TEREX CRANES

T-SERIES SERVICE TRAINING

SIMPLE
AVAILABLE
& COST
EFFECTIVE

1
 T-Series Service Training Agenda

• Carrier
 Frame
 Outriggers
 Suspension

II. Engines
 Transmission
 Drive Lines
 Steering 2
 T-Series Service Training Agenda
• Hydraulic Systems
– Pump Drives
– Pumps
– Hydraulic Reservoir

IV. Operator’s Cab/Housings

 Crane Cab
 Carrier Cab
 Engine Housings
 Controls
3
 T-Series Service Training Agenda

• Electrical Systems
– Crane Dash
– Carrier Dash
– Upper Console
– Collector Ring

4
 T-Series Service Training Agenda

• Hydraulic Telescoping Booms

– Booms
– Jibs
– Winches
– Attachments

5
 Swing Bearing

• After 40 Hours Re-Torque

Swing Bearing –725 Ft-Lbs.

• Check Torque Semi-

Annually-500 hours.

6
Swing Bearing

7
 Two Position Boom Rack
• Tip Block in the Up Position
• Boom Tip Height is 11 Feet
8 Inches.

• Tip Block Down

• Winches High Point:
11 Feet 9.1 Inches.
8
 Counterweight Storage Rack
• Weights should be
Pinned to the Storage
Rack for Road Travel

• All Fenders Transmission

Covers are Aluminum to
Reduce Weight
9
Front Bumper is the
Counterweight

10
 Fuel Tank

• Capacity 100
Gallon
• Aluminum for
Weight
Reduction
• Fuel Weight:
7.15 Lbs/Gal
• Total Weight:
715 Lbs

11
 Fuel Tank

• Capacity 60
Gallons
• Aluminum for
Weight
Reduction
• Fuel Weight:
7.15 Lbs/Gal
• Total Weight:
429 Lbs

12
 Fuel Filter
• Engine Fuel Filter with
12-volts Fluid Heat
• Heater- ON at 40 oF.
• Heater-OFF at 60 oF.
• WHEN THE GLASS
FILTER IS FILLED
WITH FUEL,THE
FILTER MUST BE
REPLACED.

13
Fuel Filter

14
 Outriggers

• Beam
• Jack Cylinder
• Note: Mounting of
Jack Cylinder
• Cylinders have
Welded Port
Tubes and Welded
Load Locking
Block
15
Outriggers

16
 Outrigger Pad Pin

• Holds Pad to the

Ball Socket of
Jack Cylinder
• 24 In. Aluminum
Pad

NOTE: On bad surfaces you should use wood cribbing between

pad & surface. This will prevent damage to the pad. 17
 Outrigger Pad Storage

• 24 in. Cast Aluminum

Outrigger Pads
• 50% Outrigger Beam
Spread Pins
• Rear Lights are
Recessed in the Frame
for Longer Life

18
 Outrigger Pad Storage Location
in the Center Outrigger Box

• Location of the
Hydraulic Tank
Sight Gauge
• Electrical Box
for All Relays

19
Outrigger Pad Storage Location
(Left-Rear)

20
Outrigger Pad Storage Location
(Right-Rear)

21
 Outrigger Ground Level
Controls (Optional)

• Front Outriggers
– Incorporated a
Self Stowing
Permanently
Attached Float

22
 Outrigger Ground Level
Controls (Optional)
• Rear Outriggers
– Top Switch to
Extend and Retract
– Lower Switch
– Front Beam
– Front Jack
Cylinder
– Rear Beam
– Rear Jack Cylinder
23
Remote Outriggers

24
Remote Outriggers

25
 Front Bumper

• Front Tool Box for the

Ball

Note: Location of front

extend outrigger control
panel.

