Terex A350

ta BENDINI
Operation and maintenance manual
year of construction: 2006
OPERATION AND MAINTENANCE MANUAL
Manufacturer: After-sales service:

TEREX ITALIA S.r.l. TEREX ITALIA S.r.l.
Via Cassoletta, 76 - 40056 Crespellano Via Cassoletta, 76 - 40056 Crespellano
BOLOGNA - ITALY BOLOGNA - ITALY
Fax (+39) 051734645 Fax (+39) 0516501055
Tel. (+39) 0516501011 Tel. (+39) 0516501059
e-mail: terexitalia@terex.it e-mail: assistance@terex.it
Code: 40450 (eng) - rev.03 A

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B Code: 40450 (eng) - rev.03

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Index
I. Characteristics........ Edition: 06-2005
II. Instructions.............. Edition: 06-2005
III. Safety and operation Edition: 01-2006
IV. Control Edition: 06-2004
instruments . Edition: 06-2005
V. Accessories............. Edition: 04-2005
VI. Maintenance............
VII. Wiring diagrams
Hydraulic diagrams
Pneumatic diagrams
VIII. 3B6 Moment limiter
PAT Moment
limiter Motor
Lifting winches
Axles
Code: 40450 (eng) - rev.03 C

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D Code: 40450 (eng) - rev.03

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Characteristics Operation and maintenance manual
I
Characteristics
Chapter I - ed. 06-2005 page 1/6

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Operation and maintenance manual Characteristics
page 2/6 Chapter I - ed. 06-2005

Crane performance data
Capacity at 3 m from slewing axis (CE)
Boom length (retracted/extended) S BENDINI 30 t
8.8 / 27.6 m
Boom head heightCharacteristics 30.2 m manual
Operation and maintenance
Truck performance data(1)

Max. travelling speed (on 14.00R24 tyres) 36 km/h
Max. travelling speed (on 16.00R25 tyres) 38 km/h
Max. theoretical ramp during operation (on 14.00R24 tyres) 111 %
Max. theoretical ramp during operation (on 16.00R25 tyres) 94 %
Weights*2*
1st axle 2nd axle Total
12.75 t 12.75 t 25.5 t
Truck
Traction/Steering 4x4x4
Frame With twin body side member.
Front tow point (back tow point on request)
Outriggers (1)Standard crane in operating conditions: no auxiliary winch and no extensions
no. 4 independent hydraulic outriggers onto hydraulic beams. Outrigger beams can be fully retracted,
partially or fully extended. Outrigger controls in the operating cab
Engine IVECO F4GE0684G:
no. 6 in-line cylinders - displacement 6.8 cu dm - water cooling with intercooler - turbo supercharger. Max.
power 107 kW at 2300 rpm - Max. torque 610 Nm at 1400 rpm.
97/68/CE Step 2 approved
Tank 240
(2)Standard crane: no l winch and no extensions, on 14.00R24 tyres
auxiliary
Transmission
DANA series 20000:
Powershift-type transmission with torque converter.
3 + 3 forward speeds and 3 + 3 reverse speed: slow and fast speed mode. Automatic engagement of
4WD after selecting slow speed mode
Brakes Operating brakes: double-circuit hydro-pneumatic drum brakes on all wheels.
Parking / Emergency brake: negative action onto front transmission shaft. Pneumatic spring brake.
Axles
no. 2 driving / steering axles equipped with planetary gearboxes into hubs. On request: differential locks
Suspension Stiff suspension for front axle, swinging suspension for rear axle.
Rear suspension is automatically locked by hydraulic jacks if lifting boom is not aligned with centreline
within front crane area
Steering Hydrostatic steering controlled by steering wheel into the operating cab. Steering of front axle alone or
both axles in concentric or crab mode.
Tyres no. 4 14.00R24 tyres
On request, no. 4 16.00R25 tubeless tyres

Upper structure
Boom ta BENDINI
no. 4 rectangular elements
Lifting no. maintenance
Operation and 1 double action manual
hydraulic jack. Boom inclination: -2° to +78° Characteristics
Extension
Continuous proportional extension of elements 2 and 3 through double action-double extension hydraulic
jack. Continuous proportional extensions of element through inner chain-driven system. Extension under
partial load possible
Winch
Controlled by fixed displacement hydraulic motor equipped with axial pistons and planetary gearbox.
Automatic negative brake for winch lowering. Cable tensioner. Two different rotation speeds.
Rope diameter 15 mm length 175 m. Max. lifting capacity 3800 daN
On request, auxiliary winch featuring same specifications as main winch. Rope diameter 15 mm length
150 m
Slewing
360° non-stop rotation controlled by hydraulic motor equipped with planetary gearbox on slewing ring
having double ball ring and inner toothing. Automatic negative brake.
Brake release for direct alignment of boom along load vertical line
Operating cab Sliding door. Wide visibility. Equipped with heating system.
Front and upper window with windscreen wiper.
Upper and back windows can be opened.
Fully adjustable seat onto shockproof suspensions. Equipped with tiltable arm rests with integrated hand
controls for crane operation.
Safety Stop valves onto extension / lifting boom jacks and outriggers.
Max. pressure valves for each hydraulic circuit.
Balancing braking valve for the slewing unit.
Balancing braking valve for the winch.
Limit switch onto boom head for hook block lift.
Limit switch for having three winding turns around the winch.
Load limiting device with indicator for:
Boom inclination Boom length Load weight
Max. load which can be lifted
Systems
Hydraulic system Feeding: no. 1 double gear pump and no. 1 double vane pump.
Movement control: distributors controlled by hydraulic hand controls. More proportional operations can be
carried out at the same time.
Outrigger control: solenoid valves controlled by separate buttons.
Filtering: no. 1 cartridge filter in return circuit.
Heat exchanger for oil cooling-down
Electric system 24 V, 70 A generator and no. 2 132 Ah batteries.
Lighting devices in compliance with current EU directives
Pneumatic system
165 cu cm compressor, no. 2 45 l reservoirs and drier. Auxiliary air intake and tyre inflating kit

Dimensions*4*
Tyres A E C B S D a BENDINI
l—в
Characteristics
14.00R24 3380 3180 150 320 370 21°
CM CM
O
o
16.00R25 3420 3220 190 360 410 Operation
21°and maintenance manual
o
o
6340
4 ruote sterzanti (quote tra parentesi)
4 wheel steering ( numbers in brackets)
8460
12500 [9900]
(4) Average reference values, which are indicative only. Values are expressed in mm

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Operation and maintenance manual Characteristics

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Instructions Operation and maintenance manual
Instructions
Chapter II - ed. 06-2005 page 1/8

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Operation and maintenance manual Instructions
page 2/8 Chapter II - ed. 06-2005

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This machine complies with Directives 98/37/CE, 89/336/CE,

2000/14/CE.
The weighted average quadratic value, in frequency, of acceleration that
the operator’s upper limbs are exposed to is below 2.5 m/s2.
The weighted average quadratic value, in frequency, of acceleration that
the operator’s body (feet or seated part) is exposed to is below 0.5
m/s2.
This crane is designed as a lifting device with hook in materials
according to class S0 - HC1 in conformity with EN 13000 standards, for
moving mainly in worksites, on hard ground and gradients up to 18%.
For greater distances (over 10 km) the crane must be carried on a trailer
or flatbed truck.
Driving on public roads is permitted in compliance with current laws and
regulations.
This crane is designed for use in countries with average temperate
climate (from -10°C to +35°C).
The crane must not be used for underground work and in the presence
of magnetic fields.
USE IN EXPLOSIVE ENVIRONMENTS IS STRICTLY FORBIDDEN.

This crane is designed to operate in winds of up to 50 kph. Use of the
crane in dusty conditions is subject to taking all the necessary
precautions for safeguarding the operator, and suitable increase in the
frequency of maintenance and lubrication intervals.
Max. sound pressure LpA, measured inside the cab at the height of the
operator’s ears, with door closed, crane stopped and with the engine at
3/4 max. rpm is 78 dB (A).
Installation of accessories
Whenever, after the FIRST start-up and subject to the permission
of TEREX, supplementary lifting equipment (extensions or winches)
is installed on the mobile crane, the user must:
1. have the necessary adjustments and calibrations carried out.
2. have correct operation of the accessories and relative safety
devices checked.
3. have the necessary load and overload tests performed.
The operations referred to in points “2” - “3” must be performed by the
competent authorities or by a body notified for that purpose.

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The crane model and manufacturer’s reference number are located near
the front axle on the outside of the main frame beam on the right, above
the tool-box.
The crane data plate is located on the outside of the operator’s cab.
V Macchina Modello
1 I
Machine Model ■
Matricola
Serial No. Anno costruzione
Manufacturing
year
Potenza
Power
Massa totale
Total weight
Kg
Portata massima
Max lifting
capacity
TEREX ITALIA S.r.l.

Via Cassoletta, 76
40056 Crespellano - BO • Italy
The plate giving details of DGM type-approval for road use (where
applicable) is located inside the cab. It gives the type-approval data and
vehicle weight in running order for road travel.
AMM.
ШЯИ
•I i]

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The owner of the machine or the person hiring it must ensure that the
operator has:
■ received all the necessary instructions for correct and safe machine
operation;
■ fully understood and memorized all the instructions in this manual.
IMPORTANT
For safe crane operation, use the load capacity tables given in this
manual or located in the operator’s cab.
ATTENTION
Before starting the engine:
Become familiar with the safety messages in this manual.
Read all safety signs on the machine and make sure no one is standing
near the machine.
Practice using the controls before operating the machine.
It is the user’s responsibility to ensure that the manufacturer’s
instructions on machine operation, and compliance with the applicable
laws and regulations.
N.B.: If the manuals and load tables are damaged or lost, request copies from your
dealer or directly from the manufacturer.

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WARNING
BUNGEE JUMPING FROM CRANES IS

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

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

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

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

• shovels, grabs, magnets or similar equipment
• Vibrating equipment.
• Demolition equipment.
It is also strictly prohibited to use the crane when visibility is poor. The
operator must be in optimal physical condition, be able to read and
understand the manual and the crane load tables, and have specific
knowledge of the crane and basic training on the operation of self-
propelled industrial equipment.
Holding of a driving license is compulsory in compliance with the current
laws and regulations.
The warranty will be invalidated in case of negligence, lack of maintenance, improper use of
the material by the purchaser or his personnel, non-compliance with the technical
instructions relevant to the warranty.

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

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

operations are outlined in the section on “Safety”. Warnings against
some hazards that can cause serious accidents are also affixed to the
machine.
TEREX Italia is not in a position to know how maintenance operations

are performed, or all the risks relevant to particular methods, and
therefore is unable to advise maintenance personnel. Therefore, anyone
using an unsuitable method or a tool not recommended in the Manual
must previously make sure there are no risks for the operator or others,
that the machine will not be damaged and safety is not compromised.
IMPORTANT
In the event of an accident, no claims against TEREX Italia will be
accepted unless a person authorized by TEREX Italia has written a
report on the actual circumstances, before the machine is
removed from the scene.

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Safety and operation Operation and maintenance manual
Safety
and
Machine operation
Chapter III - ed. 01-2006 page 1/64

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Operation and maintenance manual Safety and operation
page 2/64 Chapter III - ed. 01-2006

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Advice on safety when using mobile cranes.
INTRODUCTION
TEREX cranes are carefully designed, tested and manufactured.
When used correctly by qualified operators, they ensure safe and
reliable performance. TEREX has branches worldwide and is available
for any information regarding the products and their safe use.
The following crane is designed for handling loads in compliance with

the capacity table and the instructions contained in this manual. The
machine must be used in conformity with current laws and regulations
in the country concerned.
Never lift persons with the crane if it is not equipped with a special
platform for carrying persons, authorized and supplied by the
manufacturer.
Do not use the mobile crane for demolitions or for pushing or dragging
objects with the boom.
Whenever the hook has to be used for operations other than handling
material, the manufacturer’s prior permission is required.
Normal working conditions provide for an average operating period of
8 hours a day, 5 days a week in normal environmental conditions at
not more than 1000 metres a.s.l. For more intensive use or in more
difficult environmental conditions (high temperatures, dusty or damp
places, etc.) the crane must be used with more precautions, checking
it more frequently and increasing the frequency of lubrication and
maintenance.
Having the capacity to lift heavy loads to considerable heights, the

cranes are potentially dangerous if the safety regulations are not
respected. These pages will help the operator avoid accidents that
could cause damage or injury.
The general advice on machine operation as well as these instructions

must be followed.

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OPERATOR’S RESPONSIBILITIES
Safety must be the operator’s main concern.
He must refuse to operate if he deems it dangerous and must contact

the person in charge whenever safety is uncertain.
He must read and understand the Operator’s Manual, the load tables
and make sure that everything is in order on the machine before
operating.
He must be alert, in optimal physical condition and not be under the

influence of alcohol, drugs or medicines that affect the sight, hearing or
reflexes.
He must keep persons, equipment and materials away from the work
zone. The zone around the machine must also be adequately marked.
Whenever the operator’s visibility is blocked or he is operating in

hazardous areas, e.g. near power lines or around persons, he must use
the help of a signaler.
As the operator is not in the best position for judging distances and is
unable to see all the worksite, a signaler may have to be used also in
other situations. Operators must understand the standard signals for
cranes and only follow the signals of the appointed signalers.
SIGNALLER’S RESPONSIBILITY
The signaler’s main task is to help the operator work in the most efficient
way in safe conditions. Operators depend on the appointed signalers in
order to move without causing damage or injuring persons.
Signalers must have clearly understood the work to be performed in

order to safely coordinate every task of the operators and personnel.
Signalers must stand in a place where they can be clearly seen and
from where they can safely observe the entire operation.
The standard signals for cranes must be used unless other signaling
methods, such as two-way radios or flags, are agreed on.
Signalers must have good eyesight and good judgement, and must
know the standard signals for cranes and be able to give signals clearly.
They must have sufficient experience for recognizing risks and signaling
the operator how to avoid them.
The signaler is the only person authorized to give instructions to the

operator.

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MANUAL SIGNALS EMERGENCY STOP

ARRET D’URGENCE
GESTES DE COMMANDEMENT ARRESTO Dl EMERGENZA
SEGNALAZIONI MANUALI NOT AUSSCHALTEN
STOP STOPPEN IN GEVAL VAN NOOD
ARRET HAND SIGNALE PARADA DE EMERGENCIA
ARRESTO HANDSEINEN
AUSSCHALTEN
STOPPEN SENALIZACIONES MANUALES
PARADA
DOWN BOOM UP BOOM DOWN

DESCENDRE LEVER LA FLECHE DESCENDRE LA FLECHE
ABBASSARE SOLLEVARE IL BRACCIO ABBASSARE IL BRACCIO
SENKEN AUSLEGER HEBEN AUSLEGER SENKEN
LATEN ZAKKEN DE GIEK OMHOOG DOEN DE GIEK OMLAAG DOEN
BAJAR ELEVAR LA PLUMA BAJAR LA PLUMA
BOOM UP AND LOAD DOWN

IV
MOVE SLOWLY PULL OUT BOOM PULL IN BOOM
DEPLACER LENTEMENT LEVER FLECHE ET DESCENDRE LA
CHARGE
TELESCOPER FLECHE RENTRER LA FLECHE
MUOVERE LENTAMENTE SFILARE IL BRACCIO RIENTRARE IL BRACCIO
SOLLEVARE IL BRACCIO E
LANGSAM BEWEGEN ABBASSARE IL CARICO TELESKOP AUSFAHREN TELESKOP EINFAHREN

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RESPONSIBILITIES OF ALL RELEVANT PERSONNEL
Unsafe conditions or operations must be adequately corrected or

notified to the person in charge of work.
Anyone working around the cranes must obey the danger signs and pay
attention to their own safety and that of others. Load handling personnel
must know the relevant safety procedures.
Pay attention to risks that can arise during operations and warn the
operator and signalers of hazards such as power lines, the unexpected
presence of persons, other equipment or unsure ground.
MANAGEMENT’S RESPONSIBILITIES
Management’s task is to ensure that operators have adequate training

and competence, are in optimal physical condition and, if necessary,
that they have a driving license.
Good eyesight, judgement, coordination and an alert mind are
necessary. Those lacking any of these requisites are not allowed to
operate the crane.
Crane operators must have received adequate training to be able to

determine weights and distances, for correctly choosing and using the
lifting winch. This work is a complex subject that will not be discussed in
this manual. Management must ensure that personnel receive adequate
training.
Personnel must be given specific responsibilities on safety and are

required to inform the persons in charge of any condition involving
danger for persons or things.

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PLANNING THE WORKSITE
The person appointed must clearly understand the work to be carried

out, consider all the dangers existing on the worksite, and prepare a plan
enabling execution of the work in safe conditions which must be notified
to all those concerned. Factors such as the following must be taken into
consideration:
- The personnel needed and their responsibilities.
- The weight of the load to be lifted, lifting radius, boom angle and
nominal lifting capacity of the crane.
- The way the signaler will communicate with the operator.
- The equipment necessary for performing the work in safe conditions.
- How the equipment can be taken safely to the worksite.
- Any gas or power lines or structures to be removed or avoided.

- If the ground is strong enough to take the weight of the machine and
the load.
- How the loads will be restrained.
- Special safety precautions to be taken if the crane has to travel with a

suspended load or if other cranes are necessary to lift a load.
- If unfavourable weather conditions, such as wind or intense cold, are

forecast.
- Measures to be taken for safely keeping unnecessary persons and

equipment away from the work zone.
- How the cranes can be positioned for using the shortest possible
boom and reach.

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SAFETY CHECK BY OPERATOR
Every day before starting work the operator must carry out a safety
check to ensure that everything is in order on the machine. Some of
these checks include the following:
- Check the log book on board the machine to verify that the periodical
maintenance and inspections as well as all the necessary repairs have
been carried out.
- Check operation of the boom lifting cylinder, auxiliary alarms and other
safety devices.
- Carefully inspect the load supporting parts such as wire ropes, (load
rope, lifting rope on the winch, suspension ropes), boom, outriggers and
hooks.
- Ensure that no unauthorized modifications have been made in the

field, such as added counterweights and booms repaired in an improper
way.
- Check for any hydraulic oil and air leaks.

- Before starting the engine, check the cooling water and lubrication oil
levels.
- After starting the engine, check that the readings are correct on all
gauges.
- Check correct operation of all the controls

- Check the truck brakes. Test the load brakes by lifting and supporting
a load at a few cm from the ground.

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

factors such as the following must be considered:
The load radius is the distance between the crane upper structure
rotation axis and the center of the boom head sheaves. Remember that
the radius increases if the load is lifted due to flexing of the boom.
Weight of load, block and any lifting equipment.
Length of boom, number of tackles, work area (front, rear or side) and
possible extensions or jibs.
Use the load immediately below if the capacity or work radius are not
given in the capacity table.
Attempting to lift a load not given in the capacity table, trying to guess
the capacity for boom lengths, radius or angle is extremely dangerous as
the crane could sway or tip over during lifting.
Always keep within the nominal capacity given in the table.
The operator must reduce the load in relation to the unfavorable
conditions in the worksite and appraise the possibility of lifting loads in
complete safety.
2. The cranes can tip over or sway if the work surface is unable to take
their weight. Wooden boards, steel plates or cement slabs may have to
be placed under the outrigger support plates to distribute the load under
the crane so that the supporting strength of the ground is not exceeded.
Determine the load supporting capacity of the ground or other surface on
which the machines will be operating. Make sure the ground can support
the crane. Avoid unstable, soft, sandy ground, areas with high water-
tables and partially frozen ground. If the machines work near
excavations, these must be supported or filled in order to avoid landslips
or sliding.
3. The working capacity of a crane is established with the crane leveled.

Make sure the crane is level and that all the tyres are raised above the
ground in order to obtain the correct values given in the table of load “On
outriggers”.
4. The scissor action produced by the rotation of the upper part on the
lower part can crush or injure persons.
Keep away from the crane in the rotation phase, mark the work zones
and always make sure no one is within the crane’s operating range.
5. Persons can be struck by the rear part of the counterweight of the

machine if there is insufficient free space. Before starting work, perform
a trial rotation without load to establish the exact rotation radius.

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6. Many persons have been involved in accidents caused by the hook

or the suspended load, therefore to avoid that risk, always keep outside
the machine work area.
Do not use the cranes to lift persons. Use ladders, scaffolding, lift trucks
or other specific equipment for lifting persons, but do not use the cranes.
7. Power lines can also be the cause of accidents. Such accidents can
be avoided by respecting some simple rules.
Always establish where the high-tension lines are before starting work. It
is advisable to keep more than 6 m away from high-tension lines. Inform
the company responsible for the high-tension lines before starting work.
Use a helper to maintain a safe distance between the machine and the
high-tension lines. The operator is not in the best position for judging the
distances. Warn persons to permanently keep away from the machine. If
the load has to be shifted for positioning, check the neccessary
precautions with the company that manages the power lines Operate
slowly, taking the time necessary for being able to react to a possible
problem and with 2 different means check the distance between the
high-tension lines and any part of the machine.
What to do in case of accidental contact.

What to be done is not based on regulations but depends on an analysis
of the immediate risks. This must be the subject of rules fixed for the
operator or his training.
• The equipment or the machine is able to operate: without leaving the

cab, the operator must immediately move the machine away from
the live electrical work.
• The equipment or machine is no longer working:
Without leaving the cab, the operator must warn the other persons,
by means of signals or words, not to approach the machine or the
equipment. (Voltage risk for the entire duration of the fault).
Whenever the operator has to leave the cab, he must jump down
from it so as not to be in contact with the ground and the machine at
the same time.
Once on the ground he must move away from the
machine: jumping, with both feet together. with very small
steps.
The machine can only be subsequently approached after making
sure that the power line is definitively no longer live and after
checking the actual absence of current (operation carried out in
collaboration with the electricity company).

