Genie Simon Manuals Operator's Manual

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Terex Aerials 10600 W. Brown Deer Road Milwaukee, WI 53224 U.S.A.

Telephone:(414) 362-9300Facsimile:(414) 355-0832

Terex Aerials 106 12th Street S. E. Waverly, IA 50677 U.S.A.

Telephone: (319) 352-3920 Facsimile: (319) 352-5727

Terex Aerials Courtstown Industrial Park Little Island, Co. Cork, Ireland

Telephone: (3 Facsimile: (3

e: (353) 21-353011 (353) 21-353368

Issued: January 1998 P/N 89-750082

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Introduction	iii
Machine Specifications	iv
Machine Diagrams
Range Diagram	۷
Gradeability Conversion Chart	vi

SECTION 1: SAFETY

Safetv Symbols
Safety Rules and Precautions	1-4
Safety-Related Decals	1-8
Safety Placard Locations	1-14

SECTION 2: OPERATION

Unloading Procedures Primary Machine Components	2-3 2-4
Operation Controls
Ground Controls
Platform Console Controls
Startup Procedures	0.10
Shift Checks
Machine Startup
Ground Operation and Checks
Platform Operation and Checks	2-13
Operation
Cold Weather Operation	2-15
Driving and Steering
Braking
Elevating the Platform
Lowering the Platform	2-17
Shut-Down Procedures	2-18
Transporting the Machine
Moving of the Vertical Lift	2-19
Fork Lifting of the Vertical Lift	2-19
Single Point Lifting Hook
Truck Transport of the Vertical Lift
Emergency System and Procedures
Emergency Lowering	2-21
Emergency Drive
Emergency Procedures

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TABLE OF CONTENTS (Continued)

SECTION 3: MAINTENANCE

General Maintenance Tips
Shift Operational Checklist
Weekly Operational Checklist
Monthly Operational Checklist
Semi - Annual Operational Checklist
Troubleshooting	3-9
Lubrication Chart	3-10

INDEX

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NTRODUCTION

INTRODUCTION

This Operator's Manual has been designed to provide you with the instructions needed to properly and safely operate your Vertical Lift.

THIS OPERATOR'S MANUAL MUST BE READ AND UNDERSTOOD PRIOR TO OPERATING YOUR VERTICAL LIFT.

OPERATORS MUST BE AWARE OF AND COMPLY WITH ALL MANUFACTURER'S INSTRUCTIONS AND APPLICABLE OSHA/ANSI (OR APPROPRIATE GOVERNMENT) SAFETY GUIDELINES.

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

Your machine has been designed, built, and tested 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 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 WARRANTY.

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 Terex 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 (max.) Platform Height (max.)	25 ft. (6.35 m) 19 ft. 6 in. (5.94 m)
	35.5 m. (0.9 0 m)
With Standard Deck	750 lbs (340 kg)
With Optional Deck Extension	750 lbs. (340 kg)
Deck Extension Capacity	250 lbs. (110 kg)
Platform Dimensions:
With Standard Deck	31 in. x 96 in. (0.79 m x 2.44 m)
With Optional Deck Extended	31 in. x 132 in. (0.79 m x 3.36 m)
Length:
Without Optional Deck Extension	. 96 in. (2.44 m)
With Optional Deck Extension	. 98.5 in. (2.50 m)
Width	34 in. (0.86 m)
Wheelbase	66 in. (1.67 m)
Wheel Track	28.6 in. (0.73 m)
Outside Turning Radius	. 8 ft. 6 in. (2.59 m)
Inside Turning Radius	3 ff. 5 in. (1.04 m)
Ground Clearance	4 in. (0.10 m)
Gross Vehicle Weight (Approx.)	. 3,500 lbs. (1,587 kg)
Travel Speed:
Platform Stowed	2 mph (3.2 kph)
Platform Elevated	. 0.5 mpn (0.8 kpn)
Gradeability (on hard surface) (ref. page vi)
	4" X 8" X 16" Solid
Hydraulic Fluid Capacity	. 3.5 gal. (13.3 L)
Hyaraulic Operating Pressure	. 2600 psi(179 bui)
	. 05-70 II. IDS. (00.14-94.92 NIII) 24 Volt DC (Four & Volt
Power System (Electric)	220 amp/br Load Aoid
	Rattorios in Series
Electric Motor	1 hn (2 98 Kw)

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MACHINE DIAGRAMS

RANGE DIAGRAM

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MACHINE DIAGRAMS

GRADEABILITY CONVERSION CHART

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TV20 (JAPANESE VERSION) OPERATOR'S MANUAL

SAFETY

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Table of Contents, Section 1:

Safety Symbols	1-3
Safety Rules and Precautions	1-4
Safetý-Related Decals	1-8
Safety Placard Locations 1	-14

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SAFETY SYMBOLS

This manual contains important information on the safe use of your Vertical Lift. 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 following signals:

DANGER

"DANGER" INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY. THIS SIGNAL WORD IS TO BE LIMITED TO THE MOST EXTREME SITUATIONS.

