Terex RT700 Operator's Manual
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Terex RT700 Operator's Manual

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Summary of Contents for Terex RT700

  • Page 2 Assistance is available from the distributors of your with the Terex manuals in the shipment of each product. It is Terex product and from the Terex manufacturing facility. company policy to provide this information for the owner or user of the equipment.
  • Page 3 SUGGESTED ROUGH TERAIN CRANE 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. ITEMS TO BE ITEMS TO BE INSPECTED INSPECTED & CHECKED &...
  • Page 4 REPAIRS - ADJUSTMENTS - REMARKS ITEM REQUIREMENT DATE Issued: July 2003...
  • Page 5 understanding of the material presented in the following NOMENCLATURE pages. To aid in understanding the contents of this manual, the fol- This manual contains instructions and information on the lowing terms will always have themeanings given whenever operation, maintenance, lubrication and adjustments of the they are used.

  • Page 6: Table Of Contents

    SAFETY INDEX SECTION 1 SUBJECT PAGE Introduction ............1 - 1 Symbols .

  • Page 7: Introduction

    INTRODUCTION Owners, Users, and Operators: Terex Cranes appreciates your choice of our machine for your application. Our number one priority is user safety, which is best achieved by our joint efforts. We feel that you make a major contribution to safety if you as the equipment users and operators: Comply with OSHA, Federal, State, and Local Regulations.

  • Page 8: Symbols

    INTRODUCTION SYMBOLS The symbols below are used to inform the operator of important information concerning the operation of this unit. DANGER - Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING - Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

  • Page 9: Handling Personnel

    SAFETY 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. HANDLING PERSONNEL Cranes can only be used to lift people when it is the least hazardous way to do the job.

  • Page 10: Operator's Responsibilities

    Operator must understand crane signals and take signals only from designated signal people; except the operator must obey the stop signal from anyone. OPERATOR’S RESPONSIBILITIES Read and understand the Operator's Manual. Make sure the machine is in proper order and that all operational aids and warning signals are functional before operating.

  • Page 11: Signal Person's Responsibility

    Make sure everyone is in a safe place before moving the hook, boom, load or outriggers. Start and stop movements smoothly and swing at speeds that will keep the load under control. Keep at least two full wraps of wire rope on drum when operating. Feet must be kept on the pedals while foot pedal brake locks are in use.

  • Page 12: Responsibilities Of All Crew Members

    RESPONSIBILITIES OF ALL CREW MEMBERS Unsafe conditions 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.

  • Page 13: Planning The Job

    PLANNING THE JOB Have a clear understanding of work to be done. Consider all dangers at jobsite. Know what crew members are needed? Assign responsibilities. Know the weight of load to be lifted. Determine lift radius, boom angle, and the rated lifting capacity of crane. Establish how signal people will communicate with operator? Utilize equipment which will do job safety.

  • Page 14: Operator's Safety Check

    OPERATOR’S SAFETY CHECK Safety related items must be in place. Check machine log book, to see if periodic maintenance and inspections have been performed. Ensure that necessary repairs have been completed. Inspect wire rope for damage (kinks, broken wires etc.) Be sure no unauthorized field modifications have been made.

  • Page 15: Operation Overload Protection

    OPERATION OVERLOAD PREVENTION Know the weight of the load. Load radius will increase when the load is lifted. Reduce radius at start of lift to allow for this. Know the weight of hook, and rigging. Know boom length, jib length, parts of line and operating area. Use next lower rated capacity when working at boom lengths or radius between the figures on the rated lifting capacity chart.

  • Page 16: Operation Setup

    OPERATION SETUP Be sure the load bearing surface is strong enough to support the machine and load. Be sure cranes are level, check frequently and relevel when necessary. Stay away from rotating cranes, erect barricades to keep people away. Make sure these area's are clear before swinging.

  • Page 17: Travel

    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. Replace all broken ladders. Keep non-slip surfaces in good condition. TRAVEL Care must be taken when cranes are driven (traveled) whether on or off the job site.
  • Page 18 CONTROLS AND INSTRUMENTS INDEX SUBJECT PAGE Universal Symbol Identification ......2 - 1 Upper Controls &...

  • Page 19: Universal Symbol Identification

    LOW OIL SWING BEACON PRESSURE SWING STANDARD BRAKE FUEL STEER 4 WHEEL WATER FAST STEER TEMPERATURE CRAB ENGINE SLOW STEER OIL PRESSURE REAR STEER VOLTAGE HORN LEFT EMERGENCY REAR STEER WINCH STOP RIGHT RT700 Page 2 - 1 Revised: April 2005...
  • Page 20 RANGE SHIFT DOWN SYSTEM ON AXLE DISENGAGE / BOOM RANGE SHIFT IGNITION ON ENGINE BOOM TRANSMISSION QUICK START TEMPERATURE BOOM TRANSMISSION PRESSURE HEATER/AC OUTRIGGER HEAT SELECT HEATER/AC OUTRIGGER RETRACT HEATER/AC OUTRIGGER EXTEND RT700 Page 2 - 2 Revised: April 2005...
  • Page 21 CONTROLS AND INSTRUMENTS Page Intentionally Blank RT700 Page 2 - 3 Revised: April 2005...

  • Page 22: Upper Controls & Instruments

    CONTROLS AND INSTRUMENTS UPPER CONTROLS & INSTRUMENTS 19 20 RT700 Page 2 - 4 Revised: April 2005...

  • Page 23: Upper Controls & Instruments Key

    24. AIR PRESSURE GAUGE 50. CAB HEAT/AC SELECTOR 25. PARK BRAKE INDICATOR 51. CAB HEATER TEMPERATURE 26. LOW WATER INDICATOR 52. FIRE EXTINGUISHER 27. ENGINE WARNING INDICATOR (See Page 2-12) 28. ENGINE DIAGNOSTIC INDICATOR RT700 Page 2 - 5 Revised: April 2005...

