Grua Terex RT

Terex Mobile Telescopic Level 1:
Mobile Telescopic Level 1 Manual

Terex Mobile Telescopic Level 1: General ED.
General ED.
How AC works
ROUTH TERRAIN CRANE
CARRIER
This is the portion of the crane which supports,
And transports the superstructure. It consists of the
Chassis; frame; carrier cab; outriggers; engine;
transmission; steering; axles; brakes; and
suspension.
SUPER STRUCTURE
Above the swing bearing is called the Superstructure and
consists of the crane controls; lift cylinder; boom nose; aux boom
nose; headache ball; hook block & wedge socket; boom
extensions; hoists; wire rope; swing; counterweights; and
hydraulic system
TELECCOPIC BOOM
It hydraulically extends, and is designed to support
loads. The boom telescope cylinder extends and
retracts the boom into the desired position for a lift.
OUTRIGGERS
-provide a solid platform for the crane's safe operation and efficient use.
Anti-two
Block
switch
Boom Length reel
And
Angle transducer
LMI
510
Computer
unit
LMI SYSTEM COMPONENTS
Anti-two block system- Working in conjunction with the
LMI, the A2B stops the operator from bringing the block
or ball into contact with the boom nose.
BOOM CYLINDER
Using hydraulic pressure, the boom
cylinder lifts the boom into position
to make a lift.
STINGER/ FLY SECTION
STINGER SHEEVE
SWINGAWAY
BOOM
EXTENSION
Folds out in two sections to
erect. The boom swingaway
stows on boom base section
when not in use. The fly section
stays inside the base section
when not in use.
-Retract the boom
completely.
-Boom down to
minimum boom angle to
allow
ease of installation of
the jib pins.
-Install the upper and
lower jib mounting pins
in the right side of the
boom head.
1. -Attach a guide rope to
the eye on the bottom tip
of the jib.
-Raise the boom to
horizontal.
2.
BOOM EXTENSION
-With the engine at
idle, slowly extend the
boom to 35 feet (10.6
m). As the jib clears
the storage brackets,
the jib will swing out
approximately 45
3.
-With the engine at idle,
slowly boom down to
minimum boom angle
while another operator
uses the guide to control
the speed of the jib
rotation. The jib will swing
around until the
left side mounting holes
line up.
-Install the left upper and lower jib
mounting pins.
-Remove the guide rope.
-Disconnect the anti two-block plug from
the jib anti two-block socket and connect it
to the socket on the boom head. Move the
dummy plug from the boom head socket to
the anti two-block socket on the jib.
-Reeve the hoist line over the jib sheave.
-Test the anti two-block system by lifting
the anti two-block weight. The light and
audible alarms should be actuated in the
cab and the boom down, boom extend, and
winch up controls should disconnect.
4.
AUX BOOM NOSE/ ROOSTER SHEEVE
BOOM HEAD/ NOSE
BOOM HEAD SHEAVES
Aux boom nose is an additional
sheave, normally mounted to the front
of the boom nose, over which an
additional part of line may be run.
HOOK BLOCK
HEADACHE BALL
Hook block is a device with
multiple sheaves (wheels)
used to achieve multiple
parts of line in order to lift
loads which surpass the load
limit of the rope.
The headache ball is the
weight fitted to the wire rope,
above the lifting hook, which
causes an empty hook to
lower with gravity.
WEDGE SOCKET
The wedge socket is a
devise used at the end of the
wire rope to attach the rope
to a headache ball or hook
block.
AUX AND MAIN HOIST
Hoist motor
Hoist drum
FUEL TANK
DIESEL PLEASE
SWING MOTOR
Swing also called slewing is the rotary
motion of the superstructure around the
centerline of rotation. This motion is
achieved with a swing gear box or boxes.
Bearing Plate
Swing Reduction Unit
Swing Brake
Swing Motor
SWING BEARING
RT COUNTER WEIGHTS
Weight located at the rear of the superstructure
to counteract the effects of lifting a load. Some cranes have
power remove/install counterweight systems to reduce
weight for road travel. If no auxiliary hoist, there will be a
comparable weight in place of the hoist.
The Counterweight slugs weigh 3000 Lbs.
The Max Counterweight Slugs by design are
3 or Total 9,000 Lbs. Integral Counterweight
Removal System Permits Counterweight to
be Carried on Deck of the Truck Crane to
Optimize Axle Weights.
T340XL - 11,000 CWT
T340 - 7,200 CWT
T230 - 7,200 CWT
*Note weights are including weight of
Counter weight without slugs. Maximum
Counterweight is 11,000 lbs
TRUCK CRANE COUNTERWEIGHTS
SLUG
Hydraulic Counterweight Removal System
Hydraulic Reservoir (tank)
The reservoir is where the system starts for the hydraulics
system. The fluid must be changed every 1500 HRS. The
reservoir is equipped with a Full Flow Oil Filtration System
with By-Pass Protection. It also includes a 60 mesh screen
filter, and a 5 Micron Replaceable Return Filter. There is a
by pass spring associated with the reservoir that has a
spring length of 4 inches. This must be ensured for proper by
pass operation of system. This is an early indicator of
clogged filter. Change reservoir return filters at first 40 Hours
Then at 500 hours. Also, clean intake suctions at the same
time.
4 BYPASS SPRING
RESERVOIR
Hydraulic Reservoir
It is equipped with Internal
Baffles and Diffuser, and
easy access to filter. The
filters are screen washable
and paper disposable.
Screen: 60 Mesh
Return Filter: 5 Micron
(Replaceable)
Tank Pressure: 14 P.S.I.
to Prevent Dirt Infiltration
Crane Serial Number Location
The Serial numbers located around the
Machine are stamped in Three other
positions besides the from of the cab.
1. Top Rear Main Boom, Right Side
Toward Main Winch
2. Superstructure, Lower Right Hand
Side Next to Gear Cover
3. Right Rear Carrier Frame
Engine
The power plant for the RTs consist of the Cummins 6
Cylinder, 359 Cu. In. 2500 R.P.M., Turbocharged diesel
engine. The RT200 puts out 130 Hp while the RT300 puts
out 152 hp. The RT400 and 500 puts out 174 Hp. The
cooling system is split in half between hydraulic fluid and
transmission fluid.
RT CUMMINS ENGINE
RADIATOR
Engine
The power plant for the T-200 series consist of the Cummins
6 Cylinder, 504.5 Cu. In., 300HP @ 2000 RPM.,
Turbocharged diesel engine..
Engine
The power plant for the T-300 and T-500 series consist of the
Detroit Diesel series 50 4 Cylinder, 519 Cu. In. with 350 HP
@ 1800 Rpm., Turbocharged/After cooled diesel engine.
Later T-500 series was equipped with 6 cylinder, 778 Cu. In.
with 420 HP @ 1800 RPM.
T SERIES CUMMINS ENGINE
T SERIES CUMMINS ENGINE
RT TRANSMISSION
Clark 18000 Power-Shift with Torque Converter. Check
oil level Daily at 500 R.P.M., 180 to 200. Change oil
every 1000 hrs
10 Speed Fuller (Manual) Transmission
6-Speed Forward with Lock-Up in top 5
gears Allison (Auto.) Transmission
There are two transmissions used for the truck
cranes. There is the 10 speed fuller, which is a 10
speed manual that comes standard and a 6 speed
Automatic transmission that is optional.
MAIN PUMP
OUTRIGGER/STEERING PUMP
RT PUMPS
RT PUMP COMBINATION
Truck Crane Pump Disconnect
Disconnect is air operated at 60 120 psi. It is
equipped with an interlock system that is tied to a
relay to prevent switching coupling while under load.
The governor is set at 105 psi Cut in and 125 Cut out.
All seals, threads, and joints must be checked daily for
leaks. Used to keep from driving the pumps while
normal street driving.
NOTE: Under no circumstance should
different lubrication such as mineral oil,
synthetic oils or greases be mixed
together.
Truck Crane Tandem Pumps
Truck crane has a tandem pumping configuration.
There are three gear type pumps run off the engine
that provide the pressure for the Main/ Aux winches,
Boom hoist, Telescope, outrigger, Swing, and the
Counter weight control valves.
Terex Mobile Telescopic Level 1: Load Charts
Load Charts
Terex Mobile Telescopic Level 1: Load chart
Early cranes were heavy and bulky. This increased Early cranes were heavy and bulky. This increased
weight took the place of outriggers in crane design. weight took the place of outriggers in crane design.
Older crane operators would operate the cranes by the seat of their pants. Their
judgment on what a particular crane could lift was evaluated by experience on a
particular crane. The operator would literally feel the crane starting to tip. This is how
the operator would determine what the maximum he could safely lift with that crane.
With the engineering of longer booms the development of Outriggers /
Stabilizers began over.
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The Early Stabilizers were a screw
type. Manual force was needed to jack
the machines into the air. They were
designed to unload the weight from
the tires.
80
8
12
The single box design consists of 2
OUTRIGGER BEAMS in one box.
8 8
16 16
8 8
20 20
The DOUBLE BOX OUTRIGGERS
design consists of individual
beams in individual boxes. This
provides greater extension
The TWO STAGE DOUBLE BOX
OUTRIGGERS design consists of two
telescoping beams in two individual boxes.
These extensions provide greater than twice
the width of the carrier.
100 LB. 100 LB.
CRANE CAPACITY
is based on an old
LAW OF PHYSICS
EQUAL WEIGHTS AT
EQUAL DISTANCES ON
OPPOSITE SIDES OF
A FULCRUM POINT
RESULT IN A
BALANCED CONDITION
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50,000 LB. 50,000 LB.
200 LB. 100 LB.
HOW CAN A CRANE PICK
MORE THAN ITS OWN WEIGHT ?
DISTANCE AS WELL AS
WEIGHT, IS A FACTOR IN
ACHIEVING BALANCE
100,000 LB.
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50,000 LB.
With OUTRIGGER SPREAD far enough it
would be possible to lift the world.
... PROVIDED THE OUTRIGGER IS STRONG ENOUGH.
Strength of material becomes a consideration when
engineering Outriggers. The greater the leverage requires
a stronger lever or O/R to prevent it from breaking.
Therefore the Greater Capacities are composed of 2
Elements
REINFORCEMENT PLATES FOR MULTIPLE OUTRIGGER
CONFIGURATION
A Cranes ability to resist tipping depends on
its STABILITY. It does not normally apply to a
stationary machine.
FULCRUM
WEIGHT OF MACHINE
WEIGHT OF
LOAD
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WHY DOES A CRANE LOSE
STABILITY?
44 LB.
44 LB.
440 LB.
440 LB.
44,000 LB.
44,000 LB.
4,400 LB.
4,400 LB.
SINCE OUTRIGGER SPREAD IS LIMITED BY STRENGTH OF MATERIALS,
DISTANCE AND WEIGHT ARE FACTORS OF STABILITY.
Capacity charts are divided
into several areas depending
on the capabilities of the crane.
The rough terrain cranes have
a 360 chart for lifting all
around the crane.
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There is also an over the rear chart for
some cranes. The capacities over the
rear are generally greater since the
front of the carrier acts as additional
counterweight.
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ON RUBBER (ON TIRES) a condition existing
anytime a machine is not on outriggers. Generally
used in connection with lifting capacities.
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It tells you which CAPACITIES are limited by....
It tells you which CAPACITIES are limited by....
STRUCTURAL STRENGTH
All Capacities above the Bold
line.
STABILITY
All capacities below the BOLD
line.
The difference between the two refers to whether you are
going to break the crane structurally or whether you are
going to tip it over.
Rated loads do not account for wind on lifted load or boom. It is
recommended when wind velocity is above 20 m.p.h. (32km/h),
rated loads and boom lengths shall be appropriately reduced. For
machines not in service, the main boom should be retracted and
lowered with the swing brake set in winds greater than 30 MPH.
Counterweight:
W/AUX. WINCH8900 LBS.
W/O AUX. WINCH.10000 LBS.
Powered boom length 30 ft. retracted to 94 ft.
extended.
LOAD RATING CHART INTERPRETATION
In the following pages are examples of a load chart, these
example charts may differ from the chart supplied with your
crane. Always use the load rating chart supplied with the
crane to interpret the conditions and limitations that exist
when making a lift with the crane. The determining factors
are lifted load, radius, boom angle, working position, hoist
line reeving, tire pressure, travel data, use of a jib, and other
special conditions that exist, such as wind velocity, soil
conditions, etc.
DEFINITIONS OF LOAD CHART TERMS
Lifted Load:
The lifted load is the total weight of all the items suspended
on the wire rope.
Example:
Hook block 750 lbs.
Slings 215 lbs.
Object Lifted 19,000 lbs.
Lifted Load 19,965 lbs.
Load Radius:
The horizontal distance from the axis of rotation before
loading to the center of the vertical hoist line or tackle with a
load.
Loaded Boom Angle:
The loaded boom angle is the angle between the boom base
section and the horizontal, after lifting the rated load at the
rated radius. The boom angle before loading should be
greater to account for deflections. The loaded boom angle
combined with the boom length give only an approximation of
the operating radius.
No Load Stability Limit:
The stability limit radius shown on the range diagrams is the
radius beyond which it is not permitted to position the boom,
when the boom angle is less than the minimum shown on the
applicable load chart, because the machine can overturn
without any load.
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 in the air.
Working Area:
Areas measured in a circular arc about the centerline of
rotation as shown in the diagram below.
Boom Side Of Crane:
The side of the crane over which the boom is positioned
when in an OVER SIDE working condition.
Whip
Line
Aux Nose
Extra Parts of Line
Hook Block
Slings
Swing Away Boom Extension
Headache Ball
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ROTATION LOAD RADIUS
WHAT IS
LOAD
RADIUS?
WHAT ARE
SOME WAYS
LOAD RADIUS CAN
CHANGE?
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RADIUS WILL CHANGE IF YOU..
1. BOOM UP OR DOWN
2. TELESCOPE IN OR OUT
3. SWING UNCONTROLLABLY
4. TRAVEL OVER ROUGH TERRAIN
WITHOUT THE LOAD TIED OFF
5. EXPERIENCE HIGH WIND
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RADIUS
TRAVELING OVER PULLING A LOAD
UNEVEN GROUND SIDEWAYS
Horizontal Force
AVOID SIDELOADING
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25,000lbs
Can a Cable with 13,000 lb. line pull lift
25,000 lbs. ?
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25,000lbs
But with multiple parts of line it can.
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Load ratings are based on freely suspended
loads. No attempt shall be made to move a
load horizontally on the ground in any
direction.
Over Front and 360:
The crane working position diagram is a view looking
straight down on the crane with the upper structure and the
boom removed. The front of the crane is always the end
opposite the engine.
Over Front when the crane is on outriggers is the area
inside the are bounded by lines from the centerline of rotation
through the front outrigger vertical jack cylinders.
St. Over Front (Straight Over Front) when operating on
tires means the boom and load must be positioned straight to
the front of crane and not swung to right or left.
360 means the load can be swung to any position around
the crane.
Cut - Offs:
Rated chart values of less than approximately 1,000 lbs for
on outriggers and side-stow jib are not shown. This is done
because the effects of wind, pendulum action, jerking, etc.,
can cause a tip over. Therefore:
Extending the boom or boom and jib combination into
unrated areas of the chart can cause tip over. Do not
operate at a longer radius than those listed on the
applicable load rating charts as tipping can occur
without a load on the hook.
HOIST TACKLE CHART
HOIST TACKLE CHART
HOIST TACKLE CHART
HOIST TACKLE CHART
HOIST TACKLE CHART
HOIST TACKLE CHART
This chart only represents the maximum
permissible hoist line load per parts of line.
You must refer to the proper lift charts for
machine rated loads.
HOIST TACKLE CHART
HOIST TACKLE CHART
HOIST TACKLE CHART
Proper tire pressure should always be
maintained
HOIST TACKLE CHART
HOIST TACKLE CHART
HOIST TACKLE CHART
This chart represents the weight for the hook
blocks depending on the number of sheaves
installed. This weight must be taken into
account when making load rating
determinations.
SET-UP
1. Crane load ratings are based on the crane being leveled
and standing on a firm, uniform supporting surface.
3:1
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SET-UP
2. Crane load ratings on outriggers are based on all
outrigger beams being fully extended or in the case of
partial extension ratings mechanically pinned in the
appropriate position, and the tires free of the
supporting surface. X
x x x
SET-UP.
3. Crane load ratings on tires depend on appropriate inflation
pressure and the tire conditions. Caution must be exercised
when increasing air pressures in tires. Consult Operators
Manual for precautions.
SET-UP
4. Use of jibs, lattice-type boom extensions, or fourth section
pullouts extended is not permitted for pick and carry
operations.
SET-UP
5. Consult appropriate section of the Operators and Service
Manual for more exact description of hoist line reeving.
6. The use of more parts of line than required by the load may
result in having insufficient rope to allow the hook block to
reach the ground.
SET-UP
7. Properly maintained wire rope is essential for safe crane
operation. Consult Operators Manual for proper
maintenance and inspection requirements.
8. When spin-resistant wire rope is used, the allowable rope
loading shall be the breaking strength divided by five (5),
unless otherwise specified by the wire rope manufacturer.
