Genie Simon MP Series Operator's Manual

Page 1

Issued: Oct. 97 P/N 89-140502

Page 2

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

SAFETY

Safetv Symbols	1-3
Safety Rules and Precautions
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

OPERATION

Unloading Procedures Primary Machine Components	2-3 2-5
Operator Controls	0.0
Ground Controis
	2-10
Start-Up Procedures	0.16
	2-10
Machine Start-Up	2-17
Ground Operation and Checks	2-18
Platform Operation and Checks	2-21
Operation	0.00
Cold Weather Operation	2-26
Driving and Steering	2-27
Braking	2-27
Booms, Superstructure and Platform	2-28
Gasoline Engine Operation	2-28
Dual Fuel Engine Operation	2-29
Diesel Engine Operation	2-29
Shut-Down Procedures	2-30
Transporting the Machine
Towing Procedures	2-31
Truck or Trailer Transport	2-32
Emergency System and Procedures
Emergency Pump	2-34
Unpowered Emergency Movement	2-34
Emergency Lowering	2-36

Page 3

TABLE OF CONTENTS (CONTINUED)

MAINTENANCE

Conoral Maintenanoo Tino	2.2

Shift Operational Checklist
Weekly Operation Checklist
Monthly Operational Checklist	3-9
Quarterly Operational Checklist
Semi-annual Operational Checklist
Lubrication Chart
Lubrication Diagram
Troubleshooting

INDEX

APPENDIX

Applicable Standards and Regulations	A-3
ANSI/ SIA A92.5-1980 (Partiăl)	A-5
11. Inspection and Maintenance	A-5
12. Training	A-5
13. Operation	A-5
14. Responsibilities of Manufacturer, Dealer, Purcha	ser,
and Operators	A-8

Terex Aerials Limited Warranty

Page 4

NTRODUCTION

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 featuring OEM controls.

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.

DANGER

MODIFICATIONS OF THIS MACHINE FROM THE ORIGINAL DESIGN AND SPECIFICATION WITHOUT WRITTEN PERMISSION FROM TEREX AERIALS INC. 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 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.

Page 5

MACHINE SPECIFICATIONS

Working Height	46 ft / 14.02 m 40 ft / 12.09 m
Horizontal Peach (Boom Angle O°)	27 ft 10 in / 8 48 m
Platform Capacity (Unrestricted)	500 lbs / 225 Kg
Diatform Sizo	36 in x 72 in x 42 in /
	0.01 m v 1.83 m v 1.07 m
Cloured Length	22 ft 3 in / 6 76 m
Slowed Leight	7 ff 5 in / 2 26 m
Slowed HelyIII	7 ff 6 in / 2 20 m
	9 ff 0 in / 2 / 4 m
WheelDase
Outside Turning Radius	10 \|\| 0 \|\|\|. / 4.00 \|\|\|
Maximum Travel Speed:	2 mah/ 4 0 kab
Boom Stowed (Note 1)	3 mpn/ 4.8 kpn
Boom Extended	0.5 mpn / 0.8 kpn
Ground Clearance	8 in./ 20.3 cm
Gross Weight (Approx.) (Note 1)	11, 700 lbs ./ 5,307 kg
Gradeability (On Hard Surface) (Note 1)	15°/27%
Platform Rotation	180°
Superstructure Rotation	360° continuous, either direction
Tire Size	12 x 16.5 (8 Ply)
Tire Pressure (Disregard for foam filled tires)	65 psi / 4.48 bar/ 4.57 kg-cm ²
Wheel Lug Nut Torque (Drive Axle)	65 ft lbs./ 88 Nm/ 9.0 kg-m
Wheel Lug Nut Torque (Steer Axle)	90 ft lbs./ 122 Nm/ 12.4 kg-m
Swing Bearing Bolt Torque	170 ft lbs./ 230 Nm/ 23.5 kg-m
Drive Hub Bolt Torque	80 ft lbs./ 108 Nm/ 11.0 kg-m
Maximum Hydraulic Pressure	2500 psi / 172 bar/ 175 kg-cm ²
Hydraulic Tank Capacity	35 gal. / 132 Liters
Fuel Capacity:
Gas or Diesel	35 gal. / 132 Liters
Propane	30 lbs./ 14 kg
Electrical System	Two 12 Volt DC Batteries
Engine Avgilability:
Standard Wisconsin W41770, 35 hp (26.1 kw), Air Co	oled, Gas (Dual Fuel - Optional)
Optional Ford VSG 423, 63 hp (47.0 kw), Liquid Coole	d, Gas or Dual Fuel
Deutz F2I 912, 32 hp (23.9 kw), Air Cooled,	Diesel
Deutz F3L 1011, 42 hp (31,3 kw). Air Cooled	. Diesel
Isuzu 3KR1 35 hp (26.1 kw). Liquid Cooled.	Diesel
Perkins 104.19, 43 hp (32.1 kw), Liquid Coc	oled, Diesel

Note 1: Weight and performance shown represent typical machines, and should be used as a general guideline only. Many variables between machines can lead to significant differences in these factors. Accurate figures, when necessary for a particular application, can best be determined by testing of the specific machine.

Page 6

MACHINE DIAGRAMS

RANGE DIAGRAM

ANGLE	-19°	0 °	15°	30 °	45°	60 °	70 °
REACH	14' 5"	15' 4"	14' 4"	12' 0"	8' 6"	4' 1"	0' 8"
RETRACTED	4.39 m	4.67 m	4.36 m	3.65 m	2.59 m	1.24 m	0.20 m
HEIGHT	2' 6"	9' 6"	14' 10"	19' 10"	24' 0"	27' 1"	28' 5"
RETRACTED	0.76 m	2.89 m	4.52 m	6.04 m	7.31 m	8.25 m	8.66 m
REACH	26' 3"	27' 10"	26' 5"	22' 10"	17' 4"	10' 4"	5' 0"
EXTENDED	8.00 m	8.48 m	8.05 m	6.96 m	5.28 m	3.15 m	1.52 m
HEIGHT	-1' 6"	9' 6"	18' 1"	26' 1"	32' 10"	37' 11"	40' 0"
EXTENDED	45 m	2.89 m	5.51 m	7.95 m	10.00 m	11.55 m	12.19 m

Page 7

GENERAL ARRANGEMENT DIAGRAM

Page 8

BEAUFORT SCALE AND WIND VELOCITY CHART

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 lose 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	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

Page 9

TECHNICAL CHARTS (CONTINUED)

PERMISSIBLE SOIL CONSOLIDATIONS BY WEIGHT CHART

Ту	pe o	f Soil	daN/cm² (kp/cm²)
А	Fill	ed soil, not artificially condensed	0 - 1
В	Un	disturbed, 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

Page viii

TECHNICAL CHARTS

Page 10

MP 40 OPERATOR'S MANUAL

SAFETY

SECTION 1: SAFETY

Page 11

Safety Symbols	1-3
Safety Rules and Precautions	1-4
Environmentally Hazardous Materials
Battery (Acid/ Lead)	1-8
Diesel Fuel	1-8
Hydraulic Fluid	1-9
Radiator Antifreeze	1-9
Foam-Filled Tires	1-9
Engine Oil
Safetv-Related Decals	1-10
Safety and Control Decal Locations	1-18
Safety and Control Decal Descriptions	1-19

Page 1-2

October 1997

Page 12

SAFETY SYMBOLS

This manual contains important information on the safe use of your 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:

A 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 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.

Page 13

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 the 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.

Page 14

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.
The "UNPOWERED EMERGENCY MOVEMENT" procedure (described later in this manual) requires releasing the torque hubs, which results in there being 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 mph (1.6 kph).
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.

Page 15

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; 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 large "FORWARD" arrows on the undercarriage of the machine or the location of the superstructure lockpin hole for travel orientation.

Page 16

SAFETY RULES AND PRECAUTIONS

SAFETY RULES AND PRECAUTIONS (CONTINUED)

A WARNING

Check fuel system for leaks or damaged fuel lines before operating the 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" will apply brakes immediately, causing unexpected platform movement as the machine comes to a sudden stop. Brace vourself.
Whenever disengaging the drive torque hubs 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.

Be sure to turn all hydraulic valves back "ON" 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 or platform as a crane to lift oversized or hanging loads.
DO NOT raise, extend, retract, tilt, rotate, or lower the platform or booms 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.

October 1997

Page 17

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!

ENVIRONMENTALLY HAZARDOUS MATERIALS

Page 18

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.

