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Terex Mobile Telescopic Level 1:

Mobile Telescopic Level 1 Manual

Terex Mobile Telescopic Level 1: General ED.

General ED.
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ROUTH TERRAIN CRANE


CARRIERThis is the portion of the crane which supports, And transports the superstructure. It consists of the Chassis; frame; carrier cab; outriggers; engine; transmission; steering; axles; brakes; and suspension.


SUPER STRUCTUREAbove the swing bearing is called the Superstructure and consists of the crane controls; lift cylinder; boom nose; aux boom nose; headache ball; hook block & wedge socket; boom extensions; hoists; wire rope; swing; counterweights; and hydraulic system


TELECCOPIC BOOMIt hydraulically extends, and is designed to support loads. The boom telescope cylinder extends and retracts the boom into the desired position for a lift.


OUTRIGGERS

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


Anti-twoBlockswitch

Boom Length reelAnd

Angle transducer

LMI

510Computer

unit

LMI SYSTEM COMPONENTSAnti-two block system- Working in conjunction with the LMI, the A2B stops the operator from bringing the block or ball into contact with the boom nose.


BOOM CYLINDER

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


STINGER/ FLY SECTION

STINGER SHEEVE

SWINGAWAYBOOM

EXTENSION

Folds out in two sections to erect. The boom swingaway stows on boom base section when not in use. The fly section stays inside the base section when not in use.


-Retract the boom completely.-Boom down to minimum boom angle to allowease of installation of the jib pins.-Install the upper and lower jib mounting pinsin the right side of the boom head.

1. -Attach a guide rope to the eye on the bottom tipof the jib.-Raise the boom to horizontal.

2.

BOOM EXTENSION


-With the engine at idle, slowly extend the boom to 35 feet (10.6 m). As the jib clears the storage brackets, the jib will swing out approximately 45

3. -With the engine at idle, slowly boom down tominimum boom angle while another operatoruses the guide to control the speed of the jibrotation. The jib will swing around until theleft side mounting holes line up.

-Install the left upper and lower jib mounting pins.-Remove the guide rope.

-Disconnect the anti two-block plug from the jib anti two-block socket and connect it to the socket on the boom head. Move the dummy plug from the boom head socket to the anti two-block socket on the jib.

-Reeve the hoist line over the jib sheave.

-Test the anti two-block system by lifting the anti two-block weight. The light and audible alarms should be actuated in the cab and the boom down, boom extend, and winch up controls should disconnect.

4.


AUX BOOM NOSE/ ROOSTER SHEEVE

BOOM HEAD/ NOSE

BOOM HEAD SHEAVES

Aux boom nose is an additional sheave, normally mounted to the front of the boom nose, over which an additional part of line may be run.


HOOK BLOCK

HEADACHE BALL

Hook block is a device with multiple sheaves (wheels) used to achieve multiple parts of line in order to lift loads which surpass the load limit of the rope.

The headache ball is the weight fitted to the wire rope, above the lifting hook, which causes an empty hook to lower with gravity.

WEDGE SOCKET

The wedge socket is a devise used at the end of the wire rope to attach the rope to a headache ball or hook block.


AUX AND MAIN HOIST

Hoist motor

Hoist drum


FUEL TANK

DIESEL PLEASE


SWING MOTOR

Swing also called slewing is the rotary motion of the superstructure around the centerline of rotation. This motion is achieved with a swing gear box or boxes.


Bearing Plate

Swing Reduction Unit

Swing Brake

Swing Motor

SWING BEARING


RT COUNTER WEIGHTS

Weight located at the rear of the superstructureto counteract the effects of lifting a load. Some cranes have power remove/install counterweight systems to reduceweight for road travel. If no auxiliary hoist, there will be a comparable weight in place of the hoist.


The Counterweight slugs weigh 3000 Lbs. The Max Counterweight Slugs by design are 3 or Total 9,000 Lbs. Integral Counterweight Removal System Permits Counterweight to be Carried on Deck of the Truck Crane to Optimize Axle Weights.T340XL - 11,000 CWTT340 - 7,200 CWTT230 - 7,200 CWT

*Note weights are including weight of Counter weight without slugs. Maximum Counterweight is 11,000 lbs

TRUCK CRANE COUNTERWEIGHTS

SLUG


Hydraulic Counterweight Removal System


Hydraulic Reservoir (tank)

The reservoir is where the system starts for the hydraulics system. The fluid must be changed every 1500 HRS. The reservoir is equipped with a Full Flow Oil Filtration System with By-Pass Protection. It also includes a 60 mesh screen filter, and a 5 Micron Replaceable Return Filter. There is a by pass spring associated with the reservoir that has a spring length of 4 inches. This must be ensured for proper by pass operation of system. This is an early indicator of clogged filter. Change reservoir return filters at first 40 Hours Then at 500 hours. Also, clean intake suctions at the same time.


4 BYPASS SPRING

RESERVOIR

Hydraulic Reservoir

It is equipped with Internal Baffles and Diffuser, andeasy access to filter. The filters are screen washable and paper disposable.Screen: 60 MeshReturn Filter: 5 Micron (Replaceable)

Tank Pressure: 14 P.S.I. to Prevent Dirt Infiltration


Crane Serial Number Location

The Serial numbers located around the Machine are stamped in Three other positions besides the from of the cab.

1. Top Rear Main Boom, Right Side Toward Main Winch

2. Superstructure, Lower Right Hand Side Next to Gear Cover

3. Right Rear Carrier Frame


EngineThe power plant for the RTs consist of the Cummins 6 Cylinder, 359 Cu. In. 2500 R.P.M., Turbocharged diesel engine. The RT200 puts out 130 Hp while the RT300 puts out 152 hp. The RT400 and 500 puts out 174 Hp. The cooling system is split in half between hydraulic fluid and transmission fluid.

RT CUMMINS ENGINE

RADIATOR


EngineThe power plant for the T-200 series consist of the Cummins 6 Cylinder, 504.5 Cu. In., 300HP @ 2000 RPM., Turbocharged diesel engine..

EngineThe power plant for the T-300 and T-500 series consist of the Detroit Diesel series 50 4 Cylinder, 519 Cu. In. with 350 HP @ 1800 Rpm., Turbocharged/After cooled diesel engine. Later T-500 series was equipped with 6 cylinder, 778 Cu. In. with 420 HP @ 1800 RPM.

