236504

WTEREX
HANDLERS
OPERATOR'S
MANUAL

TH644C
TH842C
TH844C
~ TEREX HANDLERS
455 N. Superior Ave.
Baraga, MI 49908-0790
Ph. (906) 353-6675 Fax (906) 353-7543
http://www.terexlifi.com
07116/04

TABLE OF CONTENTS
SECTION 1

ROUGH TERRAIN FORKLIFT SAFETY SECTION

Introduction
Standards And Symbols
Safety
Training And Knowledge
Operator's Responsibilities
Management's Responsibilities
Maintenance And Repair
Operation Safety

1-1
1-3
1-4
1-5
1-5
1-6
1-7
1-8
1-9

SECTION 2

GENERAL SAFETY
General Safety Procedures
Jump Starting
Proper Load Chart Use

2-1
2-3
2-8
2-9

SECTION 3

CONTROLS AND INSTRUMENTS

Operator's Compartment
Joystick Control Functions
Joystick Control Functions (Button Pushed)
Service Brakes
Low Service Brake Pressure Light
Parking Brake
Frame Sway Control
Gauges
Hydraulic Pump Destroke Button
Steering
Transmission
Front Axle Differential Lock

3-1
3-3
3-4
3-5
3-6
3-6
3-7
3-8
3-9
3-9
3-10
3-10
3-11

SECTION 4

OPERATION
Operation And Safety Guidelines
Before Starting The Engine
Starting The Engine
Before Operating The Forklift
TransportingA Load
Placing A Load

4-1
4-3
4-4
4-9
4-11
4-15
4-17

SECTION 5

MAINTENANCE PROCEDURES
General Safety Practices
Service Intervals
Required Grease Intervals
Grease Fitting Locations
Daily Maintenance Procedures
50 Hour Maintenance Procedures
100 Hour Maintenance Procedures
250 Hour Maintenance Procedures
500 Hour Maintenance Procedures
750 Hour Maintenance Procedures
1000 Hour Maintenance Procedures
2000 Hour Maintenance Procedures
Filter Guide
Recommended FluidsAnd Capacities
Hydraulic Pressure Settings

5-1
5-3
5-5
5-6
5-7
5-8
5-12
5-15
5-17
5-18
5-20
5-21
5-23
5-24
5-24
5-25

SECTION 6

MATERIAL SAFETY DATA

Material Safety Data Sheets
California Proposition 65 Warnings

6-1
6-3
6-4

SECTION 1
ROUGH TERRAIN
FORK LIFT SAFETY

1- 1

TABLE OF CONTENTS

SECTION 1 - ROUGH TERRAIN FORK LIFT SAFETY

Introduction

1-3

Standards And Symbols

1-4

Safety

1-5

TrainingAnd Knowledge

1-5

Operator's Responsibilities

1-6

Management's Responsibilities

1-7

Maintenance And Repair

1-8

Operation Safety

1-9

1-2

[iLROUGH TERRAIN FORK LIFT SAFETY iL]

fi

INTRODUCTION

Owners, Users, and Operators:

Terex (Handlers) appreciates your choice of our machine for your application. Our
number one priority is user safety, which is best achieved by our joint efforts. We feel
that you make a major contribution to safety if you, as the equipment users and operators:

1. Comply with OSHA, Federal, State, and Local Regulations.

2. Read, Understand, and Follow the instructions in this and other manuals
supplied with this machine.
3. Use Good Safe Work Practices in a common sense way.
4. Only have trained/certified operators - directed by informed and
knowledgeable supervision - running the machine.
NOTE: OSHA prohibits the alteration or modification ofthis machine without written
manufacturer's approval. Use only factory approved parts to service or repair this
machine.
If there is anything in this manual that is not clear or which you believe should be added,
please send your comments to the Manager of Publications, Terex Handlers, P. O. Box

790, Baraga, Michigan 49908. Telephone number 906-353-6675.

Tbankyou!

THIS SYMBOL MEANS YOUR SAFETY IS

INVOLVED! READ, UNDERSTAND AND
FOLLOW ALL DANGER, WARNING AND
CAUTION DECALS ON YOUR ROUGH TERRAIN
FORKLIFT.

1-3

[itROUGH TERRAIN FORK LIFT SAFETY it]

fi

STANDARDS AND SYMBOLS

STANDARDS
Many aspects of rough terrain forklift operation and testing are discussed in standards
published by the American National Standards Institute. These Standards are updated on
a regular basis with addendas. Terex recommends that you purchase and refer to the
following standards.
ANSI B56.6 - Rough Terrain Fork Lifts
This Standard can be purchased from:
American National Standards Institute
25 West 43nd Street, 4th Fl.
New York, New York, 10036
Tel. 212.642.4900
Fax. 212.398.0023

SYMBOLS
The symbols below are used to inform the operator of important information concerning
the operation ofthis machine.

DANGER - Indicates an imminently hazardous situation

which, ifnot avoided, will result in death or serious injury.
WARNING - Indicates a potentially hazardous situation
which, ifnot avoided, could result in death or serious
mJury.
CAUTION - Indicates a potentially hazardous situation
which, ifnot avoided, may result in minor or moderate
mJury.

ATTENTION - Indicates a situation which, ifnot avoided,

may result in property or equipment damage.

1-4

(LtROUGH TERRAIN FORK LIFT SAFETY

fi

SAFETY

These are general safety rules, which must be followed. You are also required to read
and understand the Operator's Manual as there are instructions, which are more
detailed specific to this machine.

TRAINING AND KNOWLEDGE

1. Safety must always be the operator's most important concern.

2. This machine must only be operated by trained personnel, who have demonstrated
their ability to do so safely.
3. Comply with the requirements ofcurrent Occupational Safety and Health
Administration (OSHA) standards, including 29CFR191 0.178; and the American
National Standards Institute (ANSI) B56.6latest edition.
4. Read and Understand all Decals and Warnings.
5. Read and Understand the Rating Chart.
6. Know that the machine can safety lift each load before attempting to lift.

1-5

(iliROUGH TERRAIN FORK LIFT SAFETY LL]

fi

OPERATOR'S RESPONSIBILITIES

1. Read and understand the Operator's Manual.

2. Know the location and the purpose ofthe controls, instruments and indicator
lights.
3. Make sure the machine is in proper order and all operational aids and warning
signals are functional before operating.
4. Keep the machine clean, including all instrumentation, windows, lights and other
glazed surfaces.
5. Use protective clothing and safety equipment. Always use approved safety
equipment such as: gloves, safety boots, hard hats, safety glasses and ear
protection where necessary.
6. Wear protective clothing that is snug and belted where required.
7. Store tools and other necessary items in the toolbox.
8. Never lift a load without a Load Rating Chart in the cab.
9. Know the load to be lifted.
10. Be alert, physically fit and free from the influences of alcohol, drugs or
medications that might affect the operator's eyesight, hearing, or reactions.
11. Keep people, equipment and material out ofthe work area.
12. Keep a fully charged fire extinguisher and first aid kit in the cab at all times, and
be familiar with how to use these items.
13. Know about movements of other machinery, trucks and personnel at the jobsite.
14. Make sure everyone is in a safe place before moving the boom, forks, load or
outriggers (if so equipped.)
15. Start and stop movements smoothly and swing at speeds that will keep the load
under control.

1-6

[Li"oROUGH TERRAIN FORK LIFT SAFETY Li"o]

[

MANAGEMENT'S RESPONSIBILITIES

1. Ensure operators are competent, physically fit, trained and if required licensed.
2. Have a supervisor at the job site to be responsible for job safety.
3. Crew members given specific safety responsibilities and instructed to report any
unsafe conditions to the supervisor.
4. Supply the weight on the load to be lifted to the operator.
5. Verify that all crewmembers are familiar with OSHA,ANSI B56.6 requirements
as well as instructions in the manuals.

1-7

(itROUGH TERRAIN FORK LIFT SAFETY it)

fi

MAINTENANCE AND REPAIR

1. Practice safe maintenance procedures. Perfonn all maintenance and repairs in

accordance with instructions provided by the manufacturer in the manuals. Also
heed the warnings on the placards and decals on the machine.
2. Always use supports and braces when working on, under or around the machine
or forks.
~.

Shut offthe engine and lockout the machine while working on the machine unless
instructions specifically require the engine to be running.

4. Always make sure the machine is stationary prior to perfonning adjustments or

lubrication.
5. Replace all shields and guards afterperfonning service.
6. Always use a piece of cardboard or paper to search for leaks.
7. When perfonning work on the hydraulic system:
L

Lower the boom to horizontal.

n. Support the boom with supports or braces.

lD. Shut down the engine.
lV. Relieve all pressure before disconnecting lines.

v. Ensure all connections are tight before applying pressure.

VI. Repair or replace any damaged line, hose or fitting before
applying pressure.
8. Always have tires serviced and mounted by a qualified person with the proper
tools and guards.
9. Always use an inflation cage during tire inflation.
10. Onlyperfonn welding on the machine with approval from the manufacturer.

1-8

[itROUGH TERRAIN FORK LIFT SAFETY it]

fi

OPERATION SAFETY

1. Always inspect the machine daily. Check for leaks, worn hoses, loose belts,
broken structures, and loose or missing bolts. Repair or replace any worn,
damaged or leaking parts prior to operation ofthe machine.
2. Only inspect the coolant level when the engine and coolant are cool.
3. Be sure that all guards and screens are secure and in the proper place.
4. Inspect for and clear the work area of any obstructions that could interfere with
proper machine operation. Any obstructions that cannot be cleared should be
clearly marked and avoided during operation.
5. Refueling:
L

Always stop the engine before refueling the machine.

n. Fill the fuel tank outdoors.

m. Handle fuel with care, as it is highly flammable. Do not refuel
IV.

the machine while smoking or near open flames.

Always clean up spilled fuel.

6. Make sure the machine and access system is clean and free of dirt, oil, grease or
debris.
7. When getting on and off the machine, face the machine, use the steps and
handrails provided, and always maintain a three point contact.
8. Always remain completely inside the cab enclosure while operating the machine.
9. Always wear the seat belt while operating the machine.
10. Always completely lower the boom with the forks resting on the ground before
any work is performed on or around the machine.
11. Do not operate the machine while people are under or near an elevated boom
whether the boom is loaded or unloaded. Falling objects from the forks or
attachment may cause serious injury or death.

