Terex T300-1 Operator's Manual

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O R I G I N A L I N S T R U C T I O N S

2 0 1 3 O N - H I G H WA Y & E X P O R T T I E R 3

T 3 0 0 - 1 / T 5 0 0 - 1 / T 7 8 0

O p e r a t o r ' s Ma n u a l

R e v i s e d : J a n u a r y 2 0 1 5

1 2 2 6 1 - 6 8 3

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Summary of Contents for Terex T300-1

Page 1 O R I G I N A L I N S T R U C T I O N S 2 0 1 3 O N - H I G H WA Y & E X P O R T T I E R 3 T 3 0 0 - 1 / T 5 0 0 - 1 / T 7 8 0 O p e r a t o r ’...
Page 2: Table Of Contents
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 ..........
Page 3 T300-1_T500-1_T780 Contents 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) ...............
Page 4 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 ..............
Page 5 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 .................
Page 6 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 ..................
Page 7 T300-1_T500-1_T780 Contents 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 ..............
Page 8: Introduction
Terex manuals in the shipment of each product. It is company policy to provide this information for the owner or user of the equipment. It is...
Page 9 T300-1_T500-1_T780 Introduction Follow the recommended operating and maintenance procedures and keep your machine operating at MAXIMUM EFFICIENCY. Use the Suggested Hydraulic Crane Inspection Check List provided. In addition, we STRONGLY URGE that a MAINTENANCE LOG be kept in conjunction with all maintenance performed on the machine. If you desire any special information regarding the care and operation of the machine, we will gladly furnish it upon request.
Page 10: T Nomenclature
T Nomenclature This manual contains instructions and information on the operation, maintenance, lubrication and adjustments of the Truck Crane. The operator should not attempt to operate the machine before he has gained a thorough understanding of the material presented in the following pages.
Page 11: Intended Use
T300-1_T500-1_T780 Introduction Intended Use This machine and its approved attachments are designed to lift, lower and move freely suspended loads within the rated capacity of the crane. Use of this product in any other way is prohibited and contrary to its intended use. P/N 12261-683 REVISED: January 2015...
Page 12: Bulletin Distribution And Compliance
Bulletin Distribution and Compliance Safety of product users is of paramount importance to Terex. Various bulletins are used by Terex to communicate important safety and product information to dealers and machine owners. The information contained in bulletins is tied to specific machines using the machine model number and PIN/serial number.
Page 13: Contacting Manufacturer
Current owner updates, such as changes in machine ownership or changes in your contact information (see Transfer of Machine Ownership, in this chapter, for more information). Manufacturer contact information: Terex Cranes 106 12th Street Waverly, IA 50677 1 (877) MY-TEREX 1 (877) 698-3739 P/N 12261-683 REVISED: January 2015...
Page 14: Transfer Of Machine Ownership
Transfer of Machine Ownership If you are not the original owner of this machine, please fill out the form below and submit via Fax / scan and e-mail / or mail as indicated at bottom of form. This will ensure that you are the owner on record for this machine, allowing you to receive any applicable notices and advisories in a timely manner.
Page 15 Please send this form to: customersupport.wil@terex.com New Owner Registration Form Terex requires that the seller or owner of a Terex machine register to Terex, the model and serial number of each machine sold as well as the name and telephone number of the new owner, within 60 days of the sale.
Page 16: Safety
Many aspects of crane operation and testing are discussed in standards published by the American National Standards Institute. These Standards are updated on an annual basis with addendas, which are sent by ASME to the original purchasers of the standard. Terex recommends that you purchase and refer to the following standards.
Page 17: Alert System
T300-1_T500-1_T780 Safety Alert System SAFETY ALERT SYMBOL The safety alert symbol is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death SAFETY ALERT SYMBOL MACHINE DECAL HAZARD CLASSIFICATION SYMBOLS A multi-tier hazard classification system is used on machine decals to communicate potential personal injury hazards.
Page 18 NOTICE - Notice used without a safety alert symbol indicates a hazardous situation, which, if not avoided, could result in property damage. SYMBOLS AND PICTORIALS Hazard Avoidance CRUSH HAZARD Stay Clear of Moving Turret and Boom. Crushing of fingers hand force applied directions (pinched).
Page 19 T300-1_T500-1_T780 Safety Hazard Avoidance Falling From NO RIDERS Wheeled Machine. Hand Entanglement Keep Hands Clear of Winch In Pulley / Winch. and Load Line. Entanglement in Stay Clear of Rotating Shafts. Drive Shaft. ENTANGLEMENT Keep away from fan and belt HAZARD when engineis running.
Page 20 Hazard Avoidance BURN HAZARD No smoking. No flame. Stop Fuel and fumes can engine. explode and burn. BURN HAZARD Allow surfaces to cool before Contact with hot servicing. surfaces can cause burns. Falling from height. Use personnel lift or appropriate ladder to reach high places.
Page 21 T300-1_T500-1_T780 Safety Hazard Avoidance Electrical Shock / Stay Sufficient Distance From Electrocution from Electrical Power Lines. Crane Power Line Contact. These are general safety rules, which must be followed. You are also required to read and understand the Operators Manual as there are instructions, which are more detailed specific to this machine.
Page 22: General Safety
General Safety Safety Sign Locations P/N 12261-683 REVISED: January 2015...
Page 23 T300-1_T500-1_T780 Safety Crush Hazard Stay clear of moving boom or turrent.. Contact with moving boom or turrent can result in death or serious injury. Injection Hazard Fluid escaping under pressure can penetrate skin and result in serious injury. Relieve pressure before disconnecting Crush Hazard Stay clear of moving hydraulic lines.
Page 24 Entanglement Hazard Stay clear of belts and fan when engine Contact with rotating is running. parts can result in death or serious Stop engine before injury. servicing. P/N 12261-683 REVISED: January 2015...
Page 25 T300-1_T500-1_T780 Safety DESCRIPTION OF MOVEMENT A1 HOIST. With forearm vertical fore finger pointing up, move hand in small horizontal circle A2 LOWER. With arm extended downward, forefinger pointing down move hand in small horizontal circle. A3 USE MAIN HOIST. Tap fist on head; then use regular signals. A4 USE WHIP LINE.
Page 26 DESCRIPTION OF MOVEMENT B2 MOVE SLOWLY. Use one hand to give any motion signal and place other hand motion- less in front of hand giving the motion signal. (Hoist slowly shown as example) B3 RAISE THE BOOM AND LOWER THE LOAD. With arm extended, thumb pointing up, flex fingers in and out as load movement is desired.
Page 27 T300-1_T500-1_T780 Safety Crush Hazard Verify lock pin is fully Crush Hazard Stay clear of Contact with falling engaged in jib. outrigger path and Contact with moving lattice jib can result Read and contact point. outriggers can result in death or serious understand in death or serious injury.
Page 28 ELECTROCUTION Stay clear of machine Burn Hazard Do not loosen cap HAZARD until cool. Contact with electric Release of hot fluid power lines will result under pressure can in death or serious result in death or injury. serious injury. P/N 12261-683 REVISED: January 2015...
Page 29 T300-1_T500-1_T780 Safety Electrocution Hazard Contact with electric power lines will result in death or serious injury. Before operating the machine, contact the electric power line owner to disconnect, move or insulate power lines. Improper lifting of personnel can result in death or serious injury Use of this machine to hoist, lower, swing or otherwise handle personnel must only be done in compliance with OSHA 1926.1431 and ANSI B30.23.
Page 30 Equipment Damage Hazard Damage to equipment can result if turbo charger is not fully lubricated before loading engine. 1. Start engine and run at idle speed. 2. Wait for indicated oil pressure. 3. Operate engine normally. Improper operation or maintenance of this equipment can result in death or serious injury. Read and understand operator's manual and all safety signs before using or maintaining machine.
Page 31 T300-1_T500-1_T780 Safety Fall Hazard Use the provided Falling can result in access system. death or serious Overturning Hazard injury. Death or Serious Injury can result from an overturning crane. The boom angle must be between 35° and 70° unless the boom is positioned over the rear in-line with the cranes chassis or the outriggers are fully extended.
Page 32 Improper lifting of personnel can result in death or serious injury. Use of this machine to hoist, lower, swing or otherwise handle personnel must only be done in compliance with OSHA 1926.1431 Explosion/Burn Hazard and ANSI B30.23. Battery explosion and/or contact with corrosive acid will result in death or serious injury.
Page 33 T300-1_T500-1_T780 Safety Burn Hazard Stay clear of hot surfaces. Allow Explosion / Burn No smoking. Contact with hot machine to cool Hazard surfaces can result in before servicing. Keep all open flames death or serious Fuel and fumes can and sparks away. injury.
Page 34: Safety Sign Maintenance
Safety Sign Maintenance Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild soap and water to clean safety signs. Do not use solvent-based cleaners because they may damage the safety sign material. The graphics on the following pages illustrate the location and give you examples of each safety decal located on your machine.
Page 35: Workplace Safety
T300-1_T500-1_T780 Safety Workplace Safety HANDLING PERSONNEL Cranes can only be used to lift people when it is the least hazardous way to do the job. (See OSHA 1926.550g, and ASME / ANSI B30.23.) TRAINING AND KNOWLEDGE Safety must always be the operator's most important concern. Do not operate this crane until you have been trained in its operation.
Page 36 OPERATOR'S RESPONSIBILITIES Keep people, equipment and material outside of the work area. 10. Signal person(s) must be used when the operator's vision is blocked or when working in hazardous areas such as near power lines or people. 11. Keep a fully charged fire extinguisher and first aid kit in the operator's cab at all times and be familiar with the use of these items.
Page 37 T300-1_T500-1_T780 Safety RESPONSIBILITIES OF ALL CREW MEMBERS Unsafe conditions and/or practices must be corrected. Obey all warning signs. Watch out for your safety and the safety of others. Know and understand proper machine erection and rigging procedures. Alert operator and signal person of dangers, such as power lines, unstable ground, etc. MANAGEMENT RESPONSIBILITIES Operators must be competent, physically fit and, if required, licensed.
Page 38 PLANNING THE JOB 12. Always pre-plan the course of each lift to determine the safest method to reach the load’s target destination. 13. Identify the location of gas lines, power lines, or other structures and determine if the crane or structures need to be moved. 14.
Page 39 T300-1_T500-1_T780 Safety OPERATOR AIDS CHECK Overload Protection, Load Indicators, Rated Capacity Limiters. OPERATION OVERLOAD PROTECTION Know the weight and characteristics of all loads to be lifted. Place the boom lifting point directly above the load when lifting. The load radius will increase when the load is lifted due to boom deflection.To compensate for the boom deflection, maintain the radius by raising the boom.
Page 40 POWER LINE SAFETY Determine whether there are power lines in the area before starting any job. Only operate around power lines in accordance with Federal, State and Local Regulations as well as ANSI B30.5 latest edition. Never remove materials from under powerlines with a crane if the boom or machine is capable of contacting them.
Page 41 T300-1_T500-1_T780 Safety POWER LINE SAFETY Before operating machine, contact LINE VOLTAGE REQUIRED CLEARANCE the electric power line owner to >0 TO 50kV 10 FT ( 3.0M) disconnect, move, or insulate power >500 TO 200kV 15 FT (4.6m) lines. >200 TO 350kV 20FT (6.1m) >350 TO 500kV 25FT (7.6m)
Page 42 OPERATIONAL AIDS - EMERGENCY PROCEDURES When operational aids are inoperative or malfunctioning, the following requirements shall apply for continued use or shutdown of the crane. Steps shall be taken to schedule repairs immediately. The operational aids shall be put back into service as soon as replacement parts, if required, are available and the repairs and calibration can be carried out.
Page 43: Effects Of Wind Conditions
T300-1_T500-1_T780 Safety Effects of Wind Conditions Wind Speed Detection It is essential that you observe the permitted maximum wind speeds. To check the wind speed, the crane can be equipped with an air speed indicator (anemometer). This consists of two elements: Rotor - fitted to the head of the main boom or main boom extension.
Page 44 Pay attention to the wind speed values in table below in relation to the information in the WARNING section of the LOAD CHART. Any governmental regulations applicable to the job site must also be observed. Wind Force Wind Speed Consequences Scale Terms Described Inland Territories...
Page 45: Lightning Storm
T300-1_T500-1_T780 Safety Lightning Storm When lightning is striking in the vicinity of the crane, the operator should never attempt the following procedures: • Getting into the operator's cab; upper or lower, or attempting to get onto the carrier, superstructure or boom assembly. •...
Page 46: Temporary Interruption Of Crane Operations
Temporary Interruption of Crane Operations As a general rule, if it is not possible to maintain sufficient control over a rigged crane, the boom and the equipment shall be taken down if the crane's operations are interrupted and may be left unsupervised. The following instructions are valid for every mobile crane, regardless of the type, the configuration, the rigging mode and the environment: •...
Page 47 T300-1_T500-1_T780 Safety • The crane location and configuration does not create hazards to the road traffic, e.g. risk of collision with surrounding obstacles; this may require a specific risk assessment prior to leaving the crane unattended. • Check for leakage and unintended (slow) movement on all load bearing hydraulic cylinders and winches: Outrigger vertical cylinders Boom luffing cylinder(s)
Page 48 Slow retraction of outrigger support cylinders, luffing cylinders and/or telescoping cylinders on unpinned telescoping systems (e.g. due to changes in ambient and oil temperature, leakage). • Vandalism. Any or a combination of the above may result in the following events: •...
Page 49: Resuming Crane Operations
T300-1_T500-1_T780 Safety Resuming Crane Operations Before crane operation is resumed after a period of inactivity/crane being unattended, the operator is required to check the condition of the crane, its location and safety devices. Danger of Accident Whenever the operator has left the cab, the operating mode settings must be verified and reset.
Page 50: Ending Crane Operations
Ending Crane Operations Prior to leaving the crane, the operator must be certain the crane is in a condition acceptable to be left unattended. End of Operations checklist 1. _________ Is the load fully on the ground and unhooked from the crane? 2.
Page 51: Turning/Driving In Reverse
T300-1_T500-1_T780 Safety Turning/Driving in Reverse While operating a mobile crane in reverse, the risk of accident or injury is greater and extra caution must be exercised. Danger of accidents and personnel injury are increased when operating in reverse. To minimize the risk of personnel injury or property damage, the following cautions must be observed.
Page 52: Parking The Vehicle
Parking the Vehicle NOTE: Parking Instructions only apply to mobile cranes. Failure to adequately secure parked vehicle may result in vehicle roll-off and damage to personnel and/or property. Risk of Death The following conditions must be strictly adhered to by crane drivers- •...
Page 53: Lock Out & Tag Out
T300-1_T500-1_T780 Safety Lock Out & Tag Out Code of Federal Regulations number 1910.147 requires that employers establish and follow a Lock Out & Tag Out procedure and train their employees in that procedure before any employee can operate, service or maintain any piece of power equipment. Employers are required to make periodic inspections to see that their Lock Out &...
Page 54 Who must apply a lock & tag • Any person working on the equipment. • Foreman or other person responsible for the work being done. • If several people are working on a machine at the same time, each person must apply his or her own lock and tag.
Page 55: Access/Egress
To provide safe access and egress to/from the crane, Terex provides a number of steps, ladders and handrails allowing three--point access to all areas of the crane where it is necessary for the operator to be when moving from the ground to the operator's cab or from the operator's cab to the ground.
Page 56 Do not use item 1 as a grab handle. Only use grab handles for access or egress of the operator's cab that are marked in the illustrations. Carrier Cab Access / Egress P/N 12261-683 REVISED: January 2015...
Page 57 T300-1_T500-1_T780 Safety Rear LH Side Access / Egress Carrier Access / Egress-LH Side P/N 12261-683 REVISED: January 2015...
Page 58: Personal Safety
Personal Safety LOCK OUT/TAG OUT The purpose of a Lock Out / Tag Out procedure is to ensure that the machine is isolated from potentially hazardous energy, locked and tagged out before performing any service or maintenance where energization, start-up or release of stored energy could cause injury. Locate and identify all energy isolating devices and be certain which switch(es), valve(s), or other energy isolating devices apply to the machine to be locked out.
Page 59 T300-1_T500-1_T780 Safety SLIP AND FALL PREVENTION Keep the machine clean and dry. Remove all oil, grease, mud, ice and snow from walking surfaces. Store all tools, rigging and other items in the tool box. Replace all broken ladders or other access system components. Keep non-slip surfaces in good condition.
Page 60: Seat Belts
Seat Belts SOME SUGGESTED USAGE AND MAINTENANCE INSTRUCTIONS FOR SEAT BELTS Wear your lap belt low and snug. Manually adjustable lap belts and shoulder harnesses are adjusted by pulling the loose end of the webbing through the buckle or adjuster. Seat belts using automatic-locking or emergency-locking retractors are self-adjusting.
Page 61: Temperature Effects On Telescope And Boom Hoist Cylinders
T300-1_T500-1_T780 Safety Temperature Effects on Telescope and Boom Hoist Cylinders Background Liquids exhibit changes in volume with changes in temperature. The degree of volume expansion divided by the change in temperature is called the material's coefficient of thermal expansion and generally varies with temperature. The thermal expansion coefficient of Petroleum oils varies slightly depending on several factors including API Specific Gravity.
Page 62 RT130 Load Drop Due to Temperature 1 Part of Line, 3 Different Boom Extensions, 60° Boom angle Load Drop (inches) 100% Max Boom Length Extend Cylinder Oil Temperature Drop (F°) 50% Max Boom Length 6' Each Section RT130 Load Drop Due to Temperature 2 Part of Line, 3 Different Boom Extensions, 60°...
Page 63 T300-1_T500-1_T780 Safety RT130 Load Drop Due to Temperature 4 Part of Line, 3 Different Boom Extensions, 60° Boom angle Load Drop (inches) 100% Max Boom Length Extend Cylinder Oil Temperature Drop (F°) 50% Max Boom Length 6' each section Notes: Projected load drift will be lower for boom angles less than 60°, and slightly more for boom angles greater than 60°...
Page 64: Assembly
Assembly Erecting the Jib Jib Storage Brackets Anti Two-Block Switch Jib Mounting Pins (4) Guide Rope Anti Two-Block Pins T-Handle Anti Two-Block Plug Extend and set the outriggers. Rotate the upper structure to the “over rear” position. Retract the boom completely. Boom down to minimum boom angle to allow ease of installation of the jib pins.
