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Chapter 11 – Troubleshooting

TB42/TB50 – 0075251EE

Symptom

Hydraulic fluid temperature 93°C
(200°F ) or more.

Severe hydraulic leak.

Possible Cause

Prolonged boom operation or driving.

High pressure fluid return to reservoir
caused by kinked or twisted hose.

Hydraulic system component failure.

Failure of hose, tube, fitting, seal, etc.

Corrective Action

Stop operation until fluid cools.

Remove the kink or twist from the
hose. Let fluid cool before resuming
operation.

Stow the machine and do not oper-
ate until repairs are made.

Do not operate machine until repairs
are made.

Содержание TB42

Страница 1: ...Part Number 0075251EE November 2005 Oper Oper Oper Oper Opera a a a ator tor tor tor tor s s s s s Manual Manual Manual Manual Manual ...

Страница 2: ... not part of the aerial platform Such contact could make your body a conductor to the other object creating an electrical shock hazard resulting in death or serious injury If an aerial platform is in contact with an energized conductor the platform operator must warn ground personnel in the vicinity to stay away Their bodies can conduct electricity creating an electrical shock hazard resulting in ...

Страница 3: ...ration 12 Tip Over and Falling Hazards 12 Electrical System 13 Hydraulic System 13 Engine and Fuel Handling Precautions 13 Placards and Decals 14 Chapter 4 Safety Devices Emergency Stop Controls 15 Emergency Power System 15 Emergency Lowering Knob 15 Ground Operation Switch 16 Platform Foot Switch 16 Guardrails 16 LanyardAnchors 16 TiltAlarm 16 Platform Overload Sensing System 17 Engine Protection...

Страница 4: ...e Pads 32 Wire Ropes 32 Fasteners 33 Upper Control Station 33 Guardrail System 33 LanyardAnchors 33 Operating Controls 33 Emergency Stop 34 Emergency Power 34 Horn 34 Electrical Power Outlet 34 Drive MotionAlarm 34 Driving and Work Lights 34 Platform Control Cover 34 Tow Kit 34 Placards and Decals 35 Prestart Inspection Checklist 39 Chapter 8 Operation Cold Weather Start Up 41 Engine Cold Weather ...

Страница 5: ...Airline to platform Tow kit 76 cm x 234 cm 30 x 92 aluminum 227 kg 500 lb capacityplatform 76 cm x 152 cm 30 x 60 aluminum 272 kg 600 lb capacityplatform Operator s Manual This manual provides information for safe and proper op eration of the aerial platform Read and understand the information in this Operator s Manual before operating the aerial platform on the job Additional copies of this manua...

Страница 6: ...con dition Other maintenance functions must be performed by maintenance personnel who are qualified to work on the aerial platform ACaution Welding current can be very intense Damage to electronic components can result Connect the ground clamp as close as possible to the area be ing welded Disconnect battery cables and any mi croprocessors and engine control modules before welding on the machine I...

Страница 7: ...de Chassis Lower Controls Upper Controls Fuel Tank Wiring Box Operator s Manual Steer Wheels Left Side Platform Main Boom Tip Boom Hydraulic Fluid Tank And Filter Battery Disconnect Switch Batteries Engine Steer Wheels Platform Foot Switch Emergency Lowering Valve Intermediate Boom ...

Страница 8: ...Chapter 2 Specifications 4 TB42 TB50 0075251EE Working Envelope TB42 420 Meters Feet 9 1 30 6 1 20 3 0 10 0 3 0 10 12 2 40 0 3 0 10 6 1 20 9 1 30 12 2 40 15 2 50 ...

Страница 9: ...Chapter 2 Specifications TB42 TB50 0075251EE 5 Working Envelope TB50 Meters Feet 9 1 30 6 1 20 3 0 10 0 3 0 10 12 2 40 0 3 0 10 6 1 20 9 1 30 12 2 40 15 2 50 18 2 60 ...

Страница 10: ...umber of occupants 2 people OptionalAC generator 220 VAC Function Speed Turntable rotation 360 degrees 100 to 110 seconds Main boom Up 40 to 50 seconds Down 40 to 50 seconds Extend 40 to 45 seconds Retract 25 to 30 seconds Platform rotation 180 degrees 16 to 20 seconds Drive High booms stowed 4 8 km h 3 0 mph Low booms elevated 1 6 km h 1 0 mph Drive System Standard Four wheel drive Optional Two w...

