Operator's Manual

Table Of Contents
Fundamental Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Section 6 - Fundamental Terms

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Section 6 - Fundamental Terms

Operator's Manual
Fundamental Terms
Many terms are used which refer to crane function, as sembly, operation and maintenance. The following list gives a brief definition as to how the terms are used in this Operator's Manual and how they fit this particular crane. Accumulator: A container in which fluid is stored un der pressure as a source of hydraulic energy. Aeration: The condition when air is present in the hy draulic fluid. This causes the fluid to appear milky and components to operate erratically because of the com pressibility of air trapped in the fluid. Annually: Once a year. Anti-Two Block System: A system of electrome chanical devices used to alert or prevent the crane op erator from two blocking the crane. See Two Block. Attachment: The boom assembly, offset fly section(s), or auxiliary lifting sheave. Audio/Visual Warning System: 1. Alarm device that signals the operator of low engine oil pressure, high en gine coolant temperature and high hydraulic oil and transmission oil temperature. 2. Device utilizing buzzer and/or lights as a signal of approaching two block and/ or overload condition. See Rated Capacity Indicator. Automatic Brake: Drum brake system that is applied automatically any time the drum control lever is in neu tral. Backward Stability: Resistance to overturning of the crane in rearward direction. Base Section: The segment of the boom which at taches to the upper frame by the boom foot pin. Boom: The assembly of the base, inner mid, outer mid and tip sections used as the telescoping extension. Boom Angle: The angle above or below horizontal of the longitudinal axis of the boom. Boom Foot: Base of boom where it attaches to the up per revolving frame. Boom Hoist: The hydraulic method of raising and low ering the boom to different boom angles. Boom Length: The straight line through the centerline of the boom foot pin to the centerline of the boom head sheave shaft, measured along the longitudinal axis of the boom. Boom Section: The base, inner mid, outer mid and manual segments which are used as the telescoping extension. Bumper (5th) Outrigger: An outrigger located on the front of the carrier that provides additional stability for On Outrigger" capacities when deployed. By-Pass: A secondary passage of fluid flow, in addi tion to the main flow path. Carrier: The portion of the crane located below the turntable bearing. Carrier Cab: A housing which covers the driver's sta tion on the carrier of a truck crane. Carrier Frame: The main structure of the carrier sec tion of the crane. Cavitation: A condition where air is induced into a cav ity, line, or chamber normally filled with oil. This condi tion can cause damage to pumps, cylinder walls, etc. Check Valve: A valve which permits flow in one direc tion only. Circuit: A complete or partial path over which current or fluid may flow. Closed Center Circuit: The condition where the fluid only flows through the main control valves when a con trol valve spool is actuated. This can be done two dif ferent ways: (1) using a pressure compensated pump, or (2) using a fixed displacement pump, unloading valve, and an accumulator. Collector Ring (Slip Ring): A device used to transmit the electrical power from the carrier to the upper utiliz ing a rotating disk to allow rotation of the upper and maintain connectivity. Compressibility: The change in volume of fluid when it is subjected to a unit change in pressure. Counterbalance Valve (Holding Valve): A valve which regulated fluid flow by maintaining resistance in one direction, but allows free flow in the other direction. Counterweight: Weight used to supplement the weight of the crane in providing stability for lifting loads. Cracking Pressure: The pressure at which a pressure actuated valve begins to open to allow flow. Crane Rating Manual: A compilation of the necessary information needed to plan lifts with the crane. It in cludes instructions such as the allowable lifting capac ity charts, working range diagrams, working area dia gram, etc.