Page 65 T300-1_T500-1_T780 Assembly Booming down too quickly can result in damage to jib. 10. With the engine at idle, slowly boom down to minimum boom angle while another operator uses the guide rope to control the speed of the jib rotation. The jib will swing around until the left side mounting holes line up.
Page 66: Changing The Offset Of The Jib
Changing the Offset of the Jib Attach hoist line dead end 30º Offset Hole 0º Offset Hole Sheave Shaft 15º Offset Hole Cap Screws INCREASING OFFSET Retract the boom and set the outriggers. Boom down to minimum boom angle. P/N 12261-683 REVISED: January 2015...
Page 67 T300-1_T500-1_T780 Assembly Loosen the two (2) cap screws on the left side of the upper and lower sheave shafts. This will require a 3/ 4 inch hex wrench. Reeve the hoist line over the top center sheave on the boom head, around the jib sheave, and attach to the eye on the bottom of the jib tip.
Page 68: Extending And Retracting The Jib Pull-Out Section
Extending and Retracting the Jib Pull-out Section Anti Two-block Weight Anti Two-block Extended Socket Attach Dead-end Of Rope Anti Two-block Retracted Socket Pull Out Retaining Pin Hole Pull out Anti Two-block Plug NOTE: The jib must be erected before extending the pullout section. Do not attempt to extend the pullout section while the jib is stowed.
Page 69 T300-1_T500-1_T780 Assembly EXTENDING THE PULLOUT SECTION Retract the boom completely and boom down to minimum boom angle. Attach the dead end of the wire rope to the eye on the bottom of the jib tip. This is done to prevent the pullout from extending uncontrollably. Unplug the pull out anti two-block plug from the anti two-block Retracted socket.
Page 70: Spooling Wire Rope On Drums
Spooling Wire Rope on Drums Care must be exercised when installing wire rope on the winch drum. Improper spooling can. result in rope damage through crushing, kinking, dog- legs, abrasion and cutting. Poorly installed wire rope will also adversely affect the operating characteristics of the machine by causing uneven application of force and motion.
Page 71 T300-1_T500-1_T780 Assembly Apply braking force to the reel flange in order to prevent overrun as the rope is being drawn off. Loops formed by overrun can cause kinks and doglegs in the rope, resulting in damage and premature rope failure. A timber or block forced against the shipping reel flange can be used to provide the required braking force.
Page 72: Cable Sockets
Cable Sockets The wrong cable wedge could permit the wire rope to work loose and detach itself from the drum; possibly causing property damage or personal injury. Tension the wire rope by braking the shipping reel and slowly operate the winch in the raise mode to wind the cable onto the winch drum.
Page 73 T300-1_T500-1_T780 Assembly Insert the wedge (1) and allow the rope strands to adjust around it. Seat the wedge and loop just tightly enough to allow handling by attaching the socket to a strong support and engaging the winch to take a strain on the rope. Final seating of the wedge is accomplished by making lifts of gradually increasing loads.
Page 74: Hoist-Line Reeving
Hoist-Line Reeving 1. AUXILIARY WINCH 2. MAIN WINCH 3. 5 SHEAVE 4. 4 SHEAVE 5. DEAD END FOR EVEN PARTS OF LINE 6. DEAD END FOR ODD PARTS OF LINE 7. WINCH DEAD END 8. IDLER SHEAVE 9. LOAD SHEAVE 10.
Page 75 T300-1_T500-1_T780 Assembly NOTE: SHEAVES IN BOOM HEAD AND HOOK BLOCK ARE NUMBERED FROM LEFT TO RIGHT AS VIEWED FROM THE OPERATOR’S STATION. “D” INDICATES PINNED END OF ROPE. PARTS OF LINE BOOM HEAD (LOAD HOOK BLOCK (BLOCK SHEAVE) SHEAVE) 1 4 D 1 2 3 2 4 D 1 2 4 D...
Page 76 Test the anti two-block system by lifting the anti two block weight. The light and audible alarms should be actuated in the cab and the boom down, boom extend, and winch up controls should disconnect. As shipped from the factory, the crane has sufficient wire rope provided to allow the hook to reach ground level with any boom length and elevation when reeved with minimum parts of line required for the load being lifted.
Page 77: Counterweight Change - (T300-1 Only)
T300-1_T500-1_T780 Assembly Counterweight Change - (T300-1 Only) In some cases it may be desirable to change the counterweight on the T300 for use in locales where it can be advantageous to have a heavier or lighter crane, with the corresponding change in rated lift capacity.
Page 78 P/N 12261-683 REVISED: January 2015...
Page 79 T300-1_T500-1_T780 Assembly 13. Place new paper copy of the load chart that matches the cranes configuration in the operator's cab. 14. Verify that all functions of the crane and RLI are working properly and that the programmed load chart matches the configuration of the crane. P/N 12261-683 REVISED: January 2015...
Page 80 COUNTERWEIGHT FASTENER TORQUE TABLE LOCATION ON CRANE FASTENER SIZE TORQUE VALUE (FT. LBS) AUX WINCH to C'WT 1-8 NC X 8" GRD 5 640 (DRY) C'WT to SUPERSTRUCTURE 1.25 NC X 19.50' GRD 5 1120 (DRY) C'WT to C'WT- add on weight .75 NC X 4.50"...
Page 82: Description Of Machine And Controls
Description Of Machine and Controls Universal Symbol Identification This section is intended to familiarize the operator with the controls and instruments provided for the operation of this machine. It should be emphasized, however, that merely knowing the controls is inadequate preparation for operating hydraulic cranes. Do not attempt to operate the machine until the other sections of this manual have been covered.
Page 83 T300-1_T500-1_T780 Description Of Machine and Controls ELECTRICAL SYSTEM ON HEADLIGHTS WASHER IGNITION ON FAST ENGINE DIAGNOSTIC IGNITION SLOW INCR / IDLE ADJ INCREASE ENGINE STOP AXLE DISENGAGE / RANGE INCR / IDLE ADJ DECREASE SHIFT AIR SUSPENSION FILL KEY - ACC ENGINE STOP P/N 12261-683 REVISED: January 2015...
Page 84 AIR SUSPENSION DUMP KEY - OFF DIFF LOCK OFF HIGH SPEED REAR AXLE KEY - ON KEYSWITCH LOW SPEED REAR AXLE KEY - START PTO OUT DIFF LOCK ON PTO IN ENGINE WARN P/N 12261-683 REVISED: January 2015...
Page 85 T300-1_T500-1_T780 Description Of Machine and Controls DPF LAMP HEST LAMP CHECK ENGINE ABS-DIAGNOSTIC P/N 12261-683 REVISED: January 2015...
Page 86: Carrier Controls And Instruments-Epa 2013 Engines
Carrier Controls and Instruments-EPA 2013 Engines P/N 12261-683 REVISED: January 2015...
Page 87 T300-1_T500-1_T780 Description Of Machine and Controls Carrier Controls & Instruments 1. GAUGE LIGHT DIMMER SWITCH-Turn to 17. IGNITION SWITCH adjust brighness of gauge lights. A. Circuits other than ignition "on". B. All circuits "off". C. All circuits including ignition "on". D.
Page 88 11. TEMPERATURE ADJUST-Adjusts heat 27. 4 WAY FLASHER-Pull to activate temperature. flashers, push to deactivate. 12. AIR GUAGE (Front)-Indicates air 28. TRANSMISSION SHIFT LEVER -See pressure in front air tank. Maintain 110 to Fuller Manual or Allison Transmission 115 psi normal system air pressure. Operations instructions.
Page 89 Warning Light "ON". colored Warning Light "ON" with low fuel level. 37. BATTERY CHARGING CONDITION-Red 49. LCD DISPLAY -Readouts: Terex Logo, colored Warning Light "ON" if less than 12 Clock, Total Engine Machine Hours, Engine volts. Oil Pressure, Total Odometer, Partial Odometer, Languages menu, Engine Fault.
Page 90 38. LOW AIR PRESSURE-Red colored 50. ENGINE COOLANT TEMPERATURE Warning Light "ON" if less than 60 PSI. GUAGE-Guage and Red colored Warning Light "ON" when engine is at 230 degrees Farenheit (110 C) or above. Engine is overheating. 39. DPF TEMPERATURE-Red colored 51.
Page 91 T300-1_T500-1_T780 Description Of Machine and Controls 56. FIRE EXTINQUISHER -Fully charged 57. WINDSHIELD WASHER RESERVOIR - indicator arrow on "Green". Remove latch, Use only over the counter washer fluid made pull safety pin, point toward base of flame specifically for automotive windshields. and depress black handle to discharge fire suppressant.
Page 92 58. HEATER UNIT-Engine hot water 59. TRANSMISSION SHIFTER-Eaton Fuller supplied to carrier cab heater unit. transmission (See Trans Operations Instructions). P/N 12261-683 REVISED: January 2015...
Page 93 T300-1_T500-1_T780 Description Of Machine and Controls Manual & Automatic Transmission P/N 12261-683 REVISED: January 2015...
Page 94 The PTO light (43) will come on once the engine starts. Use this position for normal craning functions. T300-1 Pump Engagement Procedure With this system, only change the PTO switch position with the engine at low idle or with the engine off.
Page 95 T300-1_T500-1_T780 Description Of Machine and Controls Only engage pumps while the engine is OFF. Attempting to engage the pumps with the engine running will result in damage to the pump disconnect splines. To Engage Pumps: Turn the ignition switch (36) on (Positon C), DO NOT start the engine. Push PTO switch (13) all the way up.
Page 96 Never allow a spinning wheel to spin for an extended period of time. Never engage the differential locking switch when any axle is revolving. Engage only when all axles are stopped. TRANSMISSION OPERATIONS INSTRUCTIONS P/N 12261-683 REVISED: January 2015...
Page 97 T300-1_T500-1_T780 Description Of Machine and Controls P/N 12261-683 REVISED: January 2015...
Page 98 P/N 12261-683 REVISED: January 2015...
Page 99 T300-1_T500-1_T780 Description Of Machine and Controls P/N 12261-683 REVISED: January 2015...
Page 100 P/N 12261-683 REVISED: January 2015...
Page 101 T300-1_T500-1_T780 Description Of Machine and Controls P/N 12261-683 REVISED: January 2015...
Page 102 P/N 12261-683 REVISED: January 2015...
Page 103 T300-1_T500-1_T780 Description Of Machine and Controls P/N 12261-683 REVISED: January 2015...
Page 104 P/N 12261-683 REVISED: January 2015...
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Page 109 T300-1_T500-1_T780 Description Of Machine and Controls UNIDECK Operation & Instructions P/N 12261-683 REVISED: January 2015...
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Page 122: Carrier Controls And Instruments-Export
Carrier Controls and Instruments-EXPORT P/N 12261-683 REVISED: January 2015...
Page 123 T300-1_T500-1_T780 Description Of Machine and Controls Carrier Controls & Instruments 1. GAUGE LIGHT DIMMER SWITCH-Turn to 17. IGNITION SWITCH adjust brighness of gauge lights. A. Circuits other than ignition "on". B. All circuits "off". C. All circuits including ignition "on". D.
Page 124 13. PTO AIR VALVE SWITCH-Push up to 29. ACCELERATOR PEDAL-Depress to engage pumps, push down to disengage. accelerate. 14. INTER AXLE LOCKOUT VALVE-Lock out 30. BRAKE PEDAL-Depress to actuate. inter-axle differential. Should the machine become stuck, a spinning whell will receive all power transmitted by the drivetrain causing tha wheel to spin faster and worsen the condition.
Page 125 Warning Light "ON" with low fuel volts. level. 38. LOW AIR PRESSURE-Red colored 49. LCD DISPLAY -Readouts: Terex Logo, Warning Light "ON" if less than 60 PSI. Clock, Total Engine Machine Hours, Engine Oil Pressure, Total Odometer, Partial Odometer, Languages menu, Engine Fault.
Page 126: Upper Controls And Instruments
Upper Controls and Instruments UPPER CONTROLS & INSTRUMENTS 1. DEFROSTER FAN SWITCH 18. CHECK ENGINE-Red light "ON" indicates check Engine condition. 18A STOP ENGINE -Red light "ON" indicates stop engine. P/N 12261-683 REVISED: January 2015...
Page 127 T300-1_T500-1_T780 Description Of Machine and Controls 2. DASH LIGHT SWITCH-Press top part of 19. OUTRIGGER SWITCH-LF-Switch switch to backlight guages and switches. controls Left Front Jack cylinder. Push left side of switch to run beam in conjunction with (27) Master Switch. Push right side of switch to run jack in conjuction with (27) Master Swtich.
Page 128 7. CUP HOLDER 24. HYDRAULIC REMOTE CONTROL TRANSMISSION SWITCH (Option)-See Hydraulic Remote Control section for operation. 8. FRONT JACK INDICATOR-Red light "ON" 25. HYDRAULIC REMOTE POWER SWITCH indicates the front jack is "NOT" retracted. (Option)-See Hydraulic Remote Control section for operation. 9.
Page 129 T300-1_T500-1_T780 Description Of Machine and Controls 15. ENGINE OIL PRESSURE -Measures 32. SWING BRAKE RELEASE-Lift up on engine oil pressure. Graduated from 0 to 100 knob and pull to disengage the swing brake. psi and 0 to 700 kPa. Knob control can be set in two postions, "OUT"...
Page 130 P/N 12261-683 REVISED: January 2015...
Page 131 T300-1_T500-1_T780 Description Of Machine and Controls 35. HAND THROTTLE - Holds engine 40. HEATER RANGE SELECTOR SWITCH- throttle at an operator settable position. Continuously variable rotary switch. The Place the accelerator (27) at approximate lowest switch position cuts power to the RPM.
Page 132 LH JOYSTICK CONTROL 1. SWING LEFT-CCW CONTROL-Move joystick to left and upper structure will rotate CCW proportional in speed to throttle setting and movement of joystick. 2. SWING RIGHT-CW CONTROL-Move joystick to right and upper structure will rotate CW proportional in speed to throttle setting and movement of joystick.
Page 133 T300-1_T500-1_T780 Description Of Machine and Controls 3. AUXILIARY WINCH-UP CONTROL-Move 3A. AUXILARY WINCH ROTATION joystick backward to take in aux winch wire INDICATOR-Internal to the handle is a rope. Speed of wire rope is proportional to thumper indicator that is felt by the throttle setting and movement of joystick- operators hand to assist in the speed the raising the load.
Page 134 RH JOYSTICK CONTROL 7. HORN-Depress switch on front face of joystick will sound the horn. 8. BOOM DOWN CONTROL-Move joystick to right will lower the boom proportional in speed to throttle setting and movement of joystick. 9. BOOM UP CONTROL-Move joystick to left will raise the boom proportional in speed to throttle setting and movement of the joystick.
Page 135 T300-1_T500-1_T780 Description Of Machine and Controls 10. MAIN WINCH-UP CONTROL-Move 10A. MAIN WINCH ROTATION INDICATOR- joystick backward to take in main winch wire Internal to the handle is a thumper indicator rope-raising the load.. that is felt by the operators hand to assist in the speed the winch drum is traveling when the Main winch joystick is moved forward or backward.
Page 136 1. Heater & AC Unit-See Kenway Operations & Maintenence Manual on your Manual Pack Shop Manual CD. P/N 12261-683 REVISED: January 2015...
Page 137: Outrigger Controls-External (Streetside)
T300-1_T500-1_T780 Description Of Machine and Controls Outrigger Controls-External (Streetside) Your cranes is available as an Option remote outrigger control boxes. Located on the street side midship (as shown below) is a panel door to access the control switches. There will be a control box with access cover on both side of crane and one located in the front for control of front jack cylinder.
Page 138: Side-Stow Jib
Side-Stow Jib DESCRIPTION-T300-1 Optional jib extension is available to provide additional boom reach, which is a 32-49 ft. (9.75-14.9 m) side stow swing-on one-piece lattice type jib that is offsettable at 0°, 15°, or 30°. The jib is extendible to 49 ft. (14.9 m) by means of a 18 ft. (5.5 m) pull out tip section.
Page 140: Inspection
Inspection Pre-Start Inspection The following items should be checked each day before start-up and the start of operations. Also see “Daily Check.” on page 146 ENGINE OIL The level should be at the full mark. COOLANT The level should be near the bottom of fill neck in coolant tank when cold. DIESEL EXHAUST FLUID Check diesel exhaust fluid (DEF) or Urea tank level is full.
Page 141 If the light is not on, bump the starter to jog the engine on T300-1 only, and align the pump splines, until the light comes on before starting the engine.
Page 142: Suggested Hydraulic Crane Inspection Checklist
Suggested Hydraulic Crane Inspection Checklist This check list is to be used in addition to the information provided in this manual to properly operate and maintain the machine. ITEMS TO BE INSPECTION SATISFACTORY ADJUST REPAIR INSPECTED & CODE CHECKED VISUAL INSPECTION H (Complete Machine)
Page 143 T300-1_T500-1_T780 Inspection MACHINE LUBRICATION ATTACHMENT PIN BOLTS MUFFLER/ EXHAUST SYSTEM ALL CONTROL MECHANISMS INSTRUMENT GAUGES CLUTCHES & BRAKES WIRE ROPE, SHEAVES & GUARDS TWO BLOCK DAMAGE PREVENTION SYSTEM LOAD SUPPORTING COMPONENTS CONDITION FIRE EXTINGUISHER BACKUP ALARM BOOM ANGLE INDICATOR HEAD/TAIL/ BRAKE LIGHTS &...
Page 144 CABLE SPOOLING PROPERLY WEDGE SOCKETS AXLE FLUID LEVEL SWING REDUCER FLUID LEVEL DRIVE SHAFTS & U JOINTS TIRE & WHEEL CONDITION & INFLATION PRESSURE REGULATORS AIR CLEANER ELEMENT CLUTCH & BRAKE LINKAGE & PINS WHEEL LUG NUT TORQUE FAN BELT TENSION STRUCTURAL MEMBERS &...
