Terex RT700 User manual

Issued: July 2003
It is the responsibility of the owner of the construction and in-
dustrial equipment products to be knowledgeable about fed-
eral, 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 mainte-
nance manuals for various construction and industrial equip-
ment 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 appro-
priate information and training to those people who are to op-
erate, maintain and supervise the use of equipment in a proper
and safe manner.
Construction and industrial equipment is designed and man-
ufactured 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 pre-
vent accidents, reduce downtime and keep the equipment
working efficiently. These inspection programs should be de-
signed 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 equip-
ment. Assistance is available from the distributors of your
Terex product and from the Terex manufacturing facility.
CONSTUCTION AND INDUSTRIAL EQUIPMENT
PRODUCT SAFETY
When operating a hydraulic crane, the operator should realize that hydraulic and
structural competence, NOT TIPPING LOAD, is often the determinant of lifting ca-
pacity.
Therefore, THE OPERATOR MUST BE GUIDED SOLELY BY THE APPROPRI-
ATE MANUFACTURER’S LOAD RATING CHART when considering load
weights. The manufacturers rated loads must never be exceeded.
Follow the recommended operating and maintenance proce-
dures and keep your machine operating at MAXIMUM EF-
FICIENCY. 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 re-
quest. Because we build
various types of equipment, we ask that you include your ma-
chine model and serial number in all correspondence so that
we can provide the correct information.
The information, specifications, and illustrations in this pub-
lication 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.

Issued: July 2003
ITEMS TO BE
INSPECTED
& CHECKED
INSPECTION
CODE
SATISFACTORY
ADJUST
REPAIR
VISUAL INSPECTION H
(Complete Machine) D
OVERALL
CLEANLINESS D
HYDRAULIC SYSTEM
(Leaks or Damage) D
AIR SYSTEM
(Leaks or Damage) D
HYDRAULIC
FLUID D
AXLE LOCKOUT
SYSTEM D
TRANSMISSION
FLUID LEVEL D
ENGINE CRANKCASE
FLUID LEVEL D
FUEL TANK
FLUID LEVEL D
RADIATOR
FLUID LEVEL D
MACHINE
LUBRICATION D
ATTACHMENT
PIN BOLTS D
MUFFLER/EXHAUST
SYSTEM D
ALL CONTROL
MECHANISMS D
INSTRUMENT
GAUGES D
CLUTCHES
& BRAKES D
WIRE ROPE, SHEAVES
& GUARDS D
TWO BLOCK DAMAGE
PREVENTION SYSTEM D
LOAD SUPPORTING
COMPONENTS CONDITION D
FIRE EXTINGUISHER D
BACKUP ALARM D
ITEMS TO BE
INSPECTED
& CHECKED
INSPECTION
CODE
SATISFACTORY
ADJUST
REPAIR
BOOM ANGLE
INDICATOR D
HEAD/TAIL/BRAKE LIGHTS
& 4 - WAY FLASHERS D
HORN D
CABLE SPOOLING
PROPERLY D
WEDGE
SOCKETS D
AXLE FLUID
LEVEL W
SWING REDUCER
FLUID LEVEL W
DRIVE SHAFTS
& U JOINTS W
TIRE & WHEEL CONDITION &
INFLATION PRESSURE W
AIR
REGULATORS W
AIR CLEANER
ELEMENT W
CLUTCH & BRAKE
LINKAGE & PINS W
WHEEL LUG
NUT TORQUE W
FAN BELT
TENSION W
STRUCTURAL MEMBERS &
WELDS W
BOOM INSPECTION W
BATTERIES &
STARTING SYSTEM M
ALCOHOL
EVAPORATOR M
SWING BEARING
BOLT TORQUE P
MACHINERY
GUARDS P
LOAD CHART &
SAFETY WARNINGS P
SUGGESTED ROUGH TERAIN CRANE INSPECTION CHECK LIST
This check list is to be used in addition to the information provided in this manual to properly operate and maintain the
machine.
HInspect OVERALL machine (including carrier) for cracks, weld separation, leaks, damage, vandalism.
INSPECTION CODE INTERVALS
D - DAILY M - MONTHLY
W - WEEKLY P - PERIODIC
NOTES:
1. Indicate inspection result by checking in the satisfactory, adjust, or repair boxes provided.
2. When appropriate, enter your diagnosis on back of page for repairs or adjustments made.
Issued: July 2003