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• The machine operates on tyres:

after contact of a machine operating on tyres with a high-tension
overhead work, the tyres (with metal carcass) that were not
destroyed do not retain their insulating property or their strength. If
not occurring immediately, the tyres often burst later, after prolonged
exposure to the sun.
The tyres must be deflated and scrapped, after the machine has
been taken off the power line.
IMPORTANT: Planning of work and a thorough control ensure better

protection than any other device. Insulated cages or proximity sensors
have limits and can have failures without signaling them. The protection
cables or insulated cages only protect the machine, therefore they can
be current conductors due to dust or water.
The proximity sensors can be disturbed by different combinations of
high-tension lines or by the movements of vehicles or material and the
crane itself or by other factors. Relying only on these systems can be
very dangerous as the operator believes he is protected, whereas this is
not so.
In case of storms, take the following precautions:
- if possible, support the load and completely retract the boom.
- if caught by a sudden storm, switch off the heat engine and leave the
machine.
- if the machine is struck by lightning, check general machine operation
before restarting it.
You must always know the weather forecasts of your area before
starting work.
8. The lifting rope can break if the load knocks against the boom head.
This can occur during boom lowering or extension without keeping the
rope under control.
When positioning the rope, make sure it passes properly in the limit stop
device safety counterweight.
Always check the space between the hook and the boom head. Lower
the hook during extension to avoid this type of accident. Regularly check
the limit stop safety system.
9. Persons can be injured by the hook, boom, load or outriggers.

Ensure that those working around the machine are safe where they are
before starting to move the hook, load or outriggers. Do not move loads
above persons, and do not allow the load to knock or bounce on any
objects.
10. Abrupt starting or rotation movements can cause the hook and its
load to sway dangerously and loss of control of the load.

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

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20. Trying to lift a load that is blocked, frozen or stuck to something else
can cause overturning or the breakage of a lifting part.
Always make sure the loads are free.
21. For correct use of the lifting winch and rope, there must be at least
three dead turns of the rope on the drum. Regularly check the safety
system.
22. Attempting to repair or adjust a machine component when the load

or hook are suspended is very dangerous because there could be a
sudden lowering of the load or any unintentional manoeuvre of the
system. Always lower the load to the ground and put the boom in the rest
position (horizontal) before performing any repairs, maintenance or
adjustments.
23. The hydraulic oil in the machine circuit can remain pressurized for
long periods,
If not adequately released before any maintenance, this pressure could
cause sudden movements of parts, sudden jets of oil or breakage of any
hydraulic lines loosened during maintenance.
Always release the pressure before any maintenance, repair or
adjustment of machine parts.
24. The lattice elements connected to the boom by means of forks can
break if not properly fixed.
Make sure the ends of all extensions, jibs or braces are securely fixed;
never stand on the boom or equipment to be installed during its
assembly.
25. As with all heavy equipment, pay particular attention to movements

carried out with the crane on the worksite or the road.
Watch out for personnel, pay attention to high-tension lines, narrow or
low passages such as bridges, roads with load restrictions, steep climbs
or descents and uneven ground. Use a helper in case of movements in
narrow spaces.
Knowing the height, width and weight of your vehicle is very important.
Completely retract the outriggers, put the boom in the horizontal position,
fix the hook and block the rotation before travelling.
26. Shifting loads with the crane moving involves a considerable

increase in risk. Manually block rotation with the pin located in the
operator’s cab, observe the precautions described in point 25, reduce the
vehicle’s speed to minimum, always keep within the capacities indicated
in the load table, keep the weight to be moved near the crane and as
close as possible to the ground, avoiding abrupt swaying; if necessary fix
the load to the crane. Inflate the tyres to the pressure given in the table
located in the operator’s cab.
The crane could overturn if these precautions are not correctly observed.

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27. The use of more than one crane for handling loads considerably
increases the risks compared with handling or lifting loads with just one
crane. This operation must only be carried out under the supervision of a
person in charge of manoeuvres. It must be studied very carefully and
several points such as the following must be taken into consideration:
- Carefully study the load to be handled in order to be sure that during
the operation the lifting capacity of each crane is adequate for the
load.
- Make sure the slings are arranged for distributing the load evenly.
- Before lifting, check the lifting plan with all the personnel concerned.
- Carefully coordinate the crane movements before every lifting phase.
- Avoid side loads or abrupt movements.
28. Leaving the machine unattended can be very dangerous. Before

leaving the operator’s seat, make sure that:
- The load is touching the ground.
- The brake and rotation are locked.
- The emergency brake is applied.
- The engine is off and the gears are in neutral.
- The ignition key is turned off.
29. The lifting ropes must be inspected every day to check if they need
replacing. See the inspection form in the manual or directly contact the
rope manufacturers for further information.
The rope must be replaced if it is twisted, crushed, or has knots,
abrasions, marked bends or any other damage that can cause
deformation of its structure.
WARNING: Do not use bare hands to guide the wire rope on drums.
30. Incorrect securing of the rope can cause give in or loss of the load.
The rope thimbles must be fitted in the wedge so that the loaded side of
the rope is in a straight line with the edge of the thimble and not bent by
the wedge. The rope must pass through the counterweight of the safety
device fixed to the head of the boom or the extension.
31. Incorrect winding of the rope on the drum can create breakages,
tearing or flexing of the rope.
Do not use bare hands to guide the wire rope on drum; always use
suitable gloves and pay particular attention to clothes which could get
caught in the winch drum during its operation.
32. The load limiter is only an aid !!!

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List of stickers
IMPORTANT: Do not remove the stickers affixed to the crane.

Worn or deteriorated stickers must be replaced.
The following are safety stickers and must be strictly respected.
NO STANDING: no standing in the machine’s operating range during

manoeuvres.
NO ENTRY: unauthorized personnel not allowed
WARNING: do not use naked flames
WARNING: moving parts

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WARNING: moving parts with danger of crushing
WARNING: danger of crushing
WARNING: flammable
WARNING: danger of falling

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12 3 4
WARNING: pressurized components (1), high temperature (2), danger of

fire (3), moving parts (4).
WARNING: pressurized hydraulic accumulator; before performing any

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

cab
USCITA D'EMERGENZA
EMERGENCY EXIT
WARNING: emergency exit

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General instructions
IMPORTANT: all operators must know the operating instructions

described in this manual before using the machine.
The operator is responsible for use of the machine. Any non-conforming

use relieves the manufacturer of all responsibility.
Do not use the machine or have it used until all the instructions given in
this manual are perfectly understood and memorized.
Non-compliance with these instructions can result in serious damage and

injury.
For any needs, do not hesitate to contact your Dealer or area Agent
formally authorized to provide technical information or useful advice.
THE OPERATOR'S MANUAL and the LOAD TABLE must always be

kept in the operator's cab. Contact the Dealer or area Agent to obtain
additional copies of the manual.

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General
• Your safety and that of persons nearby depends on correct use of

the machine.
Make sure to perfectly know the position and function of all the
controls before carrying out any operation.
BEFORE USING YOUR MACHINE, TEST ALL THE CONTROLS IN
A SAFE AND FREE ZONE, WITH OUTRIGGERS FULLY
EXTENDED.
• The terms “right and left” given in this manual indicate the sides of
the machine seen from the operator’s control station.
• Current regulations in the workplace must always be respected.

• Always keep a fire-extinguisher and a first-aid box at hand. Make
sure you know how to use them.
• Sparks can be created on the electrical circuit or the exhaust pipe

outlet. Do not work in closed spaces in the presence of flammable
materials, powders or vapours that could cause an explosion or fire.
Failure to comply with this rule can cause serious and even fatal
accidents.
• Make sure you have read and understood all the danger signs or the
precautions to be taken (placed on the machine). Strictly respect the
maintenance instructions.
• Be particularly careful if using a different machine to that normally

used.
• Do not smoke during refuelling, as the fuel vapours are flammable.

• Avoid accidents caused by loose garments or clothes that do not
guarantee the necessary protection. Wear clothes that will not get
caught on objects and if necessary wear protective equipment
(helmet, safety shoes, ear protectors, glasses or protection mask,
work gloves and reflecting clothes).
• Wear a helmet, glasses, gloves and safety shoes when the current
laws in the country or worksite where you are operating require it.
• Before starting the engine, always make sure no one is in the

immediate vicinity of the machine. Signal the start of manoeuvres by
sounding the horn.
• If needed, it is possible to exit the cabin using the top window;

suitable sticker is applied to help you identify it as emergency exit.
Push up the window to open it, the exit is 730 mm x 560 mm with
normal manual opening and 730 mm x 850 mm if you release the
USCITA support gas-filled jacks, which is a simple operation.
D'EMERGE

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Access and cleaning
• Make sure there are no traces of oil, foreign bodies or ice in the
driving position, on walkways and access grips. Secure or remove all
personal items or those necessary for maintenance.
• Check the cleanness of the windows of your machine every day and
also the operation of wipers. Dirty windows can be the cause of
accidents.
• Use both hands when climbing on board or getting off the machine,
remaining in a frontal position.
• Put rags dirty with grease and other flammable materials in a safe
place but not on the machine.
• Never jump from the machine to get off it.

• Every precaution must be taken to keep the environment intact; make
sure to collect and recycle all the fluids used.
Do not leave them in containers without suitable labels or in open
recipients.
Make sure there are no puddles of fluids on the ground where you are
operating.
For all liquids used for maintenance:
- oil
- grease
- antifreeze
- detergents
do not swallow, inhale, store or transport them in containers for food
products (water, beer bottles, etc.), always use the original package
(if possible integral).

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Machine operation
• For your safety and for optimal machine life, carry out a complete
inspection before climbing on board or starting the engine. In
particular, pay attention to loose or missing screws, the state of the
ropes, accumulated earth, oil or coolant leaks. Check the tyres, the
equipment and systems.
• A fault in a component or machine circuit can cause an accident.

Before using the machine check all the oil and coolant levels. Make
sure all the plugs, indicators and covers are properly secured.
Replace or repair faulty parts.
• In case of malfunction depending on missing or non-adjusted parts,

turn the machine off and immediately fix them. Failure to comply with
this rule can cause serious damage or injury.
• Never use a machine with obvious defects in the braking, steering,

hydraulic or electropneumatic systems. This rule also applies to a
machine that has been repaired or adjusted without the control or
approval of the foreman.
• If malfunctions occur in the mechanical, electrical, hydraulic or

pneumatic parts, switch the machine off as soon as possible.
• Unless otherwise ordered, retract and put the boom in the rest
position, turn off the engine, apply the parking brake and block the
machine with suitable wedges or stabilize it before carrying out
maintenance or leaving the machine at the end of the day’s work.
• Only enabled operators are allowed to drive the machine.

• Know the machine’s limits and keep it under control at all times. DO
NOT TRY TO DO TOO MUCH TOO QUICKLY.
• To circulate with the vehicle, it is a good rule to know its weight and
dimensions and the characteristics of the area where you are
travelling (bridges, power lines, ground strength, slopes or climbs).
• Always be alert and do not allow unauthorized persons to enter the

work zone. You must always know the exact position of work zone
personnel.
• Standing in the machine movement zone is prohibited.

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• When the engine is switched off, do not release the parking brake if
the machine is not blocked. Make sure the braking system pressure
is sufficient for releasing the brake.
• Before starting the machine, make sure the gears are in neutral and
the parking brake is applied.
• Before carrying out night operations make sure the machine light
signals and headlights work.
• Only use the machine controls and accessories from the driving
position.
• Work cautiously in the presence of dust, smoke or fog. Reduced

visibility can be the cause of accidents.
• Before loading the machine on a semi-trailer, make sure the access

ramps and the trailer are free of snow, ice, oil or grease.
• Avoid abrupt manoeuvres with the load suspended.

• Do not grasp the ropes when the winch is working.
• Check correct operation of the block limit stop device and replace it if
necessary.
• To intervene on the block, place it on flat and level ground so it will

not tip over.
• Periodically check the wear of the block grooves and those of the
boom head.
• Without load, check that the sheaves turn correctly and the hook swivels smoothly.
• Never leave the machine unattended with a suspended load.

• If the crane is parked on a slope, the truck must be blocked by
wedges, and the rotation brake locked and the boom secured.
• Do not carry out inclined lifting; the machine must always be perfectly
level.
• Before lifting a load always make sure it comes within the limits given
in the table. If an electronic limiting system is not available, this
operation is even more important.

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Maintenance
• For maximum safety during machine maintenance, it is advisable to

use only one operator. If several operators are required, they must
have a clear idea of the work to be performed in order to ensure
perfect coordination of the manoeuvres. Everyone’s safety must be
the main concern of operators.
• Do not perform any repairs on the machine that you are unable to
complete.
• Do not allow unauthorized persons to stand on the machine during

maintenance.
• It is advisable to wear face and eye protection when performing

maintenance operations. Use a hammer with soft head (e.g. plastic,
wood, brass or leather) for hammering on equipment or hardened
metal surfaces.
• Only start the engine in well-ventilated places (risk of intoxication by

exhaust gas).
• Apply the parking brake, block the wheels and place warning signs on
the control levers during maintenance operations.
• Always use suitable equipment for maintenance, and replace or repair

worn or deteriorated equipment.
• Check the cooling circuit with the engine switched off. Undo the
radiator cap gradually, to slowly release the pressure in the circuit.
Pay attention to the steam, to avoid scalding.
• Use the cleaning solutions with care.

• Wear head and ear protectors for interventions requiring the use of
compressed air. Max. air pressure: 2 bars.
• Keep a suitable distance away from moving belts and fans.

• For your safety, only use original replacement parts.
• Arc welding of parts on the machine can deteriorate mechanical,
electrical or electronic parts and compromise the machine’s safety.
Carry out welding work only after:
- fixing the earth terminal as close as possible to the zone for
welding
- disconnecting the two poles of batteries
- disconnecting all the electrical and electronic devices.
• After every maintenance operation check correct working of the

repaired parts before using the machine.

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Electrical circuit
• Before carrying out any work on the electrical part, disconnect the
battery and remove the ignition key.
• Do not make electrical connections or disconnections without

knowing the system. An incorrect connection can cause serious injury
or damage.
• Never check the battery level by connecting the poles with metal
objects. The electric arcs produced can cause an explosion. Use a
voltmeter or ammeter.
• Do not smoke or use naked flames when checking the battery fluid
levels. The batteries give off flammable vapours.
• Do not top-up the battery levels with acid; restore the level with
distilled water.
• If the electrolyte of a battery is frozen, the battery could explode if put

under charge or if you try to start the machine using another battery.
To prevent freezing of the electrolyte always keep the batteries fully
charged.
• Never wear metal rings or wrist-watches, as these objects risk

earthing the live circuit and therefore causing burns and injuries.
• When using an external power source for starting the machine,

connect the earth cable last and disconnect it first, in order to avoid
sparks that could be produced near the batteries, causing explosions.

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Hydraulic circuit
• The hydraulic system works at a very high pressure ( 300 bars ). The
oil that could come out of even small holes risks perforating human
tissues and causing serious injuries, therefore it is advisable to use a
piece of wood, and not hands, to check for leaks. If the hydraulic fluid
perforates your skin, see a doctor immediately.
• Make sure the circuit is not pressurized before disconnecting

hydraulic lines or components. Check the tightness when
reconnecting the lines or components.
• Hydraulic oil is flammable, therefore do not weld components that are

full of oil.
• The oil and components in which it circulates are hot and can cause
burns, thus avoid any contact.
• After an operation on the hydraulic system it is essential to have a

specialized technician bleed the air.

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Tyres
• The tyre inflation pressures refer to cold tyres. Inflation and checking
must be carried out when the tyres are cold. Never inflate a hot tyre.
• For your safety and that of others, every 100 hours check the
tightness of the wheel nuts using the wrench supplied with the
vehicle.
• Check the tyres on the vehicle unloaded, always using an inflation

safety cage when the wheel is not on the vehicle.
• To avoid the risk of accident during and immediately after inflation, do

not stand in front of the wheel and make sure to use a sufficiently long
tube for inflating.
• Deflate the tyres before removing any stones from the tread.
• Never intervene on a rim with tyre inflated.
Changing tyres
1. Loosen the wheel nuts a little

2. Lift the machine on the outriggers with the wheels slightly off the
ground.
3. Unscrew the nuts and remove the wheel.
4. Fit the new wheel, fixing the wheel nuts without tightening them.
5. Lower the machine and retract the outriggers, tighten the wheel nuts
(tighten in a diagonal sequence) and adjust the torque setting to 650 Nm.
6. Retighten the wheel nuts after 16 hours’ operation.
The machine is equipped for connections for inflating the tyres (on the
left side) and an inflation kit (tube, air gun, pressure gauge) located
inside the tool-box.

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

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Choosing the best configuration

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

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1. It indicates the type of stabilization (outriggers fully opened,

intermediate or fully closed) or the type of tyres fitted.
2. It indicates the length and extension of the telescopic boom.

3. It indicates the total weight of the counterweight fitted, given by
the sum of the main counterweight and the additional
counterweight or the sum of the main counterweight and the
auxiliary winch.
4. It indicates the work zone where the work is being carried out; it
can be 360° or ±3° on the front part of the machine.
5. According to the table, it indicates the moment limiter program

or the type of accessory fitted or, for the configuration on tyres, the
use in the static or dynamic phase.
6. The lengths of the boom and the recommended number of main

rope tackles are given.
7. It indicates the boom angle under no load conditions with

machine levelled.
8. It indicates the max. permissible gross load. To know the actual

load to be lifted, subtract the weight of the block and that of any
accessory fitted (lattice extension or jib) from the value given.
9. It indicates the boom working radius. The radius is the distance

between the turret slewing axis and the vertical axis through the
rotation axis of the boom head and block sheaves.

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The capacities given refer to the radius under load and therefore take
into account boom flexing. Therefore it must be considered that the
radius measured without load is less than that measured with the load on
the hook. This must be taken into account before lifting the load in order
to maintain the same radius.
10. Index of reference symbols for reading the various configurations in

the load table.
10

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Reduction of operating loads

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

b - Weight of sling
gross load
a - Weight of main block

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

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Extension secured to brackets
When the extension or jib is secured to

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

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Special instructions for lifting on tyres
The loads on tyres authorized by the capacity tables are to be deemed

valid only if the following conditions are met:
- Tyres inflated to the pressure recommended for the work to be carried
out and for the workplace.
- According to the configurations, parking brake applied.
- Rear suspension units locked.
- Load kept as close as possible to the ground.
- Flat, firm and level ground.
IMPORTANT: TO KEEP THE MACHINE STABLE DURING

MANOEUVRES WITHOUT LOAD IN THE CONFIGURATION ON TYRES,
THE LIFTING BOOM ANGLE LIMITS GIVEN IN THE LOAD TABLE MUST
BE RESPECTED.
Example given merely as a guide

Always refer to the copy in the cab
IMPORTANT: Whenever possible, carry out lifting on outriggers fully or

partially extended rather than on tyres.

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Special instructions for lifting on outriggers
The loads on outriggers authorized by the capacity tables are to be

deemed valid only if the following conditions are met:
- Wheels completely raised above the ground
- Machine stabilized horizontally, referring to the level located in the
operator’s cab.
- Firm ground under the outrigger support plates.
- If necessary provide for stabilization with wooden boards to increase
the support surface.
Lifting of an outrigger support plate off the ground

The lifting of an outrigger support plate off the ground when the load
passes over the opposite outrigger is not a sign of imminent tipping over
of the machine.
However, when this occurs and if the stabilization conditions are
normal, check that:
- The outrigger beam on the load side is correctly extended.
- The wheels are raised above the ground as indicated in the capacity
tables on outriggers.
- The load lifted does not exceed the permissible value.
- The support plate has not sunk in the ground under the weight of the
load.
- The frame is not deformed due to incorrect stabilization.

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Special instructions for lifting with mechanical element

extended
For crane truck models with mechanical locking by means of a

special pin, the capacities with telescopic sections partially or fully
retracted must be deduced from the special load tables, referring
EXCLUSIVELY to the actual inclination of the boom not considering
its length.
mechanical element extended
boom partially extended
gross load
angle of inclination

Model П П 1, 1 n n
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ill ■ ■ In 'l 11^4 £ l1
0 525 mm 0
A300 28000
510 mm
A350 27000 Max.Шforces exerted on ground

0 525 mm
(daN)
A400 27000 0 525 mm
A450 27000 0 525 mm
RC45 39000 0 525 mm
A600 45000 0 650 mm
Model
0 kph - 360 0 kph - 0 3 kph - 0
§
14.00R24
A300 17750 17750 14000 16.00R25
14.00R24
A350 17750 17750 14000 16.00R25
16.00R25
A400 18400 18400 14450 20.5R25
16.00R25
A450 18400 18400 14450 20.5R25
16.00R25
RC45 18400 18400 14450 20.5R25
A600S 25600 25600 20100 18.00R25
23.5R25
A600L 23200 23200 18200 26.5R25

Wind force
Wind speed Consequences
Scale Terms described mps kph SInland territories BENDINI
0 Safety
Calm and operation
0 - 0.2 1 Operation
Calm, smoke rises vertically and maintenance manual
Wind direction indicated by smoke and
1 Very light 0.3 - 1.5 1-5 not by the banner
The wind can be felt on the face, the
2 Light breeze 1.6 - 3.3 6 - 11 leaves rustle, the banner moves
Actions of the wind
Leaves and small branches move,
3 Gentle breeze 3.4 - 5.4 12 - 19 banners lift
The wind raises dust and leaves.
4 Mild breeze 5.5 - 7.9 20 - 28
The crane can be safelyBranches
used by following the capacity table values up to
move
a wind speed Small
of 8.5 bushes
mps sway.
(30 kphWave
- crests5)form
force on a load area of 1.2 m 2/ton.
5 Fair breeze 8 - 10.7 29 - 38 on the sea
6 Strong breeze 10.8 - 13.9 IMPORTANT:

39 - 49 Every Large
day, check
branchesthe weather and wind speed forecast for
sway
the day by calling the nearest weather station. Do not lift the load if the
7 Strong wind 14 - 17.1 50 speed
wind - 61 is higher than the
All the maximum
trees sway permissible.
The wind breaks branches, difficulty in
8 Wind gust 17.2 - 20.7 62 - 74
walking freely
Damage to houses (tiles and chimneys
9 Strong wind gust 20.8 - 24.4 75 - 88 blown away)
Trees uprooted and considerable
10 Storm 24.5 - 28.4 89 - 102
damage to houses
11 Violent storm 28.5 - 32.6 103 - 117 Considerable and extensive damage
12 Hurricane 32.7 - 36.9 118 - 133 12 m 2 damage

Very serious and extensive
Л Л
1 ton.
Wind
10 ton.

