battery - Snorkel
Contents
1. 1 1110 XNVL 5 5 gt AO gt E Mes lt fei lt d 4 EAN 6 AO E had 4 EI L D 22 3 e 1 9 9 or t ET 619 N VN x m 718 V A V Y T 919 a 1 es 15 V ZN zio Lm m a di 1 fi Is a JepulMD 12 V A 2 Ik ern d 2 ui HY eioujod MO in 2 A EJ N e gt U 5 N 508244 103 Page 5 6 508244 103 Page 5 7 ILLUSTRAITED PARTS LIST SECTION 6 ILLUSTRATED PARTS LIST INTRODUCTION This section lists and illustrates the replaceable assemblies and parts of the 2633 Work Platform as manufactured by Snorkel Each parts list contains the component parts for that assembly indented to show relationship where applicable TABLE OF CONTENTS Basic ASSEMBLY CHassis ASSEMBLY FRONT CHassis ASSEMBLY REAR Scissor amp DECK ASSEMBLY SCISSOR ASSEMBLY DECK ASSEMBLY CONTROL MODULE ASSEMBLY POWER MODULE ASSEMBL2. 9 El 1892 81 LI sud BIgOGE um psyumdod 0 90 089 1 9241 y Josuss 2178 2 DER 81 42 1 8 4 I 62625 x Sud apu 1 81206 Reen ae D pua 995 uo Joiaauuo3 AE Ins EIA0GZ PTANG Bmd 0 002089 1 dv 81 2 AVES 0 LIUSHASHULTUDGE 05 3Inpuod 51 1 woog 2 25 5 0 24 14052 81 Jaur2607 pua6a1 203524409 Savm alpung pua aut OMY 81 naf 433 8 y 34M DAV 81 BECK GSanSunegsisenun 29 gt Wel 40128UU02 UM SAM OMY 81 and n ZH 12 wsdnsssoug amg 31 383 107284400 Wi DAV 81 mal 39 EE Sd e 540139uu03 2 40 00 6 aaf 02455 49 8 89 au 035 3 vay pua sui 12 66 82 m BI led umoug NME 5 DAV BI 2 a6uoan 989 99529 865 3 6
3. Page 5 3 PINK 3L FROM ITEM 890 TABS MOTOR CONTROLLER 508244 103 5 4 J1 CABLE SCHEMATIC pua aui pua eui pua ayi uo 9 81 pus aut Jaraauuos 5402290000 9 jO 1940 459 34 204 jouludai 8 asn VOUE PES uaawiag BI ui 10465 aui Asiop Quo aui 401220405 ui DAV aa n 5 un SEA ES uan xs 78 pua au Dee UOJO122UU02 9 in SAN OMY 81 SAN 292 EI pua au 401300402 9 UAM DAY BL qd pua aun Ui DAY BI 5201290002 2 JO 1040 401324402 DAY Bl VAM jouis Loya pue ayy uo 5 DAV et Be uniad33o 4ayalouiod 3207 agejoyiog AN pua ay DAY pua oaauuoa DAY BI O pua aui J0323uu02 DAV BT pua 40323040 DAY 81 72 7
4. 22227 vere 9 Ways 122333 m 6 Mar Tu E MA D Ar y Date 8 Le P 35 lt e E DECHE Las 25 zen 4 A TEELS IE 1 8 75 ne 63 MAS AE T I 9 Id ue 8 Z gt 2 sx E 2 anzasy L 1 stan LE D i 2 b i 916 986 2034945 62 2882941 en 348 9 panddns lt 33057576 b SEN lt 551000959 Wu ME d Ta CIT3S0g 1985 862588 515988 u 9 3 4 T as U3HILIMS 30 om Y Y 6958 3 O44303 w40340 d Joen ans uams kay 5 V uonsod yo 1045 508244 103 5 2 WIRE INFORMATION ABLE 1 COLOR DRANGE FROM RED SINGLE BLUE SINGLE BLACK SINGLE W G SINGLE IGLE GLE WIRE BLACK ORANGE SINGLE WIRE GRAY 2 FROM ITEM 890 PINK FROM ITEM 89a BLUE 43 FROM ITEM 890 5 3 CABLE ASSEMBLY RR
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6. 53 ca pua 2 5025 DAV BI 3 mi DT TOET 28V pue aux uo 2 5 aam 2 31 ERD PET 5 25 pus au uo 2 pSI9E 2 UAH DAY 1 97 1009155390927 23 ag pua aui 2 502 DAV BL vaplov 899 061 asndlasH1 848 DAY BI 21 TS WES isod 3528 za 2 pua uo Dua 2 vGISE 2 OMY BI 1 97 UND 241 5 12 g tr SAUNA 15390 2 59 4 51 93 1 90 5 3 1v ER 8 93 199 dos 3 T as x 8603 1192 9 9 02 21992 7 04043 01440153 DEEN t 0142031914993 51 Asso ssauvou aas 10107 31983 190 m Pays mg HAS 64301 Suid 130440 ER SA D TX 594 E DETES yl NT 2 exeidesaa ud LSaygl dwy EIERLECH ioulu al LA m vd i acus GE 370IHJA ZEX LINDAI NADO 3983 3 508244 103 Page 5 4 Schematics 5 5 OVERLOAD SCHEMATIC 508244 103 Page 5 5
7. douces 3 16 Removal Ee A 3 16 Installation x uuu SU khao suqu tes a E 3 16 8 11 u ______________ 3 17 Platform Gontrols is ee Ren PC 3 17 Chassis Contre csse ae ER RR amas 8 8 ER a 3 18 508244 103 Section 3 Service amp Repair 3 1 Supporting Elevating Assembly SUPPORTING ELEVATING ASSEMBLY AWARNINGA Never perform service on the work platform in the elevating assembly area while platform is elevated without first blocking the elevating assembly DO NOT stand in elevating assembly area while deploying or storing brace Figure 3 1 Elevating Assembly Brace INSTALLATION 1 Park the machine on a firm level surface 2 Pull Chassis Emergency Stop Switch to the ON position 3 Pull Platform Emergency Stop Switch to the ON position 4 Turn and hold the Chassis Key Switch to CHASSIS 5 Push the Chassis Lift Lower Switch to LIFT to elevate the platform until the maintenance brace can be rotated to the vertical position 6 From the rear of the machine lift the maintenance brace from its stowed position Rotate upward and outward then down until it is hanging vertically below its attachment point 7 Lower the platform by pushing the Chassis Lift Lower Switch to LOWER and gradually lower the platform until the maintenance brace is supporting the plat
8. 502597 000 HARNESS CHARGER DISCONNECT LINE CON4 502599 000 HARNESS CHARGER DISCONNECT LINE CON2 502601 000 LINE CONTACTOR 5 LINE CONTACTOR 3 502602 000 LINE CONTACTOR 2 MOTOR CONT B 502604 000 LINE CONTACTOR 6 PUMP MOTOR 502492 000 MOTOR CONTROLLER 504536 000 PUMP MOTOR Sec6 21 Sec6 22 HYDRAULIC ASSEMBLY Item Part Description Qty 50942000 HYDRAULIC HOSE BLOCK SERIESARABLOCK 1 509421 000 HYDRAULIC HOSE BLOCK D2 SERIES PARA D2 E E 509417 000 HYDRAULIC HOSE BLOCK BRAKE TEE EE 509423 000 HYDRAULIC HOSE BLOCK STEERING CYLINDER 2 EN II 509425 000 HYDRAULIC HOSE BLOCK POTHOLE TEE EE 509427 000 HYDRAULIC HOSE TEE RHS POTHOLE CNL Fi sis nates spouse 12 509426 000 HYDRAULIC HOSE TEE LHS POTHOLE CYL 14 509429 000 HYDRAULIC HOSE PUMP BLOCK PRESSURE 1 16 509431 000 HYDRAULIC HOSE MANIFOLD CYLINDER 1 18 504128 001 HYDRAULIC TANK 1 20 504536 000 PUMP ASSEMBLY 1 22 504129 001 HYDRAULIC CYLINDER LIFT 1 HYDRAULIC CYLINDER STEER 24 504151 000 HYDRAULIC BLOCK SERIES PARALLEL 1 Sec6 23 ILLUSTRAITED PARTS LIST ILLUSTRAITED PARTS LIST OVERLOAD SSEMBLY Item 2 3 4 Part Description 504561 002 MOUNTING PLATE CIRCUIT BOARD 1 CIRCUIT BOARD 504560 000 PRESS
9. 20 Table Torque Specifications for Hydraulic Components SAE Part Series Ft Lbs N A N A 25 30 35 40 85 90 130 140 FASTENERS THREAD CONDITION TORQUE TABLES Table Torque Specifications for Fasteners 4429 Grade 5 SAE J429 Grade 8 Nominal Thread Size Tightening Torque K 15 K 20 Tightening Torque K 15 K 20 Nominal Thread Size SAE J429 Grade 5 K 15 Tightening Torque K 20 SAE J429 Grade 8 Tightening Torque K 15 20 3 8 16 3 350 ft Ibs ft Ibs 1 4 20 2000 75 100 2850 107 143 5 16 18 157 210 4700 220 305 6950 3 8 24 5 600 1 4 28 2 300 85 115 3250 120 163 5 16 24 3700 173 230 5200 245 325 7 16 14 9600 7 16 20 7 550 1 2 13 12800 1 2 20 10 200 9 16 12 16400 9 16 18 13 000 5 8 11 20300 5 8 18 16 300 3 4 10 30100 3 4 16 Unified Fine Thread Series 23 800 7 8 9 a 7 a an E 41550 7 8 14 32 480 1 8 54540 1 12 42 270 Page3 20 Maintenance Table Torque Specifications for Metric Fasteners U S Customa
