Terex TA50RT User manual

ARTICULATED BOOM LIFT
MODEL TA50RT
OPERATOR'S
MANUAL
Terex Aerials
106 12th Street S. E.
Waverly, IA 50677
U.S.A.
Telephone: [phone]
Facsimile: [phone]
Terex Aerials
10600 W. Brown Deer Road
Milwaukee, WI 53224
U.S.A.
Telephone: [phone]
Facsimile: [phone]
Terex Aerials
CourtstownIndustrialPark
LittleIsland,
Co.Cork,Ireland
Telephone: [phone]
Facsimile: (353) 21-353368
P/No: 65002-0005 Rev.1 04/99

ModelTA50RT
Rev. 1 04/99 i
i - 1
INTRODUCTION
Owners, Users and Operators:
TerexAerialsappreciates your choice of ouraerialliftforyourapplication. Ournumber one priority is user
safety,whichis bestachievedbyour joint efforts.
Wefeel that youcanmakeamajor contribution to safetyifyouastheequipment user and operator:
1. ComplywithOSHA,Federal, State andLocalRegulations.
2. Read,understandandfollowtheinstructionsinthisandothermanualssuppliedwiththismachine.
3. Use good,safe work practicesin a common sense way.
4. Have only trainedoperators- directed by informedandknowledgeablesupervision- running
themachine.
Ifthere is anything in this manualthat is not clear or whichyou believe should be added,pleasesend your
commentstotheTechnicalPublicationsDepartment,TerexAerials, CourtstownIndustrialPark,LittleIsland,
Co.CorkIreland.Telephone: [phone]oremail: [email protected].
Tohelpyourecognizeimportantsafetyinformation,wehaveidentifiedwarningsandinstructionsthatdirectly
impactonsafetywithfollowingsignals:
THESE SYMBOLS MEAN YOUR SAFETY IS INVOLVED! SEE NEXT
PAGE FOR SPECIFIC INFORMATION. READ, UNDERSTAND AND
FOLLOWALLDANGER,WARNINGANDCAUTIONDECALSONYOUR
MACHINE.

ModelTA50RT
Rev. 1 04/99i - 2
iINTRODUCTION
"DANGER"INDICATESANIMMINENTLYHAZARDOUSSITUATION
WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS
INJURY. THIS SIGNAL WORD IS LIMITED TOTHEMOSTEXTREME
SITUATIONS.
"WARNING"INDICATESAPOTENTIALLYHAZARDOUSSITUATION
WHICH,IF NOT AVOIDED,COULD RESULT IN DEATH ORSERIOUS
INJURY.
"Caution"indicates a potentiallyhazardous situationwhich, if not avoided,
mayresultinminorormoderate injury. Itisalso used toalertagainstunsafe
practices,andforproperty-damage-onlysituations.
OneFinal Note:
Thebest methodtoprotect yourselfandothers frominjuryor deathisto usecommonsense. If youareunsure
ofanyoperation,don'tstartuntilyouaresatisfiedthatitissafetoproceedand havediscussedthesituationwith
yoursupervisor.
Thankyou!

ModelTA50RT
Rev.1 04/99
CONTENTS
Section 1
Description Page No.
1.1 DesignSpecification............................................................................ 1-1
1.1.1 ClosedDimensionsandWeights.......................................................... 1-1
1.1.2 OperatingDimensions ......................................................................... 1-1
1.1.3 DesignSpecifications .......................................................................... 1-1
1.1.4 WorkingEnvelope .............................................................................. 1-2
1.1.5 GeneralArrangement .......................................................................... 1-3
1.2 ComponentSpecifications................................................................... 1-4
1.2.1 MechanicalComponents..................................................................... 1-4
1.2.2 HydraulicComponents ....................................................................... 1-4
1.2.3 Oil...................................................................................................... 1-4
1.2.4 EquivalentOils.................................................................................... 1-5
1.2.5 ElectricalComponents ........................................................................ 1-5
1.2.6 EngineDetails ..................................................................................... 1-5
Section 2
Description Page No.
2.1 SafetyRules andPrecautions .............................................................. 2-1
2.2 SafetyFeatures................................................................................... 2-7
2.2.1 EmergencyStopPushbuttons .............................................................. 2-7
2.2.2 FootswitchControl ............................................................................. 2-7
2.2.3 TiltAlarm ........................................................................................... 2-7
2.2.4 MovementAlarm................................................................................ 2-7
2.2.5 TorqueChart ...................................................................................... 2-8