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Safety devices
Moment limiter
The limiter is designed to provide the crane operator with essential and
necessary information for operating the crane with safety. Using various
sensors, the limiter controls the various crane functions and offers the
operator a constant display of the crane’s capacity. The display changes
constantly according to the different crane movements necessary for
handling the load.
The limiter gives the crane operator information on the boom length and
angle, the nominal load lifted and the maximum liftable load in the
particular configuration. When the crane approaches non-permissible
conditions, the limiter warns the crane operator with an acoustic alarm
and an indicator light and deactivates any functions that can aggravate
the crane’s condition.
The system disables dangerous crane movements to prevent overload
conditions if:
- the load is excessive for the machine configuration.
- the radius is excessive.
- the actual loading configuration differs from the one selected for
limiter.
The limiter disables the following crane functions:
Winch lifting.
Telescopic boom rising.
Telescopic boom lowering.
Telescopic boom extension.
A special key allows the limiter to be cut-out, restoring all crane

functions.
EXCEPTING THOSE RECOMMENDED BY TEREX, ALL CRANE
OPERATIONS PERFORMED WITH THE LIMITER CUT-OUT SHALL
BE ONLY AND ENTIRELY THE RESPONSIBILITY OF THE CRANE
OPERATOR OR WORKSITE FOREMAN. TEREX IS NOT
RESPONSIBLE FOR ANY ACCIDENTS THAT COULD OCCUR
USING THE CRANE WITH THE LIMITER CUT-OUT.
The load limiter configuration must comply with the machine
configuration.
THE LIMITER IS AN INDISPENSABLE DEVICE THAT PREVENTS
DANGEROUS SITUATIONS FOR THE CRANE OPERATOR AND THE
CRANE. LIKE ALL SAFETY SYSTEMS, THE LIMITER CANNOT
COVER ALL HUMAN ERRORS.
THE CRANE OPERATOR MUST ALWAYS BE AWARE OF THE
OPERATIONS HE IS CARRYING OUT.

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Limit stop device

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

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

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Lowering limit stop device

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

- Unwind the rope so that 3 turns remain wound on the winch
- If the 3 dead turns safety is inactive, operate the adjustment screw (7 -
8) to move the cam until you hear the switch disconnect.
- Then carry out the lifting operation in descent to check that the safety
is active.
- Wind the rope additional turns and test the safety of the
movement. The “3 dead turns” safety contactors must disconnect
the winch hook descent functions.
Periodically check feeler wear and operate the device adjustment or

replace the feeler.
N.B.: In case of rope replacement, the safety must be adjusted again.
Legend:
1. Winch drum
2. Lifting rope
3. Drum feeler
4. Return spring
5. Limit switch 2

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Lifting limit stop device

Microswitch “1” is kept in operation by counterweight “3”. When the block
is raised up to contact with the counterweight, the microswitch interrupts
the electrical circuit and lifting is stopped by means of a valve located on
the servocontrol hydraulic circuit.
In this condition the block lowering movement can be activated, which
will bring the device within its normal operating limits.
IMPORTANT: Operate carefully and with moderate speed, when

activating winch lifting with block near the limit stop.
The minimum length of the limit stop device counterweight “2” chain
must be 80 cm.
Legend:
1. Limit switch
2. Counterweight chain
3. Limit stop counterweight
“Man present” safety
To guarantee the safety of the machine and operator, switches are

installed under the operator’s seat and on each hand control. They
prevent crane movements when the operator gets up from the
seat, does not grip the hand controls or does not select the
outrigger control.

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Machine operation
Introduction
This section and the safety regulations for mobile cranes given at the
beginning of the manual must be carefully read before driving the
machine.
Always respect the following precautions to ensure operation in safe

conditions:
• Always check the capacity table to know the maximum load that can
be lifted with different boom angles, lengths and other factors that can
be taken into consideration during load handling.
• Always start the machine using an engine speed suitable for the load
to be handled.
• If the load is likely to sway, always keep it as close as possible to the

machine and the ground.
• During boom extension or lowering, to prevent the block from striking

the boom head operate the winch to unwind the rope.
Preliminary checks
Every day, before using the machine, clean all the windows,
screens, lights and rear-vision mirrors to ensure good visibility for
the operator. Adjust the operator’s seat so that it is comfortable and
suitable for the machine operator.
Checks to be carried out before starting the machine:

- Engine oil level
- Transmission / gearbox oil level
- Fuel level
- Hydraulic oil level
- Engine coolant level
- Brake fluid level
- Cab heating (when provided) fuel level
- Windscreen wiper liquid level
- Winch rope

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Engine starting
Before starting the engine, make sure there are no persons or objects in
the immediate vicinity of the machine.
1. Make sure the gearshift lever is in the neutral position “N”.
2. Select the fast or slow gears according to needs.
3. Turn the ignition key.
4. The battery level, braking system air circuit, engine oil pressure and
coolant temperature warning lights on the instrument panel come on.
5. Sound the horn.
6. The parking brake must be applied.
7. Turn the ignition switch to the second position to start the engine.
N.B.: The engine cannot be started if the gearshift lever is not in the
neutral position “N”.
IMPORTANT: To avoid permanent damage to the starter motor, do not

continuously operate it for more than 30 seconds. If within that time, the
engine fails to start, wait a couple of minutes before trying again, but do
not operate the starter for more than 15-20 seconds.
If the engine still does not start, wait for the starter motor to cool before
trying again and make sure the gearshift lever is in the neutral position
“N”.
When the engine has started and idles normally, the oil pressure and
battery level lights go off, and the air pressure warning light goes off
when the pressure reaches 5.5 bars.
The parking brake light stays on.
N.B.: Do not use the machine until the air pressure lights go off.
Switching off the engine
Before switching the machine off, allow the engine to idle for a few
seconds.
IMPORTANT: Do not switch the engine off if the gearshift lever is not the
neutral position “N”.
Never accelerate before switching the engine off, as this could damage
the turbocharger due to lack of lubrication.

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

ample visibility of the surrounding zone when proceeding by road.
Only front-wheel steering is allowed on the road. Regularly check front
wheel alignment and adjust if necessary.
To avoid damaging the transmission, stop the machine before inverting
direction (forward or reverse).

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Driving on the worksite
Transporting a suspended load

1. Make sure the manual rotation locking pin is inserted.
2. Consult the load tables to ensure that the load does not exceed the
values given in the table for operation on tyres
3. Keep the load as close as possible to the ground to avoid swaying.
4. Respect the tyre inflation pressures.
5. Make sure the suspensions are locked.
6. Suspended loads must only be carried on flat, solid and horizontal
ground.
7. Select a steering mode according to transport requirements.
8. Select a slow gear.
9. Select front-axle drive (4-wheel drive).
During the transport of loads on flat ground the work radius is constant
When transporting loads uphill the reduction in the work radius can
cause the load to knock against the crane.
Travelling with no load but with the boom raised can cause the machine
to tip over.
When transporting loads downhill the increase in the work radius can
cause an overload and tipping over of the machine.

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

extended to the same length, see the configuration in the table relevant
to use on tyres, with outrigger beams partially extended or retracted.
The crane trucks have three types of stabilization
OUTRIGGER BEAMS FULLY RETRACTED

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

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

the outrigger beams fully extended. For a correct configuration, the
beam locking pin must be inserted in the special seat.
N.B.: Before retracting or extending the outrigger beams REMEMBER

TO REMOVE the locking pins.

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Support surfaces
Determine the strength of the ground on which the crane must
move. Make sure the ground can support the crane. Avoid soft,
unstable or partially frozen grounds.
Work near an excavation:

the crane must not be placed on the edge of a slope or excavation;
provide for a suitable safety distance according to the composition
of the ground.
Safety distance:
Firm, not dusty ground.
Distance 1 = Depth of excavation (A)
Dusty or filled ground.
Distance 2 = Depth of excavation (A) x 2
IMPORTANT: If the machine is working near an excavation and the

safety distance cannot be respected, the excavation must be
propped or filled to avoid landslips.
The surface must support the weight of the crane and the load to be
lifted in addition to the dynamic stresses due to crane movements
and the force of the wind.
The maximum pressure exerted on the ground through the
outrigger support plates is influenced by the crane configuration
and the weight lifted.
The operator can decide, according to the table values, if the

support plates are sufficient or if wider supports such as boards
should be placed under the plates.
The outrigger support plates must be placed in the middle of the
support.

daN/cm2
Types of ground (Kg/cm2)
Type A Naturally tamped backfill 0.5 -1.0
Intact natural ground
Dusty but firm ground:

Fine to medium sand 1.5
Coarse sand - gravel 2.0
Non-dusty ground:
Type B Soft 0.4
Compact 1.0
Semirigid 2.0
Hard 4.0
Rock with few cracks, in good condition, not altered 15

by bad weather and stratified.
Close stratification, compact stratification or column 30

Artificially tamped ground
Asphalt and bitumen 5 - 15

Type C
Cement group BI 50 - 250
Cement group BII 350 - 550
NOTE: In case of doubt the stability of the ground, perform a ground analysis
test.

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Hazards in the work zone

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

They are purely indicative.
Power line voltage Minimum distance

From 0 to 1000 V 2 metres
From 1 KV to 110 KV 4 metres
As it is often very difficult to determine the voltage of a power line,

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

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Boom extension
Boom extension under load is normally permissible within the limit of
75% of the capacities given in the table and in any case within a max.
capacity of 8 tons.
The precision of this manoeuvre is in any case lower than that obtained
with lifting the load by means of the rope, since it depends on the
mechanical efficiency of the boom (guide block friction).
Guide block friction depends on:
- greasing
- boom lifting angle
- lifted load clearance
Malfunctioning of the boom during extension causes stopping of the

function when the max. preset hydraulic pressure of extension is
reached.
To reinstate the manoeuvre, place the lifted load on the ground and
reposition the boom in better geometric conditions.
Malfunctioning of the during boom retraction may cause an abrupt

movement of the sections that can project up to 50 cm.

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Lifting rope
The lifting rope is one of the crane’s main elements, therefore it must
receive particular attention for starting and also maintenance.
The ropes must be visually inspected every day for signs of deterioration
and deformations.
Pay special attention to the rope attachment points on the equipment.
The rope must be inspected when an accident may have caused
damage to the strands and wires or attachment points, or when a rope
has been reinstalled after removal.
If the machine is put out of service for a certain period, the rope must be
inspected before resuming work.
In particular, check:
- The fixing points at the rope ends.
- Parts of the rope the run on sheaves of the supporting or drive
sections.
Rope replacement criteria.
- Broken wires (nature and number).
- Broken wire nests.
- Gradual increase number of broken wires.
- Broken strands.
- Broken rope core.
- Decrease in elasticity.
.reduction in rope diameter
.stretching of rope
.no space between the single wires and strands
.appearance of a fine brown dust between the
strands
- General wear of rope due to abrasion.
- External and internal corrosion.
- Deformation of rope (under load)
.spiral deformation
.basket deformation
.stretching of wires
.loosening of some wires or strands
.knottiness
.contractions
.flattening
.coils
.lumps
.elbows
- Deterioration induced by heat

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

gave rise to replacement (crossed strands)
Very considerable wear and breakages of wires that involved

immediate replacement (crossed strands)
Broken wires on the same strand and minor wear

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Broken crossed wires at the compensating sheave
Very many broken wires hidden by the sheave, the rope must be
removed.
Example of rope with very high internal corrosion.

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Eccentric rigging (unbalanced)

The eccentric or unbalanced orientation of the boom head causes
boom torsion not allowed by the load table.
The load tables are valid only if the boom head is symmetrically
rigged.
boom axis boom axis
if the lifting line is not

centred with respect to
the boom head. .
......the boom twists when

a
load is applied
Asymmetric rigging of the block causes its rotation and rapid wear
of the sheaves.
Asymmetrically rigged blocks turn

when a considerable load is applied.
When rigged symmetrically they work

correctly.

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Symmetric rigging (balanced)

In case of direct pulling, when the lifting line is inserted in the
middle sheave or the sheave next to the boom axis, boom twisting
is eliminated or reduced to a minimum.
—— boom axis i-_ boom axis -----boom axis

i
I— HE 1— -
ww
-T-
In case of pulling in several tackles if the latter are evenly

distributed on the boom axis, boom twisting is eliminated or
reduced to a minimum.

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Change in number of tackles

The block lifting and lowering speed decreases proportionally with
the increase in the number of tackles. This number depends on the
load being lifted and the height to which the load has to be lifted
(refer to the load tables).
Use a max. of 2 tackles when working with the lattice extension or
any jib.
1. Lower the boom and set the block on the ground

2. Remove the wedge box from the boom head.
3. Remove the clamp from the rope end.
4. Remove the wedge and the rope from the wedge box.
5. Remove the rope from the limit stop counterweight.
6. Wind or unwind the rope on the boom head sheaves or from
the block sheaves until obtaining the required number of
tackles.
7. Insert the rope in the limit stop counterweight.
8. Insert the rope in the wedge box and fit the wedge.
Incorrect
The rope section inserted in the block must be positioned on

the side of the wedge box which is on the same vertical axis as
its connecting pin. The end part of the rope must be positioned
on the inclined side of the wedge box.
9. Attach the rope clamp so that the rope cannot free itself from
the wedge box.
10. Fit the wedge box on the boom head (pay attention to which
way the rope is inserted).
11. With the load attached, slowly slacken the rope in order to
position the cable and the wedge box. Make sure the rope is
correctly positioned.

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Load slinging
• Only specially appointed personnel must be used for slinging

loads and for the orders to execute manoeuvres.
• When several persons are used for slinging loads, control of the
operations and the handling commands must be entrusted to
just one
person specifically trained and made responsible.
• For slinging loads, use ropes, chains or other intact special

equipment made available, eliminating all deteriorated
components.
• Choose ropes or chains according to the weight to be lifted,

taking
into account the angle of the supporting sections (whenever the
angle
• Arrange suitable wooden spacers or special protection mouldings
between the ropes or chains and the load being lifted, in
particular when the load has sharp edges.
• Make sure the slung load is balanced, slowly tightening the ropes
before carrying out lifting.

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Work with main winch and auxiliary winch

DANGER: The limiter cannot manage the load of two blocks at the
same time and thus enable safe work, therefore all handling
operations performed with the two blocks shall be ENTIRELY THE
OPERATOR’S RESPONSIBILITY.
TEREX CANNOT BE HELD IN ANY WAY RESPONSIBILITY OR
ACCIDENTS THAT COULD OCCUR DURING CRANE OPERATION
WITH TWO WINCHES.
Working with two blocks consists of moving a load using the main
boom block and the extension block.
First of all, the load to be handled must be only be lifted with the
extension. Check if this is possible in the capacity table.
Place the machine on fully extended outriggers, turret turned to the
front part and boom aligned with the machine axis.
The limiter correctly performs its functions when only one block at
a time is used (work with main boom or work with extension); when
working with two blocks the limiter must be adjusted to the work
mode with extension.
As the useful load is lifted by two blocks at the same time, the max.
total load is the max. load authorized with an extension during
work with extension (with only one block).
See the capacity table.
The capacity value depends on the extension used. See the table of
capacity with extension. The value indicated by the limiter will be
the value of the configured extension.
Work with two blocks could subject the boom and extension to an
overload and cause accidents, as the limiter is unable to correctly
perform its functions.
“Permissible” handling under the charge of the crane operator or

worksite foreman is that of handling a load using the two blocks,
the block extension block (this being not as strong) for lifting the
load and the main one for turning it round.

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To lift the load, use the extension block. (This part being not as
strong). Lift the load with the extension block.
Turn the load to bring it to the horizontal position using the main
boom block.
N.B.:
When the main boom block pulls the load to bring it horizontal, the
values given by the limiter are incorrect

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When handling with two blocks never lower the boom because the
limiter cannot control the overload.
Lower the load with the extension block to bring it upright.

All manoeuvres must be carried out with slow movements and
without jerking.
The main boom block tackles must be greater than or equal to the
tackles of the extension block.

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Lifting with more than one crane
Lifting involving two or more mobile cranes is a complex operation

requiring considerable skill, training and careful planning. Therefore a
detailed procedure must be drawn up, taking into account every
possible situation and that in any case includes at least one of the
following requisites:
- Lifting must be carried out under the control of a supervisor.
- The ground must be flat and firm, otherwise make provision with all
the means necessary for absolutely obtaining that result.
- All the cranes must be carefully levelled.
- The exact weight of the load and the relative centre of gravity must be
determined.
- The max. work radius that can be reached by each crane during the
entire operation must be exactly determined.
- The length and angle of the boom must be determined.
- The nominal capacity of every crane must be determined for all
phases of the operation.
- For lifting with multiple cranes, no crane must be loaded with more
than 75% its net weight; bigger reductions can be made necessary by
the specific lifting conditions.
- The speed of the block, rotation and booms of the cranes must be as
equal as possible.
- Slewing, traverse and extension movements must be reduced to the
minimum necessary.
- Translation with the load is dangerous because the swaying could
cause considerable load shifting from one crane to the other.
- Operators must know exactly what to do and what movements must
be made before starting lifting.
- If possible, carry out one or more trials without load until all operators
know how to do what is required.
- All communications during lifting must be made by radio (preferably
closed type, and not walkie-talkie).
- Only one person must direct and control the operation. This person
must be able to observe the entire operation and must stay in radio
contact with the operators.
- All crane movements must be carried out as carefully as possible, and
braking and starts must be done gently.
- The block ropes must always be kept vertical; otherwise the cranes
overload each other and very dangerous sideslipping can be caused.
- For these operations it is necessary to previously check the correct
operation of the load indicator and/or moment limiter that the cranes
involved in the operation must have.

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Towing
In case of breakdown the machine can be towed for a short distance
(less than 10 km) and at slow speed (less than 10 kph) using a tow bar.
- Put the gears in neutral
- Release the front axle parking brake. The service brakes fed by the
remaining air reserves are not involved in this operation.
- Disconnect the transmission shafts (front and rear axle). If this
operation is not carried out, the transmission could be rapidly and
permanently damaged.
Towing must be done in conformity with the highway code of the country
where the operation is carried out.
Use the special towing points, located on the front of the frame (rear
optional).
The max. horizontal traction force on the hook must be less than 50% of
the total weight of the machine in running order.
If the crane is bogged down or stuck in sand, use the towing attachment
located on each corner of the truck.

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Transporting the crane on a self-propelled trailer

Use trailers or platforms of adequate size for transporting the
machine.
Rigidly secure the crane on the trailer using chains or fixing bars.
Make sure the total height of the load is less than that permitted by
current regulations or by the motorway companies and, if
necessary, that the special road transport or circulation permit has
been issued.
Never deflate the tyres in order to come within the necessary

overall dimensions.
If the outriggers are not resting on the base of the trailer, make sure
the beams are locked in order to prevent them from accidentally
coming out.
The crane must be transported with the boom in the horizontal
position, the block secured to the frame structure, rotation blocked
with the manual pin and, when loaded, with the parking brake
applied. Carefully respect the above-mentioned rules even if
transport is only for short distances.

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Control instruments Operation and maintenance manual
IV
Control
instruments
Chapter IV - ed. 06-2004 page 1/50

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Operation and maintenance manual Control instruments
page 2/50 Chapter IV - ed. 06-2004

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Identification of the controls
The reference numbers of instruments and controls in the cab

illustrations correspond to the numbers in the text together with
the description of controls, instruments and relative functions.
Notes: The following list gives and describes all the standard
machine controls. Not all the instruments listed are supplied on
every machine.
Before starting the machine, the operator must carefully read all
the information given in this section and the safety regulations in
the first part of this manual.
The operator must know the exact position and function of every
control on the machine.
This manual contains the words WARNING, CAUTION and Notes to

stress important instructions. The indications WARNING and
CAUTION precede the section or point to which they refer, whereas
Notes relevant to the subject in question are given below the
sections or points; therefore they are defined as follows:
WARNING: any operating procedure, standard, etc., that could

result in injury or death if not strictly respected.
CAUTION: any operating procedure, instruction, etc., that could

result in damage or destruction of equipment if not strictly
respected.
Note: any regulation, operating condition, etc., that is important to

stress.

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Operator’s cab controls

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

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4. Parking brake
5. Hand accelerator
6. Right hand control
7. Left hand control
8. Outrigger movement consent button

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9 10
DX

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9. Upper structure swing brake manual release
10. Horn

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11 .Bubble level
12. Windscreen wiper liquid tank
13. Heating control

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Side instrument panel

14. Front right outrigger beam extension/retraction control
15. Front right outrigger down/up control
16. Front left outrigger beam extension/retraction control
17. Front left outrigger down/up control
18. Rear right outrigger beam extension/retraction control
19. Rear right outrigger down/up control
20. Front left outrigger beam extension/retraction control
21. Front left outrigger down/up control
22. Lifting winch speed selector
23. Boom extension mode selector
24. Pressure gauge
25. Boom synchronization key switch
26. Turret rotation speed regulator
27. Gearshift lever
28. Upper structure rotation brake released warning light
29. Emergency stop

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Central control column

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30. Steering wheel
31. Indicator panel
32. Lever switch
33. Emergency lights switch
34. Steering mode selector
35. Engine rpm limiter switch
36. Work light switch
37. Parking lights/low beam switch
38. Rear fog light switch
39. Slow (4x4) /fast (4x2) gearshift
40. Flashing light switch
41. Steering column angle adjustment lever

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Column indicator panel

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Column control panel

42. Engine coolant temperature gauge
43. Rev counter and Hour-meter
44. Fuel gauge
45. Set of warning lights

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Telescopic boom

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Machine layout
Truck: the rear end is the part of the frame where the engine is installed
Upper structure: the boom is fitted on the front, the counterweight is located at
rear end
The left and right sides are determined with respect to the operator seated in the
driving position located on the turret.
Boom base Boom head
Air tank and batteries

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Descriptio
n of
controls

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Outrigger controls
According to the choice, these controls enable beam or outrigger
extension and retraction.
Manoeuvre consent is given by the button (ref.8) located on the left arm-rest of
the driver’s seat.
DO NOT COMBINE OPPOSITE FUNCTIONS (e.g. retracting and

extending outrigger beams or lowering and lifting vertical
cylinders at the same time).
CAUTION: Make sure the machine is perfectly stabilized before

handling of loads. Frequently check the bubble level in the cab to
ensure correct level adjustment.

