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Terex T300-1, Operator'S Manual

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Terex T300-1 Operator'S Manual Download Page 401

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

Replace clutch disc

Worn or damaged flywheel

Resurface or replace flywheel

Worn or damaged clutch pressure plate

Replace pressure plate and cover assembly

Grease or oil contamination on facings

Clean facings and repair cause of
contamination. If contaminant cannot be
removed, replace clutch disc.

New clutch installation needs break-in

Perform clutch break-in procedure

CLUTCH DRAG/HARD SHIFTING

CAUSE

REMEDY

Linkage blocked from full travel

Remove blockage

Linkage incorrectly adjusted

Adjust clutch linkage

Linkage worn/damaged

Replace faulty linkage components

Clutch damaged - damaged clutch disc hub
splines - bent clutch disc - bent drive straps
- broken/warped pressure plate

Replace damaged component

Contamination/grease in release bearing bore Clean release bearing bore and transmission

input shaft

Excessive side loading on release bearing

Eliminate source of excessive side loading
(worn/damaged cross shaft bushings, worn/
damaged cross shaft, worn/damaged or
bent release yoke tips, worn/damaged or
uneven release bearing yoke contact wear
pads, excessive release bearing travel
during disengagement, worn/damaged pilot
bearing, excessive flywheel runout,
excessive engine to transmission
misalignment, etc.).

T300-1_T500-1_T780

Troubleshooting

400

P/N 12261-683 REVISED: January 2015

Summary of Contents for T300-1

Page 1: ...T 3 0 0 1 T 5 0 0 1 T 7 8 0 O p e r a t o r sMa 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 2 0 1 3O N H I G H WA Y E X P O R TT I E R3 O R I G I N A LI N S T R U C T I O N S...

Page 2: ...8 Ending Crane Operations 49 Turning Driving in Reverse 50 Parking the Vehicle 51 Lock Out Tag Out 52 Access Egress 54 Personal Safety 57 Seat Belts 59 Temperature Effects on Telescope and Boom Hoist...

Page 3: ...Engine Overview of Operation 164 Fuel Warning 164 Aftertreatment Regeneration Lamp Behaviors 165 Regeneration Modes 168 Manual Regeneration Procedure 169 Operating the Unit 171 Operating the Engine 17...

Page 4: ...nit Filter 253 Engine Indicator Lamps 258 Aftertreatment Switch 264 Operating Characteristics with Aftertreatment Particulate Filter 265 Engine Indentification 270 Diesel Exhaust Fluid Specification 2...

Page 5: ...369 Engine Storage 371 Transmission Storage 374 Restoration to Service 375 Restoring Engine to Service 376 Restoring Transmission to Service 377 Chrome Cylinder Rod Storage 378 Specifications 381 WIR...

Page 6: ...Two Block System 429 Service Parts 433 General Service Information 433 Outrigger Position Sensors 435 Torque Wrench Extensions 437 Welding Instructions 439 Outriggers 441 Rear Suspension 448 Front Axl...

Page 7: ...ensors 508 Repairs Adjustments Remarks Log 510 Appendix 513 Conversion Tables 513 Average Weight of Materials 517 Torque Specs SAE Metric 519 California Proposition 65 Warning 521 Lead Warning State o...

Page 8: ...ppropriate information and training to those people who are to operate maintain and supervise the use of equipment in a proper and safe manner Construction and industrial equipment is designed and man...

Page 9: ...garding the care and operation of the machine we will gladly furnish it upon request Because we build various types of equipment we ask that you include your machine model and serial number in all cor...

Page 10: ...used 1 UPPERSTRUCTURE The upperstructure weldment swing mechanism counterweight cab 2 BOOM ATTACHMENT The telescopic crane boom with hydraulic winch lift cylinder hook block assembly jib arrangement...

Page 11: ...s 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 T300 1_T500 1_T7...

Page 12: ...ied to specific machines using the machine model number and PIN serial number Distribution of bulletins is based on the most current owner of record along with their associated dealer so it is importa...

Page 13: ...Questions regarding product applications and safety Standards and regulations compliance information Questions regarding product modifications Current owner updates such as changes in machine ownersh...

Page 14: ...e 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 appli...

Page 15: ...lds Product Information Machine Model Name Serial Number Purchase Date mm dd yy New Owner Information Company Name Contact Name Terex Acct if applicable Mailing Address 1 Mailing Address 2 City State...

Page 16: ...e is anything in this manual that is not clear or which you believe should be added please send your comments to Technical Publications Coordinator Terex Cranes 106 12th Street SE Waverly Iowa 50677 o...

Page 17: ...rity of the potential hazard Signal words used without the safety alert symbol relate to property damage and protection only All are used as attention getting devices on decals and labels fixed to the...

Page 18: ...or hand force applied two directions pinched Stay Clear of Moving Turret and Boom CRUSH HAZARD Death or Serious Injury can result from contact with moving machine Keep clear of moving machine Safety...

Page 19: ...gineis running Stop engine before servicing Explosion Burn Hazard Will cause death burns or blindness due to ignition of explosive gases or contact with corrosive acid Keep all open flames and sparks...

Page 20: ...appropriate ladder to reach high places Maintain 3 Point Contact when using access system Two blocking the crane can cause death serious injury or property damage Do not allow the hook block to contac...

Page 21: ...Distance From Electrical Power Lines 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 d...

Page 22: ...General Safety Safety Sign Locations 21 P N 12261 683 REVISED January 2015...

Page 23: ...zard Fluid escaping under pressure can penetrate skin and result in serious injury Relieve pressure before disconnecting hydraulic lines Stay clear of leaks and pin holes Use a piece of cardboard or w...

Page 24: ...tanglement Hazard Stay clear of belts and fan when engine is running Stop engine before servicing Contact with rotating parts can result in death or serious injury 23 P N 12261 683 REVISED January 201...

Page 25: ...n move hand in small horizontal circle A3 USE MAIN HOIST Tap fist on head then use regular signals A4 USE WHIP LINE Auxiliary Hoist Tap elbow with one hand then use regular signals A5 RAISE BOOM Arm e...

Page 26: ...d slightly raise make pushing motion in direction of travel C4 DOG EVERYTHING Clasp hands in front of body C5 TRAVEL Both Tracks Use both fists in front of body making a circular motion about each oth...

Page 27: ...aged in jib Read and understand operator s manual before using or stowing jib Crush Hazard Serious injury can result from contact with moving counterweights Keep clear of counterweight slabs while low...

Page 28: ...l cool Release of hot fluid under pressure can result in death or serious injury ELECTROCUTION HAZARD Stay clear of machine Contact with electric power lines will result in death or serious injury 27...

Page 29: ...ing or otherwise handle personnel must only be done in compliance with OSHA 1926 1431 and ANSI B30 23 MAINTAIN CLEARANCE LISTED Line Voltage Required Clearance 0 to 50KV 10 ft 3m 50 to 200KV 15 ft 4 6...

Page 30: ...derstand the information in the manuals consult your supervisor the owner or the manufacture Fall Crush Hazard Two blocking the crane can result in death or serious injury Do not allow hook block to c...

Page 31: ...h or serious injury NO RIDERS Overturning Hazard 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 li...

Page 32: ...gloves face shield and long sleeve shirt Read manuals If you do not understand the information in the manuals consult your supervisor the owner or the manufacturer Improper lifting of personnel can re...

Page 33: ...hot surfaces Allow machine to cool before servicing Explosion Burn Hazard Fuel and fumes can explode and burn resulting in death or serious injury No smoking Keep all open flames and sparks away Stop...

Page 34: ...gns 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...

Page 35: ...pting to lift 7 The operator must understand crane signals and take signals only from designated signal people However the operator must obey the stop signal from anyone OPERATOR S RESPONSIBILITIES 1...

Page 36: ...t speeds that will keep the load under control 16 Keep at least two full wraps of wire rope on drum when operating 17 Use tag lines to keep loads under control when feasible 18 Keep the load as close...

Page 37: ...sor 6 Supply the weight and the characteristics of all loads to be lifted to the operator 7 Verify that all crew members are familiar with OSHA ANSI B30 5 requirements state and local jobsite requirem...

Page 38: ...must be in place 2 Check machine log book to see if periodic maintenance and inspections have been performed 3 Ensure that necessary repairs have been completed 4 Inspect wire rope for damage kinks br...

Page 39: ...owing whether it is within the rated capacity 7 Never operate with anything other than recommended counterweight Unauthorized reduction or additions of counterweight constitute a safety hazard 8 Do no...

Page 40: ...ve materials from under powerlines with a crane if the boom or machine is capable of contacting them 3 No part of crane or load must come in contact with or violate the minimum allowable clearance req...

Page 41: ...red professional engineer who is a qualified person with respect to electrical power transmission and distribution per OSHA regulation 1926 1408 TRAVEL 1 Care must be taken when cranes are driven trav...

Page 42: ...n a boom length indicator is inoperative or malfunctioning the designated person responsible for supervising the lifting operations shall establish the boom length at which the lift will be made by ac...

Page 43: ...erecting the equipment it must be ensured that the anemometer is fully functional If the values on the display change when the rotor is rotated the unit is functioning To verify functionality during...

Page 44: ...ally 1 Very Light 1 3 1 5 Wind direction indicated by the smoke and not by the banner 2 Light Breeze 4 7 6 11 The wind can be felt on the face the leaves rustle the banner moves 3 Gentle Breeze 8 12 1...

Page 45: ...er or attempting to get onto the carrier superstructure or boom assembly If on the machine do not try to get off the machine If you are in the operator s cab upper or lower during an electrical storm...

Page 46: ...place to prevent unauthorized use or unintended movement Make sure that the batteries are recharged The parking brake of the crane chassis shall be applied Transmission gear shall be set to neutral Th...

Page 47: ...nfiguration of a crane when it is to be left unattended The crane boom should be lowered before wind speeds exceed the permitted values This may not be possible depending on job site and crane setup I...

Page 48: ...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 The crane may topple over The crane may move Unsafe ope...

Page 49: ...ane 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...

Page 50: ...site crane boom all the way down and disassembled if necessary 4 _________ Is master control level to the centered 0 position 5 _________ Is parking brake on crane chassis set 6 _________ Is crane eng...

Page 51: ...areas into which he will be travelling a guide who is in communication with the driver at all times must be used who can see those areas the driver cannot An acoustical back up warning device does no...

Page 52: ...on which the crane is parked must be on even solid ground with sufficient load bearing capacity Mobile cranes can roll away if not properly prepared causing injury or property damage Under the followi...

Page 53: ...vent absolutely the unexpected or accidental startup of equipment and to alert all workers whenever it is unsafe to operate any piece of equipment When used as intended Lock Out Tag Out also protects...

Page 54: ...place 2 All work is complete and tools are put away 3 All workers are notified that a lock is being removed 4 All workers are positioned safely for startup 5 Controls are positioned for safe startup 6...

