ARM 550

USE & MAINTENACE MANUAL

Applicable Serial No. *ZA9055O09PK42002*,

1 2 3 4

DATE OF ISSUE 20/01/2010

DATE OF DESCRIPTION MODIFICATION 25/01/2010 GENERAL REVISION

EDITION

CODE

01/2010

1 INTRODUCTION
1. Thank you for buying this PC Produzioni crane. This manual has been developed by PC Produzioni(hereinafter called also Manufacturer), to help you to use the crane properly. Read it carefully in order to understand all the technical information concerning the rough-terrain crane model ARM 550 (hereinafter called also machine). Proper operation and handling of this crane will ensure safety and preserve maximum performance, leading to increased efficiency and work rate. 2. In this manual, the mobile crane operator and the authorized personnel in charge of the maintenance will find useful and important indications for:

knowing the safety procedures and the fundamental accident prevention norms that must
be adopted in order to avoid dangerous situations for people, the machine and the environment itself.

A functional description of the components assembled on the machine, and of its genuine
options supplied with the machine itself or installed after the machine has been purchased.

The technical data of the machine homologated. The procedures, checks and adjustments to make on the machine before, during and after
the job has been completed.

The correct ordinary and programmed maintenance and all the checks of extra-ordinary
interventions and maintenance. 3. This manual, with the spare-parts manual and technical documentation, is integral part of the machine and it must stay with the machine itself until the mobile crane will be no longer in working conditions.

4. All manuals and technical documentation must be kept inside the machine for a quick examination; the place for this documentation is on the right-hand side pocket into the cab. In the event that any of the manuals is lost, damaged or that it cannot be read anymore, please ask for an additional copy to PC Produzioni giving all the necessary information regarding the machine model, serial number and manufacturing year. 5.The mobile crane operator and the authorized personnel in charge of the controls, interventions and maintenance, must read and acknowledge the content of this manual, so that it becomes clear to them the way of operating of the machine and all the dangerous situations which must be avoided. 6. The machine and its components are subject to changes in order to improve the final product; in this manual are summarized all information concerning the actual technology state at the time of delivery. PC Produzioni reserves the right to make product and manuals specification changes without notice, and without the obligation to keep updated the previous manuals, except in rare cases; for this reason, when you need any technical or specific material or in case of possible technical modifications on the machine, please contact the Manufacturer. 7. The maintenance schedule written records is an index of precision and constitutes an important record of the interventions done, and it gives a clear view on the future maintenance obligations. 8. The data in the manual must be filled in; the completion of the technical data of the machine are the only information that must be given to PC Produzioni's after-sales department in case of an intervention or spare parts request.

WARNING

The inappropriate use of the machine and the maintenance tasks carried out not in accordance with the Manufacturer instructions may lead to dangerous situations which may cause serious hazard to people and even cause their death. The mobile crane operator and the personnel in charge of the maintenance must read carefully and understand the whole content of this manual before using the machine or carry on any maintenance operation. The procedures and precautions contained in this manual are intended for the correct use of the machine. Any operations which do not conform to the contents of this manual are the operators own risk and responsibility. PC Produzioni will bear no responsibility for any accidents or damage which occur as result. When the user changes through resale or other circumstances the Instruction Manual must be transferred together with the machine

THE SERIAL NUMBER AND CE PLATE

PLATE AND IMPRINTS TO IDENTIFY THE MACHINE

CE PLATE

INDICATIONS AND SAFETY RULES FOR THE MACHINE USE: WARNING

Every safety procedure is contained in the paragraphs of the single controls. The safety devices used adopt mechanical stop and electrical locks activated by micro
switches, pushbuttons and hydraulic devices. In case the machine does not start or any control is not executed in normal working conditions, contact the Dealer, in order to check the electrical system and its single components.

Avoid to by-pass all mechanical, electrical and hydraulic safety devices.

The safety devices are intended to protect the operator and the people nearby during the use of the machine on site and on road. The safety devices that electrically intervene on the controls are:

1. Engine turn on inhibited by the travel order selector when it is different from the neutral (0) position.

2. Hook-block lifting over-limit switch (also when telescoping the boom out).

NOTE: This safety can be intentionally by-passed only to fasten the hook-block to the machine carrier during traveling on road.

3. Micro-switch for winch over-lowering, when on the drum remain 3 wraps of rope.

4. Safety micro-switches on the front part of the joysticks lever, which do not allow any accidental maneuver concerning load lifting and positioning.

5. Hook uplift bypass, this push-button disabled the limit position of hook for uplift the hook to maximum height.

6. Safe-load moment indicator to control the over-load; its purpose is to block the load lifting or boom telescoping before the machine becomes instable and unsafe. When the alarm is engaged, the operator can only lower the load. The mechanical indications of safety during machine traveling on road are: 9. Connecting the hook-block to the carrier. 10. Blocking the slewing motion with its locking pin.

11. Complete retraction of the outriggers boxes and their positioning jacks.

12. Moving the sliding pads into their supports.

13. Boom completely retracted and lowered until it touches the metal ring.

The visual safety procedures and the traveling conditions described in the homologation certificate supplied with the technical documentation are summarized in the section regarding the machine safety norms.

TECHNICAL DOCUMENTATION SUPPLIED

The documentation supplied with the machine is composed of: Use and maintenance manual Spare-parts manual inclusive of electrical and hydraulic diagrams Lifting chart on outriggers Lifting chart on wheels Lifting chart with jib or/and lattice extension Safe-load moment indicator use manual Diesel engine use and maintenance manual Diesel engine spare-parts manual Axles use and maintenance manual CE declaration (only for machines sold in European countries)

1.1 CLIENT'S RESPONSIBILITY

The machine is delivered ready for operating. It is the owner's responsibility providing for local taxes, insurance and whatever is necessary for traveling and operating in the country of final destination.

1.2 SPECIFIC TECHNICAL NAMES

Inside the manual are used the following specific terms from Machine Directive 89/392/CEE and following modifications. DANGEROUS AREA: area inside or near the machine working radius where any person presence constitutes a risky or hazard situation for that person. EXPOSED PERSON: any person inside or near a dangerous zone. OPERATOR - DRIVER: person in charge of operating, adjusting and maintaining and cleaning the machine. QUALIFIED TECHNICIAN OR SKILLED PERSON: specialized and skilled person in charge of executing extra-ordinary maintenance or repair jobs, which require a deep knowledge of the machine, its main components, its functioning, its safety devices and their way of intervention. NOTE As a dangerous area it is intended also every condition to which a person is exposed to risk, danger or hazard even for short time period, such as during regular maintenance for liquids change or part line change.

1.3 TECHNICAL ASSISTANCE

The request for skilled technicians must be directly addressed to PC Produzioni. The requests for intervention must be sent by fax or E-mail to the numbers indicated in the first page of this manual, clearly specifying the reasons that justify the request (mechanical, hydraulic or electrical problems, etc. etc.).

1.4 SPARE-PARTS
Only genuine parts from PC Produzioni. must be used, or original parts from the suppliers which, besides the perfect interchangeability, guarantee also long lasting functionality and durability. Every exception to this rule must be authorized by PC Produzioni's qualified personnel. For each request please indicate always the machine model, S/N, manufacturing year and the quantity of the items desired.

1.5 NON-AUTHORIZED MODIFICATIONS

No modification whatsoever can be made to the machine or to its components without the written authorization of PC Produzioni. Any modification made to the machine can change the parameters of the design concerning the original performance or the components characteristics, making our warranty null and void including the civil and penal responsibility toward any type of accident. In the event of authorized modifications implying welding procedures, before beginning any welding make sure to disconnect the batteries, the transmission trigger box, and the electronic devices; it is advisable to protect from sparks and excessive heat also those rubber and plastic hoses which may be near the welding area.

1.6 PROPER USE INDICATED BY THE MANUFACTURER

The rough-terrain crane described in this manual is designed and manufactured to be operated only by skilled and educated personnel, with regular and specific license to use mobile cranes specifically:

vertical lifting, free load moving and positioning with the mass indicated in the load charts by the Manufacturer. Load lifting with optional equipment's (jib or lattice extension) is allowed only if those equipments are supplied by the Manufacturer.

Other equipment can be installed only after the Manufacturer's written consent and approval. NOTE Chains, ropes, carrying poles, lifting rings, shackles or any other lifting devices do not constitute optional equipments. These accessories must be suitable for the lifting, and they have to be of the right sizes keeping in mind to respect the safety coefficients requested by the laws of the country where the machine operates. The machine can: lift the load with wind force 6/8 (from 10,8 - 13,8 m/sec to 17,2 20 m/sec) with respect of the boom length; operate in explosion-proof environment with temperatures between -20C and +40C.

1.7 IMPROPER OR NOT ALLOWED USE

WARNING: in this paragraph are indicated only some of the improper or not allowed uses, which can be logically foreseen; it is impossible foreseeing all the improper uses, and we invite to consult the Manufacturer in case particular use situation arise. Rough-terrain cranes are manufactured only to lift and move goods, materials or inert loads; the following uses are prohibited:

The use of the machine by minors or inexperienced and not skilled people. The use of the machine for traveling on road without paying attention to the normal road regulations and safety procedures. The use of the machine on road with optional equipments and counterweights not contemplated in the homologation certificate. The use of the machine for lifting animals or persons. The use of the machine after drinking alcohol and taking drugs.

NOTE: When the machine is used to lift people, it needs a certification from different from the required auto certification as "lifting device".

The use of the machine to lift containers for liquids, flammable goods and bulk material without
having the necessary equipment and slings to safely operate with these materials. The use of the machine on vertical links of other lifting devices (lifting the load with 2 cranes and one single connecting point). The use of the machine to carry goods and people. The use of the machine to tow wrecks or damaged vehicles. The use of the machine to haul trailers. The use of the machine in explosive or in non aerated areas.

1.8 TECHNICAL NORMS APPLIED

In designing and manufacturing our machines, besides all the mechanical dimensioned calculations norms concerning the structures, it has been paid attention to the following rules and directives in order to guarantee the essential safety requisites:

Machine Directive CEE 89/392 modified by CEE 91/368, CEE 93/44, CEE 93/68. EN Rules 292/2: safety of machinery. Fundamental concepts, general designing principles.
Specifications and technical principles.

EN Rules 60204-1: safety of machinery. Electrical systems for industrial machines. General
requisites.

1.9

ENVIRONMENTAL CONTAMINATION FROM MAINTENANCE

All these materials are considered special waste: - engine oil; - hydraulic systems oil; - axles and reducers oil; - engine cooling liquid, if there is antifreeze solution; - batteries; - tires. For their waste disposal, please adopt all the measures allowed by the regulations and legislation's in the country where the machine operates.

1.10 MACHINE DISMANTLEMENT

WARNING: the machine dismantlement has to be carried out only by authorized and qualified companies. The mobile crane described in this manual is built with non pollutant metal materials except: 1. Plastic material parts, rubber or techno polymeric o-rings and seals, electrical wires, tyres, hydraulic system hoses, belts and soundproofing material. 2. Batteries. 3. Oil contained into the hydraulic systems. 4. Diesel fuel and engine cooling liquid. For these products waste please adopt all the measures allowed by the regulations and legislations in the country where the machine operates.

2 GENERAL INFORMATION
2.1 DESCRIPTION OF THE MOBILE CRANE
- Compact dimensions machine with 4 wheel driving (4 WD) and 4 wheel steering (4WS), suitable for off-road use. - Carrier made of high-quality cold bent steel onto which is installed the slew ring and the superstructure. - Machine traveling by hydrostatic transmission in a closed circuit, composed of one pump and one hydraulic motor with variable displacement flanged to the gear box. It is connected to the axles through transmission shafts. - The front axle is fixed whereas the rear axle is oscillating though a balance; the rear axle can be hydraulically locked from the cab during the pick-and-carry operation. - Front axle power steering and independent rear axle steering allow the following possibilities: A. front axle steering only, for traveling on road; B. crab steering, for use on site at low speed; C. coordinated steering, for use on site at low speed; D. rear steering only, for use on site at low speed. WARNING: the steering possibilities B, C and D are independent from the steering wheel, and have to be utilized only in off-road use on site at low speed.

x Double circuit hydraulic braking system, according to EEC rules, with drum brakes acting on
both axles.

x Spring applied parking brake operated by a hand lever, acting on both axles. x 4 independent hydraulic outriggers, for machine positioning, with lock valves; they are controlled
from the cab with single safety operation and air bubble level.

x 4 single wheels, 16.00 25 type. x 6 cylinder Iveco turbocharged after-cooled water cooled diesel engine, developing 169 kW (230
HP) at 2.300 rpm.

x x x x

Cold bent special steel superstructure. 360 continuous superstructure swing by a single roller slew ring with external teeth. Slewing motor with epicyclical reducer and automatic brake. 4 section fully hydraulic telescopic boom, with 1st + 2nd + 3rd section proportional, from 10,5 to 35 meter length, made of cold bent special steel. slewing motion, boom derricking, boom sections telescoping and winch lifting and lowering.

x Hydraulic system composed by one fixed displacement piston pump and three gears pumps for x Variable displacement piston pump for machine translation (forward and reverse). x The boom telescoping controls are performed through servo-controls and joysticks with safety
push-buttons, which allow simultaneity of movements. counterbalancing valve.

x Main winch operated by an hydraulic motor with epicyclical reducer, automatic brake and x 4 pulleys main hook-block, anchor type, with 50 tons capacity. x Steel made ergonomic cab for machine travel and crane operation, fully adjustable seat,
complete instrumentation for crane use.

2.2 MACHINE BREAK-IN

All PC Produzioni mobile cranes are tested in every component before shipping, and therefore they need only the normal break-in for their first 50 working hours. During this time period, the machine has to operate at low speed in order to uniformly warm up the oils in the systems and the hydraulic components. Even if the diesel engine does not necessarily need to break-in, let the engine cooling liquid warm up until it reaches 60C, before utilizing full power or work with heavy loads. During the break-in period, avoid sudden stops the engine under load, except in case of dangerous situations or emergency. To carry on the maintenance operations during break-in period and the first 200 working hours, see the maintenance schedule.

3 SAFETY INFORMATION
3.1 GENERAL INFORMATION
The rough-terrain crane ARM 550 described in this manual has been designed and manufactured according to the safety rules of the European Community Directives. In order to avoid damages and accidents, and before operating or with the machine, read, understand and follow all the procedures and indications contained in this manual and those written on the machine plates. To identify the safety indications contained in this manual, are used the following names and symbols: DANGER: This word is used in the manual safety indications and on the plates whenever there is high probability to cause severe harm, even death, if no attention is given to this signal. These indications give the normal precautions to avoid danger. Not paying attention to these indications, damage on the machine may occur.

ATTENTION: This word is used in the manual safety indications for dangerous situations if, not avoided, may cause little or moderate damages or harm. This indication can also be used for dangers which may cause machine or components damage. IMPORTANT: This word is used for precautions to take in order to avoid operations which may shorten the machine or components life. NOTE: This word is used for sentences giving useful information concerning the correct machine use or the task being performed.

WHAT YOU MUST IMMEDIATELY KNOW AND UNDERSTAND

x For ease of information, some pictures in this manual are shown without protection panels. x Do not by-pass the safety devices and do not use the machine whenever the protections are
removed.

x The machine can work with the protections removed and some safety devices by-passed, only
and exclusively during the short extraordinary maintenance procedures carried on by authorized and qualified technicians, operating in an area forbidden to non-authorized personnel.

x It is strictly prohibited to modify or alter the machine general performance: the Manufacturer is

not responsible or held liable for damages or accidents due to machine tampering or modification. more sections, for ease of consultation. These sections must be read, understood and followed as integral part of the safety instructions given.

x The information on the safety devices written in the following sections are been divided into

3.2 SAFETY RULES

The mobile crane operator, during onsite inspections and machine preparation, must wear protective helmet, appropriate nonskid rugged boots, cut-proof working gloves and his antiaccident clothes. During machine use and traveling on road, the operator must take off his gloves in order to have more manual sensitivity. During machine maintenance, avoid to wear large and fluttering clothes, rings and watch; avoid also approaching the machine with long free hair: in fact it can get stuck in moving parts and may cause hazard. During maintenance operations wear protective helmet, safety boots, glasses and ear plugs.

For maintenance of those components located on the superstructure, use a safety ladder.

x x x x x

For maintenance use only appropriate quality tools; reject worn, low quality or non appropriate tools, since they cause personal injury. Use the mobile crane during good visibility conditions and sufficient light; stop any operation when there are atmospheric events which may alter such conditions (rain, fog or snow). The mobile crane must be operated only by qualified skilled operators; the same rule is valid also for the personnel in charge of the maintenance. Avoid using the machine in altered psychophysical conditions, such as vertigo, after alcohol or drugs assumption, which may lead to low reflexes or cause sleepiness and drowsiness. Before using the machine, the qualified operators have to: 1 - Read, understand and follow completely this manual. 2 - Fully understand the functions of the controls and warning lights 3 - Be familiar with all machine controls; this is to understand the load moving speed with each single movement, the reaction speed of each maneuver, the machine reactions during traveling and braking. The operators have to follow and completely respect the safety instructions contained in this manual. Only authorized personnel can stay in the working area of the machine (intended as working radius) therefore only slingers, riggers, signal man and mobile crane operator). Do not allow unauthorized personnel to enter the working area of the machine, during machine maintenance, checks, part line change and machine operations.

x x

NOTE: in this paragraph are described all procedures and specific indications for the type of machine, not keeping into account (since they are obvious) all the necessary road rules and laws contained in the country's own regulations where the machine operates.

3.2.1 ON ROAD TRAVEL PROCEDURES AND INDICATIONS x To travel on or off-road, the machine has to follow these directions according to the
homologation document: 1. The boom has to be completely lowered and the supplied metal ring has to be installed. 2. The hook-block has to be tied to the carrier, and the ropes have to be slightly in tension to prevent jolts; try not to stretch the ropes too much because they may determine abnormal tensions on the superstructure. 3. The turret has to be locked with its locking pin. 4. The outriggers must be completely lifted up, telescoped in and connected to their support brackets. 5. The rear axle has to be locked. 6. The working lights have to be turned off. 7. The low beams have to be turned on. 8. The additional rotary beacon has to be turned on.

NOTE: for road traveling, an escort vehicle has to go with the machine.

x Before traveling on road, check all lights, turning signals and rear-view
mirrors. Replace them if they are broken.

x x

Clean the cab floor whenever there is grease, oil, mud or debris. During traveling, avoid gradients more than 40%.

x Before undergoing a bridge or similar structure, check its clearance and

compare it with the machine's.

Before crossing a bridge, make sure to check the bridge capacity, and compare it with the machine total weight.

In case of reverse driving, ask for assistance to check the available space behind and around the machine. x Stop the job whenever the normal attention diminishes, exposing the machine operator and the people around him to potential hazard.

