DOWNLOAD PDF Terex Crane RT45 RT45L Operation & Maintenance Manual 52890

RT45-RT45L

Operation and maintenance

WHEELED CRANES

m

SERIAL NUMBER..........................................

YEAR OF CONSTRUCTION...........................

Maintenance and operator's manual

This manual is valid for models RT45 ed RT45L. When consulting the manual refer to the parts that correspond to the model of crane you have purchased.

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Maintenance and operator's manual

Contents 1 - Introduction...........................Edition: 02-2015 2 - Characteristics......................Edition: 02-2015 3 - Warnings................................Edition: 02-2015 4 - Safety and operation.............Edition: 02-2015 5 - Control instruments..............Edition: 02-2015 6 - Rated capacity limiter...........Edition: 02-2015 7 - Accessories...........................Edition: 02-2015 8 - Maintenance..........................Edition: 05-2015

EN

ORIGINAL INSTRUCTIONS

Code 52890EN.CRE 52890EN.CRE

Issue 02/2015 05/2015

Revision 00 01

This manual must always be accompanied by the load tables supplied with the machine.

Translation of the original instructions This document is a translation of the original instructions for use sent with this specific machine and as such marked. It is not intended to be the basis of any further translation. Please use the original instructions as reference only, they are marked accordingly.

No part of this manual may be duplicated, translated or copied without written permission from the manufacturer.

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1 - Introduction

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1 Introduction

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Contents Manufacturer's data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ownership registration form . . . . . . . . . . . . . . . . . . . . . . . . 6 Limited product warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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1 - Introduction

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1 - Introduction

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Manufacturer's data Terex Global GmbH Bleicheplatz 2 CH-8200 Schaffhausen Switzerland

After-sales service: Go to www.terex.com for after-sales service

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1 - Introduction

Ownership registration form Terex requires owners to register their truck within 60 days of the date of purchase or ownership transfer.

To register your truck, fill in the form on the opposite page and send a copy to Terex using one of the methods shown on the form.

Registration will be accepted only if all data are entered correctly.

Taking a few minutes to update the ownership information means owners can ensure they receive all relevant important information concerning safety, servicing and operation of their truck.

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Ownership registration form

Information on the machine Model

*

Serial number

*

Purchase date (MM.DD.YY) Owner information Company

*

Contact Post Code/Town

*

Country

*

Phone

*

E--mail Information on previous owner (if machine is transferred to new owner) Company

Post Code/Town Country Phone E--mail

Send form to E--mail

alessandro.pastorelli@terex.com

Street address

TEREX ITALIA S.r.l.

Via Cassoletta, 76 – Località Crespellano 40053 Valsamoggia (Bologna) – ITALY After-sales service Fax (+39) 0516501015 Tel. (+39) 0516501053

Fields marked with an asterisk (*) are required.

Fill in this form at the time of taking into operation.

Fill in the form and forward it at the time of each change of ownership.

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2 Characteristics

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RT45

Crane performance Capacity at 3 m from slewing axis....................... 45 t Boom length (closed / open)............................... 9.8 / 31.1 m

Weights (Standard version crane: without auxiliary winch, without extensions, with 16.00R25 tyres) Front axle ........................................................... 14.1 t Rear axle ............................................................ 14.3 t Total..................................................................... 28.4 t The data refer to the standard version of the crane and may be subject to change due to the specific configuration of the truck supplied.

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RT45L

Crane performance Capacity at 2.5 m from slewing axis.................... 44 t Boom length (closed / open)............................... 9.5 / 37.4 m

Weights (Standard version crane: without auxiliary winch, without extensions, with 16.00R25 tyres) Front axle............................................................ 12.8 t Rear axle............................................................. 14.8 t Total..................................................................... 27.6 t The data refer to the standard version of the crane and may be subject to change due to the specific configuration of the truck supplied.

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Contents General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Installation of accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Position of decals on the machine . . . . . . . . . . . . . . . . . . . . 12

RC30 - RT35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 RT45 - RT45L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 QUADSTAR 1065 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 QUADSTAR 1075 - QUADSTAR 1075L . . . . . . . . . . . . . . . . . . . . . . 15 RT100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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3 - Warnings General Information This truck complies with Directives 2006/42/EC, 2004/108/EC, 2005/88/EC. The weighted average quadratic value, in frequency, of acceleration to which the operator's upper limbs are exposed is less than 2.5 m/s2.

The average frequency-weighted quadratic value of acceleration to which the operator's body (feet or seated part) is exposed is less than 0.5 m/s2.

This crane is designed as a hoisting device with hook made of materials according to class S0 - HC1 in compliance with EN 13000 standards, for travelling mainly on worksites, on hard ground and on gradients of no more than 18%.

For greater distances (over 10 km) the crane must be carried on a trailer or flatbed truck.

Driving on public roads is permitted in compliance with current laws and regulations.

This crane is designed for use at temperatures not lower than -20°C and not greater than +45°C, in relation to its configuration.

The machine does not comply with the prescriptions of directive 94/9/CE, (ATEX), so it is not suitable for use in potentially explosive atmospheres.

The crane should not be used in the presence of strong magnetic fields.

This crane is designed to operate in winds of up to 30 kph. Use of the crane in dusty conditions is subject to taking all the necessary precautions for safeguarding the operator, and suitable increase in the frequency of maintenance and lubrication intervals.

Max. sound pressure LpA, measured inside the cab at the height of the operator's ears, with door closed, crane stopped and with the engine at 3/4 max. rpm is 78 dB (A).

FUEL SPECIFICATIONS Using fuel with more than 5000 ppm of sulphur is NOT allowed.

Corrosion of the distribution system, high levels of emissions and shortening of the time between engine oil changes are just some of the negative consequences of the use of fuel with excessively high sulphur contents.

For engines to directive 2004/26 Phase IIIA (Tier 3) the regional, national or international regulations can require fuel with a low sulphur content (less than 5000 ppm). For Phase IIIB engines (Tier 4i) it is necessary to use fuel with a sulphur content less than 15 ppm.

Consult all regulations in force before selecting the fuel.

For further information on the specifications of fuel to be used contact our technical assistance service.

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Installation of accessories If the crane is fitted with supplementary lifting equipment (extensions or winches) after the FIRST start-up and subject to the permission of TEREX, the user must: 1. ensure the necessary adjustments and calibrations are carried out.

2. have correct operation of the accessories and relevant safety devices checked.

Model Identification The crane model and manufacturer's reference number are located near the front axle on the outside of the main frame beam on the right, above the tool-box.

The crane note plate is located on the outside of the operator's cab.

XXX The data on the note plate are guideline and do not correspond to real conditions.

Standard weight: the value indicated refers to the machine in its standard configuration (without auxiliary winch, without tower sections, with standard tyres) and allowing a variation of ±1%.

The plate giving details of DGM type-approval for road use (where applicable) is located inside the cab. It gives the type-approval data and vehicle weight in running order for road travel.

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The owner of the machine or the person hiring it must ensure that the operator has: •

Received all the necessary instructions for correct and safe operation of the machine.

•

Fully understood and memorized all the instructions in this manual.

CAUTION For safe crane operation, use the load capacity tables given in this manual or located in the operator's cab.

WARNING Before starting the engine: ● Become familiar with the safety messages in this manual. ●

Read all safety signs on the machine and make sure no one is standing near the machine.

●

Practise using the controls before operating the machine.

●

It is the user’s responsibility to understand and observe the manufacturer's instructions on machine operation and compliance with the applicable laws and regulations.

CAUTION The warranty will be invalidated in case of negligence, lack of maintenance, improper use of the material by the purchaser or his personnel, non-compliance with the technical instructions relevant to the warranty.

N.B.: If the manuals and load tables are damaged or lost, request copies from your dealer or directly from the manufacturer.

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WARNING BUNGEE JUMPING FROM CRANES IS DANGEROUS TEREX Italia, designs, manufactures and sells safe and reliable products for handling materials, and NOT PERSONS. Therefore, we believe that using the crane for lifting, lowering or moving persons for bungee jumping is dangerous and highly inadvisable.

Such improper use of the products is neither envisaged nor approved

by TEREX Italia.

Our products are not designed, manufactured, tested or devised to carry personnel.

Lifting persons for bungee jumping is inherently dangerous; make sure to read the section on Safety Regulations to know the risk of injury, and the warnings against using cranes to lift persons.

All Dealers and Distributors are requested to use every reasonable means to immediately warn all potential users, purchasers and hirers of cranes that: BUNGEE JUMPING FROM THE CRANE IS DANGEROUS. Dealers and Distributors are also advised not to knowingly sell and rent cranes for bungee jumping, as this constitutes serious improper use of the product.

REMEMBER: BUNGEE JUMPING FROM THE CRANE IS DANGEROUS. Use of the crane with: •

Shovels, grabs, magnets or similar equipment

•

Vibrating equipment.

•

Demolition equipment.

must be authorised by TEREX. It is also strictly prohibited to use the crane when visibility is poor.

The operator must be in optimal physical condition, be able to read and understand the manual and the crane load tables, and have specific knowledge of the crane and basic training on the operation of self-propelled industrial equipment.

Holding of a driving licence is compulsory in compliance with the current laws and regulations.

CAUTION Any operation involving overload, also at the time of supplementary maintenance of the crane, is PROHIBITED except in the presence of explicit authorisation from Terex.

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WARNING It is essential to carry out all the prescribed lubrication and maintenance operations to ensure the safety and reliability of the machine, irrespective of the type. Some of these operations, described in the Maintenance Manual, require special equipment and technical knowledge. Non-compliance with the lubrication and maintenance instructions can result in serious accidents.

CAREFULLY READ ALL THE SAFETY INSTRUCTIONS BEFORE LUBRICATING AND SERVICING THE MACHINE. Preventive measures against possible hazards in maintenance operations are outlined in the section on "Safety". Also, warnings against some hazards that can cause serious accidents are affixed to the machine.

TEREX Italia is not in a position to know how maintenance operations are performed, or all the risks relevant to particular methods, and therefore is unable to advise maintenance personnel. Therefore, anyone using an unsuitable method or a tool not recommended in the Manual must previously make sure there are no risks for the operator or others, that the machine will not be damaged and safety is not compromised.

CAUTION In the event of an accident, no claims against TEREX Italia will be accepted unless a person authorized by TEREX Italia has written a report on the actual circumstances, before the machine is removed from the scene.

CAUTION At the time of decommissioning of the machine contact local authorities to ensure correct disposal of the various parts.

Pay special attention to the counterweights since they may contain lead.

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Safety decals CAUTION Do not remove the decals affixed to the crane.

Worn or deteriorated decals must be replaced.

The following are safety decals and must be strictly respected.

General symbols

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Hazard triangle

Corrosive substance burns hazard

Crushing with impact from side

Pressurised hot fluids burns hazard (radiator)

Crushing with impact from above

Danger of explosion - general

Crushing of feed by vertical outrigger

Falling from height

Keep clear of the pulley or load line

Skin penetration of high pressure fluid

Trapping of arm in belt

Hazard symbol

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Trapping / fracture of fingers or hand in engine fan

Trapping of hand in pulley / winch

Burns from contact with hot surfaces or liquids

Electric shock/electrocution from truck due to contact with overhead power lines

Chemical burns from battery explosion

Fuel /diesel fumes explosion

Crushing of fingers or hand - force applied from two directions

Fire hazard - generic

No smoking

No open flames

Do not remove cap while hot

Keep clear of hot surfaces and liquids

Maintain 3 points of contact when using the access system

Use piece of card or wood to find escaping fluid

Read operator manual carefully before using the equipment

Block the truck/device

Switch off and remove the key

No open flames

Turn off engine

Keep hands clear from which and from load line

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2

Maintenance and operator's manual

Keep clear of truck when working near power lines

Keep clear of outriggers

Switch off heater no. 2

Access reserved for authorised personnel

Keep clear of suspended load

Keep clear of moving parts

Crushing by counterweight

Keep clear of indicated area

Only the driver is permitted to remain in the cab during operations

Keep clear of the truck

1.

Falling from wheeled machine

Raise cab with door closed

1.

1.

2.

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Raise cab with door open

2.

Do not open door when cab is raised

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Position of decals on the machine RC30 - RT35 18-20-21

2

3

5

1 4 24-25

7 MANUAL SIGNALS / GESTES DE COMMANDEMENT LAZIONI / SEGNAMANUALI HAND SIGNALE / HANDSEINEN / SENALIZACIONES ALESMANU

HOISTING THE LOAD MONTÉE DE LA CHARGE SOLLEVAMENTO DEL CARICO LAST AUF LAST OPHIJSEN IZAR CARGA

LOWERING THE LOAD DESCENTE DE LA CHARGE ABBASSAMENTO DEL CARICO LAST AB LAST LATEN ZAKKEN BAJAR CARGA

USING THE MAIN ROPE LEVAGE AVEC L'ÉLINGUE PRINCIPALE USANDO LA FUNE PRINCIPALE HAUPTSEIL VERWENDEN MET DE HOOFDKABEL USAR CABLE PRINCIPAL

USING THE AUXILIARY ROPE LEVAGE AVEC L'ÉLINGUE AUXILIAIRE USANDO LA FUNE AUSILIARIA HILFSSEIL VERWENDEN MET DE HULPKABEL USAR CABLE AUXILIAR

LOWERING THE BOOM DESCENDRE LA FLÈCHE ABBASSAMENTO DEL BRACCIO AUSLEGER AB DE GIEK OMLAAG DOEN BAJAR PLUMA

MOVING SLOWLY DÉPLACEMENT LENT SPOSTAMENTO LENTO LANGSAM BEWEGEN LANGZAAM BEWEGEN DESPLAZAMIENTO LENTO

HOISTING THE BOOM AND LOWERING THE LOAD LEVER LA FLÈCHE ET DESCENDRE LA CHARGE SOLLEVAMENTO DEL BRACCIO E ABBASSAMENTO DEL CARICO AUSLEGER AUF UND LAST AB DE GIEK OMHOOG DOEN EN DE LAST LATEN ZAKKEN IZAR PLUMA Y BAJAR CARGA

LOWERING THE BOOM AND LOWERING THE LOAD DESCENDRE LA FLÈCHE ET DESCENDRE LA CHARGE ABBASSAMENTO DEL BRACCIO E ABBASSAMENTO DEL CARICO AUSLEGER AB UND LAST AUF DE GIEK OMLAAG DOEN EN DE LAST LATEN ZAKKEN BAJAR PLUMA Y CARGA

SLEWING ROTATION ROTAZIONE DREHEN DRAAIEN ROTACIÓN

STOP ARRÊT ARRESTO HALT STOPPEN PARADA

EMERGENCY STOP ARRÊT D'URGENCE ARRESTO D EMERGENZA HALT-GEFAHR STOPPEN IN GEVAL VAN NOOD PARADA DE EMERGENCIA

MOVING DÉPLACEMENT SPOSTAMENTO BEWEGEN BEWEGEN DESPLAZAMIENTO

STOP EVERYTHING ARRÊTER TOUT FERMARE TUTTO ALLES AUSSCHALTEN ALLES STOPPEN DETENER TODO

MOVING (on two tracks) DÉPLACEMENT (sur deux chenilles) SPOSTAMENTO (sui due cingoli) BEWEGEN (auf zwei Raupenketten) BEWEGEN (op beide rupsen) DESPLAZAMIENTO (sobre dos orugas)

MOVING (on one track) DÉPLACEMENT (sur une chenille) SPOSTAMENTO (su un cingolo) BEWEGEN (auf einer Raupenkette) BEWEGEN (op één rups) DESPLAZAMIENTO (sobre una oruga)

PULL OUT BOOM TELESCOPER FLÈCHE SFILARE IL BRACCIO AUSLEGER AUSFAHREN DE GIEK UIT LATEN GAAN EXTENDER LA PLUMA

PULL IN BOOM RENTRER LA FLÈCHE RIENTRARE IL BRACCIO AUSLEGER EINFAHREN DE GIEK TERUGHALEN CERRAR LA PLUMA

PULL OUT BOOM TELESCOPER FLÈCHE SFILARE IL BRACCIO AUSLEGER AUSFAHREN DE GIEK UIT LATEN GAAN EXTENDER LA PLUMA

PULL IN BOOM RENTRER LA FLÈCHE RIENTRARE IL BRACCIO AUSLEGER EINFAHREN DE GIEK TERUGHALEN CERRAR LA PLUMA

HOISTING THE BOOM LEVER LA FLÈCHE SOLLEVAMENTO DEL BRACCIO AUSLEGER AUF DE GIEK OMHOOG DOEN IZAR PLUMA

6

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12 6 5

13

11

14

2

10

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8

(8-22)*

15 1

4 MANUAL SIGNALS / GESTES DE COMMANDEMENT LAZIONI / SEGNAMANUALI HAND SIGNALE / HANDSEINEN / SENALIZACIONES ALESMANU

LOWERING THE LOAD DESCENTE DE LA CHARGE ABBASSAMENTO DEL CARICO LAST AB LAST LATEN ZAKKEN BAJAR CARGA

USING THE MAIN ROPE LEVAGE AVEC L'ÉLINGUE PRINCIPALE USANDO LA FUNE PRINCIPALE HAUPTSEIL VERWENDEN MET DE HOOFDKABEL USAR CABLE PRINCIPAL

USING THE AUXILIARY ROPE LEVAGE AVEC L'ÉLINGUE AUXILIAIRE USANDO LA FUNE AUSILIARIA HILFSSEIL VERWENDEN MET DE HULPKABEL USAR CABLE AUXILIAR

LOWERING THE BOOM DESCENDRE LA FLÈCHE ABBASSAMENTO DEL BRACCIO AUSLEGER AB DE GIEK OMLAAG DOEN BAJAR PLUMA

MOVING SLOWLY DÉPLACEMENT LENT SPOSTAMENTO LENTO LANGSAM BEWEGEN LANGZAAM BEWEGEN DESPLAZAMIENTO LENTO

HOISTING THE BOOM AND LOWERING THE LOAD LEVER LA FLÈCHE ET DESCENDRE LA CHARGE SOLLEVAMENTO DEL BRACCIO E ABBASSAMENTO DEL CARICO AUSLEGER AUF UND LAST AB DE GIEK OMHOOG DOEN EN DE LAST LATEN ZAKKEN IZAR PLUMA Y BAJAR CARGA

LOWERING THE BOOM AND LOWERING THE LOAD DESCENDRE LA FLÈCHE ET DESCENDRE LA CHARGE ABBASSAMENTO DEL BRACCIO E ABBASSAMENTO DEL CARICO AUSLEGER AB UND LAST AUF DE GIEK OMLAAG DOEN EN DE LAST LATEN ZAKKEN BAJAR PLUMA Y CARGA

SLEWING ROTATION ROTAZIONE DREHEN DRAAIEN ROTACIÓN

STOP ARRÊT ARRESTO HALT STOPPEN PARADA

EMERGENCY STOP ARRÊT D'URGENCE ARRESTO D EMERGENZA HALT-GEFAHR STOPPEN IN GEVAL VAN NOOD PARADA DE EMERGENCIA

MOVING DÉPLACEMENT SPOSTAMENTO BEWEGEN BEWEGEN DESPLAZAMIENTO

STOP EVERYTHING ARRÊTER TOUT FERMARE TUTTO ALLES AUSSCHALTEN ALLES STOPPEN DETENER TODO

MOVING (on two tracks) DÉPLACEMENT (sur deux chenilles) SPOSTAMENTO (sui due cingoli) BEWEGEN (auf zwei Raupenketten) BEWEGEN (op beide rupsen) DESPLAZAMIENTO (sobre dos orugas)

MOVING (on one track) DÉPLACEMENT (sur une chenille) SPOSTAMENTO (su un cingolo) BEWEGEN (auf einer Raupenkette) BEWEGEN (op één rups) DESPLAZAMIENTO (sobre una oruga)

HOISTING THE LOAD MONTÉE DE LA CHARGE SOLLEVAMENTO DEL CARICO LAST AUF LAST OPHIJSEN IZAR CARGA

PULL OUT BOOM TELESCOPER FLÈCHE SFILARE IL BRACCIO AUSLEGER AUSFAHREN DE GIEK UIT LATEN GAAN EXTENDER LA PLUMA

PULL IN BOOM RENTRER LA FLÈCHE RIENTRARE IL BRACCIO AUSLEGER EINFAHREN DE GIEK TERUGHALEN CERRAR LA PLUMA

PULL OUT BOOM TELESCOPER FLÈCHE SFILARE IL BRACCIO AUSLEGER AUSFAHREN DE GIEK UIT LATEN GAAN EXTENDER LA PLUMA

PULL IN BOOM RENTRER LA FLÈCHE RIENTRARE IL BRACCIO AUSLEGER EINFAHREN DE GIEK TERUGHALEN CERRAR LA PLUMA

HOISTING THE BOOM LEVER LA FLÈCHE SOLLEVAMENTO DEL BRACCIO AUSLEGER AUF DE GIEK OMHOOG DOEN IZAR PLUMA

22130

6

12 10 16

9

6 5

19

17 12

19

23

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RT45 - RT45L

18-20-21

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2

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4 24-25 7 12

13

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15

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(8-22)*

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* = only with diesel fuel operated heater 02-2015

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QUADSTAR 1065 1

24-25

18-20-21

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2

5

4 7 12

6 6 10

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QUADSTAR 1075 - QUADSTAR 1075L 18-20-21 1

2

3

5

26

4 24-25 7 12 6

5

13

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10

14

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8

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6 9

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RT100 24-25

1

18-20-21

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4 7 12

6 6

13

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9

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Maintenance and operator's manual

Decal

Description Trapping hazard Contact with the load line in movement can cause death or serious injury.

1

Keep hands clear of the pulley and load line

52030

Crushing hazard Contact with moving parts can cause serious injury.

2

Keep clear from moving parts when machine is in operation.

41059

Improper use or incorrect maintenance of this machine may result in death or serious injury.

3

Read the operator manual carefully and pay attention to the safety indications before using or servicing the machine.

If in doubt concerning the information in the manuals, ask for clarification from your supervisor, the machine owner, or the manufacturer.

52013

Crushing hazard Contact with the moving machine can cause death or serious injury.

4

51908

Keep clear of indicated area. Access reserved exclusively for authorised personnel.

Trapping hazard Contact with the load line in movement can cause death or serious injury.

5

Keep hands clear from the moving pulley and load line.

30417

Crushing hazard Contact with the moving outriggers can cause death or serious injury.

6

Keep clear of the outriggers operating area.

44413

Burns hazard Contact with hot surfaces can cause death or serious injury.

7

Keep clear of hot surfaces. Before starting maintenance work allow the machine to cool down.

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Pos.

Decal

3 - Warnings

Description Explosion/burns hazard Fuel and fuel fumes can ignite and explode with the consequent risk of death or serious injury.

8

Do not smoke.

Keep open flames and sparks well away. Switch off the engine before refuelling the truck.

51699

Falling hazard A fall can result in death or serious injury.

9

51695

10

Use the supplied access system.

Access reserved for authorised personnel.

51696

Explosion/burns hazard Explosion of the battery and/or contact with corrosive acids can cause death or serious injury.

11

Keep open flames and sparks well away.

Wear adequate personal protective equipment and devices including gloves, face mask, and long-sleeved shirt.

51888

Read the manual. If in doubt concerning the information in the manuals, ask for clarification from your supervisor, the machine owner, or the manufacturer.

Crushing hazard Dropping of the load can result in death or serious injury.

12

Keep clear of suspended loads. Never walk under suspended loads.

51914

Burns hazard The release of hot pressurised fluid can cause death or serious injury.

13

Do not unscrew the cap until it has cooled.

51697

Burns hazard Contact with hot surfaces can cause death or serious injury.

Keep clear of hot surfaces. Before starting maintenance work allow the machine to cool down.

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Maintenance and operator's manual

Decal

Description

14

Contact with the components under this cover can cause death or serious injury.

Access reserved exclusively for authorised personnel. Keep closed and locked during operation.

Read the manual carefully.

52064

Trapping hazard Contact with rotating parts can cause death or serious injury.

Keep clear of the belts and fan when the engine is running.

Switch off the engine before starting maintenance work.

15

30951

16

Skin penetration hazard Sprays of pressurised fluid can penetrate the skin resulting in death or serious injury.

Discharge hydraulic pressure before disconnecting the lines.

Keep clear of escaping fluid and puncture points. Use piece of card or wood to find escaping fluid. Do not use your hands.

To avoid the risk of cancer, fluid injected through the skin must be surgically removed within a matter of several hours by a medical practitioner with expertise in injuries of this type.

Emergency exit.

51709

Electrocution hazard

17

Contact with overhead power lines can cause death or serious injury.

Keep clear of the truck.

51915

Electrocution hazard

18

Contact with overhead power lines can cause death or serious injury.

0 to 50 kv

>50 to 200 kv >200 to 350 kv >350 to 500 kv >500 to 750 kv >750 to 1000 kv >1000 kv

10 ft (3 m) 15 ft (4.6 m) 20 ft (6.1 m) 25 ft (7.6 m) 35 ft (10.7 m) 45 ft (13.7 m)

Before using the machine contact the owner of the overhead power lines in order to disconnect, move, or insulate them.

52042

Crushing hazard

19

Contact with the moving machine can cause death or serious injury.

Keep clear of the moving truck.

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Pos.

Decal

3 - Warnings

Description Falling hazard A fall can result in death or serious injury.

Do not carry passengers.

Keep clear of the machine when it is operating.

20

52061

21

WARNING

Operator warning decal.

IMPORTANT

Before starting the engine be sure having read and understood the instructions on operator's manual and on loading schedules.

Be sure having always in the cab copy of operator's manual and load charts.

ATTENTION

IMPORTANT

Avant demarrer le moteur s'assurer avoir lu et bien compris les instructions du manuel de service et des tableaux de charges.

AVVERTENZA

Prima di avviare il motore assicurarsi di avere letto e compreso le istruzioni contenute nel manuale d'uso e nelle tabelle di carico.

ACHTUNG

S'assurer avoir toujours en cabine une copie du manuel de service et des tableaux de charge.

IMPORTANTE

Assicurarsi di avere sempre in cabina una copia del manuale d'uso e delle tabelle di carico.

WICHTING

Versichern sich immer eine Kopie der Handbuch und belastungs- -tabellen ins Kabine haben.

Vor den Motor in betrieb setzen versichern sich die Anweisungen in der Handbuch und die Belastungstabellen verstanden haben.

WAARSCHUWING

Alvorens de Motor te starten moet men zich ervan verzekeren dat men de aanwijzingen die in de gebruikershandleiding en in de lasttabellen staan goed gelezen en volledig begrepen heeft.

ADVERTENCIA

Antes de poner en marcha el motor, asegurarse de haber leído y comprendido las instrucciones contenidas en el manual de uso y en las tablas de carga.

OSTRZEŻENIE

Przed uruchomieniem silnika upewnic się, ze operator zapoznat się z treścią oraz przyswoit zalecenia zawarte w podręczniku instrukcji obstugi i w tabelach tadunkow.

BELANGRIJK

Men moet zich ervan verzekeren dat er in de cabine altijd een exemplaar van de gebruikershandleiding en de lasttabellen ligt.

IMPORTANTE

Comprobar que haya siempre una copia del manual de uso y de las tablas de carga en la cabina.

WAŻNE

Upewnic się, ze w kabinie znajduje się zawsze jedna kopia podręcznika instrukcji oraz tabel tadunkow.

37102

Explosion/fire hazard

22

Fuel and fuel fumes can ignite and explode with the consequent risk of death or serious injury.

2.

1.

Switch off the cab heater before refuelling.

2 51707

23

Beam extension limit.

24

First aid kit.

51913

25

Fire extinguisher.

51912

26

1.

2.

1.

2.

1.

Opening the door when the cab is raised can cause death or serious injury.

Operations permitted with the cab door.

2.

52176 51908

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Contents Advice on safety when using mobile cranes...................................................................................................... 5 Introduction .................................................................................................................................................... 5 Operator's responsibility ................................................................................................................................ 6 Signaller's responsibility ................................................................................................................................ 6 Responsibilities of all relevant personnel ...................................................................................................... 8 Management's responsibilities ...................................................................................................................... 8 Planning the worksite .................................................................................................................................... 9 Safety check by operator............................................................................................................................. 10 Operation precautions ................................................................................................................................. 11 General instructions ......................................................................................................................................... 18 General ........................................................................................................................................................ 19 Access and cleaning ................................................................................................................................... 20 Machine operation ....................................................................................................................................... 21 Maintenance ................................................................................................................................................ 23 Electrical circuit ........................................................................................................................................... 24 Hydraulic circuit ........................................................................................................................................... 25 Tyres............................................................................................................................................................ 25 Replacing the tyres ...................................................................................................................................... 26 Instructions for reading the load table ............................................................................................................. 27 Choosing the best configuration .................................................................................................................. 28 Reduction of operating loads....................................................................................................................... 31 Extension secured to brackets .................................................................................................................... 32 Mounted extension ...................................................................................................................................... 32 Special instructions for lifting on tyres ......................................................................................................... 33 Special instructions for lifting on outriggers................................................................................................. 34 Special instructions for lifting with mechanical element extended .............................................................. 35 Max. forces exerted on ground (daN) ......................................................................................................... 36 Actions of the wind ...................................................................................................................................... 37 Safety devices ................................................................................................................................................. 39 Rated capacity and movement limiter ......................................................................................................... 39 Limit stop device .......................................................................................................................................... 40 Lowering limit stop device ........................................................................................................................... 40 Lifting limit stop device ................................................................................................................................ 43 Deadman Safety Device.............................................................................................................................. 44 Machine operation ........................................................................................................................................... 45 Introduction .................................................................................................................................................. 45 Preliminary checks ...................................................................................................................................... 45 Engine starting ............................................................................................................................................ 45 Switching off the engine .............................................................................................................................. 46 Securing the block (hook) to the truck crane ................................................................................................... 47 Attachment .................................................................................................................................................. 47 Release ....................................................................................................................................................... 48 Driving on road ................................................................................................................................................ 49 Preliminary operations ................................................................................................................................. 49 Driving on the worksite .................................................................................................................................... 50 Transporting a suspended load ................................................................................................................... 50 Machine stabilization ....................................................................................................................................... 51 Instructions .................................................................................................................................................. 51 Outrigger beams fully retracted ................................................................................................................... 51 Middle outrigger beams ............................................................................................................................... 51 Outrigger beams fully extended .................................................................................................................. 51 Support surfaces ......................................................................................................................................... 52 Guideline table of permissible pressures for various types of terrain ......................................................... 53 Dangers in the work area................................................................................................................................. 54 Extension of the boom 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Lifting rope ....................................................................................................................................................... 56 Eccentric rigging (unbalanced) ........................................................................................................................ 59 Symmetrical rigging (balanced) ....................................................................................................................... 60 Changing the number of tackles ...................................................................................................................... 61 Lifting blocks and hooks .................................................................................................................................. 62 Harnessing the load ......................................................................................................................................... 63 Extensions assembly – disassembly ............................................................................................................... 63 Work with main winch and auxiliary winch ......................................................................................................... 64 Lifting with several mobile cranes .................................................................................................................... 67 Towing ............................................................................................................................................................. 68 Lifting the crane truck ...................................................................................................................................... 69 Transporting the crane on a low loader .............................................................................................................. 70

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Advice on safety when using mobile cranes.

Introduction Terex® cranes are carefully designed, tested and manufactured.

When used correctly by qualified operators, they ensure safe and reliable performance. Terex® has branches worldwide and is at your disposal for any information regarding products and their safe use.

The following crane is designed for handling loads in compliance with the capacity table and the instructions contained in this manual.

The machine must be used in conformity with current laws and regulations in the country concerned.

Never lift persons with the crane if it is not equipped with a special platform for carrying persons, authorized and supplied by the manufacturer.

Do not use the mobile crane for demolitions or for pushing or dragging objects with the boom.

Whenever the hook has to be used for operations other than handling material, the manufacturer's prior permission is required.

Normal working conditions provide for an average operating period of 8 hours a day, 5 days a week in normal environmental conditions at not more than 1000 metres a.s.l. For more intensive use or in more difficult environmental conditions (high temperatures, dusty or damp places, etc.) the crane must be used with more precautions, checking it more frequently and increasing the frequency of lubrication and maintenance.

