Professional Documents
Culture Documents
45
MAINTENANCE AND OPERATORS MANUAL
N
EDITION: 08/2002
REF. P 62440---53
Page 1 of 1
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Chapter I
Information
Chapter II
Safe operating practices
Chapter III
Controls and operation
Chapter IV
Maintenance
Chapter V
Maintenance log
Chapter VI
Fuel Lubricants
Page 1 of 2
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Chapter VII
Diagrams
Appendices
Appendix 1: List of engine error codes
Page 2 of 2
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Information
Operating and Maintenance Manual
CAUTION:
THE GUARANTEE WILL BE NULL AND VOID
WHERE THERE HAS BEEN NEGLIGENCE,
FAULTY MAINTENANCE, INAPPROPRIATE
USE OF THE EQUIPMENT BY THE
PURCHASERS OR THEIR EMPLOYEES,
AND/OR FAILURE TO RESPECT TECHNICAL
INSTRUCTIONS RELATING TO THE
GUARANTEE.
BEFORE THE OPERATOR STARTS THE
ENGINE:
GIVE INSTRUCTIONS TO THE OPERATOR ON
SAFE AND CORRECT USE OF THE MACHINE.
MAKE SURE THE OPERATOR READS AND
UNDERSTANDS THE OPERATORS MANUAL
FOR THIS MACHINE.
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Chapter I - Page 1 of 8
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Information
Operating and Maintenance Manual
K-62440-49
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Information
Operating and Maintenance Manual
Information
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Information
Operating and Maintenance Manual
Important notice
In order that any type of vehicle be reliable and safe, it is most
important to carry out all lubrication and maintenance operations.
Some of them, given in the MAINTENANCE GUIDE, require special
tools and technical knowledge.
Any failure to respect the lubrication and maintenance instructions
may cause a serious accident.
Special attention must be paid to cleanliness in the engine
compartment.
READ ALL THE SAFETY INSTRUCTIONS CAREFULLY BEFORE
CARRYING OUT LUBRICATION OR MAINTENANCE
OPERATIONS ON THE MACHINE.
All precautionary measures are described in the paragraph "SAFETY"
as well as in the GUIDE, when the corresponding maintenance
operations may present dangers. Warnings are also displayed on the
machine regarding some dangers which could cause serious
accidents. In the GUIDE and on the machine, these warnings are
preceded by the word "CAUTION" or "WARNING".
P P M does not necessarily know the way that maintenance
operations are carried out, or all risks inherent in a given method and
is unable to advise the maintenance team. Consequently, anyone
using an unsuitable specific method or tool recommended in the
GUIDE must first be sure that no risk is involved for himself or
anybody else and that there will be no damage to the machine or
effect upon safety.
IMPORTANT : The information contained in this operator's
manual is subject to change without notice. In case of
disagreement, only the French version will be taken into account.
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Information
Operating and Maintenance Manual
Technical specifications
DATE OF ISSUE: 08/2002
Identification
MARK: PPM - TEREX CRANES
MANUFACTURER: PPM
TYPE : TFC 45 / 45 R
SERIAL NUMBER:. . . .
DATE OF START UP:
PPM S. A. S.
Registered office and factory
Zone Industrielle de la Saule
BP 106
71304 MONTCEAU LES MINES
FRANCE
TELEPHONE: ( 33 ) . 03 . 85 . 67 . 38 . 00
FAX: ( 33 ) . 03 . 85 . 67 . 38 . 99
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Information
Operating and Maintenance Manual
XXXX
LENGTH
Inch
Foot
Yard
Mile (Statute)
25. 4
0. 30448
0. 9144
1. 609
TORQUE
millimetres (mm)
metres (m)
metres
Kilometres (km)
in-lbs
m)
ft-lbs
ft-lbs
AREA
Inch2
Foot2
Yard2
645. 2
6. 45
0. 0929
0. 8361
Quart
Gallon
Yard3
16387.
16. 387
0. 0164
0. 9464
3. 7854
0. 7646
millimetres2 (mm2)
centimetres2 (cm2)
metres2 (m2)
metres2
horsepower
0. 4536
907. 18
0. 907
mm3
cm3
litres (l)
litres
litres
metres3 (m3)
9. 807
0. 278
4. 448
metres-metres
kg-m
0. 746
Inches of
mercury
3. 377
Inches of water 0. 2491
Pounds/sq.
in. (psi)
6. 895
Pounds/sq.
in. (psi)
0. 0703
kilowatts (kW)
kilopascals (kPa)
kilopascals
kilopascals
kg/cm2
ENERGY OR WORK
kilograms (kg)
kilograms
tonne (t)
BTU
1055.
joules (J)
Foot-pound
1. 3558
joules
Kilowatt-hours 3. 6 x 106
or
3600000 joules (J=one W. s)
FORCE
Kilogram
Ounce
Pound
1. 3558
0. 1383
VELOCITY
newtons (N)
newtons
newtons
Miles/hour
1. 6093
kilometres. hr(km/h)
TEMPERATURE
F = 9/5 C +32
C = 5/9 (F -32)
K-62440-49
(N.
PRESSURE OR STRESS
MASS
Pound
US Ton
US Ton
newton-metres
POWER
VOLUME
Inch3
0. 11298
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Information
Operating and Maintenance Manual
Operator comfort
Sound level
Inside the cab with closed doors, the noise level A measured in static
remains below 85 dB(A).
Vibrations
The average weighted quadratic value of manual cab controls
according to the frequency of measured acceleration following
measuring conditions stipulated by standard ISO 5349 remains below
of 2.5 m/s2 (2.13 m/s2).
The average weighted quadratic value of the operator's seat
according to the frequency of measured acceleration following
measuring conditions stipulated by standard ISO 2631 can attain a
maximum value of 0.59 m/s2.
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Information
Operating and Maintenance Manual
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Safe operating
practices
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Danger
Any operator must become acquainted with the operating
instructions described in this manual before using the machine.
The operator is wholly responsible for machine operation. No
liability will be accepted by the manufacturer if the instructions
contained in this manual are not strictly respected.
Never drive the machine, or let it be driven by third parties,
unless all the instructions contained in this manual have been
perfectly understood and remembered. Failure to follow these
instructions may result in serious accidents causing damage to
equipment and injury to personnel. Do not hesitate to contact
your local PPM Dealer or Agent who is authorized to offer formal
training or can give sound advice.
THE OPERATOR'S MANUAL must always be left in the driver's
cab. Contact your local PPM Dealer to obtain another copy if
required.
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General information
Your safety as well as that of ground personnel in the vicinity
depend upon the proper use of the machine. Be sure that you are
perfectly aware of the location and the use of all controls.
BEFORE USING THE MACHINE, TRY ALL CONTROLS ON A
SAFE AND FREE AREA
In the handbook, the words "RIGHT" and "LEFT" indicate right
and left hand sides of the machine as viewed from the operator's
seat in the normal forward drive position.
Local safety rules must be observed
Make sure you read and fully understand all panels indicating
dangers or special attention to be taken on the machine.
Maintenance instructions must be strictly respected.
Pay particular attention if the machine is not the one you usually
drive.
Do not smoke when filling the fuel tank: the fumes are highly
inflammable.
Keep a good fire extinguisher and a first aid kit with you at all
times. Know how to use both of these items, and check them
regularly.
Avoid accidents due to unsuitable clothing. Wear proper working
clothes that will not get tangled up in machinery, and if
necessary, use safety equipment such as helmets, safety shoes,
ear protectors, goggles or a protective mask, gloves and
reflective clothes.
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Operation
For your own safety as well as to ensure long machine life,
before starting up inspect the machine carefully.
Look for loose or missing fasteners, dirt accumulations,
hydraulic or coolant liquid leaks. Check condition of tyres as well
as the equipment and the steering gear.
Breakdown of a component or circuit can cause an accident.
Before using the machine, check all oil and hydraulic oil levels.
Check that all plugs, level gauges and caps are correctly
tightened. Replace or repair defective parts.
In case of a malfunction or a missing part, stop the machine and
carry out the repair. If this rule is not respected personnel injury
may occur.
Never use a machine with defective braking, steering or hoisting
systems. This rule applies to a machine that has been repaired or
adjusted without the agreement of the workshop supervisor, or
without being checked by him or by qualified staff.
If the engine stops, neither the power steering system nor the
brakes will operate correctly: stop the machine as quickly as
possible.
Do not use ether or any other unauthorized product to make
engine starting easier. If this rule is not strictly respected serious
personnel injury may occur.
Unless otherwise instructed: retract the boom, stop the engine,
apply the parking brake and immobilize or chock the machine
before undertaking any maintenance operation or leaving the
machine at the end of a shift.
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Maintenance
Do not try to carry out repairs that you not competent or qualified
to do.
Do not tolerate unauthorized people on the machine while
carrying out maintenance work.
Wear eye or face protection when you service the machine. Use a
hammer with a soft face, such as plastic, wood, brass or leather,
when you have to hammer hardened tools or hardened metal
surfaces. Any other procedure can cause injury from flying
chips.
