Genie Simon MP Series Operator's Manual

Page 1

Issued: Sep 97 P/N 89-180592

Page 2

Introduction	iii
Machine Specifications	iv
Machine Diagrams
Range Diagram	v
General Arrangement Diagram	vi

SAFETY

Safety Symbols
Safety Rules and Precautions
Envirónmentally Hazardous Materials
Battery (Acid/ Lead)
Hydraulic Fluid
Safety-Related Decals
Safety and Control Decal Locations	1-14
Safety and Control Decal Descriptions	1-15

OPERATION

Unloading Procedures	2-3
Primary Machine Components	2-5
Operator Controls
Ground Controls
Platform Controls	2-10
Start-Up Procedures
Shift Checks	2-14
Machine Start-Up	2-15
Ground Operation and Checks	2-16
Platform Operation and Checks	2-18
Operation
Cold Weather Operation	2-21
Booms, Superstructure and Platform
Shut-Down Procedures	2-22
Emergency System and Procedures
Emergency Pump	2-23
Emergency Lowering	2-23
5, 5

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TABLE OF CONTENTS (CONTINUED)

MAINTENANCE


General Maintenance Tips
Shift Operational Checklist
Weekly Operation Checklist
Monthly Operational Checklist
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 (Partial)	A-5
11. Inspection and Maintenance	A-5
12. Training	A-5
13. Operation	A-5
14. Responsibilities of Manufacturer, Dealer, Purchaser,
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 Aerial Work Platform featuring OEM controls.

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

A 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.

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MACHINE SPECIFICATIONS


Working Height (from top of Pedestal) Platform Height	83 ft 8 in./ 25.5 m 77 ft 8 in./ 23.67 m
Horizontal Reach (Boom Angle 0°)	74 ft 9 in. / 22.78 m
Platform Capacity (Unrestricted)	500 lbs ./ 227 Kg
Platform Size	36 in. x 72 in. x 42 in./
	91 m x 1.83 m x 1.07 m
Stowed Length	39 ft 6 in ./ 12.04 m
Stowed Height (from top of Pedestal)	6 ft 0 in./ 1.83 m
Machine Width	6 ft. 10 in./ 2.08 m

Gross Weight (Approx.) (Note 1)	20,800 lbs. / 1,360.8 kg
Platform Rotation	1 80 °
Superstructure Rotation	215° ± 10°, either direction
Swing Bearing Bolt Torque	320 ft lbs. / 434 Nm/ 44.22 kg-m
Maximum Hydraulic Pressure	3000 psi / 207 bar/ 211 kg-cm ²
Hydraulic Tank Capacity	35 gal. / 132 Liters
Emergency Power System	Two 12 Volt DC Batteries
Main Power Source:
For Serial Number AEA01530	208 VAC, 3 Phase, 50 HZ
	30 hp @ 1,460 rpm electric motor
For Serial Number AEA01531	208 VAC, 3 Phase, 60 HZ
	30 hp @ 1,760 rpm electric motor

Page 6

MACHINE DIAGRAMS

RANGE DIAGRAM

ANGLE	-15°	0 °	15°	30°	45°	60°	70 °
REACH	25' 6"	26' 3"	24' 9"	21' 2"	15' 10"	9' 0"	3' 11"
RETRACTED	7.77 m	8.00 m	7.54 m	6.45 m	4.82 m	2.74 m	1.19 m
HEIGHT	2' 0"	10' 5"	18' 7"	26' 1"	24' 1"	37' 2"	39' 3"
RETRACTED	0.61 m	3.17 m	5.66 m	7.95 m	7.34 m	11.32 m	11.96 m
REACH	67' 8"	69' 11"	66' 11"	59' 0"	46' 8"	30' 10"	18' 11"
EXTENDED	20.62 m	21.31 m	20.39 m	17.98 m	14.24 m	9.39 m	5.76 m
HEIGHT	-9' 4"	10' 5"	29' 11"	47' 11"	63' 4"	75' 0"	80' 0"
EXTENDED	-2.84 m	3.17 m	9.11 m	14.60 m	19.30 m	22.86 m	24.38 m

Side reach measured from center of rotation.

NOTE: Diagrams show a standard MP80.

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GENERAL ARRANGEMENT DIAGRAM

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MP 80 ELECTRIC OPERATOR'S MANUAL

SECTION 1: SAFETY

[]!

