User and Driving TFC 45 2002 PPM11

T. F. C. 45 MAINTENANCE AND OPERATOR’S MANUAL

N°

EDITION: 08/2002

REF. P 62440 --- 53

Registered Office and Factory Zone Industrielle de La Saule B.P. 106 71304 7130 4 – MONTCEAU MONTCEAU – LES – MINES Tel: (33) 03 85 67 6 7 38 00 Fax: (33) 03 85 67 38 99

Operating and Maintenance Manual

BEFORE PUTTING YOUR MACHINE INTO THE HANDS OF AN OPERATOR, OR IF YOU HAVE BORROWED OR HIRED IT, MAKE SURE BEFORE THE OPERATOR STARTS THE ENGINE: THAT YOU HAVE GIVEN HIM ALL THE INSTRUCTIONS NECESSARY FOR PROPER AND SAFE USE OF THE MACHINE; THAT HE HAS STUDIED AND ASSIMILATED ALL THE INSTRUCTIONS IN THIS MANUAL. BEFORE STARTING ENGINE STUDY OPERATOR'S MANUAL SAFETY MESSAGES. READ ALL SAFETY SIGNS ON MACHINE. CLEAR THE AREA OF OTHER PERSONS. LEARN & PRACTISE SAFE USE OF CONTROLS BEFORE OPERATING. IT IS YOUR RESPONSIBILITY RESPONSIBILITY TO UNDERSTAND AND FOLLOW MANUFACTURER'S MANUFACTURER'S INSTRUCTIONS ON MACHINE OPERATION AND TO OBSERVE APPLICABLE LAWS AND REGULATIONS. OPERATOR MANUALS AND PARTS CATALOGUES MAY BE OBTAINED FROM YOUR EQUIPMENT EQUIPMENT DEALER. ACCIDENTS INVOLVING MACHINES WHICH DO NOT OCCUR IN NORMAL HIGHWAY CIRCUMSTANCES. "IN THE EVENT OF AN ACCIDENT, AND IN ORDER THAT ANY CLAIM CAN BE MADE AGAINST PPM, IT IS OBLIGATORY THAT A PERSON APPROVED BY PPM CAN ESTABLISH A REPORT ON THE ACTUAL CONDITIONS OF THE ACCIDENT BEFORE THE MACHINE MACHINE IS REMOVED FROM THE SITE OF THE AFORESAID ACCIDENT."

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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

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Chapter VII Diagrams

Appendices Appendix 1: List of engine error codes

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Information


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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Information

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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


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


Metric conversion table Multiply by

XXXX

to obtain the equivalent figure for

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 2

Inch

2

Foot 2 Yard

645. 2 6. 45 0. 0929 0. 8361

3

Quart Gallon 3 Yard

16387. 16. 387 0. 0164 0. 9464 3. 7854 0. 7646

2

2

millimetres (mm ) centimetres2 (cm2) 2 2 metres (m ) 2 metres

horsepower

0. 4536 907. 18 0. 907

3

mm cm3 litres (l) litres litres 3 3 metres (m )

9. 807 0. 278 4. 448

metres-metres kg-m

0. 746

Inches of mercury Inches of water Pounds/sq. in. (psi) Pounds/sq. in. (psi)

kilowatts (kW)

3. 377 0. 2491

kilopascals (kPa) kilopascals

6. 895

kilopascals

0. 0703

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)

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(N.

PRESSURE OR STRESS

MASS Pound US Ton US Ton

newton-metres

POWER

VOLUME Inch

0. 11298


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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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Safe operating practices Maintenance and operator's manual

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 m achine. 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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Safe operating practices Maintenance and operator's manual Wear a safety helmet and glasses, as well as safety gloves and shoes, as required by state law.

Before you start the engine blow the horn for a few moments in order to let ground personnel know your intentions and, if necessary, prevent you from starting the machine.

Sparks can come from the exhaust pipe or from the electrical system. Do not operate in closed areas where there are inflammable materials, dust or fumes that can cause an explosion or fire. Severe injury or death can result i f you do not follow these instructions.

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Access to the machine and cleanliness Make sure the access area and operator's station are clear of oil, foreign material or ice. Remove or attach all maintenance or personal items. Failure to keep these areas clean and tidy can cause serious accidents.

Use your hands to get in and out of the machine: handrails and handles are provided for these manoeuvres.

Never jump off the machine.

Make sure the windows of your cab are clean. Make sure the windshield wipers are operating correctly. Dirty windows can cause accidents.

Stow away oily rags and other inflammable materials in a safe place. Never leave any rags or flammable material on the machine. The greatest attention must be paid to cleanliness around and on the engine, the hydraulic distributor and all components likely to become hot; make sure that there are no leaks from the hydraulic or air conditioning circuits.

All measures should be taken to conserv e the environment. Make sure that all used oils and fluids are correctly retrieved and recycled. Do not leave such products in incorrectly labelled, unsuitable or open containers. Do not leave any puddles of fluid, of any type, on the ground or on floors.

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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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Safe operating practices Maintenance and operator's manual The machine must be driven only by qualified and authorized operators.

Understand the limits of the machine. Keep the machine under control at all times. DO NOT TRY TO DO TOO MUCH TOO QUICKLY.

Be aware of the dimensions and the weight of the machine. Keep this in mind when operating in areas of limited space (bridges, overhead piping, etc.) or where ground stability is uncertain. Special precautions must be taken when working in the vicinity of high voltage lines. Refer to chapter Information to consult the characteristics of the machine.

When driving the machine elsewhere than in the normal working areas, make sure that you are acquainted with current machine parameters, as well as those of the area (weight, dimensions, wheel loads, permissible slopes, ground resistance and adherence,... ) Refer to chapter Information to consult the characteristics of the machine.

Be vigilant at all times. Never allow unauthorized personnel in the working area. You must always know exactly where authorized personnel are in the working zone.

Parking of vehicles in the area where the machine is working is prohibited.

Always operate the machine with closed doors as noise injury may occur.

When the engine is off, never release the parking or emergency brake unless the machine is chocked or immobilized. When wind speed exceeds 12. 2 m/s (= force 6), stacking more than two containers high is prohibited. When wind speed exceeds 19. 8 m/s (= force 9), all use of the machine is prohibited.

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Safe operating practices Maintenance and operator's manual Before starting the engine, make sure that the parking brake is applied and the gear selector is in the neutral position.

Before you operate at night, check that all signalling lights and headlamps are working correctly.

Operate the controls only from the operator's seated position. Serious personal injury can be caused if you operate the controls from any other position.

Be careful when you operate the machine in dusty, smoky or foggy conditions. Poor visibility can cause accidents.

Avoid abrupt movements when handling a load.

Never leave the machine with a suspended load.

Never leave the machine parked on a slope.

Before you put the machine on a trailer, remove all ice, oil or grease from the trailer and its loading ramp.

When the reach is increased, lifting capacity is diminished. (See table of loads in chapter Information)

Before displacing a load, make sure that no one is under or near the machine.

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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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Safe operating practices Maintenance and operator's manual When working with compressed air wear a facemask with headband and safety clothes. Maximum air pressure is 2 bar.

Be careful when using cleaning fluids.

For your own safety and to avoid liability only use original PPM parts.

Note: Repairs are best left to specialists. Do not hesitate to consult your PPM specialists or their appointed agent. ( See chapter Information for addresses, telephone/fax numbers and e-mail).

Arc welding on the machine can harm mechanical, electrical or electronic components and therefore increase safety risks. Before welding always take the following precautions: - position the earth clamp as near to the welding area as possible. - disconnect both battery terminals. - disconnect all electronic units.

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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.

Never top up batteries with acid. Always use distilled water.

When the battery electrolyte is frozen, the battery can explode if you try to charge the battery or you try to start it using a battery in parallel. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be inju red.

When using an external power unit to start the engine, connect the ground cable last and disconnect it first to avoid sparks near the batteries, as they could ignite the fumes given off by the batteries. With this method, connect the back-up battery earth cable to the machine's starter motor earth terminal.

Never wear metal rings or metal watch bands. You could earth an electrical circuit and burn yourself.

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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 posit ion 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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Safe operating practices Maintenance and operator's manual Hydraulic oil is inflammable. Never weld lines or pipes filled with oil.

Hot hydraulic oil can cause burns: let the oil cool down before draining the tank.

After any service operation on the hydraulic circuit, its components or its fluid, it is essential to bleed the circuit to remove any air which might have entered it, using the bleed nipples provided for the purpose on the rams. This job must be done by a qualified specialist.

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Safety instructions concerning tyres Note: The wheels and tyres are primary safety components on the machine so check their condition regularly. Do not forget that only specialized personnel are allowed to work on these parts. Before removing any tyres from the machine and under all circumstances: Make sure that the fixed anchorage of the internal rim is not split and that there is nothing wedged between two coupled tyres.

Start by loosening the wheel stud nuts by two or three turns only. As the remaining wheel nuts stop the rim being ejected, dislodge the external rim if necessary whilst keeping out of its trajectory in case of an eventual ejection. As the external and i nternal rims are then free, continue unscrewing the wheel nuts.

WARNING: If it is impossible to release the external and internal rims after unscrewing the wheel nuts by two or three turns, it means that something is wrong. In this case deflate the tyres before taking off wheels. The same care must be taken if something is wedged between two coupled tyres.

1/ Deflation

Remove the internal part of the inner tube valve and wait until there is no more air whistling. In winter, check that there is no ice plugged in the inner tube valve. Make sure that the tyre is totally deflated. Avoid standing in front of the tyre during this operation.

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2/ Taking off the wheel rings

Before any operation, make sure that the tyre is completely deflated. In any case do not stand i n front of the wheel during this operation.

3/ Before and during tyre fitting

Carefully inspect the rim after cleaning it to verify that no cracks are starting to form. Fixed clamp fastener side (a) Removable ring side, in the groove of the locking ring (b) Carefully inspect the removable ring and the locking ring. Replace any parts which are too corroded, show signs of cracks starting to form or are badly distorted. Check wheel discs for cracks. Check that all mobile parts: removable rings (or side rings), and locking rings correctly correspond with the rim. Check that all different parts are correctly seated (locking ring correctly seated inside its groove for example).

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Safe operating practices Maintenance and operator's manual 4/ Inflation

With the wheel or the rim fitted with the tyre laid on the ground, inflate just until the removable ring places itself against the locking ring. Then place the assembly vertically against a wall, the removable ring on the wall side, and continue inflation.

IMPORTANT: In any case and during inflation operations never stand in the probable trajectory of all or part of the wheel or the rim. When you inflate a tyre on a vehicle take the same care as above, stand to one side. Do not leave anybody in front.

5/ Wheel in two parts

When dismantling, do not confuse the assembly bolts of the two shells (a) with the mounting bolts of the wheel (b)

Before inflation, make sure that the assembly bolts of the two shells are fully tightened.

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Safe operating practices Maintenance and operator's manual For your own safety and that of others, it is compulsory to check the correct tightness of the wheels nuts using the wrench provided with the machine. Frequency: after 50 hours, then every 100 hours of service.

Note: regularly check cold tyre pressures: every 50 hours or once a week. DANGER - Never operate the machine with under-inflated tyres.

Inflation pressures are given for cold tyres, inflation and pressure checks must be carried out on cold tyres. Never deflate a hot tyre.

Check condition of tyres without any load on the machine. If the wheel is not fitted on the machine, always use an inflation cage.

With coupled tyres, always use same size, make, type, wear and pressure to avoid any damage to tyres.

Do not risk an accident while inflating the tyres. Never stand in front of the wheel. Use a flexible pipe of sufficient length with a self tightening inflation socket.

Deflate tyres before trying to remove stones from the tyre tread.

When fixing balance weights to be tack welded on the site, use only special equipment designed for the purpose.

Never cut or weld anything whatsoever on a rim fitted with an inflated tyre.

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Stacker operating conditions and recommendations

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.

General handling recommendations. Containers are generally marked with their weight. Always verify that the handling operation envisaged is compatible with the table of loads of the machine.

The handling reaches indicated on the load capacity chart are the distances measured between the spreader suspension vertical axis and the vertical tangent of the front edge of the front wheels.

In order to maintain maximum safety, never lift loads exceeding the maximum capacity.

The reach is increased by lowering and/or extending the boom. By increasing the reach the lifting capacity is reduced. Do not forget that the reach is increased when the machine goes down slopes.

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Safe operating practices Maintenance and operator's manual To pick up a container place the machine as close to it as possible in order to have the best possible stability.

Never move a container horizontally without having lifted it from the ground.

Never use the machine with safety devices shunted, or only under very special conditions under the operator's responsibility.

If the machine has not been used for a long peri od, check correct working order of the anti-tipping device by telescoping a container barely off the ground until the handling functions are automatically cut.

Never stand under the spreader, especially if a load is suspended.

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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Safe operating practices Maintenance and operator's manual The weight of the spreader on the container must be sufficient to make the twistlocks enter the corner twistlock housings. Never use boom movement functions to press the spreader down on to the container.

If the spreader safety system warning lights do not operate correctly the unit must be repaired immediately. Using a machine with faulty warning lights can cause serious accidents.

If container lock on is not achieved and the four spreader positioning detectors are in contact with the container the problem may be due to distortion of the container. Check that the container twistlock housings are not obstructed (ice, etc.) or that dirt has not accumulated in them. Never drive the machine with a suspended container if the twistlocks are not fully engaged.

It is strictly prohibited to start a container lifting manoeuvre if the red warning light is on (twistlocks not fully engaged) or if the other indicator lights are not lit. Container lifting cannot be started until the red warning light goes out and the green light comes on.

It is essential to balance the weight of the load on the vertical axis of the boom head. Do not start any other manoeuvre, especially driving the machine, before carrying out this operation. Use the side shift function to do this. Except for special or refrigerated containers the weight distribution is uniform and is balanced around the lengthwise midpoint.

Driving the machine When the machine is unladen, drive with the boom head over the front axle, never over the rear of the machine.

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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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Safe operating practices for PPM machine users

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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Safe operating practices Maintenance and operator's manual Any use of the machine other than the handling of loads must be authorized in advance by the PPM company. Normal conditions of use envisaged are an average of 17 hours per day, 7 days per week, 300 days per year under normal environmental conditions and at an altitude of less than 1,000 m. For more intensive use or under harsher environmental conditions (high temperatures, dusty or humid atmosphere, etc.), the machine must be used with precaution, checked more frequently and the lubrication and servicing intervals must be shortened. PPM has concessionaires who can answer all your questions regarding conditions of use of the machine.

Because these machines have the ability to lift heavy loads to great heights, they also have a potential for causing accidents if safe operating practices are not followed. These pages will help the operator prevent accidents which could result in property damage, personal injury or death.

General safe practices for working on machinery must be followed as well as the safe operating practices recommended here.

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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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Signalman 's responsibility The primary duty of a signalman is to assist the operator in safe and efficient operation. Operators depend on designated signalmen to assist them in making movements without endangering people or property.

Signalmen must place themselves where they can be clearly seen and where they can safely observe the entire operation.

Signalmen must have a clear understanding of the work to be done so that they can safely coordinate each job with operators and other crew members.

Standard signals must be used unless other methods of signalling such as two way radios or flags have been agreed upon.

The driver's assistant is the only person who may direct the driver.

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Responsibilities of all crew members Any unsafe condition or practice must be corrected or reported to the job supervisor.

