Name: Terex RT500-1
Brand: Terex
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Hydraulic Cylinders

HYDRAULIC CYLINDER DISASSEMBLY

GENERAL

Do not disassemble a cylinder unless no other maintenance procedure can correct the

problem. All overhaul or new cylinder installations should be done in a clean, dust-free

atmosphere with all ports plugged until hose connections are made.

RT500

Service / Parts

274 REVISED:

Table of Contents3
Introduction7
Construction and Industrial Equipment Product Safety7
Alert System8
Nomenclature9
Safety11
Safety Introduction11
General Safety12
Safety Sign Maintenance12
Safety Sign Locations13
Workplace Safety21
Personal Safety28
Assembly29
Step Installation29
Spooling Wire Rope on Drums30
Hoist-Line Reeving34
Cable Reeving37
Side Stow Jib38
Description of Machine and Controls43
Universal Symbol Identification43
Upper Controls and Instruments46
Inspection59
Pre-Start Inspection59
Wire Rope Inspection Record63
Crane Boom64
Operating Instructions67
General Operational Issues67
Operator Shutoff Devices67
Rated Capacity Indicator67
Operating the Unit110
Starting the Engine110
Cold Weather Starting111
Jump-Starting an Engine with Booster Cables112
Operating the Engine113
Making a Typical Lift114
Arm and Hand Signals120
Load Rating Chart Interpretation122
On-Tires" Lift131
Unusual Operating Conditions133
Moving the Unit137
Vehicular Operation137
Traveling Around the Jobsite140
Transportation141
Transporting the Crane141
Maintenance143
Lubrication Chart143
Maintenance Introduction145
Machine Maintenance Checklist146
Engine Maintenance149
Engine Radiator Maintenance151
Transmission Maintenance152
Axle Maintenance154
Tire Maintenance156
Air System Maintenance160
Brake System162
Turntable and Swing Pinion165
Swing Reducers167
Hydraulic System Maintenance168
Hydraulic Oil Requirements173
Cable Lubrication Methods180
Electrical System Battery Check184
Electrical System Collector Ring188
Wire Rope and Reeving189
Air Dryer191
Slider Pads192
Storage193
Machine Storage193
Engine Storage195
Transmission Storage198
Restoration to Service199
Restoring Engine to Service200
Restoring Transmission to Service201
Chrome Cylinder Rod Storage202
Specifications204
Wire Rope Specifications204
Troubleshooting206
General Procedure206
Hydraulic - General207
Operator Controls208
Axles209
Steering Circuit210
Alternator214
Starter215
Brakes216
Parking Brake217
Air Pressure218
Swing Circuit219
Boom Hoist Circuit220
Boom Telescope Circuit221
Winch Circuit222
Outrigger Circuit224
Pumps225
Control Valves229
Relief Valves230
Fluid Motor231
Cylinders232
Cylinder Leakage233
Excessive Heating of Oil in Circuit235
Electrical Controls236
Propane Heater237
Maintenance Free Battery Testing241
Anti Two Block System243
Service / Parts246
Valve Adjustments246
Swing Relief Valve Adjustment249
Rotary Manifold253
Steering Priority Valve Adjustment256
Boom Alignment and Adjustment258
Boom Chain Adjustment262
Axle Lockout System266
Swing Brake Control Adjustment268
Ring Gear Bolting Sequence271
Torque Wrench Extensions273
Welding Instructions275
Hydraulic Cylinders277
Wire Rope and Reeving281
Cable Sockets286
Applicable Standards / Regulations290
Wire Rope Users Manual290
Appendix350
Conversion Tables350
Average Weight of Materials354
Suggested Torque Ratings357

Brand	Terex
Model	RT500-1
Category	Construction Equipment
Language	English

Terex RT500-1 User Manual

Table of Contents

Questions and Answers:

Terex RT500-1 Specifications

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