Page 19

SAFETY DELATED DECALS

10-145100 Decal. "DANGER . ELECTROCUTION"

10-130600 Decal, "DANGER" (ground station)

Page 1-10

Page 20

10-142100 Decal, "DANGER" (platform station)

Page 21

SAFETY-RELATED DECALS (CONTINUED)

10-272600 Decal. "CAUTION, Safety Belt Lanvard"

Page 22

MP 40 OPFRATOR'S MANUAL

SAFETY-RELATED DECALS (CONTINUED)

OPEN HYDRAULIC TANK VALVES BEFORE STARTING ENGINE

10012600

SAFETY RELATED DECALS

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

ENSURE LOCKPIN IS DISENGAGED BEFORE OPERATING SWING FUNCTION

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

10-012900 Decal, "FORWARD" Arrow

10-148300 Decal, Platform Capacity

Page 23

SAFETY-RELATED DECALS (CONTINUED)

HYDRAULIC FLUID ONLY

10-151300 Decal, "Hydraulic Fluid Only"

GASOLINE ONLY

10-117900 Decal, "Gasoline Only" (for versions with gasoline engines)

DIESEL FUEL ONLY

10-151100 Decal, "Diesel Fuel Only" (for versions with diesel engines)

Page 1-14

SAFETY RELATED DECALS

Page 24

10-264200 Decal, Ground Electrical Controls

10-115800 Decal, "Glow Plug Indicator" (for engines with glow plug)

Page 25

SAFETY-RELATED DECALS (CONTINUED)

Page 26

MP 40 OPFRATOR'S MANUAL

SAFETY RELATED DECALS

10-278100 Decal, Platform Controls

10-139800 Decal, "Operator's Manual Enclosed"

Page 27

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.

Page 28

MP 40 OPERATOR'S MANUAL

SAFETY AND CONTROL DECAL DESCRIPTIONS

ltem No.	Part Number	Description	Qty.
1	10-130600	Decal, "DANGER", Ground Station	1
2	10-145100	Decal, "DANGER", Electrocution	2
3	10-142100	Decal, "DANGER", Platform	1
4	10-272600	Decal, "CAUTION, Safety Belt Lanyard"	1
5	10-094700	Decal, "CAUTION, Hot Water"
		(for versions with liquid cooled engine)	1
6	10-094900	Decal, "CAUTION, Rotating Fan"
		(for versions with liquid cooled engine)	1
7	10-012600	Decal, "Open tank valves"	1
8	10-007200	Decal, "ENSURE LOCKPIN IS DISENGAGED "	2
9	10-264200	Placard, Ground Electrical Controls	1
10	10-148300	Decal, "CAPACITY 500 LBS (225 kg)", Small	2
11	10-284800	Decal, Ground Function Controls	1
12	10-115800	Decal, "Glow Plug Indicator"	1
13	10-151100	Decal, "DIESEL FUEL ONLY" (Diesel engine option)	1
	10-117900	Decal, "GASOLINE ONLY" (Gasoline engine option)	1
14	10-012900	Decal, "FORWARD" Arrow	2
15	10-151300	Decal, "Hydraulic Fluid Only "	1
16	10-278100	Placard, "Platform Control"	1
17	10-139800	Decal, "Operator's Manual Enclosed"	1
18	10-121600	Decal, "Made in U.S.A."	1

October 1997

Page 29

SAFETY AND CONTROL DECAL LOCATIONS (CONTINUED)

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.

Page 30

MP 40 OPERATOR'S MANUAL

SAFETY AND CONTROL DECAL DESCRIPTIONS (CONTINUED)

ltem No.	Part Number	Description	Qty.
1	10-130600	Decal, "DANGER", Ground Station	1
2	10-145100	Decal, "DANGER", Electrocution	2
3	10-142100	Decal, "DANGER", Platform	]
4	10-272600	Decal, "CAUTION, Safety Belt Lanyard"	1
5	10-094700	Decal, "CAUTION, Hot Water"
		(for versions with liquid cooled engine)	1
6	10-094900	Decal, "CAUTION, Rotating Fan"
		(for versions with liquid cooled engine)	1
7	10-012600	Decal, "Open tank valves"	1
8	10-007200	Decal, "ENSURE LOCKPIN IS DISENGAGED "	2
9	10-264200	Placard, Ground Electrical Controls	1
10	10-148300	Decal, "CAPACITY 500 LBS (225 kg)", Small	2
11	10-284800	Decal, Ground Function Controls	1
12	10-115800	Decal, "Glow Plug Indicator"	1
13	10-151100	Decal, "DIESEL FUEL ONLY" (Diesel engine option)	1
	10-117900	Decal, "GASOLINE ONLY" (Gasoline engine option)	1
14	10-012900	Decal, "FORWARD" Arrow	2
15	10-151300	Decal, " Hydraulic Fluid Only "	1
16	10-278100	Placard, "Platform Control"	1
17	10-139800	Decal, "Operator's Manual Enclosed"	1
18	10-121600	Decal, "Made in U.S.A."	1

Page 31

MP 40 OPERATOR'S MANUAL

OPERATION

SECTION 2: OPERATION

Page 32

Unloading Procedures	3 5
Operator Controls Ground Controls	6
Platform Controls 2-	10
Start-Up Procedures
Shift Checks	16
Machine Start-Up	17
Ground Operation and Checks	18
Platform Operation and Checks	21
Operation
Cold Weather Operation 2-	26
Driving and Steering	27
Brakina	27
Booms, Superstructure and Platform 2-	28
Gasoline Engine Operation 2-	28
Dual Fuel Engine Operation2-	29
Diesel Engine Operation 2-	29
Shut-Down Procedures 2-	30
Transporting the Machine
Towing Procedures 2-	31
Truck or Trailer Transport 2-	32
Emergency System and Procedures
Emergency Pump 2-	34
Unpowered Emergency Movement	34
Emergency Lowering 2-	-36

Page 33

UNLOADING PROCEDURES

AWARNING

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

Inspect the outside of the machine for damage (including the underside). Inspect all hoses, boom sections and cables for chafing or road damage. Confirm that all wheel lug nuts and swing bearing bolts are tight (refer to specifications).
Remove the pin that locks the superstructure to the undercarriage near the swing bearing. Stow the lock pin in the location provided nearby.
Unlock and open both side compartment doors. Inspect all fuel, electrical and hydraulic connections for damage and security.
Connect battery cables to batteries if required. Check electrolyte level.
Open the fuel tank valve and check fuel level.
Check engine oil level, and add as required per engine manufacturer's recommendations.
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.
Close side compartment doors.
Attach the machine to a winch for the unloading procedure.

ALWAYS ATTACH THE MACHINE TO A WINCH WHEN LOADING OR UNLOADING FROM A TRUCK OR TRAILER. CONNECT WINCH CABLE TO THE TIE DOWN LUGS ON THE UNDERCARRIAGE. UNASSISTED 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.

October 1997

Page 34

UNLOADING PROCEDURES (CONTINUED)

• Switch the "GROUND/ PLATFORM" key switch to "GROUND". Start engine, using the around controls.

NOTE: Refer to Startup Procedures and Operator Controls Descriptions in this section.

While pressing the "MAIN PUMP" toggle switch on the ground controls, flip and hold a boom function toggle. This is called "deadheading", and will lead to maximum system pressure registering on the gauge at the ground control valve assembly. Check the hydraulic pressure (see Machine Specifications). Turn off engine.

Remove all machine tie downs (see Transporting the Machine). Remove wheel chocks, if used. Switch the "GROUND/ PLATFORM" key switch to "PLATFORM".
Enter the platform, and restart the engine using the platform controls. Select the "OPERATING" engine speed, and test all platform functions.
Raise the boom 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.

NOTE: The brakes are automatically released for driving, and will automatically apply when the machine stops.

• 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 "Receipt Inspection Adjustment Report" or "Predelivery Inspection Adjustment Report" must be completed and returned in order to activate the Terex Limited Warranty.

An Operator's Manual is included with each machine leaving the factory.

Page 35

Left Hand Side.

Page 36

OPERATOR CONTROLS

OPERATOR CONTROLS (GROUND CONTROLS)

October 1997

Page 37

MP 40 OPERATOR'S MANUAL

OPERATOR CONTROLS

OPERATOR CONTROLS DESCRIPTION (GROUND CONTROL)

ltem	Control	Location	Description
1.	Circuit Breaker	On Ground Console Panel	Pops out when the 12 Volt electrical circuit is over- loaded. Push in to reset.
2.	Choke/ Glow Plug Button	On Ground Console 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 a cold engine.
3.	Main Power Key Switch	On Ground Console Panel	Three position main power "ON/ OFF" switch. Straight up position is "OFF".
			Turn key left (counterclockwise) one position to turn power "ON" for ground control operation. Turn key right (clockwise) one position to turn power "ON" for plat- form control operation.
			With key switch "OFF", the key may be removed to prevent unauthorized operation.
4.	Engine Start Button	On Ground Console Panel	Press push button to engage engine starter. Release button immediately upon engine start.
			NOTE: Main power key switch must be in "GROUND" position.
5.	Hour Meter	On Ground Console Panel	Indicates total elapsed time that the engine has been operated in hours and tenths.
6.	Volt Meter	On Ground Console Panel	Indicates electrical system voltage.
7.	Engine Oil Pres- sure Gauge	On Ground Console Panel	Indicates engine oil pressure.
8.	Hydraulic Fluid Pressure Gauge (Not shown)	Beneath Ground Valves	Indicates hydraulic fluid pressure.

