Snorkel AB80J User Manual

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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)

(27.4)

(24.4)

(21.3)

(18.3)

(15.2)

(12.2)

(9.1)

(6.1)

(3.0)

-10

(-3.0)

4 AB80J/AB85J – 0420453

(3.0)

(6.1)

(9.1)

(12.2)

(15.2)

(18.3)

(21.3)

Chapter 2 – Specications

Working Envelope – AB85J

Feet

(Meters)

(27.4)

(24.4)

(21.3)

(18.3)

(15.2)

(12.2)

(9.1)

(6.1)

(3.0)

-10

(-3.0)

AB80J/AB85J – 0420453 5

(3.0)

(6.1)

(9.1)

(12.2)

(15.2)

(18.3)

(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

Function Speed

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

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

• 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

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

(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

GF-4

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

-4 0

-3 1

-2 2

-1 3

-4

23 324150 59 6 8 7 7 8 6 104

122

°C

-4 0

-3 5

-3 0 -2 5 -20 - 15 -1 0

-5

15 2 0 253040 5 0

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

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

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

Chapter 6 – Controls

Danger

Controls to position the platform are located on the lower control panel on the turntable and on the upper control panel in the platform. Drive controls are located on the upper control panel only.

Battery Disconnect Switch

The battery disconnect is located behind the door on the right side of the turntable in front of the batteries (refer to Figure 6.1).

Battery Disconnect Switch

Lower Controls

The lower controls (refer to Figure 6.2) are located on the left side of the turntable. Boom and platform functions can be operated from the lower controls. The following are located on the lower control panel.

• Start switch

• Emergency stop button

• Controls selector switch

• Ground operation switch

• Rotation switch

• Riser switch

• Boom elevation switch

• Boom extension switch

• Boom speed knob

• Jib rotation switch – AB85RJ only

• Jib articulation switch

• Platform level switch

• Platform rotation switch

• Engine/Emergency power switch

• Engine speed switch

• Fuel switch (dual fuel machines)

• Manifold air inlet heater (option for Deutz engines)

• Hydraulic system warm-up switch (option)

Start Switch

The start switch (refer to Figure 6.2) works like an automobile ignition switch. Hold it in the start position until the engine starts, then release it to on. If the engine dies, the key must be turned to off before it will go back to start.

Figure 6.1 – Battery Disconnect Switch

The battery disconnect removes electrical power from all electrically controlled functions when in the off position. Place the switch in the on position to electrically connect the battery to the electrical system.

Caution

Only authorized personnel should operate the aerial platform. Unqualified personnel may cause injury to coworkers or property damage. Lock the battery disconnect switch in the off position before leaving the aerial platform unattended.

Lock the battery disconnect switch in the off position to prevent unauthorized use of the aerial platform.

An alarm sounds, when the switch is turned on, to warn others that the machine engine is being started.

Emergency Stop Button

The emergency stop (refer to Figure 6.2) is a two-position, red push button. Push the button in to disconnect power to all control circuits. Pull the button out to restore power.

Controls Selector Switch

Use the controls switch (refer to Figure 6.2) to select between lower control and upper control operation. Place the switch in the upward position to operate the aerial platform from the upper controls and in the downward position for lower controls operation.

Ground Operation Switch

Hold the ground operation switch (refer to Figure 6.2) upward continually to operate the machine from the lower controls. The engine speed increases when the switch is held upward. This switch is spring returned to the off position.

Rotation Switch

The rotation switch (refer to Figure 6.2) is used to rotate the turntable in a clockwise or counterclockwise direction. The switch is spring returned to the center off position.

Hold the switch to the right to rotate the turntable counterclockwise. Hold the switch to the left to rotate the turntable clockwise.

AB80J/AB85J – 0420453 21

Chapter 6 – Controls

Riser Switch

The riser switch is used to raise or lower the riser booms. The switch is spring returned to the center off position.

Hold the switch up to raise the riser booms. Hold the switch down to lower the riser booms.

Boom Elevation Switch

The boom elevation switch is used to raise or lower the main boom. As the main boom is raised on AB85J machines, the tip boom is extended a maximum of 30″ (76.2 cm). The switch is spring returned to the center off position.

Hold the switch up to raise the main boom. Hold the switch down to lower the main boom.

Boom Extension Switch

The boom extension switch is used to extend or retract the booms. The switch is spring returned to the center off position.

Hold the switch to the right to extend the booms. Hold the switch to the left to retract the booms.

Boom Speed Knob

Use the boom speed control knob to control the speed of the following boom functions.

• Main boom raise/lower

• Main boom extend/retract

• Jib rotate – AB85J only

• Turntable rotation clockwise/counterclockwise

Set the knob to slow (turtle) when beginning a boom movement. The speed may be increased by slowly rotating the knob toward fast (rabbit). For smooth operation, rotate the knob to slow when ending boom movement.

Jib Rotation Switch – AB85J Only

The jib rotation switch is used to rotate the jib relative to the end of the tip boom. The switch is spring returned to the center off position.

Hold the switch up to rotate the jib counterclockwise. Hold the switch down to rotate the turntable clockwise.

Boom Elevation Switch

Platform Level Switch

Jib Rotation Switch

Engine Speed Switch

Fuel Switch

Rotation Switch

Riser Switch

Control Selector Switch

Boom Extention Switch

Jib Articulation Switch

Platform Rotation Switch

Hydraulic System

Warm-up Switch

Boom Speed Knob

Engine/Emergency Power Switch

Ground Operation Switch

Start Switch

Emergency Stop Button

Circuit Breaker Reset Buttons

Figure 6.2 – Lower Controls

22 AB80J/AB85J – 0420453

Chapter 6 – Controls

Jib Articulation Switch

The jib switch is used to raise or lower the jib. The switch is spring returned to the center off position.

Hold the switch up to raise the jib. Hold the switch down to lower the jib.

Platform Level Switch

The platform level switch is used to level the platform floor with respect to the ground. The switch is spring returned to the center off position.

Hold the switch up to tilt the platform floor upward or away from the ground. Hold the switch down to tilt the platform floor downward or toward the ground.

Platform Rotation Switch

The platform rotation switch is used to rotate the platform relative to the end of the tip boom. The switch is spring returned to the center off position.

Hold the switch up to rotate the platform counterclockwise. Hold the switch down to rotate the platform clockwise.

Engine/Emergency Power Switch

Hold the engine/emergency power switch down to operate aerial platform functions using the emergency power system. Release the switch to disengage the emergency power system.

Note The emergency power system is for lowering the platform during an emergency and is not intended for normal machine operation.

If the engine is running, it will stop when the switch is placed in the emergency power position.

Engine Speed Switch

The engine speed switch is used to set the engine throttle speed to either low or high idle.

Manifold Air Inlet Heater – Deutz Only

Some Deutz engines may have a glow plug type manifold or air inlet heater. The air inlet heater should only be used to start a cold engine when the ambient temperature is below 32°F (0°C).

