RC30 RT35 - ENG Rev.07 [PDF]

Zitiervorschau

RC30-RT35

Operation and maintenance

ROUGH TERRAIN CRANES

m

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

Operation and maintenance manual

Code: 46953 (eng) - rev.07

Operation and maintenance manual

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

This manual is valid for models RC30 and RT35. When consulting the manual refer to the parts that correspond to the model of crane you have purchased.

Manufacturer: TEREX ITALIA S.r.l. Via Cassoletta, 76 – 40056 Crespellano BOLOGNA – ITALY Fax (+39) 051734645 Tel. (+39) 0516501011 e-mail: [email protected] Code: 46953 (eng) - rev.07

After-sales service: TEREX ITALIA S.r.l. Via Cassoletta, 76 – 40056 Crespellano BOLOGNA – ITALY Fax (+39) 0516501015 Tel. (+39) 051736613 e-mail: [email protected]

Operation and maintenance manual

Code: 46953 (eng) - rev.07

Operation and maintenance manual

Contents

I. Characteristics

Edition: 04-2011

II. Warnings

Edition: 10-2009

III. Safety and operation

Edition: 04-2012

IV. Control instruments

Edition: 04-2011

Load Limiter

Edition: 04-2012

V. Accessories

Edition: 10-2009

VI. Maintenance

Edition: 07-2012

VII. Inspections

Edition: 04-2011



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

No part of this manual may be duplicated, translated or copied without written permission from the manufacturer. Code: 46953 (eng) - rev.07

Operation and maintenance manual

Code: 46953 (eng) - rev.07

Characteristics

Operation and maintenance manual

I Characteristics

Chapter I – ed. 04-2011

page 1/12

Operation and maintenance manual

page 2/12

Characteristics

Chapter I – ed. 04-2011

Characteristics

Operation and maintenance manual

Contents RC30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Crane performance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Truck performance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 5 5 6 7 7 8

RT35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Crane performance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Truck performance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Chapter I – ed. 04-2011

page 3/12

Operation and maintenance manual

page 4/12

Characteristics

Chapter I – ed. 04-2011

Characteristics

Operation and maintenance manual

Crane performance data Capacity at 3 m from slewing ring axis (CE)

30 t

Boom length (retracted / extended)

9.1 / 24.1 m

Boom head height

27 m

Truck performance data(1)

(1)

Max. travel speed (with tyres 14.00R24)

34 km/h

Max. travel speed (with tyres 16.00R25)

36 km/h

Max. theoretical ramp during operation (with tyres 14.00R24)

118 %

Max. theoretical ramp during operation (with tyres 16.00R25)

99 %

Standard crane in operating conditions: no auxiliary winch and no extensions

Weights(2)

(2)

1st axle

2nd axle

Total

10.7 t

12.8 t

23.5 t

Standard crane: no auxiliary winch and no extensions, on 14.00R24 tyres

Chapter I – ed. 04-2011

page 5/12

Operation and maintenance manual

Characteristics

Truck Traction/Steering

4x4x4

Frame

Double box-type member. Front tow point (optional rear tow point)

Outriggers

no. 4 independent hydraulic outriggers on hydraulic beams. Stabilization with outrigger beams retracted, partially retracted, or fully extended. Outrigger controls in the operating cab

Engine

CUMMINS QSB 4.5 : 4 in-line cylinders - electronic fuel system - displacement 4.5 dm3 - Turbocharger. Max. power 104 kW at 2000 rpm - Max. torque 504 Nm at 1800 rpm Certification 2004/26/CE Phase IIIA

Tank

240 l

Transmission

DANA 20000 series: Powershift type with torque converter. 3+3 forward speeds and 3+3 reverse speeds with low and high speed ranges. Automatic engagement of 4WD on selecting low speed range.

Brakes

Operating: double circuit hydropneumatic drum brakes on all wheels. Parking / Emergency: negative action on front transmission shaft, pneumatic spring type.

Axles

2 driving and steering axles with planetary gearboxes in hubs. Optional differential locks.

Suspension

Rigid on front axle, rocking for rear axle. Rear suspension is automatically locked hydraulic jacks if lifting boom is not aligned with centreline within front crane area.

Steering

Hydrostatic by steering wheel in the operator's cab. Steering of front axle alone or both axles in concentric or crab mode.

Tyres

4 14.00R24 tubeless tyres Optional 4 16.00R25 tubeless tyres

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Chapter I – ed. 04-2011

Characteristics

Operation and maintenance manual

Superstructure Boom

3 elements

Lifting

1 double-acting hydraulic cylinder. Boom angle from -2° to +78°

Extension

Continuous and proportional extension of elements 2 and 3 by means of a double-acting hydraulic cylinder and internal chain transmission system. Extension under partial load possible.

Winch

Controlled by fixed displacement hydraulic axial piston motor with planetary gearbox. Automatic negative brake. Rope tensioner. Two rotation speeds. Rope diameter 15 mm length 140 m Max. lifting capacity 4050 daN. Optional auxiliary winch with the same characteristics as the main winch. Rope diameter 15 mm

Rotation

360° continuous slewing controlled by hydraulic motor coupled to planetary gearbox on slewing ring having double ball ring and internal toothing. Automatic negative brake. Brake release for direct alignment of boom along load vertical line

Cab

Wide visibility with sliding door. Equipped with heating. Front and upper window with windscreen wiper. Openable upper and rear windows. Fully adjustable seat on anti-shock suspensions, equipped with tiltable arm rests incorporating the crane movement hand controls.

Safety

Stop valves on boom extension and lifting jacks and on outriggers. Max. pressure valves on each hydraulic circuit. Balancing braking valve for slewing unit. Balancing braking valve for winch. Limit switch on boom head for hook block lift. Limit switch for maintaining three turns of rope on the winch. Load limiting device with indication of: Boom angle Boom length Load weight Max. liftable load

Systems Hydraulic

24 V system

Hydraulic power source: 2 double gear pumps. Movements control: directional control valves controlled by hydraulic joysticks with the facility for simultaneous and proportional manoeuvres. Outriggers control: solenoid valves controlled by separate pushbuttons. Filtration: 1 cartridge filter on return circuit. Oil cooler electrical

Pneumatic system

Chapter I – ed. 04-2011

with 90 A alternator and two 132 Ah batteries. Lighting devices in conformity with EU directives 225 cc3 compressor, two 45 l reservoirs and drier. Auxiliary air connection and tyre inflation kit

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Characteristics

Operation and maintenance manual

() Values with auxiliary winch

Dimensions(4) A

B

C

a

ß

14.00R24

3245

3290

400

21°

21°

16.00R25

3295

3340

460

24°

24°

Tyres

(4) Average reference dimensions are guideline. Values in millimetres

The data refer to the standard version of the crane and may be subject to change due to the specific configuration of the truck supplied.

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Chapter I – ed. 04-2011

Characteristics

Operation and maintenance manual

Crane performance data Capacity at 3 m from slewing ring axis (CE)

35 t

Boom length (retracted / extended)

9.1 / 30.1 m

Boom head height

32.8 m

Truck performance data(1)

(1)

Max. travel speed (with tyres 14.00R24)

30 km/h

Max. travel speed (with tyres 16.00R25)

31 km/h

Max. theoretical ramp during operation (with tyres 14.00R24)

98 %

Max. theoretical ramp during operation (with tyres 16.00R25)

84 %

Standard crane in operating conditions: without auxiliary winch, without extensions

Weights(2) 1st axle

2nd axle

Total

11.1 t

13 t

24.1 t

Standard crane: no auxiliary winch and no extensions, on 14.00R24 tyres

(2)

Chapter I – ed. 04-2011

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Operation and maintenance manual

Characteristics

Truck Traction/Steering

4x4x4

Frame

Double box-type member. Front tow point (optional rear tow point)

Outriggers

4 independent hydraulic outriggers on hydraulic beams. Stabilization with outrigger beams retracted, partially retracted, or fully extended. Outrigger controls in the operating cab

Engine

CUMMINS QSB 4.5 : 4 in-line cylinders - electronic fuel system - displacement 4.5 dm3 - Turbocharger. Max. power 104 kW at 2000 rpm - Max. torque 504 Nm at 1800 rpm Certification 2004/26/CE Phase IIIA

Tank

240 l

Transmission

DANA 20000 series: Powershift type with torque converter. 3+3 forward speeds and 3+3 reverse speeds with low and high speed ranges. Automatic engagement of 4WD on selecting low speed range

Brakes

Operating: double circuit, hydropneumatic drum brakes on all wheels. Parking / Emergency: negative action on front transmission shaft, pneumatic spring type.

Axles

2 driving and steering axles with planetary gearboxes in hubs. Optional differential locks

Suspension

Rigid on front axle, rocking for rear axle. Rear suspension is automatically locked by hydraulic jacks if lifting boom is not aligned with centreline within front crane area. Facility for rear suspension locking from operator cab.

Steering

Hydrostatic by steering wheel in the operator's cab. Steering of front axle alone or both axles in concentric or crab mode.

Tyres

4 14.00R24 tyres. Optional 4 16.00R25 tubeless tyres

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Chapter I – ed. 04-2011

Characteristics

Operation and maintenance manual

Superstructure Boom

4 sections with octagonal cross-section

Lifting

1 double-acting hydraulic cylinder. Boom angle from -2° to +78°

Extension

Continuous and proportional extension of elements 2 and 3 by means of a double-acting hydraulic cylinder. Element 4 can be extended proportionally to the others by means of an internal rope drive system. Extension under partial load possible.

Winch

Controlled by fixed displacement hydraulic axial pistons motor with planetary gearbox. Automatic negative brake. Rope tensioner. Two rotation speeds. Rope diameter 15 mm length 175 m. Max. lifting capacity 3800 daN. Optional auxiliary winch with the same characteristics as the main winch. Rope diameter 15 mm length 150 m.

Rotation

360° continuous slewing controlled by hydraulic motor coupled to planetary gearbox on slewing ring having double ball ring and internal toothing. Automatic negative brake. Brake release for direct alignment of boom along load vertical line

Cab

Wide visibility with sliding door. Equipped with heating. Front and upper window with windscreen wiper. Openable upper and rear windows. Fully adjustable seat on anti-shock suspensions, equipped with tiltable arm rests incorporating the crane movement hand controls.

Safety

Stop valves on boom extension and lifting jacks and on outriggers. Max. pressure valves on each hydraulic circuit. Balancing braking valve for slewing unit. Balancing braking valve for winch. Limit switch on boom head for hook block lift. Limit switch for maintaining three turns of rope on the winch. Load limiting device with indication of: Boom angle Boom length Load weight Max. liftable load

Systems Hydraulic

24 V system

Hydraulic power source: 2 double gear pumps. Movements control: directional control valves controlled by hydraulic joysticks with the facility for simultaneous and proportional manoeuvres. Outriggers control: solenoid valves controlled by separate pushbuttons. Filtration: 1 cartridge filter on return circuit. Oil cooler electrical

Pneumatic system

Chapter I – ed. 04-2011

with 70 A alternator and two 132 Ah batteries. Lighting devices in conformity with EU directives 250 cc3 compressor, two 45 l reservoirs and drier. Auxiliary air connection and tyre inflation kit

page 11/12

Characteristics

Operation and maintenance manual

() Values with auxiliary winch

Dimensions(4) A

B

C

a

ß

14.00R24

3245

3290

400

21°

21°

16.00R25

3295

3340

460

24°

24°

Tyres

(4) Average reference dimensions are guideline. Values in millimetres

The data refer to the standard version of the crane and may be subject to change due to the specific configuration of the truck supplied.

page 12/12

Chapter I – ed. 04-2011

Instructions

Operation and maintenance manual

II Instructions

Chapter II - ed. 10-2009

page. 1/12

Operation and maintenance manual

page. 2/12

Instructions

Chapter II - ed. 10-2009

Instructions

Operation and maintenance manual

This machine complies with Directives 98/37/EC, 89/336/EC and 2005/88/EC. The average frequency-weighted quadratic value of acceleration to which the operator's upper limbs are exposed is less than 2.5 m/s2. The average frequency-weighted quadratic value of acceleration to which the operator's body (feet or seated part) is exposed is less than 0.5 m/s2. This crane is designed as a lifting device with hook made of materials according to class S0 - HC1 in compliance with EN 13000 standards, for travelling mainly on worksites, on hard ground and on gradients of no more than 18%. For greater distances (over 10 km) the crane must be carried on a trailer or flatbed truck. Driving on public roads is permitted in compliance with current laws and regulations. This crane is designed for use at temperatures not lower than -20°C and not greater than +45°C, in relation to its configuration. The machine does not comply with the prescriptions of directive 94/9/EC, (ATEX), so it is not suitable for use in potentially explosive atmospheres. The crane should not be used in the presence of strong magnetic fields. This crane is designed to operate in winds of up to 30 kph. Use of the crane in dusty conditions is subject to taking all the necessary precautions for safeguarding the operator, and suitable increase in the frequency of maintenance and lubrication intervals. Max. sound pressure LpA, measured inside the cab at the height of the operator's ears, with door closed, crane stopped and with the engine at 3/4 max. rpm is 78 dB (A).

Fuel specifications Fuel with more than 5000 ppm of sulphur is NOT allowed. Corrosion of the distribution system, high levels of emissions and shortening of the time between engine oil changes are just some of the negative consequences of the use of fuel with excessively high sulphur contents. Regional, national or international regulations may oblige the use of low sulphur content fuel (below 5000 ppm). Consult all regulations in force before selecting the fuel. For further information on the specifications of fuel to be used contact our technical assistance service.

Installation of accessories Whenever, after the FIRST start-up and subject to the permission of TEREX, supplementary lifting equipment (extensions or winches) is installed on the mobile crane, the user must: 1. have the necessary adjustments and calibrations carried out. 2. have correct operation of the accessories and relevant safety devices checked.

Chapter II - ed. 10-2009

page. 3/12

Operation and maintenance manual

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

The data on the dataplate are guideline and do not correspond to real conditions. The plate giving details of DGM type-approval for road use (where applicable) is located inside the cab. It gives the type-approval data and vehicle weight in running order for road travel.

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Chapter II - ed. 10-2009

Instructions

Operation and maintenance manual

The owner of the machine or the person hiring it must ensure that the operator has: received all the necessary instructions for correct and safe 0operation of the machine. fully understood and memorized all the instructions in this manual.

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

CAUTION Before starting the engine: • • • •

Become familiar with the safety messages in this manual. Read all safety signs on the machine and make sure no one is standing near the machine. Practise using the controls before operating the machine. It is the user's responsibility to ensure that he understands and observes manufacturer's instructions on machine operation, and complies with the applicable laws and regulations.

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

Note: If the manuals and load tables are defaced or lost, request copies from your dealer or directly from the manufacturer.

Chapter II - ed. 10-2009

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Instructions

Operation and maintenance manual

CAUTION BUNGEE JUMPING DANGEROUS

FROM

CRANES

IS

TEREX Italia, designs, manufactures and sells safe and reliable products for handling materials, and NOT PERSONS. Therefore, we consider that using the crane for lifting, lowering or moving persons for bungee jumping is dangerous and highly inadvisable. Such improper use of the products is neither envisaged nor approved by TEREX Italia. Our products are not designed, manufactured, tested or devised to carry personnel. Lifting persons for bungee jumping is inherently dangerous; make sure to read the section on Safety Regulations to gain an understanding of the risk of injury, and to become familiar with the warnings against using cranes to lift persons. All Dealers and Distributors are requested to use every reasonable means to immediately warn all potential users, purchasers and hirers of cranes that BUNGEE JUMPING FROM THE CRANE IS DANGEROUS. Dealers and Distributors are also advised not to knowingly sell and rent cranes for bungee jumping, as this constitutes serious improper use of the product.

ATTENTION: BUNGEE JUMPING FROM CRANES IS DANGEROUS.

Use of the crane with: • Shovels, grabs, magnets or similar equipment • Vibrating equipment. • Demolition equipment. must be authorised by TEREX.

It is also strictly prohibited to use the crane when visibility is poor. The operator must be in optimal physical condition, be able to read and understand the manual and the crane load tables, and have specific knowledge of the crane and basic training on the operation of selfpropelled industrial equipment. Holding of a driving licence is compulsory in compliance with the current laws and regulations.

page. 6/12

Chapter II - ed. 10-2009

Instructions

Operation and maintenance manual

CAUTION All the lubrication and maintenance operations must be carried out to ensure the safety and reliability of every type of vehicle. Some of these operations, described in the Maintenance Manual, require special equipment and technical knowledge. Non-compliance with the lubrication and maintenance instructions can result in serious accidents. CAREFULLY READ ALL THE SAFETY INSTRUCTIONS BEFORE LUBRICATING AND SERVICING THE MACHINE. Preventive measures against possible hazards in maintenance operations are outlined in the section on "Safety". Also, warnings against some hazards that can cause serious accidents are affixed to the machine. TEREX Italia is not in a position to know how maintenance operations are performed, or all the risks relevant to particular methods, and therefore is unable to advise maintenance personnel. Therefore, anyone using an unsuitable method or a tool not recommended in the Manual must previously make sure there are no risks for the operator or others, that the machine will not be damaged and safety is not compromised.

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

CAUTION At the time of decommissioning of the machine contact local authorities to ensure correct disposal of the various parts. Pay special attention to the counterweights since they may contain lead.

Chapter II - ed. 10-2009

page. 7/12

Instructions

Operation and maintenance manual

List of decals IMPORTANT: Do not remove the decals affixed to the crane. Worn or deteriorated decals must be replaced. The following are safety decals and must be strictly respected.

PROHIBITED: it is prohibited to remain within the machine's operating range during manoeuvres.

PROHIBITED: unauthorized personnel not allowed

PROHIBITED: do not use naked flames

CAUTION: moving parts

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Chapter II - ed. 10-2009

Instructions

Operation and maintenance manual

CAUTION: moving parts with danger of crushing

CAUTION: generic danger

CAUTION: danger of crushing

CAUTION: inflammable

CAUTION: danger of falling Chapter II - ed. 10-2009

page. 9/12

Instructions

Operation and maintenance manual

CAUTION: pressurised components (1), high temperature (2), fire hazard (3), moving parts (4).

CAUTION: pressurised hydraulic accumulator; before performing maintenance consult the instruction manual for the relevant procedures.

COMPULSORY: read the Operator's Manual located in the operator's cab

CAUTION: emergency exit

page. 10/12

Chapter II - ed. 10-2009

Instructions

Operation and maintenance manual

Position of decals on the machine

1 7

1

8

6

Chapter II - ed. 10-2009

11

3

2

5

7

4

1

10

9

2

1

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Instructions

Operation and maintenance manual

1

7

2

8

3

9

4

10

5

11

6 Hydraulic Oil

Shell Tellus ST46

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45617

Chapter II - ed. 10-2009

Safety and operation

Operation and maintenance manual

III Safety and Use of the machine

Chapter III – ed. 04-2012

page 1/66

Operation and maintenance manual

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Safety and operation

Chapter III – ed. 04-2012

Safety and operation

Operation and maintenance manual

Advice on safety when using mobile cranes. INTRODUCTION Terex® cranes are carefully designed, tested and manufactured. When used correctly by qualified operators, they ensure safe and reliable performance. Terex® has branches worldwide and is at your disposal for any information regarding products and their safe use. The following crane is designed for handling loads in compliance with the capacity table and the instructions contained in this manual. The machine must be used in conformity with current laws and regulations in the country concerned. Never lift persons with the crane if it is not equipped with a special platform for carrying persons, authorized and supplied by the manufacturer. Do not use the mobile crane for demolitions or for pushing or dragging objects with the boom. Whenever the hook has to be used for operations other than handling material, the manufacturer's prior permission is required. Normal working conditions provide for an average operating period of 8 hours a day, 5 days a week in normal environmental conditions at not more than 1000 metres a.s.l For more intensive use or in more difficult environmental conditions (high temperatures, dusty or damp places, etc.) the crane must be used with more precautions, checking it more frequently and increasing the frequency of lubrication and maintenance. Having the capacity to lift heavy loads to considerable heights, the cranes are potentially dangerous if the safety regulations are not respected. These pages will help the operator avoid accidents that could cause damage or injury. The general advice on machine operation as well as these instructions must be followed.

Chapter III – ed. 04-2012

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Operation and maintenance manual

Safety and operation

OPERATOR'S RESPONSIBILITIES Safety must be the operator's main concern. He must refuse to operate if he deems it dangerous and must contact the person in charge whenever safety is uncertain. He must read and understand the Operator's Manual, the load tables and make sure that everything is in order on the machine before operating. He must be alert, in optimal physical condition and not be under the influence of alcohol, drugs or medicines that affect the sight, hearing or reflexes. He must keep persons, equipment and materials away from the work zone. Also, the zone around the machine must be adequate marked. Whenever the operator's visibility is blocked or he is operating in hazardous areas, e.g. near power lines or around persons, he must use the help of a signaller. As the operator is not in the best position for judging distances and is unable to see all the worksite, a signaller may have to be used also in other situations. Operators must understand the standard signals for cranes and only follow the signals of the appointed signallers.

SIGNALLER'S RESPONSIBILITY The signaller's main task is to help the operator work in the most efficient way in safe conditions. Operators depend on the appointed signallers in order to move without causing damage or injuring persons. Signallers must have clearly understood the work to be performed in order to safely coordinate every task of the operators and personnel. Signallers must stand in a place where they can be clearly seen and from where they can safely observe the entire operation. The standard signals for cranes must be used unless other signalling methods, such as two-way radios or flags, are agreed on. Signallers must have good eyesight and good judgement, and must know the standard signals for cranes and be able to give signals clearly. They must have sufficient experience for recognizing risks and signalling the operator how to avoid them. The signaller is the only person authorized to give instructions to the operator.

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Chapter III – ed. 04-2012

Safety and operation

Chapter III – ed. 04-2012

Operation and maintenance manual

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Operation and maintenance manual

Safety and operation

RESPONSIBILITIES OF ALL RELEVANT PERSONNEL Unsafe conditions or operations must be adequately corrected or notified to the person in charge of work. Anyone working around the cranes must obey the danger signs and pay attention to their own safety and that of others. Load handling personnel must know the relevant safety procedures. Pay attention to risks that can arise during operations and warn the operator and signallers of hazards such as power lines, the unexpected presence of persons, other equipment or unsure ground.

MANAGEMENT'S RESPONSIBILITIES Management's task is to ensure that operators have adequate training and competence, are in optimal physical condition and, if necessary, that they have a driving licence. Good eyesight, judgement, coordination and an alert mind are necessary Those lacking any of these requisites are not allowed to operate the crane. Crane operators must have received adequate training to be able to determine weights and distances, for correctly choosing and using the lifting winch. This work is a complex subject that will not be discussed in this manual. Management must ensure that personnel receive adequate training. Personnel must be given specific responsibilities on safety and are required to inform the persons in charge of any condition involving danger for persons or things.

