TEREX AERIALS OPERATOR’S MANUAL ELF-PROPELLED ARTICULATING BOOM LIF MODEL TA33 OPERATION AND OPERATOR MAINTENANCE MANUAL FOR PARTS OR SERVICE Terex Aerials ‘Terex Aerials: ‘Terex Aerials: 10600 W. Brown Deer Road 106 12th Street S. E. Courtstown Industrial Park. 224 Waverly, IA 50677 Little Island, Co. : Cork, Ireland Telephone: (414) 362-9300 Telephone: (919) 352-9920 Telephone: (353) 21-353011 Facsimile: (414) 355-0832 Facsimile: (319) 352-5727 Facsimile: (353) 21-353368 Preliminary Issued: ‘August 97 PIN 17319TEREX AERIALS OPERATOR’S MANUAL Table of Contents AWARNING THE OPERATOR MUST READ AND UNDERSTAND ALL OF THE INSTRUCTIONS IN THIS MANUAL BEFORE OPERATING THE AERIAL LIFT. Description Section No. Introduction .. Safety Rules ..... Specifications Controls and Instruments ..... Before Operation Check .. .5 Operation... . 6 Unloading ... .7 Loading... 8 Maintenance .. Emergency Procedures... Index Issued: Jul‘97 Page i TAS3TEREX AERIALS OPERATOR’S MANUAL Introduction Owners, Users and Operators: Terex Aerials appreciates your choice of our aerial lift for your application. Our number one priority is user safety, which is best achieved by our joint efforts. We feel that you can make a major contribution to safety if you as the equipment user and operator: 1. Comply with OSHA, Federal, State and Local Regulations. 2. Read, understand and follow the instructions in this and other manuals supplied with this machine. 3, Use good, safe work practices in a common sense way. 4. Have only trained operators - directed by informed and knowledgeable supervi- sion - running the machine, If there is anything in this manual that is net clear or which you believe should be added, please send your comments to the Technical Publications Department, Terex Aerials, 10600 West Brown Deer Rd., Milwaukee, WI, 53224 or call (414) 355-0802. To help you recognize important safety information, we have identified warnings and instruc- tions that directly impact on safety with following signals: AWARNING A CAUTION THESE SYMBOLS MEAN YOUR SAFETY IS INVOLVED! SEE NEXT PAGE FOR SPECIFIC INFORMATION. READ, UNDERSTAND AND FOLLOW ALL DANGER, WARNING AND CAUTION DECALS ONYOUR MACHINE. Issued: Jul‘97 Page 1-1 TA33TEREX AERIALS OPERATOR’S MANUAL Introduction ANGER "DANGER" INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY. THIS SIGNAL WORD IS LIMITED TO THE MOST EXTREME. SITUATIONS. AWARNING "WARNING" INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY. A CAUTION “Caution” indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It is also used to alert against unsafe practices, and for property-damage-only situ tions. One final note: The best method to protect yourself and others from injury or death is to use common sense. If you are unsure of any operation, don't start until you are satisfied that itis safe to proceed and have discussed the situation with your supervisor. Thank you! TA33 Page 1-2 Issued: Jul‘97TEREX AERIALS OPERATOR’S MANUAL Safety Section 2 Description Safety Training and Knowledge ..... To Prevent Tip-over Slip and Fall Prevention ........ General Information...... Operation in the Vicinity of Electrical Conductors Issued: Jul‘97 Page 2-1 TA33TEREX AERIALS OPERATOR'S MANUAL Safety AWARNING IN ADDITION TO THE SPECIFIC MAINTENANCE AND OPERATING INSTRUCTIONS IN THIS MANUAL, THE OPERATOR MUST READ AND UNDERSTAND ALL INSTRUCTIONS IN THE INTRODUCTION, AND IN THE FOLLOWING SAFETY RULES SECTION. & Training and Knowledge Do not operate this aerial ft until you have been trained in its operation. This equip- ment may only be operated by trained personnel, who have demonstrated their abil- ity to do so safely. 2. Do not operate this aerial lift until you have read and understood the Operator's Manual, EMI Safety Manual, and Manuel of Responsibilities supplied with the aerial lift. 3. Know OSHA, Federal, State and local regulations applicable to your job. 4, Read and understand all decals and warnings on your aerial lft. & To Prevent Tip-over 1. Do not exceed the load capacity of the aerial lift. The load capacity includes the combined weight of personnel, tools, fixtures, accessories, etc 2. Do not exceed the maximum number of personnel allowed on the platform. This information is shown on a platform decal, and can be found in the “Specifications” Section of this manual. 3. Check the load capacity of floors, ramps and bridges before driving or operating the aerial lift on them. 4, Do not alter, disconnect or override any interlocks or other safety devices. 5. Do not operate this aerial lift outdoors in high wind situations. TASS Page 2-2 Issued: Jul ‘97TEREX AERIALS OPERATOR'S MANUAL 10. 11. 12. 13. 14. Safety & To Prevent Tip-over (Continued) Do not replace batteries with those of lesser weight (see “Specifications”). Check clearances overhead, around and below the aerial lift before: moving the boom up, down, in or out; tilting or rotating the platform; rotating the turret (super- structure), or traveling to prevent contact with obstacles. Do not travel on slopes (grades) and ramps without first reading “Traveling on Pre- pared Grades and Ramps’, later in this manual. This aerial liftis limited in the grades it can safely travel. Before and during traveling: ‘A. Look in the direction of travel. B. Avoid obstacles, bumps and potholes. C. Maintain safe distance from all overhead objects. D. Use a lookout if necessary! Do not raise the platform while positioned on trucks, trailers, railway cars, floating vessels, scaffolds, forklift trucks or similar equipment. Do not operate this aerial lift with wheels “cribbed” or positioned on blocks. With the platform swung away from the stowed position, use caution when se- lecting travel or steering direction. Travel and steer direction will be opposite switch or lever movement. Refer to the directional arrow decals on the undercarriage of the machine for travel orientation, Care should be taken to keep electric cords, hoses, cables, ropes, etc. from becom- ing entangled in the aerial lift. Limit travel speed to existing conditions. Do not use high speeds when maneu- vering or traveling in reverse. Issued: Jul ‘97 Page 2-3 TA33TEREX AERIALS OPERATOR’S MANUAL 15. 16. 17. 18. 10. Safety & To Prevent Tip-over (Continued) Do not tow this aerial lift. It is not equipped with a towing package! Always operate the controls in a smooth, steady manner. Do not exceed the maximum platform horizontal pull of 100 pounds (45.4 kg). Do not use the boom or platform as a crane to lift oversized or hanging loads. A Slip and Fall Protection Each person in the aerial platform must wear fall protection at all times. Do not attach fall protection devices to an adjacent structure while on the platform. Do not use planks, ladders, scaffolding or any other device on the platform to extend your reach. Always keep both feet on the platform floor while traveling and working with the aerial lift. Do not lean over or stand on platform guard railings. Keep platform, steps and shoes free from oil, mud, grease and other slippery sub- stances. In cold weather, clear snow ard ice from platform and steps. Make sure the platform guard rails are not damaged and the entry gate is closed after entering the platform. Do not attempt to climb down the boom assembly if the machine fails while the operator's platform is raised. Do not operate this machine while under the influence of any drugs or alcohol. Do not work on the platform if you are bothered by heights, seizures or dizzy spells. ‘Actuation of the red “Emergency Stop” switch will apply brakes immediately, causing the platform to jerk as the machine comes to a sudden stop. Brace yourself. TA33 Page 2-4 Issued: Jul ‘97TEREX AERIALS OPERATOR’S MANUAL 10. 1. 12. 13. 14, Safety Ay General Information Do not operate the aerial lft until it has been properly inspected, maintained and ser- viced. Any problems or malfunctions should be reported immediately to your supervi- ‘sor, and operations stopped until corrected. See the “Before Operation” section in this manual for decal listing, and replace those that are missing or illegible. Always wear approved headgear, eye protection, foot protection and fall-protection. Secure all tools and other materials in the platform to prevent them from accidentally falling or being knocked from the platform. When other vehicles or moving equipment are present, comply with all local ordi- nances, safety rules and warning rules for the workplace. Do not allow ground personnel around or under the raised platform. Do not allow ground personnel to tamper with, service or operate the machine using the ground controls while anyone is in the platform, except in an emergency. Do not use the aerial lit for horsepley, stunt driving or recreational use. Report any misuse of equipment to the appropriate personnel. Do not use the aerial lft outdoors in electrical storms. Do not block the foot switch or any function control in the operating position. Do not attempt to open any hydraulic line or component without first relieving all system pressures and shutting off fluid flow from the tank. Always attach the aerial lft to a winch when loading to or unloading from a transporting vehicle. Whenever releasing the brakes, ensure that the machine cannot roll. When transporting the machine, do not tie the platform or boom to the transporting vehicle in any way. Issued: Jul ‘97 Page 2-5 TA33TEREX AERIALS OPERATOR'S MANUAL 15. 16. 17. 18. 19. 20, at. Safety A General Information (Continued) Do not raise, lower, extend, retract, tilt or rotate the platform into stationary objects, as this will cause damage to mechanical anc hydraulic components. Do not use platform or boom functions to push or tow the aerial lift or another vehicle. Avoid sudden braking or steering, go slowly and leave more maneuvering room during cold weather operation until the aerial lif has warmed up. Immediately report any erratic noises, vibrations or malfunctions of the machine to appropriate personnel. Machine shall be removed from service until diagnosis and any necessary repairs have been completed. When leaving the aerial lift, lower platform to “full down and in” position and remove key from ground control to prevent unauthorized use. Itis not possible for us to foresee every situation that could arise during operation of this aerial lit. Even if we do not state specifically that a particular action should not be taken, that does not mean that itis safe to do so. Personal injury or damage to equip- ment may result. Use common sense! If in doubt, contact Terex Customer Service. Battery Care and Use: ‘A. Do not “jump start’ any other vehicle with your aerial lift's batteries. B. Batteries must be charged in a well-ventilated area free of flames, sparks or other such hazards. The vapors can explode if exposed to flames or sparks. 4 CAUTION Battery acid can cause serious burns. It acid comes in contact with skin or eyes, IMMEDIATELY FLUSH WITH WATER. SEEK MEDICAL ATTENTION. C. Do not use the aerial lift as a welding ground. D. Disconnect battery leads before performing any welding operations on the lit. TA33 Page 2-6 Issued: Jul‘97TEREX AERIALS OPERATOR’S MANUAL Safety A Operation in the Vicinity of Electrical Conductors If the platform, supporting structure or any other conductive part of the aerial lift contacts a non-insulated electrical conductor, the result may be SERIOUS INJURY OR DEATH for persons on or near the aerial lft. You, the owner of the electrical conductor and the electric utility must jointly deter- mine the specific procedure to complete the job safely. Always verify that the electric utility has been consulted before beginning work. Except where electrical distribution and transmission lines have been de-energized and visible ground or effective barriers have been erected to prevent physical and arcing contact with the conductors, the following provisions shall be met: A. Over lines, the operation of the aerial lift over electrical conductors is prohib- ited. B. No part of the aerial lift, tools, equipment or personnel, during operation, shall come closer than the distance shown in the table below. Voltage Range Minimum Safe Clearance (Phase to Phase) Feet Meters 0 to 300 Volts AVOID CONTACT Over 300 V TO 50 kV 10 3.05 Over 50 KV TO 200 kV 15 4.60 Over 200 kV TO 350 kV 20 6.10 Over 350 kV TO 500 kV 25 7.62 Over 500 kV TO 750 kV 35 10.67 Over 750 kV TO 1000 KV 45 13.72 ‘One foot (30.5 cm) additional clearance is required for every additional 30,000 volts. Issued: Jul‘97 Page 2-7 TA33TEREX AERIALS OPERATOR’S MANUAL Safety A Operation in the Vicinity of Electrical Conductors (Continued) 5. You must allow for platform sway, rock or sag, and electrical line movement. 6. This aerial lift is not insulated, and does not provide protection from contact with or proximity to electrically charged conductor. 