1-9

(L'tROUGH TERRAIN FORK LIFT SAFETY L't]

fi

OPERATION SAFETY

12. Maintain an appropriate clearance from electrical power lines. See the chart
below for minimum safe approach distances.
Minimum Safe Approach Distance
Power Line Vohage
Required Clearance
o to 50 kV
10 ft. (3.00 m)
50 to 200 kV
15 ft. (4.60 m)
200 to 350 kV
20 ft. (6.10 m)
350 to 500 kV
25 ft. (7.62 m)
500 to 750 kV
35 ft. (10.67 m)
750 to 1000 kV
45 ft. (13.72 m)
13. Lifting Loads:
Using the load chart, confirm that the load is within the rated
capacity ofthe machine for the required configuration.
11 Level the machine using the level gauge before lifting loads. Use
the sway control to level the machine only when the boom is at
horizontal or lower. Using the sway control with the boom above
horizontal may cause the machine to overturn.
m. Verify that the load is secured on the forks before performing a lift.
Rearrange the load ifnecessary.
IV, Before lowering a maximum load, always retract the boom
completely.
v. Use proper attachments, such as a truss boom, to lift suspended
loads.
1.

14. lfthe load to be lifted exceeds the capacity ofthe machine for the given
configuration:
1. Move the machine closer to the load so that the weight of the load
will be within the allowable load chart specifications.
11 Divide the load into smaller pieces.
m. Get a larger machine capable ofhandling the load.

15. Always move a load so that you have maximum machine stability and visibility is
not obstructed. Keep the boom at or below horizontal, with the load close to the
ground.
16. Tilt the forks back towards the machine slightly during travel to ensure stability of
the load.

1-10

(i"!\,ROUGH TERRAIN FORK LIFT SAFETY i"!\,]

fi

OPERATION SAFETY

17. Inspect the path oftravel before beginning movement. Avoid holes and dropoffs.
18. Traveling on slopes!grades.
1. Ascend and descend slowly and with caution.
n. When loaded, always travel with the load uphill.
m. When unloaded,travel with the attachment downhill.
IV. Avoid turning, travel straight up and down.
19. Always position all wheels in line with the machine before switching the steering
mode.
20. Always position the machine and set the park brake before lifting a load.
21. Do not allow riders on the machine or forks.
22. Do not transport or lift personnel into position with this forklift.
23. When leaving the operator's station:
1. Place the directional controls in neutral.
11. Apply the parking brake.
m. Lower the attachment to the ground.

1-11

SECTION 2
GENERAL SAFETY

2-1

TABLE OF CONTENTS

SECTION 2 - GENERAL SAFETY

General Safety Procedures

2-3

Jump Starting

2-8

Proper Load Chart Use

2-9

2-2

GENERAL SAFETY PROCEDURES

SAFETY ALERT SYMBOL

Stop and take time to read ALL safety alert messages. Follow
all safety messages to avoid injury and/or death.

~WARNING
ALWAYS wear eye protection and personal safety equipment.

THE OPERATOR
The operator must be fully trained and qualified to operate this
machine.
Before start-up or machine operation, the operator must learn
the location and purpose of the:

1.
2.
3.
4.

Controls
Instruments
Indicator lights
Safety and instruction labels

ACCIDENT PREVENTION
Use protective clothing and safety equipment. Always use
approved safety equipment such as: gloves, safety boots,
safety hard hats, goggles and ear protection when necessary.
Wear protective clothing that is snug and belted where
required.

FIRE PREVENTION/FIRST AID

Install a first-aid kit and fire extinguisher in the operator's cab.

KEEP THE FlRST-AID KIT and FIRE EXTINGUISHER

properly maintained. Follow the instructions provided with the
first-aid kit and fire extinguisher.

2-3

GENERAL SAFETY
GENERAL SAFETY PROCEDURES

WELDING PRECAUTIONS

& CAUTION
Any unauthorized welding can cause structural failure or
possible personal injury. DO NOT weld on any structural
member. All unauthorized welding will void the warranty.

HAND HOLDS AND STEPS

&

WARNING

Slips and falls can cause serious injury.

When getting on and off the machine, always maintain a three
point contact with steps and hand rails while facing the machine.
DO NOT use the steering wheel or any other controls as handrails.
NEVER jump on or off the machine.
Be careful of slippery conditions on platforms, steps and
handrails when getting on and off the machine.

ALWAYS shut off the engine before leaving the operator's station.

REFUELING

LL, WARNING
Fires can cause death or severe personal injury.
Handle fuel with care. It is highly flammable. DO NOT refuel the
machine while smoking or when near open flames or sparks.

ALWAYS stop the engine before refueling the machine. Fill the
fuel tank outdoors.
Prevent fires by keeping the machine clean of trash, grease and
debris. ALWAYS clean up spilled fuel.

2-4

GENERAL SAFETY PROCEDURES

HYDRAULIC SAFETY

~WARNING
Hot hydraulic oil can cause severe burns. DO NOT work on
the hydraulic system if the oil temperature exceeds
120 degrees F. (49 degrees C).
Before ANYONE works on the hydraulic system:

1.
2.
3.
4.
5.

Lower the boom to the horizontal position.

Support the boom to avoid unintentional lowering.
Shutdown the engine.
Remove the key from the ignition.
Clean the area around the oil reservoir cap (A).

FLUIDS UNDER PRESSURE

ffi WARNING
Escaping fluid under pressure can penetrate the skin and can
cause serious personal injury.
Use a piece of cardboard or paper to search for leaks.
DO NOT use hands. Before disconnecting hydraulic lines, be
sure to relieve all line pressure. Before applying pressure to the
system, be sure that all connections are tight. DO NOT apply
pressure to a damaged line, hose or fitting.
If injured by escaping fluid, see a doctor at once. Proper
medical treatment must be administered immediately. A serious
infection or reaction can result without proper medical
treatment.

SERVICE TIRES SAFELY

ffiWARNING
An improperly mounted over-pressurized tire can result in tire
explosion causing possible personal injury. An inflation cage
or other safety device must be used during tire inflation.

DO NOT attempt to mount a tire unless you have the proper

equipment and experience to perform the job. If you do not
have the proper qualifications to perform the job have your
dealer or qualified repair service perform the repair.

2-5

GENERAL SAFETY
GENERAL SAFETY PROCEDURES

LL

CAUTION

USE SEAT BELT

Always wear the seat belt while operating the machine to
reduce the risk of personal injury.

&

CAUTION

PRACTICE SAFE MAINTENANCE

...l
~

{,

Unauthorized modifications to the machine may impair the

safety, machine function and/or affect machine life.

<
i

ALWAYS use a safety support or brace when working on,

under, or around the machine or forks.
DO NOT adjust or lubricate the machine while it is in motion.
SHUT OFF the engine and LOCKOUT the ignition while
working on the machine unless maintenance instructions
require the engine to be running.
REPLACE all the shields and guards after servicing.
NEVER use the machine as a platform for lifting personnel.

&

CAUTION

BOOMSAFETY
DO NOT enter the DANGERAREA under or around the boom
when the forks are off the ground or while the engine is running.
(See diagram at right for DANGERAREA).

Serious personal injury could result if the boom should

unexpectedly drop.
Before ANY work is performed in the DANGER AREA
the boom must be COMPLETELY lowered and the forks
must be resting on the ground.

...'"c:

2-6

~.

r;.

\OJ
'-'

'"'::1

'",..

......

""

GENERAL SAFETY PROCEDURES

AVOID ELECTRICAL POWER LINES

it DANGER
REQUIRED CLEARANCE FOR NORMAL VOLTAGE IN
OPERATION NEAR HIGH VOLTAGE POWER LINES AND
OPERATION IN TRANSIT WITH NO LOAD AND BOOM
OR MAST LOWERED.

Normal Voltage, kV
(Phase to Phase)

Minimum Required
Clearance, ft. (m)

Operation Near High Voltage Power Lines

1050
Over 50 to 200
Over 200 to 350
Over 350 to 500
Over 500 to 750
Over 750 to 1000

10(3.05)
15(4.60)
20(6.10)
25(7.62)
35(10.67)
45(13.72)

Operation in Transit With No Load and Boom Lowered

100.75
Over 0.75 to 50
Over 50 to 345
Over 345 to 750
Over 750 to 1000

4(1.22)
61.83)
10(3.05)
16(4.87)
20(6.10)

it WARNING
Always remain completely inside the cab enclosure while
operating the machine.

it WARNING
Never operate this machine under the influence of drugs,
alcohol and/or medication which can cause drowsiness.

LLWARNING
Never transport or lift personnel into position with this
forklift. It is not designed as a personnel lifting device.

2-7

GENERAL SAFETY
JUMP STARTING
Location: The battery is located under the fuel tank / battery
box cover (A).

JUMP STARTING
Jump starting at the battery or battery replacement is required
when the battery is discharged to the point where the battery
will not crank the starter.

&

WARNING

Battery posts, terminals, and related accessories contain lead

and lead compounds, chemicals known to the State of California
to cause cancer and reproductive harm.
Batteries also contain other chemicals known to the State of
California to cause cancer.
Wash hands after handling.

&

WARNING

Never jump start the machine directly to the starter or the starter
solenoid. Serious injury or death could result from the machine
moving forward or backward.

&

WARNING

To avoid personal injury when jump starting with another

machine, be certain that the machines are not touching. Never
jump start a frozen battery as it will explode. Keep sparks and
flames away from the battery. Lead acid batteries generate
explosive gases when charging. Wear safety glasses when
working near batteries.
The booster battery must be a 12 volt type. The machine used
for jump starting must have a negative ground electrical system.
To jump start the machine, proceed as follows:
1. Connect the positive (+) jumper cable to the positive
(+) post of the discharged battery.
2. Connect the other end of the same jumper cable to the
positive (+) post of the booster battery.
3. Connect one end of the second jumper cable to the
negative (-) post of the booster battery.
4. Make the [mal cable connection to the engine block or
the furthest ground point away from the battery.
5. Start the engine.
6. Remove the jumper cables in the reverse order of their
connection (i.e. negative cable ground connection first, etc.)

