Genie Terex® TA Series Operator's Manual

Page 1

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

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

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

Telephone: Facsimile:

(319) 352-3920 (319) 352-5727

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

Telephone: Facsimile:

(353) 21-353011 (353) 21-353368

Revised: Feb. '98 P/N 17321

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OPERATOR'S MANUAL

Table of Contents

THE OPERATOR MUST READ AND UNDERSTAND ALL OF THE INSTRUCTIONS IN THIS MANUAL BEFORE OPERATING THE AERIAL LIFT.

Description
Section No.
Introduction 1
Safety Rules 2
Specifications 3
Controls and Instruments 4
Before Operation Check 5
Operation 6
Unloading 7
Loading 8
Maintenance 9
Emergency Procedures10
Index11
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OPERATOR'S MANUAL
Introduction

Owners, Users and Operators:

Terex Aerials appreciates your choice of our aerial lift for your application. Our number one priority is user safety, which is best achieved by our joint efforts. We feel that you can make a major contribution to safety if you as the equipment user and operator:

  • 1. Comply with OSHA, Federal, State and Local Regulations.
  • 2. Read, understand and follow the instructions in this and other manuals supplied with this machine.
  • 3. Use good, safe work practices in a common sense way.
  • 4. Have only trained operators directed by informed and knowledgeable supervision - running the machine.

If there is anything in this manual that is not clear or which you believe should be added, please send your comments to the Technical Publications Department, Terex Aerials, 10600 West Brown Deer Rd., Milwaukee, WI, 53224 or call (414) 355-0802.

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

THESE SYMBOLS MEAN YOUR SAFETY IS INVOLVED! SEE NEXT PAGE FOR SPECIFIC INFORMATION. READ, UNDERSTAND AND FOLLOW ALL DANGER, WARNING AND CAUTION DECALS ON YOUR MACHINE.

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OPERATOR'S MANUAL

Introduction

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

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

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

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

Thank you!

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OPERATOR'S MANUAL

Safety

Section 2

Description Page No.
Safety 2-2
Training and Knowledge 2-2
Slip and Fall Prevention 2-3
To Prevent Tip-over 2-4
General Information 2-6
Operation in the Vicinity of Electrical Conductors 2-8
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OPERATOR'S MANUAL

Safety

IN ADDITION TO THE SPECIFIC MAINTENANCE AND OPERATING INSTRUCTIONS IN THIS MANUAL, THE OPERATOR MUST READ AND UNDERSTAND ALL INSTRUCTIONS IN THE INTRODUCTION, AND IN THE FOLLOWING SAFETY RULES SECTION.

  • 1. Do not operate this aerial lift until you have been trained in its operation. This aerial lift may only be operated by trained personnel, who have demonstrated their ability to do so safely.
  • 2. Do not operate this aerial lift until you have read and understood the Operator's Manual, EMI Safety Manual, and Manual of Responsibilities supplied with the aerial lift.
  • 3. Know OSHA, Federal, State and local regulations applicable to your job.
  • 4. Read and understand all decals and warnings on your aerial lift.
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OPERATOR'S MANUAL

Safety

  • 1. Do not attach fall protection devices (if required) to an adjacent structure while working from the aerial platform.
  • 2. Do not use planks, ladders, scaffolding or any other device on the platform to extend your reach or gain additional height.
  • 3. Always keep both feet on the platform floor while traveling and working with the aerial lift. Do not lean over or stand on platform guard railings.
  • 4. Keep platform, steps and shoes free from oil, mud, grease and other slippery substances. In cold weather, clear snow and ice from platform and steps.
  • 5. Make sure the platform guard rails are not damaged, are securely installed (if removable), and that the entry gate is closed after entering the platform.
  • 6. Make sure that fold down guard rails are up and locked in place (if so equipped). Rails should be folded only to enable passage through doorways.
  • 7. Do not attempt to climb down the boom if the machine fails while the platform is raised.
  • 8. Do not operate this machine while under the influence of any drugs or alcohol.
  • 9. Do not work on the platform if you are bothered by heights, seizures or dizzy spells.
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OPERATOR'S MANUAL

Safety

  • 1. Do not exceed the load capacity of the aerial lift. The load capacity includes the combined weight of personnel, tools, fixtures, accessories, etc.
  • 2. Check the load capacity of floors, ramps and bridges before driving or operating the aerial lift on them.
  • 3. Loads should be evenly distributed over the platform floor.
  • 4. Do not alter, disconnect or override any interlocks or other safety devices.
  • 5. This aerial lift is rated to operate in wind speeds up to 25 mph (11.18 m/ sec).
  • 6. Do not replace batteries with those of lesser weight (See "Specifications").
  • 7. With platform raised, operate aerial lift only on flat, firm and level prepared surfaces.
  • 8. Check clearances overhead, around and below the aerial lift before ; raising, lowering, extending or retracting the platform, or traveling to prevent contact with obstacles.
  • 9. Do not travel on slopes (grades) and ramps without first reading "Traveling on Grades and Ramps", later in this manual. This aerial lift is limited in the grades it can safely travel.
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OPERATOR'S MANUAL

Safety

To Prevent Tip-over (Continued)

  • 10. Before and during traveling:
    • A. Look in the direction of travel.
    • B. Avoid obstacles, bumps and potholes.
    • C. Maintain safe distance from all overhead objects.
    • D. Use a lookout if necessary!
  • 11. Do not raise the platform while positioned on trucks, trailers, railway cars, floating vessels, scaffolds, forklift trucks or similar equipment.
  • 12. Do not operate the aerial lift with wheels "cribbed" or positioned on blocks.
  • 13. Reverse travel should only be used to maneuver the aerial lift at job location.
  • 14. Care should be taken to keep electric cords, hoses, cables, ropes, etc. from becoming entangled in the aerial lift.
  • 15. Limit travel speed to existing conditions. Do not use high speeds when maneuvering or traveling in reverse.
  • 16. Do not tow this aerial lift. It is not equipped with a towing package!
  • 17. Always operate the controls in a smooth, steady manner.
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OPERATOR'S MANUAL

Safety

  • 1. Do not operate the aerial lift until it has been properly inspected, maintained and serviced. Any problems or malfunctions should be reported immediately to your supervisor, and operations stopped until corrected.
  • 2. See the " Before Operation " section in this manual for decal listing, and replace those that are missing or not legible.
  • 3. Always wear approved headgear, eye protection, foot protection and fall-protection (if required).
  • 4. Secure all tools and other materials in the platform to prevent them from accidentally falling or being knocked from the platform.
  • 5. When other vehicles or moving equipment are present, comply with all local ordinances, safety rules and warning rules for the workplace.
  • 6. Do not allow ground personnel around or under the raised platform.
  • 7. Do not allow ground personnel to tamper with, service or operate the machine using the ground controls while anyone is in the platform, except in an emergency.
  • 8. Do not use the aerial lift for horseplay, stunt driving or recreational use. Report any misuse of equipment to the appropriate personnel.
  • 9. Do not work on the platform if you are dizzy, unsteady, or feel physically impaired in any way.
  • 10. Do not raise, lower or drive the platform into stationary objects.
  • 11. Do not use the aerial lift to push or tow another vehicle.
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OPERATOR'S MANUAL

Safety

  • 12. Immediately report any unusual noises, vibrations or malfunctions of the machine to appropriate personnel. Machine shall be removed from service until diagnosis and any necessary repairs have been completed.
  • 13. When leaving the aerial lift, lower platform to "full down" position and remove key from ground control to prevent unauthorized use.
  • 14. It is not possible for us to foresee every situation that could arise during operation of this aerial lift. Even if we do not state specifically that a particular action should not be taken , that does not mean that it is safe to do so. Personal injury or damage to equipment may result. If in doubt, contact Terex Customer Service.
  • 15. Battery Care and Use:
    • A. Do not "jump start" any other vehicle with your aerial lift's batteries.
    • B. Batteries must be charged in a well-ventilated area free of flames, sparks or other such hazards. The vapors can explode if exposed to flames or sparks.

BATTERY ACID CAN CAUSE SERIOUS BURNS. IF ACID COMES IN CONTACT WITH SKIN OR EYES,

IMMEDIATELY FLUSH WITH WATER. SEEK MEDICAL ATTENTION.

