Genie Simon AT Series Operator's Manual

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MODEL AT 60 Featuring "Full Hydraulic" Control System

OPERATOR'S MANUAL

This Operator's Manual MUST BE READ prior to operating your AT 60.

Part No. 89-446102 • Revision "0.3" dated April, 1997 •

Art # A00 004

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AT60 OPERATOR'S MANUAL

Introduction	iii
Machine Specifications	iv
Machine Diagrams
Range Diagram	V
General Arrangement Diagrams	vi
Technical Charts
Gradeability Conversion Chart	vii
Beaufort Scale and Wind Velocity Chart	vii
Permissible Soil Consolidations by Weight Chart	viii

SAFETY

Safety Symbols
Safety Rules and Precautions
Environmentally Hazardous Materials
Battery (Acid/ Lead)
Diesel Fuel
Hvdraulic Fluid
Radiator Antifreeze
Fogm-Filled Tires
Engine Oil
Safetv-Related Decals
Safety and Control Decal Locations
Safety and Control Decal Descriptions

OPERATION

Unloading Procedures	-3 -5
Cround Controls	-6
Bondant Controls (Ontional)	12
Periodi Controls (Optional)	14
Startun Drocedures	. –
Shift Checke 2-	20
Machine Startun	20
Cround Operation and Checks	22
Emergency Pump Operation and Check 2-	25
Platform Operation and Checks	26
Operation	20
	30
Driving and Steering 2-	31
Braking 2-	3i
Boom Superstructure and Platform 2-	32
Gasoline Engine Operation	33
Dual Fuel Engine Operation 2-	33
Diesel Engine Operation 2-	34
Shut-down Procedures	35
Transporting the Machine	••
Truck or Trailer Transport	36
Lifting the Machine	38
Emergency System and Procedures
Emergency Electrical Pump	40
Unpowered Emergency Movement2-	41
Emergency Lowering2-	42

TABLE OF CONTENTS

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Table of Contents (Continued)

MAINTENANCE

General Maintenance Tips Shift Operational Checklist Weekly Operational Checklist Monthly Operational Checklist Quarterly Operational Checklist Semi-Annual Operational Checklist	3-3 3-4 3-7 3-9 3-11 3-12
Troubleshooting	2 1 4
What to check if functions will not operate:
Lubrication Chart	3-15 3-17

INDEX

Applicable Standards and Regulations	A-3
ANSI/SIA A92.5 - 1992 (Partial)
5.Responsibilities of Dealers	A-5
6 Responsibilities of Owners	A-7
7.Responsibilities of Users	A-10
8. Responsibilities of Operators	A-16
9. Responsibilities of Lessors	A-20
10 Responsibilities of Lessees	A-21

Limited Warranty Transfer of Ownership Notice (Business Reply Cards) Catalog Comment Card (Business Reply Cards)

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INTRODUCTION

This Operator's Manual has been designed to provide you with the instructions needed to properly and safely operate your Self-Propelled Aerial Work Platform.

THIS OPERATOR'S MANUAL MUST BE READ AND UNDERSTOOD PRIOR TO OPERATING YOUR SELF-PROPELLED AERIAL WORK PLATFORM.

OPERATORS MUST BE AWARE OF AND COMPLY WITH ALL MANUFAC-TURER'S INSTRUCTIONS AND APPLICABLE OSHA/ANSI SAFETY GUIDE-LINES.

FAILURE TO COMPLY WITH MANUFACTURER'S INSTRUCTIONS AND OSHA/ANSI SAFETY GUIDELINES WILL RESULT IN SERIOUS INJURY OR DEATH.

Your machine has been designed and built to provide many years of safe, dependable service. To obtain the full benefit of your machine, always follow the proper operating and maintenance procedures as outlined in this manual. Only trained, authorized personnel should be allowed to operate or service this machine. Service personnel should read and study this manual in order to gain a thorough understanding of the functions of the machine prior to making any repairs.

MODIFICATIONS OF THIS MACHINE FROM THE ORIGINAL DESIGN AND SPECIFICATION WITHOUT WRITTEN PERMISSION FROM TEREX AERIALS ARE STRICTLY FORBIDDEN. A MODIFICATION MAY COMPROMISE THE SAFETY OF THE MACHINE, SUBJECTING USERS TO SERIOUS INJURY OR DEATH. ANY SUCH MODIFICATION WILL VOID ANY REMAINING WAR-RANTY.

Terex reserves the right to change, improve, modify or expand features of its equipment at any time. Specifications, models or equipment are subject to change without notice, and without incurring any obligations to change, improve, modify or expand features of previously delivered equipment.

All manuals are periodically updated to reflect changes that occur in the equipment. Please contact the factory with any questions you may have regarding your machine, or the availability of more recent manuals.

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MACHINE SPECIFICATIONS

Working Height (maximum)	. 66 ft / 20.12 m
Platform Height (maximum)	. 60 ft / 18.29 m
Horizontal Reach (maximum)	. 32 ft 6 in. / 9.91 m
Platform Capacity (unrestricted, maximum)	. 500 lbs. / 225 kg
Platform Size	. 30 in. x 60 in. / .76 m x 1.52 m
Stowed Length	. 23 ft 5.5 in. / 7.15 m
Stowed Height	. 9 ft 3 in. / 2.82 m
Machine Width	. 7 ft 10 in. / 2.39 m
Superstructure Width	. 7 ft 8 in. / 2.34 m
Tailswing Radius (beyond chassis width)	. 15 in. / .38 m
Wheelbase	. 7 ft 6 in. / 2.29 m
Ground Clearance	. 13 in. / 0.33 m
Gross Weight (approximate)	. 23,600 lbs / 10,700 kg
Maximum Travel Speed (4 Wheel Drive):	-
Booms Stowed (high speed)	. 2.2 mph / 3.5 kph
Booms Stowed (low speed)	. 1.4 mph / 2.3 kph
Booms Elevated	. 0.5 mph / 0.8 kph
Outside Curb Clearance Radius	. 16 ft 4 in. / 4.98 m
Inside Curb Clearance Radius	. 77.4 in. / 1.97 m
Gradeability (high speed)	. 11 ° / 20%
(low speed)	. 21 ° / 38%
Maximum Slope	. 5°
Maximum Wheel Load	. 11,680 lbs./ 5,298 kg
Maximum Wind Speed	. 28 mph (12.5 m/sec./6° Beaufort)
Noise Emission Value at Work Place	. <85 dB(A) @ 23 ft/ 7 m
Platform Rotation	. 180°
Superstructure Rotation	. 360°, Non-continuous
Tires (Liquid Ballasted or Foam Filled)	. 390/ 70-16,5 12 Ply (Mudder)
Tire Pressure (not required for foam)	. 90 psi / 6.21 bar / 6.33 kg/ cm ²
Pump Compensator Setting	. 3000 psi / 207 bar / 211 kg/ cm ²
Emergency Pump Relief Valve Setting	. 3000 psi / 207 bar / 211 kg/ cm ²
Hydraulic Pump Flow (Max.)	. 37 g.p.m. / 140 L.p.m.
Hydraulic Fluid Capacity: Hydraulic Tank	. 40 gal. / 151 L
Fuel Capacity: Fuel Tank	. 40 gal. / 151 L
Swing Bearing Bolt Torque (lubricated)	. 170 ft lbs. / 231 Nm / 23.5 kg-m
Axle "U" Bolt Torque (lubricated)	. 350 ft lbs. / 475 Nm / 48.4 kg-m
Front and Rear Wheel Bolt Torque (lubricated)	. 130 ft lbs. / 176 Nm / 18.0 kg-m
Front Wheel Adapter Lug Nuts (lubricated)	. 130 ft lbs. / 176 Nm / 18.0 kg-m
Rear Wheel Adapter Lug Nuts (lubricated)	. 170 ft lbs. / 231 Nm / 23.5 kg-m
Electrical Power System, Negative Ground	. 12 volt DC battery
Engine Availability:
Standard: Ford LSG 423, 63 hp (47.0 kW, Liquid Cooled, Gasolin	e (Dual Fuel option)
Optional: Deutz F4L1011, 56 hp (41 kW), Air cooled, Diesel Fue	1
Isuzu C-240, 56 hp (41 kW), Liquid Cooled, Diesel Fue	4
Hatz Silent Pack, 3L40C, 52 hp (38.8 kW), Air Cooled,	Diesel

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AT60 OPERATOR'S MANUAL

MACHINE DIAGRAMS

RANGE DIAGRAM

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MACHINE DIAGRAMS (CONTINUED)

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Beaufort Scale	Description	Wind Velocity mph (m/ sec)	Effects of Wind Inland
3	Light Breeze	7.6 to 12.08 mph 3.4 to 5.4 m/sec	Leaves and thin twigs move
4	Moderate Breeze	12.3 to 17.67 mph 5.5 to 7.9 m/sec	Lifting dust and loose paper, moves twigs and thin branches
5	Brisk Breeze 17.9 to 23.9 mph 8.0 to 10.7 m/sec		Leafy trees start to sway, foam crests form on lakes
6	6 Strong Wind 24.16 to 30.9 mph 10.8 to 13.8 m/sec		Big branches move, telephone lines whistle, use of umbrellas difficult
7	Stiff Wind	31.09 to 38.25 mph 13.9 to 17.1 m/sec	Whole trees moving, perceptible resistance when walking against the wind

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TECHNICAL CHARTS (CONTINUED)

PERMISSIBLE SOIL CONSOLIDATIONS BY WEIGHT CHART

Type of Soil	daN/cm² (kp/cm²)
A Filled soil, not artificially condensed	0 - 1
B Undisturbed, obviously untouched soil
1 Mud, peat or marshy soil	0
2 Non-binding, sufficiently solid soils
Fine to medium sand	1.5
Coarse to gravel	2.0
3 Cohesive soils
Pasty	0
Soft	0.4
Firm	1.0
semi-solid	2.0
Hard	4.0
4 Rocks with few fissures in sound unweathered condition and good stratification
In compact layer sequence	15
In massive or pillarlike formation	30

TECHNICAL CHARTS

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AT60 OPERATOR'S MANUAL

SECTION 1: SAFETY

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Safety Symbols
Safety Rules and Precautions	1-4
Environmentally Hazardous Materials
Battery (Acid/ Lead)	1-8
Diesel Fuel	1-8
Hydraulic Fluid	1-9
Rádiator Antifreeze	1-9
Foam-Filled Tires	1-9
Engine Oil	1-9
Safety-Related Decals	1-10
Safety and Control Decal Locations	1-18
Safety and Control Decal Descriptions	1-19

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SAFETY SYMBOLS

This manual contains important information on the safe use of your Terex Self-Propelled Aerial Work Platform. Your failure to read, understand and follow all safety rules, warnings and instructions will unnecessarily expose you and others to dangerous situations. For your safety and the safety of those around you, you must operate your aerial work platform as instructed in this manual.

You, the operator, are the single most important factor for safety when using any piece of equipment. Learn to operate your work platform in a safe manner.

To help you recognize important safety information, we have identified warnings and instructions that directly impact on safety with the following signals:

"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.

A WARNING

"WARNING" INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY.

"Caution" indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It is also used to alert against unsafe practices, and for property-damage-only situations.

One final note: The best method to protect yourself and others from injury or death is to use common sense. If you are unsure of any operation, don't start until you are satisfied that it is safe to proceed.

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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.

You must AVOID CONTACT between any part of the machine, or its load, and any electrical line or apparatus carrying up to 300 volts.

You must maintain a CLEARANCE OF AT LEAST 10 FEET (3.05 m) between any part of the machine, or its load, and any electrical line or apparatus carrying over 300 volts up to 50,000 volts. One foot (30.5 cm) additional clearance is required for every additional 30,000 volts.

DEATH OR SERIOUS INJURY will result from contact with, or inadequate clearance from, any electrically charged conductor.

