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Terex RT200-1, Operator'S Manual

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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.
The materials presented here are listed in accordance with the 

Machine Maintenance

Checklist on page 134

. Consideration of severe working conditions may dictate a revision

in scheduling periodic checks.

DAILY:

HYDRAULIC FLUID LEVEL

The hydraulic reservoir, fluid level indicator, and filler cap are on the right side of the machine.

Retract all cylinders to return the maximum amount of oil to the reservoir and note the oil
level in the indicator. The fluid level should be between the full and add marks. The top
mark indicates system capacity with all cylinders retracted. Reservoir capacity is 298
gallons and system capacity varies with equipment up to a maximum of approximately 527
gallons.

Do not overfill.

Maintenance

158

P/N 12261-319 REVISED: August 2012

Courtesy of Crane.Market 

Summary of Contents for RT200-1

Page 1: ...Courtesy of Crane Market...

Page 2: ...41 Lock Out Tag Out 42 Access Egress 44 Personal Safety 49 Seat Belts 50 Assembly 51 Step Installation 51 Spooling Wire Rope on Drums 52 Hoist Line Reeving 56 Cable Reeving 59 Side Stow Jib 60 Descri...

Page 3: ...124 Cold Weather Package Recommendations 129 Maintenance Introduction 133 Machine Maintenance Checklist 134 Engine Maintenance 137 Engine Radiator Maintenance 139 Transmission Maintenance 140 Axle Ma...

Page 4: ...191 Chrome Cylinder Rod Storage 192 Specifications 195 Wire Rope Specifications 195 Service Parts 197 Outrigger Position Sensors 197 Appendix 199 Conversion Tables 199 Average Weight of Materials 203...

Page 5: ...Courtesy of Crane Market...

Page 6: ...nformation and training to those people who are to operate maintain and supervise the use of equipment in a proper and safe manner Construction and industrial equipment is designed and manufactured to...

Page 7: ...ding the care and operation of the machine we will gladly furnish it upon request Because we build various types of equipment we ask that you include your machine model and serial number in all corres...

Page 8: ...PPERSTRUCTURE The upperstructure weldment swing mechanism counterweight cab 2 BOOM ATTACHMENT The telescopic crane boom with hydraulic winch lift cylinder hook block assembly jib arrangement 3 CARRIER...

Page 9: ...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 Introduction 8 P N...

Page 10: ...fic machines using the machine model number and PIN serial number Distribution of bulletins is based on the most current owner of record along with their associated dealer so it is important to regist...

Page 11: ...Questions regarding product applications and safety Standards and regulations compliance information Questions regarding product modifications Current owner updates such as changes in machine ownershi...

Page 12: ...er 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 appli...

Page 13: ...Courtesy of Crane Market...

Page 14: ...g in this manual that is not clear or which you believe should be added please send your comments to Technical Publications Coordinator Terex Cranes 106 12th Street SE Waverly Iowa 50677 or contact us...

Page 15: ...y of the potential hazard Signal words used without the safety alert symbol relate to property damage and protection only All are used as attention getting devices on decals and labels fixed to the ma...

Page 16: ...ce applied two directions pinched Stay Clear of Moving Turret and Boom CRUSH HAZARD Death or Serious Injury can result from contact with moving machine Keep clear of moving machine Safety Alert Symbol...

Page 17: ...eis running Stop engine before servicing 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 awa...

Page 18: ...ladder to reach high places Maintain 3 Point Contact when using access system Two blocking the crane can cause death serious injury or property damage Do not allow the hook block to contact the boom t...

Page 19: ...stance From Electrical Power Lines 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 deta...

Page 20: ...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 19...

Page 21: ...under pressure can penetrate skin causing serious injury Relieve pressure before disconnecting hydraulic lines Keep away from leaks and pin holes Use a piece of cardboard or paper to search for leaks...

Page 22: ...MAINTAIN REQUIRED CLEARANCE Line Voltage Required Clearance 0 to 50KV 10 ft 3m 50 to 200KV 15 ft 4 6m 200 to 350KV 20 ft 6 1m 350 to 500KV 25 ft 7 6m 500 to 750KV 35 ft 10 7m 750 to 1000KV 45 ft 13 7...

Page 23: ...tal 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 Auxiliary Hoist Tap elbow...

Page 24: ...C3 TRAVEL Arm extended forward hand open and slightly raised make pushing motion in direction of travel C4 DOG EVERYTHING Clasp hands in front of body C5 TRAVEL Both Tracks Use both fists in front of...

Page 25: ...serious injury Relieve pressure before disconnecting hydraulic lines Keep away from leaks and pin holes Use a piece of cardboard or paper to search for leaks Do not use hand Fluid injected into skin...

Page 26: ...ENTANGLEMENT HAZARD Rotating parts can cause personal injury Keep away from fan and belt when engine is running Stop engine before servicing 25 P N 12261 319 REVISED August 2012 Courtesy of Crane Mark...

