Grua Terex Rt

Mobile Telescopic Level 1 Manual

Terex Mobile Telescopic Level 1:

General ED.

How AC works

Terex Mobile Telescopic Level 1: General ED.

ROUTH TERRAIN CRANE


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. Terex Mobile Telescopic Level 1: General ED.

CARRIER

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


SUPER STRUCTURE

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. Terex Mobile Telescopic Level 1: General ED.

TELECCOPIC BOOM

OUTRIGGERS -provide a solid platform for the crane's safe operation and efficient use.


Boom Length reel And Angle transducer

Anti-two Block switch

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.


510 Computer unit

LMI

LMI SYSTEM COMPONENTS

BOOM CYLINDER


Using hydraulic pressure, the boom cylinder lifts the boom into position to make a lift.

STINGER/ FLY SECTION 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. Terex Mobile Telescopic Level 1: General ED.

STINGER SHEEVE

BOOM EXTENSION

1. -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.


2.

-Attach a guide rope to the eye on the bottom tip of the jib. -Raise the boom to horizontal.

3. -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°

4. -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.


BOOM HEAD/ NOSE

AUX BOOM NOSE/ ROOSTER SHEEVE

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. BOOM HEAD SHEAVES


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. 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.

HOOK BLOCK HEADACHE BALL

WEDGE SOCKET Terex Mobile Telescopic Level 1: General ED.

Hoist motor

Hoist drum

AUX AND MAIN HOIST


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 Motor

Swing Brake

Swing Reduction Unit

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.


SLUG

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

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.


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

4” BYPASS SPRING

RESERVOIR Terex Mobile Telescopic Level 1: General ED.

Crane Serial Number Location The Serial numbers located around the Machine are stamped in Three other positions besides the from of the cab. 1. 2. 3.

Top Rear Main Boom, Right Side Toward Main Winch Superstructure, Lower Right Hand Side Next to Gear Cover Right Rear Carrier Frame


RT CUMMINS ENGINE

Engine The power plant for the RT’s 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.

RADIATOR Terex Mobile Telescopic Level 1: General ED.

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..

T SERIES CUMMINS 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 Terex Mobile Telescopic Level 1: General ED.

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


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.

10 Speed Fuller (Manual) Transmission

6-Speed Forward with “Lock-Up” in top 5 gears Allison (Auto.) Transmission Terex Mobile Telescopic Level 1: General ED.

OUTRIGGER/STEERING PUMP

RT PUMP COMBINATION

MAIN PUMP RT PUMPS


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.


Load Charts

Terex Mobile Telescopic Level 1: Load Charts

Early cranes were heavy and bulky. This increased weight took the place of outriggers in crane design.

Terex Mobile Telescopic Level 1: Load chart

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. Terex Mobile Telescopic Level 1: Load chart

With the engineering of longer booms the development of Outriggers / Stabilizers began over.

? Terex Mobile Telescopic Level 1: Load chart

8’0” 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.


12’ 8’

The single box design consists of 2 OUTRIGGER BEAMS in one box.


20’ 8’ 16’ 16 8’

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.

The DOUBLE BOX OUTRIGGERS design consists of individual beams in individual boxes. This provides greater extension


100 LB.

100 LB.

CRANE CAPACITY is based on an old E OV GR

LAW OF PHYSICS

50,000 LB.


50,000 LB.

EQUAL WEIGHTS AT EQUAL DISTANCES ON OPPOSITE SIDES OF A FULCRUM POINT RESULT IN A BALANCED CONDITION

200 LB.

GR OV

HOW CAN A CRANE PICK MORE THAN ITS OWN WEIGHT ?

100 LB.

DISTANCE AS WELL AS WEIGHT, IS A FACTOR IN ACHIEVING BALANCE

E

50,000 LB.

100,000 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


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A Cranes ability to resist tipping depends on its STABILITY. It does not normally apply to a stationary machine. WEIGHT OF LOAD

FULCRUM WEIGHT OF MACHINE Terex Mobile Telescopic Level 1: Load chart

440 LB. 44 LB.

WHY DOES A CRANE LOSE STABILITY?

4,400 LB.

SINCE OUTRIGGER SPREAD IS LIMITED BY STRENGTH OF MATERIALS, DISTANCE AND WEIGHT ARE FACTORS OF STABILITY.