1. If el 2. If If Contact is Made operating from the platform, attempt to move the aerial lift from contact with the lectrical conductor. the aerial lift cannot be removed from contact, the following precautions should be taken to avoid possible ELECTROCUTION to yourself and ground personnel: A B. Do not attempt to operate the aerial lift from the ground control. If you can leave the aerial lift you must jump off the aerial lift and hop away, keeping your feet together as ground will be energized. Normal walking or run- ning will result in possible ELECTROCUTION, INJURY OR DEATH. Warn personnel to stay well away from the aerial lift as contact with it or the ground in the vicinity will result in possible ELECTROCUTION, INJURY OR DEATH. While on the aerial lift, do not contact poles or other structures. Such contact will provide a path to ground, leading to possible ELECTROCUTION, INJURY OR DEATH. A CAUTION You must read the complete manual before proceeding with the op- eration or unloading of the aerial lift. TA33 Page 2-8 Issued: Jul‘97@ TEREX AERIALS OPERATOR’S MANUAL Specifications Description Machine Specifications... Range Diagram Gradability (on Hard Surface) ...... General Dimensions . Section 3 Issued: Jul ‘97 Page 3-1 TASSTEREX AERIALS OPERATOR’S MANUAL Specifications Machine Specifications Model TA33 Boom Lift * Working Height Platform Height .. Horizontal Reach . Stowed Height Stowed Length Platform Capacity (Unrestricted) .. Rated Number of Occupants in Platform Platform Dimensions Width .. Wheelbase .. Inside Turning Radius... Outside Turning Radius Ground Clearance Gross Vehicle Weight (Approx.) Superstructure Rotation Travel Speed-Platform Stowed . Travel Speed-Platform Elevated Gradeability (on hard surface Tires Hydraulic Fluid Capacity Hydraulic Operating Pressure Hydraulic Pump Output 38 ft 10 in. (11.84 m) 2 ft 10 in. (10.00 m) 1 ft 0 in. (6.40 m) ft 6 in. (1.97 m) 3 ft 2 in. (4.00 m) . 500 Ibs. (225 kg) .2 . 30 in, x 50 in. (0.76 mx 1.27 m) 4 ft 11 in. (1.50 m) 63 in. (1.60 m) . 4 ft in. (1.30 m) . 9 ft 3 in. (2.82 m) 5.5 in. (14 om) . 8,530 Ibs. (3,879 kg) . 360°, non-continuous 2.5 mph (4.0 kph) . 0.5 mph (0.8 kph) . 14° (25%) 23 x 10.5 x 12 (solid) . 2.5 gal. (9.0 liters) . 2175 psi (150 bar) (153 kg-cm’) . 2.1 gpm (8 Lpm) Power System (Electric). . Eight 6-Volt batteries (24 VDC) @ 217 amp/ hr Battery Weight (wet, each) +» 62 Ibs. (28 kg) Battery Charger... 40 amp, automatic Electric Pump Motor. . 4.03 hp (3.0 kW) WARNING * CLEARANCE MUST BE ALLOWED FOR BODY PARTS OF PER- SONNEL IN PLATFORM ATTHIS AND ALL OTHER WORK HEIGHTS. Issued: Jul ‘97 Page 3-3, TAS3TEREX AERIALS OPERATOR’S MANUAL Specifications Range Diagram, Model TA33 Boom Lift PLATFORM REACH IN METERS, 765 43 21012 3 4 5 6 7 PLATFORM HEIGHT IN METERS. 12 VS 40 1 35 10 i 9 30 i 8 z 25 ; & s+ a 5 = |— 15S 4 ic 5 3 10 @ 2 (es 5 ; 0 0 25 20 15 10 5 0 5 10 15 20 25 PLATFORM REACH IN FEET ‘Ae #236 9300 (C) TA33 Page 3-4 Issued: Jul ‘97TEREX AERIALS OPERATOR’S MANUAL Specifications Gradability (on Hard Surface), Model TA33 Boom Lift ‘% Grade = (Vertical Rise/ Horizontal Distance) x 100 Example: 30" Rise over 10 ft (120") = .25 = 25% DECREE sy Issued: Jul ‘97 Page 3-5 TA33TEREX AERIALS OPERATOR'S MANUAL Specifications General Dimensions, Model TA33 Boom Lift G vacine G retaton ae G tino — | 4°11" (1.50 m) | / ‘Sian > Se 6'6°(1.97 m) Stowed Height Rear Axle 63" (1.60 m) Wheelbase 5.5" (140m) Ground Clearance ne (Stee) ja Ground tine | (Steer) 13°2" (4.00 m) a Stowed Length TA33 Page 3-6 Issued: Jul ‘97TEREX AERIALS OPERATOR’S MANUAL Controls and Instruments Section 4 Description Controls and Instruments Aerial Control Station Aerial Control Station Controls Identification Aerial Control Station Controls Description .. Additional Controls and Warnings Description Ground Control Station Ground Control Station Controls Identification Ground Control Station Controls Description Additional Ground Controls Description .... Controls and Instruments This section is intended to familiarize the operator with the controls and instruments provided for the operation of this machine. It should be emphasized, however, that merely knowing the controls is inadequate preparation for operating boom lift aerial platforms. Do not attempt to operate the machine until all sections of this manual have been read and understood. Issued: Jul‘97 Page 4-1 TA33TEREX AERIALS OPERATOR'S MANUAL Controls and Instruments Aerial Control Station Paco a Stowe Poston artxm Opposite ‘Showed Poston TA33 Page 4-2 Issued: Jul‘97TEREX AERIALS OPERATOR’S MANUAL Controls and Instruments Aerial Control Station Controls Identification KeyNo. Control Descripti 1. Emergency Stop Switch 2. Foot Operated Switch 3. Drive Control Lever 4. Steer Switch 5 Upper Boom Up/ Down and Turret (Superstructure) Rotate Control Lever 6. Upper Boom Telescope In/ Out Control Lever 7. Riser (Lower Boom) Up/ Down Control Lever 8. Platform Tilt Switch 9. Platform Rotate Switch (Option) 10. Battery Condition and Hour Meter "4 Horn Button Issued: Jul‘97 Page 4-3 TA33TEREX AERIALS OPERATOR’S MANUAL Controls and Instruments Aerial Control Station Controls Description 1. Emergency Stop Switch. Push “in” to 1 stop all functions in an emergency. Pull out or rotate clockwise (depending on style used) to release switch and restore all functions. The Emergency Stop switches at both the Aerial and Ground Control stations must be released to allow any functions to operate. 2. Foot Operated Switch. Mounted on platform floor. Step down on pedal to enable drive and lift controls. Release pedal to halt all drive and lft functions from the platform. Do not operate this switch other than by stepping down on the pedal with your foot. TA33 Page 4-4 Issued: Jul‘97TEREX AERIALS OPERATOR’S MANUAL Controls and Instruments Aerial Control Station Controls Description (Continued) 3. Drive Control Lever. Push lever for- ward to drive aerial lift forward. Pull lever back to drive aerial lift in reverse. Vary the drive speed from zero to maxi- mum by gradually moving the handle away from the center “off” position. n Release lever to stop movement. Lever is spring centered to the “off” position. dq (((E))} } Hp AWARNING WITH THE PLATFORM SWUNG OVER THE STEERING WHEELS, USE CAU- 3 TION WHEN SELECTING THE TRAVEL AND STEER DIRECTION. TRAVEL AND STEER DIRECTION WILL BE OPPOSITE TO DRIVE CON- TROL LEVER MOVEMENT AND STEER SWITCH SELECTION. 4, Steer Switch. On end of drive control lever. Press and hold down the left side of the switch to turn steer wheels to the left, and the right side to turn right. Release switch to hold steer angle. ‘Switch will return to the “off” position. Steering is not self-centering. Press and hold the switch in the opposite direction to straighten wheels. Issued: Jul ‘97 Page 4-5 TA33TEREX AERIALS OPERATOR’S MANUAL Controls and Instruments Aerial Control Station Controls Description (Continued) 5. Upper Boom Up/ Down and Turret (Superstructure) Rotate Control Lever. Upper Boom Up/ Down Control. Push lever forward (#3, see diagram) to move the upper boom section “up”. Pull back (#4) to move the upper boom “down”. Vary boom movement speed from zero to maximum by gradually moving the handle away from the center “off” posi- tion. Release lever to stop movement. Lever is spring centered to the “off” position. Each boom section can be raised and lowered independently. Turret Rotate Control. Move lever to the left (#8, see diagram) to rotate the turret (superstructure) clockwise, to the right (#7) to rotate counterclockwise. Vary rotation speed from zero to maxi- mum by gradually moving the handle away from the center “off” position. Release lever to stop movement. Lever is spring centered to the “off” position. The turret rotates 360 degrees with an electric limit switch to stop continuous rotation, TA33 Page 4-6 Issued: Jul ‘97TEREX AERIALS OPERATOR’S MANUAL Controls and Instruments Aerial Control Station Controls Description (Continued) 6. Upper Boom Telescope In/ Out Con- trol Lever. Pull lever back (#1, see diagram) to move the upper boom section “out”, Push lever forward (#2) to move the upper boom “in”, Vary boom movement speed from zero to maximum by gradually moving the handle away from the center “off” posi- tion. Release lever to stop movement. Lever is spring centered to the “off” position. 7. Riser (Lower Boom) Up/ Down Con- trol Lever. Push lever forward (#5, see diagram) to raise the riser (lower boom section). Pull lever back (#6) to lower the riser. Vary riser movement speed from zero to maximum by gradually moving the handle away from the center “off” posi- tion. Release lever to stop movement. Lever is spring centered to the “off” position. Each boom section can be raised and lowered independently. Issued: Jul ‘97 Page 4-7 TA333 TEREX AERIALS OPERATOR’S MANUAL Controls and Instruments Aerial Control Station Controls Description (Continued) 8. Platform Tilt Switch. Rotate the switch to the right (#9, see diagram) to manu- ally tlt the platform forward (toward the boom) 10 9 Rotate the switch to the left (#10) to manually tilt the platform back (away ( Ny from the boom). Release switch to stop movement. ‘Switch will return to the “off” position. 9. Platform Rotate Switch (Option). Rotate the switch to the left to rotate the \ } platform to the left (clockwise), if that option is fitted. Rotate the switch to the right to rotate platform to the right (counterclockwise). 9 Release switch to stop movement. ‘Switch will return to the “off” position. TAS Page 4-8 Issued: Jul‘973 TEREX AERIALS OPERATOR'S MANUAL Controls and Instruments Aerial Control Station Controls Description (Continued) 10 10. Battery Condition and Hour Meter. The battery condition or level of charge is indicated by an LED display of 2 red, 3 yellow and 5 green illuminated bands. At full charge all LED's are lit. As the batteries discharge, green LED's are progressively extinguished from right to left, followed by the yellow LED's. When the first red LED begins to flash, this is a warming that the batteries are heavily discharged. Both red LED's flashing alternately indicates that the batteries require recharging and that the lift functions are about to be interrupted. Hour Meter. The digital hour meter indicates the total usage of the machine in hours and tenths. Itis “on” and count- ing whenever the power (either ground or platform), is turned on. 1. Horn Button. Press and hold button to sound “automotive type” warning horn. Horn is intended for use as a signal to personnel in the area and is not a “mo- tion” or “travel” alarm. Issued: Jul‘97 Page 4-9 TA33TEREX AERIALS OPERATOR’S MANUAL Controls and Instruments Additional Controls and Warnings Description 12. High Speed Drive Cutout. With the platform raised, travel speed is automatically limited to 0.5 mph (0.8 kph). This condition is known as “creep” speed. To enable faster travel, move platform to the fully down and in position. 13, Tilt Alarm. Sounds an audible warning (after approximately a three-second delay) whenever the aerial lift is five degrees or more out of level with the platform raised. Tilt alarm will sound until machine is returned to a level condition. 14. Movement alarm. Sounds an audible warning whenever the aerial lift is in motion. Alarm will cease when motion stops. Issued: Jul ‘97 Page 4-11 TA33TEREX AERIALS OPERATOR’S MANUAL Controls and Instruments Ground Control Station ‘Ano £07 240026 TASS Page 4-12 Issued: Jul‘97TEREX AERIALS OPERATOR’S MANUAL Controls and Instruments Ground Control Station Controls Identification Key No. Control Description 1 Emergency Stop Switch 2. Main Power Key Switch 3. Upper Boom Up/ Down Switch 4. Upper Boom Telescope In/ Out Switch 5. Riser (Lower Boom) Up/ Down Switch 6. Turret (Superstructure) Rotate Switch Issued: Jul ‘97 Page 4-13 ‘TA33.TEREX AERIALS OPERATOR'S MANUAL Controls and Instruments Ground Control Station Controls Description 1, Emergency Stop Switch. Push “in’ to stop all functions in an emergency. Pull out or rotate clockwise (depending on style used) to release switch and restore all functions. With the Emergency Stop switch at the Ground Control station released, func- tions can be operated from the ground controls even though the Platform Emer- gency Stop switch has been pressed. 2 Main Power Key Switch. Main power “Onv Off three position switch. The full left position ("0") is “oft”. Tum key right (clockwise) one position to turn power “on” for platform control operation. Turn key right (clockwise) two positions to turn power “on” for ground control operation. 2 With key switch “off”, the key may be removed to prevent unauthorized opera- tion. TASS Page 4-14 Issued: Jul‘97TEREX AERIALS OPERATOR’S MANUAL Controls and Instruments Ground Control Station Controls Description (Continued) Upper Boom Up/ Down Switch. Ro- tate the switch to the right (#3, see diagram) to move the upper boom section “up”. Rotate the switch to the lett (#4) to move the upper boom “down”, Release switch to stop movement. Switch will return to the “off” position. Each boom section can be raised and lowered independently. Upper Boom Telescope In/ Out Switch. Rotate the switch to the right (#1, see diagram) to move the upper boom section “out”. 