T SERIES CUMMINS ENGINE

T SERIES CUMMINS ENGINE


RT TRANSMISSION

Clark 18000 Power-Shift with Torque Converter. Check oil level Daily at 500 R.P.M., 180 to 200. Change oil every 1000 hrs


10 Speed Fuller (Manual) Transmission

6-Speed Forward with Lock-Up in top 5 gears Allison (Auto.) Transmission

There are two transmissions used for the truck cranes. There is the 10 speed fuller, which is a 10 speed manual that comes standard and a 6 speed Automatic transmission that is optional.


MAIN PUMP

OUTRIGGER/STEERING PUMP

RT PUMPS

RT PUMP COMBINATION


Truck Crane Pump Disconnect

Disconnect is air operated at 60 120 psi. It is equipped with an interlock system that is tied to a relay to prevent switching coupling while under load. The governor is set at 105 psi Cut in and 125 Cut out. All seals, threads, and joints must be checked daily for leaks. Used to keep from driving the pumps while normal street driving.

NOTE: Under no circumstance should different lubrication such as mineral oil, synthetic oils or greases be mixed together.


Truck Crane Tandem PumpsTruck crane has a tandem pumping configuration. There are three gear type pumps run off the engine that provide the pressure for the Main/ Aux winches, Boom hoist, Telescope, outrigger, Swing, and the Counter weight control valves.

Terex Mobile Telescopic Level 1: Load Charts

Load Charts

Terex Mobile Telescopic Level 1: Load chart

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


Older crane operators would operate the cranes by the seat of their pants. Their judgment on what a particular crane could lift was evaluated by experience on a particular crane. The operator would literally feel the crane starting to tip. This is how the operator would determine what the maximum he could safely lift with that crane.


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

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The Early Stabilizers were a screw type. Manual force was needed to jack the machines into the air. They were designed to unload the weight from the tires.

80


8

12

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


881616

882020

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

The TWO STAGE DOUBLE BOX OUTRIGGERS design consists of two telescoping beams in two individual boxes. These extensions provide greater than twice the width of the carrier.


100 LB. 100 LB.

CRANE CAPACITY

is based on an old

LAW OF PHYSICS

EQUAL WEIGHTS ATEQUAL DISTANCES ONOPPOSITE SIDES OFA FULCRUM POINTRESULT IN ABALANCED CONDITION

GROVE

50,000 LB. 50,000 LB.


200 LB. 100 LB.HOW CAN A CRANE PICKMORE THAN ITS OWN WEIGHT ?

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

100,000 LB.

GROVE

50,000 LB.


With OUTRIGGER SPREAD far enough it would be possible to lift the world.

... PROVIDED THE OUTRIGGER IS STRONG ENOUGH.


Strength of material becomes a consideration when engineering Outriggers. The greater the leverage requires a stronger lever or O/R to prevent it from breaking. Therefore the Greater Capacities are composed of 2 Elements

REINFORCEMENT PLATES FOR MULTIPLE OUTRIGGERCONFIGURATION


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

FULCRUMWEIGHT OF MACHINE

WEIGHT OFLOAD

GROVE


WHY DOES A CRANE LOSESTABILITY?

44 LB.44 LB.

440 LB.440 LB.

44,000 LB.44,000 LB.

4,400 LB.4,400 LB.

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


Capacity charts are divided into several areas depending on the capabilities of the crane. The rough terrain cranes have a 360 chart for lifting all around the crane.

GROVE


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.

GROVE


ON RUBBER (ON TIRES) a condition existing anytime a machine is not on outriggers. Generally used in connection with lifting capacities.

GROVE


What do

load ch

arts me

an to yo

u?


It tells you which CAPACITIES are limited by....It tells you which CAPACITIES are limited by....

STRUCTURAL STRENGTH All Capacities above the Boldline.

STABILITYAll capacities below the BOLDline.

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. Formachines not in service, the main boom should be retracted and lowered with the swing brake set in winds greater than 30 MPH.


Counterweight:

W/AUX. WINCH8900 LBS.

W/O AUX. WINCH.10000 LBS.


Powered boom length 30 ft. retracted to 94 ft. extended.


LOAD RATING CHART INTERPRETATION

In the following pages are examples of a load chart, these example charts may differ from the chart supplied with your crane. Always use the load rating chart supplied with the crane to interpret the conditions and limitations that exist when making a lift with the crane. The determining factorsare lifted load, radius, boom angle, working position, hoist line reeving, tire pressure, travel data, use of a jib, and other special conditions that exist, such as wind velocity, soil conditions, etc.

DEFINITIONS OF LOAD CHART TERMS

Lifted Load:The lifted load is the total weight of all the items suspended on the wire rope.

Example:Hook block 750 lbs.Slings 215 lbs.Object Lifted 19,000 lbs.Lifted Load 19,965 lbs.

Load Radius:The horizontal distance from the axis of rotation before loading to the center of the vertical hoist line or tackle with a load.

Loaded Boom Angle:The loaded boom angle is the angle between the boom base section and the horizontal, after lifting the rated load at the

rated radius. The boom angle before loading should be greater to account for deflections. The loaded boom angle combined with the boom length give only an approximation of the operating radius.

No Load Stability Limit:

The stability limit radius shown on the range diagrams is the radius beyond which it is not permitted to position the boom, when the boom angle is less than the minimum shown on the applicable load chart, because the machine can overturn without any load.

Freely Suspended Load:Load hanging free with no direct external force applied except by the hoist rope.

Side Load:Horizontal force applied to the lifted load either on the groundor 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.
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Whip Line

Aux Nose

Extra Parts of Line

Hook Block Slings

Swing Away Boom Extension

Headache Ball


CL ROTATION LOAD RADIUS

WHAT ISLOAD

RADIUS?

WHAT ARESOME WAYS

LOAD RADIUS CAN CHANGE?

GROVE


RADIUS WILL CHANGE IF YOU..

1. BOOM UP OR DOWN2. TELESCOPE IN OR OUT3. SWING UNCONTROLLABLY4. TRAVEL OVER ROUGH TERRAIN

WITHOUT THE LOAD TIED OFF5. EXPERIENCE HIGH WIND

CL

GROVE

RADIUS


TRAVELING OVER PULLING A LOAD UNEVEN GROUND SIDEWAYS

Horizontal Force

AVOID SIDELOADING


GROVE

25,000lbs

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


GROVE

25,000lbs

But with multiple parts of line it can.