Page 27: ...rotating driveline Keep clear of rotating drivelines Shut off engine before performing service 10 CRUSH HAZARD Serious injury can result from contact with moving outriggers Keep clear of moving outri...

Page 28: ...the electric power line owner to disconnect move or insulate power lines 12 EXPLOSION BURN HAZARD will cause death burns or blindness due to ignition of explosive gases or contact with corrosive acid...

Page 29: ...RN HAZARD Fuel and fumes can explode and burn No Smoking No flame Stop engine 14 FALL HAZARD Serious injury or death can occur NO RIDERS Safety 28 P N 12261 319 REVISED August 2012 Courtesy of Crane M...

Page 30: ...sult from contact with moving machine Keep clear of moving machine 16 EXPLOSION BURN HAZARD Release of hot pressurized fluids can cause Burns or Blindness Allow to cool before opening 29 P N 12261 319...

Page 31: ...e 3 Disconnect all wires at alternator before disconnecting or charging battery 4 Do not interchange positive and negative battery leads 5 Do not polarize alternator 6 Do not ground field circuit exce...

Page 32: ...ve equipment including face shield gloves and long sleeve shirt READ MANUALS Read all manuals prior to operation DO NOT OPERATE equipment if you do not understand the information in the manuals Consul...

Page 33: ...ating Chart 6 Know that the crane can safely lift each load before attempting to lift 7 The operator must understand crane signals and take signals only from designated signal people However the opera...

Page 34: ...gers 15 Start and stop movements smoothly and swing at speeds that will keep the load under control 16 Keep at least three full wraps of wire rope on drum when operating 17 Feet must be kept on the pe...

Page 35: ...report any unsafe conditions to supervisor 6 Supply the weight and the characteristics of all loads to be lifted to the operator 7 Verify that all crew members are familiar with OSHA ANSI B30 5 requi...

Page 36: ...SAFETY CHECK 1 Safety related items must be in place 2 Check machine log book to see if periodic maintenance and inspections have been performed 3 Ensure that necessary repairs have been completed 4 I...

Page 37: ...d without knowing whether it is within the rated capacity 7 Never operate with anything other than recommended counterweight Unauthorized reduction or additions of counterweight constitute a safety ha...

Page 38: ...ove materials from under powerlines with a crane if the boom or machine is capable of contacting them 3 No part of crane or load must come in contact with or violate the minimum allowable clearance re...

Page 39: ...the area 6 Use a signal person when working around power lines TRAVEL 1 Care must be taken when cranes are driven traveled whether on or off the job site 2 Always pre plan the path of travel to deter...

Page 40: ...it must be ensured that the anemometer is fully functional If the values on the display change when the rotor is rotated the unit is functioning To verify functionality during conditions of no wind t...

Page 41: ...ht 1 3 1 5 Wind direction indicated by the smoke and not by the banner 2 Light Breeze 4 7 6 11 The wind can be felt on the face the leaves rustle the banner moves 3 Gentle Breeze 8 12 12 19 Leaves and...

Page 42: ...wer or attempting to get onto the carrier superstructure or boom assembly If on the machine do not try to get off the machine If you are in the operator s cab upper or lower during an electrical storm...

Page 43: ...nt absolutely the unexpected or accidental startup of equipment and to alert all workers whenever it is unsafe to operate any piece of equipment When used as intended Lock Out Tag Out also protects pe...

Page 44: ...work is complete and tools are put away 3 All workers are notified that a lock is being removed 4 All workers are positioned safely for startup 5 Controls are positioned for safe startup 6 The machine...

Page 45: ...ane 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 operato...

Page 46: ...earance 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 2 Step shown in crane working position 45 P N 1226...

Page 47: ...Safety 46 P N 12261 319 REVISED August 2012 Courtesy of Crane Market...

Page 48: ...ator 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 47 P N 12261 319 REVISED August 2012 Courtesy of Crane Ma...

Page 49: ...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 Safety 48 P N 12261 319 REVISED August 2012 Courtesy of Crane Mark...

Page 50: ...mud ice and snow from walking surfaces 4 Store all tools rigging and other items in the tool box 5 Replace all broken ladders or other access system components 6 Keep non slip surfaces in good condit...

Page 51: ...e 5 Do not bleach or re dye because such processing may severely weaken the assembly 6 Inspect seat belt assemble frequently Anytime it does not operate properly or if there are any defects in the web...

Page 52: ...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 pos...

Page 53: ...excessive undercutting at the base of the flange also indicate that repair or replacement of the drum is necessary Check the bearings for excessive wear and play After correcting any defects revealed...

Page 54: ...osition the anchor wedge in the drum slot pull firmly on the free end of the cable to secure the wedge 5 Slowly rotate the drum ensuring the first layer of cable is evenly wound on the drum 6 Install...