Only run the engine in well ventilated areas.
Apply the parking brake, chock wheels and place warning panels
on controls while maintenance operations are carried out.
Always use proper tooling. Replace or repair worn or damaged
equipment.
Always check the cooling circuit with engine shut off and cold.
Unscrew the radiator cap slowly to release pressure in the
circuit. Steam may cause burns.
Always carefully unscrew coolant and drain plugs, grease
nipples and pressure taps.
Rotating fan and belts: contact can injure. Keep clear.
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Electricity
Before working on the electrical circuit, turn the battery switch to
OFF position or cut off the current with the ignition switch.
Make sure that you understand the electrical circuit before you
connect or disconnect an electrical component. A wrong
connection can cause injury or damage.
Never put a metal object across the battery terminals to check
the charge of the battery. The sparks could cause an explosion.
Use a voltmeter or a hydrometer to check the battery.
Never smoke while checking battery liquid levels. A battery
produces inflammable fumes. The electrolyte is an acid solution
which is dangerous to the skin and the eyes.
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Hydraulics
The hydraulic system operates at a very high pressure. Hydraulic
oil, even from a minute leak, can go through your skin and cause
serious injury. When you check for leaks, do not use your hands,
use a piece of wood or paper. If you think hydraulic oil has
penetrated your skin, consult a doctor immediately.
Before disconnecting any hydraulic lines or components make
sure that pressure has been released in the circuit. Check for
leaks after reconnecting hydraulic hoses, pipes and components.
Hydraulic rams (especially derricking and telescoping rams)
must be fully retracted or the cylinder and piston rod chambers
of extended rams must be bled before any intervention is carried
out on hydraulic circuits or components (especially on relief
valve blocks flanged to rams).
The spreader must also be supported and in a horizontal position
before any intervention on the damping ram.
On any circuits using hydraulic or pneumatic reservoir bottles (e.
g. braking or suspension circuits) gas or hydraulic oil pressures
must be dropped to zero and their bottles emptied before
carrying out any intervention.
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General information
In all circumstances, the primary recommendation is prudence.
If the machine stays unused outside and with the piston rods
extended, all the rods must be greased to avoid corrosion.
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Spreader
When picking up a container always try to keep the longitudinal
axis of the machine as perpendicular as possible to that of the
container.
When slewing the spreader with respect to the container, use the
hydraulic slewing control or let the spreader down using the
container's corner guides after having activated the free slewing
function control. Never use the spreader's hydraulic slewing
control on the corner guides without having previously released
the slewing brake as mentioned above.
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When driving under load, place the container slightly above the
operator's eye level and retract the boom to obtain the best
possible stability.
When transporting the load, it must be kept as close as possible
to the front axle (height and reach) or slightly forward to this
position, never further towards the rear. The container's position
should also allow the operator good visibility from the cab.
To ensure good visibility from the cab, avoid transporting the
load positioned in the field of vision.
In normal driving conditions use the middle pedal for braking.
The left hand pedal is only to be used for final 'inching' approach.
Braking reduces both longitudinal and lateral machine stability.
Adapt braking according to speed and the load being
transported. Be particularly careful when taking bends.
This machine has rear wheel steering, so pay attention to the
trajectory of the rear wheels when turning. Keep in mind that the
space occupied by the rear end of the machine during turning
manoeuvres is different than that of other vehicles. Keep a
minimum clearance of 50 cm between the counterweight and any
obstacle.
Adjust speed according to worksite conditions: this is governed
by environmental and ground conditions, the height and size of
the load along with visibility. Avoid sudden, abrupt manoeuvres
(taking bends, braking and speed).
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Introduction
PPM machines are carefully designed, tested, and manufactured.
When used properly by qualified operators, they will give safe, reliable
service. PPM has concessionaires who are competent to answer any
questions about its products or their safe use.
This machine has been designed to handle loads in accordance with
the load capacity chart and with instructions contained in this manual.
The machine should only be used in accordance with current laws and
regulations in force in the country concerned.
It is strictly prohibited to lift people with the machine unless it is
expressly equipped with an approved man-carrying platform supplied
by PPM.
This machine is not to be used as demolition equipment.
It is strictly prohibited to push or drag objects with the boom.
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Operator's responsibility
Safety must always be the operator's most important concern. He
must refuse to operate when he knows it is unsafe and consult his
supervisor when safety is in doubt. He must read and fully understand
the Maintenance and Operator's Manual, all instructions, signs, and
decals on the machine. He must see that the machine is in proper
order and that all operational aids and warning signals are functional
before operating.
He must be alert, physically fit, and not under the influence of alcohol,
drugs, or medication that might affect his eyesight, hearing, or
reactions.
He must make sure that people, equipment, and material are kept out
of the work area.
When an operator's view is obstructed or when operating in
hazardous areas such as near power lines or around people, in these
special circumstances a signalman or an crew member must be used.
The operator must keep a fully charged fire extinguisher and first aid
kit in the cab at all times and be familiar with how to use these items.
The operator should understand the movements of other machinery,
trucks and personnel at the jobsite.
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Management responsibility
See that operators are trained, competent, physically fit and, if
required, licensed. Good vision is required as are good judgment,
coordination and mental ability. Any person who lacks any of these
qualities must not be allowed to operate a machine.
Any person who is associated with working on the SUPER STACKER,
such mechanics, must respect all safety signals and be aware of their
own safety as well as that of others. Machine personnel such as
mechanics are required to be aware of any particular procedures
concerning their jobs on the machine.
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Operating precautions
An error in determining lifting capacity can cause an accident.
Numerous factors must be taken into account:
The reach is the distance from the wheels of the machine to the axis
of the spreader. Note that the boom bends, increasing reach, when
the load is lifted.
Lifting a load which is outside the load table, reasoning that the act of
lifting will bring it into the load table, is extremely dangerous. The
machine could tip and fall over if the load is too heavy.
Always remain within the load table. The driver must reduce the load
as a function of site conditions and use his judgement to evaluate
what loads can be lifted in perfect safety.
Machines may fall over or tilt if the ground is not stable enough to
support their weight.
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No one should approach the machine again until it is certain that the
electrical equipment has been definitively isolated and the absence of
any voltage has been verified (verification effected in liaison with the
electric power supplier).
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P11-P12
P13
SAFETY DEVICE
MODE OF OPERATION
Spreader damping
Spreader damping
neutralization
LOCATION ON
MACHINE
DESCRIPTION
On chassis to
right of cab
Controls spreader
locking in lifting mode
At front under
engine cover
Controls cut-off of
raising and extension of
telescopic unit
P47
Speed limitation on
locked container
Head of boom
S25
Anti-tipping
On rear axle
PM1
Under cab
Prevents engagement of
gear while parking
brake is on
Y1-Y2
Y3-Y4
Position of catches
(twistlocks) indicator lights:
white
On spreader
catches
Controls engagement of
catches in container
Y5-Y6
Y7-Y8
Locking/unlocking
container, indicator light:
green
On spreader
catches
Controls rotation of
catches
S9-S10
Near spreader
slew ring
Controls orientation of
spreader
Gear selector
In cab
Gear selector
In cab
Switches on audible
warning and rear lights
Prevention of container
crushing
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Neutralizes the
functions of boom
lowering and boom
extension
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_______________________________________ 14
30 / Alarm warning light STOP engine_______ 14
31 / Engine fault warning light _____________ 14
32 / Low hydraulic oil level warning light ____ 14
33 / Fuel minimum level warning light _______ 14
Control desk panel, centre left ________________ 15
40 / Compteur horaire ____________________ 15
41 / Unit centrale MDM-Ecran ____________ 15
42 / Hour meter _________________________ 15
43 / Torque converter oil temperature gauge __ 15
44 / Fuel gauge __________________________ 15
45 / Gear box clutch oil pressure gauge ______ 15
46 / Hydraulic oil temperature gauge ________ 15
Control desk panel, lateral right _______________ 16
70 / Joystick controller (raise/lower extend/retract boom) _____________________ 16
70B/ High speed boom functions control _____ 16
71 / Spreader side shift control _____________ 16
72 / Spreader swing control ________________ 16
73 / Twist locks lock / release control ________ 16
Control desk panel, right ____________________ 17
74 / Spreader damping lock switch __________ 17
75 / Spreader beam telescoping switch _______ 17
Control desk panel, right ____________________ 18
76 / Ignition switch _______________________ 18
77 / Engine shut down control ______________ 18
78 / Engine test code control _______________ 18
79 / Hazard warning lights control switch ____ 18
80 / Engine test control ___________________ 18
