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
HI–RANGER
TM SERIES
Terex South Dakota, Inc.
472797 01/2015
Page 1: ...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 HI RANGER TM SERIES Terex South Dak...
Page 2: ...TM SERIES 472797 01 15 Terex South Dakota Inc TM Series Terex South Dakota Inc 500 Oakwood Road Watertown SD 57201...
Page 3: ...F ELECTROCUTION XXVII OPERATION ON OR NEAR ENERGIZED CONDUCTOR XXVII SECTION 1 1 1 OPERATION GUIDELINES 1 1 NOMENCLATURE 1 1 CAB CONTROL OPERATION 1 2 MASTER CONTROL 1 2 ENGINE STOP START OPTIONAL 1 2...
Page 4: ...1 42 EMERGENCY OPERATION 1 45 POWER LINE CONTACT ON GROUND 1 45 TOP CONTROL SHUT OFF 1 47 AUXILIARY LET DOWN POWER OPTIONAL 1 48 MANUAL LET DOWN SYSTEM 1 48 MANUAL ROTATION 1 48 HYDRAULIC LINE FAILURE...
Page 5: ...SYSTEM 2 4 ELECTRICAL TESTS 2 4 LUBRICATION CHART 2 5 WINCH ROPE INSPECTION 2 6 DAILY ROPE INSPECTION 2 7 HOOK INSPECTION 2 7 STORAGE PROCEDURE 2 8 APPENDIX A A 1 STANDARDS AND REGULATIONS A 1 OSHA E...
Page 6: ...TM SERIES toc 4 472797 1 15 Terex South Dakota Inc TM Series...
Page 7: ...ons will unnecessarily expose you and others to dangerous situations For your safety and the safety of those around you you must operate your Terex South Dakota Inc equipment as instructed in this man...
Page 8: ...h the information and actions in the bulletins are mandatory CONTACTING THE MANUFACTURER If it is necessary to contact the manufacturer of the machine supply the unit model number serial number and yo...
Page 9: ...rd NOTICE shown without the safety alert symbol is used to address specific practices or draw attention to supplemental information that is not related to personal injury This is the safety alert symb...
Page 10: ...such modification will void any remaining warranty 3 Terex South Dakota Inc reserves the right to change improve modify or expand features of its equipment at any time Specifications model or equipmen...
Page 11: ...ny interlock or safety device is malfunctioning 5 Do not bypass or remove any interlock or safety device 6 Never operate with damaged leveling chain or components 7 Stop in position if you become awar...
Page 12: ...r path of movement and its ground contact point Lower all outriggers onto solid footing 9 Do not place outriggers on ice as slippage may occur regardless of solid footing Operation on snow or slippery...
Page 13: ...eet on floor of the platform 12 Do not wear climbers while in the platform 13 Do not allow ground personnel under the platform work area 14 Do not operate with platform leveling malfunctioning 15 Do n...
Page 14: ...energized conductor and a grounded conductor without proper cover up 6 Do not wear clothing that when exposed to flames or electric arcs could increase the extent of injury from such exposure 7 Never...
Page 15: ...hoses marked NON CONDUCTIVE The hoses must be kept clean and dry and must be inspected periodically 2 All accessories must be inspected maintained and operated with the same care and safety rules that...
Page 16: ...ave 16 Use only approved and tested hot line tools for lifting energized conductors Clean and inspect all fiberglass on the conductor lifter before use Dirty or damaged fiberglass may be conductive 17...
Page 17: ...tool hoses at the boom tip and areas that bridge the insulation gap 9 Do not use replacement components that are not equal to the original components 10 Before doing any work on the hydraulic system...
Page 18: ...operation Maintenance Manual DANGER Failure to follow will cause serious injury Follow all inspection and maintenance to prevent failure Electrical Contact DANGER Will cause Serious Injury Maintain m...
Page 19: ...obstructions are clear Operator must watch the outrigger while in motion High Pressure Air or Fluid WARNING Can Cause Serious Injury or Death Relieve pressure on hydraulic and pneumatic systems before...
Page 20: ...ION TRUCK LEVEL 2 79584 2 BULLSEYE LEVEL 2 90489 3 ARROWS 18 H21503 4 NOT INSULATED BEYOND ARROWS 10 402236 5 READ CAREFULLY 1 414590 6 FAILURE TO OBEY 1 419262 7 ELECTROCUTION HAZARD 2 419263 8 FALLI...
