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RS425C
RECLAIMER/STABILIZER
SERIAL NUMBER 526320 & UP
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Table of Contents
NOTICE
The illustrations, charts, photographs and layout examples shown in this manual
are intended solely to help you understand the text. Some illustrations show details
or attachments that may be different from your machine. Also guards and covers
may have been removed for illustrative purposes.
Continuing improvement and advancement of product design may have caused
changes to your machine which are not included in this manual. The information
contained in this document is subject to change without notice.
Whenever a question arises regarding your machine or this manual, please consult
your dealer, Terex Roadbuilding Parts Sales (1-800-264-7278) or Terex Roadbuild-
ing Product Support for the latest available information.
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Table of Contents
The operator must read and understand all the instructions in this manual before operating the
machine.
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Maintenance Notes....................................94 Every 50 Service Hours Or Weekly...................... 129
Key to Lubricants..................................................94 Batteries..............................................................130
Filter Elements Part Numbers............................ 94 Cutter Transmission Cooling System.................. 131
Refill Capacities (Approximate)............................ 94 Cutter Differential Cooling System...................... 131
Cutter Drive Chains............................................132
Maintenance Schedule Chart...................95 Depth Gauge Pivot.............................................133
Hydraulic System..................................................99 Every 100 Service Hours Or Two Weeks............. 134
Ground Drive Axle Carrier and Planetary Ends.... 99
Every 250 Service Hours Or Monthly.................. 134
After First 25 Service Hours...................................99 Hydraulic Oil Filters.............................................134
After First 100 Service Hours.................................99 Engine Oil and Oil Filters....................................134
Engine Cooling System......................................136
When Required......................................................100
Engine Crankcase Breather................................138
Engine Cooling System .....................................100
Engine Valve Lash..............................................139
Engine Air Intake System....................................101
Alternator Belt and Fan Drive Belts.................... 139
Fuel System........................................................106
Ground Drive Brakes..........................................142
Fuel Tank............................................................ 110
Cutter Differential................................................145
Auxiliary Hydraulic Oil Filter................................ 111
Cutter Transmission............................................147
Compressed Air System..................................... 111
Electrical System................................................148
Cutter Drum........................................................ 112
Lubrication..........................................................149
Cutter Drive Shaft Torque Limiter Clutch............ 113
Cutter Clutch....................................................... 115 Every 500 Service Hours Or 3 Months................ 150
Walk-Around Inspection...................................... 117 Hydraulic System................................................150
Engine Crankcase..............................................151
Every 10 Hours Or Daily....................................... 117
Cutter Chaincase Hubs.......................................152
Hydraulic System................................................ 118
Fuel Tank ...........................................................152
Cooling Systems................................................. 118
Hydraulic Oil Replenishing Tank.........................153
Engine Crankcase..............................................120
Fluid Sampling....................................................153
Engine Air Cleaner..............................................121
Ground Drive Transmission................................121 Every 1,000 Service Hours Or Yearly................... 164
Ground Drive Axle Carrier and Planetary Ends.. 122 Batteries..............................................................164
Cutter Axle..........................................................123 Ground Drive Axle Carrier and Planetary Ends.. 164
Cutter Transmission............................................123 General Wheel Alignment Information................ 166
Cutter Chaincases..............................................124 Alt. Method to Check Amount of Toe Present..... 167
Cutter Drum........................................................124 Cutter Transmission Shift Linkage...................... 170
Cutter Support Bearing Lubricator...................... 125 Engine Valve Lash..............................................171
Tires....................................................................125 Engine Cooling System......................................171
Fuel Tank............................................................126 Every 2,000 Service Hours Or 2 Years................. 171
Lubrication..........................................................126
Engine Air System..............................................129
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Reference Information............................181
Pressure Settings...............................................181
Shipping Dimensions..........................................181
Fastener Torques................................................182
Standard Torque for Metric Fasteners................ 183
Standard Torque for Hose ClampsWorm Drive
Band Type...........................................................184
O-Ring Face Seal Fittings...................................184
Hydraulic Line Installation...................................185
Assembly of Fittings with Straight Threads and O-
Ring Seals..........................................................185
Torques for Flared and O-Ring Fittings............... 186
45 Flared and 45 Inverted Flare Fittings.......... 188
Common Symbols...................................190
Lines and Line Functions....................................190
Mechanical Devices............................................190
Pumps and Motors..............................................190
Reservoirs...........................................................190
Cylinders.............................................................191
Valves.................................................................191
Valve Actuators...................................................192
Accessories........................................................192
Electric Schematic Symbols...............................193
Switch Configurations.........................................193
Resistors.............................................................193
Contacts..............................................................193
Housings.............................................................193
Types of Grounds...............................................193
Lamp Symbols....................................................194
Solenoids/Coils...................................................194
Solenoids/Coils (continued)................................194
Control Relay......................................................194
Color Abbreviations.............................................195
Electrical Miscellaneous.....................................195
Electrical Miscellaneous (continued).................. 195
Common Abbreviations.......................................196
Conversion Factors.............................................198
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RS425C Safety
Owners, Users, and Operators: This machine and its approved attachments are de-
signed to reclaim and stabilize base.
Terex appreciates your choice of our machine for your
application. The number one priority at Terex is user Use of this machine in any other way is prohibited and
safety. We feel that you, as the machine owner, user, contrary to its intended use. Continuing improvement
or operator make a major contribution to safety if you and advancement of product design may have caused
changes to your equipment that are not included in this
comply with OSHA, federal, state, and local regula- publication.
tions,
Whenever a question arises regarding your equipment
read, understand and follow the instructions in this or this publication, please consult your Terex Road-
and other manuals supplied with this machine, building representative at 1-888-TEREXRB (1-888-
use good, safe work practices in a common sense 837-3972).
way,
only have trained/certified operatorsdirected by Symbols
informed and knowledgeable supervisionrunning Read and understand all safety precautions and
the machine. warnings before operating or performing lubrication,
OSHA and Terex Roadbuilding prohibit the alteration maintenance, and repair on this product.
or modification of this machine without written manu- Specific safety warnings for all of these publications
facturers approval. Use only factory-approved parts to are provided in the description of operations where
service or repair this machine. hazards exist. Labels and/or decals have also been
If there is anything that is not clear or which you put on the product to provide instructions and to iden-
believe should be added, please contact Terex Road- tify specific hazards. If these labels or decals are not
building Technical Publications, P.O. Box 1985, Okla- heeded, serious injury or death could occur to you or
homa City, OK 73101. other people.
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Safety RS425C
Hazard Classification
Specific safety warnings for all these publications are Terex cannot anticipate every possible circumstance
provided in the description of operations where haz- that might involve a potential hazard. The warnings in
ards may exist. Labels and/or decals have also been this publication and on the product are therefore not all
put on the product to provide instructions and to iden- inclusive. If a tool, procedure, work method or operat-
tify specific hazards. If these labels or decals are not ing technique not specifically recommended by Terex
heeded, bodily injury or death could occur to you or is used, you must satisfy yourself that it is safe for you
other persons. Warnings in this publication and on the and others. You should also ensure that the product
product labels are identified by the following symbols: will not be damaged or made unsafe by the operation,
lubrication, maintenance or repair procedures you
choose.
WARNING
Obtain the most complete and current information
before starting any job.
CAUTION
CAUTION indicates a hazardous situation which, if not
avoided, may result in minor or moderate injury.
NOTICE
NOTICE indicates a situation which, if not avoided,
may result in property or equipment damage.
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RS425C Safety
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Safety RS425C
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Safety RS425C
1 3
2
3
INJECTION HAZARD
Escaping fluid under
pressure can penetrate
skin, causing serious
injury.
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RS425C Safety
3
6
7
5
8
(7) 001010661000
(5) 001010658000
(8) 001010676000
FALL HAZARD
Serious injury or death can DO NOT climb on or off machine
occur. during operation.
526000943000
(6) 526000943000
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Safety RS425C
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RS425C Safety
WARNING
Inhalation Hazard
Death, serious injury, or
delayed lung disease may
result from breathing
hazardous dusts.