Read and understand all safety and control information found on the machine and in this manual before operating the machine.
Only trained, competent personnel should operate the aerial work platform.
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 machine from the platform. In addition, approved headgear and other protective equipment must be worn as required. (In the U.S.A., OSHA approved equipment is required. For other countries, the appropriate equivalent government body should be consulted.)
NEVER fasten safety belt to an adjacent structure while on the work platform.
Make sure that entry gate to platform is secured before operating machine from the platform.
DO NOT block the foot pedal or any function control in the operating position.
DO NOT exceed the platform capacity of the machine in any configuration. Review the section titled "MACHINE SPECIFICATIONS", earlier in this manual, regarding this model's capacities and dimensions.

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SAFETY RULES AND PRECAUTIONS

SAFETY RULES AND PRECAUTIONS (CONTINUED)

A DANGER

SECURE all tools and other loose items to prevent injury to persons working on or below the work platform.
DO NOT use scaffolding, ladders or similar items to extend your reach while on the work platform.
DO NOT attempt to climb down the boom assembly, if the machine fails while the operator's platform is raised or extended.
Since the machine may be operated from its ground controls, precautions should be taken to prevent unauthorized personnel from operating the work platform with the ground controls while the platform is in use.
DO NOT attempt to open any hydraulic line or component without first relieving all system pressures and shutting off fluid flow from the tank.
DO NOT allow anyone to tamper with, service or operate the machine from the ground control station while personnel are on the platform, except in an emergency.
DO NOT alter, modify or disable any safety devices or interlocks.
DO NOT refuel the machine near sparks or open flames. Gasoline and propane vapors, and Diesel fuel fumes are highly explosive.
DO NOT use the aerial work platform outdoors in electrical storms or in high wind situations.
DO NOT raise the aerial work platform unless the machine is on a firm, level surface.

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SAFETY RULES AND PRECAUTIONS (CONTINUED)

Use caution to prevent ropes, cords, hoses, etc. from becoming entangled in the machine's boom sections when being raised, lowered or repositioned.
Ensure that the area surrounding the mobile platform is clear of personnel and equipment before: driving the machine; or raising, lowering or extending the boom sections; or swinging the superstructure; or, rotating or tilting the platform.
Maintain a safe distance from overhead and ground obstacles, debris, drop-offs, holes, depressions, electrical wires and other hazards to travel.
Limit travel speed according to conditions of the ground surface, congestion, slope, location of personnel or any other factors that could cause hazard of collision or injury to personnel.
DO NOT sit, stand or climb on platform rails.
DO NOT operate this machine while under the influence of any drugs or alcohol.
DO NOT operate this machine if you are bothered by heights, seizures, or dizzy spells.
DO NOT indulge in stunt driving or horseplay while operating this machine.

Complete the "Operational Checklists" found in this manual (see Table of Contents) at designated intervals.
Ensure that the machine is in "LOW" drive speed while unloading from a truck or trailer.
Always attach the machine 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.
With the platform swung away from the stowed position, use caution when selecting travel or steering direction. Travel and steer direction will be opposite switch or lever movement. Refer to the location of the superstructure lockpin hole for travel orientation.

SAFETY RULES

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SAFETY RULES

SAFETY RULES AND PRECAUTIONS (CONTINUED)

A WARNING

Check fuel system for leaks or damaged fuel lines before operating machine. If any damage is found, contact your supervisor immediately. Machine shall be removed from service until diagnosis and any necessary repairs have been completed.
Actuation of the red "EMERGENCY STOP" button will apply brakes immediately, causing unexpected platform movement as the machine comes to a sudden stop. Brace yourself.
Immediately report any erratic noises, vibrations or malfunctions of the machine to supervisor. Machine shall be removed from service until diagnosis and any necessary repairs have been completed.
Operating this equipment without all safety and control decals in place can be hazardous.
Engine exhaust contains chemicals known to the State of California to cause cancer, birth defects and other reproductive harm.

For transporting the machine, the platform must not be tied to the trailer bed in any way.
Be sure to turn all hydraulic valves back "open" before starting the machine, or extensive pump damage will occur.
DO NOT exceed the maximum platform horizontal pull of 100 pounds (45.4 kg).
DO NOT use the boom sections or platform as a crane to lift oversized or hanging loads.
DO NOT raise, extend, retract, tilt, rotate, or lower the platform into stationary objects, as this will cause damage to mechanical and hydraulic components.
DO NOT use the platform or boom functions to push or tow the machine or another vehicle.
Avoid sudden braking or steering, go slowly and leave more maneuvering room during cold weather operation until the machine is warm.

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ENVIRONMENTALLY HAZARDOUS MATERIALS

BATTERY (ACID/LEAD)

Spilled or leaked battery acid:

Neutralize the spilled quantity with baking soda or calcium-oxide by spreading, mixing, etc. Make certain that the mixture is neutral. Then collect the residue in a suitable Container. Dispose of battery acid as special waste.
Always wear acid-resistant boots and gloves and use suitable face/ eye protection.
Do not allow non-neutralized acid to escape into the sewage system or open bodies of water.

Damaged or unuseable lead batteries filled with sulfuric acid:

Damaged or unusable batteries must be disposed only by authorized disposal companies after emptying and collecting the sulfuric acid.
Dispose lead-containing sulfuric acid as special waste.

DIESEL FUEL

Diesel fuel is a material which contaminates water and must under no circumstances reach the sewage system or open waters!
Spilled or leaked quantities must be restricted to as small an area as possible. Efforts should be made to recoup as much of the fluid as possible by scooping or vacuuming it up. Remove the remainder by sweeping with liquid absorbing materials (oil binding agents).
Scooped up or vacuumed up Diesel fuel oil may be reused after proper filtering.
Materials or soil contaminated by Diesel fuel must be placed in a suitable container and disposed of according to the State and local special waste disposal regulations!

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ENVIRONMENTALLY HAZARDOUS MATERIALS (CONTINUED)

HYDRAULIC FLUID

Hydraulic fluids are substances which contaminate water and must not reach the sewage system or open waters.
The spilled or leaked quantity must be confined to as small an area as possible. Efforts should be made to recoup as much of the fluid as possible by scooping or vacuuming it up. Remove the remainder by sweeping with liquid absorbing materials (oil binding agents).
Scooped up or vacuumed up hydraulic fluid may be reused after proper filtering.
Materials or soil contaminated by hydraulic fluid must be placed in suitable container and disposed of according to the state or local disposal regulations.

RADIATOR ANTIFREEZE

Radiator antifreeze contains glycol and is to be considered a substance hazardous to water.
Cooling water-antifreeze mixture, therefore, must be introduced into the sewage system or open waters!
Dispose of cooling water-antifreeze mixtures as special waste in accordance with the State and local regulations!

FOAM-FILLED TIRES

• Disposal of the material, classified as non-toxic, according to State and local regulations!

ENGINE OIL

Engine oil is a substance hazardous to water and must not reach the sewage system or open waters!
Remove spilled or leaked quantity wiping up with liquid absorbing materials (oil binding agents).
Materials or soil contaminated by motor oil must be placed in suitable container and disposed of according to the State and local special waste disposal regulations.

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SAFETY-RELATED DECALS

10-130600 Decal, "DANGER" (Hazard listing at ground controls)

Page 1-10

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10-151200 Decal, "DANGER" (Hazard listing at platform controls)

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SAFETY-RELATED DECALS (CONTINUED)

10-272600 Decal, "CAUTION" ("Safety Belt Lanyard Only .")

10-282900 Decal, "CAUTION" ("Crane Lift Point .")

10-012900 Decal, "FORWARD"

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AT60 OPERATOR'S MANUAL

SAFETY RELATED DECALS

SAFETY-RELATED DECALS (CONTINUED)

OPEN HYDRAULIC TANK VALVES BEFORE STARTING ENGINE

10012600

10-012600 Decal, "Open Hydraulic Tank Valves Before ."

ENSURE LOCKPIN IS DISENGAGED BEFORE OPERATING SWING FUNCTION

10-007200 Decal, "Ensure Lockpin is Disengaged ."

PLATFORM CAPACITY 500 LBs. (225 kg)

10-148300 Decal, Platform Capacity [4-1/2" (114 mm) wide]

DIESEL FUEL ONLY 10151100

10-117900 Decal, "Gasoline Only" 10-151100 Decal, "Diesel Fuel Only"

10-151300 Decal, "Hydraulic Fluid Only"

10-282800 Decal, "Max./ Min. Hydraulic Fluid Level"

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SAFETY-RELATED DECALS (CONTINUED)

10-282600 Decal, "Emergency Lowering Instructions"

10-282700 Decal, "Emergency Power System"

10-282200 Decal, "Vehicle Center of Gravity"

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10-157100 Decal, "CAUTION" ("Preparations for Unpowered Emergency Movement")

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SAFETY-RELATED DECALS (CONTINUED)

10-144300 Decal, Ground Electrical Controls 10-223900 Decal, "Main/ Emergency Pump

10-255900 Decal, Ground Control Valves

10-131500 Decal, Remote Control Pendant

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10-243900 Decal, Platform Control Valves

10-256000 Decal, Platform Electrical Controls

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SAFETY AND CONTROL DECAL LOCATIONS

OPERATING THIS EQUIPMENT WITHOUT ALL SAFETY AND CONTROL DECALS IN PLACE CAN BE HAZARDOUS.

If any of these items are damaged or missing, replace them immediately. Decals are shown for standard machine. Optional equipment may change the decal locations.

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SAFETY AND CONTROL DECAL DESCRIPTIONS

Item No. Part Number Description			Qty.
1	10-255900	Placard, Ground Control Valves	1
2	10-144300	Placard, Ground Electrical Controls	1
3	10-223900	Decal, "MAIN/ EMERGENCY PUMP"	1
4	10-131500	Decal, Remote Control Pendant	1
5	10-130600	Decal "DANGER" (Hazard listing at Ground Controls)	1
6	10-282900	Decal, "CAUTION" (Crane Lift Point")	1
7	10-282600	Decal, "EMERGENCY LOWERING INSTRUCTIONS"	1
8	10-282700	Decal, "EMERGENCY POWER SYSTEM"	1
9	10-012900	Decal, "FORWARD" Arrow	٦
10	10-012600	Decal, "OPEN HYDRAULIC TANK VALVES "	٦
11	10-007200	Decal, "DISENGAGE LOCKPIN "	2
12	10-167400	Decal, "MANUAL BRAKE RELEASE, SEE INSIDE "	1
13	10-141500	Decal, "EMERGENCY LOWERING, OPEN "	1
14	10-282200	Decal, "VEHICLE CENTER OF GRAVITY"	1
15	10-148300	Decal, "PLATFORM CAPACITY 500 LBS (225 kg)",
		[4-1/2" (114 mm) wide]	4
16	10-150500	Decal, "DANGER" ("Electrocution ")	2
17	10-117900	Decal, "GASOLINE ONLY"	1
	10-151100	Placard, "DIESEL FUEL ONLY"	1
18	10-151300	Placard, "HYDRAULIC FLUID ONLY"	1
19	10-282800	Decal, "MAX./ MIN. HYDRAULIC FLUID LEVEL"	1
20	10-157100	Decal, "MANUAL BRAKE RELEASE "	1
21	10-243900	Decal, Platform Control Valves	1
22	10-256000	Decal, Platform Electrical Controls	1
23	10-151200	Decal "DANGER" (Hazard listing at Platform Controls)	1
24	10-272600	Decal, "CAUTION" ("Safety Belt Lanyard Only")	2
25	10-139800	Decal, "OPERATOR'S MANUAL ENCLOSED"	1
26	10-016800	Decal, "GAS/ OFF/ PROPANE"	1
27	10-108600	Decal, "FOR PROPER OPERATION - SET FUEL"	1
28	10-094700	Decal, "CAUTION" ("Hot Water")	1
29	10-094900	Decal "CAUTION" ("Rotating Fan ")	1

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AT60 OPERATOR'S MANUAL

OPERATION

SECTION 2: OPERATION

[]

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Unloading Procedures
Ground Controls
Platform Controls (Oplionar)
Startup Procedures
Shift Checks
Machine Startup
Ground Operation and Checks
Platform Operation and Checks 2-25
Operation
Cold Weather Operation
Driving and Steering 2-31
Braking
Boom, Superstructure and Platform
Dual Fuel Engine Operation 2-33
Diesel Engine Operation
Shut-down Procedures
Transporting the Machine
Truck or Trailer Transport
Liming the Machine
Emergency System and Procedures
Unpowered Emergency Movement
Emergency Lowering 2-42

Page 2-2

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UNLOADING PROCEDURES

UNLOADING PROCEDURES

TO AVOID SERIOUS PERSONAL INJURY OR DEATH, ENSURE THAT THE MACHINE IS IN "LOW" DRIVE SPEED WHILE UNLOADING FROM A TRUCK OR TRAILER.

