bod TEREX ; CRANES UFTING RT200 SERIES OPERATOR AND MAINTENANCE MANUAL oo Revised: November 1998 1261-198CONGTUCTION AND INDUGITIAL RQUE-MENT ‘PRODUCT GAFETY 1k is the responsiDtiy of the omer of the con- struction and indosiral equypment prodcts 10 De knowledgeable about federal state nd local reg- fatons that elle the total usage of bis evi. meat, and rexponsbihty to working personal and the pale. Since regulations are subject (0 change, and also dsfer rom ene local to another, {hismanitren ne ate topronte mh ne Ianteeane Sromate be earogs contro ind dosent equipment products that it anu faevnren and sells. hv aditinn_ here applet. approprate rational consents standart, de try standnvdls and exiety related manuals are in ‘idea the Terex manta inthe shiner of ach predvel Ite company poiey lo promde tis, fetormation fe the comer ov user of De exp teat is expected tht theanmer or ter wl ite these mals and steadaree to prove the Appreprate information and testo thowe Peo Plier are teeny ant ou npr oe Se of equipment a proper and safe aainer Conscruttion and iadanbal equipment es When opersiing « hydraulic ecane, the operator ehoult realize that bhyiirauile and stractural competence, NOT TIFFING LOAD, is often thr determinant of Kiting eapwolty. ‘Thqeafore, THE OPERATOR MUST BE GUIDED SOLELY BY THE AP- PROPRIATE MANUFACTURER'S LOAD RATING CHART when consid Follow the recommended cparating and malnte ‘nance procaduires and hep yourmachine era tg at WACUMURLENFICISRLY. Use te Suggested Crane Ferlodie Iapecton Check List provided. 10 addiGon, we STRONGLY URGE that'a MAINTE: NANCE LOG be kept conjunction with all mat: ‘anance perDorened on the rasebine IF you desire ang spécial information regscding the care and operation of the machine, ve will lady Loentsh pon eagles. Benatie We Bld Signed and manufactured to perform heavy duly bore: Hinder areal usage, ‘he egpment will ‘ear. Ror this eason’I¢ > essential thatthe aun ec/user establish and perform 9 periodic imsper~ tion of the eqripment. The abjetive of epeetion, programs 18 to prewa tectents, reduce down: Time and keep the cquipnent Working eficteatly. "These inspection prograns should he desigacd to Aiccover worn, cracked, broken or delenomted parts arid lone of mioning fasteners before they esl a probleen Proper training and Inspect programs are es: sential to avouding mjury to persons, damage to property and excessive mauntenance coms. Read and understand the manuals provided with thle equipment. Assistance ie avallable from the @letabutors ef your Terex product apd from the ‘eres manufacturing faci. rated Joada maat never De various types of equipment. we ask thet you ine hide your maebine todel eel enc ruff flloureepondence so that We ean protiée the sor eet information ‘The informaticn, specifications, and illustrations jn the publication are based an tbe information fn efect at the time of spproval for printing. We r= serve the nght male changes atany Umme vith cut ebligation, losued: August 1908SUGGESTED ROUGH TERAIN CRANE INSPECTION CHECK LIST “This hack tis tobe used inaction to he information provided inthis manual properly opecse and rasta themachne, INSPECTED YOR RePECTION® ray (Git assny oven nacre Ho ‘sis eras) ‘ace Shes Filo warel Eevee = FEL Tae “TBE AYaiEEL CONDITION & bt TEAR Puno Lee. Feuarors tiSAgaron ees MLENEOUUST wees aa ogre aw Ete FIRE EXTINGUISHER noes BASKOPALARY Coa “erapect OVERALL macnn tug ci ek al pt al ara, aaa, INSPECTION CODE NTERVALS ores: D-aay -MONTHL” et nsec uty chesglnenacin au robo W-WEERY P-PERIOOE 2. Whenappepine slr jut agi en ask pap ees rachements Insti: August 1998~ TABLE OF CONTENTS - INTROBUCTION _ nN TROIS AND INSTRUMENT | OPERATING INSTEUCTIONS PRRIONIC MAINTENANCE AND LUBRICATION TROUBLESHOOTING a > SRRVICE AND ADJUSTMENTS ~ MACHINE STORAGE, ‘GENERAL INFORMATION & SPECIFICATIONS oo WIRE ROPE USERS MANUAL o z E : : 5 = ° Ioucd: August 108INTRODUCTION INDEX ‘SECTION 1 sUBIECT race ‘ire on gabe oneruttons. mM NOMBNCLATURE .. . pee dS RECEIVING A NEW CRANE. botnets 16 SERVICING THE CRANE, PROPERLY. ce DESCRIPTION... ven wh? sawed: August 1908INTRODUCTION Safety tea funetion of operating @ahinique, lenanceand managernent. Its the recponstilty ‘ob all personnel volved na given profet. in clung the eoerafor, slgnalmant, hand line han- ‘les, maintenence personnel and the Individual {esgonsbble lr tne ob. All must be camvted to accident avoltence end to the practice of goad Safety habit amillonity with the erane tsa prerequiaie of safe ‘operation, Betore putong your crane to use, Both, operators’ and maintenance personnel should ead end be dhoroughly faniiar with this mapual ‘and all additional publications supolled with the ‘rane, auch as the angine martafeeturer's mand: al the lead rating chart the portssmaraat, Mert cation and maintenance instrueliona, Wire Rope UUsera Mtarual, POSA Std, Na. 4, CIMA Crane Us- ers Salety Manual. and Minimum Safety Re- ‘quirements fr Work PlsUorms, In this sobsection ae sted the mone serous and onmon subjets requiring safety precatona ‘Goethe cael ring tae cancaras ane technigues neeeastiated by tnusatons and hanges tn te construction Indutry. no Ist of recall can remain compete frog. There- Fore in adoiean tf the gence sale rules ard precautions outlined inthis subeer” fon ae Coonan seme al good fuderneot ‘then operating your ene iN fey measures unique to eraies lance upen the menefactuver's bead ral cba 09 a gute te ling eapactty. Relying upon sents ‘of Upping to warn ofan evendoad condition care sult in rachine damage of person Injury. Lt Ing capoclty in bydraulte cranes Is most often termined by hydraulls sav structural cone fence, nce Upping load. Before rnakng a Ui, Ake ‘WAYS censul the aad rating chart moured on the side of the yeservolr ani in the eperauar's eats te the sight reas ofthe peralor, Adetalled inter ‘TIPS OW SAFE OPERATION pretation of the lead rating chart ver in sec- on 9 of thie mana ‘Various types of operational ade can bemounted on cranes. Some aids are intended te motltor specie operating functions and to pronde audio ‘and/or vual signals tothe crane operator when, preect mite are approached or exceeded. Other (pes ofakds aze barter or pestectie kinds. Con- sul your diotbutor regarding the avatabily of hese operational aid, No eperational ald Is a substtute forthe ofera- (ors own aleriness and thorough knowledge of the operetion and understanding of the pub- lished physical capabilites ard limitations of is OPERATOR Only qualified operators shoul be ‘authorized te operate the machine, and those 99 authorized should do 9 ony when ghvewally ‘nd mentally alerL The eperator skould be far liar with te hazards ane newessary Sat) met sures unique to the operation of bydraulle QUTRIGCERS Alvaya use outrtegare when re Guived by the load rating shart. Cerain MReapac- les are hase on outriggers being fully sxtended and properly set. eter to the load wating chert before making eny Lf, OUTRIGGER SETTING Never set the antrzéers ‘on a weak or unctable bese, auch es rey or ‘tremely soft ground, of near a hele. Tae crane ‘ey Up during a Wa, resaldng la personal IVY OF property damage, Where ficn footing or bvel aground is not omervase avaliable, ft sowie be Provided by substantial umbers, solid blocking, oF otbor atructiral members aufBicent (0 dtl: lute the foad 50.25 nol 1o exceed the safe bearing ‘opacity ofthe undeslying materia and ta erHbIe leveling of the erane, eae AuguRL 1998INTRODUCTION LIFF COORDINATOR One peron should ax ‘sume responsibiay for coordinating all fects of thelth. He mast tke to consigeration the oper: ater. the erase, other personnel, bystanders and the surrownding area. He smust be totally alert to the hazards nvalied, have In-deyth Knowledge of reper Mt procedures and ekeree good common, Senge a ell mes. LOAD OBSERVATION Watch the lad at all times when the orave fe being operates LOAD OVER PEREORNEL Nover eying the load over personnch Keep everyont frems bencach loads, Use hind lines to gilde leads whenever ecetaary, LOAD SUSPENDED IN ATE The cpexstor sould remain at his station ready far emergency tion, Stall ence hile a load te euspended. PERSONNEL ON HOOK Never operate the ma- chine with personnel ether on the hook or lad, OVERHEAD CLEARANCES Avaya be on the ser for overtcad obstacles and be sure Wiese adequate side clewrante when traveling. Gx. the oaineance ofthe man en the ground whan ces ‘ances exrmot be ascertained from te operators postion, LECTRICAL POWER LINES Refer to ANSI Standard BQO. parsgraph 094.0. for gulde- lines governing the operation of cranes near slee- ‘ale les, Cave mt be falken Unat wo pare of te crane af load comes in eontaet with, or visits the minimum allowable clearance required for operation of erancs near electrical tines. 