Terex HR Series Operator Manual

Terex Telelect
Hi-Ranger
HRM Series
Overcenter Material Handling
Aerial Device
OPERATOR’S MANUAL
This Operator’s Manual MUST BE READ prior to operating your
HRM SERIES Overcenter Material Handling Aerial Device.
PRINTED IN THE USA
463200 09/2006
TEREX TELELECT
HRM SERIES
Table of Contents
TEREX TELELECT, INC.

500 Oakwood Road
Watertown, SD 57201
46 32 00 - 09 /06 T e rex T ele le ct HR M S eri es

HRM SERIES
Table of Contents
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - I
OWNERS, USERS AND OPERATORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - I
SAFETY GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - III
GENERAL SAFETY GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - III
BEFORE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - IV
DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - V
ELECTRICAL DANGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - VI
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - VII
MATERIAL HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - VIII
TRAVELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - VIII
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - IX
SAFETY RELATED DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - X
WHAT IS INSULATED AND WHAT IS NOT INSULATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . - XV
ELECTRICAL INSULATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - XVII
PREVENTION OF ELECTROCUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - XVIII
OPERATION ON OR NEAR ENERGIZED CONDUCTOR . . . . . . . . . . . . . . . . . . . . . . . . . - XVIII
SECTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
OPERATION GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
CAB CONTROL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
MASTER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
ENGINE STOP/START (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
POWER TAKE-OFF (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
CAB CONTROL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
CONTROLS BELOW ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
OPERATOR CONTROLS AND DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
UPPER CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
SINGLE STICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
LOWER CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9
CONTROL SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10
ENGINE STOP/START CONTROL (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10
TWO-SPEED THROTTLE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10
AUXILIARY LET DOWN POWER CONTROL (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . 1 - 10
DEMAND THROTTLE (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
BOOM INTERLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
HYDRAULIC TOOLS (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
PLATFORM TILTING OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12
PLATFORM LEVELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13
MATERIAL HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 14
JIB & WINCH OPERATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 14
HYDRAULIC JIB EXTENSION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 15
HYDRAULIC JIB EXTENSION (OPTIONAL) - EXTEND UNDER LOAD. . . . . . . . . . . . . . 1 - 15
PLATFORM ROTATORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 17
PHASE LIFTERS (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 18
AUXILIARY PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 19
BOOM LIFTING EYE MATERIAL HANDLING (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 19
PERSONNEL AND TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 21
PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 22
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DAILY PRE-OPERATION CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 22

JOB SITE SURVEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 23
OPERATING TEMPERATURE RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 23
JOB SITE SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 24
SETTING THE OUTRIGGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 26
SETTING UP ON A SLOPING SURFACE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 27
TORSION BARS (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 28
SETTING UP ON A SOFT SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 28
OUTRIGGER / UNIT CONTROL SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 29
SETTING UP FOR OPERATION ON SNOW AND ICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 29
LOADING CAPACITIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 30
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 31
BOOM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 31
AERIAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 32
EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 35
POWER LINE CONTACT ON GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 35
CONTROL SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 37
MANUAL ROTATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 37
AUXILIARY LET DOWN POWER (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 37
HYDRAULIC LINE FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 38
ENGINE FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 40
HYDRAULIC PUMP FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 40
CONTROL VALVE FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 40
OPERATIONAL LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 40
PLATFORM LEVELING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 40
LEAVING THE JOB SITE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 41
SECTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
MAINTENANCE GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
PREVENTATIVE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
MAINTENANCE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
ADJUSTMENTS AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2
OPERATIONAL CHECKLISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2
FREQUENT AND PERIODIC INSPECTION INTERVALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3
DAILY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3
90 DAYS (360 HOURS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3
180 DAYS (720 HOURS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3
12 MONTHS (1,050 HOURS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3
5 YEAR (5,250 HOURS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3
LUBRICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4
SYNTHETIC ROPE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
HOOK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
STORAGE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6
APPENDIX - A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 1
STANDARDS AND REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 1
OSHA EXCERPTS: (CLEARANCE DISTANCE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 2
STANDARD HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 4
APPENDIX - B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 1
RESPONSIBILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 1
ANSI A92.2-2001 (PARTIAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 1
SURVEY OF JOB SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 9
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46 32 00 - 9/0 6 T e rex T ele le ct HR M S eri es
INTRODUCTION
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INTRODUCTION
OWNERS, USERS AND OPERATORS
Thank you for choosing TEREX TELELECT equipment for your application. User safety is our number one
priority and this is best achieved by our joint efforts.
As equipment users and operators, you make a major contribution to safety if you:
1. Comply with OSHA, federal, state, ANSI, local and company regulations.
2. Read, understand and follow the instructions in this manual and other manuals supplied with this
vehicle.
3. Only allow trained operators, directed by informed and knowledgeable supervision, to run the unit.
If there is anything in this manual that is not clear or you believe should be added, please send your
comments to:
Manager of Publications
TEREX TELELECT, INC.
500 Oakwood Road
Watertown, South Dakota 57201
You may also contact us by phone at: (605) 882-4000
This Symbol means your safety is involved! - Read, understand and follow all
danger, warning and caution decals and instructions on your Aerial Device and in
this manual.
This manual contains important information on the safe use of your TEREX TELELECT equipment. Your
failure to read, understand and follow all safety rules, warnings 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 TEREX TELELECT equipment as instructed in this manual.
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INTRODUCTION
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The operator is the single most important factor for safety when using any piece of equipment. Learn to
operate your TEREX TELELECT equipment in a safe manner.
To help you recognize important safety information, we have identified warnings and instructions that
directly impact on safety.
DANGER
Danger: Indicates an imminently hazardous situation, which if not avoided, will result in death or serious
injury.
WARNING
Warning: Indicates a potentially hazardous situation, which if not avoided, could result in death or
serious injury.
CAUTION
Caution: Indicates a potentially hazardous situation, which if not avoided, may result in minor or
moderate injury.
CAUTION
Caution: Used without the safety alert symbol indicates a situation, which if not avoided, may result in
property damage.
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, do not continue until you are satisfied that it is
safe to proceed.
In addition to maintenance and operating instructions in this manual, the operator

must read and understand all the instructions in the following safety guidelines.
1. Study all safety messages. Remember and apply them on the job.
2. Modifications to this TEREX TELELECT equipment from the original design specifications without
written permission from TEREX TELELECT are strictly forbidden. A modification may compromise the
safety of the TEREX TELELECT equipment, subjecting users to serious injury or death. Any such
modification will void any remaining warranty.
3. TEREX TELELECT reserves the right to change, improve, modify or expand features of its equipment at
any time. Specifications, model or equipment are subject to change without notice and without incurring
any obligations to change, improve, modify or expand features of previously delivered equipment.
4. Comply with manufacturer’s instructions and requirements of current OSHA regulations and ANSI
standards.
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SAFETY GUIDELINES
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SAFETY GUIDELINES
GENERAL SAFETY GUIDELINES
1. The use of this Aerial Device is subject to certain potential dangers that cannot be protected against by
mechanical means. Only the exercise of intelligence, care, and common sense can eliminate these
dangers. It is essential to have competent, careful operators who are physically and mentally fit, and
thoroughly trained in the safe operation of this Aerial Device. Learn, understand and practice safe use of
all equipment and controls - before operating this Aerial Device.
2. Never exceed the rated load capacity. Know the total weight - including the operator, platform liner,
tools, and equipment, and/or other items before entering platform.
3. Do not operate this Aerial Device if any interlock or safety device is malfunctioning.
4. Do not bypass or remove any interlock or safety device.
5. Never operate with damaged leveling chain or components.
6. Do not operate if Aerial Device does not function properly, or has leaks, get repaired before further use.
7. Never operate from the ground controls with personnel in the platform. Operation must be controlled by
the platform operator, except in case of an emergency.
8. Keep the vehicle free of obstructions that may interfere with the controls or personnel who may have to
operate them in an emergency.
9. Stop in position if you become aware of any dangerous conditions or hear any unusual noise (such as
grinding, cracking or grating) while operating the Aerial Device. Do not move the Aerial Device until the
problem has been resolved.
10. Be sure all ground personnel know the proper procedure to follow in case of an emergency.
11. Do not operate the Aerial Device in an electrical storm.
12. The hydraulic fluid is petroleum based and will burn.
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SAFETY GUIDELINES
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BEFORE OPERATION
1. Survey the conditions of the work area. Identify situations such as; soft ground, ditches, drop-offs, holes,
debris, overhead obstructions, electrical conductors, and underground utilities.
2. Plan the job (tailgate session) and clear the area of bystanders.
3. Set the vehicle parking brake and chock the wheels.
4. Make certain tire pressures are proper for operation.
5. Visually inspect condition of tires, truck suspension, and torsion bars (if equipped) for any damage.
6. The vehicle must be securely parked and stabilized before any operation is performed. If equipped with
outriggers, set all outriggers.
7. If not equipped with outriggers, or only one set of outriggers, the truck tires must equally support the
weight of the truck. One tire cannot be in a hole or depression.
8. Do not lower outriggers unless you can see that all ground personnel and bystanders are clear of the
outrigger path of movement and its ground contact point. Lower all outriggers onto solid footing.
9. Do not place outriggers on ice as slippage may occur regardless of solid footing. Operation on snow or
slippery surfaces requires extra care during set up to ensure Aerial Device and vehicle have sufficient
traction to prevent sliding.
10. The Aerial Device has been tested per the stability requirements of ANSI A92.2 and may be operated on
firm, flat, non-level surfaces up to a 5 degree slope.
11. Ground and/or barricade the vehicle per OSHA and your company rules.
12. Raise and lower booms through a complete cycle using the lower controls daily, before entering
platform, looking for any malfunction or problems. If found, shut down immediately.
13. Perform controls inspection before beginning operation. Do not operate with malfunctioning controls.
14. Barricade or cover any overhead electrical lines that may be a potential contact during operation.
15. Inspect and maintain personal protective equipment.
16. Perform maintenance as specified in the Maintenance Guidelines.
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SAFETY GUIDELINES
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DURING OPERATION
1. Never operate the Aerial Device unless you know the location, function, and operation of all the controls,
including emergency and accessory operation.
2. Avoid abrupt starts, stops and reversal of direction. Operate all controls slowly for smooth motion.
3. Keep hands off all moving parts to avoid injury.
4. Operator(s) must wear an OSHA approved fall protection system with a lanyard attached to an anchor
provided.
5. Wear personal protective equipment such as: Insulated hard hat, rubber gloves with leather protectors,
and rubber sleeves. Hearing and eye protection, proper boots and suitable clothing may also be
required.
6. Do not place the boom in open traffic lanes, stop traffic or barricade lanes to divert traffic from area.
7. Do not allow boom, platform, or any part of the Aerial Device to contact fixed objects.
8. Do not tie off to an adjacent structure, pole, or other equipment.
9. Never exceed rated capacity of platform.
10. Do not pass tools, equipment, or other objects between the occupant of the platform and other
personnel on poles or other platforms.
11. Do not sit or climb onto edge of platform or use planks, ladders, or other devices for a work position.
Always stand with both feet on floor of the platform.
12. Do not wear climbers while in the platform.
13. Do not allow ground personnel under the platform work area.
14. Do not operate with platform leveling malfunctioning.
15. Do not move the vehicle with personnel in the platform.
16. Never tie loads to the platform or booms. Always use lifting attachment when it is necessary to lift or
lower an object.
17. Do not lift loads with the Aerial Device if it is not equipped with a lifting attachment.
18. High speed should only be used when moving the platform to an aerial job site. Low speed should be
used to move into, or within the aerial job site.
19. Low engine speed, if available, should be used when an extended period of time is going to be spent at
an aerial job site.
20. Do not use the platform for lifting material. The platform was designed for lifting personnel only.
21. If, when operating the Aerial Device, you become aware of any dangerous condition, unusual operation,
or hear any unusual noise, such as grinding, cracking, or grating sounds-STOP-in position. Do not move
the Aerial Device until the problem has been diagnosed and resolved with your safety in mind. No matter
how long it may take to get help, waiting is better than a serious or fatal accident.
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ELECTRICAL DANGERS
ELECTRICITY OBEYS NO LAW, BUT ITS OWN.

1. Electricity is an ever-present danger when using an Aerial Device. Follow all OSHA, ANSI, state, federal
and company rules and regulations when working on or near energized power lines.
2. Always maintain proper clearance from energized power lines. This Aerial Device cannot protect you
from phase-to-phase or phase-to-ground contact, which occurs above the insulating boom section.
•Allow for platform sag, sway or rocking.
•If any part of boom-tip, everything beyond band of arrows on boom, contacts an energized conductor,
the entire boom-tip, including the control handle(s), must be considered energized.
•If any part of the boom-tip, everything beyond band of arrows on boom, contacts a grounded object, the
entire boom-tip, including the control handle(s), must be considered grounded.
3. The booms and boom operators shall be properly insulated from any contact with electrical conductors;
including neutral or ground lines, poles, cross arms and guy wires. Utilize proper insulation such as line
covers, rubber blankets and hot line tools.
4. The covers and guards on the boom tip components may provide limited electrical protection. DO NOT
contact energized conductors and DO NOT operate without covers. Even if covers are plastic or
fiberglass, they are not tested or maintained for dielectric protection. Always cover conductors with line
hose and maintain distance from conductive items.
5. Never place booms, platforms, or personnel between energized conductors or between an energized
conductor and a grounded conductor without proper cover up.
6. Do not wear clothing that when exposed to flames or electric arcs could increase the extent of injury
from such exposure.
7. Never operate the Aerial Device in an electrical environment if the fiberglass boom components are
damaged, contaminated by moisture or dirt, or otherwise maintained improperly. A daily inspection and
an annual dielectric testing of all fiberglass boom components are necessary to maintain the integrity of
the insulation.
8. Never allow ground personnel to come in contact with the Aerial Device, vehicle, or vehicle attachments
while in operation near energized power lines.
9. When working on or near energized power lines or equipment, the vehicle must be grounded and/or
barricaded and considered as energized.
10. Never rely on the fiberglass platform insulation when in the platform. It may contain small unseen cracks
that will allow an electrical path into the platform. Always use a platform liner.
11. Never touch the controls or boom tip area when in the platform without using proper protection (wear
rubber gloves) while holding any conductors, neutrals, grounds, or other structures.
12. Ground and neutral conductors are current carrying conductors and must be treated as energized (wear
rubber gloves).
13. Wear rubber gloves when handling duplex and triplex wires.
14. All tools, accessories and other objects must be contained within the platform when working on or near
energized power lines.
15. Check the boom tip area for any exposed conductive material and do not allow boom tip to come in
contact with an energized phase or ground.
16. Do not carry or allow a conductor to touch your body. Handle conductors only with rubber gloves even if
grounded.
17. All metal components at the boom tip beyond the band of arrows are interconnected. Contact of any part
to an energized conductor will energize the entire boom tip, including the controls.
18. Do not attach any metal objects from outside the platform to the inside of the platform. This defeats the
purpose of the platform liner.
19. Do not hang metal objects from the platform. It increases the chances of accidental contact.
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20. Use only non-metallic tool holders and tool trays.