GROVE

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


Over Front and 360:

The crane working position diagram is a view looking straight down on the crane with the upper structure and the boom removed. The front of the crane is always the end opposite the engine.

Over Front when the crane is on outriggers is the area inside the are bounded by lines from the centerline of rotation through the front outrigger vertical jack cylinders.

St. Over Front (Straight Over Front) when operating on tires means the boom and load must be positioned straight to the front of crane and not swung to right or left.

360 means the load can be swung to any position around the crane.

Cut - Offs:Rated chart values of less than approximately 1,000 lbs for on outriggers and side-stow jib are not shown. This is done because the effects of wind, pendulum action, jerking, etc., can cause a tip over. Therefore:

Extending the boom or boom and jib combination into unrated areas of the chart can cause tip over. Do not operate at a longer radius than those listed on theapplicable load rating charts as tipping can occur without a load on the hook.


HOIST TACKLE CHART

HOIST TACKLE CHART

HOIST TACKLE CHART


HOIST TACKLE CHART

HOIST TACKLE CHART

HOIST TACKLE CHART

This chart only represents the maximum permissible hoist line load per parts of line. You must refer to the proper lift charts for machine rated loads.


HOIST TACKLE CHART

HOIST TACKLE CHART

HOIST TACKLE CHART

Proper tire pressure should always be maintained


HOIST TACKLE CHART

HOIST TACKLE CHART

HOIST TACKLE CHART

This chart represents the weight for the hook blocks depending on the number of sheaves installed. This weight must be taken into account when making load rating determinations.


SET-UP1. Crane load ratings are based on the crane being leveled

and standing on a firm, uniform supporting surface.

3:1GROVE


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

xx x


SET-UP.

3. Crane load ratings on tires depend on appropriate inflation pressure and the tire conditions. Caution must be exercised when increasing air pressures in tires. Consult Operators Manual for precautions.


SET-UP4. Use of jibs, lattice-type boom extensions, or fourth section

pullouts extended is not permitted for pick and carry operations.


SET-UP

5. Consult appropriate section of the Operators and Service Manual for more exact description of hoist line reeving.

6. The use of more parts of line than required by the load may result in having insufficient rope to allow the hook block to reach the ground.


SET-UP

7. Properly maintained wire rope is essential for safe crane operation. Consult Operators Manual for proper maintenance and inspection requirements.

8. When spin-resistant wire rope is used, the allowable rope loading shall be the breaking strength divided by five (5), unless otherwise specified by the wire rope manufacturer.

9. Do not elevate the boom above 60 unless the boom is positioned in-line with the cranes chassis or the outrigger are extended. Failure to observe this warning may result in loss of stability.


OPERATION1. CRANE LOAD RATINGS MUST NOT BE EXCEEDED. DO

NOT ATTEMPT TO TIP THE CRANE TO DETERMINE ALLOWABLE LOADS.

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

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

4. The boom angles shown on the Capacity Chart give an approximation of the operating radius for a specified boom length. The boom angle, before loading, should be greater to account for boom deflection. It may be necessary to retract the boom if maximum boom angle is insufficient to maintain rated radius.

5. Power telescoping boom sections must be extended equally.

6. Rated loads include the weight of hook block, slings, and auxiliary lifting devices. Their weights shall be subtracted from the listed rated load to obtain the net load that can be lifted.When lifting over the jib the weight of any hook block, slings, and auxiliary lifting devices at the boom head must be added to the load. When jibs are erected but unused add two (2) times the weight of any hook block, slings, and auxiliary lifting devices at the jib head to the load.

7. Rated loads do not exceed 85% on outriggers or 75% on tires, of the tipping load as determined by SAE Crane Stability Test Code J765 a. Structural strength ratings in chartare indicated with an asterisk (*).

8. Rated loads are based on freely suspended loads. No attempt shall be made to drag a load horizontally on the ground in any direction.

9. The user shall operate at reduced ratings to allow for adverse job conditions, such as: soft or uneven ground, out of level conditions, high winds, side loads, pendulum action, jerking or sudden stopping of loads, hazardous conditions, experience of personnel, two machine lifts, traveling with loads, electric wires, etc. (side pull on boom or jib is hazardous). Derating of the cranes lifting capacity is required when wind speed exceeds 20 MPH. The center of the lifted load must never be allowed to move more then 3* off the center line of the base boom section due to the effects of wind, inertia, or any combination of the two. *"Use 2' off the center line of the base boom for a two section boom, 3' for a there section boom, or 4 for a four section boom.

10. The maximum load which can be telescoped is not definable, because of variations in loadings and crane maintenance, but it is permissible to attempt retraction and extension if load ratings are not exceeded.
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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.
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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 therated load of 27,700 lbs. and can be handled.


All crane load ratings are based on nonuse of the travel function while handling loads. However, cranes may be utilized for pick and carry operations. Traveling with suspended loads involves so many variables such as ground conditions, boom length, momentum in starting and stopping, etc., that it is impossible to devise a single standard rating procedure with any assurance of safety. For such operations the user must evaluate prevailing conditions and determine safe practices, exercising precautions, such as the following:

1. The boom shall be carried straight over the front of the crane.

2. Travel speed reduced to suit conditions.

3. Maintain specified tire pressures.

4. Avoid sudden starts and stops.

5. Provide tag or restraint lines to snub swinging of the load.

6. Keep the load as close to ground as possible.

7. Set the swing brake and swing lock.

8. The travel surface must be on a smooth level surface that is capable of supporting the weight of the loaded crane. The travel surface must also be free of holes or debris that can cause crane instability.

These precautions are necessary to prevent a pendulumeffect of a swinging load. The results of this happening can cause a machine tip over.

Any variation from the above conditions will require the operator to consider the prevailing conditions and reduce the lift capacities accordingly.

Always carry the load as near the ground as possible with the minimum boom length necessary to carry the load, and straight over the front with the swing brake locked and swing lock engaged since the rear axle oscillation is locked out when the boom moves off center more than 10 deg. Travel over uneven terrain with the rear axle oscillation locked out can result in instability. Also, excessive boom length can result in instability due to effect of uneven terrain and wind pressure.