2-8

LL

GENERAL SAFETY

LL

PROPER LOAD CHART USE

ffiWARNING
NEVER raise a load and drive to position it. This can cause the
machine to turnover. When placing a load, always move a
loaded machine with the boom angle indicator (B) at 0 degrees
or less. When the machine is as close as possible to where the
load needs to be placed, set the parking brake, raise the load,
then place the load into position.

The load chart shows the operating limits of a properly

maintained and operated machine. To use the load chart the
operator must know the weight of the load and how far "out"
and "up" it is to be placed. If the load is heavier than stated on
the load chart, three options can be used:

1. Move the machine closer to the load so that the weight of

the load will fall within the load chart specifications.
2. Divide the load into smaller pieces so that each piece falls
into load chart specifications.
3. Get a larger machine capable of handling the load within
specifications.

2-9

GENERAL SAFETY
PROPER LOAD CHART USE
TH644C
TEREX HANDLERS
P.O. BOX 790
455 NORTH SUPERIOR AVENUE
BARAGA, MICHIGAN 49908
PHONE 906-353-6675
FAX 906-353-754.3
MANUFACTURER'S RECOMMENDED
CAPACITY IS PER ANSI B56.6
STABILITY TESTS USING STANDARD
HOMOGENEOUS CUBES 4x4x4 FT.
(1.22x1.22x1.22 METERS). LOAD
CAPACITIES AT 24 INCH
(.61 METERS) LOAD CENTER WITH
STANDARD FORK FRAME.
RATED LIFT CAPACITIES SHOWN ARE
WITH MACHINE ON A FIRM, LEVEL
SURFACE WITH UNDAMAGED,
PROPERLY INFLATED TIRES.

FEET 28
24
20
16
12
8
4
METER- (8.54) (7.32) (6.10) (4.88) (3.66) (2.44)(1.22)

4
8
12
16
20
(1.22) (2.44) (3.66) (4.88)(6.10)

48
(14.64)

I--H--f--+-+-+-+-++++++---

44
( 1 3.42)

r-t--r-r-r-t--t--t--t--V

40
(1 2.20)

r-t--t--r-r-t--t--y

36
(10.98)

r-t--t--t--r-V

LIFT CAPACITY
CHART / TH644C

+-+-+-+-+,1

32
(9.76)

H-++-I

28 -'--'-"---L'
(8.54)
24
(7.32)
20
(6.10)
16
(4.88)
12
(3.66)
8
(2.44)

LOAD LIMITS /

HORIZONTAL BOOM

LAST FULLY VISIBLE

RETRACTED
A) LETIER VISIBLE
Bl LETIER VISIBLE
C LETIER VISIBLE

4
(1.22)

LETIER
6,000 LBS
4,000 LBS
3,000 LBS
2,000 LBS

4
(1.22)

I--f'--,,.-,---.-r-r-r-r-r-r-r-r-r-r-l-++-+-+-+--l--l--H--l--f

FEET 28
24
20
16
12
8
4
METER- (8.54) (7.32) (6.10) (4.88) (3.66) (2.44)(1.22)

PIN 2-1274

4
8
12
16
20
(1.22) (2.44) (3.66) (4.88) (6.10)

TH842C
TEREX HANDLERS
P.O. BOX 790
455 NORTH SUPERIOR AVENUE
BARAGA, MICHIGAN 49908

PHONE 906-353-6675

FAX

906~353-7543

MANUFACTURER'S RECOMMENDED
CAPACITY' IS PER ANSI 856.6
STABILITY TESTS USING STANDARD
HOMOGENEOUS CUBES 4x4x4 FT.

(1.22x1.22x1.22 METERS). lDAD

CAPACITIES AT 24 INCH
(.61 METERS) LOAD CENTER WITH

STANDARD FORK FRAME.

RATED LIFT CAPACITIES ARE WITH :

FEET 28
24
20
16
12
8
4
METER- (8.54) (7.32) (6.10)(4.88) (3.66) (2.44) (1.22)

4
8
12
16
20
(1.22) (2.44) (3.66) (4.88)(6.1O)

48
(14.64)

LIFT CAPACITY
CHART f TH842C

44
(13.42)
40
(12.20)
36
(10.98)
32
(9.76)
28
(8.54)
24
(7.32)

MACHINE ON A FIRM, LEVEL

SURFACE WITH UNDAMAGED.

20
(6.10)

PROPERLY INFLATED CALCIUM

CHLORIDE SOLUTION FILLED TIRES
OR OPTIONAL FOAM FILLED TIRES.
REAR AXLE LOCK-UP ENGAGED.

16
(4.88)
12
(3.66)

LOAD UMITS

HORIZONTAL BOOM

LAST FULLY VISIBLE

RETRACTED
LmER VISIBLE
8 LmER VISIBLE
elmER VISIBLE
o LETTER VISIBLE

Al

LETTER
8.000 L8S
6.000 LBS
4,000 lBS
3,000 LBS
2,000 las

8
(2.44)
4
(1.22)

(1.22)

PIN 3-1483

I--I-'-,,-.-.-.-.-.--.-.-.-.--.--.++++++++++-+-I

FEET 28
24
20
16
12
8
4
METER- (8.54) (7.32) (6.1O)(4.8B) (3.66) (2.44) (1.22)

2-10

4
8
12
16
20
(1.22) (2.44) (3.66) (4.88) (6.10)

it GENERAL SAFETY it
PROPER LOAD CHART USE
TH844C
TEREX HANDLERS

FEET-28
24
20
16
12
8
4
METER- (8.54) (7.32) (6.10) (4.88) (3.66) (2.44)( 1.22)

4
8
12
16
2D
(1.22)(2.44) (3.66) (4.88)(6.10)

P.O. BOX 790

455 NORTH SUPERIOR AVENUE
BARAGA. MICHIGAN 49908

PHONE 906-353-6675
FAA 906-353-7543

MANUFACTURER'S RECOMMENDED
CAPACITY IS PER ANSI 856.6
STABILITY TESTS USING STANDARD
HOMOGENEOUS CUBES 4x4x4 FT.

(1.22x1.22x1.22 METERS). LOAD

48
(14.64)

f-f-f-f--j-j-l-l-l--t--t--l-,/

44
( 1 3.42)

f-f-f--J-j,-lc-1-l--t--l-/

4D
(12.20)

f-f--Jf--Jc-1-jc-1--Y

36
( 10.98)

f-f-f--j-j-/

+-+--H-+-/

CAPACITIES AT 24 INCH
(.61 METERS) LOAD CENTER WITH

32
(9.76)

STANDARD FORK FRAME.

28
(8.54)

RATED LIFT CAPACITIES ARE WITH

MACHINE ON A FIRM, LEVEL

SURFACE WITH UNDAMAGED,

PROPERLY INFLATED CALCIUM
CHLORIDE SOLUTION FILLED TIRES
OR OPTIONAL FOAM FILLED TIRES.

REAR AXLE LOCK-UP ENGAGED.

LOAD LIMITS ! HORIZONTAL 800M

LAST FULLY VISIBLE LETTER
RETRACTED ~ 8,000 LBS

(A) LETTER VISIBLE =

LIFT CAPACITY
CHART / TH844C

H-j--t-r

24
(7.32)
20
(6.10)
16
(4.88)
12
(3.66)

8
(2.44)
4
(1.22)

6,000 l.8S

S) LEDER VISIBLE = 4,000 LBS

C) LEITER VISIBLE = 3,000 LBS
D) LETTER VISIBLE = 2,000 LBS

4
(1.22)

H-l-,.,.-',..--r-r-r,-~,---,-",,-t-t-t++++++-t--H

FEET- 28
24
20
16
12
8
4
METER- (8.54) (732) (6.10)(4.88) (3.66) (2.44) (1.22)
P/N 2-1286

2-11

4
8
12
16
20
(1.22) (2.44) (3.66) (4.88) (8.10)

SECTION 3
CONTROLS AND INSTRUMENTS

3-1

TABLE OF CONTENTS

SECTION 3 - CONTROLS AND INSTRUMENTS

Operator's Compartment

3-3

Joystick Control Functions

3-4

Joystick Control Functions (Button Pushed)

3-5

Service Brakes

3-6

Low Service Brake Pressure Light

3-6

Parking Brake

3-7

Frame Sway Control

3-8

Gauges

3-9

Hydraulic Pump Destroke Button

3-9

Steering

3-10

Transmission

3-10

FrontAxleDifferential Lock

3-11

3-2

fi

OPERATOR'S COMPARTMENT

1. Accelerator Pedal

8.

Hounneter

15. Parking Brake Switch

22. Heater Switch

2. Joystick 4-way Controller

9.

Gauges

16. Pump Off Button

23. Plug / Turn Signal Wires

3. Transmission Control Lever

10. Machine Level Gauge

17. Front Wiper Switch

24.

Interior Rear View Mirror

4. Steering Selector

11. Plug /12 Volt Access.

18. Ignition Switch

25.

Frt.Axle Differential Lock

5. Service Brake Pedal

12.

19. Auxiliary Hydraulics

26. Low Brake Press. Light

6. Rear Wiper Switch

13. Frame Level Switch

20.

Steering Wheel

27. Work Lights Switch

7. Load Chart

14.

21.

Headlight Switch

Seat

Seat Belt

13

20

22

12
18--Tn~~__-L~~

16

26

15 18 27 21 17 6

8 --+-1-+----4:

4~Fl~~~~~$

5
25

FORK TILT RELAY &

4WAY ELECTRIC TILT VALVES &
AUXILIARY HYDRAULICS &
SERVICE BRAKE LIGHTS &
TRANSMISSION CUT-OUT RELAY &
SWAY CONTROL (TH636C ONLY)
ELECTRIC ETHER AID &
12 VOLT ACCESSORY PLUG
FRONT AXLE DIFFERENTIAL L @

FUSE PANEL VIEW

3-3

14

CONTROLS AND INSTRUMENTS

fi

JOYSTICK CONTROL FUNCTIONS

A - BoomDown

B - BoomUp

t(3
~
B

C - Boom Out

D - BoomIn

D ....