Page 55: ...e 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 ope...

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 55 P N 12261 683 REVISED January 2015...

Page 57: ...Rear LH Side Access Egress Carrier Access Egress LH Side T300 1_T500 1_T780 Safety 56 P N 12261 683 REVISED January 2015...

Page 58: ...tag with the name of the individual doing the work 5 After ensuring that no personnel are exposed and to ensure that energy sources are disconnected try to start the machine and engage operating contr...

Page 59: ...the tool box 5 Replace all broken ladders or other access system components 6 Keep non slip surfaces in good condition 7 Never jump off the machine Instead use the hand holds and step designed for ent...

Page 60: ...dry in the shade 5 Do not bleach or re dye because such processing may severely weaken the assembly 6 Inspect seat belt assemble frequently Anytime it does not operate properly or if there are any def...

Page 61: ...the oil temperature change within the cylinder The rate at which the oil in a cylinder cools is dependent upon several factors These factors include the differential temperature between the oil and am...

Page 62: ...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 Boom angle Load Drop inches 100 Max Bo...

Page 63: ...s less than 60 and slightly more for boom angles greater than 60 in comparison to the values in the graphs provided herein 2 Load drift due to thermal contraction of the hydraulic oil can be mistaken...

Page 64: ...rear outriggers till boom head can be reached from ground level 5 Install the upper and lower jib mounting pins in the right side of the boom head 6 Attach a guide rope to the eye on the bottom tip o...

Page 65: ...ng jib to boom Install the left upper and lower jib mounting pins 12 Remove the guide rope 13 Disconnect the anti two block plug from the jib anti two block socket and connect it to the socket on the...

Page 66: ...tach hoist line dead end 4 30 Offset Hole 2 0 Offset Hole 5 Sheave Shaft 3 15 Offset Hole 6 Cap Screws INCREASING OFFSET 1 Retract the boom and set the outriggers 2 Boom down to minimum boom angle 65...

Page 67: ...ib offset pins 6 Remove the jib offset pins from the 0 offset hole and place in the 15 hole or if you are using 30 offset then place pins in tool box 7 With the engine at idle slowly winch down to pay...

Page 68: ...Socket 2 Attach Dead end Of Rope 5 Anti Two block Retracted Socket 3 Pull Out Retaining Pin Hole 6 Pull out Anti Two block Plug NOTE The jib must be erected before extending the pullout section Do not...

Page 69: ...be actuated in the cab and the boom down boom extend and winch up controls should disconnect RETRACTING THE PULLOUT SECTION 1 Retract the boom completely and boom down to minimum boom angle 2 Unplug t...

Page 70: ...utsized drum and excessive undercutting at the base of the flange also indicate that repair or replacement of the drum is necessary Check the bearings for excessive wear and play After correcting any...

Page 71: ...and route back to the winch drum 2 Position the winch drum with the cable anchor slot on top 3 Insert cable through slot and position around the cable wedge 4 Position the anchor wedge in the drum slo...

Page 72: ...ight winding on the drum is absolutely essential Never use a steel hammer or pry bar to move the rope over on the drum These tools can easily damage the rope After the wire rope is wound onto the winc...

Page 73: ...e wedge is accomplished by making lifts of gradually increasing loads Avoid imposing shock loading on the rope until the wedge is firmly in place 5 After the wedge has been firmly seated a short lengt...

Page 74: ...ARY 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 BLOCK SHEAVE 11 CABLE SOCKET 73 P N 122...

Page 75: ...emoval of the wedge and socket from the rope in order to change the reeving Removal of two pins in the boom head and three in the hook block will allow the wedge and socket to pass through Never use l...

Page 76: ...nd 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 wi...

Page 77: ...he winch to the counterweight 3E Using a suitable lifting device lift the Aux winch off of the crane and place it aside 4 Attach a suitable lifting device to the counterweight and support the weight o...

Page 78: ...77 P N 12261 683 REVISED January 2015...

Page 79: ...he 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 T300 1_T5...

Page 80: ...CATION 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 GRD 5 270 DRY...

Page 81: ......

Page 82: ...ed Sections 1 and 3 are especially important with respect to machine operation Diagrams of the various carrier and upper controls are illustrated on the following pages A list of these controls and in...

Page 83: ...ST ENGINE DIAGNOSTIC IGNITION SLOW INCR IDLE ADJ INCREASE ENGINE STOP AXLE DISENGAGE RANGE SHIFT INCR IDLE ADJ DECREASE AIR SUSPENSION FILL KEY ACC ENGINE STOP T300 1_T500 1_T780 Description Of Machin...

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 83 P N 12261 683 REVISED January 2015...

Page 85: ...DPF LAMP HEST LAMP CHECK ENGINE ABS DIAGNOSTIC T300 1_T500 1_T780 Description Of Machine and Controls 84 P N 12261 683 REVISED January 2015...

Page 86: ...Carrier Controls and Instruments EPA 2013 Engines 85 P N 12261 683 REVISED January 2015...

Page 87: ...t be stopped curbside at idle transmission in neutral park brake set to initiate the regeneration process See Maintenence Section 6 WIPER SWITCH Press for windshield wiper 22 WAIT TO START Red colored...

Page 88: ...the machine become stuck a spinning wheel will receive all power transmitted by the drivetrain causing the wheel to spin faster and worsen the condition Use of the lockout divides the available power...

Page 89: ...nu select deselect button See UNIDECK Manual 35 ENGINE STOP Red colored Warning Light ON when Engine should be shutdown 47 SPEEEDOMETER GUAGE MPH 0 80 Kph 0 120 36 ENGINE CHECK Amber colored Warning L...

Page 90: ...3 MENU NAVIGATION BUTTON LCD Display screen menu See UNIDECK Operations Instructions 42 DIFFERENTIAL LOCK Amber colored Warning Light ON Differential is locked 54 MIL MALFUNCTION INDICATOR LIGHT The M...

Page 91: ...point toward base of flame and depress black handle to discharge fire suppressant 57 WINDSHIELD WASHER RESERVOIR Use only over the counter washer fluid made specifically for automotive windshields T30...

Page 92: ...58 HEATER UNIT Engine hot water supplied to carrier cab heater unit 59 TRANSMISSION SHIFTER Eaton Fuller transmission See Trans Operations Instructions 91 P N 12261 683 REVISED January 2015...

Page 93: ...Manual Automatic Transmission T300 1_T500 1_T780 Description Of Machine and Controls 92 P N 12261 683 REVISED January 2015...

Page 94: ...ps engaged for example pick and carry work With the PTO switch in the upper position pumps are engaged and throttle and gauges operate from the upper cab The PTO light 43 will come on once the engine...

Page 95: ...work While damage to the pump disconnect splines will not result from making this change with the engine running it is recommended stopping the engine before making any change to the PTO switch 13 T50...

Page 96: ...l 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 95 P N 1226...

Page 97: ...T300 1_T500 1_T780 Description Of Machine and Controls 96 P N 12261 683 REVISED January 2015...

Page 98: ...97 P N 12261 683 REVISED January 2015...

Page 99: ...T300 1_T500 1_T780 Description Of Machine and Controls 98 P N 12261 683 REVISED January 2015...

Page 100: ...99 P N 12261 683 REVISED January 2015...

Page 101: ...T300 1_T500 1_T780 Description Of Machine and Controls 100 P N 12261 683 REVISED January 2015...

Page 102: ...101 P N 12261 683 REVISED January 2015...

Page 103: ...T300 1_T500 1_T780 Description Of Machine and Controls 102 P N 12261 683 REVISED January 2015...

Page 104: ...103 P N 12261 683 REVISED January 2015...

Page 105: ...T300 1_T500 1_T780 Description Of Machine and Controls 104 P N 12261 683 REVISED January 2015...

Page 106: ...105 P N 12261 683 REVISED January 2015...

Page 107: ...T300 1_T500 1_T780 Description Of Machine and Controls 106 P N 12261 683 REVISED January 2015...

Page 108: ...107 P N 12261 683 REVISED January 2015...

Page 109: ...UNIDECK Operation Instructions T300 1_T500 1_T780 Description Of Machine and Controls 108 P N 12261 683 REVISED January 2015...

Page 110: ...109 P N 12261 683 REVISED January 2015...

Page 111: ...T300 1_T500 1_T780 Description Of Machine and Controls 110 P N 12261 683 REVISED January 2015...

Page 112: ...111 P N 12261 683 REVISED January 2015...

Page 113: ...T300 1_T500 1_T780 Description Of Machine and Controls 112 P N 12261 683 REVISED January 2015...

Page 114: ...113 P N 12261 683 REVISED January 2015...

Page 115: ...T300 1_T500 1_T780 Description Of Machine and Controls 114 P N 12261 683 REVISED January 2015...

Page 116: ...115 P N 12261 683 REVISED January 2015...

Page 117: ...T300 1_T500 1_T780 Description Of Machine and Controls 116 P N 12261 683 REVISED January 2015...

Page 118: ...117 P N 12261 683 REVISED January 2015...

Page 119: ...T300 1_T500 1_T780 Description Of Machine and Controls 118 P N 12261 683 REVISED January 2015...

Page 120: ...119 P N 12261 683 REVISED January 2015...

Page 121: ...T300 1_T500 1_T780 Description Of Machine and Controls 120 P N 12261 683 REVISED January 2015...

Page 122: ...Carrier Controls and Instruments EXPORT 121 P N 12261 683 REVISED January 2015...

Page 123: ...SWITCH Press for windshield wiper 22 OPEN 7 CRUISE CONTROL On Off Press to toggle cruise on and off 23 WARNING LIGHTS GUAGE DISPLAY PANEL Refer to items 32 thru 53 for I D and function 8 CRUISE Set R...

Page 124: ...of the lockout divides the available power between the two axles of the rear tandem With the lockout engaged the stuck wheel may continue to spin but the other side of the tandem will begin driving th...

Page 125: ...ISPLAY Readouts Terex Logo Clock Total Engine Machine Hours Engine Oil Pressure Total Odometer Partial Odometer Languages menu Engine Fault See UNIDECK Operation Instructions on 2010 Tier 4 section 39...

Page 126: ...nd 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 125 P N 12261 683 REVI...

Page 127: ...er for OFF windshield wiper 21 OUTGRIGGER SWITCH RR Switch controls Right Rear jack cylinder Push right side of switch to run beam in conjunction with 27 Master Switch Push left side of switch to run...

Page 128: ...overheating 28 IGNITION SWITCH A All circuits off B Circuits other than ignition on C All circuits including ignition on D Engine start 12 SWING LOCKED INDICATOR Red light ON indicates the superstuctu...

Page 129: ...rior to lifting a load 33 SWING LOCK SWITCH Push right to engage the swing lock left to disengage the swing lock Alway engage the lock when exiting the cab or transporting the machine T780 Swing Lock...

Page 130: ...129 P N 12261 683 REVISED January 2015...