  • C. Do not use the aerial lift as a welding ground.
  • D. Disconnect battery leads before performing any welding operations on the aerial lift.
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OPERATOR'S MANUAL

Safetv

• Operation in the Vicinity of Electrical Conductors

  • 1. If the platform, supporting structure or any other conductive part of the aerial lift contacts a non-insulated electrical conductor, the result may be SERIOUS INJURY OR DEATH for persons on or near the aerial lift.
  • 2. You, the owner of the electrical conductor and the electic utility must jointly determine the specific procedure to complete the job safely.
  • 3. Always verify that the electric utility has been consulted before beginning work.
  • 4. Except where electrical distribution and transmission lines have been de-energized and visible ground or effective barriers have been erected to prevent physical and arcing contact with the conductors, the following provisions shall be met:
    • A. Over lines, the operation of the aerial lift over electrical conductors is prohibited.
    • B. No part of the aerial lift, tools, equipment or personnel, during operation, shall come closer than the distance shown in the table below.
VOLTAGE RANGE MINIMUM SAFE CLEARANCE
(Phase to Phase) Feet Meters
0 to 300 Volts AVOID CONTACT
Over 300 V TO 50 kV 10 3.05
Over 50 kV TO 200 kV 15 4.60
Over 200 kV TO 350 kV 20 6.10
Over 350 kV TO 500 kV 25 7.62
Over 500 kV TO 750 kV 35 10.67
Over 750 kV TO 1000 kV 45 13.72
One foot (30.5 cm) additional clearance is required for every additional 30,000 volts.

TA41E/ TA50E

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OPERATOR'S MANUAL

Safetv
Operation in the Vicinity of Electrical Conductors (Continued)

  • 5. You must allow for platform sway, rock or sag, and electrical line movement.
  • 6 This aerial lift is not insulated, and does not provide protection from contact with or proximity to electrically charged conductor.

If Contact is Made

WARN ground personnel to stay well away from the aerial lift as contact will provide an electrical path to ground, leading to ELECTROCUTION, INJURY OR DEATH.

Have someone contact authorized personnel to disconnect the power supply touching the machine

  • AFTER POWER IS CUT, lower or move the platform as necessary, using platform controls or emergency procedures (see "Emergency Pump", later in this manual) as necessarv.
  • If it is not possible to disconnect the power supply , proceed as follows:
    • 1. Operating from the platform, attempt to move the aerial lift from contact with the electrical conductor.
    • 2. If the aerial lift cannot be removed from contact, the following precautions should be taken to avoid possible ELECTROCUTION to yourself and ground personnel:
      • DO NOT attempt to operate the aerial lift from the ground control. Α
      • DO NOT make contact with poles or other structures or equipment. Such con-В. tact will provide an electrical path to ground, leading to ELECTROCUTION, INJURY OR DEATH.
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OPERATOR'S MANUAL

Safety

Operation in the Vicinity of Electrical Conductors (Continued)

If Contact is Made (Continued)

If it becomes both POSSIBLE and NECESSARY for you to leave the aerial lift while still in contact with the electrical conductor, you must do so WITH EXTREME CAUTION :

  • 1. DO NOT make contact with both the aerial lift and the ground or other structures or equipment at the same time. They will be ENERGIZED! JUMP OFF the aerial lift with both FEET TOGETHER, and land with both FEET TOGETHER.
  • 2. HOP away from the area keeping FEET TOGETHER as ground will be ENERGIZED! DO NOT make contact with the ground or other structures or equipment with spaced body parts (hand and foot, for example, or both feet while walking or running), as this will lead to ELECTROCUTION, INJURY OR DEATH .

You must read the complete manual before proceeding with the operation or unloading of the aerial lift.

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OPERATION AND MAINTENANCE

Specifications

Section 3

Description

Page No.

TA41E Specifications Table 3-2
TA41E Range Diagram 3-3
TA41E General Arrangement Diagram 3-3
TA50E Specifications Table 3-4
TA50E Range Diagram 3-5
TA50E General Arrangement Diagram 3-5
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Specifications

Machine Specifications
Model TA41E
* Working Height
Platform Height
. 47 ft 10 in. (14.60 m)
. 41 ft 4 in. (12.60 m)
Horizontal Reach .23 ft 10 in. (7.60 m)
Stowed Height 6 ft 7 in. (2.00 m)
Stowed Length . 16 ft (4.865 m)
Platform Capacity (Unrestricted) 500 lbs. (225 kg)
Rated Number of Occupants in Platform 2
Platform Dimensions 47 in. X 24 in. (1.20 m X 0.60 m)
Platform Dimensions (Optional) 59 in. X 24 in. (1.5 m X 0.60 m)
Width . 5 ft 11 in. (1.80 m)
Wheelbase . 63 in. (1.60 m)
Inside Turning Radius 4 ft 3 in. (1.30 m)
Outside Turning Radius. 9 ft 3 in. (2.82 m)
Ground Clearance . 5.5 in. (14 cm)
Gross Vehicle Weight (Approx.) 14,580 lbs. (6,613 kg)
Superstructure Rotation 355°, non-continuous
Travel Speed-Platform Stowed 3.0 mph (5.0 kph)
Travel Speed-Platform Elevated 0.5 mph (0.8 kph)
Gradeability (on hard surface) 12° (21%)
Tires .250 - 15 (solid)
Hydraulic Fluid Capacity 6.9 gal. (26.0 liters)
Hydraulic Operating Pressure 2755 psi (190 bar) (194 kg-cm 2 )
Hvdraulic Pump Output 2.6 gpm (10 Lpm)
Power System (Electric). Eight 6-Volt batteries (48 VDC)
@ 217 amp/ hr
Battery Charger .40 amp, automatic
Electric Pump Motor 5.0 hp (3.7 kW)

CLEARANCE MUST BE ALLOWED FOR BODY PARTS OF PERSON-NEL IN PLATFORM AT THIS AND ALL OTHER WORK HEIGHTS.

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TEREX AERIALS

Specifications
Machine Specifications

Model TA50E

* Working Height
Platform Height
.55 ft (16.77 m)
.49 ft (14.70 m)
Horizontal Reach . 29 ft 10 in. (9.09 m)
Stowed Height .7 ft 7 in. (2.20 m)
Stowed Length . 17 ft 9 in. (5.64 m)
Platform Capacity (Unrestricted) 500 lbs. (225 kg)
Rated Number of Occupants in Platform 2
Platform Dimensions 47 in. X 24 in. (1.20 m X 0.60 m)
Platform Dimensions (Optional) 59 in. X 24 in. (1.5 m X 0.60 m)
Width . 6 ft 1 in. (1.85 m)
Wheelbase . 78 in. (1.98 m)
Outside Turning Radius. 12 ft 10 in. (4.00 m)
Ground Clearance . 4 in. (0.10 m)
Gross Vehicle Weight (Approx.) 14,330 lbs. (6,500 kg)
Superstructure Rotation 355°, non-continuous
Travel Speed-Platform Stowed 3.0 mph (5.0 kph)
Travel Speed-Platform Elevated 0.5 mph (0.8 kph)
Gradeability (on hard surface) 11.3 ° (20%)
Tires .250 - 15 (solid)
Hydraulic Fluid Capacity 7.75 gal. (29.0 liters)
Hydraulic Operating Pressure 2600 psi (180 bar) (183 kg-cm 2 )
Hydraulic Pump Output 3 gpm (11 Lpm)
Power System (Electric). Eight 6-Volt batteries (48 VDC)
@ 217 amp/ hr
Battery Weight (wet, each) 62 lbs. (28kg)
Battery Charger .40 amp, automatic
Electric Pump Motor 5.0 hp (3.7 kW)

CLEARANCE MUST BE ALLOWED FOR BODY PARTS OF PERSON-NEL IN PLATFORM AT THIS AND ALL OTHER WORK HEIGHTS.

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OPERATOR'S MANUAL

Controls and Instruments

Section 4

Page No.