Having the capacity to lift heavy loads to considerable heights, the cranes are potentially dangerous if the safety regulations are not respected. These pages will help the operator avoid accidents that could cause damage or injury.

The general advice on machine operation as well as these instructions must be followed.

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4 - Safety and operation Operator's responsibility Safety must be the operator's main concern.

He must refuse to operate if he deems it dangerous and must contact the person in charge whenever safety is uncertain.

He must read and understand the Operator's Manual, the load tables and make sure that everything is in order on the machine before operating.

He must be alert, in optimal physical condition and not be under the influence of alcohol, drugs or medicines that affect the sight, hearing or reflexes.

He must keep persons, equipment and materials away from the work zone. Also, the zone around the machine must be adequate marked.

Whenever the operator's visibility is blocked or he is operating in hazardous areas, e.g. near power lines or around persons, he must use the help of a signaller.

As the operator is not in the best position for judging distances and is unable to see all the worksite, a signaller may have to be used also in other situations. Operators must understand the standard signals for cranes and only follow the signals of the appointed signallers.

Signaller's responsibility The signaller's main task is to help the operator work in the most efficient way in safe conditions. Operators depend on the appointed signallers in order to move without causing damage or injuring persons.

Signallers must have clearly understood the work to be performed in order to safely coordinate every task of the operators and personnel.

Signallers must stand in a place where they can be clearly seen and from where they can safely observe the entire operation.

The standard signals for cranes must be used unless other signalling methods, such as two-way radios or flags, are agreed on.

Signallers must have good eyesight and good judgment, and must know the standard signals for cranes and be able to give signals clearly. They must have sufficient experience for recognizing risks and signalling the operator how to avoid them.

The signaller is the only person authorized to give instructions to the operator.

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Table 1 – Standard hand signals

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4 - Safety and operation Responsibilities of all relevant personnel Unsafe conditions or operations must be adequately corrected or notified to the person in charge of work.

Anyone working around the cranes must obey the danger signs and pay attention to their own safety and that of others. Load handling personnel must know the relevant safety procedures.

Pay attention to risks that can arise during operations and warn the operator and signallers of hazards such as power lines, the unexpected presence of persons, other equipment or unsure ground.

Management's responsibilities Management's task is to ensure that operators have adequate training and competence, are in optimal physical condition and, if necessary, that they have a driving licence.

Good eyesight, judgment, coordination and an alert mind are necessary.

Those lacking any of these requisites are not allowed to operate the crane.

Crane operators must have received adequate training to be able to determine weights and distances, for correctly choosing and using the hoisting winch. This work is a complex subject that will not be discussed in this manual. Management must ensure that personnel receive adequate training.

Personnel must be given specific responsibilities on safety and are required to inform the persons in charge of any condition involving danger for persons or things.

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Planning the worksite The person appointed must clearly understand the work to be carried out, consider all the dangers existing on the worksite, and prepare a plan enabling execution of the work in safe conditions which must be notified to all those concerned. Factors such as the following must be taken into consideration: - The personnel needed and their responsibilities?

- The weight of the load to be lifted, lifting radius, boom angle and nominal lifting capacity of the crane?

- The way the signaller will communicate with the operator?

- The equipment necessary for performing the work in safe conditions?

- How the equipment can be taken safely to the worksite?

- Any gas or power lines or structures to be removed or avoided?

- If the ground is strong enough to take the weight of the machine and the load?

- How the loads will be restrained?

- Special safety precautions to be taken if the crane has to travel with a suspended load or if other cranes are necessary to lift a load?

- If unfavourable weather conditions, such as wind or intense cold, are forecast?

- Measures to be taken for safely keeping unnecessary persons and equipment away from the work zone?

- How the cranes can be positioned for using the shortest possible boom and reach?

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4 - Safety and operation Safety check by operator Every day before starting work the operator must carry out a safety check to ensure that everything is in order on the machine. Some of these checks include the following: - Check the log book on board the machine to verify that the periodical maintenance and inspections as well as all the necessary repairs have been carried out.

- Check operation of the boom lifting cylinder, auxiliary alarms and other safety devices.

- Carefully inspect the load supporting parts such as wire ropes, (load rope, lifting rope on the winch, suspension ropes), boom, outriggers and hooks.

- Ensure that no unauthorized modifications have been in the field, such as added counterweights and booms repaired in an improper way.

- Check for any hydraulic oil and air leaks.

- Before starting the engine, check the cooling water and lubrication oil levels.

- After starting the engine, check that the readings are correct on all gauges.

- Check correct operation of all the controls.

- Check the truck brakes. Test the load brakes by lifting and supporting a load at a few cm from the ground.

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Operation precautions 1. Mistakes in calculating lifting capacity can cause accidents, therefore several factors must be taken into consideration, viz: The load radius is the distance between the crane upper structure rotation axis and the centre of the boom head sheaves. Remember that the radius increases if the load is lifted due to flexing of the boom.

Weight of load, block and any lifting equipment.

Length of boom, number of tackles, work area (front, rear or side) and possible extensions or jibs.

Use the load immediately below if the capacity or work radius are not given in the capacity table.

Attempting to lift a load not given in the capacity table, trying to guess the capacity for boom lengths, radius or angle is extremely dangerous as the crane could sway or tip over during lifting.

Always keep within the nominal capacity given in the table.

The operator must reduce the load in relation to the unfavourable conditions in the worksite and appraise the possibility of lifting loads in complete safety.

2. The cranes can tip over or sway if the work surface is unable to take their weight. Wooden boards, steel plates or cement slabs may have to be placed under the outrigger support plates to distribute the load under the crane so that the supporting strength of the ground is not exceeded.

Determine the load supporting capacity of the ground or other surface on which the machines will be operating. Make sure the ground can support the crane. Avoid unstable, soft, sandy ground, areas with high water-tables and partially frozen ground. If the machines work near excavations, these must be supported or filled in order to avoid landslips or sliding.

3. The working load capacity of a crane is established with the crane levelled.

Make sure the crane is level and that all the tyres are raised above the ground in order to obtain the correct values given in the table of load "On outriggers".

4. The scissor action produced by the rotation of the upper part with respect to the base can crush or injure persons.

Keep away from the crane in the rotation phase, mark the work zones and always make sure no one is within the crane's operating range.

5. Persons can be struck by the rear part of the counterweight of the machine if there is insufficient free space. Before starting work, perform a trial rotation without load to establish the exact rotation radius.

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4 - Safety and operation 6. Many persons have been involved in accidents caused by the hook or the suspended load, therefore to avoid that risk, always keep outside the machine work area.

Do use the crane to lift persons. Use ladders, scaffolding, lift trucks or other specific equipment for lifting persons, but do not use the cranes.

7. Power lines can also be the cause of accidents. Such accidents can be avoided by respecting some simple rules.

Always establish where the high-tension lines are before starting work.

It is advisable to keep more than 7 m away from high-tension lines.

Inform the company responsible for the high-tension lines before starting work.

Use a helper to maintain a safe distance between the machine and the high-tension lines. The operator is not in the best position for judging the distances. Warn persons to permanently keep away from the machine.

If the load has to shifted for positioning, check the relevant precautions with the company that manages the power lines. Operate slowly, taking the time necessary for being able to react to a possible problem and with 2 different means check the distance between the high-tension lines and any part of the machine.

What to do in case of accidental contact.

What to be done is not based on regulations but depends on an analysis of the immediate risks. This must be the subject of rules fixed for the operator or his training.

• The equipment or the machine is able to operate: without leaving the cab, the operator must immediately move the machine away from the live electrical work.

• The equipment or the machine is unable to function: Without leaving the cab the operator must alert other persons by means of signals or verbally, informing them that they must not approach the machine or the equipment. (Risk of hazardous voltages on the structure of the machine or equipment for the entire duration of the incident). Whenever the operator has to leave the cab, he must jump down from it so as not to be in contact with the ground and the machine at the same time.

Once on the ground he must move away from the machine: jumping, with both feet together; with very small steps.

The machine can only be subsequently approached after making sure that the power line is definitively no longer live and after checking the actual absence of current (operation carried out in collaboration with the electricity company).

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• The machine operates on tyres: after contact of a machine operating on tyres with a high-tension overhead work, the tyres (with metal carcass) that were not destroyed do not retain their insulating property or their strength.

If not occurring immediately, the tyres often burst later, after prolonged exposure to the sun.

The tyres must be deflated and scrapped, after the machine has been taken off the power line.

CAUTION: properly planned work and thorough checks ensure better protection than any other safety device. Insulated cages or proximity sensors have limits and can have failures without signalling them.

The protection cables or insulated cages only protect the machine, therefore they can be current conductors due to dust or water.

The proximity sensors can be disturbed by different combinations of high-tension lines or by the movements of vehicles or material and the crane itself or by other factors. Relying only on these systems can be very dangerous as the operator believes he is protected, whereas this is not so.

In case of storms, take the following precautions: - if possible, support the load and completely retract the boom; - if caught by a sudden storm, switch off the heat engine and leave the machine; - if the machine is struck by lightning, check general machine operation before restarting it.

You must always know the weather forecasts of your area before starting work.

8. The lifting rope can break if the load knocks against the boom head.

This can occur during boom lowering or extension without keeping the rope under control.

When positioning the rope, make sure it passes properly in the limit stop device safety counterweight.

Always check the space between the hook and the boom head.

Lower the hook during extension to avoid this type of accident.

Regularly check the limit stop safety system.

9. Persons can be injured by the hook, boom, load or outriggers.

Ensure that those working around the machine are safely in their place before starting to move the hook, load or outriggers. Do not move loads above persons, and do not allow the load to knock or bounce on any objects.

10. Abrupt starting or rotation movements can cause the hook and its load to sway dangerously and loss of control of the load.

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4 - Safety and operation 11. The crane control system makes it possible to perform several movements at the same time.

In this case, the operator must use the maximum level of attention.

12. Dirty or dark windows, glare, fog, rain and other conditions can make it hard for the operator to see clearly.

Keep the windows clean. Only drive if you can do so in complete safety.

13. Wind can also cause loss of control of the load, breaking the boom and overturning the machine. The wind can be stronger aloft than at ground level.

Do not lift in uncertain wind conditions. Lower the boom if necessary.

See the capacity tables.

14. Always wait until the machine, hook or suspended load are completely still before getting off the machine. Always use two hands and make sure of your footing.

15. Slippery platforms, ladders, tools or other similar objects can cause falls.

ALWAYS KEEP THE MACHINE CLEAN AND DRY. 16. A damaged crane can be dangerous and cause accidents.

A telescopic crane must be checked every week to make sure there are no basic or guide block defects. In both these cases the reduction in solidity is very difficult to assess.

Inspect the crane rope and boom every day. Do not use a damaged boom or rope.

NOTE: Because the booms are made of high-strength steel, special procedures must be adopted when carrying out any repairs.

Always consult your dealer or the manufacturer before carrying out repairs.

17. The crane booms can twist or deform under the effect of lateral loads (lateral stress).

Typical cases of lateral stress are: - Abrupt swinging due to starting or stopping.

- Side dragging of a load.

- The wind force.

- Lifting when the crane is not level.

Take care to avoid unnecessary side forces.

18. If the boom is used for purposes other than lifting it could break.

Never allow the boom to bend abnormally under the effect of a load or other objects.

19. The load slings or ropes stretch when the load is lifted and contract when the load is released; at steep boom angles this operation can be enough to tip the crane over.

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20. The load can go out of control if it is not properly aligned with the boom head when lifted. This can cause a lateral stress that can cause tipping or breakage of the crane.

Always put the boom head directly above the load to be lifted.

21. Trying to lift a load that is blocked, frozen or stuck to something else can cause overturning or the breakage of a hoisting part.

Always make sure the loads are free.

22. For correct use of the lifting winch and rope, there must be at least three dead turns of the rope on the drum. Regularly check the safety system.

23. Attempting to repair or adjust a machine component when the load or hook are suspended is very dangerous because there could be a sudden lowering of the load or any unintentional manoeuvre of the system.

Always lower the load to the ground and put the boom in the rest position (horizontal) before performing any repairs, maintenance or adjustments.

24. The hydraulic oil in the machine circuit can remain pressurized for long periods.

If not adequately released before any maintenance, this pressure could cause sudden movements of parts, sudden jets of oil or breakage of any hydraulic lines loosened during maintenance.

Always release the pressure before any maintenance, repair or adjustment of machine parts.

25. The lattice elements connected to the boom by means of forks can break if not properly fixed.

Make sure the ends all of extensions, jibs or braces are securely fixed; never stand on the boom or equipment to be installed during its assembly.

26. As with all heavy equipment, pay particular attention to movements carried out with the crane on the worksite or the road.

Watch out for personnel, pay attention to high-tension lines, narrow or low passages such as bridges, roads with load restrictions, steep climbs or descents and uneven ground. Use a helper in case of movements in narrow spaces.

Knowing the height, width and weight of your vehicle is very important.

Completely retract the outriggers, put the boom in the horizontal position, fix the hook and block the rotation before travelling.

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4 - Safety and operation 27. Shifting loads with the crane moving involves a considerable increase in risk. Manually block rotation with the pin located in the operator's cab, observe the precautions described in point 26, reduce the vehicle's speed to minimum, always keep within the capacities indicated in the load table, keep the weight to be moved near the crane and as close as possible to the ground, avoiding abrupt swaying; if necessary fix the load to the crane. Inflate the tyres to the pressure given in the table located in the operator's cab.

The crane could overturn if these precautions are not correctly observed.

28. The use of more than one crane for handling loads considerably increases the risks compared with handling or lifting loads with just one crane. This operation must only be carried out under the supervision of a person in charge of manoeuvres. It must be studied very carefully and several points such as the following must be taken into consideration: - Carefully study the load to be handled in order to be sure that during the operation the lifting capacity of each crane is adequate for the load.

- Make sure the slings are arranged for distributing the load evenly.

- Before lifting, check the lifting plan with all the personnel concerned.

- Carefully coordinate the crane movements before every lifting phase.

- Avoid side loads or abrupt movements.

29. Leaving the machine unattended can be very dangerous.

Before leaving the operator's seat, make sure that: - The load is touching the ground.

- The brake and rotation are locked.

- The emergency brake is applied.

- The engine is off and the gears are in neutral.

- The ignition key is turned off.

If the machine is to be abandoned for prolonged periods, and at the end of each working day, lock the cab door and disconnect the batteries by means of the battery isolator switch.

Additional information is available by consulting the ICSA guide (International Crane Stakeholder Association) "Leaving mobile cranes unattended in (partially) erected mode", which can be downloaded from the European Federation of Material Handling website (www.fem-eur.com) 30. The lifting ropes must be inspected every day to check if they need replacing. See the inspection form in the manual or directly contact the rope manufacturers for further information.

The rope must be replaced if it twisted, crushed, or has knots, abrasions, marked bends or any other damage that can cause deformation of its structure.

WARNING: do not use bare hands to guide the wire rope on drums.

31. Incorrect securing of the rope can cause giving or loss of the load.

The rope thimbles must be fitted in the wedge so that the loaded side of the rope is in a straight line with the edge of the thimble and not bent by the wedge. The rope must pass through the counterweight of the safety device fixed to the head of the boom or the extension.

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32. Incorrect winding of the rope on the drum can create breakages, tearing or flexing of the rope.

Do not use bare hands to guide the wire rope on drum; always use suitable gloves and pay particular attention to clothes which could get caught in the winch drum during its operation.

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4 - Safety and operation General instructions IMPORTANT: all operators must know the operating instructions described in this manual before using the machine.

The operator is responsible for use of the machine. Any non-conforming use relieves the manufacturer of all responsibility.

Do not use the machine or have it used until all the instructions given in this manual are perfectly understood and memorized.

Non-compliance with these instructions can result in serious damage and injury.

For any needs, do not hesitate to contact your Dealer or area Agent formally authorized to provide technical information or useful advice.

THE OPERATOR'S MANUAL and the LOAD TABLE must always be kept in the operator's cab. Contact the Dealer or area Agent for obtaining additional copies of the manual.

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General  Your safety and that of persons nearby depends on correct use of the machine.

Make sure to perfectly know the position and function of all the controls before carrying out any operation.

BEFORE USING YOUR MACHINE, TEST ALL THE CONTROLS IN A SAFE AND FREE ZONE, WITH OUTRIGGERS FULLY EXTENDED.  The terms "right and left" given in this manual indicate the sides of the machine seen from the operator's control station.  Current regulations in the workplace must always be respected.  Always keep a fire-extinguisher and a first-aid kit at hand. Make sure you know how to use them.  Sparks can be created on the electrical circuit or the exhaust pipe outlet. Do not work in closed spaces in the presence of flammable materials, powders or vapours that could cause an explosion or fire.

Failure to comply with this rule can cause serious and even fatal accidents.  Make sure to have read and understood all the danger signs or the precautions to be taken, placed on the machine. Strictly respect the maintenance instructions.  Be particularly careful if using a different machine to that normally used.  Do not smoke during refueling, as the fuel vapours are flammable.  Avoid accidents potentially caused by loose-fitting clothes that do not guarantee the necessary level of protection. Wear clothes that will not get caught on objects and if necessary wear protective equipment (helmet, safety shoes, ear protectors, safety spectacles or facemask, work gloves and reflecting clothes).  Wear a helmet, glasses, gloves and safety shoes when the current laws in the country or worksite where you are operating require it.  Before starting the engine, always make sure no one is in the immediate vicinity of the machine. Signal the start of manoeuvres by sounding the horn.  If necessary, the operator can abandon the cab by using the upper openable window (marked with the specific identification sticker) as an emergency exit.

Lifting the fanlight window upwards produces a 730 mm x 560 mm opening using the normal manual opening system, or 730 mm x 850 mm by detaching the supporting gas springs by means of a simple manoeuvre.

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4 - Safety and operation Access and cleaning  Make sure there are no traces of oil, foreign bodies or ice in the driving position, on walkways and access grips. Secure or remove all personal items or maintenance equipment.  Check the cleanness of the windows of your machine every day and also the operation of wipers. Dirty windows can be the cause of accidents.  Use both hands when climbing on board or getting off the machine, remaining in a frontal position.  Put rags dirty with grease and other flammable materials in a safe place but not on the machine.  Never jump from the machine to get off it.  Every precaution must be taken to keep the environment intact; make sure to collect and recycle all the fluids used.

Do not leave them in containers without suitable labels or in open recipients.

Make sure there are no puddles of fluids on the ground where you are operating.

For all liquids used for maintenance: - oil - grease - antifreeze - detergents do not swallow, inhale, store or transport them in containers for food products (water, beer bottles, etc.), always use the original package (ideally intact).

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Machine operation  For your safety and for optimal machine life, carry out a complete inspection before climbing on board or starting the engine.

In particular, pay attention to loose or missing screws, the state of the ropes, accumulated earth, oil or coolant leaks. Check the tyres, the equipment and systems.  A fault in a component or machine circuit can cause an accident.

Before using the machine check all the oil and coolant levels.

Make sure all the plugs, indicators and covers are properly secured.

Replace or repair faulty parts.  In case of malfunction depending on missing or non-adjusted parts, turn the machine off and immediately fix them. Failure to comply with this rule can cause serious damage or injury.  Never use a machine with obvious defects in the braking, steering, hydraulic or electropneumatic systems. This rule also applies to a machine that has been repaired or adjusted without the control or approval of the foreman.  If malfunctions occur in the mechanical, electrical, hydraulic or pneumatic parts, turn the machine off as soon as possible.  Unless otherwise ordered, retract and put the boom in the rest position, turn off the engine, apply the parking brake and block the machine with suitable wedges or stabilize it before carrying out maintenance or leaving the machine at the end of the day's work.  Only enabled operators are allowed to drive the machine.  Know the machine's limits and keep it under control at all times.

DO NOT TRY TO DO TOO MUCH TOO QUICKLY.  To circulate with the vehicle, it is a good rule to know its weight and dimensions and the characteristics of the area where you are travelling (bridges, power lines, ground strength, slopes or climbs)  Always be alert and do not allow unauthorized persons to enter the work zone. You must always know the exact position of work zone personnel.  Standing in the machine movement zone is prohibited.

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 When the engine is turned off, do not release the parking brake if the machine is not blocked. Make sure the braking system pressure is sufficient for releasing the brake.  Before starting the machine, make sure the gears are in neutral and the parking brake is applied.  Before carrying out night operations make sure the machine light signals and headlights work.  Only use the driving position.

machine

controls

and

accessories

from

the

 Work cautiously in the presence of dust, smoke or fog. Reduced visibility can be the cause of accidents.  Before loading the machine on a semi-trailer, make sure the access ramps and the trailer are free of snow, ice, oil or grease.  Avoid abrupt manoeuvres with the load suspended.  Do not grasp the ropes when the winch is working.  Check correct operation of the block limit stop device and replace it if necessary.  To intervene on the block, place it on flat and level ground so it will not tip over.  Periodically check the wear of the block grooves and those of the boom head.  Without load, check that the sheaves turn correctly and the hook swivels smoothly.  Never leave the machine unattended with a suspended load.  If the crane is parked on a slope, the truck must be blocked by wedges, and the slewing brake locked and the boom secured.  Do not carry out inclined lifting; the machine must always be perfectly level.  Before lifting a load always make sure it comes within the limits given in the table. If an electronic limiting system is not available, this operation is even more important.

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Maintenance  All maintenance operations must be carried out by qualified personnel.  For maximum safety during machine maintenance, it advisable to use only one operator. If several operators are required, they must have a clear idea of the work to be performed in order ensure perfect coordination of the manoeuvres. Everyone's safety must be the main concern of operators.  Do not perform any repairs on the machine that you are unable to complete.  Do not allow unauthorized persons to stand on the machine during maintenance.  It is advisable to wear face and eye protection when performing maintenance operations. Use a hammer with soft head (e.g. plastic, wood, brass or leather) for hammering on equipment or hardened metal surfaces.  Only start the engine in well-ventilated places (risk of intoxication by exhaust gas).  Apply the parking brake, block the wheels and place warning signs on the control levers during maintenance operations.  Always use suitable equipment for maintenance, and replace or repair worn or deteriorated equipment.  Check the cooling circuit with the engine switched off. Undo the radiator cap gradually, to slowly release the pressure in the circuit.

Pay attention to the steam, to avoid scalding.  Use the cleaning solutions with care.  Wear head and ear protectors for interventions requiring the use of compressed air. Max. air pressure: 2 bar.  Keep a suitable distance away from moving belts and fans.  For your safety, only use original replacement parts.  Arc welding of parts on the machine can deteriorate mechanical, electrical or electronic parts and compromise the machine's safety.

Carry out welding work only after: - fixing the earth terminal as close as possible to the zone for welding - disconnecting the two poles of batteries - disconnecting all the electrical and electronic devices.  After every maintenance operation check correct working of the repaired parts before using the machine.

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Electrical circuit  Before carrying out any work on the electrical part, disconnect the battery and remove the ignition key.  Do not make electrical connections or disconnections without knowing the system. An incorrect connection can cause serious injury or damage.  Never check the battery level by connecting the poles with metal objects. The electric arcs produced can cause an explosion. Use a voltmeter or ammeter.  Do not smoke or use naked flames when checking the battery fluid levels. The batteries give off flammable vapours.  Do not top-up the battery levels with acid; restore the level with distilled water.  If the electrolyte of a battery is frozen, the battery could explode if put under charge or if you try to start the machine using another battery.

To prevent freezing of the electrolyte always keep the batteries fully charged.  Never wear metal rings or wrist-watches, as these objects risk earthing the live circuit and therefore causing burns and injuries.  When using an external power source for starting the machine, connect the earth cable last and disconnect it first, in order to avoid sparks that could be produced near the batteries, causing explosions.

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Hydraulic circuit  The hydraulic system works at a very high pressure (300 bars).

The oil that could come out of even small holes risks perforating human tissues and causing serious injuries, therefore it is advisable to use a piece of wood, and not hands, to check for leaks. If the hydraulic fluid perforates your skin, see a doctor immediately.  Make sure the circuit is not pressurized before disconnecting hydraulic lines or components. Check the tightness when reconnecting the lines or components.  Hydraulic oil is flammable, therefore do not weld components that are full of oil.  The oil and components in which it circulates are hot and can cause burns, thus avoid any contact.  After an operation on the hydraulic system it is essential to have a specialized technician bleed the air.  The reservoir plug is under pressure.  The temperature of the hydraulic oil is affected by the weather conditions and the work load of the hydraulic components.

These changes in temperature affect the expansion properties of the hydraulic oil. For this reason, it is necessary to pay attention to changes, sometimes very significant, in the position of the boom and outrigger cylinders. The position of a raised and extracted boom, with or without a load, can vary over time without any retraction or lowering operations being performed. These movements are caused by the change in temperature of the hydraulic oil.

Tyres  The tyre inflation pressures refer to cold tyres. Inflation and checking must be carried out when the tyres are cold. Never inflate a hot tyre.  For your safety and that of others, every 100 hours check the tightness of the wheel nuts using the wrench supplied with the vehicle.  Check the tyres on the vehicle unloaded, always using an inflation safety cage when the wheel is not on the vehicle.  To avoid the risk of accident during and immediately after inflation, do not stand in front of the wheel and make sure to use a sufficiently long tube for inflating.  Deflate the tyres before removing any stones from the tread.  Never intervene on a rim with tyre inflated.

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Replacing the tyres 1. Loosen the wheel nuts a little.

2. Lift the machine on the outriggers with the wheels slightly off the ground.

3. Unscrew the nuts and remove the wheel.

4. Fit the new wheel, fixing the wheel nuts without tightening them.

5. Lower the machine and retract the outriggers, tighten the wheel nuts (tighten in a diagonal sequence) and adjust the torque setting according to the following table.

6. Retighten the wheel nuts after 16 hours' operation.

TRUCK CRANE MODEL

TIGHTENING TORQUE M22 x 1.5

RC30-1 / RT35

450÷550 Nm

RT45 / RT45L

450÷550 Nm

450÷550 Nm 1075 / 1075L / RT100 650 Nm Table 2 – Wheel tightening torques 1065

The machine is equipped for connections for inflating the tyres (on the left side) and an inflation kit (tube, air gun, pressure gauge) located inside the tool-box.

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Instructions for reading the load table The specific load table for the machine being used is located inside the cab. The operator must have read and understood all the following information.

Attempting to lift a load not given in the capacity table, trying to guess the capacity for boom lengths, radius or angle is extremely dangerous as the crane could sway or tip over during lifting.

Always keep within the nominal capacity given in the table.

The operator must reduce the load in relation to the unfavourable conditions in the worksite and appraise the possibility of lifting loads in complete safety.

Make sure to always have a copy of the table on board the machine.

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Choosing the best configuration Before handling any load, put the machine in the best configuration for the work to be carried out and choose the table that meet all the needs.

1

2

3

4

5

6 7 8 9

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1. Indicates the type of stabilization (outriggers intermediate or fully closed) or the type of tyres fitted.

fully opened,

2. Indicates the length and extension of the telescopic boom.

3. Indicates the total weight of the counterweight fitted, given by the sum of the main counterweight and the additional counterweight or the sum of the main counterweight and the auxiliary winch.

4. Indicates the work zone where the work is being carried out; it can be 360° or ±3° on the front part of the machine.

5. According to the table, it indicates the moment limiter program or the type of accessory fitted or, for the configuration on tyres, the use in the static or dynamic phase.

6. The boom lengths are shown here.

7. Shows the boom angle (without load) with the machine levelled.

8. Indicates the max. permissible gross load. To know the actual load to be lifted, subtract the weight of the block and that of any accessory fitted (lattice extension or jib) from the value given.

9. Indicates the boom working radius. The radius is the distance between the turret slewing axis and the vertical axis through the rotation axis of the boom head and block sheaves.

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The capacities given refer to the radius under load and therefore take into account boom flexure. Therefore it must be considered that the radius measured without load is less than that measured with the load on the hook. This must be taken into account before lifting the load in order to maintain the same radius.

boom without load

loaded boom angle

10. Index of reference symbols for reading the various configurations in the load table.

10

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Reduction of operating loads To determine the net capacity of the crane truck in an assigned configuration, subtract the loads of the accessories used for the lifting operation (reduction of load) from the gross load.

Net load = gross load – reduction of load.

The load reductions can be: a - Weight of block or hook b - Weight of harness

net load gross load

a - Weight of main block b - Weight of harness c - Weight of auxiliary block d - Weight of section of rope from boom head to auxiliary block

net load gross load

a - Weight of main block b - Weight of harness c - Weight of auxiliary block d - Weight of section of rope from boom head to auxiliary block e - Weight of supplementary sheave f - Weight of extension or jib secured to brackets on main boom

net load

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gross load

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Operation and maintenance manual

4 - Safety and operation Extension secured to brackets When the extension or jib is secured to brackets alongside the main boom the "bracketed weight" as given in the notes of the "load tables" must be subtracted from the gross load given in the load tables to calculate the net capacity of the crane.

Mounted extension When the same extension or jib is mounted on the boom head the "mounted weight" as given in the notes of the "load table" must be subtracted from the gross load given in the load tables to calculate the net capacity of the crane. This load reduction must only be applied if the lifting operation is carried out with the main boom, and not when carried out with the extension or jib.

Subtract the bracketed weight of the jib from the gross load.

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Special instructions for lifting on tyres The loads on tyres authorized by the capacity tables are to be deemed valid only if the following conditions are met: - Tyres inflated to the pressure recommended for the work to be carried out and for the workplace.

- According to the configurations, parking brake applied.

- Rear suspension units locked.

- Load kept as close as possible to the ground.

- Flat, firm and level ground.

CAUTION: TO KEEP THE MACHINE STABLE DURING MANOEUVRES WITHOUT LOAD IN THE CONFIGURATION ON TYRES, THE BOOM ANGLE LIMITS GIVEN IN THE LOAD TABLE MUST BE COMPLIED WITH.

Example given merely as a guide Always refer to the copy in the cab

IMPORTANT: Whenever possible, lift loads with outriggers fully or partially extended rather than on tyres.

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Operation and maintenance manual

4 - Safety and operation Special instructions for lifting on outriggers The loads on outriggers authorized by the capacity tables are to be deemed valid only if the following conditions are met: - Wheels completely raised above the ground - Machine stabilized horizontally, referring to the level located in the operator's cab.

NOTE: Levelling must be carried out with no load attached to the hook and with the boom fully retracted and facing the front or rear of the carrier.

- Firm ground under the outrigger support plates.

- If necessary provide for stabilization with wooden boards to increase the support surface.

CAUTION: During superstructure slewing movements with no load and during lifting operations, the accuracy of the level indication may be impaired by distortion of the crane structure. This situation will not affect correct stabilization of the machine.

Lifting of an outrigger support plate off the ground The lifting of an outrigger support plate off the ground when the load passes over the opposite outrigger is not a sign of imminent tipping over of the machine.

However, when this occurs and if the stabilization conditions are normal, check that: - The outrigger beam on the load side is correctly extended.

- The wheels are raised above the ground as indicated in the capacity tables on outriggers.

- The load lifted does not exceed the permissible value.

- The support plate has not sunk in the ground under the weight of the load.

- The frame is not deformed due to incorrect stabilization.

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Special instructions for lifting with mechanical element extended For crane truck models with mechanical locking by means of a special pin, the capacities with telescopic sections partially or fully retracted must be deduced from the special load tables referring EXCLUSIVELY to the actual inclination of the boom not considering its length.

extended mechanical section

boom partially extended

gross load

inclination angle

radius

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Max. forces exerted on ground (daN)

Model 0 km/h – 360°

0 km/h – 0°

2 km/h – 0°

RC30

28000

Ø 525 mm

17800

17800

14000

14.00R24 16.00R25

RT35

27000

Ø 525 mm

17800

17800

14000

14.00R24 16.00R25

RT45

36570

Ø 525 mm

19300

19300

14500

16.00R25 20.5R25

RT45L

33500

Ø 525 mm

18900

19200

15100

16.00R25 20.5R25

1065

52500

Ø 650 mm

23200

/

18200

23.5R25 26.5R25

1075

50000

Ø 650 mm

23200

23200

18200

23.5R25 26.5R25

1075L

51600

Ø 650 mm

23200

23200

18200

23.5R25 26.5R25

RT100

70000

Ø 610 mm

34500

34500

28100

26.5R25 29.5R25

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Actions of the wind The crane can be used safely by following the values given in the load capacity tables up to a wind speed of 8.5 m/s (30 kph - force 5) on a load surface of 1.2 m²/tonne.

