Terex MAC 25-4 SL User manual

25t FRANNA Superlift Crane –Ancillary Equipment
Ancillary Equipment
Brick Cage Materials Cage Sully box
Pallet Forks Dog Box Machinery Head Hook

Terex Australia Pty. Ltd.
ABN : 86 010 671 048
E-Mail : [e-mail]
MODEL MAC 25-4 SL
RATED CAPACITY MANUAL
Book Part Number: T139154D
HYDRAULIC MOBILE ARTICULATED PICK & CARRY CRANE
25 tonne MAXIMUM RATED CAPACITY
16.6 tonne REAR AXLE WEIGHT
Do not operate this crane unless you have read
and understood the information in this book.

CONTENTS
WARNINGS............................................................................................. 3
OPERATIONAL NOTICE .......................................................................................3
ATTACHMENT NOTICE ........................................................................................3
DEFINITIONS ..........................................................................................4
SPECIAL PRECAUTIONS FOR ARTICULATED CRANES ....................5
GENERAL ...................................................................................................5
SET-UP ...................................................................................................5
OPERATION ...................................................................................................6
LIFT AND CARRY OPERATION............................................................................7
OPERATION ON SIDE SLOPES.............................................................8
SPECIFICATIONS...................................................................................9
CRANE CONFIGURATION ...................................................................11
RATED CAPACITY CHARTS................................................................12
001: NO COUNTERWEIGHT –WINCH...............................................................13
101: FRONT COUNTERWEIGHT - WINCH.........................................................14
102: FRONT COUNTERWEIGHT - RHINO HOOK..............................................15
105: FRONT COUNTERWEIGHT - FLYJIB (3m) - 0OOFFSET ..........................16
106: FRONT COUNTERWEIGHT - FLYJIB (3m) - 12.5OOFFSET......................16
109: FRONT COUNTERWEIGHT - MANBASKET...............................................17
110: FRONT COUNTERWEIGHT - FIXED LUG..................................................17
111: FRONT COUNTERWEIGHT - INNER LUG (L1)..........................................18
112: FRONT COUNTERWEIGHT - OUTER LUG (L2) ........................................19
201: REAR COUNTERWEIGHT - WINCH...........................................................20
202: REAR COUNTERWEIGHT - RHINO HOOK................................................21
205: REAR COUNTERWEIGHT - FLYJIB (3m) - 0OOFFSET.............................22
206: REAR COUNTERWEIGHT - FLYJIB (3m) - 12.5OOFFSET........................22
209: REAR COUNTERWEIGHT - MANBASKET.................................................23
210: REAR COUNTERWEIGHT - FIXED LUG ....................................................23
211: REAR COUNTERWEIGHT - INNER LUG (L1) ............................................24
212: REAR COUNTERWEIGHT - OUTER LUG (L2)...........................................25
301: REAR SL COUNTERWEIGHT - WINCH......................................................26
302: REAR SL COUNTERWEIGHT - RHINO HOOK...........................................27
305: REAR SL COUNTERWEIGHT - FLYJIB (3m) –0OOFFSET.......................28
306: REAR SL COUNTERWEIGHT - FLYJIB (3m) –12.5OOFFSET.................28
309: REAR SL COUNTERWEIGHT - MANBASKET............................................29
310: REAR SL COUNTERWEIGHT - FIXED LUG...............................................29
311: REAR SL COUNTERWEIGHT - INNER LUG (L1).......................................30
312: REAR SL COUNTERWEIGHT - OUTER LUG (L2) .....................................31
AFTERMARKET CONTACTS LIST....................................................... 32
NOTE: ALL PAGES MUST BE INCLUDED IN THIS BOOK.
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WARNINGS
OPERATIONAL NOTICE
IMPROPER CRANE USE, CARE OR OPERATION
CAN CAUSE INJURY, DEATH OR PROPERTY
DAMAGE.
DO NOT OPERATE THIS MACHINE UNLESS YOU
HAVE READ AND UNDERSTAND THE OPERATOR’S
MANUAL AND CRANE RATED CAPACITY MANUAL.