Hold the toggle switch up in the on position for about 60 seconds before trying to start the engine.

Hydraulic System Warm-up Switch

Some engines may have a hydraulic fluid warm-up system. This system may be used to warm the hydraulic fluid when the ambient temperature is below 32°F (0°C) and boom movement is sluggish because of cold fluid.

There is a toggle switch for the warm-up system on the lower control panel and one on the left side of the upper control panel.

The engine must be running and the switch used to turn the system on, must be at the same location that the engine was started. For example, if the engine was started from the lower controls, the warm-up switch at the lower controls must be used for the system to operate.

Machine functions are not operational while using the hydraulic warm-up system.

Circuit Breaker Reset Buttons

The lower control panel electrical system has a circuit breaker for the throttle, run, and main circuits (refer to Figure 6.2). There is a reset button for each circuit breaker on the bottom of the lower control panel

The upper control panel (refer to Figure 6.3) has a circuit breaker for the main and drive circuits. The circuit breaker reset buttons are on the front of the upper control panel.

Place the switch in the low (turtle) position for normal machine operation and in the high (rabbit) position for engine operation or hydraulic system warm-up.

Start Switch

Fuel Switch

Engines on machines with the dual fuel option can be operated using gasoline or liquefied petroleum gas (LPG). Dual fuel machines have a gasoline tank behind the door on the left side of the turntable and an LPG tank behind the door on the right side of the turntable.

Circuit Breaker Reset Buttons

The fuel switch may be used to select between gasoline and LPG operation.

Figure 6.3 – Upper Control Panel Front

Place the switch to the left to operate the engine using gasoline and to the right to operate on LPG.

AB80J/AB85J – 0420453 23

Chapter 6 – Controls

The electrical power outlet at the platform has a 15 amp circuit breaker. The reset button is on the right side of the electrical box (refer to Figure 6.4).

Circuit Breaker

Reset Button

Figure 6.4 – Electrical Power Outlet

The circuit breakers protect the electrical wiring and components from electrical overload in case of a short circuit or other fault.

Caution

A tripped circuit breaker indicates a malfunction in the electrical system. Component damage can result if the cause of the malfunction is not corrected. Do not operate the aerial platform if the circuit breaker trips repeatedly.

Upper Controls

The upper controls (refer to Figure 6.5) are located on the control panel at the platform. Boom, platform, and drive functions can be operated from the upper controls. The following controls are located on the upper control panel.

• Start switch

• Emergency stop button

• Boom joystick

• Boom extend joystick – AB80J

• Jib rotation/boom extend joystick – AB85J

• Drive joystick

• Drive range switch

• Steer mode switch

• Jib articulation switch

• Platform level switch

• Platform rotate switch

• Engine/emergency power switch

• Throttle switch

Start Switch

The engine can be started from the platform using the anti-restart master switch on the front of the upper control panel (refer to Figure 6.6).

Push the button to reset the circuit breaker.

Engine/Emergency

Power

Riser Switch

Boom Joystick

Jib ArticulationSwitch

Boom Extend/

Jib Rotate

Platform Rotate

Emergency Stop

Horn Button

Throttle Switch

Drive Range

Drive Joystick

Steer Mode

Platform Level

Figure 6.5 – Upper Control Panel Top

24 AB80J/AB85J – 0420453

Start Switch

Figure 6.6 – Upper Control Panel Front

Chapter 6 – Controls

Hold the joystick to the right to rotate the turntable counterclockwise and to the left to rotate the turntable clockwise.

Boom Extend Joystick – AB80J

The boom extend joystick is used to extend or retract the booms. The joystick is spring returned to the center off position.

Hold the joystick forward to retract the booms and backward to extend the booms.

Jib Rotation/Boom Extend Joystick – AB85J

The jib rotation/boom extend joystick is used to rotate the jib and to extend or retract the booms on AB85J machines. The joystick is spring returned to the center off position.

This switch is similar to an automobile ignition switch. Turn the switch to start until the engine starts, then release it to on. If the engine dies, the switch must be turned to off before it can be turned back to start.

An alarm sounds, when the switch is turned on, to warn others that the machine engine is being started.

Note On some machines it may be necessary to pause about three seconds in the on position before going to start so the starter can engage.

Turn the switch to off to turn the engine off and save fuel if the platform is to stay in a particular position for a long time.

Emergency Stop Button

The emergency stop is a two-position, red push button on the top of the upper control panel (refer to Figure

6.6). Push the button in to disconnect power to all con-

trol circuits at the upper controls. Pull the button out to restore power.

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.

Push the emergency stop button in when the upper controls are not in use to protect against unintentional operation.

Boom Joystick

The boom joystick is used to raise and lower the main boom and to rotate the turntable. The boom and turntable functions may be operated simultaneously.

As the main boom is raised on AB85J machines, the tip boom is extended a maximum of 30″ (76.2 cm).

Note The distance the joystick is moved is proportional to the speed of the function.

Hold the joystick to the right to rotate the jib counterclockwise and to the left to rotate the jib clockwise.

Hold the joystick forward to retract the booms and backward to extend the booms.

Drive Joystick

The drive joystick is used to control forward and reverse motion of the aerial platform. It is also used to steer the machine. The steering and drive functions may be operated simultaneously.

Note The distance the joystick is moved is proportional to the speed of the function.

Hold the joystick forward to move the aerial platform forward and backward to move in reverse as indicated by the directional arrows on the chassis.

Hold the joystick to the right to steer the aerial platform to the right and to the left to steer to the left as indicated by the directional arrows on the chassis. The wheels will steer only when the drive joystick is in the forward or reverse drive position, or when the booms are stowed.

Note The steering wheels are not self-centering. Set the steering wheels straight ahead after completing a turn.

Drive Range Switch

The drive range switch has three positions to select drive wheel operation when the booms are in the stowed position; intermediate boom fully retracted and main boom fully lowered.

• HI – high speed two wheel drive (3 mph) with booms in the stowed position.

• MID – high speed four wheel drive (1.5 mph) with booms in the stowed position.

• LO – creep speed (0.6 mph) with high torque four wheel drive operation with booms in any position.

Hold the joystick forward to raise the main boom and backward to lower the boom.

AB80J/AB85J – 0420453 25

Chapter 6 – Controls

The drive range operates in LO when the booms are out of the stowed position, regardless of the position of the drive range switch.

Steer Mode Switch

The steer mode switch is used to select between four wheel coordinated steer, two wheel steer, and crab steer modes (refer to Figure 6.7).

Steer Modes

Four Wheel

Coordinated

• Front wheels turn in steer direction

• Rear wheels turn in the opposite direction

Two Wheel

• Front wheels turn in steer direction

• Rear wheels do not turn

Crab

• Front and rear wheels turn in steer direction

Figure 6.7 – Steer Modes

Note The steering wheels are not self-centering. Set the steering wheels straight ahead after completing a turn and before switching from one steer mode to another.

