Sécurité GB

Safety rules
Maintenance and operator's manual
Chapter 3
Safety rules
C 64440-04/a Chapter 3 - Page 1

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

unless all the instructions contained in this manual have been
perfectly understood and remembered. Failure to follow these
instructions may result in serious accidents causing damage to
equipment and injury to personnel. Do not hesitate to contact
your local TEREX Dealer or Agent who is authorized to offer
formal training or can give sound advice.
Never drive this machine before you have read and fully
understood the instructions given in the OPERATOR'S MANUAL.
Any failure to strictly follow these instructions may cause
serious accidents.
THE OPERATOR'S MANUAL must always be left in the driver's

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

Safety rules
Majorities on the safety
Your safety and the safety of others around you depend upon the
correct use of the machine. Be sure that you know perfectly the
location and the use of all controls.
BEFORE USING THE MACHINE, TRY ALL CONTROLS ON A SAFE
AND FREE AREA WITH THE OUTRIGGERS FULY EXTENDED
In the handbook, the words "RIGHT" and "LEFT" indicate right side
and left side of the machine when viewed from the operator's seat.
Local safety rules must be observed
Keep a good fire extinguisher and a first aid kit with you at all times.
Know how to use both of these items.
Sparks can come from the exhaust pipe or from the electrical system.
DO not operate in closed areas where there are flammable materials,
dust or exhalations that can cause an explosion or fire. Severe
injury or death can be the result if you do not follow these
instructions.
Read and understand well all panels indicating dangers or cares to be

taken on the machine.
Be strict on maintenance instructions.
Be very careful if this is not the machine you normally operate.
Do not smoke while filling fuel tank, as fuel vapors are flammable.
Avoid accident due to improper clothing. Wear proper working clothes

that will not grapple on to parts, and if necessary, use safety
equipment like ear protectors, protection mask, and reflective clothes.
Wear safety helmet and glasses, as well as safety gloves and shoes,
as required by state law.

Safety rules
Make sure all persons are away from the machine before you start the
engine.
Access and cleanliness
Make sure the access area and operator's station are clear of oil,
foreign material or ice. Remove or attach all maintenance or personal
items. Failure to keep these areas clean and tidy can cause serious
accidents.
Always use your two hands to get on or off the machine, facing it.
Never jump off the machine.
Make sure the windows of your cab are clean. Make sure the
windshield wipers are operating correctly. Dirty windows can cause an
accident.
Stow away oily rags and other flammable materials in a safe place.
All measures should be taken to conserve the environment. Make

sure that all used oils and fluids are correctly retrieved and recycled.
Do not leave such products in incorrectly labeled, unsuitable or open
containers. Do not leave any puddles of fluid, of any type, on the
ground or on floors.
All areas neat to heat or sensitive sources such as exhaust lines, heat
engines, air filters, etc., must be kept perfectly clean. An accumulation
or storage of any inflammable element (leaves, twigs, paper, rags,
wood, etc.) present a definite fire risk.

Safety rules
All necessary precautions must be taken to preserve the environment.

In particular, recover and recycle all used fluids. Do not leave used
fluids in containers which are not suitably labeled, or in open
containers.
Do not leave any fluid puddles of any type on ground or floors.
Do not drink or inhale any used oils or fluids such as:
- oil
- grease
- antifreeze
- detergents
Only original containers should be used for storing or transporting oils
and fluids.
Do not use containers intended for food (water bottles, beer bottles,
etc...)

Safety rules
Driving
For your own security as well as for the life of the machine, before
starting up, inspect the machine carefully.
Look for loosen or missing screws, hydraulic or cooling liquid leaks.
Check condition of tires as well as the equipment and linkage.
A component or a circuit breakdown might cause an accident. Before

using the machine, check all oil and hydraulic oil levels. Check that all
plugs level gauges and covers are well fastened. Replace or repair
defective parts.
In case of a malfunction or missing part, shut off the machine and

carry out repair. In case of non respect of this rule, an accident may
occur.
Never use a machine with a faulty braking, steering or raising

action or with a leak. This rule applies to machines that have
been repaired or adjusted without having been checked or
approved by the workshop manager or other qualified person.
If the engine stops neither the power steering system nor the brakes
operate correctly, stop the machine as quickly as possible.
Do not use ether or any other unauthorized product to make engine

starting easier. If this rule is not strictly respected serious personnel
injury may occur.
Unless otherwise specified:

- lower the boom
- shut off the engine
- apply parking brake
- wedge the machine
before any maintenance operation or before leaving the machine at
the end of work.

Safety rules
The machine must be driven only by authorized operators.
Understand the limits of the machine. Keep the machine under control
at all times. DO NOT TRY TO DO TOO MUCH TOO FAST.
Be careful of the clearance of the machine when you are on the

limited space (bridges, electric cables, pipes in height, ground
resistance, etc...). Special precautions must be taken when working in
the vicinity of high voltage lines.
Refer to chapter Information to consult the characteristics of the
machine.
When driving the machine out of the normal working areas, make
yourself acquainted with it, as well as the area (weight, sizing, loads
per wheel, permissible slopes, ground resistance,...)
Refer to chapter Information to consult the characteristics of the
machine.
Always be watchful. Never allow anybody in the working area. You

must always know where they stand in the working zone.
It is forbidden to stand in the machine working area
Always operate the machine with closed doors as noise injury may
occur.
With the engine shut down, do not release parking brake or

emergency brake if machine is not blocked or secured in position.

Safety rules
When wind speed exceeds 12. 2 m/s (= force 6), stacking more than
two containers high is prohibited.
When wind speed exceeds 19. 8 m/s (= force 9), all use of the
machine is prohibited.
Before starting up the engine, tighten the parking brake and place the
gear shift lever and directional control levers in neutral position.
Before performing any night work, check that all machine lights and
indicators operate.
Machine controls and accessories must only be used when properly

positioned in driver's seat.
Non-observance of this rule can result in serious personal injury
Be particularly careful when working in dust, smoke or fog. Poor

visibility can cause accidents.
Avoid any abrupt movements with a load suspended on the machine..
Never leave the machine with a suspended load.
Never leave machine with a suspended load.
Before you put the machine on a trailer, remove all ice, oil or grease
from the trailer and its loading ramp.
Lifting capacity decreases as boom is extended

(see capacity table).
Avoid load swinging and abrupt maneuvers.
Before displacing a load, make sure that no one is under or near the
machine.