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Cylinder: A device which converts fluid power into me chanical force and motion. It usually consists of a moveable element such as a piston and piston rod, which operates within a cylindrical bore. Delivery: The volume of fluid discharge by a pump in a given time, usually expressed in gallons per minute (gpm) or liters per minute (L/min). Displacement: The quantity of fluid which can pass through a pump, motor, or cylinder in a single revolu tion or stroke. Double Acting Cylinder: A cylinder in which fluid force can be applied in either direction. Drum Lagging: See Winch Drum. Drum Rotation Indicator: A device that is used to indi cate winch drum motion and can also be used to moni tor speed. Filter: A device which functions to remove insoluble contaminants from a fluid by a porous media. Flow Divider: A valve which divides a flow of oil into two streams. Fly Base Section: Boom tip extension supported only at its base. Force: Any cause which tends to produce or modify motion. In hydraulics, total force is expressed by the product of pressure (P) and the area of the surface (A) on which the pressure acts. (Formula - F = P X A) Frame: Structure on which either upper or carrier ma chinery is attached. Friction: The property which tends to resist the relative motion of one surface in contact with another surface. It always exerts a Drag" in the direction opposite of the motion, thus consumes power. Full Flow: In a filter, the condition where all the fluid must pass through the filter element. Full Load Speed: The speed at which an engine runs when it is delivering its full rated horsepower. Function Limiter (Function Lockout, Hydraulic Cut outs, Hydraulic Kickouts): Devices incorporated into the anti-two block system or rated capacity indicator system which will disable the crane function of winch up, telescope out, and/or boom down (as applicable) as two block or overload situations approach. Gradablity: The slope which a crane can climb ex pressed as a percentage. (45 equals 100% slope.) Ground Pressure: Weight of crane divided by the area of the surface directly supporting the crane. Head Machinery: An arrangement of sheaves on the end of an attachment used to reeve wire rope. High Idle: Governed engine speed at full throttle and no load. Hoist: Function of lifting and lowering loads. Hoist Drum: A rotating cylindrical spool with side flanges used to wrap the winch rope during the raising and lowering with the winch. Hoist Rope: The wire rope used to reeve the winch and the attachments for lifting loads. Holding Valve (Counterbalance Valve): A valve which regulates fluid flow by maintaining resistance in one direction, but allows free flow in the other direction. Hook Block: Block with hook attached used in lifting service. It may have a single sheave for two or three part line, or multiple sheaves for four or more parts of line. HTC : Hydraulic highway truck crane. Hydraulic Reservoir: The storage tank for hydraulic fluid. Inner Mid Section: The segment of the boom which is attached to the base and outer mid sections. Lifting Capacity: The rated load for any given load ra dius and boom angle under specified operating condi tions. Line Pull: The rope pull generated off a rope drum or lagging at a specified pitch diameter. Line Speed: The rope velocity at a rope drum or lag ging at a specified pitch diameter. Load Radius: The horizontal distance from the center line of rotation of the upper to the center of gravity of a suspended load. Mat: Support, usually of timber or wire construction, for supporting the pontoons on soft surfaces where the pontoon areas are not large enough to support the load without settling. Motor (Hydraulic): A rotary motion device which changes hydraulic energy into mechanical energy, a rotary actuator. Offset Fly: A fly section that is capable of being pinned at different angles. Oil Cooler: A heat exchanger used to remove heat from the hydraulic or transmission fluid. Open Center Circuit: A circuit where the pump con tinuously circulates fluid through the control valves when they are in a neutral position. Operational Aid: An accessory that provides informa tion to faciliatate operation of a crane or that takes con trol of particular crane functions without action of the operator when a limiting condition is sensed.