Place the switch in the two wheel, four wheel coordinated, or crab steer mode position to achieve the desired machine movement.

Jib Articulation Switch

The jib switch is used to raise or lower the jib. The switch is spring returned to the center off position.

Hold the switch up to raise the jib. Hold the switch down to lower the jib.

Engine/Emergency Power Switch

The engine/emergency power switch is spring returned to the engine position for aerial platform engine operation.

Hold the switch in the emergency power position to operate aerial platform functions using the emergency power system.

Note The emergency power system is for lowering the platform during an emergency and is not intended for normal machine operation.

If the engine is running, it will stop when the switch is placed in the emergency power position.

Throttle Switch

The throttle switch is used to set the engine throttle speed to either low or high idle.

Place the switch in the low position for normal machine operation and in high to drive at maximum speed.

The engine has a three speed throttle operation from the upper controls. Independent of the throttle switch, the platform foot switch, when depressed, increases the engine speed from low to mid-range.

High engine speed is obtained when the main boom is stowed, the foot switch is depressed, the throttle switch is in the high position, and the drive joystick is moved out of neutral into the forward or reverse position.

The machine can be driven in mid-range engine speed with the throttle switch placed in the low position.

Horn Button

The horn button is to the right of the emergency stop button on the upper control panel (refer to Figure 6.8). Press the button to sound the horn.

Platform Level Switch

Horn Button

The level switch is used to level the platform floor with respect to the ground. The switch is spring returned to the center off position.

Hold the switch up to tilt the platform floor upward or away from the ground. Hold the switch down to tilt the platform floor downward or toward the ground.

Platform Rotate Switch

The platform rotate switch is used to rotate the platform relative to the end of the tip boom. The switch is spring returned to the center off position.

Hold the switch to the right to rotate the turntable coun-

Figure 6.8 – Upper Control Panel Top

terclockwise. Hold the switch to the left to rotate the turntable clockwise.

26 AB80J/AB85J – 0420453

Chapter 6 – Controls

Platform Foot Switch

The upper controls are interlocked through the platform foot switch (refer to Figure 6.9). Step down on and hold the platform foot switch to activate the drive and boom functions from the upper controls.

Platform Foot

Switch

Figure 6.9 – Platform

Machine/Generator Switch

The switch for the optional AC generator is located on the front of the upper control panel (refer to Figure 6.10).

Dual Fuel

The dual fuel switch to select between gasoline and LPG operation is on the lower control panel.

Place the switch up to operate the engine using gasoline and down to operate the engine using LPG.

Driving and Platform Work Lights

The control for the optional driving and tail lights is on the right side of the upper control panel. Place the switch in the on position to operate the driving lights. There is also an individual light control on the back of each light.

There is a control for the optional platform work lights on the back of each light (refer to Figure 6.11).

With the engine running, place the switch in the generator position to provide electrical power to the electrical outlet at the platform. Place the switch in the machine position to turn off the generator and resume machine operation.

Machine functions will not operate while the switch is in the generator position.

Machine/Generator Switch

Figure 6.10 – Platform

Light Switch

Figure 6.11 – Platform

AB80J/AB85J – 0420453 27

Chapter 6 – Controls

28 AB80J/AB85J – 0420453

Chapter 7 – Prestart Inspection

Potential service and safety problems may be detected by inspecting the aerial platform. This chapter includes information on properly inspecting the aerial platform and includes a prestart inspection check list at the end of the chapter to ensure that no areas are overlooked.

Warning

Perform a prestart inspection at the beginning of each shift, before using the aerial platform on the job. The inspection site must have a smooth and level surface.

Operator’s Manual

The manual holder is located behind the door on the left side of the machine (refer to Figure 7.1). Make certain it is securely fastened in place.

Operator’s Manual Holder

Engine Tray Latch

Latch

Handle

Keeper Pin

Figure 7.2 – Engine Tray Latch

Make sure that the engine tray is fully closed, latched, and that the keeper pin is securely fastened before operating the machine after inspection or service.

Oil Level

Check the engine oil level before starting the engine so the oil has drained to the pan. The proper oil level is between the add and full marks on the dipstick.

The distance between the top and bottom dipstick marks corresponds to about 1 quart US (1 l). Add oil, if necessary, before starting the engine.

Coolant

Cummins and GM engines are liquid cooled. When the engine is cold, there should be about 1″ (2.5 cm) of coolant in the bottom of the reservoir (refer to Figure 7.3).

Figure 7.1 – Operator’s Manual Holder

Check to see that the proper Operator’s Manual is in the holder. The manual should be complete with all pages intact and in readable condition.

The ANSI publication “Manual of Responsibilities for Dealers, Owners, Users, Operators, Lessors and Lessees of ANSI/SIA A92.5-2006 Boom-Supported Elevating Work Platforms” must also be in the manual holder.

Coolant Reservoir

Engine

Open the door on the right side of the machine. Remove the keeper pin, press down on the latch (refer to Figure

7.2) to release the engine tray, and swing the tray outward. Visually inspect the engine and its components with the engine off.

Inspect the pin and mechanism to make certain they are in good working condition to hold the engine tray in place. When the tray is fully opened, it will latch in position with a spring loaded pin at the rear of the engine. Inspect this locking pin and mechanism also.

AB80J/AB85J – 0420453 29

Engine coolant escaping under pressure can cause serious burns. Shut the engine off and let it cool before removing the radiator cap.

Figure 7.3 – Coolant Reservoir

Caution

Chapter 7 – Prestart Inspection

Add coolant, if necessary, when the engine is cold and not running. When running at operating temperature the coolant should be at the hot level.

Deutz engines are air cooled. Visually inspect the air intake and fan (refer to Figure 7.4) to be sure they are free of obstructions that could stop or slow the flow of air. Inspect the fan belt to see that it is in place and not cracked.

Fan

Fan Belt

Figure 7.4 – Deutz Air Intake

Use the following procedure to change the LPG tank.

1. Close the shutoff valve (refer to Figure 7.6).

Shutoff Valve

Latch

Slot

Quick

Disconnect

Fitting

Figure 7.6 – LPG Tank

2. Remove the fuel line from the tank using the quick disconnect fitting.

3. Pull on each latch to release the straps from the tank.

Radiator

Inspect the radiator hoses and clamps for wear, leakage, or damage. Make sure the hoses are not hardened, cracked, or feel spongy. Make sure the cap is in place and tight.

Coolant leaks are easily visible on the ground. Check under the chassis for coolant that has leaked.

Make sure the radiator core and ventilation openings on the cover are free of bugs, dirt, or foreign material that might restrict airflow.

Fuel Tank

Check the fuel level (refer to Figure 7.5) and add fuel if necessary. Make sure the cap is securely fastened on gasoline or diesel tanks.