Safety rules
Maintenance
Do not try to carry out repairs that you are unable to complete.
Do not tolerate unauthorized people on the platform of the machine

while working.
Wear eye or face protection when you service the machine. Use a
hammer with a soft face, such as plastic, wood, brass or leather.
When you hit hardened tools or hardened metal surfaces. Any other
procedure can cause injury from flying chips.
Only run the engine in well ventilated areas.

(Danger of poisoning by exhaust gases).
Apply parking brake, lock wheels and place warning panels on control
handles while maintenance is carried out.
Always use proper tooling. Replace or repair worn or deteriorated

equipment.
Always check cooling circuit with engine shut off. Unscrew carefully
radiator plug to release pressure in the circuit. Steam may cause
burns.
Always carefully unscrew coolant and drain plugs, grease nipples and
pressure taps.
Rotating fan and belts: contact can injure. Keep clear.

Safety rules
When working with compressed air wear a facemask with headband

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

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

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

Safety rules
WARNING
Failure to comply with the instructions to torsionally control and
lock section 2 with the boom base will jeopardise the boom
structure and compromise machine operation.
The machine operator or maintenance manager must ensure that
the instructions regarding checks to the operating clearances on
the 2 boom sections and to the condition of the guide pads are
followed.
Consult the maintenance instructions regarding this point.
Failure to comply with these instructions may seriously affect
machine performance.
TEREX cannot be held responsible for damage caused by failure
to follow such measures.
ALWAYS follow the instructions in the maintenance section
regarding regular checks and adjustments.

Safety rules
Electricity
Before working on the electrical circuit, turn the battery switch to OFF
position or cut off the current with the ignition switch.
Know the electrical circuit before you connect or disconnect an

electrical component. A wrong connection can cause injury or
damage.
When you check the charge of the battery, never put a metal object
across the battery posts. The sparks can cause an explosion. Use a
voltmeter or a hydrometer to check the battery.
Never smoke during the checking of battery liquid levels. A battery

produces flammable gas.
The electrolyte is an acid solution which is dangerous to the skin and

the eyes.
Never top up batteries with acid. Always use distillated water.
When the battery electrolyte is frozen, the battery can explode if you
try to charge the battery or you try to jump start and run the engine. To
prevent the battery electrolyte from freezing try to keep the battery at
full charge. If you do not follow these instructions, you or others in the
area can be injured.
When using an external power unit to start the engine, connect ground
line last and disconnect it first to avoid sparks near the batteries as
they may burst.
With this method, connect the back-up battery earth cable to the
machine's starter motor earth terminal.
Never wear metal rings or metal watch bands. You can make a
ground for the electrical circuit and get a burn on your hand or arm.

Safety rules
Hydraulics
The hydraulic system operates at a very high pressure

The hydraulic oil, even from a very small leak, can go through your
skin and cause serious injury. When you check for leaks, do not use
your hands. Use a piece of wood or paper.
Before you disconnect any hydraulic lines or components make sure

there is no pressure in the circuit. When you connect the hydraulic
lines or components, make sure the connections are tight.
If the hydraulic oil goes through your skin, get a doctor immediately.
Hydraulic rams (especially derricking and telescoping rams) must be

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

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

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

Safety rules
Hydraulic oil is flammable. Never weld lines or pipes filled with oil.
Oil or hot parts might burn. Avoid any contact with the skin.
It is essential, after any work carried out on the hydraulic circuit,

components or fluid, to have the circuit bled by a specialist to remove
any air that may have entered the circuit by using, in particular, the
bleed screws on the hydraulic cylinders.
Effects of hydraulic oil expansion.
The temperature of the hydraulic oil may change significantly in line

with weather conditions and the work load undertaken by hydraulic
mechanisms.
These temperature variations then affect the expansion properties of
the hydraulic oil.
Special attention must therefore be given when making certain,
sometimes minute, modifications to the position of the boom and the
outrigger jacks.
The position of a crane with the boom hoisted and telescoped,

whether with or without a load, may alter over time if no derricking or
telescoping operation is performed.
These changes are caused by temperature variations in the hydraulic
oil.

Safety rules
Any significant change in position other than those caused by

changes in hydraulic oil temperature should be considered abnormal
when observed on equipment that is in good operational condition,
and only when observed on such equipment.

Safety rules
Any significant change in position other than those caused by

changes in hydraulic oil temperature should be considered abnormal
when observed on equipment that is in good operational condition,
and only when observed on such equipment.
When the boom is bearing a load after a hoisting maneuver, the
telescoping or derricking jacks may retract in proportion to the load
being lifted and to the extension of the jacks.
This phenomenon is related to the compressibility of the hydraulic oil
and is normal.
This phenomenon should cease once the hydraulic oil pressure stops
rising, and it is not normal for the jacks to continue to retract.
NOTA
You are strongly advised to always keep the motor running when
a Reach Stacker is carrying a container overhead in a hazardous
position. The operator must remain in the driver’s seat at all
times and continuously check for any sign of drift by the load or
the machine sections.

Safety rules
List of Adhesive Labels
The following adhesive labels concern safety precautions, they must

be strictly respected and immediately replaced whenever they are
damaged or become deteriorated..
The pictograms on the next few pages are positioned about the
machine. They show concisely the risk posed to the component of the
function that is indicated by the pictogram. For full details on the risk in
question, please read the recommendations given in the
“Recommendations”, “Safety” and “Operating” sections.
IMPORTANT
Labels attached to the vehicle must not be removed for any
reason.
Faded or damaged labels must be replaced.
1800x25 2100x25 1800x33
7,5 Bars 10 Bars

110 PSI 145 PSI
7,5 Bars
110 PSI

Safety rules
QUANTITY BY MACHINE
Mark PICTOGRAM AC35 AC55 STACKER STACKER
AC35 AC55
L L SERIES TFC SERIES TR
REF. TEREX ENS. WORK PICTOGRAMS V64440-21 U64440-20
A RISK OF FALL
QT.4 QT.4 QT.4 QT.4 QT.3 QT.3
RISK TO STUMBLE
B QT.1 QT.1 QT.1 QT.1 QT.2 QT.2
INFLAMMABLE
C MATERIAL
D CAUTION HAS
THE HEAD QT.2 QT.2 QT.2 QT.2
DANGER OF
E CRUSHING

Safety rules
QUANTITY BY MACHINE
AC35 AC55
5L L SERIES TFC SERIES TR
DANGER OF
F CRUSHING
RISK OF BURN
G QT.1 QT.1 QT.1 QT.1 QT.2 QT.2
Height ADHESIVE 160mm
H NOT TO PARK QT.2 QT.2 QT.2 QT.2 QT.1 QT.1