26
 Front Jack
• Pad Attached to
Jack
• Pad Never
Removed
• Proximity Switch
will Tell You When
the Cylinder is
Fully Retracted

27
 Front Outrigger Jack Cylinder

• Same Cylinder as the

T300 With Long Stroke
Cylinder Plus an Added
Pressure Reduction
Valve
• Pressure Settings on
Cross Over Relief
– Extend: 400 P.S.I.
– Retract: 1100 P.S.I.
28
Front Outrigger Jack Cylinder

29
 Outrigger Pins

• Pins Used For the 50%

Spread On the
Outrigger
• High Pin Point Not
Used
• Low Pin Point will
Drop at 50% Spread

30
Outrigger Extend Cylinder

NOTE: Locations of seals

31
 Outrigger Valves

• Relief Valve for

Outriggers
– Set at 2500
P.S.I.
– Note Location
of Test Port

32
Outrigger Rear Valve

33
Outriggers

34
Front Axle Assembly
(T200/T300)

35
Front Axle Assembly
• Drag Link Adjustment.
– After Assembly Ball
Stud, Screw In End Plug
Until Solid 20 Ft-Lbs.
– Back Off 1/8 In.
Minimum to 3/8 In.
maximum.
– Assemble Cotter Pin.

36
 Rear Axle Tandem

• 40,000 Lb. Capacity (T200/T300)

• 43,000 Lb. Capacity (T500)
• Heat Treated Housings
• Brakes S Cam Type ABS
• Split Circuit Systems
• Lifetime Lubricated Brake
Actuation
• Extended Service Brakes /
Aluminum Hubs

37
 Wheels and Tires

• Aluminum Wheels Reduce

Weight
• Tires: 11R22.5 14PR
Rating

Note: Large storage areas

behind the steps.

• Step to Enter Upper

• Cab and Toolbox
Cover 38
 Cummins Diesel Engine ISC300

• 6 Cylinders
• 504.5 Cubic Inches
• 300 HP @ 2000 RPM
• Turbocharged
• 12 Volts / 100 Amp
Alternator

39
 Detroit Diesel Engine Series 50
• 4 Cylinders
• Model No. 6047 MK-57
• Spec. No. 717-0637
• 519 Cubic Inches
• 350 HP @ 2100 RPM
• Turbocharged / After
Cooled
• 12 Volts / 130 Amp
Alternator 40
 Detroit Diesel Engine Series 60

• 6 Cylinder
• Model No 6067-57
• Spec. No. 717-0183
• 778 Cu. In.
• 420 HP @1800 RPM
Maximum Gross
• Turbocharged /After Cooled
• 12 Volts/130 Amp Alternator
41
 Aluminum Engine Housing

• Sliding Cover to
Optimize Engine
Access
• Lockable

42
 Aluminum Engine Housing

• Has a Sliding Cover

For Ease of Servicing
the Engine

43
 Cummins ISC300
S
T
A
• Fuller (Manual) N
D
Transmission A
R

• 10 Speed D

• Allison (Auto.) O
Transmission P
T
• MD-3560 I
O
• 6-Speed Forward N

with “Lock-Up”
44
in top 5 gears
 Transmission

• RTO 11909ALL
– Manual
• Fuller 10 Speed Transmission

45
 Transmission

• CEEMAT Automatic
• RTO 14109 B ATE

46
 Power Steering Pump

• 8 GPM Flow Control

• 2000 P.S.I.
• Reservoir Capacity 2 Qt.
• Change Oil and Filter 6
Months and Every 6
Months After
• Filter PN 209 755

Note: AW46 Hydraulic Oil

47
Power Steering Pump
T200/T300

48
Power Steering Pump

49
 Sheppard Steering Gear

• Use AW46 Hydraulic

Oil
• Change 6 Months or
50,000 Miles Which
Ever Comes First
• Bearing Cap Grease
Point

50
 Steering Relief Valve for Carrier

• Set @ 8 GPM/2000 P.S.I.

51
Engine Ether Starting Kit

52
Engine Air Cleaner Assembly

53
 Drive Line Timing

• Torque Bolts and

Lock Tabs Place
• Location of Carrier
Bearing For the 2-
Piece Drive Shaft
• All Tubes are Shock
Mounted in Rubber
Or Plastic

54
 Left Hand Air Tank

• 150 P.S.I. Safety Valve

• Supply Line Off
Hydraulic Tank For
Main Pumps Back
• Return Line Will Return
to the 5 Micron Filter in
the Main Hydraulic Tank

