Terex RT200-1 Operator's Manual
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Terex RT200-1 Operator's Manual

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  • Page 1 Courtesy of Crane.Market...

  • Page 2: Table Of Contents

    Table of Contents Introduction ...................... 5 Construction and Industrial Equipment Product Safety ......5 Nomenclature.................... 7 Intended Use..................... 8 Bulletin Distribution and Compliance............9 Contacting Manufacturer ................ 10 Transfer of Machine Ownership .............. 11 Safety ......................13 Safety Introduction.................. 13 Alert System....................
  • Page 3 Contents Cold Weather Starting ..............89 Jump-Starting an Engine with Booster Cables........ 90 Operating the Engine ............... 91 Making a Typical Lift ................ 92 Arm and Hand Signals ..............98 Load Rating Chart Interpretation ........... 100 "On-Tires" Lift ................109 Unusual Operating Conditions ..............
  • Page 4 Storage....................183 Machine Storage................183 Engine Storage ................185 Transmission Storage ..............188 Restoration to Service ..............189 Restoring Engine to Service............190 Restoring Transmission to Service ..........191 Chrome Cylinder Rod Storage............192 Specifications....................195 Wire Rope Specifications..............195 Service / Parts ....................
  • Page 5 Courtesy of Crane.Market...

  • Page 6: Introduction

    Terex manuals in the shipment of each product. It is company policy to provide this information for the owner or user of the equipment. It is...
  • Page 7 Introduction Follow the recommended operating and maintenance procedures and keep your machine operating at MAXIMUM EFFICIENCY. Use the Suggested Hydraulic Crane Inspection Check List provided. In addition, we STRONGLY URGE that a MAINTENANCE LOG be kept in conjunction with all maintenance performed on the machine. If you desire any special information regarding the care and operation of the machine, we will gladly furnish it upon request.

  • Page 8: Nomenclature

    Nomenclature This manual contains instructions and information on the operation, maintenance, lubrication and adjustments of the Rough Terrain Crane. The operator should not attempt to operate the machine before he has gained a thorough understanding of the material presented in the following pages. To aid in understanding the contents of this manual, the following terms will always have the meanings given whenever they are used.

  • Page 9: Intended Use

    Introduction Intended Use This machine and its approved attachments are designed to lift, lower and move freely suspended loads within the rated capacity of the crane. Use of this product in any other way is prohibited and contrary to its intended use. P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...

  • Page 10: Bulletin Distribution And Compliance

    Bulletin Distribution and Compliance Safety of product users is of paramount importance to Terex. Various bulletins are used by Terex to communicate important safety and product information to dealers and machine owners. The information contained in bulletins is tied to specific machines using the machine model number and PIN/serial number.

  • Page 11: Contacting Manufacturer

    Current owner updates, such as changes in machine ownership or changes in your contact information (see Transfer of Machine Ownership on page 11 for more information). Manufacturer contact information: Terex Cranes 106 12th St reet Waverly, IA 50677 1 (877) MY-TEREX 1 (877) 698-3739 P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...

  • Page 12: Transfer Of Machine Ownership

    Transfer of Machine Ownership If you are not the original owner of this machine, please provide the model number and PIN/ serial number of your machine, along with your name and the date of transfer of ownership. This will ensure that you are the owner on record for this machine, allowing you to receive any applicable notices and advisories in a timely manner.
  • Page 13 Courtesy of Crane.Market...

  • Page 14: Safety

    Many aspects of crane operation and testing are discussed in standards published by the American National Standards Institute. These Standards are updated on an annual basis with addendas, which are sent by ASME to the original purchasers of the standard. Terex recommends that you purchase and refer to the following standards.

  • Page 15: Alert System

    Safety Alert System SAFETY ALERT SYMBOL The safety alert symbol is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death SAFETY ALERT SYMBOL MACHINE DECAL HAZARD CLASSIFICATION SYMBOLS A multi-tier hazard classification system is used on machine decals to communicate potential personal injury hazards.
  • Page 16 NOTICE - Notice used without a safety alert symbol indicates a hazardous situation, which, if not avoided, could result in property damage. SYMBOLS AND PICTORIALS Hazard Avoidance CRUSH HAZARD Stay Clear of Moving Turret and Boom. Crushing of fingers hand force applied directions (pinched).
  • Page 17 Safety Hazard Avoidance Falling From NO RIDERS Wheeled Machine. Hand Entanglement Keep Hands Clear of Winch In Pulley / Winch. and Load Line. Entanglement in Stay Clear of Rotating Shafts. Drive Shaft. ENTANGLEMENT Keep away from fan and belt HAZARD when engineis running.
  • Page 18 Hazard Avoidance BURN HAZARD No smoking. No flame. Stop Fuel and fumes can engine. explode and burn. BURN HAZARD Allow surfaces to cool before Contact with hot servicing. surfaces can cause burns. Falling from height. Use personnel lift or appropriate ladder to reach high places.
  • Page 19 Safety Hazard Avoidance Electrical Shock / Stay Sufficient Distance From Electrocution from Electrical Power Lines. Crane Power Line Contact. These are general safety rules, which must be followed. You are also required to read and understand the Operators Manual as there are instructions, which are more detailed specific to this machine.

  • Page 20: General Safety

    General Safety Safety Sign Maintenance Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild soap and water to clean safety signs. Do not use solvent-based cleaners because they will damage the safety sign material. P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...

  • Page 21: Safety Sign Locations

    Safety Safety Sign Locations ENTANGLEMENT Keep clear of HAZARD - Death or rotating drivelines. Serious Injury can Shut off engine result from contact before performing with rotating service. driveline. INJECTION HAZARD - Escaping fluid under pressure can penetrate skin causing serious injury Relieve pressure before disconnecting hydraulic lines.
  • Page 22 CRUSH HAZARD - Keep clear of moving Death or Serious machine. Injury can result from contact with moving machine. ELECTROCUTION HAZARD Contact with electric power lines will result in death or serious injury. MAINTAIN REQUIRED CLEARANCE Line Voltage Required Clearance 0 to 50KV 10 ft (3m) 50 to 200KV...
  • Page 23 Safety DESCRIPTION OF MOVEMENT A1 HOIST. With forearm vertical fore finger pointing up, move hand in small horizontal circle A2 LOWER. With arm extended downward forefinger pointing down, move hand in small circle. A3 USE MAIN HOIST. Tap fist on head; then use regular signals. A4 USE WHIPLINE.
  • Page 24 DESCRIPTION OF MOVEMENT A5 RAISE BOOM. Arm extended, fingers closed, thumb pointing upward. B1 LOWER BOOM. Arm extended fingers closed, thumb pointing downward. B2 MOVE SLOWLY. Use one hand to give any motion signal and place other hand motionless in front of hand giving the motion signal. (Hoist slowly shown as example) B3 RAISE THE BOOM AND LOWER THE LOAD.
  • Page 25 Safety INJECTION HAZARD - Escaping fluid under pressure can penetrate skin, causing CRUSH HAZARD - Keep clear of moving serious injury. Serious injury can outriggers. Relieve pressure before disconnecting result from contact hydraulic lines. Keep away from leaks and with moving pin holes.
  • Page 26 ENTANGLEMENT HAZARD - Rotating parts can cause personal injury. Keep away from fan and belt when engine is running. Stop engine before servicing. P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...
  • Page 27 Safety ENTANGLEMENT Keep clear of HAZARD - Death or rotating drivelines. Serious Injury can Shut off engine CRUSH HAZARD - Keep clear of moving result from contact before performing Serious injury can outriggers. with rotating service. result from contact driveline. with moving outriggers.
  • Page 28 EXPLOSION/BURN HAZARD - will cause death, burns or blindness due to ignition of explosive gases or contact with corrosive acid. Keep all open flames and sparks away. Wear personal protective equipment, including face shield, gloves and long sleeve shirt. READ MANUALS Read all manuals prior to operation.
  • Page 29 Safety FALL HAZARD - NO RIDERS Serious injury or BURN HAZARD - No Smoking. No death can occur. Fuel and fumes can flame. Stop engine. explode and burn. P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...
  • Page 30 EXPLOSION/BURN Allow to cool before CRUSH HAZARD - Keep clear of moving HAZARD - Release opening. Death or Serious machine. of hot pressurized Injury can result from fluids can cause contact with moving Burns or Blindness. machine. P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...
  • Page 31 Safety 18 - Inside Battery Box This unit is furnished with an alternator. BURN HAZARD Allow surfaces to Observe the following carefully Contact with hot cool before servicing. surfaces can cause Disconnect all wires at the alternator burns. before doing ant welding on this unit. Welding and improper connections cause instantaneous alternator damage.
  • Page 32 CAUTION THIS CYLINDER CAN CONTACT THE 19 - Inside Battery Box ENGINE HOUSING WHEN THE MACHINE EXPLOSION/BURN HAZARD - will cause IS SWUNG OVER THE REAR death, burns or blindness due to ignition of explosive gases or contact with corrosive acid.

