Technical Training Manual

hc275
crawler
crane
technical
training
Ferreyros / Piura, Peru Rev. 12/12

HC275 Technical Training Content
IHI Models and Specifications M/L D5A Moment Limiter
Boom Composition Electrical & Hydraulic Circuit Design & Functionality
Safety Warning Symbols Counterweight System
Mobile Crane Safety Travel System
Wire Rope M/L D5A Moment Limiter
Rigging Swing System
Schematics Overview Hoist System
Hydraulic Symbols
Hydraulic System Components
Electrical Symbols and Components
Load Charts
Controls
Terex® Hydraulic Crawler Training: Table of Contents
hc crawler cranes
Models and Specifications

Current HC Crawler Models:
HC50
HC60
HC80
HC110
HC165
HC230
HC275
Terex® Hydraulic Crawler Training: Models and Specifications 2

HC50/60
Boom – 46HI
Maximum Boom Length – 160’
Maximum Jib Length – 40’
Counterweight – 39,000 lbs.
Engine – Cummins 6BTA5.9 197HP
The HC50 differs from the HC60 in that the main

boom tip has 3 sheaves instead of the four found in
the HC60. The chip for the LMI must be changed out
so that the proper load charts are in the LMI.

HC80
Boom – 46HI / Maximum Boom Length – 160’

Boom – 47HI / Maximum Boom Length – 200’
Counterweight – 58,000 lbs.
Engine – Cummins QSB6.7 185HP
Engine – Hino HO7CT 184HP (1st 40 machines)
The HC80 lower and superstructure is larger than the

HC60. This machine normally is equipped with the
47HI boom .

HC110
Boom – 59HI
Counterweight Upper – 39,000 lbs.
Counterweight Sideframe – 23,000 lbs.
Engine – Cummins 6CTA8.3 230HP
The HC110 upper and lower are larger than the

HC80. The drum configurations are different. The A-
Frame erects differently and this model also has
side frame counterweights. Configured with a 90’
boom or greater, the auxiliary hoist line runs over the
A-Frame.

HC165
Boom – 77SI
Counterweight Standard
Upper – 102,000 lbs.
Counterweight PLUS
Car Body – 8,000 lbs.
Engine – Cummins QSC8.3 325HP
The HC165 upper and lower are larger than the

HC110. This is the first of the HC models which has
the Counterweight PLUS as an option.

HC230
Boom – 77SI / Maximum Boom Length – 280’

Boom – 77ST / Maximum Boom Length – 250’
Boom – 92SI & HI / Maximum Boom Length - 260’
Counterweight
Engine – Cummins QSC8.3 300HP
The HC230 is the newest in the HC Crawler family. It

is very similar in nature to the HC275 in that it can
also use the 92” boom.

HC275
Boom – 92HI / Maximum Boom Length - 300’

Counterweight
Engine – Cummins QSL9 325HP

HC275 Main Components

HC275 Main Components

Mast
Boom
Stops
A - Frame
Boom Inner
Counterweights
Operator’s
Cab
Crawler Side Frame

Machine Identification
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

hc crawler cranes
Boom Identification & Composition

Boom Component Identification
92 HI Inner 92 H Outer
92 HT 20’ Center 92 ST 10’ Center
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

Boom Section Identification Tag
1186701 46
29
10/03/19
Part Number – 1186701

Boom Size – 46”
Date of Manufacture – 3/19/2010
Welder ID# - 29
Crawler Crane Boom Components – Fixed Jib

Crawler Crane Boom Components – Luffing Jib

Hammerhead Tip (HH)
Hammerhead (HH) – Used in combination with shorter boom for heavy picks.

Offset Tip (OT)
Offset Tip (OT) – Enables the load to be brought in closer to the boom.

Single Sheave Extension (Rooster Sheave or Runner)
Used to further separate the single line from the multi-part line operations.

Booms are composed of two main types: Angle and Tubular

Angle booms are used in duty cycle applications such as:
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.

Terex® offers three types of angle boom; Heavy (H), Heavy Reinforced (HR) and ABSH
(American Bureau of Ships Heavy. The reinforced area in the corner of this jib indicates that
this is HR boom. ABSH boom is specially rated for maritime applications per ABS 44 reg.
Tubular boom is used for lifting applications

Terex® offers three types of tubular boom; Standard (S) and Heavy (H) and Light (L).
Depending on the size this refers to the chord OD and or wall thickness.

This is a listing of the different Terex® boom designations and types
Boom designations
S – Standard
H – Heavy
L - Light
I – IHI Only
R – Reinforced
T – Tower
SI – Standard IHI Only

ST – Standard Tower
HT – Heavy Tower
HI – Heavy IHI Only
HR – Heavy Reinforced
ABSH – American Bureau of Ships Heavy

Boom composition is determined by the load to be lifted at a particular radius and whatever
conditions are present on the job site and is reflected on the load chart .

16HL Jib

16HL Jib Hoisting & Self Erection Data

hc crawler cranes
Safety Warning Information

Horn
Machine Design Standards
Machine Serial Number
Electrocution Hazard
Terex® Hydraulic Crawler Training: Safety Warning Information 2

Cab Control Layout
Warning Winch Selector
MLD5A Overheat Warning

Boom Danger Items
Travel Lock Caution Operational Warnings

Standard Hand Signals
Electrocution Hazard Crushing Hazard

Crushing Hazard
Boom

Crushing Hazard

Burn Hazard Standard Hand
Signals
Crushing Hazards Crushing Hazards – Export Seal

hc crawler cranes
Mobile Crane Safety

INTRODUCTION Construction and Characteristics
This presentation is broken in to three sections and is based
on AMSE B30.5 which governs the operation of mobile cranes Load Ratings – Where Stability Governs Lifting
in the United States. These sections address: Performance
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 *****
Terex® Hydraulic Crawler Training: Mobile Crane Safety 2

***** The following equation shall be used for less than full Load Rating Chart
extension of all outrigger beams to find the rated capacity:
P ≤ (T − 0.1F )/1.25 A durable legible rating chart shall be provided with each
where crane and located in the operator’s cab. The information
F = load applied at boom tip that gives the same moment contained in these charts shall include the following:
effect as boom mass
P = rated capacity in the lifting direction specified • A full and complete range of load ratings at all
T = tipping load stated operating radii, boom lengths, boom angles, jib
lengths, jib angles, with various outrigger configurations
If crane operation with outriggers in positions other than fully and counterweight arrangements.
extended is permitted by the crane manufacturer, specified • A work area chart which reflects the capacities as listed in
procedures, ratings, and limitations for any configurations that the load chart as shown below.
are permitted shall be provided.
Load Ratings – Where Structural Competence Governs

Lifting Performance
Load ratings at some radii may be based on the structural

limitations of the machine rather than stability.
If the design of the machine is such that the mounting is

asymmetrical in regards to the structure, it would require a
greater load to induce tipping in some directions. Therefore
structural competence would govern the ratings rather than
stability. In this case the work area must be shown.

Load Rating Chart 5. Instructions for boom erection
• Where ratings may be limited by structural, hydraulic or
other factors rather than stability. These must be emphasized 6. Whether the hoist holding mechanism is
on those areas of the load chart. automatically controlled, manually controlled and or
whether freefall is available.
• Any areas where loads may not be handled.
7. The maximum telescoping length of each boom
• Reeving configurations for hoist lines. section.
• 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.

BOOM HOIST, LOAD HOIST, AND TELESCOPING BOOM
MECHANISMS
Boom Hoist
Boom Hoist
The boom hoist may use either a rope drum or hydraulic
Aux. Hoist
cylinders and the support system can either be a gantry or the
boom hoist cylinders. It must hold the rated loads without any
action by the operator.
No less than two full wraps of rope shall be on the drum when
Main Hoist
the boom tip is at its lowest point .
On machines that have rope supported booms, a braking HC165

mechanism and a locking device (ratchet / pawl) must be
provided to prevent inadvertent boom lowering. In addition
boom lowering can only be performed under power and no
free-fall capability is allowed.
If supported hydraulically then an integrally mounted check

valve must be used to prevent uncontrolled lowering of the
boom.

Load Hoist Telescoping Boom
The boom hoist may use either a rope drum or hydraulic Extension and retraction of boom sections may be of
cylinders. Brakes or clutches must be adjustable to hydraulic, mechanical, or manual means.
compensate for wear and must close via spring pressure
upon loss of power. The powered retract function must be capable of
controlling any rated load that can be retracted.
No less than two full wraps of rope shall be on the drum
when the hook block is at its lowest position. An integrally mounted check valve shall be provided with
the telescopic hydraulic cylinder(s) to prevent
The drum flange must extend ½” above the uppermost layer uncontrolled retraction of the boom in the event of a
of rope at all times. hydraulic system failure.
A braking mechanism and a locking device (ratchet / pawl)

must be provided to prevent inadvertent hoist lowering. Foot
operated brakes with a continuous linkage and locking device
meet this requirement.
Drum rotation sensors should be provided to alert the operator.
When provided, a power-controlled lowering system shall be

capable of handling rated loads and speeds as specified by the
manufacturer. This system is recommended to assist in
precision lowering and to reduce demand on the load brake.

Swing Crane Travel
The swing mechanism shall start and stop in a controlled On all crane types with a single control station, the
manner. controls for travel shall be located at the operator’s
station.
A braking system with the ability to prevent rotation in either
direction when desired during normal operation shall be On all wheel-mounted multiple control station
provided and be capable of maintaining that position and cranes, the travel controls shall be located in the carrier
without further actions by the operator. cab.
In addition, a locking device to prevent the superstructure from

rotating when in transit must be provided. It must be designed Travel Mechanism
to minimize inadvertent engagement or disengagement. On a crawler crane, the travel and steering mechanism
shall be arranged so that it is not possible for both
crawlers to freewheel without operator control. Control
shall be directed from the operator’s cab on the rotating
superstructure.
Travel Brakes and Locks

On crawler cranes, brakes or other locking means shall be
provided to hold the machine in place while working on the
maximum grade recommended for travel if necessary. These
brakes or locks must remain engaged in the event of loss of
operating pressure or power.

Travel Brakes and Locks Controls
On wheel-mounted cranes, means shall be provided The basic controls shall be located within reach of the
to control the crane carrier when descending maximum grades operator and be able to remain in the neutral position
specified by the manufacturer under maximum loading without the use of any latching devices.
conditions.
Cranes with remote control shall cease functioning upon
Brakes must bring the machine to a stop on level loss of any control signal to the crane.
ground within a distance of 32 ft (10 m) from a speed of 15
mph (6.7 m/s). Brakes must also hold the machine on the
maximum grade for travel specified by the manufacturer.
Rope Design Factors
Where steep grades are encountered, a retarder or similar Any live or running ropes must have a minimum safety design
device should be provided. factor of 3.5.
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.
Inspection frequency should be increased when using rotation

resistant rope due to the fact that it’s more easily damaged.

Booms
Booms and jibs must be restrained from falling over
backwards. Boom stop design must be either:
1. A fixed or telescoping bumper

2. A shock absorbing bumper
3. Hydraulic boom elevation cylinders(s).
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.
Load Hook, Ball Assemblies, and Load Blocks

Load hooks, ball assemblies, and load blocks shall have
sufficient weight to overhaul the line from the highest
hook position and the number of parts of line in use. All hook
and ball assemblies and load blocks shall be labeled with their
rated capacity and weight. Hooks shall be equipped
with latches.
Booms
A boom angle or radius indicator readable from the operator’s
station shall be provided.
A boom hoist disconnect, shutoff, or hydraulic relief shall be

provided to automatically stop the boom hoist when the boom
reaches a predetermined high angle.
A boom length indicator readable from the operator’s station

shall be provided for telescoping booms unless the load rating
is independent of the boom length.
Booms, boom sections, and jibs shall be identified and shall be

used only for the purposes recommended by the manufacturer.

Outriggers
Means shall be provided to hold all outriggers in the
retracted position while traveling and in the extended
position when operating.
Power-actuated jacks shall be equipped with integral

load hold check valves on hydraulic cylinders,
mechanical locks, etc.) to prevent loss of support under
load.
Outrigger floats must be attached to outriggers when in use.
Partially Extended Outrigger Beams, Outrigger Beam

Position
A device or system shall be provided that accurately locates
the outrigger beam(s) to coincide with the partially extended
outrigger position(s) on the load chart.
Visible indication of the manufacturer’s specified outrigger

positions shall be provided by means such as stripes painted
on the outrigger beams or an electronic display.

Operational Aids
The crane manufacturer shall provide recommendations
for continued operation or shutdown of the crane if operational
aids are inoperative or malfunctioning. In addition all cranes
with a maximum capacity of 3 tons or more must be equipped
with a rated capacity indicator or LMI.
Two Blocking Prevention

Telescoping and lattice boom cranes shall be equipped with an
anti two-blocking device.
Miscellaneous Equipment
Means to visually determine the leveleness of the crane must

be within reach of the operator.
Means to check the specified pressure settings in each

hydraulic circuit must be provided.
A sign must be installed which is visible from the operator’s

cab to warn of electrocution from inadvertent contact with
energized power lines up to 50kV and the required clearances
for safe operation.

Inspection, Testing and Maintenance Frequent Inspection Items
All control mechanisms for mis-adjustment and improper
operation — daily, when in use.
Inspection – General
The manufacturer shall furnish required field assembly, All control mechanisms for excessive wear and
operation, and maintenance information. contamination by lubricants or other foreign matter.
Inspection Classifications All crane function operating mechanisms for proper

operation and any excessive wear.
(a) Initial Inspection. Prior to initial use, all new,
reinstalled, altered, or modified construction tower cranes All hydraulic and pneumatic hoses.
shall be inspected by a qualified person to verify compliance
with the applicable provisions of this standard. Electrical apparatus for malfunctioning, signs of excessive
deterioration, dirt, and moisture accumulation.
(b) Regular Inspection. Inspection procedures for cranes in
regular service are divided into two general classifications. Hooks and latches for wear and deformation.
Intervals are dependent upon the nature of the critical
components of the crane and the degree of their exposure to Hydraulic system for proper fluid level, daily, when in use.
wear or malfunction. The two general classifications are
designated as frequent and periodic with respective Tires for recommended inflation pressure.
intervals between inspection defined as follows:
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.

Periodic Inspection Cranes Not in Regular Use
Complete inspections of the crane shall be performed at A crane that has been idle for 1 to < 6 months must be
intervals based upon its activity, severity of service, and inspected by a qualified person as per ASME B30.5
environment, or as indicated below:
paras. 5-2 1.2 and 5-2 4.2 before being placed in
Deformed, cracked, or corroded members in the crane service.
structure and boom.
A crane that has been idle for greater than 6 months
Loose bolts or rivets. must be inspected by a qualified person as per ASME
Cracked or worn sheaves and drums. B30.5 paras. 5-2 1.2, 5-2 1.3 and 5-2 4.2(a) before being
placed in service.
Worn, cracked, or distorted parts such as pins, bearings,
shafts, gears, rollers, locking and clamping devices, sprockets, Testing
and drive chains or belts.
Each new production crane shall be tested by the
Excessive wear on brake and clutch system parts, linings, manufacturer to confirm that all functional mechanisms, safety
pawls, and ratchets. devices and operational aids are operation correctly.
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.
Excessively worn or damaged tires.

Maintenance and Repairs Rope Inspection, Maintenance and Replacement
A preventive maintenance program shall be established and All running ropes in service should be visually inspected
should be based on the recommendations outlined in the crane once each working day. Distortion of the rope such as
manufacturer’s manual. It is recommended that replacement kinking, crushing, unstranding, birdcaging, main strand
displacement or core protrusion; loss of rope diameter
parts be obtained from the original equipment manufacturer. It or unevenness of outer strands provide evidence that
is also recommended that replacement parts be obtained from rope replacement should be considered.
the original equipment manufacturer.
Rotation resistant ropes and boom hoist ropes require
Adjustments shall be made within the manufacturer’s extra care when inspecting them due to the fact that they
specified tolerances to maintain correct functioning are easily damaged and more difficult to inspect.
of components.
All moving parts of the crane for which lubrication is specified

should be regularly lubricated. Lubricating systems should be
checked for proper delivery of lubricant. Care should be taken
to follow the manufacturer’s recommendations as to the points Strand nicking – adjacent Repeated bending under normal loads
and frequency of lubrication, maintenance of lubricant levels, strand abrasion
and types of lubricant to be used.
Fatigue failure – heavy loads over small sheaves

Rope Replacement Replacement rope shall have the same or higher
Removal criteria for rope replacement shall be as follows: minimum breaking strength as the original rope furnished
(1) Broken Wires or recommended by the crane manufacturer. Any
(a) in running ropes, six randomly distributed broken wires in deviation from the original size, grade, or construction
one lay or three broken wires in one strand in one lay. shall be specified by a rope manufacturer, the crane
(b) in rotation-resistant ropes, two randomly distributed broken manufacturer or qualified person.
wires in six rope diameters or four randomly distributed broken
wires in 30 rope diameters.
(2) one outer wire broken at the point of contact with the core
of the rope that has worked its way out of the rope structure
and protrudes or loops out from the rope structure. Additional All rope not in use for a period of a month or more due to
inspection of this section is required. shutdown or storage of a crane on which it is installed shall
(3) independent wire rope core (IWRC) or strand core be inspected for all types of deterioration prior to being placed
protrusion between the outer strands. in service. The inspection shall be performed by an appointed
(4) kinking, crushing, birdcaging, or any other damage or authorized person.
resulting in distortion of the rope structure.
(5) apparent damage from any heat source, including, but not Rope Maintenance
limited to, welding, power line strikes, or lightning. Rope should be stored to prevent damage or deterioration.
(6) reduction from nominal diameter of more than 5%. Unreeling of the rope shall be done as recommended by the
(7) in standing ropes, more than two broken wires in one lay in rope manufacturer as to avoid kinking or induce twist.
sections beyond end connections or more than one broken
wire at an end connection. Rope should be maintained in a well-lubricated condition to
(8) severe corrosion as evidenced by pitting. prevent corrosion and internal friction
(9) deviation shall be allowed from the removal criteria listed
above only with written approval of the manufacturer of the Prior to cutting a wire rope it should be properly seized. For
specific wire rope. pre-formed ropes one seizing on each side of the point to be
cut, on non-preformed ropes three seizings are required
Operation
Qualifications and Responsibilities of Operators
Qualifications for Operators

Operators must meet the qualifications for the specific type of
crane that they will be operating.
1. Vision of at least 20/30 in one eye and 20/50 in the other,

with or without corrective lenses.
2. Be able to distinguish colors, regardless of position, if
color differentiation is required.
3. Have adequate hearing to meet operational demands,
with or without a hearing aid.
4. Have sufficient strength, endurance, agility and
coordination to meet operation demands.
5. Have normal depth perception, field of vision, reaction
time and manual dexterity with no tendencies to dizziness or
similar undesirable characteristics.
6. A negative result for a substance abuse test. The
testing will be determined by the standard for the industry
where the crane is employed and confirmed by a recognized
laboratory service.
7. Any evidence of physical defects or emotional instability
that could prove hazardous to the operator or others, or
interfere with the operator’s performance, may be sufficient
cause for disqualification.
8. Satisfactory completion of a written examination
covering operational characteristics, controls, and
emergency control skills, such as response to fire, power
line contact, loss of stability, or control malfunction. In
addition, characteristic and performance questions
appropriate to the crane type for which qualification is
being sought.
9. Read, write, use arithmetic and comprehend a
load chart, in accordance with the crane manufacturer’s
operation and maintenance manuals.
10. Satisfactory completion of a written and verbal test on
load chart usage that covers a selection of the configurations
that the crane may be equipped to handle.
11. Satisfactory completion of an operational test in
performing lifting, lowering, booming, telescoping, and
swinging functions at various radii as well as shutdown. Testing
shall also include proficiency in pre and post start inspection,
securing procedures, and traveling by written, oral, or practical
means.
12. Demonstrated understanding of the applicable
sections of the B30 Standard and federal, state, and local
requirements.
Operator physical examinations shall be required every 3

years or more frequently if supervision deems it necessary.

