Professional Documents
Culture Documents
crawler
crane
operator
training
Boom Composition
Wire Rope
Rigging
Load Charts
Controls
HC50
HC60
HC80
HC110
HC165
HC230
HC275
Boom – 46HI
Maximum Boom Length – 160’
Maximum Jib Length – 40’
Counterweight – 39,000 lbs.
Engine – Cummins 6BTA5.9 197HP
Boom – 59HI
Maximum Boom Length – 230’
Maximum Jib Length – 80’
Counterweight Upper – 39,000 lbs.
Counterweight Sideframe – 23,000 lbs.
Engine – Cummins 6CTA8.3 230HP
Boom – 77SI
Maximum Boom Length – 240’
Maximum Jib Length – 80’
Counterweight Standard
Upper – 102,000 lbs.
Counterweight PLUS
Upper – 108,400 lbs.
Car Body – 8,000 lbs.
Engine – Cummins QSC8.3 325HP
Boom
Stops
A - Frame
Boom Inner
Counterweights
Operator’s
Cab
When ordering any parts for your machine, you will need the
serial number from the data plate or the model and production
number found on the front of the upper.
HG-103
92 HI Inner 92 H Outer
50’ 4 ½” (15,244mm
92 ST 50’ Center
Terex® Hydraulic Crawler Training: HC275 2
Components that make up a typical boom section
Chord
Wooden
Timbers
ID Tag Lacing
Pin In Castings
1186701 46
29
10/03/19
Hammerhead (HH) – Used in combination with shorter boom for heavy picks.
Offset Tip (OT) – Enables the load to be brought in closer to the boom.
Used to further separate the single line from the multi-part line operations.
1. Pile driving
2. Clam shell Duty cycle work refers to the use of a crane to do dragline,
clamshell, dynamic compaction, or pile driving work, or
3. Drag line with an electromagnet such as for handling scrap metal.
4. Magnet / Scrapyards Pile extraction using a vibrating pile extraction device is
also considered duty cycle work. In duty cycle operations
5. Demolition the loads are generally known and/or can be maintained
6. Offloading operations "safely below the rated capacity" for the crane.
Boom designations
S – Standard
H – Heavy
L - Light
I – IHI Only
R – Reinforced
T – Tower
Electrocution Hazard
Construction and Characteristics The margin of stability for determining load ratings is
taken from a percentage of the load which will induce
Inspection, Testing and Maintenance tipping with the boom in the least stable direction on the
machine.
Operation
This is determined under static conditions with the machine on
PURPOSE a level surface within 1% of grade.
(a) prevent and minimize injury to workers and damage to If the machine is to be mounted on a barge then the load rating
property. must be modified by the manufacturer or qualified person
according the ASME B30.8 (Floating Cranes and Derricks).
(b) provide direction to owners, employers, supervisors,
and others responsible for mobile crane operation. CRANE LOAD RATINGS
Crawler Without Outrigger Support 75%
(c) guide governments and other regulatory bodies in the Crawler With Outrigger Support Fully Extended 85%
development, publication, and enforcement of appropriate Wheel Mounted Without Outrigger Support 75%
safety directives. Wheel Mounted With Outrigger Support 85%
Commercial Truck Vehicle Mounted
With Stabilizers Extended and Set 85%
Commercial Truck Vehicle Mounted
With Stabilizers Partially Extended and Set *****
• If the weight of the hoist rope beyond a certain length is 8. Whether the sections are telescoped with power or
to be considered as part of the load, the method for manually.
determining the additional rope weight. 9. The proper sequence for extending and retracting the
telescopic boom section.
In addition to the items listed above which are required to be
on the load chart, the following information must be located on 10. Maximum loads permitted during telescoping operations
the load chart or in the operating manual: and any limiting conditions and or cautions.
1. Hoist rope size, type and reeving configurations for the 11. Hydraulic relief valve settings per the manufacturer.
various parts of line configurations for that machine.
Limitations in Boom Length or Boom Angle
2. Boom hoist rope size, type and reeving configurations. Cranes may not have sufficient forward stability (in the
direction of the boom) to handle some boom lengths.
3. Tire pressure if applicable. Information shall be provided on the load rating chart
stating any limitations in boom length or boom angle for
4. Position of the gantry and requirements for intermediate specified operating conditions of outriggers, direction of
boom suspension if applicable. boom, or other requirements.
No less than two full wraps of rope shall be on the drum when
Main Hoist
the boom tip is at its lowest point .
Travel brakes that are air operated must have a manual or Rotation resistant ropes must have a minimum safety factor of
automatic means of stopping the vehicle when air pressure 5.0 and are not to be used on boom hoist applications.
falls below the specified minimum level.
Boom pendants or standing ropes must have a minimum
Vehicle-mounted cranes on commercial trucks shall meet the safety factor of 3.0.
requirements of the U.S. Department of Transportation
Standards. All replacement ropes must be of the construction
recommended by the rope or crane manufacturer.
