ac 140

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all-terrain operation

Data Sheets
!! 8 t counterweight carried on the crane giving just 12 t axle load

!! 60 m main boom and optional 9.1 m to 33 m boom extension

!! State-of-the-art engine and transmission ensure high travel

comfort

!! Speed-dependent rear axle steering for increased

maneuverability and driving stability

!! Innovative Terex | Demag IC-1 crane control system with touch

screen

Terex® All-Terrain Operation: Data Sheet 2

Terex® All-Terrain Operation: Data Sheet 3
 Range Diagram – Main Boom

Terex® All-Terrain Operation: Data Sheet 4

Range Diagram – Boom Extension Range Diagram – Boom Extension

Terex® All-Terrain Operation: Data Sheet 5

Terex® All-Terrain Operation: Data Sheet 6
Terex® All-Terrain Operation: Data Sheet 7
Terex® All-Terrain Operation: Data Sheet 8
Terex® All-Terrain Operation: Data Sheet 9
Terex® All-Terrain Operation: Data Sheet 10
Terex® All-Terrain Operation: Data Sheet 11
Terex® All-Terrain Operation: Data Sheet 12
Terex® All-Terrain Operation: Data Sheet 13
NOTES:

Terex® All-Terrain Operation: Data Sheet 14

all-terrain operation

Nomenclature
Terex® All-Terrain Operation: Nomenclature 2
Carrier

Terex® All-Terrain Operation: Nomenclature 3

Combo Box Trailer / Boom Dolly Connections

Terex® All-Terrain Operation: Nomenclature 4

Hook block support Drive Unit
Diesel Motor OM502LA
Gearbox

Joint Shaft

Sensors
Gearbox

Diesel Engine

Starter

Fuel pump

Oil Filter

Oil cooler
Oil
Control unit
pressure
& temp
Terex® All-Terrain Operation: Nomenclature 5
Carrier Pumps Emergency Shut-Off

Terex® All-Terrain Operation: Nomenclature 6

Fuel Tank Air Pressure System

Valve Air dryer

Pressure
regulator

Terex® All-Terrain Operation: Nomenclature 7

Air Pressure System
Air tank distribution

Terex® All-Terrain Operation: Nomenclature 8

Brake System

Terex® All-Terrain Operation: Nomenclature 9

Hydraulic System Hydraulic Suspension
Air tank distribution

Terex® All-Terrain Operation: Nomenclature 10

Hydraulic Suspension

Terex® All-Terrain Operation: Nomenclature 11

Hydraulic Suspension

Terex® All-Terrain Operation: Nomenclature 12

Terex® All-Terrain Operation: Nomenclature 13
Terex® All-Terrain Operation: Nomenclature 14
Hydraulic Steering

Terex® All-Terrain Operation: Nomenclature 15

Carrier Electrical

Terex® All-Terrain Operation: Nomenclature 16

Support Base Detection

Terex® All-Terrain Operation: Nomenclature 17

Carrier Electrical

Computer

Digsy

ECU ECU

Axle 2
Steering
Controller Lamp
E-module
Axle 1
Steering I/O module
Controller Housing

CPU

Intarder Alarm
Transmitter
Terex® All-Terrain Operation: Nomenclature 18
Swivel

Terex® All-Terrain Operation: Nomenclature 19

Superstructure

Terex® All-Terrain Operation: Nomenclature 20

Slew

Slew gear brake (Dolly)

Terex® All-Terrain Operation: Nomenclature 21

Slew Slew bearing

Terex® All-Terrain Operation: Nomenclature 22

Superstructure Lock

Terex® All-Terrain Operation: Nomenclature 23

Slew Angle transmitter

Terex® All-Terrain Operation: Nomenclature 24

Superstructure Drive Superstructure Pump Group

Terex® All-Terrain Operation: Nomenclature 25

Superstructure Hydraulic Reservoir

Terex® All-Terrain Operation: Nomenclature 26

Oil Cooler

Terex® All-Terrain Operation: Nomenclature 27

Filters and Mounting Control Blocks, Mounting

Terex® All-Terrain Operation: Nomenclature 28

Hydraulic Pressure Transmitter Hydraulic Safety Shut Down

Terex® All-Terrain Operation: Nomenclature 29

Hoist 1 Hoist 2

Terex® All-Terrain Operation: Nomenclature 30

Counterweight

Terex® All-Terrain Operation: Nomenclature 31

Luffing Gear Tilt Cab

Terex® All-Terrain Operation: Nomenclature 32

Pump 40

Terex® All-Terrain Operation: Nomenclature 33

NOTES:

Terex® All-Terrain Operation: Nomenclature 34

all-terrain operation

Crane Chassis & Cab

 Crane Chassis & Cab Content

Content Pg. Content Pg.

Crane Chassis configurations 3

Overview of the crane chassis 6

Divers cab instrumentation 8

Indicator lights 18

Terex® All-Terrain Operation: Crane Chassis & Cab

Crane Chassis Transmission
Technical Data ZF AS!TRONIC type 16 AS 2602
All specifications apply to tires 16.00 R 25. 16 forward gears, 2 reverse gears
Dimensions, weights, axle loads for chassis / crane Distributor gear
vehicle with road! and off!road gear
Total length of the crane vehicle: 14.18 m (46.5 ft) 2.1.4 Climatic operating conditions
Total height of the crane vehicle (transport condition): 4.00 m An exact description can be found in part 1, section 1 of this
(13.1 ft) documentation.
Length of the crane chassis: 12.35 m (40.5 ft) 2.1.5 Tyres
Vehicle width: 3.00 m (9.7 ft) ! 14.00 R 25
Turning radius on the main boom head: 11.43 m (35.5 ft) on rim 9.5!25 / 1.7”
Transport weight crane vehicle (road travel): max. 60 t (132 kip) Vehicle width: 3.00 m (9.8 ft)
Axle loads for road travel: 5 x 12 t (5 x 26.4 kip) Vehicle height: 3.95 m (13 ft)
Number of axles: 5 Permissible distance per hour at an axle load of 12 t (26.4
2.1.2 Driving speed of crane vehicle 60 t (132 kip) kip): 70 km (43.5 mph)
Technically possible maximum speed: 85 km/h (53 mph) ! 16.00 R 25
Permitted maximum speed for axle loads 12 t (26.4 kip: 80 km/h on rim 11.00!25 / 1.7”
(50 mph) Vehicle width: 3.00 m (9.8 ft)
Climbing ability: Vehicle height: 4.00 m (13.1 ft)
! 37 % in road gear ! 17.5 R 25
! 71 % in off!road gear on rim 14.00!25 / 1.7”
Starting on hills: Vehicle width: 3.00 m (9.8 ft)
! 34 % in road gear Vehicle height: 3.95 m (13 ft)
! 71 % in off!road gear Permissible distance per hour at an axle load of 12 t (26.4
Drive kip): 70 km (43.5 mph)
Engine ! 20.5 R 25
DAIMLERCHRYSLER 8!cylinder diesel engine, type OM 502 on rim 17.00!25 / 1.7”
LA, water!cooled Vehicle width: 3.12 m (10.2 ft)
Output: 380 kW at 1800 rpm Vehicle height: 4.00 m (13.1 ft)
Torque: 2400 Nm at 1200 rpm
Terex® All-Terrain Operation: Crane Chassis & Cab 3
 Overview of the crane chassis

(1) Frame
(2) Spare wheel
(3) Driver’s cab
(4) Axle non!driven / steered
(5) Axle driven / steered
(6) Lift axle; can be raised for various ”steering
programs”
cannot be steered (rigid), transmission can be activated
(7) Outrigger strut
(8) Outrigger cylinder
(9) Outrigger pad
(10) Counterweight support

Terex® All-Terrain Operation: Crane Chassis & Cab 4

Preparation for Emergency Control, Superstructure
The following hydraulic connections are located on the left side
of the chassis between axle 2 and 3:
1 Connection LUW (leakage)
2 Connection TUW (tank)
3 Connection PUW (pressure oil)
If the superstructure power units break down, a hydraulic
transformer can be connected at these points, which enables
limited superstructure functions.
For exact details, see Emergency Operation section.
The hydraulic connections 1 ! 3 may only be used with a
hydraulic transformer.
A direct connection to the superstructure hydraulic system is
not permitted as there is no capacity for this in the oil tank.

Terex® All-Terrain Operation: Crane Chassis & Cab 5

Driver’s Cab

* Separate (different) pressure display, when axle 3 is in its raised

condition; otherwise the same display values with axle 4 and 5
(5!axle basic unit) or axle 4, 5 and 6 (6!axle basic unit).

Terex® All-Terrain Operation: Crane Chassis & Cab 6

Terex® All-Terrain Operation: Crane Chassis & Cab 7
Ignition starter switch (15) Only set when the vehicle is standing still and the parking
Position ”1”: All users are separated from the battery, brake is set.
except: tachograph, radio. Engine stop after external starting Always hold the steering wheel when making settings,
procedure. Removable key. since otherwise the seat will rebound when pressing the
push button (16) and you could be caught between the
Position ”2”: Ignition standby for external starting procedure.
steering wheel and the seat.
Removable key.
Position ”3”: Driving position
The ignition is switched on. Blower can be switched on.
Position ”4”: Starting position The engine starts.
! Only remove the key when the vehicle is stationary.
! Even if you are leaving the vehicle for a short time
remove the key to prevent unauthorized persons
starting the vehicle.
! When stowing/parking the vehicle, only remove the key
in position ”2”.
Steering wheel setting
Both the height and tilt of the steering wheel can be adjusted. The
steering wheel is pneumatically released (or locked according to the
setting).
Steering wheel is set as follows:
! Stop the vehicle and engage the parking brake.
! Hold the steering wheel and press the push button (16).
! Hold the push button (16) down and set the steering wheel.
! After the steering wheel has been set, release the push
button (16).

Terex® All-Terrain Operation: Crane Chassis & Cab 8

Instrument controls (assignment overview)
Driver information system
The operator’s platform is equipped with a driver information
system. This provides the driver with important information on the
vehicle when it is in driving mode.
The driver information system consists of the instrument panel
(with the pos. 31 ! 58) and the function buttons 60 ! 67 on the
steering wheel.
The ”Driver information” system (43) display is in the middle of the
instrument panel.
To the left of the instrument panel, there is another display
“Transmission information” (75) which displays the transmission
functions / gear display / error messages).
Self test
The electrical system performs a self test when the ignition is
switched on; the most important signal connections are checked.
At the same time, a control signal sounds twice and all indicator
lights (31!40 and 50.1) flash.
The function control is ended after the control signals go out.
The ”CH” display appears on the “Transmission information“ (75)
display.
Function buttons on the steering wheel
The function buttons (60!67) are used for navigating in the menu
structure of the driver information system and for confirming,
acknowledging or hiding messages.
The menus 1!6 can be selected using the “Digit” buttons
(61!66). At the same time, the digits correspond to the buttons
of the segment numbering on the “Driver information system“ (43)
display.
You can scroll upwards in the menu structure with the “Arrow”
button (60) (leave menu item and go back to previous display).
The main menu can be called up with the “M” button (67)
! and
! can be returned directly to the basic display “Indicator lights”
from any menu item.

Terex® All-Terrain Operation: Crane Chassis & Cab 9

“Driver information system” (43) display
Display fields
The display field is automatically divided into different segments.
A difference is made between permanent and changing displays.
The following is shown in the 3 permanent display fields (upper
bar):
Right field: Date, time
Middle field: Not assigned
Left field: not assigned
In the changing displays, the previously used display field can
be used for other display functions according to certain criteria.
The display is divided into segments 1!6 and is laterally marked with
these digits.
The brightness of the display can be changed with the button
(57).
All possible displays are assigned certain display priorities.
These control the urgency of each message. By setting these
priorities, you can automatically change from the current display into
a new display with higher priority, if needed.

Terex® All-Terrain Operation: Crane Chassis & Cab 10

Basic display / explanation of colors Red: Malfunction
After switching on the ignition, the basic message ”Indicator ! There is a malfunction when the “Caution” (36) warning light
lights” always appears ! after the company logo and control lights up at the same time. Determine the cause of the
malfunction and remedy the problem as quickly as possible.
signal.
! There is a serious malfunction when the “STOP” (35)
In the basic display, the selected functions that are activated by the
warning light lights up at the same time. Switch off the vehicle
corresponding switch settings are shown as symbols; e.g.
immediately. Continued operation is not permitted.
differential lock, off-road gear.
The display of the selected functions or subsequently occurring When there is a malfunction / warning display and at the
malfunction / warning messages have different colors. The colors same time the red warning light “STOP” (35) lights up,
are used as indicators for the influence of the messages on the the operational safety of the vehicle is in danger. Turn off
operation/traffic safety of the vehicle and determine the order of the the vehicle immediately and remedy the fault.
displayed indicator lights (from upper left to lower right) depending After remedying the fault, the warning display can be removed
on their (color) priority. The colors have the following meanings: by switching the ignition on and off. This is also used to check
if the fault was really remedied.
Pink: No function display possible
There is an error in the corresponding connection e.g. short
circuit, interruption. The displayed function can therefore not be
monitored.
If there is a pink!colored message, the “Caution” (36) display
also lights up automatically.
White: Function (e. g. steering programmed) is
! selected, but not yet active or
! still selected, but axles not yet synchronized.
Yellow: Function is active
The system has recognized the error when the “Caution” (36)
warning light lights up at the same time. The vehicle can still be
operated; however, determine the cause.

Terex® All-Terrain Operation: Crane Chassis & Cab 11

Main menu
Pushing the “M” button (67) on the steering wheel brings you from
the “Indicator lights” basic display to the main menu.
Pushing the “M” button (67) again brings you back to the basic
display.

Terex® All-Terrain Operation: Crane Chassis & Cab 12

Menu selection 1 ! 2 ! 3
Four menus (1, 2, 4, 5) can be selected in the main menu. The
menu items 3 and 6 are not assigned:
1 “Indicator lights” menu
! identical with the basic display after “Ignition on”
Example of a possible display:
2 “Multimedia“ menu
! Reversing camera (optional)
3 not assigned

Terex® All-Terrain Operation: Crane Chassis & Cab 13

Menu selection 4
Output basis: Main menu
4 “Control info“ menu
1 Suspension level
2 Engine data*
4 Emergency pressure supply in the braking circuits 1 and
2 * This display of the engine oil quantity (%) only serves as
additional information. The oil level may only be monitored using the
oil measuring stick.
Depending on the design, this display function is not possible for
technical reasons. The corresponding display then always
indicates 0%.
If this is the case, then B14 indicator light ”Engine oil level too low”
will also not be displayed.

Main Menu

Terex® All-Terrain Operation: Crane Chassis & Cab 14

Menu selection 5 ! 6
Output basis: Main menu
5 “Service / Diagnosis“ menu
! Operating hours counter: Press submenu 5.1
Display left row: Partial operating hours
1 = Superstructure (without function)
2 = Chassis
3 = Sum superstructure / chassis (without function)
Display right row: Total operating hours
4 = Superstructure (without function)
5 = Chassis
6 = Sum superstructure / chassis (without function)
! Software identification: Press submenu 5.4
Software display (only for customer service)
The partial operating hours can be deleted by holding down
(about 5 sec.) the steering wheel button (61 / 62 / 63).
The total operating hours cannot be changed.
6 not assigned

Terex® All-Terrain Operation: Crane Chassis & Cab 15

Indicator lights in the driver information system
The symbols given below as “Indicator lights” on the “Driver
information system” (43) display can be displayed.
Signal indicator lights
! the execution of manually activated functions (A row)
! or the existence of Malfunctions (B row).
Indicator lights for manually activated functions
A1 Maneuvering operation
A2 “Manual rear axle steering” steering program active
A3 Steering program “Close cornering” active
A4 Steering program “Driving away from the wall” active
A5 Steering program “Diagonal steering” active
A6 Release “Steering program” (for construction site
operation)
A7 Off-road distributor gear inserted
A8 Distributor gear in neutral
A9 Longitudinal differential lock actuated
A10 Transverse differential lock actuated
A11 Suspension in the three circuit system
A12 Suspension locked
A13 “Hold axles” actuated
A14 “Raise lift axle” actuated
A15 “Raise all axles” actuated
A16 Emergency operation of the superstructure
A17 Axle that can be engaged in the function
(drive is connected with longitudinal differential lock)
A18 Speed lock effective
A19 Superstructure not locked with carrier
A20 Engine quick stop (optional) actuated
A21 Sustained action brake cruise control activated
Explanation

Terex® All-Terrain Operation: Crane Chassis & Cab 16

Indicator lights resulting from malfunctions
B1 Suspension beyond limits
B2 Error in the electric hydraulic rear axle steering
B3 Emergency pressure supply in braking circuits 1 below 5.5
bar (79.8 psi)
B4 Emergency pressure supply in braking circuits 2 below
5,5 bar (79.8 psi)
B5 Clutch overload (temperature too high)
B6 Transmission malfunction
B7 Hydraulic oil filter chassis clogged
B8 Steering circuit 1 no through flow
B9 Steering circuit 2 no through flow
B10 Steering circuit 3 (emergency steering) no through flow
B11 Engine coolant level too low
B12 Engine oil pressure too low
B13 Coolant temperature engine too high
B14 Engine oil level too low
B15 Engine malfunction
B16 Charging current too low
B17 Charging current in the superstructure too low (not
assigned)
B18 Air filter clogged
B19 Fuel supply in the reserve
B20 Dolly steering circuit 1 no through flow
B21 Dolly steering circuit 3 (emergency steering) no
through flow
B22 Malfunction SPS
B23 Central lubricating system without grease (not assigned)

Terex® All-Terrain Operation: Crane Chassis & Cab 17

B24 Malfunction on dolly (dolly = optional)
Stroke length exceeded, hydraulic cylinder (if in addition to the
indicator light (B24): One-time acoustic warning signal and indicator
light “Caution” (36)) or
B24 Malfunction on dolly (dolly = optional) Critical slanted position,
hydraulic cylinder (if in addition to indicator light (B24): Repeating
acoustic
warning signal and indicator light “STOP” (35))
B25 Scroll down to next mask (if no room on display)
B26 Crane operation active (not assigned)
B27 ABS fault, vehicle, axle 4 (only with 6!axle basic unit)
B28 Malfunction exhaust brake / hydraulic retarder
B29 ABS fault, vehicle,
5!axle basic unit: all axles;
6!axle basic unit: Axles 1, 2, 3, 5 and 6
(together with indicator light (32))
B30 ABS malfunction, dolly or additional axle or trailing axle
(together with indicator light (31))
B31 Malfunction nonreturnable valves (electro hydraulic rear axle
steering)
B32 Malfunction oil supply (additional axle)
B33 Warning buzzer engine
B34 No CAN Bus connection (steering computer 1)
B35 Brake wear display (left-hand disc brakes)
B36 Brake wear display (right-hand disc brakes)

Terex® All-Terrain Operation: Crane Chassis & Cab 18

Instrument Panel

Terex® All-Terrain Operation: Crane Chassis & Cab 19

Function buttons on the steering wheel

Terex® All-Terrain Operation: Crane Chassis & Cab 20

Switch on the instrument panel

Terex® All-Terrain Operation: Crane Chassis & Cab 21

Switch on the instrument panel

* Function only possible, if the (92) “Steering program”

(construction site operation) switch was previously actuated.

Terex® All-Terrain Operation: Crane Chassis & Cab 22

 * “Raise lift axle” is done by driver in steering programs that
can be selected (for construction site operation).
“Raise all axles” is done on the switch panel of the outrigger
controls by actuating the “Raise axles” button, after previously
actuating the “Raise axles” button (101).

Terex® All-Terrain Operation: Crane Chassis & Cab 23

* Socket is fused with 5 ampere; do not overload!
Voltage is always on ! regardless of the ignition starter switch
position (danger of battery drain when device is off duty).

Terex® All-Terrain Operation: Crane Chassis & Cab 24

all-terrain operation

Driving Instructions
 Driving Instructions Content

Content Pg. Content Pg.

Instructions for all types of driving 3 Driving with a dolly 54

Transport safety locks 6 Reversing check system (optional) 62

Axle loads / speeds / tires 7

Driving on public roads 19

Driving without main boom and

luffing cylinder 22

Driving downhill 24

Checking the Driver information sys. 26

Driving on the construction site 30

Driving the crane with the equipment

erected 31

Driving tables 34

Driving the crane with a load 52

Terex® All-Terrain Operation: Driving Instructions

Instructions for all types of driving
All the control and monitoring elements required for driving the
crane are located in the driver’s cab of the crane chassis.
The pedals’ freedom of movement may not be restricted. Be
sure that there is enough room for the pedals when using
foot mats and carpet. Do not store any objects in the driver’s
foot area. Store or secure all loose objects (e.g. tins, bottles,
tools, bags, etc.) in such a way that they can’t enter the foot
area while driving. Such objects could get under the brake
pedal, block it and thereby make it impossible to brake the
crane vehicle.
Checks Before Driving the Crane ! Check the steering.
Check the capacities for all fuels and lubricants ! see lubricating The indicator lights (B8, B9 and B10) must not light up as a
and maintenance instructions for the crane chassis (part 4). rule.
The following checks must be made every time before the crane Depending on the system, in case of the fault ”No through feed
is driven, even when only driving short stretches. at the emergency steering pump” (indicator light B10), there is a
! Driving condition of the mobile crane: display only once driving speeds > approx. 8 km/h (5 mph) have
been reached.
Check the axle loads; observe the instructions (see under
“axle loads / speeds / tires” and “defined driving conditions”) Driving the crane with defective steering constitutes a major
safety hazard. Faults must be rectified before the crane is
! Check the transport position of supports and outrigger plates driven.
! Check the engine oil level, add extra oil if required.
! Check the hydraulic oil level.
In case of fault: find out cause ! only then top up.
Wait until the hydraulic oil has warmed up before running the
engine at speeds of over n=1600 U/min (rpm).
! Check the oil level in the transmission, add extra oil if required.
! Check the coolant level.
In case of fault: find out cause ! only then top up.

Terex® All-Terrain Operation: Driving Instructions 3

! Check the brake system.
! Emergency pressure supply in brake circuit 1 and 2:
! Driver’s information display, submenu 4.4: pressure is displayed.
Upper row = braking circuit 1
Lower row = braking circuit 2
! Driver’s information display, basic display:
Red indicator light, when the pressure is under 5.5 bar
(80 psi).
Indicator light (B3) = braking circuit 1
Indicator light (B4) = braking circuit 2
! Parking brake control light (39), if handbrake applied.
If the emergency pressure supply is below 7 bar (102 psi), the air
tanks of the braking system must be topped up at medium revs until
a pressure of 8 bar (116 psi) bar is reached.
Air pressure of min. 6.2 bar (90 psi) is needed to switch gears. It is
not possible to switch gears below this mark.
Immediately after starting to drive, test the brakes on a dry, anti
!skid road surface (service and parking brake). At the same
time be sure that the crane vehicle brakes evenly, does not
deviate to the side and that a faultless brake delay is achieved.
There must be no oil or water in the brake linings. If water has
permeated into the brake lining, lightly brake with the
service brake until the brakes are again fully functional.
! Check steering wheel/driver seat setting
! Vehicle lighting; check blinkers and brake lights

Terex® All-Terrain Operation: Driving Instructions 4

! Check the suspension system.
If a suspension circuit is outside the road travel level, the
indicator light (B1) on the driver’s information display lights
up. The exact level of individual suspension circuits can be
observed in submenu 4.1.
All suspension cylinders must be in the road travel position
(green range);
When driving on the road the suspension must be in the 4!way
system and it must not be locked. (Switch 99, 100 in the “off”
position, no displays A11, A12).
! Check the fuel level, add fuel if required.
The fuel supply is displayed on the instrument panel with
instrument (51). If the fuel supply is in the reserve area, the
indicator light (B19) lights up.
Do not fill up with fuel while the engine is running.
Other important specifications are outlined in the individual
sections.
Check the function of the vehicle lighting, warning and brake
lights and make sure that they are clean. Replace any defective
bulbs.
Check the tire condition and air pressure
The air pressure has a large influence on:
! The handling of the vehicle
! The running characteristics of the tires
Tire damage is inevitable if the tire pressure is too low.
It is therefore essential to apply the correct air pressure.

Terex® All-Terrain Operation: Driving Instructions 5

Transport Safety Locks
During transportation, the safety locks provided must be applied.
Following driving and before the superstructure is placed in
operation, the safety locks must be removed again.
! When driving with the hook block reeved, it must be fastened
to the front coupling ring of the crane chassis
! When driving without a hook block, the hoist rope is secured
with the rope socket on the front coupling ring of the crane
chassis.
! Apply mechanical superstructure locking device.
! The platform on the superstructure cab must be pushed into
its transport position (switch actuation;
! If the reeved hook block is set down on the crane chassis
when the crane is driven, it must be inserted in the holding
devices provided (optional equipment) and must be secured
accordingly.
The rope must be guided over the corresponding rope
configurations on the chassis cab and chassis frame.
! Outrigger struts pinned/locked in the transport position.

Terex® All-Terrain Operation: Driving Instructions 6

Axle loads / speeds / tires Calculating axle loads
The permitted driving speed is dependent on the axle load and Any addition or removal of components affects the vehicle/
the tires. There is a direct correlation between the axle load, tire size displaces the axle loads.
and permitted speed. Additional components can, depending on the centre of
With the axle loads we differentiate between the technically gravity on the crane, cause an increase or decrease of
weight on the affected axles.
possible loads and those permitted by road traffic
regulations.
Calculating axle loads into kg
All chassis parts / components are designed and approved ex
works for even axle loads of 12 t (26.4 t kip) per axle. Arithmetical basic condition (kg)
Axle loads above and below 12 t (26.4 kip) represent a deviation The basic condition serves as the basis for all axle load
from the documented EEC approved condition. calculations. The crane then weighs 48093 kg (106027 lbs) and
Uneven or excessively high axle loads negatively affects the is equipped with the following:
handling of the crane in any case. Lower axle loads also have a Crane with:
negative effect. ! Superstructure, main boom
Deviation from the approved condition always means worse ! Locking/ pinning unit in transport position (at the front in the
handling characteristics. The larger the deviations, the worse main boom)
the crane handles. ! Hoist 1
The limitations that must be observed as a result are - Drive 10x8x8
correspondingly larger. ! Tires 16.00 R 25
Observe the relevant instructions in the following ! Central lubricating system, air conditioning equipment,
subchapters. auxiliary heating, wooden box empty
Before driving in public traffic the driver must be fully Crane without:
conversant with the altered driving/steering/braking ! Outriggers, front
behavior (e.g. longer braking distances) of the crane ! ! Outriggers, rear
especially where the driving condition of the crane deviates ! Counterweights
from the standard configuration.
! Main boom extension
! Spare wheel
! Hook block
! Hoist 2

Terex® All-Terrain Operation: Driving Instructions 7

Weight table (component weights in kg)
Starting from the basic condition listed on the
previous page ! using the weights listed ! the
current axle loads can be calculated for the
different combinations.
Where there is a “minus” sign, there is actually a
reduction in the axle load by the specified amount.

Terex® All-Terrain Operation: Driving Instructions 8

Terex® All-Terrain Operation: Driving Instructions 9
Example of an axle load calculation (kg) Correspondingly the current weight of the crane,
The following calculation example shows how the current axle rounded up, is
load can be calculated with the help of the weight table. 74 t. The individual axle loads are then (rounded off):
The weights of the following components are added to the basic ! Axle 1: 14.3 t ! Axle 4: 15.2 t
condition: ! Axle 2: 14.15 t ! Axle 5: 15.2 t
! Outriggers, front and rear ! Axle 3: 15.1t
! Main boom extension 17 m folded into the main boom
This example is equivalent to the driving mode ”Driving
! Hoist 2 with an overall weight of 74 t (Technical drivability)”
! Bottom hook block, 3!sheave model 63 (700 kg) at bumper described in the subsection “Defined driving modes”.
! Counterweights 1a, 1b and 2 (3.66 t + 1.99 t + 7.92 t = 13.57 The slight deviations are a result of rounding the
t) attached to the chassis. individual items up/down and/or weight tolerances
! Counterweights 5 and 6 L/R (2.59 t + 2 x 1.3 t = 5.19 t) pinned
to the superstructure
.RISK OF ACCIDENTS due to overloading of tires!
The maximum permitted speed must be observed for
the current axle load. The determining factor is
always the axle that is placed under the highest load.
Failure to observe these instructions can result in
the tires being overloaded and bursting.
Extreme risk of accidents due to extended braking
distances!
Axle loads exceeding 12 t (26.4 kip) result in a
significantly longer braking distance and the risk of
fading.

Terex® All-Terrain Operation: Driving Instructions 10

For driving on public roads, the permitted axle loads and the
corresponding speed limits must be observed.
Risk of accidents!
For axle loads less than 12 t (26.4 kip), ”Driving with reduced
axle loads” must be observed.
Calculating axle loads into lbs
Arithmetical basic condition (lbs)
The basic condition serves as the basis for all axle load
calculations. The crane then weighs 48093 kg (106027 lbs) and is
equipped with the following:
Crane with:
! Superstructure, main boom
! Locking/ pinning unit in transport position (at the front in the
main boom)
! Hoist 1
- Drive 10x8x8
! Tires 16.00 R 25
! Central lubricating system, air conditioning equipment,
auxiliary heating, wooden box empty
Crane without:
! Outriggers, front
! Outriggers, rear
! Counterweights
! Main boom extension
! Spare wheel
! Hook block
! Hoist 2

Terex® All-Terrain Operation: Driving Instructions 11

Weight table (component weights in lbs)
Starting from the basic condition listed on the
previous page ! using the weights listed ! the
current axle loads can be calculated for the
different combinations.
Where there is a “minus” sign, there is actually a
reduction in the axle load by the specified amount.

Terex® All-Terrain Operation: Driving Instructions 12

Terex® All-Terrain Operation: Driving Instructions 13
Example of an axle load calculation (lbs) RISK OF ACCIDENTS due to overloading of tires!
The following calculation example shows how the current axle The maximum permitted speed must be observed for
load can be calculated with the help of the weight table. the current axle load (see section 6 under ”Possible
The weights of the following components are added to the axle loads / permitted speeds”). The determining
basic condition: factor is always the axle that is placed under the
highest load. Failure to observe these instructions
! Outriggers, front and rear can result in the tires being overloaded and bursting.
! Hook block holder, at the chassis (empty)
Extreme risk of accidents due to extended braking
! 3!sheave hook block type 80 (850 kg; 1874 lbs) on the
distances!
bumper
Axle loads exceeding 12 t (26.4 kip) result in a
! Main boom extension 17 m (55.8 ft) (folded into transport significantly longer braking distance and the risk of
position) fading.

For driving on public roads, the permitted axle loads and

the corresponding speed limits must be observed.
Risk of accidents!
For axle loads less than 12 t (26.4 kip), ”Driving with
reduced axle loads” must be observed.

Correspondingly the current weight of the crane, rounded up,

is 61.8 t (136.2 kip). The individual axle loads are then
(rounded off):
* Axle 1: 13.1 t (28.8 kip) * Axle 4: 12 t (26.4 kip)
* Axle 2: 13 t (28.6 kip) * Axle 5: 11.9 t (26.2 kip)
* Axle 3: 12 t (26.4 kip)

Terex® All-Terrain Operation: Driving Instructions 14

Possible Axle Loads / permitted Speeds Tire, manufactured by Michelin (XGC)
Pay attention to the relation between the axle loads, the driving
speed and the tires fitted ! as shown in the following table.
The determining factor is the axle that is placed under the
highest load.
RISK OF ACCIDENTS due to overloading of tires!
The maximum permitted speed and driving distance
must be observed for the current axle load.
Failure to observe these instructions can result in the
tires being overloaded and bursting.

Terex® All-Terrain Operation: Driving Instructions 15

Tire, manufactured by Michelin (X ! Crane) Tire, manufactured by Bridgestone, Goodyear and
Yokohama

Terex® All-Terrain Operation: Driving Instructions 16

Driving with uneven axle loads Driving with reduced axle loads
Uneven axle loads have a negative effect on the handling of the Reduced axle loads have a negative affect on the handling of the
crane. vehicle.
The braking system is designed for even axle loads of 12 t Braking:
(26.4 kip) in accordance with EC guidelines and German Risk of accidents!
road traffic regulations. The braking system is designed and approved for axle loads of
Different axle loads at the front and rear represent a 12 t (26.4 kip). At lower axle loads, the crane is over braked.
deviation from the approved crane configuration. The Vehicles without ABS:
vehicle handling will deteriorate to a greater or lesser Abrupt use of the brake pedal could cause all the wheels to
degree, depending on the amount of deviation! lock suddenly. The lower the axle loads, the greater the risk of
the axles locking.
The larger the differences, the more serious the
Use the brakes therefore with care, as appropriate to the
deterioration. Drive with appropriate caution and reduce the situation!
driving speed; possibly walking speed should be followed.
Vehicles with ABS:
React to poor road conditions by further reducing the driving
speed. The braking effect becomes less satisfactory.
Axle load ratios, heaviest axle : lightest axle > 2:1 are not Steering:
allowed, as these are too difficult too drive with. Risk of accidents!
The steering behaviour is changed.
Any driving conditions that deviate from these must be listed
under “declared driving conditions” or require express The steering system is lighter and reacts more quickly when axle
permission from case to case. loads are reduced. It becomes less smooth.
In the case of uneven axle loads, the steering can be locally RISK OF DAMAGE!
overloaded. This can result in damage to the steering. There is a risk of damage to the steering components; e.g.
Caution when braking! as a result of external resistance at the wheels.
Apply force evenly when braking. Sudden pressing of the Suspension system:
brake pedal would lead to various wheels locking; the Risk of accidents!
vehicle could swerve as a result. The standard!equipped suspension system is designed
Caution when steering! for axle loads of 12 t (26.4 kip). The suspension becomes
When driving through curves, the vehicle tends towards ”harder” with lower axle loads. When axle loads are less
the straight-ahead steering position. than 7 t (15.4 kip), the crane behaves as though the
suspension were blocked. The crane may begin to skid.

Terex® All-Terrain Operation: Driving Instructions 17

There is a way to adjust the suspension system permanently to Driving with axle loads over 12 t (26.4 kip)
the reduced axle loads. The preload pressure of the Driving with axle loads of more than 12 t (26.4 kip) is
accumulators must be adapted for this purpose. If this option is always an exceptional condition and is only permitted
for short stretches.
available for your equipment, then you will find corresponding
information on the hydraulic circuit diagram or in the respective Drive extremely carefully and reduce your maximum
driving speed.
Lubrication and Maintenance Instructions in the ”Hydraulics
The correlation between the technically possible axle
system” section. If no information concerning this is available, loads and the maximum driving speed should be
then corresponding values are obtainable upon request. observed.
Risk of accidents! All chassis parts / components are designed and approved ex
If the crane is to be moved again with axle loads of 12 t works for axle loads of 12 t (26.4 kip) (approved condition, see
(26.4 kip), then the preliminary tension of the suspension under ”Driving with total weight of 72 t (158.7 kip)” or ”Driving
accumulator must be modified again accordingly. with total weight of 84 t (185.1 kip)” .
If the crane is driven alternately with 2 axle load statuses, then Axle loads of 12.5 t (27.5 kip) mean that the approved crane
the crane can be optionally equipped for switch actuation to condition has already been exceeded.
change the suspension back and forth between the 12 t Axle loads over 12 t (26.4 kip) mean:
(26.4 kip) axis load configuration and the axis load configuration ! Higher loads.
with reduced axle loads. ! Overloading of the tires (for certain sizes).
A corresponding switch is then located in the driver’s cab. ! Extended braking distances / risk of fading.
Behavior of the driver with reduced axle loads: Increased loads
Risk of accidents! Risk of skidding! Axle loads of more than 12 t (26.4 kip) lead to increased loads
If the preload pressure of the accumulators of the on the steering, axle suspension, axles, wheel hubs, bearings,
suspension system, suspension cylinders, brakes, wheels and
suspension system is not reduced, then the maximum
tires.
driving speed must be reduced. The lower the axle load,
the slower the driving speed must be. For axle loads of This means a considerable reduction in service life and life
less than 8 t (17.7 kip), the permitted maximum speed is expectancy for the parts in question.
still no more than 30 km/h (18 mph). The maximum speed Wear on brake linings is particularly increased. There is a risk
of overheating (fading).
must be reduced even further with additional axle load Loading / overloading of tires
reduction and/or poor road conditions. Sudden loads (e.g. driving against curbs), bead damage or
Risk of accidents! Risk of skidding! cutting damage must be avoided under these more exacting
If the preload pressure of the accumulators of the operating conditions.
suspension system is reduced (manually or with
Damage to a tire can result from the combination of
switchover), then the maximum driving speed must be overloading and / or increased speed. Damage does not
reduced to 50 km/h (31 mph). necessarily have to follow a handling error. These add up over
time and can eventually lead to more major damage following a
relatively minor incident.

Terex® All-Terrain Operation: Driving Instructions 18

RISK OF ACCIDENTS in case of tire damage! Driving with axle loads of up to 16.5 t (36.4 kip)
Tire damage must be rectified by professionals. This technically possible driving condition does not meet the
regulations of the German road traffic licensing regulations and
RISK OF ACCIDENTS due to overloading of tires! the EEC directives.
The maximum permitted speed must be observed for the Therefore driving in this region is only permitted on private roads
current axle load. Failure to observe these and grounds. These must have a sufficient load bearing capacity
instructions can result in the tires being overloaded and and must be sufficiently level (e.g. no potholes).
If the crane is driven with axle loads above 12.5 t (27.5 kip) the
bursting. following points must be observed:
Extended braking distances / risk of fading ! Only short driving stretches are permitted at any time.
The braking system for this vehicle is designed in accordance ! Before driving take the axle loads from the listed driving
with EC directives and German road traffic regulations for an axle condition or recalculate based on the current configuration using
load of 12 t (26.4 kip). the weight table.
Extreme risk of accidents due to extended braking The determining factor is always the axle that is placed under
the highest load.
distances! ! With the “lift axle” raised, the crane may not be driven, as raising a
At axle loads above 12 t (26.4 kip) the braking deceleration “lift axle” represents an additional prohibited increase in the axle load.
as required in accordance with EC partial operating ! The crane must not be steered on the spot or when on very
uneven ground.
approval, can no longer be guaranteed / maintained.
! During driving the displayed pressures of the suspension circuits
The braking distances are, as a result, considerably or must be observed. They should be equal and are not to exceed 260
even extensively extended and there is a risk of bar (3773 psi).
overheating (fading). ! Calculate the maximum permitted speed based on the current axle
load and observe this maximum while the crane is driven.
Driving with axle loads of up to 12.5 t (27.5 kip)
! Before driving in public traffic, the driver must be fully conversant
RISK OF ACCIDENTS due to overloading of tires! with the changed driving / braking behavior (e.g. longer braking
The maximum permitted speed must be observed for the distances).
current axle load (see section 6 under ”Possible axle ! Shorten the maintenance interval; carry out inspections more
loads / permitted speeds”). Failure to observe these often.
instructions can result in the tires being overloaded and Risk of damage as a result of premature wear!
bursting. RISK OF ACCIDENTS as a result of worn components!
The information given here must be observed at all times.
Possible driving speeds are only permitted within the framework
The crane manufacturer shall not be held liable for damage
of the existing tire limit values; i.e. the possible highest speed resulting from premature wear when driving with axle loads
must not be fully exploited, if the tire is not approved for this above 12.5 t (27.5 kip).
speed (at certain axle loads).

Terex® All-Terrain Operation: Driving Instructions 19

Shorter maintenance intervals for axle loads above
12.5 t (27.5 kip)
Even when observing the specified, axle!load!dependent
driving speeds, driving with axle loads > 12.5 t (27.5 kip) is only
permitted temporarily.
Driving with axle loads of more than 12,5 t (27.5 kip) is always
an exceptional condition and is only permitted for short
stretches. even if, as a result of special national axle load
regulations, higher values are permitted.
The crane manufacturer shall not be held liable for damage
resulting from premature wear when driving with axle loads
above 12.5 t (27.5 kip).
Risk of damage as a result of premature wear!
If the crane is driven with axle loads above 12.5 t (27.5 kip),
steering, axle suspension, axles, wheel hubs, bearings,
suspension system, suspension cylinders, brakes, wheels and
tires must be checked regularly ! at least once every 3 months
however ! for damage and wear.
This applies especially to the setting of the steering
geometry and the brake linings!
RISK OF ACCIDENTS as a result of worn components!
When defects are discovered they must be dealt with
immediately in order to prevent safety risks, further wear
or irreparable damage to the component.
The steering geometry and other components relevant to the
safety of the crane may only be checked and, if necessary,
repaired by our customer service technicians or a
corresponding specialist workshop.

Terex® All-Terrain Operation: Driving Instructions 20

Driving on public roads As a rule, the specifications in the section “axle loads /
This crane vehicle has extraordinary dimensions and speeds / tires” and the corresponding sub!sections must
be observed exactly.
weights.
Make sure that the vehicle is driven with caution and In the interests of safety, the technically possible
maximum axle loads should not be exceeded at the
foresight (avoiding regular acceleration and braking). corresponding speed indicated in the left!hand column.
The maximum permitted speed for this vehicle in Germany is 80 km/ Adapt the driving speed to the actual axle loads and the
h (50 mph).
route conditions.
When driving on public roads the crane vehicle must be in a very
specific transport condition.
The transport condition of the mobile crane depends on the road
traffic regulations applicable in the country in which the crane is to
be operated.
In countries with EEC approval regulations, axle loads of
max. 12 t (26.4 kip) are permitted when driving on public
highways.
In countries with different national regulations the permitted
axle loads may actually be lower than 12 t (26.4 kip).
The crane operator / driver must ensure that the axle loads are
within the permitted limits and that they are evenly distributed
and that any additional restrictions are
observed.
If the axle loads are exceeded or other regulations are not
followed, they carry sole responsibility.

Terex® All-Terrain Operation: Driving Instructions 21

Checks before driving the on the road
Before driving on the road, always:
! All transport locks must be fitted (see under “Transport
locks“).
! The main boom must be in the “road travel
condition" telescopic sections pinned, locking pinning unit
locked in the transport position (see part 1, section 12)).
! The suspension must not be locked; it must be switched to
the 4!way system and be at the road travel level.
! The steering must be in the “road travel” condition.
! A disc must be inserted in the tachograph.
! Emergency devices e.g. first aid box, warning triangle, fire
extinguisher must be easy to reach and complete.
! The housing cover of the outrigger controls on the side of the
chassis must be closed.
! The ladders, which are loose (1c) must be attached to the
holders on the chassis and secured with the rubber fixtures.
! No loose parts are permitted on the equipment.
! the superstructure cab ! is locked; the superstructure cab
platform ! is retracted.
This crane vehicle has extraordinary dimensions.
Pay attention in particular to the overhead clearance and
check the route in this respect.
! The vehicle height of 4.0 m (13.1 ft) must not be exceeded.
With optional hoist 2:
To maintain the vehicle height of 4.0 m (13.1 ft) the upper rope
sheaves (”X”) (for hoist rope of hoist 2) must be moved from
the collar of the boom sections.
Risk of load being torn off!

Terex® All-Terrain Operation: Driving Instructions 22

Defined driving conditions Driving with a Total Weight of 55 t (121.3 kip)
Defined driving conditions are assigned in accordance with (with main boom, without outriggers)
national regulations or other appropriate requirements. Exceptional driving condition for reducing the axle loads
to meet respective national regulations.
Driving conditions beyond these can be determined on a case by
Crane with:
case basis using the weight table (component weights) (see
! Main boom in transport condition
under “axle loads / speeds / tires”).
Crane without:
Driving with a Total Weight of 60 t (132.3 kip) ! outriggers front and rear
(Approval condition in accordance with EEC!directive) ! wooden box rear
! Spare wheel
Crane with: ! Hook block
! Main boom in transport condition ! Counterweights
! 1!sheave hook block type 600 kg (1323 lbs) (on the bumper) ! Main boom extension
! Wooden box at rear (empty) Axle load distribution:
Crane without: * Axle 1: 11.2 t (24.7 kip) * Axle 4: 10.9 t (24.1 kip)
! Counterweight elements * Axle 2: 11.1 t (24.5 kip) * Axle 5: 10.8 t (23.8 kip)
* Axle 3: 11 t (24.3 kip)
! Hoist 2
The braking system for this vehicle is designed in
! Main boom extension
accordance with EC directives and German road traffic
! Spare wheel regulations for an axle load of 12 t (26.4 kip).
Axle loads: By lower the total weight lower axle loads are achieved;
! Axles 1 to 5: 12 t each (26.4 kip) the crane is over braked.
Use the brakes carefully, applying braking power in
stages.
Abrupt use of the brake pedal could cause all the wheels
to
lock suddenly.
Drive carefully and reduce the theoretically possible
maximum speed accordingly.
Observe the section 6.4.6 (from page 37) ”Driving with
reduced axle loads”.

Terex® All-Terrain Operation: Driving Instructions 23

Driving with a Total Weight of 39.2 t (86.5 kip) Drive carefully and reduce the theoretically possible
(without main boom, with luffing cylinder) maximum speed accordingly. It must not exceed max. 30
Exceptional driving condition for reducing the axle loads to km/h (18 mph); correspondingly less in poor road
meet respective national regulations. conditions.
Crane with:
! superstructure rotated towards the back To be observed when driving on the road:
! Luffing cylinder ! Lash the luffing cylinder to the support.
! supports complete ! Mark protruding luffing cylinder in accordance with road
Crane without: traffic regulations.
! Main boom The protruding luffing cylinder could present a danger for
the road users behind.
! Spare wheel
Only drive on public roads ! in this condition ! in
! Hoist 2
accordance with the applicable motor vehicle safety
! Hook block
standards.
! Counterweights
Axle load distribution:
* Axle 1: 6.5 t (14.4 kip) * Axle 4: 8.7 t (19.2 kip)
* Axle 2: 6.6 t (14.6 kip) * Axle 5: 8.6 t (19 kip)
* Axle 3: 8.8 t (19.4 kip)
The braking system for this vehicle is designed in
accordance with EC directives and German road traffic
regulations for an axle load of 12 t (26.4 kip).
By removing the main boom lower axle loads are achieved; the
crane is over braked.
Use the brakes carefully, applying braking power in stages.
Abrupt use of the brake pedal could cause all the wheels to
lock suddenly.

Terex® All-Terrain Operation: Driving Instructions 24

Driving with a Total Weight of > 60 t (132.3 kip)
(”Technical Drivability”)
”Technical drivability” is only permitted on construction
sites and on private roads.
Instructions and warnings in this respect in the section “axle
loads / speeds / tires” must be observed.

Terex® All-Terrain Operation: Driving Instructions 25

Driving Downhill
! Reduce the speed and select a lower gear.
! Observe the revolution counter (50) to prevent the engine speed
moving into the danger zone.
! Use non!wearing sustained action brakes (exhaust brake,
hydraulic retarder).
! Only use the service brake briefly as an auxiliary brake.
The gear range in which the crane can be maintained at a
constant speed must be selected before the crane is driven
downhill.
When transmission is in automatic operation:
When the engine independent sustained action brake is switched
on, the transmission automatically adjusts the gears to reach an
optimal braking effect (engine speed faster than U/min / rpm).
The effect of the exhaust brake is dependent on the engine speed.
The higher the rpm, the greater the braking effect. The effect of the
hydraulic retarder is dependent on the speed. The higher the speed,
the greater the braking effect.
When the hydraulic retarder is used, heat is created in the
transmission.
The transmission oil temperature is monitored indirectly (via
the coolant temperature of the engine) with the help of the
preheating indicator (B13) in the driver information display.
If the oil temperature rises to prohibited values (over 150 C (302 )) !
which leads to a coolant temperature which is too high ! the retarder
performance must be reduced until the coolant temperature has
reached a steady state at less than 95 C (203 F).
If the retarder output is not regulated by the driver, the system
automatically reduces the braking effect until the permissible
temperature has been reached (again).
The service brake may only be used to brake the crane until the
speed is read at which the transmission shifts down to the next
gear.
The service brake must not be used for sustained periods
under any circumstances. Risk of fading!

Terex® All-Terrain Operation: Driving Instructions 26

Driving over Hill Summits
When driving over hill summits, it must be ensured that all axles
remain in contact with the ground.
The crane operator bears sole responsibility for any damage to
the crane chassis caused by ”exceeding the maximum
suspension travel” or ”block position of the suspension” and
exceeding the maximum axle loads when an axle lifts off the
ground.
When driving over hill summits, it is prohibited:
! to lock the suspension
! Driving with axle loads over 14 t (30.9 kip)
as components MAY BREAK otherwise.
If an axle should however lift off the ground, proceed as follows:
1. Stop the crane in a straight position and engage the
longitudinal differential lock by actuating To do so, actuate
switch (94); the indicator light (A9) lights up.
2. Drive over the summit at walking pace (max. 5 km/h (3 mph)).
While driving over the summit:
! Avoid turning the steering
! Observe the suspension pressure continually.
If the pressure rises to 260 bar (3773 psi) in any one of the
three suspension circuits, the AXLES MAY BREAK!
Do not drive over the summit if a pressure of 300 bar
(4354 psi) has been reached.
Reverse carefully.
3. After driving over the hill summit, stop the crane immediately
and switch off the longitudinal differential lock again. To do so,
actuate switch (94); the indicator light (A9) goes out.

Terex® All-Terrain Operation: Driving Instructions 27

Checking the Operation Functions During the Journey
All indicator light/display instruments are located in the driver’s
cab.
While driving, the driver must constantly observe the display
instruments and monitoring elements.
Monitoring elements in the instrument controls

Terex® All-Terrain Operation: Driving Instructions 28

Indicator lights on the display (43)
“Driver information system”

Terex® All-Terrain Operation: Driving Instructions 29

Indicator lights on the display (43)
“Driver information system”

Terex® All-Terrain Operation: Driving Instructions 30

On the display (75)
“Transmission information”

Terex® All-Terrain Operation: Driving Instructions 31

Driving on the Construction Site
Driving in the Transport Condition
Notes on ground conditions:
The ground conditions must be suitable for the individual axle
loads as well as the overall weight.
The route must be even and the ground must be able to support the
load.
When driving with independent rear axle steering, different
rules apply.
The differential locks may only be switched on for a brief period of
time, in order to bypass obstacles when driving straight ahead.
Road speeds above 5 km/h (3 mph) overload both the tires and the
drive.
Following the obstacle the differential locks must be switched off
again immediately.
The crane must be stationary when switching the differential
locks on and off.
The hydraulic suspension of the crane chassis must not be
locked and must be set level.
When driving over hill summits or ramps, the same rules
apply as for ”driving over hill summits” on the road.
The instructions in that section must be followed.
For driving on surfaces that are not quite even, to improve the
vehicle handling the crane can be set to the 3!circuit system.
Risk of tipping!
When the suspension is switched to the three circuit
suspension system the vehicle has a lower lateral stability.

Terex® All-Terrain Operation: Driving Instructions 32

Driving the Crane with the Equipment Erected
“Driving in Erect Mode” (with main boom / equipment erected)
“Driving in the configured condition” always means:
Driving without load on the hook!
Driving with load is prohibited!
Notes on ground conditions:
The ground conditions must be suitable for the individual axle
loads as well as the overall weight.
The ground must be even and free of dips and rises, it must also have
sufficient load!bearing capacity.
”Driving when rigged” with steering program
“Construction site operation mode” (operate switch (92),
is PROHIBITED !
Driving in the configured condition is only permitted in the
4!circuit system.
When driving in rigged configuration:
! The gradient must not exceed the following values:
! 2 % in the forward direction
! 1 % laterally (without additional equipment)
! 0.5 % laterally (with additional equipment)
! Extend the outrigger struts and hold the outrigger feet just
above the ground.
When the outrigger struts are not extended, there is a risk of
crushing. Make sure that the outrigger struts are correctly pinned and
locked!
! The suspension system of the crane chassis must be locked.
! Driving speed is not to exceed walking pace.
Distributor gearbox: level “Off!road gear“ (button 93, display A7).
Driving gearbox: 1st gear, operation mode “Manual”.
Clutch: “starting mode” (switch 90 not actuated; only actuate in the last
cm (1cm = 0.4 inch) possibly in “maneuvering mode” with switch 90).
Risk of accidents!
When the warning message ’CL’ appears in the transmission display,
stop immediately and let the system cool down.
If you do not stop, the following abrupt closing of the clutch causes
the rigged crane to make jerky movements. The crane could tip
over.

Terex® All-Terrain Operation: Driving Instructions 33

! Main boom to the rear ! apply mechanical superstructure
locking device. Locking bolt (80) must be inserted in locking
strip (2). Make sure that this is the case.
Risk of tipping!
When the crane is not stabilized (free on wheels), then
the boom must not be rotated out of the vehicle’s
longitudinal axis.
For machines with dolly preparation (optional) the locking bolt (1) can only
latch into the locking strip (2) when the extension guard (screw) (81) has
previously been removed.
! The hook block must be secured on the chassis e.g. on the
maneuvering / trailer coupling, or also on the outriggers
(telescoped out) to prevent swinging movements (or it must
be raised).
! Apply the slew gear brake.
For devices with dolly equipment (option), the slewing gear brake should
not be locked open (see Driving with the dolly).
! Caution with side winds, above all if they are acting in the
same direction as a transverse gradient.
! Constantly monitor the suspension pressure on pressure
gauges (5) to (10) in the driver’s cab.
If the pressure in one of the suspension circuits climbs to
300 bar (4354 psi), stop the crane immediately and extend
the outrigger cylinders until the wheels are relieved of load.
Level the crane by resetting the hydraulic suspension and/or
correcting theboom position.
If the crane is driven further it may OVERTURN or the AXLES
MAY BREAK !
The following tables concerning superstructure position, boom angles and
lengths and axle loads correspond to the following configuration:
Basic unit with:
! Counterweight (incl. hoist 2) in accordance with corresponding table
sheet.
! Calculated hook block in accordance with the corresponding table sheet.
! Corresponding equipment (e.g. main boom extension).

Terex® All-Terrain Operation: Driving Instructions 34

Driving the crane with other configurations than the ones
specified in the following table sheets is PROHIBITED!
When changing the calculated hook block, slight adjustment of
the main boom (or of the equipment) can achieve a more
balanced axle load again.
The suspension pressure when lowering the crane from the
outriggers onto the wheels can be monitored via the pressure
gauges. At the same time, 260 bar (3773 psi) must not be
exceeded.

In general balanced loads, as specified in the following table, are to

be aimed for.
Possible driving variants in the following sections:

Terex® All-Terrain Operation: Driving Instructions 35

Driving tables
(in SI ! Units)
Driving the crane with the main boom
Axle load table: Correlation of the axle loads with the boom
position and configuration

* Superstructure to the: rear ! Main boom to the rear

The following hook block is included in the calculation:
! 3!sheave, type 80 (850 kg; 1874 lbs)

Pg 94 Carrier Op. AC140

Terex® All-Terrain Operation: Driving Instructions 36

Driving with Main Boom Extension 9 m
(in SI ! Units)
Axle load table: Correlation of the axle loads with the boom
position and configuration

* Superstructure to the: rear ! Main boom to the rear

The following hook block is included in the calculation:
! 1!sheave, type 32 (600 kg; 1323 lbs)
Terex® All-Terrain Operation: Driving Instructions 37
Additional axle load table:
Driving with Main Boom Extension 9 m in SI ! Units

* Superstructure to the: rear ! Main boom to the rear

The following hook block is included in the calculation:
! 1!sheave, type 32 (600 kg; 1323 lbs)

Terex® All-Terrain Operation: Driving Instructions 38

Driving with Main Boom Extension 17 m
(in SI ! Units)
Axle load table: Correlation of the axle loads with the boom
position and configuration

* Superstructure to the: rear ! Main boom to the rear

The following hook block is included in the calculation:
! 1!sheave, type 32 (600 kg; 1323 lbs)
Terex® All-Terrain Operation: Driving Instructions 39
Additional axle load table:
Driving with Main Boom Extension 17 m in SI ! Units

* Superstructure to the: rear ! Main boom to the rear

The following hook block is included in the calculation:
! 1!sheave, type 32 (600 kg; 1323 lbs)

Terex® All-Terrain Operation: Driving Instructions 40

Driving with Main Boom Extension 25 m (in SI ! Units)
Axle load table: Correlation of the axle loads with the boom
position and configuration

* Superstructure to the: rear ! Main boom to the rear

The following hook block is included in the calculation:
! 1!sheave, type 32 (600 kg; 1323 lbs)

Terex® All-Terrain Operation: Driving Instructions 41

Additional axle load table:
Driving with Main Boom Extension 25 m in SI ! Units

* Superstructure to the: rear ! Main boom to the rear

The following hook block is included in the calculation:
! 1!sheave, type 32 (600 kg; 1323 lbs)

Terex® All-Terrain Operation: Driving Instructions 42

Driving with Main Boom Extension 33 m (in SI ! Units)
Axle load table: Correlation of the axle loads with the boom
position and configuration

* Superstructure to the: rear ! Main boom to the rear

The following hook block is included in the calculation:
! 1!sheave, type 32 (600 kg; 1323 lbs)

Terex® All-Terrain Operation: Driving Instructions 43

Additional axle load table:
Driving with Main Boom Extension 33 m in SI ! Units

* Superstructure to the: rear ! Main boom to the rear

The following hook block is included in the calculation:
! 1!sheave, type 32 (600 kg; 1323 lbs)

Terex® All-Terrain Operation: Driving Instructions 44

Driving tables (in US ! Units)
Driving the crane with the main boom (US)
Axle load table: Correlation of the axle loads with the boom
position and configuration

* Superstructure to the: rear ! Main boom to the rear

The following hook block is included in the calculation:
! 3!sheave, type 80 (850 kg; 1874 lbs)

Terex® All-Terrain Operation: Driving Instructions 45

Driving with Main Boom Extension 9 m (29.5 ft) (in US ! Units)
Axle load table: Correlation of the axle loads with the boom
position and configuration

*
Superstructure to the: rear ! Main boom to the rear
The following hook block is included in the calculation:
! 1!sheave, type 32 (600 kg; 1323 lbs)

Terex® All-Terrain Operation: Driving Instructions 46

Additional axle load table:
Driving with Main Boom Extension 9 m (29.5 ft) in US !
Units

* Superstructure to the: rear ! Main boom to the rear

The following hook block is included in the calculation:
! 1!sheave, type 32 (600 kg; 1323 lbs)

Terex® All-Terrain Operation: Driving Instructions 47

Driving with Main Boom Extension 17 m (55.8 ft) (in US !
Units)
Axle load table: Correlation of the axle loads with the boom
position and configuration

* Superstructure to the: rear ! Main boom to the rear

The following hook block is included in the calculation:
! 1!sheave, type 32 (600 kg; 1323 lbs)
Terex® All-Terrain Operation: Driving Instructions 48
Additional axle load table:
Driving with Main Boom Extension 17 m (55.8 ft) in US
! Units

* Superstructure to the: rear ! Main boom to the rear

The following hook block is included in the calculation:
! 1!sheave, type 32 (600 kg; 1323 lbs)

Terex® All-Terrain Operation: Driving Instructions 49

Driving with Main Boom Extension 25 m (82 ft) (in US
! Units)
Axle load table: Correlation of the axle loads with the boom
position and configuration

* Superstructure to the: rear ! Main boom to the rear

The following hook block is included in the calculation:
! 1!sheave, type 32 (600 kg; 1323 lbs)

Terex® All-Terrain Operation: Driving Instructions 50

Additional axle load table:
Driving with Main Boom Extension 25 m (82 ft) in US !
Units

* Superstructure to the: rear ! Main boom to the rear

The following hook block is included in the calculation:
! 1!sheave, type 32 (600 kg; 1323 lbs)

Terex® All-Terrain Operation: Driving Instructions 51

Driving with Main Boom Extension 33 m
(108.3 ft) (in US ! Units)
Axle load table: Correlation of the axle loads with the boom
position and configuration

* Superstructure to the: rear ! Main boom to the rear

The following hook block is included in the calculation:
! 1!sheave, type 32 (600 kg; 1323 lbs)
Terex® All-Terrain Operation: Driving Instructions 52
Additional axle load table:
Driving with Main Boom Extension 33 m (108.3 ft)
in US ! Units

* Superstructure to the: rear ! Main boom to the rear

The following hook block is included in the calculation:
! 1!sheave, type 32 (600 kg; 1323 lbs)

Terex® All-Terrain Operation: Driving Instructions 53

Driving the Crane with a Load Coupling and uncoupling a dolly
Driving the crane while it is carrying a load is strictly The coupling and uncoupling, operation and maintenance
prohibited! of a dolly is exclusively the sole responsibility of the
crane operator. The crane operator is responsible for
Attachment coupling / supply connections (optional)
careful performance of the coupling and uncoupling
If the crane is equipped for a trailer (dolly) to be fitted, the sequence, operation and maintenance in accordance with
following equipment is available at the rear of the vehicle: national regulations.
1 Electric connection for dolly lighting equipment, rear The manufacturer’s instructions must be followed.
2 Compressed air connection (yellow) for braking The dolly must be attached to the crane in such a way
3 Compressed air connection (red) for supply output that no dangers arise. For instance, the axles of the dolly
4 ABS socket (7!pin) must be evenly burdened, in order to achieve an optimum
braking effect.
If a dolly coupling is part of our scope of delivery:
Risk of crushing!
5 dolly coupling
Particular attention should be paid to the road safety of the dolly The area between towing vehicle and dolly is not visible
coupling (5). during the steps in which the towing vehicle is moved.
Check the dolly coupling daily for longitudinal play. It may be advisable to assign someone the job of
Longitudinal play is not permitted. Risk of dolly ripping free! monitoring that area.
Initial situation:
! Dolly is switched off with parking brake actuated and wheel
chocks in place.
Risk of accidents!
Automatic braking by disconnecting the brake line is not
sufficient.
Sequence for coupling:
1. For dolly's with rotating shafts:
Release front axle brake (if present).
Risk of accidents!
When the front axle brake is released, the fork may slam
back and forth if the wheels are standing on a smooth,
level surface.