3.3 ENTERING THE SITE AND SETTING UP THE MACHINE

x Before entering the site a serious analysis has to be done, concerning the ground stability and
compactness, on which the machine has to transit and position itself. compact ground.

x The machine speed has to be low and quite constant, especially in presence of soft and not x Before entering the site, check the tires pressure and inflate them to the prescribed pressure
indicated on the plate located inside the cab.

x Before positioning the machine, check the load that has to be lifted, and its final position where
it will be unloaded; check the safe-load moment indicator display, the boom angle and its position in order to have clear the ideal machine positioning. leveled. If it is necessary, add some wood plates underneath the outriggers floats.

x Make sure that the outriggers are on a firm and compact ground and the machine is correctly x Check the level air bubble on the dashboard to set up the machine correctly. x The machine has to be positioned with the outriggers fully extended. x Check the ground nearby the wheel is compact, solid and able to support the machine weight
without causing the load to go out of balance.

3.4 SLINGER'S RULES

x Load slinging procedures and its connection to the hook-block must be executed by qualified
personnel, that has to make sure that all lifting equipment is in good and efficient order, and it is suitable for the load.

x Chains, ropes or slinger devices must be of adequate capacity with the weight of the load that

has to be lifted; all these devices have not to be twisted or entangled. The ropes do not have to be bent or damaged. charge of the whole operation, of the hand signals and of the load connection to the hook-block.

x If for the slinging operation more people are to be utilized, it is necessary that one person is in x That responsible slinger is the only person signaling to the crane operator all the maneuvers to
be performed using the manual international signals; the indications and the control of the load have to last until the whole operation is completed.

x The responsible slinger has to keep the unauthorized personnel off the working area. x It is forbidden to claim onto the load to check the slings, even if the load is still on the ground but
the lifting device (ropes, chains, etc.) are already in tension. cannot cause the moving of the center of mass.

x Before lifting the load completely, check its balance and that its possible swaying movements

3.5 OPERATOR'S RULES

x It is forbidden to lift loads heavier than those indicated in the lifting charts; therefore it is
advisable knowing ahead of time the load weight, in order to put the correct part lines, the boom angle and the correct distance of the machine from the load.

x In order to determine the boom angle, check it on the safe-load moment indicator display. x Before beginning to lift a load, make sure that the rear axle steering is set free and that all
outriggers clear the wheels off the ground.

NOTE:

the rear axle steering is used for pick-and carry operations; it is advisable to set the machine ready for that possibility, even though the operator does not use it immediately.

x Pick-and carry operations are dangerous; it is possible to do them for short distances only, on
even and solid ground. During these operations, lower the load to clear the ground, lift the outriggers of 5-8 cm and move the machine slowly to prevent load oscillation.

x The load has to be lifted vertically to avoid oscillations which may lead to structures overloading,
and eventually get the machine instable; avoid every crossways lifts or pulls. maneuver, use the horn.

x Every maneuver has to be carried out after the consent of the signal man; before beginning a x The starting and stopping of each maneuver has to be performed gradually and softly. Avoid
sudden starts and stops because they cause solicitations, oscillations and uncontrollable load movements which may lead to machine loss of stability and therefore hazardous situations. Pay attention in a special way to the swinging maneuver, which has to be performed at low rpm.

x The second speed of the winch has to be used to speed up the movements with light loads. x Always check the load; before looking somewhere else, stop the maneuver. x It is possible to slew the superstructure without outriggers only with the boom completely closed
and lowered.

x Stop every manoeuvre and let the load settle down whenever the load oscillation and swinging
assume proportions which may compromise the machine stability and create hazard.

x Make sure that into the working radius of the machine there are not unauthorized people; in the x It is not allowed to move the load over people, even though these are authorized personnel. x Warn the beginning of operations by using the horn; the following movements are signaled with
the horn and intermittent lights.

event that after inviting these people out of the working area, there still is someone, stop every operation and lower the load.

x Even if ropes are subject to periodic checks, before beginning to work check their conditions;
wear due to corrosion, damage or buckling due to bending must lead to the rope change.

x Check all the time that the hook-block remains suspended; when it is on the ground or on any
other surface, it can move the part lines, twist the rope and move the layers on the drum and damage the rope itself. getting entangled with any other thing.

x During lifting and swinging, the load has to be completely free and not coming in hard contact or x It is forbidden to lift and swing the load over the working cab. x Never leave the machine with the load hanging, even for short time periods.

3.6 NORMS FOR TASKS CARRIED OUT IN PARTICULAR SITUATIONS

With this definition we want to indicate those jobs done near electrical lines, during unfavorable weather conditions, jobs with more cranes, operations using two hook-blocks.

3.6.1 OPERATIONS NEAR ELECTRICAL LINES

This operation is very dangerous and may lead to death by electrocution; respect the safety minimum distances indicated by the Authority and by the safety laws concerning this subject. The minimum suggested distances are clearly shown in this chart, which refers to the support insulators of the cables. Cable tension 1,0 kV (distribution line) 6,6 kV (2-3 insulators) 33 kV (minimum 3 insulators) 66 kV (minimum 6 insulators) 154 kV (minimum 10 insulators) 275 kV (minimum 19 insulators) Minimum distance to keep 5 meter 5 meter 6 meter 6 meter 8 meter 10 meter

NOTE: the minimum distance of these aerial lines may vary from country to country.

x In order to lower the risks of this danger, besides keeping these minimum distances, you have
to: 1. Ask the Electrical Company to disconnect the power and to lower the lines to the ground. 2. Ask the technical personnel to position themselves in the most favorable place to communicate with the crane operator and to be in charge of the whole operation. 3. Work at low speed paying a lot of attention. 4. If this operation has to be done during windy conditions, remember that the cables sway and therefore the minimum safety distances have to be increased. 5. Learn how to offer first aid in case of electrocution. 6. Keep the Electrical Company and the closest First Aid place phone numbers handy. electricity, the crane operator has not to panic and shall remain into the cab until the power is turned off by the Electrical Company. In the meantime, inform all people to keep off. block or the boom, try to move the machine away by operating in the opposite way.

x If by chance the load or the machine touch the electrical lines or comes in contact with a flash of x If the machine is still working and the electrical cables are entangled with the load, the hookx If because of this contact the crane operator has to leave the cab due to a dangerous situation
(short-circuit, fire, etc.) do not get off using the crane ladder; jump out from the machine the farer away possible, keeping the feet together in order to avoid the voltaic arc.

DANGER: after being in contact with an electrical line, before utilizing the machine, check all electrical and electronic circuits.

x The ground nearby the machine is in part electrified; abandon this area jumping out and
keeping your feet together.

x Inform eventual rescuers not to approach the machine, but to wait until the power is turned off
and the minimal safety procedures are taken.

3.6.2 OPERATIONS DURING WINDY CONDITIONS

The jobs done during windy condition require a lot of attention from the operator, because the wind action on the load surface, creates a sail effect which increases the working radius, therefore putting in danger the machine stability. In windy conditions, check the intensity shown in the chart below, keeping in mind that the maximum values prescribed by the Manufacturer are: BOOM LENGTH UP TO 20 METER - MAXIMUM WIND FORCE = 8 BOOM LENGTH UP TO 42 METER - MAXIMUM WIND FORCE = 6 BOOM LENGTH UP TO 60 METER - MAXIMUM WIND FORCE = 4 DANGER: the values in this chart are valid only if the load surface is lower than 1 square meter per ton. If this ratio is not respected, stop working.

3.6.3 LIFTING WITH MORE MOBILE CRANES x Lifting with more mobile cranes is a complex procedure which needs high ability from the
operators and a previous accurate planning.

x It is necessary studying and applying a method that considers every situation and at least the

following basis norms: A. the lifting has to be executed under the direct responsibility of one supervisor who has to communicate with the cranes operators with a radio. B. The supervisor has to be in such a position to be easily seen by every crane operator. C. The ground where the mobile cranes operate has to be solid, leveled and consistent; before positioning the machines, provide to leveling and reinforcing the ground. D. All mobile cranes have to be perfectly leveled. E. Check that the safe-load moment indicator is working correctly in each machine. F. These things have to be known: 1. the load weight and its relative center of mass; 2. the maximum working radius that every crane can reach for the entire operation, its boom length and angle; 3. the nominal crane capacity in the most unfavorable condition. G. No mobile crane has to be loaded more than 70% of its net capacity in the most unfavorable conditions. H. The slewing, derricking and telescoping motions must be limited to a minimum. I. The speed of the single movement has to be slow, in order not to unbalance the load and the machine itself.

DANGER: it is forbidden to perform the pick-and-carry motion with more mobile cranes because the oscillations can cause high intensity load transfers from one machine to another. All ropes have to be kept vertical; if they are not in this position, lateral leans may arise, due to overload. L. Pay attention when lowering the load, because it should touch its final position at the same time; by laying it down only one end you will overload the other more than it is due.

3.6.4 LIFTING WITH BOTH WINCHES

A. Lifting with 2 winches is allowed even though it is not considered a normal working use. B. When performing this type of operation, the number of part lines has to be the one indicated on the load chart in the technical documentation. C. This way of operating needs optional equipment (jib or lattice extension). D. The maximum lifting load is the one allowed by the equipment installed. E. The load has to be kept even during the lifting operation, and adjusting the speed on the slower hook-block. F. The load has to be laid down on each support evenly.

3.7 INTERVENTIONS FOR BREAKAGE

3.7.1 MACHINE TOWING x
The machine has to be towed when: 1. It is in an emergency situation stuck in the mud or sand. 2. The diesel engine or the hydraulic system of the transmission is damaged or broken. The towing hooks are on the front and rear side of the carrier.

ATTENTION: Prepare equal length ropes to pull in a constant and continuous way without snaps. Pull the machine in a parallel direction of the travel order, to avoid excessive side efforts on the hooks.

x If the machine has to be towed out from mud or sand, help the towing by selecting the gear
according to the towing direction. ropes.

x To tow the machine, use appropriate dimensions ropes; do not utilize worn, damaged or twisted x During towing none is allowed near the machine or the ropes. x The machine can be towed at low speed only if the diesel engine is working. In this case,
dismantle the transmission shafts and turn on the diesel engine, letting it slightly accelerated. DANGER: x on-road machine towing has to be done by authorized vehicles only, and in accordance with the country's road laws and directives.

x The diesel engine has to be turned on in order to keep pressure on the steering and braking
circuits, to drive the machine safely. circuits do not work.

x If the problem is the diesel engine, the machine cannot be towed, since the braking and steering x If the inconvenient is in the hydraulic parking brake circuit, the negative disks brakes are
automatically engaged; in this way towing the machine is possible only if they are mechanically released (see the axle use and maintenance manual given with the technical documentation).

3.8 INTERNATIONAL HAND SIGNALS

Since the manual hand signals are very important for the crane safety working on site, the following pages contain some illustrations. These visual signals must be the same all the time, unless other instructions are given by radio or telephone.

A - EXTENDING THE TELESCOPING BOOM Both fists in front of body with thumbs pointing outward.

B - RETRACTING THE TELESCOPING BOOM Both fists in front of body with thumbs pointing at each other.

C - EXTENDING THE TELESCOPING BOOM One hand signal: fist on chest with thumbs hitting chest.

D - RETRACTING THE TELESCOPING BOOM One hand signal: fist on chest with thumb pointing outwards, fist hitting chest.

E - RAISE BOOM Arm straight out, closed fist, thumb pointing up.

F - LOWER BOOM Arm straight out, closed fist, thumb pointing down.

G - MOVE SLOWLY Use one hand to give any motion signal and place other hand motionless in front of hand giving the motion signal (hoist slowly shown as example).

H - RAISE THE BOOM With arm extended, thumb pointing up, flex fingers in and out as long as load movement desired.

I - HOIST With forearm vertical, finger pointing up, move hand in small horizontal circles.

L - LOWER With arm extended down, move forefinger pointing down, move hand in circles.

M - USE MAIN OIST Tap fist on head; then use regular signals.

N - USE WHIPLINE (AUXILIARY) Tap elbow; then use regular signals.

O - LOWER THE BOOM With arm extended, thumb down, flex fingers in and out as long as load movement is desired.

P - SWING Arm extended, point in direction of swing of boom.

Q - STOP Arm extended, palm down, move hand horizontal.

4 TECHNICAL DATA
4.1 DIMENSIONS

4.2 CHARACTERISTICS
MASS IN TRAVEL ORDER (standard machine) x Front axle load: 14 tons x Rear axle load: 18 tons x Counterweight: 8,5 tons x Machine total weight: >32 tons with 8,5 tons counterweight OPERATING SPEEDS (at 2.300 rpm) x Maximum real speed (CUNA): >35 Km/h x Maximum gradient: 40% real x Main winch speed per single line: 0-100 m/min x Main winch rope diameter and length: 16 mm/180 m x Main winch maximum pull: 60 kN at the first layer x Auxiliary winch (option): 60 kN at the first layer x Slewing speed: 0-1,3 rpm x Boom derricking speed (from -1,6 to +80): 50 sec. approximately x Boom telescoping speed (from 9,3 to 30 m): 60 sec. approximately

x x x x x x x x x x

MAIN HOOK-BLOCK Maximum capacity: 55 tons (daN) Number of pulleys: 4 Number of part lines: 8 Weight: approximately 400 kg. (daN) Distance between pulleys axle and hook-block: approx. 1.500 mm AUXILIARY HOOK-BLOCK Maximum capacity: 6 tons (daN) Number of pulleys: 0 Number of part lines: 1 Weight: approximately 170 kg.(daN) Distance between pulleys axle and hook-block: approx. 1.250 mm

OPTIONS WEIGHT x 9 meter lattice extension: 400 kg (daN) approximately x 16 meter telescopic lattice extension: 750 kg (daN) approximately x Auxiliary winch: 500 kg (daN) WHEELS x Rims: 11,25" x 4 single tires: 16.00 25 x Inflating pressure on road: 10 bar x Inflating pressure on site: 10 bar

4.3 VIBRATIONS TO WHICH THE OPERATOR IS EXPOSED

The value to which the operator's arms are exposed is lower than 2,5 m/sq.sec, whereas the value to which the body is exposed is lower than 0,5 m/sq.sec.

4.4 NOISE
x The photometer test concerning the machine noise have been carried out according the norms
ISO 3746/79, on a new machine with the engine working at 50% of the maximum power. measured in 77 dB(A). following diagram.

x The continuous acoustic pressure level to which the crane operator is exposed in his cab is x The level of the acoustic pressure in the different working configurations is shown in the MAXIMUM WORKING RADIUS: 30 m.

4.5 MAIN COMPONENTS

5 SAFETY PLATES AND PICTOGRAMS

5.1 LOCATION OF THE PLATES, SAFETY AND INFORMATION PICTOGRAMS
x The safety plates must always be complete and readable; for this reason, whenever they are
dirty, or covered with grease or oil, clean them with a detergent solution. Do not use fuels, solvents or gasoline.

x In case the plates are damaged, the end user has the obligation to replace them, asking them to

the Manufacturer; if one safety plate is in part not readable or missing, the machine cannot be used until a new plated is applied on the machine. applied on the new one as well. follow the indicated directions.

x In case you replace a part where a safety plate is applied, make sure that the same plate is x On the machine can be applied also other plates in addition to those indicted below; however

SAFETY PLATES

Access forbidden to non-authorized personnel Access in the cab allowed to the crane operator only. Position: on the cab door. Code:

Read the manual Read carefully the content of the use and maintenance manual before utilizing the machine or begin maintenance operations. Position: on the dashboard. Code:

Danger of stumbling: Position: near the ladders. Code:

Danger of fall Position: near ladders and into the cab toward the exit Code:

Corrosive liquids Position: in the battery compartment. Code:

Danger in the working area Do not approach and stay in the working radius of the machine when the crane is operating and when the load is hanging. Position:- on each side of the turret (N2). Code: Prohibition to clean or lubricate moving parts Position: near the winches (N2). Code:

Danger of cutting Position: on the main and auxiliary winch body. Code:

Obligation to engage the parking brake before turning on the diesel engine Position: inside the cab. Code:

Towing points Position: near the towing hooks Code:

Danger for hanging loads Position:- on the hook-block(s) (N 2). - on the counterweight (N 2). Code:

Tires inflation pressure Position: cab door Code:

Danger of burn Position: - near the muffler(s) N 1) - on the axles hubs (N 4) Code:

Presence of tension Position: in the battery compartment and on the electric panel. Code:

Danger of hands crushing Position: - on the side outriggers supports (N 2). - on the boom lower part (N 1). Code:

Safety rules for braking system Position: Cab door Code:

Rules for the slingers Position: Cab door Code:

5.1.1 INFORMATIVE PICTOGRAMS

Hydraulic Oil filling Hydraulic Oil filter Diesel engine cooling liquid level Hook-block and Towing hooks Connecting points

Diesel Fuel filling

Diesel Engine Oil filter

Diesel fuel filter

Diesel engine air filter Diesel engine cooling liquid

Auxiliary devices and counterweight lifting points

Hydraulic Oil level

5.2 LOCATION FOR FIRE EXTINGUISHER, FIRST-AID KIT AND GLASS HAMMER (for those countries where it is mandatory)
5.2.1 FIRE EXTINGUISHER
To install a fire extinguisher on the machine, the Manufacturer has chosen its installing position under the seat left arm. IMPORTANT x Check regularly the fire extinguisher operating conditions. x Make sure the operator knows how to use it in case of fire.

5.2.2 FIRST-AID KIT

The place to put this box containing the first-aid kit is on the back side of the cab, under the rear window. IMPORTANT x Check the box regularly, which shall contain disinfectants, bandages, adhesive plasters, medicines. x Check often the medicines expiration dates, and replace them before they expire.

5.2.3 GLASS HAMMER

On our machine is provided for an emergency exit located in the front window. In order to ease the exit from the cab, besides the turning handles, a glass hammer (installed upon request) may be used. Its location is on the rear right side of the cab. IMPORTANT x Check the hammer position, if installed.

5.3 ACCESS TO THE ENGINE COMPARTMENT, BATTERY COMPARTMENT, DISTRIBUTORS COMPARTMENT.

DANGER: x The access to these compartments is allowed only to the authorized personnel in charge of the maintenance, and only if these procedures are followed: 1. Diesel engine is off, parking brake engaged, boom completely closed with no load hanging, superstructure locked with its locking pin. 2. Travel order selection lever in neutral position. 3. Outriggers positioned.

x x

The engine turning on with the open compartment has to be done only if the maintenance controls require so; avoid turning the diesel engine on if it is not needed. Whenever the engine compartment is open, do not allow any person into the cab or near the machine.

After stopping the machine and checked that the above mentioned safety norms are respected, use the supplied key to open the compartments and lift the bonnets. Gas struts will keep the compartment doors opened. ATTENTION: before starting the machine, make sure that all compartments are perfectly closed.

6 MACHINE USE
6.1 GETTING ON AND OFF THE WORKING CAB
DANGER:

x If the ladders or the footboards are full of oil or grease, or iced due to snow or ice, clean them
accurately in order to avoid slipping and falls.

x Clean also the cab floor whenever there is oil or grease, mud or debris; make sure that the cab
is free from any material or tools used for the maintenance. the steering wheel and the controls levers.

x It is forbidden claim into the cab without using the appropriate ladders and handles, grabbing
1. To get on and off the working cab, use the ladders with antiskid steps and the apposite handles; get on and off the machine carefully. 2. To claim on or descend the cab, keep all the time three contact points to be sure not to lose balance and eventually fall down. 3. Get into and out the cab only after pushing up the seat rest arm using its lever.