Page 38

OPERATOR CONTROLS (GROUND CONTROLS, CONTINUED)

Page 39

MP 40 OPERATOR'S MANUAL

OPERATOR CONTROLS

OPERATOR CONTROLS DESCRIPTION (GROUND CONTROLS, CONTINUED)

ltem	Control	Location	Description
9.	Gas/ Off/ Propane Switch (Optional)	On Ground Console Panel	Flip toggle up to use gasoline, down to use propane. In "OFF" position, the engine does not get fuel supply.
10.	Engine Coolant Temperature Gauge (Not shown)	On Ground Console Panel	Indicates engine coolant temperature, if so equipped.
11.	Steer Wander Control Valve (Not shown)	Near Ground Console Panel	Available with optional tow package only. Pull valve knob out to allow the steering to be free wheeling. Push valve knob in to engage steering.
12.	Engine Throttle Switch	On Ground Console Panel	Flip toggle to down for low (idle) engine speed, up for mid range (operating) engine speed for generator use.
13.	Emergency Stop Button	On Ground Console Panel	Used to stop all functions in an emergency. Push for emergency stop. Pull or rotate clockwise to reset, depending on style used.
14.	Emergency/ Main Pump Toggle Switch	On Ground Console Panel	Flip and hold to "MAIN" to activate main hydraulic pump, enabling operation of boom hydraulic functions from ground.
			Flip and hold to "EMERGENCY" to activate emergency pump, enabling operation of boom hydraulic functions from ground.
15.	Boom Up/ Down Toggle Switch	On Ground Console Panel	Flip and hold to "UP" to raise boom, and "DOWN" to lower main boom.
16.	Boom Extend/ Retract Toggle Switch	On Ground Console Panel	Push up and hold to "EXTEND" to extend boom, and down to "RETRACT" to retract boom.
17.	Swing Left/ Right Toggle Switch	On Ground Console Panel	Push and hold to "LEFT" to swing the superstructure left (counterclockwise) and to "RIGHT" to swing the super- structure right (clockwise).

Page 40

Page 2-10

Page 41

Page 2-11

MP 40 OPERATOR'S MANUAL

OPERATOR CONTROLS

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS)

ltem	Control	Location	Description
1.	Emergency Stop Button	On Platform Console Panel	Used to stop all functions in an emergency. Push for emergency stop. Pull or rotate clockwise to reset, depending on style used.
			When the button is reset, the engine distress light will flash three times and the chassis tilt alarm will sound three times. If any of these indications do not occur at reset, do not operate machine
2.	Off/ On/ Start Toggle	On Platform Console Panel	Three position toggle switch. Up is "OFF". Move to center position to turn ignition "ON", down to engage starter. If the engine does not start within 10 seconds, switch must be turned off and then on again to start.
			IMPORTANT: Engine will not start with foot switch depressed.
3.	Glow Plug/ Choke/ Idle/ Operating Speed	On Platform Console Panel	Flip toggle to center position for low (idle) engine speed, up for mid range (operating) engine speed for generator use.
	(Engine Throttle)		Choke toggle for gas or dual fuel engines. Press and hold while starting a cold engine.
			Glow plug toggle for some Diesels. Press and hold (if so equipped) to preheat combustion chamber before starting a cold engine.
4.	Emergency Pump Push Button	On Platform Console Panel	Press and hold to activate battery powered hydraulic pump, allowing operation of boom or platform func- tions should the engine powered hydraulic pump be disabled. Must be used with foot switch,
5.	Engine Distress Light	On Platform Console Panel	Red light indicates low engine oil pressure, high engine coolant temperature or broken fan belt (if so equipped). Engine will shut down automatically if condition does not correct itself in approximately 10 seconds.

Page 42

Page 2-12

Page 43

OPERATOR CONTROLS

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS, CONTINUED)

ltem	Control	Location	Description
6.	Boom Extend/ Retract Lever	On Platform Console Panel	Lever controls the boom extend/ retract function. Pull back to extend boom. Push forward to retract boom. Boom speed will be proportional to handle movement.
7.	Boom Lift and	On Platform	Dual function lever.
	Swing Level		Push lever forward to raise main boom. Pull lever back to lower main boom. Boom speed will be proportional to handle movement.
			Push lever to right to swing superstructure to right (counterclockwise). Push lever to left to swing left (clockwise). Superstructure can rotate 360° continu- ously in either direction. Swing speed will be propor- tional to handle movement.
8.	Platform Rotate Toggle	On Platform Console Panel	Press and hold switch to left to rotate platform to left (counterclockwise). Press and hold switch to right to rotate platform right (clockwise). One speed only.
9.	Platform Leveling Toggle	On Platform Console Panel	Press and hold switch forward to tilt platform forward. Press and hold switch back to tilt platform backward. One speed only.
10.	Drive Lever	On Platform Console Panel	Lever controls forward and reverse travel of machine at a speed proportional to handle movement. (Engine

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

Page 44

Page 2-14

Page 45

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS, CONTINUED)

	ОР	ERATOR COI (PLATFORM CO	NTROLS DESCRIPTION Introls, Continued)	NTROLS
ltem	Control	Location	Description	CO
11.	Steer Switch	On end of Drive 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.	ERATOR
				Ю
			WITH PLATFORM SWUNG OVER THE STEER- ING WHEELS, USE CAUTION WHEN SE- LECTING THE STEERING DIRECTION. STEER- ING DIRECTION WILL BE OPPOSITE STEER SWITCH MOVEMENT.
12.	Function Speed Toggle	On Platform Console Panel	Press toggle up for "HIGH" function speed, down for "LOW" function speed for all proportional functions (boom, swing, drive). High speed travel is available only while boom is below horizontal and extended less than 3 feet (0.9 Meters).
13.	Horn Button	On Platform Console Panel	Press button to sound warning horn.	V
14.	Light Toggle (Optional)	On Platform Console Panel	Flip toggle to turn head lights on and off (if so equipped).
15.	Sensor Override Button (Optional)	On Platform Console Panel	Press button to override the position sensor (if so equipped).
16.	Foot Switch	On Platform Floor	Must be depressed to activate main or emergency hydraulic pump, allowing operation of any hydraulic function (drive, steer, boom or platform movement) from the platform. Depress foot switch before selecting function. (Engine automatically shifts to mid range for all functions.)

Page 46

START-UP PROCEDURES

SHIFT CHECKS

Before the machine 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, etc. Both compartment doors can be opened to inspect components inside.
Check engine oil and fuel levels.
Check engine coolant level (with liquid cooled engines).
____ Check volt meter on ground controls for battery condition, battery electrolyte level and wire 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 machine is running, extensive pump damage will occur.

Check wheel lug nuts tightness. Check tire pressure (see Machine Specifications).
____ Check hoses for worn areas.
____ Check hose carrier to make sure that it is not bent or sagging.
____ 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.

START-UP PROCEDURES

Page 47

START-UP PROCEDURES

MACHINE START-UP

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 lock pin before swinging the superstructure.
Ensure that "EMERGENCY STOP" buttons on ground control and platform control console panel are disengaged. Pull out or twist to reset, depending on style.
Turn the main power key switch to the "GROUND" position to energize the electrical system.
While starting a cold gasoline or dual fuel engine, press choke button.

For some optional Diesel engines, press glow plug button, and hold it there for 30 to 45 seconds prior to engaging starter motor.

Press and hold engine start button on ground control box to start engine.
Press and hold the "MAIN PUMP" toggle switch on the ground control and "BOOM UP" toggle. 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 bank assembly.
Check that the hydraulic pressure on the gauge is as stated in the Machine Specifications of this manual.

Page 48

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.

Select "GROUND CONTROLS" with the "GROUND/ PLATFORM" key switch.
While pressing the "MAIN PUMP" toggle switch on the ground control, press and hold the "BOOM" toggle to the "UP" position to raise the boom to the horizontal position or slightly above. Release the "BOOM" toggle.
- Listen for any unusual noises.
- Check for any vibration while the boom travels up.
- Check for uneven or jerky operation.
- Check for hydraulic leaks.
Press and hold the boom "EXTEND/ RETRACT" toggle on the ground control to the "EXTEND" position. Extend the boom to the end of its travel.
- Listen for any unusual noises.
- Check for any vibration while the boom extends.
- Check for uneven or jerky operation.
- Check for hydraulic leaks.
Release the "MAIN PUMP" toggle switch and "EXTEND/ RETRACT" toggle.
Inspect the boom sections visually for any damage along their entire lengths.
Push down on each of the three fastened corners of the tilt alarm located on the back side of the ground control bracket. The alarm should sound as each corner is pressed beyond 5 degrees.

