RC30 RT35 - ENG Rev.07

RC30-RT35
Operation and maintenance
ROUGH TERRAIN CRANES
SERIAL NUMBER.......................................
Operation and maintenance manual
Code: 46953 (eng) - rev.07
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: terexitalia@terex.it
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: assistance@terex.it
Code: 46953 (eng) - rev.07
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
Code: 46953 (eng) - rev.07
Characteristics
I
Characteristics
Chapter I ed. 04-2011
page 1/12
page 2/12
Characteristics
Characteristics
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
page 3/12
page 4/12
Characteristics
Characteristics
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
36 km/h
Max. theoretical ramp during operation (with tyres 14.00R24)
118 %
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
page 5/12
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
page 6/12
Characteristics
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
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
page 7/12
Characteristics
() Values with auxiliary winch
Dimensions(4)
A
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 8/12
Characteristics
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)
30 km/h
31 km/h
98 %
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)
page 9/12
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
page 10/12
Characteristics
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
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
() Values with auxiliary winch
Dimensions(4)
A
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
Instructions
II
Instructions
Chapter II - ed. 10-2009
page. 1/12
page. 2/12
Instructions
Instructions
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 -20C and
not greater than +45C, 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.
page. 3/12
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.
page. 4/12
Instructions
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.
page. 5/12
Instructions
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
Instructions
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.
page. 7/12
Instructions
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
page. 8/12
Instructions
CAUTION: moving parts with danger of crushing
CAUTION: generic danger
CAUTION: danger of crushing
CAUTION: inflammable
CAUTION: danger of falling

page. 9/12
Instructions
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
Instructions
Position of decals on the machine
1
7
11
10
page. 11/12
Instructions
10
11
6
Hydraulic Oil
Shell Tellus ST46
page. 12/12
45617
Safety and operation
III
Safety and Use of
the machine
Chapter III ed. 04-2012
page 1/66
page 2/66
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.
page 3/66
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.
page 4/66
page 5/66
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.
page 6/66
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?
page 7/66
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.
page 8/66
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.
page 9/66
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).
page 10/66
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.
page 11/66
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.
page 12/66
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.
page 13/66
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.
page 14/66
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.
page 15/66
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.
page 16/66
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.
page 17/66
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).
page 18/66
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.
page 19/66
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.
page 20/66
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.
page 21/66
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.
page 22/66
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.
page 23/66
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
450550 Nm
RC35 / RC40 / RC45-1
450550 Nm
A600-1
450550 Nm
650 Nm
RC60 / RT75 / RT100
page 24/66
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.
page 25/66
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.
6
7
8
9
page 26/66
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.
page 27/66
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
page 28/66
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

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

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
gross load
page 29/66
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.
page 30/66
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.
page 31/66
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.
page 32/66
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
page 33/66
Max. forces exerted on ground (daN)
Model:
RC30
28000
525 mm
RT35
27000
525 mm
RC35
27000
525 mm
RC40
27000
525 mm
RC45
39000
525 mm
A600
45000
650 mm
RC60
55000
650 mm
RT75
50000
650 mm
RT100
70000
610 mm
Model:
page 34/66
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
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 m/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 m
12 m
1 tonne.
Wind
10 tonne.
Wind force
Wind speed
Consequences
Scale
Terms described
mps
kph
Calm
0 - 0.2
Very light
0.3 - 1.5
1-5
Light breeze
1.6 - 3.3
6 - 11
Gentle breeze
3.4 - 5.4
12 - 19
Mild breeze
5.5 - 7.9
20 - 28
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
Strong breeze
10.8 - 13.9
39 - 49
Large branches sway
Strong wind
14 - 17.1
50 - 61
All the trees sway
Wind gust
17.2 - 20.7
62 - 74
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
Inland territories
Calm, smoke rises vertically
page 35/66
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.
page 36/66
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.
page 37/66
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.
page 38/66
Model TW8 (RT100)

Legend:
1. Winch drum
2. Lifting rope
3. Return spring
4. Limit switch
5. Adjustment screw
6. Cable clamp
2
6
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
page 39/66
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
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
3
1
page 40/66
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
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.
page 41/66
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
page 42/66
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 0C,
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.
page 43/66
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.