Operators Crane Owner Responsibilities
Cranes shall be only be operated by the following personnel: 1. Providing a crane that meets the Construction &
1. Those who have met the requirements of items 1-12 Characteristics and Inspection, Maintenance & Testing
of the qualifications criteria listed on the previous page. sections of ASME B30.5 in addition to the specific job
2. Trainees who have met the qualification criteria and who requirements of the crane user or customer.
are training for the type of crane being operated. While 2. Providing all applicable load charts and technical
operating the crane, the trainee must be under the direct information pertaining to the crane for its assembly,
supervision of a designated qualified operator. operation and disassembly. The crane must also have
3. Maintenance personnel who have completed all operator all of the warning decals and placards as supplied from
trainee qualification requirements. Operation by these persons the manufacturer.
shall be limited to those crane functions necessary to perform 3. Establish an inspection, testing, and maintenance
maintenance on the crane or to verify the performance of the program in accordance with the requirements of ASME B30.5
crane after maintenance has been performed. and informing the crane user of the requirements of this
4. Inspectors who have completed all operator trainee program.
qualification requirements. Operation by these persons shall 4. Using personnel that meet the requirements of a
be limited to those crane functions necessary to accomplish designated person as defined for maintenance, repair,
the inspection. transport assembly and disassembly.
5. Using personnel that meet the requirements of a
Only the personnel specified above, oilers, supervisors, and qualified or designated person as defined for inspections.
those specific persons authorized by supervisors shall enter a
crane cab. Persons shall only enter the cab when their duties
require them to do so, and then only with the knowledge of the
operator.

Crane User Responsibilities Site Supervisor Responsibilities
1. Complying with the requirements of ASME B30.5, the 1. Ensuring that the lift director is a qualified person.
manufacturer’s requirements, and those regulations 2. That the area is suitable for the crane with respect
applicable at the worksite. to levelness, surface conditions, support capability,
2. Providing supervision which meet the requirements of a proximity to power lines, excavations, slopes,
qualified person. underground utilities, subsurface construction, and
3. Verifying that the crane owner has provided obstructions to crane operation.
documentation which confirms that the crane has received a 3. That the crane operators are properly qualified to
frequent inspection. operate the cranes required on the job site.
4. That the crane has adequate capacity to make the
proposed lift in its respective configuration. 4. Addressing any condition that may adversely affect crane
5. Using crane operators that are qualified to operate the operations such as poor soil conditions, high wind, heavy rain,
cranes for the tasks that they are to be used for. fog, extreme cold and requirements for artificial lighting.
6. Using personnel that meet the requirements of a 5. Allowing operations near electric power lines only after
designated person as defined for maintenance, repair, satisfying the requirements per ASME B30.5.
transport assembly and disassembly. 6. Permitting special lifting operations per the applicable
7. Using personnel that meet the requirements of a safety standards such as multiple crane lifts, lifting personnel
qualified or designated person as defined for inspections. and pick and carry operations.
8. Ensuring that the inspection, testing, and maintenance 7. That all rigging is supervised by a qualified person.
programs specified by the crane owner are followed. 8. That all crane maintenance is performed by a designated
person.

Lift Director Responsibilities Crane Operator Responsibilities
The responsibilities include all of the Site Supervisor’s in The crane operator is not responsible for hazards or
addition to the following: conditions not under his direct control that adversely
1. Being present at the job site during all lifting operations. affect lifting operations. Whenever the operator has any
2. Stopping crane operations if alerted to an unsafe doubt as to the safety of lifting operations he shall stop
condition affecting those operations. all operations in a safe and controlled manner. Once all
3. Ensuring that the preparation of the area needed to safety concerns have been addressed by the lift director
support crane operations has been completed before crane only then may lifting operations resume.
operations commence.
4. Ensuring necessary traffic controls are in place to restrict
unauthorized access to the crane’s work area. The crane operator’s responsibilities include the following:
5. Ensuring that personnel involved in crane operations 1. Reviewing the requirements of the crane with the lift
understand their responsibilities, assigned duties and the director prior to commencing operation.
associated hazards. 2. Knowing what types of site conditions could adversely
6. Addressing safety concerns raised by the operator or affect the operation of the crane and consulting with the lift
other personnel and being responsible if he decides to overrule director about these conditions.
those concerns and directs crane operations to continue. 3. Understanding the crane’s operating manual, its functions
7. Assigning qualified signal persons to the job at hand. and limitations and its loads charts concerning proper
8. In addition to the special lifting operations listed under the configurations
Site Supervisor’s responsibilities, ensure that precautions are 4. Refuse to operate the crane if any portion of the load or
taken when mobile cranes are to be operated on barges. crane would enter the prohibited zone of energized power
9. Ensuring that the applicable requirements of ASME lines.
B30.23 are met when lifting personnel. 5. Perform a daily inspection as required by this standard.
10. Supplying weights of the loads to the operator and 6. Not operating the crane if physically or mentally unfit.
verifying that they do not exceed the capacity of the crane. 7. Not engaging in any activities that would divert his
11. Ensuring that the load is properly rigged and balanced. attention from operating the controls

Crane Operator Responsibilities cont’d 17. If power fails during operations the operator must:
8. Ensuring that all controls are in the off or neutral position
and that all personnel are in the clear before energizing the * Set all brakes and locking devices.
crane or starting the engine. * Move all clutches or power controls to the off or
9. Testing the crane function controls that will be used and neutral position.
operating the crane only if those function controls respond * Land any suspended load by brake control if
properly. practical.
10. Knowing and following the procedures specified by the
manufacturer or approved by a qualified person for assembly, 18. Before leaving the crane unattended the operator
disassembly, setting up, and reeving the crane. shall:
11. Knowing how to travel the crane. * Land any suspended load unless the requirements for
12. Observe each outrigger extension, setting and retraction restraining all crane functions have been met and signs or
or have a signal person observe same. barricades have been set in place.
13. Ensure that the load and rigging weights are supplied. * Disengaging the master clutch if applicable.
14. Calculating the NET capacity for all lifts and ensuring that * Setting all travel, boom, swing brakes and other locking
the crane has adequate capacity for that lift in that devices.
configuration. * Putting all controls in the off or neutral position.
15. Knowing and responding to standard hand signals and * Stopping the engine with the exception of frequent
interruptions to crane operation which occur during a shift
any special signals from the person who is directing the lift. If
and the operator must leave the crane. All four previous
a signal person is not required then the operator is responsible requirements must be satisfied. The operator must
for the movement of the crane. The operator must obey a maintain visual entry control to the crane cab.
STOP signal at all times no matter who gives it. * Securing the crane per the manufacturer’s
16. Understanding basic rigging procedures and ensuring recommendations when storm conditions arise.
that the load is rigged properly before lifting.

Operating Practices When operational aids are inoperative or malfunctioning,
the crane manufacturer’s recommendations for
Handling the Load continued operation or shutdown of the crane shall be
1. No crane shall be loaded beyond the specifications of the followed until the problems are corrected.
load rating chart, except for test purposes spelled out in this
standard.
2. The load to be lifted shall be within the rated capacity of Without such recommendations and any prohibitions
the crane in its existing configuration. from the manufacturer against further operation, the
3. When load weights are not accurately known, the following requirements shall apply:
designated person supervising the lifting operations shall
confirm that the weight does not exceed the capacity of the 1. Recalibration or repair of the operational aid shall be
crane at that radius. accomplished as soon as is reasonably possible as
determined by a qualified person.
Operational Aids 2. When a load indicator, rated capacity indicator, or rated
1. In all cases, verified weights, measured radii, and the capacity limiter is inoperative, the designated person
manufacturer ’s load/capacity chart capacities and instructions responsible for supervising the lifting operations shall establish
shall take precedence over operational aids when handling a procedures for determining load weights and for conducting
load. If it is necessary to temporarily override an operational the lifts per items 1-3 Handling the Load. If the boom angle or
aid to handle a rated capacity load within the limits established radius indicator is inoperative, the radius of the load must be
by the manufacturer’s load capacity chart and instructions, measured.
items 1 through 3 above must be satisfied. 3. If the level indicator becomes inoperative, other means
shall be used to level the crane within acceptable limits as
specified by the manufacturer.

Holding the Load 5. If outriggers are to be deployed unevenly, this must
1. No one should be allowed to pass under the load. be approved by the manufacturer and the appropriate
2. If the load hoist doesn’t have an automatic brake and the load charts and operating areas utilized. The operator
load must remain suspended, the operator must engage the must approve the setup of the crane and means to limit
locking device to prevent the load from lowering inadvertently. the crane’s movement into prohibited operating ranges
3. If a load is to be suspended for a time which exceeds shall be provided
normal lifting operations, requirements for restraining all crane 6. If outrigger deployment is other than what is
functions have been met and signs or barricades have been specified in the operations manual and load charts, the
set in place. manufacturer or a qualified person must be consulted
concerning special operating procedures.
Moving the Load
The person directing the lift shall see that:
1. That the path is clear so that the load, boom or other
parts of the crane do not come in contact with any
obstructions.
2. On wheel mounted cranes that no loads shall be lifted
over the front area, except as specified by the crane
manufacturer.
3. The operator test the brakes prior to each time a
maximum rated load is to be lifted.
4. Outriggers are deployed equally as recommended by the
manufacturer (fully or partially) and the appropriate load charts
are used.

Moving the Load cont’d Personnel Lifting
7. Neither the load nor boom hoist shall be lowered where Personnel are only permitted to ride in a personnel
the drum contains less than two full wraps of rope. platform supported by the crane load line attachment or
8. When two or more cranes are used to lift one load, one boom-mounted platform when used in accordance with
designated person shall be responsible for the operation. That the requirements of ASME B30.23 and the crane
person shall analyze the operation and instruct all personnel manufacturer’s instructions. The crane shall not be used
involved in the proper positioning, rigging of the load, and the for other purposes while handling personnel.
movements to be made.
9. When moving the boom should be in line with the
direction of motion, the superstructure should be secured from
rotating and the empty hook should be secured from swinging Signals
freely. 1. Communication between the crane operator and the
10. Before traveling a crane with a load, it shall be signalperson shall be maintained continuously during all crane
determined that this practice is not prohibited by the movements. If at any time communication is disrupted, the
manufacturer. Sudden starts and stops should be avoided. Tag operator shall stop all crane movements until communication is
lines should be used to control swinging of the load. restored and a proper signal is given and understood.
11. Personnel are not permitted to ride the hook or load 2. Standard signals to the operator shall be in accordance
suspended from the hook. with the standards prescribed in the following pages and
posted conspicuously on the job site. Signals shall be
discernible or audible at all times. No response shall be made
unless signals are clearly understood.

STANDARD HAND SIGNALS
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 Arm extended DOG EVERYTHING Clasp TRAVEL (both tracks)Use

forward, hand open and hands in front of body. both fists in front of body,
slightly raised, making pushing making a circular motion about
motion in direction of travel. each other, indicating direction
of travel forward or backward.
(For land operated cranes only)

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)

EXTEND BOOM (telescoping RETRACT BOOM

booms) One hand signal. One (telescoping booms) One
fist in front of chest with thumb fist in front of chest, thumb
tapping chest. pointing outward and heel of
hand tapping chest.

Signalperson Qualifications Special Signals
All signalpersons shall be tested by a designated person and If special signals are required, they shall be agreed upon
demonstrate their qualifications in the following areas: in advance by the person directing lifting operations, the
1. Basic understanding of crane operation and limitations. crane operator, and the signalperson. These special
2. Standard hand and voice signals. signals should conflict with the standard signals.
Standard Voice Signals Operating Near Electric Power Lines

Prior to beginning lifting operations using voice signals, the Any overhead wire shall be considered to energized
signals shall be discussed and agreed upon by the person unless and until the person owning such lines or the
directing lifting operations, the crane operator, and the electrical utility indicate that it is not energized.
appointed signalperson. Crane operators shall not rely on the coverings of wires for
1. Telephones, radios, or equivalent, if used, shall be tested their protection.
before lifting operations begin. If the system is battery
powered, extra batteries should be available at the job site. Four conditions to consider when operating a mobile crane
2. Prior to commencing a lift, the operator and signalperson near electric power lines as follows:
shall contact and identify each other.
3. All directions given to the crane operator by the 1. Power lines are de-energized and grounded.
signalperson shall be given from the operator’s direction 2. Power lines are energized and the crane is operating less
perspective (e.g., swing right). than the erected fully extended boom length away from the
4. Each series of voice signals shall contain three elements lines.
stated in the following order: 3. Power lines are energized and the crane is within the
(1) function and direction prohibited zone.
(2) distance and/or speed 4. Crane is in transit with no load and the boom lowered.
(3) function stop

Environmental conditions such as fog, smoke or Minimum radial distance of prohibited zone.
precipitation may require increased clearances.

Crane Operation Near De-energized and Grounded Crane Operation Within the Erected/Fully Extended
Electric Power Lines Boom Length of the Prohibited Zone, With the Power
This is the preferred method where the hazard of injury or Lines Energized
death due to electrocution has been removed. The following The following steps shall be taken to minimize the
steps shall be taken to ensure that the power lines are de- hazard of electrocution or serious injury as a result of
energized: contact between the energized power lines and the
1. The power company or owner of the power lines crane, load line, or load.
shall de-energize the lines. They must be visibly grounded 1. An on-site meeting between project management
and appropriately marked. A qualified representative of the and a qualified representative the electrical utility shall be
owner of the lines or the electrical utility must verify that these held to establish procedures to safely complete the job.
steps have been completed. 2. A qualified signalperson(s) whose sole responsibility
2. The necessity for grounding wiring that was manufactured is to verify that the required clearance is maintained shall be in
with a insulated covering and is 600V or less shall be constant contact with the crane operator.
determined by electrical utilities or the owner of the power line. 3. No one shall be permitted to touch the crane or the load
3. Durable signs shall be installed at the operator’s unless the signalperson indicates it is safe to do so. Only non-
station and on the outside of the crane warning that conductive tag lines may be attached to the load.
electrocution or serious bodily injury may occur unless 4. Durable signs shall be installed at the operator’s
minimum clearances are maintained between the crane or the station and on the outside of the crane warning that
load being handled and energized power lines. electrocution or serious bodily injury may occur unless
4. If cage-type boom guards, insulating links, or proximity minimum clearances are maintained between the crane or the
warning devices are used on crane, such devices shall not be load being handled and energized power lines.
a substitute for the requirements of this standard even if such 5. The operator should avoid operating over the power lines
devices are required by law. If used, the crane operator, crew, due to the perception of distance and multiple points of contact
and load-handling personnel must understand that a lethal possible.
hazard exists and must maintain the required clearances 6. If possible, ribbons or other means to improve visibility of
regardless of what safety devices may be in place. the power lines should be added by the utility company.