Page 21: ...E 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...
Page 22: ...uipment Never load beyond rated capacity Never operate Aerial Device with personnel under boom or load Never move the truck until the booms and outriggers are in a properly stowed position and secured...
Page 23: ...power lines in accordance with applicable government regulations Allow for boom platform electrical line and load line sway This machine does not provide protection from contact with or proximity to a...
Page 24: ...lations You are sure the machine is operating properly and has been inspected and maintained in accordance with manufacturer s manuals You are sure that all safety signs guards and other safety featur...
Page 25: ...sulation Comply with OSHA ANSI NESC requirements Cover all lines with insulated line hose or insulating blankets Wear Personal Protective Equipment Fall protection Eye protection Maintain proper CLEAR...
Page 26: ...owed Platform NOT allowed on this side of center line Platform allowed on this side of Center line of Rotation Extension not allowed below 55 OVERTURNING HAZARD May result from operating outside the A...
Page 27: ...TE INITIALS INITIALS DATE Follow component replacement intervals shown in your Maintenance Manual Stamp or engrave below when and who performed inspections 489119A X2 495440 X1 495441 full knowledge o...
Page 28: ...tal to rotation bearing cylinder and boom Fasteners include turntable to rotation bearing Check torque on fasteners as required in manual s all fasteners for damage signs of looseness all structural c...
Page 29: ...fluid under pressure can penetrate skin causing serious injury Relieve pressure before disconnecting hydraulic lines Keep away from leaks and pin holes Use a piece of cardboard or paper to search for...
Page 30: ...hall not allow any portion of this area to come in contact with an energized phase ground conductor or grounded objects Proper protective devices shall be used on all conductors The operator shall not...
Page 31: ...energized conductor ground line grounded line or OBJECTS Proper clearance must be maintained You must always cover the line and wear rubber gloves with rubber sleeves and an approved hard hat when an...
Page 32: ...interphase protection of the lower half of the body only Only caution on the part of platform personnel and use of proper protective equipment will protect the upper half of their body from this hazar...
Page 33: ...5 Have boom insulation TESTED annually in accordance with established rules and regulations 6 CONTROLS are not insulated and are interconnected to all other conductive components at the boom tip DO NO...
Page 34: ...can be added to the boom tip Do not depend on Aerial Device covers for insulation Plastic or fiberglass covers offer limited electrical insulation Covers are not tested certified or maintained as ins...
Page 35: ...ch contact Proper conductor cover up insulated sleeves and gloves shall be worn when working near energized lines or equipment All metal at boom tip is electrically connected Operator contact with ANY...
Page 36: ...TM SERIES XXX 472797 1 15 Terex South Dakota Inc TM Series WHAT IS INSULATED AND NOT INSULATED...
Page 37: ...TION 1 OPERATION GUIDELINES NOMENCLATURE Jib Upper Controls Platform Upper Boom Upper Boom Extension Cylinders Elbow Pin Lower Boom Lower Boom Extension Rollers Lower Boom Lift Cylinder Lower Controls...
Page 38: ...the button again POWER TAKE OFF OPTIONAL The power take off PTO is a gearbox used to transmit power from the vehicle transmission to the hydraulic pump which provides hydraulic oil for the Aerial Dev...
Page 39: ...t indicates master power is activated PTO Light Red light when lit indicates PTO is engaged Engine Stop Start Optional Push and hold to start engine Release when engine starts Push and release to stop...
Page 40: ...ergency stop by taking oil flow away from the active controls 2 Outrigger Controls Optional Allows extending and retracting of outriggers 3 Hydraulic Tools Optional Directs oil flow to the tool when c...
Page 41: ...se when engine starts Push and release to stop engine Can also be used to stop the Aerial Device in an emergency 5 Two Speed Throttle Optional Auxiliary Let Down Power Optional With engine running the...
Page 42: ...er Learn to move the platform in an arc to any desired position within reach of the platform Operate the functions with smooth gradual starts and stops Use full speed when in clear areas with no obstr...
Page 43: ...operator controls the Aerial Device during normal operation Never operate the Aerial Device from the ground control with someone in the platform except in an emergency situation All metal at boom tip...
Page 44: ...to be positioned at different angles 7 Winch Optional Used for operating the winch during material handling operations 8 Platform Rotation Optional Allows the platform to rotate toward the end of the...