4 Rotate the switch to the left (#2) to move ———_ the upper boom “in’. TT Release switch to stop movement. Switch will return to the “off” position. Issued: Jul ‘97 Page 4-15 TASSTEREX AERIALS OPERATOR’S MANUAL Controls and Instruments Ground Control Station Controls Description (Continued) 5 5, Riser (Lower Boom) Up/Down Switch. Rotate the switch to the right (#5, see diagram) to move the riser (lower boom section) “up”. Rotate the switch to the left (#6) to move the riser “down”. Release switch to stop movement. ‘Switch will return to the “off” position. Each boom section can be raised and lowered independently. 6. Turret (Superstructure) Rotate Switch. Rotate the switch to the left (#7, see diagram) to rotate the turret (superstructure) to the left (counterclock- wise). 7 8 Rotate the switch to the right (#8) to a rotate to the right (clockwise). Nu ( Release switch to stop movement. Switch will return to the “off” position. 6 The turret rotates 360 degrees non- continuously. There is an electric limit switch to stop continuous rotation. TASS Page 4-16 Issued: Jul‘97TEREX AERIALS OPERATOR’S MANUAL Controls and Instruments Additional Ground Controls Description 7. Emergency Pump. Turn the appropri- ate knob on the superstructure valve control bank in (clockwise) to shift the valve (refer to decal above valves): + Swing (rotate) the turret (super- structure) clockwise or counter- clockwise, ‘+ Move the riser (lower boom) up or down, + Move the upper boom up or down, or + Move the upper boom in or out. Pump the emergency hand pump to operate the desired function. (Pump handle is stowed on the lower boom post.) When machine has reached the desired position, turn the valve knob out (coun- terclockwise) to hold. Valve Control Bank Hand Pump Issued: Jul ‘97 Page 4-17 TAS3TEREX AERIALS OPERATOR'S MANUAL Controls and Instruments Additional Ground Controls Description (Continued) 8. Emergency Rotation. Emergency rotation of the superstructure can be performed by the emergency pump (see previous page) or by a mechanical override. For the mechanical override procedure, use a 30 mm socket, extension and ratchet handle attached to the hexagon extension shaft of the rotate drive gear- box. A CAUTION Rotate Drive Gearbox Hexagon Extension Shaft Care should be taken not to override the electrical rotation stop to avoid damaging the hoses which pass through the rotation ring. Always rotate the machine to the normal stowed position by the short- est route. After using emergency rotation, check hoses for damage. ‘TASS Page 4-18 Issued: Jul ‘97TEREX AERIALS OPERATOR’S MANUAL Before Operation Checks Section 5 Description What Needs to be Inspected? Before Operation General Inspection Check List... Safety and Control Decal Locations . Decal Check List. What Should | Know? To Check Operation, interlocks, Cut-Outs and Warnings . Ground Checks .. Emergency Operation From Ground Control Station if Main Pump is Inoperable... Platform Checks. Emergency Operation From Ground Control Station if Platform Controls Become Inoperable Platform Capacity Platform Guardrails and Gate... Platform Surface... Operating Clearances ... Platform Loads .. Travel Surfaces... Issued: Jul‘97 Page 5-1 TASS@ TEREX AERIALS OPERATOR'S MANUAL Before Operation Checks What Needs to be Inspected? Before each day's operation of the aerial if, the operator MUST perform the General Inspec- tion as outlined in the Check List that follows. The purpose of the Operator's Inspection is to keep the aerial lift in proper working condition and to detect any signs of malfunction during ncrmal operation between scheduled mainte- nance checks. While it may not be the Operator's responsibility to perform mechanical maintenance, the Operator MUST be thoroughly familiar with the aerial lift and its proper care since their own safety is involved. Model TA33 Aerial Lift TAS3 Page 5-2 Issued: Jul ‘97TEREX AERIALS OPERATOR’S MANUAL Before Operation General Inspection Check List Check each of the following items for security, leaks, missing components, hardware damage, evidence of cracks, deterioration, etc. Check all visible wiring and hydraulic hoses for cracking, loose connections or wear. If a problem is found with any of the following items, do not operate the aerial lift. The operator is authorized to perform only the maintenance items listed in the “Maintenance’ Section of this Manual. All other maintenance must be performed by a qualified Aerial Lift Technician. Item Description Item Description 1. General visual inspection of all 10. Pivot pin security (all locations). machine components. 11, Proper tilt alarm function. 2. Battery connections and electro- lyte level (both sides). 12. Damaged electrical control switches. 3. Hydraulic fluid level (see “Main- tenance” Section ). 13, All safety and control decals in place, legible and secure (see 4, Tightness of wheel lug nuts. “Decal Check List’, following. 5. Tightness of drive motor nuts. For Severe Duty Applications Add: 6. Chafing or worn areas on hoses. Item Description 7. Bent or sagging hose carrier. 14, Cylinder and valve spool boots. 8. Worn areas on safety belts. 15. Reduction drive unit oi Secure safety belt connection points. 16. Lubricate valve spool linkage. 9. Platform rail, gate or latch dam- age. Issued: Jul‘97 Page 5-3 TA33TEREX AERIALS OPERATOR’S MANUAL Before Operation Checks Safety and Control Decal Locations, TA33 Right Side. Left Side. REAR TA33. Page 5-4 Issued: Jul‘97TEREX AERIALS OPERATOR’S MANUAL Before Operation Checks Decal Check List Safety and Control Decals, TA33 Item No. PartNo. — Description Qty. Remarks 1 47011-0437 Decal, Ground Electrical Controls 1 Onenclosure 2 47011-0388 Decal, Ground Control Companion 1 Above enclosure 3 10-130600 Decal, ‘DANGER’, (Hazard listing) 1 AtGround Cntrl. 4 10-148300 Decal, “CAPACITY 500 LBs (225 kg)” 1 4.5" (114mm) 5 47004-0020 Decal, “S00 LBS" ("Max. Persons-2, Do not walk under load”) 1 12" (30.5 cm) 6 — 10-150500 Decal, ‘DANGER? (Electrocution) 2 — Onboth sides 7 Decal, Hydraulic Fluid 1 styles used 47005-0083 “Hydraulic Fluid Only” (Black on white) 47003-0036 “Hydraulic Oil Only, Shell Tellus ...” A580 “Hydraulic Oil Only” (Black on yellow) 8 Placard, “Platform Control” 1 2 versions used: 47011-0447 Top row, left position has “platform rotate” icon w/ Plat. Rotate 47011-0386 Top row, left position has “lightning arrow” icon wio Plat. Rotate 9 — 10-181200 Decal, “DANGER” (Hazard listing) 1 AtPlatform Cnt. 10 10-139800 Decal, “Operators Manual Enclosed” 1 11 47011-0408 Decal, “Emergency Towing Instructions ...” 1 12 10-282000 Decal, “Emergency Pump System 1 13 47011-0153 Decal, Direction Arrow (Diamond shape, [4] arrows) 2 Atboth ends 14 47011-0154 Decal, Pinch Point (Crossed-thru hand) 1 15 10-272600 Decal, “Caution, Safety Belt Lanyard ...” 2 — Onboth sides Issued: Jul‘97 Page 5-5 TA33TEREX AERIALS OPERATOR'S MANUAL Before Operation Checks What Should! Know? To Check Operation, Interlocks, Cut-Outs and Warnings ALL OPERATORS MUST THOROUGHLY READ AND UNDERSTAND THE “SAFETY” SECTION OF THIS MANUAL PRIOR TO OPERATING THE MACHINE. A COMPLETE VISUAL INSPECTION OF THE MACHINE MUST BE PERFORMED PRIOR TO OPERATIONAL CHECKS. + Ensure that emergency stop switch on ground control panel and platform console are disengaged. Pull out or rotate to reset, as required. * Tum and hold the main power key switch to the "GROUND" position to energize the electrical system. NOTE: If pump does not run, see “Emergency Operation”, on Page 5-9. AAWARNING BE SURE BOOM TRAVEL AREA IS CLEAR OF OBSTRUCTIONS. DO NOT OPERATE THE MACHINE IFTHE FOLLOWING CHECKS RE- VEAL A DEFECT. + Raise or extend the boom slightly, and push down on each of the three fastened comers of the tilt alarm. The alarm should sound as each corner is pressed beyond 5 degrees. NOTE: There is a three (3) second delay before the alarm sounds. TA33 Page 5-6 Issued: Jul ‘97TEREX AERIALS OPERATOR’S MANUAL Before Operation Checks What Should | Know? (Continued) To Check Operation, Interlocks, Cut-Outs and Warnings (Continued) Ground Checks: + Tum and hold the main power key switch to the “GROUND” position to energize the electrical system. + Tur the riser (lower boom) control switch to move the riser “up” to the end of its movement. [I [1 Listen for any unusual noises. Check for any vibration while the riser travels up or down. Test the “Emergency Stop" function. While the riser is moving, press the Emergency Stop switch. All machine functions should stop. Reset Emer- gency Stop switch. Cheek for uneven or jerky operation. Cheek for hydraulic leaks. Check pivot pins for security. Ensure that all securing bolts are in place on each pin locking point. + Return the riser to its stowed position by turning the control switch to the down posi- tion. * Operate the upper boom in the same manner as the riser. HT UL Listen for any unusual noises. Check for any vibration while the boom travels up or down. While the platform is moving, release the switch. The boom should stop immediately. Check for uneven or jerky operation. Check for hydraulic leaks. Check pivot pins for security. Ensure that all securing bolts are in place on each pin locking point. Issued: Jul ‘97 Page 5-7 TA33TEREX AERIALS OPERATOR'S MANUAL Before Operation Checks What Should | Know? (Continued) To Check Operation, interlocks, Cut-Outs and Warnings (Continued) Ground Checks (Continued): + Operate the boom telescope function by raising the upper boom section parallel to the ground, then moving the boom “out” and “in’. Listen for any unusual noises. Check for any vibration while the boom moves “out” and “in”. Check for uneven or jerky operation. Check for hydraulic leaks. Check cylinder pins for security. Ensure that all securing bolts are in place on each pin locking point. + Operate the turret rotate (superstructure swing) function by turning the control switch counterclockwise to rotate left and clockwise to rotate right. Listen for any unusual noises. Check for any vibration while the turret rotates. Check for uneven or jerky operation. Check for hydraulic leaks. * Retum the machine to the stowed position. + Release the main power key switch. IMPORTANT: All machine operations will stop upon release of the main power key switch. TA33 Page 6-8 Issued: Jul‘97TEREX AERIALS OPERATOR’S MANUAL Before Operation Checks What Should I Know? (Continued) To Check Operation, Interlocks, Cut-Outs and Warnings (Continued) Emergency Operation From Ground Control Station if Main Pump is Inoperable: Emergency Pump This machine has an emergency pump which can be operated from the ground control station to briefly operate the machine when it has lost power. Turn the appropriate knob on the superstructure valve control bank in (clockwise) to shift the valve: + Swing (rotate) the turret (superstructure) clockwise or counterclockwise, * Boom (upper) or riser (lower boom) up or down, or + Upper boom telescope in or out Pump the emergency hand pump to operate the desired function. (Pump handle is stowed on the lower boom post.) When machine has reached the desired position, turn the valve knob out (counter- clockwise) to hold. Emergency Rotation Emergency rotation of the turret (superstructure) can be performed by the emergency pump (see above) or by a mechanical override. For the mechanical override procedure, use a 30 mm socket, extension and ratchet handle attached to the hexagon extension shaft of the rotate drive gearbox. A CAUTION Care should be taken not to override the electrical rotation stop to avoid damaging the hoses which pass through the rotation ring. Al- ways rotate the machine to the normal stowed position by the shortest route. After using emergency rotation, check hoses for damage. Issued: Jul‘97 Page 5-9 TA33TEREX AERIALS OPERATOR’S MANUAL Before Operation Checks What Should | Know? (Continued) To Check Operation, Interlocks, Cut-Outs and Warnings (Continued) Platform Checks: Complete the Ground Operational Checks before you perform the Platform Checks. Select the "PLATFORM" control position on the ground/ platform key switch. Enter the Platform. Close the gate securely and connect your fall protection to the platform, AWARNING BE SURE BOOM TRAVEL AREA IS CLEAR OF OBSTRUCTIONS. DO NOT OPERATE THE MACHINE IF THESE CHECKS REVEAL ANY DEFECT OR ABNORMALITY. Depress the foot operated switch, mounted on the floor of the platform. Press the horn button briefly to check that the horn works. ‘Slowly move the riser (lower boom) control lever forward to operate the riser to the end of its movement. Listen for any unusual noises. Check for any vibration while the riser travels up or down. Check for uneven or jerky operation. Check for hydraulic leaks. Check pivot pins for security. Ensure that all securing bolts are in place on each pin locking point. Retum the riser to its stowed position