  • Page 24: Upper Controls & Instruments

    16. REAR STEER SWITCH - Push left to toggle rear wheels left, push right to toggle rear wheels right. 13. OUTRIGGER EXTEND/RETRACT MASTER SWITCH - This switch is used in conduction with outrigger switches 17. TACHOMETER - Indicates engine RPM. RT700 Page 2 - 6 Revised: April 2005...
  • Page 25 (13), to extend/retract outrigger jack and beam. 25. PARK BRAKE INDICATOR - Indicates parking brake is applied. 34. JACK SWITCH (RIGHT REAR) - Used in conjunction with switch (13), to extend/retract outrigger jack and beam. RT700 Page 2 - 7 Revised: April 2005...
  • Page 26 RPM and counter-clockwise to increase RPM. 39. SWING BEARING GREASE FITTING - Inject bearing grease here. 40. SWING GEAR GREASE FITTING - Inject gear grease here. RT700 Page 2 - 8 Revised: April 2005...
  • Page 27 In high speed extend the boom extend has minimal extend force. Tilt backward to retract boom. 43. ACCELERATOR - Push to increase engine RPM and release to decrease. 44. BRAKE PEDAL - Push to stop carrier movement. RT700 Page 2 - 9 Revised: April 2005...
  • Page 28 Move up for forward, down for down for left turn signal. Press button on end to reverse. Rotate handle to select speed. dispense washer fluid onto window. Rotate for windshield wiper. Pull toward operator for hazard lights. RT700 Page 2 - 10 Revised: April 2005...
  • Page 29 Horn - Press to sound horn. (Located on underside of handle) underside of handle) Hi-Speed Winch Switch - Press to toggle Hi-Speed Winch Switch - Press to toggle high speed winch. high speed winch. RT700 Page 2 - 11 Revised: April 2005...
  • Page 30 49. CAB FAN SPEED - Turn to select blower fan 52. FIRE EXTINGUISHER speed. 50. CAB HEAT/AC SELECTOR - Turn to select heat or air conditioning. 51. CAB HEATER TEMPERATURE - Turn to adjust heating or cooling temperature. RT700 Page 2 - 12 Revised: April 2005...
  • Page 31 UNUSUAL OPERATING CONDITIONS ......3 - 20 LOAD RATING CHART INTERPRETATION ......3 - 23 RT700 Series Revised: April 2005...

  • Page 32: Pre-Start Inspection

    WHEEL NUTS Torque wheel nuts to 400-500 Ft. Lbs. Tighten daily during the first 50 miles of service on new units and any time the wheels have been removed. Tighten nuts alternately around the wheel. RT700 3 - 1 Revised: October 2005...

  • Page 33: Starting The Engine

    Release the ignition switch key as soon as the engine starts. If the engine stalls during the start-up proce- dure, allow the engine to stop revolving before re-en- gaging the starter. RT700 3 - 2 Revised: October 2005...

  • Page 34: Operating The Engine

    5. Re-engage pumps. 6. Restart engine. Be alert for signs of pump cavitation as described in (3) above. Increase engine speed GRADUALLY, allowing sufficient time to warm the system before commencing operation. RT700 3 - 3 Revised: October 2005...

  • Page 35: Jump Starting An Engine With Booster Cables

    Failure to pull the hook block up to the head when traveling, or to secure it to the bumper ring, will result in excessive swinging of the hook block and possible damage to crane. RT700 3 - 4 Revised: October 2005...
  • Page 36 6. Release the Parking Brake. Four wheel drive engagement is accomplished by a solenoid shifted coupling in the transmissions. In the 7. Select the desired transmission range. ranges F1 thru F3 and R2 and R3. RT700 3 - 5 Revised: October 2005...
  • Page 37 5° and that the boom - Make sure all outriggers are completely retracted be horizontal or below. before moving the crane. RT700 3 - 5a Revised: October 2005...

  • Page 38: Making A Typical Lift

    Be certain the hook latch is not supporting any of the load. Refer to the warning tag on the hook block. RT700 3 - 6 Revised: October 2005...
  • Page 39 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, RT700 3 - 7 Revised: October 2005...
  • Page 40 6. Extend the boom to the desired length. Do not ex- taneously with the winch functions. tend the boom further than necessary to perform the lift. EXTEND the boom by tilting the extend-retract pedal FORWARD. RETRACT the boom by tilting the pedal BACK RT700 3 - 8 Revised: October 2005...
  • Page 41 In making these adjust- ments, the operator must guard against 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 RT700 3 - 9 Revised: October 2005...

  • Page 42: Crane Hand Signals

    (land cranes only.) chest. KNOW THE CRANE SIGNALS! Poor communication between the operator and personnel directing lifts can re- sult in property damage or personal injury. RT700 3 - 10 Revised: October 2005...

  • Page 43: On Tires" Lifts

    The results of this hap- pening can cause a machine tip over. Any variation from the above conditions will require the operator to consider the prevailing conditions and reduce the lift capacities accordingly. RT700 3 - 11 Revised: October 2005...

  • Page 44: Hoist Line Reeving

    1 2 3 4 5 D 1 2 3 4 5 These patterns represent some, though not all, of the options for reeving patterns for hookblocks. Always use a reeving pattern that allows the block to hang level. RT700 3 - 12 Revised: February 2006...

  • Page 45: Wire Rope Specifications

    Refer to the Crane Capacity Chart for parts of line required. RT700 3 - 13 Revised: October 2005...

  • Page 46: Transporting The Crane

    The 32ft (9.75 m) jib weighs 1,280 pounds (581 kg). The 33-57 ft. (10.05-17.37 m) jib weighs 2,070 Before erecting or stowing the pounds (939 kg). jib, ensure that no personnel or obstacles are in the swing path of the jib. RT700 3 - 14 Revised: October 2005...
  • Page 47 (.6-1 m). As the jib clears the storage brackets, should be actuated in the cab and the boom down, the jib will swing out approximately 45°. boom extend, and winch up controls should dis- connect. RT700 3 - 15 Revised: October 2005...
  • Page 48 NOTE: To prevent damaging the jib, do not winch up any more than is necessary to loosen the jib DECREASING OFFSET offset pins. 1. Reverse above procedure to return jib to 0° offset position. RT700 3 - 16 Revised: October 2005...
  • Page 49 The light and audible alarms should be actuated in the cab and the boom down, boom extend, and winch up controls should disconnect. RT700 RT700 3 - 17 3 - 17...
  • Page 50 4. Boom down to minimum boom angle. boom, make sure the jib does not strike the side of the boom. 5. Remove the hoist line from jib sheave and lay to left side. RT700 3 - 18 Revised: October 2005...
  • Page 51 17. Test the anti two-block system at the boom head by lifting the anti two-block weight. The light and audi- ble alarms should be actuated in the cab and the boom down, boom extend, and winch up controls should disconnect. RT700 3 - 19 Revised: October 2005...

  • Page 52: Unusual Operating Conditions

    Fill with methyl alcohol only. Inspect the thermostat, clamps, radiator hoses and ra- diator core for proper condition. Replace or RT700 3 - 20 Revised: October 2005...
  • Page 53 1. High temperatures necessitate the use of lubri- cants which are both more viscous and which resist deterioration at higher operating temperatures. Re- fer to the Lubrication Chart and lubricate the crane using the lubricants recommended for the expected temperatures. RT700 3 - 21 Revised: October 2005...
  • Page 54 - If the machine is struck by lightning, check general frequency of lubrication and service should be adjust- machine operation before restarting it. ed accordingly. You must always know the weather forcasts of your area before starting work. RT700 3 - 22 Revised: October 2005...