55
 Rear Air Tank

• Drain Cock
• Rear Relay Valve
Used for Parking
• Center R/H Tank
for Rear Air Brakes
• Center L/H Tank for
Front Air Brakes

56
 T500 Air Schematic

Accessory Air
Service Brake Air (to relay valves)
Brake Air
Compressed Air
Suspension Air

57
 T500 Air Schematic

Accessory Air
Compressed Air

58
 T500 Air Schematic

Service Brake Air (to relay valves)

Brake Air
Suspension Air

59
 Carrier Dash Panel

• Tachometer/Hourmeter
• Engine Coolant Temperature
Gauge
• Engine Oil Pressure Gauge
• Fuel Gauge
• Voltmeter
• Gauge Light Dimmer
Switch
• Headlight Switch
• Cruise On/Off
• Cruise Set/Resume
60
 Carrier Dash Panel
• Engine Brake On/Off
• Engine Brake Hi/Med/Low
Up/Center/Down
• AC/Fan Hi/Lo
• Temperature Adjust
• Engine Brake Light
• Low Coolant Light
• High Beam Indicator Light
• Transmission Light
• Ignition on Light
• Speedometer
• Air Gauge Front
• Air Gauge Rear
• Pump P.T.O. Light
• Low Air Light
• Parking Brake on Light
• Differential Lock Light
• Inter Axle Lockout Valve P.T.O. Air
Valve Toggle Switch
• Parking Brake Control Valve
• Idle Adjust Switch
• Diagnostic Switch
• Stop Lamp
• Warning Lamp
• A.B.S. Light
• A.B.S. Diagnostic Switch
• Ignition Switch
• Air Suspension Control
61
 Location of Crane Serial
Number (#11254) Plate
• Stamped in Three Other
Locations
• Top Rear Main Boom, Right
Side Toward Main Winch
• Superstructure, Lower Right
Hand Side Next to Gear
Cover
• Right Rear Carrier Frame

62
 360° House Lock

• Lube Point and Control Cable

63
 Boom Pivot Pin

• Lock and Torque All

Cap Screws to
Standard Torque for
Bolt Size
• Boom Hoist Cylinder
Lock Pins Same as
Above

64
 Counterweight

• Slugs are 3000 Lbs.

• Max Counterweight
Slugs 3 or Total 9,000 Lbs.
• Integral Counterweight
Removal System Permits
Counterweight to be Carried
on Deck of Carrier to
Optimize Axle Weights.
• T340XL - 11,000 CWT
• T340 - 7,200 CWT
• T230 - 7,200 CWT 65
 Counterweight

• Maximum Counterweight 11,000 Lbs.

66
Hydraulic Counterweight
Removal System

67
 Swing Reduction Unit
Braden

– Change Oil at
First 100 Hours,
Then 1000 Hours
or 6 Months,
Which Ever
Occurs First.

68
 Swing Drive

• Braden No.
04714
• 80,000 In. -Lb.
Torque
• Gear
Reduction 35:1

69
 Swing Drive

• Brake Disc Must be Flat

• Thickness New 3/32 In.
• Replace at 1/16 In.
• Service with Texaco No.
150 Gear Oil
• 10.5 Pints Plus 8 Oz. Glycol
• Weight 386 Lbs.

70
 Swing Motor

• Eaton Break Down of Motor

71
Pump Disconnect
T200/T300

72
 Pump
Disconnect
• Air Operated Pressure of 60
to 120 P.S.I.
• Coupling Must Not Be • Change Oil at First 500
Switched Under Load Hours Then 4000 Hours
• Interlock System Tied to or 12 Months After.
Relay to Prevent Switching • Governor Set at 105 P.S.I.
When Engine is Running Cut In.
• Mineral Gear Oil - • Governor Set at 125 P.S.I.
80W/90W Cut Out.
73
Pump Disconnect

74
 Pump Disconnect

• Check All Seals and

Thread Joints for Leaks,
Repair as Needed
• Check for Leaks Daily

NOTE: Under no circumstance should different lubrication

such as mineral oil, synthetic oils or greases be mixed
together.
75
 Hydraulic Pump Drive
Shaft Cover

• Do Not Run Drive Shaft

with Cover Removed
• At 2,730 R.P.M., Caution
Must be Taken

76
Pump Disconnect

• Air Shift Cylinder

77
 Hydraulic Reservoir

• All Welded Construction

• Internal Baffles and
Diffuser
• Easy Access to Filter,
Screen Washable and Paper
Disposable Filter
• Screen: 60 Mesh
• Return Filter: 5 Micron
(Replaceable)
• Tank Pressure: 14 P.S.I. to
Prevent Dirt Infiltration 78
 Hydraulic Reservoir

• Filter Spring
Length is 4
Inches.