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
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
page 44/66
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
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
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
page 45/66
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).
page 46/66
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.
page 47/66
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

the middle outrigger beams. For a correct configuration, the beam
locking pin must be inserted in the special seat.
OUTRIGGER BEAMS FULLY EXTENDED

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.
page 48/66
the
outrigger
beams
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.
page 49/66
Guideline table of permissible pressures for various types of

terrain
daN/cm
(kg/cm)
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.
page 50/66
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.
page 51/66
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.
page 52/66
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.
page 53/66
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.
page 54/66
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.
page 55/66
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.
page 56/66
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
boom axis
hoisting line
boom axis
page 57/66
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.
page 58/66
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 30C or above +100C.
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.
page 59/66
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.
page 60/66
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.
page 61/66
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
page 62/66
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.
page 63/66
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.
page 64/66
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.
page 65/66
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.
page 66/66
Control instruments
IV
Control
instruments
Chapter IV ed. 04-2011
page 1/44
page 2/44
Control instruments
Control instruments
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) . . . . . . . . . . . . . . . . . . . . .
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
page 3/44
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
page 4/44
Control instruments
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.
page 5/44
Control instruments
Operator's cab controls
1. Manual slewing locking pin

2. Accelerator pedal
3. Service brake pedal
page 6/44
Control instruments
4. Parking brake
5. Right hand control
6. Left hand control
7. Outrigger movement enable button
page 7/44
Control instruments
LH
RH
8. Superstructure slewing brake manual release

9. Horn
page 8/44
Control instruments
10
11
12
10. Spirit level

11. Windscreen washer liquid tank
12. Heater control (see the fitted model)
page 9/44
Control instruments
Side controls console
28
29
13
27
14
26
25
15
24
16
23
22
17
21
18
20
19
page 10/44
Control instruments
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
page 11/44
Control instruments
Central control column
30
31
34
32
35
33
36
40
39
37
38
41
page 12/44
Control instruments
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
page 13/44
Control instruments
Column indicator panel
43
44
42
45
42. Engine coolant temperature gauge

43. Display
44. Fuel gauge
45. Set of warning lights
page 14/44
Control instruments
Telescopic boom
Model RC30
2nd section
Main boom
3rd section
Model RT35
2nd section
4th section
Main boom
3rd section
page 15/44
Control instruments
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
page 16/44
Control instruments
Description
of controls
page 17/44
Control instruments
Outrigger controls
According to the selection, these controls enable beam or outrigger
extension and retraction.
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.
page 18/44
Control instruments
Front left outrigger controls
Front right outrigger controls
Rear left outrigger controls
Rear right outrigger controls
page 19/44
Control instruments
Symbols on outrigger controls

Left side beam extension

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

Right side beam extension

Right side beam retraction

Left side outrigger down

Left side outrigger up

Right side outrigger down

Right side outrigger up

page 20/44
Control instruments
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
page 21/44
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.
LH
page 22/44
Control instruments
Gearshift lever

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.
page 23/44
page 24/44
Control instruments
Control instruments
Central control column
page 25/44
Control instruments
Engine coolant temperature gauge
The normal temperature is between 83C and 95C. The coolant

temperature must not exceed 100C.
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
The display indicates:

A
engine error code
B
engine rev counter
C
hour-meter, showing the number of engine operating hours.
page 26/44
Control instruments
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.
page 27/44
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
page 28/44
Control instruments
Torque converter oil temperature warning light

Normal work temperature between 80C and 120C.
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.
page 29/44
Control instruments
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.
page 30/44
Control instruments
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.
page 31/44
Control instruments
Steering mode selector

2
1
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.
page 32/44
Control instruments
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
page 33/44
Control instruments
Manual slewing locking pin
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.
page 34/44
Control instruments
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.
page 35/44
Control instruments
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.
page 36/44
Control instruments
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.
page 37/44
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
page 38/44
Control instruments
Cummins engine control panel

1
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.
page 39/44
Control instruments
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.
The 24 volt socket outlet 3 is on the shelf behind the seat.
page 40/44
Control instruments
Cab heating control (optional)

