Customer Feedback

Report
(QF28A.4)

XXXX
Customer Details
Name: Contact:
Address: Phone: Fax:
E-mail:
Equipment Details
Make: Serial No: Hours:
Model: Delivery Date:
Customer Report

Reported by: Date:

Office Use Only

Customer Number: Logged:

Comment: Action Required:

Design: Production: Product Support: Other:

Note: All actions are to be reported back to customer

Signed off: Date:
 QF45D.05

Warranty Claim Form

Claim Number: wc

Crane manufacturer: Crane model: Crane serial No:

Repair order number: Bulletin No: Repair date:

Claim type: Repairs/Parts: Repair Branch: Failure date:

Spare parts / service provider invoice number/s:

Hours lower Hours upper: Klms:

Labour hours: Diagnostic hours: Klms traveled:

Engine: Model: Serial No:

Transmission: Model: Serial No:

Owner’s name:

Address:

Representative: Phone No: Fax No:

Problem statement:

Resolution statement:

Please Email to the Terex CranesWarranty Department ([email protected])

Page 1.28/07/08 QF23M.001

Terex Lifting Australia Pty. Ltd.

MODEL: MAC 25 OM906 / MD3060 SERIAL No:________________HOURS:__________________DATE:_______________
ODOMETER READING:_________________SERVICE TYPE:______________TECHNICIAN NAME:______________________
Quality Assurance Doc. No: QF23M.003
Note: ALL Items Must be "Ticked" if carried out / "Crossed" if not carried out / marked N/A if not applicable.
250 / 750 Hour Service Schedule Comments
CABIN
Check EMERGENCY Steer Pump Operation Refer Operator's Manual for Spec.
Check Air Conditioning
Check 2/4WD & HI/LO Operation
Check 4WD Audible Warning
Check Diff Lock Operation
Check Holding Brake Operation
Check Emergency Stop Button Operation
Check Reversing and Winch Camera Operation
Check AM/FM Radio Operation
Check Heater Operation
Check Wiper Operation
Refill Windscreen Washer Water & Test Operation
Check Front Spring Lockout Operation 200 bar activation pressure
Check Park Brake Operation
Check Emergency Brake Release
Check Foot Valve Operation
Check ALL Warning Lights and Buzzers
Check ALL Instruments for Operation/Illumination
Check Indicators & Audible Warning
Check Hazard Lights
Check Horn(s)
Check Hyd. Sys. Base Pressure - use Dash Gauge Refer Operator Manual for Pressures
Check Hyd. Sys. Max Pressure - use Dash Gauge Refer Operator Manual for Pressures
Check Steer Pressure at Full Lock (dash gauge)
Check SLEW Light Operation
Check ALL Hydraulics for Correct Operation
Check ALL 'Crane Control Levers' for Operation
Check Clearance Lights
Check Head Lights HI/LO
Check Stop Lights
Check Reverse Light(s) & Alarm
Check ALL Work Lights
Check Low Air Warning Devices
Check Rotating Light Operation
Check Interior Light Operation
Check Cabin for Water Leaks
Check Seat Mounting & Operation
Check Seat Belt Condition
Check Door Locks & Catches for Operation
ENGINE BAY & TRANSMISSION
Clean or Replace Air Filter ( Outer Element Only )
Visual Inspect Radiator Screen & Cooler Cores for Blockage
Check Coolant & Inhibitor Level / Concentration
Check ALL Coolant / Heater System Hoses
Visual Inspect Air Intake Pipes & Hoses
Tighten Intake Hose Clamps
Check Fan Viscous Coupling
Check Alternator & A/C Compressor Mount/Bolts
Check Engine Drive Belt
Check Engine Oil Level
Check Engine, Lines & Hoses for Abrasion & Position
Page 2.28/07/08 250 / 750 Hour Service Schedule Cont. Comments QF23M.001
Check Engine Piping for Leaks
Visual Inspect Engine Mount(s) Condition
Check for Fuel Leaks ALL Points
Check for Oil Leaks in Engine Area
Check Hydraulic Pump PTO, Mounting & Bolts
Check Transmission Oil Level
TRANSFER CASE & DRIVETRAIN
Check Planetary Reduction (s) Oil Level
Check Transfer Case Oil Level Run at 1000 rpm for 1 min, then check immediately
Check Transfer Case Cooler System for Flow & Leaks
Check Front Differential Oil Level
Check Rear Differential Oil Level
Check Clamping Bolts Front & Rear Spring Packs
Check ALL Springs for Broken Leaves
Check Radius Rods/Front Torsion Arms Tightness Refer Operators Manual for Tensions
Check ALL Drive / Jack Shaft Universal Joints
Lube ALL Universal Joints on Drive Line
Check Brake Shoe Thickness ( via insp.holes ) Document thicknesses
Adjust ALL Service Brakes
Drain ALL Air Tanks of Water / Sediments
Check ALL Steering Pins / Bearings for Wear
Lube ALL Steering Pins / Bearings Use SBX-2 Grease
Tighten Steering Pin Nuts
Inspect steering hoses As per Service bulletin SB0069
Inspect steering cylinder rod clevis As per Service bulletin SB0063
BOOM ASSEMBLY
Adjust ALL Retract & Extension Ropes/Chains Refer Operator's Manual for Spec.
Check 2nd Extension Cylinder Anchor Pins Refer Service Bulletin SB0073
Re-tension Tele Secondary Cylinder Hoses Refer Service Bulletin SB0038
Check Winch Gearbox Oil Level
Check Winch Brake Oil Level
Check Winch Rope Condition & Lubrication
Check Winch Unit Mountings & Bolts
Visual Inspection of ALL Boom Sect. Damage/Bend
Lube All Boom Sections, Sheaves & Wear Pads
Inspect ALL Compensating Sheave Bearings
Inspect ALL Sheaves on Boom Assy.
Check Boom Rear Pivot Pins/Bearings for Movement
Lube Rear Boom Pivot Bearings Use SBX-2 Grease
Check Luff Cyl. Top/Bott Pins & Bearings Movement
Lube ALL Luff Cyl. Bearings Use SBX-2 Grease
CHASSIS & FINAL CHECKS
Check Center Pivot Bearings/Pins for Movement Refer Service Bulletin SB0105
Lube Centre Pivot Bearings ALL Points Use SBX-2 Grease
Check Hydraulic Reservoir Oil Level Boom Closed Up (Lowered & Retracted)
Check Counterweight Lifting Bolts for Wear & Damage Refer Service Bulletin SB0093
Check ALL Hydraulic Cyl's for Damage/Leaks
Check ALL Hydraulic Hoses for Damage/Leaks
Check ALL Wiring for Damage & Correct Routing
Check for Air Leaks ALL Points
Check Battery Electrolyte Level
Clean & Check Battery Terminals-Holding Clamp
Check Tyre Pressures & Tyre Condition
Carry Out FULL Function/Operate Test Drive
Transmission Pre-select Downshift to 3rd
Check Exhaust Brake Operation
Lift Test Weight if Available
Check LMI Calibration
Page 3.28/07/08 500 Hour Service Schedule Comments QF23M.001
Carry Out 250 Hour Service Schedule
Add the Following:
Change Engine Oil Filter
Change Engine Oil
Change Hydraulic Oil Return Filter
Change Transfer Case Oil
Change Front Diferential Oil
Change Rear Differential Oil
Change Planetary Reduction (s) Oil
Adjust Rear Boom Pivot Bearings
Lube ALL Service Brake Actuating Shafts
Change Winch Gearbox Oil
Change Winch Brake Oil