  • Page 33: Workplace Safety

    Safety Workplace Safety HANDLING PERSONNEL Cranes can only be used to lift people when it is the least hazardous way to do the job. (See OSHA 1926.550g, and ASME / ANSI B30.23.) TRAINING AND KNOWLEDGE Safety must always be the operator's most important concern. Do not operate this crane until you have been trained in its operation.
  • Page 34 OPERATOR'S RESPONSIBILITIES Be alert, physically fit and free from the influences of alcohol, drugs or medications that might affect the operator's eyesight, hearing, or reactions. Keep people, equipment and material outside of the work area. 10. A signal person must be used when the operator's vision is blocked or when working in hazardous areas such as near power lines or people.
  • Page 35 Safety RESPONSIBILITIES OF ALL CREW MEMBERS Unsafe conditions and/or practices must be corrected. Obey all warning signs. Watch out for your safety and the safety of others. Know and understand proper machine erection and rigging procedures. Alert operator and signal person of dangers, such as power lines, unstable ground, etc. MANAGEMENT RESPONSIBILITIES Operators must be competent, physically fit and, if required, licensed.
  • Page 36 PLANNING THE JOB 11. Determine the lift radius, boom angle and the rated lifting capacity of the crane. 12. Always pre-plan the course of each lift to determine the safest method to reach the load’s target destination. 13. Identify the location of gas lines, power lines, or other structures and determine if the crane or structures need to be moved.
  • Page 37 Safety OPERATOR AIDS CHECK Boom angle indicator. Travel Alarms. Anti-Two block devices. Overload prevention devices, load indicators and rated capacity limiters. OPERATION OVERLOAD PREVENTION Know the weight and characteristics of all loads to be lifted. Place the boom lifting point directly above the load when lifting. The load radius will increase when the load is lifted due to boom deflection.To compensate for the boom deflection, maintain the radius by raising the boom.
  • Page 38 POWER LINE SAFETY Determine whether there are power lines in the area before starting any job. Only operate around power lines in accordance with Federal, State and Local Regulations as well as ANSI B30.5 latest edition. Never remove materials from under powerlines with a crane if the boom or machine is capable of contacting them.
  • Page 39 Safety POWER LINE SAFETY Maintain Required Clearance LINE VOLTAGE REQUIRED CLEARANCE 0 TO 50kV 10 FT ( 3.0M) 500 TO 200kV 15 FT (4.6m) 2000 TO 350kV 20FT (6.1m) 350 TO 500kV 25FT (7.6m) 500 TO 750kV 35 FT (10.7m) 750 TO 1000kV 45FT (1.37m) >1000kV...

  • Page 40: Effects Of Wind Conditions

    Effects of Wind Conditions Wind Speed Detection It is essential that you observe the permitted maximum wind speeds. To check the wind speed, the crane can be equipped with an air speed indicator (anemometer). This consists of two elements: Rotor - fitted to the head of the main boom or main boom extension. Display - on the screen.
  • Page 41 Safety Pay attention to the wind speed values in table below in relation to the information in the WARNING section of the LOAD CHART. Any governmental regulations applicable to the job site must also be observed. Wind Force Wind Speed Consequences Scale Terms Described...

  • Page 42: Lightning Storm

    Lightning Storm When lightning is striking in the vicinity of the crane, the operator should never attempt the following procedures: • Getting into the operator's cab; upper or lower, or attempting to get onto the carrier, superstructure or boom assembly. •...

  • Page 43: Lock Out & Tag Out

    Safety Lock Out & Tag Out Code of Federal Regulations number 1910.147 requires that employers establish and follow a Lock Out & Tag Out procedure and train their employees in that procedure before any employee can operate, service or maintain any piece of power equipment. Employers are required to make periodic inspections to see that their Lock Out &...
  • Page 44 Who must apply a lock & tag • Any person working on the equipment. • Foreman or other person responsible for the work being done. • If several people are working on a machine at the same time, each person must apply his or her own lock and tag.

  • Page 45: Access/Egress

    To provide safe access and egress to/from the crane, Terex provides a number of steps, ladders and handrails allowing three--point access to all areas of the crane where it is necessary for the operator to be when moving from the ground to the operator's cab or from the operator's cab to the ground.
  • Page 46 Step in stored position for travel and ground clearance. Always relocate to this position for travel. See "Step Installation" in the Assembly section of the manual. Do not use as a step in this position. Step shown in crane working position. P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...
  • Page 47 Safety P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...
  • Page 48 Operator's Cab Access / Egress Item 3-Use this access step only when upper structure is rotated 180 degrees so operator's cab is directly accessable. P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...
  • Page 49 Safety Do not use item 4 as a grab handle. Only use grab handles for access or egress of the operator's cab that are marked in the illustrations. P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...

  • Page 50: Personal Safety

    Personal Safety SLIP AND FALL PREVENTION Always wait until machine has stopped before getting on and off equipment. Do not jump on or off. Do not use controls and steering wheel as hand holds. Keep the machine clean and dry. Remove all oil, grease, mud, ice and snow from walking surfaces.

  • Page 51: Seat Belts

    Safety Seat Belts SOME SUGGESTED USAGE AND MAINTENANCE INSTRUCTIONS FOR SEAT BELTS Wear your lap belt low and snug. Manually adjustable lap belts and shoulder harnesses are adjusted by pulling the loose end of the webbing through the buckle or adjuster. Seat belts using automatic-locking or emergency-locking retractors are self-adjusting.

  • Page 52: Assembly

    Assembly Step Installation Steps (1) must be rotated into operation position. After delivery, remove the two capscrews (2) shown in the illustration and rotate the step down. Replace and tighten the capscrews. Do this on all four corners of the crane. Before loading the unit on a trailer, the steps must be returned to the upright position to provide sufficient ground clearance P/N 12261-319 REVISED: August 2012...

  • Page 53: Spooling Wire Rope On Drums

    Assembly Spooling Wire Rope on Drums Care must be exercised when installing wire rope on the winch drum. Improper spooling can. result in rope damage through crushing, kinking, dog- legs, abrasion and cutting. Poorly installed wire rope will also adversely affect the operating characteristics of the machine by causing uneven application of force and motion.
  • Page 54 Apply braking force to the reel flange in order to prevent overrun as the rope is being drawn off. Loops formed by overrun can cause kinks and doglegs in the rope, resulting in damage and premature rope failure. A timber or block forced against the shipping reel flange can be used to provide the required braking force.
  • Page 55 Assembly adjacent turns are tight against one another. A lead or brass hammer may be used to tap the rope over against preceding turns. Tight winding on the drum is absolutely essential. Never use a steel hammer or pry bar to move the rope over on the drum. These tools can easily damage the rope.
  • Page 56 Final seating of the wedge is accomplished by making lifts of gradually increasing loads. avoid imposing shock loads on the rope until the wedge is firmly in place. After the wedge has been firmly seated, a short length (6 inches) of the cable should be secured to the free end of the wire rope to act as a stop as shown.