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Safety Symbols
Safety Rules and Precautions	1-4
Environmentally Hazardous Materials
Battery (Acid/ Lead)	1-7
Hydraulic Fluid
Safety-Related Decals
Safety and Control Decal Locations
Safety and Control Decal Descriptions

Page 10

SAFETY SYMBOLS

This manual contains important information on the safe use of your 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 11

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.

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MP 80 ELECTRIC OPERATOR'S MANUAL

SAFETY RULES AND PRECAUTIONS

SAFETY RULES AND PRECAUTIONS (CONTINUED)

A DANGER

SECURE all tools and other loose items to prevent injury to persons working on or below the work platform.
DO NOT use scaffolding, ladders or similar items to extend your reach while on the work platform.
DO NOT attempt to climb down the boom assembly, if the machine fails while the operator's platform is raised or extended.
Since the machine may be operated from its ground controls, precautions should be taken to prevent unauthorized personnel from operating the work platform with the ground controls while the platform is in use.
DO NOT attempt to open any hydraulic line or component without first relieving all system pressures and shutting off fluid flow from the tank.
DO NOT allow anyone to tamper with, service or operate the machine from the ground control station while personnel are on the platform, except in an emergency.
DO NOT alter, modify or disable any safety devices or interlocks.
DO NOT 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.
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: raising, lowering or extending the boom; or swinging the superstructure; or, rotating or tilting the platform.
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 horseplay while operating this machine.

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SAFETY RULES AND PRECAUTIONS (CONTINUED)

Complete the "Operational Checklists" found in this manual (see Table of Contents) at designated intervals.
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.

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.

SAFETY RULES AND PRECAUTIONS

Page 14

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.

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.
Dispose of cooling water-antifreeze mixtures as special waste in accordance with the State and local regulations!

Page 15

SAFETY-RELATED DECALS

10-145100 Decal, "DANGER . ELECTROCUTION"

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

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MP 80 ELECTRIC OPERATOR'S MANUAL

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

Page 17

SAFETY-RELATED DECALS (CONTINUED)

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

Page 18


MP 80	FI FOTRIC	OPERATORS	ΜΔΝΠΔΙ

SAFETY RELATED DECALS

SAFETY-RELATED DECALS (CONTINUED)

10-148300 Decal, Platform Capacity

HYDRAULIC FLUID ONLY

10-151300 Decal, "Hydraulic Fluid Only"

Page 19

SAFETY-RELATED DECALS (CONTINUED)

10-264200 Decal, Ground Electrical Controls

10-284800 Decal, Ground Function Controls

Page 1-12

SAFETY RELATED DECALS

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MP 80 ELECTRIC OPERATOR'S MANUAL

SAFETY RELATED DECALS

SAFETY-RELATED DECALS (CONTINUED)

10-278100 Decal, Platform Controls

Page 21

SAFETY AND CONTROL DECAL LOCATIONS

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

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

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MP 80 ELECTRIC 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	10-012600	Decal, "Open tank valves"	1
6	10-007200	Decal, "ENSURE LOCKPIN IS DISENGAGED "	2
7	10-264200	Placard, Ground Electrical Controls	1
8	10-148300	Decal, "CAPACITY 500 LBS (225 kg)", Small	2
9	10-284800	Decal, Ground Function Controls	1
10	10-151300	Decal, " Hydraulic Fluid Only "	1
11	10-278100	Placard, "Platform Control"	1
12	10-139800	Decal, "Operator's Manual Enclosed"	1
13	10-121600	Decal, "Made in U.S.A."	1

SAFETY AND CONTROL DECAL DESCRIPTIONS

Page 23

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.

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MP 80 ELECTRIC 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	Decai, "DANGER", Platform	1
4	10-272600	Decal, "CAUTION, Safety Belt Lanyard"	1
5	10-012600	Decal, "Open tank valves "	1
6	10-007200	Decal, "ENSURE LOCKPIN IS DISENGAGED "	2
7	10-264200	Placard, Ground Electrical Controls	1
8	10-148300	Decal, "CAPACITY 500 LBS (225 kg)", Small	2
9	10-284800	Decal, Ground Function Controls	1
10	10-151300	Decal, "Hydraulic Fluid Only "	1
11	10-278100	Placard, "Platform Control"	1
12	10-139800	Decal, "Operator's Manual Enclosed"	1
13	10-121600	Decal, "Made in U.S.A."	1