Runaway Possible
Machine could run over you or others.
Death or serious injury may result.
DO NOT transport machine in LOW range.
Loading machine for transport
Sh ft into LOW
*Drive machine onto tra ler
*Sh ft into HIGH
*Engage brakes
*Turn off machine
*Secure machine to tra ler
Unloading machine after transport
Remove the blocks and tiedowns
*Start machine and build air pressure
*APPLY HANDBRAKE
BURN HAZARD Allow to cool before *Shift into LOW
*Release park brakes
Hot fluid under opening. *Test transmission engagement by moving drive
control handle in either direction;
pressure can scald. *If resistance is felt, release handbrake and
drive off the trailer
001010674000
*If NO resistance is felt;
1. Slowly release handbrake until machine moves
and engages the transmission
(13) 001010674000 2. Completely release handbrake
3. Drive off trailer
FOR ADDITIONAL INFORMATION REFER TO THE
OPERATION & MA NTENANCE MANUAL
526000935000
(14) 526000935000
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Safety RS425C
Terex Roadbuilding equipment is designed with the Place equipment breakers in the OFF position and
safety of all personnel in mind. Never attempt to lock the breakers in this position.
change, modify, eliminate, or bypass any of the safety Attach a DO NOT OPERATE or similar warning tag
devices installed at the factory. Guards, covers and on the breakers to alert other personnel.
shields that are installed around moving parts are
meant to prevent accidental injury to operators and For lockout/tagout standards, see OSHA regulation
other personnel. Do not remove them. 20CFR1910.147 Lockout/Tagout of Hazardous En-
ergy. Refer to state and local regulations for additional
Make sure that everyone working on or near this requirements.
equipment is familiar with safety precautions.
Terex Roadbuilding recommends the basic safety General
practices listed on this and the following pages. Do not operate this equipment without proper training
and orientation.
Protective Gear
Before starting or operating the equipment, be sure
Machine personnel should wear the following protec- that no personnel will be endangered. Ensure all
tive gear while in the machine area: personnel are clear before applying power or operating
Safety shoes the equipment.
Safety glasses Make sure that all warning devices are working.
NIOSH-approved respirator when working in Mount and dismount this equipment only where steps
confined areas. Inhaling, ingesting or contacting or hand holds are provided.
hazardous materials or fumes may cause personal Do not try to climb on or off equipment when carrying
injury or illness. Confined space permits and ad- tools or supplies. Use a hand line to pull tools or equip-
equate ventilation are required. ment up to high levels.
Do not wear loose fitting or torn clothing. Remove all Secure all loose or hanging items before traveling or
jewelry and wrist watches when working on or around lifting.
the machine.
Relieve all pressure in air systems before any lines,
fittings, or related items are loosened, disconnected or
removed.
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RS425C Safety
Crushing or Cutting Prevention Remove all flammable materials and other debris
Make all repairs with the equipment parked on a level, before they accumulate in, on or around the machine.
hard surface. Block components so they will not fall or Do not expose components to independent flames of
roll while working on or under them. any type.
Do not work on any machine that is supported only Do not bend or strike high pressure lines. Do not install
by lift jacks or a hoist. Always block up a component bent or damaged lines, tubes or hoses.
before making repairs. Repair any loose or damaged fuel lines. Leaks can
Stay clear of all rotating and moving parts. cause fires.
Keep objects away from moving conveyors. They will Make sure that all clamps, guards and heat shields are
throw or cut any object or tool that falls or is pushed installed correctly to prevent vibration, rubbing against
into them. other parts and excessive heat during operation.
Do not use kinked or frayed wire cable. Wear gloves Always have multiple fire extinguishers located
when handling the wire cable. throughout the plant. Know how to use them. Inspect
and have them serviced as recommended on the
Chips or other debris can fly off objects when struck. instruction plate.
Wear protective glasses to protect your eyes and
make sure that no one can be injured by flying debris Climbing
before striking any object. To avoid back injury, use
a hoist when lifting components that weigh 50 lb. (23 Use ladders and stairways to access all areas that
kg.) or more. Make sure that all chains, hooks, slings, cannot be reached from the ground. Be sure ladders
etc. are in good condition and have the correct capac- and stairways are securely fastened before climbing.
ity. Be sure hooks are positioned correctly. Do not side Persons who have a fear of heights should not be
load lifting eyes during a lifting operation. involved in climbing exterior ladders.
Do not use the top two rungs of a ladder as steps.
Fire or Explosive Prevention
All fuels and most lubricants are flammable. Make sure that ladders are in good condition.
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Safety RS425C
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RS425C Safety
NOTES
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Safety RS425C
NOTES
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RS425C Receive the Machine
As each load is signed for and accepted by the carrier, Before operating the machine, perform the steps de-
it becomes the property of the purchaser. To avoid scribed in the Daily Inspection chapter of this manual.
forfeiting claims, and damagewhether obvious or
hiddennormally must be reported to the transporta-
tion company within 5 days of receipt of the equipment
at the purchasers premises.
It is the responsibility of the purchaser to file for any
damage claims directly with the carrier. Terex Road-
building personnel cannot file for the purchaser.
1. When the equipment arrives at the job site,
inspect it for damage.
2. If a shipment is damaged in transit:
a. Note the damage on the bill of lading.
b. Do not unload the damaged equipment.
c. Immediately notify the carrier and request an
inspection. The inspection will be done by
the carrier or the carriers insurance com-
pany.
d. After the inspection, it will be determined
whether items will be repaired or replaced.
If the purchaser does not follow the above instructions,
the carrier may not honor any damage claims.
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Receive the Machine RS425C
1
2
6
3
5
Lower the Roll Over Protection Structure (ROPS) Raise the Roll Over Protection Structure for
for Shipping Operation
If your machine is equipped with a ROPS, the ROPS 1. Remove any tie-downs from the ROPS struc-
must be lowered for shipping and raised before un- ture. Rotate the winch handle to raise the ROPS
loading it from the trailer. roll bar (4) into position to be secured.
1. Check to see that the cable (1) is installed prop- 2. Move the arms (3) rearward to align the bolt
erly to assist in folding the ROPS to the shipping holes in the arms with the bolt holes in the
position. mounting lugs. Install the bolts (1) mounting the
arms (3) to the mounting lugs.
2. Remove the bolts (2) that hold the ROPS roll bar
arms (3) to the rear mounts.
3. Hold the arms (3) in a vertical position while low-
ering the ROPS roll bar (4) to the mounting pads
(5). The arms (3) will rest on the mounting pads
(6).
4. The weight of the ROPS will hold the structure
on the pads in the lowered position.
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NOTICE
Make sure the transmission is in low gear. The
transmission could jump out of low gear during
transportation.
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RS425C Receive the Machine
NOTICE
If the oil pressure gauge (C2) does not indicate pres-
sure within 5 seconds, stop the engine and have
necessary repairs made. Oil pressure should rise to
the normal range within 15 seconds.
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RS425C Receive the Machine
NOTES
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NOTES
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RS425C Controls
Controls
NOTICE
The machine must be stopped and the service
brake on to shift the propel transmission. To move
the machine in travel range, start with the main
axle in HI with the machine in 4-wheel drive. Once
the machine is rolling, turn off the 4-wheel drive.
NOTICE
Set the speed range selector switch (C13) at slow
when working or parking the machine.
C10. Ignition Switch: Allows the operator to start, stop
or power electronics and start engine.
Moving the key to OFF will shut down the C13. Speed Range Selector Switch (Service Brake
engine and stop all electrical power to the Engaged when Shifting): Set at the upper posi-
controls. tion and the machine travels in its maximum
(transit) speed range.
Moving the key to ON will supply electrical
power to the controls without the engine start- Set at the lower position and the machine travels
ing. in its slowest (working) speed range.
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RS425C Controls
NOTICE
Engage or disengage the cutter clutch only with
the engine at low idle. Otherwise the cutter drive
mechanism may be damaged.
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RS425C Controls
C20. Cutter Manual Depth Control Switch: Manually C25. Steering Wheel: Turns the wheels of the ma-
moves the cutter upward or downward. chine, allowing the operator to maneuver the
machine direction.