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

A CAUTION

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

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 and have discussed the situation with your supervisor.

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SAFETY RULES AND PRECAUTIONS

A DANGER

• 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 vertical lift.
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.

SAFETY RULES

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SAFETY RULES

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.
The "UNPOWERED MOVEMENT" procedure (described later in this manual) requires that the brake is released, and the free-wheeling valve is opened. After performing the procedure, the result is that there is no means to stop the machine's travel. Terex recommends using this procedure only in cases of emergency, and only for a short distance. Be on guard against machine runaway on sloping surfaces. Movement speed shall not exceed 1 M.P.H. (1.6 K.P.H.).
DO NOT attempt to open any hydraulic line or component without first relieving all system pressure 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 recharge the batteries near sparks or open flames. Lead-acid batteries generate EXPLOSIVE HYDROGEN GAS. Always wear safety glasses.
DO NOT use the vertical lift outdoors in electrical storms or in high wind situations.
DO NOT raise the vertical lift 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 or lowering 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.
Always attach the machine to a winch when loading or unloading from a truck or trailer. Unassisted loading or unloading of any vertical lift is not recommended.

SAFETY RULES

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TV20 (JAPANESE VERSION) OPERATOR'S MANUAL

SAFETY RULES

SAFETY RULES AND PRECAUTIONS (CONTINUED)

Actuation of the red "EMERGENCY STOP" button will apply brakes immediately, causing unexpected platform movement as the machine comes to a sudden stop.
Whenever disengaging the hydraulic drive motors or before disconnection from towing vehicle, ensure that the machine cannot roll.
Immediately report any erratic noises, vibrations or malfunctions of the machine to your 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.

A CAUTION

For transporting the machine, the platform must not be tied to the trailer bed in any way.
DO NOT exceed the maximum platform horizontal pull of 150 pounds (68 kg).
DO NOT use the boom or platform as a crane to lift oversized or hanging loads.
DO NOT raise, lower, or drive 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.
Check level of battery charge before operating the machine. If the machine is sluggish in operation, DO NOT USE before recharging.

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SAFETY-RELATED DECALS

SAFETY RELATED DECALS

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TV20 (JAPANESE VERSION) OPERATOR'S MANUAL

SAFFTY-RELATED DECALS (CONTINUED)

10-154400 Decal, Electrocution Hazard

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SAFETY-RELATED DECALS (CONTINUED)

10-155100 Decal, Platform Capacity (Small), 10-155400 Decal Platform Capacity (Large)

AFETY RELATED DECALS

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TV20 (JAPANESE VERSION) OPERATOR'S MANUAL

SAFETY RELATED DECALS

SAFETY-RELATED DECALS (CONTINUED)

延長作業台積載荷重 110kg

10-155600 Decal, Platform Extension Capacity (If so equipped)

前

10-157800 Decal, Front Direction

10-157900 Decal, Rear Direction

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SAFETY-RELATED DECALS (CONTINUED)

10-158000 Decal, Emergency Lowering and Brake Release

SAFETY RELATED DECALS

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TV20 (JAPANESE VERSION) OPERATOR'S MANUAL

10-155300 Decal, Warnings (Platform)

Page 1-13

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SAFETY PLACARD LOCATIONS

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TV20 (JAPANESE VERSION) OPERATOR'S MANUAL

OPERATION

SECTION 2: OPERATION

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Table of Contents, Section 2

Unloading Procedures	2- 2-	-3 -4
Operation Controls	2	- A
Platform Console Controls	2-	-8
Startup Procedures Shift Checks	2-	-10
Machine Startup	2-	-11
Platform Operation and Checks	2-2-	-12
Operation	ი	រគ
Driving and Steering	2-	-16
Braking Elevating the Platform	2-	·16
Lowering the Platform	2-	.17
Shut-Down Procedures Transporting the Machine	2-	.18
Moving of the Vertical Lift	2-	-19
Single Point Lifting Hook	2-	19
Truck Transport of the Vertical Lift	2-	-20
Emergency Lowering	2-	21
Emergency Drive	2- 2-	·21 ·22

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UNLOADING PROCEDURES

Inspect the outside of the machine for damage. Inspect all hoses, boom sections and hoses/cables for chafina or road damage. Confirm that all wheel lug nuts are tight.
Open both side compartments. Inspect all electrical and hydraulic connections for damage and security.
Connect battery cables to batteries if required. Check electrolyte level.
Check that fluid level is 2" (5.08 cm) from the top of the hydraulic tank, and add fluid as required (see Lubrication Chart).
Close side compartment covers.
Attach the machine to a winch for the unloading.

