Entretien GB

Maintenance
Maintenance and operator's manual
Chapter 5
Maintenance
C 64440-04/a Chapter 5 - Page 1

Maintenance
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.
NOTE
All personnel who carry out maintenance operations on this
machine must be aware of all instructions contained in this
manual, and respect all safety regulations before any
intervention.

Maintenance
Levels of Maintenance.
For each procedure described in this Manual, a maintenance level is

indicated.
This is given as an indication so as to serve as guide regarding the
importance of the operation.
This classification originates from the French NF X 60-010 Standard.
1st level
Upkeep, change of accessible consumables, easy adjustments

without dismantling.
2nd level:
Lubrication and checking the sound operation, repairs through routine

replacement of elements provided for this purpose, carried out by an
accredited technician with basic qualifications.
3rd level:
Adjustments, diagnosis of breakdowns, repairs through changing of

components, minor repairs, carried out by a specialized technician, in-
situ or on maintenance premises.
4th level:
Important corrective and preventive maintenance works (except

renovation and reconditioning) carried out by a team comprising very
specialized technical supervision, in a specialized workshop.
5th level:
Renovation, reconditioning carried out, by definition, by the maker with

means practically similar to those of the manufacture.
The 1st Level corresponds to instructions given in the operating

and upkeep manual.

Maintenance
Maintenance general features.

WHEN MAKING THE PRE-DELIVERY INSPECTION, CARRY OUT
INITIAL COMPLETE MAINTENANCE OF THE MACHINE, WITH THE
TEREX EXPERT (OIL CHANGES, LUBRICATION, REPLACING
FILTERS), THEN REFER TO THE MAINTENANCE INTERVALS
SHOWN IN THE FOLLOWING TABLES.
IN THE EVENT OF PROLONGED STORAGE OR USE AT A FIXED

SITE, IT IS IMPERATIVE TO CARRY OUT 500 HOURS
MAINTENANCE AFTER EACH 6 MONTH PERIOD AT THE
MAXIMUM, ESPECIALLY THE FOLLOWING COMPONENTS :
ENGINE - AXLES - GEARBOXES - SUSPENSION - STEERING..
IMPORTANT
The intervals shown in the following tables are deemed to apply to
machines used under normal conditions .
For intensive use or under conditions (heat - dampness - dust) it is
necessary to carry out maintenance more frequently.

Maintenance
Regular service intervals.
The machine should be serviced regularly.

The hourmeter on your machine shows you when it is time to carry out
maintenance. It should be checked each day.
The frequencies shown are based on 10 hours/day, 50 hours/week,
and 2000 hours/year working.
Take advantage of the opportunity to tighten screws, nuts etc during
maintenance operations.
When effecting these servicing operations, tighten nuts,
bolts,etc...where required..
Hourmeter
Its electric control is connected to the 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..
Before any daily start up
Every day, inspect the machine before getting in or start the engine.
Look carefully for : loosen or missing screws
Accumulation of scraps : oil or cooling liquid leaks
Check condition of tyres and levels.

Maintenance
Storage.
After storage for some months, check all hydraulic circuit fittings and
make sure that they are correctly tightened. Inspect the entire
machine
Apply procedure :
" BEFORE EVERY DAILY START UP ".
All the necessary steps should be taken to conserve the

environment. In particular, make sure that all used fluids are
collected and recycled.
Do not leave these products in unsuitable, incorrectly labelled
containers.
Do not tolerate fluid puddles of whatever type on floors.

Maintenance
Preventive maintenance.
Introduction.
The environmental working conditions of the machine gouvern its

maintenance. The prescribed check-list which follows indicate the
points to be verified and the frequency of the verifications.
NOTE :
The check-list takes into account the machine's operating conditions.
The type of work to be done, the dimensions of loads, climatic and
ground conditions are all factors to be taken into account. The
preventive maintenance lists are given in function of the number of
hours worked by the machine.
Any modification to the overall maintenance program must be

accompanied by a revision of the machine's new operating conditions.
Carefully study the preventive maintenance check-list before making
any changes to the verification frequencies.
The lubrification charts indicate the general greasing points and the
type of lubricant to be used on each component
Use of the prescribed Check-list
The check-list is an initial guide to preventive maintenance until

personal experience allows the definition of an appropriate
maintenance program according to different operating conditions.
The check-lists can be recopied as many times as necessary. Any

person who carries out a maintenance procedure must indicate this on
the checklist so that it can be verified as being done at the moment of
the following maintenance program.
Completed check-lists are documents which are an integral part
of the machine.

