Terex HI-RANGER TM Series Operator's Manual
  1. Manuals
  2. Brands
  3. Terex Manuals
  4. Construction Equipment
  5. HI-RANGER TM Series
  6. Operator's manual
Terex HI-RANGER TM Series Operator's Manual

Terex HI-RANGER TM Series Operator's Manual

Non-overcenter material handling aerial device
Hide thumbs
Table of Contents

Advertisement

Quick Links

HI–RANGER
TM SERIES
OPERATOR'S MANUAL
This Operator's Manual MUST BE READ prior to operating your
TM SERIES Non-Overcenter Material Handling Aerial Device.
PRINTED IN THE USA
Original Instructions in English
Terex South Dakota, Inc.
472797 01/2015

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the HI-RANGER TM Series and is the answer not in the manual?

Questions and answers

Related Manuals for Terex HI-RANGER TM Series

Summary of Contents for Terex HI-RANGER TM Series

  • Page 1 HI–RANGER TM SERIES OPERATOR’S MANUAL This Operator’s Manual MUST BE READ prior to operating your TM SERIES Non-Overcenter Material Handling Aerial Device. PRINTED IN THE USA Original Instructions in English Terex South Dakota, Inc. 472797 01/2015...
  • Page 2 TM SERIES Terex South Dakota, Inc. 500 Oakwood Road Watertown, SD 57201 47 279 7 - 0 1 / 1 5 T er e x S o u th D ako ta , I nc . T M Se r i es...

  • Page 3: Table Of Contents

    TM SERIES TABLE OF CONTENTS INTRODUCTION ..............- I OWNERS, USERS AND OPERATORS .
  • Page 4 TM SERIES JIB ROTATION ............. . .1 - 26 MANUAL JIB EXTENSION .
  • Page 5 TM SERIES 12 MONTHS (1,050 HOURS) ........... . .2 - 4 5 YEARS .
  • Page 6 TM SERIES t o c - 4 47 279 7 - 1/1 5 Te re x So uth Da kota , Inc. T M Se ri es...

  • Page 7: Introduction

    INTRODUCTION OWNERS, USERS AND OPERATORS Thank you for choosing Terex South Dakota, Inc. equipment for your application. User safety is our number one priority and this is best achieved by our joint efforts. As equipment users and operators, you make a major contribution to safety if you: 1.

  • Page 8: Intended Use

    Use of this product in any other way is prohibited and contrary to its intended use. BULLETIN DISTRIBUTION AND COMPLIANCE It is the owners responsibility to comply with all bulletins issued by Terex South Dakota, Inc. or the vehicle manufacturer. Safety of product users is of paramount importance to Terex South Dakota, Inc.. Various bulletins are used by Terex South Dakota, Inc.

  • Page 9: Safety

    The operator is the single most important factor for safety when using any piece of equipment. Learn to operate your Terex South Dakota, Inc. equipment in a safe manner. NOTE: The best method to protect yourself and others from injury or death is to use common sense.
  • Page 10 2. Modifications to this Terex South Dakota, Inc. equipment from the original design specifications without written permission from Terex South Dakota, Inc. are strictly forbidden. A modification may compromise the safety of the Terex South Dakota, Inc. equipment, subjecting users to serious injury or death. Any such modification will void any remaining warranty.
  • Page 11 TM SERIES GENERAL SAFETY GUIDELINES 1. The use of this Aerial Device is subject to certain potential dangers that cannot be protected against by mechanical means. Only the exercise of intelligence, care, and common sense can eliminate these dangers. It is essential to have competent, careful operators who are physically and mentally fit, and thoroughly trained in the safe operation of this Aerial Device.

  • Page 12: Before Operation

    TM SERIES BEFORE OPERATION 1. Survey the conditions of the work area. Identify situations such as; soft ground, ditches, drop-offs, holes, debris, overhead obstructions, electrical conductors, and underground utilities. 2. Plan the job (tailgate session) and clear the area of bystanders. 3.

  • Page 13: During Operation

    TM SERIES DURING OPERATION 1. Never operate the Aerial Device unless you know the location, function, and operation of all the controls, including emergency and accessory operation. 2. Avoid abrupt starts, stops and reversal of direction. Operate all controls slowly for smooth motion. 3.

  • Page 14: Electrical Hazards

    TM SERIES ELECTRICAL HAZARDS ELECTRICITY OBEYS NO LAW, BUT ITS OWN. 1. Electricity is an ever-present danger when using an Aerial Device. Follow all OSHA, ANSI, state, federal and company rules and regulations when working on or near energized power lines. 2.

  • Page 15: Accessories

    TM SERIES 17. All metal components at the boom tip beyond the band of arrows are interconnected. Contact of any part to an energized conductor will energize the entire boom tip, including the controls. 18. Do not attach any metal objects from outside the platform to the inside of the platform. This defeats the purpose of the platform liner.