79
 Main and Aux Winch
Control Valve
• Location Upper
Superstructure Just Under
The Winches
• Pump Flow: 59.5 G.P.M.
– Set Pressure: 3,250
P.S.I. + .25 P.S.I. With
Pressure Test Port  Winch Disconnects for
– Inlet Relief Set at Two Block System and For
Factory - Do Not Adjust. The Over Load System
3,900 P.S.I. + 100 P.S.I.
80
Main Valve
T200/T300

81
 Main Winch Control Valve

• Set Pressure: 3,250 P.S.I. +

.25 P.S.I.
• Inlet Relief Set at Factory -
Do Not Adjust. 3,900 P.S.I.
+ 100 P.S.I.
• Test Port Pressure 3,500
• Cable Functions Disconnects
P.S.I. + .50 P.S.I.
 Oil Cups Require 30W
• Left to Right Work Sections Light Oil Every 6 Months
– Main Winch
– Aux Winch
82
 Swing Valve

• Swing Pressure: 2,000 P.S.I.

• This Oil Flow Is Off The

Outrigger Pump - 24.7
G.P.M.
83
 Boom Telescope Valve

• Inlet Relief Pressure 3,900

+ 100 P.S.I.
• Test Port Pressure 3,500 +
50 P.S.I.
• Comp Pressure Setting
3,200 + 25 P.S.I.

NOTE: Test port pressure of 3,500 P.S.I. + 250 P.S.I.

is made up by the Comp Spring.
84
T500 Hydraulic Shematic

85
T300 Hydraulic Schematic

86
 Rotary Manifold
• Port #1 - 10 Line Low Pressure Return
• Port #2 - 12 Line Swing Pressure
• Port #3 - 20 Line Large Flow Return
Boom Hoist & Telescope
• Port #4 - 16 Line Winch Pump 52.5
G.P.M.
• Port #5 - 16 Line Boom Hoist &
Telescope Pump 43.1 G.P.M.
• Port #6 - 20 Line Winch Return Oil
87
 Upper Cab

• Levers Left to Right:

 Swing With Horn
 Telescope
 Foot Swing Brake
 Boom Hoist
 Auxiliary Winch
 Main Winch

88
 Upper Engine Control

• 2.5K OHM - 3 Wire,

A, B, & C Wired to
Plug C to Collector
Ring. This Plug is A
Letter Plug.

NOTE: Right hand

peddle is for lower
engine.

89
 Location of Signal Horn,
Upper Unit
• Horn button is on the swing
lever
• Two grease lines
– Ball Race:
Multipurpose Grease
– Ball Race Two Turns to
Grease the Entire
Bearing
– Fittings are in the
Operator’s Cab
– Swing Reduction Gear:
Open Gear Grease 90
 Boom Hoist Foot Pedal

• Upper Engine
Control
• Standard On All
Machines
– Left-Foot, Up
– Right Foot,
Down

91
 Upper Control Dash
Assembly Levers (left to right)
• Swing Control With Horn
Switch
• Telescope Control
• Boom Hoist Control
– Foot Pedal For Boom
Hoist
• Aux Winch Control With
2-Speed Switch
• Main Winch Control With
2-Speed Switch and Winch
Rotation Wheel
92
 Access to Console

• Wiring Through The

Removed Panel
• Plugs A & C are The
Plugs That Go to The
40 Pass Collector
Ring, PN 714-0259

93
 Operator’s Upper Cab Access

• Hydraulic Control
Cables are
Accessible By
Removing The Large
Inspection Panel
• Crane Bubble Level
Mounted in The
Upper Portion of The
Dash
94
 Collector Ring / 40 or 48 Pass

