Terex Franna AT-20 Crane Operator & Service Manual – OM906LA Engine MD3060 Transmission Repair Documentation PDF

Description

File Details

• Manual Type: Operator’s Manual and Service Documentation
• Brand: Terex Franna
• Model: AT-20
• Engine: OM906LA (DaimlerChrysler Series 900)
• Transmission: Allison MD3060
• Language: English
• File Format: PDF
• Page Count: 509

Chapters Covered

• Instrumentation & Controls
• Instrument Panel
• Seating Adjustments / Controls
• Service Intervals
• Recommended Lubricants
• Regular Maintenance
• Checking Allison Transmission
• Weekly Lubrication Points
• Engine Starting & Stopping Procedures
• Road Travel Procedure
• Crane Operation
• Lifting – Precautions
• Reeving Fall Block
• Setting Manual Extension
• Replace Winch Rope
• Adjusting Extension & Retract Ropes
• Fly Jib Installation
• Man Basket Operation
• Spreader Bar Operation
• Spare Wheel Removal
• Terex Cranes Safety Precautions
• DaimlerChrysler Diesel Engine Series 900 Repair Manual
• Service Schedules & Warranty Claim Forms
• Service Bulletins
• Spicer Driveshaft Lubrication

Operator’s Manual – Crane Controls & Operation

The AT-20 operator’s section covers every control and gauge on the machine, with numbered callouts for the slew angle indicator, load moment indicator, luff/winch/extension control levers, emergency engine shutdown, transmission declutch, emergency park brake release, parking brake, 2WD/4WD and hi/low range selector, holding brake and diff lock control, transmission shift selector, and steering wheel. The instrument panel layout is itemised gauge by gauge — fuel, hydraulic oil pressure, transmission temperature, tachometer/hour meter, air pressure, engine temperature, engine oil pressure, and the full warning lamp set including low air, check transmission, diff cross lock engaged, 4WD engaged, and low range. Seat adjustment instructions cover headrest, armrest angle, lumbar support (5-position), backrest angle, seatbelt anchorage, horizontal slide, and seat suspension height and up-stop adjustment.

Maintenance & Service Schedules

Service intervals are laid out at 100-hour first service (including engine head/valve setting), 250-hour intermediate, 500-hour intermediate, 750-hour intermediate, 1000-hour second major service (again with head/valve setting), and 2000-hour service, with 250-hour intervals thereafter. The manual includes detailed daily and weekly checklists — engine oil level, radiator water level, air cleaner service indicator, Allison transmission oil level, fuel system water traps, oil leaks, loose bolts, tyre pressures, hooks/pins/clips, winch rope condition, air tank moisture drain, wheel nut re-torque, articulation joint greasing, and emergency steering pump function checks. Recommended lubricants are specified by system: engine 28L Tection Plus, transmission 25L Dexron III, hydraulic Hyspin AWS68, transfer case EPX 85W/140, differential EPX 85W/140, radiator 20L distilled water + 20L corrosion inhibitor/anti-freeze, grease points SBX-2, universal joints EPL-2, and fan support bearing EPL-2. The 100-hour, 250/750-hour, 500-hour, 1000-hour, and 2000-hour service schedules are provided as tick-sheet forms for workshop use.

Allison MD3060 Transmission

The Allison transmission section gives detailed fluid level checking procedures: pre-startup check, cold check at idle (500-800 rpm in neutral), hot check with transmission temperature between 71°–93°C (160°–200°F), and the shift selector/display method using the up and down arrow buttons. The display codes are explained — “o”, “L” followed by “o”, “K” for correct level, “o”, “L” followed by “L”, “o” for low level with quantity required, “o”, “L” followed by “H”, “T” for overfilled with quantity, and “o”, “L” followed by “-“, “7”, “0” for fluid temperature too low to read. The transmission oil capacity is listed as 25L Dexron III.