81 / Parking brake control_________________ 18
86 / Spreader lock override control__________ 19
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F12 - 15A Spreader operating indicator lights Container lock sensor Container release sensor
Low speed telescoping spreader. __________ 22
F13 - 15A Horizontality spreader Lifting up
safety of torque Hydraulic oil coolant.______ 22
F14 - - 15A Condenser. __________________ 22
F15 - 20A Gearbox. _____________________ 22
F16 - 15A Dipped headlights. _____________ 22
F17 - 10A Spreader functions _____________ 22
F18 - 5A Front outrigger option ___________ 22
F19 - 10A Mobile cab. ___________________ 22
F20 - 10A Neutralization shock absorption. _ 22
F21 - 10A Spreader slewing - Spreader side
shift. __________________________________ 23
F22 - 10A Flow rate cab joystick. __________ 23
F23 - 5A Stop engine. ___________________ 23
F24 - 20A Headlights main beam Audible
warning. _______________________________ 23
F25 -
Not used._______________________ 23
F26 -
Not used._______________________ 23
D27 -
Diode. _________________________ 23
D28 -
Diode. _________________________ 23
K-62440-49
F30 -
Not used._______________________ 23
F31 -
Not used._______________________ 23
F32 -
Not used._______________________ 23
F33 -
Not used._______________________ 23
F34 -
Not used._______________________ 23
F35 -
Not used._______________________ 23
F36 -
Not used._______________________ 23
F37 -
Not used._______________________ 23
F38 -
Not used._______________________ 23
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Not used._______________________ 24
F47 -
Not used._______________________ 24
F48 -
Not used._______________________ 24
F49 -
Not used._______________________ 24
F50 -
Not used._______________________ 24
F51 -
Not used._______________________ 24
F52 -
Not used._______________________ 24
F53 -
Not used._______________________ 24
F54 -
Not used._______________________ 24
F55 -
Not used._______________________ 24
F56 -
Not used._______________________ 24
F57 -
Not used._______________________ 24
F58 -
Not used._______________________ 24
F34 -
Not used._______________________ 24
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Weight adjustment_______________________ 44
Height adjustment _______________________ 44
Backrest rake adjustment _________________ 44
Distance adjustment______________________ 44
Headrest _______________________________ 44
Right control panel bracket lifting handle ____ 45
Unoccupied passenger seat (OPTION) _______ 45
Recommended seat adjustment_____________ 45
Recommendations for minimizing levels of
vibration of the machine. __________________ 46
Machine operation _________________________ 48
Machine operation _______________________ 48
Preliminary Inspection and Adjustments_____ 48
Starting the engine. ______________________ 48
Prevention of fire risks in the engine compartment. 51
Machine operation _________________________ 52
Automatic transmission mode ____________ 52
Gearbox in manual mode _________________ 52
Container handling cycle __________________ 53
Stopping the engine ________________________ 56
Removing/installing the spreader _____________ 57
Function and identification of valve positions _ 58
Spreader damping __________________________ 60
Optional fixed hook ________________________ 61
Fitting the fixed hook _______________________ 61
Dismantling the fixed hook___________________ 62
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Control identification
The reference numbers for the instruments and controls shown in the
cab illustrations correspond to the numbers in the following text. The
text identifies the controls and instruments, and describes their
operation.
Notes: All standard and optional controls for this machine are
identified and described in the following list. The following list
therefore contains controls and instruments which are not furnished
on every machine.
Before attempting to operate this machine, the operator should
carefully study all of the information in this section and in the safe
operating practices for super stacker users at the front of this manual.
The operator should become thoroughly familiar with the location and
purpose of each control on the machine.
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Cab
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22
18
23
19
25
24
20
25
21
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26
31
27
25
32
33
28
29
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45
46
40 / Compteur horaire
43
42 / Hour meter
43 / Torque converter oil temperature gauge
44 / Fuel gauge
45 / Gear box clutch oil pressure gauge
46 / Hydraulic oil temperature gauge
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70
70/A
A
72
73
70 / Joystick controller
(raise/lower - extend/retract boom)
70B/ High speed boom functions control
73
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75
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78
76
79
80
81
76 / Ignition switch
77 / Engine shut down control
78 / Engine test code control
79 / Hazard warning lights control switch
80 / Engine test control
81 / Parking brake control
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87
88
89
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105
100
111
112
103
102
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Fuse board
(Box behind seat)
F1 - 10A Battery isolator safety device
F2 - 5A Parking brake
F3 - 5A Left and right ceiling light
F4 - 15A.- Screenwiper, front - rear - cab roof F5 - 5A Screenwasher audible warning indicator
lights and receivers
F6 - 20A Working light, cab spreader chassis.
F7 - 15A Stop light direction indicator lights.
F8 - 20A Working light, cab - boom.
F9 - 20A Rotating beacon lights
F10 -5A Reversing light
F11 - 15A Evaporator condenser compressor air
conditioning
F12 - 15A Spreader operating indicator lights - Container
lock sensor Container release sensor Low speed
telescoping spreader.
F13 - 15A Horizontality spreader Lifting up safety of
torque Hydraulic oil coolant.
F14 - - 15A Condenser.
F15 - 20A Gearbox.
F16 - 15A Dipped headlights.
F17 - 10A Spreader functions
F18 - 5A Front outrigger option
F19 - 10A Mobile cab.
F20 - 10A Neutralization shock absorption.
K-62440-49
06/12/2004
Not used.
F26 -
Not used.
D27 -
Diode.
D28 -
Diode.
Not used.
F31 -
Not used.
F32 -
Not used.
F33 -
Not used.
F34 -
Not used.
F35 -
Not used.
F36 -
Not used.
F37 -
Not used.
F38 -
Not used.
K-62440-49
06/12/2004
K-62440-49
F46 -
Not used.
F47 -
Not used.
F48 -
Not used.
F49 -
Not used.
F50 -
Not used.
F51 -
Not used.
F52 -
Not used.
F53 -
Not used.
F54 -
Not used.
F55 -
Not used.
F56 -
Not used.
F57 -
Not used.
F58 -
Not used.
F34 -
Not used.
06/12/2004
General fuses
(Battery compartment)
PF100 - 100A General protection of functions after
isolation of battery
PF80 -80A General protection of starter after isolation of
battery
PF50 -50A General direct protection of battery
PF100
PF80
PF50
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06/12/2004
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K-62440-49
06/12/2004
Cab
1 / Steering wheel (rear wheel steering)
The angle of the steering column can be adjusted using the
handwheel A situated on the left, under the steering wheel.
When the wheel is turned to the right, the wheels turn to the left.
When the wheel is turned to the left, the wheels turn to the right.
A
Forward and reverse travel drives are selected when the machine is at
a standstill. To check if the transmission is in neutral, carefully press
the accelerator: the machine should not move.
Rear
K-62440-49
06/12/2004
Cab
3 / Accelerator pedal
Press this pedal to increase engine speed . Release the pedal to
decrease engine speed. Engine speed will return to idle when the
pedal is released.
5
4
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06/12/2004
16
17
15
13
14
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06/12/2004
18
23
19
25
24
20
25
21
DANGER:
Never actuate the control lever(73) (spreader
lock/release control) with a suspended container.
Make sure the container is correctly positioned before
lifting. Failure to respect these instructions could
cause serious damage or injury to the machine and to
staff.
22 / Brake oil pressure warning light
This warning light goes out when the braking pressure reaches 105
bar (minimum operating pressure).
K-62440-49
06/12/2004
22
18
23
19
20
exceeded.
The audible warning sounds. Remaining authorized functions are:
25
21
30
31
25
32
26
27
28
33
29
Warning light comes on (with warm oil) when return filter to hydraulic
tank is clogged. When it remains lit, replace the filter cartridge. It also
lights up when the air filter is clogged. Stop the machine and rectify
the problem.
29 / Not used
K-62440-49
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30
26
31
27
25
If this light goes on, make sure that there are no hydraulic oil leaks
32
28
33
29
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06/12/2004
44
45
46
42 / Hour meter
The hour meter operates when the engine is running.
44 / Fuel gauge
This gauge indicates the amount of fuel remaining in the fuel tank.
K-62440-49
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71
72
70 /1 - Raise boom
70 /2 - Lower boom
70 /3 - Retract boom
2
4
3
1
70 /4 - Extend boom
Any of these functions can be performed while handling a container
and a 45-degree joystick movement will produce a combined action
such as raise boom with extend boom.
71/2
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72/2
- Releasing
Push the lever to the left to release the spreader from the container.
- Locking
Push the lever to the right to lock the spreader to the container.
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06/12/2004
74
IMPORTANT:
It is essential to immobilize the spreader's shock
absorption function in order to travel carrying a
container in logitudinal position.
75
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Use this control to apply the parking brake, warning light 20 comes on.
When the brake is released, warning light 20 goes out. Do not use as
a road brake.
K-62440-49
06/12/2004
DANGER: It is STRICTLY
PROHIBITED to override the
anti-tipping device.
DANGER:
Never use the spreader lock/release control (73) with a
container suspended from the spreader.
Make sure that the container is correctly positioned
before lifting it. Failure to respect certain safety rules
can cause damage to the machine and injury to
personnel.
Use this override only for very special cases and
under the responsibility of the site manager. Be aware
of the damage to the machine and injury to personnel
that could result from lifting a load with the device
overridden.
87
89
K-62440-49
06/12/2004
104
This control starts the air conditioning. Turn the knob for cab
100
111
112
ventilation.
