Snorkel AB80J User Manual

Serial number 090008 and after
Models AB80J/AB85J/A80J/A85JRT Replaces February 2011
OPERATOR’S
MANUAL
Part Number 0420453
March 2014
The aerial platform is not electrically insulated. Death or serious injury will result from contact with, or inadequate clearance from, an energized conductor.
Do not go closer than the minimum safe approach distance as defined by the Minimum Safe Approach Distance section in Chapter 3–Safety.
Regard all conductors as energized.
Allow for electrical wire sag and aerial platform sway.
If the platform, booms, or any part of the aerial platform contacts a high-voltage electrical conductor, the entire machine can become electrically charged.
If that happens, remain on the machine and do not contact any other structure or object. This includes the ground, adjacent buildings, poles, and any other objects that are not part of the aerial platform.
Such contact could make your body a conductor to the other object, creating an electrical shock hazard resulting in death or serious injury.
If an aerial platform is in contact with an energized conductor the platform operator must warn ground personnel in the vicinity to stay away. Their bodies can conduct electricity creating an electrical shock hazard resulting in death or serious injury.
Do not approach or leave the aerial platform until the electricity has been turned off.
Do not attempt to operate the lower controls when the platform, booms, or any part of the aerial plat­form is in contact with a high-voltage electrical conductor or if there is an immediate danger of such contact.
Personnel on or near an aerial platform must be continuously aware of electrical hazards, recognizing that death or serious injury can result from contact with an energized conductor.
California
Proposition 65 Warning
Battery posts, terminals, and related accessories contain lead and lead components, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
California
Proposition 65 Warning
Diesel and gasoline engine exhaust and some of its con­stituents are known by the State of California to cause cancer, birth defects or other reproductive harm.
Table of Contents
Electrical Danger ............................ Inside Front Cover
California Proposition 65 ................ Inside Front Cover
Chapter 1 – Introduction
Aerial Platform Features .............................................1
Options .......................................................................1
Operator’s Manual ......................................................1
Safety Alerts ...............................................................1
Operation ....................................................................2
Maintenance ...............................................................2
Manual of Responsibilities ..........................................2
Additional Information .................................................2
Chapter 2 – Specications
Component Identication ............................................3
Working Envelope – AB80J ........................................ 4
Working Envelope – AB85J ........................................ 5
General Specications – AB80J .................................6
General Specications – AB85J .................................7
Engine Specications .................................................8
Engine Oil Viscosity ....................................................8
Chapter 3 – Safety
Electrocution Hazards ..............................................11
Minimum Safe Approach Distance ........................... 11
Prestart Inspection....................................................12
Work Place Inspection and Practices .......................12
Operation ..................................................................12
Tip-Over and Falling Hazards ...................................12
Electrical System ......................................................13
Hydraulic System......................................................13
Engine and Fuel Handling Precautions ....................13
Placards and Decals.................................................14
Chapter 4 – Safety Devices
Emergency Stop Controls.........................................15
Emergency Power System .......................................15
Manual Emergency Lowering Pump.........................15
Ground Operation Switch .........................................16
Platform Foot Switch ................................................16
Guardrails .................................................................16
Lanyard Anchors.......................................................16
Ground Fault Circuit Interrupter ................................16
Tilt Alarm ...................................................................16
Engine Protection Systems ......................................17
High Engine Temperature Alarm ...........................17
Low Oil Pressure Alarm ........................................17
Horn ..........................................................................17
Drive Motion Alarm ...................................................17
Flashing Light ...........................................................17
Driving Lights ............................................................17
Platform Work Lights ................................................17
Chapter 5 – Gauges and Displays
Hour Meter................................................................19
Engine Temperature Gauge .....................................19
Ammeter ...................................................................19
Voltmeter – GM Engines...........................................19
Engine Air Filter Gauge ............................................19
Fuel Gauge ...............................................................19
Engine Oil .................................................................20
Hydraulic Fluid Filter Gauge .....................................20
Fluid Level and Temperature Gauge ........................ 20
Chapter 6 – Controls
Battery Disconnect Switch ........................................21
Lower Controls .........................................................21
Start Switch ...........................................................21
Emergency Stop Button ........................................21
Controls Selector Switch .......................................21
Ground Operation Switch ......................................21
Rotation Switch .....................................................21
Riser Switch ..........................................................22
Boom Elevation Switch .........................................22
Boom Extension Switch ........................................22
Boom Speed Knob ................................................22
Jib Rotation Switch – AB85J Only .........................22
Jib Articulation Switch ...........................................23
Platform Level Switch ...........................................23
Platform Rotation Switch ....................................... 23
Engine/Emergency Power Switch .........................23
Engine Speed Switch ............................................23
Fuel Switch ...........................................................23
Manifold Air Inlet Heater – Deutz Only .................. 23
Hydraulic System Warm-up Switch ....................... 23
Circuit Breaker Reset Buttons ..................................23
Upper Controls .........................................................24
Start Switch ...........................................................24
Emergency Stop Button ........................................25
Boom Joystick .......................................................25
Boom Extend Joystick – AB80J ............................25
Jib Rotation/Boom Extend Joystick – AB85J .......25
Drive Joystick ........................................................25
Drive Range Switch ..............................................25
Steer Mode Switch ................................................26
Jib Articulation Switch ...........................................26
Platform Level Switch ...........................................26
Platform Rotate Switch .........................................26
Engine/Emergency Power Switch .........................26
Throttle Switch ......................................................26
Horn Button ...........................................................26
Platform Foot Switch .............................................27
Machine/Generator Switch .................................... 27
Dual Fuel ..................................................................27
Driving and Platform Work Lights ............................. 27
AB80J/AB85J – 0420453
Table of Contents
Chapter 7 – Prestart Inspection
Operator’s Manual ....................................................29
Engine ......................................................................29
Oil Level ................................................................29
Coolant ..................................................................29
Radiator ................................................................30
Fuel Tank ...............................................................30
Fuel Line ...............................................................30
Air Filter ................................................................. 30
Charging System .................................................31
Cold Weather Start Kit ..........................................31
Electrical System ......................................................31
Battery Fluid Level ................................................31
Battery Terminals ..................................................31
Cables and Wiring Harness ......................................31
Hydraulic System......................................................31
Fluid Level ............................................................. 32
Fluid Filter .............................................................32
Hoses, Tubes, and Fittings ...................................32
Tires and Wheels ......................................................32
Lower Control Station ...............................................33
Operating Controls ................................................33
Emergency Stop ...................................................33
Emergency Power ................................................. 33
Manual Emergency Lowering Pump.........................33
Level Sensor.............................................................34
Flashing Light ...........................................................34
Sandblast Protection Kit ...........................................34
Structures .................................................................34
Weldments ............................................................34
Boom Slide Pads ..................................................35
Extension Cylinder Slide Pads – AB85J ...............35
Fasteners ..............................................................35
Upper Control Station ...............................................35
Guardrail System ..................................................35
Lanyard Anchors ...................................................36
Operating Controls ................................................36
Emergency Stop ...................................................36
Emergency Power ................................................. 36
Horn ......................................................................36
Electrical Power Outlet .......................................... 36
Platform Control Cover .........................................37
Drive Motion Alarm ...................................................37
Driving and Work Lights ...........................................37
Platform Glazier Package .........................................37
Placards and Decals.................................................38
Prestart Inspection Checklist ....................................45
Chapter 8 – Operation
Cold Weather Start-Up .............................................47
Engine Cold Weather Start Kit ..................................47
Cummins — Block Heater ..................................... 47
Deutz — Manifold Preheater ................................. 47
GM — Radiator Hose In-Line ................................ 47
Hydraulic System Cold Weather Warm-Up .............48
Hydraulic System Warm-up Switch ....................... 48
Manually Warming The Hydraulic System ............48
Preparing for Operation ............................................48
Lower Controls .........................................................48
Upper Controls .........................................................49
Boom Operation ....................................................50
Driving and Steering .............................................50
Drive Speeds ........................................................51
Motion Warning Alarm ...........................................51
Gradeability ..............................................................51
Percent vs. Degree of Slope .................................52
Driving on a Slope ................................................. 52
Calculating Percent Grade ....................................53
Machine Gradeability ............................................53
Electrical Power Outlet .............................................53
AC Generator ...........................................................53
Dual Fuel ..................................................................54
Air Line .....................................................................54
Driving Lights ............................................................54
Platform Work Lights ................................................55
Glazier Package .......................................................55
Platform Capacity .................................................. 55
Platform Welder ........................................................55
Platform Capacity .................................................. 55
Chapter 9 – Stowing and Transporting
Stowing .....................................................................57
Tucked Stow – AB80J ...........................................57
Transporting .............................................................57
Driving ...................................................................58
Winching ...............................................................58
Hoisting .................................................................59
Securing for Transport ..........................................59
Chapter 10 – Emergency Operation
Emergency Power System .......................................61
Lower Controls ......................................................61
Upper Controls ......................................................61
Emergency Lowering Pump .....................................62
Chapter 11 – Troubleshooting
Troubleshooting Chart ..............................................63
Appendix A – Glossary
Limited Warranty
AB80J/AB85J – 0420453

Chapter 1 – Introduction

Aerial Platform Features

The aerial platform is a boom-supported elevating work platform used to raise personnel, their tools, and material to the workstation. The booms are raised and lowered with hydraulic cylinders. Hydraulic motors on the drive wheels provide power to move the aerial platform.
The standard machine includes the following features.
• Proportional drive control
• Four wheel drive
Three steer modes; four wheel, two wheel, and crab
• Foam filled tires
• High engine temperature shut down
• Low oil pressure shut down
• Hour meter
• Ammeter
• Voltmeter – GM engine
• Spark arrestor muffler – GM engine
• Coolant temperature gauge
• Hydraulic oil level and temperature gauges
• Battery operated emergency power system
• Manual emergency lowering pump
• Horn
• 5 degree tilt alarm
• 360 degree continuous turntable rotation
• 140 degree jib rotation – AB85J
• Tie-down lugs
• Lifting lugs
• AC 110V electrical outlet with GFCI at platform
• 8 foot steel 500 lb capacity platform with a side walk­through gate (left side) and two gravity gates (right side and rear)
• Five year limited warranty
The machine may be powered with one of the following engines.
• Cummins B3.3 – Diesel
• Deutz F4L-2011F – Diesel
• General Motors 2.4 – Gasoline, LPG, or dual fuel
• 8 foot aluminum 600 lb capacity platform with rear gravity gate
• Sandblast protection kit
• Cold weather start kit
• Hydraulic fluid warm-up system
• Spark arrestor muffler – Deutz engine
• Airline to platform
• AC generator – hydraulic powered, 110 V, 2,000 W
• AC generator – hydraulic powered, 220 V 3 phase, 12kw
• Platform welder – 275 amp
• Platform glazier package
• European conformity (CE) certification
• Canadian Standards Association (CSA) certification
Operator’s Manual
This manual provides information for safe and proper operation of the aerial platform. Some information in this manual refers to options that may or may not be on your machine. Read and understand the information in this Operator’s Manual before operating the aerial platform on the job.
Additional copies of this manual may be ordered from Snorkel. Supply the model and manual part number from the front cover to assure that the correct manual will be supplied.
All information in this manual is based on the latest product information at the time of publication. Snorkel reserves the right to make product changes at any time without obligation.

Safety Alerts

A safety alert symbol is used throughout this manual to indicate danger, warning, and caution instructions. Follow these instructions to reduce the likelihood of personal injury and property damage. The terms danger, warning, and caution indicate varying degrees of personal injury or property damage that can result if the instruction is not followed.
The aerial platform has been manufactured to conform to all applicable requirements of the following organizations.
• Occupational Safety and Health Administration (OSHA)
• American National Standards Institute (ANSI)

Options

The following options may be provided on the machine.
• Drive motion alarm
• Dual fuel
• Flashing light
• Driving lights
• Platform work lights – flood or halogen
• Platform control cover
• 5 foot aluminum 650 lb capacity platform with
rear gravity gate
• 5 foot steel 600 lb capacity platform with rear
gravity gate
AB80J/AB85J – 0420453 1
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be used in the most extreme situations.
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.
Danger
Warning
Caution
Chapter 1 – Introduction
Notes Notes are used to provide special information or helpful hints to assist in aerial platform operation, but do not indicate a hazardous situation.

Operation

The aerial platform has built-in safety features and has been factory tested for compliance with Snorkel specifi­cations and industry standards. However, any personnel lifting aerial platform can be potentially dangerous in the hands of untrained or careless operators.
Warning
The potential for an accident increases when the aerial platform is operated by personnel who are not trained and authorized. Death or serious injury can result from such accidents. Read and understand the information in this manual and on the placards and decals on the machine before operating the aerial platform on the job.
Training is essential and must be performed by a quali­fied person. Become proficient in knowledge and actual operation before using the aerial platform on the job. You must be trained and authorized to perform any functions of the aerial platform. Operation of the aerial platform must be within the scope of the machine specifications.
The operator bears ultimate responsibility for following all manufacturer’s instructions and warnings, regulations and safety rules of their employer and/or any state or federal law.

Maintenance

Every person who maintains, inspects, tests, or repairs the aerial platform must be qualified to do so. Following the daily prestart inspection in this Operator’s Manual will help keep the aerial platform in optimum working condi­tion. Other maintenance functions must be performed by maintenance personnel who are qualified to work on the aerial platform.
If it becomes necessary to weld aerial platform com­ponents as a method of repair, take all precautions to prevent damage to electronic circuitry and devices on the machine. This includes, but may not be limited to, disconnecting battery cables and electronic devices.
Do not modify this aerial platform without prior written con­sent of the Snorkel Engineering Department. Modification may void the warranty, adversely affect stability, or affect the operational characteristics of the aerial platform.

Manual of Responsibilities

All owners and users of the aerial platform must read, understand, and comply with all applicable regulations. Ultimate compliance to OSHA regulations is the respon­sibility of the user and their employer.
ANSI publications clearly identify the responsibilities of all personnel who may be involved with the aerial platform. A reprint of the “Manual of Responsibilities for Dealers, Owners, Users, Operators, Lessors and Lessees of ANSI/SIA A92.5-2006 Boom-Supported Elevating Work Platforms” is available from Snorkel dealers or from the factory upon request.
Copies are also available from:
Scaffold Industry Association, Inc. P. O. Box 20574 Phoenix, AZ 85036-0574 USA

Additional Information

For additional information contact your local dealer or Snorkel at:
Snorkel International P.O. Box 1160 St. Joseph, MO 64502-1160 USA 1-800-255-0317
http://www.snorkellifts.com
Caution
Welding current can be very intense. Damage to elec­tronic components can result. Connect the ground clamp as close as possible to the area being welded. Disconnect battery cables and any microprocessors and engine control modules before welding on the machine.
2 AB80J/AB85J – 0420453
Component Identication
Chapter 2 – Specications
Engine
Interactive Link
AB85J Only
Upper Controls
Lower
Controls
Hydraulic Fluid Tank
And Filter
Emergency
Lowering
Pump
Riser Boom
Riser
Battery Disconnect
Switch
Right Side
Main Boom
Batteries
Rear
Chassis
Tip Boom
LP Fuel Tank
Front
Jib
Platform
Fuel Tank
Platform
Foot Switch
Front
Operator’s
Manual
Rear
Left Side
AB80J/AB85J – 0420453 3
Chapter 2 – Specications

Working Envelope – AB80J

Feet
(Meters)
90
(27.4)
80
(24.4)
70
(21.3)
60
(18.3)
50
(15.2)
40
(12.2)
30
(9.1)
20
(6.1)
10
(3.0)
0
-10
(-3.0)
0
4 AB80J/AB85J – 0420453
10
(3.0)
20
(6.1)
30
(9.1)
40
(12.2)
50
(15.2)
60
(18.3)
70
(21.3)
Chapter 2 – Specications
Working Envelope – AB85J
Feet
(Meters)
90
(27.4)
80
(24.4)
70
(21.3)
60
(18.3)
50
(15.2)
40
(12.2)
30
(9.1)
20
(6.1)
10
(3.0)
0
-10
(-3.0)
0
AB80J/AB85J – 0420453 5
10
(3.0)
20
(6.1)
30
(9.1)
40
(12.2)
50
(15.2)
60
(18.3)
70
(21.3)
Chapter 2 – Specications
General Specications – AB80J
Aerial Platform
Working height 85 11 (26.2 m) Maximum platform height 79 11 (24.3 m) Up and over height 27 11(8.5 m) Maximum horizontal reach 59 5″ (18.1 m) Main boom Articulation -25° to +75° Extension 21 (6.4 m) Jib Articulation -70° to +70° Tail swing 35 (88.9 cm) Turntable rotation 360° continuous Turning radius, inside (4 wheel steer) 7 10 (2.4 m) Wheelbase 10 (3 m) Ground clearance 13 (33 cm) Maximum wheel load 18,400 lbs (8,360 kg) Maximum ground pressure 65 psi (4.6 kg/cm²) Weight, EVW Approximate 36,800 lbs (16,730 kg) Width 8 6 (2.5 m) Stowed length 32 2 (9.8 m) Stowed height 9 10 (2.9 m)
Platform
Dimensions Standard Steel 36 x 96 (91 cm x 244 cm) Optional Steel 30 x 60 (76 cm x 152 cm) Optional Aluminum 30 x 60 (76 cm x 152 cm) Optional Aluminum 30 x 92 (76 cm x 233 cm) Rated work load Steel 36 x 96 500 lb (227 kg) Steel 30 x 60 600 lb (227 kg) Aluminum 30 x 60 650 lb (227 kg) Aluminum 30 x 92 600 lb (227 kg) Rotation 70° CW to 80° CCW Maximum number of occupants 2 people Optional AC generator 110 V, 2,000 W Optional AC generator 220 V, 3-phase, 12 kw Optional Welder
Function Speed
Turntable rotation Booms retracted 90 to 100 seconds Booms extended 190 to 220 seconds Riser Up 40 to 60 seconds Down 40 to 60 seconds Main boom Up Booms retracted 65 to 80 seconds Booms extended 85 to 120 seconds Down Booms retracted 65 to 80 seconds Booms extended 85 to 120 seconds Extend 43 to 60 seconds Retract 43 to 60 seconds
Platform rotation 13 to 20 seconds Jib Articulation 30 to 40 seconds Drive High, booms stowed 3.0 mph (4.8 km/h) Low, booms raised/extended 0.6 mph (1 km/h)
Drive System
Standard Four wheel drive Gradeability 30%
Tires
Foam filled 15-625NHS, 16 ply
Electrical System
Voltage 12 V DC negative chassis ground Source Gas engine One -12 V 550 CCA battery Diesel engine Two - 12 V 550 CCA batteries Fluid recommended distilled water
Hydraulic System
Maximum pressure 3,000 psi (20,684 kPa) Reservoir capacity 40 US gal (151 l) System capacity 65 US gal (246 l) Maximum operating temperature 200°F (93°C) Hydraulic fluid recommended Above 10°F (-13°C) Mobil DTE-13M (ISO VG32) Below 10°F (-13°C) Mobil DTE-11M (ISO VG15)
Engine
Diesel Cummins B3.3 Diesel Deutz F4L-2011F Gasoline and/or LPG General Motors 2.4
Fuel Tank Capacity
Gasoline or diesel 40 US gal (151 l) LPG 43.5 lbs (19.7 kg) Dual fuel Gasoline 40 US gal (151 l) LPG 43.5 lbs (19.7 kg)
Ambient Air Temperature Operating Range
Fahrenheit 0°F to 110°F Celsius -18°C to 43°C
Maximum Wind Speed
Gust or steady 28 mph (45 km/h)
6 AB80J/AB85J – 0420453
General Specications – AB85J
Chapter 2 – Specications
Aerial Platform
Working height 90 6 (27.5 m) Maximum platform height 84 6 (25.7 m) Up and over height 27 11(8.5 m) Maximum horizontal reach 61 11(18.8 m) Main boom Articulation -25° to +75° Extension 23 6 (7.1 m) Jib Articulation -65° to +70° Rotation 70° to +70° Tail swing 35 (88.9 cm) Turntable rotation 360° continuous Turning radius, inside (4 wheel steer) 7 10 (2.4 m) Wheelbase 10 (3 m) Ground clearance 13 (33 cm) Maximum wheel load 19,250 lbs (8,750 kg) Maximum ground pressure 68 psi (4.8 kg/cm²) Weight, EVW Approximate 38,500 lbs (17,500 kg) Width 8 6 (2.5 m) Stowed length 41 2 (12.5 m) Stowed height 9 10 (2.9 m)
Platform
Dimensions Standard Steel 36 x 96 (91 cm x 244 cm) Optional Steel 30 x 60 (76 cm x 152 cm) Optional Aluminum 30 x 60 (76 cm x 152 cm) Optional Aluminum 30 x 92 (76 cm x 233 cm) Rated work load Steel 36 x 96 500 lb (227 kg) Steel 30 x 60 600 lb (227 kg) Aluminum 30 x 60 650 lb (227 kg) Aluminum 30 x 92 600 lb (227 kg) Rotation 70° CW to 80° CCW Maximum number of occupants 2 people Optional AC generator 110 V, 2,000 W Optional AC generator 220 V, 3-phase, 12 kw Optional Welder
Function Speed
Turntable rotation Booms retracted 90 to 100 seconds Booms extended 190 to 220 seconds Riser Up 40 to 60 seconds Down 40 to 60 seconds Main boom Up Booms retracted 65 to 80 seconds Booms extended 85 to 120 seconds Down Booms retracted 65 to 80 seconds Booms extended 85 to 120 seconds Extend 43 to 60 seconds Retract 43 to 60 seconds
Platform rotation 13 to 20 seconds Jib Articulation 30 to 40 seconds Rotation 30 to 45 seconds Drive High, booms stowed 3.0 mph (4.8 km/h) Low, booms raised/extended 0.6 mph (1 km/h)
Drive System
Standard Four wheel drive Gradeability 30%
Tires
Foam filled 15-625NHS, 16 ply
Electrical System
Voltage 12 V DC negative chassis ground Source Gas engine One -12 V 550 CCA battery Diesel engine Two - 12 V 550 CCA batteries Fluid recommended distilled water
Hydraulic System
Maximum pressure 3,000 psi (20,684 kPa) Reservoir capacity 40 US gal (151 l) System capacity 65 US gal (246 l) Maximum operating temperature 200°F (93°C) Hydraulic fluid recommended Above 10°F (-13°C) Mobil DTE-13M (ISO VG32) Below 10°F (-13°C) Mobil DTE-11M (ISO VG15)
Engine
Diesel Cummins B3.3 Diesel Deutz F4L-2011F Gasoline and/or LPG General Motors 2.4
Fuel Tank Capacity
Gasoline or diesel 40 US gal (151 l) LPG 43.5 lbs (19.7 kg) Dual fuel Gasoline 40 US gal (151 l) LPG 43.5 lbs (19.7 kg)
Ambient Air Temperature Operating Range
Fahrenheit 0°F to 110°F Celsius -18°C to 43°C
Maximum Wind Speed
Gust or steady 28 mph (45 km/h)
AB80J/AB85J – 0420453 7
Chapter 2 – Specications
Engine Specications
Engine
Cummins
B3.3
Diesel
Deutz
F4L-2011F
GM 2.4
Displacement Fuel Grade Coolant
Diesel
ASTM No. 2D fuel with a 199 cu. in. (3.26 liter)
minimum Cetane number of
40.1 For operating tempera-
50% water
50% Antifreeze
tures below 32°F (0°C) use
winterized No. 2D.
• DIN 51 601 (February 1986).
Diesel
1
• BS 2869: A1 and A2 (with A2
190 cu. in.
(3.11 liter)
refer to Deutz manual about sulfur content)
• ASTM D 975-88: 1-D and 2-D
1
Air
• CEN EN 590 or DIN EN 590
• NATO Code F-54 and F-75
• For operating temperatures below 32°F (0°C) use winter grade diesel.
Gasoline
150 cu. in.
(2.4 liter)
• Unleaded 87 octane
LPG
• HD-5
50% Water
50% Antifreeze
Operating
Temperature
140°F to 212°F
2
(60°C to 100°C)
172°F to 203°F
(78°C to 95°C)
176°F to 183°F
(80°C to 84°C)
Oil
Capacity
2 gal (7.5 liter)
total
1.6 qt (1.5 liter) Low to High
1.59 US gal
(6.0 liter)
With lter:
1.12 US gal (4.5 liter)
Without lter:
1.18 US gal
(4.25 liter)
Oil
Grade
SAE
15W-40
API:
CH4/SG
API: CD
or higher
ILSAC
4
GF-4
3
3
Note 1: Refer to the engine manufacturers manual for specific fuel recommendations and specifications.
Note 2: Ethylene glycol or Propylene glycol may be used. Refer to the Cummins® Operation and Maintenance Manual B3.3 Series Engines for
Note 3: Refer to the engine manufacturers manual for specific lubricating oil recommendations and specifications.
Note 4: API Starburst symbol on GF-4 oils reads “API Service SM.”
specific coolant recommendations and specifications.

Engine Oil Viscosity

Cummins B3.3
8 AB80J/AB85J – 0420453
Deutz F4L-2011F
°F
°F
-4 0
-3 1
-2 2
-1 3
-4
5
14
23 324150 59 6 8 7 7 8 6 104
122
°C
°C
-4 0
-3 5
-3 0 -2 5 -20 - 15 -1 0
-5
0
10
15 2 0 253040 5 0
5
S AE 5W /3 0
S AE 0W /3 0
Chapter 2 – Specications
General Motors 2.4
Note No straight weight oils and no specialized diesel oils are to be used in GM engines.
AB80J/AB85J – 0420453 9
Chapter 2 – Specications
10 AB80J/AB85J – 0420453

Chapter 3 – Safety

Knowledge of the information in this manual, and proper training, provide a basis for safely operating the aerial plat­form. Know the location of all controls and how they oper­ate to act quickly and responsibly in an emergency.
Safety devices reduce the likelihood of an accident. Never disable, modify, or ignore any safety device. Safety alerts in this manual indicate situations where accidents may occur.
If any malfunction, hazard or potentially unsafe condi­tion relating to capacity, intended use, or safe operation is suspected, stop aerial platform operation and seek assistance.
The operator bears ultimate responsibility for following all manufacturer’s instructions and warnings, regulations and safety rules of their employer and/or any state or federal law.

Electrocution Hazards

The aerial platform is made of metal components and is not insulated. Regard all conductors as energized. Do not operate outside during a thunderstorm.

Minimum Safe Approach Distance

Minimum safe approach distances to energized power lines and their associated parts must be observed while operating the aerial platform.
Danger
The aerial platform is not electrically insulated. Death or serious injury can result from contact with, or inadequate clearance from, an energized conductor. Do not go closer than the minimum safe approach distance as defined by ANSI.
ANSI publications define minimum distances that must be observed when working near bus bars and energized power lines. Table 1 and Figure 3 are reprinted courtesy of Scaffold Industry Association, ANSI/SIA A92.5.
Voltage Range
(Phase to Phase)
0 to 300V
Over 300V to 50kV
Over 50kV to 200kV
Over 200kV to 350kV
Over 350kV to 500kV
Over 500kV to 750kV Over 750kV to 1000kV
Table 1 – Minimum Safe Approach Distance
Minimum Safe Approach Distance
Feet Meters
Avoid Contact
10
15
20
25
35
45
3.05
4.60
6.10
7.62
10.67
13.72
Figure 3 – Minimum Safe Approach Distance
AB80J/AB85J – 0420453 11
Chapter 3 – Safety

Prestart Inspection

Perform a prestart inspection before each shift as de­scribed in Chapter 7. Do not use the aerial platform on the job unless you are trained and authorized to do so.

Work Place Inspection and Practices

Do not use the aerial platform as a ground connection when welding. The welding ground clamp must be at­tached to the same structure that is being welded. Elec­trical current flow can be very intense, causing serious internal damage to some components.
Inspect the area before and during aerial platform use. The following are some potential hazards that may be in the work place.
• Debris
• Slopes
• Drop-offs or holes
• Bumps and floor obstructions
• Overhead obstructions
• Unauthorized persons
• High voltage conductors
• Wind and weather conditions
• Inadequate surface and support to withstand load forces applied by the aerial platform in all operating configurations
Before using the aerial platform in any hazardous (clas­sified) location, make certain it is approved and of the type required by ANSI/NFPA 505 for use in that particular location.
Know and understand the job site traffic-flow patterns and obey the flagmen, road signs, and signals.
Always look in the direction of movement. Drive with care and at speeds compatible with the work place conditions. Use caution when driving over rough ground, on slopes, and when turning. Do not engage in any form of horseplay or permit riders any place other than in the platform.
Secure all accessories, containers, tools, and other ma­terials in the platform to prevent them from accidentally falling or being kicked off the platform. Remove all objects that do not belong in or on the aerial platform.
Never steady the platform by positioning it against an­other platform.
Warning
The potential for an accident increases when operat­ing an aerial platform that is damaged or malfunc­tioning. Death or serious injury can result from such accidents. Do not operate the aerial platform if it is damaged or malfunctioning.
Do not operate the aerial platform if it is damaged or not functioning properly. Qualified maintenance personnel must correct the problem before putting the aerial platform back into service.

Operation

Use three points of support when entering or exiting the platform. For example, use two hands and one foot when climbing into the platform.
Never cover the platform floor grating or otherwise ob­struct your view below. Make sure the area below the platform is free of personnel before lowering.
While operating the aerial platform, a good safety prac­tice is to have qualified personnel in the immediate work area to:
• Help in case of an emergency
• Operate emergency controls as required
• Watch for loss of control by platform operator
• Warn the operator of any obstructions or hazards that may not be obvious to them
• Watch for soft terrain, sloping surfaces, drop-offs, etc. where stability could be jeopardized
• Watch for bystanders and never allow anyone to be under, or to reach through the booms while operating the aerial platform
Danger
Pinch points may exist between moving components. Death or serious injury can result from becoming trapped between components, buildings, structures, or other obstacles. Make sure there is sufficient clear­ance around the machine before moving the chassis, booms, or platform. Allow sufficient room and time to stop movement to avoid contact with structures or other hazards.
Keep both feet positioned firmly on the platform floor. Operate the controls slowly and deliberately to avoid jerky and erratic operation. Always stop the controls in neutral before going in the opposite direction.
Do not dismount while the aerial platform is in motion or jump off the platform.
Properly stow the aerial platform and secure it against unauthorized operation at the end of each work day, before transporting, or if it is left unattended.

Tip-Over and Falling Hazards

Operate the aerial platform only on a firm, flat, level sur­face capable of withstanding all load forces imposed by the aerial platform in all operating conditions. Refer to the General Specifications chart for the maximum wheel load and ground pressure. Raise the booms only when the aerial platform is on level ground.
12 AB80J/AB85J – 0420453
Chapter 3 – Safety
Danger
The aerial platform can tip over if it becomes unstable. Death or serious injury can result from a tip-over ac­cident. Do not drive or position the aerial platform for elevated use near any drop-off, hole, slope, soft or uneven ground, or other tip-over hazard.
All platform occupants must wear a fall restraint device connected to a lanyard anchor point.
It is best not to transfer from the platform to another structure or from the structure to the platform, unless that is the safest way to do the job. Judge each situation separately taking the work environment into account. If it is necessary to transfer from the platform to another structure the following guidelines apply:
1. Where possible, place the platform over a roof or walking structure to do the transfer.
2. Transfer your anchorage from one structure to the other before stepping across.
3. Remember that you might be transferring to a struc­ture where personal fall arrest is required.
4. Use the platform entrance, do not climb over or through the guardrails.
Do not operate the aerial platform in windy or gusty condi­tions. Do not add anything to the aerial platform that will increase the wind loading such as billboards, banners, flags, etc.
Never operate the aerial platform without all parts of the guardrail system in place and the gate closed. Make sure that all protective guards, cowlings, and doors are securely fastened.
Do not exceed the platform capacity as indicated on the platform rating placard on the platform. Do not carry loads that extend beyond the platform guardrails without prior written consent from Snorkel.
motion, reverse the control to free the platform. If control reversal does not free the platform, evacuate the platform before attempting to free it.

Electrical System

Charge the batteries in a well-ventilated area free of flame, sparks, or other hazards that might cause fire or explosion.
Do not operate any of the aerial platform functions while the battery charger is plugged in.
Warning
Batteries give off hydrogen and oxygen that can combine explosively. Death or serious injury can result from a chemical explosion. Do not smoke or permit open flames or sparks when checking the batteries.
Battery acid can damage the skin and eyes. Serious infection or reaction can result if medical treatment is not given immediately. Wear face and eye protection when working near the batteries.
Batteries contain sulfuric acid that can damage your eyes or skin on contact. Wear a face shield, rubber gloves, and protective clothing when working around batteries. If acid contacts your eyes, flush immediately with clear water and get medical attention. If acid contacts your skin, wash off immediately with clear water.

Hydraulic System

The hydraulic system contains hoses with hydraulic fluid under pressure.
Danger
Hydraulic fluid escaping under pressure can have enough force to inject fluid into the flesh. Serious infection or reaction can result if medical treatment is not given immediately. In case of injury by escaping hydraulic fluid, seek medical attention at once.
Do not operate the aerial platform from trucks, trailers, rail­way cars, floating vessels, scaffolds, or similar equipment unless the application is approved in writing by Snorkel.
Do not use the aerial platform as a crane, hoist, jack, or for any purpose other than to position personnel, tools, and materials.
Do not climb on the guardrails or use ladders, planks, or other devices to extend or increase the work position from the platform.
Take care to prevent rope, electrical cords, and hoses, etc., from becoming caught in or on the aerial platform. If the platform or booms becomes caught on an adjacent structure or other obstacle and is prevented from normal
AB80J/AB85J – 0420453 13
Do not place your hand or any part of your body in front of escaping hydraulic fluid. Use a piece of cardboard or wood to search for hydraulic leaks.

Engine and Fuel Handling Precautions

Refer to the engine manufacturer’s Operator’s Manual for complete information on safe engine operation, mainte­nance, and specifications.
Danger
Engine exhaust contains carbon monoxide, a poi­sonous gas that is invisible and odorless. Breathing engine exhaust fumes can cause death or serious illness. Do not run the engine in an enclosed area or indoors without adequate ventilation.
Chapter 3 – Safety
Operate dual fuel machines on LPG fuel when indoors to reduce exhaust fumes and carbon monoxide.
Be careful not to run the diesel fuel tank empty. Bleed the fuel system if air enters the lines between the tank and the injection pump.
Allow the engine to return to idle before shutting the engine off.
Do not smoke or permit open flames while fueling or near fueling operations.
Never remove the fuel cap or fill the fuel tank while the engine is running or hot. Never allow fuel to spill on hot machine components.
Maintain control of the fuel filler nozzle when filling the tank. Spilled fuel is a potential fire hazard.
Do not overfill the fuel tank. Allow room for expansion.
Clean up spilled fuel immediately.
Tighten the fuel tank cap securely. If the fuel cap is lost, replace it with an approved cap from Snorkel. Use of a non-approved cap without proper venting may result in pressurization of the tank.
Never use fuel for cleaning purposes.
For diesel engines, use the correct fuel grade for the operating season.
Caution
Engine coolant escaping under pressure can cause serious burns. Shut the engine off and let it cool before removing the radiator cap.
Let the engine and radiator cool before adding coolant.

Placards and Decals

The aerial platform is equipped with placards and decals that provide instruction for operation and accident preven­tion. Do not operate the aerial platform if any placards or decals are missing or not legible.
14 AB80J/AB85J – 0420453

Chapter 4 – Safety Devices

This aerial work platform is manufactured with safety de­vices, placards, and decals to reduce the likelihood of an accident. For the safety of all personnel, do not disable, modify, or ignore any safety device. Safety devices are included in the daily prestart inspection.
Warning
The potential for an accident increases when safety devices do not function properly. Death or serious injury can result from such accidents. Do not alter, disable, or override any safety device.
If any safety devices are defective, remove the aerial platform from service until qualified maintenance person­nel can make repairs.
Engine/Emergency
Power Switch
Figure 4.2 – Upper Controls
Emergency
Stop Button

Emergency Stop Controls

There is an emergency stop control at the lower and upper controls.
At the lower controls, the emergency stop is a two-position push button (refer to Figure 4.1). Push the emergency stop button in to disconnect power to all control circuits. Pull the button out to restore power.
Engine/Emergency
Power Switch
Ground
Operation Switch
Emergency
Stop Button
Push the emergency stop button in to disconnect power to the upper control circuits. Pull the button out to restore power.

Emergency Power System

The emergency power system includes a back-up pump, motor, and battery. Use this system to operate the boom and turntable functions to lower the platform if the main power system fails due to engine or pump failure.
Hold the emergency power switch (refer to Figure 4.1 and 4.2) in the direction of the white arrow to activate the emergency power system.
The length of time the pump can be operated depends on the capacity of the battery.

Manual Emergency Lowering Pump

The manual emergency lowering pump may be used to lower the riser and main booms if the engine will not start and the emergency power system will not work. The pump (refer to Figure 4.3) is behind the cowling door on the left side of the turntable.
Pump
Manual Emergency
Lowering Pump
Figure 4.1 – Lower Controls
Note The lower controls override the upper controls. If the up­per control emergency stop button is engaged, the lower controls can still be used to operate the aerial platform.
At the upper controls, the emergency stop is a two-posi­tion push button (refer to Figure 4.2).
AB80J/AB85J – 0420453 15
Figure 4.3 – Manual Emergency Lowering Pump
After selecting either the riser or main boom valve, the hand pump may be used for emergency lowering.
Riser Boom KnobMain Boom Knob
Chapter 4 – Safety Devices

Ground Operation Switch

The ground operation switch (refer to Figure 4.1) prevents boom and platform movement if a control switch on the lower control panel is accidentally moved.
Hold the switch up to operate the machine from the lower controls.

Platform Foot Switch

Stepping down on the platform foot switch (refer to Figure
4.4) activates the upper controls.
Walk-Through Gate

Lanyard Anchors

Platform Foot
Switch
Top Rail
Gravity Gate
Mid Rail
Toeboard
Lanyard Anchors
Two lanyard anchors for fall restraint anchorage are pro­vided below the upper controls at the front of the platform (refer to Figure 4.4).
Note The lanyard anchors are not for lifting or tying the ma­chine down.
All personnel in the platform must connect their fall restraint device to a lanyard anchor before raising the platform. Do not use the aerial platform for personal fall arrest anchorage.

Ground Fault Circuit Interrupter

The electrical power outlet at the platform (refer to Figure
4.6) contains a ground fault circuit interrupter (GFCI) to provide protection for personnel.
Electrical
Power Outlet
Figure 4.4 – Platform
The foot switch must be engaged and a control must be moved to operate the boom, drive, and/or platform from the upper controls.

Guardrails

The guardrail system includes a top rail, mid rail, and toeboards around the sides of the platform.
A gravity gate at the rear and on the right side (refer to Figure 4.4), and a walk-through gate on the left side (refer to Figure 4.5) allows for access to the platform.
Walk-Through Gate
Figure 4.5 – Platform
Figure 4.6 – Electrical Power Outlet

Tilt Alarm

If the aerial platform chassis is out of level more than five degrees when the main boom is raised or extended, or when the riser boom is raised, an alarm will sound. The tilt alarm is located under the upper control panel.
Danger
The aerial platform can tip over if it becomes unstable. Death or serious injury can result from a tip-over ac­cident. Do not drive or position the aerial platform for elevated use near any drop-off, hole, slope, soft or uneven ground, or other tip-over hazard.
Completely lower the booms and then drive to a level surface when the tilt alarm sounds.
The tilt alarm is for added protection and does not justify operating on anything other than firm, flat, level surfaces.
The gates close automatically after entering or exiting the platform. The gate is part of the guardrail system and must be securely fastened after entering the platform.
16 AB80J/AB85J – 0420453
Chapter 4 – Safety Devices

Engine Protection Systems

A constant tone alarm will sound to warn against high engine temperature or low oil pressure.
The engine will shut-down if the operating temperature ex­ceeds a preset level or if the oil pressure is too low for safe operation. An engine temperature gauge is on the gauge panel above the lower controls (refer to Figure 4.7).
Engine Temperature Gauge
Figure 4.7 – Gauge Panel

High Engine Temperature Alarm

If the coolant in a Cummins or GM engine exceeds the engine operating temperature an alarm will sound and the engine will shut off.

Horn

The horn may be used to warn personnel on the ground. The horn button is to the right of the emergency stop button on the upper control panel (refer to Figure 4.8). The horn is operational when the machine is set up for operation from the upper controls.
Horn Button
Figure 4.8 – Upper Controls

Drive Motion Alarm

An optional drive motion alarm may be provided on the machine. When the drive/steer control is moved out of neutral the alarm sounds, in short beeps, to warn person­nel in the work area to stand clear.
If the oil in a Deutz engine exceeds 230°F (110°C) an alarm will sound and the engine will shut off. Any time there is no alternator current being produced, an alarm will sound and the engine will shut off. This prevents high engine temperature if the fan belt breaks.
Do not restart the engine until the condition that caused the overheating has been corrected.

Low Oil Pressure Alarm

The low oil pressure alarm sounds when the engine oil pressure is near the lower limit for safe engine operation. If the alarm sounds, lower the platform to the ground and then turn the engine off. Do not restart the engine until the condition that caused the low oil pressure has been corrected.
If the engine oil pressure falls below a safe operating value the engine will shut off. The engine can be restarted with low oil pressure, but it will only run a few seconds before it shuts off again.

Flashing Light

An amber flashing light may be located on the top of the boom near the base end. The flashing light warns person­nel that the aerial platform is in the area.
The light flashes at about one flash per second when the engine is running.

Driving Lights

Optional headlights and blinking tail lights may be installed on the machine. The headlights are located on the top of the front cowling. The tail lights are mounted on the sides of the rear cowling.
Driving lights help improve visibility while driving the aerial platform and help others see it too. Driving lights are not for driving on public roadways.

Platform Work Lights

Optional platform work lights may be located on the top rail of the platform (refer to Figure 4.9), one on each side of the upper control panel.
AB80J/AB85J – 0420453 17
Chapter 4 – Safety Devices
Figure 4.9 – Platform Work Lights
Use the platform lights to improve visibility while working aloft in dimly lit areas. Do not use the platform work lights to drive on public roadways.
18 AB80J/AB85J – 0420453

Chapter 5 – Gauges and Displays

The aerial platform is equipped with several gauges to monitor the condition of the machine before and during operation.

Hour Meter

The hour meter is located on the lower control panel (refer to Figure 5.1). It measures the accumulated engine operating time.
Hour Meter

Ammeter

The ammeter is located on the gauge panel above the lower controls (refer to Figure 5.2). The ammeter dis­plays the level of current flow from the alternator to the batteries.
After the engine has been running for a few minutes under normal operating conditions, the ammeter needle should be to the right of “0.”

Voltmeter – GM Engines

The voltmeter is located on the gauge panel above the lower controls (refer to Figure 5.2). The voltmeter displays battery voltage.
After the engine has been running for a few minutes under normal operating condition, the voltmeter should indicate between 12.5 and 14 volts.

Engine Air Filter Gauge

The air filter gauge is located on the gauge panel above the lower controls (refer to Figure 5.2). The gauge mea­sures the air pressure between the intake manifold and the air filter.
The yellow indicator disk inside the sight glass stays at its highest level when the engine is turned off.
Figure 5.1 – Lower Controls

Engine Temperature Gauge

The temperature gauge is located on the gauge panel above the lower controls (refer to Figure 5.2).
Engine Temperature Gauge
Air Filter Gauge
Figure 5.2 – Gauge Panel
On liquid cooled engines it shows the temperature of the water and antifreeze mixture in the engine block. The gauge on air cooled engines shows the temperature of the engine oil as the oil leaves the filter.
Ammeter – Cummins and Deutz
Voltmeter – General Motors
When the yellow indicator disk reaches the red area, it’s time to change the filter element. After changing the filter, press the reset button to reset the indicator disk to the bottom of the sight glass.

Fuel Gauge

The fuel gauge is located on top of the diesel or gasoline tank (refer to Figure 5.3). Read the fuel gauge at the line in the clear plastic window. The gauge indicates the fuel tank level in fractions of a full tank.
Fuel Gauge
Figure 5.3 – Gasoline or Diesel Fuel Tank
Note Do not run a diesel fuel tank empty. Air in the fuel line makes the engine hard to start.
AB80J/AB85J – 0420453 19
Chapter 5 – Gauges and Displays
LPG tanks have a fuel gauge that has two scales. One scale measures the fuel level when the tank is mounted vertical and the other is used when the tank is mounted horizontal (refer to Figure 5.4).
Vertical Scale
Figure 5.4 – LPG Fuel Tank
The LPG tank is mounted vertically behind the cowling door on the right side of the machine. Read the vertical scale to determine the fuel level.

Fluid Level and Temperature Gauge

A gauge on the right end of the reservoir displays the level and temperature of the hydraulic fluid (refer to Figure 5.6).
Fluid Level and
Temperature Gauge
Figure 5.6 – Hydraulic Fluid Gauge
If the temperature rises above 200°F (93°C) stop ma­chine operation and let the fluid cool before resuming operation.

Engine Oil

The engine oil level is measured with a dipstick. The dip­stick is the only way to accurately determine the engine oil level. The engine oil level should always be between the add and full marks on the dipstick.

Hydraulic Fluid Filter Gauge

The fluid filter gauge (refer to Figure 5.5) is located on the return line filter on the front of the reservoir. The reservoir is behind the cowling door on the left side of the turntable. During high pump flow situations, the gauge indicates the condition of the filter. When the needle on the gauge is in the red zone, its time to change the filter.
Filter Gauge
Figure 5.5 – Hydraulic Fluid Filter Gauge
20 AB80J/AB85J – 0420453
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