Terex TM Series Operator's Manual
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Terex TM Series Operator's Manual

Terex TM Series Operator's Manual

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HI–RANGER
TM SERIES
OPERATOR'S MANUAL
This Operator's Manual MUST BE READ prior to operating your
TM SERIES Non-Overcenter Material Handling Aerial Device.
PRINTED IN THE USA
Original Instructions in English
Terex South Dakota, Inc.
472797 07/2022

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  • Page 1 HI–RANGER TM SERIES OPERATOR’S MANUAL This Operator’s Manual MUST BE READ prior to operating your TM SERIES Non-Overcenter Material Handling Aerial Device. PRINTED IN THE USA Original Instructions in English Terex South Dakota, Inc. 472797 07/2022...
  • Page 2 TM SERIES WARNING Operating, servicing and maintaining this equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. These chemicals can be emitted from or contained in other various parts and systems, fluids and some component wear by-products.

  • Page 3: Table Of Contents

    TM SERIES TABLE OF CONTENTS INTRODUCTION ..............- I OWNERS, USERS AND OPERATORS .
  • Page 4 TM SERIES PLATFORM ROTATOR (OPTIONAL) ..........1 - 28 JIB &...
  • Page 5 TM SERIES SECTION 2 ..............2 - 1 MAINTENANCE GUIDELINES .
  • Page 6 TM SERIES t o c - 4 47 279 7 - 7/2 2 Te re x So uth Da kota , Inc. T M Se ri es...

  • Page 7: Introduction

    If unit is resold, Terex South Dakota must be notified in writing, within 60 days, of new owner and what steps were taken to instruct the new owner as to the operation and maintenance of the unit. Copies of operators and maintenance manuals must accompany the unit at the time of sale.

  • Page 8: Unauthorized Use

    BULLETIN DISTRIBUTION AND COMPLIANCE It is the owners responsibility to comply with all bulletins issued by Terex South Dakota, Inc. or the vehicle manufacturer. Safety of product users is of paramount importance to Terex South Dakota, Inc. Various bulletins are used by Terex South Dakota, Inc.

  • Page 9: Safety

    The operator is the single most important factor for safety when using any piece of equipment. Learn to operate your Terex South Dakota, Inc. equipment in a safe manner. NOTE: The best method to protect yourself and others from injury or death is to use common sense.
  • Page 10 Any such modification will void any remaining warranty. 3. Terex South Dakota, Inc. reserves the right to change, improve, modify or expand features of its equipment at any time. Specifications, model or equipment are subject to change without notice and without incurring any obligations to change, improve, modify or expand features of previously delivered equipment.
  • Page 11 TM SERIES GENERAL SAFETY GUIDELINES 1. The use of this Aerial Device is subject to certain potential dangers that cannot be protected against by mechanical means. Only the exercise of intelligence, care, and common sense can eliminate these dangers. It is essential to have competent, careful operators who are physically and mentally fit, and thoroughly trained in the safe operation of this Aerial Device.

  • Page 12: Before Operation

    TM SERIES BEFORE OPERATION 1. Survey the conditions of the work area. Identify situations such as; soft ground, ditches, drop-offs, holes, debris, overhead obstructions, electrical conductors, and underground utilities. 2. Plan the job (tailgate session) and clear the area of bystanders.

  • Page 13: During Operation

    TM SERIES DURING OPERATION 1. Never operate the Aerial Device unless you know the location, function, and operation of all the controls, including emergency and accessory operation. 2. Avoid abrupt starts, stops and reversal of direction. Operate all controls slowly for smooth motion.

  • Page 14: Electrical Hazards

    TM SERIES ELECTRICAL HAZARDS ELECTRICITY OBEYS NO LAW, BUT ITS OWN. 1. Electricity is an ever-present danger when using an Aerial Device. Follow all OSHA, ANSI, state, federal and company rules and regulations when working on or near energized power lines.

  • Page 15: Accessories

    TM SERIES 17. All metal components at the boom tip beyond the band of arrows are interconnected. Contact of any part to an energized conductor will energize the entire boom tip, including the controls. 18. Do not attach any metal objects from outside the platform to the inside of the platform. This defeats the purpose of the platform liner.

  • Page 16: Traveling

    TM SERIES 5. Keep the winch rope clean and dry. 6. Inspect the winch rope daily. Do not operate with a damaged or frayed rope. 7. Use a sling. Do not use the winch rope as a sling. 8. Use only hooks with a safety latch.