9. Do not elevate the boom above 60 unless the boom is
positioned in-line with the cranes chassis or the outrigger
are extended. Failure to observe this warning may result in
loss of stability.
OPERATION
1. CRANE LOAD RATINGS MUST NOT BE EXCEEDED. DO
NOT ATTEMPT TO TIP THE CRANE TO DETERMINE
ALLOWABLE LOADS.
2. When either radius or boom length, or both, are between
listed values, the smaller of the two listed load ratings shall be
used.
3. Do not operate at longer radii than those listed on the
applicable load rating chart (cross hatched areas shown on
range diagrams.)
4. The boom angles shown on the Capacity Chart give an
approximation of the operating radius for a specified boom
length. The boom angle, before loading, should be greater to
account for boom deflection. It may be necessary to retract
the boom if maximum boom angle is insufficient to maintain
rated radius.
5. Power telescoping boom sections must be extended equally.
6. Rated loads include the weight of hook block, slings, and
auxiliary lifting devices. Their weights shall be subtracted from
the listed rated load to obtain the net load that can be lifted.
When lifting over the jib the weight of any hook block, slings,
and auxiliary lifting devices at the boom head must be added
to the load. When jibs are erected but unused add two (2)
times the weight of any hook block, slings, and auxiliary lifting
devices at the jib head to the load.
7. Rated loads do not exceed 85% on outriggers or 75% on
tires, of the tipping load as determined by SAE Crane
Stability Test Code J765 a. Structural strength ratings in chart
are indicated with an asterisk (*).
8. Rated loads are based on freely suspended loads. No
attempt shall be made to drag a load horizontally on the
ground in any direction.
9. The user shall operate at reduced ratings to allow for adverse
job conditions, such as: soft or uneven ground, out of level
conditions, high winds, side loads, pendulum action, jerking
or sudden stopping of loads, hazardous conditions,
experience of personnel, two machine lifts, traveling with
loads, electric wires, etc. (side pull on boom or jib is
hazardous).
Derating of the cranes lifting capacity is required when wind
speed exceeds 20 MPH. The center of the lifted load must
never be allowed to move more then 3* off the center line of
the base boom section due to the effects of wind, inertia, or
any combination of the two. *"Use 2' off the center line of the
base boom for a two section boom, 3' for a there section
boom, or 4 for a four section boom.
10. The maximum load which can be telescoped is not
definable, because of variations in loadings and crane
maintenance, but it is permissible to attempt retraction and
extension if load ratings are not exceeded.
11. Load ratings are dependent upon the crane being maintained
according to manufacturer's specifications.
12. It is recommended that load handling devices, including
hooks, and hook blocks, be kept away from boom head at all
times.
13. FOR TRUCK CRANES ONLY: 360 capacities apply only to
machines equipped with a front outrigger jack and all five (5)
outrigger jacks properly set. If the front (5th) outrigger jack is
not properly set, the work area is restricted to the over side
and over rear area as shown on the Crane Working Positions
diagram. Use the 360 load ratings in the over side work
areas.
14. Do not lift with outrigger beams positioned between the fully
extended and intermediate (pinned) positions
15. Truck Cranes not equipped with equalizing (bogie) beams
between the rear axles may not be used for lifting on tires.
Truck Cranes equipped with equalizing beams and rear air
suspension should dump the air before lifting on tires.
CRANE LOAD RATING MUST
NOT BE EXCEEDEDD. DO NOT
ATTEMPT TO TIP THE CRANE TO
DETERMINE ALLOWABLE
LOADS.
When either radius or boom
length, or both, are between
listed values, the smaller of the
two listed load ratings shall be
used.
Do not operate at longer radii
than those listed on the
applicable load rating chart as
tipping can occur without a load
on the hook.
Cross hatched
areas shown on range diagrams
indicate the tipping area.
Extending into this area can
cause tipping with no load or
even tipping with that of pulling
down on boom head.
The boom angles shown on the
Capacity Chart give an
approximation of the operating
radius for a specified boom
length. The boom length. The
boom angle, before loading,
should be greater
Rated loads as shown on the lift chart pertain to this
machine as originally manufactured and equipped.
Modifications to the machine or use of optional
equipment other than that specified can result in a
reduction of capacity.
Do not operate at a radius or boom
length where capacities are not
listed. At these positions, the
machine may overturn without any
load on the hook. When either
boom length or radius or both are
between values listed, the smallest
load shown at either the next larger
radius or next longer or shorter
boom length shall be used
On Outriggers Using Main Boom
To determine the lift capacity when lifting off the main boom
with the outriggers set, use the following procedure:
1. Determine the weight of the load to be lifted.
2. Determine the weight of slings, rigging hardware and hook
block.
3. Calculate weight of lifted load.
4. Determine load radius, boom angle, and boom length.
5. Determine which load chart to use for your lift. Individual
load charts exist for the following lift configurations:
on outriggers, lifting off main boom with jib stowed or
not present
on outriggers, lifting off main boom with jib erected
but unused with jib pullout extension retracted or not
present
on outriggers, lifting off main boom with jib erected
but unused with pullout extension extended
on outriggers with jib erected, jib pullout section
retracted or not present, lifting over the jib
on outriggers with jib erected, jib pullout section
extended, lifting over the jib pullout section
on 16:00 X 25-28 PR tires, lifting over main boom
with jib stowed
on 20:50 X 25-24 PR tires, lifting over main boom
with jib stowed
6. If the auxiliary 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 chart rated capacity for
the boom length and radius.
In this example, the lifted load of 19,575 lbs. is less than the
rated load of 27,700 lbs. and can be handled.
All crane load ratings are based on nonuse of the travel
function while handling loads. However, cranes may be
utilized for pick and carry operations. Traveling with
suspended loads involves so many variables such as ground
conditions, boom length, momentum in starting and stopping,
etc., that it is impossible to devise a single standard rating
procedure with any assurance of safety. For such operations
the user must evaluate prevailing conditions and determine
safe practices, exercising precautions, such as the following:
1. The boom shall be carried straight over the front of the
crane.
2. Travel speed reduced to suit conditions.
3. Maintain specified tire pressures.
4. Avoid sudden starts and stops.
5. Provide tag or restraint lines to snub swinging of the load.
6. Keep the load as close to ground as possible.
7. Set the swing brake and swing lock.
8. The travel surface must be on a smooth level surface that
is capable of supporting the weight of the loaded crane. The
travel surface must also be free of holes or debris that can
cause crane instability.
These precautions are necessary to prevent a pendulum
effect of a swinging load. The results of this happening can
cause a machine tip over.
Any variation from the above conditions will require the
operator to consider the prevailing conditions and
reduce the lift capacities accordingly.
Always carry the load as near the ground as possible
with the minimum boom length necessary to carry the
load, and straight over the front with the swing brake
locked and swing lock engaged since the rear axle
oscillation is locked out when the boom moves off
center more than 10 deg. Travel over uneven terrain with
the rear axle oscillation locked out can result in
instability. Also, excessive boom length can result in
instability due to effect of uneven terrain and wind
pressure.
Insufficient tire pressure reduces the ON TIRES
capacity. Attempts to pick rated capacity without
properly inflated tires may cause crane to tip and/or
result in damage to tires and rims.
The axle lockout system should be bled and filled
whenever oil seepage, dirt or oil is detected at the
breather plug or on the rod.
Air in the axle lockout system decreases stability. Bleed and
fill the system IMMEDIATELY when ever this condition
occurs
Excessive high hydraulic oil temperatures cause rapid
deterioration of rubber components (hose, O-rings etc.).
A hydraulic oil cooler is required if high cyclic
operations (clam, concrete bucket, unloading) are
performed. If hydraulic reservoir temperature
reaches 200 deg. F, reduce the duty cycle. Stop
operations as required to prevent further increase in the
hydraulic oil temperature.
Terex Mobile Telescopic Level 1: Crane Safety
Crane Safety
Between 1997 1999
Total number of crane accidents 158
Mobile Crane accidents 115 (73%)
Fatalities 13 Fatalities (1 Operator, 12 non crane
operators)
Injuries 102 Non fatal injuries ( 23 Operators, 79
Non operators)
SAFETY IS EVERYONES RESPONSIBILITY
Between 1997-1999 Accident Causation
Unsecured Load 5.7%
Load Capacity Exceeded 27.6%
Ground not level or too soft 3.8%
Lack of Communication 22.9%
Electrical Contact 9.5%
Other 30.5%
What is wrong with this picture?
WARNING
DO NOT transport people with personnel carrying
equipment.
In many cases, there have been serious
injuries when people have been transported using
personnel carrying equipment (or even on the hook or
on loads). In these cases, they have no control over
crane movements and are not protected against
bumps or falls. Even the smallest of errors can have
fatal consequences.
In exceptional cases (for example, the use of
personnel cages which were not supplied by the
crane manufacturer), please consult the responsible
authorities/agencies concerning relevant permits,
fixed special conditions, safety regulations, additional
tests and demands on the crane and similar issues.
The use of such additional devices is then the
responsibility of the crane operator following valid
safety and accident prevention regulations.
Risk to life and limb. It is expressly forbidden to use the
crane for jumps with rubber ropes (bungee jumping). Using
the crane for such jumps represents a misuse of the crane
and entails extreme danger for life and limb.
Crane is designed for lifting loads. It is designed exclusively
for assembly operation and is not suitable for any other use,
i.e.,. unit load changeover or grab crane operation.
Manufacturer shall NOT be held liable for any damage which
results. Operator carries full responsibility for this type of
use.
Intended use also includes observation of all loads
tables and operating instructions, and particular with regard
to specified assembly sequence, and lubrication and
maintenance specifications.
If crane operation for part load handling or another type
of use is required, please contact crane manufacturer.
Use of two hoists to raise a load (2-hook operation) is not
permitted.
Special load cases are, however, permitted with
consultation of crane manufacturer
Note
The term Operating instructions refers to the operating
instructions and lubrication and maintenance instructions in
this manual.
Crane has been designed using state-of-the-art technology
and in accordance with recognized safety regulations.
Nevertheless, its use can lead to hazards for life and limb of
operator and third parties and/or damage to vehicle and
other objects.
Use crane only when it is in full working order and only for its
intended use, paying attention at all times to safety and
potential hazard, and in observance of operating
instructions. In particular, have any malfunctions which might
impair safety corrected immediately.
Many aspects of crane operation, inspection and testing are
discussed in standards published by the American National
Standards Institute. These standards are update on an
annual basis with addenda, which are sent by ASME to the
original purchasers of the standard. TEREX recommends
that you purchase and refer to the following standards.
ANSI/ASME B30.5 Mobile & Locomotive Crane
Additional information is covered by OSHA 1926.50 and
1910.180
OSHA B30.5-3.1 Qualifications for and Conduct of
Operators and Operating Practices.
Persons who have met the requirements of Para 5-3.1.2 (d)
and who are training for the type of crane being operated.
While operating, the training must be under the direct
supervision of a designated qualified operator.
States Currently requiring Crane Licensing
California
Connecticut
Hawaii
Massachusetts
Minnesota
Montana
Nevada
New Jersey
New Mexico
New York
Oregon
Rhode Island
Washington (as of 2010)
West Virginia
Cities Currently requiring Crane Licensing
Chicago
Los Angeles
New Orleans
New York City
Omaha
Washington, DC
OSHA 192.550(a)(16)
Bans equipment modifications or additions without the
manufacturer's approval. Any changes require alteration of
capacity, operation and maintenance plates, tags and decals,
and may not diminish the crane's original safety factor.
Two blocking occurs when the hook block makes contact
with the boom head sheaves.
This can cause the wire rope to break and drop the load
or can cause damage to block or sheaves.
It can be caused by hoisting up or by failure to let out line
when extending the boom or booming down.
Watch when stowing the boom in transport position.
Two Blocking
OPERATOR RESPOSIBILITIES
1. Read and understand Operators Manual
2. Make sure the machine is in proper order and that all
operation aids and warning signals are functioning
before operating.
3. Keep the machine clean, including all instrumentation,
window lights and other glazed surfaces.
4. Remove all oil, grease, mud, ice and snow from
walking surfaces.
5. Store all tools and other necessary items in proper
storage boxes.
6. Never lift a load without a load chart in the cab.
7. Know the load to be lifted.
8. Be alert, physically fit and free from the influences of
alcohol, drugs, or medications that might affect the
operators eyesight, hearing or reactions.
9. Keep people, equipment and material out of the work
area.
10. Signal person must be used when the operators vision
in blocked or working in hazardous areas such as
power lines or people.
11. Know about movements of other machinery, trucks and
personnel at the jobsite.
12. Keep a full charged fire extinguisher and first aid kit in
the cab at all times and be familiar with how to use
them.
13. Never permit people on the machine platform while the
machine is working.
14. Make sure everyone is in a safe place before moving
the hook, boom, load or outriggers.
15. Start and stop movements smoothly and swing at
speeds that will keep the load under control.
16. Keep at least two full wraps of wire rope on drum while
operating.
17. Use tag lines to keep loads under control.
18. Keep load close to ground.
19. Use shortest boom length possible.
20. Never leave a running machine unattended or load
suspended.
21. Always use outriggers in accordance with requirements
of load char and operators manuals.
21. Lowering boom to stow, insure boom is fully retracted if
not fully retracted it is possible to crush carrier cab.
22. Do not extend the boom while the boom is in the
stowed position.
SIGNAL PERSONS RESPONSIBILITY
1. Standard crane signals must be used and understood.
2. Assist the operator in a safe and efficient operation,
without endangering people or property.
3. Have a clear understanding of the work to be done.
4. Signal people must place themselves where they can
be clearly seen and where they can safely observe the
entire operation.
RESPONSIBILITY OF ALL CREW MEMBERS.
1. Unsafe conditions or practices must be corrected.
2. Obey all warning signs.
3. Watch out for your safety and the safety of others.
4. Know and understand proper machine erection and
rigging procedures.
5. Alert operator and signal person of dangers, such as
power lines, unstable ground etc.
MANAGEMENT RESPONSIBILITY
1. Operator must be competent, physically fit and if
required licensed.
2. Operator, signal people and riggers must be trained in
correct crane operation and use.
3. Operator and signal people must know standard crane
signals.
4. Have a supervisor at job site who is responsible for job
safety.
5. Crew members given specific safety responsibilities
and instructed to report any unsafe conditions to
supervisor .
6. Supply the weight of the load to be lifted to the
operator.
7. Verify that all crew members are familiar with OSHA,
ANSI B30.5 9 (Safety and Health Regulations for
construction) requirements as well as instructions in
manuals.
Standard hand signal for controlling
crane operation
Decals markings and warning.
Warning
All safety instructions on the crane must be maintained in complete
and legible form. Failure to comply could result in injury and
damage to equipment.
DANGER- Intermediate hazards which WILL result in severe
personal injury or death.
Warning- Hazards or unsafe practices which COULD result in
severe personal injury or death.
CAUTION- Hazards or unsafe practices which COULD result in
minor or personal injury or product
Power line Safety
Know the location and voltage of all overhead power lines at
the jobsite before operating or working with any crane.
Assume that all power lines are energized and maintain the
minimum clearance required by OSHA at all times:
Power line voltage----------------Minimum safe
phase to phase (kV)---------------clearance (feet)
50 or below------------------------------ 10
Above 50 to 200------------------------ 15
Above 200 to 350----------------------- 20
Above 350 to 500----------------------- 25
Above 500 to 750----------------------- 35
Above 750 to 1,000---------------------45
If at any time the crane is working within a booms length of
the prohibited zone a qualified signal person whose sole
responsibility is to verify clearance is maintained shall be in
constant contact with the crane operator.
Terex Mobile Telescopic Level 1: HYDRAULIC SYMBOLS 101
HYDRAULIC SYMBOLS 101
Terex Mobile Telescopic Level 1: Hydraulic Symbols 101
Crossing or Joining
The shortest distance between two components that are connected
is a straight lineand it is desirable to draw it that way to avoid
following a line all over the diagram just to get back near where you
started. So we do cross lines that arent connected to each other
when it is necessary.
There are two accepted systems because the question to loop or
not to loop could not be resolved.
To show that two crossed lines are not connected, we put a short
loop in one of the lines at the intersection. However, it is just as
correct to simply to let the lines cross.
A connection between two crossing lines must be designated by
placing a dot at the crossing, if loops are used to designate
crossing. The dot is omitted if no loops are used for crossing, but
all joining lines must be shown as tees. Cross connections are not
permitted in this no dot system. Only one system or the other shall
be used throughout a diagram.
SYSTEM 1
TO LOOP
SYSTEM 1
NOT TO LOOP
PUMP SYMBOLS
Would you believe that pump symbols are even easier than
reservoir symbols? The basic symbol is a circle with a black
triangle pointing outward.
SYSTEM 1 TO LOOP
SYSTEM 1 NOT TO LOOP
FIXED DISPLACEMENT
VARIABLE
DISPLACEMENT
VARIABLE
DISPLACEMENT
PRESSURE
COMPENSATED
VARIABLE
DISPLACEMENT
There are probably a score or more of basic designs of pumps, but
they all have the same function, and one basic symbol is all we
need to depict that function.
