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LIST OF TABLES
Table 1 – Revision History ................................................................................................ 5
Table 2 - Operator Display Functions ................................................................................ 9
Table 3 – Input box navigation ........................................................................................ 10
Table 4 – Travel Mode Warning Messages ..................................................................... 20
Table 5 – Site Restriction Menu ...................................................................................... 24
Table 6 – Turbo-Timer Warning Messages ..................................................................... 26
Table 7 – Crane RC examples ........................................................................................ 29
Table 8 – Audible Alarm States ....................................................................................... 29
Table 9 – Crane Mode Warning Messages ..................................................................... 32
Table 10 – Joystick Response ........................................................................................ 36
Table 11 – LMI System Information................................................................................. 57
Table 12 – System Fuses................................................................................................ 57
WARNING: Prior to the operation of the crane the operator must read this manual
carefully and thoroughly and shall ensure that all operational instructions
and warnings are understood and complied with.
WARNING: The LMI system is equipped with an override switch which bypasses
alarms and motion limiter functions at which time the system can no
longer warn of impending overload and must only be operated strictly in
accordance with the crane manufacturer’s setup and operation
procedures. Operation of this override switch is for authorised personnel
only who shall be solely responsible for its use.
WARNING: The LMI system is not a substitute for good operator judgement,
experience and safe crane operation. The operator is solely responsible
for the safe operation of the crane.
At all times, relevant codes of practice must be followed.
ATB Anti-Two-Block
CAN Controller Area Network, commonly referred to as CAN bus
GA General Arrangement System Diagram
LMI Load Moment Indicator
LML Load Moment Limiter
PGN Parameter Group Number, J1939 Message Identifier
RC Rated Capacity
SPN Suspect Parameter Number, Values contained within a J1939 PGN
This Operator Manual applies to a range of Terex Pick & Carry Cranes; AT20,
AT22 and MAC25. This range of cranes is characterized by load moment load
calculations and limiter functions. This manual includes sections with electronic
joystick controls, although these are not fitted to all models.
Navigation through various screens is accomplished primarily using the rotary knob
and function keys. F1 through F11 are what is referred to as “soft keys”, meaning
their function changes depending upon what screen is displayed. F12 is reserved
for alarm mute functionality.
Table 2 - Operator Display Functions
Action Function
KNOB CENTRE press Screen Brightness controls.
Move green “focus” through selections, “Centre Press”
KNOB ROTATE and to select.
CENTRE press Scroll through options, “Centre Press” to confirm and
move green “focus” in selected screens.
F1 through F5
Menu and/or parameter selections.
F7 through F11
Service diagnostics Screens.
F6
Soft Key in sub-menus.
F12 Alarm cancel / mute request.
HOME Enter Top Level Menu.
CYCLE Cycle through options in selected screens.
ESC Cancel current operation and revert to previous.
Memory stick port for Data Download and Software
USB port Updates.
This is not suitable for charging mobile devices.
The display settings can be altered to suit preferences. Note that the settings will return
to default settings on the next power cycle.
When the ignition is first turned on the display will show the TEREX logo. The logo will
remain during the system boot-up sequence. During the power-up stages the LMI
system goes through a sequence of internal diagnostics and operator confirmations to
assure appropriate system setup prior to crane operation.
After the initial system boot-up sequence is finished, the system will then enter either the
Travel Mode Screen or the Crane Mode screen depending upon certain conditions being
met.
1) Transfer case is in HIGH range and dash rocker switch set to Travel Mode.
2) Boom fully retracted.
3) Boom level below 5 degrees relative to the chassis.
In the event there is a condition which is preventing the crane from entering Travel Mode,
then the Crane Mode screen (see Figure 6 below) will be displayed with a relevant
warning message such as LOWER BOOM or RETRACT BOOM. The crane must not be
driven until all conditions are met.
2 Wheel Drive,
High Range
Clock &
Message
Display
Front Diff.
unlocked
The Day screen automatically selects Maximum Brightness. This can be overridden
using the KNOB CENTRE press and editing screen preferences.
The Night screen automatically selects Minimum Brightness. This can be overridden
using the KNOB CENTRE press and editing screen preferences.