Page 145 T300-1_T500-1_T780 Inspection BATTERIES & STARTING SYSTEM TRANSMISSION FILTER ENGINE OIL FILTER ENGINE FUEL FILTER SWING BEARING BOLT TORQUE MACHINERY GUARDS LOAD CHART & SAFETY WARNINGS H Inspect OVERALL machine (including carrier) for cracks, weld separation, leaks, damage, vandalism. INSPECTION CODE INTERVALS D - DAILY W - WEEKLY M - MONTHLY...
Page 146 P/N 12261-683 REVISED: January 2015...
Page 147: Daily Check (8 Hours)
T300-1_T500-1_T780 Inspection Daily Check (8 Hours) __ Perform Daily Lubrication __ Check Hydraulic Reservoir Fluid Level __ Fill Fuel Tank __ Check Engine Oil Level __ Check Coolant Level __DEF Aftertreatment Fluid (Urea) Tank Level __ Check Hydraulic Cylinder Mounting Bushings And Pins __ Check Hydraulic Components including hoses.
Page 148: Weekly Check (40 Hours)
Weekly Check (40 Hours) __ Perform The Daily Check __ Perform Weekly Lubrication __ Check Swing Reducer Oil Level __ Check Axle Oil Level (after initial change) __ Check Battery Condition __ Check Tire Pressure And Condition __ Check Air System Safety Valve __ Check Torque On Wheel Lug Nuts __ Check Hydraulic Cylinders And Rods __ Make Thorough Inspection Of Wire Rope...
Page 149: Monthly Check (80 Hours)
T300-1_T500-1_T780 Inspection Monthly Check (80 hours) __ Perform Daily And Weekly Checks __ Perform Monthly Lubrication __ Check Engine Belts __ Check Hydraulic Reservoir For Moisture __ Check All Slider Pads __ Have Hydraulic Oil Sample Analyzed __ Clean Radiator & Oil Cooler Exterior __ Check Engine Manufacturer’s Manual For Additional Maintenance Requirements P/N 12261-683 REVISED: January 2015...
Page 150: Quarterly Checks (250 Hours)
Quarterly Checks (250 Hours) __ Perform Daily, Weekly And Monthly Checks __ Perform Quarterly Lubrication __ Drain Fuel Tank Of Water And Sediment If Necessary __ Check Brake Shoes for Wear Condition __ Change Transmission Oil And Shift Air Filter __ Change Hydraulic Return Line Filters __ Replenish Cooling System Corrosion Inhibitor (refer to engine manufactures manual) __ Check Engine Manufacturer’s Manual For Additional Maintenance Requirements...
Page 151: Semiannual Checks (1000 Hours)
T300-1_T500-1_T780 Inspection Semiannual Checks (1000 Hours) __ Perform Daily, Weekly, Monthly And Quarterly Checks __ Perform Semiannual Lubrication __ Clean Crankcase Breather __ Check Hydraulic Reservoir Relief Valve __ Clean Hydraulic Reservoir Intake Suction Filter __ Check Air Dryer Desiccant For Signs Of Oil Accumulation __ Change Power Steering Filter Element __ Check Hydraulic Relief Valve Pressure Settings __ Torque Swing Bearing Bolts (725 ft.
Page 152: Annual Check (1500 - 2000 Hours)
Annual Check (1500 - 2000 Hours) __ Perform Daily,Weekly,Monthly,Quartly and Semiannual Checks __ Perform Annual Lubrication __ Disassemble Winch And Inspect __ Drain And Clean Hydraulic Reservoir __ Change Hydraulic Fluid (unless checked by oil analysis). __ Drain and Refill The Winch Lubricant __ Change Axle Oil __ Check the hose lines (see Hydraulic Hose topic in the Maintenance section of this manual).
Page 153: Wire Rope Inspection Record
T300-1_T500-1_T780 Inspection Wire Rope Inspection Record WIRE ROPE INSPECTION RECORD (Refer to Wire Rope User's Manual for Criteria) PLACE OF INSPECTION DATE DESCRIPTION OF CRANE Make Model Serial No. Type and arrangement of attachments Date of Last Rope Inspection Hours and Time of Service Since Last Inspection Results of Inspection Rope Type and Size Conditions Noted...
Page 154: Mobile Crane Load Test Inspection
Mobile Crane Load Test Inspection General As a worldwide crane manufacturer, Terex Cranes does not recommend carrying out a regular overload test on mobile cranes. An overload test after every change of location or crane reconfiguration is not a reliable and safe inspection method and can cause premature material fatigue.
Page 155 This person must determine whether the movement can be carried out safely or whether immediate repair/modification is required. Recommendations of Terex Cranes with Regard to Load Tests Checking Assembly Checking the correct crane assembly (e.g. after reconfiguration) must include:...
Page 156 - after changes to location. This applies to all Terex mobile cranes for the static and dynamic load test. A period of 5 minutes is sufficient for the static test. The conditions listed above do not apply after reconfiguration or repairs to load- bearing crane parts.
Page 158: Operating Instructions
Operating Instructions Regeneration Process for DD Series 60 - (T500-1 & T780 Only) After-treatment System In order to meet current emissions regulations, the traditional muffler has been replaced by a new After-treatment Device (ATD). This device consists of a Diesel Oxidation Catalyst (DOC) and a Diesel Particulate Filter (DPF).
Page 159 This ash does not oxidize in the filter during the regeneration process and must be removed through a cleaning procedure. All Terex Truck Cranes equipped with diesel Tier lll engines will illuminate a dashboard warning: light indicating the need for ash cleaning.
Page 160 The operator will be notified of the need for a parked regeneration due to the illumination of the yellow DPF Regeneration Light. The sequence of lights is as follows: The DPF Regeneration Light will be illuminated prior to any engine protection measures being taken.
Page 161 T300-1_T500-1_T780 Operating Instructions NOTE: The check engine light in the upper cab of the truck crane will come on if the DPF Regeneration Light starts flashing in the lower cab. If the flashing DPF is still ignored, the AWL (Check Engine - Red Light) light will illuminate.
Page 162 If parked regeneration is still not initiated, a standard 60 second engine shutdown sequence will occur. The dash lights will have a yellow blinking light and a solid red light. Once the engine shutdown sequence is completed, a parked regeneration MUST occur to continue crane operations.
Page 163 T300-1_T500-1_T780 Operating Instructions HOT EXHAUST During parked regeneration the exhaust gases will be extremely HOT and could cause a fire if directed at combustible materials. The crane MUST be parked outside. NOTE: The operator MUST stay with the crane throughout the regeneration process. NOTE: The procedure will take up to 1 hr.
Page 164 Cycle the clutch pedal (if configured). If automatic transmission, cycle into gear and back to neutral. Park Brake must be ON and the clutch must be released. Transmission, either manual or automatic must be in neutral. Engine speed must be set at idle. PTO must be disengaged.
Page 165: Cummins 2013 Engine- Overview Of Operation
T300-1_T500-1_T780 Operating Instructions Cummins 2013 Engine- Overview of Operation Fuel Warning P/N 12261-683 REVISED: January 2015...
Page 166: Aftertreatment Regeneration Lamp Behaviors
Aftertreatment Regeneration Lamp Behaviors P/N 12261-683 REVISED: January 2015...
Page 167 T300-1_T500-1_T780 Operating Instructions P/N 12261-683 REVISED: January 2015...
Page 168 P/N 12261-683 REVISED: January 2015...
Page 169: Regeneration Modes
T300-1_T500-1_T780 Operating Instructions Regeneration Modes P/N 12261-683 REVISED: January 2015...
Page 170: Manual Regeneration Procedure
Manual Regeneration Procedure For the majority of the crane operating time, the Cummins Engine Particulate Filter is self- cleaning with no operator action required. On some occasions, the operator may need to perform a Stationary Regeneration. Under some operating conditions, such as low speed, low load, or stop and go duty cycles, the engine may not have enough opportunity to regenerate the aftertreatment diesel particulate filter during normal operation.
Page 171 T300-1_T500-1_T780 Operating Instructions _When the engine ECM detects that the aftertreatment diesel particulate filter has been regenerated, the engine will automatically return to normal idle speed, if increased. (See note 5.) NOTE 1: If a manual (non-mission) regeneration is attempted, and the High Exhaust System Temperature lamp doesn't illuminate, contact a Cummins authorized repair facility for assistance.
Page 172: Operating The Unit
Operating the Unit Operating the Engine P/N 12261-683 REVISED: January 2015...
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Page 175: Starting The Engine-Epa 2010
T300-1_T500-1_T780 Operating Instructions Starting the Engine-EPA 2010 STARTING THE ENGINE-2010 Tier 4 Check that the Emergency Stop Button is pulled out. This will allow starting of the engine. The engine may require the use of a cold weather starting aid if the ambient temperature is below 40°F (4°C).
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Page 178 P/N 12261-683 REVISED: January 2015...
Page 179 T300-1_T500-1_T780 Operating Instructions To prevent serious starting motor damage, do not press the starter switch again after the engine has started. If the engine fails to start within 15 seconds, release the starter switch and allow the starting motor to cool for 15 seconds before trying again. If the engine fails to start after four attempts, an inspection should be made to determine the cause.
Page 180 Warm-up Run the engine at part throttle for about five minutes to allow it to warm up before applying a load. Inspection Transmission - While the engine is idling, check the transmission for proper oil level and add oil as required. Look for coolant, fuel, or lubricating oil leaks at this time. If any are found, shut down the engine immediately and have leaks repaired after the engine has cooled.
Page 181: Engine Cold Weather Operation
T300-1_T500-1_T780 Operating Instructions Engine Cold Weather Operation P/N 12261-683 REVISED: January 2015...
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Page 184: Jump Starting An Engine- Booster Cable Instructions
Jump Starting an Engine- Booster Cable Instructions Position the vehicle with the booster battery adjacent to the vehicle with the discharged battery so that booster cables can be connected easily to the batteries in both vehicles. Make certain vehicles do not touch each other. On both vehicles, turn off all electrical loads.
Page 185: Unusual Operating Conditions
T300-1_T500-1_T780 Operating Instructions Unusual Operating Conditions Special problems in maintenance and operation are caused by unusual conditions such as extremes in heat, cold and humidity, high altitude, salt water, and dusty or sandy work sites. When operating under such conditions, special precautions must be taken to prevent damage, minimize wear, and avoid component deterioration.
Page 186 The battery can discharge if snow or ice short circuits the terminals. Keep the battery posts and cable connectors clean and dry. Remove any corrosion with a solution of soda and water. During extremely cold weather, it is advisable to remove and store the battery in a heated area when the crane is to remain idle for any extended period.
Page 187 T300-1_T500-1_T780 Operating Instructions Allow the engine to cool before draining and flushing the cooling system. Water containing more than small concentrations of salt or minerals should not be used in the cooling system. Salt facilitates corrosion and minerals deposited on the coolant passage walls.
Page 188 HIGH ALTITUDES Variations in altitude alter the fuel/air mixture burned in the engine and affect the engine’s performance. At high altitudes, atmospheric pressures are lower and less oxygen is available for combustion of the fuel. Above 10,000’ the engine fuel injectors may have to be changed to ensure proper performance.
Page 189: Making A Typical Lift
T300-1_T500-1_T780 Operating Instructions Making a Typical Lift LIFT PROCEDURE In making lifts, the operator must successfully coordinate several crane functions. These include the boom raise/lower, boom extend/retract, load hoist/lower and swing functions. Although experienced operators tend to operate two or more of these functions simultaneously, the lift procedure can be broken down into the following sequence of operations.
Page 190 FULL extension of the vertical jack cylinders should be avoided if not necessary to level crane and raise wheels clear of ground because oil expansion under extreme heat conditions can cause cylinder seal failure. Check to ensure that all beams are fully extended, swinging the upper if necessary to visually check that each beam reaches full extension.
Page 191 T300-1_T500-1_T780 Operating Instructions unseating the rope wedge in the winch drum, which could result in the uncontrolled fall of the hook block and load. Use of more parts of line than required for the lift increases likelihood of rope damage. Raise the boom to the required angle, consulting the boom angle indicator which indicates boom angle relative to upper structure.
Page 192 Apply the swing brake, with the foot pedal, when the swing is stopped or when emergency situations dictate that the swing be terminated abruptly. If properly executed, the load will hang motionless when the swing is terminated. If the load is oscillating, the swing was made too rapidly and/or stopped too abruptly. Never pull sideways with a crane boom.
Page 193 T300-1_T500-1_T780 Operating Instructions correctly installed and maintained anti two-block system, the block or ball will not raise, the boom cannot be extended and the boom cannot be lowered. To return to an operating condition, either lower the hook or ball, retract or raise the boom. The operator may need to raise the hook block beyond the point at which the anti two block system is activated during rigging or travel.
Page 194 When lowering light loads, be sure to maintain sufficient cable tension to prevent the cable from becoming loose on the cable drum. Loose cable can slip and then bind suddenly, causing “jerky” lowering and shock loading of the boom. Loose wraps may form loops which can be overlain when the cable is wound onto the winch drum.
Page 195: Arm And Hand Signals
T300-1_T500-1_T780 Operating Instructions Arm and Hand Signals HOIST. With LOWER. With USE MAIN USE WHIPLINE. RAISE BOOM. forearm vertical arm extended HOIST. Tap fist (Auxiliary Hoist) Arm extended, fore finger downward on head; then Tap elbow with fingers closed, pointing up, forefinger use regular one hand, then...
Page 196 STOP. Arm EMERGENCY TRAVEL. Arm TRAVEL.(Both extended, palm STOP. Both extended EVERYTHING. Tracks.) Use down, move arm arms extended, forward, hand Clasp hands in both fists in front back and forth palms down, open and slightly front of body. of body, making horizontally.
Page 197: Load Rating Chart Interpretation
T300-1_T500-1_T780 Operating Instructions Load Rating Chart Interpretation In the following pages are examples of a load chart, these example charts may differ from the chart supplied with your crane. Always use the load rating chart supplied with the crane to interpret the conditions and limitations that exist when making a lift with the crane. The determining factors are lifted load, radius, boom angle, working position, hoist line reeving, tire pressure, travel data, use of a jib, and other special conditions that exist, such as wind velocity, soil conditions, etc.
Page 198 area is restricted to the over side and over rear areas as shown on the Crane Working Positions diagram. Use the 360° load rating in the overside work areas. Crane Working Positions with Outriggers Extended: Areas measured in a circular arc about the centerline of rotation as shown in the diagram below.
Page 199 T300-1_T500-1_T780 Operating Instructions Crane Working Position without Outriggers Boom over rear working area Cut - Offs: Rated chart values of less than approximately 1,000 lbs for on outriggers and side- stow jib are not shown. This is done because the effects of wind, pendulum action, jerking, etc., can cause a tip over.
Page 200 Rated Load On Outriggers Load Loade Over 360° Load Loade Over 360° Load Loade Over 360° Radiu Rear Radiu Rear Radiu Rear s (FT) Boom (LB) s (FT) Boom (LB) s (FT) Boom (LB) Angle Angle Angle (DEG) (DEG) (DEG) Boom Length 30 FT Boom Length 39 FT Boom Length 50 FT...
Page 201 T300-1_T500-1_T780 Operating Instructions - on outriggers (fully extended, partially extended & retracted), lifting off main boom with jib stowed or not present - on outriggers (fully extended), lifting off main boom with jib erected but unused with jib pullout extension retracted or not present - on outriggers (fully extended), lifting off main boom with jib erected but unused with pullout extension extended - on outriggers (fully extended &...
Page 202 - on outriggers (fully extended & partially extended) with jib erected, jib pullout section extended, lifting over the jib pullout section - on tires, lifting over main boom with jib stowed If the auxiliary boom head is not erected, add 100 lbs to the chart rated capacity. Compare load weight with chart rated capacity from the boom length, radius, and boom angle.
Page 203: On-Tires" Lift
T300-1_T500-1_T780 Operating Instructions "On-Tires" Lift Listed below are special precautions for “On Tires” lifts. All static crane load ratings are based on nonuse of the travel function while handling loads. However, cranes may be utilized for pick and carry operations. Traveling with suspended loads involves so many variables such as ground conditions, boom length, momentum in starting and stopping, etc., that it is impossible to devise a single standard rating procedure with any assurance of safety.
Page 204 Ensure that the tires are inflated as shown in the recommended tire pressure chart. Refer to tire chart in cab of crane or to section on Vehicular Operation. P/N 12261-683 REVISED: January 2015...
Page 205: On-Tires Load Rating Chart
T300-1_T500-1_T780 Operating Instructions On-Tires Load Rating Chart ON TIRES RADIUS (FT) MAX BOOM LENGTH (FT) BOOM STRAIGHT OVER REAR 0 TO 2 1/2 MPH 13,900 12,600 10,600 7,400 5,100 3,300 1,900 1,000 P/N 12261-683 REVISED: January 2015...
Page 206: Air-Ride Suspension
As explained in Group 2, air is added or released from the air bags by depressing the switch in the carrier cab. T300-1-Dumps air only on rear axles. T500-1 & T780-Dumps air on both front & rear axles.
Page 207 T300-1_T500-1_T780 Operating Instructions Air Yoke Switch P/N 12261-683 REVISED: January 2015...
Page 208: Remote Carrier Operation
Remote Carrier Operation The electric remote option provides a means for the crane operator to maneuver the crane around the job site with (Pick & Carry) or without a load.Engage the Remote Control-Carrier Set the parking brakes in the carrier cab. Ensure that the system air pressure is high enough for operation (85 PSI or above).
Page 209 T300-1_T500-1_T780 Operating Instructions NOTE: The steering switch is a momentary type. The longer you hold down the switch in either direction, the further the wheels will turn. The wheels will stay in whatever position they are left in, (they will not returnto the straight-ahead position automatically) you must actuate the switch in the opposite direstion to bring the wheels back to center.
Page 210: Moving The Unit
Moving the Unit Removable Counterweight (T500-1 & T780) INSTALLATION NOTE: The counterweight slabs are an integral part of this crane. When the crane is to be traveled at highway speeds, a portion of these slabs are intended to be moved to and carried on the counterweight supports on the deck of the crane in order to equalize the axle loading.
Page 211 T300-1_T500-1_T780 Operating Instructions Remove the long horizontal pins, and the locking pins that secure them, from the top slabs to free it from the counterweight shell. Both pins should pull freely. NOTE: If one or both pins will not release, it may be necessary to slightly lower one side of the slabs and raise the other to get the first pin removed, then slightly lower the side still pinned and pull the other side up tightly to remove the second pin.
