Maintenance and Operator'S Manual T. F. C. 45 QSM11

T. F. C.
45 QSM11
MAINTENANCE AND OPERATOR’S MANUAL
EDITION: 03/2006 N˚ P 62440---53 S/N : 172000 --->172999

Registered Office and Factory
Zone Industrielle de La Saule
B.P. 106
71304 – MONTCEAU – LES – MINES
Tél: (33) 03 85 67 38 00
Fax: (33) 03 85 67 38 99
S/N : 172000 -> 172999
P 62440.53
Operating and Maintenance Manual
BEFORE PUTTING YOUR MACHINE INTO THE

HANDS OF AN OPERATOR, OR IF YOU HAVE
BORROWED OR HIRED IT, MAKE SURE
BEFORE THE OPERATOR STARTS THE
ENGINE:
THAT YOU HAVE GIVEN HIM ALL THE
INSTRUCTIONS NECESSARY FOR PROPER
AND SAFE USE OF THE MACHINE;
THAT HE HAS STUDIED AND ASSIMILATED
ALL THE INSTRUCTIONS IN THIS MANUAL.
BEFORE STARTING ENGINE

STUDY OPERATOR'S MANUAL SAFETY
MESSAGES.
READ ALL SAFETY SIGNS ON MACHINE.
CLEAR THE AREA OF OTHER PERSONS.
LEARN & PRACTISE SAFE USE OF
CONTROLS BEFORE OPERATING.
IT IS YOUR RESPONSIBILITY TO
UNDERSTAND AND FOLLOW
MANUFACTURER'S INSTRUCTIONS ON
MACHINE OPERATION AND TO OBSERVE
APPLICABLE LAWS AND REGULATIONS.
OPERATOR MANUALS AND PARTS
CATALOGUES MAY BE OBTAINED FROM
YOUR EQUIPMENT DEALER.
ACCIDENTS INVOLVING MACHINES WHICH

DO NOT OCCUR IN NORMAL HIGHWAY
CIRCUMSTANCES.
"IN THE EVENT OF AN ACCIDENT, AND IN
ORDER THAT ANY CLAIM CAN BE MADE
AGAINST TEREX, IT IS OBLIGATORY THAT A
PERSON APPROVED BY TEREX CAN
ESTABLISH A REPORT ON THE ACTUAL
CONDITIONS OF THE ACCIDENT BEFORE
THE MACHINE IS REMOVED FROM THE SITE
OF THE AFORESAID ACCIDENT."
P 62440-53
TABLE OF CONTENTS
Chapters
Maintenance and operator’s manual
STACKER
TFC 45 QSM11
Chapter I
Information
Chapter II
Safe operating practices
Chapter III
Controls and operation
Chapter IV
Maintenance
Chapter V
Maintenance log
Chapter VI
Fuel – Lubricants
Chapter VII
Diagrams
Chapter VIII
Appendices
P 62440-53 Page 1
Chapter I - Information
TABLE OF CONTENTS
Information - Technical spécifications
REP DESCRIPTION PAGES

Important notice......................................................................................................................3
Technical specifications..........................................................................................................4
Metric conversion table...........................................................................................................5
Operator comfort ....................................................................................................................6
P 62440-53 Page 2
Chapter II - Safety
TABLE OF CONTENTS
STACKER Safe operating practices

Danger. ...................................................................................................................................2
General information. ...............................................................................................................3
Access to the machine and cleanliness .................................................................................5
Operation ................................................................................................................................6
Maintenance ...........................................................................................................................9
Electricity. .............................................................................................................................11
Hydraulics .............................................................................................................................12
Safety instructions concerning tyres............................................................................................14

1/ Deflation................................................................................................................................15
2/ Taking off the wheel rings.....................................................................................................15
3/ Before and during tyre fitting ................................................................................................15
4/ Inflation .................................................................................................................................16
5/ Wheel in two parts ................................................................................................................16
Stacker operating conditions and recommendations .................................................................18

General information ..............................................................................................................18
General handling recommendations ....................................................................................18
Spreader ...............................................................................................................................19
Driving the machine..............................................................................................................21
Safe operating practices for TEREX machine users. ..................................................................22

Introduction ...........................................................................................................................22
Operator's responsibility .......................................................................................................24
Signalman 's responsibility ...................................................................................................25
Responsibilities of all crew members ...................................................................................26
Management responsibility...................................................................................................26
Planning the job....................................................................................................................27
Operator's safety check ........................................................................................................28
Operating precautions ..........................................................................................................29
Keep the machine clean and dry..........................................................................................35
L.M.I. SAFETY INSTRUCTIONS ......................................................................................................38

Shut-down in the case of overload when setting down a container .....................................38
Shut-down in the case of overload when attempting to lift a container................................38
Transport of containers on the terminal................................................................................39
Summary of the various safety devices installed on the machine ....................................................40
P 62440-53 Page 3
Chapter III – Driving controls
TABLE OF CONTENTS
Driving controls

Controls and operation ...........................................................................................................2
1/ Steering wheel........................................................................................................................3
2/ Gear shift control lever ...........................................................................................................3
3/ Service brake pedal and gear box neutral position ................................................................3
4/ Service brake pedal................................................................................................................3
5/ Accelerator pedal....................................................................................................................3
6/ Combined switch - lights - blinkers - horn ..............................................................................3
13 / Working light warning light......................................................................................................4
14 / Revolving beacon warning light..............................................................................................4
15 / Headlights warning light .........................................................................................................4
16 / Direction indicator warning light..............................................................................................4
17 / Parking lights warning light.....................................................................................................4
18 / Torque converter oil temperature warning light......................................................................5
19 / Gear box oil pressure warning light........................................................................................5
20 / Anti-tipping device warning light.............................................................................................5
21 / Spreader lock override warning light ......................................................................................5
22 / Brake oil pressure warning light .............................................................................................5
23 / Parking brake warning light ....................................................................................................5
24 / Anti-tipping device override warning light...............................................................................5
25 / Excessive speed warning light ...............................................................................................5
26 / Battery charging warning light ................................................................................................6
27 / Engine preheating indicator light ............................................................................................6
28 / Clogged oil and air filter warning light ....................................................................................6
29 / Not used .................................................................................................................................6
30 / Alarm warning light STOP engine ..........................................................................................6
31 / Engine fault warning light .......................................................................................................6
32 / Low hydraulic oil level warning light .......................................................................................6
33 / Fuel minimum level warning light ...........................................................................................6
34 / Correct pad clamping and hoist authorization green warning light ........................................7
35 / Opened leg warning light........................................................................................................7
36 / Closed leg warning light .........................................................................................................7
37 / Unfolded leg warning light ......................................................................................................7
38 / Folded leg warning light..........................................................................................................7
39 / Clamped leg warning light ......................................................................................................7
40 / Unclamped leg warning light ..................................................................................................7
42 / Hour meter..............................................................................................................................8
43 / Torque converter oil temperature gauge ................................................................................8
44 / Fuel gauge..............................................................................................................................8
45 / Gear box clutch oil pressure gauge........................................................................................8
46 / Hydraulic oil temperature gauge ............................................................................................8
P 62440-53 Page 4

70 / Joystick controller (raise/lower - extend/retract boom)..........................................................9
70B / High speed boom functions control ........................................................................................9
71 / Spreader side shift control......................................................................................................9
72 / Spreader swing control...........................................................................................................9
73 / Twist locks lock / release control............................................................................................9
74 / Spreader damping lock switch..............................................................................................10
75 / Spreader beam telescoping switch ......................................................................................10
76 / Ignition switch .......................................................................................................................11
77 / Engine shut down control .....................................................................................................11
78 / Engine test code control .......................................................................................................11
79 / Hazard warning lights control switch ....................................................................................11
80 / Engine test control................................................................................................................11
81 / Parking brake control............................................................................................................11
82 / Outrigger control (Option).....................................................................................................11
83 / 2 or 4 legs piggy back selection control .............................................................................12
84 / Piggy back leg control lever (option) ....................................................................................12
86 / Spreader lock override control..............................................................................................13
87 / Anti-tipping device override control ......................................................................................13
88 / Override key for gearbox operation electronic control unit .................................................13
89 / Selector control for gearbox automatic or manual mode .....................................................13
90 / Tilt control (option)................................................................................................................13
100 / Revolving beacon control switch ..........................................................................................14
101 / Cab rear windshield wiper control switch .............................................................................14
102 / Air conditioner controls (ESC) ..............................................................................................14
103 / No. 2 working light control switch .........................................................................................14
105 / Headlight control switch........................................................................................................14
111 / Right side courtesy light .......................................................................................................14
112 / Right side map reader light switch .......................................................................................14
200 / Gearbox operation electronic control unit.............................................................................15
Fuse board............................................................................................................................16
General fuses .......................................................................................................................19
Spreader operating warning lights........................................................................................20
P 62440-53 Page 5

CAB
1/ Steering wheel (rear wheel steering)....................................................................................21
2/ Gear change lever ................................................................................................................21
3/ Accelerator pedal..................................................................................................................22
4/ Service brake pedal..............................................................................................................22
5/ Service brake pedal and gear box neutral position ..............................................................22
6/ Combination control: lights - direction indicators - audible warning – screen wipers...........22
13 / Working light warning light....................................................................................................23
14 / Beacon light warning light.....................................................................................................23
15 / Full beam headlights warning light .......................................................................................23
16 / Turn signal warning light.......................................................................................................23
17 / Parking lights warning light .................................................................................................23
18 / Torque converter oil temperature warning light....................................................................24
19 / Clutch oil pressure warning light ..........................................................................................24
20 / Anti-tipping device override warning light.............................................................................24
21 / Spreader twist lock override warning light............................................................................24
22 / Brake oil pressure warning light ...........................................................................................24
23 / Parking brake warning light ..................................................................................................25
24 / Anti-tipping device override warning light.............................................................................25
25 / Overspeed warning light (Red).............................................................................................25
26 / Battery charging warning light ..............................................................................................25
27 / Engine preheating indicator light ..........................................................................................25
28 / Clogged hydraulic oil and air filter warning light ...................................................................25
29 / Not used ...............................................................................................................................25
30 / STOP engine alarm warning light.........................................................................................25
31 / Engine fault warning light .....................................................................................................26
32 / Low hydraulic oil level alarm warning light ...........................................................................26
33 / Minimum fuel level warning light ..........................................................................................26
34 / Correct pad clamping and hoist authorization green warning light ......................................27
35 / Opened leg warning light ....................................................................................................27
36 / Closed leg warning light .......................................................................................................27
37 / Unfolded leg warning light ....................................................................................................27
38 / Folded leg warning light ......................................................................................................28
39 / Clamped leg warning light ....................................................................................................28
40 / Unclamped leg warning light ................................................................................................28
42 / Hour meter............................................................................................................................29
43 / Torque converter oil temperature gauge ..............................................................................29
44 / Fuel gauge............................................................................................................................29
45 / Gear box clutch oil pressure gauge ....................................................................................29
46 / Hydraulic oil temperature gauge ..........................................................................................29
P 62440-53 Page 6

70 / Boom lift/telescope joystick ..................................................................................................30
70/1 Raise boom ..................................................................................................................30
70/2 Lower boom..................................................................................................................30
70/3 Retract boom ................................................................................................................30
70/4 Extend boom ................................................................................................................30
70A / High speed boom functions control ......................................................................................30
71 / Spreader side shift control....................................................................................................30
71/1 Side shift to the left .......................................................................................................30
71/2 Side shift to the right.....................................................................................................30
72 / Spreader slewing control ......................................................................................................31
72/1 Slewing to the left .........................................................................................................31
72/2 Slewing to the right .......................................................................................................31
73 / Twist locks lock/release control lever ...................................................................................31
Releasing..............................................................................................................................31
Locking .................................................................................................................................31
74 / Anti-tipping device override control ....................................................................................32
75 / Spreader beam telescoping control......................................................................................32
76 / Ignition switch .......................................................................................................................33
77 / Engine shut down control .....................................................................................................33
78 / Engine test code control .......................................................................................................33
79 / Hazard warning lights control ...............................................................................................33
80 / Engine test control................................................................................................................33
81 / Parking brake switch and gear box neutral position.............................................................33
82 / Outrigger control (Option).....................................................................................................34
83 / 2 or 4 legs piggy back selection control .............................................................................36
84 / Piggy back leg control lever (option) ....................................................................................36
86 / Spreader locking override control.........................................................................................37
87 / Anti-tipping device override control ......................................................................................37
88 / Override key for the electronic gear box control unit............................................................37
89 / Gearbox automatic or manual mode selection control.........................................................37
90 / Tilt control (option)................................................................................................................37
100 / Revolving beacon control .....................................................................................................38
101 / Cab rear screen wiper control ..............................................................................................38
102 / Air conditioner controls (ESC) ..............................................................................................38
105 / Road light control switch.......................................................................................................38
111 / Right side courtesy light .......................................................................................................38
112 / Right side map reader light switch .......................................................................................38
200 / Electronic gear box control unit ............................................................................................39
P 62440-53 Page 7

Engine error code display procedure ................................................................................................40
Verifying fault codes ...........................................................................................................40
Seat adjustments
Weight adjustment.............................................................................................................................42
Height adjustment .............................................................................................................................42
Backrest rake adjustment..................................................................................................................42
Distance adjustment ........................................................................................................................42
Headrest ............................................................................................................................................42
Right control panel bracket lifting handle ..........................................................................................43
Unoccupied passenger seat (OPTION) ............................................................................................43
Recommended seat adjustment........................................................................................................43
Recommendations for minimizing levels of vibration of the machine ...............................................44
Machine operation
Machine operation.............................................................................................................................45
Preliminary Inspection and Adjustments ...........................................................................................45
Starting the engine ............................................................................................................................45
Prevention of fire risks in the engine compartment ...........................................................................48
Machine operation
Automatic transmission mode ...........................................................................................................49
Gearbox in manual mode ..................................................................................................................49
Container handling cycle ...................................................................................................................50
Stopping the engine ..........................................................................................................................53
Removing/installing the spreader.....................................................................................................54
Spreader damping.............................................................................................................................57
Optional fixed hook............................................................................................................................58
Fitting the fixed hook .........................................................................................................................58
Dismantling the fixed hook ................................................................................................................59
Block stow operations .......................................................................................................................60
P 62440-53 Page 8
Chapter IV - Maintenance
TABLE OF CONTENTS
Maintenance

Maintenance. ..........................................................................................................................2
Levels of Maintenance............................................................................................................3
Maintenance: general .............................................................................................................4
Slew ring
Slew ring attachment ..............................................................................................................5
Periodic and compulsory slewing ring fastener checks..........................................................5
Checking slew ring wear.......................................................................................................11
Measuring the tilting clearance.............................................................................................11
Details about the measurement ...........................................................................................12
Acceptable wear limits..........................................................................................................13
Service intervals
Hour-meter............................................................................................................................14
Preliminary operations..........................................................................................................14
Quality of lubricants ..............................................................................................................14
Before every daily start up....................................................................................................15
Storage .................................................................................................................................15
Lubrication chart
Lubrication chart ...................................................................................................................16
List "A" - 10 h
Air filter..................................................................................................................................17
Fuel tank and hydraulic tank levels ......................................................................................18
Transmission: Converter and powershift gear box...............................................................19
Engine...................................................................................................................................20
Brake circuit: fluid level check ..............................................................................................21
Engine radiator: coolant level ...............................................................................................21
Spreader greasing operations ..............................................................................................22
List "B" - 50 h
Spreader hydraulic slewing motor ........................................................................................23
Spreader hydraulic sideshift motor.......................................................................................23
Spreader slewing ring...........................................................................................................23
Slewing ring teeth .................................................................................................................24
Boom and booming system ..................................................................................................24
P 62440-53 Page 9

List "C" – 100 h
Batteries................................................................................................................................25
Wheel fastener tightness ......................................................................................................26
Check the tightness of all spreader fasteners ......................................................................27
List "D" - 200 h / 250 h

Tyre pressures......................................................................................................................29
Batteries................................................................................................................................29
Battery anchorages ..............................................................................................................29
Transmission shafts and U-joints .........................................................................................29
Rear steering axle ................................................................................................................30
Air conditioning unit ..............................................................................................................30
Engine...................................................................................................................................30
Transmission ........................................................................................................................31
Catalytic converter................................................................................................................31
List "E" - 500 h

Air filter..................................................................................................................................32
Boom beam guide pads........................................................................................................32
Hydraulic tank.......................................................................................................................33
Transmission ........................................................................................................................34
Front axle..............................................................................................................................35
Differential unit......................................................................................................................35
Front axle reducer unit..........................................................................................................35
List "F" - 1000 h

Spreader fastener checks.....................................................................................................36
Spreader swing motor-reducer unit - TRASMITAL...............................................................36
Spreader sideshift motor-reducer unit - TRASMITAL ..........................................................36
Spreader beam guide pads ..................................................................................................37
Check condition and attachments of electric wiring harnesses............................................37
Check leaktightness of hydraulic circuit. ..............................................................................37
Check condition of alternator and starter .............................................................................37
Have brake accumulators checked ......................................................................................37
Cooling of brake circuit .........................................................................................................37
Axle coolant change .............................................................................................................38
P 62440-53 Page 10

List "G" - 2000 h
Spreader slewing motor-reducer unit ...................................................................................39
Spreader locking system ......................................................................................................39
Air conditioning unit ..............................................................................................................39
Spreader swing motor-reducer unit - DINAMIC OIL.............................................................39
Spreader sideshift motor-reducer unit - DINAMIC OIL.........................................................40
Hydraulic fluid tank ...............................................................................................................40
Front axle..............................................................................................................................41
Differential unit......................................................................................................................41
Front axle reducer unit..........................................................................................................42
KESSLER axle .....................................................................................................................42
Rim check .............................................................................................................................43
List "H" - 6000 h

Spreader ...............................................................................................................................44
List "J" - 10000 h

