Terex TA50RT Operator's Manual
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Terex TA50RT Operator's Manual

Terex TA50RT Operator's Manual

Articulated boom lift
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ARTICULATED BOOM LIFT
MODEL TA50RT
Terex Aerials
10600 W. Brown Deer Road
Milwaukee, WI 53224
U.S.A.
Telephone:
(414) 362-9300
Facsimile:
(414) 355-0832
Terex Aerials
106 12th Street S. E.
Waverly, IA 50677
U.S.A.
Telephone:
(319) 352-3920
Facsimile:
(319) 352-5727
OPERATOR'S
MANUAL
Terex Aerials
Courtstown Industrial Park
Little Island,
Co.Cork, Ireland
Telephone:
(353) 21-353011
Facsimile:
(353) 21-353368
P/No: 65002-0005
Rev.1 04/99

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  • Page 1 ARTICULATED BOOM LIFT MODEL TA50RT OPERATOR'S MANUAL Terex Aerials Terex Aerials Terex Aerials 10600 W. Brown Deer Road 106 12th Street S. E. Courtstown Industrial Park Milwaukee, WI 53224 Waverly, IA 50677 Little Island, U.S.A. U.S.A. Co.Cork, Ireland Telephone: (414) 362-9300...
  • Page 2 - 1 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: Comply with OSHA, Federal, State and Local Regulations.
  • Page 3 Model TA50RT INTRODUCTION i - 2 Rev. 1 04/99 "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. "WARNING" INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY.

  • Page 4: Table Of Contents

    Model TA50RT Rev.1 04/99 CONTENTS Section 1 Description Page No. Design Specification ................1-1 1.1.1 Closed Dimensions and Weights ............1-1 1.1.2 Operating Dimensions ................. 1-1 1.1.3 Design Specifications ................1-1 1.1.4 Working Envelope ................1-2 1.1.5 General Arrangement ................1-3 Component Specifications ..............
  • Page 5 Model TA50RT Rev.1 04/99 CONTENTS Section 3 Description Page No. Pre-use Checks .................. 3-1 Ground Control Checks ..............3-2 Cage Control Checks ................. 3-2 Unloading Procedures ................. 3-3 Driving ....................3-5 3.5.1 Drive Controls ..................3-5 3.5.1.1 Forward and Reverse ................. 3-5 3.5.1.2 Drive Speed Control ................
  • Page 6 Model TA50RT Rev.1 04/99 CONTENTS Section 4 Description Page No. Emergency Procedures ............... 4-1 4.1.1 Situation: Platform elevated, operator not incapacitated, but unit will not operate properly using the platform controls....4-1 4.1.2 Situation: Unit elevated, with operator incapacitated at platform controls.
  • Page 7 Model TA50RT Rev.1 04/99 CONTENTS Section 5 Description Page No. General Information ................5-1 5.1.1 Introduction ..................5-1 5.1.2 Hydraulic Oils ..................5-1 5.1.3 Diesel Engine Oil ................5-3 Servicing Check List (Basic Machine Only) ......... 5-4 5.2.1 Servicing (Daily) ................. 5-4 5.2.2 Servicing (Weekly) ................
  • Page 8 Model TA50RT Rev.1 04/99 CONTENTS Section 5 Description Page No. 5.3.4 Six Monthly Routine Servicing ............. 5-13 5.3.4.1 Cage Levelling ..................5-13 5.3.4.2 Boom Pivots ..................5-13 5.3.4.3 Boom Cylinders .................. 5-13 5.3.4.4 Axle ....................5-13 5.3.4.5 Suction Filter ..................5-13 5.3.4.6 Machine Systems Test ................

  • Page 9: Design Specification

    Model TA50RT Rev. 1 04/99 1 - 1 SPECIFICATIONS DESIGN SPECIFICATION 1.1.1 CLOSED DIMENSIONS AND WEIGHTS Length ...........................5.65 m Width .............................2.20 m Height .............................2.26 m Unladen Weight ........................7100 kg 1.1.2 OPERATING DIMENSIONS Maximum Cage Floor Height ....................14.80 m Maximum Working Height .....................16.80 m Maximum Working Outreach .....................9.1 m...