Crane Operation Within the Erected/Fully Extended 3. Installation of insulated barriers that are not a part
Boom Length of the Prohibited Zone, With the Power of or an attached to the crane that will not allow contact
Lines Energized (cont’d) between the energized electric power lines and the
8. If long span power lines are involved then and vertical or crane, load lines, or load.
horizontal movement which could be induced by wind must be 4. Nonconductive barricades to restrict access to the
added to the normal clearance values. The utility company crane work area.
representative will be able to provide this information. 5. A qualified signalperson(s) whose sole responsibility
9. If cage-type boom guards, insulating links, or proximity is to verify that the required clearance is maintained shall
warning devices are used on crane, such devices shall not be be in constant contact with the crane operator.
a substitute for the requirements of this standard even if such
devices are required by law. If used, the crane operator, crew, 6. All nonessential personnel shall be removed from the
and load-handling personnel must understand that a lethal crane work area. No one shall be permitted to touch the crane
hazard exists and must maintain the required clearances or the load unless the signalperson indicates it is safe to do so.
regardless of what safety devices may be in place. only non-conductive tag lines may be attached to the load.
7. If cage-type boom guards, insulating links, or proximity
Crane Operation Within the Prohibited Zone With the warning devices are used on crane, such devices shall not be
Electric Power Lines Energized a substitute for the requirements of this standard even if such
Before such operations take place, a qualified person devices are required by law. If used, the crane operator, crew,
together with a qualified representative of the utility or an and load-handling personnel must understand that a lethal
engineer qualified in power line transmission shall, after visiting hazard exists and must maintain the required clearances
the site, determine if this is the most feasible way to complete regardless of what safety devices may be in place.
the operation and set minimum required clearances and
procedures for such operations. These operations shall be Operations in Transit With No Load and Boom Lowered
under their supervision. The following may be required: While in transit with no load and boom and boom support
1. Crane grounded to the neutral line by the utility. system lowered, the required clearances must be maintained.
2. Electrical protection devices which reenergize the circuit The effect of speed and terrain on boom and crane movement
should be disengaged. shall taken into account.
Miscellaneous Items
1. A portable fire extinguisher, with a basic minimum
extinguisher rating of 10 BC, shall be installed in the cab or at
the machinery housing. Operating and maintenance personnel
shall be familiar with the use and care of the fire extinguishers.
2. Machines shall not be refueled while the engine is
running.
The information contained in this presentation pertains to

the Terex® products on the following pages

Crawler Crane All Terrain Crane
Truck Crane Rough Terrain Crane

TFC
45
Container Reach
Stacker
Telescopic Boom Boom Truck

Crawler Crane

MAIN COMPONENTS Boom point or tip
Pendant
Mast Hook Block
Lattice
Boom
Boom stop
Gantry
Counterweights
Superstructure & Cab
Base or
Carrier
Crawler Tracks or Side Frames

MAIN COMPONENTS
Main
Telescoping Boom Cab Hoist Aux. Hoist
Upper Load Block

Counterweights
Lower Load Block Boom Hoist Cylinder
Outrigger Outrigger

DEFINITIONS axle (bogie): two or more axles mounted in tandem in a
accessory: a secondary part or assembly of parts that frame so as to divide the load between the axles and
contributes to the overall function and usefulness of a permit vertical oscillation of the wheels.
machine. ballast: weight used to supplement the weight of the
administrative or regulatory authority: a governmental machine in providing stability for lifting working loads.
agency or the employer in the absence of governmental base (mounting): the traveling base on which the
jurisdiction. rotating superstructure of a crawler crane is mounted.
angle indicator (boom): an accessory that measures the boom (crane): a member hinged to the rotating
angle of the boom to the horizontal. superstructure and used for supporting the hoisting
anti–two-block device: a device that, when activated, tackle.
disengages all crane functions whose movement can cause boom angle: the angle above or below horizontal of the
two-blocking. longitudinal axis of the base boom section.
appointed: assigned specific responsibilities by the employer boom hoist mechanism: means for supporting the boom
or the employer’s representative. and controlling the boom angle.
authorized: appointed by a duly constituted administrative or boom point (tip): the outer extremity of the crane boom,
regulatory authority. containing the hoist sheave assembly.
auxiliary hoist: a secondary hoist system used either in boom point sheave assembly: an assembly of sheaves and
conjunction with, or independently of, the main hoist system. pin built as an integral part of the boom point.
axis of rotation: the vertical axis around which the crane boom stop: a device used to limit the angle of the boom
superstructure rotates. at the highest recommended position.
axle: the shaft or spindle with about which a wheel rotates. On brake: a device used for retarding or stopping motion.
wheel-mounted cranes it refers to a type of axle assembly cab: a housing that covers the rotating superstructure
including housings, gearing, differential, bearings and machinery or the operator’s or driver’s station.
mounting hardware. clutch: a means for engagement or disengagement of power.

commercial truck vehicle: a commercial motor vehicle gantry (A-frame): a structural frame, extending above
designed primarily for the transportation of materials in the superstructure, to which the boom support ropes are
connection with business and industry. reeved.
counterweight: weight used to supplement the weight of the hoist mechanism: a hoist drum and rope reeving
machine in providing stability for lifting working loads. system used for lifting and lowering loads.
crane carrier: the undercarriage of a wheel-mounted crane jib: an extension attached to the boom point to provide
specifically designed for transporting the rotating crane added boom length for lifting specified loads. The jib
superstructure. It may or may not provide its own travel may be in line with the boom or offset to various angles
mechanism. It is distinguished from a commercial truck vehicle in the vertical plane of the boom.
in that it is not designed to transport personnel, materials, or
equipment other than the crane rotating superstructure. jib backstop: a device that will restrain the jib from turning
cross-over points: in multiple layer spooling of rope on a over backward.
drum, those points of rope contact where the rope crosses the load (working): the external load in pounds (kilograms)
preceding rope layer. applied to the crane, including the weight of load attaching
designated person: a person selected or assigned by the equipment such as lower load block, shackles and slings.
employer or the employer’s representative as being competent load block, lower: the assembly of hook or shackle, swivel,
to perform specific duties. sheaves, pins, and frame suspended by the hoisting ropes.
drum: the cylindrical member around which a rope is wound load block, upper: the assembly of shackle, swivel, sheaves,
for lifting and lowering the load or boom. pins, and frame suspended from the boom point.
dynamic (loading): loads introduced into the machine or its load indicator: a device that measures the weight of the load.
components due to accelerating or decelerating forces. load ratings: crane ratings in pounds (kilograms) established
ensure: term used when the meaning “take steps to see that” by the manufacturer.
or “make sure” is intended. luffing attachment: a front end attachment for a mobile
flange point: a point of contact between rope and drum flange crane that uses an upper working boom or jib, which is capable
where the rope changes layers. of changing angle during operation.

mast (boom): a frame hinged at or near the boom hinge for qualified person: a person who, by possession of a
use in connection with supporting a boom. The head of the recognized degree in an applicable field or certificate of
mast is usually supported and raised or lowered by the boom professional standing, or who, by extensive knowledge,
hoist ropes. training, and experience, has successfully demonstrated
mast (jib): a frame hinged at or near the boom point for use in the ability to solve or resolve problems relating to the
connection with supporting a jib. subject matter and work.
operational aid: an accessory that provides information to rated capacity indicator: a device that automatically
facilitate operation of a crane or that takes control of particular monitors radius, load weight, and load rating and warns
functions without action of the operator when a limiting the crane operator of an overload condition.
condition is sensed.
outriggers: extendable or fixed members attached to the rated capacity (load) limiter: a device that automatically
mounting base, which rest on supports at the outer ends used monitors radius, load weight, and load rating and prevents
to support the crane. movements of the crane, which would result in an overload
pawl (dog): a device for positively holding a member against condition.
motion in one or more directions. reeving: a rope system in which the rope travels around
payload: that load or loads being transported by the drums and sheaves.
commercial truck chassis from place to place. repetitive pickup point: when operating on a short cycle
pendant: a rope or strand of specified length with fixed end operation, the rope being used on a single layer and being
connections. spooled repetitively over a short portion of the drum.
power-controlled lowering: a system or device in the power rope: refers to wire rope unless otherwise specified.
train, other than the load hoist brake, that can control the rotation-resistant rope: a wire rope consisting of an inner
lowering rate of speed of the load hoist mechanism. layer of strand laid in one direction covered by a layer of strand
qualified operator: an operator who has met the requirements laid in the opposite direction. This has the effect of
set forth for operator qualification in this standard. counteracting torque by reducing the tendency of the finished
rope to rotate.
running rope: a rope that travels around sheaves or drums.

shall: term used to indicate that a rule is mandatory and must swiveling: the rotation of the load attachment portion of
be followed. a load block (lower) or hook assembly about its axis of
should: term used to indicate that a rule is a recommendation, suspension in relation to the load line(s).
the advisability of which depends on the facts in each situation. tackle: an assembly of ropes and sheaves arranged for
side loading: a load applied to an angle to the vertical plane lifting, lowering, or pulling.
of the boom. telescoping boom: consists of a base boom from which
stabilizer: stabilizers are extendable or fixed members one or more boom sections are telescoped for additional
attached to the mounting base to increase the stability of the length.
crane, but that may not have the capability of relieving all of transit: the moving of a crane from one jobsite to
the weight from wheels or tracks. another.
standby crane: a crane that is not in regular service but that is travel: the function of the machine moving under its own
used occasionally or intermittently as required. power from one location to another on a jobsite.
standing (guy) rope: a supporting rope that maintains a two-block warning device: a warning device to alert the
constant distance between the points of attachment to the two operator of an impending two-blocking condition.
components connected by the rope. two-blocking: the condition in which the lower load block
structural competence: the ability of the machine and its or hook assembly comes in contact with the upper load
components to withstand the stresses imposed by applied block or boom point sheave assembly.
loads. wheel base: the distance between centers of front and rear
superstructure: the rotating upper frame structure of the axles. For a multiple axle assembly the axle center for
machine and the operating machinery mounted upon it. wheel base measurement is taken as the midpoint.
swing: rotation of the superstructure for movement of loads in whipline (runner or auxiliary): a secondary rope system
a horizontal direction about the axis of rotation. usually of lighter load capacity than that provided by the main
swing mechanism: the machinery involved in providing rope system.
rotation of the superstructure. winch head: a power-driven spool for handling loads by
swivel: a load-carrying member with thrust bearings to permit means of friction between fiber or wire rope and the spool.
rotation under load in a plane perpendicular to the direction of
the load.
hc crawler cranes
Wire Rope
Components of Wire Rope
a – Wire
b – Strand
c – Center or Core
d – Wire Rope
Terex® Hydraulic Crawler Training : Wire Rope 2

Wire Rope Specifications
An important point to consider is the selection of the proper

type of core needed in the rope. Wire ropes are made with
either fiber core or a steel wire core.
Fiber Core (FC)

The center is made of either natural fibers or poly propylene
and offers greater elasticity than the independent wire rope
core.
Independent Wire Rope Core (IWRC)

The center is composed of a separate 7x7 wire rope which is
designated as IWRC. The steel core increases the strength by
7% and the weight by 10-%. These steel cores provide more
substantial support than fiber cores to the outer strands during
the rope’s operating life. Steel centers resist crushing, are
more resistant to heat and increase the strength of the rope.

Wire Rope Specifications
6 X 7 Construction (6 strands, 7 wires to the strand)

Rope Lay Construction
Regular Lay / Right Lay - Individual wires in each strand are

wound to the left and the strands are wound to the right. This
is the most commonly used wire rope.
Regular Lay / Left Lay - Individual wires in each strand are

wound to the right and the strands are wound to the left.
Lang Lay / Right Lay - Individual wires in each strand are

wound to the right and the strands are wound to the right.
Lang Lay / Left Lay - Individual wires in each strand are

wound to the left and the strands are wound to the left.

Rotation Resistant Rope
Sometimes referred to as Anti-rotation rope. The inner core is

wound in the opposite direction of the outer core to provide
counter-torque to reduce spin.
There are different categories of rotation resistant ropes based

upon their resistance to rotation:
Category 1 – Has at least 15 outer strands with three layers of

strands (over a center) and has little or no tendency to rotate.
Category 2 – Has at least 10 or more outer strands with two or

more layers of strands (over a center) and has significant
resistance to rotation.
Category 3 – Has no more than 9 outer strands, has two

layers of strands (over a center) and has limited resistance to
rotation.
NOTE
For best performance category 2&3 ropes should not be used
with a swivel. Category 1 rope may be used with a swivel.

Recommended Applications for Wire Ropes

Machine Wire Rope Specifications
The wire rope specifications and lengths are found in the

Operators Manual. The information below represents the rope
specifications for an HC230. The boom pendants should be
replaced in pairs The respective part number and length will be
stamped into the socket. These items must be purchased
directly from Terex as the sockets are specially designed for
our pendants.

Wire Rope Replacement Criteria

Wire Rope Replacement Criteria Reduction from nominal diameter of more than 5%.
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.
In rotation-resistant ropes, two randomly distributed broken

wires in six rope diameters or four randomly distributed broken
wires in 30 rope diameters. In order to properly determine the true diameter of wire rope ,
the measurement must be taken across the largest cross-
One outer wire broken at the point of contact with the core of sectional dimension. If the rope has an odd number of outer
the rope that has worked its way out of the rope structure and strands, then special techniques must be used.
protrudes or loops out from the rope structure. Additional
inspection of this section is required.
Independent wire rope core (IWRC) or strand core

protrusion between the outer strands.
Kinking, crushing, birdcaging, or any other damage resulting in

distortion of the rope structure or severe corrosion as
evidenced by pitting.
Apparent damage from any heat source, including, but not

limited to, welding, power line strikes, or lightning.

Wire Rope Damage A kinked wire rope is shown here. It's caused by pulling
down a loop in a slack line during handling, installation or
A "birdcage" is caused by sudden release of tension and the operation. Note the distortion of the strands and
resulting rebound of rope. These strands and wires will not be individual wires. This rope must be replaced.
returned to their original positions. The rope should be
replaced immediately.
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.
Drum crushing is caused by small drums, high loads and

multiple winding conditions.

Types of Wire Breakage
A wire broken under a tensile load that exceeds its strength by

the “cup and cone” configuration at the fracture point (A). The
necking down of the wire at this point shows that failure
occurred while the wire retained its ductility. Shear-tensile
fracture (B) occurs in wire subjected to a combination of
traverse and axial loads. Fatigue breaks are usually
characterized by squared off ends perpendicular to the wire
either straight across or Z-shaped (C&D)
A B
C D

Seizing and Cutting Wire Rope
In order to cut wire rope it must be seized properly. Using a
soft grade of wire, wrap it tightly around the rope by hand and
use pliers to tension and secure it as shown, or by using a
tensioning rod as show at right Be sure to wrap it to a length
at least 1.5 – 2 times the diameter of the rope in order to
adequately secure the strands.

Application of Rope Clips
Whenever applying wire rope clips, always ensure that they

are placed as shown in the top example with the U portion of
the clip on the “dead” side and the saddle on the “live” side.
When socketing, ensure the dead side is at least 6-9 rope Live Side Dead Side
diameters in length prior to applying the rope clips .
An easy way to remember this is to “Never saddle a dead

horse”.

hc crawler cranes
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.
Terex® Hydraulic Crawler Training: Rigging 2

Wire Rope Slings - The most common and lowest cost per
ton of lift of all slings, wire rope slings are known for their
strength, ability to bend without distortion and withstand
abrasive wear. A single leg wire rope sling can be used in a
number of different hitches. They are used in the construction
industry and other industries where a variety of heavy loads
and rugged conditions exist. Sling fittings can usually be
inspected and reused, reducing replacement costs.
Kinking, crushing, or severe abrasion can cause structural

damage and loss of strength.
Wire rope slings should be padded where they bend over

sharp edges. This will help prevent fatigue damage
caused by bending around too small a radius.
For high capacity lifts, consider using a braided wire rope

sling. These slings are made of many small diameter wire
ropes braided together to form one large sling. Braided slings
have great flexibility and are almost impossible to kink.

Chain Slings - Only alloy steel grades 6, 8 and 10, and some
stainless steel chain slings are approved for overhead
lifting. They are well suited to high-temperature atmospheres
and loads that would abrade or destroy other types of
slings. Due to their superior strength and durability, chain
slings are typically used in foundries, steel mills, and heavy
machine shops which require repetitive lifts, often under
extreme conditions. They can be inspected, repaired, proof
tested and recertified.
Alloy chain slings can be heated to temperatures up to

1000°F. When they are consistently exposed to service
temperatures in excess of 400°F, the working load limits must
be reduced in accordance with the manufacturer's
recommendations.
Chain slings can have one to four legs connected to a master

link and can be fabricated with adjustable reach. Multi-leg
slings can be quicker and easier to rig than single leg slings. A
four legged chain sling has the same rating as a three legged
sling due to the difficulty in evenly balancing the load among all
four-legs.

Warnings – Wire Rope Slings & Chain Slings
Always inspect chain slings before use.
Never use worn-out or damaged slings.
Never overload or shock load a sling.
Free slings of all kinks, knots and twists.
Do not drop or rest a load on a sling.
Balance loads. Avoid tipping loads.
Do not expose to corrosive solutions.
Use pads around sharp corners.
Do not force or hammer hooks into place.
The US standard ASME B30.9 addresses inspection and

removal of worn-out or damaged chain slings.

Synthetic Web and Round Slings - Both web slings and
round slings are a good choice where highly finished parts or
delicate equipment must be protected from damage. Their
stretch and flexibility help them mold to the shape of the load,
gripping securely, while cushioning and absorbing shock far
better than wire rope or chain. They are lightweight and very
easy to handle.
Synthetic slings are unaffected by grease, oil, moisture and

certain chemicals. Nylon is used where alkaline conditions
exist. Polyester is used where acids or bleaching agents are
present. Polyester slings are also recommended where
headroom is limited since they stretch 3% less than nylon web
slings (7% vs. 10% at the working load limit). They are non-
sparking, non conductive and can be used safely in explosive
atmospheres.
Synthetic slings are susceptible to cuts, punctures and

abrasion damage, as well as damage from temperatures
above 200°F. They should be protected from sharp edges,
projections and heat sources such as steam pipes, open flame
and welding splatter.

Web slings are generally made from either polyester or more
economical nylon flat woven webbing. Web slings can be
fabricated with extremely wide load bearing surfaces (up to
48"), yet will still be easy to handle.
Round slings are constructed of a continuous loop of

polyester enclosed in a double layer woven jacket. Normal
cover damage does not affect the sling strength. The jacket
protects the load bearing core of the sling from abrasion, dirt
and ultraviolet degradation. Wear points can be moved around
to extend sling life. Round slings are extremely flexible with
limited stretch.

Warnings – Web and Round Slings
Always inspect web slings before use.
Never use worn-out or damaged slings.
Never overload or shock load a sling.
Balance loads. Avoid tipping loads.
Free slings of all kinks, knots and twists.
Do not drop or rest a load on a sling.
Avoid prolonged exposure to ultraviolet light.
Avoid exposure to temperatures above 200°F.
Protect against cuts, punctures and abrasion.
The US standard ASME B30.9 addresses inspection and

removal of worn-out or damaged web and round slings.

