Terex PPM Cranes ATT400-3 Operator & Maintenance Manual

SIEGE SOCIAL ET USINES Zone Industrielle de la Saule B.P. 106 71304 --- MONTCEAU CEDEX TEL. : (33) 03 85 67 38 00 FAX : (33) 03 85 67 38 99

THE GUARANTEE WILL BE NULL AND VOID WHERE THERE HAS BEEN NEGLIGENCE, FAULTY MAINTENANCE, INAPPROPRIATE USE OF THE EQUIPMENT BY THE PURCHASERS OR THEIR EMPLOYEES, AND/OR FAILURE TO RESPECT TECHNICAL INSTRUCTIONS ABOUT THE GUARANTEE.

Bungee jumping from cranes is dangerous PPM CRANES, Inc. designs, manufactures, and sells safe, reliable products for handling materials, NOT PEOPLE .

We believe that using a crane to lift, lower or position people for “Bungee Cord Jumping” is inherently dangerous and should not be done.

PPM Cranes, Inc. products are not intended or approved for this misuse. Our products are not designed, manufactured, tested, nor intended to primarily handle personnel.

Many people have been injured when riding crane hooks, loads or manbaskets. They have no control over how they are handled and no protection from impacts or falls. Small mistakes can be fatal.

Recognizing the inherent danger of lifting personnel for “Bungee Jumping”, we strongly recommend P&H Safety Catalog #275 as a guide for understanding the dangers and warnings against the use of cranes for lifting people.

Recognizing the inherent danger of lifting personnel for “Bungee Jumping”, we strongly recommend Safety rules chapter for understanding the dangers and warnings against the use of cranes for lifting people.

We therefore request that all dealers and distributors take all reasonable means to immediately communicate this warning, BUNGEE JUMPING FROM CRANES IS DANGEROUS, to all potential crane users, purchasers, and renters. We also strongly warn dealers and distributors to never knowingly sell or rent a crane for bungee jumping activity as this is a serious product misuse.

REMEMBER : BUNGEE JUMPING FROM CRANES IS A DANGEROUS ACT.

Informations

Maintenance and operator’s manual

Information I

Edition :

12/2000

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Informations

Maintenance and operator’s manual

IMPORTANT : THEORETICAL & PRATICAL TRAINING COURSES FOR USING PPM CRANES ARE OFFERED ON A REGULAR BASIS. FOLLOWING REQUEST YOUR DEALER CAN PROVIDE INFORMATION AND DATES FOR EVENTUAL INSCRIPTION.

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Informations

Important notice In order that any type of vehicle be reliable and safe, it is most important to carry out all lubrication and maintenance operations.Some of them, given in the MAINTENANCE MANUAL, requires special tooling and technical knowledge.

Any failure to the lubrication and maintenance instructions may cause a severe accident.

READ CAREFULLY ALL THE SAFETY INSTRUCTIONS BEFORE CARRYING OUT LUBRICATION AND MAINTENANCE OPERATIONS ON THE MACHINE. All precautionary measures are given in the paragraph “SECURITY” as well as in the Manual, when the corresponding maintenance operations may present dangers. Also on the machine, there are warnings concerning some dangers which may cause serious accidents. In the Manual, as well as on the machine, these warnings are preceded by the word “CAUTION” ,“WARNING” or ”NOTES”.

P P M does not necessarily know exactly how maintenance operations are carried out, nor the inherent risks concerning a defined method and is therefore unable to supply relative advice to the maintenance team.

Consequently, anyone using a method or tool which is not specifically recommended in this MANUAL must be previously sure that there are no risks for himself or anybody else and will not damage the machine or endanger the security.

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Informations

Maintenance and operator’s manual

DATE OF ISSUE : MARK TYPE

: PPM TEREX LIFTING :

SERIAL NUMBER :...........

DATE OF START UP : .. / ....

IMPORTANT : The information contained in this operator’smanual are subject to change without prior notice. In case of contest, only the french version will be taken into account.

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Informations

Technical specifications Identification MAKE : TYPE : MANUFACTURER : PPM Z.I. de La Saule 71304 MONTCEAU Les MINES B.P. 106 FRANCE

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Informations

Maintenance and operator’s manual Crane conform to EUROPEAN DIRECTIVES EEC 98/37 allowing EC autocertification.

Operating conditions : Working temperature between ---15˚C and +45˚C Maximum wind speed : 50 kph Maximum working altitude : 1000 m.

Transversal gradeability : a maximum of 25% on a perfectly even surface with a horizontally levelled chassis.

Horizontally levelled chassis

Crane identification data Constructors Identity Plate locations.

Carrier : In the carrier cab on the right underneath the passenger’s seat.

Upperstructure : On the right hand side of the upperstructure on the engine intake manifold. The machine’s identification number is stamped on the fixed beam of the front right outrigger.

Absorbtion coefficient (exhaust fumes) Serial No. Vehicle type

G.L.W. G.R.W.

Weight / Axle

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Presentation II

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Assembling and disassembling an auxiliary winch 1 / Adding an auxiliary winch onto a crane Extract from the CE self---certification directions. ”...Upgrading, modifications: Once the date of shipment specified on the release note has expired, any upgrading, repairs or modification of the machine’s components, or addition of supplementary equipment will mean that PPM does not guarantee the self---certification compliance of this machine. An external authority should be called in in this case.( e.g.: APAVE, VERITAS, AIF etc...).

2 / Removing an auxiliary winch from the machine If the auxiliary winch is disassembled, IT IS VITAL to fit additional counterweights in order to ensure the stability of the machine. (See counterweight table).

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Maintenance and operator’s manual

N 90038--- 22 --- 2t5 J 03137--- 05 --- 1t75

P 90038--- 23 --- 1t3 P 90038--- 23 --- 1t3

R 90038--- 25 --- 1t1 R 90038--- 25 --- 1t1

S 90038--- 26 --- 0t6 S 90038--- 26 --- 0t6

Version 2 x 12t

H 031377--- 04 --- 0t7 0t35 0t35

Q 90038--- 24 --- 3t2

J 03137--- 05 --- 1t75 M 90038--- 21 --- 0t6 M 90038--- 21 --- 0t6

R 90038--- 25 --- 1t1 R 90038--- 25 --- 1t1

S 90038--- 26 --- 0t6 S 90038--- 26 --- 0t6

Version 2 x 13 t

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Total counterweights

Machine 2 x 12 t

YES

NO

NO

NO

N90038 22 N90038--2500 kg

P9003823 1300 kg

R900038 25 R900038--1100 kg

S90038--- 26 600 kg

2500 kg

Fitted ?

Weight /Ref.

ALL TIRES

Total counterweights

Machine 2 x 12 t + 3%

2.5 t COUNTERWEIGHT CONSTITUTION

S90038--- 26 600 kg

2750 kg

NO

NO

NO

X03137--- 41 550 kg

Z03137--- 42 550 kg

NO

P9003823 1300 kg

YES

YES

V03137--- 39 250 kg

N90038--- 22 2500 kg

Fitted ?

Weight /Ref.

ALL TIRES

Total counterweights

YES

NO

NO

P9003823 1300 300 kg g

R900038--- 25 1100 kg

S90038--- 26 600 kg

3800 kg

YES

Case n˚1

Fitted ?

3800 kg

Total counterweights

S90038--- 26 600 kg

NO

X03137--- 41 550 kg

On the front of the frame

YES

P90038--- 23 1300 kg

4050 kg

NO

NO

YES

N90038--- 22 2500 kg

Z03137--- 42 550 kg

YES

Fitted ?

Case n˚1

4050 kg

On the front of the frame

On the front of the frame

On the front of the frame

YES

YES

YES

Fitted ?

Case n˚2

ALL TIRES

V03137--- 39 250 kg

Poids / Ref.

Machine 2 x 12 t + 3%

On the front of the frame

YES

YES

Case n˚2

Fitted ?

ALL TIRES

N90038--- 22 2500 kg

Weight /Ref.

Machine 2 x 12 t

3.8 t COUNTERWEIGHT CONSTITUTION

Total counterweights

Machine 2 x 13 t

S90038--- 26 600 kg

R900038--- 25 1100 kg

M90038--- 21 600 kg g

Q90038--- 24 3200 kg

Poids / Ref.

3800 kg

NO

NO

YES

YES

Fitted ?

Case n˚1

3800 kg

On the front of the frame

On the front of the frame

YES

YES

Fitted ?

Case n˚2

ALL TIRES

Total counterweights

YES

YES

R900038--- 25 1100 kg

S90038--- 26 600 kg 5500 kg

YES

YES

N90038--- 22 2500 kg

P9003823 1300 kg

Fitted ?

ALL TIRES

Weight /Ref.

Machine 2 x 12 t

Total counterweights

YES

YES

P90038--- 23 1300 kg

X03137--- 41 550 kg

S90038--- 26 600 kg

5750 kg

YES

YES

YES

N90038--- 22 2500 kg

Z03137--- 42 550 kg

YES

Fitted ?

ALL TIRES

V03137--- 39 250 kg

Weight /Ref.

Machine 2 x 12 t + 3%

5.5 t COUNTERWEIGHT CONSTITUTION

Total counterweights

Machine 2 x 13 t

S90038--- 26 600 kg

R900038--- 25 1100 kg

M90038--- 21 600 kg

Q90038--- 24 3200 kg

Weight /Ref.

5500 kg

YES

YES

YES

YES

Fitted ?

ALL TIRES

Maintenance and operator’s manual

Presentation

Recommendations for capacity chart reading Before using the functions : -----------

OUTRIGGERS HOISTING DERRICKING TELESCOPING SLEWING

WITH OR WITHOUT LOAD , it is compulsory that the operator has read and understood all the following indications ...

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Choice of the correct capacity chart : Refer to the chart corresponding to the working conditions required,

1

(mark on the following example.)

Pay particular attention to make sure that the counterweight(s) fitted on the machine is (are) compatible with the capacity chart in question (refer to indications given on capacity chart).

Select the counterwight configuration on the control display.

35 TONNES METRIQUES 2.6

t

360˚

3 éléments

0˚ 9.4 m --- > 23.4 m Lmaxi=23.4m

*

1300 ABC

ESEMPIO dato a titolo solamente indicativo.

Far riferimento alla copia in cabina SPECIMEN donné à titre indicatif seulement.

Se référer à l’exemplaire dans la cabine

1

8

For information only.

Refer to sheet in cab.

Siehe Lasttabelle in der Kabine.

Nur zur Kenntnisnahme.

Ejemplo para informacion ùnicamente.

Refiérase al ejemplar en la cabina.

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Reading a capacity chart

5

BOOM CONFIGURATION

6

9.40 m /(11)* avec équipement supplémentaire

_

SPECIMEN donné à titre indicatif seulement.

Se référer à l’exemplaire dans la cabine For information only.

Refer to sheet in cab.

Nur zur Kenntnisnahme.

Siehe Lasttabelle in der Kabine.

4

2

12.90 m /(7)*

_

7 16.40 m /(6)*

_

Max. 79˚

35.00

Max. 79˚

20.25

2.7

63.30

35.00

69.90

3.0

60.90

32.00

68.60

3.5

56.90

27.45

4.0

52.60

4.5 5.0

19.90 m /(4)*

_

Max. 79˚

17.40

Max. 79˚

12.30

20.25

75.3

17.40

78.50

12.30

20.25

74.30

17.40

77.60

12.30

66.30

20.25

72.50

17.40

76.00

12.30

23.75

63.90

20.25

70.60

17.40

74.40

12.30

48.00

20.70

61.50

20.25

68.80

17.40

72.80

12.30

43.10

18.10

59.00

19.00

66.90

17.40

71.30

12.30

6.0

31.90

14.05

53.60

15.55

63.00

15.55

68.20

12.10

7.0

17.60

10.55

47.70

11.15

58.90

11.05

65.00

10.70

8.0

41.00

8.90

54.60

8.85

61.80

8.75

9.0

32.80

7.20

50.00

7.05

58.40

7.05

10.0

21.20

5.95

45.00

5.95

55.00

5.90

11.0

39.50

5.00

51.40

4.95

12.0

33.00

4.20

47.50

4.20

13.0

25.20

3.55

43.30

3.55

14.0

12.70

2.95

38.70

2.95

15.0

33.40

2.55

16.0

26.80

2.10

17.0

17.20

1.80

0.00

1.50

18.0 19.0 20.0 21.0 mini

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0.00

8.20

0.00

5.00

0.00

2.75

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LOAD RADIUS : The radius is the horizontal distance from the slewing axis to the vertical axis given by the center of the boom head pullies.

4

The radius given are loaded radius, which take into account the deflection of the boom. An unloaded radius can be less than indicated on the chart. Take into account that it is necessary to hoist the boom just before lifting a load in order to maintain the same radius.

Reeving According to the boom length used set up hoist reeving as shown on diagram RADIUS / HEIGHT UNDER HOOK. --- Too much reeving in regards to boom length will not allow the hook to reach the ground.

--- Too little reeving may inhibit lifting a given load because of maximum line load capacity.

BOOM ANGLE UNDER LOAD This angle is indicated on the LMI unit screen display

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7

Presentation MAXIMUM AUTHORIZED GROSS LOAD

In order to determine the load to be lifted, it is necessary to : --- DEDUCT from the load indicated on the capacity chart, the weight of the hook block used. This weight is shown on the capacity chart, as well as being stamped by the manufacturer on the hook block.

NOTE : Do not use an inadequate hook block on which : sheave diameters, groove widths, hook capacities etc.... are not according to specifications.

--- DEDUCT from indicated load hoisting accessories weights such as slings, shackles, etc...

--- DEDUCT : from indicated load the weight of extension installed on the boom head even when not used for lifting loads.

The weights to deduct are shown on the capacity chart.

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Particular recommendations when lifting loads on free on wheels.

Respect the indications given on the load charts concerning this function.

AUTHORIZED LOADS GIVEN BY CAPACITY CHARTS FOR FREE ON WHEELS Suppose that the following conditions are fulfilled : --- Tires inflated to recommended pressure for lifting loads under free on wheels duty. (Generally 10 bar). This pressure is shown on an decal stuck in the cab and on the chassis above the wheels.

--- Parking brake on --- Suspension lowered and locked --- Loads manipulated as close to the machine as possible and also close to the ground.

--- Work on flat, horizontal and firm grounds

IMPORTANT : WHENEVER POSSIBLE WORK ON FULLY EXTENDED OUTRIGGERS RATHER THAN FREE ON WHEELS.

IN ORDER TO MAINTAIN MACHINE STABILTY WHEN MANEUVERING ON WHEELS WITHOUTT ANY LOAD IT IS ESSENTIAL TO RESPECT DERRICKING ANGLE LIMITATIONS AS STATED IN THE ON WHEELS LOAD CAPACITY CHART.

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Maintenance and operator’s manual

Presentation

Particular recommendations when lifting loads on outriggers.

Authorized loads given by the capacity chart on outriggers suppose that the following conditions are fulfilled : --- OUTRIGGERS FULLY EXTENDED. NOTE : When one or several outriggers cannot be fully extended it is recommended to use the free on wheels capacity chart.

--- WHEELS OFF OR HARDLY TOUCHING THE GROUND so that the axle weight is added to the machine stability.

--- MACHINE RIGGED HORIZONTALLY, check the level indicator.

Check this indicator often. Check the accuracy of the indicator, if necessary, on a known reliable level ground.

--- FIRM GROUND UNDER THE OUTRIGGER PADS. Use timber blocks if necessary to increase pad surface.

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Pad lifting : If a pad lifts from the ground when the load passes over the diagonally opposite outrigger pad it does not mean that the machine is going to overbalance.

However, if this does arrive under normal outrigging conditions, the following points should be checked : --- That the outrigger beam on the load side is correctly extended.

--- That the wheels are clear of the ground as indicated in the outrigger capacity chart.

--- That the handled load does not exceed the authorized limit.

--- That the outrigger pad has not sunk into the ground under the load.

--- That the outrigger lifting rams’ anti---return valves are not faulty.

--- That the chassis is not twisted through bad chocking.

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Presentation

BRAKING SYSTEM The braking system is one of the machine’s safety elements. It has been designed and been approved to be in compliance with the modified 71/320/CEE directive.

CAUTION : It is strictly forbidden to modify the brake circuit without having obtained the constructor’s prior permission. All replacement components must be OEM produced parts. Any welding, grinding or torch heating work on any part of the braking system is strictly forbidden.

Any suspected anomaly which is detected during operation must be immediately checked by qualified personnel.

Regular checks must be carried out at least once per year --- these should be visual, verification of correct working order and braking efficiency measurements.

1 / Visual check --- Make sure that there is no corrosion on brake fluid reservoirs and metal piping and that there are no signs of welding or grinding.

--- Make sure that all flexible hoses are in good condition.

--- After ten years operating life ---then every 5 years--- the air tanks must undergo pressure checks ( Consult the relevant authorities in your country) --- Check that there is no water in the reservoirs, if there is then bleed the reservoir by the appropriate device located on the lower part of the reservoir. Also check operation of the dessicator (cartridge).

2 / Correct operation test --- Verify that the main regulator engages and disengages.

--- Check the whole circuit for leaks : --- no operation, engine stopped --- when operating the foot brake pedal --- when disactivating the parking brake. ( CAUTION : Chock the wheels beforehand).

--- Check the condition and stroke of all brake linings by the inspection holes in the protective cover plate located behind the wheel.

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3 / Efficiency testing Maximum pressure on each axle is as follows : Pmax1 = 6.7 bar (axle no. 1) Pmax2 = 6 bar (axle no. 2) Brake efficiency can be controlled in different ways : ( values as required by technical test specifications).

a / Testing with a deceleragraph : When driving at a speed of between 30 and 40 kph the deceleration level must be at least 4.5 m/s2

b / Measuring the stopping distance : Measure the braking distance from the moment pressure is applied on the brake pedal until the machine comes to a complete standstill.

The maximum distance allowed is : 40m at 60 kph or 29m at 50 kph or 19.90m at 40 kph or 12.50m at 30 kph.

c / Roller test bench : --- The roller test must be carried out with the gear box in neutral, and without axle or interwheel lock ---ups.

--- Using the braking force measurement and corresponding pressure readings from the test bench, the machine’s braking ratio can be calculated with the following formula :

T1 * Z%=

Pm1--0,2 P1--0,2

+ T2 *

Pm2--0,2 P2--0,2

* 100

PM where T1 T2 T3 = Braking force readings from each axle P1 P2 P3 = Corresponding braking pressure readings Pm1 Pm2 Pm3 = Maximum braking pressure on each axle (see above) PM = Total machine weight.

CAUTION Braking force measurements taken on the roller test bench cannot be used to give the engine’s overall braking ratio if they are not accompanied by the corresponding pressure readings.

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Presentation

Operator’s comfort Noise level (Mobile cranes only) The continuous acoustic pressure level in the cab equivalent to A ponderated, statically measured according to measuring conditions laid down in the PREN13000 mobile crane standards project is 78.4. dB(A) and remains less than 85 dB(A).

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Edition :

09/1996

Maintenance and operator’s manual

Safety rules

Crane inspection

Edition : 03/1999

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Safety rules

Maintenance and operator’s manual

Inspection It is compulsory to have a crane inspected at least once a year by a specialist, and every 4 years by an inspector recognised by the manufacturer. (ISO 9927 --- 1).

During this inspection, the theoretical length of use of the winches must be established. (See § 1.0) The inspection of the crane chiefly involves a visual check making it possible for the inspector to judge the state of the crane and its components (including deterioration, rust, etc.). The safety devices and the brakes are subject to an operational check, and only specialists with the required skills and experience are deemed able to judge the state of the brakes and reducing gears.

All defects identified during the inspection contribute to avoiding accidents. The defect in question must be described in detail, and then be rectified and inspected once again The annual inspection should lead to the drafting of a detailed inspection report describing the measures taken, the work carried out and the name of the company handling the work.

This report should be attached to the maintenance log of the machine.

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Safety rules

Maintenance and operator’s manual

Winch inspection During the annual inspection, the theoretical length of use of the winches must be established. If necessary, the operator must consult an assessor for this task.

This requirement is compulsory in certain countries within the framework of the application of accident prevention measures at work. In those countries where these requirements are not compulsory, PPM nevertheless advises that they be observed.

1.0/ Calculating the remaining theoretical length of use The winches of the crane are assessed according to the ISO 4301/1, FEM 1001 standard, classified as follows:

ISO / FEM Usage class

T5

Spectrum class

L2

Mechanism group

M5

Spectrum factor Km: Theoretical length of use D:

0.15 5000 h

The theoretical length of use should not be compared with the actual length of use of the winch.

If the crane is used in a manner which differs from its recommended usage, the user must then carry out the calculations himself.

Several external factors may influence the actual length of use of the winch.

F Unsuitable use (overloading, etc.)

F Maintenance insufficient or totally absent. Oil change frequency not carried out, use of substandard oil, quantity incorrect, or dirty oil F Handling error. Extreme acceleration, falling load caught by the lifting cable.

F Re---assembly error during repairs or maintenance.

F

Leak remaining undetected

F Safety system incorrectly calibrated F Hidden damage following accidents F Environmental conditions: excessively high or low temperatures, hostile atmosphere (dust, dirt, etc.).

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Safety rules

Maintenance and operator’s manual

1.1/ Wear rate based on the theoretical length of use of the winches The calculation of the wear rate from the theoretical length of use takes account of the actual conditions of use, (spectrum class), and the hours of use of the lifting winch between inspections. The operator of the crane is responsible for the description in the crane booklet.

1.2/ Determination of the conditions of use (Spectrum class) The spectrum class is classified in groups (ISO 4301/1, FEM 1001).

Having determined the actual conditions of use, select the spectrum class component mentioned below and note it in the crane booklet for the respective inspection interval.

Generally, for a mobile crane used for assembly purposes, the spectrum class is L2 with a coefficient of Km = 0.15

1.3/ Determination of the actual hours of use (T).

The actual hours of use determined must be noted in the crane booklet for the corresponding inspection interval. The percentage of winch use compared to the total length of use must be estimated

1.3.1/ A single hour meter is attached for the total length of use (road and crane operation).

The normal operating time for the upper structure is given to be 60% of the overall operating time. Normal winch operating time is given to be 20% of the upper structure operating time, i.e. 12% of the overall operating time.

The 20% winch operating time is only a guideline for normal use, and may be 30%, 40% or more depending on the conditions of use.

1.3.2/ An hour meter is attached to the turning part (upper with heat engine).

Normal winch operating time is 20% of the upper structure operating time.

The 20% rate of use is only given as a guideline for normal use, and may be 30%, 40% or more depending on the conditions of use.

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Safety rules

Maintenance and operator’s manual Spectrum class

Light L1

Medium L2

Heavy L3

Very heavy L4

Definition

Mechanisms or parts of the mechanisms rarely subjected to extreme fatigue but regularly to a minimal level of fatigue

Mechanisms or parts of mechanisms frequently subjected to extreme fatigue but regularly to a minimal level of fatigue.

% of the length of use 10 % of the length of peak load operation. (dead load + 1/1 useful load) 40 % of the length of the dead weight operation + 1/3 useful load 50 % of the length of operation exclusively with dead weight

50 % of the length of peak load operation. (dead load + 1/1 useful load) 50 % of the length of operation exclusively with dead weight.

Mechanisms or parts of mechanisms regularly subjected to extreme levels of fatigue

90 % of the length of peak load operation. (dead load + 1/1 useful load) 10 % of the length of operation exclusively with dead weight.

Graph

Last/Load/Charge%/% Carga

Km = 0.125

100 80 60 40 20 0

Laufzeit Operating time

40%

%

Durée de marche Tiempo de funcionamiento

10%

0 10 20 30 40 50 60 70 80 90100

1/6 of the length of peak load operation. (dead load + 1/1 useful load) 1/6 of the length of Km = 0.25 the dead weight operation + 2/3 useful load 50 % of the length of operation exclusively with dead weight.

Mechanisms or parts of mechanisms very frequently subjected to a heavy level of fatigue and regularly to a medium level of fatigue.

Edition : 03/1999

Spectrum factor

Last/Load/Charge%/% Carga

100 80 60

Laufzeit

73%

Operating time

40

Tiempo de

20

funcionamiento

20%

0

0 10 20 30 40 50 60 70 80 90100

Last/Load/Charge%/% Carga

Km = 0.5

%

Durée de marche

47%

100 80 60 40 20 0

Laufzeit Operating time

%

Durée de marche Tiempo de

funcionamiento 40%

0 10 20 30 40 50 60 70 80 90100

Last/Load/Charge%/% Carga

100

80%

80

Km = 1

60

Laufzeit

40

Operating time

20

Durée de marche

0

%

Tiempo de funcionamiento

0 10 20 30 40 50 60 70 80 90100

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Safety rules

Maintenance and operator’s manual

1.4/ Determination of the wear rate based on the theoretical length of use of the winches For the inspection interval “ι” (one year maximum under ISO 9927---1 or VGB8) the wear rate of the theoretical length of use of the winches “Sι” is calculated according to the following formula: Sι = Kmι × Tι Km Sι= wear % of the theoretical length of use Kmι = spectrum factor in the inspection interval ”i” in accordance with §1.2 Km = spectrum factor on which the winch calculations are based.

Tι = actual hours of use in the inspection interval ”i” in accordance with §1.3.

This rate of use “Sι” is subtracted from the theoretical remaining length of use “Dι“ .

--- If the remaining theoretical length of use for the coming period of use is insufficient, the winches must undergo a general overhaul.

--- If the theoretical length of use “D“ is reached, the winches must undergo a general overhaul before being used.

In all cases, a general overhaul of the winch becomes necessary at the latest 10 years after the crane is first put into service.

The general overhaul must be ordered by the user and carried out by the manufacturer (or any other person authorised by the manufacturer) and must be recorded in the maintenance log.

After the general overhaul, the manufacturer or the persons authorised by the manufacturer should establish a new theoretical length of use “D“ .

The maximum period up to the next service should not exceed 10 years.

III--- 6

Edition : 03/1999

Table for the determination of the theoretical remaining length of service for lifting winch No. ......

Inspection Date of first entry into No. service/inspe ction date

Conditions of use since the last

Spectrum

Length of

Length of

factor

use of the

use of the

crane as a

turning part

inspection

whole

(load class)

Si = % of use of the theoretical length of use since the last inspection Di = Theoretical remaining length of use Di---1 = Theoretical length of use remaining since the last inspection.

Km = Spectrum factor established at the time of the calculations for the winch.

Kmi = Spectrum factor in the inspection interval i Ti = Actual length of use in the inspection interval i Length of use Length of of the turning use of the part since the

winch

last inspection

Length of use of the winch since the last inspection

Kmi

0

03/09/91

1

[h]

[h]

[h]

Remainin

Name of

the

g length

Inspector

theoretical

of use

[h]

[h]

0

[h]

Di= Di --- 1 --- Si

5000

160

160

4840

DUPONT

1200

480

1920

2920

DUPONT

1000

300

600

2320

DUPONT

0.15

12/06/92

L1

0.125

800

800

2

02/07/93

L3

0.5

2000

3

21/07/94

L2

0.25

3000

Comments

[h]

0

L2

Signature

length DI Kmi Si = _____ XTi Km

Ti i

% of use of

Maintenance and operator’s manual

Edition : 03/1999

Type of crane: Manufacturing No.: Date originally put into service: Serial number of the winch conforming to the identification plate: Date of the last general overhaul.

Technical characteristics of the winch: Mechanism group: M..........

Spectrum class: L Spectrum factor: ..........

Theoretical length of use: ...........

Safety rules

III--- 7 Warning: A general overhaul of the winch should be carried out at least every 10 years. Date of last overhaul:

Safety rules

Maintenance and operator’s manual

1.5/ Inspection The required diagrams and tables are contained in the maintenance log of the crane.

The theoretical remaining length of use of each winch is to be entered in these tables. Blank tables may be found with the maintenance log and may be copied if required

Example of use: Inspection No. 1 (1st year) During the year that has just gone by, the crane has been used for assembly work: Spectrum class L1, that is to say Km1 = 0.125 The hour meter of the upper shows 800 hours, and therefore the percentage of use of the winch is approximately 20 %, that is to say T1 = 160 hours.

Therefore, for the first inspection, the wear rate S1 of the theoretical length of use is: S1 = Km1 × T1 = 0.125 × 160h = 160h Km 0.125 The theoretical remaining length of use after the first year: D1 = D − S1 = 5000h = 5000h − 160h = 4840h

Example of use: Inspection No. 2 (2nd year During the year that has just gone by, the crane has been used for port unloading work: Spectrum class L3, that is to say Km2 = 0.5 The hour meter of the upper shows 2000 hours. Therefore, during this period = 2000 hours --- 800 hours = 1200 hours, and consequently the rate of use of the winch is approximately 40 %, that is to say T2 = 480 hours

Therefore, for the first inspection, the wear rate S2 of the theoretical length of use is: S2 = 0.5 × 480h = 1920h 0.125 The theoretical remaining length of use after the first year: D2 = 4840h − 1920h = 2920h

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Maintenance and operator’s manual

Safety rules

Example of use: Inspection No. 3 (3rd year During the year that has just gone by, the crane has been used for occasional port unloading work: Spectrum class L2, that is to say Km3 = 0.25 The hour meter of the upper shows 3000 hours. Therefore, during this period = 3000 hours --- 2000 hours = 1000 hours, and consequently the rate of use of the winch is approximately 30 %, that is to say T3 = 300 hours.

Therefore, for the first inspection, the wear rate S3 of the theoretical length of use is: S3 = 0.25 × 300h = 600h 0.125 The theoretical remaining length of use after the first year: D3 = D2 − S3 = 2920h − 600h = 2320h It is necessary to determine if the theoretical remaining length of use is sufficient to last up to the next inspection. If not, the winch must undergo a general overhaul.

Edition : 03/1999

III--- 9

Table for the determination of the theoretical remaining length of service for lifting winch No. ......

Inspection No.

Date of first

Conditions of

Spectrum

entry into

Length of

Length of

use since the

factor

use of the

use of the

crane as a

turning part

service/inspe last inspection ction date (load class)

whole

Length of use Length of of the turning use of the part since the

winch

last inspection

Length of use of the winch since the last inspection

Kmi

[h]

[h]

[h]

Remainin

Name of

the

g length

Inspector

theoretical

of use

[h]

[h]

Signature

Comments

length DI Kmi Si = _____ XTi Km

Ti i

% of use of

Safety rules

III--- 10

Type of crane: Si = % of use of the theoretical length of use since the last inspection Manufacturing No.: Date originally put into service: Di = Theoretical remaining length of use Serial number of the winch conforming to the identification plate: Di---1 = Theoretical length of use remaining since the last inspection.

Date of the last general overhaul.

Technical characteristics of the winch: Km = Spectrum factor established at the time of the calculations for the winch.

Mechanism group: M..........

Spectrum class: L Kmi = Spectrum factor in the inspection interval i Spectrum factor: ..........

Theoretical length of use: ........... Ti = Actual length of use in the inspection interval i

[h]

Di= Di --- 1 --- Si

[h]

Maintenance and operator’s manual

Edition : 03/1999 Warning: A general overhaul of the winch should be carried out at least every 10 years.

Date of last overhaul:

Safety rules

Maintenance and operator’s manual

Safety rules III

Edition :

12/2000

III---1

Safety rules

Maintenance and operator’s manual

Safe operating practices for mobile crane users lntroduction PPM cranes are carefully designed, tested, and manufactured. When used properly by qualified operators, they will give safe, reliable service. PPM has offices to answer any questions about its products or their safe use.

This crane has been designed to handle loads in accordance with the load capacity chart and with instructions contained in this manual. The machine should only be used in accordance with current laws and regulations practiced in the country concerned.

It is strictly forbidden to lift people with the machine unless it is expressly equipped with an agreed man---handling platform supplied

by PPM. This mobile crane is not to be used as demolition equipment.

It is strictly forbidden to push or drag objects with the boom.

If the hook is to be used for any function other than material handling prior authorization must be obtained from PPM .

Normal working conditions envisage an average working period of 8 hours per day, 5 days per week in average climatic conditions. For working under harder conditions or in more difficult climatic atmospheres (high temperatures, dusty or humid environments) greater precautions should be taken when using the crane. Checks should be carried out more frequently and maintenance and lubrication intervals reduced.

Because cranes have the ability to lift heavy loads at great heights, they also have a potential for causing accidents if safe operating practices are not followed. These pages will help the operator prevent accidents which could result in property damage, personal injury or death.

General safe practices for working on machinery must be followed as well as the safe operating practices recommended here.

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Maintenance and operator’s manual

Safety rules

Operator’s responsibility Safety must always be the operator’s most important concern. He must refuse to operate when he knows it is unsafe and consult his supervisor when safety is in doubt. He must read and fully understand the Maintenance and Operator’s Manual and make sure that the machine is ready for initial start ---up.

He must understand how to read the capacity charts and know that his machine can safely lift each load before attempting to lift it.

He must read and understand the Operator’s Manual and see that the machine is in proper order before operating.

He must be alert, physically fit, and free from the influences of alcohol, drugs, or medications that might affect his eyesight, hearing, or reactions.

He must make sure that people, equipment, and material are kept out of the work area. The area around the machine should be properly barricaded.

When an operator’s vision is blocked or when operating in hazardous areas such as near power lines or around people, a signalman must be used.

Because the operator is not in the best position to judge distances and can not see all parts of the jobsite, a signalman may also be necessary at other times. Operators must understand standard crane signals and take signals only from designated signalmen.

Signalman ’s responsibility The primary duty of a signalman is to assist the operator in safe and efficient operation. Operators depend on designated signalmen to assist them in making movements without endangering people or property.

Signalmen must have a clear understanding of the work to be done so that they can safely coordinate each job with operators and other crew members.

Signalmen must place themselves where they can be clearly seen and where they can safely observe the entire operation.

Standard crane signals must be used unless other methods of signaling such as two way radios or flags have been agreed upon.

Signalmen must have good vision and sound judgment, know standard crane signals and be able to give signals clearly. They must have enough experience to be able to recognize hazards and signal the operator to avoid them.

The driver’s mate is the only person allowed to give instructions to the driver.

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III---3

Safety rules

Maintenance and operator’s manual

Responsibilities of a!l crew members Any unsafe condition or practice must be corrected or reported to the job supervisor.

Watch for hazards during operations and alert the operator and signalmen of dangers such as power lines, the unexpected presence of people, other equipment or unstable ground conditions.

Management responsibility See that operators are trained, competent, physically fit and, if required, licensed. Good vision is required as are good judgment, coordination and mental ability. Any person who lacks any of these qualities must not be allowed to operate a crane .

Any person who is associated with working on the crane, including laborers and mechanics, must respect all safety signals and be aware of their own safety as well as that of others. Crane personnel such as mechanics or slingers are supposed to be aware of any particular procedures concerning their jobs on the machine.

Crew members must have good sight and hearing and must also understand standard crane signals, as well as how to give them.

They must have sufficient experience to react correctly in unexpected circumstances and rapidly inform the crane operator in any such event.

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Maintenance and operator’s manual

Safety rules

Planning the job Many accidents can be avoided provided that the worksite is correctly organized. The person in charge must have a clear understanding of the work to be done, consider all dangers on the jobsite, develop a plan to do the job safely, and then explain the plan to all concerned. Factors such as these should be considered : ---What crew members are needed and what responsibilities will they be given ?

---What is the weight of the load to be lifted, the lift radius, boom angle, and the rated capacity of the crane ?

---How will the signalmen communicate with the operator ?

---What equipment is required to do the job safely ? Is a crane the best equipment for the job ?

---How can the equipment be safely transported to the jobsite ?

---Are there gas lines, power lines or structures which must be moved or avoided ?

---Is the surface strong enough to support the machine and load ?

---How will loads be rigged ?

---What special safety precautions will be taken if a crane must travel with a suspended load or if more than one crane is needed to lift a load ?

---Are unusual weather conditions such as winds or extreme cold expected ?

---What steps will be taken to keep unnecessary people and equipment safely away from the work area ?

---How can cranes be positioned to use the shortest boom and radius possible ?

The rigging crew must be trained to appreciate weight, distances and the most efficient rigging methods. Rigging is a specialized job and the information herein is not exhaustive. The site foreman is responsible for all rigging operations.

Edition :

12/2000

III---5

Safety rules

Maintenance and operator’s manual

Operator’s safety check The operator must make a safety check before starting to work each day to see that the machine is in proper order. Some things to check are : ---Check the machine log book to see that periodic maintenance and inspections have been performed and all necessary repairs made.

---Check the operation of boom hoist limiter device, boom angle indicator, reversing alarms, and other safety devices.

---Carefully inspect load bearing parts such as wire rope, (load lines, boom hoist cable, suspension lines), boom, outriggers, and hooks.

---Be sure no unauthorized field modifications have been made, such as added counterweights and booms that have been improperly repaired.

---Check for air and hydraulic oil leaks.

---After starting the engine, check all gauges for proper readings.

---Test all controls for proper operation.

---Check brakes and clutches. Test load brakes by lifting a load a few inches off the ground and holding it.

Operating precautions 1. Mistakes in calculating lifting capacity can cause accidents.

Several factors must be considered, including : A. Load radius is the distance between the center line of the crane’s upper structure rotational axis and the center line of the boom head pullies. Note that the radius will increase when the load is lifted due to the flexion of the boom.

B. Weight of the load, hook, and rigging.

C. Boom length, jib, parts of line, and operating area (side, rear).

Use the next lower rated capacity when working at boom lengths or radii between the figures on the rating chart. It is dangerous to guess the capacity for boom lengths or radii between those listed on the rating chart.

Trying to lift a load without knowing whether it is within the rated capacity while expecting the crane to start to tip to warn of an overload is very dangerous. Cranes may suddenly tip over or collapse if the load is too heavy.

Always stay within rated capacity. The operator must reduce the load under adverse field conditions until, in his judgment, the machine can safely handle the lift. (Refer to precautions 3, 10, 12, 16, 19,27 et 28).

III---6

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Maintenance and operator’s manual

Safety rules

2. Cranes may tip over or collapse if the operating surface cannot support their weight. Timber blocks, steel plates or concrete rafts may be needed under outriggers pads to distribute the load under the crane so that the bearing strength of the ground is not exceeded.

Determine the load bearing capacity of the ground or other surfaces on which machines will be operating. Be sure cranes are adequately supported. Avoid soft or unstable ground, sand, areas with high water tables, and partially frozen ground. When machines are working near trenches these should be shored or sloped to prevent cave---ins or slides.