6.2 CHECKS TO PERFORM BEFORE STARTING THE DIESEL ENGINE

6.2.1 DAILY VISUAL CHECKS
DANGER:

x x

All checks and refilling have to be done in an airy place, with machine on an even ground with the parking brake engaged. Dirt, oil or fuel into the engine compartment near hot areas, may be a cause of fire. Immediately repair all leaks and it they occur frequently contact the manufacturer or your dealer. Open the tap of the water level tank only when the diesel engine is cold. If for any particular reason someone opens the tap when the diesel engine is still hot, he has to wear appropriate protective clothes and slowly unscrew to release the pressure gradually. During oil and diesel refueling, refrain from smoking and do not approach the machine with free flames or non homologated lights. When refilling diesel with the fuel distributor, make sure to keep it in touch with the tank pipe to prevent sparks due to static electricity. Do not fill up the tank completely; always leave some space for fuel expansion.

x x

x x x

Before turning the engine on, take a look at and under the machine to check for: 1. Loose screws or bolts. 2. Oil, fuel or cooling liquid leaks. 3. Rope wear and its general conditions. 4. Loose electrical connections. 5. Muffler condition. 6. Tires wear and rims general conditions.

7. Safety plates and their cleanness. 8. Ladders and handles conditions and cleanness. Any leak or abnormality found has to be reported and immediately repaired, and oil or grease has to be removed from any contact surface with feet or hands. 9. Instruments and warning lights. 10. Cab windows, beams, working lights, turning signals and rotary beacon. 11. Engine cooling liquid, oil, and hydraulic oil. At the end of the working day, refill the diesel tank to avoid the development of condense. IMPORTANT:

x x

At the end of the refuel process, screw in the tap, checking also its hole which has to be free. All oil levels must be check when the components are cold and on a leveled even surface.

6.2.2 OPERATION CHECKS

DANGER:

x All the checks must be done with the operator seated on his working seat. x After maintenance, some controls may have been moved, so before the operator starts the
machine he has to check all the levers and selectors. The main checks are: 1. the transmission has to be in neutral position. 2. The parking brake has to be engaged. 3. The vertical position of the rear steering locking selectors. The following check is obtained by turning the ignition key in the "I" position, to put in tension the dashboard and check the acoustic alarm, fuel level gauge, battery charge gauge, and all the machine warning lights (engine oil low pressure, brake oil low pressure, alternator charge, parking brake). Then check also the other warning lights functioning.

6.3 STARTING THE DIESEL ENGINE

DANGER:

x Before starting the diesel engine, study carefully the safety procedures and indications of this
manual and check your knowledge of the controls. Right after the operator turns on the engine, he is the only person directly responsible of the damages caused by wrong maneuvers and non observance of the safety and road laws and regulations. x Before turning the engine on in airless place, provide for an adequate ventilation or connect the exhaust pipe with a depression canalization; the exhaust gases are highly toxic and may lead to poisoning and death.

x Before turning on the engine, make sure none is in the machine working radius.
Then use the horn before starting the diesel engine.

x Soon after the machine starting, check the engine oil pressure on its gauge; if there is not
pressure stop the engine immediately.

6.3.1 STARTING THE DIESEL ENGINE IN NORMAL CLIMATIC CONDITIONS

1. Press completely the accelerator pedal and turn the starting key on the position START (II) 2. Right after the engine in on, release the key, which will automatically return to its original position I, and let the engine idle. IMPORTANT:

If the diesel engine does not start within 10 seconds, release the key and wait for 10 seconds before starting the engine again.

6.3.2 STARTING THE DIESEL ENGINE IN VERY COLD CLIMATIC CONDITIONS OR AFTER A PROLONGED TIME PERIOD.
DANGER: Do not use cold starting liquids or products, because they are ether made and may cause explosions. 1. Press completely the accelerator pedal and turn the starting key on the position START for 25 seconds maximum. If the diesel engine does not start within 10 seconds, release the key and wait for 10 seconds before starting the engine again. 2. Right after the engine in on, release the key, which will automatically return to its original position "I", and let the engine idle.

6.4 DIESEL ENGINE WARMING UP PROCEDURES

1. After turning the engine on, and before beginning to travel or work, the engine has to warm up. 2. The engine warming up can be done by accelerating at a constant regime (approximately 1.1001.200 rpm). IMPORTANT: do not accelerate at full power unless the cooling liquid temperature does not reach at least 60C on the temperature gauge. 3. To speed up the warming procedure, accelerate the engine every now and then up to 1.700 rpm. 4. During the warm-up, check the exhaust smoke color and it there are abnormal vibrations or noises; every abnormality has to be checked and solved.

6.5 HYDRAULIC OIL WARMING UP

During engine warm-up, the oil contained in the hydraulic systems goes around and warms itself up due to the pumps pressure. The complete warm-up is achieved during traveling on working operations, when the transmission, winch, slewing, telescoping motions are used. When the cooling liquid reaches 60C, begin traveling or working at low rpm for 5-10 minutes.

6.6 HOW TO OPERATE THE MACHINE

DANGER:

x Before operating the machine, make sure to know perfectly the controls functions and their
relative safety norms and instructions. correct position.

x The operator has to be seated on his working seat and have checked the rear-view mirrors x Before moving the machine, make sure none is in the mobile crane working area, and that the
place is free from impediments.

x Pay attention when engaging the reverse gear and always check if there are people, machines
or impediments around the machine. Before traveling on road, after having checked all instrumentation and controls, warmed-up the machine, check that the outriggers are fully lifted, telescoped in and connected to their supports. The superstructure has to locked with its locking pin and the machine in travel order. Then release the parking brake and select the traveling speed. Gradually accelerate with the gas pedal and soon after the machine moves test the brakes to check their efficiency. IMPORTANT:

x The shifting up in the same travel direction needs no deceleration. x If you have to down-shift from high to low gear, use the brakes to slow down the engine rpm. x In case you need to reverse the travel motion, you need to almost stop the machine before
engaging the reverse gear.

6.7 MACHINE LIMITATIONS DURING ON-ROAD TRAVELING

DANGER:

x Before traveling down-hill, always check the brakes and the parking brake efficiency. x On a steep hill avoid selecting the high-gear speed; not following this indication may lead to the
machine loss of control.

x Avoid to take turns at high speed. x In case the machine has to cross a river, check the water depth, its direction, the strength of the
stream, and the river-bed ground compactness; it is important to remember that sand or gravel if solicited, can be removed by the strength of the stream digging holes where the machine can get stuck.

The machine during traveling has some limitations that have to be respected. Particularly, avoid slopes more than 40% and submerging the mobile crane in water deeper than half the wheels diameter.

6.8 MACHINE PARKING

DANGER:

x Always park the machine on an even solid ground, large enough to allow checks, lubrication
and refueling.

x Always engage the parking brake. x Follow and apply all safety norms and indications to avoid every movement of the mobile crane
when the operator is not present.

x Whenever leaving the machine, take the key and lock the cab.
After you have found the parking area: 1. Lock the superstructure with its locking pin. 2. Engage the parking brake. 3. Align the rear wheels and lock the rear steering. 4. If the ground where you parked the machine is on a slope, detach the outriggers from their traveling position (1) and press them lightly to the ground. 5. Put some grip (2) wedges under all wheels. 6. Stop the engine. 7. Refill the fuel tank. 8. Take the ignition key with you and lock the cab.

6.9 DIESEL ENGINE SHUTTING OFF

ATTENTION:

x Do not turn the diesel engine off under load, if not in emergency situations; turning off the
engine in these circumstances shorten the engine and the hydraulic components life because they go through with anomalous efforts. to let the engine idle with no load for about 2-3 minutes, to cool it down. To shut the engine off, turn the key in vertical position "O" (OFF).

x It is advisable not to shut off the engine after its prolonged use; in this case it is recommended

6.10 TRAVELING ON SITE, REAR STEERING

DANGER: before leaving the site to travel on road, put the machine in travel order. On site traveling requires to follow the rules and precautions given, explicitly driving at low speed with the tires at the correct pressure indicated on the plate located on the cab door. In case the operator needs to use the rear steering, follow these directions: 1. when the machine is stopped, activate the selector to unlock the rear steering. 2. Lock the rear axle. 3. Make sure that a low speed is engaged. 4. Accelerate gradually. ATTENTION:

x The rear steering, achieved with the lever can be done also
with the machine at low speed; pay attention to the direction changes, since that with this steering are quicker.

x The rear wheels can be steered in the same direction as the

front wheels (crab) or in the opposite sense (coordinated). In any case, the steering is directly proportional to the lever movement.

x When the maneuvers with the rear steering are completed,

reset the original steering configuration: 1. Stop the machine. 2. With the lever align the wheels until the warning light is lit. 3. Lock the rear steering with its selector.

6.11 MACHINE SETTING UP

DANGER:

x Before swinging the superstructure, set up the machine; a swing without outriggers may lead to
machine instability and its turnover.

x Before positioning the machine, make sure that the ground is solid and even; if it is necessary,
reinforce the outriggers contact area with wood or cement plates.

x Avoid putting the outriggers floats near holes, river beds, excavation sites, inconsistent or
excessive slope ground, over underground water or electrical piping. that they do not come in contact with ground, poles, walls, etc.

x Check that the outriggers beams are fully extended, until the white mark appears, making sure x The machine is not considered positioned if the outriggers beams are not fully extended and the
mobile crane is not leveled with the wheels lifted from the ground. In these cases the load charts referred to the machine positioned, are no longer valid and the machine use is not consented.

6.11.1 GROUND PRESSURE CAPACITY CHECK

The machine positioning include also the surrounding ground analysis, where the outriggers floats will be, in order not to exceed the specific pressure in kg/sq/cm (daN/sq/cm or load capacity) allowed by the ground type. If the ground where the machine is positioned does not match this value, it is necessary to calculate the total surface which the board must have to apply it to every outrigger float to avoid its sinking. This is the formula to calculate it: Maximum weight on one outrigger in Kg Surface support: (sq/cm)= ground capacity (Kg/sq/cm) ATTENTION: 1. The values regarding the maximum weight on each outrigger (36.500 kg), the surface support of the outriggers floats 2825 sq/cm and the specific exerted pressure by the floats 13 kg/sq/cm daN/sq/cm) are fixed data calculated for a machine positioned on an even ground, with the air bubble located inside the circle. 2. The boards applied under the outriggers have to be centered to equally distribute the pressure on the ground. The following is a ground capacity values chart:

NOTE:

x All values contained in this chart

are indicative; in case of doubt, it is necessary checking the ground with apposite instruments. floors etc. has to be requested to the manufacturer.

x The capacity of bridges, cement

6.11.2 PARTICULAR SITUATIONS

The machine cannot be positioned near holes, excavation sites, canals, etc. because the ground can collapse and slide down. The safety distance to keep has to be measured at the bottom of the hole, and it depends on the type of ground; approximately it has to be: A. with compact ground, distance equal to the depth of the hole; B. with sliding non compact ground, distance equal to the double of depth of the hole. ATTENTION: In the event that the machine cannot be positioned respecting these safety distances, the excavation site has to be reinforced.

6.11.3 SPECIFIC DYNAMIC WHEELS GROUND PRESSURE DURING PICK-ANDCARRY OPERATION

The maximum allowed wheels ground pressure during pick-and-carry motion is 10 kg/sqcm (daN). ATTENTION:

This value is referred to correctly inflated tyres as indicated on the plate on the cab's door. When the machine performs this operation, check the ground consistency, which has to be
higher than the specified wheels pressure.

6.11.4 PROCEDURE FOR MACHINE SETTING UP

1. Setting the transmission in neutral position. DANGER Move the transmission lever in neutral position (N), corresponding to its central/down position. NOTE: FOR 2 GEAR IT IS NECESSARY TO UNLOCK THE REAR AXLES AND LOCKING THE TURRET ROTATION WITH PIN!! POSITION OF TRANSMISSION LEVER

First and Second gear

Reward gear

2.

Engaging the parking brake.

Parking brake: the push-button has to be pressed downward in order to engage the parking brake.

3. Press the relative push-buttons on PLC panel concerning the outriggers control. The pushbuttons operating the outriggers control are clearly indicated below.

F1 F2 F3 F4 F5 F6 F7 F8

= = = = = = = =

Control for front left outrigger Control for front right outrigger Control for rear left outrigger Control for rear right outrigger Control for outrigger extension Control for outrigger lowering Control for outrigger lifting Control for outrigger retraction

4. Keep the push-buttons pressed until the stroke of the beams and the vertical jacks are fully extended. Make sure the jacks lift the machine (8) from the ground.

ATTENTION:

If additional boards are used, make sure the floats are centered on these supports.

4 Set the machine properly checking the air bubble level (10) and slowly retract the outriggers jacks.

5 When the air bubble is in the middle, make sure the wheels are at least 50 mm. lifted from the ground.

6.11.5 STATIC ON WHEELS CAPACITY

During this operation, the outriggers have only a safety function, since the floats do not touch the ground but remain at 8-10 cm from it, to contrast possible machine oscillation due to the tires flexing. The superstructure has to be in travel position.

6.11.6 DYNAMIC PICK-AND-CARRY CAPACITY

DANGER: x This working procedure is allowed only if the following conditions are respected: 1. Tires inflated at the correct pressure indicated on the plate located on the cab's door. 2. The rear axle has to be locked. 3. The superstructure has to be in travel position. 4. The superstructure slewing is limited to 5 in respect of the center line of the carrier. 5. The creep speed has to be of 1 kph maximum. 6. The ground where the machine travels has to have higher capacity than the specific wheels pressure, and it has to be even and leveled.

1. Extend the outriggers beams, and as a safety procedure, lower the positioning jacks until they are 5 - 8 cm from the ground. 2. Set the safe-load moment indicator and check the number of part lines. 3. Use the right joystick to hook and lift the load; lift the load vertically and slowly only at the necessary height to travel. 4. Accelerate slowly to avoid load oscillation. ATTENTION: stop the machine if the load oscillates in such a way to danger the machine stability.

6.12 LOAD CHARTS AND DIAGRAMS USE

DANGER: all load charts and diagrams include the hook-block weight. The lifting load is given by the gross weight to which you must deduct all lifting devices weight, such as hook-block, slings and lattice extension. IMPORTANT:

x x x x x

The lifting devices weight are engraved: on the hook-block; on a plate for the lattice extension. The weight of the lifting device has to be known for each job. The lifting charts and diagrams are part of the technical documentation, and have to be kept inside the cab available for the operator quick view.

x The load charts and diagrams must be read and understood before beginning any job, since

they give the necessary indications to check whether the machine can perform the job assigned; moreover, they allow also to get the data of the machine positioning to set into the safe-load moment indicator including the number of part lines necessary for the lifting. rear, with lattice extension, etc.). The loads indicated in the load charts and diagrams are valid for the boom lengths and working radiuses shown by the Manufacturer. Always look at the boom angle (and not at the working radius) when you lift a load with shorter boom length than the one specified in the chart. and for the damages which can be caused at the structure. giving the code of the machine model.

x Pay attention when choosing among the machine's lifting charts (on outriggers, on wheels, over

x If this rule is not respected, the use of the machine becomes dangerous both for the instability x If the load charts and the diagrams become not readable, ask for copies to the Manufacturer,

6.12.1 DEFINITIONS USED IN THE LOAD CHARTS AND DIAGRAMS 6.12.1.a WORKING RADIUS (R)
It is the distance (measured horizontally) between the slewing axis of the superstructure and the hook-block center line axis. The distance to consider is that one with the load lifted from the ground; the nominal distance is increased by the boom flexion proportionally with the boom length and the load weight. ATTENTION:

x x

The working radiuses indicated in the load charts and diagrams are those referred with the load lifted from the ground. If the working radius has an intermediate value between those referred on the diagrams, use always the one with larger radius.

DANGER: The moving away of the load due to oscillations caused by wind or operator maneuvers, increase the working radius creating a danger for machine tipping; when these oscillations become dangerous, stop the operations and wait for load to settle.

6.12.1.b

NUMBER OF PART LINES (Nta)

It is the number of part lines (falls) to prepare in advance between the boom head pulleys and the hook-block to lift a load. The number of part lines is specific for each machine configuration and it is directly related to the lifting load.

Nta

6.12.1.c

BOOM LENGTH (Lb)

It is the distance between the boom fulcrum and the hook-block center line when the boom is totally closed. The diagrams curves are referred to this distance according to the under load boom inclinations.

Lb

6.12.1.d

BOOM ANGLE
It is the angle the boom makes between the horizontal axis passing through the slewing fulcrum; the machine can utilize working angles between 5 and 80. ATTENTION: x If the angle has an intermediate value between those indicated on the diagrams, always consider the lower angle load capacity.

6.12.1.e

LATTICE EXTENSION OFFSET ()

It is the angle that the lattice extension has compared with the boom axis. ATTENTION: x The angles described in the diagrams are always referred to the telescopic boom.

6.12.1.f

MACHINE CONFIGURATION (Ai)

It is the machine configuration number referred to the operative boom length. This number has to be used to quickly locate the machine correct load chart operating in this specific configuration.

Ai

6.12.1.g

CAPACITY OVER FRONT

It is referred to the pick-and-carry capacity, and it indicates that the lifting has to be done only with the superstructure in travel order.

FRONT

ATTENTION: With the machine in these conditions it is possible to travel with the load (dynamic).

6.13

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.

| Introduction

6.13

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

2 | Warnings

6.13

3
Important Notes
The limiter is supplied with a key for automatic shut-down override. Under normal working condition this key must be positioned properly not to operate the override functions. It is forbidden to use this key to lift loads exceeding the load table limits provided by the cranes manufacturer. The key must be used only in extreme cases: malfunctioning or situations justifying its use. The use of the key is allowed only by authorized personnel who is responsible for its use. The limiter has a powerful FAIL-SAFE self-diagnostics program suitable to verify the good operation of its circuits and measuring transducers. In case a failure is detected, the limiter sets itself in emergency status by blocking the manoeuvres. Nevertheless, before starting the operation of the machine, the operator must make sure that the limiter works correctly. To do this, he must verify the accuracy of the displayed values by performing some tests. He must also verify that there are not messages or alarm indications, and verify the correct operation of the shut down function Generally, the limiter does not automatically change the operating conditions of the machine (tables). The operator is responsible for the proper setting of the operating conditions of the machine and the correct use of the device. Regarding this follow the indications given in the manual concerning the operating modes. An incorrect setting of the tables can cause an incorrect operation of the limiter and this will create a dangerous situation during the crane operation. For this reason it is absolutely necessary to set the correct operating mode. These operating conditions generally vary when: outriggers are extended or retracted switching the operation from outrigger mode to on tires mode telescopic mechanical extensions are extended or not further equipment (jib, ext, etc.) is installed or not the rope number is properly selected. In general it is mandatory to follow the instructions given by the cranes manufacturer.