Page 45: ...tural support for the various components These metallic parts are interconnected The main shaft that supports the platform and controls must also support other load carrying options that can be added...
Page 46: ...unfold lower boom UP Squeeze enable lever and pull lever back to fold lower boom DOWN Boom Rotation Squeeze the enable lever and rotate lever right to rotate booms clockwise CW Squeeze the enable leve...
Page 47: ...e included with two speed throttle circuit When vehicle engine is disabled the auxiliary let down power can be activated by the two speed throttle switch NOTE Do not operate longer than 30 seconds Con...
Page 48: ...nd move lever side to side to side Push to right to rotate platform in level direction Push to left to rotate platform in dump direction 10 Jib Extend Optional Push to extend jib boom OUT Always have...
Page 49: ...an out 6 Winch Used for operating the winch during material handling operations 7 Lower Boom Extend Used to extend the lower boom 8 Upper Boom Extend Used to extend the upper boom 9 Engine Stop Start...
Page 50: ...o the control decals on unit for proper operation The control levers are self centering spring loaded and return to the neutral position when released The hydraulic platform tilt optional allows the p...
Page 51: ...e in the ON position to operate the jib winch platform rotate and hydraulic tools at the platform location 2 Lower Boom Push lever forward to RAISE lower boom up Pull lever back to LOWER lower boom do...
Page 52: ...ower boom up Upper Boom TM125 only Pull lever back to RAISE lower boom up Push lever forward to LOWER lower boom down 5 Platform Level Push lever to LEVEL platform Pull lever to DUMP platform Do not o...
Page 53: ...gine Can also be used to stop the Aerial Device in an emergency 10 Two Speed Throttle Optional With engine running the throttle is activated Push and release to increase engine RPM Push and release to...
Page 54: ...is control in an emergency TWO SPEED THROTTLE CONTROL OPTIONAL The two speed throttle control allows the engine speed to be increased to a high idle position or reduced to the normal idle speed from r...
Page 55: ...ect the function desired for the sequence planned and lift selector handle lock in out position 2 Pump handle until the function begins to move 3 To stop function move selector back to in position 4 T...
Page 56: ...E OF TOOLS When tools are not required store them in the truck storage compartments This will prevent damage to the tool and eliminate the chance of the tool falling Remove tools from the platform whe...
Page 57: ...ilting Operation 1 Rotate the platform to the end mount position 2 Use the lower controls to position lower boom up and upper boom so platform is near the ground 3 Check for obstructions or people bef...
Page 58: ...e system operating most efficient If the platform is more than 15 degrees out of level the level control system will turn off and not level until it is manually leveled to less then 15 degrees from le...
Page 59: ...form is more than 15 degrees out of level the level control system will turn off and not level until it is manually leveled to less then 15 degrees from level position The hydraulic pressure for the l...
Page 60: ...when rotating the platform When moving the booms position the platform in stowed position Rotate platform into desired work position when in work area Return to stowed position after work is complete...
Page 61: ...ystem The jib and load line should be used for vertical lifting only Never allow personnel to be under loads being lifted Increasing the horizontal distance from the vehicle to the load will affect th...
Page 62: ...tend the inner jib section 1 Pull the inner jib pin and manually pull the inner jib to the desired extension It will extend up to 17 inches 2 Replace the inner jib pin To extend the 2nd extension 1 Pu...
Page 63: ...he load capacity must be assured for the entire range of the boom motion throughout a lift Must insure capacity is not exceeded at any point during load movement After placing booms and jib in positio...
Page 64: ...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 Death or serious injury will result...
Page 65: ...location Raise boom so platform clears the body and other objects The platform shall not be used for material handling Never exceed the rated load capacity of the Aerial Device Structural damage or i...
Page 66: ...do not delay Malfunction of one component can cause serious injury to the operator or to others if not corrected immediately The ground crew must be trained to operate the Aerial Device in case of em...
Page 67: ...IPTION ITEM DESCRIPTION 1 Fuel Reservoir 14 Outrigger Pads 2 Tires and Wheels 15 Outrigger and Tool Controls 3 Engine Radiator and Cooling System 16 Body Grab Handles 4 Battery 17 Body Access Steps 5...