  • Page 10: Working Envelope

    Rev. 1 04/99 1 - 2 SPECIFICATIONS 1.1.4. WORKING ENVELOPE The TA50RT has a working height ability of 16.90 m. The following diagram shows the working envelope for the TA50RT. All dimensions are in metres. Figure 1.1 - TA50RT Working Envelope...

  • Page 11: General Arrangement

    Model TA50RT Rev. 1 04/99 1 - 3 SPECIFICATIONS 1.1.5 GENERAL ARRANGEMENT Figure 1.2 - TA50RT General Arrangement...

  • Page 12: Component Specifications

    Model TA50RT Rev. 1 04/99 1 - 4 SPECIFICATIONS COMPONENT SPECIFICATIONS 1.2.1. MECHANICAL COMPONENTS Tyre Type ..................Solideal SKS 12-16.5 10 ply rating 332 mm wide x 848 mm dia. Tyre Size ..........................12-16.5R Wheel Gearbox ........................6.73 : 1 ratio Wheel Diameter ........................42.4 cms Brakes ....Oil immersed fail-safe discs inside the front and rear axles, operate as both parking and...

  • Page 13: Equivalent Oils

    Model TA50RT Rev. 1 04/99 1 - 5 SPECIFICATIONS 1.2.4. EQUIVALENT OILS SHELL TELLUS T32 CASTROL HYSPIN AWH 32 ESSO UNIVERSE N32 CASTROL HYSPIN AWS 22 1.2.5. ELECTRICAL COMPONENTS Hand Controller Type .....................Joystick Battery ......................One 12 Volt H.D 1.2.6. ENGINE DETAILS Engine Type 1.............

  • Page 14: Safety Rules And Precautions

    Model TA50RT Rev. 1 04/99 SAFETY 2 - 1 2.1. SAFETY RULES AND PRECAUTIONS ELECTROCUTION HAZARD! THIS MACHINE IS NOT INSULATED!! Maintain safe clearance from electrical lines and apparatus. You must allow for machine sway (side to side movement) when elevated, and electrical line movement. This machine does not provide protection from contact with or proximity to an electrically charged conductor.
  • Page 15 Model TA50RT Rev. 1 04/99 SAFETY 2 - 2 Be aware of all Government and Local rules which may apply to this machine and its safe operation. Approved safety belts must be worn at all times when operating the unit from the platform. In addition approved headgear and other protective equipment must be worn as required.
  • Page 16 Terex recommends using this procedure only in cases of emergency, and only for a short distance. Be on guard against unit runaway on sloping surfaces. Movement speed shall not exceed 3 MPH (5 KPH).
  • Page 17 Model TA50RT Rev. 1 04/99 SAFETY 2 - 4 DO NOT increase wind area of cage by addition of sheltering material DO NOT raise the aerial work platform unless the unit is on a firm surface, and slope is within rated slope of the machine.
  • Page 18 Complete the “Operational Checklists” found in this manual (see Table of Contents) at designated intervals. Always attach the unit to a winch when loading or unloading from a truck or trailer. Terex does not recommend unassisted loading or unloading of any aerial work platform.
  • Page 19 Model TA50RT Rev. 1 04/99 SAFETY 2 - 6 For transporting the machine, the platform or boom must not be tied to the trailer bed in any way. DO NOT exceed the maximum platform horizontal pull of 400 N. DO NOT use the boom or platform as a crane to lift oversized of hanging loads.

  • Page 20: Safety Features

    Model TA50RT Rev. 1 04/99 SAFETY 2 - 7 2.2. SAFETY FEATURES 2.2.1. EMERGENCY STOP PUSHBUTTONS Two EMERGENCY STOP pushbuttons, one at the ground station and one in the cage, act as power on/off switches. Both switches must be ON to operate the machine. When either of the buttons is depressed, all functions stop immediately and the parking brake is automatically applied and the engine is stopped.

  • Page 21: Torque Chart

    Model TA50RT Rev. 1 04/99 SAFETY 2 - 8 2.2.5. TORQUE CHART ITEM BOLT SPECIFICATION REQUIRED TORQUE Thread Size Grade lbft. Wheel Nut 10.9 147.5 Slewring Bolt 10.9 Slew Gearbox Bolt 12.9 Axle Clamping Bolt 10.9 147.5 General Bolts 27.5 General Bolts 40.5...