  • Page 16: Traveling

    TM SERIES 5. Keep the winch rope clean and dry. 6. Inspect the winch rope daily. Do not operate with a damaged or frayed rope. 7. Use a sling. Do not use the winch rope as a sling. 8. Use only hooks with a safety latch. 9.

  • Page 17: Maintenance

    TM SERIES MAINTENANCE 1. Inspect, maintain, and repair this Aerial Device in accordance with the maintenance manual for this device and the maintenance section of this manual. 2. Only authorized and qualified personnel with complete knowledge of this Aerial Device shall be allowed to perform maintenance on this Aerial Device.

  • Page 18: Overview Of Potential Hazards

    The operators shall read and understand this manual and be trained to use the machine in an appropriate and safe manner. Should any questions arise concerning the maintenance or operation of the machine contact Terex South Dakota, Inc.. Alert Symbol DANGER: Failure to follow will Your safety is involved.
  • Page 19 TM SERIES Crushing WARNING: Will Cause Serious Do not operate outriggers unless you can verify all Crushing Injury. personnel and obstructions are clear. Operator must watch the outrigger while in motion. High Pressure WARNING: Can Cause Serious Relieve pressure on hydraulic and pneumatic systems Air or Fluid Injury or Death.

  • Page 20: Safety Related Decals

    TM SERIES SAFETY RELATED DECALS Safety signs are designed and fitted to the product to warn of possible dangers, and MUST be replaced immediately if they become unreadable or lost. If the product is repaired and parts have been replaced on which safety signs were fixed, be sure new safety signs are fitted before the product is put into service.
  • Page 21 TM SERIES TRUCK MUST BE LEVEL BEFORE OPERATING BOOMS 79584D 3. & 4. NOT INSULATED BOOM IS READ CAREFULLY BEYOND ARROWS OCCUPANTS OF THE BASKETS OF THIS AVOID CONTACT WITH ENERGIZED LINES. AERIAL DEVICE HAVE ABSOLUTELY NO 402236A ELECTRICAL PROTECTION FROM CONTACT BY THE HUMAN BODY WITH TWO ENERGIZED CONDUCTORS OR...
  • Page 22 TM SERIES FAILURE TO OBEY THE FOLLOWING WILL RESULT IN DEATH OR SERIOUS INJURY For stationary operation, truck must be securely parked, driveline disengaged, and Aerial Device properly stabilized prior to operation. To avoid tip-over, outriggers (when so equipped) must be properly extended on a solid level surface.
  • Page 23 TM SERIES FALLING FROM PLATFORM WILL RESULT IN DEATH OR SERIOUS INJURY Platform personnel must wear an OSHA approved fall protection system with lanyard attached to anchor provided. Platform doors, if provided, must be se- curely latched. 419264A ELECTROCUTION HAZARD THIS MACHINE IS NOT INSULATED DEATH OR SERIOUS INJURY...
  • Page 24 TM SERIES OUTRIGGER CONTACT AN UNTRAINED OPERATOR WILL CAUSE SUBJECTS HIMSELF AND SERIOUS CRUSHING INJURY OTHERS TO DEATH OR SERIOUS INJURY Do not operate any outrigger unless you or a signal person can see that personnel YOU MUST NOT OPERATE and obstructions are clear of the outrigger THIS MACHINE UNLESS and its contact point.
  • Page 25 TM SERIES ELECTROCUTION HAZARD CONTROLS ARE NOT INSULATED OR ISOLATED All metal at boom tip is electrically connected. Operator contact with ANY, live or grounded, line or object while operator touches CONTROLS or BOOM TIP COMPONENTS and boom tip contacts any other line or object can result in DEATH OR SERIOUS INJURY Comply with OSHA, ANSI, &...
  • Page 26 TM SERIES Platform NOT allowed on this side of Platform allowed center line on this side of OVERTURNING HAZARD Center line of Rotation DEATH OR SERIOUS INJURY May result from operating outside the proper platform & boom positions or improper outrigger setup or truck position Extension Allowed Platfrom must remain opposite lower boom...
  • Page 27 TM SERIES INSPECTION DATE RECORD Follow the Frequent and Periodic Inspection Intervals as required in the Operators and Maintenance Manuals. Maintain a record of all inspections. Stamp or engrave below when and who performed inspections. Follow component replacement intervals shown in your Maintenance Manual. CRITICAL FASTENER DIELECTRIC ANNUAL...
  • Page 28 TM SERIES FALL HAZARD FAILURE TO PROPERLY MAINTAIN THIS MACHINE CAN LEAD TO STRUCTURAL FAILURE AND RESULT IN DEATH OR SERIOUS INJURY Read and follow all inspection and maintenance schedules in the manual(s). Do not operate machine unless all deficiencies are corrected. Proper maintenance and inspection is required for safe and reliable operation.
  • Page 29 TM SERIES PINCH POINT KEEP HANDS CLEAR TO AVOID PERSONAL INJURY H23451 Escaping fluid under pressure penetrate skin causing serious injury. Relieve pressure before disconnecting hydraulic lines. Keep away from leaks holes. piece cardboard or paper to search for leaks. Do not use your hand.