4 DANGER HE WE ‘Should contact oceur, tay on the crane tbl the fbocm ts eared or uni dhe current is tara off ‘eep all personnel off the craue.Iryou wustiewve ‘the crane, JUMP. DO NOT STET GFF SWING BRARE Always adjusl Ure swing brake by agjasting taccantto)inikage When there ts an dlcadon of sping, Personal injury, ox preperty ‘Geunage could resi hts precaution s neglect oa ‘TRAVELING WETH LOAD All crane toud ratings are based on nonuve of the travel function wie Ianaling loads, However, exanes may Ue utlized orpick aud cary operations Traveling with ss petded bads Involves so many variables Such a round conditions, boem length, mowentum In Slartlagand stopping, ex. that tis imposele to devise a single standard ralng procedure with sy assurante of safey, Por such uperations ie ‘user musl evaluate prevalling conditions and de- Termine sale pracdors, cnerisiog, plecav ons sath as the following: 1. The bora shall be carried stright over the feont of Ure crane ‘Travel speed reduced to sul cetltons 3. Madea epee lane prenwures 4 Avot sudden stars an? slop 5. Piovice tagor restraint Innes Lo snub swingioy ofthe load. 6. Keep lead as close to the ground us post. 7, Sel Un swing brake, 8, Se One mechanical sing lock, fasued: August 1998,IntRopUCTION, MOVING CRANE Never attempt to getan oF off a rane ie motor, BRIDGE CAPACITY Check the capacity of any bilge to be eromsed to determine sheer wil Supporl the weight of the crane, ana lead. SLING CHECK Aiuays be orrtatn thet all lings, ties and ions are prepay placed, secure. of ad ‘equate capacity and in goed conation before Ht tne loacs ROPE AND CLAMP INSPECTION Always nent allropes and clamps atl, ROPE REPLACEMENT Never operate the crane swith worn or damaged opr. Conmult the “Wire ope Users anual er PCSA Statedendl NO. 4, oF ANSI Standart PSO. for gulde lines covering {ope inspection aed ener for replacement ODE WRAPS Never opormte the crane wilh on Inadequate rope seserie on the dria, “Mo lene than, two (2) Gall wrnp ef rope ahal era ME drums with lsadsor front and atiachrent i ef Irene positions stulated hy the manufactarer” HOIST ROPE PARTS Atvays use cuffctent parts of rope for heavy crane Hts. Maven sling C8 pacity can be obtained only when the hack hock Isreeved with suffecen! pars af line. Refer tothe Toad ratng ciarl and the applicable pages ef this ‘manual or reeving recermmendatins. MOVING ROPE anvayskeep hance clear of me ‘ng rope, ROPE TENSION always maintain adequate rope tenalon., Inadequate heist rope trata on the ‘winel when bering ight laada can teaull inca Dledanage through kinking Lanse wrape on. wives drum may sip, causing the rope in fork ‘and impose shock loading cn the boom ‘Te pro: Teta Ey personnel 200 eoperty MAIN equate hoist rope tension, PARKING BRARTE Always ‘et the parking brake with the parking brare switch whenever the Crane tale etanding. Always releane the parking brake before maving the erane, AIR SYSTEM PRESGURE Proper air aystem ‘Pressure mus! be manta at al times fr op rabon ef str prake systern. Never BtMEpL amy Operation ifthe ow pressure warring light is thi inated ne the warming burrer 8 Wann, [BANEES AND SLOPDB Never Ieave the crane an or ear the edge of any hmk. or excavatan whith ‘right give way, Back Ene crane airy fomn nach ‘eas sthen i i to be left wl or unatientel for ‘are than a Bra period When parkingthe rane fone slope, dort rely slely on the parking brake ‘mechanlsin. Set the parting brake andchook the ‘Wheels, Whenever poosble, parc on level ground, SEAT BELT All crane ons are equipped wth seat belt for wae diving reansit and travel [te Teeammended that the seat belt be se JsraNVE AMLE Always mamntain auiTolent engine speed to charge the battery whenever idling the cgi for natended periods A voltmeter indi cates the badtery outpi Idle the engine for 3 few ‘rincter before turning 2 the igrtion, LUBRICATION ARD ADSUSTING Always etop ‘he crane and cease all operation before iubriont: ing. cleaning or adjustirs. ‘REPLACING GUARDS Aways replace guards Im ‘mediately afler lebricating. or adjusting’ the cage, Remove any toatsirom the cramieand store ‘hem belire resuming operation, (SLIPPERY CONTROLS AND SURFACES Keep a ‘nose and pedals fee of grease Rnd raud fo pre vent accidents by sipping. KoA} Handles, steps, wancways and platiorms must be eept free of grease, ols, fuels, mud. stow! an ice Sand/nainted or ofser grt type anit-sip surinces smust be renewed whenever the sucface begins to Appear worn, Issued: Augnst 1308INTRODUCTION ANSI 6TANDARDS Many aspects of crane opera: fen, smspection and testing are discueced in standards published by the American Notional Standards tnatiute. These standards are updat- edn an annual baste With addendos whieh are sent by ASME to the origiral purchasers of the ‘Terex recommends that you prrshooe and role: 1oihe Sllowing standards. ANGI/ASMEBO0.5 Mobile & Locometve (Cranes ‘Latest Veralon) ‘These standards can be purchased fram : ‘American Socety of Mechanical Engines Untied Baginesring Center ‘345 Bact 47th Strect [New York, NY 10017 ‘TIRE PRESOURES Mathtain recommended ti Infation presoures in el ures. This le awn on the “Loed Rating Chart. When eriving, some increase in tee pressures ‘antbo expected duc to nent generated by Econ. Omrepeeds may also produce increased pres suet. hy etch crournstances, NEVER BLEED ‘THE TANS. Instead olow down or stzp unill the ‘tne coal WARNIN: ATWARNIN" | ‘The explosive energy stored in @ Ure and ring as sembly under prescure makes changing caret And off-road tres hazardous. Desth of pertonal Injery oan eenur while handing or maintaining these tres re ‘Spetial procedures yust be flowed aund spectal tools must be used ures are tebe chatged sale ly. Whenever posable, let your the service cou ‘pany bande this Job. I'you must cheause # Ure, follow the sicp by-step structions deiaied in Hromanaal Should low prensarey cone Hnsces ‘sary t@ add ai, never stand bestte the lice i bleads woe an ortenaion ose long ciwuigh permit you tostand behind the Urs Gead, Always ee a tre cage oF equteatent protection wlten adatng a, Iyoued: August 1998INTRODUCTION, NOMENCLATURE “This manual contains intrusions rx Inform: Uo on the operation, maintenaner, ubriestion and adjustments of the Roaghs Terrain Crane ‘The operator atiould nel aUempt te cperate the machine before hebaa gained 2 tharcngh understanding of the materta presente tn the fatlowing pages ‘To ad ip Understanding the contents of tina man ial. the hillewing trrms will always have the reoanlige given whenever they are weed 1 UPPERSTRUCTURE 2. BOOM AFTACHAENT. 2, caRriER 4, OUTRIGGERS RIGHT HAND/LEFT HAND ‘The uppersiruchire weldment, slann, countervelght, cab, swing mecha “The teleseppic crane boom with hydrous wine, ft cylinder, hook Block assembly, ib arrange: ‘The chassis complete, power unit, svingbeating, lanemission. planetary Arlen, aottyger assern- ‘ee ‘The heaws, cylinders, Moats, boxes, Sydraulle ntl ays All veferences ta rght of left hand will correspond ta the operator's night o- bet hand when he i fne- Ing forwar rom the operntor’s neat, Wath the 7ear maunted engine 1 bis Back, Issued: August 1988INTRODUCTION RECEIVING ANEW CRANE Gare gp been taten to ensure that your new Rougit Weeal Crate is delivered to you to fall operable condlvon Before the cranes are shIpDeC fiom the actery. they are gion a nal aspeetion, doving which. systems and Individual compe orto orc checked agsine: apecfiatlone, Al) ‘rave Funetlone are then tested ‘After arcving at the Distributor. de crane Is is- ‘spected for pessble demoge sustetned n tant. Banaged or mii prt are (0b ate oe billaflading a advice note and the sare reported 1 the shippers of comers. In thio manner. all pales voncerned sre properly protected until {theresponsiiiy for such damage or shortage is ‘determined. Bebore formal delwery wo the purchaser, the new rane is inapected by both the putcheser aed the “Setnbator The purehaer® verges etn ‘bre operation and inspection of the crane. A fo- Tow Inspection made bythe distbitor afler an nual perod of use by the purchaser, Dackng this peri, we strongly urge thac the wser Tale ‘ain a cauy' fog ct All inspertions, service aed maintenance perbrincd. Abaormal noises oF SMopeeprel pentormanes should be nee 23g showldthe conditions under which they occ. ‘These should be reported to the dtriputor a the UUme the folow-up Inspection. Before starting the crane, study thie maul surely it oy you aiden tat