Page 55: ...ake no substitutions Follow the procedure below when installing wedge type sockets on wire rope Be certain the correct socket and wedge are used 1 Lead the rope 3 through the socket 1 form a large loo...

Page 56: ...til the wedge is firmly in place 5 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 DO NOT clamp...

Page 57: ...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 BLOCK SHEAVE 11 CABLE SOCKET Assembly 56 P N 12261 319 R...

Page 58: ...ting chart This crane incorporates a Quick Reeving boom head and block which do not require removal of the wedge and socket from the rope in order to change the reeving Removal of two pins in the boom...

Page 59: ...of line required for the load being lifted Refer to the Crane Capacity Chart for parts of line required Assembly 58 P N 12261 319 REVISED August 2012 Courtesy of Crane Market...

Page 60: ...ting chart The minimum required number of parts is determined by referring to the load rating chart This machine incorporates a Quick Reeving boom head and block which do not require removal of the we...

Page 61: ...jib The jib is extendible to 43 ft 13 11 m by means of a 17ft 5 18 m manual pullout tip section Each optional jib extension is pinned directly to the ends of the sheave pins When not in use the jib c...

Page 62: ...the boom completely 4 Boom down to minimum boom angle to allow ease of installation of the jib pins If necessary raise rear outriggers till boom head can be reached from ground level 5 Install the upp...

Page 63: ...ad sheaves and swing over top left jib cord before pinning jib to boom Install the left upper and lower jib mounting pins 12 Remove the guide rope 13 Disconnect the anti two block plug from the jib an...

Page 64: ...s necessary to loosen the jib offset pins 6 Remove the jib offset pins from the 0 offset hole and place in the 15 hole or if you are using 30 offset then place pins in tool box Never Remove Either 30...

Page 65: ...ON 1 Pull Out Retaining Pin Hole 4 Attach Dead End of Rope 2 Pull Out Anti Two block Plug 5 Anti Two block Extended Socket 3 Two Block Weight 6 Anti Two block Retracted Socket Assembly 64 P N 12261 31...

Page 66: ...DEFROST PARKING BRAKE PARKING LIGHTS TURN SIGNAL INDICATOR LOW OIL PRESSURE BEACON SWING FUEL STANDARD STEER SWING BRAKE WATER TEMPERATURE 4 WHEEL STEER FAST Description Of Machine and Controls 65 P N...

Page 67: ...R STEER LEFT HORN EMERGENCY STOP REAR STEER RIGHT WINCH AIR PRESSURE IGNITION WINDSHIELD WASHER SWING LEFT ELECTRICAL ACCESSORIES ON WINDSHIELD WIPER Description Of Machine and Controls 66 P N 12261 3...

Page 68: ...STEM 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 67 P N 12261 319 REVISED August 2012...

Page 69: ...SMISSION OIL PRESSURE OUTRIGGER SELECT HEATER AC HEAT OUTRIGGER RETRACT HEATER AC AC OUTRIGGER EXTEND HEATER AC FAN Description Of Machine and Controls 68 P N 12261 319 REVISED August 2012 Courtesy of...

Page 70: ...SWITCH Push right to turn on work lights 3 ENGINE COOLANT TEMPERATURE GAUGE Measures engine coolant temperature 11 SWING BRAKE PEDAL RATCHET RELEASE Pull and lock to permit operation of the pedal Rela...

Page 71: ...on 15 WINDOW WASH BUTTON Push in to dispense wash fluid 8 STEERING SWITCH Provides the following Switch to crab or 4 wheel steering only when axles are centered Otherwise steering will be limited and...

Page 72: ...ure Normal range is 240 to 300 psi Never drive the machine when the charge pressure is below 240 psi 31 JACK SWITCH LEFT REAR Used in conjuction with switch 13 to extend and retract outrigger jack and...

Page 73: ...TOP INDICATOR 36 AXLE DISENGAGE RANGE SHIFT 27 ENGINE MAINTENANCE INDICATOR 28 ENGINE STOP FAULT INDICATOR 7 VOLTMETER Indicates battery or alternator condition 44 ENGINE STOP BUTTON Depress button to...

Page 74: ...0 AMP PLUG 38 HAND THROTTLE Holds engine throttle at an operator settable position Place the accelerator 42 at approximate RPM Push in button on hand throttle Pull throttle up and release button to lo...

Page 75: ...the boom Tilt the pedal all the way forward for high speed regenerative extend The boom extend will stop at the transition between power extend and high speed In high speed extend the boom extend has...

Page 76: ...ove joystick right to swing boom right 57 Hi Speed Winch Switch Press to toggle high speed winch 55A Aux Winch Rotation Indicator Thumps to signal that rope is moving Located internally in handle 58 H...