  • Page 17: Maintenance

    The operators shall read and understand this manual and be trained to use the machine in an appropriate and safe manner. Should any questions arise concerning the maintenance or operation of the machine contact Terex South Dakota, Inc.. SYMBOL...
  • Page 18 TM SERIES Operators DANGER: Failure to follow will Read and follow operator’s manual for safe operation. Manual cause serious injury. Maintenance DANGER: Failure to follow will Follow all inspection and maintenance to prevent Manual cause serious injury. failure. Electrical DANGER: Will cause Serious...
  • Page 19 TM SERIES Lanyard Attach. WARNING: Failure to Attach Attach lanyard to the anchor provided. Can Cause Serious Injury or Death. Fall DANGER: Will cause Serious Always wear an OSHA approved fall arrest system with Injury or Death. lanyard attached to anchor provided.

  • Page 20: Safety Related Decals

    TM SERIES SAFETY RELATED DECALS Safety signs are designed and fitted to the product to warn of possible dangers, and MUST be replaced immediately if they become unreadable or lost. If the product is repaired and parts have been replaced on which safety signs were fixed, be sure new safety signs are fitted before the product is put into service.
  • Page 21 TM SERIES PROP 65 OPERATING STATION 622232 CAUTION DECAL 70191 PROP 65 DRIVER SIDE WINDOW 622233 TRUCK MUST BE LEVEL BEFORE OPERATING BOOMS 79584D T M S er ie s Te r e x S o u t h D a k o t a , I n c .
  • Page 22 TM SERIES 3. & 4. NOT INSULATED BOOM IS READ CAREFULLY BEYOND ARROWS OCCUPANTS OF THE BASKETS OF THIS AVOID CONTACT WITH ENERGIZED LINES. AERIAL DEVICE HAVE ABSOLUTELY NO 402236A ELECTRICAL PROTECTION FROM CONTACT BY THE HUMAN BODY WITH TWO ENERGIZED CONDUCTORS OR BETWEEN AN ENERGIZED CONDUCTOR AND A GROUNDED CONDUCTOR.
  • Page 23 TM SERIES FAILURE TO OBEY THE FOLLOWING WILL RESULT IN DEATH OR SERIOUS INJURY For stationary operation, truck must be securely parked, driveline disengaged, and Aerial Device properly stabilized prior to operation. To avoid tip-over, outriggers (when so equipped) must be properly extended on a solid level surface.
  • Page 24 TM SERIES FALLING FROM PLATFORM WILL RESULT IN DEATH OR SERIOUS INJURY Platform personnel must wear an OSHA approved fall protection system with lanyard attached to anchor provided. Platform doors, if provided, must be se- curely latched. 419264A ELECTROCUTION HAZARD...
  • Page 25 TM SERIES OUTRIGGER CONTACT AN UNTRAINED OPERATOR WILL CAUSE SUBJECTS HIMSELF AND SERIOUS CRUSHING INJURY OTHERS TO DEATH OR SERIOUS INJURY Do not operate any outrigger unless you or a signal person can see that personnel YOU MUST NOT OPERATE...
  • Page 26 TM SERIES ELECTROCUTION HAZARD CONTROLS ARE NOT INSULATED OR ISOLATED All metal at boom tip is electrically connected. Operator contact with ANY, live or grounded, line or object while operator touches CONTROLS or BOOM TIP COMPONENTS and boom tip contacts any other line or object can result in DEATH OR SERIOUS INJURY Comply with OSHA, ANSI, &...
  • Page 27 TM SERIES Platform NOT allowed on this side of Platform allowed center line on this side of OVERTURNING HAZARD Center line of Rotation DEATH OR SERIOUS INJURY May result from operating outside the proper platform & boom positions or improper outrigger setup or truck position...
  • Page 28 TM SERIES INSPECTION DATE RECORD Follow the Frequent and Periodic Inspection Intervals as required in the Operators and Maintenance Manuals. Maintain a record of all inspections. Stamp or engrave below when and who performed inspections. Follow component replacement intervals shown in your Maintenance Manual.
  • Page 29 TM SERIES FALL HAZARD FAILURE TO PROPERLY MAINTAIN THIS MACHINE CAN LEAD TO STRUCTURAL FAILURE AND RESULT IN DEATH OR SERIOUS INJURY Read and follow all inspection and maintenance schedules in the manual(s). Do not operate machine unless all deficiencies are corrected. Proper maintenance and inspection is required for safe and reliable operation.
  • Page 30 TM SERIES PINCH POINT KEEP HANDS CLEAR TO AVOID PERSONAL INJURY H23451 Escaping fluid under pressure penetrate skin causing serious injury. Relieve pressure before disconnecting hydraulic lines. Keep away from leaks holes. piece cardboard or paper to search for leaks.
  • Page 31 TM SERIES equipment, passenger vehicle or off-highway motor vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the state of California to cause cancer and birth defects or other reproductive harm. These chemicals can be emitted from or contained in other various parts and systems, fluids and some component wear by- products.To minimize exposure, avoid breathing exhaust, do not...