SAFETY AND CONTROL DECAL DESCRIPTIONS

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MP 80 FLECTRIC OPERATOR'S MANUAL

OPERATION

SECTION 2: OPERATION

Page 26

Unloading Procedures Primary Machine Components	2-3 2-5
Operator Controls	2-6
Platform Controls	2-10
Start-Up Procedures
Shift Checks	2-14
Machine Start-Up	2-15
Ground Operation and Checks	2-16
Platform Operation and Checks	2-18
Operation
Cold Weather Operation	2-21
Booms, Superstructure and Platform	2-21
Shut-Down Procedures	2-22
Emergency System and Procedures
Emergency Pump	2-23
Emergency Lowering	2-23

Page 27

Lifting Lug Locations.

Install adapter weidment to the pedestal.
Position swing gear on the adapter weldment and install mounting bolts to hold gear to the weldment.
Position machine over the swing gear.

Page 28

Instal swing bearing bolts and torque (see Machine Specifications).
Install swing reducer (swing drive motor) assembly.
Adjust so the swing reducer pinion gear mates to the large swing gear with zero backlash and no preload.
Unlock and open both side compartment doors. Inspect all electrical and hydraulic connections for damage and security.
Connect battery cables to batteries if required. Check electrolyte level.
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.

September 1997

Page 29

Left Hand Side.

Page 30

September 1997

Page 31

OPERATOR CONTROLS DESCRIPTION (GROUND CONTROL)

ltem	Control	Location	Description
1.	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.
2.	Ground/ Off/ Platform Key	On Ground Console Panel	Three position main power "GROUND/ OFF/ PLAT- FORM" switch. Straight up position is "OFF".
	Swiich		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.
3.	Electric Motor	On Ground Console Panel	Two position switch to turn on the electric motor.
	Ownen		NOTE: Ground/ Off/ Platform key switch must be in "GROUND" position.
4.	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.
5.	Boom Up/ Down Toggle Switch	On Ground Console Panel	Flip and hold to "UP" to raise boom, and "DOWN" to lower main boom.
6.	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.
7.	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).
8.	Hour Meter	On Ground Console	Indicates total elapsed time that the engine has been operated in hours and tenths.

Page 32

September 1997

Page 33

OPERATOR CONTROLS DESCRIPTION (GROUND CONTROLS, CONTINUED)

ltem	Control	Location	Description
9.	Volt Meter	On Ground Console Panel	Indicates electrical system voltage.
10.	Circuit Breaker	On Ground Console Panel	Pops out when the 12 Volt electrical circuit is over- loaded. Push in to reset.
11.	Hydraulic Fluid Pressure Gauge (Not shown)	On Top of Ground Valves	Indicates hydraulic fluid pressure.

Page 34

Page 35

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.	Electric Motor On/ Off Toggle Switch	On Platform Console Panel	Two position toggle switch. Down is "OFF". Move toggle switch to the "UP" position to turn on the electric motor.
3.	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,
4.	Electric Motor Indicator Light	On Platform Console Panel	Red light indicates electric motor is operating.
5.	Foot Switch	On Platform Floor	Must be depressed to activate main or emergency hydraulic pump, allowing operation of any hydraulic function (boom or platform movement) from the platform. Depress foot switch before selecting function.
6. Boom Lift and		On Platform	Dual function lever.
	Swing Lever		Push lever forward to raise boom. Pull lever back to lower 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° continuously in either direction. Swing speed will be proportional to handle movement.
7.	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.

Page 36

OPERATOR CONTROLS (PLATFORM CONTROLS, CONTINUED)

Page 37

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS, CONTINUED)

				-
OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS, CONTINUED)
ltem	Control	Location	Description	R CO
8.	Function Speed Toggle	On Platform Console Panel	Press toggle up for "HIGH" function speed, down for "LOW" function speed for all proportional functions (boom and swing).	ERATO
9.	Sensor Override Button (Optional)	On Platform Console Panel	Press button to override the position sensor (if so equipped).	Ю
10.	Horn Button	On Platform Console Panel	Press button to sound warning horn.
11.	Platform Rotate	Below and to	Operate lever in direction of desired platform rotation.
	Lever	Platform Console Panel	Pull lever counterclockwise to rotate platform to the right (counterclockwise).
			Push lever clockwise to rotate platform to the left (clockwise).
12.	Platform Leveling	Below and to	Push lever forward to tilt platform forward.	V
	Levei	Platform Console Panel	Pull lever back to tilt platform back.