3 | Important Notes

6.13

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.

4 | System Operation Description

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5
Machine Component Description
In this chart all the elements connected with the Limiting Device (LMI) are indicated.

5.1 Machine Component Description

Picture 5.1Machine Component Location

1. 2. 3. 4. 5. 6. 7. 8. 9.

Unit MIDAC+ Front Unit MIDAC+ Rear CABLE REEL 32 m CAN-Bus ACMCP CABLE REEL 4,5 m CAN-Bus CCR PRESSURE TRANSDUCER ANTY TO BLOCK WEIGH DISPLAY VIEW (LMI) KEYPAD CAN-Bus

5 | Machine Component Description

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10. UNIT MC2M 11. JOYSTICK CAN-Bus 12. JOYSTICK CAN-Bus 13. SAFE KEY

5 | Machine Component Description

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6
Panel Description
The operator panel is shown in the following picture:

Picture 6.1 - Control Panel Unit

Ref. 1 2

Icon

Description Working data display Two green lights showing the safe working condition

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

The red light showing the shut off condition has occurred ; load over 100%.

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Ref. 5 Icon Description Function push-button : languages setting / outrigger configuration.

Function push-button : unit of measurement / counterweight configuration.

Function push-button : Hook configuration.

Function push-button : Main Boom configuration.

Function push-button : Jib stored location.

10

Enter push-button: it confirms an operation.

11

Up push-button.

12

Down push-button.

13

Left push-button : increase menu / list (operating mode, number of line, etc)

14

Right push-button : decrease menu / list (operating mode, number of line, etc)

15

Rope push-button : increase / decrease rope number.

16

Buzzer push-button : disabling buzzer.

17

Selection push-button : Setup and Setting machine.

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Ref. 18 Icon Description Changing pages push-button : (Not Used)

19

Escape push-button : (Not used)

20

Setting push-button : press this key to activate the Settings page.

6 | Panel Description

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7
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.

7.1 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.

Set-up page : it is used to select and confirm the Operating Mode. Settings page : it is used for the language setting and the units of measurement. 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. Panel Display page : it is used to show all the information and status of the engine. Outrigger page : it is used to show all the outrigger positions and stabilizer conditions.

7.2 How To Change LMI Page:

By means of the left push-button be changed.

or the Right push-button

the LMI page can

In particular to show the Setting page it is necessary to press the Setting push-button inside in the Setup page.

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7.3 Start-up Page
When the system gets started, some information is displayed for five seconds.

7.3.1

The Start-up Page Description

Picture 7.1- Start-up Page

7.3.2

Software Release

Software version installed in the View (LMI). Software Release Description Software version installed in the View (LMI).

7.3.3

Firmware Release
Description Firmware version installed in the View (LMI).

Firmware Release

7.3.4

Load Table Release

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Load Table Release Description loading table version installed in the View (LMI).

7.3.5

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).

Self Test

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 pushbutton 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.

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7.4 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 machine configuration is changed. In the other page of the Limiting Device (LMI) it is not possible to select it.

7.4.1

The Setup Page Description

Picture 7.2 Set-up Page

7.4.2

Outrigger / Wheel Configuration

With the Function push-button Outrigger / Wheel Configuration

it is possible to set the outrigger or wheel configuration. Description Outrigger full extended (100%)

For further details about the outrigger configuration, see the chapter How To Select The Operating Mode .

7.4.3

Counterweight Configuration

With the Function push-button

it is possible to set the counterweight configuration.

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Counterweight Configuration Desccription Counterweight 8,5 ton.

For further details about the counterweight configuration, see the chapter How To Select The Operating Mode .

7.4.4

Hook Configuration

With the Function push-button Hook Configuration

it is possible to set the 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 .

7.4.5

Main Boom And Jib Configuration

With the Function push-button Main Boom Configuration

it is possible to set the Main Boom and Jib 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 .

7.4.6

Jib Stored location

With the Function push-button Jib Stored location

it is possible to set the Jib stored location. Description

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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 .

7.4.7

Rope Number

With the Rope push-button Rope Number

it is possible to set the correct 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.

7.4.8

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 operator. information is displayed to the

7.4.9

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

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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.

7.5 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 Setting push-button Setup page is displayed on the screen. To quit the page displayed without any modification, press again the same push-button. when the

7.5.1

The Setting Page Description.

Picture 7.3 - Settings Page

7.5.2

How To Select Language.

On the Settings page, press the Function push-button towards the desired language. Confirm your choice with the Enter push-button .

to move the reference cursor

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7.5.3 How To Select the Unit of Measurement

On the Settings page, press the Function push-button towards the desired unit of measurement. Confirm your choice with the Enter push-button .

to move the reference cursor

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7.6 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.

7.6.1

LMI Page Description

Picture 7.4 - LMI Page Description

7.6.2

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 higher than 100% of maximum load allowed).

7.6.3

Actual Load Status Bar.

Description

Actual Load status Bar

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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 higher than 90% of maximum load allowed). - Red reference: Cut-off Zone ( Lifted load higher than 100% of maximum load allowed).

7.6.4

Main Boom Sections Close Position

Description The first, the second and the third sections are not completely closed.

Main Boom Sections Close Position

The first, the second and the third sections are completely closed.

The first boom arm section is completely closed. The second and the third sections are not completely closed. The first boom arm section is not completely closed. The second and the third sections are completely closed.

7.6.5

Spinned Boom
Description All main boom sections work in proportional mode.

Spinned Boom

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Spinned Boom Description The first and the second sections work in proportional mode and the third section is closed inside the second section.

7.6.6

Main Boom Working Mode

Description The crane works with the first and the second boom sections in proportional mode. The third section is closed inside the second section. The crane works with all the three boom sections in proportional mode. The system does not know the correct operating mode.

Main Boom Working Mode

7.6.7

Engine Alarm Information

Description The information about Engine Alarm is disable.

Engine Alarm Information

No Engine Alarm from truck unit.. (NOT USED)

There are one or some alarm from truck unit. Stop immediately the Engine (NOT USED)

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Engine Alarm Information Description No Engine Alarm from truck unit..

There are one or some alarm from truck unit. Stop immediately the Engine

7.6.8

Engine Alarm Information

Description The information about Engine Warning is disable.

Engine Alarm Information

No Warning from truck unit.. (NOT USED)

There are one or some Warning from truck unit. To check Engine (NOT USED) No Warning from truck unit..

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Engine Alarm Information Description There are one or some Warning from truck unit. To check Engine

7.6.9

Turret Position
Description The turret is in lateral or rear position.

Turret Position

The turret is in front position. Range (-2,5 / +2,5)

7.6.10 By-Pass LMI

By-Pass LMI Description Limiting Device enabled :the LMI monitors the crane condition and stops all the dangerous movements for the operator. Limiting Device disabled: the Safe Key is activated and all the dangerous movements are not disabled by LMI.

7.6.11 Rope Number

Rope Number Description The rope numbers selected on the Setup page are displayed. The maximum rope number selected. depends on the configuration

7.6.12 Actual Load

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Actual Load Description In this area the existing loads detected on the crane are displayed.

7.6.13 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.

7.6.14 Anti To Block Device

Anti To Block Device Description The Anti To Block device is active.

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Anti To Block Device Description The Anti To Block device is activated. The rope is completely wrapped on the winch. (End of rope Up)

7.6.15 Winch
Winch Description The rope can still be wrapped or unwrapped on the winch.

The rope is completely rolled out on the winch. (End of rope Down).

7.6.16 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. 2. 3. 4. Main Boom Outrigger full extended Counterweight 7 t Jib not used and not stored on crane

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LMI Information Description The LMI information is: 1. 2. 3. Main Boom Angle = 20 Boom Extension = 23 m 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.

7.6.17 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.

7.6.18 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.

7.7 Engine Page

To visualize this page, press the Left push-button until it appears.

or the Right push-button

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This page shows all the engine values regarding fuel, oil and water temperature, oil pressure and engine alarms.

7.7.1

Engine Page Description

Picture 7.5 - Engine Visualization

7.7.2

Oil Temperature
Description It indicates the oil temperature. Value in Celsius or Fahrenheit degrees according to the unit of measurement in the Setting page.

Oil Temperature

7.7.3

Fuel Level
Description It indicates the fuel level. (Optional)

Fuel Level

7.7.4

Engine RPM

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Engine RPM Description It indicates the engine revolution per minute. Value in RPM

7.7.5

Oil Pressure
Description It indicates the Oil pressure with an analog representation. Value in Bar or PSI according to the unit of measurement selected in the Setting page.

Oil Pressure

7.7.6

Engine Fault
Description In case of an Engine Fault, the icon changes from Grey to Red colour and the error code message is displayed.

Engine Fault

7.7.7

Water temperature
Description It indicates the water temperature with an analog representation. Value in Celsius or Fahrenheit degrees according to the unit of measurement in the Setting page.

Water Temperature

7.8 Outrigger Configuration

Use the Left push-button current page.

or the Right push-button

to choose or to quit the

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This is only a reading page where all the information about the outrigger configuration is specified. For each outrigger it shows the extension percentage and the stabilizers pressure on the floor.

7.8.1

Outrigger Description

Picture 7.6 - Outrigger Configuration

7.8.2

Outrigger Position And Stabilizer Pressure

During the outrigger motion, the actual position of each element is displayed on this page. The extension percentage is indicated with the graphic bar and the corresponding value percentage. Some examples can be found in the following table. Regarding the stabilizer pressure, the value is indicated according to the unit of measurement selected in Settings page. Outrigger Position And Pressure Description Outrigger completely extended. (Position percentage equal or over 97%). Stabilizer pressure 140 bar.

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Outrigger Position And Pressure Description Outrigger half extended. (Position percentage between 48 and 97%). Stabilizer pressure 140 bar. Outrigger closed. (Position percentage under 48%). Stabilizer pressure 140 bar.

7.8.3

Special Message Area

This side of the panel View, is like the other LMI pages and is used to give special information to the operator. Special Message Area Description Special operator. information is displayed to the

7.8.4

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.

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8
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 the crane configuration changes. The operating mode is recognized in automatic from the system according to the outrigger position or wheels. The rope number selection is a manual operation carried out by the operator. It is necessary to confirm the operating mode with the Enter push-button to proceed.

Picture 8.1- Set-up Page

8.1 Outrigger Or Wheel Configuration

With this crane model in order to change the outrigger configuration, it is necessary to use the KEY PAD located in the cabin. For further details see the chapter How To Use Key Pad. According to the outrigger configuration, the icon changes like the following examples. Outrigger Configuration Description Outrigger completely extended (100%)

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Outrigger Configuration Description Outrigger half extended (50%).

Outrigger completely retracted (Closed).

Static On Wheels. It is necessary to activate the Interlock rear axis with the Key Pad and to insert the forward or reversing gear. Pick & Carry. It is necessary to activate the Interlock rear axis with the Key Pad and to insert the forward or reversing gear. In the Special Information area when the Pick & Carry condition is enabled. The speed limit it is limited to 2,5 Km/h.

For this crane the Function push-button

is optional. in order to confirm the

If no other modification is necessary, press the Enter push-button operating mode.

8.2 Counterweight Configuration

For this crane model the selection is fixed to 8,5 ton. According to the counterweight on the machine, the icon changes like the following examples. Counterweight Configuration Description Counterweight 8,5 ton.

I 39 I

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Counterweight Configuration Description Counterweight 9,5 ton.

Counterweight 11,6 ton.

For this crane the Function push-button

is optional. in order to confirm the

If no other modification is necessary, press the Enter push-button operating mode.

8.3 Hook Location

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. When the choice of the Operating Mode is manual and the Jib extension is present on the crane, press the Function push-button to select the right Hook location.

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.

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Hook Location Description The Hook is located on the Jib.

For this crane model the Function push-button

is optional. in order to confirm the

If no other modification is necessary, press the Enter push-button operating mode.

8.4 Main Boom Configuration

For this crane model the Jib extension is not supplied and this function is not available. When the choice of the Operating Mode is manual and 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. (The Main Boom section is grey and the Jib extension is dark)

Jib Selected and Jib angle 20. (The Main Boom section is grey and the Jib extension is dark)

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Main Boom Configuration Description Jib Selected and Jib angle 40. (The Main Boom section is grey and the Jib extension is dark)

For this crane model the Function push-button

is optional. in order to confirm the

If no other modification is necessary, press the Enter push-button operating mode.

8.5 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 only a manual operation 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).

If no other modification is necessary, press the Enter push-button operating mode.

in order to confirm the

8.6 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 .

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Rope Number Description 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 . in order to confirm the

If no other modification is necessary, press the Enter push-button operating mode.

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9
How To Use Key Pad
The position of the outrigger, the use of the four drive wheels and the interlock rear axis are controlled from a dedicated Key Pad located in the control cabin. In the Key Pad the backlight is activated when the crane lights are turned on.

Picture 9.1 - Key Pad

9.1 Four Drive Wheels (4x4)

At the machine start-up, the four drive wheels are disabled in automatic mode. To enable / disable this function, press the push-button shown in the following table. The present condition is communicated to the operator with the yellow light on located above the four drive wheels push-button on the Key Pad. Four Drive Wheels Description Four drive function enabled (1) / disabled (2)

(1)

(2)

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9.2 Outrigger Positioning
The first step to move the outrigger is to select the movement with the push-button. The movement is active when the yellow light located above the function push-button is on. To start the movement choose the corresponding push-button left / right for front or rear outrigger. These operations are allowed only if: -) main boom to be must retract; In emergency case is possible to use the Safe Key. The actual outrigger position is displayed on the special page Status LMI. Outrigger Front Positioning Description Front movement Left / Right side push-button.

Rear movement Left / Right side push-button.

Outrigger

opening

function

disabled

(1)/

enabled (2). (1) (2) Outrigger closing function disabled (1)/

enabled (2). (1) (2) Outrigger down function disabled (1)/ enabled (2). (1) (2) Outrigger up function disabled (1)/ enabled (2). (1) (2)

I 45 I

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9.3 Interlock Rear Axis

This function is required to move the weight during the motion of the crane on wheels. To enable / disable this function, press the push-button shown in the following table. The enabled function is communicated to the operator with the yellow light on located above the push-button on the Key Pad. Interlock Rear Axis Description Interlock rear axis disabled (1) / enabled (2).

(1)

(2)

I 46 I

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10
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.

10.1 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 10.1 - Safe Key

It is simply necessary to move the Transponder close to the Bypass Device and afterwards to remove it , after this to keep turn on the internal key, 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

and the external buzzer and the external red lamp is coming on. The speed of the movements is limited to the 25% of the maximum speed.

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11
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. 2. Please confirm : the system is waiting for the operating mode validation. 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. 5. 6. E01: Angle Max : the main boom is on the maximum boom angle position allowed. E02 : Angle Min : the main boom is on the minimum boom angle position allowed. Syncro : the main boom parts are not in correct position. Solution : reduce the boom angle. Solution : increase the boom angle. Solution : activate the digital input dedicated to call back the main boom and to completely close it.

Solution: choose the configuration and confirm.

11.1 How to disable the buzzer

1. 2.

Disable : when the audible alarm is on, by alarm until the new alarm is detected.

push button you can disable the audible

Enable : after few seconds that the alarm is switched off the audible alarm will be automatically enabled.

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12
Trouble Shooting
Alarm Code x ALARM 1 Angle A Low Cause x Angle transducer device broken. xPossible lack of continuity connection wires. wires. x Fault in main unit. x ALARM 2 Angle A High x Potentiometer inside broken. wires. x Fault in main unit. Solution xVerify the angle transducer in integrity. xVerify that the wiring and the circuit.. x Verify the wire continuity. xVerify that the wiring and the circuit.. xVerify the angle transducer integrity. x ALARM 3 Angle Lover A of x Potentiometer inside broken. the carrying the unwinding. wires. x Fault in main unit. x ALARM 4 Angle Higher maximum calibration settings value. A of x Potentiometer inside broken. the wires. x Fault in main unit. x Verify the wire continuity . connectors are not in short xVerify the angle transducer integrity. xVerify that the wiring and the circuit.. xVerify the angle transducer integrity.

x Possible short circuit in connection connectors are not in short

x Possible short circuit in connection connectors are not in short

Value x Possible lack of continuity in wires xVerify that the wiring and the

minimum calibration x Possible short circuit in connection circuit.. settings value.

Value x Possible short circuit in connection connectors are not in short

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Alarm Code x ALARM 5 Angle B Low Cause x Angle transducer device broken. xPossible lack of continuity connection wires. wires. x Fault in main unit. x ALARM 6 Angle B High x Potentiometer inside broken. wires. x Fault in main unit. Solution xVerify the angle transducer in integrity. xVerify that the wiring and the circuit.. x Verify the wire continuity. xVerify that the wiring and the circuit.. xVerify the angle transducer integrity. x ALARM 7 Angle Lover B of x Potentiometer inside broken. the carrying the unwinding. wires. x Fault in main unit. x ALARM 8 Angle Higher maximum calibration settings value. x ALARM 10 Angle Jib Low x Angle transducer device broken. xPossible lack of continuity connection wires. wires. x Fault in main unit. xVerify the Jib angle B of x Potentiometer inside broken. the wires. x Fault in main unit. x Verify the wire continuity . connectors are not in short xVerify the angle transducer integrity. xVerify that the wiring and the circuit.. xVerify the angle transducer integrity.

x Possible short circuit in connection connectors are not in short

x Possible short circuit in connection connectors are not in short

Value x Possible lack of continuity in wires xVerify that the wiring and the

minimum calibration x Possible short circuit in connection circuit.. settings value.

Value x Possible short circuit in connection connectors are not in short

in transducer integrity. xVerify that the wiring and the circuit.. x Verify the wire continuity.

x Possible short circuit in connection connectors are not in short

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Alarm Code x ALARM 11 Angle Jib High Cause x Potentiometer inside broken. wires. x Fault in main unit. Solution xVerify that the wiring and the circuit.. xVerify the Jib angle transducer integrity. x ALARM 12 Angle Lover Jib of x Potentiometer inside broken. the carrying the unwinding. wires. x Fault in main unit. x ALARM 13 Angle Higher maximum calibration settings value. x ALARM 15 Fault M1 / M2 x Simultaneously Input M1 and M2 ON x Fault in main unit. x Verify the input status. x Deactivate the undesired one. ALARM 20 Boom Length Value Low x Potentiometer inside broken . carrying the unwinding. wires. x Fault in main unit. x Verify the transducer Jib of x Potentiometer inside broken. the wires. x Fault in main unit. x Verify the wire continuity . connectors are not in short xVerify the Jib angle

x Possible short circuit in connection connectors are not in short

Value x Possible lack of continuity in wires xVerify that the wiring and the

minimum calibration x Possible short circuit in connection circuit.. settings value. transducer integrity. xVerify that the wiring and the circuit.. xVerify the Jib angle transducer integrity.

