Terex Crane T300-1/T500-1/T78 Operator’s Manual 12261-683 PDF

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Terex Crane T300-1/T500-1/T78 Operator’s Manual 12261-683 – PDF DOWNLOAD

FILE DETAILS:

Terex Crane T300-1/T500-1/T78 Operator’s Manual 12261-683 – PDF DOWNLOAD

Language : English
Pages : 528
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Terex Crane T300-1/T500-1/T78 Operator’s Manual 12261-683 – PDF DOWNLOAD

Introduction 7
Construction and Industrial Equipment Product Safety 7
T Nomenclature 9
Intended Use 10
Bulletin Distribution and Compliance 11
Contacting Manufacturer 12
Transfer of Machine Ownership 13
Safety 15
Safety Introduction 15
Alert System 16
General Safety 21
Safety Sign Locations 21
Safety Sign Maintenance 33
Workplace Safety 34
Effects of Wind Conditions 42
Lightning Storm 44
Temporary Interruption of Crane Operations 45
Resuming Crane Operations 48
Ending Crane Operations 49
Turning/Driving in Reverse 50
Parking the Vehicle 51
Lock Out & Tag Out 52
Access/Egress 54
Personal Safety 57
Seat Belts 59
Temperature Effects on Telescope and Boom Hoist Cylinders 60
Assembly 63
Erecting the Jib 63
Changing the Offset of the Jib 65
Extending and Retracting the Jib Pull-out Section 67
Spooling Wire Rope on Drums 69
Cable Sockets 71
Hoist-Line Reeving 73
Counterweight Change – (T300-1 Only) 76
Description Of Machine and Controls 81
Universal Symbol Identification 81
Carrier Controls and Instruments-EPA 2013 Engines 85
Carrier Controls and Instruments-EXPORT 121
Table of Contents
P/N 12261-683 REVISED: January 2015 i
Upper Controls and Instruments 125
Outrigger Controls-External (Streetside) 136
Side-Stow Jib 137
Inspection 139
Pre-Start Inspection 139
Suggested Hydraulic Crane Inspection Checklist 141
Daily Check (8 Hours) 146
Weekly Check (40 Hours) 147
Monthly Check (80 hours) 148
Quarterly Checks (250 Hours) 149
Semiannual Checks (1000 Hours) 150
Annual Check (1500 – 2000 Hours) 151
Wire Rope Inspection Record 152
Mobile Crane Load Test Inspection 153
Operating Instructions 157
Regeneration Process for DD Series 60 – (T500-1 & T780 Only) 157
Cummins 2013 Engine- Overview of Operation 164
Fuel Warning 164
Aftertreatment Regeneration Lamp Behaviors 165
Regeneration Modes 168
Manual Regeneration Procedure 169
Operating the Unit 171
Operating the Engine 171
Starting the Engine-EPA 2010 174
Engine Cold Weather Operation 180
Jump Starting an Engine- Booster Cable Instructions 183
Unusual Operating Conditions 184
Making a Typical Lift 188
Arm and Hand Signals 194
Load Rating Chart Interpretation 196
“On-Tires” Lift 202
On-Tires Load Rating Chart 204
Air-Ride Suspension 205
Remote Carrier Operation 207
Moving the Unit 209
Removable Counterweight (T500-1 & T780) 209
Drivers Tips-Cummins EPA 2013 213
Vehicular Operation 218
T300-1_T500-1_T780
Contents
ii P/N 12261-683 REVISED: January 2015
Transmission Operation 221
Traveling around the Jobsite 225
Towing or Pushing Vehicle 228
Disassembly 229
Stowing the Jib 229
Transportation 231
Transporting the Crane 231
Instructions for Loading and Unloading 232
Maintenance 235
Engine Data-Tier 3 Export & EPA 2013 235
Maintenance Introduction 240
Crane Maintenence & Specification 241
Acronyms and Abbreviations 241
General Safety Instructions 243
Flow Diagram-Exhaust System 245
Engine & Cooling System Maintenence Schedule 249
Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter 253
Engine Indicator Lamps 258
Aftertreatment Switch 264
Operating Characteristics with Aftertreatment Particulate Filter 265
Engine Indentification 270
Diesel Exhaust Fluid Specification 276
Filter Specification 281
Lubrication Charts 283
Operator Observation 286
Special Break-in Requirements for New Cranes 287
Machine Maintenance Checklist 288
Lubrication Introduction 291
Hydraulic Oil Requirements 293
Koehring Spec 805 Data 296
Grade Selection Chart 297
Premium Grade Anti-Wear Hydraulic Oils 299
Cable Lubrication Methods 302
Turntable and Swing Pinion 306
Swing Reducer 308
Power Steering Maintenance 311
Drive Shaft Maintenance 312
Brake System Maintenance 315
P/N 12261-683 REVISED: January 2015 iii
Air Dryer 318
Air System Maintenance 319
TIRES 320
Slider Pads 323
Boom Lubrication 324
Swing Bearing Bolting Procedure 333
Engine Radiator Maintenance 336
Transmission Maintenance 338
Axle Maintenance 351
Tire Maintenance 355
Hydraulic System Maintenance 358
Hydraulic Hoses 362
WIre Rope and Reeving 365
Anti-Two Block System 367
Storage 369
Machine Storage 369
Engine Storage 371
Transmission Storage 374
Restoration to Service 375
Restoring Engine to Service 376
Restoring Transmission to Service 377
Chrome Cylinder Rod Storage 378
Specifications 381
WIRE ROPE SPECIFICATION-T300-1, T500-1 & T780 381
Troubleshooting 383
Introduction 383
General Procedure 385
Hydraulics – General 386
Operator Controls 387
Power Steering 388
Front Axles 389
Steering Circuit 391
Rear Axles 396
Alternator 397
Starter 399
Engine Clutch 400
Brakes 402
Parking Brakes 403
T300-1_T500-1_T780
Contents
iv P/N 12261-683 REVISED: January 2015
Air Pressure 404
Swng Circuit 405
Boom Hoist Circuit 406
Telescope Circuit 407
Winch Circuit 408
Outrigger Circuit 410
Swing Pumps Circuit 411
Swing Circuit Control Valves 414
Swing Circuit Relief Valves 416
Fluid Motor 417
Cylinders 419
Cylinder Leakage 420
Excessive Heating of Oil In System 422
Electrical Controls 423
Propane Heater 424
Maintenance -Free Battery Testing 427
Two-Block System 429
Service / Parts 433
General Service Information 433
Outrigger Position Sensors 435
Torque Wrench Extensions 437
Welding Instructions 439
Outriggers 441
Rear Suspension 448
Front Axle 450
Rear Axle 452
Propellor Shaft & Universal Joints 455
Wheel and Rim Mounting 460
Engine Clutch Adjustment & Repair 464
Shift Control Adjustment 469
Steering and Power Steering 473
Swing Reducer 474
Pumps 476
Valve Adjustments 478
Rotary Manifold 484
Control Linkage Adjustment 486
Heaters & AC Systems 487
Electrical System Battery Check 488
P/N 12261-683 REVISED: January 2015 v
Electrical System Collector Ring 491
Electrical System Voltmeter Diagnosis 495
Hydraulic Cylinder Maintenance 501
Chain Adjustment – 4-Section Boom 504
Boom Centering 506
Setting Proximity Sensors 508
Repairs-Adjustments-Remarks Log 510
Appendix 513
Conversion Tables 513
Average Weight of Materials 517
Torque Specs -SAE & Metric 519
California Proposition 65 Warning 521
Lead Warning – State of California 522
EPA / NHTSA Greenhouse Gas Standards Information – (T300 &
T500 only) 523
Greer Element VGA Operator’s Manual 525
T300-1_T500-1_T780
Contents
vi P/N 12261-683 REVISED: January 2015

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