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Front left outrigger controls
Front right outrigger controls
Rear left outrigger controls
Rear right outrigger controls

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Symbols on outrigger controls
Left side beam extension

also keep the button “8” pressed to enable the function
Left side beam retraction

Right side beam extension

Right side beam retraction

Left side outrigger down

Left side outrigger up

Right side outrigger down

Right side outrigger up


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Winch rotation speed selector
Winch first speed
Ш
• Winch second speed
*
Make sure the block is still before changing speed.
The change in speed can cause the load to sway dangerously.
CAUTION: Do not change the winch speed if the winch hand control is not in
the neutral position and the drum is turning.
Boom telescoping mode selector
This control disables the fourth section, therefore only the second
and third telescopic boom sections can be extended. This control
can only be activated when the boom is completely retracted.
This control is used to activate the fourth section, therefore

allowing extension of the three telescopic sections. This control
can only activated when the boom is completely retracted.

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Boom synchronization key switch
If the telescopic sections are not synchronized, it is necessary to:

• completely retract the boom (lifted to 40°-50° and without load on the hook)
• turn on the switch while retracting the boom. The time necessary for the
boom synchronization phase is 2 to 3 minutes for every out- of-synchro
metre.
Only use this switch when:

• there is no load on the hook
• the boom is raised and completely retracted
N.B.: Do not use this function during extension either with or

without load, as it will cause the boom to go out of
synchronization.
To avoid accidental manoeuvres, remove the switch key after
completing the synchronization manoeuvre.

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Turret rotation speed regulator
28
Turn the knob (ref.26) anticlockwise to reduce rotation speed, or

clockwise to increase it.
If the knob is turned fully anticlockwise rotation is stopped
Turret rotation brake released indicator light
The warning light (ref.28) comes on when pressing the button (ref.9) located on
the left hand control, signalling that the upper structure rotation brake has been
I
manually released.

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Gearshift
NEUTRAL position “N”

The lever must be in position “N”:
• when the machine is stationary
• to shift up and down
• to lock or release the rear axle steering
• to start the engine
Moving forward:
Positions 1 2 3
Engage first gear, release the parking brake and accelerate. In first, the machine
moves forward; change gear as the speed increases. Reversing Positions 1 2 3
Engage first gear, release the parking brake and accelerate. The machine
reverses in first; change gears as the speed increases.
CAUTION: Decrease engine rpm before shifting down.

Stop the machine before reversing.
When driving on the road make sure to always engage the proper
gear to avoid gearbox overheating.

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Engine coolant temperature gauge
The normal temperature is between 83°C and 95°C. The coolant

temperature must not exceed 100°C.
N.B.: If the temperature reaches 100°C turn off the engine

immediately and check the cooling circuit.
Fuel gauge
This gauge shows the fuel reserve in the tank
Note: there is no fuel reserve warning
light.
Rev counter and Hour-meter
The rev counter works electrically after the engine is started The hour-
meter operates after the engine started, and indicates the engine running
hours.

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

Red warning light
Blinker light
Indicates operation of the side blinkers

Green warning light
Battery charge light
It comes on when:
• The ignition is switched on but the engine has not yet started
• The alternator does not charge the batteries
Red warning light
Engine oil low pressure warning light
It comes on when:
• The engine oil pressure is below 3 bars
• The engine is idling
Red warning light
IMPORTANT: If the light stays on even when the engine is

not idling, turn the engine off and look for possible causes.

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Suspension lock warning light
The rear suspension locks automatically if the upper structure is turned
O
to the left or right by more than 3° with respect to the machine’s
longitudinal axis. This light comes on indicating that the suspension is
locked.
Red warning light
IMPORTANT: If the upper part is turned more than 3° with the

machine on the tyres and the light does not come on immediately,
stop rotation and check the suspension locking system.
Do not resume work before finding and fixing the problem.
Wheel alignment warning light

It comes on when the rear wheels are aligned with the longitudinal axis
of the truck.
Red warning light
Brake fluid low level warning light
The light comes on when the brake fluid level is too low.
Red warning light
WARNING: Stop the machine immediately and check the brake

fluid level.
Also check for any leaks.
Parking brake on warning light

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

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Torque converter oil temperature warning light
Normal work temperature between 80°C and 120°C.

Red warning light
N.B.: If the red light comes on, put the gears in neutral and rev the
engine for about 2-3 minutes until the temperature returns to
normal.
Front axle brake circuit low pressure warning light
The normal brake working pressure exceeds 5.5 bars.

The light goes off when the engine is started and the pressure has
reached 5.5 bars.
The light comes on when the braking circuit pressure falls below 5.5
bars during machine operation.
Red warning light
WARNING: Do not use the machine before the red warning light
goes off.
Rear axle brake circuit low pressure warning light
The normal brake working pressure exceeds 5.5 bars.

The light goes off when the engine is started and the pressure reaches
5.5 bars.
The light comes on when the braking circuit pressure falls below 5.5
bars during machine operation.
Red warning light
WARNING: Do not use the machine before the red warning light
goes off.

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Parking lights / low beam light

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

The light comes on when high beams are on.
Blue warning light.
Emergency light switch

When pressed, the six blinkers work at the same time, signalling a
machine emergency situation.
Intermittent red warning light.
Flashing revolving light switch

Control used for switching on the revolving flashing light on the
operator’s cab.

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Slow (4x4) / fast (4x2) speed gearshift
Press to the right (symbol with tortoise) to select the slow gears with
engaging of front and rear wheel drive (4x4 drive).
Use this drive for difficult ground, at low speed and for driving the
machine when carrying a load.
Press to the left (symbol with hares) to select the fast gears engaging
front wheel drive only (4x2).
Use of this drive is recommended for driving on the road.
N.B.: Use this control only when the machine stopped.
Rear fog light switch
Press to switch on the rear red light in case of fog.
Lights main switch
2-position switch:
1-side lights and control panel lights
2- low beams
Work light switch
Press to switch on the light at the top end of the cab, for illuminating the
work area.
Engine rpm limiter switch

Press to limit max. engine speed to 2000 rpm on model A350 and 2100
rpm on models A400-A450.
N.B.: It is advisable to use this control during work on the site, to

improve efficiency of the hydraulic system and to reduce machine
noise level.

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Steering mode selector
Before selecting steering modes, the front and rear wheels must be
aligned and parallel to the longitudinal axis of the truck.
It is a 3-position selector:
Position 1: coordinated/concentric steering Position 2: front axle
steering only Position 3: crab steering
After several hours of operation check the alignment of the front/rear

wheel axles.
Realign the wheels if necessary.
For this purpose:
- set the steering selector to position 1 or 3.
- align the rear axle wheels using the steering wheel (the red light on
the control panel comes on when the wheels are aligned).
- set the steering selector to position 2 (front axle steering only).
- align the front axle wheels by means of the steering wheel (visual
alignment check).
The front and rear axle wheels are now aligned.
After selecting the type of steering, just use the steering wheel to drive
the machine.
IMPORTANT: Only front axle steering is permitted while driving on

the road. Frequently check wheel alignment and adjust if
necessary.

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Lever switch
Press the button to sound the horn
Turn the lever switch upwards or downwards to operate the front

windscreen wiper.
Press the front wiper control sideways to clean the windscreen.
Blinkers switch:
push the lever forward to operate the left side blinkers to turn left. press
the lever down to operate the right side blinkers to turn right.
Headlight selector
Push the lever up (after turning the light switch on) to operate the high beams.
The blue light on the control panel comes on Push the lever more and the high
beams flash.

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Manual rotation locking pin
Lift the right arm-rest to access the locking pin (ref.1).

To lock the upper part of the machine, align the truck (boom on front end), lift
the pin, turn it clockwise 90° and lower it in the special seat.
WARNING: Never insert the pin when the upper structure is

turning. Failure to comply with this precaution can seriously
damage the upper part and the truck.
The upper structure must always be locked when moving the
crane on the worksite and the road.
Hand accelerator
This control is used to set an engine speed during the execution of crane
operations.

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Left hand control
The left hand control commands turret rotation, upper structure rotation brake
release and telescopic boom extension/retraction.
The left control has a safety device for preventing accidental manoeuvres,
however the operator must remain seated in the driving position.
6
, Operations with only one winch:
1. push forward to extend the boom sections
2. move right to turn the turret clockwise
3. pull back to retract the boom sections
4. move left to turn the turret clockwise
2
4 Operations with auxiliary winch:
2. move right to turn the turret clockwise
4. move left to turn the turret clockwise
4 3
5. pull back to lift the load with the auxiliary winch
AUX 0 3 6. push forward to lower the load with the auxiliary winch
Remember to remove the manual rotation locking pin before using the
rotation function.
When the hand control is in the middle position (e.g. boom extension
and turret clockwise rotation) the two functions are activated at the
same time.
IMPORTANT: Release the main or auxiliary winch rope when

extending the boom to prevent the boom head block from tripping
the limit stop device. Failure of this device can result in serious
damage to the boom head or telescopic extension and the rope.
The rope could break and drop the load, causing serious damage
or fatal accidents.

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Manual upper structure rotation brake release button on left hand

control (red light ref.28)
Use the button (ref.9) on the left hand control to manually release upper
structure rotation.
SX
Operation
On machine starting, the turret rotation unit brake is applied and automatically
released gradually during upper structure rotation.
Grip the left hand control and press the button “9” to manually release the brake,
in order to allow self-aligning of the boom head over the load perpendicular line.
The brake is automatically re-applied when the button is released.
CAUTION: Do not release/lock the rotation abruptly during work as

this may cause the load to sway. Wait until the upper structure of
the machine has completely stopped before reversing direction.

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Right hand control
The right hand control commands load lifting and lowering with the main winch
and lifting and lowering the telescopic boom.
The right hand control has a safety device for preventing accidental operations;
however,
the operator must remain seated in the control position.
Operations to be carried out:

1. push forward to lower the load with main winch
2. move left to raise the telescopic boom
3. pull back to lift the load with main winch
4. move right to lower the telescopic boom
When the hand control is in the middle position (e.g. load and boom
lowering) the two functions are activated at the same time.
IMPORTANT: Release the main or auxiliary winch rope when

extending the boom to prevent the block from tripping the limit
stop lock device. Failure of this device can result in serious
damage to the boom head or telescopic extension and the rope.
The cable could break, dropping the load and causing serious
damage or fatal accidents.

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Parking brake
Located under the right arm-rest, it is used to apply or release the parking brake
Rear axle differential lock control (optional)
This control locks the rear axle differential. The differential remains
locked until the control switch is operated.
Move the gear lever to the neutral position “N” before using this control.
Note: Select the slow gears (4x4) before using this control.
This mode must only be used for work on very rough ground.
IMPORTANT: Do not use rear axle steering when the differential is

locked.
Return to the normal position after overcoming an obstacle.
Auxiliary winch control (optional)
Press the switch to enable the auxiliary winch functions and disable
telescopic boom extension and retraction.
Press the switch again and the telescopic boom extension and
retraction functions are re-enabled.
Use the left hand control to operate these functions.

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Bubble level
Located on the left side of the instrumental board inside the operator’s cab.
It (ref.11) allows the machine to be correctly stabilized.
Cab heating control (optional)
The control unit (ref.13) is located on the left side instrument panel in the
operator’s cab.
The control is used to switch the heater on/off, for adjusting the required ambient
temperature and for clearing a fault.
The green LED is also the ignition light (the LED remains on) and signals
overheating (LED flashing).
N.B.: Remember to open the fuel cock on the tank located behind
the operator’s cab before using the heating system.

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Air conditioner control in operator’s cab (optional)
1. Air circulation fan speed regulator

2. Heating control
3. Air conditioner control
Battery disconnecting switch
This switch is located on the outside of the battery box on the left side of the
truck.
It disconnects the negative pole of the batteries from the machine frame.
N.B.: It is always advisable to disconnect the batteries at the end

of the work shift, during long work stops or for carrying out
maintenance.

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Electronic load limiter device
3B6 limiter
See the “Electronic Load Indicator Handbook” section in this manual. Contact
your agent or dealer for any doubts on correct use of the load indicator.
PAT limiter
See the “Electronic Load Indicator Handbook” section in this manual. Contact
your agent or dealer for any doubts on correct use of the load indicator.

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Operator’s seat
Adjustable head-rest
Seat back
Arm-rests
Upper part adjustment

sliding guide
Height and angle

adjustment
Weight adjustment
Console locking
device
Complete seat unit
adjustment sliding guide

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

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Accessories Operation and maintenance manual
V
Accessories
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Operation and maintenance manual Accessories
page 2/32 Chapter V - ed. 06-2005

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8 m extension
Extension stowed for travel, secured to brackets alongside the

telescopic boom.
Extension support brackets for travel:

1 - rear support
2 - front support

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

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Push the extension towards the boom head
to enable insertion of pins “C” and “D”.
Insert pins “C” and “D”.

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Remove pin “G” on the rear bracket and pin “A” on the front bracket.
Raise the boom slightly to free the extension from the supports.
Manually turn the extension around pins “C” and “D”
Insert retaining pins “E” and “F” and remove pin “C”.
To facilitate pin insertion, use a stool, but NEVER A LADDER which would
have to be placed against the boom or extension.
Position rope idler sheave “H” vertically.

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Before handling any material with the extension:

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

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Extension offset
The extension can be offset 0°, 15° or 30° with respect to the telescopic boom
axis.
The offset is obtained by means of the lockable strut and the support and
positioning rod.
Positioning rod in rest position.
Support rod in work position
Position the support rod and lower the boom to bring the support rod in contact
with the ground using the lifting, lowering and extension functions.
Use the hoisting or lift functions also to facilitate pin positioning.

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To offset the extension 0°, proceed as follows: The

jack (fig.5a) must be locked in position 1.
0°
To offset the extension 15°, proceed as follows: Release

the jack
Raise the boom to lock the jack (fig.5b) in position 2.
Position the locking pin
15°

the jack
Raise the boom to lock the jack (fig.5c) in position 3. Let
the jack retract fully and position the locking pin.
30°
Before every job with the extension, always bring the rod to the rest
position.

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

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Insert pin “C” and remove pins “E” and “F” that secure the extension to the boom
head.
Swing the extension back on the bracket supports alongside the main boom.
Raise the boom slightly to facilitate this operation
Insert pin “G” to secure the extension to the rear support.

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Insert pin “A” to secure the extension to the front support.
Remove pins “C” and “D”
Move the extension away from the telescopic boom for inserting pin “B” on the
front support.

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15 m extension
Extension stowed for travel, secured to brackets alongside the

telescopic boom
Extension support brackets for travel:

1 - rear support
2 - front support

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Raise the machine on fully extended outriggers on firm, level and horizontal
ground.
Retract the boom fully, turn the turret towards the front of the machine and
bring the boom to the horizontal position.
Remove pin “H” on the rear bracket.

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Push the extension towards the boom head
to enable insertion of pins “G” and “F”.
Insert pins “E” and “G”,

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

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Remove link rod “M” that secures the 7 m element to the 8 m extension
already fixed to the boom head.
Manually turn the 7 m insert around the fixing pins “N” and “P”

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Insert the fixing pins “Q” and “R” to secure the 7 m element to the 8 m
extension.
Position the rope idler sheave “S” vertically.

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Before handling any material with the extension:

• Disconnect the socket from the lifting limit stop electric connection box on the
boom head.
• Connect the extension lifting limit stop socket in the electric connection box on
the boom head.
• Remove the winch limit stop counterweight fixed to boom and fit it to the
device on the extension.
• Run the lifting rope over the sheaves and through the limit stop counterweight,
then secure it to the hook, if fitted.

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Extension offset
The extension can be offset 0°, 15° or 30° with respect to the telescopic boom
axis.
The offset is obtained by means of the lockable strut and the support and
positioning rod.
Positioning rod in rest position.
Support rod in work position
Position the support rod and lower the boom to bring the support rod in contact
with the ground using the lifting, lowering and extension functions.
Use the hoisting or lift functions also to facilitate pin positioning.

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To offset the extension 0°, proceed as follows: The

jack (fig.5a) must be locked in position 1.
0°

the jack
Raise the boom to lock the jack (fig.5b) in position 2.
Position the locking pin.

the jack.
Raise the boom to lock the jack (fig.5c) in position 3. Let
the jack retract fully and position the locking pin.
30°
Before every job with the extension, always bring the rod to the rest
position.

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Fold the boom in the stowed position for travel
ground, with the wheels raised and the engine idling.
Retract the boom fully, turning the turret towards the front of the frame and
bring it to the horizontal position.
Offset the extension at 0° with respect to the boom axis.
Position the winch rope idler sheave “S” horizontally.

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Remove pins “Q” and “R”.
Turn the 7 m insert alongside the 8 m extension.

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M
Secure the 7 m insert to the 8 m extension by means of link rod “M”.
Insert pin “G” and remove pins “D” and “F” that secure the extension to the
boom head.

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Manually swing the extension back on the support brackets alongside the main
boom.
Raise the boom slightly to facilitate this operation
Insert pin “L” to secure the extension to the rear support.
Insert pin “A” to secure the extension to the front support.

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Remove pins “E” and “G”
Move the extension away from the telescopic boom for inserting pins “B” and
“C” on the front support.
Insert pin “H” to secure the extension to the rear support.

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8 m extension with 7 m insert secured on

brackets alongside the boom
Raise the machine on fully extended outriggers on firm, level and

horizontal ground.
Retract the boom fully, turn the turret towards the front of the machine and move
the boom to the horizontal position.
With the extension secured to the brackets alongside the boom, disconnect the
link rod “X” securing the 7 m insert to the 8 m extension, leaving pin “Y” inserted.

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V W
Remove pins “W” and “Z”, leaving pin “V” inserted.
The 7 m insert and the 8 m extension are now secured to the main boom
brackets, but are no longer connected.
Carry out the same procedure for deploying the 8 m extension previously
described in this manual.

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Folding the extension in the stowed position for travel
ground.
Retract the boom fully, turning the turret towards the front of the frame.

Offset the extension at 0° with respect to the boom axis.
Now carry out the procedure for folding the 8 m extension previously described in
this manual.
V W
Insert pins “W” and “Z” to secure the rear end of the 7 m insert to the 8 m
extension.

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Secure link rod “X” of the 7 m insert to the 8 m extension.
At the end of the operation the 7 m insert is secured to the 8 m extension and
everything is secured to the brackets alongside the main boom in the rest
position.

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Additional rope blocks for working with lattice extensions
The manufacturer can supply blocks of different capacities for working with the
lattice extensions.
The blocks supplied have connections for eyelet terminals to allow the operator
to work directly with the block (direct pull) or to have several tackles (ALWAYS
refer to the load tables).
If a swivel hook only enabling direct pulling is required, proceed as described for
its installation on the rope.
- Pass the rope through the counterweight.

- Using the thimbles supplied, fix the rope to the swivel hook
- Pass the rope through the counterweight again, making sure to leave
sufficient free rope above the dead end.
- Doubly fasten the rope with the clamps supplied
Lifting
rope
Dead
end
Clamp
Ball
counterweights
Thimbles
Clamp
Clamp
Swivel
hook

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Maintenance
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Operation and maintenance manual Maintenance
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Maintenance
Regular maintenance will ensure long life of the machine.

Therefore make sure to follow the instructions given in this section.
The general maintenance chart gives the essential points to be observed and the
following pages give the instructions relative to such operations.
N.B.: Machine operators or maintenance personnel must know the

instructions contained in this manual and above all those
concerning safety, before carrying out any operations.
General information on maintenance

At the time of starting, a specialist will show you how to use the machine. Carry
out the first servicing with him.
Subsequently, refer to the maintenance intervals given in the following charts.
In case of prolonged storage, the 500 hours maintenance must be carried out
every 6 months, in particular on the Engine, Axles, Suspension, Steering and
Transmission.
IMPORTANT: The intervals given in the following charts apply for

the machine used in normal conditions. For intensive use or
particular conditions (excessive heat, humidity, dust) maintenance
must be carried out more frequently.
To carry out the maintenance operations, the machine must be
stabilized on fully extended outriggers on firm, flat and level
ground.

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Maintenance
Periodical maintenance is necessary.

The hour-meter on your machine tells you when maintenance operations should
be carried out. It must be checked daily.
The intervals given are based on a work time of 9 h a day, 40 h a week, 2000 h
a year.
When performing the maintenance operations also carry out the
necessary tightenings
Hour-meter
Its electric control is tied to the heat engine oil pressure.
Its hourly indications are the same as an electric clock when the heat engine is
running.
Preliminary operations
Firstly clean, the grease nipple heads, plugs, edges of filling holes and the level
sightglasses.
When lubricating, check the seals and replace them if damaged or worn.
Daily checks before start-up

Every day, carry out a complete inspection before boarding the machine or
starting the engine, checking for loose or missing screws, accumulated debris,
oil and coolant leaks.
Check the tyres and levels.
Storage
After storage for several months, the lines must be checked for tightening the
hydraulic connections. Carry out a complete inspection. Apply the procedure:
Take every precaution to safeguard the environment. In particular,

collect and recycle all used fluids. Do not leave them in incorrectly
labelled or open containers.
There must be no puddles of fluids on the ground where you are
working.

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Preventive maintenance
General
Machine maintenance also depends on the workplace. The recommended

maintenance handbook on the following pages gives the points to be checked
and the frequency of checks.
NOTE:
The recommended maintenance handbook takes into account the conditions of
use for the material. The type of work performed, the size of the loads and the
climatic and ground conditions are likewise factors to be taken into
consideration. The preventive maintenance lists are given according to hours of
operations.
Any change to the fixed maintenance schedule must be preceded by a new

analysis of the machine operation conditions. Carefully read the recommended
maintenance handbook before changing the check frequencies.
The lubrication tables give the general greasing points and the type of lubricant
to use for every component.
Using the maintenance handbook
The maintenance handbook is a maintenance guide until experience allows the

definition of a schedule according to the particular operating conditions.
The maintenance handbook can be photocopied as required.

Persons performing maintenance operations must indicate this in the
handbook, so that the machine can be checked during subsequent
maintenance.
The maintenance handbook is a document attached to the machine.