3. The rated capacity of a crane is determined with the crane leveled within 1% of grade (1 foot drop or rise in 100 foot distance).Out of level by more than 1 % will drastically reduce the lifting capacity.

Be sure cranes are level. All tires must be off the ground for ”On Outrigger” ratings.

4. People can be crushed by the scissor like action of the upper rotating on the lower.

Stay away from rotating cranes. Erect barricades to keep people away. Take the time to determine that these areas are clear before swinging.

5. People can be crushed by the rear (counterweight) of the machine if there is not enough room for it to swing. Do a trial run through 360 with no load before handling operations.

Position machines so that people cannot be trapped between the counterweight and other obstructions.

6. Many people have been injured when riding crane hooks or loads or while being lifted in manbaskets. They have no control over how they are handled and no protection from impacts or falls. Small mistakes can be fatal.

Do not lift people with cranes. Use ladders, scaffolds, elevating work platforms or other equipment designed to lift people, but do not use cranes.

7. Power lines have killed or seriously injured people working around cranes and excavators. These accidents can be avoided by following a few simple rules.

Edition :

12/2000

III---7

Safety rules

Maintenance and operator’s manual Always check if there are any power lines in the area before starting work. It is highly recommended to keep a distance of more than 6m between any part of the machine and a power line. Always stay as far as possible from power lines, NEVER violate minimum distances. The EASY SLI unit allows either the derricking angle, or the boom head height to be limited. Use this function.

How to react in case of accidental contact.

No set rules are to be followed, an analysis of the situation and its risks is necessary on each occasion. The operator should be aware of how to handle such a situation and preferably be trained for such an event The machine is in working order : The operator must immediately move the machine away from the power line or electrified equipment without getting out of the cab. The machine is no longer in working order : Without getting out of his cab the operator must inform all personnel in the vicinity, by hand signals or verbally, that they must not approach the machine. (Risk of electric arcing).

If the operator is absolutely obliged to leave the crane cab and get off the machine he must do this by jumping so as never to be simultaneously in contact with the machine and the ground.

Once on the ground he must move away from the machine : either by jumping with feet joined, or by very small footsteps.

Any new approach to the machine can only be made once that it has been confirmed and verified that power has been effectively cut. This must be done in conjunction with the local power company.

The machine is fitted with tires : When a tire fitted mobile crane comes into contact with overhead power lines the metal carcassed tires which have not been destroyed do not retain either their insulation characteristics or, above all, their mechanical resistance characteristics. Tire explosion, if not immediate, often happens later after long exposure in the sun.

The machine must not be approached until air temperature in the tires has dropped.

The tires must then be deflated and discarded once the machine is no longer in contact with the power line.

WARNING --- Proper work programming and serious checking ensure greater protection than any other method. Insulated cages or proximity detectors have limits and can fail without prior notice. Protective cables and insulated cages only protect the machine and can become conductors due to dust or water.

Proximity detectors can be influenced by different combinations of power lines, by vehicle, material or crane movements, and other prameters. Total dependance upon these systems can be dangerous because the operator can think that he is protected when, in reality, he isn’t.

In case of storms take the following precautions : ---if possible, set down the load and retract the boom.

---if you are surprised by a sudden storm, stop the engine and get down from the machine.

---if lightning strikes the machine, check the general working order of the crane before starting up.

You should always be aware of the local weather forecast.

III---8

Edition :

12/2000

Maintenance and operator’s manual

Safety rules

8. The load line can break if the hook block contacts the end of the boom. This is called ”two blocking”. Two blocking can be caused by hoisting the hook into the end of the boom, lowering the boom or extending telescopic booms without paying out load line. Two blocking can pull jibs and lattice crane booms over backwards.

Always check the space between the hook block and boom point.

Lower the hook when extending telescopic booms to avoid two blocking.

Regularly check the two block safety device.

9. People can be injured if the hook, boom, load or outriggers are moved before everyone is clear.

Make sure everyone is in a safe place before moving the hook, boom, load or outriggers. Do not move loads over people. Do not allow the load to bump or catch on anything.

10. Rapid swings or sudden starts and stops can cause the hook and attached load to swing out of control.

Always start and stop movements smoothly and swing at speeds that will keep the load under control.

11. Dirty windows, darkness, bright sunlight, fog, rain, and other conditions can make it difficult for the operator to see.

Keep windows clean. Do not operate if you cannot see clearly enough to operate safely 12. Even light winds can blow loads out of control, collapse booms, or tip machines. Winds aloft can be much stronger than at ground level.

Do no lift loads if winds create a hazard. Lower the boom if necessary See the rating plate for possible restrictions.

13. Carelessness in getting on and off equipment can result in serious injuries.

Always wait until the machine has stopped. Do not jump on or off.

Always use both hands and make sure you have good footing.

14. Slippery floors, footplates, steps, tools, trash, or other loose items can cause falls.

KEEP THE MACHINE CLEAN AND DRY 15. Damaged crane booms may collapse. Lattice type booms will be weakened by damaged chords, bent or missing lacing, or cracked welds. Telescopic booms will be weakened by distorted bottoms or side plates. In either case, the loss of strength is difficult to estimate.

Edition :

12/2000

III---9

Safety rules

Maintenance and operator’s manual Release system pressure before attempting to make adjustments or repairs.

25. Pin---connected booms and jibs may fall if not properly supported when removing pins.

Make sure both ends of each boom and jib section are supported and the boom suspension lines completely slacked off before removing pins. Never stand on, inside, or under booms or jibs during assembly or disassembly Inspect the crane boom daily for damage. Do not use damaged booms.

NOTE : due to the high tensile steels used in booms, special repair procedures are required. Repair procedures for lattice booms are described in Harnischfeger Catalog 238. Consult your agent for further information.

16. Crane booms can buckle if side loaded (pulled sideways). Typical causes of side loading are rapid starts and stops while swinging, dragging a load sideways, winds, or lifting when the crane is not level.

Take care to avoid side loading.

17. If the boom is used for anything else other than material handling the boom may collapse.

Never let the load or any other object bend the boom.

18. Boom suspension lines will stretch when the load is lifted and contract when the load is released. At high boom angles this may be enough to pull the boom backward over the crane.

When releasing loads be sure the boom never tightens against the backstops. Release loads slowly.

19. The load will swing out of control if it is not directly beneath the boom point when lifted. This can side load the boom and may cause the crane to tip or collapse.

Always place the boom point directly above the load when lifting.

20. Trying to lift a load which is stuck, frozen or attached to something else may result in tipping, boom collapse or other damage.

Be sure that loads are free before lifting.

III---10

Edition :

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Maintenance and operator’s manual

Safety rules

21. If there is not enough wire rope on the drum the rope can be pulled off.

Keep at least three full wraps of wire rope on drums when operating.

23. Trying to repair or adjust equipment with a suspended hook or load or with the boom raised could release machinery and let it move unexpectedly Always lower the load to the ground and the boom onto proper cribbing before doing maintenance or repair work.

24. Pressure in hydraulic systems can be retained for long periods of time. If not properly released before maintenance people attempt to work on the hydraulic systems this pressure can let machinery move or cause hot oil and hose ends to shoot out at high speed.

26. As with all heavy equipment, care must be taken when cranes are driven (traveled) whether on or off the jobsite.

Watch for people, power lines, low or narrow clearances, bridge or road load limits, and steep hills or uneven terrain. Use a signalman in close quarters. Know the height, width, and weight of your machine.

Retract and lock outriggers, place the boom in the cradle, and set swing brake or lock before travelling.

28. Using two or more cranes to lift a load involves many hazards not normally encountered in single crane Iifts. This operation is only to be carried out under the responsibility of the rigging foreman.

Multi---crane lifts must be carefully engineered, keeping the following points in mind.

---Since the load is not freely suspended, careful engineering studies must be made to ensure that the load carried by each machine is less than its rated capacity.

---Make sure slings are arranged to divide the load as planned.

---Review the lifting plan with operators, signalmen and other crew members before beginning the Iift.

---Carefully coordinate crane movements through every stage of the lift.

---Avoid boom side loading (see #16).

Edition :

12/2000

III---11

Safety rules

Maintenance and operator’s manual 29. Leaving a machine unattended can be very dangerous.

Before leaving his seat, the operator must take the following steps to prevent his machine from moving : --- Lower the load to the ground. Lower the boom when necessary.

---Set the slewing brake or lock.

---Set all drum pawls.

---Set parking brakes.

---Select neutral gear.

---Shut off the engine.

30. All wire rope must be inspected daily to determine whether it should be replaced. See the inspection form in the Operator’s Manual and contact wire rope manufacturers and their distributors for more information.

Ropes should be changed whenever one of the following anomalies appears : ---In running ropes, six broken wires in one lay or three broken wires in one strand in one lay.

---Wear of one---third of the nominal external dia of each strand ---Obvious abnormal wear for whatever reason.

---Reduction of nominal diameter.

---Evidence of kinking, bird caging, crushing, cuts, abrasions, sharp bends or any other damage that results in distortion of the rope structure.

---Rust or corrosion.

Warning : do not use your hands to guide wire rope onto drums.

31. Improper wire rope connections may fail under Ioad.

Wire rope end connections must be installed properly and inspected daily.

---Wedge sockets should be installed so that the loaded side of the rope is in straight line with the edge of the socket and not bent by the wedge. Prevent the rope end from slipping out of the wedge socket by attaching a short piece of rope to the rope end with two U ---bolt clamps.

---U ---bolt clamps (clips) should be installed so that the U ---bolt is on the unloaded side and the saddle is on the loaded side.

32. Incorrect wire rope winding onto drums will create ”deviation points” in the rope.

Do not use your hands to guide rope onto drums, use gloves. Keep clothing away from working winches.

III---12

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Maintenance and operator’s manual

Safety rules

Liste of Adhesive Labels The following adhesive labels concern safety precautions, they must be strictly respected and immediately replaced whenever they are damaged or become deteriorated.

Edition :

12/2000

III---13

Safety rules

III---14

Maintenance and operator’s manual

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Maintenance and operator’s manual

Edition :

12/2000

Safety rules

III---15

Safety rules

III---16

Maintenance and operator’s manual

Edition :

12/2000

Maintenance and operator’s manual

Safety rules

Danger Any operator must become acquainted with the operating instructions described in this manual before using the machine.The operator is wholly responsible for machine operation.No liability will be accepted by the manufacturer if the instructions contained in this manual are not strictly respected.

Never drive the machine, or let it be driven by third parties, unless all the instructions contained in this manual have been perfectly understood and remembered.Failure to follow these instructions may result in serious accidents causing damage to equipment and injury to personnel.Do not hesitate to contact your local PPM Dealer or Agent who is authorized to offer formal training or can give sound advice.

Never drive this machine before you have read and fully understood the instructions given in the OPERATOR’S MANUAL. Any failure to strictly followthese instructions may cause serious accidents.

THE OPERATOR’S MANUAL must always be left in the driver’s cab.Contact your local PPM Dealer to obtain another copy if required.

Edition : 12/2000

III--- 19

Safety rules

Maintenance and operator’s manual

JYour security as well as ground entourage depend upon the proper use of the machine.Be sure that you know perfectly the location and the use of all controls.

BEFORE USING THE MACHINE, TRY ALL CONTROLS ON A SAFE AND FREE AREA WITH THE OUTRIGGERS FULY EXTENDED

J In the handbook, the words “RIGHT” and ”LEFT”indicates right side and left side of the machine view from the operator’s seat.

J Safety local rules must be observed

J Keep a good fire extinguisher and a first aid kit with you at all times.

Know how to use both of these items.

J Sparks can come from the exhaust pipe or from the electrical system. DO not operate in closed areas where there are flammable materials, dust or exhalations that can cause an explosion or fire. Severe injury or death can be the result if you do not follow these instructions.

J Read and understand well all panels indicating dangers or cares to be taken on the machine.

Be strict on maintenance instructions.

J Be very careful if this is not the machine you normally operate.

J Do not smoke while filling fuel tank, as fuel vapors are flammable.

J Avoid accident due to improper clothing. Wear proper working clothes that will not grapple on to parts, and if necessary, use safety equipment like ear protectors, protection mask,and reflective clothes.

J Wear safety helmet and glasses, as well as safety gloves and shoes, as required by state law.

J Make sure all persons are away from the machine before you start the engine.

III--- 20

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Maintenance and operator’s manual

Safety rules

J Make sure the access area and operator’s station are clear of oil, foreign material or ice. Remove or attach all maintenance or personal items. Failure to keep these areas clean and tidy can cause serious accidents.

J Always use your two hands to get on or off the machine, facing it.

J Never jump off the machine.

J Make sure the windows of your cab are clean. Make sure the windshield wipers are operating correctly. Dirty windows can cause an accident.

J Stow away oily rags and other flammable materials in a safe place.

J All measures should be taken to conserve the environment. Make sure that all used oils and fluids are correctly retrieved and recycled.Do not leave such products in incorrectly labelled, unadapted or open containers.Do not leave any puddles of fluid, of any type, on the ground or on floors.

J All necessary precautions must be taken to preserve the environment. In particular, recover and recycle all used fluids. Do not leave used fluids in containers which are not suitably labelled, or in open containers.

Do not leave any fluid puddles of any type on ground or floors.

Do not drink or inhale any used oils or fluids such as: --- oil --- grease --- antifreeze --- detergents Only original containers should be used for storing or transporting oils and fluids.

Do not use containers intended for food (water bottles, beer bottles, etc...)

Edition : 12/2000

III--- 21

Safety rules

Maintenance and operator’s manual

Driving J For your own security as well as for the life of the machine, before starting up, inspect the machine carefully.

Look for loosen or missing screws, hydraulic or cooling liquid leaks.

Check condition of tyres as well as the equipment and linkage.

J A component or a circuit breakdown might cause an accident.

Before using the machine, check all oil and hydraulic oil levels.

Check that all plugs level gauges and covers are well fastened. Replace or repair defective parts.

J In case of a malfunction or missing part, shut off the machine and carry out repair.In case of non respect of this rule, an accident may occur.

J Never use a machine having brakes, steering or hoisting systems defective. This rule applies to a machine being repaired or adjusted without control or workshop superintendent agreement.

J If the engine stops neither the power steering system nor the brakes operate correctly, stop the machine as quickly as possible.

J Unless otherwise specified: --- lower the boom --- shut off the engine --- apply parking brake --- wedge the machine before any maintenance operation or before leaving the machine at the end of work.

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Maintenance and operator’s manual

Safety rules

Driving J The machine must be driven only by authorized operators.

J Understand the limits of the machine. Keep the machine under control at all times. DO NOT TRY TO DO TOO MUCH TOO FAST. J Becareful of the clearance of the machine when you are on the limited space (bridges, electric cables, pipes in height, ground resistance, etc...).

J When driving the machine out of the normal working areas, make yourself acquainted with it, as well as the area (weight, sizing, loads per wheel, permissible slopes, ground resistance,...)

J Always be watchful. Never allow anybody in the working area.

You must always know where they stand in the working zone.

J It is forbidden to stand in the machine working area

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III--- 23

Safety rules

Maintenance and operator’s manual

Driving J With the engine shut down, do not release parking brake or emergency brake if machine is not blocked or secured in position.

Check that the pressure in the brake circuit is sufficient before releasing the brake.

(Carrier). Before starting up the engine, tighten the parking brake and place the gear shift lever and directional control levers in neutral position.

J Before performing any night work, check that all machine lights and indicators operate.

J For night work, the work area must be sufficiently lit.

J

Machine controls and accessories must only be used when properly positioned in driver’s seat. Non---observance of this rule can result in serious personal injury.

J Be particularly careful when working in dust, smoke or fog.

Poor visibility can cause accidents.

J Before loading the machine on a semi---trailer, remove any snow, ice, oil or grease which may be on the semi---trailer or on the access ramp.

J Avoid any abrupt movements with a load suspended on the machine.

J Do not grab cables by hand when hook block is operating.

J Monitor correct operation of hook safety catch; replace if necessary.

J Check that cable guides are in place to avoid any derailing of cable.

J When working on hook block on ground, set hook block on flat, horizontal ground to avoid any tilt ---over.

J Monitor wear on hook sheave grooves and internal face of hook block .

J With no load, check that hook sheaves and hook turn freely.

J Never leave machine with a suspended load.

J Lifting capacity decreases as boom is extended (see capacity table).

J Never leave machine parked on sloped ground.

J Avoid load swinging and abrupt maneuvers.

J Never perform slanted hoisting operations.

J Ensure parking brake is engaged when hoisting loads on tires (outriggers not deployed).

J

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Maintenance and operator’s manual

Edition : 12/2000

Safety rules

III--- 25

Safety rules

Maintenance and operator’s manual Maintenance J Do not try to carry out repairs that you are unable to complete.

J Do not tolerate unauthorized people on the platform of the machine while working.

J Wear eye or face protection when you service the machine. Use a hammer with a soft face, such as plastic, wood, brass or leather.

When you hit hardened tools or hardened metal surfaces. Any other procedure can cause injury from flying chips.

J Only run the engine in well ventilated areas.

(Danger of poisoning by exhaust gases).

J Apply parking brake, lock wheels and place warning panels on control handles while maintenance is carried out.

J Always use proper tooling. Replace or repair worn or deteriorated equipment.

J Always check cooling circuit with engine shut off. Unscrew carefully radiator plug to release pressure in the circuit.Steam may cause burns.

J Be careful when using cleaning fluids.

J Unscrew carefully cooler plug or any drain, greaser or tap pressure line.

J Rotating fan and belts : contact can injure. Keep clear.

For your safety and to avoid being held responsible only use original PPM spare parts.

J

Note: Repair jobs should be left to specialists. Do not hesitate to consult PPM or their agreed agents.

J Arc welding of parts on the machine can damage mechanical, electrical and/or electronic equipment as well as making the machine a hazard risk. Never do welding jobs without having : --- fixed the ground clamp as near to the welded area as possible.

--- disconnected the two battery terminals.

--- disconnected all electronic devices.

Following any intervention or repair on a function, check correct operation of function before re---using machine.

J

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Maintenance and operator’s manual

Safety rules

Electricity J Before working on the electrical circuit, turn main switch on OFF position.

J Know the electrical circuit before you connect or disconnect an electrical component. A wrong connection can cause injury or damage.

J When you check the charge of the battery, never put a metal object across the battery posts. The sparks can cause an explosion.

Use a voltmeter or a hydrometer to check the battery.

J Never smoke during the checking of battery liquid levels. A battery produces flammable gas.

J The electrolyte is an acid solution which is dangerous to the skin and the eyes.

J Never top up batteries with acid. Always use distillated water.

J When the battery electrolyte is frozen, the battery can explode if you try to charge the battery or you try to jump start and run the engine. To prevent the battery electrolyte from freezing try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.

J Never wear metal rings or metal watch bands. You can make a ground for the electrical circuit and get a burn on your hand or arm.

J When using an external power unit to start the engine, connect ground line last and disconnect it first to avoid sparks near the batteries as they may burst.

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III--- 27

Safety rules

Maintenance and operator’s manual

Hydraulic

J The hydraulic system operates at a very high pressure (2900 PSI). The hydraulic oil, even from a very small leak, can go through your skin and cause serious injury. When you check for leaks, do not use your hands. Use a piece of wood or paper.

J Before you disconnect any hydraulic lines or components make sure there is no pressure in the circuit. When you connect the hydraulic lines or components, make sure the connections are tight. If the hydraulic oil goes through your skin, get a doctor immediately.

J Hydraulic oil is flammable. Never weld lines or pipes filled with oil.

J Oil or hot parts might burn. Avoid any contact with the skin.

J It is essential, after any work carried out on the hydraulic circuit, components or fluid, to have the circuit bled by a specialist to remove any air that may have entered the circuit by using, in particular, the bleed screws on the hydraulic cylinders.

J On circuits comprising hydraulic accumulators (for example brake or suspension circuits), hydraulic fluid must be depressurized and accumulators emptied prior to any intervention. (Release suspension for this purpose).

J Any intervention on circuits comprising gas accumulators or on accumulators themselves is prohibited (call PPM specialist).

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Maintenance and operator’s manual

Safety rules

Safety instructions with the tyres Before any take of tyres of the machine and in all cases Be sure that the wheel rim is not split and that there is nothing trapped.

Start by loosening wheel nuts by two or three turns only.

Free the wheel rim in such a manner that the remaining nuts stop the rim being ejected --- avoid standing in front of the during removal.

When the rim is freed continue unscrewing the nuts.

1/ Deflation Take of the internal part of the inner tube valve and wait until there is no more air whistleling.In winter, check that there is no ice plugged in the inner tube valve.Make sure that the tire is totally deflated

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Safety rules

Maintenance and operator’s manual

2/ Take off wheel rings Before any operation, be sure that the tire is completely deflated. Do not face the wheel during this operation.

3/ Before and during take off tire Control carefully the rim, after cleaning it, to be sure that there are no beginning of fatigue cracks.

Hooking fixed side (a) Detachable ring side, in the groove of the locking ring (b) Control carefully the detachable ring and the locking ring Remove parts too corroded or showing beginning of cracks or important distortions.

Check wheel discs for cracks.

Control that all mobile parts : detachable ring, (or side ring) lock ring are in conformity with the rim.

Check that all different parts fit well in normal position (lock ring well seated inside the groove, for example).

Fixed side

Detachable ring

lock ring

4/ Inflation The wheel or the rim fitted with the tire resting on the ground, start inflation only until the detachable ring places itself against the locking ring. Then place the assembly vertically against a wall, the detachable ring on the wall side, and continue inflation.If the wheel is not fitted on the machine, always use an inflation cage.

J Check condition of tire with the machine free of load. If the wheel is not fitted on the machine, always use an inflation cage.

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Safety rules

IMPORTANT : In any case and during inflation, never stand on the possible trajectory of all or part of the wheel or the rim. When you inflate a tire on a vehicle take the same care as above, stand on side. Do not leave anybody in front.

5/ Wheel in two parts When taking off, do not confuse between assembly bolts of the two shells (a) and tightening bolts of the wheel (b) Before inflation, be sure that the assembly bolts of the two shells are well tightened.

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III--- 31

Safety rules

Maintenance and operator’s manual J For your own security or others, it is compulsory to check the proper tightening of the wheels bolts using the machine wrench. After 50 hours and every 100 hours of service.

J Inflation pressures are given for cold tires, inflation and pressure control must be carried out on cold tyres. Never deflate a hot tyre.

For your own safety and that of others it is essential to check wheel nut tightness with the spanner provided with the machine.Check after the first 50 hours then every 100 hours.

J

Note : Check tire pressures weekly or every 50 hours (cold tires).

DANGER : never drive the machine with deflated tires.

J Check condition of tires with the machine free of load. If the wheel is not fitted on the machine, always use an inflation cage.

J Do not risk accident while inflating the tires. Never stand in front of the wheel. Use an inflating flexible pipe long enough with a self tightening inflation socket.

J Deflate the tire before trying to take stones off the tire surface.

J When fixing balance weights to be tack welded on the site, use only the special tooling.

J Never cut, never weld on a rim fitted with an inflated tyre.

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Safety rules

Maintenance and operator’s manual

Wind force The crane can be safely used within the limits indicated by the load capacity charts in wind speeds of up to 14 m/s 31 miles/h (50 Kph --- Force 6) and a load surface of 1.2m2ton.(0.843 square inch/Lb)

WARNING : Make a daily weather and wind speed check by telephoning the nearest meteorological station. If wind speed is greater than the acceptable level do not handle loads.

Wind force

Wind speed

Consequences

Beaufort Scale

Termes descriptifs

ft/s

miles/h

inland

0

Calm

0 --- 0.65

0.62

1

Very light

1 --- 5

0.62 --- 3.1

2

Light breeze

5.2 --- 11

3.7 --- 6.8

3

Low breeze

11.2 --- 17.7

7.5 --- 11.8

4

Reasonable breeze

18 --- 26

12.4 --- 17.4

5

Strong breeze

26.3 --- 35

18 --- 24.2

6

Fresh wind

35.5 --- 45.5

24.2 --- 30.4

Large branches start to move.

7

Strong wind

50 --- 56

31 --- 40

All trees are blown and move.

8

High winds

56.5 --- 68

38.5 --- 46

The wind breaks branches,and it becomes difficult to walk freely.

9

Very high winds

68.5 --- 80

46.6 --- 54.6

Damage caused to houses (tiles and chimneypots are blown down).

10

Gale force winds

80.5 --- 93

55.3 --- 63.4

Trees uprooted. Serious damage to houses.

11

Strong gale force winds

93.5 --- 107

64 --- 72

12

Hurricane

107.5 --- 121

73 --- 82.6

Calm, smoke rises vertically Wind direction indicated by smoke,not by a weather vane.

Wind can be felt on the face, leaves tremble, the weathervane will move.

Leaves and small branches move.Flags lift.

The wind raises dust and leaves.Branches move.

Small bushes start to sway.White horses are seen on the sea.

Important and widespread damage.

Very serious damage.

Area not to be used with the crane.

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III--- 33

Maintenance and operator’s manual

Driving controls

Driving controls

Edition :

04/2000

IV ---A --- 1

Driving controls

IV ---A --- 2

Maintenance and operator’s manual

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Maintenance and operator’s manual

Driving controls

Driving controls Control identification The reference numbers shown in the cab illustrations relate to the numbers in the list which follows,identifying the controls and instruments, or describing their operation.

Notes : All the standard and optional controls for this machine are identified and described in the following list. It therefore includes controls and instruments which are not provided with every machine.

Before driving the machine, the operator should carefully study all the information in this manual and in the safy procedures at the beginning of it.

The operator should be fully trained in the use and purpose of each control on the machine, and aware of the risks.

Each driving and operating device is described in this chapter in the section : Driving Controls.

THE CRANE OPERATOR OR SITE MANAGER IS FULLY RESPONSIBLE FOR THE USE OF ALL CRANE FUNCTIONS APART FROM THOSE EXPRESSLY DESIGNATED BY PPM WHEN THE SAFETY DEVICE INDICATOR IS OVERRIDEN. PPM WILL NOT BE HELD RESPONSIBLE FOR ANY ACCIDENT OCCURRING WHEN THE CRANE IS BEING USED WITH A RELEASED LOAD MOMENT INDICATOR.

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04/2000

IV ---A --- 3

Driving controls

Maintenance and operator’s manual

Carrier Cab controls 13 1

2

17 3

8

11 14

12

16 15

6 4 9

5 7

IV ---A --- 4

10

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Maintenance and operator’s manual

Driving controls

Carrier Cab controls 1 / Steering wheel 2 / Anti ---theft ignition switch 3 / Emergency brake control 4 / Steering column adjustment pedal 5 / Accelerator pedal 6 / Gear selector 7 / Brake pedal 8 / Cab heating 9 / Exhaust brake control 10 / Electronic gearbox control unit 11 / Windscreen wiper / washer control 12 / Combined switch :lights --- direction indicators --horn 13 / Electric retarder control 14 / Parking brake 15/ 12 and 24 volt points 16 / Troubleshooting aid connector 17 / Trailer brake test button

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IV ---A --- 5

Driving controls

Maintenance and operator’s manual

carrier control panel

27

ABS

21

28

40

50 60 70 10 80 miles/h km/h 30 20

ABS

1

2

ABS

25

26

00000

20

22 23

20 / Electronic speedometer (optional controlograph) 21 / Rear wheel steering control 23 / Axle ABS not selectioned control 25 / Default axle ABS indicator or all terrain ABS not selected 26 / Cab selection control switch and warning light 27 / Dual fuel option --- Red light red fuel 28 / Dual fuel option --- Green light diesel

IV ---A --- 6

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Maintenance and operator’s manual

Driving controls

Right control panel

37 27

ABS

35

30

32

36

31

33

28 40

50 30 60 20 70 10 80 miles/h km/h

1

2

ABS

00000

ABS

34

30 / Engine oil pressure gauge 31 / Engine water temperature gauge 32 / Front brake air pressure gauge 33 / Rear brake air pressure gauge 34 / Hour meter --- R.p.m. counter 35 / Fuel gauge 36 / Converter oil temperature indicator 37 / Clutch oil pressure gauge

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IV ---A --- 7

Driving controls

Maintenance and operator’s manual

Central carrier control panel

1

40

50 60 20 70 10 80 miles/h km/h 30

52

53

56

50

58

54

57

60

59

55

2

61

IV ---A --- 8

ABS

00000

51

1

2

ABS

62

63

64

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Maintenance and operator’s manual

Driving controls

50 / Engine warning light 51 / Engine oil pressure indicator 52 / Battery charge warning light 53 / Front brake air pressure indicator 54 / Rear brake air pressure warning light 55 / Parking brake air pressure warning light 56 / Convertor oil temperature warning light (Red) 57 / Gearbox fault warning light 58 / Water temperature warning light 59 / Emergency power steering circuit warning light 60 / Main power steering circuit warning light 61 / Front suspension locking warning light 62 / Rear suspension locking warning light 63 / Clogged air filter warning light 64 / Telma indicator

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IV ---A --- 9

Driving controls

Maintenance and operator’s manual

Upper left carrier control panel 65

66

ABS I 67

69

70

71

82

68

85

72

ABS

IV ---A --- 10

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Maintenance and operator’s manual

Driving controls

Upper left carrier control panel 65 / Carrier steering indicator 66 / Trailer steering indicator 67 / Low gear range 68 / Low gear range and front axle lock indicator 69 / Trailer ABS default indicator 70 / Parking lights indicator 71 / Dipped headlights indicator (green) 72 / Full beam indicator (blue) 82 / Axle suspension locking control : 85 / Suspension up / down control

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IV ---A --- 11

Driving controls

Maintenance and operator’s manual

Lower right and left carrier control panels ABS

27

89

28

40

50 60 70 10 80 miles/h km/h 30 20

97 93

1

2

ABS

91 92 00000

ABS

96

95

89 / Outrigger selection switch and indicator light 91 / Revolving beacon switch and indicator 92 / Fog light control switch and indicator 93 / Hazard warning lights switch 95 / Front inter ---wheel differential lock and Rear interwheel differential lock control and indicator 96 / Gear range selection switch 97 / Rear steering locking control and warning light 98 / Engine stop 98 / Commande de stop moteur

IV ---A --- 12

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98

Maintenance and operator’s manual

Driving controls 100

Outriggers control box ---left side

99C

99B

99E

99D

99A 99 A --- Pads or outrigger beams selection control 99 B ---Front right hand side pad or beam control 99C --- Rear left hand side pad control 99D ---Front right hand side pad or beam control 99 E --- Rear right hand side pad or beam control 100 --- Emergency shut down control

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IV ---A --- 13

Driving controls

Maintenance and operator’s manual 100

101C

101B

101E

101D

101A 101 A --- Pads or outrigger beams selection control 101 B --- Rear right hand side pad control 101 C ---Front left hand side pad or beam control 101D ---Rear right hand side pad or beam control 101E --- Front left hand side pad or beam control 100 --- Emergency shut down control

IV ---A --- 14

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Maintenance and operator’s manual

Driving controls

Carrier control panel 1

202

0

M A X I

200

2 3

201 102/ Air conditioner control 103/ Air conditioner fan control 104 / Air conditioner indicator

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IV ---A --- 15

Driving controls

IV ---A --- 16

Maintenance and operator’s manual

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04/2000

Maintenance and operator’s manual

Driving controls

Upper cab controls

Edition :

02/2002

IV ---B--- 1

Driving controls Upper cab control panel 201 200

210 211 209B

205

203 204 206

209

207

202

208

IV ---B--- 2

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Maintenance and operator’s manual

Driving controls

Upper cab control panel 200 / Front wheels steering wheel 201 / Accelerator pedal 202 / Brake pedal 203 / Free slewing pedal 204 / Armrest release lever 205 / Warning horn 206 / Seat safety device override switch 207/ Parking brake control 208 / Rear wheels steeringcontrol 209 / Slewing / Telescoping control joystick 209A/ Option “Simultaneous winch operation” Slewing / Telescoping or Winch 2 joystick 2209B / Slewing micro ---speed control 210 / Winch 1 or winch 2 / Derricking control joystick 210A / Option “Simultaneous winch operation” Winch 1 / Derricking control joystick 211 / Level indicator

Edition :

02/2002

IV ---B--- 3

Driving controls Central control panel 224

STOP

270

271

272

273

275

250

251

252

253

254

259

260

225 226 227 228 229 230 231 232

2

2

276

277

278

257

281

258

261 233 234

215

D

223

R N

221 222

235 236

STOP

219 282

286

218

224

214

220

287 212

213

217 / 217a

212 / Ignition switch 213 / Engine shut down switch 214 / Cigar --- lighter 215/ Gear lever 217 / Heating control switch 217a / Option --- Air conditioning fan control 218 / Anti twoblock override switch 219 / LMI override key 220 /Boom key ---switch 221 / Working ligth indicator

IV ---B--- 4

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02/2002

Driving controls

Maintenance and operator’s manual

Central control panel 221 222

224

271

272

273

275

250

251

252

253

254

259

260

225 226 227 228 229 230 231 232

2

2

276

277

278

257

281

258

261

R N

STOP

270

215

D

223

235 236

233 234 STOP

219 282

286

218

224

214

220

287 212

217 / 217a

222 / Undercarriage general warning light 223 / Clogged hydraulic filter warning light 224 / Reactivation of the derricking up function 225 / Front suspension locking warning light 226 / Rear suspension locking warning light 227 / Rear steering locking light 228 / Over rear indicator light 229 / Front interwheels differential locking light

Edition :

02/2002

IV ---B--- 5

213

Driving controls Central control panel 224

STOP

270

271

272

273

275

250

251

252

253

254

259

260

225 226 227 228 229 230 231 232

2

2

276

277

278

257

281

258

261 233 234

215

D

223

R N

221 222

235 236

STOP

219 282

286

218

224

214

220

287 213

217 / 217a

212

230 / Rear interwheels differential locking light 232 / Free slewing warning light 233 / Outriggers selector control 234 / Front axle dog clutch control 250 / Forward windscreen wiper control 251 / Cab roof windshield wiper control 252 / Windscreen washer control

IV ---B--- 6

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02/2002

Driving controls

Maintenance and operator’s manual

Central control panel 224

STOP

270

271

272

273

275

250

251

252

253

254

259

260

225 226 227 228 229 230 231 232

2

2

276

277

278

257

281

258

261 233 234

215

D

223

R N

221 222

235 236

STOP

219 282

286

218

224

214

220

287 212

217 / 217a

253 / Working light control 254 / Fan control 257 / Auxiliary winch selection control 258 / Free slewing control 259 / Turret locking control 260 / counterweight ram up / down control 261 / Counterweight lock/unlock control 270 / Front left ---hand pad control switch 271 / Front right ---hand pad control switch

Edition :

02/2002

IV ---B--- 7

213

Driving controls Central control panel 224

STOP

270

271

272

273

275

250

251

252

253

254

259

260

225 226 227 228 229 230 231 232

2

2

276

277

278

257

281

258

261 233 234

215

D

223

R N

221 222

235 236

STOP

219 282

286

218

224

214

220

287 212

213

217 / 217a

272 / Crane or outriggers selection control switch 273 / Manual accelerator 275 / Front suspension lock control 276 / Rear left ---hand pad control switch 277 / Rear right ---hand pad control switch 278 / Outriggers extension or pad selection control 281 / Rear suspension lock control 282 / Inter ---wheel differential lock control switch 286 / Front axle dog clutch control 287 / Rear steering lock control switch

IV ---B--- 8

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02/2002

Maintenance and operator’s manual

Driving controls

Upper fuses plate T1 --- Gear selector 10A T2 --- front axle lock ---up --- Interwheels differential Front steering releasing 6A T3 --- Car radio 10 A T4 --- Up and down counterweight 6A T5 --- Hydraulic oil cooler 15A T6 --- Not used T7 --- Cab heater 20A T8 --- Turret general warning --- Oil filter 6A T9 --- Windscreen wiper --- Cab fan--- Cigar lighter --- working spotlight --- horn 15 A T10 --- Not used T11 ---Seat safety switch --Telescope retraction synchronization 10 A T12 --- LMI 10 A T13 --- Outrigger functions 10A T14 --- Not used T15 --- Not used T16 --- Not used T17--- Not used T18 --- 3 wraps remaining --- Rotation locking 10A T19 --- Not used T20 --- Not used T21 --- Not used T22 --- Not used T23 --- Not used T24 --- Not used T25 --- Not used T26 --- Not used T27 --- Not used T28 --- Not used T29 --- Not used T30 --- Not used T31 --- Not used T32 --- Not used T33 --- Not used T34 --- Not used

Edition :

02/2002

IV ---B--- 9

Driving controls

IV ---B--- 10

Edition :

02/2002

Maintenance and operator’s manual

Driving controls

Driving controls

Edition :

04/2000

IV ---C--- 1

Driving controls

IV ---C--- 2

Maintenance and operator’s manual

Edition : 04/2000

Maintenance and operator’s manual

Driving controls

Boom base Turret

Cabs Boom head

Main winch Counterweights

Forward

Front outriggers

Counterweights Engine

Edition :

04/2000

Derricking ram

Rear outriggers

IV ---C--- 3

Driving controls

Maintenance and operator’s manual

Carrier cab control equipment 1

2 3

4 1 / Steering wheel THE MACHINE CAN ONLY BE STEERED FROM THE CAB WHEN CAB SELECTION SWITCH 26 IS IN CHASSIS POSITION WARNING LIGHT OUT. The rear wheels must firstly be lined up with respect to the chassis and locked into position in the following manner: --- from the chassis cab . control ref. 21 to line up wheels . control ref. 97 to lock in position ( warning light goes out) --- from the turret cab . control ref. 208 to line up wheels . control ref. 287 to lock in position ( warning light ref. 127 goes out)

2 / Antitheft ignition switch Before starting up, check the position of the engine stop control Position 1: contact + Battery electrical cut off switch on Battery charge, oil pressure, water temperature, air brake pressure, gearbox fault, power assisted steering, suspension locking, parking brake, and air filter warning lights all come on. An audible signal is activated, wait until this signal ends before starting the engine.

(Check the bulbs and change if necessary).

Position 2 --- engine start.

3 / Emergency brake control Lever forwards: brake off (Unlocked) Lever back: brake on (locked). Warning light 55 comes on.

It is possible to regulate brake application by pulling the lever back faster or more slowly.

