Terex RT500-1 User manual

Introduction ...................................................................................................... 5
Construction and Industrial Equipment Product Safety ........................... 5
Alert System.............................................................................................. 6
Nomenclature............................................................................................ 7
Safety ............................................................................................................... 9
Safety Introduction.................................................................................... 9
General Safety......................................................................................... 10
Safety Sign Maintenance ................................................................. 10
Safety Sign Locations ...................................................................... 11
Workplace Safety .................................................................................... 19
Personal Safety ....................................................................................... 26
Assembly........................................................................................................ 27
Step Installation ...................................................................................... 27
Spooling Wire Rope on Drums................................................................ 28
Hoist-Line Reeving.................................................................................. 32
Cable Reeving......................................................................................... 35
Side Stow Jib .......................................................................................... 36
Description Of Machine and Controls ............................................................ 41
Universal Symbol Identification............................................................... 41
Upper Controls and Instruments............................................................. 44
Inspection....................................................................................................... 57
Pre-Start Inspection ................................................................................ 57
Wire Rope Inspection Record ................................................................. 61
Crane Boom ............................................................................................ 62
Operating Instructions.................................................................................... 65
General Operational Issues..................................................................... 65
Operator Shutoff Devices ................................................................ 65
Rated Capacity Indicator ................................................................. 67
Operating the Unit................................................................................. 108
Starting the Engine ........................................................................ 108
Cold Weather Starting ................................................................... 109
Jump-Starting an Engine with Booster Cables.............................. 110
Operating the Engine ..................................................................... 111
Making a Typical Lift ...................................................................... 112
Arm and Hand Signals ................................................................... 118
Load Rating Chart Interpretation ................................................... 120
"On-Tires" Lift ................................................................................ 129
Unusual Operating Conditions.............................................................. 131
Table of Contents
REVISED: i

Moving the Unit..................................................................................... 135
Vehicular Operation ....................................................................... 135
Traveling around the Jobsite ......................................................... 138
Transportation .............................................................................................. 139
Transporting the Crane ......................................................................... 139
Maintenance................................................................................................. 141
Lubrication Chart .................................................................................. 141
Maintenance Introduction ..................................................................... 142
Machine Maintenance Checklist ........................................................... 143
Engine Maintenance.............................................................................. 146
Engine Radiator Maintenance ............................................................... 148
Transmission Maintenance ................................................................... 149
Axle Maintenance.................................................................................. 151
Tire Maintenance................................................................................... 153
Air System Maintenance ....................................................................... 157
Brake System........................................................................................ 159
Turntable and Swing Pinion .................................................................. 162
Swing Reducers .................................................................................... 164
Hydraulic System Maintenance ............................................................ 165
Hydraulic Oil Requirements .................................................................. 170
Cable Lubrication Methods................................................................... 177
Electrical System Battery Check........................................................... 181
Electrical System Collector Ring........................................................... 185
Wire Rope and reeving.......................................................................... 186
Air Dryer ................................................................................................ 188
Slider Pads............................................................................................ 189
Storage.................................................................................................. 190
Machine Storage............................................................................ 190
Engine Storage .............................................................................. 192
Transmission Storage .................................................................... 195
Restoration to Service ................................................................... 196
Restoring Engine to Service........................................................... 197
Restoring Transmission to Service ................................................ 198
Chrome Cylinder Rod Storage....................................................... 199
Specifications............................................................................................... 201
Wire Rope Specifications...................................................................... 201
Troubleshooting ........................................................................................... 203
General Procedure ................................................................................ 203
RT500
Contents
ii REVISED:

Hydraulic - General ............................................................................... 204
Operator Controls ................................................................................. 205
Axles...................................................................................................... 206
Steering Circuit ..................................................................................... 207
Alternator............................................................................................... 211
Starter ................................................................................................... 212
Brakes ................................................................................................... 213
Parking Brake........................................................................................ 214
Air Pressure........................................................................................... 215
Swing Circuit ......................................................................................... 216
Boom Hoist Circuit................................................................................ 217
Boom Telescope Circuit........................................................................ 218
Winch Circuit......................................................................................... 219
Outrigger Circuit.................................................................................... 221
Pumps ................................................................................................... 222
Control Valves ....................................................................................... 226
Relief Valves.......................................................................................... 227
Fluid Motor............................................................................................ 228
Cylinders ............................................................................................... 229
Cylinder Leakage .................................................................................. 230
Excessive Heating of Oil In Circuit ........................................................ 232
Electrical Controls ................................................................................. 233
Propane Heater ..................................................................................... 234
Maintenance Free Battery Testing ........................................................ 238
Anti Two Block System ......................................................................... 240
Service / Parts .............................................................................................. 243
Valve Adjustments................................................................................. 243
Swing Relief Valve Adjustment ............................................................. 249
Rotary Manifold..................................................................................... 250
Steering Priority Valve Adjustment........................................................ 253
Boom Alignment and Adjustment ......................................................... 255
Boom Chain Adjustment ....................................................................... 259
Axle Lockout System ............................................................................ 263
Swing Brake Control Adjustment.......................................................... 265
Ring Gear Bolting Sequence................................................................. 268
Torque Wrench Extensions ................................................................... 270
Welding Instructions ............................................................................. 272
Hydraulic Cylinders ............................................................................... 274
REVISED: iii

Wire rope and reeving ........................................................................... 278
Cable Sockets....................................................................................... 283
Applicable Standards / Regulations............................................................. 287
Wire Rope Users Manual ...................................................................... 287
Appendix ...................................................................................................... 347
Conversion Tables ................................................................................ 347
Average Weight of Materials ................................................................. 351
Suggested Torque ratings..................................................................... 354
RT500
Contents
iv REVISED:

Construction and Industrial Equipment Product Safety
It is the responsibility of the owner of the construction and industrial equipment products to
be knowledgeable about federal, state and local regulations that effect the total usage of
his equipment, and responsibility to working personal and the public. Since regulations are
subject to change, and also differ from one local to another, this manual makes no attempt
to provide such information.
Terex Cranes provides appropriate operation and maintenance manuals for various
construction and industrial equipment products that it manufactures and sells. In addition,
where applicable, appropriate national consensus standards, industry standards and safety
related manuals are included with the Terex manuals in the shipment of each product. It is
company policy to provide this information for the owner or user of the equipment. It is
expected that the owner or user will utilize these manuals and standards to provide the
appropriate information and training to those people who are to operate, maintain and
supervise the use of equipment in a proper and safe manner.
Construction and industrial equipment is designed and manufactured to perform heavy-
duty work. Under normal usage, the equipment will wear. For this reason it is essential that
the owner/user establish and perform a periodic inspection of the equipment. The objective
of inspection programs is to prevent accidents, reduce downtime and keep the equipment
working efficiently. These inspection programs should be designed to discover worn,
cracked, broken or deteriorated parts and loose or missing fasteners before they result in a
problem.
Proper training and inspection programs are essential to avoiding injury to persons,
damage to property and excessive maintenance costs.
Read and understand the manuals provided with this equipment. Assistance is available
from the distributors of your Terex product and from the Terex manufacturing facility.
When operating a hydraulic crane, the operator should realize that hydraulic and
structural competence, NOT TIPPING LOAD, is often the determinant of lifting
capacity. Therefore, THE OPERATOR MUST BE GUIDED SOLELY BY THE
APPROPRIATE MANUFACTURER’S LOAD RATING CHART when considering
load weights. The manufacturers rated loads must never be exceeded.
Follow the recommended operating and maintenance procedures and keep your machine
operating at MAXIMUM EFFICIENCY. Use the Suggested Crane Periodic Inspection Check
List provided. In addition, we STRONGLY URGE that a MAINTENANCE LOG be kept in
conjunction with all maintenance performed on the machine.
If you desire any special information regarding the care and operation of the machine, we
will gladly furnish it upon request. Because we build various types of equipment, we ask
that you include your machine model and serial number in all correspondence so that we
can provide the correct information.
The information, specifications, and illustrations in this publication are based on the
information in effect at the time of approval for printing. We reserve the right to make
changes at any time without obligation.
Introduction
5REVISED:

Alert System
The symbols below are used to inform the operator of important information concerning the
operation of this unit.
DANGER - Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING - Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION - Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
ATTENTION - Indicates a situation which, if not avoided, may result in property or
equipment damage.
RT500
Introduction
6REVISED:

Nomenclature
This manual contains instructions and information on the operation, maintenance,
lubrication and adjustments of the Rough Terrain Crane. The operator should not attempt
to operate the machine before he has gained a thorough understanding of the material
presented in the following pages.
To aid in understanding the contents of this manual, the following terms will always have
the meanings given whenever they are used.
1. UPPERSTRUCTURE The upperstructure weldment, swing
mechanism, counterweight, hydraulic winch,
cab.
2. BOOM ATTACHMENT The telescopic crane boom with lift cylinder,
hook block assembly, jib arrangement.
3. CARRIER The chassis complete, power unit, swing
bearing, transmission, planetary axles,
outrigger assemblies.
4. OUTRIGGERS The beams, cylinders, floats, boxes,
hydraulic control system.
RIGHT HAND/LEFT HAND All references to right or left hand will
correspond to the operator’s right or left
hand when he is facing forward from the
operator’s seat, with the rear mounted
engine to his back.
7REVISED:

Safety Introduction
Owners, Users, and Operators:
Terex Cranes appreciates your choice of our machine for your application. Our number one
priority is user safety, which is best achieved by our joint efforts. We feel that you make a
major contribution to safety if you as the equipment users and operators:
1. Comply with OSHA, Federal, State, and Local Regulations.
2. Read, Understand, and Follow the instructions in this and other manuals supplied with
this machine.
3. Use Good, Safe Work Practices in a common sense way.
4. Only have trained operators - directed by informed and knowledgeable supervision -
running the machine.
NOTE: OSHA prohibits the alteration or modification of this crane without written
manufacturer's approval. Use only factory approved parts to service or repair this
unit.
If there is anything in this manual that is not clear or which you believe should be added,
please send your comments to Technical Publications Coordinator, Terex Cranes, 106 12th
Street SE, Waverly, Iowa 50677; or contact us by telephone at [phone].
THIS SYMBOL MEANS YOUR SAFETY IS INVOLVED! READ, UNDERSTAND,
AND FOLLOW ALL DANGER, WARNING, AND CAUTION DECALS ON YOUR
MACHINE.
Many aspects of crane operation and testing are discussed in standards published by the
American National Standards Institute. These Standards are updated on an annual basis
with addendas, which are sent by ASME to the original purchasers of the standard. Terex
recommends that you purchase and refer to the following standards.
ANSI/ASME B30.5 - Mobile & Locomotive Crane (Latest Version)
These standards can be purchased from:
American Society of Mechanical Engineers
Information Central Orders/Inquiries
P.O. Box 2300
Fairfield, NJ 07007-2300
800-843-2763
Email: [email protected]
Safety
9REVISED:

General Safety
Safety Sign Maintenance
Replace any missing or damaged safety signs. Keep operator safety in mind at all times.
Use mild soap and water to clean safety signs. Do not use solvent-based cleaners because
they may damage the safety sign material. The graphics on the following pages illustrate
the location and give you examples of each safety decal located on your machine. During
the daily inspection of the equipment, check that the decals are present and in good condition.
RT500
Safety
10 REVISED:

Safety Sign Locations
1
2
34
11REVISED:

RT500
Safety
12 REVISED:

5 6
78
13REVISED:

RT500
Safety
14 REVISED:

9
10
11
12
15REVISED:

13
14
15
16
RT500
Safety
16 REVISED:

17REVISED:

17 18 - Inside Battery Box
19 - Inside Battery Box
20
RT500
Safety
18 REVISED: