RT100 - Op Manual

RT100 Operation and maintenance
m
ROUGH TERRAIN CRANES
SERIAL NUMBER.....................................
Maintenance and operator's manual
Code: 46848 (eng) - rev.00

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.
Manufacturer: After-sales service:
TEREX ITALIA S.r.l. TEREX ITALIA S.r.l.

Via Cassoletta, 76 – 40056 Crespellano Via Cassoletta, 76 – 40056 Crespellano
BOLOGNA – ITALY BOLOGNA – ITALY
Fax (+39) 051734645 Fax (+39) 0516501015
Tel. (+39) 0516501011 Tel. (+39) 051736613
e-mail: terexitalia@terex.it e-mail: assistance@terex.it
Code: 46848 (eng) - rev.00

Code: 46848 (eng) - rev.00

Index
I. Characteristics Edition: 11-2009
II. Warnings Edition: 11-2009
III. Safety and operation Edition: 11-2009a
IV. Control instruments Edition: 11-2009

Load Limiter Edition: 11-2009
V. Accessories Edition: 11-2009
VI. Maintenance Edition: 02-2010
• Control register
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: 46848 (eng) - rev.00

Code: 46848 (eng) - rev.00

Characteristics Maintenance and operator's manual
I
Characteristics
Chapter I - ed. 11-2009 page /8

Maintenance and operator's manual Characteristics
page /8 Chapter I - ed. 11-2009

Contents
Crane performance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Carrier performance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7


Crane performance
Capacity at 3 m from slewing ring axis (CE) 90 t
Boom length (retracted / extended) 11.5 / 53 m
Boom head height 55.8 m
Truck performance(1)
Maximum travel speed (on 26.5R25 tyres) 31 km/h
Maximum travel speed (on 29.5R25 tyres) 33 km/h
Max. theoretical ramp during operation (on 26.5R25 tyres) 75 %
Max. theoretical ramp during operation (on 29.5R25 tyres) 67 %
(1)
Standard crane in operating conditions: without auxiliary winch, without extensions
Weight(2)
1st axle 2nd axle Total
27.7 t 30.3 t 58 t
(2)
Standard crane: no auxiliary winch and no extensions, on 29.5R25 tyres
Truck
Traction/Steering 4x4
Frame Double box-type member.
Front tow point (optional rear tow point)
Outriggers no. 4 independent hydraulic outriggers on hydraulic beams.
Stabilization with beams retracted, partially or fully extended.
Controlled from operator's cab
Engine CUMMINS QSB6.7:
6 in-line cylinders - Displacement 6.7 dm3 - Liquid cooled with intercooler - Turbocharger -
Common rail.
Max. power 194 kW at 2200 rpm - Max. torque 987 Nm at 1500 rpm.
Certification 2004/26/CE Phase IIIA
Tank 300 l
Transmission DANA 36000 series:
Powershift type with torque converter.
4 forward gears and 4 reverse
4 permanent drive wheels.
Oil cooler.
Brakes Operating: with disc on all the pneumo-hydraulic wheels.
Parking / Emergency: with disc on the front pneumo-hydraulic propeller shaft
Axles no. 2 drive and steering axles with epicyclic reduction gears in the hubs. Possibility of blocking
the front and rear differential.
Suspensions 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.
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 no. 4 29.5R25 tubeless tyres.

Optional no. 4 26.5R25 tubeless tyres

Upper structure
Boom no. 6 elements
Lifting no. 1 double-acting hydraulic cylinder.
Boom angle from -1° to +78°
Extension Elements 2 and 3 are extracted proportionally and independently with respect to the others by
means of a two-stroke cylinder. Elements 4 and 5 are extracted proportionally and continuously
by means of a double-acting hydraulic jack. Element 6 can be extended proportionally to the
others by means of an internal chain drive system.
Extension under partial load possible.
Winch Controlled by double displacement axial piston hydraulic motor with planetary gearbox. Automatic
negative brake. Rope tensioner. Two rotation speeds. Rope diameter 18 mm length 300 m. Max.
lifting capacity 8000 daN. “Lebus" profile drum.
Optional auxiliary winch controlled by fixed displacement hydraulic axial piston motor with planetary
gearbox. Automatic negative brake. Rope tensioner. Rope diameter 15 mm length 175 m. Max.
lifting capacity 3800 daN. “Lebus" profile drum.
Rotation 360° continuous by means of hydraulic motor and epicyclic reduction gear on double row ball type
turntable with internal teeth. Automatic negative brake.
Brake release for direct alignment of boom along load vertical line
Cab Wide visibility with sliding door. Equipped with air-conditioner.

Front and upper window with windscreen wiper.
Openable upper and rear windows.
Completely adjustable seat on anti-shock suspensions, equipped with raisable arms.
Two-axis joystick fitted on the armrest.
Safety Stop valves on boom extension and lifting jacks and on outriggers.
Max. pressure valves on each hydraulic circuit.
Balancing braking valve for rotation 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 lifted
Max. liftable load
Telescopic boom movement limits and superstructure slewing angle limits can be set
Systems
Hydraulic Power source: no. 1 double gear pump and 1 double piston pump with variable displacement.
Movements control: electro-pneumatic control valve
Outriggers control: solenoid valves controlled by separate pushbuttons.
Filtration: no. 1 cartridge filter on the return circuit.
Hydraulic oil cooler.
Electrical 24 V with 70 A alternator and no. two 180 Ah - 850A batteries.

Lighting devices in conformity with EU directives
Pneumatic 247 cm3 compressor, no. two 45 l tanks, drier and electric heater.
Auxiliary air intake and tyre inflation kit

Dimensions


Instructions Maintenance and operator's manual
II
Instructions
Chapter II - ed. 11-2009 page /14

Maintenance and operator's manual Instructions
page /14 Chapter II - ed. 11-2009

Contents
General Information � �� 5

List of stickers�� 10
Position of decals on the machine � �� 13


General Information
This machine complies with Directives 98/37/EC, 2004/108/EC, 2005/88/
EC.
The weighted average quadratic value, in frequency, of acceleration to
which the operator's upper limbs are exposed is less than 2.5 m/s2.
The average frequency-weighted quadratic value of acceleration to which
the operator's body (feet or seated part) is exposed is less than 0.5 m/s2.
This crane is designed as a lifting device with hook made of materials
according to class S0 - HC1 in compliance with EN 13000 standards,
for travelling mainly on worksites, on hard ground and on gradients of no
more than 18%.
For greater distances (over 10 km) the crane must be carried on a trailer
or flatbed truck.
Driving on public roads is permitted in compliance with current laws and
regulations.
This crane is designed for use at temperatures not lower than -20°C and
not greater than +45°C, in relation to its configuration.
The machine does not comply with the prescriptions of directive 94/9/CE,
(ATEX), so it is not suitable for use in potentially explosive atmospheres.
The crane should not be used in the presence of strong magnetic fields.
This crane is designed to operate in winds of up to 30 kph. Use of the

crane in dusty conditions is subject to taking all the necessary precautions
for safeguarding the operator, and suitable increase in the frequency of
maintenance and lubrication intervals.
Max. sound pressure LpA, measured inside the cab at the height of the
operator's ears, with door closed, crane stopped and with the engine at
3/4 max. rpm is 78 dB (A).
Fuel specifications
Using fuel with more than 5000 ppm of sulphur is NOT allowed.
Corrosion of the distribution system, high levels of emissions and
shortening of the time between engine oil changes are just some of the
negative consequences of the use of fuel with excessively high sulphur
contents.
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.

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.
XXX
The data on the dataplate are guideline and do not correpond 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.

The owner of the machine or the person hiring it must ensure that the
operator has:
• received all the necessary instructions for correct and safe operation
of the machine.
• fully understood and memorized all the instructions in this manual.
Caution
For safe crane operation, use the load capacity tables given in
this manual or located in the operator's cab.
Before starting the engine:
warning
● 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 the manufacturer's
instructions on machine operation, and compliance with the applicable
laws and regulations
Caution
The warranty will be invalidated in case of negligence,
lack of maintenance, improper use of the material by the
purchaser or his personnel, non-compliance with the
technical instructions relevant to the warranty.
Note: If the manuals and load tables are defaced or lost, request copies from your dealer or
directly from the manufacturer.

warning
BUNGEE JUMPING FROM CRANES IS DANGEROUS
TEREX Italia, designs, manufactures and sells safe and reliable products
for handling materials, and NOT PERSONS.
Therefore, we believe that using tahe crane for lifting, lowering or moving
persons for bungee jumping is dangerous and highly inadvisable.
Such improper use of the products is neither envisaged nor

approved by TEREX Italia.
Our products are not designed, manufactured, tested or devised to
carry personnel.
Lifting persons for bungee jumping is inherently dangerous; make sure to

read the section on Safety Regulations to know the risk of injury, and the
warnings against using cranes to lift persons.
All Dealers and Distributors are requested to use every reasonable

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

DANGEROUS.
Use of the crane with:

• shovels, grabs, magnets or similar equipment
• Vibrating equipment.
• Demolition equipment.
must be authorised by TEREX.
It is also strictly prohibited to use the crane when visibility is poor. The
operator must be in optimal physical condition, be able to read and
understand the manual and the crane load tables, and have specific
knowledge of the crane and basic training on the operation of self-
propelled industrial equipment.
Holding of a driving licence is compulsory in compliance with the current
laws and regulations.

warning
It is essential to carry out all the prescribed lubrication and maintenance

operations to ensure the safety and reliability of the machine, irrespective
of the type. Some of these operations, described in the Maintenance
Manual, require special equipment and technical knowledge. Non-
compliance with the lubrication and maintenance instructions can result
in serious accidents.
CAREFULLY READ ALL THE SAFETY INSTRUCTIONS BEFORE

LUBRICATING AND SERVICING THE MACHINE.
Preventive measures against possible hazards in maintenance operations

are outlined in the section on "Safety". Also, warnings against some
hazards that can cause serious accidents are affixed to the machine.
TEREX Italia is not in a position to know how maintenance operations are

performed, or all the risks relevant to particular methods, and therefore
is unable to advise maintenance personnel. Therefore, anyone using
an unsuitable method or a tool not recommended in the Manual must
previously make sure there are no risks for the operator or others, that the
machine will not be damaged and safety is not compromised.
Caution
In the event of an accident, no claims against TEREX Italia
will be accepted unless a person authorized by TEREX Italia
has written a report on the actual circumstances, before the
machine is removed from the scene.
Caution
At the time of decommissioning of the machine contact local
authorities to ensure correct disposal of the various parts.
Pay special attention to the counterweights and accumulators
since they may contain lead.

List of stickers
Caution
Do not remove the decals affixed to the crane.
Worn or deteriorated stickers 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
page 10/14 Chapter II - ed. 11-2009

CAUTION: moving parts
CAUTION: moving parts with danger of crushing
CAUTION: generic danger
CAUTION: inflammable
CAUTION: danger of falling
Chapter II - ed. 11-2009 page 11/14

1 2 3 4
36985
CAUTION: pressurised components (1), high temperature (2), fire hazard

(3), moving parts (4).
CAUTION: pressurised hydraulic accumulator; before performing any

maintenance consult the instruction manual for the relevant procedures.
COMPULSORY: read the Operator's Manual located in the operator's

cab
CAUTION: emergency exit

Position of decals on the machine

10 9 4
2 2 7
3 10
2 2 6
5 5
Chapter II - ed. 11-2009 page 13/14

1 6
2 7
Hydraulic Oil
Shell Tellus T32 45618
3 8
4 9
5 10

Safety and operation Maintenance and operator's manual
III
Safety
and
Machine operation
Chapter III - ed. 11-2009a page 1/66

Maintenance and operator's manual Safety and operation
page 2/66 Chapter III - ed. 11-2009a

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.

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.


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.

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?

SAFETY CHECK BY OPERATOR
Every day. 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.

OPERATION PRECAUTIONS
1. Mistakes in calculating lifting capacity can cause accidents, therefore

factors such as the following must be considered:
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 that is not specified in the load table, trying to
guess the capacity in relation to boom length, radius, or inclination
angle is extremely dangerous; the crane could sway or tip over while
the load is being lifted.
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 slewing of the superstructure with

respect to the carrier 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.

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 power
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 machine is in working order: the operator must

move the machine away from the live electrical infrastructure without
leaving the cab.
• 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).

• 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.

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.

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.

27. Shifting loads with the crane moving involves a considerable

increase in risk. Manually block slewing movements with the pin located
in the operator's cab, observe the precautions illustrated 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 secure the load to the crane structure. 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 wire rope onto winch 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.

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.

General instructions
IMPORTANT: all operators must be familiar with the operating

instructions given 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.

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.
Opening the window upward creates an opening of 730 mm x 560
mm with the normal manual opening and of 730 mm x 850 mm by
unhooking, with a simple manoeuvre, the supporting gas struts.

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).

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.

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.

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.

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.

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 li0nes 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.

