Snorkel TB120 User Manual

Operator’s

Manual

P/N 0191914
February,2001

DANGER

ELECTRICAL HAZARD

The TB120 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 A95, 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.)

P/N 0191914

DANGER

ELECTRICAL HAZARD

THE TB120 AERIAL WORK PLATFORM IS NOT

ELECTRICALLY INSULATED.

If the platform, booms, or any other conductive part of a TB120 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 TB120 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 TB120. Such contact
could make your body a conductor to the other object creating an electrical
shock hazard resulting in
or leave the TB120 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 TB120 is in contact with a live conductor, the platform operator
others on the ground in the vicinity of the TB120 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 TB120 ground controls when the platform, booms,
or any other conducting part of a TB120 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 TB120 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

TABLE OF CONTENTS

INTRODUCTION ..................................... v

SIGNS ............................................... v

TYPE-STYLE CONVENTIONS.......... v

QUALIFIED OPERATORS................. v

MAINTENANCE................................. vi

RESPONSIBILITIES OF PARTIES .... vi

ADDITIONAL INFORMATION ........... vi

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

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

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

Work Place

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

Starting and Stopping Precautions . 1 - 3

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

Operator Maintenance Precautions ......

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

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

Inspection and Practices

.... 1 - 1

.. 1 - 3

1 - 3

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

AMPS

ENGINE OIL...................................... 4 - 1

FILTER MINDER

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

HOURS

HYDRAULIC OIL FILTER.................. 4 - 2

HYDRAULIC OIL LEVEL ................... 4 - 3

HYDRAULIC OIL TEMPERATURE ... 4 - 3

TEMPERATURE

5. AUTOMATIC SHUT-OFFS

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

AUTOMATIC SHUT-OFFS ................ 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

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

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

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

................................ 4 - 3

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

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

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

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

DRIVING LIGHTS (option)................. 2 - 1

EMERGENCY STOP

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

EMS TABLE....................................... 2 - 3

EXTENDIBLE-AXLE INTERLOCKS... 2 - 3

FLASHING LIGHTS (option).............. 2 - 3

FOOT SWITCH ................................. 2 - 4

GFCI OUTLET................................... 2 - 4

GRAVITY GATE ................................ 2 - 4

GROUND OPERATION

GUARDRAILS ................................... 2 - 5

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

LANYARD ANCHOR POINTS ........... 2 - 5

MOTION ALARM (option) .................. 2 - 5

PLATFORM WORK LIGHTS (option) .. 2 - 5

SELF-CLOSING GATE (option)......... 2 - 5

TILT ALARM HORN, SIREN, & LIGHT 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

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

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

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

TURNTABLE & BOOM NOMENCLATURE

SWITCHES ..... 2 - 1

SWITCH...... 2 - 4

. 3 - 5

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 TB120 ........................ 7 - 8

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

ELECTRICAL 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

ii

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TABLE OF CONTENTS

10. DAILY INSPECTION &

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

DAILY INSPECTION AND

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

PLACARDS AND DECALS

INSPECTION CHART 1 .................. 10 - 12

PLACARDS AND DECALS

INSPECTION DRAWING 1 ............. 10 - 13

PLACARDS AND DECALS

INSPECTION CHART 2 .................. 10 - 14

PLACARDS AND DECALS

INSPECTION DRAWING 2 ............. 10 - 15

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

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

AC GENERATOR.............................. 12 - 1

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

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

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

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

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

FLASHING LIGHTS .......................... 12 - 3

HYDRAULIC SYSTEM COLD

WEATHER WARM-UP KIT ............. 12 - 3

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

PLATFORM WORK LIGHTS............. 12 - 3

SELF-CLOSING GATE ..................... 12 - 4

SPARK ARRESTOR ......................... 12 - 4

TOW KIT ........................................... 12 - 4

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

WARRANTY.........................inside back cover

CALIFORNIA PROPOSITION 65.....back cover

P/N 0191914

iii (iv blank)

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 TB120 if not done
correctly.

Training is essential and must be performed by
a QUALIFIED person. Become proficient in
knowledge and actual operation before using
the TB120 on the job. You must be trained and
authorized to perform any functions of the
TB120. Operation of the TB120 must be within
the scope of the machine specifications.

Before operating the TB120 you must read and
understand the operating instructions in this
manual as well as the decals, warnings, and
instructions on the machine itself.

Before operating the TB120 you must be
AUTHORIZED by the person in charge to
do so.

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.

TYPE-STYLE CONVENTIONS

T

Throughout this manual the names of switches
and gauges as well as the names of switch
positions (ON/OFF, etc.) are capitalized.
Furthermore, switch and gauge names are
printed in bold type and, when they occur in
section titles, are italicized. The purpose of all
this is to emphasize the exact name of the
switch, gauge, or switch position and thus
reduce ambiguity.