21. Never use leather work gloves or bare hands on grounded conductors when energized conductors are
on the same structure. Wear insulating rubber gloves with leather protectors.
ACCESSORIES
1. When working from the platform, only use hydraulic tools equipped with orange hoses marked NON-
CONDUCTIVE. The hoses must be kept clean and dry and must be inspected periodically.
2. All accessories must be inspected, maintained and operated with the same care and safety rules that
apply to the Aerial Device.
3. Do not use hoses having less than 2000 psi working pressure ratings.
4. Tools selected for use with this Aerial Device should be open-center type and operate satisfactorily at
2000 psi and 8 GPM.
5. If this Aerial Device is equipped with a boom lifting eye, the boom position and lifting capacity must not
be exceeded.
6. Personnel or load shall not be allowed in the platform when utilizing the boom lifting eye.
7. If this Aerial Device is equipped with platform tilt, an inspection must be made before entering the
platform, to insure all locks and pins are properly in place.
8. Do not place booms or platform under trees or limbs while trimming to avoid possible damage or
overloading.
9. Do not operate hydraulic hand tools on high speed for an extended period of time without stopping.
Continuous operation can cause overheating and possible damage to the hydraulic system.
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MATERIAL HANDLING
1. Use only a synthetic rope for the winch line. Do not use a wire rope.
2. Do not permit personnel to be under loads being lifted.
3. Do not use winch or load line to raise personnel off the ground.
4. Do not allow rope to contact energized power lines. Do not rely on the rope being non-conductive.
5. Keep the winch rope clean and dry.
6. Inspect the winch rope daily. Do not operate with a damaged or frayed rope.
7. Use a sling. Do not use the winch rope as a sling.
8. Use only hooks with a safety latch.
9. Do not overload. The load chart supplied with each Aerial Device gives the machine capacity.
10. Know the weight of the load you are lifting. Do not guess.
11. The jib and winch are designed for vertical loads only. Center the load line directly above the load before
lifting.
12. Do not use the jib and winch to pull or string line.
13. Do not pull poles or objects embedded in the ground. It is impossible to know the force applied and will
overload the unit.
14. Lifting the load will cause deflection in the Aerial Device. Allow adequate clearance when applying and
removing the load.
15. When using the jib as a line lifter, remove the rope from the sheave.
16. Use only approved hot line tools for lifting energized conductors. Clean and inspect all fiberglass on the
conductor lifter before use. Dirty or damaged fiberglass may be conductive.
TRAVELING
1. Never travel with personnel in the platform.

2. Never travel with the booms raised.
3. Store booms properly in the boom rest. Lower the lower boom fully before lowering upper boom into the
rest.
4. Lock boom(s) in place with hold down system.
5. Keep all tools or other items properly stored on the vehicle while traveling. Otherwise, they may fall onto
the roadway.
6. Fully retract the outriggers, store outrigger pads, and wheel chocks.
7. Disengage the power take-off to prevent damage.
8. Ensure platform liner is retained during travel with platform cover or clips to prevent loss.
9. Follow the vehicle manufacturer's instructions for operating the vehicle.
Drive Carefully!
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MAINTENANCE
1. Inspect, maintain, and repair this Aerial Device in accordance with the maintenance manual for this
device and the maintenance section of this manual.
2. Only authorized and skilled personnel with complete knowledge of this Aerial Device shall be allowed to
perform maintenance on this Aerial Device.
3. Never drill holes in the platform.
4. Replace all illegible decals.
5. Do not alter the insulated portion of this Aerial Device. Altering this Aerial Device in any way could
reduce its insulating value.
6. Do not search for hydraulic leaks with your hands or any other part of your body.
7. All hoses must meet or exceed the working pressure as stated in the maintenance manual.
8. Only use orange hoses marked NON-CONDUCTIVE for tool hoses, at the boom tip, and areas that
bridge the insulation gap.
9. Do not use replacement components that are not equal to the original components.
10. Before doing any work on the hydraulic system, secure the booms and outriggers. Release any
hydraulic pressure before attempting repairs or disassembly of hoses, valves, cylinders or any other
hydraulic components.
11. Fuel or oil spills may require notification of appropriate Federal, State, or Local officials.
12. Do not operate the Aerial Device after adjustments or repairs until all guards have been reinstalled,
trapped air removed from the hydraulic system, safety devices reactivated, and maintenance equipment
removed.
13. The subframe, outriggers, and mounting to the vehicle must be inspected following the frequent and
periodic inspection intervals for fastener tighteners, damaged components and weld inspections.
14. Inspect, maintain, and operated the vehicle following the vehicle manufacturer’s guidelines.
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Operating this equipment without all safety and control decals in place can be
hazardous.
If any of these items are illegible or missing, replace them immediately.
NOTE: *Use decal 419265 and 465703 when Aerial Device is not certified in accordance with
latest ANSI A92.2 revision or booms are not insulated.
ITEM # DECALS QTY PART #
1. PLATFORM NOT INSULATED 1 47988
2. ARROWS 20’ 402237
3. NOT INSULATED BEYOND ARROWS 8 402236
4. READ CAREFULLY 2 414590
5. FAILURE TO OBEY 1 419262
6. ELECTROCUTION HAZARD 2 419263
7. FALLING FROM PLATFORM 2 419264
8. * ELECTROCUTION HAZARD - NOT INSULATED 2 419265
9. ELECTROCUTION HAZARD 3 419266
10. UNTRAINED OPERATOR 3 419267
11. OUTRIGGER - CRUSHING - DO NOT OPERATE 2 419268
12. OUTRIGGER - CRUSHING - STAND CLEAR 2 419269
13. CONDUCTIVE HOSE 2 419270
14. OVERTURNING HAZARD 1 458696
15. CONTROLS NOT INSULATED 1 463602
16. * NOT INSULATED 4 465703
17. ANSI WARNING 1 468476
18. LEVEL INDICATOR 2 470926
19. PINCH POINT 1 H23451
20. ESCAPING FLUID UNDER PRESSURE 1 H23877
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1. 2.
THIS BASKET, WITHOUT AN 3.
INSULATING LINER, IS NOT
CERTIFIED AS AN ELECTRICAL
INSULATING BARRIER. 47988D
4. 5.
6. 7.
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8. 9.
10. 11.
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12. 13.
14. 15.
NOT INSULATED
16. 17.
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18. 19.
20.
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The term insulated means separated from other conductive surfaces by a dielectric substance (including air
space) offering a high resistance to the passage of current (from OSHA 1926.960).
A. Area A, Upper Boom insulation, provides an insulating area between area D and earth ground when in
properly maintained condition.
B. Area B, Lower Boom Insert, provides an insulating area between area C and the vehicle when in
properly maintained condition.
C. Area C, Elbow, does not provide insulation. This area contains conductive materials such as cylinders,
pins, boom structure, and other metal components. The operator shall not allow any portion of this area
to come in contact with an energized phase, ground conductor, or grounded objects. Proper protective
devices shall be used on all conductors. Any contact with a phase line, a ground and a phase line or
between two-phase conductors will create a hazard.
D. Area D, Boom Tip, does not provide insulation. This area contains conductive materials such as control
levers, uninsulated platform(s), platform support shaft, boom tip structure, and other metal components.
These objects must be considered connected. The operator shall not allow any portion of this area to
come in contact with an energized phase, ground conductor, or grounded objects. Proper protective
devices shall be used on all conductors. The operator shall not make contact with any portion of this
area when working on or near an energized phase, ground, or grounded objects, unless wearing proper
protective clothing such as rubber gloves and sleeves rated at the voltage of the lines. Any contact with
a phase line, a ground and a phase line or between two-phase conductors will create a hazard.
Accidental contact of any portion of area D to an energized conductor will energize the entire area D.
E. Area E does not provide insulation. This area contains conductive materials such as cylinders, pins,
boom structure, turntable, pedestal, and other metal components. The operator shall not allow any
portion of this area to come in contact with an energized phase, ground, or grounded objects. Proper
protective devices shall be used on all conductors. This area is attached to the vehicle that shall be
grounded through an approved ground system when working in the vicinity of energized conductors.
Any contact with a phase or between two-phase conductors will create a hazard.
NOTE: A properly maintained platform liner will only provide protection for those portions of the
body or materials entirely within the liner and not in contact with any part of area D.
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The insulating boom section only prevents current

from passing from the band of arrows at the boom tip to the
lower band of arrows. All components above and below that
area must be considered conductive.
The boom tip is everything past the upper band of

arrows. All boom tip components are structurally and
electrically connected. Contact with any part of the boom tip
will energize the entire boom tip including, controls, jib,
winch, and platform support structure.
Death or serious injury to the operator or ground

personnel can occur if any part of the boom or boom tip
contacts an energized conductor, ground line, grounded
line, or OBJECTS. Proper clearance must be maintained.
You must always cover the line and wear rubber

gloves with rubber sleeves and an approved hard hat when
any part of the Aerial Device is working on or near
energized lines or conductors even when working on a
grounded line, neutral line, or ground line.
You must read the operators manual to fully

understand the protection the Aerial Device will give you.
Anytime the platform occupant(s) contact two items at different potential without
proper personnel protective equipment, their body may become a path for electric
current, and they may be electrocuted. This includes touching the controls, any
tools, or items on the boom tip while also contacting a line or ground.
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ELECTRICAL INSULATION
Operation on or near energized lines is extremely hazardous unless proper OSHA and ANSI work rules are
followed. The operation of this Aerial Device in proximity to high voltage electrical lines involves several
hazards to the operator of the Aerial Device, ground personnel and bystanders on the ground. These
hazards are as follows:
1. Contact of the operator with a single energized line will allow current to pass through the operator's body
to ground by means of an all-metal boom structure, unless the operator is insulated from ground.
2. Contact of the operator with two energized lines or one energized line and a grounded conductor will
cause electrocution, even if the operator is insulated from ground by the Aerial Device.
The fiberglass upper boom, fiberglass lower boom insert and fiberglass platform,
including its components, do not protect the platform operator from injury in case of
contact between two energized lines, or between an energized line and a grounded
conductor.
Working around electrical power lines is covered by ANSI and OSHA Regulations.
To reduce danger to the operator and ground personnel or bystanders on the
ground, understand and follow all rules.
IMPORTANT: Only caution and proper work practice on the part of the occupant(s) will protect
the occupant(s) from Hazard No. 2.
3. Contact of a metal section of the boom with a wire, below the insulation of the boom, will energize the
Aerial Device and the vehicle causing electrocution to ground personnel and bystanders standing on the
ground and touching the vehicle.
Ground personnel should never touch the Aerial Device, the vehicle or an attached
trailer while the Aerial Device is in operation near electrical power lines even
though the Aerial Device has an insulated boom and lower boom insert.
Avoid contact of any metal part or equipment below the insulated section of the
lower boom with an electrical power line. Serious injury or death could result.
4. Contact of the boom with a wire may break the wire or burn the wire in two, which will cause a hazard to
ground personnel and bystanders below.
Some protection against Hazard No.1 is furnished by the fiberglass upper boom. When PROPERLY
MAINTAINED, the insulated boom protects platform personnel in case they were to contact a SINGLE
energized power line within the qualification voltage limit stamped on the nameplate. However, this
protection can be nullified by accumulation of dirt and moisture on or in the boom. Operator safety requires a
regular electrical testing program.
Some protection against interphase contact, Hazard No. 2, is offered by the platform liner. The platform liner
is used for interphase protection of the lower half of the body only. Only caution on the part of platform
personnel and use of proper protective equipment will protect the upper half of their body from this hazard.
Any conductive object in the platform liner, which protrudes above the liner, will eliminate any protection the
liner may offer.
Limited protection of ground personnel against contact of the steel elbow area or lower boom with an
energized line, Hazard No. 3, is offered by the insulated lower boom and a proper grounding system. The
lower boom insert, like the insulated upper boom, must be regularly tested and cleaned to ensure continued
safety. Contact with an energized line below the lower boom insert will energize the vehicle and the ground
around the vehicle. Anyone close to the vehicle may be injured. A ground cable to a suitable ground may
prevent damage and injury. Ensure ground cables are making good contact with the vehicle and ground rod
or neutral and are not coiled on reel or storage hooks.
There is no protection against Hazard No. 4. Caution must be exercised continually to avoid making contact
with an energized line, which, if broken or burned, may drop to the ground and cause injury to ground
personnel and any bystanders.
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PREVENTION OF ELECTROCUTION
1. NEVER rely on fiberglass dielectric properties around power lines with moisture present on the
platform(s) and booms. If the Aerial Device is stored outdoors, protect the platform(s) and booms from
the weather with a cover when not in use. To preserve dielectric properties, fiberglass must be kept
clean and dry.
2. REMEMBER, auxiliary equipment, such as electrical cords, communication lines, and conductive tools,
that bridge the insulation between the operator and ground, render the insulation useless.
3. REMEMBER your Aerial Device cannot protect you against contact between two-phases, between one
phase and a pole or a grounded conductor. Never work between electrical lines unless the proper
precautions are observed.
4. DO NOT allow any ground personnel or bystanders to touch the Aerial Device, the vehicle, or an
attached trailer while the Aerial Device is in operation near electrical power lines, even if the Aerial
Device has an insulated lower boom.
5. Have boom insulation TESTED annually, in accordance with established rules and regulations.
6. CONTROLS are not insulated and are interconnected to all other conductive components at the boom
tip. DO NOT contact any conductor or wire while touching controls, unless wearing insulating rubber
gloves.
7. DO NOT depend on plastic covers, fiberglass covers, or guards installed on the Aerial Device for
dielectric protection from contact with a line or ground. The covers may provide some protection, but
they are not tested to guarantee dielectric strength. Hidden damage, dirt and contamination will make
them conductive. Use line covers or blankets when closer than the minimum approach distance.
OPERATION ON OR NEAR ENERGIZED CONDUCTOR

When working ON OR NEAR ENERGIZED CONDUCTORS (either known or suspected), special conditions
arise. While the fiberglass upper boom provides a high degree of electrical insulation between the platform
and the vehicle, there are several things it WILL NOT DO:
•IT WILL NOT PROVIDE PHASE TO PHASE PROTECTION.
•IT WILL NOT PROVIDE PHASE TO GROUND PROTECTION THROUGH STATIC LINES OR GUY
WIRES.
•IT WILL NOT PROTECT THE VEHICLE FROM BEING ENERGIZED IF STEEL BOOMS CONTACT A
LOWER LEVEL SECONDARY POWER SOURCE.
The fiberglass boom must be kept clean and dry for this type of work.
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The fiberglass boom and platform liners must be dielectrically tested periodically to
insure the insulating properties are being maintained.
Do not assume that it is so.
Ground personnel must be warned to stay away from vehicle in case of accidental
boom contact between conductor and metallic portion of boom, which will cause
serious injury or death.
The fiberglass upper boom, fiberglass lower boom insert and fiberglass platform,
including its components, do not protect the platform operator from injury in case of
contact between two energized lines or between an energized line and a grounded
conductor.
Upper Controls can become energized if any part of the boom-tip past the band of
arrows on the boom contacts a conductor. The Aerial Device upper control station
has metal parts that are necessary to provide the structural support for the
components. These metal parts at the boom-tip are interconnected. The main shaft
that supports the platform(s) and controls also support other load carrying options
that can be added to the boom-tip.
Do not depend on Aerial Device covers for insulation. Plastic or fiberglass covers
offer limited electrical insulation. Covers are not tested, certified or maintained as
insulation.
All conductors including grounds and neutral lines are current carrying conductors
and must be treated as energized unless properly grounded and tested.
The fiberglass upper and lower boom, in a well maintained condition, provides
electrical insulation between the upper boom-tip and the vehicle to ground. This
fiberglass will not protect the platform operator if any portion of the boom tip or
upper arm control station, including options is brought into contact with an
energized or non-energized conductor and the operator is in contact with a different
potential, such as grounded non-energized conductor. This type of contact can
energize or ground the controls because all components of the upper control
station are interconnected. The fiberglass will not provide protection for the
operator in phase to phase contact or a phase to ground wire contact above the
upper boom insulation. Nor will it protect the vehicle from becoming energized if the
steel boom section below the lower boom insert, if so equipped, is brought into
contact with an energized conductor. Serious injury or death could result.
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OPERATION GUIDELINES
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SECTION 1
NOMENCLATURE
PLATFORM
UPPER CONTROLS
BOOM TIP
JIB & WINCH

ASSEMBLY
JIB CYLINDER
UPPER BOOM
LINK ASSEMBLY
UPPER BOOM
CYLINDER
FIBERGLASS INSERT
UPPER
BOOM PIVOT
LOWER BOOM LOWER BOOM

CYLINDER
TURNTABLE
PEDESTAL
OUTRIGGER
1-1
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CAB CONTROL OPERATION

MASTER CONTROL
The master control (A) is located in the cab of the vehicle and has a toggle switch on the dashboard. The
toggle switch is used to energize the engine stop/start system and the throttle control options, which may be
located in the cab, at the platform, or on the pedestal. When the light is lit (B), the toggle switch is energizing
these systems. If the unit is not equipped with engine stop/start, two-speed throttle or 12V hydraulic power, it
will not require a master control.
CAB CONTROLS
ENGINE STOP/START (OPTIONAL)
The engine stop/start (C) is a push button control and is usually mounted on the dashboard of the vehicle.
To start the engine press the button and hold in for a moment until the engine starts, then release. To stop,
or shut off, the engine, press the button again.
Be sure the vehicle transmission is in neutral, the brakes are applied and the
wheels are chocked before using the engine stop/start.
POWER TAKE-OFF (OPTIONAL)

The power take-off (PTO) is a gearbox used to transmit power from the vehicle transmission to the hydraulic
pump, which provides hydraulic oil for the Aerial Device functions. The power take-off control can be a
switch on the dash, for electric control systems, or a “push-pull” knob, (usually mounted on the cab floor) and
a red light mounted in the vehicle dashboard. When lit, this red (PTO) dash light indicates the PTO is
activated and serves to remind the operator not to drive the vehicle with the PTO engaged.
Driving with the PTO engaged may damage both the pump and the PTO.
To engage the power take-off properly, refer to the PTO manufacturer's operating instructions and be sure
the manufacturer's operating decals are posted in the cab with the PTO controls.
NOTE: Typical controls are illustrated. Each installation may be unique depending on
configuration and options.
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CAB CONTROL FUNCTIONS

Master Power Push “up” to activate remote electrical systems.
ON
MASTER Push “down” to deactivate remote electrical
POWER systems.
43 70 31
OFF
Master Power Red light; when lit indicates master power is

Light MASTER ON
activated.
POWER 437032
PTO Light Red light; when lit indicates PTO is engaged.

