Genie Terex® TA Series Operator's Manual

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Issued: JUN 97 P/N 17318

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OPERATOR'S MANUAL

The operator must read and understand all the instructions in this manual before operating the aerial lift.

DESCRIPTION

SECTION NO.

INTRODUCTION	J. .		٠	•		•	•		•	•	•	•	•	٠	•		1
SAFETY				•	•		•	•	•					•		•	2
SPECIFICATION	IS .			•	•	•	•	·			•		•	•		•	3
CONTROLS AN	D INS	STR	UM	EN'	TS	•	•		•	•		•	•	•	•		4
BEFORE OPER	ATIO	NS (	СН	ECł	<	•				•	•	•			•	•	5
OPERATION .				•	•		•	•	•	·	•		•	•	•	•	6
UNLOADING .			•	•	•		•	•	•	•	•			•	•	٠	7
LOADING			·	·		•	•		·								8
MAINTENANCE		•											•			•	9
	ROC	EDI	JRE	ΞS								•	•				10
INDEX		•	•					•	•	·	٠			•	•		11

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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 users and operators:

1. Comply with OSHA, Federal, State, and Local Regulations.
2. Read, Understand, and Follow the instructions in this and other manuals supplied with this aerial lift.
3. Use Good, Safe Work Practices in a common sense way.
4. Only have trained operators directed by informed and knowledgeable supervision running the aerial lift.

If there is anything in this manual that is not clear or which you believe should be added, please send your comments to Customer Service, Terex Aerials, 106 12th Street, S.E., Waverly, Iowa 50677-9466; or contact us by telephone at (319) 352-3920 or fax at (319) 352-5727.

Thank you!

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OPERATOR'S MANUAL

SAFETY

SECTION 2 DESCRIPTION

PAGE NO.

TRAINING AND KNOWLEDGE	•	•	•	•	·	•	·	•	2 - 1
TO PREVENT TIP - OVER .						•	•		2 - 1
SLIP AND FALL PREVENTION							·	•	2 - 2
GENERAL INFORMATION .		•	•	•		•			2 - 3
OPERATION NEAR ELECTRIC	AL	СС	DNE	)UC	сто	DRS	S.	•	2 - 5

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OPERATOR'S MANUAL

SAFETY

In addition to the specific instructions in this manual, the operator must understand the general safety rules:

1. Do not operate this aerial lift until you have been trained in its operation. This equipment 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.

1. Do not exceed the load capacity of the aerial lift. The load capacity includes combined weight of personnel, tools, fixtures, accessories, etc.
2. 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.
3. Check the load capacity of floors, ramps, and bridges before operating or driving the aerial lift on them.
4. Loads should be evenly distributed over the platform floor.

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OPERATOR'S MANUAL

SAFETY

5. Do not alter, disconnect, or override any interlocks or other safety devices.
6. This aerial lift is rated of use in a 25 M.P.H. wind. Do not use this aerial lift in winds in excess of 25 M.P.H.
7. Check clearances and overhead around and below the platform before raising, lowering, or traveling to prevent contact with obstacles.
8. Do not travel on slopes (grades) and ramps without first reading the travel section of this manual. This aerial lift is limited in the grades it can safely travel.
9. 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!
10. Do not raise the platform while positioned on trucks, trailers, railway cars, floating vessels, scaffolds, or similar equipment.
11. Do not operate aerial lift with wheels "cribbed" or positioned on blocks.
12. Reverse travel should only be used to maneuver the aerial lift at job location.
13. Care should be taken to keep electric cords, hoses, cables, ropes, etc. from becoming entangled in the aerial lift.
14. Limit travel speed to existing conditions. Do not use high speeds when maneuvering or traveling in reverse.
15. Always travel up or down slopes or grades with platform pointed down slope and with boom in stowed position (fully lowered and "in" or retracted).
16. Do not tow aerial lift unless it is equipped with a towing package!
17. Always operate controls in a smooth controlled manner.
18. Each person in the aerial platform must wear a safety belt at all times.

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OPERATOR'S MANUAL

SAFETY

1. Keep platform, shoes, and steps free from oil, mud, grease, and other slippery substances.
2. Do not use planks, ladders, scaffolding, or any other device on the platform to obtain greater height or extend working area.
3. Always keep both feet on platform floor while working and traveling with aerial lift. Do not lean over or stand on platform guard-railings.
4. Make sure the platform guardrails are not damaged and the entry gate is closed after entering the platform.

1. Secure all tools and other materials in the platform to prevent them from accidently falling out or being knocked off from the platform.
2. When other vehicles or moving equipment are present, comply with all local ordinances, safety rules, and warning rules for the workplace.
3. Do not allow ground personnel around or under raised platform.
4. Do not use the aerial lift for horseplay, stunt driving, or recreational use. Report any misuse of equipment to the appropriate personnel.
5. Always wear approved headgear, eye protection, foot protection, and fall-protection.
6. Do not work on the platform if you are dizzy, unsteady, or feel physically impaired in any way.
7. When leaving aerial lift, lower platform to stowed position and remove key from ground control to prevent unauthorized use.
8. Do not operate the aerial lift until it has been properly inspected, maintained, and serviced. Any problems or malfunctions should be reported immediately to the supervisor and operations stopped until corrected.
9. See the Before Operation section of this manual for decal listing and replace those that are missing or not legible.
10. Refuel aerial lift in a well ventilated area free of any hazards which may cause fuel fumes to ignite.

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OPERATOR'S MANUAL

SAFETY

10. Battery Care And Use:
- (A) Do not "jump-start" other vehicles with your aerial lift's battery.
- (B) Batteries must be charged in a well-ventilated area free of flames, sparks, or other such hazards. The gas mixture can explode if exposed to flames or sparks.

(C) Do not use the aerial lift as a welding ground.
(D) Disconnect battery cables before performing any welding operation(s) on the aerial lift.

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OPERATOR'S MANUAL

SAFETY

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 lines, and the electric 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 were 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 AF	PROACH DISTANCE
(Phase to Phase)	(feet)	(Meters)
0 to 300V	AVOID	CONTACT
Over 300v to 50KV	10	3.05
Over 50Kv to 200KV	15	4.60
Over 200KV to 350KV	20	6.10
Over 350KV to 500KV	25	7.62
Over 500KV to 750KV	35	10.67
Over 750KV to 1000KV	45	13.72

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.

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OPERATOR'S MANUAL

SAFETY

IF CONTACT IS MADE

1. If operating from platform attempt to move aerial lift from contact with line.
2. If the aerial lift cannot be removed from contact the following precautions should be taken to avoid possible electrocution to yourself and ground personal.
- (A) Do not attempt to operate the aerial lift from the ground control.
- (B) If you can leave the aerial lift you must jump off the aerial lift and hop away keeping your feet together as ground will be energized. Normal walking or running will result in possible electrocution, injury or death.
- (C) Warn personnel to stay well away from the aerial lift as contact with it or the ground in the vicinity will result in possible electrocution, injury or death.
- (D) While on the aerial lift do not contact poles or other structures. Such contact will provide a path to ground leading to possible electrocution, injury or death.

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OPERATOR'S MANUAL

SPECIFICATIONS

SECTION 3 DESCRIPTION

PAGE NO.

SPECIFICATIONS TABLE.	•	•	•	•	•	•	•	•	٠	•	•	٠	•	3 - 1
RANGE DIAGRAM	•				•							•		3 - 2
GENERAL DIMENSIONS .														3 - 3

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OPERATOR'S MANUAL

SPECIFICATIONS TA64


Working Height (Maximum) *	70 ft. (27.73 m)
Platform Height (Maximum)	64 ft. (25.91 m)
Stowed Height	8 ft. 1 in. (2.84 m)
Horizontal Reach from CL *	50 ft. 7 in. (15.4 m)
Length (stowed)	29 ft. (8.84 m)
Width (maximum)	7 ft. 11 in (2.41 m)
Platform dimensions	72 in x 36 in x 44 in (1.8 x.91 x 1.12 m)
Boom Elevation (above horizontal)	+75 ⁰
(below horizontal)	-14 ⁰
Load capacity	500 lbs. (227 kg)
Platform Rotation	172 ⁰
Wheelbase	8 ft. (2.44 m)
Wheel track	6 ft. 7 in (2.01 m)
Turret Tailswing (Working Height)	Zero
Turret Rotation	360° continuous
Turning radius 2WS (inside)	T.B.D.
(outside/curb)	16 ft. 9 in
4WS (outside/curb)	T.B.D.
Travel speed (stowed)	0-3.0 m.p.h. (0-4.83 Km/h)
(boom elevated)	0-0.5 m.p.h. (0-0.80 Km/h)
Power source (standard)	Ford 2.3L gas 66 hp (49.2 kw)
(optional)	Continental TMD27 diesel 63 hp (46.97 kw)
Fuel tank capacity	40 gal (151 L)
Hydraulic system	Load sensing and pressure compensating
Max. operating pressure	2,500 psi (172 BAR)
Reservoir Capacity	52 gal. (196 L)
Tires (pneumatic unless noted)	15 x 19.5 13 P.R. (Mono)
Ground clearance	11 in (0.28 m)
Approx. shipping weight	26,000 lbs. (11,794 kg)
Axle Weight	TBD
Floor Loading	TBD
Wind speed rating	25 M.P.H. (maximum)
Gradeability STD 2WD	25% (140) **
Opt. 4wd	50% (270) **

* Denotes clearance must be allowed for body parts

** Gradeability data is theoretical and is limited by tire slip, stability, or engine oil pan design.

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OPERATOR'S MANUAL

SPECIFICATIONS TA64

RANGE DIAGRAM MODEL TA64 KNUCKLE BOOM LIFT

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OPERATOR'S MANUAL

SPECIFICATIONS CH64KB

TA64 KNUCKLE BOOM LIFT GENERAL DIMENSIONS

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OPERATOR'S MANUAL

CONTROLS & INSTRUMENTS

SECTION 4

DESCRIPTION

PAGE NO.

. 4	4 - 1
. 2	1 - 2
. 2	4 - 10

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OPERATOR'S MANUAL

CONTROLS & 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 knuckle boom lift aerial platforms. Do not attempt to operate the machine until all sections of this manual have been read and understood.

SAFETY HORN FAST BATTERY SLOW OFF CIRCUIT BREAKER ON HOUR METER ENGINE FUEL / PETROL START EMERGENCY PUMP WORK LIGHTS DRIVE GENERATOR

UNIVERSAL SYMBOL IDENTIFICATION

TA6 4

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OPERATOR'S MANUAL

CONTROLS & INSTRUMENTS

AERIAL CONTROL STATION

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OPERATOR'S MANUAL

CONTROLS & INSTRUMENTS

AERIAL CONTROL STATION

1. EMERGENCY STOP SWITCH
2. ENGINE OFF/ON/START & EMERGENCY PUMP SWITCH
3. FOOT OPERATED SWITCH
4. DRIVE SPEED SELECT SWITCH
5. DRIVE/STEER CONTROL LEVER
6. BOOM/RISER/TURRET ROTATE CONTROL LEVER
7. BOOM IN/OUT CONTROL LEVER
8. PLATFORM TILT SWITCH
9. PLATFORM ROTATION SPEED CONTROL
10. PLATFORM ROTATION SWITCH
11. JIB SWITCH
12. UNSTABLE CONDITION WARNING LIGHT & ALARM
13. EMERGENCY PUMP WARNING LIGHT
14. ENGINE CONDITION WARNING LIGHT & ALARM
15. PLATFORM CONTROLS CIRCUIT BREAKER
16. FUEL SELECT SWITCH (OPTION)
17. GENERATOR SWITCH (OPTION)
18. WORK LIGHT SWITCH (OPTION)
19. HORN SWITCH (OPTION)

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OPERATOR'S MANUAL

CONTROLS & INSTRUMENTS

AERIAL CONTROL STATION

1. EMERGENCY STOP SWITCH - Push "in" to stop all functions and shut engine off. Turn clockwise to release and restore function operation.