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Tyre pressures Periodically
check the tyre

pressures, making sure that the air pressures recommended for the different uses
are respected. Refer to the inflation pressures specified on the stickers in the
operator’s cab.
Turntable fixing
Periodically check the lubrication and fixing of the turntable. In case of anomaly,
request the assistance of a TEREX specialist who will advise you on the
operations to be carried out. THE TURNTABLE FIXING BOLTS ARE SAFETY
ELEMENTS.
Starting the machine after replacing a hydraulic component.
After changing a hydraulic system component, e.g. pump, distributor, cylinder,

tank, run the machine at idling speed for 20-30 minutes without using any of the
hydraulic functions, then bleed the replaced part if necessary. Then check or
change the filter cartridges.
Transmission unit fixing device
Periodically check the tightness of the transmission universal joints. In case of

any doubts on the state of the screws, replace only with screws recommended by
TEREX.
Boom telescoping chain tension check
To check the tension of the stay, proceed as follows:

- Loosen the grub screw on the stay lock nut.
- With the machine stabilized, move the boom to the horizontal
position.
- Partially extend the third and fourth telescopic sections.
- While the sections are retracting, adjust
nut “A” of the telescoping chain stay using
a torque wrench setting of 30-35 daN m.

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Lifting rope
The lifting rope is one of the crane’s main parts, and requires particular attention
for starting and maintenance.
The ropes must be visually checked for signs of deterioration or deformations

every day.
Pay special attention to the points where the ropes are attached to the
equipment.
In any case, the rope must be inspected when an accident may have caused
damage to the strands, wires or attachment points or when a rope has been put
back into service after being removed and then refitted.
If the machine has not been used for some time, the rope must be inspected
before resuming work.
-The fixing points at the rope ends.
-The parts of the rope sliding on the lifting or idle section sheaves.
-The fixing points at the rope ends.
-The parts of the rope sliding on the lifting or idle section sheaves.
Rope removal criteria.

-Broken wires (nature and number).
-Broken wire nests.
-Gradual increase in the number of broken wires.
-Broken strands.
-Broken rope core.
-Reduced elasticity.
.Reduction in rope diameter .rope
stretching
.no space between individual wires and strands
.appearance of fine brown powder between strands
-General wear of rope due to abrasion.
-External and internal corrosion.
-Rope deformation (under load)
.spiral deformation .basket deformation .stretched wires
.slackening of certain wires or strands
.knottiness
.contractions
.flattening
.loops
.lumps
.bends
-Deterioration induced by heat.

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

replacement (crossed strands)
High wear and very many broken wires that required immediate replacement
(crossed strands)
Broken wires on the same strand and slight wear

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Broken crossed wires at the equalizer pulley
Numerous broken wires hidden by the pulley, the rope must be removed.
Example of wire rope with very high internal corrosion.

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Wire rope replacement

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

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The ropes must be wound evenly on the drums. Make sure that the turns of rope
wound on the first layer of the drum are close and tight in order to prevent
overlapping or crossing during winding of the next layers and therefore crushing
of the cable. Take into account the rope winding and the rotation direction of the
drum as given below:
Rope with RIGHT twisting (use the right hand)
Case A: rope winding from top of the drum with end fixed to the left wing; use the
right rope.
Case B: rope winding from bottom of the drum with end fixed to the right wing;
use the right rope.
rope with LEFT twisting (use the left hand)
Case C: rope winding from bottom of the drum with end fixed to the left wing; use
the left rope.
Case D: rope winding from top of the drum with end fixed to the right wing; use
the left rope.

ta BENDINI
After fitting the rope on the winch, check positioning of the rope in the thimble.
Form a loop beforehand as close as possible to its final size to avoid having to pull a
long length of rope to tighten it.
The rope must come out 70 - 80 mm.
IMPORTANT: The wedge and rope must slide freely until the rope presses
against the sides of the thimble
Once the rope is fitted, use a minimum number of tackles and attach a load
(max. load x tackle). Completely unwind the rope using the telescoping and
lifting functions.
Once the rope is completely unwound, rewind it under load to tighten it and
eliminate any strain.
Rope maintenance and removal.

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

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

16.00R25 10 bars 8 bars
18.00R25 10 bars 8 bars
20.5R25 8 bars 5.5 bars
23.5R25 8 bars 5.5 bars
26.5R25 8 bars 5.5 bars
The pressures given refer to cold tyres, therefore also the inflation and pressure
checks must be carried out on cold tyres.

Pitch screws Class 10.9 Pitch screws Class 10.9
Class 8.8 Class 8.8
И BENDINI
Normal Class 12.9 End Class 12.9
M8 x 1.25 20 30 M8 x 1 25 35
M10 x 1.5
Maintenance
50 70 M10 x 1.25 50 70
M12 x 1.75 80 120 M12 x 1.25 90 130
//// /// /// Screw

M12 x 1.5 torque wrench
90 setting
120
M14 x 2 130 180 Torque
M14 x 1.5 to be applied
140 in Nm, coefficient
200 of rubbing between 0.125 and 0.150.
Use a calibrated torque wrench (precision ±6%).
M16 x 2 M16 x 1.5 300
200 280 210
M18 x 2.5 280 390 M18 x 1.5 310 440
Model Crane truck
Fixing screws type TCEI
M20 Class 10.9 M22 Class 10.9 M24 Class 10.9

Model A300 //// 650 ////
Model A350 470 //// ////
Model A400 //// 650 ////
Model A450 //// 650 ////
Model RC45 //// 650 ////
Model A600 //// //// 730
Model A600C //// //// 730
Slewing ring screws torque wrench setting

Torque to be applied in Nm, coefficient of rubbing between 0.125 and 0.150.
Use a calibrated torque wrench (precision ±6%).
N.B: The values given in the tables refer to lubricated screws.

Model A300
Max. pressure valve calib.

Winch 210
Boom up 210
(1)
Boom down 150 / 50 (2)
Retract boom ///

Extend boom 200
Rotation 140
Outriggers 130
Steering 140
Servocontrols 35
Model A350 - A400
Max. pressure valve calib.

Winch 210
Boom up 210
Boom down 160 (1) / 50 (2)
Retract boom 290
Extend boom 250
Rotation 150
Outriggers 140
Steering 150
Servocontrols 40 / 45
Model RC45
Max. pressure valves calib.

Winch 210
Boom up 240
Boom down 50
Retract boom 290
Extend boom 250
Rotation 150
Outriggers 160
Steering 150
Model A450

Winch 210
Boom up 210
(1)
Boom down 160 / 50 (2)
Retract boom 210

Extend boom 210
Rotation 150
Outriggers 140
Steering 150
Model A600C

Winch 210
Boom up 230
Boom down 160 (1) / 50 (2)
Retract boom 230
Extend boom 210

Rotation 150
Outriggers ///
Steering ///
Model A600

Winch 210
Boom up 230
Boom down 160 (1) / 50 (2)
Retract boom 230
Extend boom 210

Rotation 150
Outriggers 160
Steering 150

Description Type of lubricant “SHELL Quantity of lubricants
part Cold (< -10°C) Moderate (-10 -s- +40°C) Hot (> +40°C) um A300 A350 A400 A450 RC45 A600
Engine oil RIMULA ULTRA 5W-30 RIMULA X 15W-40 RIMULA X 15W-40 Kg 13.0 13.0 15.5 15.5 15.5 15.5
3
r+
Gearbox oil ATF DEXRON II ATF DEXRON II ATF DEXRON II Kg 16.0 16.0 16.0 16.0 16.0 24.0 CD
3
Ш
3
Front/rear axle oil TRANSAXLE 75W-90 SPIRAX A 80W-90 SPIRAX A 80W-90 Kg 36.5 36.5 42.2 42.2 42.2 55.0
o
CD
Rotation reduction TRANSAXLE 75W-90 OMALA OIL 150 OMALA OIL 150 Kg 7.1 7.1 7.1 7.1 7.1 7.1
gear oil
Hydraulic circuit
TELLUS T22 TELLUS T46 TELLUS T68 Kg 386.0 500.0 520.0 520.0 520.0 715.0 ш1
oil Cr
CD"
O
Main winch oil TRANSAXLE 75W-90 OMALA OIL 150 OMALA OIL 150 i 11.0 11.0 11.0 11.0 11.0 13.0
CO
3;
Auxiliary winch oil TRANSAXLE 75W-90 OMALA OIL 150 OMALA OIL 150 i /// 11.0 11.0 11.0 11.0 11.0 P
o
С/Г
Boom guide Ш
RETINAX HDX 2 RETINAX HDX 2 RETINAX HDX 2 Kg 14.0 18.0 18.0 18.0 18.0 20.0 =5
blocks grease Q. 4
C
ALVANIA GREASE EP2 ALVANIA GREASE EP2 ALVANIA GREASE EP2 Kg 3.0 3.0 3.0 3.0 3.0 3.0
CT
o'
0)
m
Slewing ring, pins, =5 7i
o
bearings grease Go
T3
CD
—i
m
Radiator
X
ANTIFREEZE ANTIFREEZE ANTIFREEZE 03
i 9.0 9.0 10.0 10.0 10.0 9.0 o'
antifreeze (mixture 34%) (mixture 34%) (mixture 34%)
3
03
3
Q-
ro
m
□
03
ta BENDINI
Lists and frequencies for maintenance
List “A” every 8 hours

- air filter
- winch rope
- hydraulic oil and fuel tank levels
- windscreen wiper liquid level
- engine oil level
- engine radiator coolant level
- tyre pressure
- air tanks bleeding
- block limit stop device
List “B” every 40 hours

- slewing ring rotation
- slewing ring teeth
- telescopic boom and lifting system
- rotation reduction gear
- universal joint transmission
- transmission and converter
- front and rear axles
- engine
- hydraulic oil tank filter
List “C” every 100 hours

- air filter
- parking and service brakes
- tightening and fixing of wheels
- engine / radiator
- suspension and steering
- batteries
List “D” every 250 hours
engine
air filter
transmission and converter winch
gears and reduction gear brakes

И BENDINI
List “E” every 500 hours

- engine
- air dryer
- hydraulic circuit
- air tanks
- general fixing elements
List “F” every 1000 hours

- general fixing elements
- hydraulic circuit
- steering
- electrical system
- rotation reduction gear
- fuel tank
- boom section guide blocks
- winch gears and reduction gear
- braking system
- brakes
List “G” every 2000 hours

- hydraulic oil tank
- brakes
- cooling circuit

m TEREX BENDINI
List “A"- 8 hours

Air filter
Check the air filter every 8 hours.
Clean the intake cap (1), the dust collector (2) and the clogging indicator (3).
Lifting ropes
Visually inspection the suspended rope and inside the lifting winch drum (refer
to the paragraph).
Hydraulic oil tank and fuel tank level
The checks must be carried out with the machine on level ground, all cylinders
retracted, boom retracted in the horizontal position and oil cold.
Check the hydraulic oil level (by means of the special gauge on the tank) and
the fuel level every 8 hours.
DO NOT smoke during fuel tank filling, as the vapours are flammable.

И BENDINI
Windscreen wiper liquid container

Check the windscreen wiper liquid in the tank located in the operator’s cab every
8 hours.
Engine oil level

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

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Engine radiator coolant level.

Open the cover located at the back of the engine hood to access the radiator
cap.
The antifreeze mixture consists of a solution of 34% coolant and 66% water.
Check the coolant level and if necessary add water or antifreeze solution until
the level is 2 cm from the edge of the filler.
Use the type and quality of antifreeze mixture according to the manufacturer’s
instructions; refer to the relevant specifications for further details.
• During filling, take care when handling coolants and oil.
• The components and hot oil can cause burns. Avoid any contact with the
skin.
• Never put cold coolant in an overheated engine.

Always wait for the engine to cool down first.

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Tyre pressures
Adjust the tyre pressures according to that specified on the sticker located in the
cab or in the chart given previously in this manual.
• The pressures specified on the chart in the cab or given previously refer to
cold tyres. Inflation and pressure checks must be carried out on cold tyres.
NEVER inflate hot tyres.
• Only check the tyres without suspended weights on the machine. Always
use a safety cage when the tyre is not fitted on the machine.
• Do not face the tyre. Use a sufficiently long air hose with quick connector for
inflation.
DANGER !! Never drive the machine with inadequately inflated tyres.
Bleeding the air tanks

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

Regularly check that the limit stop device works properly.

ta BENDINI
List “B" - 40 hours

Slewing ring
Using a grease pump and by means of the grease nipples on the slewing ring,
lubricate the ring with sufficient grease (four or five pump strokes).
After lubricating the first grease nipple, turn the slewing ring 90° to distribute the
grease evenly over the entire inside surface.
IMPORTANT: Maximum safety is obtained if this operation is carried out by just

one operator.
Slewing ring teeth

Check slewing ring teeth lubrication every 50 hours.
For good lubrication of the slewing ring and the pinion, grease twice, fully turning
the slewing ring firstly in one direction and then the other.
IMPORTANT: Maximum safety is obtained if this operation is carried out by just

one operator.

И BENDINI
Telescopic boom and lifting system

• Greasing the section telescoping guide blocks.
• Grease the block and boom head sheaves.
• Grease the telescopic boom pivots.
• Grease the boom lifting cylinder.
• Grease the angle indicator pin.
• Check the telescoping chain tension
Visually check the lifting rope.
Rotation reduction gear

Check the reduction unit oil level with the dipstick.
Universal joint transmission

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

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Transmission - Converter unit and powershift

Check the transmission oil level with oil at a temperature of 80° and the engine
idling.
Top-up the oil if necessary.
Carry out the first filter cartridge change.
In any case, refer to the gearbox manufacturer’s technical specifications.
Engine
Carry out the first engine oil change

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Filter on hydraulic oil tank

Keep the clogging manometer under control; when the pressure reaches 2 bars
this means the filter cartridge must be changed.
At the same time clean the hydraulic tank breather.
Front and rear axles Carry out the first oil change.
It is advisable to carry out this operation when the oil is still hot.
The oil must be drained by means of the plug (♦) located at the bottom of the
box and the plug (♦) on the bottom of the reduction unit.
With every check, control the efficiency of the breather (•) situated on the top of
the box, washing it with gas oil and drying with a jet of air.

ta BENDINI
List “C" - 100 hours

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

The cartridge must be changed after six cleanings and in any case once a year.
Always change faulty or doubtful cartridges.
Parking and service brakes

Have a specialized technician check the parking brake and service brake seals.
Wheel tightness
Regularly check the tightness of wheels every 100 hours. Torque wrench setting:
- Front axle 65 daNm
- Rear axle 65 daNm.
Engine and radiator check

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

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

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

ta BENDINI
List “D" -250 hours

Engine
Change the engine oil.
Refer to the manufacturer’s specifications for further details.
Replace the engine oil filter cartridge.
Replace the two fuel filter cartridges.
Check the condition and tension of all engine belts and replace them if
necessary.
Air filter
Clean the cap collector of dust. Check the clogging indicator. Change the air
filter cartridge.

И BENDINI

Check the oil level on the gearbox graduated dipstick.
Check the engine oil level with the oil at a temperature of 80° and the engine
idling.
Change the oil filter cartridge.
Remove the oil filter cartridge, clean the filter support base, oil the seal ring
before fitting the new cartridge.
Tighten the new filter cartridge by hand.
In any case, refer to the gearbox manufacturer’s specifications. technical
Winch gears and reduction unit

Check the oil level and gears inside the winch. Carry out the first oil change, and
subsequently every 1000 hours or at least once a year. Check the main winch
and possible auxiliary winch with the same frequency.
Brakes
Changing the brake oil (when applicable) and filter cartridges.

ш BENDINI
List “E" - 500 hours

Check the oil level on the gearbox graduated dipstick.
Check the engine oil level with the oil at a temperature of 80° and the engine
idling.
Change the oil and the filter cartridge.
Change the filter cartridge at every oil change.
Take every precaution to safeguard the environment.

Make sure that all the oils and liquids used are recovered and correctly recycled;
do not leave such products or containers without the special labels in unsuitable
or open places.
Do not leave residuals of any liquid on the ground or floor.
Engine
Check the alternator and starter motor, adjust the valve clearances and check
the injectors.

И BENDINI
Compressed air dryer

Change the cartridge of the dryer located under the metal cover.
It is advisable to disconnect the batteries before changing the cartridge.
Front and rear axles

Check the brakes.
Lubricate all connections.
Clean and lubricate the wheel hubs.
Check the oil level of the reduction units and axle casings.
Moderately grease all the steering joints (pins, joints, knuckles).

ta BENDINI
Hydraulic circuit
Change the hydraulic circuit filter.
Lubricate the filter seal table before replacing.
Check for any leaks in the hydraulic circuit; in case of leaks, replace the
damaged parts.
Air tanks
Clean the air tank automatic breathers.
Check all the fixing elements

Check the fixing of:
- counterweight bolts
- winch bolts
- slewing ring bolts
- rotation reduction unit bolts
- axle bolts
- engine / gearbox and converter bolts
For the torque settings of the various screws, see the chart given previously in
this manual.
Steering
Check the tightness of all steering screws and all components (steering wheel,
steering column, steering box, levers and connecting rods).
Make sure there are no hydraulic leaks in the power steering unit.

И BENDINI
List "F” - 1000 hours

Check all fixing elements
Check the fixing of:

- counterweight bolts
- winch bolts
- turntable bolts
- rotation reduction unit bolts
- axle bolts
- engine / gearbox and converter bolts
hydraulic circuit
Check for any leaks in the hydraulic circuit; in case of leaks, replace the
damaged components.
Steering
Check the tightness of all steering screws and all components (steering wheel,
steering column, steering box, levers and connecting rods).
Make sure there are no hydraulic leaks in the power steering unit.
Electrical system
Check the wiring and relevant fixing elements.
Rotation reduction gear

Change the reduction unit oil every 1000 hours.
Fuel tank
Remove any water or condensation from the fuel tank by means of the plug
located under the tank.

ta BENDINI
Front and rear axles

Change the transmission and gearbox oil.
It is advisable to carry out this operation when the oil is still hot.
The oil must be drained by means of the plug (♦) located on the bottom of the
box and the plug (♦) on the bottom of the reduction unit.
♦
At every control, check the efficiency of the (•) breather situated on the top of the
box, washing it with gas oil and drying with a jet of air.
Boom section guide blocks

Check the boom telescopic section guide blocks.
Check the tightness of the guide block and support fixing screws. Check the
boom sheaves.
Winch gears and reduction gear

Change the winch reduction unit and internal gear oil. Change the oil every 1000
hours or at least once a year.
Change the oil with the same frequency as for the main winch and possible
auxiliary winch.

И BENDINI

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

do not leave such products or containers without special labels in unsuitable or
open places.
Do not leave residuals of any liquids on the ground or floor.
Braking system
Check the brake cylinder fixing elements.
Check the brake circuit lines and replace them if necessary.
Brakes
Change the brake fluid (when applicable) and the filter cartridges.

ta BENDINI
List “G" - 2000 hours

Hydraulic oil tank
Change all the oil in the tank.
Change the oil filter.
Change the oil after 2000 hours or at least once a year

Changing the hydraulic circuit oil consists of methodically draining the
oil tank, pumps, cylinders, cooling radiators.

open places.
Brakes
Change the brake fluid (when applicable) and the filter cartridges.
Replace the brake circuit lines every 2000 hours or once a year.

И BENDINI
Cooling circuit
Change the radiator coolant every 2000 hours or at least once a year.
- Make sure the engine is not hot and that the coolant is at ambient
temperature.
- Remove the filler cap (A), undo the plug at the bottom of the radiator (C)
and drain the coolant.
- Refit the plug on the bottom of the radiator.
To refill the circuit:

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

Make sure that all the oils and liquids used are recovered and correctly
recycled; do not leave such products or containers without special
labels in unsuitable or open places.

ta BENDINI
Maintenance handbook
General
Periodical maintenance is required.
The hour-meter on your machine tell you when maintenance operations should
be carried out.
During the various lubrication operations, check the seals and replace them in
case of doubt.

open places.
Do not leave residuals of any liquids on the ground or floor at the end of any
maintenance.
The handbook is a guide for preventive maintenance until experience allows the
definition of a schedule according to the particular operating conditions.
The maintenance intervals given have been established to allow daily, weekly
and yearly checks.
The maintenance handbook can be photocopied when necessary. Persons

performing maintenance operations must fill out the forms given below so that
the machine can be checked during subsequent maintenance.
The completed maintenance lists form documents attached to the

machine.
IMPORTANT: For carrying out maintenance operations the machine

MUST be stabilized on fully extended outriggers on firm, flat and
level ground.

И BENDINI
Company........................................................
Address:..........................................................
Person in charge:..............................................
Reference list: “............” Hours of work:
Maintenance points:
Date.........../........./............... Signature.

ta BENDINI
Company........................................................
Address:..........................................................
Person in charge:..............................................
Maintenance points:
Date.........../........./............... Signature.

И BENDINI
Company........................................................
Address:..........................................................
Person in charge:..............................................
Maintenance points:
Date.........../........./............... Signature.

ta BENDINI
Company........................................................
Address:..........................................................
Person in charge:..........................................
Maintenance points:
Date.........../........./............... Signature.

И BENDINI
Company........................................................
Address:..........................................................
Person in charge:..........................................
Maintenance points:
Date.........../........./............... Signature.

ta BENDINI
Company........................................................
Address:..........................................................
Person in charge:..........................................
Maintenance points:
Date.........../........./............... Signature.

И BENDINI
Company........................................................
Address:..........................................................
Person in charge:..........................................
Maintenance points:
Date.........../........./............... Signature.

ta BENDINI
Company........................................................
Address:..........................................................
Person in charge:..............................................
Maintenance points:
Date.........../........./............... Signature.

И BENDINI
Company........................................................
Address:..........................................................
Person in charge:..............................................
Maintenance points:
Date.........../........./............... Signature.

ta BENDINI
Company........................................................
Address:..........................................................
Person in charge:..........................................
Maintenance points:
Date.........../........./............... Signature.