Hold upward and the cutter moves upward, if
auto/manual switch (C19) is at Man. Turn the steering wheel clockwise and the
machine turns to the right.
Hold downward and the cutter moves down-
ward, if auto/manual switch (C19) is at Man. Turn the steering wheel counterclockwise and
the machine turns to the left.
C21. Lights Switch: Controls headlights, amber lights
and work lights. C26. Rear Steering Switch: Turns both rear wheels
either to the right or left.
Move upward and the headlights at the front
of the machine, and the amber and red lights Hold to the right to turn the rear wheels to
at the rear come on. the right. The wheels at the end opposite the
direction selected with the travel A-End/B-End
Move downward and the headlights, amber switch turn to the left.
lights and the work lights that light the work
area around the cutter come on. C27. Automatic Load Control Panel: Prevents the
engine from lugging below a set speed (RPM
Set at center position and headlights, tail Setpoint). There are two controls in the panel:
lights and work lights go off. C28 and C29.
C22. Beacon Switch: Controls beacon lights, amber C28. Auto/Manual Switch: Selects automatic or man-
and red lights. ual load control. This switch should be at auto
Move upward and the beacon light (amber when the machine is working and at manual
strobe) flashes on and off continuously. At the when the machine is to be serviced or repaired
same time the amber lights at the front of the with the engine idling.
machine and the red tail lights start flashing.
C29. Sensitivity Control: Adjusts the sensitivity of the
If the machine is equipped with bi-directional
load control. This switch should normally be set
controls, the amber lights at the end selected
at the fourth mark toward Max.
with the Travel A-End/B-End switch and the
red tail lights at the opposite end start flash-
ing. The beacon light will operate only if the
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Controls RS425C
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RS425C Controls
NOTICE
C34. Circuit Breakers: If excess current passes
To avoid possible machine damage, shift the cutter
through a circuit breaker, the circuit breaker
drive transmission only when
stops the electrical power to that circuit. To
the machine is stopped and propel control is at restore power, push the breaker for that circuit
neutral, in. If the breaker repeatedly opens the circuit, an
the engine is at low idle, overload or a short circuit in the circuit must be
the cutter clutch is disengaged, corrected.
or NOTE: The circuit breakers are located on the control
the input and output shafts have stopped panel mounted on the engine cowling in the
running. operators station.
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Controls RS425C
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RS425C Controls
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Controls RS425C
NOTES
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RS425C Daily Inspection
Daily Inspection
6 12
5
14
4
4
1
3
10
Before the start of each day, walk around the machine 10. Inspect and repair damaged wheels and dam-
and check for the following: aged or excessively worn tires. Tighten any
loose wheel lug nuts and replace any that are
1. Inspect the cutter door for damage or excessive
missing. Check the air pressure.
wear. Check the cutter drum and housing.
11. Check the horn, backup alarm, lights, guards,
2. Check for loose or frayed wires. Check for loose
shields, etc., and make sure they are in working
or corroded connections.
order.
3. Inspect the radiator guards for trash buildup.
12. Inspect the operator station for cleanliness and
4. Inspect the cooling system for leaks and trash remove all trash and dirt buildup.
buildup. Check the hoses, radiator fins, radiator
13. Inspect the spray system microcontroller (if
caps, and the drain areas.
equipped) for a broken window or any signs of
5. Inspect the engine compartment for leaks and leaks. Repair any that are found.
for trash buildup.
14. Check the batteries located in the box to the left
6. Inspect the steps and handholds for good condi- of the engine compartment, in front of the left
tion and cleanliness. front tire. Make sure the battery connections are
okay and in good condition.
7. Be sure covers and guards are firmly in place.
Inspect for damage and for loose or missing 15. Check that all gauges on the control panel are
bolts. Check all ventilation holes for dirt and functioning properly.
trash buildup.
16. Check for proper tension of all belts.
8. Inspect the hydraulic system for leaks. Check for
frayed hoses and for loose hose connections.
9. Check for any leaks. If a substantial amount of
leakage exists, see the Maintenance chapter of
this manual for procedures to check the oil level.
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Daily Inspection RS425C
17. Check the engine oil level. Maintain the engine 19. Check the fuel level gauge. The tank should be
oil level between Full and Add marks on the filled at the end of the day.
dipstick.
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RS425C Daily Inspection
21. Check the oil level in the hydraulic oil tank and
keep oil level near the top of the sight gauge. Do
not overfill the tank; allow for expansion of the oil
when it gets hot.
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Daily Inspection RS425C
NOTES
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RS425C Operation
Machine Operation
NOTICE
oil, grease, dirt, and ice to avoid slipping and pos-
sible injury.
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RS425C Operation
NOTICE
chine with jumper cables.
Improper jump procedures can cause an explosion
resulting in personal injury.
If oil pressure is not indicated within 5 seconds,
stop the engine and have the necessary repairs
made. Oil pressure should rise to normal range
within 15 seconds.
NOTICE
Always connect battery positive (+) to battery posi-
8. When the engine has started, check the oil pres- tive (+) and battery negative () to machine frame.
sure gauge (C2) for an indication of oil pressure.
Jump only with a battery source and with the same
9. Allow the engine to idle for 3 to 5 minutes, or voltage as the stalled machine.
until the needle in the water temperature gauge
Turn off all lights and electrical accessories on the
(C3) begins to rise.
stalled machine.
When starting from another machine, make sure
the machines do not touch. Contact between
machines could damage the engine bearings and
electrical circuits.
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Operation RS425C
Non-Operational Travel
NOTICE
Do not downshift the machine when it is in four
wheel drive. If the four wheel drive is downshifted
when moving, the pumps can easily be damaged.
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RS425C Operation
c. Tighten the setscrew. 3. Periodically check the cutter teeth to see if they
need to be replaced. Cutter tooth life will vary
d. Check and adjust the position of the pointer from location to location.
(2) until it is correctly aligned with the indica-
tor (C41). a. Stop the machine.
b. Disengage the cutter clutch.
c. Stop the engine.
d. Be sure the cutter has stopped turning.
e. Check for and replace worn or broken cutter
teeth. For replacement procedures, refer to
Cutter Drum under Maintenance.
NOTICE
Operating the cutter with worn or broken cutter
teeth can lead to broken tooth holders. Expensive
repairs and downtime result.
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RS425C Operation
Adjust the Cutting Depth 4. Use door switches (C17) and (C16) to lower the
cutter doors until the rubber flaps are touching
the grade, then move flasher switch (C22) to
On. If the machine does not have the Travel A-B
option, there will not be a front cutter door switch
Keep all personnel at least 25 ft. (7.6 m) away from (C16).
the machine when starting a cut. Keep all person-
nel at least 25 ft. (7.6 m) away from the rear of the 5. If the machine is equipped with the Travel A-B
machine while it is in operation. Directional option, check that travel A-End/B-End
switch (C8) is positioned correctly for the cut to
be made.
NOTICE
To avoid possible machine damage, shift the cutter
transmission only when the machine is stopped
and propel control is at Neutral, the engine is at
low idle, the cutter clutch is disengaged, and the
input and output shafts have stopped turning.
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Operation RS425C
NOTICE
Engage or disengage the cutter clutch only with
Lowering the cutter too quickly when starting a
the engine at low idle. Otherwise the cutter drive
cut can cause the cutter to ride up onto the uncut
mechanism may be damaged.
surface and make the machine lunge in any direc-
tion. The machine may also lunge if the cutter hits
an obstruction while making a cut.
Either of the above can cause personal injury or
death.
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RS425C Operation
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Operation RS425C
Start a Cut
NOTICE
Do not set the depth control to a depth beyond the
extended length of the cutter lift cylinders or over-
heating of the hydraulic oil and unnecessary wear Lower the cutter slowly. Keep all personnel at least
on the housing wear plates may result. 25 ft. (7.6 m) away from the machine when start-
ing a cut. Keep all personnel at least 25 ft. (7.6 m)
away from the rear of the machine while it is in
19. Repeat steps 10 through 18 until the proper operation.
depth of cut is achieved.
