer, keeping the axis of

the cylinders perpendicular to the chassis. It is also very important to position the plates and counter-plates to hold the stabilizer completely in contact with the chassis, without any clearance.

The single fi xed leg is typically used as a front stabilizer. Reinforcement must be added between the frame rails at the front of the chassis, in order to create a strong secure vertical location where the mounting bracket can be installed. The supporting location must have a fl at surface which is larger than the dimensions of mounting bracket (AxB, below).

As a fi rst step in planning the installation, calculate the load on the front stabilizer using the “MAXIMUM REACTION CALCULATION”, and with this information contact the truck manufacturer for advice on how to reinforce the chassis.

For instructions on how to attach the cylinder to mounting bracket, see the next page section “INSTALLATION OF “CR” VERSION STABILIZERS.”

Installation under chassis

Fixed leg installation

Fig. 7

Fig. 8


The “CR” version stabilizers allows the height of the stabilizing cylinders to be changed according to the chassis of the vehicle. This is particularly useful when the height of the chassis is unknown or the stabilizer has been purchased for stock.

The modifi cation of the height of the cylinder can be made through few simple operations (see fi g.9):

1. Support the stabilizer securely on stands.

2. Disconnect the hoses (pos. A) feeding the stabilizing cylinder.

3. While holding the cylinder securely, unscrew bolts and nuts (pos. B), then remove the cylinder fasteners (pos. C).

4. Reposition the cylinder to the chosen height by inserting two of the positioning rings (pos. D) into their seats in the support bracket (pos. E).

5. Reinstall and secure the cylinder fasteners.

6. Reattach the hoses and tighten fi ttings.

“CR” version installation

BIGMAX supplementary stabilizers are delivered with their hydraulic system (ie. safety valves, rigid and fl exible pipes, couplings) already installed.

Connect oil supply lines as follows.

i) For stabilizers equipped with external tubes (fi g 10.1) connect the oil supply line to the rigid oil line.

ii) For in-line stabilizers with hydraulic lateral extensions (fi g 10.2) connect oil supply lines through hexagonal stud fi ttings.

Select appropriately sized hoses when installing stabilizers to avoid system back pressure that could cause a malfunctions of the stabilizer.

It is strongly recommended to use a control valve equipped with pressure relief valves set between 80 and 100 bar to avoid damage from accidental movement. For

example, operating the extension beams while the safety lock-pin is engaged can cause damage (see paragraph 2.2). Also, lowering the stabilizers too far and raising of the vehicle will reduce stability.

In addition, the control valve for the outrigger stabilizer should be installed in its own hydraulic circuit and/or separated from the main crane control valve by a selector or similar valve. This is especially important for stabilizers with hydraulic (pilot operated) lock valves as it reduces the possibility of accidental activation of the stabilizers.

It is up to the body builder to correctly modify the original hydraulic schematic in accordance with the directions of this manual and also add related notations to the maintenance handbooks of both crane and vehicle.

Furthermore it is very important to check all controls for correct functioning and test the vehicle carefully before using the crane.

3.4 HYDRAULIC CONNECTION

Fig. 10.1

Fig. 10.2

Fig. 9


Before operating stabilizers, make sure that bystanders move out of the working range of the crane, following all safety instructions indicated in paragraph 2.1.

Use of stabilizers:

1. Make sure that the vehicle is safely braked; if necessary, block it with wheel chocks or wedges.

2. Unlock safety lock pins by pulling the handle externally and turning it upwards of 180°, up to pos.2 (see fi g.11).

3. Pull out the extending beams, one by one, starting from the one on the control side; extend the arm (manual or hydraulic) for about 30 cm (about 12”), then rotate the safety lock pin back to pos.1 (see fi g.11); pull the arm out until the yellow line indicating stop appears (see fi g.12). Make sure that the safety lock pin clicks automatically at the stop line, blocking the beam in the fully-open position.

4. If the stabilizer is equipped with tilting cylinders (CGR version), set them in working position following the indications in the next paragraph.

5. If the stabilizer is equipped with:a) Manual lock valves, unlock them by turning the handle 90 degrees up to position “A” (see fi g 13).b) Hydraulically operated lock valves are locked or released automatically with the operation of the control of the stabilizer leg.

6. Operate the stabilizing cylinders by resting the support plates on the ground, paying careful attention not to completely unload the vehicle’s suspension or raise the wheels off the ground (see paragraph 2.1).

7. Before working with the crane, check the fi rmness of the ground: if it is yielding, lift the cylinders and widen the bearing area with proper stabilizer pads (see fi g.3 pos.14); lower the stabilizers again and check the stability of the vehicle.