Terex® All-Terrain Operation: Driving Instructions 54

2. Move the towing vehicle up to approximately 1 m (3 ft) from
the coupling ring, then use the height adjustment device to
set the coupling ring at the coupling height.
3. Open the coupling on the towing vehicle.
4. Step out of the danger zone between towing vehicle and dolly!
Risk of accidents!
Never step between the vehicles during the coupling
sequence!
5. Carry out the coupling by moving the towing vehicle backward,
never by using the forbidden method of having the dolly run up to it!
Risk of accidents!
Because of the extreme danger of accidents, it is forbidden Sequence for uncoupling
under any circumstances to allow the dolly to move forward to Uncoupling is accomplished in the same sequence as coupling,
couple the vehicles. but in reverse, whereby the vehicles should be positioned in a
6. Connect the connecting lines: straight line if at all possible.
Risk of accidents!
6.1 disconnect the compressed air connection (yellow; 2)
! Before uncoupling, first actuate the parking brakes of
for the brake line. the towing vehicle and the dolly!
6.2 disconnect compressed air connection (red; 3) for the ! Before uncoupling, first put wheel chocks in place.
supply output. Sequence for disconnecting the connecting lines:
6.3 Connect the electric connections for trailer lighting (1) ! disconnect compressed air connection (red; 3) for the supply
output.
and ABS socket (4).
! disconnect the compressed air connection (yellow; 2) for the
Risk of accidents! brake line.
The connections must be made in the sequence ! disconnect the electric connections for trailer lighting (1) and
specified. ABS socket (4).
The brakes may release if this sequence is not adhered Risk of accidents!
to. The connections must be removed in the sequence
specified.
7. Remove the wheel chocks, release the dolly parking brake, The brakes may release if this sequence is not adhered
monitor departure. to.

Terex® All-Terrain Operation: Driving Instructions 55

Driving with Dolly Dolly ! Preparation (Optional)
To reduce the axle loads for other special requirements (e.g. See instructions under “Dolly coupling / supply
national regulations), the main boom can be set down to the rear on connections” (optional).
a trailer (dolly) for transportation (superstructure position to rear). Measures for “Dolly operation”
To enable the dolly system to follow the vehicle movement during
driving operation (curves / ground undulations), the Measures before driving with the dolly
superstructure must be set to the so-called ”float position” for “Float position” of the superstructure
”Dolly operation”. To enable the dolly system to follow the vehicle movement
There are very different Dolly” designs and different types of during driving operation (curves / ground undulations), the
support devices. superstructure must be set to the so!called ”float position” for
Fully nonbinding, an example of one type of dolly is shown in ”Dolly operation”.
depiction. This does not necessarily represent the The ”floating position” must be set up before the start of
type of design on your crane. driving and consists essentially of the following measures:
Risk of tipping, risk of skidding! ! Release superstructure locking device, secure bolts,
The handling of the vehicle can be seriously impaired attach dolly
depending on the type of dolly used. ! Set the luffing gear.
The reduced axle loads represent an additional negative ! Open the slew gear brake and lock in this position.
effect. The instructions in the section “Driving with The sequence of the steps outlined below must be
reduced axle loads” must be observed. followed.
Be especially careful when driving with attached dolly.
Be particularly careful going round bends
(swerving outwards, drifting sideways, shifting centre of
gravity).
During driving observe the hydraulic oil pressures in the
suspension circuits. If the hydraulic pressures of the rear
axles are increased dramatically on a level surface
(raised axle load), the luffing cylinder must be
readjusted.
Otherwise there is the risk of the dolly not having
sufficient contact with the ground.

Terex® All-Terrain Operation: Driving Instructions 56

Release superstructure locking device, secure bolts, attach
dolly
Steps for “releasing the superstructure locking device / locking
the bolts / fitting the dolly“.
Risk of accidents!
Secure dolly with wheel chocks against rolling away.
(A)
1. Position dolly in front of crane vehicle in such a way that the
dolly can later be pinned on without it needing to be moved
(superstructure rotated to the rear).
2. Stabilize the crane (outrigger span 8.44 x 8.2 m; 27,7 ft x
26,9 ft)
3. Bring basic unit in transport configuration (in accordance
with national regulations and/or national license).
4. Check whether wheel chocks are in place to secure the dolly
against rolling away. The dolly may still need to be secured with
wheel chocks against rolling away.
5. Make the connections between the dolly and chassis frame.
6. Start the superstructure engine
(B)
7. Open superstructure locking device by pressing the push
button (21A). Indicator light in the push buttons begins to
glow.
(C)
8. Derrick out the main boom from the dolly connection
apparatus and then rotate the superstructure to the side in
a clockwise direction so that the superstructure locking pin
is accessible.
(D)
9. Lock the superstructure locking device bolt (80) with the
screw (81) .
(E)
10. Set down the main boom (lengthways) on the dolly, secure
and lock.

Terex® All-Terrain Operation: Driving Instructions 57

11. Remove the wheel chocks from under the wheels of the dolly.
Risk of accidents!
Before setting off with the dolly, the locking bolt (81) of
the superstructure locking device must be mechanically
secured in an elevated position by means of the screw
(see Step 9.).
Set the luffing gear:
12. Retract the luffing cylinders completely (up to the stop).
To retract the luffing cylinders up to the stop, the rear outrigger
cylinders may have to be extended further.
If necessary, the intermediate layers (e.g. wooden planks or
similar.) must be additionally placed between the ground and
outrigger pad. The rear support dimension figure (X) is thus larger
than the front support dimension figure (Y).
13. Close the ball tap (220), thus blocking the oil supply to the
luffing cylinder from the bottom (the luffing cylinder must be
completely retracted).

Terex® All-Terrain Operation: Driving Instructions 58

Open the slew gear brake and lock open:
Risk of tipping!
When the slew gear brake is opened, the superstructure
can turn unintentionally (as a result of wind / inclination
of the crane). In this event the crane could tip over.
Therefore only open / lock open the slew gear brake
when the boom is secured on the dolly.
One can see whether the slewing gear brake in function or
open/locked open by looking at the position of the shift rod (32).
The status ”Slewing gear brake in function” is presented in the
illustration as Position ”B”.
Shift lever (32) pulled out = slew gear brake to ”operation of the
crane”; i.e. “Dolly operation” is prohibited.
The status ”Slewing gear brake open/locked open” is
presented in the illustration as Position ”A”.
Shift lever (32) pushed in = slew gear brake to “Dolly
operation”; i.e. “operation of the crane” is prohibited.
Procedure for “opening/locking open slew gear brake”:
14. Open the slewing gear brake hydraulically by pressing the
switch (22A); indicator light in the switch begins to glow.
15. Lock the opened slew gear brake mechanically.
To this end, remove the padlock (33), push in the shift lever
(32) until the mechanical resistance can be felt (position ”A”),
refit the padlock.
In this condition the slew gear brake is locked open and
therefore nonfunctioning.
16. Close slewing gear brake by pressing the switch (22B);
Indicator light in the switch goes out.
17. Switch off the superstructure engine
The superstructure engine is not permitted to be running while
moving with the main boom set down upon the dolly.

Terex® All-Terrain Operation: Driving Instructions 59

18. Retract outrigger.
19. Set the vehicle level
20. Adjust the dolly behind the crane in accordance with the dolly
manufacturer’s specifications (e.g. level, etc.).
The available equipment, e.g. the indicator lights / warning
buzzer, must be used to monitor “Dolly operation”.
Measures when driving with the dolly
The available devices, e.g. the suspension pressure
gauges, should be monitored while driving or when at a
standstill. Should it happen that the axle loads of the basic unit
and thereby the suspension pressures have increased while
driving on level ground, then the levelling of the dolly must be
readjusted. The contact pressure on the dolly wheels, among
other things, is reduced in this condition, so that the dolly
wheels could tend to lock while braking.
This would result in a reduction of braking power.
Hill summits may only be passed at reduced speed: as a
result of the restricted telescoping path of the luffing
cylinder, the pressure on the dolly wheels could be relieved
and/or they could lift off the ground.
The dolly should be watched in the rear vision mirror while
driving, especially when driving round a bend.

Terex® All-Terrain Operation: Driving Instructions 60

Measures after driving with the dolly
Risk of tilting when raising the boom!
Only lift the boom off the dolly when the slew gear brake is
closed again. Before raising the boom make sure that the slew
gear brake is actually closed!
Unlock and close the slew gear brake following Dolly
operation
Procedure for unlocking and closing the slew gear brake after the
dolly operation:
1. Park the crane vehicle flush with the dolly.
Makes later attachment easier.
2. Secure dolly with wheel chocks.
Risk of accidents!
Secure dolly with wheel chocks against rolling away.
3. Stabilize and level out the crane (outrigger span 8.44 x 8.2
m; 27,7 ft x 26,9 ft).
4. Start the superstructure engine.
5. Open hydraulically the slewing gear brake which is still set
out of function by pressing the switch (22A); indicator light in
the switch begins to glow.
6. Pull out the shift lever (32).
To this end, remove the padlock (33), pull out the shift lever
(32) until the mechanical resistance can be felt (position ”B”),
refit the padlock.

Terex® All-Terrain Operation: Driving Instructions 61

7. Close slewing gear brake by pressing the switch (22B);
Indicator light in the switch goes out.
In this condition the slew gear brake is set to “operation of the
crane” again; i.e. “Dolly operation” is prohibited.
Bring the luffing gear into function
8. Open ball tap (220).

Terex® All-Terrain Operation: Driving Instructions 62

Superstructure locking device: relieving locked position
9. Release the connection of the main boom to the dolly.
10. Raise the main boom slightly until there is clearance
between the boom and Dolly.
11. Slew the superstructure to the side in the clockwise direction
12. Release the screw (81) on the locking bolt (80) of the
superstructure locking device.
The superstructure locking device is set to ”operation of the
crane” again. The locking bolt remains in an elevated position,
but is no longer locked/mechanically secured.
13. Place the main boom in the operating position.
14. Release connection between the dolly and the carrier frame (if
the crane is to be moved).

Terex® All-Terrain Operation: Driving Instructions 63

Reversing Check System (Optional)
General System Description
Using ultrasound, the reversing check system monitors the
space behind the vehicle during reversing. It warns visually and
acoustically of obstacles registered by the system.
The max. range is approx. 3 m (9.8 ft) for visual display and
approx. 1.5 m (4.9 ft) for acoustic display.
The height range for registering obstacles (over the road surface) is
approx. 1 m (3.3 ft).
When reversing you must always take great care. Critical
obstacles might not be registered or not precisely registered
due to physical reflection characteristics.
The reversing check system serves to help you when
reversing; however, it does not release the driver from taking
special care when reversing.
The system can only fulfill its purpose for slow reverse
motion (shunting speed).
When reversing, the driver must behave in such a way
excludes any danger to others.
When reversing, we recommend that you always have a
reliable person as a banks man.
Make sure that the hydraulic suspension is at road travel
level. The level setting directly affects obstacle recognition.
Keep the sensors clean. Remove snow, ice or dirt; these
affect the function.
The system does not register any components hanging over
the crane, i.e. toolboxes, ladders, trailer couplings or spare
wheels. The driver must plan ahead and take these into
consideration himself.
The system cannot recognize and therefore does not display
obstacles exceeding the registering range (approx. 1m =
3,3 ft). The driver must remember this and register obstacle
lying higher up himself.

Terex® All-Terrain Operation: Driving Instructions 64

Function Description
The system consists of:
! sensors (S1 ! S4) on the rear bumper
! dialogue unit (A) in the driver’s cab with
! display for visual distance illustration consisting of:
Digit display (A5) and
four LED columns (A1 ! A4) with 6 rows each
! speakers (A6) for acoustic signals
! electronic control device at the rear of the vehicle
When reversing, the sensors transmit ultrasound signals
continuously and receive ultrasound signals reflected by obstacles.
The distance to the obstacle is calculated by the run time of the
ultrasound signals and signalized by the speaker using a pulse tone
sequence. The closer the obstacle, the faster the tone sequence.
The sensors must be aligned precisely horizontal.
If they face the ground, uneven ground might be displayed as
obstacles. If they face too far upwards, lower lying obstacles are not
registered.
The display
signals the position of the obstacle using LEDs in four columns
/ six rows. Each sensor has its own column.
The digit display (A5) shows the distance to the obstacle in 1 cm
steps. It is indicated in metric form.
The sensors and the dialogue unit are connected to the
electronic control device.

Terex® All-Terrain Operation: Driving Instructions 65

Registering Range
The system’s registering range is divided into four zones:
! Zone Z1
Large objects, i.e. private cars. The distance is displayed
acoustically and using the digit display.
! Zone Z2
Small or badly reflected objects might not be registered.
Other objects are displayed visually and acoustically.
! Zone Z3
Almost all objects are displayed.
! Zone Z4
Almost all objects are displayed, but some could be in the
sensors’ blind spot.
Protruding Components
Risk of accidents and damage
If parts have been fitted to the vehicle which protrude over
the close-up range of 0.4 m (1.3 ft), they could collide with
an obstacle before the sensors (S1 ! S4) register it and issue
a STOP warning to the system.
Parts which do not protrude over the sensors more than
0.4 m (1.3 ft) are within the close-up range (Zone Z4) of up to 0.4
m (1.3 ft) in which a STOP warning will be issued and the driver
should stop.

Terex® All-Terrain Operation: Driving Instructions 66

Critical Situations in the Registering Range
Risk of accidents / damage!
The registering range is limited in height; the entire vehicle
height is not monitored. Only obstacles up to approx. 1 m (3.3
ft) over the road surface are registered.
Please observe:
The following examples show that situations can occur in which the
system does not register certain objects and does not indicate the
correct distance due to their physical composition.
Example 1
Objects which are not in the sensors’ registering range from the
start, cannot be registered.
Example 2
If the object has a jagged surface, the shortest distance is not
automatically indicated. In the example contour “A” is not
indicated, only “B” and “C”.

Terex® All-Terrain Operation: Driving Instructions 67

Example 3
If the obstacle is oblique, the shortest distance “A” is indicated.
Example 4
The system indicates the distance “A”. When driving up to the
obstacle, once the acoustic display has gone over to the stop
range, distance ”A” will be in the blind spot if driving continues,
which means that distance ”B” is indicated instead.
As the examples show, situations can occur in which an
obstacle or the shortest distance to it is not displayed.
This is why you must always take great care when reversing.
If an object is in the area which is not monitored, the system
automatically displays the distance to the next object. This
means that the acoustic signal will jump from the fast sequence
to a slower one and that the digit display (A5) will indicate a
greater distance in the display.
In this case, always stop the vehicle immediately and check the
situation.

Terex® All-Terrain Operation: Driving Instructions 68

First Operation
When reversing you must always take great care. You must be
especially careful the first time you use it. The driver must
acquaint himself with the distance indication by the acoustic
signal’s various tone sequences.
Relation between Display and Tone Sequence with
Varying Distance to the Obstacle

Obstacles might not be recognized in zone 4 if they are not in the

sensors’ registering range (due to their construction).
Colors of the Light emitting Diodes (LED’s)
The different distances are assigned certain colors (F1 ! F6). At the end of
the 6!row square color scale there is a round red
warning light (F7) which is for demanding a stop.

Terex® All-Terrain Operation: Driving Instructions 69

Example of a Display: (Top)
Obstacle at a distance of 1.20 m (3.9 ft)
! The obstacle has been registered by both middle sensors
and is shown in the display.
! Digit display “1.20” means: obstacle at a distance of
1.20 m (3.9 ft).
! LEDs in columns A2 and A3 illuminated (blue / green)
means: the obstacle is in the registering range of both
middle sensors S2 / S3 (distance zones Z1 / Z2.
! Acoustic signal: long tone sequence (Bi Bi Bi Bi).
Example of a Display: (Bottom)
Distance to the obstacle smaller than 0.40 m (1.3 ft)
! The obstacle has been registered by both middle sensors
and is shown in the display.
! Digit display “0.00” means: distance to the obstacle is less
than 0.40 m (1.3 ft).
! LEDs in columns A2 and A3 illuminated (blue / green /
yellow / red) means: the obstacle is in the registering range
of both middle sensors S2 / S3 (distance zone Z4).
! Acoustic signal: continuous tone (B i i i i i i . . . . . ).
Stop demand
If the distance to the obstacle is less than 0.40 m (1.3 ft) (zone
4) the round red LED (F7) is illuminated in each row. The acoustic
signal switches to continuous tone.
RISK OF DAMAGE!
If the round red LED (F7) is illuminated ! at the same time the
acoustic signal jumps to the continuous tone ! the vehicle
must always be stopped and the situation must be checked.

Terex® All-Terrain Operation: Driving Instructions 70

Activating and Using the System
The reversing check system is automatically activated once the
reverse gear has been applied if the ignition is switched on and the
engine is running.
As soon as an obstacle is in the registering range, a consistent
repeated signal is sounded.
At the same time the display shows where the obstacle is: if the
right-hand side of the vehicle is approaching an obstacle (sensor
S4), the right-hand LED row (A4) is illuminated.
If the vehicle approaches an obstacle on the left-hand side
(sensor S1), the left-hand LED row (A1) is illuminated.
If the obstacle is within the range of one the middle sensors (S2,
S3), the corresponding one of both middle LED rows (A2, A3) is
illuminated.
When reversing, the tone sequence is changed, depending on
which zone the obstacle is in, indicating a certain distance. The digit
display (A5) of the display shows the calculated distance in meters.
Stop the vehicle immediately and check the situation if the
following occurs:
When reversing the machine first indicates an obstacle and the
tone sequence gets faster in the usual manner (for example,
changes from the slow to the middle tone
sequence). Suddenly the tone jumps to the slow sequence
or no longer indicates an obstacle.
This means that the obstacle originally registered is no
longer in the sensors’ registering range (due to design), but
could still be in the way.
If the reverse gear is applied (rotary switch (13) to position “R”),
the standard acoustic reverse gear warning signal sounds (at an
interval). You must register this very consciously; it must not be
confused with the acoustic signal of the reversing check system.

Terex® All-Terrain Operation: Driving Instructions 71

Testing the Function / Diagnosis Function
Carry out the function test as follows:
! Apply the parking brake.
! Rotary switch to “N”.
! Activate ignition, if required start the engine; apply reverse
gear (rotary switch to ”R”).
! A short double tone sounds as a function check.
! The digit display (A5) in the display shows the distance to an
obstacle if it is within the registering range.
Diagnosis function
The system has a diagnosis function. If the sensors are faulty,
three short signals are sounded instead of the double tone if
the reverse gear is applied.
Fault Display
Defective sensor is displayed (three tones when applying
the reverse gear)
Proceed as follows if a defective sensor is displayed (see “Test
function”):
! Park the vehicle at a distance of approx. 1 m (3.3 ft) in front
of a large obstacle, i.e. a garage door.
! Apply parking brake, apply reverse gear (rotary switch to “R”).
! The slow tone sequence sounds (zone Z1) and the LEDs of
the intact sensor light up in green.
! Cover sensors one after the other (stand in front of them).
! The acoustic signal jumps to the fast tone sequence um.
The tone sequence does not change at the defective sensor.
Dialogue unit does not indicate any function
Check all connecting cables / plugs / contacts for correct fit
(display, sensors, control device).
Maintenance and Care
Occasionally clean the sensors with a damp cloth.
Do not use any abrasive or aggressive cleaning agents as
this can lead to damage of the sensors.

Terex® All-Terrain Operation: Driving Instructions 72

all-terrain operation

Machine Engines
 Machine Engines Content

Content Pg. Content Pg.

Carrier Engine 3

Start the engine on the outriggers

control 8

Electronic Engine Management 12

Monitoring the Engine 16

Superstructure Engine 18

Terex® All-Terrain Operation: Machine Engines

Carrier Engine ! Use only suitable test cables for taking measurements on
Damage prevention measures plug connections (Mercedes Benz connector set).
The following safety measures must be observed to prevent ! Telephones and radio equipment which are not connected
to an external antenna can cause malfunctions to the vehicle
injury to persons and damage to the engine, components or
electronics and endanger the operating safety of the engine.
cables.
Before commissioning, make sure that you have read the
! Only start the engine when the batteries are properly operating instructions of the engine manufacturer. These
connected. Do not disconnect the batteries when the engine are enclosed in part 5 of this documentation.
is running. The following points are primarily limited to information
! Only start the engine when the speed sensor is connected. which specifically affects the crane.
! Never use a boost charger to start the engine. Jump starting
only with separate batteries.
! For rapid charging of the batteries, the battery terminals must be
disconnected. Follow the operating instructions for the boost
charger.
! The batteries must be disconnected when electric welding
work is carried out, and the ”+” and ”!” cables are connected
to one another.
! The lines of the control units may only be disconnected and
connected when the electrical system is switched off.
! Switching the poles of the supply voltage for the control units
(e.g. by connecting the poles of the batteries incorrectly) can
lead to the destruction of the control units.
! Tighten the plug connections on the injection system to the
prescribed torque.
! For temperatures of higher than + 80° C (176 °F) (foundry
furnace) the control units must be removed.

Terex® All-Terrain Operation: Machine Engines 3

Before Starting the Engine
1. Follow the instructions in the operating manual of the engine
manufacturer.
2. Checking Before Starting Up:
! Fuel supply
! Hydraulic oil level
To avoid damage to the travelling hydraulic pumps, the engine
may no longer be started ! with normal hydraulic oil filling (ATF
! Type A Suffix A) ! at temperatures under !25C (!13F).
! Engine oil level
! Coolant level :
The cooling system is filled correctly if the coolant level
reaches the marked line in the filler neck.
! Parking brake (14) closed
! Rotary switch (13) to “N”
! Quick stop device (optional); must not be actuated.

Terex® All-Terrain Operation: Machine Engines 4

Starting aid with external batteries
If the batteries are “weak”, the chassis engine can be started with the
aid of batteries from the superstructure engine and vice versa.
In contrast to the specifications given in the separate engine
operating instructions (part 5), no foreign starting aid cables are used to
jump the batteries.
Depending on the crane version, two cable couplings (with one
plug and one socket each) are optionally located on the
right-hand side of the chassis.
On the 5!axle basic unit, the cable couplings are located in the
right-hand storage box underneath the outrigger controls.
On the 6!axle basic unit (not shown here), the cable couplings
are located behind a panel above the outrigger controls.
On the superstructure, similar connections are optionally located on the
front of the engine cowling. At the same time, “Minus” (ground) is
always installed on the plugs (1A / 1B) and “Plus” is always
installed on the sockets (2A / 2B).
Here, both supplied starting aid special cables (3, 4) (cable cross
section 95 mm2/ 0.15 in2) can be connected; the different shapes
of the connecting pieces ensures that the poles cannot be
confused.
Other crane vehicles that are equipped with these connections
from our product program can also be used as a starting aid.
We do not recommend other forms of starting aid.
Risk of injury / explosion!
! When using the starting aid, do not bend over the
batteries.
! Do not smoke in the vicinity of the batteries;
Avoid sparks or unshielded flames.
! A discharged battery can freeze at !10C (14F).
It must be thawed before using the starting aid.

Terex® All-Terrain Operation: Machine Engines 5

! To not use a starting aid with defective batteries.
! Be sure that the voltage (24 V) is the same for the flat and the
booster battery.
! Only use a starting aid with original starting aid cable.
! In no case should you use a boost charger. (Damage
to electronic parts)
! Before using the starting aid, separate mobile
communication systems from the electrical system.
! Be sure that plugs / sockets do not come into contact with the
metal parts of the device (risk of short circuit).
Action steps for the starting aid with cable couplings / special
cable:
1. Switch off ignition in the superstructure and chassis.
2. Connect the starting aid special cable to the cable couplings.
(connect and tighten with a short turn to the right.)
First connect the minus pole (cable 3) and then the plus pole
(cable 4).
Electrical components could be damaged if the connecting
sequence is reversed.
3. Start the current supply engine; let the engine run at high
speed.
4. Current consumption engine:
Turn the key in the ignition starter switch to starting position.
Start the engine and let it run at idle speed.
5. Remove the cable, first from the “plus” (cable 4) and then
from the “minus” (cable 3).

Terex® All-Terrain Operation: Machine Engines 6

Ignition!starter switch Release the key after the engine has started.
Starting procedure (engine start) 3. If the engine does not start up after the third attempt: Look
Never start the engine without the batteries connected for the cause of the fault with the help of the operating
properly. instructions.
The engine can either be started in the driver’s cab or on the
outrigger controls (external start).
Start the engine in the driver’s cab
1. Insert the key in the latch contact (15) and turn (to the right)
into the driving position (position “3”).
When the ignition has started, the electrical system carries out a self
!test; the most important signal connections to the instrument
panel are checked. At the same time, a control signal sounds
twice and all indicator lights (31!40 and 50.1) flash.
The function control is ended after the control signals go out.
Some indicator lights that have been activated may light up; e.g.
item 39 “Parking brake”.
The ”CH” display appears on the (transmission information)
display (75).
The basic display “Indicator lights” appears on the driver
information display (43). The selected functions or existing
malfunctions are shown.
For more information, see Sect. 4 in “Driver information system”.
2. Engine start
When the control signal has stopped: Turn the key on as far
as possible (position “4”) and start the engine, without
operating the accelerator pedal.
If required, interrupt the starting procedure after no more than 20
seconds and repeat after approx. 1 minute.
Before attempting to start the engine again, turn the key back to the
first stop.

Terex® All-Terrain Operation: Machine Engines 7

Start the engine on the outrigger controls
(external engine start)
1. Insert the key in the latch contact (15) (position “2”).
2. Press the ”caution” key (10 / 20) for approx. 5 secs. (ignition
on, ”ramp up” data bus).
3. Press and hold the “caution” key (10 / 20) and also press key
“engine start“ (7B / 17B).
4. After the engine has started release both buttons.
When the outriggers are operated, an engine speed of 1200
U/min (rpm) is automatically set.
When the engine is started on the outrigger controls the
warning displays are not in the operator’s line of view. It is
therefore important to listen for acoustic warning signals
(buzzer).

Terex® All-Terrain Operation: Machine Engines 8

After Starting the Engine
Never disconnect the battery terminals when the engine is
running.
Keep your eye on the engine oil pressure!
If the oil pressure is too low, the B12 indicator light will
appear on the driver information display. At the same time,
the “STOP” indicator light (35) will light up on the instrument
panel, and an acoustic warning signal (buzzer) will be emitted.
When the “Oil pressure” warning (B12) is shown, the
operating safety of the engine is in danger.
Stop the vehicle immediately and switch off the engine.
Determine the cause of the fault!
Do not leave the engine running at a standstill to warm it up.
Only operate the engine at full speed / full load once the
prescribed operating temperature has been reached.
If indicator light (B18) lights up, service the air filter.
Switch the engine off immediately in the case of:
! falling or heavily fluctuating oil pressure
! falling output / revs in spite of constant operating
conditions
! heavily smoking exhaust
! excessively high coolant and oil temperature
! sudden abnormal engine noises.

Terex® All-Terrain Operation: Machine Engines 9

Before Switching Off the Engine
Leave the engine running at idle speed for approx. 1!2 minutes
before switching off:
! when the coolant temperature is high (above 95°C / 203°F);
! after driving at full engine power (e.g. after driving on a slope),
to allow the exhaust turbocharger to cool down.
Switching Off (Engine Stop) in Normal Circumstances
The engine can be switched off both in the driver’s cab and on the
outrigger controls.
When the ignition is “off” the transmission automatically switches to
neutral.
When leaving the crane, remove the ignition key and close
off the cab.
Switching off the Engine in the Driver’s Cab
In the driver’s cab the engine is switched off with the ignition
switch (15).
The following condition ensures when the engine is started:
! If the engine is started in the driver’s cab:
Turn the ignition starter switch (15) from driving position
(position “3”) to position “2”.
! If the engine is started at the outrigger controls:
Turn the ignition starter switch (15) from position “2” to
position “1”.
Switching Off the Engine on the Outrigger Control
The engine is switched off on the outrigger control by pressing
button (7A / 17A).
At the same time, this results in the following interaction with the
ignition starter switch (15) in the driver’s cab:
! The ignition remains switched on when the ignition switch
(15) is in position “3”.
! The ignition is switched off when ignition switch (15) is in
position “1”.

Terex® All-Terrain Operation: Machine Engines 10

Switching Off the Engine in an Emergency Risk of damage!
Switching Off Procedure “Quick Stop” (Optional When the trap is closed the engine cannot be started.
Equipment”) Repeated starting attempts lead to engine damage.
On the chassis, the engines of the superstructure and chassis Before the restart, all air carrying hoses ! incl. the charge
can be switched off together at two central points. A mushroom air hoses between the engine and after cooler ! must be
checked to ensure that they are fitted correctly and are
pushbutton is located on the left! and right-hand side of the
completely free of blockages.
crane near the outrigger controls for this purpose. Press the knob to
activate the quick stop device. Once it has been activated, the
mushroom pushbutton must be released again before an
attempt is made to restart the crane (turn and unlock).
The rapid cutout device only functions when the handbrake is
applied and the gear is in neutral.
After the quick stop device has been activated the indicating light
(A20) lights up until the ”Locked” position is released again.
“Quick Stop” with Air Shutoff Valve
Using a trap between the air filter and engine the air flow is cut
off when the device is actuated.
Independently of manual activation, when a certain speed is
exceeded (approx. 2700 U/min / rpm) the quick stop device is
automatically activated. At the same time the fuel supply is
interrupted. The engine is switched off.
Before the engine is restarted the trap (1) must be manually
released. Return lever (2) to the starting position.

Terex® All-Terrain Operation: Machine Engines 11

Electronic Engine Management
The chassis engine is equipped with an electronic control
system. This monitors both the engine and itself (self-diagnosis).
The control and monitoring equipment is in the cab on the
chassis.
Engine Control
1 Increase idle speed, accelerate vehicle, store speed.
2 Reduce idle speed, slow down vehicle, store speed.
3 (Sustained action brake)
4 Switch off idle speed increase, switch off cruise control,
switch off limiter
5 Switch on limiter
Idle speed / intermediate speed / max. working speed
If required, the idle speed when the vehicle is stationary can be
increased from approx. 550 U/min (rpm) to max. 750 U/min (rpm).
The engine speed (with parking brake on) can also be adjusted to
any value ! from neutral gear to a fixed parameter maximum
working speed of 1200 U/min (rpm); e.g. for emergency operation of
the superstructure functions.
When the outriggers are operated, an engine speed of 1200
U/min (rpm) is automatically set.
When the intermediate revs are selected the engine speed can
only be changed to the max. working speed (120 U/min) (rpm) ! by
pressing the accelerator pedal (18).
If the ignition switch (15) is placed in the ”Off” position, the set
intermediate speed is deleted. It must be reset.

Terex® All-Terrain Operation: Machine Engines 12

Idle Speed The cruise control is switched on using the actuating lever on
1 Hold = increase idle speed. the right of the steering column.
Tap = increase idle speed by approx. 20 U/min (rpm). ! Accelerate the vehicle with accelerator pedal (above 40
km/h (25 mph))
2 Hold = reduce idle speed.
! Lever in position
Tap = reduce idle speed by approx. U/min (rpm).
1 Hold = accelerate. Release lever, the speed that has been
After releasing the lever the engine runs at the increased speed.
reached is stored.
4 Tap = idle speed increase switched off.
Tap = store current speed or increase stored speed by
The idle speed increase is automatically switched off after increments of 0,5 km/h (0.3 mph)
starting off. 2 Hold = slow down. Release lever, the speed that has been
reached is stored.
Cruise Control Tap = store current speed or reduce stored speed by
Using the cruise control, the vehicle drives at a stored speed increments of 0,5 km/h (0.3 mph).
(without actuating the accelerator pedal). Resume stored desired speed.
Any speed above 40 km/h (25 mph) can be stored. After releasing the lever the engine runs at the speed that
Risk of accidents! has been reached.
Do not switch on the cruise control on a slippery surface.
Risk of skidding!
Only use the cruise control when the traffic conditions enable a
constant speed. It may not be possible to hold the speed on
inclines.
Do not exceed the highest speed in the individual gears (observe
the revolution counter).
When the cruise control is switched on take your foot off the
accelerator pedal.
Switch on the cruise control:

Terex® All-Terrain Operation: Machine Engines 13

Switch off the cruise control:
Tap the lever in position 4.
The cruise control is automatically switched off:
! when the brake is activated.
(The set speed remains stored.)
! for speeds under 40 km/h (25 mph).
(The set speed remains stored.)
! when the cruise control is switched on.
(The set speed remains stored.)
By briefly tapping on the lever (position 2) the vehicle drives again
at the stored speed.
If the vehicle is accelerated with the accelerator pedal when the
cruise control is switched on, the stored speed is resumed once the
accelerator pedal is released.

Terex® All-Terrain Operation: Machine Engines 14

Limiter (for Limiting the Maximum Speed)
Using the limiter the driving speed can be limited at any level
above 40 km/h (25 mph).
Switch on limiter:
! accelerate the vehicle to the desired speed.
! Press button (5). The speed limiter is activated.
Switch off limiter:
Tap the lever in position 4.
The highest speed that can be set is automatically deleted, when the
ignition!starter switch (15) is turned back to position “2” or
when the cruise control is switched on.
To exceed the set maximum speed:
If the set maximum speed is to be exceeded (e.g. when
overtaking):
Press the accelerator pedal briefly as far as possible, past the full
throttle position (kick!down). After the vehicle has accelerated
release the accelerator pedal and press again. The set speed
limit is reactivated.
Increase the set maximum speed:
If the set maximum speed is to be increased:
Press button (5), hold and accelerate the vehicle. Once the
desired speed has been reached, release the button.
To reduce the set maximum speed:
If the set maximum speed is to be reduced:
Release the accelerator pedal (if necessary, brake the vehicle).
Once the desired speed has been reached, press button (5).

Terex® All-Terrain Operation: Machine Engines 15

Monitoring the Engine
Fault Display
All faults in the engine system and the engine electronic system are
collected. If a fault occurs, this is shown by the indicator light (B15).
Regardless of this general detection / display, certain faults are
directly shown by their own indicator lights (with the
corresponding symbol).
At the same time, the indicator light (35) “STOP” or “Caution” (36)
will light up on the instrument panel; in some cases an acoustic
warning signal (buzzer) can also be heard.
When there is a malfunction / warning display and at the
same time the red warning light “STOP” (35) lights up, the
operational safety of the engine is in danger. Stop the vehicle
immediately and remedy the fault.
! Speed monitor
(50.1) Light emitting diode, red
If it lights up: The engine speed is exceeding 2350 U/min (rpm)
(excessive engine speed).
Be sure that the engine does not exceed the permissible
speed range.
At an engine speed of 2300 U/min (rpm), the exhaust brake is
deactivated to protect the engine mechanics against damage.
! Engine faults (engine system / electronic system)
(B15) Indicating light, red
When the fault indicator lights up read off the fault
code.
All faults are stored in the system and can be read off as fault
codes. Faults which are only displayed temporarily are also
stored.

Terex® All-Terrain Operation: Machine Engines 16

! Coolant level ! Oil level
(B11) Indicating light, red (B14) Indicating light, red
The “Coolant level” (B11) warning is displayed when the The “Oil level” warning (B14) is displayed when the oil
coolant level in the expansion tank has sunk to about 2 l (0.5 gal) level in the engine has sunk considerably under the
under the normal level. At the same time, the alarm buzzer will also minimum amount. At the same time, the alarm buzzer
sound.
will also sound.
Switch off the engine immediately and determine the Switch off the engine immediately and determine the
cause of the fault. cause of the fault.
! Oil pressure This display serves only as additional information. The oil
(B12) Indicating light, red level may only be monitored using the oil measuring
The “Oil pressure” warning is displayed when ! while the engine is stick.
running ! the oil pressure is too low in the engine (= depending on
Depending on the design, this display function is not
the speed).
possible for technical reasons.
At the same time ! if the level continues to fall ! the alarm buzzer
sounds.
Switch off the engine immediately and determine the cause of the
fault.
! Coolant temperature
(B13) Indicating light, red
The “Coolant temperature” warning (B13) is displayed
when a coolant temperature of 104 °C (219°F) is
reached in driving mode. At the same time the alarm
buzzer sounds at 110 °C (230°F) and the engine
output is automatically reduced.
The engine can still be operated; however determine
the cause.

Terex® All-Terrain Operation: Machine Engines 17

! Charging current Evaluation of the Displayed Faults
(B16) Indicating light, red The error code has five digits; the first digit indicates the fault
group (0, 1 or 2). Depending on which fault group is
If the ”charging current” warning is displayed when the engine is displayed, you should proceed as follows:
running, switch off the engine and check the belt drive.
! Fault group 0
Do not let the engine run without the belt drive; the coolant pump is
The fault code is stored, but only displayed when the
not working. diagnosis instrument is connected.
Reading Off the Fault Memory The fault can, if required, be rectified during the next service.
When warning light (B15) lights up, the system has recognized The engine can still be used.
a fault. ! Fault group 1
The fault codes can be read off with the “Minidiag 2” The fault must be rectified as soon as possible.
(Mercedes!Benz) diagnosis device. This is usually done by our Risk of accidents! You must reckon with altered running
customer service or in a DaimlerCrysler AG workshop. characteristics of the engine.
Action steps for error diagnosis: ! Fault group 2
The fault must be rectified immediately.
! Switch off the engine.
Risk of accidents! The running characteristics of the
! Connect the diagnosis device to the diagnosis socket
engine are different (emergency running program).
(14!pin; in the control box “X 300” in the driver’s cab).
! Switch on the ignition.
Do not start the engine.
When the engine is running fault codes cannot be deleted. If no fault
codes are displayed, check the fuse and grounding of the diagnosis
socket.
! Call up the menu for reading the fault codes from the control
unit.
! Call up the fault codes.
A description of all fault codes can be found in the separate
operating instructions of the engine manufacturer (see part 5 in
this service literature).

Terex® All-Terrain Operation: Machine Engines 18

Superstructure Engine
Starting Procedure
Start the engine as follows:
- Insert ignition key into ignition lock (16, S 300) and turn to
the right. Indicator light (50 "Charge current too low") must
come on.
Do not press pedal when starting a warm engine.
- Turn ignition key further to the right up to the stop and hold
in this position until the engine fires.
Release the ignition key as soon as the engine starts. On
no account should the starter be operated with the engine
running.
Observe the following points if the engine fails to start up after
5 seconds:
- Slowly press down the speed adjuster (1)
- Repeat the starting procedure. Do not exceed 20 seconds.
- Wait 60 seconds before attempting another start.
- If the engine fails to start on the third attempt, determine the
cause of the fault with the aid of the engine manufacturer's
operating instructions.

Terex® All-Terrain Operation: Machine Engines 19

After Starting the Engine
- If the engine is running and no oil pressure is displayed at
the pressure gauge (66, P1367) and / or the control lamp
„Engine oil pressure too low“ is flashing (51, „Engine oil
pressure too low“), turn off the engine immediately and
determine the cause.
Avoid high revs when the engine is cold.
- Only run the engine when the battery is properly connected
as otherwise the alternator will be damaged.
- If the engine cuts out, turn the ignition key immediately to
the right.
- If the indicator light (54 "Fault ADM / engine") lights up when
the engine is running, switch off the engine immediately and
determine the cause of the fault.
Switch off the engine immediately if:
- falling or heavily fluctuating oil pressure
- a loss in power or revs without a change in the speed
adjustment or operating conditions
- heavily smoking exhaust
- coolant or oil temperature too high
- abnormal engine noises

Terex® All-Terrain Operation: Machine Engines 20

Switching off the Engine The engine can only be restarted once all engine cutout
Switch off the engine as follows: switches have been unlocked again.
1. Bring the speed control pedal (1) into the "idle" position. The flaps in the engines’ air suction channels must be
2. Leave the engine running for approx. 2 minutes at idle reopened manually before the engine is started again (lever
speed. on air suction channel).
3. Turn the ignition key (16) to the left and remove.
When leaving the cab:
- Switch off the ignition in the superstructure
- Do not blip the throttle just before switching off the engine.
- Do not switch off the engine immediately, but leaving
running without load at idle speed for a few minutes in
order to balance out the temperature..
Engine Cutout Switch (Optional)
Damage can occur to the engine, especially to the after-cooler
tubes, when the engine rapid stop switch is
activated.
Your crane is equipped with engine cutout equipment. This
includes three engine cutout switches. One switch is located in
the superstructure cab on the dashboard (item 15). Two additional
engine cutout switches are located on the chassis frame on
the right- and left-hand side (Y and Z).
The engine cutout switch is only guaranteed to work when the
parking brake is applied in the chassis cab and the
transmission is placed in “neutral”.
All engines/motors are switched off! In the chassis cab the
indicator light (53; engine cutout switch actuated) lights up.

Terex® All-Terrain Operation: Machine Engines 21

NOTES;

Terex® All-Terrain Operation: Machine Engines 22

all-terrain operation

Drive Gearbox
 Drive Gearbox Content

Content Pg. Content Pg.

Drive gearbox description 3

Shifting gears 5

Transmission information display 7

Driving and shifting gears 9

Shifting gears in the manual mode 12

Maneuvering mode 16

Towing away 17

System malfunctions/error diagnosis 21

Terex® All-Terrain Operation: Drive Gear Box

Drive gearbox / distributor gear
The drive gearbox (2) ! an automatic transmission ZF!AS
TRONIC Type 16 AS 2601 (16 forward gears, 2 reverse gears)
! is flanged together with the drive motor (1) via a dry clutch. A
two stage distributor gear (3) is rear mounted to this
combination.
You see here the drive line of the 5!axle model. In the 6!axle
model, an additional non!driven axle has been fitted between the third and
fourth axles.
Drive gearbox:
Description of the System
The ZF!AS TRONIC consists of a four speed part, a splitter unit (GV) and
a rear mounted range unit (GP) in planetary design.
The basic gearbox is dog clutched; splitter and planetary units
are synchronized.
Thanks to the automatic coupling (no clutch pedal), the driver no longer
needs to activate the clutch.
The actual gear switching is done by the electronic transmission system.
The transmission actuator and the clutch actuator are the most
important components for completely automating the
transmission.
The transmission actuator consists of the electronic gear system, shift
valves, shift cylinders and sensors.
The clutch actuator is an electro pneumatic actuator with path sensors; it
takes over the entire transmission actuation.
A hydraulic retarder (system “ZF Intarder”), a non!wearing,
functioning, hydrodynamic auxiliary brake is integrated in the
transmission.
All essential system information, e.g. neutral, gear step, clutch overload,
fault and diagnosis information are display to the driver in the
“Transmission information” display (75).
Moreover, other special indicator lights are shown in the “Driver information
system” display (43) for:
! Clutch overload (B5) and
! transmission malfunction (B6) together with “caution” (36) or
! serious transmission malfunction (B6) together with “STOP” (35)

Terex® All-Terrain Operation: Drive Gear Box 3

System Design
The transmission system consists of the transmission (2) and
components, that are required for the automation of the system.
The transmission actuator (2.1) and clutch actuator (2.2)
components are integrated into the transmission.
The driving switch (2.3), display (2.4) and e!module (2.5)
periphery components are installed in the driver’s cab.
Vehicle components such as display (75), accelerator pedal (18) and
brake pedal (19), engine electronic system, electronic
braking system with wheel speed sensors also belong to the
system.
Legend:
2 Transmission
2.1 Transmission actuator with electronic transmission control
system
2.2 Clutch actuator
2.3 Driving switch
2.4 “Transmission information” display (75)
2.5 E!module
Vehicle components:
18 Accelerator pedal
19 Brake pedal
43 “Driver information system“ display

Terex® All-Terrain Operation: Drive Gear Box 4

Shifting Gears
Driving switch
The driving switch consists of the switch lever (12) and the rotary
switch (13). It is the operating element for
! Selecting the driving range
! Selecting the gear
! Activating / deactivating the automatic mode
! Calling up the error display
Air pressure of min. 6.2 bar (90 psi) is needed to shift gears. It is not
possible to shift gears below this mark. Unsuccessful gear shifts are
saved as errors by the electronic system.
Risk of accidents!
If you shift when the air pressure is too low,
the transmission can remain in neutral, with the result
that no through drive and no engine braking effect are
available.
Rotary switch
The rotary switch has three positions:
! “D” ! Drive
! “N” ! Neutral (no gear is engaged in the transmission)
! “R” ! Reverse
If the rotary switch is in the “N” position, then the switch lever
won’t work.

Terex® All-Terrain Operation: Drive Gear Box 5

Switch lever (12)
The switch lever is used to switch gears and change the
transmission mode (manual / automatic).
The switch lever springs back into its initial position after every
actuation.
By tapping the switch lever several time, you can shift up / down over
several gear steps.
+ Shift up by one gear
+ + Shift up by two gears
! Shift down by one gear
! ! Shift down by two gears
Change transmission mode:
Manual / automatic and vice versa: press switch lever quickly to the left.
Automatic transmission mode
Rotary switch (13) in position “D”: The shifting system
automatically selects the third gear as a fixed programmed
driving gear. Rotary switch (13) in position “R”: The switching
system automatically selects the ”rapid” reverse motion as a fixed
programmed driving gear.
The shifting system automatically shifts up and down while
driving.
You can change the transmission mode from automatic to
manual at any time.
Manual transmission mode
Rotary switch (13) in position “D” or “R”: If the gear shift lever is tilted to the
left, the switching system switches to the operating mode ”Manual”.
The driver can also select another driving gear as the
programmed driving gear.
Over revving the engine must be avoided by the driver by shifting
gears at the right time.
If you use the accelerator pedal in too high a gear, you might stall
the engine.
You must avoid slow driving which puts stress on the clutch by
possibly driving slowly or by driving in a lower gear than is fixed
and programmed.

Terex® All-Terrain Operation: Drive Gear Box 6

(75) “Transmission information” display
All operating indicators (performed or preselected functions),
warning information and malfunctions / errors are shown on the
“Transmission information” display (75) with numbers and
symbols.
Malfunctions, see error code table at the end of the section.
Operating indicators
1 Self!check of the system
(during ignition, on)
2 Transmission in neutral
3 Engaged gear
4 Manual driving mode
engaged gear, possibility to shift back (two gears)
5 “Slow” reverse gear engaged
6 “Fast” reverse gear engaged
7 Automatic driving mode
is shown in the display by four bar with two arrows
(the eighth gear is engaged in the transmission)
Warning information
8 Insufficient air pressure (airless)
9 Take foot from the accelerator pedal
10 Clutch is overloaded. Select a lower gear (clutch)
11 Clutch is worn out (clutch wear)
12 Communication error to the display (electronic error)
13 Transmission temperature too high
System error
14 System malfunction. Continued operation is possible,
though limited.
15 Serious system malfunction. Continued operation is not
permitted.
16 Example: Error no. 74
17 Example: Error no. 168
Four bars are shown in addition to the number: Error no. +
100 (only for two digit display)

Terex® All-Terrain Operation: Drive Gear Box 7

(43) “Driver information system” display
Regardless of what is shown on the “Transmission information”
display (75), various malfunctions are also shown on the “Driver
information system” display (43) with the use of indicator lights.
! Indicator light (B5) = clutch overload
The clutch temperature is too high. Change travelling
operation (do not drive with dragging clutch).
! Indicator light (B6) + “caution” (36) = malfunction in the drive
gearbox Stop vehicle, read off fault code, rectify fault. Continued
operation is possible, though limited.
! Indicator light (B6) + “STOP” (35) = serious malfunction in the
drive gearbox Stop vehicle, read off fault code, rectify fault.
Continued operation is not permitted.

Terex® All-Terrain Operation: Drive Gear Box 8

Driving and Shifting Gears
You are not allowed to leave the vehicle if is the engine is
running or a gear is engaged.
Starting the Engine
1. Apply the parking brake.
2. Rotary switch to “N“ (transmission in neutral)
3. Switch on the ignition. (Ignition starter switch, position “2”)
At “Ignition on”, a self test of the shifting system is done.
After the control signal: “CH” display.
4. Starting the Engine
“N” display; Transmission is in “neutral”.
It is not possible to switch gears when the engine is at standstill.
Driving, Driving Forwards
Starting position:
Apply parking brake, engine running, transmission in “neutral”.
1. Turn rotary switch from “N” to “D”.
Automatic drive mode is activated.
The display (75) shows the driving gear engaged.
The shifting system automatically selects the third gear as a fixed
programmed driving gear.
2. Push the accelerator pedal (18) and at the same time,
release the parking brake.
The vehicle can roll away without pushing the
accelerator pedal (18).
3. The vehicle starts to drive (clutch engages automatically).

Terex® All-Terrain Operation: Drive Gear Box 9

Correcting the programmed driving gear
At road inclines or declines, you can drive with a lower or higher
gear.
The programmed driving gear (gear 3) can be corrected as
follows:
Press the switch lever (12) in the direction “ ! ” or “ + ”; the
engaged driving gear is shown on the display (75).
Change transmission mode: Manual / automatic
The transmission mode can be changed at any time, even while
driving.
Changing the transmission mode from manual to automatic:
Push the switch lever (12) to the left.
Changing the transmission mode from automatic to manual:
! Push the switch lever (12) to the left or
! in the direction “ + “ or “ ! ”.

Terex® All-Terrain Operation: Drive Gear Box 10

Changing Gears
A gear can be switched automatically while driving by the
automatic driving program, or manually by the driver.
You can shift from any gear into ”neutral” using the rotary switch
(13). This gear switch has priority.
The position of the accelerator pedal (18) must not be changed
while switching gears, because the engine is automatically
controlled.
A gear switch command is not executed when the max.
permissible engine speed was exceeded by the gearshift
mechanism.
Risk of accidents!
Shifting to “neutral” is also possible while driving. If you
shift to “neutral”, the drive train is interrupted
The engine braking effect no longer exists.
At the latest by an engine speed of 2350 U/min (rpm), the crane is to
be braked until the speed is reached at which the automatic
transmission shifts down to the next gear (possible gear range
change).
Shifting gears in the automatic transmission mode
All up shifting and downshifting is done automatically.
Shifting gears depends on various factors such as axle load,
acceleration pedal position, speed, engine speed or shift profile.
Up shifting:
When accelerating, as soon as the required speed is reached to
shift up a gear, the transmission automatically shifts into the next
higher gear.
Downshifting:
When decelerating, as soon as the required speed is reached to
shift down a gear, the transmission automatically shifts into the
next lower gear.
The gear display is shown as digits in the display (75) while
driving.

Terex® All-Terrain Operation: Drive Gear Box 11

Shifting gears in the manual transmission mode
Press the switch lever in the direction “ + ” or “ ! ”; the engaged gear
is shown on the display (75).
When you shift gears manually, the shifting system leaves the
automatic transmission mode.
If you press the switch lever (12) to the left, the automatic
transmission mode is activated again.
Skipping gears
Skipping a gear:
Press the switch lever (12) twice quickly into the desired direction.
Skipping two gears:
Press the switch lever (12) three times quickly into the desired
direction.

Terex® All-Terrain Operation: Drive Gear Box 12

Reverse driving / changing the driving direction
You can only shift gear in another driving direction is the
wheels are at a standstill. Engine at idle speed!
If the vehicle is rolling, it will not shift into the reverse gear; the
transmission shifts into “neutral”.
Engage reverse gear:
1. Stop vehicle; wait for standstill; Apply the parking brake.
2. Turn the rotary switch (13) over “N“ to “R“.
“RH“ appears in the display (75)
(clutch remains disconnected)
The switching system automatically selects the “rapid” reverse
motion as a fixed programmed driving gear.
3. Push the accelerator pedal (18) and at the same time,
release the parking brake.
(clutch engages automatically)
4. The vehicle drive in reverse.
As soon as the rotary switch (13) is set in the “R” position, the
reverse gear warning signal sounds.
Correcting the programmed driving gear
At road inclines or declines, you can drive with a lower or higher
gear.
The programmed driving gear (”rapid” reverse motion (display
“RH”)) can be corrected as follows:
Press gear shift lever (12) in direction “ ! ”. The transmission
switches to the “slow” reverse motion (display “RL”).
Changing the driving direction
Turn the rotary switch (13) from “R“ over “N“ to “D“ or reversed
from “D“ over “N“ to “R“.
Remain in position “N“ so that the gearshift is completed.

Terex® All-Terrain Operation: Drive Gear Box 13

Stopping
The vehicle can be braked in any gear to the point of standstill.
If the accelerator pedal is not actuated, the vehicle will decelerate
with the service brake to the point of standstill. Apply the parking
brake.
The clutch opens automatically before the vehicle comes to a
standstill, so that “stalling” the engine is avoided.
When engine is not in action, it is recommended to put the
transmission in neutral, because after the device has been in
standstill for a long time, the emergency pressure supply (6.2 bar
(90 psi)) level required for shifting gears could have sunk to a point
where it is no longer possible to shift into neutral.
Risk of accidents!
If the vehicle is standing with a running engine and an
engaged gear, it is enough to actuate the accelerator
pedal (18) in order to bring the vehicle into motion.
Before leaving the vehicle with the engine running, the
transmission must be in “neutral” and the parking brake
must be applied.
Applying the parking brake while driving on a smooth
surface can bring the engine to a standstill.
The hydraulic steering support is no longer available in
its previous form. A considerable amount of power is
needed for the steering wheel and the steering reacts
more slowly.

Terex® All-Terrain Operation: Drive Gear Box 14

Shutting off the engine and vehicle
1. Stop vehicle; wait for standstill; Apply the parking brake.
2. Turn rotary switch (13) to “N” (neutral).
3. Shut off the engine (ignition!starter switch (15), position “1”)
4. Place wheel chocks underneath (e.g. on inclines)
After “Ignition off”, the system automatically shifts into
neutral. If no brake is actuated, the vehicle can roll away.
“Ignition off”, special case
If the ignition is switched off while driving, it is not possible to shift
into neutral. The engaged gear remains engaged, the clutch remains
engaged.
When the driving speed goes below a certain limit, the clutch and
the transmission shifts into neutral.

Terex® All-Terrain Operation: Drive Gear Box 15

Maneuvering (Distance < 1m / 3.3 ft)
When moving slowly and carefully (e.g. hooking up / detaching
a dolly), a maneuvering operation is provided in the first driving
gear and in the first reverse gear. The transmission remains in
this gear; it does not up shift.
The maneuvering operation is not effective in other gear. If it is
selected in another gear, the shift will not be executed
(transmission remains in the first gear).
In the maneuvering operation, the clutch is switched from
“Driving mode” to “Maneuvering mode” with the switch (90). The
clutch control is different to that for the normal “Driving mode” (now:
dragging clutch).
In this way, the vehicle can be positioned slowly and carefully
forward or backwards using the accelerator pedal (18).
During maneuvering, the distributor gear should always be
shifted into ”Off-road gear” ! because of the more favorable
transmission ratio. This prevents damage to the clutch.
The maneuvering operation is associated with heat
development and increased clutch wear and can lead to
overloading the clutch.
The “CL” display (43) and the “Clutch overload” (B5) is
shown in the display (75) if the clutch is overloaded
(regardless of accelerator pedal position and driving speed).
The driver has to change the travelling operation now
(vehicle / stop) to prevent damage to the clutch.
In “Maneuvering mode”, the vehicle can only be moved slightly.
The driving time is about three minutes; only a short distance (<
1 m / 3.3 ft) can be covered until the “CL” and B5 warning displays
light up as a result of heat development.
The system needs another 15 minutes or so ! with stationary
vehicle and running engine ! to cool off the clutch.

Terex® All-Terrain Operation: Drive Gear Box 16

Towing away
The towing operation is described in detail in Sect. 14.
Observe the procedures defined there exactly.
Towing start
It is not possible to start the engine by towing it along.
Starting aid with external batteries, see Sect. 5.
Rolling down a downhill slope
Prerequisite for this procedure: Running engine
Risk of accidents!
When the vehicle is rolling without an engaged gear !
rotary switch (13) is on “N” ! there is no engine braking
effect.
Do not let the vehicle roll in the opposite direction of the
engaged gear.
If the vehicle rolls forward ! when the transmission is in neutral
! after releasing the brakes and you shift from “N“ to “D“, then the
system selects the gear that fits to the speed. The drive train is
“closed” (positively tied). ( Example with third gear)
Exhaust brake
The engine braking effect is interrupted when switching
gears. The vehicle can accelerate when travelling
downhill.
Manual driving mode
The exhaust brake is deactivated by the system when shifting.
After shifting successfully, the exhaust brake is automatically
switched on again.
Automatic driving mode
When actuating the exhaust brake, the system shifts back to the
gear where the highest brake performance was available.

Terex® All-Terrain Operation: Drive Gear Box 17

Clutch protection
Despite the automated clutch, the driver has great influence on
the service life of the clutch lining. To cut down on wear and tear, it is
recommended to always select the lowest possible gear when
driving.
See “Driving and Shifting” in this section under “Correction of the
programmed driving gear”.
To prevent damage to the mechanical parts of the clutch control,
shift the transmission to neutral for longer stops (more than 1!2
minutes, e.g. traffic jam, train crossing). In doing so, the clutch is
engaged and the clutch controller is released.
If the clutch is in danger of overloading, e.g. due to several short,
consecutive startup procedures or crawling with dragging clutch, the
“ CL “ display will appear on the display (75) and the indicator light
(B5) on the display (43).
Put the vehicle into an operating mode where the clutch is not
overloaded; for example:
! when accelerating (to apply the clutch)
! when stopping
! when driving at a low gear
! when driving at speeds below the walking speed: switch
distributor gear to terrain driving.
If the driver ignores the warning signal, the clutch engages
when the accelerator pedal (18) is pushed.
In this way, further strain on the clutch is avoided.
This can lead to the “stalling” of the engine, in which
case the vehicle may roll back if on an incline.
By releasing the accelerator pedal (18), the clutch opens
again.
Further information can be found under “Maneuvering“ in this
section.

Terex® All-Terrain Operation: Drive Gear Box 18

Over speed protection
To protect the entire drive train from too high a speed, the system
allows only gearshifts that are within a certain range.
Shifting and protective measures are in conjunction with the
permissible engine speed, that can be controlled at the revolution
counter (50) in the instrument panel.
If the engine speed exceeds 2350 U/min (rpm) (excessive engine
speed), the LED (50.1) lights up and the warning buzzer sounds
as long as the engine speed is excessive.
Be sure that the engine does not exceed the permissible
speed range. especially when driving downhill.
At an engine speed of 2300 U/min (rpm), the exhaust brake is
deactivated to protect the engine mechanic against damage.
Manual transmission mode
If the vehicle accelerates when going downhill, the automatic
transmission will not shift into a higher gear.
The engine can be damaged, if the vehicle accelerates when
going downhill and the engine comes in to the over speed
range.
The ! accordingly low ! gear range in which the crane can be
maintained at a constant speed must be selected before the
crane is driven downhill.
Automatic transmission mode
Caution when driving downhill!
At the latest by an engine speed of 2300 U/min (rpm), the
vehicle is to be braked until the speed is reached at which the
automatic transmission shifts down to the next gear.
Risk of accidents!
The vehicle can accelerate when travelling downhill.
To protect the engine during excessive engine speed, the
system up shifts.

Terex® All-Terrain Operation: Drive Gear Box 19

Roller dynamometer
After driving onto a roller dynamometer (brake dynamometer),
shift the transmission into “neutral”.
When rolling, the system recognizes the function “Driving
vehicle”. If a gear is engaged, the clutch engages.
Risk of accidents!
The vehicle can drive off the roller even without the
accelerator pedal being pressed (18).
When rolling, it is not possible to shift into reverse gear.
Hydraulic Retarder (system “ZF Intarder”)
A hydraulic retarder (system “ZF Intarder”) is integrated in the
transmission.