Fuel Level

4. Carefully lift the tank from the cradle.

5. Place a full tank in the cradle making sure the slot in the tank aligns with the pin.

6. Latch both straps to secure the tank.

7. Connect the fuel line and open the shutoff valve.

Fuel Line

Visually inspect the entire length of the fuel line. Start at the fuel tank and trace the line to the engine inspecting for leaks and damage.

Air Filter

The air filter gauge (refer to Figure 7.7) has an indicator to show when the filter needs replaced.

Air Filter Gauge

Ammeter

Reset Button

Figure 7.5 – Gasoline or Diesel Tank

30 AB80J/AB85J – 0420453

Figure 7.7 – Gauge Panel

Chapter 7 – Prestart Inspection

To inspect the air filter:

1. Turn the battery disconnect switch on and close the cowling door.

2. On dual fuel machines, set the fuel switch to either LPG or gasoline.

3. At the lower controls, place the emergency stop switch in the on position.

4. Insert the key into the start switch and turn the engine on.

5. Check the clear zone after running the engine for 30 seconds.

• If the indicator is red, replace the filter.

• If the indicator is clear, the filter is OK.

6. Shut off the engine.

Charging System

On machines with Cummins or Deutz engines, when the engine is running, the ammeter needle (refer to Figure 7.7) should be to the right of “0.” Left of the “0” is discharging.

On machines with GM engines, when the engine is running, the voltmeter (refer to Figure 7.7) should indicate between 12.5 and 14 volts.

Cold Weather Start Kit

If the machine is equipped with an optional engine block heater or radiator hose in-line heater, visually inspect the heater and power cord. Inspect for leaks around the heater and for damage to the power cord.

Machines with gasoline engines have one battery and machines with diesel engines have two batteries.

Warning

Caution

Even with low voltage electrical systems, severe arcing can occur. Electrical shock or component damage can result from contact with energized conductors. Use caution when working with any electrical device.

The batteries are automatically charged when the engine is running. Include the batteries when inspecting and servicing the electrical system.

Battery Fluid Level

Remove the caps from each battery. Visually check the battery fluid level. If the level is not within 1/4″ (6 mm) of the bottom of the filler neck inside each hole, add distilled water.

Replace the caps on the batteries. The caps must be in place and tight during machine operation.

Battery Terminals

Check the top of the batteries, the terminals, and cable ends. They should be clean and free of corrosion. Clean the top of the batteries if necessary. Clean the terminals and cable ends with a wire brush or terminal cleaning tool. All cable ends must be securely fastened to the terminals.

Electrical System

Electrical power is supplied from either one or two, 550 CCA, 12 volt batteries. The batteries are behind the door on the right side of the turntable (refer to Figure 7.8). These batteries supply 12 volt DC electrical power to operate the aerial platform electrical and electrohydraulic components, including the emergency power system.

Terminals

Cables and Wiring Harness

Inspect all cables and wiring for wear and/or physical damage such as loose connections, broken wires, and frayed insulation. Check the wiring in areas where a change in routing direction may cause them to become pinched. Make sure the cables and wires are properly routed to avoid sharp edges, pinching, and scuffing.

Hydraulic System

Hydraulic power is supplied from an engine driven variable displacement piston pump.

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

Caps

Figure 7.8 – Batteries

AB80J/AB85J – 0420453 31

not given immediately. In case of injury by escaping hydraulic fluid, seek medical attention at once.

The hydraulic reservoir is behind the door on the left side of the turntable. The pump is mounted on the engine.

Chapter 7 – Prestart Inspection

Fluid Level

Check the hydraulic reservoir fluid level with the aerial platform stowed on a level surface. The fluid level must be between the full and add marks as viewed on the sight glass (refer to Figure 7.9).

Full

Add

Figure 7.9 – Fluid Level Indicator

Caution

Not all hydraulic fluid is suitable to use in the hydraulic system. Some have poor lubricating characteristics and can increase component wear. Only use hydraulic fluid as recommended.

Figure 7.10 – Hoses, Tubes, and Fittings

Hydraulic fluid leaks are easily visible on the ground. Check under the chassis for fluid that has leaked.

Tires and Wheels

Visually inspect the tires and wheels (refer to Figure 7.11) to make sure they are suitable for service. Check the wheel lug nuts to see that none are missing, damaged, or loose.

If necessary, remove the filler cap and add fluid of the proper type. Refer to Chapter 2 for the proper type and grade of hydraulic fluid to use. The need to regularly add fluid indicates a leak that should be corrected.

The sight glass on the reservoir has an internal thermometer to measure the fluid temperature. The temperature should be less than 200°F (93°C).

Fluid Filter

Checking the condition of the hydraulic fluid filter is part of the machine maintenance schedule and should not be performed by the operator.

Hoses, Tubes, and Fittings

Inspect all hydraulic hoses, tubes, and fittings for wear, leakage, or damage (refer to Figure 7.10). Make sure the hoses are properly routed to avoid sharp edges, kinking, and scuffing. Inspect the tubes for dents or other damage that may restrict fluid flow. Make sure all hoses and tubes are held firmly in their support brackets.

Figure 7.11 – Tires and Wheels

The aerial platform has foam filled tires. Foam filled tires do not have a pressure decal or a valve core.

Inspect for large holes or cuts where foam is coming out of the tire. Look for large imbedded objects, such as angle iron, that can rip a tire open.

Punctures caused by bolts, screws, or nails are not a problem for foam filled tires.

32 AB80J/AB85J – 0420453

Chapter 7 – Prestart Inspection

Lower Control Station

With no personnel in the platform, test the operation of each control from the lower controls (refer to Figure

7.12).

Engine/Emergency Power Switch

Ground

Operation

Switch

Control

Selector

Switch

Emergency Stop Button

Figure 7.12 – Lower Controls

Operating Controls

Use the following procedure to operate the machine from the lower controls.

Start Switch

Warning

6. Test the operation of each function in both directions.

Note When checking the turntable rotation function in the clockwise direction, the turntable will rotate toward you.

Emergency Stop

Push the emergency stop button inward to turn off the engine. The lower control functions should not operate with the emergency stop in this position.

Emergency Power

Place the battery disconnect switch, the emergency stop switch, and the start switch in the on position.

Hold the engine/emergency power switch down and the ground operation switch upward to operate the aerial platform from the lower controls using the emergency power system.

1. Turn the battery disconnect switch on.

2. At the lower controls, pull the emergency stop button outward. Place the control selector switch in the lower control position.

3. Insert the key into the master switch and turn the switch to start until the engine starts, then release.

Note If the machine has a GM engine, there will be a 7 to 10 second delay after starting the engine, before the throttle will go to mid or high. Start the engine and wait 10 seconds before proceeding with machine operation.

4. Let the engine warm to operating temperature.

5. Hold the ground operation switch upward.

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 all personnel stand clear of the aerial platform while performing the prestart inspection.