44,000 LB.

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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.


GR OV E

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.


d t a h W

h c d a o l o


n a e m s t r a

y o t

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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. Terex Mobile Telescopic Level 1: Load chart


Counterweight: W/AUX. WINCH………………8900 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 Slings Object Lifted Lifted Load

750 lbs. 215 lbs. 19,000 lbs. 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 Terex Mobile Telescopic Level 1: Load chart

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.


Headache Ball Whip Line

Swing Away Boom Extension

Aux Nose Extra Parts of Line Hook Block


Slings

GR OV

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WHAT IS LOAD RADIUS?

WHAT ARE SOME WAYS LOAD RADIUS CAN CHANGE?

LOAD RADIUS


C L

ROTATION

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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

RADIUS Terex Mobile Telescopic Level 1: Load chart

C L

AVOID SIDELOADING

Horizontal Force

TRAVELING OVER UNEVEN GROUND


PULLING A LOAD SIDEWAYS

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Can a Cable with 13,000 lb. line pull lift 25,000 lbs. ?

25,000lbs


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But with multiple parts of line it can.

25,000lbs



Load ratings are based on freely suspended loads. No attempt shall be made to move a load horizontally on the ground in any direction.

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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:

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.


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 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

HOIST TACKLE CHART Proper tire pressure should always be maintained

HOIST TACKLE CHART


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.


3:1


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SET-UP 1. Crane load ratings are based on the crane being leveled and standing on a firm, uniform supporting surface.

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 Operator’s 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 Operator’s 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 Operator’s 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 crane’s 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.

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 (*).

2. When either radius or boom length, or both, are between listed values, the smaller of the two listed load ratings shall be used.

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.

3. Do not operate at longer radii than those listed on the applicable load rating chart (cross hatched areas shown on range diagrams.)

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.”

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. Terex Mobile Telescopic Level 1: Load chart

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.

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.

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.


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: Load chart

Crane Safety

Terex Mobile Telescopic Level 1: 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 EVERYONE’S 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%


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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

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.


OPERATOR RESPOSIBILITIES

11. Know about movements of other machinery, trucks and personnel at the jobsite.

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.

17. Use tag lines to keep loads under control.

Keep people, equipment and material out of the work area.

19. Use shortest boom length possible.

9.

10. Signal person must be used when the operators vision in blocked or working in hazardous areas such as power lines or people. Terex Mobile Telescopic Level 1: Crane Safety

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.

18. Keep load close to ground.

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.

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.

SIGNAL PERSONS RESPONSIBILITY

4. Know and understand proper machine erection and rigging procedures.

1.

Standard crane signals must be used and understood.

5.

2.

Assist the operator in a safe and efficient operation, without endangering people or property.

Alert operator and signal person of dangers, such as power lines, unstable ground etc.

3.

Have a clear understanding of the work to be done.

MANAGEMENT RESPONSIBILITY 1. Operator must be competent, physically fit and if required licensed.

4.

Signal people must place themselves where they can be clearly seen and where they can safely observe the entire operation.

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.

HYDRAULIC SYMBOLS 101

Terex Mobile Telescopic Level 1: HYDRAULIC SYMBOLS 101

Crossing or Joining

SYSTEM 1 – TO LOOP

The shortest distance between two components that are connected is a straight line… and 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 aren’t connected to each other when it is necessary.

SYSTEM 1 – NOT TO LOOP

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. 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.

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. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101

FIXED DISPLACEMENT

VARIABLE DISPLACEMENT

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. 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. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101

PUMP ROTATION RH LOOKING AT SHAFT

ELECTRIC MOTOR

FIXED DISPLACEMENT PUMP

Displacement Controls

MOTOR SYMBOLS

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.

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.

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 COMPENSATED

PEDAL OR TREADLE

VER CONTROL

MECHANICAL SERVO

Terex Mobile Telescopic Level 1: Hydraulic Symbols 101

VALVES

UNI-DIRECTIONAL MOTOR

VALVES

REVERSIBLE MOTOR

The direction of flow is easily evident with a single triangle… it 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 direction… always 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.

PORTS

PORTS

DOUBLE-ACTING

PORTS

SINGLE-ACTING

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.