1. Inspect the outside of the machine for damage (including the underside). Inspect all hoses, boom sections and cables for chafing or shipping damage. Confirm that all wheel lug nuts and swing bearing bolts are tight (refer to specifications).
2. Remove the pin that locks the superstructure to the undercarriage near the swing bearing. Stow the lock pin in the location provided nearby.
3. Unlock and open both side compartments. Inspect all fuel, electrical and hydraulic connections for damage and security.
4. Connect battery cables to battery if required. Check electrolyte level.
5. Open the fuel tank valves and check fuel level.
6. Check engine oil level, and add as required per engine manufacturer's recommendations.
7. Check fluid level at the sight gauge on the hydraulic tank, and add fluid as required (see Lubrication Chart). Check that shutoff valves on the hydraulic tank are open.
8. Close side compartment covers.
9. Attach the machine to a winch for the unloading procedure.

ALWAYS USE A WINCH TO ASSIST LOADING OR UNLOADING THE MACHINE FROM A TRUCK OR TRAILER. CONNECT WINCH CABLE TO THE TIE DOWN/ LIFTING LUG OPENINGS ON THE UNDERCARRIAGE. UNAS-SISTED LOADING OR UNLOADING OF ANY MOBILE PLATFORM IS NOT RECOMMENDED.

READ AND UNDERSTAND ALL SAFETY, CONTROL AND OPERATING INFORMATION FOUND ON THE MACHINE AND IN THIS MANUAL BEFORE OPERATING THE MACHINE.

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UNLOADING PROCEDURES (CONTINUED)

Perform Machine Startup procedures in this section. Refer to Operator Controls Descriptions, as necessary. Turn off engine.
Remove all machine tie downs. Remove wheel chocks, if used. Turn the Ground/ Platform key switch to "PLATFORM".
Enter the platform, and restart the engine using the platform controls. Select the "HI" engine speed, and test all platform functions.
Raise the upper boom section so that the platform will clear any obstacles as the machine is driven down the loading ramp.
Carefully drive the machine off the truck or trailer with the assistance of a winch.

A CAUTION

Winch line and machine travel must be coordinated during this procedure.

The brakes are automatically released for driving, and will automatically apply when the drive control lever is brought back to the neutral position.

• Before placing the machine into service, all operators must read and understand the contents of this Operator's Manual.

Upon initial unloading of the machine the Post Delivery Inspection Adjustment Report must be completed and returned in order to activate the Terex Limited Warranty.

An Operator's Manual and a Post Delivery Inspection Adjustment Report are included with each machine leaving the factory.

UNLOADING PROCEDURES

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Page 34

OPERATOR CONTROLS (GROUND CONTROLS)

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AT60 OPERATOR'S MANUAL

OPERATOR CONTROLS

OPERATOR CONTROLS DESCRIPTION (GROUND CONTROL, CONTINUED)

ltem	Control	Location	Description
1.	Emergency Stop Button	Ground Electrical Panel	Used to stop all functions in an emergency. Push for emergency stop. Pull out or rotate clockwise to reset, depending on style used.
2.	Circuit Breaker	Ground Electrical Panel	Pops out when the electrical circuit is overloaded. Push in to reset.
3.	Choke/ Glow Plug Button	Ground Electrical Panel	Choke button for gas or dual fuel engines. Press and hold while starting a cold engine.
			Glow plug button for some Diesels. Press and hold (if so equipped) to preheat combustion chamber before starting engine.
4.	Main Power Key Switch	Ground Electrical Panel	Main power "On/ Off" three position switch. Straight up position is "OFF".
			Turn key right (clockwise) one position to turn power "ON" for platform control operation. Turn key left (counterclockwise) one position to turn power "ON" for ground control operation.
			The key may be removed to prevent unauthorized operation. For European machines the key is removeable in any position.
5.	Engine Start Button	Ground Electrical Panel	Press push button to engage engine starter. Release button immediately upon engine start. If the engine does not start within 10 seconds, the main power key must be turned off and then on again to start.
			NOTE: Main power key switch must be in "GROUND" position.
6.	Gas/ Off/ Propane (optional)	Ground Electrical Panel	Flip toggle up for gas fuel, down for propane fuel. In "OFF" position, the engine is not supplied with fuel.
7.	Hour Meter	Ground Electrical Panel	Indicates total elapsed time that the engine has been operated in hours and tenths.
8.	Volt Meter	Ground Electrical Panel	Indicates electrical system voltage.

Page 36

OPERATOR CONTROLS (GROUND CONTROLS)

April 1997

Page 37

AT60 OPERATOR'S MANUAL

OPERATOR CONTROLS

OPERATOR CONTROLS DESCRIPTION (GROUND CONTROLS, CONTINUED)

ltem	Control	Location	Description
9.	Engine Oil Pressure Gauge	Ground Electrical Panel	Indicates engine oil pressure.
10.	Water Temp Gauge (optional)	Ground Electrical Panel	Indicates water temperature of the engine.
11.	Pump Selector Toggle Switch	Ground Electrical Panel	Push up and hold at "MAIN" to activate engine powered hydraulic pump, allowing operation of hydraulic functions (boom movement) from the ground.
			Push down and hold at "EMERGENCY" to activate battery powered hydraulic pump, allowing operation of boom functions should the engine powered hydraulic pump be disabled.
12.	Lower Boom Lever	Ground Valves, beneath Electrical Panel	Valve handle used to control the lower boom sec- tion. Each boom section can be raised and lowered independently.
13.	Middle Boom Lever	Ground Valves, beneath Electrical Panel	Valve handle used to control the middle boom section. Each boom section can be raised and lowered independently.
14.	Upper Boom Lever	Ground Valves, beneath Electrical Panel	Valve handle used to control the upper boom sec- tion. Each boom section can be raised and lowered independently.
15.	Boom Telescope Lever	Ground Valves, beneath Electrical Panel	Valve handle which allows the telescopic upper boom to extend and retract, giving the operator access over obstacles.
16.	Swing Control Lever	Ground Valves, beneath Electrical Panel	Valve handle which controls the rotation of the superstructure on the undercarriage. The superstruc- ture rotates 360 degrees with mechanical swing limiters to stop continuous rotation.
17.	Manual Brake Release Pump	Left of Ground Electrical Panel	Used to manually release the brakes and disconnect the drive. Refer to "UNPOWERED EMERGENCY MOVEMENT".

Page 38

OPERATOR CONTROLS (GROUND CONTROLS)

Page 39

AT60 OPERATOR'S MANUAL

OPERATOR CONTROLS DESCRIPTION (GROUND CONTROLS, CONTINUED)

ltem	Control	Location	Description
18.	Manual Brake Release Vaive	Left of Ground Electrical Panel	Used to engage/ disengage hand pump. Refer to "UNPOWERED EMERGENCY MOVEMENT".
19.	Fuel Select Control (optional)	Beneath Ground Valves (not shown)	Turn handle 1/4 turn counterclockwise to unlock it, and pull it out for gas fuel supply. Then turn the handle clockwise to lock in position.
			Turn handle 1/4 turn counterclockwise to unlock it, and push it in for propane fuel supply. Then turn the handle clockwise to lock in position

OPERATOR CONTROLS

Page 40

OPERATOR CONTROLS (OPTIONAL REMOTE CONTROL PENDANT)

Page 41

AT60 OPERATOR'S MANUAL

DPERATOR CONTROLS

OPERATOR CONTROLS DESCRIPTION (OPTIONAL REMOTE CONTROL PENDANT)

ltem	Control	Location	Description
1.	Pump Selector Toggle Switch	On Remote Control Pendant	Push up and hold at "MAIN" to activate engine powered hydraulic pump, allowing operation of hydraulic func- tions (drive, steer or boom movement) from the ground.
			Push down and hold at "EMERGENCY" to activate battery powered hydraulic pump, allowing operation of boom functions should the engine powered hydraulic pump be disabled.
2.	Drive Toggle Switch	On Remote Control Pendant	Push up and hold to travel forward, down to travel backward.
			AWARNING

WHEN THE PLATFORM IS SWUNG OVER THE STEER-ING WHEELS, USE CAUTION WHEN SELECTING THE TRAVEL DIRECTION. TRAVEL DIRECTION WILL BE OPPOSITE SWITCH MOVEMENT.

3. Steer Toggle On Remote Push to left and hold to turn steer wheels to left, right to Switch Control Pendant turn to right. To straighten wheels, push and hold switch in opposite direction.

WITH THE PLATFORM OVER THE STEERING WHEELS, USE CAUTION WHEN SELECTING THE STEERING DIRECTION. STEER DIRECTION WILL BE OPPOSITE SWITCH MOVEMENT.

Page 42

OPERATOR CONTROLS (PLATFORM CONTROLS)

OPERATOR CONTROLS

April 1997

Page 43

AT60 OPERATOR'S MANUAL

OPERATOR CONTROLS

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS)

ltem	Control	Location	Description
1.	Ignition Switch	On Platform Console	Three position ignition switch. Full down position is "OFF". Center position is ignition "ON", and full up engages the starter.
2.	Choke/ Glow Plug Push Button	On Platform Console	For gas or dual fuel engines. Press and hold while starting a cold engine.
			For some Diesel engines. Press and hold to preheat combustion chamber before starting the engine.
3.	Drive Speed Switch	On Platform Console	Flip toggle switch down for low travel speed and up for high travel speed.
4.	Emergency Pump Button	On Platform Console	Engage to operate any boom function should the engine become inoperable.
5.	Sensor Override Button (Optional)	On Platform Console	Press button to override the position sensor.
6.	Horn Button	On Platform Console	Press button to sound warning horn.
7.	Emergency Stop Button	On Platform Console	Used to stop all functions in an emergency. Push for emergency stop. Pull out or rotate clockwise to reset, depending on style used.
8.	Engine Warning Lamp	On Platform Console	Red light that indicates low oil pressure or high water temperature in the engine. If this lamp should light, the engine will shut down after ten seconds.
9.	Light Switch (Optional)	On Platform Console	Flip toggle switch to turn head and tail lights on and off.
10.	Drive Control Lever	On Platform Console	Controls forward and reverse machine travel at a speed proportional to handle movement and speed selected.

WITH THE PLATFORM SWUNG OVER THE STEERING WHEELS, USE CAUTION WHEN SELECTING THE TRAVEL DIRECTION. TRAVEL DIRECTION WILL BE OPPOSITE DRIVE CONTROL LEVER MOVEMENT.