Insufficient tire pressure reduces the ON TIREScapacity. 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 temperaturereaches 200 deg. F, reduce the duty cycle. Stop operations as required to prevent further increase in the hydraulic oil temperature.

Terex Mobile Telescopic Level 1: Crane Safety

Crane Safety


Between 1997 1999Total number of crane accidents 158

Mobile Crane accidents 115 (73%)

Fatalities 13 Fatalities (1 Operator, 12 non crane operators)

Injuries 102 Non fatal injuries ( 23 Operators, 79 Non operators)

SAFETY IS EVERYONES RESPONSIBILITY


Between 1997-1999 Accident Causation

Unsecured Load 5.7%

Load Capacity Exceeded 27.6%

Ground not level or too soft 3.8%

Lack of Communication 22.9%

Electrical Contact 9.5%

Other 30.5%


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WARNINGDO 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 typeof 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 itsintended 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 LicensingCaliforniaConnecticutHawaiiMassachusettsMinnesotaMontanaNevadaNew JerseyNew MexicoNew YorkOregonRhode IslandWashington (as of 2010)West Virginia

Cities Currently requiring Crane LicensingChicagoLos AngelesNew OrleansNew York CityOmahaWashington, DC


OSHA 192.550(a)(16)Bans equipment modifications or additions without the manufacturer's approval. Any changes require alteration of capacity, operation and maintenance plates, tags and decals, and may not diminish the crane's original safety factor.


Two blocking occurs when the hook block makes contact with the boom head sheaves.

This can cause the wire rope to break and drop the load or can cause damage to block or sheaves.

It can be caused by hoisting up or by failure to let out line when extending the boom or booming down.

Watch when stowing the boom in transport position.

Two Blocking


OPERATOR RESPOSIBILITIES1. Read and understand Operators Manual

2. Make sure the machine is in proper order and that all operation aids and warning signals are functioning before operating.

3. Keep the machine clean, including all instrumentation, window lights and other glazed surfaces.

4. Remove all oil, grease, mud, ice and snow from walking surfaces.

5. Store all tools and other necessary items in proper storage boxes.

6. Never lift a load without a load chart in the cab.

7. Know the load to be lifted.

8. Be alert, physically fit and free from the influences of alcohol, drugs, or medications that might affect the operators eyesight, hearing or reactions.

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

10. Signal person must be used when the operators vision in blocked or working in hazardous areas such as power lines or people.

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

12. Keep a full charged fire extinguisher and first aid kit in the cab at all times and be familiar with how to use them.

13. Never permit people on the machine platform while the machine is working.

14. Make sure everyone is in a safe place before moving the hook, boom, load or outriggers.

15. Start and stop movements smoothly and swing at speeds that will keep the load under control.

16. Keep at least two full wraps of wire rope on drum while operating.

17. Use tag lines to keep loads under control.

18. Keep load close to ground.

19. Use shortest boom length possible.

20. Never leave a running machine unattended or load suspended.

21. Always use outriggers in accordance with requirements of load char and operators manuals.
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21. Lowering boom to stow, insure boom is fully retracted if not fully retracted it is possible to crush carrier cab.

22. Do not extend the boom while the boom is in the stowed position.

SIGNAL PERSONS RESPONSIBILITY

1. Standard crane signals must be used and understood.

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

3. Have a clear understanding of the work to be done.

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

RESPONSIBILITY OF ALL CREW MEMBERS.

1. Unsafe conditions or practices must be corrected.

2. Obey all warning signs.

3. Watch out for your safety and the safety of others.

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

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

MANAGEMENT RESPONSIBILITY1. Operator must be competent, physically fit and if

required licensed.

2. Operator, signal people and riggers must be trained in correct crane operation and use.

3. Operator and signal people must know standard crane signals.

4. Have a supervisor at job site who is responsible for job safety.

5. Crew members given specific safety responsibilities and instructed to report any unsafe conditions to supervisor .


6. Supply the weight of the load to be lifted to the operator.

7. Verify that all crew members are familiar with OSHA, ANSI B30.5 9 (Safety and Health Regulations for construction) requirements as well as instructions in manuals.

Standard hand signal for controllingcrane operation


Decals markings and warning.

Warning

All safety instructions on the crane must be maintained in completeand 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 safephase to phase (kV)---------------clearance (feet)

50 or below------------------------------ 10Above 50 to 200------------------------ 15Above 200 to 350----------------------- 20Above 350 to 500----------------------- 25Above 500 to 750----------------------- 35Above 750 to 1,000---------------------45

If at any time the crane is working within a booms length of the prohibited zone a qualified signal person whose sole responsibility is to verify clearance is maintained shall be in constant contact with the crane operator.

Terex Mobile Telescopic Level 1: HYDRAULIC SYMBOLS 101

HYDRAULIC SYMBOLS 101

Terex Mobile Telescopic Level 1: Hydraulic Symbols 101

Crossing or Joining

The shortest distance between two components that are connected is a straight 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 arent connected to each other when it is necessary.

There are two accepted systems because the question to loop or not to loop could not be resolved.

To show that two crossed lines are not connected, we put a shortloop in one of the lines at the intersection. However, it is just as correct to simply to let the lines cross.

A connection between two crossing lines must be designated by placing a dot at the crossing, if loops are used to designate crossing. The dot is omitted if no loops are used for crossing, but all joining lines must be shown as tees. Cross connections are not permitted in this no dot system. Only one system or the other shall be used throughout a diagram.

SYSTEM 1TO LOOP

SYSTEM 1NOT TO LOOP

PUMP SYMBOLS

Would you believe that pump symbols are even easier than reservoir symbols? The basic symbol is a circle with a black triangle pointing outward.

SYSTEM 1 TO LOOP

SYSTEM 1 NOT TO LOOP

FIXED DISPLACEMENT VARIABLEDISPLACEMENT


VARIABLE DISPLACEMENT PRESSURE COMPENSATED

VARIABLEDISPLACEMENT

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 anarrow through it at 45 degrees.

Optional Symbols

Occasionally it may be desirable to show the prime mover and thedirection of rotation. If the prime mover is an electric motor, it appears as a circle with an M in the center. A heat engine (gasoline or diesel) is shown as two squares; one inside the other. A curved arrow crossing a line from the pump symbol indicates the direction of rotation where required.