PTO 4 39 95 0
Engine Stop/ Push and hold to start engine.

Start STOP/START
Release when engine starts.
ENGINE Push and release to stop engine.
PUSH/RELEASE
4 37 0 3 3
Can also be used to stop the Aerial

Device in an emergency.
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CONTROLS BELOW ROTATION
NOTE: Control location shown is generic. Actual layout will vary with purchasers requirements
and options.
ITEM CONTROL DESCRIPTION
1. Outrigger Controls Allows extending and retracting of outriggers.
2. Hydraulic Tools (Optional) Directs oil flow to the tool when connected to the quick couplers.
3. Two-Speed Throttle Two-speed throttle provides two engine speeds, low and high, with
engine running. Low speed is engine idle.
Auxiliary Let Down Power Auxiliary let down power provides hydraulic power to lower and stow
(Optional) the Aerial Device in the event of a prime power source failure.
4. Engine Stop/Start Allows operator to stop and start engine.
(Optional)
5. Selector (Optional) A selector valve that allows operation of boom functions when in the
“up" position and operation of the outriggers when in the “down"
position.
The Selector will function as an emergency stop by taking

oil flow away from the active controls.
The decals are an integral part of this Aerial Device. If the decals are illegible, they
must be replaced.
Always operate controls slowly and deliberately for smooth, safe platform
movements. Rough handling is never excusable and may cause damage to the
Aerial Device and endanger the operator.
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CONTROLS BELOW ROTATION FUNCTIONS

1. Outrigger Move handle “up” to raise outrigger.
Controls
(Optional)
Move handle “down” to lower outrigger.
2. Hydraulic Tools Return handle to center position to turn off.

(Optional) NOTE: Turn tool “OFF” before operating other
functions.
Move handle to energize tool quick couplers in direction
required. “ON” direction energizes male coupler.
3. Two-Speed With engine running, the throttle is activated.
Throttle
Push and release to increase engine RPM.
Push and release to return to engine idle.
*Auxiliary Let
With engine “OFF”, the auxiliary let down power is activated.
Down Power
(Optional) Push and hold to turn on auxiliary let down power.
Release to shut off auxiliary let down power.
4. Engine Push and hold to start engine. Release when engine starts.
Stop/Start
(Optional) Push and release to stop engine.
Can also be used to stop the Aerial Device in an

emergency.
5. Selector Move handle “up” to activate Aerial Device system.
(Optional)
The Selector will function as an emergency stop by

taking oil flow away from the active control.
Move handle “down” to operate outrigger system.
NOTE: *Can be included with two-speed throttle circuit. When vehicle engine is disabled, the
auxiliary let down power can be activated by the two-speed throttle switch.
NOTE: *Do not operate longer than 30 seconds. Continuous operation will drain battery and/or
overheat pump motor.
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OPERATOR CONTROLS AND DESCRIPTIONS

Aerial Device functions may be controlled from either the upper controls at the platform or the lower controls
station. The platform controls are used, in normal operation, by the operator to control the Aerial Device. The
lower controls are used for inspection, maintenance, and in emergency situations. The Control Selector at
the lower controls determines which control station is operable. Only one is operable at any time.
The upper controls may be individual levers or single stick control for the upper boom, lower boom, and
boom rotation functions. Individual levers have one control lever for each function. The single stick control
has one lever that controls all three boom functions. The control on your vehicle will depend on the options
ordered. All other controls are individual controls.
Controls provide proportional metering of the function, meaning the distance the control lever is moved
determines the speed. The farther the lever is moved from the neutral or center position, the faster the
function will operate.
While learning to operate the Aerial Device, do not operate functions at full speed. First, operate each
function separately. Then operate two or more functions together. Learn to move the platform in an arc to
any desired position within reach of the platform. Operate the functions with smooth, gradual, starts and
stops. Use full speed when in clear areas with no obstructions and slow speeds when approaching objects,
the ground or truck. Smooth operation will get you to your work area quicker and more comfortably, with less
wear and tear on the equipment. Anticipate the time it takes to stop, and begin slowing down beforehand, to
stop without overshooting.
The operator needs to be familiar with the built-in compensating system that affects movements of both
booms and the boom controls. When the lower boom function is activated the lower boom will respond as
directed and the upper boom will maintain its initial angle in relation to the ground. The platform will move
the same distance and direction as the upper end of the lower boom moves. Activating the upper boom
function will initiate a response from the upper boom only.
Only the platform operator controls the Aerial Device during normal operation.
Never operate the Aerial Device from the ground control with someone in the
platform, except in an emergency situation.
LIFT LOCK HANDLES

If a control lever at the upper controls operates a boom function, other then in the single stick, the control will
have a lift lock handle.
A spring-loaded lever on each boom function lever locks the levers in a neutral position and prevents
accidental actuation. A control lever placard indicates the direction to move the control lever to activate a
specific boom movement. To activate a boom movement the handle must be pulled "up" and held, so the
control lever can operate the desired boom function. When the handle is released the spring pulls the handle
"down" to a neutral position and locks the control lever in that position.
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UPPER CONTROLS
SINGLE STICK
UNITS BUILT BEFORE 01-01-98 UNITS BUILT AFTER 01-01-98

1. Single Stick Controls upper boom, lower boom, and rotation.
2. Emergency Dump Diverts the oil to the tank to stop all operation of platform controls.
3. Platform Leveling Allows the platform to be hydraulically tilted to level the platform. Utilized
for emergency removal and platform clean-out.
4. Platform Rotator Allows the platform to rotate toward the job being done, allowing the
person in the platform better access to their work.
5. Jib Articulation Allows the jib to be positioned at different angles.
6. Winch Used for operating the winch during material handling operations.
7. Hydraulic Tools (Optional) Controls oil flow to hydraulic tools.
8. Engine Stop/Start Allows the operator to stop and start the engine from the platform.
(Optional)
engine running. Low speed is engine idle.
Auxiliary Let Down Power Auxiliary let down power provides hydraulic power to lower and stow the
(Optional) Aerial Device in the event of a prime power source failure.
must be replaced.
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SINGLE STICK FUNCTIONS

The actuator lever must be squeezed to enable the system. A control lever placard indicates the direction to
move the single stick to activate a specific boom movement. Refer to control decals on unit for proper
operation.
SQUEEZE TRIGGER
TO OPERATE
UPPER LIFT UP TO UNFOLD
BOOM PUSH DOWN TO FOLD
UP
LOWER BOOM DOWN
ROTATION
CCW CW
! *
Be sure the control handle is in the centered neutral position before depressing
enabling lever. Return the control handle to centered neutral position before
releasing the enabling lever. Failure to observe these rules will cause sudden and
unexpected movement of the platform. Serious injury or death could result when
working in confined spaces or near electrical power lines.
The Aerial Device upper control station has metallic parts, which are necessary to
provide the structural support for the various components. These metallic parts are
interconnected. The main shaft that supports the platform and controls must also
support other load carrying options that can be added to the boom tip.
electrical insulation between the boom tip and the truck as a potential to ground.
This fiberglass will not protect the operator in the platform if any portion of the boom
tip, including options, is brought into contact with an energized or non-energized
conductor and the operator is in contact with a different potential, such as, a
grounded non-energized conductor. This type of contact can energize or ground
the controls because as stated before, all components of the boom tip are
interconnected. The fiberglass will not provide protection for the operator in phase
to phase contact or a phase to ground contact, nor will it protect the vehicle from
becoming energized if the steel boom section below the lower boom insert, if so
equipped, is brought into contact with an energized conductor.
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LOWER CONTROLS

1. Platform Tilt (Optional) Allows dumping the platform for clean out and personnel rescue.
2. Boom Rotation Controls rotation of the booms.
3. Upper Boom Controls upper boom lift.
4. Lower Boom Controls lower boom lift.
5. Winch Used for operating the winch during material handling operations.
6. Control Selector Selects platform or lower control operation.
The Control Selector will function as an emergency stop

by taking oil flow away from active controls.
7. Engine Stop/Start Controls stop and start of the engine from the pedestal.
(Optional)
(Optional Location) engine running. Low speed is engine idle.
Auxiliary Let Down Power Auxiliary let down power provides hydraulic power to lower and stow
(Optional) the Aerial Device in the event of a prime power source failure.
NOTE: Lower boom, upper boom and rotation may vary. Refer to decal on unit.
must be replaced.
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CONTROL SELECTOR
The control selector lever is used to select either operation from the lower control station or the upper control
station. It is also used to override the upper controls in case of an emergency. The upper controls are not
operable when the lower controls are selected and the lower controls are not operable when the upper
controls are selected.
Use control selector to override upper controls. The lower control position stops oil
flow to the upper controls at the boom tip.
LOWER CONTROL FUNCTIONS

The lower controls consist of two control stations. The first is a hydraulic control station positioned on the
side of the turntable. These hydraulic controls are used to operate boom movements and the rotation of the
boom. The second is an electrical control station located on the pedestal and includes the following controls:
a engine stop/start control for the truck engine (optional), a two-speed manual throttle control for the truck
engine (standard), and an auxiliary let down power control for the boom (optional). Refer to control decal on
unit for proper operation.
ACCESSORIES
ENGINE STOP/START CONTROL (OPTIONAL)
The engine stop/start system allows the truck engine to be stopped and restarted from remote locations.
Controls may be located in the cab, at the outrigger control location, at the pedestal or lower controls, or in
the platform.
Before attempting to start the engine, make sure the transmission is in neutral, the parking brake applied,
and the wheels are chocked.
To start the engine make sure the vehicle key is in the run position and the master switch in the cab is “on”.
Push the control labeled “Engine” and hold until the engine starts, then release.
The engine will crank as long as the switch is held in the “start” mode. If it fails to start, release and let the
starter cool down. The control toggles between start and stop mode, so it is necessary to push and release,
then push again to crank the engine if the engine fails to start.
To stop the engine push the switch and then release. Refer to Emergency Operation for further information
on the use of this control in an emergency.
TWO-SPEED THROTTLE CONTROL
The two-speed throttle control allows the engine speed to be increased to a high idle position or reduced to
the normal idle speed from remote locations. This gives the operator a choice of an efficient, economical
engine idle speed with slower boom movement or a faster engine speed with faster boom movements when
required. Controls may be located at the outrigger control location, at the pedestal or lower controls, or in the
platform. The control will alternate the engine speed between the high and standard idle speeds.
•To increase engine speed, push the switch or air plunger and release.
•To decrease engine speed to an idle, push the switch or air plunger and release.
NOTE: The two-speed throttle may be deleted if not required when Aerial Device is ordered or
the Aerial Device may be equipped with a “demand throttle” which increases engine
speed automatically when a control is activated.
AUXILIARY LET DOWN POWER CONTROL (OPTIONAL)
If the power source for the Aerial Device fails, the auxiliary let down power control activates power to stow
the Aerial Device if the vehicle electrical system is operable. The auxiliary let down power control is
combined with the two-speed throttle control. If the engine is not running, the auxiliary let down power is
turned on and off by pressing and holding or releasing the two-speed throttle push button. If Aerial Device is
not equipped with the two-speed throttle, the control only operates the auxiliary let down power.
NOTE: The auxiliary let down power system should not be operated longer than 30 seconds
continuously. Continuous use will drain the battery and damage (overheat) the auxiliary
pump motor.
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DEMAND THROTTLE (OPTIONAL)

A demand throttle will increase the engine RPM automatically when it senses an increase in pressure. When
a control is actuated the hydraulic pressure increases. This signals the engine speed to increase therefore
the pump output increases. The throttle activation used, electric or hydraulic, will depend on vehicle engine.
BOOM INTERLOCK
The boom interlock, if equipped, is designed to prevent the boom from being operated until the outriggers
are extended. The boom will not operate if the outriggers are not extended past a predetermined point. The
operator must be aware of the proper set up for stability of the vehicle.
HYDRAULIC TOOLS (OPTIONAL)
Hydraulic tool circuits are used to attach hydraulic powered hand tools to the hydraulic system of the Aerial
Device. Quick-disconnect couplings are used to attach hydraulic tools. There may be one or two sets of tool
couplers. Only one set of tools can be used at a time.
The tool circuit is for open center hydraulic tools only. Use of closed center hydraulic tools will create a heat
problem.
CONNECTING TOOLS
•Clean off couplers before making connections.
•Ensure the tool is off, center position, then connect the tool's return hose to the return coupling and the
pressure hose to the pressure coupling.
•To remove tools, turn tool off, center position, then disconnect the pressure coupler first then the return
coupler.
•Place dust covers on couplers to keep clean when not in use.
Only use hoses marked “non-conductive” on tools. The use of tools with hoses that
can conduct electricity may cause serious personal injury or death in the event that
such hoses come near or in contact with energized power lines.
USE OF TOOLS
•When tools are not required store them in the truck storage compartments. This will prevent damage to
the tool and eliminate the chance of the tool falling into power lines.
•Remove tools from the platform when storing Aerial Device for transport.
•Turn tool off when not using tool.
•Do not operate hydraulic hand tools continuously. Continuous operation will cause overheating of the
Aerial Device's hydraulic system.
•Turn tool circuit off when moving boom or platform.
•Use only orange, non-conductive hoses, on hydraulic tools.
•Be aware of where the tool hoses are to prevent snagging or contact with objects.
•Do not contact any conductor, pole, guy wire, or any objects with tool hoses, tool couplers or tool
fittings. Contact can damage tool circuit and cause a leak.
Contact of tool hose, quick coupler, or hose fittings against conductors can cause
an arc that will burn through hose or fitting and result in a fire.
Hydraulic oil is flammable.
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PLATFORM TILTING OPERATION
Do not allow anyone to tamper with the platform tilt device while occupants are in
the platform. Serious personal injury or death could result from platform upsetting.
The platform leveling system permits the platform to be tilted to clean out water and debris. It also allows the
platform to be tilted for personnel rescue. The control is located at the upper controls and lower controls.
The platform can be tilted from two boom positions:
1. The lower boom in the rest and the upper unfolded until the platform is close to the ground.
2. The lower boom raised fully and the upper boom folded to get close to the ground (operate from lower
controls only).
When using the tilt function do not get in the platform. Operate from the upper controls only while standing
on the ground alongside the platform or from the lower controls.
Tilting Operation:
1. Rotate the platform to its stowed position alongside the boom.
2. Move the control selector at the lower controls for the appropriate control.
3. Position the platform to either position shown so the platform is close to the ground.
4. Check for obstructions or people before moving the platform.
5. Move the leveling control as shown to dump the platform for the selected boom position from the lower
controls of while standing alongside the platform.
6. Return the platform to level position before moving the booms.
NOTE: Return the platform to level before moving the booms to prevent air forming in the
leveling system.
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PLATFORM LEVELING
The platform leveling system allows the operator to adjust the platform level. The adjustment is done with
the Platform Leveling control at the upper or lower controls.
•Operate the controls slowly and gradually to bring the platform to a level position.
•Use the level control only while close to the ground.
•Do not adjust the level position while elevated to a work position.
PURGING AIR
The platform leveling system is a closed master/slave hydraulic system. The system may become sluggish
and lag when air enters the system. Air can enter if the booms are moved before the platform is returned to
level position, in cold weather air may enter the system if the unit is stored in warm areas then taken out into
the cold, or after extended use from air in the oil. In such cases purge the air from the system before
operation by tilting the platform through its full travel. Operate from the lower controls as follows:
1. Ensure the platform is rotated to its stowed position, along side the boom.
2. Raise the platform from the platform rest by raising the Upper Boom, so platform is clear of all obstacles.
3. Tilt the platform through its full travel by actuating the leveling control.
4. Return the platform to the level position.
5. Raise lower boom fully, move upper boom as required to clear the ground and any obstructions.
6. Tilt the platform through its full travel by actuating the leveling control.
7. Return the platform to the level position.
8. If the unit is equipped with upper control leveling only, operate while standing alongside the platform. No
one shall be in the platform while performing this operation.
9. Refer to the Service Manual if this does not correct the problem.
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MATERIAL HANDLING
JIB & WINCH OPERATION (OPTIONAL)
When operating the winch under load, always use a smooth movement for lowering or raising loads to avoid
shock loads and sudden changes in truck balance. These dynamic shocks can have an effect on the
structural members of the Aerial Device. Slow movement should be used on all heavy loads at low engine
speed.
Position the Aerial Device so that the boom is properly placed to bring the material to be hoisted to the
desired location. This includes adjusting the jib length and angle position.
The jib boom sheave head must not be turned horizontal in respect to the vertical lifting direction it is
intended to be used in. Operating in this manner will cause a side load rather than the intended vertical load.
The jib and sheave head should not be used in this way. The potential for overload is high, especially to the
boom rotation system. The jib and load line should be used for vertical lifting only.
Never allow personnel to be under loads being lifted.
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HYDRAULIC JIB EXTENSION (OPTIONAL)