DOUBLE END ROD NONADJUSTABLE

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. We’re about to see that valve symbol are copiously decorated with arrows indicating the direction of flow.

PRESSURE CONTROL SYMBOLS

Normally Open

A pressure control valve, you’ll 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.

When the arrow connects the two ports, we know that the valve is normally open. It closes only when pressure overcomes the spring force.

SPRING

INLET

PILOT PRESSURE

INLET

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

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.


RELIEF VALVE PUMP We don’t attempt to show whether this is a simple or compound relief valve. All that’s important is to show its function in the circuit.

Sequence Valve

Sequence and Check 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 drain’s location in the 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.

RELIEF VALVE

PUMP

DIRECTIONAL VALVE

TO PRIMARY CYLINDER

SEQUENCE VALVE

DRAIN

TO SECONDARY CYLINDER


A- SEPARATE UNITS DIRECTIONAL VALVE TO PRIMARY CYLINDER NO FLOW DIRECTION

SEQUENCE VALVE CHECK VALVE RELIEF VALVE

FREE FLOW DIRECTION

PUMP

B-INTEGRAL SEQUENCE AND CHECK

COMPONENT ENCLOSURE


TO SECONDARY CYLINDER

A

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 isn’t shown, because the valve is internally drained. If valve body has two primary ports, a complete symbol should show one of them plugged. TO DIRECTIONAL VALVE

TO DIRECTIONAL VALVE B

PLUGGED PORT

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.

ENCLOSURE

COUNTERBALANCE 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. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101

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

FROM PUMP AND DIRECTIONAL VALVE

RETURN TO TANK 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 FLOW CONTROL

PRESSURE COMPENSATED

FROM PUMP AND DIRECTIONAL VALVE TO RETURN

FROM PUMP AND DIRECTIONAL VALVE

TO RETURN Flow controls applied to meter-out, meter-in and bleed-off circuits shown to the right.


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 SIMPLIFIED

NO FLOW

FREE FLOW

COMPOSITE Terex Mobile Telescopic Level 1: Hydraulic Symbols 101

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.

FROM PUMP

TO PILOT PRESSURE SOURCE

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.


A B

Mobile Directional Valves

P T TWO POSITION, CONTROLLED BY EXTERNAL PILOT PRESSURE

SOLENOID CONTROL SYMBOL

A B

P T TWO POSITION, CONTROLLED BY SOLENOID

The symbol for a mobile directional valve (below) resembles a fourway 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 CONTROL

SOLENOID CONTROL WITH INTERNAL PILOT PRESSURE

CHECK VALVE IN PRESSURE LINE

A B SPRING CENTERED

P T 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.

BY-PASS PASSAGE VIEW A “D” DOUBLE ACTING SPOOL

P T A

B

VIEW B “B” MOTOR SPOOL


P T

A

B

FILTER OR STRAINER

VIEW C “C’ FLOAT SPOOL COOLER P T

A

An accumulator appears as an oval and may have added inside details to indicate spring load, gas charge, or other features.

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. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101

SPRING LOADED

GAS CHARGED

SYMBOLS TABULATED In these pages, we have reviewed the major graphical symbols and how they are used. We couldn’t 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

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.


Symbol

Description

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.


Symbol

Description

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.


Symbol

Description

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


Symbol

Description

On-off (manual shut-off)

Line, Flexible

Line to vented manifold

Plug or plugged connection


Symbol

Description

Direction of flow

Flow control, adjustable (temperature and pressure compensated)

Two position Two connection

Two position Three connection


Symbol

Description

Two position Four connector

Three position Four Connection

Two position In transition

Valve capable of infinite positioning (horizontal bars indicate positioning Ability)


Symbol

Description

Spring

Manual

Push button

Push-pull lever


Symbol

Description

Symbol

Pedal or treadle

Mechanical

1 Detent

Pressure compensated


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

Accumulator, spring loaded

Heater

Cooler

Temperature controller


Symbol

Description

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).


Symbol

Description

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.


Symbol

Description

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


Symbol

Description

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. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101

Symbol

Description

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,


Symbol

Description

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.


Symbol

Description

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.


Symbol

Description

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).


Symbol

Description

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.


Symbol

Description

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.