4 / Steering column adjustment pedal IV ---C--- 4

Edition : 04/2000

Driving controls

Maintenance and operator’s manual

Carrier cab control equipment 17 3

14

16 15

5

6 5 / Accelerator pedal Press the pedal down to increase engine speed. Release the pedal to reduce engine speed. The position of the accelerator pedal affects automatic gear change. With full acceleration, upward gear changes will automatically take place at high engine speeds; with less acceleration, gear changes will take place at lower engine speeds.

6 / Gear selector pad This is an electronic push button gear selector unit. Each button (R, N, D, 3, 2, 1) is a switch. Press the switch corresponding to the required gear range, a light click will be felt, the button will light up and a bip will be heard to notify that the transmission is ready to function in the chosen range.

WARNING : Never free wheel the machine with the gear box in neutral as this can seriously damage the transmission.

Remember that there is no engine brake when in neutral (N).

R

Use this position to reverse drive the machine.

Completely stop the machine before changing from forward to reverse (and vice---versa). The reverse drive warning signal is actived when this gear is selected.

Edition :

04/2000

IV ---C--- 5

Driving controls

Maintenance and operator’s manual

N

This position is selected when starting up the engine, checking correct working order of accessories, or eventually when the engine is at idling speed for long periods.

If the engine starts with the selector in any other position it means that there is a problem with the safety device and this should be repaired as quickly as possible.

Select the neutral position when the machine is left unsupervised with the engine running, also make sure that the parking brake is always applied.

DANGER : Always make sure that the parking brake is applied (ref 4) and the wheels are blocked whenever the machine is left unattended, even for a short time.

D

When this range is selected the machine will set off in 1st or 2nd gear and will automatically shift through up to 6th gear according to acceleration. When the machine slows down the transmission will automatically shift down to the most appropriate gear. This is the position when driving in normal road conditions.

3 -- 2 -- 1 Road, load and traffic conditions sometimes mean that gear ranges have to be limited. They also provide progressively more powerful engine braking in gradient driving conditions.

In 6 x 2 mode : D : This selection authorizes 2---3---4---5---6

3 : This selection authorizes 1---2---3.

2 : This selection authorizes 1---2 1 : This selection authorizes 1.

In 6 x 6 or 6 x 4 mode : D : This selection authorizes 1---2.

3 : This selection authorizes 1---2 2 : This selection authorizes 1---2

1 : This selection authorizes 1

The display allows the selected range to be displayed (bars are displayed), along with the directional movement of the machine ( an arrow is displayed above or beneath the the bars).

An error code is displayed in case of a system anomalie.

IV ---C--- 6

Edition : 04/2000

Maintenance and operator’s manual

Driving controls

Carrier cab controls 10

8 7

9 7 / Brake pedal 8 / Cab heating control 9 / Exhaust brake control

Use this control with the engine and road brakes. Release the accelerator and press the control button (9) to activate the exhaust brake.

This control cannot be used in converter mode .

10 / Electronic gearbox control unit This unit is used for break down diagnosis. Internal controls may only be used by specialist After Sales Technicians.

The powersupply must be cut, and the unit disconnected, before any welding is done on the crane or on any objects suspended on the hook.

Edition :

04/2000

IV ---C--- 7

Driving controls

Maintenance and operator’s manual

Carrier cab controls

11 12

11 / Windscreen wiper / washer control --- First position --- Second position --- All positions

: SLOW : FAST : WINDSCREEN WASHER

12 / Lights --- direction indicators --- horn

0 V R 70

71

Direction indicators --- left hand indicator: handle back --- right hand indicator: handle forwards A flashing indicator comes on (65 --- 66) Horn --- press end of lever in any position.

Lights Battery switch off --- parkinglights and dipped headlights may be used Battery switch on --- switch at O (impulse): headlight flash the blue indicator 72 comes on when headlight flash or full beam is used --- switch at V: parkinglights ( indicator 70) --- switch at R: dipped and full beam headlights (indicator 72 --- 71)

72

IV ---C--- 8

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Driving controls

Carrier cab controls 17

14

13

16 15 13 / Electric retarder control Use the retarder to save the brakes and increase efficiency in an emergency.

This brake should be used to slow down the vehicle on slopes. It must never be used while pressing the main brake pedal at high speed. Such use, which is totally ineffective, may cause breakage on the rear axle and abnormal wear on the tires.

This is a 5 position switch.

Position 1: Retarder off; Position 5: maximum slowing.

Pause at each position before moving to the next.

In wet conditions use the retarder step by step, being careful not to exceed adherence limits. Stop using the retarder if there is any concern.

In snowy conditions, drive at reduced speed and do not exceed position no. 2. Stop using the retarder if there is any concern.

When setting off in icy conditions, place the retarder in no.2 position and accelerate slowly.

Make sure that the retarder is cut off before leaving the machine

14 / Parking brake 15/ 12 and 24 volt points 16 / Troubleshooting aid connector

Edition :

04/2000

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Maintenance and operator’s manual

Carrier cab controls ABS

27 21

28

25 40

1

50 60 70 10 80 miles/h km/h 30 20

ABS

2

ABS

26 00000

20

22 23 20 / Electronic speedometer The speedometer is calibrated before delivery. Should tyre size change, have the speedometer recalibrated.

21 / Rear wheel steering control Speed is limited to 20 Km/h with rear wheel steering unlocked.

Unlock the rear wheels on axle with control 97 .Cramped or crab steering is possible.

This control is also used to line up rear wheels before operating rear steering lock, 97.

The rear steering may be locked only if rear wheels are absolutely lined up with chassis. For this, use a very low speed ( 1 to 2 km/h), select 97 and use control 21 with light impulses.

22 / Manual accelerator Engine speed limited to 2000 rpm.

IMPORTANT : This command is only to be used to set engine speeds for crane functions. It is not to be used when traveling the crane.

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Maintenance and operator’s manual

Carrier cab controls 27

ABS

21

28

25 40

50 60 70 10 80 miles/h km/h 30 20

ABS

1

2

ABS

26 00000

20

22 23 23 / Axle ABS disconnection control This control enables the axle ABS to be disconnected. Press this button to disconnect the ABS (indicator 25 is flicking). When working on road ensure that the ABS is selected. (indicator 25 is be off) Disconnect the ABS when driving on uneven ground or on a road covered with snow.

Edition :

04/2000

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Driving controls

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Carrier cab controls 27

ABS

28 25

21

40

50 60 70 10 80 miles/h km/h 30 20

ABS

1 ABS

2

26 00000

20

22 23 25 / Default axle ABS indicator or all terrain ABS not selected This indicator goes on when ABS is not selected or when an ABS system fault has been detected.

26 / Cab selection control switch and warning light: Upper / Lower Gear selector 6 on neutral Press on switch to give permission driving from upper cab.The warning light turns on and remains lighted during the selection of turret cab.

27 / Dual fuel option --- Red light red fuel This light goes on when the turret cab is selected using command no. 26.The engine then uses fuel from the domestic fuel oil tank.

WARNING: It is essential to keep a ”consumption” record of amounts of domestic fuel oil used by the vehicle if it is fitted with the dual fuel device.

28 / Dual fuel option --- Green light diesel This light goes on when the vehicle cab is selected using command no. 26. The engine then uses fuel from the diesel oil tank.

IV ---C--- 12

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Maintenance and operator’s manual

Carrier cab controls 37

35

30

32

36

31

33

ABS

1

40

50 60 70 10 80 miles/h km/h 30 20

2

ABS

00000

ABS

34

30 / Engine oil pressure gauge Normal pressure : 5 bar at tickover speed. If pressure drops abnormally minimum (mini. : 0,25 bar or 3.6 PSI), stop the engine and look for the reason.

If the temperature reaches 100˚ C, slow down if the temperature does not drop, stop the engine immediately, and check the cooling circuit .

31 / Engine water temperature gauge Normal working temperature is between 70˚C (158 ˚F) and 95˚C (203 ˚F).The temperature of the coolant liquid must not exceed 100˚C (212˚F).

32 / Front brake air pressure gauge Do not use the machine until this minimum pressure has been reached

The normal pressure of the brakes is higher than 5.2 bar (75.30 PSI). indicator 53 goes out when the minimum pressure of 5.2 bar 75.30 PSI) has been reached.

33 / Rear brake air pressure gauge The normal pressure of the brakes is more than 5.2 bar (75.30 PSI).

Warning light 54 goes out when the minimum pressure of 5.2 bar (75.30 PSI) has been reached.

34 / Time meter --- R.p.m. counter The time meter works at the same time as the engine.

MERCEDES engine speeds.

--- Road : 2200rpm

--- idling speed: 600 rpm --- maximum: 2600 rpm

--- site: 2000rpm

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04/2000

IV ---C--- 13

Driving controls

Maintenance and operator’s manual

Carrier cab controls 37

35

30

32

36

31

33

ABS

40

50 60 70 10 80 miles/h km/h 30 20

1

2

ABS

00000

ABS

34 35 / Fuel gauge This gauge indicates the amount of diesel left in the fuel tanks. Total capacity: 120+250 litres

36 / Converter oil temperature thermometer Normal temperature: 60 to 90˚C (140 ˚F to 194˚F) Maximum temperature: 110˚C (248˚F) Note: If the convertor oil temperature reaches the maximum level indicated above: --- stop the machine --- put into neutral gear (position N) --- accelerate the engine to 1200/1500 rpm for around 2 to 3 minutes ( until the temperature returns to normal).

37 / Clutch oil pressure gauge normal operating pressure : 17 bar.

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Driving controls

Maintenance and operator’s manual

Carrier cab controls 51

52

53

56

50

58

54

57

50 / Engine warning light If this warning light goes on, stop the machine and check: --- sump oil level.

--- oil pressure.

--- temperature of coolant.

This light may also go on if the engine is turning at excessive speed.

If none of these appears to be the fault, call after---sales service.

51 / Engine oil pressure indicatort (red) This light comes on when the engine starts up and remains on until pressure reaches normal level ( do not accelerate suddenly).It goes out when pressure reaches: MERCEDES engine : Minimum pressure 0,25 bar (3.6 PSI).

This light comes on if engine oil pressure is too low. In this case stop the engine and check the reason.

52 / Battery charge indicator (Red) This warning light comes on when : the ignition switch is turned but the engine has not yet started. the alternator does not charge the batteries.

Check the reason.

53 / Front brake air pressure warning light (Red) This warning light goes out when air pressure reaches 5,2 bar (75.30 PSI).

DANGER : Never move off before this warning light is fully off

Edition :

04/2000

IV ---C--- 15

Driving controls

Maintenance and operator’s manual

Carrier cab controls 51

52

53

56

50

58

54 55

57 ABS

63

64

54 / Rear brake air pressure indicator (Red) This warning light goes out when the air pressure reaches 5,2 bar (75.30 PSI. DANGER : Never move off before this warning light is fully off.

55 / Parking brake air pressure indicator (Red) This warning light comes on when : --- the parking brake is applied --- there is a problem in the pneumatic circuit while machine is being driven (pressure drops to less than 5 bar or 72.45 PSI) NOTE : in this case the operator is warned that the parking brake will be applied automatically as a safety measure, and the machine will come to a standstill.

56 / Convertor oil temperature warning light (Red) This warning light comes on when the converter oil temperature reaches120˚C (248˚F) a maximum.

Note : If the convertor oil temperature reaches the maximum indicated above: --- stop the machine --- put into neutral gear (position N)

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Driving controls

--- accelerate the engine to 1200/1500 rpm for around 2 to minutes ( until the temperature comes back to normal).

57 / Gearbox fault warning light If this warning light comes on, note the fault code displayed and contact the After---Sales Department.

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04/2000

IV ---C--- 17

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Maintenance and operator’s manual

Carrier cab controls

1

51

52

50

58

60

59 2

58 / Water temperature warning light (Red) This warning light comes on when the water temperature is too high.

Stop the machine and check the reason. Also check the temperature according to the thermometer 31.

59 / Emergency power steering warning light (Red) This warning light is on when the engine is running at idling speed. It goes out when the machine moves off. If it comes on while the machine is moving, there is a fault in the power steering circuit.

Have the steering repaired without delay

60 / Main power assisted steering circuit warning light (red) This warning light is on when the engine is running at idling speed. It goes out when the machine moves off. If it comes on while the machine is moving, there is a fault in the power steering circuit.

Have the steering repaired without delay

IV ---C--- 18

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Maintenance and operator’s manual

Carrier cab controls 65

60

59

55

61

62

ABS I

25 ABS

63

66

67

69

64

61 / Front suspension locking warning light When this warning light is on, it indicates that the rear suspension is locked (using switch 275 located on the front panel of upperstructure or switch 82 located on the carrier instrument panel).

62 / Rear suspension locking warning light REAR

When this warning light is on, it indicates that the front suspension is locked (using switch 281 located on the side panel of upperstructure or switch 82 located on the carrier instrument panel).

63 / Clogged air filter warning light (Yellow) This light comes on when the air filter is clogged. Carry out maintenance on the filter cartridges or replace them. (Refer to MAINTENANCE CHAPTER).

64 / Retarder indicator (Yellow) Lights up if the electric braking device is being used.

65 / Carrier cab steering indicator. (Green) 66 / Trailor steering indicator. (Green) Edition :

04/2000

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Driving controls

Maintenance and operator’s manual

Carrier cab control equipment 65

66

ABS I 67 70

68

69 71

72

67 / Low gear range This light comes on when the low range mode has been selected with control switch (96).

68 / Low range + front axle dog clutch indicator (Yellow) If the indicator is lit, the front axle low range + dog clutch has been chosen using control switch (96).

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Maintenance and operator’s manual

Carrier cab controls 65

66

ABS I 67 70

68

69 71

72

69 / Trailer ABS default indicator This indicator goes on when a trailer ABS default has been detected

70 / Parking lights indicator. (Green) This light comes on when the parking lightshave been switched on using control (12).

71 / Dipped headlights indicator (Green) 72 / Full beam indicator (Blue)

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Carrier cab controls

82 85

ABS

82 / Axles suspension locking control LOCKED position.

The machine must be positioned on a hard, even, horizontal surface.

Operating conditions: Gearbox in neutral.

F Locked suspension and machine levelled: For lifting on outriggers the wheels should be clear of the ground.

F Suspension locked and lowered: --- For lifting on wheels over rear.

--- For moving with a load over the rear.

F Suspension unlocked and machine levelled: For moving on roads and on sites.

For moving on difficult terrain.

Respect tyre inflation pressures.

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04/2000

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Carrier cab controls

82 85

ABS

85 / Suspension up / down control WARNING : IT IS FORBIDDEN TO UNLOCK THE SUSPENSION when the machine is in a working position on outriggers.

The axles may drop suddenly and damage the suspension correctors

IV ---C--- 24

This control is used: --- to reduce the height of the machine by 80 mm if height clearance is insufficient.

--- to lift the wheels higher under exceptional outrigger conditions.

--- to refresh the oil in the suspension hydraulic circuit.

This operation should be carried out daily before leaving the machine.

Operation: --- engine running, suspension unlocked, hold the ”Lower suspension” control on. Indicator light on.

--- to return the suspension to normal position, start the engine, suspension unlocked, then operate the control briefly in reverse direction. The lowering indicator goes off and the machine returns to nominal position.

(Time required: about 2 minutes 30 seconds.)

Edition : 04/2000

Driving controls

Maintenance and operator’s manual

Carrier cab control equipment ABS

89 97

40

50 60 70 10 80 miles/h km/h 30 20

1

2

ABS

91 92 00000

ABS

96

93

98

95

89 / Outrigger selection control switch and warning light

Warning light on = Boom retracted

Make sure that axle suspensions are blocked (control ref. 82) before using this function.

Activate this switch to enable outrigger controls. This function enables the hand throttle control to be used.

91 / Rotating flashing light switch and tell ---tale light This switch is used to activate the external rotating flashing light.

92 / Rear fog light control This switch controls the rear fog lights.

93 / Hazard warning lights control switch Press the switch, the 4 direction indicator lights flash simultaneously indicating that the machine is on emergency stop.

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04/2000

IV ---C--- 25

Driving controls

Maintenance and operator’s manual

Carrier cab control equipment ABS

89 97

40

50 60 70 10 80 miles/h km/h 30 20

1

2

ABS

91 92 00000

ABS

96

93

98

95

95 / Interwheels differential lock control This control must only be used on difficult terrain; do not apply full lock to the steering during this manoeuvre.

Range 6x6 should be selected in order to use this control.

Control no. 95 is used: --- to lock the inter---wheel differential.

The differentials remain locked for as long as the contactors remain in this position.

Return to normal position as soon as possible after the difficult section. The indicator stays on as long as the differentials are locked.

IV ---C--- 26

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Maintenance and operator’s manual

Carrier cab control equipment ABS

40

50 60 70 10 80 miles/h km/h 30 20

89 97

1

2

ABS

91 92 00000

ABS

96

93

98

95

96 / Front axle coupling control This switch is only to be used when the gear selector is in neutral position and the machine is at a standstill or travelling at not more than 1kph.

If necessary, engage 1st gear to facilitate coupling.

97 / Rear wheel steering lock control

Warning light on = Boom retracted

STOP Edition :

04/2000

To enable rear wheel steering, reduce speed to between 15 and 20 Km/h, push the control forward, the warning light commes on to indicate that rear wheel steering is enabled.

Rear wheel steering enabling leads to the automatic selection of 2nd gear only, and speed is limited to 20 Km/h.

To lock rear wheel steering, place the rear wheels in line using control switch Ref. 21.

98 / Engine shut down control IV ---C--- 27

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Maintenance and operator’s manual

Left hand side outriggercontrol unit 100

99C

99B

99E

99D

99A Left hand side outrigger control unit Before manipulating outriggers, the control switch Ref. 89 must be in correct position 99A --- Outrigger ground pad or girder extension selector 99C --- Front right outrigger ground pad up or down selector 99B--- Rear right outrigger ground pad up or down selector 99E--- Front left outrigger ground pad or left front girder selector 99D --- Rear left outrigger ground pad or left rear girder selector Several functions working in the same direction may be combined.

For example: 2,3 or 4 ground pads can be set down together, or 2,3 or 4 outrigger beams can be extended.

IT IS FORBIDDEN TO ACTIVATE A FUNCTION ON SEVERAL OUTRIGGERS AT THE SAME TIME BUT IN OPPOSITE DIRECTIONS. For example, raise one ground pad while setting down another, or extending one outrigger beam while retracting another.

IMPORTANT : Load handling requires perfect machine stabilizing on outriggers, check with the spirit level on the chassis and regulary check that the machine is level .

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Driving controls

Right hand side outriggercontrol unit 100

101C

101B

101E

101D

101A Boîtier de commande des stabilisateurs côté droit Right hand side outrigger chassis control unit Before manipulating outriggers, the control switch Ref. 86 must be in correct position 101A --- Outrigger ground pad or girder extension selector 101C--- Left rear outrigger ground pad up or down selector 101B --- Left front outrigger ground pad up or down selector 101E--- Right rear outrigger ground pad or right rear girder selector 101D --- Right front outrigger ground pad or right front girder selector Several functions working in the same direction may be combined.

For example: 2,3 or 4 ground pads can be set down together, or 2,3 or 4 outrigger beams can be extended.

IT IS FORBIDDEN TO ACTIVATE A FUNCTION ON SEVERAL OUTRIGGERS AT THE SAME TIME BUT IN OPPOSITE DIRECTIONS. For example, raise one ground pad while setting down another, or extending one outrigger beam while retracting another.

IMPORTANT : Load handling requires perfect machine stabilizing on outriggers, check with the spirit level on the chassis and regulary check that the machine is level .

Edition :

04/2000

IV ---C--- 29

Driving controls

Maintenance and operator’s manual

Carrier controls 1

104

0

102

M A X I

2

103

3

102 / Air conditioner control 103 / Air conditioner fan control 104 / Air conditioner indicator 107

106

106 / level indicator 107 / Emergency stop switch This switch stops the engine. Push this button in case of an emergency.

Once pushed this switch is held in position, dont forget to pull it out after the engine has stopped to bring it back to the initial position.

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Driving controls

Upper cab controls 200 211

201

202

210 207

209

209B 206

203

205

204

208 200 / Steering wheel for rear wheels STEERING CAN ONLY BE CARRIED OUT FROM THE UPPERSTRUCTURE CAB (on the control panel), in other words : --- cab selection switch ref. 26 is in upperstructure cab position.

--- parking brake is applied.

--- gear box is in position N.

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04/2000

IV ---C--- 51

Driving controls

Maintenance and operator’s manual 200

211

201

202

210 207

209

209B 206

203

205

204

208 201 / Accelerator pedal Engine speed limited to : 2000 rpm

202 / Brake pedal 203 / Free slewing pedal If the slewing control Ref. 258 is in the free slewing position then : --- if this pedal is pressed slewing is braked --- if this pedal is released slewing is freed

204 / Armrest locking switch 205 / Warning horn Before starting the engine, sound a warning on the horn and wait a few seconds to give anyone in the area of operation of the machine time to withdraw.

206 / Seat safety device override switch Refer to paragraph concerning safety measures at the end of the Driving Controls chapter.

207 / Parking brake control Knob pushed down : BRAKE RELEASED Knob pulled up : BRAKE APPLIED IV ---C--- 52

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Maintenance and operator’s manual

Driving controls 200

211

201

202

210 207

209

209B 206

203

205

204

208 208 / Rear wheel control THIS CONTROL IS ONLY POSSIBLE IN THE UPPER CAB DRIVING POSITION. Remember to : --- Place the cab control switch in upper cab position (Ref. 26 in carrier cab) --- be at a speed of less than 20 Km/h --- Unlock the rear wheels with control switch Ref. 287.

BOOM ORIENTATED OVER THE REAR OF THE CHASSIS. When moving the control to the left, rear wheels turn towards the left.

When moving the control to the right, rear wheels turn towards the right.

BOOM ORIENTATED OVER THE FRONT OF THE CHASSIS When moving the control to the left, rear wheels turn towards the right. When moving the control to the right, rear wheels turn towards the left. As soon as the lever is released, the wheels remain in their current position.

When operation from the upper cab is finished : Actuate the lever to make the wheels parallel with the chassis (visual alignment check).

Lock the rear wheels in position with control switch Ref. 287.

The gear box is automatically in second and speed is limited to 20 Km/h.

Edition :

04/2000

IV ---C--- 53

Driving controls

Maintenance and operator’s manual 200

211

201

202

210 207

209

209B 206

203

205

204

208 209 / Slewing / telescoping joystick Telescoping.

Pushed forwards : boom extension Pulled backwards: boom retraction Slewing.

Pushed to the left : left hand slewing Pushed to the right : right hand slewing When the joystick is in between any two of these positions (i.e. diagonally positioned) the two concerned functions operate simultaneouslyNote: FOR CORRECT USE OF THE MACHINE: 1 --- only make handling operations with the engine at idling speed if these involve low speed handling over short distances.

2 --- work with the engine at higher speeds when handling functions are to be performed more quickly.

CARE During inwards and outwards telescoping of the boom to less than 40° , telescoping section synchronisation may not work because of the design of the telescoping cylinder and slider pad friction.

Should this happen, the boom should be re---synchronised using the synchronisation key (see page IV ---C---40, item 220).

IV ---C--- 54

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Maintenance and operator’s manual

Driving controls 200

211

201

202

210 207

209

209B 206

203

205

204

208 209 A /OPTION “ simultaneous winch operation” Slewing / Winch 2 or Telescoping joystick Select Winch 2 or telescoping with Ref. 165 Option control.

Winching 2 : auxilairy winch. Allows working with both winches at the same time Pushed forwards : lowering of the load Pulled backwards : lifting of the load Telescoping: Pushed forwards : the boom is extended Pulled backwards : the boom is retracted.

Slewing: This function do not change.

Pushed to the left : left hand slewing Pushed to the right : right hand slewing DANGER : When the operator carries out a quick movement such as hoisting, lowering or slewing with a load, it should be executed and slowed down gently and precisely.

A sudden stop would cause dangerous vibrations to the load that might cause damage to the crane and the personnel.

CAUTION : To stop the movement, bring the control switch slowly back to neutral position. NEVER REVERSE THE CONTROL TO STOP OR SLOW DOWN A MOVEMENT.

209B / Very slow slewing control This control is used to regulate the slewing speed.

Use this control to achieve great accuracy of slewing with a long boom. It is preferable to pre---set slewing speed before telescoping the boom.

Edition :

04/2000

IV ---C--- 55

Driving controls

Maintenance and operator’s manual 200

211 202

201 210 207

209

209B 206

203

205

204

208 210 / Winching 1 or winch 2 and derricking joystick Winching. (Main winch or auxiliary winch by Ref 257 control) Pushed forwards : lowering of the load Pulled backwards : lifting of the load Derricking.

Pushed to the right : lowering of the boom Pushed to the left :lifting of the boom Note: When the joystick is in between any two of these positions (i.e. diagonally positioned) the two concerned functions operate simultaneously: lowering or lifting of the boom and lowering or lifting of the load.

DANGER : When the operator carries out a quick movement such as hoisting, lowering or slewing with a load, it should be executed and slowed down gently and precisely.

A sudden stop would cause dangerous vibrations to the load that might cause damage to the crane and the personnel.

Concerning the hoisting -- lowering movement in particular, a safety system allows the movement to be stopped if the control switch is suddenly released but due to inertia the winch will continue to unwind for a short moment.

CAUTION : To stop the movement, bring the control switch slowly back to neutral position. NEVER REVERSE THE CONTROL TO STOP OR SLOW DOWN A MOVEMENT.

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Maintenance and operator’s manual

Driving controls 200

211

201

202

210 207

209

209B 206

203

205

204

208 210A / OPTION “ simultaneous winch operation” Derricking / Winch 1 joystick When the option is selected by control Ref. 165 Option.

Winching : main winch.

Pushed forwards : lowering of the load Pulled backwards : lifting of the load Derricking: Pushed to the left : lifting of the boom Pushed to the right : lowering of the boom

211 / Spirit level

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Driving controls

Maintenance and operator’s manual

224

STOP

270

271

272

273

275

250

251

252

253

254

259

260

225 226 227 228 229 230 231 232

2

2

276

277

278

257

281

258

261 233 234

215

D

223

R N

221 222

235 236

STOP

219 282

286

218

224

214

220

287 212

217 / 217a

212 / Ignition key switch Position 1 : Electrical contact Position 2 : Engine start up

213 / Engineshut down switch (emergency) Push to stop engine.

The control stays engaged.

To restart the engine, pull it out, and the engine stop is active again.

IV ---C--- 58

Edition : 04/2000

213

Driving controls 223

224

STOP

270

271

272

273

275

250

251

252

253

254

259

260

225 226 227 228 229 230 231 232

2

2

276

277

278

257

281

258

261 233 234

215

D

221 222

R N

Maintenance and operator’s manual

235 236

STOP

219 282

286

218

224

214

220

287 212

217 / 217a

214 / Cigar --- lighter 215 / Gear selector panel This appropriate push button gear selector unit. Each button is a switch. Press theappropriate switch works electronically, a slight click will be felt, the button will light up and a beep indicates that the transmission is ready to function in the chosen range.

WARNING : Never free wheel with the gear box in neutral as this can seriously damage the transmission.

Remember that there is no engine brake when in neutral (N).

R Use this position to drive the machine in reverse.

Stop the machine completely before changing from forward to reverse gear (and vice---versa). Selecting this gear activates the reversing warning signal .

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04/2000

IV ---C--- 59

213

Driving controls

Maintenance and operator’s manual

N This position is for starting the engine, checking that accessories, are in order or for leaving the engine idling for long periods.

The transmission automatically selects neutral when contact is made. If the engine starts with the selector in any other position it means that there is a problem with the stating safety device and this should be repaired as soon as possible.

Select neutral when the machine is left unsupervised with the engine running, and make sure that the parking brake is on.

DANGER : Always make sure that the parking brake is on (207) and that the wheels are blocked whenever the machine is left unattended, even for a short time.

D

In this position, the machine starts off in first or second gear.

The gears change automatically through to second during acceleration. When the machine slows down, they change down automatically.

217 / Heating control housing 218 / Anti twoblock override switch This safety device prevents the pulley block from hitting the boom head during lifting or telescoping. This could cause serious damage to the boom head and the cable. The latter might even break and lead to the load being dropped.

The device cuts off the following: Load lifting, boom extension The release enables all the functions cut off by the anti twoblock override device to be restored and also the pulley---block to be stocked in road position.

Use the release to re-- establish any function cut off by the high hook limiter device.

THE CRANE OPERATOR OR SITE MANAGER IS FULLY AND ENTIRELY RESPONSIBLE FOR ANY CRANE OPERATION WITH THE HIGH HOOK LIMITER RELEASED APART FROM THOSE EXPRESSLY DESIGNATED BY PPM. PPM WILL NOT BE HELD RESPONSIBLE FOR ANY ACCIDENT OCCURRING WHEN THE CRANE IS BEING USED WITH THE HIGH HOOK LIMITER RELEASED.

IV ---C--- 60

Edition : 04/2000

Driving controls 223

224

STOP

270

271

272

273

275

250

251

252

253

254

259

260

225 226 227 228 229 230 231 232

2

2

276

277

278

257

281

258

261 233 234

215

D

221 222

R N

Maintenance and operator’s manual

235 236

STOP

219 282

286

218

224

214

220

287 212

217 / 217a

219 / LMI override key If the crane approaches limit conditions the operator is warned by the LMI’s audible alarm and a warning light, and it cuts off those crane functions which might damage it.

The following crane functions are cut off : Load lifting Derricking down Boom extension Boom retraction in case where radius is too short.

Release allows all functions cut off by the LMI unit to be reactivated.

THE CRANE OPERATOR OR SITE MANAGER IS FULLY RESPONSIBLE FOR THE USE OF ANY CRANE FUNCTIONS APART FROM THOSE EXPRESSLY DESIGNATED BY PPM WHEN THE LMI SAFETY DEVICE IS OVERRIDEN. PPM WILL NOT BE HELD RESPONSIBLE FOR ANY ACCIDENT OCCURRING WHEN THE CRANE IS BEING USED WITH AN LMI RELEASED. LMI configuration must be in accordance with the configuration of the machine.

THE LMI UNIT IS ESSENTIAL TO ENABLE THE OPERATOR TO AVOID SITUATIONS WHICH ARE DANGEROUS FOR BOTH HIMSELF AND THE MACHINE. AS WITH ANY SAFETY SYSTEM IT CANNOT COVER ALL POSSIBLE HUMAN ERRORS. FOR THIS REASON, CHOICE IS LEFT TO THE DISCRETION OF THE OPERATOR, WHO SHOULD BE A QUALIFIED AND FULLY EXPERIENCED PERSON.

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STOP

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R N

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STOP

219 282

286

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287 212

217 / 217a

213

220 /Boom keyswitch WARNING: This key operated switch is to be used STRICTLY and SOLELY for resynchronizing the telescopic boom or retracting it when it has been fully extended in horizontal position.

After turning the key (element 2 or element 3---4) in the 55° band down to minimum angle, the load state monitor will display the message ”Synchronization fault” and authorize a maximum load of ”0.7 tonnes”. The message disappears when the crane operator has completely retracted the boom to its minimum length of 9.40m, which corresponds to correct synchronization.

Resynchronizing the boom: When retracting the boom, desynchronization of the boom elements may occur.

Retracting the boom in horizontal position: When the boom has been fully extended in horizontal position for maintenance operations, or for special loads.

In both cases, the procedure to be followed is the same: --- without load --- boom fully extended, preferably in horizontal position.

--- Retract elements 3 and 4: With the engine accelerated, turn the synchronization key to the left and hold it until elements 3 and 4 are fully retracted.

--- Retract element 2: With the engine accelerated, turn the synchronization key to the right and hold it until element 2 is fully retracted.

--- Return the key to neutral position.

The time needed for resynchronization may be as long as 2 to 3 minutes for 1 meter of desynchronization.

IMPORTANT: The boom telescopes in synchronized mode, that means, that all the elements extend or retract at the same time by the same distance. Operating this key during retraction would desynchronize the boom and send wrong data to the LMI, which would no longer be able to control the safety of the machine properly.TO AVOID ANY ACCIDENTAL OPERATION, NEVER LEAVE THE KEY IN THE SWITCH EXCEPT WHILE RESYNCHRONIZATION IS TAKING PLACE. IV ---C--- 62

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STOP

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221 / Working spotlight warning light 222 / General alarm warning light

STOP

This light comes on when one of the following alarm lights is activated in the carrier cab : Engine oil pressure Front or rear brake air pressure Engine coolant temperature Converter oil temperature Fouled air filter Immediately check which alarm is activated in the carrier cab and carry out remedial action.

223 / Clogged hydraulic filter warning light This light comes on when the hydraulic oil filter is clogged up.

Exchange the filter cartridge( Refer to maintenance chapter)

224 / Reactivation of the derricking up function In case of cut---out of boom functions by the LMI, the derricking up function can be reactivated by pressing this button.

225 / Front suspension locking warning light When this warning light is on, it indicates that the rear suspension is locked (using switch 275 located on the front panel of upperstructure or switch 82 located on the carrier instrument panel).

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STOP

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226 / Rear suspension locking warning light REAR

When this warning light is on, it indicates that the front suspension is locked (using switch 281 located on the side panel of upperstructure or switch 82 located on the carrier instrument panel).

227 / Rear steering locking warning light When the warning light is on, it indicates that the rear wheels are unlocked by action on the switch 287 located on side instrument panel.

228 / Over the rear indicator light This indicator light comes on when the upperstructure is in the centreline of the machine, with the boom pointing towards the rear and the upper locked in position on the chassis. The machine can then be used with the corresponding load chart.

(SEE LOAD CHARTS)

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STOP

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215

236

229 / Front wheel differential lock ---up warning light This warning light turns on when using control 282 and remains on as long as the differential is locked.

230 / Rear interwheels differential locking warning light This warning light turns on when using control 282 and remains on as long as the differential is locked.

232 / Upperstructure slewing inhibited warning light This warning light comes on when the counterweight cylinders are in intermediate position (between high and low positions).

It is impossible to slew the turret.

233 / Outriggers selector control The warning light comes on when control no. 272 is in the outrigger position and if the suspension is locked.

It indicates that the outrigger controls can be used as follows: --- from the turret cab or from the ground provided that the switch 26 in the carrier cab is in outrigger position and the indicator light is on.

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STOP

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234 / Front axle coupling indicator light This light goes on when control no. 286 to couple the front axle is actuated.

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250 / Forward windscreen wiper control 251 / Cab roof windshield wiper control 252 / Windscreen washer control 253 / Working light control

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254 / Fan control 2

257 / Auxiliairy winch selection control To select crane main and auxiliary winch.

Down : main winch Up : auxiliary winch

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258 / Free slewing control WARNING : It is essential for slewing to be braked before travels the machine (on roads, sites, with or without loads, etc). Always return to the braked position after any slewing manoeuvre.

Incorrect use of this control can provoke serious damage to the machine and endanger the staff.

CAUTION : Do not activate the free slewing function if the machine is not level.

Use the switch to free slewing. Indicator comes on.

At this point the slewing brake is not applied so slewing is free.

Keep your foot down on the slewing brake pedal 203 during brake release.

Slewing is automatically braked in the following situations : --- by the operator’s seat safety device which cuts out all functions if the operator leaves his seat --- when the engine is stopped.

icator on = slewing unlocked

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259 / Turret locking control Note: There are 3 locking positions for the turret.

A position with the turret locked in the axis of the machine over the front wheels for moving on the road.

A position with the turret locked in the axis of the machine over the rear wheels, for handling operations.

A position with the turret at the rear, locked at an angle of 8° 30 to the left for the operation of fitting counterweights.

Press this button to unlock the turret from the chassis.

To lock, bring the turret to the desired position and press the control button.

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260 / Counterweight table up / downlower control switch

This enables the counterweight raws to be raised or lowered so that counterweights may be placed on the turret or on the chassis.

Refer to paragraph on the counterweight system and locking.

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261 / Counterweight lock / unlock control This control locks and unlocks the counterweights.

Counterweights locked: green flag.

Counterweights unlocked: red flag.

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270 / Front left ground pad and front left outrigger beam control --- flip the switch backwards to extend the outrigger beam or set down the ground pad (following memorized function) --- flip the switch forwards to retract the outrigger beam or to raise the ground pad (following memorized function) Raising the machine should be done with the outriggers : --- completely retracted --- completely extended --- intermediately extended The machine must never be raised with the outrigger beams situated between the retracted and the intermediate positions. A load must never be set down on an outrigger beam, even if this is only partially extended.

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271 / Front right ground pad and front right outrigger beam control --- flip the switch backwards to extend the outrigger beam or set down the ground pad (following memorized function) --- flip the switch forwards to retract the outrigger beam or to raise the ground pad (following memorized function) Raising the machine should be done with the outriggers : --- completely retracted --- completely extended --- intermediately extended The machine must never be raised with the outrigger beams situated between the retracted and the intermediate positions. A load must never be set down on an outrigger beam, even if this is only partially extended.

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287

272 / Crane outriggers selection control Flip the switch upwards to selection outrigger control functions ( crane functions inhibited) Outrigger functions selection allows outrigger control either from the turret or the chassis. This control may only be used if the suspension has been locked.

The outriggers functions selection cuts all crane functions .

After ensuring that the machine is correctly levelled switch back to the crane functions : WINCHING -- DERRICKING -TELESCOPING -- SLEWING all outrigger fonctions are now inhibited.

273 / Manual accelerator This control allows manual control of the engine speed. Maximum speed: 2,000 rpm.

275 / Front suspension locking control

FRONT

Edition :

04/2000

Flip and hold switch to locking position until indicator light 225 comes on.The suspension is unlocked by flipping the switch to unlocking position.

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276 / Rear left ground pad and rear left outrigger beam control --- flip the switch backwards to extend the outrigger beam or set down the ground pad (following memorized function) --- flip the switch forwards to retract the outrigger beam or to raise the ground pad (following memorized function) Raising the machine should be done with the outriggers : --- completely retracted --- completely extended --- intermediately extended The machine must never be raised with the outrigger beams situated between the retracted and the intermediate positions. A load must never be set down on an outrigger beam, even if this is only partially extended.