Issued: July 2003
REPAIRS - ADJUSTMENTS - REMARKS
ITEM REQUIREMENT DATE

Issued: July 2003
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
1. UPPERSTRUCTURE
2. BOOM ATTACHMENT
3. CARRIER
4. OUTRIGGERS
RIGHT HAND/LEFT HAND
understanding of the material presented in the following
pages.
To aid in understanding the contents of this manual, the fol-
lowing terms will always have themeanings given whenever
they are used.
The upperstructure weldment, swing mechanism, counter-
weight, cab.
The telescopic crane boom with hydraulic winch, lift cylin-
der, hook block assembly, jib arrangement.
The chassis complete, power unit, swing bearing, transmis-
sion, planetary axles, outrigger assemblies.
The beams, cylinders, floats, boxes, hydraulic control sys-
tem.
All references to right or left hand will correspond to the op-
erator’s right or left hand when he isfacing forward from the
operator’s seat, with the rear mounted engine to his back.
NOMENCLATURE
4
4
1
2
3
RT775

SAFETY
INDEX
SECTION 1
SUBJECT PAGE
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
Handling Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Training and Knowledge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Operator’s Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
Signal Person’s Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Responsibilities of All Crew Members . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Management Responsibilty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Planning The Job. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
Operator’s Safety Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
Operator Aids Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
Operation Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9
Operation Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10
Power Line Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10
Slip and Fall Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
Travel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
Issued: July 2003

Issued: July 2002 Page 1-1
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
manufacturers 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].
Thank you!
THIS SYMBOL MEANS YOUR SAFETY IS INVOLVED!
READ, UNDERSTAND, AND FOLLOW ALL DANGER,
WARNING, AND CAUTION DECALS ON YOUR
MACHINE.
!

Issued: July 2002Page 1-2
INTRODUCTION
The symbols below are used to inform the operator of important information concerning
the operation of this unit.
SYMBOLS
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.

Issued: July 2002 Page 1-3
!
SAFETY
These are general safety rules, which must be followed. You are
also required to read and understand the Operators Manual as
there are instructions, which are more detailed specific to this
machine.
HANDLING PERSONNEL
!
TRAINING AND KNOWLEDGE
!
1. Cranes can only be used to lift people when it is the least hazardous way to do
the job. (See OSHA 1926.550g, and ASME / ANSI B30.23.)
1. Safety must always be the operators most important concern.
2. Do not operate this crane until you have been trained in its operation. This
crane must only be operated by trained personnel, who have demonstrated their
ability to do so safely.
3. Comply with the requirements of current Occupational Safety and Health
Administration (OSHA) standards, the current American National Standards
Institute (ANSI) B30.5 latest edition.
4. Read and Understand all Decals and Warnings.
5. Read and Understand the Rating Chart.
6. Know that the crane can safely lift each load before attempting to lift.

Issued: July 2002Page 1-4
7. Operator must understand crane signals and take signals only from designated
signal people; except the operator must obey the stop signal from anyone.
1. Read and understand the Operator's Manual.
2. Make sure the machine is in proper order and that all operational aids and
warning signals are functional before operating.
3. Keep the machine clean, including all instrumentation, windows, lights and
other glazed surfaces.
4. Remove all oil, grease, mud, ice and snow from walking surfaces.
5. Store tools and other necessary items in the tool box.
6. Never lift a load without a Rating Chart Manual in the cab.
7. Know the load to be lifted.
8. Be alert, physically fit and free from the influences of alcohol, drugs or
medications that might affect the operators eyesight, hearing, or reactions.
9. Keep people, equipment and material out of the work area.
10. Signal person must be used when the operators vision is blocked or working in
hazardous areas such as power lines or people.
11. 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.
12. Know about movements of other machinery, trucks and personnel at the
jobsite.
13. Never permit people on the machine platform while the machine is working.
OPERATOR’S RESPONSIBILITIES
!

