Chapter - 03 - EN - Edizione 06-2007a

Safety and operation Operation and maintenance manual
III
Safety
and
Machine operation
Chapter III – ed. 06-2007a page 1/66

Operation and maintenance manual Safety and operation
page 2/66 Chapter III – ed. 06-2007a

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.

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.


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.

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.

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.

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.

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).

• 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.

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.

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.

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 !!!

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

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

1 2 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
WARNING: emergency exit

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.

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
support gas-filled jacks, which is a simple operation.

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).

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.

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.

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.

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

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

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

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

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

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

hydraulic 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.

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.

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.

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

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.

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.
boom
without load
boom angle
with load
10.Index of reference symbols for reading the various configurations in

the load table.
10

Reduction of operating loads
To determine the net capacity of the crane truck in an assigned

configuration, subtract the loads of the accessories used for the lifting
operation (reduction of load) from the gross load.
Net load = gross load – reduction of load.
The load reductions can be:
a - Weight of block or hook

b - Weight of sling
net load
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
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
e - Weight of supplementary sheave
f - Weight of extension or jib secured to brackets on main boom
net load gross load

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

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

the jib from the gross load.

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

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

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.

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
radius

Max. forces exerted on ground (daN)
Model
Ø 525 mm
A300 28000
Ø 510 mm
A350 27000 Ø 525 mm
RC35 27000 Ø 525 mm
RC40 27000 Ø 525 mm
RC45 39000 Ø 525 mm
A600 45000 Ø 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
RC35 18400 18400 14450
20.5R25
16.00R25
RC40 18400 18400 14450
20.5R25
16.00R25
RC45 18400 18400 14450
20.5R25
23.5R25
A600 23200 23200 18200
26.5R25

Actions of the wind
The crane can be safely used by following the capacity table values up to
a wind speed of 8.5 mps (30 kph – force 5) on a load area of 1.2 m²/ton.
IMPORTANT: Every day, check the weather and wind speed forecast for
the day by calling the nearest weather station. Do not lift the load if the
wind speed is higher than the maximum permissible.
1,2 m²
12 m²
1 ton.
Wind
10 ton.
Wind force Wind speed Consequences
Scale Terms described mps kph Inland territories
0 Calm 0 – 0.2 1 Calm, smoke rises vertically

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

The wind breaks branches, difficulty
8 Wind gust 17.2 – 20.7 62 – 74 in walking freely
Damage to houses (tiles and
9 Strong wind gust 20.8 – 24.4 75 – 88 chimneys blown away)
Trees uprooted and considerable
10 Storm 24.5 – 28.4 89 – 102 damage to houses
11 Violent storm 28.5 – 32.6 103 – 117 Considerable and extensive damage
12 Hurricane 32.7 – 36.9 118 - 133 Very serious and extensive damage

Safety devices
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.

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.

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
(A – B) 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.
A
B
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.
Model SW6
Legend:
1. Winch drum
2. Lifting rope
3. Drum feeler
4. Return spring
5. Limit switch
6. Adjustment screw
7. Rope press roller
2
1
7 3
5 4

3 5
2
6
1
Models TW4 and TW5
Key:
1. Winch drum
2. Lifting rope
3. Return spring
4. Limit switch
5. Adjustment screw
6. Rope press roller and drum feeler
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.

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

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

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

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

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

Engine starting
Before starting the engine, make sure there are no persons or objects in
the immediate vicinity of the machine.
1. Make sure the gearshift lever is in the neutral position “N”.
2. Select the fast or slow gears according to needs.
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”.
CAUTION: In case of use at temperature below 0°C, start the crane and
keep engine idle for some minutes before use to allow hydraulic fluid to
reach operating temperature.
When the engine has started and idles normally, the oil pressure and
battery level lights go off, and the air pressure warning light goes off
when the pressure reaches 5.5 bars.
The parking brake light stays on.
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.