  • Page 57: Hoist-Line Reeving

    Assembly Hoist-Line Reeving 1. AUXILIARY WINCH 2. MAIN WINCH 3. 5 SHEAVE 4. 4 SHEAVE 5. DEAD END FOR EVEN PARTS OF LINE 6. DEAD END FOR ODD PARTS OF LINE 7. WINCH DEAD END 8. IDLER SHEAVE 9. LOAD SHEAVE 10.
  • Page 58 Wire Rope Specifications on page 195FOR CABLE SPECIFICATIONS AND Wire Rope and Reeving on page 179 FOR CABLE AND SOCKET SPECIFICATIONS NOTE: SHEAVES IN BOOM HEAD AND HOOK BLOCK ARE NUMBERED FROM LEFT TO RIGHT AS VIEWED FROM THE OPERATOR’S STATION. “D” INDICATES PINNED END OF ROPE.
  • Page 59 Assembly of line required for the load being lifted. Refer to the Crane Capacity Chart for parts of line required. P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...

  • Page 60: Cable Reeving

    Cable Reeving CABLE REEVING When reeving the machine for any job, remember that hoisting and lowering speeds decrease as the number of parts of line increases. For the most efficient use of the machine, it is desirable to use the minimum number of required parts for lifting the anticipated loads.

  • Page 61: Side Stow Jib

    Assembly Side Stow Jib DE S C R IP TION Two optional jib extensions are available to provide additional boom reach. One is a 26ft (7.93 m) side stow swing-on one-piece lattice type jib that is offsettable at 0°, 15°, or 30°. The second jib option is a 26-43 ft.
  • Page 62 Before erecting or stowing the jib, ensure that no personnel or obstacles are in the swing path of the jib. ERECTING THE JIB Jib Storage Brackets Anti Two-Block Switch Jib Mounting Pins (4) Guide Rope Anti Two-Block Plug T-Handle Anit Two-Block Socket Extend and set the outriggers.
  • Page 63 Assembly With the engine at idle, slowly extend the boom 2-3 feet (.6-1 m). As the jib clears the storage brackets, the jib will swing out approximately 45°. Booming down too quickly can result in damage to jib. 10. With the engine at idle, slowly boom down to minimum boom angle while another operator uses the guide rope to control the speed of the jib rotation.
  • Page 64 Retract the boom and set the outriggers. Boom down to minimum boom angle. Loosen the two (2) cap screws on the left side of the upper and lower sheave shafts. This will require a 3/ 4 inch hex wrench. Reeve the hoist line over the top center sheave on the boom head, around the jib sheave, and attach to the eye on the bottom of the jib tip.
  • Page 65 Assembly EXTENDING AND RETRACTING THE JIB PULLOUT SECTION Pull Out Retaining Pin Hole Attach Dead End of Rope Pull Out Anti Two-block Plug Anti Two-block Extended Socket Two-Block Weight Anti Two-block Retracted Socket P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...

  • Page 66: Description Of Machine And Controls

    Description Of Machine and Controls Universal Symbol Identification SWING LOCKED HEADLIGHTS DEFROST PARKING BRAKE PARKING LIGHTS TURN SIGNAL INDICATOR LOW OIL PRESSURE BEACON SWING FUEL STANDARD STEER SWING BRAKE WATER TEMPERATURE 4 WHEEL STEER FAST P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...
  • Page 67 Description Of Machine and Controls ENGINE OIL PRESSURE CRAB STEER SLOW VOLTAGE REAR STEER LEFT HORN EMERGENCY STOP REAR STEER RIGHT WINCH AIR PRESSURE IGNITION WINDSHIELD WASHER SWING LEFT ELECTRICAL ACCESSORIES WINDSHIELD WIPER P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...
  • Page 68 SWING RIGHT ELECTRICAL SYSTEM OFF AXLE ENGAGE / RANGE SHIFT BOOM DOWN ELECTRICAL SYSTEM ON AXLE DISENGAGE / RANGE SHIFT BOOM UP IGNITION ON ENGINE QUICK START BOOM IN TRANSMISSION TEMPERATURE P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...
  • Page 69 Description Of Machine and Controls BOOM OUT TRANSMISSION OIL PRESSURE OUTRIGGER SELECT HEATER/AC HEAT OUTRIGGER RETRACT HEATER/AC AC OUTRIGGER EXTEND HEATER/AC FAN P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...

  • Page 70: Upper Controls And Instruments

    Upper Controls and Instruments 1. FUEL GAUGE - Graduated in quarters of 9. DASH LIGHT SWITCH - Push left for dash full tank. lights only, push right for dash lights and head lights. 2. SWING LOCKED INDICATOR - Indicates 10. WORK LIGHT SWITCH - Push right to swing lock is engaged.
  • Page 71 Description Of Machine and Controls 5. ENGINE OIL PRESSURE GAUGE - 13. OUTRIGGER EXTEND/RETRACT Measures engine oil pressure. MASTER SWITCH - This switch is used in conduction with outrigger switches (19) to extend and retract the outrigger beams and jacks. Push left to retract and right to extend. 6.
  • Page 72 18. TRANSMISSION TEMPERATURE 29. IGNITION SWITCH GAUGE 19. RIGHT TURN SIGNAL 30. JACK SWITCH (LEFT FRONT) - Used in conjuction with switch (13), to extend and retract outrigger jack and beam. 20. TRANSMISSION OIL PRESSURE 31. JACK SWITCH (LEFT REAR) - Used in GAUGE - Indicates transmission charge conjuction with switch (13), to extend and pressure.
  • Page 73 Description Of Machine and Controls 23. AIR PRESSURE GAUGE - 105 - 125 psi 33. JACK SWITCH (RIGHT REAR) - Used in optimum operating pressure. conjuction with switch (13), to extend and retract outrigger jack and beam. 24. PARK BRAKE INDICATOR 34.
  • Page 74 17. TACHOMETER 46. LOAD MOMENT INDICATOR-Read Terex RCI 510 Operator's Manual to fully understand functional operation and safety of this unit. 22. BUBBLE LEVEL-Indicates crane level 47. DEFROSTER FAN condition. Bubble must be on center before lifting loads. 34. TRANSMISSION GEAR SELECTOR 48.
  • Page 75 Description Of Machine and Controls 40.SWING BRAKE - Apply to prohibit boom 42.ACCELERATOR - Push to increase from swinging engine RPM and release to decrease. 41.BOOM EXTEND RETRACT PEDAL - Tilt 43.BRAKE PEDAL - Push to stop carrier the pedal halfway forward to power-extend movement.
  • Page 76 55. SWING/AUX WINCH CONTROL - Move joystick forward to pay out aux winch rope. Move joystick backward to take in aux winch rope. Move joystick left to swing boom left. Move joystick right to swing 57. Hi-Speed Winch Switch - Press to boom right.
  • Page 77 Description Of Machine and Controls 59. BOOM HOIST/MAIN WINCH CONTROL - Move joystick forward to pay out main winch rope. Move joystick backward to take in main winch rope. Move joystick left to 56. WINCH DISABLE SWITCH-Press switch raise boom. Move joystick right to lower to disable winch.
  • Page 78 37. SWING BEARING GREASE FITTING- 50. HEATER ON/OFF SWITCH Attach grease gun and swing machine slowly while applying grease. 38.HAND THROTTLE - Holds engine throttle 51. HEATER FAN CONTROL at an operator settable position. Place the accelerator (42) at approximate RPM. Push in button on hand throttle.
  • Page 79 Courtesy of Crane.Market...

  • Page 80: Inspection

    Inspection Pre-Start Inspection Inspection Check List This check list is to be used in addition to the information provided in this manual to properly operate and maintain the machine. Table 1: ITEMS TO BE INSPECTION SATISFACTORY ADJUST REPAIR INSPECTED & CODE CHECKED VISUAL INSPECTION...
  • Page 81 Inspection ITEMS TO BE INSPECTION SATISFACTORY ADJUST REPAIR INSPECTED & CODE CHECKED MUFFLER/EXHAUST SYSTEM ALL CONTROL MECHANISMS INSTRUMENT GAUGES CLUTCHES & BRAKES D WIRE ROPE, SHEAVES & GUARDS TWO BLOCK DAMAGE PREVENTION SYSTEM LOAD SUPPORTING COMPONENTS CONDITION FIRE EXTINGUISHER BACKUP ALARM BOOM ANGLE INDICATOR HEAD/TAIL/BRAKE...
  • Page 82 ITEMS TO BE INSPECTION SATISFACTORY ADJUST REPAIR INSPECTED & CODE CHECKED AIR CLEANER ELEMENT CLUTCH & BRAKE LINKAGE & PINS WHEEL LUG NUT TORQUE FAN BELT TENSION STRUCTURAL MEMBERS & WELDS BOOM INSPECTION BATTERIES & STARTING SYSTEM ALCOHOL EVAPORATOR CHROMED CYLINDER RODS SWING BEARING BOLT TORQUE...
  • Page 83 Inspection FUEL Engine fuel and propane/diesel for the upper unit heater should be adequate for sustained operations. LUBRICATION Perform the daily lubrication as required in the Lubrication Chart on page 123. HYDRAULIC SYSTEM Check hoses, tubes, components, reservoir sight gauge, valves, pumps, motors, connections, reservoir oil temperature, cylinder mounting bushings and pins.