Maintenance
Tyre pressure.
Periodically control tyre pressures, and ensure that

corresponding prescribed pressures are used following the work
being done by the machine. Refer to the tyre pressure indicator
stickers on the chassis footplating above the wheels.
Starting up the machine after changing a hydraulic

component..
After having changed a hydraulic component on the machine,

e.g. pump, distributor, valve block, ram oil tank, etc.., turn the
engine over at idling speed for around 20 to 30 minutes, without
using any of the hydraulic functions, then bleed, if necessary, the
changed part. Then check or exchange the concerned filter
cartridges after this operation.
The machine must be inspected by APAVE/AIF when one of the

telescoping or lifting rams or a major component (e.g. boom
section) is replaced.
Precautions to be taken if welding is to be done on the

machine
Before starting any electric welding jobs on the machine, firstly :-

disconnect the wires marked B+ and D+ from the alternator-
disconnect all electronic equipment (i.e. load indicator, gearbox
control unit, etc..)…)
Transmission assembly fasteners.
Periodically check that all transmission shafts and their universal

joints are correctly tightened. If there is any doubt about the
condition of a fastener, then immediately replace it using ONLY
fasteners prescribed by TEREX , excluding any other types..

Maintenance
Table: tightening torques for traditional steel

screw assemblies.
Torques to be applied in m.daN (1 m.daN = about 1m.kg)
Friction coefficient between 0.125 and 0.15 inclusive.
Flat Screw, Class 10.9 Fine pitch Classe10.9

Class 8.8
normal pitch Class 8.8
dimensions & 12.9 scre & 12.9
13 M8 x 1.25 2 3 M8 x 1 2.5 3.5

17 M10 x 1.5 5 7 M10 x 1.25 5 7
19 M12 x 1.75 8 12 M12 x 1.25 9 13
22 M14 x 2 13 18 M12 x 1.5 9 12
24 M16 x 2 20 28 M14 x 1.5 14 20
27 M18 x 2.5 28 39 M16 x 1.5 21 30
M18 x 1.5
30 M20 x 2. 5 39 55 31 44
32 M22 x 2. 5 53 75 M20 x 1.5 43 61
36 M24 x 3 67 95 M22 x 1.5 58 82

41 M27 x 3 99 140 M24 x 2 73 103
M27 x 2
46 M30 x 3.5 135 190 107 150
M30 x 2
50 M33 x 3.5 185 250 150 210
M33 x 2 205 290
Use a calibrated dynamometric chuck key
(precision ± 6%)

Maintenance
Tightening torque for slotted nuts / spline nut.
Tightening torque for the slotted nuts on the spherical

pivots of the connection rods and work cylinders.
Size of the Tightening

Screw cutting
cone torque
d2 (mn)
d1 (mn) (Nm)
26 M20 x 1.5 200 - 220
30 M24 x 1.5 280 – 300
32 M27 x 1.5 290 – 320
38 M30 x 1.5 340 – 360
45 M39 x 1.5 410 - 430
The tightening torques for the various sizes of thread on the spherical
pivots are valid for nuts of S6 quality.
Tightening torque of the nut to be driven in and even the

spline nut on the drive flanges, toothed wheels, etc.
Screw cutting d1 Tightening torque

(mm) (Nm)
M24 x 1.5 360
M30 x 1.5 450
M36 x 1.5 540
M42 x 1.5 850
M45 X 1.5 850
M48 x 1.5 850
M52 x 1.5 950
M64 x 1.5 1050 - 1100

Maintenance
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 hours, and then check the
torque every 2000 hours thereafter.
a) Tooling :
1
Calibrated torque wrench (set to nominal torque rating
8 - see table below).

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.
6 7 No load.