The EMERGENCY STOP SWITCH at both aerial and ground control stations must be released to allow any functions to operate.

ENGINE OFF/ON/START & EMERGENCY PUMP SWITCH - Turn lever to START to start engine. Release lever when engine starts, lever will return to ON. Turn to OFF to stop engine.

Turn lever to EMERGENCY PUMP to operate the emergency pump. Engine will stop. Hold switch to EMERGENCY SWITCH step down on pedal of FOOT OPERATED SWITCH and operate controls.

FOOT OPERATED SWITCH - Mounted on platform floor. Step down on pedal to enable operation of controls. Release pedal to stop unintended operation of controls.

DO NOT operate this switch other than by stepping down on pedal with foot!

DRIVE SPEED SELECT SWITCH - Push up to FAST to select fastest maximum drive speed (0 - 3.0 MPH). Pull down to SLOW to select slower maximum drive speed (0 - 0.5 MPH).

FAST drive speed can only be obtained with boom stowed, lifting or extending boom out will automatically result in LOW travel speed.

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OPERATOR'S MANUAL

CONTROLS & INSTRUMENTS

AERIAL CONTROL STATION

DRIVE/STEER CONTROL LEVER - Push lever to FORWARD to drive aerial lift forward. Pull lever to REVERSE to drive aerial lift in reverse. Return lever to center/off position to stop drive operation. Function direction agrees with lever direction only with boom over steering wheels. Drive direction will be the reverse of lever direction with boom over non-steering wheels! Arrows on base demonstrate drive direction with respect to boom position and lever direction. Drive speed is varied by gradually moving lever from center/off position to end of travel in desired direction.

Push down on left side of switch on top of control lever to steer to left. Push down on right side of switch on top of control lever to steer to right. Release switch to stop steer operation. Function direction agrees with switch operation only with boom over steering wheels. Steering direction will be the reverse of switch operation with boom over non-steering wheels!

BOOM/RISER/TURRET ROTATE CONTROL LEVER - Push lever to BOOM UP to lift boom. Pull lever to BOOM DOWN to lower boom. Return lever to center/off position to stop function operation.

Push down on button in top of control lever and push lever forward to RISER UP to lift riser. Push down on button in top of control lever and pull lever backward to RISER DOWN to lower riser. Return lever to center/off position to stop function operation.

Push lever to ROTATE TURRET RIGHT to rotate turret to the right (clockwise). Push lever to ROTATE TURRET LEFT to rotate turret to the left (counterclockwise). Return lever to center/off position to stop function operation.

Speed of selected function is varied by gradually moving lever from center/off position to end of travel in desired direction.

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OPERATOR'S MANUAL

CONTROLS & INSTRUMENTS

AERIAL CONTROL STATION

BOOM IN/OUT CONTROL LEVER - Push lever to BOOM IN to move boom "in" (retract). Pull lever to BOOM OUT to move boom "out" (extend). Return lever to neutral to stop boom in/out operation.

Function speed is varied by gradually moving lever from center/off position to end of travel in desired direction.

PLATFORM TILT SWITCH - Pusn to PLATFORM TILT FWD to tilt platform toward boom. Pull to PLATFORM TILT BACK to tilt platform away from boom. Release switch to stop tilt operation.

Maximum platform tilt is 105⁰ relative to angle of boom (+25° to -80° w/boom @ horizontal).

PLATFORM ROTATION SPEED CONTROL -Use with platform rotation switch. Turn to SLOW to rotate platform at slowest possible speed. Turn to FAST to rotate platform at fastest possible speed.

Function speed increases/decreases relative to amount knob is turned. Switch remains turned to selected speed !

10.

PLATFORM ROTATION SWITCH - Push to CW to rotate platform "clockwise" (right). Push to CCW to rotate platform "counterclockwise" (left). Release switch to stop operation.

Platform can be rotated 172° (86° to each side of center).

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OPERATOR'S MANUAL

CONTROLS & INSTRUMENTS

AFRIAL CONTROL STATION

11. JIB SWITCH - Push to UP to raise jib. Pull to DN to lower jib. Release switch to stop operation.

Maximum jib articulation is 80° relative to angle of boom (+15° with boom fully up, -16° with boom fully down).

UNSTABLE CONDITION WARNING LIGHT & ALARM- Red light and dual tone audible alarm turn "on" to warn of unstable condition, when boom is out or up and aerial lift is on a 5° or greater slope. All functions will be inoperative except drive and steer.

To restore full operation drive aerial lift back onto a slope less than 5°.

13 EMERGENCY PUMP INDICATOR LIGHT - Red light turns "on" whenever ENGINE OFF/ON/START & EMERGENCY PUMP SWITCH is turned to EMERGENCY PUMP. Release to turn light "off".
- ENGINE CONDITION WARNING LIGHT & ALARM - Red light and dual tone audible alarm turn "on" whenever ENGINE OFE/ON/START & EMERGENCY PUMP SWITCH is turned to ON and engine is not running. Turning "on" of alarm while engine is running may indicate high temperature or low engine oil pressure.

DO NOT continue to use aerial lift if alarm operates while engine is running, engine may be damaged!

PLATEROM CONTROLS CIRCUIT BREAKER -Interrupts electrical power to aerial control station in event of electrical "overload". Identify cause, correct condition and push "in" to reset.

ΔΗ 14. 13 14 CHECK ENGINE EMERGENCY

INSTALLED IN R/H SIDE OF CONTROL BOX))

TA64

15.

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OPERATOR'S MANUAL

CONTROLS & INSTRUMENTS

Horn is intended for signaling only and is not an "all motion" or "travel" alarm.

____ 19

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OPERATOR'S MANUAL

CONTROLS & INSTRUMENTS

AERIAL CONTROL STATION

NON-SELECTED OPTIONS/FEATURES

20. ENGINE THROTTLE/SPEED OPERATION - (STANDARD) Engine "speed" (RPM) increases automatically to preset limit whenever foot operated switch in platform is operated. Engine speed advances to "next" preset limit whenever drive control lever is operated. Release drive control lever to return engine to lower speed. Release foot operated switch to return engine to idle speed.
21. TRAVEL ALARM - (OPTION) Operation is not selected. Dual tone alarm turns "on" whenever DRIVE/STEER CONTROL LEVER is moved from center off position to notify that aerial lift is driving. Return of lever to off position turns alarm off.
22. ALL MOTION ALARM - (OPTION) Operation is not selected. Dual tone alarm turns "on" whenever foot operated switch is depressed or ground aerial selector switch is moved to GROUND to notify that aerial lift is operating. Release of switch turns alarm off.
20. OSCILLATING AXLE - (OPTION) Operation is not selected. With boom "stowed" (fully down and in) steering axle moves 6⁰ (up or down 3⁰ from horizontal) in response to changes in contour of travel surface, to keeps all driving wheels in contact with the ground thus provide maximum traction over uneven terrain.

Lifting boom up or extending boom out "locks" axle in position. This may result in wheel on high slide of slope no longer contacting ground, if aerial lift is driven onto an even surface from an uneven surface. To lower wheel onto ground, first retract and than lower boom.

21. 4 WHEEL DRIVE - (OPTION) Operation is not selected. All 4 hydraulic drive motors are used continuously in drive operation to provide greater torque than that provided by standard 2 wheel drive system. Maximum tractive effort is obtained with drive speed select switch to LOW.
22. SELF CORECTING DIRECTIONAL CONTROLS - (OPTION) Operation is not selected. Drive and steer operation on aerial lifts "not" equipped with this option match drive control handle movement "only" when boom is centered over steering wheels (operator facing controls). Rotating boom 90⁰ or more results in operation in a direction opposite than that of handle movement.

Self correcting directional controls "REVERSE" drive and steer functions to continuously operate them in direction handle is moved. Reversal occurs "AUTOMATICALLY" whenever boom is rotated more than 90⁰ from over steering wheels.

When simultaneously driving and rotating drive/steer operation remains unchanged. Release of drive/steer lever enables reversing of operation to keep function corresponding to handle direction.

25. 4 WHEEL STEER - (OPTION) Operation is not selected. Operation of steering function results in all four wheels turning in desired steering direction at the same time, to enable greater maneuverability in close or confined areas

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OPERATOR'S MANUAL

CONTROLS & INSTRUMENTS

GROUND CONTROL STATION

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OPERATOR'S MANUAL

CONTROLS & INSTRUMENTS

GROUND CONTROL STATION

1. EMERGENCY STOP SWITCH
2. MASTER SWITCH
3. AERIAL/GROUND SELECTOR SWITCH
4. BOOM UP/DOWN SWITCH
5. RISER UP/DOWN SWITCH
6. BOOM IN/OUT SWITCH
7. TURRET ROTATE SWITCH
8. PLATFORM TILT SWITCH
9. PLATFORM ROTATE SWITCH
10. JIB UP/DOWN SWITCH
11. EMERGENCY PUMP SWITCH
12. EMERGENCY PUMP INDICATOR LIGHT
13. VOLTMETER
14. FUEL LEVEL GAUGE
15. GROUND CONTROLS CIRCUIT BREAKER
16. HOUR METER

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OPERATOR'S MANUAL

CONTROLS & INSTRUMENTS

GROUND CONTROL STATION

EMERGENCY STOP SWITCH - 1 "in" to stop all functions and shut engine off. clockwise to release and restore function operation. Switch at ground control station must be released for any functions to be operable.

Switch at aerial control station does not need to be released to operate from ground control station

MASTER SWITCH - Insert key and turn to START to start engine. Release key when engine starts, key will return to ON. Turn to OFF to stop engine. Key must in ON position to enable any operation from ground or aerial control station.

Remove key when aerial lift is not in use!

GROUND/AERIAL SELECTOR SWITCH - Pull to GROUND and hold to enable operation from ground control station. Release switch to enable operation from aerial control station. With switch to AERIAL only controls at aerial control station will be operable.

Selecting GROUND will result in automatic increase of engine speed.

BOOM UP/DOWN SWITCH - Push to UP to move boom up. Pull to DOWN to move boom down. Release switch to stop operation.

GROUND/AERIAL SELECTOR SWITCH must be held to GROUND to enable operation!

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OPERATOR'S MANUAL

CONTROLS & INSTRUMENTS

GROUND CONTROL STATION

5. RISER UP/DOWN SWITCH - Push to UP to move riser up. Pull to DOWN to move riser down. Release switch to stop operation.