The black triangle will be used with many symbols to indicate that
they are either receivers or sources of energy. It points out from a
source; into a receiver.
The pressure line from the pump is drawn from the tip of the
triangle; the suction line is drawn opposite it. Thus, the triangle also
indicates the direction of flow. If a pump is reversible, it will have
two triangles one pointing out of each port.
Port connections to the pump (or any other component will the
exception of the reservoir) are tat the points where the lines touch
the symbols.
A variable (or adjustable) component is designated by drawing an
arrow through it at 45 degrees.
Optional Symbols
Occasionally it may be desirable to show the prime mover and the
direction of rotation. If the prime mover is an electric motor, it
appears as a circle with an M in the center. A heat engine
(gasoline or diesel) is shown as two squares; one inside the other.
A curved arrow crossing a line from the pump symbol indicates the
direction of rotation where required.
PUMP ROTATION
RH LOOKING AT SHAFT
ELECTRIC FIXED
MOTOR DISPLACEMENT
PUMP
MOTOR SYMBOLS
Motor symbols also are circles with black triangles; but with
triangles point in to show that the motor is a receiver of pressure
energy. One triangle is used In a non-reversible motor symbol; two
are used for a reversible motor.
UNI-DIRECTIONAL
MOTOR
REVERSIBLE
MOTOR
Displacement Controls
A displacement control for a pump (or motor) is drawn beside the
symbol. As you can see, the control symbol sometimes has a
resemblance to the control; for instance, the lever has a knob.
The pressure compensator symbol is a small arrow parallel to short
side of symbol. This symbol is used with any pressure
compensated component, and may adjoin the symbol or be placed
right on it.
PRESSURE LE VER
COMPENSATED CONTROL
PEDAL MECHANICAL
OR TREADLE SERVO
VALVES
VALVES
The direction of flow is easily evident with a single triangleit is
the way the triangle points. In the reversible motor, we must refer to
the pump and valve symbols to trace the flow direction. The arrows
outside the lines show the flow directionalways away from the
pumps pressure port and into the motor port that is connected to
the pressure line. The opposite port then must be discharging back
to the tank.
Controls symbols and rotation direction indicators used with pump
symbols also apply to motors.
CYLINDER SYMBOLS
A cylinder symbol is a simple rectangle representing the barrel
with a T-shaped representation of a piston and rod. The symbol
can be drawn in any position.
If the cylinder is single-acting, there is only one hydraulic line
drawn to the symbol. Also, the end of the symbol opposite the port
is left open.
A double-acting cylinder symbol has both ends closed and has two
lines meeting the symbol at the port connections. A double end rod
cylinder has a rod line extending from each end.
Cylinder cushions are drawn as smaller rectangles against the
piston line. If the cushion has an adjustable orifice, the slanted
arrow is drawn across the symbol.
PORTS
PORTS
SINGLE-ACTING
DOUBLE END ROD
NON-
ADJUSTABLE
ADJUSTABLE
CUSHIONED
Flow to and from a cylinder must be traced by observing which
lines it is connected to. There is no provision in the symbol for flow
direction. This really not a problem, though. Were about to see that
valve symbol are copiously decorated with arrows indicating the
direction of flow.
DOUBLE-ACTING
PORTS
Normally Open
When the arrow connects the two ports, we know that the
valve is normally open.
It closes only when pressure overcomes the spring force.
Relief Valve
We diagram a relief valve with a normally-closed symbol
connected between the pressure line and tank. The flow
direction arrow points away from the pressure line port and
toward the tank port. This shows very graphically how a relief
valve operates. When pressure in the system overcomes the
valve spring, flow is from the pressure port to the tank port.
PRESSURE LINE
RELIEF VALVE
PUMP
We dont attempt to show whether this is a simple or
compound relief valve. All thats important is to show its
function in the circuit.
PRESSURE CONTROL SYMBOLS
A pressure control valve, youll recall, is infinitely positioned
between two flow conditions. Its basic symbol is a square with
external port connections and an arrow inside to show the direction
of flow. Usually this type valve operates by balancing pressure
against a spring, so we show a spring at one side of the symbol
and a pilot pressure line at the other.
INLET INLET
SPRING PILOT PRESSURE
OUTLET OUTLET
Normally Closed
A normally-closed valve, such as a relief or sequence, is shown
with the arrow offset from the ports toward the pilot pressure line.
This indicates that the spring holds the valve closed until it is
overcome by pressure. We mentally visualize the arrow moving
over to complete the flow path from inlet to outlet when pressure
rises to the valve setting.
The actual function of the valve is shown by its connection into the
circuit diagram.
Sequence Valve
The same symbol is used for a sequence valve. This time, though,
the inlet port is connected to a primary cylinder line; the outlet port
to the secondary cylinder line. Pilot pressure from the primary
cylinder line sequences the flow to the outlet port when it reaches
the setting of the valve.
Since the sequence valve is externally drained. We have added a
drain connection to the symbol at the drains location in the valve.
RELIEF VALVE PUMP
DIRECTIONAL VALVE TO
PRIMARY
CYLINDER
SEQUENCE VALVE
TO
SECONDARY
DRAIN CYLINDER
Sequence and Check Valve
Remember that with this connection a sequence valve must be
used with a check valve for free return flow when the cylinders are
reversed. The next diagram shows a simplified check valve symbol
and its parallel connection. As you are looking at it, free flow is to
the up.. Away from the V which represents a seat.
In the top view, we see the check valve as a separate unit when
the check valve is built into the sequence valve, we enclose both
valves with a box called an enclosure.
An enclosure is used to show the limits of a component or an
assembly containing more than one component. It is an alternate
long-and-short dash line. External ports are assumed to be on the
enclosure line and indicate connections to components.
A- SEPARATE UNITS
DIRECTIONAL
VALVE
TO PRIMARY
CYLINDER
NO FLOW
DIRECTION
FREE FLOW
DIRECTION
TO SECONDARY
CYLINDER
CHECK VALVE
SEQUENCE
VALVE
PUMP
RELIEF
VALVE
B-INTEGRAL SEQUENCE
AND CHECK
COMPONENT ENCLOSURE
Counterbalance Valve
A counterbalance valve is a normally closed pressure control within
integral check valve. For a directly controlled valve, we use the
same symbol with the primary port connected to the bottom port of
the cylinder and the secondary port of the directional valve. The
drain connection isnt shown, because the valve is internally
drained. If valve body has two primary ports, a complete symbol
should show one of them plugged.
PLUGGED PORT
TO
DIRECTIONAL
VALVE
COUNTERBALANCE
ENCLOSURE AND CHECK VALVE
Relief (Brake) Valve
A relief valve with auxiliary remote control connection can be used
as a brake valve when connected between the motor outlet and the
directional valve. It looks like the counterbalance valve diagram,
except that it has two pilot control connections. A low pressure in
line A will open the valve to permit free flow from the motor
through the valve to B, but higher braking pressure will be
required from the motor to open the valve internally if driving
pressure A is removed.
A
B
TO
DIRECTIONAL
VALVE
Pressure Reducing Valve
The normally-open pressure reducing valve is diagrammed below.
Outlet pressure is shown opposing the spring to modulate or shut
off flow when the valve setting is reached.
Flow Control Symbol
The basic flow control valve symbol (seen following page) is a
simple representation of a restriction. If the valve is adjustable, the
slanted arrow is drawn across the symbol.
NON-ADJUSTABLE
ADJUSTABLE
A complete adjustable, pressure compensation flow control with
built in by-pass is diagrammed in diagram below. The short vertical
arrow is the symbol for pressure-compensated, as you already
know.
ADJUSTABLE PRESSURE
FLOW CONTROL COMPENSATED
Flow controls applied to meter-out, meter-in and bleed-off circuits
shown to the right.
FROM PUMP AND
DIRECTIONAL
VALVE
RETURN
TO TANK
FROM PUMP AND
DIRECTIONAL VALVE
TO RETURN
FROM PUMP AND
DIRECTIONAL VALVE
TO RETURN
DIRECTIONAL CONTROL SYMBOLS
A directional control valve symbol uses a multiple envelope system
that has a separate rectangle for each position. All the port
connections are made to the envelope that shows the neutral
condition of the valve. Within each envelope are arrows showing
the flow paths when the valve is shifted to that position.
One Way Valve
You have already seen the simplified symbol for a check valve.
Compare it with the composite symbol (below) and decide for
yourself which will get the most use. However, the multiple
envelope system does provide a simple way of showing function
when applied valve has several flow paths.
NO FLOW
FREE FLOW
NO FLOW FREE FLOW
SIMPLIFIED
COMPOSITE
Unloading Valve
An unloading valve symbol (below) has two envelopes. In the
normal closed position, flow is shown blocked inside the valve. The
spring control is placed adjacent to this envelope to show that the
spring controls this position.
External pilot pressure is indicated against the bottom envelope to
show that this is the flow condition when the pilot pressure takes
over. With the lower envelope superimposed on the other, the flow
path arrow connects the pump outlet to the reservoir.
Four-Way Valve
an ordinary four-way valve has two envelopes if it is a two-position
valve (next page) or three envelopes if it has a center position. The
actuating control symbols are placed at ends of the envelops. The
extreme envelops show the flow conditions when their adjacent
controls are actuated.
FROM
PUMP
TO PILOT
PRESSURE SOURCE
A
P
B
T
A
P
B
T
A
P
B
T
TWO POSITION, CONTROLLED BY
EXTERNAL PILOT PRESSURE
TWO POSITION, CONTROLLED BY SOLENOID
SOLENOID
CONTROL
SYMBOL
SOLENOID CONTROL
WITH INTERNAL
PILOT PRESSURE
THREE-POSITION, SPRING-CENTERED, CLOSED
CENTER CONTROLLED BY SOLENOID
WITH INTERNAL PILOT PRESSURE
The manual, lever, pedal, and mechanical control symbols pictured
earlier are used as appropriate with directional valves. Spring
symbols, pilot lines, solenoid symbols and internal-pilot black
triangles also are used as appropriate.
Mobile Directional Valves
The symbol for a mobile directional valve (below) resembles a four-
way valve symbol, but it has added connections and flow paths to
represent the by-pass passage. There is a separate envelope for
each finite position and connections are shown to the center or
neutral position. A manual lever or neutral position. A manual lever
control with centering springs is shown at each end.
Complete symbols for B, C, and T spools in diagram below. Views
B, C, and D. These illustrations show only the spools. A complete
mobile valve bank would also show relief valves and internal
connections within an enclosure.
MANUAL CHECK VALVE
CONTROL IN PRESSURE LINE
SPRING
CENTERED
BY-PASS PASSAGE
VIEW A
D DOUBLE ACTING SPOOL
VIEW B
B MOTOR SPOOL
P
T
A B
P
T
A B
VIEW C
C FLOAT SPOOL
P
T
A B
VIEW D
T SINGLE ACTING SPOOL
ACCESSORIES
Fluid conditioners are represented as squares that are turned 45
degrees and have the port connections to the corners. A dotted line
at right angles t port connections tells us the conditioner is filter or
strainer . A cooler symbol has a solid at right angle to fluid line with
energy triangles (indicating heat this time) pointing out.
FILTER OR STRAINER
COOLER
An accumulator appears as an oval and may have added inside
details to indicate spring load, gas charge, or other features.
SPRING LOADED GAS CHARGED
SYMBOLS TABULATED
In these pages, we have reviewed the major graphical symbols and
how they are used. We couldnt attempt to cover every possible
symbol and combination; that would take several books the size of
this one.
For your reference, all the basic hydraulic symbols are tabulated in
the next few pages
Description Symbol
Reservoir: The hydraulic reservoir is designed to store,
cool, and clean the machines hydraulic oil supply. The
vented reservoir allows atmospheric pressure to push the oil
into the hydraulic pumps inlet ports.
Hydraulic Return Lines: Are either terminated. 2. below
fluid level. 2 above fluid level.
Description Symbol
Pump: Hydraulic pumps convert mechanical energy
transmitted by a power source, into hydraulic working
energy, flow. In some applications a variable displacement
pump may be used. Form 2.
Power Source: A power source can be in the form of
combustion engine. Form 1 or electric motor form 2.
Both provide power to operated the hydraulic pumps either
as a main power source or an emergency.
Description Symbol
Hydraulic Motor: Convert the working energy of the
hydraulic system into mechanical energy. Hydraulic motors
are positive displacement and are either vane, Gear or
Piston..
Pump Disconnect: Used to disconnect pump from power
source for extended travel, repairs, cold weather starts.
Description Symbol
Continuous Line: Supply line or Return line depending on
direction of oil flow..
Connecting Lines: Branch lines connected to main line.
Line Crossing: A line crossing over another line, but not
connected.
Dashed Line: Pilot pressure
Description Symbol
On-off (manual shut-off)
Line, Flexible
Line to vented manifold
Plug or plugged connection
Description Symbol
Direction of flow
Flow control, adjustable (temperature and pressure
compensated)
Two position
Two connection
Two position
Three connection
Description Symbol
Two position
Four connector
Three position
Four Connection
Two position
In transition
Valve capable of infinite positioning
(horizontal bars indicate positioning
Ability)
Description Symbol
Spring
Manual
Push button
Push-pull lever
Description Symbol
Pedal or treadle
Mechanical
Detent
Pressure compensated
1
Description Symbol
Solenoid, single winding
Reversing Motor
Pilot pressure
Remote supply
Internal supply
Rotating shaft
M
Description Symbol
Enclosure
Pressure gauge
Electric motor
Accumulator, spring loaded
M
Description Symbol
Accumulator, spring loaded
Heater
Cooler
Temperature
controller
Description Symbol
Dotted Line: Case drain or load sense.
Chain Line: Enclosure of two or more functions contained in
one unit. (outrigger control),
Pressure Transducer: Is a hydraulic/ electrical device
located in the lift cylinder circuit. It is used in conjunction
with the cranes load moment indicator system. (LMI).
Description Symbol
Filter: Removes contamination from hydraulic system.
Filter with Bypass Valve: The bypass valve allows the oil
to bypass the filter if it is ;plugged or the oil is too thick to
pass through filter.
Accumulator: used in a hydraulic circuit to either develop
system flow or absorb system shock. Most accumulators are
charged with nitrogen gas.
Description Symbol
Check Valve: Is designed to create back pressure in a
specific circuit. Swing, oil cooler.
Orifice: A fixed restriction that functions as a flow control
device . Designed to reduce pressure and oil flow in specific
circuits.
Adjusted Orifice: An inline restriction that functions as a
flow control device. This device is manually adjustable for
fine tuning pressure and flow rate.
Hydraulic Oil Cooler: Because of viscosity, friction, and
changing direction, hydraulic oil generates heat during
operation. To keep the oil within the required operating
temperature range, air coolers are installed in the system to
aid in the cooling process
Description Symbol
Temperature Switch: An electric switch that regulates the
temperature of hydraulic oil.
Hydraulic Pressure Switch: Senses hydraulic pressure for
the purpose of energizing electrical components. (Relay
coils, indicator lights.
Flow Switch: Provides ground for a specific electric circuit,
shown in normal position it will illuminate an indicator light
indicating a fault. When operating properly oil flow will enter
the value and at the same time as pressure builds in pilot
line shifting the spool open thus opening the switch contacts
and turning off indicator light.
Description Symbol
Relief Valve: Installed in a hydraulic circuit to protect the
system from being over pressurized.
Pressure Reducing Valve: Regulates max pressure
allowed into individual circuits. (swing brake, function
controllers).
Shuttle Valve: The inlet port connected to the high pressure
is automatically connected to the outlet port, while the other
port is closed. Used to direct maximum pressure to
components depending on application,
Description Symbol
Manually Operated: Two way valve, the oil flow has two
paths to travel, in the neutral position as shown, the oil, once
enough pressure is built to unseat the check, the oil can flow
to tank.
Pneumatic: One position valve, once the spool is shifted the
oil has a path to flow to function, in the neutral position is
blocked.
Pilot: Operated one position valve, same as pneumatic
operated valve, only the spool is shifted by pilot oil.
Description Symbol
Electric Operated: Two way valve, once the spool is shifted
the oil has two paths to travel, to the specific circuit and an
path for oil to return to tank.
Electric Operated: One position valve, once the spool is
shifted, the oil has a path to flow to function, in the neutral to
flow blocked, this spool is shifted electrically.
Brake Valve: Supplies hydraulic oil to swing brake
assembly to assist the springs to apply pressure to stop the
rotation of the superstructure, during crane operation.
Description Symbol
Open Center Cylinder Spool: Used in the directional
control valve that controls oil flow to and from a cylinder
function. When in the neutral position, as shown here, the oil
is trapped in the circuit. With the crane running and the gear
pump engaged, and the spool is in neutral position. The oil
will flow through the center of valve (A) and returned to tank
(B). This spool is shifted with a control lever. (outrigger, lift,
telescope).
Open Center Motor Spool: Used in the directional control
valve that controls oilf low to and form a hydraulic motor
function. When in the neutral position, as shown here, the
circuit is open to a return line to tank. This prevents build up
of hydraulic oil back pressure in the motor circuit. (hoist,
swing).