PUMP ROTATIONRH LOOKING AT SHAFT

ELECTRIC FIXEDMOTOR DISPLACEMENT

PUMP


MOTOR SYMBOLS

Motor symbols also are circles with black triangles; but with triangles point in to show that the motor is a receiver of pressure energy. One triangle is used In a non-reversible motor symbol; two are used for a reversible motor.

UNI-DIRECTIONALMOTOR

REVERSIBLEMOTOR

Displacement Controls

A displacement control for a pump (or motor) is drawn beside thesymbol. As you can see, the control symbol sometimes has a resemblance to the control; for instance, the lever has a knob.

The pressure compensator symbol is a small arrow parallel to short side of symbol. This symbol is used with any pressure compensated component, and may adjoin the symbol or be placed right on it.

PRESSURE LE VERCOMPENSATED CONTROL

PEDAL MECHANICALOR TREADLE SERVO

VALVES

VALVES


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 tothe pressure line. The opposite port then must be discharging back to the tank.

Controls symbols and rotation direction indicators used with pump symbols also apply to motors.

CYLINDER SYMBOLS

A cylinder symbol is a simple rectangle representing the barrelwith a T-shaped representation of a piston and rod. The symbol can be drawn in any position.

If the cylinder is single-acting, there is only one hydraulic line drawn to the symbol. Also, the end of the symbol opposite the port is left open.

A double-acting cylinder symbol has both ends closed and has two lines meeting the symbol at the port connections. A double end rod cylinder has a rod line extending from each end.

Cylinder cushions are drawn as smaller rectangles against the piston line. If the cushion has an adjustable orifice, the slanted arrow is drawn across the symbol.

PORTS

PORTS

SINGLE-ACTING

DOUBLE END ROD

NON-ADJUSTABLE ADJUSTABLE

CUSHIONED

Flow to and from a cylinder must be traced by observing which lines it is connected to. There is no provision in the symbol for flow direction. This really not a problem, though. Were about to see that valve symbol are copiously decorated with arrows indicating the direction of flow.

DOUBLE-ACTINGPORTS


Normally Open

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

Relief Valve

We diagram a relief valve with a normally-closed symbol connected between the pressure line and tank. The flow direction arrow points away from the pressure line port and toward the tank port. This shows very graphically how a relief valve operates. When pressure in the system overcomes the valve spring, flow is from the pressure port to the tank port.

PRESSURE LINE

RELIEF VALVE

PUMP

We dont attempt to show whether this is a simple or compound relief valve. All thats important is to show its function in the circuit.

PRESSURE CONTROL SYMBOLS

A pressure control valve, youll recall, is infinitely positioned between two flow conditions. Its basic symbol is a square with external port connections and an arrow inside to show the direction of flow. Usually this type valve operates by balancing pressure against a spring, so we show a spring at one side of the symbol and a pilot pressure line at the other.

INLET INLETSPRING PILOT PRESSURE

OUTLET OUTLET

Normally Closed

A normally-closed valve, such as a relief or sequence, is shown with the arrow offset from the ports toward the pilot pressure line. This indicates that the spring holds the valve closed until it is overcome by pressure. We mentally visualize the arrow moving over to complete the flow path from inlet to outlet when pressure rises to the valve setting.

The actual function of the valve is shown by its connection into the circuit diagram.


Sequence Valve

The same symbol is used for a sequence valve. This time, though,the inlet port is connected to a primary cylinder line; the outlet port to the secondary cylinder line. Pilot pressure from the primary cylinder line sequences the flow to the outlet port when it reaches the setting of the valve.Since the sequence valve is externally drained. We have added a drain connection to the symbol at the drains location in the valve.

RELIEF VALVE PUMP

DIRECTIONAL VALVE TOPRIMARYCYLINDER

SEQUENCE VALVE

TOSECONDARY

DRAIN CYLINDER

Sequence and Check Valve

Remember that with this connection a sequence valve must be used with a check valve for free return flow when the cylinders are reversed. The next diagram shows a simplified check valve symboland its parallel connection. As you are looking at it, free flow is to the up.. Away from the V which represents a seat.

In the top view, we see the check valve as a separate unit when the check valve is built into the sequence valve, we enclose both valves with a box called an enclosure.

An enclosure is used to show the limits of a component or an assembly containing more than one component. It is an alternate long-and-short dash line. External ports are assumed to be on the enclosure line and indicate connections to components.


A- SEPARATE UNITS

DIRECTIONAL VALVE

TO PRIMARYCYLINDER

NO FLOWDIRECTION

FREE FLOWDIRECTION

TO SECONDARYCYLINDER

CHECK VALVE

SEQUENCEVALVE

PUMPRELIEF VALVE

B-INTEGRAL SEQUENCEAND CHECK

COMPONENT ENCLOSURE


Counterbalance Valve

A counterbalance valve is a normally closed pressure control within integral check valve. For a directly controlled valve, we use the same symbol with the primary port connected to the bottom port of the cylinder and the secondary port of the directional valve. The drain connection isnt shown, because the valve is internally drained. If valve body has two primary ports, a complete symbol should show one of them plugged.

PLUGGED PORTTODIRECTIONALVALVE

COUNTERBALANCEENCLOSURE 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 thedirectional valve. It looks like the counterbalance valve diagram, except that it has two pilot control connections. A low pressure in line A will open the valve to permit free flow from the motor through the valve to B, but higher braking pressure will be required from the motor to open the valve internally if driving pressure A is removed.

A

B

TODIRECTIONALVALVE

Pressure Reducing Valve

The normally-open pressure reducing valve is diagrammed below. Outlet pressure is shown opposing the spring to modulate or shutoff flow when the valve setting is reached.

Flow Control Symbol

The basic flow control valve symbol (seen following page) is a simple representation of a restriction. If the valve is adjustable, the slanted arrow is drawn across the symbol.


NON-ADJUSTABLE

ADJUSTABLE

A complete adjustable, pressure compensation flow control with built in by-pass is diagrammed in diagram below. The short vertical arrow is the symbol for pressure-compensated, as you already know.

ADJUSTABLE PRESSURE FLOW CONTROL COMPENSATED

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

FROM PUMP AND DIRECTIONALVALVE

RETURNTO TANK

FROM PUMP AND DIRECTIONAL VALVE

TO RETURN

FROM PUMP AND DIRECTIONAL VALVE

TO RETURN


DIRECTIONAL CONTROL SYMBOLS

A directional control valve symbol uses a multiple envelope system that has a separate rectangle for each position. All the port connections are made to the envelope that shows the neutral condition of the valve. Within each envelope are arrows showing the flow paths when the valve is shifted to that position.