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NOTICE
To avoid possible machine damage, shift the cutter
transmission only when the machine is stopped
and propel control is at Neutral, the engine is at
low idle, the cutter clutch is disengaged, and the
input and output shafts have stopped turning.
NOTICE
Engage or disengage the cutter clutch only with
the engine at low idle. Otherwise the cutter drive
mechanism may be damaged.
11. Set the engine at low idle with the throttle switch
(C12).
12. Pull the cutter clutch control (C18) out to engage
the cutter.
13. After the cutter is turning freely, hold the throttle
switch (C12) forward until the engine is at full
speed.
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Operation RS425C
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RS425C Operation
During Operation
Hydraulic Oil Temperature Cutter Transmission Oil Cooler Temperature
It is extremely important that the hydraulic oil tempera- If the cutter transmission oil cooler temperature rises
ture be checked periodically during operation. above 220F (104C) and remains there or continues
to rise, try making a cut that is not as deep as the
a. Use an air hose to remove any loose mate- 1. Stop the machine.
rial. 2. Troubleshoot the system.
b. If necessary, use a steam cleaner to remove
any remaining material.
Ground Drive System
3. Check the condition of the engine coolant. If, during operation, the ground drive system seems to
a. If the coolant shows signs of system ero- be sluggish and/or there is a rattling or pinging noise in
sion, flush and clean the cooling system. the ground drive system, perform the following steps:
If the hydraulic oil temperature is still too high: 1. Stop the machine.
1. Stop the machine. 2. Check the ground drive suction line for a partial
blockage or if the valve is not open all the way.
2. Troubleshoot the system.
3. If the problem persists, contact your Terex Road-
building representative.
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Operation RS425C
Unexpected engagement of the cutter can cause 2. If possible, run cutter (1) deep enough to mix
personal injury or death. Push the cutter clutch some base material (2) with asphalt surface ma-
control in and move the cutter transmission shift terial (3). This will help improve the cutter tooth
lever to neutral whenever the cutter is stopped. life.
Keep all personnel at least 25 ft. (7.6 m) away from
the machine when starting a cut. Keep all person-
nel at least 25 ft. (7.6 m) away from the rear of the
machine while it is in operation.
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Operation RS425C
NOTICE
To avoid possible machine damage, shift the cutter
transmission only when:
the machine is stopped and the propel control
is at Neutral,
the engine is at low idle,
the cutter clutch is disengaged,
the input and output shafts have stopped turn-
ing.
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NOTICE
Engage or disengage the cutter only with the en-
Lowering the cutter too quickly when starting a
gine at low idle. Otherwise the cutter drive mecha-
cut can cause the cutter to ride up onto the uncut
nism may be damaged.
surface and make the machine lunge in any direc-
tion. The machine may also lunge if the cutter hits
11. Set the engine at low idle with throttle switch an obstruction while make the cut.
(C12) and pull the cutter clutch control (C18) out Either of the above can cause personal injury or
to engage the cutter. After the cutter is turning death.
freely, hold the throttle switch (C12) forward until
the engine is at full speed.
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NOTICE
machine while it is in operation.
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Operation RS425C
NOTICE
Engage or disengage the cutter only with the en-
gine at low idle. Otherwise the cutter drive mecha-
nism may be damaged.
12. Set the engine at low idle with the throttle switch
(C12).
13. Pull the cutter clutch control (C18) out to engage
the cutter.
14. After the cutter is turning freely, hold the throttle 15. Use the cutter manual depth control switch
switch (C12) upward until the engine is at full (C20) to slowly lower the cutter into the grade.
speed. The cutter depth is shown by the pointer (1)
on the depth gauge (2). If the machine starts
to bounce up and down or rock side to side,
release the manual depth control switch (C20)
momentarily before continuing into the cut.
16. As the cutter is lowered into the cut, use door
switches (C16) and (C17) to raise the cutter
doors as necessary. The front cutter door switch
(C16) will not be on the control panel if there is
not the Travel A-B option.
17. If the Travel A-End/B-End switch (C8) is at B-
end, move the hood-pull switch (C9) upward. If
the Travel A-End/B-End switch is at A-end, move
the hood-pull switch downward.
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Start Operation
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Operation RS425C
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NOTICE 14. After the cutter is turning freely, hold the throttle
switch (C12) forward until the engine is at full
To avoid possible machine damage, shift the cutter speed.
transmission only when:
the machine is stopped and the propel control
is at neutral,
the engine is at low idle,
the cutter clutch is disengaged,
the input and output shafts have stopped turn-
ing.
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Start a Cut
NOTICE
nel at least 25 ft. (7.6 meters) away from the rear of
the machine while it is in operation.
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Operation RS425C
End Operation
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RS425C Operation
Machine Cleanup
The machine should be thoroughly cleaned at the end
of each day of operation. The process of cleaning will
reveal loose bolts, loose hydraulic lines and fittings,
and other trouble spots. Be especially careful to clean
all oil, grease, dirt, or mud from the handrails, stepping
points and operators platform to prevent falls. Clean
any grease or oil from the controls so that a sure grip
is available when any control is needed.
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Operation RS425C
NOTES
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Shipping
For information on the shipping specifications of the
equipment, see Shipping Dimensions in the Appen-
dix of this manual.
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NOTES
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Transport the Equipment RS425C
NOTES
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RS425C Maintenance
Before performing any maintenance or repairs, shut Always move the battery disconnect switch to OFF
off the machine, remove the key from the ignition, when performing any maintenance or service pro-
move the battery disconnect switch to OFF, and cedure. Performing maintenance or service with a
attach a DO NOT OPERATE tag to the operators running engine could cause injury or death.
console. If the maintenance or service procedure requires a
running engine, always have at least two personnel
on hand to perform the maintenance or service as
detailed below.
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Maintenance RS425C
Maintenance Recommendations
Excessive coolant conditioner (greater than the recom-
mended 3% initial fill) together with concentrations of
antifreeze greater than 65%, cause a mud-like deposit
Always move the battery disconnect switch to OFF to form. This may result in radiator tube blockage and
when performing any maintenance or service pro- overheating.
cedure. Performing maintenance or service with a DO NOT add liquid cooling system conditioner when a
running engine could cause injury or death. cooling system conditioner element is used.
If the maintenance or service procedure requires a DO NOT use the cooling system conditioner element
running engine, always have at least two personnel with Dowtherm 209 Full-Fill coolant. Follow recom-
on hand to perform the maintenance or service as mendations provided with Dowtherm 209 Full-Fill
detailed below. coolant.
Premix coolant solution to provide protection to the
lowest expected outside temperature. Pure undiluted
Some maintenance and service procedures may
antifreeze will freeze at -10F (-23C).
require a running engine. For those procedures, one
person must always be stationed at the operators con- Coolant mixtures in excess of 50% antifreeze should
sole or near an emergency stop switch to immediately NOT be used unless temperatures below -30F
kill the engine. (-34C) are expected. In this case increase to 60%
antifreeze, but as the outside air temperatures start to
Refer to the Safety chapter of this manual for addi-
be consistently above 32F (0C), switch back to the
tional information concerning operator and machine
50/50 mixture.
safety.
Antifreeze concentrations in excess of 63% provide
NOTE: Always refer to the engine manual for all
less rather than more freeze protection.
engine-specific procedures that should be
followed. While this section does include A good practice to follow after operating an engine is
some engine-related procedures. The engine to return the engine speed to low idle for 5 minutes
manual goes into further detail and depth. If before shutting the engine down. This reduces the sur-
you do not have a copy, contact Terex Road- face temperature of the heads and liners minimizing
building at 1-888-837-3972 and speak with a localized boiling at these areas. This will also reduce
Part Sales or Product Support representative. the plating effect of the compounds in the coolant.
Use clean water that is low in scale-forming mineral.
Cooling System DO NOT use softened water.
NEVER add coolant to an overheated engine; allow Filling at over 5 U.S. gallons (19 liters) per minute can
the engine to cool first. cause air pockets in the cooling system.
