Snorkel TB100J User Manual

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Operator’s

Manual

P/N 0112478 February,2001

DANGER

ELECTRICAL HAZARD

The TB100J is an all metal boom, NOT ELECTRICALLY INSULATED, aerial work platform. Do not operate it near ELECTRICAL conductors. Regard all conductors as being energized. Use the table and figure below to determine safe clearance from electrical conductors. Table 1 and Figure 3 are reprinted courtesy of Scaffold Industry Association, ANSI/SIA A92.5, page 23.

Table 1 - Minimum safe approach distance (M.S.A.D.)

to energized (exposed or insulated) power lines

Voltage range

(phase to phase)

0 to 300V Avoid contact

Over 300V to 50KV 10 3.05

Over 50KV to 200KV 15 4.60

Over 200KV to 350KV 20 6.10

Over 350KV to 500KV 25 7.62

Over 500KV to 750KV 35 10.67

Over 750KV to 1000KV 45 13.72

Minimum safe approach distance

(Feet) (Meters)

Danger: - Do not allow machine personnel or conductive materials inside prohibited zone.

- Maintain M.S.A.D. from all energized lines and parts as well as those shown.

- Assume all electrical parts and wires are energized unless known otherwise.

Caution: - Diagrams shown are only for purposes of illustrating M.S.A.D. work positions, not all work positions.

Figure 3 - Minimum Safe Approach Distance (M.S.A.D.)

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DANGER

ELECTRICAL HAZARD

THE TB100J AERIAL WORK PLATFORM IS NOT

ELECTRICALLY INSULATED.

If the platform, booms, or any other conductive part of a TB100J contacts a highvoltage electrical conductor, the result can be persons on or near the machine.

GO NO CLOSER THAN THE MINIMUM SAFE APPROACH

DISTANCES ON THE OPPOSITE PAGE.

Be sure to allow for sag and sway in the wires and the work platform.

If a TB100J comes in contact with a live electrical conductor, the entire machine can be charged. If that happens, you should remain on the machine and not contact any other structure or object within reach. That includes the ground, adjacent buildings, poles, and any object not a part of the TB100J. Such contact could make your body a conductor to the other object creating an electrical shock hazard resulting in or leave the TB100J until you are sure the electricity has been turned off.

SERIOUS INJURY

DEATH

. Do not attempt to enter

DEATH

for

If a TB100J is in contact with a live conductor, the platform operator others on the ground in the vicinity of the TB100J to machine, since their bodies can also form a path for electricity to ground thus creating an electrical shock hazard with possible

DEATH

Do not attempt to operate the TB100J ground controls when the platform, booms, or any other conducting part of a TB100J is in contact with electrical wires or if there is an immediate danger of such contact.

Regard all conductors as energized.

Personnel working on or near a TB100J must be continuously aware of electrical hazards, recognizing that an electrical wire does occur.

SERIOUS INJURY

STAY AWAY

ELECTROCUTION

DEATH

can result if contact with

MUST

from the

and

warn

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TABLE OF CONTENTS

XX. CHAPTER TITLE

INTRODUCTION ............................................ iii

SIGNS ............................................................. iii

QUALIFIED OPERATORS.............................. iii

MAINTENANCE .............................................. iii

RESPONSIBILITIES OF PARTIES ................. iv

ADDITIONAL INFORMATION......................... iv

1. SAFETY ...................................................... 1 - 1

SAFE OPERATION......................................... 1 - 1

Pre-start Inspection..................................... 1 - 1

Work Place Inspection and Practices ......... 1 - 1

Electrocution ............................................... 1 - 2

Tipover & Falling Hazards........................... 1 - 2

Crushing...................................................... 1 - 2

GENERAL SAFETY PRECAUTIONS.............. 1 - 2

Personnel Precautions................................ 1 - 2

Operator General Precautions .................... 1 - 2

Mounting & Dismounting Precautions......... 1 - 3

Starting and Stopping Precautions ............. 1 - 3

Operating Precautions ................................ 1 - 3

Operator Maintenance Precautions ............ 1 - 3

Fuel Handling Precautions.......................... 1 - 3

SAFETY DECALS & PLACARDS.................... 1 - 3

2. SAFETY DEVICES ..................................... 2 - 1

TILT ALARM HORN, SIREN, & LIGHT ........... 2 - 1

EMERGENCY STOP SWITCHES................... 2 - 2

LANYARD ANCHORAGE POINTS ................. 2 - 2

GRAVITY GATE.............................................. 2 - 2

FOOT SWITCH ............................................... 2 - 3

GROUND OPERATION SWITCH ................... 2 - 3

EXTENDIBLE AXLE INTERLOCKS ................ 2 - 3

EMS LIGHTS & AUDIO ALARMS ................... 2 - 3

EMS TABLE .................................................... 2 - 5

OPERATOR HORN......................................... 2 - 5

MOTION ALARM............................................. 2 - 5

PLATFORM WORK LIGHTS........................... 2 - 6

DRIVING LIGHTS............................................ 2 - 6

GFCI OUTLET................................................. 2 - 6

GUARDRAILS ................................................. 2 - 6

FLASHING LIGHTS......................................... 2 - 6

3. SPECIFICATIONS ...................................... 3 - 1

GENERAL SPECIFICATIONS ........................ 3 - 1

PLATFORM SPECIFICATIONS ...................... 3 - 1

ENGINE DATA ................................................ 3 - 2

ENGINE OIL CHARTS .................................... 3 - 2

OVERALL DIMENSIONS ................................ 3 - 3

SAFE WORKING ENVELOPE ........................ 3 - 4

SERIAL-NUMBER LOCATIONS ..................... 3 - 5

CHASSIS NOMENCLATURE.......................... 3 - 5

TURNTABLE & BOOM NOMENCLATURE..... 3 - 5

4. GAUGES..................................................... 4 - 1

FILTER MINDER............................................. 4 - 1

TEMPERATURE ............................................. 4 - 1

AMPS .............................................................. 4 - 1

HOURS ........................................................... 4 - 1

FUEL ............................................................... 4 - 2

HYDRAULIC OIL LEVEL................................. 4 - 2

HYDRAULIC OIL TEMPERATURE................. 4 - 2

HYDRAULIC OIL FILTER................................ 4 - 3

ENGINE OIL.................................................... 4 - 3

5. AUTOMATIC SHUT-OFFS

& CIRCUIT BREAKERS............................. 5 - 1

AUTOMATIC SHUT-OFFS.............................. 5 - 1

Engine Temperature ................................... 5 - 1

Engine Oil Pressure .................................... 5 - 1

Alternator Not Charging .............................. 5 - 1

CIRCUIT BREAKERS ..................................... 5 - 1

6. CONTROLS................................................ 6 - 1

GROUND-CONTROL BOX ............................. 6 - 2

PLATFORM-CONTROL BOX.......................... 6 - 4

CHASSIS......................................................... 6 - 6

TURNTABLE ................................................... 6 - 6

7. OPERATION............................................... 7 - 1

CONTROL STATIONS.................................... 7 - 1

EMERGENCY STOPPING.............................. 7 - 1

STARTING FROM THE GROUND-

CONTROL BOX............................................ 7 - 1

Pre-start Conditions.................................... 7 - 1

Starting (from the ground)........................... 7 - 2

STARTING FROM THE PLATFORM-

CONTROL BOX............................................ 7 - 3

Pre-start Conditions.................................... 7 - 3

Starting (from the platform)......................... 7 - 4

MOVING THE PLATFORM............................. 7 - 5

MOVING THE TB100J.................................... 7 - 8

STEERING...................................................... 7 - 8

125 V AC OUTLET AT THE PLATFORM (GFCI) . 7 - 8

EXTEND & LOCK REAR AXLES.................... 7 - 9

RETRACT & LOCK REAR AXLES.................. 7 - 11

8. EMERGENCY OPERATION ...................... 8 - 1

EMERGENCY OPERATION FROM

THE PLATFORM-CONTROL BOX ............... 8 - 1

EMERGENCY OPERATION FROM

THE GROUND-CONTROL BOX................... 8 - 3

9. STOWING & TRANSPORTING ................. 9 - 1

STOWING....................................................... 9 - 1

TRANSPORTING............................................ 9 - 1

Trailering..................................................... 9 - 1

Securing to a Transport Vehicle ................. 9 - 2

Towing ........................................................ 9 - 4

10. DAILY INSPECTION & MAINTENANCE . 10 - 1

DAILY INSPECTION AND

MAINTENANCE TABLE .............................. 10 - 1

PLACARDS AND DECALS

INSPECTION CHART I................................10 - 10

PLACARDS AND DECALS

INSPECTION DRAWING I ..........................10 - 11

PLACARDS AND DECALS

INSPECTION CHART II...............................10 - 12

PLACARDS AND DECALS

INSPECTION DRAWING II .........................10 - 13

11. TROUBLESHOOTING .............................11 - 1

12. OPTIONS.................................................. 12 - 1

PLATFORM WORK LIGHTS ......................... 12 - 1

AIR LINE TO PLATFORM ............................. 12 - 1

DRIVING LIGHTS.......................................... 12 - 2

COLD WEATHER START KIT ......................12 - 2

Block Heaters ................................................ 12 - 2

Ether Injection................................................ 12 - 2

HYDRAULIC SYSTEM COLD

WEATHER WARM-UP KIT .........................12 - 2

AC GENERATOR.......................................... 12 - 3

MOTION ALARM........................................... 12 - 3

TOW KIT........................................................ 12 - 3

FOUR-WHEEL DRIVE (4X4).........................12 - 4

SELF-STOWING PLATFORM.......................12 - 5

FLASHING LIGHT ......................................... 12 - 6

13. FIRE FIGHTING & HAZARDOUS

CHEMICAL CONTAINMENT ................... 13 - 1

ANTI-FREEZE ............................................... 13 - 1

BATTERY, LEAD/ACID ................................. 13 - 1

DIESEL FUEL................................................ 13 - 1

FOAM IN TIRES ............................................ 13 - 1

GASOLINE .................................................... 13 - 2

HYDRAULIC OIL ...........................................13 - 2

LIQUEFIED PETROLEUM GAS.................... 13 - 2

MOTOR OIL...................................................13 - 2

INDEX................................................................ I - 1

LIMITED WARRANTY ............(inside back cover)

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INTRODUCTION

The most important chapter in this manual is “1. SAFETY.” Take time, now, to study it closely. The information in that chapter might save your life or prevent serious injury.

SIGNS

The following two conventions are used throughout this manual.

1. This sign

DANGER

means:

is involved

2. This sign

Attention! Become alert! Your safety

CAUTION

means one of two things: (1) an action, about to be performed, is potentially hazardous and might result in minor personal injury if not done correctly, or (2) an action, about to be performed, can damage the TB100J if not done correctly.

QUALIFIED OPERATORS

The TB100J aerial platform has built-in safety features and has been factory tested for compliance with Snorkel specifications and industry standards. However, any personnellifting device can be potentially dangerous in the hands of untrained or careless operators.

The following rules will help ensure the safety of personnel and help prevent

needless downtime because of damaged equipment.

1. Only TRAINED and AUTHORIZED operators shall be permitted to operate the equipment.

2. All manufacturer’s operating instructions and safety rules and all employers’ safety rules and all OSHA and other government safety rules must be strictly adhered to.

3. Repairs and adjustments shall be made only by QUALIFIED TRAINED maintenance personnel.

4. No modification shall be made to the equipment without prior written consent of the Snorkel Engineering Department.

5. You must make a pre-start inspection of the TB100J at the beginning of each shift. A malfunctioning machine must not be used.

6. You must make an inspection of the work place to locate possible hazards before operating the TB100J.

DANGER

Misuse of this machine can result in DEATH or SERIOUS INJURY.

Do not operate this equipment unless you are TRAINED and AUTHORIZED and have read and thoroughly understand all information given in this Operator’s Manual and on all DANGER and CAUTION signs on the machine.

Training is essential and must be performed by a QUALIFIED person. Become proficient in knowledge and actual operation before using the TB100J on the job. You must be trained and authorized to perform any functions of the TB100J. Operation of the TB100J must be within the scope of the machine specifications.

Before operating the TB100J you must read and understand the operating instructions in this manual as well as the decals, warnings, and instructions on the machine itself.

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MAINTENANCE

Every person who maintains, inspects, tests, or repairs these machines, and every person supervising any of these functions, must be properly trained.

This Operator’s Manual provides a daily inspection procedure that will help you keep your TB100J in good operating condition. Do not perform other maintenance unless you are a TRAINED mechanic, QUALIFIED to work on the TB100J. Call QUALIFIED maintenance

iii

INTRODUCTION

personnel if you find problems or malfunctions. Information contained in this manual concerns only current TB100Js, and the right is reserved to make changes at any time without obligation.

RESPONSIBILITIES OF PARTIES

It is imperative that all owners and users of the TB100J read, understand, and conform to all applicable regulations. Ultimate compliance to OSHA regulations is the responsibility of the employer using the equipment.

ANSI Standard A92.5 identifies requirements of all parties who might be involved with BoomSupported Elevating Work Platforms.

A reprint of the “Manual of Responsibilities for Dealers, Owners, Users, Operators, Lessors and Lessees of ANSI/SIA A92.5-1992 BoomSupported Elevating Work Platforms” is available from Snorkel dealers or from the factory upon request.

Copies are also available from:

ADDITIONAL INFORMATION

For additional information, contact your local dealer, or write:

Snorkel International, Inc.

P.O. Box 1160

St. Joseph, MO 64502-1160 USA

http://www.snorkelusa.com

Scaffold Industry Association 20335 Ventura Blvd. Suite 310 Woodland Hills, CA 91364-2471 USA

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1. SAFETY

SAFE OPERATION

The following safety information is vitally important for safe operation of the TB100J. Failure to follow these instructions can result in personal injury or DEATH.



Pre-start Inspection



Prior to each shift, the TB100J shall be given a visual inspection and function test. See the “DAILY INSPECTION & MAINTENANCE” chapter in this manual for a list of items to inspect and test.

Do not operate the TB100J unless you are trained and authorized, understand the operation characteristics of the TB100J, and have inspected and tested all functions to be sure they are in proper working order. See the “DAILY INSPECTION & MAINTENANCE” chapter.



Work Place Inspection and Practices



Do not use the TB100J as a ground for welding. Ground to the work piece.

Before the TB100J is used, and during use, check the area in which the TB100J is to be used for possible hazards such as, but not limited to:

1. drop-offs or holes

2. bumps and floor obstructions

3. debris

4. overhead obstructions and high voltage conductors

5. hazardous locations

6. inadequate surface and support to withstand all load forces imposed by the aerial platform in all operating configurations

7. wind and weather conditions

8. presence of unauthorized persons

9. other possible unsafe conditions

Before using the aerial platform in any hazardous (classified) location, make certain it is approved and of the type required by ANSI/NFPA 505 for use in that particular location.

A recommended safety practice is to have personnel that are trained in the operation of the emergency controls, working in the immediate area of the TB100J to assist the platform operator in the event of an emergency.

When moving the platform, check the clearance around the TB100J to avoid contact with structures or other hazards. Always look in the direction of motion.

Keep ground personnel from under the platform when the platform is raised.

Secure all accessories, containers, tools, and other materials in the platform to prevent them from accidentally falling or being kicked off the platform.

Do not engage in any form of “horseplay” or “stunt driving” while operating the TB100J.

Do not permit riders on the machine anyplace other than on the platform.

Remove all loose objects stored in or on the machine, particularly in the platform. Remove all objects which do not belong in or on the machine.

When other moving equipment is in the area, take special precautions to comply with local regulations regarding warnings.

Never steady the platform by positioning it against another platform.

Do not operate a TB100J that is not functioning properly, or has been damaged, until the machine has been repaired by a qualified maintenance person.

Do not operate a TB100J that does not have all its decals and placards attached and legible.

Drive the machine with care and at speeds compatible with conditions. Use extra caution when driving over rough ground, on slopes, and when turning.

Know and understand the job site traffic-flow patterns and obey the flagmen, road signs, and signals.

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Watch for bystanders and never allow anyone to be under, or to reach through, the machine and its equipment while operating.

1 1 -

1. SAFETY



Electrocution



The TB100J is an all-metal boom, NONINSULATED, aerial work-platform. Do not operate it near ELECTRICAL conductors. Regard all conductors as being energized.

Do not operate outside during a thunderstorm.



Tipover & Falling Hazards



Do not operate a TB100J from a position on trucks, trailers, railway cars, floating vessels, scaffolds, or similar equipment unless the application is approved in writing by Snorkel.

If the platform or elevating assembly becomes caught, snagged, or otherwise prevented from normal motion by an adjacent structure or other obstacles such that control reversal does not free the platform, remove all personnel from the platform before attempts are made to free the platform using ground controls.

Under normal working conditions it is best not to transfer from the platform to another structure or vice versa, unless that is the safest way to do the job. Each situation must be judged separately taking the work environment into account. The following guidelines apply:

Where possible, place the work platform

•

over a roof or walking structure to do the transfer.

Transfer your anchorage from one

•

structure to another before you step across.

Remember that you might be transferring

•

to a structure where is required.

Use the platform entrance, do not climb

•

over the rails.

All platform occupants MUST wear a fall restraint device connected to a lanyard anchor point.

Do not exceed the unrestricted platform capacity shown on the platform.

Do not raise the boom if the TB100J is on soft ground. Operate the boom only on a firm surface capable of withstanding all load forces imposed by the aerial platform in all operating conditions.

Do not carry loads from any point outside of the platform.

personal fall arrest

Care shall be taken to prevent rope, electric cords, and hoses, etc., from becoming entangled in the aerial platform.

Raise the platform only when the TB100J is on level ground.

Maintain a firm footing on the platform floor. Climbing on the guard rails is prohibited.