Engine/gearbox ....................................................................................................................44
Brakes...................................................................................................................................45
Boom ....................................................................................................................................45
Spreader ...............................................................................................................................45
Hydraulic oil tank ..................................................................................................................46
Tyres.....................................................................................................................................46
Front axle..............................................................................................................................46
Chassis .................................................................................................................................46
P 62440-53 Page 11
Chapter V - Maintenance Log
TABLE OF CONTENTS
Maintenance Log

General identification..............................................................................................................2
Service intervals
Hour meter..............................................................................................................................4
Preliminary operations............................................................................................................4
General
Using the maintenance log .....................................................................................................5
Lubrication chart ...............................................................................................................................6
Maintenance list "A" Every 10 hours or every day ..............................................................................7

Maintenance list "B" Every 50 hours or every week ...........................................................................8
Maintenance list "C" Every 100 hours .................................................................................................9
Maintenance list "D" Every 200 hours / 250 hours............................................................................10
Maintenance list "D" Every 200 hours / 250 hours (CONT'D)...........................................................11
Maintenance list "E" Every 500 hours ...............................................................................................12
Maintenance list "F" Every 1000 hours or every 6 months ...............................................................13
Maintenance list "F" Every 1000 hours or every 6 months (CONT'D) ..............................................14
Maintenance list "G" Every 2000 hours.............................................................................................15
Maintenance list "H" Every 6000 hours.............................................................................................16
Maintenance sheet "J" Service at 10000 hours ................................................................................16
P 62440-53 Page 12
Chapter VI - Lubricants
TABLE OF CONTENTS
Fuel - Lubricants
Components capacities ..........................................................................................................2

Tyre pressures........................................................................................................................3
Filter elements ........................................................................................................................4
P 62440-53 Page 13
Chapter VII - Diagrams
TABLE OF CONTENTS
Diagrams
Electric diagrams
CR107629..................................................................................................................... 1 to 47
CR107629............................................................................................................... 100 to 123
CR107629............................................................................................................... 125 to 140
CR107629............................................................................................................... 150 to 156
CR107629............................................................................................................... 175 to 180
CR107629.......................................................................................................................... 200
Hydraulic diagrams
CR107642.......................................................................................................................... 204
P 62440-53 Page 14
Chapter VIII - Annexes
TABLE OF CONTENTS
Annexes – Diagnostics – Trouble Shooting
QSM11 Codes defects ...........................................................................................................2
P 62440-53 Page 15
Table of contents
P 62440-53 Page 16
Information
Chapter I
Information
Technical
specifications
P 62440-53 Chapter I - Page 1

Information
CAUTION:
THE GUARANTEE WILL BE NULL AND VOID
WHERE THERE HAS BEEN NEGLIGENCE,
FAULTY MAINTENANCE, INAPPROPRIATE
USE OF THE EQUIPMENT BY THE
PURCHASERS OR THEIR EMPLOYEES,
AND/OR FAILURE TO RESPECT TECHNICAL
INSTRUCTIONS RELATING TO THE
GUARANTEE.
BEFORE THE OPERATOR STARTS THE

ENGINE:
GIVE INSTRUCTIONS TO THE OPERATOR ON
SAFE AND CORRECT USE OF THE MACHINE.
MAKE SURE THE OPERATOR READS AND
UNDERSTANDS THE OPERATORS MANUAL
FOR THIS MACHINE.

Information
Important notice
In order that any type of vehicle be reliable and safe, it is most

important to carry out all lubrication and maintenance operations.
Some of them, given in the MAINTENANCE GUIDE, require special
tools and technical knowledge.
Any failure to respect the lubrication and maintenance instructions

may cause a serious accident.
Special attention must be paid to cleanliness in the engine
compartment.
READ ALL THE SAFETY INSTRUCTIONS CAREFULLY BEFORE

CARRYING OUT LUBRICATION OR MAINTENANCE
OPERATIONS ON THE MACHINE.
All precautionary measures are described in the paragraph "SAFETY"
as well as in the GUIDE, when the corresponding maintenance
operations may present dangers. Warnings are also displayed on the
machine regarding some dangers which could cause serious
accidents. In the GUIDE and on the machine, these warnings are
preceded by the word "CAUTION" or "WARNING".
P P M does not necessarily know the way that maintenance

operations are carried out, or all risks inherent in a given method and
is unable to advise the maintenance team. Consequently, anyone
using an unsuitable specific method or tool recommended in the
GUIDE must first be sure that no risk is involved for himself or
anybody else and that there will be no damage to the machine or
effect upon safety.
IMPORTANT : The information contained in this operator's

manual is subject to change without notice. In case of
disagreement, only the French version will be taken into account.

Information
Technical specifications
DATE OF ISSUE: 03/2006
Identification
MARK: PPM - TEREX CRANES
MANUFACTURER : PPM - TEREX
TYPE : TFC 45 QSM11
SERIAL NUMBER : 172000->172999
DATE OF START UP:
TEREX CRANES FRANCE SAS
Registered office and factory

Zone Industrielle de la Saule
BP 106
71304 MONTCEAU LES MINES
FRANCE
TELEPHONE: ( 33 ) . 03 . 85 . 67 . 38 . 00
FAX: ( 33 ) . 03 . 85 . 67 . 38 . 99

Information
Metric conversion table
Multiply by XXXX to obtain the equivalent figure for
LENGTH TORQUE
Inch 25. 4 millimetres (mm) in-lbs 0. 11298 newton-metres (N.

Foot 0. 30448 metres (m) m)
Yard 0. 9144 metres ft-lbs 1. 3558 metres-metres
Mile (Statute) 1. 609 Kilometres (km) ft-lbs 0. 1383 kg-m
AREA POWER
Inch2 645. 2 millimetres2 (mm2) horsepower 0. 736 kilowatts (kW)

6. 45 centimetres2 (cm2)
Foot2 0. 0929 metres2 (m2)
Yard2 0. 8361 metres2
VOLUME PRESSURE OR STRESS
Inch3 16387. mm3 Inches of

16. 387 cm3 mercury 3. 377 kilopascals (kPa)
0. 0164 litres (l) Inches of water 0. 2491 kilopascals
Quart 0. 9464 litres Pounds/sq.
Gallon 3. 7854 litres in. (psi) 6. 895 kilopascals
Yard3 0. 7646 metres3 (m3) Pounds/sq.
in. (psi) 0. 0703 kg/cm2
MASS ENERGY OR WORK
Pound 0. 4536 kilograms (kg) BTU 1055. joules (J)

US Ton 907. 18 kilograms Foot-pound 1. 3558 joules
US Ton 0. 907 tonne (t) Kilowatt-hours 3. 6 x 106
or
3600000 joules (J=one W. s)
FORCE VELOCITY
Kilogram 9. 807 newtons (N) Miles/hour 1. 6093 kilometres. hr(km/h)

Ounce 0. 278 newtons
Pound 4. 448 newtons
TEMPERATURE
°F = 9/ 5 °C +32
°C = 5/ 9 (°F -32)

Information
Operator comfort
Sound level
Inside the cab with closed doors, the noise level A measured in static
remains below 85 dB(A).
Vibrations
The average weighted quadratic value of manual cab controls
according to the frequency of measured acceleration following
measuring conditions stipulated by standard ISO 5349 remains below
of 2.5 m/s2 (2.13 m/s2).
The average weighted quadratic value of the operator's seat

according to the frequency of measured acceleration following
measuring conditions stipulated by standard ISO 2631 can attain a
maximum value of 0.59 m/s2.

Chapter II
Safe operating
practices
P 62440-53 Chapter II - Page 1

Danger
Any operator must become acquainted with the operating

instructions described in this manual before using the machine.
The operator is wholly responsible for machine operation. No
liability will be accepted by the manufacturer if the instructions
contained in this manual are not strictly respected.
Never drive the machine, or let it be driven by third parties,

unless all the instructions contained in this manual have been
perfectly understood and remembered. Failure to follow these
instructions may result in serious accidents causing damage to
equipment and injury to personnel. Do not hesitate to contact
your local TEREX Dealer or Agent who is authorized to offer
formal training or can give sound advice.
THE OPERATOR'S MANUAL must always be left in the driver's

cab. Contact your local TEREX Dealer to obtain another copy if
required.

General information
Your safety as well as that of ground personnel in the vicinity

depend upon the proper use of the machine. Be sure that you are
perfectly aware of the location and the use of all controls.
BEFORE USING THE MACHINE, TRY ALL CONTROLS ON A
SAFE AND FREE AREA
In the handbook, the words "RIGHT" and "LEFT" indicate right

and left hand sides of the machine as viewed from the operator's
seat in the normal forward drive position.
Local safety rules must be observed
Make sure you read and fully understand all panels indicating
dangers or special attention to be taken on the machine.
Maintenance instructions must be strictly respected.
Pay particular attention if the machine is not the one you usually
drive.
Do not smoke when filling the fuel tank: the fumes are highly
inflammable.
Keep a good fire extinguisher and a first aid kit with you at all
times. Know how to use both of these items, and check them
regularly.
Avoid accidents due to unsuitable clothing. Wear proper working

clothes that will not get tangled up in machinery, and if
necessary, use safety equipment such as helmets, safety shoes,
ear protectors, goggles or a protective mask, gloves and
reflective clothes.

Wear a safety helmet and glasses, as well as safety gloves and

shoes, as required by state law.
Before you start the engine blow the horn for a few moments in
order to let ground personnel know your intentions and, if
necessary, prevent you from starting the machine.
Sparks can come from the exhaust pipe or from the electrical
system. Do not operate in closed areas where there are
inflammable materials, dust or fumes that can cause an
explosion or fire. Severe injury or death can result if you do not
follow these instructions.

Access to the machine and cleanliness
Make sure the access area and operator's station are clear of oil,
foreign material or ice. Remove or attach all maintenance or
personal items. Failure to keep these areas clean and tidy can
cause serious accidents.
Use your hands to get in and out of the machine: handrails and
handles are provided for these manoeuvres.
Never jump off the machine.
Make sure the windows of your cab are clean. Make sure the
windshield wipers are operating correctly. Dirty windows can
cause accidents.
Stow away oily rags and other inflammable materials in a safe

place.
Never leave any rags or flammable material on the machine.
The greatest attention must be paid to cleanliness around and on
the engine, the hydraulic distributor and all components likely to
become hot; make sure that there are no leaks from the hydraulic
or air conditioning circuits.
All measures should be taken to conserve the environment. Make

sure that all used oils and fluids are correctly retrieved and
recycled. Do not leave such products in incorrectly labelled,
unsuitable or open containers. Do not leave any puddles of fluid,
of any type, on the ground or on floors.

Operation
For your own safety as well as to ensure long machine life,

before starting up inspect the machine carefully.
Look for loose or missing fasteners, dirt accumulations,
hydraulic or coolant liquid leaks. Check condition of tyres as well
as the equipment and the steering gear.
Breakdown of a component or circuit can cause an accident.

Before using the machine, check all oil and hydraulic oil levels.
Check that all plugs, level gauges and caps are correctly
tightened. Replace or repair defective parts.
In case of a malfunction or a missing part, stop the machine and

carry out the repair. If this rule is not respected personnel injury
may occur.
Never use a machine with defective braking, steering or hoisting

systems. This rule applies to a machine that has been repaired or
adjusted without the agreement of the workshop supervisor, or
without being checked by him or by qualified staff.
If the engine stops, neither the power steering system nor the
brakes will operate correctly: stop the machine as quickly as
possible.
Do not use ether or any other unauthorized product to make

engine starting easier. If this rule is not strictly respected serious
personnel injury may occur.
Unless otherwise instructed: retract the boom, stop the engine,

apply the parking brake and immobilize or chock the machine
before undertaking any maintenance operation or leaving the
machine at the end of a shift.
.

The machine must be driven only by qualified and authorized

operators.
Understand the limits of the machine. Keep the machine under

control at all times. DO NOT TRY TO DO TOO MUCH TOO
QUICKLY.
Be aware of the dimensions and the weight of the machine. Keep

this in mind when operating in areas of limited space (bridges,
overhead piping, etc.) or where ground stability is uncertain.
Special precautions must be taken when working in the vicinity
of high voltage lines.
Refer to chapter Information to consult the characteristics of the
machine.
When driving the machine elsewhere than in the normal working

areas, make sure that you are acquainted with current machine
parameters, as well as those of the area (weight, dimensions,
wheel loads, permissible slopes, ground resistance and
adherence,... )
Refer to chapter Information to consult the characteristics of the
machine.
Be vigilant at all times. Never allow unauthorized personnel in the

working area. You must always know exactly where authorized
personnel are in the working zone.
Parking of vehicles in the area where the machine is working is

prohibited.
Always operate the machine with closed doors as noise injury

may occur.
When the engine is off, never release the parking or emergency

brake unless the machine is chocked or immobilized.
When wind speed exceeds 12. 2 m/s (= force 6), stacking more
than two containers high is prohibited.

When wind speed exceeds 19. 8 m/s (= force 9), all use of the
machine is prohibited.
Before starting the engine, make sure that the parking brake is
applied and the gear selector is in the neutral position.
Before you operate at night, check that all signalling lights and
headlamps are working correctly.
Operate the controls only from the operator's seated position.

Serious personal injury can be caused if you operate the controls
from any other position.
Be careful when you operate the machine in dusty, smoky or

foggy conditions. Poor visibility can cause accidents.
Avoid abrupt movements when handling a load.
Never leave the machine with a suspended load.
Never leave the machine parked on a slope.
Before you put the machine on a trailer, remove all ice, oil or
grease from the trailer and its loading ramp.
When the reach is increased, lifting capacity is diminished.

(See table of loads in chapter Information)
Before displacing a load, make sure that no one is under or near

the machine.

Maintenance
Do not try to carry out repairs that you not competent or qualified
to do.
Do not tolerate unauthorized people on the machine while

carrying out maintenance work.
Wear eye or face protection when you service the machine. Use a
hammer with a soft face, such as plastic, wood, brass or leather,
when you have to hammer hardened tools or hardened metal
surfaces. Any other procedure can cause injury from flying
chips.
Only run the engine in well ventilated areas.
Apply the parking brake, chock wheels and place warning panels
on controls while maintenance operations are carried out.
Always use proper tooling. Replace or repair worn or damaged

equipment.
Always check the cooling circuit with engine shut off and cold.
Unscrew the radiator cap slowly to release pressure in the
circuit. Steam may cause burns.
Always carefully unscrew coolant and drain plugs, grease

nipples and pressure taps.
Rotating fan and belts: contact can injure. Keep clear.

When working with compressed air wear a facemask with

headband and safety clothes. Maximum air pressure is 2 bar.
Be careful when using cleaning fluids.
For your own safety and to avoid liability only use original
TEREX parts.
Note: Repairs are best left to specialists. Do not hesitate to

consult your TEREX specialists or their appointed agent.
(See chapter Information for addresses, telephone/fax numbers and e-
mail).
Arc welding on the machine can harm mechanical, electrical or

electronic components and therefore increase safety risks.
Before welding always take the following precautions:
- position the earth clamp as near to the welding area as
possible.
- disconnect both battery terminals.
- disconnect all electronic units.

Electricity
Before working on the electrical circuit, turn the battery switch to

OFF position or cut off the current with the ignition switch.
Make sure that you understand the electrical circuit before you
connect or disconnect an electrical component. A wrong
connection can cause injury or damage.
Never put a metal object across the battery terminals to check

the charge of the battery. The sparks could cause an explosion.
Use a voltmeter or a hydrometer to check the battery.
Never smoke while checking battery liquid levels. A battery

produces inflammable fumes. The electrolyte is an acid solution
which is dangerous to the skin and the eyes.
Never top up batteries with acid. Always use distilled water.
When the battery electrolyte is frozen, the battery can explode if

you try to charge the battery or you try to start it using a battery
in parallel. To prevent the battery electrolyte from freezing, try to
keep the battery at full charge. If you do not follow these
instructions, you or others in the area can be injured.
When using an external power unit to start the engine, connect

the ground cable last and disconnect it first to avoid sparks near
the batteries, as they could ignite the fumes given off by the
batteries. With this method, connect the back-up battery earth
cable to the machine's starter motor earth terminal.
Never wear metal rings or metal watch bands. You could earth an
electrical circuit and burn yourself.

Hydraulics
The hydraulic system operates at a very high pressure. Hydraulic

oil, even from a minute leak, can go through your skin and cause
serious injury. When you check for leaks, do not use your hands,
use a piece of wood or paper. If you think hydraulic oil has
penetrated your skin, consult a doctor immediately.
Before disconnecting any hydraulic lines or components make

sure that pressure has been released in the circuit. Check for
leaks after reconnecting hydraulic hoses, pipes and components.
Hydraulic rams (especially derricking and telescoping rams)

must be fully retracted or the cylinder and piston rod chambers
of extended rams must be bled before any intervention is carried
out on hydraulic circuits or components (especially on relief
valve blocks flanged to rams).
The spreader must also be supported and in a horizontal position

before any intervention on the damping ram.
On any circuits using hydraulic or pneumatic reservoir bottles (e.

g. braking or suspension circuits) gas or hydraulic oil pressures
must be dropped to zero and their bottles emptied before
carrying out any intervention.

Hydraulic oil is inflammable. Never weld lines or pipes filled with

oil.
Hot hydraulic oil can cause burns: let the oil cool down before
draining the tank.
After any service operation on the hydraulic circuit, its

components or its fluid, it is essential to bleed the circuit to
remove any air which might have entered it, using the bleed
nipples provided for the purpose on the rams. This job must be
done by a qualified specialist.

Safety instructions concerning tyres
Note: The wheels and tyres are primary safety components on

the machine so check their condition regularly. Do not forget that
only specialized personnel are allowed to work on these parts.
Before removing any tyres from the machine and under all
circumstances:
Make sure that the fixed anchorage of the internal rim is not split
and that there is nothing wedged between two coupled tyres.
Start by loosening the wheel stud nuts by two or three turns only.
As the remaining wheel nuts stop the rim being ejected, dislodge
the external rim if necessary whilst keeping out of its trajectory in
case of an eventual ejection. As the external and internal rims are
then free, continue unscrewing the wheel nuts.
WARNING: If it is impossible to release the external and internal

rims after unscrewing the wheel nuts by two or three turns, it
means that something is wrong. In this case deflate the tyres
before taking off wheels. The same care must be taken if
something is wedged between two coupled tyres.