START-UP PROCEDURES

Page 49

MP 40 OPERATOR'S MANUAL

START-UP PROCEDURES

GROUND OPERATION AND CHECKS (CONTINUED)

While pressing the "MAIN PUMP" toggle switch on the ground control, press and hold "BOOM" toggle to the "UP" position. Raise the boom to the end of its travel. Then, release the "BOOM" togale.
- Listen for any unusual noises.
- Check for any vibration while the boom travels up.
- Check for uneven or jerky operation.
- Check for hydraulic leaks.
- Visually confirm that the platform has remained level during boom travel.
- Report to supervisor and repair any problem.
Press and hold the "BOOM" toggle to lower the boom slightly.
Press the "EMERGENCY STOP" button. All machine functions must stop, including the engine. Pull the button out or twist to reset. Release the "MAIN PUMP" button.

With the engine off,

Press the "EMERGENCY PUMP" toggle switch.
Press and hold the "BOOM" toggle to lower the boom slightly.
- Listen for any unusual noises.
- Check for any vibration while the boom travels down.
- Check for uneven or jerky operation.
- Check for hydraulic leaks.
Once boom movement has been established using the emergency pump, release the "EMERGENCY PUMP" toggle switch and "BOOM" toggle. Restart engine.
Return the booms to their stowed positions by using the appropriate toggles for "RETRACT" and "DOWN" correspondingly, and the "MAIN PUMP" toggle switch.
- ____ Listen for any unusual noises.
- Check for any vibration while the booms lower and retract.
- Check for uneven or jerky operation.
- Check for hydraulic leaks.
- Report to supervisor and repair any problem.

Page 50

GROUND OPERATION AND CHECKS (CONTINUED)

Operate the "SWING" toggle in each direction while holding the "MAIN PUMP" toggle switch.
- Listen for any unusual noises.
- ____ Check for any vibration while the machine rotates.
- Check for uneven or jerky operation.
- Check for hydraulic leaks.
- Report to supervisor and repair any problem.
Release the "SWING" toggle.
Return the machine to the stowed position by pressing the appropriate toggle switches correspondingly, as well as the "MAIN PUMP" toggle switch.
Shut the engine off.

START-UP PROCEDURES

Page 51

START-UP PROCEDURES

PLATFORM OPERATION AND CHECKS

Complete Ground Operation Checks before performing Platform Operation Checks.
Select "PLATFORM CONTROLS" with the "GROUND/ PLATFORM" key switch.
Enter the platform. Close gate securely.
Ensure that the "EMERGENCY STOP" button is released.
Move "OFF/ ON/ START" toggle to center position to turn ignition "ON", down to engage starter, then release it to the "ON" position.
Flip the "ENGINE THROTTLE" toggle to "OPERATING SPEED".

BE SURE BOOM TRAVEL AREA IS CLEAR OF OBSTRUCTIONS.

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

Press the "HORN" button briefly to check that the horn works. The horn also acts as a signal for the tilt alarm as well as its normal warning function.
Depress the foot switch mounted on the floor of the platform. (Activate foot switch to operate any of the machine functions.)
Slowly move the "BOOM/ SWING" lever forward to the "BOOM UP" position. The boom will start to rise. Function speed will be proportional to handle movement. Raise the boom to the horizontal position. Slowly return the lever to the center position.
Slowly move the "EXTEND/ RETRACT" lever back to the "EXTEND" position. Extend boom out a short distance. Extend speed will be proportional to handle movement.
- ____ Listen for any unusual noises.
- ____ Check for any vibration while the boom telescopes out.
- ____ Check for uneven or jerky operation.
- Check for hydraulic leaks.
- Report to supervisor and repair any problem.

Page 52

PLATFORM OPERATION AND CHECKS (CONTINUED)

Slowly return the lever to the center position.
Slowly move "BOOM/SWING" lever forward to "BOOM UP" position. The boom will start to rise. Function speed will be proportional to handle movement.
- ____ Listen for any unusual noises.
- Check for any vibration while the main boom travels up.
- Check for uneven or jerky operation.
- Check for hydraulic leaks.
- Report to supervisor and repair any problem.
Slowly return the lever to the center position.
Return the booms to the travel position by slowly operating the levers in the "RETRACT" and "BOOM DOWN" directions correspondingly.
- Listen for any unusual noises.
- ____ Check for any vibration while the booms lower and retract.
- Check for uneven or jerky operation.
- Check for hydraulic leaks.
- Report to supervisor and repair any problem.
Slowly return the levers to their center positions.
Slowly move the "BOOM/ SWING" lever right to swing right (counterclockwise) and left to swing left (clockwise). Swing speed will be proportional to handle movement.
- Listen for any unusual noises.
- Check for any vibration while the superstructure rotates.
- Check for uneven or jerky operation.
- Check for hydraulic leaks.
- _____ Report to supervisor and repair any problem.
Slowly return the lever to the center position.
Operate the platform rotate function by moving the "PLATFORM ROTATE" toggle. Move the toggle in both directions.
- ____ Listen for any unusual noises.
- Check for any vibration while the platform rotates.
- _____ Check for uneven or jerky operation.
- Check for hydraulic leaks.
- Report to supervisor and repair any problem.

Page 2-22

START-UP PROCEDURES

Page 53

MP 40 OPERATOR'S MANUAL

START-UP PROCEDURES

PLATFORM OPERATION AND CHECKS (CONTINUED)

Return the platform to the center position with the "PLATFORM ROTATE" toggle.
Operate the platform level function by moving "PLATFORM LEVEL" toggle. Move the toggle in both directions.
- ____ Listen for any unusual noises.
- Check for any vibration while the platform tilts forward or back.
- Check for uneven or jerky operation.
- Check for hydraulic leaks.
- Report to supervisor and repair any problem.
Return the platform to a level position with the "PLATFORM LEVEL" toggle.
Switch the machine "FUNCTION SPEED" toggle to "LOW".

AWARNING

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

• Slowly move the "DRIVE" lever forward. The machine should smoothly accelerate in the forward direction.

Movement alarm sounds whenever the machine is in motion.

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

Page 54

PLATFORM OPERATION AND CHECKS (CONTINUED)

Operate the "STEER" rocker 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 move the "DRIVE" lever backward. The machine will smoothly accelerate in the reverse direction.

Movement alarm sounds whenever the machine is in motion.

• Press "EMERGENCY STOP" button. All functions (including engine) must stop immediately.

AWARNING

BRACE YOURSELF FOR UNEXPECTED PLATFORM MOVEMENT BECAUSE THE MACHINE COMES TO A SUDDEN STOP.

ACTUATION OF THE "EMERGENCY STOP" BUTTON WILL APPLY BRAKES IMMEDIATELY!

• Reset "EMERGENCY STOP" button by turning or pulling, and restart engine.

Page 55

START-UP PROCEDURES

PLATFORM OPERATION AND CHECKS (CONTINUED)

• Raise the boom to above horizontal, and repeat the drive tests. Machine should travel a maximum of 0.5 M.P.H. (0.8 K.P.H.). 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", a tire makes one complete revolution in approximately twenty (20) 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 M.P.H (0.8 K.P.H.).

Return the machine to the straight ahead position, with boom below horizontal and fully retracted.
Switch the "MACHINE FUNCTION SPEED" toggle to "HIGH", and repeat the drive tests.
Move all levers and toggles back to their neutral positions. Release the foot switch.

NOTE: All machine motion should stop upon release of the foot switch.

Move "OFF/ ON/ START" toggle to the "OFF" position to shut off the engine.
While pressing the "EMERGENCY PUMP" pushbutton and depressing the foot switch, slightly raise the boom. Then return boom to stowed position.

Page 56

OPERATION

DUE TO THE DESIGN OF THE MACHINE 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 ONLY 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" key switch in the "PLATFORM" position before entering the platform to operate the machine.

Enter platform, close and secure safety gate.

COLD WEATHER OPERATION

In below zero 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(s) prior to operation.
Check that all valve levers 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 57

OPERATION

DRIVING AND STEERING

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

Depress the foot switch. Slowly push the "DRIVE" lever forward to provide forward travel, or pull the lever backward for reverse travel.

NOTE: The speed of the machine will be proportional to handle movement.

To steer, press the "STEER" rocker switch on the end of the drive 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 when the platform is over the non-steering axle.

The stowed position can be identified by the large "Forward" arrows on the undercarriage, or by the line up of the lock pin holes. When driving with the platform over the opposite axle, remember that all directions given to the steer and drive controls will be reversed.

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

BRAKING

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

RELEASE OF THE DRIVE LEVER OR ACTUATION OF THE RED "EMERGENCY STOP" BUTTON WILL APPLY BRAKES IMMEDIATELY!

BRACE YOURSELF FOR UNEXPECTED PLATFORM MOVEMENT AS THE MACHINE COMES TO A SUDDEN STOP.