  • Page 55: Load Rating Chart Interpretation

    The “crane working position” diagram is a view looking straight down on the crane with the upperstructure and the boom removed. The “front” of the crane is always the end opposite the engine. RT700 3 - 23 Revised: October 2005...
  • Page 56 60 ft. radius on tires. Do not operate at a longer radius than those listed on the applicable load rating charts as tipping can occur without a load on the hook. RT700 3 - 24 Revised: October 2005...
  • Page 57 CONDITION, TRAVELING WITH LOADS, MULTIPLE CRANE LIFTS, PROXIMITY OF ELECTRICAL WIRES, ETC. APPROPRIATE REDUC- TION OF LOAD RATINGS MUST BE MADE FOR THESE AND ANY OTH- ER CONDITIONS WHICH MAY AFFECT PRACTICAL WORKING LOADS. RT700 3 - 25 Revised: October 2005...
  • Page 58 3,039 lbs. The boom angle is 61°, the jib is at the 30° offset and the machine is on out- riggers. In this case the load can be safly lifted. = 61° 3,039 POUNDS RT700 3 - 26 Revised: October 2005...
  • Page 59 This lift cannot be made. EXAMPLE Hook & Ball 239 lbs. Slings 300 lbs. Auxiliary Head 110 lbs. Hook Block 750 lbs. Object 2,350 lbs. Actual Load = 3,749 lbs. = 61° 3,749 POUNDS RT700 3 - 27 Revised: October 2005...
  • Page 60 “Stationary” means that the crane cannot be moved when loaded to the levels shown in the on tire load chart. RT700 3 - 28 Revised: October 2005...
  • Page 61 Also, if the load is heavy enough and will not move and the boom point moves out far enough, the rating can change back to structural with the associat- ed abrupt failure discussed above RT700 3 - 29 Revised: October 2005...
  • Page 62 SPOOLING WIRE ROPE ON DRUMS ...............4 - 31 WIRE ROPE & REEVING...................4 - 32 WIRE ROPE SPECIFICATIONS ................4 - 32 CRANE BOOM ....................4 - 35 AIR DRYER ......................4 - 36 SLIDER PADS ....................4 - 36 RT700 Series Revised: November 2005...
  • Page 63 MAINTENANCE CHECKS RT700 Series 4 - 1 Revised: March 2005...

  • Page 64: Introduction

    When servicing the engine, the engine * All lights work properly manufacturer’s recommendations take precedence * Cleanliness - Free from mud and debris. over those in this manual, should any discrepancy be noted. RT700 Series 4 - 2 Revised: March 2005...

  • Page 65: Machine Maintenance Check List

    Rust And Corrosion Check Hydraulic Cylinders and Rods Check Torque on Wheel Lug Nuts Check Torque on Wheel Lug Nuts * Interval given applies only to initial period of use (break-in). RT700 Series 4 - 3 Revised: November 2005...
  • Page 66 Check Relief Valve Pressure Settings Clean Cooling System Torque Swing Bearing Bolts Check Reservoir Relief Valve Check Engine Manufacturer’s Manual For Addi- Clean Reservoir Intake Suction Filter tional Maintenance Requirements Change Transmission Oil Change Winch Oil RT700 Series 4 - 4 Revised: November 2005...
  • Page 67 100 HOURS - Retighten winch base mounting capscrews to 225 ft. lbs. of torque after one hun- dred hours of operation. 100 HOURS - Retighten counterweight cap- screws to 845 ft. lbs. RT700 Series 4 - 5 Revised: March 2005...

  • Page 68: Wire Rope Inspection Record

    Serial No. Type and Arrangement of Attachments DATE OF LAST ROPE INSPECTION HOURS AND TIME OF SERVICE SINCE LAST INSPECTION RESULTS OF INSPECTION Rope Inspected Type and Size Conditions Noted Recommendations INSPECTOR: RT700 Series 4 - 6 Revised: March 2005...

  • Page 69: Engine Maintenance

    For an accurate reading, allow 15 minutes for the oil to drain into the sump before checking. Keep the oil level as close to the full mark as possible. DO NOT OVERFILL RT700 Series 4 - 7 Revised: March 2005...

  • Page 70: Engine Radiator Maintenance

    Use a radiator cleaning compound, following the instructions on the container. Flush the system with fresh water and refill with an ethylene glycol solution of 50% by volume. RT700 Series 4 - 8 Revised: March 2005...

  • Page 71: Transmission Maintenance

    180 to 200° F. (82.2 to 93.3° C). DO NOT OVERFILL THE TRANSMISSION. Recommended Lubricant and Filter Change Inter- vals Refer to page 4-10 for lubricant recommendations. RT700 Series 4 - 9 Revised: March 2005...

  • Page 72: Transmission

    TRANSMISSION RECOMMENDED SAE J300 VISCOSITY GRADE BASED ON PREVAILING AMBIENT TEMPERATURE Preferred lubricant specifications: Caterpillar TO - 4 John Deere J20 C, D Military MIL-PRF-2104G Allison C - 4 Dexron II Equivalent RT700 Series 4 - 10 Revised: March 2005...

  • Page 73: Axle Maintenance

    Refill to the level of the bot- the hole. See lubrication chart. tom of the check plug. RT700 Series 4 - 11 Revised: March 2005...

  • Page 74: Tires

    OVERINFLATION Overinflation reduces tire deflection and tire contact area, causing the tire to ride on the crown, and results in rapid wear in the center of the tread. RT700 Series 4 - 12 Revised: March 2005...
  • Page 75 7. After inflating the tire, be sure that between a 1/16” minimum and a 1/4” maximum remains in a split ring or lock ring. 8. Inspect wheel nuts and rim clamps periodically for excessive wear, corrosion, proper centering and nut torque. RT700 Series 4 - 13 Revised: March 2005...

  • Page 76: Air System Maintenance

    This will ensure that the valve is not sticking. If the valve cannot be actuated in this manner, it should be repaired or replaced SAFETY VALVE RIGHT SIDE AIR TANK RT700 Series 4 - 14 Revised: March 2005...

  • Page 77: Brake System

    Every 12 months or annually: 1. Disassemble, clean parts with mineral spirits. Re- place all rubber parts or any part worn or damaged. Check for proper operation before placing vehicle in service. RT700 Series 4 - 15 Revised: March 2005...
  • Page 78 (This will be the point at which the drum and rotor contact. Then move the yoke 1/4” to the left and adjust jam nut until it is tight against the yoke. RT700 Series 4 - 16 Revised: March 2005...

  • Page 79: Turntable & Swing Pinion

    MOBIL TEXACO SUNOCO AMOCO EXON RACE Mobilux Mutifak Prestige Amolith Beacon 742EP GEAR Mobiltac Crater Amovis Surett 375NC Compound B Fluid 4k NOTE: Other manufacturers’ lubricants of the same quality are suitable. RT700 Series 4 - 17 Revised: March 2005...

