Terex T300-1 Manuals

T300-1/T500-1/T780 Operator’s Manual Revised: January 2015 12261-683 2013 ON-HIGHWAY & EXPORT TIER 3 ORIGINAL INSTRUCTIONS Introduction ......................................................................................................7 Construction and Industrial Equipment Product Safety ...........................7 T Nomenclature.........................................................................................9 Intended Use...........................................................................................10 Bulletin Distribution and Compliance......................................................11 Contacting Manufacturer ........................................................................12 Transfer of Machine Ownership..............................................................13 Safety .............................................................................................................15 Safety Introduction..................................................................................15 Alert System............................................................................................16 General Safety.........................................................................................21 Safety Sign Locations......................................................................21 Safety Sign Maintenance.................................................................33 Workplace Safety....................................................................................34 Effects of Wind Conditions .....................................................................42 Lightning Storm.......................................................................................44 Temporary Interruption of Crane Operations..........................................45 Resuming Crane Operations...................................................................48 Ending Crane Operations........................................................................49 Turning/Driving in Reverse......................................................................50 Parking the Vehicle .................................................................................51 Lock Out & Tag Out ................................................................................52 Access/Egress ........................................................................................54 Personal Safety .......................................................................................57 Seat Belts................................................................................................59 Temperature Effects on Telescope and Boom Hoist Cylinders .............60 Assembly........................................................................................................63 Erecting the Jib .......................................................................................63 Changing the Offset of the Jib ................................................................65 Extending and Retracting the Jib Pull-out Section.................................67 Spooling Wire Rope on Drums................................................................69 Cable Sockets.........................................................................................71 Hoist-Line Reeving..................................................................................73 Counterweight Change - (T300-1 Only) ..................................................76 Description Of Machine and Controls............................................................81 Universal Symbol Identification...............................................................81 Carrier Controls and Instruments-EPA 2013 Engines.............................85 Carrier Controls and Instruments-EXPORT ..........................................121 Table of Contents P/N 12261-683 REVISED: January 2015 i Upper Controls and Instruments...........................................................125 Outrigger Controls-External (Streetside)...............................................136 Side-Stow Jib........................................................................................137 Inspection.....................................................................................................139 Pre-Start Inspection..............................................................................139 Suggested Hydraulic Crane Inspection Checklist ................................141 Daily Check (8 Hours)............................................................................146 Weekly Check (40 Hours)......................................................................147 Monthly Check (80 hours) .....................................................................148 Quarterly Checks (250 Hours)...............................................................149 Semiannual Checks (1000 Hours).........................................................150 Annual Check (1500 - 2000 Hours).......................................................151 Wire Rope Inspection Record...............................................................152 Mobile Crane Load Test Inspection......................................................153 Operating Instructions..................................................................................157 Regeneration Process for DD Series 60 - (T500-1 & T780 Only)..........157 Cummins 2013 Engine- Overview of Operation....................................164 Fuel Warning..................................................................................164 Aftertreatment Regeneration Lamp Behaviors ..............................165 Regeneration Modes......................................................................168 Manual Regeneration Procedure ...................................................169 Operating the Unit.................................................................................171 Operating the Engine .....................................................................171 Starting the Engine-EPA 2010 .......................................................174 Engine Cold Weather Operation ....................................................180 Jump Starting an Engine- Booster Cable Instructions ..................183 Unusual Operating Conditions.......................................................184 Making a Typical Lift......................................................................188 Arm and Hand Signals ...................................................................194 Load Rating Chart Interpretation ...................................................196 "On-Tires" Lift ................................................................................202 On-Tires Load Rating Chart...........................................................204 Air-Ride Suspension ......................................................................205 Remote Carrier Operation..............................................................207 Moving the Unit.....................................................................................209 Removable Counterweight (T500-1 & T780)..................................209 Drivers Tips-Cummins EPA 2013 .................................................213 Vehicular Operation .......................................................................218 T300-1_T500-1_T780 Contents ii P/N 12261-683 REVISED: January 2015 Transmission Operation.................................................................221 Traveling around the Jobsite .........................................................225 Towing or Pushing Vehicle.............................................................228 Disassembly .................................................................................................229 Stowing the Jib .....................................................................................229 Transportation ..............................................................................................231 Transporting the Crane .........................................................................231 Instructions for Loading and Unloading................................................232 Maintenance.................................................................................................235 Engine Data-Tier 3 Export & EPA 2013.................................................235 Maintenance Introduction .....................................................................240 Crane Maintenence & Specification......................................................241 Acronyms and Abbreviations.........................................................241 General Safety Instructions............................................................243 Flow Diagram-Exhaust System......................................................245 Engine & Cooling System Maintenence Schedule.........................249 Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter..................253 Engine Indicator Lamps .................................................................258 Aftertreatment Switch ....................................................................264 Operating Characteristics with Aftertreatment Particulate Filter ...265 Engine Indentification ....................................................................270 Diesel Exhaust Fluid Specification.................................................276 Filter Specification .........................................................................281 Lubrication Charts.................................................................................283 Operator Observation ...........................................................................286 Special Break-in Requirements for New Cranes ..................................287 Machine Maintenance Checklist...........................................................288 Lubrication Introduction........................................................................291 Hydraulic Oil Requirements ..................................................................293 Koehring Spec 805 Data.......................................................................296 Grade Selection Chart...........................................................................297 Premium Grade Anti-Wear Hydraulic Oils.............................................299 Cable Lubrication Methods...................................................................302 Turntable and Swing Pinion ..................................................................306 Swing Reducer......................................................................................308 Power Steering Maintenance................................................................311 Drive Shaft Maintenance.......................................................................312 Brake System Maintenance ..................................................................315 P/N 12261-683 REVISED: January 2015 iii