The control unit (ref.12) is located on the left side instrument panel in the
operators cab.
Refer to the model fitted on the crane truck.
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.
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.
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 operators 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 operators cab before using the heating system.
page 41/44
Control instruments
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
Control instruments
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
Operator weight
adjustment lever
page 43/44
Control instruments
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.
page 44/44
Rated Capacity Limiter
Operation and Maintenance
Rated Capacity Limiter ed. 04-2012
page 1/34
page 2/34
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.
page 3/34
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 operators 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 Manufacturers instructions and procedures at any time
page 4/34
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 cranes
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 cranes manufacturer.
page 5/34
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.
N2 PRESSURE TRANSDUCERS
6.
CANBus cable 10 m
7.
CANBus LEVELLING SENSOR
8.
A2B ANTI TWOBLOCK + WEIGHT 4 Kg
page 6/34

4.2
Component Location
ACT cable reel 12m:

Extension and angle
sensor
ACMCP cable reel 32m:

Extension sensor
A2B
CONTROL PANEL
into the cabin
2 PRESSURE
TRANSDUCERS
page 7/34
4.3
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.
page 8/34
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.
page 9/34
Icon
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.
page 10/34
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.
page 11/34
6.4
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.
page 12/34

6.5
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.
page 13/34
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.
page 14/34

Icon
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 Booms extension MOD 1 or MOD 2 status.

Indication of the actual load.
XX.X
Indication of the main booms radius in meters.
XX.X
Indication of the main booms length.
XX.X
Indication of the maximum load in that machine condition.
XX.X
Indication of the main booms 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
Indication of the Shut Off from Isaac
Indication of the machine normal working condition
Indication of the machine pre-alarm working condition (90%)
page 15/34
Icon
Description
Indication of the machine Shut off working condition (100%)
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.
Its possible delete a recorded alarm once it has been restored by pressing
page 16/34
key.

6.7
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 machines configuration (boom, outriggers, counterweight, jibs 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.
page 17/34
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
page 18/34
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).
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.
Selection is possible only if Jib has been previously selected

20

40

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
page 19/34
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
page 20/34

Icon
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
REAL VALUE
Boom Radius
BLOCK VALUE
REAL 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
key. To
key.
page 21/34
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
page 22/34
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
and the limit previously set is deleted.
page 23/34
7
Diagnostic
The diagnostic function does not require password.
User can control in real time several sensors 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
page 24/34
to exit the diagnostic menu. The screen goes back to the operating mode.

Press
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.
page 25/34
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
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
page 26/34
to exit from this menu and return on the main page.
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.
page 27/34
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 drivers cab.
This operation lights up the LED on push-button 4 inside the cab;
page 28/34
afterwards, inside the cab:

-
press and hold down push-button 4 to disable the RCL.
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.
the speed of the cranes 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.
page 29/34
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.
page 30/34
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
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)
ACT is faulty
Short circuit in wires carrying the
signals
8/9
functionality
functionality
in short circuit
Main Unit is faulty
Length value less then minimum boom
length value possible

Verify the value of the boom length
functionality
Verify the calibration
Verify the wiring connection
page 31/34
Alarm Code:
Alarm:
X
Description
Cause
What to do
11 / 54
Length transducer II (potentiometer)
Transducer Length 2
Low
ACT is faulty
carrying the unwinding
12
Transducer Pressure
Piston Side Low
functionality
open
Main Unit is faulty
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
transducer
15
Angle Low
Main Unit is faulty
Angle transducer (inclinometer) ACT is
faulty
carrying the angle signal.
21
functionality
open.
Main Unit is faulty
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
page 32/34
Alarm Code:
Alarm:
X
Description
Cause
What to do
22
Low chamber pressure transducer
Replace pressure
Transducer Pressure
Piston Side High
broken
signals
transducer
Verify wires connection and
transducer
Main Unit is faulty

Contact Technical
Assistance
23
Transducer Pressure
Rod Side High
High chamber pressure transducer

broken
signals
Replace pressure
transducer
Verify wires connection and
transducer
Main Unit is faulty