1/ Deflation
Remove the internal part of the inner tube valve and wait until
there is no more air whistling. In winter, check that there is no ice
plugged in the inner tube valve. Make sure that the tyre is totally
deflated. Avoid standing in front of the tyre during this operation.
2/ Taking off the wheel rings
Before any operation, make sure that the tyre is completely

deflated. In any case do not stand in front of the wheel during
this operation.
3/ Before and during tyre fitting
Carefully inspect the rim after cleaning it to verify that no cracks

are starting to form.
Fixed clamp fastener side (a)
Removable ring side, in the groove of the locking ring (b)
Carefully inspect the removable ring and the locking ring.
Replace any parts which are too corroded, show signs of cracks
starting to form or are badly distorted.
Check wheel discs for cracks.
Check that all mobile parts: removable rings (or side rings), and
locking rings correctly correspond with the rim.
Check that all different parts are correctly seated (locking ring
correctly seated inside its groove for example).

4/ Inflation
With the wheel or the rim fitted with the tyre laid on the ground,
inflate just until the removable ring places itself against the
locking ring. Then place the assembly vertically against a wall,
the removable ring on the wall side, and continue inflation.
IMPORTANT: In any case and during inflation operations never

stand in the probable trajectory of all or part of the wheel or the
rim. When you inflate a tyre on a vehicle take the same care as
above, stand to one side. Do not leave anybody in front.
5/ Wheel in two parts
When dismantling, do not confuse the assembly bolts of the two

shells (a) with the mounting bolts of the wheel (b)
Before inflation, make sure that the assembly bolts of the two
shells are fully tightened.

For your own safety and that of others, it is compulsory to check

the correct tightness of the wheels nuts using the wrench
provided with the machine. Frequency: after 50 hours, then every
100 hours of service.
Note: regularly check cold tyre pressures: every 50 hours or

once a week.
DANGER - Never operate the machine with under-inflated tyres.
Inflation pressures are given for cold tyres, inflation and

pressure checks must be carried out on cold tyres. Never deflate
a hot tyre.
Check condition of tyres without any load on the machine. If the

wheel is not fitted on the machine, always use an inflation cage.
With coupled tyres, always use same size, make, type, wear and
pressure to avoid any damage to tyres.
Do not risk an accident while inflating the tyres. Never stand in

front of the wheel. Use a flexible pipe of sufficient length with a
self tightening inflation socket.
Deflate tyres before trying to remove stones from the tyre tread.
When fixing balance weights to be tack welded on the site, use

only special equipment designed for the purpose.
Never cut or weld anything whatsoever on a rim fitted with an

inflated tyre.

Stacker operating conditions and

recommendations
General information
In all circumstances, the primary recommendation is prudence.
If the machine stays unused outside and with the piston rods
extended, all the rods must be greased to avoid corrosion.
General handling recommendations.
Containers are generally marked with their weight. Always verify

that the handling operation envisaged is compatible with the
table of loads of the machine.
The handling reaches indicated on the load capacity chart are the
distances measured between the spreader suspension vertical
axis and the vertical tangent of the front edge of the front wheels.
In order to maintain maximum safety, never lift loads exceeding

the maximum capacity.
The reach is increased by lowering and/or extending the boom.

By increasing the reach the lifting capacity is reduced. Do not
forget that the reach is increased when the machine goes down
slopes.

To pick up a container place the machine as close to it as

possible in order to have the best possible stability.
Never move a container horizontally without having lifted it from

the ground.
Never use the machine with safety devices shunted, or only

under very special conditions under the operator's responsibility.
If the machine has not been used for a long period, check correct
working order of the anti-tipping device by telescoping a
container barely off the ground until the handling functions are
automatically cut.
Never stand under the spreader, especially if a load is

suspended.
Spreader
When picking up a container always try to keep the longitudinal

axis of the machine as perpendicular as possible to that of the
container.
When slewing the spreader with respect to the container, use the
hydraulic slewing control or let the spreader down using the
container's corner guides after having activated the free slewing
function control. Never use the spreader's hydraulic slewing
control on the corner guides without having previously released
the slewing brake as mentioned above.

The weight of the spreader on the container must be sufficient to

make the twistlocks enter the corner twistlock housings. Never
use boom movement functions to press the spreader down on to
the container.
If the spreader safety system warning lights do not operate

correctly the unit must be repaired immediately. Using a machine
with faulty warning lights can cause serious accidents.
If container lock on is not achieved and the four spreader

positioning detectors are in contact with the container the
problem may be due to distortion of the container. Check that the
container twistlock housings are not obstructed (ice, etc.) or that
dirt has not accumulated in them. Never drive the machine with a
suspended container if the twistlocks are not fully engaged.
It is strictly prohibited to start a container lifting manoeuvre if the

red warning light is on (twistlocks not fully engaged) or if the
other indicator lights are not lit. Container lifting cannot be
started until the red warning light goes out and the green light
comes on.
It is essential to balance the weight of the load on the vertical

axis of the boom head. Do not start any other manoeuvre,
especially driving the machine, before carrying out this
operation. Use the side shift function to do this. Except for
special or refrigerated containers the weight distribution is
uniform and is balanced around the lengthwise midpoint.

Driving the machine
When the machine is unladen, drive with the boom head over the
front axle, never over the rear of the machine.
When driving under load, place the container slightly above the
operator's eye level and retract the boom to obtain the best
possible stability.
When transporting the load, it must be kept as close as possible

to the front axle (height and reach) or slightly forward to this
position, never further towards the rear. The container's position
should also allow the operator good visibility from the cab.
To ensure good visibility from the cab, avoid transporting the

load positioned in the field of vision.
In normal driving conditions use the middle pedal for braking.

The left hand pedal is only to be used for final 'inching' approach.
Braking reduces both longitudinal and lateral machine stability.

Adapt braking according to speed and the load being
transported. Be particularly careful when taking bends.
This machine has rear wheel steering, so pay attention to the

trajectory of the rear wheels when turning. Keep in mind that the
space occupied by the rear end of the machine during turning
manoeuvres is different than that of other vehicles. Keep a
minimum clearance of 50 cm between the counterweight and any
obstacle.
Adjust speed according to worksite conditions: this is governed

by environmental and ground conditions, the height and size of
the load along with visibility. Avoid sudden, abrupt manoeuvres
(taking bends, braking and speed).

Safe operating practices for TEREX machine

users
Introduction
TEREX machines are carefully designed, tested, and manufactured.

When used properly by qualified operators, they will give safe, reliable
service. TEREX has concessionaires who are competent to answer
any questions about its products or their safe use.
This machine has been designed to handle loads in accordance with

the load capacity chart and with instructions contained in this manual.
The machine should only be used in accordance with current laws and
regulations in force in the country concerned.
It is strictly prohibited to lift people with the machine unless it is
expressly equipped with an approved man-carrying platform supplied
by TEREX.
This machine is not to be used as demolition equipment.
It is strictly prohibited to push or drag objects with the boom.

Any use of the machine other than the handling of loads must be
authorized in advance by the TEREX company.
Normal conditions of use envisaged are an average of 17 hours per
day, 7 days per week, 300 days per year under normal environmental
conditions and at an altitude of less than 1,000 m.
For more intensive use or under harsher environmental conditions
(high temperatures, dusty or humid atmosphere, etc.), the machine
must be used with precaution, checked more frequently and the
lubrication and servicing intervals must be shortened.
TEREX has concessionaires who can answer all your questions
regarding conditions of use of the machine.
Because these machines have the ability to lift heavy loads to great
heights, they also have a potential for causing accidents if safe
operating practices are not followed. These pages will help the
operator prevent accidents which could result in property damage,
personal injury or death.
General safe practices for working on machinery must be followed as

well as the safe operating practices recommended here.

Operator's responsibility
Safety must always be the operator's most important concern. He

must refuse to operate when he knows it is unsafe and consult his
supervisor when safety is in doubt. He must read and fully understand
the Maintenance and Operator's Manual, all instructions, signs, and
decals on the machine. He must see that the machine is in proper
order and that all operational aids and warning signals are functional
before operating.
He must be alert, physically fit, and not under the influence of alcohol,
drugs, or medication that might affect his eyesight, hearing, or
reactions.
He must make sure that people, equipment, and material are kept out
of the work area.
When an operator's view is obstructed or when operating in

hazardous areas such as near power lines or around people, in these
special circumstances a signalman or an crew member must be used.
The operator must keep a fully charged fire extinguisher and first aid
kit in the cab at all times and be familiar with how to use these items.
The operator should understand the movements of other machinery,

trucks and personnel at the jobsite.

Signalman 's responsibility
The primary duty of a signalman is to assist the operator in safe and

efficient operation. Operators depend on designated signalmen to
assist them in making movements without endangering people or
property.
Signalmen must place themselves where they can be clearly seen and
where they can safely observe the entire operation.
Signalmen must have a clear understanding of the work to be done so

that they can safely coordinate each job with operators and other crew
members.
Standard signals must be used unless other methods of signalling

such as two way radios or flags have been agreed upon.
The driver's assistant is the only person who may direct the driver.

Responsibilities of all crew members
Any unsafe condition or practice must be corrected or reported to the

job supervisor.
Watch for hazards during operations and alert the operator and
signalmen of dangers such as power lines, the unexpected presence
of people, other equipment or unstable ground conditions.
Management responsibility
See that operators are trained, competent, physically fit and, if

required, licensed. Good vision is required as are good judgment,
coordination and mental ability. Any person who lacks any of these
qualities must not be allowed to operate a machine.
Any person who is associated with working on the SUPER STACKER,

such mechanics, must respect all safety signals and be aware of their
own safety as well as that of others. Machine personnel such as
mechanics are required to be aware of any particular procedures
concerning their jobs on the machine.

Planning the job
Many accidents can be avoided provided that the worksite is correctly

organized. The person in charge must have a clear understanding of
the work to be done, consider all dangers on the jobsite, develop a
plan to do the job safely, and then explain the plan to all concerned.
Factors such as these should be considered:
-What crew members are needed and what responsibilities will they
be given?
- How will the assistant communicate with personnel members?
- What equipment is required to perform the handling in perfect

safety?
- Is the machine the most suitable means?
- Are there any high tension lines to be avoided?
- Is the ground sufficiently stable to support the machine and its load?
- Are there any extreme climatic conditions such as wind or intense

cold?
- What steps must be taken to keep staff who are not required for the
operation out of the working area of the machine?

Operator's safety check
The operator must make a safety check before starting work each day
to see that the machine is in proper order. Among other things, the
operator should:
- check the machine log book to see that periodic maintenance and
inspections have been performed and all necessary repairs made.
- check the operation of boom hoist upper angle limiter device, backup
alarms, and other operator aids.
- carefully inspect boom, outriggers, spreader, etc. according to the
type of machine.
- be sure no unauthorized modifications have been made, such as
added counterweights or improper repairs to the boom.
- check for hydraulic oil leaks.
- after starting the engine, check all instrument readings.
- test all movements for proper operation.
- check brakes and clutches.

Operating precautions
An error in determining lifting capacity can cause an accident.
Numerous factors must be taken into account:
The reach is the distance from the wheels of the machine to the axis
of the spreader. Note that the boom bends, increasing reach, when
the load is lifted.
Lifting a load which is outside the load table, reasoning that the act of
lifting will bring it into the load table, is extremely dangerous. The
machine could tip and fall over if the load is too heavy.
Always remain within the load table. The driver must reduce the load
as a function of site conditions and use his judgement to evaluate
what loads can be lifted in perfect safety.
Machines may fall over or tilt if the ground is not stable enough to
support their weight.

Establish the stability of the ground on which the machine is to

manoeuvre. Make sure that the ground can support the machine.
Avoid ground which is soft, unstable or partially frozen. If the machine
is working near a trench, this must be buttressed or filled in to avoid
subsidence.
The lifting capacity of a machine is given for a maximum angle of 60°.

Any greater slope considerably reduces its load capacity.
People behind the machine may be struck by its counterweight if there

is not enough free space. Carry out a test rotation, unladen, before
starting work.
Position the machine so as to leave enough space between the

counterweight and any obstacles (minimum 0.60 m).
Many injuries have been caused by people being struck by hooks,

loads or containers. To avoid this, remain outside the zone of
operation of the machine.
Never lift people with the machine. Use stepladders, scaffolding, work
platforms, elevator platforms or other equipment designed for the
purpose and conforming to standards in force.
Many injuries have been caused by high tension lines. Such accidents
can be avoided by obeying the simple rules given below.

The machine runs on pneumatic tyres:

After a site machine has been in contact with a high tension overhead
structure, tyres (with a metal internal structure) which have not been
destroyed do not retain either their insulating qualities or their
mechanical strength. If they do not burst immediately, they often burst
later on, after prolonged exposure to sunlight.
The machine should not be approached until the temperature of the
air in the tyres has dropped.
The tyres must be removed and scrapped after the machine has been
extricated from contact with the power line.
WARNING - Properly planned work and assiduous supervision

provide better protection than any other measure. Insulated cages and
proximity detectors have their limits and are subject to unpredictable
breakdown. Protection cables and insulated cages only protect the
machine, and can become electrically conductive in the presence of
dust or water.
Proximity detectors may be put into use for various combinations of
HT lines and movements of vehicles or equipment by the crane itself
or other parameters. It can be very dangerous to put complete trust in
these systems, as the driver may believe himself to be protected when
he is not.
In the event of thunderstorms, take the following precautions:

- If possible, put down the load and stow the boom.
- If the sudden onset of a thunderstorm takes you by surprise, stop the
engine and leave the machine.
- If the machine is struck by lightning, check its general functioning
before starting to use it again.
You should always be aware of the weather forecast for your region.

(* ) Always find out the position of any high tension lines before
starting work. It is advisable to keep more than 6 m away from high
tension lines. Make sure that you always stay as far from the lines as
possible, and never go within the minimum distance.
Always respect these precautions if there are high tension lines in the
vicinity.
Informer the company responsible for the HT lines (E. D. F in France)

before starting work.
Use an assistant to maintain a safe distance between the machine
and the HT lines. The driver is not best placed for estimating
distances.
Warn people to stay well away from the machine all the time. If the
load has to be moved to be positioned, check with EDF for any special
precautions such as insulated points or potential nodes.
Manoeuvre slowly, leaving yourself plenty of time to react to any
problem that may arise, and use two different means to estimate the
distance between the high tension lines and any part of the machine.
Conduct in case of accidental contact.
Conduct is not laid down by regulations, but depends on an analysis
of immediate risks. It should form part of the operator's instructions or
training.

The apparatus or machine is in working order:

Without leaving his cab, the driver must move the machine away from
the live electrical structure.
The apparatus or machine is no longer in working order:
Without leaving his cab, the driver must warn others, by signs or
verbally, not to approach the machine or apparatus. (Risk of step
voltage as long as the fault persists.) If it is essential that the driver
should leave the cab of the apparatus or machine, he should jump to
the ground, making sure he is not in simultaneous contact with the
ground and the machine.
Move over the ground:
either by jumping, with both feet together
or taking very small steps.
(* ND 1879-147-92 INRS Direct
contact of equipment with
No one should approach the machine again until it is certain that the
overhead electricity lines.)
electrical equipment has been definitively isolated and the absence of
any voltage has been verified (verification effected in liaison with the
electric power supplier).

People can be injured if the boom, load or spreader are moved before
everyone is clear.
Make sure everyone is in a safe place before moving the boom, load
or spreader. Do not move loads over people. Do not allow the load to
bump or catch on anything.
Rapid spreader swings or sudden starts and stops can cause the
attached load to shift.
Dirty windows, darkness, bright sunlight, fog, rain, and other

conditions can make it difficult for the operator to see.
Keep windows clean. Do not operate if you cannot see clearly enough
to operate safely.
The wind can also lead to loss of control of the load by breaking the
boom and by causing the machine to topple. High altitude wind can be
stronger than at ground level. When the wind speed exceeds 12. 2
m/s (= force 6 on the Beaufort scale), the stacking of more than 2
containers is prohibited. When the wind speed exceeds 19. 8 m/s (=
force 9 on the Beaufort scale), all use is prohibited.
Do not raise any load if the wind is uncertain or unsettled. Lower the
boom if necessary. Refer to the load diagram tables.
Always wait until the machine has stopped. Do not jump on or off.
Always use both hands and make sure you have a good footing.
Slippery floors, footplates, steps, tools, trash, or other loose items can
cause falls.

KEEP THE MACHINE CLEAN AND DRY.
A damaged machine can be dangerous and cause an accident. A

machine with a telescopic boom should be checked weekly to make
sure that there is no distortion of the base or guide shoes. In either
case, the reduction in strength is very difficult to estimate.
Inspect the boom of the machine daily.

Never use a damaged boom.
NOTE - Because the boom is made from high-strength steel, special

procedures are necessary to effect repairs.
Consult your concessionaire.
The booms of a machine may twist if subjected to lateral loads

(sideways traction).
Typical causes of lateral stress are:
Sudden slewing when starting or stopping.
Using the boom to pull a load
Wind force
Lifting when the machine is not level.
Be careful not to exert lateral efforts.
If the boom is used for purposes other than lifting, it may break.
Never allow the boom to bend under the weight of its load or from any
other cause.

Attempting to lift a load which is stuck, frozen or anchored to

something may cause the machine to fall over or the boom to break.
Make sure the load is not restrained before any attempt at lifting.
Trying to repair or adjust equipment with a load or with the boom

raised could release machinery and let it move unexpectedly.
Always lower the load to the ground and the boom into rest position
(horizontal) before doing any maintenance or repair work.
Pressure in hydraulic systems can be retained for long periods of time.