Watch for hazards during operations and alert the operator and signalmen of dangers such as power lines, the unexpected presence of people, other equipment or unstable ground conditions.

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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Planning the job Many accidents can be avoided provided that the worksite is correctly organized. The person in charge must have a clear understanding of the work to be done, consider all dangers on the jobsite, develop a plan to do the job safely, and then explain the plan to all concerned. Factors such as these should be considered:

-What crew members are needed and what responsibilities will they be given?

- How will the assistant communicate with personnel members?

- What equipment is required to perform the handling in perfect safety?

- Is the machine the most suitable means?

- Are there any high tension lines to be avoided?

- Is the ground sufficiently stable to support the machine and its load?

- Are there any extreme climatic conditions such as wind or intense cold?

- What steps must be taken to keep staff who are not required for the operation out of the working area of the machine?

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Operator's safety check The operator must make a safety check before starting work each day to see that the machine is in proper order. Among other things, the operator should:

- check the machine log book to see that periodic maintenance and inspections have been performed and all necessary repairs made. - check the operation of boom hoist upper angle limiter device, backup alarms, and other operator aids. - carefully inspect boom, outriggers, spreader, etc. according to the type of machine. - be sure no unauthorized modifications have been made, such as added counterweights or improper repairs to the boom. - check for hydraulic oil leaks. - after starting the engine, check all instrument readings. - test all movements for proper operation. - check brakes and clutches.

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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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Safe operating practices Maintenance and operator's manual Establish the stability of the ground on which the machine is to manoeuvre. Make sure that the ground can support the machine. Avoid ground which is soft, unstable or partially frozen. If the machine is working near a trench, this must be buttressed or filled in to avoid subsidence.

The lifting capacity of a machine is given for a maximum angle of 60°. Any greater slope considerably reduces its load capacity.

People behind the machine may be struck by its counterweight if there is not enough free space. Carry out a test rotation, unladen, before starting work.

Position the machine so as to leave enough space between the counterweight and any obstacles (minimum 0.60 m).

Many injuries have been caused by people being struck by hooks, loads or containers. To avoid this, remain outside the zone of operation of the machine.

Never lift people with the machine. Use stepladders, scaffolding, work platforms, elevator platforms or other equipment designed for the purpose and conforming to standards in force.

Many injuries have been caused by high tension lines. Such accidents can be avoided by obeying the simple rules given below.

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Safe operating practices Maintenance and operator's manual The machine runs on pneumatic tyres: After a site machine has been in contact with a high tension overhead structure, tyres (with a metal internal structure) which have not been destroyed do not retain either their insulating qualities or their mechanical strength. If they do not burst immediately, they often burst later on, after prolonged exposure to sunlight. The machine should not be approached until the temperature of the air in the tyres has dropped. The tyres must be removed and scrapped after the machine has been extricated from contact with the power line.

WARNING - Properly planned work and assiduous supervision provide better protection than any other measure. Insulated cages and proximity detectors have their limits and are subject to unpredictable breakdown. Protection cables and insulated cages only protect the machine, and can become electrically conductive in the presence of dust or water. Proximity detectors may be put into use for various combinations of HT lines and movements of vehicles or equipment by the crane itself or other parameters. It can be very dangerous to put complete trust in these systems, as the driver may believe himself to be protected when he is not.

In the event of thunderstorms, take the following precautions: - If possible, put down the load and stow the boom. - If the sudden onset of a thunderstorm takes you by surprise, stop the engine and leave the machine. - If the machine is struck by lightning, check its general functioning before starting to use it again. You should always be aware of the weather forecast for your region.

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Safe operating practices Maintenance and operator's manual (* ) Always find out the position of any high tension lines before starting work. It is advisable to keep more than 6 m away from high tension lines. Make sure that you always stay as far from the lines as possible, and never go within the minimum distance.

Always respect these precautions if there are high tension lines in the vicinity.

Informer the company responsible for the HT lines (E. D. F in France) before starting work. Use an assistant to maintain a safe distance between the machine and the HT lines. The driver is not best placed for estimating distances.

Warn people to stay well away from the machine all the time. If the load has to be moved to be positioned, check with EDF for any special precautions such as insulated points or potential nodes. Manoeuvre slowly, leaving yourself plenty of time to react to any problem that may arise, and use two different means to estimate the distance between the high tension lines and any part of the machine. Conduct in case of accidental contact. Conduct is not laid down by regulations, but depends on an analysis of immediate risks. It should form part of the operator's instructions or training.

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Safe operating practices Maintenance and operator's manual The apparatus or machine is in working order: Without leaving his cab, the driver must move the machine away from the live electrical structure. The apparatus or machine is no longer in working order: Without leaving his cab, the driver must warn others, by signs or verbally, not to approach the machine or apparatus. (Risk of step voltage as long as the fault persists.) If it is essential that the driver should leave the cab of the apparatus or machine, he should jump to the ground, making sure he is not in simultaneous contact with the ground and the machine. Move over the ground: either by jumping, with both feet together (* ND 1879-147-92 INRS Direct

or taking very small steps.

contact of equipment with overhead electricity lines.)

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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Safe operating practices Maintenance and operator's manual People can be injured if the boom, load or spreader are moved before everyone is clear.

Make sure everyone is in a safe place before moving the boom, load or spreader. Do not move loads over people. Do not allow the load to bump or catch on anything.

Rapid spreader swings or sudden starts and stops can cause the attached load to shift.

Dirty windows, darkness, bright sunlight, fog, rain, and other conditions can make it difficult for the operator to see.

Keep windows clean. Do not operate if you cannot see clearly e nough to operate safely.

The wind can also lead to loss of control of the load by breaking the boom and by causing the machine to topple. High altitude wind can be stronger than at ground level. When the wind speed exceeds 12. 2 m/s (= force 6 on the Beaufort scale), the stacking of more than 2 containers is prohibited. When the wind speed exceeds 19. 8 m/s (= force 9 on the Beaufort scale), all use is prohibited.

Do not raise any load if the wind is uncertain or unsettled. Lower the boom if necessary. Refer to the load diagram tables.

Always wait until the machine has stopped. Do not jump on or off. Always use both hands and make sure you have a good footing.

Slippery floors, footplates, steps, tools, trash, or other loose items can cause falls.

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Safe operating practices Maintenance and operator's manual KEEP THE MACHINE CLEAN AND DRY.

A damaged machine can be dangerous and cause an accident. A machine with a telescopic boom should be checked weekly to make sure that there is no distortion of the base or guide shoes. In either case, the reduction in strength is very difficult to estimate.

Inspect the boom of the machine daily. Never use a damaged boom.

NOTE - Because the boom is made from high-strength steel, special procedures are necessary to effect repairs. Consult your concessionaire.

The booms of a machine may twist if subjected to lateral loads (sideways traction). Typical causes of lateral stress are: Sudden slewing when starting or stopping. Using the boom to pull a load Wind force Lifting when the machine is not level.

Be careful not to exert lateral efforts.

If the boom is used for purposes other than lifting, it may break.

Never allow the boom to bend under the weight of its load or from any other cause.

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Safe operating practices Maintenance and operator's manual Attempting to lift a load which is stuck, frozen or anchored to something may cause the machine to fall over or the boom to break.

Make sure the load is not restrained before any attempt at lifting.

Trying to repair or adjust equipment with a load or with the boom raised could release machinery and let it move unexpectedly.

Always lower the load to the ground and the boom into rest position (horizontal) before doing any maintenance or repair work.

Pressure in hydraulic systems can be retained for long periods of time. If not properly released before maintenance staff attempt to work on the hydraulic systems, this pressure can cause machinery to move or allow hot oil and hose ends to shoot out at high speed.

Release system pressure before attempting to make adjustments or repairs. Lower the suspension of the machine to release the pressure in the hydraulic circuit of the suspension accumulators.

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Safe operating practices Maintenance and operator's manual As with all heavy equipment, care must be taken when moving about, both on or off the work site.

Pay attention to workers, high tension lines, awkward sections with low clearance such as bridges, limited load roadways, slopes or rough ground. Get help from an assistant when manoeuvring in limited spaces. It can be dangerous to leave a machine without taking precautions.

Before leaving the machine, the driver must take the following measures to ensure that the machine does not move:

- lower the load to the ground and lower the boom if necessary - apply the parking brake - move the gear selector into neutral position (n) - stop the engine.

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L.M.I. SAFETY INSTRUCTIONS THE FOLLOWING INSTRUCTIONS APPLY WHEN THE LOAD MOMENT INDICATOR (LMI) SHOWS AN OVERLOAD.

SHUT-DOWN IN THE CASE OF OVERLOAD WHEN SETTING DOWN A CONTAINER: When the machine gets into a position in which the LMI detects an overload and the functions Lower Boom and Extend Boom are shut down (in addition to the audible and visual warnings), the machine must not be moved. In such a case, the boom must be raised until it reaches a safe position and the warning signals cease.

SHUT-DOWN IN THE CASE OF OVERLOAD WHEN ATTEMPTING TO LIFT A CONTAINER: When the machine gets into an overload position while attempting to lift a container, so that the audible and visual warnings are triggered, the load can be lifted by raising the boom. The machine must not be moved as long as the warning signal is active. The machine can only be moved safely when the warning signal has ceased. As a general rule, movement under load in front of a pile of containers is only permissible in first gear, and must be effected with great caution. When the overload warning signal goes on in this configuration, movement of the machine is prohibited.

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Transport of containers on the terminal may only be effected with the telescopic boom completely retracted and inclined at about 45°. The speed of advance must be judged so that it is possible to stop with no danger to any third party and without having recourse to sudden braking.

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Safe operating practices Maintenance and operator's manual Summary of the various safety devices installed on the machine. SAFETY DEVICE

MODE OF OPERATION

COMPONENT

P11-P12

P13

P47

Spreader damping

Spreader damping neutralization

Lowering, raising and Active with cut-off of extension extending telescopic unit and raising of telescopic unit

Speed limitation on locked container

Boom extended: Limitation to 1st gear

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

Head of boom

Limits speed of vehicle with container locked

Boom retracted: Limitation to 1st and 2nd gears S25

Anti-tipping

Active with cut-off of raising, lowering and extension of boom

On rear axle

Prevents the capacity of the machine from being exceeded

PM1

Parking brake safety device

Active when gearbox is in neutral

Under cab

Prevents engagement of gear while parking brake is on

Y1-Y2 Y3-Y4

Position of catches (twistlocks) indicator lights: white

Active and enables locking or unlocking of container

On spreader catches

Controls e ngagement of catches in container

Y5-Y6 Y7-Y8

Locking/unlocking container, indicator light: green

Active with inhibition when lifting gear is raised

On spreader catches

Controls rotation of catches

S9-S10

Inhibition left and right slewing

Activates inhibition of slewing hydraulic

Near spreader slew ring

Controls orientation of spreader

Gear selector

Starter safety device

Active requires gearbox neutral before starting

In cab

Prevents engine from starting if gearbox is not in neutral

Gear selector

Reverse audible warning

Active with warning linked to change into reverse gear

In cab

Switches on audible warning and rear lights

Prevention of container crushing

Activates shut-down of boom lowering and boom extension

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Neutralizes the functions of boom lowering and boom extension

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Controls and operation Operating and Maintenance Manual

Controls and operation ______________________ 10

Control identification_____________________ 10 Cab _____________________________________ 11

1 / Steering wheel (actuates rear wheels) _____ 11 2 / Gear shift control lever_________________ 11 3 / Service brake pedal and gear box neutral position ________________________________ 11 4 / Service brake pedal____________________ 11 5 / Accelerator pedal _____________________ 11 6 / Combined switch - lights - blinkers - horn _ 11 Control desk panel, centre right _______________ 12

13 / Working light warning light____________ 12 14 / Revolving beacon warning light _________ 12 15 / Headlights warning light ______________ 12 16 / Direction indicator warning light________ 12 17 / Parking lights warning light____________ 12 Control desk panel, centre right _______________ 13

18 / Torque converter oil temperature warning light___________________________________ 13 19 / Gear box oil pressure warning light______ 13 20 / Anti-tipping device warning light _______ 13 21 / Spreader lock override warning light ____ 13 22 / Brake oil pressure warning light ________ 13 23 / Parking brake warning light ___________ 13 24 / Anti-tipping device override warning light 13 25 / Excessive speed warning light __________ 13 Control desk panel, centre right _______________ 14

26 / Battery charging warning light _________ 14 27 / Engine preheating indicator light _______ 14 28 / Clogged oil and air filter warning light ___ 14 29 / Not used

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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 / Unité 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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87 / Anti-tipping device override control _____ 19 88 / Override key for gearbox operation electronic control unit ____________________ 19 89 / Selector control for gearbox automatic or manual mode.___________________________ 19 Ceiling panel controls _______________________ 20

100 / Revolving beacon control switch _______ 20 101 / Cab rear windshield wiper control switch 20 102 / Air conditioner controls (ESC)_________ 20 103 / No. 2 working light control switch ______ 20 104 / No. 1 working light control switch ______ 20 105 / Headlight control switch______________ 20 111 / Right side courtesy light ______________ 20 112 / Right side map reader light switch______ 20 Box behind seat____________________________ 21

200 / Gearbox operation electronic control unit 21

Fuse board

(Box behind seat) _______ 22

F1 - 10A – Battery isolator safety device _____ 22 F2 - 5A – Parking brake __________________ 22 F3 - 5A – Left and right ceiling light_________ 22 F4 - 15A.- Screenwiper, front - rear - cab roof - 22 F5 - 5A – Screenwasher – audible warning – indicator lights and receivers ______________ 22 F6 - 20A – Working light, cab – spreader – chassis. ________________________________ 22 F7 - 15A – Stop light – direction indicator lights. _______________________________________ 22 F8 - 20A – Working light, cab - boom. _______ 22 F9 - 20A – Rotating beacon lights ___________ 22 F10 -5A – Reversing light _________________ 22 F11 - 15A – Evaporator condenser compressor air conditioning _________________________ 22

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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

F29 –3A –Protection functions pressure switch air conditioning. _________________________ 23

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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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F39 –10A – Battery isolator – Starter motor. __ 23 F40 –10A – Emergency warning lights. ______ 23 F41 –10A – Sidelights. ____________________ 23 F42 –5A – Rev. counter – Hour meter. _______ 23 F43 –10A – Vehicle radio –24V/12V converter. 23 F44 –10A – Engine electronic unit. __________ 24 F45 –10A – Engine electronic unit. __________ 24 F46 -

– 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

General fuses

(Battery compartment) _______________________________________ 25 PF100 - 100A – General protection of functions after isolation of battery __________________ 25 PF80 -80A – General protection of starter after isolation of battery _______________________ 25 PF50 -50A – General direct protection of battery _______________________________________ 25 Spreader operating warning lights __________ 26 RED - TWIST LOCKS released indicator light _______________________________________ 26

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WHITE - Position indicator light signalling possibility of actuating the TWIST LOCKS __ 26 GREEN - TWIST LOCKS applied indicator light___________________________________ 26 For conditions of use, see paragraph (locking onto a container). ________________________ 26 Cab _____________________________________ 28

2 / Gear change lever _____________________ 28 Cab _____________________________________ 29