ModelTA50RT
Rev.1 04/99 CONTENTS
Section 3
Description Page No.
3.1 Pre-use Checks .................................................................................. 3-1
3.2 GroundControl Checks...................................................................... 3-2
3.3 CageControlChecks ......................................................................... 3-2
3.4 UnloadingProcedures......................................................................... 3-3
3.5 Driving ............................................................................................... 3-5
3.5.1 DriveControls .................................................................................... 3-5
3.5.1.1 ForwardandReverse ......................................................................... 3-5
3.5.1.2 DriveSpeedControl........................................................................... 3-7
3.5.1.3 SteeringControl ................................................................................. 3-7
3.5.1.4 TravelSpeed Control.......................................................................... 3-7
3.6 DifferentialLock ................................................................................. 3-8
3.6.1 EngageDifferentialLock ..................................................................... 3-8
3.7 BrakingSystem .................................................................................. 3-9
3.7.1 BrakesinStaticMode ........................................................................ 3-9
3.7.2 BrakesinDriveMode ........................................................................ 3-9
3.7.3 EmergencyBraking............................................................................. 3-9
3.8 AccessOperations(CageControl) ..................................................... 3-10
3.8.1 CageControl Functions ...................................................................... 3-10
3.9 AccessOperations(GroundControl) .................................................. 3-10
3.10 After Useand StorageInstructions ...................................................... 3-12
3.11 SpecialPrecautions(Cold Weather) .................................................... 3-12
3.12 SpecialPrecautions............................................................................. 3-13
3.12.1 EmergencyTowing ............................................................................. 3-13
3.12.2 WindConditions ................................................................................. 3-13
3.12.3 CraneOperations ............................................................................... 3-13
3.12.4 TestingtheTiltAlarm .......................................................................... 3-13
3.12.5 BatteryCharge,EngineTemp &AirFilter WarningLamps .................. 3-14

ModelTA50RT
Rev.1 04/99
CONTENTS
4.1 EmergencyProcedures ....................................................................... 4-1
4.1.1 Situation:Platform elevated,operatornotincapacitated,
butunit willnotoperateproperlyusingtheplatformcontrols................. 4-1
4.1.2 Situation:Unit elevated,withoperatorincapacitated at
platform controls................................................................................ 4-2
4.1.3 Situation:Platform incontactwith livepowerlines,and
operatorincapacitated. ....................................................................... 4-2
4.2 EmergencySystems& Procedures...................................................... 4-3
4.2.1 EmergencyPump................................................................................ 4-3
4.2.2 EmergencyRotation............................................................................ 4-4
4.2.3 EmergencyTowing ............................................................................. 4-5
4.2.3.1 EmergencyTowing - Disengage and Re-engage Brakes ...................... 4-6
Section 4
Description Page No.