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Chapter III – ed. 04-2012

Safety and operation

Operation and maintenance manual

PLANNING THE WORKSITE The person appointed must clearly understand the work to be carried out, consider all the dangers existing on the worksite, and prepare a plan enabling execution of the work in safe conditions which must be notified to all those concerned. Factors such as the following must be taken into consideration: - The personnel needed and their responsibilities? - The weight of the load to be lifted, lifting radius, boom angle and nominal lifting capacity of the crane? - The way the signaller will communicate with the operator? - The equipment necessary for performing the work in safe conditions? - How the equipment can be taken safely to the worksite? - Any gas or power lines or structures to be removed or avoided? - If the ground is strong enough to take the weight of the machine and the load? - How the loads will be restrained? - Special safety precautions to be taken if the crane has to travel with a suspended load or if other cranes are necessary to lift a load? - If unfavourable weather conditions, such as wind or intense cold, are forecast? - Measures to be taken for safely keeping unnecessary persons and equipment away from the work zone? - How the cranes can be positioned for using the shortest possible boom and reach?

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Operation and maintenance manual

Safety and operation

SAFETY CHECK BY OPERATOR Every day before starting work the operator must carry out a safety check to ensure that everything is in order on the machine. Some of these checks include the following: - Check the log book on board the machine to verify that the periodical maintenance and inspections as well as all the necessary repairs have been carried out. - Check operation of the boom lifting cylinder, auxiliary alarms and other safety devices. - Carefully inspect the load supporting parts such as wire ropes, (load rope, lifting rope on the winch, suspension ropes), boom, outriggers and hooks. - Ensure that no unauthorized modifications have been in the field, such as added counterweights and booms repaired in an improper way. - Check for any hydraulic oil and air leaks. - Before starting the engine, check the cooling water and lubrication oil levels. - After starting the engine, check that the readings are correct on all gauges. - Check correct operation of all the controls. - Check the truck brakes. Test the load brakes by lifting and supporting a load at a few cm from the ground.

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Chapter III – ed. 04-2012

Safety and operation

Operation and maintenance manual

OPERATION PRECAUTIONS 1. Mistakes in calculating lifting capacity can cause accidents, therefore several factors must be taken into consideration, viz The load radius is the distance between the crane upper structure rotation axis and the centre of the boom head sheaves. Remember that the radius increases if the load is lifted due to flexing of the boom. Weight of load, block and any lifting equipment. Length of boom, number of tackles, work area (front, rear or side) and possible extensions or jibs. Use the load immediately below if the capacity or work radius are not given in the capacity table. Attempting to lift a load not given in the capacity table, trying to guess the capacity for boom lengths, radius or angle is extremely dangerous as the crane could sway or tip over during lifting Always keep within the nominal capacity given in the table. The operator must reduce the load in relation to the unfavourable conditions in the worksite and appraise the possibility of lifting loads in complete safety. 2. The cranes can tip over or sway if the work surface is unable to take their weight. Wooden boards, steel plates or cement slabs may have to be placed under the outrigger support plates to distribute the load under the crane so that the supporting strength of the ground is not exceeded. Determine the load supporting capacity of the ground or other surface on which the machines will be operating. Make sure the ground can support the crane. Avoid unstable, soft, sandy ground, areas with high water-tables and partially frozen ground. If the machines work near excavations, these must be supported or filled in order to avoid landslips or sliding. 3. The working load capacity of a crane is established with the crane levelled. Make sure the crane is level and that all the tyres are raised above the ground in order to obtain the correct values given in the table of load “On outriggers”. 4. The scissor action produced by the rotation of the upper part with respect to the base can crush or injure persons. Keep away from the crane in the rotation phase, mark the work zones and always make sure no one is within the crane's operating range. 5. Persons can be struck by the rear part of the counterweight of the machine if there is insufficient free space. Before starting work, perform a trial rotation without load to establish the exact rotation radius.

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6. Many persons have been involved in accidents caused by the hook or the suspended load, therefore to avoid that risk, always keep outside the machine work area. Do use the crane to lift persons. Use ladders, scaffolding, lift trucks or other specific equipment for lifting persons, but do not use the cranes. 7. Power lines can also be the cause of accidents. Such accidents can be avoided by respecting some simple rules. Always establish where the high-tension lines are before starting work. It is advisable to keep more than 7 m away from high-tension lines Inform the company responsible for the high-tension lines before starting work. Use a helper to maintain a safe distance between the machine and the high-tension lines. The operator is not in the best position for judging the distances. Warn persons to permanently keep away from the machine. If the load has to shifted for positioning, check the relevant precautions with the company that manages the power lines. Operate slowly, taking the time necessary for being able to react to a possible problem and with 2 different means check the distance between the high-tension lines and any part of the machine. What to do in case of accidental contact. What to be done is not based on regulations but depends on an analysis of the immediate risks. This must be the subject of rules fixed for the operator or his training. • The equipment or the machine is able to operate: without leaving the cab, the operator must immediately move the machine away from the live electrical work. • The equipment or the machine is unable to function: Without leaving the cab the operator must alert other persons by means of signals or verbally, informing them that they must not approach the machine or the equipment. (Risk of hazardous voltages on the structure of the machine or equipment for the entire duration of the incident). Whenever the operator has to leave the cab, he must jump down from it so as not to be in contact with the ground and the machine at the same time. Once on the ground he must move away from the machine: jumping, with both feet together. with very small steps. The machine can only be subsequently approached after making sure that the power line is definitively no longer live and after checking the actual absence of current (operation carried out in collaboration with the electricity company).

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• The machine operates on tyres: after contact of a machine operating on tyres with a high-tension overhead work, the tyres (with metal carcass) that were not destroyed do not retain their insulating property or their strength. If not occurring immediately, the tyres often burst later, after prolonged exposure to the sun. The tyres must be deflated and scrapped, after the machine has been taken off the power line. CAUTION: properly planned work and thorough checks ensure better protection than any other safety device. Insulated cages or proximity sensors have limits and can have failures without signalling them. The protection cables or insulated cages only protect the machine, therefore they can be current conductors due to dust or water. The proximity sensors can be disturbed by different combinations of high-tension lines or by the movements of vehicles or material and the crane itself or by other factors. Relying only on these systems can be very dangerous as the operator believes he is protected, whereas this is not so. In case of storms, take the following precautions: - if possible, support the load and completely retract the boom. - if caught by a sudden storm, switch off the heat engine and leave the machine. - if the machine is struck by lightning, check general machine operation before restarting it. You must always know the weather forecasts of your area before starting work. 8. The lifting rope can break if the load knocks against the boom head. This can occur during boom lowering or extension without keeping the rope under control. When positioning the rope, make sure it passes properly in the limit stop device safety counterweight. Always check the space between the hook and the boom head. Lower the hook during extension to avoid this type of accident. Regularly check the limit stop safety system. 9. Persons can be injured by the hook, boom, load or outriggers. Ensure that those working around the machine are safely in their place before starting to move the hook, load or outriggers. Do not move loads above persons, and do not allow the load to knock or bounce on any objects. 10. Abrupt starting or rotation movements can cause the hook and its load to sway dangerously and loss of control of the load.

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11. The crane control system makes it possible to perform several movements at the same time. In this case, the operator must use the maximum level of attention. 12. Dirty or dark windows, glare, fog, rain and other conditions can make it hard for the operator to see clearly. Keep the windows clean. Only drive if you can do so in complete safety. 13. Wind can also cause loss of control of the load, breaking the boom and overturning the machine. The wind can be stronger aloft than at ground level. Do not lift in uncertain wind conditions. Lower the boom if necessary. See the capacity tables. 14. Always wait until the machine, hook or suspended load are completely still before getting off the machine. Always use two hands and make sure of your footing. 15. Slippery platforms, ladders, tools or other similar objects can cause falls. ALWAYS KEEP THE MACHINE CLEAN AND DRY. 16. A damaged crane can be dangerous and cause accidents. A telescopic crane must be checked every week to make sure there are no basic or guide block defects. In both these cases the reduction in solidity is very difficult to assess. Inspect the crane rope and boom every day. Do not use a damaged boom or rope. NOTE: Because the booms are made of high-strength steel, special procedures must be adopted when carrying out any repairs. Always consult your dealer or the manufacturer before carrying out repairs. 17. The crane booms can twist or deform under the effect of lateral loads (lateral stress). Typical cases of lateral stress are: - Abrupt swinging due to starting or stopping. - Side dragging of a load. - The wind force. - Lifting when the crane is not level. Take care to avoid unnecessary side forces. 18. If the boom is used for purposes other than lifting it could break. Never allow the boom to bend abnormally under the effect of a load or other objects. 19. The load slings or ropes stretch when the load is lifted and contract when the load is released; at steep boom angles this operation can be enough to tip the crane over.

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20. The load can go out of control if it is not properly aligned with the boom head when lifted. This can cause a lateral stress that can cause tipping or breakage of the crane. Always put the boom head directly above the load to be lifted. 21. Trying to lift a load that is blocked, frozen or stuck to something else can cause overturning or the breakage of a lifting part. Always make sure the loads are free. 22. For correct use of the lifting winch and rope, there must be at least three dead turns of the rope on the drum. Regularly check the safety system. 23. Attempting to repair or adjust a machine component when the load or hook are suspended is very dangerous because there could be a sudden lowering of the load or any unintentional manoeuvre of the system. Always lower the load to the ground and put the boom in the rest position (horizontal) before performing any repairs, maintenance or adjustments. 24. The hydraulic oil in the machine circuit can remain pressurized for long periods, If not adequately released before any maintenance, this pressure could cause sudden movements of parts, sudden jets of oil or breakage of any hydraulic lines loosened during maintenance. Always release the pressure before any maintenance, repair or adjustment of machine parts. 25. The lattice elements connected to the boom by means of forks can break if not properly fixed. Make sure the ends all of extensions, jibs or braces are securely fixed; never stand on the boom or equipment to be installed during its assembly. 26. As with all heavy equipment, pay particular attention to movements carried out with the crane on the worksite or the road. Watch out for personnel, pay attention to high-tension lines, narrow or low passages such as bridges, roads with load restrictions, steep climbs or descents and uneven ground. Use a helper in case of movements in narrow spaces. Knowing the height, width and weight of your vehicle is very important. Completely retract the outriggers, put the boom in the horizontal position, fix the hook and block the rotation before travelling.

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27. Shifting loads with the crane moving involves a considerable increase in risk. Manually block rotation with the pin located in the operator's cab, observe the precautions described in point 26, reduce the vehicle's speed to minimum, always keep within the capacities indicated in the load table, keep the weight to be moved near the crane and as close as possible to the ground, avoiding abrupt swaying; if necessary fix the load to the crane. Inflate the tyres to the pressure given in the table located in the operator's cab. The crane could overturn if these precautions are not correctly observed. 28. The use of more than one crane for handling loads considerably increases the risks compared with handling or lifting loads with just one crane. This operation must only be carried out under the supervision of a person in charge of manoeuvres. It must be studied very carefully and several points such as the following must be taken into consideration: - Carefully study the load to be handled in order to be sure that during the operation the lifting capacity of each crane is adequate for the load. - Make sure the slings are arranged for distributing the load evenly. - Before lifting, check the lifting plan with all the personnel concerned. - Carefully coordinate the crane movements before every lifting phase. - Avoid side loads or abrupt movements. 29. Leaving the machine unattended can be very dangerous. Before leaving the operator's seat, make sure that: - The load is touching the ground. - The brake and rotation are locked. - The emergency brake is applied. - The engine is off and the gears are in neutral. - The ignition key is turned off. If the machine is to be abandoned for prolonged periods, and at the end of each working day, lock the cab door and disconnect the batteries by means of the battery isolator switch. 30. The lifting ropes must be inspected every day to check if they need replacing. See the inspection form in the manual or directly contact the rope manufacturers for further information. The rope must be replaced if it twisted, crushed, or has knots, abrasions, marked bends or any other damage that can cause deformation of its structure. WARNING: Do not use bare hands to guide the wire rope on drums. 31. Incorrect securing of the rope can cause giving or loss of the load. The rope thimbles must be fitted in the wedge so that the loaded side of the rope is in a straight line with the edge of the thimble and not bent by the wedge. The rope must pass through the counterweight of the safety device fixed to the head of the boom or the extension.

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32. Incorrect winding of the rope on the drum can create breakages, tearing or flexing of the rope. Do not use bare hands to guide the wire rope on drum; always use suitable gloves and pay particular attention to clothes which could get caught in the winch drum during its operation.

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General instructions IMPORTANT: all operators must know the operating instructions described in this manual before using the machine. The operator is responsible for use of the machine. Any non-conforming use relieves the manufacturer of all responsibility. Do not use the machine or have it used until all the instructions given in this manual are perfectly understood and memorized. Non-compliance with these instructions can result in serious damage and injury. For any needs, do not hesitate to contact your Dealer or area Agent formally authorized to provide technical information or useful advice. THE OPERATOR'S MANUAL and the LOAD TABLE must always be kept in the operator's cab. Contact the Dealer or area Agent for obtaining additional copies of the manual.

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General  Your safety and that of persons nearby depends on correct use of the machine. Make sure to perfectly know the position and function of all the controls before carrying out any operation. BEFORE USING YOUR MACHINE, TEST ALL THE CONTROLS IN A SAFE AND FREE ZONE, WITH OUTRIGGERS FULLY EXTENDED.  The terms “right and left” given in this manual indicate the sides of the machine seen from the operator's control station.  Current regulations in the workplace must always be respected.  Always keep a fire-extinguisher and a first-aid kit at hand. Make sure you know how to use them.  Sparks can be created on the electrical circuit or the exhaust pipe outlet. Do not work in closed spaces in the presence of flammable materials, powders or vapours that could cause an explosion or fire. Failure to comply with this rule can cause serious and even fatal accidents.  Make sure to have read and understood all the danger signs or the precautions to be taken, placed on the machine. Strictly respect the maintenance instructions.  Be particularly careful if using a different machine to that normally used.  Do not smoke during refuelling, as the fuel vapours are flammable.  Avoid accidents potentially caused by loose-fitting clothes that do not guarantee the necessary level of protection. Wear clothes that will not get caught on objects and if necessary wear protective equipment (helmet, safety shoes, ear protectors, safety spectacles or facemask, work gloves and reflecting clothes).  Wear a helmet, glasses, gloves and safety shoes when the current laws in the country or worksite where you are operating require it.  Before starting the engine, always make sure no one is in the immediate vicinity of the machine. Signal the start of manoeuvres by sounding the horn.  If necessary, the operator can abandon the cab by using the upper openable window (marked with the specific identification sticker) as an emergency exit. Lifting the fanlight window upwards produces a 730 mm x 560 mm opening using the normal manual opening system, or 730 mm x 850 mm by detaching the supporting gas springs by means of a simple manoeuvre.

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Access and cleaning  Make sure there are no traces of oil, foreign bodies or ice in the driving position, on walkways and access grips. Secure or remove all personal items or maintenance equipment.  Check the cleanness of the windows of your machine every day and also the operation of wipers. Dirty windows can be the cause of accidents. 

Use both hands when climbing on board or getting off the machine, remaining in a frontal position.

 Put rags dirty with grease and other flammable materials in a safe place but not on the machine.  Never jump from the machine to get off it.  Every precaution must be taken to keep the environment intact; make sure to collect and recycle all the fluids used. Do not leave them in containers without suitable labels or in open recipients. Make sure there are no puddles of fluids on the ground where you are operating. For all liquids used for maintenance: - oil - grease - antifreeze - detergents do not swallow, inhale, store or transport them in containers for food products (water, beer bottles, etc.), always use the original package (possibly integral).

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Machine operation  For your safety and for optimal machine life, carry out a complete inspection before climbing on board or starting the engine. In particular, pay attention to loose or missing screws, the state of the ropes, accumulated earth, oil or coolant leaks. Check the tyres, the equipment and systems.  A fault in a component or machine circuit can cause an accident. Before using the machine check all the oil and coolant levels. Make sure all the plugs, indicators and covers are properly secured. Replace or repair faulty parts.  In case of malfunction depending on missing or non-adjusted parts, turn the machine off and immediately fix them. Failure to comply with this rule can cause serious damage or injury.  Never use a machine with obvious defects in the braking, steering, hydraulic or electropneumatic systems. This rule also applies to a machine that has been repaired or adjusted without the control or approval of the foreman.  If malfunctions occur in the mechanical, electrical, hydraulic or pneumatic parts, turn the machine off as soon as possible.  Unless otherwise ordered, retract and put the boom in the rest position, turn off the engine, apply the parking brake and block the machine with suitable wedges or stabilize it before carrying out maintenance or leaving the machine at the end of the day's work.  Only enabled operators are allowed to drive the machine.  Know the machine's limits and keep it under control at all times. DO NOT TRY TO DO TOO MUCH TOO QUICKLY.  To circulate with the vehicle, it is a good rule to know its weight and dimensions and the characteristics of the area where you are travelling (bridges, power lines, ground strength, slopes or climbs)  Always be alert and do not allow unauthorized persons to enter the work zone. You must always know the exact position of work zone personnel.  Standing in the machine movement zone is prohibited.

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 When the engine is turned off, do not release the parking brake if the machine is not blocked. Make sure the braking system pressure is sufficient for releasing the brake.  Before starting the machine, make sure the gears are in neutral and the parking brake is applied.  Before carrying out night operations make sure the machine light signals and headlights work.  Only use the machine controls and accessories from the driving position.  Work cautiously in the presence of dust, smoke or fog. Reduced visibility can be the cause of accidents.  Before loading the machine on a semi-trailer, make sure the access ramps and the trailer are free of snow, ice, oil or grease.  Avoid abrupt manoeuvres with the load suspended.  Do not grasp the ropes when the winch is working.  Check correct operation of the block limit stop device and replace it if necessary.  To intervene on the block, place it on flat and level ground so it will not tip over.  Periodically check the wear of the block grooves and those of the boom head.  Without load, check that the sheaves turn correctly and the hook swivels smoothly.  Never leave the machine unattended with a suspended load.  If the crane is parked on a slope, the truck must be blocked by wedges, and the rotation brake locked and the boom secured.  Do not carry out inclined lifting; the machine must always be perfectly level.  Before lifting a load always make sure it comes within the limits given in the table. If an electronic limiting system is not available, this operation is even more important.

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Maintenance  All maintenance operations must be carried out by qualified personnel.  For maximum safety during machine maintenance, it advisable to use only one operator. If several operators are required, they must have a clear idea of the work to be performed in order ensure perfect coordination of the manoeuvres. Everyone's safety must be the main concern of operators.  Do not perform any repairs on the machine that you are unable to complete.  Do not allow unauthorized persons to stand on the machine during maintenance.  It is advisable to wear face and eye protection when performing maintenance operations. Use a hammer with soft head (e.g. plastic, wood, brass or leather) for hammering on equipment or hardened metal surfaces.  Only start the engine in well-ventilated places (risk of intoxication by exhaust gas).  Apply the parking brake, block the wheels and place warning signs on the control levers during maintenance operations.  Always use suitable equipment for maintenance, and replace or repair worn or deteriorated equipment.  Check the cooling circuit with the engine switched off. Undo the radiator cap gradually, to slowly release the pressure in the circuit. Pay attention to the steam, to avoid scalding.  Use the cleaning solutions with care.  Wear head and ear protectors for interventions requiring the use of compressed air. Max. air pressure: 2 bar.  Keep a suitable distance away from moving belts and fans.  For your safety, only use original replacement parts.  Arc welding of parts on the machine can deteriorate mechanical, electrical or electronic parts and compromise the machine's safety. Carry out welding work only after: - fixing the earth terminal as close as possible to the zone for welding - disconnecting the two poles of batteries - disconnecting all the electrical and electronic devices.  After every maintenance operation check correct working of the repaired parts before using the machine.

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Electrical circuit  Before carrying out any work on the electrical part, disconnect the battery and remove the ignition key.  Do not make electrical connections or disconnections without knowing the system. An incorrect connection can cause serious injury or damage.  Never check the battery level by connecting the poles with metal objects. The electric arcs produced can cause an explosion. Use a voltmeter or ammeter.  Do not smoke or use naked flames when checking the battery fluid levels. The batteries give off flammable vapours.  Do not top-up the battery levels with acid; restore the level with distilled water.  If the electrolyte of a battery is frozen, the battery could explode if put under charge or if you try to start the machine using another battery. To prevent freezing of the electrolyte always keep the batteries fully charged.  Never wear metal rings or wrist-watches, as these objects risk earthing the live circuit and therefore causing burns and injuries.  When using an external power source for starting the machine, connect the earth cable last and disconnect it first, in order to avoid sparks that could be produced near the batteries, causing explosions.

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Hydraulic circuit  The hydraulic system works at a very high pressure (300 bars). The oil that could come out of even small holes risks perforating human tissues and causing serious injuries, therefore it is advisable to use a piece of wood, and not hands, to check for leaks. If the hydraulic fluid perforates your skin, see a doctor immediately.  Make sure the circuit is not pressurized before disconnecting hydraulic lines or components. Check the tightness when reconnecting the lines or components.  Hydraulic oil is flammable, therefore do not weld components that are full of oil.  The oil and components in which it circulates are hot and can cause burns, thus avoid any contact.  After an operation on the hydraulic system it is essential to have a specialized technician bleed the air.  The reservoir plug is under pressure.  The temperature of the hydraulic oil is affected by the weather conditions and the work load of the hydraulic components. These changes in temperature affect the expansion properties of the hydraulic oil. For this reason, it is necessary to pay attention to changes, sometimes very significant, in the position of the boom and outrigger cylinders. The position of a raised and extracted boom, with or without a load, can vary over time without any retraction or lowering operations being performed. These movements are caused by the change in temperature of the hydraulic oil.

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

Replacing the tyres 1. Loosen the wheel nuts a little 2. Lift the machine on the outriggers with the wheels slightly off the ground 3. Unscrew the nuts and remove the wheel 4. Fit the new wheel, fixing the wheel nuts without tightening them 5. Lower the machine and retract the outriggers, tighten the wheel nuts (tighten in a diagonal sequence) and adjust the torque setting according to the following table. 6. Retighten the wheel nuts after 16 hours' operation.

TRUCK CRANE MODEL

TIGHTENING TORQUE M22 x 1.5

RC30-1 / RT35

450÷550 Nm

RC35 / RC40 / RC45-1

450÷550 Nm

A600-1

450÷550 Nm 650 Nm

RC60 / RT75 / RT100

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

Instructions for reading the load table The specific load table for the machine being used is located inside the cab. The operator must have read and understood all the following information. Attempting to lift a load not given in the capacity table, trying to guess the capacity for boom lengths, radius or angle is extremely dangerous as the crane could sway or tip over during lifting Always keep within the nominal capacity given in the table. The operator must reduce the load in relation to the unfavourable conditions in the worksite and appraise the possibility of lifting loads in complete safety. Make sure to always have a copy of the table on board the machine.