For additional information consult the FEM 5.016 guide "Aspects connected with safety in the installation and transport of wind turbines".

WARNING: Every day, check the weather and wind speed forecast by calling the nearest weather station. Do not lift the load if the wind speed is higher than the maximum permissible.

1.2 m²

12 m²

Wind 1 tonne Inland wind speed

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10 tonnes Wind speed (10 minute average)

Effect of the wind

Beaufort scale

Designation

mps

kph

0

Calm

0 - 0.2

1

1

Light air

0.3 - 1.5

1-5

2

Light breeze

1.6 - 3.3

6 - 11

3

Gentle breeze

3.4 - 5.4

12 - 19

4

Moderate breeze

5.5 - 7.9

20 - 28

5

Fresh breeze

8 - 10.7

29 - 38

6

Strong wind

10.8 - 13.8

39 - 49

7

High wind

13.9 - 17.1

50 - 61

8

Gale

17.2 - 20.7

62 - 74

9

Strong gale

20.8 - 24.4

75 - 88

10

Storm

24.5 - 28.4

89 - 102

Smoke drift indicates wind direction.

Leaves and wind vanes are stationary Wind felt on exposed skin. Leaves rustle. Wind vanes begin to move Leaves and small twigs constantly moving, light flags extended Dust and loose paper raised. Small branches begin to move Small bushes sway. Moderate waves of some length on lake surfaces Large branches in motion. Whistling heard in overhead wires. Umbrella use becomes difficult Whole trees in motion. Effort needed to walk against the wind Some twigs broken from trees.

Progress on foot is seriously impeded Construction/temporary signs and barricades blow over Trees are broken off or uprooted, structural damage likely

11

Violent storm

28.5 - 32.6

103 - 117

Widespread damage

12

Hurricane

32.7 and above

118 and above

Severe widespread damage

Calm, smoke rises vertically

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The crane out of service must be parked with the boom fully retracted in a horizontal position, no extension or jib deployed and no load applied to hook.

If the crane cannot be placed in its parking position, consider a travel speed on the basis of the following map.

Regions  ref (m/s)

A 24

B 24

C 28

D 32

E 36

 ref = average wind reference speed for a period of 10 minutes at 10 m above sea level.

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Safety devices Rated capacity and movement limiter The limiter is designed to provide the crane operator with essential and necessary information for operating the crane with safety. Using various sensors, the limiter controls the various crane functions and offers the operator a constant display of the crane's capacity. The display changes constantly according to the different crane movements necessary for handling the load.

The rated capacity limiter provides the crane operator with information on the boom length and angle, the nominal load lifted and the maximum liftable load in the particular configuration selected. When the crane approaches non-permissible conditions, the limiter warns the crane operator with an acoustic alarm and an indicator light and deactivates any functions that can aggravate the crane's condition to prevent overload conditions: Winch lifting.

Telescopic boom raising.

Telescopic boom lowering.

Telescopic boom extension.

The limiter is an indispensable device that prevents dangerous situations for the crane operator and the crane. Like all safety systems, the limiter cannot cover all human errors. The crane operator must always be aware of the operations he is carrying out.

WARNING: The limiter is unable to recognise the machine stabilization configuration automatically (outrigger beams partially or totally extended or retracted, lifting on tyres); it is therefore the operator's responsibility to program the limiter with the stabilization configuration corresponding to the configuration with which the crane is effectively operating.

WARNING: A special device allows the limiter to be inhibited, in the event of it failing, so that all crane functions are enabled.

Crane operations performed with the limiter inhibited are exclusively and entirely the responsibility of the crane operator or worksite manager. Terex® will not accept liability for any accidents that could occur using the crane with the limiter inhibited.

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Limit stop device In compliance with the safety regulations, the crane truck is equipped with: 1. Lifting limit stop device that blocks the manoeuvre, preventing the block from getting too close to the boom head.

2. A "three dead turns" lowering limit stop device that prevents complete unwinding of the rope from the winch drum.

When the limit stops cut-in blocking the lifting or lowering manoeuvre, just to carry out the opposite manoeuvre to that which led to the blocking in order to restore full efficiency of all the crane controls.

For safety reasons, it is extremely important to maintain the efficiency of the limit stop device, therefore we recommend checking its operation daily.

Lowering limit stop device The purpose of the lowering limit stop device is to stop the winch lowering movement when there are only three turns of the rope on the drum; in this condition the feeler tilts, touching the winch drum and activating the microswitch that interrupts the safety electrical circuit, blocking the lowering movement.

In this condition, the lifting movement that will bring the device within its normal operating limits can be activated.

"Three dead turns" safety switch adjustment method: - Unwind the rope so that 3 turns remain wound on the winch.

- If the 3 dead turns safety device is inactive, turn adjuster screw (A - B) to move the cam until you hear the switch trip.

- Then carry out the lifting operation in descent to check that the safety is active.

- Wind the rope additional turns and test the safety of the movement.

The "3 dead turns" safety contactors must disconnect the winch hook descent functions.

A B

Periodically check feeler wear and operate the device adjustment or replace the feeler.

NOTE: In the event of rope replacement, the safety device must be readjusted.

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Model TW8 (RT100) Legend: 1. Winch drum 2. Lifting rope 3. Return spring 4. Limit switch 5. Adjustment screw 6. Cable clamp

2

1

6 3

5

4

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Model TW6 (1065 - 1075 – 1075L) Legend: 1. Winch drum 2. Lifting rope 3. Return spring 4. Limit switch 5. Adjustment screw 6. Cable clamp 2 1

3

6

5

4

Models TW4 and TW5 (RT45 – RT45L) Legend: 1. Winch drum 2. Lifting rope 3. Cable clamp and drum feeler 4. Adjustment screw 5. Limit switch 6. Return spring 6

2

4

3 1

5

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Lifting limit stop device Microswitch "1" is kept in operation by counterweight "3". When the block assembly is lifted up into contact with the counterweight the microswitch interrupts the electric circuit and lifting is stopped.

In this condition the block lowering movement can be activated, which will bring the device within its normal operating limits.

IMPORTANT: When activating winch lifting with the block near the limit stop, work with caution and at moderate speed.

The minimum length of the limit stop device counterweight "2" chain must be 80 cm.

Legend: 1. Limit switch 2. Counterweight chain 3. Limit stop counterweight

1

2

3

The device can be temporarily shut off by holding down the on the rated capacity limiter system's display.

button

IMPORTANT: Shutting off is permissible solely to change the frame of the block assembly or to secure it to the front or top of the chassis.

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4 - Safety and operation Deadman Safety Device To guarantee the safety of the machine and driver, there are switches on each hand control. They prevent crane movements when the operator does not grip the hand controls or does not select the outrigger control.

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Machine operation Introduction This section and the safety regulations for mobile cranes given at the beginning of the manual must be carefully read before driving the machine.

Always respect the following precautions to ensure operation in safe conditions: • Always check the capacity table to know the maximum load that can be lifted with different boom angles, lengths and other factors that can be taken into consideration during load handling.

• Always start the machine using an engine speed suitable for the load to be handled.

• If the load is likely to sway, always keep it as close as possible to the machine and the ground.

• During boom extension or lowering to prevent the block from striking the boom head operate the winch to unwind the rope.

Preliminary checks Every day, before using the machine, clean all the windows, screens, lights and rear-vision mirrors to ensure good visibility for the operator.

Adjust the operator's seat so that it is comfortable and suitable for the machine operator.

Checks to be carried out before starting the machine: - Engine oil level - Transmission / gearbox oil level - Fuel level - Hydraulic oil level - Engine coolant level - Brake fluid level - Cab heating (when provided) fuel level - Windscreen washer liquid level - Winch rope

Engine starting Before starting the engine, make sure there are no persons or objects in the immediate vicinity of the machine.

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1.

2.

3.

4.

Make sure the gearshift lever is in the neutral position "N".

Select the fast or slow gears according to needs (where applicable).

Turn the ignition key.

The battery level, braking system air circuit, engine oil pressure and coolant temperature warning lights on the instrument panel come on.

5. Beep the horn.

6. The parking brake must be applied.

7. Turn the ignition switch to the second position to start the engine.

NOTE: The engine cannot be started if the gear lever is not in the neutral position "N".

IMPORTANT: To avoid permanent damage to the starter motor, do not operate it continuously for more than 30 seconds at a time. If within that time, the engine fails to start, wait a couple of minutes before trying again, but do not operate the starter for more than 15-20 seconds.

If the engine still does not start, wait for the starter motor to cool before trying again and make sure the gearshift lever is in the neutral position "N".

IMPORTANT: When operating the crane at temperatures below 0°C, after starting the engine and before using the crane, allow the engine to idle for several minutes to allow the hydraulic oil to reach its working temperature.

When the engine has started and idles normally: the oil pressure and battery level lights go out, and the air pressure warning light goes out when the pressure reaches 5.5 bar.

The parking brake light stays on.

NOTE: Do not use the machine until the air pressure lights are extinguished.

Switching off the engine Before switching the machine off, allow the engine to idle for a few seconds.

IMPORTANT: Do not stop the engine if the gear lever is not in the neutral position "N".

Never accelerate before switching the engine off, as this could damage the turbocharger due to lack of lubrication.

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Securing the block (hook) to the truck crane WARNING: when the block is tied to the crane structure use special caution when performing movements that could subject the anchor stay to tension resulting in breakage of the stay and consequent projection of the block forwards. It is therefore prohibited to perform any movements other than those that are strictly necessary to release or attach the block.

Failure to observe these precautions can result in serious personal injury.

Attachment To secure the block to the front of the chassis: Fig.1 1.

2.

3.

4.

5.

Retract the boom completely.

Attach the block anchor stay to the front of the chassis.

Position the block so that it is vertically aligned with the anchor stay.

Lower the block and secure it to the anchor stay.

Make sure that all personnel on the ground have been removed from the area around the front of the machine.

6. Bring the boom to the required angle, executing the boom lower movement alternately with the block lift movement, taking care NOT to tension the anchor stay (DO NOT perform the two movements simultaneously).

Fig.1

To secure the block to the top of the chassis: Fig.2 Retract the boom completely.

Attach the block anchor stay to the top of the chassis.

Position the block so that it is vertically aligned with the anchor stay.

Lower the block and secure it to the anchor stay.

Make sure that all personnel on the ground have been removed from the area around the front of the machine.

6. Bring the boom to the required angle, executing the boom lower movement alternately with the block lift movement, taking care NOT to tension the anchor stay (DO NOT perform the two movements simultaneously).

1.

2.

3.

4.

5.

Fig.2

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Release To release the block from the front of the chassis: Fig.1 1. Make sure that all personnel on the ground have been removed from the area around the front of the machine.

2. Align the boom axis with respect to the anchor point of the block by slewing the superstructure and taking care NOT to tension the anchor stay.

3. Bring the head of the boom to a position in which it is vertically aligned with the block by performing block lower movement alternately with the boom movement, taking care NOT to tension the anchor stay (DO NOT perform the two movements simultaneously).

4. Detach the block from the anchor stay on the front of the chassis.

5. Proceed with normal crane operations.

Fig.1

To release the block from the top of the chassis: Fig.2 1. Make sure that all personnel on the ground have been removed from the area around the front of the machine.

2. Align the boom axis with respect to the anchor point of the block by slewing the superstructure and taking care NOT to tension the anchor stay.

3. Bring the head of the boom to a position in which it is vertically aligned with the block by performing block lower movement alternately with the boom movement, taking care NOT to tension the anchor stay (DO NOT perform the two movements simultaneously).

4. Release the block from the anchor stay on the top of the chassis.

5. Proceed with normal crane operations.

Fig.2

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Driving on road Preliminary operations 1.

2.

3.

4.

5.

Align the turret with the carrier (boom on the front end).

Make sure the device locking the turret to the frame is engaged.

Secure the block to the top of the chassis.

Make sure the suspension is free (warning light off).

Make sure the ground support plates and outrigger beams are locked in place.

6. Check the general operation of the lights.

7. Check the tyre pressures.

8. Adjust the rear-vision mirrors.

9. Make sure that, once seated in the cab, the entire machine can be controlled through the rear-view mirrors.

10. Ensure all the bonnets are fastened.

11. Never drive the machine on the road with a suspended load.

12. Make sure the machine's electrical system works properly (headlights, blinkers, parking lights, etc.).

13. Carrying passengers is not allowed.

14. Respect the speed limits.

15. Strictly respect the highway code.

16. As a part of the boom projects over the front of the machine, a guiding car is necessary when crossing intersections.

17. Make sure all the roads on the route will take the road dimensions and weight of the machine.

WARNING: The operator must make sure he has complete and ample visibility of the area around the machine when proceeding by road.

Only front-wheel steering is allowed on the road. Regularly check front wheel alignment and adjust if necessary.

To avoid damaging the transmission, stop the machine before inverting direction (forward or reverse).

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4 - Safety and operation Driving on the worksite For travel operations without a load, depending on the distance and the type of terrain, it is advisable to: 1. align the turret with the carrier (boom on the front end).

2. insert the manual slewing locking pin.

3. secure the block to the front of the chassis.

4. lift the outriggers, retract the beams completely and secure with the specific pin.

Transporting a suspended load 1. Align the turret with the carrier (boom on the front end).

2. Make sure the manual slewing lock pin is inserted.

3. Consult the load tables to ensure that the load does not exceed the values given in the table for operation on tyres.

4. Keep the load as close as possible to the ground to avoid swaying.

5. Respect the tyre inflation pressures.

6. Make sure the suspensions are locked.

7. Suspended loads must only be carried on flat and horizontal ground, after first checking that the terrain is sufficiently stable to withstand the load borne by the vehicle tyres.

8. Select a steering mode according to transport requirements.

9. Select a slow gear.

10. Select front-axle drive (4-wheel drive).

During the transport of loads on flat ground the work radius is constant.

When transporting loads uphill the reduction in the work radius can cause the load to knock against the crane.

Travelling with no load but with the boom raised can cause the machine to tip over.

When transporting loads downhill the increase in the work radius can cause an overload and tipping over of the machine.

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Machine stabilization Instructions Raise the machine on the outriggers on firm and possibly level ground.

In case of sloping ground, keep the machine horizontal using thick and hard wooden blocks, adjusting the travel of the outrigger beam vertical cylinders, making them come out more or less.

The area of these spacers on the ground must be greater than the surface area of the outrigger support plates.

The machine can considered stabilized only when all the wheels are completely off the ground.

WARNING: If an obstacle prevents all the outrigger beams from being extended to the same length, refer to the configuration in the table relative to use on tyres, with outrigger beams partially extended or retracted.

The crane trucks have three types of stabilization.

Outrigger beams fully retracted Depending on the load table configuration, the crane can operate with all the outrigger beams retracted. For a correct configuration, the beam locking pin must be inserted in the special seat.

Middle outrigger beams Depending on the load table configuration, the crane can operate with the middle outrigger beams. For a correct configuration, the beam locking pin must be inserted in the special seat.

Outrigger beams fully extended Depending on the load table configuration, the crane can operate with the outrigger beams completely extended. For a correct configuration, the beam locking pin must be inserted in the special seat.

NOTE: Before extending and retracting REMEMBER TO REMOVE the locking pins.

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outrigger

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Support surfaces Check the solidity of the terrain over which the crane is to travel.

Make sure the ground can support the crane. Avoid unstable, soft and partially frozen ground.

Work in the proximity of an excavation: the crane must not be sited on the edge of an embankment or pit; in these cases keep well back from the edge by a sufficient distance in accordance with the compactness of the terrain.

Safety distance: Firm compact terrain (not powdery).

Distance 1 = Depth of excavation (A) Powdery terrain or backfill.

Distance 2 = Depth of excavation (A) x 2

2 1

A

WARNING: If the machine is working close to an excavation and the prescribed safety distance cannot be observed, the excavation walls must be shored or the hole must be filled to avoid landslides.

The surface must withstand the weight of the crane and the load to be lifted, in addition to the live loads imparted because of movements of the crane and wind force.

The maximum ground pressure applied through the outrigger ground support plates depends on the configuration of the crane and the load to be lifted.

In accordance with the values in the tables, the operator can decide whether the ground support plates are sufficient or whether it is necessary to make use of larger size supports such as boards interposed between the ground support plates and the ground.

The outrigger support plates must be positioned in the centre of such additional supports.

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Guideline table of permissible pressures for various types of terrain

Type A

Terrain Types

daN/cm² (kg/cm²)

Naturally compressed soil, backfill

0.5 -1.0

Intact natural terrain Powdery but firm soil: Fine or medium particle size sand

1.5

Large particle sand - gravel

2.0

Non-powdery terrain:

Type B

Soft

0.4

Firm

1.0

Semi-rigid

2.0

Hard Rock with few fissures in good condition, unaffected by weathering and in strata Close stratification, compact stratification or column stratification

4.0 15 30

Artificially compacted terrain

Type C

Asphalt and bitumen

5 - 15

Cement group BI

50 - 250

Cement group BII

350 - 550

NOTE: If in doubt about the stability of the terrain, perform a soil analysis test.

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Dangers in the work area Pay attention to power lines, bridges, railways, buildings and other cranes.

Electrical arcing may occur between a power line and metal parts of the machine if they come into contact with the power line or if the minimum safety distance is not observed.

Apply local regulation regarding safety distances from power lines With high voltage lines, any direct contact with the boom or the hoist rope is always dangerous.

With high voltage lines above 1000 V current can be transferred even as the lines are approached.

This hazard should be prevented by the following measures: - Switch leads to current-free.

- Cover and / or fence off the danger zone.

Both measures may only be carried out by qualified electrical specialists.

If these measures cannot be carried out, a sufficient safety clearance must be maintained between the crane (hoist rope, lifting tackle, hook block, load) and current-carrying lines.

Danger to life and limb!

Keep a clearance of at least 10 m. If this is not possible, you must obtain information on required minimum safety distances from the electric power company responsible.

With extremely long boom equipment, these safety clearances are very difficult to judge. To be on the safe side, increase the safety clearance to 20 m.

The safety clearance must still be available for unfavourable crane or load positions.

Allow for possible swinging of the load or swinging out of the free line as a result of the wind.

If, however, the crane accidentally comes into contact with high voltage power lines: - Bring the crane out of the danger zone: drive it out, swing it, adjust the boom system!

-

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If this is not possible: Do not leave the crane or the cab!

Warn anyone in the vicinity against approaching or touching the crane.

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If the crane operator leaves the crane or if another person approaches and touches the crane, they will receive an electric shock.

Even the ground around the crane is carrying an electric current.

Therefore every step on the crane, to the crane or away from the crane is potentially dangerous (step voltage)!

-

Arrange for the power in the cable to be switched off.

Only leave the crane when you are sure that the touched/damaged line has definitely been disconnected from the power source.

Extension of the boom Extension of the boom with a suspended load is normally permitted in the limit of 75% of the capacities indicated in the load table and anyway within a maximum capacity of 8 tonnes.

The precision of this manoeuvre is anyway less than the precision that can be obtained by lifting the load with the rope because it depends on the mechanical efficiency of the boom (friction of slide pads).

Friction of the slide pads depends on: - greasing - boom lifting angle - incidence of the lifted load During extension manoeuvres, very poor efficiency of the boom will result in inhibition of the function when the maximum pressure value set for the extension circuit is reached.

To re-enable the manoeuvre, place the lifted load on the ground and reposition the boom in more favourable geometrical conditions.

During retraction of the boom poor efficiency may translate into abrupt starting of the movement of the sections, which may perform sudden stick-slip type movements in steps of up to 50 cm.

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Lifting rope The lifting rope is one of the crane's main parts, and requires particular attention for starting and maintenance.

The ropes must be visually checked for signs of deterioration or deformations every day.

Pay special attention to the points where the ropes are attached to the equipment.

In any case, the rope must be inspected when an accident may have caused damage to the strands, wires or attachment points or when a rope has been returned to service after being removed and then refitted.

If the machine has not been used for some time, the rope must be inspected before resuming work.

In particular, check: - The fixing points at the rope ends.

- The parts of the rope sliding on the lifting or idle section sheaves.

Rope replacement criteria.

- Broken wires (nature and number).

- Broken wire nests.

- Gradual increase in the number of broken wires.

- Broken strands.

- Broken rope core.

- Reduced elasticity. reduction in rope diameter rope stretching no space between individual wires and strands appearance of fine brown powder between strands - General wear of rope due to abrasion.

- External and internal corrosion.

- Rope deformation (under load) spiral deformation basket deformation stretched wires slackening of certain wires or strands knottiness contractions flattening loops lumps bends - Deterioration induced by heat.

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Visual examples of various problems that can occur to the rope

Breakage and tearing of wires on two consecutive strands that required replacement (crossed strands)

High wear and very many broken wires that required immediate replacement (crossed strands)

Broken wires on the same strand and slight wear

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Broken crossed wires at the equalizer pulley

Numerous broken wires hidden by the pulley, the rope must be removed

Example of wire rope with very high internal corrosion

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Eccentric rigging (unbalanced) Eccentric or unbalanced orientation of the boom head results in twisting of the boom that is not permitted by the load table.

The load tables are valid only if the boom head is rigged symmetrically.

axis of the boom

axis of the boom

boom twisting

if the hoisting line is not centred with respect to the boom head...

…… the boom will twist when a load is applied

Asymmetrical block rigging causes its rotation and rapid wear of sheaves.

Blocks that are rigged asymmetrically will tend to rotate when a heavy load is applied.

When rigged symmetrically they work correctly.

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Symmetrical rigging (balanced) In the case of direct pull, when the hoisting line is reeved in through the central sheave or in the sheave immediately next to the boom axis, twisting of the boom is either eliminated or minimised.

boom axis

boom axis

boom axis

In the case of a rope fall with several tackles, if the tackles are uniformly distributed on the boom axis twisting of the boom is either eliminated or minimised.

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Changing the number of tackles The speed of lifting or lowering of the block decreases in proportion to the increase in the number of tackles. This number depends on the load to be lifted and the height to which it is to be lifted (refer to the load tables).

Use a maximum of two tackles when working with the lattice extension or any type of jib.

1.

2.

3.

4.

5.

6.

Lower the boom and rest the block on the ground.

Remove the wedge box from the boom head.

Remove the clamp from the rope end.

Remove the wedge and the rope from the wedge box.

Withdraw the rope from the limit stop counterweight.

Wind or unwind the rope on the boom head sheaves until obtaining the required number of tackles.

7. Insert the rope into the limit stop counterweight.

8. Insert the rope into the wedge box then insert the wedge.

Wrong

Correct The section of rope inserted in the block must be positioned on the side of the wedge box located on the same vertical axis as must be the corresponding connecting pin. The terminal part of the rope must be located on the inclined side of the wedge box.

9. Attach the rope clamp in such a way that the rope cannot become detached from the wedge box.

10. Insert the wedge block on the boom head (pay attention to the direction in which you insert the rope).

11. With a load attached slacken the rope slowly so that you can position the rope and the wedge block. Check that the rope is correctly positioned.

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4 - Safety and operation Lifting blocks and hooks The crane can be used with blocks/hooks having different characteristics and various performance levels.

It is the responsibility of the operator to use a block/hook of appropriate capacity in relation to the load to be lifted and having suitable characteristics in relation to the type of rope installed on the crane.

Before slinging the load ensure that the hook spring safety device is fully functional and the hook shows no obvious signs of wear.

Before lifting each time check that the load is perfectly aligned with the block.

Lifting more than the maximum capacity of the block, indicated by the note plates on it and stamped on the hook, must never be done.

Lifting in jerks and at temperatures below – 30°C and over + 100°C is not permissible.

Any changes of any kind made to the block and to the hook, note that welding is prohibited especially on the hook, relieve the manufacturer of all liability.

NOTE: If a load that exceeds the maximum permissible capacity has accidentally been lifted, you must, before resuming work, immediately check the extent to which the hook has opened.

This measurement must be compared with the data given on the certificate issued by the manufacturer.

If the measurement is not as shown on the certificate, you must stop work immediately and promptly notify the maintenance manager.

The hook must be replaced.

WARNING: Unauthorized removal, damage to or loss of the red note plate bearing the block identification data makes it impossible for the manufacturer to trace the product in the event of dispute.

It is therefore important that, should the above happen, we are promptly notified so as to be able to provide you with a new note plate.

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Harnessing the load  Slinging of loads and orders to perform manoeuvres must be entrusted exclusively to specifically authorised personnel.  When several persons are assigned to load slinging duties, checking of the operation and instructions for manoeuvres must be entrusted to just one specifically trained person with the necessary level of responsibility.  To sling loads use ropes, chains or other special equipment in perfect condition. All deteriorated components must be discarded.  Choose the ropes or chains on the basis of the weight to be lifted, taking account of the angle of the lifting legs (if the angle formed by the lifting legs of ropes or chains exceeds 120° the use of spreaders/equalizers is essential). The use of excessively short ropes or chains can lead to sudden breakage with consequent dropping of the load.  Place suitable wooden spacers or protecting profiles between the ropes or chains and the load to be lifted if the load has live edges.  Check that the slung load is balanced by slowly taking the strain with the ropes before instructing the crane operator to lift the load.

Extensions assembly – disassembly  Operations to install or remove extensions must be carried out exclusively by qualified personnel.  Perform these operations in an open space with no other persons in the vicinity and work in compliance with the specific instructions supplied for the extension in question.

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4 - Safety and operation Work with main winch and auxiliary winch DANGER: The rated capacity limiter cannot calculate the load of two blocks simultaneously in order to ensure safe working conditions; for this reason all load handling operations performed with two blocks are UNDER THE SOLE RESPONSIBILITY OF THE OPERATOR. Terex® CANNOT BE HELD LIABLE UNDER ANY CIRCUMSTANCES FOR POSSIBLE ACCIDENTS THAT MAY OCCUR WHEN USING THE CRANE WITH TWO WINCHES. Working with two blocks consists in handling a load using the block of the main boom and the block of the extension.

First of all, the load to be handled must be lifted exclusively with the extension. Check the load table to ensure that this is possible.

Support the machine on fully extended outriggers, slew the turret to the front and ensure the boom is aligned with the machine axis.

The limiter performs its functions correctly when a single block assembly is used at a time (work with main boom or work with tower section); when working with two block assemblies, the limiter must be set onto the work mode with tower section.

Since the effective load is lifted by two blocks simultaneously, the maximum load is equivalent to the maximum total load permitted with a tower section during load handling with the tower section (with a single block).

Check the load capacity table.

The load capacity value depends on the extension installed. Check the table of capacities with extension. The value indicated by the limiter will be the value of the configured extension.

Work with two blocks is accompanied by the risk of subjecting the boom and the extension to an overload and causing accidents, since the limiter cannot perform its functions correctly.

Handling "permitted" under the responsibility of the crane operator or the site manager is that of turning a load using two blocks, the extension block (which is less robust) to lift the load and the main block to turn it.

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To lift the load, utilise the extension block. (Since this block is less robust).

Lift the load with the extension block.

Turn the load to bring it to a horizontal position using the block on the main boom.

CAUTION: When the block of the main boom pulls the load to align it in a horizontal direction, the readings of the load limiter are unreliable.

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4 - Safety and operation When handling loads with the two blocks never lower the boom because the limiter is unable to monitor overload conditions.

Lower the load with the extension block to bring it to a vertical position.

All manoeuvres must be executed with slow movements and without snatching.

The tackles of the main boom winch must be identical in number or more than the tackles of the extension block.

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Lifting with several mobile cranes Lifting operations involving two or more mobile cranes are complex procedures that call for significant levels of skill, practice and careful planning. It is therefore necessary to prepare a detailed procedure that takes account of all possible situations and that anyway addresses at least the following minimum requirements: - Lifting must be carried out under the control of a responsible supervisor.

- The terrain must be flat and solid, otherwise it will be necessary to use all the means necessary to achieve this condition.

- All the cranes must be accurately levelled.

- The precise weight of the load and its centre of gravity must be established.

- The maximum working radius that can be reached by each crane during the entire procedure must be established.

- The length and inclination angle of the crane booms must be established.

- The nominal capacity of each crane must be established for each stage of the procedure.

- When lifting with several cranes none of the cranes involved must carry more than 75% of its net capacity; greater reductions may be required in the presence of specific lifting conditions.

- The speed of the block, slewing, and the crane boom must be the same for all the cranes as far as possible.

- Slewing, tilting and extension movements must be limited to the indispensable minimum.

- It is dangerous to travel with a load because swaying movement can result in the transfer of very significant loads from one crane to another.

- Operators must be informed of exactly how to act and the movements that are to be performed before starting the lifting operation.

- If possible, perform one or more trials with no load until all the operators are aware of what is required of them.

- All communications during the lifting procedure must take place by radio (preferably closed type rather than walkie-talkies).

- It is essential that just one person be appointed to direct and supervise the operation. Said person must be in a position to observe the entire operation and must keep in radio contact with the operators.

- All movements of the cranes must be performed as smoothly as possible with very gradual stops and starts.

- The ropes of the blocks must be kept vertical. If this rule is not observed the cranes will tend to create overload conditions with each other and cause extremely dangerous lateral swinging movements.

- For these operations it is important to check the correct functioning of the load indicator and/or limiter with which the mobile cranes taking part in the procedure must be equipped.

Additional information is available by consulting the ICSA guide (International Crane Stakeholder Association) "Lifting a load with several mobile cranes (Multiple lifting)", which can be downloaded from the European Federation of Material Handling website (www.fem-eur.com).

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Towing In the event of a breakdown the crane can be towed over short distances (less than 10 km) at reduced speed (less than 10 km/h) using a towing bar.

- Put the gear selector into neutral - Release the parking brake on the front axle. The service brakes, supplied with the remaining air pressure in the circuit, are not affected by this operation.

- Disconnect the transmission shafts (front and rear axle). If this operation is not carried out the transmission may be rapidly and irreparably damaged.

The crane must be towed in strict compliance with the rules of the highway code in force in the country in which it is working.

Use the towing points provided specifically for the purpose, which are located on the front of the chassis (optionally on the rear).

The maximum horizontal traction force on the hook must be less than 50% of the total weight of the machine in running order.

If the crane becomes lodged in mud or sand, use the towing attachments located on each corner of the carrier to pull it clear.

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Lifting the crane truck To lift the crane truck, find the 4 points identified by the decal on the truck

Use adequate equipment for lifting the crane.

The following are the maximum force values applicable to each lifting point irrespective of the direction of application of the forces.

Crane truck RC30 RT35 RT45 RT45L QUADSTAR 1060 QUADSTAR 1075 QUADSTAR 1075L RT100

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36000

76000 69000

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4 - Safety and operation Transporting the crane on a low loader Use trailers or low loaders of suitable size to transport the machine.

Secure the crane immovably to the trailer by means of chains or bar stays.

Make sure that the overall load height is lower than the height permitted by statutory legislation or by motorway authorities and, if necessary, that the specific transportation or road circulation permit has been issued.

Do not resort to deflating the tyres to comply with the maximum permissible height dimension.

If the outrigger plates are not in contact with the trailer bed, make sure the outrigger beam is locked to avoid uncontrolled extension movements.

The crane must be transported with the boom in a horizontal position, the block tied to the frame structure, and slewing movements locked with the manually inserted pin and, once the crane has been loaded, with the parking brake applied. Always comply fully with the foregoing instructions even if the crane is to be transported over very short distances.

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Contents Identification of the controls . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Operator's cab controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Side instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hand controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Left hand control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Right-hand control lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Central control column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Column indicator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Telescopic boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

RT45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 RT45L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Machine layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Outrigger controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Symbols on outrigger controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Gearshift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Central control column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Engine coolant temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . 29 Fuel gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Warning light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Blinker light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Battery charge light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Engine oil low pressure warning light . . . . . . . . . . . . . . . . . . . . . . . . 30 Suspension lock warning light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Wheel alignment warning light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Brake fluid low level warning light . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Parking brake applied warning light . . . . . . . . . . . . . . . . . . . . . . . . . 31 Torque converter oil temperature warning light . . . . . . . . . . . . . . . . 32 Front axle brake circuit low pressure warning light . . . . . . . . . . . . . 32 Rear axle brake circuit low pressure warning light . . . . . . . . . . . . . . 32 Parking lights / low beam light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 High beam light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Emergency lights switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Flashing revolving light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Rear axle oscillation lock switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Rear fog light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Lights main switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Work light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Steering mode selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Lever switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Manual rotation locking pin . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Bubble level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Cummins engine control panel . . . . . . . . . . . . . . . . . . . . . . . 39 Radio and 24V socket outlet . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Rear axle differential lock control (optional) . . . . . . . . . . . . 41 Cab heating control (optional) . . . . . . . . . . . . . . . . . . . . . . . . 42 Air conditioner control in operator's cab (optional) . . . . . . 43 02-2015a

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Battery disconnecting switch . . . . . . . . . . . . . . . . . . . . . . . . . 43 Operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Seat adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

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Identification of the controls The reference numbers of instruments and controls in the cab illustrations correspond to the numbers in the text together with the description of controls, instruments and relative functions.