This control turns on the front and rear road lights. Warning light 15
comes on.
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06/12/2004
- Switch on ignition.
- The Stop Engine control 81 must be in released position.
80
30
31
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06/12/2004
?
The last digit of the code is given by the number of flashes of
indicator light 30 (3rd digit of the code).
Indicator light 31 flashes once. (End of code).
Refer to the table of engine fault codes in the appendix to identify the
engine problem.
?
1 flash
1 to 2 s
?
2 flashes
1 to 2 s
4 flashes
?
1 to 2 s
4 flashes
1 to 2 s 1
flash
Fault code = 244
To flash the next fault code, press control 83.
Switch the engine test control 80 back again to quit test mode.
K-62440-49
06/12/2004
Seat adjustments
Weight adjustment
For maximum comfort and protection against vibrations, it is important
for the suspension to be correctly adjusted to your weight.
Turn the adjuster knob 1 until the indicated weight (read inside the
transparent knob) matches your weight in kilograms (one pound = 2.2
kg). The optimum adjustment is for the suspension to be in the middle
of the vertical stroke - "mid-ride" position - when normally seated.
Height adjustment
After having adjusted the weight, the rake of the seat and cushion as
well as stability can also be adjusted by operating levers 2 and 3.
Distance adjustment
5
Operate the control lever 5, adjust the seat alone to the required
position.
Lever 6 for the seat + bracket.
Make sure that the mechanism is properly secured after adjusting.
Headrest
The height of the head-rest is adjusted by pulling upwards or pushing
downwards and the angle is adjusted by pivoting movement from front
6
K-62440-49
to back.
06/12/2004
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06/12/2004
K-62440-49
06/12/2004
K-62440-49
06/12/2004
Machine operation
Machine operation
Both this paragraph and the instructions on safe operating practices at
the beginning of this manual must be studied before the machine is
driven.
The following instructions constitute reminders rather than advice,
since the manufacturer knows that this equipment will be entrusted to
an operator of confirmed competence.
K-62440-49
06/12/2004
Warning
Do not operate the starter motor for more than 30 seconds
at a time. If the engine fails to start within that time,
release the engine start switch and wait two minutes
before trying again. If this precaution is not followed
serious damage to the starter motor may result.
IMPORTANT: The power
steering only operates when
the engine is running. It is
dangerous to shut off the
engine while driving the
machine.
Turn and hold the key in the start position until the engine fires.
Release the key as soon as the engine fires.
4. To start the engine under cold conditions, temperatures under 12C (10F), using a starting aid, proceed as follows:
A. Perform steps 1 and 2.
B. Spray a small amount of ether into the air intake.
C. Turn the key and start the engine as previously described in step 3
above.
NOTE - During the period of starting, extra batteries (this is a 24 volt
electrical system) may be required. This will depend on the charge
condition of the machine's battery.
NOTE - Use ether sparingly and cautiously. If too much ether is used,
it has a retarding effect in starting the engine. Also, ether is not
effective at temperatures below -23 C (-10 F).
K-62440-49
06/12/2004
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06/12/2004
K-62440-49
06/12/2004
Machine operation
This machine can be driven with the gearbox in either automatic or
manual mode.
Select the desired mode using key-operated control 89.
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06/12/2004
K-62440-49
06/12/2004
5- Pull the spreader lock/release lever towards you to actuate the twist
locks. The red indicator lights go off and the white and green ones go
on once the twist locks are locked.
K-62440-49
06/12/2004
11- When the twist locks are released, the red spreader operating
lights go on and the spreader can be released from the container.
The white spreader indicator lights go off once the spreader is
disengaged from the container.
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06/12/2004
K-62440-49
06/12/2004
Removing/installing
the spreader
It may become necessary to remove and install the spreader on
certain occasions. To do so proceed as follows:
1. Install trestles approximately 1.30 m (4 feet) off the ground to
accommodate the spreader assembly. Lower the spreader onto the
trestles.
2. Shut down the engine and remove the key from the ignition.
3. Disconnect the hydraulic lines at the quickfit unions and plug the
hoses to prevent dirt from entering.
4. Disconnect the electric cables and install the shunt plug.
5. Remove the four pins securing the rotor to the rotator head.
6. To install the spreader, perform the preceding steps in reverse
order.
7 - Check the position of the damping cylinder valves.
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06/12/2004
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06/12/2004
Spreader damping
Spreader rocking is controlled by cylinders located on boom head..
The damping system is neutralized to keep spreader in a horizontal
position when boom hoisting.
When the boom hoisting function is stopped, damping is reactivated.
Damping Lock
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06/12/2004
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06/12/2004
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06/12/2004
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06/12/2004
_______________________________________ 14
30 / Alarm warning light STOP engine_______ 14
31 / Engine fault warning light _____________ 14
32 / Low hydraulic oil level warning light ____ 14
33 / Fuel minimum level warning light _______ 14
Control desk panel, centre left ________________ 16
40 / Compteur horaire ____________________ 16
41 / Unit centrale MDM-Ecran ____________ 16
42 / Hour meter _________________________ 16
43 / Torque converter oil temperature gauge __ 16
44 / Fuel gauge __________________________ 16
45 / Gear box clutch oil pressure gauge ______ 16
46 / Hydraulic oil temperature gauge ________ 16
Control desk panel, lateral right _______________ 17
70 / Joystick controller (raise/lower extend/retract boom) _____________________ 17
70B/ High speed boom functions control _____ 17
71 / Spreader side shift control _____________ 17
72 / Spreader swing control ________________ 17
73 / Twist locks lock / release control ________ 17
Control desk panel, right ____________________ 18
74 / Spreader damping lock switch __________ 18
75 / Spreader beam telescoping switch _______ 18
Control desk panel, right ____________________ 19
76 / Ignition switch _______________________ 19
77 / Engine shut down control ______________ 19
78 / Engine test code control _______________ 19
79 / Hazard warning lights control switch ____ 19
80 / Engine test control ___________________ 19
81 / Parking brake control_________________ 19
86 / Spreader lock override control__________ 21
K-62440-49
06/12/2004
K-62440-49
06/12/2004
F12 - 15A Spreader operating indicator lights Container lock sensor Container release sensor
Low speed telescoping spreader. __________ 24
F13 - 15A Horizontality spreader Lifting up
safety of torque Hydraulic oil coolant.______ 24
F14 - - 15A Condenser. __________________ 24
F15 - 20A Gearbox. _____________________ 24
F16 - 15A Dipped headlights. _____________ 24
F17 - 10A Spreader functions _____________ 24
F18 - 5A Front outrigger option ___________ 24
F19 - 10A Mobile cab. ___________________ 24
F20 - 10A Neutralization shock absorption. _ 24
F21 - 10A Spreader slewing - Spreader side
shift. __________________________________ 25
F22 - 10A Flow rate cab joystick. __________ 25
F23 - 5A Stop engine. ___________________ 25
F24 - 20A Headlights main beam Audible
warning. _______________________________ 25
F25 -
Not used._______________________ 25
F26 -
Not used._______________________ 25
D27 -
Diode. _________________________ 25
D28 -
Diode. _________________________ 25
K-62440-49
F30 -
Not used._______________________ 25
F31 -
Not used._______________________ 25
F32 -
Not used._______________________ 25
F33 -
Not used._______________________ 25
F34 -
Not used._______________________ 25
F35 -
Not used._______________________ 25
F36 -
Not used._______________________ 25
F37 -
Not used._______________________ 25
F38 -
Not used._______________________ 25
06/12/2004
Not used._______________________ 26
F47 -
Not used._______________________ 26
F48 -
Not used._______________________ 26
F49 -
Not used._______________________ 26
F50 -
Not used._______________________ 26
F51 -
Not used._______________________ 26
F52 -
Not used._______________________ 26
F53 -
Not used._______________________ 26
F54 -
Not used._______________________ 26
F55 -
Not used._______________________ 26
F56 -
Not used._______________________ 26
F57 -
Not used._______________________ 26
F58 -
Not used._______________________ 26
F34 -
Not used._______________________ 26
K-62440-49
06/12/2004
K-62440-49
06/12/2004
06/12/2004
K-62440-49
06/12/2004
Weight adjustment_______________________ 51
Height adjustment _______________________ 51
Backrest rake adjustment _________________ 51
Distance adjustment______________________ 51
Headrest _______________________________ 51
Right control panel bracket lifting handle ____ 52
Unoccupied passenger seat (OPTION) _______ 52
Recommended seat adjustment_____________ 52
Recommendations for minimizing levels of
vibration of the machine. __________________ 53
Machine operation _________________________ 54
Machine operation _______________________ 54
Preliminary Inspection and Adjustments_____ 54
Starting the engine. ______________________ 54
Prevention of fire risks in the engine compartment. 57
Machine operation _________________________ 58
Automatic transmission mode ____________ 58
Gearbox in manual mode _________________ 58
Container handling cycle __________________ 59
Stopping the engine ________________________ 62
Removing/installing the spreader _____________ 63
Function and identification of valve positions _ 64
Spreader damping __________________________ 66
Optional fixed hook ________________________ 67
Fitting the fixed hook _______________________ 67
Dismantling the fixed hook___________________ 68
K-62440-49
06/12/2004
Control identification
The reference numbers for the instruments and controls shown in the
cab illustrations correspond to the numbers in the following text. The
text identifies the controls and instruments, and describes their
operation.