  • Page 30: What Is Insulated And Not Insulated

    TM SERIES WHAT IS INSULATED AND NOT INSULATED The term insulated means separated from other conductive surfaces by a dielectric substance (including air space) offering a high resistance to the passage of current (from OSHA 1926.960). Area A. Upper Boom Insulation, provides an insulating area between area D and earth ground when in properly maintained condition.
  • Page 31 TM SERIES The insulating boom section only prevents current from passing from the band of arrows at the boom tip to the lower band of arrows. All components above and below that area must be considered conductive. The boom tip is everything past the upper band of arrows.

  • Page 32: Electrical Insulation

    TM SERIES ELECTRICAL INSULATION Operation on or near energized lines is extremely hazardous unless proper OSHA and ANSI work rules are followed. The operation of this Aerial Device in proximity to high voltage electrical lines involves several hazards to the operator of the Aerial Device, ground personnel and bystanders on the ground. These hazards are as follows: 1.

  • Page 33: Prevention Of Electrocution

    TM SERIES There is no protection against Hazard No. 4. Caution must be exercised continually to avoid making contact with an energized line, which, if broken or burned, may drop to the ground and cause injury to ground personnel and any bystanders. PREVENTION OF ELECTROCUTION 1.
  • Page 34 TM SERIES The fiberglass boom and platform liners must be dielectrically tested periodically to insure the insulating properties are being maintained. Do not assume that it is so. Ground personnel must be warned to stay away from vehicle in case of accidental boom contact between conductor and metallic portion of boom, which will cause serious injury or death.
  • Page 35 TM SERIES READ CAREFULLY OCCUPANTS OF THE BASKETS OF THIS AERIAL DEVICE HAVE ABSOLUTELY NO ELECTRICAL PROTECTION FROM CONTACT BY THE HUMAN BODY WITH TWO ENERGIZED CONDUCTORS OR BETWEEN AN ENERGIZED CONDUCTOR AND A GROUNDED CONDUCTOR. It makes no difference if this contact is accidental or deliberate or whether contact is made through metallic parts of the basket, basket support, metal tools or equipment...
  • Page 36 TM SERIES - X X X 47 279 7 - 1/1 5 Te re x So uth Da kota , Inc. T M Se ri es...

  • Page 37: Section 1

    TM SERIES SECTION 1 OPERATION GUIDELINES NOMENCLATURE Upper Boom Extension Cylinders Upper Controls Elbow Pin Boom Tip Upper Boom Platform Lower Boom Upper Boom Cylinder Lower Boom Extension Rollers Lower Boom Extension Cylinder Lower Boom Lift Cylinder Strobe Light Lower Controls Outriggers T M S er ie s Te r e x S o u t h D a k o t a , I n c .

  • Page 38: Cab Control Operation

    TM SERIES CAB CONTROL OPERATION MASTER CONTROL The master control is located in the cab of the vehicle and has a toggle switch on the dashboard. The toggle switch is used to energize the engine stop/start system and the throttle control options, which may be located in the cab, at the platform, or on the pedestal.

  • Page 39: Cab Control Functions

    TM SERIES CAB CONTROL FUNCTIONS Master Power Push “ON” to activate remote electrical systems. Push “OFF” to deactivate remote electrical systems. May also engage PTO. O O N N M M A A S S T T E E R R P P O O W W E E R R O O F F F F 4 4 3 3 7 7 0 0 3 3 1 1...

  • Page 40: Controls Below Rotation

    TM SERIES CONTROLS BELOW ROTATION These controls are usually mounted at the rear of the vehicle chassis. The controls may include outriggers, hydraulic tools, control selector, engine stop/start, two-speed throttle, and auxiliary let down power. The controls shown are generic. The actual location and functions will vary depending on the purchasers requirements and options ordered.
  • Page 41 TM SERIES CONTROLS BELOW ROTATION FUNCTIONS Selector Move handle up to activate “UNIT” system. UNIT The Selector will function as an emergency stop by taking oil flow away from the active control SELECTOR O/R’S Move handle down to operate outrigger system “O/R’S”. Outrigger Move handle “UP”...

  • Page 42: Operator Controls And Descriptions

    TM SERIES OPERATOR CONTROLS AND DESCRIPTIONS Aerial Device functions may be controlled from either the upper controls at the platform or the lower controls station. The platform controls are used, in normal operation, by the operator to control the Aerial Device. The lower controls are used for inspection, maintenance, and in emergency situations.
  • Page 43 TM SERIES ELECTROCUTION HAZARD CONTROLS ARE NOT INSULATED OR ISOLATED All metal at boom tip is electrically connected. Operator contact with ANY, live or grounded, line or object while operator touches CONTROLS or BOOM TIP COMPONENTS and boom tip contacts any other line or object can result in DEATH OR SERIOUS INJURY Comply with OSHA, ANSI, &...