A WARNING

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

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

Remove all machine tie downs. Remove wheel chocks.
Enter the platform, and start the electric motor using the platform controls. Select the "HIGH" speed, and test all platform functions.
Carefully drive the machine off the truck or trailer with the winch still attached.
Before placing the machine into service, all operators must read and understand the contents of the Operator's Manual.

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

An Operator's Manual and the Aerial Lift Inspection Report are included with each machine leaving the factory.

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PRIMARY MACHINE COMPONENTS

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OPERATOR CONTROLS

OPERATOR CONTROLS DESCRIPTION (GROUND CONTROLS, CONTINUED)

ltem	Control	Location	Description
1.	Key Switch	Ground Control Panel.	Main power disconnect. Also selects "GROUND" or "PLATFORM" operation. The key may be removed when in the center position to prevent unauthorized operation.
2.	Liff/ Lower Switch	Ground Control Panel.	Toggle switch used to control the raising and lower- ing of the platform from the ground, when key switch is in the "GROUND" position.
			Speed of platform lift will be determined by the posi- tion of the Lift/ Drive Speed Switch on the platform control console.
			Platform always lowers at low speed.
3.	Emergency Stop	Ground Control Panel.	Used to stop all functions in an emergency. Push for emergency stop. Pull out to reset. Button light is on when key switch is in ground position.
4.	Circuit Breaker, 15 Amp	Ground Control Panel.	Electrical circuit protection. Press to reset.
5.	Battery Gauge/ Hour Meter	Ground Control Panel.	Indicates level of battery charge. Also, indicates total elapsed time the machine has been operated in hours and tenths.

January 1998

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OPERATOR CONTROLS

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONSOLE CONTROLS, CONTINUED)

ltem	Control		Location	Description
1.	Emergency Button	Stop	On Platform Console	Stops all functions in an emergency. Push for emergency stop. Pull out to reset.
2.	Drive Control Lever		On Platform Console	Controls forward and reverse machine travel at a speed proportional to handle movement. Must unlock handle by pulling up.
				Return lever to center position or release lever to stop movement and apply brakes. Lever is spring centered to the "off" position.
				NOTES : Drive is limited to "LOW'" speed and gradeability reduced when platform is elevated.
3.	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.
4.	Lift Switch		On Platform Console	Used to control the raising and lowering of the platform.
				NOTE: The platform will not lift and drive at the same time. Drive function will take priority if both switches are pressed.
5.	Lift Speed Switch		On Platform Console	Shifts between "HIGH" and "LOW" platform raising speed.
6.	Power Switch	١	On Platform Console	Must be pushed to activate main hydraulic pump, allowing operation of the raise or lower functions from the platform.
7.	Low Battery Light (Option	)	On Platform Console	Illuminates to indicate low battery condition. When lights turns on, return to ground as soon as possible. There wil be enough bat- tery power to safely lower the platform to the stowed position.

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STARTUP PROCEDURES

SHIFT CHECKS

Before the Vertical Lift is operated each shift, the following checks should be completed to make sure that the machine is safe and in good condition.

Refer to check lists 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, damaged tires, etc. Both compartment doors can be opened to inspect components inside.
Check battery charge, electrolyte level and connections.
____ Raise and lower the platform. If function appears sluggish, recharge batteries before using the machine.
Check hydraulic fluid level with platform fully lowered.
Check wheel lug nuts for tightness. (Refer to machine specifications.)
Check hoses and cables for worn areas or chafing.
____ Check platform rails, safety gate and latch for damage.
____ Check pivot pins and their retainers for security.
Check that all warning and instructional labels are legible and secure.

STARTUP PROCEDURES

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MACHINE STARTUP

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 performed prior to operational checks.

Check that battery charger has been disconnected from the AC power source.
Ensure that emergency stop buttons on ground control panel and platform control console are disenaaged. To reset, pull them out.
Push down on each of the three fastened corners of the tilt alarm located along side the electrical box. The alarm should sound as each corner is pressed beyond 5 degrees.

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GROUND OPERATION AND CHECKS

BE SURE PLATFORM TRAVEL AREA IS CLEAR OF OBSTRUCTIONS.