Crane Operation & Safety

Operating procedures cover travel/crane mode selection, 4WD and hi/low range engagement, holding brake and diff lock operation, cruise control, engine starting and stopping (including the 3-minute turbo timer default shutdown delay), road travel precautions, and lifting precautions. The manual details reeving the fall block, setting the manual extension, replacing the winch rope, adjusting extension and retract ropes, fly jib installation, man basket operation, spreader bar operation, and spare wheel removal. Safety content includes rated capacity manual conditions (firm level surface, 1% slope, correct tyre pressures), lift-and-carry limits (minimum boom length, close to ground, max 0.4 m/s), and the full list of do’s and don’ts for safe lifting. Wheel nut torque is specified at 650 Nm (480 lb.ft) with re-torque after 120 km.

DaimlerChrysler OM906LA / OM904LA Engine Repair

The engine repair section is a full DaimlerChrysler Series 900 workshop manual covering OM 904 LA and OM 906 LA engines (Mod. des. 904.9, 906.9). It includes removal and installation procedures for pistons, piston rings, conrods, crankshaft front and rear radial seals, crankshaft, crankshaft sprocket, oil pump drive gear, belt pulley/vibration damper, flywheel, guide bearing, rocker arm assembly, valves, valve guides, valve stem seals, valve seat rings, camshaft, MR/PLD control unit, MR/PLD injection lines, nozzle holder combination, MR/PLD unit pump, crankshaft angle position sensor bracket, turbocharger, boost air pipes, boost air manifold, poly V-belt and tensioning device, compressor, exhaust manifold, engine brake flap connection, starter, generator, oil pump, oil-water heat exchanger, oil filter housing, oil filter bypass valve, oil pressure and temperature sensors, oil level sensor, oil spray nozzles, coolant pump, coolant thermostat, fan shroud, fan, radiator, coolant level sensor, and power steering pump. Technical data tables give engine output, torque, rated speed, bore, stroke, displacement, compression ratio, firing order, valve arrangement, injection method, and specific fuel consumption for every 904 and 906 variant. Test data includes compression pressure (≥28 bar at starter speed, permissible difference ≥4 bar), engine oil pressure (≥0.5 bar at idle, ≥2.5 bar at maximum speed), cylinder head bolt dimensions, valve setback, crankshaft journal diameters, conrod bearing clearances, and tightening torques.

Service Bulletins & Technical Updates

The service bulletins section covers winch-mounted workbox anti-two-block requirements (AS 2550.1-1993 Clause 7.16, AS 1418.5-1995 Clause 7.5.3.2), steering cylinder rod clevis inspection (every 250 hours) with replacement welded clevis part numbers for UC-10, 4WD-10/12/16, MAC 12/14/25, and AT-14/18 cranes, steering hose replacement criteria (leakage, cover damage, kinking, twisting, heat cracks, loose cover, corroded fittings, fitting slippage), and 3B6 LMI service technician passwords (black box entry 4482, service maintenance reset 2702, length/angle calibration 3577). The MEGATECH software loading procedure and laptop calibration instructions for Hino and Perkins powered machines are also included.

Spicer Driveshaft Lubrication

The driveshaft section covers Spicer universal joint lubrication requirements, including the warning that inadequate lubrication can cause driveline failure and separation. It details the relubrication procedure (purge all four bearing seals, pop the seals, move the driveshaft side to side if seals fail to purge), bolt torque specifications for Quick Disconnect half-round yokes, serrated bolt with lock patch (no lock strap) designs, and lock strap designs. Recommended lubricants and temperature ranges are specified.

What This Manual Lets You Do

IMAGES PREVIEW

This Terex Franna AT-20 operator and service documentation is not a generic overview — it is the working reference for the crane’s OM906LA engine, Allison MD3060 transmission, and the full machine systems. With it you can perform the 100-hour first service and valve setting, diagnose transmission fluid level faults using the shift selector display, adjust extension and retract ropes to the specified 15–18 mm gap, re-torque wheel nuts to 650 Nm, check emergency steering pump operation, set the manual extension, replace winch rope, install the fly jib, and operate the man basket and spreader bar correctly. The engine repair section gives you the complete DaimlerChrysler Series 900 workshop procedures — piston and conrod removal, crankshaft measurement, cylinder head bolt torque stages, valve setback measurement, and turbocharger inspection — with the test data and tightening torques needed to do the job right. Every value, clearance, and procedure is taken directly from the manufacturer’s documentation. Delivered as an instant PDF download, no shipping, printable from any device.