COPIES OF OPERATOR’S MANUALS AND CRANE RATED CAPACITY
MANUAL MAY BE OBTAINED FROM:
ATTACHMENT NOTICE
WRITTEN AUTHORISATION IS REQUIRED FROM
TEREX AUSTRALIA PTY LTD PRIOR TO THE USE OF
ANY ATTACHMENT NOT SPECIFIED IN THE MANUAL.
T139154-D
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DEFINITIONS
Articulation – The crane pivots in the middle to allow steering and slewing of the
load. Up to 40Articulation is possible in either direction. See Working Area diagram
Deration – A decrease in the Rated Capacity due to external influences, expressed as
a percentage.
Freely Suspended Load – Load hanging free with no direct external force applied
except by the winch rope.
Gradient: Generalised slope of ground measured as a percentage.
Load Radius –The horizontal distance from the centre of the freely suspended
hoisting hook perpendicular to a vertical plane containing the front axle.
Loaded Boom Angle – This is given to assist in setting up the crane only. It gives
only an approximation of the Load Radius for a specified boom length. “Boom Angle”
on Rated Capacity charts refers to the angle between the boom and true horizontal.
(Refer to image below)
Load Moment Indicator (LMI) - A system that displays rated capacity for the given
configuration. An audible warning sounds when rated capacity is approached and
reached.
Pitch Angle – The forward tilt
of the crane, the angle
between the chassis of the
front of the crane and true
horizontal in the longitudinal
direction. The pitch is positive
when the front is higher than
the rear. In the image shown,
the pitch angle is negative.
Rated Capacity (RC) – The total Freely Suspended Load, including the mass of
material and load handling equipment, that the machine can safely lift under ideal
conditions at a given configuration.
Roll – The side tilt of the crane chassis, the angle
between the front chassis of the crane and true
horizontal. The roll angle is positive when the left side
of the crane is higher than the right side. In the image
shown, which is a view on the front of the crane, the roll
angle is negative.
Side Load – Any external force applied either to the
boom or load in a horizontal direction.
Slope: Generalised angle of the ground measured in
degrees.
Tilt: Generalised combination of pitch and roll.
Work Areas – Area measured in an arc about the centre pivot as shown on the
Working Area diagram.
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SPECIAL PRECAUTIONS FOR ARTICULATED CRANES
THERE IS A POTENTIAL FOR CRUSHING BETWEEN FRONT AND REAR
CHASSIS WHEN THE MACHINE ARTICULATES. NEVER STAND IN THE PIVOT
AREA WHEN THE ENGINE IS RUNNING OR EMERGENCY STEERING PUMP IS
OPERATING. ALWAYS REMOVE THE KEY FROM THE IGNITION BEFORE
WORKING IN THE PIVOT AREA.
DO NOT LEAVE IGNITION KEY SWITCHED ON WITH ENGINE STOPPED AND
PARK BRAKE OFF, AS EMERGENCY HYDRAULIC STEERING PUMP WILL
ACTIVATE.
GENERAL
1. This machine has been designed to meet the requirements of AS1418.1 (2002)
& 1418.5 (2002) and has been tested in accordance with these standards for
pick and carry operation on tyres. The machine classification is C3.
2. Rated Capacities shown are for this machine as originally manufactured by
Terex Australia Pty Ltd. The Rated Capacities only apply when all the
instructions in this book are rigidly followed. Modifications to this machine or
use of equipment other than that specified can result in a reduction in Rated
Capacity.
3. If improperly operated or maintained, this machine can be hazardous.
Operation and maintenance of this machine must be in compliance with the
information documented in this rated capacity manual and in the operators,
service and parts manuals furnished. If these manuals are missing, obtain
replacements through Terex Australia Pty Ltd or their agents.