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

1

2

3

4

5

6 7 8 9

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1. It indicates the type of stabilization (outriggers fully opened, intermediate or fully closed) or the type of tyres fitted. 2. It indicates the length and extension of the telescopic boom. 3. It indicates the total weight of the counterweight fitted, given by the sum of the main counterweight and the additional counterweight or the sum of the main counterweight and the auxiliary winch. 4. It indicates the work zone where the work is being carried out; it can be 360° or ±3° on the front part of the machine. 5. According to the table, it indicates the moment limiter program or the type of accessory fitted or, for the configuration on tyres, the use in the static or dynamic phase. 6. The boom lengths are shown here. 7. Shows the boom angle (without load) with the machine levelled. 8. It indicates the max. permissible gross load. To know the actual load to be lifted, subtract the weight of the block and that of any accessory fitted (lattice extension or jib) from the value given. 9. It indicates the boom working radius. The radius is the distance between the turret slewing axis and the vertical axis through the rotation axis of the boom head and block sheaves.

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

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

10

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Reduction of operating loads To determine the net capacity of the crane truck in an assigned configuration, subtract the loads of the accessories used for the lifting operation (reduction of load) from the gross load. Net load = gross load – reduction of load. The load reductions can be: a - Weight of block or hook b - Weight of harness

net load gross load

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

net load gross load

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

net load

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gross load

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

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

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

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Special instructions for lifting on tyres The loads on tyres authorized by the capacity tables are to be deemed valid only if the following conditions are met: - Tyres inflated to the pressure recommended for the work to be carried out and for the workplace. - According to the configurations, parking brake applied. - Rear suspension units locked. - Load kept as close as possible to the ground. - Flat, firm and level ground.

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

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

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

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Special instructions for lifting on outriggers The loads on outriggers authorized by the capacity tables are to be deemed valid only if the following conditions are met: - Wheels completely raised above the ground - Machine stabilized horizontally, referring to the level located in the operator's cab. NOTE: Levelling must be carried out with no load attached to the hook and with the boom fully retracted and facing the front or rear of the carrier. - Firm ground under the outrigger support plates. - If necessary provide for stabilization with wooden boards to increase the support surface. CAUTION: During superstructure slewing movements with no load and during lifting operations, the accuracy of the level indication may be impaired by distortion of the crane structure. This situation will not affect correct stabilization of the machine. Lifting of an outrigger support plate off the ground The lifting of an outrigger support plate off the ground when the load passes over the opposite outrigger is not a sign of imminent tipping over of the machine. However, when this occurs and if the stabilization conditions are normal, check that: - The outrigger beam on the load side is correctly extended. - The wheels are raised above the ground as indicated in the capacity tables on outriggers. - The load lifted does not exceed the permissible value. - The support plate has not sunk in the ground under the weight of the load. - The frame is not deformed due to incorrect stabilization.

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

extended mechanical section

boom partially extended

gross load

inclination angle

radius

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Max. forces exerted on ground (daN)

Model:

RC30

28000

Ø 525 mm

RT35

27000

Ø 525 mm

RC35

27000

Ø 525 mm

RC40

27000

Ø 525 mm

RC45

39000

Ø 525 mm

A600

45000

Ø 650 mm

RC60

55000

Ø 650 mm

RT75

50000

Ø 650 mm

RT100

70000

Ø 610 mm

Model:

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0 km/h – 360°

0 km/h – 0°

2 km/h – 0°

RC30 RT35

17750

17750

14000

RC35

18400

18400

14450

RC40

18400

18400

14450

RC45

18400

18400

14450

A600

23200

23200

18200

RC60 RT75

23200

23200

18200

RT100

34500

34500

28100

14.00R24 16.00R25 16.00R25 20.5R25 16.00R25 20.5R25 16.00R25 20.5R25 23.5R25 26.5R25 23.5R25 26.5R25 26.5R25 29.5R25

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Safety and operation

Operation and maintenance manual

Actions of the wind The crane can be used safely by following the values given in the load capacity tables up to a wind speed of 8.5 m/s (30 kph - force 5) on a load surface of 1.2 m²/tonne. WARNING: Every day, check the weather and wind speed forecast by calling the nearest weather station. Do not lift the load if the wind speed is higher than the maximum permissible.

1.2 m²

12 m²

1 tonne.

Wind 10 tonne.

Wind force

Wind speed

Consequences

Scale

Terms described

mps

kph

0

Calm

0 - 0.2

1

1

Very light

0.3 - 1.5

1-5

2

Light breeze

1.6 - 3.3

6 - 11

3

Gentle breeze

3.4 - 5.4

12 - 19

4

Mild breeze

5.5 - 7.9

20 - 28

5

Fair breeze

8 - 10.7

29 - 38

Wind direction indicated by smoke and not by the banner The wind can be felt on the face, the leaves rustle, the banner moves Leaves and small branches move, banners lift The wind raises dust and leaves. Branches move Small bushes sway. Wave crests form on the sea

6

Strong breeze

10.8 - 13.9

39 - 49

Large branches sway

7

Strong wind

14 - 17.1

50 - 61

All the trees sway

8

Wind gust

17.2 - 20.7

62 - 74

9

Strong wind gust

20.8 - 24.4

75 - 88

10

Storm

24.5 - 28.4

89 - 102

The wind breaks branches, difficulty in walking freely Damage to houses (tiles and chimneys blown away) Trees uprooted and considerable damage to houses

11

Violent storm

28.5 - 32.6

103 - 117

Considerable and extensive damage

12

Hurricane

32.7 - 36.9

118 - 133

Very serious and extensive damage

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Inland territories Calm, smoke rises vertically

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Safety and operation

Safety devices Load and movement limiter The limiter is designed to provide the crane operator with essential and necessary information for operating the crane with safety. Using various sensors, the limiter controls the various crane functions and offers the operator a constant display of the crane's capacity. The display changes constantly according to the different crane movements necessary for handling the load. The load limiter provides the crane operator with information on the boom length and angle, the nominal load lifted and the maximum liftable load in the particular configuration selected. When the crane approaches non-permissible conditions, the limiter warns the crane operator with an acoustic alarm and an indicator light and deactivates any functions that can aggravate the crane's condition to prevent overload conditions: Winch lifting. Telescopic boom raising Telescopic boom lowering. Telescopic boom extension. The limiter is an indispensable device that prevents dangerous situations for the crane operator and the crane. Like all safety systems, the limiter cannot cover all human errors. The crane operator must always be aware of the operations he is carrying out.

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

WARNING: A special device allows the limiter to be inhibited, in the event of it failing, so that all crane functions are enabled Crane operations performed with the limiter inhibited are exclusively and entirely the responsibility of the crane operator or worksite manager. Terex® will not accept liability for any accidents that could occur using the crane with the limiter inhibited.

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Operation and maintenance manual

Limit stop device In compliance with the safety regulations, the crane truck is equipped with: 1. Lifting limit stop device that blocks the manoeuvre, preventing the block from getting too close to the boom head 2. A “three dead turns” lowering limit stop device that prevents complete unwinding of the rope from the winch drum. When the limit stops cut-in blocking the lifting or lowering manoeuvre, just to carry out the opposite manoeuvre to that which led to the blocking in order to restore full efficiency of all the crane controls. For safety reasons, it is extremely important to maintain the efficiency of the limit stop device, therefore we recommend checking its operation daily.

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Safety and operation

Lowering limit stop device The purpose of the lowering limit stop device is to stop the winch lowering movement when there are only three turns of the rope on the drum; in this condition the feeler tilts, touching the winch drum and activating the microswitch that interrupts the safety electrical circuit, blocking the lowering movement. In this condition, the lifting movement that will bring the device within its normal operating limits can be activated. “Three dead turns” safety switch adjustment method: - Unwind the rope so that 3 turns remain wound on the winch - If the 3 dead turns safety device is inactive, turn adjuster screw (A - B) to move the cam until you hear the switch trip. - Then carry out the lifting operation in descent to check that the safety is active. - Wind the rope additional turns and test the safety of the movement. The “3 dead turns” safety contactors must disconnect the winch hook descent functions.

A. B.

Periodically check feeler wear and operate the device adjustment or replace the feeler. NOTE: In the event of rope replacement, the safety device must be readjusted.

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Operation and maintenance manual

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

1

2 6

3

5

4

Model SW6 (A600) Legend: 1. Winch drum 2. Lifting rope 3. Drum feeler 4. Return spring 5. Limit switch 6. Adjustment screw 7. Cable clamp 2

1 7

3

6

5

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Operation and maintenance manual

Model TW6 (RC60 – RT75) Legend: 1. Winch drum 2. Lifting rope 3. Return spring 4. Limit switch 5. Adjustment screw 6. Cable clamp 2 1

3

6

5

4

Models TW4 and TW5 (RC45) Legend: 1. Winch drum 2. Lifting rope 3. Cable clamp and drum feeler 4. Adjustment screw 5. Limit switch 6. Return spring 6

2

4

3 1

5

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Operation and maintenance manual

Lifting limit stop device Microswitch “1” is kept in operation by counterweight “3”. When the block assembly is lifted up into contact with the counterweight the microswitch interrupts the electric circuit and lifting is stopped. In this condition the block lowering movement can be activated, which will bring the device within its normal operating limits.

IMPORTANT: When activating winch lifting with the block near the limit stop, work with caution and at moderate speed. The minimum length of the limit stop device counterweight “2” chain must be 80 cm. Legend: 1. Limit switch 2. Counterweight chain 3. Limit stop counterweight

1

2

3

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

button

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

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Safety and operation

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

Machine operation Introduction This section and the safety regulations for mobile cranes given at the beginning of the manual must be carefully read before driving the machine. Always respect the following precautions to ensure operation in safe conditions: • Always check the capacity table to know the maximum load that can be lifted with different boom angles, lengths and other factors that can be taken into consideration during load handling. • Always start the machine using an engine speed suitable for the load to be handled. • If the load is likely to sway, always keep it as close as possible to the machine and the ground. • During boom extension or lowering to prevent the block from striking the boom head operate the winch to unwind the rope.

Preliminary checks Every day, before using the machine, clean all the windows, screens, lights and rear-vision mirrors to ensure good visibility for the operator. Adjust the operator's seat so that it is comfortable and suitable for the machine operator. Checks to be carried out before starting the machine: - Engine oil level - Transmission / gearbox oil level - Fuel level - Hydraulic oil level - Engine coolant level - Brake fluid level - Cab heating (when provided) fuel level - Windscreen washer liquid level - Winch rope

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Engine starting Before starting the engine, make sure there are no persons or objects in the immediate vicinity of the machine. 1. 2. 3. 4.

Make sure the gearshift lever is in the neutral position “N”. Select the fast or slow gears according to needs (where applicable). Turn the ignition key. The battery level, braking system air circuit, engine oil pressure and coolant temperature warning lights on the instrument panel come on. 5. Beep the horn. 6. The parking brake must be applied. 7. Turn the ignition switch to the second position to start the engine. NOTE: The engine cannot be started if the gear lever is not in the neutral position “N”. IMPORTANT: To avoid permanent damage to the starter motor, do not operate it continuously for more than 30 seconds at a time. If within that time, the engine fails to start, wait a couple of minutes before trying again, but do not operate the starter for more than 15-20 seconds. If the engine still does not start, wait for the starter motor to cool before trying again and make sure the gearshift lever is in the neutral position “N”. IMPORTANT: When operating the crane at temperatures below 0°C, after starting the engine and before using the crane, allow the engine to idle for several minutes to allow the hydraulic oil to reach its working temperature. When the engine has started and idles normally: the oil pressure and battery level lights go out, and the air pressure warning light goes out when the pressure reaches 5.5 bars. The parking brake light stays on. NOTE: Do not use the machine until the air pressure lights are extinguished.

Switching off the engine Before switching the machine off, allow the engine to idle for a few seconds. IMPORTANT: Do not stop the engine if the gear lever is not in the neutral position “N”. Never accelerate before switching the engine off, as this could damage the turbocharger due to lack of lubrication.

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Safety and operation

Securing the block (hook) to the truck crane

WARNING: when the block is secured to the crane structure use special caution when performing movements that could subject the anchor stay to tension resulting in breakage of the stay and consequent projection of the block forwards. It is therefore prohibited to perform any movements other than those that are strictly necessary to release or attach the block. Failure to observe these precautions can result in serious personal injury.

Attachment To secure the block to the front of the chassis: Fig. 1 1. 2. 3. 4. 5.

Retract the boom completely. Attach the block anchor stay to the front of the chassis. Position the block so that it is vertically aligned with the anchor stay. Lower the block and secure it to the anchor stay. Make sure that all personnel on the ground have been removed from the area around the front of the machine. 6. Bring the boom to the required angle, executing the boom lower movement alternately with the block lift movement, taking care NOT to tension the anchor stay (DO NOT perform the two movements simultaneously).

Fig. 1

To secure the block to the top of the chassis: Fig. 2 1. 2. 3. 4. 5.

Retract the boom completely. Attach the block anchor stay to the top of the chassis. Position the block so that it is vertically aligned with the anchor stay. Lower the block and secure it to the anchor stay. Make sure that all personnel on the ground have been removed from the area around the front of the machine. 6. Bring the boom to the required angle, executing the boom lower movement alternately with the block lift movement, taking care NOT to tension the anchor stay (DO NOT perform the two movements simultaneously). Fig. 2

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Operation and maintenance manual

Release To release the block from the front of the chassis: Fig. 1 1. Make sure that all personnel on the ground have been removed from the area around the front of the machine. 2. Align the boom axis with respect to the anchor point of the block by slewing the superstructure and taking care NOT to tension the anchor stay. 3. Bring the head of the boom to a position in which it is vertically aligned with the block by performing block lower movement alternately with the boom movement, taking care NOT to tension the anchor stay (DO NOT perform the two movements simultaneously). 4. Detach the block from the anchor stay on the front of the chassis. 5. Proceed with normal crane operations

Fig. 1

To release the block from the top of the chassis: Fig. 2 1. Make sure that all personnel on the ground have been removed from the area around the front of the machine. 2. Align the boom axis with respect to the anchor point of the block by slewing the superstructure and taking care NOT to tension the anchor stay. 3. Bring the head of the boom to a position in which it is vertically aligned with the block by performing block lower movement alternately with the boom movement, taking care NOT to tension the anchor stay (DO NOT perform the two movements simultaneously). 4. Release the block from the anchor stay on the top of the chassis. 5. Proceed with normal crane operations Fig. 2

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Safety and operation

Driving on road Preliminary operations 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

Align the turret with the carrier (boom on the front end). Make sure the device locking the turret to the frame is engaged. Secure the block to the top of the chassis. Make sure the suspension is free (warning light off). Make sure the ground support plates and outrigger beams are locked in place. Check the general operation of the lights. Check the tyre pressures. Adjust the rear-vision mirrors. Make sure that, once seated in the cab, the entire machine can be controlled through the rear-view mirrors. Ensure all the bonnets are fastened. Never drive the machine on the road with a suspended load. Make sure the machine's electrical system works properly (headlights, blinkers, parking lights, etc.). Carrying passengers is not allowed. Respect the speed limits. Strictly respect the highway code. As a part of the boom projects over the front of the machine, a guiding car is necessary when crossing intersections. Make sure all the roads on the route will take the road dimensions and weight of the machine.

WARNING: The operator must make sure he has complete and ample visibility of the area around the machine when proceeding by road. Only front-wheel steering is allowed on the road (except for A600). Regularly check front wheel alignment and adjust if necessary. To avoid damaging the transmission, stop the machine before inverting direction (forward or reverse).

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Operation and maintenance manual

Driving on the worksite For travel operations without a load, depending on the distance and the type of terrain, it is advisable to: 1. align the turret with the carrier (boom on the front end). 2. insert the manual slewing locking pin. 3. secure the block to the front of the chassis. 4. lift the outriggers, retract the beams completely and secure with the specific pin. Transporting a suspended load 1. Align the turret with the carrier (boom on the front end). 2. Make sure the manual slewing lock pin is inserted. 3. Consult the load tables to ensure that the load does not exceed the values given in the table for operation on tyres. 4. Keep the load as close as possible to the ground to avoid swaying. 5. Respect the tyre inflation pressures. 6. Make sure the suspensions are locked. 7. Suspended loads must only be carried on flat and horizontal ground, after first checking that the terrain is sufficiently stable to withstand the load borne by the vehicle tyres. 8. Select a steering mode according to transport requirements. 9. Select a slow gear. 10. Select front-axle drive (4-wheel drive). During the transport of loads on flat ground the work radius is constant.

When transporting loads uphill the reduction in the work radius can cause the load to knock against the crane. Travelling with no load but with the boom raised can cause the machine to tip over.

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

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Safety and operation

Machine stabilization Instructions: Raise the machine on the outriggers on firm and possibly level ground. In case of sloping ground, keep the machine horizontal using thick and hard wooden blocks, adjusting the travel of the outrigger beam vertical cylinders, making them come out more or less. The area of these spacers on the ground must be greater than the surface area of the outrigger support plates. The machine can considered stabilized only when all the wheels are completely off the ground. WARNING: If an obstacle prevents all the outrigger beams from being extended to the same length, refer to the configuration in the table relative to use on tyres, with outrigger beams partially extended or retracted.

The crane trucks have three types of stabilization OUTRIGGER BEAMS FULLY RETRACTED Depending on the load table configuration, the crane can operate with all the outrigger beams retracted. For a correct configuration, the beam locking pin must be inserted in the special seat.

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

OUTRIGGER BEAMS FULLY EXTENDED Depending on the load table configuration, the crane can operate with the outrigger beams completely extended. For a correct configuration, the beam locking pin must be inserted in the special seat. NOTE: Before extending and retracting REMEMBER TO REMOVE the locking pins.

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the

outrigger

beams

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Safety and operation

Operation and maintenance manual

Support surfaces Check the solidity of the terrain over which the crane is to travel. Make sure the ground can support the crane. Avoid unstable, soft and partially frozen ground. Work in the proximity of an excavation: the crane must not be sited on the edge of an embankment or pit; in these cases keep well back from the edge by a sufficient distance in accordance with the compactness of the terrain. Safety distance: Firm compact terrain (not powdery). Distance 1 = Depth of excavation (A) Powdery terrain or backfill. Distance 2 = Depth of excavation (A) x 2

2 1

A.

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

The surface must withstand the weight of the crane and the load to be lifted, in addition to the live loads imparted because of movements of the crane and wind force. The maximum ground pressure applied through the outrigger ground support plates depends on the configuration of the crane and the load to be lifted. In accordance with the values in the tables, the operator can decide whether the ground support plates are sufficient or whether it is necessary to make use of larger size supports such as boards interposed between the ground support plates and the ground. The outrigger support plates must be positioned in the centre of such additional supports.

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Guideline table of permissible pressures for various types of terrain

daN/cm² (kg/cm²)

Terrain Types Type A

Naturally compressed soil, backfill

0.5 -1.0

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

1.5

Large particle sand - gravel

2.0

Non-powdery terrain:

Type B

Soft

0.4

Firm

1.0

Semi-rigid

2.0

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

4.0 15 30

Artificially compacted terrain

Type C

Asphalt and bitumen

5 - 15

Cement group BI

50 - 250

Cement group BII

350 - 550

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

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Operation and maintenance manual

Hazards in the work zone Pay attention to the presence of power lines, bridges, railway lines, constructions and other cranes. An arc can be created between the power line and the metal parts of the machine if they come into contact or if the minimum safety distance is not respected. Following are the minimum values to be respected for the distance. They are purely indicative. Power line voltage

Minimum distance

From 0 to 1000 V

2 metres

From 1 KV to 110 KV

4 metres

From 110 KV to 220 KV

5 metres

From 220 KV to 380 KV

6 metres

As it is often very difficult to determine the voltage of a power line, it is advisable to respect a minimum distance of 6 metres, also considering that power lines can sway if there is wind. In any case, comply with the regulations on works near electric lines applicable in the country of use of the machine. Accidents are caused above all by electrical discharges. Whenever the minimum recommended distance cannot be respected, request the local electricity company to switch off the power line current.

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Operation and maintenance manual

Safety and operation

Extension of the boom Extension of the boom with a suspended load is normally permitted in the limit of 75% of the capacities indicated in the load table and anyway within a maximum capacity of 8 tonnes. The precision of this manoeuvre is anyway less than the precision that can be obtained by lifting the load with the rope because it depends on the mechanical efficiency of the boom (friction of slide pads). Friction of the slide pads depends on: - greasing - boom lifting angle - incidence of the lifted load During extension manoeuvres, very poor efficiency of the boom will result in inhibition of the function when the maximum pressure value set for the extension circuit is reached. To re-enable the manoeuvre, place the lifted load on the ground and reposition the boom in more favourable geometrical conditions. During retraction of the boom poor efficiency may translate into abrupt starting of the movement of the sections, which may perform sudden stick-slip type movements in steps of up to 50 cm.

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Operation and maintenance manual

Lifting rope The lifting rope is one of the crane's main parts, and requires particular attention for starting and maintenance. The ropes must be visually checked for signs of deterioration or deformations every day. Pay special attention to the points where the ropes are attached to the equipment. In any case, the rope must be inspected when an accident may have caused damage to the strands, wires or attachment points or when a rope has been returned to service after being removed and then refitted. If the machine has not been used for some time, the rope must be inspected before resuming work. In particular, check: - The fixing points at the rope ends. - The parts of the rope sliding on the lifting or idle section sheaves. Rope replacement criteria. - Broken wires (nature and number). - Broken wire nests. - Gradual increase in the number of broken wires. - Broken strands. - Broken rope core. - Reduced elasticity. .reduction in rope diameter .rope stretching .no space between individual wires and strands .appearance of fine brown powder between strands - General wear of rope due to abrasion. - External and internal corrosion. - Rope deformation (under load) .spiral deformation .basket deformation .stretched wires .slackening of certain wires or strands .knottiness .contractions .flattening .loops .lumps .bends - Deterioration induced by heat.

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Operation and maintenance manual

Safety and operation

Visual examples of various problems that can occur to the rope

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

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

Broken wires on the same strand and slight wear.

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Operation and maintenance manual

Broken crossed wires at the equalizer pulley.

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

Example of wire rope with very high internal corrosion.

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Eccentric rigging (unbalanced) Eccentric or unbalanced orientation of the boom head results in twisting of the boom that is not permitted by the load table. The load tables are valid only if the boom head is rigged symmetrically.

axis of the boom

axis of the boom

boom twisting

if the lifting line is not centred with respect to the boom head

…… the boom will twist when a load is applied

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

Blocks that are rigged asymmetrically will tend to rotate when a heavy load is applied. When rigged symmetrically they work correctly.

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Operation and maintenance manual

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

boom axis

boom axis

boom axis

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

hoisting line

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boom axis

hoisting line

boom axis

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Changing the number of tackles The speed of lifting or lowering of the block decreases in proportion to the increase in the number of tackles. This number depends on the load to be lifted and the height to which it is to be lifted (refer to the load tables). Use a maximum of two tackles when working with the lattice extension or any type of jib. 1. 2. 3. 4. 5. 6.