IN THE
WORKING AREA
width 75 mm
RISK OF CRUSHING
I QT.9 QT.9 QT.9 QT.9 QT.6 QT.6
Caution :grey bottom =

yellow

Safety rules
QUANTITY BY MACHINE
AC35 AC55
5L L SERIES TFC SERIES TR
RISK TO BE
SNATCHED
J QT.
QT. 4 4 QT. 4 QT. 4

yellow
COLLISION RISK
QT.
K QT. 7 7 QT. 7 QT. 7 QT. 7 QT. 7

yellow
Height. 50mm
L QT.3 QT.3 QT.3 QT.3 QT.3 QT.3
width 160 mm
ACCESSPROHIBITED
TO NOT
AUTHORIZED
PERSONS
M
PROHIBITION TO
STAY IN THE ZONE
N
QT.8 QT.8

Safety rules
Safety instructions with the tires
Before removing tires and in all cases :
Deflate the tyre imperatively.
EXAMINATION OF RIMS AND WHEELS
NB
Tires and wheels are vital machine safety components. Check
their condition at regular intervals.
Remember that any work on these parts must only be performed
by specialists.
1-GENERAL
With use, rim assemblies and wheels are subject to loads and forces,
which can lead to fatigue within the material of construction. This can
lead to cracking of the rim assembly or wheel assembly. If cracks are
left undetected, the rim may suffer a catastrophic failure with potential
risk to the health and safety of persons in the vicinity. Loss of tyre
pressure can be an indication of cracking.
2-IN-SERVICE INSPECTION AND EXAMINATION

Wheels and rim assemblies should be periodically examined at
intervals, which take into account work-site conditions and usage to
allow effective monitoring of rim conditions for safety purposes.
Where appropriate, accurate service hours should be made available
which can determine overall fatigue status.
NB
the tire pressure should be checked regularly, when cold, every
50 hours or every week.
DANGER – never drive the vehicle if a tire is under-inflated
For your own security or others, it is compulsory to check the
proper tightening of the wheels bolts using the machine wrench.
After 50 hours and every 100 hours of service.

Safety rules
3-CLEANING PRIOR TO TEST

All areas to be examined shall be free of foreign materials that would
interfere with the interpretation of results, e.g. scale, dirt, grease or
paint
4- INSPECTION REQUIREMENS
4-1 GENERAL
All components of the rim assembly shall be inspected for
mechanical damage. Additionally, each component of the rim
shall be inspected in accordance with Clauses 4.2 to 4.6.
4-2 LOCKRING
The lockring shall be visually inspected for wear, corrosion flat
spots, ovality and warping.
4-3 BEAD SEAT BAND.

4-3-1 Visual inspection.
The bead seat band shall be visually inspected for
cracks, wear and corrosion in the areas in contact
with the locking, flange, rim base or any weld.
4-3-2 Magnetic particle testing.

The area of the bead seat band with which the flange
is in contact, as well as any weld on the bead seat
band, should be subject to magnetic particle testing.
4-4 FLANGES.
The area of the flanges which are in contact with the bead
seat band or the rim base as well as any butt weld, or other
form of weld on the flange, shall be subjected to visual
inspection for wear, cracking, fretting, corrosion or damage

Safety rules
4-5 RIM BASE

4-5-1 Visual Inspection.
The area of the rim base in contact with any flange,
bead seat band or lockring shall be subjected to visual
inspection for wear, cracking, fretting, corrosion or
damage. In addition, the area across the inside
surface of the rim base shall be visually inspected for
corrosion
4-5-2 Magnetic particle testing.

The following sections of the rim base shall be
subjected
(a) The area in contact with the flanges and the back
section fillet radius.
(b) The area in contact with the lockring and any 0-
ring groove
(c) Any transverse weld
(d) Any circumferential weld (see clause 4.6)
4-5-3 Ultrasonic testing.

Where a weld defect is detected by magnetic particle
testing, the extent of the damage shall be
determined. Suitable methods include ultrasonic
testing or grinding out.
4-6 WHEEL DISC

In addition to the testing requirements of Clause4.5, the area
around wheel disc welds shall be subjected to magnetic
particle testing; mounting holes should be inspected for ovality
and circumferential cracking.

Safety rules
Croquis 1
In-Service Inspection of Demountable rims
Due to the special operating conditions for demountable rims, there is

a risk of excessive wear of the lockring groove in the gutter, the
lockring itself and the 45°face on the bead seat or loose flange. In
extreme circumstances this can lead to breakage of the gutter that has
potentially dangerous consequences. To minimize the risk of an
accident the following inspection procedure must be introduced
immediately for demountable wheels in addition to the existing
TELL TALE FOOTPRINT MARKFROM instructions.
ENDS OF THE LOCKRING
Croquis 2
Inspection Procedure
After demounting the tyre according to standard procedure, the

outside diameter of the gutter is to be carefully cleaned by wire
brushing and examined as follows:
-(1) See Sketch.1

If on the gutter outside diameter it is possible to locate the telltale foot
FOR 5 - PIECE WHEELS
D = 597.1mm MINIMUM print from the ends of the lockring-measure the depth of the wear at
this point using a straight edge and feeler gauge. If the wear exceeds
THE DIAMETER 'D' TO BE MEASURED -
ADJACENT TOTHE LOCKRING GROOVE 0.5mm, the wheel, the lockring and the bead seat or loose flange must
be discarded and replaced with new.
HIGH STRESS AREAS - HOW TO IDENTIFY DAMAGED RIMS
TYPES OF FAULT - CIRCUMFERENTIAL CRACKS,

FRETTING, CORROSION PITTING, -(2) See Sketch 2
DISTORTION, WEAR
If it is not possible to find this mark measure the diameter of the gutter
using a Pi tape. If the diameter is below the minimum specified, the
wheel, the lockring and the bead seat or loose flange must be
discarded.
IT IS RECOMMENDED THAT INSPECTION OF THESEAREAS

SHOULD BE CARRIED OUT DURING EACH TYRE CHANGE

Safety rules
Safety Precautions
Always exhaust all air from a single tyre and from both tyres of a dual
assembly prior to removing any rim components, or any wheel
components, such as nuts and rim clamps. A broken rim part under
pressure can blow apart and cause serious injury or death. Make sure
to remove the valve core to exhaust all air from the tyre. Check the
valve stem by running a piece of wire through the stem to make sure it
is not plugged. Foreign material may clog the valve stem during
deflation or ice may form as the air leaves the tyre, clogging the valve
and stem. Remove valve cores from both tyres of a dual assembly.
Start by loosening wheel nuts by two or three turns only.