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.
TIGHTENING TORQUE
TRUCK CRANE MODEL
M22 x 1.5
A350-1 450÷550 Nm
RC30 / RC30-1 / RT35 450÷550 Nm
RC35 / RC40 / RC45-1 450÷550 Nm
A600-1 450÷550 Nm
RC60 / RT100 650 Nm

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 that is not specified in the load table, trying to
guess the capacity in relation to boom length, radius, or inclination
angle is extremely dangerous; the crane could sway or tip over while
the load is being lifted.
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.

Choosing the best configuration
Before handling any load, put the machine in the best configuration for
the work to be carried out and choose the table that meet all the needs.
1 2 3 4 5

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.

The capacities given refer to the radius under load and therefore take
into account boom flexure. Therefore it must be considered that the
radius measured without load is less than that measured with the load
on the hook. This must be taken into account before lifting the load in
order to maintain the same radius.
boom with
no load
boom angle
with load
10.Index of reference symbols for reading the various configurations in

the load table.
10

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

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.

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.

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.

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

Max. forces exerted on ground (daN)
Model
RC30 28000 Ø 525 mm
RT35 27000 Ø 525 mm
RC35 27000 Ø 525 mm
RC40 27000 Ø 525 mm
RC45 39000 Ø 525 mm
A600 45000 Ø 650 mm
RC60 55000 Ø 650 mm
RT100 70000 Ø610 mm
Model
0 km/h - 360° 0 km/h - 0° 2 km/h - 0°
RC30 14.00R24
17750 17750 14000
RT35 16.00R25
16.00R25
RC35 18400 18400 14450
20.5R25
16.00R25
RC40 18400 18400 14450
20.5R25
16.00R25
RC45 18400 18400 14450
20.5R25
23.5R25
A600 23200 23200 18200
26.5R25
23.5R25
RC60 23200 23200 18200
26.5R25
26.5R25
RT100 34500 34500 28100
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 m²/tonne.
WARNING: Every day, check the weather and wind speed forecast by
calling the nearest weather station. Do not lift the load if the wind speed
is higher than the maximum permissible.
1.2 m²
12 m²
1 tonne.
Wind
10 tonnes.
Wind force Wind speed Consequences
Scale Terms described mps kph Inland territories
0 Calm 0 – 0.2 1 Calm, smoke rises vertically

Wind direction indicated by smoke
1 Very light 0.3 – 1.5 1-5 and not by the banner
The wind can be felt on the face, the
2 Light breeze 1.6 – 3.3 6 - 11 leaves rustle, the banner moves
Leaves and small branches move,
3 Gentle breeze 3.4 – 5.4 12 - 19 banners lift
The wind raises dust and leaves.
4 Mild breeze 5.5 – 7.9 20 - 28 Branches move
Small bushes sway. Wave crests
5 Fair breeze 8 – 10.7 29 - 38 form on the sea
6 Strong breeze 10.8 – 13.9 39 - 49 Large branches sway
7 Strong wind 14 – 17.1 50 - 61 All the trees sway

The wind breaks branches, difficulty
8 Wind gust 17.2 – 20.7 62 - 74 in walking freely
Damage to houses (tiles and
9 Strong wind gust 20.8 – 24.4 75 - 88 chimneys blown away)
Trees uprooted and considerable
10 Storm 24.5 – 28.4 89 - 102 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

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.

Limit stop device
In compliance with the safety regulations, the crane truck is equipped

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

the limit stop device, therefore we recommend checking its operation
daily.

Lowering limit stop device
The purpose of the lowering limit stop device is to stop the winch
lowering movement when there are only three turns of the rope on the
drum; in this condition the feeler tilts, touching the winch drum and
activating the microswitch that interrupts the safety electrical circuit,
blocking the lowering movement.
In this condition, the lifting movement that will bring the device within its
normal operating limits can be activated.
“Three dead turns" safety switch adjustment method:

- Unwind the rope so that 3 turns remain wound on the winch
- If the 3 dead turns safety device is inactive, turn adjuster screw (A - B)
to move the cam until you hear the switch trip.
- Then carry out the lifting operation in descent to check that the safety
is active.
- Wind the rope additional turns and test the safety of the movement.
The "3 dead turns" safety contactors must disconnect the winch hook
descent functions.
A
B
Periodically check feeler wear and operate the device adjustment or

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

readjusted.

Model TW8 (RT100)
Legend:
1. Winch drum
2. Lifting rope
3. Return spring
4. Limit switch
5. Adjustment screw
6. Cable clamp
2 1
6
3
Model SW6 (A600)
Legend:
1. Winch drum
2. Lifting rope
3. Drum feeler
4. Return spring
5. Limit switch
6. Adjustment screw
7. Cable clamp
2
1
7 3
5 4

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

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 button
on the load limiter system's display.
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.

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 wiper liquid level
- Winch rope

Engine starting
Before starting the engine, make sure there are no persons or objects in
the immediate vicinity of the machine.
1. Make sure the gearshift lever is in the neutral position "N".

2. Select the fast or slow gears according to needs (where applicable).
3. Turn the ignition key.
4. The battery level, braking system air circuit, engine oil pressure and
coolant temperature warning lights on the instrument panel come
on.
5. Beep the horn.
6. The parking brake must be applied.
7. Turn the ignition switch to the second position to start the engine.
NOTE: The engine cannot be started if the gear lever is not in the neutral
position "N".
IMPORTANT: To avoid permanent damage to the starter motor, do not

operate it continuously for more than 30 seconds at a time. If within that
time, the engine fails to start, wait a couple of minutes before trying
again, but do not operate the starter for more than 15-20 seconds.
If the engine still does not start, wait for the starter motor to cool before
trying again and make sure the gearshift lever is in the neutral position
"N".
IMPORTANT: When operating the crane at temperatures below 0°C,

after starting the engine and before using the crane, allow the engine to
idle for several minutes to allow the hydraulic oil to reach its working
temperature.
When the engine has started and idles normally:

the oil pressure and battery level lights go off, and the air pressure
warning light goes off 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.

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. Retract the boom completely

2. Attach the block anchor stay to the front of the chassis.
3. Position the block so that it is vertically aligned with the anchor stay.
4. Lower the block and secure it to the anchor stay.
5. 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. Retract the boom completely

2. Attach the block anchor stay to the top of the chassis.
3. Position the block so that it is vertically aligned with the anchor stay.
4. Lower the block and secure it to the anchor stay.
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

Release
To release the block from the front of the chassis: Fig.1
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
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

Driving on road
Preliminary operations
1. Align the turret with the carrier (boom on the front end).
2. Make sure the device locking the turret to the frame is engaged.
3. Secure the block to the top of the chassis.
4. Make sure the suspension is free (warning light off).
5. Make sure the ground support plates and outrigger beams are
locked in place.
6. Check the general operation of the lights.
7. Check the tyre pressures.
8. Adjust the rear-vision mirrors.
9. Make sure that, once seated in the cab, the entire machine can be
controlled through the rear-view mirrors.
10. Ensure all the bonnets are fastened.
11. Never drive the machine on the road with a suspended load.
12. Make sure the machine's electrical system works properly
(headlights, blinkers, parking lights, etc.).
13. Carrying passengers is not allowed.
14. Respect the speed limits.
15. Strictly respect the highway code.
16. As a part of the boom projects over the front of the machine, a
guiding car is necessary when crossing intersections.
17. Make sure all the roads on the route will take the road dimensions
and weight of the machine.
WARNING: The operator must make sure he has complete and ample
visibility of the area around the machine when proceeding by road.
Only front-wheel steering is allowed on the road (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).

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.

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 the outrigger beams

REMEMBER TO REMOVE the locking pins.

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
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.

Guideline table of permissible pressures for various types of

terrain
daN/cm²
Terrain Types (kg/cm²)
Type A Naturally compressed soil, backfill 0.5 -1.0
Intact natural terrain
Powdery but firm soil:

Fine or medium particle size
1.5
sand
Large particle sand - gravel 2.0
Non-powdery terrain:
Type B Soft 0.4
Firm 1.0
Semi-rigid 2.0
Hard 4.0
Rock with few fissures in good condition,
15
unaffected by weathering and in strata:
Close stratification, compact stratification or
30
column stratification
Artificially compacted terrain
Asphalt and bitumen 5 - 15

Type C
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.

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
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.

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.

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.

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
Broken wires on the same strand and slight wear

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.

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.
boom axis boom axis
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.

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.
lifting line boom axis lifting line boom axis

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. Lower the boom and rest the block on the ground

2. Remove the wedge box from the boom head.
3. Remove the clamp from the rope end.
4. Remove the wedge and the rope from the wedge box.
5. Withdraw the rope from the limit stop counterweight.
6. 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.
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.

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.

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 load limiter performs its function correctly when using just one block
at a time (work with main boom or work with extension); when working
with two blocks the limited must be set to extension mode.
Since the effective load is lifted by two blocks simultaneously, the

maximum load is equivalent to the maximum total load permitted with an
extension during load handling with the extension (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.

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

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.

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.

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.

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.


Control instruments Maintenance and operator's manual
IV
Control
instruments
Chapter IV - ed. 11-2009 page /34

Maintenance and operator's manual Control instruments
page /34 Chapter IV - ed. 11-2009

Contents
Identification of the controls � �� 5

Controls in the cab � �� 6
Central controls column�� 8
Lateral instrument panel�� 15
Hand controls � �� 19
Left hand control��19
Telescopic boom extension mode selection��22
Right hand control ��27
Battery disconnecting switch�� 29
Air conditioner control in operator's cab� �� 29
Telescopic boom�� 30
Machine layout�� 31
Operator's seat � �� 32
Seat adjustments��33


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.

Controls in the cab

1 2
14
7
13
12
11 10 9
1 - Operator cab lights

2 - Lever to open the upper fanlight window.
To open the upper window press the locking pin fully down, rotate the
lever and push upwards.
3 - Armrest locking lever. Locks the armrest in the vertical position to
allow the operator to enter or leave the cab.
4 - Turret slewing locking pin.
Lift the RH armrest to access the locking pin.
To lock the upper part of the machine, align the truck (boom on front
end), lift the pin, turn it clockwise 90° and lower it in the special
seat.
Caution
Never insert the pin while the superstructure is turning.
Failure to comply with this precaution can seriously damage
the upper part and the truck.
Slewing of the superstructure must always be locked when

moving the crane.
5- Central controls column

6 - Lateral instrument panel
7 - Right hand joystick
8 - Parking brake control.
Located under the right armrest, the parking brake control serves to
apply or release the parking brake.
9 - Accelerator pedal
10 - Service brake pedal
11 - Air conditioning control
12 - Outrigger movement consent button
13 - Left hand joystick
14 - Spirit level
Allows correct stabilization of the machine

Central controls column

15 16
20
17
18
21
19
22
15 - Instrument panel with display
Direction indicator warning light

Green warning light

Engine coolant temperature warning light
Red warning light

Rear axle oscillation lock indicator light

The rear suspension locks automatically if the upper structure
is turned to the left or right by more than 3° with respect to the
machine's longitudinal axis. This light comes on indicating that
the suspension is locked.
Red warning light
warning
If the 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.
Not connected
Parking lights / low beam light

Green warning light

STOP warning light
When this red indicator light illuminates 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.
ALARM warning light

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

It comes on when the rear wheels are aligned with the
longitudinal axis of the truck.
Red warning light
Brake fluid level warning light (not connected)

Red warning light
Rear axle brake circuit low pressure warning light

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

The light comes on when the braking circuit pressure falls below 5.5 bars
during machine operation.
Red warning light
warning
Do not use the machine until the red light is extinguished.
Front axle brake circuit low pressure warning light

The normal brake working pressure exceeds 5.5 bars.
The light goes off when the engine is started and the pressure has reached
5.5 bars.
The light comes on when the braking circuit pressure falls below 5.5 bars
during machine operation.
Red warning light
warning
Do not use the machine until the red light is extinguished.
Parking brake on warning light

The light comes on when the parking brake is on.
Red warning light
Engine oil pressure warning light

Comes on when:
- The engine oil pressure is below 3 bars
- The engine is idling
Red warning light
Battery charge light

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

Yellow warning light
page 10/34 Chapter IV - ed. 11-2009

High beam light

The light comes on when high beams are on.
Blue warning light.
Fuel gauge
This gauge shows the fuel reserve in the tank
Engine coolant temperature gauge

Normal working temperature is between 83°C and 95°C. The coolant
temperature must not exceed 100°C.
NOTE: If the temperature reaches 100°C stop the engine immediately
and check the cooling circuit.
Central display showing:

A Engine error code
B Engine rev counter
C Hour-meter
16 - Steering wheel
Chapter IV - ed. 11-2009 page 11/34

17 - Steering column switch
Press the button on the end of the lever to activate the windscreen wiper
and washer jets to clean the windscreen.
Push the lever forward to operate the turn indicators to turn right.
Pull the lever backward to operate the turn indicators to turn right.
Turn the knob and select J to activate the windscreen wiper first speed or
I for the second speed (II not connected). Turn the knob to position 0 to
switch off the windscreen wiper
After activating the lights switch, move lever upwards to flash high beam
headlights and move it downwards to switch on high beam headlights.
Bring lever to central position for low beam headlights.
18 - Ignition key
Ignition switch on = OFF.
Turn clockwise to I to power the electrical circuit. Turn to position
to activate the starter motor and start the engine.
Release the key as soon as the engine starts. Once released, the
key returns automatically to position I.
Return the key to stop the engine.
19 - Steering column buttons

Main switch and lights

Two-position switch:
- side lights and control panel lights
- Low beam headlights

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

Press this button to switch on the worklight on top of the cab to
illuminate the work area.
Rear fog light switch

Press to switch on the rear red light in case of fog.
This control locks the front and rear axle differential of the
machine. The differential remains locked until the control switch
is operated.
Move the gear lever to the neutral position "N" before using this
control.
Note: This mode must only be used for work on very rough ground.
Caution
Do not use rear axle steering when the differential is locked.
Return to the normal position after overcoming an obstacle.