Terex® All-Terrain Operation: Drive Gear Box 20

System malfunctions / error diagnosis
Fault messages
The drive gearbox has a self-diagnosis system.
If the system recognizes faults / errors, this will be shown to the
driver on the (75) “Transmission information“ display.
The faults are divided into fault classes 1 to 3 and entered into the
fault memory of the transmission after the ignition has been
switched off. Up to ten different errors can be stored. If the fault
memory is full, a non!active error will be overwritten.
Error class 1
Errors that even after occurring several time do not lead to a
reduced availability of the system.
Display: None
Unlimited driving mode possible.
Error class 2
If there are two or more occurring errors from error class 2, the
system reacts as under error class 3.
Display: “Spanner” symbol
If the ”Spanner” symbol appears on the display, there is system
malfunction. It may be that the driving mode is only possible in
limited form, e.g. only in manual.
Error class 3 Reset
Display: “Spanner” symbol plus “STOP” It is possible to delete the fault message and the resulting error
If the “Spanner” symbol plus “STOP” appears in the display, there is reaction when the vehicle is at standstill using “Ignition OFF”; wait
a serious system malfunction. Continued operation is not until the display goes out.
permitted. It is necessary to bring the vehicle to the workshop. If the display does not go out after “Ignition OFF”, switch on the
Regardless of what is shown on the “Transmission information” ignition again. If the fault message is still showing, it is time to
display (75), various malfunctions are also shown on the “Driver consult out customer service department.
information system” display (43) with the use of indicator lights. In addition to this optical warning, the warning buzzer sounds in the
cab according to the error class.

Terex® All-Terrain Operation: Drive Gear Box 21

Reading off the fault code
If there is an error, the error number can be called up on the
display (75). If there is a serious system error (“Spanner” symbol
plus “STOP”), stop the vehicle and switch off the engine.
Calling up the current error numbers:
1. Switch on the ignition.
2. Turn rotary switch (13) to “N”.
3. Push the switch lever (12) to the front and hold.
An error number appears on the display (43). This corresponds to
the current error; Example: Error no. 74
Display of three!digit error numbers:
If, in addition to the display number, four bars are shown, this
means that: Error no. 100; Example: Error no. 168
Retrieving the errors stored in the fault memory:
While holding down the brake pedal (19) at the same time, all
(saved and active) errors are shown on the display (43) in
sequence.
Error list
Error list explanation
GV = transmission in GV position (splitter unit)
Even and odd gears
GP = transmission in GP position (range unit)
Slow gears (gears 1 to 8)
Fast gears (gears 9 to 16)

Terex® All-Terrain Operation: Drive Gear Box 22

Listing / explanation of possible error displays

Terex® All-Terrain Operation: Drive Gear Box 23

Distributor gear
The distributor gear is rear mounted to the actual drive gearbox.
It forms a unit with the “Lift axle”.
An emergency steering pump, that secure the steering ability of the
crane in case the engine fails, is located on the intermediate shaft. It
is driven from the rolling crane.
There are two gear levels (street / off-road gear).
A = on road gear, B = drive, C = emergency steering pump 1, D =
front drive, E = differential lock,
F = off-road gear, G = shift cylinder, H = lubricating oil pump, I =
emergency steering pump 2, (not fitted) J = rear drive
Operating the distributor gear
Engage the off-road gear early enough (on level surface and
before entering difficult terrain); and not after the crane vehicle
has become stuck.
On road gear, off-road gear and the differential lock can only be
activated when the vehicle is at a standstill (dog clutching).
On rare occasions, it is not possible to switch from on road gear to
off-road gear in one go due to the gear teeth locking.
If the attempt to shift the distributor gear fails (locked teeth), this will
be indicated on the display (43) by an indicator light (A8). The
distributor gear will then be in neutral; i.e. the drive train is not
closed.
To change the position of the teeth in the distributor gear, carry
out the following procedure:
1. Apply the parking brake.
2. Starting position for rotary switch (13): position “N” .
3. Press the dual button (93) and hold it down.
4. Change rotary switch (13) from “N” to “D” and / or “R”.
Do not push the accelerator pedal (18) (do not give it any
”gas”).
5. Observe the display (43)
If the indicator light (A7) is shown, the gear has been successfully
shifted. The off-road gear is engaged.
6. Release the dual button (93).

Terex® All-Terrain Operation: Drive Gear Box 24

In case the off-road gear ! despite carrying out the described
procedures ! cannot be engaged:
Without the parking brake being engaged, turn the steering
wheel as far as it will go in one direction and then and repeat
procedures 1!6.
If the accelerator pedal was pushed at point 4 (the clutch closed),
the rotary switch (13) must be turned back to the starting position,
position “N”, before another attempt is made to shift the gear. This
will open the clutch again. Another gear shift attempt can be
made.
! On/off-road gear
The switch (93) can be used to choose between two different
gear steps in the distributor gear:
The transmission ratio in the distributor gear changes when
shifting from on road to off-road gear.
When driving below the walking speed or during maneuvering
operation you should always switch to the gear ”Terrain driving” due
to the more favorable transmission ratio. This prevents damage to
the clutch.
The gear shifts of the distributor gear operate independently of
the driving mode / gear mode of the drive gearbox.
A supply pressure of min. 7.0 bar (101.5 psi) is required for all
distributor gear shifts.
! Distributor gear in ”on road gear” position:
The on road gear is always engaged under normal
circumstances. No indicator light is shown.
! Distributor gear in ”off-road gear” position:
Press dual button (93); the indicator light (A7) lights up.
The off-road gear is primarily intended for:
! Driving on a work site
! “Driving when rigged”
! Driving with the lowest speed possible.

Terex® All-Terrain Operation: Drive Gear Box 25

! Differential lock
The differential in the distributor gear can be locked if the drive
wheels slip in difficult ground conditions.
When locked, there is a rigid connection between forwards
output and rear output.
Be sure to follow the instructions and regulations
outlined there.
! Neutral position
If towing is required (for certain specific types of damage), the
distributor gear can also be put into the neutral position using a
manually actuated pneumatic valve.
When towing is finished, on/off-road gear must be reinstated in
the distributor gear by pressing dual button (93).
! Driving in reverse
Prolonged driving in reverse should be avoided. (The lubricating oil
pump does not operate!)

Terex® All-Terrain Operation: Drive Gear Box 26

Driving stuck crane free
If the crane is stuck on difficult terrain, it can be driven ”free” by
driving forwards and backwards.
Action steps for driving crane free:
1. Engage off-road gear (press dual button (93)).
2. Turn rotary switch (13) to “D”.
The driving gear is selected automatically, but can still be
changed using the switch lever (12).
3. Apply careful pressure to the accelerator pedal (18).
Move the vehicle as far forwards as possible.
4. Engage the service brake and stop the vehicle.
Engine at idle speed!
5. Wait for standstill.
6. Move rotary switch (13) from “D” to “N” and then to “R”).
The driving gear “RH” is automatically selected, however it
can still be modified using switching lever (12).
7. Apply careful pressure to the accelerator pedal (18).
Move the vehicle as far backwards as possible.
8. Engage the service brake and stop the vehicle.
Engine at idle speed!
9. Wait for standstill.
Repeat this procedure if the crane is getting a bit further with each
change of direction.
If the wheels are spinning, stop the attempt; the crane will have to
be towed free.
You can only shift gear in another driving direction is the
wheels are at a standstill (engine at idle speed).
If the vehicle is rolling, it will not shift gears; the
transmission shifts into “neutral”.
Keep an eye on the clutch temperature.
If the clutch is in danger of overloading, the “CL” display will
appear on the display (75) and the indicator light (B5) on the
display (43).

Terex® All-Terrain Operation: Drive Gear Box 27

NOTES;

Terex® All-Terrain Operation: Drive Gear Box 28

all-terrain operation

Brakes
 Brakes Content

Content Pg. Content Pg.

General 3

Service brake 4

Parking brake 6

Retarder brakes 8

ABS system 13

Terex® All-Terrain Operation: Brakes

Brakes
The braking system is designed in accordance with German
road traffic regulations and European EEC directives for axle
loads of up to 12 tons (26.4 kip).
Ensure therefore that these axle loads are observed.
Never drive with a defective brake system.
Emergency Pressure Supply ! Braking System
Display of the pressure supply
The pressure supply can be called up on the display (43) “Driver
information” (to do so, see notes in section 4).
1. Call up the menu selection 4 (Check information” in the main
menu.
2. Then select menu point 4 “Pressure supply in braking circuits 1
and 2”.
In the top row, the pressure in braking circuit 1 and in the bottom row
the pressure in braking circuit 2 is displayed (bar display).
If the emergency pressure supply is below 7 bar (101.5 psi), the
braking system must be topped up at medium revs, until a pressure
of 8 bar (116 psi) has been reached.
Fault / warning displays
The following warnings are displayed on display (43), if the pressure
supply falls below 5.5 bar (79.8 psi):
! Preheating indicator (B3) for braking circuit 1
! preheating indicator (B4) for braking circuit 2
At the same time the preheating indicators (B3 / B4) appear, the
“STOP” display (35) is shown and the warning buzzer sounds.
If the preheating indicators (B3 / B4) light up together with
the “STOP” display (35) and the warning buzzer sounds,
the pressure supply in the braking system is too low.
Stop the vehicle immediately; there is a serious risk of
accidents.

Terex® All-Terrain Operation: Brakes 3

Service Brake
The service brake (dual circuit compressed air braking system)
acts on all wheels.
To brake, press down pedal (19) of the brake valve sensitively.
Immediately after driving, test the brakes on a dry, anti!skid
road surface (service and retaining brake). When doing so,
make sure the crane brakes evenly, does not veer to the side
and that brake delay is faultless.
There must be no oil or water in the brake linings. If moisture
has seeped through to the brake linings, apply the service
brake lightly until braking is faultless.
The service brake must not be used for sustained periods
under any circumstances. Danger of overheating (fading)!
The service brakes may only be used when driving downhill in
order to brake the crane until a speed has been achieved where
the crane switches back to the next gear.
This is why you must select the gear before driving downhill
with which the speed of the crane can be maintained when
driving downhill.
Never drive with a defective brake system!
After the brakes have been used more intensively, do not switch off
the vehicle immediately but drive on for a little while in order to allow
the brakes to cool off faster from the driving wind.

Terex® All-Terrain Operation: Brakes 4

Display of Wear to the Brake Linings (Disc Brake)
The brake linings are monitored by wear displays. Any wear on
the left disc brake is indicated by indicator light (B35) and any
wear on the right disc brakes is indicated by indicator light (B36).
At first, the wear displays are only illuminated during braking.
They are constantly illuminated as wear increases.
RISK OF ACCIDENTS!
The brake linings are worn and the braking effect is
greatly reduced if indicator light (B35) or indicator light
(B35) is illuminated constantly or during braking.
Components of the braking system could become damaged if
driving is continued.
The brake linings must always be replaced axle by axle.

Terex® All-Terrain Operation: Brakes 5

Parking Brake
To park the crane, the parking brake (hand brake) must be applied!
It is opened with compressed air and closed with accumulated
spring force.
In the 5!axle basic unit the retaining brake is effective for axles
1, 3, 4 and 5.
In the 6!axle basic unit the retaining brake is effective for axles
1, 3, 5 and 6.
If the service brake fails, the retaining brake can be used as an
emergency brake.
If the emergency pressure supply in the spring accumulator
brake circuit is too low, the spring accumulator parking brake can be
mechanically released in an emergency.
As the parking brake does not work on all wheels, its braking
effect is less than that of the service brake.
Apply the parking brake:
Move lever (14) from the neutral position to the fully braked position
at the rear (lever locks in place). The indicator light “parking
brake” (39) lights up.
With partial braking, the lever must be held in the desired position as
it otherwise returns automatically to the released (neutral) position.
RISK OF ACCIDENTS!
Make sure that the lever (14) locks correctly in the full brake
position, as it can otherwise return automatically to the
released position.
The lever (14) must not be able to be pushed backed into the
released position (without actuating the lock).

Terex® All-Terrain Operation: Brakes 6

Release the parking brake:
Lift and hold the lock of the parking brake valve. Swing the lever (14)
forwards up to the stop. The indicator light “parking brake” (39) must
go out.
The parking brake holds the crane on a max. incline of 28 % but not
on the maximum incline on which the crane can be driven.
If required, additionally secure the crane with chocks to prevent it
from rolling on downhill slopes.
When using the parking brake as an emergency brake, do not
move the lever (14) suddenly, but slowly and evenly. The braking
effect can thus be applied increasingly. Do not allow the lever to lock
in place!
Only use the parking brake for parking or in case of an
emergency.
Never drive with a defective brake system.
Brake Pressure Limit
(Optional Equipment / National Regulations)
For special transport conditions with reduced axle loads (for special
national regulations) the vehicle can be equipped with a brake
pressure limit.
Observe the permitted axle loads and drive carefully.
Observe the information sign in the driver’s cab.
Test Points of the Braking Circuits
(Optional Equipment / National Regulations)
Depending on customer requirements and national regulations,
the vehicle can be equipped with additional test points (111, 112)
for both braking circuits. The test points have been marked with
signs so they can assigned to a braking circuit.
The test connections (111, 112) are located in the storage
compartment on the left side of the vehicle between the axles.

Terex® All-Terrain Operation: Brakes 7

Retarder Brakes
The crane vehicle is fitted with two sustained action brakes (exhaust
brake, hydraulic retarder) as standard.
Both are actuated using the combination switch (3). When switching
on (lever in level I) the indicator light (38) lights up.
Risk of skidding!
Do not activate the exhaust brake / retarder on a slippery
road surface. The wheels cannot lock.
The sustained action brake is automatically switched off as long as
there is ABS control. However, the indicator light (38) does not go
out. Afterwards, the operating mode most recently activated is
switched on.
In switching step I, only the exhaust brake is activated; from switch
stage II the hydraulic retarder is switched on as well. Depending on
the lever position, the brake effect is increased steadily from the first
to the last step.
Lever in position
“0” = switched off
“I” = exhaust brake
”II! V” = exhaust brake + retarder, 4 steps
Especially when driving down longer downhill stretches use the
sustained action brakes. Also in normal driving conditions, the non
!wearing sustained action brakes should be used where possible for
braking.
The effect of the exhaust brake and the hydraulic retarder is
dependent on the engine speed.
The higher the rpm/speed, the greater the braking effect.
The accelerator must not be pressed when the sustained!
action brakes are in operation!
The correct gear level must be selected before a downhill/
uphill stretch is reached at which the speed can be held
constant.
The effect of a sustained action brake is interrupted during
a shifting procedure. The vehicle can speed up during
downhill driving.

Terex® All-Terrain Operation: Brakes 8

Manual Driving Operation
The exhaust brake is deactivated by the system during gear
shifts. After shifting, the exhaust brake is automatically activated
again.
Automatic Driving Operation
When activating the exhaust brake the system automatically
switches back to the gear for which there is the maximum braking
performance.
Engine Brake (Exhaust Brake and Constant Throttle)
The engine brake consists of a combination of exhaust brake and
constant throttle.
The constant throttle valve is closed during normal operation.
When the exhaust brake is activated, it opens constantly and
increases the braking effect by reduced compression.
When the combination switch (3) is activated (lever in position
“I”), the exhaust brake is switched on; the indicator light (38) is
illuminated.
The exhaust brake is only effective at an engine speed of more
than 900 min!1 (rpm) . If the engine speed falls below 900
min!1 (rpm), the exhaust brake is automatically switched off (and
switched back on again when the speed increases).
The exhaust brake is deactivated even when engine speeds are
over 2300 min!1 (rpm).

Terex® All-Terrain Operation: Brakes 9

Hydraulic Retarder (System “ZF Intarder”)
The retarder is an additional hydrodynamic brake which is integrated in
the transmission and functions without causing wear.
By actuating the combination switch (3) (lever in position II!V) the
hydraulic retarder is switched on; the indicator light (38) is illuminated.
The brake effect is increased steadily from the first to the
last step.
Using the retarder has no effect on transmission operation.
If the clutch is applied (for switching gears), the braking force of the
retarder remains unchanged.
Depending on the engine speed, the retarder is activated with a short
time delay.
When the hydraulic retarder is used, heat is created in the
transmission.
The transmission oil temperature is monitored indirectly (via the
coolant temperature of the engine) with the help of the preheating
indicator (B13) in the driver information display.
Before and during downhill driving, make sure that the engine
speed does not fall below 1600 min!1 (rpm). Otherwise, sufficient
cooling is not ensured.
You might have to switch back a gear in order to increase
speed and water pump and fan performance.
If the oil temperature rises to unauthorized values (over 150C /
302F) ! which leads to a coolant temperature which is too high
! the retarder performance must be reduced until the coolant
temperature has reached a steady state at less than 95C
(203F).
If the retarder performance is not regulated by the driver, the system
automatically reduces the braking effect until the permitted
temperature has been achieved (again).
When the retarder braking effect has been reduced, the indicator
light (38) starts to flash.
The reduced braking effect must be taken into consideration
and driving must be adapted (gear selection, service brake).
Following longer downhill stretches with the retarder switched
on, the engine can only be switched off when the temperature
indicator has returned to the permitted range.

Terex® All-Terrain Operation: Brakes 10

Function “Sustained Action Brake Cruise Control”
Using the function “Sustained action brake cruise control” a set
(”fixed”) speed can be kept constant during a downhill stretch !
within the limits of the existing braking capacity (engine brake
torque, gear step).
The sustained action brake cruise control is activated using the
actuating lever (3) on the right-hand side of the steering column.
The preheating indicator (A21) in the driver display (43) is
illuminated.
The sustained action brake cruise control can only be activated if the
sustained action brake is switched on (= lever position I!V).
The desired driving speed ! in relation to the speedometer ! can be
selected and ”fixed” (lever position 6 or 7) in any lever position.
The electronic system saves the driving speed ”fixed” in this way.
The saved speed is maintained when the braking effect of the
sustained! action brake is sufficient.
If the current driving speed is lower than the “set” speed, the
sustained! action brake remains without function. If speed attains
the saved value again, the sustained action brake becomes active
again.
If speed is increased while the sustained action brake cruise
control is activated, the vehicle returns to the saved speed after the
driving pedal has been released.
If speed is to be reduced to lower than the currently set speed
using the sustained action brake, the ”sustained action brake
cruise control” must be switched off first (tap gearshift position 4).
Then the driving speed can be reduced manually via the different
steps (lever positions I!V) of the sustained action brake. To do
so, the speed must be ”set” again from lever positions 6 / 7 as
described above.
A saved speed is automatically deleted if the ignition is switched
off.

Terex® All-Terrain Operation: Brakes 11

Activating the sustained action brake cruise control:
! Lever (3) in position
0 = deactivated
I!V = sustained action brake step I!V (engine brake
and retarder)
6/7 = sustained action brake cruise control
After the lever has been released, the current
speed is saved.
After the lever has been released, the vehicle drives with the saved
brake effect (speed).
Switching off the sustained action cruise control:
Tap actuating lever (3) in position “4”.

Terex® All-Terrain Operation: Brakes 12

Anti!Blocking!System (ABS)
The vehicle is equipped with the blocking protection “ABS”.
5!axle basic unit
The ABS circuit consists of all axles (of the vehicle) and possibly a
dolly as well.
The function is monitored as follows:
! Lamps B29 + 32 for the vehicle axles.
! Lamps B30 + 31 for possible dolly axles / additional axle /
dummy axle.
6!axle basic unit
The system consists of two separate circuits (not to be confused
with braking circuits).
ABS circuit 1
consists of axles 1, 2, 3, 5 ,6 (of the vehicle) and possibly a dolly as
well.
The function is monitored as follows:
! Lamps B29 + 32 for the vehicle axles (without axle 4).
! Lamps B30 + 31 for possible dolly axles / additional axle /
dummy axle.
ABS circuit 2
is simply axle 4 of the vehicle.
The function is monitored by the preheating indicator (B27).
The ABS stops the wheels from blocking when the vehicle starts
driving at walking speed ! independent of the surface of the road
(water, iciness).
During ABS control, the sustained action brake is automatically
switched off. However, the indicator light (38) does not go out.
Afterwards, the operating mode most recently activated is switched
on.
RISK OF ACCIDENTS!
ABS does not release you from driving in a way that is adapted
to the traffic and road conditions. Track and steerability
of the vehicle are improved.
For example, ABS is not able to prevent the consequences
of keeping too small a safety distance or of increased curve
speeds.

Terex® All-Terrain Operation: Brakes 13

ABS: Full Function / Off!road Mode
ABS is always active, however, the driver can switched it to ”Terrain
mode” using key (104).
ABS in ”Terrain mode” is indicated by the flashing of the indicator
light (32).
The brake path can be reduced on terrain or unpaved roads (i.e. soft
or extremely bumpy surfaces as well as sloping roads) by switching
ABS over to ”Terrain mode”.
The control is speed dependent; at higher speeds the ABS control
also switches to full function when in ”Off-road mode”.
ABS can be switched over when the vehicle is at a standstill (key in
the ignition lock in driving position) or during driving.
After the engine has been switched off and started again, full
function is automatically activated. When driving on terrain,
switch ABS over again.
In the 6!axle basic unit, only the ABS circuit 1 is switched over
to terrain mode due to the system. The ABS circuit 2 cannot be
switched over.
Terrain mode may not be used on public roads.
ABS Functions Check / Fault Display
Every time the ignition is switched on the signal connections to
the instrument panel are checked again.
The indicator lights (32 / 31) must light up for a short period of
time.
The indicator light (B27, B29, B30) is only displayed in case of
damage (indicator light B27 only exists in the 6!axle basic unit).
The functions check is finished after the two check signals (approx.
30 sec.) have sounded.

Terex® All-Terrain Operation: Brakes 14

The indicator lights (31, 32) must light up for a short period of ! If the indicator lights (31) “ABS control, dolly” or (32) “ABS
time and must have gone out after the acoustic check signal. control, vehicle” light up, ABS will not function (defective) for
Blocking protection is not ensured if the displays for functions the dolly or towing vehicle.
check do not light up or do not go out after the check signal. ! If only the indicator light (31) “ABS control, dolly” lights up,
The preheating indicators (B27, B29, B30) may not be the dolly can lock up. In this case, the driver must observe the
illuminated. towed vehicle in the rearview mirror. The towing vehicle (with
(Indicator light B27 only exists in the 6!axle basic ABS) remains steerable; This means that the driver can keep
his towed vehicle steady.
unit) If it lights up, locking protection is not ensured at each
axle. ! If indicator light (32) “ABS control, vehicle” light up, ABS is
in “Terrain mode”.
RISK OF ACCIDENTS!
If an ABS fault is displayed, (”CAUTION” (35) would light up at
the same time), braking behavior of the vehicle can
change.
Drive especially carefully.
Have the fault rectified immediately in a specialist garage.
Braking with ABS
! In case of danger, fully activate the brake pedal. This ensures that
all wheels are monitored and optimum delay of vehicle is achieved.
! During ABS control, the sustained action brake is automatically
switched off. However, the indicator light (38) does not go out.
! If you drive with a dolly without ABS, it can lock up if you have to
make an emergency stop. In this case, the driver must observe the
towed vehicle in the rearview mirror. The towing vehicle with ABS
remains steerable; This means that the driver
can keep his towed vehicle steady.

Terex® All-Terrain Operation: Brakes 15

ABS with Dolly Operation
If the crane vehicle has been fitted with a dolly coupling (optional)
ex works, there is a special ABS socket (4) for the transfer of the
ABS function at the rear of the vehicle rear.
4 ABS socket 7!pole)
When using a dolly, the relevant regulations must be observed
(e.g. if for example ABS is required due to the number of axles).

Terex® All-Terrain Operation: Brakes 16

all-terrain operation

Differential Locks
 Differential Locks Content

Content Pg. Content Pg.

Differential Locks General 3

Activating the Longitudinal Locks 4

Terex® All-Terrain Operation: Differential Locks

Differentials / Differential Locks If the differential locks are switched on, you may only
Differentials drive at walking speed.
To distribute the drive torque to the driven wheels and to adapt The differential locks may not be activated in the steering
figures “Manual rear axle steering” and “Diagonal
the wheel speeds when driving through curves the following
steering”.
differentials (drive assemblies) are fitted:
You must avoid activating the differential locks during
! Longitudinal differential in the distributor gear
steering figures “Narrow cornering” and “Driving away
The distributor gear forms a unit with axle 3. from the wall”.
! Longitudinal differential in the axles
Activating the Differential Locks
An additional longitudinal differential is fitted in axle 4 (5!axle When the differentials are locked there is a risk of parts of the
basic unit) and / or in axle 5 (6!axle basic unit). drive being overloaded. Extreme caution is always required
Activation axle 3: when driving the crane with the differentials locked.
When the longitudinal differential locks are set, axle 3 is Only use the differential locks to drive on difficult
activated. territory (sand, mud, loose ground).
! Transverse differential Only switch on differential locks shortly before reaching an
Transverse differentials are fitted in the drive axles 2, 3, 4, 5 obstacle and switch them off immediately after the obstacle.
(5!axle basic unit) and / or 2, 3, 5, 6 (6!axle basic unit). Only switch on and off when the crane is at a standstill. There
is an extremely high risk of the crane being damaged if the
Differential Locks
differential locks are switched on when the drive wheels are
The differentials in the distributor gear and axles which work
turning.
lengthways and the transverse differentials can be locked.
When the longitudinal differential is locked, the steering can
In the locked condition, there is a rigid connection between the
be actuated with extreme caution.
two outputs of the differentials.
When the transverse differential is locked, the crane may
The differential locks need to be switched on in the following
only be driven in a straight line.
circumstances:
Only use differential locks when the crane is in the transport
! A wheel of a drive axle is on a loose surface and is spinning:
condition. Under no circumstances may they be used when
the transverse differentials must be locked.
the crane is erected!
! Both wheels of a drive axle are spinning:
Drive carefully! Do not start or stop abruptly! Do not apply
the longitudinal differentials must be locked.
Only in extreme cases may both differential locks be switched on full throttle!
together. When the differentials are locked, never drive on longer
stretches or on solid surfaces with good traction.
Terex® All-Terrain Operation: Differential Locks 3
Activating the Longitudinal Locks Activating the Transverse Locks
Activate the longitudinal locks as follows: First switch on the longitudinal locks.
1. Stop the crane; wait for it to come to a standstill! The transverse differentials may only be applied when it
2. Press switch (94). is no longer possible to proceed even though the
The longitudinal locks in the distributor gear and in axle 4 differential locks are
(5!axle basic unit) and / or in axle 5 (6!axle basic unit) are applied.
switched on and axle 3 is activated. Switch on the transverse locks:
3. The indicator light (A9) lights up. 1. Stop the crane; wait for it to come to a standstill!
Switch off the longitudinal locks as follows: 2. Press switch (95).
1. Stop the crane; wait for it to come to a standstill! The transverse locks in the drive axles 2, 3, 4, 5 (5!axle
basic unit) and / or 2, 3, 5, 6 (6!axle basic unit) are
2. Press switch (94) again.
switched on together.
The longitudinal locks in the distributor gear and in axle 4
3. The display (A10) lights up.
(5!axle basic unit) and / or in axle 5 (6!axle basic unit) are
Switch off the transverse locks as follows:
switched off and axle 3 is switched off.
1. Stop the crane; wait for it to come to a standstill!
3. The indicator light (A9) goes out.
2. Press switch (95) again.
If, when switching off the longitudinal locks, display (A9) does
The transverse locks in the drive axles 2, 3, 4, 5 (5!axle
not go out, the lock has not disengaged. basic unit) and / or 2, 3, 5, 6 (6!axle basic unit) are
activate the lock again and carry out small changes in direction switched off together.
with the crane vehicle. At the same time turn the steering a few 3. The display (A10) goes out.
times to the left and right. If, when the transverse differentials are switched off, the
At a standstill, switch off the locks again. display (A10) does not go out, the lock has not
disengaged.
Activate the transverse lock again and carry out small
changes in direction with the crane vehicle.
When at a standstill switch off the lock again.

Terex® All-Terrain Operation: Differential Locks 4

all-terrain operation

Steering
 Steering Content

Content Pg. Content Pg.

General description 3

Monitoring the rear steering 6

Steering programs 7

Raising and lowering the lift axle 19

Steering computer / fault diagnosis

and list 20

Manual emergency steering 26

Terex® All-Terrain Operation: Steering

Steering In particular when carrying out welding work the steering
General System Description computer must be removed from the vehicle.
The steering of the crane chassis consists of a hydraulic Never remove live plug connections. Safety instructions for
the protection of life and limb for maintenance / service work
two circuit steering system and electro hydraulic rear axle
steering (auxiliary steering system). Caution risk of crushing!
The direction of travel is mainly determined by the rigidly When working on the steering system (e.g. inspections,
maintenance / service work, manual emergency steering)
connected front axles.
there is an increased risk of crushing in the area of the
The rear axles, controlled by the program, are aligned and are
steered electro hydraulically, depending on the speed. axles, wheels and crossties.
A computer monitors the control of the electro hydraulic Always ensure that you have sufficient space for safe
rear axle steering. Possible fault codes can be read out there. movement.
Unauthorized persons must stay well clear of the turning
(For information pertaining to this, see “Steering computer / fault
diagnosis / fault list”) area of axles, wheels and crossties.
Various steering programs are available for road travel and For maintenance work in the turning area of axles, wheels
construction site operation. and crossties, it must be ensured that these are prevented
The oil supply of the hydraulic components consists of two from turning (switch off engine or deactivate steering
engine dependent driven steering pumps and a system).
driving dependent driven emergency steering pump. If servicing is required (e.g. balancing the angle
During driving the emergency steering pump which is driven by transducers), particular caution is required.
the moving crane controls the delivery rate from the main pump 2 It must be ensured that no movements can occur on axles,
and deactivates it as soon as the delivery rate is sufficient to supply wheels, or crossties. This can be achieved by switching off
steering circuit 2. the engine or removing the connector at the corresponding
If a steering circuit fails ! or in case of engine failure ! during non!return valves.
driving, the crane vehicle can still be steered until it comes to a Caution following servicing work!
standstill. It does require increased effort, however, to move the Errors in the steering system can lead to axle movements.
steering wheel and the steering reacts slower.
Keep a distance from the axles when starting the engine;
Safety Instructions no!one may be in the slewing range of the axles, wheels or
Safety instructions for protecting the system crossties.
Adjustments to the steering system may only be carried out by
our customer service. Caution with the manual emergency steering control!
Inspections / maintenance work must be carried out by Particular care is required in case of manual emergency
specialist personnel. steering. When actuating the valves for manual emergency
When working on the vehicle (painting, welding) suitable steering, the crossties and the wheels on the affected axle
measures must be put in place to protect the electronic will turn.
components (protection against overloading and static
charging).

Terex® All-Terrain Operation: Steering 3

Monitoring functions for all steering programs
The most important components of the steering system (function of
the steering / emergency steering pumps and
electric hydraulic rear axle steering) are monitored
electronically.
Faults are displayed on the “driver’s information” screen (43) by
means of the following indicator lights:
B2 Fault electric hydraulic rear axle steering
B8 Steering circuit 1 no flow
B9 Steering circuit 2 no flow
B10 Steering circuit 3 (emergency steering) no flow
The indicator lights can be displayed as either pink, white, yellow or
red.
The meaning of the different colors is described in detail in
section 4 (driver’s cab) under “Basic display / meaning of
colors”.
Each time the ignition is switched on the electronic system
checks the signal connections to the instrument board.
Once the dual control signal goes silent (approx. 30 sec.) the
function check has been completed.
If there is a pink colored message, the function cannot be
monitored as there is an error in the corresponding connection;
i.e. a short circuit or a disruption.
In the case of pink colored messages, the display “caution” (36)
automatically lights up as well.
When an indicator light lights up at the same time as the
warning light “caution” (36) there is a malfunction.
Determine the cause of the fault and rectify as quickly as
possible.
If an indicator light lights up at the same time as the red
warning light “STOP” (35) there is a serious malfunction.
The operational reliability of the vehicle is endangered.
Switch off the vehicle immediately and rectify the fault.

Terex® All-Terrain Operation: Steering 4

After rectifying the fault the warning display can be reset by
switching off the ignition for approx. 10 seconds. This also serves to
check that the fault has actually been rectified.
Equally, if an indicator light lights up, the system can be reset to try
and remedy the fault. To this end, stop the vehicle, switch off the
engine (switch off the ignition approx. 10 seconds) and restart.
Monitoring the steering / emergency steering pump
The steering / emergency steering pump is monitored by the
indicator lights (B8 / B9 / B10) to ensure that it is working correctly.
These have the following meaning:
B8: Steering circuit 1 (”main pump 1”) no through feed
B9: Steering circuit 2 (”main pump 2”) no through feed
B10: Steering circuit 3 (emergency steering pump) no
through feed
In case of error ”no flow on the emergency steering pump”
(indicator light B10) will only be displayed by the system at driving
speeds > approx. 8 km/h (5 mph).
The indicator lights (B8, B9 and B10) must not light up as
a rule.
If one of these indicator lights lights up red (at the same
time “STOP” (36) is displayed), there is a dangerous fault
in the steering hydraulics.
The crane must be stopped immediately and the damage
rectified. Never drive with a defective steering system!
In the case of a pink colored message, a function display is not
possible as there is a faulty connection. (See Notes under
“Monitoring functions“ in this section).
Function check
Regular inspections must be carried out to ensure that all
steering units, control units and monitoring equipment are fully
functional. Check for irregularities, e.g. leaks or pink colored
indicator lights / changing displays.

Terex® All-Terrain Operation: Steering 5

Monitoring the electro hydraulic rear axle steering
The function of the electric hydraulic rear axle steering is
monitored during driving by an alarm buzzer and the indicator
light (B2).
The indicator light (B2) signalizes an error in the
electric hydraulic rear axle steering of the basic unit or an error
in the electric hydraulic steering of the optional additional axle
(1).
The warning buzzer sounds additionally for each new fault and
in the event of malfunction during a program change.
The indicator light (B2) must not light up.
If it lights up in red (“STOP” (36) would be indicated at
the same time), there is a dangerous error in the
electric hydraulic rear axle steering of the basic unit or
the optional additional axle.
The crane must be stopped immediately and the damage
rectified. Never drive with a defective steering system!
In the case of a pink colored message, a function display is not
possible as there is a faulty connection. (see Notes under
“Monitoring functions“ in this section).
Function check
Check all steering components regularly for mechanical damage,
corrosion and wear.
In particular pay attention to the angle transducers on the front
/ rear axles and their steering (fixed properly, no corrosion).
Corroded parts must be replaced.

Terex® All-Terrain Operation: Steering 6

Steering programs
Selection of the Steering Program “Road Travel”
or “Construction Site Operation”
With the lockable switch “Enable steering programs” (92) the
system can be set to the steering program “road travel” (switch
not actuated) or ”construction site mode” (switch actuated). For
“construction site mode” the indicator light (A6) lights up.
The system can be changed back to the ”road travel” program
from all steering programs.
For normal road travel no special measures need to be carried
out (no actuation of switch!).
Briefly, for road travel, the program “narrow curving travel” can be
used.
For the purpose of road travel, all axles must be in the
synchronous position for the steering program “road travel”
(information on this available under “synchronization of wheels
when changing the program” in this section).
For the special construction site mode there are various
steering programs
! “Manual rear axle steering”,
! “Narrow curving travel”,
! “Driving away from the wall” and
! “Diagonal steering”,
which ! using various switches / buttons ! need to be selected
case by case. The driving speed is limited.
It is only possible to switch from road travel to construction site
operation (switch 92) when the speed is below the max.
permissible speed of 5 km/h (3 mph) per hour.
’Road travel’ remains active until a corresponding steering
program is selected.
Each selected steering program is assigned to a certain display.
The display follows in the form of an indicator light on the screen
(43) “Driver’s information”. A white indicator light shows a
preselected steering program; a yellow indicator light shows
the currently active steering program.

Terex® All-Terrain Operation: Steering 7

Steering program “road travel”
Caution, the vehicle swerves out.
The steering program “road travel” must be selected for driving
on public highways.
In the program “road travel” the axles are steered as follows:
! Front axles 1 and 2 (rigidly coupled) with the steering wheel.
5!axle!basic unit (A)
! Rear axles 4 and 5 using the electric hydraulic rear axle
steering (depending on the driving speed).
(Axle 3 cannot be steered = rigid axle).
6!axle!basic unit (B)
! Rear axles 5 and 6 using the electric hydraulic rear axle
steering (depending on the driving speed) (axle 3 cannot be
steered = rigid axle; axle 4 is hydraulically locked in the
straight-ahead position).
Basic unit with fitted additional axle (C)
! Axles of the basic unit: for function of steering, see
corresponding description of the basic unit.
Axle of the additional axle: electric hydraulic.
! Axle of the additional axle: electric hydraulic.
For driving speeds < 20 km/h (12 mph), the steered rear axles
steer around the steering centre of the front axles.
For driving speeds > 20 km/h (12 mph) the steering lock of the
rear axles is reduced as the speed increases.
The rear axles no longer steer for driving speeds > 45 km/h
(28 mph).

Terex® All-Terrain Operation: Steering 8

Caution !
For road travel switch (92) “Enable steering programs” may not
be actuated and the related indicator light (A6) must not light
up.
In addition the indicator light (B2) “Error electric hydraulic
rear axle steering” must not light up.
Caution RISK OF ACCIDENTS !
When one of the indicator lights (A6 or B2) lights up
together with the “STOP” display (35) and the warning
buzzer sounds, the operational reliability of the steering
is no longer guaranteed.
Stop vehicle immediately; there is a great risk of
accidents. Never drive with a defective steering system!
“Narrow cornering” for road travel
When turning/maneuvering through a small radius, for example
! as in the road travel mode ! the steering program ”tight
cornering” can be selected when the crane is driven at speeds of V
< 20 km/h / 12 mph) .
5!axle!basic unit (A):
! In the steering program, “Narrow cornering”, the 4th axle
steers more strongly than during normal road travel (as
soon as >85% has been achieved in the steering angle at
axle 1).
6!axle!basic unit (B)
! In the steering program “Narrow cornering”, the 5th axle
steers more strongly than during normal road travel (as
soon as > 85% has been achieved in the steering angle at
axle 1). The 4th axle aligns itself correctly in the geometric
sense to the new steering centre.
This achieves a smaller turning radius ! albeit with increased tire
wear.

Terex® All-Terrain Operation: Steering 9

Switch on steering program “tight cornering”:
! Reduce driving speed to < 20 km/h (12 mph).
! Press button (86) (”Narrow cornering” is preselected).
The indicator light (A3) appears (first in white).
! Continue to reduce driving speed to < 5 km/h (3 mph).
The selected program becomes active;
the indicator light (A3) changes from the color white to
yellow.
If the driving speed is not reduced to < 5 km/h (3 mph) within 20
seconds of the program being selected, the previously active
steering program (”road travel”) is automatically selected.
Switch off the steering program “narrow road travel”:
! Press button (86) again.
The indicator light (A3) changes from the color yellow to
white.
! Synchronize axles (information on this under
”Synchronizing the axles during program change” in this
section).
! Usually while the unit is rolling, the steering angle of axle 4
(5!axle!basic unit) or axle 5 (6!axle basic unit) is
automatically synchronized with the other steering axles
after a short stretch.
! As soon as the synchronized position has been achieved,
the indicator light (A3) goes out.
Even when driving speeds > 20 km/h (12 mph) have been
achieved, “Narrow cornering” is automatically switched off again;
indicator light (A3) goes out.

Terex® All-Terrain Operation: Steering 10

Steering program “construction site mode”
Depending on the selected program, the steered rear axles
are steered by the monitoring program, corresponding with
the front axles (axles 1 and 2) (computer controlled separate
hydraulic circuit).
The nonsteered axle 3 (”Lift axle”) can be raised by the driver
from case to case (information on this under “raising / lowering
the lift axle”). The pressure gauges assigned to the raised axle
(6) and (9) do not display pressure in this case.
Through the various steering programs the following steering
figures are possible:
5!axle!basic unit; 6!axle!basic unit
(5!axle!basic unit; 6!axle!basic unit)
! “Manual rear axle steering” (steering figure “A”)
! “Narrow cornering” (steering figure “B”)
! “Driving away from the wall” (steering figure “C”)
! “Diagonal steering” (steering figure “D”)
Enabling of the steering program “construction site mode” is
only permitted:
! on construction sites / non public highways
! if the crane is in the transportation state
(boom set down, axle loads max. 17 t / 37.5 kip)
The ground conditions must be suitable for driving, i.e. flat and
even ground, no dips or rises in the ground, no obstructions.
The ground must be able to support the individual axle loads (up to
17 t / 37.5 kip) and the overall weight.

Terex® All-Terrain Operation: Steering 11

The indicator light (B2) “fault electric hydraulic rear axle
steering”, with which the electric hydraulic rear axle
steering is monitored, must not light up.
When it lights up together with the “STOP” display (35)
DRIVING IS PROHIBITED!
Remember when using the steering program
“Construction site operation”:
Raising the “lift axle” inevitably leads to increased axle
loads on the axles remaining on the ground.
After the ”lift axle” is raised ! with the vehicle stationary ! a
pressure of 260 bar (3771 psi) must not be exceeded on any of
the pressure gauges (5, 8) and (7, 10).
For reasons of stability, the suspension must be set to the
“four circuit system”.
The differential locks must not be actuated in the steering
figures “manual rear axle steering” and “diagonal
steering”.
With the steering figures “tight cornering” and “driving away
from the wall” switching the differential locks on must be
avoided.
The crane may only be driven at walking speed (max. 5 km/h / 3
mph).

Terex® All-Terrain Operation: Steering 12

Shared characteristics of all steering programs for ! It is only possible to raise / lower the “lift axle” when the
the “construction site mode” vehicle is at a standstill, the hand brake is applied, the vehicle
is in the neutral position with activated transmission and
! The basic release of the various steering program
pressed switch (92).
“Construction site operation” is done by pressing the switch
! It is only possible to lower the “lift axle” when the steering /
(92) at speeds < 5 km/h (3 mph). wheel angles are within the permissible range (for state ”lift
At higher speeds the switch (92) can be activated, however, axle” not raised); otherwise reduce the steering angles by, for
there will be no release of the steering program example, turning the steering wheel (wheels straight ahead).
’Construction site operation’. In this case, the buzzer ! When the “lift axle” is raised, speed is limited to < 20 km/h
sounds. (12 mph).
! In steering program “Construction site operation” only ! If the “lift axle“ remains on the ground, the steering angles
are limited at the steering figures at which the rear axles are
driving speeds up to 20 km/h (12 mph) can be achieved
automatically steered, i.e. they are not limited for “Manual rear
(speed lock). axle steering”.
! The speed lock is only effective as long as the wheels are
! If the axles are not synchronized to the selected steering
not synchronized (again). program, for example when limiting the steering angles to
! If the preselected steering program is not active within protect against high tire wear, each indicator light does not
20 seconds, the system automatically switches back to the appear in yellow but in white.
previously active steering program.
! The program can only be selected during slow driving
(V < 5 km/h / 3 mph); they only become active when all
axles are synchronized.
! Normally “lift axle” (axle 4) remains on the ground; however,
it can be raised by the driver, in order to reduce the tire
wear. (Information on this under “Raising/lowering the lift
axle” in this section.)

Terex® All-Terrain Operation: Steering 13

“Manual rear axle steering” (steering figure “A”) The indicator light (A2) changes from white to yellow.
(Af: Principle sketch of the 5!axle!basic unit; As: Principle sketch of ! Using button (85), the rear axles can now be steered:
the 6!axle!basic unit) Press left button = wheel turn to the left
The front axles are steered with the steering wheel. Press right button = wheel turn to the right
The lift axle (non-steer) remains on the ground, but it can be raised Switch off the steering program “manual rear axle
by the driver. steering”
The rear axles steer according to the position of the front axles ! Lock switch (92) in position “Off”.
and manual activation using the dual button (85). Manual The indicator light (A6) goes out.
steering of the rear axles enables steering movements to the left or The indicator light (A2) changes from yellow to white.
right, independent of the position of the front axles. ! Synchronize axles (see ”Synchronizing the axles”).
The front and rear axles are aligned geometrically correctly ! As soon as the synchronized position has been achieved,
(within their combination). the indicator light (A2) goes out. The steering program “road
The vehicle speed is limited. travel “ is back in action.
There is no limit of the steering angles to protect against
increased tire wear (steering error); not even when the “lift axle”
remains on the ground.
Switch on the steering program “Manual rear axle steering”
! Reduce driving speed to < 5 km/h (3 mph).
! Press switch (92) “Release steering programs“.
The indicator light (A6) lights up.
Speed lock (20 km/h / 12 mph) is effective and indicator
light (A18) lights up.
! Press button (85) “Manual rear axle steering”.
The indicator light (A2) appears (first in white).
After the wheels have been synchronized, the selected
program becomes active.

Terex® All-Terrain Operation: Steering 14

“Tight cornering” (steering figure “B”) Switch off the steering program “tight cornering”
(Bf: Principle sketch 5!axle!basic unit; Bs: Principle sketch ! Lock switch (92) in position “Off”.
6!axle!basic unit) The indicator light (A6) goes out.
The front axles are steered with the steering wheel. The indicator light (A3) changes from the color yellow to
The “lift axle” (non!steered) remain on the ground, but it can be white.
raised by the driver. ! Synchronize axles (see ”Synchronizing the axles”).
The rear axles are steered analogous to the front axles by means of ! As soon as the synchronized position has been achieved,
the electric hydraulic rear axle steering. At the end axle 4 (5!axle the indicator light (A3) goes out. The steering program “road
!basic unit) or axle 5 (6!axle!basic unit) steer more strongly than travel “ is back in action.
during normal road travel.
In the 6!axle!basic unit the 4th axle aligns itself correctly in the
geometric sense to the new steering centre.
Driving speed is limited.
If the “Lift axle” remains on the ground, the steering lock is limited to
prevent excessive tire wear (steering error).
Switch on steering program “tight cornering”
! Reduce driving speed to < 5 km/h (3 mph).
! Activate switch (92) “Release steering programs“.
The indicator light (A6) lights up.
Speed lock (20 km/h / 12 mph) is effective and indicator
light (A18) lights up.
! Press button (86) (”Narrow cornering” is preselected).
The indicator light (A3) appears (first in white).
After the wheels are synchronized, the selected
program remains active.
The indicator light (A2) changes in color from white to
yellow.

Terex® All-Terrain Operation: Steering 15

“Driving away from the wall” (Steering figure “C”) ! Press button (87) (”Driving away from the wall” is
(Cf: Principle sketch 5!axle!basic unit; Cs: Principle sketch preselected).
6!axle!basic unit) The indicator light (A4) appears (first in white).
The steering centre is at the vehicle rear, the rear end does not After the wheels have been synchronized, the selected
swing out. program becomes active.
The front axles are steered with the steering wheel. The indicator light (A2) changes from white to yellow.
The “lift axle” (nonsteer) remains on the grounds, but it can Switch off the steering program “Driving away from the
be raised by the driver. wall”
The rear axles are steered analogously to the front axles by ! Lock switch (92) in position “Off”. The indicator light (A6)
goes out. The indicator light (A4) changes from yellow to
means of the electric hydraulic rear axle steering.
white.
The vehicle speed is limited.
! Synchronize axles
If the “Lift axle” remains on the ground, the steering lock is limited
to prevent excessive tire wear (steering error).
Do not lock the front axles further once the indicator light
(A4) switches from yellow to white.
The rear axles have then reached their final position ! as
specified by the program (no further movement).
Further steering leads to a deterioration in the steering
figure / system benefits and tires could be separated from
the rims.
Switch on the steering program “Drive away from the wall”
! Reduce driving speed to < 5 km/h (3 mph).
! Press switch (92) “Release steering programs“.
The indicator light (A6) lights up. Speed lock (20 km/h / 12 mph) is
effective and indicator light (A18) lights up.

Terex® All-Terrain Operation: Steering 16

! As soon as the synchronized position has been achieved, ! Press button (88) (”Diagonal steering” is preselected).
the indicator light (A4) goes out. The steering program The indicator light (A5) appears (first in white).
“road travel “ is back in action. After the wheels have been synchronized, the selected
“Diagonal steering” (steering figure “D” (crab travel)) program becomes active.
(Df: Principle sketch 5!axle!basic unit; Ds: Principle sketch the indicator light (A2) changes from white to yellow.
6!axle!basic unit) Switch off the steering program “diagonal steering”
The rear axles are steered analogous to the front axles and with the ! Lock switch (92) in position “Off”.
same angle (parallel). The steering lock is determined by the The indicator light (A6) goes out.
steering wheel.
The indicator light (A5) changes from yellow to white.
The “lift axle” (nonsteer) remains on the ground but can be ! Synchronize axles.
raised by the driver.
! As soon as the synchronized position has been achieved,
The vehicle speed is limited. the indicator light (A5) goes out. The steering program “road
If the “Lift axle” remains on the ground, the steering lock is limited to travel “ is back in action.
prevent excessive tire wear (steering error).
Do not turn front axles further, once the indicator light (A5)
changes from yellow to white.
The rear axles have then reached their final position ! as
specified by the program (no further movement).
Further steering leads to a deterioration in the steering
figure / system benefits and tires could be separated from
the rims.
Switch on the steering program “diagonal steering”
! Reduce driving speed to < 5 km/h (3 mph).
! Press switch (92) “Release steering programs“.
The indicator light (A6) lights up.
Speed lock (20 km/h / 12 mph) is effective and indicator
light (A18) lights up.
.

Terex® All-Terrain Operation: Steering 17

Synchronizing the wheels when changing program sufficient to reach the desired position, e.g. if there is an
Synchronization means that the wheels of all steered axles are obstacle on the ground, the vehicle must be driven to another
brought into one specified position in accordance with the spot.
individual steering program. or
The change to a different steering program is complete once all ! Steering movements when stationary
axles have been synchronized. Larger steering movements to the front axle when stationary
The change between the individual steering programs can only by adjusting the steering wheel (right / left).
be carried out once all axles have been synchronized. With this procedure, the so-called ”capture” of the
Synchronization can be achieved by: electric hydraulic steered axles, these are individually
! Driving off moved along with the front axles. As soon as the front axles
are moved, the rear axles begin to synchronize.
Moving the vehicle at speeds over 2 km/h (1 mph).
While the unit is rolling, the steering angle of the rear axles
is automatically synchronized with the other steering axles An axle that is not positioned in the specified geometry, is
automatically positioned to the value preset by the selected
after a short stretch program (synchronized) at the latest when the vehicle starts
or to move.
! Button activation while at a standstill When synchronizing in a stationary position, the procedure
Continuous activation of the corresponding steering can be assisted by releasing the retaining brake.
program button while at a standstill; the axles move
independently into the corresponding desired position as
long as the button remains pressed.
When changing back into the steering program ’Road
travel’, synchronization to the road travel state can be
achieved by continuously pressing the switch ’Narrow
cornering’ (E 141). To do so, the wheels of the front axles
must be aligned in the straight-ahead position.
If the adjustment force of the steering cylinders is not

Terex® All-Terrain Operation: Steering 18

Raising/Lowering the “Lift Axle”
It is only possible to raise / lower the “lift axle“ when the vehicle
is at a standstill, the retaining brake is applied, the transmission is
switched to the neutral position and the switch (92) is pressed.
With the “lift axle” raised the speed is limited to < 20 km/h
(12 mph).
Raise the “Lift Axle”
1. Stop vehicle; apply retaining brake; transmission in “neutral”!
2. Set the engine speed to approx. 1500 U/min (rpm) .
3. Actuate switch (92) “enable steering programs“.
The indicator light (A6) lights up.
4. Activate switch “Raise lift axle” (102) (unlock); this raises the
“lift axle” (axle 3) to the top final position.
The indicator light (A14) lights up.
The pressure gauges 6 and 9 display no pressure.
5. Carry out a visual check to make sure that the raised wheels
of axle 3 are actually clear of the ground.
Lower the “Lift axle”
It is only possible to lower the “lift axle” if the steering and wheel
angles are within the permissible range (for state “lift axle” not
raised); otherwise reduce steering angles by, for example, reducing
the steering wheel turns (wheels straight ahead).
1. Stop vehicle; apply retaining brake; transmission in “neutral”!
2. Switch off the switch “raise lift axle” (102) (lock).
The raised “Lift axle” is lowered to the ground again.
The indicator light (A14) goes out.
3. If the “Lift axle” is on the ground, a pressure of 105 bar
(1523 psi) is built up automatically again in the separated
suspension circuits (II / V) and they are connected again to
the individual overall suspension circuit (III or VI).
(A: 5!axle!basic unit; B: 6!axle!basic unit)
4. The overall level must be checked for road travel (re-level if
required).

Terex® All-Terrain Operation: Steering 19

Steering Computer / Fault Diagnosis / Fault List
The steering computers are in the floor of the driver’s cab under the
passenger seat. In order to get to the steering computers, the entire
seat ! along with its base plate ! must be moved into the most
frontal position and then folded up towards the front (against the
front window).
Risk of injury!
The raised seat must be secured in place with suitable
means (e.g. wooden block, strut) to prevent it falling
backwards.
Operating functions
The display (A) and the 4 function keys (F1 ! F4) are directly on the
main computer.
The buttons have the following basic functions:
ESCAPE button (F1):
! Exit the current menu.
! End without saving.
! Back one entry position.
MINUS button (F2):
! Back one selection point (e. g. previous fault).
! Reduce value by 1.
PLUS button (F3):
! One selection point further (e. g. next fault).
! Increase value by 1.
ENTER button (F4):
! Activate selected menu.
! Confirm value.
! Save value.
! One entry position further.

Terex® All-Terrain Operation: Steering 20

Registration of a fault
The electric hydraulic rear axle steering has a self-diagnosis
system.
When the system recognizes a fault, this is displayed to the driver
on the display (43) “driver’s information” by the indicator light (B2)
and additionally signaled by the warning buzzer.
At the same time, all faults are displayed on the corresponding
steering computer, however, the driver cannot see this during
driving (main steering computer: display A ; steering computer
without display: two digit segment display)

Active faults are always displayed with the indicator light (B2).

If the vehicle is moving when a fault occurs, the warning
buzzer also sounds.

The warning buzzer sounds whenever the crane moves off
in the faulty condition.

Faults that occur remain active until the ignition is switched
off, regardless of whether the fault still exists or not.

An active fault is automatically stored in the error memory.
Fault display on the display (43) “driver’s information”
Caution !
When the indicator light (B2) lights up together with the
warning light “caution” (36) the system has recognized a
malfunction. Determine the cause of the fault and rectify as
soon as possible.
An attempt can be made to rectify the fault by resetting the
system. To this end, stop the vehicle, switch off the engine
(switch off the ignition approx. 10 seconds) and restart.
Caution RISK OF ACCIDENTS !
When the indicator light (B2) lights up together with the
“STOP” display (35) and the alarm buzzer sounds, the
operational reliability of the steering is no longer
guaranteed.
Stop vehicle immediately; there is a great risk of
accidents. Never drive with a defective steering system!

Terex® All-Terrain Operation: Steering 21

See also 6 “Displays on the Driver’s information display (43)”.
Fault display on screen (A) of the steering computer
Display in the fault free condition
In addition to the display “no error” in the second text
line a “ > ” sign moves from left to right. This moving display signals
that the steering computer is active and the software is being
processed.
Display of active faults

As soon as the system has recognized a fault, the display

changes to the fault code screen.
Faults are described according to location of fault, type of fault
and category of fault. All three individual codes are displayed.
! Example fault location: 10
! Example fault type: 07
! Example fault class: 01
If several faults exist at the same time, the display automatically
switches to the next fault after 2.5 seconds.
If all faults have been rectified, the display changes back to the
fault free state (”no error”, “ >” symbol).

Terex® All-Terrain Operation: Steering 22

Error memory / fault codes
Up to 32 various faults with 3 fault codes each can be stored in
the error memory of each steering computer. If the error memory is
full, the first entered fault is overwritten.
The fault codes can be read off the display of the steering
computer. They are subdivided according to the location, type
and category.
Activate / read off error memory
To read off the error memory with the display (A), first the menu
point ”error memory” must be selected in the menu for special
functions.
Select menu special functions:
The menu for special functions is activated by pressing the ESC and
ENTER keys (F1, F4) at the same time for at least 3 seconds.
The change is made when the screen switches to “i/o data
display”.
Continue to menu point “error memory”:
By pressing the PLUS key (F 3) you change from the “i/o data
display” to the “error memory”.
Activate error memory:
By pressing the ENTER key (F4) the error memory function is
activated. The display changes to the first fault that is stored.
Read out fault memory:
Using the PLUS and MINUS keys (F2 / F3) all faults can be read out
one after the other. At the end of the error memory (fault 32) the
system automatically returns to the beginning (fault 1).As soon as
the code display “255, 255, 255” appears on the screen, there are
no additional faults in the memory.
The fault before the display “255” is the last entered fault. With
a completely deleted error memory only code entries with “255”
are maintained.
Exit error memory function:
Using the ESC key (F1), the error memory function can be exited
at any time.

Terex® All-Terrain Operation: Steering 23

Remote controlled operation:
Individual steering computers of the system do not have their own
display. The faults of all steering computers are read off centrally
on display screen (A) of the main steering computer.
To this end, the menu point ”remote control” must be selected in
the ”special functions” menu.
1. Select the ”special functions” menu (press buttons F1, F4 at
the same time for at least 3 seconds).
2. Using the ENTER button (F4) select the menu point “remote
control”.
Display text: “remote control LCD”
3. With the PLUS! and MINUS button the numbers of the
steering computer can be selected.
The display changes to select the desired steering computer.
4. Note:
When selecting the desired steering computer the display
changes constantly between “choose SLC: ?? and the
display contents of the other steering computer. If the
selected computer fails to answer, “no connection” appears.
5. Using the ENTER button (F4) change to the selected
steering computer.
6. Activating / reading out the selected steering computers:
Carry out process “Activating / reading out error memory” (as
described on the previous page).
7. Exiting the selected steering computer:
By switching the ignition off.
Delete error memory
The error memory may only be deleted in consultation with our
customer service department.

Terex® All-Terrain Operation: Steering 24

Fault categories / fault reaction
The faults are divided into the fault categories 0 to 3 and are
entered in the error memory of the steering computer.
The fault category determines the reaction of the steering to the fault
and the subsequent effect on steering operation.
Fault category 0
Display on display (43): No
reaction of the steering system: warning; steering behavior is
not limited.
Effect: unlimited driving operation is possible.
Fault category 1
Display on display (43): indicator light (B2) + “caution” (36) +
single warning signal.
Reaction of the steering system: steering of the axles / of the
system up to the next straight-ahead position.
Effect: speed lock partially effective.
Fault category 2
Display on display (43): indicator light (B2) + “caution” (36) +
single warning signal or indicator light (B2) + “STOP” (35) +
multiple warning signal.
Reaction of the steering system: independent steering in the
straight-ahead position.
Effect: speed lock effective.
Fault category 3
Display on display (43): indicator light B2 + “STOP” (35) +
multiple warning signal.
Reaction of the steering system: self centering or locking of the
axle (safe state).
Effect: speed lock effective.
If faults of categories 1, 2 and 3 are present in the error
memory, these codes must be provided to our customer
service department; they will then determine the causes of
the fault and issue suitable measures to be taken.

Terex® All-Terrain Operation: Steering 25

Manual emergency steering
Caution, increased risk of crushing!
When the valves for the manual emergency steering control are
actuated the crossties and the wheels move on the affected
axle. In the case of manual emergency steering, particular
caution is therefore required.
Make sure that you have sufficient space to move in
freely.
If the steering computer fails, all valves are without current; i.e.
the steered rear axles are locked in the current position.
To be able to adjust these axles without the computer being active,
the steering system is equipped with a manual emergency steering
control. This enables the non!return valves (Y) to be moved from
their locked position, thus releasing the axles.
Subsequently, each individual axle can be moved into a useable
position by manual actuation of the solenoid valves (X1 / X2), for
example to move the vehicle out of a hazardous area. The
requirement for this is that the steering hydraulics are available
(vehicle engine running).
Each axle has its own valve block with non!return valve (Y) and
solenoid valve (valve tappet X1 / X2) assigned to it. The valve
block is at point “A” of the undercarriage under the aluminum
cover.
There are two types of manual emergency activation devices of
the non!return valve:
Type A:
activating the non!return valve (Y) by pressing the key (Y1) in the
blue anodized knurled nut. After the key has been released, the
key jumps back into its original position.
Type B:
activating the non!return valve (Y) by pressing the turning the
black plastic rotating knob. The rotating knob locks into the
activated position.
After manual emergency activation of the axle the rotating knob
must be brought back into its original position manually. To do so,
the rotating knob is pressed and turned back at the same time.

Terex® All-Terrain Operation: Steering 26

Caution RISK OF ACCIDENTS !
For normal operation, the non!return valves must not be
actuated manually.
It may only be used in case of emergency, e.g. in order to
move the vehicle from a dangerous area. The non!return
valves must then spring back into their original position
immediately (type A) or turned back (type B).
If the non!return valves do not spring back into their
original position or are not turned back because they are
blocked, for example, the steering system is no longer
safe. The axles can change position in an uncontrolled
fashion. Safety risk!
Steps for positioning an axle
Type A:
1. Stop vehicle; apply retaining brake; secure against rolling
away; transmission in “neutral”; running engine.
2. Unlock axle:
activate non!return valve (Y) by pressing the key (Y1) in the
blue anodized knurled nut; hold button down.
The axle is no longer locked as long as this button is pressed.
3. Move axle:
! to the left: valve tappet, press left (X1).
! to the right: valve tappet, press right (X2).
4. Lock axle:
if the axle is in the desired position (usually the
straight-ahead position):
! Release the valve tappet (X1 / X2).
The axle no longer moves.
! Release the button (Y1); the valve rotor springs back into
its original position.
The axle is locked again.