Free the wheel rim in such a manner that the remaining nuts stop the
rim being ejected - avoid standing in front of the during removal.
When the rim is freed continue unscrewing the nuts
Never attempt to weld on an inflated tyre/rim assembly.
Check rim components periodically for fatigue cracks. Replace all

cracked, badly worn, damaged and severely rusted components.
Clean rims and repaint to stop detrimental effects of corrosion. Be

very careful to clean all dirt and rust from the lockring gutter. This is
important to secure the lockring in its proper position. A filter on the
air inflation equipment to remove the moisture from the airline
prevents a lot of corrosion. The filter should be checked periodically
to see that it is working properly.

Safety rules
Make sure correct parts are being assembled. Check your distributor
or the manufacturer if you have any doubts.
Double check to make sure all components are properly seated prior
to inflation.
Mixing parts of one manufacturer’s rims with those of another is

potentially dangerous. Always check manufacturer for approval.
Don’t overload or over-inflate rims. Check your rim manufacturer if

special operating conditions are required.
Don’t reinflate a tyre that has been run flat without first inspecting the
tyre, rim and wheel assembly. Double check the lockring for damage;
make sure that it is secure in the gutter before inflation.
Never run a vehicle on one tyre of a dual assembly. The carrying

capacity of the single tyre and rim is dangerously exceeded, and
operating a vehicle in this manner can result in damage to the rim.
Don’t be careless or take chances. If you are not sure about the
proper mating of rim and wheel parts, consult a wheel and rim expert.
Don’t use undersized rims. Use the right rims for the job.
Don’t seat rings by hammering while the tyre is inflated. Don’t

hammer on an inflated or partially inflated tyre/rim assembly.
Don’t inflate tyre before all side and lockrings are in place. Check
components for proper assembly again after approximately 5 PSI.

Safety rules
Don’t let anyone mount or demount tyres without proper training.
Never sit on or stand in front of a tyre and rim assembly that is being
inflated. Use a clip-on chuck and make sure inflation hose is long
enough to permit the person inflating the tyre to stand to the side of
the tyre, not in front or at the back of the tyre assembly.
Deflate the tire before trying to take stones off the tire surface.
Do not, under any circumstances, attempt to re-work, weld, heat or

braze any rim components that are cracked, broken or damaged.
Replace with new parts, or parts that are not cracked, broken, or
damaged and which are of the same size, type and make.
Inflate in a safety cage or use safety chains during inflation.
Regardless of how hard or firm the ground appears, put hardwood

blocks under the jack.
Block the tyre and wheel on the other side of the vehicle before you
place the jack in position; always crib up with blocks just in case the
jack may slip.
Remove the bead seat band slowly to prevent it from dropping off and
crushing your toes. Support the band on your thigh and roll it slowly to
the ground. This will protect your back and toes.

Safety rules
Demounting tools apply pressure to rim flanges to unseat tyre beads.

Keep your fingers clear. Slant demounting bead tool about 10°to keep
it firmly in place. If it slips off, it can fly with enough force to kill.
Always stand to one side when you apply hydraulic pressure.
When using a cable or chain sling, stand clear, it might snap and lash
out.
The condition of the tires must only be checked when no load is

attached. Always use an inflation cage when the wheel is not
attached to the vehicle.
IMPORTANT
In any case and during inflation, never stand in the way of all or
part of the wheel or the rim, in case it should fly free. When you
inflate a tire on a vehicle, stand to one side as indicated above.
Do not let anybody else stand directly in front of a wheel.
1800x25 2100x25 1800x33
7,5 Bars 10 Bars

110 PSI 145 PSI
7,5 Bars
110 PSI

Safety rules
Stacker operating conditions and

recommendations
General information
In all circumstances, the primary recommendation is prudence.
If the machine stays unused outside and with the piston rods
extended, all the rods must be greased to avoid corrosion.
General handling recommendations.
Containers are generally marked with their weight. Always verify that
the handling operation envisaged is compatible with the table of loads
of the machine.
The handling reaches indicated on the load capacity chart are the
distances measured between the spreader suspension vertical axis
and the vertical tangent of the front edge of the front wheels.
In order to maintain maximum safety, never lift loads exceeding the

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

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

Safety rules
To pick up a container place the machine as close to it as possible in

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

ground.
Never use the machine with safety devices shunted, or only under
very special conditions under the operator's responsibility.
If the machine has not been used for a long period, check correct
working order of the anti-tipping device by telescoping a container
barely off the ground until the handling functions are automatically cut.
Never stand under the spreader, especially if a load is suspended.
Spreader
When picking up a container always try to keep the longitudinal axis of

the machine as perpendicular as possible to that of the container.
To slew the spreader position in relation to the container, use the

hydraulic slewing control.

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

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

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

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

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

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

Safety rules
Driving the machine
When the machine is unlade, drive with the boom head over the front
axle, never over the rear of the machine.
Before travelling under load, position the container so that its

underside is slightly above the operator’s eyeline, and telescope in to
obtain the best possible load stability and to minimise the exertions
placed on the vehicle.
The load must be realigned centrally underneath the boom. Use the
side shift if necessary to prevent any twisting action or lateral effect on
the boom.
When transporting the load, it must be kept as close as possible to the

front axle (height and reach) or slightly forward to this position, never
further towards the rear. The container's position should also allow the
operator good visibility from the cab. The correct position is indicated
by a sticker inside the cab.
To ensure good visibility from the cab, avoid transporting the load
positioned in the field of vision.
In normal driving conditions use the middle pedal for braking. The left
hand pedal is only to be used for final 'inching' approach.
Braking reduces both longitudinal and lateral machine stability. Adapt

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

trajectory of the rear wheels when turning. Keep in mind that the
space occupied by the rear end of the machine during turning
manoeuvres is different than that of other vehicles. Keep a minimum
clearance of 50 cm between the counterweight and any obstacle.

Safety rules
Adjust speed according to worksite conditions: this is governed by

environmental and ground conditions, the height and size of the load
along with visibility. Avoid sudden, abrupt manoeuvres (taking bends,
braking and speed).
Safe operating practices for TEREX machine

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

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

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

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

well as the safe operating practices recommended here.