Page 68: ...ower Controls 23 Boom Pivot Linkage and Pins 8 Rotation Gear Box 24 Upper Boom Cylinder 9 Rotation Bearing Bolts 25 Upper Boom Cylinder Mounting Pins 10 Rotation Bearing 26 Winch Line Hook 11 Lower Bo...
Page 69: ...to allow the oil to warm up gradually Cold thick sluggish oil may not move fast enough and will starve the pump thus causing severe damage Circulate the oil through the outrigger system by cycling eac...
Page 70: ...the truck Use the following procedure after the vehicle is in position at the work site Turn on warning lights Place vehicle in neutral and set brakes before leaving cab Chock the wheels Position and...
Page 71: ...th Alert all personnel that the outriggers are being moved and positioned Units with one set of outriggers behind the rear axles on rear axle mounts extend the outriggers until the weight of the vehic...
Page 72: ...of the vehicle is low extend the low side outrigger first and make sure that firm contact is made If full extension does not make firm contact the outrigger pad must be blocked up Always chock the wh...
Page 73: ...Ensure cribbing if required provides stable support If the vehicle must be set up so an outrigger rests on a curb with the vehicle in the street the outrigger span will be shortened and stability is...
Page 74: ...chock location to prevent the truck pivoting around one chock Set units with one set of outriggers so all tires are on the ground Evaluate the terrain to determine the most flat and level set up posi...
Page 75: ...can handle IMPORTANT Know the loading capacities of your unit under all conditions of load terrain and Aerial Device Keep loads close to the ground until you determine for sure that the load can be ba...
Page 76: ...ll move up or down depending on which function was operated to keep in a non overcenter position OVERTURNING HAZARD May result from operating outside the All outriggers must be properly set before Tru...
Page 77: ...g This Aerial Device is equipped with a collector block oil distribution center in the turntable which permits the continuous rotation of the boom in either direction without stops The Platform can be...
Page 78: ...ber of lanyards may be attached to the lanyard anchor provided one or two as indicated by X1 or X2 on decals X1 495441 READ CAREFULLY DEATH OR SERIOUS INJURY WILL RESULT FROM SUCH CONTACT OR INADEQUAT...
Page 79: ...lating DO NOT Depend on machine covers for insulation Comply with OSHA ANSI NESC requirements Cover all lines with insulated line hose or insulating blankets Wear Personal Protective Equipment Fall pr...
Page 80: ...rea directly under the work point unless absolutely necessary and caution them that it is necessary to be constantly on the alert for possible falling items Use orange hose marked NON CONDUCTIVE for t...
Page 81: ...VEHICLE IS TOUCHING A POWER LINE Take these steps if your vehicle makes contact with a live power line while you are in or on the vehicle Treat any line as live unless you know for sure it is not Sta...
Page 82: ...ople to stay away from the area Immediately notify the proper authorities or people to correct the problem APPROACHING A VEHICLE THAT MAY BE ENERGIZED In an emergency situation it may be necessary for...
Page 83: ...e unless you use insulated blankets to step on as you approach the vehicle Stepping from one rubber blanket to the next Use a hot stick or hot line tool to perform the rescue operation while standing...
Page 84: ...ump Use the let down pump only to lower the booms and or raise the outriggers when either the main pump or engine malfunctions Using the pump to raise the booms may cause damage to the let down pump m...
Page 85: ...causing a short circuit which overheats the hydraulic line Improper system pressure setting Overheating the hydraulic system Snagging of hydraulic lines on fixed objects A spray or mist produced by a...
Page 86: ...the lower controls to the lower control position This will stop all flow to upper controls Push the engine stop start switch if so equipped This will stop the engine driving the pump From The Ground...
Page 87: ...The engine and the Aerial Device s motion will cease Then manually attempt to center the spring loaded control lever before restarting the engine If the spring loaded control lever at the platform wil...
Page 88: ...ry is located in the truck cab with a re charge connection To replace the battery open the battery box located on the backside of the platform disconnect the discharged battery at the quick connect an...
Page 89: ...OR 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 l...
Page 90: ...from operating outside the All outriggers must be properly set before Truck must be level before operation proper platform boom positions or Platfrom must remain opposite lower boom hinge pin from lo...
Page 91: ...ets close to the centerline of rotation the upper boom will go down along the centerline Do not use this feature in normal operation It is intended only to prevent going to an over center position If...
Page 92: ...ace if one is supplied or ensure platform liner is held in platform Lock upper boom in place with hold down latch or strap Make sure that outriggers are fully retracted Store outrigger pads and wheel...