Lower the boom and rest the block on the ground Remove the wedge box from the boom head. Remove the clamp from the rope end. Remove the wedge and the rope from the wedge box. Withdraw the rope from the limit stop counterweight. Wind or unwind the rope on the boom head sheaves until obtaining the required number of tackles. 7. Insert the rope into the limit stop counterweight. 8. Insert the rope into the wedge box then insert the wedge. Wrong

Correct The section of rope inserted in the block must be positioned on the side of the wedge box located on the same vertical axis as must be the corresponding connecting pin. The terminal part of the rope must be located on the inclined side of the wedge box. 9. Attach the rope clamp in such a way that the rope cannot become detached from the wedge box. 10. Insert the wedge block on the boom head (pay attention to the direction in which you insert the rope). 11. With a load attached slacken the rope slowly so that you can position the rope and the wedge block. Check that the rope is correctly positioned.

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Operation and maintenance manual

Blocks and hooks The crane can be used with blocks/hooks having different characteristics and various performance levels. It is the responsibility of the operator to use a block/hook of appropriate capacity in relation to the load to be lifted and having suitable characteristics in relation to the type of rope installed on the crane.

Before placing a load on the sling, check that the spring-loaded safety on the hook is in perfect working order and the hook shows no visible signs of ware. Before lifting a load, check that it is perfectly level in comparison to the block. Never lift loads that exceed the maximum safe working load specified on the plates fitted to the block and stamped on the hook. Do not lift loads with a jerking action and do not use in ambient temperatures less than –30°C or above +100°C. No responsibility is taken by the manufacturer for any modifications that are made to the block and hook (in particular, welding the hook).

NOTE: In case of accidentally lifting a load that exceeds the maximum safe working load, before restarting work, check the open measurement of the hook. The measurement must be compared with the one written on the certificate supplied by the manufacturer. If the measurement is not the same as the one stated on the certificate, stop work immeditely and report the problem to the person in charge of maintenance. The hook must be replaced.

WARNING: If the red plate stating the specification of the block is removed without permission damaged or lost, the manufacturer will not be able to trace the product in the case of claims. It is therefore important to promptly report the loss to the manufacturer, who will supply a new plate.

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

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

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Operation and maintenance manual

Work with main winch and auxiliary winch DANGER: The load limiter cannot calculate the load of two blocks simultaneously in order to ensure safe working conditions; for this reason all load handling operations performed with two blocks are UNDER THE SOLE RESPONSIBILITY OF THE OPERATOR. Terex® CANNOT BE HELD LIABLE UNDER ANY CIRCUMSTANCES FOR POSSIBLE ACCIDENTS THAT MAY OCCUR WHEN USING THE CRANE WITH TWO WINCHES Working with two blocks consists in handling a load using the block of the main boom and the block of the extension. First of all, the load to be handled must be lifted exclusively with the extension. Check the load table to ensure that this is possible. Support the machine on fully extended outriggers, slew the turret to the front and ensure the boom is aligned with the machine axis. The limiter performs its functions correctly when a single block assembly is used at a time (work with main boom or work with tower section); when working with two block assemblies, the limiter must be set onto the work mode with tower section. Since the effective load is lifted by two blocks simultaneously, the maximum load is equivalent to the maximum total load permitted with a tower section during load handling with the tower section (with a single block). Check the load capacity table. The load capacity value depends on the extension installed. Check the table of capacities with extension. The value indicated by the limiter will be the value of the configured extension. Work with two blocks is accompanied by the risk of subjecting the boom and the extension to an overload and causing accidents, since the limiter cannot perform its functions correctly. Handling “permitted” under the responsibility of the crane operator or the site manager is that of turning a load using two blocks, the extension block (which is less robust) to lift the load and the main block to turn it.

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Safety and operation

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

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

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

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When handling loads with the two blocks never lower the boom because the limiter is unable to monitor overload conditions. Lower the load with the extension block to bring it to a vertical position. All manoeuvres must be executed with slow movements and without snatching. The tackles of the main boom winch must be identical in number or more than the tackles of the extension block.

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Safety and operation

Lifting with several mobile cranes Lifting operations involving two or more mobile cranes are complex procedures that call for significant levels of skill, practice and careful planning. It is therefore necessary to prepare a detailed procedure that takes account of all possible situations and that anyway addresses at least the following minimum requirements: - Lifting must be carried out under the control of a responsible supervisor. - The terrain must be flat and solid, otherwise it will be necessary to use all the means necessary to achieve this condition. - All the cranes must be accurately levelled. - The precise weight of the load and its centre of gravity must be established. - The maximum working radius that can be reached by each crane during the entire procedure must be established. - The length and inclination angle of the crane booms must be established. - The nominal capacity of each crane must be established for each stage of the procedure. - When lifting with several cranes none of the cranes involved must carry more than 75% of its net capacity; greater reductions may be required in the presence of specific lifting conditions. - The speed of the block, slewing, and the crane boom must be the same for all the cranes as far as possible. - Slewing, tilting and extension movements must be limited to the indispensable minimum. - It is dangerous to travel with a load because swaying movement can result in the transfer of very significant loads from one crane to another. - Operators must be informed of exactly how to act and the movements that are to be performed before starting the lifting operation. - If possible, perform one or more trials with no load until all the operators are aware of what is required of them. - All communications during the lifting procedure must take place by radio (preferably closed type rather than walkie-talkies). - It is essential that just one person be appointed to direct and supervise the operation. Said person must be in a position to observe the entire operation and must keep in radio contact with the operators. - All movements of the cranes must be performed as smoothly as possible with very gradual stops and starts. - The ropes of the blocks must be kept vertical. If this rule is not observed the cranes will tend to create overload conditions with each other and cause extremely dangerous lateral swinging movements. - For these operations it is important to check the correct functioning of the load indicator and/or limiter with which the mobile cranes taking part in the procedure must be equipped.

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Towing In the event of a breakdown the crane can be towed over short distances (less than 10 km) at reduced speed (less than 10 km/h) using a towing bar. - Put the gear selector into neutral - Release the parking brake on the front axle. The operating brakes, supplied with the remaining air pressure in the circuit, are not affected by this operation. - Disconnect the transmission shafts (front and rear axle). If this operation is not carried out the transmission may be rapidly and irreparably damaged. The crane must be towed in strict compliance with the rules of the highway code in force in the country in which it is working. Use the towing points provided specifically for the purpose, which are located on the front of the chassis (optionally on the rear). The maximum horizontal traction force on the hook must be less than 50% of the total weight of the machine in running order. If the crane becomes lodged in mud or sand, use the towing attachments located on each corner of the carrier to pull it clear.

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Safety and operation

Transporting the crane on a self-propelled trailer Use trailers or platforms of suitable size to transport the machine.

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

Make sure that the overall load height is lower than the height permitted by statutory legislation or by motorway authorities and, if necessary, that the specific transportation or road circulation permit has been issued. Do not resort to deflating the tyres to comply with the maximum permissible height dimension. If the outrigger plates are not in contact with the trailer bed, make sure the outrigger beam is locked to avoid uncontrolled extension movements. The crane must be transported with the boom in a horizontal position, the block anchored to the frame structure, and slewing movements locked with the manually inserted pin and, once the crane has been loaded, with the parking brake applied. Always comply fully with the foregoing instructions even if the crane is to be transported over very short distances.

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IV Control instruments

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Contents Identification of the controls . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Operator's cab controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Side controls console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Central control column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Column indicator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Telescopic boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Model RC30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Model RT35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Machine layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Outrigger controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Symbols on outrigger controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Winch rotation speed selector . . . . . . . . . . . . . . . . . . . . . . . . Turret slewing speed regulator . . . . . . . . . . . . . . . . . . . . . . . Turret slewing brake released indicator light . . . . . . . . . . . . Gearshift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Central control column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine coolant temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . Fuel gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine temperature warning light . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery charge light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine oil low pressure warning light . . . . . . . . . . . . . . . . . . . . . . . . Suspension lock warning light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel alignment warning light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake fluid low level warning light . . . . . . . . . . . . . . . . . . . . . . . . . . Parking brake engaged warning light . . . . . . . . . . . . . . . . . . . . . . . . Torque converter oil temperature warning light . . . . . . . . . . . . . . . . Front axle brake circuit low pressure warning light . . . . . . . . . . . . . Rear axle brake circuit low pressure warning light . . . . . . . . . . . . . . Parking lights / low beam light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High beam light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel warning light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blinker light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hazard lights switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flashing revolving light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low speed (4x4) / high speed (4x2) range selector . . . . . . . . . . . . . Rear axle oscillation lock switch . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear fog light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lights main switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Work light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering mode selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering column switch control stalk . . . . . . . . . . . . . . . . . . . . . . . .

Manual slewing locking pin . . . . . . . . . . . . . . . . . . . . . . . . . . Left hand control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right hand joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary winch control (optional) . . . . . . . . . . . . . . . . . . . . . Chapter IV – ed. 04-2011

21 21 22 23 25 26 26 26 27 27 27 27 28 28 28 28 29 29 29 30 30 30 30 30 30 30 31 31 31 31 32 33

34 35 37 38 38

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Control instruments Spirit level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Cummins engine control panel . . . . . . . . . . . . . . . . . . . . . . . 39 Radio and 24V socket outlet . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Cab heating control (optional) . . . . . . . . . . . . . . . . . . . . . . . . 41 Air conditioner control in operator's cab (optional) . . . . . . 42 Battery disconnecting switch . . . . . . . . . . . . . . . . . . . . . . . . . 42 Operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Seat adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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Identification of the controls The reference numbers of instruments and controls in the cab illustrations correspond to the numbers in the text together with the description of controls, instruments and relative functions. Notes: the following list specifies all the standard machine controls complete with descriptions. Not all the instruments listed are supplied on every machine. Before using the machine the operator must carefully read all the information in this heading and the safety prescriptions in the first part of the manual for earthmoving machinery operations. The operator must know the exact position and function of every control on the machine. This manual contains the words WARNING, CAUTION and NOTES to highlight important and relevant instructions. The indications WARNING and CAUTION precede the section or point to which they refer, whereas NOTES relevant to the subject in question are given below the sections or points. In this manual the indications WARNING, CAUTION and NOTES are specified as follows: WARNING: Any operating procedure, standard, etc. that could result in injury or death if not strictly observed. CAUTION: Any operating procedure, standard, etc. that could result in damage or destruction of equipment if not strictly observed. NOTE: Any regulation, operating condition, etc. that it is important to stress.

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Operator's cab controls

1

2

3

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

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4

5

6

7

4. Parking brake 5. Right hand control 6. Left hand control 7. Outrigger movement enable button

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9

8

LH

RH

8. Superstructure slewing brake manual release 9. Horn

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10

11

12

10. Spirit level 11. Windscreen washer liquid tank 12. Heater control (see the fitted model)

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Side controls console

28

29

13

27

14 26

25

15

24 16 23

22

17

21 18 20

19

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13 Front right outrigger beam extension/retraction control 14. Front right outrigger down/up control 15. Rear right outrigger down/up control 16. Rear right outrigger beam extension/retraction control 17. Lifting winch speed selector 18. Turret rotation speed regulator 19. Gearshift lever 20. Pressure gauge 21. Not connected 22. Emergency stop 23. Load limiter inhibit pushbutton 24. Front left outrigger down/up control 25. Auxiliary winch control (optional) 26. Rear left outrigger beam extension/retraction control 27. Superstructure slewing brake released warning light 28. Front left outrigger down/up control 29. Front left outrigger beam extension/retraction control

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Central control column

30

31

34

32

35 33

36 40 39

37 38

41

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30. Steering wheel 31. Indicator panel 32. Steering column switch 33. Emergency lights switch 34. Steering mode selector 35. Rear axle oscillation lock switch 36. Work light switch 37. Parking lights/low beam switch 38. Rear fog light switch 39. Low speed (4x4) /high speed (4x2) range selector 40. Flashing light switch 41. Steering column rake adjustment lever

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Column indicator panel

43

44

42

45

42. Engine coolant temperature gauge 43. Display 44. Fuel gauge 45. Set of warning lights

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Telescopic boom Model RC30

2nd section

Main boom

3rd section

Model RT35 2nd section

4th section

Main boom

3rd section

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Machine layout Carrier: the rear is the part of the chassis in which the engine is mounted Superstructure: the boom occupies front end of the superstructure, the counterweight is located at rear end The left and right sides are determined with respect to the operator seated in the driving position located on the turret.

Boom head

Boom base

Top part

Main winch

Front Counterweight Lifting cylinder Engine Hoisting block Front outriggers

Cab

Front section

Rear outriggers

Rear section Right hand side Hydraulic oil tank and air accumulator

Front

Fuel tank and batteries

Left hand side

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Description of controls

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

7

The LH joystick is equipped with a button (ref.7) located on the left armrest of the driver's seat.

Caution DO NOT COMBINE OPPOSITE FUNCTIONS. (Example: retracting one outrigger beam while simultaneously extending another, or lowering one vertical cylinder while simultaneously raising another).

warning Make sure the machine is perfectly stabilized before handling loads. Frequently check the spirit level in the cab to ensure correct levelling.

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Front left outrigger controls



Front right outrigger controls

Rear left outrigger controls



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Rear right outrigger controls

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Symbols on outrigger controls • Left side beam extension

press and hold button "7" simultaneously to enable the function

• Left side beam retraction

press and hold button "7" simultaneously to enable the function

• Right side beam extension

press and hold button "7" simultaneously to enable the function

• Right side beam retraction

press and hold button "7" simultaneously to enable the function

• Left side outrigger down

press and hold button "7" simultaneously to enable the function

• Left side outrigger up

press and hold button "7" simultaneously to enable the function

• Right side outrigger down

press and hold button "7" simultaneously to enable the function

• Right side outrigger up

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press and hold button "7" simultaneously to enable the function

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Winch rotation speed selector

• Winch first speed

• Winch second speed

Make sure the block is at a standstill before changing speed. The change in speed can cause the load to sway dangerously.

Caution Do not change the winch speed if the winch joystick is not in the neutral position and the drum is turning.

Turret slewing speed regulator

27

18

Turn the knob anticlockwise to reduce slewing speed (ref.18), or clockwise to increase it. If the knob is turned fully anticlockwise slewing is stopped

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Control instruments Turret slewing brake released indicator light

The light (ref.27) comes on when the button (ref.8) on the left hand joystick is pressed, signalling that the superstructure slewing brake has been manually released.

8

LH

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Gearshift lever

3

2

2

1

3

1

N NEUTRAL position "N" The lever must be in position "N": • when the machine is stationary • to shift from the low speed to the high speed range • to lock or release the rear axle steering • to start the engine Moving forward: Positions 1 2 3 Engage first gear, release the parking brake and accelerate. In first gear, the machine moves forward; change gear as the speed increases. Reversing Positions 1 2 3 Engage first gear, release the parking brake and accelerate. The machine reverses in first gear; change gears as the speed increases.

Caution Reduce engine speed before shifting down. Stop the machine before reversing. When driving on the road always engage the most appropriate gear to avoid gearbox overheating.

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Central control column

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Engine coolant temperature gauge

The normal temperature is between 83°C and 95°C. The coolant temperature must not exceed 100°C. NOTE: If the temperature reaches 100 °C, turn off the engine immediately and check the cooling circuit.

Fuel gauge

This gauge shows the fuel level in the tank Note: there is no low fuel warning light.

Display A

B

C

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

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Warning light !

Simultaneous check of water, oil and battery warning lights. Red warning light

Engine temperature warning light Comes on when the engine coolant temperature reaches 115 °C.

Battery charge light Comes on when: • The ignition is switched on but the engine has not yet started • The alternator does not charge the batteries Red warning light

Engine oil low pressure warning light Comes on when: • The engine oil pressure is below 3 bar • The engine is idling Red warning light

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

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Control instruments Suspension lock warning light The rear suspension locks automatically if the superstructure is slewed left or right by more than 3° in relation to the machine's longitudinal axis. This light comes on indicating that the suspension is locked. Red warning light

warning If the superstructure is slewed by more than 3° with the machine supported by the tyres and the warning light fails to illuminate immediately, stop slewing movements and check the suspension locking system. Do not resume work before finding and fixing the problem.

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

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

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

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

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

Front axle brake circuit low pressure warning light The normal brake working pressure is above 5.5 bar. The light goes off when the engine is started and the pressure has reached 5.5 bar. The light comes on when the braking circuit pressure falls below 5.5 bar during machine operation. Red warning light

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

Rear axle brake circuit low pressure warning light The normal brake working pressure is above 5.5 bar. The light goes off when the engine is started and the pressure has reached 5.5 bar. The light comes on when the braking circuit pressure falls below 5.5 bar during machine operation. Red warning light

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

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

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

Fuel warning light Not connected

Blinker light Indicates operation of the turn indicators Green warning light

Hazard lights switch When pressed, the six blinkers flash at the same time, signalling a machine emergency situation. Intermittent red warning light.

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

Low speed (4x4) / high speed (4x2) range selector Pressed to the left (tortoise symbol), selects the low speed range with engagement of front and rear wheel drive (4x4 drive). Use this setting for difficult ground, at low speed and for driving the machine when carrying a load.

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Pressed to the right (hare symbol), selects the high speed range with engagement of rear wheel drive only (4x2 drive). Use of this setting is recommended for driving on the road. Note: This type of control should be used only when the machine is stationary.

Rear axle oscillation lock switch The rear axle oscillation lock cuts in automatically if the superstructure is slewed left or right by more than 3° in relation to the machine's longitudinal axis. This switch can be used to release the rear axle oscillation lock regardless of the position assumed by the superstructure relative to the machine's longitudinal axis.

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

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

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

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Steering mode selector 2 1

3

Before selecting steering modes, the front and rear wheels must be aligned and parallel to the longitudinal axis of the truck. The selector has three positions: Position 1: coordinated/concentric steering Position 2: front axle steering only Position 3: crab steering After several hours of operation check the alignment of the front/rear wheel axles. Realign the wheels if necessary. For this purpose: -

set the steering selector to position 1 or 3.

-

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

-

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

align the front axle wheels by means of the steering wheel (visual alignment check). The front and rear axle wheels are now aligned. After selecting the type of steering, just use the steering wheel to manoeuvre the machine. -

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

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Steering column switch control stalk

Press the button to sound the horn

Rotate the stalk in either direction to operate the windscreen wiper

Press the front wiper control sideways to operate the washer jets.

Blinkers switch: push the stalk forward to operate the left side blinkers to turn left. pull the stalk back to operate the right side blinkers to turn right.

Headlight selector Push the stalk down (after turning the lights switch on) to switch on the high beam headlights. The blue light on the control panel comes on Pull the stalk upwards to flash the high beams

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Manual slewing locking pin

1

Lift the right arm-rest to access the locking pin (ref.1). To lock the upper part of the machine, align it with the truck (boom on front end), lift the pin, turn it clockwise 90° and lower it into its seat..

Caution Never insert the pin while the superstructure is turning. Failure to comply with this precaution can seriously damage the superstructure and the truck. The superstructure must always be locked when moving the crane on the worksite and the road.

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Left hand control

RH LH

The left hand control commands turret slewing, slewing of the superstructure, brake release and telescopic boom extension/retraction. The left hand control has a safety device for preventing accidental manoeuvres, however the operator must remain seated in the driving position. Operations with only one winch: 1. push forward to extend the boom sections 2. move right to slew the turret clockwise 3. pull back to retract the boom sections 4. move left to slew the turret anticlockwise Operations with auxiliary winch: 2. move right to slew the turret clockwise 4. move left to slew the turret anticlockwise 5. pull back to lift the load with the auxiliary winch 6. push forward to lower the load with the auxiliary winch Remember to remove the manual slewing locking pin before using the slewing function. When the hand control is in the middle position (e.g. boom extension and turret clockwise rotation) the two functions are activated at the same time.

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

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Manual superstructure slewing brake release button on left hand control (red light ref.27) The LH joystick is equipped with a button (ref.8) that can be used to release the superstructure slewing lock manually.

27 8

LH

Operation On machine starting, the turret slewing unit brake is applied and automatically released gradually during slewing of the superstructure.. To release the brake manually and allow self-alignment of the boom end vertically over the centre line of the load being lifted, grip the left hand joystick and press button "8". The brake is automatically re-applied when the button is released.

Caution Do not release/lock slewing abruptly during work as this may cause the load to sway. Wait until the superstructure of the machine has completely stopped before reversing direction.

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Right hand joystick

RH LH

The RH joystick commands load lifting and lowering with the main winch and lifting and lowering the telescopic boom. The RH joystick has a safety device for preventing accidental operations; however the operator must remain seated in the control position. Operations to be carried out: 1. push forward to lower the load with main winch 2. move left to raise the telescopic boom 3. pull back to lift the load with main winch 4. move right to lower the telescopic boom When the joystick is in the middle position (e.g. load and boom lowering) the two functions are activated at the same time.

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

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Control instruments Parking brake

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

Auxiliary winch control (optional) Press the switch to enable the auxiliary winch functions and disable telescopic boom extension and retraction. Press the switch again and the telescopic boom extension and retraction functions are re-enabled. Use the left hand joystickl to operate these functions.

Spirit level Located on the left side of the instrumental board inside the operator's cab. This indicator (ref.10) allows correct stabilization of the machine. 10

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Operation and maintenance manual

Cummins engine control panel 1

2

3

4

5

1. Idle speed adjustment button Press top of button to decrease engine speed (-), press bottom of button to increase engine speed (+). 2. Diagnostic button Hold button down to check for presence of active error codes relative to the engine electronic fuel system and engine protection system. 3. STOP warning light When this red warning light comes on, the operator must stop the engine as soon as possible in conditions of safety. The engine must not be started until the fault has been repaired. 4. PREHEATING indicator light The PREHEATING warning light (WTS) is yellow and it remains lit during the preheating period that starts when the ignition key is set to the ON position before stating the engine in cold periods of the year. To limit the use of the starter motor during starting in cold periods of the year do not attempt to start the engine until the WTS indicator light is extinguished. 5. ALARM warning light This yellow indicator light informs the operator that the fault must be repaired at the earliest possible opportunity.

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Control instruments

Operation and maintenance manual

Radio and 24V socket outlet To use the radio and the 24V socket outlet, insert the key into the control panel and turn it onto I to power up the circuit. The documentation on using the radio 1 is in the compartment 2.

2

1

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

3

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Operation and maintenance manual

Cab heating control (optional) The control unit (ref.12) is located on the left side instrument panel in the operator’s cab. Refer to the model fitted on the crane truck.

B

A Start the heater - Heating operating mode: Button A is used to start the heater in the Heating operating mode (continuous operation). The desired temperature can be set with the knob F. If the heater is in the Heating operating mode, the red control LED B will light up.

C

Start the heater - Ventilation operating mode: Button E is used to start the heater in the Ventilation operating mode (continuous operation). The knob F has no function in Ventilation mode. If the heater is in the Ventilation operating mode, the blue control LED D lights up.

D

E

F

Switching off the heater: Button C is used to switch off the heater. The heating or ventilation mode is deactivated and the respective LED goes out. The Heating operating mode is deactivated with a delay. Refer to the documentation for the heater in the cab Notes: Remember to open the fuel cock on the tank located behind the operator’s cab before using the heating system.