25 Ea. 7.5 Amp Brush & Holder Assy.

3 Ea. 7.5 Amp. Silver Brush &

Holder Assy. Used for R.L.I.
System
6 Ea. 15 Amp Brush & Holder Assy.
6 Ea. 20 Amp Brush & Holder Assy.
40 Ea. Total to Make Up a 40 Pass
Collector Ring
95
 Battery Box

 Three - 12 Volt
Batteries
 2,400 C.C.A. at
0° F
 Maintenance
Free
 Two - 12 Volt
Batteries
(T200/T300)
 Three for Cold
Start (Opt.) 96
 Electric Plugs for Carrier
Cab
• All Wires Are Marked for
Easy ID
• Plug F: 1-31 Plug for
Deutsch# HD-34-24-31PN
• Plug G: 1-23 Wire Plug for
Deutsch # HD-34-24-23PN
• Plug H: 1-19 Wire Plug for
Deutsch# HD-34-24-19PN
• All Deutsch Plugs Are Different So They Can Not Be
Mixed Up.
97
Starter Relay

98
 Electrical Control Panel

• Relays
– Horn
– Pump Interlock
– RLI
– Water Temperature
– Fuel Pump
– Remote Throttle

99
Relay Panel

100
 Electrical Control Panel
• Starter Relay 1 each
• Ignition Relay 1 each
• Circuit Breaker 9 each
– Engine: 10 A, 20 A,
20 A
– ABS: 15 A, 15 A
– Air Dryer: 7.5 A
– RLI: 10 A
– Remote Outrigger:10 A
– Fuel Heater:10 A
101
 Engine Oil Pressure Switches
• Two Pressure
Switches
 One For Lower
Gauges
 One For Upper
Gauges
 Auxiliary

102
 Main Hydraulic Pump

• Driven Off The Back

Side of The Engine
• Water Shutoff Valve
For Truck Cab Heater
• Probe For Low
Coolant Level Light in
Top Tank of Radiator

103
 Main Hydraulic Pump

• 2-Port Inlet,
Triple Pump

NOTE: Air System

For Pump Clutch.

104
 Main Hydraulic Pump
• Front-Section: 59.5 G.P.M.
– 3,500 P.S.I.
– Main and Auxiliary
Winches Functions
• Mid-Section: 43.1 G.P.M.
– 3,500 P.S.I.
– Boom Hoist And
Telescope Functions
• Back-Section: 24.7 G.P.M.
– 2,500 P.S.I.
– Outrigger and Swing
System 105
 Main Hydraulic Pump

• Front Section: 59.5 G.P.M.

– Main Winch and Auxiliary
Winch (If Ordered)
– Main Relief Valve Setting:
3,500 P.S.I.
• Middle section: 43.1 G.P.M.
– Boom Hoist And Telescope

106
 Main Hydraulic Pump

• End Section: 24.7 G.P.M.

– Outriggers : 2,500
P.S.I.
– Swing And
Counterweight Control
Valves : 2,000 P.S.I.
– Hydraulic Heater
(Optional)

107
 Oil Cooler-Main Hydraulic
System
• Split Cooler
– Top Is Ram Air For
The Engine
– Cooler By-Pass
Safety Valve Set At
35 P.S.I.

108
 Boom Hoist Hold Valve

• Transducer For R.C.I.

500 Load System
• Bottom Transducer In
The Piston Side
Transducer
• Tee Transducer In The
Rod Side Transducer
• Transducers Are In The
Computer Box For The
R.C.I. 510 Unit.
109
 R.C.I. 510 Computer Box

NOTE: Location of box. This box has built-in transducers.

110
 R.C.I. 510 Screen

NOTE: Warning on dash.