Page 131: ...istribute grease 41 MODE SELECTOR SWITCH Allows the operator to set the unit to fan only AC or heat mode 37 ACCESSORY PLUG 12 VDC power 42 SWING SENSE SWITCH In OFF position shuts off AC compressor to...

Page 132: ...ructure 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 t...

Page 133: ...e Speed of wire rope is proportional to throttle setting and movement of joystick lowering the load 5 AUXILIARY WINCH DISABLE SWITCH Depress switch LED green light will come ON winch function will be...

Page 134: ...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...

Page 135: ...H TWO SPEED SWITCH Depress switch LED red light will come ON Main winch wire rope take in and payout speed will be in HIGH speed mode 13 MAIN WINCH DISABLE SWITCH Depress switch LED green light will c...

Page 136: ...1 Heater AC Unit See Kenway Operations Maintenence Manual on your Manual Pack Shop Manual CD 135 P N 12261 683 REVISED January 2015...

Page 137: ...and hold Use switch 5 to extned or retract the jack cylinder Move toggle switch Left for LR beam enable Use swtich 5 to extend or retract the beam 2 Right Rear Outrigger Jack Move toggle switch UP or...

Page 138: ...o provide additional boom reach which is a 33 57 ft 10 05 17 37 m side stow swing on lattice type jib The jib is extendible to 57 ft 17 37 m by means of a 25ft 7 62 m manual pullout tip section The 33...

Page 139: ......

Page 140: ...orm the daily lubrication as required in the Lubrication Recommendations Lubricate cylinder mounting bushings and pins LINES AND BLOCKS Inspect the hoist lines hoist block and ball hook and the crane...

Page 141: ...tem on the control linkages A check of this system should be made prior to lifting Hoist the hook block to the boom point so that actual contact between block and anti two block counterweight is made...

Page 142: ...ECTED CHECKED INSPECTION CODE SATISFACTORY ADJUST REPAIR VISUAL INSPECTION H Complete Machine D OVERALL CLEANLINESS D HYDRAULIC SYSTEM See Hydraulic Hose topic in Maintenance section Leaks or Damage D...

Page 143: ...GAUGES D CLUTCHES BRAKES D WIRE ROPE SHEAVES GUARDS D TWO BLOCK DAMAGE PREVENTION SYSTEM D LOAD SUPPORTING COMPONENTS CONDITION D FIRE EXTINGUISHER D BACKUP ALARM D BOOM ANGLE INDICATOR D HEAD TAIL B...

Page 144: ...FLUID LEVEL W DRIVE SHAFTS U JOINTS W TIRE WHEEL CONDITION INFLATION PRESSURE W AIR REGULATORS W AIR CLEANER ELEMENT W CLUTCH BRAKE LINKAGE PINS W WHEEL LUG NUT TORQUE W FAN BELT TENSION W STRUCTURAL...

Page 145: ...weld separation leaks damage vandalism INSPECTION CODE INTERVALS D DAILY W WEEKLY M MONTHLY A ANNUALLY P PERIODIC NOTES 1 Indicate inspection result by checking in the satisfactory adjust or repair b...

Page 146: ...145 P N 12261 683 REVISED January 2015...

Page 147: ...on Oil Level __ Drain Fuel Filters or Water Separator __ Check Boom Front Slider Pads __ Check Boom Chains And Ends __ Drain Air Tanks __ Check Wire Rope And Related Components __ Check Air Cleaner __...

Page 148: ...heck Torque On Wheel Lug Nuts __ Check Hydraulic Cylinders And Rods __ Make Thorough Inspection Of Wire Rope __ Visually Inspect All Structural Members And Welds For Cracks Alignment and Wear __ Check...

Page 149: ...gine 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 Addi...

Page 150: ...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 Engi...

Page 151: ...t For Signs Of Oil Accumulation __ Change Power Steering Filter Element __ Check Hydraulic Relief Valve Pressure Settings __ Torque Swing Bearing Bolts 725 ft lbs according to tightening sequence __ C...

Page 152: ...n __ 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 t...

Page 153: ...ATE 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 Inspected Type...

Page 154: ...ile cranes satisfies all applicable international standards EN ISO FEM etc and does not provide for continuous operation The cranes therefore have a service life which is defined by the permitted numb...

Page 155: ...g the safety equipment and can necessitate non destructive inspections such as magnetic particle or ultrasonic inspections Any malfunction or irregularity discovered during the inspection must be eval...

Page 156: ...due to national laws the test conditions must correspond with the conditions during the scheduled lift It is acceptable for Terex to carry out a load test for a given crane configuration with reduced...

Page 157: ......

Page 158: ...e two components burn off collected particulate matter in a process called regeneration The key to successful regeneration is high exhaust temperatures for an extended period of time Without adequate...

Page 159: ...r Red Stop Light are indications of a system problem Illumination of the yellow light indicates that a parked regeneration is required There is a need to periodically remove accumulated ash derived fr...

Page 160: ...generation Light will be illuminated prior to any engine protection measures being taken Once the light is lit the parked regeneration process should be initiated 2 If no regeneration occurs after the...

Page 161: ...F Regeneration Light starts flashing in the lower cab 3 If the flashing DPF is still ignored the AWL Check Engine Red Light light will illuminate This will be accompanied by the 25 engine torque reduc...

Page 162: ...engine and ATD from damage up to and including engine shutdown which will require the engine dealer to reset the regeneration sequence NOTE If the DDEC Vl electronics have not requested the initiatio...

Page 163: ...the regeneration process NOTE The procedure will take up to 1 hr Times could be less or more dependent on engine type and the amount of soot accumulated in the filter To initiate a parked regeneratio...

Page 164: ...ssociated warning lights If any of the above requirements are not met the engine will return to idle To cancel the parked regeneration the operator can toggle the REGEN switch to ON for five seconds T...

Page 165: ...Cummins 2013 Engine Overview of Operation Fuel Warning T300 1_T500 1_T780 Operating Instructions 164 P N 12261 683 REVISED January 2015...

Page 166: ...Aftertreatment Regeneration Lamp Behaviors 165 P N 12261 683 REVISED January 2015...

Page 167: ...T300 1_T500 1_T780 Operating Instructions 166 P N 12261 683 REVISED January 2015...

Page 168: ...167 P N 12261 683 REVISED January 2015...

Page 169: ...Regeneration Modes T300 1_T500 1_T780 Operating Instructions 168 P N 12261 683 REVISED January 2015...

Page 170: ...cally take anywhere from 45 minutes to 1 5 hours to complete A manual regeneration can be initiated with the Regeneration Switch The manual regeneration switch will only initiate a regeneration when t...

Page 171: ...e tire During regeneration exhaust gas temperature could reach 1500 degrees F and exhaust system surface temperature could exceed 1300 degrees F which is hot enough to ignite or melt common materials...

Page 172: ...Operating the Unit Operating the Engine 171 P N 12261 683 REVISED January 2015...

Page 173: ...T300 1_T500 1_T780 Operating Instructions 172 P N 12261 683 REVISED January 2015...

Page 174: ...173 P N 12261 683 REVISED January 2015...

Page 175: ...at 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 T300 1_T500...

Page 176: ...175 P N 12261 683 REVISED January 2015...

Page 177: ...T300 1_T500 1_T780 Operating Instructions 176 P N 12261 683 REVISED January 2015...

Page 178: ...177 P N 12261 683 REVISED January 2015...

Page 179: ...he oil pressure gauge immediately after starting the engine A good indicator that all of the moving parts are getting lubrication is when the oil pressure gauge registers pressure 5 psi 34 5 kPa at id...

Page 180: ...gine until the cause of the concern has been investigated and corrected Avoid unnecessary Idling During long engine idling periods with the transmission in neutral the engine coolant temperature may f...

Page 181: ...Engine Cold Weather Operation T300 1_T500 1_T780 Operating Instructions 180 P N 12261 683 REVISED January 2015...

Page 182: ...181 P N 12261 683 REVISED January 2015...

Page 183: ...T300 1_T500 1_T780 Operating Instructions 182 P N 12261 683 REVISED January 2015...

Page 184: ...t both ends of one cable to positive terminals of each battery 5 Connect one end of the other cable to negative terminal of the booster battery 6 Connect other end of cable away from battery to engine...

Page 185: ...he coolant contains ethylene glycol Use only non chromate base inhibitors Chromate base inhibitors reacting with ethylene glycol can produce chromium hydroxide commonly known as green slime This subst...

Page 186: ...being engaged and running the engine at low speed Continue warming the oil and slowly cycle all crane functions actuating all cylinders in turn swinging the upper and operating the winches in both di...

Page 187: ...ating in sand or dust on a regular basis 1 Increase frequency of lubrication and service per lube chart The increased frequency of lubrication and service discussed above should be determined by obser...

Page 188: ...ve 10 000 the engine fuel injectors may have to be changed to ensure proper performance Consult engine manufacturer should this problem arise Keeping the air cleaner clean and free of obstructions wil...

Page 189: ...rane is leveled The red light on the dash will be on if the front jack is not fully retracted It will remain on any time the front outrigger jack is extended NOTE When setting front outrigger run the...

Page 190: ...e determining factors are lifted load radius boom angle working position hoist line reeving tire pressure travel data and use of a jib The examples given in this section are given for your interpretat...

Page 191: ...nd retract cylinders have reached the limits of their travel This can cause overheating of the hydraulic oil if it is run over relief for prolonged periods 5 Swing the boom over the load Upper structu...

Page 192: ...d 7 Lower the hook block to the load and fasten the hook Before making any crane lift make sure the hook is properly engaged with the slings or lifting device employed to make the lift Be certain the...

Page 193: ...deposited 10 Lower the load and unfasten the hook When spotting the load it may be necessary to alter the boom length or boom angle In making these adjustments the operator must guard against exceedi...

Page 194: ...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 win...

Page 195: ...extended fingers closed thumb pointing downward MOVE SLOWLY Use one hand to give any motion signal and place other hand motionless in front of hand giving the motion signal Hoist slowly shown as exam...

Page 196: ...sed fist Travel opposite track in direction indicated by circular motion of other fist rotated in front of body land cranes only EXTEND BOOM Telescoping Booms Both fists in front of body with thumbs p...

Page 197: ...operating radius Freely Suspended Load Load hanging free with no direct external force applied except by the hoist rope Side Load Horizontal force applied to the lifted load either on the ground or i...

Page 198: ...Outriggers Extended Areas measured in a circular arc about the centerline of rotation as shown in the diagram below 1 Boom over front working area 2 Boom over side working area 3 Boom over rear workin...

Page 199: ...one because the effects of wind pendulum action jerking etc can cause a tip over Extending the boom or boom and jib combination into unrated areas of the chart can cause tip over Do not operate at a l...