the iorm of fener troubles and beter performance eprreneet at well ae inespeneprit:aparatee ‘wit were ay cavefil study of all material pre- sented here Because in preparing 8 expcessi tor the mexpenensed, we have ncladed many tm evant fas not ovary fod tv cone facturera manual of Os Hd After the operator has thorwghly fordhanacd Eeunnetf it be marae aod cael tn spect the crane betore attempting bs start the eb- fine Refarte the Suggested Crane Perioe Selety Tnspection Check Ust and (e Section # of thi ‘manual when making the inspection. or the operating and msintenanc: insructons {br Gre Power Unie fefer to the engine Mazulat™ furer's menus ‘SERVICING TE CRANE PROPERLY ‘You wil nd that thls Rough ‘Terrain Crane wall, require leas attention than other types of can- struction squpment. However, de not be misled by this. Dnt ipvore your eran because St is les demanding fer maintenance, THERE 18 NO- SUDSTNUTE TOR PREVENTIVE. MAINTE” NANCE" A definite Scheduled Mainterance pro ‘cedure. should "t= planted and carried ‘out regularly. In ibis way Kouble Inthe-raalang” 1s Giscoverea betore cetcnsive dana And taper ‘ve downtlme occara. “The sevicing procedures incorporated In thts manual are meant o be used by'copable service Peracortel nly, By at siteray ls caf. os sue ny components on this crane wathout a¢horough nowladge of trix equipraent. READ THIS MAN. AL COMPLETELY, lesued August 1988.INTRODUCTION KNOW THE MAINTENANCE THAT IS REQUIRED FOR TROUBLE-FREE OPERATION, Your distriutor has qualified factory teaned Ser vicemen to perform the more technical servicing of thio erane such as checkiog lydeaulle pres sures and rehef valve settings, Rey upon him. he Snows ‘ke business, Lat fin know if these are any unusual sounds or a change in erane perfor mane. DONT WATT UNTIL 4: SERIONS PROB. ‘EM ARISES! It may be a minor problem that, iF Jeftto continue, cruld develop in a mator pr0D- Jem and possible breakdovm. Distruitor servic ten can save you money ard keep you working Don't have sonpebndy else “boteh it up and then fend up calling a Distributor Serviceman to “bail” ‘you out If you. should have occasion, to repalt ‘Your erane yourself USE FACTORY PARTS. ‘This Rough Terrain Crane isa sef-propeled, fale Jy hhydrautle machine featuring upperstrustire contro of both traveling and work functions, POWER FLOW Power originales with the rear Ioanted engine which drives the transmission. ‘The transmission drives the three hydraulc Dumps which supply fld under pressure to al) ‘work functions. The tandem pump desvers fale {o the work function control valves located in the carter, The other pump delivers uid to the out riquer csinders throush lines mounted im the farsier and to the in eab steering control valve ang swing valve. Metered fluid fiom the stesring ‘congro valve is routed to the foursteerins ect hydraulic eylinders mounted on the ables. When ‘contre vale is actuated, the Suid bs disc through the rotary manifold (o that ercult te per- form work. Hydraulic eylindere astute the out riggers. boom, telescope and beom — hoist fianctlons. A hydraulic wineh raises and lowers the loads and 2 hydraulic motor swings the up- perstructure CARRIER The carrer isa two axle chassis ofall welled box type constuction with four wheel Planetary drive ailes available for offthe-road Dperation. Motive power is tansmted irom the ‘engine and converter tthe axles through the \ansmission. The machine has a rigla mounted FACTORY PARTS are speciically designed for Unis crane and willensure the eontnted safe anid DESCRIPTION fficiont operation of your crane, Whew ardering rephcement parts, be sure to give the Serial Number, Med:t Number Engine Mace and any optional or special equipment that wil hep (0 ‘dentiy the caveet component parts font axke while the rear normslly oscillates, ‘When the upper structure is cut of rave position rear axle oseillation is automatically locked out. ‘Thice slurring modes are provided: Four wheel, fon: wheel only and crab sering. The carter brakes are ait unl A parking basise automat cally applica whenever the Jgnlton swith is teiened off or the parking brake vic ta ema ally actuated. The carrer mounted cab featares destened:in comfort and corventence to reduce ‘operator fatigue and ensure high productvity, ‘The ex-way adjustable seat fr arm rest, bea! rest and adjustable back angle. The thted top, window reduces glare while permitting. view of boom, losd and other objects overhead, UPPERSTRUCTURE The all welded upper struc ‘urets equipped wits a hyetrauiic winch four ses tion telescopic boom with an ant-iwo Hock sys- tem, large diameter oon holst eyltider, aed hhydraulle swing mechanism, The uppentiuciare fn Joined t9 the earitr by a amin. bere whch, 1s belted o the earrer and bolted tthe upper Issued: August 1908CONTROLS & INSTRUMENTS: [0] supper race UNIVERSSL SYMBOL IDENTIFICATION. bee Bd CONTROLS AND INSTRUMENTS bees 2-2 CONTROL AND INSTRUMENT KEY soe 23 ENGNE CONTROLS. : cece Bod ‘TRANSMISSION CONTROLS. sie 2-8 ‘AtR BRAKE SYSTEN 25 STEERING CONTROLS, sitet een BB oureeceR CONTROLS. vines +26 SWING CONTROLS... ees 27 ATTACHMENT CONTROLS. : ve BB UioHTS -.... 2-8 ACCESORES. siete besten nee Isoued: May 1998CONTROLS AND INSTRUMENTS. ‘This section is intended to famiharize the opera: tor wath the controls and mstruments provid for the operation of tls machine. It chould be cmphaalzed, however, that merchy knowing, the ‘contrasts Inadequate preparation Jor operating hhydrauc cranes, Do not attempe to cperate the ‘machine untl ine other sections of his manual have besn covered. Sections 1 and 3 are cepectal: ly ampostantwith respect fe machane ogei ato. Diagrams of the various carrer and upper con: aus are Mlostrted cx he following pugs A it cf these cuntrels and instruments ace shown op- posite cach Wystratn. More detaited explana fon of eatl control ur rstrunent flow i same order as they appear fn the number ey [euvaxent emunor TorermncaTor | FLOOOLIGHTS: ENGINE ENCINEOL a ame «= @ case: Oy me cag | cco = be ecw OF a) russe wae woo op] Seu con Hhornawe ELECTRICAL semuCe Cd aor | ®D seme io sr wom = ® ares sow - co @ meres poner were a Tesued: May 1998CONTROLS AND INSTRUMENTS8 19. 29, 24 22, 25, 27, CONTROLS AND INSTRUMENTS ‘CONTROL AND INSTRUMENT KEY IeaTtoN swnrer DIESELSTOP COLD STARTING AID (OPT) PUMP DISCONNECT (ON REAR DECK) ACCELERATOR, HAND THROTTLE, INSTRUMENT WARNING LIGHT LOW COOLANT WARNING LIGHT OL PRESSURE GAUGE FUBL CAUCE ENGINE TEMPERATURE GAUGE. HOUR METER (Engine Compartment) VOLTMSTER ‘TRANSMISSION TEMP, GAUGE TRANSMISSION OIL PRESSURE GAUGE. ‘TRANSMISSION SHIFT LAVER (F.5,R) TRANSMISSION GEAR SELECTOR LEVER (2.3) HIGH-LOW RANGE SHIFT SWITCH AIR PRESSURE GAUGE LOW AIR WARNING LIGHT & BUZZER BRAKE PEDAL PARKING BRAKE, EMERGENCY STRERING MODE SWITCH MASTERSWICH OURIGGER SWITCHES BUBBLE LEVEL SWINGLEVER Page 2 2. 20, 20, BSSREEE Bese aeeerae HORN / SWING ALARM SWING BRAKE PEDAL SWING BRAKE PEDAL RATCIET RELEASE. SWING LOUK, BOOM LOWER PEDAL AND LEVER, BOOM RAISE PEDAL AND LEVER. BOOM ANGLE INDICATOR - not show, BOOM TELESCOPE LEVER MAIN WINCH LEVER AUXILIARY WINCH LEVER (Opt WINCH ROTATION INDICATORIS) (On Lever + Not Shown} UGHT SWITCH ‘TURN SIGNALS past uieHT WORK LIGHT SWITCH WIPER DEFROSTER . HEATER CONTROLS ‘CIRCUIT BREAMERS FIRE EXTINGUISHER ANTI-TWO BLOCK WARRING LIGAT ANTE-TWO BLOCK AUDIBLE, WARNING SWITCH ANILIWO HLUCIS BEPASS HEY SWITCH Issued: May 1998CONTROLS AND INSTRUMENTS ENGINE CONTROLS 1. IGNITION SWITCH - Turns “On” and “Cit sleseical treats ad etapa the cagine. 2 DIRSHL STOP Shute off fue engine 3. “QUICK START" - Recommended for ambient temperatures below 40" P. Follow manufar- turer's lestrections regarding Its use acd the bhandling and storage of fluid capsales. 4. PUMP DISCONNECT - For cold weather stort- ng oe extended eavel. Pull pt st * = ope, (el me uv \ } OY ( eau ook HeoK e008 | 88/) geNTER SHES DEADENO ronono PARTE LINE as * DEAD-ENO FOR TWO 4 PARTS. JIB UNE ai ER Hb Twousesck ween SF ON THIS LINE SHEAVE HOOK BLOCK NOTE: ‘SHEAVES INBOOM MEAD AND HOOK “TOAIGT As VIEWED PROM THE o> aecorue| > [= [ef fel]? EMATOR'S STATION, “0” INDICATES = + EES SEN, soon |e HE Far saab Tae war con0 [00 | vce) ra [a0 roorsiek | Os | 35] Page. 14 ‘auch: May 1998)OPERATING INSTRUCTIONS ‘HOIST LIN REEVING ‘men reeving the orane in preparation for aay fob [t should be Keptin mind that hosting and lover tng speeds dhorease na the numer ef parts ae Increases. Fer the most efficient wee of the crane, fie therefore desirable lo wet Ure minima te quized number of parts fr iting the load as do vmineel by refering to te load rating chart ‘Tha exene fncorporates 4 “Quick Recving?’ boom head an blck which do not require removal of Ue weege ond socket from the rope fo erder to ange Ute Teeving. Removal of te pins to the tboont head and three In the hook block wil allow the wedge and soekst to pase through. ICAU LION Mover are teas then the number of parte called for by the load rating cbaxt. (9 not practical o aller tae eeving drt the sourae of the wos, the required uuuber of fore pate nvust be determined om the taste of Ure Inesviest load tobe Med dus sper aisn When the required number af coye ants habeas determined, reeve te rope es Shusett as Ure prew- ‘us page. Attach a wedge Ie reve socket to lhe ‘ware rope dead end and secure hte either the ‘boom praie or hook block ay veyaired- Dead ened the rope on the Rook block for an odd number of June pars, ad onthe boon peak for even 1 ber of pas. wach te aot LHe bIGek WeIEL Lo Uke ant twee block switch and io Uie frst par of live ay down, fn the previsus page. The ail! Gworblock chain should be 48 inches long. Verify nat the chats ‘ot retoted 0 Kantted afer iamtalltin, ‘Tost tbe ant tworbloch syste by Mili the arte ‘erblock sight. The Hight and audible alanis should be aetaled in the cab ané the boom down. boom extend, and whut up eonlras should disconnect Page 8 As sluppel fro the factory, the crane has sufi- ‘dent see rupe provided :o low the hook 1oeaeh ‘Bound level wth ary boom length and elevation. ‘when seeved wit valalenoin pares of tine required (or dhe loa beaig led. Reler to ine Grane Capac ly Chart for parts of line required, WIRE ROPE SPECIFICATIONS MAIN WINCH, ‘STD. 5/8" die. 6X19 OR 6X27 CLASS IWRC REG. LAY WIRE ROPE MINIMUM BREAKING STRENGTH 179 TONS OFE- 5/8" ROTATION RESSTANT COMPACTED STRAND 16X19 OR 10X16 MIMISRM DREAIUNG STRENOTA 22.7 TOUS AUXILIARY WaneHt TN..6/6" dia, O19 OF CHT CLASS IWR REQ. LAY WIRE ROPE MMIIMIM BREAKING STRENCTI-17.9- TONS OPT, S/S" ROTATION RESISTART ‘COMPACTSD STRAND 18X19 OR 19Xts MINUMUA BREAKING STRENGTH 22,7 TOYS Tesved: May 1998 6OPERATING INSTRUCTIONS ‘TRANSPORTING THE CRANE. AJCAUTION ‘The boom extend sections should de meatrained to prevent gradual roll-out when transporting the cranc od # atm ‘taller The hydrautle ayatem witl not hold the sectlons against the hard brenking jolts while the erauc ie being tranaported., Restrain the boom by snuggtng the ok black fagelaal the boom fradl, 3 gerure ve boom Head back to the base sesiian af the boom with chains fo athle. An ectomcealing! harm ean canes sub tanta damage, SIDE STOW JIB DESCRIPTION ‘Two optional jp extensions are avallable to pro vide addtional boom reach. One is 26 M1(7 83, Im) ald otow awing-on one-pleco lattice Be ‘hatte cffsetiableat OF, 18°, or 30°. ‘The second Jb oplion us a 26-43 117.83 «13.11 1m} side atow swingsom lattice toe fb, The 6 Is exlendible to43 {19.11 m) by means of 217 (5.16 mi manual pullovt up sectn. Each optional jib extension is pinned dire to Je andr of the thaave pine: When matt Coe the Hb can be uapanaed Gon tie boom head And Sted on mneunting brackets on ie rgb side f te beam base section. ‘The 26 i 7.82 el fb wetghs 1,160 pounds 498 ‘ag The 26-49 f (7.99-10.11 mm) Jb weighs 1.800 pounds 1680 ke rage Roeforo erceting ar atesring the fb, ensure that na (personnel or obutactes are in ‘the wwiig Pork of the }0. 1OPERATING INSTRUCTIONS ERECTING THtE Jus lb Storage Beaches Ant Twotblock ‘Sain Extend and set the outrigger 2. Rotate the upper structure te the ‘ever tron! position, 8. Retract the boom completely. 4, Boom dos to minimum foom angle to allow nme of Inaailation of Hae jy pas 5. Install the upper and lower hb mounting pins In the right slide of the boom head. 6. Attach 2 guide mpe ta the eye-an the bottom tip of the ib Raise the tom to horlontal 3. Pull down and votate the T - handle to unlock. ‘he jib from the storage bracket 9. With she engine at ile, slowly extend the boom to 85%eet (10.6. As thei lears the storage Page 3 brackets, the Jib wil swing out approximately ae 10, With the engine at idle, sbwly boom down to ‘minimum boom angle while another operator tases the guide to control the speed of the rotation. The ib will swing around unt the left ide mounting hoes line up, 11 Install the lef upper and lower jib mounting pis 12, Remove the guide rope 18, Disconnect the antl twe-bloek pg fram the jib anti two block socket and connect t ta the fleet on the boom head. Move the duimy ug from the boom head socket to the antl trorblock sacle on the jb, 14. Reeve the otat line over the jb sheave 15, Test the antl two-block evstem by ting the ‘ant tvo-block weight. The light and audible ‘alarms should be actuated in the eab and the ‘boom dawn, boom extend, and wine up con- taols should disconnest. 7 Issued: May 1998OPERATING INSTRUCTIONS STOWING THE san a 1 ant two-block socket to the boom head anti wor block socket, 6, Brtend the toom to 6 fest 110.6 mn 1. Beom down to minimum boom engie 8. Altech the guide rope to ihe eye on the bot - bss sesh pe nm SESS 10.4 teenie te, by Bors pe L xen and sete anno enon oper tse ge ope oor tie etingepee a ae 2. notte the upper sete whew fant” position. 14. Doom ap te approximately 20°. Allow the jil> 9: ake suet snr the tned panna wl J ota ihe fund the jb offset Is at O° offset. ‘te side of the boom, make sure the jib does: 4. Reeve the est ine over the main boom, et etre the ade ofthe boom. 5. Disconnest the api Wwo-blodk plug from The boom head and plug it m to the jb anu two- lock sockct: Move the dummy plug Gein the Page 3-18 Ieaued: May 1908OPERATING INSTRUCTIONS os 12. ine the engine at tal, slowly veHract the ‘boom completely. The jb will engage the ib Storage bravkts ae the boom fs retracted, 15, Remove the geide rope fron the tip ofthe Js ee @ f 12. the beam te rotvaced, valy thatthe stot lage bracket mounted ts the {fb 1 engaging [properly with the stowage bracket mouutted 10 the toon 15, Rotate and reease the T- hanlle te lock the ‘te the storage beaelete V6. Ramovo tae ght upper and lewer jib mount ‘ng yins. 17. Test te antl to-bloek system at the boom hnond by ling the antl two black weight. "The Hight andl andtble arms should be actuated 1a Ue cab and the boom down, boo extend, ard winch up conte should disconnect, Page 9-19)OPERATING INSTRUCTIONS OFFSETTING THE J ‘Ata hoist ine ene and oo sShoave shat ~ Retract the boo snd set the outrister, 2. Boom down to minimum boom angle. 8. Loosen the two (2) exp serews on the left side of the upper and lower sheave shalts, This wil require a 8/4 inch hex wrench 4. Reeve the hoist ine over the top center sheare fon the bow head, srourd the ib shee, td tach (othe eye on the bottom of the jb tp. 5. Wine’ up to take the slack out ofthe hoist tine fd to take the wolght of che jb off of the ib titset pins NOTE: To prevent damaging the J, do not winch up ery mare than is necessary to lease the ib offset pins. 6. Remove the JO offset pins from the 0” offset hole and place in the 15° or SO" ote: ele (ap Screws 7. With the engine at idle, slowly winch down to pay out hoist cable. This will Lwer the up of the ib unit the jb comes in eantac: with the {ih offet pins, NOTE: While lowering the tip of thet, stnay be hesessary to raise the boom to prevent the tp of the Jb fiom touching the ‘ground, 8. Remove the hoist me from the tp ofthe jb and eave the hast line as needed. sowed: May 1998OPERATING INSTRUCTIONS TRXTENDING AND RRTRACTING THE IE PAILLOU ARCTION Ani Taerblck Woight ‘sach Daadend O1 Rope EXTENDING THE PULLOUT SECTION NOTRE: Tha jt must he seoeted bafore extending the’ putes, saction. Do not attampt te ‘extond (hs pout section whie the jE is eoweed 2. Retraet the boom compietely and boom down. te mnimem bom angle. 2. Attach the dead end of the wire ope to the eye ‘on the bottom af the lb tip. This 15 dane to pre- ene the gull frou exten unsonteolabty 3. Unplug the antl too-bloek plang Hem the antt two-bleck STUWED sockel, Have the dummy plug Wrom the erected socket to the stowed seek, 44. Renuve pull rewiomy pla Our We sewed retaining pin tole. Pay aut exble and extend the pullont until the erected retaining pin holes line up. instal retaining pin 6. Plug the ntl avo-block plug into the antl cor ‘black ERECTED sarket, 7. Test the antl bvo-Dlock system by lfing the ‘anti tyo-bleck weight. The ight and audible alarms stould be actuated in the eab and the Iboat doom. Boor extend, and witch up cone trola should disconnect Page 3-21 Ereciea Retsning Pntoe [RETRACTING THR PULLOUT SECTION 1. Retract the boom completly and boom davon re miaien Boom soa 2. Unplug the ant bwo-Block plug from dhe ant ocblock RRECTED socket, Mave the dummy foiig Gor te sewed serkee to the eveeted socket. 