Страница 11: ...s Main boom Up 52 to 57 seconds Down 52 to 57 seconds Extend 40 to 45 seconds Retract 25 to 30 seconds Platform rotation 150 degrees 16 to 20 seconds Drive High booms stowed 4 8 km h 3 0 mph Low booms elevated 1 6 km h 1 0 mph Drive System Standard Four wheel drive Optional Two wheel drive Gradeability 25 Tires Street tread foam filled 10 ply 30 cm x 42 cm 12 x 16 5 Bar lug foam filled 10 ply 30 c...

Страница 12: ...liter 125 cu in DIN 51 601 February 1986 1 BS 2869 A1 and A2 with A2 refer to Deutz manual about sulfur content 1 ASTM D 975 88 1 D and 2 D CEN EN 590 or DIN EN 590 NATO Code F 54 and F 75 For operating temperatures below 0 C 32 F use winter grade diesel Air 6 0 liter 1 59 US gal API CD or higher3 78 C to 95 C 172 F to 203 F Displacement Fuel Grade Coolant Operating Temperature Oil Capacity Oil Gr...

Страница 13: ...Chapter 2 Specifications TB42 TB50 0075251EE 9 Engine Oil Viscosity Cummins B3 3 Deutz F3L 2011F ...

Страница 14: ...Chapter 2 Specifications 10 TB42 TB50 0075251EE ...

Страница 15: ...ts and is not insulated Regard all conductors as energized Do not operate outside during a thunderstorm Minimum Safe Approach Distance Minimum safe approach distances to energized power lines and their associated parts must be observed while operating the aerial platform ADanger The aerial platform is not electrically insulated Death or serious injury will result from contact with or inadequate cl...

Страница 16: ...r hazards Always look in the direction of movement Drive with care and at speeds compatible with the work place conditions Use caution when driving over rough ground on slopes and when turning Do not engage in any form of horse play or permit riders any place other than in the platform Secure all accessories containers tools and other ma terials in the platform to prevent them from accidentally fa...

Страница 17: ...tform evacuate the platform before attempting to free it Electrical System Charge the batteries in a well ventilated area free of flame sparks or other hazards that might cause fire or explo sion Do not operate any of the aerial platform functions while the battery charger is plugged in AWarning Batteries give off hydrogen and oxygen that can combine explosively Death or serious injury could resul...

Страница 18: ...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 ACaution Engine coolant escaping under pressure can cause serious burns Shut the engine off and let it cool before removing the radiator cap Let the engine and radiator cool be...

Страница 19: ...utton is engaged the lower controls can still be used to operate the aerial platform At the upper controls the emergency stop is a two posi tion push button refer to Figure 4 2 Figure 4 2 Upper Controls Push the emergency stop button in to disconnect power to the upper control circuits Pull the button out to re store power Emergency Power System The emergency power system includes a back up pump m...

Страница 20: ...or position the aerial platform for elevated use near any drop off hole slope soft or uneven ground or other tip over haz ard Retract and lower the main boom and then drive to a level surface when the tilt alarm sounds The tilt alarm is for added protection and does not justify operating on anything other than firm flat level surfaces Ground Operation Switch The ground operation switch refer to Fi...

Страница 21: ...verload limit is exceeded The horn will sound intermittently and the red overload light refer to Figure 4 7 will blink until the excess load is removed from the platform At that time the machine func tions are again operational Note If the platform overload sensing system is tripped while operating the machine the emergency power system may still be used for emergency machine operation from ei the...

Страница 22: ...wer limit for safe engine operation If the alarm sounds lower the platform to the ground and then turn the engine off Do not restart the engine until the condition that caused the low oil pressure has been corrected If the engine oil pressure falls below a safe operating value the engine will shut off The engine can be restarted with low oil pressure but it will only run a few seconds before it sh...

Страница 23: ...eries After the engine has been running for a few minutes un der normal operating conditions the ammeter gauge in dicator should read 0 Engine Air Filter Gauge The air filter gauge refer to Figure 5 3 is located above the lower control panel The gauge measures the air pres sure between the intake manifold and the air filter Figure 5 3 Air Filter Gauge The yellow indicator disk inside the sight gla...

Страница 24: ...tick The dip stick is the only way to accurately determine the engine oil level The engine oil level should always be between the add and full marks on the dipstick Hydraulic Fluid Filter Gauge The fluid filter gauge refer to Figure 5 5 is located on the return line filter on the left side of the reservoir The reser voir is behind the door on the left side of the turntable During high pump flow si...