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287

277 / Rear right ground pad and rear right outrigger beam control --- flip the switch backwards to extend the outrigger beam or set down the ground pad (following memorized function) --- flip the switch forwards to retract the outrigger beam or to raise the ground pad (following memorized function) Raising the machine should be done with the outriggers : --- completely retracted --- completely extended --- intermediately extended The machine must never be raised with the outrigger beams situated between the retracted and the intermediate positions. Aload must never be set down on an outrigger beam, even if this is only partially extended.

Outrigger control can also be made on the chassis ( left or right hand side control unit) IMPORTANT : Load handling requires perfect machine stabilizing on outriggers, check with the spirit level on the chassis and regulary check that the machine is level .

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287

278 / Outrigger extension or outrigger lifting ram control selection To control the outriggers the desired outrigger function must firstly be chosen using momentary return flipswitch Ref.272.

--- To select the outrigger beam extension function, flip the switch to the right and release, the function is memorized.

--- To select the ground pad function flip the switch to the left and release, the function is memorized.

Now make the necessary operations using control switches 270---271---276---277 It is possible to control several outriggers at the same time ( in the same direction) For example: 2,3 or 4 ground pads can be set down together, or 2,3 or 4 outrigger beams can be extended.

IT IS FORBIDDEN TO ACTIVATE A FUNCTION ON SEVERAL OUTRIGGERS AT THE SAME TIME BUT IN OPPOSITE DIRECTIONS. For example, raise one ground pad while setting down another, or extending one outrigger beam while retracting another.

The function selection can also be made on the chassis ( left or right hand side control unit )

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281 / Rear suspension locking control

REAR

Actuate switch to locking position until indicator light 226 comes on.

The suspension is unlocked by actuating the switch to unlocking position.

282 / Inter ---wheel differential locking control Return to normal position as soon as possible after the difficult section and do not swing the wheels in this position.

This function should only be used on difficult terrain .

This function can only be used if the front axle is locked up

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287

286 / Front axle dog clutch control --- flip the switch forwards to lock ---up the front axle --- flip the switch backwards to disengage the front axle

287 /Rear wheel steering unlocking control To enable rear wheel steering, reduce speed to between 15 and 20 Km/h, --- flip the switch forwards to unlock the rear wheels --- flip the switch backwards to lock the rear wheels Rear wheel steering is controlled by the steering wheel 208.

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Driving controls

Driving the machine Introduction This paragraph, as well as safety regulations for mobile cranes indicated at the beginning of this manual, should be carefully studied before driving the machine.

The information that follows is moreover a reminder than advice, as the constructor is aware that the machine will be entrusted to an experienced operator.

Always respect the following precautions to ensure safe operation : Always check with the capacity chart to be aware of the maximum load that can be lifted at different boom lengths, boom angles and other parameters which must be taken into account when handling loads.

Always operate the machine using an engine speed which is adapted to the load to be handled.

Always use the lifting function to raise a load clear of the ground.

If the load has to be swung always keep it as close as possible to the machine and to the ground.

Always pay out rope when extending the boom or when lowering the boom to avoid two blocking (the hook block crashing into the boomhead).

Always raise the machine on outriggers before any operation. When lifting on tires always check with the load capacity chart beforehand.

Edition : 02/2001

IV ---D --- 1

Driving controls

Maintenance and operator’s manual

Preliminary checks Each day, before using the machine, run through checklist ”A” which can be found in section 4 of this manual.

Clean all windows, screens, lights and rear mirrors to ensure good all round visibility, as well as checking for correct adjustment. Adjust the driver’s seat so as to be comfortable and adapted for the person using the machine.

Checks to be carried out before starting the machine : --- Engine oil level --- Transmission oil level (gearbox) (oil warmed up).

--- Fuel level --- Hydraulic fluid level --- Engine coolant level --- Windshield wiper liquid level --- Make a visual check on the winch rope.

Starting up the engine Before starting up, make sure that there are no people or objects in the immediate vicinity of the engine.

1 --- Check that the gear selector is in the neutral position ”N” and that the engine stop control is reset.

2 --- Establish the contact with the ignition key in position 1.

The following warning lights come on on the control panel --- Battery charge warning light --- Air brake circuit pressure warning lights --- Engine oil pressure warning light --- Coolant temperature warning light --- Transmission anomaly warning light --- Air filter warning light --- Power assisted steering warning light --- Suspension lock warning light --- Parking brake light An audible signal is activated, wait until this signal ends.

3 --- Give a quick blast of the horrn 4 --- Parking brake applied 5 --- Turn key to position 2 to start the engine

NOTE : Engine start up can only be made if the gear selector is in the “N” neutral position

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Maintenance and operator’s manual

To avoid permanent damage to the starter motor, do not turn the engine over continually for more than 30 seconds. If the engine does not start during the first 30 seconds, wait a couple of minutes before trying again, but do not insist for more than 15 to 20 seconds.

If the engine still does not start, wait a further couple of minutes before retrying, also make sure that the gear selector is in the neutral position ”N” Once the engine has fired and is ticking over normally : The oil pressure and battery charge warning lights will go out.

The air pressure warning light will go out once pressure has reached 5,5 bar.

The parking brake warning light (ref. 6) stay on.

WARNING : Do not use the machine until the air pressure warning lights have gone out.

Using the machine in cold climates (less than ---10˚) To bring the equipment up to normal operating temperature. Switch on the cab heating to warm the control cab and defrost the machine.

After start up let the engine tick over at idling speed for about 20 minutes, gear selector in neutral position and parking brake applied.

Stopping the engine Let the engine slow down to idling speed a few moments before stopping the engine.

Activate the stop switch until the engine comes to a complete stop.

Switch off ignition with the key NOTE : The engine cannot be started if the gear selector is in any position other than neutral ”N”

IMPORTANT : Never stop the engine with the gear range selector in a position other than neutral ”N”

Never accelerate just before stopping the engine, the activated turbo compressor may be damaged through lack of lubrification.

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IV ---D --- 3

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Maintenance and operator’s manual

Highway driving Preliminary operations : Check the external dimensions of the machine with the machine configured for road circulation.

1 --- Make sure that the engine complies with all applicable road regulations.

2 --- Set down the counterweights on the chassis, retract the boom, position it over the front and set it down on the above mentionned counterweights.

In the 3 x 12T EUROPEAN CODE version, set down the chassis counterweights on the ground.

3 --- Attach the hook block to its cradle on the front of the carrier.

4 --- Make sure that : --- the turret to chassis locking device is in place.

--- the slewing function is braked.

--- rear wheel steering is disactivated.

--- the boom retainer sling is in place.

5 --- Make sure that the suspension is free (indicator light out).

6 --- Make sure that the outrigger ground pads are locked away in their storage position, and also the outrigger beams.

7 --- Check that all road lights work correctly.

8 --- Check tyre pressures (10 bar or 14.5 PSI).

9 --- Position the rear view mirrors and make sure that the driver, once in a seated position in the cab, can survey the full volume of his machine.

10 --- Make sure that all hoods are firmly closed.

11 --- Make sure that access ladders are folded away and secured.

12 --- To facilitate manoeuvres, always drive the machine with the boom in a lowered horizontal position and the hook block attached.

13 --- Never road drive the machine with a suspended load.

14 --- Never travel while carrying people on the upper.

15 --- Axle loading must not exceed 12.5 tons (13.8 US Tons) per axle.

16 --- Don’t let the machine gather too much speed.

17 --- Stopping on slopes : Apply the parking brake and chock the wheels if necessary.

18 --- Maximum speeds : 70 kph (43.5 mph) with 1400 x 25 tires.

76 kph (47 mph) with 1600 x 25 tires 76 kph (47 mph) with 20.5 x 25 tires 19 --- Make sure that all the roads on the itinerary accept the machine’s road dimensions and weight.

WARNING :Whenever highway driving is undertaken, it is essential that the driver makes certain that he has good all round visibility.

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Driving controls

Setting off --- gear selector : After having started the engine, --- Choose a gear range with keypad DANGER : Always make sure that the parking brake is applied (ref 4) whenever the machine is left unattended, even for a short time.

D

When this range is selected the machine will set off in 1st or 2nd gear and will automatically shift through up to 6th gear according to acceleration. When the machine slows down the transmission will automatically shift down to the most appropriate gear. This is the position when driving in normal road conditions.

3 -- 2 -- 1 Road, load and traffic conditions sometimes mean that gear ranges have to be limited. They also provide progressively more powerful engine braking in gradient driving conditions.

In 6 x 2 mode : D : This selection authorizes 2---3---4---5---6

3 : This selection authorizes 1---2---3 2 : This selection authorizes 1---2 1 : This selection authorizes 1 In 6 x 6 or 6 x 4 mode : D : This selection authorizes 1---2 3 : This selection authorizes 1---2 2 : This selection authorizes 1---2 1 : This selection authorizes 1 1st to 2nd gear changes must be made with the engine at idling speed. Engine speed must be reduced to allow this operation.

Changing down through gears : --- Before changing down, let the engine speed slow down .

--- Changing down a gear without respecting this instruction may lead to damaging the gearbox.

CAUTION :To avoid causing damage to the transmission always bring the machine to a halt before changing forward or reverse directions.

CAUTION :The machine should be brought to a standstill before changing the steering moder.

WARNING : Never freewheel the machine with the gearbox in Neutral as this can seriously damage the transmission.

Remember that there is no engine brake effect in neutral (N).

Edition : 02/2001

IV ---D --- 5

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Maintenance and operator’s manual

Downshifting Making downshifts means that a lower gear range is chosen to reply to driving conditions. Getting to know how to get the best out of downgrading will be helpful for better driving on snowbound or icy roads, as well as on steep gradients. Engine braking power is increased by downshifting. Choosing a lower range means avoiding repetitive gear changing on hilly roads.

Forward ---Reverse gear changing and downshifting safety devices Although there is no engine speed limit for upshifting, this is not the case when downshifting or changing to reverse drive. Downshifting should be avoided when engine speed exceeds the maximum speed for the next gear down. Therefore the system has been designed , when an attempt is made to make such a gear change, to inhibit such changes until the engine speed is reduced to the correct level.

Slow down the vehicle with the engine brake or the exhaust brake Downshift to use the engine brake. If the engine exceeds the maximum admissible speed for this range, use the exhaust brake or the road brakes to slow down. Engine braking allows speed to be controlled when driving down hills. When the vehicule is heavily loaded or on a steep gradient it is adviseable to select a lower range before reaching the summit of the hill.

WARNING : Do not select a gear range or change drive directions (forward---reverse and vice versa) when engine speed is greater than idling speed.

If the wheels are blocked and do not turn, do not fully accelerate during a period of at least 30 seconds.

IV ---D --- 6

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Driving controls

Jobsite driving Changing from carrier cab to upper cab Operations to be carried out : In the carrier cab.

Engine ticking over; --- Make sure that the gear selector, is in neutral ”N” --- Apply the parking brake.

--- Move the cab selection switch to the upper cab position.

The corresponding warning light comes on.

--- Block the suspension with control .

---Move the outrigger control into the outrigger position.

Outrigger manipulation from either side of the chassis is possible at this point.

In the upper cab.

Both handling and driving functions are available.

Rear axle steering is obtained by activating the lever switch.

The suspension can be locked or left free according to use of the machine.

Changing from the upper cab to the carrier cab Operations to be carried out: In the upper cab --- Prepare the machine for highway travel Lock the upper Lower and retract the boom Attach the pulley block to its cradle Line up the rear wheels with the chassis Inhibit rear axle steering Unlock the suspensions Apply the parking brake Make sure that the gear selector is in neutral ”N” Outrigger control in outrigger selection position to store away the outriggers.

WARNING : The greatest care must be taken when the upper is positioned with the boom over the rear of the chassis as directions are effectively inversed, forward drive becomes reverse drive and visa versa.

On the chassis : --- Put the ground pads into their storage position and lock them into place.(This operation is essential with 20.5 x 25 tires.)

--- Lock into place the retracted outrigger beams.

In the carrier cab : --- Place the cab selection switch into the carrier cab position --- Disactivate outrigger selection by control .

Edition : 02/2001

IV ---D --- 7

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Maintenance and operator’s manual

Conditions for using locked or unlocked suspensions Operating conditions : All axle suspensions must be locked for : --- Lifting on outriggers (360˚) with the wheels clear of the ground.

--- Lifting on tires in the centerline over the rear of the machine. ll axle suspensions must be released and the machine levelled for : --- For travelling on roads and jobsites.

--- For all---terrain travelling.

--- Respect tire inflation pressures (Road --- 10 bars or 14.5 PSI).

Eliminate oil pressure from the suspension circuit each evening by letting down the suspension with control. This drains the suspension rams and hydro---pneumatic accumulators which helps to reduce suspension circuit oil pollution.

Driving the machine with a suspended load.

--- Make sure that the load does not exceed the values indicated in the on tire handling capacity chart.

--- Keep the load as close as possible to the ground and carefully attach it with slings to the chassis to avoid swinging --- Respect tyre inflation.

--- Driving the machine with a suspended load should only be carried out on solid, flat horizontal ground.

--- The boom should be positioned over the rear of the machine in the longitudinal axis of the chassis, with the turret locked in position and slewing locked.

--- When driving the machine with a load the turret should never be slewed (turret locked in position) --- For maximum safety, extend the outriggers, lower the outrigger rams as for as possible .

MAXIMUM SPEED WHEN DRIVING THE MACHINE WITH A LOAD : 0,4 m/s (1.3 ft/s) IMPORTANT : Never use the manual accelerator to drive the machine, with or without a load. This control allows a minimum engine speed of 700 rpm.

IV ---D --- 8

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Driving controls

Hazards within the working area Be careful about power lines, bridges, railway lines, buildings and other cranes.

Arcing can be induced between a power line and the metal parts of the crane when they touch, or when they do not respect the minimal safety distance.

Power line voltage Minimum distance 0 to 1000 V 2 m (6.6 Ft) 1 KV to 110 KV 4 m (13 Ft) 110 KV to 220KV 5 m (16.4 Ft) 220 KV to 380KV 6 m ( 20 Ft) It is often very difficult to determine the voltage of a power line so we always recommend to keep a minimum distance of 6 m (20 Ft) Accidents are mostly caused by discharging.If a minimum distance of 6 m (20 Ft) cannot be respected ask the local electricity company to cut the power.

WARNING: The counterweights fitted must conform to the instructions in the booklet of load curves.

WARNING Any operator must become acquainted with the operating instructions described in this manual before using the machine.The operator is wholly responsible for machine operation.No liability will be accepted by the manufacturer if the instructions contained in this manual are not strictly respected.

Always be watchful. Never allow anybody in the working area. You must always know where they stand in the working zone.

It is forbidden to stand in the machine working area Avoid load swinging and abrupt maneuvers DANGER: Before any rotational movement, retract the cylinder of the lifting table so as to avoid all risk of collision with the turret.

Always respect the figures for boom length and reach given in the booklet of load curves.

Edition : 02/2001

IV ---D --- 9

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Maintenance and operator’s manual

A1 /Setting down the chassis counterweights To obtain a machine configuration of 2 x 12 t, the 1 300 kg counterweight and the 1 100kg+600 kg assembly must be put down on the ground. Only the 2 500 kg counterweight remains on the turret.

Visual indicators and controls used for this operation are : --- Ref. 260: Counterweight cylinders raise/lower control .

--- Ref. 261: Counterweight locking hooks lock / release control.

---

Locked/unlocked indicator flag.

Colour red/green.

--- Ref. 259 : Upperstructure slewing lock control.

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Maintenance and operator’s manual

Driving controls

A1 ---1/ Disassembly on to the chassis of counterweight(s) fixed to the turret.

Two possible set ---ups: Case 1: only the 1,300 kg counterweight (pined on the turret) must be deposited on the chassis.

Case 2: All the counterweights (1,100 kg + 600 kg) + 1,300 kg must be deposited on the chassis.

Turret with 2,500 kg counterweight

Securing pins 1,300kg pin---secured counterweight

Case 1

Case 2

DANGER: Before any rotational movement, retract the cylinder of the lifting table so as to avoid all risk of collision with the turret.

Edition : 02/2001

1,100 kg + 600 kg locking counterweight

In both cases the procedure is as follows: Carry out the cab change operations.

(See chapter: Driving).

Position machine with outriggers fully extended and wheels off the ground. On solid and horizontal ground.

Unstow pulley block if necessary.

Raise jib to clear it from its support.

Slew turret over rear of machine .

Once the turret is over the rear and on the axis of the machine, slew it to the left to an angle of 8˚30’.

To obtain this position, use the reference mark on the front of the turret; align the red arrow painted on the turret chassis with the painted screw head on the slewing ring. Lock turret in ”Fit counterweights” position using control no. 259 (8˚30’ left at rear).

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Maintenance and operator’s manual

At this stage in the operation: Case 1: Only the 1 300 kg counterweight is pinned on to the turret. The locking indicator flag shows green.

Case 2: the counterweight assembly is fixed to the turret and the locking indicator flag shows red.

Raise the counterweight lifting table using Control 260, holding it on until the whole movement is completed. Counterweights clamped under the turret.

Case 1: unpin the 1 300 kg counterweight from the turret.

Case 2: unpin the 1 300 kg counterweight from the turret.

Unlock the assembly (1 100 kg + 600 kg) from the turret by actuating Control 261, holding it on until the flag has turned right round to green position.

RED

WARNING: Lock/unlock counterweights, Control 261: Hold this control on until the locking or unlocking operation is completely finished.

GREEN

Before continuing the operation, make quite sure that the indicator flag is showing green..

Use control no. 260 to lower the lifting table and counterweight(s).

Hold the control in position until the lifting table has come all the way down. An audible warning will continue to sound until the table reaches low position.

Unlock turret slew.

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Maintenance and operator’s manual

DANGER: Before any rotational movement, retract the cylinder of the lifting table so as to avoid all risk of collision with the turret.

Driving controls

A1 ---2/ Removing counterweight(s) from the chassis on to the ground.

Slew turret to the front.

Place slings round the chassis counterweights.

Lift the chassis counterweights and slew the jib to lower them on to supports to facilitate slinging when they are to be lifted again.

DANGER: Slewing the turret with the boom fully raised and no load attached to the hook could cause the crane to tip backwards towards the counterweight.

This danger is increased with intermediate chocking or chocking at chassis level.

Always use the crane with its outriggers fully extended.

Edition : 02/2001

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Driving controls

Maintenance and operator’s manual

A2 / Removing counterweights to obtain a 2 x 12 t + 3% machine configuration.

(Machine without extension) To obtain a machine configuration of 2 x 12 t + 3%, the 1 300 kg counterweight and one of the 550 kg counterweight must be put down on the ground. Only the 2 500 kg + 250 kg counterweights remain on the turret. the 550 kg + 600 kg counterweights remain on the chassis.

Visual indicators and controls used for this operation are : --- Ref. 260: Counterweight cylinders raise/lower control .

--- Ref. 261: Counterweight locking hooks lock / release control.

---

Locked/unlocked indicator flag.

Colour red/green.

--- Ref. 259 : Upperstructure slewing lock control.

IV ---D --- 14

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Maintenance and operator’s manual

Driving controls

A2 ---1/ Disassembly on to the chassis of counterweight(s) fixed to the turret.

Two possible set ---ups: Case 1: only the 1,300 kg counterweight (pined on the turret) must be deposited on the chassis.

Case 2: All the counterweights 550 kg + 550 kg + 600 kg + 1,300 kg must be deposited on the chassis.

Turret with 2,500 kg+250 kg counterweights Securing pins

1,300kg pin---secured counterweight

Case 1

Case 2

DANGER: Before any rotational movement, retract the cylinder of the lifting table so as to avoid all risk of collision with the turret.

Edition : 02/2001

550 kg +550 kg + 600 kg locking counterweights

In both cases the procedure is as follows: Carry out the cab change operations.

(See chapter: Driving).

Position machine with outriggers fully extended and wheels off the ground. On solid and horizontal ground.

Unstow pulley block if necessary.

Raise jib to clear it from its support.

Slew turret over rear of machine .

Once the turret is over the rear and on the axis of the machine, slew it to the left to an angle of 8˚30’.

To obtain this position, use the reference mark on the front of the turret; align the red arrow painted on the turret chassis with the painted screw head on the slewing ring. Lock turret in ”Fit counterweights” position using control no. 259 (8˚30’ left at rear).

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Maintenance and operator’s manual

At this stage in the operation: Case 1: Only the 1 300 kg counterweight is pinned on to the turret. The locking indicator flag shows green.

Case 2: the counterweight assembly is fixed to the turret and the locking indicator flag shows red.

Raise the counterweight lifting table using Control 260, holding it on until the whole movement is completed. Counterweights clamped under the turret.

Case 1: unpin the 1 300 kg counterweight from the turret.

Case 2: unpin the 1 300 kg counterweight from the turret.

Unlock the assembly (1 100 kg + 600 kg) from the turret by actuating Control 261, holding it on until the flag has turned right round to green position.

RED

WARNING: Lock/unlock counterweights, Control 261: Hold this control on until the locking or unlocking operation is completely finished.

GREEN

Before continuing the operation, make quite sure that the indicator flag is showing green..

Use control no. 260 to lower the lifting table and counterweight(s).

Hold the control in position until the lifting table has come all the way down. An audible warning will continue to sound until the table reaches low position.

Unlock turret slew.

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Maintenance and operator’s manual

DANGER: Before any rotational movement, retract the cylinder of the lifting table so as to avoid all risk of collision with the turret.

Driving controls

A ---2 ---2/ 2 x 12 t + 3% machine Removing counterweight(s) from the chassis on to the ground.

Slew turret to the front.

Place slings round the 550 kg turret conterweight and 1,300 kg counterweight together.

Lift the counterweights and slew the jib to lower them on to supports to facilitate slinging when they are to be lifted again.

Edition : 02/2001

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Driving controls

Maintenance and operator’s manual 1300 kg pinned counterweight + 550 kg counterweight to be placed

600 kg + 550 kg counterweight that remain on the chassis

DANGER: Slewing the turret with the boom fully raised and no load attached to the hook could cause the crane to tip backwards towards the counterweight.

This danger is increased with intermediate chocking or chocking at chassis level.

Always use the crane with its outriggers fully extended.

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Maintenance and operator’s manual

WARNING: The counterweights fitted must conform to the instructions in the booklet of load curves.

Driving controls

B / Removing counterweights to obtain a 2 x 13 t machine configuration To obtain a 2 x 13 t machine configuration, the 600 kg and 1,100 kg counterweights must be put down on the ground. Only the 3,200 kg counterweight remains on the turret, with the 600 kg on the front of the chassis.

The controls used for this operation will be: ---

No. 260: Counterweight cylinders up/down control.

---

No. 261: Counterweight lock/unlock control

--Locked/unlocked indicator flag.

Colour red/green.

--- No. 259: Turret slewing inhibitor control.

In ”Fit counterweights” position.

Edition : 02/2001

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Maintenance and operator’s manual

B ---1/ Disassembly on to the chassis of counterweight(s) fixed to the turret.

Two possible set ---ups: Case 1: only the 600 kg counterweight is pinned to the turret and must be deposited on the chassis.

Case 2: the 600 kg counterweight is pinned to the turret and the 1,100 kg + 600 kg assembly is pinned to the turret and they must all be deposited on the chassis.

Turret with 3,200 kg counterweight Securing pins

Pin---secured 600 kg counterweight

Case 1

Case 2

DANGER: Before any rotational movement, retract the cylinder of the lifting table so as to avoid all risk of collision with the turret.

IV ---D --- 20

1,100 kg + 600 kg locking counterweight

In both cases the procedure is as follows: Carry out the cab change operations.

(See chapter: Driving).

Position machine with outriggers fully extended and wheels off the ground. On solid and horizontal ground.

Unstow pulley block if necessary.

Raise jib to clear it from its support.

Slew turret over rear of machine .

Once the turret is over the rear and on the axis of the machine, slew it to the left to an angle of 8˚30’.

Use the reference marks to obtain this position.

Lock turret in ”Fit counterweights” position using control no. 259 (8˚30’ left at rear).

Edition : 02/2001

Driving controls

Maintenance and operator’s manual At this point in the operation:

Case 1: Only the 600 kg counterweight is pinned on to the turret. The locking indicator flag shows green.

Case 2: the counterweight assembly is fixed to the turret and the locking indicator flag shows red.

Raise the counterweight lifting table using Control 260, holding it on until the whole movement is completed. Counterweights clamped under the turret.

Case 1: unpin the 600 kg counterweight from the turret.

Case 2: unpin the 600 kg counterweight from the turret.

Unlock the assembly (1 100 kg + 600 kg) from the turret by actuating Control 261, holding it on until the flag has turned right round to green position.

RED

WARNING: Lock/unlock counterweights, Control 261: Hold this control on until the locking or unlocking operation is completely finished.

GREEN

Before continuing the operation, make quite sure that the indicator flag is showing green.

Use control no. 260 to lower the lifting table and counterweights.

Hold the control in position until the lifting table has come all the way down. An audible warning will continue to sound until the table reaches low position.

Unlock turret slewing.

Edition : 02/2001

IV ---D --- 21

Driving controls DANGER: Before any rotational movement, retract the cylinder of the lifting table so as to avoid all risk of collision with the turret.

Maintenance and operator’s manual

A ---2/ Removing counterweight(s) from the chassis on to the ground.

Slew turret to the front.

Place slings round the 600 kg turret conterweight and 1,100 kg counterweight together.

Lift the counterweights and slew the jib to lower them on to supports to facilitate slinging when they are to be lifted again.

600 kg pinned counterweight + 1,100 kg counterweight to be placed

600 kg counterweight that remains on the chassis

IV ---D --- 22

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Maintenance and operator’s manual WARNING: The counterweights fitted must conform to the instructions in the booklet of load curves.

Driving controls

C / Fitting pin---secured counterweight to the turret 2 x 12 t machine (+3%): 1,300 kg pin---secured counterweight.

2 x 13 t machine: 600 kg pin---secured counterweight.

Turret with counterweight Securing pins

Pin---secured counterweight

DANGER: Before any rotational movement, retract the cylinder of the lifting table so as to avoid all risk of collision with the turret.

In both cases the procedure is as follows: Carry out the cab change operations.

(See chapter: Driving).

Position machine with outriggers fully extended and wheels off the ground. On solid and horizontal ground.

Unstow pulley block if necessary.

Raise jib to clear it from its support.

Slew turret over rear of machine .

Once the turret is over the rear and on the axis of the machine, slew it to the left to an angle of 8˚30’.

To obtain this position, use the reference mark on the front of the turret; align the red arrow painted on the turret chassis with the painted screw head on the slewing ring.

Lock turret in ”Fit counterweights” position using control no. 259 (8˚30’ left at rear).

At this stage in the operation, no counterweights are fixed to the turret and the locking indicator flag shows green.

Raise the counterweight lifting table with control no. 260, holding the control in position until the lifting table is in contact with the turret.

Edition : 02/2001

IV ---D --- 23

Driving controls

Maintenance and operator’s manual

When the table is pressed firmly against the turret, pin the 600 kg or 1,300 kg counterweight, as the case may be, to the turret counterweight and give a quarter turn to the pins to make them safe against slipping out.

The locking indicator flag shows green.

Use control no. 260 to lower the lifting table with the 1,100 kg + 600 kg counterweight assembly.

Hold this control in position until the lifting table has come all the way down.An audible warning will continue to sound until the table reaches low position.

Unlock turret slewing.

Pin in locked position after pinning Pin in position for pinning

IV ---D --- 24

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Maintenance and operator’s manual WARNING: The counterweights fitted must conform to the instructions in the booklet of load curves.

Driving controls

D / Fitting all the counterweights to the turret This operation consists in fixing all the counterweights on the chassis to the turret.

2 x 12 t (+3%) machine: 1,300 kg counterweight + assembly of 1,100kg or (550 kg+550 kg) + 600 kg counterweights.

2 x 13 t machine: 600 kg counterweight + assembly of 1,100 + 600 kg counterweights.

Turret with 3,200 or 2,500 kg or ( 2500 kg + 250 kg) counterweight Securing pins

Pin---secured 600 kg or 1,300 kg counterweight

1,100 kg or (550 kg + 550 kg) + 600 kg locking counterweight

DANGER: Before any rotational movement, retract the cylinder of the lifting table so as to avoid all risk of collision with the turret.

Edition : 02/2001

Carry out the cab change operations.

(See chapter: Driving).

Position machine with outriggers fully extended and wheels off the ground. On solid and horizontal ground.

Unstow pulley block if necessary.

Raise jib to clear it from its support.

Slew turret over rear of machine .

Once the turret is over the rear and on the axis of the machine, slew it to the left to an angle of 8˚30’.

To obtain this position, use the reference mark on the front of the turret; align the red arrow painted on the turret chassis with the painted screw head on the slewing ring.

Lock turret in ”Fit counterweights” position using control no. 259 (8˚30’ left at rear).

At this stage in the operation, no chassis counterweights are fixed to the turret and the locking indicator flag shows green or must be brought back to the green position.

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Maintenance and operator’s manual

WARNING: Make sure that the sockets of the lockable counterweight twistlock are not obstructed (by ice, snow, dirt, etc.).

Raise the counterweight lifting table with control no. 260, holding the control in position until the counterweights are in contact with the turret.

When the counterweights are correctly positioned against the turret, pin the 600 kg or 1,300 kg counterweight, as the case may be, to the turret and give a quarter turn to the pins to make them safe against slipping out.

Before continuing the operation, make perfectly certain that the pins are properly turned to make them safe against slipping out.

Pin in locked position after pinning Pin in position for pinning

When the 600 kg or 1,300 kg counterweight is pinned to the turret, lock the 1,100 kg + 600 kg counterweight assembly by means of control no. 261.

The locking flag shows red.

WARNING: Lock/unlock counterweights, Control 261: Hold this control on until the locking or unlocking operation is completely finished.

Before continuing the operation, make perfectly certain that the locking flag shows red.

Lower the lifting table by means of control no. 260.

Hold this control in position until the lifting table has come all the way down. An audible warning will continue to sound until the table reaches low position.

Unlock turret slewing.

IV ---D --- 26

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Maintenance and operator’s manual

Driving controls

E/ Disassembling all the counterweights on to the chassis DANGER: Before any rotational movement, retract the cylinder of the lifting table so as to avoid all risk of collision with the turret.

This operation consists in fixing all the removable counterweights to the chassis.

Carry out the cab change operations.

(See chapter: Driving).

Position machine with outriggers fully extended and wheels off the ground.

Unstow pulley block if necessary.

Raise jib to clear it from its support.

Slew turret over rear of machine.

Once the turret is over the rear and on the axis of the machine, slew it to the left to an angle of 8˚30’.

To obtain this position, use the reference mark on the front of the turret; align the red arrow painted on the turret chassis with the painted screw head on the slewing ring.

Lock turret in ”Fit counterweights” position using control no. 259 (8˚30’ left at rear).

At this stage in the operation, all the counterweights are fixed to the turret and the locking indicator flag shows red.

Raise the counterweight lifting table with control no. 260, holding the control in position until the lifting table is in contact with the counterweights.

When the lifting table is pressing firmly against the counterweights, unpin the 600 kg or 1,300 kg counterweight, as the case may be, to release it from the turret, and turn the pins to enable them to slide out.

Before continuing the operation, make quite certain that the pins have been removed..

Pin in locked position after pinning.

Pin in position for pinning

Edition : 02/2001

IV ---D --- 27

Driving controls

Maintenance and operator’s manual

When the 600 kg or 1,300 kg counterweight has been unpinned from the turret, unlock the 1,100 kg + 600 kg counterweight assembly by means of control no. 261.

The locking flag shows green.

WARNING: Lock/unlock counterweights, Control 261: Hold this control on until the locking or unlocking operation is completely finished.

Before continuing the operation, make quite sure that the locking flag shows green.

Lower the lifting table with the counterweights using control no. 260.

Hold this control in position until the lifting table has come all the way down. An audible warning will continue to sound until the table reaches low position.

Unlock turret slewing.

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Maintenance and operator’s manual

Driving controls

Taking a counterweight from a trailer.

Carry out the cab change operations.

(See chapter ”Driving”.)

Outriggers should be fully extended, and wheels off the ground.

Unstow the pulley block Raise the boom.

DANGER: Slewing the turret with the boom fully raised and no load attached to the hook could cause the crane to tip backwards towards the counterweight.

This danger is increased with intermediate chocking or chocking at chassis level.

Always use the crane with its outriggers fully extended.

Bring the transport trailer up as close as possible to the crane.

Before handling, check the counterweights as follows: check general condition; any damaged counterweights must be replaced, check the sling points. check the weight of the counterweights, check the stacking order of the counterweights. make sure that the sockets of the lockable counterweight twistlock are not obstructed (by ice, snow, dirt, etc.) make sure that no objects, tools or foreign bodies have been left on the counterweights.

Make sure that the counterweight lifting table is in low position and has no tools or other objects lying on it.

Sling the counterweights. WARNING: choose appropriate sling points according to the type of counterweight assembly to be lifted.

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IV ---D --- 29

Driving controls

Maintenance and operator’s manual

Lift the counterweights and slew the boom to deposit them on the lifting table.

Remove the slings.

Slew the turret over the rear of the machine.

Lock the turret in ”Fit counterweights” position (8˚30’ rear left). Use the painted reference marks to reach this position.

Lift the counterweights right up with the table (see chapter ”Driving”).

Lock the counterweights to the turret with the two locking pins.

Turn the two locking pins to safety position.

Lower the 1 100 kg chassis counterweight if necessary or lock it to the turret (see chapter ”Driving”).

Driving the machine with all its counterweights.

For movement on the road within the European Community and without special authorization, the load per axle must be equal to or less than 13 tonnes for FRANCE and SPAIN and 12 tonnes for the other countries.

Fitting all the counterweights increases the axle load of the machine.

For this reason, the machine may be driven with all its counterweights only off the public highway or in countries which impose no restrictions on axle loads.

To drive the machine under these conditions, the load has to be distributed.

Turret: 2 500kg or 3 200 kg counterweight according to model.

Chassis: on the counterweight table, all the other counterweights.

For travelling, the boom must be retracted and resting on its support with its retaining sling fitted. This position will ensure that the counterweights are kept in place.

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Maintenance and operator’s manual

Driving controls

Boom Telescoping Telescoping under load is possible to a limit of 75% of capacity chart indications and to a maximum weight of 8 tons (8.8 US Tons) The precision of this function is, however, less accurate than those of winching or derricking, because it depends upon the mechanical efficiency of the boom ( pad friction).

Pad friction depends upon : --- Lubrification --- The derricking angle of the boom --- The weight of the load lifted ( refer to capacity chart).

During BOOM EXTENSION very poor efficiency will be marked by the boom coming to a halt, when the maximum pre---adjusted pressure for the telescoping function is reached.

To re---enable the function, set down the load and readjust the boom in a more favourably geometric configuration.

During BOOM RETRACTION very poor efficiency will be marked by a sudden movement in the function over a distance of up to 50cm (1.6 Ft) CAUTION : To avoid reaching these limits : -- regularly grease the areas upon which the pads slide -- respect the radii, angles and equivalent loads indicated by the capacity charts.

Recommendation : Never completely extend the boom horizontally, if it is not possible to derrick the boom to around 30ø ( corresponding minimum angle for correct boom retraction ) WITHOUT LOAD BOOM LIMIT DANGER : FREE ON WHEELS OR OUTRRIGGERS EXTENDED, DO NOT OVERPASS WITHOUT LOAD, the maximum boom lengths and radius as showned in the load charts.

Edition : 02/2001

IV ---D --- 31

Driving controls

Maintenance and operator’s manual

In case of breakdown it is possible to tow the machine over a short distance ( less than 10km --- 6.2 miles) at a reduced speed ( less than 10 kmh --- 6.2 miles/h) using a towing bar.

--- Place the gear selector in the Neutral position --- Place the gear range selector in the Neutral position.

--- Release the parking brake on the front axle by compressing the air bottle springs by tightening the bolts on the brake cylinders.

The service brakes, fed by the remaining air reserves, are not affected by this operation.

The towing---hook is at the front of the carrier. It should only be used in compliance with local road regulations. Maximum horizontal traction force on the hook is 15 tons (16.5 US Tons). If the crane is bogged down use the specially designed towing rings which are located on the rear corners of the carrier. We advise you to use them in pairs.

Towing

IV ---D --- 32

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Maintenance and operator’s manual

Driving controls

Positions of the rear underrun bumper

Position 1 Position 2 Position 3

Edition : 02/2001

Position 1: Road travel with spare wheel.

Position 2: Road travel without spare wheel.

Position 3: Off road travel

IV ---D --- 33

Driving controls

IV ---D --- 34

Maintenance and operator’s manual

Edition : 02/2001

Driving controls

Maintenance and operator’s manual

Seat

1 / Headrest, adjustable 1 2 3 4 5

2 / Seat and backrest 3 / Armrest 4 / Horizontal adjustment (upper part ) 5 / Heigt and slope (front) 6 / Locking system for console

6 7 8

7 / Weight adjustment 8 / Horizontal adjustment ( complete seat ) 9 / Automatic lapbelt

9 10

10 / Backrest adjustment 11 / Height and slope ( rear )

11

Edition : 04/2001

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Maintenance and operator’s manual

Driving controls

Operation For easy access to the seat the rear control console can be released upwards. Once sitting in the operating position, the armrest console can be pushed downwards to lock in the original working position.

The fine backrest adjustment mechanism provides a simple and quick method for finding the optimal working position.

To provide the operator with a comfortable position for his forearms in relation to the operating controls, slide adjustment lever is located underneath the seat cushion to give the required adjustment.

In addition to the above the seat cushion can also be adjusted for height and slope, without leaving the seat, by simple controls located at the front and rear of the seat cushion.

To provide the operator with the correct operating position in relation to the cab control pedals, a second slide lever is located on the base of the seat to give the required adjustment.

Finally for the optimal driving/operating position the padded armrests located on the consoles can be adjusted in height and width by the fixing screws and locating them in the alternative position provided.

Reignition procedure for the gas oil circuit in a machine equipped with bi ---fuel Engine: --- dismantle the suction connection and return connection.

--- bring up the diesel fuel with the hand pump.

--- collect it in a container.

--- continue pumping until all air is eliminated from the flow --- refit connectors, checking leaktightness.

Starting up: --- start the engine --- let it run for 1/4 hour on diesel, then switch over to fuel oil.

In case of difficulty, repeat the purging operation on the engine.

WARNING: It is essential to keep a ”consumption” record of amounts of domestic fuel oil used by the vehicle if it is fitted with the dual fuel device.