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

must refuse to operate when he knows it is unsafe and consult his
supervisor when safety is in doubt. He must read and fully understand
the Maintenance and Operator's Manual and make sure that the
machine is ready for initial start-up.
He must understand how to read the capacity charts and know that his
machine can safely lift each load before attempting to lift it.
He must read and understand the Operator's Manual and see that the
machine is in proper order before operating.
He must be alert, physically fit, and free from the influences of alcohol,
drugs, or medications that might affect his eyesight, hearing, or
reactions.
He must make sure that people, equipment, and material are kept out
of the work area. The area around the machine should be properly
barricaded.
When an operator's vision is blocked or when operating in hazardous

areas such as near power lines or around people, a signalman must
be used.
Because the operator is not in the best position to judge distances and
can not see all parts of the jobsite, a signalman may also be
necessary at other times. Operators must understand standard crane
signals and take signals only from designated signalmen.

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

efficient operation. Operators depend on designated signalmen to
assist them in making movements without endangering people or
property.
Signalmen must have a clear understanding of the work to be done so

that they can safely coordinate each job with operators and other crew
members.
Signalmen must place themselves where they can be clearly seen and
where they can safely observe the entire operation.
Standard crane signals must be used unless other methods of

signaling such as two way radios or flags have been agreed upon.
Signalmen must have good vision and sound judgment, know

standard crane signals and be able to give signals clearly. They must
have enough experience to be able to recognize hazards and signal
the operator to avoid them.
The driver's mate is the only person allowed to give instructions to the
driver.

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

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

diplomas requested by national legislation, physically fit and, if
required, licensed. Good vision is required as are good judgment,
coordination and mental ability. Any person who lacks any of these
qualities must not be allowed to operate a crane.
Any person who is associated with working on the crane, including

laborers and mechanics, must respect all safety signals and be aware
of their own safety as well as that of others. Crane personnel such as
mechanics or slingers are supposed to be aware of all special
procedures concerning their jobs on the machine.

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

organized. The person in charge must have a clear understanding of
the work to be done, consider all dangers on the jobsite, develop a
plan to do the job safely, and then explain the plan to all concerned.
Factors such as these should be considered :
-What crew members are needed and what responsibilities will they
be given ?
-How will the signalmen communicate with the operator ?
-What equipment is required to do the job safely ?
Is a machine the best equipment for the job ?
-How can the equipment be safely transported to the jobsite ?
-Are there gas lines, power lines or structures which must be moved
or avoided ?
-Is the surface strong enough to support the machine and load ?
-Are unusual weather conditions such as winds or extreme cold

expected ?
-What steps will be taken to keep unnecessary people and equipment

safely away from the work area ?

Safety rules
Operator's safety check.
The operator must make a safety check before starting to work each
day to see that the machine is in proper order. Some things to check
are :
-Check the machine log book to see that periodic maintenance and
inspections have been performed and all necessary repairs made.
-Check the operation of boom hoist limiter device, boom angle
indicator, reversing alarms, and other safety devices.
-Carefully inspect load bearing parts such as wire rope, (load lines,
boom hoist cable, suspension lines), boom, outriggers, spreader.etc.
According to the type of the used machine.
Be sure no unauthorized field modifications have been made, such as
added counterweights and booms that have been improperly repaired.
-Check for air and hydraulic oil leaks.
-After starting the engine, check all gauges for proper readings.
-Test all controls for proper operation.
-Check brakes and clutches.

Safety rules
Operating precautions.
1. Mistakes in calculating lifting capacity can cause accidents.
Several factors must be considered, including :
The reach is the distance from the wheels of the machine to the axis
of the spreader. Note that the boom bends, increasing reach, when
the load is lifted.
Trying to lift a load without knowing whether it is within the rated

capacity while expecting the crane to start to tip to warn of an overload
is very dangerous. Cranes may suddenly tip over or collapse if the
load is too heavy.
Always stay within rated capacity. The operator must reduce the load
under adverse field conditions until, in his judgment, the machine can
safely handle the lift.
Cranes may tip over or collapse if the operating surface cannot

support their weight.

Safety rules
Determine the load bearing capacity of the ground or other surfaces

on which machines will be operating. Be sure machines are
adequately supported. Avoid soft or unstable ground, sand, areas with
high water tables, and partially frozen ground. When machines are
working near trenches these should be shored or sloped to prevent
cave-ins or slides.
The lifting capacity of a machine is given for a maximum angle of 60°.

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

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

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

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

Safety rules
The machine runs on pneumatic tyres:

When a tire fitted mobile crane comes into contact with overhead
power lines, metal frame tires that have not been destroyed do not
retain either their insulation properties or, above all, their mechanical
resistance properties. Tire explosion, if not immediate, often happens
later after prolonged exposure to the sun.
The machine must not be approached until the air temperature in the
tires has dropped.
The tires must then be deflated and discarded once the machine is no
longer in contact with the power line.
WARNING - Proper work programming and serious checking ensure

greater protection than any other method. Insulated cages or proximity
detectors have limits and can fail without prior notice. Protective
cables and insulated cages only protect the machine and can become
conductors due to dust or water.
Proximity detectors can be influenced by different combinations of
power lines, by vehicle, material or machine movements, and other
parameters. Total dependence upon these systems can be dangerous
because the operator may think that he is protected when, in reality,
this is not the case.
In case of storms take the following precautions:
-if possible, set down the load and retract the boom.
-if you are surprised by a sudden storm, stop the engine and get down
from the machine.
-if lightning strikes the machine, check the general working order of
the crane before starting up.
You should always be aware of the local weather forecast.

Safety rules
(* ) Always check if there are any power lines in the area before
starting work. It is highly recommended to keep a distance of more
than 6m between any part of the machine and a power line. Always
stay as far as possible from power lines, NEVER violate minimum
distances.
Always respect these precautions if there are high tension lines in the
vicinity.
Informer the company responsible for the HT lines (E. D. F in France)

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

No set rules are to be followed, an analysis of the situation and its
risks is necessary on each occasion. The operator should be aware of
how to handle such a situation and preferably be trained for such an
event
The machine is in working order :
The operator must immediately move the machine away from the
power line or electrified equipment without getting out of the cab. The
machine is no longer in working order :

Safety rules
Without getting out of his cab the operator must inform all personnel in
the vicinity, by hand signals or verbally, that they must not approach
the machine. (Risk of electric arcing).
If the operator is absolutely obliged to leave the crane cab and get off
the machine he must do this by jumping so as never to be
simultaneously in contact with the machine and the ground.
Once on the ground he must move away from the machine :
(* ND 1879-147-92 INRS Direct either by jumping with feet joined
contact of machines with the air or by very small footsteps.
electric lines.)
Any new approach to the machine can only be made once that it has
been confirmed and verified that power has been effectively cut. This
must be done in conjunction with the local power company.
(verification effected in liaison with the electric power supplier).
8. The hoist rope may break if the load crashes against the boom
head, which could occur if it is not watched while the boom is being
lowered or telescoped. This procedure could bring the extension
backwards.
When reeving, make sure that the rope passes unhindered into the
lifting safety device counterweight.
Always check the gap between the hook and the boom head. The
hook should be lowered during telescoping actions to prevent this type
of incident. Check the limit switch system at regular intervals.