Maintenance
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)

Maintenance
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
Vis / Screw / Schraube /

16x2 90 S 63338 94 ornillos 23
100 F 19338 68 ornillos 50 40
100 E 62338 32 Boulon / Bolt / Bolzen / Perno 50 50
110 T 19338 80 Tornillos 50 40
120 F 62338 33 Tornillos 50 40
125 J 19338 94 Tornillos 50 40
130 J 62338 13 Tornillos 50 40
20x1.50 140 G 19338 69 Tornillos 50 40
140 J 19338 71 Boulon / Bolt / Bolzen / Perno 50 50
145 C 19338 88 Boulon / Bolt / Bolzen / Perno 50 50
170 R 62338 20 Boulon / Bolt / Bolzen / Perno 50 50
200 F 19338 91 Boulon / Bolt / Bolzen / Perno 50 50
220 H 62338 35 Boulon / Bolt / Bolzen / Perno 50 50
130 K 19338 72 Boulon / Bolt / Bolzen / Perno 90 90
140 E 19338 90 Tornillos 90 70
140 L 19338 73 Boulon / Bolt / Bolzen / Perno 90 90
24x2.00 160 M 19338 74 Boulon / Bolt / Bolzen / Perno 90 90
160 H 19338 70 Tornillos 90 70
170 D 19338 89 Boulon / Bolt / Bolzen / Perno 90 90
200 Q 62338 42 Tornillos 90 70
145 U 19338 81 Tornillos 130 95
145 N 19338 75 Boulon / Bolt / Bolzen / Perno 130 130
155 G 62338 57 Tornillos 130 95
160 P 19338 76 Boulon / Bolt / Bolzen / Perno 130 130
27x2.00 175 C 62338 53 Tornillos 130 95
190 Q 19338 77 Boulon / Bolt / Bolzen / Perno 130 130
190 H 62338 58 Tornillos 130 95
210 A 19338 86 Boulon / Bolt / Bolzen / Perno 130 130
250 B 19338 87 Boulon / Bolt / Bolzen / Perno 130 130
250 X 62338 95 Tornillos 130 95
33x2.00 220 F 02340 07 Tornillos 230 175
TEREX reserves the right to alter the information in this chart without notice.

Maintenance
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 ornillos 19
100 F 19338 68 ornillos 42 34
100 E 62338 32 Boulon / Bolt / Bolzen / Perno 42 42
110 T 19338 80 Tornillos 42 34
120 F 62338 33 Tornillos 42 34
125 J 19338 94 Tornillos 42 34
130 J 62338 13 Tornillos 42 34
20x1.50 140 G 19338 69 Tornillos 42 34
140 J 19338 71 Boulon / Bolt / Bolzen / Perno 42 42
145 C 19338 88 Boulon / Bolt / Bolzen / Perno 42 42
170 R 62338 20 Boulon / Bolt / Bolzen / Perno 42 42
200 F 19338 91 Boulon / Bolt / Bolzen / Perno 42 42
220 H 62338 35 Boulon / Bolt / Bolzen / Perno 42 42
130 K 19338 72 Boulon / Bolt / Bolzen / Perno 76 76
140 E 19338 90 Tornillos 76 59
140 L 19338 73 Boulon / Bolt / Bolzen / Perno 76 76
24x2.00 160 M 19338 74 Boulon / Bolt / Bolzen / Perno 76 76
160 H 19338 70 Tornillos 76 59
170 D 19338 89 Boulon / Bolt / Bolzen / Perno 76 76
200 Q 62338 42 Tornillos 76 59
145 U 19338 81 Tornillos 110 80
145 N 19338 75 Boulon / Bolt / Bolzen / Perno 110 110
155 G 62338 57 Tornillos 110 80
160 P 19338 76 Boulon / Bolt / Bolzen / Perno 110 110
27x2.00 175 C 62338 53 Tornillos 110 80
190 Q 19338 77 Boulon / Bolt / Bolzen / Perno 110 110
190 H 62338 58 Tornillos 110 80
210 A 19338 86 Boulon / Bolt / Bolzen / Perno 110 110
250 B 19338 87 Boulon / Bolt / Bolzen / Perno 110 110
250 X 62338 95 Tornillos 110 80
33x2.00 220 F 02340 07 Tornillos 195 148
TEREX reserves the right to alter the information in this chart without notice.