10. Do a full function test from both the platform and chassis controls and note all func tions that are not operating 2 Narrow the possible causes of the malfunction Use the troubleshooting guide to determine which components are common to all circuits that are not functioning correctly 3 Identify the problem component Test components that are common to all circuits that are not functioning correctly Remember to check wires and terminals between suspect components Be sure to check connections to battery negative 4 Repair or replace any component found to be faulty 5 Verify that repair is complete Do a full function test from both the platform and chassis controls to verify that all functions are operating correctly and that the machine is performing to specified val ues SPECIAL TooLs Following is a list of tools which may be required to perform certain maintenance proce dures on the X Series work platforms Flow Meter with Pressure Gauge P N 067040 000 0 69 bar 0 1000 psi Hydraulic Pressure Gauge with Adapter Fittings P N 014124 010 0 207 bar 0 3000 psi Hydraulic Pressure Gauge with Adapter Fittings P N 014124 030 Adapter Fitting P N 063965 002 Inclinometer P N 010119 000 Crimping Tool P N 028800 009 Terminal Removal Tool P N 028800 006 ADJUSTMENT PROCEDURES Hydraulic settings must be checked whenever a component is repaired or replaced Remov
11. Page 3 9 Hydraulics Section 3 Service amp Repair HYDRAULIC PUMP The Hydraulic Pump is located in the Power Module and is mounted on the rear of the motor REMOVAL NOTE If the hydraulic tank has not been drained suitable means for plugging the hoses should be provided to prevent excessive fluid loss 1 Mark disconnect and plug the hose assemblies 2 Loosen the capscrews and remove the pump assembly from the motor INSTALLATION Figure 3 10 Hydraulic Pump Assembly 1 Lubricate the pump shaft with general purpose grease and attach the pump to the motor with the capscrews 2 Using a crisscross pattern torque each capscrew a little at a time until all capscrews are torqued to 27N m 20 ft Ibs 3 Unplug and reconnect the hydraulic hoses 4 Check the oil level in the hydraulic tank before operating the work platform a 1 Inlet Hose 4 Pump Assembly 2 Outlet Hose 5 Electric Motor 3 Capscrew Page 3 10 508244 103 Section 3 Service amp Repair Hydraulics MAIN HYDRAULIC MANIFOLD Though it is not necessary to remove the manifold to perform all maintenance procedures a determination should be made prior to beginning as to whether or not the manifold should be removed before mainte nance procedures begin Figure 3 11 Valve Location 1 TEST PORTI 7 VALVE SOLENOID DRIVE LIFT 2 FITTING 1 4 1 4 MALE MALE 8 PRESSURE RELIEF MAIN LIFT 3 FITTING 3 8 3 8 MALE MALE 9 V
12. For fault codes 54 68 the following procedure should be followed 1 Check the fault code list to identify the problem component 2 Ensure that the wiring harness is connected secure in good condition and fully intact 3 Ensure that the problem component is receiving electrical signal consult the sche matics in section 6 of this manual to identify the ECU output and harness test points 4 If no ECU output is present replace the ECU 5 f ECU output is present but no signal is reaching the component replace the wiring harness 6 If signal is reaching the component but the component is not functioning replace the component refer to section 7 of this manual for part number information 4 5 Fault Codes 4 5 FAULT CODES 01 System initialization error 02 System communication error 22 Platform Left Turn Switch ON at power up 23 Platform Right Turn Switch ON at power up 25 Platform Hi Drive Switch ON at power up 27 Platform Lo Drive Switch ON at power up 28 Platform Lift Switch ON at power up 29 Platform Joystick Enable Switch ON at power up 31 Platform Joystick not in neutral at power up 32 Lower Control Up DownToggle ON at power up 39 Lower Control Enable Switch ON at power up 51 Hi Speed Low Speed Coil fault 54 Pothole Retract Coil fault 55 Lift Up Coil fault 56 Lift Down Coil fault 59 Steer Right Coil fault 61 Steer Left Coil fault 66
13. Forward Coil fault 67 Reverse Coil fault 68 Low Battery fault Page 4 5 4 6 Electric 4 6 ELECTRIC Table 4 1 Electrical Troubleshooting Table Component Depression Mechanism Extend Depression Mechanism Retract Function Lower Controls Upper Controls Drive Forward Drive Reverse High Speed Creep Raise Platform Lower Platform Steer Left Steer Right Tilt Alarm Down Alarm Battery Charge Alarm Batteries Battery Charger 5 AMP Circuit Breaker 175 AMP Fuse ECU Motor Control Motor Chassis Emergency Stop Switch Chassis Key Switch x x x x gt x x gt gt x x Platform Emergency Stop Switch XI x x x x x x XI x x x x Interlock Switch PQ Control Handle Height Limit Switch Platform Steering Switch gt x x gt lt x x x gt x x X X zl x x x Tilt Sensor Steering Solenoid right Steering Solenoid left Platform Lift Solenoid Down Solenoid Reverse Solenoid Forward Solenoid Page 4 6 4 7 Hydraulic 4 7 HYDRAULIC Table 4 2 Hydraulic Troubleshooting Table Component Depression Mechanism Extend Depression Mechanism Retract Function Lift Platform Lower
14. BEARING TORRINGTON YCRS32 1 28 011257 028 SCREW HHC 5 8 11 X 3 1 2 1 30 504123 000 PIN CYLINDER 1 32 504122 006 WELDMENT PIVOT PIN 8 34 011239 010 WASHER FLAT 5 8 ASTM 4 fosse ___ 504122 004 PIVOT PIN i 40 504186 003 PIVOT PIN Sec6 8 ILLUSTRAITED PARTS LIST INSTALL WITH SPACER BLOCKS DOWN NOTE 1 PRESS A BEARING IN FROM EACH SIDE 3 X 5 TUBE UNTILL FLUSH WITH COLLAR USE WASHERS AS SPACERS ON BOTH SIDES UF ROLLER AS REQUIRED ALLOW FREE MOVEMENT OF ARMS PIN ITEM 8 INSTALL WITH SPACER BLOCKS DOWN 42 PLC S 2 PLUS 17 2 5 END GUSSETS INSIDE 48 PLACES PLUG LARGE HOLES IN END CAPS INSTALL WITH SPACER BLOCKS UP ILLUSTRAITED PARTS LIST PIN ASSEMBLY TYPICAL 2 ScissoR ASSIST ASSEMBLY Sec6 10 Item Part Description Qty 2 504122 003 PIVOT PIN STANDARD LONG 4 FLANGED BUSHING 50mm 4 057048 000 GREASE NIPPLE M6 16 6 504122 001 PIVOT PIN STANDARD MEDIUM 3 504120 001 PLAIN BUSH 50mm 2 Em WASHER M48 X 4mm THICK 10 056687 100 HEX HEAD BOLT M16 X 100mm 1 12 501449 000 FLANGED BUSHING 16mm 2 Es ET 14 1 056066 016 NYLOCK NUT M16 1 504176 002 WELDMENT TORSION ARM LHS 1 504176 003 WELDMENT TORSION ARM Sec6 11 ILLUSTRAITED PARTS LIST
15. ILLUSTRAITED PARTS LIST MAIN DECK ASSEMBLY Item Part Description Qty 2 066480 000 GATE 05300 010 Description SWING BAR TORSION SPRING 2 3 066497 026 WELDMENT GATE KICKRAIL 5 066441 000 PIVOT GATE 7 505300 017 WELDMENT UPPER R H 8 505300 012 GUARDRAIL MID 505300 015 WELDMENT UPPER L H 1 2 1 1 1 Sec6 12 5 502204 001 027899 000 066519 000 U BOLT WELDMENT GATE HINGE ILLUSTRAITED PARTS LIST EXTENSION DECK AssEMBLY Part Description 502148 000 WEAR PAD 502148 001 WEAR PAD Part Description 16 505300 008 EX DECK UPPER RAIL 1 18 003570 005 PULL PIN WITH KEY RING 1 504138 000 BRACKET 502141 000 DECKLOCK ASSY SLIDEOUT HARNESS HARDPOINT 066260 026 WELDMENT EXT RAIL ASSY 027966 005 SAFETY WALK 6 X 24 14 505300 006 SWING BAR 1 502145 000 LEVER BRACKET 502132 001 PLATFORM ROLLER Sec6 13 ILLUSTRAITED PARTS LIST CONTROL MODULE ASSEMBLY Part Description Ka 504128 001 HYDRAULIC TANK 062791 002 LATCH 502588 000 ALARM Item Part Description Qty 066735 001 WELDMENT POTHOLE 12 503800 001 MAIN MANIFOLD BLOCK 1 13 504536 000 PUMP ASSEMBLY 1 502489 000 LINE CONTACTOR 14 504133 000 BRACKET GUIDE PAD ANGLE 1 6 510065 000 MOUNTING PLATE FUSE 1 16 502152