... C

H,t/E
~ ~ "'G
A

E - Boom Down and Out

F - Boom Up and In

D ...
/

G - Boom Up and Out

(3

f==E~

H - Boom Down and In

3-4

...

CONTROLS AND INSTRUMENTS

fi

JOYSTICK CONTROL FUNCTIONS (BUTTON PUSHED)

A - TiltDown
B - TiltBack

3-5

CONTROLS AND INSTRUMENTS

SERVICE BRAKES
The brake pedal is the operator's control for the service brakes.
Pushing the service brake pedal (A) activates the service
brakes for all four wheels.
The brakes should be applied during normal operation to stop
machine movement.

LOW SERVICE BRAKE PRESSURE LIGHT

LL WARNING
Insufficient hydraulic pressure to the service brakes may result
in increased stopping distances causing possible injury or
death and/or damage to the machine or property.
The illumination of the "LOW BRAKE PRESSURE" light (B)
when the machine is running indicates this potentially hazardous condition. Should this condition ever exist, discontinue
use of the machine immediately. Contact a qualified service
technician to resolve this problem.

3-6

CONTROLS AND INSTRUMENTS

PARKING BRAKE

& WARNING
Failure to set the parking brake before leaving the machine may
result in unintended machine movement and possible injury or
death and/or damage to the machine or property.
The parking brake should be engaged anytime the operator
gets off the machine. To engage the parking brake, toggle the
parking brake switch (C) forward. The red light in the upper
part of the parking brake switch should illuminate.

3-7

CONTROLS AND INSTRUMENTS

FRAME SWAY CONTROL

&

WARNING

Always ensure that the machine level indicator (B) is at zero (0)
degrees before raising the boom. Raising the boom with an
unlevel machine may cause the machine to overturn, resulting
in injury or death.

LLWARNING
Use the frame sway control to level the machine only when the
boom angle indicator is at 0 degrees or less. Using the frame
sway control when the angle indicator is more than 0 degrees
may cause the machine to overturn, resulting in injury or death.

The frame sway control (A) is located on the forward side of

the right arm rest. The frame sway control is used in conjunction
with the machine level indicator (B) located in the center ofthe
cross support that the interior rear view mirror is mounted on.
The sway control switch is either toggled to the left or right
depending on the particular requirement.

3-8

GAUGES

The following gauges are used to monitor the

machine:
1 - Fuel Level
2 - Water Temperature, Engine
3 - Oil Pressure, Engine
4 - Oil Temperature, Powershift Transmission
5 - Oil Pressure, Powershift Transmission
6 - Voltmeter

HYDRAULIC PUMP DESTROKE BUTTON

&

DANGER

Depressing the pump de stroke button while operating the machine

will cause an immediate loss of hydraulic power, possibly
creating a very dangerous situation. Hydraulic functions that
will be affected are: FORK TILT, LIFT, BOOM EXTEND
and RETRACT, PARKING BRAKE and SWAY. None of these
functions will operate as long as the button is depressed. The
service brakes will continue to function if the accumulator backup
has a sufficient gas charge.

The pump destroke button (C) is the black push button

switch located on the dash panel.
o

For example, when starting the machine for the first time on a 30
degree F. day, depress the pump destroke button while starting
the engine. Continue to depress the button for 15 to 20 seconds
after the engine starts. Once the engine is running smoothly,
release the button and the hydraulic pump will engage.
Depressing the pump destroke button will not be required for
all other starts of the day, unless the engine has been allowed
to cool completely.

3-9

STEERING
In addition to the steering wheel, the machine has another
steering control, the steering selector switch.

The steering selector switch (A) is a three-position switch.

The three positions are: 4-wheel, 2-wheel , and oblique.
Switch positions are selected and function as follows:

4-WHEEL

Handle rotated forward

2-WHEEL

Handle directly centered

OBUQUE(CRAB)

Handle rotated rearward

it CAUTION
Before changing steering selections, make sure all four wheels
are in line. Failure to align the wheels to the proper settings
before changing steering positions may cause haphazard steering.
This may result in injury to personnel and/or damage to the
machine or property.

TRANSMISSION
The transmission control (B) has one lever that controls both
directional and speed requirements. It is located on the left side
of the steering column.
To shift into Forward gear gently pull the lever toward you and
move the lever upward.
To shift into Neutral move the lever to the center position.
To shift into Reverse gear gently pull the lever toward you and
move the lever downward.
To shift into a lower speed rotate the lever clockwise.
To shift into a higher speed rotate the lever counter-clockwise.
When shifting the transmission from forward to reverse while
the machine is in motion the transmission control (B) must be
in 1st or 2nd gear only.

Forward lIst
Forward I 2nd
Forward/3rd

Low speed/High torque

Medium speed/Medium torque
High speed/Low torque

3-10

FRONT AXLE DIFFERENTIAL LOCK

The front axle differential lock switch (C) is located near the
operator's left foot. It is a standard feature on all TH842C &
TH844C models. The purpose for this device is to lock the
front axle differential to gain added traction under certain
conditions.
The front axle differential lock switch must be depressed and
held in order to activate the axle differential lock. Releasing the
switch disengages the axle differential lock.
Use this differential lock when you are unable to drive through
certain types of terrain such as sand, mud, snow, etc.

iLWARNING
Always bring the front tires to a complete stop before engaging
the front axle differential lock.
Failure to stop the front tires before engaging the front axle
differential lock may result in damage to the front axle.

Never steer the front tires while using the front axle
differential lock.
Steering while the front axle differential lock is engaged may
result in damage to the front axle.

3-11

SECTION 4
OPERATION

4-1

TABLE OF CONTENTS

SECTION 4 - OPERATION

Operation And Safety Guidelines

4-3

Before Starting The Engine

4-4

Starting The Engine

4-9

Before Operating The Forklift

4-11

Transporting A Load

4-15

Placing A Load

4-17

4-2

OPERATION
OPERATION AND SAFETY GUIDELINES

ffi WARNING

Your safety and the safety of those around you depends upon you using care and judgement in the operation of this equipment.
Know the positions and functions of all controls before attempting to operate this machine. All equipment has limitations.
Understand the speed, braking, steering, stability, and load chart characteristics of this machine before operating. Read the
Operator's Manual and ask questions of your supervisor until you know the machine's limitations. It is very important to read,
fully understand, and follow these operation and safety guidelines.
1. DO NOT operate this machine while people are under or near an elevated boom whether the boom is loaded or unloaded.
Falling objects from the forks or attachment may cause serious injury or death.
2. ALWAYS remain completely within the cab enclosure while operating this machine. Falling debris can cause serious
personal injury or death.
3. NEVER extend a load beyond the load chart band. Machine tum over, component damage, injury or death could occur.

4. ABSOLUTELY NO RIDERS SHOULD BE ALLOWED ON TIllS MACIllNE OR ATTACHMENTS.

5. NEVER lower a maximum load before retracting it. Machine turn over, component damage, injury or death could occur.
6. INSPECT and clear the working area of any obstructions (rocks, fence, wire, etc.) that could cause machine damage. If
obstructions cannot be cleared, mark the obstructions with a stake or other marker that will be clearly visible to the operator.
7. DO NOT check the engine coolant level if the engine has recently been run. Injury could occur from escaping hot
pressurized coolant.
8. ALWAYS wear the seat belt when operating this machine.
9. ALWAYS inspect the machine daily. Check for leaks, worn hoses, loose belts, or anything out of the ordinary. Repair
and/or replace any worn, damaged or leaking parts immediately. Failure to do so can cause injury or death.
10. CHECK to be sure that all guards and screens are secure and in their proper place.
11. CHECK to be sure that all safety devices such as parking brake, service brake, level gauge, neutral start safety switch,
back-up alarm, and hom are functioning properly. Always make sure mirror is adjusted properly.
12. DO NOT travel on terrain or in dangerous areas that could cause the machine to tip over.
13. DO NOT attempt to start the engine by towing or pushing. Damage to the powershift transmission could result.
14. CARRY A LOAD so that you have maximum machine stability and visibility is not obstructed.
15. ALWAYS level the machine as indicated on the machine level indicator before raising boom. Raising the boom with an
unlevel machine may cause the machine to overturn causing injury or death.
16. USE the frame sway control to level the machine only when the boom position is horizontal or lower. Using the frame
sway control when the boom is higher than a horizontal position may cause the machine to overturn causing injury or death.
17. DO NOT depress the pump destroke button while operating the machine. This button should be used only during cold start
ups. Depressing the button while operating the machine will cause an immediate loss of hydraulic power that will
affect fork tilt, lift, boom extend and retract, sway and all other hydraulic functions. Brakes will continue to function if
the accumulator backup has a sufficient gas charge.

4-3

OPERATION
BEFORE STARTING THE ENGINE

ffiWARNING
DO NOT perform any procedures in this section, "BEFORE
STARTING ENGINE", unless the machine's engine is turned off
and the parking brake is applied and the engine is cool. Failure
to do so may result in serious injury, death or damage to the
equipment.

Walk around the machine and check for any parts that are
missing, worn, damaged, or leaking. Repair and/or replace
damaged parts.

John Deere

CHECK ENGINE OIL LEVEL

Location:

Dipstick (A).

To Check:

The machine must be level.

Check when the engine is cold.
Remove the dipstick from the engine.
Oil should read between the add and the
full marks.
Replace the dipstick.

NOrE:

Refer to page 5-24 of this manual for the proper oil

specifications and capacities.

4-4

OPERATION
BEFORE STARTING THE ENGINE

&

WARNING

DO NOT check the coolant level if the engine has been run
recently. Injury may occur from hot escaping pressurized coolant.

CHECK ENGINE COOLANT LEVEL

Location:

Tank cap (B).

To Check:

Coolant should be visible in the top of the tank.