  • Page 44: Upper Controls

    TM SERIES UPPER CONTROLS SINGLE STICK ITEM CONTROL DESCRIPTION Single Stick Controls upper boom, lower boom, rotation, and upper boom extension. Engine Stop/Start (Optional) Allows the operator to stop and start the engine from the platform. Two-Speed Throttle Two-speed throttle provides two engine speeds, low and high, with engine running.
  • Page 45 TM SERIES SINGLE STICK FUNCTIONS The control location shown is generic. The actual location will vary depending on purchasers requirements and options. Some of the following control functions may not be included in the controls for this Aerial Device. Refer to the control decals on unit for proper operation. SINGLE STICK CONTROL LABEL Be sure the control handle is in the centered neutral position before depressing enabling lever.
  • Page 46 TM SERIES Upper Boom Squeeze the enable lever and lift lever “UP” to unfold upper boom. Squeeze the enable lever and push lever “DOWN” to fold upper boom. DOWN Lower Boom Squeeze the enable lever and push lever forward to unfold lower boom “UP”.
  • Page 47 TM SERIES Engine Stop/Start Push and hold to start engine. (Optional) STOP/START Release when engine starts. ENGINE Push and release to stop engine. PUSH/RELEASE 437033 Can also be used to stop the Aerial Device in an emergency. Two-Speed With engine running, the throttle is activated. Throttle TWO SPEED Push and release to increase engine RPM.
  • Page 48 TM SERIES Winch (Optional) Push to lower load “DOWN” or pay-out winch line. DOWN Pull to raise load or wind winch line “UP”. WINCH Platform Rotation Push to rotate clockwise “CW” to end position. (Optional) PLATFORM ROTATION Pull to rotate counterclockwise “CCW” to stowed position. Platform Level Squeeze single stick enable lever and move lever side to side to side.

  • Page 49: Lower Controls

    TM SERIES LOWER CONTROLS 6,7,4,3,2,8,5 ITEM CONTROL DESCRIPTION Top Control and Option Controls oil flow to the option valve and hydraulic tool at the platform. In Shut-Off the “OFF” position no oil is available at the platform valve. Must be in the “ON”...

  • Page 50: Top Control And Option Shut Off

    TM SERIES TOP CONTROL AND OPTION SHUT OFF The Top Control and Option Shut Off is used to stop operation of the upper controls. It will stop all oil flow to the boom tip in case of an oil leak. It is also used to override the upper controls in case of an emergency. The upper controls are not operable when the Top Control and Option Shut Off is in the “OFF”...
  • Page 51 TM SERIES Top Control Shut- Pull up to turn “ON”. Push down to turn “OFF”. Must be in the “ON” position to operate the jib, winch, platform rotate and hydraulic tools at the platform location. Lower Boom Push lever forward to “RAISE” lower boom up. Pull lever back to “LOWER”...
  • Page 52 TM SERIES Upper Boom Push lever forward to “LOWER” lower boom down. Pull lever back to “RAISE” lower boom up. Upper Boom Pull lever back to “RAISE” lower boom up. (TM125 only) Push lever forward to “LOWER” lower boom down. Platform Level Push lever to “LEVEL”...
  • Page 53 TM SERIES Lower Boom Push lever forward to “EXTEND” out lower boom. Extend Pull lever back to “RETRACT” in lower boom. Upper Boom Push lever forward to “EXTEND” out upper boom. Extend Pull lever back to “RETRACT” in upper boom. Engine Stop/Start Push and hold to start engine.

  • Page 54: Accessories

    TM SERIES ACCESSORIES The Accessory controls and the enable on the single stick are fiber optic devices that use a light switch at the platform to operate the function. The light source uses battery power. The batteries are located in the control area enclosed in a plastic box.

  • Page 55: Manual Let Down System

    TM SERIES MANUAL LET DOWN SYSTEM Provides a way to get personnel to the ground during a unit power failure using gravity. This system provides a manual hydraulic pump that can supply enough pressure to bypass the cylinder holding valve using a pilot operated check valve.

  • Page 56: Hydraulic Tools (Optional)

    TM SERIES HYDRAULIC TOOLS (OPTIONAL) Hydraulic tool circuits are used to attach hydraulic powered hand tools to the hydraulic system of the Aerial Device. Quick-disconnect couplings are used to attach hydraulic tools. There may be one or two sets of tool couplers.

  • Page 57: Platform Tilt

    TM SERIES PLATFORM TILT Do not allow anyone to operate the platform tilt device while occupants are in the platform. Serious personal injury or death could result from platform upsetting. The platform leveling system permits the platform to be tilted to clean out water and debris. It also allows the platform to be tilted for personnel rescue.