  • Page 32: What Is Insulated And Not Insulated

    TM SERIES WHAT IS INSULATED AND NOT INSULATED UPPER BOOM RATING The ID plate on your aerial device will indicate if the unit is insulated and the voltage the insulation has been designed and tested to withstand. The manuals also indicate what areas of the machine will provide insulation.

  • Page 33: What Is Insulated

    TM SERIES WHAT IS INSULATED The term insulated means separated from other conductive surfaces by a dielectric substance (including air space) offering a high resistance to the passage of current (from OSHA 1926.960). Area A. Upper Boom Insulation, provides an insulating area between area D and earth ground when in properly maintained condition.
  • Page 34 TM SERIES The insulating boom section only prevents current from passing from the band of arrows at the boom tip to the lower band of arrows. All components above and below that area must be considered conductive. The boom tip is everything past the upper band of arrows.

  • Page 35: Electrical Insulation

    TM SERIES ELECTRICAL INSULATION Operation on or near energized lines is extremely hazardous unless proper OSHA and ANSI work rules are followed. The operation of this Aerial Device in proximity to high voltage electrical lines involves several hazards to the operator of the Aerial Device, ground personnel and bystanders on the ground. These hazards are as follows: 1.

  • Page 36: Prevention Of Electrocution

    TM SERIES There is no protection against Hazard No. 4. Caution must be exercised continually to avoid making contact with an energized line, which, if broken or burned, may drop to the ground and cause injury to ground personnel and any bystanders.
  • Page 37 TM SERIES The fiberglass boom and platform liners must be dielectrically tested periodically to insure the insulating properties are being maintained. Do not assume that it is so. Ground personnel must be warned to stay away from vehicle in case of accidental boom contact between conductor and metallic portion of boom, which will cause serious injury or death.
  • Page 38 TM SERIES READ CAREFULLY OCCUPANTS OF THE BASKETS OF THIS AERIAL DEVICE HAVE ABSOLUTELY NO ELECTRICAL PROTECTION FROM CONTACT BY THE HUMAN BODY WITH TWO ENERGIZED CONDUCTORS OR BETWEEN AN ENERGIZED CONDUCTOR AND A GROUNDED CONDUCTOR. It makes no difference if this contact is...

  • Page 39: Section 1

    TM SERIES SECTION 1 OPERATION GUIDELINES NOMENCLATURE Upper Boom Extension Cylinders Upper Controls Elbow Pin Boom Tip Upper Boom Platform Lower Boom Upper Boom Cylinder Lower Boom Extension Rollers Lower Boom Extension Cylinder Lower Boom Lift Cylinder Strobe Light Lower Controls...

  • Page 40: Cab Control Operation

    TM SERIES CAB CONTROL OPERATION MASTER CONTROL The master control is located in the cab of the vehicle and may be a display, switch panel or switch is in the dash. The switch is used to energize the engine stop/start system and the throttle control options, which may be located in the cab, at the platform, or on the pedestal.
  • Page 41 TM SERIES CAB CONTROLS OPERATION Master Power See 1 (shown below) Push to activate the remote electrical systems. A light indicates when the system is active. This light may be separate or built into the switch panel or display. Push again to deactivate the remote electrical systems. The indicator light will turn off.

  • Page 42: Controls Below Rotation

    TM SERIES CONTROLS BELOW ROTATION These controls are usually mounted at the rear of the vehicle chassis. The controls may include outriggers, hydraulic tools, control selector, engine stop/start, two-speed throttle, and auxiliary let down power. The controls shown are generic. The actual location and functions will vary depending on the purchasers requirements and options ordered.
  • Page 43 TM SERIES CONTROLS BELOW ROTATION FUNCTIONS Selector Move handle up to activate “UNIT” system. UNIT The Selector will function as an emergency stop by taking oil flow away from the active control SELECTOR O/R’S Move handle down to operate outrigger system “O/R’S”.

  • Page 44: Operator Controls And Descriptions

    TM SERIES OPERATOR CONTROLS AND DESCRIPTIONS Aerial Device functions may be controlled from either the upper controls at the platform or the lower controls station. The platform controls are used, in normal operation, by the operator to control the Aerial Device. The lower controls are used for inspection, maintenance, and in emergency situations.
  • Page 45 TM SERIES ELECTROCUTION HAZARD CONTROLS ARE NOT INSULATED OR ISOLATED All metal at boom tip is electrically connected. Operator contact with ANY, live or grounded, line or object while operator touches CONTROLS or BOOM TIP COMPONENTS and boom tip contacts any other line or object can result in DEATH OR SERIOUS INJURY Comply with OSHA, ANSI, &...