NOTE:

If coolant needs to be added. fill with a 50150 low silicate

antifreeze mix (-34 degrees F) with an approved nitrite or
nitrite-molybdate based Supplemental Coolant Additive. This
additive is required to prevent engine damage due to cylinder
liner erosion and pitting. Do not use high-silicate automotive
antifreeze or cooling system damage due to silicate dropout
can occur.
Contact your local John Deere dealer for an approved
antifreeze and Supplemental Coolant Additive.

John Deere

OPEN WATER SEPARATOR

Location:

Water separator filter (C).

To Open:

Shut off the engirie.

Turn the valve on the bottom of the water
separator filter counterclockwise.
Drain until clear fuel is present.
Retighten the valve.

NOTE:

If more than 2 oz. of fuel are drained, refilling of the

filter is required to prevent hard starting. Refer to filter
replacement on page 5-19 of this manual.

4-5

BEFORE STARTING THE ENGINE

CHECK HYDRAULIC OIL LEVEL

Location:

Sight glass (A). Behind the rear panel.

To Check:

Move the machine to level ground.

Level the frame.

Completely retract the boom.
Position the forks level.
Lower the boom to the ground.
Oil should be visible 112 way in the sight glass.
NOTE:

Refer to page 5-24 of this manual for the proper oil

specifications and capacities.

INSPECT AIR CLEANER

Location:

Air cleaner assembly.

To Check:

Remove the rear of the canister, remove the

elements.

Guideline:

Inspect the filter elements for contamination.

Inspect the tubing going to the filter body
from the engine for cracks or leaks. Inspect
the air cleaner body and gaskets for cracks
or leaks.

&

WARNING

Due to various operating conditions, the air cleaner's

elements should be changed as often as the environment
requires.

4-6

BEFORE STARTING THE ENGINE

CHECK TRANSMISSION OIL LEVEL

Location:

Dipstick (B)

To Check:

Level the machine.

Place the transmission control in neutral.

Set the parking brake.
The engine must be running to check.
Bring the transmission oil temperature to a
minimum of 180 degrees F.
Remove the dipstick. The oil level should
be between the add and full marks.
Replace the dipstick.
NOTE:

Refer to page 5-24 of this manual for the proper oil

specifications and capacities.

LLWARNING
Serious personal injury can result from a loose or damaged fan.
Never pry on a fan because this may cause fan damage and/or
failure.

CHECKENGINE FAN
To Check:

Visually inspect the cooling fan (C) for cracks,

loose bolts, bent or loose blades etc.

4-7

OPERATION
BEFORE STARTING THE ENGINE

CHECK TIRE FOR PROPER INFLATION

Location:

Wheel ends.

To Check:

Check the tire pressure with the tire cold and a

properly functioning air pressure gauge. Position
the valve stem (A) to the top of the tire.

Setting:

50 PSI.

& DANGER
All tires require a calcium chloride ballast or an optional foam
filling to be operated safely. The loss of ballast can affect
machine stability and cause a rollover hazard resulting in
damage, injury or death.

4-8

OPERATION
STARTING THE ENGINE

& DANGER
Any problems discovered in the steps prior to "BEFORE
STARTING THE ENGINE" should be corrected before the
machine is started.

& DANGER
NEVER attempt to start the machine without being seated in
the operator's compartment, the parking brake switch (B)
toggled forward in the on position and the transmission
control (C) in the neutral position. Attempting to start the
machine from outside the operator's compartment may result in
property damage, serious injury or death.

&

DANGER

If the machine should start with the transmission control lever

(C) in gear, stop operation at once or property damage, serious
injury or death may occur. Have a qualified service technician
repair the machine.

Insert the ignition key in the ignition switch (D). Rotate the key
clockwise until the engine starts. Release the key when the
engine starts.

4-9

STARTING THE ENGINE

LtCAUTION
If the engine fails to start within 30 seconds release the key,
wait at least 2 minutes to allow the starter motor to cool before
trying again. If the engine fails to start after four attempts,
trouble shoot and correct the problem. DO NOT turn the key if
the engine is running. This may cause damage to the starter
motor.

LtCAUTION
Attempting to start the engine by towing or pushing the
machine will result in damage to the powershift transmission
and will not start the engine! It also is an unsafe practice that
could cause personal injury.

4-10

OPERATION
BEFORE OPERATING THE FORKLIFT

~CAUTION
If any gauge reading does not fall within the set tolerances the
machine must be repaired before operation.

Check the dash mounted gauges for logical readings.

(1)

Fuel Level

112 toFuH

(2)

Engine Water Temperature

180F to 200F

(3)

Engine Oil Pressure

40 to 80 PSI

(4)

Transmission Oil Temperature

180F to 200F

(5)

Transmission Oil Pressure

240 to 280 PSI

(6)

Voltmeter

12 to 14 Volts

STANDARD JOYSTICK FUNCTIONS

Operate the joystick controller momentarily in all directions.

H",t/E
o ...

..

Ei"'G

A -Boom Down
B - Boom Up
C - Boom Out

D-BoomIn
Down and Out
Up and In
Up and Out
Down and In

E - Boom
F - Boom
G - Boom
H - Boom

BUTTON DEPRESSED FUNCTIONS

A - TIlt Forward
B - TIlt Back

4-11

BEFORE OPERATING THE FORKLIFT

Operate the frame sway control (A) momentarily right and left.

C--l----i-JlJ.

Check the steering operation by turning the steering wheel (B)

approximately 114 tum in each direction. Ifthe front and rear
tires are not aligned properly, straighten the rear wheels with
the steering selector valve (C) in the "4 wheel" position. Move
the steering selector valve to the "2 wheel" position. Bring the
front tires into alignment with the rear tires. Place the steering
selector valve back into the "4 wheel" position.

4-12

BEFORE OPERATING THE FORKLIFT

LLDANGER
Any problems with the service brakes or the parking brake
found while conducting the daily inspection should be
corrected immediately. Failure to do so could result in injury or
death.

Activate the transmission using the transmission control

lever (D). As soon as the machine starts to move, apply the
service brake pedal. The machine should stop immediately.

Apply the parking brake by toggling the parking brake switch

(E) forward. The red light in the upper part of the parking brake
switch should illuminate. The machine should not be able to be
driven with the parking brake in the forward I on position.
Release the parking brake by toggling the parking brake switch
rearward.

4-13

OPERATION
BEFORE OPERATING THE FORKLIFT

~DANGER
Never operate the machine with a faulty backup alarm. Doing
so may result in serious injury or death.

Place the transmission control lever (A) in reverse. The backup

alarm should sound. If it does not sound, have the backup
alarm repaired immediately.

Check and adjust both the interior rear view mirror (B) and the
exterior right hand mirror (C) if required.

4-14

OPERATION
TRANSPORTING A LOAD

LtWARNING
Transporting a load with the boom extended and the boom
angle indicator arrow (D) reading more than 0 degrees could
cause a roll over hazard.

LtWARNING
At no time should any load be suspended from the forks by
use of chains, ropes, straps etc. If a load must be suspended
the use of a truss (jib) boom is mandatory. Proper rigging
procedures should always be followed.

The forks should always be tilted back slightly during

transportation to ensure stability of the load.

The load should be kept as low to the ground as possible

while traveling. Always move a loaded machine with the boom
angle indicator (D) at 0 degrees or less.

4-15

OPERATION
TRANSPORTING A LOAD

ffiWARNING
Slower speeds should be used whenever transporting a load.
Always bring the machine to a complete stop before reversing
the transmission control lever (A). Failure to do so can result in
damage to the load, the machine and/or bystanders.

Always keep the boom retracted to ensure greater stability.

Always place the load in the center and completely against the
back of the fork frame. By doing so greater stability will result.

IMPORTANT: Never attempt to use the forks and/or attachments for prying wedged or frozen loads free. Damage to the
load, pallet and/or machine could result.

4-16

PLACING A LOAD

Lb

WARNING

Do not sway the machine with the boom angle indicator arrow
(B) at more than 0 degrees. By doing so you could cause a roll
over hazard which may result in injury or death.

Lb

DANGER

Always apply the parking brake by toggling the parking brake

switch (C) forward before lifting and/or placing a load. Failure
to do so could allow the machine to roll over which may result
in injury or death.

&

CAUTION

Always bring the machine to a complete stop before applying

the parking brake (C). Failure to do so will damage the parking
brake disc packs, which may void the axle warranty.

Before placing a load, the frame should be leveled. This can be

done by the use of the switch labeled sway control (D) located
on the forward side of the right armrest. The frame sway
control is used in conjunction with the machine level indicator
(E) located in the center of the cross support that the interior
rear view mirror is mounted on. The sway control switch is
either toggled left or right depending on the particular requirement. Adjust the sway control (D) until the indicator ball on the
level gauge (E) is on the 0 degree mark.

&

WARNING

Always ensure that the machine level indicator (E) is at zero (0)
degrees before raising the boom. Raising the boom with an
unlevel machine may cause the machine to overturn, resulting
in injury or death.

&

WARNING

Use the frame sway control to level the machine only when the
boom angle indicator (B) is at 0 degrees or less. Using the
frame sway control when the angle indicator is more than 0
degrees may cause the machine to overturn, resulting in injury
or death.

4-17

OPERATION
PLACING A LOAD
A

it DANGER
Traveling with a reading of more than 0 degress on the boom
angle indicator arrow (A) may cause a rollover hazard.

Gradually move the 4-way controller towards the letter (B) to

lift the load vertically. Hold the controller back until the
required height has been achieved.

Gradually move the 4-way controller towards the letter (E) to

bring the load DOWN and OUT into final position. Lower the
load until the weight is completely off the forks.

F~
l

Gradually move the 4-way controller towards the letter (F) to

bring the boom UP and IN. This will bring the forks out ofthe
load. Once the forks are clear of the load the boom can be
lowered.

4-18

OPERATION
PLACING A LOAD

TH644C, TH842C, TH844C

When placing a load with the Model TH644C,
TH842C, or the TH844C the rear axle stabilizing
cylinders need to be taken into consideration. When
the boom reaches an angle of 60 DEGREES, all
frame leveling and transmission functions are disabled
and the rear axle stabilizing cylinders become locked.
This DOES NOT affect any boom or fork
functions. To unlock the rear axle stabilizing cylinders
and enable the transmission functions, lower the
boom to a position less than 60 degrees.

