Terex HP-32 User manual

Operator’s Manual
HP-32
First Edition
First Printing
Part No. 216062
Serial Number Range
From 196379
with
Maintenance
Information
ANSI
North America
South America
HP-35

Operator's Manual First Edition • First Printing
Part No.216062
Copyright © 2012 by Terex Hydra Platforms Inc.
First Edition: First Printing, June 2012
These machines comply with
ANSI/SIA A92.8
Printed in U.S.A.
Table of Contents
Page
Introduction ................................................................ 1
Symbol and Hazard Pictorials Definitions ................... 5
General Safety ........................................................... 7
Personal Safety ........................................................ 14
Work Area Safety...................................................... 15
Legend ...................................................................... 24
Controls .................................................................... 25
Inspections ............................................................... 33
Operating Instructions ............................................... 43
Transport and Lifting Instructions .............................. 51
Maintenance ............................................................. 52
Specifications ........................................................... 56

Operator's ManualFirst Edition • First Printing
Part No.216062 1
About this Manual
Terex Hydra Platforms appreciates your choice of
our machine for your application. Our number one
priority is user safety, which is best achieved by
our joint efforts. This book is an operation and daily
maintenance manual for the user or operator of a
Terex Hydra Platform machine.
This manual should be considered a permanent part
of your machine and should remain with the
machine at all times. If you have any questions,
call Terex Hydra Platforms.
Product Identification
The machine serial number is located on the serial
label.
Intended Use
This machine is intended to be used only to support
personnel, along with their tools and materials, for
the purpose of inspecting, or maintaining, a bridge.
Bulletin Distribution and
Compliance
Safety of product users is of paramount importance
to Terex Hydra Platforms. Various bulletins are
used by Terex Hydra Platforms to communicate
important safety and product information to dealers
and machine owners.
The information contained in the bulletins is tied to
specific machines using the machine model
number and PIN/serial number.
Distribution of bulletins is based on the most
current owner on record along with their associated
dealer, so it is important to register your machine
and keep your contact information up to date.
To ensure safety of personnel and the reliable
continued operation of your machine, be sure to
comply with the action indicated in a respective
bulletin.
Introduction
Serial Label
Serial
Label

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Introduction
Contacting the Manufacturer
At times it may be necessary to contact Terex
Hydra Platforms about this machine. When you do,
be ready to supply the model number and PIN/
serial number of your machine, along with your
name and contact information. At minimum, Terex
Hydra Platforms should be contacted for:
Accident reporting
Questions regarding product applications and
safety
Standards and regulatory compliance information
Questions regarding product modifications
Current owner updates, such as changes in
machine ownership or changes in your contact
information. (See Transfer of Ownership, below.)
Internet: http://www.genielift.com
e-mail: [email protected]
Transfer of Machine Ownership
Taking a few minutes to update owner information
will ensure that you receive important safety,
maintenane and operating information that applies
to your machine.
Please register your machine by visiting us on the
web at www.genielift.com/registration or by calling
us toll free at 1-800-536-1800.

Operator's ManualFirst Edition • First Printing
Part No.216062 3
Introduction
Danger
Failure to obey the instructions and
safety rules in this manual will
result in death or serious injury.
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
1Avoid hazardous situations.
Know and understand the safety rules before
going on to the next section.
2Always perform a pre-operation inspection.
3Always perform function tests prior to use.
4Inspect the workplace.
5Only use the machine as it was intended.
You read, understand and obey the
manufacturer's instructions and safety rules—
safety and operator's manuals and machine
decals.
You read, understand and obey employer's
safety rules and work site regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.

Operator's Manual First Edition • First Printing
4 Part No.216062
Introduction
Safety Sign Maintenance
Replace any missing or damaged safety signs.
Keep operator safety in mind at all times. Use mild
soap and water to clean safety signs. Do not use
solvent-based cleaners because they may damage
the safety sign material.
Hazard Classification
Terex Hydra Platform uses symbols, color coding
and signal words to identify the following:
Safety alert symbol—used to alert
you to potential personal injury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a hazardous situation
that, if not avoided, will result in
death or serious injury.
Indicates a hazardous situation
that, if not avoided, could result in
death or serious injury.
Indicates a hazardous situation
that, if not avoided, could result in
minor or moderate injury.
Indicates information considered
important, but not hazard related
(e.g. messages related to property
damage).
Red
Orange
Yellow
Blue

