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Terex HI-RANGER TM Series User Manual

Terex HI-RANGER TM Series
116 pages
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OPERATORS MANUAL
This Operators Manual MUST BE READ prior to operating your
TM SERIES Non-Overcenter Material Handling Aerial Device.
PRINTED IN THE USA
Original Instructions in English
HI–RANGER
TM SERIES
Terex South Dakota, Inc. 472797 01/2015

Table of Contents

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Terex HI-RANGER TM Series Specifications

General IconGeneral
BrandTerex
ModelHI-RANGER TM Series
CategoryConstruction Equipment
LanguageEnglish

Summary

INTRODUCTION

OWNERS, USERS AND OPERATORS

Guidance for owners, users, and operators on safe equipment use and responsibilities.

PRODUCT IDENTIFICATION

Details on locating the serial number and ID plaque for equipment identification.

INTENDED USE

Defines the specific applications and limitations for the aerial device.

BULLETIN DISTRIBUTION AND COMPLIANCE

Owner's responsibility to comply with safety and product information bulletins.

CONTACTING THE MANUFACTURER

Information required when contacting the manufacturer for support or inquiries.

TRANSFER OF MACHINE OWNERSHIP

Procedure for updating ownership records for manufacturer notifications.

SAFETY

HAZARD CLASSIFICATION SYSTEM

Explains signal words (Danger, Warning, Caution) and their safety implications.

PROPERTY DAMAGE MESSAGES

Defines the 'NOTICE' signal word for non-hazard-related information.

GENERAL SAFETY GUIDELINES

Essential rules for safe operation of the aerial device, emphasizing care and common sense.

BEFORE OPERATION

DURING OPERATION

ELECTRICAL HAZARDS

ACCESSORIES

USE ONLY HYDRAULIC TOOLS EQUIPPED WITH ORANGE HOSES MARKED NON-CONDUCTIVE

Hydraulic tools must use specific hoses for safety, especially near power lines.

MATERIAL HANDLING

USE ONLY A SYNTHETIC ROPE FOR THE WINCH LINE. DO NOT USE A WIRE ROPE.

Specifies the type of rope for winch lines to ensure safety and proper function.

TRAVELING

NEVER TRAVEL WITH PERSONNEL IN THE PLATFORM.

Prohibits transporting personnel in the platform while the vehicle is in motion.

MAINTENANCE

INSPECT, MAINTAIN, AND REPAIR THIS AERIAL DEVICE IN ACCORDANCE WITH THE MAINTENANCE MANUAL

Follow the device and manual's maintenance procedures for safety and longevity.

OVERVIEW OF POTENTIAL HAZARDS

Alert Symbol

Explains the 'DANGER' alert symbol and its relation to serious injury.

SAFETY RELATED DECALS

NOTE: *Use decal 419265 and 465703 when Aerial Device is not certified...

Specific decal usage noted for devices not certified to latest ANSI A92.2 revision.

WHAT IS INSULATED AND NOT INSULATED

Area A. Upper Boom Insulation

Describes the upper boom's insulating area and maintenance requirements.

Area B. Lower Boom Insert

Details the lower boom insert's insulating function and condition requirements.

Area C. Elbow

Explains the elbow section does not provide insulation and its conductive materials.

Area D. Boom Tip

Notes the boom tip is not insulated and contains conductive materials.

Area E. Does not provide insulation

States Area E contains conductive materials and requires proper grounding.

ELECTRICAL INSULATION

PREVENTION OF ELECTROCUTION

Provides guidelines to prevent electrocution, emphasizing cleanliness and proper procedures.

OPERATION ON OR NEAR ENERGIZED CONDUCTOR

Details special conditions and limitations when working near energized conductors.

OPERATION GUIDELINES

NOMENCLATURE

Diagram and labels identifying key components of the aerial device.

CAB CONTROL OPERATION

Details operation of controls located within the vehicle cab.

MASTER CONTROL

Explains the master control switch for energizing systems and throttle options.