Page 212 Do not continue to drive the slabs down after they have seated. Insert the long horizontal pins and the locking pins into the top slab. Remove the locking pins and long horizontal pins from the lower most slab that you wish to attach to the counterweight.
Page 213 T300-1_T500-1_T780 Operating Instructions 10. Install horizontal pins and locking pins on each side to attach the stack to the counterweight. P/N 12261-683 REVISED: January 2015...
Page 214: Drivers Tips-Cummins Epa 2013
Drivers Tips-Cummins EPA 2013 Use as a guide for Cummins On-Highway Heavy-Duty Engines with Aftertreatment. This covers engine, aftertreatment and emissions-related indicator lamps found on the vehicle's instrument panel and explains what they mean and the actions drivers need to take when they illuminate.
Page 215 T300-1_T500-1_T780 Operating Instructions order for your vehicle to comply with U.S. Environmental Protection Agency (EPA) emissions regulations. Diesel Exhaust Fluid (DEF) Lamp Illuminated An illuminated DEF Lamp is an indication that the DEF level is low. This can be corrected by refilling the DEF tank with Diesel Exhaust Fluid.
Page 216 The HEST Lamp illuminates to indicate that high exhaust temperatures may exist due to aftermarket regeneration. This is normal and does not signify the need for any kind of vehicle service or engine service. When this lamp is illuminated, ensure that the exhaust pipe outlet is not directed at any combustible surface or material.
Page 217 T300-1_T500-1_T780 Operating Instructions Unnecessary or excessive use of the Regeneration Inhibit Switch will result in a loss of fuel economy, or an increased need for parked regeneration. How To Perform A Parked (Stationary) Regeneration If the vehicle has a Manual Regeneration Switch and the DPF Lamp is flashing: ●...
Page 218 Items Driver Will Notice ● Under certain conditions (cold or very dry), condensation in the form of water vapor can be seen coming from the vehicle tailpipe. This is normal. It will clear within a few minutes of normal vehicle operation. ●...
Page 219: Vehicular Operation
T300-1_T500-1_T780 Operating Instructions Vehicular Operation The Hydraulic Crane is capable of both on-road and limited off-road travel. The kind of travel undertaken determines how the carrier is operated. Before moving the crane, either around the work site or between sites, carefully consider the terrain type, road conditions, and any hazards likely to be encountered en route.
Page 220 The inflation pressures shown below are for those taken with the tires at the prevailing atmospheric temperatures and do not include any inflation pressure build-up due to vehicle operation. TIRE DATA-T300-1 & T500-1 DUALS SINGLES-FRONT Tire Size 11R22.5 14PR XDE 425/65R22.5, 20PR...
Page 221 T300-1_T500-1_T780 Operating Instructions After several minutes at idle, the engine may be shut off by pushing the engine stop button or turn the ignition switch to the OFF position. P/N 12261-683 REVISED: January 2015...
Page 222: Transmission Operation
Transmission Operation Eaton Fuller Manual The transmission provides eight highway ratios, plus a LO gear and a LL1 and LL2 gear for extra pulling power. There are three reverse ratios. The transmission has a five speed front section and a three speed auxiliary section which has an extra deep reduction gear.
Page 223 T300-1_T500-1_T780 Operating Instructions NOTE: By engaging the clutch with the gear shift lever in the neutral position, the operator is able to control the RPM of the main shaft gears since they are regulated by engine RPM. This procedure enables the operator to match the RPM of the main shaft gears with those of the main shaft driven by the cranes rear wheels.
Page 224 While in 5th and ready for the next downshift, PUSH DOWN the Range Preselection Lever and move the shift lever to the 4th speed gear position. As the shift lever passes through neutral, the transmission will automatically shift from High Range to Low Range. Continue downshifting from 4th through 3rd, 2nd, and 1st to LO while in Low Range.
Page 225 T300-1_T500-1_T780 Operating Instructions Allison Automatic (WTEC lll Controls) Shift Selector With an Allison-equipped truck crane, it is not necessary to select the right moment to upshift or downshift during changing road and traffic conditions. The Allison MD, HD or B Series does it for you.
Page 226: Traveling Around The Jobsite
Traveling around the Jobsite When traveling around a job site, it is very important that the crane operator is very aware of what is happening with the crane as well as with other vehicles and personnel on the job site. The crane operator should observe the following rules as well as good common sense while moving a crane around a job site.
Page 227 T300-1_T500-1_T780 Operating Instructions 1. Outrigger Pad Storage -Insert Lockpin as shown above (4) places 1. Front Outrigger Jack-Fully retract front jack cylinder before traveling. - Stow the boom in the boom rack. - Watch for overhead obstructions such as trees, power lines, or bridges. - If the terrain is rough or uneven it may be necessary to travel at a reduced speed to prevent instability or damage to the crane.
Page 228 - Operating on steep grades requires caution because the oil in the engine or transmission will move to one side of the engine or transmission. As a result, the engine or transmission may not be fully lubricated which could damage the engine or transmission. - The operator must be very careful on steep side slopes to avoid tipping the crane.
Page 229: Towing Or Pushing Vehicle
T300-1_T500-1_T780 Operating Instructions Towing or Pushing Vehicle The engine cannot be started by pushing or towing. P/N 12261-683 REVISED: January 2015...
Page 230: Disassembly
Disassembly Stowing the Jib Jib Storage Brackets T - Handle Jib Mounting Pins (4) Wear Pad Anti Two-block Switch Anti Two-block Socket Guide Rope Anti Two-block Plug Before erecting or stowing the jib, ensure that no personnel or obstacles are in the swing path of the jib.
Page 231 T300-1_T500-1_T780 Disassembly Extend the boom to 2-3 feet (.6-1 m). Attach the guide rope to the eye on the bottom tip of the jib. Remove the left upper and lower jib mounting pins. With guide rope, pull left jib ears out of left boom head ears.
Page 232: Transportation
Transportation Transporting the Crane The boom must be stowed in the boom rack before transporting the crane. The boom extend sections should be restrained to prevent gradual roll-out when transporting the crane on a semitrailer. The hydraulic system will not hold the sections against the hard breaking jolts while the crane is being transported.
Page 233: Instructions For Loading And Unloading
T300-1_T500-1_T780 Transportation Instructions for Loading and Unloading LOADING EQUIPMENT Prior to operation, read and understand the manuals provided with this equipment. Also read and follow all general safety rules. PREPARE TRAILER Assure that any ramps are in position or trailer is otherwise prepared for loading and path of travel is clear for loading.
Page 234 Move the transmission shift lever to the neutral position. Put the parking brake switch in the “ON” position. Turn the ignition switch to the “ON” position. Wait to start light goes off.(T300-1 ONLY) Turn the ignition switch to the “START” position to start the engine.
Page 236: Maintenance
Select which model pertains to your crane. T340-07 EXPORT (2007) DESCRIPTION TRANSMISSION MANUAL ENGINE MODEL QSC8.3 Tier 3 TEREX ENGINE NUMBER 714 1688 HP & RPM 275 @ 2200 MAX RPM 2200 PEAK TORQUE (Lb-Ft) CONTROL MODULE...
Page 237 MAX RPM 2200 PEAK TORQUE (Lb-Ft) CONTROL MODULE CM2350 CYLINDERS T560-EXPORT DESCRIPTION TRANSMISSION MANUAL ENGINE MODEL DD Series 60 14L TEREX ENGINE NUMBER T122718 HP & RPM 445@ 1800 MAX RPM 2175 PEAK TORQUE (Lb-Ft) 1450 CONTROL MODULE CYLINDERS T560-EXPORT DESCRIPTION...
Page 238 ENGINE MODEL ISX 2013 TEREX ENGINE NUMBER T125438 HP & RPM 455 @1800 MAX RPM 2100 PEAK TORQUE (Lb-Ft) 1650 CONTROL MODULE CM2350 CYLINDERS T780-EXPORT DESCRIPTION TRANSMISSION MANUAL ENGINE MODEL DD Series 60 TEREX ENGINE NUMBER T122719 HP & RPM...
Page 239 T780-2013 DESCRIPTION TRANSMISSION AUTO ENGINE MODEL ISX 2013 TEREX ENGINE NUMBER T125882 HP & RPM 500 @1800 MAX RPM 2100 PEAK TORQUE (Lb-Ft) 1650 CONTROL MODULE CM2350 CYLINDERS T300-1, T500-1, T780 Engine DEF Control Unit P/N 12261-683 REVISED: January 2015...
Page 240 DESCRIPTION TEREX PART NO. 1. DEF SUPPLY MODULE 222725 2. Dosing Control Unit - Not Used for 2013 Engine 3. RELAY-40A 222727 4. COOLANT MANIFOLD 222728 P/N 12261-683 REVISED: January 2015...
Page 241: Maintenance Introduction
T300-1_T500-1_T780 Maintenance Maintenance Introduction A regular program of periodic preventive maintenance is essential to prolong crane operating life, maximize efficient service and minimize downtime. This section details a series of checks and procedures which are to be performed at daily, weekly, monthly and semiannual intervals.
Page 242: Crane Maintenence & Specification
Crane Maintenence & Specification Acronyms and Abbreviations P/N 12261-683 REVISED: January 2015...
Page 243 T300-1_T500-1_T780 Maintenance P/N 12261-683 REVISED: January 2015...
Page 244: General Safety Instructions
General Safety Instructions P/N 12261-683 REVISED: January 2015...
Page 245 T300-1_T500-1_T780 Maintenance P/N 12261-683 REVISED: January 2015...
Page 246: Flow Diagram-Exhaust System
Flow Diagram-Exhaust System P/N 12261-683 REVISED: January 2015...
Page 247 T300-1_T500-1_T780 Maintenance P/N 12261-683 REVISED: January 2015...
Page 248 6.-Aftertreatment Diesel Particulate Filter (DPF) 10.-Decomposition Reactor 13.-Aftertreatment SCR Catalyst P/N 12261-683 REVISED: January 2015...
Page 249 T300-1_T500-1_T780 Maintenance P/N 12261-683 REVISED: January 2015...
Page 250: Engine & Cooling System Maintenence Schedule
Engine & Cooling System Maintenence Schedule P/N 12261-683 REVISED: January 2015...
Page 251 T300-1_T500-1_T780 Maintenance P/N 12261-683 REVISED: January 2015...
Page 252 P/N 12261-683 REVISED: January 2015...
Page 253 T300-1_T500-1_T780 Maintenance P/N 12261-683 REVISED: January 2015...
Page 254: Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter
Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter P/N 12261-683 REVISED: January 2015...
Page 255 T300-1_T500-1_T780 Maintenance P/N 12261-683 REVISED: January 2015...
Page 256 P/N 12261-683 REVISED: January 2015...
Page 257 T300-1_T500-1_T780 Maintenance P/N 12261-683 REVISED: January 2015...
Page 258 P/N 12261-683 REVISED: January 2015...
Page 259: Engine Indicator Lamps
T300-1_T500-1_T780 Maintenance Engine Indicator Lamps P/N 12261-683 REVISED: January 2015...
Page 260 P/N 12261-683 REVISED: January 2015...
Page 261 T300-1_T500-1_T780 Maintenance P/N 12261-683 REVISED: January 2015...
Page 262 P/N 12261-683 REVISED: January 2015...
Page 263 T300-1_T500-1_T780 Maintenance P/N 12261-683 REVISED: January 2015...
Page 264 P/N 12261-683 REVISED: January 2015...
Page 265: Aftertreatment Switch
T300-1_T500-1_T780 Maintenance Aftertreatment Switch The stationary (parked) regeneration switch used to initiate regeneration with the aftertreatment system. P/N 12261-683 REVISED: January 2015...
Page 266: Operating Characteristics With Aftertreatment Particulate Filter
Operating Characteristics with Aftertreatment Particulate Filter P/N 12261-683 REVISED: January 2015...
Page 267 T300-1_T500-1_T780 Maintenance P/N 12261-683 REVISED: January 2015...
Page 268 P/N 12261-683 REVISED: January 2015...
Page 269 T300-1_T500-1_T780 Maintenance P/N 12261-683 REVISED: January 2015...
Page 270 P/N 12261-683 REVISED: January 2015...
Page 271: Engine Indentification
T300-1_T500-1_T780 Maintenance Engine Indentification P/N 12261-683 REVISED: January 2015...
Page 272 P/N 12261-683 REVISED: January 2015...
Page 273 T300-1_T500-1_T780 Maintenance P/N 12261-683 REVISED: January 2015...
Page 274 P/N 12261-683 REVISED: January 2015...
Page 275 T300-1_T500-1_T780 Maintenance P/N 12261-683 REVISED: January 2015...
Page 276 P/N 12261-683 REVISED: January 2015...
Page 277: Diesel Exhaust Fluid Specification
T300-1_T500-1_T780 Maintenance Diesel Exhaust Fluid Specification P/N 12261-683 REVISED: January 2015...
Page 278 P/N 12261-683 REVISED: January 2015...
Page 279 T300-1_T500-1_T780 Maintenance P/N 12261-683 REVISED: January 2015...
Page 280 P/N 12261-683 REVISED: January 2015...
Page 281 T300-1_T500-1_T780 Maintenance P/N 12261-683 REVISED: January 2015...
Page 282: Filter Specification
Filter Specification FILTER SERVICE NO.S - CUMMINS ENGINES CRANE TRANSMISS FUEL FUEL CRANKCASE AFTERTREATME MODEL ION TYPE (Primary) (Secondary BREATHER NT DEF DOSING Suction UNIT Side) T340-20 MANUAL 218027 219903 219902 222678 222679 T340-20 AUTO 218027 219903 219902 222678 222679 T340-20 MANUAL 222644...
Page 283 T300-1_T500-1_T780 Maintenance FILTER SERVICE NO.S - DETROIT DIESEL EPA07 SERIES 60 ENGINE DOMESTIC & EXPORT CRAN TRANSMIS FUEL FUEL CRANKCAS FILTER KIT SION TYPE (Primary) (Secondary E BREATHER (Includes MODE Suction Side) Fuel, Oil, Air, Trans) T560- MANUAL 218624 219949 219317 216699 -2010...
Page 284: Lubrication Charts
Lubrication Charts P/N 12261-683 REVISED: January 2015...
Page 285 T300-1_T500-1_T780 Maintenance P/N 12261-683 REVISED: January 2015...
Page 286 P/N 12261-683 REVISED: January 2015...
Page 287: Operator Observation
T300-1_T500-1_T780 Maintenance Operator Observation As the operator, it is your responsibility to observe and report any unusual sounds, odors, or other signs of abnormal performance that could indicate trouble ahead. On a routine basis the following items should be checked before starting or while operating the crane. Visual Inspection - Check complete machine for any unusual condition.
Page 288: Special Break-In Requirements For New Cranes
Replace filter and strainer. ■ 40 HOURS - Retorque the swing bearing bolts to a torque of 725ft. lbs on T300-1 & T500-1 and 980 ft. lbs on T775. Recheck every 40 hours until all bolt are found properly torqued. Thereafter checks should be performed quarterly.
Page 289: Machine Maintenance Checklist
T300-1_T500-1_T780 Maintenance Machine Maintenance Checklist DAILY CHECK (8 HOURS) ___ Perform Daily Lubrication ___ Check Boom Front Slider Pads ___ Check Hydraulic Reservoir Fluid Level ___ Drain Air Tanks ___ Fill Fuel Tank ___ Check Wire Rope And Related Components ___ Check Engine Oil Level ___ Check Air Cleaner ___ Check Coolant Level...
Page 290 ___ Change Power Steering Filter Element-(T300-1 And Quarterly Checks only) ___ Perform Semiannual Lubrication ___ Check Hydraulic Relief Valve Pressure Settings ___ Torque Swing Bearing Bolts T300-1 & T500-1 (725 ft. lbs.) , T780 (980 ft. lbs.) according to ___ Clean Crankcase Breather tightening sequence.
Page 291 T300-1_T500-1_T780 Maintenance ___ Drain And Clean Hydraulic Reservoir ___See Transmission Maintenence Section ___ Hydraulic Hoses (See Hydraulic Hose topic in ___See Engine Maintenence Section Maintenance section) P/N 12261-683 REVISED: January 2015...
Page 292: Lubrication Introduction
Lubrication Introduction A regular program of periodic preventive maintenance is essential to prolong crane operating life, maximize efficient service and minimize downtime. This section details a series of checks and procedures which are to be performed at daily, weekly, monthly and semiannual intervals.
Page 293 T300-1_T500-1_T780 Maintenance * Muffler and exhaust Check battery box - For battery condition Crane boom - Check for: * Hook block for wear or damage * Two block system for proper function * Cable and cable spooling on winch * Cylinder pin connections for wear Check tires, axles, and drive lines, for wear or damage.
Page 294: Hydraulic Oil Requirements
Hydraulic Oil Requirements The hydraulic system is filled with KOEHRING SPEC 805 hydraulic oil to give the unit the highest performance as a hydraulic machine and to provide proper lubrication for the hydraulic components. To ensure the longest life for this piece of equipment, particular attention must be paid to maintain oil at the proper level with an approved hydraulic oil and to keep the circuit system clean.
Page 295 T300-1_T500-1_T780 Maintenance TRANSMISSION FLUIDS DO NOT use transmission fluids. These fluids have been designed to work in automatic transmissions and they will not necessarily work in hydraulic systems. MIXING: Mixing different brands of oil is not recommended. Various companies use different additive packages, which when mixed together, may cause problems in a hydraulic system.
Page 296 that is measured in the oil sample will be dissolved water. This should be less than .05%. If it is greater than .05%, the oil in the system should be drained and replaced. Particle Contamination- Excess contamination in a hydraulic system will greatly shorten the life of pumps and motors.
Page 297: Koehring Spec 805 Data
T300-1_T500-1_T780 Maintenance Koehring Spec 805 Data PHYSICAL TEST METHOD REQUIREMENT PROPERTIES A. A.P.I. Gravity ASTM D287 28 Min. B. Flash Point ASTM D92 380× F Min. C. Viscosity Index ASTM D445 200-220 SSU 100×F 210×F ASTM D445 46 SSU MIn. D.