Maintenance
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

1 500 hours. Tooling, verification conditions, method and torque values
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.
4 3 If the number of fasteners detected with this characteristic is

greater than 20% of the total number, then all the ring fasten
ers must be changed.
USE ONLY ORIGINAL TEREX SPARE PARTS
6 7
b) Otherwise retighten all fasteners with a torque value greater than
2 85% of the nominal value to the nominal torque value indicated in the
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
For all further detailed inferior to 85% of nominal value.
additional information ONLY USE GENUINE TEREX SPARE PARTS
concerning the method of Tighten to the value indicated in the table d1.
control, assembly,
retightening and 4 - Systematic exchange :
exchange criteria, please
consult our local agent. - 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.

Maintenance
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.

Maintenance
Checking slew ring wear:
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.

Maintenance
Details about the measurement:
The measurement points on the outer circumference are defined

starting arbitrarily from position 1.
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 New Wear (1)

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

Maintenance
Acceptable wear limits :
Contact TEREX-TEREX if the permitted wear limits (see chart) are

exceeded.
Slew rings with a single lane of bearing balls (four contact points)
Track diameter (mm) Ø of the ball (mm)
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
1500 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
We must be 2250 2.0 2.3 2.5 2.9 3.0 3.2
contacted if the
difference between 2500 2.0 2.3 2.6 2.9 3.1 3.2
the reference values 2750 2.4 2.6 3.0 3.2 3.3
and the maximum
values that have 3000 2.5 2.7 3.1 3.2 3.4
been measured is
3250 2.6 2.8 3.2 3.3 3.5
higher than as shown
in the chart. 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
7500 5.1
8000 5.3
TEREX slew ring dimensions

Machines Bearing diameter Ball diameter
Spreader TR 980 mm 35 mm
AC35 – AC35L 1272 mm 30 mm
AC55 – AC55L 1491 mm 45 mm

Maintenance
Summary of the maintenance operations.
List List
List D E List List
List List List I
C 200 500 F G
ELEMENTS A B 20000 Periodicity
100 h h 1000 2000
10 h 50 h h
h 250 600 h h
h h
Air filter Yes Yes Yes Yes Yes Yes Yes every 100 h
Transmission: Converter and
Yes Yes Yes Yes Yes Yes Yes Yes every 10 h
powershift gear box
Fuel tank and hydraulic tank All 10 h + Draining:
Yes Yes Yes Yes Yes Yes Yes Yes
levels every 2000 hours
Brake circuit: fluid level check Yes Yes Yes Yes Yes Yes Yes Yes every 10 h
All 10 h + Draining:
Engine Yes Yes Yes Yes Yes Yes Yes Yes
every 250 hours
Engine radiator: coolant level Yes Yes Yes Yes Yes Yes Yes Yes every 10 h
Spreader greasing operations Yes Yes Yes Yes Yes Yes Yes Yes every 10 h
Spreader slewing ring Yes Yes Yes Yes Yes Yes Yes every 50 h
Slewing ring teeth Yes Yes Yes Yes Yes Yes Yes every 50 h
Spreader hydraulic slewing All 50 h + Draining:
Yes Yes Yes Yes Yes Yes Yes
motor every 1000 hours
Spreader hydraulic sideshift All 50 h + Draining:
Yes Yes Yes Yes Yes Yes Yes
motor every 1000 hours
Boom and booming system Yes Yes Yes Yes Yes Yes Yes every 50 h
maintain the machine
Cleaning the machine Yes Yes Yes Yes Yes Yes Yes
clean
Tire pressures Yes Yes Yes Yes Yes Yes Yes every 50 h
Batteries Yes Yes Yes Yes Yes Yes every 100 h
Wheel fastener tightness Yes Yes Yes Yes Yes Yes every 100 h
Check the tightness of all 100 h +
Yes Yes Yes Yes
spreader fasteners every 1000 h
Slewing ring fastener
Yes Yes Yes Yes Yes Yes every 100 h
tightness
100h +
Checks on the pads Yes Yes Yes Yes Yes
every 500 h
Once a month.
Air conditioning unit Yes Yes Yes Yes Yes Installation: once a
year
Transmission shafts and U-
Yes Yes Yes Yes Yes every 200 h
joints
Rear steering axle Yes Yes Yes Yes Yes every 200 h
Catalytic converter (Option) Yes Yes Yes Yes Yes every 250 h
Transmission " filter cartridge
Yes Yes Yes Yes every 500 h
"