Manual Emergency Lowering Pump

The riser and main booms can be lowered in an emergency using the emergency lowering pump. The emergency lowering pump is behind the cowling door on the left side of the machine.

Use the following procedure to test the emergency lowering system.

1. Use the lower controls to raise the riser and main booms a few feet.

2. Turn the engine off.

Danger

Pinch points may exist between moving components. Death or serious injury can result from becoming trapped between components. Stand clear of moving components while test operating the machine.

3. The pump handle is mounted next to the Operator’s Manual holder. Insert the handle into the pump (refer to Figure 7.13).

AB80J/AB85J – 0420453 33

Chapter 7 – Prestart Inspection

Pump

Main Boom Knob Riser Boom Knob

Manual Emergency

Lowering Pump

5. Pull the level sensor to the side as far as possible to activate the tilt alarm.

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.

6. If the alarm does not sound, remove the machine from service until the problem is corrected.

7. Lower the main boom.

Figure 7.13 – Manual Emergency Lowering Pump

4. Pull and hold the riser boom knob outward while pumping to lower the riser booms. Stop pumping and release the knob to stop descent of the booms.

5. Pull and hold the riser boom knob outward while pumping to lower the main boom. Stop pumping and release the knob to stop descent of the booms.

6. Place the pump handle back in its holder.

Level Sensor

Use the following procedure to test the level sensor.

1. Position the aerial platform on a smooth, flat, level surface.

2. Remove all persons and materials from the platform.

3. Start the engine and raise the main boom above horizontal, approximately 15 to 20 degrees.

4. Open the door on the left side of the machine to access the level sensor (refer to Figure 7.14).

Level Sensor

Flashing Light

If the machine is equipped with an optional flashing light, visually check to see that it flashes. The light should flash when the engine is running.

Sandblast Protection Kit

The optional sandblast protection kit protects the cylinders from abrasion while sandblasting or from paint overspray. Rubber covers protect each cylinder rod as it extends and retracts. The covers prevent sand and paint from damaging the cylinder seals and rod.

Inspect the covers while operating the machine to ensure they are securely fastened and completely cover the cylinder rod. Make sure there are no holes in the covers.

Structures

Visually inspect all weldments and related components. It is important to inspect the fasteners that connect the components.

Weldments

Visually inspect all weldments for abnormal wear, abrasion, or deformation that could cause interference between moving parts.

Inspect the welds on the structural components. Pay particular attention to boom welds. The area to be inspected should be clean and free of dirt and grease. Look for visible cracks in the weld and at the weld to parent material joint. A bright light may be used to provide adequate visibility of the inspection area.

Figure 7.14 – Level Sensor

34 AB80J/AB85J – 0420453

Chapter 7 – Prestart Inspection

Boom Slide Pads

The main boom has slide pads (refer to Figure 7.15) between the main and tip boom sections.

Slide Pads

Figure 7.15 – Slide Pads at Tip End of Boom

Use the lower controls to raise the main boom to horizontal. Extend the tip boom about 1′ (30 cm). Visually inspect the slide pads to make sure they are in place and are not obviously loose.

Fasteners

Visually inspect all fasteners to see that none are missing or loose.

Pay particular attention to all of the bolts, nuts, rollpins, collars, and snap rings that connect the booms and cylinders. They should all be present, tight, and not damaged in any way.

Raise the riser boom to access the inner race rotation bearing bolts in the turntable (refer to Figure 7.17). The outer race bolts can be viewed from under the chassis.

Rotation Bearing Bolts

Inspect the surface where the pads contact the tip boom. The paint must be in place with no signs of bare metal.

Extension Cylinder Slide Pads – AB85J

The extension cylinder support bracket has slide pads (refer to Figure 7.16) that can be inspected by looking into the base end of the main boom.

Slide Pads

Figure 7.16 – Extension Cylinder Support Bracket

Figure 7.17 – Rotation Bearing Bolts

Inspect the inner and outer race rotation bearing bolts to ensure that none are missing, damaged, or loose.

Upper Control Station

Inspect the platform and upper controls, after verifying all functions operated properly from the lower controls.

Guardrail System

The guardrail system (refer to Figure 7.18) includes the top rail, mid rail, toeboards, gravity gates and the walkthrough gate.

Walk-Through Gate

Lanyard Anchors

Platform Foot

Switch

Top Rail

Gravity Gate

Mid Rail

Inspect the surface where the pads contact the interior

Toeboard

of the main boom. The paint must be in place with no signs of bare metal.

Figure 7.18 – Guardrail System

Inspect all components of the guardrail system. The rails and toeboards must all be in place and free of any

AB80J/AB85J – 0420453 35

Chapter 7 – Prestart Inspection

damage or deformation. Visually check the rail and toeboard welds for cracks. All bolts and nuts fastening the platform in place must be present and not show any signs of looseness.

Inspect the gravity gates to be sure they are present, are not damaged, and move freely.

Inspect the walk-through gate to see that it swings freely, closes firmly, and is not deformed in any way. Make sure the spring closes and secures the gate when closed.

Lanyard Anchors

There are two lanyard anchors below the upper control panel (refer to Figure 7.18).

Visually inspect the lanyard anchors to make sure they are in place, are not deformed and are securely fastened to the platform.

Operating Controls

Use the following procedure to operate the machine from the upper controls.

1. Turn the battery disconnect switch on.

2. At the lower controls, place the emergency stop switch and the master switch in the on position. Place the controls switch in the platform position.

3. At the upper controls (refer to Figure 7.19), pull the emergency stop button outward.

Engine/Emergency Power Switch

Emergency Stop Button

Horn Button

5. Let the engine warm to operating temperature.

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 all personnel stand clear of the aerial platform while performing the prestart inspection.

Warning

6. Test the platform foot switch by moving a boom function control without stepping on the foot switch. If movement occurs the interlock is not functioning properly. Do not operate the machine until the problem is corrected.

7. Test the operation of each control in both directions from the upper controls.

8. The drive range switch and maximum travel speeds are interlocked through limit switches on the turntable and the main boom that senses the position of the booms. When the main boom is raised approximately 8′ (2.4 m) or extended approximately 1′ (0.3 m), the machine should travel in low speed only. To operate in high speed the booms must be stowed.

Emergency Stop

Push the emergency stop button in to turn off the engine. The upper control functions should not operate with the emergency stop in this position.

Emergency Power

Pull the emergency stop button up and place the antirestart master switch in the on position.

Hold the engine/emergency power switch in the emer-

Start Switch

Figure 7.19 – Upper Controls

4. Turn the master start switch on the front of the upper control panel to start until the engine starts, then release it.

36 AB80J/AB85J – 0420453

gency power position and step on the platform foot switch to operate the aerial platform from the upper controls using the emergency power system.

Horn

Press the horn button (refer to Figure 7.19) to ensure that it sounds to warn personnel in the area.

Electrical Power Outlet

Connect a source of 125 volt AC power to the powerinput connector on the left side of the turntable (refer to Figure 7.20).