Contact Technical
Assistance
25
Angle High
Angle transducer (inclinometer) ACT is

faulty
signals
31 / 55
Transducer Length 2
High
functionality
in short circuit
Main Unit is faulty
Length transducer II (potentiometer)
ACT is faulty
signals
56
functionality
in short circuit
Main Unit is faulty
Memory data not reliable
Switch the System off / on
E2PROM KO
Contact Technical
Assistance
page 33/34
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
page 34/34
Accessories
V
Accessories
Chapter V ed. 10-2009
page 1/18
Page 2/18
Accessories
Accessories
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
page 3/18
Accessories
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.
Page 4/18
Accessories
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.
page 5/18
Accessories
Stowing the lattice extension on the boom side

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.
Page 6/18
Accessories
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
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.
page 7/18
Accessories
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
Page 8/18
Accessories
Deployment of the extension in work position

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
page 9/18
Accessories
Push the extension towards the boom head
to enable insertion of pins C and D.
Insert pins C and D.
Page 10/18
Accessories
Remove pin G on the rear bracket and pin A on the front bracket.
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.
Position rope idler sheave H vertically.
page 11/18
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.
Page 12/18
Accessories
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.
page 13/18
Accessories
To offset the extension 0, proceed as follows:

The jack (fig.5a) must be locked in position 1.
Fig.5a

Release the jack
Raise the boom to lock the jack (fig.5b) in position 2.
Position the locking pin
15
Fig.5b
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.
Fig.5c
30
Before every job with the extension, always bring the rod to the rest
position.
Page 14/18
Accessories
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.
page 15/18
Accessories
Insert pin C and remove pins E and F that secure the extension to
the boom head.
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.
Page 16/18
Accessories
Insert pin A to secure the extension to the front support.
A
B
Remove pins C and D
Move the extension away from the telescopic boom for inserting pin B
on the front support.
page 17/18
Page 18/18
Accessories
Maintenance
VI
Maintenance
Chapter VI ed. 07-2012
page 1/66
page 2/66
Maintenance
Maintenance
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.
page 3/66
Maintenance
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.
page 4/66
Maintenance
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.
page 5/66
Maintenance
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:
page 6/66
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.
Maintenance
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
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
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.
page 7/66
Maintenance
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.
page 8/66
Maintenance
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.
page 9/66
Maintenance
Check boom telescoping ropes (RC45-RC60-RT100)

Check lengthening.
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.
page 10/66
Maintenance
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.
page 11/66
Maintenance
Visual examples of various problems that can occur to the rope
Breakage and tearing of wires on two consecutive strands that required

replacement (crossed strands)
High wear and very many broken wires that required immediate replacement
(crossed strands)
Broken wires on the same strand and slight wear
Broken crossed wires at the equalizer pulley
page 12/66
Maintenance
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.
page 13/66
Maintenance
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.
page 14/66
Maintenance
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.
page 15/66
Maintenance
Rope maintenance and removal

To increase the life of the ropes, after 500 hours of operation, remove
and extend the rope on the ground (clean ground). Rewind the rope on
the winch.
The crane ropes must be checked very carefully and replaced, without
economizing, in case of the slightest mishap.
Maintenance is generally performed by greasing. The rope must be
greased at regular intervals according to needs and mainly in the bending
areas.
The lubricant must be compatible with the greases used by the
manufacturer. It is advisable to use oils which, unlike greases,
can penetrate inside the rope. Lubrication reduces breakages due
corrosion, wear and the coefficient of rubbing when the rope slides on
the sheaves and winds on the winch drum.
page 16/66
Maintenance
Availability
Pulley n
Weight
(kg)
RC30
RT35
RC35
RC40
RC45
A600
RC60
5t
50
8t
160
10t
170
12.5t
255
15t
195
25t
260
35t
280
35t
280
40t
485
40t
485
45t
400
45t
400
60t
60t
Capacity
Type
RT75
RT100
610
610
75t
750
80t
690
90t
800
page 17/66
Maintenance
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.
page 18/66
Maintenance
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
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
818 897 Nm
1257 1382 Nm
1 1/8
1098 1206 Nm
1781 1957 Nm
1 1/4"
1549 1703 Nm
2511 2762 Nm
page 19/66
Maintenance
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.
page 20/66
Maintenance
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
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
RT75 pressure points
Outrigger
pressure point
Pressure point for winches, lifting cylinder,