Page 200: ...00 25 6 0 18600 18600 30 0 28 5 16600 14500 30 0 47 0 17200 15100 34 3 0 13500 10700 35 0 38 4 13900 11200 40 0 27 6 11200 8400 45 0 7 6 8900 6400 45 3 0 8700 8200 Example Hook Block 660 lbs Slings 21...

Page 201: ...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: ...ary boom head is not erected add 100 lbs to the chart rated capacity 7 Compare load weight with chart rated capacity from the boom length radius and boom angle 8 The lifted load must not exceed the ch...

Page 203: ...ed crane The travel surface must also be free of holes or debris that can cause crane instability 9 If equipped with rear air suspension the rear air should be dumped before lifting or travelling with...

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 203 P N 12261 683 REVISED January 2015...

Page 205: ...FT MAX BOOM LENGTH FT BOOM STRAIGHT OVER REAR 0 TO 2 1 2 MPH 10 30 13 900 12 30 12 600 15 39 10 600 20 39 7 400 25 50 5 100 30 50 3 300 35 50 1 900 40 50 1 000 T300 1_T500 1_T780 Operating Instructio...

Page 206: ...osening clamp 1 This will allow the bar to slide so that the trailing arm can be rotated relative to the frame Adjust the suspension member so that its surface 2 is parallel to the frame surface 3 Pas...

Page 207: ...4 Air Yoke 5 Switch T300 1_T500 1_T780 Operating Instructions 206 P N 12261 683 REVISED January 2015...

Page 208: ...o the upper crane cab 2 Start the crane engine If the red Low Air light is ON run the crane engine for a few minutes to allow air pressure to build up before moving the carrier 3 Turn ON the Remote Po...

Page 209: ...switch as necessary to position the crane as desired 8 To stop depress the service brakes shift the Transmission switch to N neutral and engage the parking brakes with the parking brake switch 9 Turn...

Page 210: ...rweight supports on the deck of the crane in order to equalize the axle loading 1 Lower the outrigger jacks to support the weight of the crane 2 Rotate the upper to a position straight over the rear o...

Page 211: ...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...

Page 212: ...e locking pins into the top slab 8 Remove the locking pins and long horizontal pins from the lower most slab that you wish to attach to the counterweight 9 Lift both control levers to raise the counte...

Page 213: ...10 Install horizontal pins and locking pins on each side to attach the stack to the counterweight T300 1_T500 1_T780 Operating Instructions 212 P N 12261 683 REVISED January 2015...

Page 214: ...ent On Board Diagnostics monitors all emissions related engine systems during operation If the system detects any emissions related malfunctions it will alert the operator to these detected malfunctio...

Page 215: ...uge reads zero and the engine has been shut down has idled for one hour after the DEF tank has been run dry or if the vehicle s diesel fuel tank is refilled without refilling the DEF tank the Stop Eng...

Page 216: ...ast 20 minutes to increase exhaust temperatures OR b Perform a parked regeneration Flashing If a regeneration is not performed in a timely manner after the DPF Lamp is illuminated the DPF Lamp will be...

Page 217: ...crease and there may be a noticeable change to the sound of the turbocharger during the regeneration process Once the DPF is regenerated the engine will automatically return to the normal idle speed M...

Page 218: ...cessive and you also notice white vapor have the exhaust system inspected for leaks Tips for Efficient Driving 1 Lower drive speeds At interstate speeds each 1 0 mph 1 6 kph increase equals a 0 1 mpg...

Page 219: ...lock up to the head when traveling or to secure it to the bumper ring will result in excessive swinging of the hook block and possible damage to machine Continuing to pull the block up after contact h...

Page 220: ...dicated in the following table 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...

Page 221: ...ral minutes at idle the engine may be shut off by pushing the engine stop button or turn the ignition switch to the OFF position T300 1_T500 1_T780 Operating Instructions 220 P N 12261 683 REVISED Jan...

Page 222: ...Button mounted on the shift lever When operation in ratios from LO to 8th the Deep Reduction Button should be in the REARWARD position Move the Deep Reduction Button into the FORWARD position to selec...

Page 223: ...cted the crane will be moving in LL1 6 To upshift from LL1 to LO in the same gear shift lever position move the Deep Reduction Button to the REARWARD position and IMMEDIATELY release accelerator Depre...

Page 224: ...s no control over the engine speed when it its being pushed by a load When the engine speed exceeds the rated governed speed while descending a grade or downshifting at the high end of the operating r...

Page 225: ...ions ranges available and when to select them will make vehicle control and your job even easier It is recommended to select lower ranges when descending long grades to reduce wear on service brakes B...

Page 226: ...rane around a job site NOTE See the ON TIRES LIFT instructions found in the Operating Instructions section for Information on moving the crane with a load Carry the boom over the front only Lock the s...

Page 227: ...ore 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...

Page 228: ...ich could damage the engine or transmission The operator must be very careful on steep side slopes to avoid tipping the crane NOTE This machine can travel on 15 side slopes which have a firm level pre...

Page 229: ...Towing or Pushing Vehicle The engine cannot be started by pushing or towing T300 1_T500 1_T780 Operating Instructions 228 P N 12261 683 REVISED January 2015...

Page 230: ...outriggers 2 Rotate the upper structure to the over rear position 3 Make sure the stinger is in the stowed position and the jib offset is at 0 offset 4 Boom down to minimum boom angle 5 Remove the hoi...

Page 231: ...t idle slowly retract the boom completely The jib will engage the jib storage brackets as the boom is retracted 13 Remove the guide rope from the tip of the jib 1 Bracket mounted to boom 2 Bracket mou...

Page 232: ...ill not hold the sections against the hard breaking jolts while the crane is being transported Restrain the boom extend sections by snugging the hook block against the boom head or secure the boom hea...

Page 233: ...utral position 2 Put the parking brake switch in the ON position 3 Turn the ignition switch to the ON position Wait to start light goes off 4 Turn the ignition switch to the START position to start th...

Page 234: ...e starting procedure below 1 Move the transmission shift lever to the neutral position 2 Put the parking brake switch in the ON position 3 Turn the ignition switch to the ON position Wait to start lig...

Page 235: ......

Page 236: ...895 CONTROL MODULE CM850 CYLINDERS 6 T340 07 EXPORT 2007 DESCRIPTION TRANSMISSION AUTO ENGINE MODEL QSC8 3 Tier 3 TEREX ENGINE NUMBER T122717 HP RPM 275 2200 MAX RPM 2200 PEAK TORQUE Lb Ft 895 CONTRO...

Page 237: ...560 EXPORT DESCRIPTION TRANSMISSION AUTO ENGINE MODEL DD Series 60 14L TEREX ENGINE NUMBER 717 1278 HP RPM 455 1800 MAX RPM 2175 PEAK TORQUE Lb Ft 1550 CONTROL MODULE NA CYLINDERS 6 T560 2013 DESCRIPT...

Page 238: ...PM 2175 PEAK TORQUE Lb Ft 1650 CONTROL MODULE NA CYLINDERS 6 T780 EXPORT DESCRIPTION TRANSMISSION AUTO ENGINE MODEL DD Series 60 TEREX ENGINE NUMBER T122719 HP RPM 515 1800 MAX RPM 2175 PEAK TORQUE Lb...

Page 239: ...NE MODEL ISX 2013 TEREX ENGINE NUMBER T125882 HP RPM 500 1800 MAX RPM 2100 PEAK TORQUE Lb Ft 1650 CONTROL MODULE CM2350 CYLINDERS 6 T300 1 T500 1 T780 Engine DEF Control Unit T300 1_T500 1_T780 Mainte...

Page 240: ...DESCRIPTION TEREX PART NO 1 DEF SUPPLY MODULE 222725 2 Dosing Control Unit Not Used for 2013 Engine NA 3 RELAY 40A 222727 4 COOLANT MANIFOLD 222728 239 P N 12261 683 REVISED January 2015...

Page 241: ...ol detecting problem areas and reanalyzing maintenance requirements The items in each check interval on the check chart are grouped under their respective headings and covered in detail over the cours...

Page 242: ...Crane Maintenence Specification Acronyms and Abbreviations 241 P N 12261 683 REVISED January 2015...

Page 243: ...T300 1_T500 1_T780 Maintenance 242 P N 12261 683 REVISED January 2015...

Page 244: ...General Safety Instructions 243 P N 12261 683 REVISED January 2015...

Page 245: ...T300 1_T500 1_T780 Maintenance 244 P N 12261 683 REVISED January 2015...

Page 246: ...Flow Diagram Exhaust System 245 P N 12261 683 REVISED January 2015...

Page 247: ...T300 1_T500 1_T780 Maintenance 246 P N 12261 683 REVISED January 2015...

Page 248: ...6 Aftertreatment Diesel Particulate Filter DPF 10 Decomposition Reactor 13 Aftertreatment SCR Catalyst 247 P N 12261 683 REVISED January 2015...

Page 249: ...T300 1_T500 1_T780 Maintenance 248 P N 12261 683 REVISED January 2015...

Page 250: ...Engine Cooling System Maintenence Schedule 249 P N 12261 683 REVISED January 2015...

Page 251: ...T300 1_T500 1_T780 Maintenance 250 P N 12261 683 REVISED January 2015...

Page 252: ...251 P N 12261 683 REVISED January 2015...

Page 253: ...T300 1_T500 1_T780 Maintenance 252 P N 12261 683 REVISED January 2015...

Page 254: ...Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter 253 P N 12261 683 REVISED January 2015...

Page 255: ...T300 1_T500 1_T780 Maintenance 254 P N 12261 683 REVISED January 2015...

Page 256: ...255 P N 12261 683 REVISED January 2015...

Page 257: ...T300 1_T500 1_T780 Maintenance 256 P N 12261 683 REVISED January 2015...

Page 258: ...257 P N 12261 683 REVISED January 2015...

Page 259: ...Engine Indicator Lamps T300 1_T500 1_T780 Maintenance 258 P N 12261 683 REVISED January 2015...

Page 260: ...259 P N 12261 683 REVISED January 2015...

Page 261: ...T300 1_T500 1_T780 Maintenance 260 P N 12261 683 REVISED January 2015...

Page 262: ...261 P N 12261 683 REVISED January 2015...

Page 263: ...T300 1_T500 1_T780 Maintenance 262 P N 12261 683 REVISED January 2015...

Page 264: ...263 P N 12261 683 REVISED January 2015...

Page 265: ...Aftertreatment Switch The stationary parked regeneration switch used to initiate regeneration with the aftertreatment system T300 1_T500 1_T780 Maintenance 264 P N 12261 683 REVISED January 2015...

Page 266: ...Operating Characteristics with Aftertreatment Particulate Filter 265 P N 12261 683 REVISED January 2015...

Page 267: ...T300 1_T500 1_T780 Maintenance 266 P N 12261 683 REVISED January 2015...

Page 268: ...267 P N 12261 683 REVISED January 2015...

Page 269: ...T300 1_T500 1_T780 Maintenance 268 P N 12261 683 REVISED January 2015...

