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(1)Mobile Telescopic Level 1 Manual. Terex Mobile Telescopic Level 1:.

(2) General ED.. How AC works. Terex Mobile Telescopic Level 1: General ED..

(3) ROUTH TERRAIN CRANE. Terex Mobile Telescopic Level 1: General ED..

(4) 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.

(5) 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. Terex Mobile Telescopic Level 1: General ED.. SUPER STRUCTURE.

(6) 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.

(7) OUTRIGGERS -provide a solid platform for the crane's safe operation and efficient use.. Terex Mobile Telescopic Level 1: General ED..

(8) 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.. Terex Mobile Telescopic Level 1: General ED.. 510 Computer unit. LMI. LMI SYSTEM COMPONENTS.

(9) BOOM CYLINDER. Terex Mobile Telescopic Level 1: General ED.. Using hydraulic pressure, the boom cylinder lifts the boom into position to make a lift..

(10) 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.

(11) 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.. Terex Mobile Telescopic Level 1: General ED.. 2.. -Attach a guide rope to the eye on the bottom tip of the jib. -Raise the boom to horizontal..

(12) 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.. Terex Mobile Telescopic Level 1: General ED..

(13) 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. Terex Mobile Telescopic Level 1: General ED..

(14) 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..

(15) Hoist motor. Hoist drum. AUX AND MAIN HOIST. Terex Mobile Telescopic Level 1: General ED..

(16) FUEL TANK. DIESEL PLEASE. Terex Mobile Telescopic Level 1: General ED..

(17) 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.. Terex Mobile Telescopic Level 1: General ED..

(18) Bearing Plate Swing Motor. Swing Brake. Swing Reduction Unit. SWING BEARING. Terex Mobile Telescopic Level 1: General ED..

(19) 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.. Terex Mobile Telescopic Level 1: General ED..

(20) 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. Terex Mobile Telescopic Level 1: General ED.. TRUCK CRANE COUNTERWEIGHTS.

(21) Hydraulic Counterweight Removal System. Terex Mobile Telescopic Level 1: General ED..

(22) 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.. Terex Mobile Telescopic Level 1: General ED..

(23) 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..

(24) 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. Terex Mobile Telescopic Level 1: General ED..

(25) 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..

(26) 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..

(27) 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. Terex Mobile Telescopic Level 1: General ED..

(28) 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..

(29) OUTRIGGER/STEERING PUMP. RT PUMP COMBINATION. MAIN PUMP RT PUMPS. Terex Mobile Telescopic Level 1: General ED..

(30) 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.. Terex Mobile Telescopic Level 1: General ED..

(31) Truck Crane Tandem Pumps Truck crane has a tandem pumping configuration. There are three gear type pumps run off the engine that provide the pressure for the Main/ Aux winches, Boom hoist, Telescope, outrigger, Swing, and the Counter weight control valves.. Terex Mobile Telescopic Level 1: General ED..

(32) Load Charts. Terex Mobile Telescopic Level 1: Load Charts.

(33) Early cranes were heavy and bulky. This increased weight took the place of outriggers in crane design.. Terex Mobile Telescopic Level 1: Load chart.

(34) 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.

(35) With the engineering of longer booms the development of Outriggers / Stabilizers began over.. ? Terex Mobile Telescopic Level 1: Load chart.

(36) 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.. Terex Mobile Telescopic Level 1: Load chart.

(37) 12’ 8’. The single box design consists of 2 OUTRIGGER BEAMS in one box.. Terex Mobile Telescopic Level 1: Load chart.

(38) 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. Terex Mobile Telescopic Level 1: Load chart.

(39) 100 LB.. 100 LB.. CRANE CAPACITY is based on an old E OV GR. LAW OF PHYSICS. 50,000 LB.. Terex Mobile Telescopic Level 1: Load chart. 50,000 LB.. EQUAL WEIGHTS AT EQUAL DISTANCES ON OPPOSITE SIDES OF A FULCRUM POINT RESULT IN A BALANCED CONDITION.

(40) 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.. Terex Mobile Telescopic Level 1: Load chart.