If not properly released before maintenance staff attempt to work on
the hydraulic systems, this pressure can cause machinery to move or
allow hot oil and hose ends to shoot out at high speed.
Release system pressure before attempting to make adjustments or

repairs.
Lower the suspension of the machine to release the pressure in the
hydraulic circuit of the suspension accumulators.
.

As with all heavy equipment, care must be taken when moving about,
both on or off the work site.
Pay attention to workers, high tension lines, awkward sections with

low clearance such as bridges, limited load roadways, slopes or rough
ground. Get help from an assistant when manoeuvring in limited
spaces.
It can be dangerous to leave a machine without taking precautions.
Before leaving the machine, the driver must take the following
measures to ensure that the machine does not move:
- lower the load to the ground and lower the boom if necessary
- apply the parking brake
- move the gear selector into neutral position (n)
- stop the engine.

L.M.I. SAFETY INSTRUCTIONS
THE FOLLOWING INSTRUCTIONS APPLY WHEN THE LOAD

MOMENT INDICATOR (LMI) SHOWS AN OVERLOAD.
SHUT-DOWN IN THE CASE OF OVERLOAD WHEN

SETTING DOWN A CONTAINER:
When the machine gets into a position in which the LMI detects an
overload and the functions Lower Boom and Extend Boom are shut
down (in addition to the audible and visual warnings), the machine
must not be moved.
In such a case, the boom must be raised until it reaches a safe
position and the warning signals cease.
SHUT-DOWN IN THE CASE OF OVERLOAD WHEN

ATTEMPTING TO LIFT A CONTAINER:
When the machine gets into an overload position while attempting to

lift a container, so that the audible and visual warnings are triggered,
the load can be lifted by raising the boom.
The machine must not be moved as long as the warning signal is
active.
The machine can only be moved safely when the warning signal has
ceased.
As a general rule, movement under load in front of a pile of containers
is only permissible in first gear, and must be effected with great
caution.
When the overload warning signal goes on in this configuration,
movement of the machine is prohibited.

Transport of containers on the terminal may only be effected

with the telescopic boom completely retracted and inclined at about
45°.
The speed of advance must be judged so that it is possible to stop
with no danger to any third party and without having recourse to
sudden braking.

Summary of the various safety devices installed on the machine.

SAFETY DEVICE MODE OF OPERATION LOCATION ON DESCRIPTION
COMPONENT
MACHINE
P11-P12 Spreader damping Spreader damping On chassis to Controls spreader

neutralization right of cab locking in lifting mode
P13 Lowering, raising and Active with cut-off of extension At front under Controls cut-off of
extending telescopic unit and raising of telescopic unit engine cover raising and extension of
telescopic unit
P47 Speed limitation on Boom extended: Limitation to Head of boom Limits speed of vehicle
locked container 1st gear with container locked
Boom retracted: Limitation to
1st and 2nd gears
S25 Anti-tipping Active with cut-off of raising, On rear axle Prevents the capacity of
lowering and extension of the machine from being
boom exceeded
PM1 Parking brake safety device Active when gearbox is in Under cab Prevents engagement of
neutral gear while parking
brake is on
Y1-Y2 Position of catches Active and enables locking or On spreader Controls engagement of
Y3-Y4 (twistlocks) indicator lights: unlocking of container catches catches in container
white
Y5-Y6 Locking/unlocking Active with inhibition when On spreader Controls rotation of

Y7-Y8 container, indicator light: lifting gear is raised catches catches
green
S9-S10 Inhibition left and right Activates inhibition of slewing Near spreader Controls orientation of
slewing hydraulic slew ring spreader
Gear selector Starter safety device Active requires gearbox neutral In cab Prevents engine from
before starting starting if gearbox is not
in neutral
Gear selector Reverse audible warning Active with warning linked to In cab Switches on audible
change into reverse gear warning and rear lights
Prevention of container Activates shut-down of boom Neutralizes the

crushing lowering and boom extension functions of boom
lowering and boom
extension

Chapter III
Controls and
operation
P 62440-53 Chapter III - Page 1

Control identification
The reference numbers for the instruments and controls shown in the
cab illustrations correspond to the numbers in the following text. The
text identifies the controls and instruments, and describes their
operation.
Notes: All standard and optional controls for this machine are
identified and described in the following list. The following list therefore
contains controls and instruments which are not furnished on every
machine.
Before attempting to operate this machine, the operator should

carefully study all of the information in this section and in the safe
operating practices for super stacker users at the front of this manual.
The operator should become thoroughly familiar with the location and
purpose of each control on the machine.
FOR MACHINES EQUIPPED WITH L.M.I.
THE CRANE OPERATOR OR JOBSITE MANAGER WILL BE HELD

TOTALLY RESPONSIBLE FOR THE USE OF ANY CRANE
FUNCTIONS APART FROM THOSE EXPRESSLY DESIGNATED BY
PPM WHEN THE SAFETY DEVICE INDICATOR IS OVERRIDEN.
PPM CAN IN NO WAY BE HELD RESPONSIBLE FOR ANY
ACCIDENT THAT MAY OCCUR WHEN THE CRANE IS BEING
USED WITH AN OVERRIDDEN LOAD MOMENT INDICATOR.

Cab
1
2
1 / Steering wheel (actuates rear wheels)
2 / Gear shift control lever

5
3 / Service brake pedal and gear box neutral position
4 4 / Service brake pedal
3 5 / Accelerator pedal
6 / Combined switch - lights - blinkers - horn

Control desk panel, centre

right
16
17
15
13
14
13 / Working light warning light
14 / Revolving beacon warning light
15 / Headlights warning light
16 / Direction indicator warning light
17 / Parking lights warning light


right
22 18
23 19
25
24 20
25
21
18 / Torque converter oil temperature warning light
19 / Gear box oil pressure warning light
20 / Anti-tipping device warning light
21 / Spreader lock override warning light
22 / Brake oil pressure warning light
23 / Parking brake warning light
24 / Anti-tipping device override warning light
25 / Excessive speed warning light


right
30
26
31
25 27
32
28
33
29
26 / Battery charging warning light
27 / Engine preheating indicator light
28 / Clogged oil and air filter warning light
29 / Not used
30 / Alarm warning light STOP engine
31 / Engine fault warning light
32 / Low hydraulic oil level warning light
33 / Fuel minimum level warning light

Piggy-back spreader warning light

(Option)
34
35
38
36
37
39
40
34 / Correct pad clamping and hoist authorization green

warning light
35 / Opened leg warning light
36 / Closed leg warning light
37 / Unfolded leg warning light
38 / Folded leg warning light
39 / Clamped leg warning light
40 / Unclamped leg warning light


left
44
45
46
40 / Compteur horaire 43
41 / Unité centrale MDM-Ecran

42
42 / Hour meter
43 / Torque converter oil temperature gauge
44 / Fuel gauge
45 / Gear box clutch oil pressure gauge
46 / Hydraulic oil temperature gauge

Control desk panel, lateral

right
71 70
70/A
72
73
70 / Joystick controller
(raise/lower - extend/retract boom)
70B/ High speed boom functions control

73
71 / Spreader side shift control
72 / Spreader swing control
73 / Twist locks lock / release control

Control desk panel, right
74
75
74 / Spreader damping lock switch
75 / Spreader beam telescoping switch

77 76
82
78
80
81
79
76 / Ignition switch
77 / Engine shut down control
78 / Engine test code control
79 / Hazard warning lights control switch
80 / Engine test control
81 / Parking brake control
82 / Outrigger control (Option)

Piggy-back spreader controls (Option)
83
84
83 / 2 or 4 legs piggy back selection control
84 / Piggy back leg control lever (option)

86 87
88 89
86 / Spreader lock override control
87 / Anti-tipping device override control
88 / Override key for gearbox operation electronic control

unit
89 / Selector control for gearbox automatic or manual

mode.
90 / Tilt control (option)

90

Ceiling panel controls

104
103
105
100
111
112
100 / Revolving beacon control switch
101 / Cab rear windshield wiper control switch
102 / Air conditioner controls (ESC)
103 / No. 2 working light control switch
105 / Headlight control switch
111 / Right side courtesy light
112 / Right side map reader light switch
103
102 101

Box behind seat
200 / Gearbox operation electronic control unit

Fuse board
(Box behind seat)
F1 - 10A – Battery isolator safety device
F2 - 5A – Parking brake
F3 - 5A – Left and right ceiling light
F4 - 15A.- Screenwiper, front - rear - cab roof -
F5 - 5A – Screenwasher – audible warning – indicator

lights and receivers
F6 - 20A – Working light, cab – spreader – chassis.
F7 - 15A – Stop light – direction indicator lights.
F8 - 20A – Working light, cab - boom.
F9 - 20A – Rotating beacon lights
F10 -5A – Reversing light
F11 - 15A – Evaporator condenser compressor air

conditioning
F12 - 15A – Spreader operating indicator lights - Container

lock sensor – Container release sensor – Low speed
telescoping spreader.
F13 - 15A – Horizontality spreader – Lifting up – safety of

torque – Hydraulic oil coolant.
F14 - - 15A – Condenser.
F15 - 20A – Gearbox.
F16 - 15A – Dipped headlights.
F17 - 10A –Spreader functions
F18 - 5A – Front outrigger option
F19 - 10A – Mobile cab.
F20 - 10A – Neutralization shock absorption.

F21 - 10A – Spreader slewing - Spreader side shift.
F22 - 10A – Flow rate cab joystick.
F23 - 5A – Stop engine.
F24 - 20A – Headlights main beam – Audible warning.
F25 - – Not used.
F26 - – Not used.
D27 - – Diode.
D28 - – Diode.
F29 –3A –Protection functions pressure switch air

conditioning.
F30 - – Not used.
F31 - – Not used.
F32 - – Not used.
F33 - – Not used.
F34 - – Not used.
F35 - – Not used.
F36 - – Not used.
F37 - – Not used.
F38 - – Not used.
F39 –10A – Battery isolator – Starter motor.
F40 –10A – Emergency warning lights.
F41 –10A – Sidelights.
F42 –5A – Rev. counter – Hour meter.
F43 –10A – Vehicle radio –24V/12V converter.

F44 –10A – Engine electronic unit.
F45 –10A – Engine electronic unit.
F46 - – Not used.
F47 - – Not used.
F48 - – Not used.
F49 - – Not used.
F50 - – Not used.
F51 - – Not used.
F52 - – Not used.
F53 - – Not used.
F54 - – Not used.
F55 - – Not used.
F56 - – Not used.
F57 - – Not used.
F58 - – Not used.
F34 - – Not used.

General fuses
(Battery compartment)
PF100 - 100A – General protection of functions after

isolation of battery
PF80 -80A – General protection of starter after isolation of

battery
PF50 -50A – General direct protection of battery
PF100
PF80
PF50

Spreader operating
warning lights
RED - TWIST LOCKS
released indicator light
WHITE - Position indicator

light signalling possibility
of actuating the TWIST
LOCKS
GREEN - TWIST LOCKS

applied indicator light
For conditions of use, see paragraph

(locking onto a container).

Cab
1 / Steering wheel (rear wheel steering)
The angle of the steering column can be adjusted using the

handwheel A situated on the left, under the steering wheel.
When the wheel is turned to the right, the wheels turn to the left.
When the wheel is turned to the left, the wheels turn to the right.
A
WARNING
this machine has rear wheel steering: check path of rear
wheels when steering.
Front
CAUTION
Keep in mind that the space required by the rear of the
machine when turning is greater than for other machines due
Rear
to the rear wheel steering.
2 / Gear change lever
There are two possible transmission modes.

Manual and automatic.
Forward and reverse travel drives are selected when the machine is at
a standstill. To check if the transmission is in neutral, carefully press
the accelerator: the machine should not move.
When leaving the machine at the end of a shift, or whenever
necessary, use the red catch to lock the gear lever in neutral position
(N) so as to prevent any unintentional movement.

Cab
3 / Accelerator pedal
Press this pedal to increase engine speed . Release the pedal to

decrease engine speed. Engine speed will return to idle when the
pedal is released.
4 / Service brake pedal
To be used in normal travel.
5
5 / Service brake pedal and gear box neutral position
4 To be used when approaching a container (see procedure).

This pedal disengages the transmission clutch and brakes the
3 machine at the same time.
Caution
Do not use left-hand brake pedal for normal travelling.
6 / Combination control: lights - direction indicators -

audible warning (horn) – screen wipers
Direction indicators (blinkers)
- left turn indicators: lever up.

- right turn indicators: lever down.
A flashing repeater lamp confirms that the indicators are working
properly.
Audible warning (horn)
Press the end of the lever, whatever position it may be in.

Lighting
Ignition off
parking lights 105 go on.
lever towards driver: headlight flash
Ignition on
- Lever pulled once towards driver: headlights (main beam)
The blue repeater lamp goes on with main beam headlights or
headlight flash.
Screen wiper – screen washer
Position 1: Stop - Position 2: Intermittent - Position 3: Low speed

Position 4: High speed.
For screen wash, move the body of the control handle towards the
centre.
13 / Working light warning light
16 This warning light comes on when one of the working lights is

switched on with control 103 or 104.
17
14 / Beacon light warning light
15
This indicator light comes on when the rotating beacon light is
13 switched on with control 100.
14
15 / Full beam headlights warning light
This warning light comes on when the full beam headlights are turned
on with control 6.
16 / Turn signal warning light
This indicator lamp goes on when the direction indicators have been
selected with control 6.
17 / Parking lights warning light
This indicator light will come on when switch 105 is placed in the
parking light position.

18 / Torque converter oil temperature warning light
22 18 This warning light is connected to thermometer 43 and comes on

when the torque converter oil temperature is too high.
23 19
25
If this light goes on, proceed as follows:
Lower the container, shift the transmission to "N" (neutral) position,
24
20
accelerate the engine to 1,200-1,500 rpm for two to three minutes or
25 until the temperature reading is in the normal range.

21
19 / Clutch oil pressure warning light
DANGER The warning light comes ON when clutch oil pressure is below 17 bar.
Never used the machine with the anti-
This warning light is connected to pressure gauge 45.
tipping device overridden, or only in
exceptional circumstances under the If pressure drops, stop the engine immediately and ascertain the
responsibility of the operator. Be
cause.
doubly careful when manoeuvring.
If the pressure drops, stop the engine at once and

ascertain the cause.

DANGER
Never use the machine with This warning light blinks when the anti-tipping device override is
the spreader safety lock
overridden, or only in activated by means of the key 87 and the audible alarm is activated..
exceptional circumstances
under the responsibility of the 21 / Spreader twist lock override warning light
operator.
This warning light comes when the spreader twist lock override is
activated with key 86. The audible alarm is activated.
DANGER
Never actuate the control lever(73) (spreader lock/release
DANGER control) with a suspended container.
Do not start travelling Make sure the container is correctly positioned before lifting.
until the warning lamp (22) Failure to respect these instructions could cause serious damage
has gone out. or injury to the machine and to staff.
The warning lamp (22)
goes out when pressure
reaches 105 bars.
22 / Brake oil pressure warning light
This warning light goes out when the braking pressure reaches 105
bar (minimum operating pressure).

23 / Parking brake warning light
This light will come on when the parking brake switch 81 is applied.
22 18

23
25
19
This warning light goes on when the maximum permissible load is

24
20 exceeded.
The audible warning sounds. Remaining authorized functions are:
25
21 Raise Boom - Retract Boom.
25 / Overspeed warning light (Red)
Immediately slow down if this warning light comes on.
26 / Battery charging warning light
This warning light comes on if the alternator does not charge the
30
26 batteries - ascertain the cause.
31
25
27 27 / Engine preheating indicator light

32
28
28 / Clogged hydraulic oil and air filter warning light
33
29
Warning light comes on (with warm oil) when return filter to hydraulic
tank is clogged. When it remains lit, replace the filter cartridge. It also
lights up when the air filter is clogged. Stop the machine and rectify
the problem.
29 / Not used
30 / STOP engine alarm warning light
This warning light goes on when the engine protection system is no

longer in a position to perform its function. In such a case, the engine
must be stopped. Park the machine in a parking area or on the hard
shoulder of the road, making sure that it does not represent a traffic
hazard. STOP the engine.

31 / Engine fault warning light
QSM engines are equipped with a protection system.

This system analyses different parameters, such as coolant
temperature, coolant level, oil pressure, overspeed, etc.
It warns the driver of a functional problem by means of the engine fault
warning light and takes preventive measures to protect the engine by
gradually reducing power and speed (see procedure "Reading fault
30 codes").
26
31 32 / Low hydraulic oil level alarm warning light

25
27
32 If this light goes on, make sure that there are no hydraulic oil leaks
28
and make up the hydraulic oil level immediately.
33 DO NOT FORGET to respect servicing instructions.

29
33 / Minimum fuel level warning light
If this light goes on, refill the fuel tank immediately.

Piggy-back spreader warning light

(Option)
34 / Correct pad clamping and hoist authorization green

warning light
34 This warning light indicate that pads for container handling are
correctly positioned in their locations and lifting of the container is
35 permitted.
38
36
35 / Opened leg warning light
37
This warning light comes ON when upper beams legs are fully
39 extended by activating switch Ref. 85.
40
36 / Closed leg warning light
This warning light comes ON when upper beams legs are fully
retracted by activating switch Ref. 85.
37 / Unfolded leg warning light
This warning light comes ON when legs are fully unfolded by

activating switch Ref. 84.

