TEREX AERIALS TECHNICAL MANUAL SELF-PROPELLED KNUCKLE BOOM LIFT MODEL TASORT FOR PARTS OR SERVICE CONTACT: | | Terex Aerials Terex Aerials SSS OPERATION, SERVICE and PARTS MANUAL Terex Aerials 10600 W. Brown Deer Road 106 12th Street S. E. Courtstown Industrial Park Milwaukee, WI 53224 Waverly, 1A 50677 USA. Little Island, Co. Cork, Ireland Telephone: — (414)362-9300 Telephone: —_(319) 352-3920 Telephone: (353) 21-353011 Facsimile: (414) 355-0832 Facsimile: (319) 352-5727 Facsimile: (353) 21-953968 Issued: December '97 PIN 17325EREX AERIALS TASORT OPERATOR’S MANUAL c OO) ISSUE NO.: 00 DATE: DECEMBER 1997INTRODUCTION (i) AND DECLARATIONS OF CONFORMITY (ii) 1 ‘TASORT Specification 1 Design Specifications Ld Closed Dimensions and Weights L12 Operating Dimensions 113 Design Specifications 114 Working Envelope LLS General Arrangement 12 Component Specifications 1.21 Mechanical Components 122 Hydraulic Components 1.23 Oil 1.24 Equivalent Oils 125 Electrical Components 12.6 Engine Details 2. Safety Precautions 21 24 Safety Symbols 21 22 Safety Rules and Precautions 22 23 Safety Features 26 23.1 Emergency Stop Pushbuttons 26 23.2 Footswitch Control 26 233 Tilt Alarm 26 23.4 Movement Alarm 26 23.5 Torque Chart 26 3 Operating Procedures 34 3.1 Pre-use Checks 34 32 Ground Control Checks 3H 33 Cage Control Checks 32 34 Unloading Procedures 32 35 Driving 33 3.5.1 Drive Controls 33 3.5.11 Forward and Reverse 33 3.5.1.2 Drive Speed Control 35 3.5.1.3 Steering Control 3-5 3.5.14 Travel Speed Control 35 3.6 Differential Lock 3-5 3.6.1 Engage Differential Lock 35 37 Braking System 36 3.71 Brakes in Static Mode 36 3.7.2 Brakes in Drive Mode 3-463.73 38 39 3.10 B.L 3.12 3.121 321 3.12.2 3.123 3.12.4 3.12.5 3.12.6 41 4.11 412 42 421 422 4.23 423.1 42.32 424 Emergency Braking ‘Access Operations (Cage Control) ‘Access Operations (Ground Control) After Use and Storage Instructions Special Precautions (Cold Weather) Special Precautions Towing Towing without Towing Package Wind Conditions Crane Operations Driving on Slopes Testing the Tilt Alarm Oil and Battery Charge Warning Lamps ‘Emergency Procedures & Systems Emergency Procedures Situation: Platform elevated, operator not incapacitated, but unit will not operate properly using the platform controls. ‘Situation: Unit elevated, with operator incapacitated at platform controls. ‘Situation: Platform in contact with live power lines, and operator incapacitated. Emergency Systems & Procedures Emergency Pump Emergency Rotation Emergency Towing ‘Towing with towing package fitted ‘Towing without towing package Emergency Lowering from Cage (Optional) Maintenance Schedules General Information Introduction Hydraulic Oils Diesel Engine Oil Servicing Check List (Basic Machine Only) Servicing (Daily) Servicing (Weekly) Servicing (Monthly) Servicing (Six Monthly) Servicing (Yearly) Servicing (Four Yearly) Servicing, Daily Routine Servicing Hydraulic Oil Level Tyre Condition53.13 53.2 53.21 53.2.2. 53.23 53.24 53.25 53.3. 53.3.1 53.3.2 533.3 53.3.4 533.5 53.3.6 534 53.4.1 5.3.42 53.43 5.3.44 5.3.45 5.3.4.6 53.5 5.3.5.1 53.5.2 53.5.3 53.5.4 53.5.5 53.5.6 5.3.6 53.6.1 5.3.6.2 5.3.63 5.3.63.1 5.3.6.5 5.3.6.5.1 53.6.5.2 53.6.6 53.6.6.1 5.3.6.6.2 54 5.4.1 5.4.2 Cage Door Lock ‘Weekly Routine Service Control Valves Hydraulic System Steering Start Battery Pivot Pins Monthly Routine Servicing Hydraulic Oil Chassis Bolts Slew Ring Gear Teeth Lubrication Pivot Pin Security Drive Gearbox Oil Level Six Monthly Routine Servicing Cage Levelling Boom Pivots Boom Cylinders Axle Return Line Filter Machine Systems Test Yearly Routine Servicing Hydraulic Oil Hydraulic Oil Tank Hydraulic Tank Refill Procedure Structural Examination Cage Mounting Levelling Cylinders Four Yearly Routine Servicing Flexible Hoses Pivot Pins and Bearings Pin Replacement Boom Pin Replacement Tie Rail Pin Replecement Lift Cylinder Pin Replacement Self Levelling Cylinder Pin Replacement Zoom Boom Cylinder Pin Replacement Zoom Cylinder Zoom Pads Front Zoom Pad Replacement Rear Zoom Boom Replacement Lift Cylinder Seals Seal Replacement - Cylinder In-place ‘Seal Replacement - Cylinder Removed Lubrication General Lubrication Slew Bearing/Gear Lubricants 4 Page No 5-7 5-7 5-7 58 58 58 58 58 59 59 59 59 59 59 5-10 5-10 5-10 5-10 5-10 5-10 5-10 Sl Sl Sl SAL Sl 5-12 5-12 5-12 5-12 5-12 5-13 5-13 5-13 5-13 5-14 5-14 5-14 5-14 5-14 5-15 S15 5-16 5-16 5-165.4.2.1 Slew Bearing Lubrication 5-16 9.4.2.2 Slew Gear Lubrication S17 Appendix Electric circuit (schematic) Electric circuit (wiring diagram) Hydraulic circuit‘TEREX AERIALS LIMITED. TAsORT INTRODUCTION This Operator’s Manual has been designed to provide you with a full set of instructions that will be needed to safely and properly operate your Terex access platform. DANGER THIS OPERATOR’S MANUAL MUST BE READ AND UNDERSTOOD PRIOR TO OPERATING YOUR TEREX TASORT. OPERATORS MUST BE AWARE OF AND COMPLY WITH ALL MANUFACTURER'S INSTRUCTIONS AND APPLICABLE OSHA/ASHI (OR APPROPRIATE GOVERNMENT) SAFETY GUIDELINES FAILURE TO COMPLY WITH MANUFACTURER'S INSTRUCTIONS AND OSHA/ASHI (OR APPROPRIATE GOVERNMENT) SAFETY GUIDELINES WILL RESULT IN SERIOUS INJURY OR DEATH Your Terex access platform has been designed, built, and tested to provide many years of safe, dependable service, To obtain the full benefit of your machine, always follow the proper operating and maintenance procedures as outlined in this manual. Only trained, authorised personnel should be allowed to operate or service this machine. Service personnel should read and study this manual in order to gain a thorough understanding of the functions of the unit prior to making any repairs, & DANGER MODIFICATIONS OF THIS MACHINE FROM THE ORIGINAL DESIGN AND SPECIFICATION WITHOUT WRITTEN PERMISSION FROM TEREX ARE STRICTLY FORBIDDEN. A MODIFICATION MAY COMPROMISE THE SAFETY OF THE MACHINE, SUBJECTING USERS TO SERIOUS INJURY OR DEATH. ANY SUCH MODIFICATION WILL VOID ANY REMAINING WARRANTY Terex reserves the right to change. improve. modify or expand features of its equipment at any time. Specifications, models or equipment are subject to change without notice, and without incurring any obligations to change, improve, modify or expand features of previously delivered equipment, All Terex manuals are periodically updated to reflect changes that occur in the equipment. Please contact the factory with any questions you may have regarding your machine, and the availability of more recent manuals, “The manufacturers reserve the rightto change the specifications and design without prior noiceSECTION 1. ‘TASORT SPECIFICATION 1.1 DESIGN SPECIFICATION 1.1.1 CLOSED DIMENSIONS AND WEIGHTS Length .. Width... 2.20 mm, Height .. Unladen Weight (Hatz). 6500 kg 1.1.2 OPERATING DIMENSIONS Maximum Cage Floor Height 14,80 m Maximum Working Height 16.80 m_ Maximum Working Outreach 9.1m Standard Platform Dimensions 1.50 m x 0.60 m Outside Tuning Radius 5.50m Gradability 50% (45°) Maximum Speed, Booms Stowed .... 5 kaw/hr (3mph) Maximum Speed, Booms Elevated ).75 ken/hr (0.Smph) Ground Clearance Maximum Wheel Loading... 1.1.3 DESIGN SPECIFICATION Safe Working Load (2 persons) . 225 kg (496 Ibs) Maximum Horizontal Platform Pull. .. 400 N Maximum Wind Speed 12.5 m/sec (28 mph - 45 km/hr) Maximum Slope for Safe Operation... Full Range Time Up Min. Full Range Time Down .. ‘Swing LefVRight Maximum Noise Emmission.. ‘Temperature Operating Rang ‘OPERATOR'S MANUAL1.1.4 WORKING ENVELOPE ‘The TASORT has a working height ability of 16.90 m. The following diagram shows the working envelope for the TASORT. All dimensions are in metres. ‘Cd “ay Va @ t © t v a Figure 1.1 - TASORT Working Envelope 1.1.5 GENERAL ARRANGEMENT ‘OPERATOR'S MANUAL12 124. 12.2 1.23 1.24 125 Figure 1.2 - TASORT General Arrangement. COMPONENT SPECIFICATIONS MECHANICAL COMPONENTS Tyre Type .. Solideal SKS 12-16.5 10 ply rating 332 mm wide x 848 mm dia. Tyre Size 12-16.5R Axle 14.058 : 1 ratio Gearbox 6.73 21 ratio Wheel Diameter... 42.4 ems Brakes ..... Oil immersed dises integral inside front and rear axle housings and fail- safe operation serve as both parking and service brakes. The brakes are released when the footswitch is fully depressed and the joystick is moved to either forward or reverse motion. HYDRAULIC COMPONENTS Lift Cylinders Hoses . Double-acting with overcentre valves Thermoplastic & Steel braided rubber Filtration ‘Suction and pressure om Type . .-Texaco Rando HDZ-32 Oil Reservoir Capacity 62 Litres EQUIVALENT OILS SHELL TELLUS T32 CASTROL HYSPIN AWH 32 Esso UNIVERSE N32 CASTROL _| HYSPIN AWS 22 ELECTRICAL COMPONENTS Hand Controller Type .. _ Joystick Battery One 12 Volt H.D 13 ‘OPERATOR'S MANUAL12.6. ENGINE DETAILS Engine Type L. Hatz 2L4C Silentpack, 4 stroke, air cooled Displacement ww ,716 oc ‘Number of Cylinders .. 2 Engine Type 2 . Deutz F3L10114 stroke, air and oil cooled Displacement... 2,049 cc ‘Number of Cylinders... x 2 “OPERATOR'S MANUALTEREX AERIALS LIMITED. TASORT SECTION 2 SAFETY PRECAUTIONS 2.1 SAFETY SYMBOLS This manual contains important information on the safe use of your TEREX Self-Propelled Aerial Work Platform. Your failure to read, understand and follow all safety rules, wamings and instructions will unnecessarily expose you and others to dangerous situations. for your safety and the safety of those around you, you must operate your aerial work platform as instructed in this, manual. ‘You, the operator, are the single most important factor for safety when using any piece of equipment. Lear to operate your work platform in a safe manner. To help you recognise important safety information, we have identified ‘wamings and instructions thet directly impact on safety with following signals: DANGER “DANGER” INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY. THIS SIGNAL WORD IS LIMITED TO THE MOST EXTREME SITUATIONS. \ WARNING “WARNING” INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY. CAUTILIN “Caution” indicates a potentially dangerous situation, which if not avoided , may result in minor or moderate injury. It is also used to alert inst unsafe practices, and for property-damage-only situations. One final note: The best method to protect yourself and others from injury or death is to use common sense. If you are unsure of any operation, don’t start until you are satisfied that itis safe to proceed. 