GROUND/AERIAL SELECTOR SWITCH must be held to GROUND to enable operation!

BOOM IN/OUT SWITCH - Push to OUT to move boom out. Push to IN to move boom in. Release switch to stop operation.

GROUND/AERIAL SELECTOR SWITCH must be held to GROUND to enable operation!

TURRET ROTATE SWITCH - Push to RIGHT to rotate turret to right (clockwise). Push to LEFT to rotate turret left (counterclockwise). Release switch to stop operation.

GROUND/AERIAL SELECTOR SWITCH must be held to GROUND to enable operation!

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OPERATOR'S MANUAL

CONTROLS & INSTRUMENTS

GROUND CONTROL STATION

PLATFORM TILT SWITCH - Push to FWD to tilt platform toward boom. Push to BACK to tilt platform away from boom. Release switch to stop operation. GROUND/AERIAL SELECTOR SWITCH must be held to GROUND to enable operation!

Maximum platform tilt is 105⁰ relative to angle of boom (+25⁰ to -80⁰ w/boom @ horizontal).

PLATFORM ROTATE SWITCH - Push to CW to rotate platform clockwise/right. Push to CCW to rotate platform counterclockwise/left. Release switch to stop operation. GROUND/AERIAL SELECTOR SWITCH must be held to GROUND to enable operation!

Platform can be rotated 172⁰ (86⁰ to each side of center).

JIB UP/DOWN SWITCH - Push to UP to move jib up. Pull to DOWN to move jib down. Release switch to stop operation. GROUND/A FIAL SELECTOR SWITCH must be held to GROUND to enable operation!

Maximum jib articualtion is 80⁰ relative to angle of boom (+15⁰ with boom fully up, -16⁰ with boom fully down).

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OPERATOR'S MANUAL

15.

16.

CONTROLS & INSTRUMENTS

GROUND CONTROL STATION

11. EMERGENCY PUMP SWITCH - Push up to EMERGENCY PUMP to turn emergency pump "on", engine will stop . Release switch to turn emergency pump off. Operate function switches with switch held "on" (pushed up).

GROUND/AERIAL SELECTOR SWITCH does NOT need to be operated!

EMERGENCY PUMP INDICATOR LIGHT - Red light turns "on" whenever EMERGENCY PUMP SWITCH is operated. Release switch to turn light off.
VOLTMETER - Indicates battery supply voltage when MASTER SWITCH is turned to ON and EMERGENCY STOP SWITCH is released. Gauge Indicates alternator output voltage when engine is operating.

FUEL LEVEL GAUGE - Indicates gasoline/diesel fuel level in fuel reservoir when MASTER SWITCH is turned to ON and EMERGENCY STOP SWITCH is released. Gauge does not indicate LPG fuel level!

GROUND CONTROLS CIRCUIT BREAKER - Interrupts electrical power to ground control station in event of electrical "overload". Identify cause of

HOUR METER - Indicates engine operating/"run" time.

overload condition and push "in" to reset

Page 4 - 15

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OPERATOR'S MANUAL

BEFORE OPERATION CHECK

SECTION 5

DESCRIPTION

PAGE NO.

BEFORE OPERATION CHECK LIST	•	•	•	•		•	•	5 - 1
DECAL CHECK LIST		•		•	•	•		5 - 4
WHAT SHOULD I KNOW?					•	•		5 - 6
INTERLOCKS, CUT-OUTS, & WARNINGS		•					•	5 - 7
CAPACITY: WHAT SHOULD I KNOW?							•	5 - 9
GUARDRAILS AND GATE: WHAT SHOULD I	CHE	ECK	(?		•			5 - 9
PLATFORM SURFACE	•			٠	•	•		5 - 9
PLATFORM & OVERHEAD CLEARANCE .	•			•	•	•	•	5 - 9
				·	•	٠		5 - 10
			•				•	5 - 10
WIND SPEED		•	•				•	5 - 10
WHEEL LOADS				•		•		5 - 11

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OPERATOR'S MANUAL

BEFORE OPERATION CHECK

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 Maintenance Checks List on page(s) 5-2 and 5-3.

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 it's proper care since their own safety is involved.

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OPERATOR'S MANUAL

BEFORE OPERATION CHECK

BEFORE OPERATION CHECK LIST

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OPERATOR'S MANUAL

BEFORE OPERATION CHECK

BEFORE OPERATION CHECK LIST

Check the following areas and/or items for; missing, loose, or damaged hardware, evidence of cracks, signs of wear, leakage or chafing, loose connections, proper fluid level (where applicable), legibility, cleanliness, and proper operation. If a problem is found notify your supervisor, 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 service technician.

ltem	Description	ltem	Description
1.	Tires & Wheels	20.	Engine Control Panel
2.	Drive Motors & Brakes	21.	Proximity Switches (2 plcs.)
3.	Torque Hubs	22.	Riser Arms (upper & lower)
4.	Wheel Lug Nuts	23.	Master Leveling Cylinder
5.	Steering Tie Rods & Ends	24.	Riser Lift Cylinder Installation
6.	Steering Yoke King Pins (4 plcs.)	25.	Riser Installation
7.	Steering Cylinder(s)	26.	Boom Lift Cylinder Installation
8.	Oscillating Axle Installation	27.	Boom & Riser Lift Cylinder Pins (all)
9.	Oscillating Axle Cylinders (2 plcs.)	28.	Boom Assembly
10.	Turret Rotation Gear	29.	Boom Extend Cylinder
11.	Fuel & Hydraulic Reservoirs	30.	Boom Pivot Installation
12.	Return Line Filter	31.	Power Track Assembly
13.	Ground Control Station	32.	Jib Assembly
14.	Hydraulic Valve Assemblies	33.	Platform -
15.	Turret Rotation Gear Box Assembly	34.	Platform Rotator
16.	Battery	35.	Slave Leveling Cylinder
17.	Engine Assembly	36.	Aerial Control Station
18.	Hydraulic Pump (main)	37.	Foot Operated Switch
19.	Hydraulic Pump (emergency)	38.	Operator's Manual & Documents
T.	A64	Page 5 - 3	Issued: JUN 97

Page 35

Mathematical TEREX AERIALS

OPERATOR'S MANUAL

BEFORE OPERATION CHECK

DECAL CHECK LIST

Verify that each of the following decals are properly adhered to the machine, undamaged, and legible. If a decal is missing, damaged, or illegible, the decal must be replaced before operating the aerial lift.

Page 36

OPERATOR'S MANUAL

BEFORE OPERATION CHECK

DECAL CHECK LIST


Ref.	Part No.	Description	Qty	Remarks
1	MK182821	DECAL, LIQUID TANK ONLY	2
2	12400-3	DECAL, BOOSTER CABLE	1
З	MK185707	DECAL, POWER 110 VAC	1
4	MK183402	DECAL, HYD. SYS. FLUID	2
5	MK20461	DECAL, FORWARD ARROW	1
6	MK20462	DECAL, FORWARD ARROW	1
7	MK182709	DECAL, DIR. ARROW (GREEN)	2
8	MK182710	DECAL, DIR. ARROW (BLUE)	2
9	MK181321	DECAL, NO SMOKING	1
10	MK181830	DECAL, DIESEL	1
11	MK181829	DECAL, GAS	1
12	12260-701	DECAL, FAN WARNING	1
13	MK181996	DECAL, TIE DOWN TA64	2
14	MK183405	DECAL, GEN. CHK. & OP.	1
15	12400-223	DECAL, DANGER	2
16	12400-243	DECAL, CAUTION, NO STEP	2
17	MK181998	DECAL, TEREX	2
18	MK181999	DECAL, AERIALS	1
19	MK181113	DECAL, OPER. & SAFETY.	1
20	MK181828	DECAL, SAFETY BELT HERE	2
21	MK182307	DECAL, SAFETY BELT FIRST	1
22	MK181927-1	DECAL, MARKLIFT	1
23	MK183101	DECAL, TIRE REPLACE	4
24	MK181322	DECAL, RATED LOAD	2
25	MK183404	DECAL, AUX G. CONTROL	1
26	12400-664	DECAL, TEREX CROWN	\| 1
27	MK185702	DECAL, C. BREAKER 110VAC	\| 1
28	MK181328	DECAL, PINCH POINT	\| 2
29	MK20419	DECAL, DANGER - KEEP CLEAR	\| 2
30	MK182121	DECAL, DANGER CRUSHING	1
31	MK182829	DECAL, FWD ARROW	2
32	MK182852	DECAL, TA64
33	MK187854
34	MK182122	DECAL, POWER LINES	2
35	MK182839	DECAL, OPERATING INSTRUCTIONS
36	MK182840-1	DECAL, AERIAL CONTROL STATION		DRIVE/STEER
37	MK182840-2	DECAL, AERIAL CONTROL STATION		TOP FACE
38	MK182840-3
39	MK182840-4	DEGAL, AERIAL CONTROL STATION
40	MK182841-1	DEGAL, RISER OPER. SELECT
41	MK182841-2
42	WIK 182841-3			DOWN
43	INIV 101988	DECAL, GROUND CONTROL STATION

TA64

Issued: JUN 97

Page 37

OPERATOR'S MANUAL

BEFORE OPERATION CHECK

What Should I Know?

A. Emergency Operations
B. Interlocks, Cutouts, & Warnings*
C. Capacity
D. Guardrail & Entry Gate
E. Platform Surface
F. Clearance Around Platform And Overhead
G. Platform Loads
H. Travel Surfaces
I. Wind Speed
J. Wheel Loads

Emergency operation from ground control station if platform controls are inoperable:

A. Check that EMERGENCY STOP SWITCH is released by turning knob clockwise and MASTER SWITCH is turned to ON, start engine if not operating.
A. Pull AERIAL/GROUND SELECTOR SWITCH to GROUND position.
B. Make sure no hazards, material or personnel are beneath the platform or boom.
C. Determine which function must be performed first to recover aerial lift, i.e. boom "in", turret rotate, or boom down. Move boom in fully first, when possible, before moving boom/riser down.
NOTE 1: If engine cannot be started push EMERGENCY PUMP SWITCH "up" to EMERGENCY position and follow steps B and C. If engine is running, operating switch will result in engine stopping.
NOTE 2: Controls at ground control station will be operable regardless of position of EMERGENCY STOP SWITCH at aerial control station.

Emergency operation from platform if engine fails to start or main hydraulic pump is inoperable:

A. Have ground personnel check that EMERGENCY STOP SWITCH at ground control station is released by turning knob clockwise and ensure that MASTER SWITCH is turned to ON.
B. Make sure no hazards, personnel or materials are below the platform or boom.
C.Turn EMERGENCY STOP SWITCH at the aerial control station clockwise to enable controls.
D. Step down on pedal of FOOT OPERATED SWITCH.
E. Turn the ENGINE OFF/ON/START & EMERGENCY PUMP SWITCH to EMERGENCY PUMPand operate respective controls to lower the platform.