1000 Hour Service Schedule Comments

Carry Out 250 / 750 Hour Service Schedule
Carry Out 500 Hour Service Schedule
Add the Following:
Change Inner Air Filter Element NOT Applicable on 100 Hour Service
Replace Fuel Filter Element
Replace Fuel Pre-filter Element
Adjust Valve Clearances
Change Cylinder Head Valve Cover Gasket
Check & Clean Engine Breather
Change Auto Transmission Main Filter IS Applicable on 100 Hour Service
Change Auto Transmission Auxillary Filter NOT Applicable on 100 Hour Service
Change Auto Transmission Oil NOT Applicable on 100 Hour Service
Sample Hydraulic Oil using Kit PP2128300

2000 Hour Service Schedule Comments

Carry Out 250 / 750 Hour Service Schedule
Carry Out 500 Hour Service Schedule
Carry Out 1000 Hour Service Schedule
Add the Following:
Change Engine Coolant
Check Wear Pad "Clearance" & Boom Alignment If Wear is Out Limits Strip & Remove ALL Pads
Page 4.28/07/08 100 Hour First Service Schedule Comments QF23M.001
Carry Out 250 / 750 Hour Service Schedule
Carry Out 500 Hour Service Schedule
Carry Out 1000 Hour Service Schedule
Add the Following:
Tighten ALL Hose Clamps
Check Tension of ALL Engine mounts Refer Parts Manual for Tension Settings
Re-Tension ALL Wheel nuts Refer Operators Manual for Tension Settings
Re-Tension ALL 'U' Bolts & Suspension Bolts Refer Operators Manual for Tension Settings
Re-Tension All Front/Rear Diff. Carrier Bolts. Refer Operators Manual for Tension Settings
Re-Tension Centre Pivot Pins - Upper/Lower Refer Operators Manual for Tension Settings
Check & Adjust Rear Axle Alignment to Centre Adjust Alignment to Centre Pivot-Tolerance 5mm
Tighten ALL Drive Shaft / Jack Shaft Flange Bolts

Service Carried out by:______________________________Signiture________________

Service Carried out by:______________________________Signiture________________

ADDITIONAL FAULTS IDENTIFIED:

1
2
3
4
5
6
7
8
9
10
 SERVICE BULLETIN
BULLETIN NO: SB0038

DATE: 5/10/99

SUBJECT: MAC 25 Tele Cylinder Hoses

RE: MAC 25

EFFECTIVE: All Cranes With Full Power Boom

The Tele Cylinder Hoses in the Mac 25’s can experience wear and damage if they are not tensioned
properly and if the plastic sheave they move over is not free to rotate. The hoses then bunch in between the
large & small cylinders and the outer casing can be damaged.
All MAC 25’s with powered third extensions should have these hoses retensioned at their next service and
then at every 250 hourly service thereafter (when the chains/ ropes are checked)
The tension should be as tight as the average person can reasonably pull the hoses, without being excessive.
There is no way to check the pulley without removing the large tele cylinder, however if the cylinder is
removed for any reason the pulley should be checked and freed up if necessary. Removing material from
the bore of the pulley so that it is a loose fit on the shaft is acceptable.

When tensioning the hoses, be careful that the retaining collets do not cut into the outer casing of the hose.
It may be necessary to radius the back of the collets where they clamp the hoses to prevent them from
digging in. New collets have this radius.

Where the hoses are known to be leaking and insufficient tension is found to be the only problem, i.e. it is
preferred not to remove the tele cylinder to rectify another problem, the hoses can be replaced with the
boom fully assembled (use Franna part number PLMXA3032- BOOM HOSE REPLACEMENT KIT)

PLMXA3032- is available & lists all parts required & procedures for replacing the hoses without
dismantling the boom.

Yours Sincerely,

Mick Walsh
Engineer
 ABN 86 010 671 048
TEREX LIFTING AUSTRALIA PTY LTD ACN 010 671 048
™
Curtin Avenue East • P.O. Box 1396 • Eagle Farm QLD 4009 AUSTRALIA
Telephone: (+61) 7 3868 9600 Facsimile: (+61) 7 3268 2489 ™
LIFTING Internet : www.franna.com.au E-Mail : [email protected]
(QF112G.1)

SERVICE BULLETIN SB0060

DATE: 6/09/05 REVISION: A

MODEL(S): 4WD-10, 4WD-12, 4WD-16, AT-14, AT-18, AT-20,
MAC 12, MAC 14, UC-10, UC-15 & MAC 25
SUBJECT: Winch Mounted Workboxes – Anti Two-Block Requirements
EFFECTIVE: All Aforementioned Cranes

TEREX|ΦΡΑΝΝΑ aligns its standing of winch rope mounted Workboxes to that of the Australian Standards
and the relevant Workplace Health and Safety requirements. For this reason Franna Cranes endorses the
using our boom mounted Manbasket where possible. However, AS 2550.1-1993 Clause 7.16.1 accepts that
under certain special tasks of short duration it may not practical to use such means and hence a winch rope
mounted workbox may be used in strict accordance to the requirements of AS 2550.1-1993 Clause 7.16.