24 ‘OPERATOR'S MANUAL‘TEREX AGRIALS LIMITED TAsORT 22 for SAFETY RULES AND PRECAUTIONS DANGER ELECTROCUTION HAZARD! THIS MACHINE IS NOT INSULATED! Maintain safe clearance from electrical lines and apparatus. You must allow machine sway (side to side movement) when elevated, and electrical line movement. This machine does not provide protection from contact with or proximity to an electrically charged conductor. ‘You must AVOID CONTACT between any part of the machine, or its load, and any electrical line or apparatus carrying up to 300 volts. ‘You must maintain a CLEARANCE OF AT LEAST 10 FEET (3.05 M) between any part of the machine, or its load, and any electrical line or apparatus carrying over 300 volts up to 50,000 volts. One foot (30.5 cm) additional clearance is required for every additional 30,000 volts. DEATH OR SERIOUS INJURY will result from contact with, or inadequate clearance from, any charged conductor. Read and understand all safety and control information found on the machine and in this manual before operating the unit. Only trained, competent personne! shouild operate the aerial work platform. Be aware of all Government and Local rules which may apply to this machine and its safe operation. Approved safety belts must be worn at all times when operating the unit from the platform. In addition approved headgear and other protective equipment must be wor as required. (The appropriate equivalent government body should be consulted). NEVER fasten safety belt to an adjacent structure while on the work platform. Make sure that entry gate to platform is secured before operating unit from the platform. DO NOT block the foot pedal or any function control in the operating position. DO NOT exceed the platform capacity of the unit in any configuration. Review the section titled “MACHINE SPECIFICATIONS”, earlier in this manual, regarding this model’s capacities and dimensions. 22 (OPERATOR'S MANUAL‘TEREX AERIALS LIMITED. TASORT A DANGER * SECURE all tools and other loose items to prevent injury to persons working, on or below the work platform. © DO NOT use scaffolding, ladders or similar items to extend your reach while on the work platform, ‘* DONOT attempt to climb down the boom assembly, if the unit fails while the operator's platform is raised or extended, ‘© Since the machine may be operated from its ground controls, precautions should be taken to prevent unauthorised personnel from operating the work platform with the ground controls while the platform is in use. The “UNPOWERED EMERGENCY MOVEMENT” procedure (described later in this manual) required releasing the brakes and disconnecting the rear wheels, which results in there being no means to stop the unit's travel. Terex recommends using this procedure only in cases of emergency, and only for a short distance. Be on guard against unit runaway on sloping surfaces. ‘Movement speed shall not exceed 3 MPH (5 KPH). © DONOT attempt to open any hydraulic line or component without first relieving system pressures and shutting off fluid flow from the tank. * DONOT allow anyone to tamper with, service or operate the machine from the ground control station while personnel are on the platform, except in an emergency. * DONOT alter, modify or disable any safety devices or interlocks. © DONOT use the aerial work platform outdoors in electrical storms or in high wind situations. Maximum rated wind speed is 12.5 nvs. * DONOT increase wind area of cage by addition of sheltering material © DONOT raise the aerial work platform unless the unit is on a firm surface, and slope is within rated slope of the machine. © When working undemeath elevated booms, ensure they are propped using chock provided for this purpose. 23 ‘OPERATOR'S MANUAL‘TEREX AERIALS LIMITED. TASORT DANGER ‘© Use caution to prevent ropes, cords, hoses, etc. from becoming entangled in the unit’s boom sections when being raised, lowered or repositioned. ‘Ensure that the area surrounding the mobile platform is clear of personnel and equipment before: driving the unit; raising, lowering or extending the boom, or swinging the superstructure; or tilting the platform. ‘© Maintain a safe distance from overhead and ground obstacles, debris, drop- offs, holes, depressions, electrical wires and other hazards to travel. + Limit travel speed according to conditions of the ground surface, congestion, slope, location of personnel or any other factors that could cause hazard of collision of injury to personnel. * DONOT sit, stand or climb on platform rails. * DONOT operate this machine while under the influence of any drugs or alcohol. * DO NOT operate this machine if you are bothered by heights, seizures, or dizzy spells. . * DONOT indulge in stunt driving or horseplay while operating this machine. WARNING © Complete the “Operational Checklists” found in this manual (see Table of Contents) at designated intervals. © Always attach the unit to a winch when loading or unloading from a truck or trailer. Terex does not recommend unassisted loading or unloading of any aerial work platform. ‘© With the platform swung away from the stowed position, use caution when selecting travel or steering direction. Travel and steer direction will be opposite switch or lever movement. Refer to the directional arrow decals on the undercarriage of the unit for travel orientation. 24 (OPERATOR'S MANUALTEREX ABALS uMTED asonr & WARNING * Actuation of the red “EMERGENCY STOP” button will apply brakes immediately, causing unexpected platform movement as the machine comes toa sudden stop. Brace yourself. ‘© Whenever releasing the brakes, ensure that the unit cannot roll. © Immediately report any erratic noises, vibrations or malfunctions of the unit to ‘a supervisor. Machine shall be removed from service until diagnosis and any necessary repairs have been completed. ‘© Operating this equipment without all safety and control decals in place can be hazardous. * For transporting the machine, the platform or boom must not be tied to the trailer bed in any way. © DO NOT exceed the maximum platform horizontal pull of 400 N. ‘* DONOT use the boom or platform as 4 crane to lift oversized of hanging loads. * DONOT raise, extend, retract, tilt, or lower the platform into stationary objects, as this will cause damage to mechanical and hydraulic components. © DONOT use the platform or boom functions to push or tow the unit or another vehicle. © DONOT use the boom as a crane or hoist. ‘© Avoid sudden braking or steering, go slowly and leave more manoeuvring, room during cold weather operation until the machine is warm. © Noise emission levels on this machine are less than 70 dbs. @ 3m. 25 ‘OPERATOR'S MANUAL‘TEREX AERIALS LIMITED TASORT 2.3. SAFETY FEATURES 2.3.1 EMERGENCY STOP PUSHBUTTONS ‘Two EMERGENCY STOP pushbuttons, one at the ground station and one in the cage, act as power on/off switches. Both switches must be ON to operate themachine, When either of the buttons is depressed, all functions stop immediately and the parking brake is automatically applied. 2.3.2 FOOTSWITCH CONTROL The footswitch must be fully depressed before any machine operation can be carried out from the cage. ‘When the footswitch control is released, the electric supply to the hydraulic pump and the drive function is terminated and all machine functions stop. 2.3.3 TILT ALARM The tilt alarm gives an audible warning when the machine is out of level by ‘more than which the sensor has been rated. 2.3.4. MOVEMENT ALARM The movement alarm is activated as soon as the machine is in drive mode. 23.5 TORQUE CHART TTEM BOLT REQUIRED SPECIFICATION | TORQUE (Nm) ‘Wheel Nut MI8 Grade 10.9 200 SiewRing Bolt TA33_|__Mi2Gradel0.9 120 Slewring Bolt TASOE | M12 Gradel2.9 130 ‘Slewring Bolt TASORT | _M14 Grade 10.9 190) Gearbox Bolt M12 Grade 12.9 160) ‘Axle Clamping Bolt [M20 Grade 10.9 200 General Bolts Grade 8.8 M8 275 General Bolts Grade 8.8 M10 35 General Bolts Grade 8.8 M12 95 General Bolts Grade 8.8 MI6 General Bolts Grade 10.9 M8 39. General Bolts Grade 10.9 M10 70 General Bolts Grade 10.9 M12, General Bolts Grade 10.9 M16 General Bolts Grade 12.9 M10 General Bolts Grade 12.9 M12 26 ‘OPERATOR'S MANUAL‘TEREX AERIALS LIMITED. asoRT 3.1. 3.2, SECTION 3 OPERATING PROCEDURES WARNING PRE-USE CHECK Before the TASORT is used at the start of a day, or after an extended period without use, the following checks should be carried out to ensure that the machine is in good condition and safe to use: (a) Check that all labels are readable and secure. (b) Check the hydraulic oil level (©) Check tyres for damage. (a) ‘Check wheel bolts for security. (©) Check the tit alarm. (Q) Check that all pivot pins are secure. (g) Check the diesel engine oil level. (h) Check the diesel engine fuel level GROUND CONTROL CHECKS WARNING DO NOT OPERATE THE MACHINE IF THE GROUND CONTROL (CHECKS REVEAL A FAULT. Ensure that the following checks are carried out with the cage empty: (a) Test all operations (lift, rotate, etc.) (b) Check for the following: (Uneven or jerky operation Gi) Hydraulic oil leaks 3 OPERATORS MANTA“TEREX AERIALS LIMITED. TasoRt 33. 