-
Controls and Instruments4- -1
Aerial Control Station4- ·2
Aerial Control Station Controls Identification4- -3
Aerial Control Station Controls Description4 -4
Additional Controls and Warnings Description4- -11
Ground Control Station4- -18
Ground Control Station Controls Identification4- -19
Ground Control Station Controls Description4 -21

Controls and Instruments

This section is intended to familiarize the operator with the controls and instruments provided for the operation of this machine.

It should be emphasized, however, that merely knowing the controls is inadequate preparation for operating boom lift aerial platforms.

Do not attempt to operate the machine until all sections of this manual have been read and understood.

Description

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OPERATOR'S MANUAL

Controls and Instruments

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OPERATOR'S MANUAL

Controls and Instruments

Aerial Control Station Controls Identification
Key No. Control Description
1. Emergency Stop Switch
2. Foot Operated Switch
3. Drive Control Lever
4. Steer Switch
5. Lift 1 (Lower Riser Up/ Down) Control Lever
6. Lift 2 (Upper Riser Up/ Down) Control Lever
7. Lift 3 (Boom Up/ Down) Control Lever
8. Boom Zoom In/ Out Control Lever
9. Turret (Superstructure) Rotate Control Lever
10. Platform Level Control Lever
11. Platform Rotate Switch (Option)
12. Battery Condition and Hour Meter

13. Horn Button

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OPERATOR'S MANUAL

Controls and Instruments

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OPERATOR'S MANUAL

Controls and Instruments

Aerial Control Station Controls Description

1. Emergency Stop Switch. Push "in" to stop all functions in an emergency.

Pull out or rotate clockwise (depending on style used) to release switch and restore all functions.

The Emergency Stop switches at both the Aerial and Ground Control stations must be released to allow any functions to operate.

2. Foot Operated Switch. Mounted on platform floor. Step down on pedal to enable drive and lift controls.

Release pedal to halt all drive and lift functions from the platform.

Do not operate this switch other than by stepping down on the pedal with your foot.

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OPERATOR'S MANUAL

Controls and Instruments

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OPERATOR'S MANUAL

Controls and Instruments

Aerial Control Station Controls Description (Continued)

3. Drive Control Lever. Push lever forward to drive aerial lift forward. Pull lever back to drive aerial lift in reverse.

Vary the drive speed from zero to maximum by gradually moving the handle away from the center "off" position.

Release lever to stop movement. Lever is spring centered to the "off" position.

WITH THE PLATFORM SWUNG OVER THE STEERING WHEELS, USE CAU-TION WHEN SELECTING THE TRAVEL AND STEER DIRECTION.

TRAVEL AND STEER DIRECTION WILL BE OPPOSITE TO DRIVE CON-TROL LEVER MOVEMENT AND STEER SWITCH SELECTION.

4. Steer Switch. On end of drive control lever. Press and hold down the left side of the switch to turn steer wheels to the left, and the right side to turn right.

Release switch to hold steer angle. Switch will return to the "off" position.

Steering is not self-centering. Press and hold the switch in the opposite direction to straighten wheels.

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OPERATOR'S MANUAL

Controls and Instruments

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OPERATOR'S MANUAL

Controls and Instruments

Aerial Control Station Controls Description (Continued)

5. Lift 1 (Lower Riser) Up/ Down Control Lever. Push lever forward to raise the riser (lower boom section). Pull lever back to lower the riser.

Vary riser movement speed from zero to maximum by gradually moving the handle away from the center "off" position.

Release lever to stop movement. Lever is spring centered to the "off" position.

Each boom section can be raised and lowered independently.

6. Lift 2 (Upper Riser) Up/ Down Control Lever. Push lever forward to raise the riser (mid boom section). Pull lever back to lower the riser.

Vary riser movement speed from zero to maximum by gradually moving the handle away from the center "off" position.

Release lever to stop movement. Lever is spring centered to the "off" position.

Each boom section can be raised and lowered independently.

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OPERATOR'S MANUAL

Controls and Instruments

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OPERATOR'S MANUAL

Controls and Instruments

Aerial Control Station Controls Description (Continued)

7. Lift 3 (Boom Up/ Down) Control Lever. Push lever forward to move the upper boom section "up". Pull back to move the boom "down".

Vary boom movement speed from zero to maximum by gradually moving the handle away from the center "off" position.

Release lever to stop movement. Lever is spring centered to the "off" position.

Each boom section can be raised and lowered independently.

8. Boom Zoom In/ Out Control Lever. Pull lever back to move the upper boom section "out". Push lever forward to move the upper boom "in".

Vary boom movement speed from zero to maximum by gradually moving the handle away from the center "off" position.

Release lever to stop movement. Lever is spring centered to the "off" position.

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OPERATOR'S MANUAL

Controls and Instruments

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OPERATOR'S MANUAL

Controls and Instruments
Aerial Control Station Controls Description (Continued)

9. Turret Rotate Control Lever. Move lever forward to rotate the turret (super-structure) clockwise, to the back to rotate counterclockwise.

Vary rotation speed from zero to maximum by gradually moving the handle away from the center "off" position.

Release lever to stop movement. Lever is spring centered to the "off" position.

The turret rotates 360 degrees with an electric limit switch to stop continuous rotation.

10. Platform Tilt Control Lever. Move lever forward to manually tilt the platform forward (toward the boom).

Move lever to the back to manually tilt the platform back (away from the boom).

Release lever to stop movement. Lever is spring centered to the "off" position.

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OPERATOR'S MANUAL

Controls and Instruments

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OPERATOR'S MANUAL

Controls and Instruments
Aerial Control Station Controls Description (Continued)

11. Platform Rotate Switch (Option). Rotate the switch to the left to rotate the platform to the left (clockwise), if that option is fitted.

Rotate the switch to the right to rotate platform to the right (counterclockwise).

Release switch to stop movement. Switch will return to the "off" position.

Battery Condition and Hour Meter. The battery condition or level of charge is indicated by an LED display of 2 red, 3 yellow and 5 green illuminated bands.

At full charge all LED's are lit. As the batteries discharge, green LED's are progressively extinguished from right to left, followed by the yellow LED's.

When the first red LED begins to flash, this is a warning that the batteries are heavily discharged. Both red LED's flashing alternately indicates that the batteries require recharging and that the lift functions are about to be interrupted.

Hour Meter. The digital hour meter indicates the total usage of the machine in hours and tenths. It is "on" and counting whenever the power (either ground or platform), is turned on

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OPERATOR'S MANUAL

Controls and Instruments

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OPERATOR'S MANUAL

Controls and Instruments

Aerial Control Station Controls Description (Continued)

13. Horn Switch. Press and hold switch to sound "automotive type" warning horn.

Horn is intended for use as a signal to personnel in the area and is not a "motion" or "travel" alarm.

Additional Controls and Warnings Description

  • 14. High Speed Drive Cutout. With the platform raised, travel speed is automatically limited to 0.5 mph (0.8 kph). This condition is known as "creep" speed. To enable faster travel, move platform to the fully down and in position.
  • 15. Tilt Alarm. Sounds an audible warning (after approximately a three-second delay) whenever the aerial lift is five degrees or more out of level with the platform raised. Tilt alarm will sound until machine is returned to a level condition.
  • 16. Movement Alarm. Sounds an audible warning whenever the aerial lift is in motion. Alarm will cease when motion stops.
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OPERATOR'S MANUAL

Controls and Instruments

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OPERATOR'S MANUAL

Controls and Instruments

Ground Control Station Controls Identification
Key No. Control Description
1. Emergency Stop Switch
2. Master Switch
3. Power On Light
4. Cage (Platform) / Ground Selector Switch
5. Pump Enable Switch
6. Lift 1 (Lower Riser Up/ Down) Control Lever
7. Lift 2 (Upper Riser Up/ Down) Control Lever
8. Lift 3 (Boom Up/ Down) Control Lever
9. Boom Zoom In/ Out Control Lever
10. Turret (Superstructure) Rotate Control Lever
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OPERATOR'S MANUAL

Controls and Instruments

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OPERATOR'S MANUAL

Controls and Instruments

Ground Control Station Controls Description

  • 1
  • 1. Emergency Stop Switch. Push "in" to stop all functions in an emergency.

Pull out or rotate clockwise (depending on style used) to release switch and restore all functions.

With the Emergency Stop switch at the Ground Control station released, functions can be operated from the ground controls even though the Platform Emergency Stop switch has been pressed.