13 Auch the dead end of the wire rope to the eve ‘on the betiem of the jo tp. This is done to pre- vent the pullout from extending or retracting uuncontrolasly 4. Remove pullout retatsing pan from the erccted retatng pin hale 5. vine up slowiy co resract he pullout unl the stowed retaining pla holes line up and instal 6. Plug the aati ove blo plug inte Hoe ant bo, block STOWED socket 7. Test dhe uli teerLleck systew by ling the anit Wworblack weight. The: Tight and audible flaruse should be achisted in {ie eb ard the Inswed: May 1998OPERATING INSTRUCTIONS ‘UNUSUAL OPERATING CONDITIONS ‘Spresal protiems mm yeaintenanet and operation are eaured by untisal conditions such an ec Cremer te est, coi oad humidity. igh ic sat water, and diaty or sandy ork sites, When operating under ich rondtions. spetial precos ‘Hans must be taken to prevent damage, MMIENEe swear, and avoid component deterioration EXTREME COLD In penis of extreme cold. che roteme of frees damage, adequate lubrication and battery fatture may become particularly rot Diesome. With the onset of very cold westher, £15 adiisable lo “winterize the crane by servicing the Cooling systern and switching ¢9 the lubsiants recommended for cold weather usage. Follow the recommendations in this minual when the crane suet be operated in vary enld conditions, 1. Ta prevent freeze damage to the cooling system And cracking of the engine bon or bead, dra snd Thatvthe pong nystem, Clean the radistar ftevior making certain the nie peannges through the core and the cooting fins are fee at ‘areiga matter. Real the coating system. sédingan antifeeaze an- loton recnmanended by the enghve manufacturer in an amount and streagth approprinie to the a. Ucpated temperatures. A corresion inhibitor i recorarended. sail Never twas ahromate base cosrorion inhibitor vhen the evolant contains ethyl: jane yea! Den only nen-cbromate bess ‘tnhibitors. Chromate base inhibitors reset ag sith ethylene glyool on produce chro mium hydrozide, commonly known a= "green mins”. This substance reduove the Iheat tranifer rate aad cam cee scxioer smgino pvorhosting. Ingpect the thermostat, elampo, raclator hoses ant radiator core for proper ropallan, Replace Fepate any osoilng eyeter component found to be eect, 2. Ganaogation ip te fel tank centaencttes the hel supply with water, which ean ‘Peeze fy the ‘Ret ine and block ie tel fou to the erglne, ‘To minimize this possibilig. Keep the tank as fat an in practien! apving cold weather: Tals may exvall refiling the tank wiore irequently (han aig]. atthe intonenience fs ermal som pared to elewing s beled fel tine Itwater shoule be noticed fn the furl eupply. drain the tank and teil with sinonntaminated! fost 4 Lariat the crane wth the lubricate recon mended for cold westner operation an tar Ca Incation Chae. necenaary.changethe engine ‘and eter lubes order con forty eo the eeermmmndatione 4. The battery ip mere likely tosustan freeze damn- ge not Kept fly charged Because Aa electro Iyte wid freare af a higher temperature than int in felly charged battery: Be certain Ue battery is chaeging when the engine 6 running and Wet a external charger to restore fall ‘ange wien the crane je mt being operated ‘The hattery can discharge Uf enow or lee ahort cle- cuts the tereninals, Rep the battery posts and ea- ‘ble rormectors clean and dry Remove any comsion witha solution of eas and water During extremely onl weather. (tis advisable to remove and stare the battery in a heated area ‘When the orshe is fo remain idle overraght or for any eetented period ‘AIR OVER HYDRAULIC BRAKES At lesat oace ay, drain the water accunndlatien frm the air tant. ‘Water added to the battery can freese Tbolore it mises with the electcolyte. Dur ing very cold weather, add water to the Dattery juet prior to, or during, operation of the crane. if the crane Is nat tod4 Tin, ‘water may be added i an external charger seconneoted to the bateery. Page 8-22 Issued: May 1998,OPERATING INSTRUCTIONS UNUSUAL OPERATING CONDITIONS ‘Special atention must be given ta the Ryda ‘of dunngvery cold weather. NEVER ENGAGE THE HYDRAULIC PUMP AND ACTIATE THR HYDRAIILC RYSTEM BEFOHE THE HYDRAULIC OILS WARM. Onld, alnggiah ef cam cause yaemp cxvita- ton. If the erane is net equipped with & zeservokr immersion ester aud ramming the off rer salle€ will not warm Ie suff alently to prevent pump esoleation with the cngise sunning very slowly, sense atempts €9 egege the pump until an extemal beat sousce can be obteingd. ‘Once the reservorr 1s wares fo the wach, actustle the hydraule aystern by engaging Ghe hydeautte pump. Conunue warming the oll and slowly cycle Allcrane fursUons, actuating al cylinders WU, ‘Svingng te upper wea operalng the wiosley I bah dlrecune ‘The bydrautte off way be run over Fate te akd an Uns wamrup proveee. To do Une, aelaate a fare ‘den, aliow the cylniders involved to reach the i Mts of thets tenwel aed ald the control tthe erage postion for «few secures ‘When aunzing hydraulic oll over rll to warrn besute lo restric dhe flow w us slow a speed as posable by moderaUng pressure on Ube contrals being engaged end naming ie engine at. low speed LAL Ite end of the work period oF whenever Ute ‘cane bs be left ile forextexded periods, pre veut it from being fozcute the grou” Dy path. ng i on a weed, concrete, aspiull or mat surface BXYREME MEAT Lite extcine sold, cequltes Bat precauitons be tken with respect (© the cvoling System. the battery sant lubrication. Protect the crane ly perforning the (allowing veconsinended procedures: Page 8. 23, 1. High Cennperatures nevesauate the use of labr= cants which are both more visenuis and which feat deterrauon at ighes operating tenpre= tures, Ret t the Liberation Chact ard h Drleate the cone tuning the Inbri-ante recommended for the expeeted temperate, Ceanikcase ail particularly important because tt helps deripate heat Cenk thr ll levelirenently and add all se nevessary to amintsin required lev cl. Teo litle of wil hinder heat dissipation 2. Toensure peoper enntant creation, drain ane yah the conling system. clean sny ferelge mat. ter frm Ihe radiator conling Wing and chrough ‘core a passages replace defective haaes, ight fn hose clamps, tension the water pump deve belepmperiy, eliminate any leaks aeected ane £1 the aystem with w 50% aciuton of ethylene yea. A comosion inhbior In eeconenended. Engne owsheating duc lo lots of onlant willmaat often be corrected! by SLOWLY adding ecolant ‘while the engine fx running at FAST IDLE. Show le thisfall te correct the problem. dram ane flush the system and etl with fresh coolart (Rdn6 sofntion ‘ ediylene glycol) and a carresion inhibitor Allow tne engine to cool Detore érasming ‘and flushing the cooling syste ‘Water containing mote than small eonoentrations ofealt ar minerate shoal notbe ured m the eval ing system. Salt facitatss corrosion and minerals Acpootted on the coolant passage walla Both poo cesees miubit proper cooling. 3. Ate cmoplation atound the engine aad hattery ust eat be rectaeled, Keep atrial ard ex Ihxust openings clear of lewes, paper or other Toelgn rater which may estriet afr flow 4, Keep the engne clean of eit, ease and ather substances whie® (ehibit heat elosrpation. 5, Use sound judgment in operating the engine Avoid the two extremes of acing ahd lugging. Tenet: May 1606OPERATING INSTRUCTIONS. UNUSUAL OPERATING CONDITIONS advance the three only chough te handle whe load. ye: be certain thot the engine speed is igh eneugh to maintain adequate fan speed for coc ne Run the engine only when engaged in work opens ons orwhen tateling the eran Avoid prolonged pettods at idl: and shut the engine dawn IFoners- Guns ars interrupied. SANDY OR DUSTY WORK SITES The presence of large amounts of sand or dustt the woe site ean contribute to accelerated component wear. Fithet ‘substance will act as an abrasive when deposited ‘on moving parts! the erane. The preelern & comm Dated by more requent inprcatinn and My the Sh vieang of breathers and Btess at shorter tntervals Folow ine reconunendauious below when operat. igi sand ar dust oma regia haste 1. Reep sandand dust out of the aydraule system by Keeping the reservoir lar cp tight ant or ‘icing the bydrauite syatem fers Grequently, 2. The fuel systemahould be kent free of sand andt ust by Reeping the tank filler cap tight and ving the biel Blters frequently 9. The engine breathers and att clesner shoud slso be seviced Frequently to prevent sand ard ust {rom entering the engine. The englae ail and ol flter should be changed at shorter than. normal ivtervale to