3 / Accelerator pedal _____________________ 29 4 / Service brake pedal____________________ 29 5 / Service brake pedal and gear box neutral position ________________________________ 29 6 / Combination control: lights - direction indicators - audible warning (horn) – screen wipers _________________________________ 29 Direction indicators (blinkers) _____________ 29 Audible warning (horn)___________________ 29 Lighting _______________________________ 30 Ignition off ___________________________ 30 Screen wiper – screen washer ______________ 30 13 / Working light warning light____________ 30 14 / Beacon light warning light _____________ 30 15 / Full beam headlights warning light ______ 30 16 / Turn signal warning light______________ 30 17 / Parking lights warning light____________ 30 18 / Torque converter oil temperature warning light___________________________________ 31 19 / Clutch oil pressure warning light________ 31 If the pressure drops, stop the engine at once and ascertain the cause. ______________________ 31 20 / Anti-tipping device override warning light 31 21 / Spreader twist lock override warning light 31

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22 / Brake oil pressure warning light ________ 31 23 / Parking brake warning light ___________ 32 24 / Anti-tipping device override warning light 32 25 / Overspeed warning light (Red) _________ 32 26 / Battery charging warning light _________ 32 27 / Engine preheating indicator light _______ 32 28 / Clogged hydraulic oil and air filter warning light ___________________________________ 32 29 / Not used ____________________________ 32 30 / STOP engine alarm warning light _______ 32 31 / Engine fault warning light _____________ 33 32 / Low hydraulic oil level alarm warning light _______________________________________ 33 33 / Minimum fuel level warning light _______ 33 42 / Hour meter _________________________ 34 43 / Torque converter oil temperature gauge__ 34 44 / Fuel gauge __________________________ 34 45 / Gear box clutch oil pressure gauge ______ 34 4 / Hydraulic oil temperature gauge _________ 34 Control unit, right side ______________________ 35

70 / Boom lift/telescope joystick ____________ 35 70 /1 - Raise boom _____________________ 35 70 /2 - Lower boom ______________________ 35 70 /3 - Retract boom______________________ 35 70 /4 - Extend boom ______________________ 35 70A / High speed boom functions control _____ 35 71 / Spreader side shift control _____________ 35 71/1 - Side shift to the left _________________ 35 71/2 - Side shift to the right ________________ 35 72 / Spreader slewing control ______________ 36 72 /1 - Slewing to the left.__________________ 36 72 /2 Slewing to the right __________________ 36

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73 / Twist locks lock/release control lever_____ 36 - Releasing _____________________________ 36 - Locking_______________________________ 36 74 / Anti-tipping device override control _____ 37 75 / Spreader beam telescoping control ______ 37 76 / Ignition switch_______________________ 38 77 / Engine shut down control______________ 38 78 / Engine test code control _______________ 38 79 / Hazard warning lights control __________ 38 80 / Engine test control ___________________ 38 81 Parking brake switch and gear box neutral position ________________________________ 38 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. _____________________________ 38

86 / Spreader locking override control _______ 39 87 / Anti-tipping device override control _____ 39 88 / Override key for the electronic gear box control unit _____________________________ 39 89 / Gearbox automatic or manual mode selection control_________________________________ 39 100 / Revolving beacon control _____________ 40 101 / Cab rear screen wiper control _________ 40 102 / Air conditioner controls (ESC)_________ 40 103 / No. 2 working light control switch ______ 40 104 / No. 1 working light control switch ______ 40 105 / Road light control switch _____________ 40 106 / No. 2 working light control switch ______ 40 111 / Right side courtesy light ______________ 40 112 / Right side map reader light switch______ 40 200 / Electronic gear box control unit________ 41 Verifying fault codes _____________________ 42 Seat adjustments ___________________________ 44

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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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Controls and operation

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.

FOR MACHINES EQUIPPED WITH L.M.I. THE CRANE OPERATOR OR JOBSITE MANAGER WILL BE HELD TOTALLY RESPONSIBLE FOR THE USE OF ANY CRANE FUNCTIONS APART FROM THOSE EXPRESSLY DESIGNATED BY PPM WHEN THE SAFETY DEVICE INDICATOR IS OVERRIDEN. PPM CAN IN NO WAY BE HELD RESPONSIBLE FOR ANY ACCIDENT THAT MAY OCCUR WHEN THE CRANE IS BEING USED WITH AN OVERRIDDEN LOAD MOMENT INDICATOR.

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Cab 1

2

1 / Steering wheel (actuates rear wheels) 2 / Gear shift control lever 5 4

3

3 / Service brake pedal and gear box neutral position 4 / Service brake pedal 5 / Accelerator pedal 6 / Combined switch - lights - blinkers - horn

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Control desk panel, centre right 16 17

15 13 14

13 / Working light warning light 14 / Revolving beacon warning light 15 / Headlights warning light 16 / Direction indicator warning light 17 / Parking lights warning light

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Control desk panel, centre right

18

22

19

23 25

24

20

25

21

18 / Torque converter oil temperature warning light 19 / Gear box oil pressure warning light 20 / Anti-tipping device warning light 21 / Spreader lock override warning light 22 / Brake oil pressure warning light 23 / Parking brake warning light 24 / Anti-tipping device override warning light 25 / Excessive speed warning light

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30 31 25

26 27

32

33

28

29

26 / Battery charging warning light 27 / Engine preheating indicator light 28 / Clogged oil and air filter warning light 29 / Not used 30 / Alarm warning light STOP engine 31 / Engine fault warning light 32 / Low hydraulic oil level warning light 33 / Fuel minimum level warning light

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Control desk panel, centre left 44

45

46

40 / Compteur horaire

43

41 / Unité centrale MDM-Ecran 42

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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Control desk panel, lateral right 71

70

70/A

72

73

70 / Joystick controller (raise/lower - extend/retract boom) 70B/ High speed boom functions control 73

71 / Spreader side shift control 72 / Spreader swing control 73 / Twist locks lock / release control

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Control desk panel, right 74

75

74 / Spreader damping lock switch 75 / Spreader beam telescoping switch

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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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88

87

89

86 / Spreader lock override control 87 / Anti-tipping device override control 88 / Override key for gearbox operation electronic control unit 89 / Selector control for gearbox automatic or manual mode.

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Ceiling panel controls 104 103

105 100 111

112

100 / Revolving beacon control switch 101 / Cab rear windshield wiper control switch 102 / Air conditioner controls (ESC) 103 / No. 2 working light control switch 104 / No. 1 working light control switch 105 / Headlight control switch 111 / Right side courtesy light 112 / Right side map reader light switch

103

102

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101


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Box behind seat 200 / Gearbox operation electronic control unit

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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.

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Controls and operation Operating and Maintenance Manual F21 - 10A – Spreader slewing - Spreader side shift. F22 - 10A – Flow rate cab joystick. F23 - 5A – Stop engine. F24 - 20A – Headlights main beam – Audible warning. F25 -

– Not used.

F26 -

– Not used.

D27 -

– Diode.

D28 -

– Diode.

F29 –3A –Protection functions pressure switch air conditioning. F30 -

– Not used.

F31 -

– Not used.

F32 -

– Not used.

F33 -

– Not used.

F34 F35 -

– Not used. – Not used.

F36 -

– Not used.

F37 -

– Not used.

F38 -

– Not used.

F39 –10A – Battery isolator – Starter motor. F40 –10A – Emergency warning lights. F41 –10A – Sidelights. F42 –5A – Rev. counter – Hour meter. F43 –10A – Vehicle radio –24V/12V converter.

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Controls and operation Operating and Maintenance Manual F44 –10A – Engine electronic unit. F45 –10A – Engine electronic unit.

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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.


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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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Controls and operation Operating and Maintenance Manual Spreader operating warning lights

RED - TWIST LOCKS released indicator light WHITE - Position indicator light signalling possibility of actuating the TWIST LOCKS GREEN - TWIST LOCKS applied indicator light

For conditions of use, see paragraph (locking onto a container).

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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

WARNING: this machine has rear wheel steering: check path of rear wheels when steering.

CAUTION: Keep in mind that the space required by the rear of the machine when turning is greater than for other machines due to the rear wheel steering.

2 / Gear change lever There are two possible transmission modes. Manual and automatic. Front

Forward and reverse travel drives are selected when t he machine is at a standstill. To check if the transmission is in neutral, carefully press the accelerator: the machine should not move. Rear

When leaving the machine at the end of a shift, or whenever necessary, use the red catch to lock the gear lever in neutral position (N) so as to prevent any unintentional movement.

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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.

4 / Service brake pedal To be used in normal travel.

5

4

5 / Service brake pedal and gear box neutral position To be used when approaching a container (see procedure). This pedal disengages the transmission clutch and brakes the

3

machine at the same time.

Caution: Do not use left-hand brake pedal for normal travelling. 6 / Combination control: lights - direction indicators audible warning (horn) – screen wipers Direction indicators (blinkers) - left turn indicators: lever up. - right turn indicators: lever down. A flashing repeater lamp confirms that the indicators are working properly.

Audible warning (horn) Press the end of the lever, whatever position it may be in.

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Controls and operation Operating and Maintenance Manual Lighting Ignition off parking lights 105 go on. lever towards driver: headlight flash Ignition on - Lever pulled once towards driver: headlights (main beam) The blue repeater lamp goes on with main beam headlights or headlight flash.

Screen wiper – screen washer Position 1: Stop - Position 2: Intermittent - Position 3: Low speed Position 4: High speed. For screen wash, move the body of the control handle towards the centre.

13 / Working light warning light This warning light comes on when one of the working lights is

16

switched on with control 103 or 104. 17

14 / Beacon light warning light 15

This indicator light comes on when the rotating beacon light is switched on with control 100.

13 14

15 / Full beam headlights warning light This warning light comes on when the full beam headlights are turned on with control 6.

16 / Turn signal warning light This indicator lamp goes on when the direction indicators have been selected with control 6.

17 / Parking lights warning light This indicator light will come on when switch 105 is placed in the parking light position.

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Controls and operation Operating and Maintenance Manual 18 / Torque converter oil temperature warning light 22

18

This warning light is connected to thermometer 43 and comes on when the torque converter oil temperature is too high.

23

19

25

If this light goes on, proceed as follows: Lower the container, shift the transmission to "N" (neutral) position,

24

20

accelerate the engine to 1,200-1,500 rpm for two to three minutes or until the temperature reading is in the normal range.

25

21

19 / Clutch oil pressure warning light The warning light comes ON when clutch oil pressure is below 17 bar. This warning light is connected to pressure gauge 45.

DANGER: Never used the machine with the anti-tipping device overridden, or only in exceptional circumstances under the responsibility of the operator. Be doubly careful when manoeuvring.

If pressure drops, stop the engine immediately and ascertain the cause.

If the pressure drops, stop the engine at once and ascertain the cause. 20 / Anti-tipping device override warning light This warning light blinks when the anti-tipping device override is activated by means of the key 87 and the audible alarm is activated..

DANGER: Never use the machine with the spreader safety lock overridden, or only in exceptional circumstances under the responsibility of the operator. DANGER: Do not start travelling until the warning lamp (22) has gone out. The warning lamp (22) goes out when pressure reaches 105 bars.

21 / Spreader twist lock override warning light This warning light comes when the spreader twist lock override is activated with key 86. The audible alarm is activated.

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).

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Controls and operation Operating and Maintenance Manual 23 / Parking brake warning light 22

This light will come on when the parking brake switch 81 is applied. 18

24 / Anti-tipping device override warning light 23

19

25

This warning light goes on when the maximum permissible load is 24

20

exceeded. The audible warning sounds. Remaining authorized functions are:

25

21

Raise Boom - Retract Boom.

25 / Overspeed warning light (Red) Immediately slow down if this warning light comes on.

26 / Battery charging warning light This warning light comes on if the alternator does not charge the

30 31 25

32

26

batteries - ascertain the cause.

27

27 / Engine preheating indicator light

28

28 / Clogged hydraulic oil and air filter warning light 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

30 / STOP engine alarm warning light This warning light goes on when the engine protection system is no longer in a position to perform its function. In such a case, the engine must be stopped. Park the machine in a parking area or on the hard shoulder of the road, making sure that it does not represent a traffic hazard. STOP the engine.

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31 / Engine fault warning light QSM engines are equipped with a protection system. This system analyses different parameters, such as coolant temperature, coolant level, oil pressure, overspeed, etc. It warns the driver of a functional problem by means of the engine fault warning light and takes preventive measures to protect the engine by gradually reducing power and speed (see procedure "Reading fault codes").

30

26

32 / Low hydraulic oil level alarm warning light

31

27

25

If this light goes on, make sure that there are no hydraulic oil leaks 32

28

and make up the hydraulic oil level immediately. DO NOT FORGET to respect servicing instructions.

33 29

33 / Minimum fuel level warning light If this light goes on, refill the fuel tank immediately.

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44

45

46

42 / Hour meter The hour meter operates when the engine is running.

43 / Torque converter oil temperature gauge 43 42

Normal operating temperature: 82 to 93°C (180-200°F) Maximum temperature not to be exceeded: 110°C (230°F)

NOTE: if the converter oil temperature reaches the maximum value shown above: - shut down the vehicle - shift to neutral (position "N") - accelerate the engine to 1,200/1,500 rpm for two to three minutes. (Until the temperature returns to normal operating value). Warning light 18 comes on when converter oil temperature reaches 110°C.

44 / Fuel gauge This gauge indicates the amount of fuel remaining in the fuel tank.

45 / Gear box clutch oil pressure gauge Normal operating pressure: 16.9 to 19.6 bar (240 to 280 PSI) If the pressure drops abnormally, stop the engine and ascertain the cause.

4 / Hydraulic oil temperature gauge Linked with hydraulic oil cooler temperature switch (starts up at 450°C -1,130°F).The temperature may reach 80°C (1,760°F). Stop the engine and ascertain the cause.

CAUTION: DO NOT EXCEED THE TEMPERATURE OF 80°C.

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Control unit, right side 70

71

70 / Boom lift/telescope joystick This joystick controls raising/lowering and telescopic

72

extension/retraction of the boom. 73

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.

70A / High speed boom functions control This control is used for high speed execution of the following boom functions: Raise boom – Extend boom – Retract boom

71 / Spreader side shift control This control is used to shift the sliding trolley of the spreader, either to 71/1

the right (71/2) or to the left (71/1).

71/1 - Side shift to the left 71/2

Press the button to shift the spreader to the left.

71/2 - Side shift to the right Press the button to shift the spreader to the right.

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Controls and operation Operating and Maintenance Manual 72 / Spreader slewing control This control is used to slew the spreader either to the right ( 72/2) or to the left (72/1). Before slewing the spreader, the slewing function must be released by pressing control 75. 72/1

72 /1 - Slewing to the left. Press the button to slew the spreader to the left.

72/2

72 /2 Slewing to the right Press the button to slew the spreader to the right.

73 / Twist locks lock/release control lever This control is used to lock or release the twist locks.

- 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.

DANGER: 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.

During the operation of locking onto the container, all boom movements are prohibited. Locking can only be performed if all four locking contactors are pushed in. If locking cannot be effected, reposition the spreader. Once all the four locking contactors are pushed in, the white spreader indicator lights go on. The functions Lower Boom and Extend Boom are then inhibited. These functions can be made available again by using the LMI override key.

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Controls and operation Operating and Maintenance Manual 74 / Anti-tipping device override control

Position 1: The spreader's shock absorption function is immobilized. Position 2: The spreader's shock absorption function is enabled.

74

IMPORTANT: It is essential to immobilize the spreader's shock absorption function in order to travel carrying a container in logitudinal position.