SET-UP
4. Reduced crane Rated Capacities for the particular job shall be established, by
the operator, with due allowance for adverse operating conditions. These
conditions include the supporting surface, pendulum action of the load, jerking
or sudden stops of the load and other factors affecting stability, two machine
lifts, electrical wires, adverse weather, wind, hazardous surroundings,
experience of personnel, etc.
5. Rated Capacity is based on Freely Suspended Loads. Lifting, or travelling with
a load, on soft or uneven ground can be hazardous and will reduce the Rated
Capacity of the crane. Refer to the section “Operation on Slope” for further
information.
6. No attempt shall be made to drag the load along the ground in any direction.
7. Wind forces on the boom, resulting from winds up to 10 m/s (36 km/h), are
incorporated in the Rated Capacity. Any additional Side Loading due to wind
forces on the load will reduce the Rated Capacity, and must be considered.
8. Rated Capacities include the mass of hooks, blocks, slings and auxiliary lifting
devices. Their mass must be subtracted, from the listed Rated Capacity, to
determine the equivalent net load.
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9. Loaded Boom Angles at specified boom lengths give only an approximation of
the Load Radius. The Boom Angle before loading should be greater to account
for boom deflection increasing the Load Radius as the load is lifted.
OPERATION
10. Read and understand all warnings and instructional notes.
11. Do not tip the machine to determine allowable lifting capacities.
12. Loads may be lifted from:
The main boom head on the winch.
The rhino hook.
The fixed lug.
Either of the two sliding lugs on the boom.
A flyjib is also available to extend the maximum boom length
A “manbasket” can be pinned to the head of the boom.
Always use the correct Rated Capacity chart for the lifting point in use, and the
position of the counterweight. Ensure the LMI is set to the correct duty.
NOTE : Written authorisation from Terex Australia Pty Ltd is required
prior to the use of any attachment not specified in the manual.
13. “Crane mode” can only be engaged when “low range” is selected. Selecting
“crane mode” will cause the front suspension lockouts to engage.
14. Lifting from more than one lifting point simultaneously is neither intended nor
approved.
15. Handling of personnel from the boom is neither intended nor approved, except
in a Terex Australia Pty Ltd supplied manbasket, correctly installed on the head
of the boom, or other approved arrangement.
16. When either the boom length or Load Radius or both are between values listed,
the smallest load shown at either the next larger Load Radius or boom length
shall be used, or the interpolated value shown on the LMI may be used.
17. Side Loading of the machine and load swing out may cause structural failure or
machine tip-over. Side Loads may be generated by:
Lifting when not level.
Sudden acceleration or deceleration
Sudden movement when articulating with a load.
Dragging a load.
Pushing a load.
Wind forces on load and boom structure.
18. It is safe to attempt to telescope any load within the limits of the Rated Capacity
Manual. The maximum load that may be telescoped is limited by hydraulic
pressure, Loaded Boom Angle and powered boom sections lubrication.
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19. Boom extension 1 and boom extension 2 move simultaneously. The winch
rope is fully compensated for boom extension when boom extensions 1 & 2 are
being telescoped. Boom extension 3 is powered on the MAC 25 however there
is no compensation of the winch rope as the third extension is being extended.
Operator to take care to extend rope as required while boom extension 3 is
being telescoped.
20. Do not allow the winch rope to unwind fully. Always ensure a minimum of
2 wraps of rope remain on the winch drum.
21. Rated Capacity depends on tyre rating, tyre condition and tyre inflation
pressure. All tyres must be in good condition and must be inflated to the
recommended pressure before attempting a lift.
22. Pick & carry operation is permitted through the full Articulation range, however,
Rated Capacity is reduced when articulating. On the series 4 MAC 25, the LMI
dynamically calculates rated capacity taking crane tilt and articulation into
account.
23. The maximum speed for pick & carry operation is 0.4m/s (1.44km/h). The
transfer case shall be set to low range.
24. Operation of this crane in excess of the Rated Capacity and disregard of the
instructions is hazardous.
LIFT AND CARRY OPERATION
Observe the following during travel with load on the crane:
Keep the boom tip as close to the ground as possible by using:
The MINIMUM practical boom length
The MINIMUM practical Boom Angle.