Do not use ladders, planks, or other devices to extend or increase your work position from the platform.

Do not jerk the controls. Move the controls slowly and deliberately to avoid jerky and erratic operation. Always stop the controls in the neutral, off, position before going in the opposite direction.

Do not use the boom for any purpose other than to position personnel, their tools, and materials.

Do not use the TB100J as a crane, hoist, or jack.

Do not operate the TB100J in winds, or wind gusts, of 28 mph (45 km/hr) or more.

Do not add anything to the TB100J that will increase the wind loading (billboards, banners, flags, etc).



Crushing



Always look in the direction of travel. Avoid overhead obstructions.

Never cover the floor grating or otherwise obstruct your view below.

Make sure the area below the platform is free of personnel before lowering.

GENERAL SAFETY PRECAUTIONS



Personnel Precautions



If you encounter any suspected malfunction of the aerial platform, or any hazard or potentially unsafe condition relating to capacity, intended use, or safe operation, cease operation and seek assistance from management.



Operator General Precautions



Make sure that all protective guards, cowlings, and doors are in place and secure.

Be sure the guardrail system, including the gate, is in place and secure.

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

Mounting & Dismounting Precautions



Fuel Handling Precautions



1. SAFETY

Use three points of support when getting on or off the platform (two hands and one foot or a similar set of points). Keep the platform clean.

Do not jump off the machine.

Do not dismount while the machine is in motion.



Starting and Stopping Precautions



Do not start until all personnel are clearly away from the machine.

Before leaving the operator’s station, place the machine in the stowed position.

When leaving the machine parked or unattended, remove the starter key from the

MASTER KEY SWITCH

switch to OFF, then lock the



Operating Precautions



Do not modify the TB100J in any way.

When parts or components are replaced, they shall be identical or equivalent to original Snorkel parts or components.

Do not override any of the safety features of the TB100J.

Limit travel speeds according to conditions. Take into account: grade, surface, congestion, visibility, side slope, location of personnel, and other hazards.



Operator Maintenance Precautions



Do not use your hand to search for hydraulic oil leaks. High pressure hydraulic oil can easily cut and penetrate your skin — a very serious injury that requires immediate attention by a medical specialist trained in that type of injury. Use a piece of cardboard or wood to search for hydraulic oil leaks.

Do not attempt repairs unless you are trained. Refer to manuals and experienced repair personnel for help.

, set the

BATTERY

switch.

Do not smoke or permit open flames while fueling or near fueling operations.

Never remove the fuel cap or refuel a gasoline engine while the engine is running or hot. Never allow fuel to spill on hot machine components.

Maintain control of the fuel filler nozzle when filling the tank.

Do not fill the fuel tank to capacity. Allow room for expansion.

Clean up spilled fuel immediately.

Tighten the fuel tank cap securely. If the fuel cap is lost, replace it with an approved cap from Snorkel. Use of a non-approved cap without proper venting may result in pressurization of the tank.

Never use fuel for cleaning purposes.

For diesel engines, use the correct fuel grade for the operating season.

SAFETY DECALS & PLACARDS

There are several safety decals and placards on the TB100J. Their locations and descriptions are shown in this section. Take time to study them.

Be sure that all the safety decals and placards on the TB100J are legible. Clean or replace them if you cannot read the words or see the pictures. Clean with soap & water and a soft cloth. Do not use solvents.

You must replace a decal or placard if it is damaged, missing, or cannot be read. If it is on a part that is replaced, make sure a new decal or placard is installed on the replaced part. See your Snorkel dealer for new decals and placards.

Refer to PLACARDS AND DECALS INSPECTION CHARTs and DRAWINGs in the “DAILY INSPECTION AND MAINTENANCE” chapter for part numbers, location, and required quantities of all placards and decals.

Charge batteries in a well-ventilated area free of flame, sparks, or other hazards that might cause fire or explosion.

Use extreme caution when removing radiator caps. Park the machine and let it cool down before opening a pressurized compartment.

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1. SAFETY

Refer to PLACARDS AND DECALS INSPECTION CHARTs and DRAWINGs in the “DAILY INSPECTION AND MAINTENANCE” chapter for part numbers, locations, and required quantities of all placards and decals.

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For emergency-operation controls and procedures see the “EMERGENCY OPERATION” chapter in this manual.

The devices listed in this chapter are safety devices. They are on a TB100J to increase safety in the work place for both the operator and other people near a TB100J. Do not by-pass, disable, modify, or ignore any of these devices. Check them carefully at the start of each work shift to see that they are in working order (see “DAILY INSPECTION & MAINTENANCE” chapter). If any is found to be defective, remove the TB100J from service immediately until a qualified service technician can make repairs.

TILT-ALARM HORN, SIREN, & LIGHT

There is one tilt-alarm siren, one tilt-alarm horn, and one tilt-alarm warning light on a TB100J.

2. SAFETY DEVICES

The warning light is on the platform-control box.

The siren will emit a two-toned sound (high-lowhigh-low...) if the TB100J is tilted more than 3.5 (7 inch rise in 10 foot run / 18 cm rise in 3 m run) and the booms are above horizontal or extended more than 7 feet (2 m). The warning light will come on and the horn will emit a continuous sound at the same time the siren sounds.

NOTE: The platform siren will not sound if the TB100J is bring controlled from the groundcontrol box.

2. SAFETY DEVICES

The siren (1) is located under the platformcontrol box.

After the siren and/or horn begins to sound, if the tilt continues to increase, the TB100J can tip over. When you are in control of a TB100J and you hear either of these two warning sounds, or see the warning light come on, you should immediately:

1. Stop using the on the platform-control box.

2. Completely retract and completely lower the booms.

3. Use the platform-control box controller to move the TB100J to a level surface or more firm ground before extending or raising the booms again.

DRIVE/STEER

controller stick

DRIVE/STEER

The horn (2) is located in the turntable under the tilt alarm sensor (3).

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2 - 1

2. SAFETY DEVICES

EMERGENCY STOP SWITCHES

LANYARD ANCHOR POINTS

All personnel on the platform shall attach their fall restraint lanyards to one of the lanyard anchor points.

GRAVITY GATE

At the ground-control box: EMERGENCY STOP

under any conditions, and the entire machine stops, the engine turns off, and nothing moves. This switch must be pulled up (out) for anything on the TB100J to work.

At the platform-control box:

red

EMERGENCY STOP

entire machine stops, the engine turns off, and nothing moves. This switch must be pulled to its up (out) position to control the TB100J from the platform.

button in, at any time,

Press the red

Press the large

button down and the

The gravity gate (1) is the place in the platform guardrail system where you should enter and leave the platform. Raise the gate and step under it onto the platform. Once you have entered the platform and attached your fall restraint lanyard to the anchorage point (2), check to see that the gravity gate (1) has fallen back into place.

NOTE: The ground-control box is designed to override the platform-control box. If the platform-control box button is down (off) the ground-control box can still be used to start and operate the TB100J.

EMERGENCY STOP

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2. SAFETY DEVICES

FOOT SWITCH

DANGER

Serious injury can result from sudden stops. To avoid sudden stops, do not remove your foot from the foot switch while the TB 37 is in motion.

The foot switch prevents the platform from moving if something accidentally pushes one of the platform controls on the platform-control box. (It is a second action that must be performed, at the same time as another, to make the platform move.)

EXTENDIBLE AXLE INTERLOCKS

The left and right rear axles of a TB100J must be extended and locked for safe-working machine stability. The booms cannot be raised or extended unless the axles are completely extended and locked into place. Instructions for extending and locking the axles are given in the “OPERATION” chapter.

EMS LIGHTS & AUDIO ALARMS

There are six envelope management system (EMS) lights on a TB100J.

GROUND OPERATION SWITCH

The

GROUND OPERATION

platform from moving if something accidentally pushes one of the platform-moving switches at the ground-control box. (It is a second action that must be performed, at the same time as another, to make the platform move.)

switch prevents the

Three are on the instrument panel.

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2 - 3

2. SAFETY DEVICES

A second identical set of three is on the platformcontrol box.

In addition to EMS lights there are EMS audio alarms.

The

EMS ENVELOPE

information about where the platform is located relative to the platform’s safe working envelope. (See the “SPECIFICATIONS” chapter for the TB100J safe working envelope.) The

STATUS

the operator whether or not the envelope management system is operating correctly.

(2) and

NOTE: EMS lights on the platform-control box have the same names as those on the instrument panel even though they are not labeled on the platform-control box.

lights (1) give the operator

EMS

EMS WARNING

lights (3) tell

Two are above the instrument panel.

Two are on the bottom of the platform-control box. The audio alarms emit various sounds to alert the operator to unsafe conditions. The audio alarms and EMS lights work together to give valuable safety information. The table below summarizes that information.

NOTE: When a TB100J engine first starts, the EMS self-test will briefly sound all EMS audio alarms and briefly turn all six EMS lights on to check that they work. After the brief EMS self-test, conditions in the table below prevail.

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2. SAFETY DEVICES

EMS TABLE

LIGHT CONDITION AUDIO ALARM

GREEN

EMS

STATUS

WHITE

EMS

ENVELOPE

RED

: Machine is ready for normal operation.

FLASHING

technician.

OFF

: Platform is well inside the safe working envelope.

FLASHING

safe working envelope.

: Platform is at the limits of the safe working

envelope.

: EMS error detected. Press the red light in and release it. If the red stays on, use the emergency lowering procedures system described in the “EMERGENCY OPERATION” chapter to retrieve the platform.

: Calibration error. Notify qualified service

DO NOT USE MACHINE

: Platform is less than 3 feet (1 m) inside the

EMS WARNING

light

None.

Continuous tone.

EMS

WARNING

OPERATOR HORN

The operator of the platform-control box. It is used primarily to get the attention of people on the ground when you are working aloft.

FLASHING

working envelope. Move the boom into the safe working envelope.

HORN

: Platform is outside the limits of the safe

button is on the right side

4 beeps - pause - 4 beeps pause - 4 beeps - etc.

The horn itself is located below the tilt alarm sensor, it is the same horn used to sound the tilt alarm. For the horn to work the switch must be ON and the following switches, on the ground-control box, must be set as indicated:

SELECTOR SWITCH EMERGENCY STOP MASTER KEY SWITCH

MOTION ALARM

The motion alarm emits a loud beeping sound at ground level anytime the controller is in FORWARD or REVERSE. This alarm alerts people on the ground that the TB100J is traveling along the ground.

..........PLATFORM

................pulled up

....................ON

(option)

DRIVE/STEER

BATTERY

P/N 0112478

2 - 5

2. SAFETY DEVICES

PLATFORM WORK LIGHTS (option)

The platform work lights are located on top the platform guard rail. Use the lights to improve visibility when you are working aloft in dimly lit areas. Do not use the platform work lights to drive on public thoroughfares.

For more information about platform work lights see the “OPTIONS” chapter.

DRIVING LIGHTS (option)

Two 30 watt headlights are located on top of the front cowling, two 25 watt blinking taillights are on the sides of the rear cowlings. Driving lights help improve your visibility and help others see you when you are driving on dimly lit construction sites. Driving lights are not for driving on public thoroughfares.

GFCI OUTLET

The GFCI (ground fault circuit interrupt) is the electrical outlet located under the platformcontrol box. The GFCI protects against short circuits to ground. When there is a short to ground the GFCI shuts off power at the electrical outlet.

GUARDRAILS

The guardrails help protect you from falling off the platform. Be sure the guardrails are properly installed and that the gate is in place.

FLASHING LIGHTS

(option)

For more information about driving lights see the “OPTIONS” chapter.

2 - 6

The flashing lights alert people that the TB100J is present. The lights flash at about one flash per second any time the engine is running. There is no ON/OFF switch for the flashing lights.

P/N 0112478

3. SPECIFICATIONS

The TB100J is a boom-supported elevating work-platform built to conform to the following standards:

OSHA Paragraph 1910.67 Title 29, C.F.R.Vehicle-Mounted Elevating and Rotating Work Platforms - Labor.

OSHA Paragraph 1926.556 Title 29, C.F.R., Aerial Lifts - Construction.

ANSI Standard A92.5-1992 Boom-Supported Elevating Work Platforms.

GENERAL SPECIFICATIONS

Working height (nominal) .....106 ft - 0 in (32.3 m)

Platform height (maximum) ..100 ft - 0 in (30.5 m)

Platform reach (maximum).....66 ft - 0 in (20.1 m)

Length

(booms down and retracted) ...44 ft - 6 in (13.6 m)

Width:

axles retracted.........................8 ft - 6 in (2.6 m)

axles extended.....................12 ft - 10 in (3.9 m)

Height (booms down)...............10 ft - 4 in (3.1 m)

Wheelbase...............................12 ft - 0 in (3.7 m)

Ground clearance ............................17 in (0.3 m)

Weight (approximate)....... 33,000 lbs (15,000 kg)

Max. single wheel load....... 16,750 lbs (7,598 kg)

Ground pressure (max.) ............. 74 psi (511 kPa)

Travel speeds (max.):

booms down and retracted

high speed, low torque .....3.0 mph (4.8 km/hr)

high torque, low speed ...0.75 mph (1.2 km/hr)

booms up and/or extended

to mid elevation ..............0.75 mph (1.2 km/hr)

above mid elevation................................creep

Gradeability...................................................25%

Turning radius:

outside..................................30 ft - 0 in (9.1 m )

inside, axles retracted............18 ft - 8 in (5.7 m)

inside, axles extended ...........16 ft - 6 in (5.0 m)

Tires

(foam filled)

Electrical system... 12 V dc (neg. chassis ground) Environmental operating ranges:

ambient air temperature ..............0°F to +110°F

wind speed

(maximum gust or steady) .... 28 mph (45 km/hr)

Fuel tank capacity:

std. gasoline/diesel........ 40 gal USA (151 liters)

optional LPG..................... 43.5 lbs USA (20 kg)

Hydraulic oil:

tank capacity ................. 60 gal USA (227 liters)

maximum temperature (at tank)... 200°F (93°C)

system capacity............. 90 gal USA (341 liters)

maximum pressure........ 2,800 psi (19,320 kPa)

Hydraulic oil recommended:

above 10°F (-13°C) Mobil DTE 13M (ISO VG32) below 10°F (-13°C) Mobil DTE 11M (ISO VG15)

Boom elevation ...................+74°/-1° to horizontal

Boom movement times (complete range of movement):

Jib Boom

UP..........................................40 - 45 seconds

DOWN ...................................40 - 45 seconds

Turntable Swing

360° CW or CCW,

boom retracted.................110 - 120 seconds

boom extended ................320 - 330 seconds

Platform Rotation

180° CW or CCW,..................16 - 20 seconds

Main Boom Elevation

UP (boom retracted).............80 - 120 seconds

UP (boom extended) ...........120 -180 seconds

DOWN (boom retracted) .....80 - 120 seconds

DOWN (boom extended).....120 -180 seconds

Boom Extension

OUT .....................................90 - 120 seconds

IN ......................................... 90 - 120 seconds

.. 15 x 22.5 in

(38 X 57 cm)

(-18°C to +43°C)

, 18 ply

PLATFORM SPECIFICATIONS

SIZE

PLATFORM standard aluminum 30 x 92 (76 x 234) optional aluminum 30 x 60 (76 x 152) optional self-stowing

aluminum optional steel 30 x 60 (76 x 152) optional steel 30 x 92 (76 x 234)

P/N 0112478

inches (cm)

30 x 92 (76 x 234)

Unrestricted rated work load (total weight of personnel, tools, and materials that the platform is designed to carry above its floor -same as UNRESTRICTED PLATFORM CAPACITY)

Rated work load: 600 lbs (272 kg). Rated number of occupants: 3. Rated work load: 650 lbs (293 kg). Rated number of occupants: 3. Rated work load: 500 lbs (227 kg). Rated number of occupants: 2.

Rated work load: 600 lbs (272 kg). Rated number of occupants: 3. Rated work load: 500 lbs (227 kg). Rated number of occupants: 2.

1 3 -

3. SPECIFICATIONS

ENGINE DATA

ENGINE MAKE CONTINENTAL CONTINENTAL CUMMINS

MODEL TM27 4B3.9

FUEL gasoline LPG diesel

FUEL GRADE unleaded

85 octane (motor method)

CYLINDERS 4

COOLANT 50% water + 50% ethylene glycol

POWER 71.5 hp @ 3000 rpm

(53.3 kW)

OPERATING TEMPERATURE

OIL SUMP CAPACITY 6 qt USA

OIL FILTER CAPACITY 1 qt USA

OIL GRADE API: SE, SF, SE/CD, SF/CD API: CE/SF, CD/SF

OIL WEIGHT see chart below see chart below

RUNNING TIME (one tank of fuel)

180°F - 202°F (81°C - 94°C)

(5.7 liters)

(0.95 liters)

A full tank of gasoline, or diesel, will last an entire eight hour shift, under normal working conditions. It normally takes two tanks of LPG per eight hour shift.

HD5 Gas Processors Association Standard

2140. Category: special duty propane.

64.4 hp @ 3000 rpm (48.0 kW)

ASTM No. 2 D Cetane # > 40 (For operating temp. below 32°F / 0°C use “winterized” No. 2 D.)