Page 270: ...269 P N 12261 683 REVISED January 2015...

Page 271: ...Engine Indentification T300 1_T500 1_T780 Maintenance 270 P N 12261 683 REVISED January 2015...

Page 272: ...271 P N 12261 683 REVISED January 2015...

Page 273: ...T300 1_T500 1_T780 Maintenance 272 P N 12261 683 REVISED January 2015...

Page 274: ...273 P N 12261 683 REVISED January 2015...

Page 275: ...T300 1_T500 1_T780 Maintenance 274 P N 12261 683 REVISED January 2015...

Page 276: ...275 P N 12261 683 REVISED January 2015...

Page 277: ...Diesel Exhaust Fluid Specification T300 1_T500 1_T780 Maintenance 276 P N 12261 683 REVISED January 2015...

Page 278: ...277 P N 12261 683 REVISED January 2015...

Page 279: ...T300 1_T500 1_T780 Maintenance 278 P N 12261 683 REVISED January 2015...

Page 280: ...279 P N 12261 683 REVISED January 2015...

Page 281: ...T300 1_T500 1_T780 Maintenance 280 P N 12261 683 REVISED January 2015...

Page 282: ...13 AUTO 218027 219903 219902 222678 222679 T340 20 13 ROW MANUAL 222644 222645 222646 222647 222648 T560 20 13 MANUAL 222680 222681 NA 222682 222679 T560 20 13 AUTO 222680 222681 NA 222682 222679 T78...

Page 283: ...0 10 AUTO 219905 Oil Filter 218624 219949 219317 NA 216699 T780 Pre 20 10 MANUAL 218624 219949 219317 NA 216699 T780 Pre 20 10 AUTO 218624 219949 219317 NA 216699 NOTE A Change air cleaner element acc...

Page 284: ...Lubrication Charts 283 P N 12261 683 REVISED January 2015...

Page 285: ...T300 1_T500 1_T780 Maintenance 284 P N 12261 683 REVISED January 2015...

Page 286: ...285 P N 12261 683 REVISED January 2015...

Page 287: ...tension and wear Coolant level Oil level Transmission oil level Air cleaner sight gauge Air intake Muffler and exhaust DEF fluid level Check battery box For battery condition Crane boom Check for Hook...

Page 288: ...0 HOURS Make initial replacement of hydraulic return line filter 40 HOURS Perform initial axle oil change at approximately 3 000 5 000 miles 100 HOURS After one hundred hours drain and change the winc...

Page 289: ...eck DEF Urea Fluid Level in Reservoir ___Drain Water from Air Tanks WEEKLY CHECK 40 HOURS ___ Perform The Daily Check ___ Check Torque On Wheel Lug Nuts ___ Perform Weekly Lubrication ___ Check Hydrau...

Page 290: ...kly Monthly And Quarterly Checks ___ Change Power Steering Filter Element T300 1 only ___ Perform Semiannual Lubrication ___ Check Hydraulic Relief Valve Pressure Settings ___ Clean Crankcase Breather...

Page 291: ...lic Reservoir ___See Transmission Maintenence Section ___See Engine Maintenence Section ___ Hydraulic Hoses See Hydraulic Hose topic in Maintenance section T300 1_T500 1_T780 Maintenance 290 P N 12261...

Page 292: ...ensures that basic preventive maintenance requirements will be met under average operating conditions Conditions which impose greater wear loads or strain on the crane may dictate reduced check interv...

Page 293: ...ooling on winch Cylinder pin connections for wear Check tires axles and drive lines for wear or damage Check in the cab for Instruments functioning properly Control operation Glass for good visibility...

Page 294: ...perated with hydraulic reservoir temperatures in excess of 200 F 87 C due to possible excessive damage to the hydraulic oil and rubber components hoses seals shaft seals motor seals etc If overheating...

Page 295: ...stem running at normal operating temperature It is important to use good technique in obtaining an oil sample The exact same procedure should be followed each time an oil sample is taken Most fluid su...

Page 296: ...on This number should normally be less than 100 A high copper particle count indicates that a gear pump or motor is rapidly deteriorating A count of 200 or more would be cause for concern The most imp...

Page 297: ...m Test ASTM D892 Sequence I Sequence II Sequence III Foam Tendency 25 ml Max 50 ml Max 25 ml Max Foam Stability Nil 10 ml Max Nil I Demulsibility ASTM D1401 to 40 37 3 point 30 Min Max J Aniline Point...

Page 298: ...d year round in most machines in temperature climates Multi Viscosity 0 F 17 8 C 130 F 54 C 190 F 88 C Cold Climate Year Round Must Be Changed More Frequently Than Straight Grades 22 0 F 17 8 C 105 F...

Page 299: ...U S 68 30 F 1 1 C 160 F 71 C 200 F 93 C 100 35 F 1 1 C 175 F 80 C 200 F 93 C Especially Suited For Regions With Ambient Temp Range From 100 F To 120 F Minimum temperature for starting without extende...

Page 300: ...46 Duro AW 68 Duro AW 100 Conoco 32 46 68 100 Conoco DN 600 Artic Conoco Super Hyd 5W 20 Multi Viscosity Conoco Super Hyd 32 Conoco Super Hyd 46 Conoco Super Hyd 68 Conoco Super Hyd 100 D A Lubricant...

Page 301: ...l Limited Canada 32 46 68 80 100 Nuto H 32 Nuto H 46 Nuto H 68 Nuto H 80 Nuto H 100 Kendll Refining Co USA 32 46 68 100 Kenoil R O AW 32 Kenoil R O AW 46 Kenoil R O AW 68 Kenoil R O AW 100 Mobil Oil C...

Page 302: ...3 32 46 68 100 Tellus 23 Tellus 32 Tellus 46 XSL 9101 Tellus 68 Tellus 100 Sun Oil Co USA 32 46 68 100 Sunvis 816 WR Sunvis 821 WR Sunvis 831 WR Sunvis 851 WR Texaco Inc USA 32 46 68 Rando Oil HD A2 5...

Page 303: ...he rope is passed through the hot lubrication over sheaves and a center guide wheel Hot oils or greases have excellent penetrating qualities and upon cooling have high adhesive and film strength aroun...

Page 304: ...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 The rope shoul...

Page 305: ...ubricant containing solvents can be applied to a wire rope by a properly directed spray nozzle AEROSOL SPRAYING Installations requiring only small amounts of lubricants or only occasional applications...

Page 306: ...305 P N 12261 683 REVISED January 2015...

Page 307: ...otate machine back and forth as far as possible Under extremely dirty or dusty conditions sufficient grease should be added to flush out contaminated grease Under less severe conditions add grease unt...

Page 308: ...EP1 Mutifak EP1 Prestige 742EP Amolith EP1 Beacon EP1 GEAR Mobiltac 375NC Crater 2X 407 Compound B Amovis 8 X Surett Fluid 4k NOTE Refer to Kaydon Installation Maintenence Catalog 390 supplied with c...

Page 309: ...ed lubricant is AGMA 4EP Gear Oil or equivalent 2 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 gea...

Page 310: ...two holes in the housing 180 degrees apart These capscrews will align the pressure plate and steel discs when they are installed Apply an oil soluble grease or petroleum jelly to the other thrust wash...

Page 311: ...If they are clamped in place and immovable the thrust washer between the pressure plate and actuating mechanism may be out of position ITEM DESCRIPTION PART NO QTY 1 O RING 216064 2 2 O RING 216091 1...

Page 312: ...ower steering pump reservoir must be kept filled to the proper indicator level and free of air When filling the reservoir start the engine and turn the steering wheel from left to right and continue f...

Page 313: ...rally in all four directions and pull or push on the drive shaft in the direction opposite to the journal cross seal not relieving while lube gun pressure is being applied to the alemite fitting It is...

Page 314: ...to lubrication zerk 2 until lubricant appears at pressure relief hole 1 in welch plug at the sleeve yoke end of spline Cover pressure relief hole with finger and continue to apply pressure until grea...

Page 315: ...haft universal joints and slip splines will vary with service requirements and operating conditions OPERATING CONDITION RE LUBE CYCLE Miles Hours NORMAL SEVERE 6000 8000 2000 3000 150 200 50 75 For ap...

Page 316: ...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...

Page 317: ...T300 1_T500 1_T780 Maintenance 316 P N 12261 683 REVISED January 2015...

Page 318: ...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 seal...

Page 319: ...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 desicc...

Page 320: ...accumulated sediment There are five 5 tanks in the air system all having drain cocks on the bottom of the tank The accessory tank is located at the front of the machine behind the front outrigger The...

Page 321: ...h circumstances NEVER BLEED THE TIRES Instead slow down or stop until the tires cool The energy stored in a tire and rim assembly under pressure makes changing truck and off road tires hazardous Speci...

Page 322: ...ilure will result UNDERINFLATION Too little air pressure increases deflection causes the tread to wipe and scuff over the road results in extra strain on the tire and increases the chance for bruising...

Page 323: ...r driving axle Such tire mounting will cause an inter axle fight unusually high axle lubricant breakdown and possible costly axle service In addition to matching individual tire rolling radius or roll...

Page 324: ...re wear pads contact is evident The inside of the top plate of all sections except the tip section also require grease This can be applied through the holes in the side plates and piled on top of the...

Page 325: ...e operator when the zerks are aligned to holes A stable working platform is required for this procedure 3 Use MPG multi purpose grease 4 To lubricate the upper rear wear pads of the boom that ride on...

Page 326: ...ole in the base boom will line up with the zerk when the second section is fully extended as shown in photo below 1 Extend the second section for the 1st zerk hole in the second section of the boom to...

Page 327: ...rd section is extended Lining up the zerk and applying the grease 2 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 con...

Page 328: ...access to the internal wear pad contact areas thru the large circular openings in the side plates of each section 2 WARNING ENGINE MUST BE SHUT DOWN When performing lubrication internal to the boom se...

Page 329: ...bottom as shown in photo below 2 Use a 3 to 4 wide roller to apply the grease to the wear pad contact areas top and bottom See photo below 3 Apply grease to approximately the center 12 of the floor o...

Page 330: ...on 2 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 3 No greasing of the 4th section t...

Page 331: ...grease starts to protrude from bearing sides 2 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 T300 1_T...

Page 332: ...ylinder 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 331 P N 12261 683 REVISED Janu...

Page 333: ...retracted boom lowered and hook block on the ground then SHUTDOWN ENGINE 2 All sheaves require lubrication The top set of sheaves 1 zerk per sheave 3 three to 4 four shots of grease per sheave is req...

Page 334: ...found properly torqued Thereafter checks should be performed quarterly MODEL 4 1 TORQUE MULTIPIER NO TORQUE MULTIPLIER T300 1 DRY 181 FT LBS 245 NM DRY 725 FT LBS 983 NM T500 1 DRY 180 FT LBS 244 NM...