(41) With OUTRIGGER SPREAD far enough it would be possible to lift the world.. ... PROVIDED THE OUTRIGGER IS STRONG ENOUGH.. Terex Mobile Telescopic Level 1: Load chart.

(42) 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. Terex Mobile Telescopic Level 1: Load chart.

(43) E OV GR. 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.

(44) 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.. Terex Mobile Telescopic Level 1: Load chart. 44,000 LB..

(45) GR OV. E. 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.. Terex Mobile Telescopic Level 1: Load chart.

(46) 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.. Terex Mobile Telescopic Level 1: Load chart.

(47) E OV GR. ON RUBBER (ON TIRES) a condition existing anytime a machine is not on outriggers. Generally used in connection with lifting capacities.. Terex Mobile Telescopic Level 1: Load chart.

(48) d t a h W. h c d a o l o. Terex Mobile Telescopic Level 1: Load chart. n a e m s t r a. y o t. ? u o.

(49) 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.. Terex Mobile Telescopic Level 1: Load chart.

(50) 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.

(51) Terex Mobile Telescopic Level 1: Load chart.

(52) Counterweight: W/AUX. WINCH………………8900 LBS. W/O AUX. WINCH………….10000 LBS.. Terex Mobile Telescopic Level 1: Load chart.

(53) Powered boom length 30 ft. retracted to 94 ft. extended.. Terex Mobile Telescopic Level 1: Load chart.

(54) 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..


(56) Headache Ball Whip Line. Swing Away Boom Extension. Aux Nose Extra Parts of Line Hook Block. Terex Mobile Telescopic Level 1: Load chart. Slings.

(57) GR OV. E. WHAT IS LOAD RADIUS?. WHAT ARE SOME WAYS LOAD RADIUS CAN CHANGE?. LOAD RADIUS. Terex Mobile Telescopic Level 1: Load chart. C L. ROTATION.

(58) GR OV. E. 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.

(59) AVOID SIDELOADING. Horizontal Force. TRAVELING OVER UNEVEN GROUND. Terex Mobile Telescopic Level 1: Load chart. PULLING A LOAD SIDEWAYS.

(60) E OV GR. Can a Cable with 13,000 lb. line pull lift 25,000 lbs. ?. 25,000lbs. Terex Mobile Telescopic Level 1: Load chart.

(61) E OV GR. But with multiple parts of line it can.. 25,000lbs. Terex Mobile Telescopic Level 1: Load chart.


(63) Load ratings are based on freely suspended loads. No attempt shall be made to move a load horizontally on the ground in any direction.. E OV GR. Terex Mobile Telescopic Level 1: Load chart.

(64) 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.. Terex Mobile Telescopic Level 1: Load chart. 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..

(65) HOIST TACKLE CHART. HOIST TACKLE CHART. HOIST TACKLE CHART. Terex Mobile Telescopic Level 1: Load chart.

(66) 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. Terex Mobile Telescopic Level 1: Load chart.

(67) HOIST TACKLE CHART. HOIST TACKLE CHART Proper tire pressure should always be maintained. HOIST TACKLE CHART. Terex Mobile Telescopic Level 1: Load chart.

(68) 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.. Terex Mobile Telescopic Level 1: Load chart.

(69) 3:1. Terex Mobile Telescopic Level 1: Load chart. E OV GR. SET-UP 1. Crane load ratings are based on the crane being leveled and standing on a firm, uniform supporting surface..

(70) 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. Terex Mobile Telescopic Level 1: Load chart. x. x.

(71) 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.. Terex Mobile Telescopic Level 1: Load chart.

(72) SET-UP 4. Use of jibs, lattice-type boom extensions, or fourth section pullouts extended is not permitted for pick and carry operations.. Terex Mobile Telescopic Level 1: Load chart.

(73) 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.. Terex Mobile Telescopic Level 1: Load chart.

(74) 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.. Terex Mobile Telescopic Level 1: Load chart.

(75) 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..

(76) 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”.. Terex Mobile Telescopic Level 1: Load chart.

(77) 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.. Terex Mobile Telescopic Level 1: Load chart.