Do Not Extend Under Load
1. Install pin (2) and remove pin (1).
2. Extend or retract cylinder to next hole for desired direction and insert pin (1).
3. Remove pin (2).
4. Hydraulic extendable jib is now ready for use.
5. If a longer jib is required, repeat steps 1 and 2.
NOTE: One pin, either (1) or (2), must always be installed to hold jib in position.
NOTE: Cannot extend under load except as a conductor lift when the jib is within 30 degrees of
vertical.
HYDRAULIC JIB EXTENSION (OPTIONAL) - EXTEND UNDER LOAD

1. Install pin (2) and remove pin (1).
2. Extend or retract cylinder to next hole for desired direction and insert pin (1).
3. Remove pin (2).
4. Hydraulic extendable jib is now ready for use.
5. If a longer jib is required, repeat steps 1 and 2.
NOTE: One pin, either (1) or (2), must always be installed to hold jib in position.
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DETERMINING LIFT CAPACITIES

The Aerial Device is equipped with an upper boom angle indicator and load chart on the side of the upper
boom near the platform. HRM Series 42 and 46 also come with a lower boom angle indicator.
The load capacity must be assured for the entire range of the boom motion throughout a lift. Must insure
capacity is not exceeded at any point during load movement.
After placing booms and jib in position for lifting the load. Refer to the load chart and find the number below
the pointer in line with the load radius. The load radius is defined on the jib capacity chart. The capacity
given here is the capacity of the machine for the unit's position. With HRM Series 42 and 46 only, lifting is
not allowed when the lower boom angle indicator is in the red zone.
Keep the loads to be hoisted within the limits shown on the load chart - do not
overload.
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NOTE: Load chart shown is an example only. Each Aerial Device has its custom made load chart.
which may have different capacities than shown here.
AVOID TRAPPED LOOPS

When winding a line with no load back to the winch drum, lower the boom so that a crewman with gloves can
make sure that it is wound level. Trapped loops will damage the winch line or cause a load to drop on the
next winch pay out operation.
Always keep the winch line wound level and tight on the winch drum.
Do not pull poles or pull any objects embedded in ground. Death or serious injury
will result.
PLATFORM ROTATORS
Available with the side-mounted platforms, hydraulic rotators allow full platform rotation, resulting in the
reach capabilities of an end-mounted platform.
On units with dual platforms, each platform is equipped with it's own rotator and control independent of the
other platform.
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PLATFORM ROTATOR OPERATION

1. Rotate Forward - Move the control handle to the position as indicated on the decal.
2. Rotate Back - Move the control handle to the position as indicated on the decal.
Prior to platform rotation, observe all obstructions and hazards nearest the
platform's swing path to avoid collisions and contact with energized power lines.
Contact with obstructions or energized power lines could cause serious personal
injury or death.
Keep hands away from all moving parts on the rotator assembly when operating or
servicing.
Move rotator handle or lever smoothly and gradually for slow platform rotation.
Avoid sudden starts or stops when rotating the platform. Return rotator handle or
lever to the centered neutral position to stop platform rotation.
PHASE LIFTERS (OPTIONAL)

The single and multiple phase lifters are used for lifting conductors during cross arm or pole changeouts.
Single and multiple phase lifters can be used in conjunction with optional mechanical, or hydraulic jib
extension.
To operate the phase lifters, pin bracket to jib with manual pin assembly. Position the Aerial Device below
the conductors. Place conductors in conductor holders and latch holders. Lift the conductors away from the
pole.
Use only approved hot line tools that are rated, tested and maintained for the
voltage to lift energized conductors. Clean and inspect all fiberglass on the
conductor lifter before use. Dirty or damaged fiberglass may be conductive.
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AUXILIARY PUMP
When units are equipped with this option, the booms can be lowered when there is a hydraulic pump or truck
engine failure. The auxiliary pump system will allow folding booms at reduced speed if oil remains in the
hydraulic tank and the batteries have sufficient power.
Use controls to lower booms.
All boom movements, including outriggers, may be operated under normal control, but at reduced speed. To
operate boom tip options using the auxiliary pump, the truck engine must be stopped and the auxiliary pump
plunger must be depressed.
Do not use the let down pump as an auxiliary pump. Use the let down pump only to
lower the booms and/or raise the outriggers when the main pump or truck engine
malfunctions. Using the pump to raise the booms may cause damage to the let
down pump motor.
The auxiliary pump will not provide protection against an empty hydraulic oil reservoir or dead battery.
Hydraulic oil level and battery condition must be checked regularly to ensure dependability.
The auxiliary pump is operated from the truck's electrical system.
Because of the heavy battery drain of the pump unit, operation of the Aerial Device with engine stopped
should be restricted to a minimum.
BOOM LIFTING EYE MATERIAL HANDLING (OPTIONAL)

A lifting eye may be provided at the end of the lower boom to be used for limited material handling. For
maximum lifting capacity, refer to the load chart installed on the Aerial Device.
Never exceed the rated load capacity of the Aerial Device. Structural damage or
instability can result causing death or serious injury.
•Always extend the outriggers.

•Boom movements should be smooth to avoid swinging the load.
•Operate only from the lower control station.
•Do not exceed the load limits stated on the decal beside the lifting eye.
•To prevent damage to the Aerial Device, avoid dragging the loads with the lifting eye. This would
subject the Aerial Device to damaging side loads.
•When lifting loads, position the boom directly over the load before lifting.
•When the vehicle is not level, extreme caution must be used when rotating loads to the low side
because the vehicle's stability will be affected.
•Upper boom can be open a maximum of 30 degrees.
•Be aware of platform location. Raise upper boom so platform clears the body and other objects.
•When using the lifting eye, no personnel or load is allowed in the platform.
Increasing the horizontal distance from the vehicle to the load will affect the stability
of the vehicle. Be careful when lifting and lowering a load with the boom.
The platform shall not be used for material handling.
Do not open upper boom more than 30 degrees from lower boom.
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BOOM LIFTING EYE
Any hooks used in conjunction with the lifting eye must be equipped with a safety
latch.
No personnel allowed inside the platform when using the lower boom lifting eye.
Serious personal injury or death could result.
Be sure load line is capable of lifting the load. Personal injury or death could result
if load line breaks when lifting the load.
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PERSONNEL AND TRAINING

All personnel assigned to an Aerial Device shall be given an opportunity to become familiar with the
operation of the equipment before they operate it on a job. The operator and all other personnel should be
familiar with the operating procedures. The operator and personnel shall perform training operations until
they attain a safe degree of proficiency.
NOTE: Refer to the load chart for rated capacities, boom angles and load radius.
NOTE: Do not exceed load chart capacities.
Learn the operators inspection and field maintenance requirements. Many times simple maintenance
procedures can prevent expensive breakdowns. A brief preliminary check of oil levels and operating
conditions of the Aerial Device should be made daily before the unit is put into service.
If service is indicated, do not delay. Malfunction of one component can cause

serious injury to the operator or to others if not corrected immediately.
The operator should also know the brand and grade of oil used in the hydraulic system and where more can
be obtained if additional oil is needed.
It takes a desire to learn and a pride of accomplishment on the part of the operator to achieve the proficiency
and technique of operation necessary to get the most out of this equipment. The equipment will make the job
easier and more enjoyable if a high degree of proficiency is attained.
The ground crew must be trained to operate the Aerial Device in case of
emergency.
A WELL TRAINED CREW IS A PRODUCTIVE CREW!
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PRE-OPERATION
DAILY PRE-OPERATION CHECKS
Before operating the Aerial Device (with boom in stored position) check the following:
•Fuel gauge to make sure of truck fuel supply.
•Tires for damage or under-inflation.
•Hand brake and/or brake lock for proper operation.
•Truck warning lights for proper operation.
•Loose objects for proper storage.
•Hydraulic oil level in the tank. Must be at FULL mark. All booms and outriggers stored.
•Hydraulic lines for leakage.
•Power take off (PTO) must be engaged.
•Hydraulic hoses for twisting, chafing or any accidental abrasions.
•Aerial Device parts for any damage (hydraulic cylinder, pins, welds, structural members, loose bolts,
etc.)
•Fiberglass upper boom and lower boom (fiberglass) insert for cracks and cleanliness. (Could affect
structural strength and insulating properties of fiberglass.)
•Inspect the fall protection system.
•Effectiveness of controls by operating all Aerial Device functions - set outriggers before raising the
boom from the boom rest. Run unit through its complete boom travel cycle using lower controls.
•Holding valves by stopping the truck engine with booms in raised position and looking for boom drift.
•Operating decals and safety signs. Check for missing, illegible or defaced decals and sings (REPLACE
AT ONCE IF DAMAGED).
•Inspect winch line for chafing or other damage (on units so equipped).
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JOB SITE SURVEY

Before locating the vehicle in position to work, make a complete survey of the job site. During the survey,
some of the items to look for include the following:
•Ambient conditions including temperature.
•Consider the slope of the ground. Unit is tested on maximum 5 degree ground slope.
•Determine if the ground is firm enough to support the Aerial Device. If the vehicle must be parked on a
slope, always keep the boom on the uphill side, chock the wheels, and work off the rear of the vehicle. If
the ground is not firm enough, use pads under the outriggers and crib as needed to distribute the load.
•If unit is not equipped with outriggers, or only has one set of outriggers, evaluate the tire contact area.
All tires and axle suspension springs must be equally loaded prior to setting outriggers.
•Look for ditches, drop-offs, holes, debris, and overhead utility and power lines.
•If grass or shrubs will be underneath when the vehicle is setup, cover grass or shrubs with dirt to
prevent a fire.
•Determine the vehicle position needed to accomplish the work safely. If it is not safe to proceed use
another method or setup.
OPERATING TEMPERATURE RANGE
The ambient operating temperature range of the unit is given on the ID plate. Operation at the extremes of
the temperature range requires extra precautions.
Cold weather operation below 10 degrees F requires:
•The hydraulic system must be filled with hydraulic fluid having a pour point suitable for the temperature.
•The hydraulic system must be properly warmed up:
•Operate the pump at idling speed to allow the oil to warm up gradually. Cold, thick, sluggish oil
may not move fast enough and will starve the pump, thus causing severe damage.
•Circulate the oil through the system by cycling each function from the lower controls before
operation from the platform.
•The addition of oil heaters may be required.
•Operate the boom and functions slowly to prevent jerking and shock loads.
•Functions may operate sluggish and not be as responsive, so allow more time and distance when
starting and stopping movements.
Hot weather operation above 100 degrees F may require intermittent operation to allow the oil to cool or the
addition of oil coolers. Do not exceed an oil temperature of 150 degrees F.
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JOB SITE SETUP

Before locating the vehicle in position to work, make a complete survey of the job site. Select a truck position
that has a ground slope of less than 5 degrees. This Aerial Device has been tested for stability on a flat firm
surface with a maximum slope of 5 degrees. Working on slopes that exceed 5 degrees may result in vehicle
tipping over. The truck as built may have torsion bars only, one set of outriggers, or two sets of outriggers or
a combination of torsion bars and outriggers. The unit has been tested for stability as equipped. The vehicle
can only be used with the stability components as originally installed and tested. If the unit has outriggers
they must all be used and set up properly for stability of the unit. If the unit has torsion bars they must be
inspected and maintained to provide the force needed for stability.
•Determine if the vehicle is parked on a slope of 5 degrees or less by looking at the level indicator
located by the outrigger controls or on the front of the truck body on units without outriggers and also
evaluate the axle angle to the truck. The level indicators are only an operator aid, it will tell if the angle at
the indicator location is over 5 degrees but will not tell if the ground is less than 5 degrees or how much
the frame is twisted. The operator must visually verify the ground condition and that the truck axles
uniformly support the truck weight. If the tires are hanging on one axle spring, barely touching the
ground, and the other tire spring is up against the rubber stop, the frame angle is different than the axle
angle. The axle suspension is not loaded uniformly and may not provide proper stability.
•The unit may be equipped with either the pointer level indicator shown on the left (below) or the
inclinometer, shown on the right below. The bottom of the pointer (or ball) must be in the green area. If
the pointer (or ball) is in the red area or red shows behind the pointer, the truck is at an angle greater
than 5 degrees and the truck position must be changed before use. Change the position of the truck by
repositioning the truck or by cribbing the tires of the truck until it is less than 5 degrees and the
suspension on each axle is uniformly loaded. If the truck is parked in a location with less than a 5
degrees slope and the tires equally support the truck and load, proceed to setup the unit.
NOTE: The hanging pointer may contact the mounting surface if the angle is between 4 to 6
degrees out of level front to back. Make sure pointer is hanging free and properly
indicating angle.
POINTER LEVEL INDICATOR INCLINOMETER LEVEL INDICATOR
Working on slopes that exceed 5 degrees may result in vehicle tipping over. The
level indicators are only an operator aid, it will tell if the angle is over 5 degrees at
the indicator location but will not tell if the ground is less than 5 degrees or frame
twisted. The operator must visually verify the ground condition.
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•If unit is not equipped with outriggers, or only has one set of outriggers the tires and suspension on
each side of each axle must uniformly support the truck and load because they are part of the stability
system when operating the Aerial Device. If one tire and axle spring is not loaded the same as the other,
on that axle, it will not be able to provide the stability needed.
•A tire cannot be in a hole or depression even if the truck is parked and the indicators show less than 5
degree angle.
If unit is equipped with two sets of outriggers, the axles not between the outriggers must equally support the
load of the truck so the suspension on each side is equally loaded.
On Aerial Devices with no outriggers or only one set of outriggers the tires and
truck suspension are a very important part of the stability system.
•Tires must not be parked in holes or depressions.
•Truck suspension must be equally loaded on each axle to provide support
prior to setting outriggers.
•Tire pressures must be correct.
If the unit is equipped with a lower lift, the unit will have more stringent
requirements for proper stability. Refer to decals on the vehicle or the supplement
at the end of this manual.
Use the following procedure after the vehicle is in position at the work site:
•Turn on warning lights.
•Set the brakes and chock the wheels.
•Position and use signs, warning lights, and barricades in accordance with OSHA, ANSI, state, and
company rules and regulations.
•When work is to be performed on or near power lines, ground and/or barricade vehicle using an
approved grounding cable clamped to a static line or neutral, or use drive or screw type ground rod to
ground truck according to your company policy.
•Engage the power take-off (PTO) following the directions given with the specific PTO installed on the
truck.
•Turn master switch on to provide electrical power to electrically powered options.
•Set the outriggers (if equipped).
If the unit is equipped with outriggers, all outriggers must be set properly to provide
adequate stability.
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SETTING THE OUTRIGGERS