One Way Valve

You have already seen the simplified symbol for a check valve. Compare it with the composite symbol (below) and decide for yourself which will get the most use. However, the multiple envelope system does provide a simple way of showing function when applied valve has several flow paths.

NO FLOW

FREE FLOW

NO FLOW FREE FLOW

SIMPLIFIED

COMPOSITE


Unloading ValveAn unloading valve symbol (below) has two envelopes. In the normal closed position, flow is shown blocked inside the valve. The spring control is placed adjacent to this envelope to show that the spring controls this position.

External pilot pressure is indicated against the bottom envelope to show that this is the flow condition when the pilot pressure takes over. With the lower envelope superimposed on the other, the flow path arrow connects the pump outlet to the reservoir.

Four-Way Valve

an ordinary four-way valve has two envelopes if it is a two-position valve (next page) or three envelopes if it has a center position. The actuating control symbols are placed at ends of the envelops. The extreme envelops show the flow conditions when their adjacent controls are actuated.

FROMPUMP

TO PILOTPRESSURE SOURCE


A

P

B

T

A

P

B

T

A

P

B

T

TWO POSITION, CONTROLLED BY EXTERNAL PILOT PRESSURE

TWO POSITION, CONTROLLED BY SOLENOID

SOLENOIDCONTROLSYMBOL

SOLENOID CONTROLWITH INTERNALPILOT PRESSURE

THREE-POSITION, SPRING-CENTERED, CLOSEDCENTER CONTROLLED BY SOLENOID

WITH INTERNAL PILOT PRESSURE

The manual, lever, pedal, and mechanical control symbols pictured earlier are used as appropriate with directional valves. Spring symbols, pilot lines, solenoid symbols and internal-pilot black triangles also are used as appropriate.

Mobile Directional Valves

The symbol for a mobile directional valve (below) resembles a four-way valve symbol, but it has added connections and flow paths torepresent the by-pass passage. There is a separate envelope for each finite position and connections are shown to the center or neutral position. A manual lever or neutral position. A manual lever control with centering springs is shown at each end.

Complete symbols for B, C, and T spools in diagram below. Views B, C, and D. These illustrations show only the spools. A complete mobile valve bank would also show relief valves and internal connections within an enclosure.

MANUAL CHECK VALVECONTROL IN PRESSURE LINE

SPRINGCENTERED

BY-PASS PASSAGEVIEW A

D DOUBLE ACTING SPOOL

VIEW BB MOTOR SPOOL

P

T

A B


P

T

A B

VIEW CC FLOAT SPOOL

P

T

A B

VIEW DT SINGLE ACTING SPOOL

ACCESSORIES

Fluid conditioners are represented as squares that are turned 45degrees and have the port connections to the corners. A dotted line at right angles t port connections tells us the conditioner is filter or strainer . A cooler symbol has a solid at right angle to fluid line with energy triangles (indicating heat this time) pointing out.

FILTER OR STRAINER

COOLER

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

SPRING LOADED GAS CHARGED

SYMBOLS TABULATED

In these pages, we have reviewed the major graphical symbols andhow they are used. We couldnt attempt to cover every possible symbol and combination; that would take several books the size of this one.For your reference, all the basic hydraulic symbols are tabulated in the next few pages


Description Symbol

Reservoir: The hydraulic reservoir is designed to store, cool, and clean the machines hydraulic oil supply. The vented reservoir allows atmospheric pressure to push the oil into the hydraulic pumps inlet ports.

Hydraulic Return Lines: Are either terminated. 2. below fluid level. 2 above fluid level.


Description Symbol

Pump: Hydraulic pumps convert mechanical energy transmitted by a power source, into hydraulic working energy, flow. In some applications a variable displacement pump may be used. Form 2.

Power Source: A power source can be in the form of combustion engine. Form 1 or electric motor form 2.Both provide power to operated the hydraulic pumps either as a main power source or an emergency.


Description Symbol

Hydraulic Motor: Convert the working energy of the hydraulic system into mechanical energy. Hydraulic motors are positive displacement and are either vane, Gear or Piston..

Pump Disconnect: Used to disconnect pump from power source for extended travel, repairs, cold weather starts.


Description Symbol

Continuous Line: Supply line or Return line depending on direction of oil flow..

Connecting Lines: Branch lines connected to main line.

Line Crossing: A line crossing over another line, but not connected.

Dashed Line: Pilot pressure


Description Symbol

On-off (manual shut-off)

Line, Flexible

Line to vented manifold

Plug or plugged connection


Description Symbol

Direction of flow

Flow control, adjustable (temperature and pressure compensated)

Two positionTwo connection

Two positionThree connection


Description Symbol

Two position Four connector

Three positionFour Connection

Two positionIn transition

Valve capable of infinite positioning(horizontal bars indicate positioningAbility)


Description Symbol

Spring

Manual

Push button

Push-pull lever


Description Symbol

Pedal or treadle

Mechanical

Detent

Pressure compensated

1


Description Symbol

Solenoid, single winding

Reversing Motor

Pilot pressureRemote supply

Internal supply

Rotating shaft

M


Description Symbol

Enclosure

Pressure gauge

Electric motor

Accumulator, spring loaded

M


Description Symbol

Accumulator, spring loaded

Heater

Cooler

Temperaturecontroller


Description Symbol

Dotted Line: Case drain or load sense.

Chain Line: Enclosure of two or more functions contained in one unit. (outrigger control),

Pressure Transducer: Is a hydraulic/ electrical device located in the lift cylinder circuit. It is used in conjunction with the cranes load moment indicator system. (LMI).


Description Symbol

Filter: Removes contamination from hydraulic system.

Filter with Bypass Valve: The bypass valve allows the oil to bypass the filter if it is ;plugged or the oil is too thick to pass through filter.

Accumulator: used in a hydraulic circuit to either develop system flow or absorb system shock. Most accumulators are charged with nitrogen gas.


Description Symbol

Check Valve: Is designed to create back pressure in a specific circuit. Swing, oil cooler.

Orifice: A fixed restriction that functions as a flow control device . Designed to reduce pressure and oil flow in specific circuits.