Note: The following list specifies all the standard machine controls and optional items complete with descriptions. Not all the instruments listed are supplied on every machine.

Before using the machine the operator must carefully read all the information in this heading and the safety prescriptions in the first part of the manual for earthmoving machinery operations.

The operator must know the exact position and function of every control on the machine.

This manual contains the words WARNING, CAUTION, and NOTES to highlight important and relevant instructions. The indications WARNING and CAUTION precede the section or point to which they refer, whereas NOTES relevant to the subject in question are given below the sections or points. In this manual the indications WARNING, CAUTION and NOTES are specified as follows: WARNING: Any operating procedure, standard, etc., that could result in injury or death if not strictly respected.

CAUTION: Any operating procedure, instruction, etc., that could result in damage or destruction of equipment if not strictly respected.

NOTE: Any regulation, operating condition, etc. that it is important to stress.

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Operator's cab controls

1

2

3

1. Manual rotation locking pin 2. Accelerator pedal 3. Service brake pedal

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4

5

6

7

4. Parking brake 5. Right-hand lever 6. Left-hand lever 7. Outrigger movement consent button

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8

9

10

8. Bubble level 9. Windscreen wiper liquid tank 10. Heating control (refer to the model fitted)

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Side instrument panel 13

14

15

25 16 24 17 23

18

19

22

20 21

13. Front left outrigger down/up control 14. Front left outrigger beam extension/retraction control 15. Front right outrigger beam extension/retraction control 16. Front right outrigger down/up control 17. Rear left outrigger beam extension/retraction control 18. Rear right outrigger down/up control 19. Rear right outrigger beam extension/retraction control 20. Gearshift lever 21. Pressure gauge 22. Emergency stop 23. Load limiter inhibit pushbutton 24. Front left outrigger down/up control 25. Upper structure rotation brake released warning light

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Hand controls The functions of the hand controls are shown on the sticker on the window in the cab.

1 2 3

AUX

1 AUX

1

2 4 5

M1 / M2

3

2

1

3

2 3

4 5 50035

Left hand control 27

26

The left hand joystick accommodates the controls for turret slewing, release of the superstructure rotation brake, telescopic boom extension/ retraction, boom extension mode selection and auxiliary winch or boom control selection.

The left joystick has a safety device 26 for preventing accidental manoeuvres, however the operator must remain seated in the driving position.

The function of cursor 27 can be selected with the display of the rated capacity limiter.

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Selecting the joystick work mode To view the "General Configuration" page hold down (2 sec) button the "SETUP" operating page.

on

to move within the page: RH / LH buttons: Function selection (function icon)

/

Enter button: confirms function

Enter

Opens the related function configuration page Esc button pressed for 3 seconds: exits the Configuration page.

TARE ESC

Select Press

(deselected) / Enter

(selected).

.

The Joystick setting page is displayed.

The joystick operating configuration can be set on this page.

Extraction / retraction on Roller Auxiliary winch up / down on roller

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OFF / OFF /

ON ON

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Extraction / retraction mode on joystick Using buttons Press

TARE ESC

/

select

and press

Enter

to confirm.

to return to the previous page.

-

Push forward to extend the boom sections

-

Pull back to retract the boom sections

-

Move to the right to turn the turret clockwise

-

Move to the left to turn the turret counterclockwise

When the control lever is between two positions (e.g. boom extension and turret clockwise slewing) the two functions are activated simultaneously.

Extraction mode on roller Using buttons Press

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TARE ESC

/

select

and press

Enter

to confirm.

to return to the previous page.

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1

Maintenance and operator's manual

-

Press the roller forward to extend the boom sections

-

Pull the roller back to retract the boom sections

-

Move the joystick to the right to turn the turret clockwise

-

Move the joystick to the left to turn the turret counterclockwise

CAUTION Remember to remove the manual slewing locking pin 1 before using the slewing function.

Operations with auxiliary winch (optional) To enable the auxiliary winch press and release button 28.

28

On the limiter display it is indicated with the icon .

Up/down mode on joystick Using buttons Press

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TARE ESC

/

select

and press

Enter

to confirm.

to return to the previous page.

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-

Push forward to lower the load with the auxiliary winch

-

Pull back to hoist the load with the auxiliary winch

-

Move to the right to turn the turret clockwise

-

Move to the left to turn the turret counterclockwise

Up/down mode on roller Using buttons Press

1

TARE ESC

/

select

and press

Enter

to confirm.

to return to the previous page.

-

Press the roller forward to lower the load with the auxiliary winch

-

Pull the roller back to hoist the load with the auxiliary winch

-

Move the joystick to the right to turn the turret clockwise

-

Move the joystick to the left to turn the turret counterclockwise

CAUTION Remember to remove the manual slewing locking pin 1 before using the slewing function.

Press and release the button 28 to return to the boom extend/retract function.

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WARNING Release the main or auxiliary winch rope when extending the boom to prevent the hoisting block head block from tripping the limit stop device. Failure of the hoist block limit stop device can result in serious damage to the boom head or telescopic extension and the rope. The rope could break causing the load to drop, with resulting serious damage or fatal accidents.

Manual upperstructure slewing brake release on left-hand control lever Use the button 29 on the left-hand control lever to manually release upperstructure slewing.

On machine starting, the turret rotation unit brake is applied and it is released automatically and progressively when the upperstructure is slewed.

29

To release the brake manually and allow self-alignment of the boom end vertically over the centre line of the load being lifted, grip the left-hand control lever and press button 29.

The brake is automatically re-applied when the button is released.

CAUTION Do not release/lock slewing abruptly during work as this may cause the load to sway. Wait until the machine upperstructure is completely stationary before changing direction.

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Boom extension mode selection (model RT45L only) Use the button 30 on the left-hand control lever to select the desired telescopic boom extension mode.

The selected mode is indicated M1 - M2 on the limiter display.

30

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M1 -

only section "T2" of the telescopic boom can be extended.

M2 -

sections "T3" and "T4" of the telescopic boom can be extended simultaneously.

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Right-hand control lever

31

The RH control lever commands load lifting and lowering with the main winch and raising and lowering of the telescopic boom.

The RH joystick has a safety device to prevent inadvertent activation 31; however the operator must remain seated in the driving position.

-

Push forward to lower the load with main winch

-

Pull back to lift the load with main winch

-

Move to the left to lift the telescopic boom

-

Move to the right to lower the telescopic boom

When the control lever is between two positions (e.g. load and boom lowering) the two functions are activated simultaneously.

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WARNING Release the main or auxiliary winch rope when extending the boom to prevent the hoisting block from tripping the limit stop lock device. Failure of this device can result in serious damage to the boom head or telescopic extension and the rope. The rope could break and drop the load, causing serious damage or fatal accidents.

Press button 32 to sound the horn.

32

Press button 33 to select the winch speed.

33

The selected speed is indicated on the limiter display. first winch speed

second winch speed Make sure the block is stationary before changing speed.

The change in speed can cause the load to sway dangerously.

CAUTION Do not change the winch speed if the winch control lever is not in the neutral position and the drum is turning.

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Central control column

45

34

44 43

35

42 36 37

38 39

40

41

34. Indicator panel 35. Lever switch 36. Emergency lights switch 37. Steering column angle adjustment lever 38. Flashing light switch 39. Rear differential lock switch 40. Rear fog light switch 41. Parking lights/low beam switch 42. Work light switch 43. Rear axle oscillation lock switch 44. Steering mode selector 45. Steering wheel

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Column indicator panel

47 48

46

49

46. Engine coolant temperature gauge 47. Display 48. Fuel gauge 49. Set of warning lights

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Telescopic boom RT45 Element 1 Main boom

Element 2

Element 3

Element 4

RT45L

Element 1 Main boom

Element 2 Element 3 Element 4 Element 5

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Machine layout Carrier: the rear end is the part of the frame in which the engine is installed.

Upperstructure: the boom is fitted on the front, the counterweight is located at rear end.

The left and right sides are determined with respect to the operator seated in the driving position located on the turret.

Boom head

Lifting cylinder

Boom base

Counterweight

Engine

Front

Block Front outriggers

Batteries

Rear outriggers Fuel tank

Front part

Rear part Hydraulic oil tank

Right hand side

Auxiliary winch

Front

Main winch

Left hand side Cab

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Outrigger controls According to the choice, these controls enable beam or outrigger extension and retraction.

7

Manoeuvre consent is given by the button (ref.7) located on the left armrest of the driver's seat.

CAUTION DO NOT COMBINE OPPOSITE FUNCTIONS. (For example, retracting one outrigger beam while simultaneously extending another, or lowering one vertical cylinder while simultaneously raising another).

WARNING Make sure the machine is perfectly stabilized before handling loads. Frequently check the bubble level in the cab to ensure correct level adjustment.

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Front left outrigger controls

Front right outrigger controls

Rear left outrigger controls

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Symbols on outrigger controls •

Left side beam extension press and hold button "7" simultaneously to enable the function

•

Left side beam retraction press and hold button "7" simultaneously to enable the function

•

Right side beam extension press and hold button "7" simultaneously to enable the function

•

Right side beam retraction press and hold button "7" simultaneously to enable the function

•

Left side outrigger down press and hold button "7" simultaneously to enable the function

•

Left side outrigger up press and hold button "7" simultaneously to enable the function

•

Right side outrigger down press and hold button "7" simultaneously to enable the function

•

Right side outrigger up press and hold button "7" simultaneously to enable the function

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WARNING The machine is equipped with a system to aid the operator in gauging the length of extension of the outrigger beams.

If the system detects any inconsistency between the outrigger configuration set on the limiting device and the sensor reading, the following page is shown on the limiter display and the audible alarm is activated in the cab:

Although it is the sole responsibility of the operator to correct the machine configuration before starting to operate, pressing F3 on the limiter confirms the current configuration and you can continue working with the crane.

In this case the specific alarm message will be displayed on the work page.

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Gearshift lever The transmission provides: 5 forward gears in automatic mode; 3 forward gears in manual mode; 3 reverse gears in automatic mode.

Gears are selected by pressing the corresponding button.

CAUTION Press the brake pedal to select drive.

R

Reverse (automatic mode) The machine automatically selects the 3 speed ratios.

There is no manual mode.

N

Neutral Neutral must be engaged: •

when the machine is stationary

•

to pass:

•

to lock or release the rear axle steering

•

to start the engine

from R to D from R to 1, 2, 3 from D to R from 1, 2, 3 to R

D

Drive: Moving forward The machine automatically selects the 5 speed ratios.

3

third gear manual engagement

2

second gear manual engagement

1

first gear manual engagement

CAUTION When dynamic tyre mode is selected, only the first speed in forward and reverse drive is enabled.

When drive is selected the speed of manoeuvres is reduced.

Drive cannot be selected if upper structure movements are in progress.

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Central control column

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Engine coolant temperature gauge

The normal working temperature ranges from 83°C to 95°C. The temperature of the coolant must be no greater than 100°C. NOTE: If the temperature reaches 100°C, turn off the engine immediately and check the cooling circuit

Fuel gauge

This gauge shows the fuel reserve in the tank Note: There is no fuel reserve warning light.

Display A

B

C

The display indicates: A engine error code B engine rev counter C hour-meter, showing the number of engine operating hours.

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Warning light !

Simultaneous check of water, oil and battery warning lights.

Red warning light

Blinker light Indicates operation of the side blinkers.

Green warning light

Battery charge light Comes on when: •

The ignition is switched on but the engine has not yet started

• The alternator does not charge the batteries Red warning light

Engine oil low pressure warning light Comes on when: •

The engine oil pressure is below 3 bars

• The engine is idling Red warning light

WARNING If the light stays on even when the engine is not idling, turn the engine off and look for possible causes.

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Suspension lock warning light The rear suspension locks automatically if the upper structure is turned to the left or right by more than 3° with respect to the machine's longitudinal axis. This light comes on indicating that the suspension is locked.

Red warning light

WARNING If the upperstructure is slewed by more than 3° with the machine supported by the tyres and the warning light fails to illuminate immediately, stop slewing movements and check the suspension locking system.

Do not resume work before finding and fixing the problem.

Wheel alignment warning light It comes on when the rear wheels are aligned with the longitudinal axis of the truck.

Red warning light

Brake fluid low level warning light The light comes on when the brake fluid level is too low Red warning light

WARNING Stop the machine immediately and check the brake fluid level Also check for any leaks.

Parking brake applied warning light The light comes on when the parking brake is applied.

Red warning light

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Torque converter oil temperature warning light Normal work temperature between 80°C and 120°C. Red warning light NOTE: If the red light illuminates, select neutral gear and rev the engine for about 2-3 minutes until the temperature returns to normal.

Front axle brake circuit low pressure warning light The normal brake working pressure exceeds 5.5 bars.

The light goes off when the engine is started and the pressure has reached 5.5 bars.

The light comes on when the braking circuit pressure falls below 5.5 bars during machine operation.

Red warning light

WARNING Do not use the machine until the red light is extinguished.

Rear axle brake circuit low pressure warning light The normal brake working pressure exceeds 5.5 bars.

The light goes off when the engine is started and the pressure has reached 5.5 bars.

The light comes on when the braking circuit pressure falls below 5.5 bars during machine operation.

Red warning light

WARNING Do not use the machine until the red light is extinguished.

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Parking lights / low beam light The light comes on when the parking lights or low beams are on.

Green warning light

High beam light The light comes on when high beams are on.

Blue warning light.

Emergency lights switch When pressed, the six blinkers work at the same time, signalling a machine emergency situation.

Intermittent red warning light.

Flashing revolving light switch Control used for switching on the revolving flashing light on the operator's cab.

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Rear axle oscillation lock switch The rear axle oscillation lock cuts in automatically if the superstructure is slewed left or right by more than 3° in relation to the machine's longitudinal axis.

This switch can be used to release the rear axle oscillation lock regardless of the position assumed by the superstructure relative to the machine's longitudinal axis.

Rear fog light switch Press to switch on the rear red light in case of fog.

Lights main switch Two-position switch: 1- side lights and control panel lights 2- dipped beams

Work light switch Press to switch on the light at the top end of the cab, for illuminating the work area.

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Steering mode selector 2 1

3

Before selecting steering modes, the front and rear wheels must be aligned and parallel to the longitudinal axis of the truck.

It is a 3-position selector: Position 1: coordinated/concentric steering Position 2: front axle steering only Position 3: crab steering After several hours of operation check the alignment of the front/rear wheel axles.

Realign the wheels if necessary.

To do this: -

set the steering selector to position 1 or 3.

-

align the rear axle wheels using the steering wheel (the red light on the control panel comes on when the wheels are aligned).

-

set the steering selector to position 2 (front axle steering only).

-

align the front axle wheels by means of the steering wheel (visual alignment check).

The front and rear axle wheels are now aligned.

After selecting the type of steering, just use the steering wheel to drive the machine.

WARNING Only front axle steering is permitted when driving on the road Frequently check wheel alignment and adjust if necessary.

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Lever switch

Press the button to sound the horn.

Moving the switch lever upwards or downwards, the front windscreen wiper will come into operation.

Press the front wiper control sideways to clean the windscreen.

Blinkers switch push the lever forward to operate the side turn indicators to turn right. pull the lever down to operate the side turn indicators to turn left.

Headlight selector Push the stalk down (after turning the lights switch on) to switch on the high beam headlights.

The blue light on the control panel comes on.

Pull the stalk upwards to flash the high beams.

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Manual rotation locking pin

1

Lift the right arm-rest to access the locking pin (ref.1).

To lock the upper part of the machine, align the truck (boom on front end), lift the pin, turn it clockwise 90° and lower it in the special seat.

CAUTION Never insert the pin while the superstructure is turning.

Failure to comply with this precaution can seriously damage the upper part and the truck.

The upper structure must always be locked when moving the crane on the worksite and the road.

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Parking brake

Located under the right arm-rest, it is used to apply or release the parking brake.

Bubble level Located on the left side of the instrumental board inside the operator's cab.

It (ref.10) allows the machine to be correctly stabilized.

10

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Cummins engine control panel 1

2

3

4

5

1. Idle speed adjustment button Press top of button to decrease engine speed (-), press bottom of button to increase engine speed (+).

2. Diagnostic button Hold button down to check for presence of active error codes relative to the engine electronic fuel system and engine protection system.

3. STOP warning light When this red warning light comes on, the operator must stop the engine as soon as possible in conditions of safety The engine must not be started until the fault has been repaired.

4. PREHEATING indicator light The PREHEATING warning light (WTS) is yellow and it remains lit during the preheating period that starts when the ignition key is set to the ON position before stating the engine in cold periods of the year.

To limit the use of the starter motor during starting in cold periods of the year do not attempt to start the engine until the WTS indicator light is extinguished.

5. ALARM warning light This yellow indicator light informs the operator that the fault must be repaired at the earliest possible opportunity.

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Radio and 24V socket outlet To use the radio and the 24V socket outlet, insert the key into the control panel and turn it onto I to power up the circuit.

The documentation on using the radio 1 is in the compartment 2.

2

1

The 24 volt socket outlet 3 is on the shelf behind the seat.

3

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Rear axle differential lock control (optional) This control locks the rear axle differential The differential remains locked until the control switch is operated.

Move the gear lever to the neutral position "N" before using this control.

Note: Select low speed range (4x4) before using this control.

This mode must only be used for work on very rough ground.

CAUTION: Do not use rear axle steering when the differential is locked.

Return to the normal position after overcoming an obstacle.

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Cab heating control (optional) The control unit (ref.12) is located on the left side instrument panel in the operator's cab.

Refer to the model fitted on the crane truck.

B

Start the heater - Heating operating mode: Button A is used to start the heater in the Heating operating mode (continuous operation). The temperature can be adjusted as required by means of knob F. If the heater is in Heating operating mode, the red control LED B lights up.

A

Start the heater - Ventilation operating mode: Button E is used to start the heater in the Ventilation operating mode (continuous operation). Knob F has no function in Ventilation mode.

If the heater is in the Ventilation operating mode, the blue control LED D lights up.

C

D

E

F

Switching off the heater: Button C is used to switch off the heater. The heating or ventilation mode is deactivated and the respective LED goes out.

The Heating operating mode is deactivated with a delay.

Refer to the documentation for the heater in the cab.

Notes: Remember to open the fuel cock on the tank located behind the operator's cab before using the heating system.

The control is used to switch the heater on/off, for adjusting the required ambient temperature and for clearing a fault.

The green LED is also the ignition light (the LED remains on) and signals overheating (LED flashing).

Refer to the documentation for the heater in the cab.

Notes: Remember to open the fuel cock on the tank located behind the operator's cab before using the heating system.

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Air conditioner control in operator's cab (optional) 1. Air circulation fan speed regulator 2. Heating control 3. Air conditioner control

1 2

3

Battery disconnecting switch The battery cut-off switch A is located at the top of the front frame and is accessed by opening the inspection door B as shown in the figure.

It disconnects the negative pole of the batteries from the machine frame.

Notes: It is always advisable to disconnect the batteries at the end of the work shift, during long work stops or for carrying out maintenance.

A

B

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Operator's seat Adjustable head-rest

Seat back

Arm-rests

Height and angle adjustment Backrest adjustment Upper part adjustment sliding guide

Weight adjustment

Complete seat unit adjustment sliding guide

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Console locking device

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Seat adjustments The arm-rest can be raised on the operator's door side to facilitate entry.

It must then be lowered and locked in its operating position.

The back adjusts in small steps to allow the operator to quickly find the best position.

The upper runners allow the seat to be adjusted in the most comfortable position for operating the hand control devices. The runners allow the operator to change the seat position and the individual sections of the backrest with respect to the entire seat unit.

Seat height and angle can be adjusted within a range of 65 mm, regardless of the seat suspension.

The operator can set the position, with respect to the pedals, using runners for moving the whole seat.

The height of the arm-rests can be adjusted. Loosen the two mounting bolts to carry out adjustment.

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6 - Rated Capacity Limiter

Operation and Maintenance manual

6 Rated Capacity Limiter

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Operation and Maintenance manual

1 Introduction The information in this document can be subject to change without warning by the manufacturer.

The manufacturer is not responsible for any errors that may be contained in this manual.

All reproduction, translation and copying of this manual are forbidden except with the manufacturer's written authorization.

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Operation and Maintenance manual

2 Instructions Before starting operations, the user must read and understand this manual and follow the instructions it contains.

The rated capacity limiter is an electronic control device, designed to help the operator use the machine safely, warning him with visual and acoustic alarms in proximity to a hazardous condition.

However, this device is not intended to replace the operator's experience in operating the machine.

The operator is responsible for operating the machine in safety conditions in accordance with all the prescribed safety standards.

The operator is responsible for correctly setting the operating mode of the machine and for correctly using the device. Setting the operating mode incorrectly can cause the limiter to behave abnormally putting the machine in a potentially hazardous situation.

The operator must be able to identify whether the data provided by the system are correct and correspond to the actual working conditions.

He must also be able to use the data in order to operate in safety conditions.

The limiter is an electric device composed of various components that could be subject to failure or defects.

The operator must identify these events and act accordingly to make repairs if possible or call the manufacturer's technical service.

The system is supplied with self-diagnostics that constantly check its operation and that of the various components. Should a critical situation be identified, the system is put into safety conditions, shutting down all operations.

Before beginning to work with the machine, the operator must in any case check it works properly by carrying out some tests.

He must ensure that the data on the display are plausible and that the data of the load tables are displayed correctly. He must also check that there are no alarm warnings or messages and verify that the shutdown function works properly.

The operator is responsible for the correct use of the load tables and setting the RCL system.

Incorrect use of the tables can cause the machine to behave dangerously.

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Operation and Maintenance manual

3 Important Notes The limiter is equipped with a cut-out key.

Under normal conditions of operation, this device must not be activated.

It is forbidden to use this key to lift greater loads than the maximum loads envisaged in the load tables supplied by the manufacturer.

The key must only be used in the event of malfunctioning.

Use of the key is permitted only for authorized personnel that are responsible for all the consequences deriving from its activation.

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Operation and Maintenance manual

4 System Description 4.1

Layout of the RT45 system

Picture 4.1 – System Layout

1.

MIDAC+ UNIT

2.

VIEW DISPLAY UNIT

3.

ASSEMBLY KIT FOR DISPLAY UNIT + 1 CAN-Bus CABLE for View

4.

TRANSDUCER FOR EXTENSION 32 m – AC MCP

5.

ASSEMBLY KIT for AC MCP

6.

MC2M CONTROLLER

7.

JIM CANBus CONTROL LEVER

8.

JIM CANBus CONTROL LEVER

9.

PRESSURE TRANSDUCERS

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6 - Rated Capacity Limiter 4.2

Operation and Maintenance manual

System Functions

The limiter automatically compares the lifted load with the maximum content in the table supplied by the manufacturer providing the necessary instructions to remain in safety conditions.

The main information is: •

Load lifted.

•

Maximum load permitted.

•

Relative load percentage (SWL).

•

Radius.

•

Angle of the main boom.

•

Boom extension.

•

Operating mode.

•

Limiter traffic light.

The system determines this information from calculations carried out on the information measured by the sensors (transducers, load cells), and angle and extension sensors.

The lifted load is continually compared with the maximum permitted load that can be obtained from the load tables.

As a result three different conditions can arise: SAFETY: the green light is on, no acoustic alarm: the lifted load is less than 90% of the maximum load; WARNING: the amber light is on, intermittent acoustic alarm: the lifted load is between 90% and 100% of the maximum permitted load; SHUTDOWN: the red light is on, acoustic alarm on steady: the lifted load exceeds the maximum threshold allowed. In this condition, the operations for returning into safety conditions are the only ones allowed.

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5 Data Setting Panel The data setting panel is illustrated in the figure:

Figure 5.1 – View Data Setting Panel

Icon

Description Two Green lights signal that the system is in safety conditions.

The amber light signals that the lifted load is between 90% and 100% of the maximum permitted load.

The red light signals that the system has shut down.

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Description Function key “F1” SETUP page: Configuration of Outriggers/Tyres ISAAC1 and 2 page: Sets Limits on Boom Movement and Turret Slewing ENGINE page: Transmission Calibration Page View TRANSMISSION CALIBRATION page: Return to Engine Page Function key “F2” ISAAC1&2 page: Sets Limits TRANSMISSION CALIBRATION page: Start / End AEB calibration procedure Function key “F3” ISAAC pages: Sets Limits Function key “F4” SETUP page: Boom/Jib working configuration Function key “F5” SETUP page: Jib storage configuration “Enter” button SETUP page: Confirm configuration CONFIGURATION pages: Confirm selection/setting “Up” button / “down” button

/

CONFIGURATION pages: Adjust setting (increase/decrease values) “Left” / “Right” button

/

OPERATIVE pages: Scroll through operative pages (previous/next) CONFIGURATION pages: Select setting (previous/next) “Tackle” button SETUP page: Select tackle “Buzzer” button: Disables display buzzer

Boom 78° down release “Print” button SETUP page: Initialize Data Logger (see Reading the Data Logger manual)

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Icon

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Description “ESC” button: CONFIGURATION pages: Go back to the previous page/menu “Setting” button SETUP page: View General Configuration Menu (press and hold for 2 sec)

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View Pages

From the data setting panel the different operating pages allow making the settings and viewing the information for the system.

Power ON OPERATIVE PAGES Setup mode:

Work mode: Transmission Calibration

ENGINE

INIT

RCL

SETUP

ISAAC1

2 sec

ISAAC2

CONFIGURATION PAGES CALIBRATION (reserved)

Config. menu General Vibration Joystick Mode Joystick Unit of measurement

Display Date&Time

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Language

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5.1.1 Operative Pages Setup mode • •

“INIT” page: displayed for 5 seconds after switching on, it is used to identify the software loaded onto the devices.

“SETUP” page: displayed automatically immediately after the initial page, it is used to load the work settings (Machine Setup and Operating Mode). It is necessary to confirm the setting to enter work mode.

Work mode • • • • •

“RCL” page: used to monitor the present state of the machine, the percentages of load (SWL) and extension, the alarms and the warnings of the system.

“ENGINE” page: used to display the engine data.

“TRANSMISSION CALIBRATION” page: used for automatic calibration of the transmission “ISAAC1” page: used to set the main boom movement limits (if encoder installed).

“ISAAC2” page: used to set the turret slewing limits (if encoder installed).

Scroll through the Work Pages with buttons

and

.

5.1.2 Configuration Pages General Configuration Menu Page To enter the “General Configuration Menu” page hold down (2 sec) button on the “SETUP” page.

• “General Configuration Menu” page: system configuration menu.

• From the menu on this screen you can enter the System Configuration and Calibration Pages (not enabled).

System Configuration Pages • “Display” page • “Date&Time” page • “Unit of measurement” page • “Language” page • “Mode Joystick” page • “Vibration Joystick” page System Calibration Pages •

“Calibration Menu” page (not enabled)

To exit the configuration pages press button

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6 Operating Mode 6.1

INIT Page

When the system is switched on, information on the software is displayed in the first 5 seconds.

238

xxx xxx xxx xxx xxx xxx

Figure 6.2 - Screen INIT

Ref.

Description SW releases of the devices XXX

XXX

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1st ROW : Device (eg MIDAC/CPU0)

2nd ROW : Software release installed on the device

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6.2

SETUP Page

The “SETUP” page is automatically displayed after the initial screen.

The machine configuration is set on this page.

1 C 2 D 3 4 A 5 B 6 Figure 6.3 – SETUP page

•

Work Settings: Machine Setup

Ref. Button Description Main Boom/Jib setup

1

Main boom or jib configuration setting Jib storage setup

2

Jib position setting Tackle setup

3

Block winding setting 4 5

_

Block Setup (AUTOMATIC) Tyres/Outriggers setup Configuration setting on tyres or outriggers Confirm Setup

6

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• •

: Setup confirmed message : Setup not confirmed message

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Work Settings: Operating Mode (automatic)

Ref.

Description

C

Operating Mode •

D

Active operating mode code (value between 32000 and 32099)

Invalid machine configuration Configuration message Operating Mode + Setup not allowed by the system

•

Other functions

Ref.

Button

A

Description Setup Data Logger E.L. NOT INIT. : Data Logger not initialized.

To initialize the Data Logger please refer to the “Reading the Data Logger” manual B

/ /

Alarms and Warnings message area (see RCL page) General Configuration Menu Holding down the button (2 sec) takes you to the “General Configuration Menu” Page

6.2.1 Work Settings: Machine Setup & Operating Mode The system recognizes the active operating mode and selects it automatically.

If the current Setup is allowed by the system and does not have to be changed, press

to

confirm and go directly into operation.

If the system does not allow the current configuration the “Invalid configuration” message is displayed. Edit the machine configuration.

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Change the Setup To edit the machine's setup please see the following paragraphs depending on the setting you want to change On confirming the Setup by pressing

the system recognizes whether the selected mode is

permitted in the active operating mode and displays or does not display a confirmation message.

If the setup mode is accepted, the “mode confirmed” message is displayed and it automatically becomes operative (“RCL” page).

Otherwise, the “mode not confirmed” message is displayed and the SETUP page remains active.

6.2.2 Outriggers/Tyres To change the configuration of the outriggers, press button Icon

and confirm with

.

Description Outriggers completely extended

Outriggers partially extended

Outriggers completely retracted

Static tyre (black icon)

Dynamic tyre (red icon)

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6.2.3 Block assembly Function selected automatically by the system.

Icon

Description The block assembly is located on the basic boom.

The block assembly is located on the small jib.

The block assembly is located on the jib.

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6.2.4 Main Boom/Jib To select the work configuration with the boom or jib press button Icon

and confirm with

.

Description Main boom selected (black)

Small Jib /Derrick selected (black)

Jib selected (black):

A

A. Jib length in m or ft (unit of measurement selected in configuration) B

1

2

B. Jib angle in degrees

3

1 Angle1-Length 1 2 Angle1-Length 2 3 Angle1-Length 3

4

5

6

4 Angle2-Length 1 5 Angle2 - Length 2 6 Angle2 - Length 3

7

8

9

7 Angle3-Length 1 8 Angle3 - Length 2 9 Angle3 - Length 3

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6.2.5 Jib Storage Important: Select the correct position for the stored jib.

To select the stored jib position press Icon

and confirm with

.

Description Jib stored •

: not present

Jib stored •

: present

6.2.6 Tackles Tackles: number of windings on the block assembly.

To select the number of tackles, press button

and confirm with

.

The maximum number of tackles depends on the operating mode.

Icon

Description Number of selected tackles (e.g. 5)

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6.3

Stabilizers error page

This page is automatically displayed if the system detects a failure between the stabilisers configuration set and the configuration detected by the sensors.

1 50 %

50 %

C

A

4 50 %

50 %

B

D

2

Allarmi/Warning 3 Figure 6.4 – Stabilizer Error Page

Key

Description Confirm actual configuration and go to page “Work (LMI)”

Return to Setup Page

Ref. Description 1

Error message of stabilisers configuration

2

Operation messages (see LMI Page)

3

Message to request setup confirmation

4

Length % related to outriggers

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Ref. Description A

Left front stabilizer

B

Left rear stabilizer

C

Right front stabilizer

D

Right rear stabilizer /

Correct stabilizer extension •

: extension at 0%

•

: extension at 50%

• /

: extension at 100%

Stabilizers extension error •

: extension at 0%

•

: extension at 50%

•

6.4

: extension at 100%

RCL page

The RCL page is the main page where information on machine status is displayed.

1

3

2

4 5 Alarms/Warning 6 Figure 6.5 – RCL page

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Icon

Description % Extension The bar shows the percentages of extension of the main boom.