Check the specific gravity of the coolant solution fre- After draining and refilling the cooling system, AL-
quently in cold weather to ensure adequate protection. WAYS operate the engine with the radiator cap
If the machine is to be stored in, or shipped to, an area removed until the coolant level stabilizes. Recheck the
with freezing temperatures the cooling system must be coolant level and add coolant as necessary to fill the
protected to the lowest expected outside temperature. system.
All water is corrosive at engine operating tempera- The engine cooling system is protected to -40F
ture. The cooling system should be protected with a (-40C) with a permanent-type antifreeze, when
3% concentration of cooling system conditioner at all shipped from the factory.
times, regardless of the concentration of antifreeze. Operate with a thermostat in the cooling system year-
round. Overheating will occur without a thermostat.
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NOTICE
Fill the fuel tank at the end of each day of operation
to drive out moist air and to prevent condensation.
Do not fill the fuel filter with fuel before installing it.
Contaminated fuel will cause accelerated wear to the
fuel system parts.
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Maintenance RS425C
NOTICE
Change the air cleaner primary element when the
indicator red signal (1) is locked in view.
Check that the dust ejector valve (2) is not inverted,
Make-up oil added to the hydraulic oil replenishing
damaged or plugged. If the valve is inverted, check for
tank must mix with the oil already in the system. Use
restrictions in the air inlet system.
only the same type of oil as already in the system
(see Lubricant Specifications). NOTE: Refer to Engine Air Inlet System under
If the hydraulic oil becomes cloudy, water or air is When Required for procedures to change the
entering the system. Water or air in the system will air cleaner elements.
cause pump failure. Change the hydraulic oil (see The primary element can be cleaned up to three times
Hydraulic System under Every 2000 Service Hours or before replacement. This element, when cleaned,
Yearly). should be thoroughly checked for rips or tears in the
filter material. Replace the primary element every year,
even though it has not been cleaned six times.
Normally the secondary element should be replaced at
the time the primary element is replaced for the third
time. However, if the primary element has been dam-
aged to a degree that could have allowed an exces-
sive amount of dirt to enter the secondary element,
change both the primary and secondary elements.
NOTICE
Do not try to reuse the secondary element by clean-
ing it. Always use a new element.
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NOTICE
Use extreme care when arc welding on the machine Accumulated grease and oil on a machine is a fire
or the spray system microcontroller (if equipped) hazard. Remove this debris with steam cleaning or
may be damaged. Always turn the battery disconnect high-pressure water, at least every 1,000 hours or
switch to OFF and connect the ground for the welder each time any significant quantity of oil is spilled
near the part of the machine being welded. on a machine.
When boost-starting the machine, follow the instruc-
tions in the Operation chapter to start the machine
properly. Wipe all fittings, caps, and plugs before servicing.
This machine has a 24-volt electrical system. Use Keep a close watch for leaks. If leaking is observed,
only equal voltage for boost starting. Use of a find the source and correct the leak.
welder or higher voltage will damage the electrical
system. Check the fluid levels more frequently than the recom-
mended periods if leaking is suspected or observed.
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Maintenance RS425C
NOTICE
No. 2D fuel.
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Maintenance RS425C
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Maintenance RS425C
Maintenance Notes
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WHEN REQUIRED
Engine Cooling System Drain and clean if the engine overheats or the solution is dirty.
Engine Air Intake System Replace or clean the primary and/or secondary air filters.
Fuel System Replace the primary and/or secondary fuel filters.
Fuel Tank Drain any water and/or sediment from the fuel tank.
Auxiliary Hydraulic Oil Filter Replace the auxiliary system filter.
Compressed Air System Check the oil level of the air system lubricator.
Cutter Drum Check the cutter bits. Replace if necessary.
Cutter Drive Shaft Torque Check the thickness of the torque limiting clutch assembly if the
Limiter Clutch clutch seems to be slipping.
Cutter Clutch Install and/or adjust the cutter clutch as needed.
Change or clean the hydraulic filters and strainers when indicated
Hydraulic System
by alarms or visual indicators.
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Maintenance RS425C
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Maintenance RS425C
Drain Clean
1. Fill the system with a commercially available
cleaning solution and clean water. See Caterpil-
lar Operation and Maintenance Manual, C13
Engines in the Maintenance chapter, Cooling
System Flush.
2. Start and run the engine for 1/2 hour. The solu-
tion should be at least 180F (82C).
3. Stop the engine and allow it to cool. Loosen the
radiator cap slowly to relieve pressure.
4. Remove the radiator cap.
5. Open the drain valve.
6. Drain the cleaning solution.
7. Flush the system with clean water until the drain-
ing water is clean. Do not run the engine while
flushing.
8. Close the radiator drain valve.
At operating temperature, the engine coolant is hot
and under pressure. Check the coolant level only
after the engine has cooled and the fill cap is cool
enough to touch with your bare hand.
Steam and hot water can cause personal injury. Re-
move the fill cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid
contact with the skin and eyes to prevent personal
injury.
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7. Stop the engine. 5. Clean the inside surface of the body (4).
8. Bring the coolant level up to where it is visible in 6. Inspect the dust ejector valve (5) for damage.
the sight glass. 7. Be sure the valve is securely in place and is not
9. Clean the radiator cap. inverted.
10. Inspect the gasket on the cap. 8. If the primary element is to be cleaned, see
Clean the Primary Air Filter Element for clean-
a. If it is damaged, discard the old radiator cap ing procedures.
and replace it with a new cap.
9. Inspect the gasket washer on the wing nut (1).
b. Use a pressurizing pump to test the pres- Replace it if a good air seal cannot be guaran-
sure of the cap. The correct pressure should teed.
be stamped on the face of the radiator cap.
10. Install the new or cleaned primary element (2).
c. If the cap has the correct pressure, install
the cap. 11. Secure the element with the wing nut (1).
11. Start the engine and check for coolant leaks at
all of the hose connections.
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Maintenance RS425C
Change the Secondary Air Filter Element Clean the Primary Filter Element
NOTICE
Do not clean the filter elements by bumping or tap-
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Maintenance RS425C
1. Direct a jet of compressed air against the inside 1. Run water through the element from the inside
of the element. To prevent possible personal only. Use a gentle stream of water, less than 40
injury and damage to the filter medium, use less psi (275 kPa).
than 30 psi (206 kPa), and keep the nozzle at
2. Run water through the element until the water
least 1 in. (25 mm) away from the medium.
comes through clear.
2. Move the nozzle up and down each pleat, con-
3. Dry the element thoroughly before inspecting it.
tinuing until no more dust is being removed. Do
Mechanical dryers can be used, but heated air
Not blow air against the outside of the element,
must be circulated and must be less than 71C
or the dirt will merely be forced farther into the
(160F). Do not use a light bulb to dry the ele-
pleats.
ment.
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Maintenance RS425C
Fuel System
Change the Primary Fuel Filter Element
NOTICE
injectors.
1. Close the fuel shutoff valve that is located under
When replacing fuel filters, do not add fuel to the new the fuel tank.
filters before installing them. Contaminated fuel will
cause accelerated wear to fuel system parts.
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NOTICE
The primary fuel filter may be prefilled with fuel to
avoid rough running/stalling of the engine due to
air. Do not fill the secondary filter with fuel before
installation. The fuel would not be filtered and could
be contaminated. Contaminated fuel will cause ac-
celerated wear to fuel system parts.
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the vent plug is se-
curely tightened to help prevent air from entering
the fuel system.
12. Open the fuel shutoff valves (for the suction and
return lines) located under the tank.
13. Start the engine and check for leaks.
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Maintenance RS425C
NOTICE NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that Do not fill the secondary fuel filter with fuel before
will be disconnected. Fit a suitable cover over any installing. The fuel would not be filtered and could
disconnected components. be contaminated. Contaminated fuel will cause ac-
celerated wear to fuel system parts.
4. Unlock the fuel priming pump (1) in order to b. Continue to tighten according to the instruc-
relieve residual pressure in the fuel system. tions on the fuel filter. Do not overtighten the
fuel filter.