4-19

SECTION 5
MAINTENANCE PROCEDURES

5-1

TABLE OF CONTENTS

SECTION 5 - MAINTENANCE PROCEDURES

Service Intervals

5-5

Required Grease Intervals

5-6

Grease Fitting Locations

5-7

Daily Maintenance Procedures

5-8

50 Hour Maintenance Procedures

5-12

100 Hour Maintenance Procedures

5-15

250 Hour Maintenance Procedures

5-17

500 Hour Maintenance Procedures

5-18

750 Hour Maintenance Procedures

5-20

1000 Hour Maintenance Procedures

5-21

2000 Hour Maintenance Procedures

5-23

Filter Guide

5-24

Recommended Fluids And Capacities

5-24

Hydraulic Pressure Settings

5-25
5-2

MAINTENANCE PROCEDURES
GENERAL SAFETY PRACTICES

BEFORE SERVICING
Read the entire Maintenance Procedure Section.
Familiarize yourself with all the safety precautions listed in
Sections 1 & 2.
Pay close attention to all the safety alert symbols.
Be sure you understand the procedures detailed in this
section.
Wear personal protective equipment.
Remove rings and jewelry.
Move the machine to a safe level work place.
Lower the boom and support all raised equipment.
Shut down the machine.
Remove the key from the ignition.
Be careful not to spill fuels and lubricants.
Do not fill or refuel the fuel tank while the engine is running or
hot. Doing so could cause a fire and/or an explosion.
Do not smoke while refueling or working with fuel to avoid a
fire and/or explosion.
IMPORTANT! Always clean up spilled fuel and/or lubricants
to avoid polluting the earth.

5-3
------------------------------------"--

..

MAINTENANCE PROCEDURES
GENERAL SAFETY PRACTICES

HYDRAULIC SAFETY

&

WARNING

Hot hydraulic oil can cause severe burns. DO NOT work on

the hydraulic system if the oil system temperature exceeds
120 degrees F. (49 degrees C.)

Before ANYONE works on the hydraulic system:

1.
2.
3.
4.
5.

Lower the boom to the horizontal position.

Support the boom to avoid unintentional lowering.
Shutdown the engine.
Remove the key from the ignition.
Clean the area around the oil reservoir cap (A).

FLUID UNDER PRESSURE

LLWARNING
Escaping fluid under pressure can penetrate the skin and can
cause serious personal injury.
Use a piece of cardboard or paper to search for leaks.
DO NOT use hands! Before disconnecting hydraulic lines, be
sure to relieve all line pressure. Before applying pressure to the
system, be sure that all connections are tight. DO NOT apply
pressure to a damaged line, hose or fitting.
If injured by escaping fluid, see a doctor at once. Proper
medical treatment must be administered immediately. A
serious infection or reaction can result without proper
medical treatment.

WELDING PRECAUTIONS

LLWARNING
DO NOT weld on any structural member. Any unauthorized
welding can cause structural failure or possible personal
injury. All unauthorized welding or repair procedures will
void the machine warranty.

Before performing any authorized welding, be sure to disconnect the positive lead from the battery. Properly attach the
ground cable ofthe welder to the frame member that is being
welded. Failure to do so can cause electrical system damage.

5-4

MAINTENANCE PROCEDURES
SERVICE INTERVALS
DAILY
CHECK ENGINE OIL
CHECK COOLANT LEVEL
CHANGE HYDRAUUC
RETURN FILTER ELEMENT

CHANGE ENGINE OIL & FILTER

INSPECT ALTERNATOR BELT
ENGINE VALVE ADJUSTMENT
CHANGE DIFFERENTIAL
OIL (AXLE)
REPLACE FUEL FILTERS

50Hrs.

lOOHrs.

250Hrs.

.* .*
.*

OPEN WATERSEPERATOR
CHECK TIRE INFLATION
FLUSH AND PRESSURE TEST
COOLING SYSTEM
CHECK TRANSMISSION OIl.
REPLACE TRANSMISSION
OIL & FILTER

CHECK AXLE OIL LEVELS

CHANGE PLANETARY
REDUCTION OIL (AXLE)
INSPECT AIR CLEANER
AND AIR CLEANER SYSTEM
CHECK HYDRAUUC OIL LEVEL
CHECK HYDRAULIC
RETURN FILTER ELEMENT

750 Hrs.

COOLANT CONCENTRATION
CHECK ENGINE FAN

500 Hrs.

lOOOHrs.

2000 Hrs.

.*

**

.* .**

.*

For procedures to perform the above listed items turn to the following pages: 5-8 thru 5-23.

*
**

***

For initial break-in period only.

For initiall 00 hours only.
John Deere engines require valve adjustment every 2000 hours only.

5-5

MAINTENANCE PROCEDURES
REQUIRED GREASE INTERVALS

LOCATION

DAlLY

50Hrs.

SMALL BOOM ROLLERS (4)

BASE END TILT CYLINDER

HEAD END TILT CYLINDER
FORK FRAME PNOT PIN (2)
HEAD END LIFT CYLINDER (2)
BASE END LIFT CYLINDER (2)

FRONT DRIVESHAFT (3)

REAR DRIVESHAFT (3)
BASE END SWAY CYLINDER (2)
HEAD END SWAY CYLINDER (2)
BOOM PIVOT (2)

REAR AXLE TRUNIONS (4)

FRONT AXLE TRUNIONS (4)
FRONT AXLE PNOT (2)
REAR AXLE PIVOT (2)
MIDDLE BOOM ROLLERS (4)
BASE END REAR LOCK UP
CYLINDER (2)
HEAD END REAR LOCK UP
CYLINDER (2)

250Hrs

5-6

500Hrs.

MAINTENANCE PROCEDURES
GREASE FITTING LOCATIONS

TH644C & TH842C & TH844C

GREASE WITH BOOM FULLY EXTENDED / LOCATION

OF LARGE BOOM GREASE POINTS SHOWN / MIDDLE

5-7

MAINTENANCE PROCEDURES
DAILY MAINTENANCE

Perform "BEFORE SERVICING PROCEDURES" before

attempting any of the following checks.
Perform "BEFORE OPERATING CHECKS" before attempting
any of the following checks.

John Deere

CHECK ENGINE OIL LEVEL

Location:

Dipstick (A).

To Check:

The machine must be level.

Check when the engine is cold.

Remove the dipstick from the engine.
The oil level should be between the add
and full marks.
Replace the dipstick.
NOTE:

Refer to page 5-24 of this manual for the proper oil

specifications and capacities.

it WARNING
Do not check the coolant level if the engine has recently been
run. Injury may occur from hot escaping pressurized coolant.

CHECK ENGINE COOLANT LEVEL

Location:

Radiator cap (B).

To Check:

Coolant should be visible in the top of the tank.

NOTE:

salsa low silicate

antifreeze mix (-34 degrees F) with an approved nitrite or
nitrite-molybdate based Supplemental Coolant Additive. This
additive is required to prevent engine damage due to cylinder
liner erosion and pitting. Do not use high-silicate automotive
antifreeze or cooling system damage due to silicate dropout
can occur.

If coolant needs to be added, fill with a

Contact your local John Deere dealer for an approved

antifreeze and Supplemental Coolant Additive.

5-8

MAINTENANCE PROCEDURES
DAILY MAINTENANCE

&

WARNING

Serious personal injury can result from a loose or damaged fan.

Never pry on a fan because this may cause fan damage and/or
failure.

CHECKENGINE FAN
To Check:

Visually inspect the cooling fan (C) for cracks,

loose bolts, bent or loose blades, etc.

John Deere
OPEN WATER SEPARATOR
Location:

Water separator filter (D).

To Open:

Shut off the engine.

Tum the valve on the bottom of the filter
counterclockwise.

D
Drain until clear fuel is present.
Retighten the valve.
NOTE:

If more than 2 oz. of fuel are drained. refilling of the

filter is required to prevent hard starting. Refer to filter
replacement on page 5-19 of this manual.

5-9

MAINTENANCE PROCEDURES
DAILY MAINTENANCE

CHECK TRANSMISSION OIL LEVEL

Location:

Dipstick (A)

To Check:

Level the machine.

Place the transmission control in neutral.

Set the parking brake.
The engine must be running to check.
Bring the transmission oil temperature to a
minimum of 180 degrees F.
Remove the dipstick. The oil level should be
between the add and full marks.
Replace the dipstick.
NOTE:

Refer to page 5-24 of this manual for the proper oil

specifications and capacities.

CHECK HYDRAULIC OIL LEVEL

Location:

Sight glass (B). Behind the rear panel.

To Check:

Move the machine to level ground.

Level the frame.

Completely retract the boom.

Position the forks level.
Lower the boom to the ground.
Oil should be visible 112 way in sight glass (B).
NOTE:

Refer to page 5-24 of this manual for the proper oil

specifications and capacities.

5-10

MAINTENANCE PROCEDURES
DAILY MAINTENANCE

CHECK TIRE FOR PROPER INFLATION

Location:

Wheel ends.

To Check:

With the valve stem (C) positioned to the top of

the tire, check the tire pressure with the tire cold
and a properly fimctioning air pressure gauge.

Setting:

50 PSI.

& DANGER
All tires require a calcium chloride ballast or an optional foam
fill to be operated safely. The loss of ballast can affect the
machine's stability and cause a rollover hazard, resulting in
damage, injury or death.

INSPECT AIR CLEANER

Location:

Air cleaner assembly.

To Check:

Remove the rear of the canister, remove

the filter elements.

Guideline:

Inspect the filter elements for contamination.

Inspect the tubing going to the filter body
from the engine for cracks or leaks. Inspect
the air cleaner body and gaskets for cracks
or leaks.

LLWARNING
Due to various operating conditions, the air cleaner's elements
should be changed as the environment requires.