The control is used to switch the heater on/off, for adjusting the required ambient temperature and for clearing a fault The green LED is also the ignition light (the LED remains on) and signals overheating (LED flashing) Refer to the documentation for the heater in the cab Notes: Remember to open the fuel cock on the tank located behind the operator’s cab before using the heating system.

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Control instruments

Operation and maintenance manual

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

Battery disconnecting switch

This switch is located on the outside of the battery box on the left side of the truck. It disconnects the negative pole of the batteries from the machine frame. Notes: It is always advisable to disconnect the batteries at the end of the work shift, during long work stops and before carrying out maintenance. page 42/44

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Control instruments

Operation and maintenance manual

Operator's seat

Adjustable head-rest

Backrest

Armrest

Armrest

Armrest angle adjustment

Complete seat unit sliding

Seat depth adjustment Backrest adjustment

Height adjustment

Upper part adjustment sliding guide

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Operator weight adjustment lever

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Control instruments

Operation and maintenance manual

Seat adjustments The arm-rest can be raised on the operator's door side to facilitate entry. It must then be lowered and locked in its operating position. The height and angle of the armrests can be adjusted. Loosen the two mounting bolts to carry out adjustment. The backrest adjusts in small steps to allow the operator to quickly find the best position. The backrest can be folded down on top of the seat. The upper runners allow the seat to be adjusted in the most comfortable position for operating the joystick control devices. The guides allow the operator to change the seat position and the individual sections of the back with respect to the entire seat unit. Seat angle can be adjusted horizontally by 3° to 11° with respect to the horizontal plane. The seat depth adjustment facility has 4 settings to allow the operator to assume the correct position.

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Operation and Maintenance

Rated Capacity Limiter

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Operation and Maintenance

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Rated Capacity Limiter

Operation and Maintenance

1 Introduction The information on this document could be subject to change without notice. The constructor is not responsible for possible content mistakes or misprints that could be present in this manual. Any reproduction, translation or copy of parts of this manual is forbidden without prior written authorization by The constructor.

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Operation and Maintenance

Rated Capacity Limiter

2 Warnings The load limiting device is an electronic control device, designed to help the operator for the safe use of the machine, warning him by means of visual and audible alarms when approaching a dangerous condition. However, this device is not aimed at replacing the operator’s good experience when properly using the crane. The operator is responsible for operating the machine under safety conditions as well as fulfilling all the safety rules prescribed. The operator must be able to recognize if the data transmitted by the system are correct and coherent with the real conditions. He also must be able to utilize the data in order to operate under safety conditions. The limiter is an electronic device with several components and could be subject to failures or defects. The operator must recognize these events and must act consequently (to proceed to repair, if possible, or to call the constructor for assistance). Before starting to operate with the machine, the user must fully read and understand this manual and follow the instructions at any time. 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 sets itself in a safe state by stopping the operations. Despite this before starting to operate the machine, the operator 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 operation stopping functions. The operator is responsible for the correct setting of the machine load table and therefore for the right LMI setting. When switching on the machine the last selected Table is kept valid to allow the operator to check. As for 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 it can cause a dangerous situation to the machine. Generally it is compulsory to follow the Manufacturer’s instructions and procedures at any time

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Operation and Maintenance

3 Important Notes The limiter is supplied with a key for automatic shut-down override. Under normal working condition this key must be positioned properly not to operate the override functions. It is forbidden to use this key to lift loads exceeding the load table limits provided by the crane’s manufacturer. The key must be used only in extreme cases: malfunctioning or situations justifying its use. The use of the key is allowed only by authorized personnel who is responsible for its use. The limiter has a powerful FAIL-SAFE self-diagnostics program suitable to verify the good operation of its circuits and measuring transducers. In case a failure is detected, the limiter sets itself in emergency status by blocking the manoeuvres. Nevertheless, before starting the operation of the machine, the operator must make sure that the limiter works correctly. To do this, he must verify the accuracy of the displayed values by performing some tests. He must also verify that there are not messages or alarm indications, and verify the correct operation of the shut down function. Generally, the limiter does not automatically change the operating conditions of the machine (tables). The operator is responsible for the proper setting of the operating conditions of the machine and the correct use of the device. Regarding this follow the indications given in the manual concerning the operating modes. An incorrect setting of the tables can cause an incorrect operation of the limiter and this will create a dangerous situation during the crane operation.

For this reason it is absolutely necessary to set the correct operating mode. These operating conditions generally vary when: • outriggers are extended or retracted • switching the operation from outrigger mode to on tires mode • telescopic mechanical extensions are extended or not • further equipment (jib, ext, etc.) is installed or not • the rope number is properly selected. In general it is mandatory to follow the instructions given by the crane’s manufacturer.

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Operation and Maintenance

Rated Capacity Limiter

4 System Description 4.1

System Layout

System Components: 1.

HEAD MAIN UNIT

2.

VIEW DISPLAY UNIT (Black/White)

3.

ACMCP CABLE REEL 32 m

4.

ACT CABLE REEL 11 m

5.

N°2 PRESSURE TRANSDUCERS

6.

CANBus cable 10 m

7.

CANBus LEVELLING SENSOR

8.

A2B ANTI TWOBLOCK + WEIGHT 4 Kg

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Rated Capacity Limiter 4.2

Operation and Maintenance

Component Location

ACT cable reel 12m: Extension and angle sensor

ACMCP cable reel 32m: Extension sensor

A2B

CONTROL PANEL into the cabin

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2 PRESSURE TRANSDUCERS

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Operation and Maintenance

4.3

Rated Capacity Limiter

System Functionality

The Load Limiting Device is designed to help the operator with the safe functions of the crane. The limiter automatically compares the lifted load with the maximum one supplied by load table providing the necessary information to the user in order to work under safety conditions.

The main information is: • actual lifted load • maximum load allowed • tilting percentage • operating radius • boom angle • boom extension (length) • operating mode • warning lights (green, yellow, red) and audible alarm • diagnostic The system determines the lifted load by calculating it from the relevant sensing devices signals (pressure or load cell), and the operating radius is also calculated by means of the measures of boom angle and extension. The lifted load is continuously compared with the maximum load allowed that can be obtained from the load tables. Consequently three possible situations can occur: SAFETY: green lamp is on, no presence of audible alarm : lifted load is lower than 90% of the maximum load. PRE-ALARM : yellow lamp is on and audible alarm sounds intermittently; this is the warning situation. The signal occurs when the lifted load is higher than 90% and less than 100% of maximum load. ALARM : red lamp is on and audible alarm sounds continuously: lifted load exceeds the allowed load and therefore the control functions shut-down is activated. In the alarm situation, only control function operations to allow the machine under safe working condition are enabled.

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Operation and Maintenance

5 Panel Description The operator panel is shown in the following picture:

Picture 5.1 – Control Panel Unit

Icon

Description Display Two green lights showing the safe working condition.

The yellow light showing the pre-alarm condition; load between 90% and 100%

The red light showing the shut off condition has occurred ; load over 100%. “Function” push-button: Outriggers/Wheels setting in operating mode configuration “Function” push-button: Counterweight setting in operating mode configuration.

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Operation and Maintenance

Icon

Rated Capacity Limiter

Description “Function” push-button: Parts of line setting in operating mode configuration. “Function” push-button: Main Boom or Attachment setting in operating mode configuration. “Function” push-button: Attachment or Jib angle setting in operating mode configuration.

“Enter” push-button: it confirms an operation. “Up” and “Down” push-button: Increase and decrease brightness / Scroll up and down inside the menu. “Left” and “Right” push-button: Used in the setting

“Rope” push-button: Enable/Disable the anti twoblock

“Buzzer” push-button: disable buzzer.

“Selection” push-button: disable the lowering boom

“Changing pages” push-button: change the View pages “Escape” push-button: back to the main page. It also has a function of deleting the alarms once acknowledged. “Setup” push-button: enter the “Setup” page It also has the function to enter the calibration menu. The function is available only if provided with the password.

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Operation and Maintenance

6 View Pages On the Load Limiting Device (LMI) there are different pages to set the operating mode and/or to give the operator the information about the actual condition of the crane.

6.1

Pages Description

• “Start-up” page: this page is activated only for five seconds at the machine start-up. • “Setup” page: it is used to change the Operating Mode. • “LMI” page: it visualizes the Operating Mode selected and monitors the actual crane operating conditions. • “ISAAC - Boom” page: it is used to limiting angle, height and radius of the main boom. • “ISAAC - Turret” page: it is used to limiting the turret rotation (Virtual Wall).

6.2

How to change View Pages: pressing, the view pages can be changed:

By

− LMI page − ISAAC pages pressing in LMI page, the Setup page will be shown.

By

6.3

View menu

Menu displayed in LMI page: • “Diagnostic” menu: it used for the system diagnostic; By pressing

key, the Diagnostic menu will be shown.

• “Settings” menu: it is used for the language setting; By pressing

key, the Setting menu will be shown.

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Operation and Maintenance

6.4

Rated Capacity Limiter

Start-up Page

When the system gets started, some information is displayed for five seconds.

Picture 6.1 – Start-up Page

Software Release

Description Software version installed in the View.

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Rated Capacity Limiter 6.5

Operation and Maintenance

Setup Page

This page is visualized after the “Start-up” page or when the “Setup” push-button

is

pressed. In the “Set-up” page it is possible to choose the machine operating mode.

Picture 6.2 – Setup Page

To set the Operating modes refer to the paragraph “Operating mode selection”.

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6.6

LMI Page

The LMI page is the main page and the real crane operating conditions are shown on the display. On this page all the basic information for the operator is displayed.

Machine & LMI Area

Operating Mode Area

Lights Area

Alarm/Message Area

Picture 6.3 – LMI Page

Machine & LMI Area Icon

Description Load percentage bar (SWL): indicator of the lifted load in percentage to the maximum load allowed under that working condition (max 120%) 1st bar: REGULAR – Lifted load lower than 90% of maximum load allowed 2nd bar: PREALARM – Lifted load higher than 90% of maximum load allowed. 3rd bar: BLOCK – Lifted load higher than 100% of maximum load allowed.

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Rated Capacity Limiter Icon

Operation and Maintenance

Description Boom extension Bar: indication of the extension of the main

1st

2nd 3rd element

4th

boom elements in percentage (%).

Indication of the wind speed

Indication of the Boom’s extension MOD 1 or MOD 2 status. Indication of the actual load.

XX.X

Indication of the main boom’s radius in meters.

XX.X

Indication of the main boom’s length.

XX.X

Indication of the maximum load in that machine condition.

XX.X

Indication of the main boom’s angle in degrees.

XX.X

Indication of the height from the ground referred to the “head XX.X

of the boom”.

Lights Area Icon

Description Indication of the LMI Bypass key (if activated = black background) Indication of the winch limit switch status (if activated = black background) Indication of the Shut Off from Isaac (if activated = black background) Indication of the machine normal working condition (if activated = black background) Indication of the machine pre-alarm working condition (90%) (if activated = black background)

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Icon

Description Indication of the machine Shut off working condition (100%) (if activated = black background)

Operating Mode Configuration Icon

Description Indication of outriggers/tires mode

Indication of the translation mode

Indication of Parts of Line (number of ropes)

Configuration of the boom or the attachment (JIB)

Selection about the Jib inclination (if they are present)

ALARMS / MESSAGE AREA Icon

Description Screen area of Alarm Codes and Messages view: Row 1: Indication of the Alarm code that its present at the moment Row 2: Indication of the actual Operating Mode code or view of the Diagnostic/Setting Menus and operating messages.

Alarm The system recognizes the fault and malfunction conditions sending from the Main Unit. In case a trouble has been detected, the LMI sets itself in a safe state by stopping the operations and displaying the current alarm. If more than one fault is active, the errors are cyclically displayed in automatic sequence. After returning from the alarm condition the system always returns to the operative mode. The Alarm list is described in the “Alarms” chapter. It’s possible delete a recorded alarm once it has been restored by pressing page 16/34

key.

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Rated Capacity Limiter 6.7

Operation and Maintenance

Operating Mode Selection

When the system get started, the last operating mode conditions is screened on the display, the latest setting before the machine was turned off. During this procedure, the system performs an auto test and it put itself in shut off condition. Before starting the lifting operation, the user must check that the operating mode set corresponds to the real machine’s configuration (boom, outriggers, counterweight, jib’s length and angle, etc) and the number of lines. HOW TO SELECT THE OPERATING MODE: In order to change the operating mode, please proceed as follows: • At the start-up when the “Setup” page is displayed; OR • In “LMI” page by pressing the

key;

By

key you must select the geometry of outrigger/wheel;

By

key you must select the translation mode;

By

key you must select the parts of line;

By

key you must select the configuration of boom or attachment;

By

key you must select the configuration of the attachment or the angle of the jib

It is necessary to confirm the operating mode with the

button.

When you confirm it, the row2 of the Alarm/Message Area shows the number of the operating mode.

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Operation and Maintenance

Rated Capacity Limiter

6.7.1 Outrigger Or Wheel Configuration To change the outrigger configuration use the button Icon

and confirm with

.

Description Outrigger completely extended (100%)

Outrigger half extended (50%)

Outrigger completely retracted (Closed)

Static On Wheels

6.7.2 Translation Configuration

To change the Translation Mode configuration use the button Icon

and confirm with

.

Description Static Translation mode

Translation mode on front side

Translation mode with load Translation mode without load Static Translation mode at 1°

Static Translation mode at 4°

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Operation and Maintenance

6.7.3 Parts of Line Press the button Rope Number

to change (increase/decrease) the number of rope and confirm with

.

Description Rope number selected on the crane: 0 ÷ N (e.g. :0).

0

The maximum value (N) depends on the operating mode.

6.7.4 Main Boom or Attachment (Jib) Configuration Press the button Icon

to change the configuration of boom or attachment and confirm with

.

Description Main Boom Selected JIB 8 m selected

6.7.5 Jib Configuration When the Jib extension is present on the crane, press the button configuration of attachment or angle Jib is install at the moment and confirm with Icon

to change the .

Description No selection Jib Selected with angle at 0°.

0°

Selection is possible only if “Jib” has been previously selected Jib Selected with angle at 20°.

20°

Selection is possible only if “Jib” has been previously selected Jib Selected with angle at 40°.

40°

Selection is possible only if “Jib” has been previously selected Rooster sheave. Note: All maximum load will be limited at the single rope

0,5 m

Selection is possible only if “Main boom” has been previously selected

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Rated Capacity Limiter

Operation and Maintenance

6.8

ISAAC Pages

ISAAC : Interactive Space Automatic Advanced Control. ISAAC is the system allowing to select and limit a working area which the user will set by means of the panel by using text and icons. This functions can only be activated if the encoder is installed on the turret to detect the position

6.8.1 ISAAC - Boom To enter in this page, press the key

button, until this one appears.

Controls Lights Area (refert to LMI Page)

Picture 6.4 – ISAAC-Boom Page

Controls Key

Icon

Description Maximum Angle limit setting

Maximum Height limit setting

Maximum Radius limit setting

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Rated Capacity Limiter Icon

Operation and Maintenance

Description XX.X ,

XX.X ,

XX.X

Refer to LMI page

Boom Angle BLOCK VALUE: Indication of the max. value set BLOCK VALUE

REAL VALUE

REAL VALUE: Indication of the actual value

Boom Height BLOCK VALUE: Indication of the max. value set BLOCK VALUE

REAL VALUE

REAL VALUE: Indication of the actual value

Boom Radius BLOCK VALUE: Indication of the max. value set BLOCK VALUE

REAL VALUE

REAL VALUE: Indication of the actual value

Boom Li mits Setting •

Angle Setting

In order to set the maximum angle, boom up to the position and then press the delete the set value, press the •

key.

Height Setting

In order to set the maximum height, boom to the position and then press the the set value, press and hold the •

key. To

key. To delete

key.

Radius Setting

In order to set the maximum radius, set the boom to the position and press the delete the set value, press and hold the

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key. To

key.

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Rated Capacity Limiter

Operation and Maintenance

6.8.2 ISAAC - Turret To enter in this page, press the key

, until this one appears.

Machine Area (refert to LMI Page)

Controls

Picture 6.5 – ISAAC-Turret Page

Controls Key

Icon

Description Turret area setting: Left limit

Turret area setting: Right limit

Icon

Description Right/Left Limits of the Turret Area The right/left rotation control is disabled when no value is displayed in the appropriate field (i.e. Right Limit) Actual Turret Position The

turret

position

is

constantly

monitored

and

displayed

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Operation and Maintenance

The “Virtual Wall” allows to limit the Turret Area defined from two set points: 1st and 2nd SET (left and right limit of the Turret Area). The system cuts off the boom and turret movements inside the wall area (Restricted area).

Picture 6.6 – Virtual Wall

Turret Rotation Angle Setting Left Limit (1st SET of the Virtual Wall) In order to limit the left rotation (counter clock wise), drive the turret in the correct position and press

. The value of the position is stored and displayed in the appropriate field (Left Limit).

When the set value is reached, it only possible to proceed with the rotation to the opposite side. The exclusion of the movement is shown on the “Status LMI” page through the icon In order to disable the control press again the button

.

and the limit previously set is deleted.

Right Limit (2nd SET of the Virtual Wall) In order to limit the right rotation (clock wise), drive the turret in the correct position and press

. The value of the position is stored and displayed in the appropriate field (Right Limit).

When the set value is reached, it only possible to proceed with the rotation to the opposite side. The exclusion of the movement is shown on the “Status LMI” page through the icon In order to disable the control press again the button

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.

and the limit previously set is deleted.

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Rated Capacity Limiter

Operation and Maintenance

7 Diagnostic The diagnostic function does not require password. User can control in real time several sensor’s reading Vs the converted value: pressure sensor, angle sensor and length sensor.

Alarm / Message Area: Diagnostic Menu

Picture 7.1 – Diagnostic Menu

Enter / Exit the Diagnostic Menu In LMI Page, press

to enter the diagnostic menu. The menu is displayed in the

Alarm/Message Area of the screen. The system automatically exits from the diagnostic menu after some seconds. Otherwise press

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to exit the diagnostic menu. The screen goes back to the operating mode.

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Rated Capacity Limiter Press

Operation and Maintenance

to scroll up the diagnostic menu: the data are immediately displayed.

Diagnostic menu

Description Main Boom Angle (from ACT)

A1adc

A1act

700

780

A1adc: Value (bit) directly from the angle sensor A1act: converted value (0.1°) Main Boom Length1 (from ACT)

S1adc

S1act

S1adc: Value (bit) directly from the ACQ potentiometer

400

1870

S1act: converted value (cm) Main Boom Length2 (from ACMCP)

S2adc

S2act

S2adc: Value (bit) directly from the ACMCP potentiometer

400

1900

S2act: converted value (cm) Cylinder Hydraulic Pressures on piston side

PLadc

PLact

300

550

PLadc: Value (bit) read directly from the pressure sensor on piston side; PLact: converted pressure value (0.1 bar); Cylinder Hydraulic Pressures on rod side

PHadc

PHact

100

200

PHadc : Value (bit) read directly from the pressure sensor on rod side; PHact : converted pressure value ( 0.1 bar ); Digital Input

I 01234567890123

Row1: Input ID (I0 ÷ I13)

**_**_

Row2: Input Status: *=1/activated, _=0/off

*_*_*_

Digital Output C 01234567890123

Row1: Input ID (O0 ÷ O13)

**_**_

Row2: Input Status: *=1/activated, _=0/off

*_*_*_

The displayed parameters are as follows: HEAD 100

ENCODER 81

HEAD: counter control about Head unit: if this counter moves means that the unit is activate. ENCODER: counter control about Encoder: if this counter moves means that the encoder is activate.

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8 Settings 8.1

Display contrast Setting

In the Status LMI page and when the operating mode is confirmed, it is possible to increase or decrease the brightness: •

Press the button

8.2

or

to increase or decrease the contrast of the display.

Display language Setting

After the confirm the operative mode by

button is possible to entry inside the “Language”

menu where is possible to select the View language. Diagnostic menu

Description

DISPLAY Language X

* Language

X

Press the button

Press the button

or

or

to move the cursor on the digit to modify (X).

to change (increase/decrease) the language and

to

confirm. Press the button

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to exit from this menu and return on the main page.

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Operation and Maintenance

9 Rated Capacity Limiter override RC30, RT35, RC35, RC40, RC45, A600 The machine is equipped with a bridging device that must only be used in case of failure of components of RCL or in emergency situations by authorised persons in charge of use. When the RCL is disabled, a device (Data logger) records the following working configuration datas: −

stability configuration selected (wheels or outriggers);

−

boom angle;

−

boom lenght;

−

load lifted;

−

maximum load allowed at current configuration;

−

pressures in hoist cylinder

The function of the Data logger is automatically checked each time the crane is put into operation.

To bridge the limiter, on the turret: −

turn clockwise and release the key 1 on the electric box. This operation lights up the LED on push-button 2 inside the cab;

1 afterwards, inside the cab: -

press and hold down push-button 2 to disable the RCL.

2 Release the push-button 2 to turn the RCL back on.

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Operation and Maintenance

Rated Capacity Limiter

The RCL back on: −

by releasing push-button 2,

−

15 minutes after operating the key 1,

−

by turning engine off and back on again

RC60 The machine is equipped with a bridging device that must only be used in case of failure of components of RCL or in emergency situations by authorised persons in charge of use.

When the RCL is disabled, a device (Data logger) records the following working configuration datas: −

stability configuration selected (wheels or outriggers);

−

boom angle;

−

boom lenght;

−

load lifted;

−

maximum load allowed at current configuration;

−

pressures in hoist cylinder

The function of the Data logger is automatically checked each time the crane is put into operation.

To bridge the limiter, on the turret: −

turn clockwise and release the key 3 on the turret behind the driver’s cab. This operation lights up the LED on push-button 4 inside the cab;

3

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Operation and Maintenance

afterwards, inside the cab: -

press and hold down push-button 4 to disable the RCL.

4

Release the push-button 4 to turn the RCL back on.

The RCL back on: -

by releasing push-button 4,

-

15 minutes after operating the key 3,

-

by turning engine off and back on again.

Bridging the RCL: •

activates a visual-audible warning device 5 located by the connection of the lifting cylinder with the boom.

5

•

the speed of the crane’s movements (boom hoisting and extending, slewing and winches movements) is reduced to 25% of the nominal speed by means of the flow reduction solenoid valve assembly 6 located on the frame of the crane truck in the area of the slewing ring.

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Operation and Maintenance

Rated Capacity Limiter

6

WARNING It is prohibited to use the RCL bridging device for lifting loads beyond the capacities admitted by the manufacturer. The bridging device must only be used in case of failure of components (sensors, control units, etc...) of the RCL or in emergency situations. Using the device is only permissible for specifically authorised persons in charge of use. The device starter key must not be left on the machine, but must be kept by specifically authorised persons in charge of use.

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Rated Capacity Limiter

Operation and Maintenance

10 Alarms An overall self test diagnostic is provided. When each of the following alarms occurs cut-off relay is de-energized and proper alarm message appears on alphanumeric display.