16. Serial Number 51089 Manual Serial Number 500422 103 ARS 47 OLA E ES S2633 Serial Number 51089 Current English When contacting Snorkel for service or parts information be sure to include the MODEL and SERIAL NUMBER from the equipment Nameplate Should the nameplate be missing the SERIAL NUMBER is also stamped on top of the chassis above the front axle pivot E Access Rear View H y TANFIELD ENGINEERING SYSTEMS LTD EE GEE me u 29222 MODEL 52533 SERIAL NUMBER NUMBER MONTH YEAR SLOPE SENSOR 55 deg lt OF MANUFACTURE ALARM SETTING mm 2 24 mph u 1984 Ihe WHEEL SPEED 10 mis 900 Front SW id View BARE FT is CHARGER INPUT 110 220 V POWER Skw 4hp 21 N A hp N A kw BATTERY VOLTAGE 24 GRADEARILITV 25 Mamm Mam S d rones 90 LES tam pe PULL 400 6 8 9 Indoor me 1 PLATFORM 245 X 120 m N A Serial Number 63 x S05 Jon e MAXIMUM 26 MAXIMUM 26 ft PLATFORM DRIVE HEIGHT 7 93 m HEIGHT 725 m ED UNRESTRICTED 749 NUMBER OF 3 PERTEQUIP PLATFORM 240 occurs Indoor only CAPACITY kg Do remove any welght from thle machine Any
17. elevating assembly Stand clear of the elevating assembly while operating the Emergency Lowering Valve Knob The Emergency Lowering Valve is mounted on the base of the lift cylinder The cable is from the valve along the elevating assembly tube to the front of the machine through the cable access hole to the rear of the machine REPAIR 1 Figure 3 8 Emergency Lowering Knob Deploy the maintenance brace see Blocking the Elevating Emergency Lowering Knob Assembly Inspect the cable Replace if damaged Inspect the valve Replace if damaged Check for and clear any blockage in the orifice Install the orifice with the beveled side toward the cylinder block Adjust the valve At the cable mount adjust the cable cover to stop the inner cable when the valve is fully open Store the maintenance brace and lower the platform 508244 103 Section 3 Service amp Repair Hydraulics 3 8 HYDRAULICS 508244 103 HYDRAULIC OIL TANK AND FILTER FLUID LEVEL Check the fluid level daily With the platform fully lowered open the control module and remove the reservoir breather cap Fluid should be at the full mark NOTE Drain plug underneath tank OIL AND FILTER REPLACEMENT Replace the filter every 250 hours or six months 1 Unscrew the filter from the filter assembly 2 Apply a thin film of clean hydraulic fluid to the Figure 3 9 Hydraulic Tank gasket of t
18. 000 SPLIT PIN 1 504126 000 BUSHING MODULE HINGE 18 057534 000 FILLER amp DIPSTICK CAP 1 sn romo mo 3 504153 001 PIVOT PIN POTHOLE WDMENT Sec6 14 ILLUSTRAITED PARTS LIST Power MODULE ASSEMBLY Item Part Description Part Description 1 504134 000 GUIDE PAD 1 501074 000 BATTERY 504135 000 BUSHING POTHOLE PIVOT 066309 011 WELDMENT DOOR MODULE 1 SES 2 4 066735 001 WELDMENT POTHOLE 1 11 504126 000 BUSHING MODULE PIVOT 6 066713 002 HINGE 1 504132 000 HYDRAULIC CYLINDER 1 15 ILLUSTRAITED PARTS LIST HYDRAULIC MANIFOLD ASSEMBLY 503800 001 Description ES emm 058358 000 FITTING 1 4 1 4 MALE MALE ET g 057377 000 FITTING 1 2 1 2 MALE MALE 1 6 503804 000 VALVE SOLENOID DRIVE 1 503807 000 PRESSURE RELIEF MAIN LIFT 1 EE 503809 000 FLOW RESTRICTOR STEERING 1 12 1503810 000 RELIEF VALVE MAIN RELIEF Hydraulic Block Series Parallel 504151 000 Item Part Description 13 500303 000 SOLENOID COIL 18V 14 057122 000 HYDRAULIC FITTING 3 8 X 3 8 MALE MALE Sec6 16 ILLUSTRAITED PARTS LIST PoTHOLE CYLINDER AssEMBLY STEERING CYLINDER SSEMBLY 504132 000 504148 001 Part Description Qty P
19. Platform Steer Right Steer Left Drive Forward Drive Reverse Check Valve Steering Cylinder Lift Cylinder Depression Mechanism Cylinder Brake Cylinder Suction Strainer Return Filter Drive Motors 2 Pump Main Relief Valve Steering Relief Valve Lift Relief Valve Tank Steering Right Left Valve Lift Valve Down Emergency Lowering Valve Forward Reverse Valve Counterbalance Valve Page 4 7 Notes Page 4 8 Section 5 SCHEMATICS 5 1 INTRODUCTION This section contains electrical and hydraulic power schematics and associated information for maintenance purposes The diagrams are to be used in conjunction with the information in Section 4 They allow understanding of the makeup and functions of the systems for checking tracing and faultfinding during troubleshooting analysis CONTENTS Electrical Schematic 5 2 Cable Assembly J1 Harness 5 3 Schematic J1 Harness 5 4 Overload Schematic 5 5 Hydraulic Schematic 52633 5 6 Page 5 1 5 2 ELECTRIC
20. 185 OR MORE 062562 001 500771 000 066522 000 057507 010 x4 All personnel shall be qualified carfully read undrestand and obay all safety rules operating instructions and manual of reponsibilities before performing maintenance or operating any mobile elevating work platform 508772 000 20 066559 000 060197 001 BEFORE operating this equipment read understand and then follow all safety information in instruction manual 066554 000 005221 000 Sec6 29 Sec6 30 Local Distributor Distributeur local EI Distribuidor local Snorkel International Inc P O Box 1160 St Joseph MO 64502 1160 USA TEL 1 800 255 0317 Snorkel www snorkelusa com Serial number 500422 103
21. ADDER MOUNTING BRACKET 503755 000 CASTLE NUT 31 066307 001 WELDMENT LADDER Sec6 5 ILLUSTRAITED PARTS LIST Cuassis Scissor amp Deck AsssEMBLY Part Description Qty ltem Part Description 504001 011 CHASSIS ASSEMBLY 1 114200 001 SCISSOR ASSEMBLY 1 323632 504003 011 PLATFORM WELDMENT 1 12 504186 000 MOUNTING PIN 4 11 066183 001 BEARING EAGLE PICHER 2 6 066189 000 WEAR PAD 1 4 13 504186 003 MOUNTING PIN 2 066189 004 WEAR PAD 1 8 NOTES N LOCTITE ITEM 11 BEARING ITEM 1 CHASSIS AND PEEN 4 PLACES e 90 OUTSIDE EDGE DF BORE IN ITEM 1 TYP 2 USE WEAR PAD COMBINATION AS REQUIRED SECURE AND ALIGN FRONT END DF SCISSOR STACK Sec6 6 NOTES Sec6 7 ILLUSTRAITED PARTS LIST ScissoR SSEMBLY 114200 001 Description Qty 2 504129 001 LIFT CYLINDER 504129 002 ANSD 1 3 1504104 000 WELDMENT MID INNER TUBE 1 8 1 5 114202 001 WELDMENT BOTTOM INNER 3 16 1 7 504122 003 WELDMENT PIVOT PIN 2 9 1501187 000 PIN SHAFT LOCKING 2 11 114203 001 WELDMENT SAFETY STAND 1 13 011248 006 HEX 38 16 1 15 011254 044 SCREW HHC GRS 3 8 16 X 5 1 2 1 18 504046 000 PIPE RING 4 20 011248 004 NUT HEX 1 4 20 4 22 504108 002 WELDMENT MID INNER ARM 3 16 1 24 011239 032 WASHER 2 DIA ASTM 2 26 065367 001