Page 38

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 acod 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, etc. Both compartment doors can be opened to inspect components inside.
____ 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 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.

Page 39

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.
Turn the electric motor switch to "ON" to activate the electric motor.
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 40

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.
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" 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.
- 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.

Page 2-16

START-UP PROCEDURES

Page 41

START-UP PROCEDURES

GROUND OPERATION AND CHECKS (CONTINUED)

• Press the "EMERGENCY STOP" button. All machine functions must stop. Pull the button out or twist to reset. Release the "MAIN PUMP" button.

With the electric motor off,

Press the "EMERGENCY PUMP" togale switch.
Press and hold the "BOOM" togale 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" togale switch and "BOOM" togale. Turn on electric motor.
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.
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 electric motor off.

Page 42

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 electric motor togale to the "ON" position to activate the electric motor.
Select machine functions speed: either fast, toggle switch "up", or slow, toggle switch "down".

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.
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.
Slowly return the lever to the center position.

START-UP PROCEDURES

Page 2-18

Page 43

START-UP PROCEDURES

PLATFORM OPERATION AND CHECKS (CONTINUED)

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 stowed 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.

Page 44

PLATFORM OPERATION AND CHECKS (CONTINUED)

Switch the machine "FUNCTION SPEED" togale to "LOW" and repeat the tests.
Press "EMERGENCY STOP" button. All functions must stop immediately.

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

Reset "EMERGENCY STOP" button by turning or pulling, and restart engine.
Move all levers and togales back to their neutral positions. Release the foot switch.

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

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

Page 2-20

START-UP PROCEDURES

Page 45

OPERATION

OPERATION

BE SURE BOOM TRAVEL AREA IS CLEAR OF OBSTRUCTIONS.

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 and swing gear teeth prior to operation.
Check that all valve levers operate smoothly, and return freely to the neutral position.

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

Each function can be selected by moving the appropriate lever 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.

Page 46

SHUT-DOWN PROCEDURES

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

NOTE: The electrical power system (battery and charger) is a self charging system.

Page 47

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 motor/ pump power. Operation from the ground controls overrides platform controls.

Press and hold the "PUMP" togale 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.

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.

Page 48

EMERGENCY LOWERING (CONTINUED)

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.

EMERGENCY SYSTEM AND PROCEDURES

Page 49

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 50

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 51

MP 80 ELECTRIC OPERATOR'S MANUAL

MAINTENANCE

SECTION 3: MAINTENANCE

Page 52

Opported Maintenance Tine
	3-3
Shift Operational Checklist	3-4
Weekly Operation Checklist	3-6
Monthly Operational Checklist	3-7
Quarterly Operational Checklist	3-9
Semi-Annual Operational Checklist	3-10
Lubrication Chart	3-12
Lubrication Diagram	3-13
Troubleshooting	3-14

Page 53

MP 80 ELECTRIC 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 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.
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 54

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. Keep vour machine clean!!

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

INITIAL

DESCRIPTION

1. Check machine for any prior-shift or transportation damage, i.e. missing parts, torn or loose hoses, hydraulic fluid leaks, torn or disconnected wires, 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 battery electrolyte level. Check battery terminals for tight connections and cleanliness.
5. 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.

Continued on following page .

Page 3-4

Page 55

MP 80 ELECTRIC OPERATOR'S MANUAL

SHIFT OPERATIONAL CHECKLIST

SHIFT OPERATIONAL CHECKLIST (CONTINUED)

INITIAL	DESCRIPTION
	6.	Check that all shutoff valves on hydraulic tank are open (parallel to flow).
	7.	Check hoses for worn areas.
	8.	Check hose carrier to verify that it is not bent or sagging.
	9.	Inspect safety equipment as required by OSHA, government and local rules.
	10.	Check platform gate latch for damage.
	11.	Check pivot pins for security.
	12.	Check that all warning and instructional decals are legible and secure.
	13.	Start motor. Check hydraulic pressure (see Machine Specifications).
	14.	When all pre-inspection checks have been completed, test the ground controls for proper operation.
	15.	Check emergency pumps for operation and pressure (see Machine Specifications).
	16	Check platform controls for proper operation

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
	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.

Page 56

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 hydraulic connections for leaks, corrosion and wear.