Page 77: ...e Move joystick left to raise boom Move joystick right to lower boom 57 Hi Speed Winch Switch Press to toggle high speed winch 59A Main Winch Rotation Indicator Thumps to signal that rope is moving Lo...

Page 78: ...in button on hand throttle Pull throttle up and release button to lock Make fine adjustments to engine RPM by rotating the hand throttle clockwise to decrease RPM and counterclockwise to increase RPM...

Page 79: ...Courtesy of Crane Market...

Page 80: ...D HYDRAULIC SYSTEM Leaks or Damage D AIR SYSTEM Leaks or Damage D HYDRAULIC FLUID D TRANSMISSION FLUID LEVEL D ENGINE CRANKCASE FLUID LEVEL D FUEL TANK FLUID LEVEL D RADIATOR FLUID LEVEL D MACHINE LUB...

Page 81: ...UP ALARM D BOOM ANGLE INDICATOR D HEAD TAIL BRAKE LIGHTS 4 WAY FLASHERS D HORN D CABLE SPOOLING PROPERLY D WEDGE SOCKETS D AXLE FLUID LEVEL W SWING REDUCER FLUID LEVEL W DRIVE SHAFTS U JOINTS W TIRE W...

Page 82: ...djust or repair boxes provided 2 When appropriate enter your diagnosis on back of page for repairs or adjustments made H Inspect OVERALL machine including carrier for cracks weld separation leaks dama...

Page 83: ...e full mark there is enough to start the engine After the engine has been started and the transmission warmed to 180 200 F allow the engine to idle and ensure that the fluid level is between the full...

Page 84: ...ON 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 Inspected...

Page 85: ...ed With the boom fully lowered and extended visually inspect the sides top and bottom of each section for any unusual deformation scrubbing wear or cracking in either the plates or welds particularly...

Page 86: ...r 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 85 P N 12261 319 REVISED...

Page 87: ...Courtesy of Crane Market...

Page 88: ...ding engine operation You must pull the button out before you can resume normal operation of the crane 3RD WRAP Winch down function will be disabled when less than 3 wraps of rope are available on the...

Page 89: ...alls during the start up procedure allow the engine to stop revolving before re engaging the starter Do not engage the starter motor for more than 15 seconds at a time Should the engine fail to start...

Page 90: ...et pump demand and a vacuum or cavitation will be created A screaming noise indicates inadequate pump lubrication and if allowed to continue for more than a short period will result in serious damage...

Page 91: ...stem connect both ends of one cable to positive terminals of each battery 5 Connect one end of the other cable to negative terminal of the booster battery 6 Connect other end of cable away from batter...

Page 92: ...before any extended periods of low rpm operation to maintain battery charge When idling for extended periods maintain an idle speed sufficient to prevent the battery from being discharged Keeping the...

Page 93: ...d retract master switch must be actuated before the appropriate function switches can be actuated to operate the outriggers This is a safety feature to prevent accidental actuation of the outriggers w...

Page 94: ...with the crane The determining factors are lifted load radius boom angle working position hoist line reeving tire pressure travel data and use of a jib The examples given in this section are given for...

Page 95: ...e time of the adjustment but those which may be encountered during swings Think the swing through considering all obstacles before making the swing Never hold the controls in an activated position onc...

Page 96: ...must be maintained when telescoping the boom in order for the pumps to provide enough oil flow to make it operate properly While extending the boom be sure to pay out sufficient hoist rope to prevent...

Page 97: ...n audible warning will sound Some cranes may be equipped with control disconnects which will prevent the winch from raising the load and the boom from extending or lowering To continue crane operation...

Page 98: ...plate for the required counterweight total When lowering light loads be sure to maintain sufficient cable tension to prevent the cable from becoming loose on the cable drum Loose cable can slip and th...

Page 99: ...rm extended fingers closed thumb pointing downward 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 an...

Page 100: ...ne Track Lock the track on one side indicated by raised fist Travel opposite track in direction indicated by circular motion of other fist rotated vertically in front of body For land cranes only EXTE...

Page 101: ...of boom angle and length shown in the load rating chart Do not allow the radius to exceed that given for the rated load Boom Angle The boom angle is the angle of the boom measured from horizontal Use...

Page 102: ...an 600 lbs are not shown This is done because the effects of wind pendulum action jerking etc can cause a tip over Therefore Extending the boom or boom and jib combination into unrated areas of the ch...

Page 103: ...he following procedure 1 Determine weight of load to be lifted 2 Determine weight of slings and rigging hardware 3 Determine weight of hook block 4 Determine other capacity deductions 5 Calculate weig...

Page 104: ...TICAL WORKING LOADS DEPEND ON THE SUPPORTING SURFACE WIND VELOCITY PENDULUM ACTION JERKING OR SUDDEN STOPPING OF LOADS HAZARDOUS SURROUNDINGS EXPERIENCE OF PERSONNEL AND PROPER OPERATION TIRE INFLATIO...