  • Page 22: Pre-Use Checks

    PRE-USE CHECK Before the TA50RT is used at the start of a day, or after an extended period without use, the following checks should be carried out to ensure that the machine is in good condition and safe to use: Check that all labels are readable and secure.

  • Page 23: Ground Control Checks

    Model TA50RT Rev. 1 04/99 OPERATING PROCEDURES 3 - 2 3.2. GROUND CONTROL CHECKS DO NOT OPERATE THE MACHINE IF THE GROUND CONTROL CHECKS REVEAL A FAULT. Ensure that the following checks are carried out with the cage empty: Test all operations (lift, rotate, etc.).

  • Page 24: Unloading Procedures

    Model TA50RT Rev. 1 04/99 OPERATING PROCEDURES 3 - 3 3.4. UNLOADING PROCEDURES TO AVOID SERIOUS PERSONAL INJURY OR DEATH, ENSURE THAT THE MACHINE IS IN “CREEP “ DRIVE SPEED WHILE UNLOADING FROM A TRUCK OR TRAILER. Inspect the outside of the unit for damage (including the underside). Inspect all hoses, boom sections and cables for chafing or road damage.
  • Page 25 Before placing the unit into service, all operators must read and understand the contents of the Operator’s Manual. Upon initial unloading of the machine the PDI (Pre-Delivery Inspection Form) must be completed and returned in order to activate the Terex Limited Warranty.

  • Page 26: Driving

    Model TA50RT Rev. 1 04/99 OPERATING PROCEDURES 3 - 5 3.5. DRIVING It should be noted that the machine is not equipped for highway use and should only be driven on the public highway in compliance with any statutory regulation.
  • Page 27 Model TA50RT Rev. 1 04/99 OPERATING PROCEDURES 3 - 6 Emergency Stop Switch Cage Rotation Switch Engine on/off switch Horn Button Footswitch Differential Lock Switch Drive Speed Select Switch Boom Selector Button Drive/Steer Joystick Boom Selection Indicator LED Boom/Rotate Joystick...

  • Page 28: Drive Speed Control

    Model TA50RT Rev. 1 04/99 OPERATING PROCEDURES 3 - 7 3.5.1.2. Drive Speed Control The drive speed of the machine is proportionally controlled by the amount of movement made to the joystick. Note:- When elevated, the drive speed of the machine is automatically reduced.

  • Page 29: Differential Lock

    Model TA50RT Rev. 1 04/99 OPERATING PROCEDURES 3 - 8 3.6. DIFFERENTIAL LOCK Caution 1:- To avoid mechanical damage, ensure that the machine is stationary before attempting to engage or disengage the differential lock. Caution 2:- Prolonged use of the differential lock impairs steering and causes excessive tyre wear.

  • Page 30: Braking System

    3.7. BRAKING SYSTEM The TA50RT has a single braking system which serves as a parking brake when the machine is static, and as service brakes when the machine is in drive mode. The brakes are spring applied and hydraulically released.

  • Page 31: Access Operations (Cage Control)

    Model TA50RT Rev. 1 04/99 OPERATING PROCEDURES 3 - 10 3.8. ACCESS OPERATIONS (CAGE CONTROL) Note : To facilitate entry to the cage, extend the telescopic boom using the lower controls. It is recommended that the engine be started from ground controls when cold, as there is no pre-heat facility at the upper controls (See section 3-9).
  • Page 32 Model TA50RT Rev. 1 04/99 OPERATING PROCEDURES 3 - 11 Emergency Stop Button Cage Level Switch Engine Ignition Switch 10) Cage Rotate Switch Cage/Ground Select Switch Hourmeter Lift 1 Boom Switch Battery Volt Indicator Lift 2 Boom Switch Engine Condition Indicator...

  • Page 33: After Use And Storage Instructions

    AFTER USE AND STORAGE INSTRUCTIONS When the machine is no longer required, and is to be stored, the following instructions are recommended. (Note: Terex Aerials recommends indoor storage of the unit). Close cabinet doors. Bring all booms to stowed position.