Chapter 7 – Prestart Inspection

Power-Input

Connector

Figure 7.20 – Power-Input Connector

Some machines may have an electrical cable already plugged into the power-input connector. In that case, power is supplied by an optional AC generator. An external power source is not required.

With the engine running, place the machine/generator control (refer to Figure 7.21) in the generator position to provide electrical power to the two electrical outlets at the platform and to the outlet on the end of the generator housing.

Reset Button

Test Button

Figure 7.22 – Electrical Power Outlet

2. Plug an electrical tool into the outlet and verify the power is off.

• If the power was off, push the reset button to restore power.

• If the power was on, repair or replace the receptacle.

Platform Control Cover

The machine may be equipped with an optional platform control cover. Inspect the cover to ensure it fits properly over the control panel.

Machine/Generator Switch

Figure 7.21 – Upper Control Panel Front

Plug an electrical tool into the receptacle at the platform and at the generator and try to operate the tool to verify proper operation of the outlet.

The outlet is equipped with a ground fault circuit interrupter (GFCI). Use the following procedure to test the GFCI.

1. Push the test button (refer to Figure 7.22).

Drive Motion Alarm

The machine may be equipped with an optional drive motion alarm. Drive in both the forward and reverse directions to ensure that the alarm sounds to warn personnel in the area that the aerial platform is in motion.

Driving and Work Lights

The machine may be equipped with driving lights and/or platform work lights. Turn the engine on and use the switch on the back of each light to momentarily turn it on to see that it works.

Platform Glazier Package

Inspect the glazier trays (refer to Figure 7.23) and keeper pins to make sure they are in good condition and are not bent or distorted. The straps and padding must be in good condition and not worn, cut or frayed.

AB80J/AB85J – 0420453 37

Chapter 7 – Prestart Inspection

Straps

Padding

Keeper Pins

Caution

Solvents may contain hazardous ingredients. Follow the manufacturer’s label for proper use and disposal. Wear protective gloves and splash-proof safety glasses when using solvents.

Wet paint overspray may be removed using a natural biodegradable solvent and a soft cloth.

Replace any missing or illegible placards or decals before operating the aerial platform. Placard and decal kits are available from Snorkel.

Trays

Figure 7.23 – Platform Glazier Package

Placards and Decals

Inspect all safety and operational placards and decals. Make certain they are in place, in good condition, and are legible.

The placards and decals may be cleaned with soap and water, and a soft cloth if the words or pictures cannot be seen.

The safety related placards and decals are illustrated on the following pages.

38 AB80J/AB85J – 0420453

Chapter 7 – Prestart Inspection

This mach ine is equipped with foam f illed or solid tires, wheel weight is critical for stability.

To prevent machine tip over, repla ce tires with factory approv ed foam fill ed or solid tires ONLY.

attempt to inflate foam filled or solid tires.DO NOT

0073298

MACHINE TIPOVER HAZARD

DEATH or serious injury can result if machine tips over.

DANGER

DO N OT ALTE R OR DI SABLE

LIMIT S WIT CHES, S AFE TY

SWITC HES , OR INTE RLO CKS .

451986

KEEP CLEAR OF DESCENDING BOOM

DEATH OR SE RIOUS INJURY CAN

OCCU R FROM DESC ENDING BOOM

0150602

0074311

(One per Cylinder)

(Dual Fuel or LPG Only Inside Door)

451986

0150602

0081441

0323896

0073298

Right Side

451986

0323896

0074311

451986

0150602

451986

Top View of Turntable

AB80J/AB85J – 0420453 39

0081441

0323896

0073298

Chapter 7 – Prestart Inspection

SER IA L NU MB ER

MO DE L NU MB ER

EM PT Y VEH IC LE WE IG HT

lbs kg

MA XIM U M WH EE L LO AD

lbs

kg EN GIN E PO WE RE D MO DE LS

hp kW

BAT TE RY PO WE RE D MO DE LS

DR IVE MO TO RS

BAT TE RI ES

MO NT H / YE A R OF MA N UFA CT U RE

MA XIM U M PLA TF OR M HE IGH T

RAT ED NU MB ER O F OC CU PAN T S

MA XIM U M DR IVE HE IGH T

UN RE ST RIC TE D PLA TF OR M CA PAC IT Y

lbs

MA XIM U M ALL O WA BL E WIN D SP EE D

mp h

m/s

MA XIM U M PLA TF OR M RE AC H

00709 01

Axl e w ei gh ts w it h m ac hi ne in the st ow ed po si tio n.

lbs

DR IV E A XL E

STE ER A XL E

Do no t re mo ve an y w ei ght fro m thi s m ac hin e.

Any w eig ht add ed m us t be di str ibu ted eq ua lly on ea ch axl e.

MA XIM U M ALL O WA BL E MA NU AL FO R CE (SID E PU LL )

lbs N

Indo or s O utd oo rs

SLO P E S EN SO R AL AR M SE TT IN G

FRO NT TO B A CK

deg

SIDE TO S ID E

deg

MA XIM U M OU TR IGG E R LO AD

MA XIM U M GR AD EA BI LIT Y

CH AR GE R INP UT

Sno rke l In te rna tio na l 2009 R os ep ort Ro ad Elwo od , K S 66 024

1-80 0-2 55 -03 17

KEEP CLEAR OF DESCENDING BOOM

DEATH OR SE RIOUS INJURY CAN

OCCU R FROM DESC ENDING BOOM

0150602

DANGER

FAILURE TO COMPLY TO THE FOLLOWING RULES CAN RESULT IN

DEATH OR SERIOUS INJURY.

ELECTROCUTION HAZARD

 Do not operate this machine unless you are a qualified operator and

have read and thoroughly understand all information given in the Operator's Manual and on danger and caution signs on this machine.



This machine is not electrically insulated. Maintain 10 feet minimum clearance from electrical power lines and apparatus.

Do not exceed the unrestricted platform capacity shown on the platform.

Do not operate this machine on soft or unstable ground. Only operate this machine on flat level ground. Do not use machine as a crane, hoist, or jack, and do not position

machine against another object to steady the platform. Do not use machine if not functioning properly or damaged in any way. Do not modify or alter this machine. See the Operator's manual for other hazard information.

TIPPING & FALLI NG HAZARD

0074210

0323897

0074210

0070901

0150602

0074210

Left Side

40 AB80J/AB85J – 0420453

0070901

0150602

Chapter 7 – Prestart Inspection

This mach ine is equipped with foam f illed or solid tires, wheel weight is critical for stability.

To prevent machine tip over, repla ce tires with factory approv ed foam fill ed or solid tires ONLY.

attempt to inflate foam filled or solid tires.DO NOT

0073298

MACHINE TIPOVER HAZARD

DEATH or serious injury can result if machine tips over.