When in Travel Mode the operator has access to the following functions:
1) Screen Preferences, KNOB CENTRE press
2) System information, press HOME. See Section 0
3) System diagnostics, press F6. See Section 12
4) Distance to Empty, press F3 to toggle message window display
5) Time to Empty, press F3 to toggle message window display
6) Fuel Rate, press F3 to toggle message window display
7) Fuel Economy, press F3 to toggle message window display
8) Trip Meter, press F10 to toggle between Odometer and Trip Meter
9) Trip Timer, press F4 to toggle between Engine Hours and Trip Hours
The “Distance to Empty” value is calculated from current conditions and may not be
100% accurate. When the distance is low, “--“ will be displayed. The fuel tank should be
filled immediately.
The “Time to Empty” value is calculated from current conditions and may not be 100%
accurate. When the time is low, “--“ will be displayed. The fuel tank should be filled
immediately.
F4 toggles between Engine Hours and Trip Timer (F4 to left of “Hours”
window)
F10 toggles between Odometer and Trip Meter (F10 to right of “Odometer”
window)
To reset Trip Hours toggle to “Trip Timer” display first, then hold F4 for
several seconds until the timer resets to 0 hours.
To reset Trip Meter toggle to “Trip Meter” display first, then hold F10 for
several seconds until the meter resets to 0 kms.
There are several status and warning icons which may appear on the Travel Screen
depending on system conditions.
The following messages may appear on the display when in travel mode. The meanings
and actions are detailed below in Table 4:
WARNING: The LMI is NOT a fully automatic system. In order for the LMI to provide
overload warnings and limiter outputs the crane operator is responsible for the
following:
The system boot-up sequence may take up to 30 seconds when the ignition is turned on.
If the following conditions are met then the Crane Mode Screen will be displayed:
1) Dash rocker switch set to Crane Mode
2) Transfer case set to LOW Range
The first time the Crane Mode screen is entered after the crane is started the operator
will be prompted to confirm/select the Duty and Falls of hoist rope, see Section 7.1.3).
Subsequent Crane Mode selections will not require the operator to confirm duty or falls
until the crane is switched off, then on again.
The Day screen automatically selects Maximum Brightness. This can be overridden
using the KNOB CENTRE press and editing screen preferences.
The Night screen automatically selects Minimum Brightness. This can be overridden
using the KNOB CENTRE press and editing screen preferences.
The first time Crane mode is entered after the crane is started a pop-up window will
appear prompting the operator to confirm/select the duty.
ROTATE the knob to scroll through the available duties. The Duty description and
graphical icons will change with the duty number. Once the desired Duty is displayed,
KNOB CENTRE press twice (2) to confirm duty selection.
After selecting the desired duty, a pop-up window will prompt the operator to
confirm/select the number of falls (parts of line) if applicable. ROTATE the knob to scroll
through available falls. KNOB CENTRE press twice (2) to advance to the Crane Mode
screen.
A particular crane may have additional restrictions set in addition to the load chart and
slope restrictions. These settings may be viewed by the crane operator and some
settings are protected by a site supervisor password. To view the restrictions first press
HOME to bring up the Home Screen menu.
Pressing F11, “Site Restrictions” will bring up the current Site Restriction settings as
follows:
Use the function keys as detailed in Table 4 below to set the required lifting restrictions
for Crane mode, input the appropriate password if required.
FUNCTION FUNCTION
KEY RESTRICTION RESTRICTION KEY
F1 n/a Exit Menu F7
Set rigging limit, lesser of RC or Limit maximum allowable wind speed F8
F2 Rigging limit will stop dangerous (with wind speed option installed)
motion.
F3 Limit maximum allowed radius Set Time Zone Offset F9
Limit maximum allowed boom tip F10
F4
overall height
Limit maximum allowed front axle F11
F5
weight
F6 Limit available Capacity Alarm cancel / mute request F12
The System is equipped with a turbo-timer feature which can be manually overridden.
The following conditions must be met to shut the crane down safety:
1) No load on boom.
2) Park brake set.
3) Headlights off.
If all of the normal shutdown conditions are met, when the ignition is switched off, the
turbo-timer pop-up window will appear displaying a count-down timer showing time
remaining to shut-down. The turbo-timer will always default to 2 minutes but this can be
modified by using the KNOB ROTATE and CENTRE PRESS.
If an immediate shutdown is required then a single KNOB CENTRE press will select
“0 (stop immediately)” and allow the crane to shut down.
There are several system faults which can change the crane shutdown behaviour.
