Chapter 9 – Maintenance booklet

Operation and maintenance manual

TABLE OF CONTENTS

Maintenance booklet

ITEM NAME PAGES

Identification ...........................................................................................................................2
Service intervals .....................................................................................................................4
Hourmeter...............................................................................................................................4
Preparation .............................................................................................................................4
Introduction .............................................................................................................................5
Using the maintenance booklet ..............................................................................................5
Maintenance list "A" 10-hour or daily maintenance................................................................6
Maintenance list "B" 50-hour or weekly maintenance ............................................................7
Maintenance list "C" 100-hour maintenance ..........................................................................8
Maintenance list "D" 200/250-hour maintenance ...................................................................9
Maintenance list "E" 500-hour maintenance ........................................................................10
Maintenance list "E" 500-hour maintenance (cont.) .............................................................11
Maintenance list "F" 1,000-hour maintenance......................................................................12
Maintenance list "F" 1,000-hour maintenance (cont.) ..........................................................13
Maintenance list "G" 2,000-hour maintenance .....................................................................14
Maintenance list "G" 2,000-hour maintenance (cont.)..........................................................15
Maintenance list "H" 5,000-hour maintenance .....................................................................15
Maintenance list "I" 6,000-hour maintenance.......................................................................16
Maintenance list "J" 10,000-hour maintenance....................................................................16

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 Maintenance booklet
Operation and maintenance manual

Chapter 9

Maintenance
booklet

Chapter 9 - Page 1
 Maintenance booklet
Operation and maintenance manual

Identification

TYPE : E 1435
TFC 45 h/hc - TFC 45R h/hc TFCRS 45 h/hc - TFC 45RX h/hc
TFC 45L hc - TFC 45LS hc TFC 45LX hc - TFC 45LSX hc
TFC 46 M hc - TFC 46MX hc

SERIAL NUMBER: SN : 175570-175571 - SN : 177010->

SN : 20500->
SN : 176500->

Date of commissioning: .. / ....

Manufacturer: TEREX CRANES FRANCE SA

Head offices and factory: Zone Industrielle de la Saule BP 106

71304 MONTCEAU LES MINES
FRANCE

Telephone: ( 33 ) 03 . 85 . 67 . 38 . 00

Fax: ( 33 ) 03 . 85 . 67 . 38 . 99
( 33 ) 03 . 85 . 67 . 38 . 98

Chapter 9 - Page 2
 Maintenance booklet
Operation and maintenance manual

IMPORTANT
The maintenance intervals in the following tables apply to
equipment used in normal operating conditions.

Maintenance intervals should be shortened for intensive use or

special operating conditions (heat, humidity, dust).

When carrying out maintenance work the machine must be

supported on fully extended outriggers on solid, level ground.

Chapter 9 - Page 3
 Maintenance booklet
Operation and maintenance manual

Service intervals

Maintenance work must be performed at regular intervals.

The vehicle’s hourmeter lets you see when the moment is right for
maintenance work and should be consulted every day.
The maintenance intervals shown have been worked out based on a
10-hour working day, 50 hours per week, 2,000 hours per year.
Use the maintenance periods to rectify torque settings as necessary.

Hourmeter

The hourmeter’s electrical control system is linked to the status of the

engine when the engine is running.
It indicates hours the same as a clock when the heat engine is
running.

Preparation

Clean the grease nipples, plugs, around filler neck openings and sight
gauges before starting.
Check the condition of seals when applying lubricant and replace any
that show signs of wear or damage.

Every precaution must be taken to protect the environment.

All used liquids, in particular, must be recovered and recycled.
Always clearly label and close containers of used liquids.
Always clean up spillages.

Chapter 9 - Page 4
 Maintenance booklet
Operation and maintenance manual

Introduction

The machine’s working environment determines its maintenance. The

recommended lists on the following pages show which points to check
and the intervals between each inspection.

NOTE:
The recommended maintenance booklet takes into account the
conditions in which the equipment is used. The type of work carried
out, the size of the loads and the weather and ground conditions must
also be taken into consideration. The maintenance lists are set out
according to the number of operating hours.