SWL The bar shows the percentage of the lifted load in relation to the max. lifting load (max 120%) Green: Normal (load lifted < 90%) Amber: Warning (load lifted > 90%) Red: Shutdown (load lifted > 100%) Crane Configuration (see Chap. Configuration) Black icon: ON status

3

2

Grey icon: OFF status 1. Outriggers / Tyres 1

2. Main Boom / Jib 3. Jib Storage

Icon

Description

1

Main Boom work mode (RT45L): M1: 1st moves, 2nd, 3rd, 4th extension are stationary.

M2: 2nd, 3rd, 4th section move proportionally.

2

Boom extension in m or ft (unit of measurement selected in configuration)

3

Operating Mode active : Operating Mode Code from load table.

4

Boom angle in degrees

5

Boom radius in m or ft (unit of measurement selected in configuration)

6

Area of messages for the operator

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Description Current Capacity Indication of the applied load in ton or klb (unit of measurement selected in configuration) Maximum Capacity Indication of the maximum applicable load calculated according to the function of the system configuration in ton or klb (unit of measurement selected in configuration).

Number of Tackles Number of tackles set on Setup page (e.g. 6).

The maximum number depends on the operating mode selected.

Press and hold down to cut out the block assembly limit stop device temporarily (A2B) Anti-2-block device : limit stop not tripped : limit stop active: rope top limit stop condition Turret Position : The turret is in the side or rear position. : The turret is in the front position.

Winch speed : hare speed tortoise speed Auxiliary winch warning light Free slewing warning lights

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Icon

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Description RCL safety bypass warning light

•

Alarms & Warnings

Messages

Description Area of system's current alarm messages and warnings Alarm code

Warning code

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System Alarms / Warnings The system recognizes faults, errors and failures of the system.

If the system registers any of these conditions, the limiter is put into a state of safety, blocking the movements and displaying the relevant alarm message or warning (code/description) on screen.

If more than one error is registered, the relevant messages will be displayed cyclically in sequence. As soon as the error condition has passed, the system will return to being operative.

The lists of Alarm and Warning messages are described in the specific chapter.

Alarm Horn When an alarm is registered, the horn sounds too.

It can be deactivated with button

until another alarm occurs. A few seconds after the

alarm has disappeared, the buzzer is automatically reset.

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6.5

ENGINE Page 5 6 1

2

3 4 Figure 6.6 – ENGINE page

Button

Description Transmission Calibration Page View

Ref

Function

Min - Max

1

Engine Speed Indicator in rpm

0-8000 rpm

2

Vehicle speed indicator in km/h (outer) and miles/h (inner)

0-40 km/h / 0-25 mph

3

Eco Mode Function : Eco Mode Function on

4

On Indicator Drive • • •

N: Neutral R: Reverse F: Moving forward

Drive Position: (1-4)

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Icon

Function

5

Water temperature gauge in °C or °F

6

• •

Green bar: 0 - 120°C (0 - 248) Red bar: 120 - 140°C (248 - 284°F)

•

Reference mark

Oil pressure gauge in bar or psi • •

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Min / Max 0-140°C / 0 - 284°F

0 - 20 bar / 0 - 290 psi

Amber bar: 0 - 2 bar (0 - 29 psi) Green bar: 2 - 20 bar (29 - 290 psi)

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6.6

TRANSMISSION CALIBRATION Page

1 2 3 4 5 6 Figure 6.7 – AEB CALIBRATION page

Button Description Back to Engine Page

Ref.

Button

1

Function Starts / ends the transmission automatic calibration procedure • : start calibration • : end calibration

2

/

Visual display of transmission calibration main code

3

/

Calibration messages relating to current code

4

/

Visual display of transmission calibration secondary code

5

/

Calibration messages relating to the subcode

6

/

Visual display of calibration cycle code

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ISAAC Page

6.7.1 ISAAC1 Page The ISAAC1 page displays the present geometry of the boom and the limits of movement of the main boom.

Figure 6.8 – ISAAC 1

•

Main Boom Angle

Button /

/

Icon

Description Angle Limit •

Limit enabled

•

Limit not enabled

Current angle

Angle limit setting “32000”: limit not set

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•

Main Boom Height

Button

Icon

Description Height Limit

/

•

Limit on

•

Limit off

Current Height

/

Height limit setting

“3200.0”: limit not set

•

Main Boom Radius

Button /

/

Icon

Description Radius Limit •

Limit on

•

Limit off

Current radius Radius limit setting

“3200.0”: limit not set

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6.7.2 ISAAC2 Page Current turret position and slewing limit display.

Figure 6.9 – ISAAC 2

Button

Icon

Description

/

Current Turret position

/

Left Turret Limit •

Limit on

•

Limit off

Left Turret limit setting

“32000”: limit not set /

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Right Turret Limit •

Limit on

•

Limit off

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Button

Icon

Description Right Turret limit setting

“32000”: limit not set

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ISAAC Function

ISAAC: Interactive Space Automatic Advanced Control.

ISAAC is a system that enables limiting the machine's work area within a selected zone.

6.8.1 Setting Boom Movement Limits (ISAAC1 Page) The angle, height and radius limits on the movements of the boom can be enabled simultaneously or singly.

On the ISAAC1 page: Setting Boom Angle Limit The maximum angle limit is disabled when the value “32000” is displayed.

•

To set the angle limit, it is necessary to move the boom into the correct position and press .

The value of the current position is automatically saved as the maximum limit (set).

After confirming the limit, it is only possible to lower the boom.

•

To disable angle control, press again.

The maximum angle limit is disabled if the value “32000” is displayed.

Setting Boom Height Limit The maximum height limit is disabled when the value “3200.0” is displayed.

•

To set the height limit, it is necessary to move the boom into the correct position and press .

The value of the current position is automatically saved as the maximum limit (set).

After confirming the limit, it is only possible to lower and retract the boom.

•

To disable height control, press .

The maximum height limit is cancelled and replaced with the value “3200.0”.

Setting Boom Radius Limit The maximum radius limit is disabled when the value “3200.0” is displayed.

• To set the radius limit, it is necessary to move the boom into the correct position and press .

The value of the current position is automatically saved as the maximum limit (set).

After confirming the limit, it is only possible to raise and retract the boom.

•

To disable radius control, press again.

The maximum radius limit is disabled if the value “3200.0” is displayed.

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6.8.2 Setting Turret Slewing Limits (ISAAC2 Page) On the ISAAC2 page: Left Turret Limit The left limit is disabled when the value 32000 is displayed.

•

To set the right turret slewing limit it is necessary to rotate the turret into the desired position and press to acquire the value of the limit.

The value is saved and it is possible to rotate the turret only in the opposite direction.

•

To disable the function, press button again.

The left slewing limit is cancelled and replaced with the value “32000”.

Right Turret Limit The right limit is disabled when the value 32000 is displayed.

•

To set the right turret slewing limit it is necessary to rotate the turret into the desired position and press to acquire the value of the limit.

The value is saved and it is possible to rotate the turret only in the opposite direction.

•

To disable the function, press button again.

The right slewing limit is cancelled and replaced with the value “32000”.

The maximum position of the current radius is also saved. This will block the downward movement and extension of the boom.

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7 Configuration On this page it is possible to configure and calibrate (not enabled) the system.

To view the “General Configuration” menu hold down (2 sec) button

on the “SETUP”

operating page.

Figure 7.1 – General Configuration Menu Page

•

Button functions

Buttons

Description RH / LH buttons: Select configuration function

/ Enter button: Confirm configuration function.

Displays the related configuration page ESC button: Exits the General Configuration Menu page. Back to the SETUP page

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•

Configuration Pages

Icons

Function description Setting Display Contrast OFF / ON Icon (active function = ON icon) Setting the Date and Time OFF / ON Icon (active function = ON icon) Setting the Unit of Measurement OFF / ON Icon (active function = ON icon) Setting the Language OFF / ON Icon (active function = ON icon) System calibration (not available) OFF / ON Icon (active function = ON icon) Setting the Mode Joystick OFF / ON Icon (active function = ON icon) Setting the Vibration Joystick OFF / ON Icon (active function = ON icon)

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Display Contrast page

Figure 7.2 – Display Contrast page

Icons

Function description RH/LH buttons: select setting / + / - buttons: increases/decreases setting value / Enter button: confirms setting Esc button: goes back to the previous page

Contrast adjustment (adjustment active = ON) /

OFF / ON: Decrease contrast

/

OFF / ON: Increase contrast Contrast Level gauge (0 - 100) Amber bar: set level

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7.2

Date&Time page

1

Figure 7.3 – Date&Time page

Icons

Function description RH/LH buttons: select setting / + / - buttons: increases/decreases setting value / Enter button: confirms setting

Esc button: goes back to the previous page

Selector switch for function to set (time: Hours-Minutes; date: Day-MonthYear) 1

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Time and date set

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Unit of Measurement page

1

Figure 7.4 – Unit of Measurement page

Icons

Function description RH/LH buttons: select setting / Enter button: confirms setting

Esc button: goes back to the previous page

System of measurement setting (active = ON)

1

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/

OFF / ON: Metric System

/

OFF / ON: Imperial System System of measurement in use

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7.4

Language page

1

Figure 7.5 – Language Page

Icons

Function description RH/LH buttons: select setting / Enter button: confirms setting

Esc button: goes back to the previous page

Selector switch for function to set (Display language)

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Function description Display Language

1

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•

Italian

•

English

•

German

•

French

•

Spanish

•

Portuguese

•

Dutch

•

Polish

•

Russian

Language in use

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7.5

Mode Joystick page

Figure 7.6 – Mode Joystick page

Icons

Function description RH/LH buttons: select setting

/

Enter button: confirms setting

Esc button: goes back to the previous page Joystick Mode Setting (active = ON) / /

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OFF / ON Extension Activation Control OFF / ON Auxiliary Winch Activation Control

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Vibration Joystick page

Figure 7.7 – Vibration Joystick page

Icons

Function description RH/LH buttons: select setting / Enter button: confirms setting

Esc button: goes back to the previous page

Joystick Vibration Setting (setting active = ON)

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/

OFF / ON Joystick Vibration Disable Control

/

OFF / ON Joystick Vibration Enable Control

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8 Rated capacity limiter cut-out The machine is equipped with a rated capacity limiter cut-out device that is to be used should the components of the limiter break or in an emergency solely by authorized persons in charge of using it.

When the limiter is cut off, a device (Data logger) records the following machine operating parameters: -

selected configuration for stability (tyres or outriggers);

-

boom angle;

-

boom length;

-

lifted load;

-

max liftable load in the selected configuration;

-

lifting cylinder pressure.

The operation of the Data logger is check at each machine start-up.

To cut off the limiter, on the turret: -

turn clockwise and release the key 1 located on the turret behind the driver's cab.

This operation lights up the LED on push-button 2 inside the cab;

afterwards, inside the cab: - press and hold down button 2 to disable the limiter.

1 Release the push-button 2 to turn the rated capacity limiter back on.

2

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The limiter switches back on: - by releasing push-button 2, - 15 minutes after operating the key 1, - switching off and restarting the engine.

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Disabling the limiter:  activates a visual-audible warning device 3 located by the connection of the lifting cylinder with the boom.

3



the speed of the movements of the crane (lifting boom, extending boom, retracting boom, slewing and winch movement) is reduced to 15% of the nominal speed.

WARNING It is prohibited to use the load limiter cut-out device for lifting loads beyond the capacities admitted by the manufacturer.

The cut-out device must only be used in case of breakage of the limiter components (sensors, control unit, etc...) or in an emergency.

Activating the cut-out device is only permissible for authorised persons in charge of use.

The device starter key must not be left on the machine, but must be kept by specifically authorised persons in charge of use.

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9 Alarms 9.1

ALARMS

The alarms continue to be shown on the display until they are resolved, a resolved alarm therefore will no longer be displayed.

9.2

List of Alarms

Code

Description

1

CRC alarm parameters (MIDAC+)

2

CRC alarm program (MIDAC+)

3

CRC alarm load tables (MIDAC+)

4

CRC alarm runtime sw (MIDAC+)

5

CRC alarm ram (MIDAC+)

10

Pressure transducer bottom side channel “A” – open circuit

11

Pressure transducer bottom side channel “A” – short circuit

12

Pressure transducer stem side channel “A” – open circuit

13

Pressure transducer stem side channel “A” – short circuit

14

Pressure transducer bottom side channel “B” – open circuit

15

Pressure transducer bottom side channel “B” – short circuit

16

Pressure transducer stem side channel “B” – open circuit

17

Pressure transducer stem side channel “B” – short circuit

18

Bottom side pressure redundancy error

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Code

Description

19

Stem side pressure redundancy error

20

Boom angle less than minimum value

21

Boom angle greater than maximum value

22

Extension potentiometer, ACQ cable reel, value under minimum NOTE: Not present on B238

23

Extension potentiometer, AC-MCP cable reel, value under minimum

24

Boom extension less than minimum value

25

Boom extension greater than maximum value

26

Telescopic section extension from ACQ cable reel, value under minimum NOTE: Not present on B238

27

Telescopic section extension from ACQ cable reel, value over maximum NOTE: Not present on B238

30

ACQ cable reel fault, channel “A” NOTE: Not present on B238

31

ACQ cable reel fault, channel “B” NOTE: Not present on B238

32

AC-MCP cable reel fault, channel “A”

33

AC-MCP cable reel fault, channel “B”

35

Boom angle redundancy error

36

Total extension redundancy error

37

Redundancy error of telescopic extension on ACQ NOTE: Not present on B238

40

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ACQ cable reel Canbus Timeout, channel “A”

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Code

Description

41

ACQ cable reel Canbus Timeout, channel “B”

42

AC-MCP cable reel Canbus Timeout, message 1, channel “A”

43

AC-MCP cable reel Canbus Timeout, message 2, channel “A”

44

AC-MCP cable reel Canbus Timeout, message 3, channel “A”

45

AC-MCP cable reel Canbus Timeout, message 1, channel “B”

46

AC-MCP cable reel Canbus Timeout, message 2, channel “B”

47

AC-MCP cable reel Canbus Timeout, message 3, channel “B”

70

RCL safety device bypass

101

CRC alarm parameters (MC2M)

102

CRC alarm program (MC2M)

103

CRC alarm load tables (MC2M)

104

CRC alarm runtime sw (MC2M)

105

CRC alarm ram (MC2M)

110

RH Joystick, man present when switching on

111

LH Joystick, man present when switching on

112

RH joystick fault

113

LH joystick fault

114

RH joystick Canbus Timeout

115

LH joystick Canbus Timeout

116

Canbus Timeout MC2M

120

Boom angle less than minimum value – channel “B”

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Code

Description

121

Boom angle greater than maximum value – channel “B”

122

Extension potentiometer, ACQ cable reel, value under minimum – channel “B”

123

Extension potentiometer, AC-MCP cable reel, value under minimum – channel “B”

124

Boom extension less than minimum value – channel “B”

125

Boom extension greater than maximum value – channel “B”

126

Telescopic section extension from ACQ cable reel, value under minimum – channel “B”

127

Telescopic section extension from ACQ cable reel, value over maximum – channel “B”

150

ACQ cable reel fault, channel “A” (CPU1) NOTE: Not present on B238

151

ACQ cable reel fault, channel “B” (CPU1) NOTE: Not present on B238

152

AC-MCP cable reel fault, channel “A” (CPU1)

153

AC-MCP cable reel fault, channel “B” (CPU1)

155

Boom angle less than minimum value (CPU1)

156

Boom angle greater than maximum value (CPU1)

157

Extension potentiometer, ACQ cable reel, value under minimum (CPU1) NOTE: Not present on B238

158

Telescopic section extension from ACQ cable reel, value under minimum (CPU1) NOTE: Not present on B238

159

Telescopic section extension from ACQ cable reel, value over maximum (CPU1) NOTE: Not present on B238

160

Extension potentiometer, AC-MCP cable reel, value under minimum (CPU1)

161

Boom extension less than minimum value (CPU1)

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Code

Description

162

Boom extension greater than maximum value (CPU1)

170

Canbus timeout left front stabilizer sensor

171

Internal fault left front stabilizer sensor

172

Out of range value left front stabilizer sensor

173

Canbus timeout right front stabilizer sensor

174

Internal fault right front stabilizer sensor

175

Out of range value right front stabilizer sensor

176

Canbus timeout left rear stabilizer sensor

177

Internal fault left rear stabilizer sensor

178

Out of range value left rear stabilizer sensor

179

Canbus timeout right rear stabilizer sensor

180

Internal fault right rear stabilizer sensor

181

Out of range value right rear stabilizer sensor

185

Boom angle less than minimum value (CPU1) – channel “B”

186

Boom angle greater than maximum value (CPU1) – channel “B”

187

Extension potentiometer, ACQ cable reel, value under minimum (CPU1) – channel “B”

188

Telescopic section extension from ACQ cable reel, value under minimum (CPU1) – channel “B”

189

Telescopic section extension from ACQ cable reel, value over maximum (CPU1) – channel “B”

190

Extension potentiometer, AC-MCP cable reel, value under minimum (CPU1) – channel “B”

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Code

Description

191

Boom extension less than minimum value (CPU1) – channel “B”

192

Boom extension greater than maximum value (CPU1) – channel “B”

10 Warnings 10.1 WARNING The warnings refer to movements, so they are only displayed during movements; when there is a block the display shows the relevant code which will remain for a time of approximately 3 sec. once the joystick has returned to the central position (therefore without any movement).

10.2 List of Warnings Code

Description

1

Block on movements due to RCL alarm

2

Block on movements due to overload

3

Block on movements due to minimum boom angle

4

Block on movements due to maximum boom angle

5

Block on movements due to rope lifting limit stop

6

Block on movements due to rope lifting limit stop (aux winch)

7

Block on movements due to rope lowering limit stop

8

Block on movements due to rope lowering limit stop (aux winch)

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Code

Description

9

Block on movements due to rope overload

10

Block on movements due to incorrect slewing pin configuration

11

Block on movements due to inserted slewing pin

12

Block on movements due to boom / truck anti-collision device

13

Block on movements due to maximum angle in tyre configuration

15

Block on movements due to ISAAC setting

16

Block on movements due to ISAAC setting

17

Block on movements due to ISAAC setting

18

Block on movements due to ISAAC setting

19

Block on movements due to ISAAC setting

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Contents RT45 Lattice extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installation of 8m lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Stowing the 8-meter lattice extension on the boom side . . . . . . . . . 11 Angle of the 8m lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Adjustable 14m lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Angle of the 14m lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Additional rope blocks for working with lattice extensions . . . . . . . . 17

Box-welded extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Installation of 8m box-welded extension . . . . . . . . . . . . . . . . . . . . . 18 Deploying the 8m box-welded extension in the working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Offset of 8m box-welded extension . . . . . . . . . . . . . . . . . . . . . . . . . 21 Folding the 8m box-welded extension for travel . . . . . . . . . . . . . . . . 23 Installation of 15m box-welded extension . . . . . . . . . . . . . . . . . . . . 26 Deploying the 15m box-welded extension in the working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Offset of 15m box-welded extension . . . . . . . . . . . . . . . . . . . . . . . . 32 Folding the 15m box-welded extension for travel . . . . . . . . . . . . . . . 34 Deploying the 8m extension with 7m insert secured on brackets alongside the boom in the working position . . . . . . . . . 38 Deploying the 8m extension with 7m insert secured on brackets alongside the boom in the travel position . . . . . . . . . . . 40

RT45L Folding and unfolding of extensions . . . . . . . . . . . . . . . . . . . 44 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Deploying the 8m extension . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Setting up the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 A – Change the tackle of the main block. . . . . . . . . . . . . . . . . . . . . . 46 B – Deploying the jib support arm. . . . . . . . . . . . . . . . . . . . . . . . . . . 46 C – Attaching the foot of the 8m extension to the boom head. . . . . . 47 D – Freeing the 8m extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 E – Pinning the 8m extension to the boom head. . . . . . . . . . . . . . . . 49 F – Rotating the 8m extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 G – Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Folding the 8m extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Setting up the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 A – Deploying the support arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 B – Removing the top lifting limit stop box and unrigging the block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 C – Rotating the 8m extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 D – Detaching the 8m extension from the boom head. . . . . . . . . . . 57 E – Fixing the 8m extension to the base of the boom. . . . . . . . . . . . 57 F – Stowing the support arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 G – Changing the block assembly tackle. . . . . . . . . . . . . . . . . . . . . 58

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Inclination of extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

By means of the lifting function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 By means of the telescopic device . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Additional rope blocks for working with lattice extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Engine coolant heating device . . . . . . . . . . . . . . . . . . . . . . . . 68 Work light adjustable from inside the cab . . . . . . . . . . . . . . 69 Outrigger control from the truck . . . . . . . . . . . . . . . . . . . . . . 70 Engine emergency stop device . . . . . . . . . . . . . . . . . . . . . . . 71

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Lattice extensions Installation of 8m lattice extension Raise the machine on fully extended outriggers on firm, level and horizontal ground with the wheels slightly off the ground.

The boom must be completely retracted and absolutely horizontal.

To facilitate the operation, position the boom at its negative angle; this is done by adjusting the outrigger lifting cylinders in such a way that the boom side is lower than the counterweight side of the upperstructure.

•

Remove the split pin and extract the retaining pin 1.

•

Turn the support to align the eye connections 2.

1

2

•

Insert the pin 1 and lock it with the split pin.

1

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•

Remove the pin 3.

3

•

Pull the head of the lattice extension until aligning the U-bolt connections with the eye connections of the boom head.

•

Insert the pins 4 and lock them with the split pin.

4

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•

Remove the retaining pins 5.

5

•

Place the boom in the horizontal position.

•

Fasten a rope to the end of the lattice extension and pull it as far as the retainer 6 holding the extension on the support.

•

To free the lattice extension press the block 7 to lower the catch 6.

6

7

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•

Turn the extension through 180°.

•

Secure the two pins 8 that secure the other side of the lattice extension to the connections of the boom head.

8

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•

Remove the rope guide and run the winch rope along the lattice extension, routing it through the hook block and the double lock safety device. Refit the rope guide.

•

Connect the electric cable of the double-block safety device to the boom head.

CAUTION To avoid risks carefully supervise the operation of rotation of the lattice extension with the rope.

WARNING Check the weight of the lattice extension and the weight reductions in the capacity table.

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Stowing the 8-meter lattice extension on the boom side Raise the machine on fully extended outriggers on firm, level and horizontal ground with the wheels slightly off the ground.

The boom must be completely retracted and absolutely horizontal.

Unwind the winch rope from the lattice extension. Disconnect the electric cable of the double-block safety device.

•

Remove the two pins H to detach the remote side of the lattice extension.

8

•

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Attach a rope to the end of the lattice extension and pull it to cause it to rotate through 180° on the boom side.

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•

Insert the retaining pins 5 and remove the two pins on the boom head 4.

5

4

•

Push the extension towards the boom head onto the rear support stop, freeing the U-bolt connections of the front end from the boom.

•

Lock the lattice extension in position by means of pin 3.

3

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Insert the four pins (4, 8) in the U-bolt connections of the lattice for stowage and close up the boom side support.

•

4 8

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Angle of the 8m lattice extension With the extension mounted at the head of the boom, the boom retracted and in its horizontal position, and the turret slewed towards the front, stabilize the machine on solid and level ground with the wheels lifted slightly off the ground.

To lower the support rod: • remove the split pins 9 and 10 and extract the pin 11, lower the rod and position it in its seat on the extension, secure it with the pin 11 and with the split pin 10.

9

10

11

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•

Extend the rear outriggers completely in a vertical direction and retract the front outriggers in such a way as to incline the boom so that the support rod comes into contact with the ground (if these maneuvers prove insufficient to cause the rod to touch the ground, set the boom at a negative angle or extend the boom sections as necessary).

•

Remove the pins 12 from location 13, raise the boom by means of the outriggers until the support rod is detached from the ground, and reattach pins 12 in location 14.

12

12

13

14

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Adjustable 14m lattice extension The adjustable 14m lattice extension is composed of the adjustable 8m lattice extension (0.7 + 7.3m) plus a 6m lattice element. It must not be folded alongside the boom in its 14m length so to be used the 8m extension must first be put into the working position.

With the aid of a suitable crane, remove the fixed 7.3m insert, on the ground mount the 6m insert and reassemble it all at the adjustable base left secured on the head of the boom.

After assembly, electrically connect the limit stop.

CAUTION The operation of raising the lattice extension must be performed with due caution so as to avoid damage to people or property. For this purpose we recommend using straps to sling the lattice so as to prevent damaging the pipes.

Angle of the 14m lattice extension For the angle of the lattice extension, proceed as described for the 8 meter lattice extension.

CAUTION Before using the lattice extension check that all the pins are locked and that the limit stop works properly.

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Additional rope blocks for working with lattice extensions The manufacturer can supply blocks of different capacities for working with the lattice extensions.

The blocks supplied have connections for eyelet terminals to allow the operator to work directly with the block (direct pull) or to have several tackles (ALWAYS refer to the load tables).

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Box-welded extensions Installation of 8m box-welded extension

Extension stowed for travel, secured to brackets alongside the telescopic boom.

1

2 Extension support brackets for travel:

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1

rear support

2

front support

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Deploying the 8m box-welded extension in the working position Raise the machine on fully extended outriggers on firm, level and horizontal ground.

Retract the boom fully, turn the turret towards the front of the machine and move the boom to the horizontal position.

A

B

Remove pin B from the front support.

Remove pins D, C, E, F from the head of the extension.

E

D

F

C

Push the extension towards the head of the boom, aligning the fork of the extension with the relevant locations.

Insert pins C and D.

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Remove pin G on the rear bracket and pin A on the front bracket.

G

Raise the boom slightly to free the extension from the supports.

Manually turn the extension around pins C and D. Align the forks on the extension with the relevant locations on the head of the boom.

Insert retaining pins E and F and remove pin C. To facilitate pin insertion, use a step stool but DO NOT USE A LADDER as it would have to be placed against the boom or extension.

Before using the extension to handle materials: • • • •

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Disconnect the socket from the lifting limit stop electrical junction box on the boom head.

Connect the extension lifting limit stop socket in the electrical junction box on the boom head.

Remove the winch limit stop counterweight fixed to boom and insert it on the device on the extension.

Run the lifting rope over the sheaves and through the limit stop counterweight, then fix it to the hook.

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Offset of 8m box-welded extension The extension can be offset 0°, 15° or 30° with respect to the telescopic boom axis.

The offset is obtained by means of the lockable strut and the support and positioning rod.

Positioning rod in rest position.

Support rod in work position Position the support rod and lower the boom to bring the support rod in contact with the ground using the lifting, lowering and extension functions.

Use the hoisting or lift functions also to facilitate pin positioning.

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To offset the extension 0°, proceed as follows: The jack must be locked in position 1.

To offset the extension 15°, proceed as follows: Release the jack.

Raise the boom to lock the jack in position 2.

Position the locking pin.

To offset the extension 30°, proceed as follows: Release the jack.

Raise the boom to lock the jack in position 3.

Let the jack retract fully and position the locking pin.

Before every job with the extension, always bring the rod to the rest position.

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Folding the 8m box-welded extension for travel Place the machine on fully extended outriggers on firm, level and horizontal ground.

Retract the boom fully, turning the turret towards the front of the frame and bring it to the horizontal position.

Remove the winch rope from the extension.

Remove the winch lifting limit stop counterweight.

Disconnect the extension lifting limit stop safety device socket from the electrical junction box on the boom head and reconnect the main boom lifting limit stop safety device socket.

Position the extension offset 0° with respect to the boom axis.

Insert pin C and remove pins E and F that secure the extension to the boom head.

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D

F

C

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Swing the extension back on the bracket supports alongside the main boom.

Raise the boom slightly to facilitate this operation.

Insert pin G to secure the extension to the rear support.

G

Insert pin A to secure the extension to the front support.

A

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B

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Remove pins C and D.

E

D

F

C

Move the extension away from the telescopic boom to insert pin B on the front support.

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Installation of 15m box-welded extension

Extension stowed for travel, secured to brackets alongside the telescopic boom.

1

2

Extension support brackets for travel:

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1

rear support

2

front support

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Deploying the 15m box-welded extension in the working position Raise the machine on fully extended outriggers on firm, level and horizontal ground.

Retract the boom fully, turn the turret towards the front of the machine and move the boom to the horizontal position.

A

B

C

Remove pin B and pin C on the front support.

D

Remove pin D on the rear bracket.

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Remove pins F, G, H, I from the head of the extension.

Push the extension towards the boom head

F

H

G

I

to insert pins H and I. Remove pin E on the rear bracket and pin A on the front bracket.

E

Raise the boom slightly to free the extension from the supports.

Manually turn the extension around pins H and I. Insert retaining pins G and F and remove pin I.

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To facilitate pin insertion, use a step stool but DO NOT USE A LADDER as it would have to be placed against the boom or extension.

Remove link rod L that secures the 7m element to the 8m extension already fixed to the boom head.

L

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Manually turn the 7m insert around the fixing pins M and N. M

N

Insert the fixing pins O and P to secure the 7m element to the 8m extension.

O

P

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Before using the extension to handle materials: • • • •

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Disconnect the socket from the lifting limit stop electrical junction box on the boom head.

Connect the extension lifting limit stop socket in the electrical junction box on the boom head.

Remove the winch limit stop counterweight fixed to boom and insert it on the device on the extension.

Run the lifting rope over the sheaves and through the limit stop counterweight, then secure it to the hook, if fitted.

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Offset of 15m box-welded extension The extension can be offset 0°, 15° or 30° with respect to the telescopic boom axis.

The offset is obtained by means of the lockable strut and the support and positioning rod.

Positioning rod in rest position.

Support rod in work position.

Position the support rod and lower the boom to bring the support rod in contact with the ground using the lifting, lowering and extension functions.

Use the hoisting or lift functions also to facilitate pin positioning.

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To offset the extension 0°, proceed as follows: The jack must be locked in position 1.

To offset the extension 15°, proceed as follows: Release the jack.

Raise the boom to lock the jack in position 2.

Position the locking pin.

To offset the extension 30°, proceed as follows: Release the jack.

Raise the boom to lock the jack in position 3.

Let the jack retract fully and position the locking pin.

Before every job with the extension, always bring the rod to the rest position.

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Folding the 15m box-welded extension for travel Place the machine on fully extended outriggers on firm, level and horizontal ground, with the wheels raised and the engine idling.

Retract the boom fully, turning the turret towards the front of the frame and bring it to the horizontal position.

Remove the winch rope from the extension.

Remove the winch lifting limit stop counterweight.

Disconnect the extension lifting limit stop safety device socket from the electrical junction box on the boom head and reconnect the main boom lifting limit stop safety device socket.

Position the extension offset 0° with respect to the boom axis.

Remove pins O and P.

O

P Turn the 7m insert alongside the 8m extension.

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L

Secure the 7m insert to the 8m extension by means of link rod L.

Insert pin I and remove pins F and G that secure the extension to the boom head.

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F

H

G

I

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Swing the extension back on the bracket supports alongside the main boom.

Raise the boom slightly to facilitate this operation.

Insert pin E to secure the extension to the rear support.

E

Insert pin A to secure the extension to the front support.

A

B

C

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Remove pins H and I.

F

H

G

I

Move the extension away from the telescopic boom to insert pins B and C on the front support.

Insert pin D to secure the extension to the rear support.

D

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Deploying the 8m extension with 7m insert secured on brackets alongside the boom in the working position

Raise the machine on fully extended outriggers on firm, level and horizontal ground.

Retract the boom fully, turn the turret towards the front of the machine and move the boom to the horizontal position.

L

C

With the extension secured to the brackets alongside the boom, disconnect the link rod L securing the 7m insert to the 8m extension, leaving pin C inserted.

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M

D

N Remove pins M and N, leaving pin D inserted.

The 7m insert and the 8m extension are now secured to the main boom brackets, but are no longer connected.

Carry out the same procedure for deploying the 8m extension previously described in this manual.

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Deploying the 8m extension with 7m insert secured on brackets alongside the boom in the travel position Place the machine on fully extended outriggers on firm, level and horizontal ground.

Retract the boom fully, turning the turret towards the front of the frame.

Remove the winch rope from the extension.

Remove the winch lifting limit stop counterweight.