75

75 / Spreader beam telescoping control This control telescopically extends or retracts the beams of the spreader. Switch to the right: beams extend. Switch to the left: beams retract.

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Controls and operation Operating and Maintenance Manual 76 / Ignition switch This switch is used to power the electrical system and to start and stop the engine . (See chapter: Stopping the engine.)

77 / Engine shut down control Press to stop the engine. (see paragraph: Stopping engine)

IMPORTANT: As the engine is turbocharged, it is advisable to let it run for a few moments at idling speed before stopping it. 78 / Engine test code control (see procedure "Reading fault codes").

79 / Hazard warning lights control This control activates the hazard warning lights.

80 / Engine test control (see procedure "Reading fault codes").

81 Parking brake switch and gear box neutral position

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.

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Controls and operation Operating and Maintenance Manual 86 / Spreader locking override control

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 / Anti-tipping device override control 88 / Override key for the electronic gear box control unit 86

87

Only to be used in case of failure of the APC100. It provides one forward and one reverse speed for emergency use. 88

89

89 / Gearbox automatic or manual mode selection control This control is used to select automatic or manual mode of the gearbox.

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Controls and operation Operating and Maintenance Manual 100 / Revolving beacon control This control switches on the rotating beacon; indicator light 14 goes on.

101 / Cab rear screen wiper control This control is used to activate the cab rear screen wiper. 103

104

102 / Air conditioner controls (ESC) 105

This control starts the air conditioning. Turn the knob for cab 100

111

112

ventilation.

103 / No. 2 working light control switch This control switches on the working lights of the cab and the spreader.

104 / No. 1 working light control switch This control activates the boom w orking lights. 103

102

105 / Road light control switch 101

This control turns on the front and rear road lights. Warning light 15 comes on.

106 / No. 2 working light control switch

111 / Right side courtesy light

112 / Right side map reader light switch

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200 / Electronic gear box control unit YELLOW WARNING LIGHT: This lamp lights up when one of the two speed sensors indicate zero speed. As soon as the machine is moving, this lamp goes out. GREEN WARNING LIGHT: This lamp lights up when the throttle pedal is depressed. RED WARNING LIGHT: This lamp indicates that an internal APC100 problem has been detected. In this case, all the outputs of APC100 are automatically deactivated. The APC100 box must be repaired. Immediately park the machine on the roadside and call a TEREX specialist.

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Engine error code display procedure The QSM control system can display and record operational anomalies in the form of a fault code. This code provides easy identification of engine problems. The codes are recorded in the ECM and can be read from the engine fault indicator lights ( 24 and 23).

Verifying fault codes 83

- Switch on ignition. - The Stop Engine control 81 must be in released position. 80

If no engine fault code has been recorded, the two indicator lights 30 and 31 will go on and then off again when the engine starts. If fault codes have been recorded, the two indicator lights will go on.

30

- Stop the engine and release the Stop Engine control. - Press the Engine Test control 80. The code will be flashed as follows:

31

Lamp 31 flashes once.(start of code)

After this, the number of flashes of the Stop control 30 corresponds to a digit of the fault code (1st digit of the code). There is another pause of 1 to 2 seconds.

?

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Controls and operation Operating and Maintenance Manual The next digit of the code is given by the number of flashes of indicator light 30 (2nd digit of code). There is another pause of 1 to 2 seconds.

? 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.

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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.

Backrest rake adjustment Lift lever 4, set backrest to desired angle and release lever.

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

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Controls and operation Operating and Maintenance Manual Right control panel bracket lifting handle Use this handle to raise the control panel bracket to give access to the right-hand cab door.

Unoccupied passenger seat (OPTION) To avoid annoying vibration of the unused passenger seat, set t he weight adjustment to maximum, set the height adjustment as low as possible and lock the distance adjuster.

Recommended seat adjustment 1 - Push the seat+ bracket back as far as possible using lever 6. 2 - Push the seat only forward to the best position for using the pedals. Control 5. 3 - Adjust the position of the seat and back using levers 3-2 . 4 - Adjust the rake of the back using lever 4. 5 - Adjust the hardness of the seat using lever 1.

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Recommendations for minimizing levels of vibration of the machine. The level of vibration when driving depends on the following conditions: the state of the ground: potholes, lumps, etc. driving conditions: speed, cornering, braking, etc. The driver chooses his own speed and route as a function of the terrain. The result is a broad spectrum of levels of vibration which can be minimized by respecting the following recommendations: - Choose the machine and its equipment as a function of the task - Choose a machine in perfect condition (tyre pressures, condition of brakes, steering, etc.) - Changes of direction, braking, acceleration, changes of speed, all move the load and the equipment. - Keep the area where the machine operates in a good state. Remove large stones and obstacles Fill in holes Schedule maintenance work on the operating area. - Use a seat conforming to ISO 7096 and keep it in good condition and correctly adjusted. Adjust the seat and suspension as a function of the weight and height of the operator. Repair the adjustment and suspension mechanisms if they are faulty. - Suiting the speed of the machine to the nature of the ground reduces vibration. Slow down on rough ground. Avoid obstacles and bad surfaces.

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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 t han advice, since the manufacturer knows that this equipment will be entrusted to an operator of confirmed competence.

Preliminary Inspection and Adjustments Every day, before using the machine, go through maintenance check list "A" of this manual.

Clean the windows, headlights, and mirrors to ensure full vision. Also make sure the mirrors and operator's seat are properly adjusted.

Starting the engine. To start the engine, proceed as follows: 1- Put the Forward/Reverse lever in neutral position (N). 2- Tighten the parking brake. 3- Sound the audible warning. 4- Start the engine (normal temperature conditions above -12°C (10°F).

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Controls and operation Operating and Maintenance Manual This engine is designed to start wit hout any aid to starting at temperatures above -12°C (10°F). If the temperature is lower than 12°C, it is necessary to use an aid to starting or to change the engine oil to 15W40. For starting at temperatures under –12°C (10°F) proceed as described in 4.

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 12°C (10°F), 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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Controls and operation Operating and Maintenance Manual WARNING - The engine Oil Pressure Indicator Light (23) and the Transmission Oil Pressure Indicator Light (19) will illuminate until the oil pressures reach the normal operating pressure at start-up. If oil pressure does not reach normal operating pressure within 15 seconds after start-up, stop the engine immediately and correct the cause of low oil pressure.

5- Check all instruments immediately after the engine starts, to be sure they are reading properly. If the readings are incorrect, stop the engine immediately and determine the cause of the improper gauge reading before continuing operation.

6- Allow the engine to run at high idle speed for 4 to 5 minutes or preferably until the water temperature reaches the normal operating temperature before operating the machine.

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Prevention of fire risks in the engine compartment. The engine compartment must be inspected each time the machine is to be put into service, that is to say every day. When carrying out this inspection, check that the oil, fuel and air conditioning circuits are leak tight and dry. Check the tightness of the fuel and oil filters, the injection pump, the hydraulic unit, the hydraulic motors of the ventilation apparatus and their supply piping. The leaktghtness and correct operation of the exhaust system, especially the exhaust fixing flange must also be checked. Due to the heat produced by the exhaust pipes, it is important to make sure that the electric circuits are positioned and fixed far enough away from them, and that they are properly insulated. If the engine compartment is not regularly cleaned, it may become fouled with oil or fuel, especially after maintenance or repair work. In the case of a machine with sound insulation, the sound insulation panels must be cleaned regularly.

The engine compartment must only be cleaned with non-flammable cleaning products. Corrosive or chemically aggressive products should be avoided, in order to preserve the cabling and flexible hoses. Do not forget to screw back all filler plugs properly. In the event of any unusual odour in the cab, stop the engine and determine the cause.

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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.

To move the machine around in the work area, proceed as follows :

Automatic transmission mode - Start up the engine as previously described. - Select the automatic mode. - Put your foot on the travel brake pedal and release the parking brake. - Select the highest gear required by turning the gear selector button. - Push the lever forward for forward drive, or pull the lever back for reverse drive. - Release the travel brake pedal and accelerate using the accelerator pedal. - Use the travel brake pedal to slow down when approaching a container or for positioning. -

Second to first gear changing is not automatic.

Gearbox in manual mode - Start the engine as described above. - Select manual gearbox mode. - Put your foot on the travel brake pedal and release the parking brake. - Select FORWARD or REVERSE with the gear selector lever.

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Controls and operation Operating and Maintenance Manual - Push the lever forward to go forward, pull it back to reverse. - Place gear selector in 1st. - Release the travel brake pedal and accelerate the machine by pressing the accelerator pedal. - When the engine reaches its maximum corresponding speed, change up to the next gear. - Brake with the service brake pedal as you approach the container to be lifted, or in order to take up position.

Container handling cycle Before starting to operate the machine, the driver must study all the instructions given in this manual and in the chapter on safe operating practices at the beginning of this manual. The driver must familiarize himself with the controls and their operation.

The handling cycle for a container is as f ollows:

Approach the container to be moved. Lock the container to the spreader. Lift the container. Travel with the container. Deposit the container.

These operations must be performed as follows:

1- Use the service brake to slow the machine, irrespective of the type of transmission. When approaching the container, change down into 1st gear on machines with the Powershift gearbox.

2- Position the machine as close to the container as possible. Use the service brake and gearbox neutral pedal to disengage the transmission clutch and keep the full power of the engine available for the other functions of the machine (telescoping and lifting).

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Controls and operation Operating and Maintenance Manual 3- At this stage, the red indicator lights of the spreader should be on.

4- Lower the spreader onto the container to be handled. The red and white indicator lights of the spreader should now be on. During the locking operation, all boom movements are prohibited. Locking can only be effected if all the four locking contactors are pushed in. If locking is impossible, reposition the spreader. Once all the four locking contactors are pushed in, the white indicator lights of the spreader go on. At this stage, the functions Lower Boom and Extend Boom are inhibited. They can be made available again by using the LMI override key.

DANGER: This override must only used in very exceptional 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.

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.

6- Only the green indicator lights remain on during handling.

7- Balance the container by using the spreader side shift control.

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Controls and operation Operating and Maintenance Manual 8- Travel with the container as close as possible to the front axle and high enough for the drover to be able to see underneath it.

NOTE: It is impossible to see underneath a container if it is being trans ported in longitudinal position.

9- Use the same approach procedure as in points 1 and 2.

10- Position the container and lower it into place. The white spreader indicator lights will go on once the container is in place, and the twist locks can be released.

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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Stopping the engine To stop the engine, proceed as follows:

1- Place the transmission shift lever in the neutral position. 2- Pull the parking brake control lever up to set the parking brakes. 3. Allow the engine to idle for 3 to 5 minutes. This will allow the engine and turbocharger to cool down and prevents overheating due to localized residual heat. Extreme heat can seize bearings. 4. Push in and hold the engine shutdown button 87 until the engine comes to a complete stop.

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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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Function and identification of valve positions The marking position on the valve indicates the closed or open position of the valve.

The valve is open if the marking is parallel to the boom, pointed towards the cab.

If the mark is at right angles to the boom, the valve is closed.

The position of the handle is not a reliable indication unless it is aligned with the marking.

In normal use, the large valve 2 must be open and the small valve 1 closed. The damping circuit is correctly set up.

1

2

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Controls and operation Operating and Maintenance Manual If the valves are in this position when the machine is stored without the spreader, the damper cylinder piston rods will be completely extended. It is impossible to fix t he spreader in this position. The piston rods will remain fully retracted if the valve positions are inversed (small valve open, large valve closed).

An intermediate position can be obtained by closing the small valve as soon as the required position is obtained. The valves should be placed in their normal working positions once the spreader has been fixed.

The only function of these valves is to facilitate the removal and refitting of equipment.

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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

CAUTION: Use of this function should reserved strictly for: - handling a container in longitudinal position - rotating a container from transverse position.

The function is controlled by electric switch 84, and should not be used for other purposes.

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Optional fixed hook Fitting the fixed hook Place the spreader on two trestles about 1.30m (4 feet) in height.

Disconnect the hydraulic hose quickfit couplings and plug all the hoses.

Cut off the power supply by means of the main battery switch.

Disconnect the electrical connectors.

Place the shunt plug onto the P18 cable (shunt plug in the tool kit).

Switch on the electric supply.

Unpin the spreader from the joint (4 pins).

Pin the hook to the joint (4 pins).

Close the valve 1.

Open the valve 2.

Disconnect the damping cylinders by operating valve 1 in order to release pressure (2 pins).

Pin-connect the damping cylinders to the links welded on the boom head (2 pins).

LMI option: Select curve 200 on the LMI when working with the fixed hook.

The hook can be brought into use.

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Dismantling the fixed hook Unpin the damping cylinders from the links welded on the boom head.

Open the valve 1.

Close the valve 2.

Connect the damping cylinders to the joint.

Unpin the hook from the joint (4 pins).

Pin-connect the spreader to the joint (4 pins).

Remove the electric shunt plug, store it in the tool kit.

Connect the electric cables.

Connect the hydraulic hose quickfit couplings.

LMI option: Select curve 100 on the LMI when working with the spreader.

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Controls and operation ______________________ 10

Control identification_____________________ 10 Cab _____________________________________ 11

1 / Steering wheel (actuates rear wheels) _____ 11 2 / Gear shift control lever_________________ 11 3 / Service brake pedal and gear box neutral position ________________________________ 11 4 / Service brake pedal____________________ 11 5 / Accelerator pedal _____________________ 11 6 / Combined switch - lights - blinkers - horn _ 11 Control desk panel, centre right _______________ 12

13 / Working light warning light____________ 12 14 / Revolving beacon warning light _________ 12 15 / Headlights warning light ______________ 12 16 / Direction indicator warning light________ 12 17 / Parking lights warning light____________ 12 Control desk panel, centre right _______________ 13

18 / Torque converter oil temperature warning light___________________________________ 13 19 / Gear box oil pressure warning light______ 13 20 / Anti-tipping device warning light _______ 13 21 / Spreader lock override warning light ____ 13 22 / Brake oil pressure warning light ________ 13 23 / Parking brake warning light ___________ 13 24 / Anti-tipping device override warning light 13 25 / Excessive speed warning light __________ 13 Control desk panel, centre right _______________ 14

26 / Battery charging warning light _________ 14 27 / Engine preheating indicator light _______ 14 28 / Clogged oil and air filter warning light ___ 14 29 / Not used

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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 ________________ 16

40 / Compteur horaire ____________________ 16 41 / Unité 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

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87 / Anti-tipping device override control _____ 21 88 / Override key for gearbox operation electronic control unit ____________________ 21 89 / Selector control for gearbox automatic or manual mode.___________________________ 21 Ceiling panel controls _______________________ 22

100 / Revolving beacon control switch _______ 22 101 / Cab rear windshield wiper control switch 22 102 / Air conditioner controls (ESC)_________ 22 103 / No. 2 working light control switch ______ 22 104 / No. 1 working light control switch ______ 22 105 / Headlight control switch______________ 22 111 / Right side courtesy light ______________ 22 112 / Right side map reader light switch______ 22 Box behind seat____________________________ 23