  • OFF ON
  • 2 Master Switch. Main power "On/ Off" two position switch. The full left position is "off". The full right position is "on".

With key switch "off", the key may be removed to prevent unauthorized operation.

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OPERATOR'S MANUAL

Controls and Instruments

Ground Control Station

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OPERATOR'S MANUAL

Controls and Instruments

Ground Control Station Controls Description (Continued)

3. Power On Light. Light is on when the main power key switch is turned to power "on".

4. Cage (Platform) / Ground Selector Switch. Two position selector switch. Left selects cage (platform) operation and right selects ground operation.

5. Pump Enable Switch. Press and hold switch while moving one of the boom levers to enable function.

Release switch to stop movement. Switch will return to the "off" position.

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OPERATOR'S MANUAL

Controls and Instruments

Ground Control Station

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OPERATOR'S MANUAL

Controls and Instruments

Ground Control Station Controls Description (Continued)

5. Lift 1 (Lower Riser) Up/ Down Control Lever. Push lever up to raise the riser (lower boom section). Pull lever down to lower the riser.

Vary riser movement speed from zero to maximum by gradually moving the handle away from the center "off" position.

Release lever to stop movement. Lever is spring centered to the "off" position.

Each boom section can be raised and lowered independently.

6. Lift 2 (Upper Riser) Up/ Down Control Lever. Push lever up to raise the riser (mid boom section). Pull lever down to lower the riser.

Vary riser movement speed from zero to maximum by gradually moving the handle away from the center "off" position.

Release lever to stop movement. Lever is spring centered to the "off" position.

Each boom section can be raised and lowered independently.

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OPERATOR'S MANUAL

Controls and Instruments

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OPERATOR'S MANUAL

Controls and Instruments

Ground Control Station Controls Description (Continued)

7. Lift 3 (Boom Up/ Down) Control Lever. Push lever up to move the upper boom section "up". Pull lever down to move the boom "down".

Vary boom movement speed from zero to maximum by gradually moving the handle away from the center "off" position.

Release lever to stop movement. Lever is spring centered to the "off" position.

Each boom section can be raised and lowered independently.

8. Boom Zoom In/ Out Control Lever. Pull lever up to move the upper boom section "out". Push lever down to move the upper boom "in".

Vary boom movement speed from zero to maximum by gradually moving the handle away from the center "off" position.

Release lever to stop movement. Lever is spring centered to the "off" position.

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OPERATOR'S MANUAL

Controls and Instruments

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OPERATOR'S MANUAL

Controls and Instruments

Ground Control Station Controls Description (Continued)

9. Turret Rotate Control Lever. Move lever up to rotate the turret (superstructure) clockwise, and down to rotate counterclockwise.

Vary rotation speed from zero to maximum by gradually moving the handle away from the center "off" position.

Release lever to stop movement. Lever is spring centered to the "off" position.

The turret rotates 360 degrees with an electric limit switch to stop continuous rotation.

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OPERATOR'S MANUAL

Controls and Instruments

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OPERATOR'S MANUAL

Controls and Instruments

Additional Ground Controls Description

  • 10. Emergency Pump. This machine has an emergency pump located on the hydraulic tank which can be operated from the ground control station to briefly operate the machine when the unit has lost power.
  • Move black handpump lever on the hydraulic tank to the left to operate all hydraulic functions and to the right to disengage the brake and drive axle.
  • Pump emergency hand pump to perform the desired function.
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OPERATOR'S MANUAL

Controls and Instruments

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OPERATOR'S MANUAL

Controls and Instruments

Additional Ground Controls Description

11. Emergency Rotation . The emergency rotation of the turret (superstructure) is performed by a mechanical override or the emergency pump.

For the mechanical override procedure, use a 1/2" square socket, extension and ratchet handle attached to the square extension shaft of the rotate drive gearbox.

For the emergency pump procedure, move black handpump lever on hydraulic tank to the left, activate the emergency pump, and move the rotate lever.

Care should be taken not to override the electrical rotation stop to avoid damaging the hoses which pass through the rotation ring.

Always rotate the machine to the normal stowed position by the shortest route.

After using emergency rotation, check hoses for damage.

Page 53

OPERATOR'S MANUAL

Before Operation Checks

Section 5

Description Page No.
What Needs to be Inspected? 5-2
Before Operation General Inspection Check List 5-3
Safety and Control Decal Locations 5-4
Decal Check List 5-5
What Should I Know?
To Check Operation, Interlocks, Cut-Outs and Warnings 5-6
Ground Checks 5-7
Emergency Operation From Ground Control Station if
Main Pump is Inoperable
5-9
Platform Checks 5-10
Emergency Operation From Ground Control Station if
Platform Controls Become Inoperable
5-15
Platform Capacity 5-16
Platform Guardrails and Gate 5-16
Platform Surface 5-16
Operating Clearances 5-16
Platform Loads 5-17
Travel Surfaces 5-17
Page 54

OPERATOR'S MANUAL

Before Operation Checks

What Needs to be Inspected?

Before each day's operation of the aerial lift, the operator MUST perform the General Inspection as outlined in the Check List that follows.

The purpose of the Operator's Inspection is to keep the aerial lift in proper working condition and to detect any signs of malfunction during normal operation between scheduled maintenance checks.

While it may not be the Operator's responsibility to perform mechanical maintenance, the Operator MUST be thoroughly familiar with the aerial lift and its proper care since their own safety is involved.

Model TA41E / TA50E Aerial Lift

Page 55

OPERATOR'S MANUAL

Before Operation Checks

Before Operation General Inspection Check List

Check each of the following items for security, leaks, missing components, hardware damage, evidence of cracks, deterioration, etc.

Check all visible wiring and hydraulic hoses for cracking, loose connections or wear.

If a problem is found with any of the following items, do not operate the aerial lift.

The operator is authorized to perform only the maintenance items listed in the "Maintenance" Section of this Manual. All other maintenance must be performed by a qualified Aerial Lift Technician.

Item Description Item Description
1. General visual inspection of all 10. Pivot pin security (all locations).
machine components. 11. Proper tilt alarm function.
2. Battery connections and electro-
lyte level (both sides).
12. Damaged electrical control switches.
3. Hydraulic fluid level (see "Main-
tenance" Section ).
13. All safety and control decals in place, legible and secure (see
4. Tightness of wheel lug nuts. "Decal Check List", following.
For Severe Duty Applications Add:
5. Tightness of drive motor nuts. For Seve ere Duty Applications Add:
5.
6.
Tightness of drive motor nuts.
Chafing or worn areas on hoses.
For Seve Description
5.
6.
7.
Tightness of drive motor nuts.
Chafing or worn areas on hoses.
Bent or sagging hose carrier.
For Seve
Item
14.
Description
Cylinder and valve spool boots.
5.
6.
7.
8.
Tightness of drive motor nuts.
Chafing or worn areas on hoses.
Bent or sagging hose carrier.
Worn areas on safety belts.
For Seve
Item
14.
15.
Description
Cylinder and valve spool boots.
Reduction drive unit oil.
5.
6.
7.
8.
Tightness of drive motor nuts.
Chafing or worn areas on hoses.
Bent or sagging hose carrier.
Worn areas on safety belts.
Secure safety belt connection
points.
For Seve
Item
14.
15.
16.
Description
Cylinder and valve spool boots.
Reduction drive unit oil.
Lubricate valve spool linkage.
Page 56

Page 57

OPERATOR'S MANUAL

Before Operation Checks

Decal Check List
Safety and Control Decals, TA41E / TA50E
ltem
No. Part No. Description Qty. Remarks
1 AS103 Decal, Ground Control 1 Ground box
2 AS105 Decal, Ground Control 1 Levers
3 10-130600 Decal, "DANGER", (Hazard listing) 1 At Ground Cntrl.
4 10-148300 Decal, "CAPACITY 500 Lbs (225 kg)" 1 4.5" (114mm)
5 10-150500 Decal, "DANGER", (Electrocution) 2 On both sides
6 A580 Decal, "Hydraulic Oil Only " 1
7 47011-0438 Decal, Platform Control 1 At Platform Cntrl.
8 A581/B Decal, "WARNING", (Hazard listing) 1 At Platform Cntrl.
9 10-139800 Decal, "Operators Manual Enclosed" 1
10 A1240A Decal, Towing Instructions 1 At Ground Cntrl.
11 A578 Decal, Towing Instructions 1 At Ground Cntrl.
12 A577 Decal, "Emergency Lowering" 1 At Hyd. Tank
13 A1373A Decal, Warning "After towing " 1 At Hyd. Tank
14 10-272600 Decal, "Caution, Safety Belt Lanyard" 2 On both sides
15 47011-0153 Decal, Direction Arrow
(Diamond shape, [4] arrows) 2 At both ends
16 10-269700 Decal, CE Label 1 European machines
17 10-284301 Decal, "Terex" Name (Dk. Gray, 3.12" [8 cm] high) 2
18 10-284401 Decal, "Aerials" Name (Dk. Gray, 3.12" [8 cm] high) 2
19 MK 181982 Decal, Terex Crown (5.12" [13 cm] high) 2
Page 58

OPERATOR'S MANUAL

Before Operation Checks

What Should I Know?