Operator's ManualFirst Edition • First Printing
Part No.216062 5
Symbol and Hazard Pictorials Definitions
Electrocution
Hazard
Do not exceed
platform capacity.
Do not allow more
than 5 people on
the platform.
Stay Clear of
Machine
Maintain Safe
Distance
Tip-over Hazard Set Outriggers
Before
Deployment
Authorized
Personnel
Only
Burn Hazard
Do Not Touch Run-Away Hazard Set Parking Brake Level Trailer
Before Towing
Read the
Operator”s Manual
Explosion Hazard
No smoking
No Flame
Stop engine
Electrocution
Hazard
Avoid Contact
Explosion / Burn
Hazard
Keep Open
Flames Away
Fire Hazard
P
P
P
P

Operator's Manual First Edition • First Printing
6 Part No.216062
Crush Hazard Stay Clear of
Moving Machine Crush Hazard Stay Clear of
Moving Machine
Wheel Hazard
Symbol and Hazard Pictorials Definitions
Stability Hazard
Do Not Operate in
Wind Speed Over
28 mph
Maximum Super
Elevation (8%)
Maximum Grade
(5%)
Torque Wheel Lug
Nuts
Lanyard
Attachment Point
0-28mph
(0-12.5m/s)
>28mph
(>12.5m/s)
>8%(4.5 )⁰
>5%(3 )⁰

Operator's ManualFirst Edition • First Printing
Part No.216062 7
General Safety
Safety signs and locations
215974GT
215963GT
215962GT
215976GT
215963GT
215979GT
215976GT 215962GT 215963GT
215974GT
215979GT

Operator's Manual First Edition • First Printing
8 Part No.216062
Safety signs and locations
General Safety
215959GT
215966GT
215965GT
215962GT
215965GT
215970GT
215959GT 215966GT 215965GT
215962GT 215970GT 233622GT
233622GT
(Around trailer chassis)

Operator's ManualFirst Edition • First Printing
Part No.216062 9
Safety signs and locations
General Safety
215965GT
215978GT
215969GT
215965GT
215959GT
215964GT
215959GT 215964GT 215965GT
215969GT 215978GT

Operator's Manual First Edition • First Printing
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Safety signs and locations
General Safety
215267GT
216037GT
215960GT
215958GT
216968GT
215591GT
215963GT
215980GT
215972GT
215592GT
52865GT
215592GT
216037GT
215960GT
215980GT 215972GT 52865GT
215958GT 216968GT 215591GT 215963GT 215267GT

Operator's ManualFirst Edition • First Printing
Part No.216062 11
Safety signs and locations
General Safety
215972GT
215972GT
40434GT
40434GT
40434GT
1699GT
215972GT 40434GT 1699GT

Operator's Manual First Edition • First Printing
12 Part No.216062
Safety signs and locations
General Safety
215957GT
215960GT
216968GT
215591GT
215972GT
215957GT
215960GT
216968GT 215591GT
215972GT
Platform
Controls

Operator's ManualFirst Edition • First Printing
Part No.216062 13
Safety signs and locations
General Safety
215966GT
215972GT
215971GT 40434GT
40434GT
215971GT
215966GT
215972GT

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14 Part No.216062
Personal Safety
Fall Protection
When using the elevated scaffold option, PFPE is
required.
Personal fall protection equipment (PFPE) is not
required when operating this machine from the
main platform. If PFPE is required by job site or
employer rules, the following shall apply:
All PFPE must comply with applicable
governmental regulations, and must be inspected
and used in accordance with the manufacturer’s
instructions.

Operator's ManualFirst Edition • First Printing
Part No.216062 15
Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Maintain safe distances from electrical power lines
and apparatus in accordance with applicable
governmental regulations, i.e. 29 CFR 1910.333,
and the following chart.
Line Voltage Required Clearance
0 to 50kV 10 ft 3.0 m
>50 to 200kV 15 ft 4.6 m
>200 to 350kV 20 ft 6.1 m
>350 to 500kV 25 ft 7.6 m
>500 to 750kV 35 ft 10.7 m
>750 to 1000kV 45 ft 13.7 m
>1000kV See below
For power lines over 1000 kV, the minimum
clearance distance must be established by the
utility owner/operator or registered professional
engineer who is a qualified person with respect to
electrical power transmission and distribution.
Allow for platform movement, electrical line sway or
sag and beware of strong or gusty winds.
Keep away from the machine if it contacts
energized power lines. Personnel on the ground or
in the platform must not touch or operate the
machine until energized power lines are shut off.
Do not operate the machine during lightning or
storms.
Do not use the machine as a ground for welding.
Work Area Safety