3. Lubricate swing bearing and drive pinion gear (see Lubrication Chart).

ADDITIONAL MAINTENANCE REQUIREMENTS FOR SEVERE USAGE APPLICATIONS

INITIAL

DESCRIPTION

4. Lubricate all grease fittings (see Lubrication Chart).
5. Check oil level in swing drive motor assembly (see Lubrication Chart).

Page 57

MP 80 ELECTRIC 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	DESCRIPTION
	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.
	4. 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.
	Check boom hose carrier for sag and damage. If damaged, have them repaired.
	7. Check torque of swing bearing bolts (see Machine Specifications).
	8. Check adjustment and security of swing drive motor assembly. There should be a slight amount of backlash between the turntable and pedestal when properly adjusted. Check torque of mounting bolts (see Machine Specifications).
	9. Check oil level in swing drive gear box (see Lubrication Chart).

Page 58

MONTHLY OPERATIONAL CHECKLIST (CONTINUED)

INITIAL	DESC	CRIPTION
	10.	Check that the boom does not drift with a full load, no hydraulic pres- sure (motor off) and the control valve in the "BOOM DOWN" position.
	11.	Inspect boom chains. Lubricate as required (see chart).
	12.	Check to make sure boom sections are not dented or bent.
	13.	Check that all adjustable flow valves are locked. Check settings if any are not locked.

Page 59

MP 80 ELECTRIC 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.

Page 60

SEMI-ANNUAL OPERATIONAL CHECKLIST

DATE: INSPECTED BY:

MODEL NUMBER: SERIAL NUMBER:

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

GENERAL INFORMATION

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

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

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

Page 3-10

SEMI-ANNUAL OPERATIONAL CHECKLIST

September 1997

Page 61

SEMI-ANNUAL OPERATIONAL CHECKLIST (CONTINUED)

INITIAL	DESCRIPTION
	8.	Drain and replace fluid from swing drive. If badly contaminated, it may be necessary to disassemble and inspect components.
	9.	Clean and lubricate the standard open swing bearing gear teeth with dry moly lube spray.
	EVE	RY YEAR
	10.	Drain and replace fluid from hydraulic reservoir. If badly contaminated, it may be necessary to disassemble and inspect components.
	EVERY TWO YEARS
	11.	Drain and replace fluid from swing drive motor assembly. If badly contaminated, it may be necessary to disassemble and inspect components.
ADDITIONAL MAINTENANCE REQUIREMENTS FOR SEVERE USAGE APPLICATIONS
	EVE	RY SIX MONTHS

• Drain and replace fluid from swing drive motor assembly.

Page 62

LUBRICATION CHART

NO.	ITEM	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.	Boom wear pads	Silicone spray.	Monthly or every 100 hours.**
10.	Valve spool linkage	WD 40 Spray or equivalent penetrating oil.	Monthly or every 100 hours.*
11.	Platform rotate mechanism	Hydraulic fluid.	Yearly.

* Whichever occurs first.

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

LUBRICATION CHART

Page 63

Page 64

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 around/ platform selector switch in the proper position?
Is the electric motor turned to the "ON" position?
Are all emergency stop buttons or switches released?
Is the high voltage box in the "ON" position?
Are all battery cables connected?
Are the batteries charged?
Are any wires pulled out or loose?

WHAT TO CHECK IF FUNCTIONS WILL NOT OPERATE:

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

5 N

Page 65

MP 80 ELECTRIC OPERATOR'S MANUAL

NDEX

INDEX

В

Boom Extend/ Retract Lever 2-11 Boom Lift and Swing Lever 2-11 Booms, Superstructure and Platform 2-21

С

Checks, Shift 2-14 Circuit Breaker 2-9 Cold Weather Operation 2-21 Controls, Ground 2-6 Controls, Platform 2-10

Е

Electrocution Hazard 1-4 Emergency Lowering 2-23 Emergency Pump 2-23 Emergency Stop Button 2-11 Emergency System and Procedures 2-23

F

Foot Switch 2-11 Function Speed Toggle 2-13

G

Ground Operation and Checks 2-16, 2-17

Η

Hour Meter 2-7 Hydraulic Fluid Pressure Gauge 2-9

М

Machine Start-Up 2-15

0

Off/ On/ Start Toggle 2-11 Operation 2-21

Ρ

Platform Operation and Checks 2-18

S

Safety Belts 1-4 Safety Rules and Precautions 1-4 Safety Symbols 1-3 Sensor Override Button (Optional) 2-13 Shift Checks 2-14 Shut-Down Procedures 2-22 Start-Up Procedures 2-14

U

Unloading Procedures 2-3

۷

Volt Meter 2-9

Page 66

OPERATOR'S MANUAL APPENDIX

APPENDIX

Page 67

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

March 1997

Page 68

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 69

OPERATOR'S MANUAL APPENDIX

Page A-4

Page 70

ANSI/ SIA A92.5-1993

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 71

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.