telescopic cylinders, slewing
Steering
pressure point
page 22/66
Maintenance
RT100 pressure points
Outrigger
pressure point
Pressure point for winches, lifting cylinder,

telescopic cylinders, slewing
Steering
pressure point
page 23/66
Maintenance
Quantity of oils
Quantity of lubricant
Part description
um
RC30
RT35
RC35
RC40
RC45
A600
RC60
RT75
RT100
Engine oil
18
18
18
18
18
18
18
18
Gearbox oil
22
22
22
22
32
19
19
41
Front + rear axle oil
37
43
43
43
64
69
69
82
Slewing reduction gear oil
Total
460
600
600
600
800
800
900
1380
Tank
390
470
470
470
600
600
660
1000
Main winch oil
12
12
12
12
28
20
20
42
Auxiliary winch oil
12
12
12
12
12
12
20
12
Brake fluid
1.05
1.05
1.05
1.05
///
///
///
Boom guide blocks grease
kg
10
10
Slewing ring, pin,

bearings grease
kg
Radiator antifreeze
11
11
18
13
Hydraulic
circuit oil
page 24/66
Maintenance
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
page 25/66
Maintenance
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
Method:
- Machine outdoors
- Boom horizontal.
- Extend the 4th section.
- Grease
- Retract the 4th section.
- Extend the 2nd and 3rd section
- Grease
mechanism.
Boom RC40
Method:
- Machine outdoors
- Boom horizontal.
- Extend the 4th section mechanically.
- Grease
- Retract the 4th section.
- Extend the 2nd and 3rd section
- Grease
mechanism.
page 26/66
Maintenance
Boom A600 RC45 RT75

Method:
- Machine outdoors
- 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
mechanism.
Boom RC60
Method:
- Machine outdoors
- 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
mechanism.
page 27/66
Maintenance
Boom RT100
1
6
4-5
Boom lubrication chart

Frequency
Ref.
Identification
Operation:
Grease points:
50 h
Boom base section
Greasing
2 grease nipples
250 h
Slide pads
Greasing
Brush and grease nipples
Electric system
Check
Wiring harnesses
Fasteners
Check tightness
All fasteners
Slide pads
Check condition
All pads
Pulleys
Check condition
1000h
page 28/66
Maintenance
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
- Blocked boom tilted to 2.
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.
page 29/66
Maintenance
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.
page 30/66
Maintenance
Telescope T3 alone 100%.

Telescope T4, T5, and T3 alone 100%.

page 31/66
Maintenance
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.
page 32/66
Maintenance
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).
page 33/66
Maintenance
page 34/66
Maintenance
Fuses
Model RC30, RT35, RC35, RC40, RC45, A600
page 35/66
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
page 36/66
Maintenance
Maintenance
Models RC60 RT75 - RT100
RT100
RC60
page 37/66
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
page 38/66
Maintenance
Code
K1
K2
K3
K4
K5
K6
K7
K8
K9
K10
K11
K12
K13
K14
K15
K16
K17
K18
K19
K20
K21
K22
Function
Outriggers relay
2nd winch speed relay
2nd gear relay
3rd gear relay
not used
Horn relay
not used
Intermittent device
Differential lock solenoid valve relay
Relay not used
Reverse gear relay
Forward gear solenoid valve relay
High-beam headlights relay
Low-beam headlights relay
Suspension lock relay
Work light relay
1st gear relay
Air conditioning relay
Free slewing relay
Start-up interlock relay
3B-6 extended boom control relay
3B-6 retracted boom control relay
page 39/66
Maintenance
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
- 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
page 40/66
Maintenance
List D every 250 hours

Operation:
- engine
- air filter
- 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:
- engine
- air dryer
- 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
page 41/66
Maintenance
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
Efficiency of load holding valve on extension cylinder (check that
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
- boom section guide blocks
- winch gears and reduction gear
- braking system
- brakes
page 42/66
Maintenance
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
page 43/66
Maintenance
List A 8 hours
Air filter
Clean the clogging indicator (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.
page 44/66
Maintenance
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.
page 45/66
Maintenance
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.
page 46/66
Maintenance
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.
page 47/66
Maintenance
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.
page 48/66
Maintenance
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

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.
page 49/66
Maintenance
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.
page 50/66
Maintenance
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.
page 51/66
Maintenance
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.
page 52/66
Maintenance
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
-
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.
page 53/66
Maintenance
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.
page 54/66
Maintenance
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.
Air filter
Clean the cap collector of dust.
Check the clogging indicator.
Change the air filter cartridge.
page 55/66
Maintenance

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.
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.
page 56/66
Maintenance
List E 500 hours

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.
Engine
Check the alternator and starter motor, adjust the valve clearances and
check the injectors.
page 57/66
Maintenance
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.