To Check Operation, Interlocks, Cut-Outs and Warnings

A DANGER

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

A COMPLETE VISUAL INSPECTION OF THE MACHINE MUST BE PERFORMED PRIOR TO OPERATIONAL CHECKS.

  • Ensure that emergency stop switch on ground control panel and platform console are disengaged. Pull out or rotate to reset, as required.
  • Turn and hold the main power key switch to the "ON" position to energize the electrical system. and press and hold the pump switch.

NOTE: If pump does not run, see "Emergency Operation", later in this section..

AWARNING

BE SURE BOOM TRAVEL AREA IS CLEAR OF OBSTRUCTIONS.

DO NOT OPERATE THE MACHINE IF THE FOLLOWING CHECKS RE-VEAL A DEFECT.

• Raise or extend the boom slightly, and push down on each of the three fastened corners of the tilt alarm . The alarm should sound as each corner is pressed beyond 5 degrees.

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

Page 59

OPERATOR'S MANUAL

Before Operation Checks

What Should I Know? (Continued)
To Check Operation, Interlocks, Cut-Outs and Warnings (Continued)
Ground Checks:

• Turn and hold the main power key switch to the "ON" position to energize the electrical system.

While performing operation checks of all the ground functions:

  • _____ Listen for any unusual noises during operation.
  • _____ Check for any vibration during function motion.
  • _____ Check for uneven or jerky operation.
  • _____ Check for hydraulic leaks.
  • _____ Check pivot and cylinder pins, where appropriate, for security. Ensure that all securing bolts are in place on each pin locking point.
  • Press and hold the pump switch.
  • Push the Lift 1 & 2 levers to move the risers "up" to the end of their movement.

Test the "Emergency Stop " function. While the riser is moving, press the Emergency Stop switch. All machine functions should stop. Reset Emergency Stop switch.

  • Return the risers to their stowed position by moving the Lift levers to the down position.
  • Operate the upper boom in the same manner as the risers.

While the platform is moving, release the switch. The boom should stop immediately.

Page 60

OPERATOR'S MANUAL

Before Operation Checks

What Should I Know? (Continued)

To Check Operation, Interlocks, Cut-Outs and Warnings (Continued)
Ground Checks (Continued):

  • Operate the boom zoom function by raising the upper boom section parallel to the ground, then moving the boom "out" and "in".
  • Operate the turret rotate (superstructure swing) function by moving the Rotate lever up and down for counterclockwise and clockwise rotation.
  • Return the machine to the stowed position.
  • Release the Pump switch.

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

Page 61

OPERATOR'S MANUAL

Before Operation Checks

What Should I Know? (Continued)

To Check Operation, Interlocks, Cut-Outs and Warnings (Continued)
Emergency Operation From Ground Control Station if Main Pump is Inoperable:
Emergency Pump

This machine has an emergency pump which can be operated from the top of the hydraulic tank to briefly operate the machine when it has lost power.

  • Turn the lever on the hydraulic tank to the left.
  • Pump the emergency hand pump to operate the desired function. (Pump handle is stowed beneath the ground controls.)
  • Operate the desired control lever.
Emergency Rotation

Emergency rotation of the turret (superstructure) can be performed by the emergency pump (see above) or by a mechanical override.

For the mechanical override procedure, use a 30 mm socket, extension and ratchet handle attached to the hexagon extension shaft of the rotate drive gearbox.

Care should be taken not to override the electrical rotation stop to avoid damaging the hoses which pass through the rotation ring. Always rotate the machine to the normal stowed position by the shortest route. After using emergency rotation, check hoses for damage.

Page 62

OPERATOR'S MANUAL

Before Operation Checks

What Should I Know? (Continued)

To Check Operation, Interlocks, Cut-Outs and Warnings (Continued)

Platform Checks:

  • Complete the Ground Operational Checks before you perform the Platform Checks.
  • Select the "PLATFORM" control position on the ground/ platform selector switch.
  • Enter the Platform. Close the gate securely and connect your fall protection to the platform.

BE SURE BOOM TRAVEL AREA IS CLEAR OF OBSTRUCTIONS.

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

  • Depress the foot operated switch, mounted on the floor of the platform.
  • Press the horn button briefly to check that the horn works.

While performing operation checks of all the platform functions:

  • _____ Listen for any unusual noises during operation.
  • _____ Check for any vibration during function motion.
  • _____ Check for uneven or jerky operation.
  • _____ Check for hydraulic leaks.
  • _____ Check pivot and cylinder pins, where appropriate, for security. Ensure that all securing bolts are in place on each pin locking point.
  • Slowly move the risers (lower and mid boom) control levers forward to operate the risers to the end of their movement.
Page 63

OPERATOR'S MANUAL

Before Operation Checks

What Should I Know? (Continued)

To Check Operation, Interlocks, Cut-Outs and Warnings (Continued)

Platform Checks (Continued):

• Return the risers to their stowed position by slowly pulling the control levers back.

ACTUATION OF THE RED "EMERGENCY STOP" SWITCH WILL AP-PLY BRAKES IMMEDIATELY!

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

  • While operating a boom function, press the emergency stop switch on the platform control console. All machine functions should stop. Reset emergency stop switch.
  • Operate the upper boom in the same manner as the risers.
  • Operate the optional platform rotate function (if so equipped) by turning the rotate switch in each direction.
  • Operate the platform tilt function by moving the platform tilt lever in each direction.
  • Operate the boom telescope function by raising the upper boom section parallel to the ground, then moving the boom "out" and "in".
  • Operate the turret rotate (superstructure swing) function by slowly moving the control lever forward to rotate the turret clockwise and back to rotate counterclockwise.
  • Return the machine to its stowed position.
Page 64

OPERATOR'S MANUAL

Before Operation Checks

What Should I Know? (Continued)

To Check Operation, Interlocks, Cut-Outs and Warnings (Continued)

Platform Checks (Continued):

• Slowly push the drive control lever forward. The machine should smoothly accelerate in the selected direction. Movement alarm sounds whenever the machine is in motion.

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

Page 65

OPERATOR'S MANUAL

Before Operation Checks

What Should I Know? (Continued)

To Check Operation, Interlocks, Cut-Outs and Warnings (Continued)
Platform Checks (Continued):

  • Operate the steer switch and check for proper steering control. Note position of the platform to the steering wheels.
  • Return the wheels to the straight ahead position.
  • Slowly return the drive control lever to the center "neutral" position. The machine should come to a complete stop.
  • Slowly move the drive control lever backward. The machine should smoothly accelerate in the selected direction. Movement alarm sounds whenever the machine is in motion.
  • Slowly return the drive control lever to the center "neutral" position. The machine should come to a complete stop.
  • Raise either boom slightly to activate the high speed drive cutout limit switches.
  • Move the drive control lever forward and back in turn. Machine should travel a maximum of 0.5 mph (0.8 kph). This condition is referred to as "creep" speed, and is the maximum rate of travel with the boom raised or extended.
  • Return the boom to the stowed position.
  • Move all levers and switches back to their "neutral" positions. Release the foot switch.