76 hp @ 2500 rpm (56.7 kW)

141°F - 211°F (60°C - 100°C) 10 qt USA (9.5 liters)

ENGINE OIL CHARTS

CONTINENTAL ENGINE CUMMINS ENGINE

23 -

P/N 0112478

OVERALL DIMENSIONS

44'-6.4" (13.6m)

3. SPECIFICATIONS

1'-6.3" (0.5m )

33'-8.5"

(10 .3 m )

CENTER OF ROTATION & CENTER OF GRAVITY IN STOWED POSITION

57.5"

(146cm)

5'-.44" (1.5 m )

12'-0"

(3.7m )

9'-3"

(2.8m )

6'-9"

(2.1m )

10'-9.5"

(3.3 m)

1'-5"

(0.3m )

10'-4"

(3.2m )

P/N 0112478

8'-6"

(2.6 m )

AXLES RETRACTED

12'-10" (3.9 m )

AXLES EXTENDED

57.5"

(146cm)

3 3 -

3. SPECIFICATIONS

WORKING ENVELOPE

43 -

P/N 0112478

3. SPECIFICATIONS

SERIAL-NUMBER LOCATIONS

Serial Numbers are located in five places.

1. Above the ground-control box on a placard. (The last four digits are month and year shipped.)

2. On the back-right of the counterweight.

CHASSIS NOMENCLATURE

3. On a placard below the platform-control box. (Last four digits are mo. and yr. shipped.)

TURNTABLE & BOOM

NOMENCLATURE

NOTE: If the turntable is rotated 180° its FRONT is above the REAR of the chassis.

4. Below the drain hole in the turntable.

5. At the weld behind the rotation bearing turret.

P/N 0112478

3 - 5 (3 - 6 blank)

5 3 -

4. GAUGES

FILTER MINDER

The air filter gauge (1) located just above the ground-control box. The gauge measures the vacuum (air pressure) between the intake manifold and the air filter. As the filter clogs, the vacuum increases (pressure drops). As the vacuum increases, the yellow indicator (2) raises toward the red area (3) of the sight glass. When the yellow indicator reaches the red, it’s time to change the air filter.

The indicator (2) stays at its highest setting, it does not go to the bottom of the sight glass when the engine is turned off. After the filter is changed, press the small reset the indicator disk to the bottom of the sight glass.

(FILTER MINDER)

RESET

button (4) to

the engine block. The typical operatingtemperature range for a Continental engine is 180°F to 202°F (81°C to 94°C); for a Cummins engine, 141°F to 211°F (60°C - 100°C).

AMPS

The

AMPS

from the alternator to the batteries. When the engine is running, the needle in the should not be to the left of “0.” Under normal operating conditions, after the engine has been running for a few minutes, this gauge should read “0.”

HOURS

gauge shows the electric current

AMPS

gauge

TEMPERATURE

The

TEMPERATURE

above the ground-control box. It shows the temperature of the water-antifreeze mixture in

P/N 0112478

gauge is located just

The

HOURS

It accumulates time when:

BATTERY SELECTOR SWITCH MASTER KEY SWITCH

The

HOURS

gauge is basically an electric clock.

........................ON

gauge also accumulates time when:

.......GROUND

...ON.

1 4 -

4. GAUGES

BATTERY SELECTOR SWITCH ANTI-RESTART MASTER SWITCH

The

HOURS

when it is time to perform the periodic maintenance listed in the Maintenance Manual.

........................ ON

...... PLATFORM

........... ON.

gauge cannot be reset. Use it to tell

HYDRAULIC OIL LEVEL

FUEL

The fuel gauge (1) is located on top of the gasoline or diesel fuel tank (2). Read it at the line (3) in the clear plastic window (4). It reads in fractions-of-a-full-tank. The tank shown is a little more than 1/4 full.

NOTE: Do not run a diesel fuel tank dry. Air in the fuel line makes a diesel engine hard to start.

The hydraulic-oil level gauge (1) is on the side of the hydraulic oil tank (2). It shows the actual level of oil inside the tank. Read it only when the booms are completely down and completely retracted. Otherwise, the lift and/or extend cylinders become large reservoirs for hydraulic oil and the oil level in the tank will be low. The oil level (3) should be between the and

HYDRAULIC OIL TEMPERATURE

LOW

mark (5).

HIGH

mark (4)

(OPTION - LPG) LPG tanks have two fuel gauges (1) (2) on top. One measures correctly when the tank is standing on end ( the other measures correctly when the tank is laying down ( fractions-of- a-full-tank. TB100J tanks are mounted horizontally. Therefore, you should read the

HORIZONTAL

scale (2).

). Both read in

VERTICAL

)

The hydraulic-oil temperature gauge (1) is located at the bottom of the hydraulic-oil level gauge. It measures the temperature of the oil in the tank (2). The temperature should not exceed 200°F (93°C). If it does, reduce your driving speed or stop the TB100J to let the hydraulic oil cool.

24 -

P/N 0112478

HYDRAULIC OIL FILTER

4. GAUGES

CONTINENTAL CUMMINS

The hydraulic-oil filter gauge (1) is located above the hydraulic-oil filter (2). The gauge measures pressure into the filter. As the filter clogs, the pressure goes up.

The hydraulic-oil filter gauge should only be read by qualified trained maintenance personnel. An accurate reading requires very special conditions and should not be attempted by operators.

ENGINE OIL

CONTINENTAL CUMMINS

Engine oil level should always be in the crosshatched area (3) (4) of the dipstick — never above or below it. Check the oil level after the engine has been turned off a few minutes so that oil can run down out of the engine into the sump.

Engine oil level is measured with a dipstick (1) (2). Oil sump and oil filter capacities given in the “SPECIFICATIONS” chapter are approximate. True values may vary from machine to machine due to slight variations or modifications during production. The oil dipstick is the only way to accurately gauge if the engine oil level is correct.

P/N 0112478

4 - 3 (4 - 4 blank)

3 4 -

AUTOMATIC SHUT-OFFS

There is a light inside the switch at both the ground-control box and the platform-control box.

The lights come on if the engine temperature, engine oil pressure, or alternator current gets outside preset values. When the

light comes on, immediately lower the

STOP

platform and correct the problem. Use

EMERGENCY POWER OPERATION

the platform to the ground if the engine has automatically shut off. Use

BLEED DOWN OPERATION

OPERATION” chapter for instructions).

only if

does not work (see “EMERGENCY

EMERGENCY STOP

EMERGENCY

to lower

EMERGENCY

EMERGENCY POWER

5. AUTOMATIC SHUT-OFFS

& CIRCUIT BREAKERS

restart the engine. If the engine oil is low, replenish it then check for leaks. Check the engine oil filter to be sure it is in place and tight. If the engine will not restart, or if it automatically shuts off a second time, refer the problem to a qualified service technician.



Alternator Not Charging



If the alternator on either a Continental or Cummins engine fails, the lights in the

EMERGENCY STOP

TB100J will continue to run until the batteries get too weak to work and the engine automatically shuts off. Check the alternator drive belt to see if it is broken or loose (see “DAILY INSPECTION & MAINTENANCE” chapter) before you try to restart the engine. If the engine will not restart, or if it starts but the still on, refer the problem to a qualified service technician.

CIRCUIT BREAKERS

There are twelve circuit breakers on a TB100J. Their purpose is to protect electrical circuits from electrical overloads.

switches come on. The

EMERGENCY STOP

light is



Engine Temperature



If the engine temperature (check the

TEMPERATURE

or Cummins engine reaches 210°F (99°C) the lights in the come on. If the engine temperature continues to climb to 230°F (110°C) the engines will automatically shut off and cannot be restarted until they cool. Check engine coolant level (see “DAILY INSPECTION & MAINTENANCE” chapter) before you try to restart the engine. If the coolant is low, replenish it then check for leaks. If the engine will not restart, or if it automatically shuts off a second time, refer the problem to a qualified service technician.



Engine Oil Pressure



If the engine oil pressure in either a Continental or Cummins engine drops to an unsafe level, the lights in the on and the engine automatically shuts off. Check engine oil level (see “DAILY INSPECTION & MAINTENANCE” chapter) before you try to

gauge) of either a Continental

EMERGENCY STOP

switches will

switches come

Four are in the rear of the platform-control box.

Four are on the ground-control box.

P/N 0112478

1 5 -

5. AUTOMATIC SHUT-OFFS

One is on the junction wiring box assembly.

audible alarm comes on, open the box and check the breaker. If it has popped out, press it in then try to start the engine.

The other two circuit breakers are part of the ground fault circuit interrupt (GFCI).

If the 20 A circuit breaker on the GFCI outlet trips, disconnect whatever you plugged into the outlet, wait one minute, then press the circuit breaker button back in. If the circuit breaker trips a second time, refer the problem to a qualified service technician.

One is inside the junction-wiring box assembly.

If any of these circuit breakers pops out, as shown here,

wait a minute or two for the breaker to cool, then push it back in. If it pops out again, there is a problem in its electrical circuit and the TB100J should be removed from service immediately and remain out of service until it is repaired by a qualified service technician.

NOTE: Do not open the junction-wiring box assembly to check the one breaker inside unless the following occurs: the

EMERGENCY STOP

switch on the groundcontrol box is pulled out (on), but when you turn the

MASTER KEY SWITCH

to on, neither the EMS lights nor the EMS alarm comes on for their self test. If neither the lights nor

If the ground-fault circuit breaker on the GFCI outlet trips, disconnect whatever you plugged into the outlet, wait one minute, then press the RESET button back in. If the circuit breaker trips a second time, refer the problem to a qualified service technician.

When a circuit breaker trips that will not reset, immediately attempt to lower the platform to the ground by using normal operating procedures. If normal procedures do not work, use

EMERGENCY POWER OPERATION

does not work, use

DOWN

. (See “EMERGENCY OPERATION”

EMERGENCY BLEED

. If that

chapter for instructions.)

25 -

P/N 0112478

This chapter explains what each control does. This chapter does not explain how to use the controls to produce useful work: refer to the “OPERATION” chapter for that, after you have read this chapter.

The only optional equipment discussed in this chapter is the control for dual-fuel. For other optional equipment controls, see the “OPTIONS” chapter.

6. CONTROLS

The names of the controls on the platformcontrol box (6) are shown on a decal (7) on the guardrail (8) below the platform-control box.

The main operating functions of a TB100J can be controlled from the ground-control box (1) or the platform-control box (2).

The names of the different controls on the ground-control box (3) are shown on a decal (4) on the inside of the door (5). The decal also shows the names of the different settings to which each control can be set.

Controls (9) for operating the jack and extendible axles are on the rear of the chassis (11) along with the axle interlock (10).

See the “EMERGENCY OPERATION” chapter for the locations of emergency bleed down controls and for correct emergency bleed down procedures.

P/N 0112478

1 6 -

6. CONTROLS

GROUND-CONTROL BOX

Controls for operating the TB100J from the ground are located on the right side of the machine behind the small door.

NOTE: The number of each control below corresponds to the control’s call-out on the next page.

EMERGENCY STOP

1. at any time, under any conditions, and the entire machine stops — the engine turns off and nothing moves. This switch must be up for anything on the machine to work.

EMERGENCY POWER OPERATION

2. engine stops and cannot be restarted, continuously holding this switch down activates a small, battery-powered hydraulic-pump that supplies emergency hydraulic power for the machine. Boom movements will be slow and have long lag times under EMERGENCY POWER OPERATION.

SELECTOR SWITCH

3. GROUND position for the ground-control box to work. Must be in the PLATFORM position for the platform controls to work.

BOOM SPEED

4. fast the main boom moves in, out, up, or down. Set it to SLOW until you are very familiar with the way the machine works or if the platform is working in dangerous or cramped surroundings.

: Press the red button in,

: If the

: Must be in the

: This control determines how

ENGINE THROTTLE

7. LO unless you need to warm the engine and hydraulic oil up fast. Return to LO after warm-up.

BOOMS/AXLES SWITCH

8. be up (BOOMS) for the booms to move. It must be down (AXLES) anytime you use the AXLES controls, on the top-rear of the chassis, to move the jack or the rear axles.

: Leave the switch set on

: This switch must

9 through 14 are the platform-moving switches. Each is a three position, momentary contact, normally-off switch.

PLATFORM LEVEL

9. up relative to the end of the jib-boom. DN (down) rotates the platform down.

PLATFORM ROTATION

10. platform clockwise (as seen from above) relative to the end of the jib-boom. CCW rotates the platform counterclockwise.

JIB BOOM LIFT

11. relative to end of the tip-boom. DN (down) lowers the jib-boom.

TURNTABLE SWING

12. turntable clockwise (as seen from above). CCW rotates the turntable counterclockwise.

MAIN BOOM LIFT

13. boom. DN (down) lowers the base-boom.

MAIN BOOM EXT./RET.

14. the booms. RETRACT retracts the booms.

: UP rotates the platform

: CW rotates the

: UP raises the jib-boom

: CW rotates the entire

: UP raises the base-

: EXTEND extends

GROUND OPERATION

5. hold this switch up any time you use one of the six platform-moving switches (see box at right) to move the platform. Holding the switch up increases the engine speed and activates the platform-moving switches in preparation to do work.

MASTER KEY SWITCH

6. like an automobile ignition switch. Hold it at START until the engine starts then release it to ON. If the engine dies in ON, the key must be turned to OFF before it will go back to START.

NOTE: On some machines you might have to pause about three seconds in the ON position before going to START so the starter can engage.

Turn the MASTER KEY SWITCH to OFF if the platform is to stay in a particular position for a long time. That will turn the engine off and save fuel.

: You must manually

: This switch works

15. (OPTION set the FUEL switch to GASOLINE or L.P.-GAS depending on which you want to use. If you select L.P.-GAS be sure to open the valve on top the LP gas tank. To switch fuels with the engine running, see the DUAL FUEL SYSTEM decal on the inside of the ground-control box door.

FUEL

): Before starting the engine

26 -

P/N 0112478

6. CONTROLS

P/N 0112478

GROUND-CONTROL BOX

3 6 -

6. CONTROLS

PLATFORM-CONTROL BOX

Controls for operating the TB100J from the platform are located on the platform-control box, with the exception of the yellow foot switch which is on the platform floor.

NOTE: The number of each control below corresponds to the control’s call-out on the next page.

EMERGENCY STOP

1. button down at any time, under any conditions, and the entire machine stops — the engine turns off and nothing moves. This switch must be pulled to its up (or out) position if the TB100J is to be controlled from the platform.

EMERGENCY POWER OPERATION

2. engine stops and cannot be restarted, hold the switch toward you and a small, battery-powered hydraulic-pump comes on to supply power for the machine. Boom movements will be slow and have long lag times under EMERGENCY POWER.

ENGINE THROTTLE

3. on LO unless you want to speed (see DRIVE RANGE below).

PLATFORM ROTATION

4. platform clockwise (as seen from above) relative to the end of the jib-boom. CCW rotates the platform counterclockwise.

PLATFORM LEVEL

5. up relative to the end of the jib-boom. DN (down) rotates the platform down.

DRIVE RANGE

6. the position of the booms, determines how fast the TB100J can travel along the ground. See the DRIVE RANGE Table below for settings and maximum speeds.

Switching from LO to HI changes the driving conditions from low speed and high torque to the wheels to high speed and low torque to the wheels.

: Press the large red

: If the

: Leave this switch set

drive

at maximum

: CW rotates the

: UP rotates the platform

: This switch, together with

DRIVE RANGE

MAX.

SPEED

3.0 mph

(4.8 km/hr)

0.75 mph

(1.2 km/hr)

0.75 mph

(1.2 km/hr)

creep --

NOTE: ENGINE THROTTLE, at the platformcontrol box, must be set to HI for MAX. SPEED.

MAIN BOOM EXTEND/RETRACT

7. extends the booms. RETRACT retracts the booms. Speed of movement is proportional to how far you push the controller.

JIB BOOM LIFT

8. relative to end of the tip-boom. DN (down) lowers the jib-boom. Speed of movement is proportional to how far you push the controller.

ANTI-RESTART MASTER SWITCH

9. switch works like an automobile ignition switch. Hold it at START until the engine starts then release it to ON. If the engine dies in ON, the key must be turned to OFF before it will go back to START. Turn the switch to OFF if the platform is to stay in a particular position for a long time. This will turn the engine off and save fuel.

HORN

10.

11. Foot Switch: You must step down on the foot switch, and hold it down, any time you use any platform control that causes the platform to move. Stepping on the foot switch increases the engine speed and activates other switches/controls in preparation to do work. (The foot switch is to the platform what the GROUND OPERATION switch is to the groundcontrol box.)

: See ”SAFETY DEVICES” chapter.

DRIVE

RANGE

HI stowed

LO stowed

: UP raises the jib-boom

Table

boom

position

extended but

below mid-

elevation

above mid-

elevation

: EXTEND

: This

CAUTION

Prolonged driving in HI (3 mph, 4.8 km/hr) heats the hydraulic oil. Periodically check the thermometer at the hydraulic-oil tank sightglass. Do not let the oil exceed 200°F (93°C). Stop the engine and let the oil cool if necessary.

46 -

P/N 0112478

6. CONTROLS

PLATFORM-CONTROL BOX

NOTE: On some machines you might have to pause about three seconds in the ON position before

going to START so the starter can engage.

P/N 0112478

NOTE: Do not step on the foot switch while you are trying to start the engine.

5 6 -

6. CONTROLS

1312

12.

LIFT/SWING CONTROLLER

UP: Slowly push the LIFT/SWING controller forward and the main-boom raises. The further forward you push the controller the faster the main-boom raises.

DN: Same as UP only the main-boom goes down.

CW: Slowly push the LIFT/SWING controller to the left and the turntable swings clockwise (from above). The further left you push the controller the faster the turntable swings.

CCW: Same as CW only the turntable swings counterclockwise.

NOTE: There are blue and yellow arrows on top of the chassis. The blue arrows point to the FORWARD end of the chassis and to the LEFT side of the TB100J. The yellow arrows point to the REVERSE end of the chassis and to the RIGHT side of the TB100J. The color coded to match the arrows. The color coding is designed to keep you from becoming disoriented when you are aloft and the platform is rotated with respect to the chassis.

CHASSIS

AXLES

DRIVE/STEER

controller is

13.