  • Page 84: Wire Rope Inspection Record

    Wire Rope Inspection Record WIRE ROPE INSPECTION RECORD (Refer to Wire Rope User's Manual for Criteria) PLACE OF INSPECTION DATE DESCRIPTION OF CRANE Make Model Serial No. Type and arrangement of attachments Date of Last Rope Inspection Hours and Time of Service Since Last Inspection Results of Inspection Rope Type and Size Conditions Noted...

  • Page 85: Crane Boom

    Inspection Crane Boom WEEKLY: STRUCTURAL MEMBERS AND WELDS Visually inspect all structural members and welds including (but not limited to) the extended boom for straightness, roller (or pad) adjustment, and cracks. Pay special attention to the longitudinal welds joining the top, side and bottom plates.
  • Page 86 If any indicator decals are missing or illegible (either triangle markers or boom length numbers), order the applicable items through your distributor and apply them using the dimensions given on the following page. P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...
  • Page 87 Courtesy of Crane.Market...

  • Page 88: Operating Instructions

    Operating Instructions General Operational Issues Safety Devices EMERGENCY STOP The emergency stop button is located on the lower part of the dash to the left of the steering column in the operator’s cab. In an emergency, this button can be pushed in to stop all crane functions including engine operation.

  • Page 89: Operating The Unit

    Operating Instructions Operating the Unit Starting the Engine Once the pre-start inspection ( see Pre-Start Inspection on page 79) has been completed, the engine may be started. At ambient temperatures over 32 deg. F. on Cummins Engines, follow the starting procedure below: STARTING PROCEDURE Open the throttle to the idle position.

  • Page 90: Cold Weather Starting

    Cold Weather Starting At very low temperatures, when the engine is difficult to start and operator experience so indicates, follow the starting procedure outlined below: Cold Weather Procedure Disengage the pumps. Wait for “Wait to Start” light to go off. Start the engine as described above.

  • Page 91: Jump-Starting An Engine With Booster Cables

    The ground lead is connected to the engine block, frame, or some other good metallic ground. The battery terminal connected to the starter relay is the one which is not grounded. Terex Cranes are always shipped with the negative (-) as ground.

  • Page 92: Operating The Engine

    Operating the Engine If the engine oil pressure gauge does not register normal operating pressure within 30 seconds of starting, shut down the engine, determine the cause and effect repairs before re- starting the engine. When the engine reaches operating temperature, operations may begin. While the engine is running, check the gauges at frequent intervals and be alert for any abnormal engine sounds or faulty engine performance.

  • Page 93: Making A Typical Lift

    Operating Instructions Making a Typical Lift Making a Typical Lift In making lifts, the operator must successfully coordinate several crane functions. These include the boom raise/lower, boom extend/retract, load hoist/lower and swing functions. Although experienced operators tend to operate two or more of these functions simultaneously, the lift procedure can be broken down into the following sequence of operations.
  • Page 94 The operator must exercise sound judgment in positioning the outriggers. The outriggers should not be set near holes, on rocky ground or on extremely soft ground. Setting the outriggers in such locations may result in the crane tipping, causing personal injury or property damage. Where a firm footing or level ground is not otherwise available, it should be provided by substantial timbers, solid blocking, or other structural members sufficient to distribute the load so as not to exceed the safe...
  • Page 95 Operating Instructions capacity chart for all given loads. Reeving with more parts of line than required may result in all of the wire rope being payed off the winch drum. The intent of this caution is to prevent any possibility of either reverse winding of the rope on the winch drum, which could cause breakage of the winch rope, or of unseating the rope wedge in the winch drum, which could result in the uncontrolled fall of the hook block and load.
  • Page 96 GRADUALLY slow the swing by use of the joystick. First, move the joystick to the neutral position and then VERY SLOWLY into the opposite swing direction position as required to slow the swing. Apply the swing brake, with the foot pedal, when the swing is stopped or when emergency situations dictate that the swing be terminated abruptly.
  • Page 97 Operating Instructions release this lever slowly to minimize dynamic effects of the load and to prevent “birds-nesting” of the cable on the winch drum. To shift the winch into the high-speed mode the winch switch on the front of the joystick must be pressed. When slowing the winch, release switch to bring the load to a gradual stop.
  • Page 98 exceeding the rated load as determined by the load rating charts. When operating a hydraulic crane, the operator should realize that hydraulic and structural competence, NOT TIPPING LOAD, is often the determinant of lifting capacity. Therefore, THE OPERATOR MUST BE GUIDED SOLELY BY THE APPROPRIATE MANUFACTURER’S LOAD RATING CHART when considering load weight.

  • Page 99: Arm And Hand Signals

    Operating Instructions Arm and Hand Signals HOIST. With LOWER. With USE MAIN USE WHIPLINE. RAISE BOOM. forearm vertical arm extended HOIST. Tap fist (Auxiliary Hoist) Arm extended, fore finger downward, on head; then Tap elbow with fingers closed, pointing up, forefinger use regular one hand, then...
  • Page 100 STOP. Arm EMERGENCY TRAVEL. Arm TRAVEL.(Both extended, palm STOP. Both extended EVERYTHING. Tracks.) Use down, move arm arms extended, forward, hand Clasp hands in both fists in front back and forth palms down, open and slightly front of body. of body, making horizontally.

  • Page 101: Load Rating Chart Interpretation

    Operating Instructions Load Rating Chart Interpretation In the following pages are examples of a load chart, these example charts may differ from the chart supplied with your crane. Always use the load rating chart supplied with the crane to interpret the conditions and limitations that exist when making a lift with the crane. The determining factors are lifted load, radius, boom angle, working position, hoist line reeving, tire pressure, travel data, use of a jib, and any other special conditions that exist, such as wind velocity, soil conditions, etc.
  • Page 102 should be removed. In certain instances, it is advantageous, from a job set-up point of view, to lift over the boom point with the jib erected. In these instances, it is necessary to make deductions from the rated loads shown in the load rating chart “Jib Erected But Not Used“...
  • Page 103 Operating Instructions On Outriggers Load Ratings: To determine the boom extension capacities with the crane on outriggers, use the following procedure: Determine weight of load to be lifted. Determine weight of slings and rigging hardware. Determine weight of hook block. Determine other capacity deductions.
  • Page 104 Determine load radius, boom angle, and boom length. Compare load weight with chart rated capacity for the boom length, radius, and boom angle. The lifted load must not exceed the chart rated capacity for the boom length and radius. In this example, the lifted load of 25,300 lbs. is less than the rated load of 27,800 lbs. and can be handled as long as the machine is on outriggers per Notes 6 &...
  • Page 105 Operating Instructions SIDE-STOW JIB Jibs are rated by boom angle only and not by radius. This means that as long as the boom is at 61° boom angle and the jib at 30° offset, before loading, no matter if the boom is fully extended or retracted, it can only lift a maximum of 3,300 lbs. on a 33 foot side-stow jib.
  • Page 106 JIBS To determine the jib capacities of the crane with all boom lengths, use the following procedure: Determine weight of load to be lifted. Determine weight of slings and rigging hardware. Determine weight of hook block. Determine capacity deductions. Calculate weight of lifted load. Determine jib type and length, jib offset, main boom angle.
  • Page 107 Operating Instructions This lift cannot be made Example Hook & Ball 239 lbs. Slings 300 lbs. Hook Block 750 lbs. Object Lifted 2350 lbs. Total Load Lifted 3749 lbs. ON TIRES On tires operation, particularly pick and carry, must be done in a slow, smooth manner over level terrain that will support the crane, with the loads close to the ground and the boom as low as possible to avoid the load swinging unintentionally, causing injury or tip over.
  • Page 108 The maximum boom length shown on the On Tire chart is the maximum boom length that can be used at the radius shown. This is done to limit the boom height when working on tires. Do not exceed the maximum boom length for the given radius. “Stationary”...
  • Page 109 Operating Instructions 2.5 MPH means the crane can be driven at this speed, or slower, with the tires at the proper inflation pressure with the boom straight over the front. STABILITY/ STRUCTURAL STRENGTH Crane load ratings with an asterisk (*) beside them are based on the machine’s structural strength.