  • Page 58: Platform Leveling (Without Generator)

    TM SERIES PLATFORM LEVELING (WITHOUT GENERATOR) The platform level control is an electro-hydraulic system controlled by a level sensor, control system and a hydraulic servo valve to keep the platform level. As the upper boom or lower boom articulate the level will turn on to allow operation and keep the platform level.

  • Page 59: Platform Leveling (With Generator)

    TM SERIES PLATFORM LEVELING (WITH GENERATOR) The platform level control is an electro-hydraulic system controlled by a level sensor, control system and a hydraulic servo valve to keep the platform level. As the upper boom or lower boom articulate the level will turn on to allow operation and keep the platform level.

  • Page 60: Platform Rotator (Optional)

    TM SERIES PLATFORM ROTATOR (OPTIONAL) The platform rotator allows operator to rotate the platform from the stowed position to the rotated position (end position). When not in use the platform must be placed in the stowed position. Prior to platform rotation, observe all obstructions and hazards near the platform’s swing path to avoid collisions and contact with lines.

  • Page 61: Jib & Winch Operation (Optional)

    TM SERIES JIB & WINCH OPERATION (OPTIONAL) When operating the winch under load, always use a smooth movement for lowering or raising loads to avoid shock loads and sudden changes in truck balance. These dynamic shocks can have an effect on the structural members of the Aerial Device.

  • Page 62: Jib Rotation

    TM SERIES JIB ROTATION Jib rotation is a manual operation with 5 locking positions. To rotate the jib, release the locking pin located at the rear of the jib. Manually rotate the jib to one of the 5 locking positions. COVERS REMOVED FOR CLARITY Do not operate the jib without the locking pin securely locked into one of the designated locking positions.

  • Page 63: Hydraulic Jib Extension (Optional)

    TM SERIES HYDRAULIC JIB EXTENSION (OPTIONAL) The jib extension can be adjusted hydraulically in the range of cylinder movement. If the jib must be extended or retracted more than cylinder stroke allows do the following: Do not extend under load. 1.

  • Page 64: Avoid Trapped Loops

    TM SERIES Use only synthetic rope for winch line. Do not use wire rope. Do not allow winch line to come in contact with guyline, pole, crossarm, ground, or any object that can create a path to ground or energize the winch line. Dirt, grease, other foreign matter, moisture and humidity will all contaminate the winch line - keep it clean.

  • Page 65: Boom Lifting Eye Material Handling (Optional)

    TM SERIES BOOM LIFTING EYE MATERIAL HANDLING (OPTIONAL) A lifting eye may be provided to be used for limited material handling. For maximum lifting capacity, refer to the load chart installed on the Aerial Device. • Always extend the outriggers. •...

  • Page 66: Personnel And Training

    TM SERIES PERSONNEL AND TRAINING All personnel assigned to an Aerial Device shall be given an opportunity to become familiar with the operation of the equipment before they operate it on a job. The operator and all other personnel should be familiar with the operating procedures.

  • Page 67: Pre-Operation

    TM SERIES PRE-OPERATION DAILY PRE-OPERATION CHECKS Before operating the Aerial Device, check the following: 1. Perform the frequent and periodic inspections and lubrications as outlined in the maintenance section of this manual. 2. Store loose objects properly. 3. Check under the vehicle for leakage. 18 23 5, 6, 26 VEHICLE AND BODY CHECKS...
  • Page 68 TM SERIES 9, 10 21, 22 7, 14 1, 2, 4 1, 2, 4 5, 6, 21 21 Opp side AERIAL DEVICE CHECKS ITEM DESCRIPTION ITEM DESCRIPTION Outriggers Upper Controls Outrigger Cylinders Platform and Harness Outrigger Alarms Platform Step Outrigger Mounting Platform Mounting Return Line Filter Electrical Systems...

  • Page 69: Job Site Survey

    TM SERIES JOB SITE SURVEY Before locating the vehicle in position to work, make a complete survey of the job site. During the survey, some of the items to look for include the following: • Ambient conditions including temperature. • Consider the slope of the ground. Unit is tested on maximum 5 degree ground slope. •...

  • Page 70: Job Site Setup

    TM SERIES JOB SITE SETUP The unit is tested for stability per ANSI with the vehicle level and must be operated within those guidelines. Because of the effects on stability when the unit is not level, the unit must be in a level position before any boom functions are operated.

  • Page 71: Setting The Outriggers

    TM SERIES SETTING THE OUTRIGGERS Before lifting or rotating the Aerial Device, all outriggers (if equipped) must be lowered firmly to the ground on a surface that can support the load, and kept there until all work is complete and the Aerial Device is stowed for travel.
  • Page 72 TM SERIES • Two sets of outriggers: The outriggers are extended to support the weight of the unit. The tires must remain in contact with the ground. • The vehicle can be leveled slightly with the outriggers. • The axles not located between the outriggers must equally support the load of the truck so the suspension on each side is equally loaded.
  • Page 73 TM SERIES If the vehicle must be set up with the slope, always keep the boom on the uphill side of the vehicle, always chock the wheels, and always work off the rear of the vehicle. VEHICLE SETUP WITH THE SLOPE The truck must be level before operating the booms.