5. Remove the used fuel filter (2). Use a cloth or
use a container to catch excess fuel. NOTE: Do not remove the plug (4) in the fuel filter
base to release air from the fuel system during
6. Clean the filter element mounting base (3) and periodic service to the fuel filter. Periodic re-
sealing surface. Be sure all of the old seal is moval of the plug will result in increased wear
removed. of the threads in the filter base.
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9. Open the fuel shutoff valve (for the suction line) Prime the Fuel System
located under the fuel tank.
10. Prime (1) the fuel system (see the following sec-
tion, Prime the Fuel System).
Fuel leaked or spilled onto hot surfaces or electrical
NOTICE components can cause a fire. To help prevent pos-
sible injury, turn the start switch off when changing
Do not crank the engine continuously for more than fuel filters or water separator elements. Clean up fuel
30 seconds. Allow the starting motor to cool for two spills immediately.
minutes before cranking engine again.
NOTICE
Do not loosen the lines at the fuel manifold. The fit-
tings may be damaged and/or a loss of priming pres-
sure may occur when the fuel lines are loosened.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
Fuel Tank
Drain the Water and Sediment
Fuel quality is critical to the performance and the
service life of the engine. Water in the fuel can cause
excessive fuel system wear. Condensation occurs dur-
ing the heating and cooling of fuel. The condensation
occurs as the fuel passes through the fuel system and
the fuel returns to the fuel tank. This causes water to
accumulate in fuel tanks. Draining the fuel tank regu-
larly and obtaining fuel from reliable sources can help
to eliminate water in the fuel.
1. Allow the machine to stand at least 15 minutes
after adding fuel or after operation to let water
and sediment settle.
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Maintenance RS425C
Cutter Drum
Check the Cutter Bits Replace the Cutter Bits
1. Raise the cutter door and install the pin to lock The following procedure describes using an air-oper-
the door fully open. See Cutter Door Lock and ated punch to remove the cutter bits. If a manual bit
Cutter Retaining Chains earlier in this chapter. puller or drive pin and hammer will be used instead of
a punch, see the following section, Alternatives for
Removing the Cutter Bit(s).
1. Raise the cutter door and install the pin to lock
Engagement of the cutter drive system can cause the door fully open. See Cutter Door Lock and
personal injury or death. Disengage the cutter Cutter Retaining Chains earlier in this chapter.
clutch, stop the engine, move the cutter transmis-
sion shift lever to Neutral, and remove the key from
the ignition switch. Attach a Do Not Operate tag to
the controls.
Engagement of the cutter drive system can cause
personal injury or death. Disengage the cutter
clutch, stop the engine, move the cutter transmis-
sion shift lever to Neutral, and remove the key from
the ignition switch. Attach a Do Not Operate tag to
the controls.
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Maintenance RS425C
Replace the Output Hub and Friction Plate 8. Remove the pressure plate (7).
Assemblies
9. Remove the output hub (8).
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Cutter Clutch
Installation
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Maintenance RS425C
LIGHTS
P
R
O
P
T E
H L
R
O
T
T
L IGNITION
E
C
U 18. Adjust the needle valve (4) at the air cylinder to
T
T obtain smooth but rapid engagement of the cut-
HORN E
FRONT DOOR R
6 ter drive system.
P
T
R
A
19. Disengage the clutch.
N
S
REAR DOOR
CLUTCH 20. Check that the clutch is disengaged. Refer to the
P following section, Check Clutch Disengage-
526009235000
R
C
U
T
T
ment.
REAR STEERING E
R
BRAKE
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Walk-Around Inspection
Check Clutch Disengagement Inspect the Machine
1. Put the engine at low idle.
2. Push the clutch control button in.
3. Observe the cutter drive shaft; rotation should
stop.
4. If rotation continues, adjust the turnbuckle.
a. Stop the engine.
b. Disengage the clutch.
c. Adjust the turnbuckle approximately 1/16 in.
(0.16 cm).
d. Start the engine. Refer to the Operation
chapter for the proper starting procedure. See the Daily Inspection chapter.
e. Repeat steps 1 through 4 until the clutch is
properly disengaged.
NOTE: To ensure proper turnbuckle adjustment, re-
check the over-center position of the linkage
by disconnecting the air lines when the clutch
is disengaged. If the turnbuckle is correctly
adjusted, the clutch will stay disengaged, even
with the air lines disconnected.
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Clean the Radiator, Charge Air, Hydraulic Oil Clean the Cutter Transmission Oil Cooler Core
Cooler, and Differential Oil Cooler Cores
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Maintenance RS425C
Engine Crankcase
Check the Oil Level
NOTE: Before you perform this maintenance, do not
operate the machine for at least 10 minutes,
which will allow the oil to drain back into the oil
pan. This will give an accurate reading on the
dipstick.
Maintain the oil level between the ADD and FULL
marks on the Engine Stopped side of the dipstick. Do
not fill the crankcase oil level above the FULL mark on
the dipstick.
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Maintenance RS425C
Ground Drive Axle2 fittings each end, 1 above the axle and 1
below the axle
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Chaincase Lift Cylinders2 fittings each cylinder Rear Bolster Pivot Pin2 fittings
Apply lubricant slowly until excess is observed or Apply lubricant slowly until excess is observed or
resistance is felt. resistance is felt.
Apply lubricant slowly until excess is observed or Apply lubricant slowly until excess is observed or
resistance is felt. resistance is felt.
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Maintenance RS425C
The standard slip shaft drive shaft (2) has one lubrica-
tion fitting.
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Maintenance RS425C
Batteries
Clean the Batteries Check the Electrolyte Levels
NOTICE check the cells weekly due to higher cell water usage.
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Maintenance RS425C
NOTICE
Continued operation of the cutter with the hydraulic
pressure above 110 psi (760 kPa) will be detrimental
to chain and bearing life.
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Maintenance RS425C
EVERY 100 SERVICE HOURS OR TWO WEEKS EVERY 250 SERVICE HOURS OR MONTHLY
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Maintenance RS425C
EVERY 250 SERVICE HOURS OR MONTHLY EVERY 250 SERVICE HOURS OR MONTHLY
At operating temperature, the engine coolant is hot At operating temperature, the engine coolant is hot
and under pressure. Stop the engine and allow it to and under pressure. Steam can cause personal
cool before checking for leaks. injury. Check the coolant level only after the engine
has cooled and the fill cap is cool enough to touch
with your bare hand.
Remove the fill cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid
contact with the skin and eyes to prevent personal
injury.
NOTICE
All water is corrosive at engine operating tempera-
ture. Use a Caterpillar coolant conditioner element
to treat either plain water or the ethylene glycol solu-
tion. When changing antifreeze solution, replace the
maintenance element with the correct conditioner
precharge element. Excessive coolant conditioner
(greater than the recommended 3% initial fill) to-
1. Check for cracked, soft, or otherwise deterio- gether with concentrations of antifreeze greater than
rated coolant hoses and replace as necessary. 65% cause a mud-like deposit to form. This may re-
sult in radiator tube blockage and overheating. The
2. Check all coolant line joint connections and hose
Caterpillar coolant conditioner element must not be
clamps, and tighten any that are loose.
used with Dowtherm 209 coolant.
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EVERY 250 SERVICE HOURS OR MONTHLY EVERY 250 SERVICE HOURS OR MONTHLY
EVERY 250 SERVICE HOURS OR MONTHLY EVERY 250 SERVICE HOURS OR MONTHLY
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EVERY 250 SERVICE HOURS OR MONTHLY EVERY 250 SERVICE HOURS OR MONTHLY
NOTICE
Belts must be replaced in complete matched sets.
Never replace only one belt of a set. The new belt
will carry all the load and fail rapidly.
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Maintenance RS425C
EVERY 250 SERVICE HOURS OR MONTHLY EVERY 250 SERVICE HOURS OR MONTHLY
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EVERY 250 SERVICE HOURS OR MONTHLY EVERY 250 SERVICE HOURS OR MONTHLY
Adjust the Fan Drive Belt Tension Replace the Fan Drive Belts
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Maintenance RS425C
EVERY 250 SERVICE HOURS OR MONTHLY EVERY 250 SERVICE HOURS OR MONTHLY
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EVERY 250 SERVICE HOURS OR MONTHLY EVERY 250 SERVICE HOURS OR MONTHLY
Check the Brake Shoe Clearance Adjust the Brake Shoe Clearance
NOTE: Check the clearance at the center of each 1. Position the machine on level grade.
brake show, not at the ends.