  • Page 110: On-Tires" Lift

    "On-Tires" Lift Listed below are special precautions for “On Tires” lifts. "On-Tires" Lift Procedure The boom shall be carried straight over the front of the crane. Travel speed reduced to suit conditions. Maintain specified tire pressures. Avoid sudden starts and stops. Provide tag or restraint lines to snub swinging of the load.
  • Page 111 Operating Instructions Death or Serious Injury can result from an overturning crane. The boom angle must be below 53 degrees unless the boom is positioned in-line with the cranes chassis or is positioned on outriggers. On retracted outriggers, the boom angle must be below 65 degrees unless the boom is positioned in-line with the crane chassis.

  • Page 112: Unusual Operating Conditions

    Unusual Operating Conditions Special problems in maintenance and operation are caused by unusual conditions such as extremes in heat, cold and humidity, high altitude, salt water, and dusty or sandy work sites. When operating under such conditions, special precautions must be taken to prevent damage, minimize wear, and avoid component deterioration.
  • Page 113 Operating Instructions The battery can discharge if snow or ice short circuits the terminals. Keep the battery posts and cable connectors clean and dry. Remove any corrosion with a solution of soda and water. During extremely cold weather, it is advisable to remove and store the battery in a heated area when the crane is to remain idle overnight or for any extended period.
  • Page 114 Engine overheating due to loss of coolant will most often be corrected by SLOWLY adding coolant while the engine is running at FAST IDLE. Should this fail to correct the problem, drain and flush the system and refill with fresh coolant (50% solution of ethylene glycol) and a corrosion inhibitor.
  • Page 115 Operating Instructions it takes for lubricants, breathers and filters to accumulate unacceptable amounts of sand or dust. The frequency of lubrication and service should be adjusted accordingly. HIGH HUMIDITY OR SALTWATER In some locations, such as coastal areas, the crane may be exposed to the deteriorating effects of salt, moisture, or both.

  • Page 116: Moving The Unit

    Moving the Unit Vehicular Operation The Rough Terrain Crane is capable of both off road and limited on-road travel. The kind of travel undertaken will determine how the carrier is operated. Before moving the crane, either around the work site or between sites, carefully consider the terrain type, road conditions and any hazards likely to be encountered enroute.
  • Page 117 Operating Instructions MOVING THE CRANE TO A JOB SITE The procedure for moving a crane is as follows: Start the engine, following the procedure given in the topic “Starting the Engine”. Allow air pressure build-up. Apply the swing brake. Apply the swing lock. Apply the Service Brake.
  • Page 118 Four wheel drive engagement is accomplished by a solenoid shifted coupling in the transmissions. In the ranges F1 thru F3 and R2 and R3. Observe the restrictions given in the following chart during on-the-road operation. Maximum permissible running intervals are given in terms of miles and hours of travel time.

  • Page 119: Traveling Around The Jobsite

    Operating Instructions Traveling around the Jobsite When traveling around a job site, it is very important that the crane operator is very aware of what is happening with the crane as well as with other vehicles and personnel on the job site. The crane operator should observe the following rules as well as good common sense while moving a crane around a job site.

  • Page 120: Transportation

    Transportation Instructions for Loading and Unloading LOADING EQUIPMENT Prior to operation, read and understand the manuals provided with this equipment. Also read and follow all general safety rules. PREPARE TRAILER Assure that any ramps are in position or trailer is otherwise prepared for loading and path of travel is clear for loading.
  • Page 121 Transportation When equipment is in position, make sure front and rear tires are returned to center position. Move transmission lever to neutral, apply parking brake using dash switch and release the foot brake. Turn the engine off. SECURE EQUIPMENT Perform all necessary procedures to assure that machine is blocked and chained in position to trailer to eliminate any possible movement.
  • Page 122 the right side of the steering column toward you and moving it up one position. R1 position attained by pulling lever on the right side of the steering column toward you and moving in down one position. Slowly release foot brake to begin travel. Use the throttle pedal to increase speed only if necessary.

  • Page 123: Boom Restraint

    Transportation Boom Restraint The boom must be stowed in the boom rack before transporting the crane. The boom extend sections should be restrained to prevent gradual roll-out when transporting the crane on a semitrailer. The hydraulic system will not hold the sections against the hard breaking jolts while the crane is being transported.

  • Page 124: Maintenance

    Maintenance Lubrication Chart P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...

  • Page 125: Cold Weather Package Specifications

    (-12F). The standard crane includes an engine heater, either start aid (or intake air grid heater), and propane cab. Terex Cranes are designed to operate in cold weather conditions to a temperature of -40C (-40F). To operate in these extreme weather conditions, proper start up and recommended operating procedures must be followed.
  • Page 126 NOTE: It is the responsibility of the customer to use the correct mixture and type of Diesel Fuel for the environment. Failure to do so can result in clogged fuel filter due to waxing and icing formation. See Cummins Service Bulletin 3379001-21 Fuels for Cummins Engines.
  • Page 127 In the case of vehicles being started in ambient temperatures below +5°F (-15°C), vehicle warm-up procedures are required or damage can result to transmission, axles or drive line components. Your Terex Crane with Cold Weather Package is equipped with full synthetic 75W/90 Gear Oil. (See chart below). P/N 12261-319 REVISED: August 2012...
  • Page 128 Gear Oil Specifications Gear Oil Type A.P.I Spec. SAE Grade Meritor Military/ Outside Spec. SAE Spec. Temp. Non- Petroleum GL-5 85W/140 0-76-A MIL- > +10°F Extended with EP PRF-2105 E (-12°C) Drain Additives and SAE 80W/140 0-76-B > -15°F Lubricants J2360 (-26°C) 80W/90...
  • Page 129 Maintenance Power -Up Self Test Immediately following electrical power-up, the system executes a self-test which lasts for three seconds. During this time, the numerical display segments and bar graph segments are all turned on, the audible alarm will sound and alarm indicator lights are illuminated. The home display shows the machine model and rating chart number.

  • Page 130: Cold Weather Package Recommendations

    0° C (32° F) to -40° C (-40° F). When you operate your crane in temperatures above 0° C (32° F), refer to your Terex Crane Operator’s & Shop Manuals. Make sure you read and understand the information in...
  • Page 131 Maintenance Starting Recommendations Check the air cleaner daily before starting the machine. If you operate the machine in heavy snow, attach a burlap sack loosely to the pre-cleaner. Keep the burlap sack away from heated parts. In order to assist in warm-up, block the radiator. Blocking the radiator will restrict air from the fan.
  • Page 132 18°C to 21° C (64°F to 70°F) shop area will have a lower tire pressure in freezing conditions. Terex recommends the use of dry nitrogen gas to inflate the tires for cold conditions. When nitrogen gas (N2) is used, there will not be a build up of ice crystals around valve stem which could hold the valve open.
  • Page 133 Inflation Pressure (psi) Additional Cold Weather Operation Issues Contact your Terex Service Representative or Cummins Engine Service Representative if you have any questions regarding extreme environment operation or service of your crane. P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...

  • Page 134: Maintenance Introduction

    Maintenance Introduction A regular program of periodic preventive maintenence is essential to prolong crane operating life, maximize efficient service and minimize downtime. This section details a series of checks and procedures which are to be performed at daily, weekly, monthly and semi-annual intervals.