Page 72

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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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.

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ANSI/ SIA A92.5-1992

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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).

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7.12 Operation of the Aerial Platform. If a user is also the operator of an aerial platform, he shall have the responsibilities of operators specified in section 8 of this standard as well as responsibilities of users as specified in section 7 of this standard.

7.13 Assistance to Operator. If a user is unable to answer an operator's question(s) relating to rated capacity, intended use, maintenance, condition of the aerial platform, or safety of operation of the aerial platform the user shall obtain the proper information from the dealer, owner or manufacturer and provide that information to the operator before use of the aerial platform in the application of concern.

7.14 Shutdown of Aerial Platform. The user shall direct his operating personnel to cease operation of the aerial platform in case of any suspected malfunction(s) or any potentially hazardous condition(s) that may be encountered. Further information concerning safe operation shall be requested from the owner, dealer or manufacturer before further operation.

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

(a) Records of the operator(s) trained on each model of an aerial platform.
(b) Written records of the frequent and annual inspection shall be kept by the user when he performs the inspection(s). The records shall include the date of inspection, any deficiencies found, the corrective action recommended and identification of the person(s) performing the inspection.
(c) Written records of all repairs accomplished on the aerial platform shall include the date of any such repair, a description of the work accomplished and identification of the person(s) performing the repair.

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

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

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8. RESPONSIBILITIES OF OPERATORS

8.1 Basic Principles. The information in this standard must be supplemented by good judgement, safety control and caution in evaluating each situation. Since the operator is in direct control of the aerial platform, conformance with good safety practices in this area is the responsibility of the operator. The operator must make decisions on the use and operation of the aerial platform with due consideration for the fact that his own safety as well as the safety of other personnel in the platform is dependent on those decisions.

8.2 Manuals. The operator shall be aware that the operating and safety manuals, including the manual which defines the responsibilities of dealers, owners, lessors, lessees, users and operators are stored on the aerial platform and the location where they are stored. The operator shall be familiar with the manuals stored on the aerial platform and consult them when questions arise with respect to the aerial platform.

8.3 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(s) leaks.
(e) Cables and wiring harness.
(f) Loose or missing parts.
(g) Tires and wheels.
(h) Placards, warnings, control markings and operating manual(s).
(i) Outriggers, stablizers, extendible axles and other structures.
(j) Guardrail system.
(k) Items specified by the manufacturer.

8.4 Problems or Malfunctions. Any problems or malfunctions that affect the safety of operations shall be repaired prior to the use of the aerial platform.

8.5 Training. The operator shall be trained on the same model of aerial platform or one having operating characteristics consistent with the one to be used during actual work site operation. Under the direction of a qualified person, the trainee shall operate the aerial platform for a sufficient period of time to demonstrate proficiency and knowledge in the actual operation of the aerial platform. Care shall be taken to ensure the area of such operation has a minimum of obstacles and is conducive to training. Only properly trained and authorized personnel shall be permitted to operate the aerial platform.

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8.6 Before Operation. Before being authorized to operate the aerial platform, the operator shall have:

(a) Been instructed by a qualified person in the intended purpose and function of each of the controls.
(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.

8.7 Work Place Inspection. Before the aerial platform is used and during use, the operator 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.

8.8 During Operation. The aerial platform shall be used in accordance with this standard. The operator shall ensure the following before each elevation of the platform:

(a) Ensure the aerial platform is operated on a surface within the limits specified by the manufacturer.
(b) Ensure the outriggers, stabilizers, extendible axles or other stability enhancing means, are used as required by the manufacturer.
(c) Ensure that guardrails are installed and access gates or openings are closed per manufacturer's instructions.
(d) Ensure the load and its distribution on the platform and any platform extension(s) are in accordance with the manufacturer's rated capacity for that configuration.
(e) Ensure there is adequate clearance from overhead obstructions.
(f) Ensure that the minimum safe approach distances (M.S.A.D.) to energized power lines and parts are maintained. (See Fig. 3, page 23 of complete standard for examples of safe operating procedures.)
(g) Ensure all personnel in the platform are wearing fall protection devices and other safety gear as required at all times.