AS 2550.1-1993 Clause 7.16.3(e) states the requirement for an up-limit switch on hoist motion. AS 1418.5-
1995 Clause 7.5.3.2(a)(ii) gives an example of a hoisting limiter for Two-block damage prevention device.
The Franna boom design is unique in that it incorporates Hook Compensation - even whilst telescoping and
luffing the hook block will still remain at the same position relative to the boom head. This is achieved by the
physical path that the winch rope is reeved through the boom (the Operators Manual under winch rope
replacement shows this). The boom head is designed to be two blocked and the hydraulic control system for
the winch is fitted with a maximum pressure compensator to limit the maximum line pull. For this reason it is
impossible for the operator to brake an in-service condition winch rope by Two-blocking the hook. The winch
rope fully complies to AS 1418.5-1995 Clause 6.1.1 for a minimum safety factor of 4:1. It has been shown,
with Workplace Health and safety that the Franna design complies in full with the requirements of AS
1418.5-1995 Clause 7.5.3.2(a)(ii) Two-block damage prevention device.

We also note that the down limit switch refereed to in clause 7.16.3(f) is only required if the workbox is to be
lowered below the crane’s supporting surface - the crane, when correctly reeved, will have enough rope to
meet the supported surface.

Whilst AS 2550.1-1993 has not been mandated in Queensland, it serves as a guide to fulfil the requirements
of the Workplace Health and Safety Act 1995, Section 32. We only endorse any usage of a workbox is strict
accordance to AS 2550.1-1993.

In addition, the MAC 25 Crane’s telescoping boom has Hook Compensation for the first two extensions, the
third extension requires the operator to compensate, and hence it is fitted with a Anti Two-block device. This
fully complies with the requirements of AS 1418.5-1995 Clause 7.5.3.2(a)(i) and AS 2550.1-1993 Clause
7.16.3.

Note that the above statements only apply to the TEREX|ΦΡΑΝΝΑ design. Other similar cranes need to
be inspected with the same level of scrutiny, as we know that subtle differences in the basic design and
control system will cause the compliance to fail.

Should you have any further questions, please don’t hesitate to contact us.

Yours Sincerely,

Danny Black BE (mech)

Engineering Manager

Simple, available and cost effective ™

NW • BCP • KOEHRING • LORAIN • TEREX • MARKLIFT • PPM • P&H • BENDINI • BRIMONT • SIMON RO TELELECT CELLA
BPI • HOLLAND LIFT • AMERICAN • ITALMACCHINE • PEINER • COMEDIL • MATBRO • MOFFETT • PRINCETON • KOOI AAP
 SERVICE BULLETIN
BULLETIN NO: SB0063

DATE: 13/04/00

SUBJECT: Steering Cylinder Rod Clevis

RE: 4WD-10, 12, 16, UC-10, MAC 12, 14, 25, AT-14 and18

EFFECTIVE: All Aforementioned Cranes

It has been brought to our attention that, depending on the duty of usage, after many years of service
the steering cylinder rod clevis can develop excessive play in the threaded components. Whilst this
can be classed as normal wear and tear for such a component, if this process is left to continue the
result can lead to a potentially dangerous condition.

In lieu of this Terex Franna recommends periodic inspection, namely at every 250 hour service
interval, of the clevis/rod threaded connection. This can be inspected by applying the foot brake fully
and steering the crane until resistance is felt to the left and right, whilst another person inspects the
connection of the clevis to the cylinder rod. If any movement is present the components should be
replaced. NOTE: Caution should be taken to keep clear of the potential crush zone in the
articulation pivot.

To prevent any future wear in these components the cylinder rod will now be fitted with a welded
clevis. This will make this joint maintenance free. Listed below are the replacement part numbers for
the welded clevis rod assemblies, which may be purchased from our spare parts department.

CRANE MODEL CYLINDER MAKE PART NUMBER

UC-10 PTE PP8003622
4WD-10, 4WD-12, MAC 12, MAC 14, AT-14 PTE PP8003620
4WD-12 (S/N 1475) GLENROB PP8003624
AT-14, MAC 14 PARKER PP8003625
AT-14 (S/N 1618) BAKER PP8003627
MAC 14 (S/N 14095) HYDROIL PP8003628
4WD-16, AT-18 PTE PP8003621
AT-18 (S/N 3151, 3175) PARKER PP8003626
MAC 25 PTE PP8003623

Should you have any further questions, please don’t hesitate to contact us.

Yours Sincerely,

Danny Black BE (mech)

Engineering Manager

MANUFACTURERS OF ALL TERRAIN CRANES – DISTRIBUTORS OF

LARGE HYDRAULIC – CRAWLER – ROUGH TERRAIN – KNUCKLE BOOM
AND STRAIGHT BOOM TRUCK LOADING CRANES

P.O. BOX 1396, EAGLE FARM, QLD 4009

CURTIN AVENUE, EAGLE FARM, QLD 4009
Telephone: 07 3868 9600 Facsimile: 07 3268 2489
E-mail: [email protected] Web Site: www.franna.com.au
 SERVICE BULLETIN
BULLETIN NO: SB0063

DATE: 13/04/00

SUBJECT: Steering Cylinder Rod Clevis

RE: 4WD-10, 12, 16, UC-10, MAC 12, 14, 25, AT-14 and18

EFFECTIVE: All Aforementioned Cranes

It has been brought to our attention that, depending on the duty of usage, after many years of service
the steering cylinder rod clevis can develop excessive play in the threaded components. Whilst this
can be classed as normal wear and tear for such a component, if this process is left to continue the
result can lead to a potentially dangerous condition.

In lieu of this Terex Franna recommends periodic inspection, namely at every 250 hour service
interval, of the clevis/rod threaded connection. This can be inspected by applying the foot brake fully
and steering the crane until resistance is felt to the left and right, whilst another person inspects the
connection of the clevis to the cylinder rod. If any movement is present the components should be
replaced. NOTE: Caution should be taken to keep clear of the potential crush zone in the
articulation pivot.

To prevent any future wear in these components the cylinder rod will now be fitted with a welded
clevis. This will make this joint maintenance free. Listed below are the replacement part numbers for
the welded clevis rod assemblies, which may be purchased from our spare parts department.