Before lifting or rotating the Aerial Device, all outriggers (if equipped) must be lowered firmly to the ground
on a surface that can support the load, and kept there until all work is complete and the Aerial Device is
stowed for travel. The stability of the Aerial Device depends on the gross weight of the vehicle, platform and
jib load, the slope of the ground in the work area, and whether the ground is firm enough to support the load
imposed. The condition of the truck tires, axles, torsion bars, outriggers and outrigger pads or cribbing all
contribute to proper stability. These conditions are widely variable, so the operator must exercise good
judgment and caution when setting the outriggers before utilization of the Aerial Device.
The method of setting the outriggers will vary depending on the number of outriggers and configuration. If
the vehicle is equipped with one set of outriggers, the tires and the spring force of the truck axle work with
the outriggers to provide stability. The location of the outriggers relative to the truck axles and the pedestal
will determine how much the outriggers can be extended.
When lowering the outriggers:
•Determine if truck is properly parked with brakes applied and wheels chocked.
•Position the outrigger pads and ensure that the surface will support the outrigger force, crib as required.
•Before lowering the outriggers, check the area where the outriggers will extend to ensure no personnel
or other objects are in the path. Alert all personnel that the outriggers are being moved and positioned.
•Units with one set of outriggers behind the rear axles on rear axle mounts, extend the outriggers until
the weight of the vehicle is off the springs. Rear tires must remain on the ground. More outrigger
extension is allowed the closer the axle is located to the outrigger.
•Units with one set of outriggers between the axles on behind-the-cab mounts, set the outriggers firmly
on the ground, but do not raise the weight of the vehicle off the springs. Tires must remain on the ground
with the truck suspension providing equal support on each side of each axle.
•Do not attempt to correct the ground slope with the outriggers; this unloads the low side tires and
suspension. The suspension may not provide enough force for stability.
•After setting the outriggers evaluate the truck position and setup. Determine if the tires are equally
supporting the load by looking at the clearance to the fenders, body, or bed and the axle location to the
axle stop, (rubber bumper) and overload springs. If one tire is closer to the body and the other tires on
the opposite side of the same axle is father away from the body the unit is not set up properly. The
spring deflection on each side must be the same or the overload springs or rubber bumper both in
contact with their stops. Tires on the low side must be cribbed to equalize the truck suspension load so it
can provide the force needed for stability if not equally loaded as parked.
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•Two sets of outriggers: The outriggers are extended to support the weight of the unit. The tires must
remain in contact with the ground.
•The vehicle can be leveled slightly with the outriggers.
•The axles not located between the outriggers must equally support the load of the truck so the
suspension on each side is equally loaded.
•If the unit is equipped with a lower lift more stringent requirements may be required for proper stability.
Refer to decals on the vehicle or manual supplements for proper instructions.
The outrigger moving alarm will sound when the outrigger control is activated. If the
alarm does not sound, it must be repaired.
SETTING UP ON A SLOPING SURFACE

If the vehicle must be set up across a slope, the surface can be up to 5 degrees from level but must be firm
and flat where tires are located. If one side of the vehicle is low, extend the low side outrigger first and make
sure that firm contact is made. If full extension does not make firm contact, the outrigger pad must be
blocked up. Always chock the wheels. Keep the boom on the uphill side. If the slope exceeds 5 degrees
before setting the outriggers the tires must also be blocked and cribbed so the truck is parked at less than 5
degrees. If the unit has one set of outriggers do not level the truck with the outriggers. On units with one set
of outriggers using the outriggers to level the truck does not change the slope, it reduces the truck
suspension’s ability to support the load and provide stability.
VEHICLE SETUP ACROSS THE SLOPE
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If the vehicle must be set up with the slope, always keep the boom on the uphill side of the vehicle, always
chock the wheels, and always work off the rear of the vehicle.
VEHICLE SETUP WITH THE SLOPE

If the vehicle must be set up where an outrigger extends into a ditch or gutter and the full extension does not
make firm contact, the outrigger must be blocked or cribbed up. Chock the wheels carefully to prevent
motion of the truck. Ensure cribbing (if required) provides stable support. If the vehicle must be set up so an
outrigger rests on a curb with the vehicle in the street, the outrigger span will be shortened and stability is
reduced. Ensure the curb has sufficient strength to support the load. All of the previous may affect the
stability of the vehicle and restrict the load capacity of the vehicle. Proceed with caution under these
conditions. If the outrigger support surface is not level with the truck, the bank may need to be cut away or
brought up to a level so the outrigger will provide proper support. The ground must be able to support the
load of the outrigger without sinking.
TORSION BARS (OPTIONAL)

Torsion bars may be installed on the rear axle, front axle, or both; alone or in addition to outriggers. If the
vehicle has torsion bars, the tires, and suspension are important because they are providing the stability.
Check the tire pressure and condition before each use of the vehicle. The tires must be on solid footing, with
each tire equally loaded. If not, use pads and cribbing as required, or reposition the vehicle to solid ground.
Refer to the level indicators to be sure the vehicle is parked at less than 5 degrees from level. If not, wheels
must be cribbed to level the vehicle to less than 5 degrees slope. Ensure the tires are not in a depression. All
tires must be equally loaded to provide support. To determine if the tires are equally loaded, check the
spring deflection on each side. The deflection must be the same or the overload springs or rubber bumper
both in contact with their stops. Also the tire clearance to the body on each side needs to similar.
SETTING UP ON A SOFT SURFACE
If the ground is too soft to support the outrigger load or wheel load, the outriggers or tires must be padded or
cribbed until the ground will support the load or the unit cannot be used at that location. Make certain the
tires and outriggers are centered on the pads and the cribbing provides stable support as the booms are
moved.
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OUTRIGGER / UNIT CONTROL SELECTOR

The outrigger/unit control selector must be in the “outrigger” position to raise or lower the outriggers. The
lever must be in the “unit” position to operate the boom functions. If equipped with hydraulic tools at the
outrigger valve they will have priority over other operations. When the tools are “on” the “unit” and
“outriggers” will not get hydraulic oil flow and will not operate.
Do not use, connect, or disconnect the lower hydraulic tool if the booms are in or
near energized lines. Death or serious injury may result if the truck becomes
energized.
The boom interlock, if equipped is designed to prevent the boom from being operated until the outriggers are
extended. If the Aerial Device does not operate and the outrigger/unit control selector is selected to unit then
verify all outriggers are properly extended.
SETTING UP FOR OPERATION ON SNOW AND ICE
Operation on snow and ice adds an additional problem due to the slippery conditions. Normal traction is
greatly reduced. Just as you need to maintain traction to walk and drive, it is required to keep Digger
Derricks and Aerial Devices in a stable position. Rotating and moving the booms may cause the truck to jerk
and move. If the unit is not set up securely the truck can slide on ice and snow while operating. When
planning your work remember that driving in snow causes snow dust to be deposited on all surfaces. The
outriggers and outrigger pads will get snow covered and slippery. Also, as you put pressure on snow, the
snow packs down and turns to ice. The person setting the unit up for operation has the entire responsibility
for a stable position. The person on the site is the only one who can evaluate the conditions and terrain.
Proper set up requires:
•Outriggers do not slide on the outrigger pads during use.
•Outrigger pads do not slide on the ground during use.
•Set the parking brakes.
•Chock wheels as required, to prevent movement down hill. Evaluate chock location to prevent the truck
pivoting around one chock.
•Set units with one set of outriggers so all tires are on the ground.
•Evaluate the terrain to determine the most flat and level set up position.
•Set up truck so if the truck does move slightly, the result isn’t catastrophic.
•Follow Operators manual for set up instructions. Do not place outriggers on Ice as slippage may occur
regardless of solid footing.
To properly set up you may need to:
•Remove snow and ice down to bare ground to prevent sliding and to evaluate the support available.
Don’t set outriggers on a manhole cover or the edge of a slope or drop off.
•Move as far as required into the street or road so if the truck does move, the tires and outriggers will not
slide into the ditch or other hazards.
•Choose a location for the truck that gives the best stability for the work to be done.
•Come back later, to do the work, if the roads are not cleared sufficiently.
•Use traction aids under the tires and outriggers such as sand and gravel or mats.
•Operate the unit smoothly by “feathering” the controls, not jerking the levers.
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LOADING CAPACITIES
The stability of a vehicle equipped with a rotating Aerial Device depends on the gross weight of the vehicle
and load, the slope of the work area, and whether the ground is firm enough to support the weight of the
outrigger pads. These conditions are widely variable, so the operator must exercise good judgment and
extreme caution to learn just what his particular vehicle can handle.
NOTE: Learn the loading capacities of your unit under all conditions of load, terrain and Aerial
Device.
Increasing the distance from the vehicle to the load will affect the stability of the
Aerial Device. Keep loads close to the ground until you determine that the load can
be balanced safely at the maximum distance you wish to work.
This Aerial Device has been tested for stability on a maximum slope of 5 degrees.
Working on slopes that exceed 5 degrees may result in vehicle tipping over.
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OPERATION
BOOM OPERATION
All boom movements should be smooth. Avoid jerking by slowly metering the control valves when starting
and stopping all motions. Start and stop all boom movements with a low engine speed to make it easier to
"feather" the controls for smooth operation. Lift the boom off the rest and elevate it high enough to clear all
body obstructions before rotating. TEREX TELELECT Aerial Devices are equipped with a standard three
port collector block oil distribution center in the pedestal which permits the continuous rotation of the boom in
either direction without stops.
Make certain that all personnel are in the clear and that there is sufficient overhead
clearance before operating the Aerial Device.
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AERIAL OPERATION
Before using the Aerial Device, the operator should check through the pre-operational procedure to ensure
the vehicle is properly positioned with outriggers (if furnished) firmly in place. Extreme care should always be
exercised when lifting personnel.
Before entering the platform, place the outrigger control selector (if equipped) and the lower control selector
to the upper controls.
After entering the platform, connect the lanyard to the attachment ring located on the platform bracket. An
OSHA Approved Fall Protection System must be used.
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Do not allow any part of the Aerial Device to come in contact with any electrical
conductors, either energized or non-energized.
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USE PROTECTIVE EQUIPMENT SUITABLE FOR THE WORK BEING PERFORMED

•Wear your rubber gloves and sleeves when working on or near electrical equipment.
•Install hose, covers, and mats on all energized and grounded conductors.
•Wear protective and insulated headgear.
•Use a platform liner.
•Death or serious injury could result from such contact or inadequate clearance.
Do not move the vehicle with personnel in the platform. This Aerial Device is not
designed for this type of operation.
Study the movements required to reach the work location. Use a feathering technique with control levers to
ease the Aerial Device to smooth starts and stops. Use low speeds, when approaching the aerial job site.
Use high speed only between ground and job site and job site and ground. Always look in the direction the
Aerial Device is traveling to be certain there is clearance for the boom(s), platform, and operator.
Be aware of any obstacles the lower boom may strike if rotated or elevated, and any objects that the booms
may come close to as movements are made.
If equipped with engine throttle control, use low engine speed if extended time will be spent at one site.
Do not leave the platform to build trestles between the platform and another work
location.
Avoid careless handling of tools and equipment while aloft. Use a tool tray to help
prevent dropping items. Keep all ground personnel away from the area directly
under the work point unless absolutely necessary, and caution them that it is
necessary to be constantly on the alert for possible falling items.
Use orange hose marked NON-CONDUCTIVE for tool hoses, at the boom tip, and
areas that bridge the insulation gap.
Do not let hoses hang where they can catch on or contact energized conductors or
grounded conductors on any structure.
The Aerial Device upper control station has metallic parts, which are necessary to
provide the structural support for the various components. These metallic parts are
interconnected. The main shaft that supports the platform and controls must also
support other load carrying options that can be added to the boom tip.
electrical insulation between the boom tip and the truck as a potential to ground.
This fiberglass will not protect the operator in the platform if any portion of the boom
tip, including options, is brought into contact with an energized or non-energized
conductor and the operator is in contact with a different potential, such as, a
grounded non-energized conductor. This type of contact can energize or ground
the controls because as stated before, all components of the boom tip are
interconnected. The fiberglass will not provide protection for the operator in phase
to phase contact or a phase to ground contact, nor will it protect the vehicle from
becoming energized if the steel boom section below the lower boom insert, if so
equipped, is brought into contact with an energized conductor.
Do not depend on Aerial Device covers for insulation. Plastic or fiberglass covers
offer limited electrical insulation. Covers are not tested, certified or maintained as
insulating.
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EMERGENCY OPERATION
Emergency operation may be required if an operator is injured or the equipment malfunctions. In any
emergency, the first priority is always the safety of the personnel involved. It is always important to
remember to follow the standard work practices and the safety regulations that apply. If the Aerial Device is
operable, move the platform away from the danger and into the shortest, clear path of descent to get the
operator on the ground. If the Aerial Device is inoperable, consider using another Aerial Device to rescue the
operator from the platform. If an equipment defect is suspected, do not allow anyone to enter the platform.
Instead if the situation allows safe operation from the lower controls, override the upper controls and
carefully lower the platform to the ground.
Do not touch the truck or attachments and the ground at the same time. If the truck,
including Aerial Device or any attachment connected to the truck, contacts a power
line, you will be a path for the current. Death or serious injury will result.
POWER LINE CONTACT ON GROUND

VEHICLE IS TOUCHING A POWER LINE
Take these steps if your vehicle makes contact with a live power line while you are in or on the vehicle:
•Treat any line, as live unless you know for sure it is not.
•Stay inside or on the vehicle until the power is disconnected or turned off.
•Warn others to stay away from the vehicle and any trailers or attachments.
•If you must get away from the vehicle because of fire or other danger:
•Jump out and away from vehicle.
•Do not touch the vehicle and ground at the same time.
•Land with your feet close together.
•Shuffle away taking very small steps keeping feet together.
•Do not try to help others out of the vehicle, you could get electrocuted.
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STANDING ON GROUND CLOSE TO FALLEN POWER LINE

You must shuffle keeping feet together, do not run. The voltage is highest where contact is made and
decreases as you get farther away from the point of contact. The distance will depend on the ground
conditions and conductivity of the ground. If you run, your legs will bridge from higher to lower voltage and
current will pass through your feet and legs. Keep your feet together and shuffle to go from one voltage
gradient to the next gradually. This will decrease the chance of electrocution as you move away from the
vehicle or fallen wire.
•Never touch a fallen power line unless you are trained and properly equipped to handle it safely.
•Shuffle away using very small steps keeping feet together; do not run.
•Do not touch anything as you leave the area.
•Warn other people to stay away from the area.
•Immediately notify the proper authorities or people to correct the problem.
In an electrical emergency: Stay calm and think before you act. Don't become a
victim while helping someone else.
APPROACHING A VEHICLE THAT MAY BE ENERGIZED