Maintenance
List List
List List List List F List G List I
D E
ELEMENTS A B C 1000 2000 20000 Periodicity
200 h 500 h
10 h 50 h 100 h h h h
250 h 600 h
Air filter : Replacing filter
cartridges
Hydraulic tank : Replacing
cartridges
Transmission : Oil change: Yes Yes Yes Yes every 500 h
Front axle Yes Yes Yes Yes every 500 h
Bearing clearances on the 500 h +
Yes Yes Yes
Stacker axle spindle every 1500 h
500 h +
Check on welds Yes Yes Yes
every 2000 h
Every
Spreader beam guide pads Yes Yes Yes
1000 h
Every
Electric wiring harnesses Yes Yes Yes
1000 h
Leaktightness of hydraulic Every
Yes Yes Yes
circuit 1000 h
Every
Wheel toe-in Yes Yes Yes
1000 h
Condition of alternator and Every
Yes Yes Yes
starter 1000 h
Every
Brake accumulators Yes Yes Yes
1000 h
Every
Cooling of brake circuit Yes Yes Yes
1000 h
Every
Axle coolant change. Yes Yes Yes
1000 h
Every
Spreader locking system Yes Yes
2000 h
Hydraulic fluid tank : Oil Every
Yes Yes
change 2000 h
Every
Front axle : Oil change Yes Yes
2000 h
Every
Rim check Yes Yes
2000 h
Spreader : Replace the twist Every
Yes
locks 6000 h
Lifting cylinders: Replace Every
Yes
the GE balljoints 6000 h
Every
Heat engine/Gearbox Yes
10000 h
For detail of operations, to refer to the following pages.

Maintenance
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

Maintenance
Fuel tank and hydraulic tank levels
1/ Diesel filler tube
Do not forget to screw back

2/ Hydraulic oil filler tube
all 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

Level: every 10 HOURS.
up with fuel: the fumes from
- with the machine on level ground and all hydraulic rams retracted,
the fuel are highly
the level should be close to the level of tube 3/1
flammable.
Making up level:
through the filler tubes.
.

Maintenance
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).


Maintenance
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.
DANGER
An inadequately tightened
engine oil filler cap could allow
steam and oil spray to escape
and cause a fire resulting in
serious damage to the vehicle.

Maintenance
Brake circuit: fluid level check
Located on the left hand side of the machine.

Engine radiator: coolant level
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.

Maintenance
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 Volume of cooling circuit (litres)

down to
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 11 12 13 15 16 18 19
- 20°C 2 2 3 3 4 6 7 9 11 12 14 16 17 19 21 23
- 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 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.

Maintenance
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.
Do not forget to screw back all

filler plugs properly.
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.

Maintenance
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
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.

Maintenance
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.
- heck 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.

Maintenance
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.

torque settings: : Front axle : 40 mKg
Rear axle : 40 mKg 1800x25
40 mKg 2100x25
50 mKg 1800x33

Maintenance
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.)

Maintenance
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 O 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.
Checks on the front pads with retracted and

extended boom, and on the rear pads with
retracted boom
Check the tightness of the adjusting screws every 1,00 hours.
PAD
IMMOBILISING
SCREWS
OUTRIGGER
ADJUSTING
SCREWS
OUTRIGGER
ADJUSTING
SCREWS

Maintenance
List "D" - 200/250 hours

Tyre pressures
1800 x 25: 10b

2100 x 25: 7,5b
1800 x 33: 10b
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
Three grease nipples per transmission shaft.

Greasing the pump drive shaft:
It is necessary to remove the drive shaft protector tubes.

Maintenance
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.

Maintenance
Transmission
Replace the filter cartridge every 500 hours.