20 - Gear lever
Neutral position: lever in central position

The lever must be in the neutral position:
- when the machine is stationary
- to lock or release the rear axle steering
- to start the engine
Pull lever upwards and move forward to engage forward gear
Select first gear by turning the ring forward to position I, release the parking
brake and accelerate. In first gear the machine starts to move forward;
change gear (II, III and IV) as the speed increases, by turning the control
ring forward.
Pull lever upwards and move backward to engage reverse gear

Select first gear by turning the ring forward to position I, release the parking
brake and accelerate. The machine reverses in first gear; change gear (II,
III and IV) as the speed increases, by rotating the ring forward
21 - Emergency lights switch
When pressed, the six blinkers work at the same time,

signalling a machine emergency situation.
Intermittent red warning light.
22 - Steering column rake adjustment lever

Lateral instrument panel
35
23
34
24
33
32 25
31
26
30
27
29
28

23 - Alarm indicator lights

Inactive

Inactive
Turret slewing unlock

The indicator light illuminates when the button (ref.39) on the left
hand joystick is pressed, signalling that the superstructure slewing
brake has been manually released.
Free
24 - Rear axle oscillation lock
25 - Front right outrigger control
Outrigger beam extension / retraction control

Hold down button 12 to enable the function
Outrigger down / up control

26 - Rear right outrigger control


27 - Emergency stop pushbutton

28 - Boom element sixth selection button
To select boom the sixth section of the boom only, fully retract the
boom and press the button
29 - Rear left outrigger control



30 - Front left outrigger control


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. Check the spirit level in the cab frequently to ensure
levelling adjustment is correct (ref. 14).
31 - Load limiter inhibit pushbutton

32 - Winch second speed pushbutton
Make sure the block is still 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.
33 - Idle speed adjustment button

Press top of button to increase engine speed (+), press bottom of
button to decrease engine speed (-).
34 - Engine diagnostic pushbutton
Hold button down to check for presence of active error codes relative
to the engine electronic fuel system and engine protection system.

35 - Steering mode selector

B
C A
Before selecting steering modes, the front and rear wheels must be aligned
and parallel to the longitudinal axis of the truck.
It is a 3-position selector:
Position A: coordinated / concentric steering
Position B: front axle steering only
Position C: crab steering
After several hours of operation check the alignment of the front/rear

wheel axles.
Realign the wheels if necessary.

Hand controls
The functions of the hand controls are shown on the sticker on the window
in the cab.
AUX
1 1 /
2
1 3 1 2
2 2
4 3
3 M1 / M2
3
46859
Left hand control
37
36
The left hand joystick accommodates the controls for turret slewing,
release of the superstructure rotation brake, telescopic boom extension/
retraction, boom extension mode selection and auxiliary winch or boom
control selection.
The left joystick has a safety device 37 for preventing accidental
manoeuvres, however the operator must remain seated in the driving
position.

Operations with only one winch
38 - Push forward to extend the boom sections

- Pull back to retract the boom sections
- Move to the right to turn the turret clockwise
- Move to the left to turn the turret counterclockwise
Remember to remove the manual slewing locking pin 38 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.
Operations with auxiliary winch (optional)
Press and release the button 39 to switch the boom extend/retract function
onto winch down/up
39

Move to the right to turn the turret clockwise

Move to the left to turn the turret counterclockwise
Pull back to lift the load with the auxiliary winch
Push forward to lower the load with the auxiliary winch
Press and release the button 39 to return to the boom extend/retract

FUNCTION.
warning
Release the main or auxiliary winch rope when extending the

boom to prevent the hoisting block head block from tripping
the limit stop device. Failure of this device can result in
serious damage to the boom head or telescopic extension and
the rope. The rope could break causing the load to drop, with
resulting serious damage or fatal accidents.
Manual superstructure rotation brake release button on left

hand joystick
Use the button 36 on the left hand control to manually release upper
structure rotation.
36
On machine starting, the turret rotation unit brake is applied and

automatically released gradually during upper structure rotation.

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 the button 36.
The brake is automatically re-applied when the button is released.
Caution
Do not release/lock slewing abruptly during work as this may
cause the load to sway. Wait until the machine superstructure
is completely stationary before changing direction.
Use the button 40 on the left hand control to select the desired telescopic
boom extension mode.
40
Telescopic boom extension mode selection
There are two telescoping modes.
MODE 1: Extension 5 sections

MODE 2: Extension 6 sections
Mode 1 (5 section boom) is for HEAVY LIFTING, it uses short and medium
reach telescoping and has lower stability because of the weight of the boom
head, (section T6 being retracted into section T5). In mode 1, sections T2
and T3 are telescoped alone, and then sections T4, (T5 and T6).
Mode 2 (6 section boom) is for LONG REACH lifting, with greater

STABILITY the weight being less at the boom head (since Sections T4, T5
and T6 are extended) at the expense of telescoping functions. In mode 2,
telescoping of sections T4, T5 and T6 are synchronised.

Telescoping mode according to outrigger configuration.
Telescoping mode
Outrigger
authorized according to Rotation
configuration
outrigger configuration.
Maximum
360°
outrigger extension
Intermediate outrigger
360°
extension
M1/M2 360° Outrigger fully retracted
360° Tyres 0 km/h
0° Tyres 2 km/h
Telescoping in MODE 1 (5 section boom)

1- Sections T2 and T3 are telescoped to 94%
2- Sections T4 and (T5-T6) are telescoped to 94%
3- Sections T2 and T3, T4, (T5-T6) are telescoped to 100%
All the sections are independent.
Section T6 is not extended, but remains firmly within section T5 (the

telescoping system of section T6 is inactive (button 28))
Phase 1
Phase 2
Phase 3

Boom (T5-T6)
T2 T3 T4 Operate section
length *
11.60 m 0% 0% 0% 0% T2 T3
14.30 m 16.7% 16.7% 0% 0%
17.00 m 33.3% 33.3% 0% 0%
19.80 m 50% 50% 0% 0%
22.50 m 66.6% 66.6% 0% 0%
25.20 m 83.3% 83.3% 0% 0%
26.90 m 94% 94% 0% 0% T4 (T5 T6)
31.10 m 94% 94% 25% 25%
35.30 m 94% 94% 50% 50%
39.50 m 94% 94% 75% 75%
42.70 m 94% 94% 94% 94%
44.70 m 100% 100% 100% 100% T2 T3
* In mode M1, T6 is inactive (T6 is within T5).

Telescoping in MODE 2 (6 section boom)

The T6 section telescoping system is active.
1-Sections T4, T5 and T6 are synchronously telescoped to 66.6%.
3- Sections T4, T5 and T6 are telescoped to 94%
5- Sections T4, T5 and T6 are telescoped to 100%
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5

Boom length T2 T3 T4-T5-T6 Operate section
11.60 m 0% 0% 0% T4 T5 T6
17.40 m 0% 0% 23%
23.40 m 0% 0% 47%
28.30 m 0% 0% 66.6%
32.00 m 23% 23% 66.6% T2 T3
36 m 47% 47% 66.6%
39.20 m 66.6% 66.6% 66.6%
42.20 m 85% 85% 66.6%
43.70 m 94% 94% 66.6%
48.30 m 94% 94% 85% T4 T5 T6
50.60 m 94% 94% 94%
53 m 100% 100% 100% T2 T3

Right hand control
37
The RH joystick commands load lifting and lowering with the main winch
and lifting and lowering of the telescopic boom.
The RH joystick has a safety device to prevent inadvertent activation 37;
however the operator must remain seated in the driving position.
- Push forward to lower the load with the main winch

- Pull back to lift the load with the main winch
- Move to the left to lift the telescopic boom
- Move to the right to lower the telescopic boom
When the hand control 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 hoisting block from tripping the limit stop
lock device. Failure of this device can result in serious damage
to the boom head or telescopic extension and the rope. The
rope could break and drop the load, causing serious damage
or fatal accidents.
Press the button 41 to sound the horn
Button 42 is not connected
41
42

Battery disconnecting switch
43
The switch (43) is located on the outside of the battery box on the left side
of the carrier.
It disconnects the negative pole of the batteries from the machine frame.
Notes: It is always advisable to disconnect the batteries at the

end of the work shift, during long work stops or for carrying out
maintenance.
Air conditioner control in operator's

cab
1. Air circulation fan speed regulator
2. Heating control
3. Cooling control
1 2 3

Telescopic boom
section 1 (T1)
Main boom
section 2 (T2)
section 3 (T3)
section 4 (T4)
section 5 (T5)
section 6 (T6)

Machine layout
Carrier: the rear is the part of the chassis in which the engine is mounted
Superstructure: the boom is fitted on the front, the counterweight is located

at rear end
The left and right sides are determined with respect to the operator seated
in the driving position located on the turret.
Boom base Main winch
Cab
Counterweight
Front
Engine
Block
Lifting cylinder
Front outriggers Rear outriggers

Electric accumulators Fuel tank
Front part Rear section
Hydraulic oil tank

Boom head Right hand
Front
Left hand
Air tanks Auxiliary winch

Operator's seat
Adjustable head-rest
Seat back
Arm-rests
Height and angle

adjustment
Backrest adjustment
Upper part
adjustment sliding
guide
Weight adjustment
Complete seat unit adjustment

sliding guide
Console locking device

Seat adjustments
The arm-rest can be raised on the operator's door side to facilitate entry. It
must then be lowered and locked in its operating position.
The back adjusts in small steps to allow the operator to quickly find the
best position.
The upper runners allow the seat to be adjusted in the most comfortable
position for operating the hand control devices. The guides allow the
operator to change the seat position and the individual sections of the
back with respect to the entire seat unit.
Seat height and angle can be adjusted within a range of 65 mm, regardless
of the seat suspension.
The operator can set the position, with respect to the pedals, using runners
for moving the whole seat.
The height of the arm-rests can be adjusted. Loosen the two mounting
bolts to carry out adjustment.


User Manual | ViewTech – HC202 English
User Manual
ViewTech – HC202
English
Codice Manuale | Manual Code

000000-RT_100.uso.EN.00-MCR
I
Index - Chapter
Index - Chapter ................................................................................................................................................... 2
Index - Picture..................................................................................................................................................... 5
Index - Table ....................................................................................................................................................... 6
Index - Revision Notes ....................................................................................................................................... 7
Index - Manual Features..................................................................................................................................... 8
Introduction ........................................................................................................................................................ 9
Warnings ........................................................................................................................................................... 10
Important Notes ............................................................................................................................................... 11
System Operation Description ........................................................................................................................ 12
System description .......................................................................................................................................... 13
5.1 System Description Crane Model RT100 ................................................................. 13

6
Machine Component Description.................................................................................................................... 14
6.1 Machine Component Description.............................................................................. 14
000000-RT_100.uso.EN.00-MCR I2I Index - Chapter

Panel Description ............................................................................................................................................. 15
Pages Displayed On Limiting Device.............................................................................................................. 18
8.1 Pages Displayed Description.................................................................................... 18