3.4. CAGE CONTROL CHECKS WARNING DO NOT OPERATE THE MACHINE IF THE CAGE CONTROL CHECKS REVEAL A FAULT. Ensure that the following checks are carried out on a level surface: (a) Carry out the checks described in paragraph 3.2. (b) Check the drive, and emergency braking. (©) Check the stow drive speed with the lower boom slightly elevated (@) Check the fast drive speed with all the booms fully down. UNLOADING PROCEDURES TO AVOID SERIOUS PERSONAL INJURY OR DEATH, ENSURE THAT THE MACHINE IS IN “CREEP “ DRIVE SPEED WHILE UNLOADING FROM A TRUCK OR TRAILER Inspect the outside of the unit for damage (including the underside). Inspect tall hoses, boom sections and cables for chafing or road damage. Confirm that all swing bearing bolts are tight (refer to specifications) Unlock and open hydraulic compartment, Inspect all electrical and hydraulic connections for damage and security Check fluid level on the hydraulic tank, and add fluid as required (see lubrication chart) Close hydraulic cover. Attach the unit to a winch for the unloading procedure. ALWAYS ATTACH THE UNIT TO A WINCH WHEN LOADING OR UNLOADING FROM A TRUCK OR TRAILER. CONNECT WINCH TO THE TIE DOWN LUGS ON THE UNDERCARRIAGE. UNASSISTED LOADING OR UNLOADING OF ANY MOBILE PLATFORM IS NOT RECOMMENDED. READ AND UNDERSTAND ALL SAFETY, CONTROL AND OPERATING INFORMATION FOUND ON THE MACHINE AND IN THIS MANUAL. BEFORE OPERATING THE UNIT. Remove all machines tie downs. Remove wheel chocks, if used. Turn the engine on using keyswitch and set the Ground\Cage (platform) selector switch to “CAGE”. 32 ‘OPERATORS NANUAL‘TEREX AERIALS LIMITED Tason Enter the platform, Test all platform functions. Raise the boom so that the platform will clear any obstacles as the machine is driven down the loading ramp, Carefully drive the unit off the truck or trailer with the assistance of a winch Note: The brakes are automatically released for driving, and will automatically apply when the unit stops. Before placing the unit into service, all operators must read and understand the contents of the Operator's Manual. Upon initial unloading of the machine the PDI (Pre-Delivery Inspection Form) must be completed and returned in order to activate the Terex Limited Warranty. 3.8, DRIVING It should be noted that the machine is not equipped for highway use and should only be driven on the public highway in compliance with any statutory regulation. The drive controls are located in the cage and the machine can be driven with the cage positioned at either end of the machine. If driving is attempted from the ‘steering’ end of the machine, all directions given to the controls will be reversed so the operator may find driving easier with the cage positioned at the ‘drive' end. Arrows on the chassis show the true control direction. Before driving the machine, check the following; 3.5.1 DRIVE CONTROLS The drive controls are located in the cage and consist of a joystick controller and a footswitch. These controls can be seen in figure 3.1 (on the following page) 3.5.1.1 Forward and Reverse (@) Start Engine (b) At the ground controls, set the CAGE/GROUND selector switch to CAGE. (©) At the cage controls, set the LIFT/DRIVE selector switch to DRIVE. (d) Fully depress the footswitch (©) With the footswitch depressed, push the joystick forward to drive the machine forward, or pull the joystick back to drive the machine in reverse. Note: To de-activate the brakes, the footswitch must be depressed and the joystick displaced simultaneously 33 ‘OPERATORS ANTAL‘TEREX AERIALS LIMITED. @® as y 2) 3) 4) 5) 6) 72) TasoRT Emergency Stop Switch Engine on/off switch Footswitch Drive Speed Select Switch Drive/Steer Joystick BoonvRotate Joystick Teleboom Joystick 8) 9) 10) i) 12) 13) 14) Cage Levelling Switch Engine Speed Switch Cage Rotation Switch Horn Button Differential Lock Switch Boom Selector Button Boom Selection Indicator LED Figure 3.1 - Cage Controls TARUAL 34‘TEREX ABRIALS LIMITED. TasoRt 3. 3.5. 1.2 Drive Speed Control The drive speed of the machine is proportionally controlled by the amount of movement made to the joystick Note:~ When elevated, the drive speed of the machine is automatically reduced. 1.3 Steering Control WARNING THE WHEELS ARE NOT SELF-CENTRING AND MUST BE ALIGNED BY USING THE JOYSTICK ROCKER SWITCH Steering is achieved by depressing the rocker switch on top of the joystick controller to the left or right, as required. 3.5.1.4 Travel Speed Control 3.6. The travel speed control sets the two speed drive to a low ratio for on-road use or a high ratio to improve gradeability when traversing a construction site, When set to the high ratio the climb ability of the machine is increased from 20% to 50% Caution:- To avoid mechanical damage, ensure that the machine is stationary before attempting to change the setting of the travel speed control. DIFFERENTIAL LOCK Caution 1:- To avoid mechanical damage, ensure that the machine is st before attempting to engage or disengage the differential lock Caution 2:- Prolonged use of the cifferential impairs steering and causes excessive Tyre wear. The differential lock must only be engaged momentarily. The differential lock switch is located at the cage controls. The differential lock improves traction in slippery conditions and should only be engaged momentarily to reduce wheel spin 3.6.1 Engage Differential Lock. While driving on certain ground surfaces it may be necessary to engage the differential lock to improve traction. The procedure for the use of the differential lock is as follows. (@) Ensure that the machine is stationary 3.5 PERATOR'S MANUAL.‘TEREX AERIALS LIMITED. TasoR. 37. 3.7.1 3.7.2 3.73 (b) Select the differential "Lock On" position at the upper control station, (©) Drive the machine to a position where greater wheel to ground traction is available and the lock is no longer required. (4) Stop the machine and release the differential lock switch to "Lock Off" position Note:- It is usual that the differential lock will not disengage immediately, to reduce this delay it may be necessary to momentarily operate the drive control lever back and forth. BRAKING SYSTEM The TASORT has a single braking system which serves as a parking brake when the machine is static, and as service brakes when the machine is in drive mode. The brakes are spring applied and hydraulically released. Brakes in Static Mode For normal parking, the brakes are automatically applied when the joystick controller in the central (neutral) position. During lift operations, the brakes are automatically applied to the machine. Brakes in Drive Mode The brakes are spring applied when the joystick is in the central (neutral) posit and remain applied during lifting operations, Deceleration is achieved by moving the joystick controller to the central (neutral) position. Emergency Braking Emergency braking is achieved by operating the EMERGENCY STOP button, or by releasing the footswitch, or by returning the joystick controller to the central (neutral) position. 36 RRO RA“TEREX AERIALS LIMITED TAs0RT. 3.8. 3.9. ACCESS OPERATIONS (CAGE CONTROL) Note : To facilitate entry to the cage, extend the telescopic boom using lower controls. It is recommended that the engine be started from ground controls when cold. Otherwise, the machine can be started as below (a) At the ground controls, set the CAGE/GROUND switch to CAGE, (b) At the upper controls, turn the ignition momentary switch (2) to the START position and hold in position until the engine starts. (©) Release the momentary switch, which will automatically return to the ON position (@) Check that both high and low engine speeds are attainable using the ENGINE SPEED switch (9) ‘ble Control Functions: - Lift 1 Boom: Up Down (Item 6, Fig 3.1) - Lift 2 Boom: Up Down (Item 6, Fig 3.1) - Lift 3 Boom: Up Down (Item 6, Fig 3.1) = Zoom: Extend Retract (Item 7, Fig 3.1) = Rotate: Left Right (Item 6, Fig 3.1) - Cage Level Front Back (Item 8, Fig 3.1) = Cage Rotate Left Right (Item 10, Fig 3.1) Note:-The 3 lift booms are operated using the Boom joystick (Item 6, Fig 3.1). This joystick is used to control speed of each boom. Boom selection is achieved by pressing, the button (Item 13, Fig 3.1) on the Boom Joystick. The selected boom is indicated by an LED (Item14, Fig 3.1). The footswitch must be activated at all times while ‘operating from cage. ACCESS OPERATIONS (GROUND CONTROL) Control from the ground is effected as follows: a) Ensure that both ground and cage control emergency stop buttons are in the out (released) "power-on" position b) Insert the key into the ignition keyswitch (Item 2, Fig 3.2) and turn clockwise one stage.(ON position) ©) Check that the Battery LED is lit (Items 12 , Fig 3.2) If the lamp is not lit, check that both EMERGENCY STOP pust-buttons are out. Engine temp LED may be lit also in this position. 4) Turn the ignition key to the PRE-HEAT position for 60 to 90 seconds ) Turn the key to the START position and wait for the engine to start. £ Release the key which automatically returns to the ON position. 2) To operate control functions, the cage/drive keyswitch must be fully rotated (clockwise) 3-1 ‘OPERATOR'S MANUAL‘TEREX AERIALS LIMITED by) 2 3) 4 5) 6) ” TasoRT Figure 3.2 - Ground Controls Emergency Stop Button Engine Ignition Switch Cage/Ground Select Switch Lift Boom Switch Lift2 Boom Switch Lift3 Boom Switch Tele Boom Switch 8) » 10) 1) 12) 13) 14) Rotate Switch Cage Level Switch Cage Rotate Switch Hourmeter Battery Indicator Engine Temp Indicator Iter Indicator 3.10. AFTER USE AND STORAGE INSTRUCTIONS ‘When the machine is no longer required, and is to be stored, the following instructions are recommended (Note: Terex Aerials recommends indoor storage of the unit) (a) Close cabinet doors. (b) Bring all booms to stowed po! ‘OPERATORS MANUAL 38‘TEREX AERIALS LIMITED TAsoRT (c) Ensure all Emergency Stop Push-buttons are fully depressed, (d) Remove all keys from switches. Prior to re-using the unit after storage, all daily servicing checks (section 5.3.1) should be fully adhered to. After prolonged storage, weekly (section 5.3.2) and monthly (section 5.3.3) servicing checks should also be carried out. 3.9 ‘OPERATORS WANUAL‘TEREX AERIALS LIMITED TasoRT 3.11. SPECIAL PRECAUTIONS (COLD WEATHER) WARNING BRAKING IN ICY CONDITIONS: WHEN THE GROUND SURFACE IS ICY, CARE MUST BE TAKEN TO AVOID SUDDEN BRAKING. IT IS RECOMMENDED THAT ALL DRIVING OPERATIONS ARE CARRIED OUT SLOWLY AND A SAFE MARGIN OF ERROR IS ALLOWED FOR MANOEUVRING AROUND OBSTACLES. In very cold weather conditions, the hydraulic oil must be allowed to warm before full ‘operation of the machine is attempted. Regular oil maintenance must be carried out to ‘ensure that the hydraulic oil is kept free from water contamination. Emulsified water can freeze out of the oil as ice crystals, completely blocking the suction strainer and causing hydraulic pump damage. To prevent damage to the machine, the following steps should be taken, (a) Ensure that the rotation drive teeth are not blocked by ice. (b) Ensure that the steering linkages are free from ice and that the steering ‘operates smoothly. (©) Ensure that the cage floor is free from ice to allow a firm foot-hold without danger of slipping. 