Symbol

Description

Hydraulic Swivel: The hydraulic swivel is designed to allow 360 degree rotation, while supplying oil to all superstructure functions.


Symbol

Working Safety With Fluid Power

Terex Mobile Telescopic Level 1: Working Safety 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.

Terex Mobile Telescopic Level 1: Working safely with fluid power

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.

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 Terex Mobile Telescopic Level 1: Working safely with fluid power

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

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 Terex Mobile Telescopic Level 1: Working safely with fluid power

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

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 Terex Mobile Telescopic Level 1: Working safely with fluid power

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 untensioned 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

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 Terex Mobile Telescopic Level 1: Working safely with fluid power

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.

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: Working safely with fluid 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.

Outriggers

Outrigger Flowpath Electrical Flowpath

Terex Mobile Telescopic Level 1: Outriggers

CRANE OUTRIGGERS The key to lifting a maximum capacity load with a crane is the outriggers. They provide a solid platform for the crane’s safe operation and efficient use. Operators and workers within a crane’s radius must always be aware of how critical the placement and use of outriggers are to crane’s 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

Terex Mobile Telescopic Level 1: Outrigger

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. . Caution: Operating a machine with mechanical (nonhydraulic) 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.

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.

Blocking If blocking must be piled to build up height, ensure that it is stable and won’t topple when the swing and brake torque is transmitted through the outriggers to the ground.

WRONG UNSTABLE BLOCKING

Never block under the outrigger beams inside of the outrigger pads. This will create an inside tipping point and reduce stability. WRONG UNSTABLE BLOCKING Terex Mobile Telescopic Level 1: Outrigger


PADS NOT PINNED 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 crane’s frame twists and the beam lifts under the load.


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. Use solid blocking under all floats

Poor float support 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.


Anything wrong with this picture?


Check Valve With Thermal Relief

From Outrigger selector valve

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


1 From Outrigger selector valve

1. 2. 3.

PILOT PORT INLET SIDE CYLINDER SIDE

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. Terex Mobile Telescopic Level 1: Outrigger

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

LOCKING PIN

PIC 1


PIC 3

RT OUTRIGGER EXTEND/RETRACT SOLENOID RT OUTRIGGER JACK/STABILIZER 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.


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.

EXTEND/RETRACT SOLENOID

FRONT OUTRIGGER RETRACTED.

FRONT OUTRIGGER EXTEND/RETRACTSOLENOID

FRONT OUTRIGGER EXTENTDED. Terex Mobile Telescopic Level 1: Outrigger

ON OUTRIGGERS IN THE IN POSITION

ON OUTRIGGERS IN FULL OUT POSITION

ON OUTRIGGERS IN THE 50 PERCENT 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).

TYPE 1 PAD

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 2 PAD Terex Mobile Telescopic Level 1: Outrigger

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-200, T-300 Outrigger Pad Storage Location (Right-Rear)

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) Terex Mobile Telescopic Level 1: Outrigger

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.

CYLINDER JACK

T Series Outrigger Pad Storage Location (Left-Rear)

BEAM

*NOTE: CARE MUST BE TAKEN TO ENSURE THAT UPON ASSEMBLY, THE HOSES ARE INSTALLED WITH NATURAL CURVE. Terex Mobile Telescopic Level 1: Outrigger

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, Terex Mobile Telescopic Level 1: Outrigger

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. 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. 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 Once the operator has pressed the extend/retract switch CC-7, the desired side is chosen and button is pressed for 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. Due to the movement of these valve by the electrical circuit, hydraulic pressure can actuate the beam. Flow from the Terex Mobile Telescopic Level 1: Outrigger

outrigger/swing/steering pump now flows through the retract 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 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 Once the operator has pressed the extend/retract switch CC-7, the desired side is chosen and button is pressed for 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. 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. 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.

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.

FRONT OUTRIGGER CONTROLS *NOTE FRONT OUTRIGGER NOT USED TO LEVEL CRANE ONLY AS SUPPORT.


Steering

Steering Flowpath

Terex Mobile Telescopic Level 1: Steering


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 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.

88

STEERING FLOW

2-wheel Steer

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.

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.