8.2 How To Change LMI Page: ...................................................................................... 18
8.3 Start-up Page............................................................................................................ 19
8.3.1 The Start-up Page Description...................................................................... 19
8.3.2 Software Release.......................................................................................... 19
8.3.3 Firmware Release......................................................................................... 19
8.3.4 Load Table Release...................................................................................... 20
8.3.5 Self Test........................................................................................................ 20
8.4 Set-up Page.............................................................................................................. 21
8.4.1 The Setup Page Description ......................................................................... 21
8.4.2 Outrigger / Wheel Configuration ................................................................... 21
8.4.3 Counterweight Configuration ........................................................................ 21
8.4.4 Hook Configuration ....................................................................................... 22
8.4.5 Main Boom And Jib Configuration ................................................................ 22
8.4.6 Jib Stored location ........................................................................................ 23
8.4.7 Rope Number................................................................................................ 23
8.4.8 Special Message Area .................................................................................. 23
8.4.9 Alarm And Message Area ............................................................................. 24
8.5 Settings Page ........................................................................................................... 25
8.5.1 The Setting Page Description. ...................................................................... 25
8.5.2 How To Select Language............................................................................. 25
8.5.3 How To Select the Unit of Measurement ..................................................... 25
8.6 LMI Page (Home page) ............................................................................................ 26
8.6.1 LMI Page Description.................................................................................... 26
8.6.2 Boom Extension Percentage Bar.................................................................. 26
8.6.3 Actual Load Status Bar. ................................................................................ 27
8.6.4 Main Boom Working Mode............................................................................ 27
8.6.5 Turret Position............................................................................................... 27
8.6.6 Enable / disable sixth section........................................................................ 28
8.6.7 ISAAC ........................................................................................................... 28
8.6.8 LMI On / Off .................................................................................................. 28
8.6.9 By-pass LMI .................................................................................................. 29
8.6.10 Rope Number................................................................................................ 29
8.6.11 Actual Load ................................................................................................... 29
8.6.12 Maximum Load Allowed............................................................................... 30
8.6.13 Anti To Block Device..................................................................................... 30
8.6.14 Winch ............................................................................................................ 31
8.6.15 LMI Information And Operating Mode Configured ........................................ 31
8.6.16 Special Message Area .................................................................................. 32
8.6.17 Alarm And Message Area ............................................................................. 32
8.7 ISAAC Page.............................................................................................................. 33
8.8 ISAAC 1/2 Page Description..................................................................................... 33
8.8.1 Angle............................................................................................................. 33
8.8.2 Height............................................................................................................ 34
8.8.3 Radius........................................................................................................... 34
8.8.4 ISAAC 2/2 Page Description......................................................................... 35
8.8.5 Actual Turret Rotation ................................................................................... 35

8.8.6 Left limit......................................................................................................... 35

8.8.7 Right Limit ..................................................................................................... 35
9
Brightness Of The Screen ............................................................................................................................... 36
10
How To Select The Operating Mode ............................................................................................................... 37
10.1 Outrigger Or Wheel Configuration ............................................................................ 37

10.2 Counterweight Configuration ................................................................................... 38
10.3 Hook Location........................................................................................................... 39
10.4 Main Boom Configuration ......................................................................................... 39
10.5 Jib Stored Location ................................................................................................... 40
10.6 Rope Number ........................................................................................................... 41
11
How to Use ISAAC Function............................................................................................................................ 42
11.1 How To Disable/Enable ISAAC ................................................................................ 42

11.2 How To Select The Operating Limits ........................................................................ 43
11.2.1 Main Boom Angle Limit ................................................................................. 43
11.2.2 Height............................................................................................................ 44
11.2.3 Radius........................................................................................................... 45
11.3 How To Select The Limit Turret Angle Rotation ....................................................... 46
11.3.1 Actual Turret Rotation ................................................................................... 46
11.3.2 Left limit......................................................................................................... 47
11.3.3 Right Limit ..................................................................................................... 47
12
LMI Exclusion ................................................................................................................................................... 49
12.1 Safe Key ................................................................................................................... 49

13
Diagnostic ......................................................................................................................................................... 50
13.1 How to disable the buzzer ........................................................................................ 50

14
Trouble Shooting.............................................................................................................................................. 51
15
Warnings ........................................................................................................................................................... 72

I
Index - Picture
Picture 5.1 - System Description ................................................................................................ 13
Picture 6.1Machine Component Location .................................................................................. 14
Picture 7.1 - Control Panel Unit.................................................................................................. 15
Picture 8.1- Start-up Page.......................................................................................................... 19
Picture 8.2 – Set-up Page .......................................................................................................... 21
Picture 8.3 - Settings Page......................................................................................................... 25
Picture 8.4 - LMI Page Description............................................................................................. 26
Picture 8.5 – ISAAC 1/2 ............................................................................................................. 33
Picture 8.6 – ISAAC 2/2 ............................................................................................................. 35
Picture 10.1- Set-up Page .......................................................................................................... 37
Picture 11.1 – ISAAC 1/2 ........................................................................................................... 43
Picture 11.2 – ISAAC 2/2 ........................................................................................................... 46
Picture 12.1 - Safe Key .............................................................................................................. 49
000000-RT_100.uso.EN.00-MCR I5I Index - Picture

I
Index - Table
Errore. Non è stata trovata alcuna voce dell'indice delle figure.
000000-RT_100.uso.EN.00-MCR I6I Index - Table

I
Index - Revision Notes
Revision Autor Revision Revision Note

Index Date
00 Marco Craviolini 15/12/2009 -----------------------
000000-RT_100.uso.EN.00-MCR I7I Index - Revision Notes

I
Index - Manual Features
Riferimenti per l'archiviazione Fac-simile Colonna da compilare
Manual Code 000000-RT_100.uso.EN.00- Generazione del Codice

MCR Manuale ad opera di chi si
occupa dell'archiviazione
Type of System
Last Version Software -----
Machine RT_100
Customer Terex Italia
Manual Type Uso
Language Inglese
Last Progressive number of 00

Review
Last Reviser Marco Craviolini
Date Last Release 15/12/2009
MANUAL CODE example:
000000-RT_100.uso.EN.00-MCR I8I Index - Manual Features

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.
000000-RT_100.uso.EN.00-MCR I9I 1 | Introduction

2
Warnings
The load limiting device is an electronic control device, designed to help the operator for the
safe use of the machine, warning him by means of visual and audible alarms when approaching
a dangerous condition.
However, this device is not aimed at replacing the operator’s good experience when properly
using the crane.
The operator is responsible for operating the machine under safety conditions as well as
fulfilling all the safety rules prescribed.
The operator must be able to recognize if the data transmitted by the system are correct and
coherent with the real conditions.
He also must be able to utilize the data in order to operate under safety conditions.
The limiter is an electronic device with several components and could be subject to failures or
defects.
The operator must recognize these events and must act consequently (to proceed to repair, if
possible, or to call the constructor for assistance).
Before starting the machine operations, the user must fully read and understand this manual
and follow the instructions written herein.
000000-RT_100.uso.EN.00-MCR I 10 I 2 | Warnings
3
Important Notes
The limiter is supplied with a key for automatic shut-down override.

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

switching the operation from outrigger mode to on tires mode
telescopic mechanical extensions are extended or not
further equipment (jib, ext, etc.) is installed or not
the rope number is properly selected.
In general it is mandatory to follow the instructions given by the crane’s manufacturer.
000000-RT_100.uso.EN.00-MCR I 11 I 3 | Important Notes

4
System Operation Description
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)
working mode (operating mode)
warning lights (green, yellow, red) and audible alarm
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.
Warning : 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.
000000-RT_100.uso.EN.00-MCR I 12 I 4 | System Operation Description

5
System description
In this charter there are indicated all the elements connected with the Limiting Device.
The elements used depend of the Crane model.
5.1 System Description Crane Model RT100
Picture 5.1 - System Description
1. xxxxxx
2. xxxxxx
3. xxxxxx
4. xxxxxx
5. xxxxxx
6. xxxxxx
7. xxxxxx
8. xxxxxx
9. xxxxxx
10. xxxxxx
000000-RT_100.uso.EN.00-MCR I 13 I 5 | System description

6
Machine Component Description
In this chart all the elements connected with the Limiting Device (LMI) are indicated.
6.1 Machine Component Description
Picture 6.1Machine Component Location
1. xxxxxx
2. xxxxxx
3. xxxxxx
4. xxxxxx
5. xxxxxx
6. xxxxxx
7. xxxxxx
8. xxxxxx
9. xxxxxx
10. xxxxxx
000000-RT_100.uso.EN.00-MCR I 14 I 6 | Machine Component Description

7
Panel Description
The operator panel is shown in the following picture:
Picture 7.1 - Control Panel Unit
Ref. Icon Description
1 Working data display
2 Two green lights showing the safe working condition
3 The yellow light showing the pre alarm condition; load between 90%
and 100%.
4 The red light showing the shut off condition has occurred ; load over
100%.
000000-RT_100.uso.EN.00-MCR I 15 I 7 | Panel Description

5 “Function” push-button : languages setting / outrigger configuration.
6 “Function” push-button : unit of measurement / counterweight

configuration.
7 “Function” push-button : Hook configuration.
8 Function push-button : Main Boom configuration.
9 “Function” push-button : Jib stored location.
10 “Enter” push-button: it confirms an operation.
11 “Up” push-button : increase brightness.
12 “Down” push-button : decrease brightness.
13 “Left” push-button : page down.
14 “Right” push-button : page up.
15 “Rope” push-button : increase / decrease rope number.
16 “Buzzer” push-button : disabling buzzer.
17 “Selection” push-button : (Not Used).

18 “Changing pages” push-button : (Not Used)
19 “Escape” push-button : (Not used)
20 “Setup” push-button : press to activate the “Setup” page or the

“Settings” page.

8
Pages Displayed On Limiting Device
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.
8.1 Pages Displayed Description
We have the pages described below in the following order:
1. “Start-up” page : this page is activated only for five seconds at the machine start-up.
2. “Set-up” page : it is used to select and confirm the Operating Mode.
3. “Settings” page : it is used for the language setting and the units of measurement.
4. “Status LMI” page : it is used to visualize the Operating Mode selected, to change the rope
number and to monitor the actual crane operating conditions.
5. “ISAAC 1/2” page : it is used to limiting angle, height and radius of the main boom.
6. “ISAAC 2/2” page : it is used to limiting the turret rotation.
8.2 How To Change LMI Page:
By means of the “Left” push-button or the “Right” push-button the LMI page can
be changed.
In particular to show the “Setting” page it is necessary to press the “Setup” push-button
inside in the “Setup” page.
000000-RT_100.uso.EN.00-MCR I 18 I 8 | Pages Displayed On Limiting Device

8.3 Start-up Page
When the system gets started, some information is displayed for five seconds.
8.3.1 The Start-up Page Description
Picture 8.1- Start-up Page
8.3.2 Software Release
Software version installed in the View (LMI).
Software Release Description
Software version installed in the View (LMI).
8.3.3 Firmware Release
Firmware Release Description
Firmware version installed in the View (LMI).

8.3.4 Load Table Release
Load Table Release Description
loading table version installed in the View

(LMI).
8.3.5 Self Test
Self Test Description
At the start-up a special memory check is

activated and the system transmits the results
of the test to the View (LMI).
When that information is displayed, by pressing the “Enter” push-button , the message
“Code” appears and the system requires the password.
Some parameters can be modified but this operation is only for skilled operators.
In order to quit this condition, without entering the password, press again the “Enter” push-
button or reboot the LMI.
If the “Enter” push-button is not pressed, after five seconds this page will be deleted and the
“Setup” Page will appear.

8.4 Set-up Page
In the “Set-up” page it is possible to choose the machine operating mode.
This page is visualized after the “Start-up” page or when the “Setup” push-button is
pressed.
8.4.1 The Setup Page Description
Picture 8.2 – Set-up Page
8.4.2 Outrigger / Wheel Configuration
With the “Function” push-button it is possible to set the outrigger or wheel configuration.
Outrigger / Wheel Configuration Description
Outrigger full extended (100%)
For further details about the outrigger configuration, see the chapter “How To Select The
Operating Mode ”.
8.4.3 Counterweight Configuration

With the “Function” push-button it is possible to set the counterweight configuration.
Counterweight Configuration Description
Counterweight 10 ton.
For further details about the counterweight configuration, see the chapter “How To Select The
Operating Mode ”.
8.4.4 Hook Configuration
With the “Function” push-button it is possible to set the Hook configuration.
Hook Configuration Description
The Hook is located on the Main Boom.
For further details about the hook configuration, see the chapter “How To Select The Operating
Mode ”.
8.4.5 Main Boom And Jib Configuration
With the “Function” push-button it is possible to set the Main Boom and Jib configuration.
Main Boom Configuration Description
Main Boom Selected.

(The Main Boom section is dark and the Jib
extension is grey)
For further details about the main boom configuration, see the chapter “How To Select The
Operating Mode ”.

8.4.6 Jib Stored location
With the “Function” push-button it is possible to set the Jib stored location.
Jib Stored location Description
Jib not stored on the Main Boom.

(The Jib stored location picture is grey).
For further details about the Jib stored location, see the chapter “How To Select The Operating
Mode ”.
8.4.7 Rope Number
With the “Rope” push-button it is possible to set the correct rope number.
Rope Number Description
Five is the present rope number selected on

the crane (example).
The maximum value depends on the
operating mode.
For further details about the rope number, see the chapter “How To Select The Operating
Mode”.
8.4.8 Special Message Area
This side of the panel View is like the other LMI pages and it is used to provide the operator with
special information.
Special Message Area Description
Special information is displayed to the

operator.

8.4.9 Alarm And Message Area
On every page in the LMI, this area is dedicated to the alarm and message information.
Alarm And Message Area Description
The Alarm Code is visualized on the first line

of this area and on the second line there is
some message information to help the
operator.

8.5 Settings Page
On this page we can select the Languages and the Unit of Measurement.
In order to visualize this page it is necessary to press the “Setup” push-button when the
“Setup” page is displayed on the screen.
To quit the page displayed without any modification, press again the same push-button.
8.5.1 The Setting Page Description.
Picture 8.3 - Settings Page
8.5.2 How To Select Language.
On the “Settings” page, press the “Function” push-button to move the reference cursor
towards the desired language.
Confirm your choice with the “Enter” push-button .
8.5.3 How To Select the Unit of Measurement
On the “Settings” page, press the “Function” push-button to move the reference cursor
towards the desired unit of measurement.
Confirm your choice with the “Enter” push-button .