Page 58

BOOMS, SUPERSTRUCTURE AND PLATFORM

Depress the foot switch, then select the required function. Available functions are:

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

Each function can be selected by moving the appropriate lever or toggle in the proper direction.

NOTE: Function speeds will be proportional to the distance levers are moved.

Multiple control operation is possible by selecting more than one function at a time.

GASOLINE ENGINE OPERATION

• To start engine, press the "START" button and the "CHOKE" button (at ground station),

press and hold the "ENGINE THROTTLE" toggle to "CHOKE" and the "OFF/ ON/ START" toggle to "START" (at platform).

• As soon as the engine starts, release both switches.

Page 59

OPERATION

DUAL FUEL ENGINE OPERATION

GASOLINE OPERATION

• Operate the machine as normal.

GASOLINE TO PROPANE SWITCHING

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

Open valve on propane tank.
Turn dual "FUEL SELECTOR" switch on the ground controls 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, turn the selector switch on the ground controls 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.

PROPANE TO GASOLINE SWITCHING

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

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.

Turn dual fuel selector 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.
Turn the selector 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.
Close valve on propane tank.

DIESEL ENGINE OPERATION

FOR DIESEL ENGINES EQUIPPED WITH GLOW PLUGS:

• Press the "GLOW PLUG" button (at platform or ground controls), and hold for 30 to 45 seconds (when the engine is cold) prior to engaging the starter motor.

Page 60

SHUT-DOWN PROCEDURES

When finished with the machine, place the booms in the stowed position.
Park the machine on a level surface.
With all togales/ levers to "NEUTRAL" position, allow the engine to slow to idle speed.
Turn "OFF" the "GROUND/ PLATFORM" key switch. Remove key to prevent unauthorized operation.

Page 61

MP 40 OPERATOR'S MANUAL

TRANSPORTING THE MACHINE

TOWING PROCEDURES

WITHOUT OPTIONAL TOWING PACKAGE:

• If optional towing package is not installed, refer to "UNPOWERED EMERGENCY MOVEMENT" in this section.

WITH OPTIONAL TOWING PACKAGE:

Securely attach the machine to a tow vehicle with the tow bar provided.
Disengage torque hubs:

AWARNING

WHENEVER DISENGAGING THE DRIVE TORQUE HUBS OR BEFORE DISCONNECTING FROM TOWING VEHICLE, ENSURE THAT THE MACHINE CANNOT ROLL.

Type 1: remove the plate in the center of the torque hub, turn the plate so that the boss faces in, then reinstall the plate.
Type 2: Push the plunger at the center of the torque hub in to disengage the hub. Two outer plungers will pop out.
Pull steer wander control valve, located near the ground controls, to allow steering wheels to track behind tow vehicle.

The tow vehicle must have sufficient braking capability in order to safely stop itself as well as the machine. Tow speed shall not exceed 3 MPH (4.8 KPH).

FRANSPORTING THE MACHINE

Page 62

TRUCK OR TRAILER TRANSPORT

ALWAYS ATTACH THE MACHINE TO A WINCH WHEN LOADING OR UNLOADING FROM A TRUCK OR TRAILER. CONNECT WINCH CABLE TO THE TIE DOWN LUGS ON THE UNDERCARRIAGE.

UNASSISTED LOADING OR UNLOADING OF ANY MOBILE PLATFORM IS NOT RECOMMENDED.

1. Enter the platform, secure the safety gate, and start the engine using the platform controls. Select the engine "OPERATING SPEED".
2. Raise the boom to allow greater ground clearance so that the platform will clear any obstacles as the machine goes up the loading ramp.
3. Using a winch, carefully drive the machine onto the truck or trailer.
4. Lock the superstructure to the undercarriage by installing the lock pin provided.
5. Ensure that the boom is fully retracted and lowered. Next, use the platform level lever to rest the platform base on the bed of the truck or trailer, but do not apply pressure onto bed.

To avoid damaging the machine, the platform MUST NOT be tied to the trailer bed in any way and should only REST on the bed.

6. The negative battery cables should be disconnected for long distance transport. It is recommended that the fuel and hydraulic tank valves be closed as well.
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 below.

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 63

Tie Down of Machine (Recommended Method).

Page 64

EMERGENCY SYSTEM AND PROCEDURES

IF THE MACHINE FAILS TO OPERATE WHEN THE PLATFORM IS RAISED OR EXTENDED, DO NOT ATTEMPT TO CLIMB DOWN THE BOOM ASSEMBLY. SERIOUS INJURY MAY RESULT.

EMERGENCY PUMP

The machine has an emergency pump which can be operated from the operator's platform or ground controls to safely return the platform to the ground position when the machine has lost engine/ pump power. Operation from the ground controls overrides platform controls.

Press and hold the "PUMP" toggle to "EMERGENCY" on the ground control, OR
Press and hold the "EMERGENCY PUMP" button on the platform control console and depress the foot switch.

Select the proper function (boom retract, boom lower, or swing) as required to safely lower the platform to ground level.

To prevent the battery from completely discharging and the emergency pump from overheating, release the emergency pump button 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.

UNPOWERED EMERGENCY MOVEMENT

• Every attempt should be made to restore engine/ pump 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 M.P.H. (1.6 K.P.H.).

Page 65

EMERGENCY SYSTEM AND PROCEDURES

UNPOWERED EMERGENCY MOVEMENT (CONTINUED)

1. Secure the machine with chains or ropes.

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

ALWAYS CHOCK THE WHEELS BEFORE YOU RELEASE THE BRAKES TO PREVENT UNEXPECTED MACHINE MOVEMENT ON SLOPES.

2. Chock wheels.
3. Disengage torque hubs:

WHENEVER DISENGAGING THE DRIVE TORQUE HUBS OR BEFORE DIS-CONNECTION FROM TOWING VEHICLE, ENSURE THAT THE MACHINE CANNOT ROLL.

Type 1: remove the plate in the center of the torque hub, turn the plate so that the boss faces in, then reinstall the plate.
Type 2: Push the plunger at the center of the torque hub in to disengage the hub. Two outer plungers will pop out.
4. Disconnect steer cylinder.

After unchocking the wheels, the machine will be ready to be moved.

After engine/ pump power has been restored to the machine, engage the torque hubs, reset the brake circuit needle valve, and connect steer cylinder. The machine is now ready for normal operation.

October 1997

Page 66

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 ONE: 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 lever.
Machine function will not stop unless power is switched off.

CORRECTIVE ACTION

1. Remove foot from foot switch.
2. Push the red "Emergency Stop" Button.
3. Evaluate the nature of the failure. Return to the ground, using the emergency pump and lowering procedure (see "Emergency Pump", earlier in this section).

A DANGER

DO NOT TRY TO CLIMB DOWN THE BOOM.

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

4. If unable to return to the ground using the platform controls and the emergency pump, contact an experienced operator to lower the machine with the emergency pump using the ground controls (see "Emergency Pump", earlier in this section).
5. Report the incident to your supervisor immediately.

Page 67

EMERGENCY LOWERING (CONTINUED)

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

A DANGER

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 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 68

EMERGENCY LOWERING (CONTINUED)

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

A DANGER

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 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.

Page 69

MP 40 OPERATOR'S MANUAL

MAINTENANCE

SECTION 3: MAINTENANCE

Page 70

General Maintenance Tins	3-3
Shift Operational Checklist
Weekly Operation Checklist
Monthly Operational Checklist	3-9
Quarterly Operational Checklist	3-11
Semi-annual Operational Checklist	3-12
Lubrication Chart	3-14
Lubrication Diagram	3-15
Troubleshooting

Page 71

MP 40 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 disassemble engine when there are contaminants in the air.
Use only recommended lubricants. Improper lubricants or incompatible lubricants may be as harmful as no lubrication (see Lubrication Chart).
ALWAYS clean the surrounding area before opening hydraulic system or disassembling 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 operator's, service, and repair manuals of the manufacturer.

Page 72

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.

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.

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. Check machine for any prior-shift or transportation damage, i.e. missing parts, torn or loose hoses, hydraulic fluid leaks, torn or disconnected wires, flat or damaged tires etc. The compartment doors on both sides can be opened to inspect components inside.
2. Check for machine damage, broken welds, improper or makeshift repairs.
3. Check hydraulic system for leaks, examine hoses for signs of excessive wear, chafing or twisting.
4. Check engine oil and fuel levels.
5. Check engine coolant level (liquid cooled engine only).

Continued on following page .