Check the level after fitting the new filter cartridges.
Catalytic converter (Option)
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.

Maintenance
List "E" - 500 hours

Air filter
Replacing filter cartridges.
Frequency: every 500 hrs
Boom beam guide pads
Every 500 hours
CHECK THE OPERATION EACH TIME THE MACHINE

IS STARTED
1- The telescopic section must be perfectly central in width and
height to the front and rear part of the fixed section i.e. the boom
base.
2- The boom pads must be in good condition and within the wear
limits specified by TEREX, i.e. the oil groove must be deeper than 1
mm.
The pads will quickly be ruined if these conditions are not met when
the boom is used.
An outright failure to maintain standards of repair that leads to
permanent metal-to-metal friction between the telescoping section and
any other static metal part will quickly result in the telescoping section
being damaged beyond repair.

Maintenance
CHECKING CLEARANCES
3- Operating clearances both at the rear of the telescoping
section and at the front of the boom base must be maintained at all
times;
4- The rear tip of the telescoping section is fitted with 2
horizontal upper pads and 2 adjustable side pads.
The 2 side pads can be locked and adjusted using the bolt and nut to
provide full control over the maximum clearance tolerance along the 2
vertical and lateral axes.
The front tip of the boom base is fitted with 4 horizontal pads (2 lower
and 2 upper) and 4 adjustable side pads.
The 2 lower horizontal pads can be locked and the 4 side pads can be
adjusted using the bolt and nut to provide full control over the
maximum clearance tolerance along the 2 vertical and lateral axes,
thereby ensuring that the boom can be guided accurately.
This boom guidance procedure must be checked both when the boom
is retracted and extended.

Maintenance
FRONT CHECKS ON THE FRONT PADS WITH RETRACTED

AND EXTENDED BOOM:
Check that there is no more than a 2 mm height clearance between
the bearing surface of the front upper pads attached to the boom base
and the upper face of the casing of the telescoping section.
SIDE Check that there is no more than a 1.5 mm side clearance, on each
SETTING
ADJUSTING side, between the bearing surface of the front upper and lower pads
SCREWS
attached to the boom base.
Check and adjust these clearances using the shims that fit between
the bearing surface of the lower pad and the support face of the boom
base, and using the adjusting screws designed to draw in the 4 side
guide pads on the vertical face of the telescoping section.
CHECKS ON THE REAR PADS WITH RETRACTED

BOOM :
Check that there is no more than a 2 mm height clearance between
SHIM
the bearing surface of the rear upper pads attached to the tip of the
telescoping section and the upper face of the boom base casing.
Check that there is no more than a 1.5 mm side clearance, on each
PAD
side, between the bearing surface of the rear upper pads attached to
telescoping section and the internal face of the boom base casing.
Check and adjust these clearances using the special adjusting screws
REAR on the rear side pads and by setting the 2 rear upper pads.
SIDE
SETTING CHECK THE TIGHTNESS OF THE ADJUSTING SCREWS EVERY
ADJUSTING
SCREWS 100 HOURS.
PAD

Maintenance
Hydraulic tank
Hydraulic
circuit filter
Brake circuit
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.

Maintenance
Transmission
Oil change: every 500 hours.

First oil change after 50 hours.
Oil capacity:70 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 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 500 hours.
Check level after new cartridges have been fitted.


Maintenance
Front axle
Differential unit

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.
Adjusting the bearing clearances on the Stacker axle

spindle
1st inspection after 500 service hours.

Interval: Every 1,500 hours
Procedure:
- Raise the wheels off the ground
- Remove the wheel and the hub bearing cover.
- Make sure that the castellated nuts are not loose.
- Make sure that the tab on the lockwasher fitted to the spindle is not
broken.
- Check that the hub turns freely.
- Push and pull the hub to check for axial clearance.
If the free play around the hub perimeter is greater than 1 mm,
carry out the adjustment procedure again as follows to bring the
clearance between the nut and backing washer on the bearing down
to 0.2 - 0.3 mm:
- Remove the outer nut and the castellated lockwasher.
- Remove the nut touching the shim washer.

Maintenance
- Clean all the threads.