  • Page 80: Swing Reducer

    MAINTENANCE CHECK On a WEEKLY basis, check the swing reducer oil level and add oil as needed to maintain the level at the “FULL” mark on the dipstick. Recommended lubricant is Sunep # 1060 or equiva- lent. RT700 Series 4 - 18 Revised: March 2005...

  • Page 81: Hydraulic System Maintenance

    Refer to Section 4, page 23 for hydraulic oils meeting the manufacturer’s specifications. Do not use oils which have detergent additives. RT700 Series 4 - 19 Revised: March 2005...
  • Page 82 Clean the filter by immersing it in a non-caustic clean- ing solvent. Rub the screen surface with a soft brush to dislodge accumulated foreign matter. Reinstall filter, filter hold-down device and cover. RT700 Series 4 - 20 Revised: March 2005...

  • Page 83: Hydraulic Oil Requirements

    These fluids have been design- ed to work in au- If there is any doubt about the proper lubricants, inter- tomatic transmissions and they will not necessarily vals or lubrication procedures, refer to the original work in hydraulic systems. manufacturer’s manual. RT700 Series 4 - 21 Revised: March 2005...
  • Page 84 Water Contamination - All hydraulic oils in the following charts will readily separate water which will settle to the bottom of the reservoir. This water should be drained RT700 Series 4 - 22 Revised: March 2005...
  • Page 85 M. Filterability Fluid shall show no additive loss when filtered through 5.0 micron filter. N. Cleanliness Fluid shall appear bright and clear and shall be free of visible contami- nants or sludge. RT700 Series 4 - 23 Revised: March 2005...
  • Page 86 175°F gions With Ambient Temp. (-1.1°C) (93°C) (80°C) Range From 100°F To 120°F Minimum temperature for starting without extended warm-up. For lower temperatures, follow warm up proce- dure in the operators manual. RT700 Series 4 - 24 Revised: March 2005...
  • Page 87 Gulf Harmony AW 100 Imperial Oil Limited Nuto H 32 (Canada) Nuto H 46 Nuto H 68 Nuto H 80 Nuto H 100 KOEHRING SPEC 805 IS EQUIVALENT TO HYDRAULIC OILS SHOWN ABOVE RT700 Series 4 - 25 Revised: March 2005...

  • Page 88: Cable Lubrication Methods

    AEROSOL SPRAYING Installations requiring only Swabbing small amounts of lubricants, or only occasional appli- And Painting cations, may find the new aerosol cans of lubricant useful. They are available from several lubricant man- ufacturers. Aerosol Spraying RT700 Series 4 - 26 Revised: March 2005...

  • Page 89: Electrical System Battery Check

    If the “Visual Inspection” is satisfactory, proceed to Step 2. RT700 Series 4 - 27 Revised: March 2005...
  • Page 90 Voltage controls can limit the charge more consistently and accurately. Such controls also may have a safety feature that prevents sparks and reverse charging when the clamps are connected in reverse, by mistake. RT700 Series 4 - 28 Revised: March 2005...

  • Page 91: Electrical System Collector Ring

    The cover should allow for free operation of the collector dust off with compressed air. ring and the brake. If linkages bind, erratic operation may result. Check for unrestricted operation. RT700 Series 4 - 29 Revised: March 2005...
  • Page 92 Also check the cylinders for leaks at the wiper A drain line on the main drive end cover returns excess seals. Repair or replace any damaged components. oil to the reservoir. RT700 Series 4 - 30 Revised: March 2005...

  • Page 93: Cable Reeving

    If cable is wound from the storage reel onto the drum, the reel should be rotated in the same direction as the hoist. RT700 Series 4 - 31 Revised: March 2005...

  • Page 94: Wire Rope & Reeving

    34 X 7 COMPACTED STRAND, GRADE 2160 WEIGHT 1.24 LBS/FT MINIMUM BREAKING STRENGTH - 34.5 TONS Terex permits the use of rotation resistant wire rope, other types are not approved. When this rope is used the working load shall not exceed 1/5th (20%) of the rat- ed breaking strength.
  • Page 95 WINCH DRUM WEDGES WHERE USED PART NUMBER MAIN WINCH 216529 AUXILIARY WINCH 216529 CABLE SOCKETS AND WEDGES WHERE USED PART NUMBER 3/4” CABLE SOCKET & WEDGE 1234-44 3/4” SOCKET WEDGE 218534 RT700 Series 4 - 33 Revised: March 2005...
  • Page 96 A length of rope equal to at least one rope lay should be drawn back through. RT700 Series 4 - 34 Revised: March 2005...

  • Page 97: Crane Boom

    In addition, note any missing or illeg- ible indicator mark decals on the telescoping sections. RT700 Series 4 - 35 Revised: March 2005...