Page 298: Grade Selection Chart
Grade Selection Chart Maximum life of pumps, motors, hoses, and seals will be obtained by selecting an oil as far down the chart as possible. Viscosity Grade Minimum Ideal Cont. Maximum Selection Start-UP Operating Operating Guide Lines I.S.O. (New) A.S.L.E. (Old) Temp.
Page 299 T300-1_T500-1_T780 Maintenance 25×F (-3.9×C) 155×F (68×C) 200×F (93×C) Well Suited For Most 30×F (-1.1×C) 160×F (71×C) 200×F (93×C) Machines In Southern U.S. And As Summer Oil For Heavily Loaded Machines In Central And Northern U.S. 35×F (-1.1×C) 175×F (80×C) 200×F (93×C) Especially Suited For Regions With Ambient...
Page 300: Premium Grade Anti-Wear Hydraulic Oils
Premium Grade Anti-Wear Hydraulic Oils OIL COMPANY BRAND NAME Amalie Refining Co. (USA) Ama-Oil R & O 100 AW Ama-Oil R & O 200 AW Ama-Oil R & O 300 AW Ama-Oil R & O 500 AW Amoco Oil Co. (USA) Amoco AW 32 Amoco AW 46 Amoco AW 68...
Page 301 T300-1_T500-1_T780 Maintenance OIL COMPANY BRAND NAME Exxon Co. (USA) Nuto-H 32 Nuto-H 46 Nuto-H 68 Nuto-H 100 Gulf Oil Co. (USA) Gulf Harmony AW 32 Gulf Harmony AW 46 Gulf Harmony AW 68 Gulf Harmony AW 100 Imperial Oil Limited Nuto H 32 (Canada) Nuto H 46...
Page 302 OIL COMPANY BRAND NAME Pennzoil Products Co. AWX Multi-Viscosity (USA) AW 32 Hyd. Fluids AW 46 Hyd. Fluids AW 68 Hyd. Fluids AW 100 Hyd. Fluids Shell Co. (Canada) Tellus T37 (Multigrade Shell Co. (USA) Tellus 23 Tellus 32 Tellus 46 (XSL 9101) Tellus 68 Tellus 100 Sun Oil Co.
Page 303: Cable Lubrication Methods
T300-1_T500-1_T780 Maintenance Cable Lubrication Methods GENERAL We are covering the more commonly used methods of lubricating cable (wire rope). For special cable lubrication problems consult the cable manufacturer. HOT APPLICATION A heated bath is placed in the path of the wire rope, and the rope is passed through the hot lubrication over sheaves and a center guide wheel.
Page 304 DRIPPING A container can be placed above the sheave, so that the rope can be lubricated by opening a spigot. Sheaves are the best location for lubricating operating wire ropes, because the wires and strands open somewhat as they bend along the groove. POURING Lubricant can be poured on.
Page 305 T300-1_T500-1_T780 Maintenance SWABBING AND PAINTING Lubricant can be swabbed on with rags, or painted on with a brush. Both are quick methods which can be made part of the operating routine. SPRAYING A light lubricant containing solvents can be applied to a wire rope by a properly directed spray nozzle.
Page 306 P/N 12261-683 REVISED: January 2015...
Page 307: Turntable And Swing Pinion
T300-1_T500-1_T780 Maintenance Turntable and Swing Pinion Standard lubrication frequencies are shown on LUBE CHARTS for each model of crane. RACE LUBRICATION - Inject grease as recommended through fitting located to rear of console in operator’s cab as shown above. Rotate the upper while injecting grease at least two complete revolutions.
Page 308 MOBIL TEXACO SUNOCO AMOCO EXON RACE Mobilux Mutifak Prestige Amolith Beacon 742EP GEAR Mobiltac Crater Amovis Surett 375NC Compound B Fluid 4k NOTE: Refer to Kaydon Installation & Maintenence Catalog #390 supplied with crane. P/N 12261-683 REVISED: January 2015...
Page 309: Swing Reducer
Recommended lubricant is AGMA #4EP Gear Oil or equivalent. All swing drive gearboxes from Terex are shipped with an additive to the gear oil of 5 oz (148 ml) of ethylene glycol for cold weather protection. If gear oil in the unit is changed, Terex recommends the same amount of ethylene glycol is added to prevent freeze up of unit due to internal condensation.
Page 310 ASSEMBLY Place the brake housing on a work bench with motor mounting surface down. Lightly lubricate and install one of the thrust washers into the housing. Install the brake actuating assembly, with the clevis attached to it, into the housing. The clevis must fit into the opening on the side of the housing.
Page 311 T300-1_T500-1_T780 Maintenance Install a new O-Ring (item 2) into the groove on the brake housing. Install the housing adapter onto the brake housing. There is a dowel pin between these two parts for correct orientation. Turn the assembly over and install the two remaining capscrews and sealing washers and tighten all four capscrews.
Page 312: Power Steering Maintenance
Power Steering Maintenance LUBRICATION - STEERING GEARS The lubricant used in the power steering system is the medium by which hydraulic pressures are applied and relieved, under control, to effect steering assist. In addition the lubricant also lubricates moving parts and dissipates heat which reduces efficiency and accelerates wear.
Page 313: Drive Shaft Maintenance
T300-1_T500-1_T780 Maintenance Drive Shaft Maintenance Rotating shafts can be dangerous. You can snag clothes, skin, hair, hands, etc. This can cause serious injury or death. Do not work on a shaft (with or without a guard) when the engine is running. UNIVERSAL JOINTS To insure proper lubrication of the bearing assemblies, it is essential to add lubricant until it appears at all journal cross bearing seals (1).
Page 314 SLIDING SPLINE SECTIONS Steel drive shaft splines should be lubricated with good extreme pressure (EP) grease as recommended by lubricant manufacturers. Extreme pressure grease satisfying NLFI Grade 1 has been adapted by the factory. Relube spline at the intervals prescribed below. Apply grease gun pressure to lubrication zerk (2) until lubricant appears at pressure relief hole (1) in welch plug at the sleeve yoke end of spline.
Page 315 T300-1_T500-1_T780 Maintenance Grease Institute (NLGI) Grade 1 and Grade 2 specifications are preferred. The use of greases which tend to separate and cake should be avoided. Lubrication cycles for drive shaft universal joints and slip splines will vary with service requirements and operating conditions.
Page 316: Brake System Maintenance
Brake System Maintenance REAR BRAKES Using a pressure gun, lubricate the brackets and slack adjusters. An application of lubricant should be applied to the grease fittings each time (weekly) a general lubrication of chassis components is required. Use synthetic grease per specifications in chart below. P/N 12261-683 REVISED: January 2015...
Page 317 T300-1_T500-1_T780 Maintenance P/N 12261-683 REVISED: January 2015...
Page 318 Grease should be supplied to the bracket until it begins to squirt out around the camshaft adjacent to the slack adjuster. The slack adjuster should be filled until grease becomes visible around the camshaft. NOTE: Camshaft brackets with metal plugs instead of grease fittings are fitted with special seals and packed with extended lubrication interval chassis grease.
Page 319: Air Dryer
T300-1_T500-1_T780 Maintenance Air Dryer Desiccant cartridge life will vary depending on operating conditions, speeds, loads, air usage and compressor condition. It is recommended that the desiccant cartridge be replaced approximately every 2 years. If system performance is reduced, desiccant cartridge replacement is necessary. It is also recommended that the desiccant cartridge be replaced if the compressor has been rebuilt.
Page 320: Air System Maintenance
Air System Maintenance Inadequate delivery pressure or defective component operations can generally be traced to leakage, blocked lines, or the build up of moisture and sediment in the system. A regular program of periodic maintenance is an essential part of air system operation. The materials presented here are listed in accordance with the MAINTENANCE CHECK LIST in Section 4.
Page 321: Tires
T300-1_T500-1_T780 Maintenance TIRES MAINTENANCE CHECK As a part of the WEEKLY MAINTENANCE CHECK inspect the tires and rims for damage. Cuts, bruises, snags, punctures, and abrasions should be repaired before they can cause tire failure. Bent, cracked, or loose rims should be repaired or replaced. Check tire valve condition and make sure each valve has a cap.
Page 322 Inflation pressure should be checked when tires are cool, using an accurate tire pressure gauge. Check pressures at regular intervals. Bleeding the air from hot tires is dangerous and should not be attempted. While the pressure will be reduced, an increase in temperature of the tire will take place as soon as driving is resumed and tire failure will result.
Page 323 T300-1_T500-1_T780 Maintenance Unmatched tires on tandem drive units will cause tire wear and scuffing and possible damage to the drive units. Consequently, we recommend the tires be matched to within 1/8” of the same rolling radius; 3/4” of the same rolling circumference. Tandem units-IMPORTANT: The four largest tires should never be installed on one driving axle or the four smallest tires on the other driving axle.
Page 324: Slider Pads
Slider Pads The front bottom slider pad should be checked daily for wear. The remainder of the slider pads should be checked monthly for wear. All the slider pads contain a chamfer (1) on the wearing surface. When this chamfer (1) is worn off, the slider pad must be replaced.
Page 325: Boom Lubrication
T300-1_T500-1_T780 Maintenance Boom Lubrication 4 SECTION BOOM (94’)STANDARD & XL(105') Fully extend the front & rear outriggers, and level the retracted boom over the front of the machine. This procedure will require (2) people, (1) one operating the boom to align grease zerks to access holes while the other person greasing the boom can signal the operator when the zerks are aligned to holes.
Page 326 Repeat item 4. for each of the access holes going forward on the base boom as the second section is extended approximately (3) FT. each time. The last hole in the base boom will line up with the zerk when the second section is fully extended as shown in photo below.
Page 327 T300-1_T500-1_T780 Maintenance Repeat procedure above for each access hole going forward in the second section as the 3rd section is extended. Lining up the zerk and applying the grease. With the 2nd section fully extended use a roller or brush to grease the bottom section of boom on surfaces that you see wear pad contact.
Page 328 Fully extend the boom sections 3 & 4 to obtain access to the internal wear pad contact areas thru the large circular openings in the side plates of each section. WARNING-ENGINE MUST BE SHUT DOWN-When performing lubrication internal to the boom sections. P/N 12261-683 REVISED: January 2015...
Page 329 T300-1_T500-1_T780 Maintenance Through the holes in the 2nd and 3rd section apply a liberal amount of multi- purpose MPG grease to the top and bottom as shown in photo below. Use a 3" to 4" wide roller to apply the grease to the wear pad contact areas top and bottom.
Page 330 Apply multi-purpose grease along the entire length of the section to the outer 5" of both sides of the top plate of Section 3. This area can be accessed through the holes in the #3 section. Apply a fist sized portion of grease in the center of the bottom plate on the inside through each of the holes in the boom on the path where the cylinder slides.
Page 331 T300-1_T500-1_T780 Maintenance Boom Hoist Cylinder Pin lubrication, lubricate with MPG until grease starts to protrude from bearing sides. Base Boom Pin lubrication, lubricate with MPG until grease starts protruding from side of tube on each side. See image below for zerk locations (2). P/N 12261-683 REVISED: January 2015...
Page 332 Hoist Cylinder Rod end pin lubrication-Raise boom up about 20 degrees then SHUTDOWN ENGINE(1) zerk, lubricate until grease starts protruding from sides of rod eye. See below photo. P/N 12261-683 REVISED: January 2015...
Page 333 T300-1_T500-1_T780 Maintenance Chain roller pin lubrication zerk on front of base boom head, (3) to (4) shots of grease is required. See image below for location of zerk. Boom Head Sheaves lubrication-With outriggers set , boom retracted, boom lowered, and hook block on the ground then SHUTDOWN ENGINE. All sheaves require lubrication.
Page 334: Swing Bearing Bolting Procedure
“breaks loose”. If it is tightened (turned) by this procedure then it has loosened and all (26) bolts must be retorqued. Refer to the sequence illustrated below. RING GEAR BOLTING SEQUENCE-(T300-1, T500-1, T780 shown below). P/N 12261-683 REVISED: January 2015...
Page 335 T300-1_T500-1_T780 Maintenance SWING BEARING TORQUE PROCEDURE A number of causes can reduce tension in the bolts when torquing and after use. These include rust on the threads, damaged or rough threads on bolts or nuts, shanks of bolts which hang up on holes, etc. All of these causes have a tendency to absorb the torque when bolts are being tightened.
Page 336 (1) special wrench pn. 706F8697. (1) 4 to 1 torque multiplier. (1) 1" 12 pt. socket-3/4 drive. P/N 12261-683 REVISED: January 2015...
Page 337: Engine Radiator Maintenance
T300-1_T500-1_T780 Maintenance Engine Radiator Maintenance DAILY: COOLANT LEVEL Check the engine radiator coolant level and add coolant if necessary. A solution of 50% ethylene glycol by volume is the recommended yearround coolant. Replenish the corrosion inhibitor according to engine manufacturer’s recommendation. In warm climates a coolant based on water with corrosion inhibitors is approved for use.
Page 338 Clean any foreign matter from the radiator cooling fins and through core cooling passages by directing compressed air and flushing water over the total area of the core in the reverse direction of normal flow. P/N 12261-683 REVISED: January 2015...
Page 339: Transmission Maintenance
T300-1_T500-1_T780 Maintenance Transmission Maintenance Manual Transmission (EATON-FULLER) LUBRICATION Proper lubrication procedures are the key to a good all-around maintenance program. If the oil is not doing its job, or if the oil level is ignored, all the maintenance procedures in the world are not going to keep the transmission running or assure long transmission life.
Page 340 - a catastrophic failure has occurred. 3.Refilling-(Allison Auto) The operational level should always be within the limit marks on the dipstick. The exact amount of oil depends on the transmission inclination and model. Insufficient oil damages the pump and other components, and can affect the function and reduce the life of the transmission.
Page 341 T300-1_T500-1_T780 Maintenance Apply the vehicle parking brakes and place the transmission lever in neutral. Start the engine and let it idle for 5 minutes. Check the dipstick periodically while the engine is idling, adding oil as needed to obtain a level that is in the Cold Band on the dipstick. Total quantity added at this time should be approximately 10 gallons.
Page 342 5. Maintenance Interval Chart-(EATON FULLER Only) Automatic Transmission (Allison Auto) No Longer Approved Fluids DEXTRON and Allison C4 Transmission Fluids are no longer approved for new commercial On-Highway products. Approved Fluids Proper Fluid Level Because the transmission fluid cools, lubricates, and transmits hydraulic power, it is important that the proper fluid level be maintained at all times.
Page 343 T300-1_T500-1_T780 Maintenance Fluid Level Check Fluid level check by using the Lever Shift Selector and perform the following steps: Park the vehicle on a level surface, shift to N (Neutral), and apply the parking brake. Engine at idle, fluid temperature is above 60 degrees C (140F) and below 104 degrees C (220F) and transmission output shaft is stopped.
Page 344 SELECT MONITOR Description "o" "L" Represents Fluid (oil) Level Check Mode "o" "K" Fluid level is within the correct fluid level zone. P/N 12261-683 REVISED: January 2015...
Page 345 T300-1_T500-1_T780 Maintenance P/N 12261-683 REVISED: January 2015...
Page 346 Allison Transmission Filters 3000 Series High Capacity Filter Kit (4 inch)-For Replacement or Service Order: Terex No. 222661 Kit contains the following items listed below: ITEM NO. Allison PART NO. QTY. DESCRIPTION 29545778 Instruction Sheet #322 23019664 O-Ring-Packing- (drain plug)
Page 347 T300-1_T500-1_T780 Maintenance High Fluid Temperature The transmission is considered to be overheated when any of the following termperatures are exceeded: Sump fluid 121 C (250 F) Fluid to cooler 149 C (300F) Retarder out fluid 165 C (330 F) If the transmission overheats during normal operation, check the fluid level in the transmission.
Page 348 Recommeded Fluid/Filter Change Intervals P/N 12261-683 REVISED: January 2015...
Page 349 T300-1_T500-1_T780 Maintenance P/N 12261-683 REVISED: January 2015...
Page 350 Transmission Fluid Capacity Parking Brake Select N (Neutral) and be sure that the parking brake is applied to secure the vehicle when it is not attended. Always make sure the vehicle's parking brake system has been maintained. Warning: Whenever it becomes necessary to leave the vehicle, even momentarily, while the engine is running, place the transmission shift lever in N (Neutral), set the parking brake and/or emergency brakes.
Page 351 T300-1_T500-1_T780 Maintenance Transmission Inspection Checks Before Transmission Removal Air System and Connections Annually replace the filter/regulator element. If excessive contamination is present, service vehicle air/dryer system. Lubricant and Filter Change at specified service intervals. Use only the types and grades as recommended.
Page 352: Axle Maintenance
Axle Maintenance MAINTENANCE CHECK As a part of the MONTHLY MAINTENANCE CHECK, inspect the axle and differential levels. When checking the AXLE OIL LEVEL, rotate each wheel until the planet cover is positioned as shown in the illustration below. the arrow on the planet cover points horizontal when the cover is properly positioned for checking the oil.
Page 353 T300-1_T500-1_T780 Maintenance On a ANNUAL basis, drain the oil from the differential by removing the drain plug at the bottom of the differential housing. Replace the plug and refill the differential with the lubricant specified on the lubrication chart. To the level specified above. P/N 12261-683 REVISED: January 2015...
Page 354 P/N 12261-683 REVISED: January 2015...
Page 355 T300-1_T500-1_T780 Maintenance Drain the oil from hubs removing the fill and check plug by rotating the hub until the hole is at the extreme low position. After draining, rotate the hub until the hole is at the check position. Refill the hub with the lubricant specified on the lubrication chart. Refill to the level of the bottom of the check plug.
Page 356: Tire Maintenance
Tire Maintenance MAINTENANCE CHECK As a part of the WEEKLY MAINTENANCE, inspect the tires and rims for damage. Cuts and bruises, snags, punctures, and abrasions should be repaired before they can cause tire failure. Bent, cracked or loose rims should be repaired or replaced. Check tire valve condition and make sure each valve has a cap.
Page 357 T300-1_T500-1_T780 Maintenance SAFETY PRECAUTIONS FOR MOUNTING OR DEMOUNTING RIMS AND WHEELS DO’S AND DON’TS DON'T 1. Do not use loads or inflation pressures 1. Deflate tires completely prior to exceeding the manufacturer’s demounting by removing the valve core. recommendations. 2. Don’t re-inflate a tire that has been run flat or 2.