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

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

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

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

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

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

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

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

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

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

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

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

Safety rules
Make sure that each boom and extension tip is securely attached.
Never stand in the boom or underneath the boom or spreader while it
is being installed.
As with all heavy equipment, care must be taken when moving about,
both on or off the work site.
Pay attention to workers, high tension lines, awkward sections with

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

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

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

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

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

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

Safety rules
LOCK-OUT IN THE EVENT OF INTERFERENCE

BETWEEN THE CONTAINER AND THE FRAME :
If the container moves into a danger area too close to the machine,
the LMI will restrict the telescoping-in and derricking-down actions and
a message will be shown on the MDM screen. Telescope and raise
the boom.
Transport of containers on the terminal may only be effected

with the telescopic boom completely retracted and inclined at about
40° to 45°.
The speed of advance must be judged so that it is possible to stop
with no danger to any third party and without having recourse to
sudden braking.

FITTING THE TFC45 h/c STACKER FRAME ELECTRICAL COMPONENTS
C 64440-04/a
S19 Plaque arrière cabine
FP7 FP9
E287 PM5 PC4
E310
E311 PC3
E320
E290 E321 PC2
FP1 PM6 PC1
FP2
P3BV
P14
S60
M10
S157
S16
S175
S9
S14
S2
S69
DT6--- DT7
S98
S13
B137--- B14
BR
P28
PF3 S24
PFD
PM3
M11
Chapter 3 - Page 51
S25
P4
P2
PFG P1
S17
PF4
P29
PT1
PT2
S61
E13
S1
S99
S15
E220
P7BV
Safety rules
E227
PM1
S33 P9BV
P6BV PE1
PM4
E289
P8BV
E291 P5BV
B14 --- conditioning condenser PFD --- Front right spotlight
B137 --- Air--- conditioning pressure controller PFG --- Front left spotlight
BR --- Buzzer reverse gear PF3 --- Rear right light cluster
PF4 --- Rear left light cluster
C 64440-04/a
DT6 --- Sensor raised boom PM1 --- Parking brake safety sensor/APC200 info
DT7 --- Sensor boom between 25˚ and more PM3 --- Brake lights senso.
PM4 --- Front brakes oil pressure indicator sensor
E13 --- Braking system oil coolant flow solenoid. PM5 --- Derricking --- down pressure sensor.
E220 --- Engine ignition backup (accumulator load override) PM6 --- Derricking --- up pressure sensor.
E227 --- Parking brake desactivation solenoid PT1 --- Hydraulic oil coolant sensor
E287 --- Derricking --- down lock--- release solenoid PT2 --- Principal hydraulic oil filter clogged
E289 --- Parking brake desactivation solenoid
E290 --- Derricking --- down decompression solenoid S1 --- Main hydraulic oil filter clogged
E291 --- Derricking --- up decompression solenoid S2 --- Hydraulic oil temperature pressure switch
E310 --- Derricking --- down solenoid S9 --- Hydraulic oil level low (minimum)
E311 --- Derricking --- up solenoid. S13 --- Raising boom 50˚ sensor
E320 --- Telescoping --- in solenoid S14 --- Raising boom maxi. sensor
E321 --- Telescoping --- out solenoid S15 --- Front brake hydraulic oil filter clogged.
S16 --- Diesel fuel gauge
FP1 --- Protection fuse 50A. S17 --- Left--- side reversing light.
FP2 --- Protection fuse 50A. S19 --- Battery cut--- out
FP7 --- Protection fuse 100A. S24 --- Right--- side reversing light
FP9 --- Protection fuse 50A. S25 --- Anti--- tipping safety sensor
S33 --- Air filter clogged
M10 --- Batterey earth S60 --- Starter.
M11 --- Rear chassis earth S61 --- Alternator.
Chapter 3 - Page 52
S69 --- Oil clutch pressure
P1 --- Boom/frame connector S98 --- Chassis work light.
P2 --- Boom/frame connector S99 --- Chassis work light.
P4 --- Boom/frame connector S157 --- Engine ignition relay
P14 --- Electronic control unit Cummins engine S175 --- Air--- conditioning compressor
P28 --- Rear right beacon
P29 --- Rear left beacon
P3BV --- Gearbox connector
P5BV --- Drum speed sensor
P6BV --- Output speed sensor
P7BV --- Engine speed sensor
Safety rules
P8BV --- Turbine speed sensor

P9BV --- Gearbox temperature sensor
PC1 --- Chassis/cab connector
PC4 --- Chassis/cab connector .
PE1 --- Spreader flow sensor
FITTING THE TFC45 h/c TOP PICK SPREADER ELECTRICAL COMPONENTS
C 64440-04/a
DT19 DT15
DT13 --- Container RH locking sensor.
DT14 --- Container RH lock release sensor.
DT15 --- Container front RH position sensor E22
M3
P5P
DT16 --- Container rear RH position sensor
DT17 --- Container LH locking sensor DT14
DT18 --- Container LH lock release sensor. DT13
P1 E20
DT19 --- Container front LH position sensor. P5S P2
DT17 E21
DT20 --- Container rear LH position sensor. P7S
DT18
DT50 --- Extended beams deceleration sensor.
M2
P7P
E14 --- Beams telescoping --- out solenoid. DT50 M20 S2

S1
E15 --- Beams telescoping --- in solenoid. E19 E18 E23 P10
E25 E24
E16 --- Spreader LH travel solenoid. E17 E16
E17 --- Spreader RH travel solenoid. DT20 E15 E14 DT16
E18 --- Left tilt solenoid (TILT OPTION).
E19 --- Right tilt solenoid (TILT OPTION).
E20 --- Spreader LH slew solenoid.
E21 --- Spreader RH slew solenoid.
E22 --- Slew brake release solenoid.
E23 --- Beams telescoping --- out deceleration solenoid.
Chapter 3 - Page 53
E24 --- Container lock solenoid.
E25 --- Container lock release solenoid.
M2 --- Mobile beam weight.

M3 --- Mobile beam weight.
M20 --- Spreader weight.
P1 --- Boom/spreader connector.

P2 --- Boom/spreader connector.
P10 --- Boom head/spreader connector.
P5P --- Mobile cable--- --- --- mobile beam connector.
Safety rules
P7P --- Mobile cable--- --- --- mobile beam connector.