■ [31
i Г™
A
■
ЩУЗ \z T0* x
USER MANUAL
LTB1 Code Ballast Jib Angle IJib Length
C71_1: BOOM ON OUTRIGGERS 300 25 6,3
Length 9,4 19,5 24,7 28 9 30,4
19
4,3 05
62.4 32 20
3,5 58.4 27,45 69.8 20 35 75,9
54.1 24.4 67,4 20.75 74,5 18.45 76
4,5 495 21 ,8 65,2 212 73,1 18.7 75,2 14.5
45 19.4 62.8 19,3 17,3 143
33.4 155 58 14.75 68,6 13.45 12,35 77 2 10 78.2
19.1 115 53 65,2 10,9 10,1 75 2 9,55 76.4 8 85
47.7 9.4 61.7 9 05 69,2 8.5 73 2 8,05 74.5 7.9
19 41.8 7.65 57.8 7.7 67,9 7.25 712 69 72.5 6,8
19 10 35 6.4 53,7 6.45 64,4 6.25 69 70.4 5.9
21 11 24,7 5.4 49.4 61 ,8 66 8 5,25 68.2
5,4 5.4 5,15
22 12 4.65 43 4.7 59 4.75 64,4 46 65.8 4 55
23 13 40.4 05 3 55,8 4.1 62 63.4 4 05
24 14 35.6 52,6 3.6 59 , 61
55 3 4 57 36 3,6
25 15 30.6 05 3.1 3,1 59.5 3.1
16 54 2
26 23.7 2,75 45 2.75 51 , 28 55.6 2,8
27 17 12.9 40, 2.4 2,4 53
18 2 35 4 48 2,4
23 8 15 6 45 22 50.1 2.2
19 1,95
29 13 1,95 8 42 47.2 195
21 8 40 44.2
31 22 15 43.3
32 23 1,35 37.8
33 24 312 12 33.8
34 25 26 1,05 29,2 1 ,
35 26 192 0,9 24 05
36 27 0,8 18 0,9
37 23 0,5 08
29
2
INDEX
What the load moment indicator does? Pag.
LOAD MONITORING INDICATOR (LMI) FUNCTIONAL DESCRIPTION 3
Which components are included in an LMI?

SYSTEM LAY-OUT AND CONNECTIONS 4-7
How is the LMI installed on the machine?

COMPONENTS LOCATION ON THE MACHINE 8
What’s the need of the control panel?

CONTROL PANEL DESCRIPTION 9
What’s does it happen when starting the machine?

SWITCHING THE MACHINE ON 10
Is the control panel informing about safety on the machine?

PANEL MONITORING
- Lifting conditions % and alarms 11
Is the control panel giving useful information to work?
PANEL MONITORING
- Main working data reading on the display 12 , 13
Is the control panel giving useful information to work?
PANEL MONITORING
- Main working data reading through graphics 14
Can the control panel give further useful information regarding the machine?
PANEL SCREENS
- Complementary reading related to the machine functioning 15
How to select the Operating Mode?
SELECTING THE OPERATING MODE
- Operating mode set up 16
How con I select the rope number (tackle) ?

PART OF LINES SETTING UP 17
Can the LMI detect faults?

AUTO-DIAGNOSTIC 18
How the fault shows up?

ALARM CODES AND ACTIONS TO TAKE 19,20
Appendix
WORKING SPACE LIMITATION
- i.s.a.c. (interactive space automatic control) 21
- MAX Angle Setting 22
- MAX Height setting 23
- MAX Radius setting 24
- WALL (Working Area LimitingLink) limit setting 25
- SET POINT 1 (ONE) 26
- SET POINT 2 (TWO) 27,28
What should be known before starting the machine?
WARNINGS 29 , 30
What the load moment indicator does ? 3
The LMI aim is to control that the machine doesn’t

exceed working condition limits, making the Operator
aware and acting through alarms and shut-down of
dangerous movements.
LOAD MONITORING INDICATOR (LMI)

FUNCTIONAL DESCRIPTION
Working condition Load Tables storage, comparing Data display and setting
measurements and processing
CONTROL PANEL
PRESSURE
TRANSDUCERS
(Lifted load)
TEREXr
READINGS :
% Tilting Lifted
load Maximum
load
- Working radius
(outreach)
- Boom length
- Boom angle
Operating mode
Attachment used
- Diagnostic
LENGTH AND
ANGLE SENSOR ALARMS:
(Boom Geometric Green/Amber/Red lights
data )
MANUAL SELECTIONS:
- Main Boom
AUTOMATIC Automatic functions - Jib
SELECTIONS External alarm and automatic shut-down - Counter Weight
from micro-switches: - Part of Lines
- Turret rotation - Tyres
- Anti two block
Ref. Which components are included in an LMI? 4
Description Code
Main unit U2MIC-X/XX
1 It’s a system including sensors able to detect lifted load,
2 Control panel boom position, a main unit and a control panel situated
CMC1-XXX/XX
inside at the cabin.
3 Cable reel AC MCP214A/3P
4 Pressure transducer Y11 4745-350
5 Cable
SYSTEM LAY-OUT MEGAMAC.106
CV 4x0.5+SCH
6 Cable AND CONNECTIONS

CV 8x0.35+SCH
7 Cable CV ATG12/XX
Ref. Which components are included in an LMI? 5
Description Code
Main unit
1 It’s a system includingU2MIC-X/XX
sensors able to detect lifted load,
2 Control panel boom position, a mainCMC100-XX/XX
unit and a control panel situated
inside at the cabin.
5 Cable
SYSTEM LAY-OUT MEGAMAC.HC118
CV 4x0.5+SCH
6 Cable AND CONNECTIONS
CV 8x0.35+SCH
7 Cable CV ATG12/XX
Ref. Description Code
1 Main unit U2MIC-X/XX
2 Control panel CMC100-XX/XX
3 Cable reel ACT11AS100/XX

6 Cable CV 4x0.5+SCH
7 Cable CV ATG12/XX
Ref. Description Code
1 Main unit U2MIC-X/XX
2 Control panel CMC100-XX/XX

4 Cable reel ACT10AE100/XX
7 Cable CV ATG12/XX
9 Encoder CANBUS Y11 BMMH42S1N

How is the LMI installed on the machine? 8
The sensors are positioned on the boom and cylinders in

order to detect data when working, while the main unit and
the control panel are located inside the cabin.
COMPONENTS LOCATION ON THE MACHINE
Length sensor Used in

case of boom
indipendent sections
\/ T^Nr2 Pressure
Transducers:
On the lifting cylinder.
d and bottom side
Main Unit
9
What’s the need of the control panel?
It gives to the operator all information in order to work in

safe conditions and allows proper setting.
CONTROL PANEL DESCRIPTION
1 Working data display;

5 GREEN Button/lamp : if pressed, it allows the operator to scroll the pages
lit = safety
5 AMBER Button/lamp :The lamp lit indicates that the load has reached the pre-alarm
condition. Pressing the button, the buzzer will stop.
7 RED Button/lamp :The lamp lit indicates that the load has reached the maximum load
allowed and the shut off has been performed;
The flashing light indicates that the machine is in shut
down
procedures and the by pass key is activated.
8 The button can also used to confirm a selection.
9 Operating mode selection key: press to increase operating mode value;
10 Operating mode selection key: press to decrease operating mode value;
Rope number ( tackle ) selection key: press as many times as necessary to obtain the required
11 value in order to achieve a correct load reading;
Key to exclude the manoeuvre block
Note : The function of the unstable key with return spring consists on disable the automatic
alarm
function of the safety system.
12 Only the authorised staff can use the key to by-pass the safety system. In case of improper use,
the safety equipment and the crane manufacturer are relieved of any responsibility.
Buzzer ( positioned on the rear panel ) :
Intermittent beeping = prealarm condition;
What does it happen when starting the machine? 10
The system gets activated and automatically proceeds to

its self test mode giving information to the Operator.
SWITCHING THE MACHINE ON
Starting the system the display shows the last operating mode setted prior to the system
switching off.
During this phase, the system performs the self test and automatically puts itself in shut off
condition. If the machine operating mode is correct, please confirm by pressing the red button.
If the operator needs to change the operating mode, please refer to the instruction reported on
page 16 “HOW TO SELECT THE OPERATING MODE”
Is the control panel informing about safety on the machine? 11
Yes! It has been designed and its main scope is to check

the machine working conditions, comparing them to the
limits given by the load Tables previously memorised.
PANEL MONITORING
- Lifting Conditions % and alarms
1) LCD bar showing the percentage of the load lifted at this moment.
2) Green reference Safe Zone.
Alarm Zone.
3) Amber reference (Lifted load higher than 90% of maximum admitted load).
Shut-off Zone
4) Red reference (Lifted load higher than 100% of maximum admitted load).
Safe Working
5) Green light on
Alarm (Buzzer activated = intermittent)
6) Amber light on
Dangerous movements shut off
7) Red light on
(Buzzer activated = continuous)
Is the control panel giving useful information to work? 12
Yes! It shows on the display all data related to the lifted

load and the boom position
PANEL MONITORING
-Main Working Data Reading on the display
7.2) LIFTED LOAD

Reading in “Tonnes” or “Lbs”, with a decimal point
7.3) MAXIMUM ADMITTED LOAD (According to the selected load table) Reading
in “Tonnes” or “Lbs”, with a decimal point
7.4) WORKING RADIUS
Reading in “Metres” or “Feet”, with a decimal point
7.5) MAIN BOOM ANGLE

Reading in “Degrees”
7.6) BOOM LENGTH
Reading in “Meters” or “Feet”, with a decimal point.
7.7) HEIGHT FROM GROUND
Reading in “Meters” or “Feet”, with a decimal point.
Note: Imperial and U.S. readings are optional and selectable by parameter.

load and the boom position
PANEL MONITORING
-Main Working Data Reading on the display
7.8) WRITTEN TEXT

The following information are displayed : the % of boom length or boom sections, the stowed
jib, alarms and warning messages, operating mode during selection procedures. This written
message appears after the operating mode has been selected.
(Please refer to “SWITCHING THE MACHINE ON section on ” Pag.10 and “SELECTING THE
OPERATING MODE ’’section on Pag.16)
1.8a) BOOM SINGLE ELEMENT EXTENSION PERCENTAGE
(0% = element completely closed; 100% = element completely extended).
1.9a) OPERATING MODE SELECTED CODE: Corresponds to the load charts table which must be
selected related to the crane configuration.
1.9b) PART OF LINES manually selectable.
1.9c) JIB LENGTH : Corresponds to the jib’s extension related to the table chart selected 1.9d)
JIB OFFSET : Corresponds to the jib’s offset referred to the table chart selected 1.9e)
COUNTERWEIGHT VALUE : Indicates the counterweight value referred to the table chart
selected

load and the boom position through graphic.
PANEL MONITORING
- Main working data reading through graphics
By pressing the green button, it’s possible to visualize the working data through graphics.
1.1) LCD bar showing the percentage of the load lifted at this moment.
1.2) LIFTED LOAD Reading in "Tonnes” or "Lbs”, with a decimal point
1.3) MAXIMUM ADMITTED LOAD
According to the selected load table Reading in "Tonnes” or "Lbs”, with a decimal point
1.4) WORKING RADIUS Reading in "Metres” or "Feet”, with a decimal point
1.5) MAIN BOOM ANGLE Reading in "Degrees”
1.6) BOOM LENGTH. Reading in "Metres” or "Feet”, with a decimal point
1.7) HEIGHT FROM GROUND Reading in "Metres” or "Feet”, with a decimal point
1.9a) OPERATING MODE SELECTED CODE:
Corresponds to the load charts table which must be selected related to the crane configuration.
1.9b) PART OF LINES manually selectable.
1.9c) JIB LENGTH : Corresponds to the jib’s extension related to the table chart selected 1.9d)
JIB ANGLE : Corresponds to the jib’s angle referred to the table chart selected 1.9e)
COUNTERWEIGHT VALUE : Indicates the counterweight value referred to the table chart
selected
Can the control panel give further useful 15
information regarding the machine?
Yes, through the graphic display, showing

complementary reading related to the machine.
PANEL SCREENS
-Complementary reading related to the machine
functioning
The further information displayed on the panel (zone 1.8) are the following :
1)
WA ANTI TWO BLOCK ALARM
I 1.8
This message appears when the Anti two block alarm is activated.
1.8
2)
This message appears when the lifted load has overtaken the maximum load allowed
referring to the load charts table.
1.8
3)
This message appears when the load lifted overtakes the maximum load allowed on the
single rope.
How to select the Operating Mode ? 16
Simply pushing two buttons on the control panel.
SELECTING THE OPERATING MODE

- Operating mode set
To change the crane operating mode, please refer to the following instructions:
• Press the button 8 or 9, on the display appears the description (zone1.8) and the
code (zone1-9a) of the operating mode used.
• Press once again the button 8 (to increase) or 9 (to decrease) until the display will
show the description (Zone 1.8) and the code (Zone 1.9a) of the correct operating
mode.
Please refer to the load charts table supplied by the manufacturer for the Operating Mode
list.
• Press the red button (7) to confirm the selection
NOTE :It’s not possible to change an Operating Mode when a load is applied.
How can I select the rope number (tackle)? 17
%
_
ih .2 ! 1 3.4
Simply pushing two buttons on the control panel.
7 9.2Ц240Н 12 3
-
\ r"i - II % 50 III - % 50 ^
K 202 2
0 0 38_________
8 ROPE NUMBER (TACKLE) SETTING UP

9 10 7
LINES OF ROPE SETTING UP
It’s necessary to set the line of ropes value

every time that the winch rope’s number
changes.
WARNING :
A miscalculation of the lines of rope, could
lead to danger situation
1.8
To modify the line of rope, please proceed as
follows:
Press the button 10 until on the display

(zone 1.8) the description of load table in use
is shown.
Press button 8 to increase or 9 to decrease

the number of rope lines.
Press red button (7) to confirm

proper setting.
NOTE : If the load on the rope is higher than the

single rope maximum admitted load, the
system puts itself in alarm conditon and a
message will appear.
Can the LMI detect faults? 18
Of course. To be considered a reliable system, it must be

able to perform self-check in order to detect internal or
components faults.
AUTO-DIAGNOSTIC
The LMI is equipped of an auto diagnostic system which is able to detect faulty pressure
transducers, or boom angle/length sensors, broken cables or internal electronic faults. When
an alarm occurs, the LMI puts itself in a safe condition stopping the dangerous movements and
at the same time the display shows an alarm message ( zone 1.8). According to alarm code
and message, it will be possible to identify the fault.
The codes are reported in the following list, that also includes some hints to solve the problem
and get back to normal working conditions.
Alarm
Description What to do
code
• Switch the system off and on.

Memory data not If the alarm persists, please, contact Technical Assistance to:
56
reliable •Verify that E2prom chip is fitted properly in its socket.
• Re-enter data and save them again
• Replace the E2PROM chip and recalibrate the machine
Angle sensor reading

15 lower than the • Verify that the wiring and the connectors are not in short circuit.
minimum value If the alarm persists, please, contact Technical Assistance :
• Verify the angle sensor integrity.
25
Angle sensor reading •Verify that the cable or the connector wiring is not open If the
higher than the alarm persists, please, contact Technical Assistance : • Verify the
maximum value angle sensor integrity.
Pressure reading of • Verify that the cable or the connectors wiring are not in short
12 the main cylinder circuit
(bottom side) lower If the alarm persists, please, contact Technical Assistance :
than the minimum. • Verify the pressure transducer integrity
22
Pressure reading of • Verify that the cable or the connector wiring are not open If the
the main cylinder alarm persists, please, contact Technical Assistance : •Verify the
(bottom side) higher pressure transducer integrity
than the maximum.
Pressure reading of
13 the main cylinder (rod •Verify that the wiring and the connectors are not in short circuit
side) lower than the If the alarm persists, please, contact Technical Assistance :
minimum. •Verify the pressure transducer integrity
Pressure reading
pressure of the main • Verify that the cable or the connector wiring are not open If the
23 cylinder (rod side) alarm persists, please, contact Technical Assistance : •Verify the
higher than the pressure transducer integrity
maximum.
Boom length sensor • Verify that the wiring and the connectors are not in short circuit
total reading lower If the alarm persists, please, contact Technical Assistance: Verify
11 than the minimum the length transducer integrity
value
Alarm
code Description What to do
Boom length sensor total

21 reading higher than the • Verify that the cable or the connector wiring is not open
If the alarm persists, please, contact Technical Assistance
maximum value :
• Verify the length transducer integrity
E01 The boom’s angle has
RADIUS overtaken the maximum • Lower the boom
MIN value
This message appears

E02 when the boom is •Lift or close the crane boom until a load chart table can
RADIUS
positioned in a way that,
MAX be applied.
referring to the load
charts, there isn’t any load
charts table applicable
Table charts not

18 •Please, select the operating mode in use and confirm it.
available..
The operating condition
selection is missing
Group
20 Alarm.Configuration •Please, select the operating mode in use and confirm it.
errore
Boom length sensor 1 • Verify that the wiring and the connectors are not in short
6 reading lower than the circuit
If the alarm persists, please, contact Technical
minimum value
Assistance:
Verify the length transducer integrity
7
Boom length sensor 1
reading higher than the • Verify that the cable or the connector wiring is not open
If the alarm persists, please, contact Technical Assistance
maximum value :
• Verify the length transducer integrity
NOTE: The code of the alarms can change in case of particular functions or client needs
Appendix 21
Working Area Limiting Link: (option)

i.s.a.a.c. (interactive space advanced automatic control)
MEGAMAC HC is equipped with Working area limitation software. To access “isaac” menu,
press and release the green pushbutton button until the following page is shown.
Welcome to ISAAC. The 3B6 working area limiting system.

Isaac is a graphic interface, which helps the operator set restricted working area limits for the
machine. Working area limits are set by means of a self learning procedure using text and
graphic symbols.
In the upper part of the display, graphic information (1) will be indicated, in the lower part of the
display, 3 icons represent the actual function of the 3 input buttons (2).
The pushbuttons are multi-function, depending on the page of the interactive menu.
❖ to confirm and store the actual turret position.
erase previous stored values. This button also restores full machine operations.
access to next page within isaac
return to main system menu

Appendix 22

MAX Angle Setting:

Press and release the red pushbutton to access the following menu:
1) Graphic zone: the black area indicates the restricted working area (non-working area for
the boom). Blinking arrow indicates the limited movement
2)
Actual Boom angle (degrees)
3)
Push button function
4)
Text line: indicates the actual stored allowed angle. (999 means no limitation)
5)
Actual Boom angle (degrees)
6)
Boom height (meters, 1 decimal) (feet/tenths)
7)
Radius (meters, 1 decimal) (feet/tenths)
8)
Warning: it is activated when the boom reaches the maximum allowed angle. When the
maximum angle is reached, the movement is automatically stopped and the red light is
illuminated at the same time with the “STOP” symbol
How to store max angle:

■ Raise (or lower) the boom to the required maximum position.
■ Press and release the green button J .
■ In the text line [4] you will see the blocking angle value in tenth of degrees
■ To cancel the stored value, press and release the yellow pushbutton ^6Л , the
value in the line [4] will be set default to 999 (no angle limit).
Appendix 23

MAX Height setting:

У.О-.Лt C
ISO
1) Graphic zone: the black area indicates the restricted working area (non-working area
for the boom). Blinking arrow indicates the limited movement
2)
Actual Boom height (meters, 1 decimal) (feet/tenths)
3)
4)
Text line: indicates the actual stored allowed angle. (999 means no limitation)
5)
Actual Boom height (degrees)
6)
Height of the head of the boom (meters, 1 decimal) (feet/tenths)
7)
8)
Warning: it is activated when the boom reaches the maximum allowed height. When
the maximum height is reached, the movement is automatically stopped and the red
light is illuminated at the same time with the “STOP” symbol
How to store max height:

• Raise (or lower) the boom to the required maximum position.
• Press and release the green pushbutton l .
• In the text line [4] you will see the blocking height value in meters plus one
decimal.
To cancel the stored value, press and release the yellow pushbutton
the value in the line [4] will be set to 9999 (no height limit).
Appendix 24

MAX Radius setting:
*гЛ,Л 0
1) Graphic zone: the black area indicates the restricted working area (non-working area
for the boom). Blinking arrow indicates the limited movement
2)
Actual radius (meters, 1 decimal.) (feet/tenths)
3)
4)
Text line: it indicates the actual stored allowed radius. (999 means no limitation)
5)
Actual radius (meters, 1 decimal) (feet/tenths)
6)
Boom height (meters, 1 decimal) (feet/tenths)
7)
8)
Warning: it is activated when the boom reaches the maximum allowed radius. When
the maximum radius is reached, the movement is automatically stopped and the red
light is illuminated at the same time with the “STOP” symbol
How to store max angle:

• Raise or lower the boom to the required maximum position.
• Press and release the green pushbutton T .
In the text line [4] you will see the blocking radius value in meters and one decimal.
\Л, /
To cancel the stored value, press and release the yellow pushbutton д the
value in the line [4] will be set to 9999 (no radius limit).
Appendix 25

WALL limit setting.
MEGAMAC HC calculates working area limitation using “virtual wall” concept. It stops the
movement according to a “virtual wall” delimited by 2 preset points In order to enable “virtual
wall” limitation, 2 input points are required by the self learning procedure: MEGAMAC will
automatically limit lowering, lifting telescoping and rotating movements according to “virtual
wall” operation.
To set working area limits:

1) Select point number 1
2) Rotate the turret clockwise
3) Select point number 2
We have defined a “restricted” area, which will not allow the boom to move while the turret
brake stops the movement.
External area to the wall is allowed.
Appendix 26

SET POINT 1 (ONE)

Press and release the red pushbutton to access to the following menu:
This menu sets the max CCW point (point one) of the WALL.
1) Graphic zone: the black area indicates the restricted working area (non-working area for the
boom). Blinking arrow indicates the limited movement
2) Push button functions
3) Text line: indicates the first angle of the area, normally “0”.
4) Actual angle (degrees)
5) Boom height (meters, 1 decimal) (feet/tenths)
6) Radius (meters, 1 decimal) (feet/tenths)
7) Warning: it is activated when the boom reaches the maximum allowed radius. When the
maximum radius is reached, the movement is automatically stopped and the red light is
illuminated at the same time with the “STOP” symbol
How to store point 1 (one):

• Rotate the turret in the counterclockwise direction and position the hook
•
to the 1st point (radius set).
Press and release the green pushbutton T
• In the text line (3) you will see 0, as departure point. This value is expressed in
degrees.
Appendix 27

SET POINT 2 (TWO)
Press and release the green pushbutton T to access to the following menu:
This menu sets the max CW point (point two) of the WALL.
How to store point 2 (two):

■ Rotate the turret in the max CW position allowed, position the hook to the second point
(radius set).
Press and release the green button T .
In the text line (3) you will see a certain value, in degrees that is the maximum
rotation angle allowed, as final point. This value is expressed in degrees/
As soon as point 2 is confirmed, the page changes in:

Appendix 28

1) Rotation angle (degrees)

2) Operative angle limits, exceeding these values, the WALL is active. To
continue to rotate in the same direction a reduction of the radius is required,
as a virtual wall is installed in the operative area.
What should be known before starting the machine? 29
All the recommendations and rules from the Manufacturer

to work wisely and consciously in any time and situation
WARNINGS
• The LMI is an electronic device with the aim to help the operator in the
current use of the machine, warning him by means of visual and acoustic
signals while approaching dangerous conditions.
• However this device can’t replace the operator good experience in the
safe use of the machine.
• The responsibility of the operations in safe conditions of the machine is
the operator concern as well as the accomplishment of all prescribed
safety rules
• The Operator must be able to detect if the data given by the LMI are
correct and correspond to actual working conditions.
• He must be able to utilise the data given by the LMI in order to operate in
safe conditions in any time.
• The LMI is an electronic device including several sensing components,
therefore it can be subject to failures or defects.
• The operator must recognise these events and he must take action ( to
proceed to repair if possible or to call Assistance).
• Before starting the operations with the machine, the user must fully read
this manual and follow the instructions at any time.
All the recommendations and rules from the

Manufacturer to work wisely and consciously in any time
• The LMI is supplied with a key for shut-down function by-passing.
• In normal working operations, this key must be positioned not to by-pass shut-down..
• It’s forbidden to use the key to lift loads exceeding the loads values allowed by the Manufacturer.
• The key can be used only when an emergency/malfunctioning occurs or a situation justifying its
use.
• Only Authorised Personnel is allowed to the use of the key; they are also responsible for it.
• The LMI has a powerful FAIL-SAFE auto diagnosis program suitable to verify its good operations
and the one of its transducers.
In case a trouble has been detected, the LMI puts itself in a safe state by stopping the
manoeuvres (please see the AUTODIAGNOSTIC chapter).
• In spite of this, the Operator, before starting the operation with the machine, must take care that
the LMI is working correctly.
To do this, he must verify the validity of the displayed values by doing some tests.
He must verify that there are not messages or alarm indications; he must verify the correct
operation of the manoeuvre stopping functions.
• The operator is responsible for the correct setting of the machine load table and therefore for the
right LMI set.
When switching-on the machine the last selected Table is kept valid, to allow Operator check.
• About this, please follow the instructions given in the OPERATING MODE SELECTION chapter.
An incorrect setting of the tables, can cause an incorrect LMI operation and therefore can provoke
a dangerous situation for the machine.
Generally, it’s compulsory to follow the Manufacturer instructions and

procedures at any time.
Appendix 28

1) Rotation angle (degrees)

2) Operative angle limits, exceeding these values, the WALL is active. To
continue to rotate in the same direction a reduction of the radius is required,
as a virtual wall is installed in the operative area.
All the recommendations and rules from the

Manufacturer to work wisely and consciously in any time
• The LMI is supplied with a key for shut-down function by-passing.
• In normal working operations, this key must be positioned not to by-pass shut-down..
• It’s forbidden to use the key to lift loads exceeding the loads values allowed by the Manufacturer.
• The key can be used only when an emergency/malfunctioning occurs or a situation justifying its
use.
• Only Authorised Personnel is allowed to the use of the key; they are also responsible for it.
• The LMI has a powerful FAIL-SAFE auto diagnosis program suitable to verify its good operations
and the one of its transducers.
In case a trouble has been detected, the LMI puts itself in a safe state by stopping the
manoeuvres (please see the AUTODIAGNOSTIC chapter).
• In spite of this, the Operator, before starting the operation with the machine, must take care that
the LMI is working correctly.
To do this, he must verify the validity of the displayed values by doing some tests.
He must verify that there are not messages or alarm indications; he must verify the correct
operation of the manoeuvre stopping functions.
• The operator is responsible for the correct setting of the machine load table and therefore for the
right LMI set.
When switching-on the machine the last selected Table is kept valid, to allow Operator check.
• About this, please follow the instructions given in the OPERATING MODE SELECTION chapter.
An incorrect setting of the tables, can cause an incorrect LMI operation and therefore can provoke
a dangerous situation for the machine.
Generally, it’s compulsory to follow the Manufacturer instructions and

procedures at any time.
General Information
□
Important Notes 2 PAT
System Description 3
Configuration Setup
DS 160 /0005
Pre-operation Inspection5
Service and Maintenance 6
Load Moment Contents
Indicator
Troubleshooting
Appendix
Operator's Manual
Issue 1/2003 Rev. B
This document has the order no. 50

160 19 0005E - 416607
PAT
CONTENTS
1. General Information................................................................3
2. Warnings..................................................................................4
3. System Description.................................................................5
3.1 System functions....................................................................6
3.2 Operator’s console..................................................................7
3.3 Control identification..............................................................8
4. Configuration setup..............................................................16
4.1 LMI Setup procedure.............................................................16
4.1.1 Operating mode selection...................................................17
4.1.2 Reeving selection (parts of line).........................................18
5. Pre-Operation Inspection......................................................19
5.1 Operation...............................................................................20
6. Service and Maintenance.....................................................21
7. Troubleshooting....................................................................22
7.1 General...................................................................................22
7.2 Error code list........................................................................23
Appendix: Important Notes ..........................................................29
The information in this document is subject to change without notice. PAT makes no warranty of any kind with regard to this
material, including, but not limeted to the implied warranties of merchantability and fitness for a particular purpose. PAT shall
not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing, per-
formance, or use of this manual. This document contains proprietary information which is protected by copyright. All rights
reserved. No part of this document may be photocopied, reproduced, or translated to another language without the prior
written consent of PAT.
© 2003 PAT GmbH ■ D-76275 Ettlingen ■ Hertzstr. 32 - 34 ■ Ф ++49 (0) 7243 709-0 ■ FAX ++49 (0) 7243 709-222 ■ Email: pat.ettlingen@pat-group.net 2
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
System description
PAT
1. General Information
This manual describes the function, operation and maintenance of the PAT DS 160 Load Moment 1 Indicator
(LMI).
The DS 160 LMI has been designed to provide the crane operator with the essential information required to
operate the machine within its design parameters. The LMI provides the operator with infor mation
regarding the length and angle of the boom, working radius, rated load and the total calculated weight
being lifted by the crane.
The DS 160 LMI basically consists of a central microprocessor unit, operator’s console, length and angle
sensors, pressure transducer sensors and anti-two block switch(es). The system operates on the principle
of reference/real comparison. The real value, resulting from the load measurement is compared with the
reference data, stored in the central processor memory and evaluated in the microprocessor. If non
permitted conditions are approached, the DS 160 LMI will warn the operator by sounding an audible alarm,
lighting a warning light and locking out those functions that may aggravate or worsen the crane’s condition.
1
LOAD MOMENT: generally the product of a force and its moment arm; specifically, the product of the load and the load- radius.
Used in the determination of the lifting capacity of a crane.
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
PAT
2. WARNINGS
The LMI is an operational aid which warns a crane operator of approaching overload conditions which
could cause damage to equipment and personnel.
The device is not, and shall not, be a substitute for good operator judgment, experience and use of
accepted safe crane operating procedures.
A CAUTION
The responsibility for the safe operation of the loader shall remain with the operator who
shall ensure that all warnings and instructions supplied are fully understood and observed.
Prior to operating the crane, the operator must carefully and thoroughly read and under-
stand the information in this manual to ensure that he knows the operation and limitations
of the indicator and crane.
Proper functioning depends upon proper daily inspection and observance of the operating
instructions set forth in this manual. Refer to Section 6. Pre-Operation Inspection and Cali-
bration Verification of this handbook.
A WARNING
The LMI can only work correctly, if all adjustments have been properly set. For correct ad-
justment, the operator has to answer thoroughly and correctly all questions asked during
the setup procedure in accordance with the real rigging state of the crane. To prevent mate-
rial damage and serious or even fatal accidents, the correct adjustment of the LMI has to be
ensured before starting the crane operation.
Always refer to operational instructions and load charts provided by the crane manufacturer
for specific crane operation and load limits.
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
PAT
3. SYSTEM DESCRIPTION
The PAT Load Moment Indicator DS 160 consists of a central microprocessor unit, operating console,
length/angle sensors, pressure transducers, and anti-two block switch(es).
Fig. 1: Components of the LMI System PAT DS 160
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
PAT
The system operates on the principle of reference/real comparison. The real value, resulting from the load
measurement is compared with the reference data, stored in the central processor memory and evaluated
in the microprocessor. When limits are reached, an overload warning signal is generated at the operator’s
console. At the same time, the crane functions, such as hoist up and boom down, will be stopped.
The fixed data regarding the crane, such as capacity charts, boom weights, centers of gravity and
dimensions are stored in memory chips in the central processor unit. This data is the reference information
used to calculate the operating conditions.
The length/angle sensors inside the cable reel, which is mounted on the boom, measure the boom length
and angle. The boom length is measured by the cable reel cable that also serves as an electrical conductor
for the anti two-block switches.
The crane load is measured by pressure transducers attached to the piston and rod sides of the hoist
cylinders.
3.1 System functions
Upon switching on crane ignition switch, the system starts

with an automatic test of the LMI system, of lamps and audi-
ble alarm. During this test, the LC display shows the test
screen. After finishing the test, the start screen is displayed.
S YS T E M T E ST
88888888888888888888
Test Screen
[CRANE MANUFACTURER] [CRANE
TYPE] S/N [SERIAL NO]

Start Screen
[SYS Software] [CON Software]
Then the last selected operating mode will be displayed and

must only be confirmed OK if that configuration setup equals
the crane’s actual configuration. Otherwise it must be deleted
to enter a new configuration. (refer to chapter 4)
The operating configuration is determined by selecting from a
list of possible operating configurations. (refer to chapter 4)
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PAT
3.2 Operator’s console

The console has two functions:
• inputs by the crane operator (operating configuration, reeving, and calibration)
• display of important data and information
The operator’s console is mounted in the operator’s field of vision. For a better identification of displays and
operating elements, they are continuously backlit during operation.This unit contains different displays and
controls which are described in chapter 3.3.
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
PAT
3.3 Control Identification
The illustration shows the controls and displays of the DS 160 LMI.
The numbers of the illustration correspond to the numbers in the following list which describe the function
of each control.
1 Data display 9 Button “Select operation mode”

2 Bargraf (utilization) 10 Button “Tare”
3 Indicator “prewarning overload” 11 Button/Indicator “By-pass A2B”
4 Indicator “overload” 12 Button “Alarm-off”
5 Button/Indicator “By-pass LMI” 13 not used
6 Button “Tare” 14 Button “Select reeving”
7 not used 15 Selection key “down”
8 Selection key “up” 16 Button “Alarm-off”
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
r rai ©
7.:!:. :i У ■: ■: u Л
& . ...........
0 :!•
'll:'.::;:
t
»7 1
I":... h 04 21:6 IV
■■■ 0001 ,
.=,■=!" H
v 1 J
The Data display (1) used in the PAT DS 160 operator’s

console is a wide temperature-range alphanumeric display with
transflective characteristics that give it a high visibility in
sunlight and during backlit night operation.
Due to the nature of any LCD, it works on the principle of
polarization of light. It should be noted that dual polarizations
that are at a certain angle to each other can reduce the amount
of light up to completely eliminating it if that angle becomes
perpendicular. This can have significance if the operator is
wearing polarized sunglasses that happen to be perpendicularly
polarized in relation to the LCD’s polarization.
In this rare case, the operator has to work without sunglasses

or find different sunglasses that do not have this characteristic,
in order to avoid having the visibility of the display impaired.
The LCD contains an automatic temperature compensation that
will adjust the LCD’s contrast according to the surrounding
temperature.
The following figure shows the display during normal operating
(values are not real, tele indicator values only for systems with
telescoping control):
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
Control Identification
PAT
A) Utilization Bargraph * Tele indicator only visible at systems with telescoping control.
B) Actual Load (MX= tele section fully retracted # = tele retraction in %)
C) Capacity (Max Load)
d) Boom Radius after pressing button for 5 sec. the displays shows:
e) Operating Mode
f) Reeving [ length of tele 1+2 ]
G) Tele-Indicator (in %) * [ length of tele 1 ] (in meters)
H) Boom Height
J) Boom Length
K) Boom Angle NOTE: display content is depending on EEPROM configuration
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
PAT
(2) Utilization bar graph
This utilization bar graph display (2) indicates how much of the
loader‘s rated capacity is being used. (utilization)
As the rated capacity of the loader changes as it is moved
through its various motions, the utilization display will constantly
change as well.
The bar graph is marked with different colors:
• green: and safe section (0%...90% of rated cap.)
• yellow: prewarning section (90%...100% of rated cap.)
• red: overload section (>100% of safe working load)
• "Prewarning" indicator
The yellow LOAD MOMENT PRE-WARNING LIGHT (3) will

light up when the load on the crane reaches the defined pre-
warning area, thus indicating that an overload condition is
approaching.
IMPORTANT
This means for the operator to continue his crane op-
eration with caution.
(4) "Overload" indicator
The red overload light (4) warns the operator that a rated load
condition has been reached.
It lights up when the load on the crane reaches the crane load
capacity. The audible alarm also sounds when this condition
has been reached. The following crane movements will be
stopped concurrently:
• Hoist up
• Boom down
• Telescope Out
Press button to interrupt the audible alarm.
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
PAT
(5) "By-pass" button/indicator LMI
This element serves a dual purpose:

• The red “By-pass LMI Indicator” will flash during the con-
trol lever lockout function of the LMI system is by-
passed.
• By pressing the BY-PASS button (5) you can deactivate
(by-pass) the cut-off function of the LMI system momen-
tarily to override the control lever lockout.
/\ WARNING
Since this button deactivates the cut-off function of the LMI system, the following instructions must be
obeyed:
• The by-pass button shall be used with discretion, as unwarranted use of it to override the control
lever lockout system can result in harm to the crane and danger to property and persons.
• Never use the by-pass button to either overload or operate the crane in a range not permissible.
• "TARE" button
The button "TARE" (6) serves to output the net load on the
load display (see 1 B, chapter 3.3). The net load is the real
TARE
load minus tackle and hook block. The button "TARE" has to
be actuated before starting the lifting procedure.
Upon actuation of the button "TARE" (6) the load display is
set to zero (tared) and the button lights up. When the load is
lifted, the load display shows the net load (payload).
As soon as the working radius (by angle or radius modifica-
tion) is modified, the display shows again the real load and
the taring function is completed.
NOTE: The real load contains hook block, lifting rope and all
tackle. The net load is the present load on the hook without
tackle. Display errors can be caused by environmental in-
fluences such as wind acting on boom or load.
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
PAT
(7) "Info" button
no function
(8) "up" Selector
Use this button to increase values or to scroll up.
(9) Button "Select Operating mode"
Use this button to start the function "set operating mode".

For the proceeding please refer to chapter 4.
/j\ WARNING
The correct setting of the Operating Mode is of utmost

importance for the proper function of the system and
the crane. Therefore, only operators who are thoroughly
familiar with the load capacity charts and the use and
operation of the system shall input the Code.
Failure to properly program the LMI with the correct
operating mode code may result in property damage or
serious bodily injury or death to personnel.
To assure the crane is properly programmed, verify that
the operating mode code (shown at data display) and
the load capacity chart match the lifting configuration of
the crane.
(10) "Anti-Two-Block" indicator
The red "Anti Two-Block Alarm Light" lights up when the

anti-two-block limit switch contacts open, indicating that a
two-blocking condition is approaching. At the same time the
audible alarm will sound.
The following crane movements will be stopped subsequently:
hoist up and boom down (depending on your machine).
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
PAT
(11) "By-pass" button/indicator Anti-Two-Block (A2B)
This element serves a dual purpose:

• The red “By-pass A2B Indicator” will flash during the
control lever lockout function of the Anti-Two-Block sy-
stem is by-passed.
• By pressing the BY-PASS button you can deactivate
(by-pass) the cut-off function of the A2B system momen-
tarily.
/l\ WARNING
Since this button deactivates the cut-off function of the A2B system, the following instructi ons must be
obeyed:
• The by-pass button shall be used with discretion, as unwarranted use of it to override the Anti-Two-
Block system can result in harm to the crane and danger to property and persons.
• Never use the by-pass button to either overload or operate the crane in a range not permissible.
• "Audible Alarm Acknowledgement" button
An acoustical alarm message can be acknowledged by

pressing this button
The acoustical alarm will sound upon the following events:
System test, overload condition, malfunction of the load moment
indicator system, or after recognized operator errors.
(12) "LIM" button
f 'N no function
LIM
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
PAT
(13) Button "Select Reeving"
Use this button to start the function "set reeving".

For the proceeding please refer to chapter 4.
/j\ WARNING
The correct setting is of utmost importance for the pro-

per function of the system and the crane.
(14) "down" Selector
Use this button to decrease values or to scroll down.
(16) "OK" button
■o Use this button to confirm settings.

OK
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PAT
4. CONFIGURATION SETUP
4.1 LMI Setup Prucedure

The LMI setup procedure allows the operator to input the crane configuration. The operator must complete
the configuration setup procedure for the Load Moment Indicator system by confirming (pressing OK) to set
the system into operation or changing it to enter a new configuration. The previous configuration setup will
be displayed and must match the current crane operating configuration.
The LMI programming procedure consists of the following steps:
• setting the operating mode (crane configuration)
• selecting the reeving (parts-of-line)
If the system is turned off, all adjustments remain stored. When turning the system on again these
adjustments can be acknowledged by merely pressing the OK button (provided that the crane configuration
has not been modified!).
During the programming procedure the "Load Moment Prewarning" Light (3) and the "Load Moment Limit"
Light (4) will light up and the crane functions will be interrupted.
Note: If a configuration is selected which is not available, the display will indicate error code E04. In this
case, the procedure has to be repeated with valid values!
/l\ WARNING
The correct setting is of utmost importance for the proper functioning of the system and the
crane. Therefore, only operators who are thoroughly familiar with the crane and the opera-
tion of the system should execute the setting of the system according to the operating con-
figuration of the crane.
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
PAT
4.1.1 Operating Mode Selection
Input Display (Examples) Remarks
t If this operating code number cor-

responds with the current machine con-
I figuration, press
sN
OK
0001 05
Otherwise,
use the scroll buttons and to
______________or_________ scroll between the possible operating
modes (configurations) of your machi-
ne.
CODE: 002 MAIN BOOM CW
When you have found the operating
mode that corresponds with the current
0.0 t machine configuration,
OK
v____J
OUTR. BASE 7.02 x 7,40 m press
OK
t This will automatically bring you to the
reeving selection screen. >>>
I
0001 05
______________or_______
>>REEVING: 01 <<
TO INCREASE PUSH "ф"
TO DECREASE PUSH "Ф"
TO CONFIRM PUSH "OK"
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
Л -----
-
OK
—y
T
1 PAT
05
0001
4.1.2.
or
Reeving Selection (Parts of line)
Input Display (Examples) Remarks

>>REEVING:01 <<
r(
Use the scroll buttons
t and to
C
-----------
V
increase or decrease the number of parts
of line until it matches the current reeving
of your machine.
TO INCREASE PUSH "f"
TO DECREASE PUSH "Ф"
TO CONFIRM PUSH "OK"
When you have selected the correct

fЛ
reeving, press OK
V-------J
This concludes the setting of the reeving

and/or operating mode. If you have
selected a valid operating mode, the
system will bring you back to the opera-
ting screen.
If you have selected an invalid operating
mode, the system will show an E04.
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
Pre-Operation Inspection / Service / Maintenance
PAT
5. PRE-OPERATION INSPECTION
Before operating the crane, the following electrical connections must be checked to ensure that the system
is properly connected for the crane configuration.
If the crane works only with the boom and without boom extension or jib, check bypass plug(s) and the
weight on the anti two-block switch(s) is properly installed on the hoist load line(s). With even parts of
hoisting line, the weight shall be attached to the dead-end line. With odd parts of hoisting line, the weight
shall be attached to the line of lowest speed.
If the crane works with boom extension or jib, the connecting cable shall be installed between the junction
box on the boom extension and the boom junction box. The weight attached to the main hoist anti two-
block switch shall be removed
Failure to re-position the anti two-block switch weight will prevent the over hoist system from functio ning
properly. No weight shall be on the main hoist anti two-block switch when the boom extension is being
used.
After the electrical connections have been checked to insure that the system is properly connected for the
crane configuration, the following checks shall be made:
1. Check the electrical wiring connecting the various parts of the system for physical damage.
2. Check the anti two-block switches and weights for free movement.
3. Check the spring-loaded cable reel to be sure it is free to rotate, has tension and the cable is reeled
properly.
The following tests shall be performed with care to prevent damage to the machine or injury to personnel.
Proper functioning of the system requires successful completion of these tests before operating the
machine.
If the operator cannot see the load-handling device approaching the boom nose, he shall have an assistant
(signal person) watch the load-handling device. The operator shall be prepared to stop the machine
immediately should the LMI system not function properly as indicated by lighting the red warning light (4),
sounding the audible alarm and locking the crane movements, hoist up, telescope out and boom down.
4. Check the anti two-block alarm light (10) and the audible alarm by performing one of the following tests:
a. By manually lifting the weight attached to the anti two-block switches. When the weight is lifted, the
audible alarm should sound, the anti two-block alarm light (10) should light.
b. Slowly raise the main boom load-handling device to create a potential two-block condition.
When the load-handling device lifts the weight, the audible alarm should sound, the anti two- block
alarm light (10) should light and the motion of the load-handling device should be stopped. Lower the
load-handling device slightly to eliminate this condition.
c. Slowly lower the boom to create a potential two-block condition. When the load-handling device lifts
the weight, the audible alarm should sound, the anti two-block alarm light (10) should light and the
boom lowering function should be stopped. Lower the load-handling device slightly to eliminate this
condition.
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
PAT
If the light and audible alarm do not function as described and the crane movements are not stopped, the
system is not working properly. The malfunction shall be corrected before operating the crane.
5. If the crane is equipped with a boom extension, repeat the test procedure for the boom extension anti
two-block switch.
6. Check that the display of the main boom angle agrees with the actual boom angles.
7. Check that the display of the operating radius of the crane agrees with the actual radius.
8. Check the load display by lifting a load of known weight.
5.1 Operation
Upon correct inspection the LMI is operational. The operator shall be thoroughly familiar with all controls of
the LMI before operating the crane. The proper function of the system shall be checked by lifting a load of
known weight and comparing the load to the information displayed on the LMI.
Rated loads include the weight of the hook block, slings, and auxiliary load handling devices. Their
combined weights shall be subtracted from the listed load capacities as stated on the load capacity chart to
obtain the net load to be lifted.
/j\ WARNING
If any of the displays reflect a deviation between displayed and actual values an authorized
PAT service representative shall be called for repair of the system or re-verification of the
crane's LMI calibration.
/j\ WARNING
Any structural modifications or changes to the crane shall require re-verification of the cra-
ne's LMI calibration.
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
PAT
6. SERVICE AND MAINTENANCE