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

Page 66

OPERATOR'S MANUAL

Before Operation Checks

What Should I Know? (Continued)

To Check Operation, Interlocks, Cut-Outs and Warnings (Continued)

Emergency Operation From Ground Control Station if Platform Controls Become Inoperable:

  • 1. Remove foot from foot switch.
  • 2. Press the red emergency stop switch.
  • 3. Evaluate the nature of the failure.
  • 4. If unable to return to the ground using the platform controls, contact an experienced operator to lower the machine using the ground controls or 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 GROUND CON-TROLS OR EMERGENCY PUMP TO SAFELY LOWER THE PLAT-FORM.

5. Report the incident to your supervisor immediately.

Page 67

OPERATOR'S MANUAL

Before Operation Checks

What Should I Know? (Continued)
Platform Capacity

  • The capacity of the platform is posted on the platform and in the "Specifications" section of this manual.
  • The platform capacity is equal to the combined weight of personnel, tools and supplies to be carried in the platform. The combined weight of personnel, tools and supplies must not exceed the posted platform capacity.
  • Do not exceed the maximum number of personnel allowed on the platform. This information is posted on the platform and can be found in the "Specifications" section of this manual.
Platform Guardrails and Gate

  • Make sure the platform guard rails and toe plates are not bent or deteriorated. Check for cracked or broken welds.
  • Once in the platform, ensure that the entry gate is closed and latched .
Platform Surface

Make sure the platform deck surface is undamaged and free of oil, grease, loose materials or other substances which could cause a slip or fall.

Operating Clearances

  • Be sure the area through which you will be moving the aerial lift is free of obstacles.
  • Check clearances overhead, under and around the intended range of movement before: moving the boom up, down, in or out; tilting or rotating the platform; rotating the turret (superstructure), or traveling.
  • Use a lookout if necessary! Always look in the direction of intended movement of the machine, boom and platform, and maintain safe distances.
Page 68

OPERATOR'S MANUAL

Before Operation Checks

What Should I Know? (Continued)
Platform Loads

  • The capacity of the platform is based on the load being placed at any position in the platform. Even distribution is not necessary.
  • Position tools and supplies so that personnel on the platform do not trip over or collide with them.
  • Position tools and supplies so that they are not accidentally knocked off the platform.
Travel Surfaces

  • Surfaces to be traveled should be:
    • Able to support the weight of the aerial lift and its contents.
    • As level as possible whenever the platform is elevated.
    • Free from bumps and potholes .
    • Clean and free of debris and obstacles .
  • Make sure the grades to be traveled do not exceed the capabilities of the machine. Refer to "Specifications" and "Operation" sections for maximum front-to-back and side-to-side grades.
  • Ramps must be strong enough to support the weight of the aerial lift and its contents, and wide enough to provide sufficient side clearance beyond the wheels.
Page 69

OPERATOR'S MANUAL

Operation

Section 6

Description Page No.
Operation 6-2
Cold Weather Operation 6-3
Driving and Steering
Traveling on Level Surface 6-4
Traveling on Rough Terrain 6-6
Traveling on Grades (Slopes) and Ramps 6-6
Steering the Machine 6-10
Braking 6-12
Boom, Superstructure and Platform
Raising and Lowering the Boom 6-13
Extending and Retracting the Upper Boom 6-13
Swinging the Superstructure 6-14
Leveling the Platform 6-14
Rotating the Platform (with Option) 6-15
Shut Down Procedures 6-15
Page 70

OPERATOR'S MANUAL

Operation

A complete description of the individual controls and their operation can be found in the "Controls and Instruments" Section of this manual. The operator must read and understand the functions of all controls before operating the aerial lift.

Complete the "Before Operations Check" before operating the aerial lift.

If the aerial lift pump or motor fails, see "Emergency Operation" in the "Before Operation Checks" Section.

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

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

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

Page 71

OPERATOR'S MANUAL

Operation

Cold Weather Operation

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

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

Page 72

OPERATOR'S MANUAL

Operation

Driving and Steering
Traveling on Level Surface

  • 1. The platform can be raised or lowered when traveling on level surfaces.
    • With the platform raised, maximum travel speed is 0.5 mph (0.8 kph).

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

2. Route of travel must be clear of personnel, power lines, potholes, bumps, equipment and debris.

NOTE: The foot switch must be depressed to activate any of the machine functions using the platform controls.

3. Press the foot switch.

A CAUTION

Although the machine can be driven with the platform positioned at either end of the machine, the operator may find driving easier from the stowed position. The stowed position can be identified by the arrow decals on each end of the undercarriage.

If driving is attempted with the platform over the opposite axle, you must remember that all directions given to the steer and drive controls will be in reverse.

Page 73

OPERATOR'S MANUAL

Operation

Driving and Steering (Continued)
Traveling on Level Surface (Continued)

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

4. Limit travel speeds to existing factors, such as surface conditions, side clearances and congestion in the working area. Slowly push the drive control lever forward to provide forward travel, or pull the lever back for reverse travel.

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

NOTE: Movement alarm sounds whenever the vehicle is in motion.

Page 74

OPERATOR'S MANUAL

Operation

Driving and Steering (Continued)

Traveling on Level Surface (Continued)

5. The brakes are automatically applied when the drive control lever is moved to the center "neutral" position.

A WARNING

RELEASE OF THE DRIVE CONTROL LEVER OR ACTUATION OF THE PLATFORM "EMERGENCY STOP" SWITCH WILL APPLY BRAKES IMMEDIATELY!

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

Traveling on Rough Terrain

This machine is not equipped to travel on rough terrain.

Traveling on Grades (Slopes) and Ramps

This machine is capable of traveling on grades of 12° (21 %) front to back and 5° (9 %) side to side.

% Grade = (Vertical Rise/ Horizontal Distance) x 100 Example: 30" Rise over 10 ft (120") = .25 = 25%

Page 75

OPERATOR'S MANUAL

Operation

Driving and Steering (Continued)
Traveling on Grades (Slopes) and Ramps (Continued)

1. The boom and platform must be in the stowed position when traveling on grades (slopes) and ramps. If necessary, raise the platform only enough to prevent contact with the ground.

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

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

2. Route of travel must be clear of personnel and debris. Do not travel on grades or ramps that are wet, muddy, slippery or have poor traction.

NOTE: The foot switch must be depressed to activate any of the machine functions using the platform controls.

3. Press the foot switch.

Page 76

OPERATOR'S MANUAL

Operation

Driving and Steering (Continued)

Traveling on Grades (Slopes) and Ramps (Continued)

Although the machine can be driven with the platform positioned at either end of the machine, the operator may find driving easier from the stowed position. The stowed position can be identified by the arrow decals on each end of the undercarriage.

If driving is attempted with the platform over the opposite axle, you must remember that all directions given to the steer and drive controls will be in reverse.

Page 77

OPERATOR'S MANUAL

Operation

Driving and Steering (Continued)

Traveling on Grades (Slopes) and Ramps (Continued)

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

4. Slowly push the drive control lever forward to provide forward travel, or pull the lever back for reverse travel.

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

NOTE: Movement alarm sounds whenever the vehicle is in motion.

Use extreme caution when turning on a grade or ramp,

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

RELEASE OF THE DRIVE CONTROL LEVER OR ACTUATION OF THE PLATFORM "EMERGENCY STOP" SWITCH WILL APPLY BRAKES IMMEDIATELY!

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

Page 78

OPERATOR'S MANUAL

Operation

Driving and Steering (Continued)
Traveling on Grades (Slopes) and Ramps (Continued)

  • 6. The brakes are automatically applied when the drive control lever is moved to the center "neutral" position.
  • 7. It may be necessary to move the boom "up" slightly in order to prevent the platform from contacting the ground.
Steering the Machine

WITH THE PLATFORM SWUNG OVER THE STEERING WHEELS, USE CAUTION WHEN SELECTING THE STEERING DIRECTION. STEER-ING DIRECTION WILL BE OPPOSITE CONTROL MOVEMENT.

TA41E/ TA50E

Page 79

OPERATOR'S MANUAL

Operation

Driving and Steering (Continued)
Steering the Machine (Continued)

  • 1. Press the steer switch on the end of the drive control lever:
    • to the left for left turns.
    • to the right for right turns.