Metal Mesh Slings: Wire and Chain - These slings excel in
lifting objects that are hot or have sharp edges, such as bar
stock or plate steel. They grip the load firmly, resist corroding,
stretching, kinking or tangling, and can withstand temperatures
up to 550°F.
Mesh slings enhance load balancing due to their ability to

conform to irregular shapes and their wide load bearing
surface. Each sling is proof tested, certified, and stamped with
its capacity and serial number. They can be repaired, tested
and recertified for service. Machine shops and steel
warehouses typically use mesh slings.

Care and Use of Slings Do not tip load a hook. Seat sling squarely in the bowl
of the hook. Never force or hammer hooks or slings into
place.
Always inspect slings before use.
Never use worn-out or damaged slings. Follow all regulations Rig with adequate headroom for the lift. Clear the
for inspection and removal of worn-out or damaged slings. load's path of all obstructions.
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.

Hook Inspection

Hook Inspection

Hook Examination Hook Latches
Examine crane hook for excessive wear. A hook showing a

wear-reduction greater than a 5% value should be removed
from service.
Examine crane hook for nicks and gouges.
Examine crane hook periodically by magnetic particle and/or

dye penetrant test methods, or more often in severe operating
conditions. Hooks found to contain cracks should be removed
from service.
Never repair, alter, rework, or reshape any load bearing

component by welding, heating, burning or bending.

Shackles

Shackle Use and Inspection

Sling Hitch Capacities
This illustration shows the basic sling hitches. It also shows

capacities for a single sample sling, rigged with each hitch.
The sample sling's Working Load Limit in a vertical hitch is 500

lbs.

Sling Hitch Capacities
This sling has a Working Load Limit of 500 lbs. in a vertical

hitch. Used in a choker hitch, it would have a capacity of 375
lbs. Used in a basket hitch with the legs at a 90° angle to the
load, it would have a working load limit of 1,000 lbs. Used in a
basket hitch with the legs at a 60° angle to the load, it would
have a working load limit of 866 lbs., etc. - Why? The angle at
which a sling is used, and the number of legs lifting the load
can significantly effect its capacity. The formula for this
calculation is shown below.

Determining the Sling Angle
If you are unable to determine the exact angle of the sling then
it can be estimated as follows:
To calculate the reach for equal legs needed to rig at a 45 ˚ or 60˚

angle:
Reach at 60˚ : L = 2 x D Reach at 45˚ : L = 1.4 x D

Sling Inspection Removal from Service Criteria
One of the primary reasons for premature sling retirement

Initial : This level of inspection is done at the time that the
is the lack of permanent information on the sling
product is received from the manufacturer. The inspector identification tag. There are many different materials and
should ensure that no damage has occurred during shipment, just as many methods of encoding the information.
and also verify that the sling work load limits match those
ordered in the manufacturer's catalogue. If your facility Depending upon the applicable standards, basic
information, such as the material used in the construction
documents the sling inspection process through written
of the sling and the work load limits for the respective
inspection records, the paper trail should begin at this point. hitches must be clearly legible.
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.

Sling Identification Tag

hc crawler cranes
Hydraulic Symbols
Crossing or Joining
The shortest distance between two components that are A connection between two crossing lines must be
connected is a straight line… and it is desirable to draw it that designated by placing a dot at the point of crossing
way to avoid following a line all over the diagram just to get
back near where you started.
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.
Example 1 Example 2 Pump Symbols
The basic symbol is a circle with a black triangle pointing

outward.
20.5cc
P3 P1
FIXED DISPLACEMENT VARIABLE

DISPLACEMENT
Terex® Hydraulic Crawler Training: Hydraulic Symbols 2

Optional Symbols
Occasionally it may be desirable to show the prime

mover and the direction of rotation. If the prime mover
may be either an electric motor, or combustion engine. A
curved arrow crossing a line from the pump symbol
indicates the direction of rotation where required.
VARIABLE
VARIABLE DISPLACEMENT
DISPLACEMENT
PRESSURE
COMPENSATED
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 and 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 at the points where the
lines touch the symbols.
A pump with a variable output is designated by drawing an

arrow through it at 45 degrees.
Terex® Hydraulic Crawler Training: Hydraulic Symbols
Displacement Controls Motor Symbols
The displacement control for a pump or motor is drawn beside Motor symbols also are circles with black triangles; but
the symbol. As you can see, the control symbol sometimes has with triangles point in to show that the motor is a receiver
a resemblance to the control; for instance, the lever has a of pressure energy. One triangle is used In a non-
knob. 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.
VALVES UNIDIRECTIONAL
MOTOR
PRESSURE LEVER
COMPENSATED CONTROL
REVERSIBLE
MOTOR
VALVES
PEDAL OR MECHANICAL
TREADLE SERVO

The direction of flow with a single triangle is indicated by the Flow to and from a cylinder must be traced by observing
direction in which the triangle points. In the reversible motor, which lines it is connected to. There is no provision in the
we must refer to the pump and valve symbols to trace the flow symbol for flow direction. This really not a problem,
direction. The arrows outside the lines show the flow though. We’re about to see that valve symbol are
direction… always away from the pump’s pressure port and copiously decorated with arrows indicating the direction
into the motor port. The opposite port then must be the of flow.
discharge port going to the control element and then back to
tank. Controls symbols and rotation direction indicators used PORTS
with pump symbols also apply to motors.
Cylinder Symbols DOUBLE-ACTING

PORTS PORTS
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.
SINGLE-ACTING
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.
DOUBLE END ROD
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.

Pressure Control Symbols Normally Open
A pressure control valve is infinitely positioned between two When the arrow connects the two ports, we know that
flow conditions. Its basic symbol is a square with external port the valve is normally open. It closes only when pressure
connections and an arrow inside to show the direction of flow. overcomes the spring force.
Usually this type valve operates by balancing pressure against
a spring, so we show a spring at one side of the symbol and a Relief Valve
pilot pressure line at the other.
A relief valve is shown with a normally-closed symbol
INLET PILOT INLET
connected between the pressure line and tank. The flow
PRESSURE direction arrow points away from the pressure line port
SPRING
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 directed from
the pressure port to the tank port.
OUTLET OUTLET
PRESSURE LINE
Normally Closed
A normally-closed valve, such as a relief or sequence, is

shown with the arrow offset from the ports toward the pilot RELIEF
pressure line. This indicates that the spring holds the valve PUMP 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 Sequence and Check Valve
The same symbol is used for a sequence valve. This time Remember that with this connection a sequence valve
the inlet port is connected to a primary cylinder line and the must be used with a check valve for free return flow
outlet port to the secondary cylinder line. Pilot pressure when the cylinders are reversed. The next diagram
from the primary cylinder line sequences the flow to the outlet shows a simplified check valve symbol and its parallel
port when it reaches the setting of the valve. Since the connection.
sequence valve is externally drained. We have added a drain
connection to the symbol at the drain’s location in the valve. 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
DIRECTIONAL are assumed to be on the enclosure line and indicate
RELIEF PUMP VALVE connections to components.
VALVE
TO PRIMARY
CYLINDER
SEQUENCE
VALVE
TO SECONDARY
DRAIN CYLINDER

SEPARATE UNITS
DIRECTIONAL
VALVE
TO PRIMARY
CYLINDER
NO FLOW
SEQUENCE DIRECTION
VALVE
CHECK VALVE FREE FLOW
DIRECTION
RELIEF PUMP
VALVE TO SECONDARY
CYLINDER
INTEGRAL SEQUENCE
AND CHECK VALVE
COMPONENT ENCLOSURE

Counterbalance Valve Relief (Brake) Valve
A counterbalance valve is a normally closed pressure control A relief valve with auxiliary remote control connection
within integral check valve. For a directly controlled valve, we can be used as a brake valve when connected between
use the same symbol with the primary port connected to the the motor outlet and the directional valve. It looks like the
bottom port of the cylinder and the secondary port of the counterbalance valve diagram, except that it has two
directional valve. The drain connection isn’t shown, because pilot control connections. A low pressure in line “A” will
the valve is internally drained. If valve body has two primary open the valve to permit free flow from the motor through
ports, a complete symbol should show one of them plugged. 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.
TO DIRECTIONAL
CONTROL VALVE PLUGGED PORT A
TO
DIRECTIONAL
VALVE
COUNTERBALANCE
ENCLOSURE AND CHECK VALVE

Pressure Reducing Valve
FROM PUMP AND
The normally-open pressure reducing valve is diagrammed DIRECTIONAL
below. Outlet pressure is shown opposing the spring to VALVE
modulate or shut off flow when the valve setting is reached.
RETURN
TO TANK
Flow Control Symbol
The basic flow control valve symbol (seen following page) is a

FROM PUMP AND
simple representation of a restriction. If the valve is adjustable, DIRECTIONAL VALVE
the slanted arrow is drawn across the symbol.
TO RETURN
FROM PUMP AND

NON-ADJUSTABLE DIRECTIONAL VALVE
TO RETURN
ADJUSTABLE

Directional Control Symbols Check Valves
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
Unloading Valve A B
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 P T
that the spring controls this position. TWO POSITION, CONTROLLED BY
EXTERNAL PILOT PRESSURE
SOLENOID
A B CONTROL
SYMBOL
FROM
PUMP
P T
TWO POSITION, CONTROLLED BY SOLENOID
TO PILOT SOLENOID CONTROL

PRESSURE SOURCE WITH INTERNAL
PILOT PRESSURE
External pilot pressure is shown against the bottom envelope
to show that this is the flow condition when the pilot pressure A B
takes over. With the lower envelope superimposed on the
other, the flow path arrow connects the pump outlet to the
reservoir. P T
THREE-POSITION, SPRING-CENTERED, CLOSED
CENTER CONTROLLED BY SOLENOID
Four-Way Valve WITH INTERNAL PILOT PRESSURE
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 The manual, lever, pedal, and mechanical control symbols
position. The actuating control symbols are placed at ends of pictured earlier are used as appropriate with directional valves.
the envelops. The extreme envelops show the flow conditions Spring symbols, pilot lines, solenoid symbols and internal-pilot
when their adjacent controls are actuated. black triangles also are used as appropriate.

Accessories Symbology Index
Fluid conditioners are represented as squares that are turned In the following pages, the basic hydraulic symbols are
45º and have the port connections to the corners. A dotted line shown and defined in the next few pages.
at right angles t port connections tells us the conditioner is filter
or strainer. An oil cooler symbol has a solid at right angle to
fluid line with energy triangles (indicating heat this time)
pointing out.
10u
FILTER OR STRAINER COOLER
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. 1. below fluid
level. 2 above fluid level. Power Source: The power source is a combustion engine.
With the performance specifications and shaft rotation noted in
the drawing.
20.5cc
P3 P1
Pump: Hydraulic pumps convert mechanical energy Pump Disconnect: Used to disconnect pump from power
transmitted by a power source into hydraulic working energy source for extended travel, repairs, cold weather starts.
flow. Pumps may be gear driven (A) or variable displacement
(B) in design.

Connecting Lines: Branch lines connected to main line.
Hydraulic Motor: Converts the working energy of the Line Crossing: A line crossing over another line, but not
hydraulic system into mechanical energy. Hydraulic motors are connected.
positive displacement and are either vane, gear or piston
design. Rotation direction is noted as above.
Continuous Line: Supply line or Return line depending on Dashed Line: Pilot pressure or drain to tank line.
direction of oil flow..

On-off (manual shut-off) Direction of flow
Line, Flexible Flow control, adjustable (temperature and pressure

compensated)
Plug or plugged connection Two position two connection
Enclosure Two position three connection

Two position four connector Spring
Three position four connector Push / Pull Lever
Two position in transition Pedal or Treadle
Valve capable of infinite positioning (horizontal bars

indicate positioning ability) Spring Loaded Accumulator

Accumulator: used in a hydraulic circuit to either develop
system flow or absorb system shock. Most accumulators are
charged with nitrogen gas.
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.
Chain Line: Enclosure of two or more functions contained in

one unit. (outrigger control).
Filter: Removes contamination from hydraulic system. Dotted Line – Case Drain

Check Valve: Is designed to create back pressure in a
specific circuit. Swing, oil cooler.
Hydraulic Oil Cooler: Because of viscosity, friction, and

changing direction, hydraulic oil generates heat during
Orifice: A fixed restriction that functions as a flow control operation. To keep the oil within the required operating
device . Designed to reduce pressure and oil flow in specific temperature range, air coolers are installed in the system
circuits. to aid in the cooling process
Adjusted Orifice: An inline restriction that functions as a flow Hydraulic Pressure Switch: Senses hydraulic pressure
control device. This device is manually adjustable for fine for the purpose of energizing electrical components.
tuning pressure and flow rate. (Relay coils, indicator lights.

355K
Relief Valve: Installed in a hydraulic circuit to protect the Pilot: Operated one position valve, same as pneumatic
system from being over pressurized. operated valve, only the spool is shifted by pilot oil.
40K
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 Hydraulic Swivel: The hydraulic swivel is designed to allow
automatically connected to the outlet port, while the other port 360 degree rotation, while supplying oil to all superstructure
is closed. Used to direct maximum pressure to components functions.
depending on application,

Electric Operated: Two way valve, once the spool is shifted Single Acting Cylinder: Can be extended hydraulically
the oil has two paths to travel, to the specific circuit and an or pneumatically depending on application. The cylinder
path for oil to return to tank. is retracted utilizing a spring. (Axle disconnect, park
brake)
Double Acting Cylinder: Extended and retracted

hydraulically. (Steer).
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.
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
Brake Valve: Supplies hydraulic oil to swing brake assembly side of the cylinder (B) filling up with oil, causing the barrel to
to assist the springs to apply pressure to stop the rotation of move outward, the boom section that is anchored to is pushed
the superstructure, during crane operation. outward.
hc crawler cranes
Hydraulic System Components

Drain from
Aux hoist Boom hoist
block valve
brake brake release A B
pressure CWT lock cylinder Block Block Valve Control
Main hoist
brake Swing
pressure
CWT
Swing
brake
Lock out
solenoid valve
CWT
drain
Lock out
solenoid valve
Joystick
pressure
control valve Pumping System
Terex® Hydraulic Crawler Training: Hydraulic System Components 2

Pumping Systems P5- Swing brake
Aux. Winch Mode selection
The pumping system consists of 5 pumps. There are 2 Boom Hoist winch Motor
variable piston pumps as well as 3 gear pumps. P1 and P2 are
the Variable displacement pumps and P3-P5 are the gear
pumps.
P1- Left Travel

3rd drum
Aux, Hoist 2nd speed
Main Hoist 1st speed
P2- Main Hoist 2nd speed

Aux. Hoist 1st speed
Boom Hoist / Lower
Right Travel
P3- Swing
P4- Crawler Extension & Jack up

Counterweight Lift cylinders
Counterweight locking cylinders
Boom Foot Primary cylinders
A-Frame Raise / Lower
Accessories - Reeving winch & tagline

Solenoid Manifold
This bank of solenoid valves controls the Hoist drum locks

and the ability to operate travel system. There is also a Travel joystick
solenoid that controls the travel speed.
Travel speed changeover
Main Winch drum lock
Aux Winch drum lock
B/H Winch drum lock

Lever and Solenoid control Manifold
Lock
out
PUMPS

Control Levers. The levers operate various functions on the
crane. The levers have a regular range of
motion for the functions as well as a detent
which in respect to the winches gives a fast
speed. The lever range pressures are from
4.9-26.5k. This range delivered will give you
fast or regular speed. The setting for the
directional valves is set so that a range of
pressure from 3 – 14k will give you regular
speed. When the lever is pushed passed the
detent point, this greater pressure will actuate
the second directional valve from a pressure of
16.3 – 24.1 k. This will allow a greater flow to the
winch motor. Values for pressures coming from
these levers differ from those that are for other
levers on crane.

Solenoid control manifold
This bank of shuttle valves and pressure switches directs the

pressure from the levers to their corresponding directional
valves. It also sends the signal to the piston pumps to ramp
them up to provide the flow for the hoisting and travel
functions.

Pressure Control Valve The reduced pressure that supplies the pilot pressure
the levers come from here as well as the

hc crawler cranes
Electrical Symbols & Components

Common or Non-connected Fuse Diode
Connected Electrical Electrical Point
Point
L41
12V
Normally Open Normally Closed Ground Transistor Battery Indicator Lamp

Contact Contact
Terex® Hydraulic Crawler Training: Electrical Symbols & Components

PL1 SV4 T1
Solenoid Coil Electromagnetic Timer Coil 2 Way Switch 3 Way Switch DPDT Switch
Proportional (Double Pole
Valve Coil Double Throw)
RE
BZ42 PC57
EX
Buzzer Coil Pressure Switch Bi-Directional

Motor
Seat Switch N.O. Switch N.C. Time Delay

Switch N.O.
Terex® Hydraulic Crawler Training: Electrical Symbols & Components 3

Battery Relay
24VDC Power Sensor
Outlet
ACC
ST
G2
COM
B
+10V
M G1
Ignition Switch Adjustment Dial Heater Relay Intake Heater

Main Relay and Fuse Panel

Part Number
ON/OFF
ON/OFF
Older boards do not have the toggle switch.
These can be replaced with the newer board
but the new board can’t be replaced with an
old board.

Blown Fuse
Indicator
Energized Coil
Indicator

Main Fuses and Relays

Clutch Maintenance & Anti-Two Block Switches
The clutch maintenance switch is either placed in the operation

or maintenance position as desired. The Anti-two block
switches are placed in the “Function” position when the desired
hoist is to be used and in the “Release” position when not
used.

Solenoid Driver
Provides drum speed control for the main, auxiliary and

boom hoists. The speed control knobs on the panel inside the
operator’s cab feed a 0-10VDC signal into the solenoid driver.
The driver sends out a 0-,8A current signal to the
electromagnetic proportional valves.

Drum RPM Indicator & Engine Throttle Controller
The drum RPM indicator provides feedback (thumper) to the

operator through the Main/Aux. control levers.
The engine throttle controller receives and sends multiple

inputs and outputs to control the engine RPM’s. There is an
internal switch which either allows the unit to operate in AUTO
or MANUAL mode.