Страница 25: ...nau thorized use of the aerial platform Lower Controls The lower controls refer to Figure 6 2 are located on the right side of the turntable Boom and platform functions can be operated from the lower controls The following are located on the lower control panel Emergency stop button Control selector switch Start switch Ground operation switch Rotation switch Boom elevation switch Boom extend retra...

Страница 26: ...nter off position Hold the switch to the right to rotate the platform counter clockwise Hold the switch to the left to rotate the plat form clockwise Engine Emergency Power Switch Hold the engine emergency power switch refer to Figure 6 2 down to operate aerial platform functions using the emergency power system Release the switch to disen gage the emergency power system Note The emergency power s...

Страница 27: ...o rotate the turntable The boom and turntable functions may be operated simulta neously Note The distance the joystick is moved is proportional to the speed of the function Hold the joystick forward to raise the main boom and backward to lower the boom The circuit breakers protect the electrical wiring and com ponents from electrical overload in case of a short circuit or other fault ACaution A tr...

Страница 28: ...able clock wise Drive Joystick The drive joystick refer to Figure 6 5 is used to control forward and reverse motion of the aerial platform It is also used to steer the machine The steering and drive functions may be operated simultaneously Note The distance the joystick is moved is proportional to the speed of the function Hold the joystick forward to move the aerial platform for ward and backward...

Страница 29: ... light refer to Figure 6 7 Figure 6 7 Platform Work Lights Machine Generator Switch The switch for the optionalAC generator is located on the front of the upper control panel With the engine running place the switch in the genera tor position to provide electrical power to the electrical outlet at the platform Place the switch in the machine position to turn off the generator and resume machine op...

Страница 30: ...Chapter 6 Controls 26 TB42 TB50 0075251EE ...

Страница 31: ...n both sides of the machine and visually inspect the engine and its compo nents with the engine off Oil Level Check the engine oil level before starting the engine so the oil has drained to the pan The proper oil level is be tween the add and full marks on the dipstick The distance between the top and bottom dipstick marks corresponds to about 1 l 1 quart US Add oil if neces sary before starting t...

Страница 32: ...auges at Lower Controls To inspect the air filter 1 Turn the battery disconnect switch on and close the cowling door 2 At the lower controls pull the emergency stop but ton outward 3 Insert the key into the control switch and press the start button to turn the engine on 4 Check the clear zone after running the engine for 30 seconds If the indicator is in the red area replace the filter If the indi...

Страница 33: ...re brush or terminal cleaning tool All cable ends must be securely fastened to the terminals Cables and Wiring Harness Inspect all cables and wiring for wear and or physical damage such as loose connections broken wires and frayedinsulation Checkthewiringinareaswhereachange in routing direction may cause them to become pinched Make sure the cables and wires are properly routed to avoid sharp edges...

Страница 34: ...e Check the wheel lug nuts to see that none are missing damaged or loose Figure 7 9 Tires and Wheels The aerial platform has foam filled tires Foam filled tires do not have a pressure decal or a valve core Inspect for large holes or cuts where foam is coming out of the tire Look for large imbedded objects such as angle iron that can rip a tire open Punctures caused by bolts screws or nails are not...

Страница 35: ...cedure to test the emergency lower ing system 1 Use the lower controls to raise the main boom Figure 7 11 Emergency Lowering Knob 2 Turn the engine off ADanger Pinch points may exist between moving compo nents Death or serious injury will result from be coming trapped between components Stand clear of moving components while test operating the ma chine 3 Slowly turn the knob to open the bleed down...

Страница 36: ... tween moving parts Inspect the welds on the structural components Pay particular attention to boom welds The area to be in spected should be clean and free of dirt and grease Look for visible cracks in the weld and at the weld to parent material joint A bright light may be used to provide ad equate visibility of the inspection area Slide Pads The main boom has slide pads refer to Figure 7 13 be t...

Страница 37: ...s 1 Turn the battery disconnect switch on 2 At the lower controls pull the emergency stop but ton outward Insert the key in the control selector and turn the switch to the upper control position 3 At the upper controls refer to Figure 7 19 pull the emergency stop button outward Figure 7 16 Base End of Main Boom Fasteners Visually inspect all fasteners to see that none are miss ing or loose Pay par...

Страница 38: ...ol panel Tow Kit The machine may be equipped with an optional tow kit Inspect the tow bar and steering arm to verify the compo nents are present and in working condition Figure 7 19 Upper Control Panel Top 4 Turn the master start switch on the front of the upper control panel to start until the engine starts then release it 5 Let the engine warm to operating temperature ADanger Pinch points may ex...