Page 73

SHIFT OPERATIONAL CHECKLIST

SHIFT OPERATIONAL CHECKLIST (CONTINUED)

INITIAL	DESCRIPTION
	Check battery electrolyte level. Check battery terminals for tight connec- tions and cleanliness.	6. Che tion
	Check hydraulic fluid level. The level should be at the line marked on the sight gauge with the machine in stowed position. Inspect condition of hydraulic fluid in the reservoir. Fluid should be a clear amber color.	7. Che the of h
	Check that all shutoff valves on hydraulic tank are open (parallel to flow).	8. Che flov
	9. Check tires for proper inflation pressure (see Machine Specifications).	9. Che
	10. Check if wheel lug nuts are tight.	10. Che
	11. Check hoses for worn areas.	11. Che
	12. Check hose carrier to verify that it is not bent or sagging.	12. Che
	Inspect safety equipment as required by OSHA, government and local rules.	13. Insp rule
	14. Check platform gate latch for damage.	14. Che
	15. Check pivot pins for security.	15. Che
	Check that no attempt had been made to override the drive interlock system by a previous operator.	16. Che sys
	17. Check that all warning and instructional decals are legible and secure.	17. Che
	18. Start engine. Check hydraulic pressure (see Machine Specifications).	18. Sta
	19. Check that the tilt alarm is working properly.	19. Che
	20. When all pre-inspection checks have been completed, test the ground controls for proper operation.	20. Wh cor
	Check emergency pumps for operation and pressure (see Machine Specifications).	21. Che Spe

Continued on following page .

Page 74

SHIFT OPERATIONAL CHECKLIST (CONTINUED)

22.	Check platform controls for proper operation.
23.	With the platform raised, check for the smooth operation of low speed drive.
24.	Follow engine daily service requirements. Refer to the Engine Mainte- nance Manual supplied with your machine.

ADDITIONAL MAINTENANCE REQUIREMENTS FOR SEVERE USAGE APPLICATIONS

NOTE: Do not lubricate wear pads or chains 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
	25. Inspect cylinder boots, valve spool boots, etc., for cuts or other damage after every eight (8) hours of service. Repair or replace if necessary.
	Check hydraulic system for leakage after every eight (8) hours of operation.
	27. Follow engine severe usage service requirements. Refer to the Engine Maintenance Manual supplied with your Machine.

SHIFT OPERATIONAL CHECKLIST

Page 75

WEEKLY 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 WEEKLY INTERVALS OR EVERY 25 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 wheel lug nut torque (see Machine Specifications).
	3. Check hydraulic connections for leaks, corrosion and wear.
	4. Lubricate swing bearing and drive pinion gear (see Lubrication Chart).
	Follow engine weekly service requirements. Refer to the Engine Mainte- nance Manual supplied with your machine.

Continued on following page .

Page 76

WEEKLY OPERATIONAL CHECKLIST (CONTINUED)

ADDITIONAL MAINTENANCE REQUIREMENTS FOR SEVERE USAGE APPLICATIONS

INITIAL	DESCRIPTION
	6. Lubricate all grease fittings (see Lubrication Chart).
	7. Check oil level in swing drive motor assembly (see Lubrication Chart).
	8. Check oil level in power hubs (see Lubrication Chart).
	9. Follow engine severe usage service requirements. Refer to the Engine Maintenance Manual supplied with your Machine.

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Page 77

MP 40 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.
3. 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	ESCRIPTION
	1. Perform all checks listed on Shift and Weekly Operational Checklist.
	2. Lubricate all grease fittings (see Lubrication Chart).
	3. Lubricate all hydraulic valve spool linkages.
	Check hose and electrical wire routed from the boom to the platform for any damage.
	Check protective rubber cover around hoses at moving anchor, tip boom, boom hose passages, and at swing bearing.
	6. Check boom hose carrier for sag and damage. If damaged, have them repaired.
	7. Check torque of swing bearing bolts (see Machine Specifications).

Continued on following page .

Page 78

MONTHLY OPERATIONAL CHECKLIST (CONTINUED)

INITIAL	DESCRIPTION
	Check adjustment and security of swing drive motor assembly. The should be a slight amount of backlash between the turntable and undercarriage when properly adjusted. Check torque of mounting b (see Machine Specifications).	ere Polts
	9. Check oil level in swing drive gear box (see Lubrication Chart).
	10. Check oil level in power hubs (see Lubrication Chart).
	11. Check that tires are not leaning in or out.
	12. Check that wheel spindles turn freely, with no end play.
	Check drive wheel power hub mounting bolt torque (see "Machine Specifications").
	14. Check that the boom does not drift with a full load, no hydraulic pressure (engine off) and the control valve in the "BOOM DOWN" position.	)S- on.
	15. Inspect boom chains. Lubricate as required (see chart).
	16. Check to make sure boom sections are not dented or bent.
	Check that all adjustable flow valves are locked. Check settings if a are not locked.	ny
	Check fuel shutoff rack for proper operation. Loosen lever arm and lubricate with WD-40 or equivalent.
	19. Follow engine monthly service requirements. Refer to the Engine Maintenance Manual supplied with your machine.

MONTHLY OPERATIONAL CHECKLIST

Page 79

MP 40 OPERATOR'S MANUAL

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 DESCRIPTION

1. Perform all checks listed on Shift, Weekly and Monthly Operational Checklist.

ADDITIONAL MAINTENANCE REQUIREMENTS FOR SEVERE USAGE APPLICATIONS

INITIAL	DESCRIPTION
	2. Replace high pressure filter element.
	3. Replace hydraulic return line filter element.
	4. Replace emergency pump hydraulic filter.
	5. Follow engine severe usage service requirements. Refer to the Engine Maintenance Manual supplied with your Machine.

Page 80

SEMI-ANNUAL OPERATIONAL CHECKLIST

DATE: INSPECTED BY:

MODEL NUMBER: SERIAL NUMBER:

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

CENERAL INFORMATION

1 Keen 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!

AWARNING

THIS CHECKLIST MUST BE LISED 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

INITIAL	DESCRIPTION
	Perform all checks listed on Shift, Weekly, M Operational Checklists.	onthly and Quarterly
	2. Have hydraulic fluid sample analyzed at a te test results and recommendations to ensure	st laboratory. Comply with long, trouble free operation.
	NOTE: If hydraulic fluid has been regularly should only require changing once every year, maintenance, temperature, application, du atmospheric conditions.	maintained, it depending on ly cycle, and
	3. Clean and lubricate all electrical switches wi cleaner and ensure that the switches operate	th an electrical contact freely in all positions.
	4. Check the electrical mounting and hardware	connections for security.
	5. Replace high pressure filter element.
	6. Replace hydraulic return line filter element.
	7. Replace emergency pump hydraulic filter.
Continued o	bllowing page
Page 3-12		October 19

Page 3-12

SEMI-ANNUAL OPERATIONAL CHECKLIST

October 1997

Page 81

SEMI-ANNUAL OPERATIONAL CHECKLIST

SEMI-ANNUAL OPERATIONAL CHECKLIST (CONTINUED)

INITIAL	DESCRIPTION
	Drain and replace fluid from swing drive and power contaminated, it may be necessary to disassemble nents.	er hubs. If badly and inspect compo-
	. Clean and lubricate the standard open swing bear moly lube spray.	ng gear teeth with dry
	. Repack front wheel bearings.
	Follow engine semi-annual service requirements. Maintenance Manual supplied with your machine.	Refer to the Engine
	ERY YEAR
	Drain and replace fluid from hydraulic reservoir. I from drive wheel power hubs. If badly contamina sary to disassemble and inspect components.	Prain and replace fluid red, it may be neces-
	ERY TWO YEARS
	Drain and replace fluid from swing drive motor as contaminated, it may be necessary to disassembly nents.	sembly. If badly and inspect compo-
	NCE REQUIREMENTS FOR SEVERE USAGE APPI	ICATIONS
	ERY SIX MONTHS

Drain and replace fluid from swing drive motor assembly and drive wheel power hubs.
Follow engine severe usage service requirements. Refer to the Engine Maintenance Manual supplied with your machine.