Value x Possible short circuit in connection connectors are not in short

1 x Possible lack of continuity in wires integrity. x Verify the wire continuity. integrity. x Possible short circuit in connection xVerify the length transducer

12 | Trouble Shooting

6.13
Alarm Code x ALARM 21 Boom Length Value High Cause x Potentiometer inside broken. wires. x Fault in main unit. Solution xVerify that the wiring and the circuit.. xVerify the length transducer integrity. x ALARM 22 Boom Length x Potentiometer inside broken. x Verify the wire continuity . connectors are not in short xVerify the length transducer integrity. xVerify that the wiring and the circuit.. xVerify the length transducer integrity.

1 x Possible short circuit in connection connectors are not in short

1 x Possible lack of continuity in wires xVerify that the wiring and the

Value Lover of the carrying the unwinding. settings value. wires. x Fault in main unit. x ALARM 23 Boom Length x Potentiometer inside broken.

minimum calibration x Possible short circuit in connection circuit..

1 x Possible short circuit in connection connectors are not in short x Fault in main unit.

Value Higher of the wires. maximum calibration settings value. ALARM 25 Boom Length Value Low x Potentiometer inside broken . carrying the unwinding. wires. x Fault in main unit. x ALARM 26 Boom Length Value High x Potentiometer inside broken. wires. x Fault in main unit.

Verify

the

transducer

1B x Possible lack of continuity in wires integrity. x Verify the wire continuity. integrity. x Possible short circuit in connection xVerify the length transducer

xVerify that the wiring and the circuit.. xVerify the length transducer integrity.

1B x Possible short circuit in connection connectors are not in short

12 | Trouble Shooting

6.13
Alarm Code x ALARM 27 Boom Length Cause x Potentiometer inside broken. Solution x Verify the wire continuity . connectors are not in short xVerify the length transducer integrity. xVerify that the wiring and the circuit.. xVerify the length transducer integrity.

1B x Possible lack of continuity in wires xVerify that the wiring and the

Value Lover of the carrying the unwinding. settings value. wires. x Fault in main unit. x ALARM 28 Boom Length x Potentiometer inside broken.

minimum calibration x Possible short circuit in connection circuit..

1B x Possible short circuit in connection connectors are not in short x Fault in main unit.

Value Higher of the wires. maximum calibration settings value. ALARM 30 Boom Length Value Low x Potentiometer inside broken . carrying the unwinding. wires. x Fault in main unit. x ALARM 31 Boom Length Value High x Potentiometer inside broken. wires. x Fault in main unit.

Verify

the

transducer

2 x Possible lack of continuity in wires integrity. x Verify the wire continuity. integrity. x Possible short circuit in connection xVerify the length transducer

xVerify that the wiring and the circuit.. xVerify the length transducer integrity.

2 x Possible short circuit in connection connectors are not in short

x ALARM 32 Boom Length

x Potentiometer inside broken.

x Verify the wire continuity . connectors are not in short xVerify the length transducer integrity.

2 x Possible lack of continuity in wires xVerify that the wiring and the

Value Lover of the carrying the unwinding. settings value. wires. x Fault in main unit.

minimum calibration x Possible short circuit in connection circuit..

12 | Trouble Shooting

6.13
Alarm Code x ALARM 33 Boom Length Cause x Potentiometer inside broken. Solution xVerify that the wiring and the circuit.. xVerify the length transducer integrity.

2 x Possible short circuit in connection connectors are not in short x Fault in main unit.

Value Higher of the wires. maximum calibration settings value. ALARM 35 Boom Length Value Low x Potentiometer inside broken . carrying the unwinding. wires. x Fault in main unit. x ALARM 36 Boom Length Value High x Potentiometer inside broken. wires. x Fault in main unit.

Verify

the

transducer

2B x Possible lack of continuity in wires integrity. x Verify the wire continuity. integrity. x Possible short circuit in connection xVerify the length transducer

xVerify that the wiring and the circuit.. xVerify the length transducer integrity.

2B x Possible short circuit in connection connectors are not in short

x ALARM 37 Boom Length

x Potentiometer inside broken.

x Verify the wire continuity . connectors are not in short xVerify the length transducer integrity. xVerify that the wiring and the circuit.. xVerify the length transducer integrity.

2B x Possible lack of continuity in wires xVerify that the wiring and the

Value Lover of the carrying the unwinding. settings value. wires. x Fault in main unit. x ALARM 38 Boom Length x Potentiometer inside broken.

minimum calibration x Possible short circuit in connection circuit..

2B x Possible short circuit in connection connectors are not in short x Fault in main unit.

Value Higher of the wires. maximum calibration settings value.

12 | Trouble Shooting

6.13
Alarm Code ALARM 40 Boom Length Value Low Cause x Potentiometer inside broken . carrying the unwinding. wires. x Fault in main unit. x ALARM 41 Boom Length Value High x Potentiometer inside broken. wires. x Fault in main unit. xVerify that the wiring and the circuit.. xVerify the length transducer integrity. x ALARM 42 Boom Length x Potentiometer inside broken. x Verify the wire continuity . connectors are not in short xVerify the length transducer integrity. xVerify that the wiring and the circuit.. xVerify the length transducer integrity. Solution x Verify the transducer

3 x Possible lack of continuity in wires integrity. x Verify the wire continuity. integrity. x Possible short circuit in connection xVerify the length transducer

3 x Possible short circuit in connection connectors are not in short

3 x Possible lack of continuity in wires xVerify that the wiring and the

Value Lover of the carrying the unwinding. settings value. wires. x Fault in main unit. x ALARM 43 Boom Length x Potentiometer inside broken.

minimum calibration x Possible short circuit in connection circuit..

3 x Possible short circuit in connection connectors are not in short x Fault in main unit.

Value Higher of the wires. maximum calibration settings value. ALARM 45 Boom Length Value Low x Potentiometer inside broken . carrying the unwinding. wires. x Fault in main unit.

Verify

the

transducer

3B x Possible lack of continuity in wires integrity. x Verify the wire continuity. integrity. x Possible short circuit in connection xVerify the length transducer

12 | Trouble Shooting

6.13
Alarm Code x ALARM 46 Boom Length Value High Cause x Potentiometer inside broken. wires. x Fault in main unit. Solution xVerify that the wiring and the circuit.. xVerify the length transducer integrity. x ALARM 47 Boom Length x Potentiometer inside broken. x Verify the wire continuity . connectors are not in short xVerify the length transducer integrity. xVerify that the wiring and the circuit.. xVerify the length transducer integrity.

3B x Possible short circuit in connection connectors are not in short

3B x Possible lack of continuity in wires xVerify that the wiring and the

Value Lover of the carrying the unwinding. settings value. wires. x Fault in main unit. x ALARM 48 Boom Length x Potentiometer inside broken.

minimum calibration x Possible short circuit in connection circuit..

3B x Possible short circuit in connection connectors are not in short x Fault in main unit.

Value Higher of the wires. maximum calibration settings value. x ALARM 50 PressL Low

x Lower chamber pressure transducer xVerify broken. x Possible lack of continuity connection wires. wires. x Fault in main unit.

the

pressure

transducer integrity. in xVerify that the wiring and the connectors are not in short x Verify the wire continuity.

x Possible short circuit in connection circuit..

x ALARM 51 PressL High

x Lower chamber pressure transducer xVerify broken. wires. x Fault in main unit.

the

pressure

transducer integrity. connectors are not in short circuit..

x Possible short circuit in connection xVerify that the wiring and the

12 | Trouble Shooting

6.13
Alarm Code x ALARM 52 of the Cause Solution

x Lower chamber pressure transducer x Verify the wire continuity . xVerify that the wiring and the circuit.. the pressure transducer integrity.

PressL Value Lover broken. calibration settings carrying the unwinding. value. wires. x Fault in main unit. x ALARM 53 PressL Higher maximum value. x ALARM 55 PressL_B Low of

minimum x Possible lack of continuity in wires connectors are not in short x Possible short circuit in connection xVerify

x Lower chamber pressure transducer xVerify that the wiring and the Value broken. wires. connectors are not in short xVerify the pressure the x Possible short circuit in connection circuit.. transducer integrity.

calibration settings x Fault in main unit.

x Lower chamber pressure transducer xVerify broken. x Possible lack of continuity connection wires. wires. x Fault in main unit.

the

pressure

transducer integrity. in xVerify that the wiring and the connectors are not in short x Verify the wire continuity.

x Possible short circuit in connection circuit..

x ALARM 56 PressL_B High

x Lower chamber pressure transducer xVerify broken. wires. x Fault in main unit.

the

pressure

transducer integrity. connectors are not in short circuit..

x Possible short circuit in connection xVerify that the wiring and the

12 | Trouble Shooting

6.13
Alarm Code x ALARM 57 PressL_B Lover of Cause Solution

x Lower chamber pressure transducer x Verify the wire continuity . Value broken. xVerify that the wiring and the circuit.. the pressure transducer integrity. the x Possible lack of continuity in wires connectors are not in short x Possible short circuit in connection xVerify wires. x Fault in main unit.

minimum calibration carrying the unwinding. settings value.

x ALARM 58 PressL_B Higher maximum value. x ALARM 60 PressH Low of

x Lower chamber pressure transducer xVerify that the wiring and the Value broken. wires. connectors are not in short xVerify the pressure the x Possible short circuit in connection circuit.. transducer integrity.

calibration settings x Fault in main unit.

x Lower chamber pressure transducer xVerify broken. x Possible lack of continuity connection wires. wires. x Fault in main unit.

the

pressure

transducer integrity. in xVerify that the wiring and the connectors are not in short x Verify the wire continuity.

x Possible short circuit in connection circuit..

x ALARM 61 PressH High

x Upper chamber pressure transducer xVerify broken. wires. x Fault in main unit.

the

pressure

transducer integrity. connectors are not in short circuit..

x Possible short circuit in connection xVerify that the wiring and the

12 | Trouble Shooting

6.13
Alarm Code x ALARM 62 of the Cause Solution

x Upper chamber pressure transducer x Verify the wire continuity . xVerify that the wiring and the circuit.. the pressure transducer integrity.

PressH Value Lover broken. calibration settings carrying the unwinding. value. wires. x Fault in main unit. x ALARM 63 PressH Higher maximum value. x ALARM 65 PressH_B Low of

minimum x Possible lack of continuity in wires connectors are not in short x Possible short circuit in connection xVerify

x Upper chamber pressure transducer xVerify that the wiring and the Value broken. wires. connectors are not in short xVerify the pressure the x Possible short circuit in connection circuit.. transducer integrity.

calibration settings x Fault in main unit.

x Lower chamber pressure transducer xVerify broken. x Possible lack of continuity connection wires. wires. x Fault in main unit.

the

pressure

transducer integrity. in xVerify that the wiring and the connectors are not in short x Verify the wire continuity.

x Possible short circuit in connection circuit..

x ALARM 66 PressH_B High

x Upper chamber pressure transducer xVerify broken. wires. x Fault in main unit.

the

pressure

transducer integrity. connectors are not in short circuit..

x Possible short circuit in connection xVerify that the wiring and the

12 | Trouble Shooting

6.13
Alarm Code x ALARM 67 PressH_B Lover of Cause Solution

x Upper chamber pressure transducer x Verify the wire continuity . Value broken. xVerify that the wiring and the circuit.. the pressure transducer integrity. the x Possible lack of continuity in wires connectors are not in short x Possible short circuit in connection xVerify wires. x Fault in main unit.

minimum calibration carrying the unwinding. settings value.

x ALARM 68 PressH_B Higher maximum value. ALARM 100 E2prom Error of

x Upper chamber pressure transducer xVerify that the wiring and the Value broken. wires. connectors are not in short xVerify the pressure the x Possible short circuit in connection circuit.. transducer integrity.

calibration settings x Fault in main unit.

x Memory data not reliable

x Switch the system off and on. xVerify that E2prom chip is fitted property in its socket. x Re-enter data and save again it. xReplace the E2prom chip and recalibrate the machine.

ALARM 101 CRC RUN View ALARM 105 CRC TAB View ALARM 106 CRC PRG View

x CRC RUN error in View

x Call assistance

x CRC TAB error in View

x Call assistance

x CRC PRG error in View

x Call assistance

12 | Trouble Shooting

6.13
Alarm Code x ALARM 180 CANBUS ACMCP_1A KO Cause Solution

x CAN BUS cable disconnected or x Verify the CAN BUS cable. broken. CAN BUS line. x Replace unit. x Possible short circuit in connection x Fault in the MC2M Unit.

x ALARM 181 CANBUS ACMCP_1B KO

x CAN BUS cable disconnected or x Verify the CAN BUS cable. broken. CAN BUS line. x Replace unit. x Possible short circuit in connection x Fault in the MC2M Unit.

x ALARM 182 CANBUS ACMCP_2A KO

x CAN BUS cable disconnected or x Verify the CAN BUS cable. broken. CAN BUS line. x Replace unit. x Possible short circuit in connection x Fault in the MC2M Unit.

x ALARM 183 CANBUS ACMCP_2B KO

x CAN BUS cable disconnected or x Verify the CAN BUS cable. broken. CAN BUS line. x Replace unit. x Possible short circuit in connection x Fault in the MC2M Unit.

x ALARM 184 CANBUS ACMCP_3A KO

x CAN BUS cable disconnected or x Verify the CAN BUS cable. broken. CAN BUS line. x Replace unit. x Possible short circuit in connection x Fault in the MC2M Unit.

x ALARM 185 CANBUS ACMCP_3B KO

x CAN BUS cable disconnected or x Verify the CAN BUS cable. broken. CAN BUS line. x Replace unit. x Possible short circuit in connection x Fault in the MC2M Unit.

x ALARM 190 CANBUS KO

x CAN BUS cable disconnected or x Verify the CAN BUS cable. x Replace unit. x Possible short circuit in connection x Fault in the MC2M Unit. CAN BUS line.

MC2M broken.

12 | Trouble Shooting

6.13
Alarm Code x ALARM 191 CANBUS KO Cause Solution

x CAN BUS cable disconnected or x Verify the CAN BUS cable. x Replace unit. x Possible short circuit in connection x Fault in the ACMCP Unit. CAN BUS line.

ACMCP broken.

x ALARM 192 CANBUS JoyDx KO

x CAN BUS cable disconnected or x Verify the CAN BUS cable. broken. CAN BUS line. x Replace unit. Unit. x Possible short circuit in connection x Fault in the Joystick Dx

x ALARM 193 CANBUS JoySx KO

x CAN BUS cable disconnected or x Verify the CAN BUS cable. broken. CAN BUS line. x Replace unit. x Possible short circuit in connection x Fault in the Joystick Sx Unit.

x ALARM 194 CANBUS Front KO

x CAN BUS cable disconnected or x Verify the CAN BUS cable. Midac broken. CAN BUS line. x Replace unit. Unit. x Possible short circuit in connection x Fault in the Midac Front

x ALARM 195 CANBUS Rear KO

x CAN BUS cable disconnected or x Verify the CAN BUS cable. Midac broken. CAN BUS line. x Replace unit. Unit. x Possible short circuit in connection x Fault in the Midac Rear

x ALARM 196 KO

x CAN BUS cable disconnected or x Verify the CAN BUS cable. x Replace unit. x Possible short circuit in connection x Fault in the Key Pad Unit. CAN BUS line.

CANBUS Key Pad broken.

x ALARM 197 CANBUS Front Sx KO

x CAN BUS cable disconnected or x Verify the CAN BUS cable. CCRA broken. CAN BUS line. x Replace unit. Unit. x Possible short circuit in connection x Fault in the CCRA Front Sx

12 | Trouble Shooting

6.13
Alarm Code x ALARM 198 CANBUS Front Dx KO Cause Solution

x CAN BUS cable disconnected or x Verify the CAN BUS cable. CCRA broken. CAN BUS line. x Replace unit. Unit. x Possible short circuit in connection x Fault in the CCRA Front Dx

x ALARM 199 CANBUS Rear Sx KO

x CAN BUS cable disconnected or x Verify the CAN BUS cable. CCRA broken. CAN BUS line. x Replace unit. Unit. x Possible short circuit in connection x Fault in the CCRA Rear Sx

x ALARM 200 CANBUS Rear Dx KO

x CAN BUS cable disconnected or x Verify the CAN BUS cable. CCRA broken. CAN BUS line. x Replace unit. Unit. x Possible short circuit in connection x Fault in the CCRA Rear Dx

x ALARM 201 KO

x CAN BUS cable disconnected or x Verify the CAN BUS cable. x Replace unit. x Possible short circuit in connection x Fault in the Safe Key Unit. CAN BUS line.

CANBUS Safe Key broken.

ALARM 300 Ecu EEC1read ALARM 700 CRC Prg MC2M ALARM 701 CRC Tab MC2M ALARM 702 CRC Run MC2M ALARM 703 CRC Par MC2M

x Call assistance

x CRC Prg error in MC2M

x Call assistance

x CRC Tab error in MC2M

x Call assistance

x CRC Run error in MC2M

x Call assistance

x CRC Par error in MC2M

x Call assistance

12 | Trouble Shooting

6.13
Alarm Code ALARM 704 Rdn BoomLft Cause x Redudancy corrent error boom lift Solution x Verify the wire continuity . x Replace unit MC2M. x Call assistance ALARM 705 Rdn BoomLwr x Redudancy corrent error boom lower x Verify the wire continuity . x Replace unit MC2M. x Call assistance ALARM 706 Rdn WinchUp x Redudancy corrent error winch up x Verify the wire continuity . x Replace unit MC2M. x Call assistance ALARM 707 Rdn WinchDwn x Redudancy corrent error winch down x Verify the wire continuity . x Replace unit MC2M. x Call assistance ALARM 708 Rdn RotaCw x Redudancy corrent error turret rot Cw x Verify the wire continuity . x Replace unit MC2M. x Call assistance ALARM 709 Rdn RotaCCw x Redudancy corrent error turret rot x Verify the wire continuity . CCw x Replace unit MC2M. x Call assistance ALARM 710 Rdn TeleOut x Redudancy corrent error boom out x Verify the wire continuity . x Replace unit MC2M. x Call assistance ALARM 711 Rdn TeleIn x Redudancy corrent error boom In x Verify the wire continuity . x Replace unit MC2M. x Call assistance ALARM 712 Rdn WinchAuxUp x Redudancy corrent error Auxiliary x Verify the wire continuity . Winch Up x Replace unit MC2M. x Call assistance

12 | Trouble Shooting

6.13
Alarm Code ALARM 713 Rdn WinchAuxDw Cause Solution

x Redudancy corrent error Auxiliary x Verify the wire continuity . Winch Down x Replace unit MC2M. x Call assistance

x ALARM 714 TOut JoyDx

x CAN BUS cable disconnected or x Verify the CAN BUS cable. broken. CAN BUS line. x Replace unit. Unit. x Possible short circuit in connection x Fault in the Joystick Dx

x ALARM 715 TOut JoySx

x CAN BUS cable disconnected or x Verify the CAN BUS cable. broken. CAN BUS line. x Replace unit. x Possible short circuit in connection x Fault in the Joystick Sx Unit.

x ALARM 716 TOut Midac Front

x CAN BUS cable disconnected or x Verify the CAN BUS cable. broken. CAN BUS line. x Replace unit. Unit. x Possible short circuit in connection x Fault in the Midac Front

x ALARM 717 TOut Midac Rear

x CAN BUS cable disconnected or x Verify the CAN BUS cable. broken. CAN BUS line. x Replace unit. Unit. x Possible short circuit in connection x Fault in the Midac Rear

x ALARM 718 TOut Key Pad

x CAN BUS cable disconnected or x Verify the CAN BUS cable. broken. CAN BUS line. x Replace unit. x Possible short circuit in connection x Fault in the Key Pad Unit.

x ALARM 719 Sx

x CAN BUS cable disconnected or x Verify the CAN BUS cable. x Replace unit. Unit. x Possible short circuit in connection x Fault in the CCRA Front Sx CAN BUS line.