Boom Stop Limit Switches & Angle Transmitter
There are two limit switches. One is located on the boom foot
(1st boom throw out at 80º) and the second is on the boom
stop and acts as the 2nd boom throw out at 83º.
2nd Throw
The angle transmitter sends information to the M/L-D5A
moment limiter to correlate the angle of the boom with the
Out Switch
radius of the load to determine the capacity of the machine.

Two Block Device and Load Cells
The two block limit switch trips when the hook block come is
contact with the weight, lifting it and opening the circuit
stopping the hoist and preventing the boom head sheaves
from being damaged.
The load cells (one on each side) provide a signal to the M/L-
D5A moment limiter to determine the weight of the load.
These are located in the A Frame.

hc crawler cranes
Load Charts
Center of Gravity
The Center of Gravity is the point relative to a body around

which its weight is evenly distributed and is represented by this
symbol. The location of the CG does not change when the
position of the object is changed.
FULCRUM POINT
RADIUS
The radius is measured from the center of rotation to the

center of gravity of the load.
Terex® Hydraulic Crawler Level 1: Load Charts 2

Center of Rotation
FRONT SIDE
REAR
SIDE

Change in Radius
If the load is allowed to swing out and away from the

boom, the radius increases. Therefore the load capacity
decreases. How do we prevent this from happening?
DANGER!!!
RADIUS

Change in Radius
When the load swings away from the boom and

the radius increases, the CG of the load moves
outward. This in turn causes the CG of the crane
to move out past the idlers which is the fulcrum or
tipping point causing the crane to tip over.
FULCRUM
POINT

Load Calculation
What is considered to be part of the load?

Load Calculation
Reeving Correct parts of line for the lift.
Block & Ball Weight
Rigging
Actual Load Being Lifted

Load Calculation Factors

Gross & Net Load
The Gross Load include the sum of weight of all attachments,

rigging, ropes etc and are considered as part of the load. Gross
The Net Load is the actual weight of the load.
Net

Load Factors
What items are considered as part of the load in this picture?

Static and Dynamic Loading
A STATIC load is stationary and only exerts the gross weight

of the load on the crane.
A DYNAMIC load results from a sudden stop when raising ,

lowering or swinging the load. This type of load puts additional
loads and stresses on the crane and can result in tipping or
failure of the crane structure.

No operation.
Lower boom to
Boom or Boom 50-60 degrees. Lower or
Boom Size Operation
Plus Jib Position rear of secure boom
crane into
wind.
0-140' 0-30 mph 30-50 mph Over 50 mph
37"
(0-42.3m) (0-13.4 mps) (13.4-22 mps) (22.4 mps)
Over 140' 0-20 mph 20-30 mph Over 30 mph
37"
(O-42.3ml (0-8.9 mps) (8.9-13.4 mps) (13.4 mps)
0-170' 0-30 mph 30-50 mph Over 50 mph
46"-47"
(0-51.8m) (0-13.4 mps) (13.4-22 mps) (22.4 mps)
46"-47"
(51.8) (0-8.9 mps) (8.9-13.4 mps) (13.4 mps)
0-170' 0-30 mph 30-50 mph Over 50 mph
1K 1400 WIND SPEED LIMITATIONS
(0-51.8m) (0-13.4 mps) (13.4-22 mps) (22.4 mps)
1K 1400
(51.8) (0-8.9 mps) (8.9-13.4 mps) (13.4 mps) This table lists the wind speed limitations for the
0-220'' 0-30 mph 30-50 mph Over 50 mph various booms which were produced for Terex
58"-59"
(0-57.1m) (0-13.4 mps) (13.4-22 mps) (22.4 mps) American crawler cranes.. The wind speeds listed
Over 220' 0-30 mph 30-50 mph Over 50 mph refer to steady winds or gusts. Wind velocities
58"-59"
(67.1m) (0-13.4 mps) (13.4-22 mps) (22.4 mps)
must be measured at the highest boom or jib
0-220' 0-30 mph 30-50 mph Over 50 mph
77" elevation and should be taken in close proximity to
(0-67.1m) (0-13.4 mps) (13.4-22 mps) (22.4 mps)
Over 200' 0-20 mph 20-30 mph Over 30 mph the crane. No account is taken of the wind force on
77"
(88.4m) (0-8.9 mps) (8.9-13.4 mps) (13.4 mps) the load. This effect can cause side loading which
0-290' 0-30 mph 30-50 mph Over 50 mph will be substantial for loads with large surface
92"-94"-118"
(88.4m) (0-13.4 mps) (13.4-22 mps) (22.4 mps) areas and must be considered by the user and
92"-94"-118" the load ratings reduced accordingly.
(109.8m) (0-8.9 mps) (8.9-13.4 mps) (13.4 mps)
130"
(0-122m) (0-13.4 mps) (13.4-22 mps) (22.4 mps)
130'
(122m) (0-8.9 mps) (8.9-13.4 mps) (13.4 mps)
Terex® Hydraulic Crawler Level 1: Load Chart 13

Crane Ratings (Load Charts)
Ratings have been established by Terex Cranes on
the basis of sound engineering methods and testing
procedures. The machines comply with applicable U. S.
industry standards for stability and material strength
factors. These standards require operation within rated
capacities and in accordance with good operating
practices.
All ratings apply only to machines as originally manufactured

and equipped by Terex Cranes. Terex Cranes shall have no
responsibility for machines that have been modified without
factory approval or the use of unapproved replacement
components.
Load charts are established on a prepared surface that is

within ½ º of true level in which to support the crane and its
load. The level of the crane should be checked periodically to
ensure that it has not changed and should be re-leveled if
necessary.

Crane Configuration
•Boom Type
•Amount of Counterweight
Load Chart Number

All Capacities marked
with and asterisk are
Factors other than
stability (Structural)
Stability Rating
All Capacities
without asterisk
The difference between the two

refers to whether you are going
to “break” the crane structurally
or tip it over.

Boom Length
The boom length is given in the first column.

Radius
The load radius is given in the second column.

Boom Angle
The boom angle is given in the third column. As boom

angle decreases, load capacity decreases.

Load Capacity & Tip Height
The load capacity is given in the fourth column. It also

denotes the position of the side frames. Depending on
the crane model, the side frames can be fully retracted,
mid-extended or fully extended. This has a direct effect
concerning load capacity.
The fifth column gives you the height from the tip of the
boom to the ground.

50
Main Boom and Fixed Jib Configuration.
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

Main Boom and Fixed Jib Load Chart
Boom and jib combinations require the boom to be at least 2 ½

0 0 0
times the jib length. The jib angle can be set at 5 , 15 , or 25
To change the jib angle it must be lowered to the ground and
the backstay pendant line length must be changed.

hc crawler cranes
HC275 Controls
Terex® Hydraulic Crawler Training: HC275 Controls 2
Left Control Stand
Swing Lever Grip
The rocker switch for swing brake is actuated by

pressing the switch to the right Pressing the switch to
the left releases the brake
Horn Button
Engine Grip Throttle

When the grip is rotated clockwise,
the engine RPM’s will decrease. When the
grip is rotated counterclockwise, the engine
RPM’s will increase. When the grip is
Swing Brake Lamp released the throttle will remain in that
position.
3rd Drum Mode Selector Lamp When the engine is started with the grip throttle set above the idle
position, the RPM’s will not increase until the throttle is rotated
back to the minimum position. Only then can the engine RPM’s be
increased above idle.

Controls .
All operations are remotely controlled by manipulating the main

control valve from the remote control valve (control levers).
• Except for the swing lever, each lever is provided with a
(detent) at the stroke end to hold the lever in position.
The detent tension is adjustable by

loosening the lock nut and turning the
adjustment nut clockwise.
(See the figure at right.)
When tightening the nut, the tension
increases and decreases when the
nut is turned in the opposite direction.
The winch mode selection switch (automatic brake / foot

brake) is located on the main and auxiliary winch levers. The
automatic position and foot position are alternately selectable
by pressing the grip switch when the winch mode selector key
switch on the right-position control panel is set in the foot
mode.
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.

Function of the Operation Lock Device
When the operation lock switch is placed in the Lock position,

ALL controls functions are disabled.
Machine Front
When the switch is placed in the Release position, the controls

functions are enabled even if the operator is not in the seat. Lock
When the switch is at the Operation position and the operator
sits in the operator seat, the seat moves down actuating the
seat switch. If the operator gets out of the seat in this mode, Operation Release
the seat switch will de-energize the hydraulic pilot pressure
control valve (SL51) after 1.5 seconds and disable all control
functions.
If the seat weight adjustment isn’t set to a value less than

the operator’s weight, the seat switch will be not activate. Operation Of Switch

HC275 Front Control Panel Layout
Pump Flow Travel Speed Aux. Hoist Speed Drum Lock

Adjust Dial Selection Switch Selection Switch Switches
Boom Hoist Speed

Selection Switch
Main Hoist Speed

Wait to Start
Start Key Selection Switch
Indicator
Switch
Light

HC275 Rear Control Panel Layout
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

Left Side Operation Panel
Drum lock switches

3 2 1 1. Main winch drum lock switch
2. Auxiliary winch drum lock switch
3. Boom drum lock switch
When releasing the drum locks you may need to hoist up to

remove the load from the locking pawl or dog.
Don't place the switch to the lock position when the drum is
rotating or the drum may be damaged.

Winch Drum Speed Adjustment (HC110 Only)
4. Auxiliary hoist speed adjustment

5. Main hoist speed adjustment
6. Boom hoist winch speed adjustment
4 5 Drum speed is decreased by turning the dial counter-

clockwise increased by turning clockwise.
When the Pump Speed Control dial is set at minimum and

the engine RPM’s are at a low level, hunting may occur during
load lowering if any of these dials are set at high speed.

Wait To Start Lamp
The wait-to-start lamp indicates that the pre-start intake
manifold heater warm-up sequence is active. When the
operator turns the Engine Start Switch to the Run position,
he must not start the engine until the lamp goes out.
Depending on ambient temperature, the lamp will stay on
longer in cold weather while completing the air intake preheat
cycle.
Engine Start Switch

OFF( ) : Engine stop position
The key can be inserted or removed. The electric
circuit of the whole crane is "OFF" ( ).
START : Engine start position
Release the key at this position, and the switch
returns to "ON“ position automatically. Minimum re-
start time is 20 seconds.
ON Engine run position
Don't set the switch to other positions except "ON"( )
during operation to protect the electronic components
ACC Used for listening to the radio, etc. when the engine
is not running.
Note: The engine will not start if the main or auxiliary

drum winch mode selector switches are not in the
automatic mode. The interlock red lamp above the engine
tachometer will be lit when the key is placed in the
"START“ position.

Pump Independent Flow Control Dial
This dial is used to manually change the output of the variable
hydraulic pumps when the Pump Control Selector Switch is
in "MANUAL"( ). When the Pump Control Selector switch
[20] is in "AUTO"( ), the Pump Flow dial has no affect.
Turning the dial fully to the maximum level when the engine
RPM’s are low during operation may stall the engine. If the dial
is set to minimum and the winch lever is in the high speed
position and low engine RPM’s, the operator may feel Pump Flow
shuddering on lowering operations.
Travel Speed Selector Switch (HC-80 & 110)

This switch is used for select the travel speed. The high speed
is selected at the rabbit position and the low speed is selected
at the tortoise position. Speed change may only take place
while the machine is stopped.
Moment Limiter Switch Travel speed

During normal crane operation the M/L switch is placed in 1 2 3
"OPERATION"(2). When assembling or disassembling the
crane place the M/L switch to the "ERECTION“(3) position.
The display unit of the moment limiter will change to red in the
ERECTION mode and all limits previously set will not function
with the exception of "Boom hoisting 2nd throw out”. Hoisting
and lowering the boom are possible in this mode but you must
be careful because the moment limiter does not function as it
normally does. The power must be OFF when changing to the
"TRANSPORT" (1) or ERECTION (2) modes.
The key may be removed in the OPERATION mode.

Safety Device Release Switch (RELEASE) (FUNCTION)
This switch releases the automatic stop condition associated
with the 1st boom throw out limit switch (HC-110 only).
Release is accomplished by placing the switch to the
"RELEASE"( ) position. Use with extreme caution in
releasing this safety device as an accident may occur. The key
switch is set the switch to "FUNCTION"( ) for normal
operations. This device will not release an (A2B) if it is
tripped.
Pump Control Selector (Auto / Manual) Switch 1

When this switch is at "AUTO"(1), the variable displacement
pump delivery is automatically adjusted according to the
engine PRM’s. When in "MANUAL"(2), the pump delivery is
set by the Pump Independent Flow Control Dial
2
Operation Lock Switch PUMP CONTROL

This is a safety device to disable the machine controls to
prevent accidental actuation. Set this switch to "LOCK"(2) 1
prior to exiting the operator's cab.
o RELEASE (3) :Operation lock is released and not
functional. 2
o LOCK (2) :Machine controls are disabled.
o OPERATION (1): The operator can operate the machine 3
by using the control the levers only when seated.
o The machine is able to travel even if the switch is in OPERATION LOCK
the LOCK position.

Travel Lock Switch
When the switch is set to "ON"( ), the machine is unable to
travel even if the lever is actuated. The travel lock switch is
independent of the operation lock switch.
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

A-Frame Control Switch
This switch is used to operate the A-frame. When the switch is 1
in "EXTENSION, (1), the A-frame is extended. Releasing the
switch automatically returns it to “NEUTRAL“ (2),. When
placed in “RETRACT“ (3). the A-frame is retracted 2
Boom Foot Pinning Selector Switch

This switch is used to pin and unpin the boom foot.
Lower Pendant Control Activation

This switch is used to provide power to the lower pendant
control connection during assembly.

Engine Diagnostic Monitor OK Monitor / Hyd. Control Circuit Oil Pressure
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).

Diagnostics On/Off Switch
The Diagnostics On/Off operates the diagnostics feature for
the engine. The diagnostic switch enables the fault codes to
flash through the warning lamp. The fault codes can only be
read with the key switch ON and the engine OFF. For further
details, refer to the operation manual.
Idle Increment / Decrement Switch

This switch is used for changeover between error codes in
troubleshooting. To check the next error code, move the switch
to the "Increment“ ( ) position. To check the previous error
code, move the switch to the "Decrement“ ( ) position. After
error code check is completed, set diagnostic monitor switch to
OFF ( ) to exit the troubleshooting system. Finally, set the
engine start switch to OFF ( )
Engine Diagnostics Monitor
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.

OK monitor
When the engine starting switch is in the "ON“ position, all of

the monitor lamps are lit. After the engine starts, check the
monitor lamps.
If there is a "red" lamp lit and the buzzer sounds or the

red lamp is lit before or during operation, stop the engine
immediately and repair or remedy the issue.
2. Engine oil pressure

3. Battery charge
4. Radiator coolant level
6. Coolant temperature
7. Hydraulic oil temperature
9. Fuel level
10. Engine coolant temperature

Control Circuit Oil Pressure Gauge Control Circuit Oil Pressure Switch
The gauge needle should remain within the blue zone
(850 - 1280psi) during normal operating conditions. The alarm PS-80 is responsible for the low pressure alarm at 50k or
buzzer sounds when the pressure drops below 710psi. 710psi.
Blue : 850 to 1280psi

Red : 0 to 850psi / 1280 to 2130psi

Right Side Lever Stand
Engine Hour Meter
Engine Tachometer

Right Side Lever Stand
There are three indicator lamps on this console:
A : This lamp is lit when the swing brake is applied.
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.
C : Engine Start Interlock Pilot Lamp. When either the main

and or auxiliary drum winch mode selector switches are not
in the "Automatic", mode during the starting sequence, the
engine will not start and the lamp illuminates.

Right Side Controls Right Side Controls
Travel Levers Main hoist winch mode selector key switch.
Auxiliary hoist winch mode selector key switch.
Swing lock rocker switch.

hc crawler cranes
HC275 Counterweight System

HC165 / HC230 / HC275 Unload the counterweights from the truck and stack
The counterweight systems on these machines are basically them evenly on the base weight and pin the weights in
identical with the exception of the HC165 which uses the boom place.
inner to pick up and load the counterweights.
Remove the transportation frame from the base weight.
Terex® Hydraulic Crawler Training: HC275 Counterweight System 2

Move the machine to the required setup distance per the
operator’s manual and connect the lifting chains to the
links on the base counterweight.

Using the pendant control extend the CWRS cylinders
fully and when the inner holes are aligned with the
hydraulic cylinder pins, extend them fully and fasten the
ring pin in place. Then pin the rear fastening links to the
to the machine frame and insert the ring pins to keep
them in place.

Retract the counterweight lift cylinder fully and remove the
remote control unit from the machine and the machine is ready
for boom assembly.