2. Block the wheels.
1. Lock the brake springs at the compressed
3. Stop the engine.
position (see Compress and Lock the Brake
Springs). 4. Raise one wheel and tire off the ground with a
jack.
5. Position the safety stands so the tire will still be
off the ground, and lower the machine onto the
stands.
6. Lock the brake springs at the compressed
position (see Compress and Lock the Brake
Springs).
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Maintenance RS425C
EVERY 250 SERVICE HOURS OR MONTHLY EVERY 250 SERVICE HOURS OR MONTHLY
8. Use an adjusting spoon or a screwdriver to turn 10. Use a feeler gauge to check the clearance be-
the star wheel on the adjuster in the direction tween the center of the lining and the drum. The
to move the linings against the drum. Turn the clearance must be 0.20 to 0.40 in. (0.5 to 1 mm).
adjuster until you feel a heavy drag on the drum Continue to turn the star wheel until the clear-
when you rotate the wheel. ance is correct.
NOTE: If you cannot raise the wheel from the ground 11. Repeat the procedure for the other brake shoe.
or cannot turn the wheel, turn the adjuster until 12. Install the dust cover at the top of the hub.
the linings are against the drum. Do not force
the adjuster after the linings touch the drum. 13. Repeat the procedure for the other wheel.
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EVERY 250 SERVICE HOURS OR MONTHLY EVERY 250 SERVICE HOURS OR MONTHLY
Cutter Differential
Change the Oil
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Maintenance RS425C
EVERY 250 SERVICE HOURS OR MONTHLY EVERY 250 SERVICE HOURS OR MONTHLY
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EVERY 250 SERVICE HOURS OR MONTHLY EVERY 250 SERVICE HOURS OR MONTHLY
Cutter Transmission
Change the Oil 7. Take the strainer to a clean work area.
8. After noting the types and amounts of particles
trapped by the strainer, thoroughly clean it.
NOTE: If an excess of metal particles is found, find
the cause of the metal particles.
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Maintenance RS425C
EVERY 250 SERVICE HOURS OR MONTHLY EVERY 250 SERVICE HOURS OR MONTHLY
Electrical System
19. After the cutter stops turning, lower it to the Check the Wiring Harnesses
ground.
20. Stop the engine.
21. Allow the machine to stand for at least 6 min-
utes.
22. Check the oil level.
a. Unscrew the dipstick and raise it out.
b. Wipe it off, and reinsert it into the pipe.
c. Raise the dipstick out again and check the
oil level.
23. Add oil as necessary to bring the level to the
FULL mark on the dipstick. 1. Visually check the wiring for damage such as
broken insulation and frayed wires (alternator,
regulator, battery, and other wiring harness con-
nections).
2. Check for loose or corroded connections.
3. Schedule repairs if possible; make immediate
repairs if necessary.
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EVERY 250 SERVICE HOURS OR MONTHLY EVERY 250 SERVICE HOURS OR MONTHLY
Lubrication
Lubricate the Fittings
Ground Drive Axle Universal Joints2 fittings each front axle univer-
sal joint, 1 top and 1 bottom
Ground Drive Axle2 fittings on each end of the axle, connected by
hoses to grease fittings on the frame, forward from the cutter hous-
ing, on the left and right side of the machine
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Maintenance RS425C
EVERY 500 SERVICE HOURS OR 3 MONTHS EVERY 500 SERVICE HOURS OR 3 MONTHS
Hydraulic System
Change the Hydraulic Oil
NOTICE
When changing the hydraulic oil, cleanliness must be
kept in mind at all times. Dirty hydraulic oil causes
extremely accelerated wear. Clean the outside of the
hydraulic oil tank before starting, perform the work
in a clean area using clean tools, and keep your
hands clean.
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EVERY 500 SERVICE HOURS OR 3 MONTHS EVERY 500 SERVICE HOURS OR 3 MONTHS
Engine Crankcase
11. Close the drain valve. Clean the Breather
12. Disconnect the drain hose from the valve. If a
hydraulic hose was originally connected to the
valve used for draining, reconnect the hydraulic
hose to the valve. Hot oil and components can cause personal injury.
13. Open the valves with the hoses connected. Do not allow hot oil or components to contact skin.
14. Fill the tank with clean hydraulic oil. Use the
same type of oil as already in the system or
drain the rest of the system before adding the
different oil. See Lubricant Specification and
Refill Capacities.
15. Change the hydraulic oil filter elements. See
Hydraulic Oil Filters under Every 100 Service
Hours or Two Weeks.
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EVERY 500 SERVICE HOURS OR 3 MONTHS EVERY 500 SERVICE HOURS OR 3 MONTHS
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EVERY 500 SERVICE HOURS OR 3 MONTHS EVERY 500 SERVICE HOURS OR 3 MONTHS
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Maintenance RS425C
EVERY 500 SERVICE HOURS OR 3 MONTHS EVERY 500 SERVICE HOURS OR 3 MONTHS
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Maintenance RS425C
EVERY 500 SERVICE HOURS OR 3 MONTHS EVERY 500 SERVICE HOURS OR 3 MONTHS
11. Insert the free end of the tube into the fill hole
in the differential housing of the axle making
certain that the free end of the tube is in the
lube oil inside the axle housing. There should be
approximately 6 in. of tube visible between the
pump and the fill hole.
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Maintenance RS425C
EVERY 500 SERVICE HOURS OR 3 MONTHS EVERY 500 SERVICE HOURS OR 3 MONTHS
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Maintenance RS425C
EVERY 500 SERVICE HOURS OR 3 MONTHS EVERY 500 SERVICE HOURS OR 3 MONTHS
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EVERY 500 SERVICE HOURS OR 3 MONTHS EVERY 500 SERVICE HOURS OR 3 MONTHS
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Maintenance RS425C
EVERY 500 SERVICE HOURS OR 3 MONTHS EVERY 500 SERVICE HOURS OR 3 MONTHS
11. Insert the free end of the tube into the fill hole Engine Lube, Test Port in Place
in the differential housing of the axle making To check the contamination level of the engine lube
certain that the free end of the tube is in the fluid, you will need a fluid sampling kit, which is avail-
lube oil inside the axle housing. There should be able from Terex. From this kit you will need the follow-
approximately 7 in. of tube visible between the ing:
pump and the fill hole.
polyprophylene tube, 1/4 O.D. X 0.035 wall x
100 ft. bulk roll
vacuum pump
2 sampling bottles, 3 oz. and 100 mL
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EVERY 500 SERVICE HOURS OR 3 MONTHS EVERY 500 SERVICE HOURS OR 3 MONTHS
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Maintenance RS425C
EVERY 1,000 SERVICE HOURS OR YEARLY EVERY 1,000 SERVICE HOURS OR YEARLY
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2. Jack the opposite wheel up to help drain the 12. Clean and install all plugs.
oil from the planetary and wheel touching the
13. Drive the machine without a load for 1 or 2 miles
ground.
at slow speeds to circulate the lubricant through-
3. Rotate the planetary that is off the ground to out the axle and planetary ends.
place the fill/level/drain plug at the bottom.
NOTICE
To ensure proper oil level, add oil to both planetary
ends and to the carrier.
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Maintenance RS425C
EVERY 1,000 SERVICE HOURS OR YEARLY EVERY 1,000 SERVICE HOURS OR YEARLY
For example:
If measurement Y is 40 in. and measurement X is 39
in., there is 1 in. of toe-in.