DRIVE/STEER CONTROLLER

DRIVE FORWARD: Slowly push the DRIVE/STEER controller forward and the TB100J moves forward. The further forward you push the controller the faster the TB100J goes (max. 3 mph, 4.8 km/hr).

DRIVE REVERSE: Same as DRIVE FORWARD except the TB100J moves backward.

STEER RIGHT: Push the DRIVE/STEER controller to the right and the front wheels move in the direction for a right hand turn. The longer you hold the controller to the right the further the wheels turn.

STEER LEFT: Works the same as STEER RIGHT only for a left hand turn.

NOTE: The wheels stay the direction you turn them, they do not automatically return to center the way automobile wheels do.

RAISE: Lowers the jack (1) and raises the

chassis (4).

LOWER: Raises the jack and lowers the

chassis. EXTEND: Extends both rear axles (2) (3). RETRACT: Retracts both rear axles.

NOTE: The axles extend or retract one at a time, not simultaneously.

For the AXLES controls to work BOOMS/AXLES SWITCH must be set to AXLES and the SELECTOR SWITCH set to GROUND. Also, the main boom must be down and retracted.

TURNTABLE

BATTERY

When the

BATTERY

(1) is set to OFF, all of the batteries are disconnected from the electrical system.

switch

66 -

P/N 0112478

7. OPERATION

Read and understand all the previous chapters in this manual before you begin to operate a TB100J.

Dual-fuel is the only optional equipment discussed in this chapter. For operation of other optional equipment, see the "OPTIONS" chapter.

CONTROL STATIONS

A TB100J can be operated from the groundcontrol box or from the platform-control box. There are basically two differences between ground-control and platform-control operations, both are safety related:

1. The ground-control box can override the platform-control box at any time. If a person operating the machine from the platform becomes incapacitated, a person on the ground can always take over machine control.

DANGER

Do not attempt to operate the TB100J ground controls when the platform, booms, or any other conducting part of the TB100J is in contact with energized electrical wires or if there is an immediate danger of such contact.

2. The TB100J can only be driven from the platform-control box. The wheels cannot be made to move from the ground-control box. This prevents ground-control operators from running over themselves.

EMERGENCY STOPPING

Anytime you want to stop a TB100J, push either of the two in. (For a complete discussion of the

EMERGENCY STOP

“CONTROLS” chapter.)

EMERGENCY STOP

switches, see the

buttons (1) (2)

Before you begin to operate the TB100J a qualified operator must perform the "DAILY INSPECTION & MAINTENANCE" described in the chapter by that name in this manual.



Pre-start Conditions

After the DAILY INSPECTION & MAINTENANCE has been performed, put the TB100J into its prestart conditions. Pre-start conditions for starting from the ground-control box are:

1. Set the to see that the has not popped out (close the batterycompartment door).

2. Check the circuit breakers (2) to see that none has popped out.

NOTE: You do not need to check the circuit breakers on the platform-control box.

3. Set

4. Pull

5. Set

6. Set

7. Set

BATTERY

SELECTOR SWITCH

EMERGENCY STOP ENGINE THROTTLE BOOM SPEED BOOMS/AXLES SWITCH

switch (1) to ON and look

AUX. BATTERY

(6) as shown.

circuit breaker

(3) to GROUND. (4) out.

(5) to LO.

(7) to BOOMS.

STARTING FROM THE GROUND-

CONTROL BOX

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8. (OPTION - DUAL FUEL ) For machines set up to run both gasoline and LP gas: Set the switch to GASOLINE or L.P.-GAS depending on

FUEL

1 7 -

7. OPERATION

which you want to use. If you select L.P.-GAS, open the valve on top the LP gas tank.



Starting (from the ground)

Do not attempt to start a TB100J until the actions in the previous part of this section (“STARTING FROM THE GROUND-CONTROL BOX”) have been completed.

NOTE: You cannot raise or extend the main boom unless the rear axles are extended and locked. If you want to move the platform, from the ground-control station, go to the "EXTEND & LOCK REAR AXLES" section of this chapter.

CAUTION

If the engine fails to start (at the next step) in 20 seconds, turn the key to OFF and wait 60 seconds before turning the key to START again.

3. Turn the key (3) to START and hold it there until the engine starts (or for a maximum of 20 seconds) then release the key to ON.

1. Insert the key (1) into the

SWITCH

2. Turn the key (1) to ON and pause there a few seconds while an alarm sounds to alert others that the TB100J is about to start.

(2).

MASTER KEY

NOTE: If you pause 30 seconds or more an automatic protection feature will prevent the TB100J from starting. If that happens, turn the key to OFF and try again.

The engine should now be running.

27 -

P/N 0112478

STARTING FROM THE PLATFORM-

CONTROL BOX

Before you begin to operate the TB100J, a qualified operator must perform the "DAILY INSPECTION & MAINTENANCE" described in the chapter by that name in this manual.

If you want to drive the TB100J with the main boom down and retracted, you do not need to extend the rear axles. Therefore, you should go on to "Pre-Start Conditions" immediately below. If you want to start the TB100J from the platformcontrol box then extend or raise the main boom, you first need to extend and lock the rear axles for stability. Therefore, you should go to the "EXTEND & LOCK REAR AXLES" section in this chapter.

Pre-start Conditions



After the DAILY INSPECTION & MAINTENANCE has been performed, put the TB100J into its prestart conditions. Pre-start conditions for starting from the platform-control box are:

7. OPERATION

4. At the ground-control box, pull the

EMERGENCY STOP

5. At the ground-control box, insert the key into

MASTER KEY SWITCH

the

NOTE: Because you set the

SWITCH

when you set the ON (unless the platform switch and

SWITCH

6. Set the BOOMS then close the ground-control door.

to PLATFORM, no alarm will sound

ANTI-RESTART MASTER

are both ON).

BOOMS/AXLES SWITCH

switch (4) out.

(5) and turn it to ON.

SELECTOR

MASTER KEY SWITCH

EMERGENCY STOP

(6) to

1. Set the to see that the has not popped out (close the batterycompartment door).

2. Check the circuit breakers (2) to see that none has popped out.

3. At the ground-control box, set the

SWITCH

NOTE: This last step is often overlooked. Set the

BATTERY

(3) to PLATFORM.

SELECTOR SWITCH

switch (1) to ON and look

AUX. BATTERY

circuit breaker

SELECTOR

to PLATFORM.

7. (OPTION - DUAL FUEL ) For machines set up to run both gasoline and LP gas: Set the switch to GASOLINE or L.P.-GAS depending on which you want to use. If you select L.P.-GAS, open the valve on top the LP gas tank.

FUEL

P/N 0112478

3 7 -

7. OPERATION

8. Put on your fall restraint, enter the platform, close the gravity gate, and attach the lanyard of your fall restraint to the anchorage point (7).



Starting (from the platform)

Do not attempt to start a TB100J until the actions in the previous part of this section (STARTING FROM THE PLATFORM CONTROL BOX) have been completed.

9. At the platform-control box (8) set the following:

EMERGENCY STOP ENGINE THROTTLE DRIVE RANGE

NOTE: With these settings the maximum ground speed is 0.75 mph (1.2 km/hr). If you want to go faster, see the "PLATFORMCONTROL BOX" section in the "CONTROLS" chapter. Pay particular attention to the DRIVE RANGE Table in that section.

10. Check the platform-control box circuit breakers (12) to see that none has popped out.

(9)..............pulled out

(10)............LO

(11).....................LO

1. Turn the (1) to ON and pause there a few seconds while an alarm sounds to alert others that the TB100J is about to start.

ANTI-RESTART MASTER SWITCH

NOTE: If you pause 30 seconds or more an automatic protection feature will prevent the TB100J from starting. If that happens, turn the

ANTI-RESTART MASTER SWITCH

and try again.

to OFF

If the engine fails to start (at the next step) in 20 seconds, turn the

SWITCH

turning the switch to START again.

2. Turn the (2) to START and hold it there until the engine starts (or for a maximum of 20 seconds) then release the switch to ON.

CAUTION

ANTI-RESTART MASTER

to OFF and wait 60 seconds before

ANTI-RESTART MASTER SWITCH

NOTE: Do not step on the foot switch while you are trying to start the engine.

The engine should now be running.

47 -

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MOVING THE PLATFORM

The engine should already be running (as described earlier in this chapter) before you start this section.

Before you can raise or extend the main boom the rear axles must be extended (see "EXTEND & LOCK REAR AXLES" in this chapter).

7. OPERATION

DANGER

Death or serious injury can result if a TB100J tips over. A PRO- 100 might tip over if the rear axles are retracted while the booms are up or extended. The TB100J should have its booms completely retracted and completely down before retracting the rear axles.

DANGER

Be certain that the space into which you are about to move the platform, boom, turntable, and chassis is free of obstructions. Always look in the direction of movement.

Do not operate near energized electrical conductors. See the inside-front cover of this manual for the minimum safe approach distance to energized power lines.

DANGER

If you operate from the platform-control box, be sure that the lanyard of your fall restraint is attached to the anchorage point on the platform mount. Also, be sure the gravity gate is closed behind you.

Each of the ways the platform can move is shown in the following two-page spread. The photos show the switches to push to move the platform. The switch call-out numbers (on the left-hand page) correspond to the illustration numbers on the right-hand page.

NOTE: The correct procedure for retracting the rear axles is shown at the end of this chapter under "RETRACT & LOCK REAR AXLES."

NOTE: At the end of each work day the TB100J should be returned to the STOWED POSITION as described under STOWING in the "STOWING & TRANSPORTING" chapter.

P/N 0112478

5 7 -

7. OPERATION

IMPORTANT

You must hold the switch (7) up when you use any of the platformmoving switches (1 through 6) to move the platform. This is a safety feature to prevent the platform from moving if a single platform-moving switch is accidentally pushed.

(ground-control box operation):

GROUND OPERATION

GROUND-CONTROL BOX

IMPORTANT

operation):

switch (8) when you use any of the platformmoving switches (1 through 6) to move the platform. Also, you must be stepping on the foot switch to use either the the

DRIVE/STEER

safety feature to prevent the platform from moving if a single platform-moving switch or controller is accidentally pushed.

(platform-control box

You must be stepping on the foot

LIFT/SWING

controller. The foot switch is a

FOOT SWITCH

controller or

PLATFORM-CONTROL BOX

67 -

P/N 0112478

7. OPERATION

MAIN BOOM LIFT (LIFT)

JIB BOOM LIFT

MAIN BOOM EXT./RET. (EXTEND)

TURNTABLE SWING (SW ING)

INOUT

PLATFORM LEVEL

(clockwise)

PLATFORM ROTATION

CCW

(counterclockwise)

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(clockwise)

CCW

(counterclockwise)

7 7 -

7. OPERATION

MOVING THE TB100J

The TB100J chassis can only be moved form the platform-control box. You cannot move the chassis from the ground-control box.

There is a blue arrow on the DRIVE FORWARD end of the chassis and a yellow arrow on the DRIVE REVERSE end of the chassis. Pushing the

DRIVE/STEER

controller to DRIVE FORWARD causes the chassis to move in the direction of the blue arrow on the end of the chassis. Pushing the

DRIVE/STEER

controller to DRIVE REVERSE causes the chassis to move in the direction of the yellow arrow on the opposite end of the chassis.

NOTE: You must be stepping on the foot switch for the

DRIVE/STEER

controller to

work.

DRIVE/STEER

CONTROLLER

DRIVE

FORWARD

stresses from building up in the tires and steering mechanism. To release the brakes

DRIVE/STEER

the

controller must be in a “drive position” -- not in its center, off, position.

NOTE: When you release the

DRIVE/STEER

controller the wheels stay where you set them. The wheels do not return to the "straight ahead" position the way automobile wheels do.

STEER LEFT STEER RIGHT

DRIVE/STEER

CONTROLLER

DRIVE

REVERSE

STEERING

The TB100J can only be steered from the platform-control box. You cannot steer the TB100J from the ground-control box.

There are two blue arrows on the STEER LEFT side of the chassis and two yellow arrows on the STEER RIGHT side of the chassis. Pushing

DRIVE/STEER

the

controller to STEER LEFT causes the front wheels to turn for a left turn. Pushing the

DRIVE/STEER

controller to STEER RIGHT causes the front wheels to turn for a right turn.

NOTE: You must be stepping on the foot switch.

125 V AC OUTLET AT THE PLATFORM

The electrical box (1) has two 3-prong, 125 V ac electrical connectors. Their combined output is limited by a 20 A, slow-blow circuit breaker (2).

NOTE: You cannot steer the wheels while the brakes are set. This prevents high

87 -

P/N 0112478

The power-input connector (3) for the electrical box (1) is inside the left rear side of the turntable. Plug a source of power into the power-input connector (3) if you intend to use the electrical box (1) to power equipment.

CAUTION

Unplug the source of power before you move the TB100J.

7. OPERATION

At the ground-control box:

(OPTION - DUAL FUEL ) For machines set up to run both gasoline and LP gas: Set the switch to GASOLINE or L.P.-GAS depending on which you want to use. If you select L.P.GAS, open the valve on top the LP gas tank.

1. Pull

EMERGENCY STOP

(1) out.

FUEL

EXTEND & LOCK REAR AXLES

Before the main boom can be raised or extended the rear axles of the TB100J must be extended and locked. This section explains the procedure for extending and locking the rear axles.

Inside the turntable:

1. Set the popped out (close the battery-compartment door).

BATTERY

AUX. BATTERY

(1) to ON and look to see that

circuit breaker has not

2. Set

3. Set

4. Set BOOMS.

5. Insert the key (5) into

SWITCH

6. Turn the key (5) to ON and pause there a few seconds while an alarm sounds to alert others that the TB100J is about to start.

SELECTOR SWITCH

ENGINE THROTTLE

BOOMS/AXLES SWITCH

(6).

(2) to GROUND.

(3) to LO.

(4) to

the MASTER KEY

P/N 0112478

NOTE: If you pause 30 seconds or more an automatic protection feature will prevent the TB100J from starting. If that happens, turn the key to OFF and try again.

9 7 -

7. OPERATION

CAUTION

At the AXLES controls:

If the engine fails to start (at the next step) in 20 seconds, turn the key to OFF and wait 60 seconds before turning the key to START again.

7. Turn the key (7) to START and hold it there until the engine starts (or for a maximum of 20 seconds) then release the key to ON.

CAUTION

Rear axle weight is about to be lifted by the jack. Check to be sure the area under the jack shoe plate will support that weight and that the area is clear of objects that might be crushed.

1. Push and hold the jack control lever (1) to RAISE until the rear wheels (2) are off the ground and the jack (3) has stopped lifting the chassis.

2. Remove the snapper pin (4) from the pin lock (5) then remove the pin lock (5) from the upper hole (6) in the chassis.

NOTE: You might have to cycle the axle control lever (7) back and forth, to relieve pressure on the pin lock (5), while you twist and pull the pin lock (5) out of the chassis.

7 1

The engine should now be running.

8. Set

BOOMS/AXLES SWITCH

NOTE: The engine rpm should automatically increase when you switch to AXLES.

(8) to AXLES.

3. Push and hold the axle control lever (8) to EXTEND until the axles (9) (10) stop extending.

NOTE: One axle might extend before the other, they do not necessarily extend together.

4. Completely insert the pin lock (11) into the lower hole (12) in the chassis and install the

107 -

P/N 0112478

snapper pin (13) through the pin lock (11) and the hole lip.

NOTE: You might have to cycle the axle control lever (14) back and forth, to align holes inside the chassis, while you push the pin lock (11) into the chassis.

5. Pull and hold the jack control lever (15) to LOWER until the wheels are on the ground and the jack stops retracting.

7. OPERATION

RETRACT & LOCK REAR AXLES

Retracting the rear axles is basically the reverse of extending them.

DANGER

Death of serious injury can result if a TB100J tips over. A TB100J might tip over if the rear axles are retracted while the booms are up or extended. The TB100J should have its booms completely retracted and completely down before retracting the rear axles.

Inside the turntable:

At the ground-control box:

1. Set the BOOMS.

BOOMS/AXLES SWITCH

1. Set the popped out (close the battery-compartment door).

BATTERY

AUX. BATTERY

At the ground-control box:

(1) to ON and look to see that

circuit breaker has not

FUEL

What next:

1. If you want to control the platform from the ground-control box, go to the "MOVING THE PLATFORM" section of this chapter.

2. If you want to control the platform from the platform-control box, return to the "Pre-Start Conditions" in the "STARTING FROM THE PLATFORM CONTROL BOX" section of this chapter.

P/N 0112478

11 7 -

7. OPERATION

1. Pull

EMERGENCY STOP

(1) out.

2. Set

3. Set

4. Set BOOMS.

5. Insert the key (5) into the

SWITCH

6. Turn the key (5) to ON and pause there a few seconds while an alarm sounds to alert others that the TB100J is about to start.

SELECTOR SWITCH

ENGINE THROTTLE

BOOMS/AXLES SWITCH

(6).

(2) to GROUND.

(3) to LO.

(4) to

MASTER KEY

The engine should now be running.

8. Set

BOOMS/AXLES SWITCH

NOTE: The engine rpm should automatically increase when you switch to AXLES.

(8) to AXLES.

NOTE: If you pause 30 seconds or more an automatic protection feature will prevent the TB100J from starting. If that happens, turn the key to OFF and try again.

CAUTION

If the engine fails to start (at the next step) in 20 seconds, turn the key to OFF and wait 60 seconds before turning the key to START again.

7. Turn the key (7) to START and hold it there until the engine starts (or for a maximum of 20 seconds) then release the key to ON.

127 -

P/N 0112478

At the AXLES controls:

CAUTION

Rear axle weight is about to be lifted by the jack. Check to be sure the area under the jack shoe plate will support that weight and that the area is clear of objects that might be crushed.