by slowly pulling the control lever back. TA33 Page 5-10 Issued: Jul‘97TEREX AERIALS OPERATOR’S MANUAL Before Operation Checks What Should I Know? (Continued) To Check Operation, interlocks, Cut-Outs and Warnings (Continued) Platform Checks (Continued): AWARNING ACTUATION OF THE RED “EMERGENCY STOP” SWITCH WILL AP- PLY BRAKES IMMEDIATELY! THIS MAY CAUSE UNEXPECTED PLATFORM MOVEMENT AS THE MACHINE COMESTO A SUDDEN STOP. + While operating a boom function, press the emergency stop switch on the platform control console. All machine functions should stop. Reset emergency stop switch. * Operate the upper boom in the same manner as the riser. Listen for any unusual noises. Check for any vibration while the boom travels up or down. ‘Check for uneven or jerky operation. ‘Check for hydraulic leaks. Check pivot pins for security. Ensure that all securing bolts are in place on each pin locking point. + Operate the optional platform rotate function (if so equipped) by turning the platform rotate switch in each direction. Listen for any unusual noises. Check for uneven or jerky operation. Check pivot pin for security. Issued: Jul ‘97 Page 5-11 TA33TEREX AERIALS OPERATOR’S MANUAL Before Operation Checks What Should | Know? (Continued) To Check Operation, Interlocks, Cut-Outs and Warnings (Continued) Platform Checks (Continued): * Operate the platform tilt function by turning the platform tilt switch in each direction. Listen for any unusual noises. Check for uneven or jerky operation. Check for hydraulic leaks. {I each pin locking point. Check pivot pins for security. Ensure that all securing bolts are in place on * Operate the boom telescope function by raising the upper boom section parallel to the ground, then moving the boom “out’ and “in”. Listen for any unusual noises. Check for uneven or jerky operation, Check for hydraulic leaks. Check cylinder pins for security, IIT Check for any vibration while the boom moves “out” and ‘in’, * Operate the turret rotate (superstructure swing) function by slowly moving the control lever left to rotate the turret clockwise and right to rotate counterclockwise. Listen for any unusual noises. Check for any vibration while the turret rotates. Check for uneven or jerky operation. Check for hydraulic leaks. [1 + Return the machine to its stowed position. * Slowly push the drive control lever forward. The machine should smoothly acceler- ate in the selected direction. Movement alarm sounds whenever the machine is in motion. TASS Page 5-12 Issued: Jul ‘97TEREX AERIALS OPERATOR’S MANUAL To Check Operation, Interlocks, Cut-Outs and Warnings (Continued) WITHTHE PLATFORM SWUNG OVERTHE STEERING WHEELS, USE CAUTION WHEN SELECTING THE TRAVEL AND STEERING DIREC- TION. TRAVEL AND STEERING DIRECTION WILL BE OPPOSITE TO Before Operation Checks What Should I Know? (Continued) Platform Checks (Continued): AWARNING CONTROL MOVEMENT. oxo peaton decion shown hn lt eae poston of ture! supe. Tut on undercaogelck in es He up won ‘perctorin plato faces foward to stor wnees. | ARWARNING, ==] wa | Platform i Stowed Postion Platform Opposite ‘stowed Postion Listen for any unusual noises. Check for any vibration while the machine travels. Check for uneven or jerky operation, ___ Check for hydraulic leaks. Report and repair any problem. Issued: Jul‘97 Page 5-13 TAS3TEREX AERIALS OPERATOR’S MANUAL Before Operation Checks What Should | Know? (Continued) To Check Operation, Interlocks, Cut-Outs and Warnings (Continued) Platform Checks (Continued): Operate the steer switch and check for proper steering control. Note position of the platform to the steering wheels. Return the wheels to the straight ahead position. Slowly return the drive control lever to the center "neutral" position. The machine should come to a complete stop. Slowly move the drive control lever backward. The machine should smoothly accel- erate in the selected direction. Movement alarm sounds whenever the machine is in motion. Slowly return the drive control lever to the center "neutral" position. The machine should come to a complete stop. Raise either boom slightly to activate the high speed drive cutout limit switches. Move the drive control lever forward and back in turn. Machine should travel a maxi- mum of 0.5 mph (0.8 kph). This condition is referred to as "creep" speed, and is the maximum rate of travel with the boom raised or extended. Return the boom to the stowed position. Move all levers and switches back to their "neutral" positions. Release the foot switch. NOTE: All machine functions should stop upon release of the foot switch. TAS3 Page 5-14 Issued: Jul ‘97TEREX AERIALS OPERATOR’S MANUAL Before Operation Checks What Should | Know? (Continued) To Check Operation, Interlocks, Cut-Outs and Warnings (Continued) Emergency Operation From Ground Control Station if Platform Controls Become Inoperable: 1. Remove foot from foot switch. 2. Press the red emergency stop switch 3. Evaluate the nature of the failure. 4. If unable to return to the ground using the platform controls, contact an experienced ‘operator to lower the machine using the ground controls or emergency pump and lowering procedure (see “Emergency Pump” earlier in this section). DO NOTTRY TO CLIMB DOWN THE BOOM. HAVE AN EXPERIENCED OPERATOR USE THE GROUND CON- TROLS OR EMERGENCY PUMP TO SAFELY LOWER THE PLAT- FORM. 5. Report the incident to your supervisor immediately. Issued: Jul‘97 Page 5-15 TA33TEREX AERIALS OPERATOR'S MANUAL Before Operation Checks What Should | Know? (Continued) Platform Capacity * The capacity of the platform is posted on the platform and in the “Specifications” section of this manual. + The platform capacity is equal to the combined weight of personnel, tools and ‘supplies to be carried in the platform. The combined weight of personnel, tools and supplies must not exceed the posted platform capacity. * Do not exceed the maximum number cf personnel allowed on the platform. This information is posted on the platform and can be found in the “Specifications” section of this manual. Platform Guardrails and Gate + Make sure the platform guard rails and toe plates are not bent or deteriorated. Check for cracked or broken welds. * Once in the platform, ensure that the entry gate is closed and latched. Platform Surface * Make sure the platform deck surface is undamaged and free of oil, grease, loose materials or other substances which could cause a slip or fall. Operating Clearances + Be sure the area through which you will be moving the aerial lift is free of obstacles. + Check clearances overhead, under and around the intended range of movement before: moving the boom up, down, in or out; tilting or rotating the platform; rotating the turret (superstructure), or traveling. * Use a lookout ifnecessary! Always lookin the direction of intended movement of the machine, boom and platform, and maintain safe distances. TA33 Page 5-16 Issued: Jul‘97TEREX AERIALS OPERATOR’S MANUAL Before Operation Checks What Should | Know? (Continued) Platform Loads + The capacity of the platform is based on the load being placed at any position in the platform. Even distribution is not necessary. * Position tools and supplies so that personnel on the platform do not trip over or collide with them, * Position tools and supplies so that they are not accidentally knocked off the plat- form. Travel Surfaces * Surfaces to be traveled should be: * Able to support the weight of the aerial lift and its contents. + Aslevel as possible whenever the platform is elevated. + Free from bumps and potholes. + Clean and free of debris and obstacles. + Make sure the grades to be traveled do not exceed the capabilities of the machine. Refer to “Specifications” and “Operation” sections for maximum front-to-back and side-to-side grades. + Ramps must be strong enough to support the weight of the aerial lift and its con- tents, and wide enough to provide sufficient side clearance beyond the wheels. Issued: Jul ‘97 Page 5-17 TAS3TEREX AERIALS OPERATOR’S MANUAL Operation Section 6 Description Page No. Operation. Cold Weather Operation .. Driving and Steering Traveling on Level Surface .. Traveling on Rough Terrain Traveling on Grades (Slopes) and Ramps..... Steering the Machine Braking . Boom, Superstructure and Platform Raising and Lowering the Boom Extending and Retracting the Upper Boom .. Swinging the Superstructure Leveling the Platform.. Rotating the Platform (with Option) ‘Shut Down Procedures... Issued: Jul‘97 Page 6-1 TA33TEREX AERIALS OPERATOR’S MANUAL Operation A complete description of the individual controls and their operation can be found in the “Con- trols and Instruments” Section of this manual. The operator must read and understand the functions of all controls before operating the aerial lift. Complete the “Before Operations Check” before operating the aerial lft. If the aerial lift pump or motor fails, see “Emergency Operation” in the “Before Operation Checks” Section ANGER IF THE MACHINE FAILS WHILE THE OPERATOR'S PLATFORM IS RAISED OR EXTENDED, DO NOT ATTEMPT TO CLIMB DOWN THE BOOM ASSEMBLY. SERIOUS INJURY MAY RESULT. AWWARNING THE OPERATOR MUST BE AWARE OF THE GROUND CONDITIONS. DO NOT RAISE THE PLATFORM OR EXTEND THE BOOM IF THE MACHINE IS NOT ON A FIRM LEVEL SURFACE! DO NOT RELY ON THE TILT ALARMTO WARN YOU OF AN UNSAFE CONDITION. TA33 Page 6-2 Issued: Jul ‘97TEREX AERIALS OPERATOR’S MANUAL Operation Cold Weather Operation + In below freezing weather, the hydraulic fluid should be allowed to warm before full ‘operation of the machine. * Check for water contamination of the fluid. * Check for and remove ice on the platiorm, swing gear teeth and steering linkage prior to operation. * Check that all controls operate smoothly, and return freely to the "neutral" position. 4 CAUTION Avoid sudden braking or steering, go slow and leave more maneu- vering room during cold weather operation. Issued: Jul ‘97 Page 6-3 TASSTEREX AERIALS OPERATOR’S MANUAL Operation Driving and Steering Traveling on Level Surface 1. The platform can be raised or lowered when traveling on level surfaces. + With the platform raised, maximum travel speed is 0.5 mph (0.8 kph). AAWARNING ENSURE THAT THE ROUTE OF TRAVEL IS CLEAR OF PERSONNEL, POTHOLES, BUMPS AND DEBRIS. 2. — Route of travel must be clear of personnel, power lines, potholes, bumps, equipment and debris. NOTE: The foot switch must be depressed to activate any of the ma- chine functions using the platform controls. 3. Press the foot switch. 4 CAUTION Although the machine can be driven with the platform positioned at either end of the machine, the operator may find driving easier from the stowed position. The stowed position can be identified by the arrow decals on each end of the undercarriage. If driving is attempted with the platform over the opposite axle, you must remember that all directions given to the steer and drive con- trols will be in reverse. TA33 Page 6-4 Issued: Jul‘97TEREX AERIALS OPERATOR’S MANUAL Operation Driving and Steering (Continued) Traveling on Level Surface (Continued) Conta operation dco shawn Rae in ton aoe posion of ure (supers) Tet eg unéranoy et tls a up when ‘operator in ptt faces forward to stourwneets. — | AMWARNING. REVERSE a 1 uM tox a WARNING! tn oti aoe AWARNING WITHTHE PLATFORM SWUNG OVERTHE STEERING WHEELS, USE CAUTION WHEN SELECTING THE TRAVEL AND STEERING DIREC- TION. TRAVEL AND STEERING DIRECTION WILL BE OPPOSITE CONTROL MOVEMENT. 4. Limit travel speeds to existing factors, such as surface conditions, side clearances and congestion in the working area. Slowly push the drive control lever forward to provide forward travel, or pull the lever back for reverse travel. NOTE: The speed of the machine is proportional to the distance the lever is moved. NOTE: Movement alarm sounds whenever the vehicle is in motion. Issued: Jul ‘97 Page 6-5 TA33TEREX AERIALS OPERATOR’S MANUAL Operation Driving and Steering (Continued) Traveling on Level Surface (Continued) 5. The brakes are automatically applied when the drive control lever is moved to the center “neutral” position. AWARNING RELEASE OFTHE DRIVE CONTROL LEVER OR ACTUATION OF THE PLATFORM “EMERGENCY STOP” SWITCH WILL APPLY BRAKES IMMEDIATELY! THIS MAY CAUSE UNEXPECTED PLATFORM MOVEMENT AS THE MACHINE COMES TO A SUDDEN STOP. Traveling on Rough Terrain This machine is not equipped to travel on rough terrain. Traveling on Grades (Slopes) and Ramps This machine is capable of traveling on grades of 14° (25 %) front to back and 5° (9 %) side to side. % Grade = (Vertical Rise/ Horizontal Distance) x 100 Example: 30" Rise over 10 ft (120") = .25 = 25% TA33 Page 6-6 Issued: Jul‘97TEREX AERIALS OPERATOR’S MANUAL Operation Driving and Steering (Continued) 9 on Grades (Slopes) and Ramps (Continued) 1. The boom and platform must be in the stowed position when traveling on grades (slopes) and ramps. If necessary, raise the platform only enough to prevent contact with the ground. ANGER DO NOT RELY ON THE TILT ALARM TO WARN YOU OF AN UNSAFE CONDITION. AAWARNING ENSURE THAT THE ROUTE OF TRAVEL IS CLEAR OF PERSONNEL AND DEBRIS. 