Notes: All standard and optional controls for this machine are
identified and described in the following list. The following list
therefore contains controls and instruments which are not furnished
on every machine.
Before attempting to operate this machine, the operator should
carefully study all of the information in this section and in the safe
operating practices for super stacker users at the front of this manual.
The operator should become thoroughly familiar with the location and
purpose of each control on the machine.
K-62440-49
06/12/2004
Cab
K-62440-49
06/12/2004
K-62440-49
06/12/2004
22
18
23
19
25
24
20
25
21
K-62440-49
06/12/2004
26
31
27
25
32
33
28
29
K-62440-49
06/12/2004
35
36
38
37
39
40
K-62440-49
06/12/2004
45
46
40 / Compteur horaire
43
42 / Hour meter
43 / Torque converter oil temperature gauge
44 / Fuel gauge
45 / Gear box clutch oil pressure gauge
46 / Hydraulic oil temperature gauge
K-62440-49
06/12/2004
70
70/A
A
72
73
70 / Joystick controller
(raise/lower - extend/retract boom)
70B/ High speed boom functions control
73
K-62440-49
06/12/2004
75
K-62440-49
06/12/2004
77
82
78
80
81
79
76 / Ignition switch
77 / Engine shut down control
78 / Engine test code control
79 / Hazard warning lights control switch
80 / Engine test control
81 / Parking brake control
82 / Outrigger control (Option)
K-62440-49
06/12/2004
84
K-62440-49
06/12/2004
87
88
89
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06/12/2004
105
100
111
112
103
102
K-62440-49
101
06/12/2004
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06/12/2004
Fuse board
(Box behind seat)
F1 - 10A Battery isolator safety device
F2 - 5A Parking brake
F3 - 5A Left and right ceiling light
F4 - 15A.- Screenwiper, front - rear - cab roof F5 - 5A Screenwasher audible warning indicator
lights and receivers
F6 - 20A Working light, cab spreader chassis.
F7 - 15A Stop light direction indicator lights.
F8 - 20A Working light, cab - boom.
F9 - 20A Rotating beacon lights
F10 -5A Reversing light
F11 - 15A Evaporator condenser compressor air
conditioning
F12 - 15A Spreader operating indicator lights - Container
lock sensor Container release sensor Low speed
telescoping spreader.
F13 - 15A Horizontality spreader Lifting up safety of
torque Hydraulic oil coolant.
F14 - - 15A Condenser.
F15 - 20A Gearbox.
F16 - 15A Dipped headlights.
F17 - 10A Spreader functions
F18 - 5A Front outrigger option
F19 - 10A Mobile cab.
F20 - 10A Neutralization shock absorption.
K-62440-49
06/12/2004
Not used.
F26 -
Not used.
D27 -
Diode.
D28 -
Diode.
Not used.
F31 -
Not used.
F32 -
Not used.
F33 -
Not used.
F34 -
Not used.
F35 -
Not used.
F36 -
Not used.
F37 -
Not used.
F38 -
Not used.
K-62440-49
06/12/2004
K-62440-49
F46 -
Not used.
F47 -
Not used.
F48 -
Not used.
F49 -
Not used.
F50 -
Not used.
F51 -
Not used.
F52 -
Not used.
F53 -
Not used.
F54 -
Not used.
F55 -
Not used.
F56 -
Not used.
F57 -
Not used.
F58 -
Not used.
F34 -
Not used.
06/12/2004
General fuses
(Battery compartment)
PF100 - 100A General protection of functions after
isolation of battery
PF80 -80A General protection of starter after isolation of
battery
PF50 -50A General direct protection of battery
PF100
PF80
PF50
K-62440-49
06/12/2004
K-62440-49
06/12/2004
K-62440-49
06/12/2004
Cab
1 / Steering wheel (rear wheel steering)
The angle of the steering column can be adjusted using the
handwheel A situated on the left, under the steering wheel.
When the wheel is turned to the right, the wheels turn to the left.
When the wheel is turned to the left, the wheels turn to the right.
A
Forward and reverse travel drives are selected when the machine is at
a standstill. To check if the transmission is in neutral, carefully press
the accelerator: the machine should not move.
Rear
K-62440-49
06/12/2004
Cab
3 / Accelerator pedal
Press this pedal to increase engine speed . Release the pedal to
decrease engine speed. Engine speed will return to idle when the
pedal is released.
5
4
K-62440-49
06/12/2004
16
17
15
13
14
K-62440-49
06/12/2004
18
23
19
25
24
20
25
21
DANGER:
Never actuate the control lever(73) (spreader
lock/release control) with a suspended container.
Make sure the container is correctly positioned before
lifting. Failure to respect these instructions could
cause serious damage or injury to the machine and to
staff.
22 / Brake oil pressure warning light
This warning light goes out when the braking pressure reaches 105
bar (minimum operating pressure).
K-62440-49
06/12/2004
22
18
23
19
20
exceeded.
The audible warning sounds. Remaining authorized functions are:
25
21
30
31
25
32
26
27
28
33
29
Warning light comes on (with warm oil) when return filter to hydraulic
tank is clogged. When it remains lit, replace the filter cartridge. It also
lights up when the air filter is clogged. Stop the machine and rectify
the problem.
29 / Not used
K-62440-49
06/12/2004
30
26
31
27
25
If this light goes on, make sure that there are no hydraulic oil leaks
32
28
33
29
K-62440-49
06/12/2004
This warning light indicate that pads for container handling are
correctly positioned in their locations and lifting of the container is
permitted.
35
36
38
This warning light comes ON when upper beams legs are fully
extended by activating switch Ref. 85.
39
40
K-62440-49
06/12/2004
34
35
36
38
40
K-62440-49
06/12/2004
44
45
46
42 / Hour meter
The hour meter operates when the engine is running.
44 / Fuel gauge
This gauge indicates the amount of fuel remaining in the fuel tank.
K-62440-49
06/12/2004
71
72
70 /1 - Raise boom
70 /2 - Lower boom
70 /3 - Retract boom
2
4
3
1
70 /4 - Extend boom
Any of these functions can be performed while handling a container
and a 45-degree joystick movement will produce a combined action
such as raise boom with extend boom.
71/2
K-62440-49
06/12/2004
72/2
- Releasing
Push the lever to the left to release the spreader from the container.
- Locking
Push the lever to the right to lock the spreader to the container.
K-62440-49
06/12/2004
74
IMPORTANT:
It is essential to immobilize the spreader's shock
absorption function in order to travel carrying a
container in logitudinal position.
75
K-62440-49
06/12/2004
Use this control to apply the parking brake, warning light 20 comes on.
When the brake is released, warning light 20 goes out. Do not use as
a road brake.
K-62440-49
06/12/2004
K-62440-49
06/12/2004
Outrigger operation
Use the outrigger to pick up a container at a radius of up to 6.40m.
The safety system does not allow the outrigger to be raised until the
machine is brought back into a safe load carrying configuration
allowing the machine to be driven.
K-62440-49
06/12/2004
lever Ref. 84. The following settings determine which legs will be
controlled:
AR/AV Position : 4 legs selected
AV Position : 2 front legs only selected
AR Position : 2 rear legs only selected
84 /2 Legs lifting
84 /3 Leg opening
84 /4 Leg clamping
K-62440-49
06/12/2004
DANGER: It is STRICTLY
PROHIBITED to override the
anti-tipping device.
DANGER:
Never use the spreader lock/release control (73) with a
container suspended from the spreader.
Make sure that the container is correctly positioned
before lifting it. Failure to respect certain safety rules
can cause damage to the machine and injury to
personnel.
Use this override only for very special cases and
under the responsibility of the site manager. Be aware
of the damage to the machine and injury to personnel
that could result from lifting a load with the device
overridden.
87
89
left side. Push and hold this switch to the right to lower the container
on the right side.
K-62440-49
06/12/2004
104
This control starts the air conditioning. Turn the knob for cab
100
111
112
ventilation.
This control turns on the front and rear road lights. Warning light 15
comes on.
K-62440-49
06/12/2004
K-62440-49
06/12/2004
- Switch on ignition.
- The Stop Engine control 81 must be in released position.
80
30
31
K-62440-49
06/12/2004
?
The last digit of the code is given by the number of flashes of
indicator light 30 (3rd digit of the code).
Indicator light 31 flashes once. (End of code).
Refer to the table of engine fault codes in the appendix to identify the
engine problem.
?
1 flash
1 to 2 s
?
2 flashes
1 to 2 s
4 flashes
?
1 to 2 s
4 flashes
1 to 2 s 1
flash
Fault code = 244
To flash the next fault code, press control 83.