Страница 39: ...ngredients Fol low the manufacturer s label for proper use and dis posal Wear protective gloves and splash proof safety glasses when using solvents 0074210 0074311 Right Side 0074311 One per Cylinder 0190989E 0074210 0190989E 0190989E Wet paint overspray may be removed using a natural bio degradable solvent and a soft cloth Replace any missing or illegible placards or decals be fore operating the ...

Страница 40: ...42 TB50 0075251EE Right Side 0162366 0162336E 0323897 0070901 0162366 0162336E 0070901 0323897 0162366 0162366 This machine is not electrically insulated Do not operate in proximity to high voltage power lines and parts 0162336E 0162336E ...

Страница 41: ...n Only Right Side 0073298 0082160 Tow Option Only Front 0082203 Tow Option Only 0162366 0162336E 0082164 0082203 0073298 0082160 0162366 0162366 This machine is not electrically insulated Do not operate in proximity to high voltage power lines and parts 0162336E 0162336E ...

Страница 42: ...insulated Do not operate in proximity to high voltage power lines and parts 0162336E 0162336E 0162366 0162366 KEEP CLEAR Rotating Engine Parts Serious Injury Can Result 0151410E 0151410E Upper Control Panel Front 0072530 0072531 Platform Left Side 0162366 0162336E 0073298 Radiator 0151410E Cummins Engines Only ...

Страница 43: ...peration Tires and Wheels Foam filled Good condition Lower Control Station Operating controls Proper operation Emergency stop and emergency power Shuts off lower controls proper operation Emergency Lowering Proper operation Level Sensor Sounds tilt alarm Flashing Light Proper operation Sandblast Protection Kit In place and proper operation Structures Weldments Welds intact no damage or deformation...

Страница 44: ...Chapter 7 Prestart Inspection 40 TB42 TB50 0075251EE ...

Страница 45: ...thick hydraulic oil does not flow well and may cause delay in response to control movement and improper volt age output of the AC generator Cold oil may also cause cavitation and pump damage The hydraulic system may be equipped with an optional cold weather warm up kit Engine Cold Weather Start Kit The optional engine cold weather start kit may be an engine block heater or a manifold air pre heate...

Страница 46: ...onds or longer before starting the engine The control selector switch must be turned back to off before the engine will start 3 Let the engine warm to operating temperature 4 Hold the ground operation switch up while operating the control toggle switches 5 Hold the appropriate toggle switch in the desired di rection 6 Release the function toggle switch to stop movement 7 Place the ground operation...

Страница 47: ...5 per cent For operation on grades up to 25 percent it is recom mended that the main boom be lowered with the platform elevated just enough to provide adequate ground clear ance A25 percent grade is a 0 76 m 30 vertical rise in 3 05 m 10 horizontal length Avoid driving with the platform over the front steer end of the chassis In this position the machine is difficult to control because drive and s...

Страница 48: ... left to steer to the left the direction of the blue arrow Note The steering wheels are not self centering Set the steer ing wheels straight ahead after completing a turn 7 After driving to the desired location release the foot switch or push the emergency stop button to apply the parking brakes Drive Speeds The drive speed is proportional to the joystick position The farther the joystick is moved...

Страница 49: ...l air line may be used to conduct air for tool operation at the platform The input connector is at the rear of the chassis and the output connector is at the platform on the rotator guard The maximum working pres sure of the line is 1 723 kPa 250 psi stopping all functions from the upper and lower controls The horn will then sound constantly and the overload light will stay illuminated at the uppe...

Страница 50: ...he air line after using it to conduct fluids Use the following procedure to drain the air line 1 Close the input connector on the chassis 2 Open the output connector at the platform 3 Raise the boom slightly above horizontal 4 Open the input connector on the chassis 5 Allow the fluid to drain from the line 6 Lower the boom and close both connections Driving Lights The optional driving lights are f...

Страница 51: ...he ramp could cause driving to be hazardous Drive the aerial platform onto the transport vehicle if the ramp incline is within the 25 percent grade capability of the aerial platform A 25 percent grade is a 0 76 m 30 vertical rise in 3 05 m 10 horizontal length Use a winch to load and unload the aerial platform on ramps that exceed 25 percent grade A winch may also be used when conditions of the ra...