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).
page 58/66
Maintenance
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)
Check integrity of tie-rope for boom telescoping
page 59/66
Maintenance
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.

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.
page 60/66
Maintenance
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.

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.
page 61/66
Maintenance
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.

Change the oil and the filter cartridge.
Change the filter cartridge at every oil change.

page 62/66
Maintenance
Braking system
Check the brake cylinder fixing elements.
Check the brake circuit lines and replace them if necessary.
page 63/66
Maintenance
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.
Replace the brake circuit lines every 2000 hours or once a year.
page 64/66
Maintenance
Cooling circuit
Change the radiator coolant every 2000 hours or at least once a year.
A.
B.
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.

page 65/66
Maintenance
Model Company
Serial number
Head of maintenance:.
Reference list: ".........."
Operating hours: ........................................
Maintenance points:
.........................................................................................................
.........................................................................................................
.........................................................................................................
.........................................................................................................
.........................................................................................................
.........................................................................................................
.........................................................................................................
.........................................................................................................
.........................................................................................................
.........................................................................................................
.........................................................................................................
.........................................................................................................
.........................................................................................................
.........................................................................................................
Date: . / ... / .
page 66/66
Signature: ......................................
Inspections
Maintenance and operator's manual
VII
Inspections
Chapter VII ed. 04-2011
page 1/8
page 2/8
Inspections
Inspections
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
page 3/8
Inspections
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
page 4/8
Inspections
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 -)
page 5/8
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
page 6/8
Inspections
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)
page 7/8
page 8/8
Inspections

RC30 RT35 - ENG Rev.07

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

RC30 RT35 - ENG Rev.07

Încărcat de

Drepturi de autor:

Formate disponibile

RC30-RT35

Operation and maintenance

ROUGH TERRAIN CRANES

Operation and maintenance manual

Code: 46953 (eng) - rev.07

Operation and maintenance manual

Translation of the original instructions

This manual is valid for

Operation and maintenance manual

Code: 46953 (eng) - rev.07

Operation and maintenance manual

III. Safety and operation

IV. Control instruments

This manual must always be accompanied by

Operation and maintenance manual

Code: 46953 (eng) - rev.07

Operation and maintenance manual

Chapter I ed. 04-2011

Operation and maintenance manual

Chapter I ed. 04-2011

Operation and maintenance manual

Chapter I ed. 04-2011

Operation and maintenance manual

Chapter I ed. 04-2011

Operation and maintenance manual

Crane performance data

Boom length (retracted / extended)

Boom head height

Truck performance data(1)

Max. travel speed (with tyres 14.00R24)

Max. travel speed (with tyres 16.00R25)

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

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

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

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

Chapter I ed. 04-2011

Operation and maintenance manual

Double box-type member.

no. 4 independent hydraulic outriggers on hydraulic beams.

CUMMINS QSB 4.5 :

DANA 20000 series:

Operating: double circuit hydropneumatic drum brakes on all wheels.

Rigid on front axle, rocking for rear axle.

Hydrostatic by steering wheel in the operator's cab.

4 14.00R24 tubeless tyres

Chapter I ed. 04-2011

Operation and maintenance manual

1 double-acting hydraulic cylinder.

Continuous and proportional extension of elements 2 and 3 by means of a double-acting

Wide visibility with sliding door. Equipped with heating.

Stop valves on boom extension and lifting jacks and on outriggers.

Hydraulic power source: 2 double gear pumps.

Chapter I ed. 04-2011

with 90 A alternator and two 132 Ah batteries.

Operation and maintenance manual

() Values with auxiliary winch

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

Chapter I ed. 04-2011

Operation and maintenance manual

Crane performance data

Boom length (retracted / extended)

Boom head height

Truck performance data(1)