- Check that the 1st bearing and its seating on the spindle are not
damaged.
- Inject some grease between the two bearings.
- Refit the first nut with some standard thread-locking compound and
tighten to 100 mdaN to check and even block the hub, making sure
that the rear bearing is tightly in place. Use the following tools: TEREX
spanner wrench reference: EG 01 4885.
- Undo by 1/8 of a turn to free the hub.
- Check the condition of the lockwasher.
The washer must not be used if the stop tab on the spindle
seems to be broken
If in doubt, replace the washer. Fit the washer facing the direction
shown in the diagram so that the outer tab can be folded down against
the outer nut.
- Fit the outer nut with some standard thread-locking compound.
Tighten the nut to a torque of between 60 and 80 mdaN so that one of
the lockwasher’s outer tabs is placed opposite one the notches on the
outer nut.
- Fold the washer’s outer tab down against the outer nut.
- The hub should move freely with no backlash.
- Mark the position of the outer nut with a mark on both the nut and
the spindle in case the nut has to be loosened off during a subsequent
inspection or in case of malfunction.
- Fill the cap with grease and refit.
Check on welds.
(see Safety chapter)
A visual examination of all the points marked by an arrow on the
following views must be carried out in order to detect any cracking or
beginnings of cracks which could occur either through defective
realization or through usage not in compliance with our
recommendations.
Any anomaly must be repaired by qualified staff and recognized by
TEREX before using the device again.
After the first 500 hours, the periodicity is 2000 hours

Maintenance
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 (on the dipstick).

Capacity: 2.6 L (0.7 US GALLONS).
Drain holes


Maintenance
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

Maintenance
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..

Maintenance
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

Capacity: 2 L + 0.2l (0.7 + 0.07 US GALLONS)

Maintenance
Spreader sideshift motor-reducer unit -

DINAMIC OIL
The first oil change is made at 150 hours

Do not forget to screw back all Level check: every 100 hours .
filler plugs properly. 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.

Maintenance
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.
Hydraulic
circuit filter
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

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.
AXLETECH 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.
NOTE
carry out the first oil change between 50 then 200 operating
hours.

Maintenance
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.
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).
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 and turn the adjusting screw
counter-clockwise until the spring set is released before
disassembly of the circlip !

Maintenance
Rim check
CAUTION
TEREX 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.
Refer to the general procedure in the section on
Safety.
Adjusting the bearing clearances on the

Stacker axle spindle
Interval: Every 1,500 hours
Procedure:
- Raise the wheels off the ground
- Remove the wheel and the hub bearing cover.
- Make sure that the castellated nuts are not loose.
- Make sure that the tab on the lockwasher fitted to the spindle is not
broken.
- Check that the hub turns freely.
- Push and pull the hub to check for axial clearance.
If the free play around the hub perimeter is greater than 1 mm,
carry out the adjustment procedure again as follows to bring the
clearance between the nut and backing washer on the bearing down
to 0.2 - 0.3 mm:
- Remove the outer nut and the castellated lockwasher.
- Remove the nut touching the shim washer.
- Clean all the threads.
- Check that the 1st bearing and its seating on the spindle are not
damaged.
- Inject some grease between the two bearings.

Maintenance
- Refit the first nut with some standard thread-locking compound and
tighten to 100 mdaN to check and even block the hub, making sure
that the rear bearing is tightly in place. Use the following tools: TEREX
spanner wrench reference: EG 01 4885.
- Undo by 1/8 of a turn to free the hub.
- Check the condition of the lockwasher.
The washer must not be used if the stop tab on the spindle
seems to be broken
If in doubt, replace the washer. Fit the washer facing the direction
shown in the diagram so that the outer tab can be folded down against
the outer nut.
- Fit the outer nut with some standard thread-locking compound.
Tighten the nut to a torque of between 60 and 80 mdaN so that one of
the lockwasher’s outer tabs is placed opposite one the notches on the
outer nut.
- Fold the washer’s outer tab down against the outer nut.
- The hub should move freely with no backlash.
- Mark the position of the outer nut with a mark on both the nut and
the spindle in case the nut has to be loosened off during a subsequent
inspection or in case of malfunction.
- Fill the cap with grease and refit.
Check on welds.
(see Safety chapter)
A visual examination of all the points marked by an arrow on the
following views must be carried out in order to detect any cracking or
beginnings of cracks which could occur either through defective
realization or through usage not in compliance with our
recommendations.
Any anomaly must be repaired by qualified staff and recognized by
TEREX before using the device again.
After the first 500 hours, the periodicity is 2000 hours