0323896

0073298

0323896

Left Side

0323896

0073298

Front

0074311

(One per Cylinder)

Rear

Top View Of Chassis

AB80J/AB85J – 0420453 41

0074311

(One per Cylinder)

Front

0074311

Chapter 7 – Prestart Inspection

Maintain 10 feet minimum c learance from el ectrical power li nes and apparatus. You must allow for platform sw ay, rock, or sag.

This aeria l device does not provide prote ction from contact with or proxi mity to an electrically charged conducto r.

Death or serious injury will result from such contact or inadequate clear ance.

DANGER

ELECTROCUTION HAZARD

THIS MACHINE IS NOT ELECTRICALLY INSULATED

0072530

• Do not operate this machine unless you are a qualified operator and have read and thoroughly understand all information given in the Operator’s Manual and on DANGER and CAUTION signs on this machine.

• Maintain 10 feet minimum clearance from electrical power lines and apparatus. This machine is NOT electrically insulated.

• Do not exceed the unrestricted platform capacity shown on the platform.

• Do not operate this machine on soft or unstable ground.

• Operate this machine only on a flat level surface.

Deat h o r s eri ou s in ju ry can re su lt fro m n ot co m ply ing to th e f oll ow ing s afe ty rul es.

• Perform the PRESTART INSPECTION, in the Operator's Manual, prior to each work shift.

• Platform occupants MUST wear fall restraint attached to lanyard anchor points provided.

• In case of emergency, depress EMERGENCY STOP button. Pull out to reset.

• Do not use boom to lift or push this machine.

• Move controls slowly and deliberately to avoid jerky and erratic platform movement.

04206 12

Radiator – Cummins and GM

0151410

0420612

0072530

0420612

0072530

0083988

(Platform Welder Option Only)

Upper Controls

42 AB80J/AB85J – 0420453

0083988

Chapter 7 – Prestart Inspection

D A N G E R

M AC HI NE TIPO VE R H AZ ARD

D EA TH or se rio us in jur y c an re sult fro m im prope r loa din g.

M axim um to tal lo ad ca rrie d by g lazie r tr ays m ust not e xcee d 2 50 pou nd s. Total co mbin ed lo ad ca rried insid e p lat form an d by gla zie r t ra ys mus t not exc ee d m ax im um pl atfor m ca pacit y. R ea d g lazie r p ac ka ge O pe rat or’s Ma nu al be for e u sin g.

04 21 07 7

DANGER

FA LL IN G OBJECT H A ZA RD

D EAT H o r s erio us in ju ry can re su lt fro m los s o f c on tro l

of ca rrie d m aterial.

G laz ier tra ys m us t only be in sta lled aroun d v ert ica l p latf orm ra ils an d m ust be sec ure d u sin g the ke ep er pin s p rov ide d.

0421078

A lway s u se gl az ier tra ys in pa irs wi th the lo ad ev en ly d ist ribute d be twe en th e t wo tray s.

S ec ure ca rried mate ria l to pl atfo rm us ing tie d ow n s tra ps . P rotec t s traps from da m ag e d ue to sh arp e dg es . K ee p a rea b elo w pla tform cle ar of pe rso nn el. D o n ot us e in w ind y c on diti ons.

The Sn orke l gl azi er pa ck age m us t only be in sta lled

on p lat for ms w ith sid e en try ga tes.

0072531

(Platform Welder Option Only)

0083985

Platform

0083985

0421078

0421077

Glazier Package

AB80J/AB85J – 0420453 43

0421077

0421078

Chapter 7 – Prestart Inspection

44 AB80J/AB85J – 0420453

Chapter 7 – Prestart Inspection

Prestart Inspection Checklist

Item Inspect For Ok

Operator’s Manual In manual holder Engine

Oil level Between full and add marks Coolant Liquid cooled engines-proper fluid level Air cooled engines-air intake and fan free of obstructions/belt in good condition Radiator Cap tight, good condition and clean Fuel tank and line Tank full, cap in place and tight/no leaks Air filter Green indicator Swing-out tray No damage or deformation, securely latched Charging system Proper operation Cold weather start kit No damage or deformation

Electrical System

Batteries 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 Between full and add marks Fluid filter Verify operation in the green zone Hoses, tubes, and fittings No leaks Cold weather warm-up kit Proper operation

Tires and Wheels Good condition Lower Control Station

Operating controls Proper operation Emergency stop and emergency power Shuts off lower controls/proper operation

Emergency Lowering Proper operation Level Sensor Sounds tilt alarm Flashing Light Proper operation Sandblast Protection Kit In place and proper operation Structures

Weldments 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 Electrical power outlet Proper operation Drive motion alarm Sounds when aerial platform moves Driving and work lights Proper operation Platform control cover In place and proper operation

Glazier Package No damage or deformation of trays, pins, and straps Platform Welder No damage or deformation, proper operation Placards and Decals In place and readable

AB80J/AB85J – 0420453 45

Chapter 7 – Prestart Inspection

46 AB80J/AB85J – 0420453

Chapter 8 – Operation

The aerial platform may be operated from either the lower or upper controls.

Danger

The aerial platform can tip over if it becomes unstable. Death or serious injury can result from a tip-over accident. Operate the aerial platform on a firm, flat, level surface. Avoid travel speeds and/or rough terrain that could cause sudden changes in platform position. 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.

The platform rated work load is the total weight of the personnel and equipment that may be lifted in the platform.

Cold, thick hydraulic oil does not flow well and may cause delay in response to control movement and improper voltage output of the AC generator. Cold hydraulic oil may also cause cavitation and pump damage. The hydraulic system may be equipped with an optional cold weather warm-up kit.

Engine Cold Weather Start Kit

The optional engine cold weather start kit may be an engine block heater or a manifold air pre-heater. The type of starting assist system depends on the engine manufacturer.

The last two letters of the model number stamped on the serial number placard indicates the engine manufacturer (refer to Figure 8.1). The serial number placard is mounted on the front of the turntable.

Last Two Letters

of Model Number

CU Cummins Engine block heater

GM General Motors

Figure 8.1 – Engine Manufacturer/Start System

Refer to the engine manufacturer below for specific cold weather start-up information for that particular engine type and cold weather start system.

Engine

Manufacturer

Deutz Manifold air inlet heater

Cold Weather

Start System

Radiator Hose In-Line

The work loads are stated on the platform rating placard at the:

• rear of the platform

• lower controls

• upper controls.

Danger

The aerial platform can tip over if it becomes unstable. Death or serious injury can result from a tip-over accident. Do not exceed the capacity values indicated on the platform rating placard.

Capacity values indicate the rated lifting capacity and do not indicate aerial platform stability.

The operator bears ultimate responsibility for ensuring that the aerial platform is properly set up for the particular conditions encountered.

Cold Weather Start-Up

If the ambient temperature is 32°F (0°C) or below, the engine and hydraulic system oil may need to be warmed before operation. Do not operate the engine at more than a fast idle until the engine and hydraulic oil has had a chance to warm. The engine may be equipped with an optional cold weather start kit.