38 / Folded leg warning light
This warning light comes ON when legs are folded away by activating
switch Ref. 84.
39 / Clamped leg warning light

34
This warning light comes ON when legs are fully clamped by

35 activating switch Ref. 84.
38
36
40 / Unclamped leg warning light
37
This warning light comes ON when legs are fully unclamped by
39 activating switch Ref. 84.
40

44 45
42 / Hour meter
46 The hour meter operates when the engine is running.
43 / Torque converter oil temperature gauge

43
42
Normal operating temperature: 82 to 93°C (180-200°F)
Maximum temperature not to be exceeded: 110°C (230°F)
NOTE: if the converter oil temperature reaches the maximum value

shown above:
- shut down the vehicle
- shift to neutral (position "N")
- accelerate the engine to 1,200/1,500 rpm for two to three
minutes. (Until the temperature returns to normal
operating value).
Warning light 18 comes on when converter oil temperature reaches
110°C.
44 / Fuel gauge
This gauge indicates the amount of fuel remaining in the fuel tank.
45 / Gear box clutch oil pressure gauge
Normal operating pressure: 16.9 to 19.6 bar (240 to 280 PSI)

If the pressure drops abnormally, stop the engine and ascertain the
cause.
46 / Hydraulic oil temperature gauge
Linked with hydraulic oil cooler temperature switch (starts up at 450°C

-1,130°F).The temperature may reach 80°C (1,760°F).
Stop the engine and ascertain the cause.
CAUTION
DO NOT EXCEED THE TEMPERATURE OF 80°C.

Control unit, right side

71 70
70 / Boom lift/telescope joystick
72 This joystick controls raising/lowering and telescopic

extension/retraction of the boom.
73
70 /1 - Raise boom 2
4
70 /2 - Lower boom 3
1
70 /3 - Retract boom
70 /4 - Extend boom
Any of these functions can be performed while handling a container

and a 45-degree joystick movement will produce a combined action
such as raise boom with extend boom.
70A / High speed boom functions control
This control is used for high speed execution of the following boom
functions:
Raise boom – Extend boom – Retract boom
71 / Spreader side shift control
This control is used to shift the sliding trolley of the spreader, either to
71/1 the right (71/2) or to the left (71/1).
71/1 - Side shift to the left

71/2 Press the button to shift the spreader to the left.
71/2 - Side shift to the right

Press the button to shift the spreader to the right.

72 / Spreader slewing control
This control is used to slew the spreader either to the right (72/2) or to
the left (72/1). Before slewing the spreader, the slewing function must
be released by pressing control 75.
72/1
72 /1 - Slewing to the left.
Press the button to slew the spreader to the left.
72/2 72 /2 Slewing to the right
Press the button to slew the spreader to the right.
73 / Twist locks lock/release control lever
This control is used to lock or release the twist locks.
- Releasing
Push the lever to the left to release the spreader from the container.
- Locking
Push the lever to the right to lock the spreader to the container.
DANGER
Use this override only for very
special cases and under the During the operation of locking onto the container, all boom
responsibility of the site
manager. movements are prohibited.
Be aware of the damage to the Locking can only be performed if all four locking contactors are
machine and injury to
personnel that could result pushed in.
from lifting a load with the If locking cannot be effected, reposition the spreader.
device overridden.
Once all the four locking contactors are pushed in, the white spreader
indicator lights go on. The functions Lower Boom and Extend Boom
are then inhibited. These functions can be made available again by
using the LMI override key.

Position 1: The spreader's shock absorption function is immobilized.

Position 2: The spreader's shock absorption function is enabled.
74 IMPORTANT:
It is essential to immobilize the spreader's shock absorption
function in order to travel carrying a container in logitudinal
position.
75
75 / Spreader beam telescoping control
This control telescopically extends or retracts the beams of the

spreader.
Switch to the right: beams extend.
Switch to the left: beams retract.

76 / Ignition switch
This switch is used to power the electrical system and to start and
stop the engine .
(See chapter: Stopping the engine.)
77 76
77 / Engine shut down control
Press to stop the engine.

(see paragraph: Stopping engine)
78
79
IMPORTANT
As the engine is turbocharged, it is advisable to let it run for a few
80 moments at idling speed before stopping it.
81
78 / Engine test code control
(see procedure "Reading fault codes").
79 / Hazard warning lights control
This control activates the hazard warning lights.
80 / Engine test control
(see procedure "Reading fault codes").
81 Parking brake switch and gear box neutral position
Use this control to apply the parking brake, warning light 20 comes on.
When the brake is released, warning light 20 goes out. Do not use as
a road brake.

82 / Outrigger control (Option)
82 This lever allows the vertical front outriggers to be raised or lowered.

The gear selector (ref. 2) must be in the neutral (N) position and the
machine at a standstill to enable use of this function.
Push the control forward to lower the outriggers, warning light into the
control will come on.
Pull the lever backward to raise the outriggers, warning light into the
control will go out.
The outriggers can only be set down when the machine is at a

standstill (gear selector in neutral position).
The operator can raise the outriggers whenever he wishes (under
certain conditions), but it is impossible to drive the machine until the
outriggers had been fully raised.
If a gear is selected and the outriggers are not fully raised, a buzzer is
activated. Driving the machine will be impossible until the outriggers
had been fully raised.
Two detectors (on the telescoping and derricking functions) inhibit
raising of the outriggers until the boom is brought into a position
allowing safe driving with acceptable axle loading.
The outriggers can be raised whatever the position of the spreader as
long as there is no suspended load.

Outrigger operation
Use the outrigger to pick up a container at a radius of up to 6.40m.
The safety system does not allow the outrigger to be raised until the
machine is brought back into a safe load carrying configuration
allowing the machine to be driven.

Piggy-back spreader controls (Option)
83 / 2 or 4 legs piggy back selection control
Refer to chapter on Piggy Back operation.
This three position switch determines which legs will be controlled by

83 lever Ref. 84. The following settings determine which legs will be
controlled:
AR/AV Position : 4 legs selected
AV Position : 2 front legs only selected
AR Position : 2 rear legs only selected
84 / Piggy back leg control lever (option)
84 84 /1 Legs lowering
84 /2 Legs lifting
84 /3 Leg opening
84 /4 Leg clamping

86 / Spreader locking override control
DANGER:
Never use the spreader lock/release control (73) with a container
suspended from the spreader.
Make sure that the container is correctly positioned before lifting
it. Failure to respect certain safety rules can cause damage to the
machine and injury to personnel.
DANGER Use this override only for very special cases and under the
It is STRICTLY PROHIBITED to responsibility of the site manager. Be aware of the damage to the
override the anti-tipping device. machine and injury to personnel that could result from lifting a
load with the device overridden.
88 / Override key for the electronic gear box control unit

86 87
Only to be used in case of failure of the APC100.

It provides one forward and one reverse speed for emergency use.
88 89
89 / Gearbox automatic or manual mode selection control
This control is used to select automatic or manual mode of the

gearbox.
90 90 / Tilt control (option)
This spring centered switch tilts the spreader to the left and to the
right. Push and hold this switch to the left to lower the container on the
left side. Push and hold this switch to the right to lower the container
on the right side.

100 / Revolving beacon control
This control switches on the rotating beacon; indicator light 14 goes

on.
101 / Cab rear screen wiper control
This control is used to activate the cab rear screen wiper.

103 104
102 / Air conditioner controls (ESC)

105
This control starts the air conditioning. Turn the knob for cab
100
111 ventilation.
112
This control switches on the working lights of the cab and the
spreader.
This control activates the boom working lights.
103
105 / Road light control switch

102 101
This control turns on the front and rear road lights. Warning light 15
comes on.
111 / Right side courtesy light
112 / Right side map reader light switch

200 / Electronic gear box control unit
YELLOW WARNING LIGHT: This lamp lights up when one of the two
speed sensors indicate zero speed. As soon as the machine is
moving, this lamp goes out.
GREEN WARNING LIGHT: This lamp lights up when the throttle
pedal is depressed.
RED WARNING LIGHT: This lamp indicates that an internal APC100
problem has been detected. In this case, all the outputs of APC100
are automatically deactivated. The APC100 box must be repaired.
Immediately park the machine on the roadside and call a TEREX
specialist.

Engine error code display procedure
The QSM control system can display and record operational

anomalies in the form of a fault code. This code provides easy
identification of engine problems. The codes are recorded in the ECM
and can be read from the engine fault indicator lights (24 and 23).
Verifying fault codes

83
- Switch on ignition.
- The Stop Engine control 81 must be in released position.
80 If no engine fault code has been recorded, the two indicator
lights 30 and 31 will go on and then off again when the engine starts.
If fault codes have been recorded, the two indicator lights will
go on.
30
- Stop the engine and release the Stop Engine control.
- Press the Engine Test control 80.
31 The code will be flashed as follows:

Lamp 31 flashes once.(start of code)
After this, the number of flashes of the Stop control 30

corresponds to a digit of the fault code (1st digit of the code).
There is another pause of 1 to 2 seconds.

The next digit of the code is given by the number of flashes of

indicator light 30 (2nd digit of code).
There is another pause of 1 to 2 seconds.
´
The last digit of the code is given by the number of flashes of
indicator light 30 (3rd digit of the code).
Indicator light 31 flashes once. (End of code).
Refer to the table of engine fault codes in the appendix to identify the
engine problem.
´ ´ ´ ´
1 flash 1 to 2 s 2 flashes 1 to 2 s 4 flashes 1 to 2 s 4 flashes 1 to 2 s 1
flash
Fault code = 244
To flash the next fault code, press control 83.

Switch the engine test control 80 back again to quit test mode.

Seat adjustments
Weight adjustment
2/3 For maximum comfort and protection against vibrations, it is important

for the suspension to be correctly adjusted to your weight.
1
Turn the adjuster knob 1 until the indicated weight (read inside the
transparent knob) matches your weight in kilograms (one pound = 2.2
kg). The optimum adjustment is for the suspension to be in the middle
of the vertical stroke - "mid-ride" position - when normally seated.
Height adjustment
After having adjusted the weight, the rake of the seat and cushion as
4 well as stability can also be adjusted by operating levers 2 and 3.
Backrest rake adjustment
Lift lever 4, set backrest to desired angle and release lever.
Distance adjustment
5 Operate the control lever 5, adjust the seat alone to the required
position.
Lever 6 for the seat + bracket.
Make sure that the mechanism is properly secured after adjusting.
Headrest
The height of the head-rest is adjusted by pulling upwards or pushing

downwards and the angle is adjusted by pivoting movement from front
6 to back.

Right control panel bracket lifting handle
Use this handle to raise the control panel bracket to give access to the
right-hand cab door.
Unoccupied passenger seat (OPTION)
To avoid annoying vibration of the unused passenger seat, set the

weight adjustment to maximum, set the height adjustment as low as
possible and lock the distance adjuster.
Recommended seat adjustment
1 - Push the seat+ bracket back as far as possible using lever 6.

2 - Push the seat only forward to the best position for using the
pedals. Control 5.
3 - Adjust the position of the seat and back using levers 3-2 .
4 - Adjust the rake of the back using lever 4.
5 - Adjust the hardness of the seat using lever 1.

Recommendations for minimizing levels of vibration of the

machine.
The level of vibration when driving depends on the following

conditions:
the state of the ground: potholes, lumps, etc.
driving conditions: speed, cornering, braking, etc.
The driver chooses his own speed and route as a function of the
terrain.
The result is a broad spectrum of levels of vibration which can be
minimized by respecting the following recommendations:
- Choose the machine and its equipment as a function of the
task
- Choose a machine in perfect condition (tyre pressures,
condition of brakes, steering, etc.)
- Changes of direction, braking, acceleration, changes of
speed, all move the load and the equipment.
- Keep the area where the machine operates in a good state.
Remove large stones and obstacles
Fill in holes
Schedule maintenance work on the operating area.
- Use a seat conforming to ISO 7096 and keep it in good
condition and correctly adjusted.
Adjust the seat and suspension as a function of the
weight and height of the operator.
Repair the adjustment and suspension mechanisms if
they are faulty.
- Suiting the speed of the machine to the nature of the ground
reduces vibration.
Slow down on rough ground.
Avoid obstacles and bad surfaces.

Machine operation
Machine operation
Both this paragraph and the instructions on safe operating practices at

the beginning of this manual must be studied before the machine is
driven.
The following instructions constitute reminders rather than advice,

since the manufacturer knows that this equipment will be entrusted to
an operator of confirmed competence.
Preliminary Inspection and Adjustments
Every day, before using the machine, go through maintenance check

list "A" of this manual.
Clean the windows, headlights, and mirrors to ensure full vision. Also
make sure the mirrors and operator's seat are properly adjusted.
Starting the engine.
To start the engine, proceed as follows:

1- Put the Forward/Reverse lever in neutral position (N).
2- Tighten the parking brake.
3- Sound the audible warning.
4- Start the engine (normal temperature conditions above -12°C
(10°F).

This engine is designed to start without any aid to starting at

temperatures above -12°C (10°F). If the temperature is lower than -
12°C, it is necessary to use an aid to starting or to change the engine
oil to 15W40. For starting at temperatures under –12°C (10°F)
proceed as described in 4.
Warning
Do not operate the starter motor for more than 30 seconds at a
time. If the engine fails to start within that time, release the
engine start switch and wait two minutes before trying again. If
this precaution is not followed serious damage to the starter
motor may result.
IMPORTANT
Turn and hold the key in the start position until the engine fires.
The power steering only operates
Release the key as soon as the engine fires.
when the engine is running. It is
dangerous to shut off the engine
4. To start the engine under cold conditions, temperatures under -
while driving the machine.
12°C (10°F), using a starting aid, proceed as follows:
A. Perform steps 1 and 2.
B. Spray a small amount of ether into the air intake.
C. Turn the key and start the engine as previously described in step 3
above.
NOTE - During the period of starting, extra batteries (this is a 24 volt

electrical system) may be required. This will depend on the charge
condition of the machine's battery.
NOTE - Use ether sparingly and cautiously. If too much ether is used,
it has a retarding effect in starting the engine. Also, ether is not
effective at temperatures below -23° C (-10° F).

WARNING
The engine Oil Pressure Indicator Light (23) and the
Transmission Oil Pressure Indicator Light (19) will illuminate until
the oil pressures reach the normal operating pressure at start-up.
If oil pressure does not reach normal operating pressure within
15 seconds after start-up, stop the engine immediately and
correct the cause of low oil pressure.
5- Check all instruments immediately after the engine starts, to be

sure they are reading properly. If the readings are incorrect, stop the
engine immediately and determine the cause of the improper gauge
reading before continuing operation.
6- Allow the engine to run at high idle speed for 4 to 5 minutes or

preferably until the water temperature reaches the normal operating
temperature before operating the machine.

.
The engine compartment must be inspected each time the machine is
to be put into service, that is to say every day.
When carrying out this inspection, check that the oil, fuel and air
conditioning circuits are leak tight and dry.
Check the tightness of the fuel and oil filters, the injection pump, the
hydraulic unit, the hydraulic motors of the ventilation apparatus and
their supply piping.
The leaktghtness and correct operation of the exhaust system,
especially the exhaust fixing flange must also be checked.
Due to the heat produced by the exhaust pipes, it is important to make
sure that the electric circuits are positioned and fixed far enough away
from them, and that they are properly insulated.
If the engine compartment is not regularly cleaned, it may become
fouled with oil or fuel, especially after maintenance or repair work. In
the case of a machine with sound insulation, the sound insulation
panels must be cleaned regularly.
The engine compartment must only be cleaned with non-flammable

cleaning products. Corrosive or chemically aggressive products
should be avoided, in order to preserve the cabling and flexible hoses.
Do not forget to screw back all filler plugs properly.
In the event of any unusual odour in the cab, stop the engine and
determine the cause.

Machine operation
This machine can be driven with the gearbox in either automatic or
manual mode.
Select the desired mode using key-operated control 89.
To move the machine around in the work area, proceed as

follows:
Automatic transmission mode
- Start up the engine as previously described.

- Select the automatic mode.
- Put your foot on the travel brake pedal and release the parking
brake.
- Select the highest gear required by turning the gear selector button.
- Push the lever forward for forward drive, or pull the lever back for
reverse drive.
- Release the travel brake pedal and accelerate using the accelerator
pedal.
- Use the travel brake pedal to slow down when approaching a
container or for positioning.
- Second to first gear changing is not automatic.
Gearbox in manual mode
- Start the engine as described above.

- Select manual gearbox mode.
- Put your foot on the travel brake pedal and release the parking
brake.
- Select FORWARD or REVERSE with the gear selector lever.

- Push the lever forward to go forward, pull it back to reverse.

- Place gear selector in 1st.
- Release the travel brake pedal and accelerate the machine by
pressing the accelerator pedal.
- When the engine reaches its maximum corresponding speed,
change up to the next gear.
- Brake with the service brake pedal as you approach the container to
be lifted, or in order to take up position.
Container handling cycle
Before starting to operate the machine, the driver must study all the
instructions given in this manual and in the chapter on safe operating
practices at the beginning of this manual.
The driver must familiarize himself with the controls and their
operation.
The handling cycle for a container is as follows:
Approach the container to be moved.

Lock the container to the spreader.
Lift the container.
Travel with the container.
Deposit the container.
These operations must be performed as follows:
1- Use the service brake to slow the machine, irrespective of the type
of transmission. When approaching the container, change down into
1st gear on machines with the Powershift gearbox.
2- Position the machine as close to the container as possible.

Use the service brake and gearbox neutral pedal to disengage the
transmission clutch and keep the full power of the engine available for
the other functions of the machine (telescoping and lifting).

3- At this stage, the red indicator lights of the spreader should be on.
4- Lower the spreader onto the container to be handled.

The red and white indicator lights of the spreader should now be on.
During the locking operation, all boom movements are prohibited.
Locking can only be effected if all the four locking contactors are
pushed in.
If locking is impossible, reposition the spreader.
Once all the four locking contactors are pushed in, the white indicator
lights of the spreader go on. At this stage, the functions Lower Boom
and Extend Boom are inhibited. They can be made available again by
using the LMI override key.
DANGER
This override must only used in very exceptional cases and
under the responsibility of the site manager.
Be aware of the damage to the machine and injury to personnel
that could result from lifting a load with the device overridden.
5- Pull the spreader lock/release lever towards you to actuate the twist
locks. The red indicator lights go off and the white and green ones go
on once the twist locks are locked.
6- Only the green indicator lights remain on during handling.
7- Balance the container by using the spreader side shift control.

8- Travel with the container as close as possible to the front axle and
high enough for the drover to be able to see underneath it.
NOTE:
It is impossible to see underneath a container if it is being transported
in longitudinal position.
9- Use the same approach procedure as in points 1 and 2.
10- Position the container and lower it into place.