CWRS Hydraulic Circuit
HC165/230/275
Extend / Retract
Dir. Control Valve
Dir. Control Valve

CWRS
PUMP
TANK PUMP

CWRS Electrical Circuit
Shelf State HC165/230/275
24VDC
F10
X90
Located in
Relay
Panel
PB86
TS93 TS94 TS95 TS96
Power
RL86
X90
SL207 SL208 SL209 SL210 SL211 SL211 SL202 SL201
a b
Retract A-Frame
Extend A-Frame
Retract Locks
Extend Locks
Extend Right
Right Upper
Right & Left
Right & Left

Retract Left
Extend Left
Retract
Upper
Upper
Upper

CWRS Lock Circuit In Shelf State
P1’ P5
Pressure
Control
TANK Valve

Extend CWT Locks
HC165/230/275
24VDC
F10
X90
Located in
Relay
Panel
PB86
TS93 TS94 TS95 TS96
Power
RL86
X90
a b
Retract A-Frame
Extend A-Frame
Retract Locks
Extend Locks
Extend Right
Right Upper
Right & Left
Right & Left

Retract Left
Extend Left
Retract
Upper
Upper
Upper

CWRS Lock Circuit - Extend
P1’ P5
Pressure
Control
TANK Valve

Retract CWT Locks
HC165/230/275
24VDC
F10
X90
Located in
Relay
Panel
PB86
TS93 TS94 TS95 TS96
Power
RL86
X90
a b
Retract A-Frame
Extend A-Frame
Retract Locks
Extend Locks
Extend Right
Right Upper
Right & Left
Right & Left

Retract Left
Extend Left
Retract
Upper
Upper
Upper

CWRS Lock Circuit - Retract
P1’ P5
Pressure
Control
TANK Valve

CWRS Hydraulic Cylinder Circuit – Shelf State
SL209 SL207
P4
SL210 SL208
PG2 P5
Pressure
TANK Control
Valve

Extend Cylinders
HC165/230/275
24VDC
F10
X90
Located in
Relay
Panel
PB86
TS93 TS94 TS95 TS96
Power
RL86
X90
a b
Retract A-Frame
Extend A-Frame
Retract Locks
Extend Locks
Extend Right
Right Upper
Right & Left
Right & Left

Retract Left
Extend Left
Retract
Upper
Upper
Upper

CWRS Hydraulic Cylinder Circuit – Extend
SL209 SL207
P4
SL210 SL208
PG2 P5
Pressure
TANK Control
Valve

Retract Cylinders
HC165/230/275
24VDC
F10
X90
Located in
Relay
Panel
PB86
TS93 TS94 TS95 TS96
Power
RL86
X90
a b
Retract A-Frame
Extend A-Frame
Retract Locks
Extend Locks
Extend Right
Right Upper
Right & Left
Right & Left

Retract Left
Extend Left
Retract
Upper
Upper
Upper

CWRS Hydraulic Cylinder Circuit – Retract
SL209 SL207
P4
SL210 SL208
PG2 P5
Pressure
TANK Control
Valve

hc crawler cranes
HC275 Travel System

Mounting Side Frames & Car Body Counterweights The steps involved in mounting the side frames to the
HC165 / HC230 / HC275 machine are:
These machines are normally transported with the side frames 1. Raise the A-Frame or gantry
dismounted due to weight, height and width constraints. 2. Remove the transport safety pendant (230/275) or
the boom stop limit spacer (165) and set the mast.
3. Jack up the machine using the transport system.
4. Remove the trailer.
5. Mount the side frames to the machine.
Per the appropriate steps in the operations manual for that

model, raise the gantry and set the mast.
Terex® Hydraulic Crawler Training: Travel System 2

Set all four jack cylinders to the operating position and insert Connect the power cord from the cab to the relay of the
the locking pin. Connect the hydraulic hoses to the quick car body and connect the and remote control to the
disconnect couplings. connection point located on the car body . Make sure
that the power supply and remote control are
disconnected prior to swinging

Remote
Control Box
Horn
Extend/Retract Extend/Retract
Right Crawler Left Crawler
Extend/Retract Power Extend/Retract

Jack 1&2 ON/OFF Jack 3&4

In addition to the remote control, the identical controls
are mounted on the machine base.
Left Crawler RR LR RF LF Right Crawler
Pulling the control lever extends the crawlers or jacks and

pushing in the control lever retracts the crawlers or jacks.
A spirit level located below the controls to provide visual

feedback concerning machine level.

The engine should be set at 1000 rpm’s and all four jack Once the trailer has been removed, lower the machine to
controls operated simultaneously to raise the crane smoothly a height of approximately 4’ from the bottom of the
from the truck bed. Place cribbing under the jack pads to machine’s frame to the ground to allow adequate
support the weight of the machine. Make sure the crane clearance for crawler mounting.
adequately clears the tires before moving the trailer.
HC275
Clearance
between
crane body
and trailer

Remove the pin from the retention bracket and swing the Clean and grease the mounting axle, the inside of the
hydraulic cylinder out 90°to receive the crawler. crawler frame and retaining pins.

Slide on the crawler side frame approximately 6 ¼”, extend
and pin the hydraulic extension cylinder to the crawler side
frame bracket. Using the hydraulic cylinder, pull the crawler
side in until it hits the stop plate on the axle. Insert the axle
retaining pin and keeper pin.

Repeat the steps to install the crawler side frame on the Connect the hydraulic drive lines to each crawler side
opposite side. Be aware that the machine is unbalanced and frame.
block the underside of the first crawler to stabilize the machine
if necessary. Once both crawler side frames are mounted,
unpin and store the hydraulic side frame cylinders in their
original positions. Lower the crane fully to the ground and
insert the original shims between the axle the crawler side
frame and bolt them into place.
Note: Shims thicknesses are either 1/8”, 11/64” or 15/64”
Shim

Remove the jack pedestals, unpin the jacks from the working Mounting the Car Body Counterweights
position and pin them in the storage position. The pedestals Remove the car body counterweights from the trailer and
will be stored on the sides of the car body counterweights once pin them in place on the front and rear of the machine.
they are installed. The machine is now ready to load the main
counterweights.
Car Body
Frame

Travel Hydraulic Circuit
Travel
Control
Valve
Pilot
Pressure
Pilot
Pressure
Travel Travel
Motor Brake
PUMP
PUMP
PUMP
TANK

Travel Hydraulic Circuit In Shelf State
Travel
Lock
SL52
Operation
Lock
SL51
Travel Speed
Changeover
SL53
TANK P2
VDP
P2’
P5
Pressure
Control Gear
Valve Driven
Pump

Travel Hydraulic Circuit In Shelf State
TANK

Travel Circuit Forward Low Speed
Travel
Lock
SL52
Operation
Lock
SL51
Travel Speed
Changeover
SL53
TANK P2
VDP
P2’
P5
Pressure
Control
Valve

Travel Circuit Forward Low Speed
TANK

Travel Circuit Forward High Speed
Travel
Lock
SL52
Operation
Lock
SL51
Travel Speed
Changeover
SL53
TANK P2
VDP
P2’
P5
Pressure
Control
Valve

Travel Circuit Forward High Speed
TANK

Travel Circuit Backward Low Speed
Travel
Lock
SL52
Operation
Lock
SL51
Travel Speed
Changeover
SL53
TANK P2
VDP
P2’
P5
Pressure
Control
Valve

Travel Circuit Backward Low Speed
TANK

Travel Lock Circuit
Shelf State (Schematic)
24VDC
Travel
Lock TS-52
Switch
Lock Release
X1-1
F33
Travel Lock
SL52
Solenoid
The travel lock is spring operated so it must be hydraulically released. The solenoid re-
directs hydraulic pressure to release the brake.
Travel Lock Released
24VDC
Travel
Lock TS-52
Switch
Lock Release
X1-1
F33
Travel Lock
SL52
Solenoid

Travel Speed Circuit
24VDC
TS-63
Low High
Speed Speed
Travel
SL53
Speed
Solenoid
The travel speed solenoid re-directs hydraulic pressure to open the travel motor high
speed solenoid. This solenoid increases flow and pressure to the drive motors.
Travel Speed Circuit
High Speed Engaged
24VDC
TS-63
Low High
Speed Speed
Travel
SL53
Speed
Solenoid

Travel Alarm Circuit
24VDC
Alarm
Travel
TS-41
PS43
PS44
OFF ON
F43
X86
X86
BZ44 BZ43
The travel alarm may be disabled by placing it in the OFF position.

Travel Alarm Circuit
In Travel State
24VDC
Alarm
Travel
TS-41
PS43
PS44
OFF ON
F43
X86
X86
BZ44 BZ43
The travel pressure switches close when the travel motors are engaged. When the
travel alarm switch is in the ON position, the alarm will sound.
Torque Table

Lubrication Points

Lubrication Oil Table

Maintenance Lubrication Points
The mounting bolts on the following items must be re-torqued
after the first 50 hours of operation on a new machine and A – Idler Shaft Slide (left & Right)
every 250 hours afterwards: Every 250 hours or once per month.
• Travel reduction gear
• Drive tumbler B – Shoe Pins
• Crawler frame Every 50 hours or once per week.
• Travel motor
B
A

Lubrication

Travel Reduction Gear Ensure the machine is on level ground, the travel lock is
set and the oil is cool. Slowly open the oil filler and drain
plugs, remove and discard the old oil and refill to the
bottom of the filler plug as shown. Replace and tighten
filler plug.

Front Idler
Position the idler so that the fill & drain plugs are vertical.
Remove the two plugs and drain the old oil. Position the
plugs so that they are horizontal and fill until oil runs out
of both plug holes. Replace plugs and tighten securely.
Fill & Drain Ports

Floating Seal
Bushing

Lower Roller Upper Roller
Remove the roller from the crawler frame and inject the Remove the filler plug and inject the required amount of
required amount of oil in the filler port, replace the plug oil in the filler port or until it overflows. Replace the plug.
and re-install on the crawler frame.
Floating Seal
Bushing
Floating Seal Oil Filler Plug
Bushing
Oil Filler Plug
Floating Seal

Crawler Belt Adjustment (HC165-275)
1. Move the crane onto level ground and bring the sagging section
of the belt to the top.
2. Remove cover (1) to expose hydraulic cylinder.
3. Loosen the two retaining bolts of the bearing box (2).
4. Remove the ring pin from the rod (3).
5. Remove the outer guide plate from the cylinder rod (4).
6. Connect the porta-power to the cylinder and extend the ram so
that the bearing box is moved forward until the shoe makes
slight contact with the guide plate (5).
1 3
4

Crawler Belt Adjustment (HC165-275) cont’d
7. Combine shims to fill gap between the bearing box and frame
(6).
8. Reduce pressure on the porta-power and fully withdraw the
hydraulic cylinder as shown (7). If the cylinder is not fully
retracted then pressure from the front idler can damage it. Store
the remaining shims on the back of the rod end. Re-install
guide plate and ring pin removed previously.
9. Tighten the bearing box mounting bolts and adjust the crawler
7 belt on the opposite side.
6 10. After adjusting both belts, move the machine and check that the
8
belt sag is equal on both sides. The match marks (8) will
indicate whether the crawler belts are of equal alignment.
NOTE: Increase belt sag in on soft dirt or sand to prevent trapping
the material in the crawler drive system.

hc crawler cranes
M/L-D5A Moment Limiter

The M/L-D5A moment limiter is a multi-functional operator aid . Exposing the display for long periods of time to direct
The operator must fully understand the operating instructions sunlight can lead to elevated component temperatures
concerning the moment limiter to ensure safe crane operation and darkening of the screen. The sun shade helps
protect the screen during the working day. At the end of
the work day place the insulated cover over the unit to
protect it from temperature extremes.
Typical Machine Sensor Configuration
Terex® Hydraulic Crawler Training: M/L-D5A Moment Limiter 2

The moment limiter display inputs consist of the boom angle
sensor, load sensor, slewing angle sensor and the alarm unit.
The selector key must remain in the “OPERATION” position

( as shown)at all times during machine operation.
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.

Display Screen Information
% of Maximum Capacity Maximum Capacity in kips
Actual Load in kips
Boom Angle
Swing Angle Load Radius

Panel Control Functions
Alternates between the operational screen

and the load chart screen.
Displays error details and on setup screens

allows you to view more information on crane
configuration. Symbols also will appear when
an error occurs during operation.
For execution, decision and main menu

selection depending on the screen.
Cancel , previous screen function
For screen contrast, content selection,

display change

Press the key to perform the operational aid
Operating Status / LMI Setup
check and the screen will turn yellow. Push the
When the engine key is turned on the moment limiter is key to perform the check.
powered up and will revert to the Operating Status
Screen. This screen displays the present user defined
values and is also called the Checkup mode screen.
Operation may begin once an operator aid check has
been performed.

Setting the Crane Configuration (01) Configuration of an Operational Machine
Setting the crane configuration synchronizes the moment The WORK NO. refers to the configuration of the crane
limiter with the crane. Select function (01) and press the in conjunction with the capacities and load charts
key once more. For setup and calibration purposes associated with those configurations.
ensure that the Main Hook is reeved for 1 part of line.

CRAWLER – May be RET, MID or EXT depending on the Configuration of an Operational Machine
Model (Retracted, Mid or Fully Extended).
BOOM LENGTH – A variable length to be selected by the
operator.
MAIN HK CAPA – Main Hook Capacity, the operator chooses
the hook capacity that he is using for the main hoist.
MAIN HK P-LINE – The operator chooses the number of parts
of line to be used on the main hoist hook block.
MAIN HK DRUM – The operator selects whether the main
hoist is located in the front or rear of the crane.
JIB LENGTH – The operator selects the jib length if
applicable.
OFFSET ANGLE - The operator selects the jib offset angle if
applicable.
AUX. HK CAPA – The operator selects the hook capacity for
the auxiliary hoist.
AUX. HK P-LINE – The operator chooses the number of parts
of line to be used on the auxiliary hoist hook block.
AUX. HK DRUM - The operator selects whether the auxiliary
hoist is located in the front or rear of the crane.
SPECIAL 2-HOOKS – The operator can choose whether he
will use this special feature or not.

NOTE On ATT etc SET mode screen next to Main and Aux,
On ATT etc SET mode screen next to Main and Aux, Hook Parts of Line. Models HC60/80/165/230/275
Hook Capacity. A = 6x19 Class Wire Rope (Standard Rope)
M – Terex supplied hooks and balls B – Rotation Resistant Wire Rope
U – User supplied hooks and balls For the HC110
A = Must be selected for Front Drum because of the 1”
See (10) HOOK DATA on Main Menu. rope.
B – Must be selected for Rear Drum because of the 7/8”
rope.

For HC100 ONLY
Front Drum with 1” rope
A = 6x19 Class Wire Rope (Standard Rope)
B – Rotation Resistant Wire Rope
Rear Drum with 7/8” rope
A = 6x19 Class Wire Rope (Standard Rope)
B – Rotation Resistant Wire Rope

HC165 Work Number Chart
The crane is configured to make a lift or series of lifts that In the example below there are five work numbers for the
require a certain capacity at a given radius. The configuration HC165. Work #11 is for a standard crane (CR) and can
has a unique load chart that gives the boom, jib, crawler width, be used with 50-240 feet of 77SI Hammerhead boom. It
hoist and required amount of counterweight. That load chart can use different jibs and lengths and requires 102,000
has series of load charts based upon the various pounds of counterweight. The load chart is HC165.01
configurations possible depending on the combination of and that number refers back to the original load chart
components selected. which was used to determine the configuration of the
crane

Configuration of an Operational Machine (cont’d) The display will then change to the MENU of
Once all parameters have been set press the key to FUNCTION screen. Press the key to return to the
confirm the selections. The guide screen below will appear Operational screen.
and the “Work Limits” have returned to their default values and
must be reset. Press the key at any time to suspend or cancel the
settings. The display for each item will return to the
original set value and the moment limiter will
automatically return to the Operation screen.

If work limits were set previously, they have returned to their Checking the Operator Aids (02)
default settings and must be reset to the desired values. In the This function is to ensure that all operator aids are
Operational screen press the key to return to the Main working correctly concerning the auto stop and alarm
Menu screen functions. While performing these checks operate the
crane slowly by reducing engine RPM’S.
Select the Check Mode as shown below .

Press the key which will open the Output Check LMI Press the key once more to initiate the Check
screen. Mode LMI self-check procedure.

After a few seconds an intermittent beeping alarm will sound. After a more seconds a steady beeping alarm will sound.
The bar graph will indicate a 90% load capacity. The bar graph will indicate a 100% load capacity.
Confirm that the Hoist Up and the Boom Lowering
functions are disabled and press the key twice to
return to the Main Menu screen.

Setting Work Limits (03) In normal operations only one set of parameters needs
These functions can be utilized if desired by the operator in to be set (either boom angle or radius). If both
limiting the upper and lower boom limit angles. This function parameters are used then the auto stop feature will
has an integrated slow down feature and boom angle limit initiate on which ever limit is reached first.
alarm.
Select Menu item 3 and press the key.

The Work Limit Set screen is now displayed. Use the cursor Left – Right keys to change the status
from DEAD to LIVE

Press the key and the display screen will change to
the Hi Limit Boom Angle screen.
Reflects present boom angle and

will change as boom is raised.
Reflects maximum allowable boom

angle and cannot be changed.
Place cursor here and with the

Left – Right keys set the boom
angle to the desired value.
Represents the New Set Value.

If the boom high limit angle has not been determined, raise the Press the key to accept the new value. The SET
boom until the desired high boom limit angle is met. That Value will now read the desired boom angle.
value will be reflected in the NOW column. Press the key
and then press the key to reopen the screen. The
desired boom angle limit is now reflected in the BEFORE
column.

Press the key once more and the new value will now be Setting the Slowdown Angle
displayed on the Work Limit User’s Set. Repeat the process to The minimum slowdown angle is 2°and can be adjusted
set the Lo Boom Angle Limit. to a greater value if desired. Setting up the Lo Limit
Angle is exactly the same as setting the upper and lower
boom angle limits. Move the cursor to the Slow DN
Angle and press the key.

Using the INC/DEC keys change the value as desired in the The screen now indicates the desired slowdown angle
NEW Value block and press the key twice to set the for the Hi Boom Angle Limit. Repeat the process for
value. setting the slowdown angle for the Lower Boom Angle
Limit.

Once the work limits are all set, move the cursor down to the The work limits are now set and the display will return to
END of Whole SET by O and press the key. The new the Main Menu screen
values will not be set unless the previous step was performed.

The MAX RADIUS LIMIT and MAX HEIGHT LIMITS are set
the exact same way as the BOOM ANGLE LIMITS.
Depending on what limit you want to use you make that limit
LIVE and the limits DEAD.

Calibration Procedure Press the button twice and the button once
Ensure that the M/L selector is in the OPERATE position to pass through the Checkup screen to the Main Menu.
and the engine is off. Choose the Work Code Number Select (12) Dip-SW SET mode.
for the load chart and determine the boom configuration
prior to beginning calibration.
Press and hold the three top buttons and start the engine. The
buttons may be released when the rolling block icon appears
on the screen.

Press the key to select Dip-SW1 Verify the Dip switch 1 & 2 settings and confirm by
selecting (13) And pressing the key.

Press the key to select Dip-SW2 Verify Dip SW2 settings as shown. It is currently set up
for ft-lbs. To set the machine up for metric operation
select Confirm settings by selecting (08)
and pressing the key.

