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MANUAL - Snorkel

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1. 9 ZH 09 304 170 011 ZH OS LWA 02252522 118 s 555 89 War sn X18 LHM NAD La 2 th HLIMS 9015 3 o pes i 886 N3D s 33MD1 1417 MPs 7 1 i 950 088 B uu CWNILLdD ma ma 990 18 Ok 18 E JT Dv1d3238 204011 9 AYT33 J 2 048937 088 JH cd g cg cd Mm eu ya 139110 gt ITT e q fr e E n TH 9 S3HDLIMS DU TS3INI 33991310 NYI 2 47 amp E 8 di T 2 00 7110 1317 0 SOLON TE 21388 byw ULII Series Parts Manual Page 41 Electrical Schematic DC 068010 001 9 3 4 15 3 9015 3 9 xw we in o Cpu IHN a D 11 1417 el I
2. 33 Series Parts Manual Tilt Back Assembly 01 40 068200 001 Part Number 068180 0 Description LOADER BAR ASSY 068190 0 LOADER STOP BRACKET ASSY 068201 0 BACK WELDMENT 32 40 062844 0 TILTBAR WELDMENT 062846 0 TUBE CYLINDER MOUNT 068196 0 INNER 40 062884 0 TUBE CYLINDER OUTER 062885 0 FITTING CYLINDER END 062886 0 01 FITTING CYLINDER END 062887 0 01 PIN CYLINDER MOUNT 062891 0 01 LANYARD ASSY 003570 0 00 PIN RETAINING 063650 0 02 CYLINDER GAS SPRING 062843 0 01 GRIP 063926 0 04 CAPLUG 062888 0 03 PIN 3 4 X 2 1 2 011786 0 05 BUSHING 062784 0 04 CASTER 011764 0 12 RING RETAINING 011753 0 12 PIN COTTER 1 8 X 1 2 011256 0 08 SCREW HHC 1 2 13 X 1 1 2 011253 0 08 SCREW HHC 5 16 18 X 1 011256 0 22 SCREW HHC 1 2 13 2 3 4 011240 0 05 WASHER 5 16 FLAT 011238 0 08 NUT HEX ESNA 1 2 13 011248 0 05 NUT HEX ESNA 5 16 18 016590 0 01 3 4 SCHED 40 ALUM X 3 8 gt Page 34 ULII Series Parts Manual Series Parts M
3. M 2 3 Hydraulic Oil Reservoir inner 2 3 2 3 Battery Maintenance 2 4 Battery Inspection amp 2 4 Battery Charging tete eie etr An cedere esc ede esa edd 2 4 Battery Cell EQUALIZATION etre man 2 5 2 4 Setting System Relief Valve 5 Leer 2 5 UL 25 32 40 Portable Personnel Lifts 2 1 Maintenance 2 5 Mast Assembly Disassembly 2 6 Platform Assembly 1 00 awa Saa 2 6 H6 Mast 154556 1 5 52205 2 6 DiSassemblyx 2 6 H3 Mast Disassembly 2 i aun sana ane asia a tee ce 2 9 H2 Mast Disassembly tete ever m ahua aha sas 2 9 2 M st Assembly uu uns n NU en re eee es 2 9 H3 Assembly ee Mas iu R WA Dn 2 9 Mast Assembly pea BS 2 9 5 Mast Assembly usta tu eee erre e es 2 9 H6 Mast Assembly enc tete eua es 2 9 2 M astAssembly o tits ett dee ete etti eiie tenete 2 9 Platform Support Assembly nth tete ee ree enu e rane riae nhanh ree sa ee 2 10 Sequencing eee 2 10 2 6 Cylinder Assembly nan erae re e ea eere ea cats 2 10 Seal Replacemie
4. BLK SWITCH SWITCH 4 k BLK Oo 00 SWITCH SWITCI BLU BLK TO CONTROL BOX GN WHT BLK WHT RED Drawing 2 of 2 5 6 ULII Series Parts Manual Power Option 068008 011 PartNumber Description 068115 001 POWER UNIT 068115 011 VALVE LOAD 068115 012 PUMP 068115 013 SEAL KIT 068115 015 068007 021 CONTROL BOX W ELECT DOWN 020809 001 FITTING TEE 6MJ 6MB 6FJX 063965 003 GAGE PORT 011240 005 WASHER 5 16 FLAT 011240 004 WASHER 1 4 FLAT 011252 004 SCREW HHC 1 4 20 X 1 2 011248 005 NUT 5 16 18 ESNA 013540 001 WIRE NUT 12 10 011868 019 CONN CABLE ULII Series Parts Manual TO CONTROL CYLINDER SL K 220 VOLT AC 50 HZ MOTOR 1 HP MOTOR CONNECTION EUROPE 068008 011 u gt Sue 58 pu MOTOR CONNECTION DOMESTIC n CYLINDER
5. 5 8 ULII Series Parts Manual DC Power Option 068009 011 Part Number 068214 000 Description BATTERY BOX 062299 001 BATTERY 062299 004 BATTERY DRY 062782 000 068116 001 POWER 068117 0 12 068117 0 13 SEAL KIT 068116 0 13 START SOLENOID 068116 0 14 MOTOR 068116 0 15 RUSHES 029431 099 CABLE 2 AWG WELDING 029602 025 TERM 2 5 16 DIA 029602 026 R RING TERM 2 3 8 DIA 029902 0 00 CONN 175 AMP 015961 0 06 FITTING TEE 6MJ 6MB 6MJT 063965 0 03 GAGE PORT 029620 0 02 CONN BUTT 16 14 011252 0 08 SCREW HHC 1 4 20 X 1 011252 0 12 SCREW HHC 1 4 20 X 1 1 2 011240 0 05 WASHER 5 16 FLAT 011248 0 04 NUT 1 4 20 ESNA 011248 0 05 NUT 5 16 18 ESNA 062946 0 05 SCREW SOC HD SHOULDER 1 4 X 5 8 068007 0 23 CONTROL BOX W ELECTRIC DOWN 011240 0 04 WASHER 1 4 FLAT 011252 0 04 SCREW HHC 1 4 20 X 1 2 010154 0 00 COVER BATTERY rS 5 Ro ULII Series Parts Manual S eries Parts Manual Control 068007 021 PartNumb
6. s 1 CYNDI LAD ma ma 590 iB oe i8 oe 30143238 N35 224011 m 9 9 9 LVINOD AVIS 2 ra UN3931 038 i 1 1 AB c Gg vy 1 ND 8 Dan YT8 IH SSHILINS 1H DU TH3INI 9 039 990 9 X18 Y AV 138 SOLOW 1102 33m 7 afr 102 1411 SOLOW 1915373 42 ULII Series Parts Manual Hydraulic Schematic 068011 002 PDWER LINIT CHECK VALVE T RELIEF VALVE 2400PSI LIFT T CYLINDER Page 43 ULII Series Parts Manual Local Distributor Lokaler Vertiebshandler Distributeur local El Distribuidor local Il Distributore locale EUROPE MIDDLE EAST AFRICA amp ASIA PHONE 44 0 845 1550 057 FAX 44 0 845 1557 756 NORTH amp SOUTH AMERICA PHONE 1 785 989 3000 TOLL FREE 1 800 225 0317 FAX 1 785 989 3070 AUSTRALIA 612 9725 4000 61 2 9609 3057 NEW ZEALAND PHONE 64 6 3689 168 FAX 64 6 3689 164 snorkel
7. 5 38 Label 01 25 068013 012 5 40 068013 01 al 5 40 Label Kit UL32 1068014 012 v 5 42 DC 068014 013 5 42 Label Kit ULAO AC 068015 012 eet teme 5 44 DC 068015 013 5 44 Power Option 068100 001 2 tee puyuy 5 46 Electrical Schematic 068010 000 5 47 Electrical Schematic 068010 001 Rer N 5 48 Hydraulic Schematic 068011 002 pasasaq mer DRE 5 49 Section 5 0 5 1 Final Assembly ULII Series UL25 068001 002 068001 003 01 32 068002 002 068002 003 0140 068003 002 068003 003 UL25 AC UL25DC UL32AC UL32DC ULAOAC UL40DC Description 002 003 002 103 002 003 068006 024 BASIC ASSY 068006 025 BASIC ASSY 068006 026 BASIC ASSY 068008 011 POWER OPTION AC EUR 068009 011 POWER OPTION DC EUR 068013 012 LABEL KIT INST LABEL KIT INST LABEL KIT INST LABEL KIT INST LABEL KIT INST LABEL KIT INST 511128 000 EN OPERATOR MANUAL 511128 200 PARTS amp SERVICE MANUAL ULII Series Parts Manual 1 3 S NS E h V L 5 S
8. 2 84m 112 in 2 90 114 in Width 74 cm 29 in 74 cm 29 in 74 cm 29 in Depth 124 m 49 in 1 32m 52 in 1 32m 52in Diagonal Storage Height 1 94m 76 in 1 94m 76 in 2m 79 in Diagonal Storage Length System Voltage AC Electric Motor 2 59 m 102 in 2 72m 107 in 3 05m 120 in 120 VAC 60 Hz or 220 VAC 50 80 Hz DC Electric Power Source Battery Charger 12 Volt Battery Group 27 105 Amp Hrs Minimum Weight 22 kg 48 Ibs Automatic 120 60 Hz or 220 50 Hz Output 10 Amp 12 Volts DC Hydraulic Tank Capacity 5 liter 1 5 gal Maximum Hydraulic Pressure Hydraulic Fluid Normal Temperature above 0 C 32 F Low Temperature below 0 C 32 Extreme Temperature below 17 C 0 F 165 bar 2400 PSI 150 46 150 32 150 15 Control System Push Button Lift and Lower Red Mushroom EMERGENCY STOP Switch Guardrails TT 43 5 n High Toeboard 152mm 6 in High Max Chassis Inclination Outrigger Loading Zero Degrees in all directions 170 Kg 374165 Vibration 2 5m sec Sound Pressure 68dB A at Control Station Operating Temperature Range 20 50 C Specifications are subject to change without notice Hot weather or heavy use may affect performance Refer to the Service Manual for complete parts and service information The UL25 32 40 meets or exceeds the requirements of
9. ulah kus RUE E 8 Lowering the Platform sa aaa RE hana er be X pEX d ex 8 Emergency Lowering ruyru a u Wy S ER RE RR wA 8 Transporting the Work Platform 9 DG beso Gh Ste eee EE 9 EE 9 a Tre A a da EOS 10 DG Models u _____ deeper er ES S 10 Passage Through a Doorway 11 Lowerlng pate a EI 11 PRAISING LUI 11 Maintenance u SI ua m E e ae euro ot 13 Battery 1 13 5 ores eset tane EN LE NO Sed ns etg eia Eme eut 13 Inspection and Maintenance 14 Daily Preventative Maintenance 14 Labels a aya EA 16 Specifications eee ad tae ea ee eee 18 Page 2 Operation Manual Introduction Figure 1 1 UL Portable Personnel Lift Figure 1 Work Platform 1 Platform 9 Battery Box DC Units 2
10. N N 1 j ALT HOT 7 VN 5 VN lt lt E s N Q ULII Series Parts Manual Basic Assembly UL25 068006 024 UL32 068006 025 UL40 068006 026 125 UL32 UL40 125 UL32 UL40 PartNumber Description 02 05 026 Number Description 024 025 026 512805 000 LIFT CYLINDER ASSY 1 068200 003 TILTBACK ASSY 1 512789 000 LIFT CYLINDER ASSY 1 068200 000 TILTBACK ASSY 512806 000 LIFT CYLINDER ASSY 1 068200 001 TILTBACK ASSY 068050 001 2 ND STAGE MAST ASSY 1 062945 001 RETRACTILE CORD 2 068050 002 2 ND STAGE MAST ASSY 1 062945 003 RETRACTILE CORD 068050 003 2 ND STAGE MAST ASSY 1 062945 004 RETRACTILE CORD 068056 001 3 RD STAGE MAST ASSY 1 062226 002 CABLE STORAGE TUBE 3 068056 002 3 RD STAGE MAST ASSY 1 062226 003 CABLE STORAGE TUBE 068056 003 3 RD STAGE MAST ASSY 1 062226 004 CABLE STORAGE TUBE 068061 001 4 TH STAGE MAST ASSY 1 068157 000 OUTRIGGER ASSY 4 068061 002 4 TH STAGE MAST ASSY 1 068157 001 OUTRIGGER ASSY 068061 003 4 TH STAGE MAST ASSY 1 068157 002 OUTRIGGER ASSY 068066 001
11. o Page 30 ULII Series Parts Manual NOTES ULII Series Parts Manual Page 31 Tilt Back Assembly UL32 068200 000 Part Number 068180 0 Description LOADER BAR ASSY 068190 0 LOADER STOP BRACKET ASSY 068201 0 BACK WELDMENT 32 40 062844 0 TILTBAR WELDMENT 062846 0 TUBE CYLINDER MOUNT 068196 0 INNER 32 062884 0 TUBE CYLINDER OUTER 062885 0 FITTING CYLINDER END 062886 0 FITTING CYLINDER END 062887 0 01 PIN CYLINDER MOUNT 062891 0 01 LANYARD ASSY 003570 0 00 PIN RETAINING 063650 0 03 GAS SPRING 062843 0 01 GRIP 063926 0 04 CAPLUG 062888 0 03 PIN 3 4 X 2 1 2 011786 0 05 BUSHING 062784 0 04 CASTER 011764 0 12 RING RETAINING 011753 0 12 PIN COTTER 1 8 X 1 2 011256 0 08 SCREW HHC 1 2 13 X 1 1 2 011253 0 08 SCREW HHC 5 16 18 X 1 011256 0 22 SCREW HHC 1 2 13 2 3 4 RO RO RO 011240 0 05 WASHER 5 16 FLAT 011238 0 08 NUT HEX ESNA 1 2 13 011248 0 05 NUT HEX ESNA 5 16 18 016590 0 01 3 4 SCHED 40 ALUM X 3 8 gt 32 ULII Series Parts Manual
12. Pagei WORKSHOP PROCEDURES All information contained in this manual is based on the latest product information available at the time of printing We reserve the right to make changes at any time without notice No part of this publication may be reproduced stored in retrieval system or transmitted in any form by any means electronic mechanical photocopying recording or otherwise without the prior written permission of the publisher This includes text figures and tables Detailed descriptions of standard workshop procedures safety principles and service operations are not included Note that this manual does contain warnings and cautions against some specific service methods that could cause personal injury or could damage a machine or make it unsafe Please understand that these warnings cannot cover all conceivable ways in which service whether or not recommended by Snorkel might be done or of the possible hazardous consequences of each conceivable way nor could Snorkel investigate all such ways Anyone using service procedures or tools whether or not recommended by Snorkel must satisfy themselves thoroughly that neither personal safety nor machine safety will be jeopardized When in doubt contact your local distributor or Snorkel Page ii Introduction amp Specifications 0 1 1 INTRODUCTION PURPOSE The purpose of this service and parts manual is to provide instructions and illustrations for the operation and m
13. 068277 000 LATCH 014252 004 SERT 1 4 20UNC 011825 006 SCREW HD 1 4 20UNC X 3 4 083650 012 GAS SPRING 011708 003 SCREW RD HD MACH 8 32 X 1 2 068277 010 STRIKER BOLT 11252 014 SCREW 1 4 20UN X 1 3 4 15936 004 SCREW 3 8 X 1 2 SHOULDER 14924 008 U BOLT 068630 000 EXTENSION SPRING 055 WIRE 013919 009 CLAMP 5 8 DIA 026551 007 RIVET 1 8 251 312 GRIP N N 5 no PO Ro 5 a 5 5 28 ULII Series Parts Manual POWER PLATFURM ILLUSTRATION OF CE CAGE mr 88 lll I Gu B PET 28 2 Z LL amp 5 E 52 1 204 az 2 PLCS BEND 90 ULII Series Parts Manual Page 29 Loader Assembly UL25 068194 000 Hem Part Number Hem PartNumber Description 068190 000 LOADER STOP BRACKET ASSY 068220 000 WHEEL 068186 000 LOADER BAR ASSY 011252 004 SCREW HHC 1 4 20UNC X 1 2 068197 000 SHORT AXLE SHAFT 011248 004 NUT HEX ESNA 1 4 20UNC 011240 012 FASHER FLAT 3 4 011764 012 RETAINING RING
14. 1 Does the lift turn on Make sure all outriggers are extended and raised Turn off the E Stop switch and turn on the ignition key Wait five seconds for machine to turn on and outrigger lifgts to light 1a Outrigger lights do not turn on a See section LIFT DOES NOT TURN ON Ib Outrigger lights turn on immediately b Circuit board is damaged Replace and five second delay is not present circuit board Fewer than four indicator lights a Indicator light is damaged operate b Chassis harness damaged or incorrectly connected c Outrigger limit switch defective or improperly connected 14 All four indicator lights turn on five Continnue to step 2 seconds after ignition key is turned on 2 Pull out both E Stop switches Activate the common and up switch on the upper control box a Continue to step 3 a Hydraulic system failure b Coil cord is damaged c Damaged or improperly connected pump solenoids a Improperly connected or damaged motor harness b Improperly connected or damaged coil cord or upper control box c Damaged pump solenoid or motor solenoid d Battery charge is low 2a Motor does not run 2b Motor runs but will not raise 2c Lift turns off and restarts in five seconds 3 Open the lid on the lower control box Check for voltage at the E Stop switch Ignition key is turned on E Stop is pulled out on both the upper box and lower box No voltage i
15. 5 TH STAGE MAST ASSY 1 068020 001 CHASSIS WELDMENT 5 068066 002 5 TH STAGE MAST ASSY 1 068021 001 CHASSIS WELDMENT 068066 003 5 TH STAGE MAST ASSY 1 068022 001 CHASSIS WELDMENT 1 068070 001 6 TH STAGE MAST ASSY 1 068215 000 MOTOR COVER 1 1 1 6 068070 002 6 TH STAGE MAST ASSY 1 067995 000 LIFTING ARM ASSEMBLY 1 1 1 068070 003 6 TH STAGE MAST ASSY 1 068221 000 CASTER 2 2 2 068160 009 CAGE SUPPORT ASSY 1 068645 000 AXLE SHAFT 1 1 1 7 068160 010 CAGE SUPPORT ASSY 1 068222 000 WHEEL 10 X 2 1 2 2 2 2 068160 011 CAGE SUPPORT ASSY 1 068158 000 1 SECTION SLIDE 1 1 1 8 068218 000 MAST BEARING 813818 003570 000 RETAINING PIN 5 5 5 9 068217 000 MAST BEARING 12 12 12 062881 000 SWITCH 4 4 4 10 068216 000 BEARING 4 4 4 011240 012 WASHER FLAT 3 4 2 2 2 11 068122 000 MAST BEARING 4 4 4 068646 000 ROLL PIN 2 2 2 12 068121 000 MAST BEARING 4 4 4 020398 024 CLAMP 4 4 4 13 068120 000 MAST BEARING 4 4 4 011868 032 1 1 1 14 1068119 000 MAST BEARING 41414 011868 019 GROMMET 2 2 2 17 011238 006 WASHER SPLIT 3 8 8 8 8 011252 010 SCREW HHC 1 4 20UNC X 1 1 4 4 4 4 18 012553 005 SCREW SOC HD 1 4 20UNC X 5 8 12 12 12 60 011254 006 SCREW 3 8 16 X 3 4 8 8 8 19 012553 006 SCREW SOC HD 1 4 200 X 3 4 22 22 22 61 011825 004 SCREW 1 4 20 3 3 3 20 011823 005 SCREW BUTT HD 3 8 16 X 5 8 8 8 8 62 011240 004 WASHER 1 4 STD FLAT 20 20 2
16. Battery voltage is found at S28 and zero volts is found on GND 2 Check for voltage at the terminals of the key switch Turn the key switch on and the E Stop switch off 2a No voltage is found on either a Circuit board is damaged Replace circuit terminal board 2b Voltage is found only on one of the a Ignition key switch is faulty Replace two key switch terminals ignition key switch 2c Voltage is found at both sides of the a Key switch is working properly Continug key switch to step 3 3 Check for voltage at the terminals of the key switch Turn the key switch on and the E Stop switch off 3a Voltage at pin 6 does not exist or is less than 11 volts DC 3b Voltage at ground pin 1 is not zero Circuit board is damaged Circuit board is damaged b Ground on motor harness damaged or connected improperly 3c Voltage at pin 6 is between 10 and 13 Continue to step 4 VDC voltage at pin 1 is zero 4 Plug in Chassis harness Turn on ignition key turn off E Stop switch Check voltages at pin 1 and pin 6 of the chassis harness This may require the use of a sharp probe to pierce the insulation of the corresponding wires 4 Pin 6 is not between 10 and 12 VDC 4b Voltage at ground pin 1 is not zero Damaged or shorted chassis harness Circuit board is damaged b Ground on motor harness damaged or connected improperly 3 4 LIFT DOES NOT RAISE DC
17. DC units 4 4 Battery Inspection and Cleaning 4 4 Battery Charging Figure 2 3 4 4 Battery Cell Equalization 4 5 2 5 Mast Assembly Figure 2 6 2 7 Disassembly 4 6 Platform Assembly Removal 2 6 4 6 LINE 4 6 9 TE 4 6 114 4 6 2 5 Mast Assembly Cont 4 9 3 ER 4 9 2 MASt ves sisse rte dte rt eee s 4 9 Assembly Figure 2 7 sse 4 9 LIMIT 4 9 3 eere Renee exert 4 9 Masta 4 9 HS ere eet eme pee 4 9 6 ana TE 4 9 2 5 Mast Assembly Cont 4 10 Platform Support Assembly 4 10 Sequencing Strap Installation 4 10 2 6 Cylinder Assembly 4 10 Seal Replacement Figure 2 8 4 10 2 6 Cylinder Assembly Cont 4 12 Orifice Valve Cleaning esses 4 12 Cylinder Removal Figure 2 9 4 13 Installation erret tere entire 4 13 2 6 Cylinder Assembly Cont 4 14 Installation Cont 4 14 Fasteners ayasa akanan P pen 4 14 2 7 Tor
18. 10 In the event of an emergency push the Emergency Stop Button 11 Visually inspect the mast assembly for cracked welds and structural damage loose hardware hydraulic leaks loose wire connections and erratic operation Check for missing or loose parts LOWERING THE PLATFORM 12 Check that the area below the platform is clear before lowering the platform 13 Push both the middle and bottom buttons POWER and DOWN at the same time to lower the platform Release the buttons to stop EMERGENCY LOWERING Refer to Figure 2 Controls and Indicators on page 5 for the location of the Emergency Lowering Valve A WARNING If the platform should fail to lower NEVER climb down the elevating assembly Stand clear of the elevating assembly while operating the Emergency Lowering Valve Knob Ask a person on the ground to open the Emergency Lowering Valve to lower the platform This valve is located at the rear of the machine 1 Pull the knob to open the valve 2 To close the valve release the knob Note The platform will not elevate if the Emergency Lowering Valve is Open AFTER USE EACH DAY 1 Ensure that the platform is fully lowered 2 Park the machine on a firm level surface preferably under cover secure against vandals children and unauthorized operation 3 Turn the Chassis Key Switch to OFF and remove the key to prevent unauthorized operation Page 8 Operation Manual Transporting Work Platform TRA
19. Properly install all four 4 outriggers and level the base Release the tension on one 1 outrigger by turning the screwjack counter clockwise until the indicator light is no longer lit While standing on the ground activate the control panel to elevate the platform The platform should not elevate Re level the base Repeat steps 2 3 and 4 until all four 4 outriggers have been tested ADANGER A DO NOT use a machine that elevates when the tension has been released on an outrigger The machine must be repaired before using Page 6 Operation Manual Pre Operation Safety Inspection PRE OPERATION SAFETY INSPECTION Figure 4 Hydraulic Reservoir NOTE Carefully read understand and follow all safety rules operating instructions labels and National Safety Instructions Requirements Perform the following steps each day before use 1 Check that all four 4 outriggers are properly installed Check that the base is level AC Units connect the power unit plug to an approved extension cord DC Units Verify that batteries are charged Perform the Safety Interlock test Check for external damage to the mast Check the level of the hydraulic fluid with the platform fully lowered Remove the reservoir cap and check the fluid level on the dipstick Add hydraulic fluid if necessary Oil should be visible on the end of the dip stick 1 Hydraulic Reservoir 8 Ch
20. record for reference during installation The tension on the tie rods maintains the left right positioning of the cylinder within the mast assembly reinstalling the nuts with the proper tension will speed up adjustment later 3 Remove the cylinder mounting plate Be careful not to allow the tie rods to suck back inside of the mast assembly replace the nuts on the tie rod ends tempo rarily to prevent this 4 Remove hydraulic line from the cylinder fitting and cap the cylinder fitting to prevent contaminants from entering the cylinder CAUTION A Marring the surface of the cylinder rod will damage cylinder seals and cause leakage Use a strap wrench to prevent rod damage 5 Extend cylinder rod at least twelve inches by hand Apply heat to rod near end cap to loosen Loc tite Wear safety glasses and heat resistant gloves when operating torch Do not touch hot surfaces without proper protection 6 Using a Strap Wrench 062482 000 to secure the cylinder rod unscrew the cylinder rod end If neces sary thread a 9 16 x 18 bolt into end cap port to use as alever Remove rod end cap and orifice bleeder tube assembly UL 25 32 40 Portable Personnel Lifts Maintenance 2 6 7 Remove the seal retainer using the spanner wrench 14 Rod and rod end threads must be absoloutly clean 062521 010 Spray threads with Loctite primer 7471 allow to dry for five minutes Coat threads liberally with Loctite 242 Th
21. 3 7 857202 LHI SIVU SNOTLIANNOD 3310 038 or I 2 s n 00 02 Xi 033 AD HOLIMS 90153 40153 VOA 03 08 Ol 3401 29 OL Lio Jd IE 9 038 1 Dan ME 1 130 GA 0302 909 p ono MBN 144980 ma ya nO _ TH ODA ay LHe N NS 5 12 DC Control 068007 023 PartNumber Description 068274 013 PC BOARD 005440 000 KEY SWITCH 005442 000 KEY 067028 000 CONTACT BLOCK 062799 008 SWITCH PUSH 029925 000 CONN CABLE 067985 001 CONTROL BOX COVER 067958 001 BATTERY 9V 011709 004 SCREW 10 24 x 1 2 011721 006 SCREW 4 40UNC X 3 4 011703 006 SCREW HEX STSOC 1 4 20UNC X 3 8 029939 002 LOCKNUT 1 2 NPT 011248 049 NUT HEX ESNA 4 40UNC 067986 000 ENCLOSURE MODIFIED 011240 001 WASHER FLAT 6 029931 003 CONN FM PUSH 14 16 029452 099 WIRE 16 GA BLK 029454 099 WIRE 16 GA RED 068644 003 ULII WIRE LOOM DC 062179 000 POWER CORD 026525 003 SCREW SLFTP 8 X 3 8 067984 002 GASKET 066516 008 PLUG 067155 001 9 026551 004 POP RIVET L O co 1 c c c 1 ra 1 4 ra a 25 JA Ta ris 51 paqpa aan
22. ANSI A92 3 1990 Page 18 Operation Manual Maintenance 20 SERVICE AND REPAIR This section contains instructions for the maintenance of the Work Platform Refer to the General Informa tion section for information relevant to all Snorkel work platforms Referring to the Operator Manual will aid in understanding the operation and function of the various components and systems of the work platform and help in diagnosing and repair of the machine Owners of this work platform must set up a maintenance programme and have prepared a safety statement in advance as required by the relevant National Body The frequency and extent of periodic maintenance should also take into account Local National regulations AWARNINGA Be sure to read understand and follow all information in the Operation Section of this manual before attempting to operate or perform service on any Work Platform Never perform service on the work platform in the elevating assembly area while platform is elevated without first blocking the elevating assembly DO NOT stand in elevating assembly area while deploying or storing brace TABLE OF CONTENTS 2 0 2 1 2 1 Preventative Maintenance sen 2 1 Preventative Maintenance Table 2 2 2 2 L bricati li Jun u si anan ha ee eee ea 2 1 rl ETE 2 3 Gre 2 3 SCrew Br ce
23. Description 68071 001 6 TH STAGE WELDMENT UL25 026553 006 RIVET 3 16 375 500 GRIP 68071 002 6 TH STAGE WELDMENT UL32 068073 000 CHAIN BLOCK 68071 003 6 TH STAGE WELDMENT UL40 011821 005 SCREW BUTT HD 1 4 20UNC 62166 139 CHAIN 068144 000 CLEVIS PIN 6B 62166 171 CHAIN 011735 005 ROLL PIN 1 8 DIA X 5 8 LG 62166 203 CHAIN 068219 099 UHMW WEAR STRIP X 1 1 2 62753 000 STRAP ASSY 22 ULII Series Parts Manual NOTES ULII Series Parts Manual Page 23 Support Assembly UL25 068160 009 UL32 068160 010 UL40 068160 011 Part Number 068163 005 Description CAGE SUPPORT WELDMENT UL25 009 UL32 010 UL40 011 068163 006 SUPPORT WELDMENT 068163 007 CAGE SUPPORT WELDMENT 062165 133 CHAIN 062165 169 CHAIN 062165 201 CHAIN 068179 003 PLATFORM ASSY 068179 004 PLATFORM ASSY 017301 005 TUBE 1 20D X 18GA WALL X 7 8 068092 000 SLEAVE SPANNER TUBE 068093 000 ROLLER CHAIN 068094 001 CONTROL CABLE SHEAVE 068162 000 CONTROL CABLE SHEAVE BKT lt 062753 001 STRAP ASSY 1 068049 000 CONTROL BRACKET 1 011254 010 SCREW HHC 3 8 16UNC X 1 1 4 011240 006 WASHER 3 8 STD FLAT L 011250 006 NUT HEX ES
24. If equipped with battery back up remove back up battery before proceeding Diconnect both chassisonnector and coil cord connector Set voltmeter for DC voltage Plug lift into outlet 1 Check for voltage at the power terminals of the circuit board Turn off key switch and E Stop switch Power terminal is S28 and ground terminal is GND See drawing DC voltage at S28 is less than 11 VDC Extension harness excessive in length b Low line voltage c Damaged or faulty circuit board Ib Voltage is found at the ground a Damaged or faulty motor harness terminal b Damaged or faulty circuit board 1c Between 11 VDC and 26 VDCfound Continue to 2 at S28 Zero volts found at GND 2 Check for voltage at the terminals of the key switch Turn the key switch on and and the E Stop switch off 2a No voltage is found on either terminal 2b Voltage is found only on one of the two key switch terminals 2c Voltage is found at both sides of the a Continue to step 3 key switch Circuit board is damaged Ignition key switch is faulty 3 Check voltages at the chassis harness Turn on the ignition key and turn off the E Stop Disconnect the chassis harness Check voltage of pin 6 and pin 1 of chassis connector on the circuit board 3a Voltage at pin 6 does not exist or is less than 11 volts DC 3b Voltage at ground pin 1 is not zero Circuit board is damaged Circuit board
25. Mast Battery Charger 3 Chassis 10 Casters 4 Outriggers 11 Rear Wheels 5 Guardrail 12 Screw Jacks 6 Entry Drop Bar 13 Loader Assembly 7 Chassis Controls 14 Emergency Lowering Valve 8 Power Unit Motor Hydraulic Reservoir Operation Manual Page 3 Special Limitations SPECIAL LIMITATIONS Elevating the Work Platform is limited to firm level surfaces only All four 4 outriggers must be properly installed before operating the machine This machine is rated for indoor use only DANGER elevating function shall ONLY used when the work platform is level and firm surface DANGER A DO attempt to move this machine with the mast in an elevated position DANGER This machine weighs in excess of 76016 345kg and MUST only be manoeuvred on firm level ground PLATFORM CAPACITY The maximum platform capacity for the MACHINE is UL 25 159 kg 350 lbs UL 32 and UL 40 136 kg 300 Ibs One person may occupy the platform DANGER DO NOT exceed the maximum platform capacity or the platform occupancy limits for this machine MANUAL FORCE Manual force is the force applied by the occupants to objects such as walls or other structures outside the work platform The maximum allowable manual force is limited to 200 45 16 of force DANGER DO NOT exceed the maximum amount of manual force for this machine Page 4 Oper
26. NR pube gt BS 45 5 5 4 26 ULII Series Parts Manual POWER PLATFORM CONTROLLER WIRING j e CUIL CDRD Bri S 4 o 5 gg a t 2 PLCS BEND UP 90 ULII Series Parts Manual Page 27 Platform Assembly UL32 UL40 068179 004 Item Part Number Description 068082 001 CAGE SUPPORT WELDMENT 068123 000 SLIDE ANGLE 506275 001 RAIL WELDMENT 068149 002 CAGE 068096 000 RAIL BEARING 068147 000 FRONT COVER 057524 001 55 026525 003 SCREW 5 8 HWH X 3 8 011252 022 SCREW HHC 1 4 20UNC X 2 3 4 011240 004 WASHER 1 4 STD 011248 004 NUT HEX ESNA 1 4 20UNC 11264 022 SCREW HHC 5 16 18UNC X 2 3 4 11240 005 WASHER 5 168 STD 11246 010 NUT HEX ESNA 5 16 18UNC 062799 008 SWITCH PUSH PULL 067028 000 CONTACT BLOCK 062799 011 ENCLOSURE BOX amp COVER 062799 002 SWITCH OPERATOR COVER 062799 003 CONTACT BLOCK 029325 000 CONNECTOR 029939 002 LOCKNUT 1 2
27. NR e d NR ULII Series Parts Manual 5 13 584 0308 24 HILIMS AD 9015 3 718 033 L T San AB3LIVH S3N v SNDI1J3NNU3J 43107105 038 1 130 0302 XIMOd 2001 0001 acid 4015 3 23 C38 HA 1 al A33 HOLIMS 1 40153 ONUS 0808 24 OL D 34 Jd dl oo D 8 Page 15 Series Parts Manual Lift Cylinder UL25 068074 020 UL32 068074 021 UL40 068074 022 ltem Part Number 068129 0 00 Description 3 RD STAGE BOTTOM CASTING 0125 020 UL32 021 UL40 022 068128 0 00 2 ND STAGE CASTING 068113 0 06 LIFT CYLINDER 068113 0 07 LIFT CYLINDER 068113 0 08 LIFT CYLINDER 068113 0 10 SEAL KIT 068076 0 00 CYLINDER SHEAVE 062164 0 00 CHAIN 062164 1 23 CHAIN 062164 1 49 068089 0 00 MOUNT 068080 0 01 TIE RODS 068080 0 02 TIE RODS 068080 0 03 TIE RODS 011248 0 10 LOCKNUT 5 8 11 UNC 068079 0 00 CYLINDER GUIDE BEARING 011737 0 10 ROLLPIN 0680
28. SCREW 1 420UNC X 3 068102 000 OUTRIGGER TUBE UL25 068102 001 OUTRIGGER TUBE UL32 068102 002 OUTRIGGER TUBE UL40 Page 38 ULII Series Parts Manual 100 IN L BS ULII Series Parts Manual Page 39 Power Pack Option 068100 001 Mem Part Number Part Number Description 062782 000 CHARGER 029902 000 CONN 175 AMP 068214 000 BATTERY BOX 029601 015 CONN RING TERM 3 8 DIA 16 14 062299 004 BATTERY 011252 008 SCREW 1 4 20 X 1 010154 000 COVER BATTERY 011252 012 SCREW 1 4 20 X 1 1 2 029431 099 CABLE 2 WELDING 011248 004 1 4 20 ESNA 015966 005 SCREW HEX SHOULDER 5 16 X 5 8 005221 000 LABEL BATTERY FLUID 029602 025 RING TERM 2 5 16 DIA 066522 000 LABEL WARNING HYDROGEN GAS 18 LUNG ULII Series Parts Manual Page 40 Electrical Schematic 068010 000
29. and up switch on the upper control box 2a Motor does not run 2b Motor runs but will not raise a Continue to step 3 a Hydraulic system failure b Damaged or improperly connected motor harness c Damaged pump solenoid 2c Motor attempts to start but machine a Improperly connected or damaged motor turns off and then restarts in seconds harness b Improperly connected or damaged coil cord or upper control box c Damaged pump solenoid d Extension harness excessive in length e Low line voltage f Damaged pump motor 3 Open the lid on the lower control box Check for voltage at the E Stop switch Ignition key is turned on E Stop is pulled out on both the upper and lower box 3a No voltage is present at either of the a Circuit board is damaged Replace circuit terminals on the E Stop board 3b Voltage is present on both terminals a Check for correct operation of upper E Stop of the E Stop switch switch Continue to step 4 3c Voltage is only present at one side a Replace E Stop switch in whole or in the E Stop switch part 4 Check Circuit board lift circuit Place voltmeter probe at lift terminal 526 at the upper right hand side of the circuit board See drawing Page 3 5 Activate the common and up switch on the upper control box 4a When up button is pressed 10 12 VDC is not present at pin 26 a Improperly connected or damaged coil cord or upper control contr
30. cord of 16 50 feet less length Check all plugs cords used Check power output at wall outlet Check the voltage output of the Battery Charger If less than 12 VDC repair or replace After completely charging Battery test Battery Replace asrequired With the switch in the ON position check continuity across the contacts If none replace Make sure all four outriggers are in firm contact with floor Check continuity of interlock switches Test for continuity through cable assembly and repair or replace While operating the Lift function check the voltage to the Electric Motor If voltage is present 12VDC or 120 240V AC replace the motor In case low AC voltage see 1 Lift turns on and off repeatedly Low line voltage or battery charge Use minimum 11 5 12 ga cord of 16m 50 feet or less in length One or more but not all indicator lights fail to operate Indicator light damaged or faulty Outrigger limit switch damaged or faulty Chassis harness damaged or improperly connected Replace indicator light Replace switch Repair damage insure proper connection Lift function inoperable Electric Motor starts when control is activated Emergency Lowering Valve V2 open Hydraulic Reservoir Low Down Valve V2 stuck Relief Valve RV out of adjustment or faulty Lift Valve V1 fault
31. life and for complete service instructions Figure 8 Battery Charger BATTERY CHARGING 2 Battery inside box Charge the batteries at the end of each work shift or sooner if the batteries have been discharged AWARNINGA Charge the batteries in a well ventilated area Do not charge the batteries when the work platform is near a source of sparks or flames Permanent damage to the batteries will result if the batteries are not immediately recharged after discharging Never disconnect the cables from the batteries when the charger is operating Keep the charger dry Check the battery fluid level If the battery fluid level is lower than 10 mm in above the plates add distilled water only Verify the charger voltage switch is set to 12 volts Connect an appropriate extension cord to the charger plug Plug the extension cord into a properly grounded outlet of proper voltage and frequency NOTE The battery charger circuit must be used with a GFI Ground Fault Interrupt outlet NOTE DO NOT operate the machine while the charger is plugged in HYDRAULIC FLUID _ Charger j n 4 1 Ea Timer light nm The hydraulic fluid reservoir is located under the power unit cover NOTE Never add fluid if the platform is elevated CHECK HYDRAULIC FLUID 1 Make sure that the platform is fully lowered 2 Open the chassis door 3 Check the fl
32. or equivalent on the threads 7 Install 6 chain around 5 sheave and through casting secure to 4 casting with new roll pins 8 Useacenter punch to dimple pin holes after all roll pins are installed 9 Pull the sequencing strap attached to the bottom of mast 6 out through the bottom of the mast assembly Be sure not to pull the strap that is attached to the top of mast 5 2 9 Section 2 6 2 5 Mast Assembly Cont Platform Support Assembly 1 7 Slide support weldment into the top of the platform assembly weldment Install stop bracket and retaining screws washers Feed chains over sheave Install cable sheaves with cables to the top of cage support weldment Feed sequencing strap from inside mast 6 over sheave and out through the slot in the top of the cage support weldment Install cage support weldment to mast 6 using eight Screws tighten Attach chains to 5 casting front using new cotter pins Sequencing Strap Installation When installing straps make sure they are not twisted Feed fish tape up throug the bottom slot in cage support weldment and out through the top slot 2 Attach strap to fish tape and pull out through bottom slot 3 Feed fish tape down through the opening in the front of the platform support weldment and out through the bottom of the platform support weldment 4 Attach strap to fish tape and pull out through opening Attach strap to platform support
33. 0 21 062129 000 STRAP RETAINER 5 5 5 63 011240 006 WASHER 3 8 STD FLAT 16 16 16 22 1011735 020 ROLL PIN 2 2 2 64 014252 006 NUTZERT 3 8 18UNC 8 8 8 23 068145 000 PIN LEAF CHAIN 4 4 65 011248 004 NUT 1 4 20UNC 8 8 8 24 068141 000 PIN CHAIN 2 2 2 66 011868 011 BUSHING 1 1 1 25 029925 002 CABLE CONNECTOR 2 2 2 67 064350 010 SHIM 5 8 ID X 1 OD X 031 STL 4 4 4 26 066516 010 PLUG 1 68 068728 000 COVER CHASSIS 2 2 2 27 011256 014 SCREW 1 2 13 UNC X 1 3 4 4 4 4 69 005503 003 SCREW 6 SELF TAPPING 4 4 4 28 011240 009 WASHER 1 2 STD FLAT 4 4 79 014066 004 SCREW HWH SLFTP 1 4 X 1 2 4 4 4 29 011248 008 NUT HEX ESNA 1 2 13 UNC 4 4 4 90 067987 000 WIRE HARNESS 1 1 1 30 063926 007 PLUG 2 2 2 067988 006 RETRACTILE CORD 1 31 011735 020 ROLL PIN 2 2 2 91 067988 007 RETRACTILE CORD 32 068140 000 PIN 2 2 2 067988 008 RETRACTILE CORD 40 068194 000 LOADER ASSY 1 5 4 ULII Series Parts Manual Drawing 1 of 2 5 5 ULI Series Parts Manual
34. 00 rFSS99 200 12829 e er v m eee 9 sae qo Ree oye oe ng XINO 3 600 25599 XINO 5 101 110 28499 000 0829 do u DIL Dios aaAN TA T 04 pd emilie ment op ied ams Pr 402 yD Kua LES ome nai wna wm 3 0 208 5 nuda 000 71829 IL 000 01920 100 6 lt lt 99 1 1 000 9859 100 6959 LNHNNOO OL 16912 TVDhIJS S00 gZZS00 NYOY OL Tina 3ATVA AON3OH3WA A INO SLINA Y A 000 5599 SLINA 1 000 1Z S0 LY ILIVe NIVLNIVA 800 0 lt lt 99 000 ZT2c9 enba IQON 1110349194 pue y29u5 M3nsdip jo pus 13 06917 OL 10051 TVINAS 1 00 ccS0 OL TINd A
35. 42 Bolt Torque eoa tte EUR 2 14 3 1 Troubleshooting sse 3 2 4 1 Electrical Schematic Legend AC 4 2 4 2 Electrical Schematic Legend DC 4 2 4 3 Hydraulic Schematic Legend 4 4 I UL 25 32 40 SEVICE AND PARTS MANUAL FOREWORD How TO USE THIS MANUAL This manual is divided into six sections SECTION 1 INTRODUCTION General description and machine specifications SECTION 2 OPERATION AND SPECIFICATIONS Information on how to operate the work platform and how to prepare it for operation SECTION 3 MAINTENANCE Preventative maintenance and service information SECTION 4 TROUBLESHOOTING Causes and solutions to typical problems SECTION 5 SCHEMATICS Schematics and valve block diagram with description and location of components Large sche matic drawings may be located in the back of the manual SECTION 6 ILLUSTRATED PARTS BREAKDOWN Complete parts lists with illustrations Large parts drawings may be located in the back of the manual SPECIAL INFORMATION DANGER A Indicates an imminently hazardous situation which if not avoided will result in severe injury or death Indicates a potentially hazardous situation which if not avoided could result in severe injury or death Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury NOTE Gives helpful information
36. 55 Figure 4 2 Electrical Schematic DC Models UL 25 32 40 Portable Personnel Lifts 4 3 FH ________ 4 2 Schematic Table 4 3 Hydraulic Scematic Legend REFERENCE DESIGNATION NAME FUNCTION LOCATION Valve Check Allows flow in one direction Valve Block Assembly CYL Gylinder Operates Lift On lift assembly FLT Filter Seperates matter held in suspension from fluid nline with Pump ORF Orifice Controls flow out of CYL nline with CYL P Pump Supplies hydraulic pressure to system Lower Power Module RV Relief Valve Limits maximum pressure by releasing oil Valve Assembly Lower Power Module Valve Two Way Stops flow when Norm Open energized Valve Block Assembly Valve Two Way Allows flow when Norm Closed energized POWER UNIT Lift Cylinder Assembly RV Soe RELIEF VALVE 2400 Figure 4 3 Hydraulic Schematic UL 25 32 40 Portable Personnel Lifts Illustrated Parts Breakdown European Specifications This section lists and illustrates the replaceable assemblies and parts of this product as manufactured by Snorkel Inc Each parts list contains the component parts for that assembly CONTENTS Final Assem
37. 81 0 00 PIN CYLINDER 011764 0 23 RETAINING RING 062642 0 22 BEARING 16DU16 062169 0 04 MASTER LINK 062655 0 01 CHAIN GUARD 011941 0 05 FITTING ST 0 RING 6MB 6MJ 011828 0 06 SCREW FLAT HD SOCKET 1 4 20 X 3 4 068143 0 00 CHAIN PIN 011240 0 02 WASHER 8 FLAT 026553 0 08 3 16 RL RP POP IR 060861 1 15 HYD HOSE 060861 0 11 HYD HOSE 060861 0 11 HYD HOSE 011737 0 10 ROLLPIN 1 4 X 1 1 4 063988 0 06 SHIM 066179 0 01 VALVE LOWERING 069040 0 00 THREADED STUD 1 4 28 X 1 069041 0 00 KNOB RED Page 16 ULII Series Parts Manual ES PPLY LOCKTITE THREADS DD SHIMS AS REQUIRED TO CENTER CYLINDER INSIDE MAST gt 9 POWER UNIT 69 ULII Series Parts Manual Page 17 204 Stage Mast Assembly UL25 068050 001 UL32 068050 002 UL40 068050 003 PartNumber Description 068055 001 2 ND STAGE MAST ASSY UL25 068055 002 2 ND STAGE MAST ASSY UL32 068055 003 2 ND STAGE MAST ASS
38. AC Models 4 3 Figure 4 2 Electrical Schematic DC Models 4 3 Figure 4 3 Hydraulic Schematic 22 2 2 242 4 4 4 1 Schematics 4 1 Electrical Schematics Table 4 1 Electrical Schematic Legend AC REFERENCE DESIGNATION NAME FUNCTION LOCATION Table 4 2 Electrical Schematic Legend DC REFERENCE DESIGNATION NAME FUNCTION LOCATION BR Bridge Rectifier Converts AC to DC for control circuit In Control Box BAT Battery Supplies current to circuit In Power Module Relay Contacts Norm Open for R1 4 Completes ground circuit to motor and Lift Valve when R1 4 are energized In Control Box CH Charger Maintains Charge level in Battery In Power Module Indicator Light Lights when Outrigger Interlock Switches are closed On chassis next to Outrigger socket C1 4 Relay Contacts Norm Open for R1 4 Completes ground circuit to motor and Lift Valve when R1 4 are energized In Control Box Electric Motor Supplies power to drive hydraulic pump Upper portion of Power Unit Indicator Light Lights when Outrigger Interlock Switches are closed On chassis next to Outrigger socket Relay Coil When energized closes relay contacts 14 In Contro Electric Motor Supplies power to drive hydraulic pump Upper portion of Power Unit Motor Contactor S
39. Apply enough aerosol chain lubricant to exposed section of chain to allow lubricant to run down chain SCREW JACKS Apply a moderate amount of aerosol chain lubricant to each screwjack assembly Chains Casters Rear Wheels Screw Jacks Figure 2 1 Lubrication UL 25 32 40 Portable Personnel Lifts Motor Pump Reservoir Breather Dipstick Capscrew under pump Grip Plate under pump Figure 2 2 Hydraulic Power Unit HYDRAULIC OIL RESERVOIR Figure 2 2 Verify that Platform is fully lowered 1 Remove hydraulic reservoir from pump removing four screws and four plates Provide a suitable container reservoir has a 5 7 liter 1 5 U S gal capacity and dispose of hydraulic fluid properly contact your local oil recycler Note Ensure o ring is in place on pump when install ing hydraulic reservoir 3 4 Reinstall hydraulic reservoir to pump assembly with grip plates and screws Fill hydraulic reservoir through the dipstick hole with ISO 46 hydraulic fluid Hydraulic reservoir has a 5 7 liter 1 5 U S gal capacity Ensure that oil is visible on the end of the dipstick 53 Maintenance 2 3 Battery Maintenance DC units only Electrical energy for the motor is supplied by a 12 volt battery Proper care and maintenance of the battery and motor will ensure maximum performance from the lift Hazard of explosive gas mixture Keep sparks flam
40. IN 68138 000 011753 020 SHAFT 2 068136 000 LISE LUCKTITE 242 Page 20 Series Parts Manual 5th Stage Mast Assembly UL25 068066 001 UL32 068066 002 UL40 068066 003 Mem Part Number 68069 001 Description 5 TH STAGE MAST ASSY UL25 Part Number 068140 0 00 Description PIN 68069 002 5 STAGE MAST ASSY UL32 062753 0 00 STRAP ASSY 68069 003 5 STAGE MAST ASSY UL40 026553 0 02 RIVET 3 16 62167 141 CHAIN 011751 0 04 PIN COTTER 1 16 X 1 2 62167 173 CHAIN 011252 0 16 SCREW HHC 1 4 20 X 2 62167 205 CHAIN 011240 0 04 WASHER 1 4 STD FLAT 068138 001 SHAFT 011248 0 04 NUT 1 4 20 UNC ESNA 068135 000 SHEAVE 5 STAGE TOP Omi 2 068097 0 00 5 STAGE GUIDE DETATL Series Parts Manual Page 21 6th Stage Mast Assembly UL25 068070 001 UL32 068070 002 ULAO 068070 003 Mem _ PartNumber Description Hem PartNumber
41. Model No Serial No Serviced By COMPONENT INSPECTION SERVICES COMPONENT INSPECTION SERVICES Batte Check electrolyte level Emergency Operate the emergency lowering valve and check for ii Check battery cable condition Lowering System serviceability Check bubble level accuracy Hydraulic Fluid Check fluid level Check operation of outrigger interlocks Hydraulic Pump Gheck for hose fitting leaks Chassis Check casters for damage Hydraulic System Check for leaks Check hoses for pinch or rubbing points Labels Check for peeling missing or unreadable labels amp Check welds for cracks m Check the exterior of the cable for pinching binding Cane and EC NEAS TOF 018048 or wear Check condition Controller Check switch operation Mast Assembly Inspect for bends cracks or loose rivets Page 14 Operation Manual Daily Preventative Maintenance Checklist NOTES Operation Manual Page 15 Labels LABELS These labels shall be present and in good condition before operating the work platform Be sure to read understand and follow these labels when operating the work platform S00 ISS99 ewe G aan 100 81229 ejou seBeBue sabino 11980 1 1
42. NA 3 8 16UNC 068142 000 CHAIN PIN 011253 006 SCREW 5 16 18UNC X 3 4 011240 005 WASHER 5 16 STD FLAT 0 2 3 4 6 7 8 9 L 011250 005 NUT HEX ESNA 5 16 18UNC 011252 008 SCREW 1 4 20UNC X 1 PO 011240 004 WASHER 1 4 STD FLAT a 011248 004 NUT HEX ESNA 1 4 20UNC 014099 044 SCREW 3 4 10UNC X 5 1 2 gt 011248 012 NUT HEX ESNA 3 4 10UNC en 068231 000 TOP COVER e 011240 012 WASHER STD FLAT 3 4 d 011252 003 SCREW 1 4 20 UNC X 3 8 062129 000 STRAP RETAINER 012553 005 SCREW SOC HD 1 4 20UNC X 5 8 24 ULII Series Parts Manual TAUT AND SLACKEN BY 1 2 INCH A PULL STRAP NOTES Series Parts Manual Page 25 Platform A
43. NSPORTING THE WORK PLATFORM CAUTION Forklifting is for transport only See specifications for weight of machine and be certain that forklift is of adequate capacity to lift the machine Forklift from the rear by lifting from fork pockets BY TRUCK 1 Maneuver the machine into transport position and chock wheels 2 Secure the machine to the transport vehicle with chains or straps of adequate load capacity attached to the chassis lifting tie down points um DC MODELS Disconnect the plug from the battery box and remove the battery box from the rear of the machine ACAUTIONA The battery box is heavy 23 6 kg 52 Ibs Lift properly to prevent back injury LOADING Refer to Figure 6 Loading the UL for Transpor tation on page 10 EEE SS x gt WARNING Banery Box Pua A Make sure the loader fully engages the tailgate or 59 7 vehicle bed Figure 5 Battery Box DC Models Only 1 Raise the loader support brackets and engage the retaining pin in the top hole of the loader channel 2 Secure the loader to the loader support bracket with the gravity hook 3 Position the unit so the back of the machine comes into contact with the tailgate or vehicle bed 4 Release the gravity hook and slide the loader down until it comes into contact with the tailgate or vehicle bed Then reposition the loa
44. ON3942N3 W4O11V1d H3MOT1 000 2269 HOLMS TOHLNOD coma HOLIMS LV 1 000 2642 9 1 00 99 9 Tenuen 3 nsuoo suondo p ddrnb s urypew 104 Aq Sursn Aq ue 5124671 3 0N UL LIFT LABEL INSTALLATION THESE LABELS SHALL BE PRESENT AND IN GOOD CONDITION BEFORE OPERATING THE WORK PLATFORM BE SURE TO READ UNDERSTAND AND FOLLOW THESE LABELS WHEN OPERATING THE WORK PLATFORM Operation Manual Page 16 Specifications SPECIFICATIONS ITEM Platform Capacity Max No of occupants Height Working Height UL 25 159 kg 350 Ibs 1 person 9 62 m 31 6 fl UL 32 136 kg 300 Ibs 1 person 11 75 m 38 5 1t UL 40 136 kg 300 165 1 person 14 19 m 46 6 ft Max Platform Height 7 62 25 fl 9 75 m 32 fl 12 19 4011 Min Platform Height Dimensions Overall Weight 38 cm 15 in 390Kg 860165 38 cm 15 in 435 960105 38 15 in 470Kg 1040165 DC 0ption Weight 29 kg 64 Ibs 29 kg 64 Ibs 29 kg 64 Ibs Overall Width outriggers extended 2 06m 81 2 06m 81 in 2 95 116 in Overall Length outriggers extended Stowed Dimensions Vertical Height 1 98m 78 in 1 98 m 78 in 1 98 m 78 in 2 53m 100 in
45. Y UL40 068053 000 2 SECTION SLIDE 011703 016 SCREW SOCKET HEX SET 1 4 20UNC X 1 E S a USE LOCKTITE 242 Page 18 ULII Series Parts Manual Stage Mast Assembly UL25 068056 001 UL32 068056 002 UL40 068056 003 PartNumber Description 068060 001 3RD STAGE MAST ASSY 0125 Part Number Description 062753 000 STRAP ASSY 068060 002 3RD STAGE MAST ASSY UL32 026553 002 RIVET 3 16 068060 003 3RD STAGE MAST ASSY 0140 068137 000 SHEAVE 068139 000 062642 010 BEARING 011735 012 PIN 011786 005 BUSHING Series Parts Manual Page 19 4th Stage Mast Assembly UL25 068061 001 UL32 068061 002 UL40 068061 003 PartNumber Description 68064 001 4 TH STAGE MAST ASSY UL25 Part Number 068146 000 Description PIN 68064 002 4 TH STAGE MAST ASSY UL32 062753 000 STRAP ASSY 68064 003 4 TH STAGE MAST ASSY UL40 026553 002 RIVET 3 16 068065 000 4 SECTION SLIDE 62168 137 CHAIN 012553 008 SCREW SOCKET HED 1 4 20UNC X 1 62168 163 CHAIN 062642 016 BEARING 062168 111 CHA
46. age to battery will result if battery is not immediately recharged after discharging Never leave charger operating unattended for more than two days Never disconnect cables from battery when charger is operating Keep charger dry When night air temperatures fall below 18 65 F a battery charged in an unheated area should be placed on charger as soon after use as possible Under such conditions a 4 hour equalize charge once a week in the early afternoon will improve state of charge and battery life 1 Check battery fluid level If electrolyte level is lower than 10 mm 35 in above plates add distilled water only 2 Verify charger voltage switch is set to 12 volts 3 The battery charger is located at the rear of the mast Connect extension cord 1 5 mm 12 gauge conductor minimum and 15 m 50 ft in length maximum to the charger plug Connect other end of extension cord to properly grounded outlet of proper voltage and frequency 4 Setcharger control to conventional setting Charger ammeter should indicate charge rate 5 When battery is fully charged charger automatically turns itself off Disconnect extension cord UL 25 32 40 Portable Personnel Lifts Maintenance 54 BATTERY CELL EQUALIZATION The specific gravity of the electrolyte in the battery cells should be equalized monthly To do this charge batteries as outlined in Battery Charging After this initial charge check the electrolyte level
47. aintenance of the UL25 32 40 manufactured by Snorkel This manual must be stored on the machine at all times Read understand and follow all safety rules and operating instructions before attempting to operate the machine SCOPE The manual includes procedures for proper operation maintenance adjustment and repair of the UL25 32 40 as well as recommended maintenance schedules and troubleshooting 1 2 GENERAL DESCRIPTION The UL25 32 40 consists of the platform controller elevating assembly power control mod ule and chassis DO NOT use the work platform without guardrails properly assembled and in place Figure 1 1 UL25 32 40 Work Platform PLATFORM The platform has a reinforced steel floor 1 11m 43 75 inch high guardrails with midrail 6 inch 152 mm toeboards and an entrance gate at the rear of the platform PLATFORM CONTROLLER The platform controller contains the controls to operate the machine It is located at the front of the platform A complete explanation of control functions can be found in Section 2 ELEVATING ASSEMBLY The platform is raised and lowered by the ele vating assembly The hydraulic pump driven by an electric motor powers the cylinder Solenoid operated valves control raising and lowering UL 25 32 40 Portable Personnel Lifts OPERATION MANUAL WARNING All personnel shall carefully read understand and follow all safety rules and operating instructions before operating or performing m
48. aintenance on any Snorkel aerial work platform Safety Rules Electrocution Tip Over Hazard Collision Hazard Fall Hazard Hazard THIS MACHINE IS NEVER elevate the NEVER elevate the NEVER attempt to NEVER position the NEVER climb stand NOT INSULATED platform unless all platform without first push the Snorkel Lift platform without first or sit on platform o 50 2 four 4 outriggers leveling the base with people or checking for overhead guardrails or midrail have been properly materials on the obstructions or other installed platform or with the hazards platform elevated THIS MACHINE IS FOR INDOOR USE ONLY Do not use out of doors USE OF THE AERIAL WORK PLATFORM This aerial work platform is intended to lift persons and his tools as well as the material used for the job It is designed for repair and assembly jobs and assignments at overhead workplaces ceilings cranes roof structures buildings etc All other uses of the aerial work platform are prohibited THIS AERIAL WORK PLATFORM IS NOT INSULATED For this reason it is imperative to keep a safe distance from live parts of elec trical equipment DO NOT get closer than the minimum distance recommended by the National Regulations Exceeding the specified permissible maximum load is prohibited See Special Limitations on page 4 for details The use and operation of the aerial work platform as a lifting tool or a crane lifting of loads from below upwards o
49. anual Page 35 Loader Stop Bracket Assembly 068190 000 PartNumber Description 068191 000 LOADER STOP BRACKET WELDMENT 068193 000 SLIDE PAD LOADER STOP 03570 000 RETAINING PIN ASSY Drawing 014066 006 SCREW 1 4 SELF TAPPING X 3 4 Page 36 ULII Series Parts Manual Loader Bar Assembly 068186 000 Part Number 068187 0 Description LOADER BAR WELDMENT 068188 0 SLIDE PAD 061694 0 HOSE 2 5 8 00 X2 ID X5 062923 0 LOADER HANGER 015936 0 BOLT SHOULDER 3 8 X 1 2 011248 0 NUT HEX ESNA 5 16 18UNC 014066 0 SCREW HWH SLFTP 1 4 AB X 3 4 ULII Series Parts Manual Page 37 Outrigger Assembly UL25 068157 000 UL32 068157 001 UL40 068157 002 Hem Number 03471 000 Description HANDLE ARM 03508 000 KNOB 062636 000 SCREW 03532 000 PAD ASSEMBLY 011238 005 WASHER SPLIT LOCK 5 16 011240 004 WASHER 1 4 FLAT 011240 005 WASHER 5 16 FLAT 014996 010 WASHER 5 8 SAE FLAT 011248 004 NUT HEX ESNA 1 4 20UNC 011248 005 NUT HEX ESNA 5 16 18UNC 011252 018 SCREW HHC 1 4 20UNC X 2 1 4 011253 008 SCREW HHC 5 16 18UNC X 1 011253 014 SCREW HHC 5 16 18UNC X 1 3 4 026553 005 RIVET POP 3 16 X 3 8 068148 000 SCREW CASTING 011252 024
50. ard for correct output Open lid on the lower box Using a voltmeter check the voltage on terminal S27 found on the upper right hand side of the circuit board See drawing Turn on ignition key and pull out both E Stop Switches Depress the common and down switches on the upper control box 2a Lift turns off and restarts in five a Improperly connected or damaged seconds motor harness b Improperly connected or damaged coil cord or upper control box c Damaged down solenoid 2b Lift will not lower a Continue to step 2 PLUG TO CHASSIS SWITCH AND LIGHTS PLUG TO UPPER CONTROLS HOLMS ADI HOLMS ADI N OPTIONAL BATTERY DOWN LED Figure 3 1 Circuit Board UL 25 32 40 Portable Personnel Lifts 3 5 3 1 Troubleshooting 3 6 UL 25 32 40 Portable Personnel Lifts 72222 Schematies EG 4 0 Introduction This section contains electrical and hydraulic power sche matics and associated information for maintenance purposes The diagrams are to be used in conjunction with Table 3 1 Troubleshooting Guide They allow understanding of the makeup and functions of the systems for checking tracing and faultfinding during troubleshooting analysis The components that comprise the electrical and hydraulic systems are given a reference designation and are explained as to function and location in the following tables UL 25 32 40 Portable Personnel Lifts LIST OF FIGURES Figure Page Figure 4 1 Electrical Schematic
51. ation Manual Controls and Indicators CONTROLS AND INDICATORS Figure 2 Controls and Indicators Platform Controls Chassis Controls 1 Power Indicator Emergency Lowering Valve 5 Emergency Stop Orbit Level witc 3 Key Switch Wer Indicator 1 Emergency Stop Switch 2 Power On Button 3 Up Button 4 Down Button Operation Manual Page 5 Outrigger Installation OUTRIGGER INSTALLATION 1 Insert into the outrigger socket in the Push in until the locking pin engages Repeat the above steps for all other Figure 3 Installing Outriggers ble Level Indicator Lights ubble Level BRE Bubble Level kan 1 p X base Figure 1 T 7 Locking Pin Remove the outriggers from storage locations on the sides of the mast the hole in the end of the outrigger Pull 67 outward the outrigger to ensure engagement outriggers Make sure all four 4 lock ing pins are engaged Level the base centering the bubble in the orbit level on the base by adjusting the screwjacks turn clockwise at the end of each outrigger DO NOT release the tension turn counterclockwise on an outrigger to level the base All four 4 screwjack pads must be in solid contact with a firm surface and each outrigger indicator light must be lit before the platform is elevated SAFETY INTERLOCK TEST DANGER NEVER perform this test from the platform
52. aulic Schematic Legend een 4 4 5 0 Illustrated Parts Breakdown 5 1 Table of Contents uu aa Qu ass 5 1 UL 25 32 40 Portable Personnel Lifts 2 1 Maintenance 20 2 0 Introduction This section contains instructions for maintenance of the UL Series Lifts Procedures for the operational check out adjustment scheduled maintenance and repair removal are Included Referring to the Operator Manual will aid in understand ing the operation and function of the various components and systems of the UL Series Lifts and help in diagnosing and repair of the machine SPECIAL TOOLS The following is a list of special tools that are required to perform certain maintenance procedures These tools may be purchased from your dealer Description Part Number Spanner Wrench 062521 010 For UL25 32 40 Strap Wrench 062482 000 Tie Rod Tensioner 2 req d 062738 000 Tensioner Bracket 2 req d 062739 000 2 1 2 1 Preventative Maintenance Table 2 1 The complete inspection consists of periodic visual and operational checks together with all necessary adjustments to assure proper performance Daily inspection will prevent abnormal wear and prolong the life of all systems The inspection and maintenance schedule is to be per formed at regular intervals Inspection and maintenance shall be performed by personnel who are trained and familiar with mechanical and el
53. bly ULII Series UL25 068001 002 068001 003 UL32 068002 002 068002 003 ULAO 068003 002 068003 003 Basic Assembly UL25 068006 024 UL32 068006 025 ULAO 068006 026 Miscellaneous Installation 069039 000 AC Power Option 068008 011 DC Power Option 068009 011 AC Control Box 068007 021 DC Control Box 068007 023 Lift Cylinder UL25 068074 020 UL32 068074 021 ULAO 068074 022 2nd Stage Mast Assembly UL25 068050 001 UL32 068050 002 ULAO 068050 003 3rd Stage Mast Assembly UL25 068056 001 UL32 068056 002 ULAO 068056 003 4th Stage Mast Assembly UL25 068061 001 UL32 068061 002 ULAO 068061 003 5th Stage Mast Assembly UL25 068066 001 UL32 068066 002 ULAO 068066 003 6th Stage Mast Assembly UL25 068070 001 UL32 068070 002 ULAO 068070 003 Cage Support Assembly UL25 068160 009 UL32 068160 010 ULAO 068160 011 UL 25 32 40 Portable Personnel Lifts Platform Assembly UL25 008179 003 cce eee EIER 5 26 Platform Assembly UL32 ULAO 068179 004 cree ee ee ee he ey 5 28 Loader Assembly UL25 068194 000 tea eem REPE 5 30 Tilt Back Assembly UL32 068200 000 cena one mee ee Go yas 5 32 Tilt Back Assembly UL40 068200 001 pass mener m ut 5 34 Loader Stop Bracket Assembly 068190 000 mener me eI 5 36 Loader Bar Assembly 068186 000 ehem eee EIS 5 37 Outrigger Assembly UL25 068157 000 onc rct OES 5 38 UL32 068157 001 e e 5 38 ULAO 068157 002
54. der support bracket so that the retaining pin is in the first available hole above the loader 5 Release the locking pin and pull the T handle out until the locking pin engages the hole in the end of the T handle 6 Lift up on the T handle using the loader as a pivot until the unit rotates to a horizontal position in the vehicle bed 7 Push the base of the unit towards the front of the vehicle bed The machine will slide on the loader until the rear wheels are on the bed The unit may then be rolled on the rear wheels and upper casters 8 Return the T handle to the stored position making sure that the locking pin engages the T handle 9 Secure the unit with suitable tie straps using the forklift pockets located under the base of the unit and either the upper caster axle on the UL25 models or the tilt back frame on the UL32 and 0140 models CAUTION To prevent damage to the mast assembly do not place rope or tie straps across the mast assembly when securing the unit for transportation DO NOT overtighten the rope or tie straps or damage to the machine will result Operation Manual Page 9 Transporting Work Platform UNLOADING 1 Unsecure the unit 2 Release the locking pin and pull the T handle out until the locking pin engages the hole in the end of the T handle 3 Roll the unit back until the rear wheels are off the edge of the tailgate or vehicle bed 4 Pull downward on the T handle allowing the unit to sl
55. e bleeder tube into rod end cap and secure with snap ring 10 Replace static seal on red end Existing seal may have been damaged by heating rod 11 Rod and rod end threads must be absoloutly clean Spray threads with Loctite primer 7471 allow to dry for five minutes Coat threads liberally with Loctite 242 Thread rod end cap onto rod tighten using strap wrench to hold rod 12 Push rod back into cylinder for reassembly 13 Reconnect hydraulic line 14 Remove nuts from tie rod ends and set the cylinder mounting plate into place Secure mounting plate with fasteners 15 Install tie rod nuts flush with tie rod ends torque each nut the exact number of turns used to remove it 16 Reinstall retaining ring 17 Using a suitable lifting device raise the lift to its normal vertical position 18 Bleed air from cylinder by cycling the mast to full extension several times The cylinder is self bleeding air will be forced out of the cylinder during the lower ing cycle 19 If necessary remove pinch shield and check alignment of cylinder within mast assembly by peering down the mast with a flashlight The cylinder guide bearings must not be touching the inside surface of 6 mast The cylinder may be moved left or right by tightening the left or right tie rod nuts respectively CAUTION A If cylinder is not centered mast may hang when lowering Keep hands clear of the mast assembly when the pinch shield i
56. e and smoking materials away from batteries Always wear safety glasses when working with batteries Battery fluid is highly corrosive Rinse away any spilled fluid thoroughly with clear water BATTERY INSPECTION AND CLEANING Check battery fluid level daily especially if work platform is being used in a warm dry climate If required add distilled water only use of tap water with high mineral content will shorten battery life If battery water level is not maintained battery will not fully charge creating a low discharge rate which will damage Motor Pump unit and void warranty Battery should be inspected periodically for signs of cracks in the cases electrolyte leakage and corrosion of the terminals Inspect cables for worn spots or breaks in the insulation and for broken cable terminals Clean battery that shows signs of corrosion at the termi nals or onto which electrolyte has overflowed during charging Use a baking soda solution to clean the battery taking care not to get the solution inside the cells Rinse thoroughly with clear water Clean battery and cable contact surfaces to a bright metal finish whenever a cable is removed 2 4 BATTERY CHARGING Figure 2 3 Charge battery at end of each work shift or sooner if battery has been discharged CAUTION A Charge battery in a well ventilated area Do not charge battery when the lift is in an area containing sparks or flames Permanent dam
57. e when tilting 1 Be sure that the area is clear of personnel and obstructions 2 While holding the Tilt Back frame remove the hair pin retainer and the retaining pin 3 Lower the Tilt Back frame until the hole in the cylinder assembly align with the upper mounting bracket pin hole Secure the cylinder assembly to the upper mounting bracket using the retaining pin and hair pin retainer 4 Extend the Tilt Back Handle to the tilt lift position by releasing the locking pin and pulling the handle out of the Tilt Back assembly until the locking engages 5 Push down on the Tilt Back Handle until the unit comes to rest on the Tilt Back frame As the mast tilts back counterbalance the machine s weight by increasing upward force on the end of the Tilt Back Handle This allows the machine to gently come to rest on the Tilt Back casters 6 Pull down on the handle on the back of the mast to compress the cylinder assembly Return the Tilt Back Handle to the storage position making sure that the locking pin engages the han dle RAISING 1 Lift up on the mast handle to extend the cylinder assembly 2 Fully engage the Tilt Back Handle until the locking pin engages 3 Lift up on the Tilt Back Handle As the mast approaches vertical counterbalance the machine s weight by increasing downward force on the end of the tilt Back Handle This allows the machine to settle gently on the front casters 4 Return the Tilt Back ha
58. ear of the mast assembly when the pinch shield is removed for inspection purposes pinching injury to hands may result Never operate a machine with the pinch shield removed except for inspection 2 14 Maintenance 2 7 Torque Specifications HYDRAULIC COMPONENTS Use the following values to torque hydraulic components used on Snorkel Work Platforms Note Always lubricate threads with clean hydraulic oil prior to installation Table 2 2 Hydraulic Component Torque TYPE SAE PART SERIES CARTRIDGE POPPET Nm FITTINGS Ft Lbs Nm N A 14 27 34 41 47 54 115 122 135 145 215 245 430 470 680 750 950 1050 1300 1368 15 16 24 28 49 53 77 85 107 131 147 155 115 122 85 90 Coil nuts 3 Nm 30 In Lbs FASTENERS Use the following values to torque fasteners used on Snorkel Work Platforms unless a specific torque value is called out for the part being installed Table 2 3 Bolt Torque THREAD SIZE American National Standard UNF fine WIDTH ACROSS FLATS TORQUE VALUE ENGLISH In Lbs In Lbs Ft Lbs Ft Lbs Ft Lbs Ft Lbs METRIC Ft Lbs Ft Lbs Ft Lbs UL 25 32 40 Portable Personnel Lifts Troubleshooting 30 3 0 Introduction Table 3 1 provides a logical sequence of tests that are designed to isolate problems with the Snorkel Lift This table includes a list of probable causes and remedies When troubleshooting ensure that the work platform is resting on a fir
59. eck that fluid level in the batteries is correct See Battery Mainte 2 Reservoir Cap Dipstick nance on page 13 3 Motor AC Shown 4 Mast 9 Check that all guardrails are in place and all fasteners are properly tightened 10 Inspect the machine thoroughly for cracked welds and structural dam age loose or missing hardware hydraulic leaks damaged control cable and loose wire connections SYSTEM FUNCTION INSPECTION Refer to Figure 2 Controls and Indicators on page 5 for the locations of various controls and indicators AWARNINGA STAND CLEAR of the work platform while performing the following checks Check above the work platform for obstructions and electrical conductors NOTE rhe outriggers will not elevate unless all four outriggers are properly installed with screwjack pads firmly in contact with floor and each outrigger indicator lamp lit PERFORM ALL TESTS FROM THE GROUND 1 Pull the Chassis Emergency Stop Switch to the ON position 2 Turn the Key to ON 3 Pull the Platform Emergency Stop Switch to the ON position 4 Push both the middle and top buttons POWER and UP on the Control Box at the same time to elevate the platform Release the buttons to stop 5 Push both the middle and bottom buttons POWER and DOWN at the same time to lower the platform Release the buttons to stop 6 Open the Emergency Lowering Valve to verify proper operation 7 Push the Chassis Emergency Stop Switch to verify prop
60. ectrical procedures Com plete descriptions of the procedures are in the text follow ing the table Before performing preventative maintenance familiarize yourself with the operation of the machine Never enter the area below the Platform when the Platform is elevated The Preventative Maintenance Table has been designed to be used for machine service and maintenance repair Please copy the following page and use the Preventa tive Maintenance Table as a checklist when inspecting a machine for service UL 25 32 40 Portable Personnel Lifts 91 Maintenance Preventative Maintenance Table Key Interval Daily each shift or every day 30d every month or 30 days 3m every 3 months ly every year Y Yes Acceptable N No Not Acceptable Repaired Acceptable Preventative Maintenance Report Serial No Serviced By Service Interval 2 2 Table 2 1 Preventative Maintenance COMPONENT INSPECTION OR SERVICES INTERVAL Check electrolyte level 5 Check battery cable condition Charge batteries Check charger condition amp Check specific gravity Clean exterior Clean terminals Hydraulic Oil Check oil level Drain and replace oil ISO 46 Hydraulic Check for leaks System Check line connections Check for exterior wear Emergency the emergency lowering Hyd
61. er Description 068274 011 BOARD 005440 000 KEY SWITCH 005442 000 KEY 067028 000 CONTACT BLOCK 062799 008 SWITCH PUSH 029925 000 CONN CABLE 067985 001 CONTROL B0X COVER 067985 001 CONTROL B0X COVER 067958 001 BATTERY 9V 011709 004 SCREW 10 24 X 1 2 011721 006 SCREW 4 400 X 3 4 011703 006 SCREW HEX STSOC 1 4 20UNC X 3 8 029939 002 LOCKNUT 1 2 NPT 011248 049 NUT HEX ESNA 4 40UNC 067986 000 ENCLOSURE MODIFIED 026525 003 SCREW SLFTP 8 X 3 8 011240 001 WASHER FLAT 6 029931 003 CONN FM PUSH 14 16 029931 004 CONN FM PUSH 14 16 029452 099 WIRE 16AWG BLK 029454 099 WIRE 16AWG RED 013540 001 WIRE NUT 12 10 068644 002 ULII WIRE LOOM AC 062179 000 POWER CORD 029868 007 CIRCUIT BREAKER 067984 002 GASKET 026551 004 RIVET POP 067155 001 BATTERY HOLDER 9V 068643 000 SPACER HD10 SERIES INI Mm gt co 1 4 5 So a sa 5 rm 413 L L L L 1 N NR eo ULII Series Parts Manual 5 11 A 311V8 ULII Series Parts Manual 3 and 915
62. er operation All machine functions should be disabled Pull out the Chassis Emergency Stop Switch to resume 8 Push the Platform Emergency Stop Switch to verify proper operation All machine functions should be disabled Pull out the Platform Emergency Stop Switch to resume Operation Manual Page 7 Operation OPERATION Before operating the machine ensure that the Pre Operation Safety Inspection has been completed and that any deficiencies have been corrected Never operate a damaged or malfunctioning machine The operator must be thoroughly trained on this machine NOTE The platform will not elevate unless all four outriggers are properly installed with screwjack pads firmly contact with floor and each outrigger indicator lamp lit AC Units connect the power unit plug to an approved extension cord DC Units verify that the battery charger is turned OFF and that the extension cord is removed Pull the Chassis Emergency Stop Switch to the ON position Turn the Key to ON Enter the platform by raising the drop bar Ensure the drop bar falls freely to its lowered position O OI ELEVATING THE 7 Check that the area above the platform is clear before elevating the platform 8 Pull the Platform Emergency Stop Switch to the ON position 9 Push both the middle and top buttons POWER and UP on the Control Box at the same time to elevate the platform Release the buttons to stop
63. g Lowering UL Lift 2 6 3 Remove cotter pins and drive out chain retaining pins from the top front of stage 5 4 Loosen screws from strap retainer on stage 5 top casting Pull strap free of retainer 5 Remove cage support screws slide the cage support out of the sixth stage mast and set aside It should not be necessary to remove the pinch sheild Be careful not to damage the control cable Note to remove the platform assembly from the cage support assembly follow steps 6 10 below 6 Remove cable sheaves from cage support weldment and strain reliefs from stage 5 top casting 7 Loosen screws from strap retainer on platform assem bly weldment and free strap from retainer 8 Remove two screws and washers holding stop bracket located at top of platform assembly weldment Re move the stop bracket 9 Slide the cage support weldment out of the top of the platform assembly weldment 10 Slide bearings in platform assembly may now be inspected replaced if necessary Z6 Mast 1 Remove sequence strap retainer on the top of 4 mast 2 Remove the Allen head screws holding the top mast bearings between the 5 and 6 mast Remove the top mast bearings 3 Slide 6 mast out of 5 mast As mast is removed the bottom four mast bearings will fall out note their orientation for re assembly 4 Disconnect chain from top of 4 mast 5 Mast 1 Remove sequence strap retainer on the top of 3 mast 2 Remove
64. gsnorkel WLAW UR UL25 Ansi Part Number 511128 201 MAY 2013 Serial Number 21691 Current ULII 25 32 40 Portable Personnel Lifts Snorkel Vigo Centre Birtley Road Washington Tyne amp Wear NE38 9DA U K T 44 0 845 1557 755 F 44 0 845 1557 756 22 When contacting 5 for service parts information sure to include the MODEL and SERIAL NUMBERS from the equipment nameplate Should the nameplate be missing the SERIAL NUMBER is also stamped on the chassis tube on the right side of the mast Orke UL 25 oBack IAN deg To sie deg 360 N A OD 170 RADEAB N A EZ N A 159 KG 1 PERSON 79KG TOOLS Contents Table of Contents Section Page Number No 1 0 Introduction ses 1 1 Purpose of Equipment 1 1 General Description 1 1 Platforms tees 1 1 1 1 ChassiSu 1 1 Operator Controls 1 1 2 0 Introduction ss 4 1 Special Tools eene 4 1 2 1 Preventative Maintenance Table 2 1 4 1 Preventative Maintenance Table Key 4 2 Preventative Maintenance Report 4 2 2 2 Lubrication ss 4 3 GC PS 4 3 4 3 Screw moneret ete un 4 3 Hydraulic Oil Reservoir Figure 2 2 4 3 2 3 Battery Maintenance
65. ide on the loader As the unit stops sliding on the loader it will pivot on the loader to an upright position Gradually counterbalance the unit s weight by applying an upward force on the T handle This allows the unit to settle gently on the wheels avoiding undue impact on the unit 5 Return the T handle to the stored position making sure that the locking pin engages the T handle MODELS Replace the battery and reconnect the battery box plug making certain it is fully engaged Figure 6 Loading the UL for Transportation Loader Channel Loader Support Bracket Tailgate Loader Loader Load Position Retaining Pin T Handle Positioning Tilting the Machine Onto or Off of a Vehicle Page 10 Operation Manual Passage Through Doorway PASSAGE THROUGH A DOORWAY The UL32 and UL40 are equipped with a castered rear Tilt Back assembly When the unit is tilted back onto this support frame the overall height is reduced to allow the unit to pass through a standard doorway Refer to Figure 7 Passing Through Doorways page 12 LOWERING A CAUTION Before tilting the machine onto the rear Tilt Back assembly be sure that the retaining pin is fully inserted with the hair pin retainer installed and the cylinder assembly is fully extended DO the Tilt Back frame Keep out from under the Tilt Back frame and machin
66. in all cells and add distilled water as necessary Then turn the charger on for an additional eight hours During this time the charging current will be low four amps as cells are equalizing After equalization the specific gravity of all cells should be checked with hydrometer The temperature corrected specific gravity in this state should be 1 260 If any corrected readings are below 1 230 the battery should be replaced Do not check the specific gravity in a cell to which water has just been added If there is not enough electrolyte in a fully charged cell to obtain sample for the hydrometer add water and continue charging for one to two hours to adequately mix the water and electrolyte Figure 2 3 Battery Charger UL 25 32 40 Portable Personnel Lifts 2 4 Setting System Relief Valve Figure 2 4 Check the hydraulic system pressure whenever the pump or relief valve has been serviced or replaced The hydraulic oil may be of sufficient temperature to cause burns Wear safety gloves and safety glasses when handling hot oil 1 Install outriggers and level unit as normal see Opera tor Manual 3 for operating instructions and operate the hydraulic system for 5 10 minutes to warm the hydraulic oil Remove Cover from Power Unit Assembly 3 Place rated load on the platform see table 1 1 for specifications Do Not use live weight for this procedure Install pressure gauge on gauge port 5 Rem
67. installation ing cycle 13 Install the seal retainer onto rod using a sharp blow 23 If necessary Temove pinch shield and check alignment from a hard rubber mallet to overcome seal squeeze of cylinder within mast assembly by peering down the Slide seal retainer into place and tighten using the mast with a flashlight The cylinder may be moved spanner wrench left or right by tightening one or the other of the tie rod nuts Seal Kit Rod End Cap A Static Seal 1 Seal Retainer B Rod Wiper Cylinder Rod C Pressure Seal Cylinder Body D Static Seal 42 CAUTION A If cylinder is not centered mast may hang when lowering Keep hands clear of the mast assembly when the pinch shield is removed for inspection purposes pinching injury to hands may result Never operate a machine with the pinch shield removed except for inspection Figure 2 8 lift Cylinder UL 25 32 40 Portable Personnel Lifts 2 11 gt 6 Maintenance 2 6 Cylinder Assembly Cont ORIFICE VALVE CLEANING Using a suitable lifting device lower the work platform into a horizontal position Figure 2 5 If possible place the machine onto sturdy work table using forklift Never attempt to lower lift into a horizontal position without the use of a suitable lifting device bodily injury or damage to the machine may result 1 Remove cylinder mounting plate fasteners and retain ing ring 2 Remove tie rod nuts count the number of tu
68. is damaged b Ground on motor harness damaged or connected improperly 3c Voltage at pin 6 is between 10 and 12 a Continue to step 4 VDC voltage at pin 1 is zero 4 Plug in Chassis harness Turn on ignition key turn off E Stop switch Check voltages at pin 1 and 6 of the chassis harness This may require the use of a sharp probe to pierce the insulation of the corresponding wires 4a Pin 6 is not between 10 and 12 VDC 4b Voltage found at pin 1 a Damaged or shorted chassis harness Circuit board is damaged b Ground on motor harness damaged or connected improperly LIFT DOES NOT RAISE AC 1 Plug lift into outlet Make sure all outriggers are extended and raised Turn off the E Stop switch and turn on the ignition key Wait five seconds for machine to turn on and outrigger lights to light 1a Outrigger lights do not turn on a See LIFT DOES NOT TURN ON 16 Outrigger lights tun on immediately b Circuit board is damaged Replace circuit and no five second delay is present board 1c Fewer than four indicator lights will a Indicator light is damaged operate b Chassis harness damaged or incorrectly connected c Outrigger limit switch defective or improperly connected 1d All four indicator lights turn on five a Continue to step 2 seconds after ignition key is turned on UL 25 32 40 Portable Personnel Lifts 2 Pull out both E Stop switches Activate the common
69. m level surface When performing any service which re quires the Platform to be raised ensure that all four 4 outriggers are properly installed Unplug the machine or disconnect the bat tery when replacing or testing the continuity of any electrical component UL 25 32 40 Portable Personnel Lifts GENERAL PROCEDURE Troubleshooting should be carried out in two steps First thoroughly study both hydraulic and electric schematics to determine possible causes Loose terminal connections and short circuits are always a potential cause when trouble shooting Second check suspect components electrically hydraulically and mechanically to determine if they are at fault Refer to Tables 4 1 and 4 2 for Reference Designa tions used in Table 3 1 3 1 3 1 Troubleshooting TROUBLE PROBABLE CAUSE Table 3 1 Troubleshooting REMEDY TROUBLE PROBABLE CAUSE REMEDY Lift Function 1 inoperable electric motor does not start Extension cord too long or insufficient capacity Not plugged in or faulty connection AC only No power at wall outlet AC only Faulty Battery Charger DC only Faulty Battery BAT Key Switch S2 Emergency Stop Switch S1 S3 or Push button Switch S4 S5 failed open Outrigger Interlock Switch 7 58 9 810 Open circuit in cable to motor control box Faulty Electric Motor 1 Use minimum 1 5 12
70. nd R1 R4 In Outrigger Sockets Solenoid Lift coil Opens Up Valve Power Unit left hand side Solenoid Lower coil Opens down valve Power Unit front 4 2 Transformer Steps down AC voltage Inside electrical Control Box Solenoid Lift coil Opens Up Valve Power Unit left hand side UL 25 32 40 Portable Personnel Lifts Schematics LOWER COIL LIFT COIL OUTRIGGER INTERLOCK GRN WHT SWITCHES BLK za WHT BLK 12 CONTACT o ot LEGEND o C RELAY s L INDICATUR LIGHT R RELAY CUIL RECEPTACLE OPTIONAL 2155 TUE 1 CUN am E sTop SWITCH E STOP POWER DN TRANSFORMER GRN WHT BLK 220 VOLT FOR 50 HZ COIL x SOL 1 LOWER COIL SOLA RELAY BLK GRN ORG RED LEGEND C RELAY CONTACT L INDICATOR LIGHT R RELAY COIL AC RECEPTACLE OPTIONAL 30 87 30 87 30 87 30 87 C4 1 LIFT up 52 i T S3 51 54 LOWER KEY SWITCH ESTOP POWER ON LOWER S5
71. ndle to the storage position making sure that the locking pin engages the handle 5 While holding the Tilt Back frame remove the retaining pin and raise the Tilt Back assembly to the stowed position 6 Secure with the retaining pin making sure that the retaining pin is fully inserted and that the hair pin retainer is installed Operation Manual Page 11 Passage Through Doorway Figure 7 Passing Through Doorways Tilt Back Handle Cylinder Assembly Retaining Pin Lowering and Raising with the Tilt Back Handle 21 A Compressing the Cylinder Assembly Page 12 Operation Manual Maintenance BATTERY MAINTENANCE AWARNING Hazard of explosive gas mixture Keep sparks flame and smoking material away from batteries Always wear safety glasses when working near batteries Battery fluid is highly corrosive Thoroughly rinse away any spilled fluid with clean water Always replace batteries with Snorkel batteries or manufacturer approved replacements weighing 22 kg 48 Ibs each Check the battery fluid level daily especially if the work platform is being used in a warm dry climate f electrolyte level is lower than 10 mm in above the plates add distilled water only DO NOT use tap water with high mineral content as it will shorten battery life Keep the terminals and tops of the batteries clean Refer to the Service Manual to extend battery
72. nstall bottom lower bearings Install bottom upper bearings Slide mast 4 in make sure chains are not twisted Doy Install top bearings and secure with retaining screws using Loctite 242 or equivalent on the threads 6 Install chains around 3 sheave and down through 3 casting secure to 2 casting with new roll pins 7 Useacenter punch to dimple pin hole after roll pins are installed Z5 Mast 1 Set 5 mast in place with the sequencing strap inside Install bottom lower bearings Install bottom upper bearings Slide 5 mast in make sure chains are not twisted p wes cp po Install top bearings and secure with retaining screws using Loctite 242 or equivalent on the threads 6 Install chains around 4 sheaves and down through 4 casting secure to 3 casting with new roll pins 7 Useacenter punch to dimple pin holes after all roll pins are installed 8 Slide mast in leaving 25 cm 10 exposed 6 Mast 1 Set 6 mast in place with the sequencing strap inside 2 Run the remaining sequencing strap from platform assembly through the slot in the bottom of stage 6 and up through the inside Leave just enough slack on the outside to reach the attachment point at the top of stage 5 Install bottom lower bearings Install bottom upper bearings Slide 6 mast in make sure chains are not twisted Qx us Install top bearings and secure with retaining screws using Loctite 242
73. nt ur uu non per II Re D n a 2 10 Orifice Valve Cleaning RE E AIR ER RR shaded 2 12 Cylinder Removal o ert RE rt eere ra ende eee 2 13 2 13 2 7 Torque Specificatioris 2 14 Hydraulic Cormporents 2 ttt te eter 2 14 Fastener etie ee ee e OD Cer Ree nes 2 14 3 0 Troubleshooting ido eite Re esie 3 1 EE 3 1 General ProcedUre cm 3 1 3 1 Troubleshooting Cont d 3 4 Not Turn On ect ete EP eres etre 3 4 Lift DOES NOt Raise DG re ren tt 3 4 Lift Does Not Lower DCist t tg unte ud hun One 3 5 4 0 5 OD gr MEL AT wa M eb e 4 1 Iitroducti fit RR 4 1 es 56 u ma 4 1 Section 2 0 UL 25 32 40 Portable Personnel Lifts Maintenance 20 4 1 5 4 2 Electrical Schematic Legend 4 2 Electrical Schematc Legend Eh tum 4 2 4 2 Hydraulic Schematics eerte retention ocu na aee apple aa 4 4 Hydr
74. ny safety equipment is prohibited and presents a danger for the persons on the aerial work platform and in its working range NEVER charge batteries near sparks or open flame Charging batteries emit explosive hydrogen gas Modifications to the aerial work platform are prohibited or permissible only at the approval by Snorkel AFTER USE secure the work platform from unauthorized use by turning keyswitches off and removing key Page 1 CONTENTS Introduction lulu ug Lene u aa usss us 3 General Description J Lw ee ee uc eee 3 Special Limitations pus asi 4 Platform Capacity SD bu ug 4 Manual 4 Controls and Indicators mc le ele e 5 Outrigger 6 Satety lnterlock Test pex lee Aper ux ertet eire etia eg e one 6 Pre Operation Safety 7 System Function Inspection 7 Perform all tests from the ground etas ensam ea te paee a Ee pia us a anku m m I n 7 2 4 4 04 peo eens Meee ace eee ot 8 Elevatrig the Platform meme
75. ol box b Improperly connected or damaged chassis harness c Damaged circuit board a Continue to step 5 4b When up button is pressed 10 12 VDC is present at pin 26 5 Set voltometer for AC voltage Place one probe of the voltometer on 120 and the other probe on motor See drawing Page 3 5 Plug the lift into an outlet Set outriggers turn on ignition key and pull out both E Stops Press the common and up switches on the upper control box 5a Line voltage is found between 120 and motor a Damaged or improperly connected motor harness b Damaged motor 5b Line voltage is not found between a Circuit board damaged 120 and motor LIFT DOES NOT LOWER AC 1 Lift will raise but will not lower Turn on key switch pull out both upper and lower E Stops Press the common and down push buttons on the upper control box la Lift turns off and restarts in five seconds a Low line voltage b Extension harness excessive in length c Improperly connected or damaged motor harness d Improperly connected or damaged coil cord or upper control box e Damaged down solenoid 1b Outrigger lights turn on immediately a Continue to step 2 and no five second delay is present 3 3 3 1 Troubleshooting Table 3 1 Troubleshooting cont d 2 Check circuit board for correct output Open the lid on the lower control box Using a voltmeter check the voltage terminal S27 found on the u
76. ove the cap from the System Relief Valve fig 2 4 and turn the adjustment screw counterclock wise two full turns 6 Operate controls to elevate machine Machine will not raise until Relief Valve is properly adjusted 7 Turn the System Relief Valve Clockwise fig 2 4 until the machine begins to rise 8 Elevate the platform fully and verify that the pressure does not exceed 165 bar 2400 PSI at any time during the lift cycle 9 Replace cap on System Relief Valve reassemble Cover Gauge Port AC Power Unit DC Power Unit Figure 2 4 System Relief Valve 2 5 25 Maintenance 2 5 Mast Assembly Figure 2 6 2 7 Disassembly Using a suitable lifting device lower the work platform into a horizontal position Figure 2 5 If possible place the machine onto a sturdy work table using a forklift Never attempt to lower lift into a horizontal position without the use of a suitable lifting device bodily injury or damage to the machine may result NOTE Mark all components as they are removed so they can be reinstalled in the correct sequence and location Platform Assembly Removal Figure 2 6 1 Extend elevating assembly far enough to expose the eight screws attaching the cage support assembly to stage 6 by opening the emergency lowering valve and pulling on the cage guardrail 2 Remove cover from front of platform assembly To Overhead Lifting Device Forklift Figure 2 5 Liftin
77. pper right hand side of the circuit board See drawing Turn on ignition key and pull out both E Stop switches Depress the common and down switches on the upper control box 2a Motor does not run 2b Motor runs but will not raise Continue to step 3 a Hydraulic system failure b Damaged or improperly connected motor harness c Damaged pump solenoid 2c Motor attempts to start but machine a Improperly connected or damaged motor turns off and then restarts in five seconds harness b Improperly connected or damaged coil cord or upper control box c Damaged pump solenoid d Extension harness excessive in length e Low line voltage f Damaged pump motor LIFT DOES NOT TURN ON DC All voltages are referenced to Battery ground Using avoltmeter placethe negative probe directly to the negative pole of the battery If equipped with battery back up remove back up battery before proceeding Disconnect both chassisonnector and coil cord connector from the control box 1 Turn off key switch and E Stop switch Check power connections on circuit board 528 and GND found on the lower right hand side of the circuit board See drawing Page 3 5 Improperly connected or damaged motor harness b Poor battery connections S28 is less than battery voltage 19 GND is not zero volts a Improperly connected or damaged motor harness Battery power is present at PCB Continue to step 2
78. que Specifications 4 14 Hydraulic Components esses 4 14 3 0 Introduction seen 5 1 General Procedure i e ertet tetto 5 1 4 0 Introduction esse 6 1 Index PS n Rae E eem cU 6 1 4 1 Electrical Schematics 6 2 4 2 Hydraulic Schematic 6 4 UL 25 32 40 Portable Personnel Lifts List of Illustrations Figure Page Number No 1 1 UL Portable Personnel Lifts 1 1 2 Lubrication trot ies 2 3 2 2 Hydraulic Power Unit eese 2 3 2 3 Battery Charger he 2 5 2 4 System Relief Valve sss 2 5 2 5 Lifting Lowering UL Lift 2 6 2 6 Mast Assembly Strap and Chain Detail 2 7 2 7 Mast Assembly Bearing Detail 2 8 2 8 Taft Cyhnde r nurse uU RERO De Ud 2 11 2 9 Chain Tensioning Cylinder Installation 2 13 3 Circuit Board oreste 3 5 3 1 Electrical Schematic AC Models 3 3 3 2 Electrical Schematic DC Models 3 3 3 3 Hydraulic Schematic 3 4 List of Tables Table Page Number No 1 1 Specifications esee tette 1 2 2 Preventative Maintenance 2 2 2 2 Hydraulic Component Torque 2 14 2
79. r from up high on down is prohibited NEVER exceed the manual force allowed for this machine See Special Limitations on page 4 for details DISTRIBUTE all platform loads evenly on the platform NEVER operate the machine without first surveying the work area for surface hazards such as holes drop offs bumps curbs or debris and avoiding them OPERATE machine only on surfaces capable of supporting outriggers IN CASE OF EMERGENCY push EMERGENCY STOP switch to deactivate all powered functions Climbing up the railing of the platform standing on or stepping from the platform onto buildings steel or prefab concrete structures etc is prohibited Dismantling the entry gate or other railing components is prohibited Always make certain that the entry gate is closed and securely locked It is prohibited to keep the entry gate in an open position held open with tie straps when the platform is raised To extend the height or the range by placing of ladders scaffolds or similar devices on the platform is prohibited NEVER perform service on machine while platform is elevated without blocking elevating assembly INSPECT the machine thoroughly for cracked welds loose or missing hardware hydraulic leaks loose wire connections and damaged cables or hoses before using VERIFY that all labels are in place and legible before using NEVER use a machine that is damaged not functioning properly or has damaged or missing labels To bypass a
80. raulic valve and check for System serviceability Emergency Check procedure for Emergency Down batteries i Check for fitting leaks Wipe clean Check for leaks at mating surfaces Check mounting bolts for proper torque S Check condition amp operation Check the exterior of the cable for pinching binding or wear Check fasteners for proper torque Check welds for cracks ils Check condition of deck Check entry way closure 1 Inspect for external damage dents SS loose rivets or cracks Check chains and sheaves for wear Inspect and adjust sequence straps ssis Check cables for pinch or rubbing points Check welds for cracks Check casters for damage Check component mounting for proper torque i Check for leaks Check fitting for proper torque Perform pre operation inspection i Check for and repair collision damage Lubricate Check fasteners for proper torque Check for corrosion remove and repaint S Check for peeling missing or unreadable labels amp replace UL 25 32 40 Portable Personnel Lifts Maintenance 92 2 2 Lubrication Refer to Figure 2 1 for location of items that require lubrication service Use an aerosol chain lubricant for all components to be lubricated that require oil CASTERS Using a grease gun apply 1 or 2 shots of multi purpose bearing grease to each zerk fitting Swivel casters have two zerk fittings one at the wheel bearing and one at the swivel CHAINS 1 Ensure that Platform is fully lowered 2
81. read rod end cap onto rod tighten using strap wrench to hold rod 8 Clean all sealing surfaces with solvent Inspect cylinder rod for excessive wear replace if necessary 9 Remove all seals from seal retainer rod end cap and discard 15 Push rod back into cylinder for reassembly 16 t hydraulic line Note Apply clean hydraulic fluid to new cylinder seal threads and all sliding surfaces prior to assembly If 17 Remove nuts from tie rod ends and set the cylinder necessary soften new seals with warm water 82 c mounting plate into place Secure mounting plate with 180 F to aid in installation fasteners 18 Install tie rod nuts flush with tie rod ends torque each 10 Twist the pressure seal into a C shape and snap into nut tiiesxactanmbercbtmeasedinqsmoust seal groove in seal retainer making sure the lip of the seal is facing inward 19 Reinstall retaining ring 11 Using the same method install the rod wiper into the 20 Using a suitable lifting device raise the lift to its seal retainer outer groove making sure that the blade of normal vertical position the seal is facing outward from the seal retainer 22 Bleed air from cylinder by cycling the mast to full 12 Replace static seals in rod end cap and seal retainer by extension several times The cylinder 15 self bleeding streatching them into place Be carefull not to cut the will be forced out of the cylinder during the lower seal during
82. rns required to bring the nut flush with the tie rod end and record for reference during installation The tension on the tie rods maintains the left right positioning of the cylinder within the mast assembly reinstalling the nuts with the proper tension will speed up adjustment later 3 Remove the cylinder mounting plate Be careful not to allow the tie rods to suck back inside of the mast assembly replace the nuts on the tie rod ends tempo rarily to prevent this 4 Remove hydraulic line from the cylinder fitting and cap the cylinder fitting to prevent contaminants from entering the cylinder CAUTION A Marring the surface of the cylinder rod will damage cylinder seals and cause leakage Use a strap wrench to prevent rod damage 5 Extend cylinder rod at least twelve inches by hand Apply heat to rod near end cap to loosen Loc tite Wear safety glasses and heat resistant gloves when operating torch Do not touch hot surfaces without proper protection 6 Using a Strap Wrench 062482 000 to secure the cylinder rod unscrew the cylinder rod end If neces sary thread a 9 16 x 18 bolt into end cap port to use as a lever Remove rod end cap and orifice bleeder tube assembly 7 Remove snap ring to release orifice bleeder tube from rod end cap 2 12 8 Clean orifice valve hole with a straight pin Flush with solvent to remove any contamination that may remain in bleeder tube 9 Reinstall orific
83. s attaching the 2 bottom casting to the 2 mast assembly Install front and rear mast cover plates on the bottom of 1 mast Fish 4 strap between 3 and 2 mast with fish tape Slide 4 strap through 2 casting Fish 3 strap between 2 and 1 mast with fish tape Install strap 4 to 2 top casting Install strap 3 to 1 top casting While maintaining tension on the sequencing straps install strap retainers using Loctite 242 or equivalent on the threads of the retainer screws Reconnect hydraulic line Remove nuts from tie rod ends and set the cylinder mounting plate into place Secure mounting plate with fasteners Install tie rod nuts flush with tie rod ends torque each nut the exact number of turns used to remove it Reinstall retaining ring 2 13 Section 2 7 2 6 Cylinder Assembly Cont INSTALLATION CONT 17 18 19 Using a suitable lifting device raise the lift to its normal vertical position Bleed air from cylinder by cycling the mast to full extension several times The cylinder is self bleeding air will be forced out of the cylinder during the lower ing cycle If necessary remove pinch shield and check alignment of cylinder within mast assembly by peering down the mast with a flashlight The cylinder guide bearings must not be touching the inside surface of 6 mast The cylinder may be moved left or right by tightening the left or right tie rod nuts respectively Keep hands cl
84. s present at either of the Circuit board is damaged Replace terminals on the E Stop switch circuit board 3b Voltage is present on both terminals Check for correct operation of upper of the E Stop switch E Stop switch Continue to step 4 3c Voltage is only present at one side off Replace E Stop switch in whole or in the E Stop switch part 4 Click circuit board lift circuit Place voltmeter probe at terminal 26 at the upper right hand side of the circuit board See drawing Page 3 5 Activate the common and up switch on the upper control box 4 When button is pressed 10 12 VDC Improperly connected or damaged coil is not present at pin 526 cord or upper control box b Damaged circuit board Damaged or improperly wired motor harness b Damaged motor starter relay 4b When up button is pressed 10 12 VDC is present at pin S26 UL 25 32 40 Portable Personnel Lifts Troubleshooting 31 Table 3 1 Troubleshooting cont d LIFT DOES NOT LOWER DC 1 Lift will raise but will not lower Turn on key switch pull out both upper and lower E Stops Press the common and down push buttons on the upper control box Lift turns off and restarts in five a Improperly connected or damaged seconds motor harness b Improperly connected or damaged coil cord or upper control box c Damaged down solenoid Ib Lift will not lower a Continue to step 2 2 Check circuit bo
85. s removed for inspection purposes pinching injury to hands may result Never operate a machine with the pinch shield removed except for inspection UL 25 32 40 Portable Personnel Lifts Maintenance 2 6 a 1 Tensioner Bracket 062739 000 4 Bottom Casting Mast 2 2 Tie Rod Tensioners 0 62738 000 5 Bottom Casting Mast 3 3 Tie Rods 6 Cylinder Figure 2 9 Cylinder Assembly Installation CYLINDER REMOVAL Figure 2 9 Using a suitable lifting device lower the work platform into a horizontal position Figure 2 5 If possible place the machine onto a sturdy work table using a forklift Never attempt to lower lift into a horizontal position without the use of a suitable lifting device bodily injury or damage to the machine may result 1 Remove cylinder mounting plate fasteners and retain ing ring 2 Remove tie rod nuts count the number of turns required to bring the nut flush with the tie rod end and record for reference during installation The tension on the tie rods maintains the left right positioning of the cylinder within the mast assembly reinstalling the nuts with the proper tension will speed up adjustment later 3 Remove the cylinder mounting plate Be careful not to allow the tie rods to suck back inside of the mast assembly replace the nuts on the tie rod ends tempo rarily to prevent this 4 Remove hydraulic line from the cylinder fitting and cap the cylinder fitting
86. ssembly UL25 068179 003 Part Number Description 068082 001 CAGE SUPPORT WELDMENT 068123 000 SLIDE ANGLE 506275 001 RAIL WELDMENT 068149 002 CAGE PAN 068276 000 SHEAR GUARD 068096 000 RAIL BEARING TOP 068147 000 FRONT COVER 057524 001 DROP BAR ASSY 026525 003 SCREW SLFTP 8 HWH X 3 8 011252 022 SCREW HHC 1 4 20UNC X 2 3 4 011240 004 WASHER 1 4 STD 011248 004 NUT HEX ESNA 1 4 20UNC on co n2 L 1 L 011264 022 SCREW 5 16 18UNC X 2 3 4 011240 005 WASHER 5 16 STD 011246 010 NUT HEX ESNA 5 16 18UNG 510524 000 SWITCH PUSH PULL 510542 000 PUSH BUTTON ENABLE 062799 011 ENCLOSURE amp COVER 0120804 PUSH BUTTON DOWN 0120803 PUSH BUTTON UP 029925 000 029939 002 LOCKNUT 1 2 068277 000 LATCH 014252 004 NUT SERT 1 4 20UNC 011825 006 SCREW RND HD 1 4 20UNC X 3 4 063650 012 GAS SPRING 011708 003 SCREW RD HD MACH 8 32 X 1 2 068277 010 STRIKER BOLT 011252 014 SCREW HHC 1 4 20UN X 1 3 4 015936 004 SCREW 3 8 X 1 2 SHOULDER 014924 008 U BOLT 068630 000 EXTENSION SPRING 055 WIRE 013919 009 CLAMP 5 8 DIA 026551 007 RIVET 1 8 251 312 GRIP L 0 1 2 3 4 15 6 7 8 9 S en e 1 N
87. the Allen head screws holding the top mast bearings between the 4 and 5 mast Remove the top mast bearings 3 Slide 5 mast out of 4 mast As mast is removed the bottom four mast bearings will fall out note their orientation for re assembly 4 Disconnect chain from top of 3 mast 4 Mast 1 Remove sequence strap retainer on the top of 2 mast 2 Remove the Allen head screws holding the top mast bearings between the 3 and 4 mast Remove the top mast bearings 3 Slide 4 mast out of 3 mast As mast 1 removed the bottom four mast bearings will fall out note their orientation for re assembly UL 25 32 40 Portable Personnel Lifts Maintenance 25 MAST WELDMENT e L Figure 2 6 Mast Assembly Strap and Chain Detail UL 25 32 40 Portable Personnel Lifts 2 7 Section Maintenance Figure 2 7 Mast Assembly Bearing Detail 2 8 UL 25 32 40 Portable Personnel Lifts Maintenance 55 2 5 Mast Assembly Cont 4 Disconnect chain from top of 2 mast 5 Remove cylinder by following instructions in Section 2 7 3 Mast 1 Remove sequence strap the top of 1 mast 2 Remove the Allen head screws holding the top mast bearings between the 2 and 3 mast Remove the top mast bearings 3 Slide 3 mast out of 2 mast As mast 15 remo
88. to prevent contaminants from entering the cylinder 5 Remove sequence strap retainers on the top of 3 and 2 masts 6 Remove front and rear mast access plates from the bottom of the 1 mast UL 25 32 40 Portable Personnel Lifts 7 Remove the screws and washers attaching the 2 and 3 bottom castings to the 2 and 3 mast assemblies 8 While keeping tension on the tie rods slide the cylinder and 2 and 3 bottom castings out the bottom of the UL Lift far enough to expose both castings 9 Install cylinder Tensioner Brackets 062739 000 on 2 and 3 bottom castings Remove tie rod nuts and install the Tie Rod Tensioners 062738 000 Remove all slack from the chains with the Tie Rod Tensioners 10 Remove cylinder assembly from mast assembly INSTALLATION NOTE Cylinder assembly must have Tension Brack ets Tensioner Spacer and Tie Rod Tensioners installed to remove slack from chain 10 11 12 13 14 15 16 Slide cylinder assembly into mast assembly until 3 bottom casting is at the bottom of the mast assembly Install the screws and washers attaching the 3 bottom casting to the 3 mast assemby Remove cylinder Tensioner Brackets from 2 and 3 bottom castings and Tie Rod Tensioners from tie rods Install tie rod nuts finger tight While maintaining tension on the tie rods to keep slack out of the chains slide cylinder assembly completely into the mast assembly Install the screws and washer
89. uid level using the guage on the dipstick 4 To add Hydraulic fluid remove Filler Cap in 5 Add the appropriate fluid to bring the level to the end of the dipstick See Specifications Operation Manual Page 13 INSPECTION AND MAINTENANCE SCHEDULE The Complete Inspection consists of periodic visual and operational checks along with periodic minor adjustments that assure proper performance Daily inspection will prevent abnormal wear and prolong the life of all systems The inspection and maintenance schedule should be performed at the specified inter vals Inspection and maintenance shall be performed by personnel who are trained and familiar with mechanical and electrical procedures NOTE The frequency and extent of periodic maintenance should also take into account Local National Regulations A WARNING Before performing preventative maintenance familiarize yourself with the operation of the machine Always block the elevating assembly whenever it is necessary to perform maintenance while the platform is elevated The daily preventative maintenance checklist has been designed for machine service and maintenance Please photocopy the Daily Preventative Maintenance Checklist and use the checklist when inspecting the machine DAILY PREVENTATIVE MAINTENANCE MAINTENANCE TABLE KEY PREVENTATIVE MAINTENANCE REPORT Y Yes Acceptable Date N No Not Acceptable Owner R Repaired Acceptable
90. ved the bottom four mast bearings will fall out note their orientation for re assembly 2 Mast 1 Remove the Allen head screws holding the top mast bearings between the 1 and 2 mast Remove the top mast bearings 2 Slide 2 mast out of 1 mast As mast Is removed the bottom four mast bearings will fall out note their orientation for re assembly ASSEMBLY Figure 2 7 Note Use WD 40 lubricant as necessary to aid in reassembly 2 Mast 1 Set 2 mast in place 2 Install bottom lower bearings 3 Install bottom upper bearings 4 Slide 2 mast in all the way except 30 38 cm 12 15 5 Install top bearings and secure with retaining screws using Loctite 242 or equivalent on the threads 6 Slide 2 mast in completely 3 Mast 1 Set 3 mast in place with the sequencing strap inside Install bottom lower bearings Install bottom upper bearings Slide 3 mast in all the way except 30 38 cm 12 15 Install top bearings and secure with retaining screws using Loctite 242 or equivalent on the threads 6 Place a 10 25 cm long wood block between 3 and 2 masts slide 3 mast down tight against block Pull sequencing strap completely out of the bottom of assembly 7 Install cylinder assembly following instructions section 2 6 UL 25 32 40 Portable Personnel Lifts 4 Mast 1 Set 4 mast in place with the sequencing strap inside and the chains on the bottom I
91. weldment pull tightly and secure with strap clamp and screws using Loctite 242 or equivalent on the threads 5 Fish 6 strap up through mast between fourth and fifth stages with fish tape 6 Fish 5 strap up through mast between third and fourth stages with fish tape 7 Fish 4 strap up through mast between third and second stages with fish tape 8 Fish 3 strap up through mast between first and second stages with fish tape 9 Install strap 6 to 4 top casting 10 Install strap 5 to 3 top casting 11 Install strap 4 to 2 top casting 12 Install strap 3 to top of 1 mast weldment 13 Install the strap clamps and retaining screws using Loctite 242 or equivalent on the threads Pull straps tight while tightening retaining screws 2 10 Maintenance 2 6 Cylinder Assembly SEAL REPLACEMENT Figure 2 8 Note The Lift Cylinder Seal can be accessed from the bottom of the Lift without removing the Cylinder Assembly Using a suitable lifting device lower the work platform into a horizontal position Figure 2 5 If possible place the machine onto a sturdy work table using a forklift Never attempt to lower lift into a horizontal position without the use of a suitable lifting device bodily injury or damage to the machine may result 1 Remove cylinder mounting plate fasteners and retain ing ring 2 Remove tie rod nuts count the number of turns required to bring the nut flush with the tie rod end and
92. witches power to Electric Motor In Contro Relay Coil When energized closes relay contacts 1 4 In Control Switch Chassis Emergency Stop Control circuit shut off In Contro Relay Motor Supplies power to Motor Lower Power Module Switch Key Provides power upper controls In Contro Switch Chassis Emergency Stop Control circuit shut off In Control Box Switch Platform Emegency Stop Control Circuit shut off In Contro Switch Key Provides power to upper controls In Control Box Switch Power Supplies power to either Up or Down Switch Center button of platform controls Switch Platform Emegency Stop Control Circuit shut off In Control Box Switch Lift Supplies power up circuit Upper button of platform controls Switch Power On Supplies power to either Up or Down Switch Center button of platform controls Switch Lower Supplies power down circuit Lower button of platform controls Switch Lift Supplies power to up circuit Upper button of platform controls Switch Outrigger Interlock Supplies power L1 L4 and R1 R4 In Outrigger Sockets Switch Lower Supplies power to down circuit Lower button of platform controls Solenoid Lower coil Opens down valve Power Unit front Switch Outrigger Interlock Supplies power to L1 L4 a
93. y Faulty Hydraulic Pump P Close valve Check hydraulic fluid level top off as required Check or replace Down Valve V2 Adjust the Relief Valve RV If not adjustable replace Check or replaceLift Valve V1 Check pressure and delivery of the Hydraulic Pump Replace if required Platform does not lower using electrical switches Will lower using emergency lowering valve Down Valve Solenoid 5011 faulty Electrical malfunction Test for continuity across Solenoid Repair or replace Check all AC plugs and cords used only Check power output at wall outle AC only With each switch 51 52 53 54 56 in the ON position check continuity across the contacts If none replace Platform does not lower or lowers very slowly Down Orifice ORF plugged Down Valve V2 blocked or stuck closed Mechanical interference Remove and clean Down Orifice check valve Check function clear blockage of Down Valve Inspect Mast Assembly correct interference Platform continues to lower when controls are released Down Valve V1 stuck open Clean or replace Down Valve UL 25 32 40 Portable Personnel Lifts Troubleshooting 31 Table 3 1 Troubleshooting cont d LIFT DOES NOT TURN AC All voltages arereferenced Chassis ground Using avoltmeter placethe negative probe directly to a clean ground source AC motor

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