P5S --- Spreader--- --- --- mobile cable connector.
P7S --- Spreader--- --- --- mobile cable connector.
S1 --- LH work beam.

S2 --- RH work beam.
C 64440-04/a
FITTING THE TFC45 h/c STACKER 5H9’6” BOOM ELECTRICAL COMPONENTS
FSG --- Spreader LH signalling device.

FSD --- Spreader RH signalling device.
P123--- 1 --- Boom/spreader--- --- --- boom/frame connectors.

P123--- 2 --- Boom/spreader--- --- --- boom/frame connectors.
P4 --- Boom/spreader--- --- --- boom/frame connectors.
P10 --- Boom head/spreader connectors.
PH1D --- RH work beam connector

PH2D --- RH work beam connector.
PH1G --- LH work beam connector
PH2G --- LH work beam connector
E49 --- Spreader damper solenoid.

E50 --- Forward tilt solenoid.
E51 --- Backward tilt solenoid.
E54 --- Spreader horizontal levelling solenoid.
Chapter 3 - Page 54
E54 E51
PH1D
PH2D
FSD
E50
E49
P123--- 1 FSG P10 P4

Safety rules
P123--- 2
PH1G
PH2G
P123--- 2
P123--- 1
FITTING THE TFC45LShc STACKER FRAME ELECTRICAL COMPONENTS
C 64440-04/a
E286 S19 P321
PC4
P89
E287 FP7 FP9 PC3 DT6 P320
S250 PM5
PC2 DT7
DT9 E290 PC1 PM6
P88 FP1 P310
FP2 Rear plate cab.
P311
P3BV
P14
S60
M10
S16
S157
S9
S175
S2
S98
S69
B137--- B14
BR
P28
PF3
S26
S24
S26
PC4
PC3
PC2
Chapter 3 - Page 55
PC1
PM3 S25
M11
S17
PF4
S27
P29
PT1
PT2
S61
S1
E13
S99
E188
Safety rules
P7BV P4
S33 P9BV P3
E227
E288 P2
E220 S15
P6BV P1
PM4
PM1
E187
E289
PE2--- P199
PE1--- P198
DT5 PM3
P8BV
E291 P5BV
P78
B14 --- Air--- conditioning condenser.
B137 --- Air conditioning pressure switch. P8BV --- Turbine speed sensor.
BR --- Reversing buzzer. P9BV --- Transmission temperature sensor.
PC1 --- Frame/cab connector.
DT5 --- Outrigger pad top position sensor. PC2 --- Frame/cab connector.
C 64440-04/a
DT6 --- 48˚ boom elevation lock--- out sensor. PC3 --- Frame/cab connector.
DT7 --- 25˚ boom elevation lock--- out sensor when cab forward. PC4 --- Frame/cab connector.
DT9 --- Outrigger pad --- to--- ground contact sensor. PE1 --- Spreader displacement sensor.
PE2 --- Cab travel speed sensor.
E13 --- Braking system oil--- coolant flow--- rate solenoid. PF3 --- Rear RH light cluster.
E187 --- Cab forward travel solenoid. PF4 --- Rear LH light cluster.
E188 --- Cab reverse travel solenoid. PM1 --- Parking brake safety sensor/APC200 module info.
E220 --- Engine ignition assistance solenoid (accumulator load shunt). PM3 --- Stop light sensor.
E227 --- Parking brake deactivation solenoid. PM4 --- Front brake oil--- pressure indicator sensor.
E286 --- Derricking --- up regeneration trigger solenoid. PM5 --- Derricking --- down pressure sensor.
E287 --- Derricking --- down release solenoid. PM6 --- Derricking --- up pressure sensor.
E288 --- Derricking --- up regeneration trigger solenoid. PT1 --- Hydraulic oil cooler sensor.
E289 --- Derricking --- down release solenoid. PT2 --- Hydraulic oil cooler sensor.
E290 --- Derricking --- down decompression solenoid S1 --- Blockage on main hydraulic oil filter.
E291 --- Derricking --- up decompression solenoid. S2 --- Hydraulic oil temperature switch.
S9 --- Hydraulic oil level at minimum.
FP1 --- 50A safety fuse. S15 --- Blockage on front brake hydraulic oil filter.
FP2 --- 50A safety fuse. S16 --- Diesel gauge.
FP7 --- 100A safety fuse. S17 --- Left reversing light.
FP9 --- 50A safety fuse. S19 --- Battery disconnector.
S24 --- Right reversing light.
P1 --- Frame/boom connector. S25 --- Anti--- tipping sensor.
Chapter 3 - Page 56
P2 --- Frame/boom connector. S26 --- Right front headlight.
P3 --- Frame/boom connector (optional ELME 857 spreader). S27 --- Left front headlight.
P4 --- Frame/boom connector. S33 --- Blocked air filter.
P14 --- Cummins engine electronics unit. S60 --- Starter.
P28 --- Rear RH rotating beacon. S61 --- Alternator.
P29 --- Rear LH rotating beacon. S69 --- Clutch oil pressure.
P78 --- LH lifting cylinder large chamber pressure sensor. S98 --- Frame work light.
P88 --- RH lifting cylinder large chamber pressure sensor. S99 --- Frame work light.
P89 --- RH lifting cylinder small chamber pressure sensor. S157 --- Engine starting relay.
P198 --- Outrigger downstroke sensor. S175 --- Air--- conditioning compressor.
P199 --- Outrigger upstroke sensor. S250 --- Cab swept--- back position sensor.
Safety rules
P310 --- Derricking --- down sensor.

P311 --- Derricking --- up sensor. M10 --- Battery earth.
P320 --- Telescoping --- in sensor. M11 --- Rear frame earth.
P321 --- Telescoping --- out sensor.
P3BV --- Transmission connector.
P5BV --- Drum speed sensor.
P6BV --- Output speed sensor.
P7BV --- Engine speed sensor.
FITTING THE TFC45LShc TOP PICK SPREADER ELECTRICAL COMPONENTS
C 64440-04/a
DT13 --- Container RH locking sensor.
DT14 --- Container RH lock release sensor.
DT15 --- Container front right position sensor.
DT16 --- Container rear right position sensor.
DT17 --- Container LH locking sensor.
DT18 --- Container LH lock release sensor.
DT19 --- Container front left position sensor.
DT20 --- Container rear left position sensor.
DT21 --- Spreader beams 30’ position sensor. DT19 DT15
DT50 --- Extended beams deceleration sensor.
E14 --- Beams telescoping --- out solenoid.