5-11

MAINTENANCE PROCEDURES
50 HOUR MAINTENANCE

Perform "BEFORE SERVICING PROCEDURES" before

attempting any of the following checks.
Complete all "DAILY MAINTENANCE" checks prior to this
time interval.
Perform "BEFORE OPERATING CHECKS" before attempting
any of the following checks.

CHECK HYDRAULICRETURN FILTER GAUGE

Location:

Return filter gauge (A). Located behind the left hand

side screen, on top of the oil reservoir and on the
left hand side ofthe return filter assembly (B).

To Check:

Raise the boom to the horizontal position.

Extend the boom cylinder fully.
Raise the engine speed to full RPM.
Retract the boom cylinder at full speed.
The return filter gauge reading should not read more
than 25 PSI. If the reading is more than 25 PSI, the
filter element must be changed.

CHANGE HYDRAULIC RETURN FILTER ELEMENT

Location:

The return filter element (C) is located inside the

return filter assembly (B) on top of the oil reservoir.

To Change: Retract the boom and lower the forks to the ground.
Shut off the engine. Release the pressure in the oil
reservoir by loosening the filler / breather cap (D).

&

D
F

CAUTION

The return filter assembly cover is spring loaded.

Loosen, but do not remove, the four cover bolts (E)
on the top of the return filter assembly. Carefully
push down and rotate the cover clockwise .to remove.
Remove the cover spring and pull the filter element
out using the swivel handle on the element. Make
sure both o-rings are in place inside the new filter
element, then transfer the bypass valve (F) into the
new filter element. Reinstall the filter element, cover
spring and cover, making sure the o-ring is in place
between the cover and the return filter assembly.
NOTE:

This change interval is only for the first initial 50 hours of

use. Following initial replacement of filter see Service
Intervals on page 5-5 of this manual for standard change
intervals.

5-12

MAINTENANCE PROCEDURES
50 HOUR MAINTENANCE

CHANGE TRANSMISSION OIL AND FILTER

Location:

To Change:

Transmission filter (G).

Drain plug (H).
Dipstick (I).

Bring the transmission oil temperature to a

minimum of 180 degrees F.
Remove the drain plug.
Allow the oil to drain completely into a
proper collection container.
Clean the area around the filter thoroughly.
Remove the transmission filter.
Apply a thin film of clean transmission oil
to the new filter gasket surface and install
the filter according to the manufacturer's
specifications.
Install the drain plug.
Fill the transmission through the dipstick
tube (I) until the oil level is between the add
and :full marks.
Run the engine for a minimum of 2 minutes
at engine idle.
Check the oil level at the dipstick.
Raise the transmission oil temperature to a
minimum of 180 degrees F. Recheck the oil at
the dipstick.

NOTE:

This change interval is only for the first initial 50

hours of use. Following the initial replacement of oil and
filter see the Service Intervals on page 5-5 of this manual
for the standard change interval.

NOTE:

Refer to page 5-24 of this manual for the proper oil

specifications and capacities.

5-13

50 HOUR MAINTENANCE

CHECKAXLE PLANETARY OIL

Location:

Filler/drain plug (A).

To Check:

Always check the lubricant level in the wheel end

with the filler/drain plug at the 3 or 9 o'clock
position.
Remove the filler/drain plug.
Oil should flow freely from the hole.
Replace the filler/drain plug.

NOTE:

Refer to page 5-24 of this manual for the proper oil

specifications and capacities.

CHECK AXLE DIFFERENTIAL OIL

Location:

Fill plug (B).

Check plug (D).
Drainplug (C).

To Check:

Move the machine to level ground.

Remove the check plug. Oil should flow freely
from the hole.
Replace the check plug.

B
NOTE:

Refer to page 5-24 of this manual for the proper oil

specifications and capacities.

5-14

MAINTENANCE PROCEDURES
100 HOUR MAINTENANCE

Perform "BEFORE SERVICING PROCEDURES" before

attempting any of the following checks.
Complete all "DAILY MAINTENANCE" checks prior to this
time interval.
Complete all "50 HOUR MAINTENANCE" checks prior to this
time interval.
Perform "BEFORE OPERATING CHECKS" before attempting
any of the following checks.

CHANGE AXLE DIFFERENTIAL OIL

Location:

Fill plug (B).

Check plug (D).
Drain plug (C).

To Change: Remove the drain plug.

Loosen the fill plug to allow the oil to drain
completely into a proper collection container.
Replace the drain plug.
Remove the check plug and the fill plug.
Fill with oil through the fill plug hole until it
flows freely from the check plug hole.
Replace the check plug and the fill plug.
NOTE:

This time interval is for the first initial 100 hours. Refer to
page 5-5 of this manual for additional service intervals.

NOTE:

Refer to page 5-24 of this manual for the proper oil

specifications and capacities.

5 -15

100 HOUR MAINTENANCE

CHANGE AXLE PLANETARY END OIL

Location:

Filler/drain plug (A).

To Change: Rotate the wheel end until the filler/drain plug

is at the lowest point of the wheel end.
Remove the filler/drain plug and allow the oil
to drain completely into a proper collection
container.
Rotate the wheel end until the filler/drain plug
hole is at the 3 or 9 o'clock position.
Fill with oil until it flows freely from the filler/
drain plug hole.

Replace the filler/drain plug (A).

NOTE:

This time interval is for the first initial 100 hours. Refer to
page 5-5 of this manual for additional service intervals.

NOTE:

Refer to page 5-24 of this manual for the proper oil

specifications and capacities.

CHANGE TRANSMISSION OIL AND FILTER

To Change: Refer to the procedure listed on page 5-13 of this

manual.
NOTE:

This time interval is for the first initial 100 hours. Refer to
page 5-5 of this manual for additional service intervals.

5-16

MAINTENANCE PROCEDURES
250 HOUR MAINTENANCE

Perfonn "BEFORE SERVICING PROCEDURES" before

attempting any of the following checks.
Complete all "DAILY MAINTENANCE" checks prior to this
time interval.
Complete all "50 HOUR MAINTENANCE" checks prior to this
time interval.
Complete all "100 HOUR MAINTENANCE" checks prior to
this time interval.
Perfonn "BEFORE OPERATING CHECKS" before attempting
any of the following checks.

CHANGE HYDRAULIC RETURN FILTER ELEMENT

Location:

The return filter element (C) is located inside the

return filter assembly (B) on top of the oil reservoir.

To Change: Retract the boom and lower the forks to the ground.
Shut off the engine. Release the pressure in the oil
reservoir by loosening the filler I breather cap (D).

~CAUTION
The return filter assembly cover is spring loaded.
Loosen, but do not remove, the four cover bolts (E)
on the top of the return filter assembly. Carefully
push down and rotate the cover clockwise to remove.
Remove the cover spring and pull the filter element
out using the swivel handle on the element. Make
sure both o-rings are in place inside the new filter
element, then transfer the bypass valve (F) into the
new filter element. Reinstall the filter element, cover
spring and cover, making sure the o-ring is in place
between the cover and the return filter assembly.

5-17

MAINTENANCE PROCEDURES
500 HOUR MAINTENANCE

CHANGE ENGINE OIL AND FILTER

Location:

Oil filter (A).

Drain plug (B).
Fill cap (C).

To Change: Operate the engine until the engine water

temperature has reached 140 degrees F.
Turn the engine off.
Remove the drain plug (B).
Allow the oil to drain completely into a proper
collection container.

John Deere

Clean the area thoroughly around the filter area.

Remove the engine oil filter.
Apply a thin film of clean engine oil to the new
oil filter gasket surface.
Fill the oil filter with clean engine oil before
installation.
Install the oil filter to the manufacturer's
specifications.
Clean the surface around the drain plug.
Install the drain plug.
Fill the engine with the proper oil through the oil
fill cap until the oil level is between the add
and the full marks on the dipstick.
Run the engine for a minimum of2 minutes at
engine idle.
Turn the engine off.
Once the engine has cooled recheck the oil level
at the dipstick.

NOTE:

Refer to page 5-24 of this manual for the proper oil

specifications and capacities.

5-18

MAINTENANCE PROCEDURES
500 HOUR MAINTENANCE

Perform "BEFORE SERVICING PROCEDURES" before

attempting any of the following checks.
Complete all "DAILY MAINTENANCE" checks prior to this
time interval.
Complete all "50 HOUR MAINTENANCE" checks prior to this
time interval.
Complete all "100 HOUR MAINTENANCE" checks prior to
this time interval.
Complete all "250 HOUR MAINTENANCE" checks prior to
this time interval.
Perform "BEFORE OPERATING CHECKS" before attempting
any of the following checks.

REPLACE FUEL FILTERS

Location:

Filter (D).
Water separator (E).

John Deere

To Change: Wipe all the dirt from the area surrounding

the ftlter( s).
Remove the filter(s). Thoroughly clean the gasket
sealing surface after ftlter removal.
Fill the new filter( s) with fuel.
Install the new filter(s).
Install the ftlter( s) according to the filter
manufacturer's specifications.

NOTE:

John Deere engines only have one filter element. It is used as a

filter and water separator.

5 -19

D&E

MAINTENANCE PROCEDURES
500 HOUR MAINTENANCE
A
CHECK COOLANT CONCENTRATION
Location:

Radiator cap (A).

To Check:

Remove the radiator cap.

Factory recommended coolant concentration
is a 50/50 mixture oflow silicate antifreeze
(-34 degrees F.) with an approved nitrite or
nitrite-molybdate based Supplemental Coolant
Additive. This additive is required to prevent
engine damage due to cylinder liner erosion and
pitting. Do not use high-silicate automotive
antifreeze or cooling system damage due to
silicate dropout can occur.
Contact your local John Deere dealer for an
approved antifreeze and Supplemental Coolant
Additive.

750 HOUR MAINTENANCE

Perform "BEFORE SERVICING PROCEDURES" before
attempting any of the following checks.
Complete all "DAILYMAlNTENANCE" checks prior to this
time interval.
Complete all "50 HOUR MAINTENANCE" checks prior to
this time interval.
Complete all "100 HOUR MAINTENANCE" checks prior to
this time interval.
Complete all "250 HOUR MAINTENANCE" checks prior to
this time interval.
Complete all "500 HOUR MAINTENANCE" checks prior to
this time interval.
Perform "BEFORE OPERATING CHECKS" before attempting any of the following checks.