There are several warning messages which could appear in the turbo-timer message
window.
CAUTION: For the turbo-timer conditions which do not shut down automatically, it is the
operator’s responsibility to ensure the crane is in a safe state before doing a
manual shutdown using Emergency Stop or Battery Isolation Switch.
Upon successful entry into Crane Mode the crane LMI screen will be displayed. There is
a Day screen and a Night screen.
The LMI system provides the operator with real-time data for the following parameters:
• Actual Load
• Rated Capacity
• Percentage of RC
• Load Radius
• Boom Angle
• Boom Length
• Number of Falls
• Crane Configuration and Duty
• Overload Condition
• Two-Blocking Condition (if fitted with anti-two-block system)
• System Fault Conditions
Certain operational parameters may be changed by the crane operator such as:
• Crane Duty
• Number of Falls of hoist rope
The crane operator does not have access to service menus, calibration menus, and
some site restriction settings. These features are password protected and should only
be accessed by qualified personnel.
To check the LMI against the printed rated capacity manual requires moving the crane
into a position which aligns with the configuration stated on the manual. The table below
gives a range of values which can be expected based on the inputs provided. Note that
values are subject to change.
Alarms can be cancelled or muted depending on the condition. Muted alarms will un-
mute after 30 seconds if the condition still exists.
ROTATE the knob to scroll through the available duties. The Duty description and
graphical icons will change with the duty number. Once the desired Duty is displayed,
KNOB CENTRE press twice (2) to confirm new duty selection, or ESC to cancel.
The screen will display the current number of falls (parts of line). If no change is required
use KNOB CENTRE press to accept or ESC to cancel.
The duty selection will pop-up when a new valid configuration is detected and the user is
required to confirm the duty. The LMI will automatical default to no counterweight when
the counterweight is removed. No motion limits are induced in either situation as the duty
is based on the configuration detected. Faults with the detection will induce warnings on
the crane mode screen.
There are several status and warning icons and warning messages which may appear
on the Crane Screen depending on system conditions. The display will show multiple
warning messages by alternately cycling through each message (some conditions will
result in multiple warning messages).
Note: The LMI will not allow dangerous crane operation under certain conditions.
Once a warning message has been activated, it will continue to be displayed until the
condition is resolved. In this example below in Figure 27, the crane is moving faster than
the allowable pick-and-carry speed with line-pull exceeded.
The following messages may appear on the display when in crane mode. The meanings
and actions are detailed below in Table 9:
If a stuck joystick deadman is detected then the joystick will not operate until the joystick
deadman switch goes through an OFF-ON sequence. NOTE: The stuck deadman icon
may also be caused by a joystick fault.
A motion limit will also be induced if the value detected by a sensor is out of range,
including on system startup when the sensors and ECU are not active yet. This can
occur on all sensors. Always ensure the crane is operated within the configuration limits
specified.
Next pressing F1 next to “Joystick Response” will bring up the Joystick Response screen.
The curve for each joystick function associated with the selected Joystick Response may
be viewed by scrolling through the “FUNCTION – SPEED” selection. Each Joystick
Response may be viewed by scrolling through “Joystick Response” selection, see Figure
30
See Figure 31for comparison curves. Response curves are subject to change.
To perform a calibration, first press the HOME ket to bring up the Home Screen Menu.
Select Calibration and input the appropriate password. The Calibration menu will then be
shown. Each sensor can be calibrated individually. The crane serial number can be set
only once, when the system is initially configured.
Select the sensor to calibrate, the system will prompt the user with instructions to
complete the process. Boom length values are based on the fallblock duty. Return the
crane to an appropriate configuration after each calibration.
The “Comms” column indicates if the CAN bus is active. The “Faults” counters show the
number of faults present.
Selecting LMI “View” will result in a pop-up window which shows active LMI faults and
active limit functions. These may be the result of an overload or max limits being
exceeded in which case the faults will disappear when the crane is restored to a safe
state.
Selecting Engine & trans “View” will take the operator to the DIAGNOSTICS Screen
overview and menu. From there more thorough engine and transmission diagnostic data
can be viewed by selecting “SPN/FMI” and/or “Live View PGNs”. See Section 12.3 for
more discussion on viewing Engine and Transmission faults.
Selecting Controls “View” will result in a pop-up window which shows Controls status and
active faults.