Tout CCRA Front broken.

12 | Trouble Shooting

6.13
Alarm Code x ALARM 720 Dx Cause Solution

x CAN BUS cable disconnected or x Verify the CAN BUS cable. x Replace unit. Unit. x Possible short circuit in connection x Fault in the CCRA Front Dx CAN BUS line.

Tout CCRA Front broken.

x ALARM 721

x CAN BUS cable disconnected or x Verify the CAN BUS cable. x Replace unit. Unit. x Possible short circuit in connection x Fault in the CCRA Rear Sx CAN BUS line.

Tout CCRA Rear Sx broken.

x ALARM 722 Tout Dx CCRA

x CAN BUS cable disconnected or x Verify the CAN BUS cable. Rear broken. CAN BUS line. x Replace unit. Unit. x Possible short circuit in connection x Fault in the CCRA Rear Dx

x ALARM 723 TOut ACMCP

x CAN BUS cable disconnected or x Verify the CAN BUS cable. broken. CAN BUS line. x Replace unit. x Possible short circuit in connection x Fault in the ACMCP Unit.

x ALARM 724 JoyDx Fault x ALARM 725 JoySx Fault x ALARM 726 ACMCP Fault x ALARM 727 CCRA Fault x ALARM 728 CCRA Fault Front Dx Front Sx

x Fault in the Joystick Dx Unit.

x Verify the CAN BUS cable. x Replace unit.

x Fault in the Joystick Sx Unit.

x Verify the CAN BUS cable. x Replace unit.

x Fault in the ACMCP Unit.

x Verify the CAN BUS cable. x Replace unit.

x Fault in the CCRA Front Sx Unit.

x Verify the CAN BUS cable. x Replace unit.

x Fault in the CCRA Front Dx Unit.

x Verify the CAN BUS cable. x Replace unit.

12 | Trouble Shooting

6.13
Alarm Code x ALARM 729 CCRA Fault x ALARM 730 CCRA Fault x ALARM 731 CCRA Fault x ALARM 732 CCRA Fault x ALARM 733 CCRA Fault x ALARM 734 CCRA Fault x ALARM 735 Key Pad Fault x ALARM 736 MIDAC Front Fault x ALARM 737 MIDAC Rear Fault x ALARM 738 View Fault x Fault in the View Unit. x Fault in the MIDAC Rear Unit. x Fault in the MIDAC Front Unit. x Fault in the Key Pad Unit. x Verify the CAN BUS cable. x Replace unit. x Verify the CAN BUS cable. x Replace unit. x Verify the CAN BUS cable. x Replace unit. x Verify the CAN BUS cable. x Replace unit. Rear2 Dx x Fault in the CCRA Rear Dx Unit. x Verify the CAN BUS cable. x Replace unit. Rear2 Sx x Fault in the CCRA Rear Sx Unit. x Verify the CAN BUS cable. x Replace unit. Front2 Dx x Fault in the CCRA Front Dx Unit. x Verify the CAN BUS cable. x Replace unit. Front2 Sx x Fault in the CCRA Front Sx Unit. x Verify the CAN BUS cable. x Replace unit. Rear Dx x Fault in the CCRA Rear Dx Unit. x Verify the CAN BUS cable. x Replace unit. Rear Sx Cause x Fault in the CCRA Rear Sx Unit. Solution x Verify the CAN BUS cable. x Replace unit.

12 | Trouble Shooting

6.13
Alarm Code x ALARM 739 Right Fault x ALARM 740 Left Fault x ALARM 741 Right Fault x ALARM 742 Left Fault x ALARM 900 Ovl1 x ALARM 901 Ovl2 x ALARM 902 Ovl3 x ALARM 905 Mac Inp Esclusione x ALARM 906 Bridging Device x Overload Alarm, over 120 % x Overload Alarm, over 115 % x Overload Alarm, over 110 % x NOT on the screen, but only Storage in BlackBox x NOT on the screen, but only Storage in BlackBox x NOT on the screen, but only Storage in BlackBox x ByPass from Key device is activate. x This information will be All movement are free without control storage in the BlackBox. x Fault in the Pressure Transducer x Verify the cable. x Replace unit. x Fault in the Pressure Transducer x Verify the cable. x Replace unit. x Fault in the Pressure Transducer x Verify the cable. x Replace unit. Cause Solution

x Fault in the Pressure Transducer x Verify the cable. x Replace unit.

Press Trasd Front Front Right

Press Trasd Front Front Left

Press Trasd Rear Rear Right

Press Trasd Rear Rear Left

x ByPass from safe Key device is x This information will be activate. All movement are free without storage in the BlackBox. control

x ALARM 907 Bridging Device DI

x ByPass from safe Key device is x This information will be activate. All movement are free without storage in the BlackBox. control

12 | Trouble Shooting

6.13
Alarm Code x ALARM 908 Inp Esclus A2B Cause Solution

x ByPass A2B from Key device is x This information will be activate. The winch Up movement is storage in the BlackBox. activate.

12 | Trouble Shooting

6.13

13
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 operators 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 Manufacturers instructions and procedures at any time.

13 | Warnings

6.13.1

PROXIMITY POSITION

PROXIMITY 1

PROXIMITY 2

ENCODER 3

PROXIMITY 4

PROXIMITY 5

PROXIMITY 6

6.14

GENERAL VIEW INSIDE THE CAB

1. Selectors and push-buttons group. 2. Switches group. 3. Air outlets

A. Accelerator pedal. B. Brake pedal.

INSTRUMENTATION
6.14.1.1 WARNING LIGHTS, INSTRUMENTS
WARNING LIGHTS FUNCTIONS

1A 2 3 4 4 5 6

Diesel fuel level gauge It shows the fuel level inside the tank; this indication is given only when the ignition key is in 1 position (See STARTING COMMUTATOR). Working lights warning light: When the light is off all 4 working light are on. It light when only the working light on the travel order are on (2 light). Working lights warning light: it lights when the operator turns on the push-button. Turning signals warning light: it blinks when the operator uses the turning lights or the hazard lights. Hazard warning light push-button: it blinks when the operator activates the hazard push-button. See fig. n1 Speed control light: it lights when the speed control is on the position II (fast speed). Thermostater warning light. It lights when the diesel engine is cold, and its off after the engine start. If lights when while you are travelling there is a problem with plugs.

Amperemeter gauge It shows the level of tension available in the batteries; this indication is given only when the ignition key is in 1 position (See STARTING COMMUTATOR). Alternator warning light: it lights when the engine is turned off but the ignition key is on or when the engine is idling; if this warning light remains lit also when the engine is running at normal rpm, it means that the alternator does not work and does not recharge the batteries. IMPORTANT: if when the key is in the ignition in the "1" position and the warning light remains off, it means that the alternator is defective or broken; in this case the engine does not turn on even if the transmission is in neutral position. Translation pump clogging warning light. It lights when the filter is clogged. NOTE: This warning light is on until the oil temperature is not optimal. Parking brake warning light: it lights when the parking brake is on. Engine anomaly: it lights when there is a problem with engine. Contact the assistance center. Engine diagnostic: it lights at engine start and is off when the engine is on rpm regime. Slew ring lock warning light. It lights when the lock pin is inside its housing 4WD warning light. it lights when the operator turns on the push-button. Winch 2nd speed It lights when the operator presses the front push-button of the right joystick Rear axle oscillation lock warning light It lights when the push-button is activated.

8 9 10 11 12 13 14 15

16 17 18 19 20

Rear wheels light alignment warning light It lights when the rear wheels are aligned to the carrier after a steering operation. 3rd section locking warning light It lights when the section is locked 3rd section unlocking warning light It lights when the section is unlocked Water on the diesel engine filter: It lights when there is water on the diesel engine filter. Brakes oil low pressure warning light: it lights when the pressure in the braking circuit is lower than the minimum allowed. DANGER: when this warning light is on stop the machine immediately and ask the technical service assistance to check the whole braking system.

SEE THE Completely closed boom warning light DISPLAY It lights when the boom is fully closed SEE THE Slewing ring angle limit DISPLAY Superstructure slewing is limited to 5 in respect of the travel order

INSTRUMENTS FUNCTIONS

B C

Tachometer (RPM)

Water temperature gauge: It indicates the cooling liquid temperature which generally is between 8085C. Engine oil low pressure warning light: it lights as soon as the engine is on, and it turns automatically off when there is oil pressure in the circuit. If this warning light remains on, stop immediately the diesel engine and find out the reasons of the inconvenient. Forward drive engagement Reverse drive engagement Hour meter gauge It counts the working hours of the machine. The reading of this instrument is valid for time intervals for the maintenance. Air bubble level indicator

D E F G

SEE ON TURRET It displays the correct levelling of the machine, and it must be used to control the position

the machine on the outriggers. The air bubble has to be in the center of the circle

AUXILIARY PUSH-BUTTON

Fig. n1 Hazard warning light push-button

Fig. n2 Rotary beacon warning light

Fig. n3 Glass top wiper control and water for wiper

Fig. n4 Working light control

Fig. n5 Working light control of down position (frame front and rear)

Fig. n6 Cab rotation control (optional)

6.14.1.2 PUSH-BUTTONS, SWITCHES, SELECTORS

1. Ignition key 2. Temporized key for 15% more power uplifting 3. Emergency mushroom push-button 4. Air conditioning control 5. Outriggers panel control 6. Rear steering control 7. Auxiliary opening

1. RPM Engine regolation + / 2. RPM Engine regolation ON 3. RPM Engine regolation OFF 4. Third section Lock control system

MACHINE CONTROLS
1. Travel order selection lever, horn 2. Travel selector, ligh selector, windscreen wiper 3. Brake treadle 4. Accelerator treadle 5. Parking brake 6. Outriggers control 7. Joystick for boom derricking and swing control 8. Joystick for sections telescoping and winch control

FUNCTIONS CONTROLS 6.14.1.3 TRAVEL ORDER SELECTION LEVER, HORN

DANGER

FORWARD GEAR

Put the travel order selection lever in neutral position (N) when you have to turn on the diesel engine, when you park, when you stop the machine for few minutes and when the machine works. Stop the machine before engaging the reverse gear. Horn

REVERSE GEAR

6.14.1.4 TURNING SIGNALS, LIGHT SELECTOR

D
A - Right turn B - Left turn C - Front wiper control D - Water for wiper

B C
6.14.1.5 BRAKE PEDAL

Braking is done on each wheel; the only precaution to use after starting the machine is to check the machine braking system by stepping on the brakes to test them. DANGER | If the braking distance seems not good enough and the operator has some doubts about the braking system, stop the machine and ask for technical assistance.

6.14.1.6 ACCELERATOR PEDAL

It is recommended to use it wisely, especially during heavy-duty use and travelling on road. Avoiding sudden accelerator use lowers fuel consumption and extends the diesel engine, brakes and machine life.

6.14.1.7 PARKING BRAKE

DANGER

x The parking brake must be engaged every time the operator leaves the machine, even for
short time periods.

x In case of machine towing, release the parking brake.

Parking brake The switch pressed toward the bottom engages the parking brake.

10

6.14.1.8 JOYSTICKS CONTROL

Before operating the joysticks, be sure to set the safe-load moment indicator in the desired configuration. For these instructions refer to the safe-load moment indicator manual. On this joystick there is no "Dead man" consent push-button, but instead there is a sensor which feels the operator's hand on the joystick itself. DANGER: do not release suddenly the joystick: this operation will cause dangerous load oscillation and repercussion on the machine structure. Always start the manoeuvre slowly, and gradually accelerate; before stopping the manoeuvre, decelerate slowly. It is possible performing 2 movements with the same joystick, keeping it crossways. On the right joystick there is a small lever (1) allowing to use the winch second speed

Left joysticks

Right joysticks

11

6.14.1.9 JOYSTICK FOR BOOM SLEWING AND DERRICKING.

DANGER - Before performing any manoeuvre with this joystick: 1. the crane operator has to be seated in his position; 2. he has to put down the arm of the seat; 3. he has to set the turret free from the locking pin; 4. he has to release the hook-block from the carrier; 5. he has to position and level the machine; 6. he has to make sure that the travel order selection lever is in neutral position.

By moving the joystick forward the operator activates the boom derricking lowering; by moving it backward the boom derricking lifting. Moving the same joystick leftways, the operator activates the slewing toward the left; rightways toward the right.

Left joystick

6.14.1.10 JOYSTICK FOR BOOM TELESCOPING AND MAIN WINCH

DANGER x Before attempting any manoeuvre with this joystick: the crane operator has to be seated in his position; he has to position and level the machine; he has to make sure that the travel order selection lever is in neutral position. By moving the joystick forward the operator activates the main winch lowering; by moving it backward he activates the main winch lifting. Moving the same joystick sideways, the operator activates either the boom telescoping.

Right joystick

12

6.14.1.11 CAB DESCRIPTION DANGER

x If the cab is damaged by a load, ask the Manufacturer or the local Dealer to check if the repair
job will guarantee the original safety to the crane operator.

x Do not use the machine if its cab has been damaged. x During traveling on road, the door and the front window must be closed.

1. Front window 2. Top window 3. Rear window 4. Door

5. Front wiper 6. Curtain 7. Roof wiper 8. Light

The cab opens with the front and upper window and with the rear window. These features are particularly appreciated during summer or in sunny areas, since they alleviate the crane operator's psychophysical fatigue. The entrance door can be fully opened and fixed to its elastic hooking. IMPORTANT: the cab door has to be closed or fixed to its elastic hooking; the machine use with the door semi-opened is forbidden. 13

6.14.1.12 VENTILATION
The air vent and exchange are obtained with a double speed vent operated by a switch; the air flow goes through adjustable small openings to defrost and anti-fog the front window (1) and to the bottom part of the seat (2).

6.14.1.13 FUSES
DANGER

x Before replacing a fuse, make sure that the key is off in the O position. x Replace the fuse only with another of the same resistance. x Check the fuses regularly, especially if the machine operates in hot climatic and high humidity
conditions; if some fuses are loose, oxidized or corroded replace them.

x It is prohibited to connect or by-pass fuses with an electrical wire. x In case a fuse burns itself several times, look for the inconvenient before replacing it. x Do not operate the machine whenever there are burned fuses.
All fuses (1) are grouped on three bases installed on the dashboard, and are protected by a plastic cover.

14

6.14.1.14 SEAT
There are 6 possible adjustments allowing the crane operator to choose the driving and working positions; he can choose to do: 1. seat dumping according to his weight; 2. seat tilting; 3. seat back adjustment; 4. seat forward toward the controls; 5. seat backward from the controls; 6. seat armrest up/down.

15

LOCATION FOR FIRE EXTINGUISHER, FIRST-AID KIT AND GLASS HAMMER (for those countries where it is mandatory)
6.14.1.15 FIRE EXTINGUISHER
To install a fire extinguisher on the machine, the Manufacturer has chosen its installing position under the seat left arm. IMPORTANT x Check regularly the fire extinguisher operating conditions. x Make sure the operator knows how to use it in case of fire.

6.14.1.16 FIRST-AID KIT

The place to put this box containing the first-aid kit is on the back side of the cab, under the rear window. IMPORTANT x Check the box regularly, which shall contain disinfectants, bandages, adhesive plasters, medicines. x Check often the medicines expiration dates, and replace them before they expire.

6.14.1.17 GLASS HAMMER

On our machine is provided for an emergency exit located in the front window. In order to ease the exit from the cab, besides the turning handles, a glass hammer (installed upon request) may be used. Its location is on the rear right side of the cab. IMPORTANT x Check the hammer position, if installed.

ACCESS TO THE ENGINE COMPARTMENT, BATTERY COMPARTMENT, DISTRIBUTORS COMPARTMENT.

DANGER: x The access to these compartments is allowed only to the authorized personnel in charge of the maintenance, and only if these procedures are followed: 1. Diesel engine is off, parking brake engaged, boom completely closed with no load hanging, superstructure locked with its locking pin. 2. Travel order selection lever in neutral position. 3. Outriggers positioned.

x x

The engine turning on with the open compartment has to be done only if the maintenance controls require so; avoid turning the diesel engine on if it is not needed. Whenever the engine compartment is open, do not allow any person into the cab or near the machine.

After stopping the machine and checked that the above mentioned safety norms are respected, use the supplied key to open the compartments and lift the bonnets. Gas struts will keep the compartment doors opened. ATTENTION: before starting the machine, make sure that all compartments are perfectly closed. 16

7 SAFE-LOAD MOMENT INDICATOR

The mobile crane is equipped with a safe-load moment indicator that, if correctly programmed, it will facilitate the operator job, allowing him to concentrate on the lifting procedures. It is this device which controls all the parameters concerning the over-load and all the solicitations to which the machine goes through, showing the percentage of the admissible load and making acoustic sounds when the working conditions approach the limit. In this case, the safe-load moment indicator sounds without stopping and all motions are stopped, leaving only the load lowering as a possible maneuver. For the whole description, programming and use of the safe-load moment indicator, consult the use manual supplied with the technical documentation, which must remain into the cab at all times. The safe-load moment starting is done when the operator turns on the diesel engine, and it begins with an auto-check procedure; if there are found no inconvenient press the consent push-button to activate the crane controls. It is forbidden to use the crane with the safe-load moment indicator bypassed or broken. DANGER:

x Before beginning to program the safe-load moment indicator, the operator has to check if that
load can be lifted by looking at the parameters in the load charts and diagrams.

x The safe-load moment does not replace the operator, but it helps him to work; the operator has
to: 1. input the operative configuration. 2. Input the part lines (falls). 3. Set the machine according to the operative configuration or do the opposite. 4. Position the boom length according to the load chart or the corresponding diagram chosen. 5. Check if the counterweight corresponds to the chosen one. 6. Fully extend the outriggers boxes checking if their relative marks can be seen. NOTE: this operation has to be performed only with machine positioned. 7. Level the machine. 8. Check if the lattice extension and its angle are the ones that were input in the configuration chosen.

x When the safe-load moment indicator is wrongly programmed, it becomes very dangerous,
because it gives the crane operator a false safety situation. All data input into the safe-load moment indicator have to be real and true, corresponding to the machine configuration chosen; if this condition is not respected, the ratio between the real and admissible load will be not correct, causing risks for tipping and machine breakage.

x Even if the safe-load moment indicator has been correctly set and works perfectly, there still is
danger of machine tipping. The operator has to keep control of the admissible load percentage, and whenever the safeload moment indicator sounds with the pre-alarm (yellow zone), he has to reduce the motions speed, since the machine movements can stop very soon. The importance of slowing down the movements speed is justified by the need to gradually deaden the load inertial forces and to limit the oscillations.