3.12. SPECIAL PRECAUTIONS 3.12.1. TOWING 3.12.1.1 Towing without towing package Machine can be towed by slinging chains around suitable support points. Do not exceed Sknv/ar while towing the machine, as wheels may not camber correctly, (See section 4.2.3) 3.12.2. WIND CONDITIONS The unit must not be operated in wind speeds which are in excess of 12.Sm/sec (28 mph- 45 knvhr). During normal machine operations, consideration should be n to nearby objects, especially when working in the close vicinity of buildings and electrical cables. Sudden gusts of wind could cause the machine to sway and trap the operator’s arms/hands between the cage railing and any obstruction. It is recommended that a reasonable safe distance is kept between close obstructions and the cage assembly during all machine operations. 3.12.3. CRANE OPERATIONS ‘The TASORT is fitted with four lifting points in the form of eyes at each corner of the chassis. During lifting operations, take all instructions from the crane operator. Check 3-10 ‘OPERATORS HANUS‘TEREX AERIALS LIMITED. 3.12.4, 3.12.5 TasoRT identification plate TESTING THE TILT ALARM WARNING IF THE TILT ALARM SOUNDS WHILST ELEVATED, RETRACT AND LOWER BOOMS AND DRIVE TO A LEVEL LOCATION. If. wire in the tilt alarm circuit becomes disconnected whilst the machine is in use, the alarm will sound continuously. Ifthis occurs when the machine is elevated, zoom in immediately and lower the cage to the stowed position. DO NOT USE THE MACHINE UNTIL THE FAULT HAS BEEN RECTIFIED. With key switched on and before you operate machine open electrical module cover and press down one side of sensor. This will sound horn if functioning properly. Ifthere is no horn sound, the sensor must be repaired immediately before machine can be operated BATTERY CHARGE, ENGINE TEMP & AIR FILTER WARNING LAMPS The red battery charge lamp, the red engine temp lamp and the red air filter warning lamp for the diesel engine are located on the ground control unit. The battery charge lamp is lit on engine start up but should extinguish when the engine is running, If the lamp remains lit when the engine has reached operating speed, the alternator charging circuit should be checked for faults, The engine temp lamp is lit if the temperature of the engine exceeds a certain point The air filter lamp is lit when the filter is blocked to the extent that the engine doesn’t operate efficiently. Note: Should any of these warning devices engage while operating the machine, the engine stops automatically. If elevated, the booms need to be manually stowed as outlined in emergency procedures, section 4. 3:1 ‘OPERATOR'S WANUALTEREX AERIALS LIMITED. Tasort 4.1.2 SITUATION: Unit elevated, with operator incapacitated at platform controls. TRY TO DETERMINE THE CAUSE OF THE PROBLEM BEFORE YOU TOUCH THE MACHINE. CORRECTIVE ACTION: * Have someone summon first aid or rescue squad, ‘* Attempt to talk to the operator before taking any rescue measures. + Before attempting emergency lowering procedure, check to see if the operator is: a) ina pinned situation, or b) would be endangered if platform is moved, + After establishing that the machine is not in contact with live power lines, lower the platform or move the unit as necessary, using emergency procedures (see “Emergency Pump”, section 4.2.1). + Render first aid to the operator. + Report the incident to your supervisor immediately. IMPORTANT: Any incident involving personal injury must be immediately reported to the local Terex Aerials Distributorship as well as to Terex Aerials Inc. 4.1.3 SITUATION: Platform in contact with live power lines and operator incapacitated. CORRECTIVE ACTION: ‘+ Have someone summon first aid or rescue squad. ‘* Contact authorised personnel to disconnect power supply touching unit. ‘+ Before attempting emergency lowering, check to see if the operator is: a) ina pinned situation b) —_ would be endangered if platform is moved. 42 (OPERATOR'S MANUAL‘TEREX AERIALS LIMITE: TasoRT * AFTER POWER IS CUT, lower the platform or move the unit as necessary, using emergency procedures (see “Emergency Pump”, section 4.2.1). + Render first aid to the operator. ‘+ Report the incident to your supervisor immediately. IMPORTANT: Any incident involving personal injury must be immediately reported to the local Terex Aerials Distributorship as well as to Terex Aerials Inc. 4.2 EMERGENCY SYSTEMS AND PROCEDURES 4.2.1 EMERGENCY PUMP This machine is fitted with a handpump which can be operated from the ground control station when the unit has lost power. In an emergency situation the pump can be used to lower the cage to provide a safe exit for personnel ‘The pump is located at top of hydraulic tank in the main control module. The lever is stowed nearby on the side of the tank. Ground Operation: (refer to Figure 4.1) * Move black handpump lever (iter 1) to the left to operate all boom functions and to the right to disengage the brake and drive axle. (see point 423.1) * To operate main boom functions (black handpump lever moved to left) the Hydraulic bypass valve (BP) should be fully engaged by screwing in the top knob (tum clockwise by hand) and the dump valve overide button (DP) should be rotated anti clockwise and allowed to pop out. ‘Select desired function by screwing in (clockwise) the appropriate knob by hand only * Generate hydraulic pressure by pumping hand pump, to move boom to required position + The function may be deselected by screwing out (anticlockwise) the knob to its fullest extent ( by hand only), 43 ‘OPERATOR'S MANUALTEREX AERIALS UNITED asowr ‘+ Ensure that for reversing the operation of a valve, Le, rotation control from lefi to right, the knob used for the first function should be screwed out fully before the opposite knob is serewed in. Ss KEY DP Dump Valve BO Brake Override BY Hydraulic ByPass LID Lift 1 Down L2D Lift 2 Down L3D Lift 3 Down L3U_—_Lift3 Up RR Rotate Right RL Rotate Left TI Tele-boom In Figure 4.1 - Emergency Handpump - Hydraulic valve block. * ON COMPLETION OF THE REQUIRED OPERATIONS, ENSURE ALL VALVE KNOBS ARE SCREWED OUT FULLY. 4.2.2 EMERGENCY ROTATION The emergency rotation of the superstructure is performed by a mechanical override or the emergency pump. For the mechanical override procedure, use 1/2” square socket, extension and ratchet handle attached to the square extension shaft of the rotate drive gearbox. For the emergency pump procedure, activate the emergency pump move black handpump lever to the left and screw in the appropriate valve override knobs (as described in section 4.2.1 above). 4.2.3 EMERGENCY TOWING Every attempt should be made to restore primary power to the machine before using this procedure. THIS PROCEDURE REQUIRES RELEASING THE MACHINE BRAKES, WHICH RENDERS THEM IN-OPERATIVE, TEREX 44 (OPERATORS MANUAL‘TEREX AERIALS LIMITED TasoRT RECOMMENDS USING THIS PROCEDURE ONLY IN CASES OF EMERGENCY, AND ONLY FOR A SHORT DISTANCE. BE AWARE OF MACHINE RUNAWAY ON SLOPING SURFACES. MOVEMENT SPEED SHALL NOT EXCEED 3 M.P.H. (5 K.P.H.) This machine is equipped with tie down lugs (front and rear) that can be used for towing the unit. The chains or ropes must be of sufficient capacity to move the machine, ‘+ Secure the machine to the tow vehicle with chains or ropes, ALWAYS BLOCK THE WHEELS BEFORE YOU RELEASE THE BRAKES TO PREVENT UNEXPECTED UNIT MOVEMENT ON SLOPES. Figure 4.2 - Top view of hydraulic manifold block. 4.2.3.1 Towing. A. Disengage brakes (@) Push red overide button and twist clockwise. (item 1 Fig 4.2) to open the brake lines, so that hydraulic pressure can be applied to the brakes (b) Switch handpurp to brake line by moving the black handpump (item 4, fig 4.3) located on top of the hydraulic tank, to the right (© Operate handpump (item 1 Fig 4.3) until sufficient pressure has built up to release the brakes (note: P.R.V. is set at 40 bar), ‘OPERATORS MANUALTeapannuats ureo ont (d) Press in the two red studs (item 7 Fig 4.3), situated on the pump, to allow circulation of oil through pump, Studs re-engage automatically when power is restored. (E) Attempt to straighten steering. (Tow machine carefully and slowly (max. Sknv/hr) backwards using chains. B. —_ Re-engage Brakes. (a) Twist red overide button (item I Fig 4.2) counter clockwise, to release pressure so that the brakes re-engage. (4) Figure 4.3 : Hydraulic and Electrical Modules HYDRAULIC MODULE ENGINE COMPARTMENT 1) Emergency handpump 7) 2 Red studs to allow oil to 2) Oil tank circulate through pump. 3) Hydraulic valve block. 