200 / Gearbox operation electronic control unit 23

Fuse board

(Box behind seat) _______ 24

F1 - 10A – Battery isolator safety device _____ 24 F2 - 5A – Parking brake __________________ 24 F3 - 5A – Left and right ceiling light_________ 24 F4 - 15A.- Screenwiper, front - rear - cab roof - 24 F5 - 5A – Screenwasher – audible warning – indicator lights and receivers ______________ 24 F6 - 20A – Working light, cab – spreader – chassis. ________________________________ 24 F7 - 15A – Stop light – direction indicator lights. _______________________________________ 24 F8 - 20A – Working light, cab - boom. _______ 24 F9 - 20A – Rotating beacon lights ___________ 24 F10 -5A – Reversing light _________________ 24 F11 - 15A – Evaporator condenser compressor air conditioning _________________________ 24

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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

F29 –3A –Protection functions pressure switch air conditioning. _________________________ 25

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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


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F39 –10A – Battery isolator – Starter motor. __ 25 F40 –10A – Emergency warning lights. ______ 25 F41 –10A – Sidelights. ____________________ 25 F42 –5A – Rev. counter – Hour meter. _______ 25 F43 –10A – Vehicle radio –24V/12V converter. 25 F44 –10A – Engine electronic unit. __________ 26 F45 –10A – Engine electronic unit. __________ 26 F46 -

– 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

General fuses

(Battery compartment) _______________________________________ 27 PF100 - 100A – General protection of functions after isolation of battery __________________ 27 PF80 -80A – General protection of starter after isolation of battery _______________________ 27 PF50 -50A – General direct protection of battery _______________________________________ 27 Spreader operating warning lights __________ 28 RED - TWIST LOCKS released indicator light _______________________________________ 28

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WHITE - Position indicator light signalling possibility of actuating the TWIST LOCKS __ 28 GREEN - TWIST LOCKS applied indicator light___________________________________ 28 For conditions of use, see paragraph (locking onto a container). ________________________ 28 Cab _____________________________________ 30

2 / Gear change lever _____________________ 30 Cab _____________________________________ 31

3 / Accelerator pedal _____________________ 31 4 / Service brake pedal____________________ 31 5 / Service brake pedal and gear box neutral position ________________________________ 31 6 / Combination control: lights - direction indicators - audible warning (horn) – screen wipers _________________________________ 31 Direction indicators (blinkers) _____________ 31 Audible warning (horn)___________________ 31 Lighting _______________________________ 32 Ignition off ___________________________ 32 Screen wiper – screen washer ______________ 32 13 / Working light warning light____________ 32 14 / Beacon light warning light _____________ 32 15 / Full beam headlights warning light ______ 32 16 / Turn signal warning light______________ 32 17 / Parking lights warning light____________ 32 18 / Torque converter oil temperature warning light___________________________________ 33 19 / Clutch oil pressure warning light________ 33 If the pressure drops, stop the engine at once and ascertain the cause. ______________________ 33 20 / Anti-tipping device override warning light 33 21 / Spreader twist lock override warning light 33

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22 / Brake oil pressure warning light ________ 33 23 / Parking brake warning light ___________ 34 24 / Anti-tipping device override warning light 34 25 / Overspeed warning light (Red) _________ 34 26 / Battery charging warning light _________ 34 27 / Engine preheating indicator light _______ 34 28 / Clogged hydraulic oil and air filter warning light ___________________________________ 34 29 / Not used ____________________________ 34 30 / STOP engine alarm warning light _______ 34 31 / Engine fault warning light _____________ 35 32 / Low hydraulic oil level alarm warning light _______________________________________ 35 33 / Minimum fuel level warning light _______ 35 42 / Hour meter _________________________ 38 43 / Torque converter oil temperature gauge__ 38 44 / Fuel gauge __________________________ 38 45 / Gear box clutch oil pressure gauge ______ 38 4 / Hydraulic oil temperature gauge _________ 38 Control unit, right side ______________________ 39

70 / Boom lift/telescope joystick ____________ 39 70 /1 - Raise boom _____________________ 39 70 /2 - Lower boom ______________________ 39 70 /3 - Retract boom______________________ 39 70 /4 - Extend boom ______________________ 39 70A / High speed boom functions control _____ 39 71 / Spreader side shift control _____________ 39 71/1 - Side shift to the left _________________ 39 71/2 - Side shift to the right ________________ 39 72 / Spreader slewing control ______________ 40 72 /1 - Slewing to the left.__________________ 40 72 /2 Slewing to the right __________________ 40

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73 / Twist locks lock/release control lever_____ 40 - Releasing _____________________________ 40 - Locking_______________________________ 40 74 / Anti-tipping device override control _____ 41 75 / Spreader beam telescoping control ______ 41 76 / Ignition switch_______________________ 42 77 / Engine shut down control______________ 42 78 / Engine test code control _______________ 42 79 / Hazard warning lights control __________ 42 80 / Engine test control ___________________ 42 81 Parking brake switch and gear box neutral position ________________________________ 42 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. _____________________________ 42

86 / Spreader locking override control _______ 45 87 / Anti-tipping device override control _____ 46 88 / Override key for the electronic gear box control unit _____________________________ 46 89 / Gearbox automatic or manual mode selection control_________________________________ 46 100 / Revolving beacon control _____________ 47 101 / Cab rear screen wiper control _________ 47 102 / Air conditioner controls (ESC)_________ 47 103 / No. 2 working light control switch ______ 47 104 / No. 1 working light control switch ______ 47 105 / Road light control switch _____________ 47 106 / No. 2 working light control switch ______ 47 111 / Right side courtesy light ______________ 47 112 / Right side map reader light switch______ 47 200 / Electronic gear box control unit________ 48 Verifying fault codes _____________________ 49 Seat adjustments ___________________________ 51

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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

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Controls and operation

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.

FOR MACHINES EQUIPPED WITH L.M.I. THE CRANE OPERATOR OR JOBSITE MANAGER WILL BE HELD TOTALLY RESPONSIBLE FOR THE USE OF ANY CRANE FUNCTIONS APART FROM THOSE EXPRESSLY DESIGNATED BY PPM WHEN THE SAFETY DEVICE INDICATOR IS OVERRIDEN. PPM CAN IN NO WAY BE HELD RESPONSIBLE FOR ANY ACCIDENT THAT MAY OCCUR WHEN THE CRANE IS BEING USED WITH AN OVERRIDDEN LOAD MOMENT INDICATOR.

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Cab 1

2

1 / Steering wheel (actuates rear wheels) 2 / Gear shift control lever 5 4

3

3 / Service brake pedal and gear box neutral position 4 / Service brake pedal 5 / Accelerator pedal 6 / Combined switch - lights - blinkers - horn

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Control desk panel, centre right 16 17

15 13 14

13 / Working light warning light 14 / Revolving beacon warning light 15 / Headlights warning light 16 / Direction indicator warning light 17 / Parking lights warning light

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18

22

19

23 25

24

20

25

21

18 / Torque converter oil temperature warning light 19 / Gear box oil pressure warning light 20 / Anti-tipping device warning light 21 / Spreader lock override warning light 22 / Brake oil pressure warning light 23 / Parking brake warning light 24 / Anti-tipping device override warning light 25 / Excessive speed warning light

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30 31 25

26 27

32

33

28

29

26 / Battery charging warning light 27 / Engine preheating indicator light 28 / Clogged oil and air filter warning light 29 / Not used 30 / Alarm warning light STOP engine 31 / Engine fault warning light 32 / Low hydraulic oil level warning light 33 / Fuel minimum level warning light

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Piggy-back spreader warning light (Option) 34

35 36

38

37

39 40

34 / Correct pad clamping and hoist authorization green warning light

35 / Opened leg warning light

36 / Closed leg warning light

37 / Unfolded leg warning light

38 / Folded leg warning light

39 / Clamped leg warning light

40 / Unclamped leg warning light

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Control desk panel, centre left 44

45

46

40 / Compteur horaire

43

41 / Unité centrale MDM-Ecran 42

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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Control desk panel, lateral right 71

70

70/A

72

73

70 / Joystick controller (raise/lower - extend/retract boom) 70B/ High speed boom functions control 73

71 / Spreader side shift control 72 / Spreader swing control 73 / Twist locks lock / release control

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75

74 / Spreader damping lock switch 75 / Spreader beam telescoping switch

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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)

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Piggy-back spreader controls (Option) 83

84

83 / 2 or 4 legs piggy back selection control

84 / Piggy back leg control lever (option)

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88

87

89

86 / Spreader lock override control 87 / Anti-tipping device override control 88 / Override key for gearbox operation electronic control unit 89 / Selector control for gearbox automatic or manual mode.

90 / Tilt control (option) 90

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Ceiling panel controls 104 103

105 100 111

112

100 / Revolving beacon control switch 101 / Cab rear windshield wiper control switch 102 / Air conditioner controls (ESC) 103 / No. 2 working light control switch 104 / No. 1 working light control switch 105 / Headlight control switch 111 / Right side courtesy light 112 / Right side map reader light switch

103

102

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101


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Box behind seat 200 / Gearbox operation electronic control unit

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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.

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Controls and operation Operating and Maintenance Manual F21 - 10A – Spreader slewing - Spreader side shift. F22 - 10A – Flow rate cab joystick. F23 - 5A – Stop engine. F24 - 20A – Headlights main beam – Audible warning. F25 -

– Not used.

F26 -

– Not used.

D27 -

– Diode.

D28 -

– Diode.

F29 –3A –Protection functions pressure switch air conditioning. F30 -

– Not used.

F31 -

– Not used.

F32 -

– Not used.

F33 -

– Not used.

F34 F35 -

– Not used. – Not used.

F36 -

– Not used.

F37 -

– Not used.

F38 -

– Not used.

F39 –10A – Battery isolator – Starter motor. F40 –10A – Emergency warning lights. F41 –10A – Sidelights. F42 –5A – Rev. counter – Hour meter. F43 –10A – Vehicle radio –24V/12V converter.

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Controls and operation Operating and Maintenance Manual F44 –10A – Engine electronic unit. F45 –10A – Engine electronic unit.

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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Controls and operation Operating and Maintenance Manual Spreader operating warning lights

RED - TWIST LOCKS released indicator light WHITE - Position indicator light signalling possibility of actuating the TWIST LOCKS GREEN - TWIST LOCKS applied indicator light

For conditions of use, see paragraph (locking onto a container).

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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

WARNING: this machine has rear wheel steering: check path of rear wheels when steering.

CAUTION: Keep in mind that the space required by the rear of the machine when turning is greater than for other machines due to the rear wheel steering.

2 / Gear change lever There are two possible transmission modes. Manual and automatic. Front

Forward and reverse travel drives are selected when t he machine is at a standstill. To check if the transmission is in neutral, carefully press the accelerator: the machine should not move. Rear

When leaving the machine at the end of a shift, or whenever necessary, use the red catch to lock the gear lever in neutral position (N) so as to prevent any unintentional movement.

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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.

4 / Service brake pedal To be used in normal travel.

5

4

5 / Service brake pedal and gear box neutral position To be used when approaching a container (see procedure). This pedal disengages the transmission clutch and brakes the

3

machine at the same time.

Caution: Do not use left-hand brake pedal for normal travelling. 6 / Combination control: lights - direction indicators audible warning (horn) – screen wipers Direction indicators (blinkers) - left turn indicators: lever up. - right turn indicators: lever down. A flashing repeater lamp confirms that the indicators are working properly.

Audible warning (horn) Press the end of the lever, whatever position it may be in.

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Controls and operation Operating and Maintenance Manual Lighting Ignition off parking lights 105 go on. lever towards driver: headlight flash Ignition on - Lever pulled once towards driver: headlights (main beam) The blue repeater lamp goes on with main beam headlights or headlight flash.

Screen wiper – screen washer Position 1: Stop - Position 2: Intermittent - Position 3: Low speed Position 4: High speed. For screen wash, move the body of the control handle towards the centre.

13 / Working light warning light This warning light comes on when one of the working lights is

16

switched on with control 103 or 104. 17

14 / Beacon light warning light 15

This indicator light comes on when the rotating beacon light is switched on with control 100.

13 14

15 / Full beam headlights warning light This warning light comes on when the full beam headlights are turned on with control 6.

16 / Turn signal warning light This indicator lamp goes on when the direction indicators have been selected with control 6.

17 / Parking lights warning light This indicator light will come on when switch 105 is placed in the parking light position.

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Controls and operation Operating and Maintenance Manual 18 / Torque converter oil temperature warning light 22

18

This warning light is connected to thermometer 43 and comes on when the torque converter oil temperature is too high.

23

19

25

If this light goes on, proceed as follows: Lower the container, shift the transmission to "N" (neutral) position,

24

20

accelerate the engine to 1,200-1,500 rpm for two to three minutes or until the temperature reading is in the normal range.

25

21

19 / Clutch oil pressure warning light The warning light comes ON when clutch oil pressure is below 17 bar. This warning light is connected to pressure gauge 45.

DANGER: Never used the machine with the anti-tipping device overridden, or only in exceptional circumstances under the responsibility of the operator. Be doubly careful when manoeuvring.

If pressure drops, stop the engine immediately and ascertain the cause.

If the pressure drops, stop the engine at once and ascertain the cause. 20 / Anti-tipping device override warning light This warning light blinks when the anti-tipping device override is activated by means of the key 87 and the audible alarm is activated..

DANGER: Never use the machine with the spreader safety lock overridden, or only in exceptional circumstances under the responsibility of the operator. DANGER: Do not start travelling until the warning lamp (22) has gone out. The warning lamp (22) goes out when pressure reaches 105 bars.

21 / Spreader twist lock override warning light This warning light comes when the spreader twist lock override is activated with key 86. The audible alarm is activated.

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).

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Controls and operation Operating and Maintenance Manual 23 / Parking brake warning light 22

This light will come on when the parking brake switch 81 is applied. 18

24 / Anti-tipping device override warning light 23

19

25

This warning light goes on when the maximum permissible load is 24

20

exceeded. The audible warning sounds. Remaining authorized functions are:

25

21

Raise Boom - Retract Boom.

25 / Overspeed warning light (Red) Immediately slow down if this warning light comes on.

26 / Battery charging warning light This warning light comes on if the alternator does not charge the

30 31 25

32

26

batteries - ascertain the cause.

27

27 / Engine preheating indicator light

28

28 / Clogged hydraulic oil and air filter warning light 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

30 / STOP engine alarm warning light This warning light goes on when the engine protection system is no longer in a position to perform its function. In such a case, the engine must be stopped. Park the machine in a parking area or on the hard shoulder of the road, making sure that it does not represent a traffic hazard. STOP the engine.

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31 / Engine fault warning light QSM engines are equipped with a protection system. This system analyses different parameters, such as coolant temperature, coolant level, oil pressure, overspeed, etc. It warns the driver of a functional problem by means of the engine fault warning light and takes preventive measures to protect the engine by gradually reducing power and speed (see procedure "Reading fault codes").

30

26

32 / Low hydraulic oil level alarm warning light

31

27

25

If this light goes on, make sure that there are no hydraulic oil leaks 32

28

and make up the hydraulic oil level immediately. DO NOT FORGET to respect servicing instructions.

33 29

33 / Minimum fuel level warning light If this light goes on, refill the fuel tank immediately.

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Piggy-back spreader warning light (Option)

34 / Correct pad clamping and hoist authorization green warning light 34

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

35 / Opened leg warning light 37

This warning light comes ON when upper beams legs are fully extended by activating switch Ref. 85.

39 40

36 / Closed leg warning light This warning light comes ON when upper beams legs are fully retracted by activating switch Ref. 85.

37 / Unfolded leg warning light This warning light comes ON when legs are fully unfolded by activating switch Ref. 84.