Description Symbol
Closed Center Cylinder Spool: Used in a pressure
compensated directional control valve that controls oil flow
to and form a cylinder function. Oil in the cylinder circuit is
trapped in the circuit when the spool is in the neutral
position. If no functions are being operated the oil cannot
pass through the center of the valve back to tank. Instead
the unloader valve cartridge spool is shifted with hydraulic
pilot pressure. (lift, telescope).
Closed Center Motor Spool: Function the same as the
closed center cylinder spool above, except that this spool
has a open port for oil flow back to tank. This prevents build
up of back pressure in the motor circuit.
Description Symbol
Single Acting Cylinder: Can be extended hydraulically or
pneumatically depending on application. The cylinder is
retracted utilizing a spring. (Axle disconnect, park brake)
Double Acting Cylinder: Extended and retracted
hydraulically. (Steer).
Double Acting Telescope Cylinder: With holding valve.
The rod of the cylinder is anchored, as oil flow unseats the
one way check valve in the holding valve (A), the oil flow to
the piston side of the cylinder (B) filling up with oil, causing
the barrel to move outward, the boom section that is
anchored to is pushed outward.
Description Symbol
Hydraulic Swivel: The hydraulic swivel is designed to allow
360 degree rotation, while supplying oil to all superstructure
functions.
Terex Mobile Telescopic Level 1: Working Safety with Fluid Power
Working Safety With Fluid Power
Terex Mobile Telescopic Level 1: Working safely with fluid
power
Working safely is partly a state of mind. In addition to working
with safety in mind, an individual must be trained to
understand the hazardous involved with working on
machinery in order to anticipate and avoid hazardous actions
or conditions.
Fluid power manufacturers, distributors, and users have
always been concerned with the safety of persons using fluid
power systems. More attention must be given to the subject
considering the widespread use of fluid power equipment and
the wide range of skills of persons using and repairing this
equipment. Safety concerns vary widely as do the
applications of hydraulics and pneumatics. This article
discusses some of the common hazards associated with fluid
power systems. There may be omissions due to the broad
subject area. The article is meant to be a starting point for a
discussion of hazards and how to minimize or eliminate them.
Here are some important safety practices for hydraulic
and pneumatic mechanics, technicians, and equipment
operators.
1. Safety glasses and other protective face shields should be
worn as necessary.
2. Hearing protection must be worn in areas with noise levels
greater than 80dBA.
3. Protective clothing should be worn as required especially
when working on systems that have high fluid temperatures.
4. Safety shoes and hard hats should be worn in hazardous
areas.
5. Communicate with co-workers. When working with other
people, it is essential to communicate your intentions to them.
Let them know what parts of the equipment could move
during testing and troubleshooting. Make certain that no one
takes any unauthorized action. Post warnings and use
lockouts where possible.
6. Practice good housekeeping. Do not let tools and
disassembled components accumulate in the work area
where they can create a tripping hazard.
Oil on the floor is an extreme hazard at any time. Take the
time to apply oil absorbent and clean up the spill.
7. Never test to atmosphere! Never just put a hose into a
bucket or hold onto an airline and test for flow. The flow rate
may suddenly increase when a valve opens or a failed
component bypasses, causing an unrestrained hose end to
whip. Always test for flow by using a properly installed flow
meter.
8. Use lockouts. Isolate and lockout the electrical control
system and the electrical power supply. Each person working
on the system must add their own lock to any/all lockout
devices.
9. Storage of components and materials should be such that
there is no danger of items falling or shelves tipping.
10. Components and items that contain fluid must be drained
and stored in a manner that prevents fluid leakage onto floors.
power
11. Hydraulic fluid and lubricants that leak or are spilled
should be dealt with immediately using proper procedures.
When loosening hydraulic components and conductors,
always have rags ready to contain a spray leak and buckets
ready to catch any drips.
12. Many hydraulic fluids are flammable. Precautions are
required when using flammable fluids in areas that have
heaters, heating elements, and incandescent light bulbs that
could break or come into contact with the fluid, should a spill
occur.13. Safe working pressures of components and fluid
conductors are a major concern. Many hoses and
components are not marked or are marked with labeling or
printing that can be covered or worn off. Though this may not
be a concern for new manufacture, it is a problem with repair
of systems and the part of the industry that builds systems
with used components. If you can not identify the safe working
pressure of a component or fluid conductor, do not use it. If
you do not know the working pressure of a system, find out,
and use only components and fluid conductors that are rated
for or above this working pressure. Fitting types should be
matched carefully as some o ring type fittings and pipe
fittings can be assembled mismatched. They can leak, spray
dangerous jets of fluid, or blow out of the other fitting or boss.
14. Fluid injection through the skin is a danger to all persons
using hydraulic fluid or any material that is pressurized.
Pressures in the range of 400 PSI or higher, depending on
conditions, can cause injections. An injury caused by
pressurized fluid is serious. If you are injured or even suspect
an injury, go to a hospital emergency room and tell the doctor
that you suspect a fluid injection injury. Treatment must be
started immediately. An injection injury can occur when a
finger, hand, or other body part comes in contact with a
stream of pressurized fluid. A jet of fluid can come from a
crack in a component, fitting, or fluid conductor. It can also
come from a pin hole in a hose, from between bolted flanges,
from a loose fitting, from a failed seal, or from a component or
conductor that bursts. Components can burst from over
pressure, improper application, or metal fatigue. Other
sources of injection hazard are; pressure cleaning systems,
grease and lubrication dispensing systems, and airless paint
spray equipment. Never point a spray gun, grease gun or
wash gun at yourself or anyone else. Never place your finger,
hand, or any part of your body in front of a fluid spray or
dispensing gun. Never clean yourself with a pressure washer
or a pneumatic blow gun. Never look into the orifice of a spray
or wash gun that is plugged. Never tighten a leaking, fluid
conductor or bolted flange while the system is pressurized. A
crack in a fitting or conductor could be the source of the leak.
The additional stress of tightening can cause a burst type
failure. You could be injected with fluid or injured by flying
parts. Wearing a glove or holding a rag or towel over a jet of
fluid will not prevent an injection injury.
15. Air-oil or diesel explosions in hydraulic systems are rare,
though they do occur. These explosions are caused by rapid
pressurization of a component or gauge that contains air. The
heat of compression ignites the oil vapors and explodes. An
air-oil explosion can result when an elevated implement or
load is dropped uncontrolled, because a cylinder contains air
following assembly or repair. Cylinders and other components
power
15. Air-oil or diesel explosions in hydraulic systems are rare,
though they do occur. These explosions are caused by rapid
pressurization of a component or gauge that contains air. The
heat of compression ignites the oil vapors and explodes. An
air-oil explosion can result when an elevated implement or
load is dropped uncontrolled, because a cylinder contains air
following assembly or repair. Cylinders and other components
containing air should have the air removed through a proper
bleed down procedure. Safety case type gauges should be
used where ever possible. During startup of new and repaired
systems pressure should be increased gradually to prevent
explosion and to reduce the danger of fluid spills.
With forethought and planning, many accidents can be
avoided.
16. Assume pressure is present. Sources of pressure include
charged accumulators, loaded actuators, springs under load,
system capacitance (trapped pressure), and compressed air
trapped in or unbled from the system.
Relieve system pressure. Actuate all directional control valves
to all positions so that all lines will have a chance to discharge
to tank. Note that in the case of pilot-operated valves, the pilot
pressure that is necessary to accomplish this task will not be
present and the valve will not shift, preventing trapped
pressure from discharging to tank. Never tighten or loosen
lines while the system is still operating.
If it is necessary to remove pipe flanges, 4-bolt flanges, or
subplate mounted components, always release the torque on
the bolts that are furthest from first. This way, if pressure is
present, the fluid stream will be directed away from you.
Relieve the pressure on both sides of pressure intensifiers.
Hydro-pneumatic accumulators with a gas precharge can be
dangerous. Accumulators should be precharged with nitrogen
or other inert gas. Never use oxygen because a violent
explosion will occur. When accumulators are installed in a
system, the system must include an automatic bleed down
valve that vents the pressurized fluid to reservoir when the
power supply is shut down. In some clamp circuits the
pressure is maintained with accumulators for long periods
while the power supply is shut down. In this type of circuit a
manual bleed down valve can be used, but proper warning
labels as to the danger of the potential energy that is stored in
the accumulators. The proper bleed down procedure should
be posted. In an accumulator circuit or any circuit where
pressurized fluid, liquid or gas, may be trapped, precautions
should be taken when adjusting valves or actuating directional
controls. Trapped fluid can cause actuators to move even
when the power supply is off. Accumulators should be bled
down on the hydraulic side and the precharge exhausted
before any service is started. During the disassembly of
accumulators, or any component that may have trapped
pressurized fluid, if a fitting or fastener requires more wrench
torque than your judgment tells you that should be necessary,
inspect the system for retained pressurized fluid. Pressurized
fluid may be placing a load on the threads, thereby increasing
the torque required to disassemble the fitting. When
precharging piston type accumulators, make certain that the
power
piston is located at the hydraulic end of the bore. This will
prevent the piston from slamming against the end cap during
the precharging process. When removing the piston from an
accumulator, it should be pressed out. Using compressed air
to blow the piston out is dangerous because the piston
becomes a flying projectile.
17. Hydraulic cylinders that require disassembly should be
pulled apart with a winch. Using compressed air to force the
rod, piston and end cap out is dangerous for two reasons, the
first being that the entire piston and rod assembly will be
ejected with uncontrollable force. The second is, if the piston
should be separated from the rod, the rod will shoot out of the
end cap with destructive force.
18. An explosion hazard is present when reservoirs, tanks,
drums or any component that contains, or has contained, a
combustible or flammable material is modified by cutting or
welding. Even a material that has a minor component that is
combustible, such as a cleaning agent, can produce explosive
gasses. When flame or arc cutting, or welding, is attempted
on such a component, a violent explosion can occur. Heat can
produce additional vapor that can ignite and explode.
High pressure leaks can turn into a blow torch if ignited. If the
leaking oil is hot, severe burns may result.19. Transferring
hydraulic fluid from drums to reservoirs should be done with a
drum pump or by gravity flow. The practice of pressurizing
drums with compressed air is dangerous. Pressurization kits
are manufactured for this purpose. They have a
nonadjustable air regulator that limits the drum pressure to
approximately 2-psi. The downstream line from the regulator
is fitted with a relief valve for safety, should the regulator fail.
20. Rotating shafts, couplings, universal joints, gears,
sprockets, etc., require guards and shields. Never place your
finger or hand on a rotating part. Keep clothing and cleaning
towels away from rotating parts. When using a tachometer,
position yourself so that if the tachometer should slip off of the
shaft, your fingers or hands will not enter a fan, flywheel or
other moving parts.
21. Troubleshooting a machine that has an interrupted
machine cycle may result in personal injury or machine
damage. During the troubleshooting process, manual
overrides on directional controls, limit switches, or other
controls may be actuated the cycle may complete or motion
may occur out of sequence, thereby causing a hazardous
situation. Study the machine and make certain that tools,
equipment, and persons are clear of possible damaging
motion should an actuator move. Check for safe and clear
operation anytime you do anything that could cause actuators
to move. Try to move actuators to an unloaded or an un-
tensioned position. If necessary, block or wedge a load to
keep it from pressurizing a system.
22. Reservoirs may build up pressure from thermal
expansion. On some machines reservoirs are pressurized to
overcome pressure drop in pump inlet systems. Before
servicing any hydraulic system, be sure to relieve the
reservoir pressure by slowly opening the filler cap or venting
valve provided for this purpose. The next step is to move all
power
control valves through all positions to relieve trapped
pressure. Remember that without adequate pilot pressure,
pilot operated directional valves will not shift even if the pilot
valve is manually shifted. Implements and components not
pinned or blocked may move when directional valves are
shifted. If the reservoir cap is rapidly removed, the
depressurization may cause a blow out of fluid. You may
become soaked by oil or possibly be burned by hot oil.
Working on a system that has not been depressurized can
produce a major oil spill. Removing a hose, tube, or
component will allow the pressure in the reservoir to force
fluid out, in some cases spilling the entire contents of the
system. When removing a hose or tube, any implement that is
held by hydraulic lock, and not pinned or blocked, can move
or drop when the fluid is vented. Pressurized reservoirs can
cause machine motion even after the machine is shut down.
Never place yourself on either side of a compactor piston, a
mold, die, clamp, jaws, or any parts that could move and
pinch or crush you.
23. Maintenance or repair may require a vehicle or machine to
be placed on blocks or jack stands. It is usually safe to work
near or under a machine that is properly blocked.
Be sure that no other vehicle will be operated in the area.
There have been fatalities caused by a second vehicle hitting
a machine on blocks, dropping it off the blocks.
Hydraulic systems and compressors can run hot. Always
touch lightly and carefully at first, using the back
of your hand. It is a normal reaction to close the hand and grip
tightly when something hot is touched. By using the back of
your hand, you will not inadvertently grasp the hot object. If
necessary, use gloves if you cannot wait for the system to
cool down.
24. In hose applications, use nonconductive hose when
replacing nonconductive hose on boom trucks and pole saws.
Contact with electrical lines can be deadly. Use conductive
hose on applications where grounding is
required, such as paint spray and transferring flammable
materials. Static electricity can cause fire and electric shock.
Working safely is partly a state of mind.
25. Hydraulic presses can cause injury when performing
heavy pressing jobs. The press can eject parts at high
velocity. Cast iron parts can burst when pressing shafts or
pins into interference fit bores.
26. Pumps or motors should not be picked up or held by the
shaft. Keyways are extremely sharp and can cause deep cuts.
27. Carrying parts with oily hands can cause the parts to slip
out of your grasp and fall, resulting in a foot injury.
28. Self-retracting hose reels that are used for dispensing
lubricants, and are used on some extension booms, have
powerful band type springs. When servicing hose reels, tie the
spring securely with wires if it requires removal from the
assembly.
power
cause fires, some tank filling procedures require grounding
the vehicle or tank before any attempt is made to fill or
remove material.
In summary, working safely is partly a state of mind, and
partly being educated about the possible hazards that may be
encountered. Before undertaking a task, analyze the task and
determine what hazards might be encountered and what
actions to take in order to negate these hazards. Make
contingency plans in case an accident occurs. Analyze past
accidents in order to determine what happened and how to
avoid a re-occurrence. With forethought and planning, many
accidents can be avoided.
29. Cleaning fluids, hydraulic fluids, and even water can be
absorbed through the skin. Individual people have different
reactions to chemicals. Protect yourself with gloves and
protective clothing.
30. Fumes, spray mist, and dust can be dangerous, use
ventilation and respirators as required.
31. When modifying a system, use caution when installing
quick connect couplings. A quick connect coupling placed
between a pump and a directional control could leave the
pump without a relief valve in the type of system where the
relief valve is located in the directional control valve.
32. Outriggers or stabilizers that are fitted with pilot operated
check valves can trap pressurized fluid. When a power supply
has failed, stabilizer cylinders have been retracted with jacks,
without venting the fluid. This process builds extremely high
pressures in the cylinder. System pressure may not be
sufficient to open the valve against this pressure and it
becomes trapped. Removing the valve to relieve the pressure
is dangerous. Jets of fluid, seals, or propelled parts may injure
you.
33. Use personal protection and the proper cleanup
compounds when dealing with mercury spills
from manometers, thermometers, thermostats, and electric
controls.
34. Filling gasoline tanks on hot or
running engines should be avoided. Static sparks will also
Terex Mobile Telescopic Level 1: Outriggers
Outriggers
Outrigger Flowpath
Electrical Flowpath
Terex Mobile Telescopic Level 1: Outrigger
Caution:
Operating a machine with mechanical (non-
hydraulic) outriggers, make sure that the beams
and cylinders are pinned and locked in place;
otherwise they can creep in during the operation
All wheels must be clear of the ground. If they are not,
the crane has an inside tip In axis on its tires, capacity
is lost and the on rubber chart must be used.
extended. Then, later in the da y, this same operator i s
asked to swing the boom to the other side of the rig fo r
a pick. He does this without thi nking and topples the
crane.
.
CRANE OUTRIGGERS
The key to lifting a maximum capacity load with a crane
is the outriggers. They provide a solid platform for the
cranes safe operation and efficient use. Operators and
workers within a cranes radius must always be aware of
how critical the placement and use of outriggers are to
cranes performance. Without this awareness they may
place both themselves and the crane in peril
Statistics show that at least 50% of crane incidents
occur because the crane or outriggers are not set-up
properly. Specific hazards that can cause or contribute to
failure or collapse include:
* failure to extend the outriggers fully,
* not extending all outriggers,
* failure to get completely off-rubber,
* not accounting for poor ground conditions,
* failure to level the crane.
Use the Correct Load Chart. The purpose of outriggers
is to improve the stability of the crane. Accurate use of the
on-outriggers fully extended load chart, requires that
outriggers be fully extended and they must bring the rig
completely off-rubber. If the tires are touching the ground,
then the on-rubber load chart is the only one that can be
used, manufacturers do not recommend extending only one
or two of the outriggers. If outriggers are to be used, fully
extend all of them and get the tires off the ground.