8.6 LMI Page (Home 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.
8.6.1 LMI Page Description
Picture 8.4 - LMI Page Description
8.6.2 Boom Extension Percentage Bar.
The graphic bar shows the percentage of the Main boom extension .
Boom Extension Percentage Bar Description
The “Actual Status bar” showing the lifted

load in percentage to the maximum load
allowed under that working condition:
- Green reference: Safe Zone
- Orange reference: Alarm Zone (Lifted load
higher than 90% of maximum load allowed).
- Red reference: Cut-off Zone ( Lifted load

8.6.3 Actual Load Status Bar.
Actual Load status Bar Description
The “Actual Status bar” showing the lifted

load in percentage to the maximum load
allowed under that working condition:
- Green reference: Safe Zone
- Orange reference: Alarm Zone (Lifted load
- Red reference: Cut-off Zone ( Lifted load
8.6.4 Main Boom Working Mode
Main Boom Working Mode Description
The crane works with the first and the second

element in proportional mode.
The third quarter, fifth and sixth element are
stoped.
The crane works with the third quarter and

fifth element in proportional mode.
The sixth element work only if enabled
(T6_ON) (*)
The system does not know the correct

operating mode.
Auxiliary winch enabled.

Mode 1 and Mode 2 disabled.
8.6.5 Turret Position
Turret Position Description
The turret is in lateral or rear position.

Turret Position Description
The turret is in front position.
8.6.6 Enable / disable sixth section.
Enable / disable sixth section Description
In Mode 2 the sixth element is enabled and

(*) work with the quarter and fifth element.
In Mode 2 the sixth element is disabled.
Problem motion with the sixth element.
8.6.7 ISAAC
ISAAC Description
Free movement from ISAAC control.
Movement stop for activation ISAAC control.
8.6.8 LMI On / Off
LMI On / Off Description
Limiting Device enabled.
Movement stopped for overload or alarm.

8.6.9 By-pass LMI
By-pass LMI Description
Limiting Device enabled :the Safe Key is not

activated.
Limiting Device disabled: the Safe Key is

activated and all the dangerous movements
are not disabled by LMI.
8.6.10 Rope Number
The rope numbers selected on the “Setup”

page are displayed. The maximum rope
number depends on the configuration
selected.
8.6.11 Actual Load
Actual Load Description
In this area the existing loads detected on the

crane are displayed.

8.6.12 Maximum Load Allowed
According to the selected operating mode and the existing position, the maximum load allowed
is displayed.
The icon changes the colour property with the Operating Mode confirmed.
Maximum Load Allowed Description
The icon reference is Green when the load is

in the “Safe Zone” as displayed on the “Actual
Status bar”.
In the “Safe Zone” load < 90% of maximum
load allowed.
The icon reference is Orange when the Load

is in the “Alarm Zone” as displayed on the
“Actual Status bar”.
In the “Alarm Zone” 90%< load <100% of
maximum load allowed.
The icon reference is Red when the load is in

the “Cut-off Zone” as displayed on the “Actual
Status bar”.
In the “Cut-off Zone” load > 100% of maximum
load allowed.
8.6.13 Anti To Block Device
Anti To Block Device Description
The Anti To Block device is active.
The Anti To Block device is activated.

The rope is completely wrapped on the winch.
(End of rope Up)

8.6.14 Winch
Winch Description
The auxiliary winch is disabled.
The auxiliary winch is enabled.
8.6.15 LMI Information And Operating Mode Configured
LMI Information Description
On the “Status LMI” page, the information

from the sensor located on the crane and
the operating mode configured are
displayed.
In this case the crane is configured as
below:
1. Main Boom
2. Outrigger full extended
3. Counterweight 7 t
4. Jib not used and not stored on crane
The LMI information is:

1. Main Boom Angle = 20°
2. Boom Extension = 23 m
3. Range = 6,8 m
The unit of measurement is according to

the selection on the “Setting” page.
For further details about the Operating Mode selected, see the chapter “How to select the
Operating Mode”.

8.6.16 Special Message Area
This side of the panel View is used to give special information to the operator.
Special Message Area Description
In this area special message information is

displayed for the operator.
8.6.17 Alarm And Message Area
On every page in the LMI, this area is dedicated to the alarm and message information.
Alarm And Message Area Description
The Alarm Code is visualized on the first line

of this area and on the second line there is
some message information to help the
operator.

8.7 ISAAC Page
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.
By pressing the “Left” push-button or the “Right” push-button the operator will
enter into the ISAAC Menu.
8.8 ISAAC 1/2 Page Description
Picture 8.5 – ISAAC 1/2
8.8.1 Angle
Angle Description
Main boom limit angle area.
Main boom actual angle position.

Angle Description
Main boom limit angle
8.8.2 Height
Height Description
Main boom limit height area.
Main boom actual height position.

The unit of measurement is according to the
selection on the “Setting” page.
Main boom limit height.

8.8.3 Radius
Radius Description
Main boom limit radius area.
Main boom actual radius position.

Main boom limit radius.


8.8.4 ISAAC 2/2 Page Description
8.8.5 Actual Turret Rotation
Actual Turret Rotation Description
Actual Turret position.
8.8.6 Left limit
Left Turret Limit Description
Left Turret limit area.
8.8.7 Right Limit
Right Turret Limit Description
Right Turret limit area.

9
Brightness Of The Screen
In the Status LMI page and when the operating mode is confirmed, it is possible to increase or
decrease the brightness.
By pressing the “Up” push-button the brightness increases up to maximum seven levels.
By pressing the “Down” push-button the brightness decreases down to minimum seven
levels.
000000-RT_100.uso.EN.00-MCR I 36 I 9 | Brightness Of The Screen

10
How To Select The Operating Mode
The “Set-up” page is displayed after the “Start-up” page at the start-up of the system or when
press the “Setup” push-button in the “Status LMI” page.
It is necessary to confirm the operating mode with the “Enter” push-button to proceed.
Picture 10.1- Set-up Page
10.1 Outrigger Or Wheel Configuration
With this crane model in order to change the outrigger configuration, it is necessary to use the
“Function” push-button .
According to the outrigger configuration, the icon changes like the following examples.
Outrigger Configuration Description
Outrigger completely extended (100%)
000000-RT_100.uso.EN.00-MCR I 37 I 10 | How To Select The Operating Mode

Outrigger Configuration Description
Outrigger half extended (50%).
Outrigger completely retracted (Closed).
Static On Wheels.
If no other modification is necessary, press the “Enter” push-button in order to confirm the
operating mode.
10.2 Counterweight Configuration
For this crane model the selection is fixed to 10 ton.

In order to change the counterweight configuration, it is necessary to use the “Function” push-
button .
According to the counterweight on the machine, the icon changes like the following examples.
Counterweight Configuration Description
Counterweight 10 ton.
Counterweight 9,5 ton.
Counterweight 11,6 ton.

For this crane the “Function” push-button is optional.
operating mode.
10.3 Hook Location
With this crane model in order to select the right hook location, it is necessary to use the
“Function” push-button .
For this crane model the Jib extension is not supplied and this function is not available.
The Hook position is fixed on the main boom.
According to the hook location on the machine, the icon changes like the following examples.
Hook Location Description
The Hook is located on the Main Boom.
The Hook is located on the small Jib.
The Hook is located on the Jib.
operating mode.
10.4 Main Boom Configuration
When the Jib extension is present on the crane, press the “Function” push-button to
select the Jib configuration.
According to the main boom configuration, the icon changes like the following examples.

Main Boom Configuration Description
Main Boom Selected.

(The Main Boom section is dark and the Jib
extension is grey)
Small Jib selected.

(The Main Boom section is grey and the small
Jib extension is dark)
Jib Selected and Jib angle 0°.

(1) Jib short / (2) Jib long.
(1) (2) (The Main Boom section is grey and the Jib
extension is dark)

extension is dark)

extension is dark)
operating mode.
10.5 Jib Stored Location
It is important to select the correct Jib stored location when this device is not used on the crane.
The jib stored location is by means of the “Function” push-button .

According to the Jib location the icon changes like the following examples.

Jib Stored location Description
Jib not stored on the Main Boom.

(The Jib stored location picture is grey).
Jib stored on the Main Boom.

(The Jib stored location picture is dark).
operating mode.
10.6 Rope Number
The last operation before confirming the Operating Mode is to select the correct rope number as
needed.
The rope number can be increased with the “Rope” push-button .
Five is the existing rope number selected on

the crane (example).
The maximum value depends on the
operating mode.
The correct rope number can be corrected also in the “Status LMI” page always by means of
the “Rope” push-button .
operating mode.
000000-RT_100.uso.EN.00-MCR I 41 I 11 | How to Use ISAAC Function.

11
How to Use ISAAC Function.
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.
By pressing the “Left” push-button or the “Right” push-button the operator will
enter into the ISAAC Menu.
11.1 How To Disable/Enable ISAAC
To Disable ISAAC:
1. On the Status LMI page press the “Setup” push-button and the “Escape” push-
button for 5 seconds at the same time.

2. Release the two buttons when you hear an acoustic signal.
To Enable ISAAC:
1. On the Status LMI page press the “Setup” push-button and the “Escape” push-
button for 5 seconds at the same time.

2. Release the two buttons when you hear an acoustic signal.
ISAAC 1/2 page appears on View-Tech only if the encoder is located on the Crane.

11.2 How To Select The Operating Limits
The limitation of the movements angle, height and radius can be activated singularly or all in the
same moment.
11.2.1 Main Boom Angle Limit
The control of the main boom angle is disabled when the value 999 appears in the “Limit Angle
area”.
Main Boom Limit Angle Description
Limit angle disabled.
In order to limit the main boom angle it is necessary to move the boom in the correct position
and press the “Function” push-button .

The value of the actual position is automatically written and considered as maximum operating
limit.
Once the maximum limit is reached, it is only possible to drive the main boom down.
The exclusion of the movement is shown on the “Status LMI” page through the “ISAAC” icon

Main Boom Limit Angle Description
Actual angle position.
Limit angle enabled.
In order to disable the control of the angle, press again the “Function” push-button and
the limit previously set is deleted and replaced with the value “999” or exclude the whole ISAAC
control (see the chapter about how to enable/disable the ISAAC function).
11.2.2 Height
The control of the maximum height of the main boom from the ground is disabled when the
value 999,9 appears in the “Limit Height area”.
Height Description
Limit height disabled.

In order to limit the main boom height it is necessary to move the boom in the correct position

limit.
Once the maximum limit is reached, it is only possible to drive the main boom down or retract
the main boom.
Height Description
Actual height position.


Height Description
Limit height enabled.

In order to disable the control of the angle, press again the “Function” push-button and
the limit previously set is deleted and replaced with the value “999,9” or exclude the whole
ISAAC control (see the chapter about how to enable/disable the ISAAC function).
11.2.3 Radius
The control of the radius of the main boom is disabled when the value 999,9 appears in the
“Radius Limit area”.
Radius Description
Limit radius disabled.

In order to limit the main boom radius it is necessary to move the boom in the correct position

limit.
Once the maximum limit is reached, it is only possible to drive the main boom up or retract the
main boom.
Radius Description
Actual radius position.


Radius Description
Limit radius enabled.

In order to disable the control of the radius, press again the “Function” push-button and
the limit previously set is deleted and replaced with the value “999,9” or exclude the whole
ISAAC control (see the chapter about how to enable/disable the ISAAC function).
11.3 How To Select The Limit Turret Angle Rotation
This function can only be activated if the encoder is installed on the turret to detect the position.
11.3.1 Actual Turret Rotation
The turret position is constantly monitored and displayed in the “Actual turret position area”.
Actual Turret Rotation Description
Actual Turret position.

11.3.2 Left limit
The control of the left rotation is disabled when the value 9999 appears in the “Left limit value
area”.
Left Limit Description
Left limit function disabled.
In order to limit the left rotation it is necessary to drive the turret in the correct position and press
the “Function” push-button .

The value of the actual position is stored and displayed as zero and it is considerated as
operating limit on the left side.
When the set value is reached, it only possible to proceed with the rotation to the opposite side.
Left Turret Limit Description
Left Limit Enabled.
In order to disable the control press again the “Function” push-button and the limit
previously set is deleted and replaced with the value “9999” or exclude the whole ISAAC control
(see the chapter about how to enable/disable the ISAAC function).
11.3.3 Right Limit
The control of the right rotation is disabled when the value 9999 appears in the “Left limit value
area”.
Right limit function disabled.

In order to limit the left rotation it is necessary to drive the turret in the correct position and press
the “Function” push-button .

The value of the actual position is stored, and displayed the operating limit on the right side.
When the set value is reached, it only possible to proceed with the rotation to the opposite side.
Right limit enabled.
In order to disable the control press again the “Function” push-button and the limit
previously set is deleted and replaced with the value “9999” or exclude the whole ISAAC control
(see the chapter about how to enable/disable the ISAAC function).

