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danger - Snorkel

1. K2 K3 K4 na 87 87 a a Aa 85 86 85 86 85 86 30 7 30 30 3C a F T2 5 A T3 a 3 N A T m V D4 m m i l a 2 El 2 GROUND STUD 3 A D6 8 3 4 4 AD MO 5 21A 2 6 6 en Al 7 7 R5 9 9 ZN DI 10 10 11 11 12 12 l 13 13 14 14 3H R GROUND STUD LIFT DOWN SWITCH UPPER LOWER SW22 8 SELECTOR SWITCH 5 SW1 3 LIFT LID LOWER CONTROL JUMPER 3 103B 3 UPPER 102A 2 4 b p DOWN CD LOWER 3G 118 m HOURMETER HM A Figure 8 9 Lower Control Box right S1930 0361270 8 11 Chapter 8 Troubleshooting Lower Control
2. 106 207 101A TE 5 1 P Yo 2 Z 3 D3 011 E 4 v 5 6 D13 7 W D5 9 19 a AT a 8 20A 222 11 2 1 122 d D8 3P 12 z 121 13 o 1 12 c 103 o 2 1 114 14 a o 3 10 2 101 o 4 19 o 5 8 18A o 6 7 o 17A J1 Lower Box Stack Harness Connector 12 pin 1557 AT gt 113 113A FUSE FU2 Figure 8 8 Lower Control Box left 116 2 D E STOP ES1 8 10 S1930 0361270 Chapter 8 Troubleshooting
3. 6 va A po D jang TEL NG 2 Bi L Cl Fle A o du 8 A AN b en O O T HE Ho EE A Et ou O O C O g Front SHEARING HAZARD CRUSHING HAZARD Death or serious injury might result from having body parts sheared or crushed as the platform descends Keep away from closing scissor arms and keep out from under the platform as the platform comes down Chapter 1 Safety ADANGER Chassis Top View TIPOVER HAZARD DEATH OR SERIOUS INJURY MAY RESULT IF MACHINE TIPS OVER Trays must be closed when platform is elevated MODEL NUMBER OF MANUFACTURE MN OF MANUFACTURE MAXIMUM MACHINE WEIGHT ENGINE POWERED MODELS MAXIMUM ALLOWABLE MANUAL FORCE SIDE PULL PLATFORM SIZE MAXIMUM PLATFORM HEIGHT RATED NUMBER OF OCCUPANTS DO NOT ALTER OR DISABLE LIMIT SWITCHES SAFETY SWITCHES OR INTERLOCKS Snorkel HM 451986 SERIAL NUMBER SLOPE SENSOR ALARM SETTING MAXIMUM WHEEL LOAD DRIVE MOTORS BATTERY POWERED MODELS ONLY BATTERIES MAXIMUM ALLOWABLE WIND SPEED MAXIMUM PLATFORM
4. Call Oe Q 4 Front Wheels steer Hydraulic Tray V Pothole Protector Skid Chassis Platform Ladder Lower Controls right side Battery Tray left side The serial number placard is located in side the hydraulic tray at the front end of the chassis 91930 0361270 Chapter 2 Specifications S1930 Scissor Lift General Specifications Maximum platform height 19 5 8 m Maximum working height 25 7 6 m Weight GVW approximate 3 040 Ib 1 379 kg Stowed width 30 76 2 cm Stowed length 74 188 0 cm or 66 167 6 cm minus platform ladder Stowed height 79 200 6 cm Rated work load Main deck 500 lb 227 kg or two people Deck extension 250 Ib 113 kg or one person Platform size Main deck 29 X 61 5 74 cm X 156 cm Deck extension 24 X 36 61 0 cm X 91 4 cm Guardrail height 39 1 0 m Toeboard height 6 15 2 cm Maximum number of occupants 2 people Gradeability 20 Turning radius Inside 7 5 19 1 cm maximum 5 12 7 cm minimum Outside 65 5 166 4 cm maximum 64 5 163 8 cm minimum Tire size 4 X 12 10 2 cm X 30 5 cm Drive Lift Level Sensor Interlock 2 side to
5. Maintenance Manual February 2001 a DANGER The aerial platform is not electrically insulated Death or serious injury can result from contact with or inadequate clearance from an energized conductor Do not go closer than the minimum safe approach distance as defined by the Mini mum Safe Approach Distance section in Chapter 1 Safety Regard all conductors as energized Allow for electrical wire sag and aerial platform sway If the platform scissors structure or any part of the aerial platform contacts a high voltage electrical conductor the entire machine can become electrically charged If that happens remain on the machine and do not contact any other structure or object This includes the ground adjacent buildings poles and any other objects that are not part of the aerial platform Such contact could make your body a conductor to the other object creating an electrical shock hazard resulting in death or serious injury If an aerial platform is in contact with an energized conductor the platform operator must warn ground personnel in the vicinity to stay away Their bodies can conduct electricity cre ating an electrical shock hazard resulting in death or serious injury Do not approach or leave the aerial platform until the electricity has been turned off Do not attempt to operate the lower controls when the platform scissors structure or any part of the aerial platform is in contac
6. Figure 3 3 Pothole Protector Skid lowered 1 Park the machine on a flat level slab 2 Remove all persons and material from platform 3 With platform fully lowered and swing out trays closed check ground clearance under pothole pro tector skids Clearance should be 2 1 2 or more on both sides of the unit skids in retracted position 91930 0361270 4 Using lower controls raise the platform while watching the movement of the pothole protector skids figure 3 3 They should lower to approxi mately 3 4 clearance and lock into place when the platform floor reaches 6 feet 5 Watching the skids fully lower the platform They should raise to their original retracted position 2 1 2 clearance 6 Place a 1 1 2 thick board standard 2x4 lumber under the right side skid to prevent it from fully low ering figure 3 4 7 a s 3 s r Snorkel MI FORK LIFT T xr ki AS 1322 Figure 3 4 Pothole Interlock Test 7 Using the lower controls raise the platform while watching the skids When the board prevents the skid from fully lowering the interlock system should halt the platform at 6 feet or less and sound an alarm Any attempts to further raise the platform should reactivate the alarm and the platform should not move 8 Repeat steps 6 and 7 for the left side Level Sensor Interlock Test Level Sensor 4 y Figure 3 5 Level Sensor The level sensor inter
7. Figure 8 36 Location B 91930 0361270 Chapter 8 Troubleshooting suono uuo2 3148 A1aneg e g oinbi4 A 202 SM UM pouBije aq O 117 TA tn Gun ke JSNW polp JO OPIS OpPoUJE J A 9 eL s 8 21 91930 0361270 Appendix A Glossary aerial platform a mobile device that has an adjustable posi tion platform supported from ground level by a structure ambient air temperature the air temperature of the immediate environment ammeter an instrument for measuring the strength of an electric current in amperes annual maintenance the maintenance routine required af ter every 500 hours of operation authorized personnel personnel approved as assigned to perform specific duties at a specific location base the relevant con
8. 0361270 Chapter 8 Troubleshooting a l Re a kon 00 l l l pA a oa ao yon J n 9 s 38 Forwardvaive ground ls o m ac Reverse vane ground lsl cc c le Tap Steeriettvatve ground o x c o m ae Steer nghtvave ground cc a o o bak ar tate som e o a c o fo rit sensor ground m x r s bak chassis ground 0 l l msl 9 le Down valve ground ml x k o m v conactorgrowd l l ml x o o bak an Pressure switch ground o a G s bak am Suppression et vate ground sl p bak as Suppression right vale ground 16 cc F le 17 Forward ro valve no v a oc bp vme la oc me zo Rgmsteorvawo la c bp it zi foom a A 0 gt e e 6 l l A oc e 100 Pressure sure sr pe A CG it Tor nmoerina000 l l a e 102 Ponoepowr 00 l l A s 5 vme TOZA sas lsil me v Lowernginterupiowichpower 16 Aa io 7104 l l A T r r e rosa From pressure sen l l c s pA ie ros Fomstacksvich pA 2 yme 108 Fromioweringinteruptewicn to 8 2 yme Conroler output votage lsl O pA e me Kri ooo 0 prod oe fo pA o e s 52 e 207 Gonactorpone 00 l l A pp bp vm Fidhtivaivessuppression
9. Check voltage on wire 121 at K3 relay figure 8 9 Is it4 to 5 volts If yes go to 7 skip 6 If no check volt age on wire 110 at controller figure 8 22 Is it 4 to 5 volts If yes go to 6 If no go to Pump Motor Not Running Check ground wire of K3 relay If grounded replace relay and return to 5 If not grounded check or re place ground wires and return to 5 Check switch number 18A figure 8 14 Is it open If yes go to 8 If no inspect and or replace switch Check voltage of wire 101 Is it 3 to 4 volts If yes see Pump Motor Not Running lf no adjust or re place joystick potentiometer at upper control box figure 8 13 Reattach wire 22 to lift solenoid No Right or Left Steering 1 2 Perform steps 1 4 under No Lift or Drive From Up per Controls Check voltage on wire 19 left or 20 right at the steer solenoids figure 7 13 Chapter 7 Is it 24 volts If yes go to 3 If no inspect and or replace wire 19 or 20 or switch 19 or 20 on joystick Perform steps 7 through 12 under No Lift From Lower Controls 91930 0361270 Limit Switches and Level Sensor Scissor i Switch o LA Level Sensor N po 0 xi gt Li ez 77 5 Pothole A 3 Trigger a EEDE sac vwe an f Pothole rq h do Switc o Eu Figure 8 3 Switches and Sensor A Scissor Switch 1 Lower and stow the platform 2
10. System Relief Adjustment 1 Attach test gauge to the system test port figure 7 12 2 Remove wire 17 from the forward drive solenoid 17 figure 7 13 3 Atthe platform put the lift drive switch in drive and move the joystick forward to the full on stall posi tion System Test Port Right Steer Test Port Lift Relief Valve R 3 Figure 7 12 Test Ports and Lift Relief 4 Check the pressure at the test port It should read between 2750 and 2850 psi If yes the valve is properly set lf no go to steps 5 and 6 5 To adjust the relief setting remove the external cap from the system relief valve figure 7 13 System Relief Valve R 1 Steer Relief Valve R 2 Steer Right Solenoid 20 Steer Left Solenoid 19 Lift Solenoid 22 Forward Drive Solenoid 17 7 Reverse Drive Solenoid 18 Figure 7 13 Solenoids and Relief Valve 6 Turn the inner set screw clockwise to increase the pressure setting Counter clockwise will decrease the setting Note Be sure the joystick is in full on stall position when checking the pressure 7 Reattach wire 17 to the forward drive solenoid 17 Steer Relief Adjustment 1 Attach test gauge to the right steer test port figure 7 12 2 Atthe platform activate the steer switch on the joy stick to maximum right turn dead head 3 Check the pressure at the test port It should read 1500 psi If yes the valve is properly set lf no go to step
11. Battery terminals Clean connectors tight Battery charger Proper operation Cables and wiring harness No wear or physical damage Hydraulic system Fluid level Between Full and Add marks Hoses tubes and fittings No leaks Free wheeling valve Full closed Tires and wheels Good condition LI Parking brakes Proper cam operation Ground strap In place and securely fastened LI Lower control station Operating controls Proper operation Emergency stop Shuts off lower controls Lowering alarm Sounds when platform lowers Pothole protection interlock Proper operation LI Level sensor interlock Proper operation LI LI Emergency bleed down valve Proper operation Safety prop No damage or deformation LI Flashing light optional Proper operation Structures Weldments Welds intact no damage or deformation Slide blocks Proper operation no damage Fasteners In place and tight Upper control station Guardrail system Welds intact no damage or deformation Platform extension Proper operation Operating controls Proper operation Emergency stop Shuts off upper controls Lowering alarm Sounds when platform lowers Drive motion alarm Sounds when aerial platform moves Electrical power outlet Proper operation Battery condition indicator optional Proper operation Horn optional Sounds when activated Placards and decals In place and legible S1930 0361270 3 7 Chapter 3 Maintenance Frequent Maintenance 90 Day
12. a mechanical tip over prevention sys tem consisting of skids located along the bottom of the right and left sides which lower as the platform is raised pothole protection interlock a safety feature that sounds an alarm and automatically halts the platform raise function if the pothole protection is prevented from lowering properly prestart inspection a safety inspection routine required prior to daily operation Glossary qualified person a person who by reason of knowledge experience or training is familiar with the operation to be per formed and the hazards involved rated work load the designed carrying capacity of the aerial platform as specified by the manufacturer safety prop a heavy duty bar to be lowered and secured into position preventing the scissors from collapsing a safety feature designed to prevent injury slide block block made of low friction UHMW polyethylene attached to the scissors at the point of support for the platform and chassis They move within a channel allowing the scissors to open and extend stow to place a component such as the platform in its rest position turning radius the radius of the circle created by the wheel during a 360 turn with the steering turned to maximum inside radius the wheel closest to the center outside radius the wheel farthest from the center unrestricted rated work load the maximum designed car rying capacity of the aerial platform
13. e Wipe connections clean before opening them Plug or cap ports and lines opened for service Stored replacement hoses and components should be kept covered or plugged Check all components for cleanliness prior to installation e Wipe clean the reservoir filter housings and breather cap before opening Do not spray water on the filler breather cap This could force contaminants into the reservoir Hydraulic Pump Routine service is necessary to keep the pump running smoothly There are in addition several potential prob lems to watch out for Cavitation Cavitation occurs when inlet oil does not entirely fill the cavities that occur during the intake step of the pumping cycle The pump tries to draw a vacuum causing the cavitation which is characterized by a high pitched scream The following are potential causes e Excessive pump speed e Clogged suction filter e Excessive fluid viscosity too thick e A kink or sharp bend in hose or tubing e Excessive length of inlet hose 91930 0361270 e Low fluid level e Shutoff valve fully or partially closed To help prevent cavitation during cold temperatures al low the fluid to warm by initially operating the machine at a slow speed A CAUTION Cavitation can guickly destroy the pump At the first sign of a problem shut down the unit and re pair the problem Aeration Aeration occurs when air bubbles are forced into the fluid and carried along as it cir
14. 2 2 Hydraulic pump 7 1 7 7 Hydraulic system 3 1 3 8 7 1 J Joystick control 6 1 L Leaky fittings 7 5 Level sensor 2 2 8 4 Lift cylinder 7 10 Limit switches 8 4 Lower control box 6 1 Lubrication 3 5 M Manifold assembly 7 6 Maximum platform height 2 2 Minimum safe approach distance 1 2 N No lift from lower controls 8 3 No lift from upper controls 8 3 No lower 8 4 No steering 8 5 O Oxidation 7 2 P Placards 1 3 Platform 2 1 Platform extension 2 1 Pothole protection interlock 3 4 Pothole protector 2 1 Pump motor 7 7 Armature 7 8 Brushes 7 8 Commutator 7 8 Stator 7 8 Pump service 7 7 R Reservoir 3 2 Return filter 3 2 7 3 Rosin core solder 6 1 S Safety alerts 1 1 Safety prop 3 1 Safety rules 1 1 Index Scissor assembly 2 1 5 1 Steering left 8 4 Scissor switch 8 4 Steering right 8 4 Seal kit 4 1 7 9 7 11 Hydraulic function diagnostics 8 4 Signal words 1 1 Drive forward 8 5 Steer cylinder 7 9 Drive reverse 8 5 Lift 8 4 T Lower 8 4 Torgue specifications 7 4 Steering left 8 5 Flats method F F F T 7 4 Steering right 8 5 Troubleshooting 8 1 Tubes 7 5 General 8 1 Turning radius 2 2 Electrical function diagnostics 8 2 Incorrect Lift Speed 8 4 U Drive forward or reverse 8 3 Upper controls 2 1 6 1 6 2 8 3 8 10 High speed lift or drive from platform 8 3 High speed lift from lower controls 8 3 W Level sensor
15. A DANE A au 5 SR UF 4H 10 MAIN MANIFOLD BLOCK MB 1 FWD 2000 PSI aj UP VALVE ib 2H 9 FREE FC 1 50 GPM WHEELING per we STEERING w gt FLOW CONTROL NP N A N s 2 A 2 E RELIEF 7 TEST x 2800 PSI 1500 PSI O CROSSOVER PORT FIXED FIXED CBAL VALVES SYSTEM STEER CB 1 AND CB 2 1 RELIEF RELIEF P1 A r a 2500 PSI v REV LIFT gt RELIEF ia a VALVE C R 3 22 2000 PSI N e e 8 m P Pr BR Q BRAKE METERING VALVE V 2 2 x DRIVE PRESSURE TEST PORT eo 0 o RETURN FILTER Fl Pt M 10 MICRON q 26 CR RIGHT 14 CR 91930 0361270 Figure 8 4 Hydraulic Schematic BRAKE CYLINDER C 4 Chapter 8 Troubleshooting 101 TO J1 10 122 TO J1 3 121 TO J1 1 a o GN GN 2 TO J1 11 114 a 7 TO J1 4 s Er 2 2 3 s 3 Ce GN GN GN SW18A 121 b 122 O po R4 ps2 k SW17A 121 o Oo 1015 S a ai CN GN o S TO J1 12 O 17 5 6 115 SW17 125 man o 103 J3 M DN L 18 J3 H 115 SW18 126 TO J1 8 o 222 J3 E O m SW31 19 J3 J 116 2 TO 1 9 7 z r TO 41 6 SW19 TO 1 2 GND Figure 8 5 Upp
16. Pull out emergency stop at lower controls 3 Check voltage on wire 102 to scissor switch figure 8 3 Is it 24 volts If yes go to 4 If no inspect and or replace wire Check voltage on wire 106 to K1 relay figure 8 9 at scissor switch Is it 24 volts If yes go to 5 If no in spect and or replace scissors switch Check voltage on wire 121 at K1 relay Is it 4 to 5 volts If yes go to 7 skip 6 lf no check voltage on wire 110 at controller figure 8 22 Is it 4 to 5 volts If yes go to 6 If no go to Pump Motor Not Running Check ground wire of K1 relay Properly grounded lf yes replace relay and return to 5 If not check and or replace ground wire and return to 5 Check voltage on wire 111 to K2 relay figure 8 9 1s it 24 volts If yes go to B Pothole Switch and Level Sensor If no replace D1 diode figure 8 9 and go to B B Pothole Switch and Level Sensor dis Raise platform and secure the safety prop Pull out emergency stop at lower controls 3 Check voltage on wire 102 to pothole switch figure 8 3 Is it 24 volts If yes go to 4 lf no inspect and or replace wire Check voltage on wire 112 from pothole switch to level sensor figure 8 3 Is it 24 volts If yes go to 5 If no inspect and or replace pothole switch Check voltage on wire 111 from level sensor to K2 relay figure 8 9 Isit 24 volts If yes go to 6 lf no inspect and or replace wiring and
17. REACH MAXIMUM DRIVE HEIGHT UNRESTRICTED PLATFORM CAPACITY Do not remove any weight from this machine Any weight added must be distributed equally on each axle Proper stability and axle weights of this machine are based on the platform size shown above Axle weights with machine in the stowed travel position STEER AXLE DRIVE AXLE Ibs kg Ibs kg 0070901 SAA MN a A DANGER Proper position for use Death or serious injury might result if safety prop is not used and or properly positioned Use safety prop at all times when servicing machine PROPER USE OF SAFETY PROP Remove all material from platform Raise platform until the open height in between center pins is approximately 24 inches Swing safety prop up from storage position Remove hands and arms from scissors area Lower platform until scissors are supported by safety prop TO STORE SAFETY PROP Raise platform until the open height in between center pins is approximately 24 inches Left Side S1930 0361270 Chapter 1 Safety Lift Cylinder DEATH OR SERIOUS INJURY CAN RESULT FROM TIPPING
18. reprinted here with their permission New batteries need to be cycled several times before reaching full capacity 5 40 cycles depending on type Usage should be limited during this period Always fully recharge batteries immediately after use Batteries perform best when they are fully charged This practice will insure more capacity and longer life The deeperthe discharge the fewer number of cycles a lead acid battery will deliver Deep discharges deterio rate the battery quicker than light shallow cycles Battery cables should at all times be intact and con nectors kept tight Systematic inspection is recom mended Vent caps should be kept in place and tight during ve hicle operation and battery charging Batteries should at all times be kept clean free of dirt and corrosion Always keep the top of batteries clean A film on top of the battery can cause the cur rent to migrate between the posts accelerating self discharge Never let the electrolyte level of a lead acid battery fall below the plates Failure to maintain the electrolyte at proper levels causes damage to the exposed plates re ducing charge capacity Always check electrolyte level before charging Add dis tilled water to a level 1 8 above plates only if they are found to be exposed Re check electrolyte level after charging Add distilled water to a level 1 4 below the bottom of the fill tube in the cell cover Water used to replenish bat
19. 1 co 20 pP 14 White 2010942 _ Socket contact16 Deutsch _ 47 3000548 Terminal 250F1 90DEG 16 14 GA 9 wss TerminaiResor1210 0 Figure 8 28 Main Harness Wire Routing ALS ITMIOIOJO JO O P B B N O O O gt O G im riolrir NI N IN N N N TN gt gt gt gt gt M IIDIM O O A gt pare 112 Pothole to tilt sensor m ls Figure 8 31 Stack Switch H From lowering interrupt switch Pothole power Pothole to tilt sensor Figure 8 30 Pothole Switch G Lower interrupt switch power Figure 8 32 Lowering Interrupt Switch M 51930 0361270 8 19 22 A A A VVire guage 16 Terminal type 16 Deutsch socket contact part 3040342 Figure 8 34 Stack Wire Identification Figure 8 33 Stack Harness B lap Goud D few 0 T E Return power to lower control box Description Potentiometer resistors Ground Center tap Power Platform lift NG N9 no no No No no No No No n0 No Right steer Forward drive Lok de Drive reverse Left steer LET ddd Output from joystick Return power to lower control box Platform down
20. 4 2 Wheel Drive Motor e Hand wrenches 1 Remove all components from the shaft keys wire e Clean work bench rings nuts etc Draw a line with paint or marker Prior to installing new seals lightly coat them with new from the end cover 19 to the motor housing 8 to hydraulic fluid facilitate proper alignment during reassembly 2 With the shaft pointing down secure the motor in a Disassembly vise by clamping on the housing Loosen and re Refer to figure 4 2 for identification of all components in 7 the assembly bolts 21 Remove the end the motor 3 Remove the balance plate 17 rotor assembly 16 manifold boot 15 and the manifold 14 91930 0361270 4 1 Chapter 4 Base Frame Assembly Note When removing the balance plate do not allow the three check balls 18 to fall out Also take care to not allow the rolls to drop out of the rotor assembly 4 Locate and discard all seals They will be replaced during service and reassembly 5 Remove the drive link 13 and thrust bearing 12 6 From the underside gently tap the shaft 22 up ward and remove 7 Using a slide hammer bearing puller remove the rear housing bearing 11 from the housing 8 Remove the front thrust bearing 10 and the front thrust washer 9 9 Locate and discard the shaft seal 4 back up seal 3 and metal back up shim 2 10 Clean and dry all disassembled parts with solvent take care to observe
21. 4 volts If yes see Pump Motor Not Running lf no adjust or replace joystick poten tiometer at upper control box figure 8 14 No Low Speed Drive 1 Raise platform and secure safety prop 2 Check voltage on wire 121 Is it 1 1 to 1 4 volts If ves go to 4 skip 3 If no go to 3 If voltage is below 1 1 volts adjust drive speed po tentiometer figure 6 2 Chapter 6 until voltage reads 1 1 to 1 4 volts Go to 4 If the measurementis 4 to 5 volts K1 K3 or both relays are activated In this event call Snorkel technical service Check joystick switches SW18A and SW17A fig ure 8 14 Operating OK If yes go to 5 If no in spect and or replace switch es Check inspect and adjust joystick potentiometer figure 8 13 Low speed drive restored lf no re place potentiometer and go to 6 Low speed drive restored If no call Snorkel tech nical service for additional help Incorrect Lift Speed 1 9 Check voltage on wire 22 at the lift solenoid figure 7 13 Chapter 7 Is it 24 volts If yes go to 2 If no go to Lift or Drive from Upper Controls Raise platform and secure safety prop it will be necessary to have access to the upper controls during these procedures Remove wire 22 from lift solenoid figure 7 13 Chapter 7 Using the upper controls put the lift drive switch in lift and pull joystick back for full lift this procedure is necessary for steps 5 8
22. 6 Free VVheeling Valve 7 6 System Steer and Lift Relief Settings 7 6 System Relief Adjustment 7 6 Steer Relief Adjustment 7 6 Lift Relief Adjustment 7 7 Hydraulic Pump 7 7 Pump Service 7 7 PUMP Motor ga 7 7 Motor Troubleshooting 7 7 Disassembly un un san dow Aba KAEN BG 7 8 Component Exam and Repair 7 8 Heassemb y 7 8 Table of Contents Hydraulic Cylinders xs nawa vows aa a tacho a b 7 9 Steerand Brake Cylinder 7 9 Steer and Brake Cylinder Service 7 9 Disassembly ia ta AA 7 9 Cleaning and Inspection 7 10 Assembly 7 10 festing LV ou Fri ide m yo Ak si Be aye ve jis tea de 7 10 Lt pasahan ara aora da 7 10 Cylinder Removal 7 10 Service Procedure 7 11 Disassembly 7 11 Cleaning and Inspection 7 11 Assembly s n od s die avi 7 11 5100077 BKA KAG MA AG MAAGA de 7 11 Chapter 8 Troubleshooting General Purpose Troubleshooting 8 1 Electrical Function Diagnostics 8 2 Pump Motor Not Running 8 2 A Controller eden oid i 8 2 B CONTACTO nia da d 8 3 C Pump Motor mom ar owe a a o r
23. 8 4 Warranty 2 3 Lift from lower controls 8 3 Wheel drive motor 4 1 Lift from upper controls 8 3 Wheel load 2 3 Limit switches 8 4 Wheelbase 2 2 Pump Motor Not Running 8 2 Wheels 4 1 Wiring harness 6 1 91930 0361270 Limited Warranty Snorkel warrants each new machine manufactured and sold by it to be free from defects in material and workmanship for a period of one 1 year from date of delivery to a Customer or for one year after the machine has been placed in first service in a Dealer rental fleet whichever comes first Any part or parts which upon examination by the Snorkel Service Department are found to be defective will be replaced or repaired atthe sole discretion of Snorkel through its local Authorized Dealer at no charge Snorkel further warrants the structural components specifically the mainframe chassis turntable booms and scissor arms of each new machine manufactured by it to be free from defects in material and workmanship for an additional period of four 4 years Any such part or parts which upon examination by the Snorkel Service Department are found to be defective will be replaced or repaired by Snorkel through its local Authorized Dealer at no charge however any labor charges incurred as a result of such replacement or repair will be the responsibility of the Customer or Dealer The Snorkel Service Department must be notified within forty eight 48 hours of any possible warranty situation
24. Box J Overload jumper CE lowering circuit jumper High speed relay Tilt relay Ta Ten Man xo mey 0 Ra 0 Ro on speed resistor 0 AS oystok threshold ressor Figure 8 10 Lower Control Box Components U Potentiometer resistors 121 Riser o Joystick output Return power to lower 114 control box Figure 8 11 J1 Lower Box Stack Harness Connector 17 m re T Co output controler mo From lowering interrupt wich 108 Forward stvo valo w Figure 8 12 J2 Main Harness Connector 91930 0361270 Chapter 8 Troubleshooting Tea 5 le 0 r e 0 lr 2 o Figure 8 13 Joystick Components 115 Power to forward reverse switches 9 0 1 2 121 Potentiometer resister 209 Potentiometer to switch 210 Potentiometer to switch NO normally open NC normally closed C common Figure 8 14 Joystick Internal Wiring 51930 0361270 8 13 Chapter 8 Troubleshooting GROUND STUD ey E STOP ES2 DRIVE LIFT SWITCH SW31 FWD 4 4 REV J3 Upper Box Stack Harness 6 6 Connector 14 pin DOWN Fr Main Harness Connector NA 1 1212 435
25. OVER T DA N e E TO KEEP FROM TIPPING THIS MACHINE OVER FOLLOVV THESE RULES DO NOT RAISE OR DRIVE AN ELEVATED DO NOT RAISE OR DRIVE AN ELEVATED PLATFORM ON A PLATFORM ON Using incorrect parts store Ef sort on uneven can cause cylinder failure QXS Death or serious injury can result GO NO CLOSER THAN 4 feet 1 2m DO NOT RAISE THE PLATFORM to ANY DROP OFF OUTDOORS OR IN THE WIND OR HOLE FOR INDOOR Use only A ELEVATION ONLY amp OTHER ACTIONS CAN ALSO CAUSE THIS MACHINE TO TIP OVER DO NOT override safety devices DO NOT ride platform while machine is on a truck fork lift or Snor kel II DO NOT overload the machine DO NOT use ladder scaffold or other means to increase size DO NOT stand or sit on guardrails or platform height o A Ri 0074311 DO NOT attach ropes or chains to guardrails DO NOT use with improperly inflated or damaged tires or DO NOT carry loads outside the railing or use as wheels a crane ALARM MEANS TIPOVER DANGER TO AVOID LOWER PLATFORM IMMEDIATELY TIPOVER HAZARDS 2 3 USE ON FLAT LEVEL AND SOLID SURFACES fae dg ELECTRICAL SHOCK CAN KILL YOU y This machine is not electrically insulated Maintain 10 feet minimum clearance from electrical povver lines and apparatus This machine will not protect you from shock R Allow for platform sway rock or sag If voltage is 300 V to 50 kV stay at least 10 A feet 3 1m away If voltage is more than 50 kV talk wi
26. a suitable hoist or jack raise the axle until the wheel clears the ground Position a jack stand of sufficient capacity beneath the axle and lower the unit to rest on the stand Never rely solely on the jack or hoist Remove the lug nuts and wheel Wheel Drive Motors To remove a wheel drive motor for service the wheel must first be removed following the above instructions Once removed the motor shaft nut is exposed Remove the nut Wipe clean and disconnect the two hose fittings on top of the motor figure 4 1 Remove the four nuts fastening the motor to the mounting plate The motor should now be free for service Description Description Housing seal Drive link Figure 4 1 Wheel Motor and Fittings Metal back up shim Manifold Teflon back up seal Manifold boot Wheel Motor Service To prevent contamination the disassembly and service of a wheel drive motor should only be performed by au thorized personnel in a clean properly equipped shop Field service is not recommended The service proce dures will require Shaft seal Rotor assembly Body seals 2 Balance plate End cover seal Check balls 3 Front housing seal End cover 1 2 3 4 5 6 7 8 Housing I D tag e Seal kit see Parts Manual for correct part no Thrust washer Assembly bolts e Slide hammer bearing puller Front thrust bearing Shaft e Bench vise Rear housing bearing Shaft key nd Thrust bearing Shaft nut e Hand press TA j a Figure
27. and sulfation can occur Always allow batteries to cool after charging The cool ing time is very important because heat is generated during the recharge and discharge cycles Without suf ficient cooling heat increases accelerating grid corro sion one of the major causes of battery failure Deep cycle batteries need to be equalized periodically Equalizing is an extended low current charge per formed after the normal charge cycle It helps keep cells in balance Actively used batteries should be equalized once a week Manually timed chargers should have the charge time extended approximately three hours Auto matically controlled chargers should be unplugged and reconnected after completing a charge cycle In situations where multiple batteries are connected in series parallel or series parallel a replacement bat tery should be of the same size age and usage level as the companion batteries Do not put a new battery ina pack that has 50 or more cycles Either replace all the batteries with new batteries or install a good used bat tery in place of the bad New batteries should be given a full charge before use Periodic battery testing is an important preventative maintenance procedure Using a hydrometer check the specific gravity of each cell It should be 1 260 or greater Checking each cell fully charged will give an indication of balance and true charge level Imbalance could mean the need for equalizing and is often
28. attention to the disassembly proce dure so that the components may be reassembled ex actly as taken apart The seal kit contains two o rings two seals two plastic gaskets anda shaft seal Discard the old seals and gas kets Lightly coat the new seals with hydraulic fluid and replace them as you remove the old Reassemble as taken apart 91930 0361270 Chapter 7 Hydraulic System X PR 59 ca gt 3 NG 773 A rs A 4 re 177 y A i ONG Hi Pump Hydraulic gt L b r LOW m 4 Motor A PAL Pump 2 HE ANS ki a AG 0 l Tr p ya o 0 TRETIE m n yi WR Fi ra pr t EA PALA M A V Figure 7 14 Hydraulic Pump Pump Motor This permanent magnet motor figure 7 14 differs from conventional D C motors in that the field winding has been replaced with ceramic magnet pole pieces Note Do not Impact drop or squeeze the motors as this can cause damage to the ceramic pole pieces and will affect warranty considerations When disassembling the motor take care to keep the work area clean The magnet pole pieces will attract fer rous metal particles contaminating the motor Motor Troubleshooting 1 Read the nameplate to become familiar with the motor especially the rated voltage 2 Keeping motor leads separated try to turn the shaft by hand a If the shaft won t turn the followin
29. fluid leakage Be sure a thorough check of the entire system is part of each prestart inspection routine ADANGER Hydraulic fluid escaping under pressure can have enough force to inject fluid into the flesh Do not ex pose hands or any part of the body to a potential fluid leak Serious infection or reaction can result from injury by escaping hydraulic fluid Seek medi cal attention at once Be careful of leaked or spilled fluid Hydraulic fluid cre ates a very slippery fall hazard Clean up all spills at once A connection that is properly tightened but continues to leak is probably worn scratched or damaged and must be replaced Although small amounts of internal system leakage is normal due to machining tolerances major internal leaks can cause serious problems Leakage past a holding valve in a cylinder can cause drifting or malfunction and may require replacement of the valve If internal cylinder leakage is due to scoring of the cylin der wall be careful of attempted repairs Only trained professionals should attempt removal of scratches from the inside of a cylinder barrel ADANGER Do not modify the interior of a cylinder barrel be yond manufacturing tolerances This can cause the piston seal to fail leading to total cylinder failure Cylinder failure can result in death serious injury and or property damage Field service of hydraulic cylinders is not recommended for two reasons 1 potential for contami
30. kept covered Prior to reassembly inspect all parts for contamination Replacement Components Use only Snorkel approved replacement parts and components for service or repair of the machine Parts are available from OmniQuip Parts WorldWide See the Parts Manual for part numbers and ordering informa tion Component Removal and Installation Many of the heavier components will require mechani cal assistance for removal All slings chains cables etc should be parallel to each other and as near per pendicular to the top ofthe part being lifted as possible If it is necessary to lift a component at an angle be aware that the weight capacity of an eyebolt or similar 91930 0361270 bracket lessens as the angle between the supporting lift and the lifted component becomes less than 90 If a part resists removal verify that all nuts bolts ca bles brackets or wiring have been removed and that no adjacent parts are interfering Component Disassembly and Reassembly Prior to disassembling a component be sure you have read and understand the recommended procedure guidelines The steps should be completed as de scribed Do not partially disassemble one part then start on another Always recheck completed steps to assure nothing has been overlooked Replace all used o rings seals and gaskets with new prior to reassembly Dip all rings and seals in hydraulic fluid prior to reassembling Replace any part having im
31. level sensor Check voltage on wire 106 to K1 relay figure 8 8 If no voltage go to 7 If any voltage is present 1 to 24 volts replace diode D1 figure 8 9 and continue to 7 91930 0361270 T Chapter 8 Troubleshooting Check voltage on wire 104 at controller figure 8 22 Is it 24 volts If yes see Pump Motor Not Running If no check ground of K2 relay If properly grounded replace relay If not grounded check ground wire Hydraulic Function Diagnostics These troubleshooting steps are designed to isolate specific malfunctions in the hydraulic system All com ponent reference numbers are found on the hydraulic and electrical schematics at the end of the chapter The procedures require the use of a pressure gauge with the capacity to measure 3000 PSI and a flow meter Lift 1 2 Raise platform and secure safety prop Check 2H 9 up valve wire 22 Activating properly If yes go to 3 If no check and or replace valve Check emergency bleed down valve figure 5 6 Chapter 5 Activated lf no go to 4 If yes repair or replace valve Check R 3 lift relief valve figure 7 12 Chapter 7 Is it 2500 PSI If yes go to 5 If no check R 1 system relief valve figure 7 13 Chapter 7 Isit 2800 PSI If yes adjust R 3 lift relief valve to 2500 PSI If no adjust R 1 system relief valve to 2800 PSI or in spect hydraulic pump figure 7 14 Chapter 7 Inspect flow control valve at lift cy
32. perfect threads Bearings Upon removal carefully examine all bearings Discard and replace any that are pitted scored or burned All serviceable bearings should be cleaned with a nonflam mable cleaning solvent and allowed to air or drip dry Compressed air may also be used but avoid allowing the bearing to spin When dry coat them lightly in oil and wrap them in waxed paper preventing contamination until ready to be installed Make sure all bearings to be installed are freshly lubri cated When pressing the bearing into a retainer or bore apply pressure to the outer race lf bearing is to be in stalled onto a shaft apply pressure to the inner race Gaskets If gaskets are to be custom fabricated make sure the gasket material is of equivalent material and thickness to the original All holes must be cut accurately Make sure the installation alignment is accurate Improperly installed gaskets can cause serious system damage Bolts All replacement bolts must have the same SAE hard ness rating as the original Using the proper length is also very important A bolt too long will bottom before the head is snugged tightly A bolt too short will not en gage sufficient thread to hold properly Hydraulic System It is important to keep the hydraulic system clean If evi dence of contamination such as metal or rubber parti cles is found the system should be drained and flushed see Chapter 7 Before disconnecting wipe c
33. pump adjusted for a maximum of 2800 psi 19 305 kPa to the cylinder and power it through several cycles checking for smooth operation This will bleed all air from the cylinder Relieve pressure 2 Reinstall the cylinder following the removal proce dure in reverse order 3 Using the lower controls cycle the platform lift and lower functions several times watching for smooth operation Chapter 8 Troubleshooting General Purpose Troubleshooting The chart below lists a variety of potential malfunctions listed by problem followed by the diagnosis of probable cause and a recommended corrective action When performing repair work on the machine be sure to follow all safety guidelines outlined in this book All maintenance and repairs must be performed by trained and authorized per sonnel Problem Probable Cause Corrective Action All functions stop working e Motor or pump failure e Manually stow the machine and repair Low hydraulic fluid level e Check fluid level add if necessary use approved fluid only e Blown fuse in lower control box e Replace fuse e Electrical system malfunction e Manually stow the unit and repair Platform will not raise or e Control selector switch in upper e Change to lower control lower from lower controls control position e Battery switch is off e Change to on e Emergency Stop switch engaged e Pull button out to disengage Upper controls will not e Control selector switch in lower contr
34. the minimum safe ap proach distance as defined by ANSI BUS 57 a BUS BARS ANSI publications define minimum distances that must be observed when working near bus bars and ener gized power lines Table 1 and Figure 3 are reprinted courtesy of Scaffold Industry Association ANSI SIA A92 6 page 36 Minimum safe approach distance Avoid contact Voltage range phase to phase O to 300V Over 300V to SORV Table 1 Minimum Safe Approach Distance Denotes prohibited zone Figure 3 Minimum Safe Approach Distance S1930 0361270 Safety Related Placards and Decals The aerial platform is equipped with placards and de cals that provide instructions for equipment operation and accident prevention Do not operate the machine if Chapter 1 Safety any placards or decals are damaged or illegible Re placements are available through your Snorkel Dealer or directly from Snorkel International Inc Parts num bers for each are listed in the Repair Parts manual ADANGER Proper position for safety prop use Death or serious injury might result if safety prop is not used and or properly positioned Use safety prop at all times when servicing machine with platform raised PROPER USE OF SAFETY PROP Remove all material from platform Raise platform until the open height is wide enough to position the safety prop Place safety prop in the proper position Remove hands and arms
35. to 6 If no replace defective valve s 6 Inspect and or repair or replace drive motors see procedure in chapter 4 Base Frame Assembly Reverse Drive 1 Check 4H 10 reverse drive valve solenoid and car tridge Operating properly If yes go to 2 If no check and or replace wiring and or solenoid 2 Check V 3 free wheeling valve figure 7 11 Chapter 7 Closed If yes go to 3 If no close or replace if defective 3 Check brake cylinder figure 7 19 Chapter 7 Re leasing properly If yes go to 4 If no check brake shuttle and V 2 metering valve Operating prop erly If ves inspect brake cylinder see procedure in Chapter 7 Hydraulic System If no repair or re place shuttle and or valve 4 Check hydraulic pressure to wheel drive motors Is it 2800 PSI If yes go to 5 If no check and adjust R 1 system relief valve to 2800PSI Check CB 1and CB 2 counter balance valves fig ure 7 10 Chapter 7 Operating properly If yes to 6 If no replace defective valve s Inspect and or repair or replace drive motors see procedure in Chapter 4 Base Frame Assembly Left Steering 1 Check 4H 1 left steer valve solenoid figure 7 10 Chapter 7 wire 19 Operating properly If yes go to 2 If no check and or replace wiring and or valve Check FC 1 steering flow control valve Is it 50 G P M If ves go to 3 If no repair or replace valve Check R 2 steer relief valve Is it 1500 PSI I
36. to see that the control setting has not been altered Adjustment Potentiometer UR X F ir NG te Figure 6 2 Lower Control Box Upper Control Box The schematic for the upper control box is located at the back of Chapter 8 Troubleshooting The joystick control figure 6 3 is mounted on top of the upper control box Figure 6 3 Joystick Control Schematics and Drawings The following schematics and drawings are found at the back of Chapter 8 Troubleshooting e Electrical Schematics e Wiring Harness Connections e Battery Cable Connections e Joystick Chapter 7 Hydraulic System General Maintenance Maintaining the hydraulic system is critical to the perfor mance of the machine Any fluid used must meet Snor kel specifications The system is kept clean by closely following the recommended maintenance schedules Hydraulic Fluid Specifications e Mobil DTE 13M above 10 F 13 C factory installed e Mobil DTE 11M below 10 F 13 C Cleanliness In the system dirt water and air can all be damaging Because contamination is so harmful precautions are very important Be careful when adding fluid changing filters or performing other service procedures e Check fluid levels during each prestart checklist routine Replace the return filter at recommended intervals more often if conditions are dirty Filter new fluid with a 10 micron filter as it is added to the reservoir
37. washer To O ring Figure 7 7 Straight Thread adjustable 91930 0361270 1 Lubricate o ring with fluid 2 Back locknut off as far as possible Make sure back up washer is not loose and is pushed up as far as possible figure 7 8 a 3 Screw the fitting into the port until finger tight The back up washer should contact the face of the port figure 7 8 b 4 Align the fitting as needed by unscrewing the re quired amount but less than one full turn 5 Use a wrench to hold fitting in desired alignment Tighten the locknut with a torque wrench to torque spec listed below figure 7 8 c Locknut SAE Port Thread Size He24 24 45 20 7 20 Y 18 27 2 0 34 16 42 2 0 76 14 60 2 5 1512 1412 1 6 12 1 12 225 12 0 Fitting Size Torgue ft Ib 9 040 5 1141 0 14 1 0 2211 0 80 5 0 105 6 0 115 6 0 1 12 250 12 0 325 15 0 2 12 Figure 7 9 Straight Thread adjustable Leaky Fittings If any connection leaks after final assembly or once the system is pressurized check for the following e Proper number of flats used for the size being assembled e Misalignment between the connections prior to tightening 91930 0361270 Chapter 7 Hydraulic System e Mating components lubricated prior to assembly e Sealing surfaces of the components inspected for nicks burrs scratches etc Hoses and Tubes Any replacement hose or tube used on the machine must
38. your eyes flush immediately with clear water and get medical attention If acid con tacts your skin wash off immediately with clear water w 23 o xa K aR s sat Battery Charger gt Figure 3 2 Battery Tray The batteries figure 3 2 are enclosed in a tray located on the left side of the machine For access park the unit on a hard level surface lower and stow the platform then unlatch and open the tray Check cell specific gravity during each routine mainte nance First remove all vent caps from the battery Check each cell with a hydrometer The reading should be 1 260 or greater If the electrolyte of any cell is low add distilled water to a level 1 4 below the bottom of the fill tube During battery maintenance remove jewelry such as watches necklaces rings or bracelets They can short circuit and cause severe burns Look for loose or corroded connections Clean them with electrical contact cleaner or fine sandpaper 91930 0361270 Cold weather can cause problems Batteries discharge at only 70 of capacity at freezing temperature The ideal operating temperature is 68 F 20 C Batteries should not be left in a cold environment for an extended period They can discharge freeze and crack within two to three weeks of non use in cold weather Battery Maintenance The following information about battery care and main tenance was supplied by Interstate Batteries Inc and is
39. 1 7 N 102 102 102 J2 17 112 O u SW33 swi e Y Di a 1 m 2 113 K2 111 3 wio J1 11 117 E d Ha 114 114 K2 Swis TO J3 L 117 V 113 D3 111 J2 5 111 GND 118 A ee D a 3 010 Ny 207 J2 10 207 3 LA oo y 5 K5 207 T 207 3 HM SOL22 J1 5 222 22 J2 4 22 3 TO J3 E 107 S Fa N a o 22 3 S SOL21 118 118 2 21 J2 18 21 3 N 5 J2 108 J28 J1 12 103 a 103 103 TY TO J3 M J2 14 107 107 3 ZN D6 dD4 ND8 ADB K4 ki N N 5 SOL17 J1 7 17 17 a J2 9 17 3 TO J3 G o 2 J1 8 18 18 J2 1 18 3 O J3 207 SOL18 Am nf 2 D 2 2 19 J22 19 3 TO J3 J s 41 6 20 R TO J3 F SOL19 D J2 3 20 3 J1 2 3 TO J3 B SOL20 GND 91930 0361270 Figure 8 7 Lower Control Box Electrical Schematic Chapter 8 Troubleshooting H1 Ki 87 J2 Main Harness JUMPER Sm r Connector 24 pin rr 85 EM 86 104A 110
40. 16 1718 1 8 149 11 Paa HANDLE SWITCH FWD DOWN SW30 SW17 REV LIFT SW18 O RIGHT SW20 U SW18A 25 OO o THUMB STEER LEFT SVV19 ie R4 Joystick SW17A Potentiometer O gt 0 Figure 8 15 Upper Control Box S1930 0361270 Chapter 8 Troubleshooting Upper Control Box Tre 6 Potentomsierresiier 121 o seared o output om oysick 101 an seated sme 0 Figure 8 16 Main Harness Connector Non doystick Side Forvvard dovvn Reverse lift Figure 8 17 Drive Lift Switch S1930 0361270 s leong l m Power return to lower control box Figure 8 18 Upper Box Stack Harness Connector Power Power return to lower control box Power to joystick Figure 8 19 E Stop Chapter 8 Troubleshooting to lift cylinder Pothole Switch Connector Y se al Te A Ja Pe N 113 Stack Harness 112 Main Harness Lowering Interrupt Switch Connector 1 108 From lowering interrupt switch Pwr lowering interrupt switch Brit rom it sensor Stack Switch Connector m Pos al sme 7 Figure 8 20 Wiring Harnesses Connections left 91930 0361270 113 gt 112 91930 0361270 Chapter 8 Troubleshooting ee Battery positive Upper Controls Motor control negative Be Battery ground Figure 8 21 Controller Ter
41. 2 should read 3 3 K ohms R5 should read 680 ohms If yes go to 10 lf no replace resistor s Check wire 122 in the platform box Is it 2 3 volts If yes go to 11 If no replace wire Check wire 101 at controller figure 8 22 Isit2to 3 volts If yes go to 12 If no replace wire Is the pump motor running If yes see Hydraulic Troubleshooting If no see Pump Motor Not Running No Lift or Drive From Upper Controls 1 2 Pull out emergency stop at lower controls Check voltage on wire 2 at upper emergency stop switch Is it 24 volts If yes go to 3 If no check up per lower and emergency stop switches to lower controls Check voltage on wire 114 to joystick control switch Is it 24 volts If yes go to 4 If no check wire and emergency stop Check voltage on wire 115 to micro switches Is it 24 volts If yes go to Lift Drive or Steer lf no in spect and or replace wire or micro switch 30 figure 8 14 A Lift 1 2 Perform steps 1 4 above No Lift or Drive from Up per Controls Check voltage on wire 126 to drive lift selector Is it 24 volts If yes go to 3 If no inspect and or replace wire or micro switch 18 figure 8 14 Check voltage on wire 222 from drive lift selector to wire 22 Isit 24 volts If yes go to 4 If no inspect and or replace wiring or drive lift selector Chapter 8 Troubleshooting 4 Check voltage on wire 22 at lift solenoid figure
42. 7 13 Chapter 7 Is it 24 volts If yes go to 5 If no check wire 22 Check lift solenoid and ground wire at solenoid lf grounded and solenoid is OK go to 6 If not replace wire and or solenoid Is the pump motor running If yes see Hydraulic Troubleshooting lf no see Pump Motor Not Running B Drive 1 Perform steps 1 4 at No Lift or Drive from Upper Controls Check voltage on wire 125 forward or 126 re verse Is it 24 volts If yes go to 3 If no inspect and or replace wire or micro switch es 17 forward or 18 reverse figure 8 14 Check voltage at 17 forward solenoid or 18 reverse solenoid figure 7 13 Chapter 7 Is it 24 volts If yes go to 4 If no check wire 17 or 18 Check solenoids and ground wires at both sole noids If grounded and solenoids OK go to 5 If not replace wire s and or solenoid s Is the pump motor running If yes see Hydraulic Troubleshooting If no see Pump Motor Not Run ning No High Speed Drive 1 Perform steps 1 through 7 under A Scissor Switch Once complete continue to 2 Check voltage on wire 17 at the forward drive sole noid figure 7 13 Chapter 7 Is it 24 volts If yes go to 2 If no see No Lift or Drive from Upper Controls Check switch number 17A figure 8 14 Is it open If yes go to 4 If no inspect and or replace switch Check voltage of wire 101 while the machine is driv ing forward Is it 3 to
43. 8 3 No Lift From Lower Controls 8 3 No Lift or Drive From Upper Controls 8 3 5070107777 8 3 B Drive 8 4 No High Speed Drive 8 4 No Lovv Speed Drive 8 4 Incorrect Lift Speed 8 4 No Right or Left Steering 8 4 Limit Svvitches and Level Sensor 8 5 A Scissor Switch 8 5 B Pothole Switch and Level Sensor 8 5 Hydraulic Function DiagnosticS 8 5 LITE of teh ac eee oe o ce ee oa ees 8 5 LOW 705550 8 5 Forward sees a cen FI s pow agase aes 8 5 Reverse Drive 8 6 Left Steering wi is wi wi ke aid bade Kab 8 6 Right Steering nv mayan PARA en 8 6 Lower Control BOX 8 12 Upper Control BOX 8 15 Appendix A Glossary 91930 0361270 Chapter 1 Safety Introduction This maintenance service and repair manual will pro vide proper procedures that are essential for safe and reliable operation ofthe Snorkel S1930 Scissor Lift The outlined procedures should be performed as recom mended to insure operator safety and vehicle integrity Disclaimer of Liability This manual has been prepared by Snorkel Interna tional Inc for reference and use by service personnel who have been trained to properly repair and service Snorkel aerial platforms Snorkel Internati
44. If the motor has leads be sure they are not touching If they are touching a generator action will give the effect of friction in the motor 11 Once the shaft is spinning freely perform a no load test Connect an ammeter as shown on Figure 7 15 With the power connected and the mo tor running the ammeter should read less than 20 of the full load current from the nameplate A higher reading indicates a Brushes are not on neutral setting check match marks for exact alignment b Faulty armature Hydraulic Cylinders All functions of lifting steering and braking are per formed by hydraulic cylinders Their routine inspection for proper operation is a vital part of maintenance pro cedures See Chapter 3 Maintenance Steer and Brake Cylinder The steer cylinder figure 7 18 is mounted atthe front of the chassis directly above the wheel motors Figure 7 18 Steer Cylinder 91930 0361270 Chapter 7 Hydraulic System The brake cylinder figure 7 19 is mounted at the back of the chassis between the rear wheels 4 x m Brake Cylinder mr gt TITA N y un o a nan k e m S B AR u b AN A l ei A 2 2 May ee 5 Ka n x r B gt A SON IPE q Figure 7 19 Brake Cylinder Steer and Brake Cylinder Service To properly disassemble and service a steer or brake cylinder the following equipment and supplies are re quire
45. NAP RING AND SLOWLY EXTEND CYLINDER ROD UNTIL SPRING PRESSURE IS RELEASED ASSEMBLE IN REVERSE ORDER 475596 91930 0361270 1 5 Chapter 2 Specifications This Snorkel aerial platform has been manufactured to conform to all applicable requirements of the following agencies e Occupational Safety and Health Administration OSHA e American National Standards Institute ANSI e European Standard prEN 280 e Canadian Standards Association CSA Component Identification This machine has been designed and manufactured for interior use only Operate only on a firm flat level sur face capable of withstanding all load forces see gen eral specifications for wheel load floor pressure and drive lift level sensor interlock 1930 Scissor Lift Guardrails L Platform Extension Upper Controls G TE E T A 1 Lab m T Manual Al Holder _ i pi Platform I 7 5 O u O o ANDAS D O OC
46. Procedure 5 5 Safety Prop sa ta a ak nnna 5 6 Emergency Bleed Down Valve 5 6 Chapter 6 Electrical System System Components 6 1 Wiring Harness oca is 6 1 eser 6 1 Removal and Installation 6 1 Lower Control Box 6 1 Upper Control Box 6 1 Schematics and Drawings 6 1 Chapter 7 Hydraulic System General Maintenance 7 1 Hydraulic Fluid Specifications 7 1 Cleanliness 7 1 mijo UG PUD 0 bp 7 1 Cavitation 7 1 MACANO sara pa ea Be nen eat 7 1 Air Bleeding 7 1 Fluid Leakage 7 2 Heat Generation 7 2 Fluid Condition 4 5 s m ba dodo Ka WANG 7 2 Flushing the System 7 3 Fluid Replacement Guidelines 7 3 ROA NE 7777700000 7 3 Flushing nstructlons 7 3 PIS a a a r 20 7 4 Torque SpecificationS 7 4 Tube to Fitting 37 Flare 7 4 Straight Thread O Ring Fitting 7 4 Straight Thread O Ring Fitting adjustable 7 4 Leaky mhie z a pt ki ren 7 5 Hoses and Tubes 7 5 Hose Routing 7 5 HOSO WIS A ages pm r 7 5 Manifold Assemb ly 7
47. a sign of improper charging or a bad cell Voltage checks open circuit charged and discharged can locate a bad cell or weak battery Load testing will pick out a bad cell when other methods fail Be on the look out for abnormal cells A weak cell will cause premature failure of com panion cells or the entire battery As batteries age their maintenance requirements change Generally their specific gravity is higher and gassing voltage goes up This means longer charging 3 3 Chapter 3 Maintenance time and or higher finish rate higher amperage at the end of the charge Usually older batteries need to be watered more often and their capacity decreases Opportunity charging a short partial charge during an extended duty cycle is a controversial subject Gen erally the practice is a crutch to make up for under sized batteries The correct approach is to install adequate battery capacity If this is impossible because of lack of space in the battery compartment or extreme operating conditions 24 hour intermittent use for ex ample opportunity charging is better than excessive battery discharging However the practice can cause batteries to overheat require more water and usually shorten battery life Opportunity charging is a trade off something to avoid if possible One charging cycle per day is preferable Extreme temperatures can substantially affect battery performance and chargin
48. ace commutator cover on a work bench with brush assembly facing upward 3 Place the bearing spring into the bearing bore 4 Keeping the assembly in a vertical position install new bearings on the armature shaft by pressing the inner race moving the bearing into the proper posi tion 5 Align the armature assembly including bearings and insert the commutator end bearing into the bearing bore 6 Setthe brushes to the final position as shown in fig ure 7 16 7 With the armature assembly secured in a vertical position place the complete stator assembly down and securely into position on the commutator cover see figure 7 17 Figure 7 17 Assembly Procedure Note Be careful during this procedure There is a strong magnetic attraction between the stator assembly and the armature This tends to pull the stator assembly rapidly downward It is important to have a firm grasp on the stator assembly making sure fingers are free from the space between the assembly and commutator cover figure 7 17 S1930 0361270 8 Rotate the stator assembly until the match mark on its bottom lines up with the match mark on the com mutator cover Note Itis important that the stator assembly is properly aligned 9 Assemble the pulley end cover in the proper rela tionship Insertthe mounting bolts and tighten alter natively to ensure a good mechanical alignment 10 Spin the shaft by hand to see if it is free
49. aged e Not properly plugged in or defective e Blown fuse on battery charger Corrective Action e Charge batteries e Manually stow the machine and repair e Use wrench to manually disengage brake release cam e Fully open the valve e Check plug in power outlet at rear of chassis e Push reset button on outlet e Manually stow the unit and repair e Manually engage brake pins using a wrench on the brake release cam or the pins should automatically reset when the unit is driven e Check power source outlet e Replace fuse e Check battery voltage 24V e Check battery supply fuse figure 8 1 e Check lower control box fuse figure 6 2 Chapter 6 Pump Motor Not Running A Controller 1 Check voltage of wire 104 at the controller figure 8 22 Is it 24 volts If yes go to 2 If no see Limit Switches and Level Sensor unless you have al ready performed that procedure In that case go to 4 a VASES Contactor o Figure 8 2 Motor Controller and Contactor 91930 0361270 2 Check voltage of wire 110 at the controller figure 8 22 Is it 4 to 5 volts If yes go to 3 If no check ground and positive terminals on controller B and B Make sure connections are good and cables OK Check voltage of wire 101 to controller with both emergency stops pulled out and joystick control set to neutral Is it 2 to 3volts If yes go to B Contactor lf no check joystick potent
50. all OSHA safety guidelines ACAUTION Solvents can be extremely hazardous Follow the manufacturer s label for proper use and disposal Assembly 1 Stand the shaft 22 on the work space large end down and place the front thrust bearing 10 onto the shaft the washer side against the shoulder Place the thrust washer 9 on top of the bearing 2 Remembering to lightly coat allnew seals with new hydraulic fluid install anew shaft seal 4 onto the washer lip side down Install a new back up seal 3 followed by a lightly oiled new metal shim 2 3 Putthe housing 8 in a vise taking care to not de form the part with the bore hole down Install the shaft assembly down through the bore 4 The rear housing bearing 11 is now ready to be in stalled With the writing side up place the bearing into the housing bore Using a hand press partially press the bearing into the bore no more than 12 18 5 Install the thrust bearing 12 on top of the shaft 6 Install a new housing seal 1 into the housing seal groove Make sure the seal is uniformly installed and protruding approximately OO7 above the housing wall Note f there is a bump in the seal remove it and clean out the groove Any irregularity vvill defeat the seal 7 Install the drive link 13 into the housing One end of the link has a hat machined in it Place the other end in the shaft leaving the hat end exposed 8 Novv the s
51. allowed by the manufac turer in all operating configurations upper controls the controls located on or beside the plat form used for operating some or all ofthe functions ofthe aerial platform wheelbase the distance from the center of the rear wheel to the center of the front wheel working height platform height plus six feet 91930 0361270 A Air bleeding 7 1 Ambient air temperature 2 3 B Base frame assembly 4 1 4 2 Batteries 2 2 3 2 3 3 Charge cycle 3 4 Charging 3 2 Electrolyte 3 2 3 3 Equalizing 3 3 Specific gravity 3 2 3 3 3 4 Testing 3 3 Battery charger 3 3 3 4 Bearings 3 1 Bolt maintenance 3 1 Brake cylinder 7 9 C Chassis 2 1 Cleaning 3 1 D Daily inspection 3 6 Decals 1 3 Disclaimer of Liability 1 1 E Electrical function diagnostics 8 2 Electrical hazard Electrical system 6 1 Electrolyte 3 2 3 3 F Fittings 7 4 Floor pressure 2 3 Flushing instructions 7 3 Free wheeling valve 7 6 Front wheels 2 1 G Gaskets 3 1 General specifications 2 2 Glossary 9 1 Gradeability 2 2 Ground clearance 2 2 H Hoses 7 5 Hose routing 7 5 Hose twist 7 5 Hydraulic cylinders 7 9 Brake cylinder 7 9 Lift cylinder 7 10 Steer cylinder 7 9 Hydraulic fluid 7 1 7 2 7 3 91930 0361270 Index Fluid condition 7 2 Fluid leakage 7 2 Fluid replacement 7 3 Flushing instructions 7 3 Heat generation 7 2 Hydraulic fluid reservoir
52. atform Assembly Platform Removal Procedure 1 Disconnect electrical cables from base of upper control box 2 Disconnect electrical wires from rear of electrical outlet and pull free of platform 3 Remove four bolts figure 5 1 8 5 2 from the base at the rear Figure 5 2 Platform Bolts 4 Liftthe rear ofthe platform a few inches sufficient to clear the scissor assembly 5 With the platform properly supported by a hoist or lift slide it forward and off the scissor assembly 91930 0361270 Scissor Assembly The platform is mounted on the scissor assembly which contains the lift cylinder the stack wiring harness and two important safety features of the machine the safety prop figure 5 5 and the emergency bleed down valve figure 5 6 7930 Figure 5 3 Scissor Assembly Scissors Removal Procedure 1 Raise the platform drop and secure the safety prop into position 2 Detach all electrical and hydraulic connections to the base assembly be sure the battery switch is off and pressure is removed from hydraulic lines 3 Remove platform ladder figure 5 4 4 Remove pin bolt figure 5 4 5 With a hammer and punch remove the scissor pin figure 5 4 6 The back of the assembly should now be free of the base mounts With the assembly properly sup ported by a hoist or lift slide the assembly toward the rear until the slide blocks are free of the channel assembly Scissor Pin
53. ation gradeability the maximum slope that the aerial platform is capable of travel ground fault circuit interrupter GFCI a fast acting circuit breaker that opens to stop electrical circuit flow if it senses a very small current leakage to ground The GFCI is used to pro tect personnel against a potential shock hazard from defective electrical tools or wiring guardrail system a vertical barrier around the platform to prevent personnel from falling hazardous location any location that contains or has the potentialto contain an explosive orflammable atmosphere as defined by ANSI NFPA 505 91930 0361270 hydraulic tray a swing out compartment that holds the electrical panel for the lower controls the hydraulic directional control valve the free wheeling valve the pump and the hy draulic fluid filter king pin a spindle that protrudes up from the frame that pro vides a pivot point for the steering assembly lanyard anchor a tie down loop securely fastened to the base of the work platform used to anchor a fall restraint har ness level sensor an instrument that measures the degree of variation from perfect horizontal it contains an interlock that will prevent the machine from operating at a dangerous angle lower controls the controls located at ground level for oper ating some or all of the functions of the aerial platform manufacturer a person or entity who makes builds or pro duces a
54. culates When the pump operates with air in it serious damage can occur Signs of aeration are foamy fluid in the reservoir and noisy pump operation The following are potential causes e Low fluid level The pump will then tend to suck air into the system along with the fluid e Aleakinthe suction line between the reservoir and the pump e Return line outlet is located above the oil level in the reservoir The resulting turbulence can mix air into the fluid To check for a suction line leak while the pump is run ning at normal speed slowly squirt clean hydraulic fluid around each connection in the line and the O ring flange where it bolts to the pump Listen to the pump A suction leak will suck the fluid in and quiet the pump as long as the oil seals the leak Each leak must be re paired ACAUTION Serious pump damage is likely if leaked air contam inates the hydraulic fluid Atthe first sign of trouble shut down the machine and repair the problem Air Bleeding Air can bleed into the system causing pump damage This can be caused by low fluid level in the reservoir or loose connections and fittings in the system Or during maintenance opened lines can suck in air Most lines in the system will purge air during normal use However if airis detected in the system a manual purge procedure is recommended Chapter 7 Hydraulic System Fluid Leakage All hydraulic connections must be kept tight to prevent
55. d e Seal kit part number in Parts Manual e Adjustable face pin spanner wrench e Pliers or vise grip e Bench vise with cushioned jaws e Propane torch possibly e Soft mallet e New hydraulic fluid e Cleaning solvent e Power pack hydraulic test pump e Locktite 271 Threadlock e Clean work bench Disassembly 1 Wipe all dirt and grease from cylinder 2 Secure the cylinder in a vise or other acceptable holding equipment Use care to not damage the tube 3 Remove the head gland retaining wire using an ad justable face pin spanner wrench Use the wrench to turn the retaining wire out through the slot in the outside of the tube This should require one revolu tion If you can turn the head gland but the retaining wire does not feed out of the slot use a pliers or vise grip to grab the end of the wire and pull as you turn the head gland 4 Slide the rod assembly from the cylinder using care to not damage the rod do not use pneumatic or hy draulic pressure to remove the rod assembly 5 Fasten the rod end mount in a cushioned jaw vise Chapter 7 Hydraulic System 6 Remove the flange bolt from the rod assembly lt may be necessary to apply heat to break the seal ant bond between the bolt and rod The heat should be applied uniformly to a temperature of 300 to 400 F Take care not to overheat the parts 7 Remove the piston and head gland Remove and discard all seals taking care not to scratc
56. draulic Pump Figure 3 1 Hydraulic Tray po Hydraulic Fluid Reservoir Before checking the fluid level all hydraulic cylinders should be fully retracted and the platform in stowed po sition If the level is low add fluid until it reaches the indi cator line on the side of the reservoir figure 3 1 As part of the annual maintenance the reservoir should be emptied and cleaned along with the filler cap with kerosene fuel oil or similar solvent Then re install and fill with new fluid Batteries Fully recharge the batteries immediately after use One charging cycle per day is preferred The battery terminals should be periodically cleaned using a non metallic brush and a solution of baking soda and water Remove the cables then clean and dry the terminal posts Coat them with an anticorrosion compound before reattaching the cables ADANGER Batteries give off hydrogen and oxygen that can combine explosively Death or serious injury can result from a chemical explosion Do not smoke or permit open flames or sparks when servicing the batteries Battery acid can damage the skin and eyes Serious infection or reaction can result if medical treatment is not given immediately Wear face and eye protec tion when working near batteries Batteries contain sulfuric acid that can damage your eyes or skin on contact Wear a face shield rubber gloves and protective clothing when working around batteries If acid contacts
57. during the applicable warranty period Personnel performing warranty repair or replacement must obtain specific approval by Snorkel Service Department prior to performing any warranty repair or replacement Customer and Dealer shall not be entitled to the benefits of this warranty and Snorkel shall have no obligations hereunder unless the Pre Delivery and Inspection Report has been properly completed and returned to the Snorkel Service Department within ten 10 days after delivery of the Snorkel product to Customer or Dealer s rental fleet Snorkel must be notified in writing within ten 10 days of any machine sold to a Customer from a Dealer s rental fleet during the warranty period At the direction of the Snorkel Service Department any component part s of Snorkel products to be replaced or repaired under this warranty program must be returned freight prepaid to the Snorkel Service Department for inspection All warranty replacement parts will be shipped freight prepaid standard ground from the Snorkel Service Department or from Snorkel s Vendor to Dealer or Customer REPLACEMENT PARTS WARRANTY Any replacement or service part made or sold by Snorkel is not subject to the preceding Limited Warranty beyond the normal warranty period of the machine upon which the part was installed THIS WARRANTY EXCLUDES AND SNORKEL DOES NOT WARRANT 1 Engines motors tires and batteries which are manufactured by suppliers to Snorkel who furnish t
58. e damaged or im properly secured parts and to provide timely guidelines for lubrication and other minor maintenance procedures It is organized based on the frequency the procedures are recommended Maintenance Schedules e Daily prestart inspection e Frequent maintenance every 90 days or 150 hours of operation e Annual maintenance 500 hours of operation 3 6 ADANGER Failure to perform maintenance following the recom mended schedules may cause equipment failure re sulting in death or serious injury Do not operate a machine that has been found to be defective Maintenance routines require the use of checklists found in this chapter which after use should be retained in a permanent file Make additional copies for future use Daily Prestart Inspection The prestartinspection and maintenance routine must be performed by a trained operator It should be performed daily prior to the first use of the machine Frequent Maintenance The frequent maintenance routine must be performed ev ery 90 days or after 150 hours of operation by a qualified person only Annual Maintenance The annual maintenance routine must be performed an nually or after 500 hours of operation by a qualified person only 91930 0361270 Chapter 3 Maintenance Prestart Inspection Checklist Date Item Inspect for v Operator s manual In manual holder LI Electrical system Battery fluid level Proper level
59. e instructions to reduce the likelihood of personal injury and property damage The terms danger and caution in dicate varying degrees of personal injury or property damage that can result if the instruction is not followed ADANGER Indicates a situation which if not avoided can result in death or serious injury 4 CAUTION Indicates a situation which if not avoided can result in minor injury or property damage Notes Notes are used to provide special information or helpful hints to assist in aerial platform service or repair but do not indicate a hazardous situation Chapter 1 Safety Supporting Lifting Devices The weight capacity of all supporting lifting devices in cluding but not limited to overhead hoists lifts chains straps jacks or jack stands must be checked for suit ability of use that their weight capacity is not exceeded Electrocution Hazards The aerial platform is made of metal components and is not insulated Regard all conductors as energized If for transportthe machine must be outdoors do not operate during a thunderstorm Minimum Safe Approach Distance Minimum safe approach distances to energized power lines and their associated parts must be observed while operating the aerial platform ADANGER The aerial platform is not electrically insulated Death or serious injury can resultfrom contact with or inadequate clearance from an energized con ductor Do not go closer than
60. e to Fitting 37 Flare Torque Method 1 Align tube and fitting 2 Tighten nut to torque spec below SAE Tube Hose Dash Thread Torque Connection Connection Size Size ft Ib FERT EEE 2 54 24 3 1 3 24 6 1 4 7 5 20 12 1 2 2 5 12 20 15 1 2 2 6 Y 18 21 1 1 2 12 8 34 16 45 2 Y 1 Y 1 1 10 76 14 60 5 1 12 14 12 85 5 1 1 14 1944 12 105 5 1 1 16 1345 12 120 5 1 1 2 1 1 0 1 12 170 10 24 47 12 32 2 12 200 15 1 1 270 20 1 1 Figure 7 3 Tube to Flare Fitting Flats Method F F F T flats from finger tight 1 Tighten nut to finger tight 2 Mark off nut and body figure 7 4 3 Tighten to appropriate F F F T from above chart 4 Mark off final position figure 7 4 Mark nut Initial Vi and body bai Extended line After Proper Finger tight Tightening Figure 7 4 Nut Tightened to 2 F F F T Straight Thread O Ring Fitting non adjustable 1 Lubricate o ring with fluid 2 Tighten to finger tight 3 Tighten to torque spec below Figure 7 5 Fitting Size SAE PortThread Size Torque ft Ib 2 51 24 7 5 0 5 14 1 0 3 04 1 10 Ad 9025 0 12 145 12 14 1 6 12 16 1 6 12 20 154 12 24 174 12 250 12 0 32 110 5 0 145 6 0 160 6 0 225 12 0 A 325 15 0 Figure 7 6 Straight Thread non adjustable Straight Thread O Ring Fitting adjustable Adjustable fittings require alignment The following steps insure proper installation Locknut Back up
61. e to not damage the arma ture Component Exam and Repair Once the motor has been disassembled the following trouble shooting and repair steps should restore the motor to full function 1 Examine the bearings They should spin smoothly and easily free of corrosion Lubricate with a light oil 2 Carefully check the armature for grounds or shorted turns Refinish the commutator surface if pitted or excessively worn 3 Check the brushes for wear Ensure that they are free in the brush holders Note Observe how the brushes are assembled in the brush holders and the position of the brush lead New brushes must be installed in the same mamner Remove old brushes and install new as follows a Remove brush spring clip from its mounting on brush assembly b Lift brush assembly from brush holder c Disconnect brush assembly lead d Install new brushes following the previous steps in reverse order 4 Inspect the wire harness and all connections for signs of damage due to overheating 5 Checkthe magnets on the statorto be sure they are securely mounted Reassembly 1 Install new brushes making sure they are free in the holder and the lead wires are positioned as when disconnected Raise all brushes to the locked position figure 7 16 Brushes and springs in their final position Brushes raised with the Springs in locked position on the side of the brush Figure 7 16 Brush Installation 2 Pl
62. ections Approximately 12 volts while steer ing or 21 volts while driving in high or lifting If yes go to 4 If no inspect and or replace controller Check hydraulic pump and motor figure 7 14 Chapter 7 for free movement If no check and or replace pump or motor Chapter 7 No Lift From Lower Controls 1 Check connection of upper control box to the stack wiring harness Connections OK If yes go to 2 lf no reconnect the harness 91930 0361270 10 11 12 Chapter 8 Troubleshooting Check voltage on wire 116 Is it 24 volts If yes go to 3 If no check 20 amp control box fuse fig 6 2 Chapter 6 Check voltage on wire 102 Is it 24 volts If yes go to 4 If no check emergency stop Check voltage on wire 113 Is it 24 volts If yes go to 5 If no check lower upper selector switch Check voltage on wire 22 at lift solenoid figure 7 13 Chapter 7 Is it 24 volts If yes go to 6 If no check and or replace wire 22 Check lift solenoid and ground wire at solenoid If grounded and solenoid is OK go to 7 If not replace wire and or solenoid Check K4 relay figure 8 9 and wire 208 Any volt age present If yes go to 8 If no K 4 relay is acti vated In this event contact Snorkel technical Service for additional help Check R2 and R5 resistors figure 8 9 Seated properly If yes go to 9 If no reconnect Check each resistor with voltmeter R
63. ees Platform N Ladder Figure 5 4 Scissors Removal Chapter 5 Scissor Platform Assembly Safety Prop The safety prop figure 5 5 is a heavy duty bar to be dropped into position preventing the scissors from col lapsing a safety feature designed to prevent injury It is located at the rear of the scissor assembly To secure it in position raise the platform sufficiently high to allow the prop to drop and swing freely Align the bottom of the prop so that when lowered it straddles and secures itself to the scissor pin directly beneath it see figure 5 5 Slowly lower the platform until the prop fully blocks and supports the weight of the platform m Figure 5 5 Safety Prop Emergency Bleed Down Valve The emergency bleed down valve figure 5 6 will re lieve the pressure on the lift cylinder and smoothly lower the platform Itis located at the front of the scissor as sembly To activate it simply depress the lever Emergency Bleed Down Valve Figure 5 6 Emergency Bleed Down Valve S1930 0361270 Chapter 6 Electrical System System Components Maintenance of the electrical system will often require the use of a voltmeter and reference to the wiring dia grams and schematics found in Chapter 8 Trouble shooting Wiring Harness ACAUTION To avoid personal injury or damage to the electrical system do not disconnect any wiring without first turning t
64. er Control Box Electrical Schematic a Battery o Diodeinhamess orondevice m moor owe a Joystick threshold resistor SW20 E E E H CE lowering circuit jumper SOL18 Reverse drive valve SW30 Joystick handle switch High speed relay SOL19 Left steer valve SW31 Upper control drive lift selector switch Tilt relay SOL20 Right steer valve SW32 Lift relay SOL21 Down valve SW33 Pothole switch Figure 8 6 Electrical Components EN Fun co Em Da S2 U1 U2 M J1 J2 K1 K2 K3 K4 8 8 S1930 0361270 Chapter 8 Troubleshooting B oo DSW 24v M FU1 2 250A K5 d O ro oe a B T2 B 3 PWM 3 2 1 LO o co N 8 2 2 a s 5 g 101 o TO J3 K MERO 3 K4 3 R5 2 usd J1 3 122 08 330 A m B Ri 1 1 121 221 TO J3 A d KA mon 13k 10k R2 3 3 a 3 3k 121 Ki O 110 104 Be FU2 _ O PR 20A a o d J2 22 J2 11 106 SW32 121 0 O 110 2 Ki 8 106 3 y oO ES
65. f yes go to 4 If no adjust repair or replace valve Inspect steer cylinder and linkage see procedure in Chapter 7 Hydraulic System Repair or replace if defective Right Steering 1 Check 4H 2 right steer valve solenoid figure 7 10 Chapter 7 wire 20 Operating properly If yes go to 2 If no check and or replace wiring and or valve Check FC 1 steering flow control valve Is it 50 G P M If ves go to 3 If no repair or replace valve Check R 2 steer relief valve Is it 1500 PSI If yes go to 4 If no adjust repair or replace valve Inspect steer cylinder and linkage see procedure in Chapter 7 Hydraulic System Repair or replace if defective S1930 0361270 Chapter 8 Troubleshooting DRIVE WHEEL MOTORS LEFT 14 CR LOWERING Q VALVE 24 11 045 O STEERING DRIVE RIGHT STEER 8 4H 2 a gt lt gt FORWARD DRIVE 8 4H 8 gt lt LEFT STEER
66. ff all controls Lowering alarm Sounds when platform lowers Control selector switch Check lockout function When lower controls are and lockout selected upper controls won t work and vice versa Raise and lower switch Check for smooth operation Battery disconnect switch Shuts off all controls Placards and decals Order replacements for damaged or Parts numbers in Parts Manual L illegible Operators manual In manual holder LI Optional features Horn Proper operation Flashing light Proper operation Battery condition indicator Proper operation Major Repairs Part Part Description Repair Performed 51930 0361270 3 9 Chapter 3 Maintenance Annual Maintenance 500 Hours Date Component Procedure Information v Freguent Maintenance Complete all procedures LI Checklist Hydraulic fluid system Drain flush and clean system Mobil DTE 13M above and replace fluid see Chap 7 10 F 12 C Mobil DTE 11M below 10 F 12 C Hydraulic return filter Replace See Parts Manual for LI Hydraulic pressures Check pressures See relief settings Chapter 7 LI LI Wheel bearings Clean and repack Conoco Super Sta 2 OR MobilGrease CM P above 32 F 0 C MobilGrease CM L below 32 F 0 C Major Repairs Part Description Repair Performed 3 10 S1930 0361270 Chapter 4 Base Frame Assembly Wheels When removing wheels from the unit park the unit on a hard level surface Using
67. from scissors area Lower platform until scissors are supported by safety prop TO STORE SAFETY PROP Raise platform until the open height is wide enough to position the safety prop Place the safety prop in the storage position Right Side TOWING INSTRUCTIONS Before towing pushing or winching machine must be on level ground Read and understand all instructions refer to Operator s Manual Turn battery disconnect switch to OFF position Use a wrench to rotate the lock out block to DISENGAGE BRAKE disengage the rear wheel CAUTION DO NOT use hydraulic power while brake pin s disengaging brake Brake is spring loaded Rotate free wheeling ALWAYS keep hands clear of mechanism valve counterclockwise as shown Free wheeling valve is located on the main control valve After moving machine close free wheeling valve FREE WHEELING and verify that brake resets VALVE after operating drive 91930 0361270
68. g Cold reduces battery ca pacity and retards charging Heat increases water us age and can result in overcharging Very high temperature can cause thermal run away which may lead to an explosion or fire If extreme temperature is an unavoidable part of an application consult a battery charger specialist about ways to deal with the problem An overly discharged battery might need to be cycled a few times before it can fully recover If a battery begins to heat before coming up to a full charge it might be nec essary to discharge the battery and recharge it a few times The charge and discharge cycle may improve its ability to accept a charge and facilitate its recovery to usable condition Inactivity can be harmful to deep cycle batteries If they sitfor several months a boost charge should be given more frequently in a warm climate once a month than in cold every 2 3 months Never store a battery in a discharged state The sulfate that forms during discharge may make the battery im possible to fully recharge Long Term Storage Prior to long term storage of the machine insure the batteries are fully charged After storage the batteries should be fully cycled prior to operation of the machine Place the batteries under load to drain them followed by a full recharge cycle Battery Charger The machine is equipped with an onboard automatic battery charger figure 3 2 lt contains an electronic cir cuit that
69. g and correcting it 91930 0361270 Flushing the System Properly maintained the filtration system greatly ex tends the useful life of the fluid However due to the ac cumulation of contaminants during normal operation of the machine the fluid eventually will require replace ment Fluid Replacement Guidelines Because of varying environmental and operating con ditions it is impossible to recommend an exact interval for fluid replacement The following are helpful guide lines e Always flush the system and change the fluid during the annual maintenance routine e In dirty environments flush and change more frequently Always flush and change the fluid following a component failure that introduced metal particles into the system e lf you operate in a climate with wide temperature variations change to the appropriate weight of fluid each spring and fall see Chapter 2 Specifications e Always use fluid that meet or exceeds Snorkel specifications Return Filter The return filter cartridge figure 7 2 should be changed after the first 50 hours of operation thereafter change during every 90 day maintenance routine or when the system is flushed If the machine is operated in a dirty environment the filter should be changed more often The part number is listed in the Parts Man ual Flushing Instructions After draining the fluid from the reservoir itis necessary to flush the system to remo
70. g steps will help determine the problem Obtain a power source ofthe nameplate voltage Do not make a permanent connection Tap the motor leads to the power source justlong enough to observe if the shaft turns If it does turn connect the power for a longer time If the motor operates normally go to step b If the shait still won t turn or makes noise as it runs disassemble it following the instructions b If the shaft turns freely connect an ammeter to one of the povver leads as shovvn on Figure 7 15 VVith the povver connected and the motor turning freely the ammeter should read less than 20 of the full load current from the nameplate If it does the motor is functioning properly and the problem is elsevvhere A Figure 7 15 Ammeter Connection Chapter 7 Hydraulic System Disassembly 1 Remove motor assembly bolts 2 Remove pulley end cover 3 Pull the armature out of the assembly in one swift motion Note The armature must be completely removed in one continuous motion Do not pull part way out and release If this is done the magnets will pull the armature back into the stator and cause severe damage 4 Remove commutator end cover Note Do not place the stator ring in any mechanical holding device such as a vise during the disassembly or assembly operation Permanent distortion or other damage will result 5 Remove bearings from armature shait If using a bearing puller take car
71. h the grooves Cleaning and Inspection 1 Inspect all load bearing welds for signs of fatigue or cracks Replace weldments where necessary 2 Thoroughly clean all components with solvent All contaminates must be removed to assure proper operation of the cylinder ADANGER Solvents present a potential flash fire hazard Keep away from heat sparks or flame Follow the manu facturer s label for proper use and disposal 3 Inspect head gland and piston for damage Repair any damage to seal grooves 4 Replace all seals with lightly oiled new ones from the seal kit The rod oil seal lips face toward the in side of the cylinder The rod wiper lip faces the out side of the cylinder Take care to not damage the seals during their assembly 5 Inspect the tube bore for scratches or scoring Small scratches may be removed with a honing stone or very fine emery cloth Large scratches or Scoring cannot be repaired the tube weldment should be replaced Clean tube with solvent 6 Inspect the cylinder rod for scratches or dents Re pair small scratches with a honing stone or very fine emery cloth Large scratches or dents cannot be re paired and require replacement of the rod weldment Clean the rod with solvent Assembly 1 Coat all components with a thin layer of new hy draulic fluid 2 Carefully push the assembled head gland onto the rod A soft mallet may be used to gently tap the gland 3 Install the piston onto
72. haft can be seated Using the hand press apply dovvnvvard pressure on the drive link Note Do not use excessive force which may deform the thrust bearing and or the bearing races 9 Place the manifold 14 with the seven tear drop shaped holes facing down over the drive link 10 Align the seven bolt notches around the outside of the manifold with the bolt holes in the housing Place the manifold boot 15 groove side up around the manifold onto the housing 11 Install two new body seals 5 into the grooves on both faces of the rotor one on each face 12 Place the rotor deep groove side down on the manifold 13 Place the balance plate 17 with the three check ball dimples up on top of the rotor Replace the three check balls into the dimples 14 Install the end cover seal 6 into the seal groove of the end cover 19 15 Place the end cover onto the balance plate with the ID tag holes directly above the housing ports Note Be very careful that the seal does not fall out but remains securely in place 16 Align the components using the painted or drawn line from step one Install seven bolts 21 through the end cover through the aligned holes in the mo tor and into the housing Pre torque the bolts to 10 ft Ib The final torque should be 51 1 5 5 ft lb Wheel Motor Hose Attachment Guidelines Note It is very important that wheel motor hoses be attached properly The normal steering movement
73. he battery switch to off and disconnecting the battery ground cable from the battery Figure 6 1 Battery Switch Off Repair Remove a wiring harness only ifitis damaged or unus able If a wire must be spliced or repaired be sure to sol der the connection with rosin core solder If wires are to be replaced always use the same gauge never smaller Always protect the connections with electrical connectors or insulating tape Removal and Installation For efficient installation of a new harness connect the new one as you disconnect the old one or tag the wires to insure proper installation Take care to insure that the harness is installed properly Be careful to replace all harness clips and tie wraps as they were This should prevent chafing and or wear due to vibration Connection diagrams are found at the back of chapter 8 Troubleshooting Lower Control Box The schematic for the lower control box is located at the back of Chapter 8 Troubleshooting The most common maintenance point in the control box is the fuse figure 6 2 Replace a burnt out fuse with a 20 amp AGC type Buss fuse 1 4 X 1 1 4 91930 0361270 Contact corrosion is a common problem lt is a good idea to periodically clean the contacts with a contact cleaner The speed adjustment potentiometer figure 6 2 con trols the drive speed of the unit and is preset and locked at the factory If the unit develops an improper drive speed check
74. heck for proper operation See Chap 3 Maintenance Check for leaks and proper operation Date Information v Add distilled water if necessary Insure batteries fully charged Mobil DTE 13M above 10 F 12 C Mobil DTE 11M below 10 F 12 C Replace every 90 day maintenance procedure See Chap 7 Hydraulic System Do not lubricate Conoco Super Sta 2 OR Mobilgrease CM P above 32 F 0 C Mobilgrease CM L below 32 F 0 C LI LI 91930 0361270 Frequent Maintenance cont Component Procedure Information v Pothole protector interlock Check for damage proper operation LI and alarm Swing out trays Check for proper operation LI Tray hinges and latches Lubricate Powdered graphite LI Pothole protection pivot Lubricate Spray lubricant LI points Platform Lift capacity Check lift operation at maximum load 500 Ib 227 kg Raise and lower including Check for smooth operation and emergency lower proper speed Guardrail system Check for damage broken welds Platform extension Smooth operation locking pins OK Upper control station Drive steer Proper operation Emergency stop Shuts off upper controls Lowering alarm Sounds when platform lowers Drive motion alarm Sounds when unit moves Electrical power outlet Proper operation Travel speed 1 High 2 mph 3 22 kph maximum 2 Low 0 4 mph 64 kph maximum Lower control station Operating controls Proper operation Emergency stop Shuts o
75. heir own warranty Snorkel will however to the extent permitted pass through any such warranty protection to the Customer or Dealer 2 Any Snorkel product which has been modified or altered outside Snorkel s factory without Snorkel s written approval if such modification or alteration in the sole judgment of Snorkel s Engineering and or Service Departments adversely affects the stability reliability or service life of the Snorkel product or any component thereof 3 Any Snorkel product which has been subject to misuse improper maintenance or accident Misuse includes but is not limited to operation beyond the factory rated load capacity and speeds Improper maintenance includes but is not limited to failure to follow the recommendations contained in the Snorkel Operation Maintenance Repair Parts Manuals Snorkel is not responsible for normal maintenance service adjustments and replacements including but not limited to hydraulic fluid filters and lubrication 4 Normal wear of any Snorkel component part s Normal wear of component parts may vary with the type application or type of environment in which the machine may be used such as but not limited to sandblasting applications 5 Any Snorkel product that has come in direct contact with any chemical or abrasive material 6 Incidental or consequential expenses losses or damages related to any part or equipment failure including but not limited to freight cost to transpor
76. ight side to 1 1 4 11 Using the lower controls raise the platform As the floor approaches 6 feet the level sensor interlock should halt the platform and sound an alarm Fully lower the platform 12 Repeat steps 8 through 11 for the left side Lubrication Lubricants listed in this service manual should be used as specified It is important that all lubricants meet or exceed OEM specs If you contemplate using another non specified lubricant please contact the Snorkel Customer Service Center for suitability evaluation Frequent Lubrication Points 90 day or 150 hours e King pins figure 3 6 e Tray latches figure 3 6 and hinges e Pothole protection pivot points figure 3 7 Chapter 3 Maintenance King Pins and Latches Use a grease gun to lubricate the king pins figure 3 6 Wipe away any excess lubricant from exposed surfaces Use powdered graphite to lubricate the tray latches figure 3 6 or ON 7 Y a ATTERY A x FORK LIFT Figure 3 6 King Pin and Tray Latch Pothole Protection Pivot Points To access the pothole protection linkage pivot points fig ure 3 7 fully open both trays Use spray lubricant on each point Make sure to lubricate the points at each end of the skid i IE i Pivot Points Figure 3 7 Pothole Protection Pivot Points Preventive Maintenance This manual provides preventative maintenance sched ules designed to detect any defectiv
77. in allow several quarts to drain prior to catching your sample This will insure that you don t collect contaminants that may have settled to the bottom Compare the sample to a sample of new fluid and a sample of a previous inspec tion if available Condition Possible Cause Dark color Oxidation contamination Cloudiness or milkiness Water or wax in fluid Rancid or burned odor Oxidation Increase in viscosity Oxidation improper additives water in fluid Decrease in viscosity Improper additives additive deterioration Layers of fluid Water or improper additives Contamination emulsion of water Foreign particles Figure 7 1 Visual Fluid Inspection Oxidation is a chemical reaction that occurs when air reacts with various compounds in the fluid High oper ating temperatures will increase the rate of oxidation as will the presence of water or air Oxidation pro duces varnishes that bake onto hot surfaces These varnishes are acidic and will attack metal surfaces causing damage to pumps motors and valves Additionally the presence of water can cause rust and corrosion in the system and reduce the dielectric capa bility of the fluid Another more accurate method of fluid inspection is laboratory analysis Your fluid supplier should be able to supply you with the name of a test lab in your area However you inspect the fluid it is important that you quickly respond to any evidence of a problem locatin
78. installation Twisting short ens hose life and can cause premature failure It also places an unscrewing pressure on the fitting causing it to work loose If the printing on the hose is straight the hose is probably straight also To prevent twisting the hose during installation use two wrenches Use one wrench to hold the fitting and the other to tighten the nut Chapter 7 Hydraulic System Manifold Assembly The manifold assembly figures 7 10 4 7 11 contains a series of solenoid activated directional valves that direct the flow of fluid throughout the system It also contains system steering and lift pressure relief valves The test ports for pressure checks are also located here Solenoid Activated Di rectional valves Steering left and right Lift Drive forward and reverse gt Counter Balance Valves Figure 7 10 Manifold Assembly Free Wheeling Valve The free wheeling valve figure 7 11 is mounted on the manifold assembly lt is a needle valve that when opened diverts the fluid flow allowing the wheels to turn freely which allows the machine to be towed or pushed During normal operation it should be closed l n gil A Manifold Assembly Se d di Free VVheeling Valve Figure 7 11 Free Wheeling Valve System Steer and Lift Relief Settings The following adjustment procedures require the use of a 0 to 5000 psi pressure gauge
79. iometer figure 8 13 lf you cannot get any voltage on wire 101 or it is the incorrect voltage call Snorkel technical service for additional help B Contactor 1 From the lower control activate platform lift while watching and listening to see that the contactor closes Figure 8 2 If yes go to C Pump Motor If no go to 2 Check terminals on contactor under rubber boots for proper connections If yes go to 3 If no secure the connections Check wire 207 on the side tabs of the contactor figure 8 22 while activating a machine function Is it 24 volts If yes go to 4 If no replace wire Check continuity of ground wire 3M next to 207 to the B connection on the controller Continuity OK If yes go to 5 If no check and or replace wire 3M Check contactor diode figure 8 23 to insure it is oriented and seated correctly If yes go to C Pump Motor If no seat or replace diode Repeat step one If contactor closes go to C Pump Motor If no replace contactor C Pump Motor 1 Check voltage of the positive battery connection at the motor while activating a machine function Is it 24 volts If yes go to 2 If no check contactor con nections and cable between contactor K5 and pump motor Check negative cable from motor to controller Con nections OK If yes go to 3 If no tighten connec tions or replace cable Check voltage at the positive and negative motor conn
80. kd 3 1 PO ira 0700000007 3 1 Hydraulic System 3 1 Return Filter 3 2 Hydraulic Fluid Reservolr 3 2 Batteries 3 2 Battery Maintenance 3 3 Battery Charger 3 4 Pothole Protection Interlock Test 3 4 Level Sensor Interlock Test 3 5 Lubrication 6 6866468 7 we owe oo OES 3 5 King Pins and Latches 3 6 Pothole Protection Pivot Points 3 6 Preventive Maintenance 3 6 Maintenance Schedules 3 6 Daily Prestart nspection 3 6 Frequent Maintenance 3 6 Annual Maintenance 3 6 Prestart Inspection Checklist 3 7 Frequent Maintenance 90 Day or 150 Hours 3 Annual Maintenance 500 Hours 3 10 Chapter 4 Base Frame Assembly ra no ik mah ne ae ANG 4 1 Wheel Drive Motors 4 1 Wheel Motor Service 4 1 Disassembly ce wen Kap dem tha azda 4 1 Assembly gawad Kawa baa en 7 7 4 2 Wheel Motor Hose Attachment Guidelines 4 2 Pothole Protection 4 3 Chapter 5 Scissor Platform Assembly Platform Assembly 5 5 Platform Removal Procedure 5 5 Scissor Assemb ly 5 5 Scissors Removal
81. l maintenance personnel must be trained and qualified to operate the machine Safe use requires constant vigilance Safety alerts throughout the manual highlight situations in which ac cidents can occur These alerts require special atten tion When performing maintenance or service work on the machine be sure to wear safety glasses shoes and all appropriate protective clothing and equipment Be careful of rings jewelry loose clothing or long hair that may become caught in machinery or pinch points 91930 0361270 When a service procedure requires manual lifting use proper lifting technigues The potential for serious injury or damage is greatly re duced by reading and following the procedures and guidelines in this manual Do Not Perform Maintenance Unless 1 You are trained and gualified to operate and per form maintenance on this machine 2 You have read understand and obey e manufacturer s instructions and safety rules e your employer s safety rules e all applicable governmental regulations 3 You have the appropriate tools lifting equipment and suitable workshop The information in this manual does not replace any safety rules that apply to your local area Before operat ing this machine it is essential the operator is fully in compliance with local laws and regulations Safety Alerts A safety alert symbol is used throughout this manual to indicate danger and caution instructions Follow thes
82. lean all hose connections Make sure the work surface 3 1 Chapter 3 Maintenance is clean during any assembly process Thoroughly clean and lubricate all parts prior to reassembly Parts should be inspected prior to reassembly Burrs nicks or scratches may be removed by honing with 600 crocus cloth followed by athorough clean and dry Ifthis does not restore the partto serviceable condition replace the part Do not alter the contour of any part Prior to disconnecting any hydraulic hose make sure the part is sufficiently blocked or the weight is removed from the cylinder by a lifting device Mark or tag all hydraulic lines and their receptacles prior to disconnection This will facilitate the reconnecting process This tagging procedure will also aid in electri cal wiring maintenance Return Filter The hydraulic fluid return filter figure 3 1 is mounted in the right hand tray next to the hydraulic fluid reservoir The filter elementis athrow away type the part number is in the Parts Manual and should be changed after the initial break in period approximately 50 hours of opera tion Thereafter it should be changed as part of every 90 day maintenance procedure more often ifin a dirty environment During filter change examine the interior of the filter housing for deposits of metal particles If present they are a sign of excessive wear in one or more of the sys tem components Valve Manifold Hy
83. linder Operating properly lf yes go to 6 If no repair or replace valve Inspect lift cylinder see procedure in Chapter 7 Hydraulic System Lower ily 2 Raise platform and secure safety prop Check 2H 11 lowering valve wire 21 Activating properly If yes go to 3 If no inspect and or re place wire and valve Check the down orifice next to the check valve on the lift cylinder Operating properly If yes go to 4 If no repair or replace orifice Check 2H 9 up valve Deactivated lf no repair or replace valve Forward Drive 1 2 Check 4H 8 forward drive valve solenoid and car tridge Operating properly If yes go to 2 If no check and or replace wiring and or solenoid Check V 3free wheeling valve figure 7 11 Chapter 7 Closed If yes go to 3 If no close or replace if defective Chapter 8 Troubleshooting 3 Check brake cylinder figure 7 19 Chapter 7 Re leasing properly lf yes go to 4 If no check brake shuttle and V 2 metering valve Operating prop erly If ves inspect brake cylinder see procedure in Chapter 7 Hydraulic System If no repair or re place shuttle or valve 4 Check hydraulic pressure to wheel drive motors Is it 2800 PSI If yes go to 5 If no check and adjust R 1 system relief valve figure 7 13 chapter 7 to 2800PSI 5 Check CB 1 and CB 2 counter balance valves fig ure 7 10 Chapter 7 Operating properly lf yes go
84. lock is a safety feature designed to prevent a tip over hazard t vvill measure the tilt of the machine and protect against raising the platform at a dangerous angle Routine testing of its operation is es sential for safety S1930 0361270 Chapter 3 Maintenance ADANGER The machine may tip over if the level sensor inter lock does not operate properly Death or serious in ury can result from a tip over accident The interlock must be repaired or adjusted by a trained service technician before the machine can be safely used 1 Fully complete the pothole protection interlock test 2 Lower platform to stovved position 3 Remove all persons and material from platform 4 Park the unit on a flat slab Use a carpenters level to insure the floor is level vvithin 1 8 difference front to rear and 1 16 difference side to side 5 Using a sling and hoist or a floor jack raise the front of the unit 4 1 4 6 Using the lovver controls raise the platform As the floor approaches 6 feet the level sensor interlock should halt the platform and sound an alarm Any attempts to further raise the platform should reacti vate the alarm and the platform should not move Fully lovver the platform 7 Repeat steps 5 and 6 for the rear 8 Elevate the right side 3 4 9 Using the lower controls raise the platform lt should raise smoothly to its full height with no alarm Fully lower the platform 10 Elevate the r
85. meet or exceed Snorkel original eguipment speci fications Hoses are flexible tubes are rigid Check SAE working pressure and burst pressure rat ings printed on the hose Make sure they equal or ex ceed that of the original Make sure also that the diameter of the replacement is the same as the original neither larger nor smaller Any change in diameter from design specifications can have a dramatic and damag ing effect on fluid flow ADANGER Hydraulic fluid escaping under pressure can have enough force to inject fluid into the flesh Do not ex pose hands or any part of the body to a potential fluid leak Serious infection or reaction can result from injury by escaping hydraulic fluid Seek medi cal attention at once Plug or cap all open ports and lines to prevent contami nation This will also prevent damage to sealing sur faces and fitting threads Hose Routing A good rule to follow is that if the installation looks good it probably is Always route for proper appearance Routing tips e Route the hose to avoid abrasion and chafing e Always leave some slack when installing straight hose Pressure changes during operation can sometimes shorten the hose e Make sure the hose flexes in the same plane as the bend e Make bends gradual not sharp Route the hose to extend straight out from fittings for a minimum distance of double the I D before beginning a bend Hose Twist Never twist the hose during
86. minals K5 Contactor PWM Controller Figure 8 22 Wiring Harness Connections right Chapter 8 Troubleshooting CONTACTOR D GROUND GE CONTROLLER 20 8 Aa LIA s 8 El 3 SS AN GE MOTOR CONTROLLER o o N Va 23 8 2 21 LOVVER CONTROL BOX l GROUND CHASSIS 24 PIN CIRCULAR AMP PLUG 14 15 16 9 n sen __ STACK SWITCH DF 3A GI one U GROUND HYDRAULIC TRAY POTHOLE SWITCH 4 5 8 DIODE SUPPRESSION RIGHT 8 LEFT VALVES i L TILT SENSOR VALVE MANIFOLD K Figure 8 23 Main Harness 21 3K Output voltage controller From pressure switch IN From lowering interrupt switch wire 0 Pressure switch power Forward drive valve Figure 8 25 Pressure Switch C Figure 8 26 Suppression Left P Pos Wire Suppression left valve ground Suppression left valve Pos Wire Desorption Suppression right valve ground Suppression right valve Figure 8 27 Suppression Right P 8 18 91930
87. n aerial platform maximum travel height the maximum platform height or the most adverse configuration s with respect to stability in which travel is permitted by the manufacturer maximum wheel load the load or weight that can be trans mitted through a single wheel to the floor or ground Minimum Safe Approach Distance the minimum safe dis tance that electrical conductors may be approached when us ing the aerial platform Also called M S A D operation the performance of any aerial platform functions within the scope of its specifications and in accordance with the manufacturer s instructions the users work rules and all applicable governmental regulations operator a qualified person who controls the movement of an aerial platform personal fall arrest system a fall protection system that is used while working on an unprotected edge such as a roof top with no guardrail This system includes a harness lan yard or other connecting device a fall arrester an energy absorber or decelerator an anchorage connector and a se cure anchorage such as a building beam girders or columns An aerial platform is not a fall arrest anchorage platform the portion of an aerial platform intended to be occupied by personnel with their necessary tools and materi als platform height the vertical distance measured from the floor of the platform to the surface upon which the chassis is being supported pothole protection
88. n the safety prop before detaching the lift cylin der Cylinder Removal 1 Raise the platform and properly position the safety prop Lower the platform until the safety prop is se curely in place and the weight of the platform is sup ported by it 2 Activate the emergency bleed down valve figure 5 6 Chapter 5 atthe front of the scissors assembly and keep it open until all pressure has been re lieved from the cylinder ADANGER Disassembling a pressurized cylinder is hazard ous Death or serious injury can result from sudden release of pressure Make sure pressure is relieved prior to removing the cylinder from the machine 3 At the upper end remove the mounting bolt figure 7 20 and use a hammer and punch to knock out the pin attaching the cylinder to the scissor assembly figure 7 20 91930 0361270 4 With one person holding the cylinder end to prevent damage to the cylinder rod retract the cylinder us ing the lower controls A CAUTION Any dents dings or scratches in the cylinder rod can cause the cylinder to leak potentially leading to cylinder failure Take care to not damage it 5 Disconnect the fluid hoses from the base of the cyl inder Cap the hoses and the ports to prevent con tamination 6 Remove the two mounting bolts from the base and knock out the pin The cylinder should now be free Service Procedure To properly disassemble and service the lift cylinder the follo
89. nation and or 2 limited equipment and facilities Disassembly and repair of such components must be performed by authorized personnel in a clean properly equipped shop During the assembly process be sure to always replace old seals with new Seal kit parts numbers are in the Parts Manual Heat Generation Continuous operation of an overheated machine will damage the fluid seals and o rings within the system Heat is generated when pressurized fluid escapes to the reservoir prior to performing its work Heat gener ated due to the small amount of internal leakage be cause of machining tolerances has been compensated for in the system design However larger leaks due to housing cracks defective relief valves or worn seals for example allow excessive fluid return to the reser voir creating surplus heat The following conditions may also generate excessive heat e Excessive pump speed during high flow operation e Worn or faulty pump e Low fluid level e Improper fluid used Fluid Condition Visually inspecting a sample of the hydraulic fluid dur ing the 90 day maintenance routine can provide impor tant clues to potential problems in the system Before taking a fluid sample operate the unit to warm and cir culate the fluid Take the sample from the middle of the reservoir This can be done by using a clean hand pump or disposable syringe and a piece of plastic tubing If you must take the sample from the bottom dra
90. ned for safety and efficiency Following them will ensure correct installation and smooth operation of all machine com ponents and systems Many of the machine s components are bulky and heavy and will require the aid of mechanical devices if they are to be moved Always be mindful of your human limitations use correct lifting techniques Do not allow heavy parts to restin an unstable position be sure they are supported safely and securely All service work on the machine should be done with the platform fully stowed unless the work requires access under the platform In that case be sure the safety prop is Securely positioned before beginning work Cleaning Dirt and foreign matter are enemies to fight against They can and will seriously shorten the service life of vi tal components The machine has many built in safe guards to protect against contaminates Seals gaskets and filters are provided to keep components and hy draulic fluid clean However it is necessary that they be serviced following the schedules outlined in this man ual Make every attempt to keep the service area as clean as possible Prior to disconnecting any hydraulic lines be sure to wipe clean the connection area Immediately after dis connecting clean all openings and fittings then cap or cover all openings to avoid contamination Keep all new parts in their packages until ready for im mediate installation All removed parts should be cleaned and
91. of the wheels can cause premature wear and leakage of any hoses and fittings that are improperly installed If wheel motor hoses are removed during any service procedure the following connection guidelines are im portant to follow refer to the hydraulic schematic in Chapter 8 Troubleshooting for hose identification ASS Y IN ZA SS KI SS FIT Om Left Wheel Motor Right Wheel Motor U bolt Hoses Figure 4 3 Hose Routing front view S1930 0361270 e After routing the power hoses through the access hole in the back wall of the wheel chamber and through the u bolt mounted to the wall attach both hoses to the B ports of the right and left motors Measure 22 inches from the u bolt to the right motor and 18 inches from the u bolt to the left motor see figure 4 3 The ports are clearly labeled on top of each motor e Route the connecting hose from port A ofthe right motor to port A of the left motor through the u bolt with 19 1 2 inches of hose from the u bolt to the right motor and 23 inches of hose from the u bolt to the left motor figure 4 3 e All 45 hose fittings should be oriented rearward and against the motor mounting plate figure 4 1 e Following the instructions under Fittings in chapter 7 Hydraulic System secure the hose fittings to the proper ports on the motors The fittings should be torqued to 21 ft Ib e Be sure to cover all expo
92. ol Change to upper control function position e Battery switch is off e Change to on e Emergency Stop button engaged e Pull button out to disengage Platform will not raise e Platform load capacity exceeded e Remove excess weight see specifications Platform will not raise or e Drive Lift selector in drive e Change to lift lower from upper controls Platform will not raise and e Unit is not on sufficiently level surface Lower platform and move to level spot alarm is sounding e Pothole skid prevented from lowering Check pothole skids for obstruction Platform drifts downward e Emergency bleed down valve not e Check lever return to normal operating properly disengaged position e Leak or malfunction in the hydraulic e Manually stow the unit and repair system Platform will not lower e Safety prop in place e Stow prop Platform extension will not e Latch pin not removed e Remove pin extend Drive functions won t work e Drive Lift selector in lift e Change to drive e Unit is not on sufficiently level surface Lower platform and move to level spot e Free wheeling valve is open e Fully close valve e Platform load capacity exceeded e Remove excess weight see specifications e ow hydraulic pressure e Manuallv stow the unit and repair Drives in slow only e Platform elevated above six feet e For faster drive platform must be lowered Unit will not steer e Joystick interlock switch not engaged e Interlock switch must be engaged or stee
93. onal Inc has exercised reasonable care and diligence to present ac curate clear and complete information and instructions regarding the techniques required It is the responsibil ity of the service personnel to a routinely inspect the machine for wear and damage b perform mainte nance following the recommended schedules and pro cedures c perform necessary repairs following outlined safety procedures and d following any ser vice or repair to fully inspect and test the machine insur ing that the work has been correctly performed and that the machine is functioning properly Snorkel International Inc will not be liable for unautho rized alterations or modifications to the machine Nor shall it be liable forimproper or abusive operation No al teration or modification of the machine that in any way may affect its structural integrity stability and or safe use shall be performed without specific written approval from Snorkel International Inc Unauthorized alterations or modifications will void the warranty and may adversely affect the machine s per formance endangering personnel and or property Snorkel International Inc will not be responsible for un authorized alterations or modifications that cause death personal injury and or property damage Safety For maximum safety it is essential that all personnel ac tive in the care or maintenance of this machine read and understand this manual Additionally al
94. or 150 Hours Component Electrical system Batteries Battery charger Cables and wiring Right and left drive motors Hydraulic system Hydraulic fluid Hoses tubes and fittings Free wheeling valve Return filter Fluid reservoir Filler cap Motor and pump assembly Fluid inspection Structure and welds Slide blocks Bolts and fasteners King pins Wheels Steering cylinder fasteners and linkage Scissor arm assembly Pivot pins snap rings roll pins Lift cylinder and valves Safety prop Emergency bleed down valve Hydraulic tubes and hoses Wiring and electrical cables Bearings Parking brakes Procedure Clean terminals check electrolyte levels and cable connections Proper condition Check for wear or damage Check tightness proper operation Check fluid level Check for leaks Full closed position First replacement after 50 hrs more often in dirty conditions Check for leaks Securely fastened Check for proper operation Check condition Check for damage cracks dents Check for wear and proper operation All tight and snug Lubricate Check for wear torque all nuts bolts to 70 80 ft Ib Check for damage leaks and proper operation Check for damage wear or missing No damage or leaks OK operation No damage or deformation Check for proper operation Check for leaks Check for wear or damage Check condition do not lubricate replace if worn Level sensor interlock C
95. oward the in side of the cylinder The rod wiper lip faces the out side of the cylinder Take care to not damage the seals during their assembly 5 Inspect the tube bore for scratches or scoring Small scratches may be repaired with a honing stone or very fine emery cloth Large scratches or scoring cannot be repaired the tube weldment should be replaced Clean tube with solvent 6 Inspect the cylinder rod for scratches or dents Re pair small scratches with a honing stone or very fine emery cloth Large scratches or dents cannot be re paired and require replacement of the rod weldment Clean the rod with solvent ADANGER Solvents present a potential flash fire hazard Keep away from heat sparks and flame Follow the man ufacturer s label for proper use and disposal Assembly 1 Coat all components with a thin layer of new hy draulic fluid 2 Carefully push the assembled head gland onto the rod A soft mallet may be used to gently tap the gland Take care to not damage the rod seal 3 Lubricate the inside of the tube with clean hydraulic fluid Line up the tube and rod center lines and gently push the rod assembly into the tube Position the piston guide halves on the rod as the groove en ters the tube 4 Screw the head gland onto the tube weldment Torque to 250 300 ft Ib 5 Insert set screw into the head gland cap and torque to 10 11 ft lb Testing 1 Atthe bench connect a power pack hydraulic test
96. ring switch will not function S1930 0361270 8 1 Chapter 8 Troubleshooting Problem Unit drives slowly or operates sluggishly system Wheels won t turn when towing or pushing the unit e Free wheeling valve closed No power to electrical outlet e Ground fault circuit interrupter Lower control box fuse burns out continually Brakes don t function Ammeter on charger registers zero when battery charger is plugged in power source Electrical Function Diagnostics These troubleshooting steps are designed to isolate specific malfunctions in the electrical system All com ponent reference numbers are found on the electrical schematics at the end of the chapter The procedures require the use of a properly connected black to ground red to hot voltmeter with the capacity to read a range of voltages up to 50 All electrical troubleshooting procedures should begin with the following basic checkpoints e ps Battery Supply RA W g M Fuse 250 amp Ca o Figure 8 1 Battery Tray e Check drive lift selector upper controls e Check emergency stop switch upper and lower controls e Check control selector switch lower controls e Check battery switch figure 6 1 Chapter 6 8 2 Probable Cause e Low battery voltage e Kink leak or damage to hydraulic e Break pins engaged e Power supply not plugged in at base e Electrical system malfunction e Brake pins not eng
97. s 4 and 5 4 To adjust the relief setting remove the external cap from the steer relief valve figure 7 13 91930 0361270 5 Turn the inner set screw clockwise to increase the pressure setting Counter clockwise will decrease the setting Note Be sure the steer switch is in right turn dead head position when checking the pressure Lift Relief Adjustment 1 Attach test gauge to the system test port figure 7 12 2 Load the platform with 500 pounds of weight 3 Raise the platform from the lower controls while watching the test gauge lt should read approxi mately 2500 psi The reading should be taken be fore the platform reaches six feet and the scissor assembly lifts off the speed limit switch lf 2500 psi the valve is properly set f not goto steps 4 and 5 4 To adjust the relief setting remove the external cap from the lift relief valve figure 7 12 5 Turn the inner set screw clockwise to increase the pressure setting Counter clockwise will decrease the setting Hydraulic Pump The hydraulic pump figure 7 14 is responsible for the movement of all fluid in the machine and as such is the heart of the hydraulic system It is mounted directly to the pump motor inside the hydraulic tray Pump Service The service of the hydraulic pump requires a replace ment seal kit see the Parts Manual for the part number The removal of four bolts allows the disassembly of the pump Pay special
98. sed hoses with woven abrasion guard material and install zip ties every 6 inches Pothole Protection Pothole protection is a safety feature that is designed to prevent tip over lt consists of two skids figure 4 4 along each side of the machine that deploy into a down position when the platform is raised to approximately 6 feet Figure 4 4 Pothole Protector Skid These skids effectively lower the machine s wheel base to a height of only 3 4 which protects against a tipover hazard should a wheel sink or drop into a pothole S1930 0361270 Chapter 4 Base Frame Assembly Pothole See Trigger E She a a Had Ella Extension kom ta xo 57 y pa 4 Figure 4 5 Pothole Mechanism The skids retract into an up position when the platform is lowered and the pothole activator bar which is attached to the scissor assembly lowers onto and depresses the pothole trigger figure 4 5 Chapter 5 Scissor Platform Assembly Platform Assembly Most of the operating functions of the machine includ ing lift and drive can be performed on the platform at the upper controls For safety purposes any personnel op erating the machine from the upper controls should be attached to the platform by a fall restraint system m SA um i Controls i Wo mm WA Electrical L Outlet hall Mr gt 1 u Paka Ba a io A Dg Figure 5 1 Pl
99. side 4 front to rear Ground clearance Pothole skid up 2 1 2 6 35 cm Pothole skid down 3 4 1 90 cm Travel speed Platform lower than 7 2 1 m 2 mph 3 2 km h maximum Platform higher than 7 2 1 m 0 4 mph 64 km h maximum Platform function speed Raise 12 to 20 seconds Lower 20 to 26 seconds Wheelbase 54 137 2 cm Batteries 24 V DC 220 amp hr Recommended electrolyte Distilled water AC outlet on platform 120 V 17 4 amp Fuse in lower control box 20 amp AGC type Buss fuse 1 4 X 1 1 4 Recommended hydraulic fluid Mobil DTE 13M ISO VG32 above 10 F 13 C Mobil DTE 11M ISO VG15 below 10 F 13 C Hydraulic system pressure 2 800 psi 19 305 kPa Maximum fluid operating temperature 160 F 71 C Hydraulic fluid reservoir capacity 3 US gal 11 4 liter Hydraulic system capacity 3 5 US gal 13 2 liter 2 2 91930 0361270 Ambient air temperature operating range Drive system Maximum wheel load Maximum floor pressure Vibration Sound level Warranty 51930 0361270 Chapter 2 Specifications 0 F to 110 F Fahrenheit 18 C to 43 C Celsius Front two wheel drive 1 416 Ib 642 kg 175 psi 12 3 kg cm Less than 2 5 m s Below 70 dB A Five year Chapter 3 Maintenance Service Guidelines This manual provides information necessary to service and maintain the aerial platform The procedures and techniques described have been carefully desig
100. t the machine to a repair facility downtime of the machine lost time for workers lost orders lost rental revenue lost profits or increased cost This warranty is expressly in lieu of all other warranties representations or liabilities of Snorkel either expressed or implied unless otherwise amended in writing by Snorkel s President Vice President Engineering Vice President Sales or Vice President Marketing SNORKEL MAKES NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION OF THIS LIMITED WARRANTY SNORKEL MAKES NO IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND DISCLAIMS ALL LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO INJURY TO PERSONS OR PROPERTY The Customer shall make all warranty claims through its local Authorized Dealer and should contact the Dealer from whom the Snorkel product was purchased for warranty service Or if unable to contact the Dealer contact the Snorkel Service Department for further assistance Effective July 1995 O Snorkel all rights reserved Printed in USA
101. t with a high voltage electrical conductor or if there is an immediate danger of such contact Personnel on or near an aerial platform must be continuously aware of electrical hazards recognizing that death or serious injury can result from contact with an energized conduc tor CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead components chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 91930 0361270 Table of Contents Chapter 1 Safety 91930 0361270 MOGUCOM z s 5 carey od k ER ap y ara 1 1 Disclaimer of Liability 1 1 Safety 099 0000007 1 1 Safety Alerts 1 1 NOTES s a ohne fe 7 DVE AA 1 1 Supporting Lifting Devices 1 2 Electrocution Hazards 1 2 Minimum Safe Approach Distance 1 2 Safety Related Placards and DecalS 1 3 Chapter 2 Specifications Component ldentification 2 1 General Specifications 2 2 Chapter 3 Maintenance Service Guldelines 3 1 Cleaning La oa eens 2 oe a kai a ae 3 1 Component Removal and Installation 3 1 Component Disassembly and Reassemb y 3 1 Bearings 3 1 i PE AA pu
102. tact points of the aerial platform that form the stability support e g wheels casters outriggers stabilizers battery tray a swing out compartment that holds the batter les and the battery charger center of gravity the point in the aerial platform around which its weight is evenly balanced chassis the integral part of the aerial platform that provides mobility and support for the scissors structure electrolyte an electricity conducting liquid covering the cells in a lead acid battery usually distilled water fall restraint a system that is used while working on a boom lift within the boundaries of platform guardrails to provide re straint from being projected upward from the platform This system includes a harness or belt lanyard and a lanyard an chor Although federal regulations OSHA ANSI and Snorkel do not require the use of fall protection beyond the platform guardrails on scissors lift aerial platforms local state or em ployer rules may require their use floor or ground pressure the maximum pressure ex pressed in pounds per square inch a single wheel concen trates on the floor or ground free wheeling valve a needle valve that when adjusted open allows hydraulic fluid to flow through the wheel drive mo tors This allows the aerial platform to be pushed or towed without damage to the drive motors frequent maintenance the maintenance routine required after 90 days or 150 hours of oper
103. tem because of contamination due to a component failure replace the return filter with a new one prior to flushing Also drop a mag netinto the reservoir to collect metal contaminants 6 Fillthe cleaned reservoirwith new hydraulic fluid fil tered through a 10 micron filter 7 Cycle the fluid throughout the system all cylinders and motors by cycling the machine through all its functions driving and lifting This flushes the con taminated fluid from allcomponents and lines to be collected in the reservoir 8 Completely drain the reservoir again properly dis posing of the contaminated fluid Retrieve the mag net installed during Step 5 9 Replace the dirty return filter with a new one 10 Fill the reservoir with new fluid to the fill mark filtering through a 10 micron filter Note Change the filter of a new machine after the first 50 hours of operation Thereafter follow maintenance checklist guidelines Chapter 7 Hydraulic System Fittings Most hydraulic ports and fittings are SAE straight thread with o rings They have been selected because they provide excellent sealing and vibration resistant qualities When handling or storing hydraulic compo nents use caps and plugs to prevent damage or con tamination When tightening fittings be careful not to over tighten The fittings must be tight and snug but over tightening may damage or deform the part causing leaks Torque Specifications Tub
104. teries should be distilled or treated to not exceed 200 TDS total dissolved solids parts per million Particular care should be taken to avoid metallic solids iron A fully charged battery will give you the best and longest Service Be sure the batteries are fully charged before testing or using A fully charged battery without a drain or load after the surface charge has dissipated is 6 35 volts for a 6 volt battery e 6 30 volts 93 charged e 6 27 volts 89 charged e 6 22 volts 80 charged e 6 10 volts 50 charged 91930 0361270 Chapter 3 Maintenance e 5 94 volts 20 charged Batteries should not be discharged below 20 of ca pacity approximately 1 8 volts per cell under normal operating load 1 98 volts open circuit 1 145 specific gravity Proper battery sizing will help avoid excessive discharge Battery chargers should be sized to fully charge batter les in an eight hour period Chargers should be kept in proper operating condition Do not use a mismatched charger of any type i e a 12 volt charger on a 24 volt pack An undersized charger will never complete the job no matter how long it tries An oversized charger will cause excess gassing and heat possibly resulting in a battery meltdown and or ex plosion Never charge a lead acid battery with a sealed gel cell battery charger The lead acid battery needs higher voltage to finish its charge Without it the battery will never fully re charge
105. th your supervisor or read the Operator s Manual on this machine for safe distances DO NOT use this machine without the railings and the DO NOT let an untrained or unauthorized person use this machine entry gate chain or bar in place You could fall When you leave the machine unattended remove the key out and hurt or kill yourself or turn off the battery switch on the base of the machine and lock the battery switch in the off position DO NOT use this machine if it is not working right or if DO NOT replace components critical to machine stability such as any part of itis damaged worn or missing An batteries and wheel equipment with lighter weight or non accident could cause injury or death factory approved substitutes NOTE STUDY THE OPERATOR S MANUAL BEFORE OPERATING THIS MACHINE 0361258 THIS CYLINDER IS SPRING LOADED INCORRECT ASSEMBLY OR DISASSEMBLY COULD CAUSE PHYSICAL INJURY BEFORE REMOVING SNAP RING RETRACT CYLINDER ROD 25 INCH REMOVE S
106. the rod Apply Loctite 271 threadlock to the bolt threads Install the flange bolt into the rod and torque to 60 66 ft Ib 4 Lubricate the inside of the tube with clean hydraulic fluid Line up the tube and rod center lines and push the rod assembly into the tube As the piston enters the tube gently push the piston seal past the retain ing wire groove Be careful to not damage the piston seal 5 Insert the hooked end of the retaining wire into the hole in the head gland through the slot in the out side of the tube Using an adjustable face pin span ner wrench turn the wire into the cylinder tube 7 10 Testing 1 At the bench attach a power pack hydraulic test pump adjusted for a maximum of 2800 psi 19 305 kPa to the cylinder and power it through several cycles checking for smooth operation This will bleed all air from the cylinder Release pressure 2 Reinstall the cylinder following the removal proce dure in reverse order 3 Following reattachment to the machine recycle the cylinder several times checking for proper opera tion Lift Cylinder Follow these procedures to remove and repair the lift cylinder ps Cylinder Pin gen gt MA Figure 7 20 Lift Cylinder ADANGER Pinch points exist on the scissors structure Death or serious injury can result if the scissors structure drops onto personnel working within the scissors arms or under the raised platform Properly posi tio
107. ve the fluid trapped in cylin ders and lines otherwise it will contaminate the new fluid This is especially important if the system was con taminated with metal particles due to a part failure Required flushing equipment and supplies e Approximately 7 gallons of hydraulic fluid see Chapter 2 Specifications e One possibly two replacement return filter cartridge s see Parts Manual for part number e Clean lint free rags e A 10 micron filter 4 CAUTION Spilled hydraulic fluid creates a very slippery fall hazard Clean up all spills at once 91930 0361270 Chapter 7 Hydraulic System Return Filter Manifold Assembly Figure 7 2 Hydraulic Tray Flushing the hydraulic system 1 Operate the unit to warm and circulate the fluid This will suspend the bulk of contaminates allow ing them to drain out with the fluid 2 Open the drain plug in the bottom of the reservoir figure 7 2 and allow the fluid to drain completely Disposal of the old fluid must be in compliance with all local laws and regulations 3 Wipe clean the top of the reservoir filler cap and re turn filter figure 7 2 4 Remove the filler cap and inspect the inside of the reservoir Clean out any sludge or contamination using solvent and rags ADANGER Solvents present a potential flash fire hazard Keep away from heat sparks and flame Follow the man ufacturer s label for proper use and disposal 5 If flushing the sys
108. when plugged into a 115 V 60 Hz electrical outlet will completely recharge the batteries and auto matically turn off atthe end of the charge cycle The bat tery switch figure 6 1 Chapter 6 should be in the off position Note All extension cords should be 3 conductor 14 gauge or larger and of the shortest length possible ADANGER Batteries give off hydrogen and oxygen that can combine explosively Death or serious injury can result from a chemical explosion Do not smoke or permit open flames or sparks when servicing the batteries The charging cycle may last 1 1 2 to 16 hours depend ing on the existing state of charge lf the charge cycle exceeds 16 hours the charger should be shut off and the battery condition and specific gravity checked If the check reveals no problems the charger should be checked e Always check electrolyte level prior to charging e Operate charger according to instructions outlined in this manual e Battery switch in off position e Do not smoke or introduce a flame or spark in the charging area Pothole Protection Interlock Test The pothole protection interlock is a safety feature designed to prevent tip over ADANGER The machine may tip over if the pothole protection interlock does not operate properly Death or seri ous injury can result from a tip over accident The interlock must be repaired or adjusted by a trained service technician before the machine can be safely used
109. wing equipment and supplies are required e Seal kit part number in Parts Manual e Chain or pipe wrench e Bench vise with cushioned jaws Soft mallet Hex wrenches e New hydraulic fluid Cleaning solvent Power pack hydraulic test pump Clean work bench Disassembly 1 Wipe all dirt and grease from the depressurized cyl inder 2 Secure the cylinder in a vise or other acceptable holding equipment Use care to not damage the tube 3 Remove the set screw from the outside of the head gland cap Remove the head gland cap with a chain or pipe wrench 4 Slide the rod assembly from the cylinder taking care to not damage the rod do not use pneumatic or hy draulic pressure to remove rod assembly As the rod is extracted from the tube remove the halves of the piston guides 5 Fasten the rod end mount in a cushioned jawed vise 6 Remove the head gland cap Remove and discard all seals taking care to not scratch the grooves Cleaning and Inspection 1 Inspect all load bearing welds for signs of fatigue or cracks Replace weldments where necessary 2 Thoroughly clean all components with solvent All contaminates must be removed to assure proper operation of the cylinder 91930 0361270 Chapter 7 Hydraulic System 3 Inspect the head gland and piston guides for dam age Repair any damage to seal grooves 4 Replace all seals with lightly oiled new ones from the seal kit The rod oil seal lips face t

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