In an emergency situation, it may be necessary for ground personnel to operate the Aerial Device. The
entire vehicle and any attachments must be considered energized any time the booms are in the vicinity of
power lines.
Operators make sure your ground personnel know the proper operation and
emergency procedures for the Aerial Device. Your life may depend on it if you have
an accident or are incapacitated.
If you must approach a vehicle to perform a rescue operation, understand and follow your company policy. It
will take precedence over these instructions. You must be very careful not to touch the vehicle and the
ground at the same time or your body will be in a circuit and current may pass from foot to foot or foot to
hand. The condition of the ground and subsurface will determine the electric gradient around the vehicle.
BEFORE TRYING TO GET ON OR APPROACH THE VEHICLE
•Is it necessary to approach the vehicle? Can the operator handle the problem from the platform?
•The best procedure is to disconnect or shut off the power to the lines.
•Do not let anyone approach the vehicle until you evaluate where the power line contacts the Aerial
Device.
•Is it above the insulated section of the upper boom?
•Is it above the lower boom insulated section?
•Is it below any insulated sections and a direct short to the vehicle?
•If the vehicle is grounded properly:
•Use a hot stick or hot line tool to perform the operation.
•Approach the vehicle using the shuffling step.
•Lay a rubber blanket down by the vehicle and step on it before attempting to jump on the vehicle.
•Do not touch the ground and the vehicle at the same time.
•If the vehicle is not grounded:
•Do not approach the vehicle unless you use insulated blankets to step on as you approach the vehicle.
Stepping from one rubber blanket to the next.
•Use a hot stick or hot line tool to perform the rescue operation while standing on the rubber blanket.
•As a last resort, jump onto the vehicle.
•Do not touch the ground and the vehicle at the same time.
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CONTROL SELECTOR
When a situation requires use of lower controls to override the upper controls (such as, injured personnel in
the platform), use the control selector at the lower controls to select the “lower” controls for operation of the
Aerial Device. This will make the upper controls inoperable. Then “lower” controls can be used to lower the
operator to the ground, provided the upper controls are intact. The Control Selector functions as an
emergency stop by taking oil flow away from the active controls.
If the operator is unable to operate the Aerial Device, determine if any damage has occurred to make the
Aerial Device inoperable. If the situation allows safe operation from the lower controls, override the upper
controls and carefully lower the platform to the ground. If the Aerial Device will not operate due to the
damage incurred, consider one of the other auxiliary operating procedures presented in this section to solve
the problem.
MANUAL ROTATION
If all the hydraulic power sources become inoperable, the Aerial Device rotation system can be actuated
manually. Use a 7/8" hex socket, an extension, and a ratchet to rotate the input shaft on the gearbox.
Actuating the lower rotation control will reduce the effort required for the rotation.
AUXILIARY LET DOWN POWER (OPTIONAL)
The auxiliary let down power system provides power from a DC motor-pump for operation of the Aerial
Device in case of a prime power source failure. Controls for auxiliary let down power may be located at the
platform, pedestal (optional), and outrigger (optional).
At the platform, the auxiliary let down power is operated by an air cylinder located with the upper controls. To
activate this system, push and hold the air cylinder's plunger knob (labeled “Auxiliary Power”) then operate
the controls. The pump will engage after a 10 seconds delay. To turn “off” the power, release the air
cylinder's plunger knob. The auxiliary let down power system should not be continuously operated longer
than 30 seconds. Continuous use will drain the battery and damage (overheat) the motor.
At the pedestal and the outrigger controls (if equipped), the auxiliary let down power is operated by a push
button switch. To activate this system, push and hold the switch, the pump will engage after a 10 seconds
delay. To turn “off” the power, release the switch. The auxiliary let down power system should not be
continuously operated any longer than 30 seconds. Continuous use will drain the battery and damage
(overheat) the motor.
Do not use the let down pump as an auxiliary pump. Use the let down pump only to lower the booms and/or
raise the outriggers when either the main pump or engine malfunctions. Using the pump to raise the booms
may cause damage to the let down pump motor.
When the Aerial Device is equipped with engine two-speed throttle and auxiliary let down power, the same
control is used for both. When the engine is running, the engine two-speed throttle operates. When the
engine is off, the auxiliary let down power operates.
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HYDRAULIC LINE FAILURE

Hydraulic line failure during Aerial Device operation presents numerous hazards. Be aware that a hydraulic
oil mist caused by a leak or hydraulic line failure is conductive even though nonconducting oil is used.
A spray or mist produced by a hydraulic leak under pressure is very hazardous to

personnel. This spray or mist can puncture the skin or become embedded beneath
the skin. This condition would require immediate medical attention.
WHAT CAN CAUSE A HYDRAULIC LINE TO FAIL

•Poorly maintained hydraulic system
•Improperly assembled and installed hydraulic lines
•Weather checked hose assemblies
•Hydraulic tool hoses that are allowed to cross phase to phase or phase to ground
•Boom contact with phases causing a short circuit, which overheats the hydraulic line
•Improper system pressure setting
•Overheating the hydraulic system
•Snagging of hydraulic lines on fixed objects
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WHAT CAN HAPPEN WHEN HYDRAULIC LINES FAIL

Hydraulic oil, when confined within the hydraulic system and properly maintained, is non-conductive and not
subject to being ignited. There are numerous hazards that develop when there is a hydraulic line separation:
•Personnel may suffer burns from contact with hot oil.
•A vacuum may be created in the line and breech the insulated portion of the booms causing the Aerial
Device to be conductive.
•If the hydraulic line failure creates a mist of oil, it very easily can be ignited by any outside source of
ignition; such as, electric arcing, sparks, and flames.
•The reservoir may be drained of oil, which will make the Aerial Device inoperable.
WHAT TO DO IF HYDRAULIC LINE FAILS
A quick response to stop oil flow caused by a hydraulic line failure is important to prevent further damage
and prevent injury.
The following sequence can be used to stop the flow.
FROM THE PLATFORM
•Release the function being operated. Shut off tool valve if tool, tool hoses, or tool connections are
involved.
•Activate the stop control, which will divert the flow back to the tank.
•Activate the engine stop/start switch, if so equipped. This will stop the engine driving the pump.
•Get ground assistance if all these fails.
The vehicle may be energized. If mounting or operating the vehicle from the
ground, use proper personal protective equipment; such as rubber gloves, rubber
boots, rubber mats, and/or a hot stick. See Emergency Operation section for
procedure to approach vehicle.
FROM THE VEHICLE BED

•Move the control selector at the lower controls to the lower control position. This will stop all flow to
upper controls.
•Push the engine stop/start switch, if so equipped. This will stop the engine driving the pump.
FROM THE GROUND
•Shut off the pump engine. This will stop the pump.
•Disengage the power take-off. This will stop the pump.
•Move the control selector at the outrigger control valve to the outrigger position. This will stop all flow to
the Aerial Device and send it to the outrigger circuit.
•Push the engine stop/start, if so equipped. This will stop the engine driving the pump.
Once the flow is stopped, determine where the line failure is located. The following examples describe some
emergency procedures that can be followed for some specific types of hydraulic line failures:
•If the line failure is between the upper and lower controls, overriding the upper controls and only
operating from the lower controls may reduce the rate of hydraulic oil loss. The intermittent loss of
hydraulic oil may allow the Aerial Device to be stored.
•It may be necessary to use another Aerial Device to bring the operator down.
NOTE: Oil spills may require notifying Local, State, or Federal Authorities.
The Aerial Device must not be operated until repairs have been completed and the
Aerial Device cycled from the lower controls to purge air.
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ENGINE FAILURE
If the prime power source fails, the optional auxiliary let down power system can be
used for emergency operation. If the auxiliary let down power system is not
installed and the vehicle has a manual transmission, then use the engine stop/start
control (if so equipped) to crank the engine.
HYDRAULIC PUMP FAILURE

If the primary hydraulic pump fails, use the auxiliary let down power system, if equipped.
CONTROL VALVE FAILURE
A control valve malfunction could develop in either the individual control levers or the multifunction single
stick control.
If the Aerial Device motion cannot be stopped because the control valve will not return to the centered or
neutral position, activate the emergency stop mode by pushing down the emergency stop. The emergency
stop position will disable the boom controls, which will stop the Aerial Device's motion. If the engine stop/
start control is installed, shut off the engine. The engine and the Aerial Device's motion will cease. Then
manually attempt to center the spring-loaded control lever before restarting the engine. If the spring-loaded
control lever at the platform will not return to neutral, the Aerial Device can be returned to a stowed position
by overriding the upper controls from the lower controls.
After any emergency situation, it is the operator's responsibility to notify appropriate maintenance personnel
to make sure the Aerial Device is repaired and adjusted.
Identifying the problem and initiating the recommended emergency procedures will help to minimize or
possibly prevent injuries.
OPERATIONAL LIMITATIONS
PLATFORM LEVELING SYSTEM
The platform leveling system is designed to carry the rated load of the platform. Collision of the platform(s)
with a fixed object, including the ground, or attachment of any load lifting devices to the platform(s) can
damage or break the leveling system, causing the platform to be overturned. Avoidance of these hazards
and use of OSHA approved fall protection system for all personnel in the platform is essential for protection
against this type of accident.
Do not allow booms or platform to make contact with fixed objects including the
ground. Look for possible contact of booms or platform with fixed objects if you feel
the platform is not staying level.
The platform leveling mechanism is designed to carry the rated platform capacity,
applied standing over the center of the platform floor. Hoisting of material from the
outer edge of the platform, from a pole attached to and extending over the top of
the platform, places excessive loads on the leveling mechanism. This procedure
could cause overturning of the platform(s) and ejection of personnel.
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LEAVING THE JOB SITE

•Place upper and lower boom in stored position for traveling.
•Remove all tools and supplies from platform. Position the platform cover in place if one is supplied.
Place platform in stored position for travel.
•Lock upper boom in place with hold down latch.
The upper boom must be completely secured in its saddle before travel. If the
boom is allowed to bounce in its saddle, the fiberglass may craze, shatter, and
eventually buckle.
•Make sure that outriggers are fully retracted and if extra pads have been used that they are properly
stored. Stow all loose tools and equipment. Turn off vehicle warning lights.
Do not travel with tools or other items stored in the platform. Loose items may
damage the platform or fall on the roadway during road travel.
•To prevent damage be sure that PTO is disengaged before traveling.

•Remember the overall height of the unit.
Drive carefully!
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MAINTENANCE GUIDELINES
HRM SERIES
Table of Contents
SECTION 2
PREVENTATIVE MAINTENANCE
A preventative maintenance program based on the manufacturer's recommendations shall be established.
Dated and detailed inspection and repair records shall be maintained.
It is recommended that the replacement parts for your Aerial Device be obtained from a TEREX TELELECT
distributor or TEREX TELELECT.
MAINTENANCE PROCEDURE
Before maintenance, adjustments, and repairs are started the following precautions shall be taken as
applicable:
• You must be authorized by owner to operate unit.
• Place vehicle where it will cause the least interference with other equipment or operations in the area.
• All controls at the off position.
• Starting means rendered inoperative.
• Warning or “OUT OF ORDER” signs placed on the vehicle.
• Power plant stopped or disconnected at power takeoff.
• Relax all hydraulic cylinders used for boom lift and articulation.
• Relieve hydraulic oil pressure from all hydraulic circuits before loosening or removing hydraulic
components.
After adjustments and repairs have been made the Aerial Device shall not be operated until all guards have
been reinstalled, trapped air removed from hydraulic system, safety devices reactivated, and maintenance
equipment removed.
Warning or “OUT OF ORDER” signs shall be placed and removed by authorized personnel only.
ADJUSTMENTS AND REPAIRS
Any unsafe conditions disclosed by the inspection requirements of this section shall be corrected before
operation of the Aerial Device is resumed. Adjustments and repairs shall be done only by qualified
personnel.
Adjustments shall be maintained to assure correct functioning of components. The following are examples:
• All functional operating mechanisms.
• Safety devices.
• Control systems.
• Power plants.
Repairs or replacements shall be provided promptly as needed for safe operation. The following are
examples:
• All critical parts of functional operating mechanisms which are cracked, broken, corroded, bent or
excessively worn. This is for all parts of the aerial device, pedestal, subframe, outrigger, and
attachments to the vehicle.
• All critical parts of the vehicle structure which are cracked, bent, broken or excessively corroded.
• Hooks showing defects disclosed by “Frequent Inspection” requirements in the maintenance manual
shall be discarded. Field repairs by welding or re-shaping shall not be permitted.
All replacement parts or repairs shall have at least the original safety factor. Do not alter, modify, remove or
replace any part of the Aerial Device without the approval of the manufacturer.
NOTE: Do not use hoses having less than 2000 psi working pressure. Only use Orange hoses
marked "Non-Conductive" for hydraulic tools, at the boom tip and in areas that bridge the
insulation gap.
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HRM SERIES
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LUBRICATION
All moving parts of the Aerial Device and vehicle, for which lubrication is specified, shall be regularly
lubricated. Lubricating systems shall be checked for proper delivery of lubricant. Particular care should be
taken to follow manufacturer’s recommendations as to points and frequency of lubrication, maintenance of
lubricant levels and types of lubricant to be used.
Machinery shall be stationary while lubricants are being applied and protection provided as called for in
“Maintenance Procedure”.
The modification, rework, replacement, or substitution of any part of the Aerial

Device with a means not equal to the original equipment provided by the
manufacturer may cause serious personal injury.
OPERATIONAL CHECKLISTS
See Frequent and Periodic Inspection Intervals before operation of the Aerial Device.
GENERAL INFORMATION
1. Keep inspection records up-to-date.
2. Record and report all discrepancies to your supervisor.
3. A dirty Aerial Device and vehicle cannot be properly inspected. Keep your Aerial Device and vehicle
clean!
4. Follow vehicle manufacturer’s requirements for inspection, maintenance, and repairs.
5. Only qualified personnel shall do repairs and inspections.
6. Oil spills may require notifying Local, State, or Federal Authorities!
The following checklists must be used daily, 90 days (360 hours), 180 days (720
hours), 12 months (1,050 hours). Failure to do so could endanger the life of the
operator. Always remember, preventive maintenance can save much more than it
costs.
NOTE: The following check points listed are the minimum recommended by TEREX TELELECT.
They are subject to supplementation to conform with your own company regulations.
NOTE: Remember that the safety of all personnel and the operational efficiency of the Aerial
Device are dependent upon good inspection checks and maintenance practices.
NOTE: Dirty or dusty conditions or unusual weather conditions may require more frequent
maintenance.
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FREQUENT AND PERIODIC INSPECTION INTERVALS

DAILY
1. Check controls at platform and lower controls for proper operation.
2. Inspect fall protection equipment and attachments.
3. Inspect visual and audible devices.
4. Check cleanliness and dryness of fiberglass components.
5. Visually check for missing or loose covers and guards.
6. Check for missing and illegible warning, operational, or instructional markings.
7. Visually check oil level in hydraulic reservoir.
8. Visually inspect for leaks in hydraulic system.
9. Visually check all cylinders for leaks.
10. Visually inspect leveling system. (Chains and Insulator Assemblies)
11. Visually inspect all fasteners for tightness.
12. Visual inspection of all structural members for cracks and permanent deformation.
13. Check for rotational obstructions.
14. Visual inspection of all electrical wires.
15. Operational test of all boom functions.
90 DAYS (360 HOURS)
1. Replace return filter.
2. Check tension on leveling system. Inspect and lubricate chain, clean if rusty or dirty.
3. Visually inspect all sprockets, pulleys and pins.
4. Lubricate all points per lubrication chart recommendations.
5. Apply lubricant to rotation gearbox pinion and turntable bearing.
6. Repair or replace items found to be worn or damaged.
7. Daily inspections.
180 DAYS (720 HOURS)
1. Inspect exposed hoses.
2. Clean hydraulic tank breather.
3. Check tightness of rotation bearing bolts, turntable bearing, and bearing to pedestal for proper torque.
4. Daily, and 90 Days (360 Hours) inspection.
12 MONTHS (1,050 HOURS)
1. Inspect and lubricate PTO drive shaft to pump.
2. Take samples of hydraulic oil and test.
3. Check all hydraulic pressure adjustments for proper setting.
4. Perform critical weld inspection
5. Perform dielectric tests
6. Inspect leveling system.
7. Daily, and 90 Days (360 Hours), and 180 Days (720 Hours) inspection.
5 YEAR (5,250 HOURS)
1. Remove leveling chain and leveling rods for inspection.
2. Daily, 90, 180 and 12 month inspection.
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LUBRICATION CHART
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SYNTHETIC ROPE INSPECTION