Daily maintenance of the Load Moment Indicator consists of inspecting:
1. The electrical wiring connecting the various parts of the system.
If electrical wiring is damaged, it shall be replaced immediately.
2. If the insulation is worn on the electrical wiring or cable guides are damaged, these parts shall be
replaced.
3. Check the anti two-block limit switches for freedom of movement.
Other than correcting the problems identified in the Malfunctions Table and replacing faulty mechanical
parts and cables, no other repairs shall be performed by non-expert personnel.
When the LMI system is turned on, it will go through a self-test. During this time, the console must
display the following screen:
SYSTEMTEST
888888888888888888
88
Make sure the display is working and all the lights come on during this time. Listen to the buzzer
sound. If any of the components above fails, please contact your nearest service represantative before
operating the system!
Other than correcting the problems identified in the Error Code List, no other repairs shall be
performed by non expert personnel.
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PAT
7. Troubleshooting
7.1 General Information
In case of a malfunction of the system, the data display (1) will indicate a code "E##" that identifies the
system malfunction.
The error codes listed in the Malfunction Table will identify various faults which can occur with the LMI.
Following the Malfunction Table are pages which explain each fault and describe the action which shall be
taken to correct the fault.
Faults within the electronic microprocessor shall only be repaired by factory trained service personnel.
When these faults occur, the competent service organization shall be contacted.
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
Error Code Error Cause Remedy
Overload • cutoff due to overload • reduce load moment
prewarning
Error Code List
A2B switch • the A2B switch is activated • lower the hook block
PAT
E01 Fallen below radius • fallen below the minimum • luff up the boom to a radius or
range or angle range radius or gone past the ma- angle specified in the load
exceeded ximum angle specified in the chart
respective load chart due to
7.2 Error Code List
luffing up the boom too far
E02 Radius range ex- • luff down the boom to a radius
ceeded or fallen below • gone past the maximum radius or angle specified in the load
angle range or fallen below the minimum chart
angle specified in the
respective load chart due toError Code List
luffing up the boom too far
E04 Operating mode not • A non existing operating • Set the correct operating
acknowledged or non mode has been DS
permitted slewing zone
160
selected mode for the operating state
in question
• The boom is in a non- • Slew the boom to a permitted

permitted slewing zone area.
System program: L53F V 1.0 A (2003-10-01)
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
E05 Forbidden length • Boom has been extended • Retract or extend boom to
range of the main too far or not enough, e.g. the correct length.
boom if operation is only
admitted up to a certain
boom length or for load
charts of jibs with the
boom having to be ex-
tended to a certain length.
• Retract the boom. Check
• The length sensor ad- the prestress of the cable
justment was modified, reel (the rope has to be
e.g. rope slid off the length under traction). Open the
sensor reel. length sensor and carefully
turn the length pot
counterclockwise to the
detent by use of a
screwdriver.
• Clutch between length sen- • Completely replace the

sor pot and drive is clutch with the drive wheel
defective and adjust length sensor
pot
• Failure of the +5V-supply
for the analog part of the • Check +5V-voltage. If there
LMI- analog board. is no voltage or break
down at a charge of 50
ohm approximately,
exchange LMI board.
• Length potentiometer
defective. • Replace length potentiome-
ter.
E07 • Overload relay defective • Replace LMI board
Faulty acknow- • LMI board defective
ledgment by the
overload relay of the
LMI board.
Relay should be
energized but 2nd
contact is indicated
off, or the 2nd contact
is indicated on while
the relay should be
deenergized.
E08 • cf. error E07 • cf. error E07
No acknowledgement
of the anti- two-block
switch relay.
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
E11 Fallen below limit for • Replace length sensor po-
the measuring channel • .Length sensor pot defective. tentiometer.
"Length telescopic • Replace LMI board.
boom".
• Electronic board in the
measuring channel defective.
E12 Fallen below the lower • Cable between the • Check cable as well as plugs,
limit value in the central unit and pressure replace, if need be.
measuring channel transducers defective or water
"pressure piston side" inside the plugs
• Pressure transducer is de- • Replace pressure transducer
fective. • Replace LMI main board or
• Electronic component in processor board.
the measuring channel is defec-
tive.
E13 • refer to E12
Fallen below lower limit • refer to E12
value in the measuring
channel "pressure rod
side"
E15 Fallen below lower limit • Angle sensor defective. • Replace angle sensor.
value for the measuring
channel "angle main • Electronic part in the • Replace LMI board.
boom". measuring channel defective.
E16 Fallen below lower limit • Angle sensor defective. • Replace angle sensor.
value for the measuring
channel "telescopes • Electronic part in the • Replace LMI board.
1+2". measuring channel defective.
E17 • Angle sensor defective. • Replace angle sensor.
Fallen below lower limit
value for the measuring • Electronic part in the • Replace LMI board.
channel "telescope 1". measuring channel defective.
E19 Reference and/or • The supply voltage is • Check the voltages on the
supply voltage de- falsified by one of the sensors LMI main board (AGND =
fective (DAV, LWG) MP0). Check sensors, plugs
and cable, replace, if need
be.
• Electronic component is • Replace LMI board
defective
• A/D converter of CPU 80C537 • Replace LMI board
defective.
E21 Upper limit value for • Length sensor pot • Replace length sensor po-
measuring channel defective. tentiometer.
"length telescopic • Replace LMI board.
boom" exceeded.
• Electronic part in the
measuring channel defective.
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
E22 • refer to E12 • refer to E12
Upper limit value in
measuring channel
"pressure piston side"
has been exceeded
E23 Upper limit value in • refer to E12 • refer to E12
measuring channel
"pressure rod side"
has been exceeded.
measuring channel
"angle main boom"
exceeded
measuring channel
"telescopes 1+2"
exceeded
measuring channel
"telescope 1" ex-
ceeded
E31 Error in the system • The system program PROM is • Replace system program
program defective. PROM (PROM No. 0)
E38 System program and • The system program in the LMI • Replace the system program
data EPROM do not does not match to the PROM or the data EPROM
match. programming in the data (PROM No. 1)
EPROM
E39 System program and • Replace system program
TLK EPROM do not • The system program in the LMI PROM or TLK EPROM
match and the programming in the (PROM No. 2).
TLK EPROM do not match.
E41 Error in the internal • Computer component • Replace computer component
write/read memory 80C537 defective 80C537.
(RAM) of the com-
puter component • CPU module defective • Replace CPU module.
80C537
• LMI board defective. Replace LMI board with CPU •
module.
E42 Error in the external• Write/read memory (CMOS RAM) • Replace LMI board
write/read memory, or LMI board defective.
1st part (RAM)
E43 Error in the external• refer to E42 • refer to E42
write/read memory,
2nd part (RAM)
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
E48 Cyclic RAM test: error • Computer component • Replace computer component
in the internal 80C537 defective 80C537.
write/read memory
• LMI board defective. • Replace LMI board
(RAM) of the com-
puter component
80C537
E51 Error in the crane data • No valid data in the crane • Load crane data EEPROM
EPROM or EEPROM. data EEPROM. containing valid data.
• Memory module wrongly • Bridge memory module acc. to

bridged. memory type
• Replace crane data EPROM

• Crane data EPROM defective
E52 Error in load chart • Memory module wrongly • Bridge memory module acc. to
PROM. bridged. memory type.
• Replace load chart EPROM

• Load chart EPROM defective.
E56 Error in crane data • Memory module wrongly • Bridge memory module acc. to
EEPROM. bridged. memory type
• Replace crane data EE-

• Crane data EEPROM defective PROM
E57 Error in serial crane • Serial crane data EEPROM
data EEPROM. does not contain valid data. • Write data on the serial crane
data EEPROM (by means of
test program or on-line
function), then restart the LMI
• Memory module defective • Replace memory module.
E58 Error in the serial • No valid data in the serial • Write data on the serial ana-
analog data EE- analog data EEPROM. log data EEPROM by means
PROM. of the test program, then,
restart the LMI
• LMI main board defective. • Replace LMI main board.
E84 Wrong rigging con- • The selected rigging condition • Select another rigging condi-
dition. is not contained in the data tion
EPROM.
• Check the programming in the
data EPROM.
E85 Error in the radius • The computed radius is too • Check the programming in the
determination small (negative deflection) data EPROM.
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
E91 No data transmission
• 24 V supply of the console is • Check 24 V at terminal X1 of
form the console to the console electronics
interrupted
the central unit
• Interruption or accidental • Check the connection console

ground in the line between electronics - central unit. In
console electronics and cen- case of an accidental ground,
tral unit the transmitter module of the
console electronics might be
damaged. Therefore,
replaces the console
electronics.
• Transmitter/receiver module • Exchange console electronics
is defective or LMI main board resp.
E92 Error in the data • Loose connection in the • Check the connection bet-
transmission from line between console electronics ween console electronics
console to central and central unit and central unit
unit • Transmitter/receiver module • Exchange console electronics
is defective or LMI main board resp.
E93 Error in the data • refer to E92 • refer to E92
transmission from the
central unit to the
console
E94 No data transmission
from the central unit to • Interruption or accidental
the console ground in the line central unit • Check line to the console (in
- console case of accidental ground,
replace console electronics,
too).
• 5 V supply of the computer in • Check connection to the
the central unit is missing power unit
• 5 V supply is too low
• Exchange the LMI main board
• Replace console electronics
• Transmitter/receiver module or LMI main board
is defective • Replace processor board.
• Computer module is defective
• Electro-magnetic interferen- • Eliminate the source of inter-
ces (e.g. when switching ferences by inverse diodes or
contactors or valves) varistors.
E95 Error in the console • The console EPROM is • Replace the console EPROM
EPROM defective.
E96 Error in the internal • The CPU of the console is • Replace the CPU of the
RAM of the console. defective. console
• The console main board is • Replace the console main
defective. board.
Remarks:
If an error message is displayed which is not contained in the list above, please contact the competent PAT
service department.
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
Appendix: Important Notes
PAT
PAMPHLET 1 Cut-off Values for Boom Cranes with Variable Capacity depending
on Variable Radius
The crane cut-off values are calculated by us on the basis of the load charts and construction drawings supplies
by the crane manufacturers.
These theoretical cut-off values must be checked by testing the crane with weighed test loads in all operating
modes and at least in the following equipment conditions depending on the crane type.
• Cranes with fixed boom length during operation:
Minimum, medium and maximum radius with shortest, medium and longest boom length as well as with
shortest, medium and longest jib length with these boom lengths.
• Cranes with variable boom length during operation:
Minimum, medium and maximum radius at each length step as well as with all jibs.
PAMPHLET 2 Important notes for crane operators
The LMI is an operational aid which warns a crane operator of approaching overload conditions and also warns
of overhoist conditions which could cause damage to equipment and personnel.
The device is not, and shall not, be a substitute for good operator judgment, experience and use of accepted
safe crane operating procedures. The responsibility for the safe operation of the crane shall remain with the
crane operator who shall ensure that all warnings and instructions supplied are fully understood and observed.
Prior to operating the crane, the operator must carefully and thoroughly read and understand the information in
the crane/SLI manual to ensure that he knows the operation and limitations of the indicator and crane.
Proper functioning is dependent upon proper daily inspection and observations of the operating instructions set
forth in the manual.
/j\ WARNING
This system can be equipped with an override key on the central micro-processor unit. This
key switch bypasses cut-off functions of the load moment indicator device. The switch may
only be used by authorized personnel during emergency situations. Failure to follow this
instruction may result in property damage and/or personal injury.
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
PAT
PAMPHLET 3 Important notes for crane users

In the Federal Republic of Germany, the directives of the Union of German Engineers VDI (Verein Deutscher
Ingenieure) 3570 are effective for the construction of safe load indicators. There, too, it is directed to the signifi-
cant and the limits of the safe load indicator.
"Safe load indicators shall, during crane operation, hinder accidents, endangering of persons, things, the load,
the crane due to overload within the limits possible. User and crane operator must take into account that a safe
load indicator cannot realize all dangers in time and that a malfunction by non-perceptible influences indeed is
possible. Therefore they are not dispensed from circumspection and the responsibility to the observance of the
operating instructions and the load of the crane. Safe load indicators are not intended for regular operation. They
shall only respond in emergency cases. The capacity of the hoisting appliance shall not be reduced by safe load
indicator".
Instructional Pamphlet VDMA

for safe load indicators (load moment limiting devices) on boom cranes
The boom crane delivered to you has a safe load indicator (overload cut-off device) according to §24 of the accident prevention
regulation UVV "boom cranes" which will cut off the hoist and boom hoist unit of the crane when exceeding the admissi ble safe load.
The opposite movement must remain possible in order to be able to relieve the crane of the load after the safe load indicator has
reacted, e.g. it must be possible to lower the load when the hoist was cut off.
Installation of a safe load indicator (overload cut-off device) has the purpose to prevent the crane from lifting a load which would
endanger its stability. Hence the safe load indicator (overload cut-off device) is an emergency switch which, in the event of overload,
cuts off all movements increasing the load moment thus avoiding a possible damage or accident. The following must be observed for
the safe load indicator to comply with its function as a safety device.
1. Safe load indicators (overload cut-off devices) must not be used operationally to cut off the hoist or boom hoist unit. The crane
operator must in any case previously make sure that the load to be lifted will not exceed the lifting capacity of the crane.
Superheavy loads exceeding the lifting capacity of the crane must not be lifted even with a safe load indicator installed. The unit
must not be loaded beyond the respectively admissible load.
2. Freeing loads which are stuck may only be effected in agreement with the crane manufacturer and with cranes especially
equipped for this purpose. During these jobs it is not allowed to use the safe load indicator (overload cut-off device) as an
operational unit for force measurements.
3. The built-in safe load indicator must be regularly serviced and checked as to its functional safety before starting operati on.
According to the accident prevention regulation UVV "boom cranes" §35 maintenance of the crane also includes re gular checks
of the safe load indicator.
4. Generally, the safe load indicator does not adjust automatically to the various operating conditions of the crane. When changing
the operating condition of the crane, the operator is therefore responsible of changing the safe load indicator over to the new
load or load moment range as well. For this purpose, observe the manufacturers operating instructions for the safe load indicator
installed. Safe operation of the device and accident-free operation of the crane depend to a high extent on careful observance of
this instruction. Maladjusted safe load indicators, e.g. set to a high load moment with retracted outriggers, are much more
dangerous than cranes without a safe load indicator since the crane operator is given a wrong feeling of safety which might be
the cause of serious accidents.
5. When changing the crane over to various operating conditions, the safe load indicator installed must be changed over to the new
load or safe load ranges resp. by the crane operator, e.g.:
a) when extending or retracting the outriggers (changing over to high or little load moment);
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
PAT
b) when changing the boom length by:

- extending or retracting (telescoping) manually;
- mounting or dismounting intermediary parts;
c) when slewing or pivoting the crane to the range of greater or smaller stability moment (changing over to high or little load
moment);
d) when passing into another load capacity range by several parts of line in the cables of the hoist or boom hoist unit.
6. It must be strictly pointed out that due to wrong operation of the crane it might not be possible for the safe load indicator to
respond or resp. that the engine might not be cut off quickly enough. In this case you cannot exclude an accident despite of a
safe load indicator installed.
In particular, this applies to:
- underhooking the load or the load handling accessories;
- excessive retardation forces,
- loads falling into the line,
- diagonal pull,
- moving the crane to an area of higher gradient,
- yielding ground,
- wind pressure.
7. If there is a device available to switch off or bridge the safe load indicator (load moment limiting system), it must only be used
with regard to special measures of precaution and in presence of the crane super-intendance, for instance when testing the
crane and for special applications provided for by the crane manufacturer. The safe load indicator must not be switched off or
bridged operationally under no circumstances in order to lift loads which exceed the respectively admissible loading capacity
of the crane.
Careful observance of the regulations contained in this instructional pamphlet and in the operating in -
structions of the crane manufacturer is the precondition for the safe function of the safe load indicator
(overload cut-off device).
In all cases of doubt consult the operating instructions of the manufacturer. Should this be not suffi-
cient, it is necessary to inquire at the company concerned.
Unauthorized interventions in the mechanism of the safe load indicator will void the warranty.
Publisher: VDMA Fachgemeinschaft fur Hebezeuge und Fordermittel

im Verein Deutscher Maschinenbau Anstalten
e.V. Dusseldorf - Oberkassel
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
PAT
PAMPHLET 4 Instructions to ensure the electromagnetic compatibility (EMC) with

electronic systems under the effect of electromagnetic fields
Electromagnetic fields increasingly affect electronic systems and can thus cause malfunctions for whose elimi-
nation we shall indicate some preventive measures according to today's state of engineering below:
1. The preventive measures are mainly based upon the idea to shield the electronic circuits from irradiated
high frequency interferences:
- All components will have metal housings outside with grounding possibility;
- The cables used will have braided shields. The shield applied must be highly conductive as to the sur-
face of all junction areas;
- Coupling of crane ground and electronic ground at only one point of the system.
2. The general measures listed in item 1, however, cannot ensure complete protection against electromagne-
tic fields in individual cases because the size and the type of the effect depends on the local conditions.
The influencing factors, inter alia, are as follows:

- Particularly unfavorable arrangement of the antenna as to the system;
- Very high transmitter powers;
- Impossible to observe the measures of item 1 consistently by reason of local conditions;
- Long cables;
- Interferences coupling into the supply lines.
With unfavorable conditions you can therefore not do without taking any measures exceeding the preventi-
ve ones experimentally on site, taking into account the principles mentioned in item 1, e.g.:
• Adding filters or short-circuiting the interfering frequencies by means of capacitors;

• Making or removing ground connections;
• Using double shielded cables (guarded shield system).
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
PAT
PAMPHLET 5 Notes for Protection of Labour During Repair of Display and Operating
Consoles
Caution: LCD displays contain fluid chemicals.

Therefore, you have to proceed carefully when:
• operating devices with LCD displays

• storing or carrying them (risk of fracture)
• clearing spare or unusable LCD displays
Possible risks are chemical reactions because of skin contact with broken LCD displays. In
case of contact with chemicals, carefully clean the parts of body affected with soap. Caution
in case of open wounds.
PAMPHLET 6 Installation instructions for display and operator's console without closed
metal housing
In order to avoid radio interferences, high frequency devices and systems subject to the general approval the
Federal Minister of the Post Office and Telecommunication published in the gazette no. 163/1984 as order no.
1045/1984 and no. 1046/1984 have to observe the limits and requirements stipulated.
In case of display and operator's console without closed metal housing (panel-mounted) type, the cable shield
must be applied via a bare clamp on the panel directly in front of the console.
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.
Revision Date Modifications Name
Vers. A 2002-05-07 Konopka
Original Issue, english system programm L53I
Vers. B 2003-01-20 Corrections for Konopka
system programm L53F V 1.0 A (2003-01-10)
50 160 19 0005E 416607.doc / 2003-01-20 / Rev. B / rk.

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What are the specifications of the crane?

What are the specifications of the crane?

What safety measures are mentioned?

What safety measures are mentioned?

ta BENDINI

Operation and maintenance manual

year of construction: 2006

OPERATION AND MAINTENANCE MANUAL

Manufacturer: After-sales service:

Code: 40450 (eng) - rev.03 A

B Code: 40450 (eng) - rev.03

II. Instructions.............. Edition: 06-2005

III. Safety and operation Edition: 01-2006

IV. Control Edition: 06-2004

instruments . Edition: 06-2005

V. Accessories............. Edition: 04-2005

Code: 40450 (eng) - rev.03 C

D Code: 40450 (eng) - rev.03

Chapter I - ed. 06-2005 page 1/6

page 2/6 Chapter I - ed. 06-2005

Truck performance data(1)

Chapter I - ed. 06-2005 page 3/6

page 4/6 Chapter I - ed. 06-2005

Chapter I - ed. 06-2005 page 5/6

page 6/6 Chapter I - ed. 06-2005

Chapter II - ed. 06-2005 page 1/8

page 2/8 Chapter II - ed. 06-2005

This machine complies with Directives 98/37/CE, 89/336/CE,

USE IN EXPLOSIVE ENVIRONMENTS IS STRICTLY FORBIDDEN.

Chapter II - ed. 06-2005 page 3/8

TEREX ITALIA S.r.l.

page 4/8 Chapter II - ed. 06-2005

■ fully understood and memorized all the instructions in this manual.

Chapter II - ed. 06-2005 page 5/8

BUNGEE JUMPING FROM CRANES IS

Such improper use of the products is neither envisaged nor

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

All Dealers and Distributors are requested to use every reasonable

REMEMBER: BUNGEE JUMPING FROM CRANES IS DANGEROUS.

IT IS STRICTLY PROHIBITED TO USE THE CRANE WITH:

page 6/8 Chapter II - ed. 06-2005

CAREFULLY READ ALL THE SAFETY INSTRUCTIONS BEFORE

Preventive measures against possible hazards in maintenance

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

Chapter II - ed. 06-2005 page 7/8

page 8/8 Chapter II - ed. 06-2005

Chapter III - ed. 01-2006 page 1/64

page 2/64 Chapter III - ed. 01-2006

Advice on safety when using mobile cranes.

The following crane is designed for handling loads in compliance with

Having the capacity to lift heavy loads to considerable heights, the

The general advice on machine operation as well as these instructions

Chapter III - ed. 01-2006 page 3/64

Safety must be the operator’s main concern.

He must refuse to operate if he deems it dangerous and must contact

He must be alert, in optimal physical condition and not be under the

Whenever the operator’s visibility is blocked or he is operating in

Signalers must have clearly understood the work to be performed in

The signaler is the only person authorized to give instructions to the