4) Handpump selector. (Lift/Brake) 5) Lower control box. 6) Handpump handle (OPERATORS MANUAL‘TEREX AERIALS LIMITED, TASORT S.A. SLL. 5.1.2. SECTION 5 MAINTENANCE SCHEDULES GENERAL INFORMATION INTRODUCTION ‘The TASORT has been specially designed to reduce maintenance to a minimum. tis essential that the specified servicing instructions are followed to ensure safety and reliability. The hydraulic pump, motor, cylinders and pressure valves are self-lubrication internally. The turntable slewing ring is grease packed and the corrosion-resistant pivot pins and bearings are pre-lubricated and require attention only at six monthly intervals. Note:- During the guarantee period, minor oil leaks may occur until the various hydraulic components and pipe fittings are "bedded-in". During the first three months of operational use, all hydraulic components, hoses and pipe fittings must be inspected weekly for oil leaks etc. Corrective action should be taken as required. HYDRAULIC OILS The following table lists the recommended equivalent hydraulic oils for a TASORT machine SHELL SHELL TELLUS T32 MOBILE DTE 13M TEXACO RANDO HDZ 32 CASTROL HYSPIN AWH 32 ESsO UNIVISE N32 Ifa lubricant not listed in the table is to be used, the oil must comply with the following requirements: @ Highly refined mineral oil incorporating anti-oxidant, anti-dust, anti-foam, and anti-wear additives. () The oil must have good demulsibility, so that water is not circulated in the system. (©) The optimum viscosity range at operating temperature is 16/40 centi Stokes. (@ The viscosity index should preferably be 100, and not less than 90. Sel (OPERATOR'S MARUAL‘TEREX AERIALS LIMITED. TASORT 513 fitted. (©) the viscosity range will usually be: Temperate 0°C - —300¢St Temperate 40°C - 30cSt Tropical 0° = — 700eSt Tropical «40°C. - S0eSt Tropical 100°C: - 8cSt (Mineral hydraulic oils produced by different companies will usually mix with each other satisfactorily. However, the oil producers should be consulted in case of doubt. (g) For sub-zero temperatures, the use of Shell Tellus T15 or equivalent hydraulic fluid with viscosity index of 151E and pour point MINUS 50°C is recommended. (a) For tropical temperatures, the use of BP Energol HLP 100 or equivalent is recommended. HEALTH WARNING WHEN HANDLING HYDRAULIC OILS WARNING REGULAR CONTACT WITH MINERAL OILS POSES A POTENTIAL HAZARD ‘TO HEALTH. ALL PERSONS MUST BE AWARE OF THE CORRECT METHODS OF HANDLING THE OIL AND THE NEED FOR THOROUGH HYGIENE. Mineral oil act as solvents on the natural oil in the skin. Frequent and prolonged skin contact can cause dermatitis or severe irritation. Normally, mineral hydraulic oils present no health hazard when used intelligently and it is recommended that protective clothing and proper washing facilities should be provided or be accessible. If oil is splashed into the eyes, it must be washed out thoroughly using copious quantities of water. If irritation persists, medical advice must be sought. DIESEL ENGINE OIL Engine oil changes and general servicing differ, depending on the type of engine Itis recommended that the manufacturers diesel engine handbook is consulted for the particular make and type of engine fitted to your machine. However, a recommended service schedule would be as follows: = Change oil and filter after first 20 hours of operation. - Change oil and filter every 200 hours thereafter. 52 (OPERATOR'S MANUAL‘TEREX AERIALS LIMITED TASORT 5.2. SERVICING CHECK LIST (BASIC MACHINE ONLY) All checks must be completed by operator before operating unit. 5.2.1. Daily (@) Check hydraulic oil level. (&) Check tyre condition. (©) Check cage door lock. (@ Check for hydraulic leeks. (©) Check hoses for chaffing. (© Check that safety hamess points are in tack. () Check tilt alarm. (h) Check that all switches are not damaged. (Check cage controls for proper operation. G) Check wheel nuts for tightness. (&) Check wheels for damage. () Check axle securing bolts. (m) Check diesel engine oil level. (n) Check diesel engine fuel level. 5.2.2 Weekly In addition to the daily checks, the following checks should be carried out by an experienced technician :- (@ Check control valves for self-centre. (©) _ Inspect hydraulic system for leakage. (©) Check steering system for oil leakage and wear. @® Check battery electrolyte levels. (©) Check pivot pin security. (© Grease zoom pads. 53 PERT SRO‘TEREX AERIALS LIMITED. TASORT (g) Lubricate slew ring gear teeth. (b) Check rotation box securing bolts for tightness. (Grease cylinder pivot pins, steering pivot pins and slew ring (figure 5.2)(see also section 5.4). @ Check axle oil level. (&) Ensure all labels are legible and in place. () Check all hoses and cables through slew ring for wear. (m) Check the battery and mountings as follows: () Check the start battery and mounting frame for signs of damage. (i) Check battery terminals for corrosion. Clean and apply Vaseline to terminals. Gili) Check the battery electrolyte level and, if necessary, top-up with distilled or de-mineralised water. (n) Check the manifold assembly. Operate the motor and carry out the following checks: () Check the security of blocks and solenoids. (ii) Check the security and condition of hoses and cables. (©) Check the hydraulic oil tank as follows:~ @ Check the tank for security (ii) Check the tank for leakage. (ii) Check that the handpamp is operational by depressing one of the function levers and pumping the handle. (p) Check the minor equipment as follows:- (Check all minor equipment for security Gi) Check for oil leakage Gi) Check all cables for security and damage. (@) Check the nylon zoom pads for wear as follows:~ (@ Fully zoom in and check the gap at the top of the zoom boom telescope, between the inner and the outer, at the rear of the zoom boom. (ii) Fully 200m out and check the same gap at the top of the telescope, at the front of the zoom outer. (ii) Renew the pads if the gap between the pad and the zoom outer is Smm or more. 54 OPERATOR'S MANUAL‘TEREX AERIALS LIMITED. TASORT 5.2.3. Monthly In addition to the weekly checks, carry out the following:- (@) Check for hydraulic oil contamination. (b) Check chassis mounting bolts. © Grease slewing ring teeth. @ Check rotation gearbox oil level. (©) Lubricate all small pivots throughout the machine. (© Ensure all boonveylinder pins are positively secured in position. (@) Check drive gearbox and axle oil levels. (hb) Torque wheel nuts to that specified in the torque chart (ref. figure 2.1) () Check that boom lock valves are functioning. Switch off unit and operate spool. @ Check structure for any obvious defects. (Kk) Check emergency pump operation. (® Check condition of the slave cylinder. (m) Check all bushes for wear. Elevate the booms and check each pin in turn for rotation or movement. If wears detected, the bush may need to be replaced. The pins and bushes have been specially treated and should only require lubrication at 4 yearly intervals. Under certain conditions, lubrication may be required more frequently. (®) Check the slew bearing for any obvious defects. Generally, no user ‘maintenance to the slew bearing is possible. The replacement of the slew bearing is a ‘major operation and advice should be sought from Terex Aerials Ltd. Checks must be made to ensure that all securing bolts are tight. Any bolts found loose or sheared must be replaced. Slew ring play is measured at the perimeter of the ring and the maximum rock allowed is 1.7mm (refer to fig 5.1) (©) Check and maintain the superstructure as follows: (@ Steam clean the superstructure and inspect all welds and brackets. Gi) Check for pins turning in their mountings. This will indicate sheared pin lock bolt. Refer to pin replacement procedures. 55 OPERATOR'S MARUATTEREX AERIALS LIMITED, TASORT PLACED AS CLOSE TO RING AS POSSIBLE DIAL GAUGE FIG. 6 Figure 5.1 : Slew Ring Bearing Play Measurement. 5.2.4 Six Monthly In addition to the monthly check, carry out the following:- @ ) © cylinder @ © © Check cage levelling. Check cage pivots. Check boom cylinders. The lift cylinder seals can be replaced with the mounted on the machine, or by removing the cylinder before removing the Check axle. Replace suction filter element. Test all machine systems. 5.2.5 Yearly In addition to the 6 monthly check, carry out the following:- @ Change oil in rotation gearbox. 56 OFEETORS MAA‘TEREX AERIALS LIMITED. TASORT ) ©) @ © @ ® Grease slewing ring bearing. Examine the hydraulic oil. Change if necessary. ‘Check hydraulic oil tank. Examine machine structure for defects. Examine cage mountings and structure. Check zoom cylinders. The zoom cylinder is a double-acting type and must be removed from the machine before any thorough check can be carried out. 5.2.6. Four Yearly In addition to the yearly checks, carry out the following. @ @) Detailed examination of flexible hoses. Detailed examination of all pivot pins and bearings. 5.3. SERVICING Servicing to be carried out by a trained technician. 5.3.1 DAILY ROUTINE SERVICING 53.11. 53.12 5313 Hydraulic Oil Level Before checking the oil level, ensure that the machine booms are stowed in the travelling position and the machine is standing on level ground. The oil level ‘must be 1" (2.54 em) below the top of the oil level gauge. Refer to the lubrication chart for the correct grade of oil if the reservoir requires topping up. ‘After checking the oil level, ensure the oil filler cap is fully secure to prevent water contamination or contamination by other impurities . ‘Tyre Condition Check the condition of all four tyres. Cage Door Lock Check the security of the cage door. 5.3.2. WEEKLY ROUTINE SERVICING 53.2.1 Control Valves Se OPERATOR'S MARUAT‘TEREX AERIALS LIMITED TASORT 5.3.2.3 5.3.24 5.3.2.5 Cage control valves must be checked for correct operation. Check that the cage control valve handles automatically return to the central (neutral) position, Hydraulic System Inspect the hydraulic system as follows:~ (2) Pressurise the hydraulic circuit and inspect the system for any signs of oil leakage, particularly at flexible hoses, connections and hydraulic components. (b) Examine all pivot pins on booms, cylinders and the levelling system to ensure that they are positively secured in position. Steering Check the steering cylinder for oil leakage and the linkage for signs of water. Start Battery Check the battery electrolyte levels. Replenish the electrolyte with distilled water if necessary. Pivot Pins Check all pivot pins for security. Grease those pivot pins as shown in the following Fig 5.2. 