8. Lock the manual safety valves by turning the handles to position “C” (see fi g.13).

9. After the work session, fi rst lift the stabilizing cylinders, then retract the stabilizer beams and check that the safety lock pin is engaged.

3.4 OPERATING INSTRUCTIONS

Fig. 11

Fig. 12

Fig. 13


“CGR” stabilizers version, equipped with tilting legs, are used to solve clearance problems caused by the overall dimensions of the stabilizers in transport position; they allow the cylinder to turn to positions indicated in fi g. 14, operated as follows:

1. Remove the lock pin pos. B.

2. Take out the locking pin by using the handle pos. A; if the cylinder is not set in working position (0°), hold the cylinder to prevent crushing injury once it is released.

3. Turn the cylinder to the position required, then lock it with its pin.

4. Reinsert the lock pin.

5. Check always, above all while operating, that the locking pin is correctly inserted and locked.

Use of stabilizers with “CGR” option

Fig. 14

For correct and safe operation of stabilizers, it is necessary to follow proper maintenance :

• HYDRAULIC SYSTEM: Once a week, check for possible leaks, check the tightening of fi ttings, and the effi ciency of rigid and fl exible pipes.

• CYLINDERS: Once a week, check for possible oil leaks along the cylinder rods, if necessary change inner seals.

• STRUCTURE: Once a month, check the tightening of fasteners holding the stabilizing cylinders; also check the structure of the crossbar and of the extending beams, check for distortions, breakings or cracking of welding.

• GREASING: regularly grease the extending beams.

For technical assistance, including spare parts, please contact your local BIGMAX dealer or email [email protected], or phone 1-877-531-8644 toll free.

4 MAINTENANCE OF STABILIZERS

4.1 MAINTENANCE

4.1 TECHNICAL ASSISTANCE

Dealer:


5 MAXIMUM REACTION (LOADING) CALCULATION

NOTE: This information is provided to assist in the selection of primary (main) or auxiliary stabilizers based on the dynamic moment of the crane and the force it will apply against the stabilizer cylinder.

However, the selection of a stabilizer with an adequate “R” factor is NOT an indication that the vehicle with crane and other equipment is stable, according to local norms and standards.

To determine the overall stability of the vehicle, a separate more complex computerized calculation, one that takes into consideration the GVW of the vehicle, wheelbase, axle loading and body weight will be required. Contact your stabilizer supplier or an equipment engineer trained n this fi eld.

To carry out the calculation of the max. reaction (R Max.) on the cylinder of the stabilizer nearest to the crane column, (see drawing) it is essential to know:

• H (m) : Maximum distance from the centre of the stabilizing cylinder to the axle of vertical rotation of the crane (crane column).

• M dyn (daNm) : Maximum dynamic moment of the crane, given from the same crane-builder, supposing that it operates along the longitudinal plane of the axle of vertical rotation of the crane.

• The maximum dynamic moment corresponds or is parallel to the longitudinal axle of the vehicle chassis.

Vertical Axis of Rotation


It is then evident that the maximum reaction on the cylinder is the result of :

RMAX (daN) = M dyn / H

Compare the calculated value obtained above to the one indicated in the table below, relative to the model of stabilizer in question. Ensure the calculated value does not exceed the value in the table.

MAXIMUM ADMISSIBLE REACTIONS OF STABILIZERS ON THE HYDRAULIC CYLINDERS

Stabilizer Model Metric – R max. (daN) Pound Force – lbf

0A TD – F 2350 5.285

0A TD – EML 1550 3.485

0 TD – F 2950 6.630

0 TD – EML 2950 6.630

1 TD – F 6250 14.050

1 TD – EML 6250 14.050

1 TD – EHL 6250 14.050

1 TD – EMP 6100 13.715

1 TD – EHP 6100 13.715

2 TD – F 8200 18.435

2 TD – EML 8200 18.435

2 TD – EHL 8200 18.435

2 TD – EMP 8250 18.547

2 TD – EHP 8250 18.547

3 TD – EHP 10450 23.490

4 TD – EHP 12700 28.550

5 TD – EHP 17700 39.791

5 TD – EHPL 15850 13.630

5 TD – EXHP 15150 34.060

5 TD – EXHPL 15000 33.720

6 TD – EHPL 20500 46.086

6 TD – EXHP 19500 43.838

6 TD – EXHPL 19000 42.714

7 TD – EXHPL 25000 56.203

outrigger stabilizers - bigmax by · pdf fileby technocrane outrigger stabilizers...

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