Page 335: ...ur outside must be checked This includes a total of sixtyfour 64 capscrews to be checked If ANY are found to have loosened ALL sixty four 64 must be retorqued Remember it is important to perform perio...

Page 336: ...1 special wrench pn 706F8697 1 4 to 1 torque multiplier 1 1 12 pt socket 3 4 drive 335 P N 12261 683 REVISED January 2015...

Page 337: ...and flushing water over the entire area of the core in the reverse direction of normal air flow QUARTERLY CORROSION INHIBITOR FILTER Replenish the cooling system corrosion inhibitor filter every 250h...

Page 338: ...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 337 P N 12261 6...

Page 339: ...it flows out the low oil level plug hole install the low oil level plug Start and run the engine at idle speed to prime the converter oil cooler and lines Recheck the oil level with the engine running...

Page 340: ...erature range cold band under 120 F hot band between 180 and 220 F Total oil quantity needed at this time should be approximately 10 gallons this varies depending on the cooling system 3 Increase the...

Page 341: ...d on the dipstick Total quantity added at this time should be approximately 10 gallons 9 With the transmission still in neutral increase the engine idle speed t 1500 rpm and retain at this speed for 5...

Page 342: ...ts hydraulic power it is important that the proper fluid level be maintained at all times If the fluid level is too low the converter and clutches do not receive an adequiate supply of fluid If the fl...

Page 343: ...ge is met 3 The vehicle has been stationary for approximately two minutes to allow the fluid to settle 4 Lever Shift Selector Press the Display Mode Diagnostic button once 5 The delayed fluid level ch...

Page 344: ...SELECT MONITOR Description o L Represents Fluid oil Level Check Mode o K Fluid level is within the correct fluid level zone 343 P N 12261 683 REVISED January 2015...

Page 345: ...T300 1_T500 1_T780 Maintenance 344 P N 12261 683 REVISED January 2015...

Page 346: ...24449 2 Gasket Filter Cover 4 29548953 2 O Ring Low Temp Rd edge See note A below 5 29501469 2 Seal Ring Sq cut 6 29507437 2 O Ring Packing 7 29545780 2 Filter NOTE A Only one style of item 4 5 is use...

Page 347: ...ing properly run the engine at 1200 1500 rpm with the transmission in N Neutral This should reduce the transmission and engine temperatures to normal operating levels in 2 to 3 minutes If temperatures...

Page 348: ...Recommeded Fluid Filter Change Intervals 347 P N 12261 683 REVISED January 2015...

Page 349: ...T300 1_T500 1_T780 Maintenance 348 P N 12261 683 REVISED January 2015...

Page 350: ...nsmission On vehicles equipped with two transmission oil temperature gauges one gauge required senses torque converter oil as mentioned above while the other gauge optional reads oil temperature from...

Page 351: ...gs to 14 20 Lbf ft of torque 5 Capscrews and Gaskets Check all capscrews especially those on PTO covers and rear bearing covers for looseness which would cause oil leakage Check PTO opening oil sump s...

Page 352: ...positioned for checking the oil 1 Lubricant Level 3 Drain Plug Rotates to Bottom 2 Check Plug 4 Horizontal Oil Fill Level Remove the oil level plug in the planet cover and add oil as necessary to bri...

Page 353: ...oving 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 T300 1_T5...

Page 354: ...353 P N 12261 683 REVISED January 2015...

Page 355: ...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 bot...

Page 356: ...IRES Instead slow down or stop until the tires cool Inflation pressure should be checked when tires are cool using an accurate tire pressure gauge Check pressures at regular intervals Bleeding the air...

Page 357: ...at has been run flat or seriously underinflated without first demounting and inspecting the tire and rim assembly 3 Inflate tires in a safety cage 4 Inspect wheel nuts periodically for excessive wear...

Page 358: ...e of starting fluid ether or gasoline or any other flammable material to lubricate seal or seat the beads of a tubeless tire can cause the tire to explode or can cause the explosive separtion of the t...

Page 359: ...accordance with the MAINTENANCE CHECK LIST Consideration of severe working conditions may dictate a revision in scheduling periodic checks DAILY HYDRAULIC FLUID LEVEL The hydraulic reservoir fluid le...

Page 360: ...lic reservoir return line filters after the first 40 hours of the break in period thereafter follow the quarterly check recommendation MONTHLY HYDRAULIC RESERVOIR Drain any accumulated moisture from t...

Page 361: ...type filter is located inside the reservoir on the intake to the pump manifold Access to the filter is accomplished by removing the cover with filler neck and filter holding device from the top of the...

Page 362: ...manent screen type filter is located inside the reservoir on the intake to the pump manifold Access to this filter is gained by removing the cover with the filter holding device from the top of the re...

Page 363: ...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 c...

Page 364: ...raulic 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 in...

Page 365: ...T300 1_T500 1_T780 Maintenance 364 P N 12261 683 REVISED January 2015...

Page 366: ...size The wrong rope will not function properly and may even be dangerous THE USE OF NON ROTATING 18 x 7 CLASS WIRE ROPE IS NOT RECOMMENDED IN MULTIPLE REEVING APPLICATIONS AND IF USED FOR APPLICATION...

Page 367: ...NOTE IF A SOCKET IS CHANGED OR REPLACED OR IF YOU ARE CHANGING HOOK BLOCK WEIGHTS IT IS IMPORTANT TO USE THE CORRECT SOCKET T300 1_T500 1_T780 Maintenance 366 P N 12261 683 REVISED January 2015...

Page 368: ...below or in similar application on jib Check the plug and socket connection at boom head and on lib if erected and reeved for connection The jib connector must be plugged into the boom head receptacle...

Page 369: ...his may require lowering the hook block away from the trip mechanism at the boom head to enable the latching of controls THROTTLE CONTROL The throttle control consists of cables and clevis ends Adjust...

Page 370: ...oat unpainted metal surfaces with multipurpose grease after removing any rust accumulations The ENGINE should be prepared as prescribed in the topic Engine Storage The TRANSMISSION should be prepared...

Page 371: ...sion 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 Transmis...

Page 372: ...Fill the crankcase to the proper level with the recommended viscosity and grade of oil 3 Fill the fuel tank with the recommended grade of fuel oil Operate the engine for two minutes at 1200 rpm and no...

Page 373: ...rating temperature is reached 160 F to 185 F 8 Stop the engine 9 Remove the drain plug and completely drain the engine crankcase Reinstall and tighten the drain plug Install new lubricating oil filter...

Page 374: ...ase if so desired If the oil is drained reinstall and tighten the drain plug tag cap 21 Remove and clean the battery and battery cables with a baking soda solution and rinse them with fresh water Stor...

Page 375: ...dditional information STORAGE 30 DAYS TO 1 YEAR WITHOUT OIL 1 Drain Oil 2 Seal all openings and breathers except oil drain hole with moisture proof cover or tape 3 Coat all exposed unpainted surfaces...

Page 376: ...following procedure 1 Remove preservative lubricants from all surfaces 2 Check all fluid levels adding or draining as required 3 Lubricate the machine according to Section 9 making certain that all p...

Page 377: ...fications 9 Close all of the drain cocks and fill the engine cooling system with clean soft water and a rust inhibitor If the engine is to be exposed to freezing temperatures add a high boiling point...

Page 378: ...Nox Rust or equivalent was not used in preparing the transmission for storage use the following procedures to restore the unit to service 6 Remove the tape from openings and breathers 7 Wash off all t...

Page 379: ...at the equipment dealership before it is sold During these times a protective barrier must be applied to the exposed cylinder rod This protective barrier will preserve the integrity of the chrome plat...

Page 380: ...d NOTE Caution must be used when cleaning equipment in service with high pressure washes Soaps or chemicals containing chlorines or other corrosive elements should be avoided Cylinders should be clean...

Page 381: ......

Page 382: ...BREAKING STRENGTH 17 9 TONS OPT 5 8 ROTATION RESISTANT COMPACTED STRAND 18X19 OR 19X19 MINIMUM BREAKING STRENGTH 22 7 TONS Main Winch T780 STD 3 4 dia 6X19 OR 6X25 CLASS IWRC REG LAY WIRE ROPE MINIMUM...

Page 383: ...ROTATION RESISTANT COMPACTED STRAND BRIDON DYFORM 34LR 1960 MINIMUM BREAKING STRENGTH 34 51 TONS T300 1_T500 1_T780 Specifications 382 P N 12261 683 REVISED January 2015...

Page 384: ...basic preventive maintenance requirements will be met under average operating conditions Conditions which impose greater wear loads or strain on the crane may dictate reduced check intervals Before al...

Page 385: ...ling on winch Cylinder pin connections for wear Check tires axles and drive lines for wear or damage Check in the cab for Instruments functioning properly Control operation Glass for good visibility S...

Page 386: ...to cause the failure Consider the most obvious first 6 TEST YOUR CONCLUSION Test your conclusions in order of obviousness until the source of the failure is found The machine can then be repaired at...

Page 387: ...s If in spite of these precautions improper operation does occur the cause can generally be traced to one of the following 1 Use of the wrong viscosity or type of oil 2 Insufficient fluid in the syste...

Page 388: ...e outrigger extend retract and function valves by pushing the pins in prior to activating the functions Check to see if the appropriate pin has been pushed back out as the functions are activated If t...

Page 389: ...sis by DEFINING THE COMPLAINT a Talk to and question the driver b Drive the vehicle VISUAL INSPECTION a Look for poor loading practices b Check tires for mismatch and proper air pressure c Check suspe...

Page 390: ...ication intervals and procedures Severely contaminative environment Clean and lubricate more often BENT OR BROKEN TIE ROD STEERING ARM TIE ROD ARM OR BALL STUD CAUSE REMEDY Excessive power steering pr...

Page 391: ...ubrication 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...

Page 392: ...g in seal area OIL LEAKING AT ACTUATING SHAFT OF STEERING GEAR CAUSE REMEDY Worn or damaged oil seal Replace seals Damaged actuating seal surface Replace damaged parts Lube bearing cap more often OIL...

Page 393: ...oil change frequency Incorrect lubricant used Drain flush and refill with 10W 40 motor oil OIL IN RESERVOIR FOAMING CAUSE REMEDY Air leak in suction side of supply pump Refer to pump servicing instru...

Page 394: ...en load or install larger steering gear Fatigued by pass valve spring in pump Replace with flow control valve assembly Refer to pump servicing instructions Low oil level in steering system Fill oil re...

Page 395: ...ear Remove bracket Clean frame and bracket Check radius of frame making sure bracket is not bearing on radius surface Check bracket for wear from working Replace bracket and tighten to recommended tor...

Page 396: ...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 socket...

Page 397: ...g 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 Exa...

Page 398: ...RNATOR ELECTRICAL OUTPUT CAUSE REMEDY Alternator regulator out of adjustment Replace regulator Field leads shorted Replace or repair alternator Alternator regulator shorted Replace regulator ALTERNATO...

