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T780
Terex T780 User Manual
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Annual Check (1500 - 2000 Hours)
__ Perform Daily,Weekly,Monthly,Quartly and Semiannual Checks
__ Perform Annual Lubrication
__ Disassemble Winch And Inspect
__ Drain And Clean Hydraulic Reservoir
__ Change Hydraulic Fluid (unless checked by oil analysis).
__ Drain and Refill The Winch Lubricant
__ Change Axle Oil
__ Check the hose lines (see Hydraulic Hose topic in the Maintenance section of this manual).
151
P/N 12261-683
REVISED: January 2015
151
153
Table of Contents
Table of Contents
2
Introduction
8
Construction and Industrial Equipment Product Safety
8
T Nomenclature
10
Intended Use
11
Bulletin Distribution and Compliance
12
Contacting Manufacturer
13
Transfer of Machine Ownership
14
Safety
16
Safety Introduction
16
Alert System
17
General Safety
22
Safety Sign Locations
22
Safety Sign Maintenance
34
Workplace Safety
35
Effects of Wind Conditions
43
Lightning Storm
45
Temporary Interruption of Crane Operations
46
Resuming Crane Operations
49
Ending Crane Operations
50
Turning/Driving in Reverse
51
Parking the Vehicle
52
Lock out & Tag out
53
Access/Egress
55
Personal Safety
58
Seat Belts
60
Temperature Effects on Telescope and Boom Hoist Cylinders
61
Assembly
64
Erecting the Jib
64
Changing the Offset of the Jib
66
Extending and Retracting the Jib Pull-Out Section
68
Spooling Wire Rope on Drums
70
Cable Sockets
72
Hoist-Line Reeving
74
Counterweight Change - (T300-1 Only)
77
Description of Machine and Controls
82
Universal Symbol Identification
82
Carrier Controls and Instruments-EPA 2013 Engines
86
Carrier Controls and Instruments-EXPORT
122
Upper Controls and Instruments
126
Outrigger Controls-External (Streetside)
137
Side-Stow Jib
138
Inspection
140
Pre-Start Inspection
140
Suggested Hydraulic Crane Inspection Checklist
142
Daily Check (8 Hours)
147
Weekly Check (40 Hours)
148
Monthly Check (80 Hours)
149
Quarterly Checks (250 Hours)
150
Semiannual Checks (1000 Hours)
151
Annual Check (1500 - 2000 Hours)
152
Wire Rope Inspection Record
153
Mobile Crane Load Test Inspection
154
Operating Instructions
158
Regeneration Process for DD Series 60 - (T500-1 & T780 Only)
158
Cummins 2013 Engine- Overview of Operation
165
Fuel Warning
165
Aftertreatment Regeneration Lamp Behaviors
166
Regeneration Modes
169
Manual Regeneration Procedure
170
Operating the Unit
172
Operating the Engine
172
Starting the Engine-EPA 2010
175
Engine Cold Weather Operation
181
Jump Starting an Engine- Booster Cable Instructions
184
Unusual Operating Conditions
185
Making a Typical Lift
189
Arm and Hand Signals
195
Load Rating Chart Interpretation
197
On-Tires" Lift
203
On-Tires Load Rating Chart
205
Air-Ride Suspension
206
Remote Carrier Operation
208
Moving the Unit
210
Removable Counterweight (T500-1 & T780)
210
Drivers Tips-Cummins EPA 2013
214
Vehicular Operation
219
Transmission Operation
222
Traveling Around the Jobsite
226
Towing or Pushing Vehicle
229
Disassembly
230
Stowing the Jib
230
Transportation
232
Transporting the Crane
232
Instructions for Loading and Unloading
233
Maintenance
236
Engine Data-Tier 3 Export & EPA 2013
236
Maintenance Introduction
241
Crane Maintenence & Specification
242
Acronyms and Abbreviations
242
General Safety Instructions
244
Flow Diagram-Exhaust System
246
Engine & Cooling System Maintenence Schedule
250
Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter
254
Engine Indicator Lamps
259
Aftertreatment Switch
265
Operating Characteristics with Aftertreatment Particulate Filter
266
Engine Indentification
271
Diesel Exhaust Fluid Specification
277
Filter Specification
282
Lubrication Charts
284
Operator Observation
287
Special Break-In Requirements for New Cranes
288
Machine Maintenance Checklist
289
Lubrication Introduction
292
Hydraulic Oil Requirements
294
Koehring Spec 805 Data
297
Grade Selection Chart
298
Premium Grade Anti-Wear Hydraulic Oils
300
Cable Lubrication Methods
303
Turntable and Swing Pinion
307
Swing Reducer
309
Power Steering Maintenance
312
Drive Shaft Maintenance
313
Brake System Maintenance
316
Air Dryer
319
Air System Maintenance
320
Tires
321
Slider Pads
324
Boom Lubrication
325
Swing Bearing Bolting Procedure
334
Engine Radiator Maintenance
337
Transmission Maintenance
339
Axle Maintenance
352
Tire Maintenance
356
Hydraulic System Maintenance
359
Hydraulic Hoses
363
Wire Rope and Reeving
366
Anti-Two Block System
368
Storage
370
Machine Storage
370
Engine Storage
372
Transmission Storage
375
Restoration to Service
376
Restoring Engine to Service
377
Restoring Transmission to Service
378
Chrome Cylinder Rod Storage
379
Specifications
382
Wire Rope Specification-T300-1, T500-1 & T780
382
Troubleshooting
384
Introduction
384
General Procedure
386
Hydraulics - General
387
Operator Controls
388
Power Steering
389
Front Axles
390
Steering Circuit
392
Rear Axles
397
Alternator
398
Starter
400
Engine Clutch
401
Brakes
403
Parking Brakes
404
Air Pressure
405
Swng Circuit
406
Boom Hoist Circuit
407
Telescope Circuit
408
Winch Circuit
409
Outrigger Circuit
411
Swing Pumps Circuit
412
Swing Circuit Control Valves
415
Swing Circuit Relief Valves
417
Fluid Motor
418
Cylinders
420
Cylinder Leakage
421
Excessive Heating of Oil in System
423
Electrical Controls
424
Propane Heater
425
Maintenance -Free Battery Testing
428
Two-Block System
430
Service / Parts
434
General Service Information
434
Outrigger Position Sensors
436
Torque Wrench Extensions
438
Welding Instructions
440
Outriggers
442
Rear Suspension
449
Front Axle
451
Rear Axle
453
Propellor Shaft & Universal Joints
456
Wheel and Rim Mounting
461
Engine Clutch Adjustment & Repair
465
Shift Control Adjustment
470
Steering and Power Steering
474
Swing Reducer
475
Pumps
477
Valve Adjustments
479
Rotary Manifold
485
Control Linkage Adjustment
487
Heaters & AC Systems
488
Electrical System Battery Check
489
Electrical System Collector Ring
492
Electrical System Voltmeter Diagnosis
496
Hydraulic Cylinder Maintenance
502
Chain Adjustment - 4-Section Boom
505
Boom Centering
507
Setting Proximity Sensors
509
Repairs-Adjustments-Remarks Log
511
Appendix
514
Conversion Tables
514
Average Weight of Materials
518
Torque Specs -SAE & Metric
520
California Proposition 65 Warning
522
Lead Warning - State of California
523
EPA / NHTSA Greenhouse Gas Standards Information - (T300 & T500 Only)
524
Greer Element VGA Operator's Manual
526
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Terex T780 Specifications
General
Brand
Terex
Model
T780
Category
Construction Equipment
Language
English
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