Switch the engine test control 80 back again to quit test mode.
K-62440-49
06/12/2004
Seat adjustments
Weight adjustment
For maximum comfort and protection against vibrations, it is important
for the suspension to be correctly adjusted to your weight.
Turn the adjuster knob 1 until the indicated weight (read inside the
transparent knob) matches your weight in kilograms (one pound = 2.2
kg). The optimum adjustment is for the suspension to be in the middle
of the vertical stroke - "mid-ride" position - when normally seated.
Height adjustment
After having adjusted the weight, the rake of the seat and cushion as
well as stability can also be adjusted by operating levers 2 and 3.
Distance adjustment
5
Operate the control lever 5, adjust the seat alone to the required
position.
Lever 6 for the seat + bracket.
Make sure that the mechanism is properly secured after adjusting.
Headrest
The height of the head-rest is adjusted by pulling upwards or pushing
downwards and the angle is adjusted by pivoting movement from front
6
K-62440-49
to back.
06/12/2004
K-62440-49
06/12/2004
K-62440-49
06/12/2004
Machine operation
Machine operation
Both this paragraph and the instructions on safe operating practices at
the beginning of this manual must be studied before the machine is
driven.
The following instructions constitute reminders rather than advice,
since the manufacturer knows that this equipment will be entrusted to
an operator of confirmed competence.
K-62440-49
06/12/2004
Warning
Do not operate the starter motor for more than 30 seconds
at a time. If the engine fails to start within that time,
release the engine start switch and wait two minutes
before trying again. If this precaution is not followed
serious damage to the starter motor may result.
IMPORTANT: The power
steering only operates when
the engine is running. It is
dangerous to shut off the
engine while driving the
machine.
Turn and hold the key in the start position until the engine fires.
Release the key as soon as the engine fires.
4. To start the engine under cold conditions, temperatures under 12C (10F), using a starting aid, proceed as follows:
A. Perform steps 1 and 2.
B. Spray a small amount of ether into the air intake.
C. Turn the key and start the engine as previously described in step 3
above.
NOTE - During the period of starting, extra batteries (this is a 24 volt
electrical system) may be required. This will depend on the charge
condition of the machine's battery.
NOTE - Use ether sparingly and cautiously. If too much ether is used,
it has a retarding effect in starting the engine. Also, ether is not
effective at temperatures below -23 C (-10 F).
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Machine operation
This machine can be driven with the gearbox in either automatic or
manual mode.
Select the desired mode using key-operated control 89.
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5- Pull the spreader lock/release lever towards you to actuate the twist
locks. The red indicator lights go off and the white and green ones go
on once the twist locks are locked.
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11- When the twist locks are released, the red spreader operating
lights go on and the spreader can be released from the container.
The white spreader indicator lights go off once the spreader is
disengaged from the container.
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Removing/installing
the spreader
It may become necessary to remove and install the spreader on
certain occasions. To do so proceed as follows:
1. Install trestles approximately 1.30 m (4 feet) off the ground to
accommodate the spreader assembly. Lower the spreader onto the
trestles.
2. Shut down the engine and remove the key from the ignition.
3. Disconnect the hydraulic lines at the quickfit unions and plug the
hoses to prevent dirt from entering.
4. Disconnect the electric cables and install the shunt plug.
5. Remove the four pins securing the rotor to the rotator head.
6. To install the spreader, perform the preceding steps in reverse
order.
7 - Check the position of the damping cylinder valves.
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Spreader damping
Spreader rocking is controlled by cylinders located on boom head..
The damping system is neutralized to keep spreader in a horizontal
position when boom hoisting.
When the boom hoisting function is stopped, damping is reactivated.
Damping Lock
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Notice
Operating and Maintenance Manual
The markers DANGER, WARNING and NOTE are used throughout this
manual to draw attention to instructions of critical importance.
In the context of their use in this manual, they have been defined as follows:
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Maintenance
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Maintenance
Regular maintenance of your machine will ensure longevity. We
therefore earnestly recommend that you follow the instructions given
in this chapter.
The general maintenance table gives indications of the essential
points to be observed, and the following pages gives some
instructions in connection with these operations.
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Levels of Maintenance
For each procedure described in this Manual, a maintenance level is
indicated.
This is given as an indication so as to serve as guide regarding the
importance of the operation.
This classification originates from the French NF X 60-010 Standard.
1st level:
Upkeep, change of accessible consumables, easy adjustments
without dismantling.
2nd level:
Lubrication and checking the sound operation, repairs through routine
replacement of elements provided for this purpose, carried out by an
accredited technician with basic qualifications.
3rd level:
Adjustments, diagnosis of breakdowns, repairs through changing of
components, minor repairs, carried out by a specialized technician, insitu or on maintenance premises.
4th level:
Important corrective and preventive maintenance works (except
renovation and reconditioning) carried out by a team comprising very
specialized technical supervision, in a specialized workshop.
5th level:
Renovation, reconditioning carried out, by definition, by the maker with
means practically similar to those of the manufacture.
The 1st Level corresponds to instructions given in the operating
and upkeep manual.
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Maintenance: general
A PPM SPECIALIST WILL SHOW YOU HOW TO OPERATE THE
MACHINE DURING INITIAL START UP. CARRY OUT THE FIRST
COMPLETE MAINTENANCE OF THE MACHINE WITH THE PPM
EXPERT, THEN REFER TO THE MAINTENANCE PROGRAMS
SHOWN IN THE FOLLOWING TABLES.
IN THE EVENT OF PROLONGED STORAGE OR USE AT A FIXED
SITE, IT IS IMPERATIVE TO CARRY OUT 500 HOURLY
MAINTENANCE AT LEAST EVERY 6 MONTHS, ESPECIALLY ON
THE FOLLOWING COMPONENTS:
ENGINE - AXLES - GEARBOXES - SUSPENSION - STEERING.
IMPORTANT:
The intervals shown in the following tables are applicable to
machines used under normal conditions.
For intensive use or under extreme conditions (heat - humidity dust) it is necessary to carry out maintenance more frequently.
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7
2
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c) Method
Recommended order for tightening slewing ring fasten
ers.
- Nut or bolt 1 and 2, then at 90, 3 and 4,
- Afterwards at 45, nut or bolt 5 and 6, then at 90,7
and 8,
- Finally, all the intermediate nuts or bolts.
(the number of nuts and bolts depends upon the type
of machine).
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d) Torque settings for slew rings screws and bolts.
Chart d1
Nominal torque setting (m.daN) according to
assembly type
* Includes an HV or HR washer or a spacer
dxp
Lg
Rference
Description
16x2
90
S 63338 94
23
100
F 19338 68
50
100
E 62338 32
110
T 19338 80
50
40
120
F 62338 33
50
40
125
J 19338 94
50
40
130
J 62338 13
50
40
20x1.50 140
G 19338 69
50
40
140
J 19338 71
145
40
50
50
50
50
C 19338 88
50
50
170
R 62338 20
50
50
200
F 19338 91
50
50
220
H 62338 35
50
50
130
K 19338 72
90
90
140
E 19338 90
140
L 19338 73
90
90
90
90
90
90
130
130
130
130
130
130
90
90
70
160
H 19338 70
170
D 19338 89
200
Q 62338 42
90
70
145
U 19338 81
130
95
145
N 19338 75
155
G 62338 57
160
P 19338 76
27x2.00 175
C 62338 53
190
Q 19338 77
190
H 62338 58
210
A 19338 86
130
130
250
B 19338 87
130
130
250
X 62338 95
130
95
33x2.00 220
F 02340 07
230
175
130
130
130
70
95
95
95
TEREX reserves the right to alter the information in this chart without notice.
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Chart d2
Minimum torque setting (m.daN) equal to 85% of
the nominal torque. Replacement necessary when
below this level.
* Includes an HV or HR washer or a spacer.
dxp
Lg
Rference
Description
16x2
90
S 63338 94
19
100
F 19338 68
42
100
E 62338 32
110
T 19338 80
42
34
120
F 62338 33
42
34
125
J 19338 94
42
34
130
J 62338 13
42
34
20x1.50 140
G 19338 69
42
34
140
J 19338 71
145
34
42
42
42
42
C 19338 88
42
42
170
R 62338 20
42
42
200
F 19338 91
42
42
220
H 62338 35
42
42
130
K 19338 72
76
76
140
E 19338 90
140
L 19338 73
76
76
76
76
76
76
110
110
110
110
110
110
76
76
59
160
H 19338 70
170
D 19338 89
200
Q 62338 42
76
59
145
U 19338 81
110
80
145
N 19338 75
155
G 62338 57
160
P 19338 76
27x2.00 175
C 62338 53
190
Q 19338 77
190
H 62338 58
210
A 19338 86
110
110
250
B 19338 87
110
110
250
X 62338 95
110
80
33x2.00 220
F 02340 07
195
148
110
110
110
59
80
80
80
TEREX reserves the right to alter the information in this chart without notice.
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Remark :
This operation is valid for all types of slewing ring fasteners, consult
the technical specifications for the corresponding torque values.