2. Route of travel must be clear of personnel and debris. Do not travel on grades or ramps that are wet, muddy, slippery or have poor traction, NOTE: The foot switch must be depressed to activate any of the ma- chine functions using the platform controls. 3. Press the foot switch. Issued: Jul ‘97 Page 6-7 TA33TEREX AERIALS OPERATOR’S MANUAL Operation Driving and Steering (Continued) Traveling on Grades (Slopes) and Ramps (Continued) 4 CAUTION Although the machine can be driven with the platform positioned at either end of the machine, the operator may find driving easier from the stowed position. The stowed position can be identified by the arrow decals on each end of the undercarriage. If driving is attempted with the platform over the opposite axle, you must remember that all directions given to the steer and drive con- trols will be in reverse. Cont operon dean sown hae nese oe poston of resp) Trt ang undoeamep et i oles te p won ‘operator plato foces forwet tester ness. | AAWARNING: Tam ea Platform in Stowed Poston TA33 Page 6-8 Issued: Jul ‘97TEREX AERIALS OPERATOR’S MANUAL Operation Driving and Steering (Continued) Traveling on Grades (Slopes) and Ramps (Continued) AWARNING WITHTHE PLATFORM SWUNG OVERTHE STEERING WHEELS, USE CAUTION WHEN SELECTING THE TRAVEL AND STEERING DIREC- TION. TRAVEL AND STEERING DIRECTION WILL BE OPPOSITE CONTROL MOVEMENT. 4, Slowly push the drive control lever forward to provide forward travel, or pull the lever back for reverse travel. NOTE: The speed of the machine is proportional to the distance the lever is moved. NOTE: Movement alarm sounds whenever the vehicle is in motion. Use extreme caution when turning on a grade or ramp, 5. When descending a grade or ramp (incline), it is necessary to control the speed of the machine. To slow the machine, move the drive control lever slowly toward the center “neutral” position. AWARNING RELEASE OFTHE DRIVE CONTROL LEVER OR ACTUATION OF THE PLATFORM “EMERGENCY STOP” SWITCH WILL APPLY BRAKES IMMEDIATELY! THIS MAY CAUSE UNEXPECTED PLATFORM MOVEMENT AS THE MACHINE COMES TO A SUDDEN STOP. Issued: Jul‘97 Page 6-9 TAS3TEREX AERIALS OPERATOR'S MANUAL Operation Driving and Steering (Continued) Traveling on Grades (Slopes) and Ramps (Continued) 6. The brakes are automatically applied when the drive control lever is moved to the center "neutral" position. 7. _Itmay be necessary to move the boom “up” slightly in order to prevent the platform from contacting the ground. Steering the Machine AWWARNING WITHTHE PLATFORM SWUNG OVERTHE STEERING WHEELS, USE CAUTION WHEN SELECTING THE STEERING DIRECTION. STEER- ING DIRECTION WILL BE OPPOSITE CONTROL MOVEMENT. Con eprtonsrocten shown a a lon 0 ae poston of espe). ‘et an wdoarape kp Bal n wp wher ‘operator in platoon faces foward to seer sees. | ABWARNING Ton aon Soe wis AWARNING Platform in towed Poston Piotform Opposite ‘towed Position TA33 Page 6-10 Issued: Jul ‘97TEREX AERIALS OPERATOR’S MANUAL Operation Driving and Steering (Continued) Steering the Machine (Continued) 1. Press the steer switch on the end of the drive control lever: + tothe left for left tums. * tothe right for right turns. AWWARNING ENSURE THAT THE ROUTE OF TRAVEL IS CLEAR OF PERSONNEL AND DEBRIS. 2. Use extreme care in turning the machine. * No abrupt or sharp tus. + Ensure the turning area is clear of personnel, debris and pot holes. * Use extreme caution when turing on a grade or ramp. Steering is not self-centering. Push and hold switch in the opposite direction to straighten wheels. Issued: Jul ‘97 Page 6-11 TASSTEREX AERIALS OPERATOR’S MANUAL Operation Braking For parking, the brakes are automatically applied when the drive control lever is moved to the center "neutral" position. AWARNING RELEASE OFTHE DRIVE CONTROL LEVER OR ACTUATION OF THE PLATFORM “EMERGENCY STOP” SWITCH WILL APPLY BRAKES IMMEDIATELY! THIS MAY CAUSE UNEXPECTED PLATFORM MOVEMENT AS THE MACHINE COMES TO A SUDDEN STOP. TA33 Page 6-12 Issued: Jul‘97TEREX AERIALS OPERATOR’S MANUAL Operation Boom, Superstructure and Platform NOTE: The following instructions are described using platform controls. NOTE: Function speeds are generally proportional to lever movement. Multiple function control is possible by operating more than one function at the same time; however, this may reduce hydraulic fluid flow to each function, slowing response time. Moving the Riser or Upper Boom “Up” or “Down” 1. Check clearances overhead, around and below the intended path of travel of the platform, riser (lower boom) and upper boom to prevent contact with obstacles. 2. Press the foot switch. 3. Select whether riser (lower boom) or upper boom is to be repositioned. 4, Push the selected boom control lever forward to move the boom “up”. 5. Pull the selected boom control lever back to move the boom “down”. The lever is spring centered to the “off" position. Moving the Upper Boom “Out” or “In” 1. Check clearances overhead, around and below the intended path of travel of the platform to prevent contact with obstacles. 2. Press the foot switch. 3. Pull the upper boom in/ out control lever back to move the boom section “out”. 4, Push the upper boom in/ out control lever forward to retract the boom section “in”. The lever is spring centered to the "off" position. Issued: Jul ‘97 Page 6-13 TA33TEREX AERIALS OPERATOR'S MANUAL Operation Boom, Superstructure and Platform (Continued) Rotating the Turret (Swinging the Superstructure) 1. Check clearances overhead, around and below the intended path of travel of the turret, boom sections and platform to prevent contact with obstacles. 2. Press the foot switch. 3. Move the rotate (swing) control lever left to rotate the turret clockwise. 4. Move the rotate (swing) control lever right to rotate the turret counterclockwise. The lever is spring centered to the “off position. Tilting the Platform 1. Check clearances overhead, around and below the intended path of travel of the platform to prevent contact with obstacles. 2. Press the foot switch. 3. Turn the platform tilt switch to the right to tilt the platform forward. 4. Turn the platform tilt switch to the left to tilt backward. The switch is spring centered to the “off* position. TA33 Page 6-14 Issued: Jul‘97TEREX AERIALS OPERATOR’S MANUAL. Operation Boom, Superstructure and Platform (Continued) Rotating the Platform (with option) 1. Check clearances overhead, around and below the intended path of travel of the platform to prevent contact with obstacles. Press the foot switch. ‘Tum the platform rotate switch to the left to rotate the platform to the left (clockwise). Turn the platform rotate switch to the right to rotate the platform to the right (counter- clockwise). The switch is spring centered to the “off* position. Shut-Down Procedures When finished with the aerial lift, place the machine in the stowed position (platform fully in and down, and over the rear of the undercarriage. Park the machine on a level surface (preferably protected from weather). Secure to prevent vandalism and to discourage children from climbing or playing on it. Exit the platform. Tum off the main power switch. Remove the key to prevent unauthorized operation. Issued: Jul ‘97 Page 6-15 TA33TEREX AERIALS OPERATION AND MAINTENANCE Unloading Section 7 Description Page No. Unloading the Aerial Lift Under Its Own Power. Initial Unloading of the Aerial Lift so TH Unloading the Aerial Lift NOT Under Its Own Power. 7-5 1-7 Lifting With Crane... Issued: Jul ‘97 Page 7-1 TA33TEREX AERIALS OPERATION AND MAINTENANCE Unloading Unloading the Aerial Lift Under Its Own Power AWARNING ONLY TRAINED OPERATORS EXPERIENCED WITH THE AERIAL LIFT CONTROLS ARE TO UNLOAD THE MACHINE. Inspect the outside of the machine for damage (including the underside). Inspect all hoses, boom sections and cables for chafing or road damage. Confirm that all swing bearing bolts are tight (refer to specifications). Unlock and open rear compartment. Inspect all electrical and hydraulic connections for damage and security. Connect battery cables to batteries if required. Check electrolyte level. Check fluid level on the hydraulic tank, and add fluid as required (see Lubrication Chart). Close rear compartment cover. Ensure the unloading ramps have adequate capacity to support the aerial lift, and are wide enough to allow sufficient side clearance beyond the wheels. Perform procedures indicated in "Before Operation Checks", earlier in this manual. Remove all machine tie downs. Remove wheel chocks, if used. Switch the Ground/ Platform key switch to the Platform position, ‘Attach the machine to a winch for the unloading procedure. TA33 Page 7-2 Issued: Jul ‘97TEREX AERIALS OPERATION AND MAINTENANCE Unloading (Continued) Unloading the Aerial Lift Under Its Own Power (Continued) A\WARNING ALWAYS ATTACH THE MACHINE TO A WINCH WHEN LOADING OR UNLOADING FROMA TRUCK OR TRAILER. CONNECT WINCH CABLE TO THE TIE DOWN LUGS ON THE UNDERCARRIAGE. UN- ASSISTED LOADING OR UNLOADING OF ANY MOBILE PLATFORM IS NOT RECOMMENDED. READ AND UNDERSTAND ALL SAFETY, CONTROL AND OPERAT- ING INFORMATION FOUND ON THE MACHINE AND IN THIS MANUAL BEFORE OPERATING THE MACHINE. DO NOT ALLOW ANYONE ON THE AERIAL LIFT OUTSIDE THE PLATFORM WHILE UNLOADING. Tie Down Lug Location (4 Places) Issued: Jul ‘97 Page 7-3, TA33TEREX AERIALS OPERATION AND MAINTENANCE Unloading (Continued) Unloading the Aerial Lift Under Its Own Power (Continued) + Enter the platform. Close the gate securely and connéct the safety belt to the platform. Test all platform functions. + Raise the boom so that the platform will clear any obstacles as the machine is driven down the loading ramp. With either boom raised slightly, machine will travel only at "Creep" speed. AAWARNING TO AVOID SERIOUS PERSONAL INJURY OR DEATH, ENSURE THAT THE MACHINE IS IN "CREEP" DRIVE SPEED WHILE UNLOADING FROMA TRUCK OR TRAILER. THE WINCH OPERATOR AND MACHINE OPERATOR MUST COOR- DINATE MOVEMENT WHILE UNLOADING THE MACHINE. ALLOW THE WINCH TO HELP THE MACHINE OPERATOR CONTROL THE SPEED OF DESCENT. + Carefully drive the machine off the truck or trailer with the assistance of the winch. NOTE: The brakes are automatically released for driving, and will automati- cally apply when the machine stops. + Before placing the machine into service, all operators must read and understand the contents of this Operator's Manual. Initial Unloading of the Aerial Lift Upon initial unloading of the machine the Warranty Form must be completed and retumed in order to activate the Terex Limited Warranty. ‘An Operator's Manual and a Post Delivery Inspection Adjustment Report are included with each ma- chine leaving the factory. TA33 Page 7-4 Issued: Jul ‘97TEREX AERIALS OPERATION AND MAINTENANCE Unloading (Continued) Unloading the Aerial Lift NOT Under Its Own Power Every attempt should be made to restore primary power to the machine before using this procedure. Inspect the outside of the machine for damage (including the underside). Inspect all hoses, boom sections and cables for chafing or road damage. Confirm that all swing bearing bolts are tight (refer to specifications). Unlock and open rear compartment. Inspect all electrical and hydraulic connections for dam- age and security. Check fluid level on the hydraulic tank, and add fluid as required (see Lubrication Chart). Close rear compartment cover. Ensure the unloading ramps have adequate capacity to support the aerial lift, and are wide enough to allow sufficient side clearance beyond the wheels. ANGER THIS PROCEDURE REQUIRES RELEASING THE WHEEL BRAKES, WHICH MEANS THERE IS NOTHING TO STOP THE MACHINE'S ‘TRAVEL. MACHINE WILL ROLL FREELY ON SLOPES. BE ON GUARD AGAINST RUNAWAY. MOVEMENT SPEED SHALL NOT EXCEED 3 M.PH. (5 K.P-H.). DO NOT DRIVE MACHINE WITH BRAKES RE- LEASED. Raise the platform sufficiently to clear the ground during unloading. See “Emergency Opera- tion from Ground Control” procedures indicated in "Before Operation Checks", earlier in this, manual. Remove all machine tie downs. Issued: Jul ‘97 Page 7-5 ‘TA33TEREX AERIALS OPERATION AND MAINTENANCE AWARNING ALWAYS ATTACH THE MACHINE TO A WINCH WHEN LOADING OR UNLOADING FROM A TRUCK OR TRAILER. CONNECT WINCH, CABLE TO THE TIE DOWN LUGS ON THE UNDERCARRIAGE. DO NOT ALLOW UNNECESSARY PERSONNEL ON ORAROUND THE, AERIAL LIFT WHILE UNLOADING. Tie Down Lug Location (4 Places) ‘Attach the machine to a winch for the unloading procedure. Make sure the winch has ad- equate capacity to restrain the weight of the aerial lift. Release brakes and disconnect transmission by fully screwing in (turning clockwise) the dis- engage plug located in the center of both rear wheel hubs. Use a 6 mm hex key. Remove wheel chocks, if used. After unblocking the wheels, the machine will be ready to be moved; however, there is no provision for steering the machine. TA33 Page 7-6 Issued: Jul ‘97TEREX AERIALS OPERATION AND MAINTENANCE Unloading (Continued) Unloading