Страница 52: ...and transport vehicle are aligned ADanger The aerial platform can tip over if it becomes un stable Death or serious injury will result from a tip over accident Set the drive range to low before driving up or down a grade 9 Place the drive range switch in the low position 10 Drive the aerial platform onto the transport vehicle in a straight line through the grade transitions with mini mal turning 1...

Страница 53: ...ing Lugs 3 Remove all personnel tools materials or other loose objects from the platform 4 Connect the chains or straps to the lifting lugs using bolted shackles Hooks that fit properly in the lugs and that have latching mechanisms to prevent them from falling out under a slack line condition may also be used Do not run the sling cable through the lifting lugs Cable damage and or failure can resul...

Страница 54: ...Platform ACaution Ratchets winches and come alongs can produce enough force to damage machine components Do not over tighten the straps or chains when securing the aerial platform to the transport vehicle 11 Use chains or straps to securely fasten the aerial platform to the transport vehicle using the tie down lugs as attachment points Proper tie down and haul ing are the responsibility of the car...

Страница 55: ...tem fails Refer to Emergency Power System Emergency Lowering or Towing for the appropriate pro cedure Emergency Power System The emergency power system can be used to operate the machine from the lower or upper controls ACaution The emergency power system is for emergency low ering and stowing only The length of time the pump can be operated depends on the capacity of the battery Do not use this s...

Страница 56: ...ollowing procedure to manually lower the main boom 1 Slowly turn the knob refer to Figure 10 5 to open the bleed down valve Control the rate of descent by turning the knob Figure 10 5 Emergency Lowering Knob AWarning The potential for an accident increases when safety devices do not function properly Death or serious injury can result from such accidents Fully close the emergency lowering knob bef...

Страница 57: ... Death or serious injury can re sult Securely fasten the tow vehicle to the aerial platform before disabling the drive hubs Use the following procedure to manually disengage the drive hubs and tow the machine 1 With the machine in the stowed position remove the tow bar from the storage cradles at the rear of the chassis and lay the tow bar near the front of the chas sis ADanger Pinch points may ex...

Страница 58: ...Chapter 10 Emergency Operation 54 TB42 TB50 0075251EE ...

Страница 59: ...or 20 seconds and then let the starter motor cool for 60 sec onds Repeat as necessary Cummins engine plug the block heater in eight hours before starting the engine Deutz engine hold the manifold heater switch on for about a minute before starting the engine Hold the switch on until the engine starts Let engine cool Do not restart the engine until the cause of overheat ing has been corrected Do no...

Страница 60: ... Place the control selector switch in the upper control position From the upper controls Turn the start switch off Pull the emergency stop button outward Place the start switch in the on position for 5 seconds and the then turn the switch to start Do not step on foot switch while start ing the engine Turn the start switch back to off then to start within 30 seconds Push the main system circuit bre...

Страница 61: ...ht is constantly on Corrective Action Let the engine cool Do not restart the engine until the cause of overheat ing has been corrected Do not restart the engine until the cause of low oil pressure has been corrected The engine can be re started with low oil pressure but it will only run a few seconds before it shuts off again Remove load from the platform until the alarms stop Remove load until at...

Страница 62: ...nding and red overload light is constantly on The drive boom switch is in the drive position Hydraulic oil is cold and thick Wire ropes are loose Boom speed knob set too slow Corrective Action Place switch in the on position Pull the emergency stop button out to the on position Place the switch in the lower control position Hold the ground operation switch in the on position while operating the co...

Страница 63: ...position Hydraulic oil is cold and thick Corrective Action Turn the emergency lowering knob to close the valve Stow the machine and do not oper ate until repairs are made Place the switch in the drive position Lower the booms and drive to a level surface Turn drive wheel disconnect plates around so nipples point outward Stow the machine and do not oper ate until repairs are made Remove weight from...

Страница 64: ...igh pressure fluid return to reservoir caused by kinked or twisted hose Hydraulic system component failure Failure of hose tube fitting seal etc Corrective Action Stop operation until fluid cools Remove the kink or twist from the hose Let fluid cool before resuming operation Stow the machine and do not oper ate until repairs are made Do not operate machine until repairs are made ...

Страница 65: ...ad or weight that can be transmitted through a single wheel to the floor or ground Minimum Safe Approach Distance the minimum safe distance that electrical conductors may be approached when using the aerial plat form Also called M S A D operation the performance of any aerial platform functions within the scope of its specifications and in accordance with the manufacturer s instructions the users ...

Страница 66: ...Appendix A Glossary TB42 TB50 0075251EE ...

Страница 67: ...ted Warranty 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 wh...

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