Sheaves
Sheaves carrying ropes that can be momentarily unloaded and
the sheaves in the lower load block shall be provided with
close-fitting guards that will prevent ropes from jumping the
sheaves or becoming fouled when the block is lying on the
ground.
Miscellaneous Equipment
Frequent Inspection
Daily to monthly intervals by a designated person.
Periodic Inspection
One- to 12-month intervals or as specifically recommended by
the manufacturer or a qualified person.
Crane hooks inspected per the applicable national and local Any cranes that have had any load sustaining parts modified,
standards. repaired or replaced should be load tested under the direction
of a qualified person. These load tests shall not exceed 110%
Travel mechanisms for excessive wear or damage. of the manufacturer’s load rating. In addition, written reports
showing the test procedures and the above mentioned repairs
Hydraulic and pneumatic pumps, motors, valves, hoses,
shall be retained.
fittings, and tubing for excessive wear.
HOIST With forearm vertical, LOWER With forearm extended USE MAIN HOIST Tap fist on
forefinger pointing up, move downward, forefinger pointing head then use regular signals.
hand in small horizontal circle. down, move hand in small
horizontal circle.
USE WHIPLINE (Aux, Hoist) RAISE BOOM Arm extended, LOWER BOOM Arm extended,
Tap elbow with one hand, then fingers closed, thumb pointed fingers closed, thumb pointed
use regular signals. upward. downward.
MOVE SLOWLY Use one RAISE THE BOOM AND LOWER THE BOOM AND
hand to give any signal and LOWER THE LOAD Arm RAISE THE LOAD Arm
place other hand motionless in extended, thumb pointing up, extended, thumb pointing
front of the hand giving motion flex fingers in and out as long down, flex fingers in and out
signal, Hoist slowly shown as as load movement is desired. as long as load movement is
an example. desired.
SWING Arm extended, point STOP Arm extended, palm EMERGENCY STOP Both
with finger in direction of boom down, move arm back and arms extended, palms down,
to swing. forth horizontally. move both arms horizontally.
TRAVEL (one track) Lock the EXTEND BOOM RETRACT BOOM (telescoping
track on the side indicated by (telescoping booms) Both booms) Both fists in front of
raised fist. Travel opposite track fists in front of body with body with thumbs facing inward
in the direction indicated by the thumbs pointing outward. towards each other.
circular motion of the other fist,
rotating vertically in front of body.
(For land operated cranes only)
Container Reach
Stacker
Pendant
Lattice
Boom
Boom stop
Gantry
Counterweights
Superstructure & Cab
Base or
Carrier
Main
Telescoping Boom Cab Hoist Aux. Hoist
Outrigger Outrigger
Wire Rope
Components of Wire Rope
a – Wire
b – Strand
c – Center or Core
d – Wire Rope
NOTE
For best performance category 2&3 ropes should not be used
with a swivel. Category 1 rope may be used with a swivel.
Wire rope must be remove from services when any of the In standing ropes, more than two broken wires in one lay
following conditions are met: in sections beyond end connections or more than one
broken wire at an end connection.
In running ropes, six randomly distributed broken wires in one
lay or three broken wires in one strand in one lay.
Here's a wire rope that has jumped a sheave. The rope curled“
as it went over the edge of the sheave. When you study the
wires, you'll see two types of breaks here: tensile "cup and
cone" breaks and shear breaks that appear to have been cut
This is localized wear over an equalized sheave. The danger on an angle.
here is that it's invisible during the rope's operation, and that's
why you need to inspect this portion of an operating rope
regularly. The rope should be pulled off the sheave during
inspection and bent to check for broken wires.
A B
C D
Rigging
Sling Selection Reach and angle of the sling - Available headroom,
any obstructions, and type of hitch are important
No matter what kind of sling you choose, certain factors need factors in this determination. The angle at which a
to be considered to plan a safe, effective lift: sling is used significantly effects its capacity. Use the
longest reach possible for completing the lift; this will
Weight of the load - You will need to know, or accurately provide the largest angle possible for minimum stress
estimate the weight of the load. on the sling.
Type of hitch and number of slings or legs - Consider the Protect the load and sling from damage - Select the
load's size and shape, load control (balance, slippage), best sling material for the load and environment. Use
attachment points, and any fittings that will be needed to softeners such as shims, padding or sling protectors to
connect the sling to the lifting device or the load. Loads should prevent damage at corners or projections. Inspect slings
be lifted from a point directly over the center of gravity. before each use.
( CG)
Protect personnel - Position and utilize personnel safely
during rigging and lifting. Use a tag line to stabilize or
maneuver the load during the lift.
Do not exceed a sling's Working Load Limit. Select the correct sling material for the work
environment.
Never bounce or jerk a load.
Avoid exposing a sling to chemicals or temperatures which
exceed its limitations.
Balance loads to avoid slippage or tipping.
Whenever possible, lift from directly over the load's center of Never drop or rest a load on a sling. Do not pull a sling
gravity. Lift the load a few inches and check it's balance from under a load that is resting on the sling. Dragging
may damage slings.
before proceeding.