October 1997

Page 82

LUBRICATION CHART

NO.	ІТЕМ	SPECIFICATION AND QUANTITY	FREQUENCY OF LUBRICATION
1.	Hydraulic reservoir	Northland Talamar Extreme to "Full" mark with all cylinders retracted.	Check level & condition each shift. Analyze 6 months or 500 hours.* ^† Change yearly or 1000 hours.* ^†
2.	Hydraulic high pressure filter	Filter element.	Change 6 months or 500 hours.**
3.	Hydraulic return line filter	Filter element.	Change 6 months or 500 hours.**
4.	Emergency pump hydraulic filter	Filter.	Change 6 months or 500 hours.**
5.	Swing bearing (standard open style)	Lithium N.L.G.I. #2 EP. Purge old grease.	Weekly or every 25 hours.**
6.	Exposed swing bearing gear teeth	Dry moly lube spray.	Every six (6) months or 500 hours.**
7.	Swing drive gear box	Fill to plug. SAE 140 EP or N.L.G.I. #00 EP oil.	Check monthly or every 100 hours.* ^† Change every two (2) years or 2,000 hours.*
8.	Boom pivot pins and Cylinder pins	Lithium N.L.G.I. #2 EP. Purge old grease.	Monthly or every 100 hours.**
9.	Wheel bearings	Lithium N.L.G.I. #2 EP. Clean and repack.	Change every six (6) months or 500 hours.* ^†
10.	Steering spindles	Lithium N.L.G.I. #2 EP. Purge old grease.	Monthly or every 100 hours.**
11.	Steering linkage	Lithium N.L.G.I. #2 EP. Purge old grease.	Monthly or every 100 hours.**
12.	Steering tie rod ends	Lithium N.L.G.I. #2 EP. Purge old grease.	Monthly or every 100 hours.**
13.	Drive wheel power hubs	SAE 80 W 90, SAE 90 or SAE 85-140, half full.	Change after first 50 hours. Check monthly or every 100 hours. Change yearly or 1,000 hours.
14.	Boom wear pads	Silicone spray.	Monthly or every 100 hours.**
15.	Valve spool linkage	WD 40 Spray or equivalent penetrating oil.	Monthly or every 100 hours.*
16.	Platform rotate mechanism	Hydraulic fluid.	Yearly.

* Whichever occurs first.

^† Different requirements for severe usage applications. See checklists.

Page 3-14

Page 83

Page 84

TROUBLESHOOTING

SHOULD YOU EXPERIENCE ERRATIC OPERATION OR NOTICE ANY MAL-FUNCTION WHILE RUNNING YOUR MP 60, CONTINUE OPERATION ONLY LONG ENOUGH TO RETURN TO THE GROUND POSITION IF POSSIBLE.

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

WHAT TO CHECK IF UNIT WILL NOT START:

Is the key switch turned on?
Is the ground/ platform selector switch in the proper position?
Are all emergency stop buttons or switches released?
Are all battery cables connected?
Are the batteries 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?
Is the engine speed switch at the correct RPM (not at "IDLE" speed)?
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?
If equipped with manual descent valve option, are all three valves in the correct position?
If equipped with the tow package option, are the torque hubs or steering control valve disengaged?

IROUBLESHOOTING

Page 85

MP 40 OPERATOR'S MANUAL

INDEX

Α

ANSI/ SIA A92.5-1980 (Partia	I)A-5
Applicable Standards and Reg	ulationsA-3
Arrangement Diagram	vi
Auxiliary Pump Push Button	2-13

В

Boom, Su	perstructure and Platform	2-30
Braking	•

С

Choke Button
Circuit Breaker
Cold Weather Operation
Control Selector Switch

D

Diesel Engine Operation
Drive Control Lever
Drive Speed Switch
Drive Toggle Switch
Driving and Steering
Dual Fuel Engine Operation	on2-30

Ε

Electrical Storms
Electrocution Hazard	1-4
Operation and Checks
Emergency Electrical Pumps	2-36
Emergency Lowering	2-38
Emergency Stop Button	2-7, 2-13
Emergency System and Procedures	2-36
Engine Oil Pressure Gauge	2-9
Engine Speed (Throttle) Switch	2-7
Engine Warning Indicator	2-13
-

F

Foot Pedal Switch	7

G

Gasoline Engine Operation
Gasoline to Propane Switching	2-31
Glow Plug
Glow Plug/ Choke/ Idle/
Operating Speed Switch
Gradeability Conversion Chart	vi
Ground Operation and Checks	2-20

Н

ligh Wind
Jorn Button
lour Meter
- - - - - - - - - - - - - - - - - - -	d Pressure Gauge	2-9
iydraulic Valv	/es

1

gnition Toggle	Switch		2-7
ntroduction			iii

L

Lift and Swing Control Lever	2-15
Lift Lever
Lifting Procedure
Light Switch
Lubrication Chart

М

Machine Components
Machine Diagrams	v
Machine Startup
Main Power Key Switch
Maintenance
Maintenance,
Severe Usage Applications	3-6 , 3-8
Maintenance Tips	3-3
Monthly Operational Checklist	3-7

Page 86

INDEX (CONTINUED)

0

Operation	2-28
Operator Controls
(Ground Electrical Panel)
Operator Controls
(Platform Controls)	2-12

Ρ

Platform Leveling Lever	2-15
Platform Operation and Checks	2-23
Platform Rotate Lever	2-15
Propane Switch	2-9
Propane to Gasoline Switching	2-31
Pump Selector Toggle Switch	2-11

R

Range Diagram		۷

S


Safety	1-1
Safety Belts	1-4
Safety Rules and Precautions	1-4
Safety Symbols	1-3
Semi-Annual Operational Checklist	3-9
Shift Checks	2-18
Shift Operational Checklist	3-4
Shut-Down Procedures	2-32
Specifications	iv
Start Switch, On/ Off	2-13
Startup Procedures	2-18
Steer Switch	2-17
Steer Togale Switch	2-11
Steer/ Wander Control Valve	2-9
Swing Lever	2-9

Т


Telescope Lever	2-9, 2-13
Tie Down Locations (Recommended)	2-35
Towing Procedures	2-33
Transporting the Machine	2-33
Troubleshooting	3-11
Truck or Trailer Transport	2-34

U

Unloading Procedures
Unpowered Emergency	Movement	2-37

۷

/olt Meter	9

Page 87

OPERATOR'S MANUAL APPENDIX

APPENDIX

Page 88

Applicable Standards and Regulations	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

APPENDIX

March 1997

Page 89

OPERATOR'S MANUAL APPENDIX

APPENDIX

APPLICABLE STANDARDS AND REGULATIONS

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 90

OPERATOR'S MANUAL APPENDIX

Page 91

ANSI/ SIA A92.5-1992

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.

Page 92

5. RESPONSIBILITIES OF DEALERS (CONTINUED)

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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ansi/ sia a92.5-1992

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. RESPONSIBILITIES OF OWNERS (CONTINUED)

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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ANSI/ SIA A92.5-1992

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 dealer 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.

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7. RESPONSIBILITIES OF USERS

7.1 Basic Principles. The information in this standard must be supplemented by good job management, safety control and the application of sound principles of safety, training, inspection, maintenance, application and operation consistent with all data available and regarding the parameters of intended use and expected environment. Since the user has direct control over the application and operation of aerial platforms, conformance with good safety practices in this area is the responsibility of the user and his operating personnel including the operator. Decisions on the use and operation of the aerial platform must always be made with due consideration for the fact that the machine will be carrying personnel whose safety is dependent on those decisions.

7.2 Manuals. Users shall keep and maintain copy(ies) of the operating and maintenance manual(s) required in section 4.19 of this standard. The operating manual(s) shall be stored in the location required in section 4.20 of this standard. These manuals are considered an integral part of the aerial platform and are vital to communicate the necessary safety information to users and operators.

7.3 Inspection and Maintenance. Users shall inspect and maintain the aerial platform as required to ensure proper operation. The frequency of inspection and maintenance shall be determined by the manufacturer's recommendations and be compatible with operating conditions and the severity of the operating environment. Aerial platforms that are not in proper operating condition shall be immediately removed from service until repaired. Repairs shall be made by a qualified person and the repairs shall be in conformance with the manufacturer's recommendations.

7.3.1 Frequent Inspection. An inspection as outlined in section 6.5 of this standard shall be conducted.

7.3.2 Annual Inspection. An inspection as outlined in section 6.6 of this standard shall be conducted.

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7.3.3 Pre-start Inspection. Before use each day or at the beginning of each shift, the aerial platform shall be given a visual inspection and functional test including but not limited to the following:

(a) Operating and emergency controls.
(b) Safety devices.
(c) Personal protective devices, including fall protection.
(d) Air, hydraulic and fuel system leaks.
(e) Cables and wiring harness.
(f) Loose or missing parts.
(g) Tires and wheels.
(h) Placards, warnings, control markings and operating and safety manual(s).
(i) Outriggers, stabilizers, extendible axles and other structures.
(i) Guardrail system.
(k) Items specified by the manufacturer.

7.3.4 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.
(f) Precautions specified by the manufacturer.

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

7.5 Maintenance Training. The user shall train his maintenance personnel in inspection and maintenance of the aerial platform in accordance with sections 7.3, 7.3.1, 7.3.2, 7.3.3 and 7.3.4 of this standard and with the manufacturer's recommendations.

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7. RESPONSIBILITIES OF USERS (CONTINUED)

7.6 Operator Training. Whenever a user 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 and maintenance manual, the user's work instructions and requirements listed in section 8 of this standard before operating the aerial platform.

7.6.1 Model Training. The user shall be responsible for the operator being trained on the model of the aerial platform that he will be operating. Such training shall be in an area free of obstructions, under the direction of a qualified person for a time sufficient to determine that the trainee display proficiency in knowledge and actual operation of the aerial platform. Only properly trained and authorized personnel shall be permitted to operate the aerial platform.