(78) 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.. Terex Mobile Telescopic Level 1: Load chart.

(79) 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. Terex Mobile Telescopic Level 1: Load chart.

(80) 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.. Terex Mobile Telescopic Level 1: Load chart.

(81) 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. Terex Mobile Telescopic Level 1: Load chart.

















(98) 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. Terex Mobile Telescopic Level 1: Load chart. –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..

(99) 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.. Terex Mobile Telescopic Level 1: Load chart. 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..

(100) 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.

(101) Crane Safety. Terex Mobile Telescopic Level 1: Crane Safety.

(102) 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. Terex Mobile Telescopic Level 1: Crane Safety.

(103) 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%. Terex Mobile Telescopic Level 1: Crane Safety.

(104) What is wrong with this picture?. Terex Mobile Telescopic Level 1: Crane Safety.

(105) 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.. Terex Mobile Telescopic Level 1: Crane Safety. 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.

(106) 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.. Terex Mobile Telescopic Level 1: Crane Safety. 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.

(107) 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. Terex Mobile Telescopic Level 1: Crane Safety.

(108) 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.. Terex Mobile Telescopic Level 1: Crane Safety.

(109) 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.. Terex Mobile Telescopic Level 1: Crane Safety.

(110) 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..

(111) 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 .. Terex Mobile Telescopic Level 1: Crane Safety.

(112) 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. Terex Mobile Telescopic Level 1: Crane Safety.

(113) Terex Mobile Telescopic Level 1: Crane Safety.


(115) 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. Terex Mobile Telescopic Level 1: Crane Safety.




(119) 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. Terex Mobile Telescopic Level 1: Crane Safety. 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..

(120) HYDRAULIC SYMBOLS 101. Terex Mobile Telescopic Level 1: HYDRAULIC SYMBOLS 101.

(121) 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.

(122) 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.

(123) 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.

(124) 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.. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101. 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..

(125) 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.. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101. 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..

(126) 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. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101.

(127) 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. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101. TO SECONDARY CYLINDER.

(128) 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..

(129) 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.. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101.

(130) 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.

(131) 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.. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101.

(132) 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. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101.

(133) 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.

(134) 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.. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101. Symbol.

(135) 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.. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101. Symbol.

(136) 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.. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101. Symbol.

(137) 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. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101. Symbol.

(138) Description. On-off (manual shut-off). Line, Flexible. Line to vented manifold. Plug or plugged connection. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101. Symbol.

(139) Description. Direction of flow. Flow control, adjustable (temperature and pressure compensated). Two position Two connection. Two position Three connection. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101. Symbol.

(140) Description. Two position Four connector. Three position Four Connection. Two position In transition. Valve capable of infinite positioning (horizontal bars indicate positioning Ability). Terex Mobile Telescopic Level 1: Hydraulic Symbols 101. Symbol.

(141) Description. Spring. Manual. Push button. Push-pull lever. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101. Symbol.

(142) Description. Symbol. Pedal or treadle. Mechanical. 1 Detent. Pressure compensated. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101.

(143) Description. Symbol. Solenoid, single winding. Reversing Motor. Pilot pressure Remote supply Internal supply. Rotating shaft. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101. M.

(144) Description. Symbol. Enclosure. Pressure gauge. Electric motor. Accumulator, spring loaded. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101. M.

(145) Description. Accumulator, spring loaded. Heater. Cooler. Temperature controller. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101. Symbol.

(146) 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).. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101. Symbol.

(147) 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.. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101. Symbol.

(148) 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. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101. Symbol.

(149) 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.

(150) 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,. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101. Symbol.

(151) 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.. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101. Symbol.

(152) 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.. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101. Symbol.

(153) 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).. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101. Symbol.

(154) 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.. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101. Symbol.

(155) 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.. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101. Symbol.

(156) Description. Hydraulic Swivel: The hydraulic swivel is designed to allow 360 degree rotation, while supplying oil to all superstructure functions.. Terex Mobile Telescopic Level 1: Hydraulic Symbols 101. Symbol.

(157) Working Safety With Fluid Power. Terex Mobile Telescopic Level 1: Working Safety with Fluid Power.

(158) 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..

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