Snorkel TB100J User Manual
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
SERIOUS INJURY
DEATH
or
. Do not attempt to enter
or
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
or
STAY AWAY
ELECTROCUTION
DEATH
can result if contact with
MUST
from the
and
warn
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i
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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P/N 0112478
INTRODUCTION
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
T
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
T
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
T
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
T
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
T
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
1. SAFETY
SAFE OPERATION
T
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.
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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.
T
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
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.
T
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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3 1 -
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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1. SAFETY
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1. SAFETY
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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.
T
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
°
1
The siren (1) is located under the platformcontrol box.
3
2
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
T
EMERGENCY STOP SWITCHES
T
LANYARD ANCHOR POINTS
All personnel on the platform shall attach their
fall restraint lanyards to one of the lanyard
anchor points.
T
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
2 - 2
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2. SAFETY DEVICES
T
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.)
T
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.
T
EMS LIGHTS & AUDIO ALARMS
There are six envelope management system
(EMS) lights on a TB100J.
T
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.
P/N 0112478
2 - 3
2. SAFETY DEVICES
A second identical set of three is on the platformcontrol box.
2
1
In addition to EMS lights there are EMS audio
alarms.
3
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.
2 - 4
P/N 0112478
2. SAFETY DEVICES
EMS TABLE
LIGHT CONDITION AUDIO ALARM
GREEN
EMS
STATUS
WHITE
EMS
ENVELOPE
RED
ON
: Machine is ready for normal operation.
FLASHING
technician.
OFF
: Platform is well inside the safe working envelope.
FLASHING
safe working envelope.
ON
: Platform is at the limits of the safe working
envelope.
ON
: 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
EMS WARNING
light
None.
None.
None.
None.
None.
Continuous tone.
EMS
WARNING
OPERATOR HORN
T
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
T
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)
T
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)
T
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
T
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
T
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
T
(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
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
T
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
T
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
T
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
T
CONTINENTAL ENGINE CUMMINS ENGINE
23 -
P/N 0112478
OVERALL DIMENSIONS
T
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
T
43 -
P/N 0112478
3. SPECIFICATIONS
SERIAL-NUMBER LOCATIONS
T
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
T
3. On a placard below the platform-control
box. (Last four digits are mo. and yr.
shipped.)
TURNTABLE & BOOM
T
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
4. GAUGES
T
FILTER MINDER
2
4
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
3
1
is
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).
T
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.”
T
HOURS
gauge shows the electric current
AMPS
gauge
T
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
T
HYDRAULIC OIL LEVEL
4
2
1
T
FUEL
4
3
1
2
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.
5
3
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
T
HYDRAULIC OIL TEMPERATURE
LOW
mark (5).
HIGH
mark (4)
2
1
2
(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
HORIZONTAL
scale (2).
). Both read in
VERTICAL
)
1
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
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