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Maintenance and operator’s manual

Driving controls

Main winch and auxiliary winch operation DANGER : The LMI unit cannot control load handling operations using two hook blocks at the same time and therefore totally safe handling cannot be ensured. Any handling operations undertaken with two hook blocks in use WILL BE CARRIED OUT UNDER THE FULL RESPONSABILITY OF THE CRANE OPERATOR OR THE WORKSITE MANAGER. PPM CAN IN NO WAY BE HELD RESPONSIBLE FOR ANY ACCIDENT OR INCIDENT WHICH MAY OCCUR WHEN THE CRANE IS OPERATED WITH TWO HOOK BLOCKS IN USE.

Dual hook block operation consists of handling a single load using the main boom hook block along with the extension hook block.

Before dual winch handling, it is essential to verify that the load can be handled by the extension hook block alone. Check with the rating manual to see if this is possible.

Raise the machine on fully extended outriggers and position the upper in the centreline of the machine over the rear.

The LMI unit can only operate correctly when working with a single hook block at any one moment (either the main boom or the extension). When operations are undertaken using two hook blocks the RCI unit must be programmed in the extension handling mode.

Adjust the LMI unit for working with the extension.

When a load is to be lifted by two hook blocks at the same time, the maximum authorized load to be considered is that which can be handled by the extension with a single hook block.

Refer to the ratings manual.

The radius depends on the extension being used. Refer to the ratings manual with extension. The value indicated by the LMI unit will be the value relative to the programmed extension.

Working with both hook blocks at the same time can lead to overloading of the boom and the extension and may provoke accidents. The LMI unit is not 100% efficient in this configuration.

The authorized handling operation, under the responsability of the crane operator or the worksite manager, consists of turning over a load using the two hook blocks one after the other, as illustrated below.

Edition :

04/2001

IV---G--- 1

Driving controls

Maintenance and operator’s manual

Use the extension hook block to lift the load (as this is the weaker element).

Lift the load with the extension hook block.

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Maintenance and operator’s manual

Driving controls

Pivot the load to a hrizontal position by using the main boom winch.

CAUTION : As soon as the main boom winch takes up the load to bring it to a horizontal position, values indicated by the LMI unit are false.

Edition :

04/2001

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Driving controls

Maintenance and operator’s manual

Never lower the boom when carrying out handling operations using both hook blocks. The RCI unit can no longer control overload conditions. This is why the load must always correspond to the maximum admissible load for the greatest radius.

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

All manoeuvers must be executed in a smooth and steady manner without jolting.

Main hook block reeving must be superior or at least equal to that of the extension hook block.

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Maintenance and operator’s manual

Driving controls

Working with the main boom hook block and the auxiliary boom head hook block DANGER : The LMI unit cannot control load handling operations using two hook blocks at the same time and therefore totally safe handling cannot be ensured. Any handling operations undertaken with two hook blocks in use WILL BE CARRIED OUT UNDER THE FULL RESPONSABILITY OF THE CRANE OPERATOR OR THE WORKSITE MANAGER. PPM CAN IN NO WAY BE HELD RESPONSIBLE FOR ANY ACCIDENT OR INCIDENT WHICH MAY OCCUR WHEN THE CRANE IS OPERATED WITH TWO HOOK BLOCKS IN USE. Dual hook block operation consists of handling a single load using the main boom hook block along with the auxiliary boom head hook block.

Check that the load can be lifted by a single line hook block before starting any handling operations.

Refer to the ratings manual if possible.

Raise the machine on fully extended outriggers and position the upper in the centreline of the machine over the rear. Apply the free slewing brake.

The LMI unit can only operate correctly when working with a single hook block at any one moment (either the main boom or the extension).

When operations are undertaken using the auxiliary boom head the LMI unit must be programmed in the single line hook block mode.

Adjust the LMI unit for working with one single line.

Edition :

04/2001

IV---G--- 5

Driving controls

Maintenance and operator’s manual

CAUTION : The radius indicated by the LMI unit is no longer exact because the auxiliary boom head is not taken into consideration.

In case of breakdown it is possible to tow the machine over a short distance ( less than 10km --- 6.2 miles) at a reduced speed ( less than 10 kmh --- 6.2 miles/h) using a towing bar.

--- Place the gear selector (ref. 6) in the Neutral position --- Place the gear range selector (ref. 80) in the Neutral position.

--- Release the parking brake on the front axle by compressing the air bottle springs by tightening the bolts on the brake cylinders.

The service brakes, fed by the remaining air reserves, are not affected by this operation.

IV ---G--- 6

Edition : 04/2001

Maintenance and operator’s manual

Driving controls

Changing a wheel 1 --- Slightly slacken the wheel---nuts 2 --- Extend the outriggers to support the crane and raise the wheels just off the ground.

3 --- Unscrew wheel---nuts and remove wheel 4 --- Use the hook to bring the spare wheel down from its support.

5 --- Fit the new wheel and screw up the wheel---nuts without tightening them.

6 --- Retract the outriggers and finish tightening the wheel---nuts (tighten nuts in opposing pairs). Tightening torque 65 m/Kg. 7 --- Retighten the wheel---nuts after 16 hours operation.

The crane is equipped with an inflation point (on the left ---hand side of the machine) and an inflation kit (hoses, pistol grip, pressure gauge).

Edition :

04/2001

IV---H--- 1

Driving controls

Maintenance and operator’s manual

Putting the spare wheel on the ground.

· Attach the hoist hook · Hook up the spare wheel using the hoist chain.

· Apply light tension to the chain. · Undo the attachment screws on the spare wheel. · Remove the wheel from its stand. · Lower the spare wheel to the ground using the hoist.

IV---H--- 2

Edition : 04/2001

Maintenance and operator’s manual

Driving controls

Fitting the spare wheel to its stand.

· Attach the hoist hook to the bracket. · Hook up the spare wheel using the hoist chain.

· Lift the spare wheel using the hoist to bring it to the same level as its stand. · Put the spare wheel on its stand. · Attach the spare wheel to the undercarriage using the two screws. · Remove the chain from the spare wheel.

Edition :

04/2001

IV---H--- 3

Driving controls

Maintenance and operator’s manual

· Unhook the hoist from the bracket.

IV---H--- 4

Edition : 04/2001

Driving controls

Maintenance and operator’s manual

Setting up the machine on outriggers Recommendations : Raise the machine on outriggers on solid and, if possible, horizontal ground.

If the ground is sloping, make the machine horizontal by using heavy hard wooden blocks, and by adjusting the extension of the lifting ram piston rods. The ground surface of the wooden blocks must be greater than the surface of the ground pads or the full ground surface of loaded tyres.

The machine must ALWAYS be raised on FULLY EXTENDED OR INTERMEDIATELY EXTENDED OUTRIGGERS WHEELS CLEAR OF THE GROUND.

Incorrect

Incorrect

Incorrect

Correct WARNING :If an obstacle hinders the extension of one or more outrigger beams the machine can be raised by simply extending the affected outriggers’ vertical lifting cylinders. In such a case the STABILITY OF THE MACHINE IS REDUCED TO AN UNKNOWN DEGREE AND THE ON TIRE LOAD CAPACITY CHART SHOULD BE ADOPTED AS THE REFERENCE FOR LOAD HANDLING.

Edition : 04/2001

IV---J--- 1

Driving controls

Maintenance and operator’s manual

On fully retracted beams

VERY IMPORTANT The intermediate and fully extended outrigger positions are only correct if the outrigger beams are locked with their locking pins.

DO NOT FORGET TO REMOVE the locking pins before extending or retracting the outrigger beams.

Intermediately extended beams

VERY IMPORTANT

Fully extended outriggers

VERY IMPORTANT

IV---J--2

Edition : 04/2001

Driving controls

Maintenance and operator’s manual

Ground stability Evaluate the ground stability in the area where the crane will work. Make sure that the ground is firm enough to support the crane. Avoid soft, unstable or partly frozen terrains.

When working near trenches : The machine should not be positioned just next to trenches and embankments, respect sufficient safety distances according to ground conditions.

Safety distances : Solid, non---granular terrain, Distance 1 = Depth of trench Granular or backfilled terrain, Distance 2 = Twice the depth of trench.

Depth of trench

WARNING :If the machine works near a trench and the minimum safety distance cannot be respected the trench should be shored or refilled to avoid any risk of caving in.

The working surface must be able to support the weight of the crane and the load to be handled as well as dynamic stresses exerted by crane movements and winds.Maximum pressure exerted on the ground by the outrigger pads is influenced by the geometry of the crane and the load being handled.

The operator, following values indicated on the chart, can decide whether the outrigger ground pads alone are sufficient, or if it is necessary to place large, thick planks under them. The ground pads must always be positioned in the centre of any additional support.

Edition : 04/2001

IV---J--- 3

Maintenance and operator’s manual

Driving controls

Chart indicating acceptable ground pressures for different types of terrains.

Necessary load bearing area = *Bearing stress Ground bearing capacity * Bearing stress is determined on the outrigger ground pad and on tire bearing stress table which is part of the load capacity charts booklet..

daN/cm2 (Kgcm2)

LbS/SqInch

0,5-- 1

1-- 15

Granular but stable terrain: Average to fine grain sand Large grain sand to gravel

1,5 2,0

20 30

Non granular terrain : Very soft Soft Compact Semi-- rigid Hard

0 0,4 1,0 2,0 4,0

6 15 30 60

15 30

210 430

5-- 15

70-- 210

50-- 250 350-- 550

700-- 3500 5000-- 7800

Types of terrain Type A

Backfilled, naturally settled terrain

Type B

Original untouched terrain

Rock with little cracking in good condition, unaltered by atmospheric influences and with good bedding conditions : Tight bedding, Compact bedding or in columns Type C

Artificially compacted terrain Asphalt, bitumen Concrete: Groupe BI Groupe BII

If you have any doubt about ground stability it is essential to carry out a soil analysis test.

IV---J--4

Edition : 04/2001

Maintenance and operator’s manual

Driving controls

Unstoring and storing the hook block Unstoring the hook block The following conditions must be met : --- Completely retracted boom set down on its support.

--- Hook block attached to the hook block support at the front of the machine by two balancer slings and a retainer sling.

Method : --- Get into the upper cab.

--- Start up the engine.

--- Override the two block safety device. (As the the safety device counterweight is not freely suspended at the end of its chain the device will inhibit the function).

--- Pay out some rope line (Load lower control ) by raising the boom (boom raise control ).

CAUTION : Make sure that the retainer sling does not become taut. This is achieved when the operator is sat in the turret cab seat and the top of the hook block is maintained at the level of the carrier cab roof.

--- Release the override function as soon as the two block safety device counterweight is normally suspended from its cable.

--- Raise the boom (Refer to the RCI display). Pay out rope line as necessary to maintain the hook block in its present position.

--- Remove the two balancer slings which attach the hook block to its support.

CAUTION : Make sure that the retainer sling does not become taut. This is achieved when the operator is sat in the turret cab seat and the top of the hook block is maintained at the level of the carrier cab roof.

--- The cable is in a vertical position when the boom has reached, at this moment the hook block can be freed from the retainer sling which attaches it to the support.

Edition : 04/2001

IV--- 5

Driving controls

Maintenance and operator’s manual

Storing the hook block Elingues d’équilibrage

Elingue d’accrochage

--- Completely retract the boom.

--- Derrick the boom .

--- Lower the hook block to the level of its support.

--- Fit the retainer sling.

--- Fit the two balancing slings.

--- Lower the boom (Derrick down control ), and wind in the cable (Load raise control ) to bring the boom to a horizontal position on its support.

CAUTION : Taking up cable slack must be carried out with the greatest care so as not to damage the hook block.

This is achieved when the operator is sat in the turret cab seat and the top of the hook block is maintained at the level of the carrier cab roof.

--- As soon as the two block safety device is no longer suspended at the end of its sling the load raise function will be inhibited. Override the safety device to finish the operation.

--- Gently take up slack on the cable.

CAUTION : Do not put strain on the retainer sling.

This is achieved when the operator is sat in the turret cab seat and the top of the two block safety device counterweight is maintained at the level of the carrier cab roof.

To complete taking up slack on the slings bring the the two block safety device counterweight into slight contact with the dead end of the hoist cable from the cable bracket housing.

IV--- 6

Edition :

04/2001

Controls and operation Operation and maintenance manual

FOLDING AND UNFOLDING THE EXTENSION. Machine equipped with an 8 m extension.

Unfolding the 8m extension.

DANGER: Always use a safety harness when performing assembly work more than 3 m (10 ft) above ground level.

A single ladder may be used provided that it is secured in place and the top 4 rungs are not used.

Use an extendable ladder, a stepladder or a pod that meets applicable safety standards.

A - Positioning the machine Choose a manoeuvring area large enough to deploy the 8 m extension.

DANGER : It is strictly forbidden to telescope the boom whilst the extension is being unfolded.

The boom should be fully retracted and must be horizontal.

Failure to follow these instructions may cause the extension to be deployed accidentally while it is being unlocked and so increase the risk of an accident.

Machine fixed with outriggers fully extended, on flat, firm, level ground, with wheels raised off the ground.

Raise the boom and slew the turret over the rear of the machine

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Controls and operation Operation and maintenance manual Unreeve the main pulley block.

At the boom head, remove the top end-of-travel counterweight by unscrewing the shackle attaching the counterweight chain to the cable of the unit.

Remove the rope guides at the boom head to unreeve.

So that the cable may go over the extension and so that the wedge socket may be secured, unwind the cable by about 15 m.

Pass the cable over the left-hand side of the boom.

B - Deploying the boom head-member support arm Deploy the boom head-member support arm and fix it with the locking pin.

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Controls and operation Operation and maintenance manual C -Pinning the foot of the 8 m extension to the boom head Remove the two pins from the upper and lower forks and place them in readiness on the top plate.

D - Releasing the 8 m extension.

Attach the rope to control deployment.

Pivot the extension around the pivot (C) to align the forks of the 8 m extension with the lugs of the boom head.

For safety reasons, attach the rope to the chassis. The extension must remain on its support.

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Controls and operation Operation and maintenance manual The travel stop keeps the extensions on the support arm.

E – Pinning the 8 m extension to the boom head.

Secure the 8 m extension to the boom head with the two pins that were removed from the forks earlier and placed on the upper frame.

DANGER: The tilt-adjustment pins must never be used to secure the extension to the boom head under any circumstances as this will cause the extension to collapse.

Tilt-adjustment pins.

Locking pins.

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Controls and operation Operation and maintenance manual CAUTION: Do not confuse these locking pins with the two tiltadjustment pins.

The two extension tilt-adjustment pins are located in a DANGER warning sign.

Do not touch the tilt-adjustment pins located in the DANGER warning sign.

.

Insert pin (D). (Coupling at top of boom head.)

Insert pin (E).(Coupling at bottom of boom head.)

DANGER : Always refit the safety clips on the pins after reinsertion.

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Controls and operation Operation and maintenance manual

F - Pivoting the 8m extension DANGER: Before the square of the pivot is moved to release the extension, it is vital that the extension should be fixed to the boom head by the pins E and D. If this instruction is not obeyed, the extension may fall.

Using the crank stored against the 8 m extension, manipulate the square of pivot (C) to release the extension from the boom foot.

Removal of the crank from the pivot is strictly prohibited.

To make it easier to pivot the extension, incline the machine 1.5° to the left by retracting the blocking rams of the left outriggers.

Use the handling bar to disengage the travel stop, and at the same time pivot the extension by hand, keeping control by means of the rope. Replace the crank in its storage position

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Controls and operation Operation and maintenance manual The handling bar unlocks the safety travel stop securing the boom extension to the support arm.

Travel stop locked.

Travel stop unlocked.

Replace the crank in its storage position.

On the left-hand side of the boom: Insert the locking pin and safety clips (G).

(Bottom coupling of boom head)

Insert the fixing pin and safety clips (F).

(Coupling at top of boom head.)

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Controls and operation Operation and maintenance manual At the boom head, feed the lifting rope through the extension pulley.

Put the rope guides at the boom head back in position.

At the head of the 8 m extension, use the shackle to fix the counterweight chain to the cable of the end-of-travel unit.

Pass the rope through the top end-of-travel counterweight.

Re-reeve, using the appropriate pulley block.

The 8 m extension is deployed.

The extension is now in its working configuration with a 0° inclination.

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Controls and operation Operation and maintenance manual G - Electrical connections.

Make the electrical connection between the boom head and the foot of the 8 m extension to supply power to the lifting end-of-travel unit.

At the head of the 8 m extension, connect the lifting end-of-travel unit and secure into place.

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Controls and operation Operation and maintenance manual

Stowing the 8 m extension DANGER: Always use a safety harness when performing assembly work more than 3 m (10 ft) above ground level.

A single ladder may be used provided that it is secured in place and the top 4 rungs are not used.

Use an extendable ladder, a stepladder or a pod that meets applicable safety standards.

A - Positioning the machine Choose a manoeuvring area large enough to enable stowage of the 8 m extension.

DANGER : It is strictly forbidden to telescope the boom whilst the extension is being unfolded.

The boom should be fully retracted and must be horizontal.

Failure to follow these instructions may cause the extension to be deployed accidentally while it is being unlocked and so increase the risk of an accident.

Machine fixed with outriggers fully extended, on flat, firm, level ground, with wheels raised off the ground.

Raise the boom and slew the turret over the rear of the machine.

The inclination angle of the extension must be set to 0°.

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Controls and operation Operation and maintenance manual The tools required to stow the extension are: A hammer, a rope and the unlocking crank located against the 8 m extension.

B - Deploying the boom head-member support Deploy the boom head-member support arm and fix it with the locking pin.

DANGER : Always refit the safety clips on the pins after reinsertion.

C - Dismantling the top lifting end-of-travel unit and unreeving the pulley block.

Disconnect the electrical connection between the boom head and the foot of the extension.

At the head of the extension, remove the end-of-travel counterweight by unscrewing the shackle attaching the counterweight chain to the unit cable.

At the head of the boom, use the shackle to fix the lifting end-of-travel counterweight chain to the cable of the end-of-travel unit.

Unreeve the pulley block.

Release the lifting rope from the extension.

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Controls and operation Operation and maintenance manual

D - Pivoting the 8 m extension DANGER: Remaining underneath the extension during the operations of locking or unlocking the extension is prohibited.

Attach the rope to the head of the 8 m extension.

At left-hand side of boom: Remove the pin and its safety clip (F).

(Coupling at top of boom head.)

Remove the pin and its safety clip (G).

(Bottom attachment of the boom head.)

Pivot the extension manually, restraining it with the rope, and bring it round onto the deployment support arm.

The travel stop keeps the extension on the support arm.

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Controls and operation Operation and maintenance manual DANGER: Before the square of the pivot is moved to lock the extension, it is vital that the extension should be fixed to the boom head by the pins E and D. If this instruction is not obeyed, the extension may fall.

Using the crank stored against the 8 m extension, manipulate the square of pivot (C) to lock the 8 m extension on to the pivot fitted to the boom foot. Replace the crank in storage position.

Removal of the crank from the pivot is strictly prohibited.

G - Unpinning the 8 m extension from the boom head Remove pin (D). (Coupling at top of boom head.)

Remove pin (E). (Coupling at bottom of boom head.)

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Controls and operation Operation and maintenance manual

H - Fixing the 8 m extension to the boom foot Swivel the 8 m extension around the pivot (C).

Once the extension is against the foot of the boom, lock into place.

I - Stowing the boom head-member support Stow the boom head-member support arm and fix it with the locking pin.

J - Fitting the lifting block Feed the rope back through the boom hoist pulley.

Pass the lifting rope back through the safety counterweight (counterweight opens out into two parts).

Re-reeve, using the appropriate pulley block.

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Operation and maintenance manual

Controls and operation DEPLOYING THE EXTENSIONS. Machine with 15 m extension.

Deploying the 8 m and 7 m extensions DANGER: Always use a safety harness when performing assembly work more than 3 m (10 ft) above ground level.

A single ladder may be used provided that it is secured in place and the top 4 rungs are not used.

Use an extendable ladder, a stepladder or a pod that meets applicable safety standards.

A - Positioning the machine Choose a manoeuvring area large enough to deploy the 8 m extension, then the 7 m extension.

DANGER : It is strictly forbidden to telescope the boom whilst the extension is being unfolded.

The boom should be fully retracted and must be horizontal.

Failure to follow these instructions may cause the extension to be deployed accidentally while it is being unlocked and so increase the i k f

F-63440-26

id

t

Machine fixed with outriggers fully extended, on flat, firm, level ground, with wheels raised off the ground.

Raise the boom and slew the turret over the rear of the machine.

Before commencing deployment, the boom should be fully retracted and must be horizontal.

Section IV – E - d - Page 1

27/11/03

Controls and operation

Operation and maintenance manual

Unreeve the main pulley block.

At the boom head, remove the top end-of-travel counterweight by unscrewing the shackle attaching the counterweight chain to the cable of the unit.

Remove the rope guides at the boom head to unreeve.

So that the cable may go over the extension and so that the wedge socket may be secured, unwind the cable by about 27m.

Pass the cable over the left-hand side of the boom.

B - Deploying the boom head-member support arm.

Deploy the boom head-member support arm and fix it with the locking pin.

Deploying the support arm releases the extension from the boom foot.

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Operation and maintenance manual

Controls and operation C – Pinning the foot of the 8 m extension to the boom head.

Remove the 2 pins from the boom side of the upper and lower forks and place them on the upper frame.

Releasing the 8 m and 7 m extensions: - At the foot of the 8 m extension, attach the rope to control deployment.

- In the middle of the 7 m extension, remove pin (A) locking the 7 m extension to the boom foot and stow it in the storage hole provided.

- At the head of the 7 m extension, remove pin (B) locking the 7 m extension to the boom foot and stow it in the storage hole provided.

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Operation and maintenance manual

Controls and operation Use the rope to bring the extensions out of their storage cradles, standing back about 4 m to reduce the pull required on the rope.

For safety reasons, attach the rope to the chassis.

Pivot the extensions around the pivot (C) to align the forks of the 8 m extension with the lugs on the boom head.

The extensions must remain on their supports

The travel stop keeps the extensions on the support arm.

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Controls and operation

Operation and maintenance manual

D – Pinning the 8 m extension to the boom head.

Secure the 8 m extension to the boom head with the two pins that were removed from the forks earlier and placed on the upper frame.

DANGER: The tilt-adjustment pins must never be used to secure the extension to the boom head under any circumstances as this will cause the extension to collapse.

Tilt-adjustment pins.

Locking pins.

CAUTION: Do not confuse these locking pins with the two tiltadjustment pins.

The two extension tilt-adjustment pins are located in a DANGER warning sign.

Do not touch the tilt-adjustment pins located in the DANGER warning sign.

.

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Operation and maintenance manual

Controls and operation Insert pin (D) (Coupling at top of boom head).

Insert pin (E) (Coupling at bottom of boom head).

DANGER : Always refit the safety clips on the pins after reinsertion.

E –Pivoting the 8m extension.

DANGER: Before the square of the pivot is moved to release the extension, it is vital that the extension should be fixed to the boom head by the pins E and D. If this instruction is not obeyed, the extension may fall.

Using the crank stored against the 8 m extension, manipulate the square of pivot (C) to release the extension from the boom foot.

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Operation and maintenance manual

Controls and operation Removal of the crank from the pivot is strictly prohibited.

To make it easier to pivot the extension, incline the machine 1.5° to the left by retracting the blocking rams of the left outriggers.

Use the handling bar to disengage the travel stop while manually pivoting the boom extension at the same time. Use the rope to restrict the movement of the boom extension.

The handling bar unlocks the safety travel stop that secures the boom extension to the support arm.

Travel stop locked.

Travel stop unlocked.

Replace the crank in its storage position.

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Operation and maintenance manual

Controls and operation On the left-hand side of the boom: Insert the locking pin and safety clips (G).

(Coupling at bottom of boom head)

Insert the locking pin and safety clips (F).

(Coupling at top of boom head.)

At the boom head, feed the lifting rope through the extension pulley.

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Operation and maintenance manual

Controls and operation Put the rope guides at the boom head back in position.

The 8 m extension is deployed.

F- Deploying the 7 m extension At the head of the 7 m extension: Attach the rope to control movement when deploying the 7 m extension.

At the foot of the 7 m extension: Remove the two locking pins to release the forks.

Unlock the 7 m extension using the pin.

Deploy the 7 m extension, using the rope to restrain its movement.

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Operation and maintenance manual

Controls and operation Once the 7 m extension is in line with the 8 m extension, pin the two extensions together.

G - Fitting the top hook end-of-travel unit Make the electrical connection between the boom head and the foot of the 8 m extension, and then between the 8 m extension and the 7 m extension to supply power to the top lifting end-of-travel unit.

At the head of the 7 m extension, connect the lifting end-of-travel unit and pin into place.

H - Fitting the pulley block.

At the boom head, remove the top end-of-travel counterweight by unscrewing the shackle attaching the counterweight chain to the cable of the unit. At the head of the 7 m extension, use the shackle to fit the counterweight chain to the cable of the end-of-travel unit.

Pass the lifting rope through the 7m and 8 m extensions.

Feed the cable into the top end-of-travel counterweight.

Re-reeve, using the appropriate pulley block.

The extension is now in its working configuration with a 0° inclination.

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Operation and maintenance manual

Controls and operation Stowing the 8 m and 7 m extensions DANGER: Always use a safety harness when performing assembly work more than 3 m (10 ft) above ground level.

A single ladder may be used provided that it is secured in place and the top 4 rungs are not used.

Use an extendable ladder, a stepladder or a pod that meets applicable safety standards.

A - Positioning the machine Choose a manoeuvring area large enough to enable the 7 m extension and then the 8 m extension to be stowed.

DANGER : It is strictly forbidden to telescope the boom whilst the extension is being unfolded.

The boom should be fully retracted and must be horizontal.

Failure to follow these instructions may cause the extension to be deployed accidentally while it is being unlocked and so increase the i k f

F-63440-26

id

t

Machine fixed with outriggers fully extended, on flat, firm, level ground, with wheels raised off the ground.

Raise the boom and slew the turret over the rear of the machine.

The inclination angle of the extensions must be set to 0°.

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Controls and operation

Operation and maintenance manual

The tools required to stow the extensions are: A hammer, a rope and the unlocking crank located against the 8 m extension.

B - Deploying the boom head-member support.

Deploy the boom head-member support arm and fix it with the locking pin.

DANGER : Always refit the safety clips on the pins after reinsertion.

C - Dismantling the top lifting end-of-travel unit and unreeving the pulley block..

Disconnect the electrical connection between the boom head and the foot of the 8 m extension and between the 8 m extension and the 7 m extension.

At the head of the extension, remove the end-of-travel counterweight by unscrewing the shackle attaching the counterweight chain to the cable of the unit.

At the head of the boom, use the shackle to fix the lifting end-of-travel counterweight chain to the cable of the end-of-travel unit.

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Operation and maintenance manual

Controls and operation At the head of the 7 m extension, disconnect and unpin the lifting endof-travel unit and stow in the carrier cab.

Unreeve the pulley block.

Release the lifting rope from the extension.

D - Pivoting the 7 m extension against the 8 m extension.

DANGER: The area underneath the extension must be kept clear at all times while the extension is being locked or unlocked.

At the head of the 7 m extension, attach the rope to the left-hand side of the 7 m extension.

Remove the two pins that fix the extensions together in order to pivot the 7 m extension back alongside the 8 m extension.

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Operation and maintenance manual

Controls and operation E - Fixing the 7 m extension to the 8 m extension Swing the 7 m extension round alongside the 8 m extension, restraining the movement of the 7 m extension with the rope.

Lock the 7 m extension..

Stow the two locking pins on the foot of the 7 m extension.

F - Pivoting the 8 m and 7 m extensions against the boom foot DANGER: The area underneath the extension must be kept clear at all times while the extension is being locked or unlocked.

Attach the rope to the head of the 8 m extension.

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Operation and maintenance manual

Controls and operation On the left-hand side of boom: Remove the pin and its safety clip (F).

(Coupling at top of boom head.).

Remove the pin and its safety clip (G).

(Coupling at bottom of boom head.)

Pivot the extension manually, restraining it with the rope, and bring it round onto the deployment support arm.

The travel stop keeps the extension on the support arm.

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Operation and maintenance manual

Controls and operation DANGER: Before moving the square of the pivot to lock the extension to the boom, it is vital that the extension is fixed to the boom head by pins E and D. If this instruction is not obeyed, the extension may fall.

Using the crank stored against the 8 m extension, manipulate the square of the pivot (C) in order to lock the 8 m extension to the pivot fitted to the boom foot. Replace the crank in its storage position.

Removing the crank from the pivot is strictly prohibited.

G - Unpinning the 8 m extension from the boom head Remove pin (D). (Coupling at top of boom head.)

Remove pin (E) (Coupling at bottom of boom head.)

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Operation and maintenance manual

Controls and operation H - Fixing the extensions to the boom foot.

Pivot the extensions about the pivot (C). Once the extensions are positioned in the stowage cradles against the boom foot, lock them in place using the pins and cotters.

At the head of the 7 m extension: Remove pin (B) from its storage position and lock the extension to the boom foot.

At the foot of the 8 m extension: remove the rope.

In the middle of the 7m extension: remove pin (A) from its storage position and lock the extension to the boom foot.

I - Stowing the boom head-member support.

Fold the boom head-member support arm back into its storage position and secure with the locking pin.

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Operation and maintenance manual

Controls and operation J - Fitting the pulley block.

Feed the rope back through the boom hoist pulley.

Pass the lifting rope back through the safety counterweight (counterweight opens out into two parts).

Re-reeve, using the appropriate pulley block.

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Controls and operation Operation and maintenance manual

UNFOLDING THE EXTENSIONS. Machine equipped with 15m (8m+ 7m)

Unfolding the 8m extension.

DANGER: Always use a safety harness when performing assembly work more than 3 m (10 ft) above ground level.

A single ladder may be used provided that it is secured in place and the top 4 rungs are not used.

Use an extendable ladder, a stepladder or a pod that meets applicable safety standards.

A - Positioning the machine Choose a manoeuvring area large enough to deploy the 8 m extension.

DANGER : It is strictly forbidden to telescope the boom whilst the extension is being unfolded.

The boom should be fully retracted and must be horizontal.

Failure to follow these instructions may cause the extension to be deployed accidentally while it is being unlocked and so increase the

Machine fixed with outriggers fully extended, on flat, firm, level

risk of an accident.

ground, with wheels raised off the ground.

Raise the boom and slew the turret over the rear of the machine.

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Controls and operation Operation and maintenance manual Unreeve the main pulley block At the boom head, remove the top end-of-travel counterweight by unscrewing the shackle attaching the counterweight chain to the cable of the unit.

Remove the rope guides at the boom head to unreeve.

So that the cable may go over the extension and so that the wedge socket may be secured, unwind the cable by about 15 m. Pass the cable over the left-hand side of the boom.

- Deploying the boom head-member support arm.

Deploy the boom head-member support arm and fix it with the locking pin.

Deploying the support arm releases the extension from the boom foot.

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Controls and operation Operation and maintenance manual C - Pinning the foot of the 8 m extension to the boom head Remove the 2 pins from the boom side of the upper and lower forks and place them on the upper frame.

D- Releasing the 8 m extension.

At the foot of the 8 m extension, attach the rope to restrict movement.

Remove the two pins fixing the 8 m extension to the 7 m extension.

To release the 8 m extension, take out the pin connecting it to the 7 m extension.

Attach the rope to restrict movement.

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Controls and operation Operation and maintenance manual Pivot the extension around the pivot (C) to align the forks of the 8 m extension with the lugs on the boom head.

For safety reasons, attach the rope to the chassis. The extension must remain on its support.

The travel stop keeps the extension on the travel arm.

E – Pinning the 8 m extension to the boom head.

Secure the 8 m extension to the boom head with the two pins that were removed from the forks earlier and placed on the upper frame.

DANGER: The tilt-adjustment pins must never be used to secure the extension to the boom head under any circumstances as this will cause the extension to collapse.

Tilt-adjustment pins.

Locking pins.

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Controls and operation Operation and maintenance manual CAUTION: Do not confuse these locking pins with the two tiltadjustment pins.

The two extension tilt-adjustment pins are located in a DANGER warning sign.

Do not touch the tilt-adjustment pins located in the DANGER warning sign.

.

Insert pin (D). (Coupling at top of boom head.)

Insert pin (E).(Coupling at bottom of boom head.)

DANGER : Always refit the safety clips on the pins after reinsertion.

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F - Pivoting the 8m extension.

DANGER: Before the square of the pivot is moved to release the extension, it is vital that the extension should be fixed to the boom head by the pins E and D. If this instruction is not obeyed, the extension may fall.

Using the crank stored against the 8 m extension, manipulate the square of pivot (C) to release the extension from the boom foot.

Removal of the crank from the pivot is strictly prohibited.

To make it easier to pivot the extension, incline the machine 1.5° to the left by retracting the blocking rams of the left outriggers.

Use the handling bar to disengage the travel stop while manually pivoting the boom extension at the same time. Use the rope to restrict the movement of the boom extension.

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Controls and operation Operation and maintenance manual The handling bar unlocks the safety travel stop that secures the boom extension to the support arm.

Travel stop locked.

Travel stop unlocked.

Replace the crank in its storage position.

On the left-hand side of the boom: Insert the locking pin and safety clips (G).

(Bottom coupling of boom head)

Insert the fixing pin and safety clips (F).

(Coupling at top of boom head.)

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Controls and operation Operation and maintenance manual At the boom head, feed the lifting rope through the extension pulley.

Put the rope guides at the boom head back in position.

At the head of the 8 m extension, use the shackle to fix the counterweight chain to the cable of the end-of-travel unit.

Pass the rope through the top end-of-travel counterweight.

Re-reeve, using the appropriate pulley block..

The 8 m extension is deployed.

The extension is now in its working configuration with a 0° inclination.

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Controls and operation Operation and maintenance manual

G - Electrical connections.

Make the electrical connection between the boom head and the foot of the 8 m extension to supply power to the lifting end-of-travel unit.

At the head of the 8 m extension, connect the lifting end-of-travel unit and secure into place.

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Controls and operation Operation and maintenance manual

Stowing the 8 m extension Machine with 8 m and 7 m extensions.

DANGER: Always use a safety harness when performing assembly work more than 3 m (10 ft) above ground level.

A single ladder may be used provided that it is secured in place and the top 4 rungs are not used.

Use an extendable ladder, a stepladder or a pod that meets applicable safety standards.

A - Positioning the machine.

Choose a manoeuvring area large enough to enable stowage of the 8 m extension.

DANGER : It is strictly forbidden to telescope the boom whilst the extension is being unfolded.

The boom should be fully retracted and must be horizontal.

Failure to follow these instructions may cause the extension to be deployed accidentally while it is being unlocked and so increase the i k f

id

t

Machine fixed with outriggers fully extended, on flat, firm, level ground, with wheels raised off the ground.

Raise the boom and slew the turret over the rear of the machine.

The inclination angle of the extension must be set to 0°.

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Controls and operation Operation and maintenance manual The tools required to stow the extension are: A hammer, a rope and the unlocking crank located against the 8 m extension.

B - Deploying the boom head-member support.

Deploy the boom head-member support arm and fix it with the locking pin.

DANGER : Always refit the safety clips on the pins after reinsertion.

C - Dismantling the top lifting end-of-travel unit and unreeving the pulley block..

Disconnect the electrical connection between the boom head and the foot of the extension.

At the head of the extension, remove the end-of-travel counterweight by unscrewing the shackle attaching the counterweight chain to the unit cable.

At the head of the boom, use the shackle to fix the lifting end-of-travel counterweight chain to the cable of the end-of-travel unit.

Unreeve the pulley block.

Release the lifting rope from the extension.

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D - Pivoting the 8 m extension DANGER: The area underneath the extension must be kept clear at all times while the extension is being locked or unlocked.

Attach the rope to the head of the 8 m extension..

At left-hand side of boom: Remove the pin and its safety clip (F).

(Coupling at top of boom head.)

Remove the pin and its safety clip (G).

(Bottom attachment of the boom head.)

Pivot the extension manually, restraining it with the rope, and bring it round onto the deployment support arm.

The travel stop keeps the extension on the support arm.

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Controls and operation Operation and maintenance manual DANGER: Before the square of the pivot is moved to lock the extension to the boom, it is vital that the extension should be fixed to the boom head by the pins E and D. If this instruction is not obeyed, the extension may fall.

Using the crank stored against the 8 m extension, manipulate the square of pivot (C) to lock the 8 m extension on to the pivot fitted to the boom foot. Replace the crank in its storage position.

Removing the crank from the pivot is strictly prohibited.

E - Unpinning the 8 m extension from the boom head.

Remove pin (D). (Coupling at top of boom head.)

Remove pin (E). (Coupling at bottom of boom head.)

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Controls and operation Operation and maintenance manual

F - Fixing the 8 m extension to the boom foot.

Swivel the 8 m extension around the pivot (C).

Once it is alongside the 7 m extension, lock it into position.

Attach the 7 m and 8 m extensions together again.

G -Stowing the boom head-member support.

Stow the boom head-member support arm and fix it with the locking pin.

H – Fitting the pulley block Feed the rope back through the boom hoist pulley.

Re-reeve, using the appropriate pulley block.

Pass the lifting rope back through the safety counterweight (counterweight opens out into two parts).

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Controls and operation Operation and maintenance manual

Method 1: Inclining the extensions using the lift function.

Work with an extension can be done at any of three angles of inclination: 0° - 20° - 40°.

The procedure for inclining an extension varies according to the length of the extension used.

The extensions should be inclined with the help of an assistant.

DANGER: Always use a safety harness when performing assembly work more than 3 m (10 ft) above ground level.

A single ladder may be used provided that it is secured in place and the top 4 rungs are not used.

Use an extendable ladder, a stepladder or a pod that meets applicable safety standards.

A - Inclining the 8 m extension The machine must be chocked with the outriggers fully extended, on flat, firm, level ground, and the wheels raised off the ground.

The turret is to be turned to the rear.

The extension is to be at 0°.

NOTE: On machines fitted with a spare wheel, the turret can be slewed to the right or left, taking the right or left rear corner of the deck as the point of reference, so that the boom can be lowered in order to make insertion of the pins easier.

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Controls and operation Operation and maintenance manual

A1 - Inclining the 8 m extension to 20°.