Page 38

OPERATOR'S MANUAL

BEFORE OPERATION CHECK

Before operating the aerial lift, perform the following procedures:

1. Visually inspect all exposed parts of the aerial lift and report all deficiencies. DO NOT OPERATE aerial lift until all deficiencies noted have been corrected!
2. Refer to the Maintenance section and perform the periodic maintenance.
3. Check the fuel tank level. Check and/or fill the propane tank (if equipped).
4. Test the operation of the controls at the ground control station. Release the EMERGENCY STOP SWITCH by turning the knob clockwise and turn the MASTER SWITCH to START. Release the switch after the engine has started and test the EMERGENCY STOP SWITCH by pushing "in" on the knob. Restart the engine pull the GROUND/AERIAL SELECTOR SWITCH to GROUND and operate all of the function switches momentarily in both directions. Check the operation of the emergency pump by pushing the EMERGENCY PUMP SWITCH to the EMERGENCY PUMP position. Upon completion of the test inspect the aerial lift for any signs of leaks.
5. Enter the platform. Ensure that the entry gate is closed and latched. Attach the lanyard of your personnel restraint device to the indicated attachment point. Repeat the test in step 5 at the aerial control station. Release the EMERGENCY STOP SWITCH by turning the knob clockwise. Turn ENGINE OFF/ON/START & EMERGENCY PUMP SWITCH to START. Release switch after engine has started and test the EMER-GENCY STOP SWITCH by pushing "in" on the knob. Restart engine, step down on pedal of FOOT OPER-ATED SWITCH and operate all control levers and function switches momentarily in both directions. Check emergency pump by turning the ENGINE OFF/ON/START & EMERGENCY PUMP SWITCH to the EMER-GENCY PUMP position.
6. Your aerial lift is equipped with fully proportional controls. When using any proportional function, move the control lever "gradually" in the desired direction. The control lever is spring-centered and will return to the "OFF" position when released.
7. The normal drive configuration is with the boom located over the steering wheels. This provides the best weight distribution for maximum traction. If the boom is rotated 180° the drive and steer decals read in reverse, therefore the operator must reverse the drive and steer functions in order to move in the desired direction. The arrow type decals on each end of the base demonstrate the direction of the base without regard to the position of the turret.

Page 39

OPERATOR'S MANUAL

BEFORE OPERATION CHECK

A. Interlocks, Cut-outs and Warnings: What Interlocks, Cut-outs, And Warnings Do I Have?

*Operating Instructions To Check Interlocks, Cut-Outs, & Warnings

1. Unstable Condition Warning Light & Alarm

The aerial lift is equipped with an UNSTABLE CONDITION WARNING LIGHT & ALARM. When the alarm is "on" the aerial lift is in a potentially unsafe out-of-level or unstable position and all "boom" functions will be disabled. The system is automatically activated whenever the boom is elevated or extended. An unsafe out-of-level condition is defined as the boom being either raised or extended and the aerial lift is tilted at an angle greater than 5° from the front to the rear or from side to side.

The unsafe condition is indicated by a red warning light located on the top center of the aerial control station and an audible "dual-tone" alarm. When the UNSTABLE CONDITION WARNING LIGHT & ALARM turn "on" the BOOM UP/DOWN, RISER UP/DOWN, BOOM IN/OUT, TURRET ROTATE, PLATFORM TILT, PLATFORM ROTATE and JIB functions will not operate. The DRIVE and STEER operation are not affected and will operate. Should the UNSTABLE CONDITION WARNING LIGHT & ALARM come on, maneuver the aerial lift back in the direction it came from until it is, once again, on a safe level operating surface. When the UNSTABLE CONDITION WARNING LIGHT & ALARM turn "off" all functions will be restored.

To determine if unstable condition warning light & alarm are operational and controls disabled:

1. Move the boom fully "in" (retract) and down!
2. With the DRIVE SPEED SELECT SWITCH to LOW, drive the aerial lift onto a slope slightly greater than 5⁰ but not greater than 10⁰. Be sure the platform is pointed down the slope. Drive the aerial lift partially up the slope and come to a complete stop. Release the foot operated switch. The UNSTABLE CONDITION WARNING LIGHT & ALARM should turn "on". DO NOT operate the aerial lift if the alarm does not turn on!
3. If the alarm turns "on", step down on pedal of the foot operated switch (the alarm will turn off) and operate the BOOM IN/OUT control lever to extend the boom out slightly. The alarm should turn "on" and the boom out function should stop. DO NOT continue to operate the function if the alarm does not turn "on" or if the boom out function does not stop!
4. If the alarm turns "on" and the boom out function stops, check the other functions to ensure that they are not operable. DO NOT use the aerial lift if any function other than the drive or steer are operable!
5. To turn off the UNSTABLE CONDITION WARNING LIGHT & ALARM and regain full operation of the controls, drive the aerial lift back down the slope onto a level surface. Drive in a slow controlled manner with the platform pointed down the slope. Once the aerial lift is on a slope of less than 5⁰ the alarm will turn off and full operation will be restored.

Page 40

OPERATOR'S MANUAL

BEFORE OPERATION CHECK

2. Fast drive speed cut-out

The aerial lift is equipped with a fast drive speed cut-out . When the boom is slightly "up" (raised) or "out" (extended) the aerial lift's drive speed is limited to a maximum of 1.5 miles per hour (2 wheel drive, 4 wheel drive will be slightly slower). To obtain the maximum travel speed of 3.0 miles per hour, move the boom fully "in" (retract) and "down" (lower) and select FAST with the DRIVE SPEED SELECT SWITCH.

To determine if fast drive speed cut-out is operational:

1. Select a test area having a smooth, prepared surface and one which is free from obstacles or personnel posing a potential collision hazard.
2. Position the platform with the boom centered over the steering axle. Move the boom fully down. Raise the jib up sufficiently far to prevent the platform from contacting the ground and move the boom "out" approximately 12 to 15 inches.
3. Place the DRIVE SPEED SELECT SWITCH to SLOW.
4. Straighten the wheels and drive aerial lift carefully in reverse a short distance.
5. Place the DRIVE SPEED SELECT SWITCH to FAST and drive aerial lift carefully in reverse a short distance.
6. If the fast drive speed cut-out is operational, the aerial lift will have operated only in slow speed during both checks.
NOTE: If the drive speed is faster with the boom out, DO NOT operate the aerial lift until repairs have been made by a qualified technician.
7. Center the boom over the steering axle and raise the boom up approximately 12 inches (raise the jib up to obtain a good field of view to the front of the aerial lift).
9. Place the DRIVE SPEED SELECT SWITCH to SLOW.
10. Straighten the wheels and drive aerial lift forward a short distance.
11. Place the DRIVE SPEED SELECT SWITCH to FAST and drive aerial lift carefully forward a short distance.
12. If the fast drive speed cut-out is operational, the aerial lift will have operated only in slow speed during both checks.
NOTE: If the drive speed is faster with the boom up, DO NOT operate the aerial lift until repairs have been made by a qualified technician.

Page 41

OPERATOR'S MANUAL

BEFORE OPERATION CHECK

B. Capacity: What Should I Know?

1. The capacity for the platform is posted on decals on the platform and in the specifications section of this manual.
2. The platform capacity equals the combined weight of personnel, supplies, and tools carried in the platform.
3. The combined weight of personnel plus tools and supplies must not exceed the platform capacity.
4. Do not exceed the maximum number of personnel allowed on the platform. This information is posted on decals on the platform and can be found in the Specifications Section of this manual.

C. Guardrails And Entry Gate: What Should I Check?

1. Once in the platform, be sure the entry gate is closed and latched.
2. Make sure the guardrails do not have any cracked or broken welds.
3. Make sure the toe plate is secure and not bent.

D. Platform Surface

1. Make sure the platform floor is undamaged, free from oil, grease, or other substances which could cause a slip or fall and that the view directly below the floor is unobstructed.

E. Clearances Around Platform & Overhead Clearance: What Should I Look For?

1. Be sure the area in which you will be moving the aerial lift is free from any obstacles or hazards you could collide with.
2. Continuously check the overhead clearances and be aware of obstacles when elevating (raising) the platform.

F. Platform Loads: What Should I Know?

1. The capacity of the aerial lift is based on even distribution of weight in the platform. Position all tools, personnel, and supplies on the platform to assure an even distribution of weight.
2. Position all tools and supplies in a manner to prevent anything from being accidentally knocked off or out of the platform.
3. Position all tools and supplies in a manner to prevent personnel in the platform from tripping on or colliding with them.

Page 42

OPERATOR'S MANUAL

BEFORE OPERATION CHECK

G. Travel Surfaces: What Should I Check?

Surfaces Should:

1. Be as level as possible whenever platform is to be raised.
2. Be free from bumps and potholes.
3. Be able to support the weight of the aerial lift and its contents.
4. Be firmly prepared.
5. Make sure the grades to be traveled do not exceed 9% (5°) side to side and/or 25% (14°) front to back. See the Operations Section for specific traveling instructions.
6. Ramps must be strong enough to support the weight of the aerial lift and wide enough to provide plenty of side clearance beyond the wheels. Refer to the Specifications Section of the manual for this information.
7. Be clean and free of debris and obstacles.

H. Wind Speed: What Should I Know?

1. The wind speed during operation.
2. The wind-speed rating of the aerial lift--with platform raised is 25 M.P.H. Do not use the aerial lift if wind speeds exceed the wind speed rating.
3. The wind-speed rating is based on the surface area of the platform, the personnel, and tools in the platform. If items with a large surface area are in the platform, the wind speed that the aerial lift can be safely operated in will be reduced.
I. Wheel Loads: What Should I Know?
- 1. The Wheel Loading (wheel's weight on surface) for this aerial lift —when fully loaded—is listed in the Specifications Section of this manual and on the data plate attached on the aerial lift.
- 2. The traveling surface must be able to support these loads.

Page 43

OPERATOR'S MANUAL

OPERATION

SECTION 6 DESCRIPTION

PAGE NO.

	٠	6 - 1
STARTING THE ENGINE	•	6 - 1
SWITCHING FROM PROPANE TO GASOLINE		6 - 1
SWITCHING FROM GASOLINE TO PROPANE		6 - 1
IN CASE OF ENGINE OR MAIN HYDRUALIC PUMP FAILURE .		6 - 2
DRIVING ON LEVEL SURFACES		6 - 2
DRIVING ON PREPARED GRADES AND RAMPS		6 - 3
DRIVING AT FULL SPEED		6 - 5
DRIVING IN REVERSE	•	6 - 5
	•	6 - 5
	•	6 - 6
MOVING RISER UP/DOWN		6 - 6
		6 - 6
		6 - 6

Page 44

OPERATOR'S MANUAL

OPERATION

Descriptions of all of the individual controls and their operation are contained in the Controls & Instruments Section of this manual. The operator must read and understand the function of all of the controls before operating the aerial lift.

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

Engine Operation

Stopping The Engine

Engine can be stopped by pushing "in" on EMERGENCY STOP SWITCh at either ground or aerial control station, or by turning ENGINE OFF/ON/START & EMERGENCY PUMP SWITCH at aerial control station, or MASTER SWITCH at ground control station, to OFF.