Full system Diagnostics may be accessed from the Home Screen. Selecting “Menu”
from the Fault Summary pop-up window will access the Home screen. Alternatively
pressing the HOME key on the keypad will also access the Home screen.
Pressing F2 next to “Live View Analog” will bring up the Analog Input Live View pop-up
window. This window is updated in real time as conditions change.
Pressing F3 next to “SPN/FMI” will bring up the SPN / FMI viewer pop-up window.
Active Engine and Transmission fault codes can be viewed in this window.
The PGN viewer will display PGN and SPN data in real-time as conditions change.
Specific PGNs can be selected using the KNOB ROTATE and PRESS
Pressing F9 next to “Service Hours” will bring up the scheduled service hours screen.
This screen shows how many hours remaining until the next scheduled service interval.
To reset the reminder, select the appropriate service interval and input the password to
confirm.
The internal Operation Log file is a circular file. As the log memory is used up the oldest
pages are archived on the internal SD Card. Therefore the Operational data log always
maintains the latest data, typically up to a month old but this depends on the use of the
crane.
These datalogs are downloaded independently. The overall data retrieval process is as
follows:
Step 1) Insert USB stick and ensure SDCard is present in controller ECU. (The
SD card is factory installed and can only be removed by a technician).
Step 2) Go To Home → Software update Log Download → Data log downloads →
Copy Data log To USB → View Data Log pop will be active.
Step 3) Using CYCLE key Select “Most recent:” number of days of log. Example
past 6 days of log.
Step 4) Using CYCLE key Select “Save”
Step 5) “Confirmation required” pop-up will be active, Click “Yes”.
Step 6) Using CYCLE key select the directory you want to save data logger and
centre click (ensure Directory name does not have any spaces)
Step 7) Using CYCLE key select “Select” and press centre click
Step 8) Once process is completed “Remove USB stick”.
Step 9) Above process will create 2805.bin file in the folder you have selected.
Step 1) Insert USB stick again and ensure SDCard is present in controller ECU.
(The SD card is factory installed and can only be removed by a
technician).
Step 2) Go To Home → Software update Log Download → Data log downloads →
Copy Data log To USB → View Data Log pop will be active.
Step 3) Using CYCLE key Select “Log History”
Step 4) Using CYCLE key Select “Save”
Step 5) “Confirmation required” pop-up will be active, Click “Yes”.
Step 6) Using CYCLE key select the directory you want to save data logger and
centre click (ensure Directory name does not have any spaces)
Step 7) Using CYCLE key select “Select” and press centre click
Step 8) Once process is completed “Remove USB stick”.
Step 9) Above process will create 2806.bin file in the folder you have selected.
Terex provides user friendly easy to use Log viewer. It will convert the binaries generated
by LMI to the *.txt file and open automatically in excel. This makes view/ filter easier.
Step 2) Open LogViewer.exe and Click either of “Crane Log” , “Crane Lift”, “Engine
Log” or “Winch History” and then Select “Start”
Step 4) Log viewer will automatically generate a file name formatted as:
R1051587_1111_opLog_180713_0125.txt where:
Engine and Transmission fault codes are stored in the LMI system.
Figure 46 – Log Viewer Engine & Transmission Faults: Active J2012 DTC
Figure 48 – Log Viewer Engine & Transmission Faults: DM1 J1939, Red DM’s multiple DMs
Figure 50 – Log Viewer Engine & Transmission Faults: TCM communication errors.
• dotNetFx40_Client_x86.exe http://msdn.microsoft.com/en-
us/library/5a4x27ek.aspx
• vcredist_x86.exe http://www.microsoft.com/download/en/details.aspx?id=5555
• Operating system: Windows 7®, Windows Vista®, (32 bit and 64 bit); XP SP1,
SP2, SP3.
• Controller: Pentium® 4 Recommended
• RAM: 256 MB or greater Recommended
• Application: Microsoft® Office Excel 2003, SP3 or higher
Other than overload conditions, any indicated system errors require service by a qualified
Terex Service Technician. Please contact your Authorised Terex Dealer or Terex
Service directly for assistance.
When reporting service issues it is imperative to give the Terex qualified Service
Technician the following information:
Please record as much of this information as possible and have it available when placing
a service call.
Rear Counterweight
SL Counterweight
Parking Lights On
High Beams On
LMI Fault
System Diagnostics
Fault Detected