E22
E15 --- Beams telescoping --- in solenoid.
M3
P5P
E16 --- Spreader left--- travel solenoid.
E17 --- Spreader right--- travel solenoid. DT14
E18 --- Left tilt solenoid (TILT OPTION). DT13
P1 E20
E19 --- Right tilt solenoid (TILT OPTION). P2
P5S E21
E20 --- Spreader left--- slew solenoid. DT17 P7S
E21 --- Spreader right--- slew solenoid. DT18
E22 --- Slew brake release solenoid.
M2
P7P
E23 --- Beams telescoping --- out deceleration solenoid. S1
Chapter 3 - Page 57
E24 --- Container locking solenoid. DT21--- DT50 M20 S2
E25 --- Container lock--- release solenoid. E23 P10
E19 E18
E25 E24
E17 E16
M2 --- Mobile beam earth. E15 E14
DT20 DT16
M3 --- Mobile beam earth.
M20 --- Spreader earth.
P1 --- Beam/spreader connector.

P2 --- Beam/spreader connector.
P10 --- Boom tip/spreader connector.
P5P --- Mobile cable--- mobile beam connector.
P7P --- Mobile cable--- mobile beam connector.
Safety rules
P5S --- Spreader--- mobile cable connector.

P7S --- Spreader--- mobile cable connector.
S1 --- LH work light.

S2 --- RH work light.
FITTING THE TFC45LShc STACKER 5H9’6” BOOM ELECTRICAL COMPONENTS
DT8 --- Retracted --- boom position sensor.
C 64440-04/a
FSG --- Spreader LH signalling device.
FSD --- Spreader RH signalling device.
P123--- 1 --- Boom/spreader--- boom/frame connectors.

P123--- 2 --- Boom/spreader--- boom/frame connectors.
P123--- 3 --- Boom/spreader--- boom/frame connectors (ELME 857 spreader option).
P4 --- Boom/spreader--- boom/frame connectors.
P10 --- Boom tip/spreader connectors.
PH1D --- RH work light connector.
PH2D --- RH work light connector.
PH1G --- LH work light connector.

PH2G --- LH work light connector.
E49 --- Spreader damper solenoid.

E50 --- Forward tilt solenoid.
E51 --- Backward tilt solenoid.
E54 --- Spreader horizontal position solenoid.
E285 --- Telescoping --- out regeneration trigger solenoid.
S128 --- Boom length/angle winder.
Chapter 3 - Page 58
E54
E51
E285
PH1D
FSD PH2D
S128
E50
E49
Safety rules
P10 P4
P123--- 1 FSG
P123--- 3
PH1G
PH2G
P123--- 2 P123--- 2
P123--- 3 P123--- 1
DT8
Safety rules
Check on welds.
A visual examination of all the points marked by an arrow on the

following views must be carried out in order to detect any cracking or
beginnings of cracks which could occur either through defective
realization or through usage not in compliance with our
recommendations.
Any anomaly must be repaired by qualified staff and recognized by

TEREX TEREX before using the device again.
A follow-up of checks and possible reworks must be established

through the examinations and kept as justification of the crane
condition.
Periodicity : A follow-up of checks and possible reworks must be

established through the examinations and kept as justification of the
crane condition.
You are advised to carry out this type of check 500 hours after the
machine is commissioned and every 2,000 hours thereafter. However,
checks must be made at more regular intervals when the machine is
used for intensive and repetitive work (e.g. every 500 hours when
handling concrete skips).
In addition, checks must be made each time an unusual noise such as
a bang or explosion is heard during a lifting manoeuvre.

Safety rules

Safety rules

Safety rules

Safety rules

Safety rules

Safety rules

Safety rules

Safety rules

Safety rules

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Safety rules

Maintenance and operator's manual

C 64440-04/a Chapter 3 - Page 1

Never drive the machine, or let it be driven by third parties,

THE OPERATOR'S MANUAL must always be left in the driver's

C 64440-04/a Chapter 3 - Page 2

Majorities on the safety

Local safety rules must be observed

Read and understand well all panels indicating dangers or cares to be

Be very careful if this is not the machine you normally operate.

Avoid accident due to improper clothing. Wear proper working clothes

C 64440-04/a Chapter 3 - Page 3

Access and cleanliness

Never jump off the machine.

All measures should be taken to conserve the environment. Make

C 64440-04/a Chapter 3 - Page 4

All necessary precautions must be taken to preserve the environment.

C 64440-04/a Chapter 3 - Page 5

A component or a circuit breakdown might cause an accident. Before

In case of a malfunction or missing part, shut off the machine and

Never use a machine with a faulty braking, steering or raising

Do not use ether or any other unauthorized product to make engine

Unless otherwise specified:

C 64440-04/a Chapter 3 - Page 6

The machine must be driven only by authorized operators.

Be careful of the clearance of the machine when you are on the

Always be watchful. Never allow anybody in the working area. You

It is forbidden to stand in the machine working area

With the engine shut down, do not release parking brake or

C 64440-04/a Chapter 3 - Page 7

Machine controls and accessories must only be used when properly

Be particularly careful when working in dust, smoke or fog. Poor

Avoid any abrupt movements with a load suspended on the machine..

Never leave the machine with a suspended load.

Never leave machine with a suspended load.

Lifting capacity decreases as boom is extended

Avoid load swinging and abrupt maneuvers.

C 64440-04/a Chapter 3 - Page 8

Do not tolerate unauthorized people on the platform of the machine

Only run the engine in well ventilated areas.

Always use proper tooling. Replace or repair worn or deteriorated

Rotating fan and belts: contact can injure. Keep clear.

C 64440-04/a Chapter 3 - Page 9

When working with compressed air wear a facemask with headband

Be careful when using cleaning fluids.

Note: Repairs are best left to specialists. Do not hesitate to

Arc welding on the machine can harm mechanical, electrical or

C 64440-04/a Chapter 3 - Page 10

C 64440-04/a Chapter 3 - Page 11

Know the electrical circuit before you connect or disconnect an

Never smoke during the checking of battery liquid levels. A battery

The electrolyte is an acid solution which is dangerous to the skin and

Never top up batteries with acid. Always use distillated water.

C 64440-04/a Chapter 3 - Page 12

The hydraulic system operates at a very high pressure

Before you disconnect any hydraulic lines or components make sure

Hydraulic rams (especially derricking and telescoping rams) must be

The spreader must also be supported and in a horizontal position

On any circuits using hydraulic or pneumatic reservoir bottles (e. g.

C 64440-04/a Chapter 3 - Page 13