Unreeve the pulley block, unwind about 15 m of cable and fix the terminator wedge socket to the fork on the lower face of the 8 m extension using the terminator wedge socket pin. The cable must go properly over the cable guides. Slightly tension the rope until the LMI shows a residual load of 0.1 tonnes.

Take care when positioning the terminator wedge socket: the wedge must go at the bottom. Tension the rope slightly.

Carry out this procedure slowly and with the utmost care so as not to damage the extension..

WARNING: When the extension is inclined with the head in contact with the ground, use of the derricking down control is prohibited.

Pull out the 2 pins (A) and place them in the middle openings to obtain a 20° angle. Insert the locking pins.

20°

0°

Raise the boom to 45° in order to leave enough room to incline the extension. While being lowered, the extension must not strike the ground.

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Controls and operation Operation and maintenance manual

Let out some rope (using the lifting down control) to incline the extension. Proceed slowly and cautiously, avoiding jerks.

As rope is let out, the extension sinks down and the inclination system comes to a stop against the pins A. CARE: DO NOT DERRICK DOWNWARDS WITHOUT FEEDING CABLE. DERRICKING DOWNWARDS ALONE WILL PUT THE CABLE UNDER TENSION AND DAMAGE THE EXTENSION.

A2 - Inclining the 8 m extension to 40° If the extension is configured to 20°, it needs to be brought to the 0° position to configure it to 40°.

To bring the extension back to 0°, unreeve the pulley block, fix the terminator wedge socket to the fork on the 8 m extension‘s lower side using the terminator wedge socket pin.

Put the cable under slight tension.

Raise the extension, using the lifting up control.

Proceed slowly and with the utmost care.

Once the extension is near to 0°, bring the boom to horizontal using the derricking down control and pay out some rope if necessary.

Slightly tension the rope until the LMI shows a residual load of 0.1 tonnes.

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Controls and operation Operation and maintenance manual Pull out the 2 pins (A) from the 20° position to obtain a 40° angle.

Stow the pins in the two storage holes provided.

Raise the boom to 45° in order to leave enough room to incline the extension. While being lowered, the extension must not strike the ground.

Let out some rope (using the derricking down control) to incline the extension. Proceed slowly and cautiously, avoiding jerks.

As cable is played out, the extension inclines, and the inclining system arrives at a stop.

B - Inclining a 15 m extension The machine must be chocked with outriggers fully extended, on flat, firm, level ground, with wheels raised off the ground.

The turret is to be turned to the rear .

The extension is to be 0°.

NOTE: On machines fitted with a spare wheel , the turret can be turned to the right or left, taking the right or left rear corner of the deck as a point of reference, so that the boom can be lowered in order to make insertion of the pins easier.

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Controls and operation Operation and maintenance manual

B1 - Inclining the 15 m extension to 20° Remove the pin connecting the wedge socket to the hook.

Remove the hook and place on the ground.

Unwind about 27 m of the cable and fix the terminator wedge socket to the fork at the lower face of the 8 m extension using the terminator wedge socket pin. The cable must go properly over the cable guides.

Slightly tension the rope until the LMI shows a residual load of 0.1 tonnes.

Position the terminator wedge socket carefully: the wedge must go at the bottom. Tension the cable slightly.

Carry out this procedure slowly and with the utmost care so as not to damage the extension.

Pull out the 2 pins (A) and place them in the middle openings to obtain a 20° angle. Insert the locking pins.

CAUTION: When the extension is at an angle with the head touching the ground, the derricking down control must not be used.

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Controls and operation Operation and maintenance manual

Raise the boom to 45° in order to leave enough room to incline the

20°

0°

extension. While being lowered, the extension must not strike the ground.

Let out some rope (using the derricking down control) to incline the extension. Proceed slowly and cautiously, avoiding jerks..

As rope is let out, the extension sinks down and the inclination system CARE:

comes to a stop against the pins A.

DO NOT DERRICK DOWNWARDS WITHOUT FEEDING CABLE. DERRICKING DOWNWARDS ALONE WILL PUT THE CABLE UNDER TENSION AND DAMAGE THE EXTENSION.

F-63440-26

Lower the boom to refit the hook to the wedge socket.

B2 - Inclining a 15 m extension to 40°°.

If the extension is configured to 20°, it needs to be brought to the 0° position to configure it to 40°.

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Controls and operation Operation and maintenance manual To return to 0°, unreeve the pulley-block and fix the terminator wedge socket to the fork situated on the upper side of the 7 m extension using the 30mm pin. Tension the cable slightly.

Raise the extension using the LIFTING UP control.

Go slowly and take the utmost care.

Once the extension is near to 0°, bring the boom to horizontal using the derricking down control and let out some cable if necessary.

Tension the rope slightly until the LMI shows a residual load of 0.1 tonnes.

Pull out the pins to obtain a 40° angle and stow them in the two storage holes provided.

Raise the boom to 45° in order to leave enough room to incline the extension. While being lowered, the extension must not strike the ground.

Let out some rope (using the derricking down control) to incline the extension. Proceed slowly and cautiously, avoiding jerks.

As cable is played out, the extension inclines, and the inclining system arrives at a stop.

Lower the boom to refit the hook to the wedge socket.

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Controls and operation Operation and maintenance manual

Method 2: Inclining the extensions using the Telescoping function.

Work with an extension can be done at any of three angles of inclination: 0° - 20° - 40°.

The procedure for inclining an extension varies according to the length of the extension used.

The extensions should be inclined with the help of an assistant.

DANGER: Always use a safety harness when performing assembly work more than 3 m (10 ft) above ground level.

A single ladder may be used provided that it is secured in place and the top 4 rungs are not used.

Use an extendable ladder, a stepladder or a pod that meets applicable safety standards.

A - Inclining the 8 m extension The machine must be chocked with outriggers fully extended, on flat, firm, level ground, with wheels raised off the ground.

The turret is to be turned to the rear.

The extension is to be at 0°.

NOTE: On machines fitted with a spare wheel, the turret can be turned to the right or left, taking the right or left rear corner of the deck as a point of reference, so that the boom can be lowered in order to make insertion of the pins easier.

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Controls and operation Operation and maintenance manual

A1 - Inclining the 8 m extension to 20° Telescope the boom by about 1.5m.

Unreeve the pulley block, unwind about 15 m of the cable and fix the terminator wedge socket to the fork on the lower face of the 8 m extension using the terminator wedge socket pin. The cable must pass properly over the cable guides. Tension the rope slightly until the LMI shows a residual load of 0.1 tonnes.

Position the terminator wedge socket carefully: the wedge must go at the bottom. Tension the cable slightly.

Carry out this procedure slowly and with the utmost care so as not to damage the extension..

CAUTION: When the extension is at an angle with the head touching the ground, the derricking down control must not be used.

Pull out the 2 pins (A) and place them in the middle openings to obtain a 20° angle. Insert the lock pins.

20°

0°

Raise the boom to 45° in order to leave enough room to incline the extension. While being lowered, the extension must not strike the ground.

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Let out some rope (telescoping in control) to incline the extension.

Proceed slowly and cautiously, avoiding jerks.

As rope is let out, the extension drops and the inclination system comes to a stop against the pins A.

A2 - Inclining an 8 m extension to 40°.

If the extension is configured to 20°, it needs to be brought to the 0° position to configure it at 40°.

To return to 0°, unreeve the pulley-block and fix the terminator wedge socket to the fork situated on the lower side of the 8 m extension using the pin of the terminator wedge socket. Tension the cable slightly by telescoping the boom.

Raise the extension using the telescoping out control. Proceed slowly and with the utmost care.

Once the extension is near to 0°, bring the boom to a horizontal position using the derricking down control, and let out some cable if necessary.

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Controls and operation Operation and maintenance manual Tension the rope slightly until the LMI shows a residual load of 0.1 tonnes. Pull out the pins (A) a to obtain a 40° angle.

Stow the pins in the two storage holes provided.

Raise the boom to 45° in order to leave enough room to incline the extension. While being lowered, the extension must not strike the ground.

Retract the boom to incline the extension. Proceed slowly and cautiously, avoiding jerks.

When the boom is being retracted, the extension inclines and the inclining system comes to a stop against the pins A.

B - Inclining a 15 m extension.

The machine must be immobilized with outriggers fully extended, on flat, firm, level ground, with wheels raised off the ground.

The turret is to be turned to the rear.

The extension is to be at 0°.

NOTE: On machines fitted with a spare wheel , the turret can be turned to the right or left, taking the right or left rear corner of the deck as a point of reference, so that the boom can be lowered in order to make insertion of the pins easier.

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Controls and operation Operation and maintenance manual

B1 - Inclining the 15 m extension to 20° Telescope the boom by approx. 1.5 m.

Unreeve the pulley block, unwind about 27 m of the cable and fix the terminator wedge socket to the fork on the lower face of the 8 m extension using the terminator wedge socket's pin. The cable must pass properly over the cable guides. Tension the rope slightly until the LMI shows a residual load of 0.1 tonnes.

Take care when positioning the terminator wedge socket: the wedge must go at the bottom. Tension the cable slightly.

Carry out this procedure slowly and with the utmost care so as not to damage the extension.

Pull out the 2 pins (A) and place them in the middle openings to obtain a 20° angle. Insert the locking pins.

CAUTION: When the extension is at an angle with the head touching the ground, the derricking down control must not be used.

20°

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0°

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Controls and operation Operation and maintenance manual Raise the boom to 45° in order to leave enough room to incline the extension. While being lowered, the extension must not strike the ground.

Retract the boom (telescoping in control) to incline the extension.

Proceed slowly and cautiously, avoiding jerks.

When the boom is being retracted, the extension inclines and the inclining system comes to a stop against the pins A. Lower the boom to refit the hook to the wedge socket.

B2 - Inclining a 15 m extension to 40° If the extension is configured to 20°, it needs to be brought to the 0° position to configure it to 40°.

To return to 0°, unreeve the pulley-block and fix the terminator wedge socket to the fork situated on the upper side of the 8 m extension.

Telescope the boom to tension the cable slightly.

Raise the extension using the outward telescoping control.

Proceed slowly with the utmost care.

Once the extension is near to 0°, bring the boom to horizontal using the derricking down control and let out some cable if necessary.

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Controls and operation Operation and maintenance manual Tension the rope slightly until the load state monitor shows a residual load of 0.1 tonnes. Set the inclination to 40° by removing the pins (A).

Stow the pins in the two holes provided.

Raise the boom to 45° in order to leave enough room to incline the extension. While being lowered, the extension must not strike the ground.

Retract the boom (telescoping in control) to incline the extension.

Proceed slowly and cautiously, avoiding jerks.

As the boom is retracted, the extension inclines, and the inclining system arrives at a stop.

Lower the boom (derricking down) to refit the hook to the terminator wedge socket.

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Maintenance

Maintenance and operator’s manual

Maintenance V

Edition :

04/2001

V---1

Maintenance

V---2

Maintenance and operator’s manual

Edition :

03/1999

Maintenance and operator’s manual

Maintenance

Maintenance Regular maintenance of your machine will ensure longevity. We therefore earnestly recommend that you follow the instructions given in this chapter.

NOTE : All personnel who carry out maintenance operations on this machine must be aware of all instructions contained in this manual, and respect all safety regulations before any intervention.

The routine maintenance summaries indicate the main points to be dealt with, and in the following pages further details are given on these operations.

Edition :

04/2001

V---3

Maintenance

Maintenance and operator’s manual

Maintenance general features WHEN MAKING THE PRE---DELIVERY INSPECTION, CARRY OUT INITIAL COMPLETE MAINTENANCE OF THE MACHINE, WITH THE P P M EXPERT (OIL CHANGES, LUBRICATION, REPLACING FILTERS), THEN REFER TO THE MAINTENANCE INTERVALS SHOWN IN THE FOLLOWING TABLES. IN THE EVENT OF PROLONGED STORAGE OR USE AT A FIXED SITE, IT IS IMPERATIVE TO CARRY OUT 500 HOURS MAINTENANCE AFTER EACH 6 MONTH PERIOD AT THE MAXIMUM, ESPECIALLY THE FOLLOWING COMPONENTS : ENGINE --- AXLES --- GEARBOXES --- SUSPENSION --- STEERING. IMPORTANT : The intervals shown in the following tables are deemed to apply to machines used under normal conditions .

For intensive use or under conditions (heat -- dampness -- dust) it is necessary to carry out maintenance more frequently.

V---4

Edition :

03/1999

Maintenance and operator’s manual

Maintenance

Service intervals The machine should be serviced regularly.

The hourmeter on your machine shows you when it is time to carry out maintenance. It should be checked each day.

The frequencies shown are based on 10 hours/day, 50 hours/week, and 2000 hours/year working.

Take advantage of the opportunity to tighten screws, nuts etc during maintenance operations.

When effecting these servicing operations, tighten nuts, bolts,etc...where required.

Hourmeter Its electric control is connected to the engine oil pressure. It accumulates hours exactly like a clock when the engine is running.

Preliminary operations First of all clean grease fitting heads, plugs and periphery of filler ports and level check sightglasses. When lubricating, check condition of seals and replace them if they are damaged or show signs of wear.

Before any daily start up Every day, inspect the machine before getting in or start the engine.

Look carefully for : loosen or missing screws Accumulation of scraps : oil or cooling liquid leaks Check condition of tyres and levels.

Storage After storage for some months, check all hydraulic circuit fittings and make sure that they are correctly tightened.Inspect the entire machine Apply procedure “BEFORE EVERY DAILY START UP”

JAll the necessary steps should be taken to conserve the environment. In particular, make sure that all used fluids are collected and recycled . Do not leave these products in unsuitable, incorrectly labelled containers.

Do not tolerate fluid puddles of whatever type on floors.

Edition :

04/2001

V---5

Maintenance

V---6

Maintenance and operator’s manual

Edition :

03/1999

Maintenance

Maintenance and operator’s manual

Table: tightening torques for traditional steel screw assemblies.

Torques to be applied in m.daN (1 m.daN = about 1m.kg) Friction coefficient between 0.125 and 0.15 inclusive.

Classe s 10.9 and 12.9

Fine pitch screw

Class 8.8

Class 10.9 and 12.9

2

3

M8 x 1

2.5

3.5

M10 x 1.5

5

7

M10 x 1.25

5

7

19

M12 x 1.75

8

12

M12 x 1.25

9

13

22

M14 x 2

13

18

M12 x 1.5

9

12

24

M16 x 2

20

28

M14 x 1.5

14

20

27

M18 x 2.5

28

39

M16 x 1.5

21

30

30

M20 x 2.5

39

55

M18 x 1.5

31

44

32

M22 x 2.5

53

75

M20 x 1.5

43

61

36

M24 x 3

67

95

M22 x 1.5

58

82

41

M27 x 3

99

140

M24 x 2

73

103

46

M30 x 3.5

135

190

M27 x 2

107

150

50

M33 x 3.5

185

250

M30 x 2

150

210

M33 x 2

205

290

Flat dimen sions

Screw, normal pitch

13

M8 x 1.25

17

Class 8.8

Use a calibrated dynamometric chuck key (precision ± 6%)

Edition :

04/2001

V---7

Maintenance

Maintenance and operator’s manual

Preventive maintenance Introduction The environmental working conditions of the machine gouvern its maintenance.The prescribed check ---list which follows indicate the points to be verified and the frequency of the verifications.

NOTE : The check ---list takes into account the machine’s operating conditions. The type of work to be done, the dimensions of loads, climatic and ground conditions are all factors to be taken into account.The preventive maintenance lists are given in function of the number of hours worked by the machine.

Any modification to the overall maintenance program must be accompanied by a revision of the machine’s new operating conditions. Carefully study the preventive maintenance check ---list before making any changes to the verification frequencies.

The lubrification charts indicate the general greasing points and the type of lubricant to be used on each component

Use of the prescribed Check ---list The check ---list is an initial guide to preventive maintenance until personal experience allows the definition of an appropriate maintenance program according to different operating conditions.

The check ---lists can be recopied as many times as necessary. Any person who carries out a maintenance procedure must indicate this on the checklist so that it can be verified as being done at the moment of the following maintenance program.

Completed check-- lists are documents which are an integral part of the machine.

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Maintenance

Tyre pressure Periodically control tyre pressures, and ensure that corresponding prescribed pressures are used following the work being done by the machine. Refer to the tyre pressure indicator stickers on the chassis footplating above the wheels.

Slewing ring fixation Periodically check ring greasing and ring fasteners. If a problem is detected, ask for the assistance of a PPM field service engineer who will advise you on what action has to be taken. REMEMBER THAT THE SLEWING RING FASTENERS ARE A PRIMORDIAL SAFETY ELEMENT OF THE CRANE.

Starting up the machine after changing a hydraulic component.

After having changed a hydraulic component on the machine, e.g. pump, distributor, valve block, ram oil tank, etc.., turn the engine over at idling speed for around 20 to 30 minutes, without using any of the hydraulic functions, then bleed, if necessary, the changed part. Then check or exchange the concerned filter cartridges after this operation.

Precautions to be taken if welding is to be done on the machine Before starting any electric welding jobs on the machine, firstly :--disconnect the wires marked B+ and D+ from the alternator--disconnect all electronic equipment (i.e. load indicator, gearbox control unit, etc..)

Transmission assembly fasteners Periodically check that all transmission shafts and their universal joints are correctly tightened. If there is any doubt about the condition of a fastener, then immediately replace it using ONLY fasteners prescribed by PPM , excluding any other types.

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Maintenance

Maintenance and operator’s manual

Periodic and compulsory slewing ring fastener checks

1 5

8 4

3 7

6 2

V---10

1 --- Slew ring fastener tightness is checked at the factory prior to delivery.

2 --- Slewing ring fasteners have to be to be retightened to the recommended torque setting (refer to table) during the first warranty visit. a) Tooling : Calibrated torque wrench (set to nominal torque rating --- see table below).

Refer to torque wrench manufacturer’s document (torque setting tolerance : ± 5%) b) Conditions for verification : Machine set up on outriggers Short boom derricked so as to have a radius of 3m.

No load. c) Method Recommended order for tightening slewing ring fasten ers.

--- Nut or bolt 1 and 2, then at 90° , 3 and 4, --- Afterwards at 45° , nut or bolt 5 and 6, then at 90° ,7 and 8, --- Finally, all the intermediate nuts or bolts. (the number of nuts and bolts depends upon the type of machine)

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Maintenance

Maintenance and operator’s manual

d) Torque settings

dxp

16 x 2.00

20 x 1.50

24 x 2.00

27 x 2.00

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04/2001

Length

Reference

90

S 63338 94

100

F 19338 68

100

Description

Nominal torque setting

Torque rating at which exchange is necessery.

(85% of nominal torque value)

23 m.DaN +0+2

19 m.DaN

Vis / Screw / Schraube / Tornillo

50 m.DaN ± 3

42 m.DaN

E 62338 32

Boulon / Bolt / Bolzen / Perno

55 m.DaN ± 3

46 m.DaN

110

T 19338 80

Vis / Screw / Schraube / Tornillo

50 m.DaN ± 3

42 m.DaN

120

F 62338 33

Vis / Screw / Schraube / Tornillo

50 m.DaN ± 3

42 m.DaN

125

J 19338 94

Vis / Screw / Schraube / Tornillo

50 m.DaN ± 3

42 m.DaN

130

J 62338 13

Vis / Screw / Schraube / Tornillo

50 m.DaN ± 3

42 m.DaN

140

G 19338 69

50 m.DaN ± 3

42 m.DaN

140

J 19338 71

Boulon / Bolt / Bolzen / Perno

55 m.DaN ± 3

42 m.DaN

145

C 19338 88

Boulon / Bolt / Bolzen / Perno

55M.KG ± 3

46 m.DaN

170

R 62338 20

Boulon / Bolt / Bolzen / Perno

55 m.DaN ± 3

46 m.DaN

200

F 19338 91

Boulon / Bolt / Bolzen / Perno

55 m.DaN ± 3

46 m.DaN

220

H 62338 35

Boulon / Bolt / Bolzen / Perno

55 m.DaN± 3

46 m.DaN

130

K 19338 72

Boulon / Bolt / Bolzen / Perno

95 m.DaN± 5

80 m.DaN

140

E 19338 90

Vis / Screw / Schraube / Tornillo

75 m.DaN ± 5

63 m.DaN

140

L 19338 73

Vis / Screw / Schraube / Tornillo

95 m.DaN± 5

80 m.DaN

160

M 19338 74

Vis / Screw / Schraube / Tornillo

95 m.DaN± 5

80 m.DaN

160

H 19338 70

Vis / Screw / Schraube / Tornillo

75 m.DaN ± 5

63 m.DaN

170

D 19338 89

Boulon / Bolt / Bolzen

95 m.DaN ± 5

80 m.DaN

200

D 62338 42

Vis / Screw / Schraube / Tornillo

75 m.DaN ± 5

63 m.DaN

145

U 19338 81

Vis / Screw / Schraube / Tornillo

120 m.DaN± 7

102 m.DaN

145

N 19338 75

Boulon / Bolt / Bolzen / Perno

140 m.DaN ± 7

119 m.DaN

155

G 62338 57

Vis / Screw / Schraube / Tornillo

120 m.DaN ± 7

102 m.DaN

160

P 19338 76

Boulon / Bolt / Bolzen / Perno

140 m.DaN ± 7

119 m.DaN

175

C 62338 53

120 m.DaN ± 7

102 m.DaN

190

Q 19338 77

Boulon / Bolt / Bolzen / Perno

140 m.DaN± 7

119 m.DaN

190

H 62338 58

Vis / Screw / Schraube / Tornillo

120 m.DaN ± 7

102 m.DaN

210

A 19338 86

Boulon / Bolt / Bolzen / Perno

140 m.DaN ± 7

119 m.DaN

250

B 19338 87

Boulon / Bolt / Bolzen / Perno

140 m.DaN ± 7

119 m.DaN

Vis / Screw / Schraube / Tornillo

Vis / Screw / Schraube / Tornillo

Vis / Screw / Schraube / Tornillo

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Maintenance

Maintenance and operator’s manual

1 5

8 4

3 7

6 2

Remark : This operation is valid for all types of slewing ring fasteners, consult the technical specifications for the corresponding torque values.

3 --- Afterwards slewing ring fastener tightness must be checked every 500 hours. Tooling, verification conditions, method and torque values are the same as in paragraph 2. a) Verify all the fasteners. Mark all fasteners with a torque value of less than 85% of the nominal value.

If the number of fasteners detected with this characteristic is greater than 20% of the total number, then all the ring fasten ers must be changed.

USE ONLY ORIGINAL PPM SPARE PARTS b) Otherwise retighten all fasteners with a torque value greater than 85% of the nominal value to the nominal torque value indicated in the table, and in the order as shown in the illustration opposite. c) Change, one by one and in the recommended order, all the fasteners detected and marked in step (a) which have a torque value inferior to 85% of nominal value.

ONLY USE GENUINE PPM SPARE PARTS Tighten to the value indicated in the table.

4 --- Systematic exchange : All slewing ring fasteners, and the slewing ring itself, must be changed every 8000 hours. This job must be carried out by personnel authorized by PPM. ONLY USE GENUINE PPM SPARE PARTS 5 --- Retightening fasteners after their exchange : Retightening of the slewing ring fasteners must be carried out when : fasteners have been exchanged, the slewing ring has been exchanged, therefore a new set of fasteners have been employed, after an initial bedding---in period of 120 to 150 working hours.

Afterwards, periodic torque value verifications are to be carried out every 500 hours.

Please consult your local PPM agent for further detailled information concerning control, assembly, retightening and exchange criteria procedures.

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Maintenance

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Maintenance

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Maintenance

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Maintenance

Maintenance and operator’s manual

Maintenance and inspection after initial start up.

Lubrication Table Frequency 50 h

100 h

V---16

Ref.

Identification

Operation

Greasing points

Slewing ring

Check tightness

Slewing ring fasteners

Wheels

Check tightness

Tyres

Check pressure

Accumulators

Check pressure

Transfer unit

Oil change

Slewing reducer

Oil change

Winch reducer

Oil change

Axles 2 --- 4 --- 5

Oil change

Diff. and reducers

Gearbox

Oil change

Refer to chapter

Gearbox

Replace

Oil filter

Gearbox

Replace

Oil filter

All fasteners

Check tightness

Check for leaks

Tightness of connections

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Maintenance

Maintenance and operator’s manual

List ”A” --- 10h Air filter Check air filter Frequency : Every ten hours.Clean the dust collector bowl.

1

2

3

Winch cable Visual inspection. (Refer to 500 hourly list)

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Maintenance

Maintenance and operator’s manual

Hydraulic tank and fuel tank levels 1/ Hydraulic oil tank filler cap 2/ Fuel tank filler cap 3/ Hydraulic oil level 4/ Domestic fuel oil filler cap (Option) 5/ Domestic fuel oil level

1

2

3

4

5

Check level: every ten hours

--- Machine on a flat surface --- All rams retracted --- Horizontal boom

Topping up By filler cap no. 1 for hydraulic oil, and by filler cap no. 2 for fuel.

J Do not smoke when filling the fuel tank, the fumes are inflammable J Avoid any contact with the skin as hot oil and components can cause burns.

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Maintenance

Windscreen wiper liquid bottle Check level: every ten hours

Engine oil level Check level: every ten hours

Refer to manufacturers’ specifications : MERCEDES

Engine radiator coolant level Check level: every ten hours Refer to manufacturers’ specifications : MERCEDES

Check the coolant level and add, if necessary, water or anti---freeze slution until the level is within 2cms. of the filler neck. Use the type and quantity of anti---freeze mixture as prescribed by the engine manufacturer, refer to their specifications for details.

J When replacing, be careful while handling oil or coolant liquid J Carefully unscrew the radiator drain plug or oil drain plugs, grease nipples and pressure pick ---up points.

In case of breakdown of the heat sensors, it is possible to force operation of the fan by means of the valve next to the radiator.

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Maintenance

Maintenance and operator’s manual

List ”B” --- 50h

Slewing ring Frequency: every 50 hours.

Using a grease gun, inject grease into the 4 grease nipples on the slewing ring ( 4 or 5 pumps per nipple is sufficient).

After each injection rotate the ring through 90˚ in order to correctly disperse the grease over the full internal surface of the slewing ring.

Maximum safety is obtained when only one operator performs this job.

Slewing ring toothing Greasing: every 50 hours. Apply spray in two passes as shown in sketch below.

Important: to obtain correct ring and pinion greasing it is essential to fully rotate the slewing ring in both directions.

Maximum safety is obtained when only one operator performs this job.

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Maintenance

Maintenance and operator’s manual

Boom and derricking system 1 / Greasing the skids: telescope the jib by xxx m to align the grease points with their orifices. Two grease points per jib foot.

2/ Greasing of pulley block: 1 grease point.

3/ Greasing of jib foot joint: 2 grease points.

4/ Use a brush to grease the slides of the side skids on jib sections.

(Extend the jib.)

5/ Greasing the derricking ram: 2 grease points at foot of ram, 1 grease point at top of ram.

Greasing the cylinder rod: with the boom horizontal, grease the short length of cylinder rod that is exposed to the air. Repeat this operation each time the boom is greased or extensions are fitted. During these operations, the boom is lowered below 0˚ and the cylinder rod loses its protective grease.

3 1

5 2

4

Winch cable Cable inspection (Refer to 500 hourly list)

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V---21

Maintenance

Maintenance and operator’s manual

Transmission: convertor and powershift unit Level: every 50 hours Access: on the lower right ---hand side of the unit.

Filling up: By tube (1) on right ---hand side of the machine.

Topping---up: To check level: --- hot oil (temperature higher than 80˚) --- engine ticking over To raise the temperature: --- place the machine on its outriggers (wheels off the ground) --- accelerate the engine and go through all the gears, with the machine’s brakes on to heat the oil up.

--- take the brakes off and go back through all the gears to spread the oil well through the circuit.

--- when the oil reaches 80˚, (engine still ticking over) go into neutral gear.

--- open the filler cap to allow air in.

--- open the butterfly nut (3), the oil should flow slowly without overflowing --- top up if necessary.

Drive shafts 3 grease nipples per drive shaft. Check for greasing and add if necessary.

Slewing locking system 1 grease nipple on locking system housing body

Turret cab heater unit fuel tank Check the level and top up if necessary Warning: Use clean fuel. Do not use the dregs from the tank or jerrycan V---22

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Maintenance and operator’s manual

Maintenance

List ”C” --- 100 hours Batteries Electrolyte level check: every 100 hours.With the electrical circuit disconnected, --- unscrew the cell plugs, --- the level in each cell should be between 10 and 15mm above the seperators, --- top up with purified water, --- refit and tighten cell plugs.

WARNING: Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm.

Wash hands after handling.

Checking the specific gravity Check the specific gravity of the electrlyte in each cell using a hydrometer ( before adding purified water).

1.285 32˚ correctlycharged 1.200 24˚ charged to half capacity 1.120 16˚ discharged --- If necessary, recharge the batteries and have them controlled by an auto---electrical workshop.

--- If the charging current is too high( requires frequent water addition) or too weak (low specific gravity), a diagnostic should be made and the cause corrected in order to prolongate battery life.

General battery maintenance Keep the top of the batteries clean and dry to avoid short ---circuits and corrosion.Remove the battery terminals and check to see if they are attacked by corrosion. If they are scrape off the corrosion and a thin film of metal and coat them with petroleum jelly or another suitable product.Moderately tighten the terminals.Take care when using the spanner so as not to touch the battery casing or other battery terminals.Never allow a naked flame above the batteries.

Battery fixation Moderately tighten the battery securing bolts by only half flattening the washers, then tightening the counter nut.

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V---23

Maintenance

Maintenance and operator’s manual

Wheelnut tightness Check wheelnut tightness regularly, every 100 hours.

Torque setting: Front wheels:..........65 m/Kg Rear wheels:...........65 m/Kg

1

2

3

Air filter Clean the air filter If the cartridge is dry:--- blow out the interior using low pressure (not more than seven bars). --- make sure , with the aid of a lamp inside the cartridge, that it is not perforated.If the cartrdsige is greasy it must be replaced.Replacing the cartridge:The central safety cartridge (3)is not to be cleaned.Replace it every third time that the primary cartridge (2) is cleaned.The primary cartridge (2) must be replaced after being cleaned 6 times or once a year. --- make sure that the sealing ring is in good condition.If there is any doubt or apparent defect then replace the cartridge.

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Maintenance and operator’s manual

R---N

Maintenance

Slewing reducer gear motor Check level: every 100 hours (on dipstick) Capacity: 2.6l.

Combustion engine radiator Clean the cooling matrix.

V

Ancillary component belt tensions and conditions Check the condition of all belts, and replace them if necessary.

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V---25

Maintenance

Maintenance and operator’s manual

List ”D” --- 200h/250h Tyre pressures 1 14.00R x 25 : Road : 10 bars --- 145 PSI. Work on tyres : 10 bars --- 145 PSI. 16.00R x 25 : Road: 9 bars --- 131 PSI. Work on tyres: 10 bars --- 145 PSI. 20.5R x 25 / 17.5R x 25: Road : 7 bars --- 102 PSI. Work on tyres: 10 bars --- 145 PSI.

Batteries Checking the specific gravity Specific gravity

Baumé degree

observations

1.285 32˚ correctly charged 1.200 24˚ charged to half capacity 1.120 16˚ discharged --- If necessary, recharge the batteries and have them controlled by an auto---electrical workshop.

--- If the charging current is too high( requires frequent water addition) or too weak (low specific gravity), a diagnostic should be made and the cause corrected in order to prolongate battery life.

General battery maintenance Keep the top of the batteries clean and dry to avoid short ---circuits and corrosion.Remove the battery terminals and check to see if they are attacked by corrosion. If they are scrape off the corrosion and a thin film of metal and coat them with petroleum jelly or another suitable product.Moderately tighten the terminals.Take care when using the spanner so as not to touch the battery casing or other battery terminals.Never allow a naked flame above the batteries.

Battery fixation Moderately tighten the battery securing bolts by only half flattening the washers, then tightening the counter nut.

Boom base V---26

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Maintenance and operator’s manual

Maintenance

Check the boom axle fixing screw tightening torque. See the tightening torque table at the beginning of this section.

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04/2001

V---27

Maintenance

Maintenance and operator’s manual

Carrier cab 2 grease nipples on the carrier cab door.

Greasing of front and rear axle connecting rods and linkages.

2 to 3 pumps on the grease gun per grease nipple.

Graisseur Engrasador Engrasador Graisseur Engrasadors Graisseurs

Graisseurs Engrasadors

--- 1 grease nipple on each suspension ram connecting shaft ----- 4 grease nipples on axle swivel points (2 per swivel) --- 2 grease nipples on steering rams (front axle : 2 rams)

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Maintenance and operator’s manual

Maintenance

Winch reducer gear R---N

Check level : every 200 hours (plug R---N) Capcity : 4 L for 4.5 t winch

Steering block Air conditionning unit Once a month : --- clean the evaporator with compressed air ( 4 bar) --- clean the condenser with pressurized water CAUTION: In both case, excessive pressure could damage the fins.

This maintenance will not be really efficient unless there is an important build up of dust or dirt.

Check the oil level in steering block

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V---29

Maintenance

Maintenance and operator’s manual

Liste ”E” --- 500h/600 h Hydraulic circuit filters Replace the filter : every 500 hoursBetween exchanges of the filter cartridge:Keep an eye on the clogging warning light on the control panel.If this stays lit the filter cartridge must be changed.Oil the seal, screw the cartridge until contact is made the tighten by half a turn.

After any operation requiring the closure of the flow valve, never start up the machine before making sure that this valve has been reopened .

Air dessicator Frequency : every 500 hours Situated in metal casing on left hand side of chassis.

Change the cartridge situated in the upper part of casing

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Maintenance and operator’s manual

Maintenance

Front and rear axles Check the condition of the brakes.

Grease all moving joints.

Clean and then grease wheel hubs.

Axle differenrial unit Check level : every 500 hours The level should be up to the edge of the orifice R ( Filler and level check orifice)

Axle gear reducer Check level : every 500 hours.

The level should be checked when the raised mark on the reducer is in a horizontal position and the drain plug at the bottom.

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V---31

Maintenance

Maintenance and operator’s manual

Pivoting, swivelling joints and linkages. every 500 hours or every 5000 Kms Moderately grease pivot and swivel joints and linkages.

Moderately grease transmission linkages.

Air bottles Clean the bleed valves of the air bottles

Every 500 hrs or 5,000 km, check all steering screws for tightness (steering shaft, steering box, levers, steering rods, etc).

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Maintenance and operator’s manual

Maintenance

Winch cable The winch cable is the principal element on a mobile crane and therefore merits particular attention concerning its initial fitting onto the machine , as well as its maintenance.

Fitting the cable onto the machine.The selected cable must be clean and not show any signs of corrosion or damage.Normally, the new cable to be fitted should be of the same type as the original. Before fitting the new cable , ensure that the its diameter corresponds to the grooves on the winch drum and the different pullies.

When a reel of cable is unwound (either a bare reel or from a spool, and always on a clean surface to avoid picking up impurities from the ground), care should be taken so as not to twist or untwist the cable. The same attention should be paid when winding the cable onto the machine. If no precautions are taken the cable may buckle, form loops or knots.

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V---33

Maintenance

Maintenance and operator’s manual

After having unwound the cable, wind it onto the winch. Be careful when fitting the cable into the wedge retainer housing. The loop should be manually preformed to a dimension which is as close as possible to its definitive dimension in order not to have to pull a long length of cable to tighten it.

El cable debe salir de 70 a 80 mm The cable should exceed by 70 or 80 mm The wedge and the cable should side IMPORTANTE : La cuña y el cable deben deslizarse freely until the cable trapped against the libremente hasta que el cable se atranque en los cossides of the wedge retainer housing tados de la caja con cuña.

El cable no debe salir del tambor

How to section a cable Section at this

Bind the cable on each side of the point to be sectionned before hand .

Once the cable has been wound on,double reeve a pulley block and attach a load( maximum load for 1 strand).Completely unwind the cable using derricking and telescoping functions.Once the cable is completely unwound, rewind it under load to put it under strain and eliminate any strain.

Particular attention must be paid to the condition of mobile crane cables, and teir replacement is essential at the slightest doubt.

The principal maintenance job is lubrification. The cable should be regularly lubrified according to needs and especially in areas where it wound or bent around pullies and the winch drum. It is essential to use equivalent lubricants as employed by the manufacturer. These are oils, which contrarily to grease, can penetrate the cable.

Lubrification reduces corrosion problems, wear and the friction coefficient when the cable passes through pullies and is wound onto the winch drum.

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V---33

Maintenance

Maintenance and operator’s manual Cables must be visually inspected everyday in order to pinpoint any signs of deterioration or deformation.Particular attention should be paid to cable attachment points.

In any case, when an incident occurs which may have caused damage to cable strands and wires or to attachment points, or when a cable is going to be reused after having been removed and refitted, then it should be closely examined.

If the machine has not been used for quite a long period, the cable should be inspected before restarting work.

Particular attention should be paid to : --- Attachment points at each end of the cable.

--- The sections of the cable which pass over pulley block pullies and return pullies.

Reasons for removing the cable: --- Broken wires (reason and number) --- Packets of broken wires --- Gradual increase in number of broken wires --- Broken cable strands--- Broken cable core --- Reduced elasticity. . cable diameter reduction . lengthening of cable . tightening of individual wires and strands . appariton of fine brown dust between strands.

--- General wear of the cable by abrasion --- External and internal corrosion --- Deformed cable (under load) spiral form deformation stretche d wires slackening of certain wires and strands knots contracti ons flattened areas loops buckles bends --- Deterioration induced by heat

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Maintenance

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Maintenance

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Maintenance and operator’s manual

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Maintenance and operator’s manual

Maintenance

Daily inspection All cables which are in daily active use must be visually inspected every day wherever possible. This consists of a simple visual inspection where no measures are made, whose aim is to detect visible alterations and deformations.However, it is also recommende to make reasonably regular inspections which involve fully unwinding the cable for inspection over the whole length, and particularly on attachment points which are normally awkward to get access to.

Periodic inspections On regular working mobile cranes : every week.

Plastic pulleys Effects of the use of plastic pulleys on lifting cables.

Our jib heads are fitted with plastic pulleys. This increases cable life.

When lifting cables are used with plastic pulleys only, all cable wear is internal and not visible from the exterior.