  • Page 34: Special Precautions

    3.12.3. CRANE OPERATIONS The TA50RT is fitted with four lifting points in the form of eyes at each corner of the chassis. During lifting operations, take all instructions from the crane operator. Check identification plate. 3.12.4. TESTING THE TILT ALARM IF THE TILT ALARM SOUNDS WHILST ELEVATED, RETRACT AND LOWER BOOMS AND DRIVE TO A LEVEL LOCATION.

  • Page 35: Battery Charge, Engine Temp & Air Filter Warning Lamps

    Model TA50RT Rev. 1 04/99 OPERATING PROCEDURES 3 - 14 If a wire in the tilt alarm circuit becomes disconnected whilst the machine is in use, the alarm will sound continuously. If this occurs when the machine is elevated, zoom in immediately and lower the cage to the stowed position.

  • Page 36: Emergency Procedures

    Model TA50RT Rev. 1 04/99 EMERGENCY PROCEDURES 4 - 1 4.1. EMERGENCY PROCEDURES It is not possible for us to foresee every emergency situation that could arise during operation of this machine. Information on the following pages describes three typical emergency situations and lists appropriate actions that can be taken.

  • Page 37: Situation: Unit Elevated, With Operator Incapacitated At Platform Controls

    (see “Emergency Pump”, section 4.2.1). Render first aid to the operator. Report the incident to your supervisor immediately. IMPORTANT: Any incident involving personal injury must be immediately reported to the local Terex Aerials Distributorship as well as to Terex Aerials Inc. 4.1.3 SITUATION: Platform in contact with live power lines and operator incapacitated.

  • Page 38: Emergency Pump

    Model TA50RT Rev. 1 04/99 EMERGENCY PROCEDURES 4 - 3 EMERGENCY SYSTEMS AND PROCEDURES 4.2.1 EMERGENCY PUMP This machine is fitted with a handpump which can be operated from the ground control station when the unit has lost power. In an emergency situation the pump can be used to lower the cage to provide a safe exit for personnel.

  • Page 39: Emergency Rotation

    Model TA50RT Rev. 1 04/99 EMERGENCY PROCEDURES 4 - 4 Dump Valve Brake Override Hydraulic ByPass Lift 1 Down Lift 2 Down Lift 3 Down Lift 3 Up Rotate Right Rotate Left Tele-boom In Figure 4.1 - Emergency Handpump - Hydraulic Valve Block On completion of the required operations, ensure all valve knobs are screwed out fully.

  • Page 40: Emergency Towing

    Every attempt should be made to restore primary power to the machine before using this procedure. THIS PROCEDURE REQUIRES RELEASING THE MACHINE BRAKES, WHICH RENDERS THEM IN-OPERATIVE. TEREX RECOMMENDS USING THIS PROCEDURE ONLY IN CASES OF EMERGENCY, AND ONLY FOR A SHORT DISTANCE.
  • Page 41 Model TA50RT Rev. 1 04/99 EMERGENCY PROCEDURES 4 - 6 Figure 4.2 - Top View of Hydraulic Manifold Block 4.2.3.1 Towing Disengage brakes Push red overide button and twist clockwise. (Item 1, Fig 4.2) to open the brake lines, so that hydraulic pressure can be applied to the brakes.
  • Page 42 Model TA50RT Rev. 1 04/99 EMERGENCY PROCEDURES 4 - 7 HYDRAULIC MODULE ENGINE COMPARTMENT Emergency Handpump 2 studs press to allow oil to Oil Tank circulate through pump. Hydraulic Valve Block Handpump Selector. (Lift/Brake) Lower Control Box Handpump Handle Figure 4.3 - Hydraulic and Electrical Modules...

  • Page 43: General Information

    5.1.1. INTRODUCTION The TA50RT has been specially designed to reduce maintenance to a minimum. It is essential that the specified servicing instructions are followed to ensure safety and reliability. The hydraulic pump, motor, cylinders and pressure valves are self-lubrication internally. The turntable slewing ring is grease packed and the corrosion-resistant pivot pins and bearings are pre-lubricated and require atten- tion only at six monthly intervals.
  • Page 44 Model TA50RT Rev. 1 04/99 MAINTENANCE SCHEDULES 5 - 2 the viscosity range will usually be: Temperate 0°C - 300cSt Temperate 40°C - 30cSt Tropical 0°C - 700cSt Tropical 40°C - 50cSt Tropical 100°C- 8cSt Mineral hydraulic oils produced by different companies will usually mix with each other satisfactorily.