The synthetic rope must be inspected daily for any deterioration, resulting in appreciable loss of strength,
such as described below.
1. Excessive external roughness.
2. Glossy or glazed areas, which indicates heat damage.
3. Look for flat areas, bumps, or lumps, which indicates core or internal damage.
4. Cut or badly frayed strands.
5. Areas of discoloration, which could be caused by chemical contamination.
6. Stiffness, which would indicate excessive dirt or grit embedded or shock load damage.
7. Open the strands and look for powdered fibers, which means there is internal wear.
8. Inspect eye connection for proper weaving and damage.
If any of the above conditions are found it should be reported to a qualified person to determine if the
synthetic rope should remain in service. Further information can be found in the maintenance manual for
determining the replacement of the synthetic rope.
If there is any doubt or question about the condition of the synthetic rope -replace it!
HOOK INSPECTION
The load line hook and safety latch must be inspected daily. Any hooks showing defects shall be discarded.
Field repairs by welding or re-shaping shall not be permitted.
•Any damaged hook safety latch shall be replaced immediately.
•Any hook or fitting with a crack or distortion shall be removed from service immediately.
•Hook nut (if equipped) should be checked for corrosion or deformation.
•Refer to hook manufacturer for more specific inspection instructions.
Hook latches are to be used only as retention devices to retain loose rigging under
slack conditions. They are not intended to be anti-fouling devices and caution must
be exercised to prevent a latch from supporting any portion of a load. Periodic
inspection of the latch must be made to insure it’s proper operating condition. If
damage to the latch occurs, the latch must be replaced immediately.
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STORAGE PROCEDURE
When a unit will not be used for a period of time, it should be prepared for storage to reduce the deteriorating
effects of the environment. This includes the following:
• Wash and clean to remove accumulated road grime. It can discolor the paint if left on for long periods
of time.
• Clean and wax the fiberglass components. If storage is in the sun, cover the booms.
• Clean and coat the exposed cylinder rods with grease, preservative spray or heavy preservative oil.
• Clean and grease the exposed valve spools and linkage.
• Lubricate the entire Aerial Device following the lube chart.
• Check the oil for pH level and water content. Acidic oil or water in the oil may settle out during storage
and can rust the interior of the hydraulic system.
• Cover the platform to prevent water from accumulating. A platform full of water can weigh over 900 lbs.
and exceed the capacity of the platform.
• Ensure the hydraulic tank filler-breather filter is intact to prevent dirt entering the tank when the
temperature changes.
• Grease all sliding surfaces where there is metal contact to prevent rust.
• Touch up any bare metal and where the paint is chipped or cracked.
• Spray the electric collector commutators with LPS 1 or CRC 5-56 to prevent corrosion of the surface.
• Service the truck as recommended by the manufacturer.
NOTE: The period of time between uses when the unit should be prepared for storage varies
with the location. If the climate is temperate and dry it may be 4 months. If it is in a humid
area next to the ocean with the salt air it may be only 2 weeks.
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APPENDIX - A
APPENDIX A
Table of Contents
APPENDIX - A
STANDARDS AND REGULATIONS
In addition to the operational instructions provided herein, various standards and governmental regulations
must be followed in the use and operation of your TEREX TELELECT unit.
ANSI STANDARDS
ANSI standards that are applicable to the operation and maintenance of your unit:
1. ANSI A92.2 (latest revision) Vehicle Mounted Elevating and Rotating Aerial Devices
2. ANSI A10.31 (latest revision) Digger Derricks - Safety Requirements, Definitions and Specifications (A
partial extraction is included in this appendix)
3. ANSI C2, Part 4 (latest revision) (National Electric Safety Code®) Rules for the Operation of Electric
Supply and Communication Lines and Equipment
4. ANSI Z133.1 (latest revision) Safety Requirements for Tree Pruning, Trimming, Repairing, or Removal
For complete, current copies of ANSI standards, you must annually write to the following:
American National Standards Institute
11 West 42nd Street
New York, NY 10036
Copies of the standards can also be found on the Internet at: www.ansi.org
OSHA REGULATIONS
OSHA regulations that are applicable to the operation and maintenance of your unit:
1. OSHA Subpart V, Power Transmission and Distribution
2. OSHA 1910.67, Vehicle Mounted Elevating and Rotating Aerial Devices
3. OSHA 1910.268, Telecommunications
4. OSHA 1910.269, Electrical Power Generation, Transmission and Distribution
5. OSHA Subpart M, Fall Protection
6. OSHA 1910.147, The Control Of Hazardous Energy (Lockout/Tagout)
7. OSHA Subpart S, Electrical
8. OSHA 1910.333, Selection and use of work practices
For complete, current copies of OSHA regulations, you must annually write to the following or contact your
OSHA Regional Office.
Technical Data Center
Frances Perkins Department Of Labor Building
Room N2439
200 Constitution Avenue
Washington, DC 20210
Copies of the standards can also be found on the Internet at:

www.osha.gov.
These are not all inclusive of the applicable codes, standards, or regulations. It is your responsibility and
your employer's responsibility to identify and comply with applicable codes, standards and regulations.
The information provided herein is accurate as of the date your TEREX TELELECT unit was manufactured.
You must comply with the codes, standards and regulations as they are updated over time. It is your
employer's responsibility to obtain copies and comply with all tests referenced.
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APPENDIX - A
APPENDIX A
Table of Contents
OSHA EXCERPTS: (CLEARANCE DISTANCE)

The following are excerpts from OSHA Standards. They are not complete and do not cover all safety work
rules.
Partial excerpt from Subpart S - Electrical: (02-01-1998 Edition)
1910.333 Selection and use of work practices.
(c), (i) Unqualified person.
(A) When an unqualified person is working in an elevated position near overhead lines, the location shall be
such that the person and the longest conductive object he or she may contact cannot come closer to any
unguarded, energized overhead line than the following distances:
1. For voltages to ground 50kV or below - 10 feet (305 cm);
2. For voltages to ground over 50kV - 10 feet (305 cm) plus 4 inches (10cm) for every 10kV over 50kV.
(B) When an unqualified person is working on the ground in the vicinity of overhead lines, the person may
not bring any conductive object closer to unguarded, energized overhead lines than the distances given in
paragraph (c)(3)(i)(A) of this section.
NOTE: For voltages normally encountered with overhead power line, objects which do not have
an insulating rating for the voltage involved are considered to be conductive.
Excerpt from OSHA subpart V - Power Transmission and Distribution (11-14-1990 Edition)
1926.950 General Requirements (c) Clearances. The provisions of paragraph ©(1) or (2) of this section shall
be observed.
(1) No employee shall be permitted to approach or take any conductive object without an approved
insulating handle closer to exposed energized parts than shown in Table V-1, unless:
(i) The employee is insulated or guarded from the energized part (gloves or gloves with sleeves rated for the
voltage involved shall be considered insulation of the employee from the energized part), or
(ii) The energized part is insulated or guarded from him and any other conductive object at different
potential, or
(iii) The employee is isolated, insulated, or guarded from any other conductive object(s), as during live-line
bare-hand work.
(2) (i) The minimum working distance and minimum clear hot stick distances stated in Table V-1 shall not be
violated. The minimum clear hot stick distance is that for the use of line-line tools held by lineman when
performing live-line work.
(e)(15) The minimum clearance distances for live-line bare-hand work shall be as specified in Table V-2.
These minimum clearance distances shall be maintained from all grounded objects and from lines and
equipment at a different potential than that to which the insulated Aerial Device is bonded unless such
grounded objects or other lines and equipment are covered by insulated guards. These distances shall be
maintained when approaching, leaving and when bonded to the energized circuit.
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APPENDIX - A
APPENDIX A
Table of Contents
NOTE: Table V-1 - 1For 345-362kv, 500-552kvand 700-765kv, the minimum working distance and
the minimum clear hot stick distance may be reduced provided that such distances are
not less than the shortest distance between the energized part and a grounded surface.
NOTE: Table V-2 - 1For 345-362kv, 500-552kv and 700-765kv, the minimum clearance distance
may be reduced provided the distances are not made less than the shortest distance
between the energized part and a grounded surface.
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APPENDIX - A
APPENDIX A
Table of Contents
STANDARD HAND SIGNALS
HOIST. With forearm vertical, LOWER. With arm extended RAISE BOOM. Arm LOWER BOOM. Arm
forefinger pointing up, move downward, forefinger extended, fingers closed extended, fingers closed,
hand in small horizontal pointing down, move hand in thumb pointing upward. thumb pointing downward.
circles. a small horizontal circle.
MOVE SLOWLY. Use one RAISE THE BOOM AND LOWER THE BOOM AND SWING. Arm extended, point
hand to give any motion LOWER THE LOAD. With LOER THE LOAD. With are finger in direction of swing of
signal and place other hand arm extended, thumb extended, thumb pointing boom.
motionless in front of hand pointing up, flex fingers in down, flex fingers in and out
giving the motion signal. and out as long as load as long as load movement is
movement is desired. desired.
STOP. Arm extended, palm EMERGENCY STOP. Both EXTEND BOOM. RETRACT BOOM.
down, move arm back and arms extended, palms down, (Telescoping Booms). Both (Telescoping Booms). Both
forth horizontally. move arms back and forth fists in front of the body with fists in front of the body with
horizontally. thumbs pointing outward. thumbs pointing toward each
other.
EXTEND BOOM. RETRACT BOOM.

(Telescoping Booms). One (Telescoping Booms). One
Hand Signal. One fist in front Hand Signal. One fist in front
of chest with thumb tapping of chest with thumb pointing
chest. outward and heel of fist
tapping chest.
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APPENDIX - B
APPENDIX B
Table of Contents
APPENDIX - B
RESPONSIBILITIES
ANSI A92.2-2001 (PARTIAL)
Table of Contents:
7. Responsibilities of Dealers and Installers B-1
8. Responsibilities of Owners B-2
9. Responsibility of Users. B-5
10. Responsibilities of Operators B-6
11. Responsibilities of Renters, Lessors or Lessees B-7
7. Responsibilities of Dealers and Installers

7.1 General Responsibilities. Each dealer or installer as applicable shall comply with the requirements of
this section.
7.2 Vehicle Specifications. Each dealer or installer, or both, who sells an Aerial Device shall inform the
owner or user, or both, of the manufacturer’s minimum vehicle specifications.
7.3 Vehicle Weight Distribution. The installer shall be responsible for the weight distribution of the
completed mobile unit in accordance with the requirements of the Aerial Device and the applicable
regulations. Allowance shall be made for the weight of readily removable tools and material specified by the
user.
7.4 Manuals. Upon delivery of the equipment to the owner or user, the dealer or installer shall provide the
manuals as required by Paragraph 6.4 of this standard and manuals for auxiliary equipment added by the
installer.
7.5 Installations. The installer shall comply with Sections 5 and 6 of this standard relating to proper
installation and shall follow the instructions of the manufacturer. In the event the original manufacturer no
longer exists, an equivalent entity may provide these instructions. The installer of an Aerial Device shall,
before the mobile unit is placed in operation, perform stability tests in accordance with the requirements of
4.5.1 and 4.5.2, the operational and visual tests in accordance with the requirements of 6.6.1 and 6.6.2and
the appropriate electrical tests required in 5.4.3 of this standard. The installer shall, when installing an Aerial
Device on a chassis which is a highway vehicle, comply with all requirements of the applicable Federal
Motor Vehicle Safety Standards in effect at the time of installation. Certification as a manufacturer
(alteration, intermediate or final) of a motor vehicle under the Federal Motor Vehicle Safety Standards is
required. The travel height of the mobile unit shall be posted in a location that is readily visible to the vehicle
operator. For insulated Aerial Devices, the installer shall assure conformance to the Qualification test
requirements of 5.3.2 by either obtaining certification of the test and performing a periodic test after
installation, or by performing the Qualification test.
7.6 Quality Assurance. The installer shall have a documented quality assurance program which will ensure
compliance with this standard.
7.7 Welding. All welds made by the installer, whose failure could result in motion of the platform(s) shall
meet the Structural Welding Code AWS D1.1-98 and AWS Dl.2-98. The installer shall establish applicable
welding quality assurance procedures for all weldments.
7.8 Training. The dealer or installer shall offer training or training materials that aid owners and users in the
operation, inspection, testing and maintenance of the Aerial Device. This training shall be offered initially
and subsequently on request.
7.8.1 Dealer or Installer as User. Whenever a dealer or installer directs personnel to operate an Aerial
Device (inspecting, sales demonstrations, or any form of use), the dealer or installer shall assume the
responsibilities of users as specified in Section 9 of this standard. All personnel authorized to operate the
Aerial Device shall have been trained.
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APPENDIX - B
APPENDIX B
Table of Contents
8. Responsibilities of Owners
8.1 General Responsibilities. Each owner shall comply with the requirements of this section. The following
responsibilities pertain to the owner’s inspection, testing, maintenance, modification, training and transfer of
ownership. These activities shall be performed by qualified person(s).
8.2 Inspection and Testing Classifications.
8.2.1 Initial Inspection and Test. Prior to initial use, all new or modified mobile units shall be inspected and
tested to ensure compliance with the provisions of this standard. Verification by the manufacturer, the
installer or an equivalent entity(s), meets this requirement.
8.2.2 Regular Inspection and Tests. The inspection procedure for mobile units is divided into two
classifications based upon the intervals at which inspections and tests shall be performed. Intervals shall be
set by the owner in accordance with the manufacturer’s recommendations. Such intervals are dependent
upon component function and exposure to wear, deterioration and other agents which adversely affect
component life. Two classifications are designated:
(1) Frequent Inspection and Test: Daily to monthly intervals.
(2) Periodic Inspection and Test: One to twelve month intervals.
8.2.3 Frequent Inspection and Test. Items determined by the owner in accordance with the manufacturer’s
recommendations for each specific Aerial Device shall be inspected for defects. The following tests and
inspections shall be performed by the operator once daily, prior to first use:
(1) Operating controls and associated mechanisms for conditions interfering with proper operation.
(2) Visual and audible safety devices for malfunction.
(3) Hydraulic or pneumatic systems for observable deterioration or excessive leakage.
(4) Fiberglass and other insulating components for visible damage or contamination.
(5) Missing or illegible operational and instructional markings.
(6) Electrical systems of/or related to the Aerial Device for malfunction, signs of excessive deterioration, dirt
and moisture accumulation.
(7) Visual inspection of bolts, pins and other fasteners for loose, deformed or missing fasteners and other
locking devices.
Any suspected items shall be carefully examined or tested and a determination made by a qualified person
as to whether they constitute a safety hazard.
All unsafe items shall be replaced or repaired before use.
8.2.4 Periodic Inspection or Test. An inspection of the mobile unit shall be performed at the intervals
defined in 8.2.2 depending upon its activity, severity of service and environment, or as specifically indicated
below. (These inspections shall include the requirements of 8.2.3):
(1) Structural members for deformation, cracks or corrosion.
(2) Parts, such as pins, bearings, shafts, gears, rollers, locking devices, chains, chain sprockets, wire and
synthetic ropes and sheaves for wear, cracks or distortion.
(3) Hydraulic and pneumatic relief valve settings.
(4) Hydraulic system for proper oil level.
(5) Hydraulic and pneumatic fittings, hoses and tubing for evidence of leakage, abnormal deformation or
excessive abrasion.
(6) Compressors, pumps, motors and generators for loose fasteners, leaks, unusual noises or vibrations,
loss of operating speed and excessive heating.
(7) Hydraulic and pneumatic valves for malfunction and visible cracks in the external valve housing, leaks
and sticking spools.
(8) Visually inspect any vacuum prevention systems and verify function of such systems on Category “A”
Aerial Devices.
(9) Hydraulic and pneumatic cylinders and holding valves for malfunction and visible damage.
(10) Hydraulic and pneumatic filters for cleanliness and the presence of foreign material in the system
indicating other component deterioration.
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APPENDIX - B
APPENDIX B
Table of Contents
(11) Electrical systems and components for deterioration or wear including those not readily visible on a
frequent inspection.
(12) Performance test of all boom movements.
(13) Condition and tightness of bolts and other fasteners.
(14) Welds, as specified by the manufacturer.
(15) Legible and proper identification, operational and instructional markings.
(16) If the Aerial Device is rated as an insulated device, the electrical insulating components and system(s)
shall be thoroughly inspected for lack of cleanliness and other conditions that compromise insulation. Then
these components and system(s) shall be tested for compliance with the rating of the Aerial Device in
accordance with one of the applicable methods and procedures as outlined in section 5.4.3 of this standard:
(a) If the Aerial Device is used for AC bare-hand work, the unit shall undergo a 60 Hz test as shown in Table
2 at least every three years; (b) If the Aerial Device is used for DC bare-hand work, the unit shall undergo a
DC test as shown in Table 2 at least every three years; (c) After repair or modification of any component that
crosses the insulating system(s), or the repair or replacement of an insulating component(s), the unit shall
be dielectrically tested in accordance with section 5.4.3; (d) An insulated replacement boom shall be tested
to insure conformance to 5.3.3 by the supplier; (e) Bare-hand work units shall be tested as shown in Table l
after any major repair to the insulated boom or any insulated boom replacement.
as to whether they constitute a safety hazard. All unsafe items shall be replaced or repaired before use.
8.3 Inspection and Test Records.
(l) Items to be inspected shall be designated to the operator or other authorized person making frequent
inspections. Records of frequent inspections need not be made. However, where a safety hazard is found, it
shall be reported in writing to a person responsible for the corrective action and that report and a record of
the correction shall be maintained for five years, or as required by applicable regulations.
(2) Written, dated and signed reports and records shall be made of periodic inspections and tests and
retained for a period of five years or as required by applicable regulations.
8.4 Maintenance. Maintenance and frequency of maintenance shall be determined by the owner in
accordance with the manufacturer’s recommendations.
Welding repairs of components or welds, designated as critical in the manufacturers manual, shall be made
in accordance with the manufacturers recommendations.
Should the original manufacturer no longer exist an equivalent entity may determine the required procedure.
8.4.1 Maintenance Training. The owner shall train their maintenance personnel in inspection and
maintenance of the Aerial Device in accordance with the manufacturer’s recommendations and Section 8 of
this standard.
8.5 Modifications. No modifications or additions which affect the stability, mechanical, hydraulic, or
electrical integrity or the safe operation of the Aerial Device shall be made without the written approval of the
manufacturer. If such modifications or changes are made, the capacity, operation and maintenance
instruction markings shall be changed accordingly. In no case shall the safety factors be reduced below
those specified in this standard or below the manufacturers design safety factors, whichever are greater.
Should the original manufacturer no longer exist, an equivalent entity may approve required modification.
8.6 Weight Distribution. Changes in loading or additions made to the mobile unit after the final acceptance
that affect weight distribution shall meet applicable regulations by governmental agencies. In no case shall
axle loads of the fully loaded vehicle exceed the Gross Axle Weight Ratings (GAWR) assigned by the
manufacturer. Note: Any change in weight distribution may adversely affect stability.
8.7 Transfer of Ownership. When a change in ownership of an Aerial Device occurs, it shall be the
responsibility of the seller to provide the manufacturer's manual(s) for that Aerial Device to the purchaser.
It is the responsibility of the purchaser to notify the manufacturer of the unit model and serial number and the
name and address of the new owner within 60 days.
8.8 Markings. The markings on the Aerial Device shall not be removed, defaced, or altered. All missing or
illegible markings shall be promptly replaced.
8.9 Parts. When parts or components are replaced they shall be identical in specification and function
to the original Aerial Device parts or components or shall provide an equal or greater factor of safety.