  • Page 46: Upper Controls

    TM SERIES UPPER CONTROLS SINGLE STICK ITEM CONTROL DESCRIPTION Single Stick Controls upper boom, lower boom, rotation, and upper boom extension. Engine Stop/Start (Optional) Allows the operator to stop and start the engine from the platform. Two-Speed Throttle Two-speed throttle provides two engine speeds, low and high, with engine running.
  • Page 47 TM SERIES SINGLE STICK FUNCTIONS The control location shown is generic. The actual location will vary depending on purchasers requirements and options. Some of the following control functions may not be included in the controls for this Aerial Device. Refer to the control decals on unit for proper operation.
  • Page 48 TM SERIES Upper Boom Squeeze the enable lever and lift lever “UP” to unfold upper boom. Squeeze the enable lever and push lever “DOWN” to fold upper boom. DOWN Lower Boom Squeeze the enable lever and push lever forward to unfold lower boom “UP”.
  • Page 49 TM SERIES Engine Stop/Start Push and hold to start engine. (Optional) STOP/START Release when engine starts. ENGINE Push and release to stop engine. PUSH/RELEASE 437033 Can also be used to stop the Aerial Device in an emergency. Two-Speed With engine running, the throttle is activated.
  • Page 50 TM SERIES Winch (Optional) Push to lower load “DOWN” or pay-out winch line. DOWN Pull to raise load or wind winch line “UP”. WINCH Platform Rotation Raise lever by pulling upward to unlock. (Optional) Push to rotate clockwise “CW” to end position.

  • Page 51: Lower Controls

    TM SERIES LOWER CONTROLS 6,7,4,3,2,8,5 ITEM CONTROL DESCRIPTION Top Control and Option Controls oil flow to the option valve and hydraulic tool at the platform. In Shut-Off the “OFF” position no oil is available at the platform valve. Must be in the “ON”...

  • Page 52: Top Control And Option Shut Off

    TM SERIES TOP CONTROL AND OPTION SHUT OFF The Top Control and Option Shut Off is used to stop operation of the upper controls. It will stop all oil flow to the boom tip in case of an oil leak. It is also used to override the upper controls in case of an emergency. The upper controls are not operable when the Top Control and Option Shut Off is in the “OFF”...
  • Page 53 TM SERIES Top Control Shut- Pull up to turn “ON”. Push down to turn “OFF”. Must be in the “ON” position to operate the jib, winch, platform rotate and hydraulic tools at the platform location. Lower Boom Push lever forward to “RAISE” lower boom up.
  • Page 54 TM SERIES Upper Boom Push lever forward to “LOWER” lower boom down. Pull lever back to “RAISE” lower boom up. Upper Boom Pull lever back to “RAISE” lower boom up. (TM125 only) Push lever forward to “LOWER” lower boom down.
  • Page 55 TM SERIES Lower Boom Push lever forward to “EXTEND” out lower boom. Extend Pull lever back to “RETRACT” in lower boom. Upper Boom Push lever forward to “EXTEND” out upper boom. Extend Pull lever back to “RETRACT” in upper boom.

  • Page 56: Accessories

    TM SERIES ACCESSORIES The Accessory controls and the enable on the single stick are fiber optic devices that use a light switch at the platform to operate the function. The light source uses battery power. The batteries are located in the control area enclosed in a plastic box.

  • Page 57: Manual Let Down System

    TM SERIES MANUAL LET DOWN SYSTEM Assess the boom position and identify any obstructions. Remember when using the manual letdown, the lowering of the upper boom, lower boom, and the lower boom extension are all done by gravity. None of the interlock systems will operate.
  • Page 58 TM SERIES When the manual letdown is used, none of the safety limit systems are operational. Unless the unit needs to be rotated to clear obstacles. If the platform or the boom is near any obstacles and needs to be rotated away before lowering the unit, rotate it by turning the far right knob to 3 o’clock.
  • Page 59 TM SERIES When the manual override button is released, rotation will be stoped. Turning the knob back to its original position will also stop rotation. If the brake valve does not have the manual override button, a lot of force is needed to rotate. You can turn the counterbalance valves in clockwise to decrease the pressure and allow manual rotation.
  • Page 60 TM SERIES This includes the over-center limit system. Do not allow the platform to go past the vertical center of rotation at any time. The safety limit systems are not operational when using the manual letdown. Do not allow the platform to go past the vertical center of rotation at any time.
  • Page 61 TM SERIES The lower boom extension must be fully retracted before lowering the lower boom. Lowering both booms individually back and forth will help prevent the platform from completely dumping upside down. If the upper boom is lowered first, the platform could be completely upside down depending on the angle of the boom starting position.

  • Page 62: Hydraulic Tools (Optional)

    TM SERIES HYDRAULIC TOOLS (OPTIONAL) Hydraulic tool circuits are used to attach hydraulic powered hand tools to the hydraulic system of the Aerial Device. Quick-disconnect couplings are used to attach hydraulic tools. There may be one or two sets of tool couplers.