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

Turn the key switch on the ground panel to the "GROUND" position. Switch lift speed togale to "LOW" at the platform control console.
Switch the lift toggle on the ground panel "UP" to raise the platform to the end of its movement.
Listen for any unusual noises.
Check for any vibration while the platform travels up.
Test the "Emergency Stop" function. While platform is moving, press the red button. Platform should stop. Light should turn off.
Reset button by pulling out, to continue platform operation.
Check for uneven or jerky operation.
Check for hydraulic leaks.
Check pivot pin security. Ensure that all snap rings and keeper pins are in place at each pin locking point.
Lower the platform about half way by switching the lift toggle on the ground panel "DOWN". Note operation of audible "down alarm" during lowering procedure.
- Listen for any unusual noises.
Check for any vibration while the platform travels down.
____ Check for uneven or jerky operation.
Check for hydraulic leaks.
Check pivot pin security. Ensure that all snap rings and keeper pins are in place at each pin locking point.
Release the lift switch when platform is approximately half way to stowed position.

IMPORTANT: Platform lowering should stop immediately upon release of lift switch.

• Lower platform to the stowed position.

STARTUP PROCEDURES

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TV20 (JAPANESE VERSION) OPERATOR'S MANUAL

STARTUP PROCEDURES

PLATFORM OPERATION AND CHECKS

Complete the Ground Operational Checks before you perform the Platform Checks.
Select the "PLATFORM" position on the ground/platform key switch at the ground control box.
Enter the platform. Close the gate securely to the platform.
For machines with optional deck extension, manually slide extension into working position. Check that front guard rails are in position, and railing pins are in place.

BE SURE PLATFORM TRAVEL AREA IS CLEAR OF ANY OBSTRUCTIONS.

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

Press the horn button (if so equipped) briefly to check that the horn works.
Press the power switch on the side of the platform control.

IMPORTANT: The power switch must be activated to operate any of the machine functions.

____ Switch the speed toggle to "LOW".
Press the power switch.
_____ Switch the lift toggle "UP" to raise the platform part way.
Test the "Emergency Stop" function. While platform is moving, press the red button. Platform should stop.
Reset button by pulling out, to continue platform operation.
Switch the lift toggle "DOWN" to lower the platform to the stowed position.

IF PLATFORM SHOULD FAIL TO LOWER, DO NOT ATTEMPT TO CLIMB DOWN THE BOOM. SERIOUS INJURY MAY RESULT.

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PLATFORM OPERATION AND CHECKS (CONTINUED)

• Pull up on the drive control lever to unlock it. Push the drive control lever forward to move the machine in a forward direction. Machine should travel smoothly in the forward direction. Travel speed is proportional to handle movement. Release the drive control lever.

IMPORTANT: Machine travel should stop upon release of drive control lever.

Push the drive control lever backward to move the machine in the reverse direction. Machine should travel smoothly in the reverse direction. Travel speed is proportional to handle movement. Release the drive control lever.
Test the "Emergency Stop" function. While travelling, press the red button on the platform control console. Machine should stop.

MACHINE TRAVEL SHOULD STOP UPON ACTUATION OF EMERGENCY STOP BUTTON. BEWARE OF UNSECURED ITEMS ON PLATFORM.

Pull out emergency stop button to reset.
While traveling, move the steer switch "LEFT" and "RIGHT" to test proper steering control.
Return the machine to the stowed position (this includes rolling in the deck extension).
Exit the platform. Turn the key switch on the ground control panel "OFF".

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DPERATION

OPERATION

DUE TO THE DESIGN OF THE VERTICAL LIFT, IT IS POSSIBLE TO DRIVE THROUGH LOCATIONS IN WHICH IT WOULD BE UNSAFE TO RAISE THE PLATFORM.

THE OPERATOR MUST BE AWARE OF THE ENVIRONMENT. DO NOT RAISE THE PLATFORM 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" position before going to the platform for operation.

Enter platform, close and lock safety gate on the platform.

COLD WEATHER OPERATION

Check for water contamination of the fluid.
Check for and remove ice on the steps, platform and steering linkage prior to operation.
Check that all controls operate smoothly.

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

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DRIVING AND STEERING

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

Pull up on the drive control lever to unlock it. Push the drive control lever forward to travel forward. Slow travel speed will be maintained during the first half of drive control lever movement. Fast travel speed occurs when drive control lever is pushed all the way forward.

To steer, press the steer toggle switch to the left or right as required.

NOTE: Steer wheels will not center themselves after a turn, and must be returned to the straight-ahead position with the steer toggle switch.

Although the control panel can be positioned anywhere on the platform, the operator may find driving easier if facing the "steering" end of the machine. If driving is attempted while facing the "non-steering" end, it must be remembered that all directions for steer and drive will be reversed.

When descending a ramp (incline), it is necessary to flip the lift/ drive speed toggle switch to "LOW".

BRAKING

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

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.

BRACE YOURSELF AND SECURE LOOSE OBJECTS ON PLATFORM DURING OPERATION OF THE MACHINE.