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

  • 2. Use extreme care in turning the machine.
    • No abrupt or sharp turns.
    • Ensure the turning area is clear of personnel, debris and pot holes.
    • Use extreme caution when turning on a grade or ramp.

Steering is not self-centering. Push and hold switch in the opposite direction to straighten wheels.

Page 80

OPERATOR'S MANUAL

Operation

Braking

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

RELEASE OF THE DRIVE CONTROL LEVER OR ACTUATION OF THE PLATFORM "EMERGENCY STOP" SWITCH WILL APPLY BRAKES IMMEDIATELY!

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

Page 81

OPERATOR'S MANUAL

Operation
Boom, Superstructure and Platform

NOTE: The following instructions are described using platform controls.

NOTE: Function speeds are generally proportional to lever movement.

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

Moving the Riser or Upper Boom "Up" or "Down"

  • 1. Check clearances overhead, around and below the intended path of travel of the platform, riser (lower boom) and upper boom to prevent contact with obstacles.
  • 2. Press the foot switch.
  • 3. Select whether riser (lower boom) or upper boom is to be repositioned.
  • 4. Push the selected boom control lever forward to move the boom "up".
  • 5. Pull the selected boom control lever back to move the boom "down".

The lever is spring centered to the "off" position.

Moving the Upper Boom "Out" or "In"

  • 1. Check clearances overhead, around and below the intended path of travel of the platform to prevent contact with obstacles.
  • 2. Press the foot switch.
  • 3. Pull the upper boom in/ out control lever back to move the boom section "out".
  • 4. Push the upper boom in/ out control lever forward to retract the boom section "in".

The lever is spring centered to the "off" position.

Issued: Aug '97 Page 6-13 TA41E/ TA50E
Page 82

OPERATOR'S MANUAL

Operation

Boom, Superstructure and Platform (Continued)
Rotating the Turret (Swinging the Superstructure)

  • 1. Check clearances overhead, around and below the intended path of travel of the turret, boom sections and platform to prevent contact with obstacles.
  • 2. Press the foot switch.
  • 3. Move the rotate (swing) control lever forward to rotate the turret clockwise.
  • 4. Move the rotate (swing) control lever back to rotate the turret counterclockwise.

The lever is spring centered to the "off" position.

Tilting the Platform

  • 1. Check clearances overhead, around and below the intended path of travel of the platform to prevent contact with obstacles.
  • 2. Press the foot switch.
  • 3. Move the tilt lever forward to tilt the platform forward.
  • 4. Move the tilt lever back to the left to tilt backward.

The switch is spring centered to the "off" position.

Page 83

OPERATOR'S MANUAL

Operation

Boom, Superstructure and Platform (Continued)
Rotating the Platform (with option)

  • 1. Check clearances overhead, around and below the intended path of travel of the platform to prevent contact with obstacles.
  • 2. Press the foot switch.
  • 3. Turn the platform rotate switch to the left to rotate the platform to the left (clockwise).
  • 4. Turn the platform rotate switch to the right to rotate the platform to the right (counterclockwise).

The switch is spring centered to the "off" position.

Shut-Down Procedures

  • When finished with the aerial lift, place the machine in the stowed position (platform fully in and down, and over the rear of the undercarriage.
  • Park the machine on a level surface (preferably protected from weather). Secure to prevent vandalism and to discourage children from climbing or playing on it.
  • Exit the platform.
  • Turn off the main power switch.
  • Remove the key to prevent unauthorized operation.
Page 84

OPERATOR'S MANUAL

Unloading

Section 7
Description
Page No.
Unloading the Aerial Lift Under Its Own Power 7-2
Initial Unloading of the Aerial Lift 7-4
Unloading the Aerial Lift NOT Under Its Own Power 7-5
Lifting With Crane 7-7
Page 85

OPERATOR'S MANUAL

Unloading

Unloading the Aerial Lift Under Its Own Power

ONLY TRAINED OPERATORS EXPERIENCED WITH THE AERIAL LIFT CONTROLS ARE TO UNLOAD THE MACHINE.

  • Inspect the outside of the machine for damage (including the underside). Inspect all hoses, boom sections and cables for chafing or road damage. Confirm that all swing bearing bolts are tight (refer to specifications).
  • Unlock and open side compartments. Inspect all electrical and hydraulic connections for damage and security.
  • Connect battery cables to batteries if required. Check electrolyte level.
  • Check fluid level on the hydraulic tank, and add fluid as required (see Lubrication Chart).
  • Close side compartment covers.
  • Ensure the unloading ramps have adequate capacity to support the aerial lift, and are wide enough to allow sufficient side clearance beyond the wheels.
  • Perform procedures indicated in "Before Operation Checks", earlier in this manual.
  • Remove all machine tie downs. Remove wheel chocks, if used. Switch the Ground/ Platform key switch to the Platform position.
  • Attach the machine to a winch for the unloading procedure.
Page 86

OPERATOR'S MANUAL

Unloading (Continued)

Unloading the Aerial Lift Under Its Own Power (Continued)

ALWAYS ATTACH THE MACHINE TO A WINCH WHEN LOADING OR UNLOADING FROM A TRUCK OR TRAILER. CONNECT WINCH CABLE TO THE TIE DOWN LUGS ON THE UNDERCARRIAGE. UN-ASSISTED LOADING OR UNLOADING OF ANY MOBILE PLATFORM IS NOT RECOMMENDED.

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

DO NOT ALLOW ANYONE ON THE AERIAL LIFT OUTSIDE THE PLAT-FORM WHILE UNLOADING.

Tie Down Lug Location (4 Places)

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OPERATOR'S MANUAL

Unloading (Continued)

Unloading the Aerial Lift Under Its Own Power (Continued)

  • Enter the platform. Close the gate securely and connect the safety belt to the platform. Test all platform functions.
  • Raise the boom so that the platform will clear any obstacles as the machine is driven down the loading ramp. With either boom raised slightly, machine will travel only at "Creep" speed.

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

THE WINCH OPERATOR AND MACHINE OPERATOR MUST COOR-DINATE MOVEMENT WHILE UNLOADING THE MACHINE. ALLOW THE WINCH TO HELP THE MACHINE OPERATOR CONTROL THE SPEED OF DESCENT.

• Carefully drive the machine off the truck or trailer with the assistance of the winch.

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

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

Initial Unloading of the Aerial Lift

Upon initial unloading of the machine the Warranty Form must be completed and returned in order to activate the Terex Limited Warranty.

An Operator's Manual and a Terex Limited Warranty are included with each machine leaving the factory.

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OPERATOR'S MANUAL

Unloading (Continued)

Unloading the Aerial Lift NOT Under Its Own Power

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

  • Inspect the outside of the machine for damage (including the underside). Inspect all hoses, boom sections and cables for chafing or road damage. Confirm that all swing bearing bolts are tight (refer to specifications).
  • Unlock and open side compartments. Inspect all electrical and hydraulic connections for damage and security.
  • Check fluid level on the hydraulic tank, and add fluid as required (see Lubrication Chart).
  • Close side compartment covers.
  • Ensure the unloading ramps have adequate capacity to support the aerial lift, and are wide enough to allow sufficient side clearance beyond the wheels.

THIS PROCEDURE REQUIRES RELEASING THE WHEEL BRAKES, WHICH MEANS THERE IS NOTHING TO STOP THE MACHINE'S TRAVEL.

MACHINE WILL ROLL FREELY ON SLOPES. BE ON GUARD AGAINST RUNAWAY. MOVEMENT SPEED SHALL NOT EXCEED 3 M.P.H. (5 K.P.H.). DO NOT DRIVE MACHINE WITH BRAKES RE-LEASED.

  • 1. Raise the platform sufficiently to clear the ground during unloading. See "Emergency Operation from Ground Control" procedures indicated in "Before Operation Checks", earlier in this manual.
  • 2. Remove all machine tie downs.
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OPERATOR'S MANUAL

Unloading (Continued)

Unloading the Aerial Lift NOT Under Its Own Power

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

DO NOT ALLOW UNNECESSARY PERSONNEL ON OR AROUND THE AERIAL LIFT WHILE UNLOADING.