1. Push and hold the jack control lever (1) to RAISE until the rear wheels (2) are off the ground and the jack (3) has stopped lifting the chassis.

7. OPERATION

3. Push and hold the axle control lever (8) to RETRACT until the axles stop retracting.

NOTE: One axle might retract before the other, they do not necessarily retract together.

4. Completely insert the pin lock (9) into the upper hole (10) in the chassis and install the snapper pin (11) through the pin lock (9) and the hole in the lip.

NOTE: You might have to cycle the axle control lever (8) back and forth a few times, to align holes inside the chassis, while you push the pin lock (9) into the chassis.

2. Remove the snapper pin (4) from the pin lock (5) then remove the pin lock (5) from the lower hole in the chassis (6).

NOTE: You might have to cycle the axle control lever (7) back and forth a few times, to relieve pressure on the pin lock (5), while you pull the pin lock (5) out of the chassis.

5. Pull and hold the jack control lever (12) to LOWER until the wheels are on the ground and the jack stops retracting.

P/N 0112478

13 7 -

7. OPERATION

At the ground-control box:

1. Set the

BOOMS/AXLES SWITCH

BOOMS.

What next:

At this point you will probably want to do one of the following two things.

1. Turn the TB100J off by pushing the

EMERGENCY STOP MASTER KEY SWITCH

button in and turning the

to OFF.

2. Or you might want to drive the TB100J as described under "MOVING THE TB100J" earlier in this chapter.

147 -

P/N 0112478

The following procedures are emergency procedures only. Do not use them for normal operation. Their purpose is to get the platform and operator safely to ground when the TB100J motor will not start or some other problem keeps the platform from lowering in the normal way.

EMERGENCY OPERATION FROM THE

PLATFORM-CONTROL BOX

Try Procedure A first. If Procedure A does not work, use Procedure B.

Procedure A

8. EMERGENCY OPERATION

1. The

BATTERY

switch (1) must be ON.

5. Set the (pulled up).

6. Set the (6) to ON.

7. Step on the foot switch (7).

EMERGENCY STOP

ANTI-RESTART MASTER SWITCH

switch (5) to on

8. Pull down and hold the

POWER OPERATION

9. Use the switches and/or controllers, on the top of the platform-control box, to move the platform as desired.

EMERGENCY

switch (8).

2. The

3. The pulled out (on).

4. The PLATFORM.

P/N 0112478

MASTER KEY SWITCH

EMERGENCY STOP

SELECTOR SWITCH

(2) must be ON.

switch (3) must be

(4) must be set to

NOTE: Boom movements will be slow and have long lag times under

POWER OPERATION

EMERGENCY

1 8 -

8. EMERGENCY OPERATION

Procedure B

If the red reset it by pressing it in then releasing it several times. If the red light goes out, try to restart the motor and lower the platform in the normal way.

If the red light stays on and the green

STATUS

retracted in the normal way (if it is extended) or lowered in the normal way (if it is almost completely retracted). Use one or the other of those two functions to retrieve the platform as long as the green

If the red light stays on and the green light stays off, continue with this procedure.

EMS WARNING

light (2) is on, the main boom can be

EMS STATUS

NOTE: If the green light goes out, try to reset the red the green light will come back on.

EMS WARNING

light (1) is on, try to

EMS

light is on.

light again to see if

2. The pulled out (on).

3. The PLATFORM.

4. Set the (pulled up).

EMERGENCY STOP

SELECTOR SWITCH

EMERGENCY STOP

switch (4) must be

(5) must be set to

switch (6) to on

1. The

28 -

BATTERY

switch (3) must be ON.

5. Set the (7) to OFF.

ANTI-RESTART MASTER SWITCH

DANGER

Death or serious injury can result if a TB100J tips over. A TB100J can tip over if the booms lower without retracting. At the next step, stop immediately if the booms lower without retracting.

If you have control over turntable swing, align the turntable with the chassis to take advantage of the extended base of support.

6. Pull up and hold both

DOWN

booms retract as they lower.

switches (8) (9) and watch to see that the

EMERGENCY BLEED

P/N 0112478

EMERGENCY OPERATION FROM THE

GROUND-CONTROL BOX

Try Procedure C first. If Procedure C does not work, try Procedure D second and Procedure E third.

Procedure C

8. EMERGENCY OPERATION

7. Push and hold any of the six platform-moving switches (7) to move the platform as desired.

1. Set the

BATTERY

2. Set the

3. Pull the (on).

4. Set the

5. Push and hold the switch (5) up.

6. Push and hold the

OPERATION

MASTER KEY SWITCH

EMERGENCY STOP

SELECTOR SWITCH

switch (6) down.

switch (1) to ON.

(2) to ON.

switch (3) out

(4) to GROUND.

GROUND OPERATION

EMERGENCY POWER

NOTE: Boom movements will be slow and have long lag times under

POWER OPERATION

Procedure D

If the red reset it by pressing it in then releasing it. If the red light goes out, try to restart the motor and lower the platform in the normal way.

If the red light stays on and the green

STATUS

NOTE: If the green light goes out, try to reset the red the green light will come back on.

EMS WARNING

light (2) is on, the main boom can be

EMS STATUS

EMS WARNING

EMERGENCY

light (1) is on, try to

EMS

light is on.

light again to see if

P/N 0112478

If the red light stays on and the green light stays off, continue with this procedure.

3 8 -

8. EMERGENCY OPERATION

1. Set the

2. Set the

3. Pull the (on).

BATTERY

MASTER KEY SWITCH

EMERGENCY STOP

switch (3) to ON.

switch (5) out

(4) to OFF.

5. Pull up and hold both

DOWN

booms retract as they lower.

switches (7) (8) and watch to see that the

Procedure E

EMERGENCY BLEED

4. Set the

SELECTOR SWITCH

(6) to GROUND.

DANGER

Death or serious injury can result if a TB100J tips over. A TB100J can tip over if the booms lower without retracting. At the next step, stop immediately if the booms lower without retracting.

If you have control over turntable swing, align the turntable with the chassis to take advantage of the extended base of support.

48 -

1. Set the

BATTERY

switch (1) to OFF.

P/N 0112478

DANGER

Death or serious injury can result from being crushed by the main boom as it lowers. At the next step do not reach for the manual bleeddown valve from above the turntable.

Death or serious injury can result if a TB100J tips over. A TB100J can tip over if the booms lower without retracting. At the next step, stop immediately if the booms lower without retracting.

If you have any control over turntable swing, align the turntable with the chassis to take advantage of the extended base of support.

8. EMERGENCY OPERATION

3. Very slowly open the bleed-down valve (2). The further it is opened, the faster the booms come down.

2. Reach the manual bleed-down valve from the position shown above.

DANGER

Be certain you close the emergency bleeddown valve (2) at the next step. Failure to do so prevents the main boom from remaining stationary in an elevated position.

4. Close the emergency bleed-down valve (2) when the main boom is horizontal.

P/N 0112478

8 - 5 (8 - 6 blank)

5 8 -

STOWING

9. STOWING & TRANSPORTING

TRANSPORTING

9. STOWING & TRANSPORTING

At the end of each work day (or in preparation for transporting, lifting, towing, or storage) a qualified operator should put the TB100J into its STOWED POSITION then lock it.

The correct STOWED POSITION is shown here.

To bring the TB100J into the STOWED POSITION use the controls on the groundcontrol or platform-control box to:

1. Fully retract the main boom.

2. Fully lower the main boom.

The user assumes all responsibility for choosing the proper method of transportation, and the proper selection and use of transportation and tie-down devices, making sure the equipment used is capable of supporting the weight of the aerial platform and that all manufacturer’s instructions and warnings, regulations and safety rules of their employer, the DOT and/or any other state or federal law are followed.



Trailering



DANGER

A TB100J weighs approximately 33,000 pounds (15,000 kg). Loading ramps must be able to support that weight. Transport trailers must be able to safely transport that weight.

Do not load a TB100J on grades over 25% or on ramps with poor traction, uneven surfaces, or steps.

To safely drive a TB100J onto a transport trailer:

3. Fully lower the jib boom.

4. Center the main boom between the rear wheels.

5. Use the the axles and completely raise the jack.

To lock the TB100J:

1. If the engine has just been under load and is hot, set the the engine idle for one minute.

2. Set the remove the key, and close the ground-control box door.

3. Set the

BATTERY

4. (OPTION - LPG) For machines equipped with LPG, close the valve on the LPG-tank (completely screwed in).

5. Close and latch all other doors.

AXLES

ENGINE THROTTLE

MASTER KEY SWITCH

BATTERY

switch.

controls to completely retract

to LO and let

to OFF,

switch to OFF and lock the

1. Visually inspect the alignment of the loading ramp (1) and the truck or trailer (2). They should both be on the same straight line.

2. Chock (3) the wheels of the truck or trailer so it cannot roll away form the loading ramp (1) while the TB100J is being loaded.

3. Set the ground-control box for platform operation.

P/N 0112478

1 9 -

9. STOWING & TRANSPORTING

weighs approximately 14,300 pounds (6,500 kg) and the rear (extending) axle weighs approximately 18,700 pounds (8,500 kg). If you need to shift trailer axle-weight you can transport a TB100J with the booms over the front axle. However, you should drive the TB100J onto the trailer with the booms over the rear axle so that you do not get disoriented using the controls.

Securing to a Transport Vehicle



4. Enter the platform and attach the lanyard of your fall restraint to the anchorage point (4) on the platform.

5. Use the controls of the platform-control box (5) to raise the jib-boom (6) to its horizontal position.

6. Use the platform controls to bring the TB100J into the STOWED POSITION (except jib-boom horizontal) at the foot of the loading ramp (7) with the steering wheels (8) nearest the ramp.

7. Visually check (from the platform) to be sure the TB100J is aligned with the ramp and the ramp is still aligned with the truck or trailer. All should be in a straight line.

DANGER

Death or serious injury can result from losing control of a TB100J while loading. Always set the ENGINE THROTTLE and DRIVE RANGE to LO anytime you drive up or down a grade.

8. Set the

9. Set the

10. Use the platform slightly to the side so you are aligned with the wheels and can see them better.

11. Use the drive the TB100J straight onto the ramp and trailer.

12. Use the base boom between the rear wheels.

13. Lower the jib-boom until it is about a foot (0.3 m) above the trailer.

14. Leave the engine running in preparation for the next section.

15. Chock the TB100J wheels.

NOTE: In the stowed position (boom over rear axles), the TB100J front (steering) axle

ENGINE THROTTLE

DRIVE RANGE

LIFT/SWING

DRIVE/STEER

LIFT/SWING

to LO.

controller to move the

controller to slowly

controller to align the

to LO.

This procedure assumes that you have just finished the previous section, that the TB100J engine is still running, and that the wheels are chocked.

1. Place a wooden block (1) under the rotator pylon (2) then use the controls at the platformcontrol box to lower the rotator pylon (2) onto the block (1).

NOTE: If the platform will not come down far enough to touch the wooden block, use a larger block. If neither a larger block nor suitable trailer is available, you may resort to Procedure B in the “Emergency Operation” chapter. However, you should not use Procedure B on a regular basis because it involves an emergency system that should be held in reserve.

2. Set the OFF.

3. Set the remove the key, and close the ground-control box door.

4. Set the

BATTERY

5. (OPTION - LPG) For machines equipped with LPG, close the valve on the LPG tank (completely screwed in).

6. Use a nylon strap (3) to hold the platform (4) on the blocks (1) as shown.

ANTI-RESTART MASTER SWITCH

MASTER KEY SWITCH

BATTERY

switch.

switch to OFF and lock the

to OFF,

29 -

P/N 0112478

7. Attach two nylon straps (5) (6) from the underside of the base boom (7), as shown, to the trailer (8).

9. STOWING & TRANSPORTING

DANGER

A loose TB100J can cause death or serious injury. Do not attach tie downs to the steering tie rods. The tie rods are not strong enough to safely hold a TB100J.

8. Fasten a nylon strap (9) from the underside of the base boom (7) to the weldment (10) across the lower end of the jib-boom (11).

NOTE: The nylon strap (9) keeps the jibboom from bouncing away from the chassis during transportation. In extreme cases, without the strap (9), the platform can be pushed off the wooden block (1) and into the end of the trailer or cab.

9. Attach chains to the front (12) and back (13) tie-down lugs. Chocks may be removed at this time, though it is a good idea to leave them in place.

10. Use rubber straps (14), as shown, to keep the rear cowling doors (15) from opening during transport.

P/N 0112478

11. Hook a long rubber strap (16) through the hole (17) in the inside of one of the front cowling doors (18).

3 9 -

9. STOWING & TRANSPORTING

12. Stretch the rubber strap (16) under the turntable (19) to a similar hole in the opposite front cowling door. (This prevents the front doors from opening during transport.) Fasten the engine compartment door with a similar strap (20).

14. Use a wire-tie on each end of the gravitygate to keep it from bouncing around.

Reverse the above procedure after transporting.



Towing



Do not tow a TB100J unless it is equipped with the optional tow package. See the “OPTIONS” chapter.

13. Use a wire-tie, as shown, to keep the foot switch from bouncing around the platform.

49 -

P/N 0112478

At the start of each work day (or 8 hour shift) a TB100J qualified operator must perform the DAILY INSPECTION AND MAINTENANCE listed in the table below.

The purpose of the daily inspection and maintenance is to keep the TB100J in proper working condition and to detect signs of malfunction at the earliest possible time.

10. DAILY INSPECTION & MAINTENANCE

Do not operate a TB100J that is known to be damaged or malfunctioning. Defective parts or equipment malfunctions jeopardize the safety of the operator and other people, and can cause damage to the machine.

10. DAILY INSPECTION

DANGER

DAILY INSPECTION AND MAINTENANCE TABLE

(Set the

ITEM SERVICE REQUIRED

1. Engine fuel level Check fuel gauge (full)

2. Fuel tank cap Visually inspect (installation)

MASTER KEY SWITCH

to OFF before you begin this inspection)

AND MAINTENANCE

3. Engine oil Check oil level (between dipstick lines)

4. Fuel leaks Visually inspect (hoses, connections, etc.)

5. Engine coolant Check fluid level and radiator hoses

6. Wiring harnesses Visually inspect (installation, condition)

7. Battery terminals Visually inspect (no corrosion)

8. Battery fluid level Check fluid level (in contact with filler neck)

9. Hydraulic oil Check fluid level (between lines on gauge)

10. Hydraulic oil leaks Visually inspect (hoses, tubes)

11. Tires and wheels Visually inspect (condition)

12. Bolts and fasteners Visually inspect (looseness)

13. Structural damage & welds Visually inspect (weld cracks, dents)

14. Platform gravity gate Visually inspect (operation)

15. Axle/boom interlock Check operation

16. Emergency power motor/pump Check operation (causes correct motion)

17. Air filter Check condition (gauge)

18. Charging system Visually inspect (gauge)

19. Control switches Actuate and visually inspect for operation

20. Slide pads Visually inspect (boom wear marks)

21. Whiffles and wire ropes Visually inspect (even tension, condition)

22. Envelope management system Check operation

23. Placards and decals Visually inspect (installation, condition)

24. GFCI

P/N 0112478

(Ground Fault Circuit Interrupt

) Check operation

10 - 1

10. DAILY INSPECTION & MAINTENANCE

The rest of this chapter shows how to perform the SERVICE REQUIRED for each ITEM in the DAILY INSPECTION AND MAINTENANCE TABLE.

1. Engine fuel level

Visually check to see that the gasoline or diesel tank is full — this one is not.

Open the straps (4).

Manually lift the tank (5) out.

2. Fuel tank cap

Check to see that the tank cap is in place and is tight.

(OPTION - LPG) Visually check to see that the LPG tank is full (1).

To replace an LPG tank:

Close the valve (2).

Manually disconnect the fuel hose at the knurled ring (3).

NOTE: Notice the positioning pin (6). At reinstallation be sure the slot (7) in the top of the LPG tank (5) aligns with the pin (6).

3. Engine oil

CONTINENTAL GASOLINE ENGINE

10 - 2

P/N 0112478

CUMMINS DIESEL ENGINE

10. DAILY INSPECTION & MAINTENANCE

5. Engine coolant

Both Continental and Cummins engines are liquid cooled. At operating temperature the coolant should be at the HOT level. When cold, there should be about 1 inch (2.5 cm) of coolant in the bottom of the reservoir.

Keep the oil level between the marks on the dipsticks.

The distance between the top and bottom dipstick marks corresponds to about 1 qt (one liter). Add oil, if needed at top of the engines.

NOTE: See the “SPECIFICATIONS” chapter for the correct engine-oil grade and weight.

4. Fuel leaks

The coolant is half water and half ethylene glycol.

To add coolant:

Turn the engine OFF at the ground-control box

MASTER KEY SWITCH

Remove the cap from the coolant reservoir.

Add coolant and replace the cap.

6. Wiring harnesses

Visually inspect the entire length of the fuel line, from the engine to the fuel tank, for leaks.

P/N 0112478

Inspect all the wiring harnesses, on the machine, for loose connections, broken wires, and frayed insulation.

10 - 3

10. DAILY INSPECTION & MAINTENANCE

7. Battery terminals

Battery terminals should be clean and free of corrosion.

9. Hydraulic oil

8. Battery fluid level

DANGER

Batteries emit hydrogen and oxygen, elements that can combine explosively. Do not smoke or permit open flames or sparks when checking batteries.

Remove the caps (1) from each battery and visually check to see that the battery fluid is 1/4” (6 mm) below the bottom of the filler neck inside each hole (2).

To check the hydraulic oil level:

Completely lower and completely retract the booms.

The hydraulic oil temperature (1) should be less than 200°F (93°C).

The hydraulic oil level should be between the two marks on the sight-glass gauge (2).