10.1 How to disable the buzzer When the audible alarm is on, by “Buzzer” push-button you can disable the audible alarm until the new alarm is detected. After few seconds that the alarm is switched off the audible alarm will be automatically enabled.

10.2 Alarm List Alarm Code: “Alarm: X” Description

Cause

What to do

6

• Length transducer (potentiometer)

• Verify the transducer

Transducer Length 1 Low

ACT is faulty • Possible lack of continuity in wires carrying the unwinding

7 Transducer Length 1 High

Boom Length Low

• Verify that the cable is not open

• Main Unit is faulty

• Replace the Main Unit

• Length transducer (potentiometer)

• Verify the transducer

ACT is faulty • Short circuit in wires carrying the signals

8/9

functionality

functionality • Verify that the cable is not in short circuit

• Main Unit is faulty

• Replace the Main Unit

• Length value less then minimum boom

• Verify the transducer

length value possible • Verify the value of the boom length

functionality • Verify the calibration

• Verify the wiring connection

Rated Capacity Limiter – ed. 04-2012

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Rated Capacity Limiter

Operation and Maintenance

Alarm Code: “Alarm: X” Description

Cause

What to do

11 / 54

• Length transducer II (potentiometer)

• Verify the transducer

Transducer Length 2 Low

ACT is faulty • Possible lack of continuity in wires carrying the unwinding

12 Transducer Pressure Piston Side Low

functionality • Verify that the cable is not open

• Main Unit is faulty

• Replace the Main Unit

• Low chamber pressure transducer

• Replace pressure

broken • Possible lack of continuity in connection wires

transducer • Check connection wires. or insertion of connector on transducer

13 Transducer Pressure Rod Side Low

• High chamber pressure transducer broken • Possible lack of continuity in connection wires

• Replace pressure transducer • Check connection wires. or insertion of connector on transducer

15 Angle Low

• Main Unit is faulty

• Replace the Main Unit

• Angle transducer (inclinometer) ACT is

• Verify the transducer

faulty • Possible lack of continuity in wires carrying the angle signal.

21

functionality • Verify that the cable is not open.

• Main Unit is faulty

• Replace the Main Unit

• Simultaneously M1 & M2 Input ON

• Check the status of M1 and

Fault M1 / M2

M2 input and disable the input not used. • Main Unit is faulty

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• Replace the Main Unit

Rated Capacity Limiter – ed. 04-2012

Rated Capacity Limiter

Operation and Maintenance

Alarm Code: “Alarm: X” Description

Cause

What to do

22

• Low chamber pressure transducer

• Replace pressure

Transducer Pressure Piston Side High

broken • Short circuit in wires carrying the signals

transducer • Verify wires connection and insertion of connector on transducer

• Main Unit is faulty

• Replace the Main Unit Contact Technical Assistance

23 Transducer Pressure Rod Side High

• High chamber pressure transducer broken • Short circuit in wires carrying the signals

• Replace pressure transducer • Verify wires connection and insertion of connector on transducer

• Main Unit is faulty

• Replace the Main Unit Contact Technical Assistance

25 Angle High

• Angle transducer (inclinometer) ACT is faulty • Short circuit in wires carrying the signals

31 / 55 Transducer Length 2 High

functionality • Verify that the cable is not in short circuit

• Main Unit is faulty

• Replace the Main Unit

• Length transducer II (potentiometer)

• Verify the transducer

ACT is faulty • Short circuit in wires carrying the signals

56

• Verify the transducer

functionality • Verify that the cable is not in short circuit

• Main Unit is faulty

• Replace the Main Unit

• Memory data not reliable

• Switch the System off / on

E2PROM KO

• Contact Technical Assistance

Rated Capacity Limiter – ed. 04-2012

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Rated Capacity Limiter

Operation and Maintenance

Alarm Code: “Alarm: X” Description

Cause

What to do

190

• CANBus cable broken

• Check of the CANBus cable

CANBus HEAD KO

• Internal problem

• Replace HEAD Unit

191

• Cable broken

• Check of the cable

ASA CBO TRUCK

• ASA broken

• Replace ASA

192

• CANBus cable broken

• Check of the CANBus cable

Turret rotation

• Internal problem

• Replace Encoder

CANBus Encoder KO

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Rated Capacity Limiter – ed. 04-2012

Accessories

Operation and maintenance manual

V Accessories

Chapter V – ed. 10-2009

page 1/18

Operation and maintenance manual

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Accessories

Chapter V – ed. 10-2009

Accessories

Operation and maintenance manual

Contents RC30 – RT35 Lattice extensions................................................................. 4 Deploying the 8 m lattice extension............................................ 4 Stowing the lattice extension on the boom side ......................... 6 Angle of the 8 m ......................................................................... 7

RT35 Boxed extensions ................................................................. 8 Deploying the 8 m boxed extension ........................................... 8 Angle of the 8 m boxed extension .............................................. 13 Stowing the boxed extension on the boom side......................... 15

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Accessories

Operation and maintenance manual

RC30 – RT35 Lattice extensions Deploying the 8 m lattice extension Raise the machine on fully extended outriggers on firm, level and horizontal ground with the wheels slightly off the ground. The boom must be completely retracted and absolutely horizontal. To facilitate the operation, position the boom at its negative angle; this is done by adjusting the outrigger lifting cylinder in such a way that the boom side is lower than the counterweight side of the superstructure. Remove retaining pin “A”.

Pull the head of the lattice extension until aligning the U-bolt connections with the eye connections of the boom head. Insert two pins into aligned connections “D”. Remove retaining pins “B”. Place the boom in the horizontal position.

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Accessories

Operation and maintenance manual

Attach a rope to the end of the lattice extension and pull it to cause it to rotate through 180°. Secure the two pins that secure the other side of the lattice extension to connections "C” of the boom head.

CAUTION: To avoid risks carefully supervise the operation of rotation of the lattice extension with the rope. Remove the rope guide and run the winch rope along the lattice extension, routing it through the hook block and the double lock safety device. Refit the rope guide. Connect the electric cable of the double-block safety device to the boom head.

WARNING: Check the weight of the lattice extension and the weight reductions in the capacity table.

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Accessories

Operation and maintenance manual

Stowing the lattice extension on the boom side Raise the machine on fully extended outriggers on firm, level and horizontal ground with the wheels slightly off the ground. The boom must be completely retracted and absolutely horizontal. To facilitate the operation, position the boom at its negative angle; this is done by adjusting the outrigger lifting cylinders in such a way that the boom side is lower than the counterweight side of the superstructure. Unwind the winch rope from the lattice extension. Disconnect the electric cable of the double-block safety device. Remove the two pins “C” to detach the remote side of the lattice extension.

Attach a rope to the end of the lattice extension and pull it to cause it to rotate through 180° on the boom side. Insert retaining pin “B” and remove two pins “D” on the boom head.

I Push the extension towards the boom head onto the rear support stops, freeing the U-bolt connections of the front end from the boom. Lock the lattice extension in position by means of pin “A”. Refit the four pins (“C” “D”) in the U-bolt connections of the lattice boom for stowing purposes.

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Accessories

Operation and maintenance manual

Angle of the 8 m lattice extension

With the extension in the transport position, the boom retracted and in its horizontal position, and the turret slewed towards the front, stabilise the machine on solid and level ground with the wheels lifted slightly off the ground.

a F

H X

G

Position rod “E” in the specific seat on the extension and secure it by means of pin “F”.

Extend the rear outriggers completely in a vertical direction and retract the front outriggers in such a way as to incline the boom so that support rod “E” comes into contact with the ground (if these manoeuvres prove insufficient to cause the rod to touch the ground, set the boom at a negative angle or extend the boom sections as necessary).

Remove pin “X” from location “G”, raise the boom by means of the outriggers until rod “E” is detached from the ground, and reattach pin “X” in location “H”.

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Accessories

Operation and maintenance manual

RT35 Boxed extension

Extension stowed for travel, secured to brackets alongside the telescopic boom.

2 1

Extension support brackets for travel: 1 – rear support 2 – front support

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Accessories

Operation and maintenance manual

Deployment of the extension in work position Raise the machine on fully extended outriggers on firm, level and horizontal ground. Retract the boom fully, turn the turret towards the front of the machine and move the boom to the horizontal position.

A B

Remove pin “B” on the front support

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Accessories

Operation and maintenance manual

Push the extension towards the boom head

to enable insertion of pins “C” and “D”.

E

D

F

C

Insert pins “C” and “D”.

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Accessories

Operation and maintenance manual

Remove pin “G” on the rear bracket and pin “A” on the front bracket.

G

Raise the boom slightly to free the extension from the supports. Manually turn the extension around pins “C” and “D” Insert retaining pins “E” and “F” and remove pin “C”. To facilitate pin insertion, use a stool, but NEVER A LADDER which would have to be placed against the boom or extension.

H

Position rope idler sheave “H” vertically.

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Operation and maintenance manual

Accessories

Before handling any material with the extension: • Disconnect the socket from the lifting limit stop electric connection box on the boom head. • Connect the extension lifting limit stop socket in the electric connection box on the boom head. • Remove the winch limit stop counterweight fixed to boom and insert it on the device on the extension. • Run the lifting rope over the sheaves and through the limit stop counterweight, then fix it to the hook.

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Accessories

Operation and maintenance manual

Extension offset The extension can be offset 0°, 15° or 30° with respect to the telescopic boom axis. The offset is obtained by means of the lockable strut and the support and positioning rod.

Positioning rod in rest position.

Support rod in work position

Position the support rod and lower the boom to bring the support rod in contact with the ground using the lifting, lowering and extension functions.

Use the hoisting or lift functions also to facilitate pin positioning.

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Accessories

Operation and maintenance manual

To offset the extension 0°, proceed as follows: The jack (fig.5a) must be locked in position 1.

1

Fig.5a

0°

To offset the extension 15°, proceed as follows: Release the jack Raise the boom to lock the jack (fig.5b) in position 2. Position the locking pin

2

15° Fig.5b To offset the extension 30°, proceed as follows: Release the jack Raise the boom to lock the jack (fig.5c) in position 3. Let the jack retract fully and position the locking pin.

3

Fig.5c

30°

Before every job with the extension, always bring the rod to the rest position.

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Accessories

Operation and maintenance manual

Fold the boom in the stowed position for travel Place the machine on fully extended outriggers on firm, level and horizontal ground. Retract the boom fully, turning the turret towards the front of the frame and bring it to the horizontal position. Remove the winch rope from the extension. Remove the winch lifting limit stop counterweight. Disconnect the extension lifting limit stop device socket from the electric connection box on the boom head and reconnect the lifting limit switch socket in the electric connection box on the boom head. Position the extension offset 0° with respect to the boom axis. Position the winch rope idler sheave “H” horizontally.

H

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Accessories

Operation and maintenance manual

Insert pin “C” and remove pins “E” and “F” that secure the extension to the boom head.

E

D

F

C

Swing the extension back on the bracket supports alongside the main boom. Raise the boom slightly to facilitate this operation

Insert pin “G” to secure the extension to the rear support.

G

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Chapter V – ed. 10-2009

Accessories

Operation and maintenance manual

Insert pin “A” to secure the extension to the front support.

A B

Remove pins “C” and “D”

E

D

F

C

Move the extension away from the telescopic boom for inserting pin “B” on the front support.

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Operation and maintenance manual

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Accessories

Chapter V – ed. 10-2009

Maintenance

Operation and maintenance manual

VI Maintenance

Chapter VI – ed. 07-2012

page 1/66

Operation and maintenance manual

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Maintenance

Chapter VI – ed. 07-2012

Maintenance

Operation and maintenance manual

Maintenance Regular maintenance will ensure long life of the machine. Therefore make sure to follow the instructions given in this section. The general maintenance chart gives the essential points to be observed and the following pages give the instructions relative to such operations. NOTE: All maintenance operations must be carried out by qualified personnel. Crane operators or maintenance personnel must be familiar with the instructions contained in this manual and above all those concerning safety, before carrying out any operations. At the time of starting, a specialist will show you how to use the machine. Carry out the first servicing with him. Subsequently, refer to the maintenance intervals given in the following charts. The intervals given are based on a work time of 8 h / day, 40 h / week, 2000 h / year. The intervals given in the following charts apply for the machine used in normal conditions. For intensive use or particular conditions (excessive heat, humidity, dust) maintenance must be carried out more frequently. To carry out the maintenance operations, the machine must be stabilized on fully extended outriggers on firm, flat and level ground. The machine running hours are shown on the hour-meter in the cab. The hour-meter measures the diesel engine run time. Every day, carry out a complete inspection before boarding the machine or starting the engine, checking for loose or missing screws, accumulated debris, oil and coolant leaks. Check the tyres and levels.

Any change to the fixed maintenance schedule must be preceded by a new analysis of the machine operation conditions. Carefully read the recommended maintenance handbook before changing the check frequencies. In case of prolonged storage, the 500 hours maintenance must be carried out every 6 months, in particular on the Engine, Axles, Suspension, Steering and Transmission. Take every precaution to safeguard the environment. In particular, collect and recycle all used fluids. Do not leave them in incorrectly labelled or open containers. There must be no puddles of fluids on the ground where you are working.

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Maintenance

Operation and maintenance manual

Maintenance handbook All the maintenance operations carried out according to the instructions given below must be recorded. A specimen chart showing how to keep the records in question is given at the end of the chapter. The collection of records constitutes the machine maintenance handbook. Persons performing maintenance operations must indicate this in the handbook, so that the machine can be checked during subsequent maintenance. The maintenance handbook is a document attached to the machine.

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Chapter VI – ed. 07-2012

Maintenance

Operation and maintenance manual

Welding operations CAUTION: Before carrying out any welding operations on the crane, consult the technical assistance service for approval. WARNING: The component to be welded must be connected to earth before performing welding operations on the crane. This precaution reduces the risk of electrical arcing through bearings, cylinders, etc, which would otherwise damage the components in question. Remove the paint from surfaces used as an earth connection point. WARNING: Take all the necessary precautions when welding in the vicinity of fuel tanks, oil tanks, batteries, pipes and pressurised devices. WARNING: When welding in the vicinity of glass, cylinder rods, or other smooth or polished surfaces, protect said surfaces from potential damage caused by welding slag. WARNING: Never weld with the crane engine running. Disconnect always the battery terminals. WARNING: Never weld on wet surfaces or the characteristics of the weld bead will be negatively affected. CAUTION: Always keep a fire extinguisher at hand in case of fire. Adequate ventilation and dry surfaces are necessary. All persons in the welding area must wear protective apparel and safety spectacles. Follow the instructions for welding and cutting painted materials. WARNING: The welding filler material must be checked with our after-sales service. CAUTION: Welding operations must be carried out by qualified operators.

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Maintenance

Operation and maintenance manual

Welding and cutting painted surfaces DANGER: Cutting or welding painted steel with certain systems exposes the operator to potentially harmful decomposition by-products (metallic fumes, gas or vapor and particles). The following procedures must be adopted when welding or cutting painted steel:

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•

Use a power tool wire brush or grinder to strip the paint from the steel in the area of the cut or weld to be executed. Also remove paint in the vicinity of the weld area to prevent it from heating and blistering. If this should occur, keep removing paint.

•

When removing paint it is compulsory to wear a protective mask to filter out toxic dust and safety spectacles.

•

The welder must wear a supplementary fresh air respirator and use all the other personal protective equipment required for welding operations.

•

The other employees must depart from the area or move to a safe distance from the welder. Employees must ensure they are not exposed to drifting welding fumes.

•

If available, use an air-cleaner suction unit to remove welding fumes while welding or cutting.

Chapter VI – ed. 07-2012

Maintenance

Operation and maintenance manual

Tyre pressures Periodically check the tyre pressures, making sure that the air pressures recommended for the different uses are respected Refer to the inflation pressures specified on the stickers in the operator's cab.

Turntable fixing Periodically check the lubrication and fixing of the turntable. In case of anomalies, request the assistance of a Terex® specialist who will advise you on the operations to be carried out. THE TURNTABLE FIXING BOLTS ARE AN INTEGRAL PART OF THE CRANE STRUCTURE.

Winches fixing Periodically check the lubrication and fixing of the winches. In case of anomalies, request the assistance of a Terex® specialist who will advise you on the operations to be carried out. THE WINCH FIXING BOLTS ARE AN INTEGRAL PART OF THE CRANE STRUCTURE.

Wheel fixing Periodically check the lubrication and fixing of the wheels. In case of anomalies, request the assistance of a Terex® specialist who will advise you on the operations to be carried out. THE WHEEL FIXING BOLTS ARE AN INTEGRAL PART OF THE CRANE STRUCTURE.

Starting the machine after replacing a hydraulic component After changing a hydraulic system component, e.g. pump, distributor, cylinder, tank, run the machine at idling speed for 20-30 minutes without using any of the hydraulic functions, then bleed the replaced part if necessary Then check or change the filter cartridges.

Transmission unit fixing device Periodically check the tightness of the transmission universal joints. In case of any doubts on the state of the screws, replace only with screws recommended by Terex®.

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Maintenance

Operation and maintenance manual

Boom telescoping chain tension check (Only mod. RC30-RC40-A600-RT75) Check that the boom sections are synchronised by extending and retracting the sections several times. If the sections are not synchronised, check boom telescoping chain tension: - With the machine stabilized, move the boom to the horizontal position. - Partially extend the second and third telescopic sections for RC30 and RC40, the third and fourth telescopic sections for A600. - Retract the telescopic sections and check that the second and third sections are aligned for RC30 and RC40, and the fourth and third sections are aligned for A600. - Loosen the grub screw on the stay lock nut. - Adjust nut “A” of the telescoping chain stay assuming tightening torque of 30-35 daN/m until the boom sections are completely synchronised. - Retract the boom and check that all sections are aligned.

Checking telescoping chains (RT100) Cleaning the chains Brushing the chains will remove impurities from the exterior surfaces, after they have been impregnated with petrol-based solvents compatible with oils and greases. Cleaning chains with high pressure steam or water jets, or with acid cleansing products or those which might risk causing a release of hydrogen is forbidden. Using strong grease-removing solvents (for example chlorinated solvents) is not advised. If nevertheless they are used, heavy lubrication must follow immediately afterwards, and this must be with oil. Painting chains is strictly forbidden

Lubrication Use Alvania EP2 grease. Apply manually, using a brush. Enough should be used to the joints between the pins and the plates. Apply along the full length of the chains, including the anchoring pins at the extremities, preferably while the chain is not in use and slack.

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Maintenance

Operation and maintenance manual

Inspection This includes visual inspection and an estimate of chain lengthening. Visually inspect the chains seeking: - missing, broken or split plates; - lengthening of the holes in one of the four outer plates (distortion or risk of a pin coming out); - pin partly dislodged from an outside plate; - pin broken, or distorted (major distortion, discernible to the naked eye, so that the pin is no longer straight); - general corrosion of the outer surfaces; - corrosion between the surfaces in contact with adjacent plates; - pin turning freely in outer plate; - sticking point during movement of the return roller. If even a single one of these faults appears in a single point on a chain, replace it. some corrosion points on the outer surfaces of the chains; chain not corroded but dry, not lubricated; visible wear, but moderate, on the surfaces of the plates resting on the roller. In such cases, correct chain lubrication must be restored.

-

Check integrity of tie-rope for boom telescoping. (Only mod. RT35) Close up the boom completely and check the integrity of the ropes 1 comprising the tie-rope of the telescopic boom. Adjust the tensioning with the adjuster screw 2.

2

1

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Maintenance

Operation and maintenance manual

Check boom telescoping ropes (RC45-RC60-RT100) Check lengthening. Retract the boom completely. Ensure it is horizontal. Telescope sections 4, 5 and 6 so that the boom is about 13 m long. Check the telescoped length of sections 4 and 5. They should be the same.

Se If the telescoped length of section 5 (A) is shorter than that of section 4 (A) by 15 to 20 mm, a Terex® specialist should be called in immediately. The cable ply lengthening arises from the loss of mechanical qualities from the cable. It risks breaking.

Structural components Check yearly for the presence of cracking and/or damage of the machine structural components (chassis, turret, telescopic boom sections, extensions). If damage is noted contact our technical assistance service.

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Maintenance

Operation and maintenance manual

Lifting rope The lifting rope is one of the crane's main parts, and requires particular attention for starting and maintenance. Carry out checks in compliance with ISO4309. The ropes must be visually checked for signs of deterioration or deformations every day. Pay special attention to the points where the ropes are attached to the equipment. In any case, the rope must be inspected when an accident may have caused damage to the strands, wires or attachment points or when a rope has been put back into service after being removed and then refitted. If the machine has not been used for some time, the rope must be inspected before resuming work. In particular, check: -The fixing points at the rope ends. -The parts of the rope sliding on the lifting or idle section sheaves. Rope removal criteria: -Broken wires (nature and number). -Broken wire nests. -Gradual increase in the number of broken wires. -Broken strands. -Broken rope core. -Reduced elasticity. .reduction in rope diameter .rope stretching .no space between individual wires and strands .appearance of fine brown powder between strands -General wear of rope due to abrasion. -External and internal corrosion. -Rope deformation (under load) .spiral deformation .basket deformation .stretched wires .slackening of certain wires or strands .knottiness .contractions .flattening .loops .lumps .bends -Deterioration induced by heat.

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Maintenance

Operation and maintenance manual

Visual examples of various problems that can occur to the rope

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

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

Broken wires on the same strand and slight wear

Broken crossed wires at the equalizer pulley

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Chapter VI – ed. 07-2012

Maintenance

Operation and maintenance manual

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

Example of wire rope with very high internal corrosion.

The boom heads are equipped with plastic sheaves, therefore the life of the ropes is increased. When the lifting ropes are only used with plastic pulleys, rope wear is inside the rope and cannot be seen on the outside. Our blocks are equipped with cast iron sheaves, therefore rope wear is visible externally because it is due to the rubbing of the rope on the cast iron sheaves.

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Maintenance

Operation and maintenance manual

Wire rope replacement The wire chosen for use on the machine must be clean, without corrosion or deterioration. Normally, a rope the same as the original is chosen for replacement. Before fitting a new rope, make sure its diameter matches the grooves of the drums and the sheaves. The type of rope fitted on the machine is specified in the certificates attached to the documentation. When pulling a rope from a winder, or unwinding a roller (on clean ground to avoid picking up impurities), every precaution must be taken to avoid twisting it; the same applies when fitting the rope on the crane. If these precautions are not taken the rope may buckle, form loops or knots.

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Chapter VI – ed. 07-2012

Maintenance

Operation and maintenance manual

The ropes must be wound evenly on the drums. Make sure that the turns of rope wound on the first layer of the drum are close and tight in order to prevent overlapping or crossing during winding of the next layers and therefore crushing of the cable. Take into account the rope winding and the rotation direction of the drum as given below:

Rope with RIGHT twisting (use the right hand)

A Rope winding from the top of the drum with end fixed to the left flange; use the right rope. After fitting the rope on the winch, check positioning of the rope in the thimble. Form a loop beforehand as close as possible to its final size to avoid having to pull a long length of rope to tighten it.