Starting The Engine

From ground control station: Turn knob of EMERGENCY STOP SWITCH clockwise. Turn MASTER SWITCH to START. Release switch after engine starts. MASTER SWITCH will return to ON position.

From aerial control station: Turn MASTER SWITCH at ground control station to ON. Turn knob of EMERGENCY STOP SWITCH at ground control station clockwise. Enter platform, close and latch entry gate. Attach fall protection gear to designated attaching point. Turn knob of EMERGENCY STOP SWITCH at aerial control station clockwise. Turn ENGINE OFF/ON/START & EMERGENCY PUMP SWITCH to START. Release switch after engine starts. DO NOT step down on pedal of FOOT OPER-ATED SWITCH while starting engine, starter will not operate!

Note: If engine fails to start and ENGINE OFF/ON/START & EMERGENCY PUMP SWITCH has been released, turn switch to OFF before returning to START, starter will not operate otherwise.

Dual Fuel System

The aerial lift may be equipped with an optional dual fuel system which enables the selection of either gasoline or propane gas (LPG) for operation. The FUEL SELECT SWITCH is located at the aerial control station. The engine can be started or operated on either type of fuel, as long there is a sufficient quantity present.

Switching From Propane To Gasoline

Push up on the FUEL SELECT SWTCH to GASOLINE.

Switching From Gasoline To Propane

Pull down on the FUEL SELECT SWITCH to PROPANE.

Note: It is not necessary to stop the engine when changing to a different fuel type.

Page 45

OPERATOR'S MANUAL

OPERATION

IN CASE OF ENGINE OR MAIN HYDRAULIC PUMP FAILURE , all boom hydraulic functions J operable with the emergency pump.

The emergency pump is intended for emergency use only. Do not continuously run the aerial lift from the emergency pump for an extended period of time.

From the aerial control station: turn the ENGINE OFF/ON/START & EMERGENCY PUMP SWITCH to EMERGENCY PUMP and hold, engine will stop (if operating) and emergency pump will start. Step down on the pedal of the FOOT OPERATED SWITCH and operate the function controls as normal to return the platform to ground level.

Note: The EMERGENCY STOP SWITCH at both the aerial and ground control station must be "released" (turned clockwise) and the MASTER SWITCH must be turned to ON.

From the ground control station ; Check that EMERGENCY STOP SWITCH is released (turn clockwise) and MASTER SWITCH is turned to ON. Push EMERGENCY PUMP SWITCH to EMERGENCY PUMP and hold. Operate appropriate function control switches to lower platform to ground.

Note: The EMERGENCY STOP SWITCH at the aerial control station does not need to be "released" (turned clockwise) to enable operation of the emergency pump from the ground control station.

How Can The Aerial Lift Be Driven?

A. ON LEVEL, PREPARED SURFACES
B. ON PREPARED GRADES AND RAMPS
C. AT FULL SPEED
D. IN REVERSE
NOTE: With the boom and/or riser "up" (lifted) or the boom "out" (extended), the fast drive speed cut-off should limit the aerial lift's traveling capability to slow speed.

'Things You Need To Know'

A. Driving On Level Surfaces

1. The platform can be in a raised or lowered position when driving on level surfaces.

2. Path must be free from pot holes and bumps.

3. Before driving, make sure that the path you will be traveling is clear of any personnel, hazards, debris or obstructions which could pose a threat or cause a collision.

Page 46

OPERATOR'S MANUAL

OPERATION

4. Consider all traveling situations such as; surface condition, side and/or vertical clearances, number of personnel in or about working area when choosing a "fast" or "slow" traveling speed. Refer to part C for instructions on fast-speed travel.
5. Drive the aerial lift by stepping down on the pedal of the FOOT OPERATED SWITCH and moving the DRIVE/STEER CONTROL LEVER (when the boom is centered over the steering wheels):
- forward for forward drive
- ٠
- backward for reverse drive.

When released, the DRIVE/STEER CONTROL LEVER will automatically return to its neutral position.

B. Driving On Prepared Grades (Slopes) And Ramps

1. The boom and platform must be in the "stowed" (fully down and in) position when traveling on grades (slopes).
2. When driving up or down a grade the platform should always be pointed down the slope (riser or counterweight end pointed up slope) and with boom over the steering wheels. Descend the slope in "increments". Allow the brakes to apply completely before once again operating the controller. Do not permit the aerial lift to "free-wheel" (uncontrolled acceleration) down any grade!
3. Surface must be prepared and the travel path free from hazards such as pot holes and bumps.
4. Do not travel on grades or ramps that are wet, muddy, slippery, or have poor traction.
5. Do not attempt to turn the aerial lift on grades or ramps.
6. The aerial lift must be in SLOW speed and driven in a controlled and careful manner while operating on grades (slopes).

Page 47

OPERATOR'S MANUAL

OPERATION

8. This aerial lift is capable of traveling on grades of 14° (25%) front to back and 5° (9%) = to side

% Grade = A/B

This is a vertical rise of 'A' feet over a horizontal distance of 'B' feet.

% Grade = C/D

This is a vertical rise of 'C' feet over a horizontal distance of 'D' feet.

Note: When traveling on slopes, it may be necessary to raise jib up slightly beforehand in order to prevent the platform from contacting the ground.

Page 6 - 4

Page 48

OPERATOR'S MANUAL

OPERATION

C. Full Speed (maximum FAST)

1. Do not drive on any slope at a fast speed.
2. Use extreme caution when driving this aerial lift at a fast speed:
- Never drive across potholes or bumps.
- Do not operate in FAST speed whenever ground personnel are anywhere near the area in which the aerial lift is operating.
3. The fast drive speed is activated by selecting FAST with the DRIVE SPEED SELECT SWITCH located at the aerial control station.

D. In Reverse

1. Use extreme caution when driving this aerial lift in reverse:
- Never drive across potholes or bumps.
- Do not operate in reverse whenever ground personnel are anywhere near the area in which the aerial lift is operating.
- Use extreme caution driving this aerial lift in reverse whenever platform is raised.
2. The reverse drive function is activated by stepping down on the pedal of the FOOT OPERATED SWITCH and pulling the DRIVE/STEER CONTROL LEVER back to REVERSE (with the boom centered over steering wheels).

E. Turning (Steering)

1. Use extreme caution when turning this aerial lift:
- Never make turns across potholes or bumps.
- Never make sharp or abrupt turns whenever platform is raised.
- DO NOT turn aerial lift on slopes or grades
2. This aerial lift can be turned by stepping down on the pedal of the FOOT OPERATED SWITCH and pushing down on the switch on top of DRIVE/STEER CONTROL LEVER (with boom centered over steering wheels):
- left side for left turns.
- right side for right turns.

If the boom is over the nonsteering wheels, the directions are reversed.

The steering switch will automatically return to its neutral position, however the steering wheels will remain turned in the direction they were steered.

Page 49

OPERATOR'S MANUAL

OPERATION

Moving The Platform of the Aerial Lift From the Aerial Control Station

What Do I Check?

1. Check the overhead clearances and be aware of any obstacles or hazards when moving the platform.
2. Be sure that there are no personnel or obstacles under the platform when lowering the platform.

A. How Do I Move the Boom Up or Down?

Push the BOOM/RISER/TURRET ROTATE CONTROL LEVER forward to BOOM UP to lift the boom up.
Pull the BOOM/RISER/TURRET ROTATE CONTROL LEVER backward to BOOM DOWN to lower the boom down.
The BOOM/RISER/TURRET ROTATE CONTROL LEVER is fully proportional. The speed of the operation increases as the control lever is moved farther in the desired direction.

B. How Do I Move the Riser Up or Down?

Push down on button in top of BOOM/RISER/TURRET ROTATE CONTROL LEVER and push control lever forward to RISER UP to lift the riser up. Push down on button in top of BOOM/RISER/TURRET ROTATE CONTROL LEVER and pull lever backward to RISER DOWN to lower the riser down.
The BOOM/RISER/TURRET ROTATE CONTROL LEVER is fully proportional. The speed of the operation increases as the control lever is moved farther in the desired direction.

C. How Do I Rotate the Turret?

Push the BOOM/RISER/TURRET ROTATE CONTROL LEVER left to ROTATE TURRET LEFT to rotate turret to the left or counterclockwise. Push the BOOM/RISER/TURRET ROTATE CONTROL LEVER right to ROTATE TURRET RIGHT to rotate turret to the right or clockwise.
The BOOM/RISER/TURRET ROTATE CONTROL LEVER is fully proportional. The speed of the operation increases as the control lever is moved farther in the desired direction.

D. How Do I Move the Boom In or Out?

Pull backward on BOOM IN/OUT CONTROL LEVER to BOOM OUT to move boom out (extend).
Push forward on BOOM IN/OUT CONTROL LEVER to BOOM IN to move boom in (retract).
The BOOM IN/OUT CONTROL LEVER is fully proportional. The speed of the operation increases as the control lever is moved farther in the desired direction.

Page 50

OPERATOR'S MANUAL

UNLOADING

SECTION 7

DESCRIPTION

PAGE NO.

UNLOADING AERIAL LIFT UNDER OWN POWER .

UNLOADING AERIAL LIFT NOT UNDER OWN POWER . 7 - 3

Page 51

OPERATOR'S MANUAL

UNLOADING

How Can The Aerial Lift Be Unloaded?

A. Under Own Power
B. Not Under Own Power
C. Lifting With Crane

A. Unloading Aerial Lift Under Own Power

1. Visually inspect aerial lift for any sign of damage, leaks, or loose wires. If any problems are identified, repairs must be made prior to unloading.
2. If unloading ramps are being used, select ramps of adequate capacity to support the weight of the aerial lift. These ramps must be wide enough to allow plenty of side clearance beyond the wheels. Information on the weight and width of the aerial lift is contained in the Specifications Section of this manual.
3. It is suggested to use a winch for loading and unloading the aerial lift. If the angle of the ramp(s) exceeds 14° (25%), a winch must be used to unload the aerial lift. Attach the winch cable to the loops provided for this purpose on the front of the base. Using a winch will assure greater safety in unloading the aerial lift and limit the speed that it can descend the ramp.

Page 52

OPERATOR'S MANUAL

UNLOADING

4. Make sure the winch cable is properly attached to the aerial lift and remove all tie-downs.
5. When going up or down a grade the platform should always be pointed down the slope (riser or counterweight end facing up slope) and with the boom centered over the steering wheels. Descend the slope in "increments". Allow the brakes to apply completely before once again operating the DRIVE/STEER CONTROL LEVER. Do not permit the aerial lift to "free-wheel" (uncontrolled acceleration) down any grade!
6. At ground control station, turn MASTER SWITCH to ON and turn knob of EMERGENCY STOP SWITCH clockwise to activate controls at aerial control station.
7. At aerial control station: enter platform, ensure entry gate is closed and latched. Attach fall protection gear to designated attaching point. Turn knob of EMERGENCY STOP SWITCH clockwise and start engine.
8. Straighten the wheels to allow direct travel down ramp.
9. Switch the DRIVE SPEED SELECT SWITCH to SLOW.
10. Remove all unnecessary personnel from the unloading area.
11. Use great care while driving and steering the aerial lift down the ramp. Use SLOW drive speed and keep all slack out of the winch cable (if used). Keep the drive function engaged while winching, to avoid damaging the aerial lift.
12. Lift and/or lower the jib as needed to prevent the bottom of the platform from contacting the ground, ramps, or truck, do not raise the jib any higher than necessary to do so.
13. When all wheels are on level ground, disconnect the winch cable from the aerial lift.