Press the key to return to the Main Menu. If the MLD5A display was previously in Japanese or any
parameters were changed on Dip-SW1 or 2, a message
will appear. It will direct you to turn off the engine wait
5-10 seconds and restart the engine. The display will
now be in English and all new parameters saved.

Select (08) Property Record the program version, P1, P2 and IDD number.
Press the key to return to the Main Menu.

Select (01) ATT SET and choose the desired Work Number Calibration Procedure Boom Angle and Load Cell
code and input the boom and machine configuration that will Select (07) Adjustment – 2 mode and press the key.
be used.

Select (03) ZERO OF BOOM ANGLE and press the key. This screen indicates the actual BOOM ANGLE at
39.8°

In order to calibrate the boom zero angle, the completed boom
must be lowered to 0.0°. The angle can be confirmed either
by attaching a plumb line from the center of first boom center
upper pinning point and centered through the lower pinning
point or by placing an electronic level on the upper chord face
of the first boom center section. It is important to have the
crane as level as possible especially using the latter method.

Once the 0°boom angle has been confirmed, if the BOOM Select (04) SPAN OF BOOM ANGLE and press the
ANGLE does not read 0°, change the NEW Value setting to key. Increase the boom angle to 70°and confirm
0°by pressing the scroll buttons . Once this has been the radius is correct per the load chart.
accomplished press the key. The value will now be
reflected in the BOOM ANGLE block. Record the COUNT
value and press the key a second time to store the value
in the computer.

If the BOOM ANGLE is not 70°when the radius is confirmed, The value will now be reflected in the BOOM ANGLE
change the NEW Value setting to 70°by pressing the scroll block. Record the COUNT value and press the key
buttons and press the key. a second time to store the value in the computer.

CALIBRATION OF LOAD CELLS (On main screen choose With the ball suspended just below the boom and the
MAIN for Main Boom or AUX for JIB before proceeding). Both boom at 70°enter the weight of the ball in the SETTING
have to be calibrated but the MAIN must be done first. VALUE block. If the ball weighs 650 lbs enter the value
of .7 kips. Press the key once and record the
If a jib is in place make sure that the ball is lowered fully COUNT Value. Press the key again to store the
to the ground prior to calibrating the Main Boom. value in the computer. The value will be reflected in the
MAIN W block.
Calibration must be done with a single part of line in order to
reduce the amount of weight required to span the load cells.
Return to the MAIN MENU (01) ATT Menu and configure the
MAIN Hoist for a single part of line before continuing. Return
to the calibration screen and select (01) ZERO OF LOAD
CELL and press the key.

Scroll to (02) ZERO OF LOAD CELL and press the key. Lift the weight and correct the boom angle back to
at this time a known weight must be lifted that will equal 70°to correct for boom deflection. Enter the weight of
75% - 85% of maximum capacity for a single part of line. the ball and the rigging 700 lbs. If the known weight is
18,700, then the total weight would be 19,400 lbs. Enter
19.4 kips. Press the key once and record the
COUNT Value. Press the key again to store the
value in the computer. The value will be reflected in the
MAIN W block.

You’ve now returned to the previous menu. Press the key Select (04) MONITOR Mode and press the key.
to go back to the Main Menu.

Select (01) SENSOR MONITOR and press the key. Verify that the calibration data. Press the key twice
to return to the Main Menu.

Select (11) SLEW Limit Mode and press the key. Select (01) ZERO Adjust of Slew Angle and press the
key.

Slew the crane forward to the 0°angle, set the slewing lock Select (13) PC MODE and press the key.
and press the key twice to set the angle at 0 degrees.
Press the key once to return to the Main Menu.

Select (03) History Set mode and press the key. Using the L/R keys adjust the REC-Interval to 1.0
seconds and the LOAD Ratio to 98%. Select the End of
SET and Press the key to save the settings.

Select (04) Time Set mode and press the key. Adjust the SET time and date to today’s date and time,
then select End of SET and press the key.

Select (05) History Data CLEAR mode and press the Select YES and press the key. It will take10-15
key. seconds for the data to be cleared from memory.

Select (06) Best3 Data CLEAR mode and press the key. Select YES and press the key. It may take a few
seconds for the data to be cleared from memory.

Make sure the M/L selector switch is in the OPERATE position Select (07) Over Load Monitor mode and press the
and then switch OFF the engine. Wait 5-10 seconds and key.
restart the engine. Return to the Main Menu and select
(04) Monitor mode and press the key.

Verify all counters are zero. Press the key twice to return
to the Main Menu. Make sure the M/L selector switch is in the
OPERATE position before switching OFF the engine.
Calibration of the MLD5A is complete.

Maintenance Items Unplug the Analog and Digital interface plugs and 24V
The M/L-D5A has a battery backup which will require power supply cables. Remove the four face plate screws
replacement after a number of years. An error message E129 and remove the unit from the housing. Remove the rear
Battery Fall Off with an alarm indicates the need to change cover and place it on the bench. Unplug the multiple
the battery. connectors to the printed circuit board.

Make a mark on the printed circuit board to orient it correctly Start the engine and the alarm should be silenced. If not
on the mounting plate (match mark). Remove the four screws the battery will take an hour or two to fully recharge and
holding the printed circuit board and cut the tie wrap holding the alarm condition will go away.
the battery in place. Unplug the old battery and replace with
the new one orienting the plug as before and tie wrap it in
place. Remount printed circuit board in reference to match
mark and install plugs. Reinstall back plate onto unit and plug
back in the interface and power plugs.

Basic Hydraulic Control Circuit M/L-D5A

Basic Electrical Control Circuit M/L-D5A
?
? Fuse F7
Erection
Operation
Transport
MLD5A
24VDC

hc crawler cranes
HC275 Swing System

The swing system is made up of the gear driven hydraulic
pump that supplies flow and pressure to the swing motors .
The upper and lower halves of the crane are joined
together by the swing bearing.
Hydraulic Gear
Driven Pump
Swing
Bearing
Swing
Motors
HC230
Terex® Hydraulic Crawler Training: Swing System 2

The axial piston swing motors are housed in the front of the The swing lock or “house” lock may be engaged at
crane where they engage the swing bearing by pinions. 0,90,180 and 270°intervals via the swing lock control
switch in the operator’s cab.

The swing lever is moved forward or rearward to swing the There are two swing brake indicator lights, one located
crane left or right. The crane will continue to swing until the on the left front console below the swing lever and the
loss of inertia brings it to a stop or the operator counter-swings other located on the right front console above the
in the opposite direction. The swing brake switch is located on tachometer.
the upper side of the swing lever handle. The brake is a wet
type, multi-disc which is hydraulically released and spring
loaded.
Swing Lever
Swing Brake
Switch
Swing Brake Indicator

The swing lock control switch is located on the right side The swing lock switch energizes an electric motor which
control console where the travel control levers are located. extends and retracts a steel pin to engages the swing
There is no indicator light for this function when it is engaged. lock fixture or boss. The swing lock can be manually
locked in place by turning in the retention bolt.

Swing Hydraulic Circuit
Swing
Control
Valve
Pilot
Pressure
Pilot
Pressure
Swing Swing
Motor Brake
PUMP
PUMP
PUMP
TANK

Shelf State
B A
P2
Pressure
Control
Valve
P2
Control Valve
Manifold
Operation
Lock
P2’
P5
A B Pressure
Control Gear
Valve Driven
Pump
TANK
TANK
P3

Swing Left
B A
P2
Pressure
Control
Valve
P2
Control Valve
Manifold
Operation
Lock
P2’
P5
A B Pressure
Control Gear
Valve Driven
Pump
TANK
TANK
P3

Swing Right
B A
P2
Pressure
Control
Valve
P2
Control Valve
Manifold
Operation
Lock
P2’
P5
A B Pressure
Control Gear
Valve Driven
Pump
TANK
TANK
P3

Swing Brake Circuit
24VDC
RX36 RX36 X1-3
TS-63
Brake
Swing
X1-3
Safety
Lock
Release
Circuit Relay
F56 S F57
Swing Swing Swing

Ratchet
RX36 SL63 Brake RL63-1 Brake RL63-2 Brake
Solenoid
Solenoid Light Light
The swing brake is spring operated so it must be hydraulically released. The solenoid re-
directs hydraulic pressure to release the brake.
Swing Brake Disengaged
24VDC
RX36 RX36 X1-3
TS-63
Brake
Swing
X1-3
Safety
Lock
Release
Circuit Relay
F56 F57
Swing Swing Swing

Ratchet
Solenoid

Swing Brake Engaged
24VDC
RX36 RX36 X1-3
TS-63
Brake
Swing
X1-3
Safety
Lock
Release
Circuit Relay
F56 F57
Swing Swing Swing

Ratchet
Solenoid

Swing Lock Circuit
Lock Extended
24VDC
TS-57
Unlock
Lock
S F31
RE
Locking
PC57
Motor
EX
The swing lock motor polarity is reversed to extend and retract the locking pin.

Swing Lock Circuit
Lock Retracted
24VDC
TS-57
Unlock
Lock
S F31
RE
Locking
PC57
Motor
EX

Swing Lock Motor Assembly
Motor
Cylinder
Limit
Switches

Swing Flicker Circuit
24VDC
Swing
PS41
PS42
Pressure
Switches
Flicker Timer
Circuit
L1 L2 BZ
X2
L41 L42 BZ41 BZ42
Swing Travel Swing

Flashers Buzzer Buzzer
Circuit
The swing pressure switches close when the swing motors are engaged activating the
swing flashers and swing buzzer.
Swing Flicker Circuit Current Configuration
TS-42 no longer provided. Terminal 166 & 169 are jumpered together and the swing
buzzer is always operational.
Swing Lights and Buzzer

Torque Table

Lubrication Oil Table (HC230)

Maintenance When greasing the swing bearing, use the four grease
The swing bearing mounting bolts must be re-torqued after the fittings at the front of the machine. If using a pneumatic
first 50 hours of operation on a new machine and every 250 grease gun ensure that the pressure is reduced so that
hours afterwards. the bearing seals are not damaged. Pump grease in
until it comes out of the seal.
Grease type EP-2 Lithium.

Lubrication of the swing pinion and ring gear is by grease
bath. Remove cover from discharge port at the bottom
of the car body to remove the old grease
Grease type EP-2 Lithium.
4” Grease
Fill Ports
Discharge
Port

The swing reduction gear must be re-torqued after the
first 50 hours of operation on a new machine and every
250 hours afterwards.
Grease type API GL-5 SAE-90

Swing Lock Adjustment HC275 Check stroke of swing lock pin to ensure full engagement
of the swing lock boss on the car body. Stroke should be
2 50/64” or 70.5mm. When swing lock pin is fully
retracted the clearance between the bottom of the pin
and the car body boss weldment should be 26/64” or
Adjustment Nut
10.6mm. Use the adjustment nut to lengthen or shorten
the stroke length of the pin for proper engagement.

hc crawler cranes
Hoist Systems
Hoist Winches & Locations HC275
Aux.
Hoist
Main
Hoist
Boom
Hoist
Terex® Hydraulic Crawler Level 1: Hoist Systems 2

Hoist Winch Controls
PTO / 3rd Aux.

Drum Winch
Main Boom
Winch Hoist
Winch Mode
Selection
Indicator

Slow Down Switch
Press the slow down switch on the head of the boom hoist
lever, and the slow down mode is enabled. During the slow
down operation, the green slow down indicator lamp is lit
above the engine tachometer. Press the switch again, and the
slow down operation is released and the lamp is turned off.
When the slow down operation is selected, the down of
main/auxiliary hoisting, and travelling is also set in the “Slow
Down“ mode,
Slow Down Lamp
Slow Down Switch

Operating Modes Automatic Mode
The Main, Auxiliary and Third Drum hoists have two operating In the automatic mode the brake pedal for the hoist being
modes Automatic & Foot or Freefall Mode: used is always UP or disengaged. The Hoist Mode
Selection Switch is in the Automatic position and the
Automatic – The brake releases and applies automatically Winch Mode Indicator Lamp for the hoist is OFF
without operator interaction.
When the hoist lever is moved, the clutch engages the
Foot or Freefall Mode – The operator controls the release of drum and then the brake releases automatically taking
The brake and therefore controls the load. control of the load .
.
This should only Be performed by experienced operators
who are very familiar with this type of hoist operation!
Terex® Hydraulic Crawler Training: Hoist Systems 5

Foot or Freefall Mode
In the foot or freefall mode the brake pedal for the hoist being
used is always depressed or locked in the DOWN position.
The Hoist Mode Selection Key Switch is in the FOOT position.
The Hoist Mode Selection Pushbutton on the hoist lever is
depressed and the Winch Mode Indicator Lamp for the hoist
will come ON.
ALL THREE ACTIONS ARE REQUIRED FOR FREEFALL!
When the hoist lever is moved, the clutch engages the

drum and then the brake must be manually released by the
operator to control the load. The actuation of the hoist lever
and the release of the brake must be timed correctly to
prevent dropping the load or trying to lift the load against the
brake. We will look at this circuit in great detail electrically and
hydraulically later on in this presentation.

HC-275 Hydraulic Brake
The light red area represents the friction

braking portion of the brakes. The yellow
represents the foot brake assist. The
parking brake in blue which engages in
emergencies as well as in the automatic
mode. It also indicates the direction of
engagement of the brakes when the peddle
is pressed. The green area represents the
clutch.
The brake is released in automatic when

the lever is moved and is engaged when
the joystick is moved back to neutral. The
foot brake is left in up position
(disengaged).
In free fall the brake is released by the

operator when the hoist lever is moved.

Brake Assist Device Assembly
This brake mechanism consists of two systems: Foot mode,
dependent on pedal operation, and one for Automatic mode, in
which the brake is controlled with the automatic brake cylinder.
Foot Mode: Although this mode is basically the same as a

mechanical brake, in which the brake band is controlled by the
pedal force, a hydraulic assist mechanism is designed to boost
the pedal force.
Automatic mode: Returning the winch control lever to neutral,

the automatic brake cylinder activates to engage the brake
band, thereby applying the brake. The automatic brake
cylinder functions as an emergency brake to keep the brake
engaged in an emergency such as a drop in control hydraulic
pressure. The brake is spring applied and hydraulically
released.

The Clutch
The clutch is a mechanical device which provides for the
transmission of power (and therefore usually motion) from one
component (the driving member) to another (the driven
member). The opposite component of the clutch is the brake
The clutch is released in FREEFALL. At all other times the
clutch is engaged.
1. In the case of this clutch, the band is always

expanded by the tension of the clutch spring (clutch
is engaged), The clutch cylinder serves to disengage
the clutch. When placing the winch lever to neutral
with the winch set in foot mode, oil is supplied to the
clutch cylinder and the clutch is disengaged. As a
result, the drum and spider are disengaged to allow
free fall of the load.
2. To rotate the clutch spider independently for

adjustment, depress the brake pedal, then set the
winch mode selector switch to the foot mode. Next,
turn the clutch maintenance switch to the
“MAINTENANCE" position. The clutch spider can
now be rotated to the desired position by the winch
lever.

Operation Lock Circuit
The operation lock circuit is responsible for supplying hydraulic

pilot pressure to the control levers. Unless the seat switch
TS-51 energizes the hydraulic solenoid valve SL-51, all control
functions are rendered non-functional.

Winch Speed Adjustment HC275
The HC275 has the ability to adjust speed variably on the

Main, Aux. and Boom hoist winches. The dials provide a
voltage input to the solenoid driver which provides an output to
the proportional valves to stroke / de-stroke the respective
winch motors.
Aux Hoist drum Main Hoist drum
Boom Hoist drum

Drum Locking System HC275 Drum Locking System HC275
The Main, Aux, and Boom drums all have a locking systems
that hold the load or boom in place when engaged.

Drum Locking System HC275
When the drum locking solenoids are energized, it allows

hydraulic pressure to compress the springs and release the
drum dogs. The dogs are spring applied / hydraulic pressure
release which ensures that they engage upon a loss of power
(as mandated by B30.5).

Hoisting Hydraulics
BOOM AUX MAIN

HOIST HOIST HOIST

HC275 Control Block Valve Piping
The numbers shown on the piping match the component

piping found on the hydraulic schematics.

Control Block Valves HC275
P2
P1
Tank

Safety Circuit
The hydraulic pressure switch for the respective function

sends an Input to the MLD-5A which in turn sends 24VDC to
the coil for that function allowing the hoist to operate as
desired.

Safety Circuit HC275

Safety Circuit HC275
027

Unload Circuit

Unload Circuit

Unload Circuit
The solenoids (when de-energized) isolate the pilot pressure to

the directional control valves.

Unload Circuit (Main Hoist)
The solenoid SL-106 when energized, provides pilot pressure

to the directional control valves for both 1st and 2nd speed.

Main Hoist Automatic Mode (Shelf State)
004 – Start Terminal

09 – Safety Relay
F9
021

Main Hoist Automatic (Hoist in Neutral)

09 – Safety Relay
F9
021

Main Hoist Automatic (Hoist in Neutral)
028

Main Hoist Automatic (Hoist Activated)

09 – Safety Relay
F9
021

Main Hoist Automatic (Hoist Activated)
028

Main Hoist / In Freefall (Start Circuit)

09 – Safety Relay
F9
022

Main Hoist / In Freefall (Start Circuit)
028
Seal In
Contact

Main Hoist / In Freefall (Hoisting)

09 – Safety Relay
F9
022

Main Hoist / In Freefall (Hoisting)
028
Seal In
Contact

Main Hoist / In Freefall (Brake Set / Hoist in Neutral)

09 – Safety Relay
F9
022

Main Hoist / In Freefall (Brake Set / Hoist in Neutral)
028
Seal In
Contact

Main Hoist HC275 / Shelf State
80K
P5

Main Hoist In Freefall Mode HC275 / Lever in Neutral
80K
P5

Main Hoist In Freefall Mode HC275 / Lever in Neutral
Brake Released
80K
P5

Main Hoist HC275 / Hoisting 1st Speed
Pilot pressure for directional control valve for 1st speed ranges
from 3 - 14k. Notice that the pressure range supplied from the
control lever is 4.9 – 26.5k.
P2
Tank
P1

Main Hoist HC275 / Hoisting 1st Speed
80K
P5

Main Hoist HC275 / Hoisting 2nd Speed
Pilot pressure for directional control valve from 16.3 - 24.1k. At

16.3k the directional control valve for 2nd speed begins to open
allowing oil from P2 to flow to the main hoist increasing speed.
P2
Tank
P1

Booming Up
80k

Booming Down
80k

Maintenance
Band clearance adjusting
roller (7 places in the
whole circumference)
Bolt inserting portion

for disengaging clutch
manually: (Loosen the clutch by
using the M20 x 4,7“ bolt.)
Clutch cylinder
(for disengaging
clutch)
Caution
Before adjusting or repairing the brake or clutch, the hook
block and any suspended load must be lowered to the
ground. Lower the boom, if necessary, for safety.