Terex® All-Terrain Operation: Steering 27

Type B:
1. Stop vehicle; apply retaining brake; secure against rolling
away; transmission in “neutral”; running engine.
2. Unlock axle:
activate non!return valve (Y) by pressing and turning the
black plastic rotating knob at the same time. The rotating
knob locks into the activated position.
The axle is no longer locked as long as the rotating knob is
locked in place.
3. Move axle:
! to the left: valve tappet, press left (X1).
! to the right: valve tappet, press right (X2).
4. Lock axle:
if the axle is in the desired position (usually the
straight-ahead position):
! Release the valve tappet (X1 / X2).
The axle no longer moves.
! Bring the rotating knob (Y2) back into its original position:
to do so the rotating knob is pressed lightly and turned
back at the same time.

Terex® All-Terrain Operation: Steering 28

all-terrain operation

Suspension
 Suspension Content

Content Pg. Content Pg.

Hydraulic suspension general 3

Setting for transport position 6

Manual setting of the level 7

Raising axles 14

Terex® All-Terrain Operation: Suspension

Hydraulic Suspension
All axles of the crane chassis have hydraulic suspension.
During normal use (e.g. when driving on the road) the hydraulic
suspension is divided into four separate circuits.
When driving on road surfaces which are very uneven (extreme
ramps, slopes, humps), the suspension can be switched over to
a three circuit system to improve road handling.
You switch to the three circuit system by pressing the lockable
switch (99).
When indicator light (A6) comes on, the suspension is in the
three circuit system.
Driving with the three circuit system means less lateral
stability. The max. road speed should therefore not exceed
15 km/hour (9 mph).
When the crane’s equipment is erected, it must be driven
with the four circuit system.
All operating and monitoring equipment is located in the cab of
the chassis.
You can call up the current settings of the suspension circuits on
display (43) under menu point 4.1 “Suspension levels”. (Example
middle position Z 200 151)
Proceed with caution when carrying out adjustment
work! Risk of crushing!
Make sure that no one is in the danger zone of the
vertically extending / retracting suspension cylinders.

Terex® All-Terrain Operation: Suspension 3

Distribution of the suspension circuits / assignment
of the pressure gauge
Normal case: 4!way system
The figure ’A’ in figure shows a principle sketch of the distribution of
the suspension circuits of the 4!way system in the 5!axle basic unit.
The figure ’B’ in figure shows a principle sketch of the distribution of
the suspension circuits of the 4!way systems in the 6!axle basic
unit. In the 7!axle design the suspension cylinders of the additional
axle are added to the individual rear suspension circuit of the basic
unit.
! Suspension circuit 1:
axles 1 and 2, front
right Pressure gauge I (5)
! Suspension circuit II:
*separate suspension circuit for Lift axle ”axle 3,
right pressure gauge II (6)
! Suspension circuit III:
axles 4 to 5 (5!axle basic unit),
axles 4 to 6 or 7 (6!axle basic unit or 7!axle basic unit):
rear right
pressure gauges III (7) + II (6)
! Suspension circuit IV:
axles 1 and 2, front left
pressure gauge IV (8)
! Suspension circuit V:
*separate suspension circuit for Lift axle”
axle 3, left
pressure gauge V (9)
! Suspension circuit VI:
axles 4 to 5 (5!axle basic unit), axles 4 to 6 or 7 (6!axle basic
unit or 7!axle basic unit):
rear left
pressure gauges VI (10) + V (9)

Terex® All-Terrain Operation: Suspension 4

! When the lift axle (axle 3) is raised, the suspension circuits II
/ V assigned to this axle are automatically separated from the
other axles (separate pressure display on pressure gauges
II / V (6 / 9)) and ! after it has been lowered to the ground !
switched to suspension circuits III / VI again.
Special case: 3!way system
The figure ’C’ in figure Z 200 371 shows a principle sketch of the
distribution of the suspension circuits of the 3!circuit system in the
5!axle basic unit.
The figure ’D’ in figure Z 200 371 shows a principle sketch of the
distribution of the suspension circuits of the 3!circuit system in the
6!axle basic unit. In the 7!axle design the suspension cylinders of
the additional axle are added to the individual rear suspension
circuit of the basic unit.
! Suspension circuit I + IV:
axles 1 to 2, front right and left
pressure gauge I (5) / IV (8)
! Suspension circuit III:
axles 3 to 5 (5!axle basic unit),
axles 3 to 6 or 7 (6!axle basic unit or 7!axle basic unit):
rear right pressure gauges III (7) + II (6)
! Suspension circuit VI:
axles 3 to 5 (5!axle basic unit),
axles 3 to 6 or 7 (6!axle basic unit or 7!axle basic unit):
rear left pressure gauges VI (10) + V (9)

Terex® All-Terrain Operation: Suspension 5

Setting for Driving in the Transport Position
General
When driving the mobile crane in the transport position
(construction site or road travel) the suspension must be at the
road travel level (all suspension cylinders in the road travel
position).
The clearance between the fastening eyes on the suspension
cylinder (dimension ”X”) is then 630 mm (24.8 in). Only in this
condition can it be guaranteed that there is sufficient suspension
travel available for driving operation.
At road travel level the suspension travel is + 110 / !110 mm (110
mm upward / 110 mm downward) or + 4.3 / ! 4.3 in (4.3 in upward /
4.3 in downward).
The hydraulic suspension can only be set if:
! ”Hold axles” is activated (display (A13) lights up).
! ”Raise axles” is activated (display (A15) lights up).
”Raise all axles” is activated on the switch panel of the outrigger
controls (button 9/19).
First “Hold axles” (button 101) must be actuated in the cab.
When the ”Lift axle” is raised (steering program “Construction site
operation”), the suspension circuits only react partially. The two front
ones can be set, the two rear ones cannot (with the exception of
axle 3).
The levels of the suspension circuits can either be set together
(dual button 76) or individually (dual buttons 78 / 79 / 80 / 81).
“Automatic” setting road travel level
Using the “AUTO” (77) button the road travel level is set
automatically.
The road travel level is the condition for normal driving operation.
All suspension cylinders are located in the road travel position.
The individual suspension travel is ! 110 / +110 mm (+ 4.3 / ! 4.3
in).
The requirement for smooth functioning is a level, even road
surface (no potholes, no lateral gradient).

Terex® All-Terrain Operation: Suspension 6

“Manual” Setting of the Level
Using manual setting of the level, the individual suspension
circuits can be set independently of each other. Any level in the
entire range of suspension travel (between 0 and 220 mm or 0
and 8.6 in) is adjustable.
Manual level setting is only possible when standing still (parking
brake applied, transmission “in neutral”).
Starting position:
! Set the crane on level and even ground, apply the parking
brake; transmission in “neutral”!
! Set the engine speed to approx. 1500 U/min (rpm).
Function of the dual buttons (78, 79, 80, 81)
! Press dual button in pos. “A”: the corresponding suspension
circuit is raised
! Press dual button in pos. “B”: the corresponding suspension
circuit is lowered.
Setting the Suspension Circuits (Four!circuit System)
The suspension circuits can be reset using the “Raise / lower”
function of the dual buttons (78, 79, 80, 81).
To level the crane quickly and/or evenly, different (or all) circuits
must be filled or emptied at the same time.
It is not possible to set circuits in different directions (filling one
circuit while emptying another) at the same time.
Suspension circuit 1 (front right)
! Press double button (79A):
”raise level” (extend suspension cylinder)
! Press double button (79B):
”lower level” (retract suspension cylinder)

Terex® All-Terrain Operation: Suspension 7

Suspension circuit 2 (rear right)
! Press double button (81A):
”raise level” (extend suspension cylinder)
! Press double button (81B):
”lower level” (retract suspension cylinder)
Suspension circuit 3 (front left)
! Press double button (78A):
”raise level” (extend suspension cylinder)
! Press double button (78B):
”lower level” (retract suspension cylinder)
Suspension circuit 4 (rear left)
! Press double button (80A):
”raise level” (extend suspension cylinder)
! Press double button (80B):
”lower level” (retract suspension cylinder)
Information for setting the overall level:
The difference with this compared to the individual settings is that all
suspension circuits can be reset together using key (76). Any
possibly existing level differences remain.
Press / hold key (76A) = raise total level
Press / hold key (76B) = lower total level.
Control: on the display (43) in menu point 4.1 Suspension level”.
With the manual level setting, the suspension cylinders can be
extended / retracted up to the stop (”in a block”). In this case
make sure that the pressures shown at the middle position are
not exceeded. It is prohibited to drive
suspension cylinders that are set to ”in a block”.
Setting the Suspension Circuits (Three circuit
System)
The suspension circuits are normally set in the four circuit
system (road travel).
However, the setting can also be made in the three circuit
system (off-road travel).
You must then make sure that both front circuits react together;
even if only one of the assigned dual buttons (78, 79) is pressed.

Terex® All-Terrain Operation: Suspension 8

Monitoring the Hydraulic Suspension
Monitoring the Pressure
For constant control of the pressure in the hydraulic suspension,
there are corresponding pressure gauges (items 5!10) in the
driver’s cab.
The desired value of the suspension pressure can only be
determined precisely after the suspension cylinders have been
leveled. With a 12 t (26.4 kip) axle load, the suspension pressure
should be approximately 105 bar / approx. 1524 psi (average value)
and can be different for each suspension circuit.
If the suspension system is switched to ”road travel”, the
suspension pressure can fall on one side and rise on the other
side of the vehicle when driving around corners.
If the suspension pressure in one of the suspension circuits
drops quickly during road travel, and / or the level changes
noticeably (display B1 is illuminated), then there is a dangerous
fault.
In this case you must stop the mobile crane, find the cause of
the fault and rectify it.

Terex® All-Terrain Operation: Suspension 9

Level Control, Level Indicator
Level control of the suspension circuits takes place on the display
(43) in the driver’s cab. The current level of the individual
suspension circuits is indicated with symbols under menu point
4.1 “Suspension level”.
! Symbol (A): suspension circuit I (front, right)
! Symbol (B): suspension circuit III (rear, right)
! Symbol (C): suspension circuit IV (front, left)
! Symbol (D): suspension circuit VI (rear, left)
A level indicator has been assigned to each suspension circuit
which consists of fixed vertical bars (1) and a ”piston” (2) which
moves up and down as the level goes up or down.
At the road travel level
the bar (1) is coloured green and the “piston” (2) is located in the
middle ! in accordance with the road travel position of the
suspension cylinders.
In all intermediate positions
outside the road travel level the bar (1) is coloured yellow and the
“piston” (2) moves further upwards or downwards.
Carry out a level check on level, even ground with the wheels
facing straight ahead.
Deviating suspension circuits must be reset.
If constant deviations occur, the suspension must be
checked by our customer service.

Terex® All-Terrain Operation: Suspension 10

to lock the suspension
The hydraulic suspension system must be blocked for driving in an
erect mode.
When driving in the transport position (on the road and
construction site) the hydraulic suspension may not be
blocked.
If the suspension were blocked, it would cause great
damage to the chassis at speeds > 5 km/h (3 mph)!
Activating the Suspension Block
. . . Before Driving in an Erect Mode
Driving in the erect condition always means driving
without load!
Driving with load is prohibited!
Before supporting the crane on outriggers:
! Align the crane horizontally (”level”).
! Activate switch ”Hold axles”(101), display (A13) is illuminated.
All axles remain in the prescribed position
The crane can be lowered onto the wheels after it has been
supported on outriggers for driving in the erect condition by
retracting the vertical outrigger cylinders.
The crane is aligned horizontally and the suspension cylinders
are in the road travel position.
Before driving in the erect mode:
! The regulations for ground characteristics and road slope
(see section 6) must apply.
! Extend the outrigger struts and hold the outrigger feet just
above the ground.
! Before the crane is lowered onto the wheels ! for driving in
the erect/configured condition, all suspension cylinders must
be in the road travel position.
This is always guaranteed if the axles which are level are set to
”Hold axles” before extending the outriggers.

Terex® All-Terrain Operation: Suspension 11

Bring the crane into state ”Driving when configured”; to do so:
Starting position:
The crane is supported on outriggers.
Switch (101) ”hold axles” is activated; display (A13) lights up.
1. Retract outrigger cylinders slowly and evenly until the wheels of
all axles are pressed evenly on the ground.
Pressure check at the pressure gauge (5 to 10) in cab.
2. Switch off ”Hold axles” with switch (101).
The display (A13) goes out.
3. Switch on ”Lock suspension” with switch (100).
The display (A12) is illuminated.
4. Check the level of the crane (horizontal alignment) optically.
The suspension cylinders of all axles must be approximately
in the road travel position.
The clearance between the fastening eyes on the
suspension cylinder (dimension ”X”) is then 630 mm (24.8 in).
If the crane is not level, extend the outrigger cylinders again
and support the crane lightly on the outriggers.
Fill up the corresponding suspension circuit by pressing
buttons (78A, 80A) for the left!hand side or (79A, 81A) for the
right!hand side.
The suspension may only be filled up to a maximum
suspension pressure of 270 bar (3919 psi).
An attempt to fill the suspension up to higher pressures
can cause the suspension to sag.
5. Then extend the outrigger cylinders until the crane is
standing free on its wheels; check that it is aligned
horizontally. Outrigger plates just above the ground!

Terex® All-Terrain Operation: Suspension 12

Repeat this procedure until the crane is horizontally aligned and When adjusting the height, always leave some clearance to
level with the outrigger cylinders retracted. the final upper and lower position so that there is a degree of
Observe the road travel position of the suspension cylinders. suspension play remaining.
The suspension cylinders must be in the road travel position. In this state the suspension is only effective in a limited
capacity.
The clearance between the fastening eyes on the suspension
cylinder (dimension ”X”) is then 630 mm (24.8 in). Drive with extreme caution and return the level to normal
(road travel level) once the obstacle has been passed.
The suspension pressure should be monitored continually.
If the pressure in one of the suspension circuits rises up to 300
bar (4354 psi), stop the crane immediately and extend outrigger
cylinders until the load is taken off the wheels.
Make sure the crane is evened out by resetting the hydraulic
suspension and / or correcting the boom position.
If the crane is driven further there is a risk of the crane
TIPPING or of AXLE BREAKAGE !
Height Adjustment
The level of the suspension circuits can ! in the context of the
suspension travel ! be adjusted up or down. This can be helpful,
for example
! if the height clearance is too low;
! if more ground space is required;
! if the mobile crane is stuck on terrain;
! before retracting the outriggers.

Terex® All-Terrain Operation: Suspension 13

Raising Axles
Raise all axles when supporting on the outriggers,.
Raise “Lift axle” in the steering program “Construction site
operation”, .
Hold axles
Holding axles when supporting on outriggers,.
Driving the crane in the ”Hold axles” position leads to heavy
damage to the hydraulic suspension.
DRIVINGPROHIBITED!
After every special setting:
! ”Activate suspension block”
! ”Height setting”
! ”Raise axles”
The hydraulic suspension must be reset for ”Driving in the
Transport Position”.
Lowering Brake Valves in the Basic Suspension Block
The lowering brake valves are set ex works to ensure slow and
even lowering of the suspension.
The lowering brake valves may only be adjusted by our
customer service technicians.

Terex® All-Terrain Operation: Suspension 14

Selection of the Operating Modes (Optional) If the switch is in position “ON” (switch position “Y”), the
(”Axle Loads 12 t / 26.5 kip” or “Reduced Axle suspension is in operating mode “Reduced axle loads”.
Loads”) After a new operating mode has been selected, the levels
Due to special country regulations, it might be necessary to of the suspension circuits must be checked. If required,
the level must be reset.
reduce the axle loads under 12 t (26.4 kip) when driving on roads.
If the machine is driven in dolly operation mode, you
In the operating mode “Reduced axle loads” there might be
must follow the “Instructions on dolly operation”.
various driving states. Examples:
The suspension can be blocked in both operating modes
! driving without main boom (switch 100).
! driving without superstructure
! driving with different axle loads < 12 t / 26.5 kip
! driving with dolly (”dolly operation”)
Risk of accidents!
The suspension must always be set to the operating mode
in which the mobile crane is driven. The mode may only be
switched when the crane is at a standstill.
If this instruction is not adhered to, there is increased risk of
accidents.
When selecting the operating mode “Reduced axle loads”, only
the hydraulic suspension is set to the changed axle loads. All
other components (e.g. braking system and steering) remain
unchanged.
The operating mode is selected using a switch (96) that can be
unlocked.
If the switch is in the position “OFF” (switch position “X”), the
suspension is in the operating mode “Axle load 12 t / 26.5 kip”.

Terex® All-Terrain Operation: Suspension 15

NOTES;

Terex® All-Terrain Operation: Suspension 16

all-terrain operation

Outriggers
 Outriggers Content

Content Pg. Content Pg.

Outriggers General 3

Outrigger controls 5

Automatic leveling 18

Hold Axles / ”Raise Axles” Functions 20

Raise Axles Function 23

Measures before Stabilizing 26

Stabilizing procedure 29

Supporting variants 38

Superstructure operation 49

Terex® All-Terrain Operation: Outriggers

Outriggers ! After being put on outriggers (before beginning work
Notes on Outriggers: with the crane), the tires must no longer touch the
Always observe the following information, in order to ensure safe
working:
ground.
! Before stabilizing: ! Make sure the ground is even and capable of carrying
Main boom in longitudinal direction; superstructure locked in the load before setting down the outrigger plates!
transport position. No foreign material (for example: stones, metal objects,
! Only rotate the superstructure if the crane is stabilized on
outriggers. etc.) are permitted under the outrigger plates!
! Before taking up the load, always support the crane on outriggers. The max. surface pressure with standard outrigger plates:
! During the stabilizing procedure the outrigger pads need some ! Outrigger plate, front ø 600 mm (23.6 in)
space for shifting movements to the sides.
Surface pressure approx. 295 N/cm2 (428 lbs/ in2)
! Always extend the outrigger struts up to the corresponding
pinning position (color or arrow marking) and pin. Outrigger force 834 kN (85 t / 187.4 kip)
! For reasons of safety, the outrigger struts can only be extended on ! Outrigger plate, rear ø 700 mm (27.6 in)
the same side as the corresponding switch panel. Surface pressure approx. 255 N/cm2 (370 lbs/ in2)
The crane operator can thus only extend outrigger struts which he
can observe continuously. The outrigger struts on one side can be Outrigger force 981 kN (100 t / 220.5 kip)
activated at the same time. The surface may only be tilted by a maximum of 5o (9%).
Caution: risk of crushing and collision when the outrigger struts ! Where there is insufficient load bearing capacity the soil
are driven at the same time!
pressure in the area of the outrigger plate must be reduced
The outrigger cylinders on the opposite, non!visible side must
be activated for leveling (see relevant section).
using rigid underlay plates (mats).
In order to avoid risk of crushing, the crane operator may only drive ! The maximum permitted support forces must be
an outrigger cylinder until the outrigger plate is positioned on the observed.
ground when he can directly observe an outrigger cylinder. This ! Only level the crane with counterweight and fitted
means that he may only drive an outrigger cylinder if he is on the side
where the relevant cylinder is. However, before extending the equipment by extending the vertical support cylinders.
outrigger cylinder further for supporting on outriggers or for leveling ! In order to protect the supporting cylinders from
from one side he must make sure that there is no further risk of
crushing or collision. If necessary, the crane operator must assign a overloading,
banks man. they must not be extended to the limit; there
! Always keep both switch panels locked. must always be a remaining lift of 2 to 3 cm (0.8 to 1.2 in)
Only the switch panel that is needed directly for operating
after leveling.
may be opened.
To prevent misuse, it must be closed again immediately The remaining lift is also necessary, so that actual support
afterwards. pressure values can be displayed.

Terex® All-Terrain Operation: Outriggers 3

Extending and retracting the supports with a load Notes on Leveling with Counterweight
attached is not permitted. Risk of tipping! Before attaching the counterweight, the crane must be on
outriggers and leveled.
In order to avoid damage to the outriggers as well as After attaching the counterweight, the crane must be re
accidents in the course of driving or operating the crane, ! leveled in the range of 360 (in steps of 90o) .
take special care to do the following: Starting position:
! Crane on outriggers; outrigger basis depending on required
! Unlock the supports before they are extended or configuration state.
retracted. ! Superstructure position 180 degrees = main boom to the rear.
! Pin / secure the supports for work with the crane. Procedure for leveling with counterweight:
1. Check the supporting forces at the support pressure display
! Pinning / locking of the (retracted) struts in transport on the crane chassis (see ”Support pressure display”).
position. Make sure that the supporting forces are symmetrically balanced
! Secure the outrigger pads in transport position (left / right).
2. By adjusting the inclination of the main boom or by extending
There is a danger of accidents, if the prescribed outrigger telescope 1, distribute the load moment of the counterweight in such
support area, specified in the load capacity table, is not a way, that the outrigger pressure on all 4 supports is roughly
identical.
used. 3. Check the leveling of the crane, if necessary repeat the procedure
No other outrigger support area is permitted ! HIGH RISK (see ”Checking the leveling of the chassis”).
Risk of accidents!
OF DAMAGE ! ! The leveling can be done by extending or retracting the
supporting cylinders, up to a maximum supporting force
of 50 t (110 kip).
! If the supporting force of one of the 4 supports exceeds
50 t (110 kip), then the leveling procedure may only be
carried out by extending the supporting cylinders (no
longer by retraction).
However, this is only possible, if the supporting force of
the support to be extracted does not exceed 50 t (110
kip).
Therefore the support force must be distributed by
slightly adjusting / turning the superstructure / main
boom / equipment.
4. Rotate superstructure by 180° .
5. Repeat steps 2 and 3.

Terex® All-Terrain Operation: Outriggers 4

Arrangement of Outrigger Controls
Outrigger controls are located on the chassis to the left and right (in the
direction of travel).
Switch panel left side
Pos. Function
1 Rocker switch “outrigger cylinder front right”
1A: Retracting
1B: Extending
2 Rocker switch “outrigger cylinder front left”
2A: Retracting
2B: Extending
3 Rocker switch ”Supporting cylinder, back right ”
3A: Retracting
3B: Extending
4 Rocker switch ”Supporting cylinder, back left”
4A: Retracting
4B: Extending
5 Rocker switch “outrigger strut front left
5A: Retracting
5B: Extending
6 Rocker switch “outrigger strut rear left”
6A: Retracting
6B: Extending
7 Rocker switch “engine start/engine stop”
7A: Engine stop
7B: Engine start
8 Self return rocker switch ”all outrigger cylinders together”
8A: Retracting
8B: Extending
8B with key 10: Level automatically
9 Button ”raise all axles”
10 Button “caution” (safety key)
1.) “Boot data bus” (hold pressed approx. 5 sec.)
2.) forwards / with button (7B) “engine start”
3.) forwards / with button (8B) with ”automatic leveling”
21 Display with crane symbol left-hand side
The symbol on the push buttons always determines the function
of the outrigger cylinder.

Terex® All-Terrain Operation: Outriggers 5

Switch panel right side:
Pos. Function
11 Rocker switch ”Supporting cylinder, back left”
11A: Retracting
11B: Extending
12 Rocker switch ”Supporting cylinder, back right ”
12A: Retracting
12B: Extending
13 Rocker switch “outrigger cylinder front left”
13A: Retracting
13B: Extending
14 Rocker switch “outrigger cylinder front right”
14A: Retracting
14B: Extending
15 Rocker switch “outrigger strut back right”
15A: Retracting
15B: Extending
16 Rocker switch “outrigger strut front right
16A: Retracting
16B: Extending
17 Rocker switch “engine start/engine stop”
17A: Engine stop
17B: Engine start
18 Rocker switch ”Supporting cylinders together”
18A: Retracting
18B: Extending
18B with key 20: Level automatically
19 Button ”raise all axles”
20 Button “caution” (safety key)
1.) “Boot data bus” (hold pressed approx. 5 sec.)
2.) forwards / with button (17B) “engine start”
3.) forwards / with button (18B) for “automatic leveling”
22 Level
The symbol on the push buttons always determines the function
of the outrigger cylinder.

Terex® All-Terrain Operation: Outriggers 6

Information System for the Outrigger Controls
The information is shown on the display of the outrigger
controls (left on the chassis).
The system on the left vehicle side is described and illustrated
as an example (crane symbol ”P” to the left).
The system consists of the display (21) and the function keys
F1 ! F6.
Legend:
(K) Function keys F1 ! F6
F1 = Contrast
F2 = Brightness
F3 = Inverting
F4 = Support position for outrigger support area
display (optional)
F5 = Inclination
F6 = Support Forces
(L) Symbols for the function keys
(M) Support forces at the front struts (and support
position
for the outrigger support area display (optional))
(N) Level
(O) Electronic level
(P) Crane symbol
(Q) Support forces at the rear struts (and support position
for the outrigger support area display (optional))
If the crane is not equipped with the optional outrigger support
area display, the corresponding space in the display is free.

Terex® All-Terrain Operation: Outriggers 7

Indicators on the Display
Diagram ”A: (Level, support force,
support position (optional))
! Basic display with electronic level indicator / bubble and
indication of supporting force.
When the supporting cylinders are operated, the moving
direction is displayed in the form of an arrow, as well as the
supports, indicated as symbols.

Terex® All-Terrain Operation: Outriggers 8

Diagram ”A: (Level, support force,
support position (optional))
Diagram “B“ (Inclination)
Legend:
(L) Symbols for the function keys
L1 = Exiting the display
L6 = Adjustment, menu assisted (results in diagram ”F”)
(M) Support forces on the front struts
M1 = Support force front right
M2 = Support force front left
(N) Level
(O) Electronic level
(P) Crane symbol
(Q) Support forces on the rear struts
Q1 = Support force rear right
Q2 = Support force rear left
(R) Retraction / extension movement of the outrigger
cylinders
(S) Support position for outrigger support area display
(optional)
S1 = Support position, front right
S2 = Support position, front left
S3 = Support position, rear right
S4 = Support position, rear left
If the crane is not equipped with the optional outrigger support
area display, the corresponding space in the display is free.
(X) Tilt across the driving direction
(Y) Tilt in the driving direction

Terex® All-Terrain Operation: Outriggers 9

Diagram ”C” (supporting force)
Diagram ”D” (Support position of the strut, menu
assisted)
(optional)
Legend:
(L) Symbols for the function keys
L1 = Exiting the display
L4 = Support force (results in diagram ”D”)
L6 = Support position of the strut, menu assisted
(optional) (leads to depiction ”C”)
(M) Support forces on the front struts
M1 = Support force front right
M2 = Support force front left
(P) Crane symbol
(Q) Support forces on the rear struts
Q1 = Support force rear right
Q2 = Support force rear left
(S) Support position of the strut, menu assisted
S1 = Support position, front right
S2 = Support position, front left
S3 = Support position, rear right
S4 = Support position, rear left

Terex® All-Terrain Operation: Outriggers 10

Diagram ”E” (contrast), menu assisted
Modify contrast:
! Key F2 = darker
! Key F5 = lighter
! Key F1 (Exit) leads to view ”A” (level and support force)
Diagram ”F” (brightness), menu assisted
Modify brightness:
! Key F2 = darker (corresponding bar display)
! Key F5 = lighter (corresponding bar display)
! Key F1 (Exit) leads to view ”A” (level and support force)
Diagram ”G” (coding; only for service)

Terex® All-Terrain Operation: Outriggers 11

Functions
Starting position:
! Crane parked in transport position
! parking brake applied
! Ignition switch in position ”0” (external start standby)
”Boot” data bus:
Press key ”caution” (10 / 20) approx. 5 secs.
External engine start:
Press key ”caution” (10 / 20) before / with key ”engine
start” (7B /17B) until the engine is running.
External engine stop:
“Caution” key (10 / 20) ahead / press ”Engine stop” key (7A /
17A)
and hold until engine has stopped.
Modify contrast:
! Call up diagram ”A”
! Key F1 = diagram ”E” (contrast)
! Key F2 = darker
! Key F5 = lighter
! Key F1 = Quit, back to diagram ”A”

Terex® All-Terrain Operation: Outriggers 12

Modify brightness:
! Call up diagram ”A”
! Key F2 = diagram ”F” (brightness)
! Key F2 = darker (corresponding bar display)
! Key F5 = lighter (corresponding bar display)
! Key F1 = Quit, back to diagram ”A”
Inverting
! Call up diagram ”A”
! Key F3 = Inverting
Inclination indicator
! Call up diagram ”A”
! Key F5 = diagram ”B” (inclination)
! Key F1 = Quit, back to diagram ”A”
Support pressure display
! Call up diagram ”A”
! Key F6 = diagram ”C” (supporting force)
! Key F1 = Quit, back to diagram ”A”

Terex® All-Terrain Operation: Outriggers 13

Support Pressure Display
The support force is determined by pressure contacts in the
four outrigger cylinders and shown in the outrigger control
display.
Monitor the supporting forces at every support procedure
with the help of the support pressure display.
”Boot” data bus:
Press key ”caution” (10 / 20) approx. 5 secs.
Displaying supporting force:
! Call up diagram ”A”
! Key F6 = diagram ”C” (supporting force)
! Key F1 (L1) = Quit, back to diagram ”A”
The following supporting force values must not be
exceeded:
85 tons (187.4 kip) at the front supporting cylinders.
100 tons (220.5 kip) at the rear supporting cylinders.
Important note on complying with limit values:
The limit values to be followed are not monitored
automatically.
The support pressure display shows tolerance values. The
display value can differ from the actual value by up to
approx. 10% (plus / minus).
Keep this in mind, e.g. in relation with limited load
!carrying capacity of the ground.
While the crane is in operation, the support pressure display is
supplied with power from the superstructure via an electrical
swiveling connection.

Terex® All-Terrain Operation: Outriggers 14

Inclination Indicator
The inclination of the crane is detected by an electronic
inclination transmitter and displayed at the switch panels of the
outrigger controls on the chassis.
The display consists of an electronic level indicator / bubble
and numerical values for the X and Y axes (one each).
Depending on the direction of a deviation, a negative value
(with a minus before the value) can also be displayed.
The level is used for basic orientation; the numerical values
are definitely the decisive values.
”Boot” data bus:
Press key ”caution” (10 / 20) approx. 5 secs.
Display of inclination
! Call up diagram ”A”
! Key F5 = diagram ”B” (inclination)
! Key F1 (L1) = Quit, back to diagram ”A”
The inclination indicator must be observed during the
leveling procedure.
Deviations must not exceed 0.1 degrees (equivalent to
approx. 0.2 %).
The numerical values X and Y are always decisive. They
show the current deviation of the crane system.

Terex® All-Terrain Operation: Outriggers 15

Outrigger Support Area Display (Optional)
If the crane is equipped with an outrigger support area display,
there is a length measuring device (1) fitted to each
strut in order to determine the support position (outrigger width
B) of each strut.
The values shown under S1 to S4 in the basic display “A”
or the outrigger support area display “D”
indicate the pinning position of the individual struts.
The strut length (L) is always the same in a crane with
H!shaped outriggers (as in this type of crane).
Risk of overturning!
The support position of each strut is ONLY displayed.
The value which corresponds to the support position is
not passed on the LLD.
There are NO instructions and there is NO shutdown if
the displayed outrigger support area does not correspond
with the outrigger support area set in the IC!1.
”Boot” data bus:
Press key ”caution” (10 / 20) approx. 5 secs.
Show outrigger support area display:
! Call up diagram ”A”
! Key F4 = Depiction ”D” (strut width)
! Key F1 (L1)
= Quit, back to diagram ”A”
Observe the instructions and warnings on the outrigger
support area display on the following page!

Terex® All-Terrain Operation: Outriggers 16

Instructions on display of the support position (S1 to S4): Risk of tilting and breaking!
! The support position of the strut is only displayed if the The correct position of the outrigger struts in
current extension length of the outrigger strut corresponds relation to each other must be observed, in
with a permitted strut variant (8.2 m (26.9ft); 6.85 m particular with reduced
(22.5 ft); 5.7 m (18.7 ft) and 2.8 m (9.2 ft)). outrigger support areas.
If the outrigger strut is in a state of extension which does The optional “Outrigger support area display” does
not recognize when the crane is supported on
not correspond with any permitted strut variant, the number outriggers with a permitted strut width but both
”0” appears at the corresponding strut. outrigger struts are not in the correct position in
! For this crane type, two outrigger struts are moved within relation to each other.
each other at each strut in order to achieve the required If required, the correct support on outriggers must
strut width. be monitored manually.
The correct position of both outrigger struts in relation to Risk of accidents!
each other ! dependent on the desired strut width ! is The required insertion / pinning of the struts is not
described in the section “Strut variants” (section 12.9). monitored and is the responsibility of the operating
personnel.
The optional length measuring device for the display of
The corresponding instructions in section 12 of the
the support position only recognizes the strut’s extension
operating instructions of the crane chassis must be
length. observed. The required insertion / pinning of the
The length measuring device does not recognize when struts is not monitored and is the responsibility of
both outrigger struts are in an “incorrect” position to each the operating personnel.
other or when the outrigger struts are not pinned to each The corresponding instructions in section 12 of the
other. operating instructions of the crane chassis must be
observed.

Terex® All-Terrain Operation: Outriggers 17

Automatic Leveling
The crane can also be leveled automatically (by extending the
outrigger cylinders together). This is only possible when ”Extending”
cylinders.
It is of no importance for the function, in which starting position
the supporting cylinders are.
Risk of crushing!
When leveling automatically, all supporting cylinders are
extended simultaneously; that means also those cylinders
that cannot be seen from the switch panel. It must be ensured that no
one is in the hazardous area.
Starting position:
! Crane parked in transport position
! parking brake applied
! outrigger struts extended / pinned / locked (outrigger pads
are fitted)
! display: Diagram ”B” (inclination)
Steps for automatic leveling:
1. Press key ”caution” (10 / 20) and key ”extend all outrigger cylinders
together” (8B / 18B) together.
Inverse display during ”Automatic operation”.
The engine runs at increased speeds so that the required
pressure oil quantity is made available by the hydraulic
pump.
The outrigger cylinders are extended to a check support force.
This ensures that all outrigger cylinders have contact with the
ground before the actual leveling procedure begins.
If supporting forces are identical, then all supporting cylinders are
extended together in this (possibly different) condition, as long as
both keys are held pressed (10 / 20) and (8B / 18B).
2. If there is sufficient clearance between wheels and the
ground (including bending after taking up a load later on), let
go of button (8B / 18B) and continue to keep “Caution” key
(10 / 20) pressed.
The speed increase of the engine is reduced when fine leveling
begins.

Terex® All-Terrain Operation: Outriggers 18

3. As soon as the crane is level (angle tolerance value 0.1
degrees),
the procedure is automatically stopped.
The information on the display is shown in standard format
again.
After the procedure, the system might change the displayed
inclination value from 0.1 to 0.2.
This however has no negative effect on the required precision.
4. Let go of key (10 / 20).
Make sure there is a remaining lift (2 to 3 cm / 0.8 to 1.2 in) in
the supporting cylinders; Compare supporting forces.
The system does not automatically take the remaining lift into
consideration.
If relevelling is necessary:
Hold button „Caution“ (10 / 20) and press „Extend all outrigger
cylinders“
button shortly (8B / 18B).
Leveling is carried out as already described.
Combined retraction of all supporting cylinders:
Press the button ”caution” (10 / 20) and key ”retract all
outrigger cylinders” (8A / 18A) together.

Terex® All-Terrain Operation: Outriggers 19

”Hold Axles” / ”Raise Axles” Functions
When the crane is on outriggers, the wheels must not touch
the ground. The “Hold axles” or “Raise axles“ functions are
available for this purpose.
The decision as to which function should be selected to
achieve clearance, depends on the ground conditions at the
site.
(flat, firm ground), select ”Hold axles”.
If the ground conditions at the site are not as described in
section then select ”Raise axles”.
”Hold Axles” Function
“Hold axles” is selected before the crane is stabilized.
All axles are fixed in the starting position (horizontally aligned
and suspension cylinders in the middle position).
If the crane is lowered back on to the wheels for moving (by
retracting the supporting cylinders), then it does not have to be
relevelled.
It is aligned horizontally and the suspension cylinders are in
the middle position.
Switching on ”Hold axles” after ”Moving on the
Road” ! Suspension is Not Locked
1. Stop the crane, switch to neutral gear, apply the parking
brake.
2. Actuate switch (101, S4428) ”hold axles”. Message (A38.6)
lights up .
If ”hold axles” is switched on, the crane must not be
moved as ”R I S K O F B R E A K A G E” !
3. Support the crane (see section ”Extend the back stop”)
Extend the support until no wheel is in contact with the ground.
Terex® All-Terrain Operation: Outriggers 20
Switching on ”Hold Axles” after
”Driving in the Configured State”! Suspension Locked
1. Stop the crane, switch to neutral gear, apply the parking
brake.
! the crane is aligned horizontally,
! suspension cylinder in the middle position.
2. Extend horizontal support.
3. Extend the outrigger cylinder, until the outrigger pads are
pressed to the ground. Set the contact pressure so that the
suspension pressure is at approximately 100 bar (1450 psi).
Pressure check on pressure gauges (6, 9), (8, 11) and (7, 10).
The clearance between the mounting eyelets on the
suspension cylinders equals 630 mm (24.8 in) (compare
section ”Extending the outriggers”).
4. Switch off the suspension locking using switch (100,
S4401).
Message (A38.5) goes out.
5. Actuate switch (101, S4428) ”hold axles”. Display (A38.6)
lights up.
6. The supporting cylinders are extended further and the crane
is stabilized.
Extend the support until no wheel is in contact with the ground.
Keep to the sequence!

Terex® All-Terrain Operation: Outriggers 21

Switching off ”Hold Axles” for ”Moving on the Road”
! Suspension Not Locked or Switching to
”Driving in the Configured State”! Suspension Locked
1. Retract supporting cylinders, until the wheels of all axles
have light and even contact with the ground.
Pressure check on pressure gauges (6, 9), (8, 11) and (7, 10).
Nominal value: approx. 100 bar (1450 psi).
(see section ”Retracting outriggers”)
2. Lock the switch ”hold axles” (101, S4428) in the ”off”
position.
Message (A38.6) goes out.
If the crane is now to be ”driven in the erect mode”, switch on
the suspension lock using switch (100, S4401).
The message (A38.5) lights up.
In ”Driving in a configured state“, the outriggers (outrigger
support area 8.4 m x 8.2 m / 27.6 ft x 26.9 ft) remain right
above the ground with fitted outrigger plates.
”Driving in a configured state“ is only permitted when the
ground conditions correspond to those described in section
”Driving in a configured state“.
3. Continue to retract supporting cylinder / retract outrigger
entirely and lock.
4. For ”Moving the crane in transport position” (on!road
driving, axle load max. 12 t / 26.4 kip) see section 6 of the
operating instructions for the carrier.

Terex® All-Terrain Operation: Outriggers 22

”Raise Axles” Function
The ”axles are raised” after the crane is supported on
outriggers.
Switch on “Raise axles”:
2 work steps are required for ”Raise axles”.
Between the two steps, the crane must be stabilized.
1. Press switch ”hold axles” (101, S4428) in the driver’s cab.
Message (A38.6) lights up .
The axles remain in the middle position (on the ground).
The crane must now be supported on outriggers (cf. support
procedure).
If the axles still have contact with the ground:
2. Press/hold button (9 / 19) on the outrigger control. All axles
are raised as long as the button is pressed.
DRIVING IS FORBIDDEN if „Axles raised“ is activated
signal A38.6 appears and stop light A30 is illuminated).
Switch off ”raise axles”:
When switch (101, S4428) is switched off in the driver’s cab,
all wheels are lowered to the ground again.
Before being driven the crane must be leveled again (aligned
horizontally and the spring actuators placed in the middle
position).
When the suspension is locked (locking switch 100, S4401 on,
message A38.5 appears), ”Raise axles” or ”Hold axles” is not
possible.

Terex® All-Terrain Operation: Outriggers 23

Switching on ”Raise Axles” after
”Moving on the Road” ! Suspension is Not Locked.
If the crane is in ”On!road driving” position before being stabilized,
then raise the axles as described in the following:
1. Stop the crane, switch to neutral gear, apply the parking
brake.
2. Press switch ”hold axles” (101, S4428) in the driver’s cab.
Message (A38.6) lights up.
3. Support the crane (see section ”Extend the back stop”)
If the wheels still have contact with the ground:
4. Press/hold the button ”raise axles” (9 / 19) on the outrigger
controls.
All axles are raised as long as the button is pressed.
Extend the support until no wheel is in contact with the ground.
Switching on ”Raise Axles” after
”Driving in the Configured State” ! Suspension Locked
If the crane is in ”Driving in the configured state” mode (supports
extended, outrigger pads on the ground) before stabilizing, then
proceed as follows to raise the axles:
1. Stop the crane, switch to neutral gear, apply the parking
brake.
2. Extend the outrigger cylinder, until the outrigger pads are
pressed to the ground. Set the contact pressure so that the
suspension pressure is at approximately 100 bar (1450 psi).
Pressure check on pressure gauges (6, 9), (8, 11) and (7, 10).
3. Switch off the suspension locking using switch (100, S4401).
Message (A38.5) goes out.
4. Press switch ”hold axles” (101, S4428) in the driver’s cab.
Message (A38.6) lights up .
5. Keep the crane stabilized.
6. If necessary: Press/hold button ”hold axles” (9 / 19) on the
outrigger controls until all wheels are free of the ground.

Terex® All-Terrain Operation: Outriggers 24

Switching off ”Raise Axles” for
”Driving on the Road” ! Suspension Not Locked
or Switching to
”Driving in the Configured State”! Suspension Locked
The procedure ”Raise Axles” is switched off using switch (101,
S4428) ”Hold axles” in the cab. All wheels are then lowered to
the ground.
1. Switch off switch ”Hold Axles“ (101, S4428) in the driver’s
cab.
Message (A38.6) goes out.
When switch (101, S4428) is switched off in the driver’s cab,
all wheels are lowered to the ground again.
2. Actuate button (76 or 77). Fill all suspension circuits to
approx. 100 bar (1450 psi).
Monitor the rise in pressure on pressure gauges (6 to 11).
3. Retract supporting cylinders; reset the suspension.
Before the supporting cylinders are retracted, the wheels
of all axles must first be in contact with the ground. Then
the suspension must be readjusted (aligned horizontally
and suspension cylinder in central position; see section
11 of these operating instructions).
If they are not readjusted, the suspension cylinders are
”locked”.
Driving is not permitted in this condition. Damage to
undercarriage!

Terex® All-Terrain Operation: Outriggers 25

Measures before Stabilizing:
1. Apply parking brake (14).
On sloping ground in the longitudinal direction of the
vehicle,
the vehicle must be prevented from rolling away by
placing
wheel chocks at the axle last released.
2. Shift the transmission to the neutral position (12).
3. Lock the slew gear brake in the superstructure cab.
The superstructure may only be slewed in the supported
condition!
4. Start crane chassis engine.
The engine can also be started at the switch panels of the
outrigger controls. The ignition switch (4) must then be in the
position ” 2” (external ignition standby).
When the outriggers are operated, an engine speed of 1200
rpm is automatically set.

Terex® All-Terrain Operation: Outriggers 26

Pinning Positions of the Outrigger Struts
(1) = Inner outrigger strut
(2) = Outer outrigger strut
(3) = Chassis frame / outrigger box
(4) = Driving bolt
(5) = Bolt for transportation state and pinning of the chassis frame to
the outer outriggers
(6) = Bolt for pinning the inner outriggers to the outer outriggers
(A) = Marking point on chassis frame for driving bolt (4)
(B) = Marking point on chassis frame for transportation position of
the outriggers and all outrigger support areas
(C) = Marking point on outer outrigger strut (2) for outrigger support
area 8.2 m (26.9 ft)
(D) = Stop outrigger support area 6.85 m (22.5 ft)
(E) = Marking point on outer outrigger strut (2) for outrigger support
area 6.85 m (22.5 ft)
(F) = Stop for outrigger support area 5.7 m (18.7 ft)
(G) = Marking point on outer outrigger strut (2) for outrigger support
area 5.7 m (18.7 ft), transportation position
of outriggers and outrigger support area 2.8 m
(9.2 ft).
(I) = Support point for bolts (5)
(J) = Support point for driving bolt (4)
(X) = Support surface on inner outrigger strut (1) for transportation
safety lock
Bolt (5) is used for pinning the outriggers and the chassis frame
in the transportation position and / or in the 4 outrigger widths. In
the transportation position, bolt (5) is then flush with surface (X)
of the inner outrigger strut (1).
The pin (4) is used for driving the stops (D / F) for the support base
areas 5.7 m (18.7 ft) and 6.85 m (22.5 ft).
The marking points (A / B) are located on the separating plates
of the front or rear outrigger box sets.

Terex® All-Terrain Operation: Outriggers 27

Transportation State of the Outrigger Struts
(detail Q)
! Outriggers completely retracted
! Bolt (5) fitted into point (B) in the chassis frame (Bolt (5) is
fitted through the outer outrigger box and is flush with surface
(X) in the inner outrigger box.)
! Driving bolt (4) is set down on point (J) or fitted into point
(A) (must be removed first when setting on outriggers.)
! Bolt (6) set down on point (H).

Terex® All-Terrain Operation: Outriggers 28

Stabilizing Procedure
Extending the Outriggers
(Outrigger Support Area 8.40 m x 8.20 m / 27.6 ft x
26.9 ft)
When the crane is on outriggers, the wheels must not touch
the ground (”Hold axles” / ”Raise axles” functions).
Once you have convinced yourself that no obstacles or
persons are present in the extension area for the stabilisers
and that all notes on dangers in section 12.1 have been
observed, then proceed as described in the following.
1.! Bring outrigger pad in operating position
Clean the bottom of the outrigger cylinder’s piston rod and
the top of the outrigger plate (if contaminated), remove the
forelocks (3), remove the socket pins (2), pull the outrigger
plates (1) into the support position.
Attach plug bolts and forelock again.
Risk of accidents!
The contact surface between the outrigger cylinder’s
piston rod and the outrigger plate must be clean. In
particular, no foreign matter is permitted (for example:
stones, sand, etc.).
2. Remove safety bolts (5) from the outrigger struts.
Open required switch panel.
Only the switch panel that is needed directly for operating
may be opened.
In order to avoid improper use, it must be locked again,
directly after use !

Terex® All-Terrain Operation: Outriggers 29

3. Extending the outrigger struts
Left side: press self return rocker switch 5B or 6B
Right side: press self return rocker switch 15B or 16B
The outrigger struts can only be extended / retracted
(horizontally) at the switch panel of the corresponding side.
Extend the outrigger struts one at a time up to the colored
marking.
Hold on to the rocker switch while extending.
Risk of crushing!
Before extending the outrigger struts, make sure that
nobody is present in the danger area where the outrigger
struts are extended horizontally !
4. Fit and secure locking bolts (5) and (6) between the chassis
frame and the outer outrigger strut, or between the outrigger
struts.

Terex® All-Terrain Operation: Outriggers 30

5. Extending the outrigger cylinders
Risk of crushing!
There is a risk of crushing while the outrigger cylinders are The
outrigger cylinders may only be extended at the side that is
within the crane operator’s view at the switch panel.
Extend the outrigger cylinders of the relevant side until
they have made contact with the ground.
While operating the outriggers, no corrections may be
made to the positions of the outrigger pads.
Risk of accidents!
When attaching the outrigger plates in this operating step,
make sure that there is no foreign matter (for example: stones,
metal objects, etc.) under the outrigger plates!
Switch panel left side: press self return rocker switch 1B,
2B, 3B or 4B.
Switch panel right side: press self return rocker switch 11B,
12B, 13B or 14B.
In order to protect the supporting cylinders from overloading,
they must not be extended to the limit; a remainder of
2 to 3 cm (0.8 to 1.2 in) should still be left.
The remaining clearance is also necessary, so that actual
support pressure values can be displayed.
If the crane is tilted visibly, then carry out a rough correction by
further extending the appropriate outrigger cylinders.
When doing so, make sure that the outrigger cylinders can be
further extended for the following leveling procedure.
6. Attach counterweight (see load capacity table and operating
instructions for the superstructure, section 9).
7. Position superstructure in the direction of travel and thereby
position counterweight above the rear outrigger.
8. Move boom to steep position.
The slew gear brake must be released at points 5 and 6.
Now reinsert it.

Terex® All-Terrain Operation: Outriggers 31

9. ”Raise axles” now
”Raise axles” consists of two steps:
9.1 Press switch ”hold axles” (101, S4428) in the driver’s
cab.
Message (A38.6) lights up .
The axles are still on the ground.
9.2 Press and hold down the key (9/19) at the outrigger
controls.
All axles are raised.
Raise the axles until all wheels are free of the ground.
If ”hold axles” is selected before the crane is supported on outriggers,
message (A38.6) lights up, the axles are no longer raised.
It must be ensured however that all wheels are free of the ground.
When putting the crane on outriggers, make sure that the
ground has sufficient load bearing capacity.
The individual support forces are displayed on the screen of the
outrigger controls (left and right on the chassis) and on the PDC
system of the superstructure.
Only the current supporting forces are displayed; not those that will
occur when a load is picked up.
10. Extend rear supporting cylinder, until the lateral axis is balanced.
Switch panel left side: press self return rocker switch 3B /
4B.
Switch panel right side: press self return rocker switch 11B
/ 12B.
11. Extend the supporting cylinders at the front, in order to also
bring the longitudinal axis in the balance.
Switch panel left side: press self return rocker switch 1B /
2B.
Switch panel right side: press self return rocker switch 13B
/ 14B.
Then use inclination indicator on the crane chassis to level
it to 0.1° (equivalent to approx. 0.2 %).
In order to achieve a most even coordination of the supporting
forces, the supporting cylinders at the front should finally
be briefly pressed further together and then the same
applies to the supporting cylinders at the rear. Make sure
that all outrigger cylinders are loaded equally.

Terex® All-Terrain Operation: Outriggers 32

12. Check the set level once more.
If the transverse axis has come out of alignment, the leveling
procedure must be repeated.
a.) Level the rear transverse axle.
b.) Retract the front support cylinders slightly and then
extend to level the longitudinal axis.
Retracting the supporting cylinders is only permitted if
the supporting forces are not exceeded.
In order to level the crane precisely, it will finally be
necessary to operate all supporting cylinders from the
switch panel on one side. In this case be particularly
careful, especially when the supporting cylinders are
operated that are not in the direct line of view.
Immediately afterwards, lock the switch panel !

Terex® All-Terrain Operation: Outriggers 33

Checking the Level at the Chassis
After each new configuration, the level of the crane must be
rechecked (see ”Inclination indicator”).
Careful leveling is essential for safe working with the
crane.
Deviations must not exceed 0.1 degrees (equivalent to
approx. 0.2 %).
The numerical values X and Y are always decisive. They
show the current deviation of the crane system.

Terex® All-Terrain Operation: Outriggers 34

Retracting the Outriggers
The outriggers are retracted analogously in the reverse order of their
extension.
Important notes on retracting the outrigger:
! Retract the outriggers separately and completely.
! Unbolt only the outrigger strut to be retracted.
! As soon as a support is in the transport position, insert
the transport lock.
! When retracting the outrigger struts, reeving and crushing
movements around the retracting parts and the carrier frame
are possible.
It must be ensured that no persons are present in the
danger zone.
! Retracting the outrigger supports when a load is attached to
the crane is prohibited. Risk of tipping!
! The struts may only be retracted if the superstructure
is in the transportation position or in position 0 to the
rear for mobile operation. Risk of tipping!
Retracting the Outriggers
. . . .for ”Driving in Transport Position”

1. Lower main boom to transport position.

2. Remove counterweight.
Risk of crushing!
When lowering the suspension / retracting the supporting
cylinders, crushing movements between tires and ground
space are possible. Watch your feet!
It must be ensured that no persons are present in the danger
zone.
3. Lock the switch ”hold axles” (102, S4427) in the ”OFF” position.
The axles are lowered.

Terex® All-Terrain Operation: Outriggers 35

If ”hold axles” was switched on, this point does not apply.
4. Pressing down the wheels
Press button (78 / 79 / 80 / 81) or button (76 or 77) until the
wheels of all axles are pressed down on the ground.
The outrigger cylinders must be retracted if the outrigger
height is greater than the suspension cylinder hoist.
5. Retracting the supporting cylinders:
Switch panel left side: Press rocker switch 1A, 2A, 3A or
4A.
Switch panel right side: Press rocker switch 11A, 12A, 13A
or 14A.
Retract all outrigger cylinders completely!
When retracting the supporting cylinders on slopes in the
longitudinal direction of the vehicle, the vehicle must be
secured with support blocks at the axle that is to touch
the ground first.
6. Retracting the outrigger struts:
Left side: press self return rocker switch 5A or 6A
Right side: press self return rocker switch 15A or 16A
Retract all outrigger struts individually and completely!
It is forbidden to retract or extend the cylinders with
hanging load or if the superstructure is not in the
transportation position or in position ”mobile operation“.
RISK OFTILTING!
Risk of crushing and reeving !
When retracting the outrigger struts, reeving and crushing
movements around the retracting parts and the carrier
frame are possible.
Make sure that there is no one in the danger zone!

Terex® All-Terrain Operation: Outriggers 36

Secure the outrigger boxes which have been pushed into each
other, using bolt (5) in point (B) in the chassis frame
(3). The bolt (5) is fitted through the outer bumper brace and is
flush with the inner bumper brace on surface (X). The driving
bolt (4) is inserted in point (A) in the chassis frame or fitted in
point (J).
The marking points (A) and (B) can be found on the bulk heads
of the front and rear outrigger box pairs.
7. Bring the outrigger plates into the transport position
Remove the fore locks (3), remove the socket pins (2), pull
the outrigger plates (1) into the transport position.
Attach plug bolts and forelock again.
8. If ”Raise axles” was actuated:
Press button (76, S441 or 77, S4424) to level all axles. See
section 11 ”Adjusting for driving in the transport position”.
Or
9. If ”Hold axles” was actuated:
Lock switch (101, S4428) ”hold axles“ in the ”OFF” position.
Message (A38.6) goes out.
Driving in the ”Hold axles” condition is prohibited.
Damage to undercarriage!
Retracting the Outriggers
. . . . for ”Driving in the Configured State”
. . . . Before driving in the configured state”.
Before lowering the crane on to the wheels (for subsequent
”Driving in the configured state”), always pay attention to
the permitted axle loads relating to rigging mode,
counterweights,
superstructure position, main boom length and angle
(see section 6 ”Driving in the configured state”).
When lowering the crane onto the wheels, the suspension
pressure is monitored on the pressure gauges (6) to (11) in
the driver’s cab.
It must not exceed 270 bar (3916 psi).

Terex® All-Terrain Operation: Outriggers 37

Supporting Variants
Outrigger Support Area 8.40 m x 8.20 m
(27.6 ft x 26.9 ft) (Standard Outrigger Support Area)
Outrigger struts (1) and (2) are fully extended for the outrigger
support area 8.40 m x 8.20 m (27.6 ft x 26.9 ft).
The bolt (5) pins the chassis frame (fitting point B) to the outer
outrigger strut (2) in point (C).
The bolt (6) pins the outer outrigger strut (2) to the inner outrigger
strut (1) in point (G).
Working with the crane is permitted only with the load capacity
tables supplied with the crane. The crane’s construction
number is noted on the load capacity tables.
If there are no specifications for the outrigger support area in
the load capacity tables, then the outrigger struts must be
extended completely and pinned.
Outrigger Support Area 8.40 m x 6.85 m (27.6 ft x 22.5 ft)
Outrigger strut (1) is fully and outrigger strut (2) is partially extended
for the outrigger support area 8.40 m x 6.85 m
(27.6 ft x 22.5 ft).
The measurement from the outer edge of the chassis frame to the
outer edge of the outrigger strut (2) is 670 mm (26.4 in)
The extension length of 670 mm (26.4 in) is color marked on
the outrigger strut (2).
If the outriggers are to be driven from the ”normal“ outrigger basis to
reduced outrigger basis, pin bolt ”B“ in the locking position for
driving.
If the outrigger support area is reduced, then only certain
counterweights / main boom lengths / equipment are permitted.
Details of these can be found in the corresponding load
capacity tables.
Only the combinations specified there are permitted.
Drive the outrigger support area as follows:
! Remove bolt (5) from point (B)
(remove transportation safety lock)

Terex® All-Terrain Operation: Outriggers 38

! Extend strut until the pinning hole (G) on the outer outrigger strut
(2) is visible.
! Insert driving bolt (4) in point (A) on the chassis frame and secure.
! Extend strut until stop (D) of the outer outrigger strut (2) is
flush with the driving pin (4) and the inner outrigger strut (1)
is completely extended.
! Pin the chassis frame (fitting point B) to the outer outrigger
strut (2) using bolt (5).
! Pin the outer outrigger strut (2) (fitting point G) to the inner
outrigger strut (1) using pin (6).
Outrigger Support Area 8.40 m x 5.70 m (27.6 ft x 18.7 ft)
The inner outrigger strut (1) is completely extended and the outer
outrigger strut (2) is not extended for the outrigger support area 8.40
m x 5.70 m (27.6 ft x 18.7 ft).
Drive the outrigger support area as follows:
! Remove bolt (5) from point (B)
(remove transportation safety lock)
! Insert driving bolt (4) in point (A) on the chassis frame and secure.
! Extend strut until the inner outrigger strut (1) is completely
extended.
! Pin the chassis frame (fitting point B) to the strut using bolt (5).
! The pin (5) is then pinned by the retracted outer outrigger
strut (2) in the inner outrigger strut (1).
If the outrigger support area is reduced, then only certain
counterweights / main boom lengths / equipment are permitted.
Details of these can be found in the corresponding load
capacity tables.
Only the combinations specified there are permitted.

Terex® All-Terrain Operation: Outriggers 39

Outrigger Support Area 8.40 m x 2.80 m (27.6 ft x 9.2 ft)
This outrigger support area is similar to the transportation state
of the struts. The outrigger struts are completely retracted.
Bolt (5) is fitted in point (B) in the chassis frame. Only the
outrigger cylinders are extended.
If the outrigger support area is reduced, then only certain
counterweights / main boom lengths / equipment are
permitted.
Details of these can be found in the corresponding load
capacity tables.
Only the combinations specified there are permitted.

Terex® All-Terrain Operation: Outriggers 40

Fitting and Removing the Outrigger Struts (Optional
Equipment)
Removing the Outrigger Struts
An auxiliary crane is required to remove and fit the outrigger
struts. The weight is marked on plates on the sides of the
struts.
Observe the centre of gravity when fitting the attachment
equipment for dismantling the outrigger struts. Risk of
tipping!
The quick disconnect couplings on hydraulic lines ”R”, ”E” and
”P” are marked with plates.
If there are no plates on the quick!release couplings, the
couplings must be marked before they are disconnected.
Connection „R“ = extending the horizontal cylinders:
The outer connection to the piston rod of the horizontal
cylinder on outrigger strut (2) without ”T!union”
Connection ”E“ = retracting the horizontal cylinders and
the vertical cylinders :
The inner connection to the piston rod of
the horizontal cylinder on outrigger strut
(2) with ”T!union”
Connection ”P“ = extending the vertical cylinder

Terex® All-Terrain Operation: Outriggers 41

To remove the outrigger struts, proceed as follows:
1. Remove locking bolt (5) at position (B).
The inner outrigger strut (1) (with fitted outrigger cylinder) is
completely retracted.
2. Extend outrigger struts (2) completely.
3. Disengage the quick!release couplings of the hydraulic
lines ”R”, ”E”, ”P” and the electrical line.
When disconnecting or connecting the quick disconnect
couplings, all buttons on the outrigger control panel must
be off.
4. Remove connecting bolt (15) from the piston rod of the
horizontal cylinder (12).
Disconnect plug ”Q” of the support pressure display.
Depending on the friction conditions, it could be necessary to
first completely extend the struts and then to retract the inner
outrigger struts:
After the strut has been extended, bolt (5) must be fitted in
point (B) in the chassis frame in such a way that the outer
outrigger strut (2) is pinned to the chassis frame, but has not
been fitted through.
The inner outrigger box is then mobile. Then the inner
outrigger strut must be retracted.