B. Unloading Aerial Lift Not Under Own Power

1. Visually inspect aerial lift for any sign of damage, leaks, or loose wires. If any problems are identified, repair before unloading aerial lift.
2. If unloading ramps are being used, select ramps of adequate capacity to support the aerial lift's weight. These ramps must be wide enough to allow plenty of side clearance beyond the wheels. This information can be found in the Specifications Section of this manual.

Page 53

OPERATOR'S MANUAL

UNLOADING

3. Attach the winch cable to the loops provided for this purpose on the front of the base.

4. Disengage the "non-steering axle" torque hubs (steering axle torque hubs can remain engaged).

Note: The aerial lift must be on a level surface with the wheels blocked (front and back) before disengaging the torque hubs!

Note: The brakes of the aerial lift will be disabled with the torque hubs disengaged!

To disengage torque hubs:

a. Remove the two (2) bolts securing the disconnect cap onto the torque hubs.
b. Turn the cap over and insert back into the torque hub so that the raised "nipple" on the cap depresses the "plunger" located beneath it.
c. Reinstall the disconnect cap and bolts.

Page 54

OPERATOR'S MANUAL

UNLOADING

5. Make sure the winch cable is properly attached to the aerial lift. Remove all tie-downs and wheel blocks.
Note: If unloading aerial lift from a "roll-back" or "tilt-back" truck, make sure the winch cable is properly attached to the base of the aerial lift and that all of the "slack" has been removed from the cable before raising the bed of the truck.
6. At ground control station: turn knob of EMERGENCY STOP SWITCH clockwise and turn MASTER SWITCH to START to start engine.
7. At aerial control station: enter platform, turn knob of EMERGENCY STOP SWITCH clockwise and turn ENGINE OFF/ON/START & EMERGENCY PUMP SWITCH to ON.
8. Step down on pedal of FOOT OPERATED SWITCH and operate DRIVE/STEER CONTROL LEVER to straighten out the steering wheels.
9. Remove all unnecessary personnel from the unloading area and position steering wheels to permit lowering the aerial lift down the ramp(s). If you must steer the aerial lift to keep it properly aligned on the ramp(s), block the non-steering wheels and enter the platform only to operate the DRIVE/STEER CONTROL LEVER. Do not stand in the platform when unloading the aerial lift not under it's own power!
11. The jib can be raised and/or lowered as needed to prevent the bottom of the platform from contacting the ground, ramps, or truck. Raise or lower the jib from the ground control station only, stop the winch before performing this task.
12. When all wheels are on level ground, block the wheels and re-engage the torque hubs prior to disconnecting the winch cable or before attempting to move the aerial lift.
To re-engage the torque hubs:
- a. Remove the two (2) bolts fastening the disconnect cap to the torque hub.
- b. Rock the wheel until the plunger in the center of the torque hub "pops" back out. DO NOT operate the drive function until the torque hubs are properly engaged.
- c. Turn the disconnect cap back over so that the nipple is pointed away from the face of the torque hub.
- d. Reinstall the cap back over the plunger, install the two (2) bolts and torque to approximately 84 inch pounds.

Page 55

OPERATOR'S MANUAL

UNLOADING

C. Lifting With Crane

1. Verify weight of aerial lift, this information can be found in the Specification Section of this manual and on the identification plate on the base of the aerial lift.
2. Use crane of correct capacity for weight of aerial lift and radius to be lifted.
3. Use rigging equipment capable of lifting the weight and designed to accommodate the geometry of the aerial lift.
4. Remove all personnel from the aerial lift and surrounding area.
5. Lift the aerial lift carefully and place it slowly on ground.
6. Remove all rigging equipment before moving aerial lift.

Page 56

OPERATOR'S MANUAL

LOADING

SECTION 8 DESCRIPTION

PAGE NO.

	•	•	8 - 1
LOADING AERIAL LIFT NOT UNDER OWN POWER			8 - 3
			8 - 6
	•	•	8 - 7

Page 57

OPERATOR'S MANUAL

LOADING

How Can The Aerial Lift Be Loaded?

A. Under Own Power
B. Not Under Own Power
C. Lifting Aerial Lift With Crane

A. Loading Aerial Lift Under Own Power

1. Visually inspect aerial lift for any sign of damage, leaks, or loose wires. If any problems are identified, repairs must be made before loading.
2. If loading ramps are being used, select ramps of adequate capacity to support the weight of the aerial lift. These ramps must be wide enough to allow plenty of side clearance beyond the wheels. Information on the weight and width of the aerial lift is contained in the Specifications Section of this manual.
3. It is suggested to use a winch for loading and unloading the aerial lift. If the angle of the ramp(s) exceeds 14° (25%), a winch must be used to load the aerial lift. Attach the winch cable to the loops provided for this purpose on the front of the base. Using a winch will assure greater safety in loading the aerial lift.

Page 58

OPERATOR'S MANUAL

LOADING

4. Position ramp or truck bed so that the centerline is in line with the centerline of aerial lift to ensure the aerial lift will not run off side of ramp.
5. Position the aerial lift at the bottom of the ramp(s) directly behind the bed of the truck with the nonsteering wheels touching the ramp(s) and the platform pointed away from the truck.
6. When going up or down a grade the platform should always be pointed down the slope (riser or counterweight end facing up slope) and with the boom centered over the steering wheels.
7. At ground control station, turn MASTER SWITCH to ON and turn knob of EMERGENCY STOP SWITCH clockwise to activate controls at aerial control station.

8. At aerial control station, enter platform, ensure entry gate is closed and latched. Attach fall protection gear to designated attaching point. Turn knob of EMERGENCY STOP SWITCH clockwise and start engine.
9. Straighten the wheels to allow direct travel up ramp
10. Switch the DRIVE SPEED SELECT SWITCH to SLOW.
11. Remove all unnecessary personnel from the loading area.
12. Use great care while driving and steering the aerial lift up the ramp. Use SLOW drive speed and keep all slack out of the winch cable (if used). If a winch is used and the ramp is too steep for the aerial lift to climb, the winch will pull the aerial lift up the ramp. Keep the drive function control engaged while winching, to avoid damaging the aerial lift.
13. Lift and/or lower the jib as needed to prevent the bottom of the platform from contacting the ground, ramp(s), or truck, do not raise the jib any higher than neccesary to do so (do not raise the boom )
14. When the aerial lift is on the truck and the aerial lift's weight is properly distributed on the truck's axles, the aerial lift is ready to be tied down. Turn the ENGINE OFF/ON/START & EMERGENCY PUMP SWITCH to OFF and push "in" on the EMERGENCY STOP SWITCH at both the aerial and ground control stations. Turn the MASTER SWITCH at the ground control station to OFF.
15. Tie down the aerial lift as shown later in this section.

Page 59

OPERATOR'S MANUAL

LOADING

B. Loading Not Under Own Power

1. Visually inspect hydraulic and electric lines and structure for any sign of damage, leakage, or loose wires. If any problems are identified, repair before loading aerial lift.
2. If loading ramps are being used, select ramps of adequate capacity to support the aerial lift's weight. These ramps must be wide enough to allow plenty of side clearance beyond the wheels. This information can be found in the Specifications Section of this manual.
3. Attach the winch cable to the tie down loops on the front of the base.

Page 60

OPERATOR'S MANUAL

LOADING

4. Disengage the "non-steering axle" torque hubs (steering axle torque hubs can remain engaged).

Note: The aerial lift must be on a level surface with the wheels blocked (front and back) before disengaging the torque hubs.

Note: The brakes of the aerial lift will be disabled with the torque hubs disengaged.

To disengage torque hubs:

a. Remove the two (2) bolts securing the disconnect cap onto the torque hub.
b. Turn the cap over and insert back into the torque hub so that the raised "nipple" on the cap depresses the "plunger" located beneath it.
c. Reinstall the disconnect cap and bolts.

5. Make sure winch cable is properly attached to the aerial lift and remove the wheel blocks.
6. At ground control station, turn knob of EMERGENCY STOP SWITCH clockwise and turn MASTER SWITCH to START to start engine.
7. At aerial control station, enter platform, turn knob of EMERGENCY STOP SWITCH clockwise and turn ENGINE OFF/ON/START & EMERGENCY PUMP SWITCH to ON.
8. Step down on pedal of FOOT OPERATED SWITCH and operate DRIVE/STEER CONTROL LEVER to straighten out the steering wheels.

Page 61

OPERATOR'S MANUAL

LOADING

9. Remove all unnecessary personnel from the loading area and position steering wheels to permit winching the aerial lift up the ramp(s) and exit the platform. If you must steer the aerial lift to keep it properly aligned to the ramp(s), block the non-steering wheels and enter the platform only to operate the DRIVE/STEER CONTROL LEVER. Do not stand in the platform when loading the aerial lift not under it's own power.
10. The jib can be raised and/or lowered as needed to prevent the platform from contacting the ground, ramps, or truck. Raise or lower the jib from the ground control station only, stop the winch before performing this task.
11. When the aerial lift is on the truck and it's weight is properly distributed on the truck's axles, turn the MASTER SWITCH to OFF and push "in" on the EMERGENCY STOP SWITCH at both the aerial and ground control stations.
12. The torque hubs must be reengaged before the aerial lift is tied down.

To reengage the sorque hubs:

a. Remove the two (2) bolts fastening the disconnect cap to the torque hub.
b. Rock the wheel until the plunger in the center of the torque hub "pops" back out. DO NOT operate the drive function until the torque hubs are properly engaged.
c. Turn the disconnect cap back over so that the nipple is pointed away from the face of the torque hub.
d. Reinstall the cap back over the plunger, install the two (2) bolts and torque to approximately 84 inch pounds.
13. Tie down the aerial lift as shown later in this section.

Page 62

OPERATOR'S MANUAL

LOADING

C. Lifting With Crane

1. Verify weight of aerial lift, this information can be found in the Specification Section of this manual and on the identification plate on the base of the aerial lift.
2. Use crane of correct capacity for weight of aerial lift and radius to be lifted.
3. Use rigging equipment capable of lifting the weight and designed to accommodate the geometry of the aerial lift.
4. Remove all personnel from the aerial lift and surrounding area.
5. Lift the aerial lift carefully and place it on the bed of the truck.
6. Remove all rigging equipment and tie down aerial lift as shown later in this section.

Page 63

OPERATOR'S MANUAL

LOADING

How Do I Tie Down The Aerial Lift?

1. Select chains strong enough to restrain the aerial lift during travel.

2. Lower the boom and riser fully! Do not place the platform down on the bed of the vehicle.

3. Attach the chains through the two (2) tie down loops on the sides of the aerial lift and "snug" them with chain binders or come-alongs.
4. The tie down chains must be attached as illustrated below and on decals on base of aerial lift. Restraining the aerial lift in locations other than the approved locations could cause serious damage to the aerial lift.

