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TM SERIES

1-1

T M S e r i e s

T e r e x S o u t h D a k o t a , I n c .

4 7 2 7 9 7 - 1 / 1 5

OPERA

ION

GUIDEL

INES

SECTION 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

Outriggers

Strobe Light

Boom Tip

Upper Boom
Cylinder

Lower Boom
Extension
Cylinder

Содержание HI-RANGER TM Series

Страница 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...

Страница 2: ...TM SERIES 472797 01 15 Terex South Dakota Inc TM Series Terex South Dakota Inc 500 Oakwood Road Watertown SD 57201...

Страница 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...

Страница 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...

Страница 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...

Страница 6: ...TM SERIES toc 4 472797 1 15 Terex South Dakota Inc TM Series...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 36: ...TM SERIES XXX 472797 1 15 Terex South Dakota Inc TM Series WHAT IS INSULATED AND NOT INSULATED...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 97: ...TM SERIES 2 5 TM Series Terex South Dakota Inc 472797 1 15 MAINTENANCE GUIDELINES LUBRICATION CHART...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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