If necessary, add hydraulic oil at the filler cap (3). See the “SPECIFICATIONS” chapter for type and grade of hydraulic oil.

10. Hydraulic oil leaks

DANGER

Leaking hydraulic oil can cause burns, fires, falls (slipping), cuts, and puncture wounds (if under high pressure). Have a qualified trained maintenance person repair all hydraulic fluid leaks before you operate the TB100J.

10 - 4

Hydraulic oil leaks are easily visible and can show up anyplace. Visually inspect the entire machine for hydraulic oil. Check the ground under the machine for leaked oil.

P/N 0112478

Look at the platform end of each boom. Oil can run down the inside of a boom and drip out the end.

11. Tires

10. DAILY INSPECTION & MAINTENANCE

Pay particular attention to all of the wheel nuts. None should be visibly loose, missing, or deformed.

TB100J tires are foam filled. Punctures of the type caused by bolts, screws, or nails are not a problem. Look for large holes or long cuts completely through the tire body: holes or cuts where foam is being forced or eroded out of the tire. Also, look for large imbedded objects, such as angle iron, that can rip a tire body open under some conditions.

12. Bolts & fasteners

Visually inspect all fasteners to see that none is missing or obviously loose.

Pay particular attention to all of the upper rotation-bearing bolts. None should be visibly loose, missing, or have broken heads.

Pay particular attention to all of the safety-wired bolts. Neither the wire nor the bolt heads should be damaged in any way. (Check the turntable end of the boom and the end of the lift cylinder for other safety-wired bolts. Check both sides of the machine.)

P/N 0112478

Pay particular attention to all of the lower (view from under the machine) rotation-bearing bolts. None should be visibly loose, missing, or have broken heads.

10 - 5

10. DAILY INSPECTION & MAINTENANCE

13. Structural damage & welds

Visually inspect all welds for cracks, all structural members for deformity, and all sheet metal for dents that could interfere with machine operation.

15. Axle/boom interlock

With the axles (1) (2) retracted and the pin lock (3) in place, you should not be able to raise the main booms over a couple of degrees above the horizontal nor should you be able to extend the platform much beyond four feet (1.2m).

With the axles (4) (5) extended and the pin lock (6) out, you should not be able to raise the main booms over a couple of degrees above the horizontal nor should you be able to extend the platform much beyond four feet (1.2m).

Pay particular attention to boom welds. Closely inspect boom welds, all the way around, for cracks.

14. Platform gravity gate

Inspect the gate to be sure it is present and moves freely.

10 - 6

With axles (7) (8) extended and pin lock (9) in lower hole, extend the main boom 10 - 20 feet (3 - 6 m).

P/N 0112478

10. DAILY INSPECTION & MAINTENANCE

With axles (10) (11) extended and the pin lock (12) out, you should not be able to lower the jack to raise the rear axles.

16. Emergency power motor/pump

DANGER

When the turntable rotates clockwise (CW) it will move directly toward you. When you check TURNTABLE SWING at CW (1) be sure you have room to step backward.

Check each of the boom-movement functions from the platform-control box (4), using

EMERGENCY POWER

of each control. (For correct emergency power operating procedures see the “EMERGENCY OPERATION” chapter.)

17. Air filter

Start the engine from the ground-control box.

(5). Check all positions

Check each of the six boom-movement switches (2), using they work correctly. Check both positions of each switch (2). (For correct emergency power operating procedures see the “EMERGENCY OPERATION” chapter.)

P/N 0112478

EMERGENCY POWER

(3), to see that

The

FILTER MINDER

indicator in it (2). As the air filter clogs the yellow indicator raises toward the red area (3) of the sight glass. If the indicator is in the red, after the engine has been running for 30 seconds in HI

ENGINE THROTTLE

replaced. (For further explanation of the

MINDER

gauge, see the “GAUGES” chapter.)

NOTE: Leave the engine running for the next step.

gauge (1) has a yellow

, the air filter needs to be

FILTER

10 - 7

10. DAILY INSPECTION & MAINTENANCE

18. Charging system

With the engine running in LO

THROTTLE

should not be to the left of “0” (left of “0” is discharging).

NOTE: Leave the engine running for the next step.

19. Control switches

, the needle in the

ENGINE

AMPS

gauge

Check all of the boom-movement, drive, and steering functions from the platform-control box (4) to see that they cause the TB100J to move the way it should. (For correct operating procedures see the “OPERATION” chapter.)

NOTE: Leave the engine running for the next step.

20. Slide pads

DANGER

When you check TURNTABLE SWING at CW (1) the turntable will move directly toward you. Be sure you have room to step backward.

Check each of the six boom-movement switches (2) using they cause the TB100J to move the way it should. Check both positions of each switch. (For correct operating procedures see the “OPERATION” chapter.)

GROUND OPERATION

(3) to see that

With the engine running, use the ground-control box to extend the booms about 10 feet (three metes). Visually inspect to see that all 12 slide pads (1) are in place at the rear end of the base and intermediate booms (six per boom).

Look at the surfaces (2) that slide on each slide pad. The paint should still be in place and there should not be any signs of bare metal gouging or lubricant.

Check the slide pads and paint inside the front end (3) of the base boom similarly.

10 - 8

Completely retract the booms then turn the engine OFF at the ground-control box

KEY SWITCH

MASTER

P/N 0112478

21. Whiffles and wire ropes

10. DAILY INSPECTION & MAINTENANCE

If any set of spring washers is found with gaps, remove the TB100J from service immediately and have a qualified service technician repair the condition.

While you are inspecting the whiffles check the condition of the wire ropes near the whiffles. The wire ropes should not have any broken strands

or be distorted in any way.

Visually inspect the whiffle (1) at the platform end of the base boom (2).

3 4

The “inside” whiffle face (3) should not be touching the whiffle support (4).

22. Envelope management system

Extend and lock the rear axles.

Use the controls on the ground-control box to raise the main boom slightly above horizontal.

Use the controls on the ground-control box to extend the booms until they automatically stop.

The black & yellow tape (1) should be within 2 inches (5 cm) of being flush with the end of the hose carrier cover (2) and the lights (3) (4) should be on.

EMS ENVELOPE

The top whiffle (5) should not be against either whiffle stop (6) (7). If either whiffle (1) (5) is canted so far it is against a stop, take the TB100J out of service until a qualified service technician adjusts the wire-ropes.

Check all spring washers (8) at both whiffles to see that they are squashed completely together. There should not be any gaps as shown here.

NOTE: The should start to flash a few feet before boom extension stops.

If the booms stop in the wrong place or the light does not work correctly, take the TB100J out of service immediately until a qualified service technician makes repairs.

EMS ENVELOPE

lights (3) (4)

P/N 0112478

10 - 9

10. DAILY INSPECTION & MAINTENANCE

23. Placards and decals

Look to see that all placards and decals are in place and legible. Replace any missing or illegible placards or decals before placing the TB100J into service for the daily work shift.

The

OPTIONAL PLACARDS AND DECALS

, listed below on this page, are only installed on machines

that have the corresponding options.

Placard and decal kits for the TB100J are available from Snorkel dealers.

PLACARDS AND DECALS INSPECTION CHART I

NO PART # DESCRIPTION REQ

1 0073667 Inspect wire ropes 2

2 0190989 Danger - do not reach through

holes

3 969449 Stripe 22 inches long

4 0323899 Danger - electrocution hazard 2

5 0073668 Caution - do not use boom to

lift

6 0072531 Danger - electrocution hazard 1

7 0070921 125 volt 20 amp 1

8 0071425 Platform identification 1

9 0074311 Danger - cylinder failure 8

10 0070418 Snorkelift logo 2

11 0191139 Danger - platform control box

top

12 0191245 Platform control symbol

definition

13 0150448 Attach fall restraint 1

14 0190992 Emergency bleed down 2

15 0191150 Platform control box front 1

16 0191138 Platform control box top 1

17 0190994 Danger - emergency bleed

down Procedure

OPTIONAL PLACARDS AND DECALS

NO PART # DESCRIPTION REQ

A 0111342 High range speed selector

location (4x4 units only)

B 0181376 Lights on/off switch (head/tail

light option)

C 0191030 Machine/generator (hydraulic

AC generator option)

D 0191436 Warm-up at platform

(hydraulic warm-up option)

E 0191251 Danger - platform slide

controls (8ft aluminum self stow platform option)

F 0090589 Platform capacity 500 (8ft steel

non-stow platform option or 8ft aluminum self stow platform option)

G 0110492 Platform capacity 600 (8ft

aluminum or 5ft steel non-stow platform option)

H 0073085 Platform capacity 650 (5ft

aluminum non-stow platform option)

J 0181571 Fuel empty (fuel empty

indicator option)

K 0191253 Platform slide interlock switch

(8ft aluminum self stow platform option)

L 0082164 Danger - do not ride platform

(towing option)

M 0191252 Platform latches (8ft aluminum

self stowing platform option)

10 - 10

P/N 0112478

10. DAILY INSPECTION & MAINTENANCE

PLACARDS AND DECALS INSPECTION DRAWING I

P/N 0112478

10 - 11

10. DAILY INSPECTION & MAINTENANCE

PLACARDS AND DECALS INSPECTION CHART II

NO PART # DESCRIPTION REQ

20 0070418 Snorkelift logo 3

21 0323896 Danger - electrocution hazard 5

22 0073298 Danger - foam/solid tires 2

23 0073585 Made in USA 2

24 0071925

0071926

25 0191390 PRO100 logo 2

26 0191491 Danger - EMS tampering 1

27 0071927 Hydraulic oil 2

28 0070540 Yellow arrow 3

29 0073491 Safe operation information 1

30 0070541 Blue arrow 3

31 0070901 Caution - serial number 1

32 0323897 Danger - you must not operate 1

33 0190988 Danger - ground control

34 0191173 EMS ground operation 1

35 0190937 Rear door (white stripe) 1

36 7030003 Lube recommendations 1

37 0151410 Danger - rotating engine parts 2

38 451986 Danger - do not alter limit

39 0070921 125 volt 20 amp 1

40 0323899 Danger - electrocution hazard 1

41 0110708 Danger - axles/jack 1

42 0073492 Rotate while greasing 2

43 7050004 Record pouch 1

44 0181562 ANSI A92.5-1992 1

45 0191244 Ground control symbol

46 0190992 Emergency bleed down 2

47 0190995 Danger - emergency bleed

48 0190999 EMS status 1

49 0073224 Notice manual re-order 1

50 0073043 Manual holder 1

51 0111623 Engine protection system 1

52 0191174 EMS lights 1

53 0191137 Ground controls 1

54 0072276 Lug nut torque 450-500ft lb 4

55 0191236 EMS circuit breaker location 1

56 0073089 Battery disconnect switch 1

Gasoline fuel (gasoline units only)

Diesel fuel (diesel units only)

instructions

switch

definition

down procedure

1 1

OPTIONAL PLACARDS AND DECALS

NO PART # DESCRIPTION REQ

N 0081441 Caution - liquid withdrawal

(dual fuel & LP only option)

P 0090492 Dual fuel switch (dual fuel

option)

R 0191435 Warm-up at ground (hydraulic

warm-up option)

S 0082203 Danger - crushing hazard (tow

package option)

T 0111343 High range speed selector

valve (4x4 units only)

U 0071793 Hydraulic warm-up system

instructions (hydraulic warmup option)

V 0090493 Dual fuel instructions (dual fuel

options)

W 0082160 Danger - towing hazard (tow

package option)

X 0073080 Cold start (cold start option) 1

Y 0090760 Steering float valve (tow

package option)

Z 0082171 Towing instructions (tow

package option)

10 - 12

P/N 0112478

10. DAILY INSPECTION & MAINTENANCE

PLACARDS AND DECALS INSPECTION DRAWING II

P/N 0112478

10 - 13

10. DAILY INSPECTION & MAINTENANCE

24. GFCI (Ground Fault Circuit Interrupt)

Connect the power-input connector (at the rear of the turntable) to a source of 125 V ac, 20 A electrical power. (If the TB100J is equipped with the optional ac generator, connect the power-input connector to the ac generator, start the engine, then set the switch to ON.)

AC GENERATOR

Push the

RESET RESET

TEST

button (2) should pop out. Press the button (2) back in. (Set the

GENERATOR

button (1) in on the GFCI. The

switch to OFF if you used the

optional ac generator.)

10 - 14

P/N 0112478

11. TROUBLESHOOTING

All of the actions described in this chapter may be performed by a TB100J

operator

-- a trained and qualified service technician is not required. Any problem that cannot be fixed by actions listed below should be referred to a trained and qualified TB100J

service technician.

TB100J OPERATOR’S TROUBLESHOOTING CHART

PROBLEM CAUSE REMEDY

Engine will not start from the

ground-control box

Engine will not start from the

platform-control box

1. Switches are set wrong. (Engine will not crank.)

2. The breaker, on the groundcontrol box, has tripped. (Engine will not crank.)

3. Out of fuel. (Gasoline or diesel engine cranks but will not start.)

4. LPG OPTION.

FUEL

control box is set wrong. (Engine cranks but will not start.)

1. Stepping on foot switch. (Engine will not crank.)

2. Switches are set wrong. (Engine will not crank.)

MAIN SYSTEM

switch on the ground-

The first column, of the following chart, lists some common problems encountered by TB100J operators. The second column lists some of the causes for each problem. The third column lists remedies.

circuit

At the ground-control box:

B. C. D. E.

seconds then turn START.

Push the If the button pops out again, refer the problem to a qualified service technician.

Add fuel to tank then alternately crank engine for 20 seconds and let starter motor cool for 60 seconds (20 on / 60 off).

L.P.-GAS or GASOLINE.

see if there is fuel in tank.

valve, on top L.P. tank, is open.

then let starter motor cool for 60 seconds. Be sure you are not stepping on the foot

switch, or that the foot switch is not “blocked” in any way, while you are trying to start the engine.

At the ground-control box:

B. C. D.

At the

E. SWITCH

G. SWITCH

H. SWITCH

BATTERY

Set

MASTER KEY SWITCH

Set

EMERGENCY STOP

Pull

SELECTOR SWITCH

Set

MASTER KEY SWITCH

Set

MAIN SYSTEM

FUEL

Set

Check the fuel gauge, on top of the tank, to

For L.P.-GAS only: Check to see that fuel

Alternately crank engine for 20 seconds

BATTERY

Set

MASTER KEY SWITCH

Set

EMERGENCY STOP

Pull

SELECTOR SWITCH

Set

switch to ON.

to OFF.

out (on).

to GROUND.

to ON for 5

MASTER KEY SWITCH

(25) button back in.

switch (ground-control box) to

switch to ON.

to ON.

out (on).

to PLATFORM.

platform-control box:

Set the

Pull the

Turn the

ANTI-RESTART MASTER

to OFF.

EMERGENCY STOP

ANTI-RESTART MASTER

to ON.

ANTI-RESTART MASTER

to START.

button up.

P/N 0112478

11 - 1

11. TROUBLESHOOTING

TB100J OPERATOR’S TROUBLESHOOTING CHART

PROBLEM CAUSE REMEDY

Engine will not start from the

platform-control box

(Continued)

Cannot raise or extend the main boom.

Jerky platform movement during extension.

Cannot attain maximum speed (3 mph, 4.8 km/hr).

Tilt alarm does not work. Booms are completely down

Boom raises but will not stay elevated.

Front wheels do not turn during STEER RIGHT or STEER LEFT.

3. The

BREAKER

control box, and/or the

SYSTEM

the ground-control box, has tripped. (Engine will not crank.)

4. Out of fuel. (Gasoline or diesel engine cranks but will not start.)

5. LPG OPTION.

FUEL

control box is set wrong. (Engine cranks but will not start.)

1. Rear axles not extended. Extend rear axles.

2. Pin lock not installed. Install pin lock.

Loose cables. Report problem to a trained & qualified service

1. Booms are not completely down and completely retracted.

3. 4x4 OPTION machines only:

SELECTOR VALVE

and completely retracted. (Tilt alarm is not designed to work under these conditions as a convenience to personnel loading and unloading TB100J onto/from transport vehicle.)

Manual bleed-down valve is open.

1. Drive controller must be in DRIVE FORWARD or DRIVE REVERSE for steer wheels to turn.

2. TOW OPTION machines only: The

VALVE

MAIN CIRCUIT

, on the platform-

circuit breaker, on

switch on the ground-

DRIVE RANGE

HIGH RANGE SPEED

STEERING FLOAT

is open.

set to LO. Set

is down.

MAIN

Push the circuit breaker button(s) in. If the button pops out again, refer the problem to a qualified service technician.

Add fuel to tank then alternately crank engine for 20 seconds and let starter motor cool for 60 seconds.

FUEL

Set

L.P.-GAS or GASOLINE.

Check the fuel gauge, on top of the tank, to

see if there is fuel in tank.

For L.P.-GAS only: Check to see that fuel

valve, on top L.P. tank, is open.

Alternately crank engine for 20 seconds

then let starter motor cool for 60 seconds.

technician.

Completely lower & completely retract the booms.

DRIVE RANGE

Pull the

VALVE

Extend and raise the booms a little.

Close the manual bleed-down valve.

Push drive controller slightly forward or backward when using STEER RIGHT or STEER LEFT.

Close the

switch (ground-control box) to

to HI.

HIGH RANGE SPEED SELECTOR

up.

STEERING FLOAT VALVE

11 - 2

P/N 0112478

PLATFORM WORK LIGHTS

The platform work lights are located on top the platform guard rail. For the lights to work the

BATTERY

switches, on the ground-control box, must be set as indicated:

SELECTOR SWITCH EMERGENCY STOP MASTER KEY SWITCH

The toggle switch on the back of a light turns it on.

switch must be ON and the following

.......PLATFORM

........UP FOR RUN

...ON

12. OPTIONS

AIR LINE TO PLATFORM

The input to the air line is on the bottom leftrear of the turntable.