Some paragraphs in this manual are printed in
italic. Those paragraphs apply to optional
equipment. If your TB120 does not have the
optional equipment ignore the paragraphs.

QUALIFIED OPERATORS

T

The TB120 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.

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

5. You must make a pre-start inspection of the
TB120 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 TB120.

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.

P/N 0191914

v

INTRODUCTION

MAINTENANCE

T

ADDITIONAL INFORMATION

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 TB120 in good operating condition. Do not
perform other maintenance unless you are a
TRAINED mechanic, QUALIFIED to work on
the TB120. Call QUALIFIED maintenance
personnel if you find problems or malfunctions.

Information contained in this manual concerns
only current TB120’s, 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
TB120 read, understand, and conform to all
applicable regulations. Ultimate compliance to
OSHA regulations is the responsibility of the
employer using the equipment.

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

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

A reprint of the “

Dealers, Owners, Users, Operators, Lessors
and Lessees of ANSI/SIA A92.5-1992 Boom­Supported Elevating Work Platforms

available from Snorkel dealers or from the
factory upon request.

Copies are also available from:

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

Manual of Responsibilities for

” is

vi

P/N 0191914

1. SAFETY

1. SAFETY

SAFE OPERATION

T

The following safety information is vitally
important for safe operation of the TB120.
Failure to follow these instructions can result in
personal injury or DEATH.



Pre-start Inspection



Prior to each shift, the TB120 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 TB120 unless you are trained
and authorized, understand the operation
characteristics of the TB120, 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 TB120 as a ground for welding.
Ground to the work piece.

Before the TB120 is used, and during use, check
the area in which the TB120 is to be used for
possible hazards such as, but not limited to:

drop-offs or holes,

•

side slopes,

•

bumps and floor obstructions,

•

debris,

•

overhead obstructions and electrical

•

conductors,

hazardous locations,

•

inadequate surface and support to withstand

•

all load forces imposed by the aerial platform
in all operating configurations,

wind and weather conditions,

•

presence of unauthorized persons,

•

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 TB120 to assist the platform operator
in the event of an emergency.

When moving the platform, check the clearance
around the TB120 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.

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.

Do not engage in any form of “horseplay” or
“stunt driving” while operating the TB120.

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

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

Never steady the platform by positioning it
against another platform.

Do not operate a TB120 that is not functioning
properly, or has been damaged, until the
machine has been repaired by a qualified
maintenance person.

Do not operate a TB120 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.

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

Use the recommended transport device when
loading the machine.

P/N 0191914

1 - 1

1. SAFETY



Electrocution



The TB120 is an all-metal boom, NON­INSULATED, aerial work-platform. Do not
operate it near ELECTRICAL conductors.
Regard all conductors as being energized.

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

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

Do not operate outside during a thunderstorm.



Tipover & Falling Hazards



Do not operate a TB120 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

•

structure where
required.

personal fall arrest

is

Maintain a firm footing on the platform floor.
Climbing on the guardrails 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 TB120 as a crane, hoist, or jack.

Do not operate the TB120 in winds, or wind
gusts, of 28 mph (45 km/h) or more.

Do not add anything to the TB120 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.

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 TB120 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.

Raise the platform only when the TB120 is on
level ground.

1 - 2

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.

P/N 0191914



Mounting & Dismounting Precautions



Use three points of support (e.g., two hands and
one foot) when getting on or off the platform.

1. SAFETY

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

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 TB120 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
TB120.

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.

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

, set the

BATTERY

BATTERY

switch.



Fuel Handling Precautions



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 TB120. 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 TB120 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.

P/N 0191914

1 - 3

1. SAFETY

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

1 - 4

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1. SAFETY

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1 - 5

1. SAFETY

1 - 6

P/N 0191914

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 TB120 to increase safety
in the work place for both the operator and other
people near a TB120. 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 TB120
from service immediately until a qualified service
technician can make repairs.

DRIVING LIGHTS (option)

T

2. SAFETY DEVICES

T

EMERGENCY STOP

2. SAFETY DEVICES

SWITCHES

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.

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

At the ground-control box:
EMERGENCY STOP

under any conditions, and the entire machine
stops, the engine turns off, the brakes
automatically set, and nothing moves. This
switch must be pulled out for anything on the
TB120 to work.

At the platform-control box:

red

EMERGENCY STOP

entire machine stops, the engine turns off, the
brakes automatically set, and nothing moves.
This switch must be pulled to its up (out) position
to control the TB120 from the platform.

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
TB120.

button in, at any time,

Press the red

Press the large

button down and the

EMERGENCY STOP

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2 - 1

2. SAFETY DEVICES

EMS LIGHTS & AUDIO ALARMS

T

There are six envelope management system
(EMS) lights on a TB120.