OPERAT

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OPERATION

ELEVATING THE PLATFORM

Switch the speed toggle switch to "LOW". Press and hold the power switch. Push the lift toggle switch to the "UP" position. If desired, switch the speed toggle switch to "HIGH" to allow faster rise.

TRAVEL WITH PLATFORM ELEVATED ONLY ON HARD, LEVEL SURFACES.

NOTE: The machine will travel only at the slower speed when platform is raised.

IMPORTANT: If the load capacity of the machine is exceeded, a beeper sounds and only the lowering function will operate. All other functions are disabled until the machine load is below capacity. The overload valve automatically resets when load is below capacity.

LOWERING THE PLATFORM

Press and hold the power switch. Push the lift toggle switch to the "DOWN" position.

NOTE: The platform will only descend at "LOW" speed, regardless of the position of the speed toggle switch.

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SHUT-DOWN PROCEDURES

When finished with the machine, lower the platform to the stowed position and retract the roll out deck.
Park the machine on level ground. Secure to prevent vandalism and to discourage children from climbing or playing on it.
Turn off the key switch, and remove key to prevent unauthorized operation.
Plug in the battery charger to recharge the batteries.

Refer to battery charger manufacturer's instructions for operating procedures.

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TRANSPORTING THE MACHINE

Platform should be in the stowed position when the machine is being transported. Do not operate the machine while it is being transported.

MOVING OF THE VERTICAL LIFT

If your machine is equipped with the UNPOWERED MOVEMENT OPTION, it can be winched or moved short distances in case of power failure. The brake release valve is located on the valve block with the black palm button, inside the hydraulic compartment. The motor free-wheel valve is the hand lever located to the left of the brake release valve.

To move the machine:

Fully close the brake release valve by turning the knob until fully closed.
Open the motor free-wheel valve by pulling the hand lever up.
Operate the brake release hand pump (black palm button) to release brake.
The machine is now ready to move.

To return to normal operation, fully open the brake release valve by turning the knob counterclockwise. Fully close the motor free-wheel valve by pushing the hand lever down.

FORK LIFTING OF THE VERTICAL LIFT

• Lift the Vertical Lift from the sides only. Position forks under the modules, between the front and rear wheels and as near to the rear (driving) wheels as possible. Ensure that lift truck used has adequate capacity to lift the machine (see "Machine Specifications" for gross vehicle weight).

A CAUTION

Do not use tie down lugs to lift the Vertical Lift.

SINGLE POINT LIFTING HOOK

• Lift machine by engaging overhead crane to lifting eye located directly below center portion of platform.

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TRUCK TRANSPORT OF THE VERTICAL LIFT:

The Vertical Lift may be winched onto a transporting vehicle IF THE MACHINE IS EQUIPPED WITH THE UNPOWERED MOVEMENT OPTION. Return both release valves to normal operating position (engaging the brake) when the machine is on the transporting vehicle.
Securely attach the machine to the transporting vehicle using the tie down lugs, located at the center front and center rear of the undercarriage. Ensure that chains or straps have adequate load capacity, and DO NOT OVERTIGHTEN.

Do not use tie down lugs to lift the FALCON.

• Always chock the wheels of the machine while on the transporting vehicle.

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EMERGENCY SYSTEM AND PROCEDURES

IF PLATFORM SHOULD FAIL TO LOWER, DO NOT ATTEMPT TO CLIMB DOWN THE BOOM ASSEMBLY. SERIOUS INJURY MAY RESULT.

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

THIS MACHINE IS NOT INSULATED AND EXTREME CARE MUST BE TAKEN WHEN WORKING AROUND POWER LINES.

DO NOT TOUCH THE MACHINE IF THERE IS A CHANCE IT IS IN CONTACT WITH POWER LINES. WAIT UNTIL THE POWER TO THE LINES HAS BEEN SHUT OFF.

EMERGENCY LOWERING

• Close the emergency lowering valve by turning the handle clockwise. (This valve is located on the valve block with the red palm button, inside the hydraulic compartment.) Pump red palm button by hand and the platform will lower.

NOTE: Drive and steer functions should not be used when using the emergency lowering valve.

IMPORTANT: The emergency lowering system is designed to be used only for emergency descent.

• Once the platform has been fully lowered, open the emergency lowering valve by turning the handle counterclockwise.

NOTE: Platform will not elevate if this valve is closed.

• Report the incident to your supervisor immediately.

EMERGENCY DRIVE

The emergency lowering system will not provide control or operation of the drive or steering functions. Should it be necessary to move the machine, see "Transporting the Machine", earlier in this section.

Page 43

EMERGENCY PROCEDURES

It is not possible for us to foresee every emergency situation that could arise during operation of this machine. Information on the following pages describes three typical emergency situations, and lists appropriate actions that can be taken.