The white spreader indicator lights will go on once the container is in
place, and the twist locks can be released.
11- When the twist locks are released, the red spreader operating
lights go on and the spreader can be released from the container.
The white spreader indicator lights go off once the spreader is
disengaged from the container.

Stopping the engine

To stop the engine, proceed as follows:
1- Place the transmission shift lever in the neutral position.

2- Pull the parking brake control lever up to set the parking brakes.
3. Allow the engine to idle for 3 to 5 minutes. This will allow the engine
and turbocharger to cool down and prevents overheating due to
localized residual heat. Extreme heat can seize bearings.
4. Push in and hold the engine shutdown button 87 until the engine
comes to a complete stop.

Removing/installing
the spreader
It may become necessary to remove and install the spreader on
certain occasions. To do so proceed as follows:
1. Install trestles approximately 1.30 m (4 feet) off the ground to

accommodate the spreader assembly. Lower the spreader onto the
trestles.
2. Shut down the engine and remove the key from the ignition.
3. Disconnect the hydraulic lines at the quickfit unions and plug the
hoses to prevent dirt from entering.
4. Disconnect the electric cables and install the shunt plug.
5. Remove the four pins securing the rotor to the rotator head.
6. To install the spreader, perform the preceding steps in reverse

order.
7 - Check the position of the damping cylinder valves.

Function and identification of valve positions
The marking position on the valve indicates the closed or open

position of the valve.
The valve is open if the marking is parallel to the boom, pointed

towards the cab.
If the mark is at right angles to the boom, the valve is closed.
The position of the handle is not a reliable indication unless it is

aligned with the marking.
In normal use, the large valve 2 must be open and the small valve 1
closed. The damping circuit is correctly set up.

If the valves are in this position when the machine is stored without
the spreader, the damper cylinder piston rods will be completely
extended. It is impossible to fix the spreader in this position. The
piston rods will remain fully retracted if the valve positions are
inversed (small valve open, large valve closed).
An intermediate position can be obtained by closing the small valve as

soon as the required position is obtained. The valves should be
placed in their normal working positions once the spreader has been
fixed.
The only function of these valves is to facilitate the removal and

refitting of equipment.

Spreader damping
Spreader rocking is controlled by cylinders located on boom head..
The damping system is neutralized to keep spreader in a horizontal

position when boom hoisting.
When the boom hoisting function is stopped, damping is reactivated.
Damping Lock
CAUTION
Use of this function should reserved strictly for:
- handling a container in longitudinal position
- rotating a container from transverse position.
The function is controlled by electric switch 84, and should not be

used for other purposes.

Optional fixed hook

Fitting the fixed hook
Place the spreader on two trestles about 1.30m (4 feet) in height.
Disconnect the hydraulic hose quickfit couplings and plug all the
hoses.
Cut off the power supply by means of the main battery switch.
Disconnect the electrical connectors.
Place the shunt plug onto the P18 cable (shunt plug in the tool kit).
Switch on the electric supply.
Unpin the spreader from the joint (4 pins).
Pin the hook to the joint (4 pins).
Close the valve 1.
Open the valve 2.
Disconnect the damping cylinders by operating valve 1 in order to

release pressure (2 pins).
Pin-connect the damping cylinders to the links welded on the boom

head (2 pins).
LMI option: Select curve 200 on the LMI when working with the fixed
hook.
The hook can be brought into use.

Dismantling the fixed hook

Unpin the damping cylinders from the links welded on the boom head.
Open the valve 1.
Close the valve 2.
Connect the damping cylinders to the joint.
Unpin the hook from the joint (4 pins).
Pin-connect the spreader to the joint (4 pins).
Remove the electric shunt plug, store it in the tool kit.
Connect the electric cables.
Connect the hydraulic hose quickfit couplings.
LMI option: Select curve 100 on the LMI when working with the
spreader.

Block stow operations
To lift the container

- Move the machine in front of the container.
- Boom up to allow the legs to be lowered.
- Telescope fully retracted.
Place switch 74 on AV-AR position.
Open the legs by mean of switch 84 : warning light 35 comes ON.
Select rear legs with switch 83.
Lower the rear legs by means of switch 84/1, warning light 37 comes
ON.
Clamp on the rear legs by mean of switch 84/4, warning light 39comes
ON.
Manoeuver to enter the pads in their locations, for this purpose use
spreader motions ( translation - etc...)
Select the front legs by means of switch 83.
Open the front legs by means of switch 84/3 : warning light 40 comes
ON.
Lower the front legs by means of switch 84/1 : warning light 37 comes
ON.
Clamp on the legs by means of switch 84/4 : warning light 39 comes

ON.
Manoeuvred to enter the legs in their locations.

Maintenance
Maintenance
Chapter IV
P 62440-53 Chapter IV - Page 1

Maintenance
Maintenance
Regular maintenance of your machine will ensure longevity. We
therefore earnestly recommend that you follow the instructions given
in this chapter.
The general maintenance table gives indications of the essential

points to be observed, and the following pages gives some
instructions in connection with these operations.

Maintenance
Levels of Maintenance
For each procedure described in this Manual, a maintenance level is

indicated.
This is given as an indication so as to serve as guide regarding the
importance of the operation.
This classification originates from the French NF X 60-010 Standard.
1st level:
Upkeep, change of accessible consumables, easy adjustments

without dismantling.
2nd level:
Lubrication and checking the sound operation, repairs through routine

replacement of elements provided for this purpose, carried out by an
accredited technician with basic qualifications.
3rd level:
Adjustments, diagnosis of breakdowns, repairs through changing of

components, minor repairs, carried out by a specialized technician, in-
situ or on maintenance premises.
4th level:
Important corrective and preventive maintenance works (except

renovation and reconditioning) carried out by a team comprising very
specialized technical supervision, in a specialized workshop.
5th level:
Renovation, reconditioning carried out, by definition, by the maker with

means practically similar to those of the manufacture.
The 1st Level corresponds to instructions given in the operating

and upkeep manual.

Maintenance
Maintenance: general
A TEREX SPECIALIST WILL SHOW YOU HOW TO OPERATE THE
MACHINE DURING INITIAL START UP. CARRY OUT THE FIRST
COMPLETE MAINTENANCE OF THE MACHINE WITH THE TEREX
EXPERT, THEN REFER TO THE MAINTENANCE PROGRAMS
SHOWN IN THE FOLLOWING TABLES.
IN THE EVENT OF PROLONGED STORAGE OR USE AT A FIXED

SITE, IT IS IMPERATIVE TO CARRY OUT 500 HOURLY
MAINTENANCE AT LEAST EVERY 6 MONTHS, ESPECIALLY ON
THE FOLLOWING COMPONENTS:
ENGINE - AXLES - GEARBOXES - SUSPENSION - STEERING.
IMPORTANT
The intervals shown in the following tables are applicable to
machines used under normal conditions.
For intensive use or under extreme conditions (heat - humidity -
dust) it is necessary to carry out maintenance more frequently.

Maintenance
Slew ring attachment.

Check the lubrication and attachment of the slew ring at regular
intervals. If a fault is found, seek the assistance of a TEREX specialist,
who will advise you on the subsequent action to be taken.
THE SLEW RING CONNECTING SCREWS ARE SAFETY PARTS..
Periodic and compulsory slewing ring fastener

checks.
DANGER
Faulty tightening is one of the factors that can lead to fracture of
the slew ring fixing.
It is vital that this method should be respected to ensure the
safety of this assembly.
1 - Slew ring fastener tightness is checked at the factory prior to

delivery.
2 - Slewing ring fasteners have to be to be retightened to the
recommended torque setting (refer to table) during the first warranty
visit.
Carry out the 1st check after 500 operating hours, and then check the
torque every 2000 hours thereafter.
a) Tooling :
1 Calibrated torque wrench (set to nominal torque rating
8 - see table below).

5
Refer to torque wrench manufacturer's document
(torque setting tolerance : ± 5%)
4 3 b) Conditions for verification :
Machine set up on outriggers
Short boom derricked so as to have a radius of 3m.
6 7 No load.

Maintenance
c) Method
Recommended order for tightening slewing ring fasten
ers.
- Nut or bolt 1 and 2, then at 90°, 3 and 4,
- Afterwards at 45°, nut or bolt 5 and 6, then at 90°,7
and 8,
- Finally, all the intermediate nuts or bolts.
(the number of nuts and bolts depends upon the type
of machine).

Maintenance
d) Torque settings for slew rings screws and bolts.
Chart d1
Nominal torque setting (m.daN) according to
assembly type
* Includes an HV or HR washer or a spacer
dxp Lg Réference Description
Vis / Screw / Schraube /

16x2 90 S 63338 94 ornillos
23
100 F 19338 68 ornillos
50 40
Boulon / Bolt / Bolzen / Perno
100 E 62338 32 50 50
110 T 19338 80 Tornillos
50 40
120 F 62338 33 Tornillos
50 40
125 J 19338 94 Tornillos
50 40
50 40
20x1.50 140 G 19338 69 Tornillos
50 40
140 J 19338 71 50 50
145 C 19338 88 50 50
170 R 62338 20 50 50
200 F 19338 91 50 50
220 H 62338 35 50 50
130 K 19338 72 90 90
140 E 19338 90 Tornillos
90 70
140 L 19338 73 90 90
24x2.00 160 M 19338 74 90 90
160 H 19338 70 Tornillos
90 70
170 D 19338 89 90 90
200 Q 62338 42 Tornillos
90 70
145 U 19338 81 Tornillos
130 95
145 N 19338 75 130 130
155 G 62338 57 Tornillos
130 95
160 P 19338 76 130 130
27x2.00 175 C 62338 53 Tornillos
130 95
190 Q 19338 77 130 130
130 95
210 A 19338 86 130 130
250 B 19338 87 130 130
250 X 62338 95 Tornillos
130 95
33x2.00 220 F 02340 07 Tornillos
230 175
TEREX reserves the right to alter the information in this chart without notice.

Maintenance
Chart d2
Minimum torque setting (m.daN) equal to 85% of
the nominal torque. Replacement necessary when
below this level.
* Includes an HV or HR washer or a spacer.
dxp Lg Réference Description

16x2 90 S 63338 94 ornillos
19
100 F 19338 68 ornillos
42 34
100 E 62338 32 42 42
110 T 19338 80 Tornillos
42 34
120 F 62338 33 Tornillos
42 34
42 34
42 34
20x1.50 140 G 19338 69 Tornillos
42 34
140 J 19338 71 42 42
145 C 19338 88 42 42
170 R 62338 20 42 42
200 F 19338 91 42 42
220 H 62338 35 42 42
130 K 19338 72 76 76
140 E 19338 90 Tornillos
76 59
140 L 19338 73 76 76
24x2.00 160 M 19338 74 76 76
76 59
170 D 19338 89 76 76
200 Q 62338 42 Tornillos
76 59
145 U 19338 81 Tornillos
110 80
145 N 19338 75 110 110
155 G 62338 57 Tornillos
110 80
160 P 19338 76 110 110
27x2.00 175 C 62338 53 Tornillos
110 80
190 Q 19338 77 110 110
110 80
210 A 19338 86 110 110
250 B 19338 87 110 110
250 X 62338 95 Tornillos
110 80
33x2.00 220 F 02340 07 Tornillos
195 148
TEREX reserves the right to alter the information in this chart without notice.

Maintenance
Remark :
This operation is valid for all types of slewing ring fasteners, consult
the technical specifications for the corresponding torque values.
3 - Afterwards slewing ring fastener tightness must be checked every

1 500 hours. Tooling, verification conditions, method and torque values
are the same as in paragraph 2.
8 5 a) Verify all the fasteners. Mark all fasteners with a torque value of
less than 85% of the nominal value.
4 3 If the number of fasteners detected with this characteristic is

greater than 20% of the total number, then all the ring fasten
ers must be changed.
USE ONLY ORIGINAL TEREX SPARE PARTS
6 7
b) Otherwise retighten all fasteners with a torque value greater than
2 85% of the nominal value to the nominal torque value indicated in the
table, and in the order as shown in the illustration opposite.
c) Change, one by one and in the recommended order, all the
fasteners detected and marked in step (a) which have a torque value
For all further detailed inferior to 85% of nominal value.
additional information ONLY USE GENUINE TEREX SPARE PARTS
concerning the method of Tighten to the value indicated in the table d1.
control, assembly,
retightening and 4 - Systematic exchange :
exchange criteria, please
consult our local agent. - If 20% of the screws have been replaced.
- If the slew ring is replaced.
ONLY USE TEREX ORIGINAL PARTS..
NB :
The slew ring must be replaced:
. If it has reached its maximum wear limit (see paragraph on Checking

slew ring wear).
. Following an expert report after an accident, incorrect use of the
crane, etc.

Maintenance
5 - Retightening fasteners after their exchange :

Retightening of the slewing ring fasteners must be carried out when :
fasteners have been exchanged,
the slewing ring has been exchanged, therefore a new set of
fasteners have been employed,
after an initial bedding-in period of 500 working hours.
Afterwards, periodic torque value verifications are to be carried out
every 2000 hours.

Maintenance
Checking slew ring wear:
We recommend that the clearances be gauged in order to determine

the condition of the slew ring. Wear on the raceways can be revealed
by tilting the upperstructure and measuring the changes in axial
clearance. The measurement must be made after the connection has
been checked (refer to the relevant paragraph).
Measuring the tilting clearance.
To determine the extent of wear, measure the tilting clearance as

follows using a comparator that is accurate to 0.01 mm:
Cranes:
- Stabilize the machine on fully-extended outriggers using the
fullest possible counterweight arrangement attached to the
upperstructure.
- Position the comparator as illustrated.
- Extend the boom to an average of 15 to 20 metres, and raise
as high as possible.
- Set the comparator to zero.
- Lower the boom until it is horizontal. Do not exceed the
indications given in the load chart.
- Take the reading of the tilting clearance from the comparator.
Stackers:
- Travel the spreader carrier left or right as far as possible.
- Set the comparator to zero. The comparator must be
positioned parallel to the spreader centreline by either the left
or right locks.
- Travel the carrier as far as possible in the opposite direction.
- Take the reading of the tilting clearance from the comparator.
The clearance is measured before the machine is put into

commission, and acts as the base measurement for subsequent
checks. A clearance of 0.5 to 0.7 mm may be used as a reference.

Maintenance
Details about the measurement:
The measurement points on the outer circumference are defined

starting arbitrarily from position 1.
Take the measurement between the support frame and the slew ring
race bolted to the superstructure (see illustration).
The measurement must be taken as close as possible to the slew ring

to avoid any distortion caused by elastic deformation.
The measurement is to be repeated for each position marked on the

support frame, and the reference values are to be noted in a table like
Diagram showing tilting clearance
measurement. the one below :
Reading for … hour period :
Measurement Reference New Wear (1)

measurement measurement
Measurement point 0,5 à 0,7
1
2
3
4
Checked by
Signature
Date
(1) Wear = New measurement – Reference measurement
This measurement must be repeated in the exact same conditions as

the original measurement, 500 hours after the machine is put into
service and every 2,000 hours thereafter.
The difference between the last measurement readings and the

reference measurement denotes the extent of wear on the slew ring. If
the wear is growing at an increasingly faster rate, the checks will have
to be performed more frequently (e.g. every 1,000 or even 500 hours).

Maintenance
Acceptable wear limits :
Contact TEREX-PPM if the permitted wear limits (see chart) are

exceeded.
Slew rings with a single lane of bearing balls (four contact points)
Track diameter (mm) Ø of the ball (mm)
Up to 20 22 25 30 35 40 45 50 60 70
Acceptable wear limit in mm
1000 1.4 1.4 1.4 1.5 1.7 1.9 2.1 2.5
1250 1.5 1.5 1.6 1.7 2.0 2.2 2.6 2.7
1500 1.6 1.7 1.7 2.0 2.3 2.6 2.8
1750 1.7 1.8 2.1 2.3 2.7 2.9 3.0
2000 1.8 1.9 2.2 2.4 2.8 2.9 3.1
We must be 2250 2.0 2.3 2.5 2.9 3.0 3.2
contacted if the
difference between 2500 2.0 2.3 2.6 2.9 3.1 3.2
the reference values 2750 2.4 2.6 3.0 3.2 3.3
and the maximum
values that have 3000 2.5 2.7 3.1 3.2 3.4
been measured is
3250 2.6 2.8 3.2 3.3 3.5
higher than as shown
in the chart. 3500 2.9 3.2 3.4 3.5
3750 3.0 3.3 3.5 3.6
4000 3.3 3.6 3.7
4500 3.5 3.8 3.9
5000 3.7 4.0 4.1
5500 3.9 4.2 4.3
6000 4.1 4.5 4.6
6500 4.6 4.7
7000 4.8 4.9
7500 5.1
8000 5.3
TEREX slew ring dimensions

Machines Bearing diameter Ball diameter
Spreader TR 980 mm 35 mm
AC35 – AC35L 1272 mm 30 mm
AC55 – AC55L 1491 mm 45 mm

Maintenance
Service intervals
It is essential for your machine to be regularly serviced.
The hour-meter mounted on your crane tells you when servicing
operations should be carried out. It should be consulted every day.
The intervals are based on a 10 hour working day, 50 hours per week
and 2,000 hours per year
When carrying out these maintenance operations, tighten nuts,

bolts, etc. where required.
Hour-meter
Its electric control is actuated by engine oil pressure. It accumulates

hours exactly like a clock when the engine is running.
Preliminary operations
First of all clean grease fitting heads, plugs and periphery of filler ports
and level check sight-glasses. When lubricating, check condition of
seals and replace them if they are damaged or show signs of wear.
Quality of lubricants
It is essential that the correct lubricant for each application should be

employed.