Page 44

OPERATOR CONTROLS (PLATFORM CONTROLS)

Page 45

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS, CONTINUED)


OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS, CONTINUED)
ltem	Control	Location	Description	CO
11.	Steer Switch	On End of Drive Control Lever	Move switch left and hold to turn steer wheels to left, and right to turn steer wheels to right. Push and hold in opposite direction to straighten wheels.	RATOR
				OPE
			WITH THE PLATFORM SWUNG OVER THE STEERING WHEELS, USE CAUTION WHEN SELECTING THE STEERING DIRECTION. STEERING DIRECTION WILL BE OPPOSITE STEER SWITCH MOVEMENT.
12.	Lower Boom Lever	On Platform Console	Valve handle used to control the lower boom section. Each boom section can be raised and lowered inde- pendently.
13.	Middle Boom Lever	On Platform Console	Valve handle used to control the middle boom section. Each boom section can be raised and lowered independently.
14.	Upper Boom Lever	On Platform Console	Valve handle used to control the upper boom sec- tion. Each boom section can be raised and lowered independently.	V
15.	Boom Telescope Lever	On Platform Console	Valve handle which allows the telescopic upper boom to extend and retract, giving the operator access over obstacles.
16.	Swing Control Lever	On Platform Console	Valve handle which controls the rotation of the superstructure on the undercarriage. Move lever forward to swing the superstructure to the left (clock- wise), back to swing to the right (counterclockwise). The superstructure rotates 360 degrees with me- chanical swing limiters to stop continuous rotation.
17.	Platform Rotate Lever	On Platform Console	Valve handle which controls the rotation of the platform. Move lever forward to rotate the platform to the left (clockwise), back to rotate to the right (counterclockwise). The platform will rotate 90 degrees from center in each direction.

Page 46

OPERATOR CONTROLS (PLATFORM CONTROLS)

Page 2-18

Page 47

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS, CONTINUED)

ltem	Control	Location	Description
18.	Platform Level Lever	On Platform Console	Valve handle which allows the platform to be manu- ally leveled.
19.	Foot Pedal Switch	On Platform Floor	Must be depressed to activate main hydraulic pump, allowing operation of any hydraulic function (drive, steer, boom or platform movement) from the platform. Depress pedal before selecting function.
20.	Lift/ Drive Switch (Option)	On Platform Console	When this switch is found on the console, lift and drive functions cannot be used at the same time. The switch must be in the "LIFT" position for the lift function to be operational. The switch must be in the "DRIVE" position for the machine to be driven.

OPERATOR CONTROLS

Page 48

STARTUP PROCEDURES

SHIFT CHECKS

Before the Work Platform is put into use each shift, the following checks should be completed to make sure that the machine is safe and in good condition.

Refer to checklists at back of this manual for periodic maintenance requirements and additional procedures for severe duty applications:

Visually inspect all machine components, i.e. missing parts, torn or loose hoses, hydraulic fluid leaks, torn or disconnected wires, flat or damaged tires, bent or damaged structural components, etc. Both compartment doors can be opened to inspect components inside.
Check engine oil and fuel levels.
Check engine coolant level (on liquid cooled machines).
Check battery electrolyte level and connections.
Check hydraulic fluid level with booms fully retracted and lowered.
____ Check that all shutoff valves on the hydraulic tank are open. When open, valve handles will be parallel with the length of the valve.

The shutoff values on the hydraulic tank must be left open at all times, except during repairs or transport. If one or more of these values are closed when the unit is running, extensive pump damage will occur.

Check hoses and cables for worn areas.
Check hose carrier to make sure that it is not bent or sagging.
- Inspect safety belt connections and check for worn areas on the belts.
- ____ Check platform rails and safety gate latch for damage.
- ____ Check pivot pins for security.
- ____ Check that all warning and instructional labels are legible and secure.

STARTUP PROCEDURES

Page 49

STARTUP PROCEDURES

MACHINE STARTUP

A DANGER

ALL OPERATORS MUST THOROUGHLY READ AND UNDERSTAND THE "SAFETY RULES AND PRECAUTIONS" SECTION OF THIS MANUAL PRIOR TO OPERATING THE MACHINE.

A COMPLETE VISUAL INSPECTION OF THE MACHINE MUST BE PER-FORMED PRIOR TO OPERATIONAL CHECKS.

Disengage lockpin before using the turntable.
Ensure that emergency stop button on ground control panel and platform console are disengaged. Reset, as required.
Turn the main power key switch to the "GROUND" position to energize the electrical system.
For gasoline engines, press the "CHOKE" button, and hold it prior to engaging starter motor; or

for Diesel engines equipped with glow plugs, press the "GLOW PLUG" button and hold for 30 seconds prior to engaging starter motor.

Press and hold engine start button to start engine.
Refer to the "Machine Specifications" section of this manual for the "Maximum Hydraulic Pressure" for this machine.
On the ground control box or optional remote control pendant, press and hold the pump selector switch to "MAIN", but do not operate any drive or boom function. This is called "deadheading", and will lead to maximum compensator setting of the pump system pressure registering on the gauge at the ground control valve assembly.
Check that the hydraulic pressure is as stated in the specifications.
Raise or extend the boom, and push down on each of the three fastened corners of the tilt alarm located behind the electrical box. The alarm should sound as each corner is pressed beyond 5 degrees. For European machines alarm sounds at 4 degrees and at 5 degrees the drive is cut out.

NOTE: There is a three (3) second delay before the alarm sounds.

Page 50

GROUND OPERATION AND CHECKS

BE SURE BOOM TRAVEL AREA IS CLEAR OF OBSTRUCTIONS.

DO NOT OPERATE THE MACHINE IF THE FOLLOWING CHECKS REVEAL A DEFECT.

Perform Machine Startup procedures, earlier in this section.
Press and hold the pump selector toggle switch to "MAIN" position.

The pump selector switch is a "Deadman" type control. If released, all machine movement will stop.

Slowly move the lower boom control lever up to operate the lower boom to the end of its movement.
Listen for any unusual noises.
Check for any vibration while the boom travels up or down.
_____ Check for uneven or jerky operation.
_____ Check for hydraulic leaks.
Check pivot pin security. Ensure that all securing bolts are in place on each pin locking point.
Return the lower boom to its stowed position by slowly moving the control lever to the down position.

STARTUP PROCEDURES

Page 51

STARTUP PROCEDURES

GROUND OPERATION AND CHECKS (CONTINUED)

Operate the middle boom and upper boom in the same manner as the lower boom.
Listen for any unusual noises.
Check for any vibration while the boom travels up or down.
_____ Check for uneven or jerky operation.
Check for hydraulic leaks.
Check pivot pin security. Ensure that all securing bolts are in place on each pin locking point.
Operate the boom telescope function by raising the upper boom section parallel to the around and extending and retracting the boom.
Listen for any unusual noises.
Check for any vibration while the boom extends and retracts.
_____ Check for uneven or jerky operation.
Check for hydraulic leaks.
Check cylinder pin security. Ensure that all securing bolts are in place on each pin locking point.
Operate the swing function by slowly moving the control lever up to swing left and down to swing right.
Listen for any unusual noises.
Check for any vibration while the superstructure rotates.
Check for uneven or jerky operation.
_____ Check for hydraulic leaks.
While operating a boom function, press the emergency stop button on the ground control console. All machine functions should stop, including the engine. Reset emergency stop button and restart engine.
Return the machine to a stowed position. Push valve levers in turn, while still pressing the pump selector toggle switch to "MAIN".
Slowly return the valve levers to center position. Release the pump selector toggle switch.

IMPORTANT: All machine operations will stop upon release of the pump selector toggle switch.

• Shut the engine off.

Page 52

GROUND OPERATION AND CHECKS (CONTINUED)

For machines with the optional Pendant Control, leave the engine running and perform the following checks:

• With the pump selector toggle switch to "MAIN" position, press the drive toggle to the "FORWARD" position. The machine will move forward.

AND STEERING DIRECTION WILL BE OPPOSITE TO DIRECTIONS INDI-CATED ON PLACARD.

____ Listen for any unusual noises.
Check for any vibration while the machine travels.
Check for uneven or jerky operation.
____ Check for hydraulic leaks.
Report and repair any problem.
Push the steer switch in the left or right direction, and check for proper steering control. Note position of the platform to the steering wheels.

Page 2-24

STARTUP PROCEDURES

Page 53

STARTUP PROCEDURES

GROUND OPERATION AND CHECKS (CONTINUED)

Return the wheels to the straight ahead position by pressing the steer switch in the opposite direction. When wheels are straight, release the steer switch.
Press the emergency stop button. All functions (including the engine) should stop immediately. Pull up or rotate the button clockwise to reset. Restart engine. Press and hold the pump selector toggle switch.
Press the drive togale to "REVERSE". The machine will move in the backward direction.
Release the drive togale. The machine will come to a complete stop.
Return the machine to the stowed position. Press the appropriate toggle switches and push valve levers in turn, while still pressing the pump selector toggle switch to "MAIN".
Slowly return the toggles and valve levers to center position. Release the pump selector togale switch.

NOTE: All machine operations will stop upon release of the pump selector togale switch.

• Shut the engine off.

EMERGENCY PUMP OPERATION AND CHECK

With engine off:

Actuate the emergency pump switch.
Slowly move the lower boom lever in the up position.
_____ Listen for any unusual noises.
_____ Check for any vibration while the boom travels up or down.
_____ Check for uneven or jerky operation.
_____ Check for hydraulic leaks.
Check pivot pin security. Ensure that all securing bolts are in place on each pin locking point.
Once movement has been established, return the boom section to the stowed position and release the emergency pump switch.

IMPORTANT: The emergency pump is designed for emergency operation only and should not be operated for extended periods of time.

Page 54

PLATFORM OPERATION AND CHECKS

Complete the Ground Operational Checks before you perform the platform checks.
Select the "PLATFORM" control position on the ground/platform selector switch.
Enter the Platform. Close the gate securely and connect the safety belt to the platform.
Press the ignition toggle switch to "START" while engaging the "CHOKE" or "GLOW PLUG" with the choke/glow plug button. As soon as the engine starts, release both switches.

NOTE: If engine has been running for ground operational checks, it should not require choke or alow plug to restart.

BE SURE BOOM TRAVEL AREA IS CLEAR OF OBSTRUCTIONS.

DO NOT OPERATE THE MACHINE IF THESE CHECKS REVEAL ANY DEFECT OR ABNORMALITY.

Actuate the foot pedal power switch, mounted on the floor of the platform.
Slowly move the lower boom control lever up to operate the lower boom to the end of its movement.
Listen for any unusual noises.
_____ Check for any vibration while the boom travels up or down.
_____ Check for uneven or jerky operation.
_____ Check for hydraulic leaks.
Return the lower boom to its stowed position by slowly moving the control lever to the down position.
Operate the middle boom and upper boom in the same manner as the lower boom.
_____ Listen for any unusual noises.
Check for any vibration while the boom travels up or down.
_____ Check for uneven or jerky operation.
_____ Check for hydraulic leaks.

Page 2-26

Page 55

AT60 OPERATOR'S MANUAL

STARTUP PROCEDURES

PLATFORM OPERATION AND CHECKS (CONTINUED)

Operate the boom telescope function by raising the upper boom section parallel to the around and extending and retracting the boom.
Listen for any unusual noises.
Check for any vibration while the boom extends or retracts.
Check for uneven or jerky operation.
Check for hydraulic leaks.
Operate the swing function by slowly moving the control lever up to swing left and down to swing right.
Listen for any unusual noises.
Check for any vibration while the superstructure rotates.
_____ Check for uneven or jerky operation.
Check for hydraulic leaks.
Operate the platform level function by slowly operating the platform level lever forward and backward. Return the platform to a level position.
Listen for any unusual noises.
Check for any vibration while the platform levels.
_____ Check for uneven or jerky operation.
_____ Check for hydraulic leaks.
Check pivot pin security. Ensure that all securing bolts are in place on each pin locking point.
Operate the platform rotate function by slowly moving the platform rotate lever forward and backward. Return the platform to the center position.
_____ Listen for any unusual noises.
_____ Check for any vibration while the platform rotates.
Check for uneven or jerky operation.
_____ Check for hydraulic leaks.

Page 56

PLATFORM OPERATION AND CHECKS (CONTINUED)

A WARNING

ACTUATION OF THE RED "EMERGENCY STOP" BUTTON WILL APPLY BRAKES IMMEDIATELY! THIS MAY CAUSE UNEXPECTED PLATFORM MOVEMENT AS THE MACHINE COMES TO A SUDDEN STOP.