ModelTA50RT
Rev.1 04/99 CONTENTS
Section 5
Description Page No.
5.1 GeneralInformation ............................................................................ 5-1
5.1.1 Introduction ........................................................................................ 5-1
5.1.2 HydraulicOils..................................................................................... 5-1
5.1.3 DieselEngineOil ................................................................................ 5-3
5.2 ServicingCheckList(BasicMachineOnly) ......................................... 5-4
5.2.1 Servicing(Daily) ................................................................................. 5-4
5.2.2 Servicing(Weekly) ............................................................................. 5-5
5.2.3 Servicing(Monthly) ............................................................................ 5-7
5.2.4 Servicing(SixMonthly)....................................................................... 5-8
5.2.5 Servicing(Yearly) ............................................................................... 5-8
5.2.6 Servicing(FourYearly) ....................................................................... 5-8
5.3 Servicing ............................................................................................ 5-9
5.3.1 DailyRoutineServicing ....................................................................... 5-9
5.3.1.1 HydraulicOilLevel ............................................................................. 5-9
5.3.1.2 TyreCondition.................................................................................... 5-9
5.3.2 WeeklyRoutineService ...................................................................... 5-9
5.3.2.1.HydraulicSystem................................................................................ 5-9
5.3.2.2 Steering .............................................................................................. 5-9
5.3.2.3 StartBattery ....................................................................................... 5-10
5.3.2.4 PivotPins ........................................................................................... 5-10
5.3.3. MonthlyRoutineServicing .................................................................. 5-12
5.3.3.1 HydraulicOil ...................................................................................... 5-12
5.3.3.2 ChassisBolts ...................................................................................... 5-12
5.3.3.3 SlewRing GearTeeth ......................................................................... 5-12
5.3.3.4 Lubrication ......................................................................................... 5-12
5.3.3.5 PivotPinSecurity ............................................................................... 5-12
5.3.3.6 DriveGearboxOilLevel ..................................................................... 5-12

ModelTA50RT
Rev.1 04/99
CONTENTS
Section 5
Description Page No.
5.3.4 SixMonthlyRoutineServicing ............................................................. 5-13
5.3.4.1 CageLevelling .................................................................................... 5-13
5.3.4.2 BoomPivots....................................................................................... 5-13
5.3.4.3 BoomCylinders.................................................................................. 5-13
5.3.4.4 Axle ................................................................................................... 5-13
5.3.4.5 SuctionFilter ...................................................................................... 5-13
5.3.4.6 MachineSystems Test ........................................................................ 5-13
5.3.5 YearlyRoutineServicing ..................................................................... 5-14
5.3.5.1 HydraulicOil ...................................................................................... 5-14
5.3.5.2 HydraulicOilTank.............................................................................. 5-14
5.3.5.3 HydraulicTankRefillProcedure .......................................................... 5-15
5.3.5.4 StructuralExamination ........................................................................ 5-15
5.3.5.5 CageMounting ................................................................................... 5-15
5.3.5.6 LevellingCylinders.............................................................................. 5-15
5.3.6 FourYearlyRoutineServicing ............................................................. 5-16
5.3.6.1 FlexibleHoses .................................................................................... 5-16
5.3.6.2 PivotPinsandBearings....................................................................... 5-16
5.3.6.3 PinReplacement ................................................................................. 5-16
5.3.6.3.1 BoomPinReplacement ....................................................................... 5-17
5.3.6.3.2 TieRailPinReplecement..................................................................... 5-17
5.3.6.3.3 LiftCylinderPinReplacement ............................................................. 5-17
5.3.6.3.4 SelfLevellingCylinderPinReplacement .............................................. 5-18
5.3.6.3.5 ZoomBoomCylinderPin Replacement ............................................... 5-18
5.3.6.4 ZoomCylinder ................................................................................... 5-18
5.3.6.5 Zoom Pads......................................................................................... 5-19
5.3.6.5.1 FrontZoomPad Replacement ............................................................ 5-19
5.3.6.5.2 RearZoom BoomReplacement .......................................................... 5-19
5.3.6.6 LiftCylinderSeals ............................................................................. 5-19
5.3.6.6.1 SealReplacement- CylinderIn-place ................................................. 5-19
5.3.6.6.2 SealReplacement -CylinderRemoved ............................................... 5-20
5.4 Lubrication ......................................................................................... 5-21
5.4.1 GeneralLubrication ............................................................................ 5-21
5.4.2 SlewBearing/GearLubricants ............................................................. 5-22
5.4.2.1 SlewBearingLubrication .................................................................... 5-22
5.4.2.2 SlewGearLubrication ........................................................................ 5-23