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8. RESPONSIBILITIES OF OPERATORS (CONTINUED)

8.9 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.

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

8.10 Warnings and Instructions. The operator shall ensure the operation of the aerial platform is in compliance with this standard.

8.10.1 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.

8.10.2 Precaution for 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.

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

8.10.4 Reporting Potentially Hazardous Locations. The operator shall immediately report to his supervisor any potentially hazardous location(s) (environment) which become evident during operation.

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

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

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

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

8.10.9 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.

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

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

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

8.10.13 Unusual Operating Support Conditions. 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.

8.10.14 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.

8.10.15 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.

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

8.10.17 Unauthorized Use. The operator shall implement means provided to protect against use by unauthorized person(s).

8.10.18 Misuse as a Jack. The boom and platform of the aerial platform shall not be used to jack the wheels off the ground unless the machine is designed for that purpose by the manufacturer.

8.10.19 Driving on Slopes. The aerial platform shall not be driven on grades, side slopes or ramps exceeding those for which the aerial platform is rated by the manufacturer.

8.10.20 Snagged Platform. If the platform or elevating assembly become caught, snagged or otherwise prevented from normal motion by adjacent structure or other obstacles such that control reversal does not free the platform, all personnel shall be removed from the platform before attempts are made to free the platform using ground controls.

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8. RESPONSIBILITIES OF OPERATORS (CONTINUED)

8.11 Assistance to Operator. If an operator encounters any suspended malfunction of the aerial platform, or any hazard or potentially unsafe condition relating to capacity, intended use or safe operation, he shall cease operation of the aerial platform and request further information as to safe operation from his management or the owner, dealer, or manufacturer before further operation of the aerial platform.

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

9. RESPONSIBILITIES OF LESSORS

9.1 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 responsibilities of lessors with due consideration of the knowledge that the unit will be carrying personnel.

9.2 Lessor. A lessor is a person(s) or entity who leases, rents, loans or otherwise provides an aerial platform to another party for the beneficial use of that party (the user). A lessor may also be a dealer, owner, lessee, user or operator.

9.2.1 Lessor as a Dealer. When a lessor uses the aerial platform as a dealer, he shall have the responsibilities of dealers as specified in section 5 of this standard.

9.2.2 Lessor as an Owner. When a lessor uses the aerial platform as an owner, he shall have the responsibilities of owners as specified in section 6 of this standard.

9.2.3 Lessor as a User. When a lessor uses the aerial platform as a user, he shall have the responsibilities of users as specified in section 7 of this standard.

9.2.4 Lessor as an Operator . When a lessor uses the aerial platform as an operator, he shall have the responsibilities of operators as specified in section 8 of this standard.

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ANSI/ SIA A92.5-1992

10. RESPONSIBILITIES OF LESSEES

10.1 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 responsibilities of lessees with due consideration of the knowledge that the unit will be carrying personnel.

10.2 Lessee. A Lessee is a Person(s) or entity to whom an aerial platform is provided by lease, rental, loan or other arrangement. A lessee may also be a user or operator.

10.2.1 Lessee as a Dealer. When a lessee uses the aerial platform as a dealer, he shall have the responsibilities of dealers as specified in section 5 of this standard.

10.2.2 Lessee as an Owner. When a lessee uses the aerial platform as an owner, he shall have the responsibilities of owners as specified in section 6 of this standard.

10.2.3 Lessee as a User. When a lessee uses the aerial platform as a user, he shall have the responsibilities of users as specified in section 7 of this standard.

10.2.4 Lessee as an Operator. When a lessee uses the aerial platform as an operator, he shall have the responsibilities of operators as specified in section 8 of this standard.

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Page 87

T SERIES WARRANTY

TEREX AERIALS , hereafter referred to as TEREX , warrants new products sold by it to be free from defects in material or workmanship starting at the date of delivery to the first rental or retail user and subject to the following conditions:

The complete machine, except for those items specifically excluded by this warranty, such as but not limited to, tires, engines, and batteries, which are warranted directly by their manufacturer, for twelve (12) months from date of delivery.
Structural components, consisting of Carrier Frame, Superstructure, Boom Section, Jibs and Stingers, for an additional forty-eight (48) months from date of delivery.