  • Page 98: Air Dryer

    Remember to do both sides. Grease intervals vary and should be more frequent if noise or jerking of the boom is evident. RT700 Series 4 - 36...
  • Page 99 Anti Two Block System ............. . . 5 - 37 RT700...
  • Page 100 5 - REACH A CONCLUSION Review your list of possible of “do’s” and “don’ts”. Stay clear of all moving parts. causes and decide which are the most likely to cause the fail- ure. Consider the most obvious first. RT700 Series Page 5 - 1 Issued: August 2003...
  • Page 101 Keep them clean and change the oil and oil filter at established intervals. Clean the preservative compound from all machined surfaces of new parts before installing them. RT700 Series Page 5 - 2 Issued: August 2003...
  • Page 102 If pressure (2500 psi) is indicated, the spool is shifting. If the spools shift, see page 5-19, “Outrigger Cir- cuit”. RT700 Series Page 5 - 3 Issued: August 2003...
  • Page 103 RAPID WEAR OF TIE ROD ENDS CAUSE REMEDY Inadequate or improper lubrication ............Consult lubrication chart for proper lubricant, lubrication intervals and procedures. Severely contaminative environment ............ Clean and lubricate more often. RT700 Series Page 5 - 4 Issued: August 2003...
  • Page 104 EXCESSIVE WEAR OF KNUCKLE PINS AND BUSHINGS CAUSE REMEDY Inadequate or improper lubrication ............Consult lubrication chart for proper lubricant, lubrication intervals and procedures. Increase lubri- cation frequency when operating in extrem condi- tions. RT700 Series Page 5 - 5 Issued: August 2003...
  • Page 105 Worn mechanical linkage..................Repair or replace. Bending of linkage or cylinder rod ................. Repair or replace. Loose cylinder piston ....................Repair or replace. Severe wear in steering control unit................ Replace the steering control unit. RT700 Series Page 5 - 6 Issued: August 2003...
  • Page 106 “SPONGY” OR SOFT STEERING -CAUSE- -REMEDY- Air in hydraulic system. Most likely air trapped in cylinders or lines ..................Bleed air out of system. Low fluid level ......................Add fluid and check for leaks. RT700 Series Page 5 - 7 Issued: August 2003...
  • Page 107 Broken or worn linkage between cylinder and steered wheels ......................Check for loose fitting bearings and anchor points in steering linkage between cylinder and steered wheels. Leaky cylinder seals ....................Replace cylinder seals. RT700 Series Page 5 - 8 Issued: August 2003...
  • Page 108 Cab facing toward rear reverses response ............... Be alert when operating with cab over rear. STEERING WHEEL KICKS AT START OF STEERING -CAUSE- -REMEDY- No inlet check valve on steering control unit............Install a check valve. RT700 Series Page 5 - 9 Issued: August 2003...
  • Page 109 Alternator regulator out of adjustment ..........Replace regulator. Field leads shorted................. Replace or repair alternator. Alternator regulator shorted ..............Replace regulator. ALTERNATOR MECHANICALLY INOPERATIVE CAUSE REMEDY Belt loose ....................Tighten belt. Armature shaft sheared................Replace or repair alternator. RT700 Series Page 5 - 10 Issued: August 2003...
  • Page 110 Commutator dirty .................. Clean commutator. Brushes worn..................Replace brushes. Starter relay malfunctioning..............Repair or replace relay. Pinion spring broken or weak..............Replace or repair starter. Frame housing defective ............... Replace or repair starter. RT700 Series Page 5 - 11 Issued: August 2003...
  • Page 111 Grease or oil on linings .................Clean linings or replace linings or pad assemblies. Defective brake valve................Replace faulty unit. Brakes need relining................Replace brake pads. Brake chamber diaphragm leaking............Tighten all fittings; if caused by broken or faulty unit, replace the unit. RT700 Series Page 5 - 12 Issued: August 2003...
  • Page 112 Leaks in system ..................Repair leaks. Frozen lines ................... Thaw out lines. Defective compressor ................Inspect for sticking unloader valve, replace if neces- sary. Reservoir leaking...................Replace. Tank to compressor supply line damaged ..........Replace. RT700 Series Page 5 - 13 Issued: August 2003...
  • Page 113 Excessive leakage around swing control valve spool ......Replace or replace control valve. SWING MOTION ERRATIC CAUSE REMEDY Brake not releasing completely .............Check operation of swing brake and/or swing lock. Low hydraulic oil level .................Add oil as required. RT700 Series Page 5 - 14 Issued: August 2003...
  • Page 114 Air in cylinder ..................Bleed cylinder. BOOM DROPS SLIGHTLY AS RAISE CONTROL IS RELEASED CAUSE REMEDY Air in cylinder ..................Bleed cylinder. Boom hoist hold valve free flow check not seating properly ................Replace hold valve. RT700 Series Page 5 - 15 Issued: August 2003...
  • Page 115 Wear pads damaged ................Replace wear pads. Wear pads shimmed to boom too tight..........Reshim wear pads. Faulty counter balance valve..............Replace counter balance valve. Loose chain system ................Adjust chains as required. RT700 Series Page 5 - 16 Issued: August 2003...
  • Page 116 Winch motor worn excessively or damaged ......... See section on “Fluid Motor”. Tandem pump worn excessively or damaged ........See section on “Pumps”. Rotary manifold leaking internally ............Reseal rotary manifold. Low oil level..................Add oil as required. RT700 Series Page 5 - 17 Issued: August 2003...
  • Page 117 The automatic brake is not applying ............. Be certain that the winch brake release line is not plugged and no foreign objects are in the brake assembly. The winch brake friction plates are worn..........Replace friction plates. RT700 Series Page 5 - 18 Issued: August 2003...
  • Page 118 Line to or from steer pump plugged or liner collapsed ..............Clear blockage or replace hose. Low oil level..................Add oil as required. Steer pump worn or damaged..............See section on “Pumps”. RT700 Series Page 5 - 19 Issued: August 2003...
  • Page 119 JACK CYLINDER DRIFTS DOWN CAUSE REMEDY Hold valve on top of cylinder malfunctioning ........Replace cartridge. Thermal relief cartridge mounted in wrong end........Check for proper assembly. Cylinder by-passing................See section on “Cylinders”. RT700 Series Page 5 - 20 Issued: August 2003...
  • Page 120 Internal leakage in control valves or cylinders........To determine location, progressively block off vari- ous parts of circuit. When trouble is located, repair. (Do not block between pump and relief valve). RT700 Series Page 5 - 21 Issued: August 2003...
  • Page 121 Too high oil viscosity ................Work only with oil at recommended operation tem- perature. Oil intake suction filter plugged ............Clean filter. Rag, paper, etc., pulled into suction line or pump......... Remove. Worn or broken parts................Replace. RT700 Series Page 5 - 22 Issued: August 2003...
  • Page 122 Seizure due to lack of oil............... Check reservoir level, oil filter and possibility of restriction in suction line more often. Solid matter being wedged in pump............Check suction line filter, drain and flush system as necessary. RT700 Series Page 5 - 23 Issued: August 2003...
  • Page 123 Cut or scored seal .................. Replace faulty parts. LOAD DROPS WHEN CONTROL MOVED FROM NEUTRAL CAUSE REMEDY Dirt in check valve ................Disassemble and clean. Scored check valve poppet or seat ............Replace poppet or lap poppet to seat. RT700 Series Page 5 - 24 Issued: August 2003...