Page 93: ...pment removed Warning or OUT OF ORDER signs shall be placed and removed by authorized personnel only ADJUSTMENTS AND REPAIRS Any unsafe conditions disclosed by the inspection requirements of this sect...
Page 94: ...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 NOTE Remember that the sa...
Page 95: ...for rotational obstructions 14 Visual inspection of all electrical wires 15 Operational test of all boom functions 16 Inspect winch line hook and slings 17 Verify operation of limit system 30 DAYS 120...
Page 96: ...ll moveable hydraulic and control hoses operate over full range of boom and turntable movements without stretching kinking or rubbing on sharp corners CONTROL SYSTEM 1 Check that all moveable hydrauli...
Page 97: ...TM SERIES 2 5 TM Series Terex South Dakota Inc 472797 1 15 MAINTENANCE GUIDELINES LUBRICATION CHART...
Page 98: ...This can best be determined by examination and comparison of the bulk of an individual strand which is exposed and subject to wear with that same strand where it crosses under other strands and is pr...
Page 99: ...ce Further information can be found in the maintenance manual for determining the replacement of the synthetic rope If there is any doubt or question about the condition of the synthetic rope replace...
Page 100: ...idic oil or water in the oil may settle out during storage and can rust the interior of the hydraulic system Cover the platform to prevent water from accumulating A platform full of water can weigh ov...
Page 101: ...ble to the operation and maintenance of your unit 1 OSHA Subpart V Power Transmission and Distribution 2 OSHA 1910 67 Vehicle Mounted Elevating and Rotating Cable Placers 3 OSHA 1910 268 Telecommunica...
Page 102: ...TION 1926 950 General Requirements c Clearances The provisions of paragraph 1 or 2 of this section shall be observed 1 No employee shall be permitted to approach or take any conductive object without...
Page 103: ...MUM DISTANCES VOLTAGE RANGE PHASE TO PHASE KILOVOLT MINIMUM WORKING AND 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 0...
Page 104: ...b points down with other fingers closed USE AUXILIARY HOIST WHIPLINE With arm bent at elbow and forearm vertical elbow is tapped with other hand Then regular signal is used to indicate desired action...
Page 105: ...al tests in accordance with the requirements of 6 6 1 and 6 6 2 and the appropriate electrical tests required in 5 4 of this standard For insulating aerial devices the installer shall assure conforman...
Page 106: ...e Two classifications are designated 1 Frequent Inspection and Test Daily to monthly intervals 2 Periodic Inspection and Test One to twelve month intervals 8 2 3 Frequent Inspection and Test Items det...
Page 107: ...ion Then these components and system s shall be tested for compliance with the rating of the aerial device in accordance with one of the applicable methods and procedures as outlined in Section 5 4 3...
Page 108: ...l manufacturer no longer exist and equivalent entity may determine the required procedure 8 5 Modifications No modifications or additions which affect the stability mechanical hydraulic or electrical...
Page 109: ...e retrained when so directed by the user based on the user s observation and evaluation of the operator 8 12 3 Familiarization When an operator is directed to operate an aerial device they are not fam...
Page 110: ...d provide such proof if requested by the trainee The document evidencing training shall include the following information 1 Name of trainee 2 Name of entity providing training or retraining 3 Name of...
Page 111: ...return to neutral when released and not sticking c Control functions and operation clearly marked 3 Check visual and audible safety devices for proper operation 4 Visually inspect fiberglass and othe...
Page 112: ...d shall include but not necessarily be limited to the following issues and requirements 1 The purpose and use of manuals 2 That operating manuals are an integral part of the aerial device and must be...
Page 113: ...s and brokers of Vehicle Mounted Elevating and Rotating Aerial Devices These manuals shall be stored on the mobile unit 11 3 1 Inspection and Test Prior to delivery the lessor of an aerial device shal...
Page 114: ...r shall pass them on to the user without delay 11 6 Use of Brokers If Brokers are employed in leasing the responsibility of lessors and lessees as specified in this Section continue even though a Brok...
Page 115: ...on for floor and roof openings e Illumination 2 Vehicles a Roads 1 Turn space 2 Parking area 3 Mud areas b Materials storage areas and dump areas c Signs and signals to route vehicles on the job d Mai...
Page 116: ...d 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...