Page 399: ...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 T300 1_T500 1_T780 Troubl...

Page 400: ...r 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 rep...

Page 401: ...eak in procedure CLUTCH DRAG HARD SHIFTING CAUSE REMEDY Linkage blocked from full travel Remove blockage Linkage incorrectly adjusted Adjust clutch linkage Linkage worn damaged Replace faulty linkage...

Page 402: ...clutch disc splines Clean clutch disc and input shaft splines or replace clutch disc as necessary Flywheel housing to clutch housing excessive misalignment Replace faulty housing Grease or oil contami...

Page 403: ...eplace brake valve Relay or quick release valve exhaust ports obstructed Clean or replace faulty unit ONE BRAKE DRAGS WITH PEDAL RELEASED CAUSE REMEDY Insufficient brake shoe clearance Adjust brake sh...

Page 404: ...rvice reservoir CAUSE REMEDY Restricted hose or tube Remove restriction or replace Defective spring brake valve Repair or replace spring brake valve MAXI BRAKES WON T RELEASE CAUSE REMEDY Control valv...

Page 405: ...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 T300 1_T...

Page 406: ...king internally Reseal rotary manifold Swing pump faulty See section on Pumps SWING MOTION SLUGGISH CAUSE REMEDY Main relief valve stuck in open position Replace Faulty swing pump Repair or replace sw...

Page 407: ...oil level Add oil as required Hose plugged or liner collapsed Replace hose Air in cylinder Bleed cylinder BOOM DROPS SLIGHTLY AS RAISE CONTROL IS RELEASED CAUSE REMEDY Air in cylinder Bleed cylinder...

Page 408: ...himmed to boom too tight Reshim wear pads Faulty counter balance valve Replace counter balance valve Loose chain system Adjust chains as required TELESCOPE CYLINDER EXTENDS BUT WILL NOT RETRACT CAUSE...

Page 409: ...OWER CAUSE REMEDY The winch hold valve is mounted on the winch motor incorrectly Be certain that the winch is assembled properly The winch hold valve spool is sticking Repair or replace The winch brak...

Page 410: ...The winch hold valve is set wrong or is malfunctioning Check the hold valve setting If the winch continues to chatter the holding valve is sticking Inspect it for worn or damaged seals or contaminati...

Page 411: ...replace Line plugged or collapsed between outrigger valve and cylinder Replace hose Beam wedged in extended position Extend jack far enough to pick up end of beam and retract Replace slider pad block...

Page 412: ...M CAUSE REMEDY Pumps not engaged Engage pumps Pump not delivering oil for any of the reasons listed previously Follow remedies given previously Relief valve not functioning due to Valve setting not hi...

Page 413: ...Rag paper etc pulled into suction line or pump Remove Worn or broken parts Replace EXTERNAL OIL LEAKAGE AROUND PUMP CAUSE REMEDY Shaft seal worn causing oil to leak into gear drive housing Replace Lo...

Page 414: ...rating Check relief valve setting 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...

Page 415: ...thermal equilibrium Let system warm up LEAKING SEALS CAUSE REMEDY Paint on or under seal Remove and clean Excessive back pressure Open or enlarge line to reservoir Dirt under seal Remove and clean Sc...

Page 416: ...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 mo...

Page 417: ...damaged parts Clean dirt and remove surface marks for free movement PRESSURE SETTING NOT CORRECT CAUSE REMEDY Wear due to dirt Lock nut adj screw loose See section on Valve Adjustments LEAK CAUSE REME...

Page 418: ...rotary manifold Worn pump Repair or replace pump Extremely high fluid temperatures causing pump and motor to slip temperature increases as pump and motor wear Add heat exchangers Relief setting too lo...

Page 419: ...se Clean mating surfaces and tighten nuts to appropriate value Pinched O ring seal Replace LEAK AT OIL PORTS CAUSE REMEDY Damaged seal or O ring Replace O ring or seal Poor fittings Replace fittings c...

Page 420: ...loose Check cylinder heads and tighten if loose Misalignment Check mounting pins and bushings Tighten rod eyes ERRATIC ACTION OF CYLINDERS CAUSE REMEDY Air in system Oil level is too low Add or chang...

Page 421: ...Y A DEFECTIVE HOLD VALVE in the cylinder which drifts excessively by interchanging the hold valve cartridge with one removed from a cylinder that is not drifting or by replacement with a new cartridge...

Page 422: ...own the cause is within the hold valve IF CYLINDER LEAK DOWN OCCURS with no oil leak from the hold valve ports the cause is within the cylinder OUTRIGGER JACK CYLINDER The suggested procedure for iden...

Page 423: ...mps assembled after overhaul may be assembled too tightly This reduces clearances and increases rubbing friction Follow instructions when reassembling Leaking relief valves Repair Improper functioning...

Page 424: ...rcuit 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 Cle...

Page 425: ...the igniter wire completely and remove the igniter Try to start the heater and listen for the solenoid click Check for the odor of propane in the burner If propane odor is present at bulkhead fitting...

Page 426: ...he igniter and the burner tube It should be 1 16 to 1 8 With the burner head grounded move the STARTRUN OFF switch to the START position and check the gap for spark If no spark is produced the igniter...

Page 427: ...switch is in the RUN position the solenoid should produce an audible click and remain open until heater cycles off In extremely cold weather the regulator may become frosted As it thaws and freezes t...

Page 428: ...ow charge Charge then turn on high beam head lamps or 15 amp load for 15 seconds Proceed to load test Stabilized voltage above 12 4 volts or indicator indicates charged Perform load test LOAD TEST Per...

Page 429: ...8 7 0 18 C 8 5 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 T300 1_T500 1_T780 Troubleshooting 428 P N 12261 683 REV...

Page 430: ...boom head Plug in Boom head weight wire rope broken or hung up Check that weight is attached to wire and hanging freely If rope is caught up on something correct Jib or auxiliary boom head switch plug...

Page 431: ...sconnect terminals If 12 volts check override key switch in control panel If 0 volts repair or replace disconnect Check other disconnects for condition To operate the crane the solenoid must have 12 v...

Page 432: ...p If not the solenoid must be replaced If the solenoid engages but the disconnect breaks under load the spool ball and case should be replaced Contaminated function disconnect 1 Ensure that a drain ho...

Page 433: ......

Page 434: ...lace parts until the trouble is found Once the cause of a problem or malfunction has been diagnosed take the corrective action specified in this manual Follow the procedures given for the specific pro...

Page 435: ...should be placed into their respective holes when removing guards cases etc so that proper bolt will be on hand when reassembling these parts T300 1_T500 1_T780 Service Parts 434 P N 12261 683 REVISE...

Page 436: ...Capacity Indicator RCI or Rated Capacity Limiter RCL Visually inspect sensors for damage the condition of related wiring harness connections and dirt debris that could inhibit the sensor signal or pro...

Page 437: ...1 Proximity Sensor Outrigger Position T300 1_T500 1_T780 Service Parts 436 P N 12261 683 REVISED January 2015...

Page 438: ...mmercially made or fabricated by the user When using an extension it must be remembered that the wrench torque the actual torque reading or setting of the wrench and the wrench force the force applied...

Page 439: ...T300 1_T500 1_T780 Service Parts 438 P N 12261 683 REVISED January 2015...

Page 440: ...d and all persons in the welding area should have protection for their eyes Follow instructions for welding and cutting on paint AWS CLASS E7018 Low hydrogenrod for normal repairs on low alloy to medi...

Page 441: ...he cut or weld is to be made Remove the paint far enough from the weld to prevent any remaining paint from becoming heated and bubbling If this happens continue to brush or grind the paint away A toxi...

Page 442: ...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 441 P N 12261 683 REVISED Jan...

Page 443: ...r pad 2 can be replaced by removing one bolt BEAM REMOVAL AND REPLACEMENT The outrigger beams must be removed to service the outrigger extend cylinder The beams are removed by the following procedure...

Page 444: ...s form the jack cylinder and remove the extend cylinder live end pin Remove the cylinder from the back end of the beam DISASSEMBLY Disassemble the extend cylinder by means of the following procedure 1...

Page 445: ...n place before proceeding to the next step See Group 3 of the parts book for a complete listing of cylinder parts JACK CYLINDERS The jack cylinders on this crane can be removed without removing the ou...

Page 446: ...in any serviceable parts If the hold valve cartridge is broken replace the entire hold valve cartridge Replace O rings wear rings seals or other components as required ASSEMBLY Assemble the jack cylin...

Page 447: ...ngine 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 Ther...

Page 448: ...1 T780 Relief Valve 2 Test Port 3 Relief Pressure Adjustment NOTE Relief is pre set at 600 PSI 447 P N 12261 683 REVISED January 2015...

Page 449: ...S Both center and end bushings 4 are replaceable The beams 1 must be removed prior to servicing the bushings 4 Remove the beams 1 by the following procedure 1 Remove the capscrews and saddle caps from...

Page 450: ...rse 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 449 P N 12261 683 REVISED January 2...

Page 451: ...or checking Outriggers can be used when jacks of a capacity to raise the vehicle are unavailable If an adjustment is found necessary we recommend consulting your local distributor Check the toe in usi...

Page 452: ...adjust pointers to line up with scribe lines and lock in place Repeat for front of tires 6 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...

Page 453: ...in the power divider If the oil level is up to the bottom of the rear filler hole the power divider is also adequately lubricated If the oil level is low add oil as necessary If the axles have been dr...

Page 454: ...he forward filler hole at the right top portion of the differential carrier Refer to Section 9 for the recommended lubricant WHEEL BEARING ADJUSTMENT Remove the lock nut 1 from the hub spindle prior t...

Page 455: ...1 Lock Nut 2 Adjusting Nut T300 1_T500 1_T780 Service Parts 454 P N 12261 683 REVISED January 2015...

Page 456: ...om the forward driving axle to the rear axle End yokes are used at all shaft ends and all couplings use bearing cap type cross journal retainers 1 Flange Yoke 6 Stub Yoke 2 Journal and Bearing Kit 7 E...

Page 457: ...nit SLIP JOINT REMOVAL Before removing the slip joint be certain there are arrow marks stamped on the shaft and sleeve yoke If the arrow marks are not readily seen mark both members so that when reass...

Page 458: ...trunnion of the journal cross into the bearing hole in the yoke lug from the inside between the lugs and tilt until the trunnion of the journal cross will clear hole in opposite yoke lug NEEDLE BEARIN...

Page 459: ...sirable due to the resulting unbalance 4 Mounting flanges and pilots should be free from burrs paint and foreign substances which would not allow proper seating at assembly SLIP JOINT ASSEMBLY Lubrica...

Page 460: ...d and second shafts between the transmission and the intermediate axle must be assembled In Phase 2 The inter axle drive shaft yokes at the third shaft must be assembled In Phase 3 When drive shafts a...