When faced with an emergency, above all please remember:

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

Page 44

SITUATION: Platform elevated, operator not incapacitated, but machine will not respond to platform controls.

POSSIBLE CONDITION:

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

CORRECTIVE ACTION

1. Don't press the power switch.
2. Push the red "Emergency Stop" Button.
3. Evaluate the nature of the failure. Return to the ground, using the emergency lowering valve and lowering procedure (see "Emergency Lowering").

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

4. Report the incident to your supervisor immediately.

Page 45

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

DO NOT TOUCH MACHINE !!!

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. Check to see if the operator is in a pinned position, or would be endangered if platform is moved, before attempting emergency lowering procedure.
4. After establishing that the machine is not in contact with live power lines, lower the platform using the emergency lowering procedure (see "Emergency Lowering", 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.

EMERGENCY SYSTEM AND PROCEDURES

Page 46

TV20 (JAPANESE VERSION) OPERATOR'S MANUAL

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

DO NOT TOUCH MACHINE !!!!

ELECTROCUTION HAZARD!!!

CORRECTIVE ACTION

1. Contact authorized personnel to disconnect power supply touching machine.
2. Have someone summon first aid or rescue squad.
3. If operator is unconscious, check to see if he is in a pinned position, or would be endangered if platform is moved.
4. AFTER POWER IS CUT , use the emergency lowering procedure to bring platform with operator to a safe location to render first aid (see "Emergency Lowering").
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.

Page 47

TV20 (JAPANESE VERSION) OPERATOR'S MANUAL

MAINTENANCE

SECTION 3: MAINTENANCE

Page 48

Table Of Contents, Section 3

General Maintenance Tins	3-3
Shift Operational Checklist	3-4
Weekly Operational Checklist	3-6
Monthly Operational Checklist
Semi - Annual Operational Checklist
Troubleshooting
Lubrication Chart	3-10

Page 49

TV20 (JAPANESE VERSION) OPFRATOR'S MANUAL

GENERAL MAINTENANCE TIPS

GENERAL MAINTENANCE TIPS

NEVER PERFORM SERVICE ON THE MACHINE (WITH PLATFORM ELEVATED) WITHOUT FIRST BLOCKING THE ELEVATING ASSEMBLY IN PLACE !

USE 4" X 4" WOOD POSTS OR SIMILAR MATERIAL WITH SUFFICIENT STRENGTH TO HOLD PLATFORM AND BOOM.

BLOCK BETWEEN LOWER BOOM OR MIDPOST AND UNDERCARRIAGE. DO NOT BLOCK BETWEEN MIDPOST AND GROUND, AS RETRACTING CYLINDER MAY CAUSE STEER END OF MACHINE TO RISE OFF THE GROUND.

Never leave hydraulic components or hoses open. They must be protected from contamination (including rain) at all times.
Never open a hydraulic system 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 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.

January 1998

Page 50

SHIFT OPERATIONAL CHECKLIST

All checks must be completed before operation of the Vertical Lift

DATE

MODEL NUMBER

SERIAL NUMBER

INSPECTED BY

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 THE BEGINNING OF EACH SHIFT. 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

Perform a visual inspection of all machine components, i.e. missing parts, torn or loose hoses, hydraulic fluid leaks, torn or disconnected wires, damaged tires etc. Replace components as necessary. The module covers on both sides can be opened to inspect components inside.
- 2. Check battery charge level and connections.
- 3. Check hydraulic fluid level with the machine in stowed position.
- 4. Check tires for damage.
- 5. Check hoses and cables for worn areas.
- 6. Check platform rails and safety chains for damage.

Continued on following page .

Page 51

SHIFT OPERATIONAL CHECKLIST (CONTINUED)

INITIAL	DES	CRIPTION
	7.	Check pivot pins for security.
	8.	Check that all warning and instructional labels are legible and secure.
	ADDITIONAL MAIN	ENANCE REQUIREMENTS FOR SEVERE USAGE APPLICATIONS
INITIAL	DES	CRIPTION
	9.	Check hydraulic system for leakage after every eight (8) hours of operation.

SHIFT OPERATIONAL CHECKLIST

Page 52

WEEKLY OPERATIONAL CHECKLIST

All checks must be completed before operation of the Vertical Lift.

DATE INSPECTED BY

MODEL NUMBER

WEEKLY OPERATIONAL CHECKLIST

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 vour machine clean!!