Disconnect the extension lifting limit stop safety device socket from the electrical junction box on the boom head and reconnect the main boom lifting limit stop safety device socket.

Position the extension offset 0° with respect to the boom axis.

Now carry out the procedure for folding the 8m extension previously described in this manual.

M

N Insert pins M and N to secure the rear end of the 7m insert to the 8m extension.

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L

Secure link rod L of the 7m insert to the 8m extension.

At the end of the operation the 7m insert is secured to the 8m extension and everything is secured to the brackets alongside the main boom in the rest position.

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Folding and unfolding of extensions Introduction You must retract all boom sections before folding and deploying the extensions.

WARNING When performing installation operations at heights above 3m from the ground, a safety harness must be used.

A single ladder may be used provided that it is secured in place and the top 4 rungs are not used.

Use a stepladder, scaffolding or a platform that meets applicable safety standards.

Recommended positions to prevent the ladder from moving.

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Deploying the 8m extension Setting up the machine Choose a manoeuvring area large enough to allow the 8m extension to be deployed.

WARNING It is strictly forbidden to telescope the boom during the entire deployment operation.

The boom must be completely retracted and absolutely horizontal. If this instruction is not followed, the risk of accident is increased by the involuntary deployment of the extension when unlocking it.

R > 8m Raise the machine on fully extended outriggers on firm, level and horizontal ground.

Retract the boom fully, turn the turret towards the front of the machine and move the boom to the horizontal position.

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A – Change the tackle of the main block.

At the head of the extension, remove the lifting limit stop counterweight 1 by unscrewing the shackle 2 which links the chain of the counterweight to the box's rope.

2

3

1

Remove the rope guides on the boom head 3 to change the tackle of the block assembly.

Unwind about 15m of rope to run it into the extension and fix the thimble.

Run the rope on the left side of the boom.

B - Deploying the jib support arm.

Swing out the jib support arm and lock it using pin 4.

4

Deploying the support arm frees the extension from the boom.

Partially insert the rope guides 3 46/72

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C – Attaching the foot of the 8m extension to the boom head.

Remove the 4 pins from the lower forks 5 and upper forks 6 of the extension and place them on the upper plate.

6

5

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D – Freeing the 8m extension.

Attach the line to control the deployment.

Remove pin 7 that secures the head of the extension to the boom and completely remove bracket 8 from the boom.

8

7

Rotate the extension around the pivot 9 to align the forks with the lugs of the boom head.

For safety reasons, attach the rope to the chassis.

9

The extension is held on the support arm by the limit stop.

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E – Pinning the 8m extension to the boom head.

This operation consists in connecting the 8m extension to the boom head using the pins previously extracted from the forks and stowed on the upper plate.

WARNING it is prohibited to use the inclination adjustment pins (10) to couple the extension to the boom head. The use of these pins will result in the extension becoming detached and falling

Attachment pin

Attachment pin

On the right side of the boom:

10

position pins 6 for coupling the upper part of the boom head and 5 for coupling the lower part of the boom head.

6

5

WARNING Always refit the safety restraints on the pins after inserting them.

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F – Rotating the 8m extension.

WARNING Before using the square of the pivot 9 to release the extension, it is vital that the extension be attached to the boom head by pins 6 and 5.

If this instruction is not followed, there is a risk that the extension will fall.

Use the crank stored against the 8m extension to turn the square of pivot 9 fully clockwise to free the extension from the boom foot.

9

Overturn the limit stop using the manual crank and at the same time manually rotate the extension while controlling it using the line.

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The crank unlocks the safety travel stop that secures the boom extension to the support arm.

LOCKED UNLOCKED POSITION POSITION

Return the crank to its storage position.

On the left side of the boom: position the pins for coupling of the lower part 5 and upper part 6 of the boom head and the associated safety clips.

6

5

Reposition the rope guides 3 and secure them.

3

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At the boom head, run the lifting rope over the extension sheave.

At the head of the 8m extension, fix the counterweight chain to the limit stop box rope using the shackle.

Run the rope into the top limit stop counterweight.

The 8m extension is deployed.

The extension is in the 0° inclination working configuration.

G - Electrical connection.

Make the electrical connection between boom head and foot of the 8m extension to power the lifting limit stop box.

At the head of the 8m extension connect and attach the lifting limit stop box.

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Folding the 8m extension WARNING When performing installation operations at heights above 3m from the ground, a safety harness must be used.

A single ladder may be used provided that it is secured in place and the top 4 rungs are not used.

Use a stepladder, scaffolding or a platform that meets applicable safety standards.

Setting up the machine.

Choose a manoeuvring area large enough to allow the 8m extension to be folded.

WARNING It is strictly forbidden to telescope the boom during the entire folding operation.

The boom must be completely retracted and absolutely horizontal. If this instruction is not followed, the risk of accident is increased by the involuntary deployment of the extension when locking it.

R > 8m Raise the machine on fully extended outriggers on firm, level and horizontal ground.

Retract the boom fully, turn the turret towards the front of the machine and move the boom to the horizontal position.

The tools necessary for stowing the extension again are: A hammer, a rope and the unlocking crank kept against the 8m extension.

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A – Deploying the support arm.

Swing out the jib support arm and lock it using pin 4.

WARNING Always refit the safety restraints on the pins after inserting them.

4

B – Removing the top lifting limit stop box and unrigging the block.

Unplug the electrical connection at the boom head to the foot of extension.

At the head of the extension, remove the lifting limit stop counterweight by unscrewing the shackle which links the chain of the counterweight to the box's rope.

On the boom head, fix the chain of the lifting limit stop counterweight to the limit stop box rope using the shackle.

Change the tackle of the main block.

Remove the lifting rope from the extension.

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C – Rotating the 8m extension.

WARNING It is forbidden to remain under the extension while locking or unlocking the extension.

Hang the line on the head of the 8m extension.

On the left side of the boom: remove the pins for coupling of the lower part 5 and upper part 6 of the boom head and the associated safety clips.

6

5

Pivot the extension manually controlling it with the line and bring it onto the deployment support.

The extension is maintained on the supporting arm by the stop.

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WARNING Before using the square of the pivot 9 to lock the extension to the boom, it is vital that the extension remain fixed to the boom head on the right-hand side by means of pins 5 and 6.

If this instruction is not followed, there is a risk that the extension will fall.

6

5

Use the crank stored against the 8m extension to turn the square of pivot fully anti-clockwise to lock the 8m extension to pin 9. Return the crank to its storage position.

9

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D – Detaching the 8m extension from the boom head.

Remove the pin 5 (Coupling at top of boom head).

Remove the pin 6 (coupling at bottom of boom head).

E – Fixing the 8m extension to the base of the boom.

Rotate the 8m extension around the pivot 9.

Refit bracket 8 to the boom and secure the head of the extension to the bracket by means of pin 7.

8

7

F - Stowing the support arm.

Fold the jib support arm and lock it using pin 4.

4

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G – Changing the block assembly tackle.

Run the rope on the boom lifting sheave.

Run the lifting rope into the safety counterweight.

(Counterweight opens out into two parts).

Restore the appropriate tackle in relation to the block.

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Inclination of extensions By means of the lifting function.

Work with extensions can be done with 3 inclination angles: 0° - 20° - 40°.

The procedure for inclining the extensions varies according to the length of the extension used.

For these operations, you are advised to have the help of an assistant.

WARNING When performing installation operations at heights above 3m from the ground, a safety harness must be used.

A single ladder may be used provided that it is secured in place and the top 4 rungs are not used.

Use a stepladder, scaffolding or a platform that meets applicable safety standards.

Inclining the 8m extension.

Raise the machine on fully extended outriggers on firm, level and horizontal ground.

Retract the boom fully, turn the turret towards the front of the machine and move the boom to the horizontal position.

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Inclining the 8m extension to 20°.

Change the tackle of the main block, unwind approximately 15m of rope, secure the wedge socket to the fork located on the lower face of the 8m extension by means of the wedge socket pin.

The rope must run correctly on the rope guides.

Put the rope under slight tension until displaying a residual charge of 0.1 tonne on the load moment limiter.

Pay attention to the position of the wedge socket, the wedge must be positioned downwards. Put the rope under slight tension.

During this manoeuvre, proceed slowly and with very great care in order not to damage the extension.

CAUTION When the extension is inclined with the head in contact with the ground, it is forbidden to use the telescoping-in control.

Remove the 2 pins 11 and place them in the middle holes to obtain an inclination of 20°. Fit the safety cotters.

11

0 °

20 ° 0 °

20 ° 11

Raise the boom to 45° to obtain sufficient space to swing it out.

When deploying, the extension must not hit the ground.

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20 °

20 °

Release some rope (lifting lower control) to incline the extension. Proceed slowly and carefully to avoid jerking.

When releasing the rope, the extension inclines and the inclining system comes up against pins 11.

CAUTION Do not use the lower control without releasing rope.

Using the lowering control in isolation would put the rope under tension and damage the extension

Inclining an 8m extension to 40° If the extension is in the 20° configuration, it must be returned to the 0° position to configure it to 40°.

To return to 0°, change the block tackle, fix the wedge socket to the fork located on the inside surface of the 8m extension using the wedge socket pin.

Put the rope under slight tension.

Raise the extension using the lifting up control.

Proceed slowly and with the utmost care.

When the extension angle is close to 0°, return the boom to horizontal using the lifting lower control and release rope if necessary.

Put the rope under slight tension until displaying a residual charge of 0.1 tonne on the load moment limiter.

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Position the extension at 40° by removing pins 11 from the 20° position.

Insert the pins in the relevant locations.

Raise the boom to 45° to obtain sufficient space to swing it out.

When deploying, the extension must not hit the ground.

Release some rope (lifting lower control) to incline the extension. Proceed slowly and carefully to avoid jerking.

40 °

40 °

When releasing the rope, the extension inclines and the inclining system comes up against the stop limit.

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By means of the telescopic device Work with extensions can be done with 3 inclination angles: 0° - 20° - 40°.

The procedure for inclining the extensions varies according to the length of the extension used.

For these operations, you are advised to have the help of an assistant.

CAUTION When performing installation operations at heights above 3m from the ground, a safety harness must be used.

A single ladder may be used provided that it is secured in place and the top 4 rungs are not used.

Use a stepladder, scaffolding or a platform that meets applicable safety standards.

Inclining the 8m extension.

Raise the machine on fully extended outriggers on firm, level and horizontal ground.

Retract the boom fully, turn the turret towards the front of the machine and move the boom to the horizontal position.

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Inclining the 8m extension to 20°.

Telescope the boom by about 1.5m.

Change the tackle of the main block, unwind approximately 15m of rope, secure the wedge socket to the fork located on the lower face of the 8m extension by means of the wedge socket pin.

The rope must run correctly on the rope guides.

Put the rope under slight tension until displaying a residual charge of 0.1 tonne on the load moment limiter.

Pay attention to the position of the wedge socket, the wedge must be positioned downwards. Put the rope under slight tension.

During this manoeuvre, proceed slowly and with very great care in order not to damage the extension.

CAUTION When the extension is inclined with the head in contact with the ground, it is forbidden to use the telescoping-in control.

Remove pins 11 and place them in the middle holes to obtain an inclination of 20°. Fit the safety cotters.

11

0 °

20 ° 0 °

20 ° 11

Raise the boom to 45° to obtain sufficient space to swing it out.

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20 °

20 °

When deploying, the extension must not hit the ground.

Retract the boom (telescoping-in control) to incline the extension. Proceed slowly and carefully to avoid jerking.

When the boom is being retracted, the extension inclines and the inclining system comes to a stop against pins 11.

Inclining an 8m extension to 40°.

If the extension is in the 20° configuration, it must be returned to the 0° position to configure it to 40°.

To return to 0°, change the block tackle, fix the wedge socket to the fork located on the inside surface of the 8m extension using the wedge socket pin.

Put the rope under slight tension by activating the telescopic boom.

Raise the extension by using the extend telescopic boom control.

Proceed slowly and with the utmost care.

When the extension angle is close to 0°, return the boom to horizontal using the lifting lower control and release rope if necessary.

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Put the rope under slight tension until displaying a residual charge of 0.1 tonne on the load moment limiter.

Position at 40° by removing pins 11.

Insert the pins in the relevant locations.

CAUTION Do not use the lower control without releasing rope.

Using the lowering control in isolation would put the rope under tension and damage the extension.

Raise the boom to 45° to obtain sufficient space to swing it out.

When deploying, the extension must not hit the ground.

Retract the boom (telescoping-in control) to incline the extension.

Proceed slowly and carefully to avoid jerking.

When the boom is being retracted, the extension inclines and the inclining system comes to a stop against pins 11.

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Additional rope blocks for working with lattice extensions The manufacturer can supply blocks of different capacities for working with the lattice extensions.

The blocks supplied have connections for eyelet terminals to allow the operator to work directly with the block (direct pull) or to have several tackles (ALWAYS refer to the load tables).

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Engine coolant heating device The machine can be equipped, on request, with an engine coolant electric heating device.

This heater, with power of 750W, is located on the engine block and is powered by the 240V external electrical mains via the special socket (A).

A

CAUTION The system is not equipped with a thermostat and fuse and it is therefore the operator's responsibility to check it works properly in order to prevent overheating or malfunctioning.

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Work light adjustable from inside the cab The machine can be equipped, on request, with a work light that is adjustable from inside the cab.

The light is switched on together with the other work lights using the button on the steering column.

It is possible to orientate the light with the special knob.

B

To prevent switching on the light use the selector B.

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Outrigger control from the truck The machine can be equipped, on request, with the outrigger control on both sides of the truck.

5

6

4

7

3

2

5

6

4

3

1

7 2

1. Spirit level Used to stabilize the machine correctly 2. Key switch UP position: beam re-entry / vertical cylinder up DOWN position: beam extension / vertical cylinder down 3. Left rear outrigger button (beam and vertical cylinder) Press to select the outrigger to activate with the key switch 2 4. Left front outrigger button (beam and vertical cylinder) Press to select the outrigger to activate with the key switch 2 5. Right front outrigger button (beam and vertical cylinder) Press to select the outrigger to activate with the key switch 2 6. Right rear outrigger button (beam and vertical cylinder) Press to select the outrigger to activate with the key switch 2

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7. Outrigger beam / vertical cylinder selector UP position: the vertical cylinder is selected DOWN position: the outrigger beam is selected

WARNING For reasons of safety, the outrigger control on the truck does NOT control beam extension/re-entry on the opposite side.

Engine emergency stop device The machine can be equipped, on request, with the engine emergency stop device on both sides of the truck.

On both sides of the truck there is the emergency button for stopping the engine.

In an emergency, press to stop the engine.

To use the crane again, unlock the button and start the engine with the starter key in the cab.

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Contents General ...............................................................................................................................................................7 Maintenance handbook ......................................................................................................................................8 Welding operations .............................................................................................................................................9 Welding and cutting painted surfaces .................................................................................................................10 Tyre pressures ..................................................................................................................................................11 Turntable fixing .................................................................................................................................................11 Winches fixing...................................................................................................................................................11 Wheel fixing ......................................................................................................................................................11 Starting the machine after replacing a hydraulic component ...........................................................................11 Transmission unit fixing device.........................................................................................................................11 Boom telescoping chain tension check (models RC30-1065-1075 only) ...........................................................12 Checking telescoping chains (RT100) ................................................................................................................12 Cleaning the chains ..................................................................................................................................... 12 Lubrication ................................................................................................................................................... 12 Inspection .................................................................................................................................................... 13 Check integrity of tie-rope for boom telescoping. (Only mod. RT35 – RT45 – 1075L) ....................................13 Check boom telescoping ropes (RT45L-RT100) ..............................................................................................14 Structural components ......................................................................................................................................14 Lifting rope ........................................................................................................................................................15 Wire rope replacement ................................................................................................................................ 18 Rope maintenance and removal ................................................................................................................. 20 Adjusting the brake control and releasing the parking brake ...........................................................................20 Blocks ...............................................................................................................................................................22 Maintenance charts ..........................................................................................................................................23 Tyre inflation pressures ............................................................................................................................... 23 Changing a tyre ........................................................................................................................................... 23 Screw torque wrench setting ....................................................................................................................... 24 Slewing ring screws torque wrench setting ................................................................................................. 25 Max. pressure valve calibration ................................................................................................................... 25 Pressure points RT45-RT45L...................................................................................................................... 27 Pressure point 1065 .................................................................................................................................... 28 Pressure points 1075 – 1075L .................................................................................................................... 29 RT100 pressure points ................................................................................................................................ 30 Fluid quantities ............................................................................................................................................ 31 "SHELL" lubricants ...................................................................................................................................... 32 Boom lubrication ...............................................................................................................................................33 Boom RC30 RT35 ....................................................................................................................................... 33 Boom RT45 ................................................................................................................................................. 33 Boom 1065 – RT45L – 1075 – 1075L ......................................................................................................... 33 Boom RT100 ............................................................................................................................................... 34 Diagnostics of engine (CUMMINS)...................................................................................................................38 Engine protection system ............................................................................................................................ 38 Error codes .................................................................................................................................................. 38 Error codes instantaneous data .................................................................................................................. 39 Fuses ................................................................................................................................................................41 Model RC30, RT35 ...................................................................................................................................... 41 Model RT45 – RT45L .................................................................................................................................. 43 Model RT100 ............................................................................................................................................... 46 Lists and frequencies for maintenance .............................................................................................................49 List "A" every 8 hours .................................................................................................................................. 49 Operation: ............................................................................................................................................... 49 Oil level of transmission and converter DANA................................................................................. 49 (RT35 – A600 – 1065 – 1075 – 1075L – RT100) ................................................................................... 49 Safety ...................................................................................................................................................... 49 List "B" every 40 hours ................................................................................................................................ 49 Operation ................................................................................................................................................ 49 05-2015

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List "C" every 100 hours .............................................................................................................................. 49 Operation ................................................................................................................................................ 49 List "D" every 250 hours .............................................................................................................................. 50 Operation ................................................................................................................................................ 50 Safety ...................................................................................................................................................... 50 List "E" every 500 hours .............................................................................................................................. 50 Operation ................................................................................................................................................ 50 Safety ...................................................................................................................................................... 50 List "F" every 1000 hours ............................................................................................................................ 51 Operation ................................................................................................................................................ 51 List "G" every 2000 hours ............................................................................................................................ 52 Operation ................................................................................................................................................ 52 Safety ...................................................................................................................................................... 52 List "H" every 4000 hours ............................................................................................................................ 52 Safety ...................................................................................................................................................... 52 List "I" every 5000 hours (Motor phase IIIB) ............................................................................................... 52 Operation ................................................................................................................................................ 52 Maintenance .....................................................................................................................................................53 List "A" – 8 hours ......................................................................................................................................... 53 Air filter .................................................................................................................................................... 53 Lifting rope .............................................................................................................................................. 53 Hydraulic oil tank and fuel tank level ...................................................................................................... 53 Windscreen wiper liquid container .......................................................................................................... 54 Engine oil level ........................................................................................................................................ 54 Engine radiator coolant level................................................................................................................... 55 Transmission – Converter unit and powershift (RT35 – A600 – 1065 – 1075 – 1075L – RT100) ......... 56 Tyre pressures ........................................................................................................................................ 56 Bleeding the air tanks ............................................................................................................................. 57 Block limit stop device ............................................................................................................................. 57 List "B" – 40 hours ....................................................................................................................................... 58 Slewing ring............................................................................................................................................. 58 Slewing ring teeth ................................................................................................................................... 58 Telescopic boom and hoisting system .................................................................................................... 59 Rotation reduction gear ........................................................................................................................... 59 Universal joint transmission .................................................................................................................... 59 ZF transmission fluid level (RT45 – RT45L) ........................................................................................... 60 Engine ..................................................................................................................................................... 60 Filter on hydraulic oil tank ....................................................................................................................... 61 Front and rear axles ................................................................................................................................ 61 Hoisting block assembly ......................................................................................................................... 62 List "C" – 100 hours ..................................................................................................................................... 63 Clean the air filter .................................................................................................................................... 63 Parking and service brakes..................................................................................................................... 63 Wheel tightness ...................................................................................................................................... 63 Engine and radiator check ...................................................................................................................... 63 Lubrication of the steering cylinders and suspension locking cylinders ................................................. 64 Batteries .................................................................................................................................................. 64 General battery maintenance.................................................................................................................. 64 Hoisting block assembly ......................................................................................................................... 65 Transmission – Converter unit and powershift ....................................................................................... 65 ZF transmission (RT45 – RT45L) ........................................................................................................... 65 Changing the filter ................................................................................................................................... 66 List "D" –250 hours ...................................................................................................................................... 69 Engine ..................................................................................................................................................... 69 Air filter .................................................................................................................................................... 69 Transmission – Converter unit and powershift ....................................................................................... 69 Winch gears and reduction unit .............................................................................................................. 70 Brakes (RC30-RT35-RT45L-RT100) ...................................................................................................... 70 Cab air conditioning filter ........................................................................................................................ 70 List "E" – 500 hours ..................................................................................................................................... 71 4/100

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Transmission – Converter unit and powershift ....................................................................................... 71 Engine ..................................................................................................................................................... 71 Compressed air dryer ............................................................................................................................. 71 Front and rear axles ................................................................................................................................ 72 Hydraulic circuit ....................................................................................................................................... 72 Air tanks .................................................................................................................................................. 72 Check all the fixing elements .................................................................................................................. 73 Steering ................................................................................................................................................... 73 Telescopic jib and hoisting system (RT35) ............................................................................................. 73 Air conditioning dryer .............................................................................................................................. 73 List "F" – 1000 hours ................................................................................................................................... 74 Check all the fixing elements .................................................................................................................. 74 Hydraulic circuit ....................................................................................................................................... 74 Steering ................................................................................................................................................... 74 Electrical system ..................................................................................................................................... 74 Rotation reduction gear ........................................................................................................................... 74 Checking pinion - slewing ring backlash ................................................................................................. 75 Fuel tank ................................................................................................................................................. 75 Front and rear axles ................................................................................................................................ 76 Boom section guide blocks ..................................................................................................................... 76 Winch gears and reduction unit .............................................................................................................. 76 Transmission – Converter unit and powershift ....................................................................................... 77 ZF transmission (RT45 – RT45L) ........................................................................................................... 78 Changing the filter ................................................................................................................................... 79 Braking system ....................................................................................................................................... 81 Brakes (RC30-RT35-RT45L-RT100) ...................................................................................................... 81 List "G" – 2000 hours .................................................................................................................................. 82 Hydraulic oil tank ..................................................................................................................................... 82 Brakes (RC30-RT35-RT45L-RT100) ...................................................................................................... 82 Cooling circuit.......................................................................................................................................... 83 Calibration of transmission TE15 (1075, 1065, 1075L) .......................................................................... 84 Transmission heating using 'HEATING' mode........................................................................................ 87 Air conditioning refrigerant ...................................................................................................................... 89 Execution of safety checks ...............................................................................................................................90 NOTES .................................................................................................................................................... 90 KEY ......................................................................................................................................................... 90 DAILY CHECKS (G) .................................................................................................................................... 91 MONTHLY CHECKS (M) ............................................................................................................................ 93 QUARTERLY CHECKS (T) ......................................................................................................................... 95 ANNUAL CHECKS (A) ................................................................................................................................ 97 TWO-YEAR CHECKS (B) ........................................................................................................................... 99

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General Regular maintenance will ensure long life of the machine.

Therefore make sure to follow the instructions given in this section.

The general maintenance chart gives the essential points to be observed and the following pages give the instructions relative to such operations.

NOTE: All maintenance operations must be carried out by qualified personnel. Crane operators or maintenance personnel must be familiar with the instructions contained in this manual and above all those concerning safety, before carrying out any operations.

WARNING: All work involving the removal of structural parts, such as the counterweight, telescopic boom, lift cylinder and turret, is to be performed with the outriggers fully extended and the machine stabilized on the ground At the time of starting, a specialist will show you how to use the machine. Carry out the first servicing with him.

Subsequently, refer to the maintenance intervals given in the following charts.

The intervals given are based on a work time of 8 h / day, 40 h / week, 2000 h / year.

The intervals given in the following charts apply for the machine used in normal conditions. For intensive use or particular conditions (excessive heat, humidity, dust) maintenance must be carried out more frequently.

To carry out the maintenance operations, the machine must be stabilized on fully extended outriggers on firm, flat and level ground.

The machine running hours are shown on the hour-meter in the cab.

The hour-meter measures the diesel engine run time.

Every day, carry out a complete inspection before boarding the machine or starting the engine, checking for loose or missing screws, accumulated debris, oil and coolant leaks.

Check the tyres and levels.

Any change to the fixed maintenance schedule must be preceded by a new analysis of the machine operation conditions. Carefully read the recommended maintenance handbook before changing the check frequencies.

In case of prolonged storage, the 500 hours maintenance must be carried out every 6 months, in particular on the Engine, Axles, Suspension, Steering and Transmission.

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8 - Maintenance Take every precaution to safeguard the environment. In particular, collect and recycle all used fluids. Do not leave them in incorrectly labelled or open containers.

There must be no puddles of fluids on the ground where you are working.

Maintenance handbook All the maintenance operations carried out according to the instructions given below must be recorded.

A specimen chart showing how to keep the records in question is given at the end of the chapter.

The collection of records constitutes the machine maintenance handbook.

Persons performing maintenance operations must indicate this in the handbook, so that the machine can be checked during subsequent maintenance.

The maintenance handbook is a document attached to the machine.

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Welding operations CAUTION: Before carrying out any welding operations on the crane, consult the technical assistance service for approval.

WARNING: The component to be welded must be connected to earth before performing welding operations on the crane. This precaution reduces the risk of electrical arcing through bearings, cylinders, etc. which would otherwise damage the components in question.

Remove the paint from surfaces used as an earth connection point.

WARNING: Take all the necessary precautions when welding in the vicinity of fuel tanks, oil tanks, batteries, pipes and pressurised devices.

WARNING: When welding in the vicinity of glass, cylinder rods, or other smooth or polished surfaces, protect said surfaces from potential damage caused by welding slag.

WARNING: Never weld with the crane engine running. Disconnect always the battery terminals.

WARNING: Never weld on wet surfaces or the characteristics of the weld bead will be negatively affected.

CAUTION: Always keep a fire extinguisher at hand in case of fire.

Adequate ventilation and dry surfaces are necessary. All persons in the welding area must wear protective apparel and safety spectacles.

Follow the instructions for welding and cutting painted materials.

WARNING: The welding filler material must be checked with our aftersales service.

CAUTION: Welding operations must be carried out by qualified operators.

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Operation and maintenance manual

Welding and cutting painted surfaces DANGER: Cutting or welding painted steel with certain systems exposes the operator to potentially harmful decomposition byproducts (metallic fumes, gas or vapor and particles).

The following procedures must be adopted when welding or cutting painted steel:

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•

Use a power tool wire brush or grinder to strip the paint from the steel in the area of the cut or weld to be executed.

Also remove paint in the vicinity of the weld area to prevent it from heating and blistering. If this should occur, keep removing paint.

•

When removing paint it is compulsory to wear a protective mask to filter out toxic dust and safety spectacles.

•

The welder must wear a supplementary fresh air respirator and use all the other personal protective equipment required for welding operations.

•

The other employees must depart from the area or move to a safe distance from the welder. Employees must ensure they are not exposed to drifting welding fumes.

•

If available, use an air-cleaner suction unit to remove welding fumes while welding or cutting.

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Operation and maintenance manual

Tyre pressures Periodically check tyre inflation pressures making sure that the pressures recommended for various applications are complied with. Refer to the inflation pressures specified on the stickers in the operator's cab.

Turntable fixing Periodically check the lubrication and fixing of the turntable. In case of anomalies, request the assistance of a Terex® specialist who will advise you on the operations to be carried out. THE TURNTABLE FIXING BOLTS ARE AN INTEGRAL PART OF THE CRANE STRUCTURE.

Winches fixing Periodically check the lubrication and fixing of the winches. In case of anomalies, request the assistance of a Terex® specialist who will advise you on the operations to be carried out. THE WINCH FIXING BOLTS ARE AN INTEGRAL PART OF THE CRANE STRUCTURE.

Wheel fixing Periodically check the lubrication and fixing of the wheels. In case of anomalies, request the assistance of a Terex® specialist who will advise you on the operations to be carried out. THE WHEEL FIXING BOLTS ARE AN INTEGRAL PART OF THE CRANE STRUCTURE.

Starting the machine after replacing a hydraulic component After changing a hydraulic system component, e.g. pump, distributor, cylinder, tank, run the machine at idling speed for 20-30 minutes without using any of the hydraulic functions, then bleed the replaced part if necessary. Then check or change the filter cartridges.

Transmission unit fixing device Periodically check the tightness of the transmission universal joints. In case of any doubts on the state of the screws, replace only with screws recommended by Terex®.

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Operation and maintenance manual

Boom telescoping chain tension check (models RC30-1065-1075 only) Check that the boom sections are synchronised by extending and retracting the sections several times.

If the sections are not synchronised, check boom telescoping chain tension: - With the machine stabilized, move the boom to the horizontal position.

- Partially extend the second and third telescopic sections for RC30 and RC40, the third and fourth telescopic sections for 1065.

- Retract the telescopic sections and check that the second and third sections are aligned for RC30, and the fourth and third sections are aligned for 1065.

- Loosen the grub screw on the stay lock nut.

- Adjust nut "A" of the telescoping chain stay assuming tightening torque of 30-35 daN/m until the boom sections are completely synchronised.

- Retract the boom and check that all sections are aligned.

Checking telescoping chains (RT100) Cleaning the chains Brushing the chains will remove impurities from the exterior surfaces, after they have been impregnated with petrol-based solvents compatible with oils and greases.

Cleaning chains with high pressure steam or water jets, or with acid cleansing products or those which might risk causing a release of hydrogen is forbidden.

Using strong grease-removing solvents (for example chlorinated solvents) is not advised. If nevertheless they are used, heavy lubrication must follow immediately afterwards, and this must be with oil. Painting chains is strictly forbidden.

Lubrication Use Alvania EP2 grease.

Apply manually, using a brush. Enough should be used to the joints between the pins and the plates. Apply along the full length of the chains, including the anchoring pins at the extremities, preferably while the chain is not in use and slack.

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Inspection This includes visual inspection and an estimate of chain stretching.

Visually inspect the chains seeking: - missing, broken or split plates; - lengthening of the holes in one of the four outer plates (distortion or risk of a pin coming out); - pin partly dislodged from an outside plate; - pin broken, or distorted (major distortion, discernible to the naked eye, so that the pin is no longer straight); - general corrosion of the outer surfaces; - corrosion between the surfaces in contact with adjacent plates; - pin turning freely in outer plate; - sticking point during movement of the return roller.

If even a single one of these faults appears in a single point on a chain, replace it. some corrosion points on the outer surfaces of the chains; chain not corroded but dry, not lubricated; visible wear, but moderate, on the surfaces of the plates resting on the roller.

In such cases, correct chain lubrication must be restored.

-

Check integrity of tie-rope for boom telescoping. (Only mod. RT35 – RT45 – 1075L) Close up the jib completely and check the integrity of the ropes 1 comprising the tie-rope of the telescopic boom.

Adjust the tensioning with the adjuster screw 2.

2

1

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Operation and maintenance manual

8 - Maintenance Check boom telescoping ropes (RT45L-RT100) Check lengthening.

Retract the boom completely.

Ensure it is horizontal.

Telescope sections 4, 5 and 6 so that the boom is about 13m long.

Check the telescoped length of sections 4 and 5.

They should be the same.

If the telescoped length of section 5 (A) is shorter than that of section 4 (A') by 15 to 20mm, a Terex® specialist should be called in immediately. The cable ply lengthening arises from the loss of mechanical qualities from the cable. Excessively stretched cables are at risk of breaking.

Structural components Check yearly for the presence of cracking and/or damage of the machine structural components (chassis, turret, telescopic boom sections, extensions).

If damage is noted contact our technical assistance service.

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Lifting rope The lifting rope is one of the crane's main parts, and requires particular attention for starting and maintenance.

Carry out checks in compliance with ISO4309.

The ropes must be visually checked for signs of deterioration or deformations every day.

Pay special attention to the points where the ropes are attached to the equipment.

In any case, the rope must be inspected when an accident may have caused damage to the strands, wires or attachment points or when a rope has been put back into service after being removed and then refitted.