Page 105: ...after loading and deflection Never use a jib for clamshell or magnet operation The heavy side load due to swinging and bouncing that can occur could damage jib or boom point This is also true of pick...

Page 106: ...ollowing example the crane is set up as follows 1 On outriggers 2 Side stow jib erected at 30 offset 3 Auxiliary boom head sheave erected but not used 4 Hook block off the main head but not used 5 Boo...

Page 107: ...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 ov...

Page 108: ...d chart Ensure that the tires are inflated as shown in the recommended tire pressure chart Refer to procedure for tire inflation in Tire Maintenance Section Creep means the crane can be moved at a max...

Page 109: ...int moves out to a greater radius than the load centerline which it tends to do due to boom deflection and machine tipping In this condition when the load comes free of the ground it swings out rapidl...

Page 110: ...ons will require the operator to consider the prevailing conditions and reduce the lift capacities accordingly Insufficient tire pressure reduces the ON TIRES capacity Attempts to pick rated capacity...

Page 111: ...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 Failure to obse...

Page 112: ...ontains ethylene glycol Use only non chromate base inhibitors Chromate base inhibitors reacting with ethylene glycol can produce chromium hydroxide commonly known as green slime This substance reduces...

Page 113: ...ct the flow to as slow a speed as possible by moderating pressure on the controls being engaged and running the engine at low speed 6 At the end of the work period or whenever the crane is to be left...

Page 114: ...of large amounts of sand or dust at the work site can contribute to accelerated component wear Either substance will act as an abrasive when deposited on moving parts of the crane The problem is comba...

Page 115: ...the entry of water 4 Hoist rope must be kept well lubricated to prevent moisture and salt from penetrating the cable strands HIGH ALTITUDES Variations in altitude alter the fuelair mixture burned in t...

Page 116: ...override switch 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 Contin...

Page 117: ...F4 or F2 In addition to conditions of terrain gear selection while traveling is also determined by transmission temperature Normal operating temperature is 160 to 200 deg F If the transmission temper...

Page 118: ...the engine speed Always idle the engine for at least 5 minutes before stopping it This gives the engine a chance to cool down and prevents overheating which can be caused by localized hot spots in th...

Page 119: ...with boom above horizontal unless the surface is firm level and free of bumps and potholes Watch for overhead obstructions such as trees power lines or bridges If the terrain is rough or uneven it may...

Page 120: ...E CHECK LIST Perform Pre Move Checklist as described in Vehicular Operation on page 115 VEHICULAR OPERATION Direction of travel depends on the method of loading used When backing the equipment onto th...

Page 121: ...edure below 1 Move the transmission shift lever to the neutral position 2 Put the parking brake switch in the ON position 3 Turn the ignition switch to the ON position Wait to start light goes off 4 T...

Page 122: ...d possible Use the steering wheel to control direction of front tires Use the brake pedal to stop If necessary you may use rear steer if equipped Toggle switch to move tires left or right When equipme...

Page 123: ...e hydraulic system will not hold the sections against the hard breaking jolts while the crane is being transported Restrain the boom extend sections by snugging the hook block against the boom head or...

Page 124: ...Lubrication Chart Maintenance 123 P N 12261 319 REVISED August 2012 Courtesy of Crane Market...

Page 125: ...ids lubricants can be exchanged by draining old fluids refilling with recommended fluids or by applying recommended greases Use of improper fluids for ambient conditions can damage equipment COLD WEAT...

Page 126: ...re available that can provide some winter performance benefits Cummins Filtration Winter Conditioner and Turbo Diesel All Season Fuel Additive are the only diesel fuel additives approved by Cummins In...

Page 127: ...gine oils The same oil change intervals must be applied to synthetic oils that are applied to petroleum mineral based engine oils Axles In the case of vehicles being started in ambient temperatures be...

Page 128: ...6 L 40 F 40 C Extended Drain Lubricants Petroleum with Extended Drain Additives GL 5 80W 90 MIL PRF 2105 E and SAE J2360 15 F 26 C Semi Synthetic 80W 90 15 F 26 C Full Synthetic 75W 140 0 76 M 40 F 40...

Page 129: ...ee 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 m...

Page 130: ...ll help prevent the intake valves and exhaust valves from sticking The cooling system and the lubrication system for the engine do not lose heat immediately upon shutdown The transmission and the hydr...

Page 131: ...page 124 To avoid valve damage always run the engine until the coolant temperature is at least 82 C 180 F After the engine is warm proceed with warming up the other systems Start with the hydraulics R...

Page 132: ...ure they will have a shortened life A tire that is inflated to the correct pressure in a 18 C to 21 C 64 F to 70 F shop area will have a lower tire pressure in freezing conditions Terex recommends the...