If you want to change the direction a light points, use two 1/2” box-end wrenches to loosen the clamp immediately below the light, point the light where you want it, then retighten the clamp.

CAUTION

Incandescent lights draw three amperes (35 watts) each. Halogen lights draw four amperes (50 watts) each. If you work with the lights turned on and the engine turned off, the batteries can discharge to the point they will neither start the engine nor run the hydraulic pump. If you cannot leave the engine running while the lights are on, start and run the engine at least 15 minutes in each hour.

EMERGENCY POWER

The outlet is on the platform mounting frame. The maximum safe working pressure for the air line is 250 psi (1725 kPa).

CAUTION

Water or anti-freeze solution in the air line might damage some air tools. If you use the air line to conduct water or anti-freeze solution be sure to drain and blow out the air line before attaching air tools.

The air line can be used to conduct air, water, or anti-freeze solution. If you want to conduct other liquids, contact the Snorkel Engineering Department for compatibility information.

P/N 0112478

112 -

12. OPTIONS

To drain the air line:

1. Close the turntable end of the air line.

2. Open the platform end of the air line.

3. Raise the jib boom completely up.

4. Raise the main boom slightly above the horizontal.

5. Open the turntable end of the air line.

DRIVING LIGHTS

CAUTION

Together the four lights draw seven amperes. If you work with the lights turned on and the engine turned off, the batteries can discharge to the point they will neither start the engine nor run the

EMERGENCY POWER

cannot leave the engine running while the lights are on, start and run the engine at least 15 minutes in each hour.

Driving lights are for driving on dimly lit construction sites, they are not for driving on public thoroughfares. Two 30 watt headlights are located on top of the front cowling, two 25 watt blinking taillights are on the sides of the rear cowlings. Each headlight has a toggle switch to turn it on and off. Both blinking taillights are controlled by a switch just in front of the right taillight. For any of the lights to work both the

BATTERY SWITCH

switch and the

must be ON.

hydraulic pump. If you

MASTER KEY

expected to be 32°F (0°C) or below, plug the power cord from the heater into 110 - 120 V ac, 600 watt source eight hours before starting the engine.



Ether Injection

A Cummins diesel engine might have ether injection instead of a block heater. Ether injection should only be used to start a cold engine when the ambient temperature is below 32°F (0°C).

Check to see that there is a can of ether installed in the holder in the battery compartment. If there is no can of ether:

1. Turn the

2. Unscrew the holding cup.

3. Put a can of ether in the cup.

4. Screw the cup firmly back into place.

5. Set the Start the engine from the ground-control box in

the normal way. While the

SWITCH

cranking) press the Pressing the measured amount of ether into the intake manifold regardless of how long you hold the button in.

NOTE: Do not crank the engine longer than 20 seconds. If the engine does not start, wait two minutes then try again.

HYDRAULIC SYSTEM COLD WEATHER

BATTERY

is in START (and the engine is

COLD START

switch to OFF.

switch to ON.

MASTER KEY

COLD START

button injects a

button.

WARM-UP KIT

COLD WEATHER START KIT



Block Heaters

CAUTION

Unplug the block heater just before starting the engine. That will keep you from driving off while the heater is still plugged in.

The block heater in a Continental or Cummins engine is a freeze-plug type block-heater. The engine is heated by convection of water that is warmed by the heater. The heater is located in a freeze-plug hole just below the engine exhaust manifold. If the engine starting temperature is

212 -

The control switch for the HYDRAULIC SYSTEM COLD WEATHER WARM-UP KIT is located on the ground-control box near the

SWITCH

control box. When the ambient air temperature is below 32°F (0°C) and boom movement is sluggish because of cold hydraulic oil, turn the

WARM-UP

temperature, in the hydraulic oil tank, reaches 50°F.

For the warm-up system to work, the engine must be running and you must turn the

started the engine. (If you started the engine from the ground-control box, turn the switch on from the ground-control box. If you started the engine from the platform-control box, turn it on there.)

and/or on the left side of the platform-

switch to ON until the hydraulic oil

switch ON from the same station that you

MASTER KEY

WARM-

WARM-UP

P/N 0112478

AC GENERATOR

CAUTION

Do not use the AC GENERATOR unless the hydraulic oil is over 70°F (21°C). The output voltage of the generator depends on the temperature of the hydraulic oil. Temperature below 70°F (21°C) will cause dangerously low output voltages that can burn out some kinds of electrical equipment.

The hydraulically powered, 120 V ac generator can be used anytime the TB100J engine is running and the TB100J is completely stationary. Turning the generator on stops all machine movement.

Set the platform-control box, to GENERATOR and a total of 2 kW, continuous duty, 120 V ac power is available from the two electrical outlets under the platform-control box or the one electrical outlet on the end of the generator housing.

The motion alarm emits a loud ...beep...beep...beep..., at ground level, anytime the REVERSE. This alarm alerts people on the ground that the TB100J is traveling along the ground.

MACHINE/GENERATOR

NOTE: To energize the two platform electrical outlets, the power cord from the platform outlets must be plugged into the receptacle on the generator.

MOTION ALARM

DRIVE/STEER

controller is in FORWARD or

switch, on the

12. OPTIONS

TOW KIT

DANGER

Improper towing can cause a TB100J to break away from the towing vehicle. A “runaway” TB100J can cause death or serious injury.

Do not tow a TB100J faster than 10 mph (16 km/hr). A TB100J can behave erratically above 10 mph (16 km/ hr).

Check with the tow vehicle manufacture or manufacturer's literature to be sure the towing vehicle can safely tow and stop a 33,000 pound (15,000 kg) TB100J on the steepest grade and type of surface you will encounter. Remember, the TB100J does not have brakes when it is towed.

When you tow the TB100J around a corner or a curve do not turn so sharply that either of the tow bar chains is pulled tight. If a chain is pulled tight the steering mechanism might be damaged or the tow vehicle and TB100J might jackknife.

1. Remove the tow bar and tie rod weldment from the storage cradles and lay them near the front of the chassis.

2. Rotate the turntable until the counterweight is to the side of the chassis.

DANGER

Death or serious injury can result from being crushed between the counterweight and tow vehicle. Do not attempt to attach the tow bar to the tow vehicle unless the counterweight is to the side.

P/N 0112478

3. Attach the tow bar to the towing lug with the tow pin and snap pin.

4. Attach the tie rod weldment to the tow bar and the right hand steering yoke.

5. Attach the two tow bar chains to the tie down lugs.

6. Attach the ring-end of the tow bar to the tow vehicle.

312 -

12. OPTIONS

7. Rotate the turntable until the counterweight is to the front, then raise the platform about 3 feet (1 m) to keep it from hitting the ground when you start up a grade.

8. Pull the of chassis) knob out.

STEERING FLOAT VALVE

(top front

DANGER

A “runaway” TB100J can cause death or serious injury. Disconnecting the disconnectplates will allow the TB100J drive wheels to turn freely. Before proceeding, be certain the tow bar is installed and connected to a towing vehicle that can safely control both itself and the 33,000 pound (15,000 kg) TB100J. Be certain the tow vehicle brakes are set.

FOUR-WHEEL DRIVE (4x4)

From the operational point of view, the only difference between the optional four-wheel drive (4x4) and the standard two-wheel drive is that the maximum speed of the 4x4 is determined, in part, by the settings of both the switch and the

SELECTOR (HRSS) VALVE

HIGH RANGE SPEED

DRIVE RANGE

9. Remove the two bolts that hold each drivewheel disconnect-plate.

10. Turn each disconnect-plate over so that the nipple points inward, then retighten the bolts.

The

HRSS VALVE

RANGE

the following table, to determine the maximum speed the chassis can travel along the ground.

SPEED

3.0 mph

(4.8 km/hr)

1.5 mph

(2.4 km/hr)

0.75 mph

(1.2 km/hr)

0.75 mph

(1.2 km/hr)

NOTE: control box, must be set to HI for MAX. SPEED.

switch and boom position, according to

MAX.

RANGE

creep -- --

ENGINE THROTTLE

works with the

DRIVE RANGE

DRIVE

HI up stowed

HI down stowed

LO -- stowed

-- --

HRSS

VALVE

DRIVE

Table

boom

position

extended but

below mid-

elevation

above mid-

elevation

, at the platform-

DANGER

At the end of the tow, before you disconnect the TB100J from the towing vehicle, turn the disconnect-plates back over so the nipples are out. This will prevent the TB100J from rolling when you disconnect it from the tow vehicle.

11. Reverse the above procedure at the end of the tow.

412 -

P/N 0112478

SELF-STOWING PLATFORM

12. OPTIONS

Here is the recommended transport position for a TB100J, with a self-stowing platform, on a conventional step-deck trailer. Drive the machine forward onto the trailer, then rotate the turntable 180°.

Here is the recommended transport position for a TB100J, with a self-stowing platform, on a folding tail (beaver tail) trailer. Drive the machine forward onto the trailer as far as possible.

The following procedure shows how to transport a TB100J. This procedure assumes that you have loaded the TB100J as described in the “STOWING & TRANSPORTING” chapter, that the TB100J engine is still running, and that the wheels are chocked.

DANGER

Death or serious injury can result from being crushed between the platform and the rotator frame. Do not reach through any part of the platform when the over-center hooks are undone. Do not operate the slide controls from inside the platform.

3. Push in and hold the button (6) at the same time that you push and hold the the chassis. Continue to hold both switches (5) (6) until the platform (7 below), moves as far back toward the chassis as it will go.

SLIDE ACTUATOR SWITCH

SLIDE INTERLOCK

(5) toward

DANGER

Death or serious injury can result from falling from the platform. Do not work from a TB100J that has the platform slid to the side or that has the over-center hook latches open. The platform should only be slid to the side to save space during transportation.

1. Use the platform-control box (1) to rotate the platform (2) completely to the side as shown.

2. Release both over-center hook latches (3) (4).

P/N 0112478

4. Place wooden blocks (8, 9) under the bellcrank (10) and platform (7) then use the controls on the platform-control box to lower the bellcrank (10) and platform (7) onto the blocks (8, 9).

5. Set the OFF.

6. Set the remove the key, and close the ground-control door.

7. Set the

BATTERY

ANTI-RESTART MASTER SWITCH

MASTER KEY SWITCH

BATTERY

switch.

switch to OFF and lock the

to OFF,

512 -

12. OPTIONS

8. (OPTION - LPG) For machines equipped with LPG, close the valve on the LPG tank (completely screwed in).

9. Attach two nylon straps (11, 12) from the underside of the base boom (13) , as shown, to the trailer (14).

10. Use a nylon strap (15) to hold the platform (7) on the blocks (8, 9) as shown.

11. Fasten a nylon strap (16) from the underside of the base boom (13) to the bar (17) across the lower end of the jib-boom (18).

FLASHING LIGHTS

The flashing lights alert people that the TB100J is present. The lights flash at about one flash per second any time the

STOP

(at the ground), and

SWITCH

for the flashing lights.

are all ON. There is no ON/OFF switch

BATTERY, EMERGENCY

MASTER KEY

612 -

P/N 0112478

13. FIRE FIGHTING & HAZARDOUS

13. FIRE FIGHTING

CHEMICAL CONTAINMENT

A TB100J contains the following materials and objects that potentially could become significant fire or environmental hazards during the lifetime of a TB100J:

Anti-freeze (ethylene glycol) Battery, lead/acid Diesel fuel Foam in tires Gasoline Hydraulic oil Liquefied petroleum gas Motor oil

The rest of this chapter lists manufacturers’ information you will need if you ever have to control any of the above items during an upset or emergency.

ANTI-FREEZE

Fire extinguishing media

or CO2.

Special fire fighting procedures

may be ineffective on fire but can protect fire fighters and cool closed containers. Use fog nozzles if water is used. Do not enter confined fire-space without full bunker gear. (Helmet with face shield, bunker coats, gloves & rubber boots). Use a NIOSH approved positive pressure self-contained breathing apparatus. Keep container tightly closed. Isolate from oxidizers, heat & open flame.

Spill or leak

material & transfer to hood.

Waste disposal method

all vapors are gone. Dispose of remainder by legally applicable methods.

BATTERY

Extinguishing media

CO2.

Special fire fighting procedures

pressure, self-contained breathing apparatus.

Unusual fire and explosion hazards

and oxygen gases are produced in the cells during normal battery operation

(hydrogen is flammable and oxygen supports combustion). These gases enter the air through the vent caps. To avoid the chance of a fire or explosion, keep sparks and other sources of ignition away from the battery.

Spill or leak

all sources of ignition. Contain spill by diking with soda ash (sodium carbonate) or quicklime

: Small - mop up with absorbent

: Remove combustible materials and

(UN 1993)

: Small - evaporate until

, LEAD/ACID

: Dry chemical, foam, or

: Dry Chemical, foam,

: Water spray

(UN 2794)

: Use positive

: Hydrogen

(calcium oxide). Cover spill with either chemical. Mix well. Make certain mixture is neutral then collect residue and place in a drum or other suitable container. Dispose of as hazardous waste.

Wear acid resistant boots, face shield, chemical splash goggles, and acid resistant gloves. DO NOT RELEASE UNNEUTRALIZED ACID!

Waste disposal method - Sulfuric Acid

Neutralize as above for a spill, collect residue, and place in a drum or suitable container. Dispose of as hazardous waste.

DO NOT FLUSH LEAD CONTAMINATED ACID TO SEWER.

Waste disposal method - Batteries

lead smelter for reclamation following applicable federal, state, and local regulations.

DIESEL FUEL

Extinguishing media

chemical, foam, or CO2.

Special fire fighting procedures

keep fire-exposed containers cool. If leak or spill has not ignited, use water spray to disperse the vapors and to provide protection for personnel attempting to stop a leak. Water spray may be used to flush spills away from exposures.

Unusual fire and explosion hazards

of combustion may contain carbon monoxide, carbon dioxide, and other toxic materials. Do not enter enclosed or confined space without proper protective equipment including respiratory protection.

Spill or leak

smallest area possible. Recover as much of the product itself as possible by such methods as vacuuming, followed by soaking up of residual fluids by use of absorbent materials. Remove contaminated items including contaminated soil and place in proper containers for disposal. Avoid washing, draining, or directing material to storm or sanitary sewers .

Waste disposal method

the recoverable product as possible. Dispose of nonrecyclable material as a RCRA hazardous waste by such methods as incineration, complying with federal, state, and local regulations.

FOAM IN TIRES

Extinguishing media

foam, or CO2.

: Contain spill immediately in

(NA 1993)

: Use water spray, dry

: Use water to

: Recycle as much of

: Water, dry chemical,

: Send to

: Products

P/N 0112478

13-

13. FIRE FIGHTING

Special fire fighting procedures

emergency personnel to a safe area.

: Evacuate non

By itself, the liquid is expected to be a RCRA ignitable hazardous waste.

Unusual fire and explosion hazards

fighters should use self-contained breathing apparatus. Avoid breathing smoke, fumes, and decomposition products. Use water spray to drench smoldering elastomer. Product may melt, after ignition, to form flammable liquid. Burning produces intense heat, dense smoke, and toxic gases, such as carbon monoxide, oxides of nitrogen, and traces of hydrogen cyanide.

Spill or leak

inert solid material.

Waste disposal method

hazardous material. Dispose of material according to any local, state, and federal regulations.

GASOLINE

Extinguishing media

CO2.

Special fire fighting procedures

be ineffective to extinguish, but water should be used to keep fire-exposed containers cool. If a leak or spill has not ignited, use water spray to disperse the vapors and to protect personnel attempting to stop a leak. Water spray may be used to flush spills away from areas of potential ignition.

Unusual fire and explosion hazards

Flammable. Products of combustion may contain carbon monoxide, carbon dioxide and other toxic materials. Do not enter enclosed or confined space without proper protective equipment including respiratory protection.

Spill or leak

before proceeding with clean up. Use appropriate personal protective equipment during clean up. Dike spill. Prevent liquid from entering sewers, waterways, or low areas. Soak up with sawdust, sand, oil dry or other absorbent material. Shovel or sweep up.

Remove source of heat, sparks, flame, impact, friction or electricity including internal combustion engines and power tools. If equipment is used for spill cleanup, it must be explosion proof and suitable for flammable liquid and vapor.

NOTE: Vapors released from the spill may create an explosive atmosphere.

: Pick up and handle as any other

: Not considered a

(UN 1203)

: Dry chemical, foam, or

: Review fire and explosion hazards

: Fire

: Water may

: Highly

HYDRAULIC OIL

Extinguishing media

chemical, foam, or CO2.

Special fire fighting procedures

foam may cause frothing. Use water to keep fireexposed containers cool. Water spray may be used to flush spills away from exposures.

Unusual fire and explosion hazards

of combustion may contain carbon monoxide, carbon dioxide, and other toxic materials. Do not enter enclosed or confined space without proper protective equipment including respiratory protection.

Spill or leak

smallest area possible. Recover as much of the product itself as possible by such methods as vacuuming, followed by soaking up of residual fluids by use of absorbent materials. Remove contaminated items including contaminated soil and place in proper containers for disposal. Avoid washing, draining or directing material to storm or sanitary sewers .

Waste disposal method

the recoverable product as possible. Dispose of nonrecyclable material as a RCRA hazardous waste by such methods as incineration, complying with federal, state, and local regulations.

LIQUEFIED PETROLEUM GAS

: Contain spill immediately in

(UN 1270)

: Use water spray, dry

: Water or

: Products

: Recycle as much of

(UN

1075)

Extinguishing media

or BC fire extinguishers.

Special fire fighting procedures

gas. Use water to keep fire-exposed containers cool. Use water spray to disperse unignited gas or vapor. If ignition has occurred and no water available, tank metal may weaken from overheating. Evacuate area. If gas has not ignited, LP-gas liquid or vapor may be dispersed by water spray or flooding.