If the set maintenance schedule is to be altered, the machine’s

conditions of use must be reviewed beforehand. Study the
maintenance booklet carefully before changing the intervals between
inspections.

Using the maintenance booklet

This booklet offers a guide to preventive maintenance until experience

allows a schedule to be drawn up based on specific operating
conditions.

The maintenance handbook can be copied as many times as

necessary. Every person who carries out maintenance must record
the work done on the maintenance list so that the machine can be
checked at the next service.
Completed maintenance lists are machine identity papers and
must be kept with the machine.

Chapter 9 - Page 5
 Maintenance booklet
Operation and maintenance manual

Maintenance list "A"

10-hour or daily maintenance

Company:_____________________________________________

Address: ______________________________________________

Maintenance manager:___________________________________
_____________________________________________________

Date of maintenance: ____________________________________

Serial number: _________________________________________

MAINTENANCE CHECKS PERFORMED BY:

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

Check and clean the air filter: ___________

Check hydraulic oil tank level: ___________

Check fuel tank level: ___________

Check heat engine oil level: ___________

Check gearbox oil level: ___________

Check heat engine radiator level: ___________

Check braking system oil reservoir level: ___________

Lubricate all the spreader hinge joints: ___________

Chapter 9 - Page 6
 Maintenance booklet
Operation and maintenance manual

Maintenance list "B"

50-hour or weekly maintenance

Company:_____________________________________________

Address: ______________________________________________

Maintenance manager:___________________________________
_____________________________________________________

Date of maintenance: ____________________________________

Serial number: _________________________________________

MAINTENANCE CHECKS PERFORMED BY:

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

Repeat list "A": ___________

Lubricate all the joints: ___________

Check the oil level of the telescoping reduction gear: ___________

Check the oil level of the slewing reduction gear. ___________

Lubricate the slew ring teeth: ___________

Lubricate the slew ring: ___________

Lubricate all the slide pads: ___________

Lubricate the twist locks: ___________

Steering filter check ___________

Chapter 9 - Page 7
 Maintenance booklet
Operation and maintenance manual

Maintenance list "C"

100-hour maintenance

Company:_____________________________________________

Address: ______________________________________________

Maintenance manager:___________________________________
_____________________________________________________

Date of maintenance: ____________________________________

Serial number: _________________________________________

MAINTENANCE CHECKS PERFORMED BY

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

Repeat lists "A" and "B": ___________

Check electrolyte level in the batteries: ___________

Check tightness of wheelnuts: ___________

Check all the spreader attachments: ___________

Check the boom pads: ___________

Chapter 9 - Page 8
 Maintenance booklet
Operation and maintenance manual

Maintenance list "D"

200/250-hour maintenance
Company:_____________________________________________

Address: ______________________________________________

Maintenance manager:___________________________________
_____________________________________________________

Date of maintenance: ____________________________________

Serial number: _________________________________________

MAINTENANCE CHECKS PERFORMED BY

............................................................................................................
Repeat lists "A", "B" and "C": ___________

Check tyre pressures: ___________

Clean battery lugs, check electrolyte density

and battery attachments: ___________

Lubricate the steering rods: ___________

Lubricate the universal shafts: ___________

Lubricate the linkages: ___________

Check the valve clearances: ___________

250 h – Check tension and condition of the belts: ___________

250 h – Check condition of the gearbox breather: ___________

Clean the evaporator and air-conditioning condenser : __________

Clean the catalytic converter: ___________

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 Maintenance booklet
Operation and maintenance manual

Maintenance list "E"

500-hour maintenance

Company:_____________________________________________

Address: ______________________________________________

Maintenance manager:___________________________________
_____________________________________________________

Date of maintenance: ____________________________________

Serial number: _________________________________________

MAINTENANCE CHECKS PERFORMED BY

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

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

Replace hydraulic system oil filter cartridge: ___________

Replace air filter cartridges: ___________

Check condition of the boom pads: ___________

Check the oil level in the front axle

pinion carrier and reduction gears: ___________

Replace the engine oil filter: ___________

Heat engine oil change: ___________

Check DCA rate for replacement

of engine water filter: ___________

Inspect the welds: ___________

Chapter 9 - Page 10
 Maintenance booklet
Operation and maintenance manual

Maintenance list "E" (continuation)