3 - Afterwards slewing ring fastener tightness must be checked every
500 hours. Tooling, verification conditions, method and torque values
a) Verify all the fasteners. Mark all fasteners with a torque value of
less than 85% of the nominal value.
greater than 20% of the total number, then all the ring fasten
ers must be changed.
USE ONLY ORIGINAL PPM SPARE PARTS
7
2
NB :
The slew ring must be replaced:
. If it has reached its maximum wear limit (see paragraph on Checking
slew ring wear).
. Following an expert report after an accident, incorrect use of the
crane, etc.
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5 - Retightening fasteners after their exchange :
Retightening of the slewing ring fasteners must be carried out
when :
fasteners have been exchanged,
the slewing ring has been exchanged, therefore a new set
of fasteners have been employed,
after an initial bedding-in period of 500 working hours.
Afterwards, periodic torque value verifications are to be carried
out every 2000 hours.
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We recommend that the clearances be gauged in order to determine
the condition of the slew ring. Wear on the raceways can be revealed
by tilting the upperstructure and measuring the changes in axial
clearance. The measurement must be made after the connection has
been checked (refer to the relevant paragraph).
Stackers:
-
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Take the measurement between the support frame and the slew ring
race bolted to the superstructure (see illustration).
The measurement must be taken as close as possible to the slew ring
to avoid any distortion caused by elastic deformation.
The measurement is to be repeated for each position marked on the
support frame, and the reference values are to be noted in a table like
Diagram showing tilting clearance
measurement.
Reference
measurement
0,5 0,7
New
measurement
Wear (1)
Measurement point
1
Measurement point
0,5 0,7
2
Measurement point
0,5 0,7
3
Measurement point
0,5 0,7
4
Checked by
Signature
Date
(1) Wear = New measurement Reference measurement
This measurement must be repeated in the exact same conditions as
the original measurement, 500 hours after the machine is put into
service and every 2,000 hours thereafter.
The difference between the last measurement readings and the
reference measurement denotes the extent of wear on the slew ring. If
the wear is growing at an increasingly faster rate, the checks will have
to be performed more frequently (e.g. every 1,000 or even 500 hours).
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Up to
20
22
25
30
35
40
45
50
60
70
1.4
1.4
1.5
1.7
1.9
2.1
2.5
1250
1.5
1.5
1.6
1.7
2.0
2.2
2.6
2.7
1.6
1.7
1.7
2.0
2.3
2.6
2.8
1750
1.7
1.8
2.1
2.3
2.7
2.9
3.0
2000
1.8
1.9
2.2
2.4
2.8
2.9
3.1
2250
2.0
2.3
2.5
2.9
3.0
3.2
2500
2.0
2.3
2.6
2.9
3.1
3.2
2750
2.4
2.6
3.0
3.2
3.3
3000
2.5
2.7
3.1
3.2
3.4
3250
2.6
2.8
3.2
3.3
3.5
3500
2.9
3.2
3.4
3.5
3750
3.0
3.3
3.5
3.6
4000
3.3
3.6
3.7
4500
3.5
3.8
3.9
5000
3.7
4.0
4.1
5500
3.9
4.2
4.3
6000
4.1
4.5
4.6
6500
4.6
4.7
7000
4.8
4.9
1500
We must be
contacted if the
difference between
the reference values
and the maximum
values that have
been measured is
higher than as
shown in the chart.
7500
5.1
8000
5.3
Bearing diameter
Ball diameter
Spreader stacker
980 mm
35 mm
ATT400/3 ATT400/3L
1272 mm
30 mm
ATT600/3
1491 mm
45 mm
Service intervals
It is essential for your machine to be regularly serviced.
The hour-meter mounted on your crane tells you when servicing
operations should be carried out. It should be consulted every day.
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The intervals are based on a 10 hour working day, 50 hours per week
and 2,000 hours per year
When carrying out these maintenance operations, tighten nuts,
bolts, etc. where required.
Hour-meter
Its electric control is actuated by engine oil pressure. It accumulates
hours exactly like a clock when the engine is running.
Preliminary operations
First of all clean grease fitting heads, plugs and periphery of filler ports
and level check sight-glasses. When lubricating, check condition of
seals and replace them if they are damaged or show signs of wear.
Quality of lubricants
It is essential that the correct lubricant for each application should be
employed.
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Storage
After several months' storage, check piping and tighten hydraulic
fittings.
Inspect the machine thoroughly.
Apply procedure
"BEFORE EVERY DAILY START UP"
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LUBRICATION CHART
COMPONENT
Cold climates
Temperate climates
Tropical climates
-25 +25
-15 +35
-5 +45
Boom chains
MOLYKOTE BR 2
MOLYKOTE BR 2
Grease nipples
ALVANIA EP2
MALLEUS GL 205
ALVANIA EP2
SPIRAX HD 80W90
SPIRAX HD 80W90
SPIRAX HD 85W140
OMALA EP VG220
OMALA EP VG220
Hydraulic fluid
TELLUS T 22
HYDRAU TP
(TELLUS T 46)
TELLUS T 68
or
SHELL NATURELLE
HF - E
(biodegradable)
Axle differential + reducer
units
SPIRAX HD 80W90
SPIRAX HD 80W90
SPIRAX HD 85W140
Engine
RIMULA X 10W30
RIMULA X 15W40
RIMULA X 20W40
Cooling circuit
GLYCOSHELL +
CLARK gearbox
RIMULA X 10W
RIMULA X 10W
RIMULA X 10W
DONAX TD
DONAX TD
DONAX TD
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PRIMARY
SAFETY
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- with the machine on level ground and all hydraulic rams retracted,
the level should be close to the level of tube 3/1
flammable.
Making up level:
through the filler tubes.
.
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Engine
Level check: every 10 hours
Capacity: Mini 26 L Maxi 38 L.
The dipstick on the Cummins engine is located on the right hand side.
The oil level must always be between the "LOW' and the "FULL"
marks on the dipstick. If the level is below the "LOW" mark, add oil by
the filler orifice.
CAUTION: Never run the engine when the oil level is below the "L"
mark (low), or when it is above the "F" (full) mark on the dipstick.
Hot oil can cause burns, so let the oil cool down sufficiently
before draining.
Refer to the Cummins Manual for further details.
Do not forget to screw back all
filler plugs properly.
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Capacity : 50L
Located on the right hand side of the machine.
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10 15 20 25 30 35 40 45 50 55 60 65
- 15C
- 20C
11 12 14 16 17 19 21 23
- 25C
10 12 14 16 18 20 22 24 26
- 30C
11 14 16 18 20 22 25 27 29
- 35C
10 12 15 17 20 22 24 27 29 32
11 12 13 15 16 18 19
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Density checking
WARNING: Battery Posts, terminals and related accessories
contain lead and lead compounds, chemicals known to the
State of California to cause cancer and reproductive harm.
Wash hands after handling.
Degrees Baum
Remarks
1.285
32
correctly charged
1.200
24
semi-charged
1.120
16
discharged
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Rear axle:
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4/ Slewing ring fastener tightening order recommendations:
Nut and bolt assemblies 1 and 2, then at 90, 3 and 4.
* Then at 45, fasteners 5 and 6, then at 90, 7 and 8.
* Lastly, the intermediate fasteners,
(the number of fasteners is variable depending on the slewing ring
model).
5) Play in the slewing ring and drive gear meshing.
* Position the zone of maximum eccentricity (blue coloured tooth
marked B or A depending on the supplier) in line with the slewing
motor pinion.
Minimum play: 0.1 mm
Maximum play: 0.3 mm.
NOTE: A 5 rotation of the eccentric ring corresponds approximately
to a clearance variation of 0.1 mm between teeth
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10 bar
1,800 x 33:
10 bar
2,100 x 25:
7.5 bar
Batteries
Keeping the batteries clean
Keep the top of the batteries dry to avoid current leaks
Remove the battery terminals and make sure they are not corroded or
sulphated. If they are, lightly scratch off the deposits and coat them
with neutral grease.
Moderately tighten the terminals.
Be careful when using spanners, so as not to touch the battery case
or battery bars.
Make sure there are no flames above the batteries.
Battery anchorages
Tighten the tension rods securing the batteries moderately,
compressing the springs to half their length, and tighten the locknuts.
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Engine
Oil change: every 250 hours
Replace oil filter
Check DCA units. If the level of concentration is lower than 3 units,
replace engine water filter cartridge. (Use a water filter cartridge of 15
DCA units. )
Check valve clearances.
Capacity: 38 L
On the CUMMINS engine, the dipstick is located on the right hand
side. The oil level must remain between the "LOW" and "FULL" marks
on the dipstick. If the level falls below the "LOW" mark, top up by the
filler orifice.
CAUTION: Never run the engine when the oil level is below the "L"
mark (LOW), or above the "F" mark (FULL) on the dipstick.
Hot hydraulic oil can cause serious burns, let the oil cool down before
making the oil change.
Please refer to the CUMMINS Manual for further details.