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Operator's Cab (Upper Cab): A housing which cov ers the operator's station. Outer Mid Section: The segment of the boom which is attached to the inner mid and tip sections. Outrigger: An extendable supporting device used to level the crane and increase stability. Outrigger Beam: The part of the outrigger which ex tends horizontally and acts as the support for the out rigger jack. Outrigger Jack: The hydraulic cylinder on the outrig ger beam which extends vertically to raise and lower the crane. Pick And Carry: The crane operation of lifting a load and traveling with it suspended. Pilot Pressure: Auxiliary pressure used to actuate or control hydraulic components. Pinion: The small gear in a gear train which drives the other gears. Pitch Diameter: Root diameter of drum, lagging, or sheave, plus the diameter of the rope. Planetary: A set of gears used to either speed up or slow down the input vs the output to gain speed or power, whichever is applicable. Pontoon: The support which attaches to the outrigger jack to increase the supporting area. Poppet: A disc, ball, or cone shaped part of certain valves, which when closed against a seat prevents flow. Port: The open end of a passage. May be within or at the surface of a hydraulic component housing or body. Pressure: Force per unit of area usually expressed in pounds per square inch (psi) or Kilopascals (kPa). Pressure Drop: The reduction in pressure between two points in a line or passage due to the energy lost in maintaining flow. Pressure Reducing Valve: A valve which limits the maximum pressure at its outlet regardless of the inlet pressure. Pump (Hydraulic): A device which converts mechani cal force and motion into hydraulic fluid power. Radius Of Load: The horizontal distance from the cen terline of rotation of the crane to the center of gravity of the suspended load. Rated Capacity Indicator (RCI): A device that auto matically monitors radius, load weight, and load rating and warns the crane operator of an overload condition. Rated Capacity Limiter (RCL): A device that automat ically monitors radius, load weight, and load rating and prevents movements of the crane that would result in an overload condition. Reeving: Passing of ropes over pulleys or sheaves. Relief Valve: A pressure operated valve which by-passes pump delivery to the reservoir, limiting sys tem pressure to a predetermined maximum valve. Reservoir: A container for storage of fluid in a fluid power system. Restriction: A reduced cross-sectional area in a line which produces a pressure drop. Rotating Joint: Component which transfers fluid be tween a stationary and a rotating member. Schematic: A diagram or representation of a system showing everything in a simple way. No attempt is made to show the various devices in their actual rela tive positions. A schematic points out the operation of a circuit for troubleshooting purposes. Seasonally: Four times per year. Semiannually: Twice per year. Service Brake: A foot operated brake which regulates the amount of air or fluid delivered to the brake cham ber, which determines the braking force. Single Acting Cylinder: A cylinder in which fluid power can only be used in one direction. Another force must be used to return the cylinder. Spool: Term applied to almost any moving cylindrically shaped part of a hydraulic component which moves to direct flow through the component. Strainer: A filtering device for the removal of coarse solids from a fluid. Stroke: The length of travel of a piston or spool. Suction Line: The hydraulic line connecting the pump inlet port to the hydraulic reservoir. Sump Tank: See Hydraulic Reservoir. Surge: A very sudden rise in hydraulic pressure in a circuit. Swing: The rotation of the upper with the carrier re maining stationary. Swing Brake: A brake which is used to resist the rota tion of the upper during normal, stationary crane op erations.

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Swing Motor: Hydraulic device which uses a plane tary to rotate the upper on the carrier. Swing Park Brake: A self contained brake used for holding the upper, in any position, during normal, sta tionary crane operations. Tailswing: The swing radius from the centerline of ro tation of the upper frame to the extreme rear edge of the counterweight. Tip Section: The outer most live segment of a tele scopic boom. It is attached to an outer mid section and contains the head machinery of the attachment. Torque: Turning or twisting force usually measured in foot pounds (ft lb) or Newton meters (Nm). Travel Swing Lock (2 Position Swing Lock): A me chanical lock that engages with the upper directly over either the front or the rear of the carrier only. Use of the travel swing lock is mandatory when traveling or trans porting the crane and during pick and carry operations. Turntable Bearing: A large bearing which attaches the upper to the carrier allowing the upper to rotate on the carrier. Two Block: The situation when the crane's hook block or hook ball contacts the attachment's head machin ery. Two Block Warning System: A system of electrome chanical devices used to warn the crane operator of im pending two block condition. Unloading Valve: A valve which by-passes flow to tank when a set pressure is maintained on its pilot port. Upper: The portion of the crane located above the turntable bearing. Upper Revolving Frame: The main structure of the upper section of the crane which serves as mounts for other components in the upper section. Valve: A device for controlling flow rate, flow direction or pressure of a fluid. Viscosity: The resistance to flow. High viscosity indi cates a high resistance, low viscosity, a low resistance. Winch: Function of lifting and lowering loads. Winch Drum: A rotating cylindrical spool with side flanges used to wrap the winch rope during the raising and lowering with the winch. Winch Rope: The wire rope used to reeve the winch and the attachments for lifting loads. Wire Rope: A flexible, multiwired member usually con sisting of a core member around which a number of multiwired strands are helically wrapped. Wiring Diagram: A diagram which included all the de vices in an electrical system and shows their functional relationships to each other. Such a diagram gives the necessary information for actual wiring or physically tracing circuits when troubleshooting is necessary. Working Weight: Weight of crane with full radiator, half full fuel tank, and attachments installed. 360 Swing Lock: A positive mechanical lock against rotation of the upper over the carrier during normal, sta tionary crane operations.

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Section 6 - Fundamental Terms