Accidents commonly occur because the operator is lifting
from only one side of the rig, with only two outriggers
Outriggers
Set the outrigger as follows before initiating any lifting
operations:
1. Remove the outriggers beam retaining pins.
2. To set the four(4) outriggers evenly, operate switches to
raise crane to a level position. When level, retract jacks
(together) at one end of crane an inch or so, and then
extend them again (together) until crane is level. Then
repeat this process for the opposite end of crane. This
equalizes pressure in all four jacks. The controls for the
out and down outriggers are mounted on the dash. The
extend/ retract master switch must be actuated before
the appropriate function switches can be actuated to
operate the outriggers.
This is a safety feature to prevent accidental actuation
of the outriggers while the crane is in motion because
the STEERING IS NONFUNCTIONAL WHILE THE
OUTRIGGERS ARE BEING OPERATED.
The machine may be operated with the outrigger beams fully
retracted, pinned mid-position or fully extended. See the
capacity chart for boom and jib limitations. The crane
must be leveled prior to extending the boom or lifting
loads. To achieve this condition, the vertical jack
cylinders should be extended only enough to lift the
wheels off the ground.
FULL extension of the vertical jack cylinders should be
avoided if not necessary to level crane and raise wheels
clear of ground because oil expansion under extreme heat
conditions can cause cylinder seal failure. Check to ensure
that all beams are fully extended, swinging the upper
if necessary to visually check that each beam reaches full
extension. Level the crane using the bubble indicator to
determine when a level condition is achieved. While
operating the crane, frequently check and level the
outriggers between lifts.
The operator must exercise sound judgment in positioning
the outriggers. The outriggers should not be set near holes,
on rocky ground or on extremely soft ground. Setting the
outriggers in such locations may result in the crane tipping,
causing personal injury or property damage. Where a firms
footing or level ground is not otherwise available, it should
be provided by substantial timbers, solid blocking, or other
structural members sufficient to distribute the load so as not
to exceed the safe bearing capacity of the underlying
material, and to enable leveling of the crane. Make sure all
outriggers are completely retracted before moving the crane.
The pads found on all crane outriggers are designed for
good ground conditions. Poor conditions reduce the
amount of load a crane can safely place on the outrigger
pad. Because of this, many crane operations require
additional support or "floats." Supplemental floats are
made of substantial material and must always be larger
than the outrigger pad. These floats disperse the weight
of the crane and its load over more ground area than
does the pad. Any float or cribbing which is smaller than
the pad, actually increases the pressure placed on the
ground. This increase in pressure, particularly in poor
ground conditions, can cause an outrigger to "punch
through," and bring about an accident. The soft ground
on most construction sites cannot withstand these
pressures without deflecting or sinking. To prevent this
from happening, blocking must always be used under
outrigger floats to distribute the crane loads as large an
area as possible
It is strongly recommended that blocking should be fairly
rigid, tightly spaced, at least 3 times larger in area than
the float and completely support the float.
Span blocking or corner blocking will cause the float to
fail at approximately half its design load. The float will be
subjected to bending and shear loads and will crack from
the base up to the collar
Blocking must always be level to guarantee a right
angle (90 degrees) between the cylinder and the float.
If the cylinder and float do not meet at right angles,
the float collar can fail or the float can slip along the
blocking and damage or cause the cylinder to fail.
If blocking must be piled to build up height, ensure
that it is stable and wont topple when the swing and
brake torque is transmitted through the outriggers to
the ground.
Blocking
WRONG UNSTABLE BLOCKING
WRONG UNSTABLE BLOCKING
Never block under the outrigger beams inside of the
outrigger pads. This will create an inside tipping point
and reduce stability.
The outrigger pad must be connected to the outrigger
float. If it is not, and while under load the crane lifts an
outrigger, the cylinder may not re-engage the pad
when it comes back down. If this happens, there will
be no support under the outrigger.
If the float is not pinned to the outrigger beam or
cylinder, it will separate from the beam if the cranes
frame twists and the beam lifts under the load.
PADS NOT PINNED
If the crane swings and puts load on the outrigger, the
cylinder will return but will not re-engage the float
collar. It can miss completely and leave the outrigger
without any support.
If the crane swings and puts load on the outrigger, the
cylinder will return but will not re-engage the float
collar. It can miss completely and leave the outrigger
without any support.
Load chart ratings apply only when the ground
conditions are firm enough to support the crane and
keep it level during the lift. If the ground is soft or
unstable, the tires, crawlers or outriggers will sink or
subside causing loss of capacity. In almost all cases,
heavy duty blocking having large bearing areas will
be necessary to prevent sinking and provide a solid
base for the crane.
Poor float
support
Poor float support
On soft ground or on backfilled
material, timber or steel mats
must be used to prevent the
crane from sinking or settling.
Poor float
support
Use solid blocking under all floats
Anything wrong with this picture?
From Outrigger
selector valve
Check Valve With Thermal Relief
The check valve with thermal relief performs the
same function as a standard check valve. It allows
free flow in one direction. In the opposite direction,
it performs as a normal check valve preventing
flow, while also venting excess pressure caused by
the thermal expansion of fluid. This type of valve
can be used with an external pilot piston to provide
a pilot operated valve that will vent trapped
pressure due to thermal expansion. These valves
work best when used in conjunction with a control
valve that vents the valve ports to tank when
centered.
Operation
The check valve is a guided poppet design. As the
pressure on the inlet exceeds the spring rated, the
poppet is pushed off of its seat allowing flow to
pass. Once the pressure on the inlet side on the
inlet side drops below the spring force, the spring
then pushes the poppet back on its seat blocking
flow form the outlet to the inlet of the check valve.
If the pressure on the outlet side of the check valve
(when it is in a load holding function) rises (through
thermal expansion), the direct acting relief will vent
the excess pressure caused by the thermal
expansion to inlet side of check
From Outrigger
selector valve
Holding valve
Purpose of the valve is to lock the fluid in the piston
side of the cylinder once the outrigger jack has
been extended to desired position. Once there is
no longer fluid pressure acting on the pilot of the
holding valve the spring pressure will over come
the system pressure of that part of the system and
shut the check valve. Now with a combination of
spring pressure and pressure being exerted by the
fluid on piston side, the check valve is locked and
shut into place.
1
1. PILOT PORT
2. INLET SIDE
3. CYLINDER SIDE
PINNING OUTRIGGER
Purpose of the pins are to hold the outriggers in place and
set the outriggers to desired extend position. The pins, when
outriggers are fully retracted hold the outriggers in place.
Once the pins are pulled the out (PIC 2) the outriggers can
be pushed outward. The pins are also used to lock the
outriggers in retracted, 50 percent position and fully
extended position. The 50 percent position is accomplished
by pulling pins out and extending outriggers slowly until pins
drop in the locking hole (PIC 3) at the mid position. Once the
pin are in the hydraulic fluid will just dump through the relief
letting the operator know that the outriggers have been
stopped. For full extension the pin are pulled out and the
outriggers are extended out till they stop.
PIC 2
PIC 3
PIC 1
LOCKING PIN
RT OUTRIGGER EXTEND/RETRACT SOLENOID
There is one Extend/Retract valve that controls all four
outriggers on the RT models located on the left handrail
frame forward of the swing gear. There are also two
solenoid valves per side. Each one has one position that
controls the individual outrigger horizontal stabilizers and
the other controls the jack.
RT OUTRIGGER JACK/STABILIZER SOLENOID
Front Outrigger
T Series Front Outrigger pad Attached to Jack and
Pad is never Removed. There is a proximity switch which
tells you when the cylinder is fully retracted.
FRONT OUTRIGGER RETRACTED.
FRONT OUTRIGGER EXTENTDED.
EXTEND/RETRACT SOLENOID
FRONT OUTRIGGER EXTEND/RETRACTSOLENOID
ON OUTRIGGERS IN THE IN POSITION
ON OUTRIGGERS IN THE 50 PERCENT POSITION
ON OUTRIGGERS IN FULL OUT POSITION
50 PERCENT EXTEND LINE
OUTRIGGER PAD
This is an important component that should not be
neglected. As seen earlier, the pads support the weight of
the crane. The pockets should be kept clean in in storage
position when not being used (below).
RT STORAGE POSITION
The Rough Terrain and Truck crane have two styles of
pads that can be used. The most common in production
today is the type 2 pad.
TYPE 1 PAD
TYPE 2 PAD
OUTRIGGER PAD STORAGE
The pads on the Truck cranes are located in various
locations on the crane. Two of the rear outrigger pads are
located in the rear of the crane.
T-500 series rear outrigger pads are stored on the rear
bumper. T-200 and T-300 series cranes store the pads on
the rear inner sides ahead of the rear outriggers.
T-200, T-300 Outrigger Pad Storage Location
(Left-Rear)
T-200, T-300 Outrigger Pad Storage Location
(Right-Rear)
T Series Outrigger Pad Storage Location
(Left-Rear)
OUTRIGGER STABALIZER
The stabilizer is the portion of the out rigger that extends the
jacks outward and retract it inward. It consists of the beam,
extend cylinder, and the jacks assembly.
*NOTE: CARE MUST BE TAKEN TO ENSURE THAT
UPON ASSEMBLY, THE HOSES ARE INSTALLED WITH
NATURAL CURVE.
BEAM
CYLINDER
JACK
RT OUTRIGGER OPERATION
To place the crane on outrigger there is a sequence of
things that take place to get them in the desired position.
The outriggers take priority over swing and steering as
stated earlier. To operate the outriggers the outrigger
extend/retract switch must be pushed and held down CC-1,
CC-2. This is important due to the interaction between the
interlocks in the electrical circuit and the movement of the
outriggers. The pressing of the switch aligns the electrical
circuit for either extend or retract.
Extending Beam
Once the operator has pressed the extend/retract switch
CC-2, the desired side is chosen and button is pressed for
that beam. (Remember that in electric circuits, when closed
movement of the electricity is basically instantaneous). Once
the switch for the selected side is pushed for extend, the
circuit will be closed and current will have a path through the
circuit and be directed to the diverter valve solenoid. The
current energizes the R-15 relay which will shut the R-15
contact CC-5. This causes the diverter valve directional
valve to shift and dump the hydraulic fluid traveling up to the
steering and swivel (during outrigger operation there is no
pressure to operate the steering and swing) CC-6. At the
same instance the contact shuts and now current is sent to
the extend/retract solenoid and shifts it to the extend
position. Also the left solenoid control valve is shifted to the
beam actuating position.
Due to the movement of these valve by the electrical circuit,
hydraulic pressure can actuate the beam. Flow from the
outrigger/swing/steering pump now flows through the extend
path of the ext/ret valve into the beam actuating section of
the solenoid control valve. The pressure leaving the valve
now pushes against the piston side of the beam cylinder.
The fluid leaves the rod side of the cylinder and returns
through the ext/ret valve and back to the tank. C-2.
Extending The Jack
Once the operator has pressed the extend/retract switch, the
desired side is chosen and button is pressed for that jack.
Once the switch for the selected side is pushed for extend,
the circuit will be closed and current will have a path through
the circuit and be directed to the diverter valve solenoid. The
current energizes the R-15 relay which will shut the R-15
contact CC-3. This causes the diverter valve directional
valve to shift and dump the hydraulic fluid traveling up to the
steering and swivel CC-3. At the same instance the contact
shuts and now current is sent to the extend/retract solenoid
and shifts it to the extend position. Also the left solenoid
control valve is shifted to the beam actuating position.
the solenoid control valve. Flow now travels to the holding
valve of the jack, unseating the check valve. At the same
time pressure is felt through the pilot of the thermal relief
check valve and cracks it off its seat. Now pressure from the
rod side of the jack overcomes the spring pressure of the
thermal relief check valve and provides a flow path out of the
rod side through the ext/ret valve and back to the tank. The
beam would move in this situation also if not for the pinning
of the beam and also because of the hydraulic lock caused
by the circuit design. C-3. All four outrigger jacks can be
extended at the same time but at a lower rate due to all the
outriggers using the pressure provided by the pump at the
same time.
Retracting The Beam
that beam. Once the switch for the selected side is pushed
for retract, the circuit will be closed and current will have a
path through the circuit and be directed to the diverter valve
solenoid. The current energizes the R-16 relay which will
shut the contact R-16 contact CC-10. This causes the
diverter valve directional valve to shift and dump the
hydraulic fluid traveling up to the steering and swivel CC-11.
At the same instance the contact shuts and now current is
sent to the extend/retract solenoid and shifts it to the extend
position. Also the left solenoid control valve is shifted to the
beam actuating position.
outrigger/swing/steering pump now flows through the retract
the solenoid control valve. The pressure leaving the valve
now pushes against the rod side of the beam cylinder. The
fluid leaves the piston side of the cylinder and returns
through the ext/ret valve and back to the tank. C-4.
Retracting The Jack
that beam. Once the switch for the selected side is pushed
for retract, the circuit will be closed and current will have a
path through the circuit and be directed to the diverter valve
solenoid. The current energizes the R-16 relay which will
shut the contact R-16 contact CC-8. This causes the diverter
valve directional valve to shift and dump the hydraulic fluid
traveling up to the steering and swivel CC-9. At the same
instance the contact shuts and now current is sent to the
extend/retract solenoid and shifts it to the extend position.
Also the left solenoid control valve is shifted to the beam
actuating position.
the solenoid control valve. Flow now travels to the holding
valve of the jack, unseating the check valve. At the same
time pressure is felt through the pilot of the thermal relief
check valve and cracks it off its seat. Now pressure from the
rod side of the jack overcomes the spring pressure of the
thermal relief check valve and provides a flow path out of the
rod side through the ext/ret valve and back to the tank. The
beam would move in this situation also if not for the pinning
of the beam and also because of the hydraulic lock caused
by the circuit design. C-5. All four outrigger jacks can be
retracted at the same time but at a lower rate due to all the
outriggers using the pressure provided by the pump at the
same time.
OPTIONAL TRUCK CRANE GROUND LEVEL
CONTROLS.
FRONT OUTRIGGER CONTROLS
*NOTE FRONT OUTRIGGER NOT USED TO LEVEL CRANE
ONLY AS SUPPORT.
REAR GROUND OUTRIGGER CONTROLERS
On the rear outriggers the top switch is used to extend and
retract. The lower switches control the front beam, front jack
cylinder, rear beam, and the rear jack cylinder.
Terex Mobile Telescopic Level 1: Steering
Steering
Steering Flowpath
Steering Switch
Switch to crab or 4-wheel steer only when both axles
are centered. Otherwise, steering will be limited and
may be locked.
If wheels should become locked, switch to 2-wheel
steer, turn front wheels, switch back to crab or 4-wheel
steer and center wheels.
Exercise caution when the upperstructure is not in the
travel position as the steering will appear to be reversed
when the boom is over the rear.
Metered fluid from the steering control valve is routed to
the four steering control hydraulic cylinders mounted on
the axles. When a control valve is actuated, the fluid is
directed through the rotary manifold to that circuit to
perform work.
STEERING FLOW
Flow moves from the reservoir through the Auxiliary pump
(direct coupled, Horizontally mounted, 2500 rpm, 20 GPM,
gear type pump) through the 2500 psi main system relief.
The relief will direct all hydraulic fluid to the tank in case the
pressure in the system exceeds the relief set point. Flow
now enters the diverter valve circuit. Flow now travels up
through port 7 of the hydraulic swivel where it is directed to
the priority valve circuit. Flow moves up through the spring
return pilot actuated directional valve. During normal
operation when the steering is not being used, flow goes up
through the valve, unseats the check valve and moves up to
the Steering control unit. Flow through the directional valve
is directed through an orifice and pressure is felt on the load
sensing line through the filter and is stopped at the 2600 psi
priority relief valve. A-1 Fluid takes the least path of
resistance so going through this path pressure starts to build
up in this circuit. Pilot pressure is felt on one side of the
directional valve back in the priority valve circuit and as
pressure goes up the pressure felt on the pilot. The pilot
starts to reposition the directional valve and sends the
excess pressure that is felt (which is lower than the priority
valve relief setpoint) away from the steering circuit. Fluid
now flows through the swing circuit into port 1 of the
hydraulic swivel and back to the tank. A-2 The steering
system is also equipped with an axle center light so the
operator will know when the rear axle is straight. This allows
the operator to know when to reposition the steering switch.
2-wheel Steer
The operator places the Steering switch to 2- wheel steer
and now the flow leaving the directional control valve in the
priority valve up to the servo operated directional control
valve (steering control valve). Now that the wheel is being
turned the hydraulic fluid now has a path for flow up to the
Gerotor (acts like a pump in times of power loss) turning it
in either clockwise or counter clockwise direction. Flow
now leaves the Steering control unit and is directed by the
directional control valve to port 5 of the hydraulic swivel
towards the carrier. Leaving port 5 fluid pressure is used to
actuate the piston side of one of the steering cylinder and
the rod side of the other steering cylinder (pushing out one
side of a tire as it pulls on the other associated tire causing
both wheels to point in one direction). Fluid now moves
through the steering valve inlet port and is directed to the
outlet port back towards the return line going to the swivel.
The returning fluid now enters the hydraulic swivel through
port 6 going into the super structure. From the swivel the
fluid goes back to the steering control unit where it goes
through the spool and goes to port 9 in the swivel. After
traveling from the superstructure through the swivel and
coming out in the carrier section, the return fluid goes to
the tank. A-3.