Page 64

OPERATOR'S MANUAL

MAINTENANCE

SECTION 9 DESCRIPTION

PAGE NO.

INTRODUCTION.		•	•	•	•	•	•	•	•	•	•	. 9 - 1
MAINTENANCE SCH	EDULE.	•			•		•			•		. 9-2
OWNER'S INSPECTION	ON RECOR	RD.		•								. 9-5
MAINTENANCE PRO	CEDURES.		·			•						. 9 - 6
AIR CLEANER	/COOLANT	•		•	•			٠	•	٠		. 9-6
ENGINE/HYDF	RAULIC OIL			٠	•		•	•	·		•	. 9-7
BATTERY							•				•	. 9-8

Page 65

OPERATOR'S MANUAL

MAINTENANCE

INTRODUCTION

In addition to the "Before Operation Checks" described in Section 5, a regular program of periodic preventive maintenance is absolutely essential to prolonging the life of the aerial lift, maximizing efficient service and minimizing downtime. This section details a series of checks and procedures which are performed at daily, weekly, monthly and semi-annual intervals.

Even if the operator is not directly responsible for maintenance of the aerial lift, he should perform daily, all of the inspections listed in the "Before Operation Check", in Section 5 of the "Operator's Manual".

NOTE: Report and repair all deficiencies noted during the "Before Operation Check". The operator should be assured that the aerial lift has been properly maintained and inspected before operating it.

MAINTENANCE SCHEDULE (ref pg. 9-2 - 9-3)

The maintenance checks prescribed for longer intervals include those required for the shorter intervals. Thus, the weekly check includes all items in the daily check, the monthly check includes all items in the weekly and daily checks, and so on through the semiannual check, which includes the quarterly, monthly, weekly and daily checks.

The maintenance schedule provided serves a guide to assure that the minimum basic preventive maintenance requirements will be met under average operating conditions. Conditions which impose greater wear, loads or strain on the aerial lift may dictate reducing the interval between these checks. Before altering the recommended maintenance schedule, reevaluate the aerial lift's operation and review the owner's inspection records. Consider all factors involved and develop a revised schedule adequate to meet routine maintenance requirements.

Refer to the engine manufacturer's manual for engine maintenance requirements. Should any discrepancy occur relative to the maintenance schedule provided in this manual and those provide by the engine manufacturer, the engine manufacturer's recommendations take precedence over those in this manual.

OWNER'S INSPECTION RECORD (ref pg. 9-5

Periodic maintenance of the aerial lift is the responsibility of the owner. The "Aerial Lift Inspection Report" shown on page 9-3 is to be used for recording the date of each inspection, person(s) performing the inspection, any deficiencies found, and corrective action.

This record also serves as a tool toward detecting problem areas and reanalyzing maintenance requirements.

Page 66

OPERATOR'S MANUAL

MAINTENANCE

Page 67

OPERATOR'S MANUAL

MAINTENANCE

Table 1: RECOMMENDED INSPECTION AND MAINTENANCE SCHEDULE

ITEM	ITEM DESCRIPTION	LUBRICANT	SERVICE/FREQUENCY
1	Rotation Gear Box	Gear Oil - SAE EP 90	Check Monthly
2	Battery, Terminals & Cables		Check Weekly
	Battery		Inspect Daily
3	Tie Rod Pins	Mobilcote Type - S	Lubricate Monthly
4	Ring Gear - (Race) (Gear Teeth)	Multi-Purpose Grease EP-2 (rotate while greasing) Mobilcote Type - S	Lubricate Monthly
5	Engine	Refer to Mfgs. Instructions	See Manufacturer's Instructions
6	Radiator (if applicable)	Refer to Mfgs. Instructions	Check Daily
7	Hydraulic Reservoir Fluid	Dexron II or equivalent	Check Daily Replace/Yearly
8	Torque Hubs	Gear Oil - SAE EP 90	Check Monthly Replace Yearly
9	Hydraulic Tank Strainer		Clean Yearly
10	Hydraulic Tank Filler Breather		Clean Yearly
11	Hydraulic Return Line Filter		Replace 100 Hours
13	Boom & Riser Pivot Pins	Mobilcote Type - S	Lubricate Monthly
14	Steering Yoke King Pins	Mobilcote Type - S	Lubricate Monthly
15	Air Filter	Change according to eng. manufacturer's recommen- dations	Inspect Weekly or as conditions dictate
16	Fuel Filter		Replace 100 Hours
17	Engine Oil Filter		See Manufacturer's Instructions
18	Engine Oil Level	Refer to Manufacturer's Instructions for Type	Check Daily
19	Fuel Tank(s)		Check/Fill Daily
20	Wheel Bearings	Multi-purpose Grease EP-1	Repack Yearly
21	Oscillating Axle Pivot Pin (if option is incorporated)	Mobilcote Type - S	Lubricate Monthly

Check each of the above items for security, loose or missing fasteners, leaks, wear, or evidence of cracks. Check all visible electric wiring and hydraulic hoses for cracking or "checking", loose connections, fraying, chafing or excessive wear. If a problem is found with any of the following items, do not operate the aerial lift until a qualified aerial-lift technician makes the necessary repairs.

TA6 4

Page 68

OPERATOR'S MANUAL

MAINTENANCE

NOTES







	and the standard of the standards and standard standards at the standards at the standard standards at the standard standards at the standards at the standard standards at the standards at the standards at the standard standards at the standard








······································

···· ·

Page 69

	MarkIndu	ıstries			Returr	n To:	Mark Industries 106 12th Street S.E. Waverly, IA 50677-946	6
AERIAL LIFT INSPECTION REPORT
			30-DAY INSPECTION
MACHINE: SCISS		SCISSOR I
				OWNED
DISTRIBUTOR				ENGINE S/N						_
ADDRESS				MODEL SERIAL NO
CUST					IETER

Sciss	sors - Inspections	OK	NOT OF	K N/A	Bo	ooms a	Ind Knucklebooms-	0K	NOT OK	N/A
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.	Platform Gate Latch Platform Gate Platform Gate Platform Deck Collars on Scissor-pivot Hydraulic Pump Wear (Slide) Pads Tires and Wheels Wheel Bearings Steering Brackets Wheel Lug Nuts Hydraulic fluid Return Fi Lift Cylinder and Pins Hydraulic fluid Return Fi Lift Cylinder and Pins Hydraulic Valve Batteries Battery Compartments Battery Tops, Terminals. and Cables Proximity Switches Drive Motors Steering Cylinder and P Extendable Platform De (Slide, Roller, and Hand Assemblies) Hoses Electrical Wiring Hydraulic Hoses Decals Operator's Manual in Pla	Pins	00000000000000000000000000000000000000	000000000000000000000000000000000000000	1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.	Platfor Platfor Platfor Platfor Boom Air Filt Engine Torque Boom Platfor Tie Ro Steeri Steeri Fuel 1 Return Hydra Hydra Whee Boom Exten Proxid Boom Rotat Powe Opera Opera Tires Deca Elect Hydra	m Gate Latch m Gate & Gaurd Rails m Floor & Toe Plate Pivot Pin er e Oll e Hub, Drive Motor/Brake e Ring-gear Bolts Assembly rm Rotator od Pin ng-yoke King Pins ng Cylinder ank n-line filter whic Reservoir Fluid whic Pump whic Valve I Lug Nuts cable Equalizer Brackets d & Retract Cables mity Switches l/Riser-lift Cylinder Pins l/Riser-lift cylinder ion Gear Box rr Track ation and Maintenance ators Manual in Platform	000000000000000000000000000000000000000	000000000000000000000000000000000000000
			_ DATE:			TITLE:

Explain any deficiencies found, corrective action taken, and identification of the person(s) performing the repair:

_____

Page 70

OPERATOR'S MANUAL

MAINTENANCE

Air Cleaner

The air cleaner should be checked and cleaned on a weekly basis. To clean the air cleaner:

Loosen the clamp securing the cup to the air cleaner
Remove the cup and clean out any dirt or foreign matter in the cup.
Reinstall the cup and tighten the clamp.

Coolant Level

The coolant level must be checked daily. The coolant level is checked at the coolant reservoir. Ensure that the coolant level is between the Full and Low marks on the coolant reservoir while the engine is cool. If the coolant level is near or below the Low mark, add a equal amounts of antifreeze and water until the level is at the Full mark. Do not add alcohol or methanol antifreeze. Refer to the engine manufacturers manual for additional information. CAUTION do not open hot radiator! Allow radiator to cool if engine has been operated recently.

Page 71

OPERATOR'S MANUAL

MAINTENANCE

Hydraulic & Engine Oil

Various hydraulic fluid manufacturer's use different additives which may cause problems in a hydraulic system when mixed together. This situation is rare but can cause sludge, which can plug filters, or acid which can etch machined surfaces in hydraulic components or deteriorate seals. Any of the above conditions can result in a hydraulic component warranty being voided. If, knowing all this, you still choose to add fluid different from that initially supplied ("NORTRAN automatic transmission fluid", equivalent DEXRON II), stay with a single brand as this will minimize the likelihood of problems occurring. Then at the first complete hydraulic fluid change, you may switch to the brand you prefer to use.

If engine oil needs to be added, the aerial lift owner must be contacted to find out what brand and viscosity of oil is being used. Use the same brand and viscosity of oil that is presently being used in the aerial lift when adding engine oil. The aerial lift owner should refer to the engine manufacturers manual to select the proper oil to use.

Hydraulic Oil

Check the hydraulic fluid level on a daily basis. The oil level must be between the "HIGH" and "LOW" marks in the sight glass of the hydraulic tank. Add fluid as needed through the filler neck on top of the hydraulic tank. The hydraulic system was filled at the factory with Nortran automatic transmission fluid (equivalent Dexron II). Any oil used in this aerial lift's hydraulic system must meet the specifications of Dexron II.

Engine Oil

Check the engine oil level on a daily basis. The oil level must be within the "SAFE" level on the engine oil dipstick. Add oil as needed in the filler cap on top of the engine. Refer to the engine manufacturer's manual for the recommended type oil.

Page 72

OPERATOR'S MANUAL

MAINTENANCE

BATTERY

Avoid Battery Hazards!

Batteries produce flammable and explosive gasses. Keep electric arcs, sparks, flames, and lit cigarettes (pipes, cigars, etc.) away from batteries.
Battery acid will damage eyes or skin on contact. Always wear a face shield during battery maintenance to avoid getting acid in eyes. Always wear rubber gloves and protective clothing to keep acid off skin.
Never check the battery by placing a metal object across the posts. Serious burns or an explosion can result.

Checking the Battery Electrolyte Level

Check the colored "eye" in the top of the battery, a green color indicates that battery electrolyte level is okay.

Water or Acid Loss to Batteries

Water loss from the battery occurs mainly as the result of evaporation brought on by temperature rises during charging. A small amount may be lost due to gasses formed during charging. Electrolyte may be lost if the case becomes cracked or the battery tips over. Therefore, electrolyte is seldom needed.