ModelTA50RT
Rev. 1 04/99
SPECIFICATIONS 1
1 - 1
1.1 DESIGN SPECIFICATION
1.1.1 CLOSED DIMENSIONS AND WEIGHTS
Length ...................................................................................................................................5.65 m
Width .....................................................................................................................................2.20 m
Height .....................................................................................................................................2.26 m
Unladen Weight .....................................................................................................................7100 kg
1.1.2 OPERATING DIMENSIONS
Maximum Cage Floor Height .................................................................................................14.80 m
Maximum Working Height .....................................................................................................16.80 m
Maximum Working Outreach .....................................................................................................9.1 m
Standard Platform Dimensions ...................................................................................1.50 m x 0.60 m
Outside Turning Radius ............................................................................................................5.50 m
Gradability .........................................................................................................................50% (45°)
Maximum Speed, Booms Stowed ................................................................................5 km/hr (3mph)
MaximumSpeed, Booms Elevated .......................................................................0.75 km/hr (0.5mph)
Ground Clearance ....................................................................................................................0.28 m
MaximumWheel Loading........................................................................................................2950kg
1.1.3 DESIGN SPECIFICATION
Safe Working Load (2 persons) ...................................................... ..........................225 kg (500 lbs)
MaximumHorizontal PlatformPull .......................................................................................... 400 N
Maximum Wind Speed ..................................................................... 12.5 m/sec (28 mph - 45 km/hr)
MaximumSlope for Safe Operation .................................................................................................5°
FullRange TimeUpMin........................................................................................................100secs
Full Range Time Down ............................................................................................................70 secs
Swing Left/Right .....................................................................................................................85 secs
MaximumNoise Emmission.......................................................................................72dB(A) @ 3m
Temperature Operating Range......................................................................................-5°C to +40°C

ModelTA50RT
Rev. 1 04/99 SPECIFICATIONS
1
1 - 2
1.1.4. WORKING ENVELOPE
TheTA50RThasaworkingheightabilityof 16.90m.Thefollowingdiagramshowstheworkingenvelopefor
theTA50RT. Alldimensionsareinmetres.
Figure 1.1 - TA50RT Working Envelope

ModelTA50RT
Rev. 1 04/99
SPECIFICATIONS 1
1 - 3
1.1.5 GENERAL ARRANGEMENT
Figure 1.2 - TA50RT General Arrangement

ModelTA50RT
Rev. 1 04/99 SPECIFICATIONS
1
1 - 4
1.2 COMPONENTSPECIFICATIONS
1.2.1. MECHANICAL COMPONENTS
Tyre Type .......................................................................................Solideal SKS 12-16.5 10 ply rating
332 mm wide x 848 mm dia.
Tyre Size ............................................................................................................................. 12-16.5R
Wheel Gearbox ..................................................................................................................6.73 : 1 ratio
Wheel Diameter .......................................................................................................................42.4 cms
Brakes....................Oil immersed fail-safediscsinside the frontand rear axles,operate as bothparkingand
servicebrakes. The brakesare released when the footswitch is fully depressed and the
joystick is moved to enable either forward or reverse drive.
1.2.2. HYDRAULIC COMPONENTS
LiftCylinders ................................................................................. Double-acting with overcentrevalves
Hoses .......................................................................................... Thermoplastic & Steel braided rubber
Filtration..................................................................................................................Suction and pressure
1.2.3. OIL
Type .................................................................................................................Texaco Rando HDZ-32
Oil Reservoir Capacity .............................................................................................................62 Litres

ModelTA50RT
Rev. 1 04/99
SPECIFICATIONS 1
1 - 5
1.2.4. EQUIVALENT OILS
SHELL TELLUS T32
CASTROL HYSPIN AWH 32
ESSO UNIVERSEN32
CASTROL HYSPIN AWS 22
1.2.5. ELECTRICAL COMPONENTS
Hand Controller Type .....................................................................................................Joystick
Battery ..............................................................................................................One 12 Volt H.D
1.2.6. ENGINE DETAILS
Engine Type 1............................................................. Hatz 2L4C Silentpack, 4 stroke, air cooled
Displacement ................................................................................................................ 1,716 cc
Number of Cylinders ................................................................................................................ 2
Fuel ............................................................................................................................. Diesel Oil