188
4-wheel steer
The operator takes the steering switch and positions it in 4
wheel steer mode and now the flow leaving the directional
control valve in the priority valve up to the servo operated
directional control valve (steering control valve is energizes
by allowing power to go from the battery source to through
the switch and on to the solenoid repositioning it). Now that
the wheel is being turned the hydraulic fluid now has a path
for flow up to the Gerotor (acts like a pump in times of power
loss) turning it in either clockwise or counter clockwise
direction. Flow now leaves the Steering control unit and is
directed by the directional control valve to port 5 of the
hydraulic swivel towards the carrier. Leaving port 5 fluid
pressure is used to actuate the piston side of one of the
steering cylinder and the rod side of the other steering
cylinder (pushing out one side of a tire as it pulls on the
other associated tire causing both wheels to point in one
direction). Fluid now moves through the steering valve inlet
port and is directed to rod side of opposite rear side tire and
the opposite piston side of rear actuator (this forces the rear
tires to turn in the opposite direction of that the front wheels.
This allows for a tighter turning radius. pressure also
unseats the check valve of the piston pressurized actuator to
allow the fluid to move from the cylinder side out). The
returning fluid now enters the hydraulic swivel through port 6
going into the super structure. From the swivel the fluid goes
back to the steering control unit where it goes through the
spool and goes to port 9 in the swivel. After traveling from
the superstructure through the swivel and coming out in the
carrier section, the return fluid goes to the tank. A-4
Crab steer
The operator takes the steering switch and positions it in
Crab steer mode and now the flow leaving the directional
control valve in the priority valve up to the servo operated
directional control valve (steering control valve is energizes
by allowing power to go from the battery source to through
the switch and on to the solenoid repositioning it). Now that
the wheel is being turned the hydraulic fluid now has a path
for flow up to the Gerotor (acts like a pump in times of
power loss) turning it in either clockwise or counter
clockwise direction. Flow now leaves the Steering control
unit and is directed by the directional control valve to port 5
of the hydraulic swivel towards the carrier. Leaving port 5
fluid pressure is used to actuate the piston side of one of
the steering cylinder and the rod side of the other steering
cylinder (pushing out one side of a tire as it pulls on the
other associated tire causing both wheels to point in one
direction). Fluid now moves through the steering valve inlet
and also causes fluid pressure is used to actuate the piston
side of one of the steering cylinder and the rod side of the
other steering cylinder (this causes the rear tires wheels to
turn in the same direction as the front tires. This allows the
crane to move diagonally right or left). The returning fluid
now enters the hydraulic swivel through port 6 going into
the super structure. From the swivel the fluid goes back to
the steering control unit where it goes through the spool
and goes to port 9 in the swivel. After traveling from the
superstructure through the swivel and coming out in the
carrier section, the return fluid goes to the tank. A-5
There are a few components that make up the steering
section. The system consists of:
-Orbitrol Unit
-Flow Divider
-Rotary Manifold
-Solenoid Valve for 4 Wheel, & Crab Steering
-Steering Cylinders
-20 GPM Pump
FRONT AXLE WITH STEERING CYLINDERS
REAR AXLE WITH STEERING CYLINDERS
STEERING PRIORITY VALVE
STEERING CONTROL VALVE
The 2 Wheel, 4 Wheel & Crab Steering, Steering Cylinders
are in the center of the carrier.
AXLE CENTERING SWITCH
Axle centering light
This light is merely used as a Guide to Switch the Two, Four,
and Crab Switch.
Independent Rear Steering
This feature provides all the same functions as the regular
steering options with one important difference. Now rear
steering can be adjusted independently of direction steering
wheel is turned. The steering wheel can be kept still and the
crane can be steered with the rear wheels alone. 2 wheel
steer, 4 wheel steer, and crab steer can now be
accomplished with finer control of the cranes steering. Since
flow coming into the steering section now first goes to the
steering control valve prior to going up through the swivel to
the priority valve, you are able to adjust the rear steering and
front steering independently with more control over steering
(A-6)
POWER STEERING PUMP
Truck Crane Steering
The steering system consists of the Sheppard Integral
Power Steering Gear, a hydraulic supply pump with pressure
and flow controls and an oil reservoir, the front axle and
mechanical components and the steering column or input
shaft and connecting linkages. The front tires and wheels
must also be considered as part of the total steering system.
The Sheppard Gear uses AW46 hydraulic fluid. This gear
transfers the rotational input from the steering wheel to a 90
degree movement to shift axle position. The power steering
pump provides 8 GPM of pressure to aid with turning.
SHEPPARD GEAR
T 500 STEERING SYSTEM
SHEPPARD GEAR
T 500 FRONT AXLE
T SERIES REAR TANDEM AXLE
T 200/300 FRONT AXLE
Terex Mobile Telescopic Level 1: Axle Lock
Axle Lock
The axle lockout system should be bled and filled
whenever oil seepage, dirt or oil is detected at the
breather plug or on the rod.
Air in the axle lockout system decreases stability. Bleed
and fill the system IMMEDIATELY whenever this
condition occurs.
RT AXLE LOCKOUT SYSTEM
The Axle lockout system is used to allow the rear axle
to oscillate up and down to stabilize the crane during on tire
pick and carry operations. The rear axle is equipped with a
cylinder on each side that has oil on the piston side and the
rod side is open to atmosphere. As one piston is moved up
by a bump or uneven ground, the oil on the piston side
moves over to the other pistons piston side and pushes
down on that piston. The air from the rod side goes in and
out through an air breather port on the side of the cylinder.
This system allows the axle to oscillate when the boom is
not moved more than 10 degrees from the travel position. If
the axle does not hold in the blocked position or oscillates
when the upper structure is swung 10 degrees from the
travel position, bleed the system. The system only oscillates
inside this 20 degree position to prevent oscillation when
boom is over side, causing possible tip over. With the cam
plunger fully retracted, adjust valve position for .005-.010
inches gap between the cam roller and the cam travel area
on the manifold. Do not measure at the low point on the
manifold.
ADJUSTMENT
With the cam plunger fully retracted, adjust valve position for
.005-.010 inches gap between the cam roller and the cam
travel area on the manifold. Do not measure at the low point
on the manifold.
Tighten and secure with nuts, washers, and cap screws.
OPERATION CHECK
For safe operation of the crane when operating on rubber,
the axle lockout valve should be checked daily as follows:
1. Place boom in travel position.
2. Drive one tire of the rear (oscillating) axle up on an eight
inch block.
3. Swing the retracted unloaded boom approximately 20
degrees from the center position.
4. Drive the crane off the block. If the tire remains in the
up position proceed with step (5). If the tire does not remain
in the up position readjust or replace lockout valve.
5. Allow crane to set for three to five minutes.
6. Observe the tire, it should remain in the up position.
7. Swing the crane back to the center position, the tire
should return to its original position. If not readjust or
replace the lockout valve and repeat this procedure.
REAR AXLE CYLINDER
Drain
Plunger
Air breather
Terex Mobile Telescopic Level 1: Air system
Air System
Terex Mobile Telescopic Level 1: Air Systems
AIR SYSTEM
Air System Pressure
The air is supplied by the attached air compressor on the
Cummins engine. Full air over hydraulic drum type brakes
with air dryer. The system is set to kick on at 106 PSI and cut
out at 120 127 PSI. The compressor supplies pressure for
the brake and range systems. The system is equipped with an
alcohol evaporator to keep water in the lines from freezing in
lower temperatures. The alcohol is injected in the system
because alcohol has a lower freezing temperature then water.
Check the alcohol evaporator fluid level and add fluid if
necessary. The evaporator is located in the engine
compartment next to the radiator and can be accessed by
opening the side engine access cover on the right side of the
machine. Replenish fluid with pure methanol alcohol only.
Air system should be kept as clean as possible. Dirt in system
ALCOHOL EVAPORATOR
can cause detonation. Check the alcohol evaporator fluid level
and add fluid if necessary. The evaporator is located in the
engine compartment next to the radiator and can be accessed
by opening the side engine access cover on the right side of
the machine. Replenish fluid with pure methanol alcohol only.
Proper air system pressure must be maintained at all times for
operation of air brake system. Never attempt any operation if
the low pressure warning light is illuminated or the warning
buzzer is sounding. The brakes are automatically applied
whenever the engine is off and the keys are removed or
manually actuated while the crane is operational.
Inadequate delivery pressure or defective component
operations can generally be traced to leakage, blocked lines,
or the build up of moisture and sediment in this system. A
regular program of periodic maintenance is an essential part
of air system operation. Consideration of severe working
conditions may dictate a revision in scheduling periodic
checks.
Air Dryer
An air dryer is a device that is mounted directly after an air
compressor and dries the air. Compressed air is kept in
pressure vessels, mostly made out of steel. Wet air will
corrode the pressure vessels inside and rust in a pressure
vessel may contaminate the pneumatic system so that the
components will not operate properly.
If your machine is equipped with an air dryer, inspect the
dryers desiccant at least twice each year for signs of oil
accumulation. If oil is found, replacement of the desiccant is
recommended. An increase in the amount of water blown out
of the air tanks may indicate that the air dryer is losing
effectiveness.
If system performance is reduced, desiccant replacement is
necessary. Desiccant replacement instructions are included
with the desiccant recharge kit.
AIR DRYER
DESICCANT
Braking System
There are 3 air flasks installed in the system. One is the
supply tank and you also have a tank for the front and rear
respectively. Each one has its own pressure gage in the cab.
Open the air tank drain cocks at least once daily to blow out
moisture and accumulated sediment. The drain cocks are
located on the frame rail by the battery box. Simply open
valve and purge fluid until steady air issues out. The system
is equipped with a parking brake and foot brake. The
parking brake automatically engages when the ignition is
switched off. The dash switch is for engaging the brake while
the ignition switch is on. The system is also equipped with
FRONT
REAR
SUPPLY
A full air over hydraulic drum brakes system. An air over
hydraulic system combines the use of compressed air and
hydraulic pressure for brake operation. The air over hydraulic
brake system has an air over hydraulic power cylinder that
contains an air cylinder and a hydraulic cylinder in tandem.
Each cylinder is fitted with a piston and a common rod. The air
piston is of greater diameter than the hydraulic pistons cylinder
and this higher air pressure causes a stronger braking action.
Pressing the brake pedal Actuates the air-over-hydraulic
brakes. Do not attempt to drive the machine until the service
brakes are fully operational (normal operating air pressure
is reached).
BRAKES
TREADLE VALVE (FOOT PEDAL)
RESERVOIRS
ALCOHOL
EVAPORATOR
PARKING
BRAKE
AIR COMPRESSOR
AIR OVER HYD.
ACTUATOR
C
SWIVEL
ROTATION
AIR CLEANER
DISK BRAKES
Parking Brake
This Brake should be Adjusted to Hold the Crane on a 30%
Slope. Brake disk adjustment Is limited to.010 to .020 Pad to
Disc Clearance with a maximum adjustment of .390.
HI-LO Range Shift and Rear Disconnect
Shifts only when transmission is in neutral. Hi- Range
automatically shifts into 2-wheel drive and Lo- Range into 4-
wheel drive. The machine may have to be moved slightly to
completely engage or disengage. Do NOT ATTEMPT TO
SHIFT WHILE MACHINE IS IN MOTION.
When operating on hard surfaces, use high range two-
wheel drive only. Failure to do so may result in severe
drive line windup and component failure.
Hi-lo range shifts and rear axle disconnects, should only be
performed when the transmission is in neutral. Hi-range
automatically shifts into two wheel drive and lo-range into four
wheel drive. The crane may have to be moved slightly to
completely engage or disengage.
When shifting between ranges is required, crane travel must
be stopped before shifting. Resume travel in 1st gear and up
shift if conditions permit. Full power shifts under load may be
made without endangering the transmission or drive
components. However, downshifts should not be made
when the vehicle speed exceeds the maximum speed of the
next lower range. Downshifting at excessive speeds will over
speed the drive train components with possible resultant
damage to the drive shafts.
MAINTENANCE CHECK
On a monthly basis, check the brakes for proper functioning.
As a part of your semi-annual check, perform a leakage test
on the air/hydraulic intensifier by applying soapy water to
the exhaust port. A one inch bubble in 3 seconds is acceptable.
If the leakage is greater than this, the cause should be
determined and corrected.
Every two years or 4000 hours, disassemble the air/hydraulic
intensifier assembly and replace all worn parts. Depending
upon the condition of the unit, either a minor or major overhaul
kit may be installed.
Terex Mobile Telescopic Level 1: Swivel
Swivel
RT SWIVEL
Rotary Manifold G-1
The swivel is used to direct the flow or fluid from the
pump to the valve that is being actuated to perform
work. The rotary manifold is the conduit for transporting
the hydraulic fluid from the carrier up to the
superstructure and return from the superstructure back
to the carrier. Design ensures ease of operation
without fear of entangling hoses or necessity of more
complex designs.
Center Swivel Assembly G-2
Using brushes and rings, electrical signals and current
is sent from the battery to the alternator, to where ever
it is needed. This current flow, similar to the hydraulic
fluid uses the center swivel assembly to transfer back
and forth the current from the carrier to the
superstructure.
Rotary Manifold
Port #1 Return Line
Port #2 Boom, telescope
Port #3 Winch return
Port #4 Main boom hoist / Telescope pump line
Port #5 Steering cylinders
Port #6 Steering cylinders
Port #7 Steering / Swing main pump line
Port #8 Drain line
Port #9 Steering return line
TRUCK CRANE ROTARY MANIFOLD
Port #1 - Line Low Pressure Return
Port #2 - Line Swing Pressure
Port #3 - Line Large Flow Return Boom Hoist & Telescope
Port #4 - Line Winch Pump 52.5 G.P.M.
Port #5 - Line Boom Hoist & Telescope Pump 43.1 G.P.M.
Port #6 - Line Winch Return Oil
ELECTRICAL COLLECTOR RING
When troubleshooting the electrical system, always check the
collector ring first to see that spring-loaded brushes are
centered in the bands. Keep free of any foreign material.
Keep the setscrews on the collector ring frame tight.
Otherwise the wire harness may wrap up as the machine is
swung.
The cover should allow for free operation of the collector ring
and the throttle. If linkages bind, erratic operation may result.
Check for unrestricted operation.
COLLECTOR RING MAINTENANCE AND SERVICE
If not revolved for some time, under some conditions, the ring
will have a tendency to collect fine silt, or a salt atmosphere
will cause corrosion. If this happens, the crane should be
rotated through several revolutions if possible. The cleaning
action of the brushes should clean rein surfaces. If it does not,
or it is not practical to revolve the machine, it may be
necessary to use a standard non-residue solvent to clean the
ring. Then lightly sand the brushes and rings with a fine grade
of sandpaper and dust off with compressed air.
To replace a brush and arm assembly, remove the hex nuts
and washers at the top of the brush stud along with the
outboard bearing. This will allow the brush assemblies to be
removed. Carefully remove the brushes without over
stretching the brush springs and arrange in order of removal
with the spacers. Replaced the damaged brush assembly and
then reassemble the brushes and spacers in reverse removal
order. This will ensure the correct spacing between electrically
live parts. Be sure that all brushes are snapped in tight and
T SERIES ROTARY MANIFOLD
making full contact with their corresponding brass ring.
Also check that all springs are hooked correctly
through the brush arm.
Center Swivel Assembly
The center swivel assembly consists of:
Collector Ring 46 Passes
which has:
3 each 30 amp passes
7 each 15 amp passes
36 each 7.5 amp passes
46 each total passes
Rotary Manifold 8 Passes
Air Swivel 4 Passes
The air tube works with the throttle cable for engine
R.P.M.
Center Swivel assembly
Terex Mobile Telescopic Level 1: Swing
Swing
Swing Flowpath
Swing
Swing is accomplished when the operator - Pushes to swing
right, pulls the lever to swing left. When the upper structure is
swung 10 off front center, the rear axle pivot cylinders are
locked into position to maintain stability for crane work.
Swing speed increases as the lever is moved further forward
or back. Swing speed also varies with the engine speed.
There is also a swing brake pedal and a ratchet release. The
swing has two different types of locks that can be used.
There is a 2-position pin type lock which prevents upper
rotation during crane travel and an optional 360 degree lock
which allows upper to be locked in any position.
Always engage lock before travelling the crane. NEVER
ENGAGE THE LOCK WHILE SWINGING THE MACHINE.
Before attempting to swing the superstructure, make sure the
swing brake is not set and the swing lock is not engaged. Be
certain that no obstructions will block the swing. When ready,
try for a smooth, controlled, safe swing. The swing should be
SLOW. Start the swing SLOWLY and allow the load to build
up only enough momentum to carry it through to the point
where it is to be lowered. Begin slowing the swing in advance
of the point where the load is to be lowered. Slow the swing
GRADUALLY, so that it appears to coast to a stop over the
desired spot. GRADUALLY slow the swing by use of the
swing lever. First, move the lever to the neutral position
and then VERY SLOWLY into the opposite swing direction
position as required to slow the swing. Apply the swing
2 POSITION PIN LOCK
360 DEGREE LOCK
brake, with the foot pedal, when the swing is stopped or when
emergency situations dictate that the swing be terminated
abruptly. Caution must be used when house brake is not in
use that foot must be on the brake. Superstructure will move
if this is not done due to outside forces over coming hydraulic
pressure in swing circuit.
