Terex Demag AC75 / AC25 :

Manufacturer's Specifications
Foreword
1 Safety Instructions
1 Safety Instructions .................................................................... 1
1.1 General ..................................................................................... 1
1.2 Intended Use ............................................................................ 3
1.3 Operating Conditions and Computed Design of the Crane....... 7
1.3.1 General ..................................................................................... 7
1.3.2 Classification of the Crane ........................................................ 7
1.3.3 Classification of the Engines ..................................................... 9
1.3.4 Workplace Ergonomics ........................................................... 11
1.3.5 Load and Utilisation of the Crane ........................................... 11
1.3.6 Required Ambient Conditions ................................................. 13
1.3.7 Service Life ............................................................................. 15
1.3.8 Standards and Calculation Regulations.................................. 17
1.3.9 Dangers to Air Traffic .............................................................. 19
1.4 Safety Regulations ................................................................. 21
1.4.1 Organisational Measures ........................................................ 23
1.4.2 Selection and Qualifications of Personnel .............................. 25
1.4.3 Particular Hazards .................................................................. 27
1.4.4 Combination of Hazards with Combined Operation“of Two
or More Cranes ....................................................................... 39
1.4.5 Driving Operation .................................................................... 43
1.4.6 Crane Operation ..................................................................... 47
1.4.7 Power Supply Failure.............................................................. 65
1.4.8 When Assembling and Dismantling Crane Components ........ 67
1.5 Hand Signals .......................................................................... 73
1.5.1 General Hand Signals ............................................................ 75
1.5.2 Hand Signals for Working Movements ................................... 77
1.5.3 Hand Signals for Driving Movements ..................................... 79
2 Structure of the Mobile Crane
2.1 Overview ................................................................................... 3
2.2 Safety Signs ............................................................................. 5
2.3 Boom System ........................................................................... 7
2.3.1 Boom Lengths .......................................................................... 7
2.4 Serial Plates ............................................................................. 9
2.4.1 Serial Plate ............................................................................... 9
3 Cab
3.1 Operating Elements in the Driver's Cab ................................... 3
3.1.1 Operating Elements in the Driver's Cab ................................... 5
3.2 Monitoring Equipment ............................................................... 7
3.2.1 Monitoring Equipment in the Cab ............................................. 9
3.2.2 Monitoring Equipment in the Cab ........................................... 11
3.3 Symbols in Outrigger Control Box, Left-Hand Side................. 13
3.3.1 Symbols in Outrigger Control Box, Right-Hand Side .............. 13
e25-1000-193 2/5
Contents
4 Engine
4.1 Checks Before Starting the Engine ........................................... 3
4.2 Starting Procedure .................................................................... 5
4.3 Switching off the engine............................................................ 9
4.4 Jump Starting ......................................................................... 11
4.5 Automatic Engine Shutoff (Optional) ...................................... 11
5 Driving
5.1 Checks before Driving .............................................................. 3
5.2 General ..................................................................................... 7
5.2.1 Driving the Crane in Transport Condition ................................. 9
5.2.2 Driving with Axle Loads over 10 t or 11 t up to a Max. of 13 t . 13
5.3 Driving on the Construction Site ............................................. 15
5.4 Driving in Erect Mode ............................................................. 17
5.4.1 360o-Driving the Crane without Load ...................................... 19
5.4.2 Driving the Crane with the Main Boom Extension (7.1 or
13 m) Fitted ............................................................................ 19
5.4.3 Driving the Crane with Load (Travel Operation) ..................... 21
6 Transmission
6.1 Gear Lever ................................................................................ 3
6.1.1 Neutral Position “N” .................................................................. 5
6.1.2 Reverse Gear "R" ..................................................................... 5
6.1.3 Drive Position "D" ..................................................................... 5
6.1.4 Drive Positions "1" to "6" ........................................................... 5
6.2 All-Terrain Transmission (Optional) .......................................... 7
6.3 Starting ..................................................................................... 9
6.4 Stopping ................................................................................... 9
6.5 Driving on Downgrades .......................................................... 11
6.6 Procedure when the Crane is Stuck ....................................... 11
6.7 Gear Oil Information ............................................................... 13
6.8 Fault Codes ............................................................................ 15
6.9 Troubleshooting with the Fault Table ...................................... 17
7 Brakes
7 Braking System ........................................................................ 3
7.1 Service Brake ........................................................................... 3
7.2 Parking Brake ........................................................................... 3
7.3 Engine Brake (Sustained-Action Brake) ................................... 5
8 Steering
8.1 Steering during Road Travel ..................................................... 3
8.2 Independent Rear Axle Steering............................................... 5
8.2.1 Steering Combinations ............................................................. 7
9 Differential Locks
9 Differential Locks ...................................................................... 3
e25-1000-193 3/5
Contents
10 Hydraulic Suspension
10.1 Suspension Circuits .................................................................. 3
10.2 Level Adjustment ...................................................................... 5
10.3 Monitoring the Level ................................................................. 7
10.4 Locking the Suspension (Travel Operation) ............................. 9
10.4.1 Engaging Procedure ................................................................. 9
10.4.2 Disengaging Procedure .......................................................... 11
10.5 Height Adjustment .................................................................. 11
10.6 Raising the Axles .................................................................... 13
11 Outriggers
11.1 Instructions for Supporting the Crane on the Outriggers .......... 3
11.1.1 Support Pressure Display (optional) ......................................... 3
11.2 Arrangement of the Control Elements for the Outriggers .......... 5
11.3 Before Extending the Outriggers .............................................. 7
11.4 Procedure for Extending the Outriggers ................................... 9
11.4.1 Extending the Outriggers (Support Area 4 m x 5.95 m and
5.9 m x 5.95 m) ......................................................................... 9
11.4.2 Retracting the Outriggers
(for Driving the Crane in Transport Condition) ........................ 15
11.4.3 Retracting the Outriggers
(for Driving the Crane in Configured Condition) ...................... 17
11.5 Permissible Ground Pressures ............................................... 19
11.5.1 Safety Distances from Slopes and Ditches ............................. 21
12 Parking
12.1 Leaving the Vehicle in Transport Condition .............................. 1
12.2 Leaving the Crane in Configured Condition and with
Outriggers Extended ................................................................. 1
13 Towing the Crane and Towing the Crane to Start
13.1 Towing the Crane to Start ......................................................... 1
13.2 General Towing Regulations .................................................... 1
13.2.1 Towing the Crane in case of Engine demage or defective
Automatic Transmission ........................................................... 1
13.2.2 Towing the Crane with Defective Distributor Gear
(4 x 4 Drive) .............................................................................. 7
13.2.3 Towing the Crane in the event of Engine Failure or Defective
Automatic Transmission (4 x 2 Drive) ....................................... 7
13.3 Towing the Crane Free on Soft Ground .................................... 7
14 Heating and Ventilation
14.1 Operating the Heating and Ventilation ...................................... 3
e25-1000-193 4/5
Contents
Stand: 26.KW/94
15 Safety Equipment
15.1 Load Limit Device Console (LMB) ............................................ 3
15.1.1 Operating Elements .................................................................. 3
15.1.2 Display Contents During Crane Operation ............................... 5
15.2 Operating the Load Limit Device .............................................. 9
15.2.1 Setting the Screen Contrast .................................................... 11
15.2.2 Displaying the Fault Codes (4) ............................................... 11
15.2.3 Data Logger (Optional) ........................................................... 11
15.3 Hoist Limit Switch ................................................................... 11
15.3.1 Assembling the Hoist Limit Switch .......................................... 11
15.3.2 Caution, Function Test of the Hoist Limit Switch .................... 13
15.4 Troubleshooting ...................................................................... 15
15.4.1 Fault Codes ............................................................................ 16
15.5 Service and Maintenance ....................................................... 17
15.6 Bridging the Limit Switch ........................................................ 19
15.7 Bridging the Load Limit Device ............................................... 21
16 Notes on Operation
16.1 General Notes on Operation ..................................................... 1
16.2 Raising a Load Using Several Cranes ...................................... 7
16.3 Checking the Safety Measures ................................................. 9
16.4 Operating Information on Pilot Control.................................... 11
16.5 Emergeny Control ................................................................... 13
17 Slewing
17.1 Preparations for Slewing........................................................... 3
17.2 Slewing the Superstructure....................................................... 5
17.3 Slew Speeds............................................................................. 5
17.4 Braking the Superstructure ....................................................... 7
18 Telescoping
18.1 Telescoping the Main Boom ..................................................... 3
18.1.1 Extension Length of the Telescopic Sections ........................... 5
18.1.2 Control Levers for Telescoping ................................................. 7
18.2 Telescoping Procedure ............................................................. 7
18.2.1 Telescoping without Load ......................................................... 7
18.2.2 Telescoping Loads ................................................................... 9
18.2.3 Telescoping Speeds ................................................................. 9
e25-1000-193 5/5
Contents
19 Luffing
19.1 Raising and Lowering the Main Boom ...................................... 3
19.2 Luffing Speeds.......................................................................... 3
20 Hook Operation "Hoist"
20.1 Raising and Lowering the Load ................................................ 3
20.2 Hoist Speeds ............................................................................ 5
21 Main Boom Extension
21.1 Fitting the Main Boom Extension .............................................. 3
21.2 Folding the Main Boom Extension ............................................ 3
21.2.1 Folding the 7.1 m Basic Boom out of the Transport Position
into Operating Position ............................................................. 5
21.2.2 Folding the 13 m Main Boom Extension from the Transport
Position into Operating Position .............................................. 13
21.2.3 Folding the Main Boom Extension ( 7.1 m or 13 m) from 0o
into the 30o Operating Position ............................................... 19
21.3 Fitting Procedure .................................................................... 23
21.4 Boom Point (Hall Point, Option) .............................................. 25
21.4.1 Lift loads with a main boom angle of 24-44o
(medium length boom point) ................................................... 25
21.4.2 Lift loads with a main boom angle of less than 24o
(short boom point)................................................................... 27
21.4.3 Lift loads with a main boom angle of greater than 44o
(long boom point) .................................................................... 27
21.4.4 Lifting loads ............................................................................ 29
21.4.5 Boom Point in the Transport Condition ................................... 29
21.5 Hook (15t) for boom point (Option 1) ...................................... 31
21.5.1 Double Load Hook (15t) for boom point (Option 2) ................. 35
21.6 Searcher Hook (Option) .......................................................... 39
21.6.1 Operating with the Searcher Hook .......................................... 39
22 Reeving
22.1 Rope Equipment and Reeving .................................................. 3
22.1.1 Reeving the Hoist Rope on the Main Boom Head .................... 5

Contents (Part 2)
Foreword (Part 2)
Notes for the Operator
1 Notes on Safety
1 Notes on Safety ....................................................................... 1
1.1 General Recommendations for the Lubrication and
Maintenance Tasks ................................................................. 1
1.2 Notes on Safety ....................................................................... 5
1.3 Recurrent Inspections of the Crane ......................................... 9
1.4 Measures to Ensure Safe Operating Periods ........................ 10
1.4.1 General .................................................................................. 10
1.4.2 Theoretical Service Life ......................................................... 10
1.4.3 Actual Operating Conditions .................................................. 11
1.4.3.1 Determining the Operating Conditions (Load Spectrum) ....... 11
1.4.3.2 Operating Hours of the Hoists per Inspection Interval........... 11
1.4.4 Determining the Spent Share of the Theoretical Service Life
of the Winches ....................................................................... 13
1.4.5 Documentation....................................................................... 15
2 Fuels and Lubricants
3 Capacities
4 Lubrication and Maintenance Schedule
4 Lubrication and Maintenance Schedule ................................... 2
4.1 Initial Lubrication and Maintenance .......................................... 2
4.2 Regular Routine Lubrication and Maintenance ........................ 3
4.3 Maintenance List ...................................................................... 4
5 Drive
5 Drive ........................................................................................ 1
5.1 Engine Perkins Phaser 210 TI ................................................. 1
6 Transmission
6 Transmission ........................................................................... 1
6.1 Drive Gear - Checking and Topping Up the Oil Level .............. 1
6.2 Changing the Oil in the Drive Gearbox and Replacing the Filter .. 4
6.3 Distributor Gear - Checking and Topping Up the Oil Level ...... 7
6.4 Distributor Gear - Changing the Oil .......................................... 7
7 Joint Shafts
7 Joint Shafts .............................................................................. 1
7.1 Flange Connections ................................................................. 1
7.2 Lubricating the Joint Shafts ..................................................... 1
bs_e075-2000 2/4
Contents
Date: 08.CW/05
8 Axles
8 Axles ........................................................................................ 1
8.1 Checking and Tightening the Axle Fixings ............................... 1
8.2 Lubricating the Axles ............................................................... 2
8.3 Steering and Track Arm ........................................................... 2
8.4 Axle Drive - Checking and Topping Up the Oil Level ............... 3
8.5 Wheel Hub Drive - Checking and Topping Up the Oil Level .... 4
8.6 Axle Drive - Changing the Oil .................................................. 4
8.7 Wheel Hub Drive - Changing the Oil ........................................ 5
8.8 Wheel Hub Bearing - Changing the Grease ............................ 6
8.9 Suspension Cylinders ............................................................. 6
9 Steering
9 Steering ................................................................................... 1
9.1 Steering Components .............................................................. 1
9.2 Lubricating the Steering Components ..................................... 1
9.3 Replacing the Hoses................................................................ 2
9.4 Angular Gear ........................................................................... 2
9.5 Lubricating Independent Rear Axle Steering ........................... 2
10 Braking System
10 Braking System........................................................................ 1
10.1 Check brake linings for wear ................................................... 2
10.2 Renew brake linings ................................................................ 2
10.3 Replace brake drums............................................................... 3
10.4 Perform brake function check .................................................. 3
10.5 Check expanding cylinder........................................................ 3
10.6 Replace other brake parts ....................................................... 3
10.7 Air Drier with Integrated Pressure Regulator ........................... 4
10.8 Draining Water from the Air Tanks........................................... 4
11 Wheels and Tyres
11 Wheels and Tyres .................................................................... 1
11.1 Tightening the Wheel Nuts ...................................................... 1
11.2 Tyres - Checking Pressure and Tread Depth and
Checking for Damage .............................................................. 1
12 Hydraulic System
12 Hydraulic System ..................................................................... 1
12.1 Hydraulic Tank - Checking and Topping Up the Oil Level ....... 2
12.2 Hydraulic Tank - Filter .............................................................. 3
12.3 Hydraulic Tank - Replacing the Aeration Filter ...................... 12
12.4 Changing the Hydraulic Oil .................................................... 13
12.5 Hydraulic System - Pressure Accumulator, Checking the
Preliminary Gas Tension ....................................................... 15
bs_e075-2000 3/4
Contents
Date: 08.CW/05
13 Outriggers
13 Outriggers ................................................................................ 1
13.1 Lubricating the Sliding Surfaces on the Outrigger Struts ......... 1
14 Electrical System
14 Electrical System .................................................................... 1
14.1 Checking the Lighting System ................................................. 1
14.2 Replacing the Headlamp Bulbs ............................................... 1
14.3 Servicing the Battery ................................................................ 1
15 Fuel System
15 Fuel System ............................................................................. 1
16 Air Intake and Cooling System
16 Air Intake and Cooling System ................................................ 1
17 Piston Rods
17 Piston Rods ............................................................................. 1
18 Optional Equipment
18 Optional Equipment ................................................................. 1
18.1 Refilling the Central Lubrication System .................................. 1
19 Visual Inspections
19 Visual Inspections .................................................................... 1
20 Slew Ring
20 Slew Ring................................................................................. 1
20.1 Lubricating the Bearing ............................................................ 1
20.2 Lubricating the Gear Ring ........................................................ 1
20.3 Check slew ring bolt connections ............................................ 2
21 Slew Gear
21 Slew Gear ................................................................................ 1
21.1 Slew Gear Mechanism - Checking and Topping Up the Oil Level ... 1
21.2 Slew Gear Mechanism - Changing the Oil ............................... 1
21.3 Checking and Tightening the Screw Connections ................... 2
bs_e075-2000 4/4
Contents
Date: 08.CW/05
22 Hoists
22 Hoists ....................................................................................... 1
22.1 Hoist Gear - Checking and Topping Up the Oil Level .............. 1
22.2 Hoist