Page 133: ...108 111 90 96 99 101 104 106 109 112 115 116 95 102 104 107 109 112 115 118 121 124 100 107 109 112 115 118 121 124 127 130 105 112 115 118 120 123 127 130 133 137 110 118 120 123 126 129 132 136 139...

Page 134: ...ecting problem areas and reanalyzing maintenance requirements The items in each check interval on the check chart are grouped under their respective headings and covered in detail throughout the Maint...

Page 135: ...___ Check Boom Front Slider Pads WEEKLY CHECK 40 HOURS ___ Perform The Daily Check ___ Check Hydraulic Cylinders and Rods ___ Perform Weekly Lubrication ___ Check Torque on Wheel Lug Nuts ___ Check Sw...

Page 136: ...xterior Painted Surfaces ___ Change Hydraulic Return Line Filters ___ Check Brake Reservoir Fluid Level SEMI ANNUAL CHECK 1000 HOURS ___ Perform Daily Weekly Monthly And Quarterly Checks ___ Change Wi...

Page 137: ...until all bolts are found properly torqued Thereafter checks should be performed semi annually 40 HOURS After forty hours of travel drain and refill the transmission with new fluid 100 HOURS After one...

Page 138: ...be noted DAILY FUEL LEVEL The fuel tank is located on the left side of the machine Keep the tank as full as possible to minimize condensation in cold weather Use grade No 2 diesel fuel The tank capac...

Page 139: ...and can damage or destroy the indicator Reset the filter indicator each time the hood is opened as it provides a built in check to assure proper functioning If it does not reset then the orifice is pl...

Page 140: ...through core cooling passages by directing compressed air and flushing water over the entire area of the core in the reverse direction of normal air flow QUARTERLY CORROSION INHIBITOR Replenish the co...

Page 141: ...ll the low oil level plug Start and run the engine at idle speed to prime the converter oil cooler and lines Recheck the oil level with the engine running at idle speed and bring level to the low oil...

Page 142: ...TURE WHICHEVER COMES FIRST AT FULL GOVERNED ENGINE RPM STALL SPEED RECOMMENDED SAE J300 VISCOSITY GRADE BASED ON PREVAILING AMBIENT TEMPERATURE POWER SHIFT TRANSMISSION AND TORQUE CONVERTER HYDRAULIC...

Page 143: ...ecking the oil 1 Lubricant Level 3 Drain Plug Rotates to Bottom 2 Check Plug 4 Horizontal Oil Fill Level Remove the oil level plug in the planet cover and add oil as necessary to bring the oil level t...

Page 144: ...n 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 After draining rotate the hub until the...

Page 145: ...down or stop until the tires cool Inflation pressure should be checked when tires are cool using an accurate tire pressure gauge Check pressures at regular intervals Bleeding the air from hot tires is...

Page 146: ...anged safely Whenever possible let your service company handle this job If you must change a tire follow the step by step instructions detailed in a tire repair manual Should low pressures make it nec...

Page 147: ...ake sure side ring and lock ring designations match those of the base 2 Deflate tires completely prior to demounting by removing the valve core 2 Do not use loads or inflation pressures exceeding the...

Page 148: ...d ring butting Either one of these conditions is an indication of mismatched parts 6 Inflate tires in a safety cage 7 After inflating the tire be sure that between a 1 16 minimum and a 1 4 maximum rem...

Page 149: ...in photo to support wheel assembly 4 Remove the lug nuts using air impact wrench or breaker bar and 1 1 2 deep well socket with 12 extension If difficult to remove slightly raise the front or rear ou...

Page 150: ...149 P N 12261 319 REVISED August 2012 Courtesy of Crane Market...

Page 151: ...onsideration of severe working conditions may dictate a revision in schedule periodic checks DAILY AIR TANKS Open the air tank drain cocks at least once daily to blow out moisture and accumulated sedi...

Page 152: ...151 P N 12261 319 REVISED August 2012 Courtesy of Crane Market...

Page 153: ...e stop button should be adjusted so that the roller and plunger just contact 3 Apply oil or light grease between plunger and valve body Do not overoil 4 Clean exhaust check depending on type of servic...

Page 154: ...ng circuits are operating normally LEAKAGE CHECK 1 Make and hold full brake application 2 Coat the exhaust port and body of the brake valve with soap solution 3 Leakage is not to exceed a 1 bubble in...

Page 155: ...confirm appropriate setting Parts are under spring and air pressure Also the machine must be running to confirm brake adjustment and you are adjusting the braking system Chock the wheels before beginn...

Page 156: ...greased Under extremely dirty or dusty conditions sufficient grease should be added to flush out contaminated grease Under less severe conditions add grease until it appears at the bottom seal While s...

Page 157: ...NOTE Other manufacturers lubricants of the same quality are suitable Maintenance 156 P N 12261 319 REVISED August 2012 Courtesy of Crane Market...