  • Page 124 Poppet seal damaged ................Replace damaged parts. Clean dirt and remove sur- face marks for free movement. PRESSURE SETTING NOT CORRECT CAUSE REMEDY Wear due to dirt. Lock nut adj. screw loose ......... See section on “Valve Adjustments”. RT700 Series Page 5 - 25 Issued: August 2003...
  • Page 125 Extremely high fluid temperatures causing pump and motor to slip (temperature increases as pump and motor wear) ..............Add heat exchangers. Relief setting too low ................Set relief valve for proper psi. RT700 Series Page 5 - 26 Issued: August 2003...
  • Page 126 Motor housing bolts loose ..............Clean mating surfaces and tighten nuts to appropri- ate value. Pinched “O” ring seal ................Replace. LEAK AT OIL PORTS CAUSE REMEDY Damaged seal or “O” ring ..............Replace “O” ring or seal. RT700 Series Page 5 - 27 Issued: August 2003...
  • Page 127 Foaming in reservoir ................Use hydraulic oil containing a foam depressant. Internal leakage ..................See “Cylinder Leakage” next page. Main Relief pressure too low or valve sticking........See section on “Relief Valve”. RT700 Series Page 5 - 28 Issued: August 2003...
  • Page 128 (1) foot from or by replacement with a new cartridge. Before installing ground level. Shut of engine. the cartridge, visually inspect the external “O” rings and RT700 Series Page 5 - 29 Issued: August 2003...
  • Page 129 Viscosity of oil too high or too low............Follow recommendations for correct viscosity grade to be used. Pumps assembled after overhaul may be assembled too tightly. This reduces clearances and increases rubbing friction..................Follow instructions when reassembling. RT700 Series Page 5 - 30 Issued: August 2003...
  • Page 130 Open circuit ................... Check with test light. Repair or replace. Low voltage................... Check wires and grounds. Poor engine solenoid connection............Clean and tighten. Defective solenoid ................. Replace. Solenoid failure ..................Replace. Poor ground connections ............... Clean and tighten connections. RT700 Series Page 5 - 31 Issued: August 2003...
  • Page 131 Temperature control &/or microswitch defective or out of adjustment ............... Check temperature control switch and microswitch and microswitch for adjustment. Adjust, repair, or replace as necessary. See Section 6, “Repairs and Adjustments”. RT700 Series Page 5 - 32 Issued: August 2003...
  • Page 132 Fuel not suitable for temperatures encountered ........Check with your propane supplier to be sure your fuel is suitable for the temperatures encountered. Around -10°F, propane may not produce enough pressure to pass through the regulator. RT700 Series Page 5 - 33 Issued: August 2003...
  • Page 133 As it thaws and freezes, the heater will burn intermittently............... No action recommended. Clogged or restricted exhaust ..............Check exhaust for blockage or restrictions. Clean and clear as necessary. RT700 Series Page 5 - 34 Issued: August 2003...
  • Page 134 ELECTROLYTE LEVELS & STATE OF CHARGE NOTE: PROCEED DIRECTLY TO CAUSE THAT APPLIES CAUSE REMEDY Level at top of plates. Water cannot be added ........Replace. If there is an indicator and it shows low level........Replace. RT700 Series Page 5 - 35 Issued: August 2003...
  • Page 135 * IF WATER CAN BE ADDED TO A BATTERY, A HYDROMETER READING OF 1.225 @ 80° F (27° C) CAN BE USED INSTEAD OF THE 12.4 VOLTAGE READING. RT700 Series Page 5 - 36 Issued: August 2003...
  • Page 136 If the wires are OK, check the anti-two block switch. If there is continuity between #3 and #6 check the relay in the panel. RT700 Series Page 5 - 37 Issued: August 2003...
  • Page 137 (With no electrical power to the relay, pins #30 and #87a should show continuity. With 12 volts to either #85 or #86 and the other grounded, there should be continuity between pins #87 and #30.) RT700 Series Page 5 - 38 Issued: August 2003...
  • Page 138 CABLE SOCKETS ........... . . 6 - 24 RT700 Series...
  • Page 139 The gauge must have a proper snubber to read center of pump pressure ripple or erroneous readings will result. 6 - 1 RT700 Series Issued: August 2003...
  • Page 140 Adjustment is accomplished by loosening the jam nut and either turning the adjusting screw in to increase pressure or backing it off to lower pressure. Retighten the jam nut when the desired pressure is obtained. 6 - 2 RT700 Series Issued: August 2003...
  • Page 141 NOTE: If the swing pressure is low be certain to use cation pressure at winch valve. when adjusting, if the swing brake is not in proper working order the increase in pressure may allow the machine to 6 - 3 RT700 Series Issued: August 2003...
  • Page 142 Turn in to increase pressure, out to decrease. After completing adjustment, replace cap on the relief valve. 6 - 4 RT700 Series Issued: August 2003...
  • Page 143 No satisfactory method of repairing All overhaul should be done in a clean, enclosed facility with this type of damage can be conducted in the field. personnel familiar with hydraulic systems and cleanliness procedures. 6 - 5 RT700 Series Issued: August 2003...
  • Page 144 Ports should be properly protected, capped, and, prefera- bly, oil filled without pressure. NOTE: If the rotary manifold is oil filled and plugged, ample air space should be allowed for the expan- sion of oil due to temperature changes. 6 - 6 RT700 Series Issued: August 2003...
  • Page 145 Reinstall Fitting “A” and the hydraulic hose. STEERING PRIORITY VALVE ADJUSTMENT Adjust this valve using the following procedure: FITTING “A” ADJUSTMENT “B” TURN IN UNTIL BOTTOMED OUT THEN OUT 2 FULL TURNS STEERING PRIORITY VALVE 6 - 7 RT700 Series Issued: August 2003...
  • Page 146 2. With the boom still retracted adjust the cast iron blocks “D”, “H”, and “L” to center the boom sections at the CHECKING FOR PROPER ALIGNMENT TOP BOOM PLATE STRING 6 - 8 RT700 Series Issued: August 2003...
  • Page 147 1/16 inch. Tighten the lock bolts. This is “stringing” as described earlier and also by a visual in- done with the boom retracted. spection with the boom fully extended and at maximum angle. 6 - 9 RT700 Series Issued: August 2003...
  • Page 148 A and B equal amounts until the measurement is within specifications. If the gap is less than .25 inch, loosen adjustment B and tighten adjustment A until the gap is within specifica- tions. 6 - 10 RT700 Series Issued: August 2003...
  • Page 149 If the gap is more than .38 inch, loosen adjustment C tion to the top of the extend chain. and tighten adjustment D until the gap is within specifi- cations. 6 - 11 RT700 Series Issued: August 2003...
  • Page 150 Do not measure at the low point on the manifold. Tighten and secure with nuts, washers, and capscrews. OPERATION CHECK For safe operation of the crane when operating on rubber, the 6 - 12 RT700 Series Issued: August 2003...
  • Page 151 RPM. swing brake pedal to the first click position. Adjust the Swing brake cable should be adjusted bumper to rest against the swing brake pedal. and/or brake pads may need replacing. RT700 Series Issued: August 2003 6 - 13...
  • Page 152 RPM should be brought up to full governed speed slowly. (e) If the swing brake fails to prevent the boom from rotat- ing or if the swing brake pedal continues to operate in RT700 Series Issued: August 2003 6 - 14...
  • Page 153 The gear and bearing assembly consists of an inner race and ring gear, an outer race, bearing rollers, spacer and a seal ring. The inner race is bolted to the carrier; the outer race to the turntable. RT700 Series 6 - 15 Issued: August 2003...