CHANGE AXLE OILS

To Change: Refer to the procedures listed on pages 5-15 &
5-16 of this manual.

5-20

1000 HOUR MAINTENANCE

Perform "BEFORE SERVICING PROCEDURES" before

attempting any of the following checks.
Complete all "DAILY MAINTENANCE" checks prior to this
time interval.
Complete all "50 HOUR MAINTENANCE" checks prior to this
time interval.
Complete all "100 HOUR MAINTENANCE" checks prior to
this time interval.
Complete all "250 HOUR MAINTENANCE" checks prior to
this time interval.
Complete all "500 HOUR MAINTENANCE" checks prior to
this time interval.
Complete all "750 HOUR MAINTENANCE" checks prior to
this time interval.
Perform "BEFORE OPERATING CHECKS" before attempting any of the following checks.

MANUFACTURER ENGINE MANUALS ARE AVAILABLE

FROM YOUR LOCAL TEREX HANDLER DEALER.

ADJUST ENGINE VALVES

To Adjust:

See engine manual for procedure.

CHECK FAN BELT TENSION

To Check:

See engine manual for procedure.

CHECK FAN BELT CONDITION

To Check:

See engine manual for procedure.

CHANGE TRANSMISSION OIL AND FILTER

To Change: Refer to procedure listed on page 5-13 of this
manual.

5-21

MAINTENANCE PROCEDURES
1000 HOUR MAINTENANCE

ADJUST EXTENSION -RETRACTION CHAINS

TO CHECK: Raise the boom to the horizontal position. The

proper adjustment can be checked with a tape measure. Extend
the boom fully, then retract the boom about one inch. On either
side of the middle boom section estimate the center. Place one
end of the tape measure on the top surface of the boom
directly above the estimated center.

c-~

IJXo

0 0 0 0 0 0 0 0 0

000000000000000000

TOLERANCE: The measurement from the top surface of the

boom to the lowest part of the extension chain should be no
less than 2 3/8 inches.

MIDDLE BOOM
MIDPOINT

TO ADJUST: If the measurement is less than 23/8 inches,

tighten the chain anchor (A), which is located on the top, front
of the large boom tube, as follows:
A. Tighten an adjustable wrench across the flat part of the
chain just ahead of the chain anchor (A).
B. With a 1 7/16 inch wrench tighten the one inch nut to
collapse the spring. Continue to tighten until the chain is in
tolerance.
C. With a feeler gauge check the gap between the spring (B).
The gap should be no less than .030. The spring coils should
never be collapsed completely.

5-22

2000 HOUR MAINTENANCE

Perform "BEFORE SERVICING PROCEDURES" before

attempting any of the following checks.
Complete all "DAILY MAINTENANCE" checks prior to this
time interval.
Complete all "50 HOUR MAINTENANCE" checks prior to this
time interval.
Complete all "100 HOUR MAINTENANCE" checks prior to
this time interval.
Complete all "250 HOUR MAINTENANCE" checks prior to
this time interval.
Complete all "500 HOUR MAINTENANCE" checks prior to
this time interval.
Complete all "750 HOUR MAINTENANCE" checks prior to
this time interval.
Complete all "1000 HOUR MAINTENANCE" checks prior
to this time interval.
Perform "BEFORE OPERATING CHECKS" before attempting
any of the following checks.

FLUSH AND PRESSURE TEST COOLING SYSTEM

To Test:

See engine manual for procedure.

5-23

FILTER GUIDE
FILTER

PART NO.

Engine Oil Filter I John Deere

7-183-184

Transmission Oil Filter

7-126-349

Hydraulic Oil Reservoir Return Filter Element

7-118-02

Engine Air Cleaner Element / Primary

7-109-04

Engine Air Cleaner Element / Safety

7-109-14

Engine Fuel Filter I John Deere

7-183-45

Filler-Breather (Hydraulic Oil Reservoir)

7-272-11

RECOMMENDED FLUIDS AND CAPACITIES

DESCRIPTION

CAPACITY

TYPE

Engine Oilt John Deere

14 Quarts

Refer to John Deere engine manual

Transmission Oil

13.6 Quarts

Chevron RPM SAE 10W

Axles
Differential
Planet Ends

9 Quarts
1 Quart (Each End)

Chevron Supreme 80W90 LS

Chevron Supreme 80W90 LS

Hydraulic Oil Reservoir

34 Gallons

Chevron AW 46

Hydraulic System

50 Gallons

Chevron AW 46

Fuel Tank

30 Gallons

# 2 Diesel Fuel

NOTE: Fluid levels may vary slightly from machine to machine so fluid levels should always be checked manually.

5-24

MAINTENANCE PROCEDURES
HYDRAULIC PRESSURE SETTINGS

GAUGE PORT 1 (G1)

MAIN PUMP PRESSURE
Location: Test port 1 (A). Behind the right hand rear side screen.
Hydraulic pump (B). Under the transmission cover.
Adjuster (C). On the hydraulic pump.
To Check: Attach a pressure gauge to test port 1 (A). Start
the engine. Do not operate any controls. The
pressure reading should be as follows:
TH644C
TH842C
TH844C

3000 PSI
3000 PSI
3000 PSI

ToAdjust: Remove the acorn nut from the adjuster (C). Loosen
the jam nut and turn the allen head adjusting screw
clockwise to increase the pressure and counterclockwise to decrease the pressure. Retighten the jam
nut. Replace the acorn nut.

GA UGE PORT 1 (G1)

SERVICE BRAKE ACCUMULATOR
Location: Test port 1 (A). Behind the right hand rear side screen.
To Check: Attach a pressure gauge to test port 1 (A). Start
the engine. Do not operate any controls. Apply
and release the service brakes a few times. With
the service brakes released, shut down the engine.
The pressure reading should be as follows:
TH644C
TH842C
TH844C

3000 PSI
3000 PSI
3000 PSI

ToAdjust: Not adjustable. If the pressure drops below 2000

PSI after a period of two minutes, troubleshoot the
brake circuit.

5-25

HYDRAULIC PRESSURE SETTINGS

GAUGE PORT 2 (G2)
STEERING SYSTEM PRESSURE

Location: Test port 2 (A). Behind the right hand rear side screen.
Control block (B). On the front face ofthe oil reservoir.
Cartridge (C). On the control block.

To Check: Attach a pressure gauge to test port 2 (A). Start the

engine. Do not operate any controls. The pressure
reading should be as follows:

TH644C
TH842C
TH844C

2250 PSI
2250 PSI
2250 PSI

ToAdjust: Loosen the jam nut on the steering cartridge

(C) and turn the allen head adjusting screw
clockwise to increase the pressure and
counterclockwise to decrease the pressure.
Retighten the jam nut.

E
GAUGEPORT3(G3)
CONTROL (PILOT) PRESSURE

Location: Test port 3 (D). Behind the right hand rear side screen.
Control block (B). On the front face of the oil reservoir.
Cartridge (E). On the control block.

To Check: Attach a pressure gauge to test port 3 (D). Start the

engine. Do not operate any controls. The pressure
reading should be as follows:

TH644C
TH842C
TH844C

500 PSI
500 PSI
500 PSI

ToAdjust: Loosen the jam nut on the controller cartridge (E)

and turn the allen head adjusting screw clockwise to
increase the pressure and counterclockwise to
decrease the pressure. Retighten the jam nut.

5-26

MAINTENANCE PROCEDURES
HYDRAULIC PRESSURE SETTINGS

GAUGE PORT 4 (G4)

TILT LIMITER PRESSURE
Location: Test port 4 (F). Behind the right hand rear side screen.
Tilt Limiter Block (H). On the front of the oil reservoir.
Cartridge (I). On the Tilt Limiter Block.
To Check: Attach a pressure gauge to test port 4 (F). Start the
engine. Completely collapse the fork tilt cylinder and
hold in a dead head position. (The tilt cylinder must
be collapsed completely and dead headed to get a
pressure reading). The pressure reading should be
as follows:
TH644C
TH842C
TH844C

1200 PSI
1200 PSI
1200 PSI

To Adjust: Loosen the jam nut on the tilt limiter cartridge (I)
and tum the allen head adjusting screw clockwise
to increase the pressure and counterclockwise to
decrease the pressure. Retighten the jam nut.

5-27

SECTION 6

MATERIAL SAFETY DATA

6-1

TABLE OF CONTENTS

SECTION 6 - MATERIAL SAFETY DATA

Material Safety Data Sheets

6-3

California Proposition 65 Warnings

6-4

6-2

MATERIAL SAFETY DATA

MATERIAL SAFETY DATA SHEETS (MSDS)

The Federal Occupational, Safety and Health Administration (OSHA) Standard 29 ctr 1910.1200, and in some
cases state and local Right-To-Know laws, may require specific MSDS be available to employees prior to
operating this equipment. This may include information on substances contained in the equipment such as
antifreeze, brake fluid, battery acid and hydraulic fluid.
TEREX HANDLERS will provide, at no cost, Material Safety Data Sheets which are applicable to their
product line. Simply request them from your local TEREX HANDLER dealer or contact us at:
TEREX HANDLERS
P.O. Box 790
Baraga, MI 49908-0790

To ensure a prompt response, please be sure to include your return address and zip code, along with the
machine model and serialnumbeL

6-3

MATERIAL SAFETY DATA

CALIFORNIA PROPOSITION 65 WARNINGS

The following warnings are required on all offroad equipment operating in the State of California. Ifyou are
operating a TEREX HANDLER in the State of California and do not see the approved warning labels,
please contact us for a replacement at no charge. Our address is:

TEREX HANDLERS
P.O. Box 790
Baraga, MI 49908-0790

CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State
of California to cause cancer, birth
defects, and other reproductive harm.

CALIFORNIA
Proposition 65 Warning
Batteryposts, tenninals, and related accessories
contain lead and lead compounds, chemicals
known to the State of California to cause cancer
and reproductive harm.
Batteries also contain other chemicals known to
the State of California to cause cancer.
Wash hands after handling.

6-4