Page 158: ...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...

Page 159: ...34 Consideration of severe working conditions may dictate a revision in scheduling periodic checks DAILY HYDRAULIC FLUID LEVEL The hydraulic reservoir fluid level indicator and filler cap are on the r...

Page 160: ...line filters after the first 40 hours of the break in period thereafter change every 3 months or 500 hours which ever comes first MONTHLY HYDRAULIC RESERVOIR Drain any accumulated moisture from the hy...

Page 161: ...7 Intake Suction Filter 4 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 deteri...

Page 162: ...itions Although conditions may necessitate shorter change intervals do not use hydraulic oil for more than 1500 hours Whenever a visual inspection chemical test or light test indicates that an oil cha...

Page 163: ...Where dust dirt high humidity or extreme heat are encountered lubrication intervals should be shortened accordingly Maintenance 162 P N 12261 319 REVISED August 2012 Courtesy of Crane Market...

Page 164: ...hydraulic reservoir temperatures in excess of 200 F 87 C due to possible excessive damage to the hydraulic oil and rubber components hoses seals shaft seals motor seals etc If over heating occurs disc...

Page 165: ...Viscosity Many hydraulic fluids will shear or thin out with use The viscosity at each check should be compared to the viscosity when new At no time should the viscosity be less than 45 SSU at 210 F If...

Page 166: ...ear pump or motor has suddenly begun deteriorating and a catastrophic failure can be expected shortly VISCOSITY Oils are available in various grades viscosities The ISO International Organization for...

Page 167: ...ered through 5 0 micron filter N Cleanliness Fluid shall appear bright and clear and shall be free of visible contaminants or sludge Maximum life of pumps motors hoses and seals will be obtained by se...

Page 168: ...ith Ambient Temp Range From 100 F To 120 F 1 1 C 80 C 93 C Minimum temperature for starting without extended warm up For lower temperatures follow warm up procedure in the operators manual Premium Gra...

Page 169: ...ydra Shield 68 68 Tellus 68 100 D A Hydra Shield 100 100 Tellus 100 Dryden Oil Co USA 32 Paradene Anti Wear 32 AW Sun Oil Co USA 32 Sunvis 816 WR 46 Paradene Anti Wear 46 AW 46 Sunvis 821 WR 68 Parade...

Page 170: ...Factory filled with Northland Talamar 215 or equivalent KOEHRING SPEC 805 IS EQUIVALENT TO HYDRAULIC OILS SHOWN ABOVE 169 P N 12261 319 REVISED August 2012 Courtesy of Crane Market...

Page 171: ...rope is passed through the hot lubrication over sheaves and a center guide wheel Hot oils or greases have excellent penetrating qualities and upon cooling have high adhesive and film strength around...

Page 172: ...eaves 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 The rope should be lightly...

Page 173: ...icant 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 ma...

Page 174: ...173 P N 12261 319 REVISED August 2012 Courtesy of Crane Market...

Page 175: ...damage and correct Check the condition and size of the cables Are the cable clamps tight Check for corrosion on the terminal or clamps Clean corroded parts and or tighten clamps if necessary Replace...

Page 176: ...ery to service If the state of charge of a battery cannot be determined and the battery fails the load test it must be recharged and retested If it meets the specified voltage on the second test retur...

Page 177: ...ion before connecting the leads to the battery If you have any doubts that the charger is actually OFF disconnect it from the power source The state of charge of maintenance free batteries can be dete...

Page 178: ...5 amperes for above 80 to 125 minutes reserve capacity batteries Batteries over 125 minutes should be charged at the specified SLow Charge rate BOOST CHARGE If a battery requires a boost charge it sho...

Page 179: ...d nonresidue solvent to clean the ring Then lightly sand the brushes and rings with a fine grade of sandpaper and dust off with compressed air MAINTENANCE CHECKS On a daily basis inspect the cylinder...

Page 180: ...ling a new or replacement rope make certain the rope to be used is the proper type and size The wrong rope will not function properly and may even be dangerous WIRE ROPE SPECIFICATIONS MAIN AUXILIARY...

Page 181: ...This machine incorporates a Quick Reeving boom head and block which do not require removal of the wedge and socket from the rope in order to change the reeving Removal of two pins in the boom head and...

Page 182: ...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 des...

Page 183: ...t is evident he inside of the top plate of all sections except the tip section also require grease This can be applied through the holes in the side plates and piled on top of the next section out jus...

Page 184: ...ose grease Coat unpainted metal surfaces with multipurpose grease after removing any rust accumulations The ENGINE should be prepared as prescribed in the topic Engine Storage on page 185 The TRANSMIS...

Page 185: ...th lubricant 8 Coat exposed cylinder rods with grease The ENGINE should be prepared as prescribed in the topic Engine Storage on page 185 The TRANSMISSION should be prepared as prescribed in the topic...