Checking the Electrolyte (Battery Water) level "physically"

When checking the electrolyte level, don't allow dirt to enter into the battery cells once the caps have been removed. Take particular care to avoid setting the battery-cell caps down on a dirty surface. Replace the caps immediately after checking the level.

Page 73

OPERATOR'S MANUAL

MAINTENANCE

BATTERY

Battery Fill Instructions

FILLING THE BATTERY

MATERIALS AND EQUIPMENT REQUIRED

1. Battery Filler Bottle
2. Distilled Water

If the battery water level is below the plates add only enough water to cover the plates approximately 1/2 inch, DO NOT fill to indicator ring.

Note : With proper attention to water level the battery should have a long, useful life.

Page 74

OPERATOR'S MANUAL

EMERGENCY PROCEDURES

SECTION 10 DESCRIPTION

PAGE NO.

A. ENGINE DIES WITH PLATFORM ELEVATED.	. 10 - 1
B. OPERATOR IN PLATFORM BECOMES INCAPACITATED.	. 10 - 1
	. 10 - 1

Page 75

OPERATOR'S MANUAL

EMERGENCY PROCEDURES

This section provides information on the procedures to be followed and on the systems and controls to be used in the event of an emergency.

A. Engine Dies With Platform Elevated

If the engine dies; make sure the EMERGENCY STOP SWITCH is released by turning the knob clockwise. Attempt to restart the engine by first turning the ENGINE OFF/ON/START & EMERGENCY PUMP SWITCH to the OFF position and then back to START. If the engine does not start promptly, do not hold the starter engaged for an extended period.

Prolonged "engagement" (operating) of the starter may damage the starter or drain battery power. The battery may be needed to operate the EMERGENCY PUMP to enable the platform to be lowered. If the engine restarts, lower the platform to the ground and determine the cause of the engine failure before attempting further of use the aerial lift.

If the engine fails to start after a number of attempts, turn the IGNITION SWITCH to the OFF position and back to the ON position. Turn the ENGINE OFF/ON/START & EMERGENCY PUMP SWITCH to EMERGENCY PUMP, step down on the pedal of the FOOT OPERATED SWITCH and operate the platform controls in the normal manner to lower the platform to the ground.

Once the platform is safely on the ground, exit the platform and DO NOT attempt to operate the aerial lift again until the cause of the engine failure has been determined and corrected.

B. Operator In Platform Becomes Incapacitated

If the operator in the platform becomes incapacitated or is unable to lower the platform from the aerial control station, the platform can be lowered from the GROUND CONTROL STATION.

To lower the platform from the ground control station:

turn the knob of the EMERGENCY STOP SWITCH clockwise.
make sure the MASTER SWITCH is turned to ON.
if the engine is not running or cannot be started, push the EMERGENCY PUMP SWITCH to EMERGENCY PUMP.
use the BOOM IN/OUT, BOOM UP/DOWN RISER UP/DOWN and TURRET ROTATE switches as needed to lower the platform to the ground (it is not necessary to hold the AERIAL/GROUND SELECTOR SWITCH to GROUND to enable operation of the controls)

C. Incident Notification

It is imperative that Mark Industries be notified immediately of any incident involving a Marklift. Even if no injury or property damage is evident, the factory should be contacted and provided with all necessary details.

TA6 4

Page 76

OPERATOR'S MANUAL

INDEX

SECTION 11

- A -

Aerial Control Station 4 - 2 Air Cleaner, Maintenance 9 - 6 Antifreeze 9 - 6

- B-

Battery Maintenance 9 - 8 Battery Fill 9 - 9

· - C -

Capacity, Platform 5 - 10 Check List, Before Operation 5 - 2 Clearances 5 - 10 Conductors, Operating Near 2 - 5 Coolant, Maintenance 9 - 6 Cut-outs 5 - 8

- D -

Decal List 5 - 4 Dimensions 3 - 3 Dual Fuel System 6 - 1

- E -

EMI Safety Manual 2 -1 Emergency Procedures 10 - 1 Emergency Pump Operation 6 - 2 Engine Stopping 6 - 1 Starting 6 - 1 Engine Oil Maintenance 9 - 7 Entry Gate 5 - 10

- F-

Fast-speed Cut-out 5 - 9

- G -

Gasoline To Propane, Switching From 6 - 1 Gate 5 - 10 Ground Control Station 4 - 10 Guardrails 5 - 10

- H -

Hydraulic Oil Maintenance 9 - 7

- 1 -

Incident Notification 10 - 1 Interlocks 5 - 8 Inspection Report 9 - 5

- L -

Lifting Aerial Lift With A Crane 7 -5/8 - 6 Loading Aerial Lift 8 - 1 Loads, Platform 5 - 10 Loads, Wheel 5 - 11

- M -

Maintenance 9 - 1 Manual Of Responsibilities 2 - 1

-0-

Operating In Windy Conditions 5 - 11 Operation 6 - 1 Overhead Clearance 5 - 10

- P -

Platform Capacity 5 - 10 Platform Loads 5 - 10 Platform Surface 5 - 10 Power Lines, Operating Near 2 - 5 Prestart Check List 5 - 2 Propane To Gasoline, Switching From 6 - 1

Page 77

OPERATOR'S MANUAL

INDEX

SECTION 11

- R -

Radiator 9 - 6 Responsibilities, Manual Of 2 - 1

- S -

Safety 2 - 1 Safety, Battery 2 - 4 Slip And Fall Prevention 2 - 3 Specifications 3 - 1 Switching From Gasoline To Propane 6 - 1 Switching From Propane To Gasoline 6 - 1 Symbol Identification 4 - 1

- T -

Tie Down For Transport 8 - 7 Tip Over Prevention 2 - 1 Towing 2 - 2 Training 2 - 1 Transporting 8 - 7 Travel Surfaces 5 - 11 Travelling 6 - 2 Full Speed 6 - 5 In Reverse 6 - 5 On Grades (Slopes) Or Ramps 6 - 3 On Level Surfaces 6 - 2 Turning 6 - 5

- U -

Universal Symbol Identification 4 - 1 Unloading Aerial Lift 7 - 1 Unstable Condition Warning Light & Alarm 5 - 7

- W -

Wheel Loads 5 - 11 Wind, Operating In 2 - 1, 5 - 10

Page 78

DETROIT DIESEL

—Q

CALIFORNIA PROPOSITION 65 INFORMATION

CORPORATION

TO CALIFORNIA CUSTOMERS AND TO COSTOMERS SELLING DIESEL ENGINE EQUIPMENT INTO OR FOR USE IN CALIFORNIA

Proposition 65, a California law, requires warnings on products which expose individuals in California to chemicals listed under the law, including certain chemicals in diesel engine exhaust.

Obligations of Manufacturers of Diesel-Powered Off-Road Equipment. The California Superior Court has approved either of the following two methods of compliance with Proposition 65 requirements by manufactures of off-road equipment containing diesel engines. (The court order containing these provisions may be furnished on request.)

On-Equipment Warning. Place the warning pictured in attachment 1 on all equipment shipped by you into or for sale in California after January 1, 1996. The warning must be in a location where it is easily visible to the operator of the equipment when (s)he is operating the equipment. The warning must be secured to the equipment. If warnings or operating instructions are provided through a digital display, you may use that method of providing the warning.
2. Operator Manual Warning. When the operator manual is next revised or by December 31, 1995, whichever is earlier, place the warning in attachment 2 in the operator manual. The warning may be either printed in the manual or a sticker.

The warning must appear in one of the following locations.

* Inside the front cover
* Inside the back cover
* Outside the front cover
* Outside the back cover
* As the first page of text

Under either alternative, the warning must appear in the same size, print and format as the attachment selected or be of equally conspicuous size and format. If the warning is provided in an on-screen display, the warning must contain the language in the attachment and must be provided at the time of or in connection with ignition in the same manner as other safety warnings electronically communicated on screen.

Obligation of Resellers of Diesel Engines. This letter must accompany any loose diesel engine sold in California.

Should you have any questions, please call Detroit Diesel Corporation, Mr. John F. Farmer on (313) 592-7111, Fax (313) 592-5014.

Page 79

CALIFORNIA Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm.

Genie Terex® TA Series Operator's Manual

TABLE OF CONTENTS

DESCRIPTION

SECTION NO.

INTRODUCTION

Owners, Users, and Operators:

SAFETY

SECTION 2

DESCRIPTION

PAGE NO.

SAFETY

OPERATOR'S MANUAL

SAFETY

OPERATOR'S MANUAL

SAFETY

SAFETY

SAFETY

OPERATION IN THE VICINITY OF ELECTRICAL CONDUCTORS

SAFETY

IF CONTACT IS MADE

SECTION 3

DESCRIPTION

PAGE NO.

OPERATOR'S MANUAL

SPECIFICATIONS TA64

RANGE DIAGRAM MODEL TA64 KNUCKLE BOOM LIFT

TA64 KNUCKLE BOOM LIFT GENERAL DIMENSIONS

OPERATOR'S MANUAL

CONTROLS & INSTRUMENTS

SECTION 4

DESCRIPTION

PAGE NO.

OPERATOR'S MANUAL

CONTROLS & INSTRUMENTS

SAFETY HORN FAST BATTERY SLOW OFF CIRCUIT BREAKER ON HOUR METER ENGINE FUEL / PETROL START EMERGENCY PUMP WORK LIGHTS DRIVE GENERATOR

UNIVERSAL SYMBOL IDENTIFICATION

CONTROLS & INSTRUMENTS

CONTROLS & INSTRUMENTS

CONTROLS & INSTRUMENTS

AERIAL CONTROL STATION

OPERATOR'S MANUAL

CONTROLS & INSTRUMENTS

CONTROLS & INSTRUMENTS

CONTROLS & INSTRUMENTS

NON-SELECTED OPTIONS/FEATURES

CONTROLS & INSTRUMENTS

OPERATOR'S MANUAL

CONTROLS & INSTRUMENTS

GROUND CONTROL STATION

CONTROLS & INSTRUMENTS

GROUND CONTROL STATION

CONTROLS & INSTRUMENTS

OPERATOR'S MANUAL

CONTROLS & INSTRUMENTS

GROUND CONTROL STATION

BEFORE OPERATION CHECK

SECTION 5

DESCRIPTION

PAGE NO.

BEFORE OPERATION CHECK

WHAT NEEDS TO BE INSPECTED?

OPERATOR'S MANUAL

BEFORE OPERATION CHECK

BEFORE OPERATION CHECK LIST

Mathematical TEREX AERIALS

BEFORE OPERATION CHECK

OPERATOR'S MANUAL

BEFORE OPERATION CHECK

DECAL CHECK LIST

BEFORE OPERATION CHECK

What Should I Know?

Emergency operation from ground control station if platform controls are inoperable:

Emergency operation from platform if engine fails to start or main hydraulic pump is inoperable:

OPERATOR'S MANUAL

BEFORE OPERATION CHECK

Before operating the aerial lift, perform the following procedures:

OPERATOR'S MANUAL

BEFORE OPERATION CHECK

A. Interlocks, Cut-outs and Warnings: What Interlocks, Cut-outs, And Warnings Do I Have?

*Operating Instructions To Check Interlocks, Cut-Outs, & Warnings