ModelTA50RT
Rev. 1 04/99
SAFETY 2
2 - 1
2.1. SAFETYRULESAND PRECAUTIONS
ELECTROCUTIONHAZARD! THIS MACHINEIS NOTINSULATED!!
Maintainsafe clearance fromelectricallines and apparatus. You must allowfor machine sway(side to side
movement)when elevated,and electricalline movement. Thismachine doesnot provide protection from
contactwithorproximitytoanelectricallychargedconductor.
YoumustAVOIDCONTACTbetweenany part of the machine,oritsload,andanyelectricalline or appara-
tuscarryingup to 300 volts.
Youmustmaintain a CLEARANCE OFATLEAST 10 FEET (3.05M)betweenany part ofthemachine,or
itsload, and any electrical lineor apparatuscarrying over 300 volts upto 50,000volts. One foot (30.5 cm)
additionalclearanceisrequiredforeveryadditional30,000volts.
DEATHORSERIOUS INJURY willresult fromcontact with,or inadequate clearance from, any charged
conductor.
Readandunderstandallsafetyandcontrolinformationfoundon the machine and in this manual beforeoper-
atingtheunit.

ModelTA50RT
Rev. 1 04/99 SAFETY
2
2 - 2
BeawareofallGovernmentandLocalruleswhichmayapplytothis machine and its safe operation.
Approved safety belts must be worn at all times when operating the unit from the platform. In addition
approvedheadgear and otherprotective equipment mustbe worn asrequired. (The appropriate equivalent
governmentbodyshouldbeconsulted).
NEVERfastensafetybeltto an adjacent structurewhileontheworkplatform.
Makesurethatentrygatetoplatform is secured before operatingunitfromtheplatform.
DONOTblockthe foot pedal oranyfunctioncontrol in theoperatingposition.
DONOTexceedtheplatformcapacityoftheunitinanyconfiguration. Reviewthesectiontitled“MACHINE
SPECIFICATIONS”,earlierinthis manual,regardingthismodel’scapacitiesanddimensions.

ModelTA50RT
Rev. 1 04/99
SAFETY 2
2 - 3
SECUREalltoolsandotherlooseitemstopreventinjurytopersonsworkingonorbelowtheworkplatform.
DONOTusescaffolding,laddersorsimilar items to extend yourreachwhileontheworkplatform.
DONOTattempttoclimbdowntheboomassembly,iftheunitfailswhiletheoperator’splatformisraisedor
extended.
Sincethemachinemaybeoperatedfromitsgroundcontrols,precautionsshouldbetakentopreventunauthorised
personnelfromoperatingthework platform with thegroundcontrolswhiletheplatformisinuse.
The“UNPOWERED EMERGENCY MOVEMENT”procedure (describedlater in thismanual) required
releasingthebrakesanddisconnectingtherearwheels,whichresultsintherebeingno meanstostoptheunit’s
travel. Terexrecommendsusingthisprocedureonlyincasesofemergency,andonlyforashortdistance. Be
onguard against unitrunawayon sloping surfaces. Movementspeed shall notexceed 3 MPH(5KPH).
DONOTattempttoopenanyhydrauliclineorcomponentwithoutfirstrelievingsystempressuresandshutting
offfluidflowfromthetank.
DONOTallowanyonetotamperwith,serviceoroperatethemachinefrom the ground control station while
personnelareontheplatform,exceptin an emergency.
DONOTalter,modifyordisable any safety devicesorinterlocks.
DONOTusetheaerialworkplatformoutdoorsinelectricalstormsorinhighwindsituations. Maximumrated
windspeed is 12.5 m/s.

