Terex RMX HI-RANGER Operator'S Manual Download Page 1

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OPERATOR’S MANUAL

This Operator’s Manual MUST BE READ prior to operating your

RMX SERIES Non-Overcenter Material Handling Articulating Aerial Device.

PRINTED IN THE USA

Original Instructions in English

HI–RANGER

RMX SERIES

483018 03/2015

Summary of Contents for RMX HI-RANGER

Page 1: ...This Operator s Manual MUST BE READ prior to operating your RMX SERIES Non Overcenter Material Handling Articulating Aerial Device PRINTED IN THE USA Original Instructions in English HI RANGER RMX SER...

Page 2: ...RMX SERIES 483018 03 15 Terex South Dakota RMX Series Terex South Dakota Inc 500 Oakwood Road Watertown SD 57201...

Page 3: ...HAT IS NOT INSULATED XXIII ELECTRICAL INSULATION XXV PREVENTION OF ELECTROCUTION XXVI OPERATION ON OR NEAR ENERGIZED CONDUCTOR XXVI SECTION 1 1 1 OPERATION GUIDELINES 1 1 NOMENCLATURE 1 1 CAB CONTROLS...

Page 4: ...1 36 OUTRIGGER UNIT CONTROL SELECTOR 1 36 BOOM INTERLOCK 1 36 TORSION BARS OPTIONAL 1 37 STABILITY 1 37 OPERATION 1 38 BOOM OPERATION 1 38 UNSTORE THE BOOM 1 38 AERIAL OPERATION 1 39 EMERGENCY OPERAT...

Page 5: ...MOUNT 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 EXCERPTS CLEARANCE DISTANCE A 2 STANDARD HAND...

Page 6: ...RMX SERIES toc 4 483018 3 15 Terex South Dakota RMX Series...

Page 7: ...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 equipment as instructed in this manual Thi...

Page 8: ...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 your na...

Page 9: ...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 symbol...

Page 10: ...modification will void any remaining warranty 3 Terex South Dakota reserves the right to change improve modify or expand features of its equipment at any time Specifications model or equipment are sub...

Page 11: ...y 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 aware...

Page 12: ...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: ...for a work position Always stand with both feet 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...

Page 14: ...e Aerial Device in an electrical environment if the fiberglass boom components are damaged contaminated by moisture or dirt or otherwise maintained improperly A daily inspection and an annual dielectr...

Page 15: ...and dry and must be inspected periodically 2 All accessories must be inspected maintained and operated with the same care and safety rules that apply to the Aerial Device 3 Do not use hoses having le...

Page 16: ...the Aerial Device Allow adequate clearance when applying and removing the load 15 When using the jib as a line lifter remove the rope from the sheave 16 Use only approved and tested hot line tools fo...

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 s...

Page 18: ...eration 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 mini...

Page 19: ...bstructions 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: ...l decals in place can be hazardous ITEM DECALS QTY PART 1 PLATFORM NOT INSULATED 1 47988 2 ARROWS 18 H21503 3 NOT INSULATED BEYOND ARROWS 8 402236 4 READ CAREFULLY 1 414590 5 FAILURE TO OBEY 1 419262...

Page 21: ...lating components of this aerial device do not offer protection in the event of such contact Proper conductor cover up insulated sleeves and gloves shall be worn when working near energized lines or e...

Page 22: ...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 an electrically charged power li...

Page 23: ...sway This machine does not provide protection from contact with or proximity to an electrically charged power line Boom and platform must be kept below all electric power lines Do not use for work on...

Page 24: ...ations 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 feature...

Page 25: ...perator 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 Plastic or fiberglass cover...

Page 26: ...ion Intervals as required in the Operators and Maintenance Manuals Maintain a record of all inspections DIELECTRIC CRITICAL FASTENER ANNUAL DATE INITIALS INITIALS DATE Follow component replacement int...

Page 27: ...l 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 com...

Page 28: ...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 29: ...onnected The operator shall 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...

Page 30: ...s an 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 whe...