If the machine has not been used for some time, the rope must be inspected before resuming work.

In particular, check: -The fixing points at the rope ends.

-The parts of the rope sliding on the lifting or idle section sheaves.

Rope removal criteria: -Broken wires (nature and number).

-Broken wire nests.

-Gradual increase in the number of broken wires.

-Broken strands.

-Broken rope core.

-Reduced elasticity. reduction in rope diameter rope stretching no space between individual wires and strands appearance of fine brown powder between strands -General wear of rope due to abrasion.

-External and internal corrosion.

-Rope deformation (under load) spiral deformation basket deformation stretched wires slackening of certain wires or strands knottiness contractions flattening loops lumps bends -Deterioration induced by heat.

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Operation and maintenance manual

8 - Maintenance Visual examples of various problems that can occur to the rope

Breakage and tearing of wires on two consecutive strands that required replacement (crossed strands)

High wear and very many broken wires that required immediate replacement (crossed strands)

Broken wires on the same strand and slight wear

Broken crossed wires at the equalizer pulley

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Numerous broken wires hidden by the pulley, the rope must be removed

Example of wire rope with very high internal corrosion

The boom heads are equipped with plastic sheaves, therefore the life of the ropes is increased.

When the lifting ropes are only used with plastic pulleys, rope wear is inside the rope and cannot be seen on the outside.

Our blocks are equipped with cast iron sheaves, therefore rope wear is visible externally because it is due to the rubbing of the rope on the cast iron sheaves.

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Wire rope replacement The wire chosen for use on the machine must be clean, without corrosion or deterioration.

Normally, a rope the same as the original is chosen for replacement.

Before fitting a new rope, make sure its diameter matches the grooves of the drums and the sheaves.

The type of rope fitted on the machine is specified in the certificates attached to the documentation.

When pulling a rope from a winder, or unwinding a roller (on clean ground to avoid picking up impurities), every precaution must be taken to avoid twisting it; the same applies when fitting the rope on the crane.

If these precautions are not taken the rope may buckle, form loops or knots.

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The ropes must be wound evenly on the drums. Make sure that the turns of rope wound on the first layer of the drum are close and tight in order to prevent overlapping or crossing during winding of the next layers and therefore crushing of the cable. Take into account the rope winding and the rotation direction of the drum as given below:

Rope with RIGHT twisting (use the right hand)

A Rope winding from the top of the drum with end fixed to the left flange; use the right rope.

After fitting the rope on the winch, check positioning of the rope in the thimble.

Form a loop beforehand as close as possible to its final size to avoid having to pull a long length of rope to tighten it.

The rope must come out 70 – 80 mm.

IMPORTANT: The wedge and rope must retract freely until the rope presses against the sides of the thimble Once the rope is fitted, use a minimum number of tackles and attach a load (max. load x tackle). Completely unwind the rope using the telescoping and lifting functions.

Once the rope is completely unwound, rewind it under load to tighten it and eliminate any strain.

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Operation and maintenance manual

8 - Maintenance Rope maintenance and removal To increase the life of the ropes, after 500 hours of operation, remove and extend the rope on the ground (clean ground). Rewind the rope on the winch.

The crane ropes must be checked very carefully and replaced, without economizing, in case of the slightest mishap.

Maintenance is generally performed by greasing. The rope must be greased at regular intervals according to needs and mainly in the bending areas.

The lubricant must be compatible with the greases used by the manufacturer. It is advisable to use oils which, unlike greases, can penetrate inside the rope. Lubrication reduces breakages due corrosion, wear and the coefficient of rubbing when the rope slides on the sheaves and winds on the winch drum.

Adjusting the brake control and releasing the parking brake The pneumatic drum brake functions both for positive service braking and negative parking braking. The axle leaves the factory with the parking brake function deactivated. Before putting it into operation you will need to reactivate it, carrying out the following operation in manual mode only: - Tighten the activation screw, with a 24 mm wrench, on the back of the actuator cylinder, until you feel strong resistance to the screwing movement, in this way it will have moved forward by approximately 70 mm, thereby activating the parking brake function.

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If needed, because of a failure in the compressed air system or other causes, it is possible to release the parking brake, carrying out the following operation in manual mode only: - Unscrew the activation screw, with a 24 mm wrench, on the back of the actuator cylinder, until you feel strong resistance to the unscrewing movement, in this way it will have moved out by approximately 70 mm, thereby deactivating the parking brake function.

Should the positive service braking no longer function, you will need to check the efficiency of the compressed air system, without there being any need to adjust the pads and the actuator cylinder. If this is not sufficient, you will need to replace the pads and possibly the actuator cylinder.

Should the negative parking braking no longer function, you will need to check the activation screw is in the correct position and then check the efficiency of the compressed air system, without there being any need to adjust the pads and the actuator cylinder.

If this is not sufficient, you will need to replace the pads and possibly the actuator cylinder.

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Blocks Availability No. pulleys

Weight (kg)

RC30

RT35

RT45

RT45L

5t

0

50

●

●

●

●

8t

0

160

10t

1

170

12.5t

1

255

15t

2

195

●

●

●

●

25t

3

260

●

●

●

●

35t

4

280

●

●

●

35t

4

280

●

●

●

40t

4

40t

Capacity

Type

1065

1075

1075L

RT100 ●

●

●

●

●

●

●

●

485

●

●

●

●

4

485

●

●

●

●

45t

5

400

●

●

45t

5

400

●

●

60t

6

610

●

●

60t

6

610

●

●

75t

6

750

80t

5

690

●

90t

6

800

●

●

●

●

●

●

●

Table 1

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Maintenance charts Tyre inflation pressures To check the tyre inflation pressure, refer to the following chart located in the operator's cab, taking into account the model of tyres fitted on the crane truck.

MICHELIN R24 XMH S TT 170 E

9 bar

9 bar

MICHELIN XMP

10 bar

10 bar

PIRELLI

10.25 bar

8.5 bar

ADVANCE

10 bar

7.5 bar

MICHELIN

8 bar

8 bar

PIRELLI

9.5 bar

8 bar

ADVANCE

10.5 bar

7.5 bar

PIRELLI

7 bar

5.75 bar

MICHELIN

5.5 bar

5.5 bar

TRIANGLE

6.9 bar

4.5 bar

PIRELLI

7 bar

5.75 bar

MICHELIN

5 bar

5 bar

TRIANGLE

6.9 bar

4.5 bar

23.5 - 25

ADVANCE

6.6 bar

4 bar

26.5 R25

MICHELIN

5.5 bar

5.5 bar

TRIANGLE

6.9 bar

4.5 bar

ADVANCE

5.7 bar 7 bar 7 bar

3.5 bar 6 bar 6 bar

385/95

14.00 R24

16.00 R25 16.00 - 25 20.5 R25

23.5 R25

26.5 - 25 29.5 R25

ADVANCE TRIANGLE Table 2

The pressures given refer to cold tyres, therefore also the inflation and pressure checks must be carried out on cold tyres.

Changing a tyre The weight of the tyre is in excess of 500N. Use adequate equipment to handle the tyre.

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Screw torque wrench setting Torques to be applied in Nm, coefficient of rubbing between 0.125 and 0.150.

Use a calibrated torque wrench (precision ±6%) Tightening torque of hex screws in Nm (according to UNI CNR10011) Size x Wheelbase

Class 8.8

Class 10.9

Class 12.9

M10 x 1.5

51

64

76

M12 x 1.75

89

110

132

M14 x 2

142

176

211

M16 x 2

221

275

330

M18 x 2.5

304

379

453

M20 x 2.5

431

537

643

M22 x 2.5

587

731

875

M24 x 3

746

929

1112

M27 x 3

1091

1358

1626

M30 x 3.5

1534

1910

2287

M33 x 3.5

2015

2510

3005

M36 x 4

2588

3224

3859

M39 x 4

3350

4172

4994

Table 3

Degree of identification Screw

5

8

Tightening torque

Tightening torque

3/8"

43 ÷ 47 Nm

61 ÷ 66 Nm

7/16"

68 ÷ 74 Nm

97 ÷ 106 Nm

1/2"

104 ÷ 114 Nm

147 ÷ 161 Nm

9/16"

151 ÷ 165 Nm

212 ÷ 232 Nm

5/8"

208 ÷ 228 Nm

294 ÷ 322 Nm

3/4"

368 ÷ 405 Nm

520 ÷ 572 Nm

7/8"

545 ÷ 598 Nm

838 ÷ 922 Nm

1"

818 ÷ 897 Nm

1257 ÷ 1382 Nm

1 1/8"

1098 ÷ 1206 Nm

1781 ÷ 1957 Nm

1 1/4"

1549 ÷ 1703 Nm

2511 ÷ 2762 Nm

Thread

Table 4

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Slewing ring screws torque wrench setting Torques to be applied in Nm, coefficient of rubbing between 0.125 and 0.150.

Use a calibrated torque wrench (precision ±6%) N.B.: The values given in the tables refer to lubricated screws.

Hex socket fixing screws Model: Crane truck

M20 Class 10.9

M22 class 10.9

M24 class 10.9

M27 class 10.9

RC30 – RT35

470

/ / / /

/ / / /

/ / / /

RT45 - RT45L

/ / / /

650

/ / / /

/ / / /

1065

/ / / /

/ / / /

730

/ / / /

1075 – 1075L

/ / / /

/ / / /

730

/ / / /

RT100

/ / / /

/ / / /

/ / / /

1100

Table 5

Max. pressure valve calibration To calibrate the max. pressure valves of the various elements, refer to the crane truck model being used.

The values are given in bars.

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Max. pressure valves calibration (bar) RT35

RC30

RT45 RT45L

Winch

210

210

240



250



Cylinder lifting Boom

210

210

260



250

Boom lowering cylinder with servo-controlled valve

50

50

80



130

Boom lowering line SV block relief valve

18/20

18/20

/

Boom retraction cylinder

290

210

270

Boom extension cylinder

250

210

260

Slewing Reduction Gear

150

150

◊140

◊140



160



160



160

Outrigger cylinders

160

160

160

160



160



160



160

Steering

150

150

175

170



160



160



180

Servocontrols

40/45

40/45

/

/

/

/

/

Winch speed 2 valve

150

150

/

/

/

/

/

Air conditioning valve

150

150

150

150

150

150

150

Gearbox oil cooler bypass valve

/

/

/

/

/

/

/

1065

1075

1075L

RT100

215



215



240



225



225



280



100



100



80

/



/



250  250 3° and 4° Section



250 2° Section

/



200



 200 3° and 4° Section

200 2° Section

/

200  200 3° - 4° - 5° Section



200 2° Section

 200 2°+3° Section

 200 4°+5°+6° Section

 200 2°+3° Section

 200 4°+5°+6° Section

Table 6

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Pressure points RT45-RT45L Outrigger pressure point

Pressure point for winches, lifting cylinder, telescopic cylinders

Slewing pressure point

◊ Steering pressure point

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Pressure point 1065 Outrigger pressure point

Steering pressure point

Slewing pressure point

◊

Pressure point for winches, lifting cylinder, telescopic cylinders

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Pressure points 1075 – 1075L Outrigger pressure point

Pressure point for winches, lifting cylinder, telescopic cylinders, slewing

Steering pressure point

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RT100 pressure points Outrigger pressure point

Pressure point for winches, lifting cylinder, telescopic cylinders, slewing

Steering pressure point

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manual

Fluid quantities

Quantity of lubricant Part description

um RC30 - RT35

RT45

RT45L

1065

1075 - 1075L

RT100

Engine oil

l

18

18 (IIIA) 13 (IIIB)

18 (IIIA) 13 (IIIB)

18

18

18

Gearbox oil

l

22

32

32

32

19

41

Front + rear axle oil

l

37

43

43

64

69

82

Slewing reduction gear oil

l

6

6

6

6

6

6

Total

l

600

595

595

800

900

1380

Tank

l

470

470

470

600

660

1000

Main winch oil

l

12

12

12

20

20

42

Auxiliary winch oil

l

12

12

12

20

20

12

Brake fluid

l

1.05

///

///

///

///

2

Boom guide blocks grease

kg

5

7

10

8

8

9

Slewing ring, pin, bearings grease

kg

3

3

3

3

4

5

Radiator antifreeze

l

9

22

22

18

18

13

Hydraulic circuit oil

Table 7

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"SHELL" lubricants

Model:

Type of hydraulic oil in relation to the operating temperature Tellus S2 V32

Tellus S3 V46

RC30 RT35

-20 C / +45 C

RT45 RT45L

-10 C / +45 C

-20 C / +25 C

1065 1075

-20 C / +45 C

1075L RT100

-10 C / +45 C Table 8

Operating temperature -20 C / +45 C Part description

Lubricant

Part description

Lubricant

Engine

RIMULA R4X 15W-40

Slewing reduction gear

OMALA S4 WE 150

Gearbox

SPIRAX S2 ATF AX

Winches

OMALA 150

Axles

SPIRAX S2 A 80W-90

Brakes

DOT4 ESL

Table 9

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Boom lubrication Boom RC30 RT35 Grease the boom section sliders with a brush.

Method: - Two people are needed for this operation.

- Machine outdoors.

- Machine on outriggers, fully extended.

- Boom horizontal.

- Extract all the sections.

- Grease.

- Retract the sections with the aid, if necessary, of the boom lifting mechanism.

Use a ladder. DO NOT walk or stand on the boom.

Boom RT45 Grease the boom section sliders with a brush.

Method: - Two people are needed for this operation.

- Machine outdoors.

- Machine on outriggers, fully extended.

- Boom horizontal.

- Extend the 4th section mechanically.

- Grease.

- Retract the 4th section.

- Extend the 2nd and 3rd section.

- Grease.

- Retract the sections with the aid, if necessary, of the boom lifting mechanism.

Use a ladder. DO NOT walk or stand on the boom.

Boom 1065 – RT45L – 1075 – 1075L Grease the boom section sliders with a brush.

Method: - Two people are needed for this operation.

- Machine outdoors.

- Machine on outriggers, fully extended.

- Boom horizontal.

- Extend the 2nd section.

- Grease.

- Retract the 2nd section.

- Extend the 3rd and 4th section as well as the 5th section if there is one.

- Grease.

- Retract the sections with the aid, if necessary, of the boom lifting mechanism.

Use a ladder. DO NOT walk or stand on the boom.

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Boom RT100

3

1 6 4-5

2

Boom lubrication chart Frequency

Ref.

Identification

Operation

Grease points

50 h

1

Boom base section

Greasing

2 grease nipples

250 h

2

Slide pads

Greasing

Brush and grease nipples

3

Electric system

Check

Wiring harnesses

4

Fasteners

Check tightness

All fasteners

5

Slide pads

Check condition

All pads

6

Pulleys

Check condition

1000h

Table 10

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Greasing: see lubrication table Using a grease pump, grease the rear top pads of sections T2, T3, T4, T5 and T6.

Four grease nipples per section. Two grease nipples per pad.

Access by four holes on the sides of sections T1, T2, T3, T4, and T5 The two grease nipples should not be given the same amount of grease.

A considerable amount should be applied to the one on the left, but the one on the right should receive much less (one or two deliveries).

Grease the section sliders with a brush.

Method: - Machine outdoors.

- Machine on outriggers, fully extended.

- Blocked boom tilted to 2°.

- Two people are needed for this operation.

GREASING T2 and T3 T5 and T6 released (remaining however in T4).

Telescope T2/T3 61% (+/-2%). Boom 21.80 m.

Grease T2 pads through the first hole on each side of T1.

Telescope T2/T3 90% (+/-2%). Boom 26.40 m.

Grease T2 and T3 pads through the second hole on each side of T1 and T2.

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T4 GREASING Retract T2/T3 54% (+/-2%).

Grease T4 pads through holes on each side of T3.

GREASING T5 and T6 Telescope T4, T5, T6 to 62% {+/-2%) Grease T4, T5, and T6 pads through the 2nd hole on each side of T3 and the first holes on the sides of T4 and T5.

Telescope T4, T5, T6 to 90% (+/-2%) Grease T4, T5, and T6 pads through the first holes on T3, T4, and T5.

Telescope T2 100%.

Grease the section sliders with a brush. Use a stepladder or a folding ladder. DO NOT walk or stand on the boom.

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Telescope T3 alone 100%.

Grease the section sliders with a brush. Use a stepladder or a folding ladder.

DO NOT walk or stand on the boom.

Telescope T4, T5, and T3 alone 100%.

Grease the section sliders with a brush. Use a stepladder or a folding ladder.

DO NOT walk or stand on the boom.

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Diagnostics of engine (CUMMINS) Engine protection system QSB series Cummins engines installed on models RC30, RT35, RT45, RT45L, 1065, 1075, 1075L and RT100 are equipped with an engine protection system.

The system monitors critical engine pressure and temperature values and records any diagnostic errors in the event of anomalous operating conditions. In the presence of out of tolerance values and if it becomes necessary to derate engine power, the operator is warned by illumination of an ALARM warning light in the cab. The ALARM warning light starts flashing if the out of tolerance condition continues to worsen.

When the red STOP warning light illuminates the operator must stop the engine as soon as possible in order to limit possible damage.

NOTE: The engine speed and power will be reduced gradually in accordance with the degree of gravity of the condition in question.

Error codes The QSB system can highlight and record operating anomalies and communicate them in the form of error codes. The error codes can be used to facilitate troubleshooting tasks. The error codes are recorded in the ECM (engine control module).

The error codes can be read by means of the indicator lights on the control panel in the cab.

NOTE: Not all anomalies relative to the QSB system or the engine are communicated by means of error codes.

There are two basic types of error codes: •

Engine electronic control system error codes

•

Engine protection system error codes

All the error codes recorded can be either active (error code present) or inactive (error code present at a specific time but not currently present).

Certain electronic error codes (although not all) cause a warning light to illuminate when they are present. There are two warning lights that can illuminate when an error is detected.

To check for the presence of error codes relative to the engine electronic fuel system and engine protection system switch off the engine and turn the ignition key to ON. Press the DIAGNOSTICS pushbutton.

If no error codes are present, both the STOP and ALARM warning lights will illuminate and remain illuminated.

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In the presence of error codes both the warning lights illuminate briefly and then start flashing to communicate a code relative to the errors that have been recorded.

The error code will flash in the sequence indicated below: The yellow ALARM warning light flashes initially. This will be followed by a 1-2 second pause, after which the number of the recorded error code will flash on the red STOP warning light. There will be a 1-2 second pause between each number. When the red warning light has stopped flashing the yellow warning light will illuminate again.

The error code will now be repeated in the same sequence.

The warning lights will flash three times for each error code before progressing to the next code in the memory. To go to the next error code, temporarily set the idle speed adjustment switch to the (+) position. You can return to the previous error code by temporarily setting the idle speed adjustment button to the (-) position. If just one error has been detected, the QSB system will continue to display the same code when the (+) or (-) switch is pressed.

Error codes instantaneous data Additional information concerning error codes can be obtained by means of the INSITE service software. The engine management system instantaneously saves the values and status of the control sensors as soon as a malfunction is detected. These data serve to recreate or establish the operating conditions of the engine when the anomaly occurred.

The ECM communicates with INSITE by means of an SAE J1939 data connection (for the connector see ref."A").

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A

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Fuses Model RC30, RT35

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Code

Function

F1

Fan 1 fuse

F2

Fan 2 fuse

F3

Horns fuse

F4

Slewing brake release fuse

F5

Fans relay fuse

F6

RH and LH servocontrol fuse

F7

Third and fourth boom indicators and selector fuse

F8

Auxiliary winch descent fuse

F9

R14-R15-R16 optional relay fuse

F10

Rotating light fuse

F11

Worklight fuse

F12

Winch second speed slow-fast fuse

F13

Engine stop supply fuse

F14

Boom reset key fuse

F15

Stop lights, carrier junction box, and rpm reduction fuse

F16

Rear fog light fuse

F17

Cab supply fuse

F18

Lights selector switch fuse

F19

Gear change fuse

F20

15 emergency supply fuse

F21

Microswitch fuse "deadman"

F22

RCL supply fuse

F23

Steering supply fuse

F24

Compattino instrument cluster fuse

F25

Outriggers fuse

F26

PPM boom and normal winch descent microswitch fuse

F27

Auxiliary winch fuse

F28

Front-rear differential lock opt. fuse

F29

Optional direct power supply fuse

F30

Heating system fuse

F31

30 emergency supply fuse

F32

RH sidelight fuse

F33

LH sidelight fuse

F34

Headlights high beam fuse

F35

Headlights low beam fuse

F36

RCL central unit fuse

F37

Relay control unit general power fuse

F38

Alternator fuse

F39

Diagnostic connector fuse

F40

Engine control unit supply fuse

F41

Pre-heater fuse

F42

Starter motor fuse Table 11

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Model RT45 – RT45L Truck control unit

Code

Fuses Function

FC FG1 FG2 FG3 FU101 FU102 FU103 FU104 FU105 FU106 FU107 FU108

Glow plug fuse Battery cut-off switch main fuse Collector fuse Engine control unit fuse Diesel fuel heater fuse Gearbox oil fan fuse Drier fuse Reverse gear fuse Steering pump fuse Fuse for parking brake / transm. +15 Fuse for transmission +30 Oil cooler 70° bulb fuse

FU109 FU110 FU111 FU112 FU113 FU114 FU115 FU116

Keyswitch signal fuse Engine diagnostics fuse Collector fuse Collector fuse

Code

Contactors Function

K01 K02

Key-controlled utilities contactor Glow plug contactor

Code

Relays Function

REL101 REL102 REL103 REL104 REL105 REL106 REL107

Starting relay Engine lockout starter relay ZF Interlock starter relay Parking brake relay Steering pump relay Oil fan relay Reverse gear relay

Table 12

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Tower control unit

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Fuses

Fuses

Code

Function

Code

Function

F1

Fan 1 oil cooler fan fuse

F27

Fuse for A/C unit and lower tower section microswitch

F2 F3 F4 F5 F6

Fan 2 oil cooler fan fuse Horns fuse Free slewing fuse Oil cooler controls fuse Relay fuse

F28 F29 F30 F31 F32

F7

Spare

F33

F8

Fuse for auxiliary and main winch microswitch

F34

Headlights high beam fuse

F9 F10 F11 F12 F13

Transmission push-button panel fuse Rotating lamp fuse Work lights fuse Fuse for setting rpm / differential lock Engine switch panel fuse

F35 F36 F37

Headlights low beam fuse MIDAC fuse MC2M supply fuse

F14 F15 F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26

Air-conditioner fuse Brake lights fuse Rear fog light fuse Cab utilities fuse Fuse for wipers / horn relay coil Winder fuse Emergency stop switch fuse Joystick fuse Encoder fuse Steering selector fuse Instrumentation fuse Outriggers fuse Winch speed 2 relay fuse

Code

Relays Function

REL1 REL2 REL3 REL4 REL5 REL6 REL8 REL17 REL18 REL13A REL21

Free slewing relay Limiter cut-out lamp-alarm relay Suspension block relay Heat exchanger fan relay Spare Spare Winch speed 2 relay Heat exchanger fan relay Horn relay Turn indicators relay MC2M supply relay

Fuse for radio / instrument panel fittings Instrumentation 30 fuse Emergency stop switch 30 fuse Ignition key 30 fuse Parking lights fuse Fuse for parking lights / instrument backlighting

Table 13

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Model RT100

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Code F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23

Function Cab heating system Warning Cab lights supply Horn relay supply Load limiter control unit supply Emergency mushroom supply Transmission supply Outriggers relay supply Load limiter inhibition diodes control unit common power supply Deadman safety devices / 15 minutes timer supply Low beams relay / Boom head light supply Rear suspension locks solenoid valve supply Air conditioning supply Warning STOP pressure switch supply Flashing alarm / Beeper / Buzzer supply Air conditioning pressure switch / Reverse gear / air conditioning solenoid valve l lifting solenoid valve / Slewing brake release solenoid valve Winch

F24

Differential locks solenoid valve / Winch 2nd speed / AUX winch supply

F25 F26 F27 F28 F29 F30

Boom lifting cylinder supply Frame Can / Roof windscreen wiper supply Parking lights supply Parking lights supply Worklights supply

Carrier / Rear fog light supply Column / Switches locating indicator lights supply Rotating light supply Side instrument panel switches High beams relay supply

Table 14

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Code K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K18 K19 K20 K21 K22

Function Outriggers relay 2nd winch speed relay 2nd gear relay 3rd gear relay not used Horn relay not used Intermittent device Differential lock solenoid valve relay Relay not used Reverse gear relay Forward gear solenoid valve relay High-beam headlights relay Low-beam headlights relay Suspension lock relay Work light relay 1st gear relay Air conditioning relay Free slewing relay Start-up interlock relay 3B-6 extended boom control relay 3B-6 retracted boom control relay Table 15

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Lists and frequencies for maintenance List "A" every 8 hours Operation: -

Hydraulic oil filter clog indicator Winch ropes Hydraulic oil and fuel tank levels Screen wash level Engine oil level Engine radiator coolant level Oil level of transmission and converter DANA (RT35 – A600 – 1065 – 1075 – 1075L – RT100) Tyres inflation pressure Tanks air bleeding Block limit stop device

Safety • • •

Hook block limit stop microswitch operation (check that the microswitch interrupts the manoeuvre) Load limiter operation (check that the limiter inhibits boom lowering and extension, winch lifting and turret slewing manoeuvres) No warning lights illuminated

List "B" every 40 hours Operation -

Slewing ring rotation Slewing ring teeth Telescopic boom and hoisting system Slewing reduction gear Universal joint transmission Front and rear axles Engine Hydraulic oil tank filter Transmission oil level ZF (RT45 – RT45L) Front and rear axles Hoisting block assembly

List "C" every 100 hours Operation -

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Air cleaner Parking and service brakes Tightening and fixing of wheels Engine / radiator Suspension and steering Batteries Hoisting block assembly Change transmission oil and filter DANA TE15 (1075, 1065, 1075L) – ZF (RT45 – RT45L)

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List "D" every 250 hours Operation -

Engine Air filter Cab air conditioning filter Transmission and converter Winch gears and reduction unit Brakes

Safety • • •

Check condition of tyres (no gouges or cuts) Check tyre inflation pressure with machine unloaded (see specifications in the following table) Hook block anchor rope (check ropes wear according to ISO4309)

List "E" every 500 hours Operation -

Transmission and converter Engine Air dryer Air conditioning dryer Front and rear axles Hydraulic circuit Air tanks General fixing elements Wear of boom head sheaves

Safety • • • • • • • • • • • • • •

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Horn operation Main winch limit stop device (check that the device blocks the manoeuvre with at least three rope turns around the drum) Auxiliary winch limit stop device (check that the device blocks the manoeuvre with at least three rope turns around the drum) Hook block limit stop microswitch operation (check that the microswitch interrupts the manoeuvre) Correct fixing of thimble on boom head The rope of the main winch is wound and unwound correctly The rope of the auxiliary winch is wound and unwound correctly (if present) Correct extension of the telescopic boom Correct retraction of the telescopic boom Extending and retracting the outrigger beams Extending and retracting the stabiliser vertical cylinders Load limiter operation (check that the limiter inhibits boom lowering and extension, winch lifting and turret slewing manoeuvres) Automatic selection between front sector ± 3° and 360° load table Confirm selection of the front sector load table (travelling) only with the turret slewing locking pin inserted

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• • • • • • • • • • •

"Deadman device" (microswitch on joysticks) Ropes (check ropes wear according to ISO4309) Hooks (check wear of hooks according to UNI9473-1) Boom (check intact condition of cable stay for boom extension only for RT35) Efficiency of load holding valves on outrigger cylinders (check that cylinder rod retraction is no more than 3 mm over a period of 15 minutes with the machine stopped) Efficiency of load holding valve on hoisting cylinder (check that cylinder rod retraction is no more than 3 mm over a period of 15 minutes with the machine stopped) Efficiency of load holding valve on extension cylinder (check that cylinder rod retraction is no more than 3 mm over a period of 15 minutes with the machine stopped) Holding capacity of winch brake (check that drum rotation (in rope unwinding direction) is no more than 5° over a period of 15 minutes Holding capacity of turret slewing unit (with crane stabilised on just one side and inclined by 4° in a lateral direction, check that the turret does not rotate) Alignment of the boom (completely extend the boom and check visually to ensure that the sections are reciprocally aligned) Efficiency of the rear axle swing restriction cylinders

List "F" every 1000 hours Operation -

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General fixing elements Hydraulic circuit Steering Electrical system Slewing reduction gear Check of pinion - slewing ring backlash Fuel tank Front and rear axles Boom section guide blocks Winch gears and reduction unit Transmission and converter Braking system Brakes

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List "G" every 2000 hours Operation -

Hydraulic oil tank Brakes Cooling circuit Air conditioning refrigerant Calibration of automatic transmission TE15 (1075, 1065, 1075L) Inspect hydraulic lines in compliance with FEM 5.020

Safety • • • • • • • • • • • • • • • •

Tightening wheel nuts (check that tightening torque of the M22x1.5 nuts is 45...55 Nm) The engine cannot be started unless the transmission is in neutral Correct operation of front axle steering Correct operation of crab steering Correct operation of concentric steering Rear axle steering locking device Correct operation of the service brake Correct operation of the parking brake Correct insertion of manual lock on outrigger extension beams Correct insertion of turret slew locking pin Correct operation of booms selection (where present) Tightening of slewing ring fixing screws to eliminate the risk of loose screws Tightening of screws securing the winch to the superstructure to prevent screws from working loose Tightening of screws securing the front axle to the chassis and rear axle to the swinging support Visual check of condition of structural welds, chassis, turret, and boom girders (absence of cracking) Check tightness of superstructure slewing unit screws

List "H" every 4000 hours Safety •

Checking load limiting device calibration When lifting known weights at assigned distances check that these values are within 10% of the load (UNI ISO 10245-2)

List "I" every 5000 hours (Motor phase IIIB) Operation -

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Clean the diesel particulate filter (DPF) – Refer to the manufacturer's technical specifications

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Maintenance List "A" – 8 hours Air filter Clean the clogging indicator (1).

1

Lifting rope Visually inspection the suspended rope and inside the lifting winch drum (refer to the paragraph).

Hydraulic oil tank and fuel tank level The checks must be carried out with the machine on level ground, all cylinders retracted, boom retracted in the horizontal position and oil cold.

Check the hydraulic oil level (by means of the special gauge on the tank) and the fuel level every 8 hours.

DO NOT smoke during fuel tank filling, as the vapours are flammable.

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Windscreen wiper liquid container Check the windscreen wiper liquid in the tank located in the operator's cab every 8 hours.

Engine oil level Check the engine oil level every 8 hours.

To check the oil level, open the hood on the frame and check that the level is between max. and min. on the dipstick.

If necessary, top-up with oil immediately.

The engine oil must always be checked before starting work or in any case with engine cold.

In any case, refer to the engine manufacturer's technical specifications.

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Engine radiator coolant level Open the cover located at the back of the engine hood to access the radiator cap.

The antifreeze mixture consists of a solution of 34% coolant and 66% water.

Check the coolant level and if necessary add water or antifreeze solution until the level is 2 cm from the edge of the filler.

Use the type and quality of antifreeze mixture according to the manufacturer's instructions; refer to the relevant specifications for further details.

• During filling, take care when handling coolants and oil.

• The components and hot oil can cause burns. Avoid any contact with the skin.

• Never put cold coolant in an overheated engine.

Always wait for the engine to cool down first.

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Transmission – Converter unit and powershift (RT35 – A600 – 1065 – 1075 – 1075L – RT100) Check the transmission oil level with oil at a temperature of 80° and the engine idling.

Top-up the oil if necessary.

In any case, refer to the gearbox manufacturer's technical specifications.

Tyre pressures Adjust the tyre pressures according to that specified on the sticker located in the cab or in the chart given previously in this manual.

• The pressures specified on the chart in the cab or given previously refer to cold tyres. Inflation and pressure checks must be carried out on cold tyres. NEVER inflate hot tyres.

• Check the tyres only when there are no suspended weights on the crane. Always use a safety cage when the tyre is not fitted on the machine.

• Do not stand in front of the tyre. Use a sufficiently long air hose with quick connector for inflation.

DANGER!! Never drive the machine with inadequately inflated tyres.

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Bleeding the air tanks Bleed the air tanks to remove deposits and moisture.