The rope must come out 70 – 80 mm IMPORTANT: The wedge and rope must retract freely until the rope presses against the sides of the thimble Once the rope is fitted, use a minimum number of tackles and attach a load (max. load x tackle). Completely unwind the rope using the telescoping and lifting functions. Once the rope is completely unwound, rewind it under load to tighten it and eliminate any strain.

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Maintenance

Operation and maintenance manual

Rope maintenance and removal To increase the life of the ropes, after 500 hours of operation, remove and extend the rope on the ground (clean ground). Rewind the rope on the winch. The crane ropes must be checked very carefully and replaced, without economizing, in case of the slightest mishap. Maintenance is generally performed by greasing. The rope must be greased at regular intervals according to needs and mainly in the bending areas. The lubricant must be compatible with the greases used by the manufacturer. It is advisable to use oils which, unlike greases, can penetrate inside the rope. Lubrication reduces breakages due corrosion, wear and the coefficient of rubbing when the rope slides on the sheaves and winds on the winch drum.

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Maintenance

Operation and maintenance manual

Availability Pulley n°

Weight (kg)

RC30

RT35

RC35

RC40

RC45

A600

RC60

5t

0

50

●

●

●

●

●

●

●

8t

0

160

10t

1

170

12.5t

1

255

15t

2

195

●

●

●

●

●

25t

3

260

●

●

●

●

●

35t

4

280

●

●

●

●

35t

4

280

●

●

●

●

40t

4

485

●

40t

4

485

45t

5

400

●

●

●

45t

5

400

●

●

●

60t

6

60t

Capacity

Type

RT75

RT100 ●

● ●

●

●

●

●

●

● ●

●

●

●

●

●

●

●

●

610

●

●

●

6

610

●

●

●

75t

6

750

80t

5

690

●

90t

6

800

●

Chapter VI – ed. 07-2012

●

●

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Maintenance

Operation and maintenance manual

Maintenance charts Tyre inflation pressures To check the tyre inflation pressure, refer to the following chart located in the operator's cab, taking into account the model of tyres fitted on the crane truck.

MICHELIN R24 XMH S TT 170 E

9 bar

9 bar

MICHELIN XMP

10 bar

10 bar

10.25 bar

8.5 bar

ADVANCE

10 bar

7.5 bar

MICHELIN

8 bar

8 bar

9.5 bar

8 bar

10.5 bar

7.5 bar

7 bar

5.75 bar

MICHELIN

5.5 bar

5.5 bar

TRIANGLE

6.9 bar

4.5 bar

PIRELLI

7 bar

5.75 bar

MICHELIN

5 bar

5 bar

TRIANGLE

6.9 bar

4.5 bar

23.5 - 25

ADVANCE

6.6 bar

4 bar

26.5 R25

MICHELIN

5.5 bar

5.5 bar

TRIANGLE

6.9 bar

4.5 bar

ADVANCE

5.7 bar

3.5 bar

ADVANCE

7 bar

6 bar

TRIANGLE

7 bar

6 bar

385/95

14.00 R24

16.00 R25 16.00 - 25

PIRELLI

PIRELLI ADVANCE PIRELLI

20.5 R25

23.5 R25

26.5 - 25

29.5 R25

The pressures given refer to cold tyres, therefore also the inflation and pressure checks must be carried out on cold tyres.

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Maintenance

Operation and maintenance manual

Screw torque wrench setting Torques to be applied in Nm, coefficient of rubbing between 0.125 and 0.150. Use a calibrated torque wrench (precision ±6%). Tightening torque of hex screws in Nm (according to UNI CNR10011) Size x Wheelbase

Class 8.8

Class 10.9

Class 12.9

M10 x 1.5

51

64

76

M12 x 1.75

89

110

132

M14 x 2

142

176

211

M16 x 2

221

275

330

M18 x 2.5

304

379

453

M20 x 2.5

431

537

643

M22 x 2.5

587

731

875

M24 x 3

746

929

1112

M27 x 3

1091

1358

1626

M30 x 3.5

1534

1910

2287

M33 x 3.5

2015

2510

3005

M36 x 4

2588

3224

3859

M39 x 4

3350

4172

4994

Degree of identification Screw

Thread

Chapter VI – ed. 07-2012

5

8

Tightening torque

Tightening torque

3/8”

43 ÷ 47 Nm

61 ÷ 66 Nm

7/16”

68 ÷ 74 Nm

97 ÷ 106 Nm

1/2"

104 ÷ 114 Nm

147 ÷ 161 Nm

9/16”

151 ÷ 165 Nm

212 ÷ 232 Nm

5/8”

208 ÷ 228 Nm

294 ÷ 322 Nm

3/4"

368 ÷ 405 Nm

520 ÷ 572 Nm

7/8”

545 ÷ 598 Nm

838 ÷ 922 Nm

1”

818 ÷ 897 Nm

1257 ÷ 1382 Nm

1 1/8”

1098 ÷ 1206 Nm

1781 ÷ 1957 Nm

1 1/4"

1549 ÷ 1703 Nm

2511 ÷ 2762 Nm

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Maintenance

Operation and maintenance manual

Slewing ring screws torque wrench setting Torques to be applied in Nm, coefficient of rubbing between 0.125 and 0.150. Use a calibrated torque wrench (precision ±6%). N.B.: The values given in the tables refer to lubricated screws. Hex socket fixing screws Model: Crane truck

M20 Class 10.9

M22 Class 10.9

M24 Class 10.9

M27 Class 10.9

Model RC30 – RT35

470

/ / / /

/ / / /

/ / / /

Model RC35

/ / / /

650

/ / / /

/ / / /

Model RC40

/ / / /

650

/ / / /

/ / / /

Model RC45

/ / / /

650

/ / / /

/ / / /

Model A600

/ / / /

/ / / /

730

/ / / /

Model RT75

/ / / /

/ / / /

730

/ / / /

Model RC60

/ / / /

/ / / /

730

/ / / /

Model RT100

/ / / /

/ / / /

/ / / /

1100

Max. pressure valve calibration To calibrate the max. pressure valves of the various elements, refer to the crane truck model being used. The values are given in bars.

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Chapter VI – ed. 07-2012

Maintenance

Operation and maintenance manual

Max. pressure valve calibration RT35 RC35

RC30 RC40

RC45-1

A600-1

RC60

Winch

210

210

210

210

210



215



240

Cylinder lifting Boom

210

210

240

230

230



240



280

Boom lowering cylinder with servo-controlled valve

50

50

50

50

50



150



80

18/20

18/20

18/20

18/20

18/20

Boom retraction cylinder

290

210

260

230

220

Boom extension cylinder

250

210

220

Slewing Reduction Gear

150

150

150

150

150



160



160

Outrigger cylinders

140

140

140

160

160



160



160

Steering

150

150

150

150

150



160



180

40/45

40/45

40/45

40/45

40/45

/

/

Winch speed 2 valve

150

150

150

150

/

/

/

Air conditioning valve

150

150

150

150

150

140

150

/

/

/

200

200

/

/

Boom lowering line SV block relief valve

Servocontrols

Gearbox oil cooler bypass valve

Chapter VI – ed. 07-2012

230 2° Section

210 3° and 4° Section

RT75

/



/

200

 170

RT100

 200 3° and 4° Section

200 2° Section

 200 2°+3° Section

 200 4°+5°+6° Section

 200 2°+3° Section

 200 4°+5°+6° Section

page 21/66

Maintenance

Operation and maintenance manual

RT75 pressure points

Outrigger pressure point

Pressure point for winches, lifting cylinder, telescopic cylinders, slewing

Steering pressure point

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Chapter VI – ed. 07-2012

Maintenance

Operation and maintenance manual

RT100 pressure points

Outrigger pressure point

Pressure point for winches, lifting cylinder, telescopic cylinders, slewing

Steering pressure point

Chapter VI – ed. 07-2012

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Maintenance

Operation and maintenance manual

Quantity of oils

Quantity of lubricant Part description

um

RC30 RT35

RC35

RC40

RC45

A600

RC60

RT75

RT100

Engine oil

l

18

18

18

18

18

18

18

18

Gearbox oil

l

22

22

22

22

32

19

19

41

Front + rear axle oil

l

37

43

43

43

64

69

69

82

Slewing reduction gear oil

l

6

6

6

6

6

6

6

6

Total

l

460

600

600

600

800

800

900

1380

Tank

l

390

470

470

470

600

600

660

1000

Main winch oil

l

12

12

12

12

28

20

20

42

Auxiliary winch oil

l

12

12

12

12

12

12

20

12

Brake fluid

l

1.05

1.05

1.05

1.05

///

///

///

2

Boom guide blocks grease

kg

5

6

7

10

8

10

8

9

Slewing ring, pin, bearings grease

kg

3

3

3

3

3

3

4

5

Radiator antifreeze

l

9

9

9

9

11

11

18

13

Hydraulic circuit oil

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Chapter VI – ed. 07-2012

Maintenance

Operation and maintenance manual

“SHELL” lubricants

Model:

Type of hydraulic oil in relation to the operating temperature Tellus S2 V32

Tellus S2

Tellus S2 V46

RC30 RT35

-20 C / +45 C

RC35 RC40 RC45

-20 C / +25 C

0 C / +45 C

-10 C / +45 C

A600

-20 C / +45 C

RC60

-10 C / +45 C

RT75

-20 C / +45 C

RT100

-20 C / +45 C

Operating temperature -20 C / +45 C Part description

Lubricant

Part description

Lubricant

Engine

RIMULA R3X 15W-40

Rotation reduction gear

TIVELA S150

Gearbox

DONAX TA

Winches

OMALA 150

Axles

SPIRAX A 80W-90

Brakes

DOT4 ESL

Chapter VI – ed. 07-2012

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Maintenance

Operation and maintenance manual

Boom lubrication Boom RC30 RT35 Grease the boom section sliders with a brush. Method: - Two people are needed for this operation. - Machine outdoors. - Machine on outriggers, fully extended. - Boom horizontal. - Extract all the sections. - Grease. - Retract the sections with the aid, if necessary, of the boom lifting mechanism. Use a ladder. DO NOT walk or stand on the boom.

Boom RC35 Grease the boom section sliders with a brush. Method: - Two people are needed for this operation. - Machine outdoors - Machine on outriggers, fully extended. - Boom horizontal. - Extend the 4th section. - Grease - Retract the 4th section. - Extend the 2nd and 3rd section - Grease - Retract the sections with the aid, if necessary, of the boom lifting mechanism. Use a ladder. DO NOT walk or stand on the boom.

Boom RC40 Grease the boom section sliders with a brush. Method: - Two people are needed for this operation. - Machine outdoors - Machine on outriggers, fully extended. - Boom horizontal. - Extend the 4th section mechanically. - Grease - Retract the 4th section. - Extend the 2nd and 3rd section - Grease - Retract the sections with the aid, if necessary, of the boom lifting mechanism. Use a ladder. DO NOT walk or stand on the boom.

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Chapter VI – ed. 07-2012

Maintenance

Operation and maintenance manual

Boom A600 – RC45 – RT75 Grease the boom section sliders with a brush. Method: - Two people are needed for this operation. - Machine outdoors - Machine on outriggers, fully extended. - Boom horizontal. - Extend the 2nd section. - Grease - Retract the 2nd section - Extend the 3rd and 4th section as well as the 5th section if there is one - Grease - Retract the sections with the aid, if necessary, of the boom lifting mechanism. Use a ladder. DO NOT walk or stand on the boom.

Boom RC60 Grease the boom section sliders with a brush. Method: - Two people are needed for this operation. - Machine outdoors - Machine on outriggers, fully extended. - Boom horizontal. - Extend the 2nd section. - Grease - Retract the 2nd section - Extend the 3rd and 4th section - Grease - Retract the 3rd and 4th section - Extend the 5th section - Grease - Retract the sections with the aid, if necessary, of the boom lifting mechanism. Use a ladder. DO NOT walk or stand on the boom.

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Maintenance

Operation and maintenance manual

Boom RT100

3

1 6 4-5

2

Boom lubrication chart Frequency

Ref.

Identification

Operation:

Grease points:

50 h

1

Boom base section

Greasing

2 grease nipples

250 h

2

Slide pads

Greasing

Brush and grease nipples

3

Electric system

Check

Wiring harnesses

4

Fasteners

Check tightness

All fasteners

5

Slide pads

Check condition

All pads

6

Pulleys

Check condition

1000h

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Chapter VI – ed. 07-2012

Maintenance

Operation and maintenance manual

Greasing: see lubrication table Using a grease pump, grease the rear top pads of sections T2, T3, T4, T5 and T6. Four grease nipples per section. Two grease nipples per pad. Access by four holes on the sides of sections T1, T2, T3, T4, and T5 The two grease nipples should not be given the same amount of grease. A considerable amount should be applied to the one on the left, but the one on the right should receive much less (one or two deliveries). Grease the section sliders with a brush. Method: - Machine outdoors - Machine on outriggers, fully extended. - Blocked boom tilted to 2°. - Two people are needed for this operation.

GREASING T2 and T3 T5 and T6 released (remaining however in T4). Telescope T2/T3 61% (+/-2%). Boom 21.80 m. Grease T2 pads through the first hole on each side of T1.

Telescope T2/T3 90% (+/-2%). Boom 26.40 m. Grease T2 and T3 pads through the second hole on each side of T1 and T2.

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Maintenance

Operation and maintenance manual

T4 GREASING Retract T2/T3 54% (+/-2%). Grease T4 pads through holes on each side of T3.

GREASING T5 and T6 Telescope T4, T5, T6 to 62% {+/-2%). Grease T4, T5, and T6 pads through the 2nd hole on each side of T3 and the first holes on the sides of T4 and T5.

Telescope T4, T5, T6 to 90% {+/-2%). Grease T4, T5, and T6 pads through the first holes on T3, T4, and T5.

Telescope T2 100%. Grease the section sliders with a brush. Use a stepladder or a folding ladder. DO NOT walk or stand on the boom.

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Chapter VI – ed. 07-2012

Maintenance

Operation and maintenance manual

Telescope T3 alone 100%. Grease the section sliders with a brush. Use a stepladder or a folding ladder. DO NOT walk or stand on the boom.

Telescope T4, T5, and T3 alone 100%. Grease the section sliders with a brush. Use a stepladder or a folding ladder. DO NOT walk or stand on the boom.

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Maintenance

Operation and maintenance manual

Diagnostics of engine (CUMMINS) Engine protection system The QSB series Cummins engines installed on models RC30, RT35, RC35, RC40, RC45, A600, RC60, RT75, RT100, TCC40, TCC45 and TCC60 are equipped with an engine protection system. The system monitors critical engine pressure and temperature values and records any diagnostic errors in the event of anomalous operating conditions. In the presence of out of tolerance values and if it becomes necessary to derate engine power, the operator is warned by illumination of an ALARM warning light in the cab. The ALARM warning light starts flashing if the out of tolerance condition continues to worsen. When the red STOP warning light illuminates the operator must stop the engine as soon as possible in order to limit possible damage. NOTE: The engine speed and power will be reduced gradually in accordance with the degree of gravity of the condition in question.

Error codes The QSB system can highlight and record operating anomalies and communicate them in the form of error codes. The error codes can be used to facilitate troubleshooting tasks. The error codes are recorded in the ECM (engine control module). The error codes can be read by means of the indicator lights on the control panel in the cab. NOTE: Not all anomalies relative to the QSB system or the engine are communicated by means of error codes. There are two basic types of error codes: •

Engine electronic control system error codes

•

Engine protection system error codes.

All the error codes recorded can be either active (error code present) or inactive (error code present at a specific time but not currently present). Certain electronic error codes (although not all) cause a warning light to illuminate when they are present. There are two warning lights that can illuminate when an error is detected. To check for the presence of error codes relative to the engine electronic fuel system and engine protection system switch off the engine and turn the ignition key to ON. Press the DIAGNOSTICS pushbutton. If no error codes are present, both the STOP and ALARM warning lights will illuminate and remain illuminated.

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Chapter VI – ed. 07-2012

Maintenance

Operation and maintenance manual

In the presence of error codes both the warning lights illuminate briefly and then start flashing to communicate a code relative to the errors that have been recorded. The error code will flash in the sequence indicated below: The yellow ALARM warning light flashes initially. This will be followed by a 1-2 second pause, after which the number of the recorded error code will flash on the red STOP warning light. There will be a 1-2 second pause between each number. When the red warning light has stopped flashing the yellow warning light will illuminate again. The error code will now be repeated in the same sequence. The warning lights will flash three times for each error code before progressing to the next code in the memory. To go to the next error code, temporarily set the idle speed adjustment switch to the (+) position. You can return to the previous error code by temporarily setting the idle speed adjustment button to the (-) position. If just one error has been detected, the QSB system will continue to display the same code when the (+) or (-) switch is pressed.

Error codes instantaneous data Additional information concerning error codes can be obtained by means of the INSITE service software. The engine management system instantaneously saves the values and status of the control sensors as soon as a malfunction is detected. These data serve to recreate or establish the operating conditions of the engine when the anomaly occurred. The ECM communicates with INSITE by means of an SAE J1939 data connection (for the connector see ref. “A”).

Chapter VI – ed. 07-2012

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Maintenance

Operation and maintenance manual

A

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Chapter VI – ed. 07-2012

Maintenance

Operation and maintenance manual

Fuses Model RC30, RT35, RC35, RC40, RC45, A600

Chapter VI – ed. 07-2012

page 35/66

Operation and maintenance manual

Code

Function

F1

Fan 1 fuse

F2

Fan 2 fuse

F3

Horns fuse

F4

Slewing brake release fuse

F5

Fans relay fuse

F6

RH and LH servocontrol fuse

F7

Third and fourth boom indicators and selector fuse

F8

Auxiliary winch descent fuse

F9

R14-R15-R16 optional relay fuse

F10

Rotating light fuse

F11

Worklight fuse

F12

Winch second speed slow-fast fuse

F13

Engine stop supply fuse

F14

Boom reset key fuse

F15

Stop lights, carrier junction box, and rpm reduction fuse

F16

Rear fog light fuse

F17

Cab supply fuse

F18

Lights selector switch fuse

F19

Gear change fuse

F20

15 emergency supply fuse

F21

Microswitch fuse “deadman”

F22

RCL supply fuse

F23

Steering supply fuse

F24

Compattino instrument cluster fuse

F25

Outriggers fuse

F26

PPM boom and normal winch descent microswitch fuse

F27

Auxiliary winch fuse

F28

Front-rear differential lock opt. fuse

F29

Optionals direct power supply fuse

F30

Heating system fuse

F31

30 emergency supply fuse

F32

RH sidelight fuse

F33

LH sidelight fuse

F34

Headlights high beam fuse

F35

Headlights low beam fuse

F36

RCL central unit fuse

F37

Relay control unit general power fuse

F38

Alternator fuse

F39

Diagnostic connector fuse

F40

Engine control unit supply fuse

F41

Pre-heater fuse

F42

Starter motor fuse

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Maintenance

Chapter VI – ed. 07-2012

Maintenance

Operation and maintenance manual

Models RC60 – RT75 - RT100

RT100

Chapter VI – ed. 07-2012

RC60

page 37/66

Operation and maintenance manual

Maintenance

Code F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23

Function Cab heating system Warning Cab lights supply Horn relay supply Load limiter control unit supply Emergency mushroom supply Transmission supply Outriggers relay supply Load limiter inhibition diodes control unit common power supply Deadman safety devices / 15 minutes timer supply Low beams relay / Boom head light supply Rear suspension locks solenoid valve supply Air conditioning supply Warning STOP pressure switch supply Flashing alarm / Beeper / Buzzer supply Air conditioning pressure switch / Reverse gear / air conditioning solenoid valve supply Winch lifting solenoid valve / Slewing brake release solenoid valve Carrier / Rear fog light supply Column / Switches locating indicator lights supply Rotating light supply Side instrument panel switches High beams relay supply

F24

Differential locks solenoid valve / Winch 2nd speed / AUX winch supply

F25 F26 F27 F28 F29 F30

Boom lifting cylinder supply Frame Can / Roof windscreen wiper supply Parking lights supply Parking lights supply Worklights supply

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Chapter VI – ed. 07-2012

Maintenance Code K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K18 K19 K20 K21 K22

Operation and maintenance manual

Function Outriggers relay 2nd winch speed relay 2nd gear relay 3rd gear relay not used Horn relay not used Intermittent device Differential lock solenoid valve relay Relay not used Reverse gear relay Forward gear solenoid valve relay High-beam headlights relay Low-beam headlights relay Suspension lock relay Work light relay 1st gear relay Air conditioning relay Free slewing relay Start-up interlock relay 3B-6 extended boom control relay 3B-6 retracted boom control relay

Chapter VI – ed. 07-2012

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Maintenance

Operation and maintenance manual

Lists and frequencies for maintenance List “A” every 8 hours Operation: - Hydraulic oil filter clog indicator - winch rope - hydraulic oil and fuel tank levels - windscreen wiper liquid level - engine oil level - engine radiator coolant level - tyre pressure - air tanks bleeding - block limit stop device Safety • Hook block limit stop microswitch operation (check that the microswitch interrupts the manoeuvre) • Load limiter operation (check that the limiter inhibits boom lowering and extension, winch lifting and turret slewing manoeuvres) • No warning lights illuminated

List “B” every 40 hours Operation: - slewing ring rotation - slewing ring teeth - telescopic boom and lifting system - rotation reduction gear - universal joint transmission - transmission and converter - front and rear axles - engine - hydraulic oil tank filter - front and rear axles - hoisting block assembly

List “C” every 100 hours Operation: - air filter - parking and service brakes - tightening and fixing of wheels - engine / radiator - suspension and steering - batteries - hoisting block assembly

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Chapter VI – ed. 07-2012

Maintenance

Operation and maintenance manual

List “D” every 250 hours Operation: - engine - air filter - transmission and converter - winch gears and reduction gear - brakes Safety • Check condition of tyres (no gouges or cuts) • Check tyre inflation pressure with machine unloaded (see specifications in the following table) • Hook block anchor rope (check ropes wear according to ISO4309)

List “E” every 500 hours Operation: - transmission and converter - engine - air dryer - front and rear axles - hydraulic circuit - air tanks - general fixing elements - boom head pulleys wear Safety • Horn operation • Main winch limit stop device • (check that the device blocks the manoeuvre with at least three rope turns around the drum) • Auxiliary winch limit stop device • (check that the device blocks the manoeuvre with at least three rope turns around the drum) • Hook block limit stop microswitch operation (check that the microswitch interrupts the manoeuvre) • Correct fixing of thimble on boom head • The rope of the main winch is wound and unwound correctly • The rope of the auxiliary winch is wound and unwound correctly (if present) • Correct extension of the telescopic boom • Correct retraction of the telescopic boom • Extending and retracting the outrigger beams • Extending and retracting the stabiliser vertical cylinders • Load limiter operation (check that the limiter inhibits boom lowering and extension, winch lifting and turret slewing manoeuvres) • Automatic selection between front sector ± 3° and 360° load table • Confirm selection of the front sector load table (travelling) only with the turret slewing locking pin inserted

Chapter VI – ed. 07-2012

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Maintenance

Operation and maintenance manual • • • • • • • • • •

“Deadman device” (microswitch on joysticks) Ropes (check ropes wear according to ISO4309) Hooks (check wear of hooks according to UNI9473-1) Efficiency of load holding valves on outrigger cylinders (check that cylinder rod retraction is no more than 3 mm over a period of 15 minutes with the machine stopped) Efficiency of load holding valve on hoisting cylinder (check that cylinder rod retraction is no more than 3 mm over a period of 15 minutes with the machine stopped) Efficiency of load holding valve on extension cylinder (check that cylinder rod retraction is no more than 3 mm over a period of 15 minutes with the machine stopped) Holding capacity of winch brake (check that drum rotation (in rope unwinding direction) is no more than 5° over a period of 15 minutes Holding capacity of turret slewing unit (with crane stabilised on just one side and inclined by 4° in a lateral direction, check that the turret does not rotate) Alignment of the boom (completely extend the boom and check visually to ensure that the sections are reciprocally aligned) Efficiency of the rear axle swing restriction cylinders

List “F” every 1000 hours Operation: - general fixing elements - hydraulic circuit - steering - electrical system - rotation reduction gear - checking pinion - slewing ring backlash - fuel tank - front and rear axles - boom section guide blocks - winch gears and reduction gear - transmission and converter - braking system - brakes

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Chapter VI – ed. 07-2012

Maintenance

Operation and maintenance manual

List “G” every 2000 hours Operation: - hydraulic oil tank - brakes - cooling circuit Safety • Tightening wheel nuts (check that tightening torque of the M22x1.5 nuts is 45...55 Nm) • The engine cannot be started unless the transmission is in neutral • Correct operation of front axle steering • Correct operation of crab steering • Correct operation of concentric steering • Rear axle steering locking device • Correct operation of the service brake • Correct operation of the parking brake • Correct insertion of manual lock on outrigger extension beams • Correct insertion of turret slew locking pin • Correct operation of booms selection (where present) • Tightening of slewing ring fixing screws to eliminate the risk of loose screws • Tightening of screws securing the winch to the superstructure to prevent screws from working loose • Tightening of screws securing the front axle to the chassis and rear axle to the swinging support • Visual check of condition of structural welds, chassis, turret, and boom girders (absence of cracking) • Check tightness of superstructure slewing unit screws

List “H” every 4000 hours Safety • Checking load limiting device calibration When lifting known weights at assigned distances check that these values are within 10% of the load (UNI ISO 10245-2)

List “I” every 5000 hours (Motor phase IIIB) Operation: - Clean the diesel particulate filter (DPF) – Refer to the manufacturer's technical specifications

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Maintenance

Operation and maintenance manual

List “A” – 8 hours Air filter Clean the clogging indicator (1).