4-wheel steer

Crab 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

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

REAR AXLE WITH STEERING CYLINDERS

FRONT AXLE WITH STEERING CYLINDERS


STEERING PRIORITY VALVE The 2 Wheel, 4 Wheel & Crab Steering, Steering Cylinders are in the center of the carrier.

STEERING CONTROL VALVE Terex Mobile Telescopic Level 1: Steering

Axle centering light This light is merely used as a Guide to Switch the Two, Four, and Crab Switch. Independent Rear Steering

AXLE CENTERING SWITCH


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

SHEPPARD GEAR

T 500 STEERING SYSTEM


T 200/300 FRONT AXLE T SERIES REAR TANDEM AXLE

T 500 FRONT AXLE Terex Mobile Telescopic Level 1: Steering

Axle Lock

Terex Mobile Telescopic Level 1: Axle Lock

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.


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.

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. Terex Mobile Telescopic Level 1: Axle Lock


Plunger

REAR AXLE CYLINDER Drain

Air breather


Air System

Terex Mobile Telescopic Level 1: Air system

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

Terex Mobile Telescopic Level 1: Air Systems

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.

of the air tanks may indicate that the air dryer is losing effectiveness.

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 dryer’s 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

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.

FRONT

REAR SUPPLY

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 Terex Mobile Telescopic Level 1: Air Systems

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).

TREADLE VALVE (FOOT PEDAL)

C

SWIVEL ROTATION

PARKING BRAKE RESERVOIRS

ALCOHOL EVAPORATOR

AIR OVER HYD. ACTUATOR AIR COMPRESSOR AIR CLEANER

BRAKES Terex Mobile Telescopic Level 1: Air Systems

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 4wheel 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 twowheel 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. Terex Mobile Telescopic Level 1: Air Systems

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.


Swivel

Terex Mobile Telescopic Level 1: 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 Port #2 Port #3 Port #4 Port #5 Port #6 Port #7 Port #8 Port #9

Return Line Boom, telescope Winch return Main boom hoist / Telescope pump line Steering cylinders Steering cylinders Steering / Swing main pump line Drain line Steering return line


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

T SERIES ROTARY MANIFOLD 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. Terex Mobile Telescopic Level 1: Swivel

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

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 – Air Swivel

8 Passes 4 Passes

The air tube works with the throttle cable for engine R.P.M.


Center Swivel assembly

Swing

Swing Flowpath

Terex Mobile Telescopic Level 1: Swing

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. 360 DEGREE LOCK Always engage lock before travelling the crane. NEVER ENGAGE THE LOCK WHILE SWINGING THE MACHINE.

2 POSITION PIN LOCK Terex Mobile Telescopic Level 1: Swing

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

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.

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

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 Terex Mobile Telescopic Level 1: Swing

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.

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

The upper structure is joined to the carrier by a swing bearing which is bolted to the carrier and bolted to the upper.

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. CLICK

DESCRIPTION

1

Bumper should rest against the pedal.

2

Brake disks should begin to engage.

3 4

Brake discs should be fully engaged

5

and should hold at full engine RPM.

6

Swing brake cable should be adjusted

7

and /or brake pads may need replacing

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


Boom

Boom Flowpath

Terex Mobile Telescopic Level 1: Boom

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.

BOOM

HOLD VALVE 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

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 misadjustment 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.

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

RT AND TRUCK CRANE MAIN VALVE


Telescope

Telescope Flowpath

Terex Mobile Telescopic Level 1: Boom Tele

First movable section

BOOM SECTION 1

Terex Mobile Telescopic Level 1: Boom tele

SECTION 2

SECTION 3

SECTION 4

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 Terex Mobile Telescopic Level 1: Boom tele

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 hasn’t been addressed. There is a retract chain that is anchored on one end to the base section and the other end to the 3rd 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 2nd section due to it being bolted to the cylinder) and pushes on the retract cable which in turn pulls the 3rd 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 it’s Terex Mobile Telescopic Level 1: Boom tele

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.

RETRACTING THE PULLOUT SECTION (F-9) 1. Retract the boom completely and boom down to minimum boom angle.

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.

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. 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

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 erected retaining pin hole.

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. Terex Mobile Telescopic Level 1: Boom tele

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 weight. The light and audible alarms should be actuated in the cab and the boom down, boom extend, and winch up controls should disconnect.