Page 461: ...ht hand Hub piloted wheels are straight through bolt holes with no ball seat which provides a visual way of identifying them See figure below A 10 Hole 11 25 Bolt Circle DCN Mounting 1 Inflate tire pr...

Page 462: ...ub and drum Tighten nuts to 450 500 ft lbs item 1 dry using the same criss cross sequence 1 Torque each nut to 450 500 ft lbs dry 2 Install 1222 356 Cover Lug Nut 10 b Dual Rear Wheels Slide the inner...

Page 463: ...proper torque level Maintain nut torque at the recommended level through planned periodic checks If air wrenches are used they must be periodically calibrated for proper torque output Use a torque wr...

Page 464: ...uds 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 463 P N 12261 683 RE...

Page 465: ...Engine Clutch Adjustment Repair T300 1_T500 1_T780 Service Parts 464 P N 12261 683 REVISED January 2015...

Page 466: ...465 P N 12261 683 REVISED January 2015...

Page 467: ...T300 1_T500 1_T780 Service Parts 466 P N 12261 683 REVISED January 2015...

Page 468: ...lutch 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 467 P N 12261 683 REV...

Page 469: ...sh or free travel may prevent complete clutch disengagement while insufficient clutch pedal lash or free travel will cause slippage and short clutch life T300 1_T500 1_T780 Service Parts 468 P N 12261...

Page 470: ...pring DO NOT overcome the spring tension and shift to reverse The shift finger must remain in this position while you are making all the adjustments 1 REACH ROD 2 TURNBUCKLE 3 SELECTION LEVER 4 INNER...

Page 471: ...splines of the two parts Disregard any movement of the gear shift lever at this point You will adjust the gear shift lever later Tighten capscrew B Re connect pivot link assembly ball joint to select...

Page 472: ...kle 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 REACH ROD 2 TURNBUCKLE 3 SELECTI...

Page 473: ...1 SELECTION LEVER 2 SHIFT ARM T300 1_T500 1_T780 Service Parts 472 P N 12261 683 REVISED January 2015...

Page 474: ...ut 2 b Adjust the power steering unit to stop approximately 1 16 to 1 8 before axle steering stops 3 contact maximum turning angle 1 The adjustment of both axle steering stops and power steering unit...

Page 475: ...Examine thrust bushings located between input gear and lower planet drive gear Replace if necessary 6 The lower planet carrier is splines to the output shaft Remove the cap and shims to disassemble th...

Page 476: ...1 Swing Reducer Dipstick 2 Shim 3 Thrust Bushings 475 P N 12261 683 REVISED January 2015...

Page 477: ...g tension on the adjusting screw is relieved This will avoid the possibility of immediate damage to the replacement unit in the event that the relief valve setting had been increased beyond the recomm...

Page 478: ...y new parts have been used When rebuilding the pump with parts from the original pump which while worn appear satisfactory for re use a 10 or 15 lower reading may be permitted depending on the perform...

Page 479: ...good quality 5000 psi gauge in the designated test port locations and proceed with pressure check and adjustment as follows THIS MACHINE USES A PRESSURIZED HYDRAULIC RESERVOIR THE PRESSURE MUST BE REL...

Page 480: ...g procedure First retract the boom completely and continue to retract over relief with the engine running at full governed rpm Initially set the retract port relief valve located on spring cap end of...

Page 481: ...to swing test port 2 Set the swing brake and attempt to swing against the brake with the engine running at maximum governed rpm Adjust the swing relief valve if necessary per the chart below 3 The T7...

Page 482: ...F 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 enga...

Page 483: ...ilot poppet and its seat provides positive seating and very seldom requires any maintenance The pilot section can be removed from the cartridge housing without disturbing the setting With it will come...

Page 484: ...MENT 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...

Page 485: ...D INTO OPERATION IT SHOULD BE SLOWLY ROTATED SEVERAL MINUTES TO ALLOW ANY ENTRAPPED AIR TO ESCAPE AND TO FACILITATE REFORMING OF SEALS THAT MAY HAVE TEMPORARILY DEFORMED DURING STORAGE All overhaul sh...

Page 486: ...replaced without removing the spool Removing the top cover exposes the top O ring The spool will drop out of the case exposing the bottom O ring UPON REASSEMBLY INSTALL THE UPPER O RING AND BACK UP RI...

Page 487: ...by loosening cable lock nuts at pedal anchor Increase tension by shifting cable out of the U shaped bracket with adjustment of the locking nuts SWING WINCH BOOM TELESCOPE BOOM HOIST VALVE CONTROL The...

Page 488: ...nual 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 Subu...

Page 489: ...inal damage If obvious physical damage is found replace the battery If possible determine the cause of damage and correct Check the condition and size of the cables Are the cable clamps tight Check fo...

Page 490: ...ied in the Voltage Chart see Maintenance Free Battery Testing Chart in Troubleshooting section replace the battery If the voltage meets or exceeds the specified minimum clean and return battery to ser...

Page 491: ...ttery 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 Follow the manufacturers instructions...

Page 492: ...emoved Carefully remove the brushes without over stretching the brush springs and arrange in order of removal with spacers Replace the damaged brush assembly and then reassemble the brushes and spacer...

Page 493: ...NGINE STOP 9 WHITE 001AA O R EXTEND 33 RED 211AA WTS 10 BLACK 002AA O R RETRACT 34 RED 129AA THROTTLE 11 RED 003AA RIGHT REAR JACK 35 BLACK 130AA THROTTLE 5V 12 YELLOW 004AA LEFT REAR JACK 36 WHITE 13...

Page 494: ...ATION CHART ROW EXPORT ENGINE CIRCUIT COLOR WIRE TAG FUNCTION CIRCUIT COLOR WIRE TAG FUNCTION 1 RED 0A HOT 25 RED 24 REMOTE STEER 2 RED 0B HOT 26 YELLOW 25 REMOTE STEER 3 RED 0C HOT 27 GREEN 26 REMOTE...

Page 495: ...BLUE 13 FRONT JACK 44 YELLOW 176 TRANS SHIFT 21 BLACK 16B GROUND 45 BLACK 143 TRANS SHIFT 22 BLUE 20 E STOP 46 VIOLET 192 TRANS SHIFT 23 BROWN 21 E STOP 47 YELLOW 194 TRANS SHIFT 24 BLACK 23 SPARE 48...

Page 496: ...indicates the condition of the battery alternator and voltage regulator and what to so to correct the condition ENGINE NOT RUNNING OR RUNNING AT SLOW IDLE Dead or disconnected battery Disconnected or...

Page 497: ...y 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...

Page 498: ...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 Engine...

Page 499: ...voltage regulator is out of adjustment or that current being drawn from battery by lights heater fan or accessories exceeds alternator output When engine is started pointer may stay in this area tempo...

Page 500: ...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 w...

Page 501: ...T300 1_T500 1_T780 Service Parts 500 P N 12261 683 REVISED January 2015...

Page 502: ...assembly piston rod head gland and piston assembly 3 To remove piston remove the setscrews which secure the piston retaining ring to piston rod 4 Remove piston and gland which allows access to all se...

Page 503: ...oil the piston ring or wear ring to aid in the installation MOST PISTON RING BREAKAGE IS DUE TO CARELESS OR HASTY ASSEMBLY AT THIS POINT BOOM LIFT CYLINDERS With the piston piston rod head gland reta...

Page 504: ...r is ready to be placed in operation it should be slowly cycled under no load conditions for several minutes in order to allow the entrapped air within the cylinder to escape to the reservoir and also...

Page 505: ...e second boom section the hole closer to the base section measure the sag of the retract chain This measurement must be taken from the bottom of the second section to the bottom of the chain This dime...

Page 506: ...tract chain This measurement must be taken from the bottom of the third section to the bottom of the chain This dimension should be 2 75 inches 70 mm to 3 inches 76 mm 9 If the dimension is greater th...

Page 507: ...hin its respective outer boom section 1 WEAR PAD 1 Remove the pad plate on both sides Add shims 1 until the pad plate will not touch the boom section Then remove one shim and tighten the inner two bol...

Page 508: ...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 4 507 P N 12261 683 REVISED Jan...

Page 509: ...ng 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 less t...

Page 510: ...509 P N 12261 683 REVISED January 2015...

Page 511: ...Repairs Adjustments Remarks Log ITEM REQUIREMENT DATE T300 1_T500 1_T780 Service Parts 510 P N 12261 683 REVISED January 2015...

Page 512: ...511 P N 12261 683 REVISED January 2015...

Page 513: ......

Page 514: ...0 0406 3 572 5 32 0 1563 3 969 11 64 0 1719 4 366 3 16 0 1875 4 762 13 64 0 2031 5 159 7 32 0 2188 5 556 15 64 0 2344 5 953 1 4 0 2500 6 350 17 64 0 2656 6 747 9 32 0 2813 7 144 19 64 0 2969 7 541 5 1...

Page 515: ...085 11 16 0 6875 17 462 45 64 0 7031 17 859 23 32 0 7188 18 256 47 64 0 7344 18 653 3 4 0 7500 19 050 49 64 0 7656 19 447 25 32 0 7813 19 843 51 64 0 7969 20 240 13 16 0 8125 20 637 53 64 0 8281 21 0...

Page 516: ...tre 61 023 cu in 1 litre 2 202 lbs of water 62oF 1 cu foot 28 32 litres 1 gallon 3 785 litres 1 cu inch 0 0164 litre MEASURES OF WEIGHTS U S 16 ounces 1 pound 2000 pounds 1 short ton 2240 pounds 1 lon...

Page 517: ...ees 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 1 mile T30...

Page 518: ...148 3996 Dolomite Crushed Fine 1521 90 95 2565 Dolomite Broken Lump 1521 90 95 2565 Earth Loamy Dry Loose 1201 50 75 2025 Earth Dry Packed 1521 90 95 2565 Earth Wet Mud 1762 20 110 2970 Flue Dust Bla...

Page 519: ...ing Mill Wet 2114 64 132 3564 Shale Broken 1361 70 85 2295 Slag Blast Furnace Broken 2210 76 138 3726 Slag Open Hearth Crushed 1682 10 105 2835 Slag Granulated Dry 606 76 38 1026 Slag Granulated Wet 9...

Page 520: ...Torque Specs SAE Metric 519 P N 12261 683 REVISED January 2015...

Page 521: ...T300 1_T500 1_T780 Appendix 520 P N 12261 683 REVISED January 2015...

Page 522: ...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 Califor...

Page 523: ...rnia 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...

Page 524: ...tp www michelintruck com michelintruck toolbox reference material jsp Bridgestone Tire Warranty Maintenance and Safety Manual http www trucktires com bridgestone us eng load general pdf bridgestone li...

Page 525: ...tion may deny you warranty coverage if your vehicle has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for initiating the warranty process Terex Corpo...

Page 526: ...mpletely 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 Troublesho...

Page 527: ...Notes T300 1_T500 1_T780...

Page 528: ...ons 106 12th 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 o...

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