12
LMI Exclusion
In case of a fault of the load limiting device an emergency operation on the machine may be
needed.
In this particular case a bypass device has to be provided. Such device, that is located inside
the control cabin, has to enable again the movements for a pre-set time preventing this device
from being continuously used.
12.1 Safe Key
In order to meet all these needs a Bypass Device has been developed.
The use of a transponder instead of a traditional key provides one more safety function
preventing this device from being used by unauthorized personnel.
Picture 12.1 - Safe Key
It is simply necessary to move the Transponder close to the Bypass Device and afterwards to
remove it in order to exclude the control of the LMI and consequently to easily move each part
of the machine.
The exclusion of the limiting device is shown on the “LMI” page through the “LMI Bypass” icon
.
The speed of the movements is limited to the 25% of the maximum speed.
000000-RT_100.uso.EN.00-MCR I 49 I 12 | LMI Exclusion

13
Diagnostic
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.
1. Please confirm : the system is waiting for the operating mode validation.
Solution: choose the configuration and confirm.
2. Rope Overload : the actual load on the boom exceeds the maximum load allowed by the
actual position and the selected operating mode.
Solution : reduce the boom range.
3. Mode not Present : the operating mode M1 or M2 is not allowed in the actual
configuration.
Solution : check the operating mode configuration or check the configuration input for mode1
and mode2.
4. E01: Angle Max : the main boom is on the maximum boom angle position allowed.
Solution : reduce the boom angle.
5. E02 : Angle Min : the main boom is on the minimum boom angle position allowed.
Solution : increase the boom angle.
6. Syncro : the main boom parts are not in correct position.
Solution : activate the digital input dedicated to call back the main boom and to completely
close it.
13.1 How to disable the buzzer
1. Disable : when the audible alarm is on, by “Buzzer” push-button you can disable the
audible alarm until the new alarm is detected.
2. Enable : after few seconds that the alarm is switched off the audible alarm will be
automatically enabled.
000000-RT_100.uso.EN.00-MCR I 50 I 14 | Trouble Shooting

14
Trouble Shooting
Alarm Code Cause Solution
• ALARM 1 • Angle transducer device broken. •Verify the angle transducer

Angle A Low •Possible lack of continuity in integrity.
connection wires. •Verify that the wiring and the
• Possible short circuit in connection connectors are not in short
wires. circuit..
• Fault in main unit. • Verify the wire continuity.
• ALARM 2 • Potentiometer inside broken. •Verify that the wiring and the
Angle A High • Possible short circuit in connection connectors are not in short
wires. circuit..
• Fault in main unit. •Verify the angle transducer
integrity.
• ALARM 3 • Potentiometer inside broken. • Verify the wire continuity .

Angle A Value • Possible lack of continuity in wires •Verify that the wiring and the
Lover of the carrying the unwinding. connectors are not in short
minimum calibration • Possible short circuit in connection circuit..
settings value. wires. •Verify the angle transducer
• Fault in main unit. integrity.
Angle A Value • Possible short circuit in connection connectors are not in short
Higher of the wires. circuit..
maximum • Fault in main unit. •Verify the angle transducer
calibration settings integrity.
value.

• ALARM 5 • Angle transducer device broken. •Verify the angle transducer

Angle B Low •Possible lack of continuity in integrity.
wires. circuit..
Angle B High • Possible short circuit in connection connectors are not in short
wires. circuit..
• Fault in main unit. •Verify the angle transducer
integrity.

Angle B Value • Possible lack of continuity in wires •Verify that the wiring and the
settings value. wires. •Verify the angle transducer
Angle B Value • Possible short circuit in connection connectors are not in short
maximum • Fault in main unit. •Verify the angle transducer
value.
• ALARM 10 • Angle transducer device broken. •Verify the Jib angle

Angle Jib Low •Possible lack of continuity in transducer integrity.
wires. circuit..

Angle Jib High • Possible short circuit in connection connectors are not in short
wires. circuit..
• Fault in main unit. •Verify the Jib angle
transducer integrity.

Angle Jib Value • Possible lack of continuity in wires •Verify that the wiring and the
settings value. wires. •Verify the Jib angle
• Fault in main unit. transducer integrity.
Angle Jib Value • Possible short circuit in connection connectors are not in short
maximum • Fault in main unit. •Verify the Jib angle
calibration settings transducer integrity.
value.
• ALARM 15 • Simultaneously Input M1 and M2 ON • Verify the input status.

Fault M1 / M2 • Fault in main unit. • Deactivate the undesired
one.
ALARM 20 • Potentiometer inside broken . • Verify the transducer

Boom Length 1 • Possible lack of continuity in wires integrity.
Value Low carrying the unwinding. • Verify the wire continuity.
• Possible short circuit in connection •Verify the length transducer
wires. integrity.
• Fault in main unit.

Boom Length 1 • Possible short circuit in connection connectors are not in short
Value High wires. circuit..
• Fault in main unit. •Verify the length transducer
integrity.

Boom Length 1 • Possible lack of continuity in wires •Verify that the wiring and the
Value Lover of the carrying the unwinding. connectors are not in short
settings value. wires. •Verify the length transducer
Value Higher of the wires. circuit..
maximum • Fault in main unit. •Verify the length transducer
value.

Boom Length 1B • Possible lack of continuity in wires integrity.
wires. integrity.
Boom Length 1B • Possible short circuit in connection connectors are not in short
integrity.


Boom Length 1B • Possible lack of continuity in wires •Verify that the wiring and the
value.

wires. integrity.
integrity.


value.

wires. integrity.
integrity.

value.


wires. integrity.
integrity.

value.

wires. integrity.

integrity.

value.
• ALARM 50 • Lower chamber pressure transducer •Verify the pressure

PressL Low broken. transducer integrity.
• Possible lack of continuity in •Verify that the wiring and the
connection wires. connectors are not in short
• Possible short circuit in connection circuit..
wires. • Verify the wire continuity.

PressL High broken. transducer integrity.
• Possible short circuit in connection •Verify that the wiring and the
wires. connectors are not in short
• Fault in main unit. circuit..

• ALARM 52 • Lower chamber pressure transducer • Verify the wire continuity .

PressL Value Lover broken. •Verify that the wiring and the
of the minimum • Possible lack of continuity in wires connectors are not in short
calibration settings carrying the unwinding. circuit..
value. • Possible short circuit in connection •Verify the pressure
wires. transducer integrity.
• ALARM 53 • Lower chamber pressure transducer •Verify that the wiring and the
PressL Value broken. connectors are not in short
Higher of the • Possible short circuit in connection circuit..
maximum wires. •Verify the pressure
calibration settings • Fault in main unit. transducer integrity.
value.

PressL_B Low broken. transducer integrity.

PressL_B High broken. transducer integrity.

• ALARM 57 • Lower chamber pressure transducer • Verify the wire continuity .

PressL_B Value broken. •Verify that the wiring and the
Lover of the • Possible lack of continuity in wires connectors are not in short
minimum calibration carrying the unwinding. circuit..
settings value. • Possible short circuit in connection •Verify the pressure
• ALARM 58 • Lower chamber pressure transducer •Verify that the wiring and the
PressL_B Value broken. connectors are not in short
value.

PressH Low broken. transducer integrity.
• ALARM 61 • Upper chamber pressure transducer •Verify the pressure

PressH High broken. transducer integrity.

• ALARM 62 • Upper chamber pressure transducer • Verify the wire continuity .

PressH Value Lover broken. •Verify that the wiring and the
of the minimum • Possible lack of continuity in wires connectors are not in short
calibration settings carrying the unwinding. circuit..
value. • Possible short circuit in connection •Verify the pressure
• ALARM 63 • Upper chamber pressure transducer •Verify that the wiring and the
PressH Value broken. connectors are not in short
value.

PressH_B Low broken. transducer integrity.
• ALARM 66 • Upper chamber pressure transducer •Verify the pressure

PressH_B High broken. transducer integrity.

• ALARM 67 • Upper chamber pressure transducer • Verify the wire continuity .

PressH_B Value broken. •Verify that the wiring and the
Lover of the • Possible lack of continuity in wires connectors are not in short
minimum calibration carrying the unwinding. circuit..
settings value. • Possible short circuit in connection •Verify the pressure
• ALARM 68 • Upper chamber pressure transducer •Verify that the wiring and the
PressH_B Value broken. connectors are not in short
value.
ALARM 100 • Memory data not reliable • Switch the system off and
E2prom Error on.
•Verify that E2prom chip is
fitted property in its socket.
• Re-enter data and save
again it.
•Replace the E2prom chip
and recalibrate the machine.
ALARM 101 • CRC RUN error in View • Call assistance

CRC RUN View
ALARM 105 • CRC TAB error in View • Call assistance

CRC TAB View
ALARM 106 • CRC PRG error in View • Call assistance

CRC PRG View

• ALARM 180 • CAN BUS cable disconnected or • Verify the CAN BUS cable.
CANBUS broken. • Replace unit.
ACMCP_1A KO • Possible short circuit in connection • Fault in the MC2M Unit.
CAN BUS line.
ACMCP_1B KO • Possible short circuit in connection • Fault in the MC2M Unit.
CAN BUS line.
CAN BUS line.
CAN BUS line.
CAN BUS line.
CAN BUS line.
CANBUS MC2M broken. • Replace unit.
KO • Possible short circuit in connection • Fault in the MC2M Unit.
CAN BUS line.

CANBUS ACMCP broken. • Replace unit.
KO • Possible short circuit in connection • Fault in the ACMCP Unit.
CAN BUS line.
CANBUS JoyDx KO broken. • Replace unit.
• Possible short circuit in connection • Fault in the Joystick Dx
CAN BUS line. Unit.
CANBUS JoySx KO broken. • Replace unit.
• Possible short circuit in connection • Fault in the Joystick Sx Unit.
CAN BUS line.
CANBUS Midac broken. • Replace unit.
Front KO • Possible short circuit in connection • Fault in the Midac Front
CAN BUS line. Unit.
CANBUS Midac broken. • Replace unit.
Rear KO • Possible short circuit in connection • Fault in the Midac Rear
CAN BUS line. Unit.
CANBUS Key Pad broken. • Replace unit.
KO • Possible short circuit in connection • Fault in the Key Pad Unit.
CAN BUS line.
CANBUS CCRA broken. • Replace unit.
Front Sx KO • Possible short circuit in connection • Fault in the CCRA Front Sx
CAN BUS line. Unit.

Front Dx KO • Possible short circuit in connection • Fault in the CCRA Front Dx
CAN BUS line. Unit.
Rear Sx KO • Possible short circuit in connection • Fault in the CCRA Rear Sx
CAN BUS line. Unit.
Rear Dx KO • Possible short circuit in connection • Fault in the CCRA Rear Dx
CAN BUS line. Unit.
CANBUS Safe Key broken. • Replace unit.
KO • Possible short circuit in connection • Fault in the Safe Key Unit.
CAN BUS line.
ALARM 300 • • Call assistance

Ecu EEC1read
ALARM 700 • CRC Prg error in MC2M • Call assistance

CRC Prg MC2M
ALARM 701 • CRC Tab error in MC2M • Call assistance

CRC Tab MC2M
ALARM 702 • CRC Run error in MC2M • Call assistance

CRC Run MC2M
ALARM 703 • CRC Par error in MC2M • Call assistance

CRC Par MC2M

ALARM 704 • Redudancy corrent error boom lift • Verify the wire continuity .
Rdn BoomLft • Replace unit MC2M.
• Call assistance
ALARM 705 • Redudancy corrent error boom lower • Verify the wire continuity .
Rdn BoomLwr • Replace unit MC2M.
• Call assistance
ALARM 706 • Redudancy corrent error winch up • Verify the wire continuity .
Rdn WinchUp • Replace unit MC2M.
• Call assistance
ALARM 707 • Redudancy corrent error winch down • Verify the wire continuity .
Rdn WinchDwn • Replace unit MC2M.
• Call assistance
ALARM 708 • Redudancy corrent error turret rot Cw • Verify the wire continuity .
Rdn RotaCw • Replace unit MC2M.
• Call assistance
ALARM 709 • Redudancy corrent error turret rot • Verify the wire continuity .
Rdn RotaCCw CCw • Replace unit MC2M.
• Call assistance
ALARM 710 • Redudancy corrent error boom out • Verify the wire continuity .
Rdn TeleOut • Replace unit MC2M.
• Call assistance
ALARM 711 • Redudancy corrent error boom In • Verify the wire continuity .
Rdn TeleIn • Replace unit MC2M.
• Call assistance
ALARM 712 • Redudancy corrent error Auxiliary • Verify the wire continuity .
Rdn WinchAuxUp Winch Up • Replace unit MC2M.
• Call assistance

ALARM 713 • Redudancy corrent error Auxiliary • Verify the wire continuity .
Rdn WinchAuxDw Winch Down • Replace unit MC2M.
• Call assistance
TOut JoyDx broken. • Replace unit.
• Possible short circuit in connection • Fault in the Joystick Dx
CAN BUS line. Unit.
TOut JoySx broken. • Replace unit.
• Possible short circuit in connection • Fault in the Joystick Sx Unit.
CAN BUS line.
TOut Midac Front broken. • Replace unit.
• Possible short circuit in connection • Fault in the Midac Front
CAN BUS line. Unit.
TOut Midac Rear broken. • Replace unit.
• Possible short circuit in connection • Fault in the Midac Rear
CAN BUS line. Unit.
TOut Key Pad broken. • Replace unit.
• Possible short circuit in connection • Fault in the Key Pad Unit.
CAN BUS line.
Tout CCRA Front broken. • Replace unit.
Sx • Possible short circuit in connection • Fault in the CCRA Front Sx
CAN BUS line. Unit.