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38 / Folded leg warning light This warning light comes ON when legs are folded away by activating switch Ref. 84.

39 / Clamped leg warning light 34

This warning light comes ON when legs are fully clamped by activating switch Ref. 84.

35 36

38

40 / Unclamped leg warning light 37

39

This warning light comes ON when legs are fully unclamped by activating switch Ref. 84.

40

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44

45

46

42 / Hour meter The hour meter operates when the engine is running.

43 / Torque converter oil temperature gauge 43 42

Normal operating temperature: 82 to 93°C (180-200°F) Maximum temperature not to be exceeded: 110°C (230°F)

NOTE: if the converter oil temperature reaches the maximum value shown above: - shut down the vehicle - shift to neutral (position "N") - accelerate the engine to 1,200/1,500 rpm for two to three minutes. (Until the temperature returns to normal operating value). Warning light 18 comes on when converter oil temperature reaches 110°C.

44 / Fuel gauge This gauge indicates the amount of fuel remaining in the fuel tank.

45 / Gear box clutch oil pressure gauge Normal operating pressure: 16.9 to 19.6 bar (240 to 280 PSI) If the pressure drops abnormally, stop the engine and ascertain the cause.

4 / Hydraulic oil temperature gauge Linked with hydraulic oil cooler temperature switch (starts up at 450°C -1,130°F).The temperature may reach 80°C (1,760°F). Stop the engine and ascertain the cause.

CAUTION: DO NOT EXCEED THE TEMPERATURE OF 80°C.

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Control unit, right side 70

71

70 / Boom lift/telescope joystick This joystick controls raising/lowering and telescopic

72

extension/retraction of the boom. 73

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.

70A / High speed boom functions control This control is used for high speed execution of the following boom functions: Raise boom – Extend boom – Retract boom

71 / Spreader side shift control This control is used to shift the sliding trolley of the spreader, either to 71/1

the right (71/2) or to the left (71/1).

71/1 - Side shift to the left 71/2

Press the button to shift the spreader to the left.

71/2 - Side shift to the right Press the button to shift the spreader to the right.

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Controls and operation Operating and Maintenance Manual 72 / Spreader slewing control This control is used to slew the spreader either to the right ( 72/2) or to the left (72/1). Before slewing the spreader, the slewing function must be released by pressing control 75. 72/1

72 /1 - Slewing to the left. Press the button to slew the spreader to the left.

72/2

72 /2 Slewing to the right Press the button to slew the spreader to the right.

73 / Twist locks lock/release control lever This control is used to lock or release the twist locks.

- Releasing Push the lever to the left to release the spreader from the container.

- Locking Push the lever to the right to lock t he spreader to the container.

DANGER: 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.

During the operation of locking onto the container, all boom movements are prohibited. Locking can only be performed if all four locking contactors are pushed in. If locking cannot be effected, reposition the spreader. Once all the four locking contactors are pushed in, the white spreader indicator lights go on. The functions Lower Boom and Extend Boom are then inhibited. These functions can be made available again by using the LMI override key.

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Controls and operation Operating and Maintenance Manual 74 / Anti-tipping device override control

Position 1: The spreader's shock absorption function is immobilized. Position 2: The spreader's shock absorption function is enabled.

74

IMPORTANT: It is essential to immobilize the spreader's shock absorption function in order to travel carrying a container in logitudinal position.

75

75 / Spreader beam telescoping control This control telescopically extends or retracts the beams of the spreader. Switch to the right: beams extend. Switch to the left: beams retract.

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Controls and operation Operating and Maintenance Manual 76 / Ignition switch This switch is used to power the electrical system and to start and stop the engine . (See chapter: Stopping the engine.)

77 / Engine shut down control Press to stop the engine. (see paragraph: Stopping engine)

IMPORTANT: As the engine is turbocharged, it is advisable to let it run for a few moments at idling speed before stopping it. 78 / Engine test code control (see procedure "Reading fault codes").

79 / Hazard warning lights control This control activates the hazard warning lights.

80 / Engine test control (see procedure "Reading fault codes").

81 Parking brake switch and gear box neutral position

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.

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82 / Outrigger control (Option) 82

This lever allows the vertical f ront outriggers to be raised or lowered. The gear selector (ref. 2) must be in the neutral (N) position and the machine at a standstill to enable use of this function. Push the control forward to lower the outriggers, warning light into the control will come on. Pull the lever backward to raise the outriggers, warning light into the control will go out.

The outriggers can only be set down when the machine is at a standstill (gear selector in neutral position). The operator can raise the outriggers whenever he wishes (under certain conditions), but it is impossible to drive the machine until the outriggers had been fully raised. If a gear is selected and the outriggers are not fully raised, a buzzer is activated. Driving the machine will be impossible until the outriggers had been fully raised. Two detectors (on the telescoping and derricking functions) inhibit raising of the outriggers until the boom is brought into a position allowing safe driving with acceptable axle loading. The outriggers can be raised whatever the position of the spreader as long as there is no suspended load.

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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.

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Piggy-back spreader controls (Option) 83 / 2 or 4 legs piggy back selection control Refer to chapter on Piggy Back operation.

This three position switch determines which legs will be controlled by 83

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 / Piggy back leg control lever (option) 84 /1 Legs lowering 84

84 /2 Legs lifting

84 /3 Leg opening

84 /4 Leg clamping

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Controls and operation Operating and Maintenance Manual 86 / Spreader locking override control

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 / Anti-tipping device override control 88 / Override key for the electronic gear box control unit 86

87

Only to be used in case of failure of the APC100. It provides one forward and one reverse speed for emergency use. 88

89

89 / Gearbox automatic or manual mode selection control This control is used to select automatic or manual mode of the gearbox.

90 / Tilt control (option) This spring centered switch tilts the spreader to the left and to the right. Push and hold this switch to the left to lower the container on the 90

left side. Push and hold this switch to the right to lower the container on the right side.

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Controls and operation Operating and Maintenance Manual 100 / Revolving beacon control This control switches on the rotating beacon; indicator light 14 goes on.

101 / Cab rear screen wiper control This control is used to activate the cab rear screen wiper. 103

104

102 / Air conditioner controls (ESC) 105

This control starts the air conditioning. Turn the knob for cab 100

111

112

ventilation.

103 / No. 2 working light control switch This control switches on the working lights of the cab and the spreader.

104 / No. 1 working light control switch This control activates the boom w orking lights. 103

102

105 / Road light control switch 101

This control turns on the front and rear road lights. Warning light 15 comes on.

106 / No. 2 working light control switch

111 / Right side courtesy light

112 / Right side map reader light switch

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200 / Electronic gear box control unit YELLOW WARNING LIGHT: This lamp lights up when one of the two speed sensors indicate zero speed. As soon as the machine is moving, this lamp goes out. GREEN WARNING LIGHT: This lamp lights up when the throttle pedal is depressed. RED WARNING LIGHT: This lamp indicates that an internal APC100 problem has been detected. In this case, all the outputs of APC100 are automatically deactivated. The APC100 box must be repaired. Immediately park the machine on the roadside and call a TEREX specialist.

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Engine error code display procedure The QSM control system can display and record operational anomalies in the form of a fault code. This code provides easy identification of engine problems. The codes are recorded in the ECM and can be read from the engine fault indicator lights ( 24 and 23).

Verifying fault codes 83

- Switch on ignition. - The Stop Engine control 81 must be in released position. 80

If no engine fault code has been recorded, the two indicator lights 30 and 31 will go on and then off again when the engine starts. If fault codes have been recorded, the two indicator lights will go on.

30

- Stop the engine and release the Stop Engine control. - Press the Engine Test control 80. The code will be flashed as follows:

31

Lamp 31 flashes once.(start of code)

After this, the number of flashes of the Stop control 30 corresponds to a digit of the fault code (1st digit of the code). There is another pause of 1 to 2 seconds.

?

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Controls and operation Operating and Maintenance Manual The next digit of the code is given by the number of flashes of indicator light 30 (2nd digit of code). There is another pause of 1 to 2 seconds.

? 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.

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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.

Backrest rake adjustment Lift lever 4, set backrest to desired angle and release lever.

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

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Controls and operation Operating and Maintenance Manual Right control panel bracket lifting handle Use this handle to raise the control panel bracket to give access to the right-hand cab door.

Unoccupied passenger seat (OPTION) To avoid annoying vibration of the unused passenger seat, set t he weight adjustment to maximum, set the height adjustment as low as possible and lock the distance adjuster.

Recommended seat adjustment 1 - Push the seat+ bracket back as far as possible using lever 6. 2 - Push the seat only forward to the best position for using the pedals. Control 5. 3 - Adjust the position of the seat and back using levers 3-2 . 4 - Adjust the rake of the back using lever 4. 5 - Adjust the hardness of the seat using lever 1.

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Recommendations for minimizing levels of vibration of the machine. The level of vibration when driving depends on the following conditions: the state of the ground: potholes, lumps, etc. driving conditions: speed, cornering, braking, etc. The driver chooses his own speed and route as a function of the terrain. The result is a broad spectrum of levels of vibration which can be minimized by respecting the following recommendations: - Choose the machine and its equipment as a function of the task - Choose a machine in perfect condition (tyre pressures, condition of brakes, steering, etc.) - Changes of direction, braking, acceleration, changes of speed, all move the load and the equipment. - Keep the area where the machine operates in a good state. Remove large stones and obstacles Fill in holes Schedule maintenance work on the operating area. - Use a seat conforming to ISO 7096 and keep it in good condition and correctly adjusted. Adjust the seat and suspension as a function of the weight and height of the operator. Repair the adjustment and suspension mechanisms if they are faulty. - Suiting the speed of the machine to the nature of the ground reduces vibration. Slow down on rough ground. Avoid obstacles and bad surfaces.

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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.

Preliminary Inspection and Adjustments Every day, before using the machine, go through maintenance check list "A" of this manual.

Clean the windows, headlights, and mirrors to ensure full vision. Also make sure the mirrors and operator's seat are properly adjusted.

Starting the engine. To start the engine, proceed as follows: 1- Put the Forward/Reverse lever in neutral position (N). 2- Tighten the parking brake. 3- Sound the audible warning. 4- Start the engine (normal temperature conditions above -12°C (10°F).

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Controls and operation Operating and Maintenance Manual This engine is designed to start wit hout any aid to starting at temperatures above -12°C (10°F). If the temperature is lower than 12°C, it is necessary to use an aid to starting or to change the engine oil to 15W40. For starting at temperatures under –12°C (10°F) proceed as described in 4.

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 12°C (10°F), 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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Controls and operation Operating and Maintenance Manual WARNING - The engine Oil Pressure Indicator Light (23) and the Transmission Oil Pressure Indicator Light (19) will illuminate until the oil pressures reach the normal operating pressure at start-up. If oil pressure does not reach normal operating pressure within 15 seconds after start-up, stop the engine immediately and correct the cause of low oil pressure.

5- Check all instruments immediately after the engine starts, to be sure they are reading properly. If the readings are incorrect, stop the engine immediately and determine the cause of the improper gauge reading before continuing operation.

6- Allow the engine to run at high idle speed for 4 to 5 minutes or preferably until the water temperature reaches the normal operating temperature before operating the machine.

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Prevention of fire risks in the engine compartment. The engine compartment must be inspected each time the machine is to be put into service, that is to say every day. When carrying out this inspection, check that the oil, fuel and air conditioning circuits are leak tight and dry. Check the tightness of the fuel and oil filters, the injection pump, the hydraulic unit, the hydraulic motors of the ventilation apparatus and their supply piping. The leaktghtness and correct operation of the exhaust system, especially the exhaust fixing flange must also be checked. Due to the heat produced by the exhaust pipes, it is important to make sure that the electric circuits are positioned and fixed far enough away from them, and that they are properly insulated. If the engine compartment is not regularly cleaned, it may become fouled with oil or fuel, especially after maintenance or repair work. In the case of a machine with sound insulation, the sound insulation panels must be cleaned regularly.

The engine compartment must only be cleaned with non-flammable cleaning products. Corrosive or chemically aggressive products should be avoided, in order to preserve the cabling and flexible hoses. Do not forget to screw back all filler plugs properly. In the event of any unusual odour in the cab, stop the engine and determine the cause.

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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.

To move the machine around in the work area, proceed as follows :

Automatic transmission mode - Start up the engine as previously described. - Select the automatic mode. - Put your foot on the travel brake pedal and release the parking brake. - Select the highest gear required by turning the gear selector button. - Push the lever forward for forward drive, or pull the lever back for reverse drive. - Release the travel brake pedal and accelerate using the accelerator pedal. - Use the travel brake pedal to slow down when approaching a container or for positioning. -

Second to first gear changing is not automatic.

Gearbox in manual mode - Start the engine as described above. - Select manual gearbox mode. - Put your foot on the travel brake pedal and release the parking brake. - Select FORWARD or REVERSE with the gear selector lever.

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Controls and operation Operating and Maintenance Manual - Push the lever forward to go forward, pull it back to reverse. - Place gear selector in 1st. - Release the travel brake pedal and accelerate the machine by pressing the accelerator pedal. - When the engine reaches its maximum corresponding speed, change up to the next gear. - Brake with the service brake pedal as you approach the container to be lifted, or in order to take up position.

Container handling cycle Before starting to operate the machine, the driver must study all the instructions given in this manual and in the chapter on safe operating practices at the beginning of this manual. The driver must familiarize himself with the controls and their operation.

The handling cycle for a container is as f ollows:

Approach the container to be moved. Lock the container to the spreader. Lift the container. Travel with the container. Deposit the container.

These operations must be performed as follows:

1- Use the service brake to slow the machine, irrespective of the type of transmission. When approaching the container, change down into 1st gear on machines with the Powershift gearbox.

2- Position the machine as close to the container as possible. Use the service brake and gearbox neutral pedal to disengage the transmission clutch and keep the full power of the engine available for the other functions of the machine (telescoping and lifting).

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Controls and operation Operating and Maintenance Manual 3- At this stage, the red indicator lights of the spreader should be on.

4- Lower the spreader onto the container to be handled. The red and white indicator lights of the spreader should now be on. During the locking operation, all boom movements are prohibited. Locking can only be effected if all the four locking contactors are pushed in. If locking is impossible, reposition the spreader. Once all the four locking contactors are pushed in, the white indicator lights of the spreader go on. At this stage, the functions Lower Boom and Extend Boom are inhibited. They can be made available again by using the LMI override key.

DANGER: This override must only used in very exceptional 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.

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.

6- Only the green indicator lights remain on during handling.

7- Balance the container by using the spreader side shift control.

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Controls and operation Operating and Maintenance Manual 8- Travel with the container as close as possible to the front axle and high enough for the drover to be able to see underneath it.

NOTE: It is impossible to see underneath a container if it is being transported in longitudinal position.

9- Use the same approach procedure as in points 1 and 2.

10- Position the container and lower it into place. The white spreader indicator lights will go on once the container is in place, and the twist locks can be released.

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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Stopping the engine To stop the engine, proceed as follows:

1- Place the transmission shift lever in the neutral position. 2- Pull the parking brake control lever up to set the parking brakes. 3. Allow the engine to idle for 3 to 5 minutes. This will allow the engine and turbocharger to cool down and prevents overheating due to localized residual heat. Extreme heat can seize bearings. 4. Push in and hold the engine shutdown button 87 until the engine comes to a complete stop.