22. ALVE SOLENOID STEERING 4 FITTING 1 2 1 2 MALE MALE 10 FLOW RESTRICTOR STEERING 5 CROSS LINE RELIEF VALVE DRIVE 11 RELIEF VALVE STEERING 6 VALVE SOLENOID DRIVE 12 RELIEF VALVE MAIN RELIEF Figure 3 12 SETTING HYDRAULIC MANIFOLD PRESSURES AWARNINGA The hydraulic oil may be of sufficient temperature to cause burns Wear safety gloves and safety glasses when handling hot oil The oil in the hydraulic system is under very high pressure which can easily cause severe cuts Obtain medical assistance immediately if cut by hydraulic oil NOTE Check the hydraulic pressures whenever the pump manifold or relief valves have been serviced or replaced 508244 103 Page 3 11 Hydraulics Page 3 12 Section 3 Service amp Repair MAIN RELIEF VALVE Operate the hydraulic system 10 to 15 Install a 0 207 bar 0 3000 psi pressure Turn the Chassis Keyswitch to CHASSIS While holding the Chassis Lift Switch to Replace the cap or tighten the locknut on Lower the platform Figure 3 13 Hydraulic Manifold with Valves minutes to warm the oil Remove the cap or loosen the locknut on cyeeK valve POTHOLE MAIN RELIEF VALVE the Main Relief Valve gauge to the gauge port and elevate the machine fully the UP position adjust the Main Relief Valve until the pressure gauge reads 165 bar 2400 psi St N 38 N RELIEF VALVE Release the Chassis Lift Switch CRossUNEREUEE C s STE
23. ANCE REPORT Interval Date Daily each shift or every day Owner 50h 30d every 50 hours or 30 days 250h 6m every 250 hours or 6 months Model No 1000h 2y every 1000 hours or 2 years Serial No YzYes Acceptable N No Not Acceptable Serviced By R Repaired Acceptable COMPONENT INSPECTION OR SERVICES COMPONENT INSPECTION OR SERVICES INTERVAL Y Check electrolyte level Inspect for external damage Daily Check battery cable condition dents loose rivets or cracks Charge batteries Elevating Check welds for cracks Daily Battery Check charger condition 8 Assembly Lubricate 30d System operation Check specific gravity Clean exterior Check cables for pinch or Daily Service Interval Clean terminals Hydraulic Oil Check oil level Change Filter Drain and replace oil Chassis rubbing points Check welds for cracks Check component mounting for proper torque Hydraulic System Check for leaks Check hose connections Check hoses for exterior wear Lift Cylinder Check for leaks Check for proper torque Drive Motors Check for operation and leaks Emergency Down Check procedure for Emergency Down Hydraulic Pump Check for fitting leaks Wipe clean Check for leaks at mating surfaces Check mounting bolts for proper torque Entire Unit Perform pre operation inspection Check for and repair
24. BOTTOM EACH SIDE ILLUSTRAITED PARTS LIST CHassis ASSSEMBLY FRONT Part Description Part Description 505042 000 BEARING 8 504153 001 PIN 5 8 2 2 2 504144 000 BEARING 9 066159 001 L H STEERING LINK 1 4 114055 002 MOTOR HYDRAULIC 11 BS E STEERING ANGLE 1 12 114058 000 STEERING ANGLE 1 6 066869 000 CHASSIS 13 BELL CRANK 1 HUB FRONT 14 066307 001 R H STEERING LINK 1 15 011254 010 Bolt 3 8 UNC X 1 1 4 1 16 011250 006 3 8 UNC 1 USE ONE OR THRUST BEARINGS BETWEEN STEERING YOKE PIN AND CHASSIS 1 16 3 16 CLEARANCE UNTIL CONTACTS SPINDLE BACK OFF 1 8 1 4 TURN AND LOCK IN PLACE WITH JAM NUT ITEM 4 NOTE SCREW IN SET SCREW ITEM 18 SET OUTER BEARING FLUSH SET INNER BEARING TO WITH ENO OF BORE BOTTOM OF BORE Sec6 4 ILLUSTRAITED PARTS LIST CHassis AsssEMBLY REAR Part Description Part Description Qty 504151 000 VALVE ASSEMBLY 1 502152 000 COTTER PIN 062642 001 BEARING GARLOCK 100012 066865 100 COUNTERWEIGHT R BULKHD 1 15 16 17 58819 000 M6 GREASE NIPPLE 18 19 20 21 24 25 26 066866 000 COUNTERWEIGHT CASTING 1 504154 000 PIN BELL CRANK 27 503673 000 BUSH 12DU06 28a 504157 000 CUP BEARING 066158 001 STEERING LINK SLIDE PAD 30 066862 000 L
25. Box Seal 3 Joystick 7 Circuit Board 4 Decal 8 Socket Main Harness 508244 103 Page 3 17 Controls CHASSIS CONTROLS The chassis control assembly is mounted on the inside of the chassis door to the left of the Hydraulic tank Page 3 18 Section 3 Service amp Repair Figure 3 20 Lower Control Box LCB Box Lid LCB Box Emergency Stop Toggle Switch Enable Button Key Key Switch 508244 103 508244 103 Page3 19 Maintenance TORQUE SPECIFICATIONS HYDRAULIC COMPONENTS NOTE Always lubricate threads with clean hydraulic oil prior to installation Torque Specifications Use the following values to torque hydraulic components used on Snorkel Work Platforms Cartridge Poppet Nm Ft Lbs Fittings Nm Ft Lbs Nm N A N A N A 135 145 15 16 N A 10 20 14 27 215 245 24 28 34 41 25 30 34 41 430 470 49 53 47 54 35 40 47 54 680 750 77 85 115 122 85 90 115 122 950 1050 107 119 176 190 130 140 176 190 1300 1368 147 155 This standard applies to the preloading of fasteners measured by installation torque NOTE For other preloading methods or fasteners consult Snorkel Engineering Department This general standard applies to all SAE and Metric fasteners unless otherwise specified For lubed or zinc plated fasteners use 15 For dry unplated fasteners use
26. ERING VALVES DRIVE N PRESSURE RELIEF FLOW RESIRICTOR MAIN STEERING the Lift Relief Valve and torque to 8N m 6 ft Ibs COUNTERBALANCE VALVES 1 OQ ND 10 11 12 13 Operate the work platform for 10 15 minutes to bring the hydraulic oil up to normal operating temperature Remove the gauge port cap and install the pressure gauge assembly Lift work platform and block front wheels off ground Loosen the locknuts on Counterbalance Valves With the machine fully powered up depress the DRIVE button on the upper control box depress the interlock lever and slowly pull the control lever to REVERSE to drive the wheels Adjust the Forward Counterbalance Valve by turning the adjustment screw until the pressure gauge indicates 83 bar 1200 psi Slowly push the Control Lever to FORWARD to drive the wheels Adjust the Reverse Counterbalance Valve by turning the adjustment screw until the pressure gauge indicates 83 bar 1200 psi Check the settings by slowly moving the Control Lever FORWARD then REVERSE checking the gauge to ensure pressures are properly set Re adjust as needed Tighten locknuts on valves to 8N m 6 ft Ibs Remove blocks and lower work platform to ground Reconnect the red Control Cable wire to terminal 9 Remove the gauge from the gauge port and re install cap Check for proper operation of the drive system and brake STEERING RELIEF VALVES 1 O
27. RING PULL OUT TO LOWER PLATFORM 066558 000 MAXIMUM DISTRIBUTED PLATFORM LOAD 700LBS 7 OR 3 OCCUPANTS MAXIMUM SIDE LOAD 150LBS 101250 005 x2 8 POWER TO PLATFORM 068639 000 068635 001 x2 MEETS OR EXEEDS THE REQUIREMENTS OF ANSI A92 6 1999 10 061220 002 Failure to read understand and obey the following safety rules will cause death or serious injury 23 Collision Hazard Impact from decending platform may cause injury stand clear FALL HAZARD TIP OVER HAZARDS ELECTROCUTION HAZARD DON levtedon DO NOT operate with tof power 066556 000 TIP OVER HAZARD MAXIMUM DISTRIBUTED LOAD 250 LES OR 1 OCCUPANT ON EXTENDED DECK MAXIMUM SIDE LOAD 100 LBS 24 066561 900 101251 000 508770 000 CRUSHING HAZARD KEEP ALL BODY PARTS AWAY 0665536 001 066556 001 4 066561 900 OPERATORS CHECKLIST INSPECT AND OR TEST THE FOLLOWING DAILY OR AT THE BEGINING OF EACH SHIFT 1 HIGVJ JHB H BPL KLIO PO OPP 300699 BATTERY DISCONNECT LOCATED INSIDE MAXIMUM WHEEL LOAD 17505 USE DISCONNECT BEFORE SERVICING WORK OR BATTERIES 101252 005 107051 000 014222 003 x2 10076 001 DANGER TIP OVER HAZARD BATTERIES ACT AS COUNTERWEIGHTS EACH REPLACEMENT BATTERY SHALL WEIGH 60