  • Page 63: Platform Tilt

    TM SERIES PLATFORM TILT Do not allow anyone to operate the platform tilt device while occupants are in the platform. Serious personal injury or death could result from platform upsetting. The platform leveling system permits the platform to be tilted to clean out water and debris. It also allows the platform to be tilted for personnel rescue.

  • Page 64: Platform Leveling (Without Generator)

    TM SERIES PLATFORM LEVELING (WITHOUT GENERATOR) The platform level control is an electro-hydraulic system controlled by a level sensor, control system and a hydraulic servo valve to keep the platform level. As the upper boom or lower boom articulate the level will turn on to allow operation and keep the platform level.

  • Page 65: Platform Leveling (With Generator)

    TM SERIES PLATFORM LEVELING (WITH GENERATOR) The platform level control is an electro-hydraulic system controlled by a level sensor, control system and a hydraulic servo valve to keep the platform level. As the upper boom or lower boom articulate the level will turn on to allow operation and keep the platform level.

  • Page 66: Platform Rotator (Optional)

    TM SERIES PLATFORM ROTATOR (OPTIONAL) The platform rotator allows operator to rotate the platform from the stowed position to the rotated position (end position). When not in use the platform must be placed in the stowed position. Prior to platform rotation, observe all obstructions and hazards near the platform’s swing path to avoid collisions and contact with lines.

  • Page 67: Jib & Winch Operation (Optional)

    TM SERIES JIB & WINCH OPERATION (OPTIONAL) When operating the winch under load, always use a smooth movement for lowering or raising loads to avoid shock loads and sudden changes in truck balance. These dynamic shocks can have an effect on the structural members of the Aerial Device.

  • Page 68: Jib Rotation

    TM SERIES JIB ROTATION Jib rotation is a manual operation with 5 locking positions. To rotate the jib, release the locking pin located at the rear of the jib. Manually rotate the jib to one of the 5 locking positions.

  • Page 69: Hydraulic Jib Extension (Optional)

    TM SERIES HYDRAULIC JIB EXTENSION (OPTIONAL) The jib extension can be adjusted hydraulically in the range of cylinder movement. If the jib must be extended or retracted more than cylinder stroke allows do the following: Do not extend under load.

  • Page 70: Avoid Trapped Loops

    TM SERIES Use only synthetic rope for winch line. Do not use wire rope. Do not allow winch line to come in contact with guyline, pole, crossarm, ground, or any object that can create a path to ground or energize the winch line.

  • Page 71: Lower Boom Lifting Eye Material Handling (Optional)

    TM SERIES LOWER BOOM LIFTING EYE MATERIAL HANDLING (OPTIONAL) A lifting eye may be provided to be used for limited material handling. For maximum lifting capacity, refer to the load chart installed on the Aerial Device. • Always extend the outriggers.

  • Page 72: Personnel And Training

    TM SERIES PERSONNEL AND TRAINING All personnel assigned to an Aerial Device shall be given an opportunity to become familiar with the operation of the equipment before they operate it on a job. The operator and all other personnel should be familiar with the operating procedures.

  • Page 73: Pre-Operation

    TM SERIES PRE-OPERATION DAILY PRE-OPERATION CHECKS Perform all daily inspections as shown in Frequent and Periodic Inspection immediately prior to first use at the beginning of each shift. JOB SITE SURVEY Before locating the vehicle in position to work, make a complete survey of the job site. During the survey, some of the items to look for include the following: •...

  • Page 74: Operating Temperature Range

    TM SERIES OPERATING TEMPERATURE RANGE The ambient operating temperature range of the unit is given on the ID plate. Operation at the extremes of the temperature range requires extra precautions. Cold weather operation below 10 degrees F (-12 degrees C) requires: •...

  • Page 75: Job Site Setup

    TM SERIES JOB SITE SETUP The unit is tested for stability per ANSI with the vehicle level and must be operated within those guidelines. Because of the effects on stability when the unit is not level, the unit must be in a level position before any boom functions are operated.

  • Page 76: Setting The Outriggers

    TM SERIES SETTING THE OUTRIGGERS Before lifting or rotating the Aerial Device, all outriggers (if equipped) must be lowered firmly to the ground on a surface that can support the load, and kept there until all work is complete and the Aerial Device is stowed for travel.
  • Page 77 TM SERIES • Two sets of outriggers: The outriggers are extended to support the weight of the unit. The tires should remain in contact with the ground. • The vehicle can be leveled slightly with the outriggers. • The axles not located between the outriggers must equally support the load of the truck so the suspension on each side is equally loaded.
  • Page 78 TM SERIES If the vehicle must be set up with the slope, chock the wheels and work off the rear of the vehicle. VEHICLE SETUP WITH THE SLOPE The truck must be level before operating the booms. If the vehicle must be set up where an outrigger extends into a ditch or gutter and the full extension does not make firm contact, the outrigger must be blocked or cribbed up.