the Aerial Lift NOT Under Its Own Power (Continued) AWARNING THE WINCH OPERATOR MUST CAREFULLY CONTROL MOVE- MENT WHILE UNLOADING THE MACHINE. ALLOW THE WINCH TO CONTROL THE SPEED OF DESCENT. + Carefully roll the machine off the truck or trailer with the assistance of the winch. + After primary power has been restored to the machine, fully unscrew (turning counterclock- wise) the disengage plug with a 6 mm hexagon key. + The machine is now ready for normal operation. Lifting With Crane This machine is not equipped with lifting lugs. DO NOT attempt to lift the machine with a crane. AWWARNING DO NOT LIFT THE MACHINE USING THE TIE DOWN LUGS. Issued: Jul ‘97 Page 7-7 TA33TEREX AERIALS OPERATION AND MAINTENANCE TA33 Page 7-8 Issued: Jul ‘97TEREX AERIALS OPERATION AND MAINTENANCE Loading Section 8 Description Loading the Aerial Lift Under Its Own Power Loading the Aerial Lift NOT Under Its Own Power Lifting With Crane... : Tie Down of the Aerial Lift Issued: Jul ‘97 Page 8-1 TA33TEREX AERIALS OPERATION AND MAINTENANCE Loading Loading the Aerial Lift Under Its Own Power AWARNING ONLY TRAINED OPERATORS EXPERIENCED WITH THE AERIAL, LIFT CONTROLS ARE TO LOAD THE MACHINE. The booms and platform should be in the stowed position when the machine is being transported. Do not operate the machine while it is being transported. + Ensure the unloading ramps have adequate capacity to support the aerial lift, and are wide enough to allow sufficient side clearance beyond the wheels. + Perform procedures indicated in "Before Operation Checks", earlier in this manual. AAWARNING ALWAYS ATTACH THE MACHINE TO A WINCH WHEN LOADING OR UNLOADING FROMA TRUCK OR TRAILER. CONNECT WINCH CABLE TO THE TIE DOWN LUGS ON THE UNDERCARRIAGE. UN- ASSISTED LOADING OR UNLOADING OF ANY MOBILE PLATFORM IS NOT RECOMMENDED. READ AND UNDERSTAND ALL SAFETY, CONTROL AND OPERAT- ING INFORMATION FOUND ON THE MACHINE AND IN THIS MANUAL BEFORE OPERATING THE MACHINE. DO NOT ALLOW ANYONE ON THE AERIAL LIFT OUTSIDE THE PLATFORM DURING THE LOADING PROCEDURE. TA33 Page 8-2 Issued: Jul ‘97TEREX AERIALS OPERATION AND MAINTENANCE Loading (Continued) Loading the Aerial Lift Under Its Own Power (Continued) Tie Down Lug Location (4 Places) 1. Attach the machine to a winch for the loading procedure. Make sure the winch has adequate capacity to pull the weight of the aerial lift. 2. Select the "PLATFORM" control position on the ground/ platform key switch. 3. Enter the platform. Close the gate securely and connect the safety belt to the platform. Test all platform functions. 4. Raise the boom so that the platform will clear any obstacles as the machine is driven down the loading ramp. With either boom raised slightly, machine will travel only at "Creep" speed. Issued: Jul ‘97 Page 8-3, TA33TEREX AERIALS OPERATION AND MAINTENANCE Loading (Continued) Loading the Aerial Lift Under Its Own Power (Continued) AAWARNING TO AVOID SERIOUS PERSONAL INJURY OR DEATH, ENSURE THAT THE MACHINE IS IN "CREEP" DRIVE SPEED WHILE LOADING ONTO A TRUCK OR TRAILER. THE WINCH OPERATOR AND MACHINE OPERATOR MUST COOR- DINATE MOVEMENT WHILE LOADING THE MACHINE. AVOID THE POSSIBILITY OF THE WINCH TRYING TO PULL A STATIONARY MACHINE. 5. Carefully maneuver the machine onto the truck or trailer with the aid of the winch. NOTE: The brakes are automatically released for driving, and will automati- cally apply when the machine stops. 6. Block or chock the front and rear wheels to prevent unexpected rolling 7. Tie the aerial lift to the truck or trailer bed. See “Tie Down of the Aerial Lift”, later in this section. TA33 Page 8-4 Issued: Jul ‘97TEREX AERIALS OPERATION AND MAINTENANCE Loading (Continued) Loading the Aerial Lift NOT Under Its Own Power Every attempt should be made to restore primary power to the machine before using this procedure. + Ensure the unloading ramps have adequate capacity to support the aerial lift, and are wide ‘enough to allow sufficient side clearance beyond the wheels. DANGER THIS PROCEDURE REQUIRES RELEASING THE WHEEL BRAKES, WHICH MEANS THERE IS NOTHING TO STOP THE MACHINE'S TRAVEL. MACHINE WILL ROLL FREELY ON SLOPES. BE ON GUARD AGAINST RUNAWAY. MOVEMENT SPEED SHALL NOT EXCEED 3 M.PH. (5 K.P-H.). DO NOT DRIVE MACHINE WITH BRAKES RE- LEASED. 1. Raise the platform sufficiently to clear the ground during loading. See “Emergency Opera- tion from Ground Control” procedures indicated in "Before Operation Checks", earlier in this manual. AWARNING ALWAYS ATTACH THE MACHINE TO A WINCH WHEN LOADING OR UNLOADING FROM A TRUCK OR TRAILER. CONNECT WINCH CABLE TO THE TIE DOWN LUGS ON THE UNDERCARRIAGE. DO NOT ALLOW UNNECESSARY PERSONNEL ON OR AROUND THE AERIAL LIFT DURING THE LOADING PROCEDURE. Issued: Jul ‘97 Page 8-5 TA33TEREX AERIALS OPERATION AND MAINTENANCE Loading (Continued) Loading the Aerial Lift NOT Under Its Own Power (Continued) 2. Attach the machine to a winch for the loading procedure. Make sure the winch has adequate capacity to pull the weight of the aerial lift. Tie Down Lug Location (4 Places) 3. Block or chock the front and rear wheels to prevent unexpected rolling 4. Release brakes and disconnect transmission by fully screwing in (turning clockwise) the dis- engage plug located in the center of both rear wheel hubs. Use a 6 mm hex key. 5. Unblock the wheels. The machine is now ready to be winched onto the truck or trailer; however, there is no provision for steering the machine. TA33, Page 8-6 Issued: Jul ‘97TEREX AERIALS OPERATION AND MAINTENANCE Loading (Continued) Loading the Aerial Lift NOT Under Its Own Power (Continued) AWARNING THE WINCH OPERATOR MUST CAREFULLY CONTROL MOVE- MENT WHILE LOADING THE MACHINE. 6. Carefully pull the machine onto the truck or trailer using the winch. 7, Block or chock the front and rear wheels to prevent unexpected rolling 8. Tie the aerial lift to the truck or trailer bed. See “Tie Down of the Aerial Lift”, later in this section. Loading (Continued) Lifting With Crane This machine is not equipped with lifting lugs. DO NOT attempt to lift the machine with a crane. AAWARNING DO NOT LIFT THE MACHINE USING THE TIE DOWN LUGS. Issued: Jul ‘97 Page 8-7 TA33J TEREX AERIALS OPERATION AND MAINTENANCE Tie Down Confirm that the boom sections are fully retracted, and that the platform will not contact any other item, including the bed of the truck or trailer. 4 CAUTION The platform or boom must not be tied down to the truck or trailer bed in any way. The negative battery cables should be disconnected for long distance transport. Tie down locations are located on all four corners of the undercarriage. Use four (4) 1/2 inch, "Grade 7" chains from each of the tie down lugs, and run the chains as shown in the diagram. (Refer to illustration on facing page.) Ratchet type load binders are recommended. If using lever type load binders, wire or strap them shut, or wrap chains around them to prevent opening. TA33 Page 8-8 Issued: Jul ‘97TEREX AERIALS OPERATION AND MAINTENANCE Tie Down of the Aerial Lift (Continued) ‘Tie Down of the Aerial Lift (Recommended Method). Issued: Jul ‘97 Page 8-9 TA33TEREX AERIALS OPERATION AND MAINTENANCE ‘TA33 Page 8-10 Issued: Jul ‘97TEREX AERIALS OPERATOR’S MANUAL Maintenance Section 9 Description Page No. Introductior Maintenance Schedule .. Owner's Inspection Records... Lubrication . Lubrication Diagram .. Recommended Lubrication Schedule .. Shift Operational Check List - Owners Inspection Record . Additional Shift Maintenance for Severe Usage Applications .. Additional Weekly Maintenance for Severe Usage Applications. 9-10 Monthly Operational Check List - Owners Inspection Record .. Quarterly Operational Check List - Owners Inspection Record ........ Additional Maintenance for Severe Usage Applications ‘Semi Annual Operational Check List - Owners Inspection Record... 9-15 Additional Maintenance for Severe Usage Applications ... Continues... Issued: Jul ‘97 Page 9-1 TA33TEREX AERIALS OPERATOR’S MANUAL Maintenance Section 9 Description Page No. Environmentally Hazardous Materials Battery (Acid/ Lead) . Hydraulic Fluid Hydraulic Fluid. Hydraulic Pressure Check .. Hydraulic Fluid Filter Check... Controller Controller Diagnostic: Controller Fault Codes . Battery Charger Battery Charger Troubleshooting... Troubleshooting ... Issued: Jul ‘97 Page 9-3 TA33TEREX AERIALS OPERATOR’S MANUAL Maintenance Introduction In addition to the “Before Operation Checks” described in Section 5, a regular program of periodic preventive maintenance is absolutely essential to ensuring the safety of the operator, prolonging the life of the aerial lift, maximizing efficient service and minimizing downtime. This section details a series of checks and procedures which are performed at periodic inter- vals. Even if the operator is not directly responsible for maintenance of the aerial lift, he should perform daily all of the inspections listed in the “Before Operation Checks” described in Sec- tion 5 of this Operator's Manual. AWARNING REPORT AND REPAIR ALL DEFICIENCIES NOTED DURING THE “BE- FORE OPERATION CHECKS”. THE OPERATOR MUST BE ASSURED THAT THE AERIAL LIFT HAS BEEN PROPERLY MAINTAINED AND INSPECTED BEFORE OPERATION. TA33 Page 9-4 Issued: Jul ‘97TEREX AERIALS OPERATOR’S MANUAL Maintenance Maintenance Schedule Maintenance checks prescribed for longer intervals include those required at shorter inter- vals. Thus, a Weekly Check (if applicable) includes all items in the Shift Check, the Monthly Check includes all items in the Shift and Weekly Checks, etc. The maintenance schedule provided serves as a guide to assure that minimum basic preven- tive maintenance requirements will be met under normal operating conditions. Severe usage conditions which impose greater wear, loads or strain on the aerial lift may dictate reducing the intervals between these checks. Before altering the recommended maintenance schedules, evaluate the operation of the aerial lift and review the Owner's Inspection Records. Consider all factors involved, and, ifnecessary, develop a revised schedule adequate to meet routine maintenance requirements. Owner's Inspection Records Periodic maintenance of the aerial lift is the responsibility of the owner. The “Inspection Re- ports” are to be used for recording the date of each inspection, personnel performing the inspection, deficiencies found, and corrective action taken. This record will also serve as a tool to detect potential problem areas and in re-analyzing maintenance requirements. Lubrication Correct lubrication is an essential part of preventive maintenance to minimize wear on work- ing parts and ensure against premature failure. By maintaining correct lubrication, the possi- bility of mechanical failure and resulting downtime is reduced to a minimum. Issued: Jul‘97 Page 9-5 TA33TEREX AERIALS OPERATOR’S MANUAL Maintenance Lubrication Diagram TASS Page 9-6 Issued: Jul‘97@ TEREX AERIALS OPERATOR’S MANUAL Maintenance Recommended Lubrication Schedule Item Type and Quantity Frequency of Lubrication 1. | Hydraulic reservoir | Shell TELLUS 22. With all | Check each shift. Analyze every cylinders retracted, fll to six (6) months or 500 hours". second baffle on cap dipstick. | Change yearly or every 1,000 hrs."t 2. | Hydraulic filter Filter element. Change every six (6) months or 500 hours.** 3. | Swing bearing Lithium N.L.G.1. #2 EP. Monthly or every 100 hours.** (grease outside of | Purge old grease. swing gear at 180°) 4. | Swing bearing gear | "Keystone-Moly 29 Open _| Monthly or every 100 hours." teeth Gear Compound’. Coat gear | Clean every six (6) months or faces. 500 hours.* 5. | Reduction drive unit | Mobil Glygoyle 22, Glygoyle | Check monthly or every 100 hours."t 30, or SHC 630 Change yearly or 1,000 hours.” 6. | Boom wear pads _| Silicone spray. Monthly or every 100 hours.** 7. | Hydraulic control | WD 40 Spray or equivalent — | Monthly or every 100 hours.” handle pivot pins | penetrating oil. 8. | Steering spindles | Lithium N.L.G.1. #2 EP. Monthly or every 100 hours." {king pin bearings) | Disassemble and pack. 9. | Valve spool linkage | WD 40 Spray or equivalent | Monthly or every 100 hours.” penetrating oil. 10. | Electrical switches | Electrical Contact Cleaner _| Clean and Lubricate every six (6) months or 500 hours*. * Whichever occurs first. + Different requirements for severe duty applications. See check lists. Issued: Jul‘97 Page 9-7 TA33TEREX AERIALS OPERATOR’S MANUAL Maintenance Shift Operational Check List - Owners Inspection Record All checks must be completed before operation of the machine. These check lists can be copied as needed to aid in performing these inspections. GENERAL INFORMATION 1. _ Keep inspection records up-to-date. 2. Record and report all discrepancies to your supervisor. 