If properly executed, the load will hang motionless when the
swing is terminated. If the load is oscillating, the swing was
made too rapidly and/ or stopped too abruptly.
Stopping the swing too abruptly will cause the load to oscillate
and impose side loads on the boom. Because side loading
can damage boom, ALWAYS START AND STOP SWINGS
GRADUALLY.
Swing Operation
Push to swing right, pull to swing left. When the upper
structure is swung 10 off front center, the rear axle pivot
cylinders are locked into position to maintain stability for crane
work. As long as steering is not being used, there will be flow
provided for the swing. Steering has priority over swing for
safety reasons. As the operator pushes the controls to swing,
the directional valve for swing will shift the spool and allow
flow up to one side of the swing motor rotating clockwise. The
return fluid will travel back to the directional valve and travel
through the tank line through the swivel, and then back to the
tank. B-2
To swing to the left or counter clockwise direction the
operator will pull the swing lever. This will send flow from the
pump up through the swivel and through the steering circuit.
Since steering is not being used flow will travel to the swing
directional valve and up to the swing motor turning it. The
returning fluid will travel through the directional valve back to
the swivel and back to the tank. B-3
RT SWING
VALVE
TRUCK CRANE
SWING VALVE
Swing Bearing
Swing bearing is a single row, ball type, with external teeth.
The swing bearing is
bolted to the revolving
upper structure and
welded to the carrier
frame.
The upper structure is joined to the carrier by a swing bearing
which is bolted to the carrier and bolted to the upper.
After 40 hrs the swing bearing must be retorqued to 600 ft.
lbs. Recheck every 40 hours until all bolt are found properly
torqued. Thereafter checks should be performed quarterly. It
is very important to perform periodic swing bearing bolt
checks. The bolts must be kept torque tightened to a rating
of 181 ft lbs dry, 137 ft lbs wet using a 4 to 1 torque
multiplier, or 725 ft lbs dry 550 ft lbs wet without the torque
multiplier. After the first day and again after the initial 40
hours of machine operation, check and tighten the bolts. If
additional torque is required after the first 8 or 40 hours,
recheck each 8 or 40 hours until all bolts are found properly
torqued. Thereafter, checks should be preformed
semiannually.
SWING BEARING BOLTING PROCEDURE
A number of causes can reduce tension in the bolts when
torquing and after use. These include rust on the threads,
damaged or rough threads on bolts or nuts, shanks of bolts
which hang up on holes, etc. All of these causes have a
tendency to absorb the torque when bolts are being
tightened.
All the fasteners inside the upper structure and the four
outside must be checked. If any are found to have loosened,
all twenty eight (28) must be retorqued.
Remember, it is important to perform periodic checks of the
swing bearing bolts. The bolts must be kept torque tightened.
The following equipment is required for checking swing
bearing bolt torque:
(1) 3/4 drive ratchet head torque wrench with 200 lb
capacity
(1) 16 extension - 3/4 drive
(1) 8 extension - 3/4 drive
(1) 7/8 12 pt socket - 3/4 drive
(1) special wrench
(1) 4 to 1 torque multiplier
Check and torque the fasteners inside the upper structure. In
order to get the socket on the bolts on the right hand inside,
loosen the tube clamps on pressure tubes and raise slightly.
This should permit access to the (22) bolts inside the upper
structure. Use the special wrench to reach the
inside front bolts of the upper structure. (4) of the (6) bolts
outside should be accessible without the need to remove any
components. Use the 8 extension to reach the bolt behind
the swinger and the 16 between the cab and upper structure.
Bolt torques are checked by applying the stated torque while
observing to determine if the bolt breaks loose. If it is
tightened (turned) by this procedure, then it has loosened,
and all (28) bolts must be retorqued. Refer to the sequence
illustrated.
Swing Reduction Unit
The swing motor is a double reduction with a swing brake. It is
equipped with an oil sight gage. The gear takes 7.5 pints plus
5 oz of glycol. It has a 35:1 reduction ratio and weighs 326 lbs.
It has a swing speed of 2.8 RPM at 2000 PSI. Service for this
component is not difficult. Change Oil at First 100 Hours, then
1000 hours or 6 months, which ever occurs first.
SWING LOCK CONTROL
360
Swing Brake
Always adjust the swing brake by adjusting the control
linkage when there is an indication of slipping. Personal
injury, or property damage could result if this precaution
is neglected
Control Adjustment B-5
a) During normal operation, the swing brake pedal should
be operating in the 4 to 5 click range if the swing brake
pedal is properly adjusted. If the swing brake pedal is
operating in the 6 or 7 click range during normal
operation, the swing brake cable will need to be
adjusted.
and /or brake pads may need replacing 7
Swing brake cable should be adjusted 6
and should hold at full engine RPM. 5
Brake discs should be fully engaged 4
3
Brake disks should begin to engage. 2
Bumper should rest against the pedal. 1
DESCRIPTION CLICK
The cables used on this machine are sealed. Never
adjust a cable to the point that the threads on the
rod end are pulled into the seal.
b) Refer to B-5. Release the swing brake and move the
swing brake pedal to first click position. Adjust the
bumper to rest against the swing brake pedal.
c) Adjust the pedal end of the swing brake cable by
increasing the thread length as indicated in B-5 until
the swing brake pedal is operating in the 4 to 5 click
range. After the adjustments are made, sufficient
thread must remain so that all the threads of the jam
nuts are engaged.
Note: Any adjustment required on the swing speed reducer
end of the swing brake cable will require that the
swing brake cable is disconnected from the swing
brake pedal.
d) Set the swing brake and begin to attempt to swing the
machine against the swing brake. You should exercise
caution in doing this until you know that the swing brake is
in good working order and will hold against the swing
pressure. Once you have verified that the swing brake
is holding, the engine RPM should be brought up to
full governed speed slowly.
e) If the swing brake fails to prevent the boom from rotating
or if the swing brake pedal continues to operate in the 6 or
7 click range, the swing brake cable and/or the brake
discs may need to be replaced.
LUBE POINT
SWING LOCK LUBE POINT
Terex Mobile Telescopic Level 1: Boom
Boom
Boom Flowpath
The boom is used to elevate the telescope section upward
and to lower it. There is an angle sensor associated with
orientation of the boom. The boom angle is one of the
functions that go into the load chart when deciding if a pick
can be performed. The BOOM elevation is controlled by foot
pedals or hand levers. To RAISE the boom, slowly depress
the left boom control pedal or pull the lever back. To Lower
the boom, slowly depress the RIGHT boom control or push
the lever forward. Fine control is obtained by operating the
engine at low speed while metering the controls. Always
operate and release the controls slowly to minimize dynamic
effects of the load. During a lift where precise control of the
load is required. Do not attempt to use more than one
function at a time.
Always maintain adequate rope tension. Inadequate hoist
rope tension on the winch when lowering light loads can
result in cable damage through kinking. Loose wraps on the
winch drum may slip, causing the rope to jerk and impose
shock loading on the boom. To protect near by personnel
and property maintain adequate hoist rope tension.
Never pull sideways with a crane boom. Crane booms are
not designed for excessive side pull and may collapse if
subjected to excessive side loading.
Always consider possible obstructions when varying boom
height or length; not only those to the front of the cab at the
time of the adjustment, but those which may be encountered
during swings.
The boom extend function on this crane has two positions
and two speeds. When the lever is all the way forward, the
regenerative mode provides increased speed. With the lever
approximately one half of the way forward, increased
PUSH is available at reduced speed.
HOLD VALVE
BOOM
Press crown for demo
BOOM FLOWPATH
To RAISE the boom, the operator slowly depress the left
boom control pedal or pull the lever back. The flow pressure
from the pump goes through the repositioned directional
valve for the boom. Flow travels through the check valve for
the holding valve and actuates the piston side of the
cylinder. The returning fluid from the rod side travels back to
the directional valve, through the telescope circuit, to the
swivel then back to the tank. E-2
To lower the boom, the operator slowly depress the RIGHT
boom control pedal or push the lever forward. Hydraulic flow
and pressure from the pump travels up through the swivel
and goes through the directional valve and into the rod side
of the cylinder. Due to the holding valve, there is a hydraulic
lock that keeps the rod from moving. There is a pilot sensing
line attached to the rod side of the line. When the pressure
of the pilot overcomes the spring pressure of the holding
valve, it repositions the holding valve. Now flow has a path
through the holding valve back to the directional valve. Flow
now goes through the telescope, to the swivel, and back to
the tank. E-3
SWING, WINCH, BOOM TELESCOPE, BOOM E-6
HOIST, VALVE CONTROL
The swing, winch, boom telescope, and boom hoist valve
control linkages are all clevis and cable connections. No
major adjustments should be required unless a component is
replaced or valve fails to function because of a defect or mis-
adjustment in the linkage. Minor adjustments may be
required at either the clevis end or at the control end to
change to travel engagement of the cable.
RT AND TRUCK CRANE MAIN VALVE
Terex Mobile Telescopic Level 1: Boom Tele
Telescope
Telescope Flowpath
Terex Mobile Telescopic Level 1: Boom tele
BOOM SECTION 1 SECTION 2
SECTION 3
SECTION 4
First movable section
Telescopic booms may be a pinned boom, full-powered
boom, or a combination of both. A "pinned boom" means
sections are pinned in the extended or retracted position. A
"full-powered boom" means sections extend or retract
hydraulically. Some models have a full-powered main boom
with a pinned boom tip section. Read the operator's manual
for the proper operation of the type of boom that is equipped
on the crane you are assigned to operate.
On a full-powered boom, the sections are extended and
retracted (except for the base section) by hydraulic cylinders,
called extension cylinders. The cylinders are mounted
parallel to the boom center line within each section. The
boom extension cylinders on most telescopic booms have
sequencing valves that allow the sections to extend
(telescope) by equal amounts. These cranes usually have a
single telescope control lever in the cab. However, on cranes
not equipped with sequencing valves, the operator will have
to extend each section equally. (The crane will have two or
three boom telescope control levers in the cab, each
controlling only a single boom section.) If the boom sections
are extended unequally, the most fully extended section of
boom could bend to uneven stresses. Additionally, the load
chart will be invalidated for determining rated capacity of the
crane.
When a load is placed on a telescopic boom, the load weight
on the boom causes the hydraulic rams within the boom to
stiffen up and slightly curve. As the load is removed from the
boom, the rams return straight. Because of this, do not
extend the boom while it is under load. Read the operator's
manual for boom extension information.
The extend-retract function on this crane has two positions
and two speeds. When the lever is all the way forward, the
regenerative mode provides increased speed. With the lever
approximately one half of the way forward, increased
PUSH is available at reduced speed.
Be sure full powered sections are extended equally before
lifting load. If sections are out of phase by more than one of
the triangular decals, then the sections must be
resynchronized by either fully extending or fully retracting the
boom.
Operation of Boom
Extend the boom to the desired length. Do not extend the
boom further than necessary to perform the lift. EXTEND the
boom by pushing the extend-retract lever FORWARD and
RETRACT it by pulling the lever BACK.
While extending the boom, be sure to pay out sufficient hoist
rope to prevent the hook block from being drawn up to the
boom peak. The force of the extend cylinders can easily
break the hoist line, dropping the hook block and load which
may result in personal injury or property damage. Be sure full
powered sections are extended equally before lifting load. If
sections are out of phase by more than one of the triangular
decals, then the sections must be resynchronized by either
fully extending or fully retracting the boom.
72 Boom Operation
The booms have been constructed to extend and retract with
a series of cylinder and chain movements. In the movement
of the 72 boom section, the operator extends the boom by
pushing the extend-retract lever forward. Hydraulic fluid
pressure comes from the pump and travels up through the
hydraulic swivel. The hydraulic fluid now travels through the
hoist section and then out of the telescope directional valve.
Fluid now travels up to the piston side of the cylinder. The
rod is pushed out against the #1 boom section which causes
the cylinder to move outward. The cylinder is bolted to the #2
boom section which causes it to move also as the cylinder is
moved out. At the end of the cylinder is attached a sheave
which allows the #3 extend chain to travel on. As the piston
extends out and pushes against the sheave, this causes the
extend cable chain to be pulled up and over the sheave
because of the out ward motion (the chain is anchored to the
base section by a threaded rod which keeps the cable from
moving back and forth). The other end of the cable chain is
anchored to base of the 3rd section. Because of the series of
movements and connections, the 3rd section is forced up
because of the chain being anchored to its section. The
hydraulic fluid being forced out of the rod side is directed
back to the directional valve of the telescope. Flow now
travels out of the directional valve, up to and through the
drain line and back to the swivel. The fluid now travels back
to the tank.
Retracting the boom is done by reversing the action but with
another chain that hasnt been addressed. There is a retract
chain that is anchored on one end to the base section and
the other end to the 3
rd
section. To retract the boom, the
operator retracts the boom by pulling the extend-retract lever
back. This repositions the tele directional valve to allow flow
to the rod side of the cylinder. Flow does not have a
complete path to leave the piston side due to the check valve
and the counterbalance valve. When the set point pressure
felt from the pilot overcomes the spring pressure of the
counterbalance valve, the counterbalance valve repositions
to allow flow to leave the piston side and return to the
directional valve and back to the tank. The cylinder is
retracted (this action also retracts the 2
nd
section due to it
being bolted to the cylinder) and pushes on the retract cable
which in turn pulls the 3
rd
section.
94 Boom Operation
The operation with the 94 boom is relatively the same with
the exception of having another section and 2 other cable
chains. The difference is that now the 3rd section does not
have the boom head but is an extension. The anchor points
are the same with the addition of another sheave located at
the base end of the 3rd section for retract and a sheave
located on the front part of the 3rd section for extension. The
new extend chain cable is anchored to the 2nd section and
the 4th section. The new retract chain is anchored to the 3rd
and 2nd.
ANTI TWO-BLOCK SYSTEM
This machine is equipped with an anti-two block warning
system designed to alert the operator of impending two-block
conditions (i.e., a condition where the hook or hook block
may be drawn into the boom point sheaves) and disconnect
the boom down, winch up, and boom extend function control
linkages. Boom raise, boom retract, and winch down
functions remain active. Inspect all anti-two block switches A
switch has been provided so that under certain
circumstances, an operator may override the anti-two block
system: thereby allowing the hook or block to be drawn
closer to, or in contact with, the boom point. found on boom,
jib, and auxiliary sheave heads for damage.
Check the freedom of counterweight attached to these
switches; and also, that counterweight is attached around
correct line of hoisting cable in the proper manner. Inspect all
electrical connections and wires as well as the
entire length of cable attached to the cable reel and its
connections for evidence of excessive wear, damage, or
improper installation. Check spring loaded cable reel for
proper tension and to insure that reel is free to rotate. Verify
visual and audible warning devices by lifting each of the
counter weights.
NOTE: A warning light will appear on the dash
mounted panel and an audible signal
should be heard if horn switch is in ON
position.
This crane is equipped with a disconnect system 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. If all functions are operating
properly, winch hoisting will cease and the boom cannot be
extended or lowered. Should any of these functions
continue, dIsconnect system is functioning improperly and a
complete system check must be made. Boom raise, boom
retract, and winch down-functions remain active and will be
unaffected by anti-two block system.
JIB OPERATION
Purpose of jib is to extend reach of lift. It is also used for
offset lifts where extra reach is necessary for blind lifts.
Commonly used for top of building lifts and over tall object
lifts.
Description
Two optional jib extensions are available to provide
additional boom reach. One is a 26 ft (7.93 m) side stow
swing-on one-piece lattice type jib that is off settable at 0,
15, or 30.
The second jib option is a 26-43 ft (7.93 - 13.11 m) side stow
swing-on lattice type jib. The jib is extendible to 43 ft (13.11
m) by means of a 17 ft (5.18 m) manual pullout tip section.
Each optional jib extension is pinned directly to the ends of
the sheave pins. When not in use, the jib can be unpinned
from the boom head and stored on mounting brackets on the
right side of the boom base section.
The 26 ft (7.92 m) jib weighs 1,100 pounds (499 kg). The
26-43 ft (7.93-13.11 m) jib weighs 1,500 pounds (680 kg).
EXTENDING THE PULLOUT SECTION (F-9)
NOTE: The jib must be erected before extending
the pullout section. Do not attempt to
extend the pullout section while the jib is
stowed.
1. Retract the boom completely and boom down to minimum
boom angle.
2. Attach the dead end of the wire rope to the eye on the
bottom of the jib tip. This is done to prevent the pullout from
extending uncontrollably.
3. Unplug the anti two-block plug from the anti two-block
STOWED socket. Move the dummy plug from the erected
socket to the stowed socket.
4. Remove pullout retaining pin from the stowed retaining pin
hole.
5. Pay out cable and extend the pullout until the erected
retaining pin holes line up. Install retaining pin.
6. Plug the anti two-block plug into the anti two block
ERECTED socket.
7. Test the anti two-block system by lifting the anti two-block
weight. The light and audible alarms should be actuated in
the cab and the boom down, boom extend, and winch up
controls should disconnect.