Y X = TOE
40 39 = 1
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EVERY 1,000 SERVICE HOURS OR YEARLY EVERY 1,000 SERVICE HOURS OR YEARLY
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Maintenance RS425C
EVERY 1,000 SERVICE HOURS OR YEARLY EVERY 1,000 SERVICE HOURS OR YEARLY
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EVERY 1,000 SERVICE HOURS OR YEARLY EVERY 1,000 SERVICE HOURS OR YEARLY
Rear AlignmentCheck Amount of Toe Present 3. Using a piece of chalk or a magic marker, mark
NOTE: See Alternate Method to Check the Amount this measurement at the front center and rear
of Toe Present under Front Alignment center of each rear tire.
Check Amount of Toe Present for another 4. Measure the amount of toe present on the rear
way to check the amount of toe present. axle.
a. Measure the distance between the molding
marks at the marked level on the rear of the
tires (Y dimension).
b. Measure the distance between the marks on
the front of the tires (X dimension).
c. Subtract dimension X from dimension Y.
d. Use the resulting figure as the amount of toe
present.
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Maintenance RS425C
EVERY 1,000 SERVICE HOURS OR YEARLY EVERY 1,000 SERVICE HOURS OR YEARLY
NOTE: One rear axle tie rod end has left hand Cutter Transmission Shift Linkage2 fittings, 1 fitting in each univer-
threads, and the other tie rod end has right sal joint; the linkage is located under the deck grating at the left side
of the operators station.
hand threads. This allows easy toe adjust-
ment. Apply lubricant slowly until excess is observed at all
four cross seals. If a seal does not relieve (pop), move
1. Loosen the jamnuts (1) on the rear tie rod (2).
the shaft laterally in all four directions opposite the
cross seal not relieving while continuing to apply lubri-
cant gun pressure until lubricant appears at that seal.
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EVERY 2,000 SERVICE HOURS OR 2 YEARS EVERY 2,000 SERVICE HOURS OR 2 YEARS
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Maintenance RS425C
EVERY 2,000 SERVICE HOURS OR 2 YEARS EVERY 2,000 SERVICE HOURS OR 2 YEARS
Clean
1. Fill the system with a commercially available
cleaning solution.
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Maintenance RS425C
NOTES
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RS425C Schematics
Electrical Schematic
Sheet 1 of 4
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Schematics RS425C
Electrical Schematic
Sheet 2 of 4
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Electrical Schematic
Sheet 3 of 4
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Schematics RS425C
Electrical Schematic
Sheet 4 of 4
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RS425C Schematics
NOTES
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Schematics RS425C
NOTES
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RS425C Appendix
Reference Information
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Appendix RS425C
Fastener Torques
General Torque for Standard Bolts, Nuts and Ta- Torques for Taperlock Studs with Standard
perlock Studs Threads
The following charts give general torques for bolts, Thread Size Standard Torque
nuts and taperlock studs of SAE Grade 5 or better Inch Nm ftlb
quality.
1/4 83 62
Exceptions to these torques are given in Service 5/16 17 5 13 4
Manuals where needed.
3/8 35 5 26 4
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NOTICE
Torques for Bolts and Nuts with Metric Threads
Metric ISO* Thread
Be very careful never to mix metric with U.S. custom- Thread Size Standard Torque
ary (standard) fasteners. Mismatched or incorrect Nm** ftlb
fasteners will cause machine damage or malfunction M6 12 4 93
and may even result in personal injury.
M8 25 7 18 5
M10 55 10 40 7
Original fasteners removed from the machine should M12 95 15 70 10
be saved for reassembly whenever possible. If new M14 150 20 110 15
fasteners are needed, they must be of the same size
and grade as the ones that are being replaced. M16 220 30 160 20
M18 325 50 240 35
The material strength identification is usually shown on
the bolt head by numbers (8.8, 10.9, etc.). The follow- M20 450 70 330 50
ing chart gives standard torques for bolts and nuts with M22 600 90 440 65
Grade 8.8. M24 775 100 570 75
M27 1150 150 840 110
M30 1600 200 1175 150
M33 2000 275 1480 200
M36 2700 400 2000 300
* ISOInternational Standard Organization
** 1 Newton meter (Nm) is approximately the same as
0.1 mkg.
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Appendix RS425C
Initial Installation
Torque on New Hose (1) O-Ring Face Seal Fitting. (2) O-Ring Groove. (3) Straight Thread
O-Ring Port Fitting End. (4) O-Ring. (5) O-Ring Face Seat Nut.
Clamp Width Nm* lb in.
0.625 in. (16 mm) 7.5 0.5 65 5
Straight Thread O-Ring Fitting
0.531 in. (13.5 mm) 4.5 0.5 40 5
0.312 in. (8 mm) 0.9 0.2 82 (For O-Ring Face Seal Fitting Only)
Reassembly or THREAD SIZE STANDARD TORQUE
(in.) Nm* ftlb
Retightening Torque
5/16 - 24 5 1.5 41
Clamp Width Nm* lb in.
3/8 - 24 12 2 91
16 mm (.625 inch) 4.5 0.5 40 5
7/16 - 20 20 4 15 3
13.5 mm (.531 inch) 3.0 0.5 25 5 1/2 - 20 30 5 22 4
8 mm (.312 inch) 0.7 0.2 62 9/16 - 18 40 5 30 4
* 1 Newton meter (Nm) is approximately the same as 3/4 - 16 100 15 75 10
0.1 mkg. 7/8 - 14 135 15 100 10
1 1/16 - 12 200 25 150 20
1 3/16 - 12 250 25 185 20
1 5/16 - 12 300 40 220 30
1 5/8 - 12 300 40 220 30
1 7/8 - 12 300 40 220 30
2 1/2 - 12 300 40 220 30
* 1 Newton meter is approximately the same as 0.1 mkg.
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Appendix RS425C
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1. Put the nut and sleeve over the tubing with the
short heavy end of the sleeve facing the end of
1. Make sure the tube has been put through the the tubing.
nut and makes contact against the tube shoulder
in the fitting body. 2. Put the tube end against the counterbore in the
body of the fitting.
2. Turn the nut with a wrench until a small de-
crease in torque is felt. This indicates that the 3. Tighten until nut is over the last thread on the
sleeve has been broken off the nut. body.
3. Hold the tube to prevent turning and tighten the The remainder of space is used whenever the
nut 1 1/2 turns. fitting is removed and installed again.
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Appendix RS425C
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Appendix RS425C
Common Symbols
Variable Displacement
Dotted Line Exhaust or Hydraulic Pump
Drain Line
Pressure Compensated
Enclosure Outline
Variable Displacement Pump
Hydraulic Oscillator
Gaseous Supply
Flexible Line
Reservoirs
Reservoir Open to
Atmosphere
Mechanical Devices
Two Parallel Lines Pressurized
Mechanical Connection
(Drive Shaft, Actuating
Lever, etc.)
Line to Reservoir Below Fluid
Level
Flexible Line
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RS425C Appendix
Double Acting
2 Position 4 Way Valve
Double Rod End
Valves
Non-Adjustable Restrictor
Check Valve
Adjustable Restrictor
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Appendix RS425C
Solenoid Filter
Detent
Cooler
Spring
Heater
Manual
Temperature Controller
Shuttle
Reversible Motor
Push Pull Lever
Pedal Operated
Pressure Indicator
Pressure Switch
Pressure Compensated
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Fuse Maintained
Connection Symbols
Housings
Control Relay
Switch Configurations
S.P.S.T.
Volt Meter
S.P.D.T.
Pressure Gauge
D.P.S.T.
Temperature Gauge
Motor
D.P.D.T.
Types of Grounds
Ground
Resistors
Fixed
Internal External
Variable
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Appendix RS425C
Head/park Light
Proximity Switch/Sensor
Solenoids/Coils
Limit Switch
Valve Coil
Pressure
Dual Solenoid
Temperature
Hand
Control Relay
Relay Assembly
Diode
Circuit Crossing
Normally Open (N.O.) Relay
Contact
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RS425C Appendix
Magnetic Pick-Up
Electrical Miscellaneous
Horn/Alarm EDC
(Electronic Displacement
Control)
Alternator
Starter
Back Up Alarm
Battery
Switch Bank
Circuit Breaker
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Appendix RS425C
Common Abbreviations
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Appendix RS425C
Conversion Factors
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