Page 358 Re-inflation of any type of tire and rim assembly that has been operated in a run- flat or under inflated condition (80% or less of recommended operating pressure) can result in serious injury or death. The tire may be damaged on the inside and can explode while you are adding air.
Page 359: Hydraulic System Maintenance
DAILY: HYDRAULIC FLUID LEVEL The hydraulic reservoir, fluid level indicator, and filler cap are on the right side of the machine. MODEL HYDRAULIC TANK CAPACITY T300-1 70 GAL. (265 Liters) T500-1 117 GAL. (443 Liters) T780 195 GAL. (738 Liters) Retract all cylinders to return the maximum amount of oil to the reservoir and note the oil level in the indicator tube.
Page 360 top mark indicates system capacity with all cylinders retracted. Fluid capacity varies with each model as indicated above. Do not overfill. Refer to Section 4 for hydraulic oils meeting the manufacturer’s specifications. Do not use oils which have detergent additives. HYDRAULIC CYLINDERS Check the cylinder mounting brackets, bushings, and pins for wear, alignment, tightness, and damage.
Page 361 T300-1_T500-1_T780 Maintenance When replacing the filters, clean the spring and bypass valves. Inspect the “O” ring for damage and replace if necessary. Before discarding the old filter element, examine the type of material trapped in it. This may indicate which, if any, hydraulic system components are deteriorating. SEMI ANNUALLY: SUCTION FILTER Remove and clean the hydraulic reservoir intake suction filter.
Page 362 1000 HOURS: HYDRAULIC RESERVOIR Drain and clean the hydraulic reservoir. Change the hydraulic oil. A change interval cannot be established which would apply to all oils and all operating conditions of temperature and cleanliness. However, a reputable brand of turbine grade oil can be expected to deliver 1000 hours of service under average operating conditions.
Page 363: Hydraulic Hoses
The daily check might indicate irregularities and / or leakages in the hydraulic system that should be taken care of immediately. In addition to these daily checks Terex recommends annual inspections of all hose assemblies as a minimum maintenance of the crane. Older cranes may require more frequent inspections.
Page 364 Recommended Hydraulic Hose Maintenance & Replacement Schedule: Task Minimum Maintenance Checking the hose lines Annually Recommended replacement of hose lines Every 6 years Recommendations for the replacement of hydraulic hose assemblies: If replacement of hydraulic hose assemblies is required, it is recommended to use original spare parts from the OEM or hose assemblies according to the OEM specification which includes the fittings, bulk hose material and manufacturing process.
Page 365 T300-1_T500-1_T780 Maintenance P/N 12261-683 REVISED: January 2015...
Page 366: Wire Rope And Reeving
WIre Rope and Reeving MAINTENANCE All wire ropes in active service should be inspected DAILY along with spooling, sheaves, wedge sockets, and any other wire rope fittings for damage. Once WEEKLY a thorough wire rope inspection should be made by a competent inspector. A record should be kept of the inspections on the WIRE ROPE INSPECTION RECORD on page 152...
Page 367 T300-1_T500-1_T780 Maintenance NOTE: IF A SOCKET IS CHANGED OR REPLACED, OR IF YOU ARE CHANGING HOOK BLOCK WEIGHTS; IT IS IMPORTANT TO USE THE CORRECT SOCKET P/N 12261-683 REVISED: January 2015...
Page 368: Anti-Two Block System
Anti-Two Block System MAINTENANCE This crane is equipped with an anti-two block system for both main boom head and jib which sounds a horn (when in the "on" position) and lights a light when a two-blocking condition is imminent. If equipped with control disconnects, it will also disengage the hydraulic functions.
Page 369 T300-1_T500-1_T780 Maintenance With the engine ignition key in the "off" position, check that free action (no self- centering) occurs on the boom lowering pedal, the boom telescope lever- extended direction, and the winch lever (S) - raising direction. With the engine ignition key in the "on" position, check to be sure that these controls latch (remain in the neutral position) and provide a normal centering action.
Page 370: Storage
Storage Machine Storage Machines being placed in storage must be adequately protected from deterioration during the period of idleness. This will ensure that they can be restored to active service with a minimum effort. Before removing this hydraulic crane from service for extended periods, it should be prepared for storage as prescribed in the following paragraphs.
Page 371 T300-1_T500-1_T780 Maintenance Coat wire rope with lubricant. Coat exposed cylinder rods with"CRC SP-400 Corrosion Inhibitor". This can be removed with "CRC HD Degreaser". The ENGINE should be prepared as prescribed in the topic “Engine Storage”. The TRANSMISSION should be prepared as prescribed in the topic “Transmission Storage.” P/N 12261-683 REVISED: January 2015...
Page 372: Engine Storage
Engine Storage PREPARING ENGINE FOR STORAGE When an engine is to be stored or removed from operation for a period of time, special precautions should be taken to protect the interior and exterior of the engine, transmission, and other parts from rust accumulation and corrosion. The parts requiring attention and the recommended preparations are given below.
Page 373 T300-1_T500-1_T780 Maintenance EXTENDED STORAGE (30 DAYS OR MORE) When An Engine Is To Be Removed From Operation For An Extended Period Of Time,prepare It as follows: Drain and thoroughly flush the cooling system with clean, soft water Refill the cooling system with clean, soft water. Add a rust inhibitor to the cooling system (refer to Corrsion Inhibitor).
Page 374 16. With an all-purpose grease such as Shell Alvania No. 2, or equivalent, lubricate the clutch throwout bearing, clutch pilot bearing, drive shaft main bearing, clutch release shaft, and the outboard bearings (if so equipped). 17. Remove the inspection hole cover on the clutch housing and lubricate the clutch release lever and link pins with a hand oiler.
Page 375: Transmission Storage
T300-1_T500-1_T780 Maintenance Transmission Storage PRESERVATIVE SELECTION When transmissions are to be stored or remain inactive for extended periods of time, specific preservative methods are recommended to prevent rust and corrosion damage. The length of storage will usually determine the preservative method to be used. Various methods are described below.
Page 376: Restoration To Service
Restoration to Service Refer to “Restoring Engine to Service”, and “Restoring Transmission to Service”, for the procedures required to restore these components to service. Remove the MACHINE from storage via the following procedure: Remove preservative lubricants from all surfaces. Check all fluid levels, adding or draining as required. Lubricate the machine according to Section 9, making certain that all points with grease fittings are lubricated.
Page 377: Restoring Engine To Service
T300-1_T500-1_T780 Maintenance Restoring Engine to Service Remove the valve rocker cover(s) and pour at least one-half gallon of oil, of the same grade as used in the crankcase, over the rocker arms and push rods. Reinstall the valve rocker cover(s). Remove the covers and tape from all of the openings of the engine, fuel tank, and electrical equipment.
Page 378: Restoring Transmission To Service
Restoring Transmission to Service If Nox Rust, or equivalent, was used in preparing the transmission for storage, use the following procedures to restore the unit to service. Remove the tape from openings and breather. Wash off all the external grease with solvent. Add hydraulic transmission fluid, per chart below to proper level.
Page 379: Chrome Cylinder Rod Storage
T300-1_T500-1_T780 Maintenance Chrome Cylinder Rod Storage Hard chrome plating is primarily applied to steel cylinder rods for its wear resistant properties, although it does provide considerable corrosion resistance as well. Once the chrome-plated rod is assembled into a cylinder and put into service, the hydraulic fluid on the surface of the rod provides all the corrosion resistance required for the rod during its life cycle.
Page 380 wool can be used, but abrasives such as sandpaper should never be used to clean the exposed surfaces of the cylinder rod. If surface damage to the chrome plate is discovered, the frequency of corrosion barrier applications should be increased. NOTE: Caution must be used when cleaning equipment in service with high pressure washes.
Page 382: Specifications
Specifications WIRE ROPE SPECIFICATION-T300-1, T500-1 & T780 Main Winch-T300-1 & T500-1 STD.-5/8” dia. 6X19 OR 6X37 CLASS IWRC REG. LAY WIRE ROPE MINIMUM BREAKING STRENGTH-17.9 TONS OPT.- 5/8” ROTATION RESISTANT COMPACTED STRAND 18X19 OR 19X19 MINIMUM BREAKING STRENGTH 22.7 TONS Auxilary Winch-T300-1 &...
Page 383 T300-1_T500-1_T780 Specifications ROTATION RESISTANT COMPACTED STRAND BRIDON-DYFORM 34LR 1960 MINIMUM BREAKING STRENGTH 34.51 TONS P/N 12261-683 REVISED: January 2015...
Page 384: Troubleshooting
Troubleshooting Introduction A regular program of periodic preventive maintenance is essential to prolong crane operating life, maximize efficient service and minimize downtime. This section details a series of checks and procedures which are to be performed at daily, weekly, monthly and semi annual intervals.
Page 385 T300-1_T500-1_T780 Troubleshooting • Muffler and exhaust Check battery box - For battery condition Crane boom - Check for: • Hook block for wear or damage • Two block system for proper function • Cable and cable spooling on winch • Cylinder pin connections for wear Check tires, axles, and drive lines, for wear or damage.
Page 386: General Procedure
General Procedure KNOW THE SYSTEM Study this manual and learn what makes the machine “tick”, how it should behave, sound and smell. OPERATE THE MACHINE Test operate all machine functions. Note all abnormal sounds, odors and movements. Always proceed in the most logical order to determine the cause.
Page 387: Hydraulics - General
T300-1_T500-1_T780 Troubleshooting Hydraulics - General Before any troubleshooting is attempted, become fully acquainted with the following two (2) basic fundamental facts of a hydraulic system: SPEED The speed of a hydraulic function is directly related to the system flow. A reduction in speed of a cylinder or motor is caused by an insufficient quantity of oil being delivered to the component.
Page 388: Operator Controls
WITH THE ELECTRICALLY CONTROLLED VALVES on the outriggers, three (3) spools must be checked. On the T300-1 and T500-1 the diverter valve should be checked by using a test gauge on the test port and activating the outrigger controls. If pressure (2500 psi) is indicated, the spool is shifting.
Page 389: Power Steering
T300-1_T500-1_T780 Troubleshooting Power Steering GENERAL DIAGNOSIS Whenever steering complaints are encountered, it is important that the complete steering system be inspected. Special body or equipment installations should also be considered for their effect on steering performance. The steering system consists of the Sheppard Integral Power Steering Gear, a hydraulic supply pump with pressure and flow controls and an oil reservoir, the front axle and mechanical components and the steering column or input shaft and connecting linkages.
Page 390: Front Axles
Front Axles RAPID OR UNEVEN TIRE WEAR CAUSE REMEDY Incorrect toe-setting Check and reset toe-in if necessary Improper tire inflation Inflate to proper pressure Unbalanced Tires Balance HARD STEERING CAUSE REMEDY Inadequate or improper lubrication of Consult lubrication chart for proper knuckle pins lubricant, lubrication intervals and procedures.
Page 391 T300-1_T500-1_T780 Troubleshooting EXCESSIVE WEAR OF KNUCKLE PINS AND BUSHINGS CAUSE REMEDY Inadequate or improper lubrication Consult lubrication chart for proper lubricant, lubrication intervals and procedures. Increase lubrication frequency when operating in extreme conditions. FRONT AXLE SHIMMY OR VIBRATION CAUSE REMEDY Incorrect caster setting Adjust caster Wheels and/or tires not properly balanced...
Page 392: Steering Circuit
Steering Circuit OIL LEAKING AT OUTPUT SHAFT OF STEERING GEAR CAUSE REMEDY Clogged oil filter in reservoir (high back Replace filter. Increase change frequency pressure) Pinched or restricted oil return line Locate and correct. Check back pressure Damaged quad ring seal Replace quad ring seal Damaged bronze bearings Replace bronze bearings.
Page 393 T300-1_T500-1_T780 Troubleshooting OIL FORCED OUT OF RESERVOIR CAUSE REMEDY Clogged oil filter Change oil and oil filter. Increase change intervals Air in system Bleed air from system. Check for air leak on suction side of supply pump Faulty supply pump (Cavitation) Check supply pump following “Hydraulic Supply- Diagnosis”.
Page 394 ERRATIC STEERING OR NO STEERING AT ALL CAUSE REMEDY Insufficient volume of oil being metered by Polish flow divider valve to remove foreign flow divider to steering gear induced by particles and burrs. Refer to pump servicing foreign particles on flow divider valve, instructions causing the valve to hang up in the bore HARD STEERING...
Page 395 T300-1_T500-1_T780 Troubleshooting STEERING EXTREMELY LIGHT IN ONE OR BOTH DIRECTIONS CAUSE REMEDY Bent or damaged reversing springs Check for impact or accident damage. Replace damaged parts EXCESSIVE BACKLASH CAUSE REMEDY Worn universal joint Replace universal joint Worn pins and keys in universal joint to Replace pins and keys actuating shaft and universal joint to steering shaft...
Page 396 NO ATTEMPT TO RETURN STRAIGHT AHEAD FROM TURNS CAUSE REMEDY No positive caster Set to 4° to 6° positive caster Steering column bind Check and repair U-joints and support bearings Steering gear mounting distorted Shim mounting pads to correct piston to bore interference Linkage ball sockets seized or binding Check and repair or replace...
Page 397: Rear Axles
T300-1_T500-1_T780 Troubleshooting Rear Axles HUMMING NOISE WHILE DRIVING CAUSE REMEDY Improper or inadequate lubrication Consult lubrication chart for proper lubricant, lubrication interval, and procedure Bearing rollers worn Replace bearing. Always replace both cups and cones EXCESSIVE VIBRATION CAUSE REMEDY Twisted or broken axle shaft Replace axle shaft Fractured axle shaft at flange Replace axle shaft.
Page 398: Alternator
Alternator OPERATION NOISY CAUSE REMEDY Worn or dry bearings Replace worn bearings Alternator mounting loose Tighten alternator mounting Belt loose Replace worn belt or tighten loose belt Brush holders out of alignment Replace brush holders Brushes not seated properly Reseat or replace brushes Armature unbalanced Replace armature Commutator out-of-round...
Page 399 T300-1_T500-1_T780 Troubleshooting ALTERNATOR OVERHEATS CAUSE REMEDY Loose or worn belt or pulley Adjust belt, or replace worn belt or pulleys Misalignment Inspect mounting brackets and tension adjusting arm for looseness. Tighten or replace parts as required P/N 12261-683 REVISED: January 2015...
Page 400: Starter
Starter STARTER INOPERATIVE CAUSE REMEDY Commutator dirty Clean commutator Brushes worn Replace brushes Starter relay malfunctioning Repair or replace relay Pinion spring broken or weak Replace or repair starter Frame housing defective Replace or repair starter P/N 12261-683 REVISED: January 2015...
Page 401: Engine Clutch
T300-1_T500-1_T780 Troubleshooting Engine Clutch CLUTCH SLIPPAGE CAUSE REMEDY Insufficient clutch pedal free play Adjust release bearing position, then adjust linkage if necessary Damaged cable Replace cable Linkage blocked from complete return Remove blockage Linkage needs lubrication Lubricate linkage Release bearing locknut loose Adjust release bearing length and tighten locknut Worn clutch disc facings...
Page 402 Failed pilot bearing Replace pilot bearing and input shaft if damaged. Transmission input shaft splines worn/ Replace input shaft. damaged Tight or contaminated clutch disc splines Clean clutch disc and input shaft splines or replace clutch disc as necessary Flywheel housing to clutch housing Replace faulty housing excessive misalignment Grease or oil contamination on facings...
Page 403: Brakes
T300-1_T500-1_T780 Troubleshooting Brakes INSUFFICENT BRAKE ACTION CAUSE REMEDY Improper brake shoe adjustment Adjust brake shoes Worn brake linings Adjust for lining wear or replace brake shoes Blocked, bent, or broken tubing or hose Remove obstructions in line or replace faulty tubing Brake valve delivery pressure below normal Clean and replace worn parts if brake valve...
Page 404: Parking Brakes
Parking Brakes MAXI-BRAKES WON’T APPLY (From Park Brake Button) CAUSE REMEDY Restricted hose or tube Remove restriction or replace Defective relay valve Repair or replace Defective spring brake valve Repair or replace Defective control valve Repair or replace MAXI-BRAKES WON’T APPLY (With loss of air pressure in one service reservoir) CAUSE REMEDY Restricted hose or tube...
Page 405: Air Pressure
T300-1_T500-1_T780 Troubleshooting Air Pressure INADEQUATE AIR PRESSURE CAUSE REMEDY Leaks in system Repair leaks Frozen lines Thaw out lines Defective compressor Inspect for sticking unloader valve, replace if necessary Reservoir leaking Replace Tank to compressor supply line damaged Replace P/N 12261-683 REVISED: January 2015...
Page 406: Swng Circuit
Swng Circuit SWING COMPLETELY INOPERATIVE CAUSE REMEDY Mechanical swing lock applied, if equipped Disengage the swing lock Swing brake applied Disengage the swing brake Spring brake stuck in applied position Disassemble swing brake and free-up unit Swing valve main relief valve stuck in open See section on “Relief Valves”...
Page 407: Boom Hoist Circuit
T300-1_T500-1_T780 Troubleshooting Boom Hoist Circuit BOOM DRIFTS DOWN CAUSE REMEDY Hold valve not seating properly Replace hold valve Hoist cylinder by-passing See section on “Cylinder Leakage” BOOM HOIST ONLY - INOPERATIVE OR ERRATIC CAUSE REMEDY Boom will drift down Repair or replace hold valve Boom won’t lower Repair, replace, or backflush hold valve Boom hoist cylinder binding...
Page 408: Telescope Circuit
Telescope Circuit TELESCOPE FUNCTION ONLY - WILL NOT OPERATE CAUSE REMEDY Load too great Move lever to first position, not “high speed”. Reduce load or set boom length before lifting load Both port relief valves sticking See section on “Relief Valves” Hose plugged or liner collapsed Replace hose BOOM EXTENSION JERKY OR ERRATIC...
Page 409: Winch Circuit
T300-1_T500-1_T780 Troubleshooting Winch Circuit WINCH WILL NOT DEVELOP MAXIMUM LINE PULL CAUSE REMEDY Main relief valve is set too low Readjust the main relief Main relief valve is sticking See section on “Relief Valves” Winch motor worn excessively or damaged See section on “Fluid Motor”...