RETRACTING THE PULLOUT SECTION (F-9)
1. Retract the boom completely and boom down to minimum
boom angle.
2. Unplug the anti two-block plug from the anti two-block
ERECTED socket. Move the dummy plug from the stowed
socket to the erected socket.
3. Attach the dead end of the wire rope to the eye on the
bottom of the jib tip. This is done to prevent the pullout from
extending or retracting uncontrollably
4. Remove pullout retaining pin from the erected retaining
pin hole.
5. Winch up slowly to retract the pullout until the stowed
retaining pin holes line up and install retaining pin.
6. Plug the anti two-block plug into the anti two block
STOWED socket.
7. Test the anti two-block system by lifting the anti two-block
OFFSET JIB
STRAIGHT JIB
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:
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.
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 steps
3 through 5 if necessary.
7. Fully extend the boom horizontal.
8. Thru 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 .25 inches, tighten
adjustments A and B equal amounts until the measurement
TIP SECTION EXTEND AND RETRACT CHAINS:
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.
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 D and
tighten adjustment C until the gap is within specifications.
6. Fully retract the boom and recheck the gap. Repeat steps
3 through 5 if necessary.
7. Fully extend the boom horizontal.
8. Thru 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.
9. If the dimension is greater than 3.00 inches loosen
adjustments C and D equal amounts until the measurement
10. If the dimension is less than 2.75 inches, tighten
adjustments C and D equal amounts until the measurement
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.
Terex Mobile Telescopic Level 1: Winch
Winch
Winch Flowpath
Hydraulic Winch
A hydraulic winch raises and lowers the loads and a hydraulic
motor swings the upper structure. The winch is classified as a
bent Axis Piston Motor & Planetary Reduction Gear Provides
2 Speed Operation. Hoisting or lowering of the load with the
winch is controlled by the winch joystick. LOWER the load by
pushing the joystick FORWARD and RAISE the load by
pulling the joystick BACK. Improved control is obtained by
operating the engine at low speed while metering the
control. There is equal speed for powering up and down with
the winch. Low Speed is 184 F.P.M, while high is 369 F.P.M.
The cable is usually in regularly laid. Always actuate and
release this joystick slowly to minimize dynamic effects of the
load and to prevent birds-nesting of the cable on the winch
drum. To shift the winch into the high-speed mode, move the
rocker switch to high-speed. The crane is equipped with a two
block system, in the event that the hook or block is raised
beyond a safe position, a warning light appears on the dash
and, if horn switch is activated, an audible warning will sound.
Some cranes may be equipped with control disconnects
which will prevent the winch from raising the load and the
boom from extending or lowering. To continue crane
operation, retract or raise the boom and/or lower the hook. If
the operator wishes to raise the hook block beyond the point
at which the two block is activated, he may override the
system by using the key switch.
The winch hydraulic circuit flow path
Flow comes in and overcomes spring pressure of the check
valve and goes through and travels up to the bent axle motor
of the winch. Flow also goes down through the check valve
and makes its way to the center swash plate rod and
repositions the swash plate for displacement desired for
desired control. The displaced fluid from this piston goes
through the solenoid and back to the tank. After the flow
leaves the motor it goes down and returns to tank. The brake
is equipped with a sprag clutch and move freely in the hoist
up direction. When lowering the winch flow comes into the
winch motor from the opposite direction but the motor will not
move due to nowhere for the fluid to go. The spring loaded
check valve in the system keeps the flow from leaving. First
the pressure in the system will build to compress the spring
and release the winch brake. Pressure then continues to build
until it repositions the counterbalance valve and allows flow to
leave the system
* NOTE: Two speed winch will operate in low speed mode
ONLY if operating telescope simultaneously with
the winch function
Continuing to pull the block up after contact has been made
with the boom head may result in damage to boom head and
sheaves or the cable may be broken causing the load to drop.
Cranes which are factory equipped with auxiliary winches
may require additional counterweight if the auxiliary winch is
removed. Refer to the capacity chart (load rating plate) for the
required counterweight total.
When lowering light loads, be sure to maintain sufficient cable
tension to prevent the cable from becoming loose 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 winch drum. These conditions can
result in personal injury or property damage.
The anti two-block system should be tested by lifting the anti
two-block weight. The light and audible alarms should be
actuated in the cab and the boom down, boom extend, and
winch up controls should disconnect.
Apply breaking force to the reel flange in order to prevent
overrun as the rope is being drawn off. Loops formed by
overrun can cause kinks and doglegs in the rope, resulting
in damage and premature rope failure. A timber or block
forced against the shipping reel flange can be used to
provide the required braking force.
Install cable on the winch drum in accordance with the
following procedure.
1. Position the cable over the boom nose sheave and route
back to the winch drum.
2. Position the winch drum with the cable anchor slot on
top.
Spooling Wire Rope On Drums
Care must be exercised when installing wire rope on the
winch drum. Improper spooling can result in winch damage
through crushing, kinking, doglegs, abrasion, and cutting.
Poorly installed wire rope will also adversely affect the
operating characteristics of the machine by causing uneven
application of force and motion. This can cause premature
fatiguing and failure of the rope.
Thoroughly inspect and clean the winch before proceeding
with the installation. Check the lagging and drum flanges
for cracks, breaks, and excessive wear. Deformed or
outsized drum and excessive undercutting at the base of the
flange also indicate the repair or replacement of the drum is
necessary.
Check the bearings for excessive wear or play.
After correcting any defects revealed by the inspection and
determining that the winch is in good operating condition,
spool the wire rope as follows:
Mount the cable shipping reel vertically on jacks or a suitable
supporting structure, with a pipe or bar through the reel
center. The cable should be drawn from the top of the reel,
as shown, in order to avoid reverse bending as it is spooled
onto the winch drum.
If cable is wound from the storage reel onto the drum, the
reel should be rotated in the same direction as the hoist.
Never use a steel hammer or punch bar to move the rope
on the drum. These tools can easily damage the rope.
After the wire rope is wound onto the winch drum, reeve
the cable as desired.
Use only factory supplied sockets, wedges, and pins of
the
proper size; make no substitutions.
Follow the procedure below when installing wedge type
sockets on wire rope. Be certain the correct socket and
wedge are used.
1. Lead the rope through the socket, form a large loop and
draw the rope end back through the socket. A length of
rope equal to at least one rope lay should be drawn back
through.
3. Insert cable through slot and position around the cable
wedge.
4. Position the anchor wedge in the drum slot; pull firmly
on the free end of the cable to secure the wedge.
5. Slowly rotate the drum, ensuring the first layer of cable
is evenly wound onto the drum.
6. Install the remainder of cable, as applicable.
The end of the cable should be even with the bottom of the
anchor wedge.
Note: If the wedge does not seat securely in the slot,
carefully tap the top of the wedge with a mallet.
The wrong cable wedge could permit the wire rope to
work loose and detach itself from the drum, possibly
causing property damage or personal injury.
Tension the wire rope by braking the shipping reel and slowly
operate the winch in the raise mode to wind the cable onto
the winch drum. As the spooling proceeds, make sure that
adjacent turns are tight against one another. A lead or brass
hammer may be used to tap the rope over against preceding
turns. Tight winding on the drum is absolutely essential.
2. Insert the wedge and allow the rope strands to adjust
around it.
3. Seat the wedge and loop just tightly enough to allow
handling by attaching the socket to a strong support and
engaging the winch to take a strain on the rope.
4. Final seating of the 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 length
(6 inches) of the cable should be secured to the free end
of the wire rope to act as a stop as shown. Do not clamp the
free end to the load supporting end as this will weaken the
rope.
Hoist Line Reeving
When reeving the crane in preparation for any job, it should
be kept in mind that hoisting and lowering speeds decrease
as the number of parts of line increases. For the most
efficient use of the crane, it is therefore desirable to use the
minimum required number of parts for lifting the load as
determined by referring to the load rating chart.
This crane incorporates a Quick Reeving boom head and
block which do not require removal 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 less than the number of parts
called for by the load rating chart.
If it is not practical to alter the reeving during the course of
the work, the required number of rope parts must be
determined on the basis of the heaviest load to be lifted
during operations.
When the required number of rope parts has been
determined, reeve the rope as shown on the previous page.
Attach a wedge type rope socket to the
wire rope dead end and secure it to either the boom peak or
hook block as required. Dead end the rope on the hook
block for an odd number of line parts, and on the boom peak
for an even number of parts.
Attach the anti two-block weight to the anti two block switch
and to the first part of line as shown on the previous page.
The anti two-block chain should be 48 inches long. Verify
that the chain is not twisted or knotted after installation.
Test the anti two-block system by lifting the anti two-block
As shipped from the factory,
the crane has sufficient wire
rope provided to allow the
hook to each ground level
with any boom length and
elevation when reeved with
minimum parts of line
required for the load being
lifted. Refer to the Crane
Capacity Chart for parts of
line required.
Dual Brake System- Description
The dual brake system consists of a dynamic brake system
and a static brake system.
The dynamic brake system has two operating components:
1. Holding valve
2. Hydraulic Motor
The holding valve is basically a counterbalance valve. It
contains a check valve to allow free flow of oil to the motor in
the hoisting direction and a pilot operated , spring-loaded
spool valve that blocks the flow of oil out of the motor when
the control valve is placed in neutral. When the control valve
is placed in the lowering position, the spool valve cracks
open, the pilot pressure becomes flow-dependent and
modulates the spool valve opening which controls the
lowering speed.
The static brake is released by the holding valve pilot
pressure at a pressure lower than that required to open the
pilot operated spool valve. This sequence assures that
dynamic braking takes place in the holding valve and that
little, if any, heat is absorbed by the friction brake.
The friction brake is a load holding brake only and has
nothing to do with dynamic braking or rate of descent of a
load.
The brake clutch is splined to the primary sun gear shaft
between the motor and the primary sun gear. It will allow
this shaft to turn freely in the direction to raise a load and
lock up to force the brake discs to turn with the shaft in the
direction to lower a load. D-4 and 5.
The hydraulic cylinder, when pressurized, will release the
spring pressure on the brake disks, allowing the brake discs
to turn freely.
Dual Brake system-Operation
When hoisting a load, the brake clutch which connects the
motor shaft to the primary sun gear, allows free rotation. The
sprag cams lay over and permit the inner race to turn free of
the outer race. D-4. The friction brake remains fully
engaged. The winch, in raising a load, is not affected by any
braking action. D-1.
When the lifting operation is stopped, the load attempts to
turn the primary sun gear in the opposite direction. This
reversed input causes the sprag cams to instantly roll
upward and firmly lock the shaft to the fully engaged friction
brake. D-5.
When the winch is powered in reverse, to lower the load, the
motor cannot rotate until sufficient pilot pressure is present
to open the holding valve. D-2 & 3.
The friction brake within the winch will completely release at
a pressure lower than that required to open the brake valve.
The extent to which the holding valve opens will determine
the amount of oil that can flow through it and the speed at
which the load will be lowered. Increasing the flow of oil to
the winch motor will cause the pressure to rise and the
opening in the brake valve to enlarge, speeding up the
descent of load. Decreasing this flow causes the pressure to
lower and the opening in the holding valve to decrease thus
slowing the descent of the load.
When the control valve is shifted to neutral, the pressure will
drop and the brake valve will close, stopping the load. The
friction brake will engage and hold the load after the holding
valve has closed.
When lowering a load very slowly for precise positioning, no
oil flow actually occurs through the winch motor. The
pressure will buildup up to a point where the brake will
release sufficiently to allow the load to rotate the motor
through its own internal leakage. This feature results in a
very slow speed and extremely accurate positioning.
The friction brake receives very little wear in the lowering
operation. All of the heat generated by the lowering and
stopping of a load is absorbed by hydraulic oil where it can
be readily dissipated.
Hoisting or lowering of the load with the winch is controlled
by the winch lever. LOWER the load by pushing the lever
FORWARD and RAISE the load by pulling the lever back.
Improved control is obtained by operating the engine at low
speed While metering the control. Always actuate and
release this lever slowly to minimize dynamic effects of the
load and to prevent bird-nesting of the cable on the winch
drum.
To shift the winch into the high-speed mode, move the
rocker switch to high-speed. The motor is a variable speed
motor.
Terex Mobile Telescopic Level 1: RCI 510
Rated Capacity/Limiter System
Theor y of Oper at i on
System compares Actual Load Vs. Rated Load as
per load chart.
Load Chart Parameters are: Length/Angle/Radius
and Load
Actual Load is the load with hook block or ball and
cable, slings, etc.
Actual load is computed by a method called Total
Moment includes the load, boom, and all
attachments.
Input data for calculation of Moment of the Boom
includes:
-Boom Angle
-Boom Extension
-Lift Cylinder Pressure
What i s l oad moment
Moment is the tendency to produce a twisting
motion about a point or axis.
Total Moment is the moment produced by the Boom
and the Load.
What Makes Up Load Moment?
The Moment of the Boom: The weight and center
of gravity of the boom sections relative to the boom
pivot.
The Moment of the Load: The load and its
horizontal distance from the boom pivot.
Weight and Center of Gravity
of Booms Relative to Boom
Pivot
Moment of t he Boom
Moment of t he Load
The Load and its
Horizontal Distance
from the Boom Pivot
Load
Distance
Tot al Moment =
Boom + Load
Weight of Boom
PRESSURE
TRANSDUCER
BOOM EXT'N
SENSOR
SENSOR
BOOM ANGLE
CAPACITY
CHART
PERCENT
LOAD
ACTUAL
LOAD
ACTUAL
LOAD
BARGRAPH
RATED
CAPACITY
BOOM
LENGTH
DISPLAYS
BOOM
ANGLE
RADIUS
SENSOR
SWING
SENSORS
BOOM
MOMENT
MOMENT
LOAD
MOMENT
TOTAL
RADIUS
Crane
Setup
Computer Data Input
How Boom Angle is Measured
BOOM PIVOT
BOOM
ANGLE
(BA)
There is an angle potentiometer,
magnetically dampened capable of
measuring angle from -15 to +90
mounted on the side of the boom.
How We Measure Boom Length
BOOM
PIVOT
BOOM ROOT/BASE BOOM EXTENSION SPAN
B
O
O
M

L
E
N
G
T
H

(
L
)
Swing
Center
SWING
OFFSET
RADIUS (r)
PIVOT RADIUS (pr)
How Boom Radius is Measured
What Effect Does Boom Deflection Have?
15% Radius here=
15% increase in Total
Moment here
Total
Moment
How a Transducer Works
Strain Gauge
Pressure
from
Lift
Cylinder
Transducer Body
Typical Wheat Stone Bridge
Output i s 0 f or 0
pressure

Output voltage will in-
crease in proportion to
increase in pressure.
Drive - Drive +
Signal +
Signal -
350
350
VELOCITY FUSE PISTON SIDE
HOLDING VALVE
ROD SIDE TRANSDUCER INPUT
ROD SIDE
PISTON SIDE
Boom Length Reel and Angle Sensor
JIB ANTI-TWO BLOCK SWITCH
RCI 510 CABLES AND GUIDES
ROUSTER ANTI-TWO BLOCK SWITCH
Rod Side Transducer
When loads are in motion (as in booming down
There is a tendency for the actual load to change.
The rod side transducer collects this signal and
inputs it into the computer so it can calculate
compensation for this movement.
Percentage of Load
-The system displays percentage as a bar graph.
-The percentage is calculated from rated load and
actual load.
-Calculated % of load is used to regulate load
warnings
Bar Graph Alarms
There are basically 2 alarms:
Alarm one is: At 90% of rated load yellow
light and pulsating alarm tone.
Alarm two is: At 100% of rated load. Red
light and steady alarm tone with function
lockout
Normal Operations
100% Warning
90% Warning
Rated Load Factors
Factors Determining Rated Load:
Crane on Outriggers
Stowed or Erected Attachments
Lifting Point
Parts of Line in Use
Wire Rope Strength
As a Recap!
Moment is the product of a twisting motion
about an axis or point.
Moment = Force X Distance
Total Moment = Boom Moment + Load
Moment
MicroGuard 500 Rated Computer
Operation
ATB Switch Assy.
RCI 510 Display
90 Ft. Reeling Drum Assy.
With Piston and Rod Side
Transducers
MG 500 Computer
MG500 Component
Overview
Question? Why put the transducers inside the
enclosure?
With that change, we were able to remove about
75% of the Calibration Requirement
We can now match and Pre-Calibrate our
transducers.
Every Unit goes through an 11 hour
environmental chamber sequence in which
temperature goes from cold to hot.
RCI 510 Display
7. Boom Length 13. Information Screen11
1. 100% Red 8. Boom Angle 14. Operator Set Alarm2
2. 90% Red 9. Boom Radius 15. Moment Bar
4. Load on Hook 10. Alarm Cancel
5. Max Capacity 11. Test Button
6. ATB Light 12. Select Buttons
15
The Pictogram Pictogram
Erect Jib
Manual Boom
Stowed Jib
Select Winch
Aux Head
Pick From Jib or Main
boom
Outriggers
Travel Rig
Counterweight

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Terex Mobile Telescopic Level 1:

Mobile Telescopic Level 1 Manual

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