Our pulley blocks are fitted with steel pulleys. Consequently, the cable also wears visibly on the outside due to friction against the steel cables.

Nevertheless, we strongly recommend regular magnetoscopic examination of the cables in order to detect any internal cracks.

If the pulleys of the pulley block are replaced with plastic pulleys, magnetoscopic examination becomes obligatory.

Brakes

Visually check the brake linings.Check the tightness of brake pipe castle nuts.Torque setting : 160Ndan. This check has to be carried out during the first warranty visit, then every 500 hours.

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V---37

Maintenance

Maintenance and operator’s manual

Combustion engine (600h): Oil change

Remitirse al documento MERCEDES para más detalles.

Please refer to manufacturers’ specifications for further details (MERCEDES) The engine’s data card is part of its identity papers, and must therefore always be kept with the engine’s service booklet. It holds the data on the engine’s production condition, including special versions. To obtain spare parts, it is absolutely essential to show the engine’s data cardy to ensure that ordering the parts goes without a hitch.

To order oil filters, use the engine’s data card. Show it to your Mercedes agent, or send it by fax to our spare parts department.

Clean the fuel pre---filter Remítase al documento MERCEDES para más detalles.

Please refer to manufacturers’ specifications for further details (MERCEDES) At 600 hours --- change engine oil filter At 600 hours --- change fuel filter Refer to manufacturer’s specifications for further details(MERCEDES)

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Maintenance

List ”F” --- 1000h R---N

Check all fasteners Check tightness

Slewing reducer gear oil change.

Check level : every 100 hours ( on dipstick ) Oil change : every 1000 hours Capacity : 2.6 L. Filler orifices : 2 lateral orifices ”V”

V

Winch reducer gear V R---N

Check level : every 200 hours (plugs R --- N) Oil change : first oil change after 120/150 hours of service, then every 1000 hours or at least once a year.

Capacity : 4 L for 4.5 ton winch To drain reducer gear:--- unwind the winch cable to gain access to the orifice on the drum. --- positon the orifice ”V” towards the bottom to drain off the oil

Boom section slide pads Every 1000 hours Check the condition of the slide pads.Verify tightness of pad and pad support fixation bolts Check the condition of the boom pullies.

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V---39

Maintenance

Maintenance and operator’s manual In case of change, check the accumulator pressure.

Have the airbrake bottles checked by a PPM specialist Combustion engine Check the condition of the starter motor and alternator Refer to the manufacturer’s specifications for further details (CUMMINS or MERCEDES)

Hydraulic circuit Check for leaks on the hydraulic circuit, and change any damaged flexible hoses.

Steering Every 500 hrs or 5000 km, check that the steering screws are fully tight (steering axis, steering box, gears, rods, etc) Check wheel alignment

Have the steering geometry checked by a PPM specialist.

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Maintenance

Transmission : convertor and powershift unit.

Oil change : every 1000 hours.

First oil change after 100 / 120 hours Capacity : 36 L Refer to oil level indicator N Do the transmission unit oil change with the engine stopped, empty by draining orifice V. Replace oil filter cartridges.

Fill the transmission circuit with about 18 l. oil using filler hole 1.

Top up: See page 31, chapter V.

AEB Cycle ”Automatic determination of filling parameters” (”Automatisiertes Ermitteln der Befüllparameter” or ”AEB”) is used to compensate tolerances (disc clearance and pressure level) which can influence the process of filling the clutch. Since this can affect the quality of the gear change, ZF recommends repetition of the AEB cycle at each maintenance interval, i.e. once after 100 hours of operation, and again every 1,000 hours of operation or once a year.

If gear change quality deteriorates, ZF recommends repeating the AEB cycle as a first step. To perform an AEB cycle, contact the nearest ZF agent.

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V---41

Maintenance

Maintenance and operator’s manual

List ”G” --- 2000 h Hydraulic tank 1/ Filler cap 3/ Level 4/ Hydraulic circuit shut---off control Check level : every 10 hours.

1

3

4

Oil change: The first oil change must be made after 2000 hours or 1 year of service, afterwards every 2000 hours.Doing the hydraulic circuit oil change involves draining the following components: Tanks, pumps, rams, hydraulic motors, radiators,......

The procedure is not explained in this document, please consult the PPM specialist in your area.

When the oil change is done, also change the oil filter situated on the right hand side of the turret.

--- Machine on a level surface --- all rams retracted

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Maintenance

Maintenance and operator’s manual

Front and rear axles Differential unit Oil change : every 2000 hours ( or at least once per year ) Drain oil from orifice ”V” after having driven the machine a few minutes to warm up the oil.

The drain plug is situated underneath the housing.

Fill by orifice ”R” Front axle housing oil capacity : 13,5 L Rear axle housing oil capacity : 17 L Clean the breather situated on the upper part of the housing.

NOTE : Do the first oil change after 500 hours of service.

V Axle reducer gear Oil change : every 2000 hours.

The drain plug must be positioned towards the bottom for draining, after having warmed up the oil by driving the machine for a few minutes.

Oil capacity : Front axle : ATT250 --- ATT300 : 1,5 L per reducer gearRear axle : ATT350 --- ATT400 : 1,6 L per reducer gear Note : Do the first oil change after 500 hours of service.

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Boom Check the telescoping chain attachments.

Counterweight Every 2000 hours or every 6 months Check the tightness of fixation bolts Torque setting : +5mdaN 0

Brakes Every 2000 hours or once a year.

Change all flexible hoses on the brake circuit

Electrical circuit Check all wiring loom attachments

Air conditioning unit Once year : It is recommended to ask a specialist to check your installation.

Peroid of idleness It is recommended to operate the equipment for at least 10 consecutive minutes once every fortnight.

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Maintenance

Upper heating fuel tank Outside periods of use, purge and clean the independant tank From september : --- fill the fuel tank --- check the state of the spark plug --- clean the fuel filters NB: The recommendations for use are in the heating manual.

All maintenance operations should be carried out by the EBERSPÄCHER or one of their agents.

List “H” --- 8000 hrs Slew ring Every 8000 hours, have the slew ring and its accessories changed by PPM ---approved personnel.

ONLY USE PPM PARTS.

List “I” --- 20000 hrs Telescopic boom Dismantle the telescopic boom and check every part making up the boom thoroughly.

Check welds, change the telescoping cables and the telescoping chains. Check the condition of the pulleys, the rollers, the cable bushings, all the hydraulic components, the hoses, everything.

CAUTION : Use clean fuel Do not use the bottom of the tank or jerrican .

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Fuel---lubrifiants

Maintenance and operator’s manual

Fuel --- lubrifiants VI

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Maintenance and operator’s manual LUBRICATION CHART COMPONENT

Cold climates

Temperate climates

Tropical climates

---25˚C +25˚C

---15˚C +35˚C

---5˚C +45˚C

Boom chains

ALVANIA EP2

Boom slide pads

MOLYKOTE BR 2

Grease nipples

ALVANIA EP2

Slewing ring teeth

MALLEUS GL 205

Slewing ring bearing

ALVANIA EP2

Slewing reducer gear

SPIRAX HD 80W90

SPIRAX HD 80W90

SPIRAX HD 85W140

Winch reducer gear

SPIRAX HD 80W90

SPIRAX HD 80W90

SPIRAX HD 85W140

HYDRAU TP ou

Hydraulic fluid

TELLUS T 22

SHELL NATURELLE

TELLUS T 68

Axle differential + reducer units

SPIRAX HD 80W90

SPIRAX HD 80W90

SPIRAX HD 85W140

Engine

RIMULA X 10W30

RIMULA X 15W40

RIMULA X 20W40

HF --- E (biodegradable)

GLYCOSHELL +

Cooling circuit CLARK gearbox

RIMULA X 10W

RIMULA X 10W

RIMULA X 10W

ALLISON gearbox

DONAX TA

DONAX TA

RIMULA X 15W40

ZF gearbox

RIMULA X 10W

RIMULA X 10W

RIMULA X 15W40

ZF gearbox

DONAX TA

DONAX TA

RIMULA X 15W40

Transfer unit

SPIRAX HD 80W90

SPIRAX HD 80W90

SPIRAX HD 85W140

Transfer unit

SPIRAX HD 80W90

SPIRAX HD 80W90

SPIRAX HD 85W140

ECH---FCH55&77 wet brakes

RIMULA X 10W + 3.12%--->5% LUBRISOL 6279

RIMULA X 10W + 3.12%--->5% LUBRISOL 6279

RIMULA X 10W + 3.12%--->5% LUBRISOL 6279

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Component capacities Engine................................................. refer to constructor’s manual Gas oil tank....................................... 250 L Hydraulic tank.................................... 360 L Swing reducer................................. 3 L Winch reducer ............................. 4 L Steering :..................................... 0,5 l Torque converter + gear box :.....28 L Front axle housing :.....................13,5 L Front axle reduction gears .......... 1,6 L Rear axle housing :.................... 17 L Rear axle reduction gears :....... 1,5 L The above capacities are given for guidance only. Whenever possible, it is advisable to be guided by the levels shown on the components to be lubricated.

WARNING: NEVER MIX SYNTHETIC OILS WITH MINERAL OILS

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Filter elements (MERCEDES engine) Engine oil filter .......................................S 63505---69 Gas oil filter........................................... M 63505---18 Fuel preflter : . . . . . . . . . . . . . . . . . . . . . . D 26505---92 Gearbox filter : . . . . . . . . . . . . . . T 63505---70 Air filter...........primary............................ A 63505---53 security............................. B 63505---54 Hydraulic circuit filter :............................... W 27505---90 Element service indicator..........................W 63505---26K 18416---42 Dessicator filter :...................................... A 27505---24 The engine data card is one of the engine document which should be kept with the maintenance booklet. It contains details about the production condition of the engine, including special versions.

Presenting the engine data card is absolutely necessary for acquiring parts, in order to ensure unproblematical ordering of the required parts.

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M.L.I.

Maintenance and operator’s manual

Load Moment Indicator DS 350C VIII

Edition : 12/1992

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1 --- General information The purpose of the load moment indicator PPM (LMI) DS 350 is to give the crane driver the essential information he needs to use his machine in complete safety.

Using the information from the various sensors, the load moment indicator oversees all the various crane functions and provides the driver with a continuous display of crane lifting capacity. The display varies constantly in relation to the different crane movements needed for load---handling.

The LMI (load moment indicator) gives the driver information about the length and angle of the boom, useable reach and the total weight calculated and lifted by the crane.

When the load limit is being approached, the load moment indicator tells the driver that this is so by an audible warning, a warning signal lights up and all crane functions are cut off if the situation gets worse.

The LMI is an additional means of control which warns the crane driver about imminent overload conditions and the end of lifting which could well cause damage to goods and to people.

The device does not and must not replace the sound judgement and experience of the driver nor his carrying out safe manoeuvres within the rules.

The crane driver is responsible for the crane handling; it is his responsibility to ensure that all the warnings and instructions are completely understood and observed.

Before using the crane the driver must carefully read and understand the information in this manual. He must know how to handle both the LMI and the crane and their limits.

For the LMI to work well, it should be inspected daily and the instructions given in this manual must be observed.

We draw your specific attention to section 5 of the manual.

WARNING The display unit (1) can only help the crane driver if the crane’s configuration operating code has been chosen correctly in relation to the type of work being carried out. In order to avoid serious accident, it is necessary for the LMI programming to be correctly carried out before the crane is used.

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3 --- Description of system The DS 350 C load moment indicator system is made up of a microprocessor central unit, a control board, a length and angle sensor, pressure sensors and travel limit switches.

The system works on the principle of comparing theoretical value with actual value.

The actual value resulting from measuring force or pressure is compared with the theoretical data memorised in the memory of the central processor.

If the limits are reached, there is a warning signal on the control board. At the same time, dangerous crane movements (lifting, telescoping, derricking up and down, and slewing) are cut off.

The crane’s theoretical data, like load capacity charts, the weight of the boom, centres of gravity and dimensions, are memorised in the memories situated in the central unit. These sets of data constitute the theoretical data used for calculating the conditions in which the crane may be used.

The length and the angle of the boom are measured by the length and angle sensor installed in the drum mounted on the boom. The length of the boom is measured by the drum cable which also serves as an electric conductor for the travel limit switches.

The load on the crane is measured by pressure sensors fixed on the large chamber and the small chamber of the derricking rams.

3.1 --- Functioning of system The load moment indicator (LMI) works with a system which guides the user, simplifying use of the crane and of the LMI system. After the crane motor starts up, the system makes an automatic check on all the indicators, the audible warning and the entire LMI system.

If there is an error in the system, an error code number is displayed on the board.

Once the automatic check has finished, the operator must program the LMI with the crane’s configuration. The system is then ready for use.

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3.2 Control Board This has two functions: Input by the crane driver of the necessary system instructions Display of information data and instructions

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1 / Display 2/ Travel limit warning light 3/ Advance load moment warning light 4/ Load moment warning light 5/ Release warning light 6/ ’Incremention’ control 7/ ’Stop audible alarm’ control 8/ ’Tara’ control 9/ ’Operating code’ control 10/ ’Number of lines’ control 11/ ’Decrementation’ control 12/ Moveable key release switch

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3.3 Control items Illustration 1 shows the control elements and the displays of the DS 350 C load moment indicator. The numbers on the illustration correspond to the numbers in the following list which describes the function of each control item

1/ Display This shows technical and operating information and instructions for the driver.

1.1 / The MAX LOAD is the maximum permissible load as in the load capacity chart or the maximum load permitted by the reeving selected using control 10 (’Number of lines’). The intermediate values of the capacity chart are interpolated linearly by the computer.

1.2/ The ACT.LOAD is the actual load (gross load). The weight of the slings and the pulley---block are included.

1.3/ The display shows the operating code number selected by the driver.

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1.4/ The display indicates the length of the boom.

1.5/ The load moment is shown by bar graph. This shows instantly the used capacity percentage.

As the capacity of the crane changes with the various movements, this display changes constantly to correspond with the nominal power of the crane.

This indicator has three zones: --- a green zone (0 to 90% of nominal capacity) --- a yellow warning zone (90 --- 100% of nominal capacity) --- a red overloaded zone (more than 100% of nominal capacity) 1.6/ the display shows the reach of the crane 1.7/ the display shows the height under the boom head 8/ The display indicates the number of lines selected by the crane driver using control (10).

1.9/ The display shows the boom angle.

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2/ Travel limit warning light This red light goes on when the end of travel switch contacts are open. The audible alarm is heard at the same time. Dangerous crane movements are stopped.

3/ Advance load moment warning light This yellow light goes on when the load acting on the crane has entered between 90% and 100% of nominal capacity, indicating that overload is not far off.

For the crane driver this means that he must continue to handle the crane with all necessary precautions.

4/ Load moment warning light This red warning light tells the crane driver that the nominal load state has been reached.

It goes on when the load on the crane has reached 100% of its nominal load.

5/ Release indicator This red light flashes when the LMI is released.

6/ ’Incrementation’ control This touch control is used to increase the operating mode code or the number of lines.

How to use this control is described in detail in sections 4.1 and 4.2.

7/ ’Stop audible alarm’ control To cut off the audible alarm. Press it to stop the alarm.

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8/ ’Tara’ control The ’Tara’ control is used to display the lifted load at the hook. The slings and the pulley---block are not included in this load.

Use. Sling the load without lifting it.

Press TARA control for the LMI system to memorise the weight of the pulley---block and the slings.

The display flashes and shows the value of 0.0. Calibration is finished.

Lift the load WITH THE WINCH without derricking or telescoping. The display flashes and shows the exact weight of the lifted load.

If the length or angle of the boom is changed (derricking or telescoping) the display unit gives the total lifted weight again (load + pulley--block + slings).

9/ ’Operating code’ control This is used to enter a new operating mode identification figure in the system.

When this is activated, it lights up to indicate that the ’enter an operating mode identification number’ function has been started. At the same time, the ’advance load moment’ and the ’load moment’ warning lights go on and crane movements are cut off.

After an operating mode identification number has been entered, press the ’operating code’ control again, the function has finished, the lights go out and crane movements are no longer blocked.

The procedure for entering an operating mode identification number is described in detail in section 4.1.

CAUTION Selecting the right code is crucially important for the crane system to work properly. For this reason, the codes must be selected only by the crane driver who has perfect knowledge of the load capacity charts and of how to use and operate the system.

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10/ ’Number of lines’ control This is used to enter a different new number of lines in the system.

When the ’number of lines’ control is pressed, it lights up to indicate that the ’number of lines’ function has been started. Once the number of lines has been entered, press the ’number of lines’ control again, and the function has finished.

The procedure, ’Entering the number of lines’ is described in detail in section 4.2.

CAUTION Selecting the right number of lines is crucially important for the crane system to work properly. For this reason, the number of lines must be selected only by the crane driver who has perfect knowledge of the load capacity charts and of how to use and handle the system.

11/ ’Decrementation’ control This is used to lower the operating mode code or the number of lines.

How to use this button is described in detail in sections 4.1 and 4.2.

12/ Moveable key release switch The switch is a touch control. This key release switch enables LMI cut---off to be de---activated so that crane movements are not blocked.

Given that this switch de---activates the LMI and travel limit cut---off systems, the crane driver must observe the following instructions: --- the release switch must be used with circumspection and only in extreme cases, under the responsibility of the site manager.

--- He should be completely aware of what could happen by way of damage to the machine and to personnel if a load is lifted with the system released.

--- The release switch may never be used either for overloading or for handling the crane in a forbidden configuration.

Turning the key to the right releases the LMI system and unblocks crane movements. The system remains released for as long as the LMI is cut off.

Warning light (5) and an outside warning device are active for as long as the LMI is released.

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4 --- Programming procedure Each time the crane is reconfigured, the crane driver must reprogram the LMI. This procedure has two parts: Programming the LMI in the crane’s working configuration Programming the LMI for the current number of lines.

Caution Selecting the right operating code and the right number of lines is crucially important for the crane system to work properly.

For this reason, the codes and numbers must be selected only by the crane driver who has perfect knowledge of the load capacity charts and of how to use and handle the system.

4.1 / Selecting Operating Modes 4.1.1/ Using ’operating mode identification number’ control When control (9) is pressed, it lights up and shows that the enter function has been set off. At the same time the ’advance load moment ’ and the ’load moment’ warning lights, (3) and (4), go on and dangerous crane movements are cut off.

The display unit shows the operating mode identification code and the text matching the selected operating mode.

4.1.2/ Selecting operating mode The two controls ’forward’ (6) and ’backwards’ (11) are used to select a new operating mode. When these touch controls are used, the operating modes are displayed one after another.

4.1.3 / Using ’operating mode identification number’ control When the desired operating mode is reached, valid it by pressing control (9).

The warning lights ’advance load moment’ (3) and ’overload’ (4) go out as does the light in control (9). The formerly blocked crane movements may now be used again.

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4.2/ Adjusting the number of lines Adjusting the LMI for the number of lines used on the crane is done in the same way as ’adjusting operating mode’ described in 4.1:

4.2.1 / Activating ’number of lines’ control Once control (10) is pressed it lights up to show that the ’enter a new number of lines’ has been started.

4.2.2 / Selecting the number of lines The two controls ’forwards’ (6) and ’backwards’ (11) are used to increase or decrease the number of lines in order to select the desired number of lines.

4.2.3 / Using control ’number of lines’ When the desired number of lines is displayed, validate it by pressing ’number of lines’ control (10).

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5 --- Inspection before starting up Before using the crane, the following electrical connections must be checked to ensure that the system is connected correctly depending on crane configuration.

Machines with PRINCIPAL LIFTING mechanism If the crane is working only with the boom and with neither extension nor fly---jib, there is no need for supplementary connections.

However, the driver must ensure that the travel limit switch counterweight is correctly installed around the lifting cable. The counterweight must be installed to the cable fixing line.

If the crane is working with extension/fly---jib, the connection cable must be installed between the by---pass box on the boom.

The counterweight fixed to the boom head travel limit switch must be removed and remounted on the extension/fly---job travel limit switch and around the cable at the extension head.

WARNING If the travel limit switch is not repositioned, the travel limit system cannot work properly. When the extension/fly ---jib is being used, the counterweight must not be attached to the travel limit switch at the boom head.

Once the electrical connections have been checked to ensure that the system is correctly connected for the crane’s configuration, the following checks must be carried out: 1. the cabling joining the various parts of the system for mechanical damage.

2. the degree of mobility of the travel limit switches and counterweights.

3. the spring drum to ensure that it may turn freely, and that the cable winds correctly and is properly taut.

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CAUTION The following tests must be carefully carried out to avoid damaging the machine or injuring people.

For the system to work well, these tests must be carried out correctly.

If the driver cannot see the pulley---block clearly when it is approaching the boom head, he must be assisted by another person.

The driver must be ready to stop the machine immediately if the LMI system is not working properly.

1. Check the travel limit indicator (2) and the audible alarm (7) by manually lifting the counterweight fixed to the travel limit switches.

2. Raise the boom head pulley---block slowly, using the winch, in order to engage the switch. At the point when the pulley---block takes the weight, the audible alarm (7) should sound, the travel limit indicator (2) should go on and crane movements should be stopped.

Lower the pulley---block to return to normal crane functioning.

If the warning light and if the audible alarm do not function as described and if crane movements are not stopped, then the system is not working properly.

It must be put right before the crane is used.

3. If the crane has an extension/fly---jib, the test procedure must be repeated for the extension/fly---jib’s travel limit switch.

4. Check to see if the length of the principal boom is the same as the actual boom length.

5. Check to see if the display of the principal boom angle is the same as the actual angles.

6. Check to see if the display of the crane’s useable reach is the same as the actual reach.

HANDLING When the LMI has been set correctly, it will work entirely automatically.

The crane driver must therefore know all the LMI control items perfectly and he must set each switch correctly before handling the crane.

All the settings must be checked by handling a load of known weight and comparing this with the information shown on the load moment display.

The theoretical loads contain the weight of the pulley---block, the slings and auxiliary lifting devices. These weights should be deducted form the theoretical data to obtain the net load to be handled.

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6 --- SERVICE AND MAINTENANCE Maintenance of the load moment indicator is as follows: 1. Checking the cabling between the various parts of the system. Any defective cable should be replaced immediately.

2. Checking the insulation of the length sensor cable and the cable guides. If the insulation is worn or if the cable guides are damaged, these parts must be replaced.

3. Checking the mobility of the travel limit switches.

4. Checking the drum cable tension.

5. Checking the pressures sensors at the derricking rams and the flexible connection hoses (for oil leakage). It is absolutely forbidden for non---specialist staff to carry out any repairs except to correct those problems identified in the Disruption Table and to replace mechanical parts or defective cables.

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7--- Detecting errors General Information During a system error, the display (1) shows an error code which identifies the disruption.

The error codes in the Disruption Table identify several errors which could occur in the LMI. The pages following the Disruption Table explain each fault and describe the measures to be taken to rectify it.

Faults in the electronic microprocessor should be repaired by after--sales staff trained in the factory. Where there are such faults, the appropriate after---sales department should be contacted.

FALSE MANOEUVRES Disruptions in the system caused by the driver exceeding fields or making false manoeuvres are shown on the display with an explanation.

The error codes are E01, E02, E03, E04, E05 and E06 and they may normally be dealt with by the crane driver.

Disruption Table Error code, Error, Cause, Rectification E01: Minimum reach field reached or maximum angle field exceeded.

The boom has been raised too far so the minimum reach or the maximum angle appearing in the load capacity table has been exceeded.

Lower the boom to a reach or an angle appearing in the table.

E02: Maximum reach field in load capacity table being exceeded or minimum angle field not reached.

The boom has been lowered too far so the maximum reach or the minimum angle appearing in the load capacity table has been exceeded.

Raise the boom to a reach or an angle which appears in the table.

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E04: Operating mode does not exist, Present crane configuration is not acceptable for the selected operating mode.

Modify operating mode selected.

E05: Length field forbidden, a. The boom has been telescoped too far or not far enough. For example: the driver may work only to a certain boom length or where there are fly---jib load charts, the principal boom must be telescoped to a determined length, a. Telescope the boom to the correct length b. The setting of the length sensor has changed, e.g. the cable has jumped from the length sensor cable drum, b. Retract the boom. Check that the cable drum is tensioned correctly (the cable must be taut). Open the length sensor and turn the length potentiometer very carefully anticlockwise up to the stop, using a screwdriver. ++++++++++++++++++++++++++++++++++ c. Coupling between the length sensor potentiometer and the control mechanism is defective, c. Change the couple with the cog wheel completely and set the length potentiometer (see b.) d. The 5V supply for the analog part of the LMI’s supply board is missing, d. Check the 5V supply. If there is none or if it cuts out with a charge of approx. 50 Ohms, change the supply board e. The cable of the length sensor central unit is defective or disconnected, e. Check the cables and their connectors, change them if necessary. f. Defective length potentiometer, f. Change the length potentiometer.

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Maintenance and operator’s manual E07: Overload relay no reply The overload relay is defective.

Replace the relay. If this makes no difference, replace the connection board.

E08: Travel limit switch relay no reply, The travel limit switch relay is defective, Replace the relay. If this makes no difference, replace the connection board.

E11: The lower limit of the measurement channel ’length telescopic boom’ is being exceeded, a. The cable between the central unit and the sensor is defective or disconnected, or there is water in the connector, a. Check cables and connectors, replace if necessary b. The length potentiometer is defective, b. Replace the length potentiometer c. The electronic component in the measurement channel is defective, c. Replace the CPU board or the analog board

E12: The lower limit of the measurement channel ’piston side pressure’ is being exceeded, a. The cable between the central unit and the pressure sensor is defective or disconnected, or there is water in the connector, a. Check the cables and the connectors, replace if necessary b. The pressure sensor is defective, b. Replace the pressure sensor c. The electronic component in the measurement channel is defective, c. Replace the CPU board or the analog board

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E13: The lower limit of the measurement channel ’rod side pressure’ is being exceeded, a. The cable between the central unit and the pressure sensor is defective or disconnected or there is water in the connector, a. Check the cables and the connectors, replace if necessary b. The pressure sensor is defective, b. Replace the pressure sensor c. The electronic component in the measurement channel is defective, c. Replace the CPU board or the analog board E15: The lower limit of the ’principal boom angle’ measurement channel is being exceeded, a. The cable between the central unit and the angle sensor is defective or disconnected, or there is water in the connector, a. Check the cables and the connectors, replace if necessary b. The angle sensor is defective, b. Replace the angle sensor c. The electronic component in the measurement channel is defective, c. Replace the CPU board or the analog board

E19: The reference current is defective, a. The sum of the reference current and the supply current is lower than 2.7V, a. Check the supply currents b. The analog---digital converter is defective, Replace the analog board

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Maintenance and operator’s manual E20 Reference currents do not exist, a. The crane’s battery current is too low, a. Check the crane’s battery current b. The current converter is defective, b. Change the supply board b) Der Spannungsumsetzer ist defekt. b) Die Einspeiseplatte auswechseln. b. The length potentiometer is defective, b. Replace the length potentiometer c. The electronic component in the measurement channel is defective, c. Replace the CPU board or the analog board E22: The upper limit of the measurement channel ’piston side pressure’ is being exceeded, a. The cable between the central unit and the pressure sensor is defective or disconnected, or there is water in the connector, a. Check the cables and the connectors, replace if necessary b. The pressure sensor is defective, b. Replace the pressure sensor c. The electronic component in the measurement channel is defective, c. Replace the CPU board or the analog board.

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E23 The upper limit of the measurement channel ’rod side pressure’ is being exceeded, a. The cable between the central unit and the pressure sensor is defective or disconnected or there is water in the connector, a. Check the cables and the connectors, replace if necessary b. The pressure sensor is defective, b. Replace the pressure sensor c. The electronic component in the measurement channel is defective, c. Replace the CPU board or the analog board E25 The upper limit of the ’principal boom angle’ measurement channel is being exceeded, a. The cable between the central unit and the angle sensor is defective or disconnected, or there is water in the connector, a. Check the cables and the connectors, replace if necessary b. The angle sensor is defective, b. Replace the angle sensor c. The electronic component in the measurement channel is defective, c. Replace the CPU board or the analog board

E29: The reference current is defective, a. The sum of the reference current and the supply current is less than 2.7V, a. Check the supply currents b. The analog---digital converter is defective, b. Replace the analog board E31: System program error, Replace the system program PROM

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VIII--- 23

M.L.I.

Maintenance and operator’s manual E38: System program wrong in the LMI, System program does not match the programs in the data EPROM 1, Replace the system program EPROM 1 E39: System program wrong in the LMI, System program does not match the programs in the data EPROM 2, Replace the system program EPROM 2 E41: Error in the read/write internal memory (RAM), --- Replace the read/write memory --- Replace the CPU board E42: Error in part 1 of the read/write external memory (RAM), --- Replace the read/write memory --- Replace the CPU board E43: Error in part 2 of the read/write external memory (RAM), --- Replace the read/write memory --- Replace the CPU board E45: Addressing error in the A/D converter of the LMI’s CPU board, --- Replace the CPU board E49: Transmission data wrong, Having loaded the data, the read/write memory on the memory extension contains no valid data, --- replace the memory extension --- replace the on---line interface --- replace the LMI’s system board

VIII--- 24

Edition : 12/1992

Maintenance and operator’s manual

M.L.I.

E51: data PROM error, Data PROM defective, Change the data PROM E52: load capacity table PROM error, Table PROM defective, Change the table’s PROM E56: Crane data EEPROM error Crane data EEPROM defective, Change the crane data EEPROM. E57: Crane data serial EEPROM error, The serial EEPROM has no valid data or the memory module is defective, Load a serial EEPROM with valid data using the test program, then start the LMI up again or change the memory module.

E58: Analog board EEPROM series error, The analog board EEPROM series has no valid data or the analog board is defective, Load an analog board EEPROM series with valid data, then start the LMI up again or change the analog board.

Edition : 12/1992

VIII--- 25

M.L.I.

Maintenance and operator’s manual E71: Acknowledgement incorrect on 1. relay on the connection board Relay 1 on the connection board is defective, Replace the relay. If this makes no difference, replace the connection board or the system board.

E72: Acknowledgement incorrect on 2. relay on the connection board Relay 2 on the connection board is defective, Replace the relay. If this makes no difference, replace the connection board or the system board.

E73: Acknowledgement incorrect on 3. relay on the connection board Relay 3 on the connection board is defective, Replace the relay. If this makes no difference, replace the connection board or the system board.

E74: Acknowledgement incorrect on 4. relay on the connection board Relay 4 on the connection board is defective, Replace the relay. If this makes no difference, replace the connection board or the system board.

E81: Maximum crane slant exceeded, Acceptable crane slant is exceeded, Correct the wedging state.

E82: Wedging error, At least one of the four girders is not completely extended or is not firmly resting on the ground or wrong operating code selected, Extend the girders or the support rams completely on to the ground.

E83 Data PROM error, Data PROM defective or programming wrong, Change the data PROM.

VIII--- 26

Edition : 12/1992

Maintenance and operator’s manual

M.L.I.

E86: Length field forbidden, see error E05 see error E05 NOTE: If an error code is shown on the control board which does not appear in the Disruption Table, contact the after---sales department.

Edition : 12/1992

VIII--- 27

M.L.I.

VIII--- 28

Maintenance and operator’s manual

Edition : 12/1992

3B6 LOAD MOMENT INDICATOR (LMI) TELESCOPIC CRANES Series ATT USER MANUAL LTB1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

Name C71_1: BOOM ON OUTRIGGERS 0 Length I II III IV

1

Amax Amin

79 0 2 62,4 58,4 54,1 49,5 45 33,4 19,1

3 3,5 4 4,5 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

2

Code 300

3

9,4 0 0 0

4

Ballast

14,4 24 24 24

32 8 32 27,45 24,4 21,8 19,4 15,5 11,5

79 0 2 71,9 69,8 67,4 65,2 62,8 58 53 47,7 41,8 35 24,7 11

Outrigger 2,5

5

7

19,5 48 48 48

19 4,3 20 20,35 20,75 21,2 19,3 14,75 11,7 9,4 7,65 6,4 5,4 4,65

Jib Angle

Jib Length

Zone 0

6,3 6

8

9

24,7 73 73 73

79 0 2

17 2

75,9 74,5 73,1 71,7 68,6 65,2 61,7 57,8 53,7 49,4 43 40,4 35,6 30,6 23,7 12,9

18 18,45 18,7 17,3 13,45 10,9 9,05 7,7 6,45 5,4 4,7 4,05 3,55 3,05 2,75 2,35

10

11

28,9 93 93 93

79 0 2

14 1,05

76 75,2 74,6 72,9 71,2 69,2 67,9 64,4 61,8 59 55,8 52,6 48,9 45 40,8 36,2 31,4 26,4 22,6 12,4

14 14,5 14,3 12,35 10,1 8,5 7,25 6,25 5,4 4,75 4,1 3,6 3,1 2,75 2,4 2,15 1,95 1,7 1,5 1,35

12

13

14

30,4 100 100 100

79 0 2

10 0,5

77,2 75,2 73,2 71,2 69 66,8 64,4 62 59,4 57 54,2 51,4 48,6 45,8 42,8 40 36 31,2 26 19,2 11

10 9,55 8,05 6,9 6 5,25 4,6 4,1 3,6 3,1 2,8 2,4 2,2 1,95 1,7 1,5 1,35 1,2 1,05 0,9 0,8 0,5

79 18 2

9 0,8

78,2 76,4 74,5 72,5 70,4 68,2 65,8 63,4 61 59,5 55,6 53 50,1 47,2 44,2 43,3 37,8 33,8 29,2 24 18

9 8,85 7,9 6,8 5,9 5,15 4,55 4,05 3,6 3,1 2,8 2,4 2,2 1,95 1,7 1,5 1,35 1,2 1,05 0,9 0,8

2

24/12/2001 Up-Grade Complies to the MACHINES DIRECTIVE Standards: EN60204-1, EN954, EN12077-2 EMC according to the “ Heavy Industrial Environment” category: EN50081-2, EN50082-2

2

INDEX What the load moment indicator does?

LOAD MONITORING INDICATOR (LMI) FUNCTIONAL DESCRIPTION

Pag. 3

Which components are included in an LMI? SYSTEM LAY-OUT AND CONNECTIONS

4

How is the LMI installed on the machine?

COMPONENTS LOCATION ON THE MACHINE

5

What’s the need of the control panel?

CONTROL PANEL DESCRIPTION

6

What’s does it happen when starting the machine?

SWITCHING THE MACHINE ON

7

Is the control panel informing about safety on the machine?

PANEL MONITORING – Lifting conditions % and alarms

8

Is the control panel giving useful information to work?

PANEL MONITORING – Main working data reading on the display

9, 10

Is the control panel giving useful information to work?

PANEL MONITORING – Main working data reading through graphics

11

Can the control panel give further useful information regarding the machine?

PANEL SCREENS – Complementary reading related to the machine functioning

12

How to select the Operating Mode?

SELECTING THE OPERATING MODE – Operating mode set up and stowing the jib

13

How con I select the rope number (tackle) ?

PART OF LINES SETTING UP

14

Can the LMI detect faults?

AUTO-DIAGNOSTIC

15

How the fault shows up?

ALARM CODES AND ACTIONS TO TAKE

16, 17

Apart the codes alarms, is the LMI able to give further data about its own internal operations?

AUTO-DIAGNOSTIC – System internal working conditions monitoring Geometric data and load data Hydraulic pressures data Sensors Digital Signals Status of digital inputs from outside Status of digital outputs to outside

18 19 20 21 22

What should be known before starting the machine?

WARNINGS

23, 24

What the load moment indicator does ?

3

The LMI aim is to control that the machine doesn’t exceed working condition limits, making the Operator aware and acting through alarms and shut-down of dangerous movements.

LOAD MONITORING INDICATOR (LMI) FUNCTIONAL DESCRIPTION Working condition measurements

LTB1

PRESSURE TRANSDUCERS (Lifted load)

Data display and setting

Load Tables storage, comparing and processing 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

Name C71_1: BOOM ON OUTRIGGERS 0 Length I II III IV

1

Amax Amin

79 0 2 62,4 58,4 54,1 49,5 45 33,4 19,1

3 3,5 4 4,5 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

2

Code 300

3

9,4 0 0 0

4

Ballast

14,4 24 24 24

32 8 32 27,45 24,4 21,8 19,4 15,5 11,5

79 0 2 71,9 69,8 67,4 65,2 62,8 58 53 47,7 41,8 35 24,7 11

Outrigger 2,5

5

7

19,5 48 48 48

19 4,3 20 20,35 20,75 21,2 19,3 14,75 11,7 9,4 7,65 6,4 5,4 4,65

Jib Angle

Jib Length

Zone 0

6,3 6

8

9

24,7 73 73 73

79 0 2

17 2

75,9 74,5 73,1 71,7 68,6 65,2 61,7 57,8 53,7 49,4 43 40,4 35,6 30,6 23,7 12,9

18 18,45 18,7 17,3 13,45 10,9 9,05 7,7 6,45 5,4 4,7 4,05 3,55 3,05 2,75 2,35

10

11

28,9 93 93 93

79 0 2

14 1,05

76 75,2 74,6 72,9 71,2 69,2 67,9 64,4 61,8 59 55,8 52,6 48,9 45 40,8 36,2 31,4 26,4 22,6 12,4

14 14,5 14,3 12,35 10,1 8,5 7,25 6,25 5,4 4,75 4,1 3,6 3,1 2,75 2,4 2,15 1,95 1,7 1,5 1,35

12

13

30,4 100 100 100

79 0 2

10 0,5

77,2 75,2 73,2 71,2 69 66,8 64,4 62 59,4 57 54,2 51,4 48,6 45,8 42,8 40 36 31,2 26 19,2 11

10 9,55 8,05 6,9 6 5,25 4,6 4,1 3,6 3,1 2,8 2,4 2,2 1,95 1,7 1,5 1,35 1,2 1,05 0,9 0,8 0,5

14

CONTROL PANEL

79 18 2

9 0,8

78,2 76,4 74,5 72,5 70,4 68,2 65,8 63,4 61 59,5 55,6 53 50,1 47,2 44,2 43,3 37,8 33,8 29,2 24 18

9 8,85 7,9 6,8 5,9 5,15 4,55 4,05 3,6 3,1 2,8 2,4 2,2 1,95 1,7 1,5 1,35 1,2 1,05 0,9 0,8

2

READINGS :

LENGTH AND ANGLE SENSOR (Boom Geometric data )

AUTOMATIC SELECTIONS from micro-switches: - Turret rotation - Anti two block

- % Tilting - Lifted load - Maximum load - Working radius (outreach) - Boom length - Boom angle - Operating mode -Attachment used - Diagnostic

ALARMS: Green/Amber/Red lights MANUAL SELECTIONS:

Automatic functions - Main Boom External alarm and automatic shut-down - Jib

- Counter Weight - Part of Lines - Tyres

Which components are included in an LMI? It’s a system including sensors able to detect lifted load, boom position, a main unit and a control panel situated inside at the cabin.