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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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Function and identification of valve positions The marking position on the valve indicates the closed or open position of the valve.

The valve is open if the marking is parallel to the boom, pointed towards the cab.

If the mark is at right angles to the boom, the valve is closed.

The position of the handle is not a reliable indication unless it is aligned with the marking.

In normal use, the large valve 2 must be open and the small valve 1 closed. The damping circuit is correctly set up.

1

2

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Controls and operation Operating and Maintenance Manual If the valves are in this position when the machine is stored without the spreader, the damper cylinder piston rods will be completely extended. It is impossible to fix t he spreader in this position. The piston rods will remain fully retracted if the valve positions are inversed (small valve open, large valve closed).

An intermediate position can be obtained by closing the small valve as soon as the required position is obtained. The valves should be placed in their normal working positions once the spreader has been fixed.

The only function of these valves is to facilitate the removal and refitting of equipment.

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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

CAUTION: Use of this function should reserved strictly for: - handling a container in longitudinal position - rotating a container from transverse position.

The function is controlled by electric switch 84, and should not be used for other purposes.

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Optional fixed hook Fitting the fixed hook Place the spreader on two trestles about 1.30m (4 feet) in height.

Disconnect the hydraulic hose quickfit couplings and plug all the hoses.

Cut off the power supply by means of the main battery switch.

Disconnect the electrical connectors.

Place the shunt plug onto the P18 cable (shunt plug in the tool kit).

Switch on the electric supply.

Unpin the spreader from the joint (4 pins).

Pin the hook to the joint (4 pins).

Close the valve 1.

Open the valve 2.

Disconnect the damping cylinders by operating valve 1 in order to release pressure (2 pins).

Pin-connect the damping cylinders to the links welded on the boom head (2 pins).

LMI option: Select curve 200 on the LMI when working with the fixed hook.

The hook can be brought into use.

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Dismantling the fixed hook Unpin the damping cylinders from the links welded on the boom head.

Open the valve 1.

Close the valve 2.

Connect the damping cylinders to the joint.

Unpin the hook from the joint (4 pins).

Pin-connect the spreader to the joint (4 pins).

Remove the electric shunt plug, store it in the tool kit.

Connect the electric cables.

Connect the hydraulic hose quickfit couplings.

LMI option: Select curve 100 on the LMI when working with the spreader.

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Block stow operations To lift the container - Move the machine in front of the container. - Boom up to allow the legs to be lowered. - Telescope fully retracted.

Place switch 74 on AV-AR position.

Open the legs by mean of switch 84 : warning light 35 comes ON.

Select rear legs with switch 83.

Lower the rear legs by means of switc h 84/1, warning light 37 comes ON.

Clamp on the rear legs by mean of switch 84/4, warning light 39comes ON.

Manoeuver to enter the pads in their locations, for this purpose use spreader motions ( translation - etc...)

Select the front legs by means of switch 83.

Open the front legs by means of switch 84/3 : warning light 40 comes ON.

Lower the front legs by means of switch 84/1 : warning light 37 comes ON.

Clamp on the legs by means of switch 84/4 : warning light 39 comes ON.

Manoeuver to enter the legs in their locations.

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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:

DANGER: If a procedure, technique of use etc., is not executed correctly, this entails a risk of serious or fatal injury to staff.

WARNING : If a procedure, technique of use etc., is not executed correctly in strict accordance with the instructions, this entails a risk of damage or destruction of equipment.

NOTE : A procedure or a state, etc., which requires emphasis.

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Maintenance Operating and Maintenance Manual

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.

2 nd 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.

5 th level: Renovation, reconditioning carried out, by definition, by the maker with means practically similar to those of the manufacture.

st

The 1 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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Slew ring attachment. Check the lubrication and attachment of the slew ring at regular intervals. If a fault is found, seek the assistance of a TEREX specialist, who will advise you on the subsequent action to be taken. THE SLEW RING CONNECTING SCREWS ARE SAFETY PARTS..

Periodic and compulsory slewing ring fastener checks. DANGER: Faulty tightening is one of the factors that can lead to fracture of the slew ring fixing. It is vital that this method should be respected to ensure the safety of this assembly.

1 - Slew ring fastener tightness is checked at the factory prior to delivery. 2 - Slewing ring fasteners have to be to be retightened to the recommended torque setting (refer to table) during the first warranty visit. Carry out the 1st check after 500 operating ho urs, and then check the torque every 2000 hours thereafter.

a) Tooling : Calibrated torque wrench (set to nominal torque rating

1

- see table below).

8

5

Refer to torque wrench manufacturer's document (torque setting tolerance : ± 5%)

4

3

b) Conditions for verification : Machine set up on outriggers Short boom derricked so as to have a radius of 3m. No load.

6

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

Réference

Description

16x2

90

S 63338 94

Vis / Screw / Schraube / ornillos

23

100

F 19338 68


50

100

E 62338 32

Boulon / Bolt / Bolzen / Perno

110

T 19338 80

Vis / Screw / Schraube / Tornillos

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

Boulon / Bolt / B olzen / Perno

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

24x2.00 160

M 19338 74


90

90

160

H 19338 70


170

D 19338 89


90

90

200

Q 62338 42


90

70

145

U 19338 81


130

95

145

N 19338 75


130

130

155

G 62338 57


160

P 19338 76


130

130

27x2.00 175

C 62338 53


190

Q 19338 77


130

130

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

90

90

130

130

130

70

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

Réference

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

145 170

34 42

42


42

42

C 19338 88


42

42

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

24x2.00 160

M 19338 74


76

76

160

H 19338 70


170

D 19338 89


76

76

200

Q 62338 42


76

59

145

U 19338 81


110

80

145

N 19338 75


110

110

155

G 62338 57


160

P 19338 76


110

110

27x2.00 175

C 62338 53


190

Q 19338 77


110

110

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

76

76

110

110

110

59

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

1

are the same as in paragraph 2.

8

5

a) Verify all the fasteners. Mark all fasteners with a torque value of less than 85% of the nominal value. If the number of fasteners detected with this characteristic is

4

3

greater than 20% of the total number, then all the ring fasten ers must be changed. USE ONLY ORIGINAL PPM SPARE PARTS

6

7

b) Otherwise retighten all fasteners with a torque value greater than 85% of the nominal value to the nominal torque value indicated in the

2

table, and in the order as shown in the illustration opposite. c) Change, one by one and in the recommended order, all the fasteners detected and marked in step (a) which have a torque value inferior to 85% of nominal value. ONLY USE GENUINE PPM SPARE PARTS Tighten to the value indicated in the table d1. 4 - Systematic exchange :

-

If 20% of the screws have been replaced.

-

If the slew ring is replaced.

ONLY USE TEREX ORIGINAL PARTS..

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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Maintenance Operating and Maintenance Manual 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.

Checking slew ring wear:

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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).

Measuring the tilting clearance. To determine the extent of wear, measure the tilting clearance as follows using a comparator that is accurate to 0.01 mm: Cranes: -

Stabilize the machine on fully-extended outriggers using the fullest possible counterweight arrangement attached to the upperstructure.

-

Position the comparator as illustrated.

-

Extend the boom to an average of 15 to 20 metres, and raise as high as possible.

-

Set the comparator to zero.

-

Lower the boom until it is horizontal. Do not exceed the indications given in the load chart.

-

Take the reading of the tilting clearance from the comparator.

Stackers: -

Travel the spreader carrier left or right as far as possible.

-

Set the comparator to zero. The comparator must be positioned parallel to the spreader centreline by either the left or right locks.

-

Travel the carrier as far as possible in the opposite direction.

-

Take the reading of the tilting clearance from the comparator.

The clearance is measured before the machine is put into commission, and acts as the base measurement for subsequent checks. A clearance of 0.5 to 0.7 mm may be used as a reference.

Details about the measurement: The measurement points on the outer circumference are defined starting arbitrarily from position 1.

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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.

the one below :

Reading for … hour period : Measurement

Reference measurement 0,5 à 0,7

New measurement

Wear (1)

Measurement point 1 Measurement point 0,5 à 0,7 2 Measurement point 0,5 à 0,7 3 Measurement point 0,5 à 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).

Acceptable wear limits : Contact TEREX-PPM if the permitted wear limits (see chart) are exceeded.

Slew rings with a single lane of bearing balls (four contact points) Track diameter (mm)

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Ø of the ball (mm)


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Up to

20

22

25

30

35

40

45

50

60

70

Acceptable wear limit in mm 1000 1.4

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

PPM slew ring dimensions Machine

Bearing diameter

Ball diameter

980 mm

35 mm

ATT400/3 ATT400/3L

1272 mm

30 mm

ATT600/3

1491 mm

45 mm

Spreader stacker

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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Before every daily start up Every day, inspect the machine before getting in or starting the engine. Look carefully for: loose or missing bolts, dirt accumulation, oil or coolant liquid leaks. Check condition of tyres and levels.

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

Boom slide pads

MOLYKOTE BR 2

Grease nipples

ALVANIA EP2

Slewing ring teeth

MALLEUS GL 205

Slewing ring bearing

ALVANIA EP2

Slewing reducer gear TRASMITAL

SPIRAX HD 80W90

SPIRAX HD 80W90

SPIRAX HD 85W140

Slewing reducer gear + brake DINAMIC OIL

OMALA EP VG220

OMALA EP VG220

TIVELA OIL VG2200

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

Brake circuit Axle

DONAX TD

DONAX TD

DONAX TD

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List "A" - 10 hours Air filter Air filter cleaning and verification If the clogging indicator light goes on, clean the primary cartridge. If the cartridge is dry: - Blow it out from the inside towards the outside using very low pressure (7 bars max. (101 PSI)). - Check inside with an inspection lamp and make sure that the cartridge is not perforated. Replace if the elements are greasy. Replacing the cartridge: The central safety cartridge should not be cleaned. Replace it at every third cleaning of the primary cartridge. The primary cartridge must be replaced after being cleaned six times, or annually.

PRIMARY

SAFETY

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Fuel tank and hydraulic tank levels 1/ Diesel filler tube

Do not forget to screw back all

2/ Hydraulic oil filler tube

filler plugs properly.

3/1 Maximum level tube 3/2 Minimum level tube and minimum oil level warning

4/ Oil circuit closure control

Never smoke while filling up with fuel: the fumes

Level: every 10 HOURS.

from the fuel are highly

- 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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Transmission: Converter and powershift gear box Level check: every 10 hours. Access: Under the chassis on the right hand side. On the side of the gear box (winged plug with 'FULL' marked next to it). Under the carrier chassis, right -hand side.

To fill: by filler tube at the front end next to the converter.

Topping up procedure: Check the oil level with the engine running at idling speed and oil temperature between 82°C (180°F) and 93°C (200°F). Keep the level at 'FULL' (upper plug).

Do not forget to screw back all filler plugs properly.

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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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Brake circuit: fluid level check Level check: every 10 hours

Capacity : 50L Located on the right hand side of the machine.

Do not forget to screw back all

Engine radiator: coolant level

filler plugs properly. Level check: every 10 hours

Check the level of the coolant liquid and, if necessary, add water or antifreeze solution to within two centimetres of the filler orifice To ensure that the cooling circuit is properly filled, you must: fill the circuit to maximum with engine stopped run the engine briefly and stop it fill up again repeat the operation until the level no longer drops check the level again after 1 hour's operation. Use the type and quantity of antifreeze recommended by the engine manufacturer. See manufacturer's documentation.

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GLYCOSHELL PLUS - TO BE MIXED WITH WATER. Warning: Do not add more than 2 1/2 volumes of pure water per volume of this concentrate.

Protection down to

Volume of cooling circuit (litres)

4

6

7

8

10 15 20 25 30 35 40 45 50 55 60 65

Quantity of GLYCOSHELL PLUS to use (litres) - 10°C

-

2

2

-

3

-

-

-

-

-

-

-

-

-

-

- 15°C

2

2

2

3

3

5

6

8

9

- 20°C

2

2

3

3

4

6

7

9

- 25°C

2

3

3

4

4

6

8

10 12 14 16 18 20 22 24 26

- 30°C

2

3

3

4

5

7

9

11 14 16 18 20 22 25 27 29

- 35°C

2

3

4

4

5

8

11 12 13 15 16 18 19

11 12 14 16 17 19 21 23

10 12 15 17 20 22 24 27 29 32

NEVER MIX DIFFERENT TYPES OF ANTIFREEZE

When draining, be careful of the oil or coolant liquid.

The engine should be stopped; do not release the parking or emergency brake unless the vehicle is chocked or immobilized. Be cautious when unscrewing radiator caps or any drain plugs, grease nipples or pressure injectors . Hot oil and components can cause burns: avoid all contact with the skin.

Spreader greasing operations Frequency: every 10 hours

- One grease nipple on each spreader twist lock. - One grease nipple on each probe. - Two grease nipples on the sideshift cylinder. - Slide pad greasing.

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-

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List "B" - 50 hours Spreader hydraulic slewing motor Level check: every 50 hours (on dipstick). Drain and filling orifices.

Spreader hydraulic sideshift motor Level check: every 50 hours (on dipstick). Drain and filling orifices.


Spreader slewing ring Frequency: every 50 hours.

Insert grease with a pump through the 4 grease nipples on the slewing ring, give 4 or 5 strokes of the gun per grease nipple.

Rotate the ring by a quarter of a turn after each pump stroke so that the grease is uniformly dispersed inside the ring.

As a safety measure only one operator must carry out this operation.

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Slewing ring teeth Greasing: every 50 hours. Apply the spray in two passes as illustrated opposite.

Note: It is necessary to make a full rotation in each direction to correctly grease the ring and its drive pinion.

As a safety measure, only one operator must carry out this operation.

Boom and booming system Frequency: every 50 hours.

One grease nipple on the boom base swivel point. One grease nipple on the boom head shaft. Two grease nipples on each anti sway cylinder. Greasing of the slide pads.

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List "C" - 100 hours Batteries Electrolyte level check: every 100 hours. Cut the electric circuit supply. - remove the cell plugs. - the level in each cell should be between 10 and 15 mm above the top of the plates. - top up with distilled water. - refit the plugs.

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.

- check the electrolyte density with a density tester (before adding distilled water). Specific density

Degrees Baumé

Remarks

1.285

32°

correctly charged

1.200

24°

semi-charged

1.120

16°

discharged

- If necessary, have the batteries recharged and tested by a specialized workshop. - If the charging current is too high (water has to be added frequently), or too low (density too low), find the cause and rectify the problem in order to ensure long battery life.

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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.

Securing the batteries Moderately tighten the battery tie bars by semi-compression of the springs, then tighten the locknuts.

Wheel fastener tightness Check wheel fastener tightness every 100 hours.

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torque settings: Front axle:

38 mKg (280 ft.-lbs)

Rear axle:

38 mKg (280 ft.-lbs)


06/12/2004


Check the tightness of all spreader fasteners Balance the rotating section of the spreader and eliminate any radial effort by centring the sliding frame. Check fastener tightness after 100 working hours. Recheck every 1,000 hours.

Slewing ring fastener tightness General guidelines for tightening slewing ring fixing screws.

NOTE: Torque settings apply to phosphated, ungreased but clean bolts. Torque settings are identical for: * nut and bolt assemblies, * bolts screwed into threaded holes. Slewing ring assembly: 1/ Degrease and clean support surfaces on the spreader. 2/ Degrease the slewing ring. 3/ Fit the ring, keeping in mind that the internal plug (roller assembly access) must be positioned at 90° with respect to the longitudinal axis of the machine. (Refer to sketch below.)