Three are on the instrument panel.

whether or not the envelope management
system is operating correctly.

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.

In addition to EMS lights there are EMS audio
alarms.

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

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.

EMS ENVELOPE

The
information about where the platform is located
relative to the platform’s working envelope. (See
the “SPECIFICATIONS” chapter for the TB120
working envelope.) The

EMS WARNING

lights (1) give the operator

EMS STATUS

lights (3) tell the operator

(2) and

2 - 2

NOTE: When a TB120 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 self­test, conditions in the table below prevail.

P/N 0191914

2. SAFETY DEVICES

EMS TABLE

LIGHT CONDITION AUDIO ALARM

GREEN

EMS

STATUS

WHITE

EMS

ENVELOPE

RED

EMS

WARNING

ON

: Machine is ready for normal operation.

FLASHING

technician.

OFF

: Platform is well inside the working envelope.

FLASHING

working envelope.

ON

: Platform is at the limits of the working envelope.

ON

: EMS error detected. Press the red

light completely in and release it

WARNING

procedures described in the “EMERGENCY
OPERATION” chapter to lower the platform.

FLASHING

envelope. Move boom into working envelope.

: Calibration error. Notify qualified service

DO NOT USE MACHINE

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

light stays on, use the emergency

: Platform is outside the limits of the working

.

slowly

EMS WARNING

. If the red

None.

None.

None.

None.

None.

Continuous tone.

EMS

Beeping

EXTENDIBLE-AXLE INTERLOCKS

T

The left and right rear axles of a TB120 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.

FLASHING LIGHTS

T

The flashing lights alert people that the TB120
is present. The lights flash at about one flash
per second anytime the engine is running.
There is no ON/OFF switch for the flashing
lights.

(option)

P/N 0191914

2 - 3

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 TB120 is in motion.

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

NOTE: See “ELECTRICAL OUTLET AT
THE PLATFORM (GFCI)” in the
“OPERATION” chapter for more information
about how to use the GFCI.

T

GRAVITY GATE

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 an anchor point (2), check
to see that the gravity gate (1) has fallen back
into place.

T

GROUND OPERATION

SWITCH

T

GFCI OUTLET

The GFCI (Ground Fault Circuit Interrupt)
protects against electricity flowing to ground.
When electricity flows to ground the GFCI shuts
off power to the electrical outlets.

To use the outlets, connect the power-input
connector, inside the left-rear of the turntable,
to a source of 125 V ac, 15 A electrical power.

NOTE: If the TB120 has the optional ac
generator, plug the power-input connector
(inside the left-rear of the turntable) into the
generator. Then, set the

MACHINE/GENERATOR

platform-control box, to GENERATOR.

switch, on the

The

GROUND OPERATION

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

GROUND OPERATION

switch prevents

switch up

42 -

P/N 0191914

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.

HORN

T

2. SAFETY DEVICES

LANYARD ANCHOR POINTS

T

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

MOTION ALARM (option)

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
TB120 is traveling along the ground.

DRIVE/STEER

The operator
the attention of people on the ground when you
are working aloft. 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
following switches, on the ground-control box,
must be set as indicated:

SELECTOR SWITCH
EMERGENCY STOP
MASTER KEY SWITCH

HORN t

BATTERY

is used primarily to get

switch must be ON and the

..........PLATFORM

...............pulled out

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

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.

P/N 0191914

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

5 2 -

2. SAFETY DEVICES

SELF-CLOSING GATE (option)

T

The self-closing gate is designed to
automatically close after you enter or leave the
platform. It helps prevent people from falling off
the platform.

TILT-ALARM HORN, SIREN, & LIGHT

T

There is one tilt-alarm siren, one tilt-alarm horn,
and one tilt-alarm warning light on a TB120.

The tilt-alarm warning light is on the platform­control box.

The siren will emit a two-toned sound (high-low­high-low...) if the TB120 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 TB120 is being controlled from the
ground-control box.

°

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

3

After the siren and/or horn begins to sound, if
the tilt continues to increase, the TB120 can tip
over. When you are in control of a TB120 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 TB120 to a level surface
or more firm ground before extending or raising
the booms again.

DRIVE/STEER

controller stick

DRIVE/STEER

2

The horn (2) is located inside the left-rear of the
turntable, under the tilt alarm sensor (3).

62 -

P/N 0191914

3. SPECIFICATIONS

3. SPECIFICATIONS

The TB120 is a boom-supported elevating work­platform 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) .....126 ft - 0 in (38.4 m)

Platform height (maximum) ..120 ft - 0 in (36.6 m)

Platform reach (maximum).....62 ft - 0 in (18.9 m)

Length

(booms down and retracted)..42 ft - 4 in (12.9 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 - 0 in (3.0 m)

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

Ground clearance ........................... 13 in (33 cm)

Tailswing:

rear axles stowed ....................6.54 ft (1.99 m)

rear axles extended.................4.38 ft (1.33 m)

Weight (approximate)......... 39,500 lb (17,917 kg)

Ground pressure, max..