ENGINE STOP/START (OPTIONAL)

Describes the push-button operation for starting and stopping the engine.

POWER TAKE-OFF (OPTIONAL)

Explains the PTO's function in transmitting power to the hydraulic pump.

CAB CONTROL FUNCTIONS

Illustrates and describes functions of various controls found in the cab.

CONTROLS BELOW ROTATION

UTILITY VEHICLE CONTROL LOCATIONS

Diagram showing typical locations of controls at the rear of the vehicle chassis.

CONTROLS BELOW ROTATION FUNCTIONS

Detailed explanation of functions for controls located below the rotation.

OPERATOR CONTROLS AND DESCRIPTIONS

SINGLE STICK

Describes the single stick control for boom functions and its enable lever.

LIFT LOCK HANDLES

Explains the spring-loaded levers that lock control levers in neutral position.

UPPER CONTROLS

SINGLE STICK

Details the controls and descriptions for the single stick operation.

SINGLE STICK FUNCTIONS

Explains the functions controlled by the single stick, including safety notes.

LOWER CONTROLS

ITEM CONTROL DESCRIPTION

Table listing controls and their descriptions for the lower control station.

TOP CONTROL AND OPTION SHUT OFF

Function of the shut-off to stop upper controls and override in emergencies.

LOWER CONTROL FUNCTIONS

Describes functions of various controls at the lower station, including platform tilt.

OPERATIONAL LIMITATIONS

PLATFORM LEVELING SYSTEM

Details the platform leveling system and its limitations, including collision avoidance.

PLATFORM LEVELING SYSTEM WITH GENERATOR

Description of the platform leveling system charged by an onboard generator.

PLATFORM LEVELING (WITHOUT GENERATOR)

Describes the battery-powered platform leveling system and its maintenance.

PLATFORM ROTATOR (OPTIONAL)

Prior to platform rotation, observe all obstructions and hazards...

Pre-rotation checks for obstructions, hazards, and contact with lines are crucial.

JIB & WINCH OPERATION (OPTIONAL)

Never allow personnel to be under loads being lifted.

Critical safety warning against having personnel beneath lifted loads.

JIB ROTATION

MANUAL JIB EXTENSION

Procedure for extending the inner and second outer jib sections manually.

HYDRAULIC JIB EXTENSION (OPTIONAL)

DETERMINING LIFT CAPACITIES

Explains how to use the boom angle indicator and load chart for capacity.

AVOID TRAPPED LOOPS

Use only synthetic rope for winch line.

Specifies synthetic rope for winch lines, not wire rope, for safety.

BOOM LIFTING EYE MATERIAL HANDLING (OPTIONAL)

Never exceed the rated load capacity of the Aerial Device.

Crucial warning against exceeding load capacity to prevent injury or instability.

PERSONNEL AND TRAINING

FAILURE TO OBEY THE FOLLOWING WILL RESULT IN DEATH OR SERIOUS INJURY

Emphasizes consequences of not following safety rules for stationary operation.

AN UNTRAINED OPERATOR SUBJECTS HIMSELF AND OTHERS TO DEATH OR SERIOUS INJURY

Highlights risks of operating without proper training and certification.

PRE-OPERATION

DAILY PRE-OPERATION CHECKS

List of daily checks required before operating the Aerial Device.

AERIAL DEVICE CHECKS

Checklist of components for the aerial device to be inspected.

JOB SITE SURVEY

OPERATING TEMPERATURE RANGE

WIND SPEED

JOB SITE SETUP

SETTING THE OUTRIGGERS

OUTRIGGER CONTACT WILL CAUSE SERIOUS CRUSHING INJURY

Warning about outrigger hazards and the need to stand clear.

SETTING UP ON A SOFT SURFACE

SETTING UP FOR OPERATION ON SNOW AND ICE

BOOM INTERLOCK

STABILITY

Keep loads close to the ground until you determine for sure that the load can be balanced safely...