3. Adirty machine cannot be properly inspected. Keep your machine clean! AAWARNING THIS CHECK LIST MUST BE USED AT DAILY INTERVALS OR AF- TER EVERY 670 8 HOURS OF USE, WHICHEVER IS SOONER. FAIL- URE TO DO SO COULD ENDANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS. O.K. NOT DESCRIPTION QQ 4. Perform a visual inspection of all machine components, i.e. structural damage, missing parts, tom or loose heses, hydraulic fluid leaks, torn or disconnected wires, damaged tires, etc. Open rear compartment cover to inspect compo- nents inside. Q GQ — 2 Check battery electrolyte level and connections. 3. Check that the wheel lug nuts are tight. Q 4. Check hydraulic fluid level. The level should be at the second baffle on the cap dipstick, with the machine in stowed posit QQ 5. Check that all drive motor nuts are tight. Continued on following page ... TASS Page 9-8 Issued: Jul ‘97TEREX AERIALS OPERATOR'S MANUAL Maintenance Shift Operational Check List (Continued) - Owners Inspection Record Q a NOT DESCRIPTION oO Check hoses for worn areas or chafing. 7. Check hose carrier to verify that itis not bent or sagging. 8. Inspect safety belt connections, and check for worn areas on the belts. 9. Check platform rails and gate latch for damage. 10. Check pivot pins for security. 11. Check that all warning and instructional decals are legible and secure. 12. Check that the tilt alarm is working properly. 13. Check that the electrical control switches are not damaged. cooooncaoocnsa oooooadonosd 14, When all pre-inspection checks have been completed, the operator is ready to test the ground controls for proper operation. oa a 15. Check platform controls for proper operation. Q Q 16. With the platform raised, check for the smooth operation of low speed drive. any deficiencies found; and describe corrective action taken, and by whom: DATI INSPECTED BY: TITLE: MODEL: SERIAL NO.: HOUR METER: Continued on following page... Issued: Jul ‘97 Page 9-9 TA33TEREX AERIALS OPERATOR'S MANUAL Maintenance Shift Operational Check List (Continued) - Owners Inspection Record ADDITIONAL SHIFT MAINTENANCE FOR SEVERE USAGE APPLICATIONS NOTE: Do not lubricate wear pads in dusty or sandblast environments. There are boots and guards available to extend machine life in these applications. Consult Terex Aerials Service Department. ©.K. NOT DESCRIPTION Q 17. Inspect cylinder boots, valve spool boots, etc., for cuts or other damage after every eight (8) hours of service. Repair or replace if necessary. Q C18. Check hydraulic system for leakage after every eight (8) hours of service. ADDITIONAL WEEKLY MAINTENANCE FOR SEVERE USAGE APPLICATIONS O.K. NOT DESCRIPTION = Q 19. Lubricate swing bearing and swing bearing gear teeth. a a 20. Check oil in reduction drive unit. QQ G21. Lubricate valve spool linkage. Explain any deficiencies found; and describe corrective action taken, and by whom: DATE: INSPECTED BY: TITLE: MODEL: SERIAL NO.: HOUR METER: TAS3 Page 9-10 Issued: Jul ‘973 TEREX AERIALS OPERATOR’S MANUAL Maintenance Monthly Operational Check List - Owners Inspection Record All checks must be completed before operation of the machine. These check lists can be copied as needed to aid in performing these inspections. GENERAL INFORMATION 1. Keep inspection records up-to-date. 2. Record and report all discrepancies to your supervisor. 3. _Adirty machine cannot be properly inspected. Keep your machine clean! AAWARNING THIS CHECK LIST MUST BE USED AT MONTHLY INTERVALS OR EVERY 100 HOURS, WHICHEVER OCCURS FIRST. FAILURE TO DO SO COULD ENDANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS. ©.K. NOT DESCRIPTION aoa 1. Perform all checks listed on Shift Operational Check List. aoa 2. Apply lubricant to swing bearing gear teeth and drive pinion gear teeth (see Lubrication Chart) aoa 3. Inspect condition of hydraulic fluid in the reservoir. Fluid should have a clear amber color. oa 4. Check hydraulic system for leaks, examine hoses for signs of excessive wear, chafing or twisting. Adjust the hoses and/ or replace them if necessary. aa 5. Inspect the work platform and boom structure for signs of damage and broken welds. Check all bolts (including platform rotator bolts) for tightness. aoa 6. Check for structural damage, broken welds, loose bolts, improper or makeshift repairs. Continued on following page ... Issued: Jul ‘97 Page 9-11 TA33TEREX AERIALS OPERATOR’S MANUAL Maintenance Monthly Operational Check st (Continued) - Owners Inspection Record OK. NOT aoa aa aa aoa a aoa aoa aoa aoa aoa aoa 10. 11. 12. 13. 14. 15. 16. 17. DESCRIPTION Check torque of wheel lug nuts (see Specifications). Check torque of swing bearing bolts (see Specifications). Check adjustment and security of swing drive. Check torque of swing drive mounting bolts (see Specificatons). There should be no backlash between the turntable and undercarriage when properly adjusted. Check oil level in reduction drive unit (see Lubrication Chart) Check front whee! motors mounting bolt torque (see Specifications). Check that the boom does not drift with a full load, no hydraulic pressure (motor off) and the control valve in the "OOM DOWN' position. Check to make sure boom sections are not dented or bent. Check that all adjustable flow valves are locked. Lubricate boom wear pads (see Lubrication Chart). Lubricate hydraulic control handle pivot pins (see Lubrication Chart). Check emergency pump operation (see Emergency Pump). Explain any deficiencies found; and describe corrective action taken, and by whom: DATE: INSPECTED BY: TITLE: MODEL: ‘SERIAL NO.: HOUR METER: ‘TASS Page 9-12 Issued: Jul‘97TEREX AERIALS OPERATOR’S MANUAL Maintenance Quarterly Operational Check List - Owners Inspection Record All checks must be completed before operation of the machine. These check lists can be copied as needed to aid in performing these inspections. GENERAL INFORMATION 1. Keep inspection records up-to-date. 2. Record and report all discrepancies to your supervisor. 3. dirty machine cannot be properly inspected. Keep your machine clean! AWARNING THIS CHECK LIST MUST BE USED AT QUARTERLY INTERVALS OR EVERY 300 HOURS, WHICHEVER OCCURS FIRST. FAILURE TO DO SO COULD ENDANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS. O.K, NOT DESCRIPTION QQ 4. Perform all checks listed on Shift and Monthly Operational Check Lists. Explain any deficiencies found; and describe corrective action taken, and by whom: DATE: INSPECTED BY: TITLE: MODEL: SERIAL NO.: HOUR METER: Continued on following page... Issued: Jul ‘97 Page 9-13 TA3TEREX AERIALS OPERATOR’S MANUAL Maintenance Quarterly Operational Check List (Continued) - Owners Inspection Record ADDITIONAL QUARTERLY MAINTENANCE FOR SEVERE USAGE APPLICATIONS NOTE: Do not lubricate wear pads in dusty or sandblast environments. There are boots and guards available to extend machine life in these applications. Consult Terex Aerials Service Department. O.K. NOT DESCRIPTION G GQ — 2 Replace hydraulic filter element. Q OQ 3. Analyze hydraulic fluid, qa 4 Disassemble and pack steering spindles. Explain any deficiencies found; and describe corrective action taken, and by whom: DATE: INSPECTED BY: TITLE: MODEL: SERIAL NO.: HOUR METER: TA33 Page 9-14 Issued: Jul‘97TEREX AERIALS OPERATOR’S MANUAL Maintenance Semi-Annual Operational Check List - Owners Inspection Record All checks must be completed before operation of the machine. These check lists can be copied as needed to aid in performing these inspections. GENERAL INFORMATION 1. Keep inspection records up-to-date. 2. Record and report all discrepancies to your supervisor. 3. dirty machine cannot be properly inspected. Keep your machine clean! AWARNING THIS CHECK LIST MUST BE USED AT SIX MONTH INTERVALS OR EVERY 500 HOURS, WHICHEVER IS SOONER. FAILURE TO DO SO COULD ENDANGER THE LIFE OF THE OPERATOR. ALWAYS RE- MEMBER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS. OK. NOT DESCRIPTION Q QQ 4. Perform all checks listed on Shift, Monthly and Quarterly Operational Check Lists. Q Q 2 Have hydraulic fluid sample analyzed at a test laboratory. Comply with test results and recommendations to ensure long, trouble free operation. NOTE: If hydraulic fluid has been regularly maintained, it should only require changing once every year, depending on maintenance, temperature, applica- tion, duty cycle, and atmospheric conditions. Q Q 3. Clean and lubricate all electrical switches with an electrical contact cleaner and ensure that the switches operate freely in all positions. QQ GQ — 4, Check the electrical mounting and hardware connections for security. Continued on following page .. Issued: Jul‘97 Page 9-15 TA33TEREX AERIALS OPERATOR'S MANUAL Maintenance Semi-Annual Operational Check List (Continued) - Owners Inspection Record O.K. NOT DESCRIPTION Q Q 5. Replace hydraulic fiter element. Q G6 Lubricate all valve spool linkages. Q Q 7. Clean and lubricate the swing bearing gear teeth with Keystone Moly #29. Q Q _— &. Check that hydraulic pressure is as stated in the machine specifications. (Re- fer to Hydraulic Pressure Check, earlier in this section.) Q D9. Lubricate steering spindles (see Lubrication Chart). ADDITIONAL SEMI-ANNUAL MAINTENANCE FOR SEVERE USAGE APPLICATIONS NOTE: Do not lubricate wear pads in dusty or sandblast environments. There are boots and guards available to extend machine life in these applications. Consult Terex Aerials Service Department. 0.K. NOT DESCRIPTION = Q — 10. Change hydraulic fluid Explain any deficiencies found; and describe corrective action taken, and by whom: DATE: INSPECTED BY: TITLE: MODEL: SERIAL NO.: HOUR METER: TASS Page 9-16 Issued: Jul ‘97TEREX AERIALS OPERATOR’S MANUAL. Maintenance Environmentally Hazardous Materials Battery (Acid/ Lead) Spilled or leaked battery acid: + Neutralize the spilled quantity with baking soda or calcium-oxide by spreading, mix- ing, etc. Make certain that the mixture is neutral. Then collect the residue in a suitable container. Dispose of battery acid as special waste. + Always wear acid-resistant boots and gloves and use suitable face/ eye protection. * Donat allow non-neutralized acid to escape into the sewage system or open bodies of water. Damaged or unusable lead batteries filled with sulfuric acid: * Damaged or unusable batteries must be disposed of only by authorized disposal companies after emptying and collecting the sulfuric acid. + Dispose of lead-containing sulfuric acid as special waste. Hydraulic Fluid * Hydraulic oils are substances which contaminate water and must not reach the sew- age system or open waters. + The spilled or leaked quantity must be confined to as small an area as possible. Efforts should be made to recoup 2s much of the fluid as possible by scooping or vacuuming it up. Remove the remainder by sweeping with liquid absorbing materials (oil binding agents) + Scooped up or vacuumed up hydraulic fluid may be reused after proper filtering. + Materials or soil contaminated by hydraulic fluid must be placed in suitable container and disposed of according to the state or local disposal regulations. Issued: Jul‘97 Page 9-17 TA33TEREX AERIALS OPERATOR'S MANUAL Maintenance Hydraulic Fluid Different hydraulic fluid suppliers use various additives which, when mixed together, may cause problems in a hydraulic system. This situation is rare, but can cause sludge, which can plug filters or acid, which can etch machined surfaces in hydraulic components or deteriorate seals. Any of the above conditions can result in the voiding of the warranty for the components. Knowing this, if you still choose to add hydraulic fluid different from that initially supplied (see “Recommended Lubrication Schedule” Chart), stay with a single brand as this will minimize the possibility of problems. A CAUTION Any hydraulic fluid used in the hydraulic system of this aerial Ii must meet or exceed the specifications of the fluid initially sup- plied. ‘At the next complete hydraulic fluid change, the fluid may be switched to your preferred brand. AWARNING HYDRAULIC FLUID UNDER PRESSURE IS HOT, AND CAN PEN- ETRATE AND BURN THE SKIN, DAMAGE EYES, AND MAY CAUSE SERIOUS INJURY, BLINDNESS, AND EVEN DEATH. CORRECT LEAKS IMMEDIATELY. FLUID LEAKS UNDER PRESSURE MAY NOT ALWAYS BE VISIBLE. IF A MINERAL-BASED HYDRAULIC FLUID HAS PENETRATED THE SKIN, IT MUST BE MEDICALLY TREATED, WITHIN A FEW HOURS, BY A DOCTOR FAMILIAR WITH THIS TYPE OF INJURY. ALWAYS CLEAN UP FUEL, HYDRAULIC FLUIDS AND LUBRICAT- ING OILS SPILLED ONTHE MACHINE. SPILLS CAN CAUSE FALLS, AND ARE A SERIOUS FIRE HAZARD. TA33 Page 9-18 Issued: Jul‘97TEREX AERIALS OPERATOR’S MANUAL. Maintenance Hydraulic Pressure Check + Install a hydraulic pressure gauge (5000 psi [345 bar] rated) into port P1 of the valve manifold located inside the rear compartment. + Turn the main power key switch to the “PLATFORM” position. + Enter the platform and press the steer rocker switch with the foot switch depressed. When the wheels have turned to the full limit of travel, continue pressing the rocker switch and foot switch. This procedure is called “deadheading’, and will lead to maxi- mum compensator setting of the pump system pressure registering on the gauge at the valve manifold. Have a second person read the hydraulic pressure gauge. * Check that the hydraulic