In winter, the condensate could freeze and block the breather. At the end of every work day, bleed the air from tanks.

One bleeding operation on each tank is sufficient.

Block limit stop device Regularly check that the limit stop device works properly.

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List "B" – 40 hours Slewing ring Using a grease pump and by means of the grease nipples on the slewing ring, lubricate the ring with sufficient grease (four or five pump strokes).

After lubricating the first grease nipple, turn the slewing ring 90° to distribute the grease evenly over the entire inside surface.

CAUTION: For the maximum safety this operation should be carried out by just one operator.

Slewing ring teeth Check slewing ring teeth lubrication every 50 hours.

For good lubrication of the slewing ring and the pinion, grease twice, fully turning the slewing ring firstly in one direction and then the other.

CAUTION: For the maximum safety this operation should be carried out by just one operator.

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Telescopic boom and hoisting system • • • • • •

Greasing the section telescoping guide blocks.

Grease the hoisting block and boom head sheaves.

Grease the telescopic boom pivots.

Grease the boom lifting cylinder.

Grease the angle indicator pin.

Check the boom telescoping chain tension.

Visually check the lifting rope.

Rotation reduction gear Check the reduction unit oil level with the dipstick.

Universal joint transmission Check the lubrication and lubricate again if necessary.

The cardan shafts have three grease nipples each for ensuring good lubrication.

Moderately lubricate the universal joint near the parking brake disk.

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ZF transmission fluid level (RT45 – RT45L) The oil level must be checked as follows: - With the vehicle in a horizontal position.

- With the gearbox in Neutral "N".

- During cold starting, the engine must idle for approximately 2 - 3 minutes, then the mark of the oil level on the dipstick must be above the word "COLD".

- At the gearbox operating temperature (approximately 80° - 90° C).

- At engine idle speed.

- Loosen the oil level dipstick by turning it anti-clockwise, and then pull it out and clean it.

- Slowly insert the dipstick into the oil level tube as far as it will go, then pull it out again.

- The oil level on the dipstick must be in the "HOT" sector.

- Re-insert the oil level dipstick and tighten it by turning it clockwise.

If, at the operating temperature, the oil level has dropped below the "HOT" sector, it is vital to top it up.

An oil level above the word "HOT" will produce an excessive temperature of the oil. In any case, refer to the gearbox manufacturer's technical specifications.

Engine Carry out the first engine oil change.

In any case, refer to the engine manufacturer's technical specifications.

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Filter on hydraulic oil tank Keep the clogging manometer under control; when the pressure reaches 2 bars this means the filter cartridge must be changed.

At the same time clean the hydraulic tank breather.

Front and rear axles Carry out the first oil change.

It is advisable to carry out this operation when the oil is still hot.

The oil must be drained by means of the plug (♦) located at the bottom of the box and the plug (♦) on the bottom of the reduction unit.

♦

• ♦ At the time of each service check the efficiency of the breather (•) situated on the top of the gearbox, washing it with diesel fuel and drying with a jet of air.

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Hoisting block assembly Check the tightness of the lock nuts of the support tie-rods.

Check the lock of the grub screw of the hook ring nut.

Check that the block assembly always has the plate indicating the capacity and if necessary replace it quickly should it become indecipherable.

Grease the crossbeam pins and the hook bearing.

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List "C" – 100 hours Clean the air filter If the cartridge is dry: - Blow from the inside outwards at a very low pressure - Using a lamp, make sure the cartridge is not perforated.

If the cartridge is greasy it must be changed.

The cartridge must be changed after six cleanings and in any case once a year.

Always change faulty or doubtful cartridges.

Parking and service brakes Have a specialized technician check the parking brake and service brake seals.

Wheel tightness Regularly check the tightness of wheels every 100 hours.

Torque wrench settings: - Front axle 65 daNm - Rear axle 65 daNm.

Engine and radiator check Clean the radiator fins with compressed air.

Check the condition and tension of all engine belts and replace them if necessary.

Check the engine mounts and replace them if necessary.

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Lubrication of the steering cylinders and suspension locking cylinders Lubricate the steering cylinders, the suspension locking cylinders and the fixing pins of the front and rear axle steering cylinders by means of the grease points indicated (♦).

♦

♦ ♦

♦

♦

♦

♦

♦

♦

♦

Batteries -

-

In normal use, the batteries do not require topping-up. However, in special cases, e.g. high number of working hours, high operating temperature, the user can top-up with distilled water. Never add sulphuric acid.

Whenever frequent additions of water are necessary, have the vehicle's electrical system checked.

An electrical system check is also necessary whenever the battery tends to go flat.

Maintenance-free batteries have the good characteristic of keeping their charge, therefore if the battery (new or used) is not used for a long time, a recharge every 4-5 months is sufficient. When the battery has been used for more than 2 years, it advisable to have it periodically checked.

General battery maintenance Keep the top part of the battery clean and dry, to avoid short-circuits and corrosion. Remove the battery terminal clamps and check for any corrosion. In case of corrosion, remove the deposits and a thin layer of metal. Cover with Vaseline or another suitable product. Tighten the clamps moderately. When using the wrench, make sure not to touch the battery casing or other terminals. Do not use naked flames near the batteries.

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Hoisting block assembly Check the play of the pulleys on their axis.

Check for any wear on the lug of the hook.

Transmission – Converter unit and powershift Check the oil level on the gearbox graduated dipstick.

Check the engine oil level with the oil at a temperature of 80° and the engine idling.

Change the oil filter cartridge for the first time.

Remove the oil filter cartridge, clean the filter support base, oil the seal ring before fitting the new cartridge.

Tighten the new filter cartridge by hand.

In any case, refer to the gearbox manufacturer's technical specifications.

ZF transmission (RT45 – RT45L) The oil must be changed as follows: - At the gearbox operating temperature, with the vehicle in the horizontal position, remove the oil drain plug and collect the used oil.

- Clean the oil drain plug along with the magnetic insert and the surface of the seat, then reinstall it with the O-ring.

- Add oil (approximately 21 litres), choosing the fluid from the list of lubricants (The capacity of the sump, external capacities such as for example the heat exchanger, piping, etc. depend on the vehicle).

The indicated value is used as a reference.

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It is imperative to make sure that the oil and filter are perfectly clean! In any case, you must observe the mark shown on the dipstick!

- Start the engine – at slow idle speed - Gearbox in Neutral "N" - Top up with oil to the word "COLD" - Lock the vehicle securely in place and warm up the gearbox - Engage the gearbox control in every position - Check the oil level again and top up if necessary - The oil level on the dipstick must be in the "HOT" sector (see FigureNo.: 4.2 B2) - Re-insert the oil level dipstick and tighten it by turning it clockwise.

When filling the gearbox for the first time, you must remember that the heat exchanger, delivery line filter and pipes must be filled with oil.

Taking account of these volumes, the amount of oil to be added is greater than that required when filling up later on during normal maintenance work.

Changing the filter When replacing the ZF filter on the main delivery line, carefully check that no dirt or grime can get into the circuit. In addition, the parking brake must be covered or protected from splashes of oil.

When installing the filter, proceed without forcing.

The filters are installed separately from the gearbox on the vehicle!

Handle the filter carefully during installation, transport and storage!

Damaged filters must not be installed!

The filter differential valve (bypass valve) is equipped with a maintenance switch (disconnecting switch) to warn the driver that there is contamination in the ZF fine filter.

When this symbol lights up, you need to replace the ZF fine filter.

Mount the filter as described below: - Moisten the gasket with a film of oil.

- Screw in the filter snug against the sealing surface, then tighten it manually by approximately 1/3 to 1/2 of a turn.

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After each oil change it is necessary to calibrate the transmission with the following procedure: 1. Warm the transmission until the fan of the transmission oil cooler located on the truck switches on 2. Turn the engine off 3. Select neutral N on the gear selector 4. Apply the parking brake 5. Start the engine On the limiter display 6. Using buttons

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view the engine page

7. Press

to display the TRANSMISSION CALIBRATION page.

8

to start the TRANSMISSION CALIBRATION procedure.

Press

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During calibration, the following codes are shown on the display Code displayed AEB maincode

Description

AEB subcode

1-6 7 8 9-14 7 8 5 6 5 or 6

Clutch calibration Calibration for all clutches completed AEB cancellation (activation stopped) AEB stopped, the clutch cannot be calibrated Engine speed too low, increase engine rpm Engine speed too high, decrease engine rpm Transmission oil temperature too low, increase its temperature Transmission oil temperature too high, cool the transmission Transmission temperature in a range not defined during calibration and the software is configured to stop if the temperature is out of range

1

Operating mode not NORMAL or the temperature sensor is defective or saving the calibration values to EPROM has failed

4 2 3

Output speed not zero Gear selector not in neutral N Parking brake not engaged Table 16

9

Wait for calibration to complete, OK on the display.

10 Turn the engine off.

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List "D" –250 hours Engine Change the engine oil.

Refer to the manufacturer's specifications for further details.

Replace the engine oil filter cartridge.

Replace the two fuel filter cartridges.

Check the condition and tension of all engine belts and replace them if necessary.

In any case, refer to the engine manufacturer's technical specifications.

Air filter Clean the cap collector of dust.

Check the clogging indicator.

Change the air filter cartridge.

Transmission – Converter unit and powershift Check the oil level on the gearbox graduated dipstick.

Check the engine oil level with the oil at a temperature of 80° and the engine idling.

Change the oil filter cartridge.

Remove the oil filter cartridge, clean the filter support base, oil the seal ring before fitting the new cartridge.

Tighten the new filter cartridge by hand.

In any case, refer to the gearbox manufacturer's technical specifications.

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Winch gears and reduction unit Check the oil level and gears inside the winch. Carry out the first oil change, and subsequently every 1000 hours or at least once a year.

Check the main winch and possible auxiliary winch with the same frequency.

Brakes (RC30-RT35-RT45L-RT100) Change the brake fluid (in model where present) and change also the filter cartridges.

Cab air conditioning filter If working in very dusty and dirty surroundings, it is advisable to change the cab internal air filter (if present) and clean the external ambient air filter every 200 hours.

Clean the condenser regularly using compressed air and water (no pressure washers).

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List "E" – 500 hours Transmission – Converter unit and powershift Check the oil level on the gearbox graduated dipstick.

Check the engine oil level with the oil at a temperature of 80° and the engine idling.

Change the oil and the filter cartridge.

Change the filter cartridge at every oil change.

Take every precaution to safeguard the environment.

Make sure that all the oils and liquids used are recovered and correctly recycled; do not leave such products or containers without the special labels in unsuitable or open places.

Do not leave residuals of any liquid on the ground or floor.

In any case, refer to the gearbox manufacturer's technical specifications.

Engine Check the alternator and starter motor, adjust the valve clearances and check the injectors.

In any case, refer to the engine manufacturer's technical specifications.

Compressed air dryer Change the cartridge of the dryer located under the metal cover.

It is advisable to disconnect the batteries before changing the cartridge.

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Front and rear axles Check the brakes.

Lubricate all connections.

Clean and lubricate the wheel hubs.

Check the oil level of the reduction units and axle casings.

Moderately grease all the steering joints (pins, joints, knuckles).

Hydraulic circuit Change the hydraulic circuit filter.

Lubricate the filter seal table before replacing.

Check for any leaks in the hydraulic circuit; in case of leaks, replace the damaged parts.

Air tanks Clean the air tank automatic breathers.

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Check all the fixing elements Check the fixing of: - counterweight bolts - winch bolts - slewing ring bolts - rotation reduction unit bolts - axle bolts - engine / gearbox and converter bolts For the torque settings of the various screws, see the chart given previously in this manual.

Steering Check the tightness of all steering screws and all components (steering wheel, steering column, steering box, levers and connecting rods).

Make sure there are no hydraulic leaks in the power steering unit.

Telescopic jib and hoisting system (RT35) •

Check integrity of tie-rope for boom telescoping

Air conditioning dryer Change the dryer filter Clean the condenser regularly using compressed air and water (no pressure washers)

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List "F" – 1000 hours Check all the fixing elements Check the fixing of: - counterweight bolts - winch bolts - slewing ring bolts - rotation reduction unit bolts - axle bolts - engine / gearbox and converter bolts

Hydraulic circuit Check for any leaks in the hydraulic circuit; in case of leaks, replace the damaged parts.

Steering Check the tightness of all steering screws and all components (steering wheel, steering column, steering box, levers and connecting rods).

Make sure there are no hydraulic leaks in the power steering unit.

Electrical system Check the wiring and relevant fixing elements.

Rotation reduction gear Change the reduction unit oil every 1000 hours.

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Checking pinion - slewing ring backlash Check adjustment of pinion - slewing ring backlash and adjust by means of the reduction unit flange (fig.1) if necessary.

Fig.1

Backlash between pinion and slew ring (Jn) measured as shown in fig. 2 must be checked at the 3 teeth marked with green on the slew ring teeth and must be between 0.3 and 0.35 mm.

Fig.2

Fuel tank Remove any water or condensation from the fuel tank by means of the plug located under the tank.

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Front and rear axles Change the transmission and gearbox oil.

It is advisable to carry out this operation when the oil is still hot.

The oil must be drained by means of the plug (♦) located at the bottom of the box and the plug (♦) on the bottom of the reduction unit.

♦

• ♦ At the time of each service check the efficiency of the breather (•) situated on the top of the gearbox, washing it with diesel fuel and drying with a jet of air.

Boom section guide blocks Check the boom telescopic section guide blocks.

Check the tightness of the guide block and support fixing screws.

Check the boom sheaves.

Winch gears and reduction unit Change the winch reduction unit and internal gear oil.

Change the oil every 1000 hours or at least once a year.

Change the oil with the same frequency as for the main winch and possible auxiliary winch.

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Transmission – Converter unit and powershift Change the oil and the filter cartridge.

Drain and fill the transmission as described below: 1. Drain the transmission oil.

2. Remove and dispose of the oil filter. Install the new filter.

3. Fill the transmission up to the FULL indicator.

4. Run the engine at 500 – 600 rpm to distribute the oil inside the transmission.

5. Check the level again with the engine running at 500-600 rpm and add oil to bring the level up to the LOW indicator. When the oil temperature reaches the range 82.2-93.3°C (hot oil) perform the final check on the oil level and top up if necessary to bring the level up to the FULL indicator.

Change the filter cartridge at every oil change, maintenance or repair job.

Take every precaution to safeguard the environment.

Make sure that all the oils and liquids used are recovered and correctly recycled; do not leave such products or containers without the special labels in unsuitable or open places.

Do not leave residuals of any liquid on the ground or floor.

In any case, refer to the gearbox manufacturer's technical specifications.

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ZF transmission (RT45 – RT45L) The oil must be changed as follows: - At the gearbox operating temperature, with the vehicle in the horizontal position, remove the oil drain plug and collect the used oil.

- Clean the oil drain plug along with the magnetic insert and the surface of the seat, then reinstall it with the O-ring.

- Add oil (approximately 21 litres), choosing the fluid from the list of lubricants.

(The capacity of the sump, external capacities such as for example the heat exchanger, piping, etc. depend on the vehicle).

The indicated value is used as a reference.

It is imperative to make sure that the oil and filter are perfectly clean! In any case, you must observe the mark shown on the dipstick!

- Start the engine – at slow idle speed - Gearbox in Neutral "N" - Top up with oil to the word "COLD" - Lock the vehicle securely in place and warm up the gearbox - Engage the gearbox control in every position - Check the oil level again and top up if necessary - The oil level on the dipstick must be in the "HOT" sector (see FigureNo.: 4.2 B2) - Re-insert the oil level dipstick and tighten it by turning it clockwise.

When filling the gearbox for the first time, you must remember that the heat exchanger, delivery line filter and pipes must be filled with oil.

Taking account of these volumes, the amount of oil to be added is greater than that required when filling up later on during normal maintenance work.

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Changing the filter When replacing the ZF filter on the main delivery line, carefully check that no dirt or grime can get into the circuit. In addition, the parking brake must be covered or protected from splashes of oil.

When installing the filter, proceed without forcing.

The filters are installed separately from the gearbox on the vehicle!

Handle the filter carefully during installation, transport and storage!

Damaged filters must not be installed!

The filter differential valve (bypass valve) is equipped with a maintenance switch (disconnecting switch) to warn the driver that there is contamination in the ZF fine filter.

When this symbol lights up, you need to replace the ZF fine filter.

Mount the filter as described below: - Moisten the gasket with a film of oil.

- Screw in the filter snug against the sealing surface, then tighten it manually by approximately 1/3 to 1/2 of a turn.

After each oil change it is necessary to calibrate the transmission with the following procedure: 1. Warm the transmission until the fan of the transmission oil cooler located on the truck switches on 2. Turn the engine off 3. Select neutral N on the gear selector 4. Apply the parking brake 5. Start the engine On the limiter display 6. Using buttons

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7. Press page

to display the TRANSMISSION CALIBRATION

11 Press procedure

to start the TRANSMISSION CALIBRATION

During calibration, the following codes are shown on the display Code displayed AEB maincode

Description

AEB subcode

1-6 7 8 9-14 7 8 5 6 5 or 6

Clutch calibration Calibration for all clutches completed AEB cancellation (activation stopped) AEB stopped, the clutch cannot be calibrated Engine speed too low, increase engine rpm Engine speed too high, decrease engine rpm Transmission oil temperature too low, increase its temperature Transmission oil temperature too high, cool the transmission Transmission temperature in a range not defined during calibration and the software is configured to stop if the temperature is out of range

1

Operating mode not NORMAL or the temperature sensor is defective or saving the calibration values to EPROM has failed

4 2 3

Output speed not zero Gear selector not in neutral N Parking brake not engaged Table 17

12 Wait for calibration to complete, OK on the display 13 Turn the engine off

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Braking system Check the brake cylinder fixing elements.

Check the brake circuit lines and replace them if necessary.

Brakes (RC30-RT35-RT45L-RT100) Change the brake fluid (in model where present) and change also the filter cartridges.

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List "G" – 2000 hours Hydraulic oil tank Change all the oil in the tank.

Change the oil filter.

Breather

Change the oil after 2000 hours or at least once a year.

Changing the hydraulic circuit oil consists of methodically draining the oil tank, pumps, cylinders, cooling radiators.

Take every precaution to safeguard the environment.

Make sure that all the oils and liquids used are recovered and correctly recycled; do not leave such products or containers without the special labels in unsuitable or open places.

Do not leave residuals of any liquid on the ground or floor.

Brakes (RC30-RT35-RT45L-RT100) Change the brake fluid (in model where present) and change also the filter cartridges.

Replace the brake circuit flexible hoses every 2000 hours or once a year.

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Cooling circuit Change the radiator coolant every 2000 hours or at least once a year.

A

B

C

To drain the circuit: -

Make sure the engine is not hot and that the coolant is at ambient temperature.

Remove the filler cap (A), undo the plug at the bottom of the radiator (C) and drain the coolant.

Refit the plug on the bottom of the radiator.

To refill the circuit: -

-

-

-

Disconnect the engine breather pipe (B).

Pour in the coolant (1/3 antifreeze - 2/3 water) through the filler neck (A) until the level corresponds to 2 cm. from the rim of the filler neck. Use the type and quality of antifreeze mixture according to the manufacturer's instructions; refer to the relevant specifications for further details.

Reconnect the engine breather pipe and close the filler cap.

Start the engine and let it idle for a few minutes, checking the temperature gauge on the control panel in the cab, in order to prevent possible overheating.

Stop the engine, wait a few minutes for it to cool down, unscrew the cap, check the liquid level and if necessary top-up to the required level.

Refit the filler cap and repeat the last two operations until the level of the coolant stabilizes.

Take every precaution to safeguard the environment.

Make sure that all the oils and liquids used are recovered and correctly recycled; do not leave such products or containers without the special labels in unsuitable or open places.

Do not leave residuals of any liquid on the ground or floor.

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Calibration of transmission TE15 (1075, 1065, 1075L)

Automatic calibration of the transmission is required in the following cases: − at the time of vehicle production − every 2000 hours of transmission duty − when the transmission is overhauled − when the transmission is repaired − when the APC200 is replaced

Calibration must only be carried out by competent and qualified personnel. Incorrect calibration can cause limitations or anomalies of machine operation.

Activation of calibration mode

Overview of display pages in calibration mode

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Automatic calibration mode is activated by pressing, for at least 15 seconds, switch 'S' on the APC200 front panel during crane startup. On entering calibration mode the display shows the following wording (see also the above overview):

Calibration mode can be quit only by removing the crane ignition contact. Press button ‘M’ to display the available calibration modes (see the above overview), press button ‘S’ to start calibration of the currently displayed mode.

Certain calibration modes can be inhibited by the control unit software when they are not required. In this case, when switch ‘S’ is pressed to start the calibration process, the display shows the following message:

Before starting automatic calibration ensure the following conditions are fulfilled: − Vehicle parking brake must be applied. − Transmission temperature must be above 60°C. Refer to the next heading for explanations on how to use 'HEATING' mode to achieve this condition rapidly. − The engine speed must be maintained at approximately 800 rpm (± 200 rpm) for the entire duration of the calibration procedure.

To activate the automatic calibration procedure press button S once.

If all the above conditions are fulfilled the APC200 display will show:

The APC200 requires the gear lever to be set to FORWARD.

If one of the required conditions is absent the corresponding message is displayed. For a list of these messages, refer to the heading Calibration condition and calibration error messages.

The automatic transmission calibration procedure starts. The following appears on the APC2000 display:

;

;

;

etc.

‘c1’ means ‘clutch 1’ forward, while ‘M1’ means calibration 'mode 1'.

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Operation and maintenance manual

8 - Maintenance When all the clutches have been calibrated, the APC200 will show:

At this point the automatic calibration procedure has been completed successfully. Complete automatic calibration of the transmission can take between 10 and 15 minutes.

To quit automatic calibration mode the vehicle ignition must be switched off. Make sure that APC200 is completely powered off - wait for 2 seconds. At this point the vehicle can be restarted; the new calibration parameters are activated automatically.

This power-off operation is critical because it is in this period that the new calibrated parameters are saved in the permanent memory of the APC200.

NOTE 1: If the APC2000 display shows information other than the information described above, there are two possible reasons: • •

the calibration conditions have not been met (temperature too low, handbrake off, vehicle moving, engine speed too high or too low) a calibration error has occurred during the procedure (message starting with letter 'E').

For more details refer to the heading Calibration condition and calibration error messages.

NOTE 2: If the gear lever is set to REVERSE during an automatic calibration procedure, the procedure is automatically cancelled at the APC200 is rebooted. This routine can be used as an emergency manoeuvre if anything fails to function during the calibration procedure.

Note: when the automatic calibration procedure is cancelled, calibration is not completed and must be repeated from the beginning.

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Transmission heating using 'HEATING' mode Heating mode is specifically provided to allow rapid heating of the transmission before performing an automatic calibration procedure.

When this heating mode is active the following normal signals are disregarded: − Gear requested (cabpos): irrespective of the requested gear the transmission is set to the highest ratio. − Parking brake input: the parking brake switch signal is completely disregarded to allow selection of forward or reverse travel with the handbrake applied. − Brake pedal position: this signal is disregarded to avoid the transmission from disengaging if the brakes are applied fully.

This translates into reduced operating mode of the transmission, which will always have the highest gear engaged and reacts only to direction changes. The required direction will be selected irrespective of the state of the parking brake or brake pedal signal.

Once activated, this mode makes it possible to heat the transmission easily. Simply apply the parking brake and select a travel direction.

The transmission will stall against the brakes but without creating an overload on the machine since the highest gear ratio is selected (minimum torque transfer).

The heading Activation of calibration mode, in addition to explaining how to access calibration mode, also shows how to activate 'HEATING' mode. Once the message "tran" appears on the display, press M once to enter "heating" mode. The APC200 will show:

To activate 'HEATING' mode, press button S. The APC200 will show the sump temperature:

This indication means that the effective transmission sump temperature is 20°C.

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8 - Maintenance To heat the transmission adopt the following procedure: 1. Make sure the parking brake is applied and is operating correctly.

2. Set the transmission to forward movement by selecting forward gear with the gear lever, then accelerate the engine to max rpm.

3. Keep the engine at max rpm for around 15 seconds and then set the gearbox to neutral with the gear selector. Keep the engine running at full revs!

4. Keep the gearbox in neutral with the engine at full revs for around 15 seconds.

5. Release the accelerator pedal and allow the engine to drop to idle speed.

6. Return to point 2 and repeat the procedure until the APC200 display shows a temperature above 60°C, When the temperature exceeds 60°C the temperature value starts to flash on the display.

At this point you can switch to automatic calibration by pressing button M repeatedly until the message "tran" appears on the APC200.

NOTE:

During this heating procedure the transmission converter external temperature may exceed the maximum limit. This is a consequence of heating of the transmission using this rapid procedure.

When this event occurs the engine speed is limited by 50% (if the APC200 is functioning as an engine controller) or forced transition of the gearbox to neutral (if APC200 is not functioning as an engine controller). To solve this problem just leave the transmission in neutral and bring the engine to around 1300 rpm. This will allow the converter to dissipate the heat.

After one of two minutes you can resume the heating procedure if the transmission temperature has not yet reached 60 °C.

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Operation and maintenance manual Calibration condition messages and calibration alarms This chapter offers an overview of the various calibration status messages. Normally the calibration condition messages can be corrected without requiring a service call-out. However, if a calibration error is displayed always make a note of the error code and inform the Terex technical assistance service.

Calibration status messages

The APC200 requires the gear lever Return the gear lever to the neutral position. in neutral position but it detects it in a different position (forward or reverse).

The APC200 requires the parking brake to be applied, but the brake is released.

Apply the parking brake.

The APC200 has detected an output speed.

Check that the parking brake is applied and is functioning correctly. If affirmative, use the brake pedal to hold the machine at a complete standstill.

Once the machine has been stopped, the APC200 will prompt the operator to select forward gear before continuing the calibration routine.

The engine speed is too low with respect to the permissible limit for calibration.

If the vehicle is equipped with a throttle-by-wire system, the engine speed will be adapted automatically. Vice versa the operator must change the accelerator pedal position until the display appears as follows:

The engine speed is too high with respect to the permissible limit for calibration.

After having been too high or too low, the engine speed is returning to the correct limits for calibration.

When the temperature falls excessively during the transmission automatic calibration procedure the APC200 display shows the effective transmission temperature.

Use button M on the APC200 to return to 'HEATING' mode and button S to activate this mode. At this point the transmission must be heated again until reaching a temperature above 60°C, then resume automatic calibration mode by pressing button M and reactivate it to continue the calibration routine.

Table 18

Calibration errors Calibration errors are in ‘E1.xx’ or ‘E2.xx’ format (e.g.: E1.25). If the display shows an error in this format take a note of the error code and contact the Terex assistance service.

Air conditioning refrigerant Charge the circuit with R134A refrigerant – see gas note plate – and perform a general check of the plant once a year (at the start of the summer season).

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Execution of safety checks The checks shown below serve to assess the condition of the components and equipment and identify any damage, wear, corrosion or other alterations.

In addition, it is also used to check the integrity and functionality of the safety equipment.

Take as reference the technical standard ISO 9927

NOTES Instructions for safe-keeping The following inspection sheets are to be considered as an integral part of the machine and must accompany it throughout its lifetime, until final demolition.

Instructions These instructions are provided according to the provisions known at the date of the machine first being taken to market.

New provisions may change the user's obligations.

The inspection sheets are laid out, in accordance with the proposed layouts, to note down the following events concerning the useful life of the machine: • failures of a certain entity and associated repairs and/or renewal of main components • safety checks If the inspection sheets are insufficient, add the necessary sheets drawn up according to the layouts shown here. The user must write the machine's identification data on the additional sheets.

KEY List

ID

Control description

 Check performed confirmation

Control description Control identification G: Daily M: Monthly T: Quarterly A: Annually B: Two-yearly Reference to the maintenance list

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DAILY CHECKS (G) Before taking the crane into operation each day, make a thorough inspection before getting into the cab or starting the engine, checking that there are no obvious signs of impairment to the structure or the safety devices; then get into the cab, start the engine and check:

List

A



ID

Control description

G1

Hook block limit stop microswitch operation (check that the microswitch interrupts the manoeuvre)

G2

Load limiter operation (check that the limiter inhibits boom lowering and extension, winch lifting and turret slewing manoeuvres)

G3

No warning lights illuminated Table 19

Notes ID ………

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MONTHLY CHECKS (M)

List

D



ID

Control description

M1

Check condition of tyres (no gouges or cuts)

M2

Check tyre inflation pressure with machine unloaded (see specifications Table 2).

M3

Hook block anchor rope (check ropes wear according to ISO4309) Table 20

The pressures given refer to cold tyres, therefore also the inflation and pressure checks must be carried out on cold tyres

Notes ID ………

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QUARTERLY CHECKS (T) With the machine with no load, check:

List

ID

Control description

T1

Horn operation

T2

Main winch limit stop device (check that the device blocks the manoeuvre with at least three rope turns around

T3

Auxiliary winch limit stop device (check that the device blocks the manoeuvre with at least three rope turns around

T4

Hook block limit stop microswitch operation (check that the microswitch interrupts the manoeuvre)

T5

Correct fixing of thimble on boom head

T6

The rope of the main winch is wound and unwound correctly

T7

The rope of the auxiliary winch is wound and unwound correctly (if present)

T8

Correct extension of the telescopic boom

T9

Correct retraction of the telescopic boom

T10

Extending and retracting the outrigger beams

T11

Extending and retracting the stabiliser vertical cylinders

T12

Load limiter operation (check that the limiter inhibits boom lowering and extension, winch lifting and turret slewing manoeuvres)

T13

Automatic selection between front sector ± 3° and 360° load table

T14

Confirm selection of the front sector load table (travelling) only with the turret slewing locking pin inserted

T15

"Deadman device" (microswitch on joysticks)

T16

Ropes (check ropes wear according to ISO4309)

T17

Hooks (check wear of hooks according to UNI9473-1)

T18

Boom (check intact condition of cable stay for boom extension only for RT35-RT45-1075L)



E

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With a load that can vary between 30% and 50% of the machine's maximum capacity, check:

List

E

ID

Control description

T19

Efficiency of load holding valves on outrigger cylinders (check that cylinder rod retraction is no more than 3 mm over a period of 15 minutes with the machine

T20

Efficiency of load holding valve on hoisting cylinder (check that cylinder rod retraction is no more than 3 mm over a period of 15 minutes with the machine

T21

Efficiency of load holding valve on extension cylinder (check that cylinder rod retraction is no more than 3 mm over a period of 15 minutes with the machine

T22

Holding capacity of winch brake (check that drum rotation (in rope unwinding direction) is no more than 5° over a period of 15 minutes

T23

Holding capacity of turret slewing unit (with crane stabilised on just one side and inclined by 1° in a lateral direction, check that the turret does not rotate)

T24

Alignment of the boom (completely extend the boom and check visually to ensure that the sections are reciprocally aligned)

T25

Efficiency of the rear axle swing restriction cylinders



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8 - Maintenance

Operation and maintenance manual

ANNUAL CHECKS (A) With the machine with no load, check:

List

G

ID

Control description

A1

Tightening wheel nuts (check that tightening torque of the M22x1.5 nuts is 550 Nm ±55 Nm)

A2

The engine cannot be started unless the transmission is in neutral

A3

Correct operation of front axle steering

A4

Correct operation of crab steering

A5

Correct operation of concentric steering

A6

Rear axle steering locking device

A7

Correct operation of the service brake

A8

Correct operation of the parking brake

A9

Correct insertion of manual lock on outrigger extension beams

A10

Correct insertion of turret slew locking pin

A11

Correct operation of booms selection (where present)

A12

Tightening of slewing ring fixing screws to eliminate the risk of loose screws

A13

Tightening of screws securing the winch to the superstructure to prevent screws from working loose

A14

Tightening of screws securing the front axle to the chassis and rear axle to the swinging support

A15

Visual check of condition of structural welds, chassis, turret, and boom girders (absence of cracking)

A16

Check tightness of superstructure slewing unit screws

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8 - Maintenance

Operation and maintenance manual

TWO-YEAR CHECKS (B) With the machine with no load, check:

List

ID

Control description

H

B1

Checking load limiting device calibration When lifting known weights at assigned distances check that these values are within 10% of the load (UNI ISO 10245-2)

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