While operating a boom function, press the emergency stop button on the platform control console. All machine functions should stop, including the engine. Reset emergency stop button and restart engine.
With speed switch in low, slowly push the drive control lever forward. The machine should smoothly accelerate in the selected direction. Movement alarm sounds whenever the vehicle is in motion.

WITH THE PLATFORM SWUNG OVER THE STEERING WHEELS, USE CAUTION WHEN SELECTING THE TRAVEL AND STEERING DIRECTION. TRAVEL AND STEERING DIRECTION WILL BE OPPOSITE CONTROL MOVE-MENT.

____ Listen for any unusual noises.
____ Check for any vibration while the machine travels.
Check for uneven or jerky operation.
- Check for hydraulic leaks.
____ Report and repair any problem.

Page 2-28

STARTUP PROCEDURES

Page 57

STARTUP PROCEDURES

PLATFORM OPERATION AND CHECKS (CONTINUED)

Operate the steer switch and check for proper steering control. Note position of the platform to the steering wheels.
Return the wheels to the straight ahead position.
Slowly return the drive control lever to the center "neutral" position. The machine should come to a complete stop.
Slowly push the drive control lever backward. The machine should smoothly accelerate in the selected direction. Movement alarm sounds whenever the vehicle is in motion.
Slowly return the drive control lever to the center "neutral" position. The machine should come to a complete stop.
If conditions permit, flip drive speed switch to high and repeat the drive tests.
Raise the lower boom to horizontal. Repeat the drive tests. Machine should travel a maximum of 0.5 mph (0.8 kph). This condition is referred to as "creep speed", and is the maximum rate of travel with the boom raised or extended.

NOTE: At "creep speed", an AT60 wheel makes one complete revolution in approximately thirteen (13) seconds. If one revolution takes much less than this time, the machine must be adjusted to bring the "creep speed" back down to 0.5 mph (0.8 kph.).

Return the boom to the stowed position.
Move all levers and switches back to their neutral positions. Release the foot pedal.

NOTE: All machine functions should stop upon release of the foot pedal.

• Press emergency stop button. Engine will shut off.

Page 58

OPERATION

THE AT60 HAS A HIGH PERFORMANCE 4 WHEEL DRIVE SYSTEM FOR OPERATION IN SOFT GROUND CONDITIONS AND/ OR ROUGH TERRAIN. SOME OF THESE GROUND CONDITIONS MAY CREATE AN UNSAFE WORK-ING CONDITION WHEN THE BOOMS ARE ELEVATED AND/ OR EXTENDED.

THE OPERATOR MUST BE AWARE OF THE GROUND CONDITIONS. DO NOT RAISE THE PLATFORM OR EXTEND THE BOOM IF THE MACHINE IS NOT ON A FIRM LEVEL SURFACE!

DO NOT RELY ON THE TILT ALARM TO WARN YOU OF AN UNSAFE CONDITION.

SAFE OPERATION BEGINS WITH A SAFE OPERATOR.

Perform Start-Up Procedures. Remember to place the ground/ platform control switch in the "PLATFORM CONTROLS" position before going to the platform for operation.

Enter platform, close and secure safety gate, and attach safety belt.

COLD WEATHER OPERATION

In below freezing weather, the hydraulic fluid should be allowed to warm before full operation of the machine.
Check for water contamination of the fluid.
Check for and remove ice on the platform, swing gear teeth and steering linkage prior to operation.
Check that all valves operate smoothly, and return freely to the neutral position.

Avoid sudden braking or steering, go slow and leave more maneuvering room during cold weather operation.

OPERATION

Page 59

OPERATION

DRIVING AND STEERING

ENSURE THAT THE ROUTE OF TRAVEL IS CLEAR OF PERSONNEL AND DEBRIS.

Press the foot switch. Slowly push the drive control lever "FORWARD" to provide forward travel, or pull the lever back for reverse travel.

NOTE: The speed of the machine is proportional to the distance the lever is moved.

To steer, press the steer switch on the end of the drive control lever to the left or right as required.

Although the machine can be driven with the platform positioned at either end of the machine, the operator may find driving easier from the stowed position. The stowed position can be identified by the steer axle on the undercarriage, or by the line up of the lock pin holes. If driving is attempted with the platform over the opposite axle, you must remember that all directions given to the steer and drive controls will be in reverse.

When descending a ramp (incline), it is necessary to control the speed of the machine. To slow the machine, move the drive control lever slowly toward the center "neutral" position.

BRAKING

For parking, the brakes are automatically applied when the drive control lever is moved to the center "neutral" position.

AWARNING

RELEASE OF THE DRIVE CONTROL LEVER OR ACTUATION OF THE PLATFORM "EMERGENCY STOP" BUTTON WILL APPLY BRAKES IMMEDI-ATELY!

THIS MAY CAUSE UNEXPECTED PLATFORM MOVEMENT AS THE MACHINE COMES TO A SUDDEN STOP.

Page 60

BOOM, SUPERSTRUCTURE AND PLATFORM

Press the foot pedal, then select the required function. Available functions are:

Lower Boom UP or DOWN
Middle Boom UP or DOWN
Upper Boom UP or DOWN
Upper Boom EXTEND or RETRACT
Superstructure swing LEFT or RIGHT
Platform level FORWARD or BACKWARD
Platform rotate LEFT or RIGHT

Each of these functions can be selected by moving the appropriate lever in the proper direction.

NOTE: Function speeds are proportional to lever movement.

Multiple function control is possible by operating more than one function at the same time; however, this may reduce hydraulic fluid flow to each function, slowing response time.

OPERATION

Page 61

OPERATION

GASOLINE ENGINE OPERATION

• Press the "START" button and the "CHOKE" button at ground station, or operate the start toggle and choke button at platform. As soon as the engine starts, release both switches.

DUAL FUEL ENGINE OPERATION

GASOLINE OPERATION

• Operate the machine as normal.

GASOLINE TO PROPANE SWITCHING

This switching can only be done using the ground controls. The machine should only be switched to propane while the engine is running.

• Open valve on propane tank.

Wisconsin and Ford engines:

Move dual fuel selector toggle switch on the ground control panel to the "OFF" position. Allow the engine to run until it consumes the fuel in the carburetor bowl.
As soon as the engine starts to miss, flip the selector toggle on the ground control panel to the "PROPANE" position. Turn the fuel select control handle a quarter turn counterclockwise to unlock it, and push it in. Then, turn the handle clockwise to lock in position. The engine should run normally as soon as the switch engages and handle is pushed in.

Page 62

PROPANE TO GASOLINE SWITCHING

This switching can only be done using the ground controls.

Wisconsin and Ford engines:
- Move dual fuel selector toggle switch on the ground control panel to the "OFF" position. Allow the engine to run until it consumes the propane in the intake manifold. ENGINE WILL STALL.
- Move the selector toggle switch on the ground control panel to "gas". Turn the fuel select control handle a quarter turn counterclockwise, and pull it out. Then turn it clockwise to lock in position, and restart engine. The engine will run normally.

NOTE: When operating on propane, the engine will run for several seconds after the ignition is shut off. This allows the propane to clear the intake manifold.

DIESEL ENGINE OPERATION

FOR DIESEL ENGINES EQUIPPED WITH GLOW PLUGS:

• Press the glow plug button (at platform or ground control cabinet), and hold for 30 seconds (when the engine is cold) prior to engaging the starter motor.

Page 2-34

OPERATION

Page 63

SHUT-DOWN PROCEDURES

When finished with the machine, place the machine in the stowed position.
Park the machine on a level surface. Secure to prevent vandalism and to discourage children from climbing or plaving on it.
Turn off the main power key switch. Remove key to prevent unauthorized operation.

For European machines only:

IMPORTANT: The emergency power system is provided with an independent battery equipped with its own charger. Check the emergency power system battery condition frequently and recharge at regular intervals or as required.

• Use the following procedure to recharge the battery for the emergency pump:

LEAD-ACID BATTERIES GENERATE EXPLOSIVE GASES. KEEP SPARKS AND FLAME AWAY FROM BATTERIES. NO SMOKING!

ENSURE DOOR ON ENGINE SIDE COMPARTMENT IS OPEN TO ALLOW VENTING OF FUMES WHILE CHARGING THE BATTERY.

1. Open the door on the engine side compartment to allow venting of fumes while recharging the battery.
2. Connect the charger power supply cord to properly grounded outlet of proper voltage and frequency.
3. Charger turns off automatically when battery is fully charged.

IN THE UNLIKELY EVENT THAT THE CHARGER DOES NOT TURN OFF AUTOMATICALLY, OVERCHARGING AND POSSIBLE BATTERY DAMAGE MAY RESULT. FOR BEST BATTERY LIFE CHECK TO BE SURE THE CHARGER HAS TURNED OFF PROPERLY AFTER EACH CHARGE CYCLE.

DO NOT OPERATE THE MACHINE WHILE CHARGING THE BATTERY.

• Be sure to disconnect the charger from the outlet before moving the machine.

Page 64

TRANSPORTING THE MACHINE

TRUCK OR TRAILER TRANSPORT

ALWAYS ATTACH THE MACHINE TO A WINCH WHEN LOADING OR UNLOADING FROM A TRUCK OR TRAILER. UNASSISTED LOADING OR UNLOADING OF ANY MOBILE PLATFORM IS NOT RECOMMENDED.

THE WINCH OPERATOR AND MACHINE OPERATOR MUST COORDINATE MOVEMENT WHILE LOADING THE MACHINE.

1. Enter the platform, and start the engine using the platform controls.
2. Raise the upper boom so that the platform will clear any obstacles as the machine is driven up the loading ramp.
3. Carefully maneuver the machine onto the truck or trailer with the aid of a winch.
4. Lock the superstructure to the undercarriage by installing the lock pin provided.
5. Confirm that the boom sections are fully retracted, and that the platform will not contact any other item, including the bed of the truck or trailer.

The platform or boom must not be tied down to the truck or trailer bed in any way.

6. The negative battery cable should be disconnected for long distance transport. It is also recommended that the fuel and hydraulic tank valves be closed.
Tie down locations are located on all four corners of the undercarriage. Use four (4) 1/2 inch, "Grade 7" chains from each of the tie down lugs, and run the chains as shown in the diagram. (Refer to illustration on facing page.)

Ratchet type load binders are recommended. If using lever type load binders, wire or strap them shut, or wrap chains around them to prevent opening.

Page 65

AT 60 Tie Down (recommended)

Page 66

LIFTING THE MACHINE

IMPORTANT: The swing begring lock pin should be installed.

1. Completely lower all booms to the stowed position.
2. Raise upper boom so that lift cylinder rod extension measures 33 inches (0.84 m) from the center of the rod end cylinder pin to top of cylinder head gland (see illustration).
3. Attach machine to hoist with chains from the rear lifting lug shackles and the lower boom post lifting lug shackle as shown.
- Left rear lifting lug chain length (each): approximately 138 inches (3.51 m) Pass chain between rails of lower boom parallel arm and between lower boom and mid boom.

Right rear lifting lug chain length (each): approximately 138 inches (3.51 m) Pass chain between mid boom and upper boom.

Lower boom post lifting lug chain length: approximately 78 inches (1.98 m)

The lifting devices should be strong enough to lift the machine. Refer to Machine Specifications.

To avoid damaging the machine, position chains so they do not contact any part of the booms.

Carefully lift the machine straight up and slowly set it on a level surface clear of personnel and debris.

4. Lift the machine straight up.
5. Slowly set the machine down on a level surface, making certain the area is clear of personnel and debris.
6. Unhook the chains from the hoist, and the lifting lugs.

Page 67

Page 68

EMERGENCY SYSTEM AND PROCEDURES

IF THE MACHINE FAILS WHILE THE OPERATOR'S PLATFORM IS RAISED OR EXTENDED, DO NOT ATTEMPT TO CLIMB DOWN THE BOOM ASSEMBLY. SERIOUS INJURY MAY RESULT.

EMERGENCY ELECTRICAL PUMP

The AT60 Mobile Platform has a battery powered emergency pump. This pump can be activated from the operator's platform or ground control station to briefly operate the machine when the machine has lost engine power.