  • Page 135: Machine Maintenance Checklist

    Maintenance Machine Maintenance Checklist DAILY CHECK (8 HOURS) ___ Perform Daily Lubrication ___ Drain Air Tanks ___ Check Hydraulic Reservoir Fluid Level ___ Check Wire Rope And Related Components ___ Fill Fuel Tank ___ Check Air Cleaner ___ Check Engine Oil Level ___ Check Controls ___ Check Instruments, Gauges, &...
  • Page 136 MONTHLY CHECK (160 HOURS) ___ Perform Daily And Weekly Checks ___ Obtain Hydraulic Oil Sample for Analysis. ___ Perform Monthly Lubrication ___ Clean Radiator Exterior ___ Check Engine Manufacturer’s Manual For ___ Check Engine Belts Additional Maintenance Requirements ___ Drain Hydraulic Reservoir Of Moisture QUARTERLY CHECK (500 HOURS) ___ Perform Daily, Weekly And...
  • Page 137 Maintenance 2000 HOURS/1 YEAR: Disassemble And Inspect Winch Components SPECIAL BREAK IN REQUIREMENTS FOR NEW CRANES 8 HOURS - During the first 50 miles of service and any time the wheels have been removed, retorque the wheel nuts to 400-500 ft.lbs. 40 HOURS - Swing bearing bolts must be kept torque tightened to a dry rating of 720 ft.lbs.

  • Page 138: Engine Maintenance

    Engine Maintenance For Cummins engine maintenance refer to Cummins Operation and Maintenance Manual Engine productivity, longevity, and low-cost performance depend on a regular program of periodic maintenance. The materials presented here are listed in accordance with the Machine Maintenance Checklist on page 134.
  • Page 139 Maintenance WATER SEPARATOR A water separator is used to remove water contamination from the fuel before it enters the engine. Water contamination should be drained daily or before it becomes 1/2 full. AIR CLEANER Inspect the air cleaner and it’s connections for leaks, dents and damage. A vacuum actuated indicator mounted on the air cleaner assembly indicates conditions of restricted flow through the air cleaner.

  • Page 140: Engine Radiator Maintenance

    Engine Radiator Maintenance DAILY/8 HOURS COOLANT LEVEL Check the engine radiator coolant level and add coolant if necessary. The coolant should be visible in the sight gage near the top of the radiator tank. A solution of 50% ethylene glycol by volume is the recommended year-round coolant. Replenish the corrosion inhibitor if necessary.

  • Page 141: Transmission Maintenance

    Maintenance Transmission Maintenance DAILY MAINTENANCE CHECK WEEKLY MAINTENANCE CHECK On a weekly basis, check the TRANSMISSION OIL LEVEL. Start the engine and run it at 1000 to 1500 rpm until the transmission reaches a normal operating temperature of (180° to 200° F.). Then idle the engine and shift through all range positions slowly.
  • Page 142 WHEN STALLING THE CONVERTER MAKE SURE THE TRANSMISSION IS IN HIGH GEAR, THE VEHICLE BRAKES SET, AND THE IMMEDIATE AREA IS CLEAR OF PERSONNEL AND OBSTRUCTIONS. DO NOT EXCEED 30 SECONDS OR 250°F CONVERTER OUT OIL TEMPERATURE, WHICHEVER COMES FIRST, AT FULL GOVERNED ENGINE RPM STALL SPEED.

  • Page 143: Axle Maintenance

    Maintenance Axle Maintenance MAINTENANCE CHECK As a part of the MONTHLYMAINTENANCE CHECK, inspect the axle and differential levels. When checking the AXLE OIL LEVEL, rotate each wheel until the planet cover is positioned as shown in the illustration below. the arrow on the planet cover points horizontal when the cover is properly positioned for checking the oil.
  • Page 144 On a ANNUAL basis, drain the oil from the differential by removing the drain plug at the bottom of the differential housing. Replace the plug and refill the differential with the lubricant specified on the lubrication chart. To the level specified above. Drain the oil from hubs removing the fill and check plug by rotating the hub until the hole is at the extreme low position.

  • Page 145: Tire Maintenance

    Maintenance Tire Maintenance MAINTENANCE CHECK As a part of the WEEKLY MAINTENANCE, inspect the tires and rims for damage. Cuts and bruises, snags, punctures, and abrasions should be repaired before they can cause tire failure. Bent, cracked or loose rims should be repaired or replaced. Check tire valve condition and make sure each valve has a cap.
  • Page 146 The energy stored in a tire and rim assembly under pressure makes changing truck and off-road tires hazardous. Death or personal injury can occur while handling or maintaining these tires. Special procedures must be followed and special tools must be used if tires are to be changed safely. Whenever possible, let your service company handle this job.
  • Page 147 Maintenance WRONG WAY SAFETY PRECAUTIONS FOR MOUNTING OR DEMOUNTING RIMS AND WHEELS DO’S AND DON’TS DON'T 1. Follow mounting and demounting procedures outlined in the manufacturer’s instruction manual or 1. Don’t use mis-matched parts. Mis-matched other recognized industry instruction parts are dangerous. Make sure side ring and manual.
  • Page 148 4. Double check to see that removable 4. Never use tire and rim combinations that are rings are seated properly before inflating. not approved by the Tire & Rim Association. 5. Check for excessive side ring play and ring butting. Either one of these conditions is an indication of mismatched parts.

  • Page 149: Wheel Removal & Installation Procedure

    3. Extension-12" CRANE MODEL TIRE SIZE WHEEL ASSEMBLY WEIGHT RT200-1 20.5 X 25 1300 LBS (590 Kg) To properly remove or install a wheel & tire assembly, the use of a forklift is required due to the weight of tire & rim.
  • Page 150 P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...

  • Page 151: Air System Maintenance

    Maintenance Air System Maintenance Inadequate delivery pressure or defective components operations can generally be traced to leakage, blocked lines, or the buildup of moisture and sediment in the system. A regular program of preventive maintenance is an essential part of air system operation. The materials presented here are listed in accordance with the Machine Maintenance Checklist on page...
  • Page 152 P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...

  • Page 153: Brake System

    Maintenance Brake System BRAKE PEDAL: 1. Adjusting Screw 3. Plunger 2. Jam Nut 4. Roller MAINTENANCE Every 3 months or quarterly: Lubricate fulcrum and roller pin with oil. Free pedal travel should be checked as follows: Check to be certain plunger is in contact with spring seat.
  • Page 154 NOTE: All rubber components in the treadle valve should be replaced yearly. An increase in stopping distance or a low pressure warning light indicated a malfunction in the brake system, and although the vehicle brake system may continue to function, the vehicle should not be operated until the necessary repairs have been made and both braking circuits are operating normally.
  • Page 155 Maintenance ROUTINE MAINTENANCE Under normal operating conditions the parking brake is maintenance free. The parking brake is spring actuated. When the machine is operating and the brake is supplied with air pressure, it is released. If at, any point the machine loses air pressure (i.e. it is not running) the brake will be activated.

  • Page 156: Turntable And Swing Pinion

    Turntable and Swing Pinion Lubricate every 100 operating hours as follows: Inject grease as recommended below through one fitting located in the operator’s cab on the right console by the heater controls as the machine is rotated at least two complete revolutions.
  • Page 157 Maintenance NOTE: Other manufacturers’ lubricants of the same quality are suitable. P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...

  • Page 158: Swing Reducers

    Swing Reducers MAINTENANCE CHECK On a WEEKLY basis, check the swing reducer oil level. Oil level should be visible in the sight glass in the brake housing. Add additional oil through fill plug located just above sight glass if needed. Recommended gear oil is Texaco Meropa 150 or equivalent. P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...