ModelTA50RT
Rev. 1 04/99 SAFETY
2
2 - 4
DONOTincreasewind area of cage byadditionofsheltering material
DONOTraisethe aerial work platformunlesstheunit is onafirmsurface, and slope iswithinratedslope of
themachine.
Whenworkingunderneath elevated booms, ensuretheyare propped.
Usecaution to preventropes, cords,hoses, etc. frombecoming entangled in the unit’s boom sectionswhen
beingraised,loweredor repositioned.
Ensurethattheareasurroundingthemobile platform is clear ofpersonnelandequipmentbefore:drivingthe
unit;raising,loweringorextendingtheboom,orswingingthesuperstructure;ortiltingthe platform.
Maintainasafedistancefromoverheadandgroundobstacles,debris, drop-offs, holes, depressions, electrical
wiresandother hazards totravel.
Limittravelspeedaccording to conditions ofthegroundsurface, congestion, slope,locationofpersonnel or
anyotherfactorsthatcouldcausehazardofcollisionofinjurytopersonnel.
DONOTsit, stand or climbonplatform rails.
DONOToperatethismachinewhileundertheinfluenceofanydrugsor alcohol.
DONOToperatethis machine if youarebotheredby heights, seizures,ordizzyspells.
DONOT indulgeinstunt drivingorhorseplaywhileoperatingthismachine.

ModelTA50RT
Rev. 1 04/99
SAFETY 2
2 - 5
Completethe“OperationalChecklists”foundinthismanual(seeTable of Contents) atdesignatedintervals.
Alwaysattachtheunittoawinchwhenloadingorunloadingfromatruckortrailer. Terexdoesnotrecommend
unassistedloadingorunloading ofanyaerialworkplatform.
Withtheplatformswungawayfromthestowedposition, usecautionwhenselectingtravelorsteeringdirec-
tion. Travel and steer direction will beopposite switchor lever movement. Refer to the directional arrow
decalsontheundercarriageoftheunitfortravelorientation.
Actuationofthered “EMERGENCYSTOP”buttonwillapplybrakesimmediately,causingunexpectedplat-
formmovementas the machine comestoa sudden stop. Braceyourself.
Wheneverreleasingthebrakes,ensurethattheunitcannotroll.
Immediatelyreportanyerraticnoises, vibrations or malfunctionsoftheunittoasupervisor. Machineshall be
removedfromserviceuntildiagnosisandanynecessaryrepairshavebeencompleted.
Operatingthisequipmentwithoutallsafetyandcontroldecalsinplacecanbe hazardous.

ModelTA50RT
Rev. 1 04/99 SAFETY
2
2 - 6
Fortransportingthe machine, the platformorboom must notbetied to the trailerbedin any way.
DONOTexceedthemaximumplatformhorizontalpullof400N.
DONOT use theboomor platform asa crane tolift oversized ofhangingloads.
DONOTraise,extend,retract, tilt, or lowertheplatformintostationaryobjects, as this willcausedamageto
mechanicalandhydrauliccomponents.
DONOTuse the platformorboom functions topushor tow theunit or anothervehicle.
DO NOT use the boom as a crane or hoist.
Avoidsuddenbrakingorsteering,goslowlyandleavemoremanoeuvringroomduringcoldweatheroperation
untilthemachineiswarm.
Noiseemissionlevelson this machine arelessthan72 dB(A) @3m.

ModelTA50RT
Rev. 1 04/99
SAFETY 2
2 - 7
2.2. SAFETYFEATURES
2.2.1. EMERGENCY STOP PUSHBUTTONS
Two EMERGENCY STOPpushbuttons, oneat theground station andone in thecage, actas power on/off
switches. Bothswitches must be ON tooperatethe machine. When either of the buttonsis depressed, all
functionsstopimmediatelyandthe parking brake isautomaticallyappliedandtheengineisstopped.
2.2.2. FOOTSWITCH CONTROL
Thefootswitchmustbe fully depressed beforeanymachineoperation can be carriedoutfromthe cage.
Whenthe footswitchcontrol isreleased, theengine speedis cut back to idle and all machine functions are
terminated.
2.2.3. TILT ALARM
Thetiltalarmgivesanaudiblewarningwhenthemachineisoutoflevelbymorethanwhichthesensorhasbeen
ratedandcutsboomsfunctions(allowingboomdownonly).
2.2.4. MOVEMENT ALARM
Themovementalarmisactivatedassoon as the machine isindrivemode.