  • Page 79: Setting Up On A Soft Surface

    TM SERIES SETTING UP ON A SOFT SURFACE If the ground is too soft to support the outrigger load or wheel load, the outriggers or tires must be padded or cribbed until the ground will support the load or the unit cannot be used at that location. Make certain the tires and outriggers are centered on the pads and the cribbing provides stable support as the booms are moved.

  • Page 80: Stability

    TM SERIES STABILITY The stability of a vehicle equipped with a rotating aerial device depends on the gross weight of the vehicle and load, the slope of the work area, and whether the ground is firm enough to support the weight of the outrigger pads.

  • Page 81: Operation

    TM SERIES OPERATION BOOM OPERATION The boom movement is limited to non-overcenter positions by a limit system. Do not depend on the limit system to recognize when the booms are approaching a limit. Operate the unit knowing where the booms and platform are in the work envelope to keep operation in the working area.

  • Page 82: Unstore The Boom

    TM SERIES When the upper boom up or the lower boom down motion is stopped by the limit valves it may be necessary to lower the upper boom or raise the lower boom slightly to reset the valves. All boom movements should be smooth. Avoid jerking by slowly metering the control valves when starting and stopping all motions.

  • Page 83: Aerial Operation

    TM SERIES AERIAL OPERATION Before using the Aerial Device, the operator should check through the pre-operational procedure to ensure the vehicle is properly positioned with outriggers (if equipped) firmly in place. Extreme care should always be exercised when lifting personnel.
  • Page 84 TM SERIES FALLING FROM PLATFORM WILL RESULT IN DEATH OR SERIOUS INJURY Platform personnel must wear an OSHA approved fall protection system with lanyard attached to anchor provided. Platform doors, if provided, must be se- curely latched. 419264A ELECTROCUTION HAZARD...
  • Page 85 TM SERIES Use protective equipment suitable for the work being performed: Follow your employer’s policies for personal protective equipment. Failure to wear proper PPE can result in death or serious injury. • Wear insulating gloves and sleeves when working on or near electrical equipment.

  • Page 86: Emergency Operation

    TM SERIES EMERGENCY OPERATION Emergency operation may be required if an operator is injured or the equipment malfunctions. In any emergency, the first priority is always the safety of the personnel involved. It is always important to remember to follow the standard work practices and the safety regulations that apply. If the Aerial Device is operable, move the platform away from the danger and into the shortest, clear path of descent to get the operator on the ground.
  • Page 87 TM SERIES STANDING ON GROUND CLOSE TO FALLEN POWER LINE You must shuffle keeping feet together, do not run. The voltage is highest where contact is made and decreases as you get farther away from the point of contact. The distance will depend on the ground conditions and conductivity of the ground.

  • Page 88: Top Control Shut-Off

    TM SERIES BEFORE TRYING TO GET ON OR APPROACH THE VEHICLE: • Is it necessary to approach the vehicle? Can the operator handle the problem from the platform? • The best procedure is to disconnect or shut off the power to the lines.

  • Page 89: Auxiliary Let Down Power (Optional)

    TM SERIES AUXILIARY LET DOWN POWER (OPTIONAL) The auxiliary let down power system provides power from a DC motor-pump for operation of the Aerial Device in case of a prime power source failure. Controls for auxiliary let down power may be located at the platform, pedestal (optional), and outriggers (optional).

  • Page 90: Hydraulic Line Failure

    TM SERIES HYDRAULIC LINE FAILURE Hydraulic line failure during Aerial Device operation presents numerous hazards. Be aware that a hydraulic oil mist caused by a leak or hydraulic line failure is conductive even though nonconducting oil is used. A spray or mist produced by a hydraulic leak under pressure is very hazardous to personnel.
  • Page 91 TM SERIES WHAT CAN HAPPEN WHEN HYDRAULIC LINES FAIL? Hydraulic oil, when confined within the hydraulic system and properly maintained, is non-conductive and not subject to being ignited. There are numerous hazards that develop when there is a hydraulic line separation: •...

  • Page 92: Engine Failure

    TM SERIES ENGINE FAILURE If the prime power source fails, the optional auxiliary let down power system can be used for emergency operation. If the auxiliary let down power system is not installed and the vehicle has a manual transmission, then use the engine stop/start control (if so equipped) to crank the engine.

  • Page 93: Operational Limitations

    TM SERIES OPERATIONAL LIMITATIONS PLATFORM LEVELING SYSTEM The platform leveling system is designed to carry the rated load of the platform. Collision of the platform(s) with a fixed object, including the ground, or attachment of any load lifting devices to the platform(s) can damage or break the leveling system, causing the platform to be overturned.

  • Page 94: Platform Leveling System With Generator

    TM SERIES PLATFORM LEVELING SYSTEM WITH GENERATOR This system operates on a 12 volt battery which is charged by an onboard generator. Routine service of this battery is not necessary. If the low battery indicator light turns on, replace the battery located beneath the servo and/or check the generator for proper operation.

  • Page 95: Limit System (Operational Range)

    LIMIT SYSTEM (OPERATIONAL RANGE) The TM Series is a non-overcenter Aerial Device. It operates with the platform opposite the centerline of rotation from the lower boom at all times. If the platform moves toward the elbow side the machine may become unstable and overturn to the elbow side.

  • Page 96: Units With Limiting Valve Mounted Inside The Lower Boom

    TM SERIES Preventing these three movements keeps the boom from going into a more unstable position toward the elbow side. It is accomplished with valves at various locations that work together to prevent the unit from getting into unstable conditions. This system limits the boom extension in conjunction with the position and angle of the boom.

  • Page 97: Fall Arrest

    TM SERIES FALL ARREST Fall arrest is required whenever in an aerial or digger derrick platform. An OSHA compliant fall arrest system with the lanyard attached to the provided anchor at the boom tip must be used. The issue is not falling from the platform;...

  • Page 98: Folding For Travel

    TM SERIES FOLDING FOR TRAVEL Do not travel with tools or other items stored in the platform. Loose items may damage the platform or fall on the roadway during road travel. It is essential to follow the correct procedure whenever booms are folded for travel: •...

  • Page 99: Maintenance Guidelines

    Failure to inspect and maintain equipment endangers operators and crew. Not performing inspections and maintenance is false economy. It is recommended that the replacement parts for your Aerial Device be obtained from a Terex South Dakota, Inc. distributor or Terex South Dakota, Inc.

  • Page 100: Lubrication

    Always remember, scheduled maintenance can save much more than it costs. NOTE: The following check points listed are the minimum recommended by Terex South Dakota, Inc. They are subject to supplementation to conform with your own company regulations.

  • Page 101: Frequent And Periodic Inspection Intervals

    TM SERIES FREQUENT AND PERIODIC INSPECTION INTERVALS DAILY 1. Check all controls and interlock for proper operation. 2. Inspect fall arrest equipment and attachments. 3. Inspect visual and audible devices. 4. Check cleanliness and dryness of fiberglass components. 5. Visually check for missing, damaged, or loose covers and guards.

  • Page 102: Days (720 Hours)

    TM SERIES 180 DAYS (720 HOURS) 1. Inspect exposed hoses. 2. Clean hydraulic tank breather. 3. Check tightness of rotation bearing bolts, turntable to bearing, and bearing to pedestal for proper torque. 4. Check lubricant of winch speed reducer and rotation speed reducer.

  • Page 103: Operational Tests

    TM SERIES OPERATIONAL TESTS Perform all of the tests and checks that follow. Cycle times must be within limits. Repair the problem that is evident in the component. SPEED TESTS Speed tests should be taken with one man in platform and hydraulic fluid at normal operating temperature.

  • Page 104: Lubrication Chart

    TM SERIES LUBRICATION CHART 2 - 6 47 279 7 - 7/2 2 Te re x So uth Da kota , Inc. T M Se ri es...

  • Page 105: Winch Rope Inspection

    TM SERIES WINCH ROPE INSPECTION All stable braid ropes in continuous service should be visually inspected once every working day. A thorough inspection of all ropes in use should be made at least once a month and a full written, dated and signed report of rope condition kept on file where readily available.

  • Page 106: Daily Rope Inspection

    TM SERIES DAILY ROPE INSPECTION The synthetic rope must be inspected daily for any deterioration, resulting in appreciable loss of strength, such as described below. 1. Excessive external roughness. 2. Glossy or glazed areas, which indicates heat damage. 3. Look for flat areas, bumps, or lumps, which indicates core or internal damage.

  • Page 107: Storage Procedure

    TM SERIES STORAGE PROCEDURE When a unit will not be used for a period of time, it should be prepared for storage to reduce the deteriorating effects of the environment. This includes the following: • Wash and clean to remove accumulated road grime. It can discolor the paint if left on for long periods of time.
  • Page 108 TM SERIES 2 - 1 0 47 279 7 - 7/2 2 Te re x So uth Da kota , Inc. T M Se ri es...
  • Page 109 The information provided herein is accurate as of the date your Terex South Dakota, Inc. unit was manufactured. You must comply with the codes, standards and regulations as they are updated over time. It is your employer's responsibility to obtain copies and comply with all standards and regulations.

  • Page 110: Osha Excerpts: (Clearance Distance)

    APPENDIX A OSHA EXCERPTS: (CLEARANCE DISTANCE) The following are excerpts from OSHA Standards. They are not complete and do not cover all safety work rules. Refer to the most current version of OSHA regulations available at for any changes www.osha.gov since this manual was printed.
  • Page 111 APPENDIX A Clearance to energized components and lines These minimum approach distance charts are provided for reference only. Follow your companies, OSHA's or NESC for specific clearance distances required. DISTANCE NOMINAL VOLTAGE (KV) PHASE-TO-GROUND PHASE-TO-PHASE (PHASE TO PHASE) EXPOSURE EXPOSURE ²...

  • Page 112: Standard Hand Signals

    APPENDIX A STANDARD HAND SIGNALS STOP. With arm extended EMERGENCY STOP. With both arms extended HOIST. With upper arm RAISE BOOM. With arm horizontally to the side, horizontally to the side, palms down, arms are swung back extended to the side, extended horizontally to the palm down, arm is swung and forth.

  • Page 113: Responsibilities (Ansi A92.2-2021)

    ANSI/SAIA A92.2 standard or the ANSI/SAIA A92.2 Manual of Responsibilities. https://webstore.ansi.org/Standards/SIA/ANSISAIAA922021 You can purchase the ANSI/SAIA A92.2 Manual of Responsibilities from Terex Utilities P/N 494633. The AEM Safety Manual provides important safety information, (Terex Utilities P/N 494635). It can be ordered from AEM at : https://shop.aem.org/en/AEM%20Safety/aem-safety-products/aerial-devices-safety- manual/ AEM also has other languages available.

  • Page 114: Owner Responsibilities (Section 8)

    APPENDIX B • The installer must complete stability tests, dielectric tests, operational tests, and visual inspections before delivery. • Install a label the driver can see stating the overall travel height. • Training and training material for inspection, service, and operation shall be offered to the owner or user if requested.
  • Page 115 APPENDIX B • Periodic inspections and test include the same items as the daily pre-shift inspection, but are more involved. Follow the manufacturer’s instructions and manuals to include but not limited to: • Inspect condition of fiberglass for damage, cleanliness, and insulating material condition inside and outside of all components in the insulating span.
  • Page 116 APPENDIX B • All decals, labels and plaques must be legible or replaced if not. • Safety bulletins issued by the manufacturer, dealer or installer must be completed as instructed. • Manuals are on the vehicle available to the Operator. •...

  • Page 117: User Responsibilities (Section 9)

    APPENDIX B • Operating characteristics of the specific unit. The function of safety devices and operator aids. • Operate the aerial device long enough to become proficient in its safe operation. • Users can self-familiarize if authorized by the owner and the above items are completed. Owner as Lessor •...

  • Page 118: Operator Responsibilities (Section 10)

    APPENDIX B • Users can self-familiarize if above items are completed. • Proof of training should be provided if requested and maintained in the employee’s file. • The user shall only use the aerial device for the intended application as defined by the manufacture following all safe work requirements.
  • Page 119 APPENDIX B • Observation of any defects shall be ongoing during operation. • Pre-Start Inspection shall be performed by the operator daily prior to each shift. Following the manufacturer’s recommendations for the aerial device. The following tests and inspections shall be performed by the operator prior to first use: •...
  • Page 120 APPENDIX B • Use outrigger pads or cribbing when necessary to provide firm footing. • When operating aerial device the operator detects any suspected malfunction of the aerial device, any hazard or potentially unsafe condition stop operation and request information from the user before further use or movement.

  • Page 121: Responsibilities Of Lessors Or Lessees (Section 11)

    APPENDIX B Familiarization • When directed to operate an aerial device they are not familiar with, a qualified person shall instruct them on the following, prior to operation: • The purpose and use of manuals. • Warnings and instructions provided by the manufacturer. •...

  • Page 122: Responsibilities Of Broker (Section 12)

    APPENDIX B • Know the safety rules and regulations, such as Part 4, ANSI/IEEE C2, National Electrical Safety Code (applies to utility workers as defined in ANSI/IEEE C2). Other safety rules will apply to use of aerial devices in other industries. •...

  • Page 123: Survey Of Job Site

    Construction and electrical workers are subject to certain hazards that cannot be eliminated by mechanical means and must be controlled by care, common sense and intelligence. Terex South Dakota, Inc. realizes the importance of safety and strongly recommends that prior to commencing any operation, the employer make a survey of the conditions of the site to determine the hazards and the kind and number of safeguards that the employer will install.
  • Page 124 APPENDIX B (7) Workers and foremen (a) Job assignment (b) Training and supervision (c) Number of workers (d) Plans for maintaining interest in safety: • (1) Safety bulletins, record charts and posters • (2) Recognition for groups or individuals • (3) Investigation and reporting on reportable accidents •...

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