Securing the hook block
Secure the hook block to frame front end as follows:
1. Fully retract the boom

2. Secure the block tie-down to frame front end.
3. Bring the hook block on the vertical of the block tie-down.
4. Lower the hook block and attach hook to tie-down.
5. Be sure that ground staff has moved away from the machine front.
6. Otherwise, you may lower the boom and then raise the hook block
until setting the boom at the desired angle. Be sure not too stretch
the tie-down taut.
Secure the hook block to frame upper end as follows:
1. Fully retract the boom

2. Secure the block tie-down to frame upper end.
3. Bring the hook block on the vertical of the block tie-down.
4. Lower the hook block and attach hook to tie-down.
5. Be sure that ground staff has moved away from the machine front.
6. Otherwise, you may lower the boom and then raise the hook block
until the boom is 4 metres above ground. Be sure not too stretch the
tie-down taut.
IMPORTANT: Failure to comply with such instructions can

lead to serious personal injuries

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).

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 and level ground,
taking care to first check if it can support the tyre load.
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.

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.

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
2
1
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.

Chart of permissible pressures for different types of ground
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
15
altered by bad weather and stratified.
Close stratification, compact stratification or
30
column
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.

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.

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.

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

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

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.

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
boom torsion
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.

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 boom axis boom axis
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.
lifting line boom axis lifting line boom axis

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
Correct
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.

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
formed by the rope or chain sections exceeds 120° equalizers must
be used). Using ropes or chains that are too short could cause
sudden breakage and therefore dropping of the load.
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.

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.

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

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.

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.

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.

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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Safety and operation Operation and maintenance manual

Chapter III – ed. 06-2007a page 1/66

page 2/66 Chapter III – ed. 06-2007a

Advice on safety when using mobile cranes.

TEREX cranes are carefully designed, tested and manufactured.

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. 06-2007a page 3/66

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

page 4/66 Chapter III – ed. 06-2007a

Chapter III – ed. 06-2007a page 5/66

RESPONSIBILITIES OF ALL RELEVANT PERSONNEL

Unsafe conditions or operations must be adequately corrected or

Management’s task is to ensure that operators have adequate training

Crane operators must have received adequate training to be able to

Personnel must be given specific responsibilities on safety and are

page 6/66 Chapter III – ed. 06-2007a

PLANNING THE WORKSITE

The person appointed must clearly understand the work to be carried

- The personnel needed and their responsibilities.

- 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.

- How the loads will be restrained.

- Special safety precautions to be taken if the crane has to travel with a

- If unfavourable weather conditions, such as wind or intense cold, are

- Measures to be taken for safely keeping unnecessary persons and

Chapter III – ed. 06-2007a page 7/66

SAFETY CHECK BY OPERATOR

- Ensure that no unauthorized modifications have been made in the

- Check for any hydraulic oil and air leaks.

- Check correct operation of all the controls

page 8/66 Chapter III – ed. 06-2007a

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

3. The working capacity of a crane is established with the crane

5. Persons can be struck by the rear part of the counterweight of the

Chapter III – ed. 06-2007a page 9/66

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

What to do in case of accidental contact.

• The equipment or the machine is able to operate: without leaving the

page 10/66 Chapter III – ed. 06-2007a

• The machine operates on tyres:

IMPORTANT: Planning of work and a thorough control ensure better

9. Persons can be injured by the hook, boom, load or outriggers.

Chapter III – ed. 06-2007a page 11/66

15. A damaged crane can be dangerous and cause accidents. A

page 12/66 Chapter III – ed. 06-2007a

20. Trying to lift a load that is blocked, frozen or stuck to something

22. Attempting to repair or adjust a machine component when the load or

25. As with all heavy equipment, pay particular attention to movements

26. Shifting loads with the crane moving involves a considerable

Chapter III – ed. 06-2007a page 13/66

28. Leaving the machine unattended can be very dangerous. Before

32. The load limiter is only an aid !!!

page 14/66 Chapter III – ed. 06-2007a