Notice
Clutch slippage affects the operation of the crane. Check
the following points to prevent the clutch from slipping,
Replace, repair, or clean the lining if necessary.
1. Is the thickness of the clutch lining over the minimum

allowable limit?
2. Is the spring tension of the clutch lining adjusted
properly?
3. Is water or oil contaminating the clutch lining?
4. Does oil leak from the clutch cylinder? Is the piston of
the clutch cylinder in contact with the cylinder bottom?
1. In the case of this clutch, the band is always expanded by

the tension of the clutch spring (clutch is engaged). The
clutch cylinder serves to disengage the clutch. When setting
the winch lever to "NEUTRAL" with the winch set in "FOOT"
mode, oil is supplied to the clutch cylinder and the clutch is
disengaged. As a result, the wire drum and spider are
disconnected to allow free fall of the load.
2. To rotate the clutch spider independently for adjustment,
etc., depress the brake pedal, and then set the winch mode
selector switch to the "FOOT" mode, Next, tum the clutch
maintenance switch to the “MAINTENANCE“ position. The
clutch spider can now be rotated to the desired position by
the winch lever.

Initial Adjustment (4) Turn the nut "b" to ensure spring length 11 ".
(1) Assemble the clutch as illustrated above. Contact the band (5) Turn the band clearance adjusting bolt "d" and adjust the
lightly with the housing. band clearance of 7 places to "0.012"-. The clearance
(2) Set the bolt (M20 x 4.72") into the clutch manual between the lining and housing is 0.012" when the clutch is
disengaging unit to turn the clutch OFF. Screw in the bolt OFF.
until the swivel pin contacts lightly with the clutch spider. (6) Remove the clutch manual disengaging boll.
(3) Ensure the cylinder mounting dimension, 6.93". (7) Adjust the band with the band adjusting bolt so that there is

(7) Adjust the band with the band adjusting bolt so that
there is a 0.2" at the left end of the swivel pin and check
hole.
(8) After adjustment, lock the band adjusting nut and
clearance adjusting nut.
CAUTION
When the clutch is worn, the spring becomes loose and
the dimension "C" increases. If this dimension 0.315“or
greater, adjust the band with the band adjusting nut to
decrease the dimension to 0.2“.
CAUTION
1. After adjusting the clutch band, tighten the lock nut
securely.
2. Apply oil to the indicated points every 2000 hours.
Apply the molybdenum disulfide grease to "G“ section
every 2000 hours. Be careful not to get any oil and
grease on the lining

1. After operation, the clutch housing and clutch spider are
hot. Begin adjustment after they have cooled to a safe
temperature.
2. The clutch disengaging cylinder and hydraulic hose are

critical items. Replace them periodically. Overhaul or replace
the disengaging cylinder every 2000 hours or every 2 years.
After remounting, bleed the air from the system. Replace the
hydraulic hose every 2000 hours or every 2 years.
3. Apply oil to the areas (as illustrated above by arrow marks)

every 2000 hours or every 2 years. Apply molybdenum
disulfide grease to the "G” area every 2000 hours or every 2
years. Be careful not to gat any oil on the lining.
4. If the clutch lining is worn to a minimum thickness of 6mm,

replace the lining.
5. Check the mounting bolts and nuts every 250 hours or every
2 months and if necessary, retighten the bolts and nuts.
When the machine is often operated in the "FOOT' mode,
check the clutch-disengaging cylinder mounting bolt to
ensure that it Is properly tightened.

Caution
Remove the brake linkage pin and apply grease or
oil to it every 2000 hours or 2 years. Fit the pinhole
visually. Don't put your finger into the pin hole.
Caution
The limit switch must operate where the second ratchet is
applied to the lock plate and the braking force must hold
the rated load safely. Adjust the brake as required to
maintain control of the load.

Brake assist device assembly
This brake mechanism consists of two systems: Foot mode,
dependent on pedal operation, and Automatic mode, in which
the brake is controlled with the automatic brake cylinder.
Foot mode: Although this mode is basically the

same as a mechanical brake in
which the brake band is controlled by
the pedal force, a hydraulic assist
mechanism is designed to boost the
pedal force.
Automatic mode: Upon returning the winch control

lever to "NEUTRAL”, the automatic
brake cylinder activates to engage
the brake band, thereby applying the
brake.
The automatic brake cylinder functions as an emergency brake

to keep the brake engaged in an emergency such as a drop in
control hydraulic pressure.

Adjustment of Brake Band
CAUTION
Before adjusting the band, loosen the lock
Adjust the brake to hold a rated load. If the brake is not nut (for fastening bolts) and loosen the both
operating properly, the load may be dropped. Check the fastening bolts to adjust the clearance at
following points. Replace the lining, adjust the band the head of each bolt. After adjustment, re-
tension or clean the lining if necessary. fasten the band as before.
1. Is the thickness of the brake lining under the minimum
dimension?
2. Is the tension of the brake band adjusted properly?
3. Is water or oil contaminating the brake lining?
4. Is the band clearance maintained over the entire drum
circumference? Is the brake pedal force correct?
5. Is the lag of the brake band deformed? Is the brake rod
or linkage OK?

Continued From the Previous Page (Adjustment)
1) Lower the load or the hook to the ground.

2) Raise the brake pedal to release the brake after the "FOOT
MODE- is selected.
3) Loosen the nut of the band adjusting bolt and turn the bolt to
provide a gap between the heads of the two bolts.
4) Tighten the band adjustment nut to adjust the brake band.
For adjustment, make sure that the rated load can be held
when the brake pedal has proper force and the second
ratchet is hooked on the lock plate while the pedal is being
depressed. Adjust the brake band so that the limit switch
can operate when the second ratchet is hooked on the lock
plate. Make sure that the third ratchet is hooked on the lock
plate when the pedal is depressed further.
5) When brake is engaged. move the band fastening bolts until
their heads come in contact with each other.
6) Adjust the tension of the band clearance adjustment springs
to provide clearance. Adjustment is satisfactory when the
lining and brake drum are separated over the entire
circumference when the brake is released.

Adjustment of Pedal Stroke
If the correct pedal stroke is not set, the hydraulic assist device
will not operate satisfactorily. This may cause dragging of the
band. Make sure that the pedal moves 3.8" with the
pedal stroke-adjusting bolt.
1. Depress the pedal down to second ratchet pawl as a
reference,
2. Allow the pedal to rise by 4.6". At this position, bring the
stroke adjustment bolt into contact with the stop.
3. Confirm that the limit switch is activated at the position
where the pedal is depressed to the second ratchet pawl. At
this state pedal stroke is 3.8",
Brake Valve Stroke

1) When the brake is loosened, the distance between the
roller and the brake valve is 9/32" (7 mm).
2) When the brake pedal is depressed down to the 3rd
ratchet, the brake valve reduction stroke is 52/64” (20.5
mm). The dimension shown in the figure above when the
pedal is not depressed is 5-5/32". This dimension will be as
follows when the pedal is depressed down to the third
ratchet: 5-5/32- (131 mm) - 52/64" (20.5 mm) = 4-12/32"
(110.5 mm)
The oil pressure sent to the brake assist cylinder from the
brake valve is 6.9 MPa (70 kg/cm2) when the brake pedal
is depressed down to the third ratchet
3) The reduction stroke of the brake valve is 43/64" (17 mm)
when the brake pedal is depressed down to the second
ratchet
4) The reduction stroke of the brake valve is 31/64" (12.3 mm)
when the brake pedal is depressed down to the first
ratchet.
Releasing Pedal Lock

If the pedal lock function is not required with clamshell
operation, etc., the ratchet can be locked by tightening the bolt
(shown at left) so that the pedal lock cannot be engaged. (For
normal operation, the bolt should be in the housing hole,)

Composition of Assist Device
Below figure is in the brake-engaged state.

Bleeding the Air From the Braking System
Caution
1. Lock the hoist drum. 6. Place the winch in “FOOT” mode, depress the brake
2. Two people are necessary for bleeding the air. One pedal and loosen the bleeder gradually to bleed the air
person must start the engine and operate the pedal, and from the brake cylinder. When the air stops bleeding
the other must bleed the air. out, tighten the bleeder. The air inside the brake valve is
3. Set the engine speed at idle. bled at the same time. If the winch mode is at "FOOT",
the automatic brake cylinder is pressurized. Loosen the
4. Attach a vinyl hose to the end of the air bleeder and air bleeder to bleed air gradually in the same method.
place it in a container to prevent the oil from spilling.
7. The hydraulic hose is a critical item and must be
5. Oil pressure is applied to the hydraulic circuit. Loosen replaced every 2000 hours or every 2 years.
the air bleeder gradually. Don't place your face and
body in front of the bleeder.

Control Circuit Pressure Control Valve Manifold Block Pressure
Switch
Pressure Switch
P3
1134 psi (80 kg/cm2)
567 psi (40 kg/cm2)
Line filter
Check valve
1134 psi (80 kg/cm2) 567 psi (40 kg/cm2)

Gauge port PG1 Gauge port PG2
These are the relief valves for the 1134 psi (80kg/cm2) control
circuit, reducing valve for the 567 psi (40kg/cm2) control circuit Note 1:
and line filter. 1134 psi (80 kg/cm2) is a main control circuit pressure for changing the
main/auxiliary winch mode. It is adjusted to 1063 psi (75 kg/cm2) under engine
low idling condition.
(1) Set pressure gauge on the gauge port, loosen the lock nut 567 psi (40 kg/cm2) is a control pressure for the remote control valve, pump
and motor. It is adjusted to 496 psi (35kg/cm2) under engine low idling
and turn the adjusting handle clockwise to increase the condition.
pressure. Tum the handle counterclockwise to decrease the
pressure. Note 2:
(2) After adjustment, tighten the lock nut securely. The gauge port is equipped with a mini check valve (PF1/4”) for the pressure
gauge.

Accumulator
Accumulator
Brake Cylinder Winch Mode

The winch mode selector solenoid valve manifold blocks are
Selector
mounted near the brake linkage at the left of the main/auxiliary
Solenoid Valve
hoist drum shafts. The accumulator located on each block.
Manifold Block
Accumulator Winch mode selector

SOL valve
Brake valve Clutch cylinder

(Pedal brake)
Automatic Brake
Cylinder
(Emergency
Automatic brake cylinder Brake cylinder
Brake)
Notice
1. The accumulator is a pressurized component. Handle it 5. Check the gas pressure every 500 hours (4 months) if
with care and don’t drop it. required. Newer machines have accumulators which are
2. Don't store or use the accumulator near a fire. pressurized from the factory. These and are NOT
chargeable nor checked for pressure.
3. Don't touch the valve cap.
4. Don't lean on the accumulator or put anything heavy on
it when working on the machine. 6. Don‘t attempt to disassemble the accumulator.

Chargeable Accumulators
Gas is charged in the accumulator at a pressure of 779 psi
(55kgf/cm2) .
When the gas pressure drops to about 638 psi (45kgf/cm\ the
nitrogen gas assembly will need to be replaced.
On the newer machines these accumulators must be replaced

and are received fully charged from the factory.

BAND LINING (MAIN AND AUXILIARY HOISTING)
CAUTION
Minimum lining surface thickness reduces the clutch
transmission or drum braking force.
1. The lining thickness is 9.5mm and its minimum
thickness is 6.0mm. If one lining reaches the minimum
allowable limit, replace them both.
2. If the lining surface is hardened or is contaminated with
oil, disassemble it and either polish with sandpaper or
clean with gasoline.
3. Test the clutch transmission and brake force.
4. Perform adjustment so that the rated load can be held
where the second ratchet pawl of the foot brake pedal is
locked. Make sure that the limit switch operates when
depressing the pedal to the second ratchet pawl.

Periodic Maintenance Table.

Lubrication Oil Table
1. The oil marked ' in the Hydraulic Oil section should be used 5. We recommend Shell Tellus oil K46 for tropical countries
above 32°F. such as Taiwan, the Philippines, Hong Kong, Singapore,
2. If oil is contaminated or degraded excessively, it should be Malaysia, Indonesia, Thailand, and China (south of
replaced even before the regular replacement lime point. Shanghai).
3. The lubricant inside is the one used at the time of 6. We recommend Shell Tellus T32 oil for cranes working in
shipment from the factory. cold weather or frigid countries.
4. Use oil and grease of the same brands and avoid mixing
lubricants of different brands.

Lubrication Points

Lubrication Chart

Caution
1. When replacing oil or doing other repairs, put the

load on the ground and, if necessary, put the
attachment on the ground. Then, stop the engine
and hang a "REPAIR" sign on the operator's cab.
2. Be careful to avoid spills when draining the old oil
from the reduction gear. Wipe off spilled oil to
maintain safe footing and to prevent fire.
Notice
1. Replace the old oil with recommended new oil at specified

intervals. If the presence of metallic particles are found in
the oil, check the reduction gear for abnormal wear.
2. Do not dispose old oil at the job site, recycle the oil as pr
local, state or national regulations.

Main/Aux Winch Reduction Gear CAUTION
During operation, the units are heated. Allow the

units to cool to a proper temperature before
replacing the oil..
Oil replacement
(1) Remove the oil drain port plug from the ball valve. Turn the
handle of the ball valve to drain the old oil.
(2) Replace the oil drain port plug and close the drain valve.
(3) Pour oil through the filler port. When the oil level has risen
up to the center of the oil level gauge, filling should be
stopped.
(4) Replace the oil filler port plug.
(5) If oil is spilled. clean off with a cloth.
Notice
After rotating the drum, make sure that the air is flowing
properly through the air breather. Recheck the oil level to
confirm it is at the proper level.

Reduction Gear Oil filter port Air breather
Winch motor
Mounting position
Oil Replacement
(1) Remove the plug from the oil drain port and oil filler port
and allow the old oil to flow out.
(2) Replace the oil drain port plug.
(3) Inject oil through the filler port. When the oil level has risen
up to the center of the oil level gauge, filling should be
stopped.
Oil Level
(4) Replace the oil filler port plug.
Gauge
(5) If oil is spilled, clean off with a cloth
Oil drain port (PT ¾ “)
Notice
After rotating the drum, make sure that the air is flowing
properly through the air breather. Recheck the oil level to
confirm it is at the proper level.

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hc275

Ferreyros / Piura, Peru Rev. 12/12

IHI Models and Specifications M/L D5A Moment Limiter

Boom Composition Electrical & Hydraulic Circuit Design & Functionality

Safety Warning Symbols Counterweight System

Mobile Crane Safety Travel System

Wire Rope M/L D5A Moment Limiter

Rigging Swing System

Schematics Overview Hoist System

Hydraulic System Components

Electrical Symbols and Components

Models and Specifications

Terex® Hydraulic Crawler Training: Models and Specifications 2

The HC50 differs from the HC60 in that the main

Terex® Hydraulic Crawler Training: Models and Specifications 3

Boom – 46HI / Maximum Boom Length – 160’

The HC80 lower and superstructure is larger than the

Terex® Hydraulic Crawler Training: Models and Specifications 4

The HC110 upper and lower are larger than the

Terex® Hydraulic Crawler Training: Models and Specifications 5

The HC165 upper and lower are larger than the

Terex® Hydraulic Crawler Training: Models and Specifications 6

Boom – 77SI / Maximum Boom Length – 280’

The HC230 is the newest in the HC Crawler family. It

Terex® Hydraulic Crawler Training: Models and Specifications 7

Boom – 92HI / Maximum Boom Length - 300’

Terex® Hydraulic Crawler Training: Models and Specifications 8

Terex® Hydraulic Crawler Training: Models and Specifications 9

Terex® Hydraulic Crawler Training: Models and Specifications 10

Crawler Side Frame

Terex® Hydraulic Crawler Training: Models and Specifications 11

Terex® Hydraulic Crawler Training: Models and Specifications 12

Boom Identification & Composition

92 HT 20’ Center 92 ST 10’ Center

Terex® Hydraulic Crawler Training: HC275 3

Part Number – 1186701

Terex® Hydraulic Crawler Training: HC275 5

Terex® Hydraulic Crawler Training: HC275 6

Terex® Hydraulic Crawler Training: HC275 7

Terex® Hydraulic Crawler Training: HC275 8

Terex® Hydraulic Crawler Training: HC275 9

Terex® Hydraulic Crawler Training: HC275 10

Terex® Hydraulic Crawler Training: HC275 11

Terex® Hydraulic Crawler Training: HC275 13

Terex® Hydraulic Crawler Training: HC275 14

SI – Standard IHI Only

Terex® Hydraulic Crawler Training: HC275 15

Terex® Hydraulic Crawler Training: HC275 16

Terex® Hydraulic Crawler Training: HC275 20

Terex® Hydraulic Crawler Training: HC275 21

Safety Warning Information

Machine Design Standards

Machine Serial Number

Terex® Hydraulic Crawler Training: Safety Warning Information 2

Warning Winch Selector

MLD5A Overheat Warning

Travel Lock Caution Operational Warnings

Terex® Hydraulic Crawler Training: Safety Warning Information 3

Electrocution Hazard Crushing Hazard

Terex® Hydraulic Crawler Training: Safety Warning Information 4

Terex® Hydraulic Crawler Training: Safety Warning Information 5

Crushing Hazards Crushing Hazards – Export Seal

Terex® Hydraulic Crawler Training: Safety Warning Information 6