NOTE:

x Even though the safe-load moment indicator intervenes and block the maneuvers, the load

inertial forces caused by the rapid movement cannot be annulled, and can cause the machine tipping or structure overload and breakage. release the machine from very dangerous situations, utilizing the opposite movements of those which caused the manoeuvres block. that using this key the machine can lift loads heavier than to ones indicated in the load charts, causing in this way machine breakage or tipping with possible people death.

x The safe-load moment indicator is supplied with a by-pass key; this key has to be used only to

x This key has to be used only in emergency cases by the crane operator, considering the fact

x Do not use the key to lift heavier loads than the ones indicated in the diagrams and load charts.

8 PART LINES CHANGE (FALLS)

DANGER:

x After changing the part lines, it is necessary to program the same number in the safe-load
moment indicator. ATTENTION:

x The number of part lines to prepare in advance between the hook-block and the boom head is
always referred to the load that has to be lifted, regardless of the working radius. diagrams.

x The number of part lines necessary to lift a load is shown on the general load chart and lifting x When the operator changes the number of part lines, make sure to equally distribute the rope
return lines on the boom head and on the hook-block pulleys. This procedure permits to keep the parallelism between the hook-block and boom head pulleys.

x Perform the part lines change with the boom completely lowered. x Wear safety anti-cut gloves, and do not allow people in the working area.
1. 2. 3. 1. Retract all boom sections and lower the main boom. Lay the hook-block on the ground letting the cables loose. Take off the safety elastic spring (1) and open the small weight (2) from the last cable line (3). Take off the safety clamp (4).

1. Take off the safety elastic spring (5) and the pin (6) of the wedge socket (7) from the last part line.

6. Dismantle the wedge (8) and set the cable free from the socket (7). 7. Remove the rope from the hook-block pulleys (9) and from the boom head, leaving it on the ground.

8. Seeing these drawings, wind the rope on the pulleys (10) of the hook-block (9) and on the boom lower pulleys (11).

9. Apply the wedge socket (7) to the last part line.

ATTENTION:

x Pay attention at the socket (7) orientation; the axis of the connecting pin has to be on the
extension axis of the cable itself. 10. Connect the socket to the boom using its pin (6) and its safety spring (5). DANGER: removing it; after using it 3-4 times, replace it with a new one. 11. Use the safety clamps keeping the correct orientation and the distance of 6-8 times the rope diameter (84-112 mm). 12. Winch the rope up until it lifts the hook-block and clean the rope from dust and gravel. 13. Install the small weight on the last part line.

x The safety spring has to be installed toward the outside of the boom to avoid the rope from

OPTIONAL EQUIPMENTS

9.1 GENERAL INSTRUCTIONS

1. The optional equipments have to be supplied by the mobile crane Manufacturer which certifies their quality and characteristics. Do not install different equipments if not after written approval of the Manufacturer. 2. Before the assembly, check the whole equipment; if it is damaged in one of its components, it must be repaired or replaced by the Manufacturer only. 3. It is forbidden to replace in part or totally the equipments or their accessories parts such as pins, bolts, nuts, etc. without the written consent by the Manufacturer, which may authorize such replacements indicating the materials specifications to use or supply the spares requested. 4. The optional equipments use has to be carried out by hooking their apposite holes indicated by pictograms. 5. To use these equipments, utilize suitable machines, looking at the engraved mass written on the equipment plate. If this plate is damaged and cannot be read anymore, ask the Manufacturer to have another one. 6. The installation and removal of the equipments has to be done with the machine stopped following the indicated procedures. 7. Do not allow unauthorized people in the working area or into the cab. 8. To reach the telescopic boom head, use safety ladders or homologated lifting machines. 9. Before using the equipment, carefully check that all its connecting parts are locked or tightened and are correctly positioned on the machine; check also if the over-limit switch works. 10. Before beginning to work, check that the number of part linear the same as those indicated in the load chart. ATTENTION:

x On the load charts and diagrams, are indicated the gross lifting weights. In order to determine
the net lifting weight, and according to the machine configuration, there are two possibilities: A. If the machine is equipped with auxiliary winch and the main hook-block remains hanging, the lifting load is that indicated on the load chart minus: 1. the optional equipment weight; 2. the auxiliary hook-block weight; 3. the main hook-block weight. B. If the machine is not equipped with auxiliary winch, to perform the lifting the operator uses the main winch only, the lifting load is that indicated on the load chart minus: 1. the optional equipment weight; 2. the main hook-block weight.

10 TROUBLE-SHOOTING PROCEDURE
10.1 ELECTRICAL SYSTEM
( ) : Always contact your agent when you have to do this operation.

: In case the inconvenient or the problem which caused it is not found in the indicated defects, contact your agent for the necessary repair. PROBLEM CAUSE SOLUTION ( Check or repair the losse connections) Defective cables Adjust the alternator belt tension (See every 400 hours) ( Replace it) ( Check and repair it) ( Replace it) ( Check and repair it) ( Charge the batteries) .Charge the batteries Charge the batteries ( Replace it) ( Check and repair it) Charge the batteries ( Replace it) ( Replace it) ( Replace it) ( Check and repair it)

The lights do not lit properly even with the engine at high rpm: The lights work only sometimes, when the engine is running:

The alternator warning light does Faulty alternator. not go off when the engine is on Defective cables. and it is accelerated: The alternator makes a not normal noise: Faulty alternator.

The starter does not crank when Defective cables. the key is in starting position: Insufficient battery charge. The starter pinion engages and disengages: The starter makes the engine turn slowly: The starter disengages before the engine is turned on: The engine oil pressure warning light does not lit when you stop the engine (the key is on I): Insufficient battery charge. Insufficient battery charge. Defective starter. Defective cables. Insufficient battery charge. Defective bulb. Defective oil pressure sensor.

The alternator warning light does Defective bulb. not lit when you stop the engine Defective cables. (the key is on I):

10.2 HYDRAULIC SYSTEM

( ) Always contact your agent PROBLEM A pump makes a not normal noise: CAUSE SOLUTION

Insufficient oil into the tank. Refill to level Defective pump. ( Repair it or replace it) Hydraulic oil not suitable to the Replace it local temperature. ( Repair it or replace it) Defective pump. ( Re-set them or replace them) Valves damaged, not set properly or clogged for dirty oil. Dirty oil filter. Replace it

The manoeuvres work at low speed only:

10.3 BRAKING SYSTEM

( ) Always contact your agent. PROBLEM CAUSE Worn braking shoes. The braking is not regular on both wheels: The braking is not regular on one side: Insufficient oil. Worn braking shoes. SOLUTION ( Replace it) ( Refill to level and drain the system) ( Drain the system) ( Replace it)

10.4 HYDROSTATIC TRANSMISSION

( ) Always contact your agent : In case the inconvenient or the problem which caused it is not found in the indicated defects, contact your agent for the necessary repair. PROBLEM CAUSE Insufficient oil. Intake filter clogged or intake tap closed. Maximum valves defective or clogged. Defective variable displacement motor. SOLUTION Refill to level Replace filter or check that the intake tap is open ( Clean them or replace them) ( Repair it or replace it)

The machine does not move forward nor backward:

The machine moves with delay, making not normal noise:

Refill to level Insufficient oil. Use correct oil Foam in the system. Intake pipe leaking or pressure ( Check and eliminate leak) loss. Replace it Intake filter clogged. ( Disassemble it and clean it or Defective delivery maximum valve. replace it) Defective variable ( Repair it or replace it) displacement motor. The diesel engine does not reach full power. Defective auxiliary pump. Maximum valve unset. Pressure-cut valve unset. High oil temperature. Defective variable displacement motor. ( Replace the fuel filter and check the injection pump) ( Repair it or replace it) ( Set it) ( Set it) Check oil level and clean the oil coolers ( Repair it or replace it)

There is insufficient traction force in both travelling directions:

There is insufficient traction force in one travelling direction:

Maximum valve unset.

( Set it)

PROBLEM

CAUSE Insufficient oil. Dirty oil coolers. Non-suitable oil. Intake pipe pressure loss Maximum working pressure valves unset. Defective axial piston pump. Pressure-cut valve with high setting. Defective variable displacement motor

SOLUTION Refill to level ( Check them, clean them or replace them) Use correct oil ( Check and eliminate the leak) ( Check and set or replace them) ( Repair it or replace it) ( Set the valve) ( Repair it or replace it)

Oil overheating:

The machine does not reach its maximum speed:

Replace it Intake filter clogged. The diesel engine not reach full Replace the fuel filter and check the injection pump) power. ( Check its flow, repair it or Defective gear pump. replace it) ( Set it) Insufficient servo-controls pressure. ( Set it at its nominal value) Pressure-cut valve unset. Mechanical connection with the ( Check the slewing) joystick hard. Engine loss of power. ( Check if the fuel filter is clogged, the injection pump and the valves) ( Set it at its nominal value) ( Replace them) Return pipes obstructed or damaged) Check it and set it righte)

The machine decelerates jerkily:

The machine accelerates slowly: Pressure-cut valve unset. Defective o-rings. Counter-pressure in the pump. Excessive by-pass valve pressure.

Oil leak from shaft of the motor and/or the pump:

10.5 DIESEL ENGINE

( ) Always contact your dealer. PROBLEM Low oil pressure warning light remains on even at high rpm: CAUSE Insufficient oil. Oil filter is clogged. Non-suitable oil. SOLUTION Refill to level Replace it Replace it

Steam comes out from the radiator breather pipe:

Refill to level and repair it Insufficient liquid or leak in the system. Check its tension Lose vent belt. Replace the liquid and clean Mud or limestone pile in the the system cooling system. Repair them or clean them Radiator fins damaged or closed. ( Replace it) Defective thermostat. Tight the tapor replace the Lose radiator tap, damaged or whole group the machine works at high altitude. Faulty gauge. Faulty gauge. Faulty thermostat. Insufficient fuel. Air in the injection system. Defective compression (valves unset) Excessive oil in the engine sump. Not proper fuel. Air filter obstructed. Faulty injectors. Wrong compression (valves unset). Faulty injectors. Low scale fuel. Overheating. Damaged muffler Excessive valve timing. ( Replace it) ( Replace it) ( Replace it) Refill the tank Breath the system ( Adjust valve clearance) Set the level Replace it with suitable fuel Replace it ( Replace them) ( Set correct valve timing) ( Replace them) Replace it with suitable fuel See Defects of the temp gauge ( Replace them) ( Adjust them)

Water temperature gauge is always at the right end: Water temperature gauge is always at the left end:

The engine does not start when the starter is operated:

Exhaust gases are white or bluish:

Exhaust gases sometimes are black: Sometimes combustion noise seems a buzz: Not normal noises (combustion or mechanical parts)

12 BOLTS AND NUTS TIGHTENING TORQUE

12.1 STANDARD TIGHTENING TORQUE
Nm (Newton meter): 1 Nm = 0.102 Kgm Diameter of thread (in mm) 6 8 10 12 14 16 18 20 22 24 27 30 wrench measure (in mm) 10 13 17 19 22 24 27 30 32 36 41 46 Kgm 0.96 0.1 2.3 0.2 4.6 0.5 7.8 0.8 12.5 1 19.5 2 27 3 38 4 52 6 66 7 96 10 131 14 Nm 9.5 1 23 2 45 4.9 77 8 122 13 191 21 262 28 372 40 511 57 644 70 945 100 1287 140 Kgm 1.3 0.15 3.2 0.3 6.5 0.6 11 1 17.5 2 27 3 37 4 53 6 73 8 92 10 135 15 184 20 Nm 13.5 1.5 32.2 3.5 63 6.5 108 11 172 18 268 29 366 36 524 57 719 80 905 98 1329 140 1810 190

IMPORTANT: this chart is not applicable for bolts and nuts which have to lock nylon particulars or nylon, aluminum or copper washers.

12.2 SPECIFIC TIGHTENING TORQUE

PARTICULAR Cab Slew-ring Wheels Engine Transmission shafts Fixing bolts Fixing bolts between slew-ring and turret Fixing bolts between slew-ring and carrier Fixing bolts Support central bolts Fixing bolts DESCRIPTION Kgm 4,6 67 67 62 8 3.6 Nm 45 657 657 608 78 35

13 MAINTENANCE PROGRAM
13.1 DAILY MAINTENANCE (EVERY 8 WORKING HOURS)
13.1.1 DIFFERENT CHECKS
DANGER: Dirt, oil and fuel on the engine compartment close to hot areas may be a cause of fire and may damage the machine. Check often and immediately repair the leaks; if they happen frequently, contact your dealer. Before turning the engine on, check the following: 1. If there are lose bolts and nuts. 2. If there are oil, fuel or cooling liquid leaks. 3. If the batteries are fully charge. 4. Rims and tires conditions. 5. Warning lights and gauges functioning, road, turning and working lights, rotary beacon. 6. Horn. 7. Conditions of the safety and warning plates. 8. Cleanliness of the ladder, handles and cab.

13.1.2 COOLING LIQUID LEVEL CHECK

DANGER:

Do not remove the tap (1) of the expansion tank when the liquid is hot, since it may come out as a spray and cause burns. Open the tap slowly to release the pressure before taking it off. The expansion tank (2) is mounted on the right rear side of the machine. The liquid level has to be between the MIN. and MAX. marks. If necessary top up with water and anti-freeze liquid; in case there is a constant lack of liquid, check the radiator and its connecting hose with the diesel engine.

13.1.3 DIESEL FUEL LEVEL CHECK

DANGER:

Whenever refueling, avoid to spill diesel fuel outside the tank, to prevent fire. In case of spill,
clean the area immediately.

Fuel is flammable; do not use free flames or smoke during refueling. Keep the fuel gun attached to the tank pipe. The tank cap is located on the left rear side of the machine. To check the fuel level, use the indicator gauge on the dash-board; never fill completely up the tank, but leave some space for expansion.

IMPORTANT:

Refill the tank at the end of the working day, to avoid water condensation. After refueling screw in the tank tap.

13.1.4 DIESEL ENGINE OIL LEVEL CHECK

DANGER: The engine is very hot right after stopping the machine, and may cause burns; leave it cool down before checking the oil. The oil dipstick is located on the right side, on the engine compartment. Check the oil when the engine is cold, on an even ground. The oil level is checked on the dipstick and it has to be in between MIN. and MAX. marks; if the oil level is near the MIN. mark, add oil suitable to the outside temperature indicated in the lubricants chart. IMPORTANT: In case the oil level has to be checked during operations, stop the engine and wait for 5 minutes before checking the level.

13.1.5 HYDRAULIC SYSTEM OIL LEVEL CHECK

DANGER:

To check the level, the oil has to be cold and the machine parked on an even ground; the oil
level has to be visible on the indicator installed on the tank. To refill, use the same oil type

In the event of anomalous power decrease, inspect the hydraulic system pressure, cylinders and
pumps.

13.1.6 ROPES AND PULLEYS CHECK

This is a visual check, and it consists of verifying that the rope is not damaged due to corrosion, broken threads, thorn or bent, and it is lubricated. Check also the boom and hook-block pulleys for any damage or cracks.

13.2 MAINTENANCE AFTER THE FIRST 50 WORKING HOURS

This maintenance has to be carried out after the first 50 working hours, and it has to be added to the maintenance of EVERY 50 WORKING HOURS.

Change diesel engine oil. Change diesel engine oil filter. Change hydrostatic transmission filters. Change discharge transmission filters. Change braking circuit and power steering filter. Change servo-controls feeding filter. Check transmission shafts bolts. Check slew-ring bolts tightening. Check vent belt tension. Check telescopic boom ropes.

For details of the maintenance schedule, see the sections: EVERY 200 WORKING HOURS, EVERY 400 WORKING HOURS, EVERY 800 WORKING HOURS.

13.3 MAINTENANCE EVERY 50 WORKING HOURS

13.3.1 CLEANING OF DIESEL ENGINE AIR FILTER EJECTOR
The ejector is located on the rear side of the machine; the cleaning has to be done with the diesel engine off, and it can be done pressing the ejector (1) with two fingers, that after opening it will release the dust contained inside. When releasing it, make sure that the rubber lips are perfectly closed but that they do not stick to one another due to oil or grease in between them. IMPORTANT: If the machine works in a dusty environment, this operation has to be carried out more frequently.

13.3.2 CHECK OF THE BATTERIES LIQUID LEVEL (EXCLUDING MAINTENANCE FREE BATTERIES)
DANGER:

Before beginning the check, cut-off the accumulators. Check the liquid level only when the diesel engine is off; if necessary, add distilled water before
beginning to work.

Always wear protective glasses and water-proof gloves. To avoid gas explosion, do not use free flames, smoke and cause sparks by poles contacts. The electrolyte liquid is dangerous; if it penetrates into a person's eyes or in contact with the
skin, wash with a lot of water and consult a doctor.

The batteries (1) are located on the front left compartment (2). The liquid level of each battery has to be of approximately 6 mm over the top of the elements; in case of low level, add only distilled water. If the level is low because of a spill, add sulphuric acid until it reaches the correct concentration suitable to the outside temperature.

IMPORTANT:

The distilled water tipping up has to be done before beginning to work, in order to avoid freezing. Before reinstalling the taps, check that the breath holes are free. Check that the clamps are free from oxide; in case, clean them and apply anti-oxide grease.

13.3.3 WATER DRAINAGE FROM THE FUEL FILTER

DANGER:

Fuel is flammable; do not approach with free flames and smoke during drainage. If diesel fuel is spilled, immediately clean the area. This is an operation that drains condensed water from the fuel filter, and it has to be done with a full tank to avoid air into the fuel feeding circuit. The drainage has to be performed at the end of the working day, before the total diesel engine cooling, to avoid freezing in case of low temperature. The diesel fuel filters (1) is on under the upper right panel, which has to be taken off. The condense is drained by unscrewing the taps (2) as long as clean diesel does not come out. After the drainage, reinstall the upper panel.

13.3.4 TIRES PRESSURE CHECK

ATTENTION:

Inflate the tires only after having installed a protective cage. During inflation position yourself aside the outer belt. Do not over-inflate tires. Tires pressure has to be the one indicated in the specifications. During tires pressure check, verify also their thread and side conditions. ATTENTION:

The pressure has to be checked when tires are cold. Normal tires inflation indicated in "CHARACTERISTICS" is referred to 18 C temperature. When traveling on road, keep into account the correct inflating pressure according to the area temperature.

INFLATING PRESSURE TIRES CHART AT 18C TEMPERATURE Outside temp. -20C 9,3 Tires pressure 10,6 11,8 -10C 8,9 10,2 11,4 0C 8,6 9,9 11,1 10C 8,3 9,5 10,8 18C 8 9 10 30C 8,4 9,5 10,6 40C 8,7 9,9 11

13.4 MAINTENANCE AFTER THE FIRST 100 WORKING HOURS

This maintenance has to be carried out after the first 100 working hours, and it has to be added to the maintenance of EVERY 50 WORKING HOURS and EVERY 100 WORKING HOURS.