pressure is as stated in the specifications. Refer to the “Machine Specifications” of this manual for the “Maximum Hydraulic Pressure” for this machine. Hydraulic Fluid Filter Check * Position booms over side of the undercarriage for convenience. + Select one of the boom controls. While running the hydraulic pump observe the filter condition indicator. If the indicator shows a green band, the filter condition is satisfactory. If the indicator shows a red band, the filter should be changed as soon as possible. Issued: Jul ‘97 Page 9-19 TAS3TEREX AERIALS OPERATOR'S MANUAL Maintenance Controller Controller Diagnostics This machine is fitted with a Controller in the rear undercarriage compartment. This unit controls the variable output signals to both the traction motors and the boom power pack. ‘The Controller contains a green diagnostic LED which illuminates constantly whenever the ma- chine is powered up and functional (machine switched “ON’ and foot switch depressed). In the event of a fault condition occurring, the Controller LED will automatically indicate the type of fault by varying the number of times the LED flashes between pauses. The most important checks to perform on a machine which does not operate are: + check battery condition + check the cable connections and Controller connection plug. NOTE: When the key switch is turned to either “Ground” or “Platform” con- trols, the LED will indicate a “6 Flash” condition, which is normal operation. If a boom or drive function is selected, the LED will remain on constantly. Controller Fault Codes * 2 Flashes: procedure fault + Incorrect startup sequence - Turn machine off for 5 seconds, then back on. * Acceleration demand excessive - Joystick controller moved too fast - Move joystick slower. + Moisture interference - Contact Terex Service. * 3 Flashes: motor permanently low + Faulty Controller - Replace Controller. * Voltage spikes - Contact Terex Service. * Check for short circuit on control wiring. * If machine locks out, turn off all power and wait 5 seconds; then, reapply power. TA33 Page 9-20 Issued: Jul‘97TEREX AERIALS OPERATOR'S MANUAL Maintenance Controller (Continued) Controller Fault Codes (Continued) * 4 Flashes: motor permanently high * Ensure directional contactor not welded. * Drive motor fault - Check for short circuit in control wiring. * Check for dirt on directional contactors. 5 Flashes: motor neither high nor low + Ensure directional contactor not welded. Cheek for short circuit in power wiring. Check motor for open circuits. Check control wiring for open circuits. Check for dirt on directional contactors. 6 Flashes: traction accelerator fault * Incorrect startup sequence - Turn machine off for 5 seconds, then back on. . Check accelerator control circuit - Contact Terex Service. * Check control wiring for open circuits. 7 Flashes: battery voltage low * Measure battery voltage. + Check operation of charger unit and batteries. 8 Flashes: thermal cutback + Ensure machine is being operated within specification * Check input current value to motors + Allow unit to coo! 9 Flashes: speed encoder fault 10 Flashes: speed encoder fault 11 Flashes: speed encoder fault * Check tachogenerator (on drive motor) operation - Replace interface (tacho) card. * If machine locks out, turn off all power and wait 5 seconds; then, reapply power. Issued: Jul ‘97 Page 9-21 TAS3TEREX AERIALS OPERATOR’S MANUAL Maintenance Battery Charger ‘The battery charger supplied with this machine is designed to recharge deep-cycle, lead-acid batteries. It is a highly reliable unit with a minimum of moving parts. A\WARNING CONNECT ONLY TO A PROPERLY GROUNDED THREE-PRONG, SINGLE PHASE OUTLET. TO AVOID ELECTRIC SHOCK, DO NOT TOUCH UNINSULATED PARTS OFTHE CHARGER DC OUTPUT CON- NECTOR, BATTERY CONNECTOR OR TERMINALS. BE SURE CHARGER IS IN GOOD CONDITION, AND THAT BAT- TERY CONNECTORS MAKE ADEQUATE ELECTRICAL CONTACT AND ARE NOT CRACKED OR CORRODED. OVERHEATING AND PROPERTY DAMAGE MAY RESULT. LEAD-ACID BATTERIES GENERATE EXPLOSIVE GASES. NO SMOKING! KEEP SPARKS AND FLAME AWAY FROM BATTERIES. NEVER DISCONNECT THE DC OUTPUT CONNECTOR FROM THE BATTERIES WHILE THE CHARGER IS OPERATING. IF THE CHARGE CYCLE MUST BE INTERRUPTED, DISCONNECT THE AC POWER SUPPLY CORD FROMITS OUTLET; DO NOT DIS- CONNECT THE DC OUTPUT CONNECTOR FROMTHE BATTERY CONNECTOR. To operate, turn key to “OFF” position, and connect the power supply cord to the proper electrical outlet. A green light illuminates while charging the batteries. As the batteries approach full charge, the green light dims, and the charger outputs a trickle charge. The charger DC output cord should remain connected to the batteries at all times. Required charge time varies with depth of discharge. TA33 Page 9-22 Issued: Jul ‘97TEREX AERIALS OPERATOR’S MANUAL Batt Due form 1. 2. Maintenance Battery Charger (continued) ery Charger Troubleshooting AAWARNING HIGH VOLTAGE! WITH THE CHARGER “ON”, THE INTERNAL CHARGER CAPACITOR VOLTAGE IS APPROXIMATELY 650 VOLTS. ALWAYS UNPLUG THE ELECTRICAL CORDS FROM THE AC OUT- LET ANDTHE BATTERIES BEFORE ATTEMPTING ANY REPAIRSTO. THE CHARGER. NOTE: Modifying the charger for use other than that for which it was specifically intended, repairs by unqualified persons or use of other than original equipment replacement parts will void the warranty. to the way these chargers are constructed, only basic troubleshooting is practical. Per- the following checks: Make sure battery connections are electrically and mechanically sound. Check AC source for power. 3. For models that have an exterior fuse, check it and replace it, if required, with one having the same rating. 4. Check battery condition. A highly sulfated battery may take some additional time before current begins to flow through it. Issued: Jul'97 Page 9-23 TASSOPERATOR’S MANUAL TEREX AERIALS Maintenance Troubleshooting AAWARNING SHOULD YOU EXPERIENCE ERRATIC OPERATION OR NOTICE ANY MALFUNCTION WHILE RUNNING YOUR MACHINE, CONTINUE OP- ERATION ONLY LONG ENOUGH TO RETURN TO THE GROUND PO- SITION IF POSSIBLE. IMMEDIATELY REPORT THE INCIDENT TO YOUR SUPERVISOR, AND DISCONTINUE USING THE MACHINE UNTIL IT HAS BEEN CHECKED BY A TRAINED, QUALIFIED MECHANIC. Symptom Check Action No boom operations from ground controls. Is the main power key switch in the “ground controls” position? Are both emergency stop switches in released (power-on) position? Are batteries sufficiently charged? Select correct switch position. Pull out or turn emergency stop switches. Select platform operation. Read battery condition monitor. Charge batteries, as required. No boom Is the main power key switch in the Select correct switch position. operations from | platform controls position? platform con- trols. Are both emergency stop switches in | ‘Pull out or turn emergency released (power-on) position? stop switches. Is foot switch activated? Step down on foot switch pedal, Are batteries sufficiently charged? Read battery condition monitor. Charge batteries, as required. TASS Page 9-24 Issued: Jul'97tj TEREX AERIALS OPERATOR’S MANUAL Maintenance Troubleshooting (Continued) Symptom Check Action Booms will not lift - other func- tions operate. Emergency lower taps have been left open. Close taps. No drive func- tion. Batteries low; brakes will not release; drive control system locks out. Drive control diagnostic system has registered a fault and lock out. Charge batteries, as required. Switch ground controls off for 5 seconds, then on. Try drive again. Check fault code. (See Controller Fault Codes, earlier in this section.) Issued: Jul ‘97 Page 9-25 TASSTEREX AERIALS OPERATOR’S MANUAL Emergency Procedures Section 10 Description Page No. Emergency Procedures 10-2 Platform in Contact with Live Power Lines and Operator Incapacitated 10-3 Machine Elevated, with Operator Incapacitated at Platform Controls 10-4 Emergency Operation From Ground Control Station if Platform Controls Become Inoperable .... 210-5 Emergency Operation From Ground Control Station if Main Pump is Inoperable. 10-6 Unpowered Emergency Vehicle Movement 10-7 Issued: Jul ‘97 Page 10-1 TA33TEREX AERIALS OPERATOR'S MANUAL Emergency Procedures Itis not possible for us to foresee every emergency situation that could arise during operation of this machine. Information on the following pages describes several typical emergency situations, and lists appropriate actions that can be taken. When faced with an emergency, above all please remember: + Stay calm. + Think through the situation before operating the machine. + Get help if necessary. NGER IF THE MACHINE FAILS WHILE THE OPERATOR’S PLATFORM IS RAISED OR EXTENDED, DO NOT ATTEMPT TO CLIMB DOWN THE BOOM ASSEMBLY. SERIOUS INJURY MAY RESULT. HAVE AN EXPERIENCED OPERATOR USE THE EMERGENCY PUMP PROCEDURE TO SAFELY LOWER THE PLATFORM. THIS MACHINE IS NOT INSULATED. EXTREME CARE MUST BE TAKEN WHEN WORKING AROUND POWER LINES. DO NOT TOUCH THE MACHINE IF THERE IS A CHANCE IT IS IN CONTACT WITH POWER LINES. WAIT UNTIL THE POWER TO THE LINES HAS BEEN SHUT OFF. ‘TASS Page 10-2 Issued: Jul‘97TEREX AERIALS OPERATOR’S MANUAL Emergency Procedures Platform in Contact with Live Power Lines and Operator Incapacitated: NGER DO NOT TOUCH THE MACHINE!!! ELECTROCUTION HAZARD!!! Corrective Action: 1, Have someone summon first aid or rescue squad. 2. Contact authorized personnel to disconnect power supply touching the machine. 3. Before attempting emergency lowering, check to see if the operator is: + ina pinned position, or + would be endangered if platform is moved. 4. AFTER POWERIS CUT, lower or move the platform as necessary, using emergency procedures (see "Emergency Pump’, later in this section). 5. Render first aid to the operator. 6. Report the incident to your supervisor immediately. IMPORTANT: Any incident involving personal injury must be immedi- ately reported to the local Terex Aerials Distributorship as well as to Terex Aerials Inc. Issued: Jul ‘97 Page 10-3 TAS3TEREX AERIALS OPERATOR'S MANUAL Emergency Procedures Machine Elevated, with Operator Incapacitated at Platform Controls: DO NOT TOUCH THE MACHINI TRY TO DETERMINE THE CAUSE OF THE PROBLEM BEFORE YOU TOUCH THE MACHINE. Corrective Action: 1 Have someone summon first aid or rescue squad. 2. Attempt to talk to the operator before taking any rescue measures. 3. Before attempting emergency lowering procedure, check to see if the operator is: + inapinned position, or * would be endangered if platform is moved. 4. After establishing that the machine is not in contact with live power lines, lower or move the platform as necessary, using emergency procedures (see "Emergency Pump', later in this section). 5. Render first aid to the operator. 6. Report the incident to your supervisor immediately. IMPORTANT: Any incident involving personal injury must be immedi- ately reported to the local Terex Aerials Distributorship as well as to Terex Aerials Inc. TASS Page 10-4 Issued: Jul‘97TEREX AERIALS OPERATOR’S MANUAL Emergency Procedures Emergency Operation From Ground Control Station if Platform Controls Become Inoperable: 1. Remove foot from foot switch. 2. Press the red emergency stop button. 3. Evaluate the nature of the failure. 4. If unable to return to the ground using the platform controls, contact an experienced operator to lower the machine using the ground controls or emergency pump and lowering procedure (see “Emergency Pump’ later in this section). DO NOTTRY TO CLIMB DOWN THE BOOM. HAVE AN EXPERIENCED OPERATOR USE THE GROUND CON- TROLS OR EMERGENCY PUMP TO SAFELY LOWER THE PLAT- FORM. 5. Report the incident to your supervisor immediately. Issued: Jul‘97 Page 10-5 TA33TEREX AERIALS OPERATOR’S MANUAL Emergency Procedures Emergency Operation From Ground Control Station if Main Pump is Inoperable: Emergency Pump This machine has an emergency pump which can be operated from the ground con- trol station to briefly operate the machine when it has lost power. Turn the appropriate knob on the superstructure valve control bank in (clock- wise) to shift the valve: + Swing (rotate) superstructure clockwise or counterclockwise, + Boom (upper or lower) raise or lower, or * Upper boom telescope in or out. Pump the emergency hand pump to operate the desired function. (Pump handle is stowed on the lower boom post.) When machine has reached the desired position, turn the valve knob out (coun- terclockwise) to hold. Emergency Rotation Emergency rotation of the superstructure can be performed by the emergency pump (see previous page) or by a mechanical override. For the mechanical override procedure, use a 30 mm socket, extension and ratchet handle attached to the hexagon extension shaft of the rotate drive gearbox. 4 CAUTION Care should be taken not to override the electrical rotation stop to avoid damaging the hoses which pass through the rotation ring. Always rotate the machine to the normal stowed position by the shortest route. After using emergency rotation, check hoses for damage. TA33 Page 10-6 Issued: Jul‘97