Page 31: ...proper protective equipment will protect the upper half of their body from this hazard Any conductive object in the platform liner which protrudes above the liner will eliminate any protection the li...

Page 32: ...ulated and are interconnected to all other conductive components at the boom tip DO NOT contact any conductor or wire while touching controls unless wearing insulating rubber gloves rated for the volt...

Page 33: ...at 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 i...

Page 34: ...f such 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...

Page 35: ...ELINES NOMENCLATURE Upper Controls Jib Platform Boom Tip Upper Fiberglass Boom Elbow Cylinder Elbow Upper Boom Pivot Pin Fiberglass Insert Lower Boom Steel Main Boom Pivot Pin Turntable Platform Rest...

Page 36: ...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 Device f...

Page 37: ...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 38: ...rgency 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 co...

Page 39: ...e 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 40: ...e two or more functions together 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 whe...

Page 41: ...form Leveling Allows the platform to be hydraulically tilted to level the platform Utilized for emergency removal and platform clean out 3 Platform Rotation Optional Allows the platform to rotate towa...

Page 42: ...ial Device upper control station has metallic parts which are necessary to provide the structural support for the various components These metallic parts are interconnected The main shaft that support...

Page 43: ...trigger and pull lever back to fold the lower boom DOWN Boom Rotation Squeeze the trigger and twist lever right to rotate booms clockwise CW Squeeze the trigger and twist lever left to rotate booms co...

Page 44: ...unterclockwise CCW NOTE Directions are for end mount platform 4 Stop Push to stop all operations at the platform controls This diverts all oil to the tank Pull to resume operation 5 Winch Optional Pus...

Page 45: ...th engine OFF the auxiliary let down power is activated Push and hold to turn on auxiliary let down power Release to shut off auxiliary let down power NOTE Can be included with two speed throttle circ...

Page 46: ...itch must be depressed and held in order for lower hydraulic controls to be operational 7 Top Control and Option Shut Off Controls oil flow to the option valve and hydraulic tool at the platform In th...

Page 47: ...are self centering spring loaded and return to the neutral position when released The hydraulic platform tilt optional allows the platform to be tilted for cleaning out the platform and for personnel...

Page 48: ...to rotate RIGHT or counterclockwise CCW 2 Upper Boom Pull lever up to unfold upper boom UP Push lever down to fold upper boom DOWN 3 Lower Boom Pull lever up to fold lower boom UP Push lever down to u...

Page 49: ...inch Pull up to raise load or wind up winch line UP Push down to lower load or pay out winch line DOWN 6 Palm Switch Depress and hold switch to operate lower hydraulic controls 7 Top Control and Optio...

Page 50: ...ontrol allows the engine speed to be increased to a high idle position or reduced to the normal idle speed from remote locations This gives the operator a choice of an efficient economical engine idle...

Page 51: ...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 when...

Page 52: ...OPERATION 1 Rotate the platform to its stowed position alongside the boom 2 Move the control selector at the lower controls for the appropriate control 3 Position the platform to position shown so the...

Page 53: ...ntrol lever slowly in the direction shown on the decal as required to level To tilt the platform for clean out or rescue from the lower control station Select the lower controls Position booms so plat...

Page 54: ...he 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 to travel back...

Page 55: ...stem 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 the...

Page 56: ...ow 1 Install pin 1 and remove pin 2 2 Extend or retract cylinder for desired direction to next hole and insert pin 2 3 Remove pin 1 4 Hydraulic extendable jib is now ready for use 5 If a longer jib re...

Page 57: ...hart The capacity given here is the capacity of the machine for the unit s position NOTE Load charts shown are for an example only Each Aerial Device has its custom made load chart which may have diff...

Page 58: ...ttachments must be tested maintained and inspected before each use PHASE LIFTERS OPTIONAL The single and multiple phase lifters are used for lifting conductors during crossarm or pole changeouts Singl...

Page 59: ...Device from the lower controls with no one in the personnel platform s The upper boom should be raised out of the boom rest approximately twenty degrees 20 such that platforms will clear platform res...

Page 60: ...on 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 instabil...