Advice to keep loads low until stability is confirmed at desired distance.

OPERATION

BOOM OPERATION

Details boom movement limitations and the non-overcenter positioning system.

AERIAL OPERATION

READ CAREFULLY DEATH OR SERIOUS INJURY WILL RESULT FROM SUCH CONTACT OR INADEQUATE CLEARANCE

Crucial warning about electrical contact hazards and the need for proper clearance.

EMERGENCY OPERATION

POWER LINE CONTACT ON GROUND VEHICLE IS TOUCHING A POWER LINE

Step-by-step procedure for handling a vehicle that has contacted a power line.

AUXILIARY LET DOWN POWER (OPTIONAL)

MANUAL LET DOWN SYSTEM

MANUAL ROTATION

HYDRAULIC LINE FAILURE

Escaping fluid under pressure can penetrate skin causing serious injury.

Warning about hazardous nature of high-pressure hydraulic fluid leaks.

ENGINE FAILURE

HYDRAULIC PUMP FAILURE

CONTROL VALVE FAILURE

OPERATIONAL LIMITATIONS

PLATFORM LEVELING SYSTEM

Details the platform leveling system and its limitations, including collision avoidance.

PLATFORM LEVELING SYSTEM WITH GENERATOR

LIMIT SYSTEM (OPERATIONAL RANGE)

The TM Series is a non-overcenter Aerial Device.

States the TM Series is non-overcenter and has limits for stability.

FOLDING FOR TRAVEL

LEAVING THE JOB SITE

MAINTENANCE GUIDELINES

PREVENTATIVE MAINTENANCE

Importance of a preventative maintenance program based on manufacturer recommendations.

LUBRICATION

GENERAL INFORMATION

FREQUENT AND PERIODIC INSPECTION INTERVALS

DAILY

Daily inspection checklist for controls, equipment, and systems.

30 DAYS (120 HOURS)

30-day inspection requirements, including battery exchange for non-generator units.

90 DAYS (360 HOURS)

90-day inspection requirements, including filter replacement and lubrication.

180 DAYS (720 HOURS)

180-day inspection requirements, including hose inspection and bearing bolt tightness.

12 MONTHS (1,050 HOURS)

5 YEARS

Five-year maintenance task: disassembly and inspection of leveling gearbox.

OPERATIONAL TESTS

Procedures for testing boom movements, controls, and system functions.

SPEED TESTS

Checks for smooth boom travel and hose operation within specified limits.

CONTROL SYSTEM

Tests for control handle return, smooth starting motion, and trigger function.

ELECTRICAL TESTS

Mandatory dielectric testing of booms and insulation components.

LUBRICATION CHART

WINCH ROPE INSPECTION

DAILY ROPE INSPECTION

HOOK INSPECTION

STORAGE PROCEDURE

APPENDIX A STANDARDS AND REGULATIONS

ANSI STANDARDS

Lists applicable ANSI standards for operation and maintenance of the unit.

OSHA REGULATIONS

Lists applicable OSHA regulations for operation and maintenance of the unit.

OSHA EXCERPTS: (CLEARANCE DISTANCE)

Excerpts from OSHA Standards regarding clearance distances near overhead lines.

STANDARD HAND SIGNALS

APPENDIX B RESPONSIBILITIES

7. RESPONSIBILITIES OF DEALERS AND INSTALLERS.

Details responsibilities for dealers and installers regarding vehicle specs, installation, and training.

8. Responsibilities of Owners.

Owner's duties for inspection, testing, maintenance, training, and transfer of ownership.

9. Responsibility of Users.

User's general responsibilities for operation, inspection, and maintenance.

9.3.1 General Training

Requirements for general training for aerial device operators.

10. Precautions.

Operator precautions before and during use, including checks and load limits.

10.11 Mobile Operation.

Determining if the device is designed for mobile operation before engaging.

11. Responsibilities of Lessors or Lessees.

APPENDIX B SURVEY OF JOB SITE

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