THIS CHECKLIST MUST BE USED AT WEEKLY INTERVALS OR EVERY 30 TO 40 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 Operational Checklist.
	2. Check battery electrolyte level and specific gravity (fully charged specific gravity should be 1.265).
	3. Check wheel lug nuts for proper torque (65-70 ft. lbs.).
ADDI	IONAL MAINTENANCE REQUIREMENTS FOR SEVERE USAGE APPLICATIONS
INITIAL	DESCRIPTION
	4. Inspect condition of hydraulic fluid in the reservoir. Fluid should have a clear amber color.
	5. Lubricate all grease fittings (see Lubrication Chart).
	6. Lubricate all steering linkages and pivot points.



3-6	January

Page 53

MONTHLY OPERATIONAL CHECKLIST

All checks must be completed before operation of the Vertical Lift

DATE INSPECTED BY

SERIAL NUMBER

GENERAL INFORMATION

1 Keep inspection records up-to-date
2 Record and report all discrepancies to your supervisor.
2 A dirty machine cannot be properly inspected. Keep vour 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 AI WAYS REMEMBER, AL ITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS

INITIAL	DESC	RIPTION
	1.	Perform all checks listed on Shift and Weekly Operational Checklists.
	2.	Lubricate all grease fittings (see Lubrication Chart).
	3.	Lubricate all steering linkages and pivot points.
	4.	Lubricate deck extension roller surfaces (if so equipped).
	5.	Inspect condition of hydraulic fluid in the reservoir. Fluid should have a clear amber color.
	6.	Inspect the entire machine for signs of damage, broken welds, loose bolts, improper or makeshift repairs.
	7.	Check the electric motor brushes.
	8.	Check pin joints and retaining bolts for security.
	9.	Check hydraulic system pressure.
	10.	Check left and right spindles for free turning with no end play.
	11.	Visually inspect power wheel mounting bolts. Bolts should be flush to retainer, with no gap between retainer and hub flange. (Refer to "Machine Specifications" for toraue value.)

Page 54

SEMI - ANNUAL OPERATIONAL CHECKLIST

All checks must be completed before operation of the Vertical Lift.

DATE _____ INSPECTED BY

SERIAL NUMBER

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!

AWARNING

THIS CHECKLIST MUST BE LISED AT SIX MONTH INTERVALS OR EVERY 500 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.

	DESCRIPTION
	1. Perform all checks listed on Shift, Weekly and Monthly Operational Checklist.
	2. Have hydraulic fluid sample analyzed at a test laboratory. Comply with test results and recommendations to ensure long, trouble free operation
IMPOR	TANT: If hydraulic fluid has been regularly maintained, it should
only re tempero	quire changing once every year, depending on maintenance, iture, application, duty cycle, and atmospheric conditions.
only re tempero	quire changing once every year, depending on maintenance, iture, application, duty cycle, and atmospheric conditions. 3. Check tightness of platform frame and linkage pins.
only re tempero	quire changing once every year, depending on maintenance, iture, application, duty cycle, and atmospheric conditions. 3. Check tightness of platform frame and linkage pins. 4. Check overall platform stability.
only re tempero	quire changing once every year, depending on maintenance, iture, application, duty cycle, and atmospheric conditions. 3. Check tightness of platform frame and linkage pins. 4. Check overall platform stability. 5. Check the electrical mounting and hardware connections for security.
only re tempero	quire changing once every year, depending on maintenance, iteration, duty cycle, and atmospheric conditions. 3. Check tightness of platform frame and linkage pins. 4. Check overall platform stability. 5. Check the electrical mounting and hardware connections for security. 6. Replace return filter element.

January 1998

Page 55

IROUBLESHOOTING

TROUBLESHOOTING

SHOULD YOU EXPERIENCE ERRATIC OPERATION OR NOTICE ANY MAL-FUNCTION WHILE RUNNING THIS 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 OPERATE:

Key switch turned to proper position?
Emergency stop buttons at both ground and platform released? (Pull to release.)
Batteries fully charged?
Battery cables connected?
Wires pulled out or loose?
Hydraulic fluid level low?
Obvious fluid leak or damaged component?

Page 56

LUBRICATION CHART

NO.	ITEM	SPECIFICATION AND QUANTITY	FREQUENCY OF LUBRICATION
1.	Hydraulic reservoir	Mobil DTE-13M or NORTHLAND TALAMAR EXTREME to 2" from top of tank with platform fully lowered.	Check daily. Analyze every 6 months or 500 hours. Change yearly or every 1,000 hours.
2.	Hydraulic return filter	Filter element.	Change every 6 months or 500 hours.**
3.	Pivot pins	Mobilgrease Special or equivalent (N.L.G.I. #2 EP Lithium, plus EP & Moly) Purge old grease.	Monthy or every 100 hours.* ^† Lubricate at every 3 feet (1M) of vertical displacement.
4.	Steering spindles	Lithium N.L.G.I. #2 EP. Purge old grease.	Monthly or every 100 hours.**
5.	Steering hubs	Lithium N.L.G.I. #2 EP. Clean and repack.	Change every 6 months or every 500 hours.* ^†
6.	Steering linkage	Silicone spray.	Monthly or every 100 hours.**
7.	Deck extension roller pins (Option)	Silicone spray.	Monthly or every 100 hours.**
8.	Deck extension tubes (Option)	Coat with petroleum jelly.	Every 6 months or every 500 hours.**

* Whichever occurs first.

