SELF PROPELLED BOOM LIFT SERVICE MANUAL
Contents
1. 4 9 m 0 to 3 0 m p h 0 to 4 83 km h Ford LRG 425 62 hp 46 2 kw water cooled gasoline dual fuel optional Deutz F3L1011 40 8 hp 30 0 kw air cooled diesel 25 gal 94 6 L Load sensing and pressure compensating 2 500 psi 172 BAR 38 gal 1441 12x 16 5 8 P R Mono 10 5 in 26 m 15 900 lbs 7212 kg 170 psi 11 95 kg sq cm 7350 lbs 3334 kg 25 m p h 40 23 km h 6 Beaufort 25 14 50 27 Clearance must be allowed for body parts for this and other work heights Page 2 12 TB42 TB50 TB60 TB66 TB85 TB100 TB110 Issued Jun 01 TEREX AERIALS LIP TIRES SERVICE MANUAL TB50 BOOM LIFT GENERAL DIMENSIONS 342 0 in G ROTATION 368 086 71 30 in 181 102 cm 270 7 in 687 578 cm my 48 0 in 121 92 cm 96 0 in 243 84 cm 129 0 in 827 66 cm 342 0 in 868 68cm 83 0 in 210 82 cm GA 10 5 in 26 67 cm 82 0 in 208 28 cm 95 0 in 241 3 cm Issued Jun 01 TB42 TB50 TB60 T B66 TB85 TB100 TB110 19 5 in 49 53 cm Page 2 13 TEREX AERIALS LIP TINGS SERVICE MANUAL TB50 BOOM LIFT RANGE DIAGRAM 60 ft 18 288 m 55 ft 16 764 m 50 ft 15 24 m 45 ft 13 716 m 40 ft 12 192 m 3 048 m 10 20 ft 30 ft 3 048 m 6 096 m 9 144 m 12 192 m 5 ft 5 ft 15 ft 25 tt 35 ft 45 ft 1 524 m 1 524m 4 572 m 7 62 m 10 668 m 13 716 m Page 2 14 TB42 TB2. 0 0 702 O O OO 7207 0 0 9 O O O O O O O O O O O O O O O e O O O Q O 0 TEREX AERIALS SERVICE MANUAL LIFTING MAINTENANCE SCHEDULE 4 WHEEL DRIVE TB44 SHOWN INSPECTION CRITERION IS TYPICAL FOR ALL MODELS 10 11 12 13 10 11 12 13 4 5 24 4 5 24 10 11 12 13 10 11 12 13 3 4 42 50 60 1 66 85 100 1 110 Issued Jun 401 gt TEREX AERIALS LIP TIRES SERVICE MANUAL MAINTENANCE SCHEDULE DESCRIPTION SERVICE FUNCTION FREQUENCY BATTERY ENGINE CHECK DAILY App ELECTROLYTE IF NECESSARY REFER TO MANUFACTURER S INSTRUCTIONS HYDRAULIC FLUID CHECK DAILY add only Dexron III or equivalent PIVOT BUSHINGS LUBRICATE MONTHLY 100 HOURS TYPE s PIVOT PIN RETAINERS CHECK DAILY secure SCREWS W LOC TITE 242 REFER TO TORQUE TABLE BOOM OPERATING CABLES POWER TRACK ASSEMBLY PLATFORM BOOM WEAR PADS TIRES amp WHEELS WHEEL BEARINGS LUBRICATE ANUALLY TYPE STEERING SPINDLES LUBRICATE MONTHLY 100 HOURS WHEEL NUTS CHECK DAILY RE TORQUE 40 HRS amp THEN 6 EVERY MOS ROTATION SLEW BEARING LUBRICATE MONTHLY 100 HOURS CHECK DAILY RE TORQUE 100 HRS OR EVERY 3 MOS REFER TO TORQUE PROCEDURE CHECK DAILY CHECK DAILY CHECK MONTHLY 100 HRS DRv LUBRICANTS ONLY NO GREASE CHECK DAILY N o fo o 2 4 mi lt MULTI PURPOSE GREASE EP 2 APPLY WHILE
3. TEREX AERIALS Kai SERVICE MANUAL SELF PROPELLED BOOM LIFT SERVICE MANUAL MODELS TB42 TB50 TB60 TB66 TB85 TB100 TB110 a ETIEX AERIALS TESO W E Terex Aerials 106 12th Street SE Waverly la 50677 9466 Phone 319 352 3920 Fax 319 352 5727 E mail waverly terexlifting com Issue date Jun 01 TEREX AERIALS LIP TINS SERVICE MANUAL WARNING IF OPERATION OF THIS MACHINE IS REQUIRED TO PERFORM SERVICE OR MAINTENANCE THEN THE OPERATOR MUST READ AND UNDER STAND ALL THE INSTRUCTIONS IN THE OPERATOR S MANUAL BEFORE OPERATING THE AERIAL LIFT DESCRIPTION SECTION NO CRT RE 1 GENERAL INFORMATION A 2 MAINTENANCE amp LUBRICATION NENNEN 3 TR ERT EE 4 TROUBLESHOOTING 5 SCHEMATIC asas 6 INDEX O 7 Issued Jun 01 TB42 TB50 TB60 T B66 TB85 T B100 TB110 Page 1 TEREX AERIALS LIFTING SERVICE MANUAL INTRODUCTION Owners Users and Operators Terex Aerials appreciates your choice of our machine for your application Our number one priority is user safety which is best achieved by our joint efforts We feel that you can make a major contribution to safety if you as the eguipment owners users and operators 1 Comply with OSHA Federal State and Local Regulations 2 Read Understand and Follow the instructions in this and other manuals supplied with this machine 3 Use Good
4. Explain any deficiencies found corrective action taken and identification of the person s performing the repair on the reverse side 30 Day Inspection o Yearly Inspection o Boom Lift Aticulated Boom o Owned o Engine S N Model Serial Number Hour Meter Date Delivered Boom Articulated Boom Inspection OK Not OK Platform Gate Latch Platform Gate amp Guard Rails Platform Floor amp Toe Plate Boom Pivot Pin Air Filter Engine Oil Torque Hub Drive Motor Brake Torque Ring Gear Bolts Boom Assembly Platform Rotator Tie Rod Pin Steering Yoke King Pins Steering Cylinder Fuel Tank Return Line Filter High Pressure Filter Hydraulic Reservoir Fluid Hydraulic Pump Hydraulic Valve Wheel Lug Nuts Boom Cable Equalizer Brackets Extend and Retract Cables Proximity Switches Boom Riser Lift Cylinder Pins Boom Riser Lift Cylinder Rotation Gear Box Power Track Hose Track Tires Decals Electric Wiring Hydraulic Hoses Wear Slide Pads Batteries Battery Tops Terminals and Cables Operator s Manual in Platform COPE gy P Coe e DN DN N NN DN 4 a 00 35 03 01 de NN O O S U O Ol NW 0 e te 6 O O 0700 0 O O OO O O O O OO OQ 0 10 00 Q O Q Ov O OO n Title Date N A