Issued: July 2002 Page 1-5
14. Make sure everyone is in a safe place before moving the hook, boom, load or
outriggers.
15. Start and stop movements smoothly and swing at speeds that will keep the load
under control.
16. Keep at least two full wraps of wire rope on drum when operating.
17. Feet must be kept on the pedals while foot pedal brake locks are in use.
18. Use tag lines to keep loads under control.
19. Keep load close to ground.
20. Use shortest boom possible.
21. Never leave a running machine unattended or load suspended.
22. Always use outriggers in accordance with requirements of Load Rating Chart
and operators manuals.
1. Standard crane signals must be used, and understood.
2. Assist the operator in safe and efficient operation, without endangering people
or property.
3. Have a clear understanding of the work to be done.
4. Signal people must place themselves where they can be clearly seen and where
they can safely observe the entire operation.
SIGNAL PERSON’S RESPONSIBILITY
!

Issued: July 2002Page 1-6
RESPONSIBILITIES OF ALL CREW MEMBERS
!
MANAGEMENT RESPONSIBILITY
!
1. Unsafe conditions or practices must be corrected.
2. Obey all warning signs.
3. Watch out for your safety and the safety of others.
4. Know and understand proper machine erection and rigging procedures.
5. Alert operator and signal person of dangers, such as power lines, unstable
ground etc.
1. Operator's must be competent, physically fit and if required licensed.
2. Operator, signal people and riggers must be trained in correct crane operation
and use.
3. Operator and Signal people must know standard crane signals.
4. Have a supervisor at job site to be responsible for job safety.
5. Crew members given specific safety responsibilities and instructed to report
any unsafe conditions to supervisor.
6. Supply the weight on the load to be lifted to the operator.
7. Verify that all crew members are familiar with OSHA, ANSI B30.5
requirements as well as instructions in manuals.

Issued: July 2002 Page 1-7
PLANNING THE JOB
!
1. Have a clear understanding of work to be done.
2. Consider all dangers at jobsite.
3. Know what crew members are needed?
4. Assign responsibilities.
5. Know the weight of load to be lifted.
6. Determine lift radius, boom angle, and the rated lifting capacity of crane.
7. Establish how signal people will communicate with operator?
8. Utilize equipment which will do job safety.
9. Establish how equipment can be safety transported to job site?
10. Determine where gas lines, power lines, or structures are which must be
moved.
11. Ensure that surface is strong enough to support machine and load.
12. Determine how load will be rigged.
13. Establish special safety precautions, if necessary.
14. Consider weather conditions.
15. Keep unnecessary people and equipment away from work place.
16. Position machine to use shortest boom and radius possible.

Issued: July 2002Page 1-8
OPERATOR’S SAFETY CHECK
!
1. Safety related items must be in place.
2. Check machine log book, to see if periodic maintenance and inspections have
been performed.
3. Ensure that necessary repairs have been completed.
4. Inspect wire rope for damage (kinks, broken wires etc.)
5. Be sure no unauthorized field modifications have been made.
6. Check for air and hydraulic oil leaks.
7. Check control positions before starting engine.
8. After starting engine, check all gauges and indicators for proper readings.
9. Test all controls.
10. Check brakes and clutches.
11. Check load brakes by lifting a load a few inches off the ground and holding it.
OPERATOR AIDS CHECK
!
Ensure that the listed items are in place and operational.
1. Boom hoist upper angle limit switch. (Lattice Boom).
2. Boom angle indicator.
3. Backup Alarms.
4. Anti-Two Block devices.
5. Overload Protection, Load Indicators, Rated Capacity Limiters

Issued: July 2002 Page 1-9
OPERATION OVERLOAD PREVENTION
!
1. Know the weight of the load.
2. Load radius will increase when the load is lifted. Reduce radius at start of lift
to allow for this.
3. Know the weight of hook, and rigging.
4. Know boom length, jib length, parts of line and operating area.
5. Use next lower rated capacity when working at boom lengths or radius
between the figures on the rated lifting capacity chart.
6. Never lift a load without knowing whether it is within the rated capacity.
7. Never operate with anything other than recommended counterweight.
Unauthorized reduction or additions of counterweight constitute a safety
hazard.
8. Do not lift loads if winds create a hazard. Lower the boom if necessary. See
the Rating Chart Manual for possible restrictions.
9. Avoid side loading.
10. Never let the load or any other object strike the boom.
11. Release load slowly, be sure boom never tightens against back stops. (Lattice
Boom).
12. Place the boom point directly above the load when lifting.
13. Be sure loads are freely suspended.