Tie Down Lug Location (4 Places)

3. Attach the machine to a winch for the unloading procedure. Make sure the winch has adequate capacity to restrain the weight of the aerial lift.

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OPERATOR'S MANUAL

Unloading (Continued)

Unloading the Aerial Lift NOT Under Its Own Power (Continued)

  • 4. Move black handpump lever on the hydraulic tank to the right to disengage the brake and drive axle..
  • 5. Remove wheel chocks, if used. After unblocking the wheels, the machine will be ready to be moved; however, there is no provision for steering the machine.

THE WINCH OPERATOR MUST CAREFULLY CONTROL MOVEMENT WHILE UNLOADING THE MACHINE. ALLOW THE WINCH TO CON-TROL THE SPEED OF DESCENT.

  • Carefully roll the machine off the truck or trailer with the assistance of the winch.
  • After primary power has been restored to the machine, return the black handpump • lever on the hydraulic tank to the neutral position.
  • The machine is now ready for normal operation.

Lifting With Crane

When lifting the machine with a crane, the tie down lugs may be used as lifting lugs.

AWARNING

THE LIFTING CRANE AND CHAINS SHOULD BE STRONG ENOUGH TO LIFT THE MACHINE. REFER TO MACHINE SPECIFICATIONS.

All booms should be in the stowed position.

Lift the machine straight up.

Slowly set the machine down on a level surface, making certain the area is clear of personnel and debris.

Revised: Feb. '98

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OPERATOR'S MANUAL

Loading

Section 8
Description

Page No.

Loading the Aerial Lift Under Its Own Power 8-2
Loading the Aerial Lift NOT Under Its Own Power 8-5
Lifting With Crane 8-7
Tie Down of the Aerial Lift 8-8
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OPERATOR'S MANUAL

Loading

Loading the Aerial Lift Under Its Own Power

ONLY TRAINED OPERATORS EXPERIENCED WITH THE AERIAL LIFT CONTROLS ARE TO LOAD THE MACHINE.

The booms and platform should be in the stowed position when the machine is being transported. Do not operate the machine while it is being transported.

  • Ensure the unloading ramps have adequate capacity to support the aerial lift, and are wide enough to allow sufficient side clearance beyond the wheels.
  • Perform procedures indicated in "Before Operation Checks", earlier in this manual.

ALWAYS ATTACH THE MACHINE TO A WINCH WHEN LOADING OR UNLOADING FROM A TRUCK OR TRAILER. CONNECT WINCH CABLE TO THE TIE DOWN LUGS ON THE UNDERCARRIAGE. UN-ASSISTED LOADING OR UNLOADING OF ANY MOBILE PLATFORM IS NOT RECOMMENDED.

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

DO NOT ALLOW ANYONE ON THE AERIAL LIFT OUTSIDE THE PLAT-FORM DURING THE LOADING PROCEDURE.

Page 93

OPERATOR'S MANUAL

Loading (Continued)

Loading the Aerial Lift Under Its Own Power (Continued)

Tie Down Lug Location (4 Places)

  • 1. Attach the machine to a winch for the loading procedure. Make sure the winch has adequate capacity to pull the weight of the aerial lift.
  • 2. Select the "PLATFORM" control position on the ground/ platform key switch.
  • 3. Enter the platform. Close the gate securely and connect the safety belt to the platform. Test all platform functions.
  • 4. Raise the boom so that the platform will clear any obstacles as the machine is driven down the loading ramp. With either boom raised slightly, machine will travel only at "Creep" speed.
Page 94

OPERATOR'S MANUAL

Loading (Continued)

Loading the Aerial Lift Under Its Own Power (Continued)

TO AVOID SERIOUS PERSONAL INJURY OR DEATH, ENSURE THAT THE MACHINE IS IN "CREEP" DRIVE SPEED WHILE LOADING ONTO A TRUCK OR TRAILER.

THE WINCH OPERATOR AND MACHINE OPERATOR MUST COOR-DINATE MOVEMENT WHILE LOADING THE MACHINE. AVOID THE POSSIBILITY OF THE WINCH TRYING TO PULL A STATIONARY MA-CHINE.

5. Carefully maneuver the machine onto the truck or trailer with the aid of the winch.

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

  • 6. Block or chock the front and rear wheels to prevent unexpected rolling
  • 7. Tie the aerial lift to the truck or trailer bed. See "Tie Down of the Aerial Lift", later in this section.
Page 95

OPERATOR'S MANUAL

Loading (Continued)

Loading the Aerial Lift NOT Under Its Own Power

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

Ensure the unloading ramps have adequate capacity to support the aerial lift, and are wide enough to allow sufficient side clearance beyond the wheels.

THIS PROCEDURE REQUIRES RELEASING THE WHEEL BRAKES, WHICH MEANS THERE IS NOTHING TO STOP THE MACHINE'S TRAVEL.

MACHINE WILL ROLL FREELY ON SLOPES. BE ON GUARD AGAINST RUNAWAY. MOVEMENT SPEED SHALL NOT EXCEED 3 M.P.H. (5 K.P.H.). DO NOT DRIVE MACHINE WITH BRAKES RE-LEASED.

1. Raise the platform sufficiently to clear the ground during loading. See "Emergency Operation from Ground Control" procedures indicated in "Before Operation Checks", earlier in this manual.

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

DO NOT ALLOW UNNECESSARY PERSONNEL ON OR AROUND THE AERIAL LIFT DURING THE LOADING PROCEDURE.

Page 96

OPERATOR'S MANUAL

Loading (Continued)

Loading the Aerial Lift NOT Under Its Own Power (Continued)

  • 2. Attach the machine to a winch for the loading procedure. Make sure the winch has adequate capacity to pull the weight of the aerial lift.
  • 3. Block or chock the front and rear wheels to prevent unexpected rolling

Tie Down Lug Location (4 Places)

  • 4. Move black handpump lever on the hydraulic tank to the right to disengage the brake and drive axle..
  • 5. Unblock the wheels. The machine is now ready to be winched onto the truck or trailer; however, there is no provision for steering the machine.
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OPERATOR'S MANUAL

Loading (Continued)

Loading the Aerial Lift NOT Under Its Own Power (Continued)

THE WINCH OPERATOR MUST CAREFULLY CONTROL MOVEMENT WHILE LOADING THE MACHINE.

  • 6. Carefully pull the machine onto the truck or trailer using the winch.
  • 7. Block or chock the front and rear wheels to prevent unexpected rolling
  • 8. Tie the aerial lift to the truck or trailer bed. See "Tie Down of the Aerial Lift", later in this section.
Lifting With Crane

When lifting the machine with a crane, the tie down lugs may be used as lifting lugs.

THE LIFTING CRANE AND CHAINS SHOULD BE STRONG ENOUGH TO LIFT THE MACHINE. REFER TO MACHINE SPECIFICATIONS.

All booms should be in the stowed position.

Lift the machine straight up.

Slowly set the machine down on a level surface, making certain the area is clear of personnel and debris.

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OPERATOR'S MANUAL

Loading (Continued)

Tie Down of the Aerial Lift

1. Confirm that the boom sections are fully retracted, and that the platform will not contact any other item, including the bed of the truck or trailer.

A CAUTION

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

  • 2. The negative battery cables should be disconnected for long distance transport.
  • Tie down locations are located on all four corners of the undercarriage. Use four (4) 1/2 inch, "Grade 7" chains from each of the tie down lugs, and run the chains as shown in the diagram. (Refer to illustration on facing page.)

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

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OPERATOR'S MANUAL

Loading (Continued)

Tie Down of the Aerial Lift (Continued)

Tie Down of the Aerial Lift (Recommended Method).

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OPERATOR'S MANUAL

Maintenance

Section 9

Description Page No.
Introduction 9-3
Maintenance Schedule 9-4
Owner's Inspection Records 9-4
Lubrication 9-4
Lubrication Diagram 9-6
Recommended Lubrication Schedule 9-7
Environmentally Hazardous Materials
Battery (Acid/ Lead) 9-8
Hydraulic Fluid 9-8
Hydraulic Fluid 9-9
Hydraulic Pressure Check 9-10
Hydraulic Fluid Filter Check 9-10
Battery Charger 9-11
Battery Charger Troubleshooting 9-12
Troubleshooting 9-13
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