  • Page 74: Setting Up On A Soft Surface

    TM SERIES SETTING UP ON A SOFT SURFACE If the ground is too soft to support the outrigger load or wheel load, the outriggers or tires must be padded or cribbed until the ground will support the load or the unit cannot be used at that location. Make certain the tires and outriggers are centered on the pads and the cribbing provides stable support as the booms are moved.

  • Page 75: Stability

    TM SERIES STABILITY The stability of a vehicle equipped with a rotating aerial device depends on the gross weight of the vehicle and load, the slope of the work area, and whether the ground is firm enough to support the weight of the outrigger pads.

  • Page 76: Operation

    TM SERIES OPERATION BOOM OPERATION The boom movement is limited to non-overcenter positions by a limit system. Do not depend on the limit system to recognize when the booms are approaching a limit. Operate the unit knowing where the booms and platform are in the work envelope to keep operation in the working area.

  • Page 77: Unstore The Boom

    TM SERIES When the upper boom up or the lower boom down motion is stopped by the limit valves it may be necessary to lower the upper boom or raise the lower boom slightly to reset the valves. All boom movements should be smooth. Avoid jerking by slowly metering the control valves when starting and stopping all motions.

  • Page 78: Aerial Operation

    TM SERIES AERIAL OPERATION Before using the Aerial Device, the operator should check through the pre-operational procedure to ensure the vehicle is properly positioned with outriggers (if equipped) firmly in place. Extreme care should always be exercised when lifting personnel. Before entering the platform, place the outrigger control selector (if equipped) and the lower control selector to the upper controls.
  • Page 79 TM SERIES FALLING FROM PLATFORM WILL RESULT IN DEATH OR SERIOUS INJURY Platform personnel must wear an OSHA approved fall protection system with lanyard attached to anchor provided. Platform doors, if provided, must be se- curely latched. 419264A ELECTROCUTION HAZARD THIS MACHINE IS NOT INSULATED DEATH OR SERIOUS INJURY...
  • Page 80 TM SERIES USE PROTECTIVE EQUIPMENT SUITABLE FOR THE WORK BEING PERFORMED: • Wear your rubber gloves and sleeves when working on or near electrical equipment. • Install hose, covers, and mats on all energized and grounded conductors. • Wear protective and insulated headgear. •...

  • Page 81: Emergency Operation

    TM SERIES EMERGENCY OPERATION Emergency operation may be required if an operator is injured or the equipment malfunctions. In any emergency, the first priority is always the safety of the personnel involved. It is always important to remember to follow the standard work practices and the safety regulations that apply. If the Aerial Device is operable, move the platform away from the danger and into the shortest, clear path of descent to get the operator on the ground.
  • Page 82 TM SERIES STANDING ON GROUND CLOSE TO FALLEN POWER LINE You must shuffle keeping feet together, do not run. The voltage is highest where contact is made and decreases as you get farther away from the point of contact. The distance will depend on the ground conditions and conductivity of the ground.

  • Page 83: Top Control Shut-Off

    TM SERIES BEFORE TRYING TO GET ON OR APPROACH THE VEHICLE: • Is it necessary to approach the vehicle? Can the operator handle the problem from the platform? • The best procedure is to disconnect or shut off the power to the lines. •...

  • Page 84: Auxiliary Let Down Power (Optional)

    TM SERIES AUXILIARY LET DOWN POWER (OPTIONAL) The auxiliary let down power system provides power from a DC motor-pump for operation of the Aerial Device in case of a prime power source failure. Controls for auxiliary let down power may be located at the platform, pedestal (optional), and outriggers (optional).

  • Page 85: Hydraulic Line Failure

    TM SERIES HYDRAULIC LINE FAILURE Hydraulic line failure during Aerial Device operation presents numerous hazards. Be aware that a hydraulic oil mist caused by a leak or hydraulic line failure is conductive even though nonconducting oil is used. A spray or mist produced by a hydraulic leak under pressure is very hazardous to personnel.
  • Page 86 TM SERIES WHAT CAN HAPPEN WHEN HYDRAULIC LINES FAIL? Hydraulic oil, when confined within the hydraulic system and properly maintained, is non-conductive and not subject to being ignited. There are numerous hazards that develop when there is a hydraulic line separation: •...

  • Page 87: Engine Failure

    TM SERIES ENGINE FAILURE If the prime power source fails, the optional auxiliary let down power system can be used for emergency operation. If the auxiliary let down power system is not installed and the vehicle has a manual transmission, then use the engine stop/start control (if so equipped) to crank the engine.