111
Extension Reel for RLI 510

112
Anti-Two Block Assembly
– Used with the R.C.I. 510
System
 Jib Anti-Two
Block
 Auxiliary Head
Anti-Two Block
 Main Boom Head
Anti-Two Block

113
Anti-Two Block Assembly

114
 Boom 35 Ft. to 110 Ft.

• Four Section Full Power

• Mechanically Synchronized
• High Strength Four Plate
Construction
• Coined Side Plate Holes
– Weight Reduction
– Increase Strength
• Side and Bottom Anti-Friction
Pads
115
 Main and Aux Winch
• Braden Model PD15
• Bent Axis Piston Motor And
Planetary Reduction Gear
• Two Speed Operation With
Equal Speed For Power Up
And Down With Brake Valve
• Cable 5/8 In. x 500 Ft. Fifth Layer
6x19 IWRC IPS High Low
533 F.P.M. 266 F.P.M.
• Both Winches Are The Same Fifth Layer Pull
5,052 Lbs. 10,827 Lbs.
116
Boom Chain Adjustment
Third Section Extend and Retract Chains

BOOM CHAIN ADJUSTMENT: For proper

operation and boom life the extend and retract
chains must be adjusted properly. To adjust
these chains use the following procedure.

THIRD SECTION EXTEND AND

RETRACT CHAINS (4 SECTION BOOMS):

1. Fully retract the boom.

2. Measure the gap between the front of second

section and the back of the third section. This
gap should be .25 inch to .38 inch.

3. If adjustment is required, extend the boom

approximately 1/2 way.

117
 Boom Chain Adjustment
Third Section Extend and Retract Chains (Cont.)
NOTE: Before attempting to turn one of the
adjusting nuts, extend or retract the boom
slightly to relieve the tension on that nut. After
extending the boom, adjustment A will be under
tension and B will be free. After retracting the
boom, adjustment B will be under tension and
A will be free.

4. If the gap is less than .25 inch, loosen

adjustment B and tighten adjustment A until the
gap is within specifications.

5. If the gap is more than .38 inch, loosen

adjustment A and tighten adjustment B until the
gap is within specifications.

6. Fully retract the boom and recheck the gap.

Repeat step 3 through 5 if necessary.

118
 Boom Chain Adjustment
Third Section Extend and Retract Chains (Cont.)

7. Fully extend the boom horizontal.

8. Through the first hole in the side plate of the

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 dimension should be 2.25
inches to 2.50 inches.

9. If the dimension is greater than 2.50 inches,

loosen adjustments A and B equal amounts
until the measurement is within specifications.

10. If the dimension is less than 2.25 inches,

tighten adjustments A and B equal amounts
until the measurement is within specifications.

119
Boom Chain Adjustment
Tip Section Extend and Retract Chains
FOURTH SECTION EXTEND AND
RETRACT CHAINS (4 SECTION BOOMS):

1. Fully retract the boom.

2. Measure the gap between the front of third

section and the back of the tip section. This gap
should be .25 inch to .38 inch.

3. If adjustment is required, extend the boom

approximately 1/2 way.

NOTE: Before attempting to turn one of the

adjusting nuts, extend or retract the boom
slightly to relieve the tension on that nut. After
extending the boom, adjustment C will be under
tension and D will be free. After retracting the
boom, adjustment D will be under tension and C
will be free.

120
Boom Chain Adjustment
Tip Section Extend and Retract Chains (Cont.)
4. If the gap is less than .25 inch, loosen
adjustment D and tighten adjustment C until the
gap is within specifications.

5. If the gap is more than .38 inch, loosen

adjustment C and tighten adjustment D until the
gap is within specifications. 6. Fully retract
the boom and recheck the gap. Repeat step 3
through 5 if necessary.

7. Fully extend the boom horizontal.

8. Through the first hole in the side plate of the

third boom section (the hole closer to the second
section), measure the sag of the retract 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 to 3.00
inches.

121
Boom Chain Adjustment
Tip Section Extend and Retract Chains (Cont.)

9. If the dimension is greater than 3.00 inches,

loosen adjustments C and D equal amounts until
the measurement is within specifications.

10. If the dimension is less than 2.75 inches,

tighten adjustments C and D equal amounts
until the measurement is within specifications.

11. Under the same condition, the maximum sag

in the extend chain should be 7.00 inches to
7.50 inches. This measurement is from the
bottom of the third boom section to the top of
the extend chain.

122
Jib

123
Tool Box (Option)
T200/T300

124
Air Tanks

125
 END OF T-SERIES SERVICE
TRAINING
SIMPLE
AVAILABLE
& COST
EFFECTIVE

126