ensure a clean ot supply 12 the engine's mowing parts 4. When lubricating the erane, thoroaghiy clean ach grease fitting before atinching the gree fun, Pump generous amaunte of grease fall lubrication polats, using the track gress (0 Pump oat the old ‘5. Adequate yround besng aoppart must be pro+ ‘ded forthe cofrigger feats when aparating in sand. Be alert for signs af carrier moverent uring operations. ‘The imeressed ferquency of Mbrteaton and service diszussed abire about be determined by ahser= vations made at the wark sie Inspection el de (ermine ow iong & tates for lubreants, breathers and Mere ta accurtulate unncceptabe aruenn's Of sane oF die. The Frequency of Wibreation ane serve should he adjusted accordingly \WEOH RUMIDITY OR BALTWATER In rome loca- tions, stich as coastal seeue, Be crane may be et posed 1 the deteriorating cflerts ofealtmotsture. ‘Br hetb, To prelactexpaned wmtalle curiae, wie Ing. hotet rope, paint and ether teams, beep Them OPE and well kibrnated ere aalt igh mera Ty are encountered. Fallow the recammendations ‘below when operating tn these conditions 1. Make fequent inepections for rast and oorro= sion ard remove them as soon 8 they arr de tected. Dry and paint exposed surtoes afler Gt and Corosion have baer Henoved 2, Where paint may not he applied, such28 oF pale Ished or machined surfaces, coat the acea with {grtanc or habrlenoh ta opel water 3, Keep hearinge and thelr munrounding auttnces ‘wel lubricated to prevent the enlty of water 4, Hoist rope rast be kept wl lubricated to pre- eat metered nal from penateatig th c= ble strands, IIQH ALTITUDES Vanationain alttusde ster the fel-air mibsture burned in the engine and affect the engine's performance, At Righ aldeutes, atmo= sphere peeswures are Inwer and leva oxygen Is svalable or eemnbustion of the fel Ahore 10.000" the engine fel Injoetors may have to be changed {in ensure proper performance. Consult engine sarilfactarer shawl this prem arise. ‘Keeping the ait leaner dean and ive of cherrace Lone wll help alleviate high altos problems, AU ah altitudes, lonely monitor the sngine ta erate for overeating Page 3-94 suet: May 1096OPERATING INSTRUCTIONS LOAD RATING CHART INTERPRETATION Im the following pages are examples of a load chart, these example charts may differ from the hart supplied woh your ezane. Alweys use the load rating chart supplied with the crane to inter pFet theeondttions andiimmations that exist when, Imlcing ft with the erane. The determining fac- tore are ted load, radius, boom ange, Working, postion, host line recving, Ure pressure, travel Hata, cs of aft, ond ether epecial conditions that ‘exist, such as wind velocity, sol eanditions, te. DEFINITIONS OF LOAD CHART TERMS Lifted Lo8a: ‘The ler lose 4s che total weight of al the tems suspenced on the ware rope, Example Hook block 750 Ibs Slingx 215 the Object Lifted 19,000 ths, Lifted Lead 19,965 tbs. Losd Radius ‘Theload radius isthe horizontal distance from the axis of rotation before lading to the center of the ‘vertical hoist line or tackle wala load Losded Boom Angle: ‘The Ioaded boom angle is the angle between the ‘bow base section and the horizontal, after Ling the rated load atthe rated radius. The boom ange ‘before leading should be greater ty account for de~ flections. The loaded boom angle combined with ‘the boom length gwve only an appresisation of the operating radius. ‘NoLoad Stabitity Limit; ‘The stability imit radius shown on the range ia- grams i the sadus beyond which iis wot peal ted to pasition the boom, when the boom angles Test than the minimum shin on the appileable load chart, because the machine can overturn wilhoutany bad. Freely Suspended Load: Loed hanging freewith na direct external force ap- plied except by the hoist rope Poge 8-25, side Lose: Horizontal foree applied to thelifted load elther on Use ground or in ie ae Working Arca Areas measured ina circular are about the center= Iine af rotation as showin the diagram below. RANE WORKING POSTIONS aa ES Sinai ‘ies ones TR TE Tar | toe snore mac car fo ‘es Soo eC Cec Cue Over Front and 36 The “crane working position” diagram is a view Joking stralght down on the crane with the upper structure and the boom removed, The "kont of theerane Is always ther apposite the engine, ‘Over Front” waen the crane ison outriggersf the area inside the are bounded by lines from theeen- {ee of sotatin enroug tne rant outgger Ver~ luca jack cylinders. “St, Over Front” (Siralght Over Front) when op- crating on res means the boom and load must Be positioned straight to the front of eran and not fovang to right or e&, 160" means the fond can he song to ary position fous the erane, cut - ons: Rated chart values of less than approximately 1,000 tbs for on outriggers and side stow [Ib are not shown. This Is done bocause the effecis of ‘wine peels action, Jerking, ete, ean ease 3 tip over, Merelore: AICAUTION Extending the boom or boom and jib com- ination Into unrated areas of thie chart can canse tip over Do not operate at a Tonger radius than those listed on the applicable load rating charts as tipping ‘can occur withowt a load on the hosk lesued: May 1998OPERATING INSTRUCTIONS On Outsiggers Using Main Boom, ‘To determine te ht capacity when liking of the ‘main boom with the oubiggers get, uve the flame Ing procedure 1, Determine the weight of ths load tobe Utd 2. Determine the welgt of eng, rigging Inde ware and hook block. 3, Calculate weight of Uted lad. 4 Determine load radins. boom angle, aid boom length. 5, Determine whish loed chart to use for Your lit individual load ehars evs for the following it configurations. + on outrggers, fftng off main Loon with jl on oubiggere, Mfg off asin Loon with > erected tat unwood with ji pulloct extension Fetracted or not present on outegers, Ming aff ln boots wits JO erected bul unused wilh pulloa! extension extended on oulragers with Ub exeted, jb pullout sex ‘don relracled or nol prevent iting over the pb on celriggero wit ib erected. sb pullout cee: tion extonded MRing over ae ib pullout seo ion fon 16-00 X 25.28 PR tires, ting ever main boom with tb stowed -0n 20,50 X 25-24 PR tree, ting ever man boom wih ib stowed 8. the suaiary boom head fo nat ercated, add 100 fos to the cea rated copacty, 7 Compare load weight with chart sated capacity fram the boom lengts radius, and boom Sage. 8. Thelified toad must nal exceed the chart rated rapaety for che boom length and eae In tue example. the ited load of 19.575 Iba. 0 Jess than the rated Inad ¢f 27.700 Ibs. and can be ane, Page 3-26 leoued: May 1908OPERATING IRGTRUCTIONS ow arms ots Onaines rr casts NGPACHIONN ‘The Stalonany” seen ofthe chart oan ondy be On ties openttion, particulary plck and carry, ommst be done ta a cow, smooth ‘mnher over evel terzai that wil support the crams, with the leeds close to the Eround 20d the honm ox low a sesetite to avoid the load winging unlatentionslty, ‘auing lnjory oF tp over De not pick and ‘tarry with the jb since the load is fether tatended fromthe machine end the jh ean ‘be eusfly damaged, Enaute that the Urea art faded ae shown In the revormmended tine presoure chart. Refer to Geetion # foc the tire inflation procedure. "FRESE | EWTOINY [CREEP = TNH ATE rasta Tera [nePa| sa | wPET leesoxasectm] vera [aera] vere [OPH used when the outrggers are not set an the ane nol meted when loaded. Pex a carry: ‘When using the “Creep” section of the char, dhe crane cat be auvedat a uealnunespeed of ae) MPH for @ distaner of 200 Teec snd then a 30 minute walling period is necewonry to coed de lures. Querealng wl prealy ceduse the if oF dhe Whew using he "2.6 MPH section of the chart the crane can be driven at this speed. o slower, vath the tes atthe prover Inflation presouce with the Doon stralghtner the fo 2x Boom Langs Bo bot ext the “MAX BOOM LENGTH” shown {ort a yo! wl be working ste 0 iy ftheeranc inves apd ven he eight Ritter fara nore ee ating fe toc, Inceaed ton engl ane ‘ShNcontbute teas aetbaiy. ON TRE anus | :00w Cae CAR (| exo sumonsty ——_fcaer [2s ura @ » ee Siewga Qvee FRONT io) 72400 | «Zao» | 333004 | 228000 a aa 17.300 [38,000 | 79.008 | 13 Boe is 38 wano [26.860 | te.000% | ve 000% 70 2 7500 [16,600 _| vs.g0_|_n1 800m me 20 2380 [ 19.800 | wits [8 900~ Page s- 27 tssued: May 1998OPERATING INSTRUCTIONS “ON TIRES” LIPre PRCT ACEO IN| aver move the arane carrying a oad ath ‘the boom in any position except stralght cover te froat NOTE: lifts en tine may be mads at any boom angle from harazanial to the maxtrum oom angie provided the RADIUB and AXMUM BOOM LENGTH stay wahln the uta se forth tn the ‘On Tires” boa hart Ail crane land ralings are based on nenuse of the ‘warel fanelion while handling leads. Hewever, cranes may be utllied for pile and carry apa tioas. Traveling with suspended loads iwvolves 60 many vactables sveh 35 ground corattions. boom Iength, memzntum in starting aed stopping. ec, thal it impossible to devise a singe standard vallng peovedare with any assurance cf elety. Far such operations the user rust evaluate prevating conditions and determine safe prectens, exerele ing precautions, eich 26 the fllesing 4. The booem shall be eared straight oer the front ofthe crane 2, Travel speed reduced to suit candliuons. 