  • Page 159: Hydraulic System Maintenance

    Maintenance Hydraulic System Maintenance MAINTENANCE A regular program of periodic maintenance is an essential part of continued hydraulic system operation. Allowing accumulations of moisture and sediment to build-up in the system will damage hydraulic valves, pumps and motors. The presence of leaking connections or damaged components effect the efficiency of operation and are dangerous.
  • Page 160 Refer to Hydraulic Oil Requirements on page 163 for hydraulic oils meeting the manufacturer’s specifications. Do not use oils which have detergent additives. The hydraulic reservoir is sealed and has a 14 psi relief valve. Exercise extreme care when removing the filter cap. The pressure is relieved by turning the reservoir cap counterclockwise to the first stop.
  • Page 161 Maintenance By-Pass Valve Drain Plugs Filler Cap Immersion Heater Return Line Filter Intake Suction Filter Oil Level Indicator Before discarding the old filter element, examine the type of material trapped in it. This may indicate which, if any, hydraulic system components are deteriorating. P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...
  • Page 162 SEMI ANNUALLY: SUCTION FILTER Remove and clean the hydraulic reservoir intake suction filter. This permanent screen type filter is located inside the reservoir on the intake to the pump manifold. Access to the filter is accomplished by removing the cover with filler neck and filter holding device from the top of the reservoir.
  • Page 163 Maintenance Where dust, dirt, high humidity or extreme heat are encountered, lubrication intervals should be shortened accordingly P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...

  • Page 164: Hydraulic Oil Requirements

    Hydraulic Oil Requirements The hydraulic system is filled with KOEHRING SPEC 805 hydraulic oil to give the unit the highest performance as a hydraulic machine and to provide proper lubrication for the hydraulic components. To ensure the longest life for this piece of equipment, particular attention must be paid to maintain oil at the proper level with an approved hydraulic oil and to keep the circuit system clean.
  • Page 165 Maintenance TRANSMISSION FLUIDS: DO NOT use transmission fluids. These fluids have been designed to work in automatic transmissions and they will not necessarily work in hydraulic systems. MIXING: Mixing different brands of oil is not recommended. Various companies use different additive packages, which when mixed together, may cause problems in a hydraulic system.
  • Page 166 per milliliter greater than a given micron size. The number of particles in your sample should be less than the following: Particle Size No. of Particles/Milliliter 10 micron or larger 3,000 20 micron or larger 30 micron or larger 40 micron or larger 50 micron or larger 100 micron or larger If your oil sample shows numbers greater than in the chart, your hydraulic system is...
  • Page 167 Maintenance PHYSICAL PROPERTIES TEST METHOD REQUIREMENT D. Viscosity Index ASTM D2270 95 Min. E. Pour Point ASTM D97 -25° F Max. F. Oxidation Test ASTM D943 2500 Hours Min. to 2.0 Neut. No. ASTM D943 2500 Hours Min. G. Rust Test ASTM D665 Procedure A Pass ASTM D892...
  • Page 168 Viscosity Minimum Ideal Cont. Maximum Selection Guide Grade Start-up Operating Operating Lines I.S.O. A.S.L.E. Temp. Hyd. Oil Hyd. Oil (New) (Old) Temp. Temp. 5°F 120°F 180°F (-15°C) (49°C) (82°C) 10°F 120°F 180°F For Ambient Temperatures (-12.2°C) (49°C) (82°C) Up To 80°F (27°C) 15°F 140°F 200°F...
  • Page 169 Maintenance OIL COMPANY ISO BRAND NAME OIL COMPANY ISO BRAND NAME AWX Multi- Conoco DN 600 (Artic) Viscosity Conoco Super Hyd. 5W-20 AW 32 Hyd. Fluids (Multi Vicosity) AW 46 Hyd. Fluids Pennzoil Conoco Super Hyd. 32 AW 68 Hyd. Fluids Products Co.
  • Page 170 *Factory filled with Northland Talamar 215 or equivalent. KOEHRING SPEC 805 IS EQUIVALENT TO HYDRAULIC OILS SHOWN ABOVE P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...

  • Page 171: Cable Lubrication Methods

    Maintenance Cable Lubrication Methods GENERAL We are covering the more commonly used methods of lubricating cable (wire rope). For special cable lubrication problems consult the cable manufacturer. HOT APPLICATION A heated bath is placed in the path of the wire rope, and the rope is passed through the hot lubrication over sheaves and a center guide wheel.
  • Page 172 DRIPPING A container can be placed above the sheave, so that the rope can be lubricated by opening a spigot. Sheaves are the best location for lubricating operating wire ropes, because the wires and strands open somewhat as they bend along the groove. POURING Lubricant can be poured on.
  • Page 173 Maintenance SWABBING AND PAINTING Lubricant can be swabbed on with rags, or painted on with a brush. Both are quick methods which can be made part of the operating routine. SPRAYING A light lubricant containing solvents can be applied to a wire rope by a properly directed spray nozzle AEROSOL SPRAYING Installations requiring only small amounts of lubricants, or only occasional applications,...
  • Page 174 P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...

  • Page 175: Electrical System Battery Check

    Maintenance Electrical System Battery Check MAINTENANCE CHECK Observe all instruments and gauges while operating machine and carrying out your DAILY MAINTENANCE checks. Replace or repair any malfunctioning instruments or gauges. BATTERY The maintenance free battery is located under the battery cover on the left hand side of machine.
  • Page 176 method of stabilization is to turn on the headlamps for 15 seconds. Read the voltage at least three minutes after the discharge load is removed. When a hydrometer reading can be taken, a value of 1.225 @ 80°F (26.7°C) can be used instead of the 12.4 voltage reading.
  • Page 177 Maintenance Typical Charge Voltage Caracteristics Maintenance Free Battery Battery Volts (CMEF) Standard Battery Battery State of Charge Place a wet cloth over the vent opening or openings. If, when charging the battery, violent gassing or spewing of electrolyte occurs, or the battery case feels hot (125°F, 52°C), reduce or temporarily halt charging to avoid damaging the battery.
  • Page 178 Any battery which is known to be discharged or has a stabilized voltage below 12.2 volts should be charged as shown below. 12-VOLT MAINTENANCE-FREE BATTERY CHARGING GUIDE Battery Capacity (Reserve Minutes) Above 125 to 170 Minutes Slow Charge 20 Hours @ 5 Amps 10 Hours @ 10 Amps NOTE: If a battery is to be charged overnight, (16 hours) a timer or voltage controlled charger is recommended.

  • Page 179: Electrical System Collector Ring

    Maintenance Electrical System Collector Ring ELECTRICAL COLLECTOR RING When troubleshooting the electrical system, always check the collector ring first to see that the spring-loaded brushes are centered in the bands. Keep free of any foreign material. Keep the set screws on the collector ring tight. Otherwise the wire harness may wrap up as the machine is swung.

  • Page 180: Wire Rope And Reeving

    Wire Rope and reeving MAINTENANCE All wire ropes in active service should be inspected daily along with spooling, sheaves, wedge sockets, and any other wire rope fittings for damage. Once weekly a thorough wire rope inspection should be made by a competent inspector. A record should be kept of the inspection on the form provide in the Inspection section.
  • Page 181 Maintenance machine, it is desirable to use the minimum number of required parts for lifting the anticipated loads. Never use less than the number of parts called for by the load rating chart. The minimum required number of parts is determined by referring to the load rating chart.

  • Page 182: Air Dryer

    Air Dryer Desiccant cartridge life will vary depending on operating conditions, speeds, loads, air usage and compressor condition. It is recommended that the desiccant cartridge be replaced approximately every 2 years. If system performance is reduced, desiccant cartridge replacement is necessary. It is also recommended that the desiccant cartridge be replaced if the compressor has been rebuilt.

  • Page 183: Slider Pads

    Maintenance Slider Pads The front bottom slider pad should be checked daily for wear. The remainder of the slider pads should be checked monthly for wear. All the slider pads contain a chamfer (1) on the wearing surface. When this chamfer is worn off, the slider pad must be replaced.

  • Page 184: Storage

    Storage Machine Storage Machines being placed in storage must be adequately protected from deterioration during the period of idleness. This will ensure that they can be restored to active service with a minimum effort. Before removing this hydraulic crane from service for extended periods, it should be prepared for storage as prescribed in the following paragraphs.
  • Page 185 Maintenance Fill the hydraulic reservoir to the top AFTER THE MACHINE IS PARKED IN ITS STORAGE SPOT. Coat wire rope with lubricant. Coat exposed cylinder rods with grease. The ENGINE should be prepared as prescribed in the topic Engine Storage on page 185.