TEREX'S obligation and liability under this warranty is expressly limited, at TEREX'S option, to repairing or replacing with re-manufactured or new any parts which appear to TEREX upon inspection to have been defective in material or workmanship. Such parts shall be provided at no cost to the user, F.O.B. TEREX'S parts facility or other source at TEREX'S option. TEREX shall pay, to the extent established by it in its applicable published Product Support policy in effect at the time of shipment, the cost of labor to install any repaired or replacement part provided under this warranty. This warranty shall not apply to component parts or accessories of products not manufactured by TEREX and which carry the warranty of the manufacturer thereof or to normal maintenance, such as but not limited to engine tune-up, or to normal maintenance parts, such as but not limited to filters. TEREX MAKES NO OTHER WARRANTY, EXPRESSED OR IMPLIED, AND MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

TEREX'S OBLIGATION UNDER THIS WARRANTY SHALL NOT INCLUDE DUTY, TAXES OR ANY OTHER CHARGES WHATSOEVER, OR ANY LIABILITY FOR DIRECT, INDIRECT, INCIDENTAL, SPECIAL, OR CONSEQUENTIAL DAMAGES OR DELAY. If requested by TEREX, products or parts for which a warranty claim is made are to be returned to the designated location. Any improper use, including operation after discovery of defective or worn parts shall void this warranty. Improper use also includes operation beyond rated capacity, substitution of parts not approved by TEREX or any alteration, modification or repair by others in such manner as in TEREX'S sole judgement affects the Product materially and adversely, shall void this Warranty.

NO EMPLOYEE OR REPRESENTATIVE IS AUTHORIZED TO CHANGE THIS WARRANTY IN ANY WAY OR GRANT ANY OTHER WARRANTY UNLESS SUCH CHANGE IS MADE IN WRITING AND SIGNED BY AN OFFICER OF TEREX AT ITS HOME OFFICE.

REVERSE SIDE OF THE WARRANTY CERTIFICATE MUST BE COMPLETED AND SIGNED FOR WARRANTY TO BE VALID.

T SERIES WARRANTY

P/N 12261-225

CUSTOMER COPY

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

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)

ENVIRONMENTALLY HAZARDOUS MATERIALS

BATTERY (ACID/LEAD)

HYDRAULIC FLUID

SAFETY-RELATED DECALS

HYDRAULIC FLUID ONLY

SAFETY-RELATED DECALS (CONTINUED)

SAFETY-RELATED DECALS (CONTINUED)

SAFETY AND CONTROL DECAL LOCATIONS

MP 80 ELECTRIC OPERATOR'S MANUAL

SAFETY AND CONTROL DECAL DESCRIPTIONS

SAFETY AND CONTROL DECAL LOCATIONS (CONTINUED)

SAFETY AND CONTROL DECAL DESCRIPTIONS

OPERATION

SECTION 2: OPERATION

Table of Contents

Lifting Lug Locations.

OPERATOR CONTROLS DESCRIPTION (GROUND CONTROL)

OPERATOR CONTROLS DESCRIPTION (GROUND CONTROLS, CONTINUED)

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS)

OPERATOR CONTROLS (PLATFORM CONTROLS, CONTINUED)

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS, CONTINUED)

START-UP PROCEDURES

SHIFT CHECKS

GROUND OPERATION AND CHECKS

BE SURE BOOM TRAVEL AREA IS CLEAR OF OBSTRUCTIONS.

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)

PLATFORM OPERATION AND CHECKS (CONTINUED)

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

OPERATION

BE SURE BOOM TRAVEL AREA IS CLEAR OF OBSTRUCTIONS.

SAFE OPERATION BEGINS WITH A SAFE OPERATOR.

COLD WEATHER OPERATION

BOOMS, SUPERSTRUCTURE AND PLATFORM

SHUT-DOWN PROCEDURES

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

EMERGENCY LOWERING

EMERGENCY LOWERING (CONTINUED)

POSSIBLE CONDITION:

CORRECTIVE ACTION

A DANGER

EMERGENCY LOWERING (CONTINUED)

A DANGER

DO NOT TOUCH MACHINE !!!

CORRECTIVE ACTION

EMERGENCY LOWERING (CONTINUED)

A DANGER

DO NOT TOUCH MACHINE !!!!

ELECTROCUTION HAZARD!!!

CORRECTIVE ACTION

MAINTENANCE

SECTION 3: MAINTENANCE

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