7.6.2 Trainee Records. A record of the trainee's aerial platform instructions shall be maintained by the user for at least three (3) years.

7.7 Before Operation. Before authorizing an operator to operate an aerial platform, the user shall ensure that the operator has:

(a) Been instructed by a qualified person in the intended purpose and function of each control.
(b) Read and understood the manufacturer's operating instruction(s) and users safety rules, or been trained by a qualified person on the contents of the manufacturer's operating instruction(s) and users safety rules.
(c) Understood by reading or by having a qualified person explain all decals, warnings and instructions displayed on the aerial platform.
(d) Determine that the purpose for which the aerial platform is to be used is within the scope of the intended applications defined by the manufacturer.
(e) Been provided with approved fall protection devices and other safety gear for all personnel in the platform.

7.8 Work Place Inspection. Before the aerial platform is used and during use, the user shall check the area in which the aerial platform is to be used for possible hazards such as but not limited to:

(a) Drop-offs or holes.
(b) Bumps and floor obstructions.
(c) Debris.
(d) Overhead obstructions and high voltage conductors.
(e) Hazardous locations.
(f) Inadequate surface and support to withstand all load forces imposed by the aerial platform in all operating configurations.
(g) Wind and weather conditions.
(h) Presence of unauthorized persons.
(i) Other possible unsafe conditions.

ANSI/ SIA A92.5-1992

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ANSI/ SIA A92.5-1992

7.9 During Operation. The aerial platform shall be used in accordance with this standard. The user shall ensure that before each movement of the aerial platform, if repositioning of the platform, that the operator shall ensure:

(a) The aerial platform is operated on a surface within the limits specified by the manufacturer.
(b) The outriggers, stabilizers, extendible axles, or other stability enhancing means, are used as required by the manufacturer.
(c) Guardrails are installed and access gates or openings are closed per manufacturer's instructions.
(d) The load and its distribution on the platform and any platform extension are in accordance with the manufacturer's rated capacity for that specific configuration.
(e) There is adequate clearance from overhead obstructions.
(f) The minimum safe approach distance (M.S.A.D.) to energized power lines and parts, as listed in Table 1 are maintained. (See Fig. 3, page 23 of complete standard, for examples of safe operating procedures.)
(g) The precautions defined in 7.3.3, 7.7, 7.8, 7.9, 7.10 and 7.11 of this standard are followed during operation of the aerial platform.

7.10 Hazardous Locations. It shall be the responsibility of the user to determine the hazard classification of any particular atmosphere or location according to ANSI/NFPA 505 - 1987.

7.10.1 Hazardous Locations. Aerial platforms operated in hazardous locations shall be approved and of the type required by ANSI/NFPA 505-1987.

7.11 Warnings and Instruction. The user shall direct his operating personnel and supervise their work to ensure operation of the aerial platform in compliance with this standard.

7.11.1 Personnel Footing. Personnel shall maintain a firm footing on the platform floor while working therein. Use of planks, ladders or any other device on the aerial platform for achieving additional height or reach shall be prohibited.

7.11.2 Precaution from Other Moving Equipment. When other moving equipment or vehicles are present, special precautions shall be taken to comply with local ordinances or safety standards established for the workplace. Warnings such as, but not limited to, flags, roped-off areas, flashing lights and barricades shall be used.

7.11.3 Reporting Problems or Malfunctions. The operator shall immediately report to his supervisor any problem or malfunctions which become evident during operation. Any problems or malfunctions that affect the safety of operations shall be repaired prior to continued use.

7.11.4 Altering Safety Devices. Altering or disabling of interlocks or other safety devices shall be prohibited.

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7. RESPONSIBILITIES OF USERS (CONTINUED)

7.11 Warnings and Instruction (Continued).

7.11.5 Entanglement. Care shall be taken to prevent rope, electric cords and hoses from becoming entangled in the aerial platform.

7.11.6 Capacity Limitation. Rated capacities shall not be exceeded when loads are transferred to the platform at any height.

7.11.7 Work Area. The operator shall ensure that the area surrounding the aerial platform is clear of personnel and equipment before lowering the platform.

7.11.8 Fueling. The engine shall be shut down while fuel tanks are being filled. Fueling shall be done in a well-ventilated area free of flame, sparks or other hazards which may cause fire or explosion.

7.11.9 Battery Charging. Batteries shall be charged in a well-ventilated area free of flame, sparks or other hazards which cause fire or explosion.

7.11.10 Improper Platform Stabilization. The aerial platform shall not be positioned against another object to steady the platform.

7.11.11 Misuse as a Crane. The aerial platform shall not be used as a crane.

7.11.12 Operating Area. The aerial platform shall not be operated from a position on trucks, trailers, railway cars, floating vessels, scaffolds or similar equipment unless the application is approved in writing by the manufacturer.

7.11.13 Travel Speed. Under all travel conditions, the operator shall limit travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel, and other factors causing hazards of collision or injury to personnel.

7.11.14 Elevated Driving Requirements. Before and during driving while the platform is elevated, the operator shall:

(a) Maintain a clear view of the path of travel.
(b) Maintain a safe distance from obstacles, debris, drop-offs, holes, depressions, ramps and other hazards to ensure safe elevated travel.
(c) Maintain a safe distance from overhead obstacles.

7.11.15 Stunt Driving. Stunt driving and horseplay shall not be permitted.

7.11.16 Unauthorized Use. Means shall be used to protect against use by unauthorized person(s).

Genie Simon MP Series Operator's Manual

TABLE OF CONTENTS

SAFETY

OPERATION

TABLE OF CONTENTS (CONTINUED)

MAINTENANCE

INDEX

APPENDIX

INTRODUCTION

MACHINE SPECIFICATIONS

MACHINE DIAGRAMS

RANGE DIAGRAM

GENERAL ARRANGEMENT DIAGRAM

BEAUFORT SCALE AND WIND VELOCITY CHART

TECHNICAL CHARTS (CONTINUED)

PERMISSIBLE SOIL CONSOLIDATIONS BY WEIGHT CHART

SAFETY

SECTION 1: SAFETY

TABLE OF CONTENTS

SAFETY SYMBOLS

A DANGER

A CAUTION

SAFETY RULES AND PRECAUTIONS

SAFETY RULES AND PRECAUTIONS (CONTINUED)

A DANGER

SAFETY RULES AND PRECAUTIONS (CONTINUED)

SAFETY RULES AND PRECAUTIONS (CONTINUED)

ENVIRONMENTALLY HAZARDOUS MATERIALS

BATTERY (ACID/LEAD)

DIESEL FUEL

ENVIRONMENTALLY HAZARDOUS MATERIALS (CONTINUED)

HYDRAULIC FLUID

RADIATOR ANTIFREEZE

FOAM-FILLED TIRES

ENGINE OIL

SAFETY DELATED DECALS

OPEN HYDRAULIC TANK VALVES BEFORE STARTING ENGINE

HYDRAULIC FLUID ONLY

GASOLINE ONLY

DIESEL FUEL ONLY

SAFETY-RELATED DECALS (CONTINUED)

SAFETY AND CONTROL DECAL LOCATIONS

SAFETY AND CONTROL DECAL DESCRIPTIONS

SAFETY AND CONTROL DECAL LOCATIONS (CONTINUED)

SAFETY AND CONTROL DECAL DESCRIPTIONS (CONTINUED)

OPERATION

SECTION 2: OPERATION

Table of Contents

UNLOADING PROCEDURES

UNLOADING PROCEDURES (CONTINUED)

OPERATOR CONTROLS DESCRIPTION (GROUND CONTROL)

OPERATOR CONTROLS (GROUND CONTROLS, CONTINUED)

OPERATOR CONTROLS DESCRIPTION (GROUND CONTROLS, CONTINUED)

MP 40 OPERATOR'S MANUAL

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS)

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS, CONTINUED)

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS, CONTINUED)

START-UP PROCEDURES

SHIFT CHECKS

GROUND OPERATION AND CHECKS

GROUND OPERATION AND CHECKS (CONTINUED)

GROUND OPERATION AND CHECKS (CONTINUED)

PLATFORM OPERATION AND CHECKS

BE SURE BOOM TRAVEL AREA IS CLEAR OF OBSTRUCTIONS.

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

PLATFORM OPERATION AND CHECKS (CONTINUED)

MP 40 OPERATOR'S MANUAL

PLATFORM OPERATION AND CHECKS (CONTINUED)

AWARNING

PLATFORM OPERATION AND CHECKS (CONTINUED)

PLATFORM OPERATION AND CHECKS (CONTINUED)

OPERATION

COLD WEATHER OPERATION

DRIVING AND STEERING

BRAKING

BOOMS, SUPERSTRUCTURE AND PLATFORM

GASOLINE ENGINE OPERATION

DUAL FUEL ENGINE OPERATION

GASOLINE OPERATION

GASOLINE TO PROPANE SWITCHING