Adjusted Orifice: An inline restriction that functions as a flow control device. This device is manually adjustable for fine tuning pressure and flow rate.

Hydraulic Oil Cooler: Because of viscosity, friction, and changing direction, hydraulic oil generates heat during operation. To keep the oil within the required operating temperature range, air coolers are installed in the system to aid in the cooling process


Description Symbol

Temperature Switch: An electric switch that regulates the temperature of hydraulic oil.

Hydraulic Pressure Switch: Senses hydraulic pressure for the purpose of energizing electrical components. (Relay coils, indicator lights.

Flow Switch: Provides ground for a specific electric circuit, shown in normal position it will illuminate an indicator light indicating a fault. When operating properly oil flow will enter the value and at the same time as pressure builds in pilot line shifting the spool open thus opening the switch contacts and turning off indicator light.


Description Symbol

Relief Valve: Installed in a hydraulic circuit to protect the system from being over pressurized.

Pressure Reducing Valve: Regulates max pressure allowed into individual circuits. (swing brake, function controllers).

Shuttle Valve: The inlet port connected to the high pressure is automatically connected to the outlet port, while the other port is closed. Used to direct maximum pressure to components depending on application,


Description Symbol

Manually Operated: Two way valve, the oil flow has two paths to travel, in the neutral position as shown, the oil, onceenough pressure is built to unseat the check, the oil can flow to tank.

Pneumatic: One position valve, once the spool is shifted the oil has a path to flow to function, in the neutral position is blocked.

Pilot: Operated one position valve, same as pneumatic operated valve, only the spool is shifted by pilot oil.


Description Symbol

Electric Operated: Two way valve, once the spool is shifted the oil has two paths to travel, to the specific circuit and an path for oil to return to tank.

Electric Operated: One position valve, once the spool is shifted, the oil has a path to flow to function, in the neutral to flow blocked, this spool is shifted electrically.

Brake Valve: Supplies hydraulic oil to swing brake assembly to assist the springs to apply pressure to stop the rotation of the superstructure, during crane operation.


Description Symbol

Open Center Cylinder Spool: Used in the directional control valve that controls oil flow to and from a cylinder function. When in the neutral position, as shown here, the oil is trapped in the circuit. With the crane running and the gear pump engaged, and the spool is in neutral position. The oil will flow through the center of valve (A) and returned to tank (B). This spool is shifted with a control lever. (outrigger, lift, telescope).

Open Center Motor Spool: Used in the directional control valve that controls oilf low to and form a hydraulic motor function. When in the neutral position, as shown here, the circuit is open to a return line to tank. This prevents build upof hydraulic oil back pressure in the motor circuit. (hoist, swing).


Description Symbol

Closed Center Cylinder Spool: Used in a pressure compensated directional control valve that controls oil flow to and form a cylinder function. Oil in the cylinder circuit is trapped in the circuit when the spool is in the neutral position. If no functions are being operated the oil cannot pass through the center of the valve back to tank. Instead the unloader valve cartridge spool is shifted with hydraulic pilot pressure. (lift, telescope).

Closed Center Motor Spool: Function the same as the closed center cylinder spool above, except that this spool has a open port for oil flow back to tank. This prevents build up of back pressure in the motor circuit.


Description Symbol

Single Acting Cylinder: Can be extended hydraulically or pneumatically depending on application. The cylinder is retracted utilizing a spring. (Axle disconnect, park brake)

Double Acting Cylinder: Extended and retracted hydraulically. (Steer).

Double Acting Telescope Cylinder: With holding valve. The rod of the cylinder is anchored, as oil flow unseats the one way check valve in the holding valve (A), the oil flow to the piston side of the cylinder (B) filling up with oil, causingthe barrel to move outward, the boom section that is anchored to is pushed outward.


Description Symbol

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

Terex Mobile Telescopic Level 1: Working Safety with Fluid Power

Working Safety With Fluid Power

Terex Mobile Telescopic Level 1: Working safely with fluid power

Working safely is partly a state of mind. In addition to workingwith safety in mind, an individual must be trained to understand the hazardous involved with working on machinery in order to anticipate and avoid hazardous actions or conditions.

Fluid power manufacturers, distributors, and users have always been concerned with the safety of persons using fluid power systems. More attention must be given to the subject considering the widespread use of fluid power equipment and the wide range of skills of persons using and repairing this equipment. Safety concerns vary widely as do the applications of hydraulics and pneumatics. This article discusses some of the common hazards associated with fluid power systems. There may be omissions due to the broad subject area. The article is meant to be a starting point for a discussion of hazards and how to minimize or eliminate them. Here are some important safety practices for hydraulic and pneumatic mechanics, technicians, and equipment operators.

1. Safety glasses and other protective face shields should be worn as necessary.

2. Hearing protection must be worn in areas with noise levels greater than 80dBA.

3. Protective clothing should be worn as required especially when working on systems that have high fluid temperatures.

4. Safety shoes and hard hats should be worn in hazardous areas.

5. Communicate with co-workers. When working with other people, it is essential to communicate your intentions to them. Let them know what parts of the equipment could move during testing and troubleshooting. Make certain that no one takes any unauthorized action. Post warnings and use lockouts where possible.

6. Practice good housekeeping. Do not let tools and disassembled components accumulate in the work area where they can create a tripping hazard.

Oil on the floor is an extreme hazard at any time. Take the time to apply oil absorbent and clean up the spill.

7. Never test to atmosphere! Never just put a hose into a bucket or hold onto an airline and test for flow. The flow rate may suddenly increase when a valve opens or a failed component bypasses, causing an unrestrained hose end to whip. Always test for flow by using a properly installed flow meter.

8. Use lockouts. Isolate and lockout the electrical control system and the electrical power supply. Each person working on the system must add their own lock to any/all lockout devices.

9. Storage of components and materials should be such that there is no danger of items falling or shelves tipping.

10. Components and items that contain fluid must be drained and stored in a manner that prevents fluid leakage onto floors.