5. Safe Work Practices in a common sense way 4 Only have trained operators directed by informed and knowledgeable supervision running the machine 5 Only have gualified aerial lift mechanics perform the service and maintenance procedures provided in the Service and Maintenance Manual The information specifications vendor information and illustrations in this publication are based on the information available at the time of approval for printing Do to on going changes and revisions by our many suppliers it is often impossible to show all changes or variations We reserve the right to make changes at any time without obligation If there is anything in this manual that is not clear or which you believe should be added please send your comments to Customer Service Department Terex Aerials 106 12th Street Waverly lowa 50677 9466 or call 319 352 3920 or fax 319 352 5727 Thank you THIS SYMBOL MEANS YOUR SAFETY IS INVOLVED READ UNDERSTAND AND FOLLOW ALL DANGER WARNING AND CAUTION DECALS ON YOUR MACHINE Page 2 TB42 TB50 TB60 TB66 TB85 TB100 TB110 Issued Jun 01 TEREX AERIALS LIP TINS SERVICE MANUAL INTRODUCTION Aerial lift longevity and low cost performance depend on Periodic Maintenance Trouble shooting and proper Service and Adjustment procedures It is the responsibility of the owner user and operator to detect any unusual sounds odors or other signs of abnormal performance tha
6. 3 048 m 0 0 m 3 048 m 6 096 m 9 144 12 192 2 10 TB42 TB50 TB60 TB66 TB85 TB100 TB110 Issued Jun 01 gt TEREX AERIALS LIP TRS SERVICE MANUAL NOTES Issued Jun 01 42 50 60 66 85 100 110 2 11 TEREX AERIALS LIP TINGS SERVICE MANUAL SPECIFICATIONS TB50 Working Height Maximum Platform Height Maximum Stowed Height Length stowed Width Platform Dimensions 6 ft Horizontal Reach Boom Angle Above horizontal 75 Below horizontal 16 Platform Capacity Maximum weight Rated Number of Occupants Wheelbase Wheel Track Tailswing Turret Rotation Turning Curb Radius Travel Speed Power Source standard optional Fuel Tank Capacity Hydraulic System Max operating pressure Reservoir Capacity Tires monofilled Ground Clearance Approximate Shipping Weight Approx Wheel Loading Maximum concentrated pressure Wheel Load Maximum Wind speed rating Gradeability approximate hard surface Two wheel drive Four wheel drive 56 ft O in 17 07 m 50 ft 0 15 24 m 7 ft 1 in 2 16 m 28 ft 8 5 in 8 75 7 ft 11 in 2 41 m 72 x36 in x 44 in 1 8x 0 91 x 1 12 43 ft O in 13 11 m 75 15 articulation 16 8 articulation 500 Ibs 227 kg Including Occupants 2 Occupants 8 ft O in 2 44 6 ft 10 in 2 08 m 33 in 0 84 m 360 continuous rotation 16 ft 0
7. 40 ft 50 ft 0 0 3 048 6 096 9 144 m 12 192 m 15 24 m Page 2 18 TB42 TB50 TB60 TB66 TB85 TB100 TB110 Issued Jun 01 TEREX AERIALS LIP TIG SERVICE MANUAL NOTES Issued Jun 01 TB42 TB50 TB60 T B66 TB85 TB100 TB110 Page 2 19 Page 2 20 TEREX AERIALS LIP TIRES SERVICE MANUAL SPECIFICATIONS TB66 Working Height Maximum Platform Height Maximum Stowed Height Length stowed Width Platform Dimensions 6 ft Horizontal Reach Boom Angle Above horizontal 75 Below horizontal 20 Platform Capacity Maximum weight 6 ft Rated Number of Occupants Wheelbase Wheel Track Tailswing Turret Rotation Turning Curb Radius Travel Speed Power Source standard optional optional Fuel Tank Capacity Hydraulic System Max operating pressure Reservoir Capacity Tires monofilled Ground Clearance Approximate Shipping Weight Wheel Loading Maximum concentrated pressure Wheel Load Maximum Wind speed rating Gradeability approximate hard surface Two wheel drive Four wheel drive 72 ft Oin 21 95 m 66 ft O 20 12 m 9 ft 3 2 82 28 ft 11 in 8 81 m 7 ft 11 in 2 41 m 72 in x 36 in x 44 in 1 8 x 0 91 x 1 12 57 ft 4 625 in 17 49 m 75 15 articulation 20 8 articulation 500 Ibs 227 kg Including Occuppants 2 Occupants 8 ft O in 2 44 m 6 ft 7 in 2 01 m 42 in 1 07 m 360 conti
8. ROTATING 15 INCREMENTS ROTATION GEAR BOX CHECK 100 OPERATING HOURS QUARTERLY ROTATION BEARING BOLTS CHECK DAILY secure SCREWS W LOC TITE 242 REFER TO BOLT TORQUE PROCEDURE INLET STRAINER INSPECT ANNUALY RETURN FILTER REPLACE 100 OPERATING HOURS QUARTERLY VALVE ASSEMBLY CHECK DAILY DRIVE MOTOR amp BRAKE CHECK DAILY secure SCREWS W LOC TITE 242 REFER TO TORQUE TABLE STEERING CYLINDER CHECK DAILY AERIAL CONTROLS CHECK DAILY GROUND CONTROLS CHECK DAILY HYDRAULIC INSTALATION CHECK DAILY ELECTRICAL WIRING CHECK DAILY DAILY INSPECTION REFER TO APPLICABLE OPERATORS MANUAL NI N Issued Jun 01 TB42 TB50 TB60 TB66 TB85 TB100 TB110 Page 3 5 TEREX AERIALS SERVICE MANUAL LIP TINGS MAINTENANCE PROCEDURES Air Cleaner The air cleaner should be checked and cleaned ona weekly basis To clean the air cleaner Loosen the clamp securing the cup to the air cleaner Remove the cup and clean out any dirt or foreign matter in the cup Reinstall the cup and tighten the clamp Coolant Level The coolant level must be checked daily The coolant level is checked at the coolant reservoir Ensure the coolant level is between the Full and Low marks the coolant reservoir while the engine is cool If the coolant level is near or below the Low mark add an equal amounts of antifreeze and water until the level is at the Full mark Do not add alcohol or methanol antifreeze Refer to the engine ma
9. adding engine oil The aerial lift owner should refer to the engine manufacturer s manual to select the proper oil to use Hydraulic Oil Check the hydraulic fluid level on a daily basis The oil level must be between the HIGH and LOW marks in the sight glass of the hydraulic tank Add fluid as needed through the filler neck on top of the hydraulic tank The hydraulic system was filled at the factory with NORTRAN Automatic Transmission Fluid equivalent DEXRON 1 Any oil used in this aerial lift s hydraulic System must meet the specifications of these two types of fluids ENGINE OIL Check the engine oil level on a daily basis The oil level must be within the SAFE level on the engine oil dipstick Add oil as needed in the filler cap on top of the engine Refer to the engine manufacturer s manual for the recommended type oil Issued Jun 01 TB42 TB50 T B60 TB66 T B85 TB100 TB110 Page 3 7 TEREX AERIALS SERVICE MANUAL LIP TINGS MAINTENANCE PROCEDURES HYDRAULIC SYSTEM HYDRAULIC RESERVOIR CHECK amp FILL Check the hydraulic oil level on a daily basis The oil level must be between the HIGH and LOW marks on the sight glass on the hydraulic tank Add oil as needed in the filler cap on top of the hydraulic tank Add oil as needed in the filler cap on top of the hydraulic tank Refer to the decal on the hydraulic reservoir for the type of hydraulic fluid used DO NOT MIX
10. corrective action This record also serves as a tool toward detecting problem areas and reanalyzing maintenance requirements Issued Jun 01 Pre Delivery o Machine Demo o Distributor Return To Terex Aerials Inc 10600 W Brown Deer Rd Milwaukee WI 53224 1520 AERIAL LIFT INSPECTION REPORT Delivery o Scissor Lift o Rental o Address Customer Machine Location Scissor Lift Inspection Controls Decals Operator s Manual in Platform Platform Gate Main Platform Deck Extendable Platform Deck Collars on Scissor Arm Pivot Pins Scissor Arms amp Bushings Lift Cylinder and Pins Wear Slide Pads Wheels amp Tires Wheel Lug Nuts Wheel Bearings Steering Brackets Steering Cylinder and Pins Drive Motors Battery Tops Terminals and Cables Batteries amp Charging System Electrical Wiring Proximity Switches Hydraulic Valve Hydraulic Pump amp Motor Hydraulic Reservoir Fluid Hydraulic Fluid Return Filter Hydraulic Hoses Hydraulic Fluid Inlet Strainer Fuel Filter Engine Oil Fuel Tank Engine F OD TO O m m N N N N N N 4 4 4 4 4 S LENON ON O EG m N o or wv P Inspected by OK OLO Or O Q O0 00 O O O O 009 OF Or Ov 0 09 0 0 0 0000000 0000000000000 o o NotOK N A Q O O 30 Or Or OF 0 0 10 10 o O O gt GQ 201 G Or Os Ov 07 10 OF O
11. on for prolonged periods of time period of storage 5 If the batteries are to be removed for storage SHORT TERM STORAGE 30 DAYS OR LESS disconnect the charger from the batteries Short term storage requires minimal preparation and clean and tape the battery cables The AERIAL LIFT should be thoroughly cleaned 6 Fill the hydraulic reservoir to the top AF7ER lubricated in accordance with Section 3 and paint THE MACHINE IS PARKED IN ITS STORAGE ed surfaces retouched where the paint has deterior SPOT ated Exposed portions of all hydraulic cylinders should be coated with multipurpose grease Coat 7 Coat exposed cylinder rods with grease unpainted metal surfaces with multipurpose grease after removing any rust accumulations RESTORING AERIAL LIFT TO SERVICE LONG TERM STORAGE 30 DAYS OR MORE Remove the AERIAL LIFT from storage via the following procedure Long term storage requires greater preparation than short term storage and must be undertaken with 1 Remove preservative lubricants from all greater care surfaces The MACHINE should be prepared as follows 2 Check all fluid levels adding or draining as required 1 Perform the short term machine storage preparation making certain that ALL points with grease fittings 3 If the batteris have been removed for storage are liberally lubricated then install the batteries and reconnect the battery charger 2 Drain and refill the hydraulic reservoir Refer to Section 3 wh
12. p h 0 to 4 83 km h Ford LRG 425 62 hp 46 2 kw water cooled gasoline dual fuel optional Cummins 4B3 7 L 76 hp 56 7 kw water cooled diesel Deutz F3L1011 40 8 hp 30 0 kw air cooled diesel 40 gal 151 L Load sensing and pressure compensating 2 500 psi 172 BAR 52 gal 197 L 15 x 19 5 13 P R Loader Lug 10 0 in 0 25 m 23 000 Ibs 10443 kg 170 psi 11 95 kg sq cm 7350 Ibs 3334 kg 25 m p h 40 23 km h 6 Beaufort 30 16 50 27 Clearance must be allowed for body parts for this and other work heights TB42 TB50 T B60 T B66 TB85 T B100 TB110 Issued Jun 01 TEREX AERIALS SERVICE MANUAL TB60 BOOM LIFT GENERAL DIMENSIONS UPDATE ILLUSTRATION 26ft 1 25 in 7 96 m E ROTATION 90 0 in 0 in 223 5 n 228 6 cm 567 69 cm 95 5 in 242 57 cm Issued Jun 01 TB42 TB50 TB60 TB66 TB85 TB100 TB110 Page 2 17 4 TEREX AERIALS LIP TIG SERVICE MANUAL TB60 BOOM LIFT RANGE DIAGRAM 70 ft 21 336 m en ne 19 812 m 60 ft 18 288 m 55 ft 16 764 m 50 ft 15 24 45 ft 13 716 m 40 ft 12 192 m 35 ft 10 668 m 30 ft 9 144 m 25 ft 7 62 m 20 ft 6 096 m 15 ft 4 572 m 10 ft 3 048 m 5 ft 1 524 m O ft 0 0 m 5 TL 10 ft 3 048 m 5 ft 5 ft 15 ft 1 524 m 1 524 m 4 572 m 0 ft 10 ft 20 ft 30 ft
13. 50 TB60 TB66 TB85 TB100 TB110 Issued Jun 01 gt TEREX AERIALS LIP TIG SERVICE MANUAL NOTES Issued Jun 01 42 50 60 66 85 100 110 2 15 Page 2 16 TEREX AERIALS LIP TIG SERVICE MANUAL SPECIFICATIONS TB60 Working Height Maximum Platform Height Maximum Stowed Height Length stowed Width Platform Dimensions 6 ft 8 ft Horizontal Reach Boom Angle Platform Capacity Maximum weight 6 ft 8 ft Rated Number of Occupants Wheelbase Wheel Track Tailswing Turret Rotation Turning Curb Radius Travel Speed Power Source standard optional optional Fuel Tank Capacity Hydraulic System Max operating pressure Reservoir Capacity Tires monofilled Ground Clearance Approximate Shipping Weight Wheel Loading Maximum concentrated pressure Wheel Load Maximum Wind speed rating Gradeability approximate hard surface Two wheel drive Four wheel drive 66 ft Oin 20 12 m 60 ft O in 18 29 m 8 ft 6 in 2 59 m 26 ft 1 25 in 7 96 m 7 ft 11 in 2 41 m 72 in x 36 x 44 in 1 8 x 0 91 x 1 12 96 in x 36 in x 44 in 2 4 x 0 91 x 1 12 m 51 ft 4 625 in 15 66 m 20 to 75 above horiz plane 650 16 295 kg Including Occuppants 600 Ibs 272 kg Including Occuppants 2 Occupants 8 ft O in 2 44 m 6 ft 10 in 2 08 m 42 in 1 07 m 360 continuous rotation 16 ft 9 in 5 1 m 0 to 3 0 m
14. Continuous 160 F Intermittent 200 F 3 Oil Change Initial After 50 hours Preferably in a loaded condition Subsequent 1000 hours or 1 year whichever comes first Higher temperatures make it necessary to change oil more frequently 4 Oil Fill Level Remove fill plug Remove vent plug Pour oil into fill plug Fill to half full approximately 44 oz at a slow pace to allow air to escape WENT PLUG FILL FLLI _ LEVELS IG AT HOLE PARALLEL TO GROWN Issued Jun 01 TB42 TB50 TB60 TB66 TB85 TB100 TB110 Page 3 9 TEREX AERIALS SERVICE MANUAL LIFTING MAINTENANCE PROCEDURES BATTERY AVOID SERIOUS BURNS EXTREME CARE SHOULD BE USED WHEN HANDLING WORKING NEAR BATTTERIES Avoid Battery Hazards Batteries produce flammable and explosive gasses Keep electric arcs sparks flames and lit cigarettes pipes cigars etc away from batteries Battery acid will damage eyes or skin on contact Always wear a face shield during battery maintenance to avoid getting acid in eyes Always wear rubber gloves and protective clothing to keep acid off skin Never check the battery by placing a metal object across the posts Serious burns or an explosion can result Checking the Battery Electrolyte Level Check the colored eye in the top of the battery a green color indicates that battery electrolyte level is okay Water or Acid Loss to batteries Water loss from the battery occ
15. FLUIDS Any oil added in this aerial lift s hy draulic system must meet the specifications of the existing fluid HYDRAULIC SYSTEM RETURN LINE FILTER The hydraulic system return filter provided on a new aerial lift upon delivery is a 3 micron filter intended for use only during the initial break in cycle and MUST be replaced within a minimum of 25 hours The hydraulic system return line filter should be changed at minimum every 100 hours or quarterly Increasing the fre quency to a period less than the minimum interval will greatly enhance hydraulic system cleanliness To ensure cleanli ness during the break in period it is recommended that the hydraulic return filter be changed at a minimum interval of 50 hours for the first 150 to 200 hours of operation HYDRAULIC FILTER CHANGING Open the pet cock bleed screw on top of the filter head this will vent negative pressure in the return line to atmo sphere and minimize spillage Apply a thin film of clean hy draulic fluid to the seal of the new filter Screw the filter onto the filter head by hand until it can no longer be turned Wipe the area clean and close the pet cock valve Start the en gine operate a function and check for leaks Tighten the filter with the aid of a filter wrench only if any leaks appear DO NOT OVERTIGHTEN Page 3 8 TB42 TB50 T B60 T B66 T B85 T B100 TB110 HYDRAULIC SYSTEM BLEEDING The hydraulic system is self bleeding with the exception of
16. IBIO cr ra 2 30 SPECIFICATIONS TABLE ios 2 GENERAL DIMENSIONS 110 0 0 RANGE DIAGRAM DER ib Issued Jun 01 TB42 TB50 TB60 TB66 TB85 TB100 TB110 Page 2 7 Page 2 8 TEREX AERIALS LIP TINGS SERVICE MANUAL SPECIFICATIONS TB42 Working Height Maximum Platform Height Maximum Stowed Height Length stowed Width Platform Dimensions 6 ft 8 ft Horizontal Reach Boom Angle Platform Capacity Maximum weight 6 ft 8 ft Rated Number of Occupants Wheelbase Wheel Track Tailswing Turret Rotation Turning Curb Radius Travel Speed Power Source standard optional Fuel Tank Capacity Hydraulic System Max operating pressure Reservoir Capacity Tires monofilled Ground Clearance Approximate Shipping Weight Wheel Loading Maximum concentrated pressure Wheel Load Maximum Wind speed rating Gradeability approximate hard surface Two wheel drive Four wheel drive 49 ft 15 09 m 43 ft 13 26 m 7 ft 1 2 16 m 25 ft 10 75 in 7 89 m 7 ft 11 in 2 41 m 72 x 36 in x 44 in 1 8x 0 91 x 1 12 m 96 in x 36 in x 44 in 2 4 x 0 91 x 1 12 m 37 ft O in 11 27 m 16 to 759 above horiz plane 650 Ibs 295 kg Including Occuppants 600 Ibs 272 kg Including Occuppants 2 Occupants 8 ft O in 2 44 m 6 ft 10 in 2 08 m 33 in 0 84 m 360 continuou
17. ICE MANUAL SECTION 3 DESCRIPTION PAGE NO INTRODUCTION X ue ee 3 2 OWNER S INSPECTION RECORD 3 3 MAINTENANCE SCHEDULE 3 4 MAINTENANCE PROCEDURES 3 6 ENGINE Ze om eux 3 6 ENGINE amp HYDRAULIC OILS 3 7 HYDRAULIC SYSTEM uocem 3 8 TJORQUEHRUB BA 3 9 BATTERY gt lt XX og Bo hoe 3 10 Issued Jun 01 TB42 TB50 TB60 TB66 TB85 TB100 TB110 Page 3 1 TEREX AERIALS SERVICE MANUAL LIFTING INTRODUCTION INTRODUCTION In addition to the Before Operation Checks described in Section 5 a regular program of periodic preventive mainte nance is absolutely essential to prolonging the life of the aerial lift maximizing efficient service and minimizing down time This section details a series of checks and proce dures which are performed at daily weekly monthly and semiannual intervals Even if the operator is not directly responsible for mainte nance of the aerial lift he should perform daily all of the inspections listed in the Before Operation Check in sec tion 5 of the Operator s Manual NOTE Report and repair all deficiencies noted during the Before Operation Check The operator should be assured that the aerial lift has been properly maintained and in spected before operating it MAINTENANCE SCHEDULE The maintenance checks
18. REX AERIALS LIP TIG SERVICE MANUAL SECTION 2 GENERAL INFORMATION amp SPECIFICATIONS DESCRIPTION PAGE NO GENERAL SERVICE INFORMATION soisessa s de ibn 2 2 RECEIVING ANEW MACHINE oo tocino e to itta save 2 3 EXPORT PRESERVATIVE REMOVAL citas ca ati 2 3 MACHINE STORAGE 2 4 GEN CLEANING A PREP FOR COMPONENT OVERHALULL 2 5 WEEDING INSTRUCTIONS cesaci n orcos 2 6 SPECIFICATIONS 8 RANGE DIAGRAMS eene 2 7 TORQUE CHARTS QUICK REFERENCE 2 32 CAPSCREW OR BOLT REPLACEMEN 2 33 RECOMMENDED SPARE PARTS LIST eese 2 34 MAJOR COMPONENT IDENTIEICATION 2 40 GEREENT Ee 2 41 Issued Jun 01 TB42 TB50 TB60 TB66 TB85 TB100 TB110 Page 2 1 TEREX AERIALS LIP TINGS SERVICE MANUAL SECTION 2 GENERAL SERVICE INFORMATION Keep parts in order when large components are disassembled particularly so when it has a great number of similar parts Loosely reassembly assemblies whenever possible to prevent small parts from being lost Keep sub assembly parts together but be careful not to get right and left hand parts mixed up When an assembly is removed to correct only one difficulty it is good practice to recondition the whole assembly at that time to avoid repetition to work at a later date Bolts and nuts should be placed into their r
19. RVICE MANUAL SECTION 2 WELDING INSTRUCTIONS CAUTION When doing repair welding on your aerial lift take precaution attaching your ground to the component being repaired This will eliminate the chance of arcing hrough a bearing cylinder etc damaging the component Paint should be removed from the surface to be used as the ground earth ANI CAUTION Use necessary precaution when welding around fuel tanks oil reservoir batteris tubing and pressure systems When welding close to glass cylinder rods or any polished surface provide adeguate protection from splatter Always disconnect the battery cables and applicable grounds before welding If eguipped with an engine Page2 6 TB42 TB50 TB60 TB66 TB85 TB100 TB110 CAUTION Do not weld on wet surfaces since this will cause hydrogen embrittlement of the weld Always have fire extinguisher hand in case of fire Adequate ventilation and dry area are neces sary Protective clothing should be used and all persons in the welding area should have protection for their eyes AWS CLASS E7018 Low hydrogen rod for normal repairs on low alloy to medium carbon steel All position welding good penetration and crack resist ing up to 80 000 yield Also suitable for repair of previous intershield welds AWS CLASS E11018G Low hydrogen rod for repair on high strength alloy steel such as T 1 80 000 to 100 000 yield All positi
20. en servicing the reservoir 4 Perform all maintenance and lubrication of the aerial lift in accordance with the maintenance 3 Distribute the new hydraulic fluid to all parts of the chart on Pages 3 2 and 3 3 system by operating all functions Page 2 4 TB42 TB50 TB60 TB66 TB85 TB100 TB110 Issued Jun 01 TEREX AERIALS LIP TIG SERVICE MANUAL SECTION 2 GENERAL CLEANING INSPECTION AND PREPARATION FOR MAJOR COMPONENT OVERHAUL A Clean parts having ground and polished surfaces D To prevent corrosion parts that have been such as gears bearings and shafts with solvent cleaned and dried then inspected should be type cleaners such as emulsion cleaners or petro reassembled immediately and coated with a light leum solvents excluding gasoiline Do not clean film of oil these parts in a hot tank solution or sodium hy droxide orthosilicates or phosphates When E Itis impossible to overstress the importance of cleaning remember to clean and or replace careful and thorough inspection of component breathers if applicable parts prior to reassembly Thorough visual inspec tion for indications of wear or stress and the replacement of such parts as are necessary will WA CAUTION eliminate costly and avoidable unit failure Exercise extreme care to avoid skin rashes fire hazards and inhalation of vapors when using solvent 1 Inspect all bearings and replace any that are worn pitted or damaged in any way type cleaner
21. espective holes when removing guards cases etc so that the proper bolts will be on hand for reassembling Safety should always by the first consideration when performing maintenance or service to equipment Always be conscious of a component s weight Never attempt to move a heavy part without a proper lifting device Ensure that adequate support is provided and that objects are setina stable position Any hydraulic component disassembly or reassembly must be done in a clean enclosed environment by personnel familiar with hydraulic systems and cleanliness procedures Page 2 2 TB42 TB50 TB60 TB66 TB85 TB100 TB110 Issued Jun 01 TEREX AERIALS LIP TRS SERVICE MANUAL SECTION 2 RECEIVING A NEW MACHINE Before removing a new machine from the delivery vehicle 1 Check and follow the Operation amp Maintenance Manual for unloading procedure 2 Check battery batteries for cracks and for proper water level if applicable 3 Check for bent broken or otherwise damaged functional components 4 Check for sufficient oil levels both hydraulic and engine if applicable 5 Check for fluid leaks in hydraulic or fuel delivery systems 6 Check lug nuts for looseness Upon receipt of a new machine the customer must 1 Remove all packing materials and inspect for any damage incurred during transport 2 Complete the NEW EQUIPMENT CONDITION REPORT 3 Complete the WARRANTY REGISTRATION 4 If your machine is an export model the
22. export preservative must be removed EXPORT PRESERVATIVE REMOVAL Before an export machine leaves the factory the exterior surfaces are given a coating de signed to protect the paint from the environment encountered when shipping items overseas or for great distances This coating can be removed using warm soapy water Do not use a steam cleaner to clean or wash the machine Do not spray water directly on any control panels or electrical compartments This preservative is applied to export machines only Issued Jun 01 42 50 60 66 85 100 110 2 3 TEREX AERIALS LIP TINGS SERVICE MANUAL SECTION 2 MACHINE STORAGE Machines being placed in storage must be adequately 4 The battery charger may be left connected to protected from deterioration during the period of idle the batteries and should be turned on for a full ness This will ensure that they can be restored to charge period once a month In extremely cold active service with a minimum effort conditions it may be necessary to charge more frequently After each charge cycle the charger Before removing this aerial lift from service for an should be checked to insure that it has turned extended period it should be prepared for storage as off Severe overcharging and possible damage prescribed in the following paragraphs The specific to the batteries could result if the charger re procedure to be followed depends upon the expected mains
23. lectrical action of the battery greatly reducing its capacity Therefore it is highly recom mended that the battery be kept fully charged during cold weather Issued Jun 01 TB42 TB50 TB60 TB66 TB85 TB100 TB110 Page 3 11 TEREX AERIALS LIP TINGS SERVICE MANUAL MAINTENANCE PROCEDURES BATTERY Temperature Specific Gravity Correction table For Batteries Actual Hydrometer Reading At Actual Temperature F Table 1 80 F 20 F 30 F State of ETO C18 C 23 C 2990 C34 O 43 C 54 Charge 1338 1192 1204 120 1218 o Table 2 Specific Gravity Corrected to 80 F 17 C Freezing Temperatures 1 280 90 F 68 C 1 250 62 F 52 C TOE APO OFF 1570 07 C 1 000 19 F 07 Page 3 12 TBA2 TB50 TB60 TB66 TB85 TB100 TB110 Issued Jun 01 gt TEREX AERIALS LIP TIG SERVICE MANUAL NOTES Issued Jun 01 TB42 TB50 TB60 TB66 TB85 TB100 TB110 Page 3 13
24. nufacturer s manual for additional information CAUTION Do not open hot radiator Allow radiator to cool if engine has been operated recently DO when HOT Riesaren Page 3 6 TBA42 TB50 TB60 TB66 TB85 TB100 TB110 Issued Jun 01 TEREX AERIALS SERVICE MANUAL LIP TIRES MAINTENANCE PROCEDURES ENGINE amp HYDRAULIC OIL Hydraulic amp Engine Oil Various hydraulic fluid manufacturers use different additives which may cause problems in a hydraulic system when mixed together This situation is rare but can cause sludge which can plug filters or acid which can etch machined surfaces in hydraulic components or deteriorate seals Any of the above conditions can result in a hydraulic component warranty being voided If knowing all this you still choose to add fluid different from that initially supplied RED fluid NORTRAN Automatic Transmission Fluid equivalent DEXRON II BLUE fluid TALAMAR EXTREME equivalent Mobil DTE 13M Shell TELLUS T 32 Texaco RANDO OIL HD Z 36 PREMIUM HVI Exxon UNIVIS N32 stay with a single brand as this will minimize the likelihood of problems occurring Then at the first complete hydraulic fluid change switch to the brand you prefer to use If engine oil needs to be added the aerial lift owner must be contacted to find out what brand and viscosity of oil is being used Use the same brand and viscosity of oil that is presently being used in the aerial lift when
25. nuous rotation 16 ft 9 in 5 1 m 0 to 3 0 m p h 0 to 4 83 km h Ford LRG 425 62 hp 46 2 kw water cooled gasoline dual fuel optional Cummins 4B3 7 L 76 hp 56 7 kw water cooled diesel Deutz F3L1011 40 8 hp 30 0 kw air cooled diesel 40 gal 151 L Load sensing and pressure compensating 2 500 psi 172 BAR 52 gal 197 L 15 x 19 5 13 P R Loader Lug 10 0 in 0 25 m 25 000 Ibs 11340 kg 170 psi 11 95 kg sq cm 7350 Ibs 3334 kg 25 m p h 40 23 km h 6 Beaufort 25 14 50 27 Clearance must be allowed for body parts for this and other work heights TB42 TB50 TB60 TB66 TB85 TB100 TB110 Issued Jun 01 TEREX AERIALS SERVICE MANUAL UPDATE ILLUSTRATION 28 ft 11 in ROTATION 8 81 90 0 in 261 5 in 228 6 cm 664 21 cm m 9 ft 3 in 282m S AN EI 9 1 0 in 121 92 cm 8 ft O in 2 44 m 10 0 in 0 25 m 6 ft 7 in 2 01 m 95 5 in 242 57 cm Issued Jun 01 TB42 TB50 T B60 TB66 TB85 TB100 TB110 Page 2 21 TEREX AERIALS SERVICE MANUAL TB66 BOOM LIFT RANGE DIAGRAM 40 ft 50 ft 60 ft a E 3 Ger m 6 SC m 9 J m 12 192 m 15 24 m 18 288 m Page 2 22 TB42 TB50 TB60 TB66 TB85 TB100 TB110 Issued Jun 01 TEREX AERIALS LIP TINGS SERVICE MANUAL NOTES Issued Jun 01 TB42 TB50 TB60 T B66 TB85 TB100 TB110 Page 2 23 gt TEREX AERIALS LIP TRS SERV
26. on welding good penetra tion and high tensile strength up to 110 000 NOTE Low hydrogen rod E7018 must be used within four 4 hours upon removal from a freshly opened container or from a storage oven Low hydrogen rod E11018G must be used within 1 2 hour upon removal from its container or from a storage oven Issued Jun 01 TEREX AERIALS LIP TINS SERVICE MANUAL SPECIFICATIONS amp RANGE DIAGRAMS DESCRIPTION PAGE NO SPECIFICATIONS TABLE TBA3 emeret teeeer nene rnn 2 8 GENERAL DIMENSIONS 2 2 9 RANGE DIAGRAM id 2 10 SPECIFICATIONS TABLE 50 4 0 000 6 2 12 GENERAL DIMENSIONS TB50 2 19 RANGE DIAGRAM IB50Y casita e n 2 14 SPECIFICATIONS TABLE TrBen 2 16 GENERAL DIMENSIONS Iber tese Hte tn 2 17 RANGE DIAGRAM TIBOO rcr 2 18 SPECIFICATIONS TABLE 66 2 0 00 2 20 GENERAL DIMENSIONS 66 0 6 2 21 RANGE DIAGRAM IB66 deerit eset eie eda 2 22 SPECIFICATIONS TABLE Bai 2 24 GENERAL DIMENSIONS 7885 2 25 RANGE DIAGRAM ERED icp is eet ea ot recte tee decer 2 26 SPECIFICATIONS TABLE TBTOOI Zo ola te Ed 2 28 GENERAL DIMENSIONS 100 0 0 2 29 RANGE DIAGRAM T
27. prescribed for longer intervals include those reguired for the shorter intervals Thus the weekly check includes all items in the daily check the monthly check includes all items in the weekly and daily checks and so on through the semiannual check which includes the quarterly monthly weekly and daily checks The maintenance schedule provided serves as a guide to assure that the minimum basic preventive maintenance reguirements will be met under average operating condi tions Conditions which impose greater wear loads or strain on the aerial lift may dictate reducing the interval between these checks Before altering the recommended mainte nance schedule reevaluate the aerial lift s operation and review the owner s inspection records Consider all factors involved and develop a revised schedule adequate to meet routine maintenance requirements Page 3 2 TB42 TB50 T B60 T B66 T B85 T B100 TB110 Refer to the engine manufacturer s manual for engine maintenance requirements Should any discrepancy occur relative to the maintenance schedule provided in this manual and those provided by the engine manufacturer s recommendations take precedence over those in this manual INSPECTION RECORD Periodic maintenance and inspection of the aerial lift is the responsibility of the owner The Aerial Lift Inspection Report can be used for recording the date of each inspec tion person s performing the inspection any deficiencies found and
28. s Remove parts needing replacement with a suitable puller or in a press with sleeves B Rough parts such as gear case housings may be Avoid the use of drifts and hammers as cleaned in hot solution tanks with mild alkali solu tions providing these parts are not ground and polished The parts should remain in the tank long enough to be thoroughly cleaned and heated 2 through This will aid and speed up the evapora tion of the cleaning solution and the rinse water they may easily mutiliate or severely dis tort component parts Inspect all gears for wear or damage Gears which are scored pitted ridged or worn should be replaced EN CAUTION If repair is evident replace all worn or damaged parts Hex nuts with rounded corners all lock washers oil seals o rings and gaskets should all Exercise care to avoid skin rashes and inhalation of be replaced the time of overhaul vapors when using alkali cleaners Parts cleaned in solution tanks or with alkali clean ers should be thoroughly rinsed after cleaning to remove all traces of alkali C Parts should be thoroughly dried immediately after cleaning Use soft clean lint free absorbent paper towels or wiping rags free of abrasive mater ial such as lapping compound metal filings or contaminated oil Bearings should never be dried by spinning with compressed air Issued Jun 01 TB42 TB50 TB60 TB66 TB85 TB100 TB110 Page2 5 TEREX AERIALS LIP TINGS SE
29. s rotation 16 ft 0 in 4 9 m 0 to 3 0 m p h 0 to 4 83 km h Ford LRG 425 62 hp 46 2 kw water cooled gasoline dual fuel optional Deutz F3L1011 40 8 hp 30 0 kw air cooled diesel 25 gal 94 6 L Load sensing and pressure compensating 2 500 psi 172 BAR 38 gal 144 L 12x16 5 8 P R Mono 10 5 in 26 m 13 050 Ibs 5920 kg 170 psi 11 95 kg sq cm 7350 Ibs 3334 kg 25 m p h 40 23 km h 6 Beaufort 35 19 55 35 Clearance must be allowed for body parts for this and other work heights TB42 TB50 TB60 TB66 TB85 TB100 TB110 Issued Jun 01 TEREX AERIALS LIP TINGS SERVICE MANUAL TB42 BOOM LIFT GENERAL DIMENSIONS 25 ft 10 75 in ROTATION 7 89 m 5 ft 1 3 in 19 ft 2 5 in 1 81 m d 5 85 m 7 ft 1 in i Cl M 8 ft 0 in 2 44 12 ft 9 0 in 3 27 m 6 ft 10 0 in 2 08 m 7 ft 11 0 in 2 4 m Issued Jun 01 TB42 TB50 TB60 TB66 TB85 TB100 TB110 Page 2 9 TEREX AERIALS LIP TINGS SERVICE MANUAL TB42 BOOM LIFT RANGE DIAGRAM 55 ft 16 764 m 50 ft 15 24 m 45 tt 13 716 m 40 ft 12 192 m 35 ft 10 668 m 30 ft 9 144 m 25 ft 7 62 m 20 ft 6 096 m 15 ft 4 572 m 10 ft 3 048 m 5 ft 1 524 m O ft 0 0 m 5 ft 1 524 m 10 ft 3 048 m 5 ft 1 524 m 10 ft 0 ft 10 ft 20 ft 30 ft 40 ft
30. t could indicated trouble ahead By detecting any problems in their early stages you can save yourself unnecessary downtime and your employer a lot of money Therefore it is also your responsibility to use good judgment in detecting failures quickly and repairing them If you don t one failure can lead to another NOTE THE SERVICE AND MAINTENANCE PROCEDURES PROVIDED IN THIS MANUAL SHOULD ONLY BE PERFORMED BY QUALIFIED AERIAL LIFT MECHANIC Before attempting to make an adjustment your self ask yourself if you have the RIGHT TOOLS IF you have the PROPER TEST EQUIPMENT and IF you can accurately DIAG NOSE the cause of the problem Issued Jun 01 TB42 TB50 TB60 T B66 TB85 T B100 TB110 If you can t answer YES to all three questions rely on your Distributor Serviceman He has the right tools testing equipment and service knowledge to pin point the problem in minutes instead of the hours consumed in hit or miss methods TIME IS MONEY He will save it for you If you decide to attempt an adjustment your self follow a logical TROUBLE SHOOTING PROCEDURE Don t simply replace parts until the trouble is found Once the cause of the problem or malfunction has been diagnosed take the corrective action specified in this manual Follow the proce dures given for the specific problem If the difficulty is not covered consult your Terex Aerials distributor or the Terex Aerials Cus tomer Service Department Page 3 TE
31. the hydraulic pump refer to the manufacturers instructions on correct installation After the hydraulic system has been drained such as during the replacement of a component operate the affected function three complete cycles Recheck the oil level and fill as required HYDRAULIC CYLINDER INSPECTION Wash the cylinder bore and all the components with solvent and make the following inspections CYLINDER BORE For signs of scoring and deep scratches In the event of any defects reassemble the entire cylinder and contact your distributor CYLINDER SHAFT For dents deep scratches or damaged chrome plating File any sharp edges on ends of shaft to protect the seals upon reassemble Always protect the shaft finish when clamping in a vice or when welding against weld splatter PISTON RINGS For cracks or other damage Particularly check the interlocking ends that they are not missing or bro ken PISTON SEALS For signs of severe damage Do not re move unless replacemnt is necessary PISTON amp HEAD GLAND It is not normally necesary to replace the piston piston rings or head gland Issued Jun 01 TEREX AERIALS LIP TIG SERVICE MANUAL MAINTENANCE PROCEDURES TORQUE HUB For normal application use EP 90 For applications where the lubricant must met special requirements the manufacturer of the lubricant should be able to recommend a suitable substitute 1 90 2 Oil Temperature
32. urs mainly as the result of evaporation brought on by temperature rises during charging A small amount may be lost due to gasses formed during charging Electrolyte may be lost if the case becomes cracked or the battery tips over Therefore electrolyte is seldom needed Checking the Electrolyte Battery Water level physically When checking the electrolyte level don t allow dirt to enter into the battery cells once the caps have been removed Take particular care to avoid setting the battery cell caps down on a dirty surface Replace the caps immediately after checking the level Page 3 10 TBA2 TB50 TB60 TB66 TB85 TB100 TB110 Issued Jun 01 TEREX AERIALS SERVICE MANUAL LIP TIG MAINTENANCE PROCEDURES BATTERY MATERIALS AND EQUIPMENT REQUIRED 1 Battery Filler Bottle 2 Distilled Water 3 Hydrometer FILLING THE BATTERY Use a hydrometer to see how much charge the battery has A reading of 1 260 or more in all cells indicates a fully charged condition See chart on following page If the battery is fully charged add water up to the level indicator If the battery s water level is below the lead plates add only enough water to barely cover the plates Note Either excessive overcharge or moderate undercharge can shorten battery life With proper attention to water level charging time and hydrometer readings the batteries should have a long useful life Note Cold temperatures have a numbing effect on the e
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