Maintenance
Before every daily start up
Every day, inspect the machine before getting in or starting the

engine.
Look carefully for: loose or missing bolts, dirt accumulation, oil or
coolant liquid leaks.
Check condition of tyres and levels.
Storage
After several months' storage, check piping and tighten hydraulic

fittings.
Inspect the machine thoroughly.
Apply procedure
"BEFORE EVERY DAILY START UP"

Maintenance
LUBRICATION CHART
COMPONENT Cold climates Temperate climates Tropical climates
-25° +25° -15° +35° -5 +45°

Boom chains MOLYKOTE BR 2
Boom slide pads MOLYKOTE BR 2
Grease nipples ALVANIA EP2
Slewing ring teeth MALLEUS GL 205
Slewing ring bearing ALVANIA EP2
Slewing reducer gear SPIRAX HD 80W90 SPIRAX HD 80W90 SPIRAX HD 85W140

TRASMITAL
Slewing reducer gear + OMALA EP VG220 OMALA EP VG220 TIVELA OIL VG2200
brake
DINAMIC OIL
Hydraulic fluid TELLUS T 22 HYDRAU TP TELLUS T 68

(TELLUS T 46)
or
SHELL NATURELLE
HF - E
(biodegradable)
Axle differential + reducer SPIRAX HD 80W90 SPIRAX HD 80W90 SPIRAX HD 85W140

units
Engine RIMULA X 10W30 RIMULA X 15W40 RIMULA X 20W40
Cooling circuit GLYCOSHELL +
CLARK gearbox RIMULA X 10W RIMULA X 10W RIMULA X 10W
Brake circuit Axle DONAX TD DONAX TD DONAX TD

Maintenance
List "A" - 10 hours

Air filter
Air filter cleaning and verification
If the clogging indicator light goes on, clean the primary cartridge.
If the cartridge is dry:
- Blow it out from the inside towards the outside using very low
pressure (7 bars max. (101 PSI)).
- Check inside with an inspection lamp and make sure that the
cartridge is not perforated.
Replace if the elements are greasy.
Replacing the cartridge:
The central safety cartridge should not be cleaned.
Replace it at every third cleaning of the primary cartridge.
The primary cartridge must be replaced after being cleaned six times,
or annually.
PRIMARY
SAFETY

Maintenance
Fuel tank and hydraulic tank levels
1/ Diesel filler tube
2/ Hydraulic oil filler tube

Do not forget to screw back all
filler plugs properly.
3/1 Maximum level tube

3/2 Minimum level tube and minimum oil level warning
4/ Oil circuit closure control
Never smoke while filling

up with fuel: the fumes Level: every 10 HOURS.
from the fuel are highly - with the machine on level ground and all hydraulic rams retracted,
flammable. the level should be close to the level of tube 3/1
Making up level:
through the filler tubes.
.

Maintenance
Transmission: Converter and powershift gear

box
Level check: every 10 hours.

Access: Under the chassis on the right hand side. On the side of the
gear box (winged plug with 'FULL' marked next to it).
Under the carrier chassis, right-hand side.
To fill: by filler tube at the front end next to the converter.
Topping up procedure:
Check the oil level with the engine running at idling speed and oil
temperature between 82°C (180°F) and 93°C (200°F).
Keep the level at 'FULL' (upper plug).


Maintenance
Engine
Level check: every 10 hours
Capacity: Mini 26 L – Maxi 38 L.
The dipstick on the Cummins engine is located on the right hand side.
The oil level must always be between the "LOW' and the "FULL"
marks on the dipstick. If the level is below the "LOW" mark, add oil by
the filler orifice.
CAUTION: Never run the engine when the oil level is below the "L"
mark (low), or when it is above the "F" (full) mark on the dipstick.
Hot oil can cause burns, so let the oil cool down sufficiently
before draining.
Refer to the Cummins Manual for further details.


Maintenance
Brake circuit: fluid level check
Capacity : 50L
Located on the right hand side of the machine.
Engine radiator: coolant level

filler plugs properly. Level check: every 10 hours
Check the level of the coolant liquid and, if necessary, add water or
antifreeze solution to within two centimetres of the filler orifice
To ensure that the cooling circuit is properly filled, you must:
fill the circuit to maximum with engine stopped
run the engine briefly and stop it
fill up again
repeat the operation until the level no longer drops
check the level again after 1 hour's operation.
Use the type and quantity of antifreeze recommended by the engine
manufacturer. See manufacturer's documentation.

Maintenance
GLYCOSHELL PLUS - TO BE MIXED WITH WATER.
Warning: Do not add more than 2 1/2 volumes of pure water per volume of
this concentrate.
Protection Volume of cooling circuit (litres)

down to
4 6 7 8 10 15 20 25 30 35 40 45 50 55 60 65
Quantity of GLYCOSHELL PLUS to use (litres)
- 10°C - 2 2 - 3 - - - - - - - - - - -
- 15°C 2 2 2 3 3 5 6 8 9 11 12 13 15 16 18 19
- 20°C 2 2 3 3 4 6 7 9 11 12 14 16 17 19 21 23
- 25°C 2 3 3 4 4 6 8 10 12 14 16 18 20 22 24 26
- 30°C 2 3 3 4 5 7 9 11 14 16 18 20 22 25 27 29
- 35°C 2 3 4 4 5 8 10 12 15 17 20 22 24 27 29 32
NEVER MIX DIFFERENT TYPES OF ANTIFREEZE
When draining, be careful of the oil or coolant liquid.
The engine should be stopped; do not release the parking or

emergency brake unless the vehicle is chocked or immobilized.
Be cautious when unscrewing radiator caps or any drain plugs,
grease nipples or pressure injectors.
Hot oil and components can cause burns: avoid all contact with
the skin.
Spreader greasing operations
Frequency: every 10 hours
- One grease nipple on each spreader twist lock.

- One grease nipple on each probe.
- Two grease nipples on the sideshift cylinder.
- Slide pad greasing.

Maintenance
List "B" - 50 hours

Spreader hydraulic slewing motor
Level check: every 50 hours (on dipstick).

Drain and filling orifices.
Spreader hydraulic sideshift motor
Level check: every 50 hours (on dipstick).

Drain and filling orifices.

Spreader slewing ring
Frequency: every 50 hours.
Insert grease with a pump through the 4 grease nipples on the slewing
ring, give 4 or 5 strokes of the gun per grease nipple.
Rotate the ring by a quarter of a turn after each pump stroke so that
the grease is uniformly dispersed inside the ring.
As a safety measure only one operator must carry out this

operation.

Maintenance
Slewing ring teeth
Greasing: every 50 hours. Apply the spray in two passes as illustrated

opposite.
Note: It is necessary to make a full rotation in each direction to

correctly grease the ring and its drive pinion.
As a safety measure, only one operator must carry out this

operation.
Boom and booming system
One grease nipple on the boom base swivel point.

One grease nipple on the boom head shaft.
Two grease nipples on each anti sway cylinder.
Greasing of the slide pads.

Maintenance
List "C" - 100 hours

Batteries
Electrolyte level check: every 100 hours.

Cut the electric circuit supply.
- remove the cell plugs.
- the level in each cell should be between 10 and 15 mm above the
top of the plates.
- top up with distilled water.
- refit the plugs.
Density checking
WARNING
Battery Posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of California
to cause cancer and reproductive harm.
Wash hands after handling.
- check the electrolyte density with a density tester (before adding

distilled water).
Specific density Degrees Baumé Remarks
1.285 32° correctly charged
1.200 24° semi-charged
1.120 16° discharged
- If necessary, have the batteries recharged and tested by a
specialized workshop.
- If the charging current is too high (water has to be added frequently),
or too low (density too low), find the cause and rectify the problem in
order to ensure long battery life.

Maintenance
Keeping the batteries clean
Keep the top of the batteries dry to avoid current leaks.

Remove the battery terminals and make sure they are not corroded or
sulphated. If they are, lightly scratch off the deposits and coat them
with neutral grease.
Moderately tighten the terminals.
Be careful when using spanners so as not to touch the battery case or
battery bars.
Make sure there are no flames above the batteries.
Securing the batteries
Moderately tighten the battery tie bars by semi-compression of the

springs, then tighten the locknuts.
Wheel fastener tightness
Check wheel fastener tightness every 100 hours.

torque settings: Front axle: 38 mKg (280 ft.-lbs)
Rear axle: 38 mKg (280 ft.-lbs)

Maintenance
Check the tightness of all spreader fasteners
Balance the rotating section of the spreader and eliminate any radial
effort by centring the sliding frame.
Check fastener tightness after 100 working hours.
Recheck every 1,000 hours.
Slewing ring fastener tightness
General guidelines for tightening slewing ring fixing screws.
NOTE: Torque settings apply to phosphated, ungreased but clean

bolts. Torque settings are identical for:
* nut and bolt assemblies,
* bolts screwed into threaded holes.
Slewing ring assembly:
1/ Degrease and clean support surfaces on the spreader.
2/ Degrease the slewing ring.
3/ Fit the ring, keeping in mind that the internal plug (roller assembly
access) must be positioned at 90° with respect to the longitudinal axis
of the machine. (Refer to sketch below.)

Maintenance
4/ Slewing ring fastener tightening order recommendations:

Nut and bolt assemblies 1 and 2, then at 90°, 3 and 4.
* Then at 45°, fasteners 5 and 6, then at 90°, 7 and 8.
* Lastly, the intermediate fasteners,
(the number of fasteners is variable depending on the slewing ring
model).
5) Play in the slewing ring and drive gear meshing.
* Position the zone of maximum eccentricity (blue coloured tooth
marked B or A depending on the supplier) in line with the slewing
motor pinion.
Minimum play: 0.1 mm
Maximum play: 0.3 mm.
NOTE: A 5° rotation of the eccentric ring corresponds approximately
to a clearance variation of 0.1 mm between teeth

Maintenance
List "D" - 200/250 hours

Tyre pressures
1,800 x 25: 10 bar

1,800 x 33: 10 bar
2,100 x 25: 7.5 bar
Batteries
Keeping the batteries clean
Keep the top of the batteries dry to avoid current leaks

Remove the battery terminals and make sure they are not corroded or
sulphated. If they are, lightly scratch off the deposits and coat them
with neutral grease.
Moderately tighten the terminals.
Be careful when using spanners, so as not to touch the battery case
or battery bars.
Make sure there are no flames above the batteries.
Battery anchorages
Tighten the tension rods securing the batteries moderately,

compressing the springs to half their length, and tighten the locknuts.
Transmission shafts and U-joints
Three grease nipples per transmission shaft.

Greasing the pump drive shaft:
It is necessary to remove the drive shaft protector tubes.

Maintenance
Rear steering axle

Frequency: every 200 hours
Grease the joints, the steering cylinder and pivots.
Air conditioning unit

Once a month:
- clean the evaporator with compressed air (max. 4 bars).
- clean the condenser with high pressure water
WARNING: In both cases, excessive pressure could damage the fins.
This operation is only necessary if the accumulation of dust and dirt is
really severe.
Engine
Oil change: every 250 hours

Replace oil filter
Check DCA units. If the level of concentration is lower than 3 units,
replace engine water filter cartridge. (Use a water filter cartridge of 15
DCA units. )
Check valve clearances.
Capacity: 38 L
On the CUMMINS engine, the dipstick is located on the right hand

side. The oil level must remain between the "LOW" and "FULL" marks
on the dipstick. If the level falls below the "LOW" mark, top up by the
filler orifice.
CAUTION: Never run the engine when the oil level is below the "L"
mark (LOW), or above the "F" mark (FULL) on the dipstick.
Hot hydraulic oil can cause serious burns, let the oil cool down before
making the oil change.
Please refer to the CUMMINS Manual for further details.

Maintenance
Transmission
Replace the filter cartridge every 250 hours.

Check the level after fitting the new filter cartridges.
Catalytic converter
To clean the converter, loosen both ends and remove the central part.
No flanges to be unscrewed, no exhaust system to dismantle.
Furthermore, the honeycomb material of the converter has been
designed for minimum build up of solid and oily deposits. Less
stopping time is therefore required for cleaning.
Maintenance procedure:
1. Brush the surface on the intake side of the converter.
2. Air clean the surface on the outlet side of the converter.
3. Continue with steps 1 and 2 until the surface of the intake side is
clean.
4. Clean the converter with high pressure steam on the outlet side.
The nozzle should be 5 cm from the surface of the converter.
5. Air dry. Max. pressure 50 psi.
6. Refit the converter.

Maintenance
List "E" - 500 hours

Air filter
Replacing filter cartridges.
Frequency: every 500 hrs
Boom beam guide pads
Every 500 hours
On the boom:
Check wear pads clearance ( 2 to 3 mm maximum).
shim if necessary.
Change the wear pads when they reach a thickness of 15 mm.
Check torque of bolts.

Maintenance
Hydraulic tank
Hydraulic
circuit filter
Brake circuit
filter
Hydraulic circuit filter
Filter replacement: every 500 hours.

Between filter cartridge replacements:
keep a check on the clogging indicator on the instrument panel.
When this stays on, it is time to replace the filter cartridge.
After any operation that has involved closing the valve, never
start up again without making sure it has been opened again.

Maintenance
Transmission
Oil change: every 500 hours.

First oil change after 50 hours.
Oil capacity:41 l.
Oil temperature at between 65°C (149°F) and 90°C (194°F).
Change the oil when the engine is not running.
Replace the two oil filter cartridges and clean the filter cases.
Clean the strainer located in the lower section "LOW", prime the circuit
by running the engine at idling speed for 2 minutes while topping up
the level to the "LOW" mark.
Raise the oil temperature to between 65°C (149°F) and 90°C (194°F).
Complete topping up to the "FULL" mark with the engine at idling

speed.
Access: Level on the gearbox (wing-nut with FULL marked beside it).
Under carrier chassis, right-hand side.
Filling: by tube protruding at front, converter side.
Process of making up level:
Check oil level with engine idling and oil at a temperature between 82
and 93°C.
Keep the level up to the FULL mark (higher level)
Replace filter cartridge: every 250 hours.
Check level after new cartridges have been fitted.


Maintenance
Front axle
Differential unit

The level should be flush with port R (filler and level check port).
Front axle reducer unit

filler plugs properly. The level is checked when the raised mark on the reducer unit is in a
horizontal position - the drain plug is towards the bottom.

Maintenance
List "F" - 1,000 hours

Spreader fastener checks
Balance the rotating section of the spreader and eliminate all radial
effort by centring the sliding frame.
Check fastener tightness after 100 operating hours.
Afterwards, recheck tightness every 1,000 hours.
Spreader swing motor-reducer unit -

TRASMITAL
Level check: every 100 hours (on the dipstick).

Oil change: every 1,000 hours.
Capacity: 2.6 L (0.7 US GALLONS)
Drain holes
Spreader sideshift motor-reducer unit -

TRASMITAL
Level check: every 100 hours (dipstick).

Capacity: 2.6 L. (0.7 US GALLONS)
filler plugs properly. Drain holes

Maintenance
Spreader beam guide pads
Every 1,000 hours
On the spreader:
Check lateral friction pad play (max. 1 mm).
Change the friction pads when they reach a thickness of 15 mm.
Check tightness of pad and pad support fasteners.
Check condition and attachments of electric

wiring harnesses.
Check leaktightness of hydraulic circuit.

Check wheel toe-in.
Check condition of alternator and starter.
Have brake accumulators checked.
Cooling of brake circuit
1st oil change: after 200-250 hrs or 1 month, replace filter cartridge if
clogged.
Oil change: every 1,000 hrs or 6 months. Replace filter cartridge each
time.
Brake circuit
filter

Maintenance
Between changes, watch the clogging indicator on the instrument

panel. If this stays on, replace filter cartridge.
Axle coolant change
1/ Place the machine on level ground

2/ Switch off engine and apply parking brake
4/ Put a container under each brake housing.
5/ Open the filler of the 30L tank.
6/ Unscrew the magnetic drain plugs of the two brake housings.
7/ Let the liquid flow out and clean the two magnetic drain plugs.
The change affects: the 30l tank, the coolant in the brake circuit,
the accumulators and the pipework.
8/ Unscrew the filter bowl to remove the liquid and residual dirt. If
necessary, replace the filter cartridge.
9/ Replace filter bowl, taking care that the joint is properly seated.
10/ Replace the magnetic drain plugs, tightening them to 27 Nm.
11/ Fill the circuit with hydraulic brake fluid via the tank; quantity about
50 L.
12/ Once the hydraulic fluid has reached its level in the tank (circuit
full), start the machine to circulate the fluid and drive out part of the
air.
13/ If necessary, make up the level.
Purging the system is a LEVEL 3 maintenance operation. Contact

your Concessionaire for this type of operation.

Maintenance
List "G" - 2,000 hours

Spreader slewing motor-reducer unit
Every 2,000 hours or every 6 months:

Check the tightness of fasteners.
12 bolts HM 16 x 150 - CL 8.8.
Torque setting: 21 mdaN. (155 ft-lbs)
Spreader locking system

Every 2,000 hours or every 6 months:
Check the condition of electric switches (mechanisms and safety)
Change any component which is not in a satisfactory condition.
Check adjustment of control rods (stroke and alignment).
Do not modify hydraulic settings on the lock and release cylinders.
Air conditioning unit
Once a year:
It is advisable to have the installation checked by a specialist.
Period out of use
It is advisable to operate the equipment for at least 10 minutes on end

once a fortnight.
Spreader swing motor-reducer unit - DINAMIC

OIL
The first oil change is made at 150 hours

Capacity: 2 L + 0.2l (0.7 + 0.07 US GALLONS)

Maintenance
Spreader sideshift motor-reducer unit -

DINAMIC OIL
The first oil change is made at 150 hours

Level check: every 100 hours .
Capacity: 2 l + 0.3 l. (0.7 + 0.07 US GALLONS)
filler plugs properly. Hydraulic fluid tank
Oil change:
Capacity: 750 L (198 us gallons) (1100 L including circuit- 290 us
gallons).
The first oil change is made at 2,000 hours or 1 year's service.
Subsequent oil changes are made every 2,000 hours.
The hydraulic circuit oil change includes systematic draining of the
following components:
hydraulic tank, hydraulic pump, cylinders, hydraulic motors.
This procedure is not described in detail, please consult your local
TEREX specialist.
When carrying out the oil change, replace the filter strainer and filter
cartridge.