58 OPERKTOR'S MARUAT‘TEREX AERIALS LIMITED. TASORT Figure 5.2 : Location of Grease Nipples 53.3. MONTHLY ROUTINE SERVICING 53.3.1 Hydraulic Oil Allow the machine to stand for at Jeast 8 hours without operating the pump. ‘This will allow water and other impurities to separate out of the oil and settle to the bottom of the tank. Disconnect the 3/4" pipe at the bottom of the pump side of the ball valve and block off to prevent oil leakage from the system. Open the ball valve at the bottom of the tank just enough to allow a gradual trickle of oil and drain fluid from the tank into a transparent container, until clean oil flows. Under normal operating conditions, a maximum of 0.25 litres, (1/2 pint) is usually sufficient to remove all impurities. If the oil does not flow clear but has a cloudy appearance, itis usually an indication that water is present. If this condition occurs, a complete coil change will be necessary. 5.3.32 Chassis Bolts Check all bolts for tightness. 59 (OPERATOR'S MANUAL‘TEREX AERIALS LIMITED TASORT 5333 5.3.3.4 53.3.5 that 5.3.3.6 necessary, Slewing Ring Gear Teeth Remove any dirt from between the gear teeth and lubricate. Note:- If solvents or a high-pressure washer are used for cleaning, re-grease the slewing ring bearings. Lubrication Lubricate all small pivots throughout the machine with any good quality medium grade oil. Special attention should be given to the cage control lever pivots. DO NOT lubricate the main pivot pins . Pivot Pin Security Examine all pivot pins on booms, cylinders and levelling system and ensure they are all positively secured in position. Drive Gearbox Oil Level ‘Check the gearbox oil level with the machine on level ground and, if top-up with E 90 5.3.4 SIX MONTHLY ROUTINE SERVICING 53.4.1 any 5.3.4.2 any $3.43 ‘Cage Levelling Check the cage levelling system as follows:- (@) Examine both levelling cylinders, particularly at the pivot points, for sign of wear or damage. Ensure that the end fittings are secure. (b) Check cylinders and hose fittings for leaks. Boom pivots ‘The main pivots on the booms, cylinders and levelling system are fitted with corrosion-resistant pins and per-lubricated bearings. Check the bushing for signs of wear ‘The bushings are stecl-backed, acetal co-polymer lined. If the bearings show any defect, they should be replaced with the correct type. Consult Terex Aerials Ltd. Boom Cylinders 5:10 OPERATOR'S MARUAT‘TEREX AERIALS LIMITED. TASORT Check the boom cylinders as follows:- (@) — Hydraulically test the cylinders at fully retracted and extended positions, Check that there is no movement between rod and bearing housing, or between cap and tube (&) Check all cylinders for oil leakage. 5.3.4.4 Axle Check the oil level in the axle_with the machine on level ground and, if necessary, top us with EP 90 oil. 53.4.5 Suction Filter Change the suction filter element. 5.3.4.6 Machine Systems Test. Test the following systems:- (@) Drive assembly, including drive shaft, axle, couplings, drive motor and gearbox. (b) — Slewing ring. (©) Cage rotation worm drive. (@) All machine functions. 5.3.5 YEARLY ROUTINE SERVICING 53.5.1 Hydraulic Oi Providing the hydraulic oil has been regularly maintained, it should only require changing at approximately two-yearly intervals. This is dependent on maintenance, amount of use, application, temperature, atmospheric conditions and other factors. A cloudy appearance in the hydraulic oil indicates that water is present. A change from clear amber to dark brown, accompanied by a strong “burt” smell, indicates overheating of the oil. The cause should be investigated and rectified. The presence of either requires a complete drain and refill of the entire hydraulic system. 53.82 Hydraulic Oil Tank Sl OPERATOR'S MARUAT‘TEREX AERIALS LIMITED TASORT 53.5.3 53.5.4 any 5.3.55 @) 53.5.6 Carefully check the condition of the oil inside the tarik to ensure that it flows casily and is a clear amber colour. In cases of gross contamination, it will be necessary to completely draia and refill the entire hydraulic system. Hydraulic Tank Refill Procedure. Refilling the hydraulic oil tank requires approximately 62 litres of TEXACO RANDO HDZ 32 hydraulic oil (or equivalent). To refill the hydraulic tank, proceed as follows:- (@) Ensure that the oil temperature is sufficiently high to allow the oil to flow freely. (0) Place a suitable container under the drain tap or attached to a suitable hose to lead from the drain tap to the waste oil container. (©) Open the drain tap and drain off all the oil from the tank. (@ Remove the tank top plate for internal inspection and cleaning. (©) Renew or clean the suction hose and close the drain tap. ( Renew the cover plate, renew the gasket if necessary and refill the reservoir to the correct level, filling through the suction filter. Structural Examination A thorough examination of the complete machine should be carried out for signs of damage, corrosion, misalignment, material fractures, etc. Particular attention must be given to the condition of all welded joints. ‘Cage Mounting Check the cage mounting as follows:- (@ Check that all mounting bolts are secure. Check cage frame members are in good condition. Levelling Cylinders Check seals at rod and if in need of replacement change as follows 53.6 FOUR YEARLY ROUTINE SERVICING Note:- The following recommendations are based on the advice of suppliers and the requirements of various national safety regulations. They should be applied ‘with discretion, depending on such factors as the amount and type of use, 5.12 OPERKTOR'S MARUAT‘TEREX AERIALS LIMITED, TASORT 5.3.6.1 showing wear 5.3.6.2 require pins 53.6.3 53.6.3. environmental conditions, local safety regul Flexible Hoses Inspect all flexible hoses over their complete length. Renew any hoses looseness or corrosion at the end fittings, cracking, blistering or excessive of outer protective covering. Pivot Pins and Bearings All pivot pins have beea treated with Tufirite and only require lubrication checks at 4-yearly intervals. All pivot pin bearings are steel-backed, acetal co-polmer lined and only lubrication checks at 4-yearly intervals. Note:- In tropical climates, pins and bearings may require more frequent lubrication. ‘The recommended lubricant for pivot pin bearings is MALACHITE LONGTERN 2 PLUS extreme pressure grease or equivalent. Note:- There are no grease nipples for Boom pin bearing lubrication. The must be removed and lubricated by hand. Cylinder pins are lubricated by greased nipples. These should be greased weekly or every 100 hrs. Pin Replacement To replace a pin, the following procedures should be adhered to, 1 Boom Pin Replacement To replace a boom pin, proceed as follows;- @ ® © @ Support the boom and upper structure securely on a fork lift, or similar rigid platform. Remove the pin locking bolts. Drive out the boom pin. Take care to ensure that the inside bore is not damaged during this procedure. Fit new pin and locking bolts. Lubricate the bolts before fitting. 5.13 (OPERATOR'S MANUAL‘TEREX AERIALS LIMITED TASORT Note: It is very important to maintain the correct mating position between the boom © 5.3.6.3.2 and side plates during this ogeration. Any movement between the two parts, will make pin fitting more difficult. Apply grease to pins. Tie-Rail Pin Replacement To replace a tie-rail, proceed as follows; (a) () Note:- On removal of the pin, th © @ 5.3.6.3.3 Support the Boom Remove the pin locking bolts and pivot pin, rail will fall from position if not held. Since the tie-rail is a relatively light components, it can be held in position manually while the new pin is fitted. Fit new pin and locking bolts. Lubricate bolts before fitting. Apply grease to the pin. Lift Cylinder Pin Replacement To replace lift cylinder pin, proceed as follows:- @ ) © @ 53.6.3.4 ‘Support the Boom. Release the oil pressure to ensure there is no load on the cylinder. Remove the pin locking bolts, support the cylinder and remove the pin. Fit new pin and pin locking bolts. Lubricate the bolts before fitting. Apply grease to the pin. Self Levelling Cylinder Pin Replacement To replace a self levelling cylinder pin, proceed as follows:- @ ) © @ 53.635 Support the cage to ensure that there is no load on the self levelling cylinders. This also applies when changing pins on the rear levelling cylinder. Remove the pin locking bolts and remove the pin. Fit new pin and new pin locking bolts. Lubricate the bolts before fitting. Apply grease to the pin. Zoom Boom Cylinder Pin Replacement To replace a zoom boom cylinder pin, proceed as follows:- Note:- If the zoom has been greased, the location recess may be filled and not visible. ) ®) © Remove the pin locking bolts. Support the cylinder and remove the pin. When changing the rod pin, it may necessary to zoom out to reveal the pin location. Fit new pin and new pin locking bolts. Lubricate the bolts before fitting. S14 JPERRTOR'S MANUAL.‘TEREX AERIALS LIMITED. TASORT @ 53.6.4 5.3.6.5 5.3.6.5.1 5.3.6.5.2 5.3.6.6 Apply grease to the pin. Zoom Cylinder Check condition of cylinder as follows: a) Remove the pins and hoses. b) Withdraw the cylinder backwards out of the zoom boom. ©) Elevate the zoom boom to the horizontal position. Note:- The 2oom boom must be secured fully in to prevent the zoom inner from sliding out without the constraint of the zoom cylinder. Zoom Pads Zoom pads should be replaced as follows, depending on the type of pad: Front Zoom Pad Replacement To replace the front zoom pads, proceed as follows:- a) Support the inner 200m boom. Unbolt the front pad, keep pads and remove pads as necessary. b) Replace the pads by hammering gently into place. ©) Replace and secure the keep plates. 4) Repeat this procedure for the side and top pads if replacement is required, Rear Zoom Boom Replacement To replace the rear zoom pads, proceed as follows: a) __ Remove the rear zoom cylinder pins, cage and cage levelling brackets that are bolted fo the front of the zoom boom inner. b) Pull the inner boom backwards, until the pads are accessible at the rear of the zoom boom. ©) Replace the pads and re-assemble the zoom boom. Lift Cylinder Seals Should the lift cylinder seals be damaged, they can be replaced as follows sas (OPERATOR'S MARUAT‘TEREX AERIALS LIMITED. TASORT 5.3.6.6.1 Note:- 5.3.6.6.2 Seal Replacement - Cylinder In-place. To replace the lift cylinder seals without removing the cylinder from the machine, proceed as follows:- (@) Support the boom and release the cylinder pressure. (&) Clean the cylinder end and loosen the cylinder end cap. Undo the end cap several turns. (©) Remove the rod end pin and support the cylinder barrel. Undo the end cap end and withdraw it carefully over the piston rod. Take care to ensure that no dirt enters the system. It is recommended that the bearing ring at the base of the piston rod is replaced when seals are replaced. Examine the rod of score marks and damage. This is most easily achieved by extending the cylinder and examining the protruding rod. (@ __ Replace the seals in the end cap and replace the end cap. Care should be taken during this procedure to ensure that no damage occurs to the rod surface. (©) Bleed the cylinder by allowing air to escape around the end cap ( Fully tighten the end cap. (g) Clean the over-centre valves and examine for signs of leakage. (ht) Check for efficiency, by extending the cylinder and selecting descent, via the spool valves at either cage of ground. Seal Replacement - Cylinder Removed ‘The cylinder can be removed from the machine before replacing the seals. The replacement procedure is the same as that detailed in paragraph 19.1.1 516 OPERATOR'S MANUATTEREX AERIALS LIMITED rasoRt 5.4 LUBRICATION 5.4.1 General Lubrication The following table lists the recommended lubricants for the TASORT COMPONENT LUBRICANT FREQUENCY REMARKS Drive and Steer EP 90 Check 6 monthly : Axle Change yearly Drive Gearbox EP 90 Check monthly Change yearly Starter Battery Vaseline Grease 6 monthly ‘Smear Electrical Terminals connections Hydraulic Oil TEXACORANDO | Check weekly Fill to 1 inch HDZ 32(0r Change yearly (2.54ems) below the cequivalent- refer to top of oil level para 1) gauge Pins/Bearings Molykote 2 Grease 4 yearly Grease more freq. in tropical climates. Wheel Bearings Ls2 Grease Yearly Zoom Boom (Inner) | Molykote 2 Grease monthly Zoom Boom (Outer) | WD 40 Monthly Slew Ring EP2 Refer to section 5.4.2.1 Diesel Engine Refer to Refer to manufactures manufacturers handbook. handbook - 5.4.2 Slew Bearing/Gear Lubricants S421 Slew Bearing lubrication Terex Aerials recommends lubrication of the slew bearing with an EP2 grease. ‘The slewing rings are equipped with greasing holes tapped to the European standard and suitable for:‘TEREX AERIALS LIMITED. TASORT 5.4.2.2 - Centralised greasing. - Standard greasing; straight or angled spherical head grease nipples (AFNOR norms NFR 165-21 - DIN 3410) Lubrie: - Regular Operation .. every 100 hours - Intensive Operation every 50 hours Note:- The slewing ring should be rotated through 360° after the lubrication operation and the lubricants should then be topped up. Slew Gear Lubrication The teeth must be thoroughly cleaned, particularly within the gaps between the teeth, before lubrication. For this operation we recommend a proprietary solvent, Use a suitable caulking gun to apply a6 mm diameter bead of grease around the full circumference of the gear. Brush the grease into the gear surfaces. Lubrication Frequency- Slew Gear - Approximately 50 hours. Grease Characteristics - Slew Gear. ‘The grease used on the slew gears must comply with the following characteristics: = ‘Extreme pressure grease. = Water and temperature resistant. 125° F to 400° F (-4°C to 200°C) - Temperature range .. Terex Aerials Limited recommend the following grease for the slew gear. = KEYSTONE MOLY 25 OPEN GEAR COMPOUND (S.A-Part No. 10126400) It is possible to use other brands of grease provided that they offer greasing. characteristics similar to the type listed above. S18 OPERKTOR'S MARUAT‘TEREX AERIALS LIMITED. TASORT 519 OPERATOR'S MANUAL‘TEREX AERIALS LIMITED TasoRT SECTION 6 ILLUSTRATED SPARE PARTS When ordering Spare Parts, please quote the Machine Model, the Machine Serial Number and Part Number reference in this section, 61 ‘OPERATING HANUAT‘TEREX AERIALS LIMITED. TAsoRT TASORT UPPER CHASSIS ASSEMBLY Figure 6.1 - Upper Chassis Assembly ITEM PART NO DESCRIPTION QTy. 1 GS594 CHASSIS ASSEMBLY 1 2 13019-0001 | DIESEL FUEL TANK 1 3 10124 LEVEL GAUGE 1 4 11667 FILLER BREATHER CAP 1 5 13121 ‘SLEW RING 1 15924 M14 X 80 BOLTS 18 12092 M14 X90 BOLTS 18 62 ‘OPERATING HANUAL‘TEREX AERIALS LIMITED TASORT LOWER CHASSIS ASSEMBLY TasoRT Figure 6.2 - Lower Chassis Assembly TTEMNO [PART NO_| DESCRIPTION QTY. 1 18276 RIGID AXLE 1 18322 DRIVE AXLE 1 2 Gs504 CHASSIS ASSEMBLY 1 3 44022-0361 | WHEEL ASS’Y (RIGHT HAND) 2 4 13169 MI8 X 1.Sp HEX. NUT 24 15169 MI8 SPHERICAL WASHER 24 5 17596 PROP SHAFT 1 6 17201 ‘TRANSFER GEARBOX 1 41018-0022 | TWO SPEED MOTOR 1 7 Ds905 AXLEMOUNTING ASSEMBLY =| 4 Ms478_| AXLE MOUNTING PLATE 4 17543 M20 X 200 LG. HEX. HEAD BOLT | 16 15138 M20 HEAVY DUTY FLAT WASHER | 16 15291 M20 NYLOC NUT 16 8 44022-0360 | WHEEL ASSEMBLY (LEFT HAND) | 2 ‘OPERATING MANUAL 63‘TEREX AERIALS LIMITED. TASORT TRANSFER GEARBOX TAsoRT 4 S 3 Tl —| A Figure 6.3 - Transfer Gearbox [rem T PartNo. ‘DESCRIPTION QTy. 1 18215 SEAL 1 2 | 18206 “0” RING 1 3 18207 NUT 1 4 | 18208 SEAL 4 5 | 18209 SCREW 4 6 | 18211 WASHER 4 7 | 18210 SCREW 4 8 | 18212 WASHER 4 9 | 18213 SCREW 1 10 | 18214 BREATHER 1 u1__| 18216 SEAL 1 “OPERATING MARUAL‘TEREX AERIALS LIMITED. (Refer to Figure 6.4) TASORT. REAR AXLE ASSEMBLY TAsoRT. ITEM_| PART NO. | DESCRIPTION QTy. "AXLE AND BRAKES 1 17893 BELL SPRINGS, FAIL-SAFE SPRINGS BRAKE. 36 17894 PISTON, FAIL-SAFE SPRINGS BRAKE 2 2 17861 SEAL SPRING FOR BRAKE 2 17862 SNAP RING FOR SEAL SPRING 2 17859 BACK SPRING BRAKE PISTON 2 17860 BALL 4 1786 CLAMP FOR BRAKE RUBBER PIECE. 2 17867 BRAKE COVER 1 17874 ‘SNAP RING FOR BELL SPRINGS 2 17886 ‘O-RING FOR BUSH, FAIL-SAFE SPRINGS BRAKE, 2 17887 O-RING FOR BUSH, FAIL-SAFE SPRINGS BRAKE 2 17888, CAP SCREW, FAIL-SAFE SPRINGS BRAKE 8 3 17889 LEVER, INSIDE FAIL-SAFE SPRINGS BRAKE 2 17890 FLANGE, FAIL-SAFE SPRINGS BRAKE. 2 17891 PIN, FAIL-SAFE SPRINGS BRAKE 2 17892 BUSH, FAIL-SAFE SPRINGS BRAKE 2 17851 CENTRAL BOX 1 17352 FLANGE FOR HUB (RH) 1 17853 FLANGE FOR HUB (LH) 1 17854 CAP SCREW 1 17855 BRAKE HOLES PLUG 1 17856 OIL PLUG WASHER 5 17857 OIL PLUG : 3 17858 OIL PLUG 2 17863, ACTUATOR 2 17864 BRAKE DISK 10 17865 ‘COUNTER BRAKE 6 17868. SNAP RING FOR PULL PIN 2 17869 BRAKE PULL PIN 2 17870 BRAKE FORK (COMPLETE) 2 4 v7 CAP SCREW FOR BRAKE COVER 4 17872 ‘SPHERICAL WASHER 2 5 17873, NUT SET-UP BRAKE 2 6 17875 BRAKE INSPECTION PLUG 2 17876 WASHER 2 7 17877 ‘CAP SCREW FOR BRAKE COVER 4 17878, COUNTER PLATES PIN LOCK 6 17879 AXLE HOUSING (RH) 1 17880 ‘AXLE HOUSING (LH) 1 17881 ‘STUD BOLT, AXLE HOUSING 2 17882 STUD BOLT NUT 24 17883 SPRING WASHER’ 24 17884 CAP SCREW, BRAKE. 4 17885 CAP SCREW, CROWN DELOCK BRAKE 2 ‘OPERATING MANUAL 65‘TEREX AERIALS LIMITED. TASORT - REAR AXLE ASSEMBLY (continued) TAsoRT (Refer to Figure 6.4) ITEM | PART NO. . DESCRIPTION ory] DIFFERENTIAL AND HALF SHAFT 8 17924 BEVEL DRIVE 1 17925, WASHER, DIFF. CASE SCREW n 17926, CAP SCREW, CROWN WHEEL 2 17927 BEARING, DIFF. CASE 2 17928 SHIM, DIFF. BEARING 4 17929 SHIM, DIFF. BEARING 4 17930, HALF SHAFT 2 17931 HALF SHAFT SLEEVE 2 17932 ROLL PIN SHAFT CONNECTION 2 17933, DIFFERENTIAL (COMPLETE) 1 17934 DIFF. CASE 1 17935 DIFF. GEAR (COMPLETE) 1 17936 DIFF. GEAR (COMPLETE) 1 17937 DIFF. GEAR 1 17938, ‘THRUST WASHER 2 17939 ‘THRUST WASHER 4 27940 DIFF. PINION GEAR 2 17941 DIFF. CASE 1 17942 DIFF. GEARS 1 17943 THRUST WASHER 2 17944 THRUST WASHER 4 17985 DIFF. PINION GEAR PIN 2 17946 PINION BEARING 1 17947 SHIM. PINION BEARING 3 17988 SHIM. PINION BEARING 3 17939 OIL SEAL, PINION 1 9 17950 CAP SCREW, PLANETARY BOX 10 27982 PLANETARY BOX 1 17953 O-RING, PLANETARY BOX 1 17954 CIRCLIP 1 17955 PINION SPACER 1 17956 PINION RINGNUT 1 17957 PINION BEARING t 17938 SHIM, PINION BEARING 0.15 2 17939 SHIM, PINION BEARING 0.20 2 17960 SHIM, PINION BEARING 0.50 2 17961, DIFF. PIN 1 DIFFERENTIAL LOCK 17962, SNAP RING 1 17963 DIFF, LOCK SPRING 1 17964 FORK PIN 1 17965 ‘SPRING WASHER, DIFF. LOCK 1 17966 SNAP RING 2 17967 DIFF. LOCK FORK 1 17968 DIFF. LOCK SPRING 1 17969 DIFF. LOCK PISTON 1 17970 O-RING, DIFF. LOCK PISTON 1 1971 DIFF. LOCK SLEEVE L ‘OPERATING HANUAL‘TEREX AERIALS LIMITED TASORT - REAR AXLE ASSEMBLY (continued) (Refer to Figure 6.4) TasoRT TTEM PART NO. DESCRIPTION ‘OTY. 10 u 12 13 14 17895 17896 17897 17898 17899 17900 17901 17902 17903 17904 17905 17906 17907 17908 17909 17910 17911 17912 17913 17914 17915 17922 17916 17917 17918 17919 17920 17921 17923 WHEEL HUB OIL SEAL, HUB BEARING, WHEEL HUB WHEEL HUB (COMPLETE) WHEEL HUB WHEEL BOLT WHEEL BOLT O-RING, WHEEL HUB RING RING GEAR CARRIER FLANGE CAP SCREW, CROWN DELOCK BRAKE PLANETARY RING GEAR SNAP RING PLANET SET PLANET PIN ROLLER BEARING (COMPLETE) PLANETARY REDUCTION GEAR SHIM, BUTTON SHAFT STOP BUTTON SHAFT STOP PLANETARY CARRIER WHEEL HUB SUPPORT (COMPLETE) WHEEL HUB SUPPORT CAP SCREW, WHEEL HUB HUB WEAR RING DUST COVER, WHEEL HUB HUB WEAR RING DUST COVER, WHEEL HUB CAP SCREW, PLANETARY SPRING WASHER, WASHER, PLANETARY GEAR BRR VR RRP NO NNAANANROOngZeevan (continued) ‘OPERATING MANUAL 67‘TEREX AERIALS LIMITED. ‘TAsoRT TASORT - REAR AXLE ASSEMBLY (continued) 12 13 =(14 Section A-A 4 . 10 Figure 6.4 - Rear Axle Assembly ‘OPERATING WANUAL‘TEREX AERIALS LIMITED TASoRT TASORT. STEER AXLE ASSEMBLY Figure 6.5 - Steer Axle Assembly (Annotation numbers indicate area where parts are located) ITEM _|PARTNO. DESCRIPTION 1 17864 DISC 2 17865 DISC 3 18204 BEARING 4 18202 SEAL 5 18203 BEARING 6 18205 BEARING 7 17949 SEAL 8 17956 NUT 9 17873 NUT 10 17886 “O" RING i 17887 “O" RING 12 17901 “0” RING 69‘TEREX AERIALS LIMITED. TASORT TASORT PLINTH ASSEMBLY Figure 6.6 - Plinth Assemb! a sl ] N ADJUSTING BOLT (M12) SECURING BOLT © WASHERS (4112) BALLAST RETAINING ASSEMBLY Figure 6.7 Ballast Security 6-10 ‘OPERATING HANUAL“TEREX AERIALS LIMITED PLINTH COMPONENTS LISTING TASORT ITEM _| PART NO. DESCRIPTION QTY 1 SS185 SUCTION FILTER BRACKET 1 2 13011-0092 | PLINTH ASSEMBLY 1 3 | 23010-0037 | FIRST POST 1 4 14029-0003 | BALLAST (LEFT HAND) 1 14029-0004 _| BALLAST (RIGHT HAND) 1 Gs149 BALLAST RETAINING ASSEMBLY 2 10932 M12 X 60 LG. HEX. HEAD SCREW 6 11410 M12 HEX. HEAD LOCK NUT 6 5 |Ms320 MOUNTING FOOT (HATZ ENGINE) 4 6 14315 SLEW GEARBOX 1 7 | 44006-0005 | M12°X 35 LG. HEX. HEAD 12.9 4 8 | 44013-0075 | HARDENED WASHER 4 9 10854 ROTATION MOTOR 1 10 __| Gs406 STARTER BATTERY BOX 1 PERATING MANUAL. 61‘TEREX AERIALS LIMITED Figure 6.8 - PART NO. DESCRIPTION| 11844 ss102 MS128 GSs41 GS527 MS143 11085 14541 10288 Gs179 21002-0115 23015-0135 GLACIER PM (PART OF LI CABLE COVE! CABLE COVER] OFFSET POST ZOOM BOOM NYLON PAD M8 X25 GI M8 DISC LOCI PERMAGLIDE FIRST TIE RAI] LIFT CYLINDB FIRST BOOM‘TEREX AERIALS LIMITED TAsoRT TASORT SECOND LIFT STAGE oak of | ~l [0 Pret a Pe 7 N . ~- él \ oN 17) a ® © Se ~® 7 ROO) Figure 6.9 - 2nd Lift Stage ITEM | PART NO. DESCRIPTION | QTY. 1 10288, PERMAGILDE PAP 40X40 BUSHING 8 2 23015-0136 | SECOND BOOM 1 3 $S102 CABLE COVER 1 MS128 CABLE COVER STUD 4 4 GS602 SECOND OFFSET POST 1 5 GS308 SECOND TIE RAIL 1 6 21002-0115 | LIFT CYLINDER 1 7 11844 GLACIER PM 25 X 25 DX BUSH 4 (PART OF LIFT CYLINDER) 8 11085 M8 X 25 GRADE 8.8 HEX HEAD SCREW 12 9 14541 M8 DISC LOCK WASHER, 24 ‘OPERATING MANUALTASORT ZOOM BOOM ASSEMBLY. Figure 6.10 - Zoom Boom Assembly‘TEREX AERIALS LIMITED TASORT - ZOOM BOOM ASSEMBLY “TasoRT ITEM | PART NO. DESCRIPTION. Qry. 1 [21002-0097 | ZOOM CYLINDER (REF SECTION 11.3.1) 1 2 | S179 WEAR PAD (SIDE) 4 3 | 23015-0140 | ZOOM BOOM (OUTER) 1 4 | Msi28 CABLE COVER STUD 6 5 | $8329 CABLE COVER 2 6 | ss271 END COVER 1 7 | 14265 PERMAGLIDE PAP 20X20 BUSHING 2 8 | 10288 PERMAGLIDE PAP 40X40 BUSHING 2 9 | 21002-0086 | LEVEL CYLINDER (MASTER) 1 (REF SECTION 11.5.7) 10 | Msi78 WEAR PAD (TOP/BOTTOM) 4 11 | 23015-0141 | ZOOM BOOM (INNER) 1 12 | 21002-0114 | LIFT CYLINDER (REF SECTION 11.1.3) 1 13 | 14265 GLACIER PM 20 X 20 DX BUSH 4 (PART OF MASTER LEVEL CYLINDER) 14 | 11844 GLACIER PM 25 X 25 DX BEARING 4 (PART OF LIFT CYLINDER) 15 | 44029-0182 | CAT TRACK 1 16 | 33020-0090 | CABLE TRAY COVER 1 17 _ | 33020-0089 | CABLE TRAY 1 14265 GLACIER PM 20 X 20 DX BUSH 4 18 (PART OF SLAVE LEVEL CYLINDER) 19 | 21002-0089 | LEVEL CYLINDER (SLAVE) 1 (REF SECTION 11.5.8) 20 | 11758 CIRCLIP 2 ‘OPERATING HANUAL GAS‘TEREX AERIALS LIMITED. TasoRT TASORT CAGE\CRADLE ASSEMBLY Figure 6.11 - Cage\Cradle Assembly ITEM | PART NO. DESCRIPTION QTy. 1 | 13016-0082 | CAGE sft 1 2 | 13017-0070 | CRADLE 1 3 | 42020-0022 | UPPER CONTROL BOX 1 4 | 42002-0322 | FOOTSWITCH 1 42002-0335 | FOOTSWITCH CONTACT 33014-0075 | DROP BAR 44004-0135 | CYL. PIVOT BOLT (M10 x 75mm Grade 12.9) 44004-0129 | CYL. PIVOT BOLT (M10 x 100mm Grade 12.9) 21002-0116 | CAGE ROTATION CYL Gs628 STUB POST 44021-0666 | MAIN PIVOT PIN 44019-0093 | M6 ROLL PIN(not illustrated) HS emrd4 ‘OPERATING MANUAL‘TEREX AERIALS LIMITED. TASORT HATZ DIESEL ENGINE MODULE TASORT > 5 D Figure 6.12 - Hatz Diesel Engine Module [item] PartNo. DESCRIPTION ‘ary. | 1 [41017-0045 | DRIVE PUMP 1 2 41017-0046 | GEAR PUMP 1 3. | 14113 HATZ ‘SILENT PACK’ DIESEL ENGINE 1 17066 CENTRAL COUPLING 1 4 | ssis2 EXHAUST TAILPIPE 1 16152 EXHAUST CLAMP 1 5 | 33030-0074 | SIDE COVER 1 6 23032-0005 _| COVER - HYDRAULIC PUMPS 1 ‘OPERATING MANUAL‘TEREX AERIALS LIMITED. TAsoRT TASORT HYDRAULIC MODULE Figure 6.14 - Hydraulic Module M PART NO. | DESCRIPTION ‘42020-0023 | LOWER CONTROL BOX 41017-0048 | HAND PUMP HANDLE 23032-0002 | HYDRAULIC TANK 12398 LEVEL GAUGE 41017-0042 | HANDPUMP 41030-0039 | RETURN FILTER 41028-0031 | VALVE BLOCK 23032-0006 | HYDRAULIC MODULE ASSY 23032-0008 | DOOR ASSY (not shown) 49041-0068 | DOOR STAY (not shown) i Roe aAnaene se 5 Seetaroatair— | 6-18 ‘OPERATING HANUALTAsoRT ‘TEREX AERIALS LIMITED TASORT GROUND CONTRO} 6 7 640 © FIG 6.3 - LOWER CONTROL BOX (EXTERNAL VIEW) (42020-0023) 6-19 ‘OPERRTING HANUAL‘TEREX AERIALS LIMITED. TA SORT LOWER CONTROLS - COMPONENTS LISTING “TasoRT ITEM PART NO. DESCRIPTION "42002-0349 | ENGINE KEYSWITCH 42002-0348 | FUEL HEATER SWITCH (OPTIONAL) 42002-0350 | CAGE/GROUND SELECT SWITCH 42019-0049 | HOURMETER, 42002-0342 | EMERGENCY STOP BUTTON, 42002-0343 | CONTACT (NORMALLY CLOSED) 42002-0346 | CAGE LEVEL SWITCH 42002-0346 | CAGE ROTATE SWITCH 42002-0346 | TELEBOOM SWITCH 42002-0346 | LIFT 3 BOOM SWITCH 42002-0346 | LIFT 2 BOOM SWITCH 42002-0346 | LIFT 1 BOOM SWITCH 42002-0346 | ROTATE SWITCH 42010-0296 | AIR FILTER INDICATOR 42010-0294 | ENGINE TEMP INDICATOR 42010-0293 | BATTERY INDICATOR 42011-0053 | 10AMP FUSE * *NOT SHOWN IN ILLUSTRATION ‘OPERATING HANUAL ee ee eee etter 6-20‘TEREX AERIALS LIMITED. TA SORT LOWER CONTROL BOX FIG 6.4- LOWER CONTROL BOX - INTERNAL VIEW [ITEM PART NO. DESCRIPTION Qry.] 1 42014-0140 | PCB - DMR-30 1 2 | 42013-0345 | TILT SENSOR(S degree) 1 3 42015-0133 | RELAY 7 4 | 42013-0391 | HARNESS FROM BOX TO VALVE BLOCK* 1 * NOT SHOWN IN ILLUSTRATION “OPERATING HARUAL TASORT CAGE CONTROLS 6-21‘TEREX AERIALS LIMITED. TAsoRT Figure 6.1 - Cage Controls PART NO. DESCRIPTION Q 32019-0012 | BOOM/ROTATE JOYSTICK 42010-0292 | BOOM INDICATOR LED 42002-0342 | EMERGENCY STOP BUTTON 42002-0343 | CONTACT (NORMALLY CLOSED) * 32019-0013 | TELEBOOM JOYSTICK 42002-0347 | HORN BUTTON 32019-0011 | DRIVE/STEER JOYSTICK 42002-0345 | DRIVE SPEED SELECT SWITCH 42002-0348 | DIFFERENTIAL LOCK SWITCH 42002-0344 | ENGINE ON/OFF SWITCH 42002-0345 | ENGINE SPEED SWITCH 42002-0346 | CAGE LEVELLING SWITCH 42002-0346 | CAGE ROTATION SWITCH 42002-0322 | FOOTSWITCH ence eee ene e 8 * Not shown on fig. 6.1 6-22 ‘OPERATING MANUAL‘TEREX AERIALS LIMITED TasonT TASORT UPPER CONTROL BOX (42020-0022) ; a4 3 FIG 6.2 - UPPER CONTROL BOX (INTERNAL VIEW) PART NO. DESCRIPTION ‘42014-0139 | PCB - DMT-30 42013-0386 | CAPACITOR 42013-0387 | ALARM 42004-0005 | CONNECTION BLOCK 42015-0130 | RELAY 42015-0131 | CIRCUIT BREAKER 42013-0390 | WIRING LOOM TO LOWER CONTROLS* wow nee cl = 2} aaa * NOT SHOWN IN ILLUSTRATION 6.23 ‘OPERATING WANUALTAsoRT ‘TEREX AERIALS LIMITED, LABELS Figure 6.19 - Label Positions 6.24‘TEREX AERIALS LIMITED TasonT TASORT PIVOT PINS 25 » 158 [44021-0688 on_e20 «116 [oss0" in 025 1 160 [65498 Sn 020» 153 165500 BN 020 «98 _[usire Bn 020 + 191 [6se76 Pn o4o + 265 [6se72 PH 025 «144 [c5475 PIN 025 « 90 [4021-0606 Pi 025 + 225 [ose73 PI 020 « 108 [os605 Pin e40 + 270 [os3i5 IPE PPPrre Figure 6.17 - Pin position 6-25 ‘OPERATING MANUAL‘TEREX AERIALS LIMITED TASORT LIFT CYLINDER TAsoRT Figure 6.18 : First and Second Lift Cylinders for TASORT M___| PART NO. DESCRIPTION TY, Lift Cylinder 41034-0126 Seal Kit 44029-0022 Grease Nipple ‘41031-0009 Overcentre Cartridge ITE 1 21002-0115 2 3 5 6 ‘41007-0020 Restrictor Cartridge =|=Isl=-lo ‘OPERATING HANUAL 6:26‘TEREX AERIALS LIMITED. TasoRT TASORT LIFT CYLINDE] ® Figure 6.19 : Third Lift Cylinder for TASORT M___|PARTNO. | DESCRIPTION ‘41034-0125 | Seal Kit “44029-0022 | Grease Nipple ‘41031-0009 | Overcentre Cartridge ITE 1 21002-0114 | Lift Cylinder 2 3 4 5 =|=|s|=l=le 41007-0020 | Restrictor Cartridge ‘OPERATING MANUAL 627‘TEREX AERIALS LIMITED “TasoRT TASORT TELESCOPIC CYLINDER Figure 6.20 : Telescopic Cylinder for TASORT M___| PART NO. | DESCRIPTION 41034-0124 | Seal Kit 44029-0022 | Grease Nipple 41028-0028 | PO Check Vaive ITE! 1 21002-0097 | Telescopic Cylinder 2 3 4 5 =|=|S]=I]e 41006-0041 | Relief Valve ‘OPERATING MANUAL 6.28‘TEREX AERIALS LIMITED TAsoRT TASORT MASTER CYLINDER Figure 6.21 : Master Cylinder for TASORT ITEM | PART NO. | DESCRIPTION QTY 1 21002-0086 | Master Cylinder 1 2 41034-0090 | Seal Kit 1 3 44029-0022 | Grease Nipple 2 ‘OPERATING HANUAL 6:29‘TEREX AERIALS LIMITED TasoRT TASORT SLAVE CYLINDER Figure 6.22 : Slave Cylinder for TASORT ITEM | PARTNO. | DESCRIPTION 21002-0089 | Slave Cylinder 41034-0090 | Seal Kit “44029-0022 | Grease Nipple aps I= lle KE ‘OPERATING HANUAL 6:30‘TEREX AERIALS LIMITED CAGE ROTATION CY! TASORT TASORT Figure 6.23 : Cage Rotation Cylinder for TASORT ITEM __|PARTNO. | DESCRIPTION Qry 1 21002-0116 | Cage Rotation Cylinder 1 2 41034-0099 | Seal Kit 1 3 44029-0022 | Grease Nipple 2 ‘OPERATING HARUAL 631‘TEREX AERIALS LIMITED. ‘TAsoRT. TASORT. HYDRAULIC TANK TS] MEX BO CHP SCREW AOOT=UISE YT TEP SSPRING WASHER AA0TS=OOIS [TO TS| We STEEL WASHER 44073-0006 [10 | TORN OO A OORT YT TT] 1/7858 F BLANK 31013-0135] 7 TO| WB SPRING WASHER 44013-0027 | 6 9 | wex50 CAP. ScREW 44004-0087 | 2 a @ | MBx20 CAP, SCREW 44004-0087 7 | GASKET 6 | LeveL CAUCE 12398. 1 [HAND PUMP a1or7-0042_ [1 3 [RETURN FLTER 41030-0039 | 1 2_[ INSPECTION COVER S190 1 1 TANK FABRICATION 21024-0054 | 1 Figure 6.24 : Hydraulic Tank for TASORT 6-32 ‘OPERATING MANUALTAsORT ‘TEREX AERIALS LIMITED Figure 6.25 : Manifold Block for TASORT. 6:33 ‘OPERATING ARUAL‘TEREX AERIALS LIMITED TASORT. Manifold Block Components TasoRT Item | Part No Qty 1 ‘41029-0032 __| Manifold Block 1 1 41009-0037 | Check Valve 2 12 41009-0038 | Check Valve 2 13 “41006-0047 ___| Pressure Relief Valve 1 14 41003-0091 | Flow Control valve 1 LS 41020-0350 __| Cavity Plug 1 16 41003-0092 | Solenoid Valve 1 17 “41003-0094 | Solenoid Valve 1 18 41020-0351 | Flow Control Insert 1 19 41003-0095 | Solenoid Valve 2 110 | 41015-0087 | O-ring 2 fo 41020-0352 __| Cap Screw 4 Be 41015-0088 | AV Seal* 7 1.13 | 41015-0089 [AV Seal*™ 5 [4 41020-0353 Flush Plug* 3 1.15 | 41020-0354 | Blank Plug* 4 1.16 [41020-0355 | Blank Plug* 1 1.17 [41014-0003 | Spring Washer 4 [is 41003-0096 | Manual Override Solenoid Valve. 1 2 41029-0033 ‘Manifold Block 1 [2a 41003-0097 | Solenoid Valve 2 [22 41003-0098 | Manual Override Solenoid Valve 3 [23 41003-0099 | Manual Override Solenoid Valve 2 2.4 41003-0100 | Pilot Operated Check Valve comprising 1 2.41 | 41023-0133 | Sandwich Boot 1 2.4.2 | 41009-0039 [ Check Valve 2 2.43 | 41023-0134 | Pilot Piston 1 4 25 41015-0090 | AV Seal 14 2.6 41020-0356 | Blank Plugs 3 3 41020-0357 __ | Protection Plug 20 ‘OPERATING HANUAL 6:34