  • Page 154 NOTE: If the Torque wrench setting at length “B” would be 600 ft. lb. (813 NM) for capscrews not requiring us of adapter, then the following shows the use of an adapter and the calculation for that setting. FORMULA RT700 Series 6 - 16 Issued: August 2003...
  • Page 155 All welding procedures and welding operator qualifications shall be in accordance with ANSI/AWS D14.3 when weld- ing on load sustaining members (ANSI/ASME B30.5) Do not weld on wet surfaces since this will cause hydrogen embrittlement of the weld. RT700 Series 6 - 17 Issued: August 2003...
  • Page 156 10 feet from the welder. Do not be in direct line with the weld fumes. • Use a local exhaust hood to remove fumes during the welding or cutting operation if one is available. RT700 Series 6 - 18 Issued: August 2003...
  • Page 157 SERVICE AND ADJUSTMENTS HYDRAULIC CYLINDERS RT700 Series 6 - 19 Issued: August 2003...
  • Page 158 For signs of severe damage. Do not remove unless replace- dure: ment is necessary. Remove the locking socket head cap screw from the draw ring. With an adjustable spanner wrench, remove the draw ring and head gland. RT700 Series 6 - 20 Issued: August 2003...
  • Page 159 Note: When installing the piston ring nut on the piston rod, torque to 400 ft. lbs and then secure with setscrew lock. Use Loctite Grade 242 on ring nut and set- screws. RT700 Series 6 - 21 Issued: August 2003...
  • Page 160 34 x 7 Grade 2160 Minimum Breaking Strength 34.5 Tons (31.4 MT) If a socket is changed or replaced, or if you are changing hook block weights; it is important to use the correct socket. RT700 Series 6 - 22 Issued: August 2003...
  • Page 161 The end of the cable should be even with the bottom of the anchor wedge. Note: If the wedge does not seat securely in the slot, care- fully tap the top of the wedge with a mallet. RT700 Series 6 - 23 Issued: August 2003...
  • Page 162 A length of the free end to the load supporting end as this will rope equal to at least one rope lay should be drawn back weaken the rope. through. RT700 Series 6 - 24 Issued: August 2003...
  • Page 163 SERVICE AND ADJUSTMENTS CABLE SOCKETS CABLE SOCKETS AND WEDGES WHERE USED PART NUMBER 3/4” CABLE SOCKET & WEDGE 1234-44 3/4” SOCKET WEDGE 218534 RT700 Series 6 - 25 Issued: August 2003...
  • Page 164 MACHINE STORAGE INDEX SECTION 7 SUBJECT PAGE SHORT TERM STORAGE..........7 - 1 LONG TERM STORAGE.
  • Page 165 MACHINE STORAGE Machines being placed in storage must be ade- 2. Drain and refill the swing reducer, winch(es), quately protected from deterioration during the axle differentials, planetary hubs and the hy- period of idleness. This will ensure that they can draulic reservoir.
  • Page 166 MACHINE STORAGE The engine should be stored in a building which EXTENDED STORAGE (30 DAYS OR MORE) is dry and can be heated during the winter When An Engine Is To Be Removed From Opera- months. Moisture absorbing chemicals are avail- tion For An Extended Period Of Time,prepare It able commercially for use when excessive damp- as follows:...
  • Page 167 MACHINE STORAGE 13. Operate the engine for 5 minutes to circulate 20. Remove and clean the battery and battery ca- the rust preventive throughout the engine. bles with a baking soda solution and rinse them with fresh water. Store the battery in a cool (nev- 14.
  • Page 168 MACHINE STORAGE 13. Remove the inspection hole cover and inspect the clutch release lever and link pins and the RESTORING ENGINE TO SERVICE bearing ends of the clutch reliease shaft. Apply engine oil sparingly, if necessary to these areas. 1. Remove the valve rocker cover(s) and pour at 14.
  • Page 169 MACHINE STORAGE 4. Atomize or spray 4 ounces of Nox Rust VCI No. 10 oil, or equivalent, into the transmission RESTORATION TO SERVICE through the oil drain hole. Install the drain plug. 5. If additional storage time is required, (3) and Refer to page 7-4, “Restoring Engine to Service”, (4) above should be repeated at yearly intervals.
  • Page 170 MACHINE STORAGE 4. Inspect the cylinder rod surfaces and reapply CHROME CYLINDER ROD STORAGE at three to six month intervals. 5. If the equipment is to be moved and then Hard chrome plating is primarily applied to steel stored again for an extended period of time cylinder rods for its wear resistant properties, al- or if the cylinder is cycled, steps 1 thru 4 though it does provide considerable corrosion re-...
  • Page 171 GENERAL INFORMATION INDEX SECTION 8 SUBJECT PAGE CONVERSION TABLES ............8 - 1 AVERAGE WEIGHT OF MATERIALS .
  • Page 172 GENERAL INFORMATION CONVERSION TABLES DECIMAL AND METRIC EQUIVALENTS OF FRACTIONS OF AN INCH Fractions of Decimals of Fractions of Decimals of Millimeters Millimeters an inch an inch an inch an inch 1/64 .0156 0.397 33/64 .5156 13.097 1/32 .0313 0.794 17/32 .5313 13.494...
  • Page 173 GENERAL INFORMATION LIQUID WEIGHTS AND MEASURES METRIC EQUIVALENTS LIQUID MEASURE LIQUID MEASURE 1 litre equals .0353 cu. ft. 4 gills equals 1 pint 1 litre “ .2642 gallon 2 pints “ 1 quart 1 litre “ 61.023 cu. in. 4 quarts “...
  • Page 174 GENERAL INFORMATION AVERAGE WEIGHT OF MATERIALS Lb. per Cu. Ft. EARTH METALS, ALLOYS, ORES Clay, Dry Aluminum, Cast-Hammered Clay, Damp, Plastic Brass, Cast-Rolled Clay & Gravel, Dry Bronze Earth, Dry Loose Copper, Cast-Rolled Earth, Dry Packed Gold, Cast-Hammered 1205- Earth, Moist Loose Iron, Gray-Cast Earth, Moist Packed Iron Slag...
  • Page 175 GENERAL INFORMATION TORQUE RATINGS ES - 100.0 TORQUE RATINGS DRY - UNCOATED FASTENERS TORQUE VALUES TO BE WITHIN ± 5% ALL FIGURES IN FOOT POUND THIS TABLE DOES NOT APPLY TO HY- DRAULIC CONNECTIONS. WHEN TORQUING HYDRAULIC CONNEC- TIONS REFER TO ES-100.1 NOM.
  • Page 176 GENERAL INFORMATION TORQUE RATINGS ES - 100.1 TORQUE RATINGS LUBRICATED OR PLATED FASTENERS TORQUE VALUES TO BE WITHIN ± 5% ALL FIGURES IN FOOT POUND REFER TO THIS TABLE WHEN TORQU- ING HYDRAULIC CONNECTIONS (Piping & Cylinders). NOM. DIA. IN. GRADE 2 GRADE 5 GRADE 8...
  • Page 177 GENERAL INFORMATION 8 - 6...
  • Page 178 GENERAL INFORMATION 8 - 7...
  • Page 179 GENERAL INFORMATION 8 - 8...
  • Page 180 GENERAL INFORMATION 8 - 9...
  • Page 181 WIRE ROPE USER’S MANUAL INDEX SECTION 9 SUBJECT PAGE WIRE ROPE USER’S MANUAL ........9-1...
  • Page 182 FactSheet Subpart CC – Cranes and Derricks in Construction: Wire Rope – Inspection This fact sheet describes the inspection requirements of subpart CC – Cranes and Derricks in Construction, as specified in 29 CFR 1926.1413. These provisions are effective November 8, 2010. This document is intended to assist wire rope inspectors and supervisors.
  • Page 183 Apparent Deficiencies – Category II Removal from Service Criteria • Visible broken wires: If a Category II deficiency is identified, operations ° In running wire ropes: six randomly distributed involving use of the wire rope in question must be broken wires in one rope lay or three broken wires prohibited until: in one strand in one rope lay, where a rope lay is the • Employer complies with the wire rope manufacturer’s length along the rope in which one strand makes a established criterion for removal from service, or with complete revolution around the rope. a different criterion that the wire rope manufacturer ° In rotation-resistant ropes: two randomly has approved in writing for that specific wire rope. distributed broken wires in six rope diameters or (See 1926.1417). four randomly distributed broken wires in 30 rope • The wire rope is replaced. (See 1926.1417), or diameters. • If the deficiency is localized, the problem is corrected ° In pendants or standing wire ropes: more than two by severing the wire rope in two; the undamaged broken wires in one rope lay located in rope beyond portion may continue to be used. Joining lengths...