  • Page 45: Diesel Engine Oil

    Model TA50RT Rev. 1 04/99 MAINTENANCE SCHEDULES 5 - 3 5.1.3. DIESEL ENGINE OIL Engine oil changes and general servicing differ, depending on the type of engine fitted. It is recommended that the manufacturers diesel engine handbook is consulted for the particular make and type of engine fitted to your machine.

  • Page 46: Servicing Check List (Basic Machine Only)

    Model TA50RT Rev. 1 04/99 MAINTENANCE SCHEDULES 5 - 4 5.2. SERVICING CHECK LIST (BASIC MACHINE ONLY) All checks must be completed by the operator before operating the unit. 5.2.1. DAILY Check hydraulic oil level. Check tyre condition. Check for hydraulic leaks.
  • Page 47 Model TA50RT Rev. 1 04/99 MAINTENANCE SCHEDULES 5 - 5 5.2.2. WEEKLY In addition to the daily checks, the following checks should be carried out by an experienced technician :- Check control valves for self-centre. Inspect hydraulic system for leakage.
  • Page 48 Model TA50RT Rev. 1 04/99 MAINTENANCE SCHEDULES 5 - 6 5.2.2. WEEKLY (continued) Check the nylon zoom pads for wear as follows:- Fully zoom in and check the gap at the top of the zoom boom telescope, between the inner and the outer, at the rear of the zoom boom.
  • Page 49 The replacement of the slew bearing is a major operation and advice should be sought from Terex Aerials Ltd. Checks must be made to ensure that all securing bolts are tight. Any bolts found loose or sheared must be replaced. Slew ring play is measured at the perimeter of the ring and the maximum rock allowed is 1.7mm (refer to Fig 5.1)
  • Page 50 Model TA50RT Rev. 1 04/99 MAINTENANCE SCHEDULES 5 - 8 Figure 5.1 : Slew Ring Bearing Play Measurement 5.2.4. SIX MONTHLY In addition to the monthly check, carry out the following:- Check cage levelling. Check cage pivots. Check boom cylinders. The lift cylinder seals can be replaced with the cylinder mounted on the machine, or by removing the cylinder before removing the seals.

  • Page 51: Servicing (Six Monthly)

    Model TA50RT Rev. 1 04/99 MAINTENANCE SCHEDULES 5 - 9 5.3. SERVICING Servicing to be carried out by a trained technician only. 5.3.1 DAILY ROUTINE SERVICING 5.3.1.1. Hydraulic Oil Level Before checking the oil level, ensure that the machine booms are stowed in the travelling position and the machine is standing on level ground.

  • Page 52: Start Battery

    Model TA50RT Rev. 1 04/99 MAINTENANCE SCHEDULES 5 - 10 5.3.2.3. Start Battery Check the battery electrolyte levels. Replenish the electrolyte with distilled water if necessary. 5.3.2.4. Pivot Pins Check all pivot pins for security. Grease those pivot pins as shown in Fig. 5.2.
  • Page 53 Model TA50RT Rev. 1 04/99 MAINTENANCE SCHEDULES 5 - 11 Figure 5.2 - Location of Grease Nipples...

  • Page 54: Monthly Routine Servicing

    Model TA50RT Rev. 1 04/99 MAINTENANCE SCHEDULES 5 - 12 5.3.3. MONTHLY ROUTINE SERVICING 5.3.3.1. Hydraulic Oil Allow the machine to stand for at least 8 hours without operating the pump. This will allow water and other impurities to separate out of the oil and settle to the bottom of the tank.

  • Page 55: Six Monthly Routine Servicing

    The main pivots on the booms, cylinders and levelling system are fitted with corrosion-resistant pins and per- lubricated bearings. Check the bushing for any signs of wear The bushings are steel-backed, acetal co-polymer lined. If the bearings show any defect, they should be replaced with the correct type. Consult Terex Aerials Ltd. 5.3.4.3. Boom Cylinders Check the boom cylinders as follows:- Hydraulically test the cylinders at fully retracted and extended positions.

  • Page 56: Yearly Routine Servicing

    Model TA50RT Rev. 1 04/99 MAINTENANCE SCHEDULES 5 - 14 5.3.5 YEARLY ROUTINE SERVICING 5.3.5.1. Hydraulic Oil Providing the hydraulic oil has been regularly maintained, it should only require changing at approximately two- yearly intervals. This is dependent on maintenance, amount of use, application, temperature, atmospheric conditions and other factors.

  • Page 57: Hydraulic Tank Refill Procedure

    Model TA50RT Rev. 1 04/99 MAINTENANCE SCHEDULES 5 - 15 5.3.5.3. Hydraulic Tank Refill Procedure Refilling the hydraulic oil tank requires approximately 62 litres of TEXACO RANDO HDZ 32 hydraulic oil (or equivalent). To refill the hydraulic tank, proceed as follows:- Ensure that the oil temperature is sufficiently high to allow the oil to flow freely.

  • Page 58: Four Yearly Routine Servicing

    Model TA50RT Rev. 1 04/99 MAINTENANCE SCHEDULES 5 - 16 5.3.6 FOUR YEARLY ROUTINE SERVICING Note:- The following recommendations are based on the advice of suppliers and the requirements of various national safety regulations. They should be applied with discretion, depending on such factors as the amount and type of use, environmental conditions, local safety regulations etc.

  • Page 59: Boom Pin Replacement

    Model TA50RT Rev. 1 04/99 MAINTENANCE SCHEDULES 5 - 17 5.3.6.3.1. Boom Pin Replacement To replace a boom pin, proceed as follows;- Support the boom and upper structure securely on a fork lift, or similar rigid platform. Remove the pin locking bolts.

  • Page 60: Self Levelling Cylinder Pin Replacement

    Model TA50RT Rev. 1 04/99 MAINTENANCE SCHEDULES 5 - 18 5.3.6.3.4 Self Levelling Cylinder Pin Replacement To replace a self levelling cylinder pin, proceed as follows:- Support the cage to ensure that there is no load on the self levelling cylinders. This also applies when changing pins on the levelling cylinders.

  • Page 61: Zoom Pads

    Model TA50RT Rev. 1 04/99 MAINTENANCE SCHEDULES 5 - 19 5.3.6.5 Zoom Pads Zoom pads should be replaced as follows, depending on the type of pad: 5.3.6.5.1 Front Zoom Pad Replacement To replace the front zoom pads, proceed as follows:- Support the inner zoom boom.

  • Page 62: Seal Replacement - Cylinder Removed

    Model TA50RT Rev. 1 04/99 MAINTENANCE SCHEDULES 5 - 20 Note:- It is recommended that the bearing ring at the base of the piston rod is replaced when seals are replaced. Examine the rod of score marks and damage. This is most easily achieved by extending the cylinder and examining the protruding rod.

  • Page 63: Lubrication

    Model TA50RT Rev. 1 04/99 MAINTENANCE SCHEDULES 5 - 21 5.4. LUBRICATION 5.4.1. General Lubrication The following table lists the recommended lubricants for the TA50RT COMPONENT LUBRICANT FREQUENCY REMARKS Drive and Steer EP 90 Check 6 monthly Axle Change yearly...

  • Page 64: Slew Bearing/Gear Lubricants

    Slew Bearing/Gear Lubricants 5.4.2.1. Slew Bearing Lubrication Terex Aerials recommends lubrication of the slew bearing with an EP2 grease. The slewing rings are equipped with greasing holes tapped to the European standard and suitable for: - Centralised greasing. - Standard greasing; straight or angled spherical head grease nipples...

  • Page 65: Slew Gear Lubrication

    - Water and temperature resistant. - Temperature range .....25° F to 400° F (-4°C to 200° C) Terex Aerials Limited recommend the following grease for the slew gear. - KEYSTONE MOLY 25 OPEN GEAR COMPOUND (S.A.Part No. 10126400) It is possible to use other brands of grease provided that they offer greasing characteristics similar to the type...

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