Issued: July 2002Page 1-10
POWER LINE SAFETY
!
1. Be sure the load bearing surface is strong enough to support the machine and
load.
2. Be sure cranes are level, check frequently and relevel when necessary.
3. Stay away from rotating cranes, erect barricades to keep people away. Make
sure these area's are clear before swinging.
1. Determine whether there are power lines in the area before starting any job.
Only operate around power lines in accordance with Federal, State and Local
Regulations as well as ANSI B30.5 latest edition.
2. Never remove materials from under powerlines with a crane if the boom or
machine is capable of contacting them.
3. No part of crane or load must come in contact with, or violate the minimum
allowable clearance required for operation of crane dear electrical lines.
4. Should contact occur stay on crane until the boom is cleared or until the current
is turned off.
5. If in contact keep all personnel off the crane. If you must leave the crane,
JUMP, DO NOT STEP OFF, leave area by jumping with feet together.
6. Use a signal person when working around power lines.
OPERATION SETUP
!

Issued: July 2002Page 1-11
TRAVEL
!
1. Always wait until machine has stopped before getting on and off equipment.
Do not jump on or off.
2. Do not use controls and steering wheel as hand holds.
3. Keep the machine clean and dry.
4. Replace all broken ladders.
5. Keep non-slip surfaces in good condition.
1. Care must be taken when cranes are driven (traveled) whether on or off the job
site.
2. Watch for people, power lines, low or narrow clearance, bridge or road load
limits, steep hills or uneven terrain.
3. Position boom in line with the direction of travel.
4. Inflate tires to specified pressure.
5. Travel slowly and avoid sudden stops and starts.
6. It is recommended that the seat belt be used during transit and travel.
7. Make sure travel surface can support weight of machine and load.
8. Always set parking brakes when parking machine.

CONTROLS AND INSTRUMENTS
Revised: April 2005
INDEX
SECTION 2
SUBJECT PAGE
Universal Symbol Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
Upper Controls & Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4
Upper Controls & Instruments Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
Upper Controls & Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6

CONTROLS AND INSTRUMENTS
Diagrams of the various carrier and upper controls are
illustrated on the following pages. A list of these con-
trols and instruments are shown opposite each illustra-
tion. More detailed explanations of each control or
instrument follow in the same order as they appear in
the number key.
This section is intended to familiarize the operator with
the controls and instruments provided for the operation
of this machine. It should be emphasized, however,
that merely knowing the controls is inadequate prepa-
ration for operating hydraulic cranes. Do not attempt to
operate the machine until the other sections of this
manual have been covered. Sections 1 and 3 are es-
pecially important with respect to machine operation.
UNIVERSAL SYMBOL IDENTIFICATION
RT700 Revised: April 2005Page 2 - 1
HEADLIGHTS
BEACON
VOLTAGE
SWING LOCKED
LOW OIL
PRESSURE
FUEL
EMERGENCY
STOP
WATER
TEMPERATURE
ENGINE
OIL PRESSURE
PARKING LIGHTS
STANDARD
STEER
4 WHEEL
STEER
CRAB
STEER
REAR STEER
LEFT
REAR STEER
RIGHT
DEFROST
TURN SIGNAL
INDICATOR
SWING
SWING
BRAKE
FAST
SLOW
HORN
WINCH
PARKING BRAKE

CONTROLS AND INSTRUMENTS
UNIVERSAL SYMBOL IDENTIFICATION (cont.)
RT700 Revised: April 2005Page 2 - 2
AXLE ENGAGE /
RANGE SHIFT
HEATER/AC
HEAT
HEATER/AC
AC
SWING
LEFT
SWING
RIGHT
OUTRIGGER
EXTEND
OUTRIGGER
RETRACT
AXLE DISENGAGE /
RANGE SHIFT
BOOM
DOWN
BOOM
UP
BOOM
IN
BOOM
OUT
ELECTRICAL
ACCESSORIES
ON
ELECTRICAL
SYSTEM OFF
ELECTRICAL
SYSTEM ON
IGNITION ON
IGNITION
OUTRIGGER
SELECT
TRANSMISSION
PRESSURE
TRANSMISSION
TEMPERATURE
AIR
PRESSURE WINDSHIELD
WASHER
WINDSHIELD
WIPER
HAZARD
LIGHTS
HEATER/AC
FAN
ENGINE
QUICK START