500-hour maintenance

Company:_____________________________________________

Address: ______________________________________________

Maintenance manager:___________________________________
_____________________________________________________

Date of maintenance: ____________________________________

Serial number: _________________________________________

MAINTENANCE CHECKS PERFORMED BY

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

Pipe Exhaust: ___________

Motor cowling cover ___________

Chapter 9 - Page 11
 Maintenance booklet
Operation and maintenance manual

Maintenance list "F"

1,000-hour maintenance

Company:_____________________________________________

Address: ______________________________________________

Maintenance manager:___________________________________
_____________________________________________________

Date of maintenance: ____________________________________

Serial number: _________________________________________

MAINTENANCE CHECKS PERFORMED BY

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

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

Check condition and attachments of wiring harnesses: ___________

Check the tightness of all the spreader fastenings : ___________

Oil change on slewing reduction gear: ___________

Oil change on telescoping reduction gear: ___________

Check for leaks on the hydraulic system: ___________

Check the toe-in of the wheels: ___________

Check for leaks on the steering system: ___________

Check condition of the alternator and starter motor: ___________

Chapter 9 - Page 12
 Maintenance booklet
Operation and maintenance manual

Maintenance list "F"

1,000-hour maintenance
(CONT.)

Have the brake accumulators checked: ___________

Drain and refill the brake cooling system: ___________

Gearbox oil change: ___________

Replace gearbox filter cartridges: ___________

1500 hours Check the valve clearance

and adjust if necessary __________

Chapter 9 - Page 13
 Maintenance booklet
Operation and maintenance manual

Maintenance list "G"

2,000-hour maintenance
Company:_____________________________________________

Address: ______________________________________________

Maintenance manager ___________________________________

_____________________________________________________

Date of maintenance: ____________________________________

Serial number: _________________________________________

MAINTENANCE CHECKS PERFORMED BY

............................................................................................................
Repeat lists "A", "B" ,"C", "D","E" and "F": ___________

Replace braking system oil filter cartridge: ___________

Oil change on hydraulic tank: ___________

Replace the brake hoses: ___________

Check condition of the injection pump: ___________

Replace the hydraulic filters: ___________

Check condition of the counterweight

mounting assembly: ___________

Check condition of the slide pads: ___________

Change oil on front-axle drive pinion

carrier and reduction gear ___________

Check the air conditioner: ___________

Inspect the welds: ___________

Chapter 9 - Page 14
 Maintenance booklet
Operation and maintenance manual

Maintenance list "G" (continuation)

2,000-hour maintenance
Company:_____________________________________________

Address: ______________________________________________

Maintenance manager ___________________________________

_____________________________________________________

Date of maintenance: ____________________________________

Serial number: _________________________________________

MAINTENANCE CHECKS PERFORMED BY

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

Heat engine radiator: draining ___________

Motor cowling cover ___________

Rim inspections ___________

Replacement Steering filter ___________

Hydraulic tank return line filter ___________

Hydraulic oil tank breather filter ___________

Maintenance list "H"

5,000-hour maintenance

Pipe Exhaust __________

Chapter 9 - Page 15
 Maintenance booklet
Operation and maintenance manual

Maintenance list "I"

6,000-hour maintenance

Replace the twist locks: __________

Replace the GE balljoints on the lifting cylinders: __________

Replace In-line filters __________

Maintenance list "J"

10,000-hour maintenance

Heat engine overhaul: _________

Replace the brake accumulators: _________

Replace the boom pads: _________

Replace the anti-sway accumulator: _________

Replace the spreader pads: _________

Replace the hydraulic oil: _________

Dye penetrant test on the rims: _________

Replace the parking brake pads: _________

Visual inspection of all welded parts of the machine: _________

Chapter 9 - Page 16