Terex® All-Terrain Operation: Outriggers 42

5. Connect extension hoses to the quick disconnect couplings
of the hydraulic leads „R“ and „E“. Clean the quick disconnect
couplings before assembling.
Check the O!rings for sealing the quick disconnect coupling.
The quick disconnect couplings should be screwed in up
to the stop.
The hydraulic lines must not be mixed up.
The non!return valve in the quick disconnect coupling
can open only if the coupling is screwed in up to the stop.
Closed or only partially open non!return valves can cause
damage to the hydraulic system.
Mixed!up hydraulic lines can also damage the hydraulic
system and cause malfunctions.
6. Connect the extension cable for activation of the hydraulic
valves.
7. Retract the horizontal cylinder. Disconnect the connection
hoses on the quick disconnect couplings of hydraulic lines
”R” and ”E” on the chassis.
8. Attach auxiliary crane to the outer outrigger struts (2) using
suitable lifting tackle.
9. Unscrew rollers (4) on both sides and extend outrigger strut
(2) horizontally using the auxiliary crane.
10. Disconnect the connection hoses on the quick disconnect
couplings of hydraulic lines ”R” and ”E”.
Place dust caps on all quick disconnect couplings. Remove
the electrical cable.
Load outrigger struts on an adequate transport vehicle and
secure.
Terex® All-Terrain Operation: Outriggers 43
Installation of the Outrigger Struts
The outrigger struts are fitted analogously in the reverse order.
Please observe the cautionary notes for the corresponding
working steps.
Before fitting : clean and grease the sliding surfaces on the
outrigger struts and on the chassis.
After fitting and before extending the struts: ensure that the
hydraulic lines can move freely.

Terex® All-Terrain Operation: Outriggers 44

Supporting the Outrigger Plates Due to Insufficient
Load!bearing Capacity of the Ground
The load!bearing capacity of the ground must be sufficient to
absorb the maximum support forces which can occur.
Normally, the outrigger plates would not be sufficient by
surface area to set the crane up safely on backfilled or natural
ground.
If necessary, increase the support area by stacking suitable
materials under the outrigger plates.
Suitable materials (for example, timbers with the same
dimensions, special panel constructions made of wood or
metal) must be used for the support! The crane operator
must make these available.
The struts must be in the centre of the support and must
cover all supporting timbers sufficiently.
You must also check whether channels, covered pits or
cellars are in the vicinity of the scheduled crane location
and how they are laid out. You must also take hidden
dangers such as melting ice or flooding into
consideration.
These dangers are often the cause for cranes falling over.
In the following segment you will find details on “Permitted
ground pressures” of various types of ground and how to
determine the required support area.

Terex® All-Terrain Operation: Outriggers 45

Permitted Ground Pressure If doubts exist with regard to the load!bearing
The permitted loading of the ground is determined by type and capacity of the ground, an examination of the
condition of the ground. Instructions on permitted ground ground must be carried out (e. g. with a pile sensor).
pressures can be found for example, in the standard DIN 1054
“Permitted loading of the construction ground” (for excerpt see
the following table).

Terex® All-Terrain Operation: Outriggers 46

 Determining the Required Support Area
For this type of machine, the maximum support forces vary at the
front and rear supports.
The maximum support force is 100 t (220.5 kip) at the rear supports
and it is 85 t (187.4 kip) at the front supports.
The rear outrigger plates have a diameter of 700 mm (27.6 in)
(support surface of 0.4 m2 / 4.3 ft2).
The front outrigger plates have a diameter of 600 mm (23.6 in)
(support surface of 0.3 m2 / 3 ft2).
Procedure
The permitted ground pressure “p” for the type of ground on
which the supporting procedure is to be carried out can be found
in the table in segment .
The corresponding curve (1 to 6) must then be selected for the
assigned graph out of the table in figure.
The support force FS is depicted on the y ! coordinate (ordinate)
in the graph in figure bottom).
The required support surface AS is noted on the x - coordinate
(abscissa).
Curves 1 to 6 show the relation between the support force FS and
the required support area AS with regard to the permitted ground
pressure “p”.
Example
For a “stiff” mixed granular ground (clay to sand, gravel and
stone areas) (p=15 N/cm2 (21 PSI)) in accordance with the table
“Permitted ground pressure” in segment, the following
values can be taken for the adjacent diagram:
For p=15 N/cm2 (21 PSI), the values of the curve 3 are the decisive
ones (see table (Z 200 617 top).
The support surface (As= 6.6 m2 / 71.0 ft2) required for the outrigger
plates is calculated from this with a maximum support force
(Fs = 100 t / 220.5 kip) at the rear supports.
In order to increase the outrigger pad’s support surface area !
which is too small in this example ! to the required support surface
area, suitable supports (i.e: timber planks) must be laid underneath.

Terex® All-Terrain Operation: Outriggers 47

Safe Distance to Slopes and Pits
Erect the crane with a sufficiently safe distance to slopes or
pits.
The distance also depends on the type of ground.
The distance to the edge of a slope (X) must be at least 2
m (6.6 ft).
A general rule is:
! For loose or backfilled soils the safety distance (a) must be
twice the size of the ditch depth (b)
The slope angle a must be < 30 °.
! for natural, firm soils the safety distance (a) must be as large
as the ditch depth (b).
The slope angle a must be < 45 °.
The safety distance is measured starting at the base of the pit
(C).

Terex® All-Terrain Operation: Outriggers 48

Superstructure operation

Supporting the crane on outriggers from the crane

operator’s cab In order to support the crane on outriggers
from the crane operator’s cab, you must follow the
procedure as well as the danger and safety instructions
detailed in the chassis section.
The outriggers should generally be set using the operating
elements in the chassis.
However, it is possible to operate the outriggers from the crane
operator’s cab for follow-up leveling.
This should only be done in exceptional cases and only if the
crane operator has a clear view of all outriggers.
(If necessary, appoint a spotter.)

Terex® All-Terrain Operation: Outriggers 49

 Proceed as follows:
- Slew superstructure to the rear and lock the
superstructure using button (21).
- Activate slewing gear parking brake (22, S8805).
The outriggers are driven using the following button:
26 S4316 Double- Outriggers front left, retract /
button extend horizontally
27 S4315 Double- Outriggers front right, retract/
button extend horizontally
28 S4320 Double- Outriggers front left, retract /
button extend vertically
29 S4319 Double- Outriggers front right, retract/
button extend vertically
30 S4322 Double- Outriggers rear left, retract /
button extend vertically
31 S4321 Double- Outriggers rear right, retract /
button extend vertically
32 S4318 Double- Outriggers rear left, retract /
button extend horizontally
33 S4317 Double- Outriggers rear right, retract /
button extend horizontally
34 S4331 Double- Outriggers complete, retract/
button extend vertically

There is a danger of crushing in the area between the tires

and the base if the crane is lowered directly onto the tires
when retracting the outriggers.
Ensure that no persons enter this area before lowering the
crane.
The crane may only be driven within an area where all the
outrigger struts can be seen by the crane operator, either
directly or by using the mirrors. Check the position of the
mirrors before operating the outrigger struts.
Terex® All-Terrain Operation: Outriggers 50
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all-terrain operation

General Crane Operation

Center of Gravity

Symbol for Center of Gravity

Center of
Center of Gravity; is the point relative to a body around which gravity of
its weight is evenly distributed. load

RADIUS
Center of
Radius rotation
The horizontal distance from the center of rotation of the crane
Location of center of gravity does not change with
to the center of gravity of the load with the load suspended.
repositioning of the object or load.

Terex® All-Terrain Operation: General Crane Operation 2

Radius
Uncontrolled loads will increase or decrease
the working radius causing damage and / or harm
to persons and / or the machine.

What can be done

to prevent this?

RADIUS

RADIUS
RADIUS

Terex® All-Terrain Operation: General Crane Operation 3

What is to be considered for
“LOAD”?

Terex® All-Terrain Operation: General Crane Operation 4

What is to be considered for
“LOAD”?

Reeving-
If not properly
reeved (over reeved)
(3/4”=1 lbs. per foot)

Hook block or ball

Rigging

Act. Load

Terex® All-Terrain Operation: General Crane Operation 5

 What is to be considered for
“LOAD”? Extension
Reeving
Hoist
Aux. Tip
Headache ball Cable

Reeving-
If not properly
reeved (over reeved)

Stowed
Headache ball Extension Hook block or ball
Rigging

Act. Load Rigging

All items below ground

such as; Act. Load
Act. Load
Rigging
Hook block
and wire rope

Terex® All-Terrain Operation: General Crane Operation 6

Gross and Net load

GROSS LOAD
is the sum of the
weights of
attachments, act. load,
rigging, ropes, etc.,
that are considered
load as from
previous pages.

NET LOAD
is the weight
of the actual
load.

Terex® All-Terrain Operation: General Crane Operation 7

Static load and Dynamic load

STATIC LOAD
is the weight of the
GROSS load when the
load is STATIONARY.

stationary

Terex® All-Terrain Operation: General Crane Operation 8

Static load and Dynamic load

DYNAMIC LOADING
is caused by the sudden
change in speed of the
lift lowered
act. load and attachments
such as;
sudden stopping
snatching the load
swing out

lift stopped

TOTAL LOAD on the crane is equal to:

STATIC LOAD
+
DYNAMIC LOADING

Terex® All-Terrain Operation: General Crane Operation 9

Effective weight
REPRESENTS THE FORCE AN MORE EFFECT
on load than
ATTACHMENT EXERTS ON A CRANE
its actual weight
•! used in the calculating of the net
capacity of cranes
•! because of its position and leverage
the effective weight of the attachment
may be higher or lower than its actual
weight

LESS EFFECT

NO EFFECT

Terex® All-Terrain Operation: General Crane Operation 10

Effective weight
EFFECTIVE WEIGHT MAY BE HIGHER Center of
OR LOWER THAN ACTUAL WEIGHTS. Gravity of
jib

Effective weight of the jib or any

extension on the boom
tip & crane (because of its leverage) is
higher than the actual weight of the jib.

stowed
extension

Effective weights of stowed

extension & block are lower
than the actual weights.

Terex® All-Terrain Operation: General Crane Operation 11

Ultimate strength and Rated strength

ULTIMATE STRENGTH
(OR BREAKING STRENGTH)

STRUCTURAL FAILURE
can happen when;
exceeding capacity charts
improper maintenance
operating with damage components
exceeding components structural strength

Terex® All-Terrain Operation: General Crane Operation 12

Ultimate strength and Rated strength

RATED STRENGTH

SAFE WORKING LOAD (S.W.L.)

as specified by the manufacturer (s)
of all components.

Terex® All-Terrain Operation: General Crane Operation 13

Safety Factor

THE AMOUNT BY WHICH THE ULTIMATE

STRENGTH (OR LOAD) IS DIVIDED TO GET THE
RATED STRENGTH (OR SAFE WORKING LOAD)

ULTIMATE
LOAD
SAFE
WORKING
LOAD
Divide by
safety
factor
to get

(Safety factor of 8 shown)

Example:
If a part or hoist line has an ultimate
(or breaking) strength of 51,450 lbs.

S.W.L. or rated strength for:

5 to 1 S.F. = 10,290 lbs. S.W.L.

3 to 1 S.F. = 17,150 lbs. S.W.L.

Terex® All-Terrain Operation: General Crane Operation 14

Stowed or stored extensions

STOWED
When jibs or boom extensions not in use,
are pinned to the base section of the boom.

(Review the capacity chart and/or

operators manual for proper deductions.)

STORED
When jibs or boom extensions not in use,
are stored off of the crane.

(Capacities could increase in this condition

depending on crane configuration.)

DANGER; This condition has more risk of damage,

INSPECT completely before using.

Terex® All-Terrain Operation: General Crane Operation 15

Tipping axis or Fulcrum point

Where is the tipping axis

or the fulcrum point?

Terex® All-Terrain Operation: General Crane Operation 16

Tipping axis or Fulcrum point

TIPPING AXIS /
FULCRUM POINT
The point or line about The point on the crane
which a crane tips that is in contact with the
ground that is closes to the load.

Fulcrum Point

Terex® All-Terrain Operation: General Crane Operation 17

Tipping axis or Fulcrum point

Fulcrum
Point
Fulcrum
Point

Fulcrum Fulcrum
Point Point

Terex® All-Terrain Operation: General Crane Operation 18

Load moment

THE FORCE WHICH CAUSES, OR

TENDS TO CAUSE, A CRANE TO
ROTATE AROUND ITS TIPPING AXIS.

Leverage Fulcrum
of load Point

Terex® All-Terrain Operation: General Crane Operation 19

 Anti-two-block
Load moment indicator
switch (es)
Is an operator aide which can and
will fail.

A device which visually, or audibly, Length sensor

provides the crane operator with all
relevant crane geometry and load
data within the crane’s safe
operating parameters.
CPU
Such devices, IF PROGRAMMED Pressure
CORRECTLY, will automatically
warn the operator, stop or restrict transducer
crane motion or function when the
safe working load is approached or
has been exceeded.

Display

Terex® All-Terrain Operation: General Crane Operation 20

Load moment indicator
The system retrieves information from the length, angle and
pressure transducers to determine safe operating conditions.

The radius is a calculated value determined by the length and

angle transducers.

If the system is not programmed correctly or the sensors and

transducer are not calibrated
properly, the system WILL NOT
be able to warn the operator
in time before damage or harm
has occurred.

Terex® All-Terrain Operation: General Crane Operation 21

Jib angle to ground Jib
offset
A C
B

Jib angle
to ground

JIB ANGLE TO GROUND

(B) = boom angle (A) – jib offset (C)

Main Boom Angle

(A) = jib angle (B) + jib offset (C)

Boom Angle A

Terex® All-Terrain Operation: General Crane Operation 22

all-terrain operation

Superstructure Safety
 Superstructure Safety Content

Content Pg. Content Pg.

Intended use 3

Safety regulations 7

Electrical energy 8

Crane operation 11

Hand signals 16

Terex® All-Terrain Operation: Superstructure Safety

Intended Use The crane is designed exclusively for assembly operation.
The crane is designed for lifting loads. Any other type of use which goes beyond the limits specified,
for example handling of general cargo or grab operation, are
It is prohibited to transport people with personnel carrying
not classified as intended use.
equipment! In many cases, there have been serious injuries when
people have been transported using personnel carrying equipment
(or even on the hook or on loads). In these cases, they have no The manufacturer shall not be held liable for any damage that
control over crane movements and are not protected against bumps results. The operator carries full responsibility for this type of
or falls. Even the smallest of errors can have fatal consequences. use.
In exceptional cases (for example, the use of personnel
cages which were not supplied by the crane manufacturer), please
consult the responsible authorities / agencies concerning relevant
permits, fixed special conditions, safety regulations, additional tests
and demands on the crane and similar issues. In Germany, the Intended use also includes the observation of all load tables,
authority / institution concerned in the first place is the the operating instructions - in particular with regard to the
Berufsgenossenschaft.
specified assembly sequence - and the lubrication and
The use of such additional devices is then the responsibility of the
maintenance specifications.
crane operator following the valid safety and accident prevention
regulations! If operation of the crane for part-load handling or another type
of use is required, please contact the crane manufacturer.
Risk of death! The use of two hoists to raise the load (2-hook operation) is not
permitted.
It is expressly forbidden to use the crane for jumps with
Special load cases are however permitted in consultation with
rubber ropes (bungee jumping)!
the crane manufacturer.
Using the crane for such jumps represents a misuse of the
The crane operator is responsible for the operation of additional
crane and entails extreme danger for life and limb!
equipment which is not included in the manufacturer’s scope of
supply (e.g. personnel cages), under observation of the applicable
safety and accident prevention regulations.

Terex® All-Terrain Operation: Superstructure Safety 3

Operating Conditions and Computed Design of the Crane Operating conditions or types of use other than assembly
General operation require the permission of the manufacturer and
normally lead to a reduction in the lifting capacities.
The crane has been constructed using state of the art
technology and in accordance with recognized safety Workplace Ergonomics
The following noise levels can occur near the crane operator’s
regulations. Nevertheless, its use can lead to hazards for the life and
seat in the cab of the superstructure:
limb of the operator and third parties, and/or damage to the machine
and other objects. - Engine (S.S.) idle speed (610 rpm) < 75 dB(A)
Use the crane only when it is in full working order and only for -!Max. engine speed (S.S.) without load (2750 rpm) < 85
its intended use, paying attention at all times to safety and dB(A)
potential hazards, and in observance of the operating - Engine speed at maximum engine torque without load
instructions. In particular have any malfunctions which might (1300 rpm) < 80 dB(A)
impair safety rectified immediately.
The term „operating instructions“ refers to the operating
Measurements were taken using a noise level measuring unit
instructions and the lubrication and maintenance instructions.
with the test microphone at the ear position of the crane
Classification of the Crane
operator.
The crane is classified as follows
The A-assessed equivalent permanent sound level at the
(ISO 4301-2 and FEM 1.001):
- Operating class => U2 operator’s seat measured over the shift duration of 8 hours is
- Load class => Q2 below 70 dB(A). For this purpose, measurements were taken
during operation on construction sites using dosimeters.
- Crane group => A1
All important components of the crane are designed and
The crane operator is protected against mechanical vibrations
manufactured for normal assembly operation. This assumes
by means of a tilting seat which can be adjusted to his weight.
that crane operations under full load, crane operations with
lower load and operating breaks occur in a ratio that is typical The crane operator’s seat offers infinite adjustment options for
for an assembly crane. More exacting operating conditions the seat height and tilt, backrests and armrests. It is therefore
possible to select the optimum working position for every driver.
necessarily lead to a shorter life expectancy for the crane.

Terex® All-Terrain Operation: Superstructure Safety 4

The weighted effective value of acceleration to which the upper body The crane can also be operated without danger with high / low
is exposed is below 2.5 m/s2. relative air moisture.
The weighted effective value of acceleration to which the lower Continuous operation in aggressive air (e.g. harbors,
body is exposed (feet and seat) is below 0.5 m/s2. chemicals industry, steelworks etc.) combined with high
Both values are therefore below the statutory specifications. relative air moisture can require an adapter kit / optional
equipment.
High levels of dust require the filter to be changed more
Load and Utilization of the Crane
regularly. Dust concentration levels of up to 35 mg/m3 are
The maximum permitted load changes in relation to the permitted for a short period of time.
configuration, boom length and working radius. It is specified by the
crane manufacturer in the load capacity tables.
The load capacity tables supplied with the crane specify limit
values which must not be exceeded. With an oncoming wind the crane operator must follow the rules
The load limit of the winches is effectively reached when the outlined in the operating instructions, operating rules and
rope force has reached its permitted value. Low loads with a instructions in the operating instructions of the superstructure.
small amount of reeving can place the winch under just as
much load. The ground, on which the crane is supported - or driven with
load - must be strong enough to support the load.
Required Ambient Conditions
The permitted temperature range for operating the crane is Use of the crane in a potentially explosive atmosphere or in
-20C to +40C, if the maximum or minimum temperature occurs operating conditions where combustible gas can be drawn in is
only a few days a year. only permitted following corresponding conversion.
Optional equipment for other operating conditions can be
supplied.
The crane can be operated under full load up to a height of
1000 m above mean sea level. It is not hazardous to operate
the crane up to an operating height of 2000 m above mean sea
level.

Terex® All-Terrain Operation: Superstructure Safety 5

Service Life Harder operating conditions naturally lead to a reduction in
Classification of the crane is based on a total operating life the service life.
(service life) of 20 years under the following conditions: For the winches, however, the rules for calculating the
remaining theoretical service life must be observed, as
- the crane is operated as an assembly crane.
outlined in Lubrication and Maintenance Instructions.
The load capacity tables that are authorized for the crane
Some components (e.g. ropes) are not designed for the
are based on assembly operation only. General cargo entire service life of the crane, but must be replaced after
handling or grab operation can only be permitted following a certain amount of time.
express permission from the manufacturer under suitable
Information on this can be found in the lubrication and
conditions.
maintenance instructions for the superstructure.
-!the total number of load cycles in this period is less than
32,000 (e. g. 5 -10 lifts / day on 200 days / year).
A „LOAD CYCLE“ encompasses processes which begin when a Standards and Calculation Regulations
load is raised and end when the crane is ready to raise the next
The specifications contained in this on service life,
load.
loading and utilization of the crane are taken from the European
- the type of load (load collective) of the entire crane shows
standards ISO 4301-2 and FEM 1.001, FEM 5.004 and ISO 9927-1.
values no worse than the following:
The proof of stability for the framework, the components and
-!for 1/10 of the load cycles the crane is placed under max.
parts of the crane is based on the standards: FEM 5.004,
load
ISO 4301-1, ISO 4301-2, FEM 1.001 and ISO 4308-2.
- for 4/10 of the load cycles with 44 % of the max. load
The ropes are selected and calculated in accordance with ISO
- for 5/10 of the load cycles with 16 % of the max. load
4308-2. All required proofs of stability (buckling and bending) were
„Load“ in this context refers to the sum of the load, load-handling carried out in accordance with DIN 18800. The minimum safety
devices and lifting tackle (e.g.: load + hook block + sling ropes). factors are taken from FEM 5.004.
The proof of standing stability for the crane is based on ISO
Under these conditions, assuming that maintenance work is
4305.
carried out properly, the theoretical service life can be more For countries in which different standards and calculation
than 20 years. regulations apply, special calculations or proofs can be carried
out.
If required, these calculations must be specially ordered by the
crane operator. This does not alter the operating conditions for
the crane. If necessary the lifting capacities must be limited.

Terex® All-Terrain Operation: Superstructure Safety 6

Safety Regulations Selection and Qualifications of Personnel
While carrying out power—driven erection and assembly In order to operate a crane optimally with in its proper
procedures only the crane operator is allowed on the crane (and he parameters, the crane operator and personnel working on
must be in the crane operator’s cab). Remaining personnel must maintenance, assembly and dismantling must be properly
remain clear of the hazardous area on and around the crane. qualified and trained.
The only exception to this rule is when the counterweight The crane operator / owner is responsible for providing this
is being fitted and when a load is being attached or released with the training.
help of a fitter. Use only reliable, trained and/or experienced personnel for
When stacking the counterweight the person attaching work on and with the crane.
the equipment must leave the crane and the slewing area
as soon as the erection work is completed. During stacking, the
person attaching the equipment must remain outside the hazardous
area. Make sure that only authorized personnel are allowed to carry out
work .
When attaching and disconnecting the load, particular care should
be taken as a result of swinging loads or hook blocks. The person Pay attention to the minimum working age.
attaching the equipment must be Clearly specify all areas of responsibility:
proficient in handling hook blocks. - for operating, erecting and servicing.
Once the load has been attached or released, the fitter - for the crane driver, also with regard to his responsibilities as
must leave the slewing or hazardous area immediately. a result of road traffic regulations. Allow him to refuse
The fitter must be easily recognizable to the crane operator. instructions from third parties which contravene safety
The fitter must wear one or more means of identification regulations!
e.g. jacket, helmet, special collars, armbands, signaling Personnel who are still being trained and instructed in the use of the
discs. crane, or who are completing a general apprenticeship, may only be
allowed to work on the crane under the constant
These means of identification should be in a distinctive
color and where possible of an identical design and supervision of an experienced member of staff .
must be exclusive to the fitter.

Terex® All-Terrain Operation: Superstructure Safety 7

Particular Hazards If, however, the crane accidentally comes into contact with
Electrical Energy high voltage power lines:
High voltage -!Move the crane out of the danger zone: drive out,
With high voltage lines, any direct contact with the boom or the swing away, adjust the boom!
hoist rope is always dangerous. If this is not possible:
With high voltage lines above 1000 V current can be transferred - Do not leave the crane or driver’s cab.
even as the lines are approached. - Warn those outside not to approach or touch the crane.
This hazard should be prevented by the following measures:
- Switch off the power to the lines.
- Cover or cordon off the danger zone.
Both measures may only be carried out by qualified
electrical specialists. If the crane operator leaves the crane or if another person
If these measures cannot be carried out, a sufficient safety approaches and touches the crane, they will receive
clearance must be maintained between the crane (and hoist an electric shock.
rope, lifting tackle, hook block, load) and current-carrying lines. Even the ground around the crane is carrying an electric
Risk to life and limb! current. Therefore every step on the crane, to the crane
Keep a clearance of at least 10 m. If this is not possible, you or away from the crane is potentially dangerous (step
must obtain information on required minimum safety distances voltage)!
from the electric power company responsible. - Arrange for the voltage to be switched off.
With extremely long boom equipment, these safety clearances - Only leave the crane when you are sure that the touched/
are very difficult to judge. To be on the safe side, increase the damaged line has definitely been disconnected from the
safety clearance to 20 m. power source.
The safety clearance must still be available for unfavorable
crane or load positions.
Allow for possible swinging of the load or swinging out
of the free line as a result of the wind.

Terex® All-Terrain Operation: Superstructure Safety 8

High-frequency radiation / operating in vicinity of This is especially valid if the crane is used in the close
transmitters vicinity of high-frequency radiation sources (e.g. radar
stations, radio transmission stations, radio and television
Charging
stations).
It can cause dangerous electrical charging if track-free mobile
Lightning
cranes are used in the vicinity of transmission systems (e.g.
If storms are approaching, if possible lower the crane
radio transmitters). equipment and leave the crane.
In this case, the following measures must be taken:
If this is not possible, lower the load from the hook, switch off
- agreement with the operator of the transmitter (possibly the engine and leave the crane.
switching off the transmitter). Only remain in the crane operator’s cab if you cannot carry
- grounding (of the track-free mobile crane). out these measures in good time.
In order to protect the rotating connection the grounding
cable must be fastened directly to the superstructure of the Under no circumstances must the crane operator approach the
crane or to the boom. crane or its immediate vicinity during the storm. Warn any other
people in the vicinity of the crane.
Risk of injury!
If the prescribed measures are not taken the persons The general functions of the crane must be checked if it is
suspected that it has been struck by lightening. It is especially
connecting the charged components to ground will be
important that the following is checked:
violently and painfully electrified at touch.
- general electrics, especially:
Interference with the crane electrics
At the same time, the crane electrics, especially the IC-1, - load limit device; if defective, there is a fault message in the
cannot be considered function safe, depending on the strength display.
and frequency of the transmitter. - limit switch for function.
inductive proximity switch for function.
The danger of the IC-1 being influenced by high-frequency
- luffing and outrigger cylinders with a visual inspection for
radiation has been minimized with up-to-date technology
external damage caused by flashover voltages or melting.
(shields). However, it cannot be fully discounted, especially
By retracting and extending the relevant cylinders several
under extreme circumstances.
times, check if there are suspected internal leaks due
to damaged seals.
- hoists, especially for damage to the ball and roller bearings.

Terex® All-Terrain Operation: Superstructure Safety 9

Combination of Hazards with Combined Operation - The mass (the weight) and the center of gravity of the load
of Two or More Cranes must be known exactly.
Operating Areas of Several Cranes Overlap - The load must be shaped in such a way as to avoid extra
hazards during the lifting procedure.
If the operating areas of several cranes overlap, there is a risk of
collisions. - The other cranes which are taking part in the operation must
have nearly the same lifting capacity.
The operating company or its representative must:
- Additional dynamic load effects when the load is raised and
- specify the working procedure in advance!
set down and load effects as a result of environmental
- make sure that there is a clear line of communication with influences (e.g. wind) must be allowed for during planning.
the crane operator !
If the crane operator does not have spoken or visual contact,
suitable measures must be taken, e.g. use of radios, spotters/
banks men etc. The actual danger is during joint lowering of the load.
If spotters are used, suitable signals must be agreed between the Using the relevant reeving and control. the lowering
spotters and the crane operators. In this regard, please refer to speeds of both cranes must be as similar as possible,
“Safety Instructions“.
otherwise there is danger of the slow crane becoming
Crane operators must operate the crane in such a way that
overloaded.
uncontrolled movements and subsequent collisions are avoided.
The „Accident Prevention Regulations for Cranes“ by the
They must receive suitable training and instructions to this end.
Employer’s Liability Insurance Association (BGV D6) can
serve as a helpful guide. It contains regulations and safety
Combined Raising of a Load by More Than One Crane
instructions for operation with several cranes. It especially
If a load is to be raised by more than one crane, the operator of the emphasizes the importance of sufficient safety
crane or his representative must first set up a working
reserves for each crane and that the full load value of the
procedure and appoint a supervisor, in whose presence the
load capacity table may never be used.
operations are carried out.
If there are any doubts concerning the accuracy of the
The most important requirement for this type of operation is,
data, e.g. the accuracy of the details with regard to mass
however, careful planning, covering the following points:
and the position of the centre of gravity of the load, the
safety reserves must be increased accordingly.

Terex® All-Terrain Operation: Superstructure Safety 10

Before carrying out heavy-duty operations, the crane Before commencing work at the operating site, familiarize
manufacturer should be consulted to see whether the crane can be yourself with the working environment. The working
fitted with any additional safety devices (e.g. limiters) or environment includes, for example, obstructions in the
whether the lifting capacity needs to be restricted additionally for the operating and traffic areas, the load-bearing capacity of the
operation in question. ground and the necessary safety precautions required to
cordon off the construction site from public traffic areas.
Avoid pulling a load sideways or at an angle!
To operate the crane, unhindered sight of the crane, load and
load path must be ensured.
Crane Operation Carry out the necessary measures to ensure that the crane is
Before Crane Operation operated in a safe and functional condition.
Check the load conditions again before commencing crane
operation: Is the mass (the weight) of the load and the operating
procedure known and is there sufficient lifting capacity, working
Before commencing work, check that all crane movements are
radius and lifting height? Compare the values with the load capacity
table. functioning correctly and safely.
Check whether outside conditions such as wind, snow, poor Operate the crane only if all safety guards and equipment are
visibility, unfavorable temperatures etc. could limit crane work. fitted and functional.
Compare the conditions with the corresponding sections in the Check the correct function of the brakes, signal and lighting
operating instructions. equipment, limit switches and overload cut-off device daily, for
Make sure that the ground has sufficient load-bearing capacity cranes that are seldom used - every time that they are operated.
when supporting the crane on outriggers. Before commencing work with the crane make sure that no-one is in
the hazardous area. If necessary give a warning sign
For more detailed information, “Working Instructions“ in the
operating instructions of the superstructure (actuate the horn before starting the engine for example! ).
and section “Outriggers“ in the operating instructions of the As oil can be emitted during maintenance and assembly work,
crane chassis. suitable collecting vessels and binding agents must be kept
ready.

Terex® All-Terrain Operation: Superstructure Safety 11

The weight of the load must be known. When carrying out power-driven working procedures
It is difficult to calculate the load weight during dismantling (raise / lower load) only the crane operator is allowed on
work. If a load that is attached to the crane is released from its the crane (and he must be in the crane operator’s cab).
previous connection to other parts and is too heavy, the crane Remaining personnel must remain clear of the hazardous
will be unavoidably destroyed or will tip over, regardless of the area on and around the crane.
load limit switch. The crane operator must give a warning signal when starting
When dismantling hollow components (pipelines, cement the drive motor and before starting crane movements (horn).
silos etc.) allowance must be made for the weight of Stop work immediately if persons fail to leave the hazardous
area in spite of the warning.
possible residues inside these components.
When determining the size of the components that are to
be dismantled, never utilize the full values allowed in the
load capacity tables of the crane, but allow for a safety
The crane operator may only start movements if he has good
buffer.
visibility of the hazardous areas. In case of poor visibility suitable
Select the correct boom length and reeve the hoist rope in
persons must be selected as spotters and must be instructed on the
accordance with the individual load case. correct signals before commencing work.
Select the lifting tackle in accordance with the weight of the load, the This also applies if normal voice communication is not possible
type of attachment and the angle of inclination.
as a result of an increased noise level.
Only hook blocks supplied by the crane manufacturer may be
Keep the windows of the crane operator’s cab clean to maintain
used. The use of other hook blocks is only allowed following good visibility at all times.
permission from the crane manufacturer. In order to allow immediate reaction when the crane is subjected to
Pay attention to the rules and regulations for working with load changing environmental conditions, it is prohibited to switch off the
handling equipment (attachment ropes etc.). Never use lifting drive of the crane when a load is attached and / or to leave the
tackle if there is any doubt as to its lifting capacity. Check to crane operator’s cab.
make sure that the lifting tackle is in perfect condition. Exceptions are only permitted in emergency situations.
To avoid hazardous situations, in the final instance the drive
source (diesel engine) can be switched off using the
emergency off button in the crane operator’s cab.
First - where possible - movements that have been started
should be completed using the control levers.
Before raising a load, you must always make sure that the hook
block is positioned vertically over the load’s centre of gravity.
Terex® All-Terrain Operation: Superstructure Safety 12
The crane (superstructure) may only be placed in operation when position and/or the working movement that is underway has
the crane chassis engine is switched off, the driver’s cab closed and been completed.
the control panels of the outriggers locked. RISK OF ACCIDENTS!
The erected crane without load may only be left without the Actuation of one of these buttons when the control lever
supervision of a trained crane operator if certain conditions is fully deflected leads to an abrupt activation or braking
are met (see operating instructions of the crane chassis, “Parking“). of the corresponding movement.
The carrying of persons with the load or the load handling For all crane movements, pay particular attention to the load,
for unladen operation the load-handling device, and the boom
equipment is prohibited.
tip !
The crane may only be accessed and left following agreement
Watch the slewing radius of the counterweight etc.
with the crane operator and onlywhen the crane is at a standstill.
Observe all safety and hazard warnings on the crane.
Avoid any actions which may impair safety (e.g. risk to the Watch out for obstacles (on the crane and on the operating site)
stability of the crane). which could lead to a collision.
Never slew loads over people. The load must never come into contact with the framework of the
Only start the crane engine from the driver’s seat. Only actuate crane (boom system, superstructure, crane chassis, outriggers etc.).
the control lever from the cab.
Keep the controls lever within reach as long as a load is
suspended on the crane or the crane is driven.
To prevent the unintended activation of crane movements, both
control levers are equipped with an additional button (dead-man’s
button).
The crane movement can only be carried out as long as one of
these buttons is pressed.
The dead man’s switch may only be actuated (pressed and
released) and the limit switches in the instrument panel bridged,
when the corresponding control lever is in the „O“

Terex® All-Terrain Operation: Superstructure Safety 13

Dragging and scraping of the load is prohibited during crane Be aware of the location and availability of fire warning and
operation. fire fighting equipment.
It is prohibited to pull loads free that have become lodged. Pay attention to the weight and surface area of the load
exposed to the wind.
Do not jump from the crane.
Loads that are in water are lighter for the crane than
Use the ladders and the handrails provided.
those in air (due to buoyancy). When the load leaves the
Secure the doors with the available locks to prevent them water it becomes heavier. If this results in the crane being
slamming open or closed. overloaded the load limit device would be triggered.
Check the crane at least once a shift to check for any visible There is a risk to the lifting tackle, however, if this is not
signs of damage or faults. Any changes (including to operating measured for the actual load weight.
behavior) should be reported immediately to the point / person
responsible. If necessary, switch off and safeguard the crane.
In case of a malfunction on the crane, switch off the crane Set the computer of the IC-1 in accordance with the load
immediately and secure it. Have any faults rectified immediately! capacity tables supplied.
Pay attention to the procedures for switching equipment on and off Working in the overload range (load limit switch has shut
as well as the behavior of the indicator lights as outlined in the down) is prohibited.
operating instructions.
Observe the permitted wind speeds.
In case of poor visibility and darkness always switch on the
The superstructure may only be slewed when the crane is
outside lighting. The inside lighting should be switched off to
supported on outriggers. Note that slewing is only
enable proper sight of the load and the immediate environment
permitted for certain crane configurations (e.g. with regard to
of the crane. outrigger support area, counterweight etc.). Always observe the
Always keep the operating instructions at the crane operating specifications of the load capacity tables.
site in the storage compartments provided. These are located on the Slewing of the superstructure in the overload range (load
superstructure on the back wall of the cab and on the crane chassis limit device has shut off) is generally prohibited.
on the driver’s door.
In an emergency the wide-opening front window can be used
as an exit.

Terex® All-Terrain Operation: Superstructure Safety 14

Following Crane Operation As soon as the control pressure reaches zero, all actuators
When you leave the crane: return spring-loaded to the zero position, regardless of the
position of the pilot control lever.
- the load must be detached from the crane hook or set down
on the ground. In the hydraulic circuits which are directly relevant to safety,
there is redundant braking of the winches and cylinders as a
- the engine must be switched off and all control levers placed result of the locked position or additional retaining brake.
in the „O“ position or the „locked“ position.
- the heating must be switched off.
- the parking brake of the crane chassis must be closed.
- the crane must be secured to prevent unauthorized use and
unintentional movement.
If the crane is parked on steep ground, the travel gear must be
additionally secured with chocks, the slew brake applied and the Winches and cylinders
boom secured. The oil column on the lever side of the winch motors and
Close all control panels that are fitted with a lock when they are not cylinders is safeguarded by means of load-independent brake
being used. valves (lowering brake valves). The winches and cylinders can
When parking the crane pay attention to the permitted wind no longer be moved in the event of a failure to the power supply.
speeds (also for the time when the crane is at a standstill). If The lower brake valves are directly fitted to the winch motors and
necessary telescope in and set down the boom. cylinders (no hose lines).
As the described case is extremely seldom, there is no in—built
Power Supply Failure option for lowering a load on the hook. In this event the customer
General service department must be informed.
If the power supply fails, all movements are stopped. An If hoses or pipes should burst, therefore, there will be no
unintentional restart is not possible. When the diesel engine dangerous crane movements as a result.
comes to a standstill, the driven hydraulic pumps also stop. In addition, in the case of a standstill the hydraulically actuated
The oil which is currently in circulation also comes to a standstill. disc brake of the slew gear is applied.

Terex® All-Terrain Operation: Superstructure Safety 15

Driving the crane in the erect (configured) condition Hand Signals
When the crane is driven in the configured position, the load If the crane operator cannot oversee the operation and
rests on the suspension cylinders. These are not equipped with pipe working direction (and/or hazardous areas) from the crane
burst valves, in order to guarantee problem-free suspension operator’s cab (or driver’s cab), a spotter must be used.
behavior during driving of the crane. To avoid hazardous situations, This also applies if normal spoken communication is not
the regulations outlined in the operating instructions for the crane possible as a result of the increased noise level.
chassis, ‘Driving in the Configured Only responsible and reliable persons who know the
Condition“ must be strictly observed. symbols may be employed as spotters.
The spotter should be in a safe position, from where he
can SEE THE LOAD and can himself be clearly

SEEN BY THE CRANE OPERATOR.

The spotter must be easily recognizable for the crane
operator. The spotter should wear one or more suitable
means of identification e.g. jacket, helmet, collars,
armbands, signaling discs.
These signs of identification must be in a distinctive
color and uniform in design and must be worn exclusively
by the spotter.
If the load is attached by several people, only one person
may give the signals. These must be made known to the
crane operator.
If the crane operator does not fully understand a signal, he
should not carry out any movement with the crane. Before
commencing work the crane operator and spotter must work
out a signal for this scenario.

Terex® All-Terrain Operation: Superstructure Safety 16

 START
Attention, pay attention to the following
signals END
Arms stretched out horizontally of a movement
sideways, palms of the Hands folded at chest height.
hands facing forwards.

DANGER !
Emergency stop
Both arms raised, palms of the hand
STOP ! facing forwards.
Interruption, end a movement
Right arm raised, palm of the right
hand facing forwards.

Terex® All-Terrain Operation: Superstructure Safety 17

 RAISE load
Right arm raised, palm of the right hand RAISE boom
facing forward, moving slowly in a circle. Signal with one hand. Right arm
stretched outwards, thumb
pointing upwards.

LOWER load
Right arm down, palm of the hand LOWER boom
facing inwards, moving Signal with one hand. Right arm
slowly in a circle. stretched outwards, thumb
pointing downwards.

Terex® All-Terrain Operation: Superstructure Safety 18

 TELESCOPE OUT boom
Signal with both hands. Thumbs pointing
outwards.

TELESCOPE IN boom
Signal with both hands. Thumbs pointing
inwards.

Terex® All-Terrain Operation: Superstructure Safety 19

NOTES;

Terex® All-Terrain Operation: Superstructure Safety 20

all-terrain operation

Superstructure Controls
 Superstructure Controls Content

Content Pg. Content Pg.

Serial plate locations 3

Components 4

Joystick configuration 16

Terex® All-Terrain Operation: Superstructure Controls

 The serial plate can be found on the cab (1).
(For the CE-design see the serial plate in the driver's
cab)

Terex® All-Terrain Operation: Superstructure Controls 3

 1 Main boom
2 Superstructure
3 Crane chassis

Terex® All-Terrain Operation: Superstructure Controls 4

 1 Frame
2 Driver's cab
3 Axle 1: steered
4 Axle 2: steered and driven
5 Axle 3: rigid, switchable drive
6 Axle 4: independently steered and driven
7 Axle 5: independently steered and driven
8 Outrigger
9 Outrigger pad

Terex® All-Terrain Operation: Superstructure Controls 5

 1 Main boom
2 Crane operator's cab
3 Superstructure frame
4 Counterweight
5 Slew ring
6 Luffing cylinder
7 Slew gear
8 Rope drum (HW 2, option)
9 Hydraulic carrier
10 Diesel engine
11 Hydraulic tank

Terex® All-Terrain Operation: Superstructure Controls 6

 1 Main boom
2 Luffing cylinder
3 Main boom extension
4 Hook block
5 Hoist rope (hoist 1)
2.5.1 Boom Lengths

Main boom 12.4 - 67.8 m

(Main boom length during operation with
main boom extension 67.0 m)

Main boom extension 9.2 - 33.0 m

For combinations of the different boom

components and the resulting total lengths,
please refer to the load tables.

Terex® All-Terrain Operation: Superstructure Controls 7

 1 Pedal - engine speed control
2 Lever - door catch
3 Actuating lever - retract/extend platform
5 Control lever left hand side: different modes can
be selected
6 Pedal – slew gear brake
7 Horn
8 Warning buzzer
9 Radio / CD
10 Control lever right-hand side: different modes can
be selected

Terex® All-Terrain Operation: Superstructure Controls 8

 S.S. Dash

Terex® All-Terrain Operation: Superstructure Controls 9

15 S1260 Knob Engine shutoff switch
22 S8805 Switch Slew gear parking brake
16 S300 Ignition lock Engine start / stop, superstructure 23 S8817 Switch Switch slewing gear open / closed circuit
operation 24 S1250 Double Engine control button (Speed change)
17 Screen IC-1 25 S1210 Switch / Engine start / stop chassis Button (optional)
(Intelligent Control System) 2-step Step 1: Ignition chassis on
Step 2: Engine start chassis
18 S9380 Button Raise / lower counterweight
19 S9370 Button Pin / unpin counterweight The location of switches, buttons or lamps may be different in your
20 Mask crane
21 S0960 Button Unpin / pin slewing gear
(State is displayed in the line
„Current configuration information“

Terex® All-Terrain Operation: Superstructure Controls 10

 31 S4321 Double- Outriggers rear right, retract /
button extend vertically
32 S4318 Double- Outriggers rear left, retract /
button extend horizontally
33 S4317 Double- Outriggers rear right, retract /
button extend horizontally
34 S4331 Double- Outriggers complete, retract/
button extend vertically
35 Dummy plate
36 Dummy plate
26 S4316 Double- Outriggers front left, retract / 37 Dummy plate
button extend horizontally 38 Dummy plate
27 S4315 Double- Outriggers front right, retract/ 39 H7924 Lamp “LLD” bridged
button extend horizontally 40 S7924 Key button Bridging “LLD”
41 H7270 Lamp “Hoist limit switch” bridged
28 S4320 Double- Outriggers front left, retract /
42 S7270 Key button Bridging “hoist limit switch”
button extend vertically 43 H7925 Lamp “Raise luffing gear” bridged
29 S4319 Double- Outriggers front right, retract/ 44 S7925 Key button Bridging “raise luffing gear”
button extend vertically 45 Cigarette lighter
30 S4322 Double- Outriggers rear left, retract / 46 24V connection
button extend vertically

Terex® All-Terrain Operation: Superstructure Controls 11

 50 Lamp Charge current too low
51 Lamp Engine oil level too low
52 Lamp Engine stop
53 Lamp Engine shutoff switch
54 Lamp Fault ADM / engine
55 Lamp Fault chassis engine*
56 Lamp Air filter clogged
57 Lamp Storage tank diesel
58 Lamp Hydraulic oil filter clogged
59 Lamp Hydraulic oil temperature too high

*If light 55 is lit up, the following faults may be indicated:

- Air filter contaminated
- Fault engine
- Fault transmission
- Filter hydraulic oil chassis contaminated

Terex® All-Terrain Operation: Superstructure Controls 12

 66 P1367 Pressure gauge Engine oil pressure display
67 P1351 Pressure gauge Engine temperature display
68 P3251 Pressure gauge Hydraulic temperature display
69 P0460 Pressure gauge Fuel display
70 Mask
71 A5155 Operating Engine independent warm water
element heater
72 S5152 Rotary switch Fan
73 R5170 Rotary switch Regulation of engine indep. warm water
heater
74 S5177 Rotary switch Air conditioning control

Terex® All-Terrain Operation: Superstructure Controls 13

 80 S6540 Switch Dual obstacle fire (optional)
81 S6411 Switch Rota-flare lighting
82 S1262 Switch Switch illumination
83 S6130 Switch Spot light superstructure, left
84 S6211 Switch Spot light outriggers
85 S6140 Switch Switch spot light on boom on / off
86 S6145 Double button Adjust spot light on boom
87 S6120 Switch Spot light on superstructure, right
88 S5251 Switch Windscreen wiper - Roof window
89 S5261 Button Windscreen wash pump
90 S5253 Switch Windscreen wiper - Front windscreen
91 S9310 Button Fold cab up or down

Terex® All-Terrain Operation: Superstructure Controls 14

 5) Control lever, left different modes can be selected

100 Button Fine tuning Crane motion *

101 Button High speed
102 Rockerswitch Fine tuning Crane motion *
103 Button Hoist rotation indicator
104 Button Dead man’s switch
(10) Control lever, right different modes can be selected

110 Button Fine tuning Crane motion *

111 Button Overdrive gear
112 Rocker switch Fine tuning Crane motion *
113 Button Hoist rotation indicator
114 Button Dead man’s switch
* The speeds of the crane movements „Slewing gear“, „Hoist 1“, Hoist
2“ and „Luffing gear down“ can be finely tuned additionally. The
movements that are carried out via the x-axle (horizontal movement of
pilot control lever) of the individual pilot control lever can be regulated
via the corresponding self return
rocker switch (102/112). The movements that are
carried out via the y-axle (vertical movement of the pilot control lever)
of the individual pilot control lever can be regulated via the
corresponding self-return rocker switch (102/112) and by pressing the
keys (100/110; on the front side of the pilot control lever in the direction
of travel, always left) at the same
time.

Terex® All-Terrain Operation: Superstructure Controls 15

Depending on the crane equipment, different modes (IC-1) can Mode 1:
be selected. The option Hoist 2 is an example for a new JLH = Slewing gear JRH = Luffing gear
assignment, see below: JLV = Tele JRV = Hoist 1
Mode 2:
JLH = Slewing gear JRH = Luffing gear
Option: JLV = Hoist 2 JRV = Hoist 1
Mode 3:
JLH = Slewing gear JRH = Hoist 2
Option: JLV = Tele JRV = Hoist 1

Mode 4:
JLH = Luffing gear JRH = Slewing gear
JLV = Tele JRV = Hoist 1
Mode 5:
JLH = Luffing gear JRH = Slewing gear
Option: JLV = Hoist 2 JRV = Hoist 1
Mode 6:
JLH = Slewing gear JRH = Tele
Option: JLV = Luffing gear JRV = Hoist 1

(J = Joystick, R = Right, L = Left, H = Horizontal, V = Vertical)

Observe the selected pilot control assignment in order to
avoid unintentional movements. Risk of accidents!

Terex® All-Terrain Operation: Superstructure Controls 16

all-terrain operation

Crane Operation
 Crane Operation Content

Content Pg. Content Pg.

Permitted wind speeds 3

General notes on operation 6

Raising a load using several cranes 7

Operating info. on pilot control 8

Terex® All-Terrain Operation: Crane Operation

Permitted wind speeds
With all crane configurations, the boom system may only be
erected when the expected wind speeds (weather forecast) are also
permissible for operating the crane.
Observe the permissible wind speed.

The applicable national regulations must also be adhered

to.
It is part of the planning for every operation that an enquiry
is made at the meteorological office responsible for
forecasting wind conditions.
In any case, pay attention to the information in the lifting
capacity tables, as there can, under certain circumstances,
be reductions in the permitted wind speeds.

Terex® All-Terrain Operation: Crane Operation 3

To enable the wind speed to be determined precisely, the
crane may be fitted with an air speed indicator (anemometer).
The rotor, secured to the head of the main boom or main boom
extension;
You can read the wind speed (1) in m/s at the display of the
LLD.
If the crane is to be switched off for longer periods, e. g. at
night, without supervision, the main boom must be
retracted. If winds stronger than 20 m/s are expected, set
the boom system in transport position.

Wind speed and dynamic pressure

The dynamic pressure is calculated as:
q = v2 / 1.6 v = wind speed in [m/s]
q= dynamic pressure [N/m2]
The resulting wind force is calculated as:
Fw = cw x q x A A = surface area of load exposed to wind
cw = coefficient of wind resistance
Crane in the wind with load
Unless otherwise specified in the tables, the following
parameters are assumed for the lifting capacities:
Wind speed v = 9.8 m/s
Dynamic pressure q = 9.82 / 1.6 = 60 N/m2
Surface area of load exposed A = 1.0 m2 per ton to wind
Lifting capacity, however at
least 2 m2
Coefficient of wind resistance cw = 1.2

Terex® All-Terrain Operation: Crane Operation 4

Example: Lifting capacity = 20 t Example 2: Lifting capacity = 20 t
A = 20 m2 Hoist load = 10 t
The resulting wind force on the load is then calculated as: Here, however, the following values are
Fw = cw x q x A = 1.2 x 60 x 20.0 = 1440 N known: A = 5 m2
Caution: The coefficient of wind resistance cw is not a cw value = 1.5
constant. The loads can also have different cw values. The permitted dynamic pressure is calculated by
cw values can, for example be taken from DIN 1055 / part 5. adjusting the formula as:
q = Fw / (cw x A) = 1440 / (1.5 x 5) = 192 N/m2 > 150 N/m2 !
With the exception of crane operation with the main boom qmax = 150 N/m2 must be observed.

extension, wind speeds of up to 15.5 m/s (dynamic The permitted wind speed then equals:
pressure 150 N/m2) are permitted if the surface area of the
load exposed to the wind or the lifting capacity is reduced
in accordance with the above-mentioned values. For loads with a larger surface area exposed to the wind,
please contact the crane manufacturer.
Example 1: Lifting capacity = 20 t
Hoist load = 10 t
Assumption: A = 10 m2
The permitted dynamic pressure is calculated by adjusting the
formula as: q = Fw / (cw x A) = 1440 / (1.2 x 10) = 120 N/m2
The permitted wind speed then equals:

Terex® All-Terrain Operation: Crane Operation 5

General notes on operation
- For main boom operation, the missing hoist limit switch
for the main boom extension must be bridged by means
of the blind plug (22).
- When operating the crane with the main boom
extension:
* Plug (8) for the hoist limit switch of the main boom must
be removed from the socket on the main boom head
and plug (9) for the hoist limit switch of the main boom
extension plugged in.
* The shift weight (21) of the hoist limit switch of the main
boom must be removed.
If a hoist rope has not been reeved the shift weight must be
coupled to the attachment provided, so that the cable from
the junction box on the main head to the cable reel is not
damaged.
- For crane operation with the main boom extension locked in
the transport position, the loads specified in the load table
are reduced, i.e. the proportional weight of the main boom
extension in the transport position must be added to the load
that is to be lifted (see Notes on crane operation).
- Crane operation with additional equipment fitted:
* The lifting of loads simultaneously on the main boom
and the main boom extension is prohibited.
* The lifting of a load on the main boom with main boom
extension with load or without load is prohibited.
* The number of falls given in the load tables must be
adhered to.
- The crane may be operated with the main boom extension
only with the crane supported on outriggers.
The lifting capacity of the crane in consideration of the main
boom length and the counterweight fitted can be taken from
the load tables. The axle suspension must be locked.

Terex® All-Terrain Operation: Crane Operation 6

Raising a load using several cranes Checking the safety measures
If a load is to be raised using several cranes, the working Before work is begun, i.e before a load is lifted, the
procedure must be determined beforehand, following points are to be checked:
in particular when: - Crane chassis suspension system is switched to “raise
- the cranes do not have the same lifting capacities; axles”.
- the suspended load is not of uniform shape or the center of - Underlying ground is firm enough to support the weight
gravity is not known; of the crane.
- dynamic influences are expected when releasing - All 4 outrigger struts are extended to the support area
the load. given in the duty chart.
The load must then be raised in the presence of a supervisor. - Outrigger plates are secured.
When raising a load using several cranes, it must be ensured - Crane is in level position.
during raising and lowering that: - Crane is not situated near a ditch or sloping ground.
- the permissible load for each crane is not exceeded. - All axles are without load, i.e no wheel is in contact with
- the load is not damaged by excessive strain on the the ground.
attachment points (fixing the crane hook to the load). - No live cables are situated within the operating radius
- the load is lifted at an even rate. of the crane.
The permissible crane load will be exceeded or the attachment - Crane is positioned such that it can be operated with a
point of a load will be excessively strained if: minimal operating radius.
- a crane raises the load too quickly during the simultaneous - There are no obstructions which may restrict necessary
raising of the load; crane movements.
- a crane lowers the load too slowly during the simultaneous
lowering of the load.

Terex® All-Terrain Operation: Crane Operation 7

- If visibility is poor or if it is dark, the immediate area in front of Operating information on pilot control
the cab, the outriggers and the boom must be lit using spot Electric pilot control
lights which are on the machine. The control levers have differing effects on the various crane
movements.
The relevant operating elements are in the crane cab:
1. Crane movements dependent on engine speed:
83 (S6130) Switch Spot light superstructure, left
- Hoist up / down
84 (S6211) Switch Spot light outriggers
- Luffing gear up
85 (S6140) Switch Switch on / off spot light on main boom - Slew gear left / right (without any further movements)
86 (S6145) Double Adjust spot light on main boom button For these crane movements, proportional valves which are
87 (S6120) Switch Spot light superstructure, right dependent on engine speed are activated. This means that with
Other surrounding areas (load, load path, slewing range, driving the lever of the pilot control sensor (control lever) in the same
path, and similar) must be lit using suitable means, independent of position, the valves are opened wider at high than at low engine
the crane. This is the responsibility of the crane operator. speeds.
This ensures an adequate supply to the valves.
As a result:
with the lever in the same position, movement is, for example,
slower at 1200 rpm than at 2350 rpm.
2. Crane movements independent of engine speed:
- Retracting / extending telescopic sections
- Slewing gear (when the slewing gear is activated before other movements
are introduced). These movements operate in accordance with a fixed
control characteristic which cannot be altered by external control elements
(e.g. rocker switch on control lever when operating telescopic sections).
As a result:
movement speed remains the same even if engine speed is increased
(throttle opened).
3. Crane movements altered at the press of a button:
- Luffing gear down
- Hoist up / down
- Slewing gear right / left
The speed of these movements is not dependent on engine speed. In the
pilot control levers there are rocker switches which can be used to vary
speed manually. This device is designed to enable more sensitive operation.

Terex® All-Terrain Operation: Crane Operation 8

When the buttons are actuated, speed is indicated (in %) on the
LMB display. This also remains visible a short time after the
buttons have been activated, then jumps back to the previous
display mode.
When the ignition is switched on, the following values are preset
for the speed:
- Luffing gear down 40 %
- Hoist up / down 100 %
- Slewing gear right / left 50 %
4. Dead man’s switch (104/114)
To prevent the unintended activation of crane movements, both
control levers are fitted with an additional button (dead man’s
switch).
A crane movement can only be carried out when one of the
buttons is pressed.
5. High-range button (101/111)
The high-range button at the left of the pilot control sensor is
only active for the following:
- Hoist up / down
- Luffing gear up
i.e. crane movements dependent on engine speed.
This means that within a given speed range, the control current
to the proportional valve is readjusted proportionally to the
change in engine speed in the high range.
6. Using “0o- facing-rear carrier weight tables”
Prerequisites:
- Position superstructure in the angle range from +2o or +358o
Select in the operating-mode pre-selection mask type “HA-0”.
The “0o-facing-rear carrier weight tables” can only be selected
for the above-mentioned prerequisites.

Terex® All-Terrain Operation: Crane Operation 9

NOTES;

Terex® All-Terrain Operation: Crane Operation 10

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all-terrain operation

IC-1 Symbols and Screens

 IC-1 Symbols and Screens Content

Content Pg. Content Pg.

IC-1 control general 3

Load limit device 4

Control and display elements 8

Programming pilot control sensor 22

Operating range limits 25

Data Logger (optional) 29

Bridging load limit and limit switches 32

Terex® All-Terrain Operation: IC-1 Symbols and Screens

 Safety Equipment
IC-1 symbol and screen
explanation IC!1 crane control

The crane control IC!1 (Intelligent Control System)

combines several devices which provide the crane driver with
essential information for operating the crane within the
parameters specified by the manufacturer:
POWER

ON/OFF

! Overload cut!off device (load limit device LLD)

! Telescoping Information System
! Display of numerous crane functions, for example, support
pressure, tilt, crane configuration, lifting capacities etc.
! Warning (optical and acoustic) in case of prohibited
conditions.

This crane control (incl. load limit device) is an operating aid.

Temp
It provides the crane operator with essential information
HD

Power
concerning crane data such as length and angle of the boom,
sheave head height, nominal lifting capacity, the total load
suspended from the boom, etc. and gives warning when an
overload condition is being approached or when the hook block
gets too close to the boom head.

This safety device is no substitute for the judgment and

experience of the crane operator and use of recognized
safe operating procedures for the use of cranes.
The crane operator still carries the ultimate responsibility
for safe operation of the crane.

Terex® All-Terrain Operation: IC-1 Symbols and Screens 3

Load limit device (LLD)

Function

If, when raising a load or increasing the working radius with load,
the permissible load moment/the permissible load is exceeded,
both the movements which increase the load moment and the
movement which decreases the load moment ”Raise luffing gear”
and ”Raise load on hook” are disabled. ”Lower load on hook” is
permitted.

A continuous tone sounds and the Stop symbol appears.

The warning message LLD appears (red). In addition, the color

of the bar display (C) changes from yellow to red. Lifting of loads
is not permitted!
After a shutdown by the load limit device, only movements which
decrease the load moment may now be initiated.

RISK OF ACCIDENTS!
It is absolutely forbidden to override the load limit device
to overload the crane above its load bearing capacity!
Lifting a load with the load limit device overridden is prohibited!

The load limit device should only be activated in an emergency

situation. Under no circumstances may it be used as
a standard operating tool!
This means that the crane operator must be satisfied, before
hoisting the load, that the load bearing capacity of the crane
is not exceeded by the load to be lifted. Loads that are too
heavy and exceed the load bearing capacity of the crane
must not be accepted, even if there is a load limit device installed!

Even without a load, the boom may only be moved in those

ranges where load bearing capacities are specified.

Before a load is raised, its weight must be known. The safety device
may not be used to determine the weight.

Terex® All-Terrain Operation: IC-1 Symbols and Screens 4

To ensure that the load limit device functions properly, it must: The load may only be taken up by the hoist in hook operation.
If the load is still in contact with the ground and raising of
! be set by the crane operator in accordance with the crane the hoist has been switched off, the load is too heavy. In this
configuration before work is commenced (as soon as the case, activating the ”Lift main boom” movement is not permitted!
configuration is achieved) after the ignition/engine is switched This movement is not to be used to lift the load under any
on. circumstances!

! reset by the crane operator in accordance with the new operating It is essential for the operating safety of the crane that the
mode once the crane configuration has been changed. IC!1 crane control functions in its original condition.
Necessary updates can be obtained from the after sales
This is set by selecting the operating mode. service department of the crane manufacturer.
Only when the load limit device has been correctly set by the
crane operator in accordance with the current operating Danger of crushing!
mode/crane configuration, can it operate automatically. The swinging out of the load during switch off cannot always
The crane operator is responsible for the correct setting by be avoided, even with the use of automatic safety devices!
acknowledging the crane configuration. It can be avoided only by all crane movements being carried
out at appropriate speeds.
Danger of accident ! limits of the load limit device! Also take note of the continuous display of the load moment
Despite a functional load limit device that is correctly set in with preliminary warning at 90% of the permissible
accordance with the crane configuration, the load limit device load moment prior to switch off.
can become ineffective in particular cases/operating
errors: Risk of crane control system being influenced!
The risk of the load limit device being influenced by high!
! insufficient load bearing capacity on the ground used for frequency radiation is minimized by the latest technology
the set!up site of the crane (shielding). It cannot, however, be completely excluded ! in
! support errors particular under extreme conditions, for example near powerful
! not switching on the prescribed telescoping sequences transmitters.
! influence of the wind
! diagonal pull
! dynamic influences, e.g. by crane movements that are
too fast and end with an abrupt stop
! dismounting work, if loads are unscrewed/burnt off after
slinging, then hang loosely from the crane and prove to
be too heavy
! lifting overloads with the luffing gear
! cooperation of several cranes.

The crane operator must observe these system limits

when setting up and operating the crane!