3. Matatain apecied tee presoures 4 Avot eullen starts aad stops 5, Provide tag or restraint ines to snub singing of ie tone. 6, Keep the load as clo to ground as passtble. 7. Saf fae suing brake and swinglonle 18. The travel surface mel be oa 2 smooth level! surfane thot te rapable of supportiag the weight ‘rte Inadea crane, The trabel surface must ‘ao be from of tntes or debts that can onase crane fnatabaty, ‘These precautions are nenmssary 40 prevent a ‘pendulum fect ofa avinghog load Tan renulln of this happening can eine a machine tip et AICAUTION ‘Any veeiation (rom the shore conditie AICAUION] Always carry the load 45 noar the ground fos posible ith tha minimum boom length necessary to carry the lead, and ctuntght over the front mith the sing. ‘brake lackod and owing Jock sagaged elnce he roar aafe ogellation Je lecked out when, the hoem moves off center more than 10 dog Tmvel over umeven terrain with the rear azie oscillation Incked ont oan Teault fr Guntebiity. Ales, oroensfro booze temtth coun ronult in featability due to effect of cooeven terrain and wind provmre. AJCAUTION Insufficient Ure preaiure reduces the “OR ‘THRES* capacity. Attempta to plek rated pacley without penperly inflated thes may cane crane to tip and/or reantt in damoge to tees and sims. AJCAUTION The axle lockout systam should be bled and fed whenever ol seepage, dist or ol fo detacted at the breather plug or on the Inswed: May 1058OPERATING INSTRUCTIONS “ON THIRDS” Lirre red. ‘Air in the aude lockout systor decreases stabi, Bleed and fit the system IMMEDIATELY when. tee this condition eccnr CAUTION Bxcesaive high hydrunte oll temperatures ‘cause vapid deterioration of rubber compe: nents (hose, O-rings ete). & hydraulic vit ‘onler La required If high cystic operatiune {elam, concrete bneket, unloading) are per formed. I hyécanlie reservoir temperature reaches 200 deg. F, reduce the duty epete, ‘Stop eperations as required to prevent far ther increace in the hypdzeulic oll compera. tae. Page 3-29) Issued: May 1998PERIODIC MAINTENANCE AND LUBRICATION INDEX SECTION 4 sunmect WERICATION CHART. PREVENTATIVE MAINTENANCE. check ust ‘WIRE, ROPE INSPECTION CHECK SHERT GRNFRA, LTTBRICATION. HYDRAULIC GIL REQUIREMENTS KOEHRING SPEC 805 GRADE SELECTION CHART RECOMMENDED EYDRAULIC OWLS "TURNTABLE AND SWING PINION PAGE a2 a8 48 “7 “7 49 leaned: May 1988PERIODIC MAINTENANCE AND LUBRICATION IE] | RSL EE] BSSISSIS IS Ieoued: May 1998 Page 4-1PERIODIC MAINTENANCE AND LUBRICATION A regular program of periodic preventive marnts. ‘asace is essential to prolong crane operating Ie, uxiadte eflcienl seraice and tnfulinize dow (Ome, This section delals a sents of checks and Drecedures whieh are to be performed at dally ‘weedy, monthly and semiannus! intervals, These Intervals are stated both in terms of calendar pe- ods ard hours of operation, ‘Th checks prescribed for longer tnterals include all the checks required for the shorter interes ‘Tins, the weekly check includes all ems in the dddy check, the monthly check includes weeldy sm daly checks, and s0.0n throagh the eom-an nual check, whch inclades We quarterly, riouch> ly. weeRy and daly checks. ‘A conventent che chart provides a means of re- cutding preeentive mainterance periormed 2nd ‘etves 25a tool detecting problem areas and reat- aping maintenance requirements, The stetns in ‘each check Interval on the check chart are ‘Breuped under ther respective headings abd co? ‘eed im detail owar the utrae nf Section 6 Thx mantenance schedule fs guide which cn: sures that basle preventive magntenance sequiree ents will be inet uniier averge operating ‘corklivons. Conditions which wmpose greate wet, aaa oF stvnit On the crane muy dictate radioed cheek intervals. Hefore altering the maintenance Schedule, reevaluate crane operation and reetevt the crare maintenance records, Consider al far> tor involved and develop a nevteed schedule ade (quate te meet routine maintenanre requirements ‘Ata part ofeach periodic chack, refer te the en Gino menufsctarare manual for engine malate nonce requirements. When servicing the engine, ie engine manufctsrers reconemedalions lake peccedence aver tbose in this manval, should any Alserepency be rite INTRODUCTION OPERATOR OBSERVATION ‘As the operator, stisyour responsibility to abserve ‘and report any unusual sounds, odors, or other Sign of cbnotmal performance that orld Indl ‘cate Wouble ahead. On @ routine bants the fallaw- lig Revie should be checked before starting oe while operating the crane ‘Visual Inspection - Chedk sample muchine for ‘Check tor any Josie or damage te the hydraulic system. ‘Check in the engine compartment * Belts for tenon sind wear + Gaolant level + oillevel *Transmieoion oil vel + Aurcdoaner aight uge + Airintale Maule aid exdiauat ‘cheek battery box «For battery eonarucn ‘crane boom - Cheek for: * Hook block for wear or damage 2 Two black system for proper funcion * Cable and eable specting on winch * Cynder pia connections for west ‘Cheek bres, axles, and anwve lines, far west oF damage. ‘check i the ea for + imatruments functioning preperty ‘*onteol operation 1 Glace fer good wicBity + Safety equapmentis ready for use + Allhighte work properly + Cleantiness - Free from mind and doris Issued: My 1998PERIODIC MAINTENANCE AND LUBRICATION MACHINE MAINTENANCE CHECK LIST DAILY CHECK (6 MoURS) Pesform Datly Lubrication (Check llyfreutle Reservotr Faia Levet on Fuel Tank, Check Engine OM Level (Check Coolant Level ooo0o000 (Cheek ly feaulle Cylinder Mounting Busb- ings And Pins (cheek liydroulle Components Check Transmssion OM Level Drain uel Filters or Water Separator 030g ‘heck Front Sider Pas a ogaoda ooaog Dramn AUrTante Cheek Wire Rope Ad Related Components Cheek As Cleaner check Contos Cheek Instruments, Gauges, & Sally Equipment Make Overall Vou Iaspection “Tomjae Sung Bearing Bats * Torque Wheel Nuts Fist 50 Wiles™ ‘Chek Ant-Two Block Systems Check Engine Manvlactoey’s Mania} Foe ‘Addnional Maintenence Req items WEEKLY CHECK (40 HOURS) Perform The Daily Check Pesformn Wieekty Lubrication Cheek Swing Redueer Oil Lev Perform ina Aude Onl Change trek Ale 1 Letel daft Inte tang) Chace atery Condition Cheek Tire Petsire And Condition Check Air System Safety Vale heck Torae in Whee Lag Nuts ooaogoog000 ‘Ensure Swing Brake ts AbleTo Hold Against Fal Tore Of Swing Motor (Check Hydraulic Cylinders And Rots ‘ake Thorough Inspection OF Wire Rope ‘Make intial Replacement OF Kyte arn Line Plker* Re Cheek Alsohol Evaporator Fuld (vet ‘Visually Inspect Al Structural Merabere And Weldr Rar Crucka, Aigament and Waar ‘Chaske Room For Wear, Cracked hide, ‘Alggumen:, ane Mlasing Gr Migibte scala ‘Check Brine Manufacturer's Mana! Far ‘Aalditional Masatenanne Requirements * texeeval given applies only to iniaal period of use tbreak- bi leoued: May 1098PERIODIC MAINTENANCE AND LUBRICATION ‘MACHINE MAINTENANCE (CHECK LIST MONTHLY CHECK (160 HOURS) U1 Pertorm Daty And Weekly Checks 1 obtain Hydrate Semple for Analysis C_eeform monthiy Lubrication 1 Clean Radiator Berar GO Coeak engrce Hele has gine Moncton an or beam nyaraube Reserve 01 Metature Adidonal Maintenance Requirements DD caeck an saee acts ‘QUARTERLY CILECK (600 HOURS) CO Perform Daly, Weekly And Monthly Checks Change Tranamisoun Ol And Filter 1D Perform Querterty Lubrication chang: Bydraulte Return Live Fira 1D Drala Fuel Tank OF Water And Sediment EL Replenish Coding staan Cervo Inhibit 1 check Torque On Front Spring U-bole Huts + D chek Basins Manufactiers Masel For ‘Adional Maintsnanoe Roguiremsna SENTANNUAL, CHRCI (1000 HOURS) Perform Davy, Weekly, Monthly And Guar Change Fower Sieenng Fikertlement telly Checks change ante on OG Ferfore Sentanoual Lubrieaios, TD Chesk Brake Shon for Wear Condition Cl chan crankcase Breather Chace Rebel Vane Pens Sends clean Cooking System Torque Sing Bearing Bots 1 Cheek Reser Rell Valve 1D Lubricate Anti Twn Block Disconnects (Clean Reservoir intake Sucton Fier C1 check Engine Manafacuter's Manus For check ar Dyer Desiccant For Signs OF 08 ‘Adddlonat Master Resparements ‘Acoumanlation + Perform inital check after first 90 & 250 mle paged Inoue May 19935PERIODIC MAINTENANCE AND LUBRICATION onmmnanreRvals 1D 20 HouRs Change Transmission OU Filter 1260 HOURS. Cummins Engine: Change Engine 00 and Fiter Check Engine Air intake 1D change sngine Al Cleaner Blerment check Engine Drie Bel Tension S00 HOURS: Change Tranamission OM D1 1500 HOURS: Hyiule Reservoir Dron And Clean Change Hyaraumte Mois 14000 HOURS / 2 YEARS: Wmnet C1 Disssoemble And Inspect Componente SPECIAL BREAK I REQUIREMENTS FOR NEW CRANES | NOURS- During wieArat 50 mes ofservee and any lime the Wheels haze been removed, te torque the wert nuts © 200-5008 Ibs. 20 HOURS - Aner forgy hours of rave. arsin and refill he tansmiasion with new od 20 HOURS -Retorque the ewing bearing bats toa tongue of 800 Ie Ite. Recheck every 40 hours ‘aptlall bolt are found proper torqued, These alter checks should be pertormed quart. 