1

Lifting rope Visually inspection the suspended rope and inside the lifting winch drum (refer to the paragraph).

Hydraulic oil tank and fuel tank level The checks must be carried out with the machine on level ground, all cylinders retracted, boom retracted in the horizontal position and oil cold. Check the hydraulic oil level (by means of the special gauge on the tank) and the fuel level every 8 hours. DO NOT smoke during fuel tank filling, as the vapours are flammable.

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Maintenance

Operation and maintenance manual

Windscreen wiper liquid container Check the windscreen wiper liquid in the tank located in the operator's cab every 8 hours.

Engine oil level Check the engine oil level every 8 hours. To check the oil level, open the hood on the frame and check that the level is between max. and min. on the dipstick. If necessary, top-up with oil immediately. The engine oil must always be checked before starting work or in any case with engine cold.

In any case, refer to the engine manufacturer's technical specifications.

Chapter VI – ed. 07-2012

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Maintenance

Operation and maintenance manual

Engine radiator coolant level Open the cover located at the back of the engine hood to access the radiator cap. The antifreeze mixture consists of a solution of 34% coolant and 66% water.

Check the coolant level and if necessary add water or antifreeze solution until the level is 2 cm from the edge of the filler. Use the type and quality of antifreeze mixture according to the manufacturer's instructions; refer to the relevant specifications for further details.

• During filling, take care when handling coolants and oil. • The components and hot oil can cause burns. Avoid any contact with the skin.

• Never put cold coolant in an overheated engine. Always wait for the engine to cool down first.

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Chapter VI – ed. 07-2012

Maintenance

Operation and maintenance manual

Tyre pressures Adjust the tyre pressures according to that specified on the sticker located in the cab or in the chart given previously in this manual. • The pressures specified on the chart in the cab or given previously refer to cold tyres. Inflation and pressure checks must be carried out on cold tyres. NEVER inflate hot tyres. • Check the tyres only when there are no suspended weights on the crane. Always use a safety cage when the tyre is not fitted on the machine. • Do not stand in front of the tyre. Use a sufficiently long air hose with quick connector for inflation.

DANGER !! Never drive the machine with inadequately inflated tyres.

Bleeding the air tanks Bleed the air tanks to remove deposits and moisture. In winter, the condensate could freeze and block the breather. At the end of every work day, bleed the air from tanks. One bleeding operation on each tank is sufficient. The tanks are situated on the left side of the machine and a smaller one is under the truck (only for model A600).

Block limit stop device Regularly check that the limit stop device works properly.

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Maintenance

Operation and maintenance manual

List “B” – 40 hours Slewing ring Using a grease pump and by means of the grease nipples on the slewing ring, lubricate the ring with sufficient grease (four or five pump strokes). After lubricating the first grease nipple, turn the slewing ring 90° to distribute the grease evenly over the entire inside surface. CAUTION: For the maximum safety this operation should be carried out by just one operator.

Slewing ring teeth Check slewing ring teeth lubrication every 50 hours. For good lubrication of the slewing ring and the pinion, grease twice, fully turning the slewing ring firstly in one direction and then the other. CAUTION: For the maximum safety this operation should be carried out by just one operator.

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Maintenance

Operation and maintenance manual

Telescopic jib and hoisting system • • • • • •

Greasing the section telescoping guide blocks. Grease the hoisting block and boom head sheaves. Grease the telescopic boom pivots. Grease the boom lifting cylinder. Grease the angle indicator pin. Check the boom telescoping chain tension.

Visually check the lifting rope

Rotation reduction gear Check the reduction unit oil level with the dipstick.

Universal joint transmission Check the lubrication and lubricate again if necessary. The cardan shafts have three grease nipples each for ensuring good lubrication. Moderately lubricate the universal joint near the parking brake disk.

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Maintenance

Operation and maintenance manual

Transmission – Converter unit and powershift Check the transmission oil level with oil at a temperature of 80° and the engine idling. Top-up the oil if necessary. Carry out the first filter cartridge change.

In any case, refer to the gearbox manufacturer's technical specifications.

Engine Carry out the first engine oil change.

In any case, refer to the engine manufacturer's technical specifications.

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Maintenance

Operation and maintenance manual

Filter on hydraulic oil tank Keep the clogging manometer under control; when the pressure reaches 2 bars this means the filter cartridge must be changed. At the same time clean the hydraulic tank breather.

Front and rear axles Carry out the first oil change. It is advisable to carry out this operation when the oil is still hot. The oil must be drained by means of the plug (♦) located at the bottom of the box and the plug (♦) on the bottom of the reduction unit.

♦

•

♦ At the time of each service check the efficiency of the breather (•) situated on the top of the gearbox, washing it with diesel fuel and drying with a jet of air.

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Maintenance

Operation and maintenance manual

Hoisting block assembly Check the tightness of the lock nuts of the support tie-rods. Check the lock of the grub screw of the hook ring nut. Check that the block assembly always has the plate indicating the capacity and if necessary replace it quickly should it become indecipherable. Grease the crossbeam pins and the hook bearing.

List “C” – 100 hours Clean the air filter If the cartridge is dry: - Blow from the inside outwards at a very low pressure - Using a lamp, make sure the cartridge is not perforated.

If the cartridge is greasy it must be changed. The cartridge must be changed after six cleanings and in any case once a year. Always change faulty or doubtful cartridges.

Parking and service brakes Have a specialized technician check the parking brake and service brake seals.

Wheel tightness Regularly check the tightness of wheels every 100 hours. Torque wrench settings: - Front axle 65 daNm - Rear axle 65 daNm.

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Maintenance

Operation and maintenance manual

Engine and radiator check Clean the radiator fins with compressed air. Check the condition and tension of all engine belts and replace them if necessary. Check the engine mounts and replace them if necessary.

Lubrication of the steering cylinders and suspension locking cylinders Lubricate the steering cylinders, the suspension locking cylinders and the fixing pins of the front and rear axle steering cylinders by means of the grease points indicated (♦).

♦

♦ ♦

♦

♦

♦

♦

♦

♦

♦

Batteries -

-

Chapter VI – ed. 07-2012

In normal use, the batteries do not require topping-up. However, in special cases, e.g. high number of working hours, high operating temperature, the user can top-up with distilled water. Never add sulphuric acid. Whenever frequent additions of water are necessary, have the vehicle's electrical system checked. An electrical system check is also necessary whenever the battery tends to go flat. Maintenance-free batteries have the good characteristic of keeping their charge, therefore if the battery (new or used) is not used for a long time, a recharge every 4-5 months is sufficient. When the battery has been used for more than 2 years, it advisable to have it periodically checked.

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Maintenance

Operation and maintenance manual

General battery maintenance Keep the top part of the battery clean and dry, to avoid short-circuits and corrosion. Remove the battery terminal clamps and check for any corrosion. In case of corrosion, remove the deposits and a thin layer of metal. Cover with vaseline or another suitable product. Tighten the clamps moderately. When using the wrench, make sure not to touch the battery casing or other terminals. Do not use naked flames near the batteries.

Hoisting block assembly Check the play of the pulleys on their axis. Check for any wear on the lug of the hook.

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Maintenance

Operation and maintenance manual

List “D” –250 hours Engine Change the engine oil. Refer to the manufacturer's specifications for further details. Replace the engine oil filter cartridge. Replace the two fuel filter cartridges.

Check the condition and tension of all engine belts and replace them if necessary. In any case, refer to the engine manufacturer's technical specifications.

Air filter Clean the cap collector of dust. Check the clogging indicator. Change the air filter cartridge.

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Maintenance

Operation and maintenance manual

Transmission – Converter unit and powershift Check the oil level on the gearbox graduated dipstick. Check the engine oil level with the oil at a temperature of 80° and the engine idling. Change the oil filter cartridge. Remove the oil filter cartridge, clean the filter support base, oil the seal ring before fitting the new cartridge. Tighten the new filter cartridge by hand.

In any case, refer to the gearbox manufacturer's technical specifications.

Winch gears and reduction unit Check the oil level and gears inside the winch. Carry out the first oil change, and subsequently every 1000 hours or at least once a year. Check the main winch and possible auxiliary winch with the same frequency.

Brakes (RC30-RT35-RC35-RC40-RC45-RT100) Changing the brake oil (when applicable) and filter cartridges.

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Maintenance

Operation and maintenance manual

List “E” – 500 hours Transmission – Converter unit and powershift Check the oil level on the gearbox graduated dipstick. Check the engine oil level with the oil at a temperature of 80° and the engine idling. Change the oil and the filter cartridge. Change the filter cartridge at every oil change.

Take every precaution to safeguard the environment. Make sure that all the oils and liquids used are recovered and correctly recycled; do not leave such products or containers without the special labels in unsuitable or open places. Do not leave residuals of any liquid on the ground or floor. In any case, refer to the gearbox manufacturer's technical specifications.

Engine Check the alternator and starter motor, adjust the valve clearances and check the injectors.

In any case, refer to the engine manufacturer's technical specifications.

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Maintenance

Operation and maintenance manual

Compressed air dryer Change the cartridge of the dryer located under the metal cover.

It is advisable to disconnect the batteries before changing the cartridge.

Front and rear axles Check the brakes. Lubricate all connections. Clean and lubricate the wheel hubs. Check the oil level of the reduction units and axle casings.

Moderately grease all the steering joints (pins, joints, knuckles).

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Maintenance

Operation and maintenance manual

Hydraulic circuit Change the hydraulic circuit filter. Lubricate the filter seal table before replacing. Check for any leaks in the hydraulic circuit; in case of leaks, replace the damaged parts.

Air tanks Clean the air tank automatic breathers.

Check all the fixing elements Check the fixing of: - counterweight bolts - winch bolts - slewing ring bolts - rotation reduction unit bolts - axle bolts - engine / gearbox and converter bolts For the torque settings of the various screws, see the chart given previously in this manual.

Steering Check the tightness of all steering screws and all components (steering wheel, steering column, steering box, levers and connecting rods). Make sure there are no hydraulic leaks in the power steering unit.

Telescopic jib and hoisting system (RT35) •

Chapter VI – ed. 07-2012

Check integrity of tie-rope for boom telescoping

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Maintenance

Operation and maintenance manual

List “F” – 1000 hours Check all the fixing elements Check the fixing of: - counterweight bolts - winch bolts - slewing ring bolts - rotation reduction unit bolts - axle bolts - engine / gearbox and converter bolts

Hydraulic circuit Check for any leaks in the hydraulic circuit; in case of leaks, replace the damaged parts.

Steering Check the tightness of all steering screws and all components (steering wheel, steering column, steering box, levers and connecting rods). Make sure there are no hydraulic leaks in the power steering unit.

Electrical system Check the wiring and relevant fixing elements.

Rotation reduction gear Change the reduction unit oil every 1000 hours.

Checking pinion - slewing ring backlash Check adjustment of pinion - slewing ring backlash and adjust by means of the reduction unit flange (fig.1) if necessary.

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Maintenance

Operation and maintenance manual

Fig.1

Backlash between pinion and slew ring (Jn) measured as shown in fig. 2 must be checked at the 3 teeth marked with green on the slew ring teeth and must be between 0.3 and 0.35 mm. Fig.2

Fuel tank Remove any water or condensation from the fuel tank by means of the plug located under the tank.

Front and rear axles Change the transmission and gearbox oil. It is advisable to carry out this operation when the oil is still hot. The oil must be drained by means of the plug (♦) located at the bottom of the box and the plug (♦) on the bottom of the reduction unit.

♦

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Maintenance

Operation and maintenance manual

At the time of each service check the efficiency of the breather (•) situated on the top of the gearbox, washing it with diesel fuel and drying with a jet of air.

Boom section guide blocks Check the boom telescopic section guide blocks. Check the tightness of the guide block and support fixing screws. Check the boom sheaves.

Winch gears and reduction unit Change the winch reduction unit and internal gear oil. Change the oil every 1000 hours or at least once a year.

Change the oil with the same frequency as for the main winch and possible auxiliary winch.

Transmission – Converter unit and powershift Change the oil and the filter cartridge. Change the filter cartridge at every oil change.

Take every precaution to safeguard the environment. Make sure that all the oils and liquids used are recovered and correctly recycled; do not leave such products or containers without the special labels in unsuitable or open places. Do not leave residuals of any liquid on the ground or floor.

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Maintenance

Operation and maintenance manual

In any case, refer to the gearbox manufacturer's technical specifications.

Braking system Check the brake cylinder fixing elements. Check the brake circuit lines and replace them if necessary.

Brakes (RC30-RT35-RC35-RC40-RC45-RT100) Changing the brake oil (when applicable) and filter cartridges.

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Maintenance

Operation and maintenance manual

List “G” – 2000 hours Hydraulic oil tank Change all the oil in the tank. Change the oil filter. Breather

Change the oil after 2000 hours or at least once a year. Changing the hydraulic circuit oil consists of methodically draining the oil tank, pumps, cylinders, cooling radiators. Take every precaution to safeguard the environment. Make sure that all the oils and liquids used are recovered and correctly recycled; do not leave such products or containers without the special labels in unsuitable or open places. Do not leave residuals of any liquid on the ground or floor.

Brakes (RC30-RT35-RC35-RC40-RC45-RT100) Changing the brake oil (when applicable) and filter cartridges.

Replace the brake circuit lines every 2000 hours or once a year.

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Maintenance

Operation and maintenance manual

Cooling circuit Change the radiator coolant every 2000 hours or at least once a year.

A.

B.

C

To drain the circuit: -

Make sure the engine is not hot and that the coolant is at ambient temperature. Remove the filler cap (A), undo the plug at the bottom of the radiator (C) and drain the coolant. Refit the plug on the bottom of the radiator.

To refill the circuit: -

-

Disconnect the engine breather pipe (B). Pour in the coolant (1/3 antifreeze - 2/3 water) through the filler neck (A) until the level corresponds to 2 cm. from the rim of the filler neck. Use the type and quality of antifreeze mixture according to the manufacturer's instructions; refer to the relevant specifications for further details. Reconnect the engine breather pipe and close the filler cap. Start the engine and let it idle for a few minutes, checking the temperature gauge on the control panel in the cab, in order to prevent possible overheating. Stop the engine, wait a few minutes for it to cool down, unscrew the cap, check the liquid level and if necessary top-up to the required level. Refit the filler cap and repeat the last two operations until the level of the coolant stabilizes.

Take every precaution to safeguard the environment. Make sure that all the oils and liquids used are recovered and correctly recycled; do not leave such products or containers without the special labels in unsuitable or open places. Do not leave residuals of any liquid on the ground or floor.

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Maintenance

Operation and maintenance manual

Model……………………… Company……………………………………… Serial number………………………………………………………………… Head of maintenance:………………………………………………………. Reference list: ".........."

Operating hours: ........................................

Maintenance points:  .........................................................................................................  .........................................................................................................  .........................................................................................................  .........................................................................................................  .........................................................................................................  .........................................................................................................  .........................................................................................................  .........................................................................................................  .........................................................................................................  .........................................................................................................  .........................................................................................................  .........................................................................................................  .........................................................................................................  .........................................................................................................

Date: ….… / …... / ……….

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Signature: ......................................

Chapter VI – ed. 07-2012

Inspections

Maintenance and operator's manual

VII Inspections

Chapter VII – ed. 04-2011

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Maintenance and operator's manual

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Inspections

Chapter VII – ed. 04-2011

Inspections

Maintenance and operator's manual

Periodical inspection is essentially a visual and functional check that includes the following: - identity check on the crane with the information given in the crane's logbook. - check on the state of the components and equipment to see whether they are damaged, worn, corroded or whether there are any other changes. - check on the completeness and functionality of the safety equipment and brakes. This must be done by taking as reference the technical standard ISO 9927.

DAILY CHECKS (G) Before putting into service each day, make a thorough inspection before getting into the cab or starting the engine, checking that there are no obvious signs of impairment to the structure or the safety devices; then get into the cab, start the engine and check:

G1

Hook block limit stop microswitch operation (check that the microswitch interrupts the manoeuvre)

G2

Load limiter operation (check that the limiter inhibits boom lowering and extension, winch lifting and turret slewing manoeuvres)

G3

No warning lights illuminated

Group G checks are not to be noted down in the inspection log

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Inspections

Maintenance and operator's manual

MONTHLY CHECKS (M) M1

Check condition of tyres (no gouges or cuts)

M2

Check tyre inflation pressure with machine unloaded (see specifications in the following table).

M3

Hook block anchor rope (check ropes wear according to ISO4309)

The pressures given refer to cold tyres, therefore also the inflation and pressure checks must be carried out on cold tyres

385/95

14.00 R24

MICHELIN R24 9 bar XMH S TT 170 E

9 bar

MICHELIN XMP

10 bar

10 bar

PIRELLI

10.25 bar

8.5 bar

ADVANCE

10 bar

7.5 bar

MICHELIN

8 bar

8 bar

PIRELLI

9.5 bar

8 bar

ADVANCE

10.5 bar

7.5 bar

PIRELLI

7 bar

5.75 bar

MICHELIN

5.5 bar

5.5 bar

TRIANGLE

6.9 bar

4.5 bar

PIRELLI

7 bar

5.75 bar

MICHELIN

5 bar

5 bar

TRIANGLE

6.9 bar

4.5 bar

MICHELIN

5.5 bar

5.5 bar

ADVANCE

5.7 bar

3.5 bar

TRIANGLE

6.9 bar

4.5 bar

ADVANCE

7 bar

6 bar

16.00 R25 16.00 - 25

20.5 R25

23.5 R25

26.5 R25 26.5 - 25 29.5 R25

Group M checks are not to be noted down in the inspection log

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Inspections

Maintenance and operator's manual

QUARTERLY CHECKS (T) With the machine with no load, check: T1

Horn operation

T2

Main winch limit stop device (check that the device blocks the manoeuvre with at least three rope turns around the drum)

T3

Auxiliary winch limit stop device (check that the device blocks the manoeuvre with at least three rope turns around the drum)

T4

Hook block limit stop microswitch operation (check that the microswitch interrupts the manoeuvre)

T5

Correct fixing of thimble on boom head

T6

The rope of the main winch is wound and unwound correctly

T7

The rope of the auxiliary winch is wound and unwound correctly (if present)

T8

Correct extension of the telescopic boom

T9

Correct retraction of the telescopic boom

T10

Extending and retracting the outrigger beams

T11

Extending and retracting the stabiliser vertical cylinders

T12

Load limiter operation (check that the limiter inhibits boom lowering and extension, winch lifting and turret slewing manoeuvres)

T13

Automatic selection between front sector ± 3° and 360° load table

T14

Confirm selection of the front sector load table (travelling) only with the turret slewing locking pin inserted

T15

“Deadman device" (microswitch on joysticks)

T16

Ropes (check ropes wear according to ISO4309)

T17

Hooks (check wear of hooks according to UNI9473-1)

T18

Boom (check integrity of cable stay for boom extension - only for RT35 -)

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Maintenance and operator's manual

Inspections

With a load that can vary between 30% and 50% of the machine's maximum capacity, check:

T19

Efficiency of load holding valves on outrigger cylinders (check that cylinder rod retraction is no more than 3 mm over a period of 15 minutes with the machine stopped)

T20

Efficiency of load holding valve on hoisting cylinder (check that cylinder rod retraction is no more than 3 mm over a period of 15 minutes with the machine stopped)

T21

Efficiency of load holding valve on extension cylinder (check that cylinder rod retraction is no more than 3 mm over a period of 15 minutes with the machine stopped)

T22

Holding capacity of winch brake (check that drum rotation (in rope unwinding direction) is no more than 5° over a period of 15 minutes

T23

Holding capacity of turret slewing unit (with crane stabilised on just one side and inclined by 4° in a lateral direction, check that the turret does not rotate)

T24

Alignment of the boom (completely extend the boom and check visually to ensure that the sections are reciprocally aligned)

T25

Efficiency of the rear axle swing restriction cylinders

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Inspections

Maintenance and operator's manual

TWO-YEAR CHECKS (B) With the machine with no load, check:

B1

Checking load limiting device calibration When lifting known weights at assigned distances check that these values are within 10% of the load (UNI ISO 10245-2)

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Maintenance and operator's manual

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Inspections

Chapter VII – ed. 04-2011