Terex Crane T300-1 / T500-1 / T780 Operator Manual 12261-478 PDF

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Terex Crane T300-1 / T500-1 / T780 Operator Manual 12261-478 – PDF DOWNLOAD

FILE DETAILS:

Terex Crane T300-1 / T500-1 / T780 Operator Manual 12261-478 – PDF DOWNLOAD

Language : English
Pages : 477
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Terex Crane T300-1 / T500-1 / T780 Operator Manual 12261-478 – PDF DOWNLOAD

Introduction 7
Construction and Industrial Equipment Product Safety 7
Alert System 8
T Nomenclature 9
Safety 11
Safety Introduction 11
Workplace Safety 12
Personal Safety 20
Seat Belts 22
Assembly 23
Erecting the Jib 23
Changing the Offset of the Jib 25
Extending and Retracting the Jib Pull-out Section 27
Spooling Wire Rope on Drums 29
Cable Sockets 31
Hoist-Line Reeving 35
Description Of Machine and Controls 39
Universal Symbol Identification 39
Carrier Controls and Instruments-DOMESTIC (PRE 2010) 43
Carrier Controls and Instruments-2010 TIER 4 46
Carrier Controls and Instruments-EXPORT 83
Upper Controls and Instruments 87
Outrigger Controls-External (Streetside) 98
Side-Stow Jib 99
Inspection 101
Pre-Start Inspection 101
Suggested Hydraulic Crane Inspection Checklist 103
Daily Check (8 Hours) 108
Weekly Check (40 Hours) 109
Monthly Check (80 hours) 110
Quarterly Checks (250 Hours) 111
Semiannual Checks (500 Hours) 112
Annual Check (1000 Hours) 113
Wire Rope Inspection Record 114
Operating Instructions 115
Cummins 2010 Engine- Overview of Operation 115
Fuel Warning 115
Manual Regen Initiate Switch 116
Table of Contents
RELEASED: February 2011 i
HEST Lamp Functionality 117
DPF Lamp Functionality 118
Aftertreatment Regeneration Lamp Behaviors 120
Engine Idle Speed Increase 123
Hazard Mitigation Tool Box 124
Safety Hazards during Regeneration 125
DPF Regeneration 127
Regeneration Modes 128
Manual Regeneration Procedure 129
Operating the Unit 131
Operating the Engine 131
Operating the Engine 134
Operating the Engine 139
Engine Cold Weather Operation 145
Jump Starting an Engine- Boster Cable Instructions 148
Unusual Operating Conditions 149
Making a Typical Lift 153
Arm and Hand Signals 159
Load Rating Chart Interpretation 161
“On-Tires” Lift 167
On-Tires Load Rating Chart 169
Air-Ride Suspension 170
Remote Carrier Operation 173
Moving the Unit 175
Driver Tips-Cummins EPA ’07 Engines 175
Vehicular Operation 176
Transmission Operation 178
Traveling around the Jobsite 182
Towing or Pushing Vehicle 185
Disassembly 187
Stowing the Jib 187
Transportation 189
Transporting the Crane 189
Instructions for Loading and Unloading 190
Maintenance 193
Engine Data-Tier 3 Export & EPA 2010 193
Maintenance Introduction 197
Crane Maintenence & Specification 198
Contents
ii RELEASED: February 2011

Acronyms and Abbreviations 199
General Safety Instructions 201
Flow Diagram-Exhaust System 203
Engine & Cooling System Maintenence Schedule 207
Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter 211
Engine Indicator Lamps 216
Aftertreatment Switch 222
Operating Characteristics with Aftertreatment Particulate Filter 223
Engine Indentification 228
Diesel Exhaust Fluid Specification 234
Filter Specification 239
Lubrication Charts 241
Operator Observation 244
Special Break-in Requirements for New Cranes 245
Machine Maintenance Checklist 246
Lubrication Introduction 248
Hydraulic Oil Requirements 250
Koehring Spec 805 Data 253
Grade Selection Chart 254
Premium Grade Anti-Wear Hydraulic Oils 256
Cable Lubrication Methods 259
Turntable and Swing Pinion 263
Power Steering Maintenance 265
Drive Shaft Maintenance 266
Brake System Maintenance 269
Air Dryer 272
Air System Maintenance 273
TIRES 274
Slider Pads 277
Boom Lubrication 278
Swing Bearing Bolting Procedure 288
Engine Radiator Maintenance 291
Transmission Maintenance 293
Axle Maintenance 306
Tire Maintenance 310
Swing Reducer 313
Hydraulic System Maintenance 316
RELEASED: February 2011 iii
WIre Rope and Reeving 320
Anti-Two Block System 322
Storage 324
Machine Storage 324
Engine Storage 326
Transmission Storage 329
Restoration to Service 330
Restoring Engine to Service 331
Restoring Transmission to Service 332
Chrome Cylinder Rod Storage 333
Specifications 335
WIRE ROPE SPECIFICATION-T300-1, T500-1 & T775 335
Troubleshooting 337
Introduction 337
General Procedure 339
Hydraulics – General 340
Operator Controls 341
Power Steering 342
Front Axles 344
Steering Circuit 346
Rear Axles 351
Alternator 352
Starter 354
Engine Clutch 355
Brakes 357
Parking Brakes 358
Air Pressure 359
Swng Circuit 360
Boom Hoist Circuit 361
Telescope Circuit 362
Winch Circuit 363
Outrigger Circuit 365
Swing Pumps Circuit 366
Swing Circuit Control Valves 369
Swing Circuit Relief Valves 371
Fluid Motor 372
Cylinders 374
Cylinder Leakage 375
Contents
iv RELEASED: February 2011
Excessive Heating of Oil In System 377
Electrical Controls 378
Propane Heater 379
Maintenance -Free Battery Testing 382
Two-Block System 384
Service / Parts 387
General Service Information 387
Torque Wrench Extensions 389
Welding Instructions 391
Outriggers 393
Rear Suspension 400
Front Axle 402
Rear Axle 404
Propellor Shaft & Universal Joints 407
Wheel and Rim Mounting 412
Engine Clutch Adjustment & Repair 416
Shift Control Adjustment 421
Steering and Power Steering 425
Swing Reducer 426
Pumps 428
Valve Adjustments 432
Rotary Manifold 438
Control Linkage Adjustment 440
Heaters & AC Systems 441
Electrical System Battery Check 442
Electrical System Collector Ring 445
Electrical System Voltmeter Diagnosis 448
Hydraulic Cylinder Maintenance 454
Chain Adjustment – 4-Section Boom 457
Boom Centering 459
Setting Proximity Sensors 461
Repairs-Adjustments-Remarks Log 463
Appendix 465
Conversion Tables 465
Average Weight of Materials 469
Suggested Torque ratings 472
California Proposition 65 Warning 474
RELEASED: February 2011 v
Lead Warning – State of California 475
Contents
vi RELEASED: February 2011

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