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1. 3 9 Hydraulic PUMP Mey SWS 3 10 Main Hydraulic 0 eee uen 3 11 Setting Hydraulic Manifold Pressures 3 12 3 9 Cylinders cia ee ee ee Dee 3 13 Depression 3 13 Steering 1 1 1 3 14 Lift Cylinder 3 15 3 10 Drive MOlOrS d 3 16 3 16 Installation 3 16 3 11 Controls aura nn ae 3 17 Platform COMO a ea do a 3 17 Chassis Controls sss eds e Rm Rm a a a er 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 S
2. CLEAR OF SCISSORS BLOCK SCISSORS BEFORE SERVICING 066553 000 x2 066553 000 14 066555 000 EMERGENCY LOWERING PULL OUT TO LOWER PLATFORM 066558 000 MAXIMUM DISTRIBUTED PLATFORM LOAD 700LBS 7 3 OCCUPANTS MAXIMUM SIDE LOAD 150185 101250 005 2 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 tof power 066556 000 TIP OVER HAZARD MAXIMUM DISTRIBUTED LOAD 250 LBS OR 4 OCCUPANT ON EXTENDED DECK MAXIMUM SIDE LOAD 100 LBS 24 066561 900 101251 000 E 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 11 HIGVJ JHB BPL KLIO PO OPP 300699 DISCONNECT LOCATED INSIDE MAXIMUM WHEEL LOAD 17505 USE DISCONNECT BEFORE SERVICING WORK OR BATTERIES 26 101252 005
3. MAXIMUM DISTRIBUTED LOAD generated when charging 3 batteries 7 m E 24 or flames 066561 900 250 LBS OR 1 OCCUPANT ON EXTENDED DECK MAXIMUM SIDE LOAD 100 LBS 066552 000 066552 000 066561 900 CLEAR OF 4 SCISSORS BLOCK SCISSORS BEFORE SERVICING 066553 000 11 HIGVI JHB BPL KLIO PO OPP 066553 000 2 300699 BATTERY DISCONNECT LOCATED INSIDE MAXIMUM 14 WHEEL LOAD 17505 USE DISCONNECT BEFORE SERVICING WORK OR BATTERIES 066555 000 101252 005 107051 000 014222 003 x2 EMERGENCY LOWERING PULL OUT TO LOWER PLATFORM 066558 000 10076 001 MAXIMUM DISTRIBUTED PLATFORM LOAD 7001 85 7 3 OCCUPANTS MAXIMUM SIDE LOAD 150185 TIP OVER HAZARD BATTERIES ACT AS COUNTERWEIGHTS EACH REPLACEMENT BATTERY SHALL WEIGH 60185 OR MORE 101250 005 x2 066522 000 062562 001 101251 000 OPERATORS CHECKLIST INSPECT AND OR TEST THE FOLLOWING DAILY OR AT THE BEGINING OF EACH SHIFT 2 LUIOHLWNC EIOFLEI 25 DIFJWPEIOFJDN E Sera 5 UNOBUHIOU YT 1 10 UGVUVUV GUY YGUYY BNDFSES 508770 000 26 a CRUSHING HAZARD KEEP ALL BODY PARTS AWAY 0665536 001 066556 001 4 2 7 DO NOT REPLACE COMPONENTS CRITICAL TO MACHINE STABILITY SUCH AS BATTERIES AND WHEEL EQUIPMENT WITH N G E R LIGHTER WEIGHT OR NON FACTORY APPROVED SUBSTITUTES
4. m TIT amp 2 Ir 9 gy T as cs Spor era 13 211 5 aen vy v 2 Y Wd Hora dois 3 sansa o p N uacgseld jauna 508244 103 5 2 5 3 CABLE ASSEMBLY WIRE INFORMATION ITEM 25 A 26 27 28 29 30 WEITE BLACK SINGLE WIRE 31 32 BIO 33 34 35 36 N N M A WE uu AI ACC 5459 MOTOR CONTROLLER 5 3 508244 103 5 4 1 CABLE 5 21002 2 21092 3 suid ayou BIg0GE UHA pazomdod 0 9361 gt Mosuss E ana 3 2 AVEC SIJeH BLJNT
5. 500771 000 All personnel shall be qualified carfully read undrestand 068639 000 057507 010 x4 066559 000 068635 001 x2 BEFORE operating this MEETS OR EXEEDS equipment read understand 1 0 THE REQUIREMENTS OF and then follow all safety ANSI A92 6 1999 information in instruction manual 061220 002 066554 000 Page 19 and obay all safety rules operating instructions and manual reponsibilities before performing maintenance 8 POWER TO PLATFORM 2 0 Es on or operating any mobile elevating work platform u 508772 000 060197 001 005221 000 DECALS Control lo XN va YA Page 21 2 22 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 A WARNING 4 Be sure to read understand and follow all information in the Operation Section of this manual before attempting to operate or perform service on any Work Platform DANGER Never perfo
6. x x x x gt x X x x x x 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 4 7 HYDRAULIC Table 4 2 Hydraulic Troubleshooting Table Component Depression Mechanism Extend Depression Mechanism Retract Function Lift Platform Lower 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 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
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8. Emergency Lowering System Operate the emergency lowering valve and check for serviceability Entire Unit Check for and repair collision damage Hydraulic Fluid Check fluid level Hydraulic Pump Check for hose fitting leaks Hydraulic System Check for leaks Labels Check for peeling missing or unreadable labels amp replace Platform Deck and Rails Check welds for cracks Platform Deck and Rails Check condition of deck Tires and Wheels Page 2 18 Check for damage MAINTENANCE REPORT 11 SPECIFICATIONS 10 SPECIFICATIONS Platform Size Platform Extension In 0 71 mx 2 21 m 28 in x 87 in Platform Extension Out 0 71 m x 3 20 m 28 x 126 in Standard 340 kg 750 Ibs on Extension 110 kg 250 Ibs Max No of occupants Standard total 3 People Indoors 1 Person Outdoors Max Wind Speed 7 5 on Extension 1 person Maximum Wheel Load 818 800 Ib Maximum Chassis Inclination U side side 2 0 front rear Helg Working Height 9 93 m 32 5 ft Max Platform Height 7 93 m 26 ft Min Platform Height 1 09 m 43 in Dimensions Weight 2358 kg 5200 lbs Overal Width 0 82 m 32 5 in Overal Height 2 19 m 86 in Overal Height Rails Lowered 1 99 m 78 25 in Overal Length Extension In 2 35 m 92 5 in Overal Length Extension Out 3 26 m 128 5 in Drive Speed Platform Lowered 010 3 2 km h 0 to 2 0 mph Platform Raised 0 to 0 8 k
9. appear at the edges of the pivot NR 4 Wipe off any excess grease 7 3 6 5 The batteries are located 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 batteries will not fully charge creating a low discharge rate AWARNINGA 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 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 bat
10. 6122 49 556 536 2 715 4 24 35 711 4204 562 0 49 400 5834 7781 57 733 682 2 9094 27 46 435 617 3 84 8 64 235 8534 1138 1 75 069 9972 1329 8 30 56 753 837 9 1117 4 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 14641 1952 3 114 334 2025 3 2700 9 133 620 2367 6 3156 0 Table Torque Specifications for Metric Fasteners SI Units 8 8 10 9 12 9 8 8 10 9 12 9 Tightening Torque Clamp Tightening Torque Clamp Tightening Torque Size Load K 15 20 Load 15 20 Load K 15 K 20 3 3 660 1 65 2 2 3 5 4 932 2 59 3 45 4 i 6 387 3 83 5 11 5 6 177 4 63 2 2 8 840 6 63 22 10 330 7 75 10 3 6 8 743 7 87 3 2 12512 113 32 14 623 132 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 36 105 541 72 2 42195 633 84 4 12 36 670 66 88 52 475 945 125 61 328 110 147 14 50 025 105 140 71 587 150 200 83 663 175 234 16 70 650 170 226 97 732 235 313 114218 274 365 18 86 400 233 311 119 520 323 430 139 680 377 503 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 27 206 550 837 115 285 728 115
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12. INSPECT the machine thoroughly for cracked welds loose or missing hardware hydraulic leaks loose wire connections and damaged cables or hoses before using VERIFY that all labels are in place and legible before using NEVER use a machine that is damaged not functioning properly or has damaged or missing labels To bypass any safety equipment is prohibited and presents a danger for the persons on the aerial work platform and in its working range NEVER charge batteries near sparks or open flame Charging batteries emit explosive hydrogen gas Modifications to the aerial work platform are prohibited or permissible only at the approval by UpRight AFTER USE secure the work platform from unauthorized use by turning the Keyswitch OFF and removing key Page 1 CONTENTS PAGE 1 IHtroduction ne RR Rb aa EA EVE 3 Special Inmormnatloni em ns Ren paka 3 2 General Description aa B RR q 4 3 Special Limitations rc eee 5 Platform Capacity Gad oe ated Pt e 5 Manual Force i202 cnet A AR 5 Lift Overload Alarm nun Bare eet 5 4 Controls and Indicators 6 5 P
13. Serial Number 51119 Manual Serial Number 500244 104 oe R Ae FO PA ATS 52633 www snorkelusa com 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 Access Rear View Front View Snorkel PART 508244 103 FOREWORD How USE THIS MANUAL This manual is divided into six sections SECTION 1 INTRODUCTION General description and machine specifications SEcTION 2 OPERATION AND SPECIFICATION Information on how to operate the work platform and how to prepare it for operation SEcTION 3 MAINTENANCE Preventative maintenance and service information SEcTION 4 TROUBLESHOOTING Causes and solutions to typical problems SECTION 5 SCHEMATICS Schematics and valve block diagram with description and location of components SECTION 6 ILLUSTRATED PARTS BREAKDOWN Complete parts lists with illustrations SPECIAL INFORMATION A DANGER Indicates imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury NOTE
14. p G2701 duy E Dan sands LA Fr WUOFZ Od vd w Nwa o ma AO 370IHJA ZEX LE 1110412 NADG A2ON3933W3 508244 103 Page 5 4 Schematics 5 5 OVERLOAD 5 508244 103 5 5 1 0119 0 gt i i E SAV PI Cs _ 1 ial 1 1 ug Owl 3 4 7 t 619 ET VN X LJ 718 AVAV A T 915 dd 3 25 15 VR zu e N gt il 3 Jepun Ao WO TID A Es B dii ejoujod S wies H148punAo z un gt saputo yn n Ol 508244 103 5 6 508244 103 5 7 ILLUSTRAITED PARTS List SECTION 6 ILLUSTRATED PARTS LIST INTRODUCTION This section lists and illustrates t
15. 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 Operate 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 sup
16. RR a er 19 11 Labels AA RR CREE Ron AA RR 20 Lable Location 21 2 1 INTRODUCTION 1 INTRODUCTION This manual covers the S2633 Work Platform Figure 1 Manual Storage Information The manual MUST be stored in the box provided in the machine cage AT ALL TIMES All Operators must read understand and follow all safety rules and operating instructions before attempting to operate the machine SPECIAL INFORMATION ADANGER A Indicates an imminently hazardous situation which if not avoided WILL result in severe injury or death AWARNINGA Indicates a potentially hazardous situation which if not avoided could result in severe injury or death ACAUTIONA Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury Page 2 3 2 GENERAL DESCRIPTION 2 GENERAL DESCRIPTION NOT use the machine if all guardrails are not in place and secured 1 Platfo Page 2 4 ON O X N gt rm Controls Manual Case Platform Extension Platform Elevating Assembly Chassis Batteries Charger Outlet Plug Chassis Controls Emergency Lowering Valve Knob Hydraulic Fluid Reservoir Pothole Support Rails not visible when machine is Stowed in raised Drive position see fig 5 page 10 Power Module
17. ux E 530 lo O pua aui DMY Bl vl ja O O pua UO DAY BI 72 7 X85 PERERA O 5 SNA J8j win O pua aui Bh 2 CO2E DAV BT asnd v 20CI asndias41 04 DAY BI 21 OES HES 22 a pua uo 2 502 dv DAY BI 270 mi IT 1398 8 cy I ay pue aux uo 6n 2 pEI9E 2 day 2 91 318 ev 35 pua aux uo 2 pSI9E 2 DAY 1 97 1022915534092 291 pua aui Om 2 502E DAY BL vaplov asndlasH1 O3 DAY BI 21 Ta I se 28 pue ayy uo 2 pGI9E 2 OMY 1 27 Ind 2v 5 pau5HWS Dl og tr ETENEE a z Zi 521000 1 90353 2 MI p403 193 L doys 3 T as gt E x 9405 102 DAY OZ 81909 7 Jus 3 91300183 50130 9196419499155 203 Msso 552004 aas 10301 2003 102 2 Nad D3u3iMS TN amp and GLPPOL suld 3303409 4 veu ui E DEIES alalo4da3a4 ud
18. 5 2 Cable Assembly J1 55 5 3 Schematic J1 5 4 Overload Schematic 5 5 Hydraulic Schematic 52633 5 6 Page 5 1 5 2 ELECTRIC 17 lt lt FETT 95 RESI idw Josue 1 ve ir lt lt 9 UDPS 322443 NOH S spa ano UnA Fre H aare ar az Ir lt lt E En Hg VETTA SIT mager vor 4 sens I java Der ver D gt ITER 8 45 e mu 50 393104104 9 95 17 YORE em ne E aad d amp MAS L 8 1 di T 2 o TORT 8 Z E n i P 2 cd asosl lt T FE ec ccm a 1 62 2882941 Te tea n panddns lt yee vere a a lt P diit lt 551000959 Wu PI 33 ANA UG WEG emp ME le ll we ir
19. 7 ILLUSTRAITED PARTS LIST Scissor ASSEMBLY 114200 001 Item Part Description 1 066183 001 BEARING OILITE EP3236 24 2 504129 001 LIFT CYLINDER 504129 002 ANSI 504129 010 SEAL KIT LIFT CYLINDER 504104 000 WELDMENT MID INNER TUBE 1 8 114201 002 WELDMENT TOP BOTOM OUTER 114202 001 WELDMENT BOTTOM INNER 3 16 504103 000 WELDMENT MID OUTER 1 4 504122 003 WELDMENT PIVOT PIN 504122 001 PIN LIFT CYLINDER 501187 000 PIN SHAFT LOCKING 011764 032 RET RING TRUARC 5100 200 11 114203 001 WELDMENT SAFETY STAND 12 011248 005 NUT HEX 5 16 18 13 011248 006 NUT HEX 3 8 16 14 015936 023 SCREW SHOULDER 3 8 16 X 3 1 2 15 011254 044 SCREW HHC GRS 3 8 16 X 5 1 2 17 504103 001 WELDMENT MID OUTER ARM 1 8 18 504046 000 PIPE RING 19 504029 000 CHANNEL CABLE 2 025m N lt 10 20 011248 004 1 4 20 21 011252 008 SCREW HHC GRS 1 4 20 X 1 22 504108 002 WELDMENT MID INNER ARM 3 16 23 114203 001 WELDMENT TOP INNER ARM 1 8 24 011239 032 WASHER 2 DIA ASTM 25 011740 024 ROLL PIN 1 2 X 3 26 065367 001 BEARING TORRINGTON YCRS32 27 504176 002 WELDMENT TORSION ARM L H 28 011257 028 SCREW HHC 5 8 11 X 3 1 2 29 011246 010 NUT 5 8 11 THIN HEX 30 504123 000 PIN LIFT CYLINDER 31 503790 001 CHANNEL CABLE 1 054m 32 504122 006 WELDMENT PIVOT PIN 33 504176 003 WELDMENT TORSION ARM R H 3
20. 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 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 the replacement filter 3 Screw the replacement filter onto the filter head until gasket makes contact then turn filter of a turn CAUTION The hydraulic oil may be 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 Fill the 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
21. caps INSTALLATION Figure 3 16 Steering Cylinder Assembly WIPER CYLINDER BODY PLAIN BUSHING fh 0 AN ES f ff SJ FLANGED BUSHING cYUNDERROD 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 expel trapped air and check for leaks Page 3 14 508244 103 Section 3 Service amp Repair Cylinders LIFT CYLINDER REMOVAL Figure 3 17 Lift Cyminder Assembly me 1 Provide a suitable container to catch the hydraulic P fluid then disconnect the hydraulic hoses PA Immediately plug hoses to prevent foreign material DA from entering 2 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 BL 4 Remove capscrews locknuts securing lift cylinder pins 5 Remove lower pivot pin and lower cylinder to rest on chassis XA 6 Attach a suitable hoisting device and sling to the gt cylinder and remove upper 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 pre
22. have been discharged AWARNINGA Charge the batteries in a well ventilated area Do not charge the batteries when the machine is near a source of sparks or flames Permanent damage to the batteries will result if the batteries are not immediately recharged after discharging Never leave the battery charger operating for more than two days Never disconnect the cables from the batteries when the charger is operating Keep the charger dry 1 Battery Charger 1 Check the battery fluid level If the battery fluid level is lower than 2 Charge Indicator 10 mm in above the plates add distilled water only 3 Charger Plug 2 Connect an appropriate extension cord to the charger outlet plug in 4 Batteries the left module door Plug the extension cord into a properly grounded outlet of proper voltage and frequency 3 The charger turns on automatically after a short delay The LED charge indicator will illuminate After completion of the charge cycle the LED will blink indicating that the charger is in a continuing maintenance mode DO NOT leave the charger plugged in for more than 48 hours as permanent damage to the batteries may occur NOTE The battery charger circuit must be used with Ground Fault Interrupt outlet NOTE DO NOT operate the machine while the charger is plugged in Page 2 17 DAILY INSPECTION AND MAINTENANCE SCHEDULE DAILY INSPECTION AND MAINTENANCE SCHEDULE The Complete Inspectio
23. of the platform extension Push the platform extension forward until the pin engages the front stop 3 retract the platform extension depress the foot lever and pull platform extension toward the rear of the machine until the pin engages the rear stop TRAVEL WITH THE PLATFORM LOWERED 1 Check that the route is clear of obstacles persons obstructions holes drop offs bumps and debris is level and is capable of supporting the wheel loads 2 Verify that the Chassis Key Switch is turned to ON and the Chassis Emergency Stop Switch is ON pulled out 3 Mount the platform and properly close the entrance 4 Check clearances above below and to the 1 Platform Extension sides of platform 2 Foot Lever deck lock assembly 5 the Platform Emergency Stop Switch out to the ON position 6 Select DRIVE mode NOTE Choose between standard drive and extra torque depending on the gradient 7 Engage the Interlock Switch and move the Control Handle to FORWARD or REVERSE to travel in the desired direction The speed of the machine will vary depending on how far from centre the Control Handle is moved STEERING 1 Turn the Lift Drive Switch to DRIVE 2 While engaging the Interlock Switch push the Steering Switch to the RIGHT or LEFT to turn the wheels in the desired direction Observe the tires while manoeuvring the machine to ensure proper direction NOTE Steering is not self centering Whee
24. performing checks PORN Move the machine if necessary to an unobstructed area to allow for full elevation Twist and pull the Chassis Emergency Stop button to the ON position Twist and pull the Platform Emergency Stop button to the ON position Turn and hold the Chassis Key Switch to the ON position Push the Chassis Lift Lower Switch to the UP position and raise the platform approximately 2 1 m 7 feet 5 BLOCK THE ELEVATING ASSEMBLY AS DESCRIBED ON page 15 6 Visually inspect the elevating assembly lift cylinder cables and hoses for cracked welds and structural 11 12 13 14 15 damage loose hardware hydraulic leaks loose wire connections and erratic operation Check for missing or loose parts Verify that the Pothole Support Rails have rotated into position under the machine REMOVE THE SCISSOR BRACE AS DESCRIBED ON page 15 Push the Chassis Lift Lower Switch to the UP position and fully elevate the platform Partially lower the platform by pushing Chassis Lift Lower Switch to LOWER and check for proper operation of the audible lowering alarm Open the Emergency Lowering Valve see Figure 5 by pulling the knob out to check for proper operation When the platform is lowered release the knob Push the Chassis Emergency Stop Switch to check for proper operation All machine functions should be disabled Pull out the Chassis Emergency Stop Switch to resume Check that the route is clear of obstacles pe
25. platform is elevated The switch is located on the left side of the chassis at the rear ofthe machine No adjustment of the switch should be necessary LEVEL SENSOR Figure 3 7 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 EMERGENCY LOWERING AWARNINGA If the platform should fail to lower NEVER climb down the elevating assembly Stand clear of the elevating assembly while operating the Emergency Lowering Valve Knob Figure 3 8 Emergency Lowering Knob The Emergency Lowering Valve is mounted on the base of the lift cylinder The cable is routed 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 Deploy the maintenance brace see Blocking the Elevating Assembly 2 Inspect the cable Replace if damaged 3 Inspect the valve Replace if damaged 4 Check for and clear any blockage in the orifice Install the orifice with the beveled side toward the cylinder block 5 Adjust the valve the cable mount adjust the cable cover to stop the inner cable when the valve is fully open 6 Store the maintenance brace and lower the platform Page 3 8 508244 103 Section 3 Service amp Repair Hydraulics 3 8 HYDRAULICS 508244 103 HYDRAULIC TANK AND FILTER FLUID LEVEL
26. your conditions FLUID OUTLET SCREEN Clean or replace the outlet screen at the same time that the fluid is changed 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 Page 3 9 Hydraulics Section 3 Service amp Repair HYDRAULIC PUMP 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 CEU 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 HYDR
27. 0 115 122 950 1050 107 119 176 190 130 140 176 190 1300 1368 147 155 This standard applies to preloading of fasteners measured 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 K 20 Table Torque Specifications for Hydraulic Components Type 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 SAE Fasteners SAE 4429 Grade 5 SAE 4429 Grade 8 Nominal Thread Size Tightening Torque K 15 K 20 in in Ibs Tightening Torque K 15 20 Nominal Thread Size SAE J429 Grade 5 K 15 Tightening Torque K 20 SAE 4429 Grade 8 Tightening Torque K 15 K 20 3 8 16 ft I DS ft Ibs 174 20 2 000 75 100 2850 107 143 5 16 18 3 350 157 210 4700 220 305 6950 3 8 24 5 600 1 4 28 2 300 85 115 3250 120 163 5 16 24 3 700 173 230 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 Ser
28. 0 13 Moving By Forklift ene Ea bar ice ES 13 Driving or Winching onto a Truck or 14 9 Maintenance m RR SO UA SCR CR RD AUR OCCUR aa 15 Blocking The Elevating Assembly 4 4 15 Scissor Brace Installation u uu uq rimas p nee Re Rm Ee EORR ew EEE 15 Scissor Brace Sforage redo ERA ER der RES RR Rig aped Sd md ers 15 Level Sensori e 16 Testing the Level 1 16 eir EROR RR esce RR esos dus 17 Check Hydraulic Fluid 42 17 Battery 1 1 4 4 17 Battery 4 1 17 Daily Inspection and Maintenance 18 Daily Preventative Maintenance Check 1 6 18 Maintenance Table 4 18 Maintenance 18 10 5
29. 065 000 MOUNTING PLATE FUSE 1 16 502152 000 1 504126 000 BUSHING MODULE 18 057534 000 FILLER amp DIPSTICK CAP 1 tion 3 504153 001 Sec6 14 ILLUSTRAITED PARTS LIST Power MODULE ASSEMBLY Item Part Description Part Description 1 504134 000 GUIDE PAD Qty 1 501074 000 BATTERY 504135 000 BUSHING POTHOLE PIVOT 066309 011 WELDMENT DOOR MODULE 1 ERE 2 4 066735 001 WELDMENT POTHOLE 1 11 504126 000 BUSHING MODULE PIVOT 6 066713 002 HINGE 1 504132 000 HYDRAULIC CYLINDER POT 1 Sec6 15 ILLUSTRAITED PARTS List HYDRAULICc MANIFOLD AssEMBLY 503800 001 Part Description ES emm 058358 000 FITTING 1 4 1 4 MALE MALE 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 503810 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 SSEMBLY STEERING CYLINDER SSEMBLY 50
30. 107051 000 014222 003 x2 10076 001 A DANGER TIP OVER HAZARD BATTERIES ACT AS COUNTERWEIGHTS EACH REPLACEMENT BATTERY SHALL WEIGH 60185 OR MORE 062562 001 500771 000 066522 000 Es 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 5 30 Local Distributor Distributeur local El Distribuidor local Snorkel International Inc P O Box 1160 St Joseph MO 64502 1160 USA TEL 1 800 255 0317 Snorkel www snorkelusa com
31. 3 Remove the filler cap from the hydraulic fluid reservoir 4 Check the fluid level on the dipstick on the filler cap 5 Add the appropriate fluid to bring the level to the FULL mark See Specifications on page 21 Page 2 16 9 MAINTENANCE AWARNINGA Hazard of explosive gas mixture Keep sparks flame and smoking material away from batteries Always wear safety glasses when working near 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 weighing 30 kg 66 Ibs each Check the battery fluid level daily especially if the machine is being used in a warm dry climate If electrolyte level is lower than 10 mm above plates add distilled water only NOT use tap water with high mineral content as it will shorten battery life Inspect the battery regularly for signs of cracks in the case electrolyte leakage and corrosion of the terminals Inspect cables regularly for worn spots or breaks in the insulation and for broken cable terminals Keep the terminals and tops of the batteries clean to the Service Manual to extend battery life and for complete service instructions BATTERY CHARGING Figure 13 Battery Charger Charge the batteries at the end of each work shift or sooner if the batteries
32. 4 011239 010 WASHER FLAT 5 8 ASTM 064462 035 PLUG 3 4 CAP PLUG 36 013919 006 HOSE CLAMP 38 504122 004 39 504186 000 40 504186 003 41 504186 002 42 504122 014 5 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 ROLLER AS REQUIRED ALLOW FREE MOVEMENT OF ARMS PIN ITEM 8 INSTALL WITH SPACER BLOCKS DOWN 42 PLC S 2 PLC S 4 PLC S 17 2 PLC S 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 Part Description Qty 504122 003 PIVOT PIN STANDARD LONG FLANGED BUSHING 50mm 057048 000 GREASE NIPPLE M6 16 504122 001 PIVOT PIN STANDARD MEDIUM 504120 001 PLAIN BUSH 50mm WASHER M48 X 4mm THICK 056687 100 HEX HEAD BOLT 16 X 100mm 501449 000 FLANGED BUSHING 16mm 056066 016 NYLOCK NUT M16 504176 002 WELDMENT TORSION ARM LHS 1 504176 003 WELDMENT TORSION ARM RHS 1 10 11 12 13 4 5 6 F 2 4 6 1 1 1 5 11 ILLUSTRAITED PARTS LIST ILLUSTRAIT
33. 4132 000 504148 001 Part Description Qty Part Description Qty LIFT CYLINDER ASSEMBLY Pai 504129 001 ANSI 504129 002 Item Part Description 058819 000 M6 GREASE NIPPLE 2 504120 000 FLANGED BUSHING 4 504129 011 SEAL REF Sec6 17 ILLUSTRAITED PARTS LIST Lower 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 n 501882 001 RUBBER BOOT JOYSTICK 6 501592 000 MOUNTING PLATE 1 502453 000 CIRCUIT BOARD 1 a re 10 502605 000 SOCKET OVERLOAD 1 Sec6 19 ILLUSTRAITED PARTS List ILLUSTRAITED PARTS LIST ELECTRICAL ASSEMBLY 5 20 ELECTRICAL SSEMBLY Item Part Description Qty 502531 000 J1 HARNESS MANIFOLD BLOCK 1 504349 000 UPPER CONTROLS 1 505566 001 TILT SENSOR 502588 000 ALARM 502494 000 FUSE 1 502594 000 HARNESS DISCONNECT 501074 000 BATTERY 16 069199 001 CHARGER 502597 000 HARNESS CHARGER
34. 7 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 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 the 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 15 listed under each machine function that does not operate properly 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 con
35. AULIC 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 VALVE 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 AWARNING A 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 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 VALVE Operate the hydraulic system 10 to 15 Install 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 platfor
36. Beaufort 4 Refer wind chart on page 7 Page 2 5 4 CONTROLS AND INDICATORS 4 CONTROLS AND INDICATORS The operator shall know the location of each control and indicator and have a thorough knowledge of the function and operation of each before attempting to operate the unit Figure 3 Controls and Indicators Platform Controls Drive Selectors Horn Button Lift Lower Button Emergency Stop Button Display Joystick DO wm Chassis Controls 1 Keyswitch 2 Enable Button 3 Toggle Switch amp Down 4 Emergency Stop Button Page 2 6 5 INSPECTION 5 PRE OPERATION SAFETY INSPECTION NOTE Carefully read understand and follow all safety rules operating instructions labels and National Safety Instructions Requirements Perform the following steps each day before use 1 Open modules and inspect for damage fluid leaks or missing parts 2 Check the level of the hydraulic fluid with the platform fully lowered See Fluid on 16 Add recommended hydraulic fluid if necessary See Specifications on page 21 3 Check that fluid level in the batteries is correct See Battery Maintenance on page 17 4 Verify that the batteries are charged 5 Check that the A C extension cord has been disconnected from the charger plug 6 Check that all guardrails are properly in place and secured 7 Inspect the machine thoroughly f
37. DISCONNECT LINE 502599 000 HARNESS CHARGER DISCONNECT LINE 502601 000 LINE CONTACTOR 5 LINE CONTACTOR 3 502602 000 LINE CONTACTOR 2 MOTOR CONT B 502604 000 LINE CONTACTOR 6 PUMP MOTOR 27 502492 000 MOTOR CONTROLLER 28 504536 000 PUMP MOTOR 10 11 12 13 14 15 18 19 20 21 22 23 Em 2 4 6 24 25 26 Sec6 21 ILLUSTRAITED PARTS LIST 5 22 HYDRAULIC ASSEMBLY Item Part wo 1 509420 000 HYDRAULIC HOSE BLOCK SERIES PARA BLOCK 509421 000 HYDRAULIC HOSE BLOCK D2 SERIES PARA D2 1 kin 509417 000 HYDRAULIC HOSE BLOCK BRAKE TEE 509423 000 HYDRAULIC HOSE BLOCK STEERING CYLINDER 2 ms 509425 000 HYDRAULIC HOSE BLOCK TEE O fic 509427 000 HYDRAULIC HOSE TEE RHS POTHOLE CYL Ett essen mau es eco 12 509426 000 HYDRAULIC HOSE TEE LHS POTHOLE CYL 14 509429 000 HYDRAULIC HOSE PUMP BLOCK PRESSURE 1 16 509431 000 HYDRAULIC HOSE MANIFOLD LIFT CYLINDER 1 18 504128 001 HYDRAULIC TANK 1 20 504536 000 PUMP ASSEMBLY 1 22 504129 001 HYDRAULIC CYLINDER LIFT 1 HYDRAULIC CYLINDER 5 24 504151 000 HYDRAULIC BLOCK SERIES PARALLEL 1 5 23 ILLUSTRAITED PARTS LIST ILLUSTRAITED PARTS List O
38. E ROUTE CABLE FROM EMERGENCY LOWERING VALVE ALONG SCISSOR ARM THRU CABLE ACCESS HULE TO REAR OF 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 BOTTOM EACH SIDE ILLUSTRAITED PARTS LIST CHassis AsssEMBLY FRONT It Part Description Part Description 505042 000 BEARING 8 504153 001 PIN 5 8 em 2 504144 001 BEARING 9 066159 001 L H STEERING LINK 1 10 504150 000 BEARING 2 Time 5 1 6 1 7 1 114055 002 MOTOR HYDRAULIC 11 114057 000 L H STEERING ANGLE IRE 12 114058 000 R H STEERING ANGLE 066869 000 CHASSIS 13 066313 001 BELL CRANK 502171 000 FRONT 14 066 07 001 STEERING LINK USE ONE OR MORE THRUST BEARINGS BETWEEN STEERING PIN AND CHASSIS FOR 1 16 TO 3 16 CLEARANCE UNTIL IT CONTACTS SPINDLE SHAFT BACK 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 WITH END BORE BOTTOM OF BORE Sec6 4 CHassis AsssEMBLY REAR Ite Part Description Qty 504151 000 VALVE ASSEMBLY 1 504154 000 PIN BELL CRANK 503673 000 BUSH 12DU08 ILLUSTRAITED PA
39. ED PARTS LIST Main Deck ASSEMBLY Item Part Description Qty 2 066480 000 GATE Part 05300 010 Description SWING BAR TORSION SPRING 2 000 Gr 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 5 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 502131 000 WEAR PAD Part Description 16 505300 008 1 18 003570 005 PULL PIN WITH KEY RING 1 504138 000 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 502132 001 PLATFORM ROLLER Sec6 13 ILLUSTRAITED PARTS LIST ConTRoL MODULE ASSEMBLY Item Part Description 504128 001 HYDRAULIC 062791 002 502588 000 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 6 510
40. Figure 2 S2633 3 SPECIAL LIMITATIONS 3 SPECIAL LIMITATIONS A DANGER A Travel with the platform raised is limited to creep speed range Elevating the Work Platform is limited to firm level surfaces ONLY A DANGER A The elevating function shall ONLY be used when the work platform is level and on a firm surface The work platform is NOT intended to be driven over uneven rough or soft terrain PLATFORM CAPACITY The maximum capacity for the MACHINE including occupants is determined by model and options and is listed in Specifications on page 20 A DANGER A DO NOT exceed the maximum platform capacity or the platform occupancy limits for this machine MANUAL FORCE Manual force is the force applied by the occupants to objects such as walls or other structures outside the work platform The maximum allowable manual force is limited to 200 N 45 Ibs of force per preson with a maximum of 400 N 90 Ibs for two or more occupants A DANGER A DO NOT exceed the maximum amount of manual force for this machine LIFT OVERLOAD ALARM All models include a feature that alerts the operator when the platform load is exceeded If the alarm sounds during the lift function lower the platform and reduce the platform load A DANGER A NEVER operate the machine with a platform load greater than the rated capacity and never in wind conditions that exceed the maximum allowable for this machine
41. Gives helpful information Pagei 2 WORKSHOP PROCEDURES All information contained in this manual is based on the latest product information available at the time of printing We reserve the right to make changes at any time without notice No part of this publication may be stored in retrieval system or transmitted in any form by any means electronic mechanical photocopying recording or otherwise without the prior written permission of the publisher This includes text figures and tables Detailed descriptions of standard workshop procedures safety principles and service operations are not included Please note that this manual does contain warnings and cautions against some specific service methods which could cause personal injury or could damage a machine or make it unsafe Please understand that these warnings cannot cover conceivable ways which service whether or not recommended by Snorkel might be done or of the possible hazardous consequences of each conceivable way nor could Snorkel investigate all such ways Anyone using service procedures or tools whether or not recommended by Snorkel must satisfy themselves thoroughly that neither personal safety nor machine safety will be jeopardized Page ii Section 1 INTRODUCTION 1 1 INTRODUCTION PURPOSE The purpose of this service and parts manual is to provide instructions and illustrations for the opera
42. RK PLATFORM IS NOT INSULATEDI For this reason it is imperative to keep safe distance from live parts of electrical equipment Exceeding the specified permissible maximum load is prohibited See Platform Capacity on page 5 for details The use and operation of the aerial work platform as a lifting tool or a crane is prohibited This machine is designed for INDOOR USE ONLY DISTRIBUTE all platform loads evenly on the platform NEVER operate the machine without first surveying the work area for surface hazards Holes drop offs bumps curbs and debris etc should ALWAYS be AVOIDED OPERATE machine only on surfaces capable of supporting wheel loads IN CASE OF EMERGENCY push Emergency Stop Switch to deactivate all powered functions IF ALARM SOUNDS while platform is elevated STOP carefully lower platform Move machine to a firm level surface Climbing up the railing of the platform standing on or stepping from the platform onto buildings steel or prefab concrete structures etc is prohibited Dismantling the entry gate or other railing components is prohibited Always make certain that the entry gate is closed and securely locked It is prohibited to keep the entry gate in an open position when the platform is raised To extend the height or the range by placing of ladders scaffolds or similar devices on the platform is prohibited NEVER perform service on machine while platform is elevated without blocking elevating assembly
43. RTS LIST Part Description Qty 502152 000 COTTER PIN 066865 100 COUNTERWEIGHT R BULKHD 1 m 15 16 062642 001 BEARING GARLOCK 1000012 17 6 18 19 20 21 503673 000 BUSH 120006 510668 000 22 504155 001 STEERING LINK SLIDE PAD 504157 000 CUP BEARING 502171 003 HUB REAR 066866 000 COUNTERWEIGHT CASTING 1 502097 000 FLAT WASHER 2 23 503755 000 CASTLE NUT 4 24 25 26 27 28 BEARING With Seal 28 29 30 31 066862 000 LADDER MOUNTING BRACKET 066307 001 WELDMENT LADDER 510672 000 OLITE BUSH small Sec6 5 ILLUSTRAITED PARTS LIST CHASSIS Scissor amp Deck AsssEMBLY Item Part Description Qty ltem 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 2 6 066189 000 WEAR PAD 1 4 13 504186 003 MOUNTING 2 066189 004 WEAR PAD 1 8 NOTES N LOCTITE ITEM 11 BEARING ITEM 1 CHASSIS AND PEEN 4 PLACES e 90 OUTSIDE EDGE OF BORE IN ITEM 1 TYP 2 PLUS x USE WEAR PAD COMBINATION AS REQUIRED SECURE AND ALIGN FRONT END DF SCISSOR STACK Sec6 6 5 5
44. VERLOAD SSEMBLY Part Description 2 504561 002 MOUNTING PLATE CIRCUIT BOARD 1 CIRCUIT BOARD 4 504560 000 PRESSURE TRANSDUCER 1 Qty 24 5 Sec6 25 DECALS Control 1 2 XN va YA Sec6 26 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 ANC 508339 000 x2 101210 000 066556 900 x2 066561 900 4 11 503724 000 2 100102 900 014222 903 014222 903 x4 502480 000 e 2 14 ee 5 58 068635 001 2 503721 000 066551 950 503723 000 5 27 067195 001 062562 951 AN 501453 000 x4 066522 900 060197 001 005221 000 ANSI DecaLs Control Module Upper Control Box Access Rear Sec6 28 ANSI DEcALs Snorkel 596295 000 x2 5 2093 508339 000 2 N Explosive gas is generated when charging 3 batteries DO NOT expose to sparks or flames 066552 000 066552 000
45. ardrails and rear guardrail as one unit Pull up on the side guardrails and raise them until all the retaining pins engage 2 Raise the rear top rail Pull up on the rear top rail until the retaining pins engage 3 Raise the platform extension guardrail Pull up on the platform extension guardrail and raise it until all the retaining pins engage 4 Hang the controller on the platform extension guardrail Page 2 11 7 OPERATION PARKING RELEASE Perform the following only when the machine will not operate under its own power and it is necessary to move the machine or when winching onto a transport vehicle see Transporting the Machine WARNING NEVER winch or move the machine faster than 0 3 m sec 1 ft sec NEVER operate the machine with the parking released Serious injury or damage could result DO NOT release the parking brakes if the machine is slope The parking brakes are integral to the drive motors Each drive motor has two brake release screws Release and engage the parking brakes one wheel at a time Turn the brake release screws in stages turn at a time to prevent possible binding of the brake mechanism Figure 7 Parking Brake Release RELEASE THE PARKING BRAKE The front wheel motors each have two brake release nuts IMPORTANT Turn the nuts alternately in 2 turn increments to insure uniform adjustment an
46. 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 Check 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 sele
47. ctive of the work platform is to provide a quickly deployable self propelled variable height work platform to elevate personnel and materials to overhead work areas SPECIAL LIMITATIONS Travel with the platform raised is limited to a creep speed range Elevating of the work platform is limited to firm level surfaces only ADANGERA The elevating function shall ONLY be used when the work platform is level and on a firm surface The work platform is NOT intended to be driven over uneven rough or soft terrain when elevated Page 1 2 WARNING All personnel shall carefully read understand and follow all safety rules and operating instructions before operating or performing maintenance on any UpRight Powered Access work platform Safety Rules Electrocution Hazard Tip Over Hazard Collision Hazard Fall Hazard THIS MACHINE IS NOT NEVER operate the boom or drive NEVER position the machine NEVER climb stand or sit on the INSULATED with the platform elevated unless without first checking for overhead platform guardrails or midrail on firm level surface obstructions or other hazards USE OF THE AERIAL WORK PLATFORM This aerial work platform is intended to lift persons and his tools as well as the material used for the job It is designed for repair and assembly jobs and assignments at overhead workplaces ceilings cranes buildings etc All other uses of the aerial work platform are prohibited THIS AERIAL WO
48. ctor buttons are depressed Ensure that 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 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 harness test points 4 If no ECU output is present replace the ECU 5 If 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 Platfor
49. d 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 scissor brace is supporting the platform SCISSOR BRACE STORAGE on Weldment 1 Using the Chassis Controls gradually elevate when n the platform until the scissor brace is clear Blocking Position 2 Rotate the scissor brace outward and upward over its mounting 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 Page 2 15 9 MAINTENANCE LEVEL SENSOR AWARNINGA Never perform service while the platform is elevated without first blocking the elevating assembly DO NOT stand in the elevating assembly area while deploying or storing the brace The Level Sensor 15 located on the chassis between the scissor sections and is covered with protective metal box Figure 10 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 HYDRAULIC FLUID The hydraulic fluid reservoir is located in the cont Figure 12 Hydraulic Fluid Reservoir and Dipstick TT Agnes NOTE Never add fluid if the platform is elevated CHECK HYDRAULIC FLUID 1 Make sure that the platform is fully lowered 2 Open the chassis door
50. d prevent binding 1 Chock the rear wheels to prevent the machine from rolling 2 Using a 5mm Allen Key remove the two G1 8 plugs from the motor body turning counter clockwise 3 Using a 5mm Allen Key turn the inner G1 8 plug as far as possible in a clockwise direction 4 The brake is released Motor Mount 3 Brake Release Nut 2 Drive Motor 4 Wheel CAUTION avoid confusion the outer plugs should ENGAGE THE PARKING BRAKE 1 Chock the rear wheels to prevent the machine from rolling 2 Using a 5mm Allen Key turn the inner G1 8 plug as far as possible in the counter clockwise direction 3 Fitthe two outer G1 8 plugs then using the 5mm Allen Key screw clockwise until tight AFTER USE EACH DAY 1 Ensure that the platform is fully lowered 2 Park the machine on a firm level surface preferably under cover secure against vandals children and unauthorized operation 3 Turn the Chassis Key Switch to OFF and remove the key to prevent unauthorized operation Page 2 12 8 TRANSPORTNG THE 8 TRANSPORTING THE MACHINE Always use a transport vehicle when moving a machine to a work site Towing the machine over long distances will damage the machine and void the warranty LIFTING BY CRANE Figure 8 Secure Crane St
51. dder 1 Check that the route is clear of surface hazards such as holes drop offs bumps curbs or debris Check that the route is level and is capable of supporting the wheel loads Check clearances above below and to the sides of platform Select DRIVE mode Engage the Interlock Switch and move the Control Handle to FORWARD or REVERSE to travel in the desired direction The speed of the machine will vary depending on how far from centre the Control Handle is moved If the machine is not level the level sensor alarm will sound and the machine will not lift or drive If the level sensor alarm sounds the platform must be lowered and the machine moved to a firm level surface before attempting to elevate the platform is in contact with the machine Engage the Interlock Switch and pull back on the Control Handle to lower the platform safety cutout height Inspect around the machine to ensure no one is in contact with the machine After a four second time delay lower the platform as in step 2 Pothole Protection Rails Lowered Figure 5 Emergency Lowering Knob 7 Emergency Open the Emergency Lowering Valve by pulling and holding agli Zu the knob To close release the knob The platform will not elevate if the Emergency Lowering Valve is open 7 GUARDRAILS Figure 6 Guardrails The guardrails may be lowered for the Platform Extension purpose of passing through a standard Platfo
52. fusion When troubleshooting ensure that the work platform 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 Do a full function test from both the platform and chassis controls and note all func tions that are not operating correctly 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 w
53. he replaceable assemblies and parts of the 52633 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 Deck ASSEMBLY SCISSOR SSEMBLY Deck ASSEMBLY CoNTROL MODULE ASSEMBLY Power MopuLE ASSEMBLY HYDRAULIC MANIFOLD CYLINDER ASSEMBLYS Lower CONTROL Box ASSEMBLY UPPER CONTROL Box ASSEMBLY ELECTRICAL SSEMBLY HYDRAULIC ASSEMBLY PLATFORM CE Decal ANSI DECAL Kir PAGE 6 14 6 15 6 16 6 19 6 20 6 22 6 24 6 26 6 28 Sec6 1 ILLUSTRAITED PARTS LIST Bas c AssEMBLY Description Part Description 3 POWER MODULE 2 066310 026 CONTROL MODULE 4 501425 000 SWITCH PROXIMITY 19 20 21 22 23 24 25 26 27 28 9 30 504348 000 LOWER CONTROL ASSY 1 WIRE HARNESS ASSY J3 066623 020 LIFT OVERLOAD ALARM LOWERING CABLE 6 505566 001 LEVEL SENSOR CONTROLLER ASSEMBLY 500996 1 00996 000 HARNESS ASSY 9 501074 000 BATTERY 6 V CABLE ASSY X 14 11 066250 026 PLATFORM GUARDRAIL ASSY UC E 13 066763 000 SHIM 16GA CEST 15 066713 001 WELDMENT DOOR HINGE 17 504033 000 ALARM COVER WELD 029601 039 2 18 502164 000 CONTROLLER GUIDE WIDE REF CABLE ACCESS HOL
54. heck welds for cracks Daily 27 Change Filter Check component mounting for gm torque Hydraulic r crest torque m System Check hose connections Check hoses for exterior wear Perform pre operation Daily Drive Motors Check for operation and leaks Specto Emergency Check procedure for a Down Emergency Down Entire Unit 30d Sene fasteners for Wipe clean torque 6m Hydraulic Check for leaks at mating Check for corrosion remove Pump em Check mounting bolts for proper Check for peeling missing or torque M Labels unreadable labels amp replace Dally Controller Check condition amp operation Wheels Check for loose components Daily cri fasteners for proper Oil pivot pins 30d Platform va welds for cracks Oil king pins 30d Deck amp Rails Check condition of deck ui Check steering cylinder for 30d eering leaks Checkentry way closure System Check hardware 8 fittings for en proper torque Check Wheel Yoke Securing Bolt and Nut 30d NOTE Use 150 46 during summer and ISO 32 during winter Page 3 4 Section 3 Service Repair 3 4 PARTS LOCATION JO Q oo sas oll WIN 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Entry Gate Deck Lock Assembl
55. ial 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 discard Cleaning and Inspection Section 3 Service 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 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
56. ies 23 800 7 8 9 n 7 E n 41550 7 8 14 32 480 1 8 54540 1 12 42 270 Page3 20 Table Torque Specifications for Metric Fasteners U S Customary Units 8 8 10 9 12 9 ade 8 8 10 9 12 3 Clamp Tightening Torque Clamp Tightening Torque Clamp Tightening Torque Size Load K 15 K 20 Load K 15 K 20 Load K 15 K 20 3 823 14 6 19 5 3 5 1109 229 30 5 4 1436 33 9 45 2 5 1 389 41 0 19 5 1 987 587 19 5 2 322 68 6 91 2 6 1 966 697 283 2 813 1000 283 3 287 116 8 155 8 7 2 826 1168 372 4 044 1673 372 4 727 1956 2602 8 3 579 141 188 5 122 201 269 5 986 23 6 31 4 10 11 742 279 372 8 117 3959 53 3 9 486 467 62 3 12 8 244 487 64 9 11 797 69 7 922 13 787 81 1 108 4 14 11 246 774 103 3 16 093 110 6 147 5 18 808 129 1 172 6 16 15 883 1254 166 7 21 971 173 3 230 9 25 677 2021 269 2 18 19 424 171 9 2294 26 869 238 2 317 2 31 401 278 1 371 0 20 2 304 2434 325 3 34 286 337 8 449 9 40 070 394 6 525 9 22 30 653 331 9 4425 42 403 458 8
57. ith 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 Remove 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
58. ls must be returned to the straight ahead position by operating the Steering Switch Page 2 9 7 OPERATION 2 10 ELEVATING PLATFORM gt Locate firm level surface Select LIFT mode While engaging the Interlock Switch push the Control Handle FORWARD If the machine is not level the level sensor alarm will sound and the machine will not lift or drive If the level sensor alarm sounds the platform must be lowered and the machine moved to firm level surface before attempting to elevate the platform NOTE The Pothole Support Rails will deploy automatically as the platform elevates and will remain deployed when traveling in the Elevated position refer fig 5 They will automatically retract when the platform has been lowered completely and machine is about to be driven refer fig 2 amp 4 TRAVEL WITH WORK PLATFORM ELEVATED NOTE The machine will travel at reduced speed when the platform is elevated ak gt LOWERING THE PLATFORM 1 Select LIFT mode 2 Check around the base of the platform to ensure that no one 3 The platform will stop when it reaches the pre determined EMERGENCY LOWERING AWARNINGA If the platform should fail to lower NEVER climb down the scissor assembly second operative should operate the Emergency Lowering Valve Knob while keeping clear of the scissor assembly The Emergency Lowering Valve Knob is located at the rear of the machine behind the la
59. m Figure 3 13 Hydraulic Manifold with Valves minutes to warm the oil Remove the cap or loosen the locknut on 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 Lo RELIEF VALVE Release the Chassis Lift Switch cROSSUNEREUE Aoa S STEERING 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 Iv 10 11 12 13 Operate work platform for 10 15 minutes to bring the hydraulic 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 the control lever to REVERSE to drive the wheels 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
60. m 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 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 x x gt lt x x x x x x gt x x x x x x Platform Emergency Stop Switch x x lt x x x x x x x x x x x x x x Interlock Switch PQ Control Handle Height Limit Switch Platform Steering Switch x x x x x x gt x x lt x x x
61. m h 0 to 0 50 mph Motor 4 Volt 4 Horse Power D ectric Motor Harp Battery Charger 0 220 Hydraulic Reservoir Capacity 4 US Gallons ydraulic Normal Temperature 0 C gt 32 F ISO 32 Low Temperature 0 C lt 32 F ISO 32 Extreme Temperature 17 C lt 0 F ISO 15 One Single Stage Lift Cylinder Speed 42 sec Lower 40 sec Proportional Control Handle with Interlock Switch Rotary Lift Drive Switch and Red Control System Emergency Stop Switch 81 mm 15 in Diameter Solid Rubber non marking urning Radius 03 8 in Inside TIER Sound Power Level 69dBA Wind speed for this machine is Beaufort wind force 4 refer page 7 Specifications are subject to change without notice Hot weather or heavy use may affect performance Refer to the Service Manual for complete parts and service information Meets or exceeds all applicable CE and machinery directive requirements MD98 37 EC Page 19 ANSI DEcALs Failure to read understand and obey the following safety rules will cause death or serious injury 23 Collision Hazard Impact from decending platform Snorkel _ TIP OVER HAZARDS DON levated on 596295 000 x2 2 5 066556 000 ELECTROCUTION HAZARD FALL HAZARD DO NOT operat tof power 508339 000 2 TIP OVER HAZARD Explosive gas is
62. n consists of periodic visual and operational checks along with periodic minor adjustments that assure proper performance Daily inspection will prevent abnormal wear and prolong the life of all systems Perform the inspection and maintenance items daily 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 perform maintenance while the platform is elevated DAILY PREVENTATIVE MAINTENANCE CHECK LIST The daily preventative maintenance checklist has been designed for machine service and maintenance Please photocopy the Daily Preventative Maintenance Checklist and use the checklist when inspecting the machine MAINTENANCE TABLE KEY Y Yes Acceptable N No Not Acceptable R Repaired Acceptable Serviced By Date Owner Model No Serial No COMPONENT Battery INSPECTION OR SERVICES Check electrolyte level Check battery cable condition Chassis Check hoses for pinch or rubbing points Check welds for cracks Control Cable Check the exterior of the cable for pinching binding or wear Controller Check switch operation Drive Motors Check for operation and leaks Elevating Assembly Inspect for structural cracks
63. or cracked welds loose or missing hardware hydraulic leaks damaged cables or hoses loose wire connections and wheel bolts Note 52633 operates in Maximum Wind conditions equivalent to Beaufort 4 TABLE OF WIND SPEED VELOCITY BEAUFORT CONDITIONS 3 7 Beaufort Average Wind Wind Velocity Description Conditions Number Speed km h m sec 3 17 4 5 Gentle Breeze Leaves amp Twigs in constant motion flags wave 4 24 6 7 Moderate Dust 4 Loose paper raise Breeze Small Branches begin to sway 5 35 9 7 Fresh Breeze Small Trees Sway Waves apparent in ponds 6 44 12 5 Strong Breeze Large Branches in motion Whistling Heard in overhead wires Umbrella use 15 difficult 7 56 15 5 Near Gale Whole trees in motion Effort to walk against the wind If in doubt always check wind conditions before machine use Note that wind speeds vary considerable at higher levels Page 2 7 6 SYSTEM INSPECTION 6 SYSTEM FUNCTION INSPECTION Page 2 8 NOTE Refer to Figure 3 for the locations of various controls and indicators AWARNINGA STAND CLEAR of the work platform while performing the following checks Before operating the work platform survey the work area for surface hazards such as holes drop offs bumps and debris Check in ALL directions including above the work platform for obstructions and electrical conductors Protect the control console cable from possible damage while
64. porting 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 the metal parts cleaning solvent blow 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 onto the shaft 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 OQ Lubricate and install new wiper 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 mater
65. raps DANGER 4 See specifications for the weight of the machine and be certain that the crane is of adequate capacity to lift the machine Secure straps to chassis tie down lifting points only see Figure 8 MOVING FORKLIFT Fork lifting is for transport only See specifications for the weight of the machine and be certain that the forklift is of adequate capacity to lift the machine Forklift from the rear of the machine using the forklift pockets provided If necessary the machine may be forklifted from the side by lifting under the Chassis Modules see Figure 9 Figure 9 Tie Down and Lift Points Rear Tie Down Lift Point Rear Tie Down Lift Point Forklift Pockets Forklift Here REAR Front Tie Down Lift Point Page 2 13 8 TRANSPORTING THE DRIVING OR WINCHING ONTO TRUCK OR TRAILER AWARNINGA Never winch faster than 0 3 m sec 1 ft sec Never operate the machine with the parking brakes released Serious injury or damage could result 1 Loading the machine onto the truck or trailer A To Drive the machine onto the transport vehicle Turn the Lift Drive Switch to DRIVE LOW hi torque mode and drive the machine up the ramp and into transport position Set the wheels straight and turn off the machine Chock the wheels B To Winch
66. re Operation Safety 7 6 System Function Inspection 8 6 Operation o Rhe 9 PlattortmiEXIenslOF x tesisa da ur 9 Travel With the Platform 9 SICH ERR PHIL ewe 9 Elevating th Platform cre 10 Travel with Work Platform Elevated 2 10 Lowering the Platform mz eb Rene pri 10 Emergency Lowering insieme RR qe RECEN e a 10 Guardralls nee De Es 11 Lowering 11 Raising Procedure i seca be RR RR E aca 11 Parking Brake 2 12 Release the Parking 12 Engage the Parking Brake enu nei Sade ead PER de 12 After Use Each Day Rua 12 8 Transporting the 13 Lifting By 23 sme ERES EH PER PER abre eru
67. rm Controls doorway Platform Extension Retaining Pins gt Side rail Retaining Pins Guardrails must be returned to proper Retaining Pins position before using the machine AWARNINGA DO NOT use the machine if all guardrails are not properly in place and secured LOWERING PROCEDURE 1 Ensure that the platform extension is fully retracted and the deck lock pin is engaged see Platform Extension on page 9 2 Place the Platform Controls on the deck of the platform extension 3 Lower the platform extension guardrail x E S 6 2 Pull to retract retaining pins Retaining Pin Detail ES f b As the retaining pin is pulled the rail will aL drop slightly and hold the pin in the EN retracted position c Hold the mid rail with one hand as you retract the final retaining pin Retracted CAUTION The guardrail could drop suddenly when the final retaining pin is retracted Keep hands away the slide tubes to prevent injury 4 Push down on the platform extension guardrail to lower it completely e The retaining pins will remain in the retracted position 4 Lower the side guardrails and rear guardrail as a single unit Repeat steps 3a through 3c 5 Lower the rear top rail Pullthe two retaining pins and lower the rear top rail completely RAISING PROCEDURE 1 Raise the side gu
68. rm service on work platform in elevating assembly area while platform 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 3 3 Installation RR RU een EROGO REG 3 3 Removal de e Eod le GENE AO VERRE a dde 3 3 3 2 Preventative 3 3 3 3 Preventative Maintenance Check 3 4 3 4 Parts Location coi a an area aaa 3 5 3 5 General 3 6 3 6 Batteries ci AS 3 6 Battery Maintenance 3 7 Battery 3 7 3 7 Safety Ancillary 3 8 Proximity re 3 8 THE SENSOR cT 3 8 Emergency Lowering sers oran ETER E aputa ee een ml 3 8 3 8 Hydraulics riro eee ae eee ed W eee ee 3 9 Hydraulic Oil Tank And
69. rsons obstructions holes and drop offs bumps and debris is level and is capable of supporting the wheel loads Mount the platform and properly close the entrance Mount the platform and select DRIVE mode NOTE Use both HI and LOW drive if applicable when performing the following step 16 17 18 19 20 While engaging the Interlock Switch move the Control Handle to FORWARD then REVERSE to check for speed control Push the Steering Switch RIGHT then LEFT to check for steering control Select LIFT mode Grasp the Control Handle engaging the Interlock Switch and push it forward to check platform lift controls Raise the platform to full elevation Pull back on the Control Handle The platform should descend and the audible lowering alarm should sound Push the Platform Emergency Stop Switch to check for proper operation All machine functions should be disabled Pull out the Platform Emergency Stop Switch to resume 7 7 OPERATION Before operating the work platform ensure that Pre Operation Safety Inspection and System Function Inspection have been completed and that any deficiencies have been corrected NOTE Never operate a damaged or malfunctioning machine The operator must be thoroughly trained on this machine PLATFORM EXTENSION Figure 4 Platform Extension 1 Mount the platform and properly close and secure the entrance 2 Depress the foot lever located atthe rear
70. ssembly 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 3 3 PREVENTATIVE CHECK LIST Section 3 Service amp Repair PREVENTATIVE MAINTENANCE KEY PREVENTATIVE MAINTENANCE 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 Y Yes Acceptable N No Not Acceptable Serviced By R Repaired Acceptable Service Interval COMPONENT INSPECTION OR SERVICES INTERVAL Y N COMPONENT INSPECTION OR SERVICES INTERVAL Y N R 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 amp Assembly Lubricate 30d System operation Check specific gravity Clean exterior Check cables for pinch or Daily Clean terminals rubbing points Check oil level Chassis C
71. tery separately using a 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 If switches are ON a spark will occur at the ground terminal which could cause an explosion if hydrogen gas or fuel vapors are present 2 Open the power module 3 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 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 WIN 508244 103 Page 3 7 Safety Equipment Section 3 Service amp Repair 3 7 SAFETY ANCILLARY EQUIPMENT PROXIMITY SWITCH Figure 3 6 Proximity Switch The Proximity Switch cuts power to the High Speed Drive when the
72. the machine onto the transport vehicle Drive the machine up to the ramp Attach the winch cable to the tie down lifting points Release the parking brakes refer to Parking Brake Release on page 12 Winch the machine into transport position Chock the wheels Re engage the parking brakes 2 Secure the machine to the transport vehicle with chains or straps of adequate load capacity attached to the chassis tie down lifting points refer to Figure 8 A CAUTIONA Overtightening chains or straps attached to the Tie Down points may result in damage to the machine Page 2 14 9 9 MAINTENANCE AWARNINGA Never perform service while the platform is elevated without first blocking the elevating assembly DO NOT stand in the elevating assembly area while deploying or storing the brace BLOCKING THE ELEVATING ASSEMBLY Figure 10 Scissor Brace SCISSOR BRACE INSTALLATION 1 Park the machine on a firm level surface 2 Pull Chassis Emergency Stop Switch to the 2 ON position 3 Pull Platform Emergency Stop Switch to the ON ition Rotate B postion A ee 4 Turn and hold the Chassis Key Switch to Ny Block CHASSIS Counterclockwise to Store 5 Push the Chassis Lift Lower Switch to LIFT to elevate the platform until the scissor brace can be rotated to the vertical position 6 From rear of the machine lift the scissor brace from its stowed position Rotate upward and outwar
73. tion and maintenance of this work platform manufactured by Snorkel SCOPE The manual includes procedures for proper operation maintenance adjustment and repair of this product as well as recommended maintenance schedules and troubleshooting 1 2 GENERAL DESCRIPTION The work platform consists of the platform controller elevating assembly power module control module and chassis DO NOT use the work platform without guardrails properly assembled and in place Figure 1 1 52633 PLATFORM 1 Platform 2 Platform Controller The platform has a reinforced steel Assembly floor 1 1m 43 5 inch high guardrails 3 Chassis Controls with midrail 152 mm 6 inch 4 Chassis toeboards and an entry chain at the Flevating Assembly rear of the platform The guardrails can be folded down for access through doors or for shipment PLATFORM CONTROLLER The platform controller contains the controls to operate the machine It is located at the front of the platform cage A complete explanation of control functions can be found in Section 2 Page 1 1 Introduction 1 2 General Description ELEVATING ASSEMBLY The platform is raised and lowered by the elevating assembly The hydraulic pump driven by the engine powers the cylinder Solenoid operated valves control raising and lowering CHASSIS The chassis is a structural frame that supports all the components of the S2633 work platform PURPOSE OF EQUIPMENT The obje
74. tter 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 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 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 9
75. ve 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 lower 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 bolt until 6mm from bolt 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 the 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 Ibs Install a new cotter pin DO NOT back off the nut to install co
76. vious 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 ABC Install the cable bracket Connect the emergency lowering valve 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 Y 508244 103 Page 3 15 Drive Motors 3 10 DRIVE 5 REMOVAL 1 2 3 4 Section 3 Service amp Repair Use a 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 remo
77. witch 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 platform 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 a
78. y 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 Depression 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 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 2 Clean the grease fittings and surrounding area NR 3 Using multipurpose grease in a grease gun pump the grease into the fitting until grease just begins to N d

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