100 HOURS - After one hundred hours drsia snd change the win:h luerieant. 100 HOURS - Retighten winch bese mounting cap Screws to 225 f. Ibs, ol torque after one hun red hours of eperation, 100 HOURS. Relighten counterueigh cap screws 10 845 8. be. ‘Al handles, steps, walkways and platforms wet De Rept fee oF gieaae, alls, furl -med,suew, and ice af all thmes. FAUT Send-patuted or other grit type antietlp ‘surfaces must be renewed when ever the irines bagine bo nppene worn, PagePERIODIC MAINTENANCE AND LUBRICATION ‘WIRE ROPE INSPECTION RECORD (Refer to Wire Rope Users Manual Por Crteri} PLACR OF INSPECTION. pare DESCRIPTION OF ORANR Mate Moaet SerlatNe, Type ana arvangeenent of Attachments DATE OF LAST ROPE INSPECTION HOURS AND TIME OF SERVICE SINCE LAST INSPECTION RESULTS OF INSPECTION Ropelnspected —Typrand Size «Conditions Noted Recommendations aerecror: Page 4-8 ‘souel: Mey 1908PERIODIC MAINTENANCE AND LUBRICATION 4 ood lubrication program requires thet all nor ‘mal wear ports be lubricated according to a set schedule with spec ypes of lubricants Refer ls ‘the tabsation chart aad the special lems covered 1m thie section foe the recommended tubricants, ‘me Intervals sav lubrication procedures, mere components such as the engone, (canst slon and axles are aot manufactured by Terex. the ‘origina! manulacusrer’s cecommendalans ake ‘precedence should any disercnanes aocar there {Bany doubt abour the proper lubricants. terval cr tebrieauon pracedutes, reer ta Une ortgina ‘manufacturer's manual, ‘The lnbrieatien intervals recommended im this section assume normal operating emditons, ‘Where dust. dirt. high humidity orexrreane heat fe encountered. Inbrication Intervals shed he shortened accordtnay, HYDRAULIC Off REQUIREMENTS: Toe hydraulk: system is led with TEREX SPEC 1805 nydaule oll w give the unit the highest por formance as a hydrauie machine and fo prowde reper lubrication for the bydraalic componente, To easure the longest life for thls plece of equi. iment, particular atlenton mist be waldo mat tam oll at the proper level wath an approved Inydeauie ofan to keep the circuit system clean, “Te ett or the hydraule eystem performs the ut function of Iubrtetion and tranamiaelon of paver. ‘Ob wt, erefare, be selected wy cave auld wl the asabotance of a reputable supple. To gande in de selecuon OF Wis iL Une general cequirements are specified below. Goed olla are economical in (dre ong rus Cheek wih the oll manucaetirer pre orto the use of his preduct (Ots which conform to Terex Specfication £05 are recommended for mast conditions, Uader pectin cllateand aperating conditions. may be advist Abie to use a ltuld of hesvier or lighter viscosity in order te malntatn a vseaeity less than 7560 $80 at startup and more than 50 S8U dicing opera: oa. These machines should nubs operated wl, hyaraule reservolr (emperatures in exceas of ‘200°F (87°C) due to poseible excessive damage to the hydraulic al and rubber components Thooee, seals. shaft seals, motor seals ete). IFover-heating ‘occurs. discontinue operation and: 1. Check the nyavaue Iuié level 2. Cheek the ol neler fr eeaninese. Page 7 ‘3 Check die oll viscosity versus Derecommended ‘Ambient Temperature may require an oil change. 4, Check the hydraulle system effictency- » pump aay be falling ora rele valve set low. 5. Reduce the duty cycle of the mists, 6. Consultan authored ausenbuLr CUE ONS Enghne os Hat meet Mil Spec 2108 and have the anii-vesr additive aint dithiophesphave cam be used a6 hydraulle ols. NO ROT USE €.D. rated! engine oll, some of which will nt protect againet ‘wearin hdraulle pumpe and meters, NTION, Not all motor ifs have zine dehlophosrhate, ‘Those that er cod lanes this fay ey oe can cause immediate fatare f pamps. Ea Engine ois tend to form sludge In tbe presence of water ‘Thin alvge can pg the ilore tx thoy wl Tequire frequent changirg, Tis & not @etimentat to the machine unless the flters are allevrd to plugs baily that they By-pass wil ewer aise mult-siscosily grades of engine al be- cause ofthe shear and thin out characienctes of this type ot oi Towed: May 1208PERIODIC MAINTENANCE AND LUBRICATION HYDRAULIC OIL REQUIREMENTS: “TRANGMIBSION FLUIDS DO NOT use Uansmission fois. These ‘lusts vnave been designed to work (a automatic (rans issloes and they will not necessarily work on by” rau systems, MULING: Stung diferent brand of ole not ree cermended. Various companion iv dist oat lUve packages, which when rabied together, may conuse problems ina hydrous system Tle ype of pivblern Us rave bat cat eave sludge which can leg the Sera or actd which wall ateh the pump plates, in eer cose, the Warranty Wotkt be void ‘edi, enowing ll tie, you etl shoose to add eit dlferent from the inital 1, sty with a since ‘rend on this wl minimize the Wkeliboed of pra Temes occurring. Then at the frst complete oil hunge you nay awttch 6 the het you prefer to PRE-PILTER: Oil chould be filtered rough a 10 seron aounlaal fcr before Itenters tue Irae vyslean, New ydraulle und ae reoeived by the User fy gewerally nox ma sausfactary cleanliness condition foe fong component Ife (OW MAINTRNANCE: Optimum ie rom bydraul equipment can only be obtained with proper hy Areulle ofl maintenance. This Includes checking Ue oll every three eo 6ix mentne, an an shuld be henked for viscesty, axidatlon, water evntent contamination andl copper paricles A record sheuld be kept ol each check te doteet signs of Progressive deterioration Oi) semples shoukl be taken with Use system running at normal wperal- Ing temperatere Lis umperant to use good teeh- iigae tn obtaining an ef} sample, The exact same proredtve should be tojlowed each ime atoll sanple is taken. Most Mud suppllers will provice assistance in analyzing your olf sample. The fal- {owing are seme gukielines to usein ths analyse. Pissostty - Hany hydrant Mulds vill shear or thin our with use. The visnosity at each ebeck should be conpared tothe Viscosity When nes. AL no ume should the viscosity bess than 45 SU Paget 8 ‘a 210" Ff viscosity fs les than 45 $80 at 210° F the off must be replaced immediatly ‘Oxidation +O! oxséation vill accur wath age andl use and ls evidenced ty 2 change in calor a/or fedor, inersased acy. and passtile fomatian af sludge, gum oF varnish in the system, The rate of cexidation increases sigriflcantly with, eperaivite at lemperstures over 140" F (60°C). The aft shoul be oheckel mare often Hf operation te a high tem- perature. The oxidation presets Increases the aciday ofthe fixid ands measured by a neutral ‘cation number. The oxidation process fe typ slow at frst and Gren inereases sharply m Wie fra stages of complete audation. A sharp iereage (oy acter of2- 3} na nettreizattin numer ts 9 good tmatestion that the Bld i reaching Ene enitoF tts cexldabion Ife and shouldbe replaced, Water Contamination - Al! bydesulls city tthe {otloving charts wil readily srparate weter which ‘il sett the batter af the renervatr This water should be drained off. The twalcr that if measured tm the oil azrople will bo dioeolved water, Tito ‘should be less than OO, Jat & greater than (058, the il Gs the aytany abil bn deatned nc replaced. ‘Particle Contamination - Excess contamination ‘ma Kydrwolte qretem wit greatly shorten the Ife of pumps and motors. Your of] sample analysis veil show the number of particles pes sulitier ateaier than. a given micron size, The number of ‘articles im your anmple ahonld be less thn Ue bellowing. Fartile Soe No.of Parlea/Milater 10 ateron or larger 4000 20 meron or lorger 300 30 eterno larger 106 40 aoron or lager 36 50 micron or lager we 100 micron or larger ' lesucd: May 1998