SYSTEM LAY-OUT AND CONNECTIONS MAIN UNIT AND CONTROL PANEL : UMC1-1/10

Anti Two Block TEREX CRANES

X1

INPUT/OUTPUT SIGNALS AND EXTERNAL SUPPLY

PRESSURE TRANSDUCERS Y11 4745-450

X2

LENGTH/ANGLE SENSOR L=32 mt AC MCP214I/3P

4

How is the LMI installed on the machine?

The sensors are positioned on the boom and cylinders in order to detect data when working, while the main unit and the control panel are located inside the cabin.

COMPONENTS LOCATION ON THE MACHINE Length/Angle sensor: On the left side of the boom

Nr.2 Pressure Transducers: On the lifting cylinder. Rod and bottom side

Main Unit and Control Panel : into the cabin

5

6

What’s the need of the control panel?

It gives to the operator all information in order to work in safe conditions and allows proper setting .

CONTROL PANEL DESCRIPTION

1

6 5 8 11 13 1 5 6 7

8 9 10 11 12 13

7 10 9 12

Working data display; GREEN Button/lamp :if pressed, it allows the operator to scroll the pages lit = safety AMBER Button/lamp :The lamp lit indicates that the load has reached the pre-alarm condition. Pressing the button, the buzzer will stop.

RED Button/lamp : The lamp lit indicates that the load has reached the maximum load allowed and the shut off has been performed; The flashing light indicates that the machine is in shut down procedures and the by pass key is activated.

The button can also used to confirm a selection.

Operating mode selection key press to increase operating mode value; Operating mode selection key press to decrease operating mode value; Rope number ( tackle ) selection key: press as many times as necessary to obtain the required value in order to achieve a correct load reading; Dimmer Serial link connector for external Pc; Buzzer ( positioned on the rear panel ) : Intermittent beeping = prealarm condition; Continuous beeping = alarm condition ( shut off movements).

What does it happen when starting the machine?

The system gets activated and automatically proceeds to its self test mode giving information to the Operator.

SWITCHING THE MACHINE ON Starting the machine the system automatically goes on and, for a few seconds, the software version and the software date of development shows up ( dd.mm.yy)

m

000 .0 00 .0

t

ma x 0°

00

000.0 m

00.0 m

RUN

%

UM192-X dd/mm/yy m

Afterwards, the display shows the last operating mode setted prior to the system switching off.

m

000 .0 00 .0

t

ma x 0°

RUN

00

000.0 m

00.0 m

%

MAIN BOOM ON OUTRIG. 200 1 .0 0 3.8 m

During this phase, the system performs the self test and automatically puts itself in shut off condition. If the machine operating mode is correct, please confirm by pressing twice the red button.

If the operator needs to change the operating mode, please refer to the instruction reported on page 13 “HOW TO SELECT THE OPERATING MODE”

7

Is the control panel informing about safety on the machine?

Yes! It has been designed and its main scope is to check the machine working conditions, comparing them to the limits given by the load Tables previously memorised.

PANEL MONITORING - Lifting Conditions % and alarms 1

2

5

3

6

4

7

1)

LCD bar showing the lifted load in percentage to the maximum admitted load in that working condition.

2) Green reference : Safe Zone.

3) Amber reference : Alarm Zone (Lifted load higher than 90% of maximum admitted load).

4) Red reference : Shut-off Zone (Lifted load higher than al 100% of maximum admitted load).

5) Green light on : Safe Working 6) Amber light on

: Alarm (Buzzer activated = intermittent)

7) Red light on

: Dangerous movements shut off (Buzzer activated = continuous)

The red flashing light indicates that the machine is in shut down procedures and the by pass key is activated

8

Is the control panel giving useful information to work?

Yes! It shows on the display all data related to the lifted load and the boom position

PANEL MONITORING -Main Working Data Reading on the display

1-2

1-3

1-4

1-6

1-5

1-7

1-2)

LIFTED LOAD WEIGHT Reading in “Tonnes”, with a decimal point

1-3)

MAXIMUM ADMITTED LOAD: In machine present configuration.

Reading in “Tonnes”, with a decimal point

1-4)

WORKING RADIUS Reading in “Metres”, with a decimal point

1-5)

MAIN BOOM ANGLE Reading in “Degrees”

1-6)

BOOM LENGTH Reading in “Meters”, with a decimal point.

1-7)

HEIGHT FROM GROUND Reading in “Meters”, with a decimal point.

9

Is the control panel giving useful information to work?

Yes! It shows on the display all data related to the lifted load and the boom position

PANEL MONITORING -Main Working Data Reading on the display

1-8 1-8b

1-8a

1-9a 1-8)

1-9b

1-9c

1-9d

1-9e

WRITTEN TEST The following information are displayed : the % of boom length, the stowed jib, alarms and warning messages, operating mode during selection procedures.

This written message appears after the operating mode has been selected.

(Please refer to “SWITCHING THE MACHINE ON section on ” Pag.7 and “SELECTING THE OPERATING MODE ”section on Pag.13)

1-8a) BOOM SINGLE ELEMENT EXTENSION PERCENTAGE (0% = element completely closed; 100% = element completely extended).

1-8b) JIB STOWED INDICATION ON THE BOOM SIDE (S: _ = no Jib selected ; S:A = Jib 7mt; S:B = Jib 8mt; S:C = Jib 7+8mt) 1-9a) OPERATING MODE SELECTED CODE: Corresponds to the load charts table which must be selected related to the crane configuration.

1-9b) PART OF LINES manually selectable.

1-9c) JIB LENGTH : corresponds at the jib’s extension related to the table chart selected 1-9d) JIB ANGLE : corresponds to the jib’s angle referred to the table chart selected 1-9e) COUNTERWEIGHT VALUE :It indicates the counterweight value referred to table chart selected

10

Is the control panel giving useful information to work?

11

Yes! It shows on the display all data related to the lifted load and the boom position through graphic.

PANEL MONITORING - Main working data reading through graphics By pressing the green button, it’s possible to visualize the working data through graphics

1-1

1-7

1-6

12.3 1-3 1-2 1-9a 1-9b 1-9c

1-1) 1-2) 1-3) 1-4) 1-5) 1-6) 1-7) 1-9a) 1-9b) 1-9c) 1-9d) 1-9e)

13.4 .2

m %

101

1

MAX ACT

.0 m

24° 9.2 0

1-5 1-4

5.5 1-9e 1-9d

LCD bar showing the lifted load in percentage refer to the max admitted load in that working condition.

LIFTED LOAD WEIGHT Reading in “Tonnes”, with a decimal point MAXIMUM ADMITTED LOAD In machine present configuration.

Reading in “Tonnes”, with a decimal point WORKING RADIUS Reading in “Metres”, with a decimal point MAIN BOOM ANGLE Reading in “Degrees” BOOM LENGTH. Reading in “Metres”, with a decimal point HEIGHT FROM GROUND Reading in “Metres”, with a decimal point OPERATING MODE SELECTED CODE : Corresponds to the load charts table which must be selected related to the crane configuration.

PART OF LINES manually selectable.

JIB LENGTH : corresponds at the jib’s extension related to the table chart selected JIB ANGLE : corresponds to the jib’s angle referred to the table chart selected COUNTERWEIGHT VALUE :It indicates the counterweight value referred to table chart selected

Can the control panel give further useful information regarding the machine?

Yes, through the graphic display, showing complementary reading related to the machine.

PANEL SCREENS -Complementary reading related to the machine functioning The further information displayed on the panel (zone 1-8) are the following :

1)

ANTI TWO BLOCK ALARM

1-8

This message appears when the Anti two block alarm is activated.

2)

OVERLOAD

1-8

This message appears when the lifted load has overtaken the maximum load allowed referring to the load charts table.

3)

SYNCRO ALARM

1-8

This message appears every time the operator uses the telescopic boom syncro key, simultaneously the max allowed load decreases to 1 Ton. This alarm will be erased when the boom will be completely closed.

4)

E01 MINIMUM RADIUS

1-8

This message appears when the boom’s angle is higher than the pre setted angle.

5)

E02 MAXIMUM RADIUS

1-8

This message appears when the boom is positioned in a way that, referring to the load charts, there isn’t any load charts table applicable.

12

How to select the Operating Mode ?

13

Simply pushing two buttons on the control panel.

SELECTING THE OPERATING MODE - Operating mode set up and stowing the jib Setting up the operating mode: To change the crane operating mode, please refer to the following instructions: • Press once the button 8 or 9, on the display appears the description (zone1-8) and the code (zone1-9a) of the operating mode used.

• Press once again the button 8 (to increase) or 9 (to decrease) until the display will show the description (Zone 1-8) and the code (Zone 1-9a) of the correct operating mode.

.2 9.2

m

13.4

t

ma x

0°

24°

m

12.3 m

RUN

%

MAIN BOOM ON OUTRIG. 200 1 .0 0 3.8

1-8

m

1-9a

Please refer to the load charts table supplied by the manufacturer for the Operating Mode list.

• Press the red button (7) to confirm the selection NOTE :It’s not possible change an Operating Mode meanwhile a load is applied.

8

9

7

JIB STOWING SETTING UP After the Operating Mode has been selected, it’s necessary to proceed with the jib’s stowing up ( the jib could be folded next to the boom in all its configuration, part of it or none of them ).

Press the button 8 (to increase) or 9 (to decrease) until the display will show the correct stowed jib description (Zone 1-8) •Press the red button (7) to confirm the selection

.2 9.2

m

0°

RUN

13.4

t

ma x

24°

m

12.3 m

%

1-8

JIB 200

7m STOWED 1 .0 0 3.8 m

Now, the machine is ready to work.

Switching On or Off the machine, it won’t make the selected chart change until the next manual selection will be performed.

8

9

7

How can I select the rope number ( tackle )?

14

Simply pushing two buttons on the control panel.

ROPE NUMBER ( TACKLE ) SETTING UP

LINE OF ROPES SETTING UP It’s necessary to set the line of ropes value everytime that the winch rope’s number changes.

.2 WARNING : A miscalculation of the line of ropes, could lead to danger situation To modify the line of rope, please proceed as follows: • Press the button 10 until on the display (zone 1-9b) the correct number will appear • Press twice the red button (7) to confirm the selection.

NOTE : If the load on the rope is higher than the single rope maximum pre setted load, the system puts itself in alarm and a message will appear.

9.2

m

0°

13.4

t

ma x

24°

m

12.3 m

RUN

%

1-9b

% 202

0/ 2

0/ 0

0 0

S:A 38

m

10

7

15

Can the LMI detect faults?

Of course. To be considered a reliable system, it must be able to perform self-check in order to detect internal or components faults.

AUTO-DIAGNOSTIC The LMI is equipped of an auto diagnostic system which is able to detect faulty pressure transducers, or boom angle/length sensors, broken cables or internal electronic faults.

When an alarm occurs, the LMI puts itself in a safe condition stopping the dangerous movements and at the same time the display shows an alarm message ( zone 1-8).

According to alarm code and message, it will be possible to identify the fault.

.2 9.2

m %

1-8

0°

13.4

t

ma x

24°

m

12.3 m

RUN

ALARM :……………

101

1

.0

0

5.5

m

The codes are reported in the following list, that also includes some hints to solve the problem and get back to normal working conditions.

16

How the fault shows up?

Through codes automatically shown on the display.

Here follows the list including some hints to solve them.

ALARM CODES AND ACTIONS TO TAKE Alarm code

Description

What to do

Memory data not reliable

• Switch the system off and on.

If the alarm persists, please, contact Technical Assistance to: •Verify that E2prom chip is fitted properly in its socket.

• Re-enter data and save them again • Replace the E2PROM chip and recalibrate the machine

Angle sensor reading lower than the minimum value

• Verify that the wiring and the connectors are not in short circuit.

If the alarm persists, please, contact Technical Assistance : • Verify the angle sensor integrity.

25

Angle sensor reading higher than the maximum value

•Verify that the cable or the connector wiring is not open If the alarm persists, please, contact Technical Assistance : • Verify the angle sensor integrity.

12

Reading pressure of the main cylinder (bottom side) lower than the minimum.

• Verify that the cable or the connectors wiring are not in short circuit If the alarm persists, please, contact Technical Assistance : • Verify the pressure transducer integrity

22

Reading pressure of the main cylinder (bottom side) higher than the maximum.

• Verify that the cable or the connector wiring are not open If the alarm persists, please, contact Technical Assistance : •Verify the pressure transducer integrity

56

15

17

How the fault shows up?

Through codes automatically shown on the display.

Here follows the list including some hints to solve them.

Alarm code

Description

13

Reading pressure of the main cylinder (rod side) lower than the minimum.

•Verify that the wiring and the connectors are not in short circuit If the alarm persists, please, contact Technical Assistance : •Verify the pressure transducer integrity

23

Reading pressure of the main cylinder (rod side) higher than the maximum.

• Verify that the cable or the connector wiring are not open If the alarm persists, please, contact Technical Assistance : •Verify the pressure transducer integrity

11

Reading of the boom length sensor lower than the minimum value

• Verify that the wiring and the connectors are not in short circuit If the alarm persists, please, contact Technical Assistance: Verify the length transducer integrity

21

Reading of the boom length sensor higher than the maximum value

• Verify that the cable or the connector wiring is not open If the alarm persists, please, contact Technical Assistance : • Verify the length transducer integrity

The boom’s angle has overtaken the maximum value

• Lower the boom

This message appears when the boom is positioned in a way that, referring to the load charts, there isn’t any load charts table applicable

•Lift or close the crane boom until a load chart table can be applied.

E01 MINIMUM RADIUS

E02 MAXIMUM RADIUS

What to do

And more, to make things easier, the internal operating conditions can be displayed directly on the display as follows.

Apart the codes alarms, is the LMI able to give further data about its own internal operations?

Yes, through the display, which gives several data regarding sensors and Input/Output’s status signals. These data are valuable in order to inform the Technical Assistance even from remote locations.

AUTO DIAGNOSTIC System internal working conditions monitoring Geometric data and load data These readings show on some pages the internal status of the system which become very useful when a fault occurs.

Starting from the main working data page press twice the GREEN button: The display will show the control page, giving geometric data and main cylinder differential pressure summary.

The displayed parameters are as follows: • P : Main cylinder differential pressure in Bar; • W : Lifted load weight in Tonnes; • M : Maximum admitted load in present position in Tonnes;

.2 9.2

m

0°

RUN

13.4

t

ma x

24°

m

12.3 m

%

• A : Actual angle in Degrees; • L : Actual boom length in Meters;

% P49 A24

0/ 0/ W 0.2 L12.3 m

• R : Radius from turret rotation centre in Meters;

To return to the main page, press the Green button.

0 S: M13.4 R 9.2

18

Apart the codes alarms, is the LMI able to give further data about its own internal operations?

Yes, through the display, which gives several data regarding sensors and Input/Output’s status signals. These data are valuable in order to inform the Technical Assistance even from remote locations.

AUTO DIAGNOSTIC System internal working conditions monitoring Hydraulic pressures data By pressing the RED BUTTON the display shows the individual hydraulic pressures summary :

The displayed parameters are as follows: • P : Main cylinder differential pressure in Bar; • PL : Main cylinder bottom side pressure in Bar; • PH : Main cylinder rod side pressure in Bar;

.2 9.2

m

0°

RUN

13.4

t

ma x

24°

m

12.3 m

%

• A : Actual angle in Degrees; • L : Actual boom length in Meters; • W : Lifted load weight in Tonnes;

To return to the main page, press the Green button.

% P49 A24

0/ 0/ PL 54 L12.3 m

0 S: PH 17 W 0.2

19

Apart the codes alarms, is the LMI able to give further data about its own internal operations?

Yes, through the display, which gives several data regarding sensors and Input/Output’s status signals. These data are valuable in order to inform the Technical Assistance even from remote locations.

AUTO DIAGNOSTIC System internal working conditions monitoring Sensors Digital Signals Pressing once again the RED button the display will show the first page giving pressure transducers and length/angle sensors digital signals corresponding to the actual measurements.

The displayed parameters are as follows: 0 xxx : Main cylinder bottom side pressure value in Bits; between 0 and 1023 (*)

.2 1 xxx : Main cylinder rod side pressure value in Bits; between 0 and 1023 (*)

9.2

m %

2 xxx : Angle value in Bits; between 0 and 1023 (*)

% 0 2

0°

13.4

t

ma x

24°

m

12.3 m

RUN

0/ 0/ XXX 1 XXX 3

0 S: XXX XXX

m

3 xxx : Boom Length value in Bits; between 0 and 1023 (*) (*) = Due to 10bits A/D Converter Pressing once again the RED button the display will show the second page giving digital signals corresponding to the measurements of the other analogic inputs:

The displayed parameters are as follows: 4 xxx : not used; 5 xxx : not used; 6 xxx : Anti two block status: in safety condition, the value must be around 530(*); 7 xxx : not used; (*) = Due to 10bits A/D Converter

To return to the main page, press the Green button.

.2 9.2

m %

% 4 6

0°

24°

RUN

0/ 0/ XXX 5 XXX 7 m

13.4

t

ma x m

12.3 m

0 S: XXX XXX

20

Apart the codes alarms, is the LMI able to give further data about its own internal operations?

Yes, through the display, which gives several data regarding sensors and Input/Output’s status signals. These data are valuable in order to inform the Technical Assistance even from remote locations.

AUTO DIAGNOSTIC System internal working conditions monitoring Status of Digital Inputs from outside Pressing once more the RED button, the display shows the summary of the ON/OFF selections given by external micro-switches:

.2 9.2

m %

% I

0°

13.4

t

ma x

24°

RUN

m

12.3 m

0/ 0/ 0 S: 01234567890123 -------------* m

Digital Inputs (I) The upper row indicates the Input number, while the lower row indicates its status.

The symbol “*” means active Input, the symbol “-” means non active Input .

• 0 : Not used • 1 : Not used • 2 : Not used • 3 : Turret position sensor :“*” micro switch active • 4 : Not used • 5 : Anti two block by pass key :“*” when the anti two block by pass button is pressed • 6 : Boom synchronizing key:“*” When the Boom synchronizing key is activate • 7 : Main by pass key :“*”When the main by pass key is activated.

• 8-N.: Not used To return to the main page, press the Green button.

21

Apart the codes alarms, is the LMI able to give further data about its own internal operations Yes, through the display, which gives several data regarding sensors and Input’s/Output’s status signal. These data are valuable in order to inform the Technical Assistance even from remote locations.

AUTO DIAGNOSTIC System internal working conditions monitoring Status of Digital Outputs to outside Pressing once more the RED button, the display shows the Outputs of the system status summary ( automatic signals):

.2 9.2

m

0°

13.4

t

ma x

24°

RUN

m

12.3 m

%

% O

0/ 0/ 0 S: 01234567890123 **--*---*----m

Digital Outputs (O) The upper row indicates the Output number, while the lower row indicates its status.

The symbol “*” means active Output, the symbol “-” means non active Output .

0 : Shut off Movements : “*” when the machine works in safety condition.

“-” when the machine is entered in shut off procedures (100%) 1 : Anti two block shut off : “*” when the anti two block is not activated “-” when the anti two block is activated.

2 : Not used 3 : Non used 4 : Maximum angle shut off : “*”when the maximum angle shut off is not activated “-”when the maximum angle shut off is activated 5-N.:Not used

To return to the main page, press the Green button.

22

What should be known before starting the machine?

All the recommendations and rules from the Manufacturer to work wisely and consciously in any time and situation

WARNINGS • The LMI is an electronic device with the aim to help the operator in the current use of the machine, warning him by means of visual and acoustic signals while approaching dangerous conditions.

• However this device can’t replace the operator good experience in the safe use of the machine.

• The responsibility of the operations in safe conditions of the machine is the operator concern as well as the accomplishment of all prescribed safety rules • The Operator must be able to detect if the data given by the LMI are correct and correspond to actual working conditions.

• He must be able to utilise the data given by the LMI in order to operate in safe conditions in any time.

• The LMI is an electronic device including several sensing components, therefore it can be subject to failures or defects.

• The operator must recognise these events and he must take action ( to proceed to repair if possible or to call Assistance).

• Before starting the operations with the machine, the user must fully read this manual and follow the instructions at any time.

23

What should be known before starting the machine?

All the recommendations and rules from the Manufacturer to work wisely and consciously in any time and situation.

• The LMI is supplied with a key for shut-down function by-passing.

• In normal working operations, this key must be positioned not to by-pass shut-down..

• It’s forbidden to use the key to lift loads exceeding the loads values allowed by the Manufacturer.

• The key can be used only when an emergency/malfunctioning occurs or a situation justifying its use.

• Only Authorised Personnel is allowed to the use of the key; they are also responsible for it.

• The LMI has a powerful FAIL-SAFE auto diagnosis program suitable to verify its good operations and the one of its transducers.

In case a trouble has been detected, the LMI puts itself in a safe state by stopping the manoeuvres (please see the AUTODIAGNOSTIC chapter).

• In spite of this, the Operator, before starting the operation with the machine, must take care that the LMI is working correctly.

To do this, he must verify the validity of the displayed values by doing some tests.

He must verify that there are not messages or alarm indications; he must verify the correct operation of the manoeuvre stopping functions.

• The operator is responsible for the correct setting of the machine load table and therefore for the right LMI set.

When switching-on the machine the last selected Table is kept valid, to allow Operator check.

• About this, please follow the instructions given in the OPERATING MODE SELECTION chapter. An incorrect setting of the tables, can cause an incorrect LMI operation and therefore can provoke a dangerous situation for the machine.

• Operating conditions usually change when: Further attachment are fitted or removed ( jib counterweight) and relevant Table selecting mode is set on the control panel.

Outriggers Extension / Withdrawn, Turret Front/360° rotation , On Wheels/Outriggers, operating Modes are set in automatic way by micro-switches.

Generally, it’s compulsory to follow the Manufacturer instructions and procedures at any time.

24

Maintenance

Maintenance and operator’s manual

Maintenance booklet IX

Edition :

03/1999

IX---1

Maintenance

Maintenance and operator’s manual

Identification Type :.................

Serial number :...........

Date of start up : .. / ....

Manufacturer : TEREX LIFTING --- PPM SA PPM Z.I. de La Saule B.P. 106 71304 MONTCEAU Les MINES FRANCE Fax

IX---2

:

( 33 ) 03 . 85 . 67 . 38 . 99 ( 33 ) 03 . 85 . 67 . 38 . 98

Edition :

03/1999

Maintenance and operator’s manual

Maintenance

NOTE : All personnel who carry out maintenance operations on this machine must be aware of all instructions contained in the operator’s manual, and respect all safety regulations before any intervention.

IMPORTANT : The intervals shown in the following tables are deemed to apply to machines used under normal conditions .

For intensive use or under conditions (heat --- dampness --- dust) it is necessary to carry out maintenance more frequently.

Edition :

03/1999

IX---3

Maintenance

Maintenance and operator’s manual

Service intervals It is essential for your machine to be regularly serviced.

The hourmeter mounted on your crane tells you when servicing operations should be carried out, ant it should be consulted every day.

When effecting these servicing operations, tighten nuts, bolts,etc...where required.

Hourmeter Its electric control is connected to the engine oil pressure. It accumulates hours exactly like a clock when the engine is running.

Preliminary operations First of all clean grease fitting heads, plugs and periphery of filler ports and level check sightglasses. When lubricating, check condition of seals and replace them if they are damaged or show signs of wear.

JAll the necessary steps should be taken to conserve the environment. In particular, make sure that all used fluids are collected and recycled . Do not leave these products in unsuitable, incorrectly labelled containers.

Do not tolerate fluid puddles of whatever type on floors.

IX---4

Edition :

03/1999

Maintenance and operator’s manual

Maintenance

Introduction The environmental working conditions of the machine gouvern its maintenance.The prescribed check ---list which follows indicate the points to be verified and the frequency of the verifications.

NOTE : The maintenance booklet takes into account the machine’s operating conditions. The type of work to be done, the dimensions of loads, climatic and ground conditions are all factors to be taken into account.The preventive maintenance lists are given in function of the number of hours worked by the machine.

Any modification to the overall maintenance program must be accompanied by a revision of the machine’s new operating conditions. Carefully study the preventive maintenance booklet before making any changes to the verification frequencies.

Use of the maintenance booklet The maintenance booklet is an initial guide to preventive maintenance until personal experience allows the definition of an appropriate maintenance program according to different operating conditions.

The maintenance booklet can be recopied as many times as necessary. Any person who carries out a maintenance procedure must indicate this on the list so that it can be verified as being done at the moment of the following maintenance program.

Completed maintenance lists are documents which are an integral part of the machine.

Edition :

03/1999

IX---5

Maintenance

Maintenance and operator’s manual LUBRICATION CHART

COMPONENT

Cold climates

Temperate climates

Tropical climates

---25° +25°

---15° +35°

---5 +45°

Boom chains

ALVANIA EP2

Boom slide pads

GRAFLOSCON C---SG 0 ULTRA

Grease nipples

ALVANIA EP2

Slewing ring teeth

MALLEUS GL 205

Slewing ring bearing

ALVANIA EP2

Slewing reducer gear

SPIRAX HD 80W90

SPIRAX HD 80W90

SPIRAX HD 85W140

Winch reducer gear

SPIRAX HD 80W90

SPIRAX HD 80W90

SPIRAX HD 85W140

HYDRAU TP ou

Hydraulic fluid

TELLUS T 22

SHELL NATURELLE

TELLUS T 68

Axle differential + reducer units

SPIRAX HD 80W90

SPIRAX HD 80W90

SPIRAX HD 85W140

Engine

RIMULA X 10W30

RIMULA X 15W40

RIMULA X 20W40

HF --- E (biodegradable)

GLYCOSHELL +

Cooling circuit CLARK gearbox

RIMULA X 10W

RIMULA X 10W

RIMULA X 10W

ALLISON gearbox

DONAX TA

DONAX TA

RIMULA X 15W40

ZF gearbox

RIMULA X 10W

RIMULA X 10W

RIMULA X 15W40

ZF gearbox

DONAX TA

DONAX TA

RIMULA X 15W40

Transfer unit

SPIRAX HD 80W90

SPIRAX HD 80W90

SPIRAX HD 85W140

Transfer unit

SPIRAX HD 80W90

SPIRAX HD 80W90

SPIRAX HD 85W140

ECH---FCH55&77 wet brakes

RIMULA X 10W + 3.12%--->5% LUBRISOL 6279

RIMULA X 10W + 3.12%--->5% LUBRISOL 6279

RIMULA X 10W + 3.12%--->5% LUBRISOL 6279

IX---6

Edition :

03/1999

Maintenance and operator’s manual

Maintenance

Maintenance Liste ”A” Daily or10 hourly maintenance

Company : __________________________________________________ Adress : ____________________________________________ Person responsible for the maintenance:_______________ __________________________________________________ Date of maintenance:_______________________________ Serial number:_____________________ MAINTENANCE OPERATIONS

Edition :

03/1999

DONE BY

Check air filter

______________

Check hydraulic tank oil level

______________

Check fuel tank level

______________

Check engine oil level

______________

Check windscreen wiper liquid level

_____________

Check engine radiator coolant level

______________

IX---7

Maintenance

IX---8

Maintenance and operator’s manual

Edition :

03/1999

Maintenance and operator’s manual

Maintenance

Maintenance list ”B” Weekly or 50 hourly maintenance Company:__________________________________________ Adress:_____________________________________________ Person responsible for the maintenance:______________ ___________________________________________________ Date of maintenance:_______________________________ Serial number:___________________________________ MAINTENANCE OPERATIONS

Edition :

03/1999

DONE BY

Perform list ”A”

______________

Grease derricking ram

______________

Grease slewing ring teeth

______________

Grease slewing ring bearing

______________

Grease linkages and moving parts

_____________

Grease slewing locking pin

______________

Check oil level in gearbox and convertor

______________

Grease boom slide pads

______________

Grease base end of boom

______________

Check heater unit fuel level

______________

Check turret cab windscreen wiper liquid level

_____________

Grease transmission shaft assemblies

_____________

IX---9

Maintenance

IX---10

Maintenance and operator’s manual

Edition :

03/1999

Maintenance and operator’s manual

Maintenance

Maintenance list ”C” 100 hourly maintenance Company:_______________________________________ Adress:_____________________________________________ Person responsible for the maintenance:____________ ___________________________________________________ Date of maintenance:_______________________________ Serial number:___________________________________ MAINTENANCE OPERATIONS

Edition :

03/1999

DONE BY

Perform lists ”A” and ”B”

______________

Check level of electrolyte in batteries

______________

Check wheelnut tightness

______________

Check oil level in slewing reducer gear

______________

Clean fuel pre---filter

______________

Clean engine radiator

______________

Clean air filter

______________

Check engine ancillary component belt tensions

______________

IX---11

Maintenance

IX---12

Maintenance and operator’s manual

Edition :

03/1999

Maintenance and operator’s manual

Maintenance

Maintenance list ”D” Monthly or 200/250 hourly maintenance

Dirección :__________________________________________ Adress:_____________________________________________ Person responsible for maintenance:_________________ ___________________________________________________ Date of maintenance:_______________________________ Serial number:___________________________________ MAINTENANCE OPERATIONS

Edition :

03/1999

DONE BY

Perform lists ”A”, ”B”, and ”C”

______________

Check tyre pressures

______________

Clean battery lugs, check electrolytic density and battery fixation

______________

Lubricate the carrier cab door

______________

Check slewing reducer gear oil level

______________

Grease front axle and ancillary parts

_____________

Grease rear axle and ancillary parts

_____________

IX---13

Maintenance

IX---14

Maintenance and operator’s manual

Edition :

03/1999

Maintenance and operator’s manual

Maintenance

Maintenance list ”E” 3 monthly or 500 hourly maintenance Company:__________________________________________ Adress:_____________________________________________ Person responsible for maintenance:___________________ ___________________________________________________ Date of maintenance:_______________________________ Serial number :_____________________________________ AINTENANCE OPERATIONS Perform lists ”A”, ”B”, ”C” and ”D”

______________

Check that fuel tank is free from impurities

______________

Check front axle oil level

_____________

Check rear axle oil level

______________

Change hydraulic circuit oil filter

______________

Check condition of winch cable

______________

Chech condition of brakes

______________

Clean the air tanks’ automatic bleed system

______________

600 h Do engine oil change

______________

At 600 h, change engine oil filter

______________

At 600 h, change fuel filter

______________

Change the air dessication cartridge

Edition :

03/1999

DONE BY

______________

IX---15

Maintenance

IX---16

Maintenance and operator’s manual

Edition :

03/1999

Maintenance and operator’s manual

Maintenance

Maintenance list ”F” 6 monthly or 1000 hourly maintenance Company:__________________________________________ Adress:_____________________________________________ Person responsible for maintenance:__________________ Date of maintenance:_______________________________ Serial number:______________________________________ MAINTENANCE OPERATIONS

Edition :

03/1999

DONE BY

Perform lists ”A”, ”B”, ”C”, ”D” and ”E”

______________

Check all wiring loom attachments

______________

Check tightness of all fasteners

______________

Check for leaks on hydraulic circuit

______________

Do convertor oil change

______________

Change convertor oil filter cartridge

______________

Check brake rams attachments

______________

Check wheel geometry

______________

Check for leaks on steering circuit

___________

Check condition of alternator and starter motor

___________

Do oil change on slewing reducer gear

______________

Do oil change on winch reducer gear

_____________

Check condition of boom slide pads and pullies

______________

Have the airbrake bottles checked

______________

Chech the oil level in the hydraulic tank

______________ IX---17

Maintenance

IX---18

Maintenance and operator’s manual

Edition :

03/1999

Maintenance and operator’s manual

Maintenance

Maintenance list ”G” Yearly or 2000 hourly maintenance

Company:__________________________________________ Adress:_____________________________________________ Person responsible for the maintenance:_______________ ___________________________________________________ Date of maintenance:_______________________________ Serial number:______________________________________

Edition :

03/1999

MAINTENANCE OPERATIONS

DONE BY

Perform lists ”A”, ”B”, ”C”, ”D”, ”E” and ”G”

______________

Do oil change on hydraulic tank

______________

Exchang brake circuit flexible hosing

______________

Change hydraulic filters

______________

Check condition of counterweight attachments

______________

Do oil change on front axle differential unit and reducer gears

______________

Do oil change on rear axle differential unit and reducer gears

______________

Check condition of telescoping chain attachments

______________

Check wiring loom attachments

______________

Check tightness of all fasteners

______________

Check for leaks on all flexible hosing

______________

IX---19

Maintenance

IX---20

Maintenance and operator’s manual

Edition :

03/1999

Maintenance and operator’s manual

Maintenance

Maintenance list ”H” 8000 hourly maintenance Company:__________________________________________ Adress:_____________________________________________ Person responsible for the maintenance:_______________ ___________________________________________________ Date of maintenance:_______________________________ Serial number:______________________________________ MAINTENANCE OPERATIONS

DONE BY

............................................................................................................

Edition :

03/1999

IX---21

Maintenance

Maintenance and operator’s manual All slewing ring fasteners, and the slewing ring itself, must be changed every 8000 hours. This job must be carried out by personnel authorized by PPM. ONLY USE GENUINE PPM SPARE PARTS

IX---22

Edition :

03/1999

Maintenance and operator’s manual

Edition :

03/1999

Maintenance

IX---23

Maintenance

Maintenance and operator’s manual

Maintenance list ”I” 20000 hourly maintenance Company:__________________________________________ Adress:_____________________________________________ Person responsible for the maintenance:_______________ ___________________________________________________ Date of maintenance:_______________________________ Serial number:______________________________________ MAINTENANCE OPERATIONS

DONE BY

............................................................................................................

Telescopic boom Dismantle the telescopic boom and check every part making up the boom thoroughly.

Check welds, change the telescoping cables and the telescoping chains. Check the condition of the pulleys, the rollers, the cable bushings, all the hydraulic components, the hoses, everything.

IX---24

Edition :

03/1999

Maintenance

Maintenance and operator’s manual Spectrum class

Light L1

Medium L2

Heavy L3

Very heavy L4

Edition :

Definition

Mechanisms or parts of the mechanisms rarely subjected to extreme fatigue but regularly to a minimal level of fatigue

Mechanisms or parts of mechanisms frequently subjected to extreme fatigue but regularly to a minimal level of fatigue.

% of the length of use 10 % of the length of peak load operation. (dead load + 1/1 useful load) 40 % of the length of the dead weight operation + 1/3 useful load 50 % of the length of operation exclusively with dead weight

50 % of the length of peak load operation. (dead load + 1/1 useful load) 50 % of the length of operation exclusively with dead weight.

Mechanisms or parts of mechanisms regularly subjected to extreme levels of fatigue

90 % of the length of peak load operation. (dead load + 1/1 useful load) 10 % of the length of operation exclusively with dead weight.

Graph

Last/Load/Charge/Carg

100 80 60 40 20 0

a%

Km = 0.125

Laufzeit Operating time

%

40% Durée de marche Duración de funcionamiento

10%

0 10 20 3040 50 6070 80 90100

1/6 of the length of peak load operation. (dead load + 1/1 useful load) 1/6 of the length of Km = 0.25 the dead weight operation + 2/3 useful load 50 % of the length of operation exclusively with dead weight.

Mechanisms or parts of mechanisms very frequently subjected to a heavy level of fatigue and regularly to a medium level of fatigue.

03/1999

Spectrum factor

Last/Load/Charge/Carga%

100 80 60

73%

Laufzeit Operating time

47%

%

Durée de marche

40

Duración de funcionamiento

20

20%

0

0 10 20 30 40 50 60 70 80 90100

Last/Load/Charge/Carga %

Km = 0.5

100 80 60 40 20 0

Laufzeit Operating time

%

Durée de marche

40%

Duración de funcionamiento

0 10 20 30 40 50 60 70 80 90100

Last/Load/Charge/Carga %

100

80%

80

Km = 1

60 40 20 0

Laufzeit Operating time

%

Durée de marche Duración de funcionamiento

0 10 20 30 40 50 60 70 80 90100

IX---25

IX---26

Conditions

0.25

0.5

0.125

0.15

Kmi

[h]

3000

2000

800

0

[h]

turning part

whole

crane as a

factor

Length of use of the

Length of use of the

Spectrum

1000

1200

800

[h]

Ti

last inspection

part since the

[h]

winch

Length of use Length of of the turning use of the

300

480

160

[h]

inspection

since the last

of the winch

Length of use

600

1920

160

0

[h]

Kmi Si = _____ XTi Km

length DI

theoretical

the

% of use of

2320

2920

4840

5000

[h]

Name of

DUPONT

DUPONT

DUPONT

Inspector

Signature

Date of last overhaul:

Di= Di --- 1 --- Si

of use

g length

Remainin

Ti = Actual length of use in the inspection interval i

Kmi = Spectrum factor in the inspection interval i

Comments

Km = Spectrum factor established at the time of the calculations for the winch.

Di---1 = Theoretical length of use remaining since the last inspection.

Di = Theoretical remaining length of use

Si = % of use of the theoretical length of use since the last inspection

Warning: A general overhaul of the winch should be carried out at least every 10 years.

3

L2

02/07/93

21/07/94

L3

12/06/92

1

2

L1

03/09/91

L2

(load class)

inspection

the last

of use since

0

i

ction date

service/inspe

Inspection Date of first entry into No.

Type of crane: Manufacturing No.: Date originally put into service: Serial number of the winch conforming to the identification plate: Date of the last general overhaul.

Technical characteristics of the winch: Mechanism group: M..........

Spectrum class: L Spectrum factor: ..........

Theoretical length of use: ...........

Table for the determination of the theoretical remaining length of service for lifting winch No. ......

Maintenance Maintenance and operator’s manual

Edition :

03/1999

Maintenance and operator’s manual

Edition :

03/1999

Maintenance

IX---27