28. URE TRANSDUCER 1 Qty 24 NOTES Sec6 25 CE DECALS Control Module Upper Control Box I XN 127 YA Sec6 26 CE DECALS Snorkel ILLUSTRAITED PARTS LIST Failure to read understand and obey the following safety rules will cause death or serious injury 596295 000 x2 52088 9 508339 000 2 101210 000 066556 900 2 066561 900 4 11 503724 000 2 100102 900 014222 903 014222 903 4 502480 000 7 Me 2 14 1 5 825 E 068635 001 x2 503721 000 066551 950 503723 000 Sec6 27 067195 001 A 062562 951 x4 XN 501453 000 x4 066522 900 060197 001 005221 000 ANSI DECALS Control Module Upper Control Box Access Rear Battery Module Sec6 28 ANSI DECALS Snorkel 596295 000 x2 5260399 508339 000 2 N Explosive gas is generated when charging 3 batteries DO NOT expose to sparks or flames 066552 000 066552 000 KEEP CLEAR OF SCISSORS BLOCK SCISSORS BEFORE SERVICING 066553 000 x2 066552000 14 066555 000 EMERGENCY LOWE
29. Y HYDRAULIC MANIFOLD CYLINDER ASSEMBLYS LOWER CONTROL BOX ASSEMBLY UPPER CONTROL BOX ASSEMBLY ELECTRICAL ASSEMBLY HYDRAULIC ASSEMBLY PLATFORM OVERLOAD DECAL KIT ANSI DECAL KIT PAGE 6 14 6 15 6 16 6 19 6 20 6 22 6 24 6 26 6 28 Sec6 1 ILLUSTRAITED PARTS LIST Basic AssEMBLY Part Description Part Description 1 066309 011 POWER MODULE 19 1504348 000 LOWER CONTROL ASSY 1 066310 026 CONTROL MODULE WIRE HARNESS ASSY 13 W gt CHARGER 21 066623 020 LIFT OVERLOAD ALARM 501425 000 SWITCH PROXIMITY LOWERING CABLE MANUAL CASE 23 W CONTROLLER ASSEMBLY 25 500996 000 HARNESS ASSY 1 CABLE ASSY X 14 ER Yost ES ER 501074 000 BATTERY 6 V EXTENSION DECK 064195 040 CABLE ASSY X 40 066250 026 PLATFORM GUARDRAIL ASSY nn 066763 000 SHIM 16GA E 066713 001 WELDMENT DOOR HINGE R H 17 504033 000 TILT ALARM COVER WELD 1 502164 000 CONTROLLER GUIDE WIDE 029601 039 2 1 2 3 4 S 6 7 9 10 11 12 13 14 15 16 8 REF CABLE ACCESS ROUTE CABLE FROM EMERGENCY LDWERING VALVE ALONG SCISSDR ARM THRU CABLE ACCESS HULE REAR MACHINE EMERGENCY LOWERING CABLE CABLE MOUNT ADJUST EMERGENCY LOWERING SUPPLIED WITH CABLE COVER STOP INNER LIFT CYLINDER CABLE WHEN EMERGENCY LOWERING VALVE IS FULLY OPEN Sec6 2 ILLUSTRAITED PARTS LIST THRUST WASHER
30. an explosion if hydrogen gas or fuel vapors are present 2 Open the power module 8 Disconnect battery pack connector 4 Disconnect the battery negative lead IMPORTANT Disconnect the battery negative lead first 5 Disconnect the remaining battery leads 6 Lift the batteries out of the module Batteries Installed INSTALLATION IMPORTANT Connect the battery negative lead last 1 Verify that the Chassis Key Switch and the Chassis and Platform Emergency Stop Switches are in the OFF position Place the batteries into the power module Connect the battery to battery leads Connect the battery positive lead Connect the battery negative lead Connect the battery pack connector 508244 103 Page 3 7 Safety Ancillary Equipment Section 3 Service amp Repair 3 7 SAFETY ANCILLARY EQUIPMENT Page 3 8 PROXIMITY SWITCH The Proximity Switch cuts power to the High Speed Drive when the platform is elevated The switch is located on the left side of the chassis at the rear of the machine No adjustment of the switch should be necessary Figure 3 6 Proximity Switch LEVEL SENSOR The Level Sensor is located on the chassis of the machine These units are sealed and pre set and require no recalibration or adjustment Figure 3 7 Level Sensor LOWERING WARNING If the platform should fail to lower NEVER climb down
31. ard Cleaning and Inspection Section 3 Service amp Repair Figure 3 15 Steering Cylinder Mount Assemblt 1 Steering Cylinder 2 Steering Link 3 Pivot Pin 4 Bushing 5 Wheel Yoke 1 Wash all the metal parts in cleaning solvent and blow dry with filtered compressed air 2 Inspect all the threaded components for stripped or damaged threads 3 Check the inside surface of the cylinder barrel for scoring or excessive wear 4 Check the piston and headcaps for scoring or excessive wear 5 Inspect the surface of the shaft for scoring or excessive wear ASSEMBLY 1 Lubricate and install new rod wiper U cup O ring and backup ring on the headcaps 2 Install the headcap onto the shaft 3 Install the new piston rings and O ring on the piston Re install the piston 4 Lubricate the piston seal with clean hydraulic fluid and install the shaft assembly in the cylinder barrel Install the head cap into the cylinder barrel and tighten the head caps INSTALLATION Figure 3 16 Steering Cylinder Assembly WIPER CYLINDER BODY PLAIN BUSHING 1 0 N ESI f ff 2 4 FLANGED BUSHING CYLINDER ROD RETAINING RING 1 Position the cylinder assembly in the chassis and insert pivot pins and secure with new cotter pins 2 Connect the hose assemblies to the fittings 3 Operate the steering circuit several times throughout its entire range of travel to exp
32. art Description Qty y CYLINDER ASSEMBLY Ps 504129 001 ANSI 504129 002 Item Part Description Qty 058819 000 M6 GREASE NIPPLE 2 504120 000 FLANGED BUSHING 4 504129 011 SEAL KIT REF Sec6 17 ILLUSTRAITED PARTS LIST LOWER CONTROL Box ASSEMBLY Item Part Description Qty 504141 001 COVER LOWER CONTROL BOX 504142 000 BOX LOWER CONTROL BOX 501867 000 EMERGENCY STOP BUTTON 2 4 502251 000 TOGGLE SWITCH 6 501866 000 KEY 1 Sec6 18 UPPER CONTROL Box AssEMBLY 504349 000 Item Part Description M 501867 000 EMERGENCY STOPBUTTON 501882 002 RUBBER BOOT STEERING 501882 001 RUBBER BOOT JOYSTICK 6 501592 000 MOUNTING PLATE 1 502453 000 CIRCUIT BOARD 1 0 8 10 502605 000 SOCKET OVERLOAD 1 19 ILLUSTRAITED PARTS LIST ILLUSTRAITED PARTS LIST ELECTRICAL ASSEMBLY Sec6 20 ILLUSTRAITED PARTS LIST ELECTRICAL SSEMBLY Item Part Description Qty 2 502531 000 HARNESS 1 504349 000 UPPER CONTROLS 1 505566 001 TILT SENSOR 502588 000 ALARM 1 502494 000 FUSE 1 BATTERY DISCONNECT PLUG 4 6 10 12 502594 000 HARNESS BATTERY DISCONNECT BATT 14 501074 000 BATTERY 16 069199 001 CHARGER 18 20 22 24 26
33. charge creating a low discharge rate A WARNING Hazard of explosive gas mixture Keep sparks flame and smoking materials away from batteries Always wear safety glasses when working with batteries Battery fluid is highly corrosive Thoroughly rinse away any spilled fluid with clean water Always replace batteries with Snorkel batteries or manufacturer approved replacements Before disconnecting the battery negative lead make sure all switches are OFF If ON a spark will occur at the ground terminal which could cause an explosion if hydrogen gas or fuel vapors are present Page 3 6 508244 103 Section 3 Service amp Repair Batteries BATTERY MAINTENANCE Refer to the Operation Manual included in this Service Manual for specific maintenance and charging instructions NOTE If system voltage drops below 17 volts on a 24 volt system the charger will not recharge the batteries If this extreme voltage drop occurs disconnect and recharge each battery separately using 6 volt charger to bring the voltage in each up to at least 4 1 2 volts BATTERY REPLACEMENT Battery cables must be installed as shown in the Battery Cable Installation Diagram Figure 3 5 Battery Cable Installation Diagram 1 Turn the Chassis Key Switch to the OFF position and push the Chassis and Platform Emergency Stop Switches down to the OFF position NOTE switches are ON a spark will occur at the ground terminal which could cause