Terex® All-Terrain Operation: IC-1 Symbols and Screens 5

Bridging load limit device This is the case, for example, if ”Raise luffing gear” is switched
off due to the permissible minimum radius being reached.
Bridging shutdown of movement which decreases
the load moment ”Raise luffing gear” In this instance, bridging is not allowed and the load!moment!
reducing movement ”Raise luffing gear” cannot be
If a prohibited overload condition has occurred, the load!moment! continued, because the crane could tip over backwards.
reducing movement ”Raise luffing gear” is also shut down
by the load limit device. Only lowering of the load on the hook is
permitted.

Once an overload condition has been switched off by the load limit
device, load moment reducing movements can be carried out
to move a freely suspended load out of the overload range
again, back into the normal operating range. In this case the key!
operated pushbutton (116) must be pressed. Indicator light (115)
lights up.
The status display ”LLD” (or LMI) changes from red to black on
the IC!1 display.

The override can only be initiated if the control levers are in

the neutral position and/or the initiated crane movement is
finished.

RISK OF ACCIDENTS!
This load moment reducing movement may only be enabled
if it does not present a hazard. Make sure that this is
the case before pressing the key!operated pushbutton.

If the load is still in contact with the ground and raising of

the hoist has been switched off, the load is too heavy. In this
case, activating the ”Raise luffing gear” movement is not
permitted!

This movement is not to be used to lift the load under any

circumstances!

Danger of falling backwards!

In some cases, enabling the movements which reduce the
load moment is not permissible.

Terex® All-Terrain Operation: IC-1 Symbols and Screens 6

Bridging the shutdown of all movements

The load limit device can be overridden using key!operated

pushbutton (112).

The override can only be initiated if the control levers are in

the neutral position and/or the initiated crane movement is
finished.

The button must be turned in the clockwise direction and held in

this position.

When overridden, indicator light (111) lights up.

The status display ”LLD” (or LMI) changes from red to black on
the IC!1 display.

The load limit device may only be overridden in exceptional

cases, for example in case of repairs, fitting a rope etc.
This can only be done by authorized personnel who are familiar
with the operation of the crane!
The bridging of the load limit device may not be used to increase
the load moment under any circumstances.
Lifting a load with the load limit device overridden is prohibited!

Terex® All-Terrain Operation: IC-1 Symbols and Screens 7

Control and display elements

(1) ! Adjustment toggle for adjusting inclination of the display

(2) ! IC!1 display
This display has a large color monitor to enable the information
shown to be read easier. The brightness adjusts
itself automatically to the ambient conditions.
All keys are activated by tapping the symbol (touch
screen) directly with the finger.

RISK OF DAMAGE!
Adhesive materials may not be affixed to the monitor! Mounting
stick-on labels would destroy the monitor (touch screen)!
You will get the best results when cleaning the monitor by using
a clean, damp, nonabrasive cloth and any commercially available
window cleaning agent without ammonia. The window cleaning
agent should be applied to the cloth first instead of directly POWER

onto the surface of the monitor. ON/OFF

(3)! On/Off switch

For rebooting the IC!1 when necessary: switch off ignition,
wait at least 30 s, press switch for at least 3 s.
Switch ignition on again.

(4)! key: brightness ”+” (manual)

(5)! key: brightness ”!” (manual)
(6)! key not allocated
(7)- lamp: temperature warning
Temp

HD

Power

If the temperature in the computer is lower than C, the LED lights up red
00
and the computer is heated internally. When the temperature is more than 00
C, the computer starts automatically.
The heating procedure can take between one and eight minutes, depending
on the outside temperature.
The computer is ready for use as soon as the red LED (temp, 7) goes out and
the green LED (power, 9) illuminates.

(8)- lamp: hard drive

(9)- lamp: operating condition
Terex® All-Terrain Operation: IC-1 Symbols and Screens 8
 Operating the IC!1

For this system, all functions are operated by ”tapping” the keys
or buttons shown on the monitor (touch screen).

By tapping a key/active button, a selection window is opened for

parameter selection (1), or the display changes to another selection
window.
When opening a selection window, a list of selection options
(pull down menu) appears in the selected area. A value must
then be selected from the selection list. If the set value is not to
be modified, then the previous value must be selected again from
the selection list.

The values selected are always dependent on the previously selected

settings. If, for example, crane mode is selected without
main boom extension, then no values are offered for setting the
parameter with main boom extension. These keys then only appear
”grey”. All parameters which can be set appear on a key in
a black frame.

In principle, the following applies:

Diskette ”Save” symbol:

selected setting is saved, and the display is
changed

Door ”Exit” symbol:

the display is left without saving the
modified settings

”Red” entries
The displayed value must be changed or,
at least, confirmed by tapping. Otherwise,
the settings for the crane mode cannot be
saved.

Terex® All-Terrain Operation: IC-1 Symbols and Screens 9

System start/Switching the system off

The IC!1 is automatically started when the ignition is switched ”Operating mode selection” (fig.3) screen appears after the
on. At the same time, a system check is made automatically. Depending CAN initialization is completed.
on the temperature of the computer (monitor), the display
of the previously set crane status with the ”CAN initialization”
screen positioned above it appears after an appropriate warm!
up time.
Momentary ”error” displays appearing during the automatic
check serve to test the functional reliability of the system, and are
of no importance to you.

If the computer is recognized by the PLC within 30 s, the CAN initialization

screen closes automatically. The CAN status in the uppermost line changes
to ”OK”.

The CAN status can have the following conditions:

STOP crane operation not permissible

a subscriber is missing, but not relevant
OK crane operation permissible

If CAN initialization is not initialized within 30 s, the screen is not

closed automatically. The two keys and ”CAN reset” are

activated and must be actuated manually:

1. Option: actuate ”CAN reset”: the initialization is restarted. If

that doesn’t work:

2. Option: actuate: a screen appears (fig.3) for selecting

the operating mode in non!active status. That means that an

entry is not possible for the ”type” field, so crane operation is not
permissible.
The existing error must be located ! for example, with the help
of diagnostics screens ! and removed. It is only then that the initialization
can be restarted.

Terex® All-Terrain Operation: IC-1 Symbols and Screens 10

 If the assembly or operating condition remains unchanged, the

screen can be exited via .

If the assembly or operating condition has been changed, the

specifications in the screen must be adjusted accordingly
(fig.1). In order to be able to transfer the modifications to the

control system, the screen must be exited in this case via .

In both cases, the ”Crane operation” screen then appears

(fig.2).

As a starting point for using the IC!1 functions, the most important
screens are ”crane operation, (fig.2) ” ! and specifically
area ”E”, the screen ”Quick Menu” and the screen ”main menu

Using these screens the desired functions can be selected by calling

up the corresponding submenus.

Terex® All-Terrain Operation: IC-1 Symbols and Screens 11

 Power control

When the electric power supply fails, or after switching off the
ignition, the display changes automatically to the ”Power control”
screen. The remaining time (starting at 15 min.) up to switching
off the computer is displayed here. If the ignition is switched on
again within this time, the display changes directly to the ”Operating
mode selection” screen. IC!1 is immediately ready for use
again.

The ignition can be checked after three minutes. If the ignition is

switched on and then switched off directly after, it can take approx.
three minutes until the ”Power control” screen is selected.

Terex® All-Terrain Operation: IC-1 Symbols and Screens 12

 Section (C): loaded display

Continuously changing display of the load moment as ”bar display”

with superimposed display percentage/overload display.
For loading in longitudinal code (LC 1), the whole field (C)

is shown in red with 3 stars instead of the bar display .

Raising of loads is prohibited.

A warning buzzer sounds when the pre-warning range (90!99%

of the max. permissible load moment) is reached, and a warning

symbol appears the color of the bar display changes from

Section (B): display of load and radius green to yellow.

(1) ! Net load When the overload range is reached, the load limit device shuts
By pressing the ”Net” button, the current load is down movements which increase the load moment and ”Raise
tared. luffing gear”. A continuous tone sounds and the Stop symbol

(2) ! Maximum load (for the set crane configuration) appears. In addition, the color of the bar display
For loading in the longitudinal code (LC 1), the
loading symbol appears instead of the maximum changes from yellow to red. Lifting of loads is not permitted!
load.

It is then prohibited to raise loads

(3) ! Current total load (gross load)

This includes load, hook block, all lifting tackle and,
if applicable, additional device attached.

(4) ! Current radius

Terex® All-Terrain Operation: IC-1 Symbols and Screens 13

 Section (D): display of status information on crane condition

(1) ! ”Error” display: is superimposed when an error occurs

(2) ! ”HES (red)”: lifting limit switch triggered, and not bypassed
”HES (black)”: lifting limit switch bypassed, regardless
whether triggered or not
(3) ! ”SES (red)”: lowering limit switch triggered, and not
bypassed
(4) ! Emergency operation (optional) is active (see Section 36)
(5) ! ”LLD (or LMI) (red)”: load limit device is switched off, and
is not bypassed ”LLD (or LMI) (black)”: , load limit device is
bypassed, regardless whether it is switched off or not;

simultaneously appears.

(6) ! Reading below min. permissible outrigger pressure (< 1 t)

(7) ! Current wind speed
(8) ! Fade!in of different symbols:

: Pre-warning range; 90%!99% of the permissible

crane load reached

: ! Load limit device is switched off

! Load limit device is bypassed

: Load capacity table being loaded; only appears

for a few seconds; crane operation is not
permissible during this time

(9) ! Counterweight control overridden

(10) ! Current tilt
(11) ! Working range limit
active; can be deactivated by tapping
(12) ! Length main boom

Terex® All-Terrain Operation: IC-1 Symbols and Screens 14

 (13) !
Max. main boom length reached
(15) !
High speed
(16) !
Configuration mode: raising of loads prohibited
(17) !
Current slewing angle (see Section 8 ”Slewing”)
(18) !
Slewing operation in open circuit (see Section 8 ”Slewing”)
(19) !
Key for calling up the ”Quick menu” screen; is used
especially if the free is assigned with a submenu which
otherwise provides no option to exit.
(20) ! Current radius
(21) ! LLD relevant LC and radius step

(22) ! (red): min./max. radius reached,

LLD switches off

(black): min./max. radius reached

LLD shutdown bypassed

(23) ! Angle of the main boom to horizontal (foot angle)

(24) ! (red): min./max. main boom angle

reached, LLD switches off

(black): min./max. main boom angle

reached, LLD shutdown
bypassed

(25) ! Telescoping is only possible with bridging of the load limit

device due to telescoping error.
(26) ! Head height
(27) ! Radio remote control (optional) active operation no longer
possible on the IC!1 display
(28) ! Angle of the main boom to horizontal (head angle)

Terex® All-Terrain Operation: IC-1 Symbols and Screens 15

(E) - Quick menu:
In addition to the display mask of the main menu, further
masks can be called up here:
- E11 Main menu
- E51 Telescoping information system
-!E52 Support pressure gauge

Display of support pressures as well as tilt. The display bars are colored
red if the support pressures are in the limit range.
- E53/54 Activates the pumps together or separates
them. The current mode is displayed in the top left-hand button. The
corresponding movements are displayed in the right-hand button.
A mode is changed by pressing the buttons.
The following modes are available.:

Option hoist 2.
-!E55 Display of the operating range limits
The active limits are displayed in the top status bar (E1). The valid
operating range is always displayed in green.
- E56 Switches to engine display.
1: Button for automotive driving. The button is green when automotive
driving is active.
2: Slide control switch for manual minimum speed.
Min. value is 800, max. value is 2100. The current value is displayed in
the center.
3: Slide control switch for various engine information.
Terex® All-Terrain Operation: IC-1 Symbols and Screens 16
 E57 Changes to the counterweight display.
Display aid when configuring the counterweight.

def. / undefined state

Driving slewing gear permitted / not

permitted.

Superstructure pinned /
superstructure unpinned.

The arrow in figure „Counterweight pinned status 2“ is always displayed when

the switch for driving the counterweight is displayed.
The quick menu can be called up again for every other display using button
(A1).

Terex® All-Terrain Operation: IC-1 Symbols and Screens 17

(Quick menu E21) Operating Mode Pre-selection Mask

In the manual view the individual configuration parameters can

be set.
If changing a parameter results in another parameter being
changed as well, the second parameter is displayed in red.

Values in red must be confirmed by the operator, i.e. he must

press the button again. If the button appears again with a red
background and black writing,
this configuration cannot be set due to the current crane
condition.
Selection options that contain only one parameter cannot be
changed.
If a parameter is displayed in red, the mask cannot be left by
saving. The following dialogue appears:

Special types of operating modes

* The main boom extension can only be selected if the main boom length is
shorted than 23 m.
* MS can only be selected if the main boom angle is smaller than 10o.
The previously set configuration state is disregarded when you leave using
Exit. The mask automatically changes to the mask that was last displayed.
The operating mode selection mask is always called up when the computer
is started again. The LLD mask is started up when this mask is exited for
the first time.

Terex® All-Terrain Operation: IC-1 Symbols and Screens 18

Exiting / saving
The system first checks if the current extension sequence of the tele
cylinders (length code LC) exists for the selected configuration state when
exiting the mask using Save. If the LC is not in the selected table, the
following dialog appears and the operating mode selection mask is not
exited.

If a release is given after the check, the set configuration state is

transmitted to the SPS and the system switches to the previously displayed
mask. The following figure is displayed during the data transmission to the
SPS.

By pressing „table“ in the operating mode mask, the loads of

the set configuration state are indicated.
1: Length code LK
2: Main boom end length
3: Radius
4: Loads
5: Min. reeving
6: Unpinned loads
7: Table identification number
8: Information on special loads. An information dialog
appears when the button is pressed.
It is only visible if there is an existing special load.

Terex® All-Terrain Operation: IC-1 Symbols and Screens 19

Search
The load and radius can be determined by pressing “Search” in
the operating mode mask, and the system automatically
searches possible configuration states.
The data is entered using the buttons Load and Radius. The
search is started using the button Magnifying Glass. All found
configuration states are entered in the bottom selection element
after the search.
Error Message

All active errors of the SPS are indicated in the dialogue Error
Messages. All error messages remain until viewed.
Error button

The error button is always visible in the main menu. If the main
menu is active and a new fault is transmitted from the SPS to
the computer, it is displayed in „red“.
The fault button is always displayed in „red“ in all other masks
when a new fault has occurred, an existing fault no longer
exists or the last fault signal has not been called up. This
means that as long as the fault button is displayed in „red“,
something has changed and this must be confirmed be
pressing the button.

Terex® All-Terrain Operation: IC-1 Symbols and Screens 20

 (Quick menu E23) Pilot control valve assignment

Depending on the crane equipment, different modes can be selected. The

option Hoist 2 is an example for a new assignment, see below:

The speeds of the crane movements “Slewing gear“, “Hoist 1“, “Hoist 2“ and
“Luffing gear down“ can be finely tuned additionally.
The movements that are carried out via the x-axle (horizontal movement of
pilot control lever) of the individual pilot control lever can be regulated via the
corresponding self-return rocker switch (102/112). The movements that are
carried out via the y-axle (vertical movement of the pilot control lever) of the
individual pilot control lever can be regulated via the corresponding self return
rocker switch (102/112) and by pressing the keys (100/110; on the front
side of the pilot control lever in the direction of travel, always left) at the
same time.
Terex® All-Terrain Operation: IC-1 Symbols and Screens 21
Programming pilot control sensor
If a dialogue “pilot control assignment” is started from the main
menu, an additional button “setup” appears.
The setup button provides the option of programming a left control to be a
right control. This option is protected by a special PIN and can only be
carried out with the help of our customer services.

Hour meter

The operating hours of the crane movements slewing gear, hoists, luffing
gear and tele unit are shown here. The display of the operating hours is in
„Hours : Minutes“.
There is a differentiation between load and rope load in the
hoist unit (H1-L, H1-S).

Terex® All-Terrain Operation: IC-1 Symbols and Screens 22

(Quick menu E22) Parameter mask
(fig;1)
The solenoid valve data for the individual crane functions is set in the
parameter menu. The data set “slewing gear left” of the SPS is shown
when changing to the mask.
Selection of a crane function (fig;1) fig;1
The popup dialogue (fig;2) is opened by pressing the Combo Box (1).
A new function can be selected here. The SPS sends your data to the
display as soon as you have made your selection.
Entering a parameter (fig;1)
The entry dialogue (fig;3) is opened by activating a parameter button (2).
The valid entry area is indicated behind the OK symbol. If this area is
exceeded, the entry is indicated in red. The last symbol entered can be
deleted with the arrow. The entry is saved by pressing the diskette and
directly transmitted to the SPS. Entry is cancelled via the Exit button.
Selection of a stored data set
The menu window (fig;4) is opened by clicking on the menu button (3).
fig;2
1 Load setting 1
2 Load setting 2
3 Load setting 3
4 Load factory setting
5 Load current setting of the SPS
6 Save settings
7 Exit parameter menu
Various settings can be loaded or saved here. The parameter
menu is ended via the Exit symbol.

fig;3 fig;4

Terex® All-Terrain Operation: IC-1 Symbols and Screens 23

If a new setting is loaded from the computer it must be saved with the disc INFORMATION
symbol. That means that the setting will then be transmitted to the SPS. Display of crane type and construction number.

The factory setting cannot be modified. Only the factory setting can be
selected for the functions Tele On and Off as well as the slewing gear
43
brake and emergency clutch, which means that the crane operator cannot
store any personal settings.
Status display

Data set which is currently saved in the SPS (1, 2, 3, D). If the data record
of the SPS does not correspond to any stored on the computer, SPS
appears in the symbol. Otherwise the number of the corresponding data
record is displayed.
Control value of the pilot control transducer
Output current
Graphic display
The graphics display can be changed by activating the button, position 5.
The time ramp and the PWM ramp can be selected.
Copying a data set
If for example the factory setting is to be assigned to setting 1, the
procedure is as follows:
Load the factory setting from the menu window and save with
the diskette .

Afterwards load setting 1 from the menu window.

Then load the current SPS setting via the menu into the data set
setting 1.
Finally, conclude the procedure with .

Terex® All-Terrain Operation: IC-1 Symbols and Screens 24

(Quick menu E24) Operating range limits Access to the mask for setting an operating range is achieved using
the button .
The crane operator can define the following limits so that the crane or
boom do not enter existing danger zones, e.g. near overhead lines: The limits which are active are displayed in green. The button
- Slewing angle limit Operating range limits must be pressed again to deactivate the set
- Radius and height limit operating range, the button is then displayed in grey.
The position (1) indicates the current position of the main boom
- Operating range limit by virtual wall
head.
The setting of operating range limits does not relieve the crane
operator of his responsibility for safe crane operation. Activation of the slewing angle limit.
He must ensure that he fully understands and follows the indicated The background behind the buttons
instructions and applications. is green when the slewing angle limit
Make sure you deactivate any activated limits as soon as operation is active.
within a limited operating range is finished.
Otherwise this could lead to an unintentional and abrupt shutdown Setting and saving the left slewing angle.
during a later crane operation without limits, which accordingly
causes the hook block / load to swing out widely. Setting and saving the right slewing angle.

Activation of the max. radius limit.

Setting and saving the max. radius.

Activation of the min. radius limit.

Setting and saving the min. radius.

Especially make sure that the selected limit angle (= shutdown point)
actually ensures sufficient distance to the danger area in extreme
situations (e.g. the hook block swinging out after the crane motion
has been switched off).
All crane movements must always be carried out with adapted speed.

Terex® All-Terrain Operation: IC-1 Symbols and Screens 25

 Activation of the wall limit.

Setting and saving wall point A.

Setting and saving wall point B.

Switching over of the operating range to the wall.

When the inverted display is switched on the background is

displayed in green.

When setting and saving a wall a minimum distance of 8 m between the

wall points must be adhered to.
If the distance is too small, the wall area will be displayed in red.

Especially make sure that the selected limit angle (= shutdown point)
actually ensures sufficient distance to the danger area in extreme
situations (e.g. the hook block swinging out after the crane motion
has been switched off).
All crane movements must always be carried out with adapted speed.

Activation of the height limit.

Setting and saving the height.

Terex® All-Terrain Operation: IC-1 Symbols and Screens 26

(Quick menu E31) Diagnosis Joystick (Quick menu E33) Diagnosis CAN bus
The function can be checked by moving the pilot control The status of each individual CAN participant can be checked in the CAN
transducer. diagnosis menu. The status of a participant is OK if the bits B1 and B2 are
on 1. This information is important for our customer service department
in case of malfunctions.

(Quick menu E32) Diagnosis of all control inputs / outputs

The individual inputs and outputs of the control unit can be checked in the
IO menu. If the selected unit is a CPU unit, software version (1) is
displayed above the Combo Box (2). The various units can be selected
by pressing the Combo Box (2).

Terex® All-Terrain Operation: IC-1 Symbols and Screens 27

(Quick menu E34) Diagnosis LS
Diagnosis of the electrical Load Sensing System.
The display indicates the state of the pump: „coupled“ or
„separated“, at the same time pump pressure and electric
control can be read from each pump.

Terex® All-Terrain Operation: IC-1 Symbols and Screens 28

Data logger (optional)
The data logger saves each set configuration state of the crane. The
current configuration state is displayed in grey font (1).
Date and time indicate when these configuration states were set.

Quantity: The quantity of the currently set data records

Current: The currently visible data records
LLD: 0= Release
1= No release
CAN: 0= CAN bus OK
1= CAN bus fault
U-LLD: 0= Bridging switch LLD not activated
1= Bridging switch LLD activated
U-HES: 0= Bridging switch HES (hoist limit switch) not
activated
1= Bridging switch HES (hoist limit switch)
activated
U_AUF: 0= Bridging switch UP (luffing up) not activated
1= Bridging switch UP (luffing up) activated
TELE_M: 0= Tele automatic active
1= Tele manual active
LK: Selected length code
LK-RV: Length code which is relevant for load calculation
EIN: Hoist rope reeving
AUSL: Current crane load
MAX: Maximum load capacity
Last: Current load
RAD: Current Radius
RAD-RV: Radius which is relevant for load calculation
HA-W: Current main boom angle
HA-KW: Current main boom head angle
HA-L: Current main boom length
DREHW: Current superstructure slewing angle

Terex® All-Terrain Operation: IC-1 Symbols and Screens 29

 Risk of tipping! Risk of breaking!
B The load capacities indicated in the load capacity tables
A
correspond 100 % with the permissible maximum load of the
C
individual crane configuration. If these limit values are
exceeded there is risk of the crane tipping and / or risk of the
D crane components or supplementary equipment breaking.
E
F
G H 1. Select load capacity table (paper) which corresponds with
the current crane configuration.
The following example shows where you can find these values in the
load capacity table.
J
The opposite load capacity table is only an example. Only the
I
load capacity tables supplied with the crane are valid for crane
operation.
(A)! - Crane type
K
L (B) -Main boom operation (all telescopes pinned)
M The computer automatically switches to a telescoping or
configuration curve.

(C) - Abbreviation of operating mode( here; HA for working with Main

Boom)
Setting the operating mode
(D) - Permissible slew range: 0 - 360o
In order for the load limit device to function faultlessly, it must:
(E) - Outrigger Length
- be set by the crane operator according to the crane configuration before
beginning work (as soon as the configuration state has been reached) after (F) - Outrigger Width
ignition / engine has been switched on. (G) - Counterweight
-!be reset by the crane operator according to the new operating mode after (H) - Main boom length
the crane configuration has been changed. (I) - Radius
(J) - Maximum load capacity
The load limit device can only function automatically when it has been (K) - Reeving number of the hoist rope
set correctly by the crane operator in accordance with the individual (L) - Length code no. of extension sequence (LK)
operating mode / crane configuration.
(M) - Extension sequence of telescopes

Terex® All-Terrain Operation: IC-1 Symbols and Screens 30

Load Monitoring Assembly
It is possible to check the weight of the raised load (net load) with the help
of the computer of the load limit device.
The load monitoring assembly may not be used for determining
weight; instead it serves for checking previously determined weights
of loads in order to better evaluate the load stroke and to avoid
possible dangerous situations.
The maximum load for the relevant operating mode must be determined
before raising the load. It is indicated on the display in MAX (B) in relation
to the selected operating mode.
Load check
1.Press the button of the net display (B) when the hook block is hanging
free (no load, with load handling device). The stop devices are tared and
set to 0.0 t net load.
2.Raise load with hoist.
The net display now indicates the net load (actual load on hook without
load handling device).
The gross load contains – apart from the load weight – the weight of the
main boom extension in transport position, the weight of the hook block,
the hoist rope and all load handling devices. The net load is the actual load
on the hook block without the load handling devices. Display faults are
possible due to external factors, such as wind which effects crane and
load.
The load may only be raised with the hoist. It is forbidden to raise the
load by extending the telescopes or luffing cylinders.

Terex® All-Terrain Operation: IC-1 Symbols and Screens 31

Bridging the Load Limit Device Limit Switches
Bridging the Shut-off of the Load Moment Reducing Movement “Raise Bridging the Hoist Limit Switch
Luffing Gear” A hoist limit switch is triggered when the red hoist limit symbol
In case of overload, the load-moment-reducing movement „raise luffing (HES) lights up. The alarm sensor sounds.
gear“ of the load limit device is also shut down. The hoist limit switch “hoist 1 or 2 – raise” is bridged with the
After the overload state has been switched off by a load limit device, the key button (42).
load moment reducing movement can be driven in order to take a hanging
load from the overload range into the normal working range. The release to The indicator light (41) must light up when the limit switch is
“raise luffing gear” is carried out via the key button (44). To do so, the key bridged.
must be turned clockwise and held in this position. The limit switch may only be bridged in exceptional cases, e.g.
The indicator light (43) lights up in the bridged state. when configuring the crane (fitting or changing of device
components, putting on ropes, etc.).
Release of this load moment reducing movement can only occur if it
does not create a dangerous situation. Lower Limit Switch
The load is too heavy if it still has contact with the ground and “raise When the red lower limit symbol (SES) lights up the relevant lower
hoist” has been switched off. The movement “raise luffing gear” may limit switch is triggered.
not be released in this case! The lower limit switches may be bridged
Under no circumstances may “raise luffing gear” may be used to for changing or putting on ropes.
raise the load!
Crane operation with bridged limit
Bridging the Shut-Down of all Movements switches is forbidden.
The load limit device can be bridged using the key button (40).
To do so, the key must be turned clockwise and held in this position. RISK OF ACCIDENTS!
The indicator light (39) lights up in the bridged state. The proximity switch on the slip ring of
the hoist drum must be bridged in order to
The load limit device may only be bridged in exceptional cases, e.g.
bridge the lower limit switch.
repairs, putting on a rope, or similar activities.
It may only be done by authorized persons who are acquainted with
the operation of the crane!
Under no circumstances may bridging of the load limit device may be
used to increase the load moment.
It is forbidden to raise a load with a bridged load limit device!

Terex® All-Terrain Operation: IC-1 Symbols and Screens 32

 Click for interactive IC-1
Click for interactive IC-1

POWER

ON/OFF

Temp

HD

Power

Terex® All-Terrain Operation: IC-1 Symbols and Screens 33

NOTES;

Terex® All-Terrain Operation: IC-1 Symbols and Screens 34

all-terrain operation

Hoist 1
 Hoist 1 Content

Content Pg. Content Pg.

Raising and lowering the load 3

Camera surveillance of the Hoist 5

Terex® All-Terrain Operation: Hoist 1

”Hoist 1” Hook Operation
Raising and Lowering the Load with Hoist 1
Depending on the crane equipment, different modes can be
selected.

To prevent the unintended activation of crane movements, both control

levers are fitted with an additional button (36/32) (dead man’s switch).
A crane movement can only be carried out when one of the
buttons is pressed.
In order to avoid unplanned movements, take each selection of pilot
control assignment into consideration.
Risk of accidents!
! The movement ”raise load” is automatically shut down when:
! LLD has shut down. Lifting capacity of 100% is reached (bar display C)
! the hook block has tripped the hoist limit switch.
Lowering load is possible.

Terex® All-Terrain Operation: Hoist 1 3

! The movement ”lower load” is automatically shut down, when
the lower limit switch for hoist 1 has tripped.
Raising of the load is possible.
! When actuating control lever (24/16), feel the cone of the
hoist rotation indicator (25/15).
As soon as the hoist rotates, you will feel a definite vibration
there.
Raising the Load in High Range
The high range for hoist 1 is switched on by pressing button (30)
and lever (24/16) simultaneously.
High-speed mode may only be used for up to a maximum of
30% of the corresponding load capacity.
High speed may not be used for one rope crane operation
with main boom extension.
Hoist speeds
The hoist is electrically pre!controlled. The hoist speed depends
on the speed of the hydraulic pump and the position of control
lever.
The speed of the crane movement „Hoist 1“ can also be precision
controlled. The movements that are carried out via the X!axle
(horizontal movement of pilot control lever) of the individual pilot
control lever can be regulated via the corresponding self return
rocker switch (26/14) (button actuated to the right ! fast; button
actuated to the left ! slow). The movements that are carried out
via the Y!axle (vertical movement of the pilot control lever) of
the
individual pilot control lever can be regulated via the
corresponding self return rocker switch (26/14) and by pressing
the keys (35/31; on the front side of the pilot control lever in the
direction of travel, always left) at the same time.
As long as the speed is being regulated via button (26/14), the
corresponding percentage is shown in the display of the load limit
device (B,).

Terex® All-Terrain Operation: Hoist 1 4

Camera Surveillance of the Hoist (Optional)
A camera is fitted to the hoist in order to monitor the reeling
behavior of the hoist rope from display (27) in the crane
operator’s cab. It is in a protective case.
The entire unit must be slid up and clamped in place for operation.
When the crane is in the transportation state the entire unit must be
slid down and clamped in place.
The display (27) is on the top of the instrument panel in the
superstructure cab.
The following settings can be made on display (27):
Key Meaning
27.1 LED: display readiness for operation
27.2 Manual switchover camera 1 / camera 2
27.3 Switchover brightness between 2 levels of brightness
27.4 Switchover camera or AV input for the screen
27.5 On / Off switch
Changing the setting Color (contrast) and brightness is only
possible for hoist 1. The selected setting remains for hoist 2
(optional).
When the display is switched on hoist 1 is automatically shown
as soon as the ignition is activated. As soon as the control lever for
hoist 2 is activated, hoist 2 (optional) is displayed instead of hoist 1.

Terex® All-Terrain Operation: Hoist 1 5

NOTES;

Terex® All-Terrain Operation: Hoist 1 6

all-terrain operation

Hoist 2
 Hoist 2 Content

Content Pg. Content Pg.

Hoist 2 (option) 3

Fitting and removing 4

Rope guide 10

Pilot control assignment 11

Terex® All-Terrain Operation: Hoist 2

Hoist 2 (Optional)
You can use the second hoist when working with the main boom
extension and when utilizing an auxiliary head sheave and/or a
runner.
Information on Transport and Attachment Points
Attachment Points
In transport configuration, the actual hoist 2 (1a) is mounted
together with the assembly aid (1b) the transport condition.
The connecting bolts must be fitted and secured against falling
out.
Use the attachment points (A) as shown in figure.
Risk of accidents!
The parts must not swing out or dangle at an angle when they
are raised. If necessary, lifting chains fitted with shortening
claws must be used.
The securing equipment must be supplied by the customer.
Transport Dimensions / Weights

Transport dimensions Approx.

Length Width Height weight
mm mm mm kg
(in) (in) (in) (lbs)
Hoist 2 with
mounting 1730 mm 795 mm 710 mm 1800 kg
device (68.1 in) (31.3 in) (28.0 in) (3968 lbs)
Additional top 953 mm 61 mm 242 mm 15 kg
roller (37.5 in) (2.4 in) (9.5 in) (33.1 lbs)

Terex® All-Terrain Operation: Hoist 2 3

Fitting and Removing Hoist 2
Equipment may only be fitted and removed by trained
and qualified personnel!
The hoist 2 (1) can be assembled with the help of an
auxiliary crane, or mounting aid (1b) in combination with
counterweight (2) as support.
In transport configuration, the actual hoist 2 (1a) is mounted
together with the assembly aid (1b). shows the
transport conditions.
Risk of tipping!
Hoist 2 needs to be secured against falling when
transported separately.
A risk of crushing exists during attachment of hoist 2
between the hoist housing and the superstructure frame
and the counterweight that has been set down.
The outrigger span needs to be selected in accordance
with subsequent crane operation.

Terex® All-Terrain Operation: Hoist 2 4

Fitting and Removing Hoist 2with the Auxiliary Crane
Fitting
1. Stabilize the crane and make it level.
2. Hitch the entirety of hoist 2 to the slinging points (A) provided on
the auxiliary crane and raise slightly.
Persons must not stand or walk beneath suspended loads
or in areas where loads/equipment could fall.
The auxiliary crane must be able to hold the load until the
bolting at all locking points has been completed.
3. Separate the hoist 2 (1a) from the mounting aid (1b):
to do this, loosen bolts (3) and (4), push the connecting rod
(5) up and lock.
The rod of the hydraulic cylinder (8) can not be locked with
the pins (3) at point (B) until after connection with the
superstructure hydraulic system.
4. Hoist 2 using the upper securing forks, place Hoist 2 on the
guide rail on the superstructure frame and push towards the
superstructure. Fasten hoist 2 using the 4 biconical pins (7)
into points (F) and (G), and secure (4xeach).
Risk of crushing!
Risk of crushing exists between hoist 2 and the respective
fastening points on the superstructure frame.
5. Release the auxiliary crane.
6. Connect up the hydraulics connections (C, A, L, ST, BO, X)
and electrics connections (E) between hoist and superstructure
frame.
The hydraulic lines and connections are equipped with signs
which indicate which belongs where.
All hydraulic couplings are fitted with protective caps which
must be removed before fitting.

Terex® All-Terrain Operation: Hoist 2 5

Make sure in each case that the hydraulic connections have
been joined correctly, i.e. that the couplings open properly.
Joining and releasing of hydraulic connections is always
permitted only in depressurized condition, in other words,
the superstructure engine must not be running
Connect the mobile control panel (9) to the connection (F).
7. Using the mobile control panel (9), retract the
hydraulic cylinder (8) via button (9B) until the rod can be
connected and secured with bolt (3) in point (C).
8. Place the mounting aid on the counterweight and secure.
9. Pull up the counterweight (2) using the counterweight
cylinder and bolt.
10. Reeve the hoist rope of hoist 2.
Removal
Proceed in reverse sequence when dismounting Hoist 2 with the aid
of an auxiliary crane.
No persons may be in the area where there is a risk of falling
items when loosening the biconical pins.

Terex® All-Terrain Operation: Hoist 2 6

Fitting and Removing Hoist 2with Your Own Crane
Fitting
Assembling and dismantling hoist 2 with your own crane is carried
out using mounting aid (1b) and the 43.5 t (96 kip) counterweight.
A risk of crushing exists when fitting and removing hoist 2
between the individual elements and the superstructure
frame and the crane chassis!
In particular, make sure that you allow sufficient safety
clearance.
Persons must not stand or walk beneath suspended loads
or in areas where loads/equipment could fall.
The auxiliary crane must be able to hold the load until the
bolting at all locking points has been completed.
1. Stabilize the crane and make it level.
2. Adjust crane controls in accordance with the rigging situation.
3. Place minimum counterweight combination of 43.5 t (96 kip)
on the counterweight support on the superstructure frame.
4. Attach hoist 2 with assembled mounting aid (1b)
onto designated suspension points (A), place on
counterweight stack and secure.
For positioning aid, the counterweight has cams, which
catch in the corresponding grooves in the mounting aid.
According to design: secure mounting aid in point (P).
5. Release the auxiliary crane.
6. Rotate superstructure to the rear and pin (superstructure) to
the undercarriage.
7. Connect up hydraulic connections (C, A, L, ST, BO, X)
and electronic connections (E) between hoist and
superstructure frame.

Terex® All-Terrain Operation: Hoist 2 7

All hydraulic couplings are fitted with protective caps which
must be removed before fitting.
Make sure in each case that the hydraulic connections have
been joined correctly, i.e. that the couplings open properly.
Joining and releasing of hydraulic connections is always
permitted only in depressurized condition, in other words,
the superstructure engine must not be running.
Connect the mobile control panel (9) to the connection (F).
8. On the mobile control panel (9), extend the hydraulic cylinder
(8) via button (9A).
Hoist 2 performs a movement thereby by which the securing
forks (H) are guided along the guide rails of the
superstructure frame. Carry out the adjusting movement
of the hydraulic cylinder (8) until the biconical pins (7) can
be rigged in point (G).
9. Pin and secure hoist 2 with the biconical pins (7) in point (G) (2
x) .
10. Remove bolts (4), push connecting rod (5) up, and
secure using bolts (6).
11. Using the mobile control panel (9), run in the
hydraulic cylinder (8) via button (9B) until the pins (7) can
be mounted in point (F).
12. Pin and secure hoist 2 with the biconical pins (7) in point (F) (2
x) .
13. Using the mobile control panel (9) run in the hydraulic cylinder
(8) via button (9B) until the eye of the rod can be fastened with
bolt (3) in point (C) ! secure bolts.
14. Pull up the counter weight using the counterweight
cylinder, and bolt.
15. Reeve the hoist rope of hoist 2.

Terex® All-Terrain Operation: Hoist 2 8

Removal
Proceed in reverse sequence when dismounting hoist 2 .
Risk of injury!
Wind the hoist rope onto the drum completely prior to
dismantling the hoist and fasten the rope end to the frame
of hoist 2.
No persons may be in the area where there is a risk of falling
items when loosening the biconical pins.
Fitting and Removing the Additional Top Rollers
In order to stop the hoist ropes from rubbing against each other, they
must be separated by additional top rollers.
The additional top rollers must be removed in order to
maintain the vehicle height of 4.0 m (13.1 ft) (transport state).
Risk of ripping off!
In order to carry out the work described in the following,
you must use the supplied foldaway sliding ladder or
another suitable step-up aid, e.g. hoist operating platform.
Depending on the design of the crane there are 5 additional top
rollers (1 to 5;) or 3 additional top rollers (2 to 4;) on the main
boom.
In order to have an advantageous run of the rope, we recommend
that you only use 3 additional top rollers (2 to 4;) in the crane with
5 additional top rollers.
The additional top rollers must each be fastened using screw (6) (4 x
each).
The additional top rollers are removed in the same way in the
opposite sequence.

Terex® All-Terrain Operation: Hoist 2 9

Rope Guide
When reeving both hoists together, the hoist rope (11) of hoist 1 is
fed through the rope guides of the standard top roller or the
additional top roller and laid on the main boom head over the
sheave (14).
The hoist rope (12) for hoist 2 is to be placed over the respective
upper rope guide of the auxiliary carrying roller, and over the rope
sheave (13) on the main boom head (centre of the main boom
head).
Now the hoist limit switches must be fitted in accordance with the
equipment used.

Terex® All-Terrain Operation: Hoist 2 10

Hook Operation with Hoist 2
Pilot Control Assignment
Depending on the crane equipment, different control lever
assignments can be selected.
To prevent the unintended activation of crane movements, both
control levers are fitted with an additional button (36/32) (dead
man’s switch).
All crane movements can be performed if one of the keys is
pressed.
Observe the selected pilot control assignment in order to
avoid unintentional movements. Risk of accidents!
! The movement ”raise load” is automatically shut down when:
! the load limit device has shut down. Lifting capacity of
100% is reached
(bar display C,)
! the hook block in the hoist limit switch is activated.
Lowering load is possible.
The movement ”Lower load” is automatically shut down if the
lower limit switch for hoist 2 has been activated.
Raising of the load is possible.

Terex® All-Terrain Operation: Hoist 2 11

! When activating control lever (24/16), touch the cone of the
hoist rotation indicator (25/15). As soon as the hoist rotates,
you will feel a definite vibration there.
Hoist Speeds
The hoist is pilot controlled electrically. The hoist speed is
influenced by the engine speed, steering of the control lever as
well as the number of movements carried out at the same time.
Fine tuning:
The speed of the crane movement ”Hoist 2” can be additionally
fine tuned. The movements that are carried out via the X!axle
(horizontal movement of pilot control lever) of the individual pilot
control lever can be regulated via the corresponding self return
rocker switch (26/14) (button actuated to the right ! fast; button
actuated to the left ! slow). The movements that are carried out
via the Y!axle (vertical movement of the pilot control lever) of
the individual pilot control lever can be regulated via
the corresponding self return rocker switch (26/14) and
by pressing the keys (35/31); on the front side of the pilot
control lever in the direction of travel, always left) at the same
time.
As long as the speed is adjusted via key (26/14), the
corresponding percentage appears in the display of the LLD (D,).
High range :
The high range for hoist 2 is switched on by pressing button (30)
and lever (24/16) simultaneously.
High-speed mode may only be used for up to a maximum of
30% of the corresponding load capacity.
High speed may not be used for one rope crane operation
with main boom extension.

Terex® All-Terrain Operation: Hoist 2 12

all-terrain operation

Slewing
 Slewing Content

Content Pg. Content Pg.

Preparation for slewing 3

Braking the S.S. using the control

lever (closed circuit) 6

Terex® All-Terrain Operation: Slewing

Preparations for slewing
The superstructure may be slewed only with the mobile
crane supported on outriggers.
Please observe the specifications in the carrier load tables.
Release the superstructure locking via button (21, S0960
“Unbolt / bolt slewing gear”). The respective status is displayed
in the line C6 “Current loading information“ in the IC-1.
RISK OF DAMAGE!
Never start a slewing motion via the joystick without having
previously unbolted the superstructure!
Release the slew gear brake by pressing switch (22, S8805) on the
dash board.
Raise the boom sufficiently high for it not to catch on other parts of
the crane.
Danger of tipping over!
Slewing is only permissible within the overhang ranges for which the
respective load capacities are specified in the tables.
Nevertheless, due to the load limit device, slewing
movements are NOT switched off when loading in the
overhang ranges where load capacities have not been
specified in the carrier load tables. This is why there is a
danger of tipping over to the front!
Slewing in the overload range (LMI has switched off) is
categorically forbidden.
Do not slew over persons.
Do not jump off the slewing crane.

Terex® All-Terrain Operation: Slewing 3

Mode 1: Observe the selected pilot control assignment in order to
JLH = Slewing gear JRH = Luffing gear avoid inadvertent movements. Risk of accident!
- Lever (5/14) must not be switched from one slewing
JLV = Tele JRV = Hoist 1
position to the other; it must first be allowed to rest in the
Mode 2: “Off” position.
JLH = Slewing gear JRH = Luffing gear Do not switch on slewing in the opposite direction until the
Option: JLV = Hoist 2 JRV = Hoist 1 superstructure has come to a halt.
Mode 3:
JLH = Slewing gear JRH = Hoist 2
Option: JLV = Tele JRV = Hoist 1

Mode 4:
JLH = Luffing gear JRH = Slewing gear
JLV = Tele JRV = Hoist 1
Mode 5:
JLH = Luffing gear JRH = Slewing gear
Option: JLV = Hoist 2 JRV = Hoist 1
Mode 6:
JLH = Slewing gear JRH = Tele
Option: JLV = Luffing gear JRV = Hoist 1

(J = Joystick, R = Right, L = Left, H = Horizontal, V = Vertical)

To prevent inadvertent activation of crane movements, both
control levers are fitted with an additional button (104/114) (dead
man’s switch).
Only as long as one of the buttons is pressed is it possible to
carry out a crane movement.

Terex® All-Terrain Operation: Slewing 4

- The superstructure may be slewed only within the
overhang range for which lifting capacity values are
specified in the tables.
- Do not slew above people.
-!Do not jump off the crane during slewing.
Slewing speeds

The slew gear is electrically pre-controlled. Slewing speed

depends on the position of control lever.
A precision setting is also possible using button (102/112) in
control lever (5/14) (switch to the right - fast; switch to the left -
slow).
As long as the speed is being regulated via button (102/112),
the corresponding percentage is shown in the display of the
load limit device (A).
Make sure slewing speed is reduced
(lower scale range) when:
- working with loads > 30 % of the maximum load
- working with a long boom
- working with main boom extension fitted

Terex® All-Terrain Operation: Slewing 5

Braking the superstructure using the control lever (Keep clear of buildings.)
(closed slewing gear circuit) - Before the crane operator’s cab is left, the slew gear
Proceed as follows to brake the superstructure: brake must be locked by pressing switch 22, S8805 ).
Switch (23, S8817 “Switch slewing gear open/closed circuit“) is
not activated.
1. Slowly return lever (5/10) to 0-position.
Avoid jerky lever movements – danger of tipping over due
to load swinging.
If the main boom extension is fitted, only work with
low slewing speeds.
- Before the crane operator’s cab is left, the slew gear
brake must be locked by pressing switch (22, S8805).
Braking the superstructure using the pedal (opened
slewing gear circuit)
To brake the superstructure, proceed as follows:
1. Bring lever (5/10) slowly back into 0 position.
2. Press down pedal (6) until the superstructure comes to a
standstill.
Risk of tipping over caused by swinging of the load;
therefore do not brake the slewing movement suddenly.
If the main boom extension is fitted, only work with low
slewing speeds.
When the slew gear brake is released and the pedal raised, the slew
gear is set to free-running.
- With the slew gear brake released, the superstructure
can slew of its own accord if the crane is at an angle or
as a result of wind forces.

Terex® All-Terrain Operation: Slewing 6

all-terrain operation

Luffing
 Luffing Content

Content Pg. Content Pg.

Luffing operation 3

Preparing luffing gear for operation 6

Luffing speeds 8

Terex® All-Terrain Operation: Luffing

Luffing
Luffing Operation
The main boom is luffed (raised and lowered) by extending and
retracting the luffing cylinder.
On devices with dolly preparation, the ball tap terminating the
luffing cylinder during road driving must be open (see section
in the carrier operating instructions).
Proceed as follows to luff the main boom:
1. Stabilize crane according to planned working position (mbe,
cwt etc.) (for specifications, see load capacity chart).
2. With the engine running, select the desired hydraulic supply
for the luffing gear using buttons “E53” and “E54” on the
quick menu.
With the ”E53” status shown, both hydraulic
pumps are connected. Telescoping, luffing, HW1 and, if
available, HW2 movements (“E54” button) are performed by
means of the hydraulic oil of the connected gear oil pumps.
3. If necessary, use the “E23” button to change the control lever
function.

Terex® All-Terrain Operation: Luffing 3

4. Start luffing movement by pressing one of the buttons Risk of accidents!
(36/32) “Dead man’s switch system” and carefully moving To prevent the load or hook block from swinging out and
the appropriate control lever (24/16). creating a crushing / impact hazard when a movement is
switched off, it is critical to ensure that the speed and
Dead man’s switch system
acceleration of all crane movements are carefully set and
modulated.
To prevent unintentional activation of crane movements, both Control levers (24/16) must not be switched immediately
control levers (24/16) are equipped with an extra button (dead from one luffing direction to the opposite luffing
man’s switch). Button (36) on control lever (24) and button (32) direction, but must be first allowed to rest in neutral
on control lever (16). position. Do not switch to the opposite direction until the
main boom has come to a halt.
The crane movement can only be carried out as long as one of
these buttons is pressed.
Activating (pressing and releasing) of a dead man’s switch as well
as activating a limit switch override on the control panel is only
permitted when the control lever is positioned in ”neutral” and/or
after the initiated crane movement has been completed.

Risk of accidents!
Activating one of these dead man’s switches when the
control lever has been moved as far as possible from
neutral position causes abrupt activation or, when the lever is
released, abrupt termination of the corresponding
movement.
Keep in mind the control lever function selected in step 3.

Terex® All-Terrain Operation: Luffing 4

When released, the control lever automatically returns to neutral
position. The crane movement which has been started is stopped.
If the hook is fully raised, and if the hoist limit switch has triggered,
the main boom can no longer be lowered. First the hoist (the hook)
must be lowered.
The drive of the luffing gear has 2 speed ranges:
Level 1: normal operation
Level 2: high speed
Buttons (34/30) are used to select speed levels.
In addition, it is possible to fine-tune the speed of crane
movement “Luffing gear down”.
If a prohibited overload condition has occurred, the
load!moment!reducing movement ”raise main boom” is also
shut down by the load limit device.
Lifting loads using luffing gear
Risk of accidents!
Lifting loads using the luffing gear is prohibited in all
cases.

Terex® All-Terrain Operation: Luffing 5

Preparing luffing gear for operation
On devices with dolly preparation, the ball tap terminating the
luffing cylinder during road driving must be open.

Selecting hydraulic supply for luffing gear

You can select the hydraulic supply for individual movements
depending on which movements are to be performed
simultaneously. There are four operating modes that can be
used.
You can select the operating mode by pressing “E53” until you
find the mode you want. On “E53” and “E54” you can see the
movements and the pumps that have been assigned to them. In the
upper left!hand corner of the “E53” button, you can see the number
of the current operating mode.
Operating modes 2 and 4 are best used for delicate,
simultaneous movement of the luffing gear and hoist.
Operating mode 3 can only be selected if hoist 2 is among the
assigned control lever functions.

Terex® All-Terrain Operation: Luffing 6

Assigning control lever functions
Depending on the crane equipment, different modes (IC!1) can be
selected. After the “E23” button has been selected, an image will
appear in area “E” of the crane operation mask to show the current
control lever function. By selecting a new mode (e.g. mode 4), you
can display the corresponding control lever function. The newly
selected mode becomes active after you select the ”Save” symbol
(disk) to quit the display. The current control lever function is shown
at position “A9” in field “A”.

Keep in mind the selected pilot control assignment in order to

avoid inadvertent movements. Risk of accidents!

Terex® All-Terrain Operation: Luffing 7

Luffing speeds
Luffing up main boom in high speed mode
To switch the luffing gear to high-speed mode, activate button
(30) and control lever (24/16) at the same time.
High-speed mode may only be used for up to
a maximum of 30% of the corresponding load capacity.
Switching to high-speed mode is not permitted in the
following cases:
! ! with suspended loads
! with attached main boom extension
! to lift or lower a boom, which has been either fully or
partially extended, out of a flat position.
Fine-tuning downward luffing (”luffing gear down”)
The luffing gear is electrically pre!controlled. The speed when
lifting the main boom is determined by the rotation speed of the
hydraulic pump and movement of the control lever.
The speed of the crane movement ”Luffing gear down” can be
additionally fine-tuned. Movements performed along the X!axis of
the control lever (horizontal movement of control lever), can be
adjusted using the corresponding rocker switch (26/14) (switch
moved to right ! fast; switch moved to left ! slow). Movements
performed along the Y!axis of the control lever (vertical movement
of control lever), can be adjusted by activating the corresponding
rocker switch (26/14) and pressing button (35/31); on front side of
control lever, always on left side in relation to direction of travel) at
the same time.
While the speed is being adjusted using the buttons, a
corresponding percentage value will appear on the SLI display(C).

Terex® All-Terrain Operation: Luffing 8

Overriding the load limit device
If the load has exceeded the limit, movements which increase the
load moment are switched off by the load limit device. Lowering the
load on the hook is the only movement still permitted (Unless the
movement has also been switched off by the lowering limit switch.
Overriding shutdown of movement ”Raise luffing gear”
To move a suspended load from the overload area into the
permitted operating area, it is possible to raise the main boom.
Key!operated push button (116) is used to permit the ”Raise
luffing gear” movement. To do this, turn the key clockwise and
hold in this position.
During override, the indicator light (115) is illuminated.
This movement is only permitted if it is clear that no
dangerous situations can arise as a result.
If the load is still in contact with the ground and raising of
the hoist has been shut down, the load is too heavy. In this
case, activating the ”Raise luffing gear” movement is not
permitted!
Using the ”Raise luffing gear” movement to lift the load is
not permitted under any circumstances!
Using the key operated push button (116), it is possible to move the
load out of the shutdown area without switching off the entire SLI
(including all monitoring functions).

Terex® All-Terrain Operation: Luffing 9

NOTES;

Terex® All-Terrain Operation: Luffing 10

all-terrain operation

Runner (Optional)
 Superstructure Electric Content

Content Pg. Content Pg.

Runner general information 3

Separate transport 7

Converting to the folded position 13

Folding into transport position 15

Terex® All-Terrain Operation: Runner (Optional)

 Runner (Optional)
General
The hoist rope can be reeved up to four times using the
runner (80). Figure (Z 200 492, ”a”) shows the runner (80) in
the load raising position.
The hook block can remain reeved on the main boom head.
The runner can be folded and it can be folded away to the
side of the main boom head in accordance with the permitted
axle loads (“b”).
Main boom operation with the runner fitted in the transport
position results in a reduced load capacity of the crane.
The optional “head sheave” (see section 21) can be folded to
the side of the main boom head in the transport position in the
same place.
However, only the runner or the head sheave can be folded to
the left of the main boom head at the same time.
If the runner is fitted to the main boom head in the transport
position, the main boom extension cannot be fitted in the load
raising position.
Important Notes
The runner is marked with the construction number of the
crane. It can only be fitted onto a crane with this
construction number.
Exceptions are only permitted if this is clearly indicated
in the crane documents (e.g. the crane passport).
Only trained and instructed personnel may fit and remove
the runner!
Check that there is no damage to the tubes on the runner
components. If you find damaged tubes during a visual
check, it is prohibited to continue working with the
runner.

Terex® All-Terrain Operation: Runner (Optional) 3

Risk of accidents! The following checks should be carried out:
When fitting or removing the runner, there is risk of ! Check for cracks
crushing between the main boom head and the runner. ! Check the length
Especially take the notes on risks in section ! Check for wear
”Assembling and dismantling crane components” into ! Check the paintwork
consideration as well as the procedure described in the ! Check for plastic deformation.
following.
All assembly work is to be carried out with the help of
suitable equipment (ladders, lifting platforms, frames,
auxiliary cranes).
It is prohibited to walk on the boom!
Risk of breaking!
The runner’s draw bars must be checked at least once a
year by a specialist (in accordance with the accident
prevention regulations ”Load receptacle devices in hoist
operation (VBG 9a / BGV D6)”. In addition, depending on
the operating conditions and environment, they should be
checked between these intervals by an expert.
The inspection intervals are generally determined by the
operating and site conditions. This means that the more the
equipment is used, the shorter the inspection intervals
should be.
This inspection must be documented once it has been
carried out (e.g. in the examination log book for the crane).

Terex® All-Terrain Operation: Runner (Optional) 4

Supplied folding / sliding ladder (72):
Risk of falling!
In order to carry out all assembly work with as little risk as
possible, a ladder is supplied with the machine.
If the supplied ladder is not used, the assembly work must
be carried out using other suitable aids (ladders, hoist
platforms, scaffolding, auxiliary crane).
It is not permitted to climb or walk on the main boom.
The supplied folding / sliding ladder (72) can be fastened to the main
boom extension for transportation, for example.
There are brackets on the folding / sliding ladder (72) for
fastening the actuating rod (73). This actuating rod (73) can be
used as an aid when fitting the hoist rope.
There are metal plates on the main boom for attaching the
ladders (72) safely during the corresponding working procedures.
Risk of unchecked runner movement!
Generally, the main boom must be aligned horizontally
when fitting or folding the runner. Any exceptions to this
rule are clearly listed.

Terex® All-Terrain Operation: Runner (Optional) 5

The runner is always connected to the main boom head using 4
bolts (31).
Each bolt must be secured against falling out with two
functioning locking springs (32).
Risk of accidents!
Only the supplied bolts may be used for fitting the runner.
(They have a cylindrical design at one end (see detail A).)
Each bolt must be secured against falling out using 2
functioning locking elements (32).
Only the locking elements may be used which are fitted on
the crane in the first delivery.
The runner can be folded and it can be folded away to the side
of the main boom head in accordance with the permitted axle
loads (“c”).
In this case, the runner must be converted from the operating
position (“a”) into the “folded position” (“b”).
Only then may the runner be folded into the transport position
(“c”).
The conversion from the transport position (“c”) into the operating
position (“a”) is similar, but in the opposite sequence.
If the runner is transported separately, the runner is fitted and
removed in the folded position (“b”) on the main boom
head. Then the runner must be converted into the transport
position (“c”) or into the operating position (“a”).
Depending on the initial situation, carry the working procedures
described in the following.

Terex® All-Terrain Operation: Runner (Optional) 6

Separate Transport
Attachment Points
Use the 4 attachment points (E) as they can be seen in figure
(“a”, “b”).
RISK OF ACCIDENTS!
When being raised, the runner may not swing out or hang
crookedly. If necessary, lifting chains fitted with shortening
claws must be used.
The securing equipment must be supplied by the customer.
Transport Dimensions / Weights

Terex® All-Terrain Operation: Runner (Optional) 7

Fitting and Removing the Runner for Separate
Transportation (in the Folded Position)
The runner is in the folded position for fitting, i.e. the runner frame
(80a) is pulled up to the adapter (80b) using the adjustment rope
(86) of the auxiliary winch. The entire component group is on the
ground on the fork ends and the standing pipes of the runner frame
(80a).
1. Attach the runner (80) to the prescribed attachment points
”E” (x 4)in the fitting position on the main boom head using
the auxiliary crane.
To do so, each drilled hole in the fork ends of the runner
adapter (80b) must correspond with the ones on the right!
and left!hand head axle, top and bottom.
No!one may be in the area at risk of falling equipment, etc. as
long as the runner is attached to the auxiliary crane or has not
yet been completely pinned!
2. Knock in the bolts (31) at the pinning points (4 times). Secure the
bolts (31) against falling out using 2 locking springs (32).
The then achieved ”folded” fitting position (“c”) only
serves as an intermediate state when fitting and removing or
folding in and out of the transport position.
Risk of accidents!
This “folded” fitting position may NEVER be used for
raising loads. To do so, the runner must first be brought in
the operating position.

Terex® All-Terrain Operation: Runner (Optional) 8

Converting from the Folded Position to the Load
Raising Position (and Vice Versa)
Converting to Load Raising Position
The condition for this procedure is that the runner (80) is fitted to the
main boom head in the folded position.
Figure (top view) shows this state.
Procedure:
1. Lower runner frame (80a).
To do so:
1.1 (“c”): Fit the crank (84) to the attachment eyelet (85.1) of the
auxiliary winch (85) and unreel the adjustment rope (86) of the
auxiliary winch, until the bracing rods (81, 82) are straight on both
sides (“a”).
1.2 With the runner in the operating position (bracing rods
straight), loosen the adjustment rope (86) by slightly
unreeling it, so that it is never under load during runner
operation.
2. For even reevings (“b”):
Bring the rope attachment point (88) into the operating
position. To do so, loosen the trigger snab (83) of the fastening chain
of the rope attachment point: rope attachment point (88) swings
down.
During reeving, there is a risk that all involved sheaves
become wrapped and wound up.
Proceed with appropriate caution!
3. Feed the hoist rope from the hoist drum to the intake sheaves on
the main boom head.

Terex® All-Terrain Operation: Runner (Optional) 9

4. Feed hoist rope to the sheave (R1) of the runner via intake
sheave (E2).
Risk of damage to the rope!
The rope may not be fed via intake sheave (E1) as this would
make the deviation angle of the hoist rope too large.
5. Reeve the hoist rope in accordance with the desired reeving.
Reeving of the hoist rope can be up to 4!fold over the runner.
E ! Intake sheaves on the main boom head
R ! Sheaves on the runner
U ! Hook block pulleys
FR ! Fixing point on the runner
FU ! Fixing point on the hook block

6. Fit the hazard light (61) to the runner frame (80b) as well as
the rotor of the anemometer (62) to the head of the main
boom.
The hazard light (61) must be in the swinging position (”b”) during
crane operation.
The locking pin (61.1) may not be locked in place.
Figure (“a”) shows the locking pin (61.1) locked in place for the
transport condition.

Terex® All-Terrain Operation: Runner (Optional) 10

7. Fit the hoist limit switch (63) with attached shift
weight (64) in point “L” and secure against falling out.
If a second hoist limit switch is not used and the hoist limit switch
from the main boom head is used: connect the bridging plug (’B2’)
on the right!hand side of the main boom head to the usual
connection for the hoist limit switch (HR).
The bridging plug “B2” is marked with the letter “W”.
Risk of malfunctions!
The bridging plug (B2) supplied with the crane must be used.
You must make sure that the shift weight is fitted over the
hoist rope and is hanging freely.
Only then is it guaranteed to function properly.
Observe the details in section 17 “Reevings”.
8. Connect the plug of the runner cable harness to the junction
box “X0550” on the main boom head (connection ’A’).

Terex® All-Terrain Operation: Runner (Optional) 11

9. If a second hoist limit switch is used:
To prevent risk to persons or damage to equipment, attach
the shift weight or the hoist limit switch, which is fitted to the
head of the main boom, in the transport position (left!hand
side of the main boom head) and secure against falling out.
If a second hoist limit switch is fitted and the hoist limit switch shift
weight of the hoist limit switch of the main boom head is fitted in the
transport position (on the left!hand side of the main boom head),
the switch must be locked mechanically in the open position
(bridged). Figure (figure ’R’) shows the hoist
limit switch in the bridged state. In order to bridge the hoist limit
switch, the restrainer (63.2) must first be fitted onto the actual hoist
limit switch (63.1) 1 . Then the jumper wire is pulled away to the side
2 , then rotated in the longitudinal direction of the restrainer (63.2), 3
and finally relaxed. This procedure jams the restrainer (63.2) by the
jumper wire’s spring resistance.
10. Connect the plug of the hoist limit switch (63) to connection
“H”, connect the plug of the hazard light (61) to the
connection “F” and connect rotor plug of the anemometer
(62) to connection “A” of the junction box “X0566” on the
runner.
Risk of accidents!
If the rotor of the anemometer is not fitted or not connected, the
wind speed is not displayed on the IC!1. A prohibited high wind
speed might not be recognized.