Keep the load as CLOSE to the ground as possible.
Keep the load as CLOSE to the front of crane as possible
Use the MINIMUM Articulation angle practical - REMEMBER the crane will side tilt
when articulated and hence the hook will move towards the direction of Articulation
whilst steering.
Load swing greatly reduces stability – REMEMBER to tagline loads to prevent
pendulum motion of the load. Travel and crane motions should be applied gently
to minimise this effect.
Always REMEMBER:
On flat ground - Increased articulation reduces load capacity
On sloping ground – Downhill articulation reduces load capacity.
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OPERATION ON SLOPE
The operation on slope of cranes that travel with a freely suspended loads should be
avoided if at all possible (refer to AS 2550.5). Mobile Cranes are primarily designed to
operate on firm, flat, level ground - within a 1% gradient (refer to AS 1418.5 (2002)).
Any deviation from this requires that the Rated Capacity shall be reduced (derated)
accordingly.
If it is necessary to operate on slope the
precautions listed below must be taken.
REMEMBER that surface depressions and
potholes will create the same effect as a
sloping surface.
Ensure the ground condition is FIRM
enough to support the axle loads.
Ensure the tyres are inflated to the correct
operating pressures.
Keep the load on the UPHILL side of the
crane where possible. REMEMBER the
working Load Radius will increase if the
load is suspended in the downhill position.
NOTE:
The MAC 25 crane must at no time be
operated on a slope greater than
5(8.75% gradient).
In order to determine the slide slope of a
particular site the crane’s LMI can be used to
give an approximation. Before commencing
the lift, drive the un-laden crane slowly across
the sloping surface and note the maximum
slope displayed. Take the reading when the
crane’s articulation is zero (straight ahead)
and with the boom (fully retracted) in its
lowest position practical.
The MAC 25 is fitted with an LMI that
calculates the rated capacity for the crane
when the crane tilts in any direction.
SLOPE RATED CAPACITY
The degree of tilt of the front body results from a number of factors. Articulation of the
crane induces tilt as does working on a slope. In combination the body tilt is
increased when the load is on the DOWNHILL side of the crane (when the crane
articulation direction is down a side slope).
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The degree of tilt of the front body and boom is further increased by the deflection of
the tyres. This is illustrated in Figure 1. For instance, a 5Oground side slope may
result in chassis tilt of say 7O.
The LMI determines and displays the degree of body tilt measured by a sensor that is
attached to the front body. This sensor measures the angle of the front body, not the
angle of slope of the ground. When the crane is un-laden, the boom fully down, and
the crane is at zero articulation, the body will be close to the same angle as the
ground, for up to 5o slope.
This body tilt angle (the “Roll”) is used by the LMI to derate the crane as this is also
the angle the boom has been tilted sideways. When lifting or carrying a load in slope
situations, the tilt of the body will change as the weight of load is taken by the crane.
In most circumstances, this change will be further derate the crane. Hence in planning
a lift, it is important to be conservative on lift capacity in any circumstance where the
lift will induce significant front body tilt.
SPECIFICATIONS
ATTACHMENT MASSES
Single part hook block PL16M2090 30 kg
Four/six part hook block PLMXA3033 230 kg
Rhino Hook PLMXF3015 25 kg
9 tonne hook PP2190200 10 kg
25 tonne hook PP2087500 26 kg
12 tonne spreader bar PL16A3035 94 kg
15 tonne spreader bar PL15A8023 107 kg
Adapter - Flyjib & Manbasket PLMXF3018 25 kg
Flyjib (3m) PL16A3056 79 kg
Mount arm - Manbasket C2061 85 kg
Manbasket C2062 130 kg
NOTE : These masses apply only to Terex Australia Pty Ltd supplied
equipment.
HOOK BLOCK
Hook Block: Number of
Falls of Rope Maximum Hook Block RC (kg)
1 4200
2 8400
4 16800
6 25000
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