Page 410 WINCH CHATTERS WHEN LOWERING CAUSE REMEDY The winch hold valve is set wrong or is Check the hold valve setting. If the winch malfunctioning continues to chatter, the holding valve is sticking. Inspect it for worn or damaged seals or contamination P/N 12261-683 REVISED: January 2015...
Page 411: Outrigger Circuit
T300-1_T500-1_T780 Troubleshooting Outrigger Circuit ALL OUTRIGGERS INOPERATIVE CAUSE REMEDY Electrical malfunction See section on “Electrical Controls” Outrigger relief valve malfunctioning See section on “Relief Valves” Outrigger diverter valve malfunctioning Repair or replace Line to or from steer pump plugged or liner Clear blockage or replace hose collapsed Low oil level...
Page 412: Swing Pumps Circuit
Swing Pumps Circuit FAILURE OF PUMP TO DELIVER FLUID CAUSE REMEDY Pumps not engaged Engage pumps Low fluid level in reservoir Add recommended oil and check level Oil intake suction filter plugged Clean filter Air leak in suction line, preventing priming or Repair leaks causing noise and irregular action of control circuit...
Page 413 T300-1_T500-1_T780 Troubleshooting PUMP MAKING NOISE CAUSE REMEDY Pump disconnect not engaged Shut engine off and engage pump disconnect Partially clogged intake line, intake filter or Clean out intake filter screen or eliminate restricted intake pipe restriction. Be sure suction line is completely open Air leaks: At pump intake pipe joints...
Page 414 BREAKAGE OF PARTS INSIDE PUMP HOUSING CAUSE REMEDY Excessive pressure above maximum pump Check relief valve setting rating Seizure due to lack of oil Check reservoir level, oil filter and possibility of restriction in suction line more often Solid matter being wedged in pump Check suction line filter, drain and flush system as necessary P/N 12261-683 REVISED: January 2015...
Page 415: Swing Circuit Control Valves
T300-1_T500-1_T780 Troubleshooting Swing Circuit Control Valves STICKING PLUNGERS CAUSE REMEDY Excessively high oil temperature See section on “Excessive Heating of Oil in System” Dirt in oil Change oil. Clean system. Fittings too tight Check torque Valve warped from mounting Loosen valve mounting bolts and check Excessively high flow in valve Check to see if hoses from pump are not crossed or reversed...
Page 416 POOR HYDRAULIC SYSTEM PERFORMANCE OR FAILURE CAUSE REMEDY Dirt in relief valve Disassemble and clean Relief valve defective See section on “Relief Valves” Load too heavy Check line pressure Internal valve crack Replace valve Plunger not at full stroke Check movement and linkage P/N 12261-683 REVISED: January 2015...
Page 417: Swing Circuit Relief Valves
T300-1_T500-1_T780 Troubleshooting Swing Circuit Relief Valves CAN’T GET PRESSURE CAUSE REMEDY Poppet stuck open or dirt under seal Check for foreign matter between poppets and their mating members. Members must slide freely ERRATIC PRESSURE CAUSE REMEDY Poppet seal damaged Replace damaged parts. Clean dirt and remove surface marks for free movement PRESSURE SETTING NOT CORRECT CAUSE...
Page 418: Fluid Motor
Fluid Motor MOTOR WILL NOT TURN CAUSE REMEDY Pumps not engaged Engage pumps No oil Fill reservoir to proper oil level Pump broken Replace pump Relief valve stuck open or set too low Clean and free relief valve spool and adjust to proper setting Work load jammed or stuck Remove obstruction from work load...
Page 419 T300-1_T500-1_T780 Troubleshooting LEAK BETWEEN HOUSING AND WEAR PLATE OR BETWEEN WEAR PLATE AND GEROLER ASSEMBLY CAUSE REMEDY Motor housing bolts loose Clean mating surfaces and tighten nuts to appropriate value Pinched “O” ring seal Replace LEAK AT OIL PORTS CAUSE REMEDY Damaged seal or “O”...
Page 420: Cylinders
Cylinders CYLINDER STICKING OR BINDING CAUSE REMEDY Damaged parts Repair or replace Dirt or contamination Check oil condition. Check filters. Clean or replace filter elements. Change oil if condition requires it Loose parts Tighten cylinder rod eyes, if loose. Check cylinder heads and tighten, if loose.
Page 421: Cylinder Leakage
T300-1_T500-1_T780 Troubleshooting Cylinder Leakage Hydraulic cylinders may retract due to the cooling of the oil in cylinder. Oil shrinks approximately 1% per 100°F of cooling, or as an example, if a cylinder is extended 100” and it cools 100°F, it would shorten approximately 1”. TELESCOPE CYLINDER If excessive leak-down is encountered, check items in the following sequence: With boom offside and horizontal, extend the boom approximately 6 ft.
Page 422 WHEN REASSEMBLING THE CYLINDER, care should be taken to keep the piston rod assembly parallel in all planes with the cylinder barrel as the piston enters and is pushed down the barrel prior to gland engagement. NOTE: An external leak from telescope cylinders or hydraulic line within the boom assembly does not cause leak-down without also having one or more of the above conditions present.
Page 423: Excessive Heating Of Oil In System
T300-1_T500-1_T780 Troubleshooting Excessive Heating of Oil In System HEATING CAUSED BY POWER UNIT (RESERVOIR, PUMP, RELIEF VALVE, AND COOLERS) CAUSE REMEDY Relief valve set at a higher or lower pressure Reset relief valve to recommended pressure than specified. Excess oil dissipated through increased slippage in various parts, or through relief valve Internal oil leakage due to wear...
Page 424: Electrical Controls
Electrical Controls ELECTRICAL FAILURE CAUSE REMEDY Rocker switch sticking Remove switch, check if hole is too tight. Cut out decal or file hole larger. Tripped circuit breakers Reset breaker Disconnected or broken wires Replace or repair Open circuit Check with test light. Repair or replace Low voltage Check wires and grounds Poor engine solenoid connection...
Page 425: Propane Heater
T300-1_T500-1_T780 Troubleshooting Propane Heater HEATER FAILS TO START (MOTOR DOES NOT RUN) CAUSE REMEDY Fuse defective or burnt out Check fuse; replace if necessary Electrical connection(s) defective Check all electrical connections, including ground; repair any defects Full voltage not available at heater Check for power at the heater: at least 11 VDC with heater turned on.
Page 426 Ignition pack defective or inoperative Check for spark by holding an insulated- handle screwdriver with the shaft grounded and the tip approximately 1/8” away from the high tension lug of the ignition coil. There should be a continuous strong spark. If no spark is produced, check that there is voltage applied to the ignition pack.
Page 427 T300-1_T500-1_T780 Troubleshooting EXCESSIVE POPPING OR BACKFIRING CAUSE REMEDY Ignition pack defective or inoperative Check for spark by holding an insulated- handle screw driver with the shaft grounded and the tip approximately 1/8” away from the high tension lug of the ignition coil. There should be a continuous strong spark.
Page 428: Maintenance -Free Battery Testing
Maintenance -Free Battery Testing VISUAL INSPECTION CAUSE REMEDY Visible damage, terminal leakage, etc Cannot be used. Replace. ELECTROLYTE LEVELS & STATE OF CHARGE NOTE: PROCEED DIRECTLY TO CAUSE THAT APPLIES CAUSE REMEDY Level at top of plates. Water cannot be added Replace If there is an indicator and it shows low level Replace Level OK, unknown, or water can be added.
Page 429 T300-1_T500-1_T780 Troubleshooting 20° (-7° C) 10° (-12° C) 0° (-18° C) NOTE: IF WATER CAN BE ADDED TO A BATTERY, A HYDROMETER READING OF 1.225 @ 80° F (27° C) CAN BE USED INSTEAD OF THE 12.4 VOLTAGE READING. P/N 12261-683 REVISED: January 2015...
Page 430: Two-Block System
Two-Block System PANEL LIGHT & HORN WILL NOT COME ON WITH BOOM SWITCH WEIGHT LIFTED (IF EQUIPPED WITH DISCONNECTS, CONTROLS WILL NOT ENGAGE) CAUSE REMEDY Burned out fuse Check and replace fuse (8 amp only). Broken wire Check voltage in control panel between terminals #0 and #37.
Page 431 T300-1_T500-1_T780 Troubleshooting Defective relay in panel Check for 12 volts between relay pins #30 (hot) and #86 (ground). If voltage is 0, check for voltage between pin #87a and ground. If 12 volt, replace relay (With no electrical power to the relay, pins #30 and #87a should show continuity.
Page 432 NO LIGHT AND HORN, BUT CONTROL WILL NOT ENGAGE CAUSE REMEDY Broken wire or bad connection Check voltage across disconnect terminals. If 0 volts, check voltage across terminals in the control panel. If 12 volts, replace wire. If 12 volts across disconnect, then disconnect is defective.
Page 434: Service / Parts
Service / Parts General Service Information Machine productivity, longevity and low cost performance depend on periodic maintenance, troubleshooting and proper service and adjustment procedures. As the operator, it is your responsibility to detect any unusual sounds, odors or other signs of abnormal performance that could indicate trouble ahead.
Page 435 T300-1_T500-1_T780 Service / Parts Bolts and nuts should be placed into their respective holes when removing guards, cases, etc. so that proper bolt will be on hand when reassembling these parts. P/N 12261-683 REVISED: January 2015...
Page 436: Outrigger Position Sensors
Outrigger Position Sensors If your crane is equipped with Outrigger Position Sensors-each outrigger box will contain (4) four proximity sensors for determining the location of outrigger beams at mid extend position and full extension. Each sensor has an air gap to maintain to operate properly and send signals to the Rated Capacity Indicator (RCI) or Rated Capacity Limiter (RCL).
Page 437 T300-1_T500-1_T780 Service / Parts Proximity Sensor-Outrigger Position P/N 12261-683 REVISED: January 2015...
Page 438: Torque Wrench Extensions
Torque Wrench Extensions In some applications, a standard torque wrench and socket cannot be fitted to the bolt(s) to be tightened because of restricted access. In other instances, the torque value specified cannot be obtained because sufficient force cannot be applied to the standard length wrench.
Page 439 T300-1_T500-1_T780 Service / Parts P/N 12261-683 REVISED: January 2015...
Page 440: Welding Instructions
Welding Instructions When doing repair welding on your unit take precaution attaching your ground to the component being repaired. This will reduce the chance of arcing through a bearing, cylinder, etc., damaging the component. Paint should be removed from the surface to be used as the “ground” (earth). Use necessary precaution when welding around fuel tanks, oil reservoir, batteries, tubing and pressure systems.
Page 441 T300-1_T500-1_T780 Service / Parts Special Considerations for Welding Painted Surfaces When welding or cutting steel coated with a certain paint systems, the worker is exposed to decomposition products (metal fumes, gases or vapors, particulate) which vary depending on the type of process being used to weld or cut, the nature of the base metal, and the type of coating system.
Page 442: Outriggers
Outriggers T300-1 & T500-1 -Use single beam outriggers as shown below. 1. Hose Disconnects 2. Wear Pad 3. Outrigger Extend Cylinder Deadend T780-Use a double beam outrigger as shown below. P/N 12261-683 REVISED: January 2015...
Page 443 T300-1_T500-1_T780 Service / Parts 1. Hose Disconnects 2. Wear Pad 3. Outrigger Extend Cylinder Deadend NOTE: The outriggers section coincides with section 3 in the parts manual. WEAR PAD (2) A wear pad (2) is mounted on the back end of each outrigger beam to prevent the beam from gouging the outrigger box when extending or retracting the outrigger beams.
Page 444 Retaining Nut Piston Cylinder Barrel Head Gland BEAM EXTEND CYLINDER The outrigger beam must be removed from the crane and the extend cylinder removed from the outrigger beam before servicing. With the beam removed, disconnect the hydraulic hoses form the jack cylinder and remove the extend cylinder live end pin. Remove the cylinder from the back end of the beam.
Page 445 T300-1_T500-1_T780 Service / Parts Remove the piston retaining nut (1) and slide the piston (2) and head gland (4) off the rod (5). O-rings, back-up rings and seals may now be replaced. ASSEMBLY Reassemble the extend cylinder by reversing the disassembly procedure. Torque the piston retaining nut to 100-150 ft.
Page 446 Extend the cylinder rod far enough to allow the head gland to be screwed out of the cylinder barrel. Remove the head gland, piston rod and piston as a unit. Remove the lower port tube fitting before removing the piston from the barrel. Remove the piston retaining nut.
Page 447 RPM. The relief setting should be 2500 psi ±50 psi. If necessary, adjust the relief valve (1). T300-1 & T500-1 OUTRIGGER RELIEF VALVE ADJUSTMENT Adjust this relief using the following procedure: NOTE: There are two relief valves shown in the illustration. The relief valve in the lower valve section (3) is not used and should be deactivated by turning it in until it bottoms out.
Page 448 T780 Relief Valve Test Port Relief Pressure Adjustment NOTE: Relief is pre-set at 600 PSI. P/N 12261-683 REVISED: January 2015...
Page 449: Rear Suspension
T300-1_T500-1_T780 Service / Parts Rear Suspension Equalizer Beam Torque Rod Part of Axle Bushing Shims The rear suspension incorporates equalizer beams (1), which link front and rear driving axles, and torque rods (2) which locate the axles. Servicing these components consists of replacing worn bushings (4).
Page 450 Reverse the beam removal procedure to reinstall the beam. Torque the center pin saddle clamp capscrews to 225- 275 ft. lbs and beam end through bolt nuts to 210-240 ft. lbs. P/N 12261-683 REVISED: January 2015...
Page 451: Front Axle
T300-1_T500-1_T780 Service / Parts Front Axle WHEEL BEARING AND ADJUSTMENT Before adjusting the wheel bearings, be certain there is sufficient clearance between the brake shoe and drum so that shoe drag will not interfere with bearing adjustment. Use a torque wrench to make the adjustment. Torque the adjusting nut to 50 ft.
Page 452 Position trammel bar at rear of tires and adjust pointers to line up with scribe lines and lock in place. (Repeat for front of tires.) Read toe-in (or toe-out) from scale. The recommended loaded toe-in is 1/32” - 1/16”. NOTE: Set radial tires from 0 to 1/32”. P/N 12261-683 REVISED: January 2015...
Page 453: Rear Axle
T300-1_T500-1_T780 Service / Parts Rear Axle MAINTENANCE CHECK As a part of MONTHLY MAINTENANCE CHECK, inspect the differential oil level by removing the fill-and-check plug in the rear cover of each differential housing. The oil should be level with the bottom of the hole. Before checking the forward driving axle, the axle should be run first, because the power divider and forward driving axle have a common lubrication system.
Page 454 1. Fill Hole 2. Temperature Sensor Mounting Hole As part of the SEMI-ANNUAL MAINTENANCE CHECK, completely drain the oil from the rear axle by removing the plug at the bottom of the differential and the plug at the bottom of the power divider. Replace the plugs and fill differential through rear filler hole. Add two (2) pints of oil through the forward filler hole at the right top portion of the differential carrier.
Page 455 T300-1_T500-1_T780 Service / Parts 1. Lock Nut 2. Adjusting Nut P/N 12261-683 REVISED: January 2015...
Page 456: Propellor Shaft & Universal Joints
Propellor Shaft & Universal Joints The drive train on this machine incorporates three drive shafts and five universal joints: The front shaft extends from the transmission to a point just above and aft of the forward outrigger box. The shaft runs in a “Hanger” bearing at this point. The second shaft couples with the front shaft and extends rearward to the intermediate axle.
Page 457 T300-1_T500-1_T780 Service / Parts Remove the capscrews and bearing caps from the intermediate axle end yoke. Remove capscrews, lock plates, and bearing caps from rear end yoke of front shaft. Remove the second shaft with journal crosses and remaining bearings as a unit. Intermediate axle end yoke remains on machine.
Page 458 Turn the yoke over and tap the exposed end of the journal cross until the opposite needle bearing is free. TO PREVENT DAMAGE TO THE BEARING, USE A SOFT ROUND DRIFT WITH FLAT FACE AND DIAMETER ABOUT 1/32" SMALLER THAN YOKE HOLE. Remove the journal cross by sliding it to one side of the yoke and tilting it over the top of the yoke lug.
Page 459 T300-1_T500-1_T780 Service / Parts No damage or dents on drive shaft tubing which could cause unbalance. If the dents are severe enough, they can weaken the tube and a failure might occur under torque load. Splines should slide freely with slight drag from spline seal. Bearings should flex and be free from excessive bind.
Page 460 UNIVERSAL JOINT PHASING When yokes are assembled to their shafts in the same plane, they are in phase. To obtain vibration-free operation, check the following: The forward and second shafts, between the transmission and the intermediate axle, must be assembled “In Phase”. The inter-axle drive shaft yokes, at the third shaft, must be assembled “In Phase”.
Page 461: Wheel And Rim Mounting
T300-1_T500-1_T780 Service / Parts Wheel and Rim Mounting MAINTENANCE CHECK As a part of your WEEKLY MAINTENANCE, check the wheel retaining nuts to insure proper tightness. Torque values and correct torquing procedures are offered in this section. HEAVY TRUCK ALUMINUM DISC WHEEL INSTALLATION PROCEDURE HUB-PILOTED MOUNTING Wheels with the hub-piloted mounting system are called hub piloted wheels.
Page 462 Slide front wheel over studs, being careful not to damage the stud threads. Snug up nuts in the sequence shown in Figure 4. Do nut tighten them fully until all have been seated. This procedure will permit the uniform seating of nuts and ensure the even, face- to-face contact of wheels, hub, and drum.
Page 463 T300-1_T500-1_T780 Service / Parts Torque each nut to 450-500 ft.- lbs (dry). Install 1222-356 Cover, Lug Nut (10) Align the hand holes to allow access to the air valves. Slide the outer dual wheel over the inner cap nuts and repeat the entire procedure except using the nut tightening sequence in Figure 5.
Page 464 Not all nuts and studs can be used with all types of wheels. The use of improper nuts and studs can cause nut loosening, stud failure, or premature wheel failure, which could cause an accident or injury. P/N 12261-683 REVISED: January 2015...