Terex® All-Terrain Operation: Runner (Optional) 12

Converting to the Folded Position
“Conversion from the load raising position to the
folded position” is done in the same manner as
“Conversion from the folded position to the load raising position”,
just in the opposite sequence.
If a second hoist limit switch was used:
After removing the runner from the load raising position, the hoist
limit switch (63) on the main boom head must be reset to a
functioning state. The restrainer (63.2) of the hoist limit switch (63)
must be removed again.
Figure (“R”) shows the hoist limit switch in a functioning state.
If only one hoist limit switch is used:
After removing the runner from the load raising position, the hoist
limit switch (63) must be fitted to the main boom head again and
connected.
Risk of collision!
If the hoist limit switch is not put back into a functioning
state, there is risk of collision between the hook block and
the head of the main boom during main boom operation.
For the further procedure for
! Converting to transport position:
see “Folding from the folded position to the transport position
(and vice versa)”
! Removing the runner for separate transport:
see ”Fitting and removing the runner for separate transport
(in the folded position)”.

Terex® All-Terrain Operation: Runner (Optional) 13

Folding from the Folded Position to the Transport
Position (and Vice Versa)
General
If the runner is not needed, it can be folded onto the side of the
main boom head while in the folded position (“b”).
When folding the runner, there is risk of crushing between
the main boom head and the runner. Proceed with
appropriate caution!
No!one may be in the area at risk of falling equipment
during the folding procedure!
Before folding on the main boom side, the runner has to be
folded out of the working position into the transport position
(“a”) !
If the runner is fitted in the transport position on the
left!hand head side, the head sheave cannot
be fitted in the operating position or in the transport position.
If the runner is then fitted to the left!hand side of the head in the
transport position, neither the main boom extension in the
load!raising position nor the head in the transport position can be
fitted.
You need a pulling and guidance rope for the actual slewing. The
pulling and guidance rope for slewing the main boom extension can
be used.

Terex® All-Terrain Operation: Runner (Optional) 14

Folding into the Transport Position
Conditions for the procedure:
! The runner is fitted to the front of the main boom head in the
folded position (”a”).
! The mounting adapter (4) is fitted to the left!hand side of the
main boom head, using the drilled holes (5) and (6) in the
prescribed welding components (”c”).
Procedure:
Risk of falling
For the following removal of the bolts (31) from points (F)
and (G): do not lean the ladder onto the runner.
If the runner is not held by the pulling and guidance rope, it can
swing away to the side when unpinning the pins (31).
1. Attach the pulling and guiding rope to the attachment eyelet
on the runner frame.
2. Remove bolts (31 ”a”) from points (F) and (G).
3. Slew the runner on the pulling and guidance rope until the
runner dips into the mounting adapter.
4. Insert pins (7”c”) and secure.
Bolts (31) incl. each of both locking springs (32) remain
pinned in points (H) and (I).
Bolts (31) incl. each of both locking springs (32) remain pinned
in points (H) and (I).

Terex® All-Terrain Operation: Runner (Optional) 15

Folding into the Folded Position
Folding from the transport position into the folded position is done in
the same manner as folding from the folded position into the
transport position.
Risk of accidents! Risk of falling!
For pinning and unpinning procedures: do not lean the
ladder onto the runner.
For the further procedure for
! raising loads:
see ”Converting from the folded position to the load raising
position (and vice versa)”
Operation
1. Fit the runner in the operating position (load!raising position
and reeve hoist rope.
2. Setting the crane configuration in the operating mode
pre-selection mask
Operating mode: “MS” “Boom point / runner’ other settings in
accordance with the fitting state.
The load capacity tables also have the designation “ MS ”.

Terex® All-Terrain Operation: Runner (Optional) 16

all-terrain operation

Head Roller
 Head Roller Content

Content Pg. Content Pg.

General information 3

Folding from the operating position

to the transport position 10

Separate transport 11

Terex® All-Terrain Operation: Head Roller

Head Roller (Optional)
General
The head sheave (101) is for raising loads with single strand
reeving. If the crane is equipped with a second hoist, the hook
block can remain reeved on the main boom head.
The head sheave (101) consists of a basic body (101a) and the
hinged rocker arm (101b).
The head sheave can be folded to the side of the main boom for
transportation (if the permitted axle loads allow for it).
Figure shows the head sheave in the operating position (with rocker
arm (101b) folded down).
Main boom operation with the head sheave fitted in the transport
position results in the crane having a reduced load capacity.
The optional “runner” (see section 41) can also be folded to the side
of the main boom head in the transport position at the same point.
However, only the runner or the head sheave can be folded to the
left of the main boom head at the same time.
Important Notes
The head roller is marked with the factory number of the
crane. It can only be fitted onto a crane with this
construction number.
Exceptions are only permitted if this is clearly indicated in
the crane documents (e.g. the crane passport).
Only trained and instructed personnel may fit and remove
the head sheave!

Terex® All-Terrain Operation: Head Roller 3

When fitting and removing the head sheave there is a risk
of crushing between the main boom head and head sheave.
”Assembling and dismantling crane components” into
consideration as well as the procedure described in the
following.
It is prohibited to walk on the boom!
Supplied folding / sliding ladder (72):
Risk of falling!
In order to carry out all assembly work with as little risk as
possible, a ladder is supplied with the machine.
If the supplied ladder is not used, the assembly work must
be carried out using other suitable aids (ladders, hoist
platforms, scaffolding, auxiliary crane).
It is not permitted to climb or walk on the main boom.
The supplied folding / sliding ladder (72) can be fastened to the
main boom extension for transportation, for example.
There are brackets on the folding / sliding ladder (72) for
fastening the actuating rod (73). This actuating rod (73) can be
used as an aid when fitting the hoist rope.
There are metal plates on the main boom for attaching the
ladders (72) safely during the corresponding working procedures.
There are also metal plates on the head sheave for hanging up
the ladders (72). However, these can only be used if the head
sheave is pinned firmly in the transport position or when the head
sheave is not to be folded over in the load raising position.
Risk of falling!
The ladders’ (72) attachment facilities on the head sheave
may only be used if the head sheave is pinned firmly in the
transport position or when the head sheave is not to be
folded over in the load raising position.

Terex® All-Terrain Operation: Head Roller 4

Risk of unchecked head sheave movement!
Generally, the main boom must be aligned horizontally
during fitting or folding the head sheave. Any exceptions to
this rule are clearly listed.
Folding from the Transport Position to the Operating Position

When folding the head sheave there is a risk of crushing between the
main boom head and head sheave. Proceed with appropriate caution!
Risk of falling!
During the folding procedure, the head sheave is only held in place by
pin (107) in point “F” on the left-hand side of the head.
Pin (107) may not be removed during the folding procedure.
No one may be in the area at risk of objects falling!
1. Remove pins (106) (2x) from their pinning positions in the
head sheave (101).
2. Loosen pin (108, “a”) and insert in the “resting position” on the head
sheave ( “b”); secure against falling out.
3. Fold the head sheave (101) forwards, over the fitted pin (107) (point (F)),
until pin (106) can be inserted at point (B) ( “b”).
4. Insert pin (106) in point (B) and secure against falling out.
5. Remove pin (107) from point (F).
6. Continue to fold head sheave (101) over the fitted pin (106) (point (B)),
until the holes of the mounting shackles of the head sheave are flush with
the corresponding holes of the retainer welded to the main boom head in
point (A).
7. Insert pin (107) in point (E) in the resting position and secure against
falling out.
8. Insert pin (106) in point (A) and secure against falling out ( “c”).

Terex® All-Terrain Operation: Head Roller 5

9. Raise the hinged rocker arm (101b) slightly to relieve pin
(105) of load and to remove pin (105) from position (D)
(“d”)
Risk of crushing!
There is a risk of crushing between the rocker arm and the
frame of the head sheave as soon as the rocker arm moves or
is moved.
Proceed with appropriate caution!
10. Fold the rocker arm (101b) down, until the corresponding
rocker arm (101b) hole is flush with the hole in the frame (101a) of
the head sheave.
Then insert pin (105) in position (D) and secure( “e”) .
Risk of accidents!
Operation with the head sheave may not be carried out
under any circumstances in the raised position (transport
position)!

Terex® All-Terrain Operation: Head Roller 6

11. Feed the hoist rope from the hoist drum to the intake sheaves on
the main boom head.
Observe for this the detailed specifications contained in
”Reevings” in the sub point ”Reeving the hoist rope in and out”.
12. Feed the hoist rope over the intake sheave (E2) on the main
boom head to the head sheave’s sheave (R) and pin on
suitable hook suspension gear (105).
Risk of accidents!
The head sheave is only permitted to be operated with
single strand lines!
The rope may not be fed via intake sheave (E1) as this
would make the deviation angle of the hoist rope too large.
Risk of damage to the rope!
During reeving, there is a risk that all involved sheaves
become wrapped and wound up. Proceed with appropriate
caution!
13. Fit the hazard light (61) and the anemometer (62) rotor to the
main boom head.
The hazard light (61) must be in the swinging position (”b”) during
crane operation.
The locking pin (61.1;) may not be locked in place.
Figure (“a”) shows the locking pin (61.1) locked in
place for the transport condition.

Terex® All-Terrain Operation: Head Roller 7

14. Fit the hoist limit switch (63) with attached shift
weight (64) to the head sheave and secure against falling
out.
If a second hoist limit switch is not used and the hoist limit switch
from the main boom head is used: connect the bridging plug (’B2’)
on the right-hand side of the main boom head to the
usual connection for the hoist limit switch (HR).
The bridging plug “B2” is marked with the letter “W”.
Risk of malfunctions!
The bridging plug (B2) supplied with the crane must be used.
You must make sure that the shift weight is fitted over the
hoist rope and is hanging freely.
Only then is it guaranteed to function properly.
Observe the details in section 17 “Reevings”.
15. Connect the plug of the head sheave’s cable harness to the
junction box “X0550” on the main boom head (connection ’A’).

Terex® All-Terrain Operation: Head Roller 8

16. If a second hoist limit switch is used:
To prevent risk to persons or damage to equipment, attach
the shift weight or the hoist limit switch, which is fitted to the
head of the main boom, in the transport position (left-hand
side of the main boom head) and secure against falling out.
If a second hoist limit switch is fitted and the hoist limit switch shift
weight of the hoist limit switch of the main boom head is fitted in the
transport position (on the left-hand side of the main boom head), the
switch must be locked mechanically in the open position (bridged).
Figure ( figure ’R’) shows the hoist limit switch in the bridged state.
In order to bridge the hoist limit switch, the restrainer (63.2) must
first be fitted onto the actual hoist limit switch (63.1) 1 . Then the
jumper wire is pulled away to the side 2 , then rotated in the
longitudinal direction of the restrainer (63.2), 3 and finally relaxed.
This procedure jams the restrainer (63.2) by the jumper wire’s spring
resistance.
17. Connect the plug of the hazard light (61) to the connection
“F” of the junction box “X0550” on the main boom head.
18. Connect the plug of the hoist limit switch (63) to the
connection “H” and the plug of the anemometer (62) rotor to
the connection “A” of the junction box “X0566” on the head sheave.
Risk of accidents!
If the rotor of the anemometer is not fitted or not connected, the
wind speed is not displayed on the IC!1. A prohibited high wind
speed might not be recognized.

Terex® All-Terrain Operation: Head Roller 9

Folding from the Operating Position to the Transport
Position
If the head sheave is not required, it can be folded laterally
backwards to the main boom head.
When folding the head sheave there is a risk of crushing
between the main boom head and head sheave. Proceed
with appropriate caution!
No one may be in the area at risk of falling equipment
during the folding procedure!
The head sheave is folded from the operating position into the
transport position as described in (’Folding from the
transport position into the operating position’), just in the opposite
sequence.
Hoist limit switches must be removed or hung in the
corresponding transport position.
The hoist rope must be reeled in.
Risk of falling!
During the folding procedure, the head sheave is only held in
place by pin (107) in point “F” on the left-hand side of the head.
Pin (107) may not be removed during the folding procedure.
No one may be in the area at risk of objects falling!

Terex® All-Terrain Operation: Head Roller 10

Separate Transport
Attachment Points
Risk of accidents!
There are no attachment points welded to the head
sheave. For this reason, it must be attached with a
looping tackle.
The actual attachment procedure must be undertaken
with the utmost care.
RISK OF ACCIDENTS!
When being raised, the head sheave may not sing out or
hang crookedly. If necessary, lifting chains fitted with
shortening claws must be used.
The securing equipment must be supplied by the customer.

Transport Dimensions / Weights

Terex® All-Terrain Operation: Head Roller 11

Assembly and Removal of the Head Roller during
Separate Transport
1. Move head roller against auxiliary crane.
When raising, the head sheave must be straight and must
not swing.
The head roller is in transport position, i.e. the hinged rocker arm
(101b) is connected in point (D) with pins (105), and secured with a
forelock.
2. Bring the head roller (101) into assembly position
using auxiliary crane on the main boom head. To do so, the
relevant holes of the head sheave’s mounting shackles must
be flush with those on the corresponding mounting shackles
on the main boom head on the right (points ”A”) and left
(points ”B”).
Rig both points with pins (106), and secure these
using forelocks.
As long as the head sheave is being attached to the
auxiliary crane or is not yet completely pinned, there must
be no one in the area at risk of falling!
The head roller is now fastened on the main boom head.
No loads may be raised in this state!
3. In order to fit the head sheave in the operating position:
Carry out steps “9.“ to “18.”.
4. In order to fit the head sheave in the transport position on the side
of the main boom head.

Terex® All-Terrain Operation: Head Roller 12

Operation
1. Fit the head sheave in the operating position, fit the hoist limit
switch with the accompanying shift weight, connect the head sheave
electrically, reeve the hoist rope, pin the hook
suspension gear in place and then fit the shift weight to the
hoist rope.
This is described in detail in ’Folding from the
transport to the operating position’ .
2. The operating mode “HA” (“Main boom”) must be selected on the
LLD.
3. Set the reeving to “1”.
Risk of accidents!
The head sheave is only permitted to be operated with
single strand lines!
4. Select all other parameters in accordance with the actual
crane configuration, which must correspond to the relevant
load capacity table.

Terex® All-Terrain Operation: Head Roller 13

NOTES;

Terex® All-Terrain Operation: Head Roller 14

 all-terrain operation

Dismantling & Assembly of the Main Boom

 Dismantling & Assembly of the Main Boom Content

Content Pg. Content Pg.

General 3

Dismantling the boom 4

Assembly of the boom 15

Terex® All-Terrain Operation: Dismantling & Assembly of the Main Boom

Dismantling and Assembly of the Main Boom (Optional) General
In the course of assembling and dismantling the main The main boom can be removed from the superstructure
boom there is the danger of being crushed: with the auxiliary crane for repair purposes or in order to
! between the main boom base and bearings. reach certain axle loads.
! between the main boom and superstructure frame. The transport configuration without the main boom is
described in the operating instructions for the crane
This is why no person is permitted in the danger zone! chassis.
All assembly work is to be carried out with the help of
Before starting to dismantle or assemble, pay special
suitable equipment (ladders, lifting platforms, frames,
attention to the following:
auxiliary crane).
! Before the main boom is dismantled or assembled, the
Should it not be possible to carry out work either using
crane’s counter weight must be removed. The crane
such equipment or from the ground, then the assembling must be stabilized in the course of this procedure, in
personnel must protect themselves with suitable means accordance with the configuration for the counter
(e.g. safety belt) against the RISK OF FALLING ! weights.
It is especially prohibited to spend any time in the area ! Before the main boom is dismantled, the telescopic
where there is the risk of the attached load (main boom) units must be retracted completely and pinned.
falling in the course of assembling (dismantling)! ! The crane must always be supported on outriggers
(outrigger span at least 8.2 m x 2.8 m (26.9 ft x 9.2 ft))
for the actual dismantling and assembly of the main
boom.

Terex® All-Terrain Operation: Dismantling & Assembly of the Main Boom 3

Dismantling the Main Boom
The dismantling of the main boom can be divided into 3 steps:
preparations for dismantling, pulling the luffing cylinder
head pin and extracting the boom foot pin /taking off the main
boom. These working steps must be carried out in the
sequence listed.
Preparation for dismantling
1. Stabilize crane and align horizontally (counterweight
removed).
2. Un-reeve bottom hook block or hook suspension gear and
wind hoist cable on to cable drum, secure hoist rope end.
3. Lift main boom over luffing gear. Rotate superstructure so
that the main boom faces the rear and insert the mechanical
superstructure locking device. Operate switch (74) to do so.
For further information on pinning and fixing the superstructure
to the carrier see section ”Rotating” in ”Preparations for
rotating”.
4. Use open lashing strap to mount luffing cylinder support
mount to the designated attachment devices at the rear end
of the chassis frame.
5. Fully lower the main boom so that the luffing cylinder is lying
on the luffing cylinder support.
6. Close the safety stop valve on the side of the luffing
cylinder.

Terex® All-Terrain Operation: Dismantling & Assembly of the Main Boom 4

7. Insert remote control into plug (100) in the hydraulic carrier
on the right! hand side of the machine.
In order to be able to operate the mobile hydraulic cylinder, a
remote control must be inserted in the corresponding
connection in the hydraulic carrier.
If a movement is to be carried out with the mobile
hydraulic cylinder, an assistant must activate the switch
in the relevant remote control.
Depending on the design of the crane, either the remote
control in figure or the remote control in figure must be
activated.

Terex® All-Terrain Operation: Dismantling & Assembly of the Main Boom 5

8. Using an auxiliary crane, hang the main boom with 4
auxiliary reeving ropes onto the top head axles on the boom
head and onto the attachment shackles on the boom foot.
The weight of the main boom is approx. 21 t (46.3 kip).
Select the auxiliary crane and the auxiliary ropes in
accordance with the rope forces that occur (see below).
The centre of gravity of the main boom is about 5970 mm
(19.6 ft) from the main boom base bearing in the direction
of the pulley head.
The length of the lifting gear (provision of material for
customers) can be taken from the diagram opposite. If
necessary, adjust the length to fit a minimally differing
centre of gravity.
The ropes must be arranged in such a way that, in the extreme
case, the total load can also be held securely by just 2 ropes.
There are ! for the specified angles of the sling ropes ! the
following maximum rope forces per rope:
front : approx. 15 t (33 kip) (according to head weight of
approx. 10 t (22 kip))
rear : approx. 16 t (35.3 kip) (according to foot weight of
approx. 11 t (24.3 kip)).
9. Pull auxiliary ropes tight with auxiliary crane.

Terex® All-Terrain Operation: Dismantling & Assembly of the Main Boom 6

10. Release hydraulic connections B1, ST, P, L, T and B2 and
electric connections of the main boom on the back of the
superstructure frame.
Please make sure that the designation signs for the
hydraulic connections are attached to the hose and
connection.
Otherwise, mark the hydraulic connections before
disconnecting.
Connecting and disconnecting hydraulic connections is
only ever permitted in the depressurized condition, in
other words, the superstructure engine must not be
running.
Retracting the Luffing Cylinder Head Pin
1. In order to extract the connecting bolt main boom / luffing
cylinder, you must use a mobile hydraulic cylinder.
In the following, this connecting pin is called the luffing cylinder
head pin.
To do so, insert the mobile cylinder into the receptacle on the
connecting bolt so that the support elements (10) of the mobile
cylinder lie in the inner bearing points (7).
Danger of tipping!
When relieving the mobile cylinder there is the danger of
it over turning in the course of all of the working
procedures described as follows: the mobile cylinder
could tip over to the rear out of the locating shell.
Risk of crushing!
In the course of inserting the mobile cylinder there is the
danger of being crushed between the mobile cylinder and
the mounting plate. Please act carefully.
The weight of the mobile cylinder is approx. 20 kg (44 lbs)

Terex® All-Terrain Operation: Dismantling & Assembly of the Main Boom 7

2. Connect the mobile cylinder hydraulically. To do so, first
connect both supplied hydraulic hoses (L = 11 m (36.1 ft)) with
the connections P, T (12) of the mobile cylinder.
Then connect the free hose ends to the corresponding
connections P and T on the back of the superstructure
frame. These are the same connections with which
normally also P and T of the main boom are connected.
Connect the identically marked connections.
Make sure in each case that the hydraulic connections
have been connected correctly, i.e. that the couplings
open properly.
Connecting and disconnecting hydraulic connections is
only ever permitted in the depressurized condition, in
other words, the superstructure engine must not be
running.
3. Start superstructure engine.
4. By activating the control lever (11), drive the
clamshell in the piston rod of the mobile cylinder (9) into the
corresponding groove of the luffing cylinder head pin (62).
Extend the mobile cylinder until the groove of the clamshell
(9) and the most exterior hole (22) of the luffing cylinder
head pin (62) correspond with each other.
5. Guide the pin (21) that has been pulled out of the vertical
locking position (19) through the slots of the mounting
plates so that it passes through the outermost bore hole (22)
of the luffing cylinder head pin (62) main boom / luffing
cylinder and through the groove of the clamshell. Secure pin
(21) again with the fore lock.

Terex® All-Terrain Operation: Dismantling & Assembly of the Main Boom 8

(I+II)
6. Fully retract the cylinder rods by activating the control lever
on the mobile cylinder (61) accordingly, pulling out the
luffing cylinder head pin (62).
(II)
7. Remove pin (21), thereby disconnecting luffing cylinder
head pin (62) and mobile cylinder (61).
(III)
8. Move mobile cylinder (61) on to the outer bearing points
(8)
of the mounting plate. Extend mobile cylinder until the
groove of the clamshell (9) and the inner bore of the luffing
cylinder head pin (62) correspond.
9. Stick pin (21) through the slots of the mounting plate,
the inner bores of the luffing cylinder head pin (62) and the
groove of the clamshell (9) and secure.
(IV)
10. Extract the whole luffing cylinder head pin (62).
11. Switch off superstructure engine and disconnect hydraulic
hoses from mobile cylinder. Remove mobile cylinder and
have it ready for further use in order to extract the boom foot
pin.
12. Lash luffing cylinder (4) on to luffing cylinder support (5)
with lash strap (3).
After dismantling the main boom, bring the luffing cylinder
head pin into the transport position.

Terex® All-Terrain Operation: Dismantling & Assembly of the Main Boom 9

Extracting the Boom Foot Pin / Lifting the Main Boom
Especially the operations listed in the following that are
necessary to draw out the main boom foot pin must be
carried out with special care and in accordance with all
necessary safety measures because there is a repeated
risk of stumbling and falling.
1. The connecting pin main boom / superstructure is also
extracted using the mobile hydraulic cylinder. In the following,
this connecting pin is called boom foot pin.
To do so, insert the mobile cylinder (62) in the pin extracting
device on the left-hand page of the superstructure frame
(crane cab side) so that the support elements (10) of the
mobile cylinder are inserted in the inner bearing points (B).
The pin extractors extractable.
With this step, the pin extracting device is used in the retracted
condition: the extractable part (4) is inserted in the basic
carrier which is fitted on the superstructure frame (3) and is
inserted through the bolt (2) in point (D).
Risk of crushing!
In the course of inserting the mobile cylinder there is the
danger of being crushed between the mobile cylinder and
the mounting plate. Please act carefully.
The weight of the mobile cylinder is approx. 20 kg (44 lbs)

Terex® All-Terrain Operation: Dismantling & Assembly of the Main Boom 10

2. Connect the mobile cylinder hydraulically. To do so, first
connect both supplied hydraulic hoses (L = 11 m (36.1 ft)) with
the connections P, T (12) of the mobile cylinder.
Then connect the free hose ends to the corresponding
connections P and T on the back of the superstructure
frame. These are the same connections with which
normally also P and T of the main boom are connected.
Connect the identically marked connections.
Make sure in each case that the hydraulic connections
have been connected correctly, i.e. that the couplings
open properly.
Connecting and disconnecting hydraulic connections is
only ever permitted in the depressurized condition, in
other words, the superstructure engine must not be
running.
3. Remove lock nuts (7) from the axle holder (8). The fixing
nuts (6) remain fitted. These nuts (6) serve to secure the
entire pin extracting device.
The axle stirrup (8) remains screwed fast to the boom foot
pin (1) and is designed in such a way that the mobile
cylinder can later be attached in order to pull.
4. Start superstructure engine.
5. Extend the mobile cylinder by operating the control lever
(11). The mobile cylinder is raised out of the bearing points (B)
of the pin extracting device. To ensure that the groove of
the clamshell (9) can be latched into the axle stirrup (8), the
mobile cylinder must be held at an angle. Now the mobile
cylinder must be extended until the support elements (10) can
be put back on to the bearing points (B) of the pin extractor.
Set down mobile cylinder on to the bearing points (B) of the
pin extractor

Terex® All-Terrain Operation: Dismantling & Assembly of the Main Boom 11

(II)
6. By operating the control lever of the mobile cylinder (61)
accordingly, retract cylinder rods completely thereby extracting the
boom foot pin (1).
7. Fit retaining rope (14) between the pin extracting device and
the boom foot pin (1) (on the axle stirrup (8)).
(III)
8. Move mobile cylinder (61) on to the outer bearing points (A) of
the pin extractor. To do so extend the mobile cylinder until the
support elements (10) fit on to the bearing points (A). The
changed length lifts the mobile cylinder diagonally out of the pin
extractor. The groove of the clamshell (9) thereby remains attached
to the axle holder (8).
(IV)
9. Retract the cylinder rods completely by operating the control
lever on the mobile cylinder (61) accordingly thereby further
extracting the boom foot pin (1).
(IV)
10. The connecting pin (2) that is between the fixed part (3) and
the extractable part (4) of the pin extractor is now pulled out of
the locking point (D) and set down.
(V)
11. By operating the control lever on the mobile cylinder (61)
accordingly, extend cylinder rod, thereby extending the extractable
part (4) of the dismantling device until the connecting pin (2)
can be connected to the locking point (C). Insert connecting pin
(2) in pinning point (C). To do so, the extractable part (4) of the
pin extractor might have to be raised a little.
(VI)
12. Retract the cylinder rods completely by operating the control
lever on the mobile cylinder (61) accordingly thereby further
extracting the boom foot pin (1).

Terex® All-Terrain Operation: Dismantling & Assembly of the Main Boom 12

13. Switch off superstructure engine and disconnect hydraulic
hoses from mobile cylinder. Remove the mobile cylinder.
(VII)
14. Fit retaining rope (14) between the pin extracting device
and the boom foot pin (1) (on the axle stirrup (8)).
Push the basic bolt manually over the guide rollers until the
retaining rope is tensioned. The basic bolt is then lying on the
pin extracting device and in the hole of the superstructure
frame. The main boom can now be lifted out.
Danger of tipping
If the guide rope is not seated in the pin extracting device
and the basic bolt, the basic bolt can slip backwards
out of the pin extracting device.
15. Use the auxiliary crane to move main boom vertically out of
the bearings of the main boom base and of the luffing cylinder
and if required set it down on the transport vehicle.
Risk of crushing!
When the main boom is raised there is the danger of being
crushed between the main boom and the superstructure
frame or between the main boom and the rack on the
ground or the rack of the transport vehicle.
Make sure that tilting of the main boom on the bearing
points is avoided.
16. Remove lifting gear from main boom.

Terex® All-Terrain Operation: Dismantling & Assembly of the Main Boom 13

17. Bring boom foot pin in transport condition. To do so insert
extractable part (4) of the dismounting device and fix
connecting pin (2) to the locking point (D).
To do so the extractable part (4) of the pin extractor might
have to be raised a little. Push boom foot pin by hand into the
superstructure frame until the locking pin (5) can be inserted
and secured.
Lash boom foot pin together with the dismounting device
with lashing strap (15).
18. Bring luffing cylinder head pin in transport condition.
To do so reinsert luffing cylinder head pin (62) completely. Fix
pin (21) vertically.
19. Insert warning light (40) in the luffing cylinder head hole
and secure. Plug in the electric supply lead on the rear of the
vehicle in the corresponding socket.
To prevent the electric supply lead of the warning light being
destroyed, it must be fastened to the luffing cylinder so that it
does not fall onto the road surface.

Terex® All-Terrain Operation: Dismantling & Assembly of the Main Boom 14

Assembly of the Main Boom
The assembly of the main boom is done in the same way but
in the opposite sequence as dismantling.
Make sure that:
! main boom base and luffing cylinder set up on their bearing
correctly.
! the electric connections and hydraulic connections B1, ST, P,
L, T and B2 of the main boom are connected properly at
the rear of the superstructure frame (plug and plug
connections with the same designation, the hydraulic
couplings must open correctly).
The diagram shows the connections on the superstructure
frame with hydraulic hoses not connected to the main boom.
The mobile cylinder is used again for pushing in the bolts.
As soon as the main boom is assembled, the unloaded
rocker cylinder frame (5) must be removed again and
transported separately.
After reattaching of the main boom foot pin and the
connecting pin main boom/luffing cylinder these pins
must be secured unconditionally, (bottom left figure)
shows the fixed locking pin (21) of the luffing cylinder
head pin. Bottom right figure shows the axle stirrup
bolted on the boom foot pin (6) with mounted lock nut (7).

Terex® All-Terrain Operation: Dismantling & Assembly of the Main Boom 15

NOTES;

Terex® All-Terrain Operation: Dismantling & Assembly of the Main Boom 16

all-terrain operation

Telescoping
 Telescoping Content

Content Pg. Content

General 3 Pg.

Telescoping procedure 8

Automatic telescoping 17

Manual telescoping 19

Monitoring the extension lengths

during telescoping 31

Lifting capacities in intermediate

positions 33

Telescoping Capacities 36

Terex® All-Terrain Operation: Telescoping

Telescoping
General
The main boom is made up of a basic case and 6 telescopic
sections (inner sections).
When completely telescoped in, the main boom length is 12.4
m, when completely telescoped out 67.8 m. Normally, all
telescopes are pinned with these and all other permissible
operating lengths.
That means that each boom section is secured with the next
largest boom section on the left and right at the rear with two
pins (3).
All 6 telescopic sections are telescoped in and out using the
following elements:
- a telescoping cylinder (1), which is fastened to the back of
the basic case.
- a locking and pinning unit (LPU), which is connected to the tip
of the piston rod of the telescoping cylinder using a tie frame.
This is therefore moved accordingly as soon as the
telescoping cylinder is driven.
- the LPU is activated via two hydraulic cylinders.
All necessary steps are shown to the crane operator on the
telescoping information system.
“Telescoping” refers to both the extension and retraction of the
telescoping cylinder. A differentiation is made between two
different cases:
- A telescopic section (boom inner section) is not locked on the
locking and pinning unit. The locking and pinning unit is moved
“empty”.
- A telescopic section (boom inner section) is locked on the
locking and pinning unit. The telescopic / boom section is
moved also. This is the actual “telescoping”.

Terex® All-Terrain Operation: Telescoping 3

Before each telescoping procedure, all telescopic sections
must be pinned and unlocked. The corresponding telescopic
section is then locked and unpinned.
After each telescoping procedure, the individual telescopic
section is pinned and unlocked, before the next telescopic
section is telescoped out.
If the main boom has been extended or retracted to its final
operating length and pinned, the locking and pinning unit
must be completely retracted. Otherwise, the max.
indicated load capacities would not be achieved.
The telescoping procedure is only ended once the LPU is
completely retracted again. Only then are the max. lifting
capacities enabled for the selected length code. The button of
the length code is marked green.
Below, the procedure for telescoping the main boom without
load on the hook is describe.

Locking and Pinning Unit

The locking and pinning unit is connected to the tip of the piston
rod of the telescoping cylinder using a draw bar and is
therefore moved accordingly as soon as the telescoping
cylinder is driven.
On the locking and pinning unit, the selected procedure is
carried out which consists of two interconnected processes:
- Locking and unpinning
- Pinning and unlocking
The locking and pinning unit is designed in such a way that,
once the corresponding movement has been initiated, the
system always locks (or pins) before the following action of
unpinning (or unlocking) can be activated.
This ensures that the system is never in an unsafe condition
(unpinned and unlocked at the same time).
All telescopes can be pinned at 0% / 45% / 90 % and 100%.

Terex® All-Terrain Operation: Telescoping 4

Locking / unpinning
Two pins (2) on each side of the locking and pinning unit are
used for mechanical locking between the locking and pinning
unit and the corresponding boom section. This is described as
“locking” (A).

The LPU has now locked the boom section to be moved. This
boom section is still pinned to the next larger one.

Immediately after the locking procedure follows the “unpinning”

procedure (B). In this case, the grippers (4) draw the pins (3)
inwards to lock the corresponding boom section with the next
largest section.

You can telescope in this state. The locking and pinning unit is
moved along accordingly with the locked boom section.

Pinning / unlocking
This occurs in the same way as locking and unpinning. First
the clamshells (4) let the bolts (3) recreate the lock between
the two relevant sections (=“Pinning“ (C)).

Then both horizontal locking pins (2) are retracted so that there
is no longer a connection between the locking and pinning unit
and the boom section (=“Unlocking“ (D)).

Terex® All-Terrain Operation: Telescoping 5

Supply of the LPU with hydraulic oil
Supply of the LPU with hydraulic oil is done through the
telescoping cylinder with an internal oil conduit. A hydraulic
accumulator is needed to do this. This accumulator should
always be within a pressure range of 65 ! 85 bar (943 ! 1233
psi).
The pressure display is shown at (3) in the display
“TeleManual”. This can be activated in the following way:
On the screen ”Quick Menu” press the key.

The input screen of the telescoping information system, the

”telescoping display”, appears instead of the ”Quick Menu”.
Press the button there.
If the pressure in the accumulator falls below 76 bar (1100 psi),
normally the loading procedure is started automatically.
The loading procedure is not carried out if:
1. the pressure in the accumulator is >86 bar (1247 psi)
2. the telescopic cylinder is retracted
3. the LPU is in the state ”locked / unpinned” and the
telescopic cylinder is not telescoped (unpinned loads)
4. the LPU is in the state ”unlocked / pinned”, the telescopic
cylinder is not telescoped and the entire telescoping drive is
telescoped out less than 1.5 m (4.9 ft)
5. the LPU is in the approach position, fine position or
follow!up position during the locking and pinning procedure.

Terex® All-Terrain Operation: Telescoping 6

If the pressure sensor malfunctions, the fault symbol appears

on the left side of the IC!1 display. When the fault message
is called up, the fault code no. “E:325” appears.

Then the accumulator pressure has to be manually brought

into the normal range of 65 ! 85 bar (943 ! 1233 psi). The
button next to the accumulator symbol has to be pushed to do
this.
The button is left green when the pressure is within the normal
range and is left red when the pressure is NOT within the
normal range.
During the loading procedure ! a maximum of 15 s ! the
button is yellow.

Terex® All-Terrain Operation: Telescoping 7

Telescoping
General
There are two possible operating modes for telescoping the main
boom:
! Automatic telescoping;
As long as there is no fault, telescoping must always be carried
out in automatic operation.
Automatic telescoping is carried out with the help of the telescoping
information system.
The telescoping information system is an aid to operation.
It is not a replacement in any way for the judgment and
experience of the crane operator as well as recognized safe
operating procedures for the operation of cranes.
When using the operating aid, the crane operator still remains
fully responsible for the safe operation of the crane.
He must ensure that he fully understands and follows the notes
and instructions in their entirety. The system can only be
guaranteed to work correctly if it is checked daily and used
in accordance with the operating instructions.
! Manual telescoping;
Manual telescoping is done without monitoring by the load limit
device, which is why it is only permitted in exceptional cases :
! when the automatic telescoping system is not working
(e.g., fault with a sensor)
! to achieve lengths for which there is no length code (e.g.,
when greasing the main boom).

Terex® All-Terrain Operation: Telescoping 8

Telescoping Procedure
Proceed in the following manner when telescoping:
1. Support and align the crane on outriggers in accordance
with the regulations see operating instructions of the crane
chassis.
2. Start the superstructure engine.
3. Enter the operating mode. Press the button there.
The screen for preselecting the operating mode appears.
Make a selection of all relevant fields in accordance with the
actual state of the crane (e.g. “type” here: main boom) and exit
the screen via .
4. Check which mode has been selected for the assignment of
the control levers. The current mode (here: 1) is displayed by
the corresponding symbol in the top line of the IC!1
display.
RISK OF ACCIDENTS
It is the crane operator’s responsibility to check the
current control lever assignment before initiating a crane
movement.
Otherwise there is risk of accidents if accidental crane
movements are triggered.

Terex® All-Terrain Operation: Telescoping 9

5. Select the operating mode of the hydraulic pumps.
The hydraulic pumps can be connected so that they supply
all hydraulic functions together.
The pumps can be separated for improved control.
To do so, press the left-hand key. The selected

mode “1 ! 4” is displayed in the top left-hand corner in the key

field. Then the movements of the assigned pumps are
displayed in the two keys.
The key displays change according to the mode selection.

Terex® All-Terrain Operation: Telescoping 10

 6. Start telescoping by pressing one of the buttons (32/36) Control levers (16/24) may not be switched directly
“dead man’s control” and carefully moving the corresponding to the opposite direction, but must first remain in the
control lever (16/24):
neutral position.
Only initiate the opposite movement once the
movement has come to a standstill.
Automatic telescoping Manual telescoping The control lever automatically returns to the zero
Activate control after entering the LK Telescoping Out position once released. The current crane movement is
lever (16/24) (length code) of the
forwards / to the preselected process stopped.
right If the hook is raised, and if the hoist limit switch has
Control lever Activate LK 1 (length Telescoping In triggered, the main boom can no longer be extended.
916/24) back- code 1) and activate First the hoist (the hook) must be lowered.
wards / to the left complete telescoping in
of the main boom

You must take the current position of the control levers into
consideration.
In order to prevent accidental initiation of crane movements, both
control levers are equipped with an additional key (dead man’s
control). Only when one of the buttons is pressed is it possible to
carry out a crane movement.
You may only activate (press or release) a dead man’s switch if
the corresponding control lever is in the neutral position and/or
the initiated working movement has been completed.
RISK OF ACCIDENTS
Pressing/releasing one of these dead man’s switches
when the control lever is fully engaged causes abrupt initiation/
braking of the corresponding movement.
RISK OF ACCIDENTS
Only by adapting the acceleration or speeds of all crane
movements can you avoid that the load or the hook block
swings out, causing risk of crushing or crashing when
each movement is switched off.

Terex® All-Terrain Operation: Telescoping 11

Telescoping display
On the screen ”Quick Menu” press the key .
The input screen of the telescoping information system, the
”telescoping display”, appears instead of the ”Quick Menu”.
This is where submenus can be selected and information on
the status of the telescoping system can be found:
(1)! Entering the length see ”Selection of the length code”
code
Grey: The selected length code has not
been achieved.
Green: The selected length code has
been achieved.
(2) Final length of the main boom
(3) Actual length of the main boom

Terex® All-Terrain Operation: Telescoping 12

(4) Changes to the display of the tele aid
Electrical limit switches are fitted on the LPU and on the drive unit of
the LPU:
B 9160 ! B 9163 used to recognize the telescopic
section (”D”). The corresponding
digit after the designation “tele”
indicates which boom section
is being dealt with.
Example: 1st boom section;
description “Tele 1”:
As shown, both lamps are illuminated,
which symbolize the limit switches
B 9160 and B 9161.
B 9164 ! B 9165 show the position of the LPU to the
telescopic section.
When both light up, the LPU can lock
the affected telescopic section, i.e.,
create the connection to the telescopic
section.
B 9156, B 9157, B 9158, show the status of the LPU.
B 9168, B 9169
“A”: pinned / unlocked
“B”: pinned / locked
“C”: unpinned / locked

(5) Display of the current condition of the telescopic cylinder

and/or of the LPU
forwards / backwards with reduced
speed
forwards / backwards with high
speed
Telescopic section pinned / unpinned

LPU locked / unlocked

Point black: telescoping system
stop
Point red: fault in the telescoping
system.

Terex® All-Terrain Operation: Telescoping 13

(6) Telescoping speed display of main boom / telescoping
cylinder
Just before the pinning position is reached, the telescoping
speed is reduced, so that the telescopic sections can be
pinned.
(7) Switches to the “TeleManual” screen
(8) LPU position display
(9) Extension length for a telescopic section in percent
telescopic section blue: these telescopic sections are already
extended to the selected length code

telescopic section grey: these telescopic sections are

retracted and yet to be extended
telescopic section black: in combination with grey
background:
this telescopic section must be
retracted or the new LK (length code), and
extended again later

in combination with white

background:
this telescopic section must be
retracted for the new LK (length
code)
telescopic section this telescopic section extends or
yellow: retracts with the LPU
telescopic section white: these telescopic sections are
retracted

telescopic section this telescopic section’s position is

orange: teached

Terex® All-Terrain Operation: Telescoping 14

Length code
Selection of length code
In order to select the length code (LK) for the desired main
boom length, press ”LK” button. The “Tele operation mode”
screen appears.
Here, all length codes are displayed that can be selected and
that are compatible with the selected operating mode,
including main boom length, extension configuration for the
individual telescopes and possible max. lifting capacities.
Press to select the desired length code (entire line 1, is touch
sensitive). By pressing the button,
the length code is saved and you exit the screen. Now the
“Telescoping display”
screen appears.
The “LK” button with the newly selected length code now has a
grey background. <This means that the corresponding length
has not yet been reached. This LK code is also displayed in
black in the topmost line of the IC!1 display.
As soon as the following telescoping procedure has been
completed and thus the appropriate target length reached,
both displays change their color to green.

Terex® All-Terrain Operation: Telescoping 15

“Tele operating mode” screen
(1) ! Length code number (LK No.)
(2) ! Main boom length
(3) ! Extension configuration of telescopes 1 to 5 (from left to
right)

(4) ! Max. lifting capacity in high position

(5) ! Radius in high position
(6) ! Max. lifting capacity in low position
(7) ! Radius in low position
(8) ! Activation of the mask for selection of the length code for
lubrication of the main boom (only for operating mode HA)
(9) ! Scrollbar for browsing through the length codes, line by
line
(10) ! Exit the mask with save; the settings are assumed
(11) ! Leafing through the length code, page by page:
> one page down;
(12) ! Length code selection for the LPU position for moving
the crane (only for operation mode HA)
(13) ! Leafing through the length code, page by page:
< one page up
(14) ! Exit the mask without save; the settings are not
assumed

Terex® All-Terrain Operation: Telescoping 16

Selection of the Length Code for Lubrication of the
Main Boom
In order to select the length code (LK) for lubrication of the
main boom, the crane must be switched to operating mode
’HA’ (’main boom operation’).
In the mask ’Tele operating mode’, the ’lubrication
symbol’ is displayed at the marked place.
By selecting the lubrication symbol mask is displayed
with the selection list of the corresponding length code.
Instead of displayed the details on load capacities and radius,
the values for counterweight combination and outrigger
support area are indicated, which must be fulfilled at the very
least:
(17) ! minimum counterweight
(18) ! minimum outrigger support area
(19) ! key: back to the mask “Tele operating mode”
Risk of tipping!
Only when the actual crane configuration fulfils the
minimum requirements for counterweight combination
and outrigger support area is it ensured that lubrication of
the main boom is risk free.
You will find the actual lubrication procedure in the
maintenance and lubrication instructions of the
superstructure.
After activating the corresponding length code for lubrication of
the main boom, you can exit the mask with ’Save’.
If the configuration of the crane currently reserved in control
does not fulfill the indicated minimum requirements for
counterweight and outrigger support area, the relevant value
will be displayed in red. The mask then cannot be exited with
’Save’.

Terex® All-Terrain Operation: Telescoping 17

Automatic telescoping
The IC!1 enables automatic telescoping, after selecting the
required final length (by entering the corresponding length
code “LK”), by operating the corresponding control lever.
This means that if the boom is to be extracted to a new length,
the corresponding control lever must be moved explicitly in
extending direction and held (when selecting an operating
mode with which telescoping is possible).
This is also the case, if the new main boom length is less than
the current length.
If the control lever is moved to retracting direction, then LK 1
(all telescopes 0%) is activated and the automatic system
begins to retract the main boom entirely.
The telescoping speed varies throughout the procedure.
Just before the pinning position is reached, the telescoping
speed is reduced, so that the telescopic sections can be
pinned.
The telescoping procedure can be observed at the telescope
display on the right side of the IC!1 display. As soon as the
desired final length is reached, the color of the ”LK” button
switches from grey to green.
During the telescoping procedure, the current total length of
the main boom as well as other geometric data are displayed
at the crane symbol to the left of the IC!1 display.
Also, the configuration of sensors and pins for the LPU can be
monitored during the telescoping procedure. To do so operate
“?” button. The screen (top right corner) appears.
The displayed configuration is unlocked and pinned.

Terex® All-Terrain Operation: Telescoping 18

The system uses the Is!values, provided by the length
transmitter, to calculate the most advantageous run sequence,
by making comparisons with the stored operating programs
and other factors.
The sequence is displayed using different colored telescopic
sections in illustration. Each step required is displayed until the
telescoping procedure is completed.
The display of the movement of the individual telescope levels
as well as the locking and pinning unit (LPU) and the
configuration of the locking and pinning elements is
continuously adapted to correspond to the changes made.
If work has to be stopped, the system automatically saves the
values last displayed, so that work can be resumed
accordingly.
Error routines monitor the correct locking / pinning of the
main boom. System errors are displayed by a red mark (see
illustration. At the same time a symbol appears to the left
of the IC!1 display. The error must then be identified and
eliminate.
After eliminating the error, work can only be continued, once
the error message has been acknowledged.

Terex® All-Terrain Operation: Telescoping 19

Manual telescoping
Manual telescoping is carried out without the supervision of the
load limit device and is therefore only permitted in exceptional
cases:
! if the automatic tele system fails (e.g. malfunction of a sensor).
! to achieve lengths for which there is no length code (e.g.,
when greasing the main boom).
In manual operation, it is not possible to monitor of the
crane via the LMI! Maximum risk of accidents!
The crane operator is responsible for any damage or accidents
that might be caused in this situation!
Under certain circumstances (no monitoring of the crane
control during manual telescoping) the telescopic drive can be
extended so much that it slides off the inner guide rails.
For this reason there is a table with the LPU’s approximate
locking and pinning positions under sub point
“Locking and pinning positions of the telescopic drive” on.
The table values correspond with the LPU position (1) in the
’TeleManuell’ mask.
The corresponding locking and pinning positions may be
exceeded by approx. 0.05 m (approx. 0.164 ft) at the most.
If the corresponding locking and pinning position is not
found, probably several electronic sensors are defective at
once. In this case or when the telescopic drive has come off the
inner sliding rails please contact our customer services
department.
If the telescopic drive has come off the inner guiding slides,
telescoping is no longer possible. Locking and pinning (or
unpinning) the telescopic sections of the main boom is then no
longer possible either. The telescopic drive can be extended but
will always stick at the same place when being retracted.

Terex® All-Terrain Operation: Telescoping 20

You will find the required information ! specially on position
and configuration of the LPU ! in the ”TeleManual” screen.
In order to call up the “TeleManual” screen, press the button in
the “Quick Menu” screen .
The “Telescoping display” appears in place of the ”Quick
menu”.
Press the button button ! the “TeleManual” screen
appears.
When the “TeleManual” screen opens, the hand symbol is
crossed out .
This means that the automatic mode is still active.
One can then take a look at information e.g. on the
configuration of the initiators and then return to the original
screen.

Terex® All-Terrain Operation: Telescoping 21

“TeleManual” screen
(1) ! LPU position
(2) ! LPU speed
(3) ! Hydraulic supply for LPU
(4) ! Number of the telescopic section, which is connected to
the LPU; the depicted no. “0” means that the LPU is not
connected to any telescopic section and can be driven
”empty” in the basic case.
(5) ! Secure preselection
(6) ! Status display telescoping system
(7) ! Pinning
(8) ! Unpinning
(9) ! Locking
(10) ! Unlocking
(11) ! Back to the telescoping display; is locked after hand
operation
(12) ! Teaching (setting and saving) telescope position
(13) ! Switching between automatic (hand symbol crossed
out) and manual telescoping operation (hand symbol not
crossed out)

Terex® All-Terrain Operation: Telescoping 22

(14) ! Initiators for the configuration of the LPU (connected
initiators are highlighted in red)
The following states are indicated by letters in German and by
a number in brackets in all other languages:
ES / VB (1) Unlocked / Pinned
? / VB (12) Intermediate position
GS / VB (2) Locked / Pinned
GS / ? (23) Intermediate position
GS / EB (3) Locked / Unpinned
(15) ! Initiators for the identification of the telescopes. The
telescope currently identified by the LPU is specified at
pos. 4 (switched initiators on a red background)
(16) ! Initiators for initial and subsequent position for locking
(switched initiators on a red background)
(17) ! Initiators for initial and subsequent position for pinning
(switched initiators on a red background)

Terex® All-Terrain Operation: Telescoping 23

Manual telescoping procedure
Please make sure you observe the instructions on the permissible
employment of manual telescoping and on calling up the
“TeleManual” screen.
To activate manual telescoping in the “TeleManual” screen, press
the key . It turns into .

High risk of accidents!

In manual operation mode it is not possible to monitor the
crane with the load limit device. The load limit device must
be bypassed.
It is only permitted to bypass the load limit device in
exceptions!
Bypassing must be reversed immediately after manual
telescoping!
Crane operation with bypassed load limit device is
FORBIDDEN!
To bypass the load limit device, operate the key operated button
(112). The corresponding indicator light (111) goes on.
The tele system must be informed about the extension status of
the main boom after manually telescoping the main boom. This
procedure is called ”teaching”. The ”TeleManual” screen cannot be
exited without ”teaching”.
After the manual telescoping or “teaching” procedure the load limit
device can only be operated again and hence be reactivated after
passing or reaching a valid length code.
If the telesystem is activated without bypassing the LMI before
reaching a valid length code (key , appears in the
crane display symbol.
On principle, the smallest (furthest inward) telescopic section to
be telescoped must be started with whenever the main boom is
to be extended.
The largest (furthest outward) telescopic section to be telescoped
must be started with whenever the main boom is to be retracted.

Terex® All-Terrain Operation: Telescoping 24

Example of manual telescoping (Z 54 133):
The 1st boom section must be driven out of the 100% pinning
hole into the 0% pinning hole.
1. Check the “TeleManual” screen, (14, right field), to see
whether the LPU is unlocked and pinned ( or digit “1”).

The LPU can be operated in this state using the respective

control lever without moving any telescopic section.
This can be seen in the mask “TeleManual” at (2): a speed
value > 0 mm/s (ft/min) must then be displayed without the
main boom moving.
2. Since the LPU has been fully retracted (1, LPU position
0.000 m / ft), it must be “extended” in order to be locked (as
desired) to the fully extended first telescopic section.
Steer the respective control lever in order to extend the LPU.
The LPU is driven to the 1st boom section.
As soon as the 1st boom section has been reached, the
display (4) changes from “IK 0” to “IK 1”.
Then the telescopic drive is telescoped out approx. 9,595 m
(31.48 ft) (1st boom section, 100% pinning hole: for further
extension lengths of the telescopic drive, see table in section
“Locking and pinning positions of the telescopic drive”.
During the following procedure, telescoping can be interrupted
or resumed with the appropriate control lever, depending on
which action step is specified.

Terex® All-Terrain Operation: Telescoping 25

3. Interrupt telescoping, then actuate the Preselection key,
(5, )press the lock key (9, ) and slowly continue
telescoping.
The keys are displayed on a red background after actuation.
They automatically turn grey again as soon as the selected
procedure is over.
You must make sure that you follow the correct sequence:
first preselection, then locking! The locking process is now
automatically actuated when the fine position is approached.
In the “Lock” fine position, the two initiators VPS and
NPS (16) are active, i. e. on a green background.
The locking process is over as soon as the locked and pinned
state is indicated for the LPU by the symbol or digit ’2’ at
(14, at the end of the line).
4. The telescopic section must be locked manually if it is unable
to be locked automatically. Operate the key (9, ).

This key may only be operated in the “Lock” fine position

(VPS and NPS “16” active, i. e. on a green background).
After locking the telescopic section the pinning fine position must
be reached, i.e. both initiators NPV and VPV (17) must be on a
green background. Only then may the unpinning process begin.
5. To unpin, actuate key (8, ).

The keys are displayed on a red background after actuation.

They automatically turn grey again as soon as the selected
procedure is over.

Terex® All-Terrain Operation: Telescoping 26

6. Extend the LPU about 1 to 2 cm (0.5 ! 1 in) by steering the
respective control lever. The unpinning process is then carried
out.
The unpinning procedure is over as soon as the locked and
unpinned state is indicated for the LPU by the symbol
or digit ’3’ at (14, at the end of the line).
In this state, the telescopic section is attached to the LPU and can
be retracted in the following.
7. Retract the first telescopic section from the 100% locking
hole to the 0% locking hole locked to the LPU by steering the
control lever accordingly.
The 90% and 45% pinning hole positions are crossed during the
retraction process. The initiators for pinning then indicate whether
any potential pinning positions have been crossed. In this
case the two initiators “VPV” and “NPV” (17) are on a green
background.
The unpinning procedure may only be actuated once the two
initiators “VPV” and “NPV” (17) are on a green background after
reaching the 0% pinning position.
Then the telescopic drive is telescoped out approx. 0,035 m
(0.115 ft) (1st boom section, 0% pinning hole: for further
extension lengths of the telescopic drive, see table in section
“Locking and pinning positions of the telescopic drive”).
8. As soon as the two initiators “VPV” and “NPV” (17) for the 0%
pinning hole of telescopic section 1 are on a green background,
actuate key (7, ). It is displayed on a red background.
The pinning procedure is accomplished as soon as the locked
and pinned state is indicated for the LPU by the symbol
or digit ’2’ at (14, at the end of the line).

Terex® All-Terrain Operation: Telescoping 27

9. In this state, actuate the key (7, ) again in order to
complete the pinning procedure. It turns grey again.
The respective valve remains in a switched position and the key
remains on a red background if the key (7) is not actuated again.
10. To unlock the LPU, press first the Preselect key , (5, )
then the Unlock key (10, ) and slowly continue telescoping.
The unlocking procedure is then actuated automatically
when the fine position (VPS and NPS “16” initiators active,
i. e. on green background) is approached.
The keys are displayed on a red background after actuation.
They automatically turn grey again as soon as the selected
procedure
is over.
If the unlocking procedure can not be started automatically, it can
be started manually by pressing the unlock button. (10).
In this case the Preselection key (5, ) may not be
actuated.
The unlocking procedure is over as soon as the locked and pinned
state is indicated for the LPU by the symbol or digit ’1’
at (14, at the end of the line).
As a result, the sample manual telescoping procedure is in effect
over.
In order to now switch to the automatic telescoping, the positions
of all individual telescopic sections ”must be taught” (defined
and saved).

Terex® All-Terrain Operation: Telescoping 28

Teaching the extension status of the telescopes
The telescoping system must be informed about the extension
status of each telescope after manually telescoping the main
boom. This procedure is referred to as ”teaching”.
Proceed as follows:
1. Push button on the “TeleManual” screen,
left side. The “TeleTeach” screen, right side) appears.
All of the keys assigned to individual telescopes T1 ! T5 are at
first only filled in with a star. Subsequently, the current extension
statuses for all telescopes must be selected manually. There are
the following possibilities for selection:
“0”, “45”, “90” and “100” for the pinned state and “LPU” when the
telescopic section is unpinned and locked to the LPU.
2. Press key next to T1 until the value appears which corresponds
to the actual extension state of T1 (here: 0, i.e. telescopic
section 1 is 0% extended).
3. Repeat the procedure specified for telescope 1 accordingly
for the remaining telescopes T2 ! T5.
4. Make sure the defined status corresponds to the actual extension
status for all telescopes. If so, actuate the “Teach”
key. The initial screen “TeleManuell” appears.
The saved values are adopted by the control system in precisely
the same way. Incorrect values are unable to be identified
as such.
RISK OF ACCIDENTS
During the “teaching” process only those values may be
transferred to the control system which correspond to
the actual state. The crane operator is solely responsible
for this!

Terex® All-Terrain Operation: Telescoping 29

If the extension state of the telescopic sections correspond
with a length code, the selection can be made faster than
described:
press key “LK” and select the line of the length code which
corresponds to the actual extension state of the telescopic
sections.
Use button to exit the screen.

The screen ”TeleManual” appears again and all field AC140

concerning the individual telescopes are then filled out
together.

Terex® All-Terrain Operation: Telescoping 30

Locking and Pinning Positions of the
Telescopic Drive
The locking and pinning positions are required during manual
telescoping.
The indicated extension lengths may be exceeded by
approx. 0.05 m (approx. 2 in) at the most during manual
telescoping so that the telescopic drive does not come off
the inner guide rails.
The table values correspond to the ’SVE_Pos’ (1) in the
TeleManuell display.

Terex® All-Terrain Operation: Telescoping 31

Monitoring the Extension Lengths During the
Telescoping Procedure
During the telescoping procedure the current length of the
boom as well as additional geometric data are displayed in
field ”D” on a crane symbol.
The current extension condition of the individual telescopic
sections can be read off the telescoping information system
(E51).
In addition, using switch (E51.4) the condition of the sensors
and pins of the LPU can be followed during the telescoping
procedure.

Extension Sequence of the Telescopic Sections

The extension sequence of the telescopic sections is the
sequence in which the individual telescopic stages are brought
to their final lengths.
When the main boom is fully extended, the extension
sequence is (6!5!4!3!2!1), i.e. first telescopic section 6, then
telescopic section 5, etc. and finally telescopic section 1 is fully
extended and pinned.
If all the telescopic stages are not required for the extension
length selected, the extension sequence for the telescopic
stages required is analogous.
When the telescopic sections are retracted the sequence is
followed in reverse.

Terex® All-Terrain Operation: Telescoping 32

Load capacities in the pinned condition
The lifting capacities that are specified in the load capacity
tables in relation to the radius (see marked area in the display)
only apply when all telescopic sections are pinned.
The following load table is only a specimen. Only the load
tables supplied with the crane may be used for operating
the crane.
Lifting Capacities in the Unpinned Condition
In addition to the load capacities in the pinned condition of the
main boom there are also load capacities for the case in which
the largest extended boom section is unpinned:
! Unpinned lifting capacities for which the main boom length
remain unchanged, so-called “lifting capacities in
intermediate positions”.
! Unpinned load capacities, for which the main boom length is
changed under load, so-called “telescoping load
capacities“.

Terex® All-Terrain Operation: Telescoping 33

Lifting Capacities in Intermediate Positions
The lifting capacities that are specified in the load capacity tables
in relation to the radius only apply when all telescopic sections
are pinned.
Example:
In straight main boom operation (operating mode HA), with a main
boom length (A) of 20.9 m (68.6 ft), an extension state (E) of the
individual telescopic sections of (0/45/45/0/0/0) (LK9) and a radius
(B1) of 5 m (16.4 ft), the corresponding pinned lifting capacity (C1)
would be 104 t (229 kip).
There are however also lifting capacities for the unpinned
condition of the main boom. These enable load cases for the case
that the crane cannot be operated with pinned lengths due to
particular restricted space conditions. The bottom extended boom
section is then connected to the telescoping cylinder via the LPU.
When attaching loads in the unpinned intermediate positions the
attachable loads are limited additionally by the load capacity of the
telescoping cylinder and the bend of the main boom.
These influences are contained in an additional table.
With the above example:
With a main boom length (A) of 20.9 m (68.6 ft), an extension
state (E) of the individual telescopic sections of (0/45/45/0/0/0)
(LK9) and a radius (B1) of 5 m (16.4 ft), the corresponding
unpinned lifting capacity (D1) would be 30.7 t (67.7 kip).
The specification in this additional table is a maximum value,
which is not absolutely applicable. This maximum value
“unpinned” is ! related to the resulting radius ! balanced
against the value “pinned” of the load limit device.
If ! as in this case ! the value “pinned” of 104 t (229 kip) (C1)
is larger than the value “unpinned” of 30.7 t (67.7 kip) (D1),
the permitted load is reduced to 30.7 t (67.7 kip).
If the radius were 16 m (52.5 ft) (B2), the value “pinned” 29 t
(63.9 kip) (C2) would be smaller than the value “unpinned”,
in this case also 30.7 t (67.7 kip) (D2). The permitted load is
reduced to the pinned value of 29 t (63.9 kip).