  • Page 88: Operational Limitations

    TM SERIES OPERATIONAL LIMITATIONS PLATFORM LEVELING SYSTEM The platform leveling system is designed to carry the rated load of the platform. Collision of the platform(s) with a fixed object, including the ground, or attachment of any load lifting devices to the platform(s) can damage or break the leveling system, causing the platform to be overturned.

  • Page 89: Platform Leveling System With Generator

    TM SERIES PLATFORM LEVELING SYSTEM WITH GENERATOR This system operates on a 12 volt battery which is charged by an onboard generator. Routine service of this battery is not necessary. If the low battery indicator light turns on, replace the battery located beneath the servo and/or check the generator for proper operation.

  • Page 90: Limit System (Operational Range)

    TM SERIES LIMIT SYSTEM (OPERATIONAL RANGE) The TM Series is a non-overcenter Aerial Device. It operates with the platform opposite the centerline of rotation from the lower boom at all times. If the platform moves toward the elbow side the machine may become unstable and overturn to the elbow side.

  • Page 91: Use Of Category A Units

    TM SERIES Preventing these three movements keeps the boom from going into a more unstable position toward the elbow side. It is accomplished with valves at various locations that work together to prevent the unit from getting into unstable conditions. This system limits the boom extension in conjunction with the position and angle of the boom.

  • Page 92: Folding For Travel

    TM SERIES FOLDING FOR TRAVEL Do not travel with tools or other items stored in the platform. Loose items may damage the platform or fall on the roadway during road travel. It is essential to follow the correct procedure whenever booms are folded for travel: •...

  • Page 93: Section 2

    A preventative maintenance program based on the manufacturer's recommendations shall be established. Dated and detailed inspection and repair records shall be maintained. It is recommended that the replacement parts for your Aerial Device be obtained from a Terex South Dakota, Inc. distributor or Terex South Dakota, Inc..

  • Page 94: Lubrication

    Always remember, preventive maintenance can save much more than it costs. NOTE: The following check points listed are the minimum recommended by Terex South Dakota, Inc.. They are subject to supplementation to conform with your own company regulations.

  • Page 95: Frequent And Periodic Inspection Intervals

    TM SERIES FREQUENT AND PERIODIC INSPECTION INTERVALS DAILY 1. Check controls at platform and lower controls for proper operation. 2. Inspect fall protection equipment and attachments. 3. Inspect visual and audible devices. 4. Check cleanliness and dryness of fiberglass components. 5.

  • Page 96: Months (1,050 Hours)

    TM SERIES 12 MONTHS (1,050 HOURS) 1. Inspect and lubricate PTO drive shaft to pump. 2. Take samples of hydraulic oil and test. 3. Check all system pressure adjustments for proper setting. 4. Replace hi-pressure filters. 5. Perform cylinder drift tests. 6.

  • Page 97: Lubrication Chart

    TM SERIES LUBRICATION CHART T M S er ie s Te r e x S o u t h D a k o t a , I n c . 4 72 79 7 - 1 / 1 5...

  • Page 98: Winch Rope Inspection

    TM SERIES WINCH ROPE INSPECTION All stable braid ropes in continuous service should be visually inspected once every working day. A thorough inspection of all ropes in use should be made at least once a month and a full written, dated and signed report of rope condition kept on file where readily available.

  • Page 99: Daily Rope Inspection

    TM SERIES DAILY ROPE INSPECTION The synthetic rope must be inspected daily for any deterioration, resulting in appreciable loss of strength, such as described below. 1. Excessive external roughness. 2. Glossy or glazed areas, which indicates heat damage. 3. Look for flat areas, bumps, or lumps, which indicates core or internal damage. 4.

  • Page 100: Storage Procedure

    TM SERIES STORAGE PROCEDURE When a unit will not be used for a period of time, it should be prepared for storage to reduce the deteriorating effects of the environment. This includes the following: • Wash and clean to remove accumulated road grime. It can discolor the paint if left on for long periods of time.

  • Page 101: Standards And Regulations

    The information provided herein is accurate as of the date your Terex South Dakota, Inc. unit was manufactured. You must comply with the codes, standards and regulations as they are updated over time. It is your employer's responsibility to obtain copies and comply with all standards and regulations.

  • Page 102: Osha Excerpts: (Clearance Distance)

    APPENDIX A OSHA EXCERPTS: (CLEARANCE DISTANCE) The following are excerpts from OSHA Standards. They are not complete and do not cover all safety work rules. PARTIAL EXCERPT FROM SUBPART S - ELECTRICAL: (02-01-1998 EDITION) 1910.333 Selection and use of work practices. (c), (i) Unqualified person.
  • Page 103 APPENDIX A ALTERNATING CURRENT MINIMUM DISTANCES VOLTAGE RANGE MINIMUM WORKING AND (PHASE-TO-PHASE) KILOVOLT CLEAR HOT STICK DISTANCES 2.1 to 15 2 ft. 0 in. (0.61 m) 15.1 to 35 2 ft. 4 in. (0.71 m) 35.1 to 46 2 ft. 6 in. (0.76 m) 46.1 to 72.5 3 ft.

  • Page 104: Standard Hand Signals

    APPENDIX A STANDARD HAND SIGNALS STOP. With arm extended EMERGENCY STOP. With both arms extended HOIST. With upper arm RAISE BOOM. With arm horizontally to the side, horizontally to the side, palms down, arms are swung back extended to the side, extended horizontally to the palm down, arm is swung and forth.

  • Page 105: Responsibilities

    APPENDIX B APPENDIX - B RESPONSIBILITIES ANSI A92.2-2009 (PARTIAL) Table of Contents: Responsibilities of Dealers and Installers. B - 1 Responsibilities of Owners. B - 2 Responsibility of Users. B - 5 Responsibilities of Operators. B - 7 Responsibilities of Lessors or Lessees. B - 9 Responsibilities of Brokers.
  • Page 106 APPENDIX B 7.8.1 Dealer or Installer as User. Whenever a dealer or installer directs personnel to operate an aerial device (inspecting, sales demonstrations, or any form of use), the dealer or installer shall assume the responsibilities of users as specified in Section 9 of this standard. All personnel authorized to operate the aerial device shall have been trained in a program that meets the requirements of this standard.
  • Page 107 APPENDIX B 8.2.4 Periodic Inspection or Test. An inspection of the mobile unit shall be performed at the intervals defined in 8.2.2 depending upon its activity, severity of service, and environment, or as specifically indicated below. (These inspections shall include the requirements of 8.2.3): (1) Structural members for deformation, cracks or corrosion.
  • Page 108 APPENDIX B 8.2.5 Post Event Inspection or Test. After any reported event during which structural members of an aerial device or mobile unit are suspected of being subjected to loading or stresses in excess of design stress such as after an accident involving overturning of the mobile unit or application of unintended external mechanical or electrical forces to the aerial device, the aerial device shall be removed from service and subjected to the applicable periodic inspection requirements in 8.2.4.
  • Page 109 APPENDIX B 8.12.1 General Training. Only personnel who have received general instructions regarding the inspection, application and operation of aerial devices, including recognition and avoidance of hazards associated with their operation, shall operate an aerial device. Such items covered shall include, but not necessarily be limited to, the following issues and requirements: (1) The purpose and use of manuals.
  • Page 110 APPENDIX B (6) The purpose of placards and decals. (7) Workplace inspection. (8) Applicable safety rules and regulations, such as Part 4, ANSI C2-2007, National Electrical Safety Code (applies to utility workers as defined in ANSI C2). The above standard is an example; other industries using aerial devices have safety rules pertinent to that industry.
  • Page 111 APPENDIX B 10.4 Work Platform. The operator shall not use railing, planks, ladders or any other device in or on the work platform for achieving additional working height or reach. 10.5 Brakes. The vehicle parking brake(s) shall be set at all times that the boom is elevated except when the aerial device is being used in accordance with 10.11.
  • Page 112 APPENDIX B 10.10 Precautions. Before and during each use the operator shall: (1) Check for overhead obstructions and electrical conductors. (2) Insure that the load on the platform and/or load lifting device is in accordance with the manufacturer's rated capacity. (3) Insure that outriggers and stabilizers are used if the manufacturer's instructions require their use.
  • Page 113 APPENDIX B 10.13 Electrical Hazard. All applicable safety related work practices intended to protect personnel from electrical hazards shall be defined and explained to the operator by a qualified person. The operator shall maintain the appropriate Minimum Approach Distance (MAD) from energized conductors and apparatus commensurate with the operator’s qualification.
  • Page 114 APPENDIX B (12) Electrical hazards and Minimum Approach distance to energized conductors and apparatus. See Appendix F. 11.4.2 Familiarization. When an operators are directed to operate an aerial device with which they are not familiar, they shall be instructed, prior to operating the aerial device, regarding the following items: (1) The location of the manuals.

  • Page 115: Survey Of Job Site

    Construction and electrical workers are subject to certain hazards that cannot be eliminated by mechanical means and must be controlled by care, common sense and intelligence. Terex South Dakota, Inc. realizes the importance of safety and strongly recommends that prior to commencing any operation, the employer make a survey of the conditions of the site to determine the hazards and the kind and number of safeguards that the employer will install.
  • Page 116 APPENDIX B (c) Number of workers (d) Plans for maintaining interest in safety: (1) Safety bulletins, record charts and posters (2) Recognition for groups or individuals (3) Investigation and reporting on reportable accidents (4) Knowledge of safety orders (5) Safety meetings (6) Specific safety instructions for new employees (e) Establishment of provisions to take immediate action to correct unsafe conditions or acts (f) First aid and medical treatment of injuries...

Table of Contents

Save PDF