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. Terex Mobile Telescopic Level 1: Boom tele

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 is within specifications.

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 is within specifications. 10. If the dimension is less than 2.75 inches, tighten adjustments C and D equal amounts until the measurement is within specifications. 11.Under the same condition, the maximum sag in the extend chain should be 7.00 inches to 7.50 inches. This measurement is from the bottom of the third boom section to the top of the extend chain.

Winch

Winch Flowpath

Terex Mobile Telescopic Level 1: Winch

Hydraulic Winch

The winch hydraulic circuit flow path

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.

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

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.


* 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. Terex Mobile Telescopic Level 1: Winch

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. Terex Mobile Telescopic Level 1: Winch

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.

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.

Never use a steel hammer or punch bar to move the rope on the drum. These tools can easily damage the rope.

5. Slowly rotate the drum, ensuring the first layer of cable is evenly wound onto the drum.

After the wire rope is wound onto the winch drum, reeve the cable as desired.

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. Terex Mobile Telescopic Level 1: Winch

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.

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.

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.

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. Terex Mobile Telescopic Level 1: Winch

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 weight. The light and audible alarms should be actuated in the cab and the boom down, boom extend, and winch up controls should disconnect. 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.


Rated Capacity/Limiter System

Terex Mobile Telescopic Level 1: RCI 510

Theory of Operation 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 is load 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.

Moment of the Boom Weight and Center of Gravity of Booms Relative to Boom Pivot


Moment of the Load The Load and its Horizontal Distance from the Boom Pivot


Total Moment = Boom + Load

Weight of Boom Load


Distance

ACTU AL LOAD PRESSU RE T RANSDUCER

TOTAL MOMENT

LOAD MOMENT

ACTUAL LOAD

PERCENT LOAD

BARGRAPH RAT ED CAPACITY

SENSO RS

BOOM MOMENT

R ADIUS

CAPACITY CHART

BOOM EXT 'N SENSO R

BOO M LENG TH BOO M ANG LE

BOOM ANGLE SENSO R SW IN G SENSO R

RADIUS

Com puter D ata Input


DISPLAYS

Crane Setup

How Boom Angle is Measured There is an angle potentiometer, magnetically dampened capable of measuring angle from -15° to +90° mounted on the side of the boom.

BOOM ANGLE (BA)


BOOM PIVOT

How We Measure Boom Length

BOOM PIVOT

BOOM EXTENSION SPAN


BOOM ROOT/BASE

How Boom Radius is Measured

BO OM

LE NG TH

(L )

SWING OFFSET

RADIUS (r) Swing Center PIVOT RADIUS (pr) Terex Mobile Telescopic Level 1: RCI 510

What Effect Does Boom Deflection Have?

15% Radius here= 15% increase in Total Moment here


Total Moment

How a Transducer Works

Pressure from Lift Cylinder

Strain Gauge


Transducer Body

Typical Wheat Stone Bridge

Signal +

Output is “0” f or “0 ” pressure 350

Signal Drive -

350


Drive +

Output voltage will increase in proportion to increase in pressure.

HOLDING VALVE

VELOCITY FUSE PISTON SIDE

ROD SIDE TRANSDUCER INPUT


PISTON SIDE ROD SIDE


Boom Length Reel and Angle Sensor


RCI 510 CABLES AND GUIDES

ROUSTER ANTI-TWO BLOCK SWITCH Terex Mobile Telescopic Level 1: RCI 510

JIB 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.

100% Warning

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

90% Warning

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

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


MG500 Component Overview ATB Switch

.

Assy

90 Ft. Reeling Drum Assy.

MG 500 Computer RCI 510 Display

With Piston and Rod Side Transducers Terex Mobile Telescopic Level 1: RCI 510

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 15

1. 2. 4. 5. 6.

100% Red 90% Red Load on Hook Max Capacity ATB Light


7. Boom Length 8. Boom Angle 9. Boom Radius 10. Alarm Cancel 11. Test Button 12. Select Buttons

13. Information Screen11 14. Operator Set Alarm2 15. Moment Bar

The “Pictogram”

Manual Boom

Erect Jib

Select Winch

Aux Head

Counterweight

Pick From Jib or Main boom

Travel Rig

Outriggers


Stowed Jib

Grua Terex Rt

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