Pumps coupler oil change. Axles (differentials) oil change. Axles (hubs) oil change. Negative brake adjustment. Wheels nuts tightening check.

For details of the maintenance schedule, see the section EVERY 2400 WORKING HOURS and axles use and maintenance manual.

13.5 MAINTENANCE AFTER EVERY 100 WORKING HOURS

Do also at the same time the maintenance for EVERY 50 WORKING HOURS.

13.5.1 SLEW-RING LUBRICATION

IMPORTANT:

Clean the slew-ring teeth before applying new grease. Clean the grease holes before using the grease gun. Clean the excessive grease off the greasing points. Whenever the machine is used in severe working conditions, perform this operation more frequently. Slew-ring lubrication consists of two operations: A. Internal lubrication to do with the greasing gun (1). B. External lubrication to do with the brush, after having cleaned the old one. NOTE: To clean the old grease, use kerosene, diesel fuel or any other solvent which does not damage the machine paint. For the correct lubrication, use the indicated grease.

13.5.2 LUBRICATION OF REAR AND FRONT AXLE JOINTS

Joints lubrication points are indicated in the picture, and they are positioned on the machine in a symmetric way. Lubrication is done after having cleaned the greasing holes, applying the greasing gun with the indicated grease. When the lubrication is finished, clean the excessive grease off the greasing points.

13.5.3 LUBRICATION OF TRANSMISSION SHAFTS AND HYDRAULIC MOTORS SUPPORTS

Lubrication is done after having cleaned the greasing holes, applying the greasing gun with the indicated grease. When the lubrication is finished, clean the excessive grease off the greasing points.

13.5.4 AIR FILTER CLEANING

DANGER:

Take off the filter only when the diesel engine is off, and do not turn the diesel engine on with
the air filter not completely assembled.

During the cleaning, wear safety glasses.

NOTE: in case the machine works in a dusty environment, this operation has to be done more frequently. To clean the cartridge is necessary: 1. Unscrew the bolt on the outside and remove the cover (1). 2. Unscrew the bolt (2).

3. Take off the filter cartridge (3). 4. Clean the element with compressed air keeping the flow 15 cm away from the filter, with a maximum pressure of 4 bar. 5. Clean the filter box accurately, making sure no foreign matter is into the intake pipe, reassemble the group.

13.6 MAINTENANCE AT THE FIRST 200 WORKING HOURS

This maintenance has to be carried out after the first 200 working hours, and it has to be added to the maintenance of EVERY 200 WORKING HOURS.

Check and adjustment of diesel engine valves timing (see diesel engine manufacturer). Slew-ring reducer oil change. Slew-ring reducer brake oil change. Main winch reducer brake oil change.

For details of the maintenance schedule, see the section EVERY 400 WORKING HOURS AND EVERY 2400 WORKING HOURS.

13.7 MAINTENANCE EVERY 200 WORKING HOURS

Do also at the same time the maintenance for EVERY 50 WORKING HOURS and EVERY 100 WORKING HOURS.

13.7.1 DIESEL ENGINE OIL AND OIL FILTER CHANGE

To perform this operation, see the diesel engine use and maintenance manual, supplied with the technical documentation.

13.7.2 TIGHTENING OF WHEELS NUTS

This check is to put back in operation the wheels tightening torque on the hubs. This torque is controlled by a torque wrench set with the values indicated. IMPORTANT:

Do not exceed the tightening torque, and always maintain it within the tolerances indicated. Whenever the tightening torque is checked, do not lubricate the thread.

When the wheels are taken off for any maintenance, to put them back on follow this procedure: 1. Tight the nuts slightly until the rim touches the axle hub. 2. Set the torque wrench equal to half the value of the total tightening torque; tight the nuts in a crossed way. 3. Set the torque wrench to the prescribed torque value and tight the nuts completely following the same procedure explained above.

13.7.3 OIL LEVEL CHECK IN THE DIFFERENTIALS AND HUBS

For this operation, consult the axles manual supplied with the technical documentation.

13.7.4 OIL LEVEL CHECK IN THE SLEWING REDUCER

Follow the norms of the manual given with the documents of the machine.

13.7.5 OIL LEVEL CHECK IN THE PUMPS COUPLER

Follow the norms of the manual given with the documents of the machine.

13.7.6 OIL LEVEL CHECK IN THE WINCH REDUCER

DANGER:

Keep a safe distance from the moving winch. Never put hands or arms between the rope and the winch drum.

To carry on the check, the boom sections have to be telescoped out and the rope unwound until it shows the first half of the drum where there is a tap used to fill, check and drain the oil. To check the oil level, the tap has to be positioned vertically. Take off the tap and check that the oil reaches the lower side of the hole. If it is necessary to add some oil, rotate the drum by 90 until the hole is on the upper position to be used as a filling hole. Use oil according to the lubricants chart.

Follow the norms of the manual given with the documents of the machine. You can see in the pictures the oil filling hole of the reducer, and of its brake.

13.8 MAINTENANCE AFTER EVERY 400 WORKING HOURS

Do also at the same time the maintenance for EVERY 50 WORKING HOURS, EVERY 100 WORKING HOURS and EVERY 200 WORKING HOURS.

13.8.1 DIESEL ENGINE FUEL FILTER CHANGE

DANGER:

Change the filter element when the diesel engine cooled down at 45-50C after finishing work. If diesel fuel is spilled, immediately clean the area to avoid fire and slipping. Follow the norms of the diesel engine manual given with the documents of the machine.

13.8.2 ALTERNATOR BELT TENSION CHECK

This is a manual check and it consists of pressing with a thumb the belt (1) with a force of about 4,5 kg. (44 N); there should be a belt flexion of 7-10 mm. In case this flexion is higher, unscrew the bolts which support the alternator, and with a lever between the alternator body and the diesel engine block move the alternator. Tight the bolts and check again.

Follow the norms of the diesel engine manual given with the documents of the machine. The diesel engine is located in the right compartment; the diesel engine is installed in the opposite sense compared to the traveling direction, therefore the alternator belt will be on the rear side of the engine. IMPORTANT: In case the belt is worn, replace it, and after few working hours check its tension again.

13.8.3 AIR FILTER REPLACEMENT

DANGER:

Take off the filter only when the diesel engine is off, and do not turn the diesel engine on with
the air filter not completely assembled. For this replacement follow the instructions described in the paragraph relative to EVERY 100 WORKING HOURS.

13.8.4 TIGHTENING OF THE TRANSMISSION SHAFTS BOLTS

This check is to put back in operation the bolts tightening torque on the shafts. This torque is controlled by a torque wrench set with the values indicated in paragraph <<14.2 SPECIFIC TIGHTENING TORQUE>>.

13.8.5 TIGHTENING OF THE SLEWING RING BOLTS

This check is to put back in operation the wheels tightening torque on the hubs. This torque is controlled by a torque wrench set with the values indicated in paragraph <<14.2 SPECIFIC TIGHTENING TORQUE>>. ATTENTION:

Do not exceed the tightening torque, and always maintain it within the tolerances indicated. Whenever the tightening torque is checked, do not lubricate the thread.

13.8.6 LUBRICATION OF THE DERRICKING CYLINDER AND BOOM CONNECTION POINTS AND WINCH
IMPORTANT:

Clean the grease holes before using the grease gun. Clean the excessive grease off the greasing points. Whenever the machine is use in severe working conditions, perform this operation more
frequently. Lubrication is done after having cleaned the greasing holes, applying the greasing gun with the indicated grease. When the lubrication is finished, clean the excessive grease off the greasing points.

NOTE: A part from the winch axis, which has only one lubricating point, the other components have two symmetric lubricating points.

13.8.7 TELESCOPIC BOOM LUBRICATION

IMPORTANT: Before lubricating the boom, clean the old grease off the boom sections. Boom sections lubrication has to be done with machine positioned, boom completely lowered and telescoped out, diesel engine off. Lubrication consists of applying by brush prescribed grease on the areas where all the sliding pads work. After lubrication, telescope in and out the boom sections, and clean the excessive grease off the boom to avoid dust collection; this foreign matter may come in contact with the sliding pads causing abnormal components wear.

13.8.8 CHANGE OF INTAKE FILTERS IN THE HYDROSTATIC TRANSMISSION

DANGER:

The hydraulic oil is very hot right after stopping the machine, and may cause burns; leave it cool
down at 45- 50C before replacing the filters.

The oil spilled during the filters replacement may cause slipping; wear anti-skid boots and
immediately clean the oil off the surface.

Do not turn the diesel engine on when the spherical valve (2) is closed.

For the replacement, follow these instructions: Take off the safety plastic (1) and close the spherical valve (2). With an apposite wrench, take off the old filters (3) and throw them away. Clean the seals surfaces on the filters support. Lubricate the seals, insert them in their place and screw the filters in until they touch the seals.

Screw the filters (3) of half-a-turn by hand. Open the spherical valve (2) and lock its position with a new safety plastic (1). Turn the diesel engine on at idle to let the oil flow circulate for some minutes in the system before using the machine. Stop the diesel engine and check the filter tightness.

13.8.9 CLEANING OF THE RADIATOR AND HYDRAULIC SYSTEM OIL COOLERS

DANGER: If compressed air, steam or hot water are sprayed on a person, they may cause injuries. Always wear safety glasses, shoes and gloves. This cleaning has to be performed only when the diesel engine and hydraulic system are cold. 1. Clean by hand the radiator and the oil coolers from paper, plastic or any other big debris. 2. Using compressed air or hot water (2 bar max) at a distance of 15 - 20 cm from the radiator, clean all the surfaces accurately. ATTENTION:

The cleaning has to be done on a solid even ground.

Air, water of steam flow has to be directed perpendicularly to the radiators not to bend or
damage its cooling fins.

Do not use detergents containing oily components also in minimal percentage, since they favor
dust to stick to the fins jeopardizing thermal exchange.

Clean the radiators every time that for accidental reasons they become dirty with oil, diesel fuel
or greasy matter.

13.8.10
DANGER:

TELESCOPIC ROPES WEAR CHECK

Operate on the boom only when the diesel engine is off. To replace the ropes, pulleys and cables contact the Manufacturer or its Authorized Service
Centers. Telescopic ropes wear has to be carefully checked, and this control is used to determine if there are broken threads, abnormal ropes and pulleys wear, and return cables wear. Even the smallest defect has to cause the immediate ropes, pulleys or cables replacement. ATTENTION: In order to determine what defects may cause ropes replacement, see 15.12.e ROPES AND PULLEYS CHECK AND MAINTENANCE.

13.9 MAINTENANCE EVERY 800 WORKING HOURS

Do also at the same time the maintenance for EVERY 50 WORKING HOURS, EVERY 100 WORKING HOURS, EVERY 200 WORKING HOURS and EVERY 400 WORKING HOURS.

13.9.1 FUEL TANK DRAINAGE AND INTAKE FILTER CLEANING

DANGER:

Whenever draining the tank, avoid diesel fuel spill because it may cause fire. If there is diesel fuel spill, clean the area immediately to avoid fire and slipping.

This operation is to discharge impurities and condense from the tank; do the following: 1. Unscrew the draining tap (1) from the tank (2) and let the fuel, condense and possible impurities down-flow. 2. Screw in the tap (1). 1. Disconnect the fuel intake and return hoses and mark them in order not to misplace them when connecting them again.

4. Remove the flange (4) and pull out the pipes group (5). 5. Wash accurately the intake filter (6). 6. Install the group, connect the hoses and refill the tank. NOTE: If the diesel engine starts regularly and then it stops or works in an irregular way, bleed the air from feeding system.

13.10 MAINTENANCE EVERY 1600 WORKING HOURS

Do also at the same time the maintenance for EVERY 50 WORKING HOURS, EVERY 100 WORKING HOURS, EVERY 200 WORKING HOURS, EVERY 400 WORKING HOURS and EVERY 800 WORKING HOURS.

13.10.1

AXLES OIL CHANGE (DIFFERENTIALS

AXLES OIL CHANGE (HUBS) NEGATIVE BRAKE ADJUSTMENT IN THE AXLES

To see details concerning this maintenance procedure, take a look at the axles manual supplied with the technical documentation.

13.10.2

VALVE TIMING CHECKING AND ADJUSTMENT

For this operation consult your dealer or the engine manufacturer.

13.10.3
ATTENTION:

OIL FILTERS CHANGE IN THE HYDRAULIC SYSTEM

The hydraulic oil is very hot right after stopping the machine, and may cause burns; leave it cool
down at 45- 50C before replacing the filters.

The oil spilled during the filters replacement has to be cleaned immediately to avoid slipping and
dust sticking. 1 - With the boom fully retracted, set the machine on the outriggers and rotate the turret of 45. 2 - Stop the diesel engine and unload the residual pressures 3 - Take suitable containers capable of about 450 liter and unscrew one of the 2 discharge taps (1). 4 - When all the oil is drained, take off the flange cover of the return filters. 5 - Clean accurately the inside of the hydraulic tank from the mud deposited. 6 - Re-install the flange cover of the return filters checking the oring conditions; tighten the screws crossways. 7 - Using one of the 2 return filters, for the 800 working hours maintenance program, fill up the tank up to the sight level. 8 - Re-install the filters. 9 - Turn on the engine at low rpm, lift the outriggers, moving several times every cylinder, to bleed the air out. 10 - Stop the diesel engine and if necessary, refill the tank.

ATTENTION:
It is strictly prohibited to turn the diesel engine on when the tank is empty; in this case all the pumps will be surely damaged.

13.11 OCCASIONAL MAINTENANCE

The maintenance described below have to be carried on when they are necessary, since they
depend on how the machine is used, the climatic conditions, the environment where the machine works and so on.

More than real maintenance, the majority of the operations described are important checks that,
if not done, may create hazardous situations.

Do not hesitate to contact your Dealer in case those checks create doubts concerning some
components reliability.

13.11.1

CHECK DRUMS BRAKES WEAR IN THE AXLES

For this control, consult the axles maintenance manual supplied with the technical documentation.

13.11.2
DANGER:

RIMS CONDITIONS CHECK

Rims welding is strictly forbidden. Immediately replace rims presenting damages or cracks. It is forbidden to repair nuts and tightening bolts thread; they must be replaced with new ones. Rims check is usually done when tires are demounted for repair or when they are replaced with new ones. inspection on the rim circumference, the disk and central connection flange.

This maintenance, after tires demounting, includes an accurate cleaning which allow an Rims have not to present deformations, corrosions, wear, cracks or breakage which may
compromise their reliability. Check also that the surfaces in contact with the tire and hub do not have oxide. If necessary, remove the oxide and paint the rim.

13.11.3

TIRES CHECK

Check periodically tires wear to detect alignment problems, excessive steering joints tolerances
or brakes not perfectly efficient.

The main wear indications are:

A. Front tires quick wear (defective alignment). B. Irregular wear (faulty bearings, excessive joints tolerances). C. Localized or variable wear from one point to another of the thread (defective brakes).

If the tires are uniformly worn, there is no need for tires rotation. If tires rotation is done, check that the tires with the thread less worn are mounted on the front
axle. ATTENTION: do not mount different tire brand names or types on the same axle.

13.11.4

ROPES AND PULLEYS CHECK AND MAINTENANCE

Ropes checks and maintenance are a summary of what is prescribed by the norm UNI-ISO 4309, which contains all the defect cases that regulate rope replacement. ROPES MAINTENANCE

Ropes maintenance is limited to their periodical cleaning and lubrication. Their time interval have to be determined by the mobile crane operator, who, during his daily
checks, has to visually control their lubrication and general conditions.

This lubrication has to be preceded by brush cleaning or with the opposite air compressed tool;
to soften and remove easily the old lubricant together with dust, use some old clothes with kerosene.

Before applying the new lubricant, the rope has to be perfectly dry. The lubricant used has to be of specific type for metal ropes and suitable with the original one
utilized by the rope manufacturer. In case of doubts, consult your dealer.

Avoid using used oil or lubricants and utilize only quality lubricants with high penetration factor
with adhesive characteristics, that resist to temperature variations and are chemically neutral.

The lubricant can be applied with brush, spray or with immersion.

To facilitate the lubricant penetration, the rope has to run on a pulley, applying the lubricant where the rope bends. WHEN THE ROPE MUST BE CHANGED

Any rope has to be changed when during the daily check or a wrong maneuver the following
conditions are found:

Threads breakage in or near the connecting points. Breakage of more threads in part length equal to 6 times the rope diameter, or breakage
concentrated on one single wobble.

Small reduction on the rope diameter due to the metal deterioration (nominal diameter reduced
by 1,2 mm).

Rope elasticity decrease. External or internal wear due to lack of lubrication. Internal and external corrosion due to atmospheric conditions (salty, or industrial chemical
environments); these conditions reduce the rope resistance and accelerate its breakage for threads fatigue.

Rope deformation. Rope burns caused by contact with hot surfaces or welding parts.
NOTE: for the illustrations showing rope defects, take a look at UNI-ISO 4309 norm.

HOW TO MEASURE ROPE DIAMETER Rope diameter check is done with a caliper and its measure has to be checked on two opposite wobblers.

HOW TO UNWIND A ROPE Rope life can be compromised and a new rope damaged by an incorrect unwind. The rope reel has to be unwound as it is shown in the above drawing, paying attention to stop the reel every time the rope unwinds too much, in order to avoid rope damage.

PULLEYS CHECK

Before installing a new rope, it is necessary to check boom and hook-block pulleys; particularly, check the rim into which the rope runs that it is not worn, damaged or cut by the old rope. Also check the bearings and flanges conditions; if they are cracked, replace them.

END OF THE ROPE FASTENING Rope fastening to the boom is done with a wedge socket. The lifting rope has to be on the same line of the socket eye; if it is fastened in the opposite way, there will be a bending at the beginning of the socket, which will solicit the rope in an abnormal way. The remaining part of rope has to be clamped at the lifting rope for safety reasons. This clamping is done with two rope clamps applied with the curve on the part of rope not lifting at a distance between them of 6-8 times the rope diameter (approximately 100 mm).

13.11.5

PROCEDURES FOR AIR BUBBLE LEVELING

The air bubble level (10) to position the machine is calibrated at the factory. It is an annual procedure providing to check its setting; this check has to be done also every time that for accidental reasons, the level is unset or damaged.

The procedure for calibration is the following: 1. Level the machine with an air bubble on the carrier both in longitudinal and transversal direction; 2. center the air bubble by adjusting the small bolts. ATTENTION:

The calibration has to be accurate, with the air bubble perfectly centered into the level circle.
At the end of the calibration, tight the adjusting bolts with the counter nuts.

P.C PRODUZIONI S.R.L Via D.Marchesi 42022 Boretto (RE) Italy Tel. +39 0522/965590 Fax +39 0522/965444 EMail: info@pcproduzioni.com Web: www.pcproduzioni.com