Page 186: ...ankcase to the proper level with the recommended viscosity and grade of oil 3 Fill the fuel tank with the recommended grade of fuel oil Operate the engine for two minutes at 1200 rpm and no load NOTE...

Page 187: ...he proper level with a 30 weight preservative lubricating oil MIL L 21260 Grade 2 P10 or equivalent 10 Drain the engine fuel tank 11 Refill the fuel tank with enough rust preventive fuel oil such as A...

Page 188: ...solution and rinse them with fresh water Store the battery in a cool never below 32 F dry place Keep the battery fully charged 21 Insert heavy paper strips between the pulleys and belts to prevent st...

Page 189: ...tional information STORAGE 30 DAYS TO 1 YEAR WITHOUT OIL 1 Drain Oil 2 Seal all openings and breathers except oil drain hole with moisture proof cover or tape 3 Coat all exposed unpainted surfaces wit...

Page 190: ...procedure 1 Remove preservative lubricants from all surfaces 2 Check all fluid levels adding or draining as required 3 Lubricate the machine according to Lubrication Chart on page 123 making certain...

Page 191: ...cations 9 Close all of the drain cocks and fill the engine cooling system with clean soft water and a rust inhibitor If the engine is to be exposed to freezing temperatures add a high boiling point ty...

Page 192: ...level NOTE It is not necessary to drain C3 oil and Nox Rust mixture from the transmission 5 If Nox Rust or equivalent was not used in preparing the transmission for storage use the following procedure...

Page 193: ...ent dealership before it is sold During these times a protective barrier must be applied to the exposed cylinder rod This protective barrier will preserve the integrity of the chrome plating by preven...

Page 194: ...plications should be increased NOTE Caution must be used when cleaning equipment in service with high pressure washes Soaps or chemicals containing chlorines or other corrosive elements should be avoi...

Page 195: ...Courtesy of Crane Market...

Page 196: ...TONS AUXILIARY 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 ST...

Page 197: ...Courtesy of Crane Market...

Page 198: ...RCI or Rated Capacity Limiter RCL Visually inspect sensors for damage the condition of related wiring harness connections and dirt debris that could inhibit the sensor signal or proper air gap SENSOR...

Page 199: ...1 Proximity Sensor Outrigger Position Service Parts 198 P N 12261 319 REVISED August 2012 Courtesy of Crane Market...

Page 200: ...5 32 0 1563 3 969 11 64 0 1719 4 366 3 16 0 1875 4 762 13 64 0 2031 5 159 7 32 0 2188 5 556 15 64 0 2344 5 953 1 4 0 2500 6 350 17 64 0 2656 6 747 9 32 0 2813 7 144 19 64 0 2969 7 541 5 16 0 3135 7 9...

Page 201: ...5 11 16 0 6875 17 462 45 64 0 7031 17 859 23 32 0 7188 18 256 47 64 0 7344 18 653 3 4 0 7500 19 050 49 64 0 7656 19 447 25 32 0 7813 19 843 51 64 0 7969 20 240 13 16 0 8125 20 637 53 64 0 8281 21 034...

Page 202: ...u in 1 litre 2 202 lbs of water 62oF 1 cu foot 28 32 litres 1 gallon 3 785 litres 1 cu inch 0 0164 litre MEASURES OF WEIGHTS U S 16 ounces 1 pound 2000 pounds 1 short ton 2240 pounds 1 long ton 100 cu...

Page 203: ...s 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 Appen...

Page 204: ...47 Nickel 537 Steel 481 489 Tin Cast Hammered 459 Tungsten 1200 Zinc Cast Rolled 440 MASONRY Ashlar Masonry 143 162 Ashlar Masonry 143 162 Rubble Masonry 137 156 Dry Rubble Masonry 110 130 Granite Sye...

Page 205: ...d 95 Earth Moist Loose 78 Earth Moist Packed 96 Earth Mud Flowing 108 Earth Mud Packed 115 Riprap Limestone Sandstone Shale 80 105 Sand Gravel Dry Loose 90 105 Sand Gravel Dry Packed 100 120 Sand Grav...

Page 206: ...rtz 95 Sandstone 82 Shale 92 Greenstone Hornblend 107 MISCELLANEOUS Water 4o C 62 4 Water 100o C 59 8 Paper 58 Glass Common 162 Petroleum 45 54 Coal Anthracite 47 5 Coal Bituminous 40 54 Coal Coke 23...

Page 207: ...Torque Specs SAE Metric Appendix 206 P N 12261 319 REVISED August 2012 Courtesy of Crane Market...

Page 208: ...207 P N 12261 319 REVISED August 2012 Courtesy of Crane Market...

Page 209: ...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 TROUBLES...

Page 210: ...talled 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 TR...

Page 211: ...Notes Courtesy of Crane Market...

Page 212: ...rly 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 co...

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