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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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List "D" - 200/250 hours Tyre pressures 1,800 x 25:

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.

Transmission shafts and U-joints Frequency: every 200 hours.

Three grease nipples per transmission shaft. Greasing the pump drive shaft: It is necessary to remove the drive shaft protector tubes.

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Chapter Chapter IV - Page 29 of 47

06/12/2004 06/12/20 04


Rear steering axle Frequency: every 200 hours Grease the joints, the steering cylinder and pivots.

Air conditioning unit Once a month: - clean the evaporator with compressed air (max. 4 bars). - clean the condenser with high pressure water WARNING: In both cases, excessive pressure could damage the fins. This operation is only necessary if the accumulation of dust and dirt is really severe.

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. converter.

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List "E" - 500 hours Air filter Replacing filter cartridges.

Frequency: every 500 hrs

Boom beam guide pads Every 500 hours

On the boom: Check wear pads clearance ( 2 to 3 mm maximum). shim if necessary. Change the wear pads when they reach a thickness thickness of 15 mm.

Check torque of bolts.

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Hydraulic tank

Hydraulic circ circ uit filter

Brake circ circ uit filter

Hydraulic circuit filter Filter replacement: every 500 hours. Between filter cartridge replacements: keep a check on the clogging indicator on the instrument panel. When this stays on, it is time to replace the filter cartridge.

After any operation that has involved closing the valve, never start up again without making sure it has been opened again.

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06/12/2004 06/12/20 04


Transmission Oil change: every 500 hours. First oil change after 50 hours. Oil capacity:41 l. Oil temperature at between 65°C (149°F) and 90°C (194°F). 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 65°C (149°F) and 90°C (194°F).

Complete topping up to the "FULL" mark with the engine at idling speed. Access: Level on the gearbox (wing-nut with FULL marked marked beside 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 93°C. 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).


Front axle reducer unit The level is checked when the raised mark on the reducer unit is in a horizontal position - the drain plug is towards the bottom.

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List "F" - 1,000 hours Spreader fastener checks Balance the rotating section of the spreader and eliminate all radial effort by centring the sliding frame. Check fastener tightness after 100 operating hours. Afterwards, recheck tightness every 1,000 hours.

Spreader swing motor-reducer unit TRASMITAL Level check: every 100 hours (on the dipstick). Oil change: every 1,000 hours. Capacity: 2.6 L (0.7 US GALLONS)

Drain holes

Spreader sideshift motor-reducer unit TRASMITAL Level check: every 100 hours (dipstick). Oil change: every 1,000 hours. Capacity: 2.6 L. (0.7 US GALLONS)

Drain holes


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Spreader beam guide pads Every 1,000 hours

On the spreader: Check lateral friction pad play (max. 1 mm). Change the friction pads when they reach a thickness of 15 mm.

Check tightness of pad and pad support fasteners.

Check condition and attachments of electric wiring harnesses. Check leaktightness of hydraulic circuit. Check wheel toe-in. Check condition of alternator and starter. Have brake accumulators checked.

Cooling of brake circuit

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.

Axle coolant change 1/ Place the machine on level ground 2/ Switch off engine and apply parking brake 4/ Put a container under each brake housing. 5/ Open the filler of the 30L tank. 6/ Unscrew the magnetic drain plugs of the two brake housings. 7/ Let the liquid flow out and clean the two magnetic drain plugs. The change affects: the 30l tank, the coolant in the brake circuit, the accumulators and the pipework. 8/ Unscrew the filter bowl to remove the liquid and residual dirt. If necessary, replace the filter cartridge. 9/ Replace filter bowl, taking care that the joint is properly seated. 10/ Replace the magnetic drain plugs, tightening them to 27 Nm. 11/ Fill the circuit with hydraulic brake fluid via the tank; quantity about 50 L. 12/ Once the hydraulic fluid has reached its level in the tank (circuit full), start the machine to circulate the fluid and drive out part of the air. 13/ If necessary, make up the level.

Purging the system is a LEVEL 3 maintenance operation. Contact your Concessionaire for this type of operation.

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List "G" - 2,000 hours Spreader slewing motor-reducer unit Every 2,000 hours or every 6 months: Check the tightness of fasteners. 12 bolts HM 16 x 150 - CL 8.8. Torque setting: 21 mdaN. (155 ft-lbs)

Spreader locking system Every 2,000 hours or every 6 months: Check the condition of electric switches (mechanisms and safety) Change any component which is not in a satisfactory condition. Check adjustment of control rods (stroke and alignment). Do not modify hydraulic settings on the lock and release cylinders.

Air conditioning unit Once a year: It is advisable to have the installation checked by a specialist.

Period out of use

It is advisable to operate the equipment for at least 10 minutes on end once a fortnight.

Spreader swing motor-reducer unit - DINAMIC OIL The first oil change is made at 150 hours Level check: every 100 hours Oil change: every 2,000 hours. Capacity: 2 L + 0.2l (0.7 + 0.07 US GALLONS)

Spreader sideshift motor-reducer unit DINAMIC OIL

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The first oil change is made at 150 hours Do not forget to screw back all

Level check: every 100 hours .


Oil change: every 2,000 hours. Capacity: 2 l + 0.3 l. (0.7 + 0.07 US GALLONS)

Hydraulic fluid tank Oil change: Capacity: 750 L (198 us gallons) (1100 L including circuit- 290 us gallons). The first oil change is made at 2,000 hours or 1 year's service. Subsequent oil changes are made every 2,000 hours. The hydraulic circuit oil change includes systematic draining of the following components: hydraulic tank, hydraulic pump, cylinders, hydraulic motors. This procedure is not described in detail, please consult your local TEREX specialist. When carrying out the oil change, replace the filter strainer and filter cartridge.

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Hydraulic circuit filters Oil filter replacement: every 500 hours. Between filter cartridge exchanges: Keep an eye on the filter clogging warning light on the control panel. Change the filter cartridges whenever this stays lit. Filtrer

Opening and closing the hydraulic tank. Operation to be carried out when there is a major leak or there is a job to be done on the pump's suction circuit.

Never restart the machine after any job requiring the valve to be closed before having made sure that it has been reopened.

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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Front axle reducer unit Level check: every 500 hours.

The level is checked when the raised mark on the reducer unit is in a horizontal position - the drain plug is towards the bottom.

Oil change every 2,000 hours. Drain the oil when the drain plug is positioned towards the bottom after having driven the machine for a few minutes in order to raise oil temperature. ROCKWELL axle reducer capacity: 11 L (3 US GALLONS). KESSLER axle reducer capacity: 14 L (3.7 US GALLONS). Do not forget to screw back all filler plugs properly.

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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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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List "H" - 6,000 h Spreader Replace all the twist locks.

List "J" - 10,000 h Engine/gearbox Engine service, particularly: pump injectors, turbo-compressor, compression rate.

Change engine and gearbox shock mounts.

Check crossbars for wear and box outlet coupling balancing.

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 spreader’s 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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Hydraulic oil tank Change the hydraulic oil. To replace hydraulic circuit oil, all of the following must be drained: tank, hydraulic pump, rams, hydraulic motors This operation is not described in detail; consult your TEREX specialist. During the oil change, change the return filter strainer and the two filter elements.

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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Chapter V - Page 1 of 16

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General identification

Type: . . . . . . . . . . . . . . . . .

Serial no.:. . . . . . . .

Commissioning date: . . / . . . .

Name of manufacturer: TEREX CRANES

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 ( 33 ) 03 . 85 . 67 . 38 . 98

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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 it s 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.

Using the maintenance log

This booklet constitutes a guide to preventive maintenance until such time as experience enables definition of a plan corresponding to special conditions of use.

As many copies as desired may be made of the maintenance log. Each person performing a service operation must show it on the maintenance list so that the machine can be checked at the next service. Completed maintenance lists constitute documents inseparable from the machine.

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Maintenance log Operating and Maintenance Manual LUBRICATION CHART COMPONENT

Cold climates

Temperate climates

Tropical climates

-25° +25°

-15° +35°

-5 +45°

Boom chains

MOLYKOTE BR 2

Boom slide pads

MOLYKOTE BR 2

Grease nipples

ALVANIA EP2

Slewing ring teeth

MALLEUS GL 205

Slewing ring bearing

ALVANIA EP2

Slewing reducer gear TRASMITAL

SPIRAX HD 80W90

SPIRAX HD 80W90

SPIRAX HD 85W140

Slewing reducer gear + brake DINAMIC OIL

OMALA EP VG220

OMALA EP VG220

TIVELA OIL VG2200

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

Brake circuit Axle

DONAX TD

DONAX TD

DONAX TD

WARNING: NEVER MIX SYNTHETIC OILS AND MINERAL OILS.

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Maintenance list "A" Every 10 hours or every day Company:

Address:____________________________________________

Person responsible for maintenance: ___________________________________________________

Date of maintenance:

Serial No.:

MAINTENANCE OPERATIONS

DONE BY

......... ......... .......... .......... ......... ......... ........ ......... ......... ......... .......... .......

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Check and clean air filter:

_______________

Check hydraulic oil level

________________

Check fuel level

________________

Check engine oil level

________________

Check converter oil level

________________

Check converter oil level

______________

Check brake fluid level

______________

Grease all spreader links and joints

________________


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Maintenance list "B" Every 50 hours Company:

Address:

Person responsible for maintenance: __________________________________________________ Date of maintenance:

Serial No.:


DONE BY

......... ......... .......... .......... ......... ......... ........ ......... ......... ......... .......... .......

Repeat list "A"

_______________

Grease all links and joints

_______________

Check telescoping reduction gear unit oil level ______________

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Check swing reduction gear unit oil level

______________

Grease slewing ring teeth

______________

Grease the slewing ring (internal):

______________

Grease all slide pads

______________

Grease the twist locks

______________


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Maintenance list "C" Every 100 hours Company:

Address:_


Date of maintenance:_

Serial No.:


DONE BY

...... ....... ...... ....... ....... ...... ....... .......... ........ ......... ......... ......... .......... .......

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Repeat lists "A" and "B"

_______________

Check battery electrolyte levels

_______________

Check wheelnut tightness

________________

Check all spreader fixings:

________________


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Maintenance list "D" Every 200 hours/250 hours Company:_

Address:___



Serial No.:


DONE BY

......... ......... .......... .......... ......... .........

Repeat lists "A", "B" and "C"

_______________

Check tyre pressures

_______________

Check battery cleanliness, density and fastening_______________

Grease steering track rod and links

_______________

Grease transmission shafts and joints

_______________

Grease steering gear

_______________

Check valve clearances

_______________

250 hrs - Replace engine oil filter

_______________

250 hrs - Engine oil change

_______________

250 hrs - Check DCA levels for engine water filter replacement:

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_______________

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Maintenance list "D" Every 200 hours /250 hours (CONT'D) 250 hrs - Check belt tensions

______________

250 hrs - Check condition of gearbox breather: ______________

Clean air conditioning evaporator and condenser: ______________

Clean catalytic converter:

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______________

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Maintenance list "E" Every 500 hours Company:_

Address:__________________________________________

Person responsible for maintenance:________________ ___________________________________________________


Serial No.:_


DONE BY

.... .... .... ................ .................. .......... ........ ......... ......... ......... .......... .......

Repeat lists "A", "B", "C" and "D"

______________

Drain and refill gearbox:

______________

Replace hydraulic circuit oil filter cartridge

______________

Replace gear box oil filter cartridges

______________

Replace air filter cartridge

______________

Check condition of slide pads (Boom)

______________

Check front axle oil levels drive input unit and reduction gear units

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______________

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Maintenance list – "F" Every 1,000 hours or every 6 months Company:

Address:



Serial No.:_


DONE BY

......... ......... .......... .......... ......... ......... ........ ......... ......... ......... .......... .......

Repeat lists "A", "B", "C", "D" and "E"

_______________

Check wiring harness condition + fastenings

_______________

Check tightness of all fasteners

_______________

Drain and refill slewing reduction gear:

_______________

Drain and refill telescoping reduction gear:

_______________

Check leaktightness of hydraulic circuit:

_______________

Check wheel toe-in:

_______________

Check leaktightness of steering circuit:

_______________

Check condition of alternator and starter motor: _______________

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Maintenance list – "F" Every 1,000 hours or every 6 months (CONT'D)

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Have brake accumulators checked:

_____________

Drain and refill brake circuit:

_____________


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Maintenance list "G" Every 2,000 hours Company:

Address:



Serial No.:


DONE BY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .. . . . . . . .. ........ ......... ......... ......... .......... .......

Repeat lists "A", "B", "C", "D", "E" and "F"

_______________

Replace brake circuit oil filter cartridge:

_______________

Replace hydraulic fluid:

_______________

Replace brake hoses

_______________

Check the injection pump

_______________

Replace hydraulic oil filters

_______________

Check counterweight condition and fastenings _______________

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Check condition of slide pads

_______________

Drain and refill pinion carrier of front axle

_______________

Check air conditioning unit:

_______________


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Maintenance list – "H" Every 6,000 hours Replace the twist locks:

_________

Maintenance sheet "J" Service at 10,000 hrs Overhaul engine:

_________

Replace brake accumulators:

_________

Replace boom shoes:

_________

Replace damping accumulator:

_________

Replace spreader shoes:

_________

Replace hydraulic oil:

_________

Dye penetration test on wheel rims:

_________

Replace parking brake pads:

_________

Visual inspection of all welded components of the machine_________

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Lubrication Manuel de conduite et d'entretien

Fuel - lubricants

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Chapter VI - Page 1 sur 4

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Component capacities Engine CUMMINS QSM 11:

Min. 26 L Max. 38 L

CLARK gearbox:

41 L

Fuel tank:

520 L

Hydraulic oil tank:

720 L

Hydraulic oil tank + circuit:.

1,100 L

Hydraulic oil tank, braking:

30 L

Tank + circuit approx.

50 L

Engine cooling circuit:

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

ROCKWELL front axle:

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Drive pinion carrier:

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

The above capacities are given as guidance only. Whenever possible, rely on the levels shown on the components to be lubricated.

Tyre pressures: GOOD YEAR 1800 x 25

10 bar (145

psi) MICHELIN X MINE D2 1800 x 25

10 bar (145 psi)

MICHELIN X K D1 B 1800 x 25

10 bar (145 psi)

GOOD YEAR 2100 x 25

7.5 bar (110

psi) BRIDGESTONE 2100 x 25

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7.5 bar (110 psi)

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Filter elements Engine oil filter cartridge, QSM11:

Fuel filter cartridge, QSM11:

T-64505-51

S-64505-50

Water filter cartridge 15 DCA units, QSM11 engine: G-61505-97

DCA test kit

V-64505-53

Oil cartridge, CLARK gearbox:

B 61505-92 Qty 2

Oil strainer, converter:

W 61505-88

Air filter cartridge Primary cartridge: Safety cartridge:

C 61505-93 D 61505-94

Hydraulic oil tank cartridges:

W-27505-90 Qty 2

Braking circuit filter cartridge:

W-27505-90 Qty 1

Alternator belt:

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Annexe - 1 Manuel de conduite et d'entretien

Page 1 sur 3

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Annexe - 1 Manuel de conduite et d'entretien

Page 2 sur 3

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User and Driving TFC 45 2002 PPM11

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