• Turn and hold the pump switch on the ground control console to "EMERGENCY"; or

press and hold the emergency pump button on the platform control console.

• Select the proper function as desired to fit the situation.

To prevent the battery from completely discharging and the emergency pump from overheating, release the emergency pump switch to allow a 30 second rest period after every 30 seconds of operation. Once the machine has been safely positioned, correct the cause of the failure before returning the machine to service.

Page 69

UNPOWERED EMERGENCY MOVEMENT

• Every attempt should be made to restore primary power to the machine before using this procedure.

THIS PROCEDURE REQUIRES RELEASING THE VEHICLE BRAKES, WHICH RESULTS IN NO MEANS TO STOP THE MACHINE'S TRAVEL. TEREX RECOMMENDS USING THIS PROCEDURE ONLY IN CASES OF EMER-GENCY, AND ONLY A SHORT DISTANCE.

BE AWARE OF MACHINE RUNAWAY ON SLOPING SURFACES. MOVE-MENT SPEED SHALL NOT EXCEED 1 MPH (1.6 KPH).

• Secure the machine with chains or ropes.

The AT60 is equipped with tie down lugs (front and rear) that can be used for towing the machine. The chains or ropes must be of sufficient capacity to move the machine.

Chock wheels.
Disconnect both front torque hubs by removing the plate in the center of the torque hub, turning the plate so that the boss faces in, then reinstalling the plate.
Release brakes.

There is a hand pump located to the left of the ground control mounting bracket. Close the valve under the pump plunger by turning it to the right (clockwise) and operate hand pump. Continue to pump until high resistance is felt in the pump plunger. At this point, wheel brakes will be released.

After unchocking the wheels, the machine will be ready to be moved; however, there is no provision for steering the vehicle.

After primary power has been restored to the vehicle, fully open the needle valve under the hand pump plunger to engage wheel brakes.
Engage both front torque hubs by removing the plate in the center of the torque hub, turning the plate so that the boss faces out, then reinstalling the plate.
The machine is now ready for normal operation.

Page 70

EMERGENCY LOWERING

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.

When faced with an emergency, above all please remember:

Stay calm.
Think through the situation before operating the machine.
Get help if necessary.

SITUATION: Platform elevated, operator not incapacitated, but machine will not operate properly using the platform controls.

POSSIBLE CONDITION:

One or more functions not operating correctly.
Machine movement from unselected control lever.
Machine function will not stop unless power is switched off.

CORRECTIVE ACTION

1. Remove foot from foot pedal.
2. Press the red emergency stop button.
3. Evaluate the nature of the failure. Return to the ground, using the emergency pump (see "Emergency Pump", earlier in this section).
4. If unable to return to the ground using the platform controls and the emergency pump, contact an experienced operator to lower the machine using the emergency pump and lowering procedure (see "Emergency Pump" earlier in this section).

DO NOT TRY TO CLIMB DOWN THE BOOM.

HAVE AN EXPERIENCED OPERATOR USE THE EMERGENCY PUMP TO SAFELY LOWER THE PLATFORM.

5. Report the incident to your supervisor immediately.

Page 71

EMERGENCY LOWERING (CONTINUED)

SITUATION: Platform elevated, with operator incapacitated at platform controls.

DO NOT TOUCH MACHINE !!!

TRY TO DETERMINE THE CAUSE OF THE PROBLEM BEFORE YOU TOUCH THE MACHINE.

CORRECTIVE ACTION

1. Have someone summon first aid or rescue squad.
2. Attempt to talk to operator before taking any rescue measures.
3. Before attempting emergency lowering procedure, check to see if the operator is:
- in a pinned position, or
- would be endangered if platform is moved.
4. After establishing that the machine is not in contact with live power lines, lower the platform or move the machine as necessary, using emergency procedures (see "Emergency Pump", earlier in this section).
5. Render first aid to the operator.
6. 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.

Page 72

EMERGENCY LOWERING (CONTINUED)

SITUATION: Platform in contact with live power lines and operator incapacitated.

DO NOT TOUCH MACHINE !!!!

CORRECTIVE ACTION

1. Have someone summon first aid or rescue squad.
2. Contact authorized personnel to disconnect power supply touching machine.
3. Before attempting emergency lowering, check to see if the operator is:
- in a pinned position, or
- would be endangered if platform is moved.
4. AFTER POWER IS CUT, lower the platform or move the machine as necessary, using emergency procedures (see "Emergency Pump", earlier in this section).
5. 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.

EMERGENCY SYSTEM AND PROCEDURES

Page 73

AT60 OPERATOR'S MANUAL

MAINTENANCE

SECTION 3: MAINTENANCE

Page 74

General Maintenance Tips Shift Operational Checklist Weekly Operational Checklist Monthly Operational Checklist Quarterly Operational Checklist Semi-Annual Operational Checklist	3-3 3-4 3-7 3-9 3-11 3-12
Troubleshooting
What to check if machine will not start:	3-14
What to check if functions will not operate:	3-14
Lubrication Chart	3-15
Lubrication Diagram	3-17

Page 3-2

Page 75

AT60 OPERATOR'S MANUAL

GENERAL MAINTENANCE TIPS

GENERAL MAINTENANCE TIPS

Never leave hydraulic components or hoses open. They must be protected from contamination (including rain) at all times.
Never open a hydraulic system or engine when there are contaminants in the air.
Use only recommended lubricants. Improper lubricants or incompatible lubricants may be as harmful as no lubrication.
ALWAYS clean the surrounding area before opening hydraulic or engine systems.
Watch for makeshift "fixes" which can jeopardize safety as well as lead to more costly repairs.
Any work platform found not to be in safe operating condition should be removed from service until repaired. All repairs should be made by authorized personnel in conformance with the manufacturer's operating, maintenance, and repair manuals.

Page 76

SHIFT OPERATIONAL CHECKLIST

All checks must be completed before operation of the machine.

These checklists can be copied as needed to aid in performing these inspections.

ATE:	INSPECTED BY:

MODEL NUMBER: SERIAL NUMBER:

GENERAL INFORMATION

1. Keep inspection records up-to-date.
2. Record and report all discrepancies to your supervisor.
3. A dirty machine cannot be properly inspected.

Keep your machine clean!!

THIS CHECKLIST MUST BE USED AT DAILY INTERVALS OR AFTER EVERY 6 TO 8 HOURS OF USE, WHICHEVER IS SOONER. FAILURE TO DO SO COULD ENDANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS.

INITIAL

DESCRIPTION

1. Perform a visual inspection of all machine components, i.e. structural damage, missing parts, torn or loose hoses, hydraulic fluid leaks, torn or disconnected wires, flat or damaged tires, etc. Open both compartment doors to inspect components inside.
2. Check battery electrolyte level and connections. Check fuel, engine oil and coolant levels.
3. Check tire pressure (not required for foam filled).
4. Check that the lug nuts are tight.
5. Check hydraulic fluid level. The level should be at the line marked on the sight gauge with the unit in stowed position.
6. Check that all shutoff valves on hydraulic tank are open (parallel to flow).

Continued on following page .

SHIFT OPERATIONAL CHECKLIST

April 1997

Page 77

SHIFT OPERATIONAL CHECKLIST

SHIFT OPERATIONAL CHECKLIST (CONTINUED)

INITIAL	DESC	RIPTION
	7.	Check all drive motor nuts for tightness.
	8.	Check hoses for worn areas.
	9.	Check hose carrier to verify that it is not bent or sagging.
	10.	Inspect safety belt connections, and check for worn areas on the belts.
	11.	Check platform rails and gate latch step for damage.
	12.	Check pivot pins for security.
	13.	Check that all warning and instructional labels are legible and secure.
	14.	Start engine. Check that hydraulic pressure is as stated in the machine specifications.
	15.	Check that the tilt alarm is working properly.
	16.	Check that no attempt had been made to override the drive interlock system by a previous operator.
	17.	When all pre-inspection checks have been completed, the operator is ready to test the ground controls for proper operation.
	18.	Check platform controls for proper operation.
	19.	With the platform raised, check for the smooth operation of low speed drive.
	20.	Follow engine daily service requirements. Refer to the Engine Mainte- nance Manual supplied with your machine.

Continued on following page .

Page 78

SHIFT OPERATIONAL CHECKLIST (CONTINUED)

ADDITIONAL MAINTENANCE REQUIREMENTS FOR SEVERE USAGE APPLICATIONS

NOTE: Do not lubricate wear pads in dusty or sandblast environments. There are boots and guards available to extend machine life in these applications. Consult Terex Aerials Service Department.

INITIAL	DESCRIPTION
	21.	Inspect cylinder boots, valve spool boots, etc., for cuts or other damage after every eight (8) hours of service. Repair or replace if necessary.
	22.	Check hydraulic system for leakage after every eight (8) hours of operation.
	23.	Follow engine severe usage service requirements. Refer to the Engine Maintenance Manual supplied with your machine.

Page 79


and planetary ends, and front torque hubs
ig gear teeth (see Lubrication Chart).
Page 3-7


MANUAL

WEEKLY OPERATIONAL CHECKLIST

WEEKLY OPERATIONAL CHECKLIST

All checks must be completed before operation of the machine.

These checklists can be copied as needed to aid in performing these inspections.

DATE: ____ INSPECTED BY:

MODEL NUMBER: _____ SERIAL NUMBER:

GENERAL INFORMATION

1 Keep inspection records up-to-date
2. Record and report all discrepancies to your supervisor.
3 A dirty machine cannot be properly inspected. Keen your machine clean!

THIS CHECKLIST MUST BE USED AT WEEKLY INTERVALS OR AFTER EVERY 30 HOURS OF USE, WHICHEVER IS SOONER, FAILURE TO DO SO COULD ENDANGER THE LIFE OF THE OPERATOR AI WAYS REMEMBER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS.

INITIAL	DESCRIPTION
	1.	Perform all checks listed on Shift Operational Checklist.
	2.	Follow weekly engine service requirements. Refer to the Engine Mainte- nance Manual supplied with your machine.
MAINTENANCE REQUIREMENTS FOR SEVERE USAGE APPLICATIONS ONLY
INITIAL	DES	CRIPTION
	3.	Inspect condition of hydraulic fluid in the reservoir. Fluid should have a clear amber color.
	4.	Lubricate all pivot and cylinder pin grease fittings (see Lubrication Chart).
	5.	Apply proper lubricant to axle and planetary ends, and front torque hubs (see Lubrication Chart).
	6.	Apply lubricant to swing bearing gear teeth (see Lubrication Chart).

Continued on following page .

Page 80

WEEKLY OPERATIONAL CHECKLIST (CONTINUED)

INITIAL	DESCRIPTION
	7.	Spray WD 40 or equivalent penetrating oil on the hydraulic control valve handle pivot pins (including platform level and rotate valve lever pins).
	8.	Purge old grease from steering spindles and steering cylinder bearings, tie rod bearings and apply Lithium N.L.G.I. #2 EP.
	9.	Follow engine severe duty service requirements. Refer to the Engine Maintenance Manual supplied with your machine.

Page 81

AT60 OPERATOR'S MANUAL

MONTHLY OPERATIONAL CHECKLIST

DATE: INSPECTED BY:

MODEL NUMBER: ______ SERIAL NUMBER: ______

These checklists can be copied as needed to aid in performing these inspections.

GENERAL INFORMATION

1. Keep inspection records up-to-date.
2. Record and report all discrepancies to your supervisor.
A dirty machine cannot be properly inspected. Keep your machine clean!!

THIS CHECKLIST MUST BE USED AT MONTHLY INTERVALS OR EVERY 100 HOURS, WHICHEVER OCCURS FIRST. FAILURE TO DO SO COULD ENDANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS.