Terex® All-Terrain Operation: Telescoping 34

This comparison of the pinned load with the table value is
automatically carried out by the load limit device. The crane
operating mask then always shows the actual attachable load
at For (D20) the length code relevant to the load limit device
and the resulting radius for this extension condition and luffing
angle is displayed in ”red”. With the LLD!relevant LC and the
radius, the additional table can be consulted to find the
corresponding unpinned maximum value.
In the first case the red spec. would be (LC9/5) (= length code
9 / radius step 5 m / 16.4 ft).
In the second case the red spec. would be (LC9/16) (= length
code 9 / radius step 16 m / 52.5 ft).
Intermediate values are interpolated.
The additional table “unpinned loads” can be displayed on the
screen.
Procedure:
! Select the button (E21) in the crane operating mask
! The operating mode selection mask appears
! Select the button (T, table symbol) in the operating
mode selection mask:
The table “pinned load capacity” for the set operating
mode appears. On the button (7) a symbol of a crane boom
is displayed (without arrow).
! Select button (7): switch to additional table “unpinned
load capacities”. The table “unpinned load capacities”
appears. On the button (7) a symbol of a crane boom is
shown with a double arrow.

Terex® All-Terrain Operation: Telescoping 35

Example
Operational planning has shown that due to lack of space, when
there is a radius of 5 m (16.4 ft), a main boom length of approx. 18
m (59.1 ft) is needed. The mass of the load to be raised is 30 t (66.1
kip).
Proceed then as follows:
! Select the locked main boom length above the one actually
required (here: 20.9 m / 68.6 ft).
! Search for the length combination that offers the best
values in the unpinned intermediate positions for the desired
radius (here: LC 12, extension condition: 0/0/0/0/45/45).
For 30 t (66.1 kip) of load to be raised LC 9/10/11 could also be
relevant.
! Enter the corresponding length code (here: LC 12) and
telescope out the main boom in accordance with the
information in the tele control system without load until
telescopic section 6 is pinned at 45% and telescopic section 5 is
extended out in the locked and unpinned condition to the point
where the required main boom total length of approx. 18 m (59.1 ft)
has been reached.
At this point calculate the telescoping procedure using the
information of the tele control system.
The permitted unpinned load capacity corresponds with the
table value of the additional table “unpinned” (here: 38.1 t /
84 kip), as it is lower than the pined value (here: 53.5 t / 118 kip).
The load of 30 t (66.1 kip) can then be raised with the telescopic
boom in the unpinned condition.
At the current point in time, the max. authorized load capacities
in the intermediate position for operation with main boom
extension are 2 t (4.4 kip).

Terex® All-Terrain Operation: Telescoping 36

Telescoping Lifting Capacities
The lifting capacities in intermediate positions are also
authorized during a telescoping procedure.
However, the lifting capacities that are actually achievable
during telescoping under load are only given as approximate
values due to the large number of variable external influences.
The telescopic load capacities (on request) are achieved
under the following conditions:
! Sliding surfaces well lubricated
! normal ambient temperature
! The systematic of the tele control system when carrying out
the extension sequences are predetermined and do not need
to be determined by the crane operator.
! The main boom angle may not be changed by the luffing
gear during the telescoping procedure.

Terex® All-Terrain Operation: Telescoping 37

Main boom state to move the crane in transport position
To move the crane in transport position, all telescopic sections
have to be completely retracted and pinned and the LPU has
to be secured for transport configuration in the prescribed
position (6th telescopic section).
Otherwise there is a risk of the locking and pinning unit
moving/ sliding by itself in an uncontrolled manner. If the
LPU is secured in the wrong place the indicated axle
loads are incorrect.
Starting situation:
main boom telescoped in and set down on the crane chassis in
transport position; current LK = 1.
Proceed then as follows:
1. Switch on the ignition on the superstructure and start the
engine.
The IC!1 will start and the “Operation mode pre selection” (top
left) will then appear.
2. Select “HA” operating mode and save by actuating the
button.
The input screen “Quick Menu” appears on the right side of
the IC!1 display (”A”).
3. Push button there. The mask “Telescoping display”
(“B”) appears.
4. Push the “LK” button. The “Tele operating mode” screen
appears (top right).

Terex® All-Terrain Operation: Telescoping 38

5. Press push button and steer the corresponding
control lever in the direction “Telescoping out” ! the LPU is
driven accordingly and locked onto the 5th boom section.
The control lever has to be actuated long enough that crane
represented on the screen appears (right side).
Only then is the main boom (including the LPU) in transport
position for moving the crane.
After moving, a length code can be selected again for the main
boom working range using the “LK” button.

Terex® All-Terrain Operation: Telescoping 39

NOTES:

Terex® All-Terrain Operation: Telescoping 40

all-terrain operation

Counterweight
 Counterweight Content

Content Pg. Content Pg.

Important fitting instructions 3

Op. elements / aux. equip. 4

Assembling the counterweight 7

Load capacities for fitting and

removing the counterweight elements 8

Suspending and bolting the CW 9

Automatic fitting of the CW 10

Assignment of the CW to the different

configurations 15

Terex® All-Terrain Operation: Counterweight

Counterweight It is forbidden to remain under hanging loads or in areas
Important fitting instructions where there is risk of loads falling.
When fitting and removing individual counterweight All counterweight elements must be attached at the
elements there is a risk of crushing between the individual attachment points provided.
counterweight elements, between the counterweight and Make sure that the attached element is not at an angle or
swinging when it is raised! The counterweight is attached
superstructure frame, between the counterweight and
in the desired configuration from the crane operator’s
undercarriage (counterweight support) and between the cab.
counterweight base frame and the individual counterweight
The crane operator operates the erection and pin locking
elements! cylinders using buttons.
To avoid these hazards, the safety instructions in section 1,
sub-point “When assembling and dismantling crane
components” must be observed.
Especially make sure you keep a sufficient safety distance.
Individual counterweights are stacked with the help of an
additionally trained person who is, as an exception, on the
crane with the crane operator during fitting and removal of
the counterweight. This person must leave the crane or the
endangered area immediately after completing the actual
configuration procedure.
The crane operator must be in continual visual contact with this
person and ensure that there is no-one else
in the hazardous areas. Before the superstructure is
slewed, the crane operator must make sure that this person has
left the crane and/or hazardous areas.
When rotating the superstructure, there is risk of crushing
between the counterweight and any obstacles which are
nearby.

Terex® All-Terrain Operation: Counterweight 3

The execution of the relevant movements are displayed to the
crane operator on the display of the IC-1. In order to see the
relevant display in field “E“, you select the „Quick
menu E57“.
If the support bases are reduced, the largest counterweight
assigned to the loading status specified in the table may be
assembled as a maximum. If a larger counterweight is used,
there is a danger of tipping over to the rear during slewing

Operating elements / auxiliary equipment

1.! Counterweight cylinder
When the button (18, S9380) is activated, the piston rods of
the counterweight cylinder (1) on the left and right side of the
superstructure are driven down (18B) or up (18A) together.

Terex® All-Terrain Operation: Counterweight 4

2. Control display on IC-1
After button (E57) has been selected, the counterweight
configuration view appears at (E). This displays the current status
information for the state of the counterweight
fitting. E57.1: Bridging switch in case of malfunctions
By selecting this switch the locking functions for fitting the
counterweight are switched off.
Before bridging the counterweight, a warning sign will
ensue. This must be acknowledged.
The crane operator should know the instructions on
configuring the counterweight from the manual. He must be
aware of the endangered area, especially of the risk of
people being crushed.
Danger of crushing and damage!
If the counterweight has been bridged, there is no
monitoring by the SPS.
By pressing the switching surface 1, this mask can be exited
with bridging.
By pressing the switching surface 2, the bridging will be active:
In the top picture, the symbol for bridging is displayed. The symbol
(25)then appears in the crane operating mask.
E57.2: Switching “Manual Fitting – Automatic Fitting”;
Automatic counterweight: Green/Grey = On/Off
E57.3: Status of the current condition of the
removal procedure
E57.4: visual display of the current condition of the
fitting procedure and/or when the counterweight
is fitted the selected counterweight combination
in the operating mode selection mask
E57.5: Extension status of the counterweight
lift cylinder in %

Terex® All-Terrain Operation: Counterweight 5

E57.6: Upper cross bar: E57.13: Symbolic display of switch 18 on the
Counterweight lift cylinder in upper end position instrument panel
E57.7: Arrow symbols for the movements Raise and Green/Red = release/no release for raising or lowering
Lower. When the switch is activated, the relevant page is
E57.8: Lower cross bar: depicted in grey.
Counterweight lift cylinder in the lower end A14: shows the current superstructure angle
position
E57.9: current hydraulic pressure in the counterweight
hoist cylinders
E57.10: Angular indicator
Mask showing the important angle settings for the fitting
procedure are displayed here
E57.10.1: Line display showing the position of the
superstructure
E57.11: Display showing whether the superstructure can
be slewed in its current counterweight condition:
red arrow: slewing not permitted
green arrow: slewing permitted
E57.12: Display to show whether the superstructure can
be slewed with the counterweight lift cylinder
retracted in the counterweight:
red arrow: slewing not permitted
green arrow: slewing permitted

Terex® All-Terrain Operation: Counterweight 6

Assembling the counterweight
Preassembly of the counterweight on superstructure frame
- The appropriate counterweight combination is preassembled
on the superstructure frame on the counterweight support.
For this purpose, guide lines are welded onto the chassis frame
as a visual centering aid. There are suitable indentations on the
lower part of the counterweight for this reason.
The counterweight support is between the chassis-cab and the
superstructure frame mounting (slew ring).
If the support bases are reduced, the largest counterweight
assigned to the loading status specified in the table may be
assembled as a maximum. If a larger counterweight is used,
there is a danger of tipping over to the rear during slewing.
An overview of the counterweight:
A - 5.7 t
B - 7.3 t
C - 9.0 t
D - 9.0 t
E - 9.1 t
F - 3.2 t
G - 12.77 t
H - 12.77 t

All counterweights are equipped with grooves and cams. Generally,

any configuration may only be continued when the grooves
of all components lying on top are exactly flush with and lying on
top of the corresponding cams.

Terex® All-Terrain Operation: Counterweight 7

Load capacities for fitting and removing the counterweight - the sections (A) and (B) form one unit. They are always
elements. marked with a serial number (xxx xxx 12-A and xxx xxx 12-
All counterweight combinations can, as a rule, be fitted and B) and must not be replaced or
removed using your own crane. The load capacity tables 0 t mixed with sections with other serial numbers.
are valid for the resulting load types. - to attach the saddle weights (G and H) the sections (C
Only lifting tackle with sufficient dimensions may be and D) must be seated (identically). The saddle weights must
deployed. be attached to the upper of the two sections (D) - the
sections (E and F) can be fitted either before or after
Special suspension gear is available as an option for attaching
attaching the saddle weights.
single counterweight elements or several elements together in
accordance with the specifications of the corresponding load
capacity tables. This special suspension gear can be ordered at the
crane manufacturer.
- the load blocks on section (A) may be loaded with 5 t, the load
blocks on section (B) may be loaded with 8 t, the cast bolts of the
sections (C, D, E, G and H) may be loaded with max. 6.5 t.
- with the sections „A - F“ the centre of gravity is exactly
between the load blocks and bolts.
The sections “B - E” may only be attached with 4 chains
- when fitting the section (F) on the superstructure frame using
the auxiliary crane, this must be attached diagonally with 2 chains to
avoid damaging the superstructure hydraulic tank.
- the saddle weights (G) and (H) must be attached with 2
chains.
- It is possible to raise the entire counterweight package using
the jack; however, it is only permitted when suitable shackle pins are
attached to the jack eyelets (shackle pins through the eyelet!).

Terex® All-Terrain Operation: Counterweight 8

Suspending and bolting the counterweight
Starting status for assembling the counterweight is:
- The counterweight configuration to be fit is set down on the
chassis.
- The counterweight cylinder is retracted.
- Rotate the superstructure back so that it is approx. +/- 10o
to the longitudinal axle.
The counterweight can be fitted in automatic mode or
manually:
Basic procedure:
- Turn the superstructure to the rear: main boom angle 4.5o or
355.5o
- Telescope counterweight lift cylinder into the kidney-shaped
grooves of the counterweight sections.
- Rotate superstructure to position “0o back”.
- Retract the counterweight lift cylinder: The draw bar of the
counterweight and the rod end of the hydraulic cylinder are
made so that the counterweight on the superstructure frame is
raised
After selecting the button (E57) a display of the
current condition appears at point “E” of the counterweight
(top graphic).
When switching on the counterweight configuration view
you are in manual mode. The symbol (E57.2) is shown “grey”.
The hand symbol is not crossed out.
When the counterweight is ready fitted after the fitting procedure,
and the selection mask is set in the operating mode, the current
counterweight is shown at point (E57.4).
The status display (E57.3) then is “S: 0”.

Terex® All-Terrain Operation: Counterweight 9

Automatic Fitting of the Counterweight
- Activate button (E57.2):
In automatic operation, the “hand symbol” is then
crossed through and the symbol shown “green”.
- Depending on the assignment of the pilot control sensors, the
lever used for slewing the superstructure must be actuated:
The slewing direction must be selected so that the angle range
of 4.5o to 355.5o is approached. (Example: the superstructure
is at 10o: The lever must be actuated so that the
superstructure turns anticlockwise as seen from above.)
Throughout the entire fitting procedure, the pilot sensor must
now be held in this direction. After fitting has been completed,
the superstructure remains in the “0o back position”, even
though the pilot sensor is still held to the side. The pilot sensor
must then be released temporarily.
When the lever is actuated again the crane is once again in
the crane operating condition. During the fitting procedure the
individual operating steps are worked through as described in
the “basic procedure” at the beginning of this point.
On the display the individual steps can be followed.
If, at the beginning of the fitting procedure, the slewing angle
was between 355.5o and 4.o, the fitting procedure is interrupted
depending on the slewing direction when the counterweight lift
cylinder is lowered.
The automatic fitting procedure is continued when the pilot
sensor is steered out of the opposite direction.
The slew gear is in the closed circuit during the fitting procedure.
This setting cannot be modified. The control system also assumes
control of the engine speed, in order to achieve a sufficient
sensibility.

Terex® All-Terrain Operation: Counterweight 10

Example Fitting the Counterweight with Automatic Operation:
Automatic operation can only be selected when the top cylinders or
the counterweight are fitted.
Activate automatic operation and steer out the pilot sensor for
the slew gear. The configuration procedure is now carried out by the
program.
The configuration procedure is completed when status S:3 has
been achieved. Then the pilot sensor must return to 0o position
once, so that the slew gear is released again. The color of the
automatic display changes from “green” to “grey”.
Special case: If the automatic device begins at 0o +/- 5.5o the
pilot control lever must be moved in the other direction, once
status S:2 has been reached.
Manual Fitting of the Counterweight
- After the button (E57) has been activated, the
crane is the mode for manual operation. The „automatic
symbol“ (E57.2) is now NOT crossed through.
- During the fitting procedure, the individual
steps are carried out by alternate actuation of the pilot lever and the
switch (18) in the instrument panel.
- Depending on the pilot control lever assignment, the lever
must be actuated which starts the superstructure slewing
movement:
The slewing direction must be selected so that the angle
range of 4.5o to 355.5o is approached from the outside.
(Example: the superstructure is at 10o: the pilot control sensor
must be actuated so that the superstructure turns
anticlockwise as observed from above).
- “S: 0” (E57.3) indicates the start and end state. The
CWT is displayed that has been selected in the operating
mode selection mask.
- When an angle range of approx. 5o or 355o “superstructure-to
chassis-
angle” is reached a line appears (E57.10.1) on the
display (E57.10), which marks the current angle.

Terex® All-Terrain Operation: Counterweight 11

 (Example: the superstructure stands at 10o: After starting the
slewing movement in the direction “0o-to the rear position”
when the 5o angle range is reached, the line (E57.10.1)
appears at the left end of the display which indicates the
current rotation angle.)
- The rotation movement must be continued until the line is in
the colored area at 4.5o or 355.5o, depending on the fitting
direction.
- Status (E57.3) is then changed to “S:1”.
If you leave the colored angle area (4.5o or. 355.5o +/- 1o), the
status display (E57.3) jumps back to „S:0“.
- Throughout the entire rotation movement, the rotation circuit
(E57.11) is displayed in “green”. This means that rotation
of the superstructure is permitted.

Terex® All-Terrain Operation: Counterweight 12

 - Extension of the counterweight lift cylinder by actuating
switch (18B) in the instrument panel (only possible in “S:
1” status):
For (E57.7) the arrow symbol then appears. At (E57.6) the
bar then disappears.
- If the counterweight lift cylinder is completely extended, a
bar appears at (E57.8).
After releasing the switch (18B) at (E57.7) the arrow symbol
disappears. At (E57.12) the permitted slewing direction is
then shown “green”.
- Continued rotation of the superstructure in the “0o back
position”. Status (E57.3) changes to “S:2”.
- S:3: Position in which the cylinders in the CWT are located
and lifting is allowed. The arrow of display (E57.13) which is
pointing upwards is shown in “green”.
- Retraction of the counterweight lift cylinder by activating the
switch (18A). While switch (18) is activated, the arrow symbol
appears at (E57.7). The cross bar disappears from (E57.8) after
you remove the counterweight lift cylinder from the bottom end
position.
- When the counterweight lift cylinder has reached its top end
position, the figure changes to a status “S:0” display. Then the
figure of the counterweight set in the operating mode
pre-selection mask is displayed.
Example Fitting the Counterweight without Automatic
Operation:
Rotate superstructure to 4.5o, S:1.
Actuate the button “counterweight downwards” until
condition S:2 is reached.
Continue to rotate the superstructure on 0o, S:3.
Activate button “Counterweight up“ until state S:0 has been
reached and Release slew gear has been achieved.
The fitting procedure is thereby completed. They are removed in a
similar manner in the reverse sequence.

Terex® All-Terrain Operation: Counterweight 13

 Mounting the Counterweight (F) to the Superstructure
The section (F) can either be assembled using an auxiliary
crane or your own crane.
Fitting with the auxiliary crane:
When fitting section (F) on the superstructure frame
using the auxiliary crane, this must be attached
diagonally with 2 chains, in order to avoid damage to the
superstructure hydraulic tank.
- Pin section (F) on the superstructure frame using pin (1).
Assembly with your own crane:
- Layer counterweight stack (A - F) (counterweight
combination 43.5 t) on the counterweight support of the
chassis.
- Fit the counterweight stack on the superstructure frame.
- To lock: remove pin (1) from holder (2) and insert
in the pin eyelets of the section.
- Make sure that the pins are locked correctly.
- When the section is not pinned on the superstructure, the
pins (1) are inserted in the holder (2).
- The section (F) is dismantled in the same way
in the reverse sequence.

Terex® All-Terrain Operation: Counterweight 14

 Assignment of the Counterweights to the Different
Configurations
As a rule, for driving (axle loads, transport condition) the
requirements from section 6 of the operating instructions of
the chassis must be observed. Other configurations as
described in the following, may not be fitted, even when this is
obviously possible. There is a considerable risk of damage to
the crane’s component group.
Counterweight Combination 0 t
(travel mode configuration, axle load version 12 t)
For the counterweight combination 0 t, no counterweight
elements are required to raise the permissible load in
accordance with the load capacity tables.
This represents the road driving condition with the 12 t axle
load.
Carrying the counterweight is then not permitted.
The swinging through radius on the superstructure from the
centre of the slew ring to the rear edge of the superstructure
frame is approx. 4170 mm.
Counterweight Combination 5.7 t
- only counterweight base plate (A) on the superstructure
for raising loads.
The slewing radius on the superstructure from the middle of
the slew ring to the rear edge of the counterweight equals
approx. 4450 mm.
Counterweight Combination 8.9 t
(travel mode configuration, axle load version 14.5 t)
Travel mode configuration:
-!Counterweight base plate (A) laid at the front on the
chassis.- Section (F) pinned on the superstructure frame
using pin (1).

Terex® All-Terrain Operation: Counterweight 15

 Raising loads:
Counterweights (A and F) fitted on the superstructure
frame.
The swinging through radius on the superstructure from the
center of the slew ring to the rear edge of the superstructure
frame is approx. 4450 mm.
Counterweight Combination 13 t
Counterweights (A and B) fitted for raising loads on the
superstructure frame.
The swinging through radius on the superstructure from the
center of the slew ring to the rear edge of the superstructure
frame is approx. 4800 mm.
Counterweight Combination 14.8 t
Counterweights (A and C) for raising loads fitted on the
superstructure frame.
The swinging through radius on the superstructure from the
center of the slew ring to the rear edge of the superstructure
frame is approx. 4800 mm.
Counterweight combination 16.3 t Configuration / axle
load version 16 t
Travel mode configuration:
counterweights (A) and (B) fitted at the front on the
chassis.
-!Section (F) pinned on the superstructure frame using bolt
(1).
Raising loads:
Counterweights (A, B, F) fitted for raising loads on the
superstructure frame.
The swinging through radius on the superstructure from the
center of the slew ring to the rear edge of the superstructure
frame is approx. 4800 mm.

Terex® All-Terrain Operation: Counterweight 16

 Counterweight Combination 18.0 t
Counterweights (A, C and F) for raising loads fitted on the
superstructure frame. Section (F) pinned on the
superstructure frame using bolt (1).
The swinging through radius on the superstructure from the
center of the slew ring to the rear edge of the superstructure
frame is approx. 4800 mm.
Counterweight Combination 22.1 t
Counterweights (A, B, C) for raising loads fitted on the
superstructure frame.
The swinging through radius on the superstructure from the
center of the slew ring to the rear edge of the superstructure
frame is approx. 4800 mm.
Counterweight Combination 25.3 t
Counterweights (A, B, C and F) (F pinned directly on the
superstructure frame) fitted on the superstructure frame for
raising loads.
The swinging through radius on the superstructure from the
center of the slew ring to the rear edge of the superstructure
frame is approx. 4800 mm.
Counterweight Combination 31.1 t
Counterweights (A, B, C, D) for raising loads fitted on the
superstructure frame.
The swinging through radius on the superstructure from the
center of the slew ring to the rear edge of the superstructure
frame is approx. 4800 mm.

Terex® All-Terrain Operation: Counterweight 17

 Counterweight Combination 34.3 t
Counterweights (A, B, C, D and F) (F pinned directly on the
superstructure frame) for raising loads on the superstructure
frame.
The swinging through radius on the superstructure from the
center of the slew ring to the rear edge of the superstructure
frame is approx. 4800 mm.
Counterweight Combination 40.2 t
Counterweights (A, B, C, D, E) fitted on the superstructure
frame for raising loads.
The swinging through radius on the superstructure from the
centre of the slew ring to the rear edge of the superstructure
frame is approx. 4800 mm.
Counterweight Combination 43.4 t
Counterweights (A, B, C, D, E and F) fitted on the
superstructure frame for raising loads.
The swinging through radius on the superstructure from the
centre of the slew ring to the rear edge of the superstructure
frame is approx. 4800 mm.
Counterweight combination 59.9 t (optional)
Counterweights (A, B, C, D, F, G and H) (F pinned directly
on the superstructure frame) fitted on the superstructure
frame for raising loads.
The swinging through radius on the superstructure from the
centre of the slew ring to the rear edge of the superstructure
frame is approx. 4950 mm.

Terex® All-Terrain Operation: Counterweight 18

 The section (F) can be fitted either before or after attaching
the saddle counterweights.
To attach the saddle counterweights (G) and (H) sections (C
and D - are identical) must be fitted. The saddle
counterweights must be attached in the upper of the sections
(D).
Counterweight combination 69. 0t (optional)
Counterweights (A, B, C, D, E, F, G and H) fitted on the
superstructure frame for raising loads.
The swinging through radius on the superstructure from the
centre of the slew ring to the rear edge of the superstructure
frame is approx. 4950 mm.
To attach the saddle counterweights (G) and (H) sections (C
and D - identical) must be fitted. The saddle
counterweights must be attached in the upper of the
sections (D).
The sections (E) and (F) can either be fitted before or after
attaching the saddle counterweights.
Operation with a Fitted Counterweight Combination
Due to physical reasons, the counterweight can sink
slightly when fitted.
In order to avoid damage to the counterweight hoist and
pin locking unit, you must check regularly whether the
counterweight is still firmly fitted to the superstructure
frame.
Otherwise, the electrical limit switch which releases
superstructure slewing could “lose the signal” under
unfortunate conditions.
This would result in the superstructure slewing
movement locking.
In this case the counterweight must be pulled up to the
superstructure frame again by activating the double
button 18B, as described above.

Terex® All-Terrain Operation: Counterweight 19

NOTES;

Terex® All-Terrain Operation: Counterweight 20

all-terrain operation

Reeving
 Reeving Content

Content Pg. Content Pg.

General notes 3

Load lifting equipment 5

Reeving / Unreeving the hoist rope 11

Hook blocks 14

Fitting and removing of one sided

fitted HD attachment 20

Fitting and removing of doubled sided

fitted HD attachment 21

Terex® All-Terrain Operation: Reeving

Reeving
General Notes
The safety of the crane is endangered by incorrect reeving.
Every configuration is assigned a corresponding reeving
number that is shown in the load capacity tables supplied.
Work only in accordance with the reeving numbers listed!
The corresponding reeving number must be set on the
load limit device (IC!1).
Unless otherwise specified in the load capacity tables, the
number of reevings must not be lower than 2 rope lines.
If, however, single line reeving is required, the lifting
capacities specified in the table must be reduced by 20%.
This also applies when the lifting capacity is less than the
maximum permitted cable tension per strand (see Notes
on Crane Operation).
When fitting a new hoist rope, which has never been
placed under load, twisting problems can occur. For this
reason, we recommend that a spin stabilizer be used (1).

Approx.
Transport dimensions spin stabilizer weight
Length Width Height
mm mm mm kg (lbs)
(in) (in) (in)
350 mm 80 mm 80 mm 8.0 kg
(13.8 in) (3.2 in) (3.2 in) (17.6 lbs)

Terex® All-Terrain Operation: Reeving 3

If a spin stabilizer (1) is fitted to the rope attachment point
of the main boom head, the length of the chain of the shift
weight of the hoist limit switch (up to the bottom edge of
the hoist limit switch) must be AT LEAST approx. 1500
mm (59 in) (see ”a” in figure Z 55 732). Only then is it
ensured that the switch off of ”Raise hoist” is carried out
by the hoist limit switch within a sufficient distance of the
lowest point of the main boom head. Otherwise there is
risk of damage!
If the chain is not long enough for this, the additional
chain which is supplied with the spin stabilizer must be
fitted as an
extension.
If a spin stabilizer is not fitted to the rope attachment point
of the main boom head, the length of the chain of the shift
weight of the hoist limit switch (up to bottom edge of the
hoist limit switch) must be AT LEAST approx. 1250 mm
(49 in) (see ”b” ).
In order to achieve maximum hoist heights, a longer chain
could be used once it is shortened. However, the length
must always be at least 1250 mm (49 in). RISK OF
DAMAGE!

Terex® All-Terrain Operation: Reeving 4

Load Lifting Equipment
If a load is to be raised with the crane, so-called load lifting
devices are required to raise the said load. These are:
! Carrying Equipment
Carrying equipment is permanently connected to the crane.
This includes:
! hoist ropes (1)
! hook blocks (3)
! Load handling devices
Load handling devices are equipment, for example lifting
beams, that are not part of the crane. They are connected to
the carrying equipment and take up the load.
Their selection and subsequent safe operation of the crane
are the responsibility of the crane operator.
! Lifting tackle
Lifting tackle is equipment, e.g. sling ropes, which does not
belong to the crane. They connect the carrying equipment
and load or carrying equipment and lifting devices.
Their selection and subsequent safe operation of the crane
are the responsibility of the crane operator.
To ensure that the load handling equipment is used
correctly the individual national regulations, must be
observed.

Terex® All-Terrain Operation: Reeving 5

Hoist Ropes
General Notes
Information on how to handle ropes safely and correctly is
contained in the lubrication and maintenance instructions for
the chassis.
When reeving there is a risk of becoming caught and
entangled in the head! and deflection rollers as well as in
the hook blocks !
Proceed with appropriate caution and make sure that the
safety guards and intake guards are fitted.
Risk of overloading and accidents!
If a rope has to be replaced, the new rope must satisfy the
technical parameters of the original rope, for example with
regard to rope diameter, nominal tensile strength,
calculated breakage force, minimum breakage force, type
of lay etc. in accordance with the rope certificate in the
crane logbook.
If this is not the case, the operational reliability of the
crane in the normally permitted lifting capacity range is no
longer guaranteed!
The length of the ropes of hoist 1 and hoist 2 is 345 m (1132 ft)
each.

Terex® All-Terrain Operation: Reeving 6

Rope End Connections
Risk of accidents!
If the rope connection is not made correctly as described
below, the hook block / load could fall!
Rope end connection with press fitting
The rope end connection with press fitting is made up of the
following elements:
(1) ! Locking pin and mushroom handle
(2) ! Protect trap
(3) ! Press fitting on the end of the hoist rope
(4) ! Rope pocket
Proceed as follows to make the rope end connection as
described below.
1. Release the locking pin (1) from the lock at the
corresponding bore hole of the rope pocket (4) by pulling its
domed head handle against the spring resistance, and fold
out the safety flap (2).

Terex® All-Terrain Operation: Reeving 7

2. Attach hoist rope with press fitting (3) to rope pocket (4).
3. Fold over the safety flap (2) on the mushroom handle of
locking pin (1) into position ”lock” and allow the locking pin
(1) to lock in the corresponding hole of rope pocket (4).
Safety flap (2) prevents the press fitting being released from
the rope pocket when the hoist rope is not under load (e.g.
when the hook block is set down suddenly on the ground).
Risk of accidents!
The hoist rope may only be placed under load later when
the press fitting (3) is secured with safety flap (2) and the
locking pin (1) is locked in place.
In the design that is described and shown, the rope
pocket
may only be used for low twisting / non!twisting ropes.
Before reeving a hoist rope with press fitting all rope
protection arrangements such as rollers or bolts on the
deflection rollers or idlers to be reeved must be removed
or opened.
If this is not done the hoist rope cannot be drawn through
with the press fitting or may cause damages.

Terex® All-Terrain Operation: Reeving 8

Rope end connection without press fitting
The illustrations of the rope socket (1) and the cable clip
(3)
are principle drawings and do not correspond exactly with
the components supplied by the crane manufacturer.
Use only original parts supplied by the crane
manufacturer.
In order to fit the rope socket (1), first the free rope end is
pulled through the conical rope pocket, laid in a loop and then
pulled out of the rope pocket again. The rope key (2) is laid
into the rope loop and the hoist rope is pulled through the rope
socket (1), so that the free end juts out by approx. 8 times the
width of the rope diameter.
Danger of the load and / or the hook block falling down!

Terex® All-Terrain Operation: Reeving 9

Using a cable clip (3), the ”unloaded“ rope end (4a)
is now secured where it comes out of the rope socket at a
distance of approx. 3 times the width of the rope, so that the
hoist rope is not pulled through.
The free end is connected with Litz wire (5) ø1.5 mm (0.06 in)
from the rope clamp to prevent the hoist rope from being
pulled through.
Risk of damage to the rope!
The cable clip may not be attached in such a way that it
connects the ”loaded” (4b) and ”unloaded” ropes (4a)
with each other.
When fitting the rope socket you must make sure that the
”loaded” rope (4b) runs through the rope socket in such a way
that the tension force’s line of action runs exactly through the
fastening pin without bending the cable when the end
connection is loaded.
When fitted incorrectly, the end connection will align itself
whenever loaded so that the tension force’s line of action
runs through the fastening pin, bending the highly loaded
”loaded” rope of the cable at the rope pocket exit every
time.
On one hand, this reduces the maximum transmittable
tension force of the end connection, on the other hand the
pressure coupled with the frequent bending within a very
small radius creates a premature wear of the rope cables
in this area, so that the end connection can fail
prematurely even when there are only small tension
forces.

Terex® All-Terrain Operation: Reeving 10

Reeving / Unreeving the Hoist Rope 5. Guide the hoist rope via guide sheave (E1) to the
Reeving sheaves (K) in the main boom head and reeve in
Before reeving and before starting crane work, check the accordance with the corresponding reeving.
status of all accessible ropes (including the end 6. Fit the bolt for rope guard (11) on the hook block and
(13) reattach on the main boom head and secure. To this
connections), winches and sheaves.
end the rope protection plate (12) must be folded in
1. Position the hook block beneath the main boom head so again on the hook block.
that it is stable. 7. Fit rope end into rope socket (if this has not already
Risk of overturning!
been done).
Work may only be carried out on the hook block (reeving
and unreeving) when it is set down and stable on solid
ground.
2. Remove bolts for rope guard (11) from the hook block and
fold out the rope protection plate (12).
3. Remove the bolt for the rope guard (13) from the main boom
head.
4. Guide the hoist rope from the hoist via the main boom to the
guide sheave (E1) on the main boom head.
Guide sheave (E2) is optional.
While the crane operator is using the hoist, the hoist rope
must be guided by a helper to prevent slack rope from
forming.
If it is unavoidable for personnel to walk on the main
boom during this procedure, suitable safety measures
must be put in place.
There is a risk of accidents as a result of slipping /
stumbling on the main boom or if the hoist is incorrectly
operated.

Terex® All-Terrain Operation: Reeving 11

8. Bolt the rope socket or rope pocket to the corresponding
fixing point:
! with uneven number of rope strands fixing point on the
hook block (FU,)
! with even number of rope strands fixing point on the main
boom head, here: right side
9. Release the shift weight of the hoist limit switch from the
transport position (”A”), remove both clip pins and
pull the two halves (2a) and (2b) of the shift weight apart.
10. Guide the separated halves of the shift weight around the
hoist rope and secure again with clip pins.
The condition shown in picture must be shown.
The shift weight should be fitted on the ”resting” rope.
This avoids wearing of the hoist rope and shift weight.
The ”resting” rope is the rope line that goes to the fixing
point:
Make sure that the shift weight is hanging free. Only then
is it guaranteed to function properly.
RISK OF DAMAGE!
If the shift weight of the hoist limit switch is not ! as
described ! fitted on the hoist rope, the hoist stroke
limitation does not work.
There is a risk of damage to the rope, sheave and shift
weight.

Terex® All-Terrain Operation: Reeving 12

Unreeving
In principle, unreeving is carried out in the same as reeving,
only in the reverse order.
In particular pay attention to the following points:
! Tipping over of the stationary hook block
Risk of overturning!
Work may only be carried out on the hook block (reeving
and unreeving) when it is set down and stable on solid
ground.
! Sudden release of the hoist rope end from the hook block
Risk of accidents!
When unreeving, the hoist must be operated carefully and
the hoist rope wound slowly.
The area around the hook block must be kept clear at all
times.
! Watch the winding pattern of the hoist rope when reeling in
the rope. There must be no slack rope.

Terex® All-Terrain Operation: Reeving 13

Hook Blocks
Definition
In DIN 15002 the hook block is defined as the ”multiple line
suspension of carrying equipment with a hook”.
A single!line suspension would be referred to as a hook
suspension gear. As this differentiation is not relevant for the
following general contexts, only the description ”hook block” is
used.
Only hook blocks may be used which have been obtained
from the crane manufacturer.
The use of other hook blocks is only permitted following
consultation with the crane manufacturer.
Markings
The following details must be permanently and legibly marked
on
hook blocks:
! Warning marking
! Manufacturer or supplier
! Year of construction
! Type, if type designation applies
! Factory or serial number
! Permitted load
! Rope diameter
! Drive group
! Dead weight.

Terex® All-Terrain Operation: Reeving 14

Operation The crane operator must have visual contact with
When reeving there is a risk of persons becoming caught the operating personnel and must give a warning
and dragged into equipment and crushing near rotating signal before starting the crane movements.
and moving components on the hook blocks !
Proceed with appropriate caution and make sure that the
safety guards and intake guards are fitted.
In particular the following points must be observed:
! The personnel (person attaching/detaching the load) must
be
qualified and conversant with the handling of hook blocks and
must be wearing suitable protective clothing.
When attaching and disconnecting the load, particular
care should be taken as a result of swinging loads or
hook blocks.
Once the load has been attached or released, the fitter
must leave the slewing or hazardous area immediately.
The fitter must be easily recognizable to the crane
operator.
The fitter must wear one or more means of identification
e.g. jacket, helmet, special collars, armbands, signaling
discs.
These items of recognition must be of a distinctive color
and preferably all in the same design and must be worn/
carried exclusively by the person connecting up the
load.
Before starting movements of the winches (raising or
lowering) all persons must leave the danger zone in the
proximity of the rope drums and sheaves.
Terex® All-Terrain Operation: Reeving 15
! Touch the hook block only using the handrails provided.
The hands must be KEPT CLEAR of the following areas:
! between the sheaves, side plates and covers.
! in the area of the fixing points (sometimes of a folding
design), the hook, the hook nut, the lifting beam or the
protecting cages.
! Make sure that items of clothing do not get caught in rotating
parts.
! Work on the hook block may only be carried out (i.e.
reeving),
when it is set down in a stable position on firm ground.
Risk of overturning!
Be aware that the hook block could still tip over however!
Proceed with appropriate caution!
! Only use the hook block for lifting in the vertical direction.
Pulling sideways is not permitted.
! Place the hook block under load slowly and evenly.
No sudden loads! No one-sided loads!
! Always fit the load / load handling device in the middle of the
hook (hook jaw), never at the tip.
! Never load only one side of the twin hook.
Welding on the hook block is prohibited.

Terex® All-Terrain Operation: Reeving 16

Hook Block Types / Transport Dimensions / Weights

* Hook size in accordance with DIN 15401 (single hook) or DIN

15402 (twin hook)
** If there are removable weight elements on a hook block and
they are fitted, they must be screwed or bolted on tightly,
depending on the design, and secured against falling off.

Terex® All-Terrain Operation: Reeving 17

 The weights of the hook blocks, hook suspension gear,
lifting devices, etc. must be deducted from the working
loads in the tables.
Reeving the Hoist Rope on the Main Boom Head
The safety of the crane is impaired by incorrect
reeving!
This is why you must follow the reeving examples.

Other reeving configurations would disrupt the function

of the load limit device.
The following hook blocks can be used:
The weights of the hook blocks, hook suspension gear,
lifting devices, etc. must be deducted from the working
loads in the tables.
Only use original hook blocks suitable for this crane.
If you wish to use other hook blocks, you must first
contact our customer service departments.

Terex® All-Terrain Operation: Reeving 18

Reeving the Hoist Rope on the Main Boom Head with Transport Dimensions / Weights
Auxiliary Sheaves (HD attachment, optional)
Risk of accidents!
Only the original HD attachment of the crane manufacturer
for this crane type may be used!
For the use of other additional equipment the crane
operator carries sole responsibility.

Information on Transport and Attachment Points

Attachment Points

Risk of accidents!
There are no attachment points welded to the HD
attachment. For this reason, it must be attached with a
looping tackle.
The actual attachment procedure must be undertaken
with the utmost care.
RISK OF ACCIDENTS!
The parts must not swing out or dangle at an angle when
they are raised. If necessary, lifting chains fitted with
shortening claws must be used.
The securing equipment must be supplied by the
customer.

Terex® All-Terrain Operation: Reeving 19

Fitting and Removal of One-Sided Fitted HD Attachment
In the standard design there are 6 sheaves on the axle (2) of
the main boom.
For reevings above 12 falls, it is possible to attach
additional sheaves (3, HD attachment).
Stand the main boom axis (2) on its end, push on HD
attachment (3) and secure with bolt (1) as shown.
Secure the bolts (1) on both sides with locking pins (5).
To reeve the hoist rope on the HD attachment (3) the three
rope locking pins (4) can be removed.
Immediately after fitting the hoist rope all 3 rope locking pins
(4) must be fitted again and locked.
The HD attachment is removed in the same way, in the
reverse order.
When using the heavy duty device, you must move the hoist
limit switch from the head and hang it onto the heavy duty
equipment.
The existing forelock must be used for locking.
Only the heavy duty equipment supplied by the crane
manufacturer may be used.
The crane manufacturer is not responsible for possible
accidents or damage caused by the use of incorrect
optional equipment.

Terex® All-Terrain Operation: Reeving 20

Fitting and Removal of Double sided Fitted HD attachment
In the standard design there are 6 sheaves on the axle (2) of the
main boom.
For the heavy duty equipment mounted at both sides, there are
additional sheaves mounted to the left and right side of the main
boom head. The hook block is reeved with the hoist rope of
the hoist 1 and the hoist rope of the hoist 2. This means that
17!foldreeving is possible with the hook block ”Type 200”.
Only the heavy duty equipment supplied by the crane
manufacturer may be used.
The crane manufacturer is not responsible for possible
accidents or damage caused by the use of incorrect
optional equipment.
Risk of rope damage!
The fact that two hoist ropes are reeved at the same time for
this reeving can cause slight crooked positions of the hook
block. This is not permitted.
For this reason an additional person must observe the
behavior of the hook block from the outside and, if the
hook block is in a crooked position, he must instruct the
crane operator to straighten the hook block again by
driving the corresponding movement!
Connecting the hoist limit switches / Electrical safety chain
In the event of a reeving in which two hoist ropes are participating,
two hoist limit switches on the ”X0550” junction box on the
left-hand side of the main boom head must also be connected.
To connect the first hoist limit switch, see description of the
”Electrical safety chain” in section 10 (”Safety devices”).
An adapter cable is connected for the purpose of connecting the
second hoist limit switch to Connection ”A”. The
second hoist limit switch is connected to the free end of the
adapter cable.

Terex® All-Terrain Operation: Reeving 21

NOTES;

Terex® All-Terrain Operation: Reeving 22

all-terrain operation

Emergency Operation
 Emergency Operation Content

Content Pg. Content Pg.

Emergency Operation (optional) 3

Connecting the transformer 4

Recovering a small load 6

Terex® All-Terrain Operation: Emergency Operation

Emergency Operation (Optional) The following movements can then be driven by
Follow all safety instructions which are also valid for activating the control lever in the superstructure:
normal operation! ! Luffing
The emergency operation procedures described in the ! Raising / lowering hoists
following are only for when the superstructure engine or a ! Rotating (in connection with a stop valve on the
pump fail so that small loads (load pressures < 210 bar (< superstructure)
3046 psi)) can be recovered safely. The required hydraulic transformer and all required
Emergency operation is not equipped or suitable for hoses must be supplied by the customer or can be
maintaining normal crane operation. delivered as optional equipment.
General
The required connections (hydraulic interfaces) are
standardized.
The required auxiliary power unit is a hydraulic transformer,
which basically consists of a pump and an engine. Such a
transformer can be ordered from the crane manufacturer.
The transformer has the following connections:
TUW ! Tank connection crane chassis
PUW ! Pressure connection crane chassis
LUW ! Leakage oil connection crane chassis
T ! Tank connection superstructure
P ! Pressure connection superstructure.
The shut!off lever (6) of the hydraulic transformer is
set to open through feed and is only closed when a movement
is to be driven immediately afterwards.
The engine of the transformer (4) is driven by an external
hydraulic system (e.g. from the crane chassis, a second
crane or a special unit) and it then drives the transformer
pump (5), which supplies the superstructure hydraulic
system.
Terex® All-Terrain Operation: Emergency Operation 3
Connecting the Transformer
Initial situation:
! Crane in relevant operating configuration (outrigger support
area, counterweight and similar) with hanging small load.
! Superstructure:
! Failure of diesel engine or pump
! Hydraulics and electrics functioning
! Engine and ignition off
! Crane chassis:
! Hydraulic external supply from the crane chassis or external
machine with connections for driving the transformer
! Engine and ignition off
! Use of a standard transformer In the following, an example
of the transformer supplied by the crane manufacturer
is described.
1. Unfold protection caps on the relevant couplings of the
transformer and unscrew hydraulic hoses.

Terex® All-Terrain Operation: Emergency Operation 4

2. Connect transformer engine (4) to the corresponding
hydraulic couplings on the crane chassis using hoses.
These hydraulic couplings (x 3) are on the left!hand side of
the chassis between the wheels of axles 2 and 3 on the
bottom of the covering. There are protection caps on the
hydraulic couplings which must be removed.
The corresponding coupling sleeves and plugs are marked
with plates as follows:
TUW ! tank connection crane chassis
LUW ! Leak oil crane chassis
PUW ! pressure connection crane chassis.
There is no risk of them being confused as the connections of
the different hoses have different sizes.
For transformers without a leak oil connection, coupling “LUW”
remains free on the crane chassis.
The shut!off lever (6) of the hydraulic transformer is
set to ”open through feed”. Figure (top view) shows the stop
valve (6) in the closed position.
3. Connect pump (5) of the transformer to the
corresponding hydraulic couplings of the superstructure
using hoses. To do so, unscrew each protection cap and screw
on the hydraulic hose.
The coupling sleeves and plugs which belong together can
be marked with plates as follows:
P ! Pressure connection superstructure
T ! Tank connection superstructure
There is no risk of them being confused as the connections of
the different hoses have different sizes.
4. Connect bridging hose ”S” on the superstructure between
the connections 1.1 and 2.1 (rotate for function
Superstructure).

Terex® All-Terrain Operation: Emergency Operation 5

Recovering a Small Load
1. Connect the transformer in accordance with section 36.2.
2. Switch on the ignition of the superstructure.
3. Activate the function Emergency lowering (optional) (203.3,)
in the service line in the main menu of the crane control
system.
The function surface then displays “ON”.
When the crane operating mask is switched on, a red cross
with ”ON” written on it is displayed at (25) in the crane
display (A).
4. Open stop valve (6) of the hydraulic transformer (=
pressure! free circuit from pump side), if this has not already
been done!
The stop valve is only closed shortly before a movement is
executed.
5. Start up the engine of the crane chassis.
6. Press switch (103, S 2430) in the chassis cab.
To do so, the hand brake must be applied and the transmission
must be in ”neutral position”.
The engine of the hydraulic transformer is supplied with oil.
7. Close stop valve (6) of the hydraulic transformer: The
superstructure hydraulic system is supplied with oil.
The further procedure depends on the movement to be
carried:
Hoist and luffing
8. The crane movements ”Hoist and luffing” can be carried out
as before using the joystick.

Terex® All-Terrain Operation: Emergency Operation 6

Rotating the superstructure
9. In order to rotate the superstructure, the position of the stop
valve (H) must be modified: During normal crane operation, the stop
valve (H) is in the middle position. In order to rotate the
superstructure clockwise, the lever of the stop valve must be pressed
inwards. In order to rotate the superstructure anticlockwise the lever
of the stop valve must be pulled outward. The lever of the stop valve
is moved in
the final position each time (locks in place!)
The speed of the slewing movement is set using the knob of the
throttle (D). You will have a slewing speed that is easily manageable
when you turn the rotating knob half a turn from the completely screwed in
position (closed). Further opening of the throttle results in an increase of
the slewing speed.
The actual slewing movement is introduced by pressing the
corresponding joystick to the right or the left.
(Steering direction immaterial!)
Risk of crushing and pushing!
The slewing direction of the superstructure is determined by the
position of the hand stop valve (H) and not by steering the joystick.
10. Open stop valve (6) of the hydraulic transformer after the
movement has been carried out (= pressure free circuit from
pump side).
Only operate the transformer as long as is required for recovering
the load and do not let it run at idle speeds for longer
periods of time. If the transformer is operated for a longer period
of time, the oil can overheat.
11. After the load has been recovered, switch off the ignition in
the superstructure and with there was a slewing movement
previously: return hand stop valve (H) to the middle position
(locks in place).
12. Switch off switch (103, S 2430) in the crane chassis and turn
off the engine.
13. Disconnect all connections of the transformer again and refit
the protective caps on the couplings.

Terex® All-Terrain Operation: Emergency Operation 7

NOTES;

Terex® All-Terrain Operation: Emergency Operation 8

all-terrain operation

Radio Remote Control (Optional)

 Remote Control Content

Content Pg. Content Pg.

Radio remote control 3

Control lever assignment 8

Operation 10

Battery 15

Troubleshooting 18

Terex® All-Terrain Operation: Radio Remote Control (Optional)

Radio Remote Control (Optional)
Your crane is equipped with a radio remote control, which
basically consists of 2 components:
! mobile radio transmitter with control panel (201)
! radio receiver (202)
All crane movements can be controlled ”remotely”, from
outside the cab, using this radio remote control.
General
Before using the radio remote control you must read and
observe the operating instructions from the radio remote
control’s manufacturers!
If instructions are unclear, please contact our customer
service department before operating the remote control
system.
Every crane movement activated by the radio remote
corresponds exactly with a crane movement activated
from the crane operator’s cab.
All instructions and descriptions of the corresponding
sections of the crane operating manual must therefore be
observed.
The minimum command period and the crane’s reaction time
increase minimally due to the radio remote control.
All movements of the crane and the load must be in the
field of view of the crane operator. If necessary a spotter
must be used.
You, too, as the operator of the radio control must remain
clear of the hazardous area of the crane during crane
operations!
Terex® All-Terrain Operation: Radio Remote Control (Optional) 3
Safety Regulations ! Pull out connection cable from the radio receiver.
Applicable regulations on work safety and accident Take even small faults in the radio remote control
prevention for operations using radio remote control must into consideration! They can lead to serious
be observed! malfunctions!
The radio remote control may only be placed in operation Do not continue to work with a defective radio
upon receipt of a special radio permit. remote control!
Important Information before Using the Radio Remote Defective radio remote controls may only be
Control repaired by a specialist! Only use original spare
Only operate the radio transmitter with the transportation parts of the manufacturer!
belt in the DBM!supplied delivery (risk of confusing the Depending on country specifications or as an optional
operating elements)! extra there could be a green lamp, which flashes during
Before working with the radio remote control, make sure operation with radio remote control.
that you are fully conversant with how the system works!
Only authorized and suitably trained personnel may
therefore work with the radio remote control!
Check function of the STOP switch (7) every time before
commencing work!
If one procedure with radio remote control has been
completed, the slew gear brake (retaining brake) must be
applied for safety reasons!
Never leave the activated transmitter unattended!
Stop operation immediately if there is a defect, an
emergency or any other malfunction in the operating
range of the radio remote control in order to rectify the
cause, i.e.:
! Switch off the radio transmitter using the STOP switch
(7)
! Pull out key (13) from the radio transmitter

Terex® All-Terrain Operation: Radio Remote Control (Optional) 4

Radio Receiver (202.4) ! “SI 2”
The radio receiver is on the left!hand side of the The green LED is assigned to the internal safety circuit
superstructure. “SI 2”, which switches the driving commands off twice
Make sure that the radio receiver and the antenna do not when the command sensor is in the ”Off” position, i.e. “SI
come into contact with other objects 2” is not illuminated.
There are 4 indicator lights (LEDs) in the lid of the radio Only when one or more drive commands (e.g. slew,
receiver, which indicate the operating condition of the radio hoist, etc.) are output should the display ”SI 2” light up!
remote control:
(202.1) ! “On”
The yellow LED is illuminated as soon as the receiver is under
operating voltage. The connection to the crane electrical
system has been made, the internal operating voltage is live.
(202.2) ! “HF”
The red LED is illuminated when the transmitter is switched off
and goes out as soon as the transmitter is switched on, i.e.
when the receiver receives a signal on its radio frequency.
If the LED ”HF” goes out when the transmitter is switched off,
this indicates that the radio channel is also being used by
another transmitter.
In the event of the system being shut down as a result of radio
faults, you should switch off your transmitter and watch to see
if the LED “HF” goes out anyway.
(202.3) ! “SI 1”
The green LED flashes briefly approx. 2 x per second when
the transmitter is switched off. In this time the safety circuit is
checked. After switching on the transmitter, the LED lights up
permanently, i.e. the receiver has recognized its transmitter at
the same system address (code). Safety circuit ”SI 1” is
enabled.
Terex® All-Terrain Operation: Radio Remote Control (Optional) 5
Control Elements of the Radio Transmitter

The keys for both key switches are marked with “M1” or “M2”
and only fit in accordance with their designation.

Terex® All-Terrain Operation: Radio Remote Control (Optional) 6

Terex® All-Terrain Operation: Radio Remote Control (Optional) 7
Control Lever Assignment
As soon as the radio remote control is switched on, the
position of rotary switch (8) determines the control lever
assignment. In this case it does not matter which mode of
control lever assignment is selected via IC!1.
The display of the selected mode in the top line of the IC!1
display adapts accordingly.

! Main boom extension which can be luffed down hydraulically

S = control lever, R = right, L = left, H = horizontal, V = vertical
Risk of accidents!
Observe the selected pilot control assignment in order to
avoid unintentional movements.

Terex® All-Terrain Operation: Radio Remote Control (Optional) 8

Display (2.8) ! Overload symbol
Using push button (12), you can select between two different Overload range (from 100 % of the load moment)
displays during operation of the crane. Overload symbol flashes up.
Operating display (“A”) The LLD switches off the movement ”Raise load”,
(2.1) ! Bar display of load utilization (also appears at the same ”telescope out” and ”lower luffing gear”.
place in the telescoping display “B”)
(2.2) ! Percentage display of load utilization
(2.3) ! Radius
(2.4) ! Hoist limit symbol
When the hoist limit symbol lights up (HE) the hoist limit
switch has been triggered.
(2.5) ! Current gross load
The gross load includes the weight of the hook block, the
hoist rope and all load lifting attachments.
(2.6) ! Max. load capacity in accordance with the load capacity
table
Telescoping display (“B”)
(2.9) ! Selected LC
(2.10) ! Display appears when selected LC has been
achieved.
(2.11) ! Position indicator of the locking and pinning unit (LPU)
(2.12) ! Bar display of the selected LC
The following symbols are shown in the bottom right-hand
corner for both displays as required:
(2.7) ! Pre-warning symbol
Pre-warning range (90 ! 100 % of the load moment)
Pre-warning symbol flashes.

Terex® All-Terrain Operation: Radio Remote Control (Optional) 9

Starting Operation of the Radio Remote Control
The sequence described below for starting operations must be
followed (for finishing operation, in the reverse order).
1. Insert charged battery with the decals facing outwards in the
corresponding compartment on the bottom of the control
panel. Observe correct polarity of the battery.
2. Switch on the ignition(62) in the cab.
The IC!1 ramps up and mask
“Selection of the operating mode” appears.
3. Switch over the key switch (54) to radio remote control (and
pull out key). Indicator light “53” lights up. In mask “Selection
of the operating mode”, key .

Terex® All-Terrain Operation: Radio Remote Control (Optional) 10

4. The in the display of the IC!1. In addition, an
”Information” mask appears, in which the parameters for the
currently set configuration are indicated. Either activate the
correct configuration with the “Continue” key or return to the
”Configuration” mask using the ”Return” key and adapt setting
to the actual crane state.
Risk of accidents!
All parameters must be selected by the crane operator so
that they correspond with the actual state of the crane.
This is the sole responsibility of the crane operator. Only
when this entry is correct can the load limit device reliably
monitor crane operation.
After activating the configuration, the “Operation of the crane”
mask appears with symbol (27).
As soon as crane operation with ”Radio remote control“ has
been activated, it is not possible to change the crane
configuration on the IC!1.
In order to prevent unwanted crane movements or
disruptions, pull out the key switch “Operational
readiness of radio remote control”, close the crane
operator’s cab and take both keys with you.

Terex® All-Terrain Operation: Radio Remote Control (Optional) 11

5. Make sure that the STOP switch (7) is unlocked. If required,
unlock the STOP switch by turning it.
6. Switch the radio transmitter on. To do so, turn the key
switch M2 (13) in the direction of the arrow. The state display
(202.3) flashes green, the transmitter is ready for operation.
If the red LED of the state display (202.3) is illuminated and /
or an acoustic signal goes off via buzzer signal (21), it means
that the battery is almost empty. Then you must immediately
proceed as follows:
! Replace the empty battery with a charged one.
! Charge empty battery.
If the empty rechargeable battery is not replaced with a fully
charged one, the transmitter will switch itself off in a few
minutes.
The radio connection to the receiver (Z 200 426) has been
created if the red LED ”HF” (202.2) goes out after the
transmitter has been switched on, and the green LED
”Si1” (202.3) is illuminated.
Control commands can then be entered using the radio
transmitter’s control panel.
7. Start the crane engine using the radio remote control;
(engine start; flip switch ”11” ! top)
Every time before starting work you must:
Press button (5) ”Horn”. This warns your colleagues that
crane or hook movements must be taken into
consideration at this point in time.
Check function of the STOP switch (7).

Terex® All-Terrain Operation: Radio Remote Control (Optional) 12

If the transmitter has been switched off using the STOP switch
(7), the following steps must be carried out for further
transmission operation:
1. Switch off the radio transmitter. To do so, turn the key
switch M2 (13) against the direction of the arrow.
2. Unlock the STOP switch (7) by turning it.
3. Switch the radio transmitter again. To do so, turn the key
switch M2 (13) in the direction of the arrow.
Switch the transmitter on and off using the key switch M2
(13). Only use the STOP switch (7) in case of emergency
and if there are malfunctions in the area of operation.

Terex® All-Terrain Operation: Radio Remote Control (Optional) 13

The control command is also transmitted outside the
visible range to the crane. Therefore, if out of use, remove
the key (13) from the transmitter and store in a safe place.
Automatic transmitter shutdown
The transmitter is equipped with an automatic transmitter
shutdown and switches itself off approx. 15 minutes after
entering the last control command.
The automatic transmitter shutdown is for safety purposes and
increases the battery’s standstill time.
Always be very careful and observant when using the
radio remote control!
Select a safe operating location where you can see the
workplace fully.
During operational breaks or when operation is finished,
switch the transmitter off using key switch (13) or stop
switch (7) and pull out the connection plug from the
receiver!
The automatic transmitter shutdown never absolves the
operator from his responsibility to switch off the radio
transmitter if it is no longer needed!
Operation may not be continued with a defective radio
system!
Unintended or improper use of the radio remote control will
lead to its manufacturer’s warranty being invalidated!

Terex® All-Terrain Operation: Radio Remote Control (Optional) 14

Battery
The battery (41) must be in the corresponding compartment on
the bottom of the radio transmitter’s control panel ! as
depicted.
The length of the battery’s operating period depends on the
age of the battery and the surrounding temperature. Older
batteries lose their functioning capacity with age. If
temperatures are below 0° C / 32° F, the battery does not
achieve full capacity.
If treated correctly, the battery can have 500 charging cycles.
For this reason:
! Only charge the battery when it is empty, i.e. if the red
display flashes on the transmitter and / or the acoustic signal
goes off.
Charge the batteries before using them for the first time!
Batteries that have been stored for a longer period of time
must be charged before use.
! Do not keep the battery in the toolbox or in trouser pockets
(risk of short circuiting).
! Always use the supplied protection caps for storage.
! Store the batteries at room temperature (approx. 20° C / 68°
F).

Terex® All-Terrain Operation: Radio Remote Control (Optional) 15

Battery Charging Set
Only HBC batteries of the type FuB 10 AA and FuB 10 XL
may be charged with the charging set FLG 110D!
Only use original HBC batteries. Not using original HBC
batteries can cause performance and safety problems
during charging (from overheating to explosion of the
battery)!
Do not operate the charging set in areas at risk of
explosions!
Only use the charging set with the network voltage
indicated on the bottom!
Only use the charging set in vehicles!
Only operate the charging set within the indicated
temperature range and protect it from overheating, dust
and damp!
Disconnect the charging set from the power supply before
opening the unit!
Do not cover the charging set during operation!
Disconnect the charging set from the power supply if it is
not being used!
Stop operation of the unit immediately if there is a fault in
the unit or the cable!
Do not make any technical changes to the charging set or
the cables!
Only have repairs carried out by a specialist!

Terex® All-Terrain Operation: Radio Remote Control (Optional) 16

Charging the battery
1. Connect the charging set to a vehicle socket.
2. Insert the battery in the charging compartment (52) with the
decals facing outward. Make sure that the polarity of the
battery is correct.
The charging state of an inserted battery is displayed via 4
LEDs:
LED (56), red ! Battery defective or exhausted
LED (55), yellow ! battery is charged.
LED (54), green ! Battery is charged
LED (53), yellow ! Battery is discharged

Function “Discharging”
The battery’s capacity can decrease with increasing service
life.
In this case, the battery charging set enables an improvement
of the available battery capacity using a function “Discharging”.
All that is needed is to briefly press the button (51)
“Discharging“.
The battery is completely discharged and recharged
automatically.

Terex® All-Terrain Operation: Radio Remote Control (Optional) 17

Troubleshooting Servicing
First please check the functions using the cab or cable control. The radio system is largely maintenance!free. However,
the following points should be observed:
! Make sure that the STOP switch moves easily. Mortar
remnants and dirt can hinder activation of the switch or
render it impossible.
! Check the control lever’s bellows regularly to make sure
they are sealed. Change bellows early enough if cracks
start to appear as invading damp and dirt hinder the
function of the control lever.
! Charge and discharge the transmitter batteries regularly.
! Never “clean” the radio system with high!pressure cleaners
or with steam cleaners. If required, use a paintbrush of a
cloth.
! If electrical welding work is to be carried out on the crane:
! switch off the radio system
! remove the plug on the receiver.
Failure to carry out these safeguards will result in the
receiver electronics being destroyed.
If problems occur with the radio remote control, please contact
our service department.
Take even small faults in the radio remote control into
consideration! They can lead to serious malfunctions!
Only have defective radio systems repaired by a specialist!
Only use original spare parts of the manufacturer!

Terex® All-Terrain Operation: Radio Remote Control (Optional) 18