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Transmission
Replace the filter cartridge every 250 hours.
Check the level after fitting the new filter cartridges.
Catalytic converter
To clean the converter, loosen both ends and remove the central part.
No flanges to be unscrewed, no exhaust system to dismantle.
Furthermore, the honeycomb material of the converter has been
designed for minimum build up of solid and oily deposits. Less
stopping time is therefore required for cleaning.
Maintenance procedure:
1. Brush the surface on the intake side of the converter.
2. Air clean the surface on the outlet side of the converter.
3. Continue with steps 1 and 2 until the surface of the intake side is
clean.
4. Clean the converter with high pressure steam on the outlet side.
The nozzle should be 5 cm from the surface of the converter.
5. Air dry. Max. pressure 50 psi.
6. Refit the converter.
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Hydraulic tank
Hydraulic
circuit filter
Brake circuit
filter
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Transmission
Oil change: every 500 hours.
First oil change after 50 hours.
Oil capacity:41 l.
Oil temperature at between 65C (149F) and 90C (194F).
Change the oil when the engine is not running.
Replace the two oil filter cartridges and clean the filter cases.
Clean the strainer located in the lower section "LOW", prime the circuit
by running the engine at idling speed for 2 minutes while topping up
the level to the "LOW" mark.
Raise the oil temperature to between 65C (149F) and 90C (194F).
Complete topping up to the "FULL" mark with the engine at idling
speed.
Access: Level on the gearbox (wing-nut with FULL marked beside it).
Under carrier chassis, right-hand side.
Filling: by tube protruding at front, converter side.
Process of making up level:
Check oil level with engine idling and oil at a temperature between 82
and 93C.
Keep the level up to the FULL mark (higher level)
Replace filter cartridge: every 250 hours.
Check level after new cartridges have been fitted.
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Front axle
Differential unit
Level check: every 500 hours.
Do not forget to screw back all
The level should be flush with port R (filler and level check port).
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1st oil change: after 200-250 hrs or 1 month, replace filter cartridge if
clogged.
Oil change: every 1,000 hrs or 6 months. Replace filter cartridge each
time.
Brake circuit
filter
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Between changes, watch the clogging indicator on the instrument
panel. If this stays on, replace filter cartridge.
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The first oil change is made at 150 hours
Do not forget to screw back all
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Front axle
Differential unit
Level check: every 500 hours.
The level should be flush with port R (filler and level check port).
Oil change every 2,000 hours.
Drain by port V after having driven the machine a few minutes to raise
the oil temperature.
The drain plug is located underneath the front axle differential
housing.
Fill by port R.
ROCKWELL axle oil capacity: 44 L (12 US GALLONS)
KESSLER axle oil capacity: 77 L (20 US GALLONS)
Clean the breather located on the upper part of the housing.
Do not forget to screw back all
filler plugs properly.
NOTE: carry out the first oil change between 50 then 200 operating
hours.
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Note: Carry out the first oil changes between 50 and 200 operating
hours. After changing the oil, drive the machine for a few minutes at
low speed (2 km/h) and with no load in order to adequately lubricate
all internal components.
KESSLER axle
WARNING:
Before commencing work on the parking brake, ensure that no
unintended machine movement can happen when the braking
effect is removed. Danger to life!
DANGER:
The parking brake is under spring tension. Parts could become
loose and fly out suddenly if improper brake opening. Danger to
life!
Therefore release the lock nut (2) and turn the adjusting screw (3)
counter-clockwise until the spring set is released before
disassembly of the circlip (1)!
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Operating and Maintenance Manual
Rim check
CAUTION:
PPM recommends checking the rims by radioscopy every 2,000
hrs and each time the tyres are changed.
When removing a wheel, always deflate the tyre.
A pressure of 0.2 bar should never be exceeded.
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Brakes
Change brake accumulators.
This operation is not described in detail. Consult your PPM specialist
who has the inflation kit.
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Boom
Change the boom pads.
Change the anti-sway accumulator.
This operation is not described in detail. Consult your TEREX
specialist who has the inflation kit.
Check all the welded parts of the boom visually.
Spreader
Change the spreader pads.
Check for any play in the spreader slew ring.
To do this:
- take a container.
- install a comparator on the slew-ring in order to measure play in the
ring in relation to the spreaders chassis.
- set the comparator to zero.
- pivot the container sideways.
- take a reading from the comparator.
Play must be less than 3mm.
Change the slew-ring if play is greater than 3mm.
Replace the twist locks of the spreader.
Carry out a visual inspection of all the welded components of the
spreader.
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Tyres
Tyres
Front axle
Change the parking brake pads.
Chassis
Check of all the chassis welded parts visually.
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Maintenance log
Operating and Maintenance Manual
Maintenance log
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General identification
Type: . . . . . . . . . . . . . . . . .
Serial no.:. . . . . . . .
Commissioning date: . . / . . . .
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IMPORTANT:
The intervals given in the following tables are applicable to
equipment used under normal conditions.
For intensive use or under exceptional conditions (heat,
humidity, dust), servicing intervals should be reduced.
For all maintenance work, it is essential that the machine should
be supported with its outriggers fully extended on firm, flat, level
ground.
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Service intervals
It is essential for your machine to be regularly serviced.
The hour meter mounted on your crane tells you when servicing
operations should be carried out. It should be consulted every day.
The intervals are based on a 10 hour working day, 50 hours per week
and 2,000 hours per year
When carrying out these maintenance operations, tighten nuts,
bolts, etc. where required.
Hour meter
Its electric control is actuated by engine oil pressure. It accumulates
hours exactly like a clock when the engine is running.
Preliminary operations
First of all, clean grease fitting heads, plugs and periphery of filler
ports and level check sightglasses. When lubricating, check condition
of seals and replace them if they are damaged or show signs of wear.
Every precaution must be taken to protect the environment.
In particular, all liquids should be recovered and recycled.
Do not leave them in improperly labelled or open containers.
Do not permit any puddles of liquid on floors.
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General
Maintenance of the machine is conditioned by its operating
environment. The lists provided in the following pages show the points
to check and the intervals between each service.
NOTE:
The maintenance log provided takes into account the operating
conditions of the equipment. The type of work, size of loads and
climatic and ground conditions are also factors to be taken into
account. The servicing lists are given as a function of hours of
operation.
Any change in the servicing schedule must be preceded by a fresh
analysis of the operating conditions of the machine. Study the
maintenance log with care before making any change in service
intervals.
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Operating and Maintenance Manual
LUBRICATION CHART
COMPONENT
Cold climates
Temperate climates
Tropical climates
-25 +25
-15 +35
-5 +45
Boom chains
MOLYKOTE BR 2
MOLYKOTE BR 2
Grease nipples
ALVANIA EP2
MALLEUS GL 205
ALVANIA EP2
SPIRAX HD 80W90
SPIRAX HD 80W90
SPIRAX HD 85W140
OMALA EP VG220
OMALA EP VG220
Hydraulic fluid
TELLUS T 22
HYDRAU TP
(TELLUS T 46)
TELLUS T 68
or
SHELL NATURELLE
HF - E
(biodegradable)
Axle differential + reducer
units
SPIRAX HD 80W90
SPIRAX HD 80W90
SPIRAX HD 85W140
Engine
RIMULA X 10W30
RIMULA X 15W40
RIMULA X 20W40
Cooling circuit
GLYCOSHELL +
CLARK gearbox
RIMULA X 10W
RIMULA X 10W
RIMULA X 10W
DONAX TD
DONAX TD
DONAX TD
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DONE BY
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DONE BY
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Check front axle oil levels drive input unit and reduction gear units
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(CONT'D)
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Lubrication
Manuel de conduite et d'entretien
Fuel - lubricants
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Lubrication
Manuel de conduite et d'entretien
Component capacities
Engine CUMMINS QSM 11:
Min. 26 L Max. 38 L
CLARK gearbox:
41 L
Fuel tank:
520 L
720 L
1,100 L
30 L
50 L
45 L
TRASMITAL
Slewing reduction gear:
2.8 L
DINAMIC OIL
Slewing reduction gear:
2L
Brake:
0.2 L
TRASMITAL
Telescoping reduction gear:
2.8 L
DINAMIC OIL
Telescoping reduction gear:
2L
Brake:
0.3 L
K-62440-49
44 L
Reduction gear:
11 L x 2
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Lubrication
Manuel de conduite et d'entretien
KESSLER front axle:
Drive pinion carrier:
77 L
Reduction gear:
14 L x 2
10 bar (145
psi)
MICHELIN X MINE D2 1800 x 25
MICHELIN X K D1 B 1800 x 25
psi)
BRIDGESTONE 2100 x 25
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Manuel de conduite et d'entretien
Filter elements
Engine oil filter cartridge, QSM11:
Fuel filter cartridge, QSM11:
T-64505-51
S-64505-50
V-64505-53
B 61505-92 Qty 2
W 61505-88
C 61505-93
D 61505-94
W-27505-90 Qty 2
W-27505-90 Qty 1
Alternator belt:
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