Wheel load, max. single ..... 19,750 lbs (8,977 kg)

Travel speeds (max.) (See “CONTROLS”
chapter for explanation of settings for different
speeds.):

booms down and retracted

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

mid speed, mid torque....... 1.5 mph (2.4 km/h)

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

booms up and/or extended

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

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

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

................. 87

psi

(600 kPa)

Turning radius

outside................................ 33 ft - 0 in (10.0 m )

inside, axles retracted............ 22 ft - 0 in (6.7 m)

inside, axles extended ...........20 ft - 0 in (6.1 m)

Tires (foam filled)

.............. 18 x 22 in (46 X 56 cm), 18 ply or radial

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

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

(-18°C to +43°C)
wind speed

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

Fuel tank capacity:

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

optional LPG....................... 43.5 lb 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 ...................+75°/-1° to horizontal

Boom movement times in seconds (complete
range of movement):

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).............90 - 120 seconds

UP (boom extended) ........... 150 -180 seconds

DOWN (boom retracted) .....90 - 120 seconds

DOWN (boom extended).....150 -180 seconds

Boom Extension

OUT ...................................130 - 160 seconds

IN .......................................130 - 160 seconds

PLATFORM SPECIFICATIONS

T

Unrestricted rated work load (total weight of personnel, tools,

SIZE

PLATFORM

standard aluminum 30 x 92 (76 x 234) Rated work load: 500 lbs (227 kg)

P/N 0191914

inches (cm)

and materials that the platform is designed to carry above its
floor when the platform is within its working envelope -- same
as UNRESTRICTED PLATFORM CAPACITY)

Rated number of occupants: 2 people

3 - 1

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)

COOLANT 50% water + 50% ethylene glycol

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 full tank of gasoline or diesel will last an entire eight hour shift,

ENGINE OIL CHARTS

T

180°F - 202°F
(81°C - 94°C)

(5.7 liters)

(0.95 liters)

under normal working conditions. It normally takes between one and
two tanks of LPG per eight hour shift.

HD5
Gas Processors
Association Standard
2140
Category: special
duty propane

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

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

CONTINENTAL ENGINE CUMMINS ENGINE

3 - 2

P/N 0191914

OVERALL DIMENSIONS

T

3. SPECIFICATIONS

P/N 0191914

3 - 3

3. SPECIFICATIONS

WORKING ENVELOPE

T

3 - 4

P/N 0191914

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

TURNTABLE & BOOM

T

NOMENCLATURE

3. On a placard on the platform brace, above
the platform anchor points. (Last four digits are
mo. and yr. shipped.)

4. Below the drain hole in the turntable.

5. At the weld behind the rotation bearing turret.

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

P/N 0191914

3 - 5 (3 - 6 blank)

3 - 5

4. GAUGES

4. GAUGES

AMPS

T

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

ENGINE OIL

CONTINENTAL CUMMINS

gauge shows the electric current

AMPS

gauge

CONTINENTAL CUMMINS

4

3

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.

FILTER MINDER

T

2

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.

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

is

P/N 0191914

4 - 1

4. GAUGES

T

FUEL

4

3

1

2

The fuel gauge (1) is located on top of the
gasoline or diesel fuel tank (2), inside the front­right of the turntable. Read it at the line (3) in the
clear plastic window (4). It reads in fractions-of-a­full-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.

1

HOURS

T

The

HOURS

It accumulates time when:

BATTERY
SELECTOR SWITCH
MASTER KEY SWITCH

Or when:

BATTERY
SELECTOR SWITCH
ANTI-RESTART
MASTER SWITCH

The

HOURS

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

gauge is basically an electric clock.

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

...... GROUND

.. ON.

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

...... PLATFORM

......... ON.

gauge cannot be reset. Use it to tell

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. TB120 tanks are
mounted horizontally. Therefore, you should read
the

HORIZONTAL

HORIZONTAL

scale (2).

). Both read in

VERTICAL

)

T

HYDRAULIC OIL FILTER

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.

4 - 2

P/N 0191914

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.

T

HYDRAULIC OIL LEVEL

TEMPERATURE

T

4. GAUGES

The hydraulic-oil level gauge (1) is on the side of
the hydraulic oil tank. 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 (2)
should be between the high mark (3) and low
mark (4).

T

HYDRAULIC OIL TEMPERATURE

The

TEMPERATURE

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

gauge is located just

The hydraulic-oil temperature gauge (1) is inside
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
TB120 to let the hydraulic oil cool.

P/N 0191914

4 - 3 (4 - 4 blank

4 - 3