Spill or leak

of gas. Eliminate sources of ignition. Ventilate the area. Disperse with water spray. Contact between skin and these gases in liquid form can cause freezing of tissue causing injury similar to thermal burn.

: Keep public away. Shut off supply

: Water spray. Class A-B-C

: Stop flow of

Waste disposal method

transportation and disposal must be in accordance with applicable federal, state, provincial, and local regulations. Do not flush to surface water or sanitary sewer system.

: Treatment, storage,

213-

Waste disposal method

MOTOR OIL

OIL (UN 1270) above.

(UN 1270)

: Controlled burning.

See HYDRAULIC

P/N 0112478

INDEX

Ac generator, 12-3 Adjustments, and maintenance personnel, iii Air filter, 10-7 and ENGINE THROTTLE, 10-7 when to change, 4-1 Air line, 12-1 Alarm, EMS, 2-4 Alarm, motion warning, 2-5, 12-2 Alternator, shut-off, 5-1

see

Ammeter, 10-8, AMPS gauge, 4-1 correct value, 10-8 Anchorage point, and fall restraint, 1-2, 2-2 ANSI/NFPA 505-1987, hazard classification, ANSI standard A92.5-1992, requirements, Antifreeze, 10-3, 13-1 ANTI-RESTART MASTER SWITCH, 6-4 to 6-5 Authorized, iii Automatic shut-offs, 5-1 Axle/boom interlock, 6-1, 10-6 Axle weights, 9-2 AXLES control, 6-6

AMPS

iv,

1-1

3-1

Batteries emergency handling, 13-1 fluid level, 10-4 terminals, 10-4 where to charge, 1-3 BATTERY switch, 6-6 locking, 1-3 Bleed-down valve, use and location, 8-4 to 8-5 Block heater, 12-2 Bolts and fasteners, 10-5 Boom and platform movement, illustrated 7-7 elevation, 3-1 movement times, specifications, 3-1 speed, with EMERGENCY POWER OPER., 8-3 use to, 1-2 BOOM SPEED control, 6-2 to 6-3 Booms, names of, 3-5 BOOMS/AXLES SWITCH, 6-2 to 6-3

California proposition 65, back cover Cap, fuel tank, 10-2 CAUTION, signs, iii Center of gravity, 3-3 Charging system, 10-8 Chassis, sides and ends, 3-5 Chocks, 9-1, 9-2, 9-3 Circuit breakers, 5-1 to 5-2 Cold weather start kit, 12-2 COLD START button, 12-2 Continental engines, iv Controls, 6-1 checking function, 10-8 movement of, 1-2 Coolant, engine, 10-3 Crane, TB100J as, 1-2 Crushing, 1-2 Cummins engines, iv

D-ring, DAILY INSPECTION & MAINTENANCE, 1-1, 10-1 to 10-11 DANGER, signs, iii Decals & placards attached and legible, 1-1 cleaning, 1-3 safety, 1-3 to 1-5 when to replace, 1-3 Diesel fuel, 13-1, Dimensions, TB100J overall, 3-3 Dipstick, 4-3, 10-3 Disconnect-plates, 12-4 DRIVE RANGE switch, 6-4 to 6-5 Drive range, table, 6-4, 12-4 Drive speed, how to set, 6-4 DRIVE/STEER CONTROLLER, 6-6, 7-8 and optional motion alarm, 12-3 Dual-fuel, definition, iv

see

anchorage point

see

fuel

Electrical

see

box, platform outlet, 7-8, conductor, as hazards, frontispiece, i, 1-2 outlets, ac generator, 12-3 plug, 7-9 system ground, 3-1 Electrocution, 1-2 Emergency operation from ground-control box, 8-3 to 8-5 from platform-control box, 8-1 to 8-2

GFCI

P/N 0112478

I - 1

INDEX

(Continued)

Emergency power, checking function, 10-7

EMERGENCY POWER OPERATION

and boom speed, 8-3 EMERGENCY STOP switches, 2-2, 6-2 to 6-5 EMS audio alarm, 2-4 ENVELOPE, checking function, 10-9 ENVELOPE, description, 2-4 to 2-5 lights, 2-3 STATUS, description, 2-4 to 2-5 STATUS, emergency operation, 8-2 WARNING, description, 2-4 to 2-5 WARNING, emergency operation, 8-2 Engine data, 3-2 oil charts, 3-2 oil, checking, 4-3 oil pressure shut-off, 5-1 temperature shut-off, 5-1 ENGINE THROTTLE switch, 6-2 to 6-5 and battery charging, 10-8 checking air filter, 10-7 Envelope management system, Envelope, working, 3-4 Environmental operating ranges, 3-1 Ether injection, 12-2 Extend and lock, rear axles, 7-9 to 7-11 Extendible axle, controls, 6-1 Extendible axle, interlock, 2-3

switch, 6-2 to 6-5

see

EMS

Fall arrest, 1-2 Falling hazards, 1-2 Flashing lights, 2-6, 12-6 FILTER MINDER, 4-1, 10-7 Floor grating, visibility, 1-2 Foam in tires, emergency handling, 13-1 Foot switch, 6-4 as safety device, 2-3 with platform-moving switches, 7-6 Four-wheel drive, 12-4 Front end, nomenclature, 3-5 Fuel as cleaner, 1-3 cap, 1-3 grade, 3-2 handling precautions, 1-3 level, 10-2 tank capacity, 3-1 filling, 1-3 pressurizing, 1-3 FUEL, gauge, 4-2 FUEL switch (option), 6-2

Gasoline, emergency handling, 13-2, Gate, gravity, 2-2, 10-6 Generator, ac, 12-3 GFCI, 2-6, 5-2 Gradeability, 3-1 Ground bearing strength, 3-1 clearance, 3-1 fault circuit interrupt, 2-6, 5-2 soft, raising boom, 1-2 speed, how to set, 6-4 GROUND OPERATION switch, 6-2 to 6-3 with platform-moving switches, 7-6 as safety device 2-3 Guardrail, 2-6 climbing, 1-2 Guardrail, gate, 2-2

see

fuel

Height platform, 3-1 working, 3-1 HIGH RANGE SPEED SELECTOR VALVE, 12-4 Hoist, TB100J, 1-2 Hooks, over-center latches, 12-5 Horn, purpose, 2-5 Horn, tilt alarm, 2-1 HOURS, gauge, 4-1 HRSS VALVE, 12-4 Hydraulic oil and ac generator, 12-3 emergency handling, 13-2 filter, gauge, 4-3 leaks, 10-4 how to find, 1-3 level, 10-4 temperature, maximum, 6-4 specifications, 3-1 Hydraulic system, cold weather warm-up kit, 12-2 HYDRAULIC OIL level gauge, 4-2 HYDRAULIC OIL temperature gauge, 4-2

Inspection chart, placards and decals, 10-10 Inspection drawing, placards and decals, 10-11 Interlock, axle, 2-3, 6-1, 10-6

I - 2

P/N 0112478

INDEX

Jack controls, 6-1 shoe plate, lifting weight, 7-10, 7-13, 9-2 TB100J used as, 1-2 JIB BOOM LIFT switch, 6-2 to 6-5

Ladders and planks, used on platform, 1-2 Latches, over-center hook, 12-5 Leaks, fuel, 10-3 Leaks, hydraulic oil, 10-4 Left side, nomenclature, 3-5 Length, of TB100J, 3-1 LIFT/SWING CONTROLLER, 6-6 Lights, driving, 2-6, 12-2 EMS, 2-3 to 2-4 EMS ENVELOPE, 2-4 checking function, 10-9 EMS STATUS, 2-4, 8-2, 8-3 EMS WARNING, 2-4, 8-2, 8-3 flashing, 2-6, 12-6 inside EMERGENCY STOP switches, 5-1 platform work, 2-6, 12-1 tilt alarm, 2-1 Liquefied petroleum gas, emergency handling, 132 Loads, where to carry, 1-2 Locking TB100J for transport, 9-1 LPG tank, 4-2 fuel in, 10-2 replacing, 10-2

M.S.A.D., frontispiece MACHINE/GENERATOR switch, 12-3 Main boom, definition, 3-5 Main boom, raising, axles extended, 7-9 MAIN BOOM EXT./RET switch, 6-2 to 6-3

MAIN BOOM EXTEND/RETRACT switch, 6-4 to 6-5

MAIN BOOM LIFT switch 6-2 to 6-3 Maintenance, who does, iii MASTER KEY SWITCH, 6-2 to 6-3 Minimum safe approach distance, frontispiece, i Modifications, consent to do, iii, 1-3 Motor oil emergency handling, 13-2 grade, 3-2 weight, 3-2 Mounting & dismounting precautions, 1-3 Moving the chassis, how to, 7-8

Nomenclature boom, 3-5 chassis, 3-5 turntable, 3-5 Nuts, wheel, 10-5 Nylon straps, 9-2, 9-3, 12-6

Oil, engine, emergency handling, 13-2 Oil level, engine, 10-2 Operating precautions, 1-3 Operation, when to cease, 1-2 Operator authorized, 1-1 general precautions, 1-2 maintenance precautions, 1-3 qualified, iii trained, 1-1 OSHA fall restraint, 1-2, 2-2 paragraph 1910.67 title 29, 3-1 paragraph 1926.556 title 29, C.F.R., 3-1 regulations, iv safety rules, iii Outlet box, 7-8 Overheating engine, 5-1

Paint, 10-8 Parking, 9-1 Parts, replacement, 1-3 Personnel precautions, 1-2 Placards and decals, 1-4 to 1-5, 10-10 to 10-11 Platform and boom movement, illustrated 7-7 Platform entering and leaving, 2-2 materials hanging from, 1-2 self-stowing, 12-5 snagged, 1-2 specifications, 3-1 transfer from, 1-2 when and where to raise, 1-2 PLATFORM LEVEL switch, 6-2 to 6-5 PLATFORM ROTATION switch, 6-2 to 6-5 Platform-moving switches, 6-2, 7-6 Pre-start conditions ground-control operation, 7-1 to 7-2 platform-control operation, 7-3 to 7-4 Pre-start inspection, as safety feature, iii, 1-1 Pressurizing, fuel tank, 1-3 Proposition 65, back cover

Moving the platform, how to, 7-5

P/N 0112478

I - 3

INDEX

Qualified operator, daily inspection and maintenance, 10-1 Qualified trained maintenance personnel, iii

Radiator cap, removing, 1-3 Reach, platform, 3-1 Rear axles, extend and lock, 7-9 to 7-11 Rear axles, retract and lock, 7-11 to 7-14 Rear end, nomenclature, 3-5 Regulations, local, 1-1 Retract and lock, rear axles, 7-11 to 7-14 Right side, nomenclature, 3-5 Running time, 3-2

Safety devices, 2-1 to 2-5 Scaffold Industry Association, Inc., reprints, iv SELECTOR SWITCH, 6-2 to 6-3 Serial number locations, 3-5 Shut-offs, automatic, 5-1 Signs, caution, iii Signs, danger, iii Siren, tilt alarm, 2-1 Slide pads, 10-8 SLIDE ACTUATOR SWITCH, 12-5 SLIDE INTERLOCK button, 12-5 Snorkel address, iv approval for special use, 1-2 decals and placards, new, 1-3 engineering department, modifications, iii fuel cap, 1-3 parts, 1-3 reprints, iv Specifications, 3-1 to 3-5 Speed maximum driving, 3-1 how to set, 6-4, 12-4 safe driving, 1-1 wind, 3-1 Spring washers, checking, 10-9 Starting and stopping precautions, 1-3 Starting, from ground-control box, 7-1 to 7-3 Starting, from platform-control box, 7-3 to 7-4 Stations, control, 7-1 Steering, 7-8 STEERING FLOAT VALVE, 12-4 Stopping, emergency, 7-1, Stowed position, 9-1 Stowing, 9-1 Structural damage, 10-6

Temperature ambient air, 3-1 engine operating, 3-2 hydraulic oil, 3-1, 4-2 TEMPERATURE, gauge, 4-1 Thunderstorms, 1-2 Tie-downs chains, 9-3 nylon strap, 9-2, 9-3 rubber straps, 9-3 wire-tie, 9-4 Tilt alarm, 2-1 Tipover hazards, 1-2 Tires, 3-1, 10-5 foam in, emergency handling, 13-1 Tow kit, 12-3 Towing, 9-1, 9-4 Trailering, 9-1 to 9-4 Trained mechanic, iii Transferring from platform, when and how, 1-2 Transporting, 9-1 to 9-4 Travel speed, 1-3 how to set, 6-4 Troubleshooting, 11-1 to 11-2 Turning radius, 3-1 Turntable, sides and ends, 3-5 TURNTABLE SWING switch, 6-2 to 6-3

WARM-UP switch, 12-2 Warranty, inside back cover Water, coolant, 10-3 Weight of TB100J, 3-1 Weight on axles, 9-2 Welding, ground for, 1-1 Welds, 10-6 Wheelbase, 3-1 Whiffles, 10-9 Width, of TB100J, 3-1 Wind loading, 1-2 Wind speed, safe 3-1 Wire ropes, checking, 10-9 Wiring harnesses, 10-3 Work place, hazards, 1-1 Work place, inspection, iii, 1-1 Working envelope, 3-4 and EMS lights and audio alarm, 2-4

I - 4

P/N 0112478

LIMITED WARRANTY

Snorkel warrants each new machine manufactured and sold by it to be free from defects in material and workmanship for a period of one (1) year from date of delivery to a Customer or for one year after the machine has been placed in first service in a Dealer rental fleet, whichever comes first. Any part or parts which, upon examination by the Snorkel Service Department, are found to be defective, will be replaced or repaired, at the sole discretion of Snorkel, through its local Authorized Dealer at no charge.

Snorkel further warrants the structural components; specifically, the mainframe chassis, turntable, booms and scissor arms, of each new machine manufactured by it to be free from defects in material and workmanship for an additional period of four (4) years. Any such part or parts which, upon examination by the Snorkel Service Department, are found to be defective will be replaced or repaired by Snorkel through its local Authorized Dealer at no charge; however, any labor charges incurred as a result of such replacement or repair will be the responsibility of the Customer or Dealer.

The Snorkel Service Department must be notified within forty-eight (48) hours of any possible warranty situation during the applicable warranty period. Personnel performing warranty repair or replacement must obtain specific approval by Snorkel Service Department prior to performing any warranty repair or replacement.

Customer and Dealer shall not be entitled to the benefits of this warranty and Snorkel shall have no obligations hereunder unless the "Pre-Delivery and Inspection Report" has been properly completed and returned to the Snorkel Service Department within ten (10) days after delivery of the Snorkel product to Customer or Dealer's rental fleet. Snorkel must be notified, in writing, within ten (10) days, of any machine sold to a Customer from a Dealer's rental fleet during the warranty period.

At the direction of the Snorkel Service Department, any component part(s) of Snorkel products to be replaced or repaired under this warranty program must be returned freight prepaid to the Snorkel Service Department for inspection. All warranty replacement parts will be shipped freight prepaid (standard ground) from the Snorkel Service Department or from Snorkel's Vendor to Dealer or Customer.

REPLACEMENT PARTS WARRANTY

Any replacement or service part made or sold by Snorkel is not subject to the preceding beyond the normal warranty period of the machine upon which the part was installed.

THIS WARRANTY EXCLUDES AND SNORKEL DOES NOT WARRANT:

1. Engines, motors, tires and batteries which are manufactured by suppliers to Snorkel, who furnish their

own warranty. Snorkel will, however, to the extent permitted, pass through any such warranty protection to the Customer or Dealer.

2. Any Snorkel product which has been modified or altered outside Snorkel's factory without Snorkel's

written approval, if such modification or alteration, in the sole judgment of Snorkel's Engineering and/or Service Departments, adversely affects the stability, reliability or service life of the Snorkel product or any component thereof.

3. Any Snorkel product which has been subject to misuse, improper maintenance or accident. "Misuse"

includes but is not limited to operation beyond the factory-rated load capacity and speeds. "Improper maintenance" includes but is not limited to failure to follow the recommendations contained in the Snorkel Operation, Maintenance, Repair Parts Manuals. Snorkel is not responsible for normal maintenance, service adjustments and replacements, including but not limited to hydraulic fluid, filters and lubrication.

4. Normal wear of any Snorkel component part(s). Normal wear of component parts may vary with the

type application or type of environment in which the machine may be used; such as, but not limited to sandblasting applications.

5. Any Snorkel product that has come in direct contact with any chemical or abrasive material.

6. Incidental or consequential expenses, losses, or damages related to any part or equipment failure,

including but not limited to freight cost to transport the machine to a repair facility, downtime of the machine, lost time for workers, lost orders, lost rental revenue, lost profits or increased cost.

This warranty is expressly in lieu of all other warranties, representations or liabilities of Snorkel, either expressed or implied, unless otherwise amended in writing by Snorkel's President, Vice President-Engineering, Vice President-Sales or Vice President-Marketing.

SNORKEL MAKES NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION OF THIS LIMITED WARRANTY. SNORKEL MAKES NO IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND DISCLAIMS ALL LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING BUT NOT LIMITED TO INJURY TO PERSONS OR PROPERTY.

The Customer shall make all warranty claims through its local Authorized Dealer and should contact the Dealer from whom the Snorkel product was purchased for warranty service. Or, if unable to contact the Dealer, contact the Snorkel Service Department for further assistance.

Limited Warranty

Effective July 1995

CALIFO RNIA

Proposition 65 Warning

Battery posts, terminals and related accessories contain lead and lead components, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

CALIFORNIA

Proposition 65 Warning

Diesel and gasoline engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects or other reproductive harm.

Snorkel TB100J User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual