Chapter 2 – Maintenance

Every person who maintains, inspects, tests or repairs the Repair all defects before returning the machine to service.
aerial platform must be qualified to do so. Maintenance
functions must be performed by maintenance personnel Parts Replacement
who are qualified to work on the aerial platform. The parts drawings located in the Repair Parts section
of the Parts Manual are designed for use as a guide for
proper disassembly of the machine and components, as
Caution well as, for parts replacement.
Welding current can be very intense. Damage to elec-
tronic components can result. Connect the ground
clamp as close as possible to the area being welded. Danger
Disconnect the battery cables and any microproces- Hydraulic fluid escaping under pressure can have
sors and engine control modules before welding on enough force to inject fluid into the flesh. Serious
the machine. infection or reaction will result if medical treatment is
not given immediately. In case of injury by escaping
If it becomes necessary to weld aerial platform com- hydraulic fluid, seek medical attention at once.
ponents as a method of repair, take all precautions to
prevent damage to electronic circuitry and devices on Always refer to the hydraulic system installation drawings
the machine. This includes, but may not be limited to, and the electrical wiring diagram before removing or
disconnecting battery cables and electronic devices. disassembling associated parts.

Do not modify this aerial platform without prior written When disassembling or reassembling components, com-
consent of the Snorkel Engineering Department. Modifi- plete the procedural step in sequence. Do not partially
cation may void the warranty, adversely affect stability or disassemble or assemble one part, then start on another.
affect the operational characteristics of the aerial platform. Always check your work to assure that nothing has been
overlooked.
Maintenance Schedules
The manufacturer has established a preventative main- Keep the following in mind when disassembling or as-
tenance schedule to detect any defective, damaged or sembling the machine.
improperly secured parts and provide information re-
garding lubrication and other minor maintenance items. yy Always be conscious of weight.

This schedule includes the following: yy Never attempt to lift heavy objects without the aid of
a mechanical device.
yy Daily Prestart Inspection
yy Do not allow heavy object to rest in an unstable
yy Frequent Inspection and Maintenance – Every 90 condition.
Days or 150 Hours
yy Always make sure the work platform is in the stowed
yy Annual Maintenance – Every 500 Hours position, blocked or the weight removed by a suitable
lifting device before removing any components from
The Daily Prestart Inspection must be performed by a the machine.
trained operator. All other maintenance and inspection
must be performed by a trained service technician only. yy When raising a portion of the machine, be sure that ad-
Retain a copy of these forms for your records. equate blocking is properly positioned. Do not depend
solely on the lifting device to hold and secure weight.
All placards and decals on the machine must be in place
and legible. Use the Placards and Decals parts pages in yy If a part resists removal, check to see if all fasteners,
the Repair Parts section of the Parts Manual to check electrical wiring, hydraulic lines, etc., have been re-
these placards and decals. moved or that other parts are not interfering.

Snorkel recommends that you make additional copies of Parts should be thoroughly inspected before restoring
the preventative inspection and maintenance checklists to service at the time of reassembly. Burrs, nicks or
for your use in performing these inspections. scratches may be removed from machines surfaces by
honing or polishing with a #600 crocus cloth, followed by a
thorough cleaning with an approved cleaning solvent, and
Warning blown dry with compressed air. Do not alter the contour
The potential for accident increases when operating of any part. If this operation does not restore the part to
an aerial platform that is damaged or malfunction- a serviceable condition, replace the part.
ing. Death or serious injury can result from such
accidents. Do not operate the aerial platform if it is Replace all o-rings, seals and gaskets at reassembly.
damaged or malfunctioning. Use new roll pins or cotter pins. Dip all packing rings and

A46JRT – 0261166 9
Chapter 2 – Maintenance

seals in hydraulic oil before reassembling in cylinder and

manifolds. Replace any part having imperfect threads.
In general, machines that have been disassembled can
be reassembled by reversing the order of disassembly.

The service life of a machine can be increased by keep-

ing dirt and foreign materials out of the vital components.
Shields, covers, seals and filters help to keep air and oil
supplies clean. However, these items must be maintained
on a scheduled basis in order to function properly.

Clean surrounding areas, as well as the opening and

fittings before disconnecting air or oil lines. As soon as
a line or component is disconnected, cap or cover all
openings to prevent the entry of dirt or foreign materials.

New parts should remain in their container until they are

ready to be used.

Clearly mark or tag hydraulic lines and electrical wiring

connections when disconnecting or removing them from
the machine. This will assure that they are correctly
reinstalled.

Proper assembly is critical to the successful rebuilding

of any machine. Carefully, inspect any parts which are to
be reused. If in doubt, replace.

“Safety First” is a good slogan.

Replace any guards and protective devices that have been

removed to carry out maintenance and repair work.

Checklist Legend
P – Pass
F – Fail
R – Repaired

10 A46JRT – 0261166
 Chapter 2 – Maintenance

Daily Prestart Inspection

Item Inspect For P/F/R

Operator’s Manual In place, all pages readable and intact
Engine
Oil level Between full and add marks
Coolant Proper fluid level
Radiator Cap tight, good condition and clean
Fuel tank and line Tank full, cap in place and tight/no leaks
Electrical System
Battery Condition and charged for proper operation
Battery fluid level and terminals Proper level/clean, connectors tight
Cables and wiring harness No wear or physical damage
Hydraulic System
Fluid level Visible in bottom of sight gauge
Fluid filter Verify operation in the green zone
Hoses, tubes and fittings No leaks
Cold weather warm-up kit Proper operation
Tires
Air filled Good condition, proper inflation
Foam filled Good condition
Wheels All wheel lug nuts present and properly torqued
Lower Control Station
Operating controls Proper operation
Emergency stop and emergency power Shuts off lower controls/proper operation
Level Sensor Sounds tilt alarm
Flashing Light Proper operation
All Motion Alarm Sounds when machine is operated and/or driven
Structures
Weldments – Chassis, turntable, booms, platform, etc. Welds intact, no damage or deformation
Slide pads In place, no damage or deformation
Fasteners In place and tight
Upper Control Station
Guardrail system and lanyard anchors Welds intact, no damage or deformation
Operating controls Proper operation
Emergency stop and emergency power Shuts off upper controls/proper operation
Horn Sounds when activated
Snorkel Guard Proper operation
Electrical power outlet – GFCI Proper operation
Placards and Decals In place and readable

Performed by: Date:

A46JRT – 0261166 11
Chapter 2 – Maintenance

Frequent Inspection and Maintenance – Every 90 Days or 150 Hours

Item Procedure Information P/F/R

Chassis
Structural Check for damage and cracked welds
Pins Check for wear and damage
Steering cylinder pin caps and Verify that all fasteners are in place
retaining bolts
Oscillating axle lock cylinders, Verify that all fasteners are in place
rollpin, and lynch pin
Steering linkage Check for proper operation
Tires Check for wear and damage
Proper inflation 70 psi to 75 psi
Air filled tires only
Hydraulic tubes and hoses Check for leaks, wear, and damage
Decals and placards Check for damage and readability
Order replacements as necessary
Torque drive and steer wheel Torque lug bolts/nuts to proper value 4x4 front: 200 to 225 ft lb
lug nuts per placard on wheel on machine placard 4x2 front: 70 to 80 ft lb
All rear: 200 to 225 ft lb
Right drive motor(s) Check for leaks
Left drive motor(s) Check for leaks
Turntable
Structural Check for damage and cracked welds
Pins Check for wear and damage
Torque turntable top bolts Torque to proper value 190 ft lbs
Torque turntable bottom bolts Torque to proper value 190 ft lbs
Hydraulic tubes and hoses Check for leaks, wear, and damage
Cowling Check for wear/damage and that
fasteners are in place and are tight
Wire harness Check for wear/damage and that
fasteners are in place and are tight
Tilt alarm Check for proper operation
Lower Booms
Structural Check for damage and cracked welds
Pins Check for wear and damage
Boom lift cylinder retaining bolts Verify that all fasteners are in place
and are tight
Boom lift cylinder and holding Check for leaks, wear, damage, and
valve for proper operation
Riser lift cylinder forged pin Verify that all fasteners are in place
retainer/retaining bolt and are tight
Riser lift cylinder and holding Check for leaks, wear, damage, and
valve for proper operation
Master level cylinder forged pin Verify that all fasteners are in place
retainer and are tight
Hydraulic tubes and hoses Check for leaks, wear, and damage
Electrical Wires Check for wear and damage
Left Hand Access Door
Boom control valve Check for leaks, wear, damage, and
for proper operation
Boom circuit system pressure Check maximum system pressure 2,700 to 2,800 psi
Filter minder gauge Check for proper operation

12 A46JRT – 0261166
 Chapter 2 – Maintenance

Frequent Inspection and Maintenance – Every 90 Days or 150 Hours

Item Procedure Information P/F/R

Engine Compartment
Structural Check for damage and cracked welds
Fuel tank Check for leaks, wear, and damage
Fuel gauge Check for proper operation
Fuel tank cap Check for leaks, wear, and damage
Engine air filter Check for wear and damage
Engine belts and hoses Check for wear and damage
Engine oil Check for wear and damage/level Between add and full marks
Engine coolant level Check for level Between hot and cold level
Engine Check for proper operation
Engine start – stop Check for proper operation
Electric throttle Check for proper operation
Engine charging system Check for proper operation
Engine shutdown, low oil Check for proper operation
pressure
Hydraulic pump Check for proper operation
Hydraulic oil reservoir Check for wear/damage/leaks
Hydraulic oil reservoir filler/ Verify that all fasteners are in place
breather cap and are tight
Hydraulic oil reservoir fluid level Check for proper level Above 10°F (-12°C)
ISO VG32
Below 10°F (-12°C)
ISO VG15
Hydraulic oil return filter Replace after the first 50 hours, every
90 days or 150 hours thereafter
Inspect filter for foreign matter that
could indicate component wear
Drive system control valve Verify that all fasteners are in place
and are tight
Upper Booms
Structural Check for damage and cracked welds
Pins Check for wear and damage
Electrical wires Check for wear and damage
Extension cylinder pins, snap Verify that all fasteners are in place
rings, and forged pin retainers and are tight
Extension cylinder and holding Check for leaks, wear, damage, and
valve for proper operation
Jib cylinder pin and retainer bolt Verify that all fasteners are in place
and are tight
Jib cylinder and holding valve Check for leaks, wear, damage, and
for proper operation
Slave level cylinder pin caps Verify that all fasteners are in place
and retainer bolt and are tight
Slave level cylinder holding Check for leaks, wear, damage, and
valves for proper operation
Hose carrier assembly Check for residue buildup/proper
operation
Hydraulic hoses and tubes Check for leaks, wear, and damage

A46JRT – 0261166 13
Chapter 2 – Maintenance

Frequent Inspection and Maintenance – Every 90 Days or 150 Hours

Item Procedure Information P/F/R

Upper Booms
Platform rotator, pin and forged Verify that all fasteners are in place
pin retaining system and are tight
Platform rotator, pin and forged Verify that all fasteners are in place
pin retaining system and are tight
Platform rotation holding valve Verify that all fasteners are in place
and are tight
Rotator mounting bolts Verify that all fasteners are in place
and are tight
Overload cell Check for proper operation
Platform
Structural Check for damage and cracked welds
Decals and placards Check for damage and readability
Order replacements as necessary
Platform gates Check for damage/proper operation
Platform mounting bolts Verify that all fasteners are in place
and are tight
Operator’s Manual Proper manual in document holder
Batteries
Battery terminals Clean terminals and check cable
condition
Electrolyte Check for proper level Add distilled water if
necessary
Indicator gauges (if equipped) Check for proper operation/condition
Lower Control Station
Station selector switch in the Check for proper operation With the selector in the
lower controls position lower controls position, the
upper controls do not work
Station selector switch in the Check for proper operation With the selector in the
upper control position upper controls position, the
lower controls do not work
Preheat button Check for proper operation
Keyed start switch Check for proper operation
Throttle interlock Check for proper operation
Audible alarms Check for proper operation
Turntable rotation CW – CCW Check for proper operation 65 to 85 seconds for each direction
Riser boom lift Up – Down Check for proper operation Up: 35 - 40 sec Down: 20 - 25 sec
Main boom lift Up – Down Check for proper operation Up: 25 - 30 sec Down: 20 - 25 sec
Jib boom lift Up – Down Check for proper operation Up: 20 - 25 sec Down: 30 - 35 sec
Boom extension In – Out Check for proper operation Ext: 20 - 25 sec Ret: 22 - 27 sec
Platform leveling Up – Down Check for proper operation
Platform rotation CW – CCW Check for proper operation Full cycle: 16 - 20 seconds
Emergency power, all functions Check for proper operation
Emergency stop Check for proper operation
Hour meter Check for proper operation

14 A46JRT – 0261166
 Chapter 2 – Maintenance

Frequent Inspection and Maintenance – Every 90 Days or 150 Hours

Item Procedure Information P/F/R

Upper Control Station
Foot switch Check for proper operation Functions should be
operational when foot
switch is engaged
Start switch Check for proper operation
Throttle Check for proper operation Engine should throttle up
when the foot switch is
engaged
Preheat switch Check for proper operation
Boom speed knob Check for proper operation
Horn Check for proper operation
Turntable rotation CW – CCW Check for proper operation
Riser boom lift Up – Down Check for proper operation
Main boom lift Up – Down Check for proper operation
Boom extension In – Out Check for proper operation
Jib boom lift Up – Down Check for proper operation
Emergency power, all functions Check for proper operation
Emergency stop Check for proper operation
Gradual start to stop, drive/steer Check for proper operation
controls
Drive speed limit switch, main Check for proper operation
boom lift
Drive speed limit switch, tip Check for proper operation
boom extend
Drive speed limit switch, riser Check for proper operation
boom lift – CE only
110 volt AC power to platform Check for proper operation
Boom extension In – Out Check for proper operation
Platform leveling Up – Down Check for proper operation
Platform rotation CW – CCW Check for proper operation
Drive range – booms stowed Check for proper operation Slow speed only with boom
raised
Drive speed Boom down and retracted 50 ft in 7.6 to 8 sec
High – 4.25 to 4.5 mph
Boom up or extended 50 ft in 42.5 to 48.5 sec
Low – 0.7 to 0.8 mph
Optional Equipment
Air line to platform Check for proper operation
All motion warning alarm Check for proper operation
Flashing light Check for proper operation
Hydraulic warm-up system Check for proper operation
AC generator Check for proper operation

Performed by: Date:

A46JRT – 0261166 15
Chapter 2 – Maintenance

Frequent Maintenance – Every 90 Days or 150 Hours

Item Procedure Information P/F/R

Daily maintenance Perform maintenance as per schedule Retain copy of checklist
Preventive inspection Perform inspection, complete form Retain copy of checklist
maintenance checklist
Placards and decals inspection Inspect using drawing and parts listing Replace any missing or
in Section 1 – Repair Parts Manual unreadable decals/placards
Door hinges and latches Lubricate SAE 10W oil or spray
lubricant
Rotation bearing Lubricate Extreme pressure grease
Above 10° F
NLGI Grade 2
Below 10° F
NLGI Grade 1
Rotation bearing teeth and Lubricate Open gear lubricant
pinion ASTM D 445
Gear hubs Check fluid level, fill if low Gear lubricant
SAE Grade 80W-90
Platform rotator Check for proper operation Repair or replace if not
working properly
Platform controller Check smooth operation & speeds
Batteries Check specific gravity 1.260/1.275 at 80° F
Charging system Check operation
Engine RPM Check for proper engine RPM See engine owner’s manual
Engine oil and filter Replace per engine owner’s manual See engine owner’s manual
Engine fuel filter Check condition Replace every 6 months or if
dirty

Performed by: Date:

16 A46JRT – 0261166
 Chapter 2 – Maintenance

Annual Maintenance – Every 500 Hours

Item Procedure Information P/F/R

90 day or 150 hour maintenance Perform maintenance per Retain copy of checklist
schedule
Hydraulic oil reservoir Clean and replace fluid Above 10°F (-12°C)
ISO VG32
Below 10°F (-12°C)
ISO VG15
Hydraulic return filter Replace After first 50 hours, then at
recommended interval
Hydraulic reservoir suction filter Clean and reinstall
Hydraulic pressures Drive pump setting Differential pressure:
450-500 psi
Maximum pressure:
5,000-5,100 psi
Boom pump setting Maximum pressure:
2,750-2,800 psi
Function pressures: check at Steer right/left:
manifold, except level 2,700-2,800 psi
Riser boom down:
3,300-3,400 psi
Main boom down:
1,400-1,500 psi
Extend:
1,900-2,000 psi
Jib up/down:
2,700-2,800 psi
Rotate:
1,200 psi max on level
Pressure reducing valve:
2,700-2,800 psi
Drive/boom relief: 3,000 psi
Level Pressure: install gauge Level:
between valve and slave 2,000-2,050 psi
cylinder
Gear hubs Replace fluid Gear lubricant
SAE Grade 80W-90
Swing drive Replace fluid Gear lubricant
SAE Grade 80W-90
Engine coolant Check condition See engines owner’s manual

Performed by: Date:

A46JRT – 0261166 17