INITIAL	DESCRIPTION
	1. Perform all checks listed on Shift and Weekly Operational Checklists.
	2. Lubricate all boom pivot pins and cylinder pins (see Lubrication Chart).
	Apply lubricant to swing bearing gear teeth and drive pinion gear teeth (see Lubrication Chart).
	4. Inspect condition of hydraulic fluid in the reservoir. Fluid should have a clear amber color.
	Check hydraulic system for leaks, examine hoses for signs of excessive wear, chafing or twisting. Adjust the hoses and/ or replace them if necessary (refer to your Service Manual).
	Inspect the work platform and boom structure for signs of damage and broken welds. Check all bolts (including platform rotator bolts) for tightness.
	Check for structural damage, broken welds, loose bolts, improper or makeshift repairs.

Continued on following page .

Page 82

MONTHLY OPERATIONAL CHECKLIST (CONTINUED)

INITIAL	DESCRIPTION
	8.	Check protective rubber cover around hoses at moving anchor, tip boom, boom hose passages, and at swing bearing.
	9.	Check torque of wheel lug nuts (see specifications).
	10.	Check torque of swing bearing bolts (see specifications).
	11.	Check adjustment and security of swing drive. Check torque of swing drive mounting bolts (see specifications). There should be no backlash between the turntable and undercarriage when properly adjusted.
	12.	Check oil level in axle differential and planetary ends (see Lubrication Chart).
	13.	Check front wheel motors mounting bolt torque (see specifications).
	14.	Check that the boom does not drift with a full load, no hydraulic pres- sure (engine off) and the control valve in the "BOOM DOWN" position.
	15.	Check to make sure boom sections are not dented or bent.
	16.	Check that all adjustable flow valves are locked.
	17.	Check fuel shutoff rack for proper operation. Loosen lever arm and lubricate with WD-40 or equivalent.
	18.	Lubricate boom wear pads (see Lubrication Chart).
	19.	Lubricate hydraulic control handle pivot pins (see Lubrication Chart).
	20.	Lubricate steering spindles (see Lubrication Chart).
	21.	Lubricate steering cylinder bearings (see Lubrication Chart).
	22.	Lubricate tie rod bearings (see Lubrication Chart).
	23.	Follow engine monthly service requirements. Refer to the Engine Maintenance Manual supplied with your machine.

Page 83

AT60 OPERATOR'S MANUAL

QUARTERLY OPERATIONAL CHECKLIST

QUARTERLY OPERATIONAL CHECKLIST

DATE: ______ INSPECTED BY: _____

MODEL NUMBER: SERIAL NUMBER:

These checklists can be copied as needed to aid in performing these inspections.

GENERAL INFORMATION

1. Keep inspection records up-to-date.
2. Record and report all discrepancies to your supervisor.
3. A dirty machine cannot be properly inspected.

Keep your machine clean!!

THIS CHECKLIST MUST BE USED AT QUARTERLY INTERVALS OR EVERY 250 HOURS, WHICHEVER OCCURS FIRST. FAILURE TO DO SO COULD ENDANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS.

INITIAL	SCRIPTION
	Perform all checks listed Checklists.	d on Shift, Weekly and Monthly Operational
	2. Follow engine quarterly Maintenance Manual su	service requirements. Refer to the Engine upplied with your machine.
ADDITIONAL MAINTENANCE REQUIREMENTS FOR SEVERE USAGE APPLICATIONS
INITIAL	ESCRIPTION
	3. Change high pressure f	lter and emergency pump filter elements.
	4. Analyze hydraulic fluid.
	5. Follow engine severe du Maintenance Manual su	uty service requirements. Refer to the Engine upplied with your machine.

Page 84

SEMI-ANNUAL OPERATIONAL CHECKLIST

DATE: INSPECTED BY: _____

MODEL NUMBER: ______ SERIAL NUMBER: _____

These checklists can be copied as needed to aid in performing these inspections.

GENERAL INFORMATION

1. Keep inspection records up-to-date.
2. Record and report all discrepancies to your supervisor.
3. A dirty machine cannot be properly inspected. Keep your machine clean!!

THIS CHECKLIST MUST BE USED AT SIX MONTH INTERVALS OR EVERY 500 HOURS, WHICHEVER IS SOONER. FAILURE TO DO SO COULD ENDANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS.

DESCRIPTION

1. Perform all checks listed on Shift, Weekly, Monthly and Quarterly Operational Checklists.
2. Have hydraulic fluid sample analyzed at a test laboratory. Comply with test results and recommendations to ensure long, trouble free operation.

NOTE: If hydraulic fluid has been regularly maintained, it should only require changing once every year, depending on maintenance, temperature, application, duty cycle, and atmospheric conditions.

3. Clean and lubricate all electrical switches with an electrical contact cleaner and ensure that the switches operate freely in all positions.
4. Check the electrical mounting and hardware connections for security.
5. Replace hydraulic filter element (earlier replacement if reduced speed of drive function is indicated).

Continued on following page .

SEMI-ANNUAL OPERATIONAL CHECKLIST

April 1997

Page 85

SEMI-ANNUAL OPERATIONAL CHECKLIST (CONTINUED)

INITIAL	DES	CRIPTION
	6.	Lubricate all valve spool linkages.
	7.	Clean and lubricate the swing bearing gear teeth with Keystone Moly #29.
	8.	Follow engine semi-annual service requirements. Refer to the Engine Maintenance Manual supplied with your machine.
	TENAN	ICE REQUIREMENTS FOR SEVERE USAGE APPLICATIONS
INITIAL	DES	CRIPTION
	9.	Drain and replace fluid from front torque hubs, and planetary axles (rear).
	10.	Change hydraulic fluid.
	11.	Follow engine severe usage service requirements. Refer to the Engine Maintenance Manual supplied with your machine.

Page 86

TROUBLESHOOTING

SHOULD YOU EXPERIENCE ERRATIC OPERATION OR NOTICE ANY MAL-FUNCTION WHILE RUNNING YOUR MACHINE, CONTINUE OPERATION ONLY LONG ENOUGH TO RETURN TO THE GROUND POSITION IF POS-SIBLE.

IMMEDIATELY REPORT THE INCIDENT TO YOUR SUPERVISOR, AND DISCONTINUE USING THE MACHINE UNTIL IT HAS BEEN CHECKED BY A TRAINED, QUALIFIED MECHANIC.

WHAT TO CHECK IF MACHINE WILL NOT START:

Is the key switch turned on?
Is the around/ platform selector switch in the proper position?
Are all emergency stop buttons released?
Are battery cables connected?
Is the battery charged?
Are any wires pulled out or loose?
Is there proper fuel (gas, propane, or diesel) in the fuel tank?
If equipped for propane fuel operation, is the propane tank valve open?
If equipped for dual fuel operation, is the fuel selector switch in the proper position?

WHAT TO CHECK IF FUNCTIONS WILL NOT OPERATE:

Is a function control lever or the platform foot pedal not activated?
Is the ground/ platform selector switch in the proper position?
Has the turntable lock pin not been removed?
Is there an obvious oil leak or damaged component?
Is the hydraulic fluid level low?
Are any wires pulled out or loose?

IROUBLESHOOTING

Page 87

- 10

LUBRICATION CHART

NO.	ITEM	SPECIFICATION AND QUANTITY	FREQUENCY OF LUBRICATION
1.	Hydraulic reservoir	Mobil DTE-13M to "Full" mark with all cylinders retracted.	Check level & condition each shift. Analyze 6 months or 500 hours.* ^† . Change yearly or 1000 hours.* ^†
2.	High pressure filter and emergency pump filter	Filter elements.	Change every 3 months or 500 hours.* ^†
3.	Tie rod bearings	Lithium N.L.G.I. #2 EP. Purge old grease	Monthly or every 100 hours.**

* Whichever occurs first.

^† Different requirements for severe duty applications. See Operational Checklist.

Page 88

LUBRICATION CHART (CONTINUED)

NO.	ITEM	SPECIFICATION AND QUANTITY	FREQUENCY OF LUBRICATION
4.	Swing bearing gear teeth	"Keystone - Moly 29 Open Gear Compound" Coat gear faces	Monthly or every 100 hours.**
5.	Swing bearing	Lithium N.L.G.I. #2 EP. Purge old grease.	Monthly or every 100 hours.**
6.	Boom pivot pins and Cylinder pins	Lithium N.L.G.I. #2 EP. Purge old grease.	Monthly or every 100 hours.**
7.	Boom wear pads	Silicone spray.	Weekly or every 75 hours.**
8.	Hydraulic control valve handle pivot pins	WD 40 Spray or equivalent penetrating oil.	Weekly or every 75 hours.**
9.	Axle and planetary ends, and front torque hubs	SAE 80/ 90 APIGL5	Check monthly or every 100 hours.* ^† Change every year or 1,000 hours.*
10.	Platform level and rotate valve lever pins	WD 40 Spray or equivalent penetrating oil	Weekly or every 75 hours.**
11.	Steering spindles (king pin bearings)	Lithium N.L.G.I. #2 EP. Purge old grease.	Weekly or every 75 hours.**
12.	Steer cylinder bearings	Lithium N.L.G.I. #2 EP. Purge old grease.	Weekly or every 75 hours.**

* Whichever occurs first.

^† Different requirements for severe duty applications. See Operational Checklist.

LUBRICATION CHART

Page 89

Page 90

AT60 OPERATOR'S MANUAL

INDEX

В

Battery (Acid/Lead)	1-8
Beaufort Scale and Wind Velocity Chart	. vii
Boom, Superstructure and Platform	2-32
Boom Telescope Lever 2-9,	2-17
Braking	2-31

С

Caution	1-3
Choke/ Glow Plug Button	2-7
Choke/ Glow Plug Push Button	2-15
Circuit Breaker	2-7
Cold Weather Operation	2-30

D

Danger	1-3
Diesel Engine Operation	2-34
Diesel Fuel	1-8
Drive Control Lever	2-15
Drive Speed Switch	2-15
Drive Toggle Switch	2-13
Driving and Steering	2-31
Dual Fuel Engine Operation	2-33

Ε

Emergency Electrical Pump	2-40
Emergency Lowering 2-42, 2-43,	2-44
Emergency Pump Operation and Check	2-25
Emergency Pump Button	2-15
Emergency Stop Button 2-7,	2-15
Emergency System and Procedures	2-40
Engine Oil	1-9
Engine Oil Pressure Gauge	2-9
Engine Start Button	2-7
Engine Warning Lamp	2-15
Environmentally Hazardous Materials 1-8	3, 1-9

F

Foam-Filled Tires	1-9
Foot Pedal Switch	2-19
For Diesel Engines Equipped with Glow Plugs	2-34
Fuel Select Control	2-11

G


Gas/ Off/ Propane	2-7
Gasoline Engine Operation	2-33
Gasoline Operation	2-33
Gasoline to Propane Switching	2-33
General Arrangement Diagrams	vi
General Maintenance Tips	3-3
Gradeability Conversion Chart	. vii
Ground Controls 2-6, 2-7, 2-8, 2-9, 2-10,	2-11
Ground Operation and Checks 2-22, 2-23, 2-24	1, 2-25

Η

Horn Button	2-15
Hour Meter	2-7
Hydraulic Fluid	1-9

Ignition Switch	2-15
Introduction	. iii

L

Lift/ Drive Switch		2-19
Lifting the Machine	2-38,	2-39
Light Switch		2-15
Lower Boom Lever	2-9,	2-17
Lubrication Chart	3-15,	3-16
Lubrication Diggram		3-17

М

Machine Diagrams	v, vi
Machine Specifications	iv
Machine Startup	2-21
Main Power Key Switch	2-7
	3-1
Manual Brake Release Pump	2-9
Manual Brake Release Valve	2-11
Middle Boom Lever 2-9	, 2-17
Monthly Operational Checklist	, 3-10

0

Operation				2-1,	2-30
Derator Controls	2-6,	2-8,	2-10,	2-12,	2-14,
•				2-16,	2-18
Operator Controls Descrip	tion	2-7	, 2-9,	2-11,	2-13,
			2-15,	2-17,	2-19
Operator Controls	2-6, tion	2-8, 2-7	2-10, , 2-9, 2-15,	2-12, 2-16, 2-11, 2-17,	2-14, 2-18 2-13, 2-19