Page 61: ...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 eme...

Page 62: ...iquid VEHICLE AND BODY CHECKS ITEM DESCRIPTION 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 H...

Page 63: ...Mounting 6 Main or Auxiliary Pump 21 Hydraulic Plumbing 7 Lower Controls 22 Cylinder Holding Valves 8 Rotation Gear Box 23 Electrical Systems 9 Rotation Bearing Bolts 24 Operator s Manual 10 Rotation...

Page 64: ...o 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 each...

Page 65: ...condition and that the truck axles uniformly support the truck weight If the tires are hanging on one axle spring barely touching the ground and the other tire spring is up against the rubber stop th...

Page 66: ...y rules and regulations When work is to be performed on or near power lines ground and or barricade vehicle according to your company policy If using a temporary ground connect grounding cable clamped...

Page 67: ...h 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 vehicl...

Page 68: ...and flat where tires are located If one side 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 outrigge...

Page 69: ...span will be shortened and stability is reduced Ensure the curb has sufficient strength to support the load All of the previous may affect the stability of the vehicle and restrict the load capacity...

Page 70: ...down to bare ground to prevent sliding and to evaluate the support available Don t set outriggers on a manhole cover or the edge of a slope or drop off Move as far as required into the street or road...

Page 71: ...bumper both in contact with their stops Also the tire clearance to the body on each side needs to similar STABILITY The stability of a vehicle equipped with a rotating aerial device depends on the gro...

Page 72: ...e the upper boom at this position you must back the lower boom off slightly below 90 degrees This allows the platform to get close to the ground to get in and out of the platform To get to the ground...

Page 73: ...er 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 INADEQUATE...

Page 74: ...ating 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 pro...

Page 75: ...ea 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 to...

Page 76: ...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 Stay...

Page 77: ...circuit and current may pass from foot to foot or foot to hand The condition of the ground and subsurface will determine the electric gradient around the vehicle BEFORE TRYING TO GET ON OR APPROACH TH...

Page 78: ...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 outrigger optional At the platform th...

Page 79: ...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 80: ...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 S...

Page 81: ...elp to minimize or possibly prevent injuries OPERATIONAL LIMITATIONS PLATFORM LEVELING SYSTEM The platform leveling system is designed to carry the rated load of the platform Collision of the platform...

Page 82: ...perly store outrigger pads and chocks 5 Stow all loose items or equipment 6 Disengage PTO to prevent damage 7 Shut off master switch 8 Make final inspection that everything is properly stored 9 Turn o...

Page 83: ...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 section s...

Page 84: ...NOTE The following check points listed are the minimum recommended by Terex South Dakota They are subject to supplementation to conform with your own company regulations NOTE Remember that the safety...

Page 85: ...boom functions 16 Visual inspection of winch line and hooks 90 DAYS 360 HOURS 1 Check tension on leveling system 2 Visually inspect all sprockets chains pulleys and pins 3 Lubricate all points per lu...

Page 86: ...ARING ROTATION GEAR TEETH ELBOW PIVOT BEARING BOOM PIVOT BEARING CHAIN PULLEYS ROTATION BEARING LINK BEARING 10 9 8 7 6 5 4 3 CYLINDER BEARING ITEM 2 1 4 2 2 1 A R 1 2 6 QTY 8 2 LEG 448708H NOTE ALWAY...

Page 87: ...ROTATOR CYLINDER BASKET SHAFT BEARING ROTATION DRIVE BEARING ROTATION GEAR TEETH ELBOW PIVOT BEARING BOOM PIVOT BEARING CHAIN PULLEYS ROTATION BEARING LINK BEARING 10 9 8 7 6 5 4 3 CYLINDER BEARING I...

Page 88: ...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 pro...

Page 89: ...e 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 i...

Page 90: ...dic 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 ove...

Page 91: ...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 92: ...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 93: ...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 94: ...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 95: ...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 96: ...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 97: ...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 98: ...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 99: ...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 100: ...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 101: ...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 102: ...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 103: ...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 104: ...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 105: ...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 106: ...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...

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