34. collision damage Lubricate Check fasteners for proper torque Check for corrosion remove and repaint Controller Check condition amp operation Labels Check for peeling missing or unreadable labels amp replace Platform Deck amp Rails Check fasteners for proper torque Wheels Check for loose components Check welds for cracks Check condition of deck Check entry way closure Steering System Oil pivot pins Oil king pins Check steering cylinder for leaks Check hardware amp fittings for proper torque Check Wheel Yoke Securing Bolt and Nut NOTE Use ISO 46 during summer and ISO 32 during winter Page 3 4 Section 3 Service amp Repair 3 4 PARTS LOCATION JO ON A oll 0 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Entry Gate Deck Lock Assembly Work Platform Fold Down Guardrails Platform Extension Platform Controls Rear Guardrail Retaining Pin Guardrail Retaining Pin Elevating Assembly Control Module Chassis Controls Circuit Board Motor Controller Hydraulic Fluid Reservoir Hydraulic Fluid Filter Hydraulic Pump and Motor Main Valve Manifold 175 AMP Fuse Overload Protection Solenoid Motor Relay Audible Alarm De
35. e counterbalance valves and bench test them if they are suspect Connect a pressure gauge of appropriate range to the test port located on the hydraulic manifold Correct pressure settings are listed in the hydraulic schematic CHECKING PUMP PRESSURES Remove hose from pump port and connect pressure gauge Page 4 2 4 3 TROUBLESHOOTING GUIDE TROUBLE All functions inoperable electric motor does not start 4 3 Troubleshooting Guide PROBABLE CAUSE REMEDY 1 Blown electric motor fuse 2 Faulty battery charger Faulty battery ies Loose or broken battery lead Emergency Stop switch es failed open Blown control fuse Check 160 amp electric motor fuse Replace if blown Check the voltage output of the battery charger If less than 24 VDC After completely charging batteries test each battery Replace as Check continuity of all battery and motor leads Replace if necessary With emergency stop switch in the ON position check continuity Check 7A circuit control fuse Replace if blown All functions inoperable Electric motor starts when control is actuated Platform will not elevate or elevates slowly Platform drifts down after being elevated Oil level in hydraulic reservoir is low Faulty hydraulic pump Emergency Lowering valve open Platform overloaded Faulty controller at upper controls Blown control fuse 5 Battery level low Chec
36. el trapped air and check for leaks Page 3 14 508244 103 Section 3 Service amp Repair Cylinders CYLINDER REMOVAL Figure 3 17 Lift Cyminder Assembly me 1 Provide a suitable container to catch the hydraulic fluid then disconnect the hydraulic hoses BA Immediately plug hoses to prevent foreign material DA from entering ND 2 Remove emergency lowering valve cable and down valve wires from the emergency lowering down valve 3 Remove the cable bracket from the lift cylinder O N 4 Remove capscrews and locknuts securing lift cylinder pivot pins 5 Remove lower pivot and lower cylinder to rest on chassis XA 6 Attach a suitable hoisting device and sling to the cylinder and remove upper pivot pin 5 7 Carefully remove cylinder 1 Lift Cylinder 2 Pivot Pit 3 Capscrew and Lockplate 4 Solenoid Emergency Down 5 Hose Connections REPAIR Refer to Pothole Steering Cylinder Repair on previous page INSTALLATION 1 Coat both pivot pins with anti seize compound 2 Attach a suitable hoisting device and sling to the cylinder Carefully position cylinder in the elevating assembly and install the upper pivot pin Install the capscrew and locknut Carefully lift the cylinder and align the lower mount and install the pivot pin Install the capscrew and locknut securing the pivot pin Install the cable bracket Connect the emergency lowe
37. form REMOVAL 1 Using the Chassis Controls gradually elevate the platform until the maintenance brace is clear 2 Rotate the maintenance brace outward and upward over its attachment point until it rests in the stowed position 3 Lower the platform by pushing the Chassis Lift Lower Switch to LOWER to completely lower the platform 3 2 PREVENTATIVE MAINTENANCE 508244 103 The complete inspection consists of periodic visual and operational checks along with periodic minor adjustments to assure proper performance Daily inspection will prevent abnormal wear and prolong the life of all systems The inspection and maintenance schedule is to be performed at regular intervals Inspection and maintenance shall be performed by personnel who are trained and familiar with mechanical and electrical procedures AWARNINGA Before performing preventative maintenance familiarize yourself with the operation of the machine Always block the elevating assembly whenever it is necessary to enter the scissor assembly to perform maintenance while the platform is elevated The preventative maintenance table has been designed for machine service and maintenance repair Please copy the following page and use the table as a checklist when inspecting the machine for service Page 3 3 Preventative Maintenance Check List Section 3 Service amp Repair 3 3 PREVENTATIVE MAINTENANCE CHECK LIST PREVENTATIVE MAINTENANCE KEY PREVENTATIVE MAINTEN
38. he cause of problems and suggests proper corrective action Careful inspection and accurate analysis of the symptoms listed in the Troubleshooting Guide will localize the trouble more quickly than any other method This manual cannot cover all possible problems that may occur If a specific problem is not covered in this manual call our number for service assistance Referring to Section 2 0 and 5 0 will aid in understanding the operation and function of the various components and systems and help in diagnosing and repair of the machine GENERAL PROCEDURE Thoroughly study hydraulic and electronic schematics in Section 5 Check for loose connections and short circuits Check repair replace each component in the Truth Table that is listed under each machine function that does not operate Use the charts on the following pages to help determine the cause of a fault NOTE Spike protection diodes at components have been left out of the charts to eliminate confusion When troubleshooting ensure that the work platform is resting on a firm level surface When performing any service that requires the platform to be raised ensure that the platform and booms are supported by a crane capable of supporting the load Unplug the machine or disconnect the battery when replacing or testing the continuity of any electrical component Page 4 1 Troubleshooting 4 2 Troubleshooting 4 2 TROUBLESHOOTING 1 Verify your problem
39. he replacement filter 3 Screw the replacement filter onto the filter head until gasket makes contact then turn filter 3 4 of a turn CAUTION The hydraulic oil may be of sufficient temperature to cause burns Wear safety gloves and safety glasses when handling hot oil FLUID REPLACEMENT Replace the hydraulic fluid every 1000 hours or two years 1 Operate the machine for 10 15 minutes to bring the hydraulic fluid up to normal operating temperature Provide a suitable container to catch the drained fluid Hydraulic reservoir capacity 15 L 4 U S gal Open the control module door Remove the drain plug and allow all the fluid to drain Dispose of hydraulic fluid properly contact your local fluid recycler Install the drain plug Fillthe hydraulic reservoir with the appropriate hydraulic fluid until the fluid is up to the full mark on the dipstick Refer to Specifications at the end of the Operator Manual included in this Service Manual to identify the proper fluid for your conditions FLUID OUTLET SCREEN Clean or replace the outlet screen at the same time that the fluid is changed Go Drain the fluid see Fluid Replacement Disconnect and plug the outlet hose to prevent foreign material from entering the hose Remove the suction screen Clean or replace as necessary Install the suction screen Fill the hydraulic reservoir see Fluid Replacement
40. k for fault code 68 1 Emergency lowering valve open 2 Leaking piston seals in lift cylinders Check hydraulic fluid level top off as required Check pressure and delivery of the hydraulic pump Replace if Close emergency down valve Observe maximum load rating see Operation section of this manual Check functionality of controller Replace if faulty Check 7A circuit contrrol fuse Replace if blown Check Battery Voltage Charge if necessary Ensure that emergency lowering valve is completely closed Replace Check for leakage at cylinder return line replace seals if necessary Page 4 3 Fault Codes introduction FAULT CODES INTRODUCTION The X Series is equipped with a fault detection system if you have a faulty component bad electrical connection or start up error a fault code will be displayed on the read out located on the upper control box For fault codes 01 39 the following procedure should be followed Ensure that no selector buttons are depressed Ensure that the deadman switch on the joystick is not held Ensure that the joystick is in neutral Ensure that the steer rocker is not activated Ensure that toggle switch is in neutral Then re cycle power do this by pushing and releasing the emergency stop button Ifthe fault code is still displayed you may have a faulty upper or lower control box consult the error code list to identify the problem component and replace if necessary
41. low dry with filtered compressed air Inspect all the threaded components for stripped or damaged threads Check the inside surface of the cylinder barrel for scoring or excessive wear Check the piston and headcaps for scoring or excessive wear Inspect the surface of the shaft for scoring or excessive wear ASSEMBLY 1 Install the headcap the shatft Install the new piston rings and O ring on the piston Re install the piston Lubricate the piston seal with clean hydraulic fluid and install the shaft assembly in the cylinder barrel Install the head cap into the cylinder barrel and tighten the head caps ND Lubricate and install new rod wiper U cup O ring and backup ring on the headcaps INSTALLATION Installation is reverse of removal 508244 103 Page 3 13 Cylinders STEERING CYLINDER REMOVAL 1 Mark and disconnect the hose assemblies from the cylinder fittings and immediately cap the openings to prevent foreign material from entering 2 Remove the cotter pins from the pivot pins 3 Remove the pivot pins while supporting the cylinder Remove the cylinder REPAIR DISASSEMBLY 1 Unscrew the head cap from the barrel removing the head cap piston and shaft assembly from the barrel tube 2 Unscrew the piston 3 Remove all rod wipers U cups O rings and backup rings from the headcap and discard 4 Remove the piston ring and O ring from the piston and disc
42. n 3 3 3 2 Preventative Maintenance 3 3 3 3 Preventative Maintenance Check List 3 4 3 4 Parts Location RE EE EE EE A EE EE ER OE EN 3 5 3 5 General 3 6 3 6 ci A 3 6 Battery Maintenance 3 7 Battery Replacement oooocooooo ete tenes 3 7 3 7 Safety Ancillary 3 8 Proximity SWiteli ua a hide cd EED 3 8 ER OE OE NE ba Dd EE ade tates 3 8 Emergency Lowering 4 mmm 3 8 3 8 Hydrauli s ss sa oo EER a e RE BOER WER ER A 3 9 Hydraulic Oil Tank And 1 3 9 Hydraul Pumps e ERE re As RETE 3 10 Main Hydraulic Rm e trantan 3 11 Setting Hydraulic Manifold Pressures 3 12 3 9 Cylinders enim AREE ERN A diese 3 13 Depression 3 13 Steering Cylinder Las east wet ek 3 14 Blue let TEE 3 15 3 10 Drive MOTOTS csi uu cena eee ieee
43. perate the work platform for 10 15 minutes to bring the hydraulic oil up to normal operating temperature Install gauge in the gauge port Loosen locknut or remove cover on the Steering Relief Valve and turn adjusting screw counter clockwise two full turns While one person holds the Steering Switch to steer right or left slowly turn the Steering Relief Valve adjusting screw clockwise to increase the pressure until the gauge reads 69 bar 1000 psi Tighten locknut or replace Steering Relief Valve cover and torque to 8N m 6 ft Ibs Remove gauge and replace cap 508244 103 Section 3 Service amp Repair Cylinders 3 9 CYLINDERS DEPRESSION CYLINDER REMOVAL 1 Figure 3 14 Depression Cylinder Mark and disconnect the hose assemblies from the cylinder fittings and immediately cap the openings to prevent foreign material from entering 2 Place a support under the depression guard 3 Remove the circlips from the pivot pins 4 Remove the pivot pins while supporting the cylinder 5 Remove the cylinder REPAIR DISASSEMBLY 1 Unscrew the head cap from the barrel removing the head cap piston and shaft assembly from the barrel tube 2 Unscrew the piston 3 Remove all rod wipers U cups O rings and backup rings from the headcap and discard 4 Remove the piston ring and O ring from the piston and discard CLEANING AND INSPECTION Wash all the metal parts in cleaning solvent and b
44. pression Mechanism Depression Mechanism Cylinder Battery Charger Plug Battery Charger Battery Pack Cable Connector Power Module Drive Motors Steering Cylinder Lift Cylinder Maintenance Brace Level Sensor Proximity Switch Height Limit Switch Series Parallel Valve Emergency Lowering Valve Emergency Lowering Valve Knob Horn 508244 103 Parts Location Figure 3 2 Parts Location Page 3 5 General Lubrication Section 3 Service amp Repair 3 5 GENERAL LUBRICATION NOTE Apply grease to each grease fitting Figure 3 3 Steering Lubrication Points There are four lubrication points on the machine steering system two on each steering pivot see Figure Lubricate the steering pivots every 125 hours or three months 1 Deploy the maintenance brace see Blocking the Elevating Assembly gt 2 Clean the grease fittings and surrounding area 3 Using multipurpose grease in a grease gun pump the grease into the fitting until grease just begins to appear at the edges of the pivot 4 Wipe off any excess grease 3 6 BATTERIES The batteries are located in a slide out tray in the rear of the machine Electrical Energy for the motor is supplied by four 6 volt batteries wired in series for 24 volts DC Correct care and maintenance of the bat teries and motor will ensure maximum performance from the work platform CAUTION If battery water level is not maintained batteries will not fully
45. r thrust washer thrust bushing and retaining ring To ensure that the Wheel Yoke Assembly does not fall out of the Chassis when the vehicle is lifted off the ground fit a 3 8 UNC nut and a 1 1 4 long bolt screw nut onto until 6mm from head Hand screw bolt into Chassis thread and tighten until bolt hits inner pin groove Loosen bolt by a HALF turn of the bolt head Whilst 1 Drive Motor still holding bolt head with either 2 Wheel Yoke ratchet socket or spanner turn 3 Wheel down the nut till it hits Chassis 4 Cotter Pin outer casing and then tighten using 5 Slotted Nut a 9 16 spanner until nut is tight to 6 Shaft Key outer material This is to lock bolt 7 Capscrew in position 8 Locknut steering link Remove the plugs from the hose assemblies and connect to the drive motor Install the shaft key wheel washer and slotted nut Torque the locknut to 102 N m 75 ft lbs Install a new cotter pin DO NOT back off the nut to install cotter pin Remove blocks lower the jack and remove Operate the drive system and check for leaks Figure 3 18 Drive Motor Assembly 508244 103 Section 3 Service amp Repair Controls 3 11 CONTROLS PLATFORM CONTROLS The Proportional Controller can be disassembled to replace defective switches See the Parts Manual for replacement part numbers Figure 3 19 Platform Control Box 1 Control Box 5 Mounting Plate 2 Emergency Stop 6
46. ring cable and down valve wires Unplug hydraulic hoses and attach to the cylinder Replace hydraulic fluid removed from lift cylinder Test with weight at rated Platform load to check system operation Check for leaks 0 Y 508244 103 Page 3 15 Drive Motors 3 10 DRIVE 5 REMOVAL 1 2 3 4 Section 3 Service amp Repair Use 1000Kg one ton capacity jack to raise the front of the machine Position blocks under the machine to prevent the work platform from falling if the jack fails Block the rear wheels to prevent the machine from rolling Remove the cotter pin nut and washer Remove the wheel NOTE Before disconnecting hoses thoroughly clean off all outside dirt around fittings After disconnecting hoses and before removing from vehicle IMMEDIATELY plug port holes 5 Tag disconnect and plug the hose assemblies to prevent foreign material from entering 6 Support the drive motor wheel yoke assembly and remove the retaining ring at the top of the wheel yoke pivot Remove the drive motor wheel assembly from the machine 7 Remove the locknuts flat washers capscrews and drive motor from the wheel yoke INSTALLATION 1 Page 3 16 Install the drive motor wheel yoke Align the steer pin with the hole in the Position the drive motor in the wheel yoke and secure with capscrews flat washers and locknuts assembly into the pivot bearing along With the lowe
47. ry Units 8 8 10 9 12 9 ade 8 8 ade 10 9 ade 9 Clamp Tightening Torque Clamp Tightening Torque Clamp Tightening Torque Size Load K 15 K 20 Load 15 K 20 Load K 15 K 20 3 823 14 6 19 5 3 5 1 109 22 9 30 5 4 1 436 33 9 45 2 5 1 389 41 0 19 5 1 987 58 7 19 5 2 322 686 91 2 6 1 966 697 28 3 2 813 100 0 28 3 3 287 1168 155 8 7 2 826 116 8 372 4 044 1673 372 4 727 195 6 2602 8 3 579 141 188 5 122 201 26 9 5 986 23 6 31 4 10 11 742 279 37 2 8 117 399 53 3 9 486 467 62 3 12 8 244 487 64 9 11 797 697 92 2 13 787 814 108 4 14 11 246 774 103 3 16 093 110 6 147 5 18 808 129 1 1726 16 15 883 125 4 166 7 21 971 173 3 230 9 25 677 2024 269 2 18 19 424 171 9 229 4 26 869 238 2 317 2 31 401 2784 371 0 20 2 304 243 4 325 3 34 286 337 8 449 9 40 070 394 6 525 9 22 30 653 331 9 442 5 42 403 458 8 612 2 49 556 536 2 715 4 24 35 711 420 4 562 0 49 400 583 4 778 1 57 733 682 2 909 4 27 46 435 6173 848 64 235 853 4 1138 1 75 069 997 2 1329 8 30 56 753 837 9 11174 78 509 1159 4 1545 2 91 751 1354 9 1807 0 33 70 208 1140 3 1520 1 97 121 1576 9 2102 8 113 503 1843 9 2457 5 36 82 651 1464 1 1952 3 114 334 2025 3 2700 9 133 620 2367 6 3156 0 Table Torque Specifications for Metric Fastener
48. s SI Units 8 8 10 9 12 9 ade 8 8 ade 10 9 ade Clamp Tightening Torque Clamp Tightening Torque Clamp Tightening Torque Size Load 15 K 20 Load k 15 K 20 Load K 15 K 20 3 3 660 1 65 2 2 3 5 4 932 2 59 3 45 4 6 387 3 83 5 11 5 6 177 4 63 2 2 8 840 6 63 2 2 10 330 7 75 10 3 6 8 743 7 87 3 2 12 512 11 3 3 2 14 623 13 2 17 6 7 12 570 13 2 4 2 17 990 18 9 4 2 21 025 221 29 4 8 15 921 19 1 255 22 784 273 36 5 26 626 32 42 6 10 25 230 37 8 505 36 105 544 722 42 495 633 844 12 36 670 66 88 52475 945 125 61 328 110 147 14 50 025 105 140 71 87 150 200 83 663 175 234 16 70 650 170 226 97 732 235 313 114218 274 365 18 86 400 233 311 119 320 323 430 139680 377 503 20 10 250 330 441 152 513 458 610 178 238 535 713 22 136 350 450 600 188 618 622 830 220 433 727 970 24 158 850 570 762 219 743 791 1055 256 808 925 1233 27 206 550 837 115 285 728 1157 1543 333 923 1352 1803 30 252 450 1136 1515 349 223 1572 2095 408 128 1837 2450 33 312 300 1546 2061 432 015 2138 2851 504 885 2500 3332 36 367 650 1985 2647 508 582 2746 3662 594 368 3210 4279 Page3 21 Page 3 22 508244 103 Section 4 TROUBLESHOOTING 4 1 INTRODUCTION The following section on troubleshooting provides guidelines on the types of problems users may encounter in the field helps determine t
49. welght added must distributed equally on sach axle Proper stability and axle weights 4 this machine are based on the platform size shown above Arde weelgihte with machine In the stowed travel position STEER AXLE 2447 1110 kg o REAR AXLE 2800 Ibs 1270 kg Snorkel www snorkelusa com 508244 103 Section 3 SERVICE AND REPAIR INTRODUCTION This section contains instructions for the maintenance of the Work Platform Refer to the General Information section for information relevant to all Snorkel work platforms Referring to the Operator Manual will aid in understanding the operation and function of the various com ponents and systems of the work platform and help in diagnosing and repair of the machine WARNING Be sure to read understand and follow information in the Operation Section of this manual before attempting to operate or perform service on any Work Platform DANGER Never perform service on the work platform in the elevating assembly area while platform is elevated without first blocking the elevating assembly DO NOT stand in elevating assembly area while deploying or storing brace 508244 103 3 1 Section 3 Service amp Repair TABLE OF CONTENTS Page 3 2 3 1 Supporting Elevating Assembly 3 3 Installation en 3 3 REMOVAL assia pas E ee
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