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16 Part No.216062
Tip-over Hazards
Occupants, equipment and materials shall not
exceed the selected platform capacity for the
restricted or unrestricted range of motion.
Maximum distributed platform 1000 lbs 453 kg
capacity
Maximum platform capacity 500 lbs 227 kg
at the end of platform
Maximum occupants 5
Do not exceed the maximum platform capacity.
Do not erect the platform unless all outriggers are
fully extended, lowered, and the wheels are in firm
contact with the bridge deck.
The weight of options and accessories, will reduce
the rated platform capacity and must be factored
into the total platform load.
Do not operate the machine from a position on
trucks, trailers, railway cars, floating vessels,
scaffolds, or similar equipment.
If using accessories, read, understand and obey
the decals and instructions with the accessory.
Do not erect the platform unless the machine is on
a firm, bridge deck that does not exceed the
maximum grade (5%) and super elevation (8%) for
deployment.
Work Area Safety
Platform Retracted
= 1000 lb / 554 kg
= 500 lb 227 kg= 500 lb / 227 kg
Platform Extended
Super Elevation
Grade
>8%(4.5°)
>5%(3°)
= 500 lb / 227 kg = 500 lb 227 kg
= 1000 lb / 554 kg

Operator's ManualFirst Edition • First Printing
Part No.216062 17
Work Area Safety
Do not use the machine as a crane.
Do not push other objects with the any part of the
machine.
Do not contact adjacent structures with the any part
of the machine.
Do not tie the platform, or any other part of the
machine, to adjacent structures.
Do not place loads outside the platform perimeter.
Do not alter or disable machine components that in
any way affect safety and stability.
Do not replace items critical to machine stability
with items of different weight or specification.
Do not modify or alter an any component or
structure of the machine, including welding, without
prior written permission from Terex Hydra
Platforms. Mounting attachments for holding tools
or other materials onto the platform, toeboards or
guard rail system can increase the weight in the
platform and the surface area of the platform or the
load.
Do not place or attach overhanging loads to any
part of this machine.
Do not place ladders or unauthorized scaffolds in
the platform or against any part of this machine.
Do not transport tools and materials unless they are
evenly distributed and can be safely handled by
person(s) in the platform.
Do not use the machine on a moving or mobile
surface or vehicle.
Do not use the controls to free a platform that is
caught, snagged or otherwise prevented from
normal motion by an adjacent structure. All
personnel must be removed from the platform
before attempting to free the platform using the
base controls.
Do not alter or disable the limit switches.
Do not deploy the platform when wind speeds may
exceed 28 mph / 12.5 m/s. If wind speeds exceed
28 mph / 12.5 m/s when the platform is deployed,
exit the platform and fully stow until wind speeds
fall below the allowable limit.
Do not operate the machine in strong or gusty
winds. Do not increase the surface area of the
platform or the load. Increasing the area exposed to
the wind will decrease machine stability.
Use extreme care and slow speeds while driving
the machine in the stowed position across uneven
terrain, debris, unstable or slippery surfaces and
near holes and drop-offs.
Do not drive the machine on or near uneven terrain,
unstable surfaces or other hazardous conditions
with the platform deployed.
> 28 mph
( > 12.5 m/s )
0 - 28 mph
> 28 mph
( > 12.5 m/s )
> 28 mph
( > 12.5 m/s )
(0 - 12.5 m/s)

Operator's Manual First Edition • First Printing
18 Part No.216062
Do not overload your tow vehicle. Observe the
manufacturer’s Gross Vehicle Weight Rating
(GVWR).
Be sure all lights, mirrors and hitch components
conform to federal and local regulations.
Be sure that all driving lights are operational.
Be sure the tires are properly inflated.
Do not tow the machine unless it has been properly
stowed and secured in the travel position.
Do not load cargo on the machine. The machine is
not designed to carry any extra cargo.
Be sure the safety chains (if required) are securely
attached to the tow vehicle. Cross the chains under
the hitch. This will create a cradle to catch the
tongue of the trailer if it becomes disconnected
from the tow vehicle.
Do not tow the machine on public roads unless it
meets all governmental regulations for towing.
Tow the machine at speeds that will keep the
machine under control considering the road and
weather conditions. Obey all local and national
towing speed laws.
Be sure to chock the wheels of the trailer when
parking on a hill.
Be sure all wheel lug nuts are properly tightened to
120 ft-lbs.
Work Area Safety
Operation on Slopes Hazards
Do not deploy the machine on a slope that exceeds
the maximum grade or super elevation slope rating
of the machine. Slope ratings apply to the
machine in the stowed position.
Maximum grade, and slope rating
Grade (Front/Back) 5% (3°)
Super Elevation (Side/Side) 8% (4.5°)
Towing Hazards
Read, understand and obey all of your tow vehicle
manufacturer’s recommendations, warnings and
instructions before towing this machine.
Make sure your tow vehicle is properly maintained
and capable of towing this machine.
Be sure the hitch is properly and securely attached
to your tow vehicle.