Tout CCRA Front broken. • Replace unit.
Dx • Possible short circuit in connection • Fault in the CCRA Front Dx
CAN BUS line. Unit.
Tout CCRA Rear Sx broken. • Replace unit.
• Possible short circuit in connection • Fault in the CCRA Rear Sx
CAN BUS line. Unit.
Tout CCRA Rear broken. • Replace unit.
Dx • Possible short circuit in connection • Fault in the CCRA Rear Dx
CAN BUS line. Unit.
TOut ACMCP broken. • Replace unit.
• Possible short circuit in connection • Fault in the ACMCP Unit.
CAN BUS line.
• ALARM 724 • Fault in the Joystick Dx Unit. • Verify the CAN BUS cable.
JoyDx Fault • Replace unit.
• ALARM 725 • Fault in the Joystick Sx Unit. • Verify the CAN BUS cable.
JoySx Fault • Replace unit.
• ALARM 726 • Fault in the ACMCP Unit. • Verify the CAN BUS cable.
ACMCP Fault • Replace unit.
• ALARM 727 • Fault in the CCRA Front Sx Unit. • Verify the CAN BUS cable.
CCRA Front Sx • Replace unit.
Fault
• ALARM 728 • Fault in the CCRA Front Dx Unit. • Verify the CAN BUS cable.
CCRA Front Dx • Replace unit.
Fault

• ALARM 729 • Fault in the CCRA Rear Sx Unit. • Verify the CAN BUS cable.
CCRA Rear Sx • Replace unit.
Fault
• ALARM 730 • Fault in the CCRA Rear Dx Unit. • Verify the CAN BUS cable.
CCRA Rear Dx • Replace unit.
Fault
• ALARM 731 • Fault in the CCRA Front Sx Unit. • Verify the CAN BUS cable.
CCRA Front2 Sx • Replace unit.
Fault
• ALARM 732 • Fault in the CCRA Front Dx Unit. • Verify the CAN BUS cable.
CCRA Front2 Dx • Replace unit.
Fault
• ALARM 733 • Fault in the CCRA Rear Sx Unit. • Verify the CAN BUS cable.
CCRA Rear2 Sx • Replace unit.
Fault
• ALARM 734 • Fault in the CCRA Rear Dx Unit. • Verify the CAN BUS cable.
CCRA Rear2 Dx • Replace unit.
Fault
• ALARM 735 • Fault in the Key Pad Unit. • Verify the CAN BUS cable.
Key Pad Fault • Replace unit.
• ALARM 736 • Fault in the MIDAC Front Unit. • Verify the CAN BUS cable.
MIDAC Front Fault • Replace unit.
• ALARM 737 • Fault in the MIDAC Rear Unit. • Verify the CAN BUS cable.
MIDAC Rear Fault • Replace unit.
• ALARM 738 • Fault in the View Unit. • Verify the CAN BUS cable.
View Fault • Replace unit.

• ALARM 739 • Fault in the Pressure Transducer • Verify the cable.

Press Trasd Front Front Right • Replace unit.
Right Fault

Press Trasd Front Front Left • Replace unit.
Left Fault

Press Trasd Rear Rear Right • Replace unit.
Right Fault

Press Trasd Rear Rear Left • Replace unit.
Left Fault
• ALARM 900 • •
Ovl1
• ALARM 901 • •
Ovl2
• ALARM 902 • •
Ovl3
• ALARM 905 • •
Inp Esclus
• ALARM 906 • •
Bridging Device
• ALARM 907 • •
Bridging Device DI
• ALARM 908 • •
Inp Esclus A2B

15
Warnings
The LMI is an electronic device aimed at aiding the operator with the current use of the
machine, warning him by means of visual and audible alarms when approaching dangerous
conditions.
However this device cannot replace the operator’s good experience in the safe use of the
machine.
The operator is responsible for operating the machine under safe conditions of the machine as
well as for accomplishing all prescribed safety rules.
The operator must be able to detect if the data given by the LMI are correct and if they
correspond to the actual working conditions.
He must be able to utilize the data given by the LMI in order to operate under safe conditions at
any time.
The LMI is an electronic device including several sensing components, therefore it can be
subject to failures or defects.
The operator must recognize these events and he must take action ( to proceed to repair if
possible or to call 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 is supplied with a transponder for the by-pass key function.
With normal working operations this transponder must not be positioned on by-pass key.
It is forbidden to use the key to lift loads exceeding the loads values allowed by the
Manufacturer.
The key can be used only when an emergency/malfunctioning occurs or in case of a situation
justifying its use.
Only Authorized Personnel is allowed to the use the transponder; they are also responsible for
it.
The LMI has a powerful FAIL-SAFE auto diagnosis program suitable to verify its good
operations and the one of its transducers. In case a trouble has been detected, the LMI 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.
Operating conditions usually change when: Further components are fitted or removed ( jib
counterweight) and relevant Table selecting mode is set on the control panel. Outriggers
Extension / Withdrawn, Turret Front/360° rotation , On Wheels/Outriggers, operating Modes are
set in automatic mode by means of micro-switches.
Generally it is compulsory to follow the Manufacturer’s instructions and procedures at any time.
000000-RT_100.uso.EN.00-MCR I 71 I 15 | Warnings
Le informazioni contenute in
questo documento sono fornite a
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Accessories Operation and maintenance manual
V
Accessories
L E
A B
I L
VA
A
T
N O
Chapter V – ed. 11-2009 page /2

Operation and maintenance manual Accessories
page /2 Chapter V – ed. 11-2009

Maintenance Maintenance and operator's manual
VI
Maintenance
Chapter VI - ed. 11-2009 page 1/60

Maintenance and operator's manual Maintenance
page 2/60 Chapter VI - ed. 11-2009

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.

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.

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.

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 vapour and particles). The following procedures
must be adopted when welding or cutting painted steel:
• 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.

Tyre pressures
Periodically check tyre inflation pressures
making sure that the pressures recommended for various applications
are complied with. Refer to the inflation pressures specified on the
stickers in the operator's cab.
Turntable fixing
Periodically check the lubrication and fixing of the turntable. In case of
anomalies, request the assistance of a Terex® specialist who will
advise you on the operations to be carried out. THE TURNTABLE
FIXING BOLTS ARE AN INTEGRAL PART OF THE CRANE
STRUCTURE.
Winches fixing
Periodically check the lubrication and fixing of the winches. In case of
advise you on the operations to be carried out. THE WINCH FIXING
BOLTS ARE AN INTEGRAL PART OF THE CRANE STRUCTURE.
Wheel fixing
Periodically check the lubrication and fixing of the wheels. In case of
advise you on the operations to be carried out. THE WHEEL FIXING
BOLTS ARE AN INTEGRAL PART OF THE CRANE STRUCTURE.
Starting the machine after replacing a hydraulic

component
After having changed one of the components in the hydraulic system:
pump, directional control valve, cylinder, tank, run the engine at idle
speed for 20-30 minutes without using any of the hydraulic functions,
then bleed air from 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®.

Boom telescoping chain tension check

(Only mod. RC30-RC40-A600)
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.

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 (distorsion 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 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 jib completely and check the integrity of the ropes 1
comprising the tie-rope of the telescopic jib.
Adjust the tensioning with the adjuster screw 2

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

(A') by 15 to 20 mm, a Terex® specialist should be called in quickly.
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.

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.

Visual examples of various problems that can occur to the rope
Breakage and tearing of wires on two consecutive strands that required

High wear and very many broken wires that required immediate
Broken wires on the same strand and slight wear
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.
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.

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.

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)
Rope winding from the top of the drum with end fixed to the left wing;
use the right hand 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 protrude by 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.

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.

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
385/95 XMH S TT 170 E
9 bar 9 bar
MICHELIN XMP 10 bar 10 bar

14.00 R24 PIRELLI 10.25 bar 8.5 bar
ADVANCE 10 bar 7.5 bar
MICHELIN 8 bar 8 bar
16.00 R25
PIRELLI 9.5 bar 8 bar
16.00 - 25 ADVANCE 10.5 bar 7.5 bar
PIRELLI 7 bar 5.75 bar
20.5 R25 MICHELIN 5.5 bar 5.5 bar
TRIANGLE 6.9 bar 4.5 bar
PIRELLI 7 bar 5.75 bar
23.5 R25 MICHELIN 5 bar 5 bar
26.5 R25 MICHELIN 5.5 bar 5.5 bar
26.5 - 25
ADVANCE 5.7 bar 3.5 bar
29.5 R25 ADVANCE 7 bar 6 bar
The pressures given refer to cold tyres, therefore also the inflation and
pressure checks must be carried out on cold tyres.

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
5 8
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
1” 818 ÷ 897 Nm 1257 ÷ 1382 Nm
1 1/8” 1098 ÷ 1206 Nm 1781 ÷ 1957 Nm
1 1/4" 1549 ÷ 1703 Nm 2511 ÷ 2762 Nm

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 M22 class M24 class M27 class
10.9 10.9 10.9 10.9
Model RC30 -
470 / / / / / / / / / / / /
RT35
Model RC35 / / / / 650 / / / / / / / /
Model RC40 / / / / 650 / / / / / / / /
Model RC45 / / / / 650 / / / / / / / /
Model A600 / / / / / / / / 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.
Max. pressure valve calibration
RT35 RC30
RC45-1 A600-1 RC60 RT100
RC35 RC40
Winch 210 210 210 210 210 260 U
Lifting cylinder Boom 210 210 240 230 230 260 U
Boom lowering cylinder
50 50 50 50 50 70 U
with servo-controlled valve
Boom lowering line SV

18/20 18/20 18/20 18/20 18/20 /
block relief valve
220 U 220 U
Boom retraction cylinder 290 210 260 230 220 2°+3° 4°+5°+6°
Section Section
230 210 210 U 220 U
Boom extension cylinder 250 210 220 2° 3° and 4° 170 2°+3° 4°+5°+6°
Section Section Section Section
Rotation reduction gear 150 150 150 150 150 180 U
Outrigger cylinders 140 140 140 160 160 160 {

Steering 150 150 150 150 150 180
Servocontrols 40/45 40/45 40/45 40/45 40/45 /
Winch speed 2 valve 150 150 150 150 / /

Air conditioning valve 150 150 150 150 150 150
Gearbox oil cooler bypass
/ / / 200 200 /
valve

Outrigger pressure
point
Pressure point for winches, lifting cylinder,

telescopic cylinders, slewing
Steering pressure
point

Quantity of lubricants
Part description
page 22/60
RC30
um RC35 RC40 RC45 A600 RC60 RT100
RT35
Engine oil l 18 18 18 18 18 18 18
Gearbox oil l 22 22 22 22 32 19 41
Front/rear axle + oil l 37 43 43 43 64 69 82

Rotation reduction
l 6 6 6 6 6 6 6
gear oil
Total l 460 600 600 600 800 800 1380

Hydraulic
circuit oil
Tank l 390 470 470 470 600 600 1000
Quantity of oils
Main winch oil l 12 12 12 12 28 20 42
Auxiliary winch oil l 12 12 12 12 12 12 12
Brake fluid l 1.05 1.05 1.05 1.05 /// /// 2
Boom guide blocks

kg 5 6 7 10 8 10 9
grease
Slewing ring, pin,

kg 3 3 3 3 3 3 5
bearings grease
Radiator antifreeze l 9 9 9 9 11 11 13
Maintenance
Chapter VI - ed. 11-2009

"SHELL" lubricants
Type of hydraulic oil in relation to the operating temperature

Model
Tellus T32 Tellus T46 Tellus T68 Tellus ST46
RC30
RT35
-20 C / +45 C
RC35
RC40 -20 C / +25 C -10 C / +35 C 0 C / +45 C
RC45 -10 C / +45 C
A600 -20 C / +45 C
RC60 -10 C / +45 C
RT100 -20 C / +45 C
Operating temperature -20 C / +45 C
Part description Lubricant Part description Lubricant
Engine RIMULA X 15W-40 Rotation reduction gear TIVELA S150

Gearbox DONAX TA Winches OMALA 150
Axles SPIRAX A 80W-90

Diagnostics of engine (CUMMINS)
Engine protection system
The QSB series Cummins engines installed on models RC30, RT35,

RC35, RC40, RC45, A600, RC60, 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.

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") .