Page Index-1

Page 91

INDEX (CONTINUED)

Ρ

Permissible Soil Consolidations by Weight Chart	viii
Platform Controls 2-14, 2-15, 2-16, 2-17, 2-1	8, 2-19
Platform Level Lever	2-19
Platform Operation and Checks 2-26, 2-27, 2-28	8, 2-29
Platform Rotate Lever	2-17
Primary Machine Components	2-5
Propane to Gasoline Switching	2-34
Pump Selector Toggle Switch	2-9
Pump SelectorToggle Switch	2-13

Q

Quarterly Operational Checklist	3-11
addition per anere en een een

R

Radiator Antifreeze		1-9
Range Diagram		v
Remote Control Pendant	2-12,	2-13

S

Safety 1-1 Safety and Control Decal Descriptions 1-19 Safety and Control Decal Locations 1-18
Safety Pules and Precautions 1-4 1-5 1-6
Safety Symbols
Safety-Related Decals 1-10, 1-11, 1-12, 1-13,
1-14, 1-15, 1-16, 1-17
Semi-Annual Operational Checklist
Sensor Override Button
Shift Checks
Shift Operational Checklist 3-4, 3-5, 3-6
Shut-Down Procedures 2-35
Startup Procedures
Steer Switch
Steer Toggle Switch
Swing Control Lever 2-9, 2-17

т

Technical Charts	vii, viii
Transporting the Machine	2-36
Troubleshooting	3-14
Fruck or Trailer Transport	2-36

U

Unloading Procedures	2-3, 2-4
Unpowered Emergency Movement	2-41
Upper Boom Lever	2-9, 2-17

v

Volt Meter ...................................

w

Warning Water Temp Gauge	1-3 2-9
Weekly Operational Checklist	3-8
What to check if functions will not operate	3-14
What to check if machine will not start	3-14

Page 92

OPERATOR'S MANUAL APPENDIX

APPENDIX

Page 93

Applicable Standards and Reaulations	A-3
ANSI/SIA A92.5 - 1992 (Partial)	A-5
5. Responsibilities of Dealers	A-5
6. Responsibilities of Owners	A-7
7. Responsibilities of Users	A-10
8. Responsibilities of Operators	A-16
9. Responsibilities of Lessors	A-20
10. Responsibilities of Lessees	A-21

Page 94

APPENDIX

In addition to the operational instructions provided herein, various standards and governmental regulations also apply to the use and operation of your Simon Aerial Work Platform.

Attached hereto are copies of some of the applicable codes, regulations and standards with which you must comply if this unit is operated in the U.S.A. These standards were in effect (as attached) on the date your unit was manufactured. You must comply with these, or other applicable standards as defined by your governing bodies as they are updated over time.

For complete, current copies of U.S.A. standards, you must annually write to:

American National Standards Institute 11 West 42nd Street New York, NY 10036 Phone: 212-642-4900

Request: ANSI/ SIA A92.5 (current)

Specific state or local regulations may also apply. You must consult the appropriate regulating authority for the area in which the equipment will be operated in order to obtain current copies of these regulations.

Page 95

OPERATOR'S MANUAL APPENDIX

March 1997

Page 96

ANSI/SIA A92.5 - 1992 (PARTIAL)

5. RESPONSIBILITIES OF DEALERS

5.1 Basic Principles. Sound principles of safety, training, inspection, maintenance, application and operation consistent with all data available regarding the parameters of intended use and expected environment shall be applied in the training of operators, in maintenance, application, safety provisions and operation of the aerial platform with due consideration of the knowledge that the unit will be carrying personnel.

5.2 Manuals. Dealers shall keep and maintain copy(ies) of the operating and maintenance manual(s) required in section 4.19 of this standard. Operating manual(s) shall be provided with each rental, lease, or sale delivery. These manual(s) shall be stored in the location required by section 4.20 of this standard. These manual(s) are considered an integral part of the aerial platform and are vital to communicate necessary safety information to users and operators. In addition, parts and maintenance manual(s) shall be provided with each sale delivery.

5.3 Predelivery Preparation. Aerial platforms shall be inspected, serviced and adjusted to manufacturer's requirements prior to each delivery by sale, lease or rental.

5.4 Maintenance Safety Precautions. Before adjustments and repairs are started on an aerial platform, the following precautions shall be taken as applicable:

(a) Powerplant stopped and starting means rendered inoperative.
(b) All controls in the "off" position and all operating systems secured from inadvertent motion by brakes, blocks, or other means.
(c) Boom and platform lowered to the full down position, if possible, or otherwise secured by blocking or cribbing to prevent dropping.
(d) Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components.
(e) Safety props or latches installed where applicable as prescribed by the manufacturer.

5.5 Replacement Parts . When parts or components are replaced, they shall be identical or equivalent to original aerial platform parts or components.

5.6 Training. Whenever a dealer directs or authorizes an individual to operate an aerial platform he shall ensure that the individual has been trained under the direction of a qualified person in accordance with the manufacturer's operating manual and requirements listed in section 8, of this standard, before operating the aerial platform.

5.6.1 Training on Delivery. Manufacturer's operating instruction and required training on the proper use and operation of the aerial platform shall be provided upon each delivery by sale, lease or rental.

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5.7 Operation. When a dealer operates an aerial platform in sales demonstrations or otherwise for his beneficial use, he and his operating personnel shall assume the responsibilities of users as specified in section 7 and responsibilities of operators as specified in section 8 of this standard.

5.8 Assistance to Owners and Users. If a dealer is unable to answer an owner's or user's question relating to rated capacity, intended use, maintenance, repair, inspection or operation of the aerial platform, the dealer shall obtain the proper information from the manufacturer and provide that information to the owner or user.

5.9 Record Retention. Dealer(s) shall retain the following records for at least three years:

(a) Name and address of the purchaser of each aerial platform by serial number and date of delivery.
(b) Records of the person(s) trained upon each delivery of an aerial platform.
(c) Records of the predelivery preparation performed prior to each delivery.

5.10 Modifications. Modification or alteration of an aerial platform shall be made only with prior written permission of the manufacturer.

5.11 Manufacturers Safety Bulletins. The dealer shall comply with safety related bulletins as received from the manufacturer.

5.12 Ownership Records. When a change in ownership of an aerial device occurs, it shall be the responsibility of the seller to notify the manufacturer, or successor, of the unit, model and serial number and the name and address of the new owner within sixty (60) days.

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6. RESPONSIBILITIES OF OWNERS

6.1 Basic Principles. Sound principles of safety, training, inspection, maintenance, application and operation consistent with all data available regarding the parameters of intended use and expected environment shall be applied in the performance of the responsibilities of owners with due consideration of the knowledge that the unit will be carrying personnel.

6.2 Manuals. Owners shall keep and maintain copy(ies) of the operating and maintenance manual(s) required in section 4.19 of this standard. Operating manual(s) shall be provided with each rental, lease or sale delivery. The operating manual(s) shall be stored in the location required in section 4.20 of this standard. These manual(s) are considered an integral part of the aerial platform and are vital to communicate the necessary safety information to users and operators. In addition, parts and maintenance manual(s) shall be provided with each sale delivery.

6.3 Predelivery Preparation. Aerial platforms shall be inspected, serviced and adjusted to manufacturer's requirements prior to each delivery by sale, lease or rental.

6.4 Maintenance. The owner of an aerial platform shall arrange that the maintenance specified in this standard is properly performed on a timely basis. The owner shall establish a preventive maintenance program in accordance with the manufacturer's recommendations and based on the environment and severity of use of the aerial platform. The owner shall arrange that frequent and annual inspections are performed. All malfunctions and problems identified shall be corrected before the aerial platform is returned to service.

6.5 Frequent Inspection. The owner of an aerial platform shall cause a frequent inspection to be performed on the aerial platform:

(a) That has been in service for three (3) months or 150 hours, whichever comes first.
(b) Before putting into service a machine which has been out of service for a period longer than three (3) months of time.

The inspection shall be made by a person qualified as a mechanic on the specific make and model of the aerial platform. The inspection shall include all items specified by the manufacturer for a frequent inspection and shall include but not be limited to the following:

(a) All functions and their controls for speed(s), smoothness and limits of motion.
(b) Lower controls including the provisions of overriding of upper controls.
(c) All chain and cable mechanisms for adjustment and worn or damaged parts.
(d) All emergency and safety devices.
(e) Lubrication of all moving parts, inspection of filter element(s), hydraulic oil, engine oil, and coolant as specified by the manufacturer.
(f) Visual inspection of structural components and other critical components such as fasteners, pins, shafts, turntable attachment bolts, and locking devices.
(g) Placard, warnings and control markings.

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6.5 Frequent Inspection (continued).

(h) Additional items specified by the manufacturer.
(i) Correction of all malfunctions and problems identified and further inspection if necessary.
(j) After correction or replacement of any component, the unit shall be inspected and tested in accordance with above paragraph 6.5.

6.6 Annual Inspection. The owner of an aerial platform shall cause an annual inspection to be performed on the aerial platform no later than thirteen (13) months from the date of the prior annual inspection. The inspection shall be performed by a person(s) qualified as a mechanic on the specific make and model of the aerial platform. The inspection shall include all items specified by the manufacturer for an annual inspection.

6.7 Maintenance Safety Precautions. Before adjustments and repairs are started on an aerial platform, the following precautions shall be taken as applicable:

(a) Powerplant stopped and starting means rendered inoperative.
(b) All controls in the "off" position and all operating systems secured from inadvertent motion by brakes, blocks or other means.
(c) Elevating assembly and platform lowered to the full down position, if possible, or otherwise secured by blocking or cribbing to prevent dropping.
(d) Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components.
(e) Safety props or latches installed where applicable as prescribed by the manufacturer.

6.8 Replacement Parts. When parts or components are replaced, they shall be identical or equivalent to original aerial platform parts or components.

6.9 Maintenance Training. The owner shall train his maintenance personnel in inspection and maintenance of the aerial platform in accordance with sections 6.4, 6.5, 6.6, 6.7, 6.8 and 7.3.3 of this standard and with the manufacturer's recommendations.

6.10 Operator Training. Whenever an owner directs or authorizes an individual to operate an aerial platform, he shall ensure that the individual has been trained in accordance with the manufacturer's operating manual and requirements listed in section 8 of this standard before operating the aerial platform.

6.10.1 Training on Delivery. Manufacturer's operating instructions and required training on the proper use and operation of the aerial platform shall be provided upon each delivery by sale, lease or rental.

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6.11 Operation. When an owner operates an aerial platform, he shall have the responsibilities of users as specified in section 7 of this standard and his operating personnel shall have responsibilities of operators as specified in section 8 of this standard.

6.12 Assistance to Users and Operators. If an owner is unable to answer a user's or operator's questions relating to rated capacity, intended use, maintenance, repair, inspection or operation of the aerial platform, the owner shall obtain the proper information from the degler or manufacturer and provide that information to the user or operator.

6.13 Record Retention. The owner shall retain the following records for at least three (3) years:

(a) Name and address of the purchaser of each aerial platform by serial number and date of delivery.
(b) Records of the person(s) trained upon each delivery of an aerial platform.
(c) Written records of the frequent and annual inspections shall be kept by the owner when he performs the inspection. The record shall include deficiencies found, corrective action and identification of the person(s) performing the inspection and repairs.
(d) Records of the predelivery preparation performed prior to each delivery.

6.14 Modifications. Modification or alteration of an aerial platform shall be made only with prior written permission of the manufacturer.

6.15 Manufacturer's Safety Bulletins. The owner shall comply with safety related bulletins as received from the manufacturer or dealer.

6.16 Ownership Records. When a change in ownership of an aerial device occurs, it shall be the responsibility of the seller to notify the manufacturer, or successor, of the unit, model and serial number and the name and address of the new owner within 60 days.