CRANE MODEL CYLINDER MAKE PART NUMBER

UC-10 PTE PP8003622
4WD-10, 4WD-12, MAC 12, MAC 14, AT-14 PTE PP8003620
4WD-12 (S/N 1475) GLENROB PP8003624
AT-14, MAC 14 PARKER PP8003625
AT-14 (S/N 1618) BAKER PP8003627
MAC 14 (S/N 14095) HYDROIL PP8003628
4WD-16, AT-18 PTE PP8003621
AT-18 (S/N 3151, 3175) PARKER PP8003626
MAC 25 PTE PP8003623

Should you have any further questions, please don’t hesitate to contact us.

Yours Sincerely,

Danny Black BE (mech)

Engineering Manager

MANUFACTURERS OF ALL TERRAIN CRANES – DISTRIBUTORS OF

LARGE HYDRAULIC – CRAWLER – ROUGH TERRAIN – KNUCKLE BOOM
AND STRAIGHT BOOM TRUCK LOADING CRANES

P.O. BOX 1396, EAGLE FARM, QLD 4009

CURTIN AVENUE, EAGLE FARM, QLD 4009
Telephone: 07 3868 9600 Facsimile: 07 3268 2489
E-mail: [email protected] Web Site: www.franna.com.au
 ABN 86 010 671 048
TEREX LIFTING AUSTRALIA PTY LTD ACN 010 671 048

Curtin Avenue East • P.O. Box 1396 • Eagle Farm QLD 4009 AUSTRALIA
Telephone: (+61) 7 3868 9600 Facsimile: (+61) 7 3268 2489 
LIFTING Internet : www.franna.com.au E-Mail : [email protected]

SERVICE BULLETIN
BULLETIN NO: SB0069

DATE: 10/01/01

SUBJECT: Inspection of Steering Hoses

RE: All Models

EFFECTIVE: Immediately

All current Franna cranes achieve there steering function by means of a hydraulic control
system. This has proven itself as being safe and reliable, however the system needs to be
correctly serviced to ensure this is maintained. To assist in this process we have
developed a recommended inspection for hose replacement criteria, which will be added
to the service inspection procedures – please find details below.

HOSE REPLACEMENT CRITERIA

HOSE DESCRIPTION :
PASS OR
DESCRIPTION OF INSPECTION REJECT COMMENTS

LEAKAGE

DAMAGE TO COVER

KINKED OR CRUSHED

TWISTED

HEAT CRACKS OR CHARRED

LOOSE COVER
CRACKED, DAMAGED OR BADLY
CORRODED FITTINGS
FITTING SLIPPAGE ON HOSE
REPLACEMENT CRITERIA – A REJECT ON ANY OF THE ABOVE ITEMS
REQUIRES THAT THE HOSE SHOULD BE REPLACED
INSPECTED BY : DATE: / /

Simple, available and cost effective 

NW • BCP • KOEHRING • LORAIN • TEREX • MARKLIFT • PPM • P&H • BENDINI • BRIMONT • SIMON RO TELELECT CELLA
BPI • HOLLAND LIFT • AMERICAN • ITALMACCHINE • PEINER • COMEDIL • MATBRO • MOFFETT • PRINCETON • KOOI AAP
This addresses the external condition of the hose and time in service. The inspection
must be carried out on the entire hydraulic steering flow path - this can be traced through
on the hydraulic circuit, if in doubt please don’t hesitate to contact us. Typically this will
include the following hoses:

• Main pump suction.

• Main pump pressure outlet to rear body pipe.
• Rear body pipe to priority valve.
• Priority valve to steering unit.
• Steering unit to left and right steering cylinders.
• Left and right steering cylinders cross over hoses.
• Steering unit load sensing to shuttle valve.
• Shuttle valve to main pump load sensing.
• Emergency steering pump suction.
• Emergency steering pump pressure outlet to manifold/tee.

We recommend that the inspection should be performed at the next service interval, then
take place at every 250 hr period thereafter.

Should you have any further questions, please don’t hesitate to contact us.

Yours Sincerely,

Danny Black
Engineer Manager (B.E. Mech)
Terex Lifting Australia Pty. Ltd.

Simple, available and cost effective 

 ABN 86 010 671 048
TEREX LIFTING AUSTRALIA PTY LTD ACN 010 671 048

Curtin Avenue East • P.O. Box 1396 • Eagle Farm QLD 4009 AUSTRALIA
Telephone: (+61) 7 3868 9600 Facsimile: (+61) 7 3268 2489 
LIFTING Internet : www.franna.com.au E-Mail : [email protected]
(QF112G.1)

SERVICE BULLETIN SB073

DATE: 16-12-02 REVISION:

MODEL(S): MAC-25 (All Serial Numbers)
SUBJECT: 2nd Extension Cylinder Anchor Pins
EFFECTIVE: Immediately

It has come to our attention that MAC-25 2 nd Extension Cylinder Anchor Pin mounting bolts
can come loose and thus could result in the tele cylinder anchor pins coming out. This
problem appears to be due to wear in the pin mounting hole.

We are now issuing this Bulletin, so that the above mentioned mounting bolts and pins are
checked as per the following recommendations. Obviously if there is considerable wear
between the pin and hole, repairs should done to restore the components to original
specification.

Please check the below diagram for actual placement of bolt and pin, and ensure that
these are secure and that the bolt is set to correct torque setting, at each 250-Hour service
interval.

Torque Setting on Bolts (3/8” UNC x ¾” GR.5 ZP) shall be 27 lbf.ft / 36.6 Nm.

Should you have and questions or comments concerning this bulletin, please contact
Terex Lifting Australia Pty Ltd Product Support Department on (07) 3868 9600.

Simple, available and cost effective 

NW • BCP • KOEHRING • LORAIN • TEREX • MARKLIFT • PPM • P&H • BENDINI • BRIMONT • SIMON RO TELELECT CELLA
BPI • HOLLAND LIFT • AMERICAN • ITALMACCHINE • PEINER • COMEDIL • MATBRO • MOFFETT • PRINCETON • KOOI AAP
 ABN 86 010 671 048
TEREX LIFTING AUSTRALIA PTY LTD ACN 010 671 048
™
Curtin Avenue East • P.O. Box 1396 • Eagle Farm QLD 4009 AUSTRALIA
Telephone: (+61) 7 3868 9600 Facsimile: (+61) 7 3268 2489 ™
LIFTING Internet : www.franna.com.au E-Mail : [email protected]
(QF112G.1)

SERVICE BULLETIN SB0084

DATE: 14th April, 2004 REVISION: C

MODEL(S): All AT-15, UC-15, AT-20, MAC-25 cranes containing 3B6
LMI’s
SUBJECT: Service Technician Passwords & Current Procedures
EFFECTIVE: Immediately

Issue:

We require passwords to gain entry to certain configuration areas of the 3B6 Load Moment
Indicator system, on above-mentioned cranes.

Action:

Black Box entry: Password for entry into downloading Data logging lift data is 4482. No
Laptop required. Gains entry to last 15 lift details.

Service Maintenance reset:

1. Ensure 3B6 display is in the main menu.
2. Press F5 (spanner) button.
3. Press F7 (maintenance reset) button.
4. Enter password 2702.
5. Press F6 (maintenance) to access maintenance menu. Do not press the F7 button again
as this will reset the whole schedule field.
6. Press the ‘RESET TIME’ yellow button corresponding to the schedule just completed .
7. Press F6 to exit to previous menu.
8. Press F10 to exit to main menu.

New Generation Length / Angle Calibration: Password to change length and angle
calibration on later model machines is 3577. No Laptop required. Only relevant for
Mercedes engine cranes.

Please note procedures on the above will be distributed accordingly.

Additional Notes:

Laptop required for the following procedures:

1. Software Loading Procedure for MEGATECH system
2. Calibration of Length and Angle for MEGATECH system (all Hino and Perkins powered
machines)
3. Parameter 105: Engine Hours reset
4. Parameters 100 - 104. 100 - 100 hour, 101 - 250 hour, 102 - 500 hour, 103 - 1000 hour
& 104 - 2000 hour.

Simple, available and cost effective ™

NW • BCP • KOEHRING • LORAIN • TEREX • MARKLIFT • PPM • P&H • BENDINI • BRIMONT • SIMON RO TELELECT CELLA
BPI • HOLLAND LIFT • AMERICAN • ITALMACCHINE • PEINER • COMEDIL • MATBRO • MOFFETT • PRINCETON • KOOI AAP
 Software Loading Procedure for MEGATECH System

1) Connect Laptop to CPU via cable CV BSHP-4/10 to Serial connection.

2) Switch on System, and select Mode 1 (Winch), refer to operator’s manual. It is advisable to have this
procedure in hard copy so that each step can be ticked on completion to avoid omitting or repeating any steps.
3) Open MS program as follows:
3.1) Select MS-DOS Prompt
3.2) Type “cd ..” >enter
3.3) “cd m” >enter
3.4) “cd um” >enter
3.5) “cd uc15 or mac25” >enter (depending on crane model).
3.6) “ms” >enter (twice)
3.7) Go to “Parametri” >enter; scroll down to “Trasduttori” > enter, check if laptop is communicating with
system: figures should be displayed next to parameters.
(If no figures appear, it means the Laptop is not communicating, therefore the program must be re-started, go to
paragraph 5.6 to exit and shut down.
Restart the Laptop and begin again from paragraph 1 ensuring that the serial cable is properly connected),
otherwise proceed on.
3.8) Press “Esc”
3.9) Go to “File” and scroll down to “Uscita” (exit) >enter.
3.10) At prompt [c:\m\um\UC15>] type “h2f” >enter, (the Flash Loader v 1.32 menu is displayed).

4) Load Software as follows: Press “3” [Carica (load) utility U2MIC] >enter.
4.1) Press “11” [Carica (load) Page 1] >enter, wait until loading completed.
4.2) Press “12” >enter, wait until page 2 loading is completed.
4.3) Press “13” >enter to load page 3; (only 3 pages can be loaded each step).
4.4) Press “2” > enter [Avvia (Start) Programma].
4.5) Exit H2F program by pressing “0” >enter.
4.6) Re-enter program same as 3.10 by typing “h2f”>enter.
4.7) Press “3” [Carica (load) utility U2MIC] >enter.
4.8) Press “14” >enter to load page 4, repeat for page 5 “15” .
4.9) Repeat steps: 4.4, 4.5,
4.10) Type "ms" and ENTER twice to go to parameters and save.

Simple, available and cost effective ™

5) Parameters corrections and save procedure.
5.1) At prompt [c:\m\um\AT15>] “ms” >enter twice.
5.2) From “File” scroll down to “Carica (load)” >enter.
5.3) Select applicable file >enter.
5.4) Answer “Y”(yes) to prompt “Trasferimento a tutte le unità (Transferral to all the units) [Y/N]”; the
next message will be: “Trasferimento a macchina in corso ( Transferral to machine in progress)”; when
transferral completed, the message “Caricamento Ok (Loading Ok)” press >enter.
5.5) Go to “Correzioni (Corrections)”, scroll down to “Comandi (Commands)” and press “Enter”.
5.6) Go to Parameter #150 (COorder), make value “98” >enter, program will count down to 0 (zero), then
make value “420”>enter; the program will count down to 0 (zero) again thus saving all corrections.

Simple, available and cost effective ™

For AT-15 with engine monitoring proceed with the following steps.

5.7) Press “Esc”, go to “Parametri”, scroll down to “Macchina” > enter.

5.8) Page up to parameter 40 and enter the following values:
40 …… 0 50 …… 50
41 …… 0 51 …… 50
42 …… -10 52 …… 50
43 …… 0 53 …… 50
44 …… 0 54 …… 50
45 …… 0 55 …… 600
46 …… 0 56 …… 0
47 …… 50 57 …… 300
48 …… 50 58 …… 0
49 …… 50 59 …… 0
5.9) Page up to parameter 180 and enter the following values:
183 …… 38
184 …… 900
185 …… 120
186 …… 2000
Then repeat steps 5.5 and 5.6.

6) Test program on simulator or on actual machine, select each individual duty (mode), and check performance.
If some data is incorrect in any mode: select the faulty mode, and
6.1) Repeat step 5.5, then go to Parameter #150 and make value “360” >enter, program will count down to 0
(zero), cancelling the program for the selected mode, then repeat step 5.6 to memorize corrections.
6.2) To exit program: press “Esc”, go to “File”, scroll down to “Uscita (Exit)” > enter.
6.3) At prompt [c:\m\um\AT15>] type “exit” to completely exit the MS-DOS.
Simple, available and cost effective ™
 Calibration Procedure for MEGATECH System.

Boom Angle and Length.

1) Select Mode (Duty) 1.

2) Start Program as per step 3.1 to 3.7.
3) Page up to parameters 200 to 206 for Angle.
4) Lower the boom to 0(zero) degrees and verify with inclinometer or spirit level.
5) Make parameter 204 “Angolo noto 1”(known angle 1) = 0(zero).
6) Copy value of 202 in 203 by typing manually > enter.
7) Lift boom to maximum angle (60 deg), and measure actual angle.
8) Go to par. 206 and enter actual angle value (600 for 60 deg).
9) Copy value of 202 in 205 by typing manually > enter.
10) Page up to 220 to 226 for Length.
11) Retract boom fully.
12) Verify that parameter 224 “Sfilo noto” (known length) = 5.65M.
13) Copy value of 222 in 223 by typing manually > enter.
14) Extend boom fully and enter actual length (1385).
15) Copy value of 222 in 225 by typing value manually > enter.
16) Press “Esc”, and go to “Correzioni” (Corrections).
17) Repeat steps 5.5 and 5.6, then exit program.

Yours sincerely,

Adam Dickens BE Mech

Terex Lifting Australia

Should you have and questions or comments concerning this bulletin, please contact
Terex Lifting Australia Pty Ltd Product Support Department on (07) 3868 960

Simple, available and cost effective ™

 ABN : 86 010 671 048
ACN : 010 671 048
E-Mail : [email protected]
Internet : www.terex.com.au

Terex Lifting Australia Pty. Ltd.

SERVICE BULLETIN SB0093

DATE: 06 December 2004 REVISION: -

MODEL(S): All MAC25’s
SUBJECT: Bolts Fitted to Counterweight Lifting Chains Wearing
EFFECTIVE: Immediately

Issue:

Recent inspections on MAC25 Counterweight Lifting cylinders have found that the bolt that
attaches the lifting chain to the counter-weight lifting rams at the rear of the crane have shown signs
of wear & distortion. These chains must only be used to lift the counterweight into the pinning
position. The counterweight must be secured using the pins provided. Once the counterweight is
pinned, the tension must be released from the chains. (Under no circumstances should the crane
be operated using the lifting chains to secure the counter-weight)

Actions required:

Periodic inspection of the bolts and replace if any wear or bolt distortion is visible. Two bolt sizes
were fitted M8 x 40mm long grade 10.9 or M12 x 45mm long grade 10.9; original size must be
fitted. Ensure a new nyloc nut is used with the replacement bolt.

Should you have and questions or comments concerning this bulletin, please contact
Terex Lifting Australia Pty Ltd Product Support Department on (07) 3868 9600.

Simple, available and cost effective 

FRANNA • LORAIN •P&H •RO STINGER •PPM •BENDINI •AMERICAN •PEINER •COMEDIL • DEMAG
 ABN : 86 010 671 048
ACN : 010 671 048
E-Mail : [email protected]
Internet : www.terex.com.au

Terex Lifting Australia Pty. Ltd.

(QF112G.2)

SERVICE BULLETIN SB0105

DATE: 30/10/07 REVISION: -

MODEL(S): 4WD 8/10/12/16; AT-14/15/18/20; UC-10/15; MAC 12/14/25
SUBJECT: Centre Pivot Bearing Wear
EFFECTIVE: Immediately

This Service Bulletin has been issued as guideline for assessing Centre Pivot Bearing
Wear in TEREX|FRANNA cranes. To check bearing wear follow the steps below:

1. Fully retract the boom and set at zero degrees boom angle.
2. Use a dial gauge to measure axial clearance:
(i) 4WD 8/10/12, UC-15, AT-14/15 - Place the magnetic base of the dial
gauge on the bottom plate of the rear body, with the spindle positioned as
close as possible to the centre of the pin (as shown in Figure 1.1).
(ii) 4WD 16, AT-18/20 – Place the magnetic base of the dial gauge on the
bottom plate of the front body, with the spindle on the centre pivot pin (As
shown in Figure 1.2).
(iii) MAC12/14/25 – Place the base of the dial gauge on the top plate of the
front body with the spindle placed on the centre of the pin (as shown in
Figure 1.3).
(iv) UC-10 - Place the magnetic base of the dial gauge underneath the
bottom plate of the front body, with the spindle on the centre pivot pin (As
shown in Figure 1.4).
3. Zero out the dial gauge with crane boom fully retracted.
4. With the dial gauge reset to zero, fully extend the boom and record the reading from
the dial gauge.
5. Repeat the above steps to ensure consistency.

An adjustable bearing assembly is installed in UC-15, AT-15 Series II/III, AT-20 Series III
and MAC 25 cranes. The bearing should be adjusted every 250 hours to achieve an axial
clearance of less than 0.1mm (Refer to Centre Pivot Adjustment Procedures UXA1013,
15A1011 & MXA1013). However if an axial clearance of less than 0.5mm cannot be
achieved with adjustment, then the centre pivot bearings/pins need to be replaced.

All other TEREX|FRANNA models have a non-adjustable bearing assembly; if the axial
clearance is greater than 1mm, then the centre pivot bearings/pins need to be replaced.

QLD (Head Office) N.S.W. W.A.

585 Curtin Avenue East 114 Hassall Street 93 Poole Street
P.O. Box 1396 Wetherill Park, NSW 2164 Welshpool, WA 6106
Eagle Farm QLD 4009 PH: (+61) 2 8786 4444 PH: (+61) 8 9358 9806
PH: (+61) 7 3868 9600 Fax: (+61) 2 8786 4455 Fax: (+61) 8 9358 9851
Fax: (+61) 7 32682489

Simple, available and cost effective ™

FRANNA • LORAIN •P&H •RO STINGER •PPM •BENDINI •AMERICAN •PEINER •COMEDIL • DEMAG
 Terex Lifting Australia Pty. Ltd.

Figure 1.1 Dial Gauge Set-up for 4WD 8/10/12, AT-14/15.

(AT-15 Series II/III shown, bearing assembly differs on other models)

Figure 1.2 Dial Gauge Set-up for 4WD 16, AT-18/20.

(AT-20 Series III shown, bearing assembly differs on other models)

Simple, available and cost effective ™

 Terex Lifting Australia Pty. Ltd.

Figure 1.3 Dial Gauge Set-up for MAC12/14/25.

(MAC25 shown, bearing assembly differs on other models)

Figure 1.4 Dial Gauge Set-up for UC-10.

Should you have and questions or comments concerning this bulletin, please contact
Terex Lifting Australia Pty Ltd Product Support Department on (07) 3868 9600.

Simple, available and cost effective ™

 ABN : 86 010 671 048
ACN : 010 671 048
E-Mail : [email protected]
Internet : www.terex.com.au

Terex Lifting Australia Pty. Ltd.

(QF112G.2)

SERVICE BULLETIN SB0116

DATE: 9/08/2007 REVISION: -

MODEL(S): All TEREX|FRANNA Cranes
SUBJECT: Major Inspections - Design Life
EFFECTIVE: Immediately

Australian Standards AS 2550.1 & 5 specify the requirements for Major Inspections of
Mobile Cranes. The Major Inspection covers items over and above routine maintenance.
The philosophy behind the Major Inspection is to ensure that components which have
reached the end their design life are repaired/replaced for continued safe operation.
Components reach their design life primarily from use, but they can also be affected by
their storage or operating environment.

In considering past usage we need to take into account the past state of loading and
utilization as compared to the crane’s design classifications. In the absence of detailed
crane duty cycle history, the crane’s operating hours can be used. This must be assessed
in conjunction with the crane’s maintenance records to verify the operating hours are
correct and that the crane has been properly maintained over the life of the crane.

Once it has been verified that the component’s past usage is less than its design life, it is
safe to continue using the component and carry out routine maintenance until it has
reached the end of its design life. This approach applies only to components that reach
their design by fatigue (number of cycles). The Major Inspection also covers items that
reach their design life subject to their operating environment, for example corrosion and
material breakdown. Specifically the materials used in hydraulic hoses tend to break down
over time; hence it is also recommended that the steering hoses be replaced at 10 years.

In addition, Australian Standard AS 2550.1 states that the Major Inspection shall address
any manufacturer’s safety upgrades and to consider the viability of upgrading the crane to
the requirements of the latest Australian Standard. These are considered to be
independent of the crane’s usage and hence should be carried out at 10 years.

Please refer to our MAJOR INSPECTION CRITERIA, document number QF23O, for
detailed requirements of TEREX|FRANNA cranes.

Should you have and questions or comments concerning this bulletin, please contact
Terex Lifting Australia Pty Ltd Product Support Department on (07) 3868 9600.

QLD (Head Office) N.S.W. W.A.

585 Curtin Avenue East 114 Hassall Street 93 Poole Street
P.O. Box 1396 Wetherill Park, NSW 2164 Welshpool, WA 6106
Eagle Farm QLD 4009 PH: (+61) 2 8786 4444 PH: (+61) 8 9358 9806
PH: (+61) 7 3868 9600 Fax: (+61) 2 8786 4455 Fax: (+61) 8 9358 9851
Fax: (+61) 7 32682489

Simple, available and cost effective ™

FRANNA • LORAIN •P&H •RO STINGER •PPM •BENDINI •AMERICAN •PEINER •COMEDIL • DEMAG
LUBRICATION SPECS
UNIVERSAL JOINTS

MEDIUM AND HEAVY DUTY

LUBRICATION SPECS
Don’t Neglect Spicer Driveshaft Lubrication U-joint that may not purge. Release seal tension using the
Lack of proper lubrication is the most common cause of following procedure:
premature failure of universal joint kits and slip assemblies. • On Quick Disconnect™ half round end yokes, Figure A,
Properly sized Spicer U-joints that are adequately relubricated remove the U-joint Kit from the yoke and apply grease.
at recommended intervals will normally meet or exceed fleet Reinstall the U-joint Kit, with new bolts in the yoke, and
operational requirements. Inadequate relube cycles and torque to the specs shown in Chart 1.
failure to lubricate the joints and slip spline properly not QUICK DISCONNECT (HALF ROUND)
only cause joint failures, but lead to other problems such as
slip spline seizures. Proper relubrication flushes the U-joints
and removes abrasive contaminants from the U-joint bearings.

Warning
Inadequate lubrication can cause driveline failure which can
result in separation of the driveline from the vehicle. A separated Figure A
driveline can result in serious injury or death. In order to avoid SERIES BOLT P/N THREAD SIZE BOLT TORQUE

driveline failure, including driveline separation, you must: (LB-FT) (NM)

1) Carefully review the lubrication specifications in this manual. SPL90 6-73-412 .375-24 45-60 61-81

2) Be sure that you use only approved lubricants. 1610 6-73-412 .375-24 45-60 61-81

3) Be sure that you relubricate at recommended intervals. 1710 8-73-316 .500-20 115-135 156-183
1760 8-73-316 .500-20 115-135 156-183
1810 8-73-316 .500-20 115-135 156-183
Lubrication Procedure For Universal Joints
Chart 1
Spicer replacement universal joint kits contain only enough
grease to provide needle bearing protection during storage. Warning
It is therefore necessary to completely lubricate each journal Half round bearing strap retaining bolts should not be reused.
cross and bearing assembly prior to assembly into the
driveshaft yokes. Each journal cross lube reservoir should be • On full round closed hole yokes, Figures B & C, loosen
fully packed with a grease as recommended in Chart 4. Each the bolts holding the bearing assembly that doesn’t purge
bearing assembly should also be wiped with the same to release seal tension. It may be necessary to loosen the
grease, filling all the cavities between the rollers and applying bearing assembly approximately 1/16 inch minimum. Apply
a liberal grease coating on the bottom of each bearing cap. grease gun pressure to purge seal or seals. If loosening
After the kits are installed into the driveshaft yokes and prior does not cause purging, remove the bearing assembly to
to placing into service, relube as follows: determine cause of blockage.
1. Using the proper lubricant, purge all four bearing seals of 4. Re-tighten or replace bolts based on bolt designs as
each U-joint. This flushes abrasive contaminants from each detailed in Chart 1, 2 or 3.
bearing and assures all four bearings are filled properly. Pop
the seals. Spicer seals are made to be popped.

2. If any of the seals fail to purge, move the driveshaft from

side to side while applying gun pressure. This allows greater
clearance on the thrust end of the bearing that is not
Warning- Rotating shafts can be dangerous. You can snag
purging.
clothes, skin, hair, hands, etc. This can cause injury or death.
3. Because of the superior sealing capability of the Spicer Do not go under the vehicle when the engine is running.
Seal design on the 1610, 1710, 1760, 1810 and 1880 Series,
there will occasionally be one or more bearing seals of a
Serrated Bolt Design OLD LOCK STRAP DESIGN (FULL ROUND)
The new self-locking design (Figure B) for full-round
yokes uses serrated bolts with lock patch and DOES
NOT require a lock strap (as in Figure C). When
re-installing this type, it is important that the old
serrated bolt be replaced and the new bolt torqued to
the proper specifications.
NEW–SERRATED BOLT WITH LOCK PATCH (FULL ROUND)

Figure C
OLD-LOCK
Retightening of Bolts: Lock Strap Design. After lubricating
the joint, run the bolts down until the bearing plates are flush to
the yoke faces, torque bolts to specification shown in Chart 3
and then bend the tabs of the lock strap against the side of the
bolt heads to lock the bolts in place. See Warning
Figure B
Re-Installing Serrated Bolts: Loosely install new bolts. (See Torque Specifications
the following chart below for bolt part numbers.) Tighten the new BOLT WITH LOCK STRAP (PRE-SPRING 1994 MODELS)
bolts to the torque specified in Chart 2. See Warning SERIES BOLT P/N THREAD SIZE BOLT TORQUE

Torque Specifications (LB-FT) (NM)

1610 5-73-109 .312-24 26-35 35-48

SERRATED BOLTS WITH LOCK PATCH/NO LOCK STRAP
1710 6-73-109 .375-24 38-48 52-65
(MODELS AFTER SPRING 1994)
1760 6-73-109 .375-24 38-48 52-65
SERIES BOLT P/N THREAD SIZE BOLT TORQUE
1810 6-73-109 .375-24 38-48 52-65
(LB-FT) (NM)
1880 7-73-115 .438-20 60-70 81-95
1610 5-73-709 .312-24 26-35 35-48
Chart 3
1710 6-73-209 .375-24 38-48 52-65
Recommended Lubricants For Universal Joints
1760 6-73-209 .375-24 38-48 52-65
1. Standard Application - Use a good quality E.P. (Extreme
1810 6-73-209 .375-24 38-48 52-65
1880 7-73-315 .438-20 60-70 81-95
Pressure) grease (Timken Test Load 45 lbs. min.) meeting
N.L.G.I (National Lubricating Grease Institute) grade 2
Chart 2
specification. Grease must have an operating range of
+325°F/+163°C to -10°F/-23°C and be compatible with
Warning commonly used multipurpose greases such as Lithium
Failure to properly tighten bolts, and reuse of serrated bolts, Soap Types.
could cause the driveshaft to loosen and separate from the 2. Low Speed Application - For driveshaft applications
vehicle or machine, which could cause a loss of control and involving shaft speeds below 500 RPM, a mineral oil in the
could result in serious personal injury or death. SAE 140 to 250 viscosity range should be used.

Consult your local lubricant source for greases that

meet specifications or use one of Spicer’s recommended
lubricants shown in Chart 4.
LUBRICANTS FOR U-JOINTS Cover the hole in the plug with your finger and continue pres-
Chevron Ultra-Duty EP-2 sure until grease appears at the slip yoke seal. (See Photo 2)
Chevron Heavy-Duty EP-2
Amoco Rykon Premium EP-2
Chemplus EP-2BG

Chart 4

Recommended Relube Cycles for Universal Joint Kits

and Slip Assemblies
Relubrication cycles vary depending on the service
requirements and operating conditions of the equipment.
Chart 5 shows a recommended lube cycle for various types
of service.
RELUBE SERVICE SCHEDULE Photo 2

TYPE OF SERVICE MILES OR TIME Important - In cold winter months, activate the slip spline
City 5000/8000 3 Months assembly by driving the vehicle sufficiently to cause displacement
On-Highway (Mid-Range) 10000/15000 3 Months of the grease prior to its stiffening. Otherwise, the slip yoke plug
On-Highway (Line Haul) 10000/15000 30 Days may be forced out due to hydraulic pressure causing loss of grease
On/Off Highway 5000/8000 3 Months and allowing abrasive contaminants to enter the slip spline.
Off Highway/Industrial 500/200 Hours*
Recommended Lubricants for Slip Assemblies
Chart 5
Always use a good E.P. grease, meeting N.L.G.I. Grade 2
*Relubrication cycles for off-highway and industrial use vary depending on the
application and operating conditions. In general, to obtain maximum life, specifications, on Glidecoat™ and steel splines. The same
relubrication should occur every 500 hours for normal service and every 200 lubricant used for universal joint kits is satisfactory for slip
hours for continuous service or severe environmental conditions.
assemblies.
On-highway is defined as all applications requiring less than
10% operating time on gravel, dirt or unimproved roads. If Lubrication Procedure for Center Bearing Assemblies
longer than 10% operating time off-highway, use on/off Initial lubrication is done by Spicer manufacturers. (No
highway recommendations. attempt should be made to add or change grease within the
bearing itself.) However, when servicing a driveshaft in the
Lubrication Procedure for Slip Assemblies
field with a new center bearing, it is necessary to fill the
Relube slip assemblies at the same intervals as universal joint
entire cavity around the bearing with waterproof grease
kits. Apply grease gun pressure until grease appears at the
to shield the bearing from water and contaminants. The
pressure relief hole in the slip yoke plug. (See Photo 1)
quantity should be sufficient to fill the cavity to the extreme
edge of the slinger surrounding the bearing.

Lubricants must be waterproof. See Recommended

Lubricants for Center Bearings, Chart 6.

LUBRICANTS FOR CENTER BEARINGS

RECOMMENDED LUBRICANTS SOURCE
Rykon Premium No. 3 Amoco Oil Company
Amolith 8516 Amoco Oil Company
Van Talgar No. 4 Exxon Company
Chart 6

Photo 1 Commercial Vehicle Service Parts

Dana Corporation
P.O. Box 321
Toledo, Ohio 43697-0321
Phone: 419-866-3900
Fax: 419-866-3924 3306-6-DSD 2/03 ©Dana Corporation, 2003