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 suspectan injury, go to a hospital emergency room and tell the doctor

that you suspect a fluid injection injury. Treatment must be started immediately. An injection injury can occur when a finger, hand, or other body part comes in contact with a stream of pressurized fluid. A jet of fluid can come from a crack in a component, fitting, or fluid conductor. It can also come from a pin hole in a hose, from between bolted flanges, from a loose fitting, from a failed seal, or from a component orconductor 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
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15. Air-oil or diesel explosions in hydraulic systems are rare, though they do occur. These explosions are caused by rapid pressurization of a component or gauge that contains air. The heat of compression ignites the oil vapors and explodes. An air-oil explosion can result when an elevated implement or load is dropped uncontrolled, because a cylinder contains air following assembly or repair. Cylinders and other components containing air should have the air removed through a proper bleed down procedure. Safety case type gauges should be used where ever possible. During startup of new and repaired systems pressure should be increased gradually to prevent explosion and to reduce the danger of fluid spills.

With forethought and planning, many accidents can be avoided.

16. Assume pressure is present. Sources of pressure include charged accumulators, loaded actuators, springs under load, system capacitance (trapped pressure), and compressed air trapped in or unbled from the system.

Relieve system pressure. Actuate all directional control valves to all positions so that all lines will have a chance to discharge to tank. Note that in the case of pilot-operated valves, the pilot pressure that is necessary to accomplish this task will not be present and the valve will not shift, preventing trapped pressure from discharging to tank. Never tighten or loosen lines while the system is still operating.If it is necessary to remove pipe flanges, 4-bolt flanges, or subplate mounted components, always release the torque on

the bolts that are furthest from first. This way, if pressure ispresent, 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 wrenchtorque 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
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piston is located at the hydraulic end of the bore. This will prevent the piston from slamming against the end cap during the precharging process. When removing the piston from an accumulator, it should be pressed out. Using compressed air to blow the piston out is dangerous because the piston becomes a flying projectile.

17. Hydraulic cylinders that require disassembly should be pulled apart with a winch. Using compressed air to force the rod, piston and end cap out is dangerous for two reasons, the first being that the entire piston and rod assembly will be ejected with uncontrollable force. The second is, if the piston should be separated from the rod, the rod will shoot out of the end cap with destructive force.

18. An explosion hazard is present when reservoirs, tanks, drums or any component that contains, or has contained, a combustible or flammable material is modified by cutting or welding. Even a material that has a minor component that is combustible, such as a cleaning agent, can produce explosive gasses. When flame or arc cutting, or welding, is attempted on such a component, a violent explosion can occur. Heat can produce additional vapor that can ignite and explode.

High pressure leaks can turn into a blow torch if ignited. If the leaking oil is hot, severe burns may result.19. Transferring hydraulic fluid from drums to reservoirs should be done with a drum pump or by gravity flow. The practice of pressurizing drums with compressed air is dangerous. Pressurization kits are manufactured for this purpose. They have a nonadjustable air regulator that limits the drum pressure to

approximately 2-psi. The downstream line from the regulator is fitted with a relief valve for safety, should the regulator fail.

20. Rotating shafts, couplings, universal joints, gears, sprockets, etc., require guards and shields. Never place your finger or hand on a rotating part. Keep clothing and cleaning towels away from rotating parts. When using a tachometer, position yourself so that if the tachometer should slip off of the shaft, your fingers or hands will not enter a fan, flywheel or other moving parts.

21. Troubleshooting a machine that has an interrupted machine cycle may result in personal injury or machine damage. During the troubleshooting process, manual overrides on directional controls, limit switches, or other controls may be actuated the cycle may complete or motion may occur out of sequence, thereby causing a hazardous situation. Study the machine and make certain that tools, equipment, and persons are clear of possible damaging motion should an actuator move. Check for safe and clear operation anytime you do anything that could cause actuators to move. Try to move actuators to an unloaded or an un-tensioned position. If necessary, block or wedge a load to keep it from pressurizing a system.

22. Reservoirs may build up pressure from thermal expansion. On some machines reservoirs are pressurized to overcome pressure drop in pump inlet systems. Before servicing any hydraulic system, be sure to relieve the reservoir pressure by slowly opening the filler cap or venting valve provided for this purpose. The next step is to move all
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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 backof your hand. It is a normal reaction to close the hand and grip

tightly when something hot is touched. By using the back of your hand, you will not inadvertently grasp the hot object. If necessary, use gloves if you cannot wait for the system to cool down.

24. In hose applications, use nonconductive hose whenreplacing nonconductive hose on boom trucks and pole saws. Contact with electrical lines can be deadly. Use conductive hose on applications where grounding isrequired, 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.


cause fires, some tank filling procedures require grounding the vehicle or tank before any attempt is made to fill or remove material.

In summary, working safely is partly a state of mind, and partly being educated about the possible hazards that may be encountered. Before undertaking a task, analyze the task and determine what hazards might be encountered and what actions to take in order to negate these hazards. Make contingency plans in case an accident occurs. Analyze past accidents in order to determine what happened and how to avoid a re-occurrence. With forethought and planning, many accidents can be avoided.

29. Cleaning fluids, hydraulic fluids, and even water can be absorbed through the skin. Individual people have different reactions to chemicals. Protect yourself with gloves and protective clothing.

30. Fumes, spray mist, and dust can be dangerous, use ventilation and respirators as required.

31. When modifying a system, use caution when installing quick connect couplings. A quick connect coupling placed between a pump and a directional control could leave the pump without a relief valve in the type of system where the relief valve is located in the directional control valve.

32. Outriggers or stabilizers that are fitted with pilot operated check valves can trap pressurized fluid. When a power supply has failed, stabilizer cylinders have been retracted with jacks,without venting the fluid. This process builds extremely high pressures in the cylinder. System pressure may not be sufficient to open the valve against this pressure and it becomes trapped. Removing the valve to relieve the pressure is dangerous. Jets of fluid, seals, or propelled parts may injure you.

33. Use personal protection and the proper cleanup compounds when dealing with mercury spillsfrom manometers, thermometers, thermostats, and electric controls.

34. Filling gasoline tanks on hot orrunning engines should be avoided. Static sparks will also

Terex Mobile Telescopic Level 1: Outriggers

Outriggers

Outrigger Flowpath

Electrical Flowpath
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Terex Mobile Telescopic Level 1: Outrigger

Caution: Operating a machine with mechanical (non-hydraulic) outriggers, make sure that the beams and cylinders are pinned and locked in place; otherwise they can creep in during the operation

All wheels must be clear of the ground. If they are not, the crane has an inside tip In axis on its tires, capacity is lost and the on rubber chart must be used.

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