Use pads to protect slings from sharp edges and
Keep all employees safely clear of suspended loads or projections.
loads about to be lifted.
Use a tag line to maneuver loads during a lift. Never place Protect web slings against prolonged exposure to
hands or fingers between a sling and the load while the sling is ultraviolet light.
being tightened.
Hang slings in a cool dry location away from work site
when not in use to avoid damage.
Rig to the smallest angle when legs and lift angles are not
equal. The leg with the smallest angle will carry the greatest Keep slings as clean as possible.
load. Grit such as sand or metal shavings can abrade wire rope
or web slings from within and wear chain slings at link
contact areas.
Never shorten slings with knots, bolts or other makeshift 122
devices. Free slings of all kinks, knots and twists before
lifting.
If you are unable to determine the exact angle of the sling then
it can be estimated as follows:
Frequent: The frequent level of inspection should be done by The second most prevalent reason for removal from
the sling user before each and every use. The entire sling service would be tears or cuts. The sling inspector should
not simply replace the damaged sling, but suggest the use
should be thoroughly examined and removed from service if
of wear protection to prevent further damage of the
damage is detected. The sling user should also determine that replacement sling.
the sling is proper for the hitch, load and environment.
Web slings shall be removed immediately from service if
Periodic: Designated persons should conduct the periodic any of the following conditions exist:
* acid or caustic burns
level of inspection at regular intervals. The interval should be
* melting or charring of any part of the sling
based upon the frequency of use, severity of the service cycle * snags, punctures, tears or cuts
and previous results found during the inspection process. If * broken or worn stitches
written inspection records are maintained, they should always * distortion of fittings
reference the unique sling identification number, and be * missing, illegible or incomplete tag
* knots in any part of the sling
updated to record the condition of the sling.
* ‘excessive’ abrasion
* other visible damage that causes doubt as to the
strength of the sling.
Load Charts
Center of Gravity
FULCRUM POINT
RADIUS
FRONT SIDE
REAR
SIDE
DANGER!!!
RADIUS
FULCRUM
POINT
Rigging
Net
•Boom Type
•Amount of Counterweight
Stability Rating
All Capacities
without asterisk
The fifth column gives you the height from the tip of the
boom to the ground.
0 0 0.
The jib can be set at 5 , 15 , or 25 and once set the work will 150
be done at the degree set that has been chosen. To change
the degree set the boom must be lowered and jib angle
changed.
250
HC275 Controls
Terex® Hydraulic Crawler Training: HC275 Controls 2
Terex® Hydraulic Crawler Training: HC275 Controls 3
Left Control Stand
Horn Button
If the pilot lamp bulb has burned out or if the contact or wire
connection is bad, the indicator will not function.
Before commencing operations, perform a lamp test by turning
on and off the automatic / foot winch mode key selector switch
and the control button on the hoist levers.
Machine Front
Manual / Auto
Pump Selection
Travel Alarm
Boom Foot
Raise / Lower Pinning
A-Frame
Moment
Limiter
Selector
Operation
Lock
Momentary
Travel Lock Bypass Key
Gentle Stop
Switch
Energize Lower for Slow Speed
Pendant Control Mode
Don't place the switch to the lock position when the drum is
rotating or the drum may be damaged.
Travel lock
Travel Alarm Switch
This switch alerts surrounding personnel with an alarm when
the machine travels. The alarm may be turned off when the
switch is placed in the "OFF"( ).
Travel Alarm
Slow Down (Gentle Stop) Switch
This feature decreases the hoisting speed when the moment
limiter indicates that the load ratio is 90 % or when the boom
angle reaches the upper or lower limit. This prevents inducing
a shock load to the crane structure. When the crane is in the
"GENTLE OPERATION“ condition, the slow speed lamp is lit
above the engine tachometer.
Slow Down
Fault Detection:
Faults are detected while the key switch is on and during the
operation of the machine. If a fault becomes active, a fault is
logged in memory and a snapshot of the engine parameters is
logged. In addition, certain faults may illuminate the warning
lamp (yellow) or the stop lamp (red).
Warning Lamp:
The Warning lamp provides important operator messages.
These messages require timely operator attention. The
warning lamp is also used to delineate diagnostics fault codes.
Stop Lamp:
The stop lamp provides critical operator messages. These
messages require immediate and decisive operator response.
The stop lamp is also use to flash out diagnostic fault codes
for the engine.
Engine Tachometer
B : This is the slow down mode indicator lamp. It is lit when the
switch on the boom hoist lever is pressed. All winches and A B C
the travel speed are in the slow down mode. The indicator
is also lit when entering into the gentle stop operation
mode.
With the engine running, the key may be turned to the right
“ERECTION” position only during assembly, disassembly,
changing the boom configuration or parts of line.
The key must NEVER be turned all the way to the left “
TRANSPORT” position when the engine is running. This will
interfere with the data exchange between the mother board
and compact flash cards. The engine must be OFF and the
moment limiter off and after it has completed its timed power
down delay, then change the selector switch to the
“TRANSPORT” position and restart the engine.
Boom Angle