  • Page 184 Annual/Comprehensive Inspection At least every 12 months, wire ropes in use on equipment must be inspected by a qualified person as stated under “Shift Inspection” above. In addition to the criteria for shift inspection, annual inspections require that – • The inspection must be complete and thorough, covering the surface of the entire length of the wire ropes, with particular attention given to all of the following: Critical review items from 1926.1413(a)(3)–(see “Critical Review Items” above). ° Those sections that are normally hidden during shift and monthly inspections. ° Wire rope subject to reverse bends. ° Wire rope passing over sheaves. ° Exception In the event an annual inspection under 1926.1413(c)(2) is not feasible due to existing set-up and configuration of the equipment (such as where an assist crane is needed) or due to site conditions (such as a dense urban setting), such inspections must be conducted as soon as it becomes feasible, but no longer than an additional 6 months for running ropes and, for standing ropes, at the time of disassembly. • If a deficiency is determined to constitute a safety hazard, operations involving use of the wire rope in question must be prohibited until: The wire rope is replaced (see 1926.1417), or ° If the deficiency is localized, the problem is corrected by severing the wire rope in two; the undamaged ° portion may continue to be used. Joining wire rope by splicing is prohibited. If a rope is shortened under this paragraph, the employer must ensure that the drum will still have two wraps of wire when the load and/or boom is in its lowest position. • If a deficiency is identified and the qualified person determines that, though not presently a safety hazard, the deficiency needs to be monitored, the employer must ensure that the deficiency is checked in the monthly inspections. Additionally • The inspection must be documented according to 1926.1412(f)(7). • Rope lubricants of the type that hinder inspection must not be used. • All documents produced under this section must be available, during the applicable document retention period, to all persons who conduct inspections under this section.
  • Page 345           TEST    GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 1 of 35...
  • Page 346 Brightness and Contrast Controls ...................... 11 System Setup Counterweight..........................12 GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 2 of 35...
  • Page 347 Setting the Left and Right Swing Alarms ................... 29 Work Area Selection Mode ....................30-31 Glossary............................32-35 GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 3 of 35...
  • Page 348 The boom angle sensor is mounted inside the cable extension reel assembly. GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 4 of 35...
  • Page 349 3 LEDs. One will illuminate to show the point of lift. GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 5 of 35...
  • Page 350 Rated Capacity and provides a visual indication of approach to overload. GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 6 of 35...
  • Page 351 GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 7 of 35...
  • Page 352 (if applicable). extension, or retracted. 18. JIB STOWED ON BOOM. GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 8 of 35...
  • Page 353 The information display shows the crane model and rating chart number. GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 9 of 35...
  • Page 354 (item 27) will acknowledge the information display message and allow the system to start normal operation. GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 10 of 35...
  • Page 355 During adjustment of the contrast or brightness, the information window will automatically display the reminder window shown. GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 11 of 35...
  • Page 356 Start the choice by pressing the counterweight push button (item 20). GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 12 of 35...
  • Page 357 "No other chassis options" will appear on the information screen (item 1). GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 13 of 35...
  • Page 358 ALL CRANE CONTROLS REMAIN ACTIVE WHILE THE RIGGING/TRAVEL MODE IS SELECTED. GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 14 of 35...
  • Page 359 If only a single option is available, it push button (item 18). will automatically be selected. GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 15 of 35...
  • Page 360 The available erected jib options will be displayed in the information screen (item 1). GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 16 of 35...
  • Page 361 This will toggle the auxiliary head on and off SCREEN (ITEM 1). each time the button is pressed. GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 17 of 35...
  • Page 362 "No other winch options" will appear for three seconds on the information screen (item 1). GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 18 of 35...
  • Page 363 (item 1). and from main boom back to jib again. GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 19 of 35...
  • Page 364 GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 20 of 35...
  • Page 365 Always check the point of lift and parts-of-line following selection of the winch. GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 21 of 35...
  • Page 366 (such as A2B) or if a previous condition GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 22 of 35...
  • Page 367 GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 23 of 35...
  • Page 368 Return to the main screen by pressing the operator alarm push button (item 24) two times. GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 24 of 35...
  • Page 369 MAX ANGLE OFF. GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 25 of 35...
  • Page 370 MAX LENGTH OFF. MAX HEIGHT OFF. GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 26 of 35...
  • Page 371 29). Each one of these push buttons relates to the alarm to which it points. GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 27 of 35...
  • Page 372 IS MOVED OR IF A DIFFERENT SIZE LOAD IS LIFTED THE SWING ALARMS MUST BE RESET. GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626...
  • Page 373 LEFT SWING OFF RIGHT SWING OFF. left/right swing limits is set. GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 29 of 35...
  • Page 374 FROM THE OBSTACLE. IF THE CRANE OR OBSTACLE IS MOVED, OR IF A DIFFERENT SIZE LOAD IS LIFTED, THE WORK AREA ALARM MUST BE RESET. GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 30 of 35...
  • Page 375 LEFT POINT OFF RIGHT POINT OFF limits is set. GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 31 of 35...
  • Page 376 CONFIGURATION An arrangement of the lifting elements of a crane. GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 32 of 35...
  • Page 377 A point which is either longer than the longest permitted radius or lower than the lowest permitted angle on a capacity chart GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 33 of 35...
  • Page 378 The structural part of a crane above the carrier, usually rotating. GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 34 of 35...
  • Page 379 Permits the operator to define an operating zone by the means of only two set points. GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00 TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626 35 of 35...
  • Page 404 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. WARNING: Battery posts, terminals, and related accesories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm.

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