APPENDIX - B
APPENDIX B
Table of Contents
8.10 Safety Bulletins. Owners shall comply with safety related bulletins as received from the manufacturer,
dealer or installer.
8.11 Manuals. The owner shall insure that the operating manual(s) is stored on the mobile unit.
8.12 Training, Retraining and Familiarization of Operators.
8.12.1 Owner as a Renter or Lessor. When an owner functions as a renter or lessor he shall have the
same responsibilities as specified under Section 11 of this standard.
8.12.2 General Training. Only personnel who have received general instructions regarding the inspection,
application and operation of Aerial Devices, including recognition and avoidance of hazards associated with
their operation, shall operate an Aerial Device. Such items covered shall include, but not necessarily be
limited to, the following issues and requirements:
(1) The purpose and use of manuals.
(2) That operating manuals are an integral part of the Aerial Device and must be properly stored on the
vehicle when not in use.
(3) A pre-start inspection.
(4) Responsibilities associated with problems or malfunctions affecting the operation of the Aerial Device.
(5) Factors affecting stability.
(6) The purpose of placards and decals.
(7) Workplace inspection.
(8) Applicable safety rules and regulations, such as Part 4, ANSI C2-1997, National Electrical Safety Code
(applies to utility workers as defined in ANSI C2). The above standard is an example; other industries using
Aerial Devices have safety rules pertinent to that industry.
(9) Authorization to operate.
(10) Operator warnings and instructions.
(11) Actual operation of the Aerial Device.
Under the direction of a qualified person, the trainee shall operate the Aerial Device for a sufficient period of
time to demonstrate proficiency in the actual operation of the Aerial Device.
(12) Proper use of personal fall protection equipment
8.12.3 Retraining. The operator shall be retrained, when so directed by the user, based on the user’s
observation and evaluation of the operator.
8.12.4 Familiarization. When an operator is directed to operate an Aerial Device he/she is not familiar with,
the operator, prior to operating, shall be instructed regarding the following items and issues:
(1) The location of the manuals.
(2) The purpose and function of all controls.
(3) Safety devices and operating characteristics specific to the Aerial Device.
9. Responsibility of Users
9.1 General Responsibilities. Each User shall comply with the requirements of this section.
9.2 Personnel. Only trained and authorized personnel shall be permitted to operate the Aerial Device.

APPENDIX - B
APPENDIX B
Table of Contents

(8) Applicable safety rules and regulations, such as Part 4, ANSI C2-1997, National Electrical Safety Code.
(12) Proper use of personal fall protection equipment.
9.4 Application. The employer and assigned operator shall insure that the Aerial Device is used only for
intended applications as defined in the operating manual and that recognized safety practices are observed.
9.5 Mobile Operation. Before and during driving, the driver shall:
(1) Avoid traveling on any surface that adversely affects vehicle stability.
(2) Maintain a safe distance from obstacles and over-head lines.
(3) Maintain communications between the driver and the operator.
(4) Under all travel conditions, the driver shall limit travel speed in accordance with conditions of the ground
surface, congestion and slope.
9.6 Alterations. Altering or disabling of safety devices, guards, or interlocks if so equipped shall be
prohibited.
9.7 Bare-Hand Work. For bare-hand work, a Category “A” Aerial Device shall be used.
9.8 Lower Controls. The lower controls of Aerial Devices shall not be used for continuous operation with
personnel in the platform.
10. Responsibilities of Operators
10.1 General Responsibilities. Each operator shall comply with the requirements of this section.
10.2 Operation. During operation of the Aerial Device all platform occupants shall use appropriate fall
protection connected to the Aerial Device at the platform position.
10.3 Work Platform. The operator shall not use railings, planks, ladders or any other device in or on the
work platform for achieving additional working height or reach.
10.4 Brakes. The vehicle parking brake(s) shall be set at all times that the boom is elevated except when
the Aerial Device is being used in accordance with 9.5.
10.5 Loading. Any loading which includes a horizontal load shall be avoided unless the mobile unit is
designed for that application.
10.6 Observations. Observations during operation for any defects shall be conducted on an ongoing basis.
10.6.1 Pre-start Inspection. Items determined by the owner in accordance with the manufacturer’s
recommendations for each specific Aerial Device shall be inspected for defects prior to each day’s
operation.

APPENDIX - B
APPENDIX B
Table of Contents
The following tests and inspections shall be performed by the operator once daily, prior to first use:
(1) Operating controls and associated mechanisms for conditions interfering with proper operation.
(2) Visual and audible safety devices for malfunction.
(3) Hydraulic or pneumatic systems for observable deterioration or excessive leakage.
(4) Fiberglass and other insulating components for visible damage or contamination.
(5) Missing or illegible operational and instructional markings.
(6) Electrical systems of/or related to the Aerial Device for malfunction, signs of excessive deterioration, dirt
and moisture accumulation.
(7) Visual inspection of bolts, pins and other any other fasteners for loose, deformed or missing fasteners
and other locking devices.
as to whether they constitute a safety hazard. All unsafe items shall be replaced or repaired before use.
10.7 Worksite. Before the Aerial Device is used the worksite shall be surveyed for hazards such as:
(1) Untamped earth fills.
(2) Ditches.
(3) Drop-offs and floor obstructions.
(4) Debris.
(5) Overhead obstructions and electrical conductors.
(6) Weather conditions.
(7) Presence of unauthorized persons.
10.8 Precautions. Before and during each use the operator shall:
(1) Check for overhead obstructions and electrical conductors.
(2) Insure that the load on the platform and/or load lifting devices are in accordance with the manufacturer's
rated capacity.
(3) Insure that outriggers and stabilizers are used if the manufacturer's instructions require their use.
(4) Insure that guardrails are properly installed and the gates are closed.
(5) Use outrigger pads when necessary to provide firm footing.
10.9 Mobile Operation. Before engaging in mobile operation the operator shall determine that the Aerial
Device is specifically designed for mobile operation.
10.10 Personnel. Only trained and authorized personnel shall be permitted to operate the Aerial Device.

APPENDIX - B
APPENDIX B
Table of Contents

10.11.3 Familiarization. When an operator is directed to operate an Aerial Device he/she is not familiar
with, the operator, prior to operating, shall be instructed regarding the following items and issues:
11. Responsibilities of Renters, Lessors or Lessees
11.1 General Responsibilities. Each renter or lessor or lessee shall comply with the requirements of the
applicable section or sections below.
11.1.1 Lessor or Lessee as Dealer or Installer. When a lessor or lessee uses the Aerial Device as a
dealer or installer he shall have the same responsibilities as specified under Section 7 of this standard.
11.1.2 Lessor or Lessee as Owner. When a lessor or lessee uses the Aerial Device as an owner he shall
have the same responsibilities as specified under Section 8 of this standard.
11.1.3 Lessor or Lessee as User. When a lessor or lessee uses the Aerial Device as a user he shall have
the same responsibilities as specified under Section 9 of this standard.
11.1.4 Lessor or Lessee as Operator. When a lessor or lessee uses the Aerial Device as an operator he
shall have the same responsibilities as specified under Section 10 of this standard.
11.2 Ownership Duties. The renter or lessor shall carry out the duties of ownership specified in this
standard which are not assigned to the renting entity or lessee as the user.
11.3 Obligations. Upon delivery each renter or lessor of an Aerial Device shall provide the operators
manual and the ANSI/SIA A92.2-xxx Manual of Responsibilities for dealers, owners, users, operators,
lessors and lessees of Vehicle Mounted Elevating and Rotating Aerial Devices. These manuals shall be
stored on the mobile unit.
11.4 Training. The renter or lessor shall offer training or training materials that aid the renting entity or
lessee in the operation, inspection, testing and maintenance of the Aerial Device. This training shall be
offered initially and subsequently on request.
11.4.1 General training. Only personnel who have received general instructions regarding the inspection,
(applies to utility workers as defined in ANSI C2). The above standard is an example; other industries
using Aerial Devices have safety rules pertinent to that industry.

APPENDIX - B
APPENDIX B
Table of Contents

11.5 Communications. In the event the manufacturer or installer provides the renter or lessor manuals,
bulletins, or other materials for the information of the user of an Aerial Device, the renter or lessor shall pass
them on to the user without any undue delay.

APPENDIX - B
APPENDIX B
Table of Contents
SURVEY OF JOB SITE

Appendix (This Appendix is not part of American National Standard A92.2-2001 - but is included for
information only.)
Construction and electrical workers are subject to certain hazards that cannot be eliminated by mechanical
means and must be controlled by care, common sense and intelligence. TEREX TELELECT realizes the
importance of safety and strongly recommends that prior to commencing any operation, the employer make
a survey of the conditions of the site to determine the hazards and the kind and number of safeguards that
the employer will install.
The survey should include, but not be limited to, the following:
(1) Safe access and movement
(a) Work areas
(b) Walkways, runways and passageways
(c) Ladders, stairways and elevators
(d) Protection for floor and roof openings
(e) Illumination
(2) Vehicles
(a) Roads
(1) Turn space
(2) Parking area
(3) Mud areas
(b) Materials storage areas and dump areas
(c) Signs and signals to route vehicles on the job
(d) Maintenance and repairs of vehicles
(3) Utilities and service
(a) Location of temporary buildings
(b) Location and identification of high-voltage lines (identify by signs; move, de-energize or erect barrier
to prevent contact)
(c) Location of sanitary facilities and drinking water
(4) Scheduling work for safety
(a) Providing hard hats, life belts, goggles, work vests and the like on the job
(b) Establishing liaison among contractors to prevent congestion among trades
(c) Providing temporary flooring, safety nets and scaffolding where required
(5) Work Procedures
(a) Space
(b) Equipment such as cranes, hoists, elevators and trucks
(c) Rigging procedures
(d) Personal protective equipment
(6) Tools and equipment
(a) Repair, maintenance and care
(b) Inspection
(c) Supplies of tools for each job
(7) Workers and foremen
(a) Job assignment
(b) Training and supervision
(c) Number of workers

APPENDIX - B
APPENDIX B
Table of Contents
(d) Plans for maintaining interest in safety:

(1) Safety bulletins, record charts and posters
(2) Recognition for groups or individuals
(3) Investigation and reporting on reportable accidents
(4) Knowledge of safety orders
(5) Safety meetings
(6) Specific safety instructions for new employees
(e) Establishment of provisions to take immediate action to correct unsafe conditions or acts
(f) First aid and medical treatment of injuries

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What safety guidelines are outlined for operating the aerial device?

What safety guidelines are outlined for operating the aerial device?

Terex Telelect

PRINTED IN THE USA

TEREX TELELECT, INC.

46 32 00 - 09 /06 T e rex T ele le ct HR M S eri es

DAILY PRE-OPERATION CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 22

In addition to maintenance and operating instructions in this manual, the operator

GENERAL SAFETY GUIDELINES

ELECTRICITY OBEYS NO LAW, BUT ITS OWN.

20. Use only non-metallic tool holders and tool trays.

1. Never travel with personnel in the platform.

SAFETY RELATED DECALS

If any of these items are illegible or missing, replace them immediately.

WHAT IS INSULATED AND WHAT IS NOT INSULATED

The insulating boom section only prevents current

The boom tip is everything past the upper band of

Death or serious injury to the operator or ground

You must always cover the line and wear rubber

You must read the operators manual to fully

OPERATION ON OR NEAR ENERGIZED CONDUCTOR

JIB & WINCH

LOWER BOOM LOWER BOOM

CAB CONTROL OPERATION

POWER TAKE-OFF (OPTIONAL)

CAB CONTROL FUNCTIONS

Master Power Red light; when lit indicates master power is

PTO Light Red light; when lit indicates PTO is engaged.

Engine Stop/ Push and hold to start engine.

Can also be used to stop the Aerial

CONTROLS BELOW ROTATION

The Selector will function as an emergency stop by taking

CONTROLS BELOW ROTATION FUNCTIONS

Move handle “down” to lower outrigger.

2. Hydraulic Tools Return handle to center position to turn off.

Can also be used to stop the Aerial Device in an

The Selector will function as an emergency stop by

Move handle “down” to operate outrigger system.

OPERATOR CONTROLS AND DESCRIPTIONS

LIFT LOCK HANDLES

UNITS BUILT BEFORE 01-01-98 UNITS BUILT AFTER 01-01-98

SINGLE STICK FUNCTIONS

ITEM CONTROL DESCRIPTION

The Control Selector will function as an emergency stop

LOWER CONTROL FUNCTIONS

DEMAND THROTTLE (OPTIONAL)

Hydraulic oil is flammable.

PLATFORM TILTING OPERATION

Never allow personnel to be under loads being lifted.

HYDRAULIC JIB EXTENSION (OPTIONAL)

HYDRAULIC JIB EXTENSION (OPTIONAL) - EXTEND UNDER LOAD

DETERMINING LIFT CAPACITIES

AVOID TRAPPED LOOPS

PLATFORM ROTATOR OPERATION

PHASE LIFTERS (OPTIONAL)

BOOM LIFTING EYE MATERIAL HANDLING (OPTIONAL)

•Always extend the outriggers.

The platform shall not be used for material handling.