  • Page 186: Engine Storage

    Engine Storage PREPARING ENGINE FOR STORAGE When an engine is to be stored or removed from operation for a period of time, special precautions should be taken to protect the interior and exterior of the engine, transmission, and other parts from rust accumulation and corrosion. The parts requiring attention and the recommended preparations are given below.
  • Page 187 Maintenance EXTENDED STORAGE (30 DAYS OR MORE) When An Engine Is To Be Removed From Operation For An Extended Period Of Time,prepare It as follows: Drain and thoroughly flush the cooling systemwith clean, soft water Refill the cooling system with clean, soft water. Add a rust inhibitor to the cooling system (refer to Corrsion Inhibitor).
  • Page 188 16. Remove the inspection hole cover on the clutch housing and lubricate the clutch release lever and link pins with a hand oiler. Avoid getting oil on the clutch facing. 17. Apply a non-friction rust preventive compound, to all exposed parts. If it is convenient, apply the rust preventive compound to the engine flywheel.

  • Page 189: Transmission Storage

    Maintenance Transmission Storage PRESERVATIVE SELECTION When transmissions are to be stored or remain inactive for extended periods of time, specific preservative methods are recommended to prevent rust and corrosion damage. The length of storage will usually determine the preservative method to be used. Various methods are described below.

  • Page 190: Restoration To Service

    Restoration to Service Refer to “Restoring Engine to Service” on page 190, and “Restoring Transmission to Service” on page 191, for the procedures required to restore these components to service. Remove the MACHINE from storage via the following procedure: Remove preservative lubricants from all surfaces. Check all fluid levels, adding or draining as required.

  • Page 191: Restoring Engine To Service

    Maintenance Restoring Engine to Service Remove the valve rocker cover(s) and pour at least one-half gallon of oil, of the same grade as used in the crankcase, over the rocker arms and push rods. Reinstall the valve rocker cover(s). Remove the covers and tape from all of the openings of the engine, fuel tank, and electrical equipment.

  • Page 192: Restoring Transmission To Service

    Restoring Transmission to Service If Nox Rust, or equivalent, was used in preparing the transmission for storage, use the following procedures to restore the unit to service. Remove the tape from openings and breather. Wash off all the external grease with solvent. Add hydraulic transmission fluid, type C3 to proper level.

  • Page 193: Chrome Cylinder Rod Storage

    Maintenance Chrome Cylinder Rod Storage Hard chrome plating is primarily applied to steel cylinder rods for its wear resistant properties, although it does provide considerable corrosion resistance as well. Once the chrome-plated rod is assembled into a cylinder and put into service, the hydraulic fluid on the surface of the rod provides all the corrosion resistance required for the rod during its life cycle.
  • Page 194 portions of each cylinder rod is required. Solvent applied with plastic or copper wool can be used, but abrasives such as sandpaper should never be used to clean the exposed surfaces of the cylinder rod. If surface damage to the chrome plate is discovered, the frequency of corrosion barrier applications should be increased.
  • Page 195 Courtesy of Crane.Market...

  • Page 196: Specifications

    Specifications Wire Rope Specifications MAIN WINCH STD. - 5/8” 6X19 OR 6X37 IWRC IPS PREFORMED RIGHT REG. LAY WIRE ROPE MINIMUM BREAKING STRENGTH - 17.9 TONS OPT. - 5/8” ROTATION RESISTANT COMPACTED STRAND 18X19 OR 19X19 MINIMUM BREAKING STRENGTH - 22.7 TONS AUXILIARY WINCH STD.
  • Page 197 Courtesy of Crane.Market...

  • Page 198: Service / Parts

    Service / Parts Outrigger Position Sensors If your crane is equipped with Outrigger Position Sensors-each outrigger box will contain (4) four proximity sensors for determining the location of outrigger beams at mid extend position and full extension. Each sensor has an air gap to maintain to operate properly and send signals to the Rated Capacity Indicator (RCI) or Rated Capacity Limiter (RCL).
  • Page 199 Service / Parts Proximity Sensor-Outrigger Position P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...

  • Page 200: Appendix

    Appendix Conversion Tables DECIMAL AND METRIC EQUIVALENTS OF FRACTIONS OF AN INCH Fractions of an Inch Decimals of an inch Millimeters 1/64 0.0156 0.397 1/32 0.0313 0.794 3/64 0.0469 1.191 1/16 0.0625 1.588 5/64 0.0781 1.985 3/32 0.0938 2.381 7/64 0.1094 2.778 0.1250...
  • Page 201 Appendix Fractions of an Inch Decimals of an inch Millimeters 0.5000 12.700 33/64 0.5156 13.097 17/32 0.5313 13.494 35/64 0.5469 13.891 9/16 0.5625 14.287 37/64 0.5781 14.684 19/32 0.5938 15.081 39/64 0.6094 15.478 0.6250 15.875 41/64 0.6406 16.272 21/32 0.6563 16.688 43/64 0.6719...
  • Page 202 WEIGHTS AND MEASURES LIQUID MEASURE (U.S.) 4 gills 1 pint 2 pints 1 quart 4 quarts 1 gallon 7.48 gallons 1 cu. ft. 240 gallons of water 1 Ton 340 gallons of gasoline 1 Ton LIQUID MEASURE (METRIC) 1 litre 0.0353 cu.
  • Page 203 Appendix CIRCULAR MEASURE 60 seconds 1 minute 60 minutes 1 degree 90 degrees 1 quadrant 360 degrees 1 circumference ELECTRICAL UNITS 1 kilowatt 1.34 H.P. 1 horsepower 746 watts SURVEYOR’S MEASURE 7.92 inches 1 link 100 links 66 feet or 4 rods or 1 chain 80 chains 1 mile...

  • Page 204: Average Weight Of Materials

    Average Weight of Materials All weights are shown in units of Lb. per Cu. Ft. METALS, ALLOYS, ORES Aluminum, Cast- Hammered Brass, Cast-Rolled Bronze Copper, Cast-Rolled Gold, Cast-Hammered 1205 Iron, Gray-Cast Iron Slag Lead Manganese Mercury Nickel Steel 481-489 Tin, Cast-Hammered Tungsten 1200 Zinc, Cast-Rolled...
  • Page 205 Appendix Fir, Douglas 42-54 Pine, Oregon Pine, Southern 38-42 Redwood Spruce Black Walnut EARTH Clay, Dry Clay, Damp, Plastic Clay & Gravel, Dry Earth, Dry Loose Earth, Dry Packed Earth, Moist Loose Earth, Moist Packed Earth, Mud Flowing Earth, Mud Packed Riprap, Limestone, 80-105 Sandstone, Shale...
  • Page 206 STONE, QUARRIED, PILED Basalt, Granite, Gneiss Limestone, Marble, Quartz Sandstone Shale Greenstone, Hornblend 107 MISCELLANEOUS 62.4 Water, 4 59.8 Water, 100 Paper Glass, Common Petroleum 45-54 Coal, Anthracite 47-5 Coal, Bituminous 40-54 Coal, Coke 23-32 P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...

  • Page 207: Torque Specs -Sae & Metric

    Appendix Torque Specs -SAE & Metric P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...
  • Page 208 P/N 12261-319 REVISED: August 2012 Courtesy of Crane.Market...

  • Page 209: Greer Rci 510 Operator's Manual

    Appendix Greer RCI 510 Operator's Manual Your crane will be set up with an RCI 510 or Element VGA system. Determine which system is installed and completely read the attached manual in the Appendix section before attempting to operate the crane. For Troubleshooting the system refer to your SHOP MANUAL-CD where you will find a GREER TROUBLESHOOTING MANUAL for both the RCI 510 and ELEMENT VGA systems.

  • Page 210: Greer Element Vga Operator's Manual

    Greer Element VGA Operator's Manual Your crane will be set up with an RCI 510 or Element VGA system. Determine which system is installed and completely read the attached manual in the Appendix section before attempting to operate the crane. For Troubleshooting the system refer to your SHOP MANUAL-CD where you will find a GREER TROUBLESHOOTING MANUAL for both the RCI 510 and ELEMENT VGA systems.
  • Page 211 Notes Courtesy of Crane.Market...
  • Page 212 Waverly, IA 50677 USA Tel: +1 319 352 3920 Fax: +1 319 352 9378 P/N 12261-319 Copyright Terex Corporation - Terex is a registered trademark of Terex Corporation in the United States of American and many other countries. Courtesy of Crane.Market...

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