^† Different requirements for severe duty applications. See check lists.

LUBRICATION CHART

Page 57

Page 58

TV20 (JAPANESE VERSION) OPERATOR'S MANUAL

INDEX

В

Battery Go	uge/Hour Meter
Braking

С

U C
Circuit Breaker		2-7
Cold Weather Ope	eration	15

D

D
Drive Switch
Driving and Steering

Е

–
Electrocution Hazard	1-4
Elevating the Platform
Emergency Drive	2-21
Emergency Lowering	2-21
Emergency Procedures
Emergency Stop
Emergency Stop, Control Console	2-9
Emergency System and Procedures

F

•
Fork Lifting	of the Vertical Lift

G

General Maintenance Tips
Gradeability Conversion Chart	vi
Ground Operation and Checks

Horn Button	•••••••••••••••••••••••••••••••••••••••	2-9
I Introduction		iii
K Key Switch		2-7
L Lift Switch		2-9
Lift Speed Switch		2-9
Lift/ Lower Switch		2-7
Low Battery Light		2-9
Lowering the Platfo		. 2-17
Lubrication Chart		. 3-10

D 2-15 Dperation 2-15 Dperator Controls, Control Console 2-8 Dperator Controls, Ground Controls 2-6 D Platform Operation and Checks 2-13 Power Switch 2-9 Primary Machine Components 2-4 R Range Diagram V S Safety Placard Locations 1-14 Safety Placard Locations 1-4 Safety Rules and Precautions 1-4 Safety Symbols 1-3 Safety Symbols 1-3 Safety Placard Locations 1-4 Safety Rules and Precautions 1-4 Safety Symbols 1-3 Safety Symbols 1-3 Safety Placard Locations 1-4 Safety Rules and Precautions 1-4 Safety Symbols 1-3 Safety Symbols 1-3 Safety Rules and Precautions 1-4 Safety Symbols 1-3 Safety Symbols 1-3 Safety Symbols 2-10 Shift Checks 2-10 Shift Checks 2-10	M Machine Startup2-11 Monthly Operational Checklist3-7 Moving of the Vertical Lift2-19
Platform Operation and Checks	D Dperation 2-15 Dperator Controls, Control Console
Range Diagram v S Safety Placard Locations 1-14 Safety Rules and Precautions 1-4 Safety Symbols 1-3 Safety-Related Decals 1-8 Semi - Annual Operational Checklist 3-8 Shift Checks 2-10 Shift Operational Checklist 3-4 Shut-Down Procedures 2-18 Single Point Lifting Hook 2-19 Specifications iv Startup Procedures 2-10 Stering Switch 2-9 T Transportation Tie Down 2-20 Transporting the Machine 2-19 Troubleshooting 3-9 Truck Transport of the Vertical Lift 2-20 U Unloading Procedures 2-3 W Weekly Operational Checklist 3-6	D Platform Operation and Checks
S Safety Placard Locations 1-14 Safety Rules and Precautions 1-4 Safety Symbols 1-3 Safety-Related Decals 1-8 Semi - Annual Operational Checklist 3-8 Shift Checks 2-10 Shift Operational Checklist 3-4 Shut-Down Procedures 2-18 Single Point Lifting Hook 2-19 Specifications iv Startup Procedures 2-10 Steering Switch 2-9 T Transportation Tie Down 2-20 Transporting the Machine 2-19 Troubleshooting 3-9 Truck Transport of the Vertical Lift 2-20 U Unloading Procedures 2-3 W Weekly Operational Checklist 3-6	Range Diagram
T Transportation Tie Down	Safety Placard Locations 1-14 Safety Rules and Precautions 1-4 Safety Symbols 1-3 Safety-Related Decals 1-3 Seriety-Related Decals 1-8 Semi - Annual Operational Checklist 3-8 Shift Checks 2-10 Shift Operational Checklist 3-4 Shut-Down Procedures 2-18 Single Point Lifting Hook 2-19 Specifications iv Startup Procedures 2-10 Steering Switch 2-9
U Unloading Procedures2-3 W Weekly Operational Checklist3-6	T Transportation Tie Down
W Weekly Operational Checklist	U Unloading Procedures
	W Weekly Operational Checklist

INDEX