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

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

Model RC60

Code Function
F1 Cab heating system
F2 Warning
F3 Cab lights supply
F4 Horn relay supply
F5 Load limiter control unit supply
F6 Emergency mushroom supply
F7 Transmission supply
F8 Outriggers relay supply
F9 Load limiter inhibition diodes control unit common power supply
F10 Deadman safety devices / 15 minutes timer supply
F11 Low beams relay / Boom head light supply
F12 Rear suspension locks solenoid valve supply
F13 Air conditioning supply
F14 Warning
F15 STOP pressure switch supply
F16 Flashing alarm / Beeper / Buzzer supply
F17 Air conditioning pressure switch / Reverse gear / air conditioning solenoid valve
F18 Winchl lifting solenoid valve / Slewing brake release solenoid valve
F19 Carrier / Rear fog light supply
F20 Column / Switches locating indicator lights supply
F21 Rotating light supply
F22 Side instrument panel switches
F23 High beams relay supply
F24 Differential locks solenoid valve / Winch 2nd speed / AUX winch supply
F25 Boom lifting cylinder supply
F26 Frame
F27 Can / Roof windscreen wiper supply
F28 Parking lights supply
F29 Parking lights supply
F30 Worklights supply

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
List "C" every 100 hours
Operation
- air filter
- parking and service brakes
- tightening and fixing of wheels
- engine / radiator
- suspension and steering
- batteries

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 the thimble on the 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

• “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 crane engine stopped)
• Efficiency of load holding valve on lift cylinder (check that rod
retraction is no more than 3 mm over a period of 15 minutes with
the crane engine stopped)
• Efficiency of load holding valve on extension cylinder (check that
rod retraction is no more than 3 mm over a period of 15 minutes
with the crane engine stopped)
• Holding capacity of winch brake (check that drum rotation (in rope
unwinding direction) is no more than 5° over a period of 15 minutes
• Holding capacity of turret slewing unit (with crane stabilised on just
one side and inclined by 4° in a lateral direction, check that the
turret does not rotate)
• Alignment of the boom (completely extend the boom and check
visually to ensure that the sections are reciprocally aligned)
• Efficiency of the rear axle swing restriction cylinders
List "F" every 1000 hours
Operation
- general fixing elements
- hydraulic circuit
- steering
- electrical system
- rotation reduction gear
- checking pinion - slewing ring backlash
- fuel tank
- boom section guide blocks
- winch gears and reduction gear
- braking system
- brakes

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)

Boom
6
4-5
Boom lubrification chart

Frequency Ref. Identification Operation Grease points:
50 h 1 Boom base section Greasing 2 grease nipples
250 h 2 Slide pads Greasing Brush and grease nipples
3 Electric system Check Wiring harnesses
4 Fasteners Check tightness All fasteners
1000h
5 Slide pads Check condition All pads
6 Pulleys Check condition

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.

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.

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 rim of the filler hole.
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.

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.

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.

Telescopic jib and hoisting system
• Greasing the section telescoping guide blocks.

• Grease the hoisting block and boom head sheaves.
• Grease the telescopic boom pivots.
• Grease the boom lifting cylinder.
• Grease the angle indicator pin.
• Check the boom telescoping chain tension
Visually check the lifting rope
Rotation reduction gear
Check the reduction unit oil level with the dipstick.
Universal joint transmission
Check the lubrication and lubricate again if necessary.

The cardan shafts have three grease nipples each for ensuring good
lubrication.
Moderately lubricate the universal joint near the parking brake disk.

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

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 gearbox and the plug (♦) on the bottom of the reduction unit.
With every check, control the efficiency of the breather (•) situated on
the top of the box, washing it with gas oil and drying with a jet of air.

List "C" - 100 hours

Clean the air filter
If the cartridge is dry:

- Blow from the inside outwards at a very low pressure
- Using a lamp, make sure the cartridge is not perforated.
If the cartridge is greasy it must be changed.

The cartridge must be changed after six cleanings and in any case once
a year.
Always change faulty or doubtful cartridges.
Parking and service brakes
Have a specialized technician check the parking brake and service

brake seals.
Wheel tightness
Regularly check the tightness of wheels every 100 hours.

Torque wrench settings:
- Front axle 65 daNm
- Rear axle 65 daNm.
Engine and radiator check
Clean the radiator fins with compressed air.
Check the condition and tension of all engine belts and replace them if
necessary.
Check the engine mounts and replace them if necessary.

Lubrication of the steering cylinders and suspension locking

cylinders
Lubricate the steering cylinders, the suspension locking cylinders and

the fixing pins of the front and rear axle steering cylinders by means of
the grease points indicated (♦).
♦ ♦
♦
♦
♦ ♦ ♦ ♦ ♦ ♦
Batteries
- In normal use, the batteries do not require topping-up. However, in

special cases, e.g. high number of working hours, high operating
temperature, the user can top-up with distilled water. Never add
sulphuric acid.
- Whenever frequent additions of water are necessary, have the
vehicle's electrical system checked.
- An electrical system check is also necessary whenever the battery
tends to go flat.
- Maintenance-free batteries have the good characteristic of keeping
their charge, therefore if the battery (new or used) is not used for a
long time, a recharge every 4-5 months is sufficient. When the
battery has been used for more than 2 years, it advisable to have it
periodically checked.
General battery maintenance
Keep the top part of the battery clean and dry, to avoid short-circuits
and corrosion. Remove the battery terminal clamps and check for any
corrosion. In case of corrosion, remove the deposits and a thin layer of
metal. Cover with vaseline or another suitable product. Tighten the
clamps moderately. When using the wrench, make sure not to touch
the battery casing or other terminals. Do not use naked flames near the
batteries.

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.

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.

specifications.
Winch gears and reduction unit
Check the oil level and gears inside the winch. Carry out the first oil
change, and subsequently every 1000 hours or at least once a year.
Check the main winch and possible auxiliary winch with the same
frequency.
Brakes (RC30-RT35-RC35-RC40-RC45-RT100)
Change the brake oil (when applicable) and filter cartridges.

Boom (RT100)
Greasing: see oil table
Using a grease pump, grease the rear top pads of sections T2, T3, T4,
T5 and T6.
Four grease nipples per section. Two grease nipples per pad.
Access by four holes on the sides of sections T1, T2, T3, T4, and T5
The two grease nipples should not be given the same amount of
grease. A considerable amount should be applied to the one on the left,
but the one on the right should receive much less (one or two
deliveries).
Grease the section sliders with a brush.

Method:
- Machine outdoors
- Machine on outriggers, fully extended.
- Blocked boom tilted to 2°.
- Two people are needed for this operation.
GREASING T2 and T3
T5 and T6 released (remaining however in T4).

Telescope T2/T3 61% (+/-2%). Boom 21.80 m.
Grease T2 pads through the first hole on each side of T1.
Telescope T2/T3 90% (+/-2%). Boom 26.40 m.

Grease T2 and T3 pads through the second hole on each side of T1
and T2.

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.

Telescope T3 alone 100%.

ladder.
DO NOT walk or stand on the boom.
Telescope T4, T5, and T3 alone 100%.

ladder.
DO NOT walk or stand on the boom.

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.

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

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).

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 boom and lifting system (RT35)
• Check integrity of tie-rope for boom telescoping

List "F" - 1000 hours

Check all the fixing elements
Check the fixing of:

- counterweight bolts
- winch bolts
- slewing ring bolts
- rotation reduction unit bolts
- axle bolts
- engine / gearbox and converter bolts
Hydraulic circuit
Check for any leaks in the hydraulic circuit; in case of leaks, replace the
damaged parts.
Steering
Check the tightness of all steering screws and all components (steering
wheel, steering column, steering box, levers and connecting rods).
Make sure there are no hydraulic leaks in the power steering unit.
Electrical system
Check the wiring and relevant fixing elements.
Rotation reduction gear
Change the reduction unit oil every 1000 hours.
Checking pinion - slewing ring backlash
Check adjustment of pinion - slewing ring backlash and adjust by

means of the reduction unit flange (fig.1) if necessary.

Fig.1
The clearance between the pinion and slewing ring (Jn) measured as in
fig. 2 must be checked at the three 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 gearbox and the plug (♦) on the bottom of the reduction unit.

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

Check the tightness of the guide block and support fixing screws.
Check the boom sheaves.
Winch gears and reduction unit
Change the winch reduction unit and internal gear oil.

Change the oil every 1000 hours or at least once a year.
Change the oil with the same frequency as for the main winch and
possible auxiliary winch.
Change the oil and the filter cartridge.

Change the filter cartridge at every oil change.



specifications.
Braking system
Check the brake cylinder fixing elements.

Check the brake circuit lines and replace them if necessary.
Changing the brake oil (when applicable) and filter cartridges.

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.

Changing the brake oil (when applicable) and filter cartridges.
Replace the brake circuit lines every 2000 hours or once a year.

Cooling circuit
Change the radiator coolant every 2000 hours or at least once a year.
B
A
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 hole
(A) until the level corresponds to 2 cm. from the rim of the filler hole.
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.


Model...........................Company:.............................................................
Serial number............................................................................................
Head of maintenance:...............................................................................
Reference list: ".........." Operating hours: ...........................................
Maintenance points:
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Date: ....... / ...... / .......... Signature: .........................................

Model...........................Company:.............................................................
Serial number............................................................................................
Head of maintenance:...............................................................................
Reference list: ".........." Operating hours: ...........................................
Maintenance points:
............................................................................................................
............................................................................................................
............................................................................................................
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Date: ....... / ...... / .......... Signature: .........................................

RT100 - Op Manual

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RT100 Operation and maintenance

Code: 46848 (eng) - rev.00

Translation of the original instructions

Manufacturer: After-sales service:

TEREX ITALIA S.r.l. TEREX ITALIA S.r.l.

Code: 46848 (eng) - rev.00

Code: 46848 (eng) - rev.00

I. Characteristics Edition: 11-2009

II. Warnings Edition: 11-2009

III. Safety and operation Edition: 11-2009a

IV. Control instruments Edition: 11-2009

V. Accessories Edition: 11-2009

VI. Maintenance Edition: 02-2010

This manual must always be accompanied by

Code: 46848 (eng) - rev.00

Code: 46848 (eng) - rev.00

Chapter I - ed. 11-2009 page /8

page /8 Chapter I - ed. 11-2009

Crane performance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Carrier performance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Chapter I - ed. 11-2009 page /8

page /8 Chapter I - ed. 11-2009

Tyres no. 4 29.5R25 tubeless tyres.

Chapter I - ed. 11-2009 page /8

Cab Wide visibility with sliding door. Equipped with air-conditioner.

Electrical 24 V with 70 A alternator and no. two 180 Ah - 850A batteries.

page /8 Chapter I - ed. 11-2009

Chapter I - ed. 11-2009 page /8

page /8 Chapter I - ed. 11-2009

Chapter II - ed. 11-2009 page /14

page /14 Chapter II - ed. 11-2009

General Information � ������������������������������������������������������������������ 5

Chapter II - ed. 11-2009 page /14

page /14 Chapter II - ed. 11-2009

This crane is designed to operate in winds of up to 30 kph. Use of the

Whenever, after the FIRST start-up and subject to the permission of

Chapter II - ed. 11-2009 page /14

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

page /14 Chapter II - ed. 11-2009

Before starting the engine:

Chapter II - ed. 11-2009 page /14

Such improper use of the products is neither envisaged nor

Lifting persons for bungee jumping is inherently dangerous; make sure to

All Dealers and Distributors are requested to use every reasonable

ATTENTION: BUNGEE JUMPING FROM THE CRANE IS

Use of the crane with:

page /14 Chapter II - ed. 11-2009

It is essential to carry out all the prescribed lubrication and maintenance

CAREFULLY READ ALL THE SAFETY INSTRUCTIONS BEFORE

Preventive measures against possible hazards in maintenance operations

TEREX Italia is not in a position to know how maintenance operations are

Chapter II - ed. 11-2009 page /14

Worn or deteriorated stickers must be replaced.

The following are safety decals and must be strictly respected.

PROHIBITED: it is prohibited to remain within the machine's operating

PROHIBITED: unauthorized personnel not allowed

PROHIBITED: do not use naked flames

page 10/14 Chapter II - ed. 11-2009

CAUTION: moving parts

CAUTION: moving parts with danger of crushing

CAUTION: generic danger

CAUTION: danger of falling

Chapter II - ed. 11-2009 page 11/14

Chapter I - ed. 11-2009 page /8

page /8 Chapter I - ed. 11-2009

Chapter I - ed. 11-2009 page /8

page /8 Chapter I - ed. 11-2009

Chapter I - ed. 11-2009 page /8

page /8 Chapter I - ed. 11-2009

Chapter I - ed. 11-2009 page /8

page /8 Chapter I - ed. 11-2009

Chapter II - ed. 11-2009 page /14

page /14 Chapter II - ed. 11-2009

General Information � �� 5

Chapter II - ed. 11-2009 page /14

page /14 Chapter II - ed. 11-2009

Chapter II - ed. 11-2009 page /14

page /14 Chapter II - ed. 11-2009

Chapter II - ed. 11-2009 page /14

page /14 Chapter II - ed. 11-2009

Chapter II - ed. 11-2009 page /14