Maintenance
List "H" – 6,000 hours

Spreader
Replace the twist locks.
Lifting cylinders
Replace the GE balljoints.
List "J" – 10,000 hours

Heat engine/Gearbox
Inspection of the heat engine in particular:

Pump injectors, turbocharger, compression ratio.
Replace engine and gearbox shock mounts.
Check the cross pieces for wear and balance the output universal
joint.

Maintenance
Brakes
Change brake accumulators.

This operation is not described in detail. Consult your TEREX
specialist who has the inflation kit.
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.

Maintenance
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.

Maintenance

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Maintenance

Maintenance and operator's manual

C 64440-04/a Chapter 5 - Page 1

Regular maintenance of your machine will ensure longevity. We

The general maintenance table gives indications of the essential

C 64440-04/a Chapter 5 - Page 2

For each procedure described in this Manual, a maintenance level is

Upkeep, change of accessible consumables, easy adjustments

Lubrication and checking the sound operation, repairs through routine

Adjustments, diagnosis of breakdowns, repairs through changing of

Important corrective and preventive maintenance works (except

Renovation, reconditioning carried out, by definition, by the maker with

The 1st Level corresponds to instructions given in the operating

C 64440-04/a Chapter 5 - Page 3

Maintenance general features.

IN THE EVENT OF PROLONGED STORAGE OR USE AT A FIXED

ENGINE - AXLES - GEARBOXES - SUSPENSION - STEERING..

C 64440-04/a Chapter 5 - Page 4

Regular service intervals.

The machine should be serviced regularly.

Its electric control is connected to the engine oil pressure. It

Before any daily start up

C 64440-04/a Chapter 5 - Page 5

All the necessary steps should be taken to conserve the

C 64440-04/a Chapter 5 - Page 6

The environmental working conditions of the machine gouvern its

Any modification to the overall maintenance program must be

Use of the prescribed Check-list

The check-list is an initial guide to preventive maintenance until

The check-lists can be recopied as many times as necessary. Any

C 64440-04/a Chapter 5 - Page 7

Periodically control tyre pressures, and ensure that

Starting up the machine after changing a hydraulic

After having changed a hydraulic component on the machine,

The machine must be inspected by APAVE/AIF when one of the

Precautions to be taken if welding is to be done on the

Before starting any electric welding jobs on the machine, firstly :-

Transmission assembly fasteners.

Periodically check that all transmission shafts and their universal

C 64440-04/a Chapter 5 - Page 8

Table: tightening torques for traditional steel

Torques to be applied in m.daN (1 m.daN = about 1m.kg)

Friction coefficient between 0.125 and 0.15 inclusive.

Flat Screw, Class 10.9 Fine pitch Classe10.9

13 M8 x 1.25 2 3 M8 x 1 2.5 3.5

19 M12 x 1.75 8 12 M12 x 1.25 9 13

22 M14 x 2 13 18 M12 x 1.5 9 12

24 M16 x 2 20 28 M14 x 1.5 14 20

27 M18 x 2.5 28 39 M16 x 1.5 21 30

32 M22 x 2. 5 53 75 M20 x 1.5 43 61

36 M24 x 3 67 95 M22 x 1.5 58 82

M33 x 2 205 290

Use a calibrated dynamometric chuck key

C 64440-04/a Chapter 5 - Page 9

Tightening torque for slotted nuts / spline nut.

Tightening torque for the slotted nuts on the spherical

Size of the Tightening

26 M20 x 1.5 200 - 220

30 M24 x 1.5 280 – 300

32 M27 x 1.5 290 – 320

38 M30 x 1.5 340 – 360

45 M39 x 1.5 410 - 430

Tightening torque of the nut to be driven in and even the

Screw cutting d1 Tightening torque