Page 465: Engine Clutch Adjustment & Repair
T300-1_T500-1_T780 Service / Parts Engine Clutch Adjustment & Repair P/N 12261-683 REVISED: January 2015...
Page 466 P/N 12261-683 REVISED: January 2015...
Page 467 T300-1_T500-1_T780 Service / Parts P/N 12261-683 REVISED: January 2015...
Page 468 Never wait for a clutch to slip before making adjustment. It is too late then to make adjustment. Facings quickly disintegrate once they become burned through slippage, and have short life thereafter. P/N 12261-683 REVISED: January 2015...
Page 469 T300-1_T500-1_T780 Service / Parts Excessive clutch pedal lash or free travel may prevent complete clutch disengagement, while insufficient clutch pedal lash or free travel will cause slippage and short clutch life P/N 12261-683 REVISED: January 2015...
Page 470: Shift Control Adjustment
Shift Control Adjustment Proper adjustment of the L.R.C. is necessary for smooth shift linkage operation. Use the procedure listed below to insure correct adjustment. The steps should be followed as listed to avoid confusion and prevent mistakes. MOVE THE INNER SHIFT FINGER TO THE NEUTRAL POSITION Move gear shift lever forward or backward to the neutral position.
Page 471 T300-1_T500-1_T780 Service / Parts NOTE: Ideally, the shift arm should be adjusted 90° to the selection lever as described, but in some chassis configurations, it may be necessary to index the shift arm in the vertical position. This is done to prevent a shift lever jump out complaint. This type of adjustment will cause an unequal amount of gear shift lever travel between neutral and a forward lever position as compared to neutral and a rearward lever position.
Page 472 Rotate turnbuckle to obtain proper forward-backward neutral position of the gear shift lever in the cab. Tighten one turnbuckle capscrew D Move gear shift lever to desired left-right neutral position. Tighten second turnbuckle capscrew D Check for linkage obstructions in all gear positions. 1.
Page 473 T300-1_T500-1_T780 Service / Parts 1. SELECTION LEVER 2. SHIFT ARM P/N 12261-683 REVISED: January 2015...
Page 474: Steering And Power Steering
2. Jam Nut 3. Stop Screw POWER STEERING MAINTENANCE CHECK-(T300-1 ONLY) On a SEMI-ANNUAL basis, remove the reservoir cover and filter element. Clean the inside of the reservoir with a lint-free cloth. Install a new filter element, refill with oil and replace the cover.
Page 475: Swing Reducer
T300-1_T500-1_T780 Service / Parts Swing Reducer MAINTENANCE CHECK On a WEEKLY basis, check the swing reducer oil level. See section 4 for the type of oil recommended. DISASSEMBLY Remove the upper cover along with the brakes and motor. Examine the ring gear bolted to the cover and the seal located in brake housing.
Page 476 1. Swing Reducer Dipstick 2. Shim 3. Thrust Bushings P/N 12261-683 REVISED: January 2015...
Page 477: Pumps
T300-1_T500-1_T780 Service / Parts Pumps GENERAL INSTRUCTIONS In the event of pump failure, we strongly recommend that you contact your local distributor. However, should you decide to facilitate the repair of these units - CONSULT THE MANUFACTURER’S REPAIR MANUAL - read all of the steps used in disassembly and all of the steps used in building up the unit.
Page 478 The oil should be a good quality hydraulic oil rated at 150 SSU at 100°F, with the oil temperature held at 120°F plus or minus 5°F. The feed line must be of adequate size with no more than 5” mercury vacuum adjacent to the pump inlet.
Page 479: Valve Adjustments
Attach a calibrated pressure gauge to test port on the inlet pressure port at the valve bank. Lower the boom completely and continue to boom down with the engine running at full governed rpm. The relief setting per chart below: T300-1 BOOM HOIST SET TO:3500 psi T500-1...
Page 480 Adjust the boom hoist, retract, and telescope reliefs using the following procedures. Adjust the boom hoist relief by loosening jam lock nut on relief valve. Adjust valve with adjusting screw while booming up or down over relief withe engine at maximum governed rpm.
Page 481 Winch down and hold the lever in the “lower” position while obtaining a pressure reading. See chart below for proper settings. If required, adjust the relief at the auxiliary winch valve. This relief is adjusted in the same manner at the boom relief. T300-1 MAIN & AUX WINCH SET TO:3500 psi T500-1 MAIN &...
Page 482 1. JAM NUT 2. ACORN NUT 3. WASHER 4. ADJUST SCREW SETTING RELIEF VALVE PRESSURES ON SWING VALVE Attach the pressure gauge on the swing valve test port, and follow these steps: Remove acorn nut and loosen jam nut, make sure several threads on adjusting screw are engaged in pilot section.
Page 483 T300-1_T500-1_T780 Service / Parts Use a screw driver and set adjusting screw as follows: Run the pump at low operating speed (approximately 1/4 of full engine rpm) but fast enough so that the pump is developing the required pressure. Operate the control valve at its extreme position long enough to get a pressure reading on the gauge.
Page 484 T300-1 OUTRIGGERS SET TO:2500 psi T500-1 OUTRIGGERS SET TO:2500 psi T780 OUTRIGGERS SET TO: 2500 psi OUTRIGGER RELIEF ADJUSTMENT With the test gauge still attached to the test port, remove the hex cap, insert an allen wrench. adjust to the proper setting while holding the outrigger in the retract position. Turn in to increase pressure, out to decrease.
Page 485: Rotary Manifold
T300-1_T500-1_T780 Service / Parts Rotary Manifold 1. END PLATE 2. "O" RING 3. SPOOL 4. SEAL 5. RECTANGULAR RING 6. CASE 7. WEAR RING 8. "O" RING 9. BACK-UP RING 10. THRUST WASHER Use the following procedures when disassembling, inspecting, repairing, and reassembling the rotary manifold AS SOON AS THE ROTARY MANIFOLD IS READY TO BE PLACED INTO OPERATION, IT SHOULD BE SLOWLY ROTATED SEVERAL MINUTES TO...
Page 486 NOTE: Be sure to mark an index point on the case and spool to insure proper reassembly. INSPECTION AND SEAL REPLACEMENT The “case” bore should be thoroughly washed with solvent or diesel fuel and inspected for signs of “scoring” or deep scratches. This type of damage is generally caused by the presence of foreign material in the hydraulic system.
Page 487: Control Linkage Adjustment
T300-1_T500-1_T780 Service / Parts Control Linkage Adjustment The cable and mechanical controls used on this machine are designed to require little or no adjustment. The use of standardized cable-mechanical linkage means that one adjustment procedure may be applied to several control functions. Should adjustment become necessary, refer to Group 28 of the Parts Book when making them.
Page 488: Heaters & Ac Systems
Heaters & AC Systems Refer to the Shop Manual CD in your Manual Packet for the following Service & Operations Manuals. PART NO. MANUFACTURER TXCR-325 & 326 Kenway AC/HYD. Heater Manual-PRE 2010 Models OM-TXCR406 Kenway AC/HYD. Heater Manual-2010 Models NT-20S-TC Suburban Users Manual P/N 12261-683 REVISED: January 2015...
Page 489: Electrical System Battery Check
BATTERY The maintenance-free batteries are located under the battery cover on the left-hand side of machine for the T300-1 and on the right-hand side for the T500-1 & T780. Use maintenance- free battery charging information. A maintenance-free battery does not require the addition of water during its life in normal service.
Page 490 If the battery has been on charge, the voltage can be stabilized by placing a 15 ampere load across the terminals for 15 seconds. Another method of stabilization is to turn on the headlamps for 15 seconds. Read the voltage at least three minutes after the discharge load is removed.
Page 491 T300-1_T500-1_T780 Service / Parts limit the charge more consistently and accurately. Such controls also may have a safety feature that prevents sparks and reverse charging when the clamps are connected in reverse, by mistake. Place a wet cloth over the vent opening or openings. If, when charging the battery, violent gassing or spewing of electrolyte occurs, or the battery case feels hot (125°F, 52°C), reduce or temporarily halt charging to avoid damaging the battery.
Page 492: Electrical System Collector Ring
Electrical System Collector Ring ELECTRICAL COLLECTOR RING When troubleshooting the electrical system, always check the collector ring first to see that spring loaded brushes are centered in the bands. Keep free of any foreign material. Keep the setscrews on the collector ring frame tight. Otherwise, the wire harness may wrap up as the machine is swung.
Page 493 T300-1_T500-1_T780 Service / Parts CIRCUIT COLOR WIRE FUNCTION CIRCUIT COLOR WIRE FUNCTION TAG # TAG # 000AB BATT (ACC) YELLOW 025EA STEER SWITCH 000AC BATT GREEN 026EA STEER SWITCH BLACK 016AA GROUND BLACK 203AB WARN SWITCH WHITE 015AA START YELLOW 063AJ CLEARANC E LIGHTS 017AB...
Page 494 CIRCUIT COLOR WIRE FUNCTION CIRCUIT COLOR WIRE FUNCTION TAG # TAG # YELLOW 011AA FRONT YELLOW 176 SPARE JACK PROX. BLUE 013AA FRONT GRAY 143BK SHIFT COM JACK RET. BLACK 016AB GROUND BLUE 192BA REVERSE BLUE 020AA E-STOP 194BA FORWARD BROWN 021AA E-STOP...
Page 495 The collector ring is not servicable internally, thus if defective, broken terminals, brush circuits not functional, contact your Terex Parts Department for a complete replacement collector ring. P/N 12261-683 REVISED: January 2015...
Page 496: Electrical System Voltmeter Diagnosis
Electrical System Voltmeter Diagnosis This electrical system has a voltmeter installed in it. It is used as an aid to diagnose the condition of the battery and electrical system. The following illustrations show how the voltmeter indicates the condition of the battery, alternator, and voltage regulator and what to so to correct the condition.
Page 497 T300-1_T500-1_T780 Service / Parts Well-charged battery. This indicates a good battery and also that alternator and voltage regulator are operating properly The pointer might remain in this position temporarily when the engine has been stopped after considerable use, due to a "surface charge" in the battery. To get a correct reading, turn on lights for a few minutes or let machine stand for an hour or so.
Page 498 Under normal conditions, a 12V battery is fully charged at 12.8V. A slightly higher reading may occur under the conditions outlined in the last step, but, generally speaking, any reading above 12.8 when the engine is stopped is not a true reading. ENGINE RUNNING FAST ENOUGH TO MAKE ALTERNATOR PRODUCE CHARGE Disconnected voltmeter.
Page 499 T300-1_T500-1_T780 Service / Parts When voltmeter pointer stays below 13.3 with the engine running fast enough to operate the alternator, it shows that the alternator is not operating or voltage regulator is out of adjustment, or that current being drawn from battery by lights, heater fan, or accessories exceeds alternator output.
Page 500 This is the area in which the pointer should be when alternator, voltage regulator, and battery are all in good condition and working properly. When the pointer goes above 15.2, the voltage regulator is set too high or is jammed and continued operation of the engine will burn out the battery.
Page 501 T300-1_T500-1_T780 Service / Parts P/N 12261-683 REVISED: January 2015...
Page 502: Hydraulic Cylinder Maintenance
Hydraulic Cylinder Maintenance HYDRAULIC CYLINDER DISASSEMBLY GENERAL Refer to pages 5-37 and 5-38 for removal of cylinders from the boom. Do not disassemble a cylinder unless no other maintenance procedure can correct the problem. All overhaul or new cylinder installations should be done in a clean, dust-free atmosphere with all ports plugged until hose connections are made.
Page 503 T300-1_T500-1_T780 Service / Parts For dents, deep scratches, or damaged chrome plating. File any sharp edges on ends of shaft to protect the seals upon reassembly. Always protect the shaft finish when clamping in a vice or when welding against weld splatter. PISTON RINGS For cracks or other damage.
Page 504 gland into place using a wood block and hammer. In this event, cover the rod with rags or a rubber tube to prevent damage from a glancing hammer blow. The head gland is then spun in and tightened. NOTE: Apply Loctite Gr. 242 to piston retaining rings at assembly. Also apply to locking setscrews.
Page 505: Chain Adjustment - 4-Section Boom
T300-1_T500-1_T780 Service / Parts Chain Adjustment - 4-Section Boom For proper operation and boom life the extend and retract chains must be adjusted properly. To adjust these chains use the following procedure. THIRD SECTION EXTEND AND RETRACT CHAINS (4 SECTION BOOMS): Fully retract boom.
Page 506 If the gap is less than .25 inch (6 mm), loosen adjustment D and tighten adjustment C until the gap is within specifications. If the gap is more than .38 inch (10 mm), loosen adjustment C and tighten adjustment D until the gap is within specifications. Fully retract the boom and recheck the gap.
Page 507: Boom Centering
T300-1_T500-1_T780 Service / Parts Boom Centering 5 SECTION BOOM (138’) On both sides of every boom section (except 5) there are wear pads (1) located near the bottom of the section, approximately 10’ from the tip end. These pads are used to adjust each each inner boom section left and right within its respective outer boom section.
Page 508 1. WEAR PAD SHIM 2. After the pad plates are set, adjust the lower tip pads of each section until they are within 1/16” of the inner section. 3. Repeat this process on Sections 2, 3, and 4. P/N 12261-683 REVISED: January 2015...
Page 509: Setting Proximity Sensors
T300-1_T500-1_T780 Service / Parts Setting Proximity Sensors 5 SECTION BOOM (138’) Section 2 Proximity Sensor: The Section 2 proximity sensor determines if Section 2 is fully extended. To install and set, begin by fully extending the external cylinder. Measure the distance from the sensor block to the outside of the mounting plate Set the distance from the face of the proximity switch to the inside of the plate to 3/8”...
Page 510 P/N 12261-683 REVISED: January 2015...
Page 511: Repairs-Adjustments-Remarks Log
T300-1_T500-1_T780 Service / Parts Repairs-Adjustments-Remarks Log ITEM REQUIREMENT DATE P/N 12261-683 REVISED: January 2015...
Page 512 P/N 12261-683 REVISED: January 2015...
Page 514: Appendix
Appendix Conversion Tables DECIMAL AND METRIC EQUIVALENTS OF FRACTIONS OF AN INCH Fractions of an Inch Decimals of an inch Millimeters 1/64 0.0156 0.397 1/32 0.0313 0.794 3/64 0.0469 1.191 1/16 0.0625 1.588 5/64 0.0781 1.985 3/32 0.0938 2.381 7/64 0.1094 2.778 0.1250...
Page 515 T300-1_T500-1_T780 Appendix Fractions of an Inch Decimals of an inch Millimeters 0.5000 12.700 33/64 0.5156 13.097 17/32 0.5313 13.494 35/64 0.5469 13.891 9/16 0.5625 14.287 37/64 0.5781 14.684 19/32 0.5938 15.081 39/64 0.6094 15.478 0.6250 15.875 41/64 0.6406 16.272 21/32 0.6563 16.688 43/64...
Page 516 WEIGHTS AND MEASURES LIQUID MEASURE (U.S.) 4 gills 1 pint 2 pints 1 quart 4 quarts 1 gallon 7.48 gallons 1 cu. ft. 240 gallons of water 1 Ton 340 gallons of gasoline 1 Ton LIQUID MEASURE (METRIC) 1 litre 0.0353 cu.
Page 517 T300-1_T500-1_T780 Appendix CIRCULAR MEASURE 60 seconds 1 minute 60 minutes 1 degree 90 degrees 1 quadrant 360 degrees 1 circumference ELECTRICAL UNITS 1 kilowatt 1.34 H.P. 1 horsepower 746 watts SURVEYOR’S MEASURE 7.92 inches 1 link 100 links 66 feet or 4 rods or 1 chain 80 chains...
Page 518: Average Weight Of Materials
Average Weight of Materials KG/CU. MATERIAL METER KG/CU. FOOT 1 CU. YARD Ashes - Piled Dry 560.70 Brick Bats 881.10 1485 Cement - Portland 1505.88 2538 Charcoal 400.50 Cinders 881.10 1485 Clinker - Portland Cement 1361.70 2295 Clay - Dry, in Lumps 1009.26 1701 Clay - Compact, Natural Bed...
Page 519 T300-1_T500-1_T780 Appendix KG/CU. MATERIAL METER KG/CU. FOOT 1 CU. YARD Limestone - 1 1/2 or 2 Graded 1361.70 2295 Limestone - Above 2 Graded 1281.60 2160 Phosphate, Acid (Fertilizer) 1361.70 2295 Phosphate, Rock 1281.60 2160 Pyrites 2167.70 3645 Salt 929.16 1566 Sand - Dry, Loose 1521.90...
Page 520: Torque Specs -Sae & Metric
Torque Specs -SAE & Metric P/N 12261-683 REVISED: January 2015...
Page 521 T300-1_T500-1_T780 Appendix P/N 12261-683 REVISED: January 2015...
Page 522: California Proposition 65 Warning
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. 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.
Page 523: Lead Warning - State Of California
T300-1_T500-1_T780 Appendix Lead Warning - State of California Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. Battery posts, terminals, and related accesories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm.
Page 524: Epa / Nhtsa Greenhouse Gas Standards Information - (T300 & T500 Only)
MANUFACTURER'S WARRANTY COVERAGE: Terex Corporation must warrant the tires on your vehicle for the periods of time of 2 years or 24,000 miles. Tires are warranted against defect for this period (not tread wear). Where a warrantable condition exists, Terex Corporation will repair your vehicle at no cost to you including diagnosis, parts and labor.
Page 525 As the vehicle owner, your are responsible for the performance of the required maintenance listed in your owner's manual. As the vehicle owner, you should however be aware that Terex Corporation may deny you warranty coverage if your vehicle has failed due to abuse, neglect, improper maintenance or unapproved modifications.
Page 526: Greer Element Vga Operator's Manual
Greer Element VGA Operator's Manual Your crane will be set up with an Element VGA system. Completely read the attached manual in the Appendix section before attempting to operate the crane. For troubleshooting or calibrations refer to your SHOP MANUAL-CD where you will find a Greer Troubleshooting &...
Page 527 T300-1_T500-1_T780 Notes...
Page 528 Street S.E. Waverly, IA 50677 USA Tel: +1 319 352 3920 Fax: +1 319 352 9378 P/N 12261-683 Copyright Terex Corporation - Terex is a registered trademark of Terex Corporation in the United States of American and many other countries.

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