Maintenance
Hydraulic circuit filters
Oil filter replacement: every 500 hours.

Between filter cartridge exchanges:
Keep an eye on the filter clogging warning light on the control panel.
Change the filter cartridges whenever this stays lit.
Filtrer
Opening and closing the hydraulic tank.
Operation to be carried out when there is a major leak or there is a job

to be done on the pump's suction circuit.
Never restart the machine after any job requiring the valve to be
closed before having made sure that it has been reopened.
Front axle
Differential unit

The level should be flush with port R (filler and level check port).
Oil change every 2,000 hours.
Drain by port V after having driven the machine a few minutes to raise
the oil temperature.
The drain plug is located underneath the front axle differential
housing.
Fill by port R.
ROCKWELL axle oil capacity: 44 L (12 US GALLONS)
KESSLER axle oil capacity: 77 L (20 US GALLONS)
Clean the breather located on the upper part of the housing.
NOTE: carry out the first oil change between 50 then 200 operating
hours.

Maintenance
Front axle reducer unit
The level is checked when the raised mark on the reducer unit is in a
horizontal position - the drain plug is towards the bottom.
Oil change every 2,000 hours.

Drain the oil when the drain plug is positioned towards the bottom
after having driven the machine for a few minutes in order to raise oil
temperature.
ROCKWELL axle reducer capacity: 11 L (3 US GALLONS).
KESSLER axle reducer capacity: 14 L (3.7 US GALLONS).
Note: Carry out the first oil changes between 50 and 200 operating
hours. After changing the oil, drive the machine for a few minutes at
low speed (2 km/h) and with no load in order to adequately lubricate
all internal components.
KESSLER axle
WARNING:
Do not forget to screw back all Before commencing work on the parking brake, ensure that no
filler plugs properly. unintended machine movement can happen when the braking
effect is removed. Danger to life!
DANGER:
The parking brake is under spring tension. Parts could become
loose and fly out suddenly if improper brake opening. Danger to
life!
Therefore release the lock nut (2) and turn the adjusting screw (3)
counter-clockwise until the spring set is released before
disassembly of the circlip (1)!

Maintenance
Rim check
CAUTION:
TEREX recommends checking the rims by radioscopy every
2,000 hrs and each time the tyres are changed.
When removing a wheel, always deflate the tyre.

A pressure of 0.2 bar should never be exceeded.

Maintenance
List "H" - 6,000 h

Spreader
Replace all the twist locks.
List "J" - 10,000 h

Engine/gearbox
Engine service, particularly:

pump injectors, turbo-compressor, compression rate.
Change engine and gearbox shock mounts.
Check crossbars for wear and box outlet coupling balancing.
Brakes
Change brake accumulators.

This operation is not described in detail. Consult your TEREX
specialist who has the inflation kit.

Maintenance
Boom
Change the boom pads.
Change the anti-sway accumulator.

This operation is not described in detail. Consult your TEREX
specialist who has the inflation kit.
Check all the welded parts of the boom visually.
Spreader
Change the spreader pads.

Check for any play in the spreader slew ring.
To do this:
- take a container.
- install a comparator on the slew-ring in order to measure play in the
ring in relation to the spreader’s chassis.
- set the comparator to zero.
- pivot the container sideways.
- take a reading from the comparator.
Play must be less than 3mm.
Change the slew-ring if play is greater than 3mm.
Replace the twist locks of the spreader.
Carry out a visual inspection of all the welded components of the

spreader.

Maintenance
Hydraulic oil tank
Change the hydraulic oil.

To replace hydraulic circuit oil, all of the following must be drained:
tank, hydraulic pump, rams, hydraulic motors
This operation is not described in detail; consult your TEREX
specialist.
During the oil change, change the return filter strainer and the two
filter elements.
Tyres
Tyres
Front axle
Change the parking brake pads.
Chassis
Check of all the chassis’ welded parts visually.

Maintenance Log
Maintenance Log
Chapter V
P 62440-53 Chapter V - Page 1

Maintenance Log
General identification
Type : TFC45 QSM11
Serial no.: 172000 -> 172999
Commissioning date : .. / ....
Name of facturer : TEREX CRANES FRANCE SAS
Registered office and factory :

Zone Industrielle de la Saule BP 106
71304 MONTCEAU LES MINES
FRANCE
Telephone : ( 33 ) 03 . 85 . 67 . 38 . 00
Fax : ( 33 ) 03 . 85 . 67 . 38 . 99
( 33 ) 03 . 85 . 67 . 38 . 98

Maintenance Log
IMPORTANT:
The intervals given in the following tables are applicable to
equipment used under normal conditions.
For intensive use or under exceptional conditions (heat,

humidity, dust), servicing intervals should be reduced.
For all maintenance work, it is essential that the machine should

be supported with its outriggers fully extended on firm, flat, level
ground.

Maintenance Log
Service intervals
It is essential for your machine to be regularly serviced.

The hour meter mounted on your crane tells you when servicing
operations should be carried out. It should be consulted every day.
The intervals are based on a 10 hour working day, 50 hours per week
and 2,000 hours per year
When carrying out these maintenance operations, tighten nuts,

bolts, etc. where required.
Hour meter
Its electric control is actuated by engine oil pressure. It accumulates

hours exactly like a clock when the engine is running.
Preliminary operations
First of all, clean grease fitting heads, plugs and periphery of filler
ports and level check sightglasses. When lubricating, check condition
of seals and replace them if they are damaged or show signs of wear.
Every precaution must be taken to protect the environment.

In particular, all liquids should be recovered and recycled.
Do not leave them in improperly labelled or open containers.
Do not permit any puddles of liquid on floors.

Maintenance Log
General
Maintenance of the machine is conditioned by its operating

environment. The lists provided in the following pages show the points
to check and the intervals between each service.
NOTE:
The maintenance log provided takes into account the operating
conditions of the equipment. The type of work, size of loads and
climatic and ground conditions are also factors to be taken into
account. The servicing lists are given as a function of hours of
operation.
Any change in the servicing schedule must be preceded by a fresh

analysis of the operating conditions of the machine. Study the
maintenance log with care before making any change in service
intervals.
Using the maintenance log
This booklet constitutes a guide to preventive maintenance until such

time as experience enables definition of a plan corresponding to
special conditions of use.
As many copies as desired may be made of the maintenance log.

Each person performing a service operation must show it on the
maintenance list so that the machine can be checked at the next
service.
Completed maintenance lists constitute documents inseparable
from the machine.

Maintenance Log
LUBRICATION CHART
COMPONENT Cold climates Temperate climates Tropical climates
-25° +25° -15° +35° -5 +45°

Boom chains MOLYKOTE BR 2
Boom slide pads MOLYKOTE BR 2
Grease nipples ALVANIA EP2
Slewing ring teeth MALLEUS GL 205
Slewing ring bearing ALVANIA EP2
Slewing reducer gear SPIRAX HD 80W90 SPIRAX HD 80W90 SPIRAX HD 85W140

TRASMITAL
Slewing reducer gear + OMALA EP VG220 OMALA EP VG220 TIVELA OIL VG2200
brake
DINAMIC OIL
Hydraulic fluid TELLUS T 22 HYDRAU TP TELLUS T 68

(TELLUS T 46)
or
SHELL NATURELLE
HF - E
(biodegradable)
Axle differential + reducer SPIRAX HD 80W90 SPIRAX HD 80W90 SPIRAX HD 85W140

units
Engine RIMULA X 10W30 RIMULA X 15W40 RIMULA X 20W40
Cooling circuit GLYCOSHELL +
CLARK gearbox RIMULA X 10W RIMULA X 10W RIMULA X 10W
Brake circuit Axle DONAX TD DONAX TD DONAX TD
WARNING: NEVER MIX SYNTHETIC OILS

AND MINERAL OILS.

Maintenance Log
Maintenance list "A"

Every 10 hours or every day
Company:_____________________________________________
Address: ______________________________________________
Person responsible for maintenance:________________________
Date of maintenance : ___________________________________
Serial No.: ____________________________________________
MAINTENANCE OPERATIONS DONE BY:

_____________________________________________________
Check and clean air filter:_________________________________
Check hydraulic oil level__________________________________
Check fuel level ________________________________________
Check engine oil level ___________________________________
Check converter oil level _________________________________
Check converter oil level _________________________________
Check brake fluid level ___________________________________
Grease all spreader links and joints _________________________

Maintenance Log
Maintenance list "B"

Every 50 hours
Company:_____________________________________________
Address: ______________________________________________
Serial No.: ____________________________________________

_____________________________________________________
Repeat list "A" _________________________________________
Grease all links and joints ________________________________
Check telescoping reduction gear unit oil level ________________
Check swing reduction gear unit oil level _____________________
Grease slewing ring teeth_________________________________
Grease the slewing ring (internal): __________________________
Grease all slide pads ____________________________________
Grease the twist locks ___________________________________

Maintenance Log
Maintenance list "C"

Every 100 hours
Company:_____________________________________________
Address: ______________________________________________
Serial No.: ____________________________________________

_____________________________________________________
Repeat lists "A" and "B" __________________________________
Check battery electrolyte levels ____________________________
Check wheelnut tightness ________________________________
Check all spreader fixings: _______________________________

Maintenance Log
Maintenance list "D"

Every 200 hours/250 hours
Company:_____________________________________________
Address: ______________________________________________
Serial No.: ____________________________________________

_____________________________________________________
Repeat lists "A", "B" and "C" ______________________________
Check tyre pressures ____________________________________
Check battery cleanliness, density and fastening_______________
Grease steering track rod and links _________________________
Grease transmission shafts and joints _______________________
Grease steering gear ____________________________________
Check valve clearances __________________________________
250 hrs - Replace engine oil filter___________________________
250 hrs - Engine oil change _______________________________
250 hrs - Check DCA levels for engine

water filter replacement: _________________________________

Maintenance Log
Maintenance list "D"

Every 200 hours /250 hours
(CONT'D)
250 hrs - Check belt tensions______________________________
250 hrs - Check condition of gearbox breather: ________________
Clean air conditioning evaporator and condenser: ______________
Clean catalytic converter: _________________________________

Maintenance Log
Maintenance list "E"

Every 500 hours
Company:_____________________________________________
Address: ______________________________________________
Serial No.: ____________________________________________

_____________________________________________________
Repeat lists "A", "B", "C" and "D" ___________________________
Drain and refill gearbox: __________________________________
Replace hydraulic circuit oil filter cartridge ____________________
Replace gear box oil filter cartridges ________________________
Replace air filter cartridge ________________________________
Check condition of slide pads (Boom) _______________________
Check front axle oil levels -

drive input unit and reduction gear units _____________________

Maintenance Log
Maintenance list – "F"

Every 1,000 hours or every 6 months
Company:_____________________________________________
Address: ______________________________________________
Serial No.: ____________________________________________

_____________________________________________________
Repeat lists "A", "B", "C", "D" and "E" _______________________
Check wiring harness condition + fastenings __________________
Check tightness of all fasteners ____________________________
Drain and refill slewing reduction gear: ______________________
Drain and refill telescoping reduction gear: ___________________
Check leaktightness of hydraulic circuit: _____________________
Check wheel toe-in: _____________________________________
Check leaktightness of steering circuit: ______________________
Check condition of alternator and starter motor: _______________

Maintenance Log
Maintenance list – "F"

Every 1,000 hours or every 6 months
(CONT'D)
Have brake accumulators checked: _________________________
Drain and refill brake circuit:_______________________________

Maintenance Log
Maintenance list "G"

Every 2,000 hours
Company:_____________________________________________
Address: ______________________________________________
Serial No.: ____________________________________________

_____________________________________________________
Repeat lists "A", "B", "C", "D", "E" and "F" ____________________
Replace brake circuit oil filter cartridge: ______________________
Replace hydraulic fluid: __________________________________
Replace brake hoses ____________________________________
Check the injection pump _________________________________
Replace hydraulic oil filters________________________________
Check counterweight condition and fastenings ________________
Check condition of slide pads______________________________
Drain and refill pinion carrier of front axle ____________________
Check air conditioning unit: _______________________________

Maintenance Log
Maintenance list – "H"

Every 6,000 hours
Replace the twist locks: __________________________________
Maintenance sheet "J"

Service at 10,000 hrs
Overhaul engine: _______________________________________
Replace brake accumulators:______________________________
Replace boom shoes:____________________________________
Replace damping accumulator: ____________________________
Replace spreader shoes: _________________________________
Replace hydraulic oil: ____________________________________
Dye penetration test on wheel rims: _________________________
Replace parking brake pads: ______________________________
Visual inspection of all welded components of the machine ______

Lubrication
Fuel
-
Lubricants
Chapter VI
P 62440-53 Chapter VI - Page 1

Lubrication
Component capacities
Engine CUMMINS QSM 11: Min. 26 L Max. 38 L
CLARK gearbox: 41 L
Fuel tank : 520 L
Hydraulic oil tank : 720 L
Hydraulic oil tank + circuit: 1100 L
Hydraulic oil tank, braking: 30 L

Tank + circuit approx. 50 L
Engine cooling circuit: 45 L
TRASMITAL
Slewing reduction gear : 2,8 L
DINAMIC OIL
Slewing reduction gear : 2L
Brake: 0.2 L
TRASMITAL
Telescoping reduction gear : 2,8 L
DINAMIC OIL
Telescoping reduction gear : 2L
Brake: 0.3 L
ROCKWELL front axle:

Drive pinion carrier : 44 L
Reduction gear: 11 L x 2

Lubrication
KESSLER front axle:

Drive pinion carrier : 77 L
Reduction gear: 14 L x 2
The above capacities are given as guidance only. Whenever possible,

rely on the levels shown on the components to be lubricated.
Tyre pressures:
GOOD YEAR 1800 x 25 10 b (145 PSI)
MICHELIN X MINE D2 1800 x 25 10 b (145 PSI)
MICHELIN X K D1 B 1800 x 25 10 b (145 PSI)
GOOD YEAR 2100 x 25 7.5 bar (110 PSI)
BRIDGESTONE 2100 x 25 7.5 bar (110 PSI)

Lubrication
Filter elements
Engine oil filter cartridge QSM11: T-64505-51
Fuel filter cartridge, QSM11 QSM11: S-64505-50
Water filter cartridge 15 DCA units, QSM11 engine: G-61505-97
DCA test kit V-64505-53
Oil cartridge, CLARK gearbox: B 61505-92 Qté 2
Oil strainer, converter: W 61505-88
Air filter cartridge

Primary cartridge : C 61505-93
Safety cartridge : D 61505-94
Hydraulic oil tank cartridges : W-27505-90 Qty 2
Braking circuit filter cartridge : W-27505-90 Qty 1
Alternator belt :

Diagrams
Diagrams
Chapter VII
P 62440-53 Chapter VII - Page 1

Diagrams
P 62440-53 Chapter VII - Page 2

Appendices
Appendices
Chapter VIII
P 62440-53 Chapter VIII - Page 1

Appendices

Appendices

Appendices

Maintenance and Operator'S Manual T. F. C. 45 QSM11

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T. F. C.

EDITION: 03/2006 N˚ P 62440---53 S/N : 172000 --->172999

S/N : 172000 -> 172999

BEFORE PUTTING YOUR MACHINE INTO THE

BEFORE STARTING ENGINE

ACCIDENTS INVOLVING MACHINES WHICH

Information - Technical spécifications

REP DESCRIPTION PAGES

STACKER Safe operating practices

REP DESCRIPTION PAGES

Safety instructions concerning tyres............................................................................................14

Stacker operating conditions and recommendations .................................................................18

Safe operating practices for TEREX machine users. ..................................................................22

L.M.I. SAFETY INSTRUCTIONS ......................................................................................................38

Summary of the various safety devices installed on the machine ....................................................40

REP DESCRIPTION PAGES

REP DESCRIPTION PAGES

REP DESCRIPTION PAGES

REP DESCRIPTION PAGES

REP DESCRIPTION PAGES

Recommendations for minimizing levels of vibration of the machine ...............................................44

Prevention of fire risks in the engine compartment ...........................................................................48

REP DESCRIPTION PAGES

REP DESCRIPTION PAGES

List "D" - 200 h / 250 h

List "E" - 500 h

List "F" - 1000 h

REP DESCRIPTION PAGES

List "H" - 6000 h

List "J" - 10000 h

REP DESCRIPTION PAGES

Lubrication chart ...............................................................................................................................6

Maintenance list "A" Every 10 hours or every day ..............................................................................7

REP DESCRIPTION PAGES

Components capacities ..........................................................................................................2

REP DESCRIPTION PAGES

Annexes – Diagnostics – Trouble Shooting

REP DESCRIPTION PAGES

QSM11 Codes defects ...........................................................................................................2

P 62440-53 Chapter I - Page 1

BEFORE THE OPERATOR STARTS THE

P 62440-53 Chapter I - Page 2

In order that any type of vehicle be reliable and safe, it is most

Any failure to respect the lubrication and maintenance instructions

READ ALL THE SAFETY INSTRUCTIONS CAREFULLY BEFORE

P P M does not necessarily know the way that maintenance

IMPORTANT : The information contained in this operator's

P 62440-53 Chapter I - Page 3

DATE OF ISSUE: 03/2006

MARK: PPM - TEREX CRANES

MANUFACTURER : PPM - TEREX

TYPE : TFC 45 QSM11

SERIAL NUMBER : 172000->172999

DATE OF START UP:

TEREX CRANES FRANCE SAS

Registered office and factory

P 62440-53 Chapter I - Page 4

Metric conversion table

Multiply by XXXX to obtain the equivalent figure for

Inch 25. 4 millimetres (mm) in-lbs 0. 11298 newton-metres (N.

Inch2 645. 2 millimetres2 (mm2) horsepower 0. 736 kilowatts (kW)

VOLUME PRESSURE OR STRESS

Inch3 16387. mm3 Inches of