Cummins — Block Heater

Plug the heater cord into a 125 Volt AC, 600 watt source eight hours before starting the engine. The heater will warm the engine block to make cold weather starting easier.

Unplug the power cord before starting the engine.

Deutz — Manifold Preheater

At the lower controls, hold the manifold heater switch on for about a minute before starting the engine. A glow plug in the manifold preheats the air to help start the engine. Continue to hold the switch while starting the engine. Do not release the switch until the engine starts.

If the engine does not start within 20 seconds, continue to hold the manifold heater switch and turn the start switch off. Wait for one minute before trying to start the engine again.

GM — Radiator Hose In-Line

Plug the heater cord into a 125 Volt AC, 600 watt source eight hours before starting the engine. The heater will warm the water in the lower radiator hose to make cold weather starting easier.

Unplug the power cord before starting the engine.

AB80J/AB85J – 0420453 47

Chapter 8 – Operation

Hydraulic System Cold Weather Warm-Up

Some machines may have a hydraulic fluid warm-up system that will automatically warm the fluid upon activating the warm-up switch. The hydraulic fluid may also be warmed manually if the machine is not equipped with the optional warm-up system.

Caution

Not all hydraulic fluid is suitable to use in the hydraulic system. Some have poor lubricating characteristics and can increase component wear. Only use hydraulic fluid as recommended.

Use cold weather hydraulic oil as recommended in the machine General Specifications in temperatures of 10°F (0°C) or below.

Hydraulic System Warm-up Switch

This system may be used to warm the hydraulic fluid when the ambient temperature is below 32°F (0°C) and boom movement is sluggish because of cold fluid.

There may be a toggle switch for the warm-up system on the lower control panel and/or one on the left side of the upper control panel.

The engine must be running and the switch used to turn the system on must be at the same location that the engine was started. For example, if the engine was started from the lower controls, the warm-up switch at the lower controls must be used for the system to operate.

Use cold weather hydraulic oil as recommended in the machine General Specifications in temperatures of 10°F (0°C) or below.

Preparing for Operation

Use the following procedure to prepare the aerial platform for operation.

Perform a prestart inspection as described in Chapter 7.

2. Place the battery disconnect switch in the on position.

3. Close and latch the doors.

4. Before painting or sandblasting make sure the sandblast protection kit and the platform control cover are properly installed. These options, when used properly will protect the control placards and cylinder rods from paint overspray and abrasion while sandblasting.

Lower Controls

The lower controls override the upper controls. This means that the lower controls can always be used to operate the platform regardless of the position of the upper control emergency stop button.

Boom, turntable, and platform functions may be operated from the lower controls. The lower controls may be used for initial set up of the aerial platform, and for testing and inspection.

To operate the warm-up system:

1. Start the engine and place the engine throttle in the low position.

2. From the same control station that the engine was started, place the warm-up switch in the on position.

3. After the hydraulic fluid reaches 50°F (10°C) as indicated on the thermometer, place the warm-up switch in the off position.

Manually Warming The Hydraulic System

The hydraulic oil may be warmed by bottoming out the boom extension cylinder. Raise the main boom so it is horizontal and operate the boom retract function while the machine is stowed. With the cylinder bottomed out the oil flow will produce heat to warm the hydraulic oil.

Caution

Not all hydraulic fluid is suitable to use in the hydraulic system. Some have poor lubricating characteristics and can increase component wear. Only use hydraulic fluid as recommended.

Use the following procedure to operate boom, turntable, or platform functions using the lower controls.

1. On dual fuel machines, set the fuel switch to either LPG or gasoline.

2. Open the shut-off valve on the tank if using LPG.

3. Place the emergency stop switch (refer to Figure 8.2) in the on position and place the controls switch in the ground position.

48 AB80J/AB85J – 0420453

Control

Selector

Switch

Engine/Emergency Power Switch

Emergency Stop Button

Figure 8.2 – Lower Controls

Ground

Operation

Switch

Start Switch

Chapter 8 – Operation

Upper Controls

The upper controls may be used for driving the aerial platform and positioning the booms and platform while on the job.

Use the following procedure to operate machine functions using the upper controls.

1. At the lower controls, place the emergency stop switch in the on position and turn the start switch on. Place the controls switch in the platform position.

2. On dual fuel machines, set the fuel switch to either LPG or gasoline.

3. Open the shut-off valve on the tank if using LPG.

4. Enter the platform and securely close the gate.

5. Attach the fall restraint lanyard to one of the anchor points.

4. Turn the start switch to on and pause a few seconds while the alarm sounds to alert others that the machine is about to start. Turn the switch to start, then release it to on. The engine will not start if the switch is left in the on position for 30 seconds or longer before turning it to start. The switch must be turned back to off before the engine will start.

5. Let the engine warm to operating temperature.

6. Turn the boom speed knob to slow.

7. Hold the ground operation switch in the on position while operating the boom and turntable control toggle switches.

8. Hold the appropriate toggle switch in the desired direction.

9. Gradually turn the boom speed knob to control the main boom raise/lower, extend/retract, jib rotate, and turntable rotation speed.

6. Pull the emergency stop outward (refer to Figure

8.3).

Emergency Stop Button

Top

Master Start Switch

10. Release the function toggle switch to stop movement.

11. Place the ground operation switch in the off position when no functions are being operated.

Front

Figure 8.3 – Upper Controls

AB80J/AB85J – 0420453 49

Chapter 8 – Operation

7. Turn the anti-restart master switch to on and pause a few seconds while the alarm sounds to alert others that the machine is about to start. Turn the switch to start, then release it to on. The engine will not start if the switch is left in the on position for 30 seconds or longer before turning it to start. The switch must be turned back to off before the engine will start.

8. Let the engine warm to operating temperature.

Boom Operation

Use the following procedure to operate the turntable, boom, or platform functions.

1. Step down on the platform foot switch (refer to Figure

8.4). This switch must be held down to operate the upper controls.

jib be elevated just enough to provide adequate ground clearance.

A 30 percent grade is a 36″ (0.91 m) vertical rise in 10′ (3.05 m) horizontal length.

Avoid driving with the platform over the front end of the chassis. In this position the machine is difficult to control because:

• drive and steer control movements and their resulting machine movements are reversed.

• when driving fast, sudden turns or stops produce more severe reactions to platform occupants.

• more turning space is required to prevent the platform from colliding with obstacles several feet beyond the path of the tires.

Warning

Death or serious injury can result from improperly driving or steering the aerial platform. 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.

Lanyard Anchors

Platform Foot

Switch

Figure 8.4 – Platform

Hold the appropriate control in the desired direction. As the main boom is raised on AB85J machines, the tip boom is extended a maximum of 30″ (76.2 cm). Always look in the direction of movement.

3. Releasing the control to its neutral position, or releasing the foot switch will stop movement.

Driving and Steering

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 an elevated aerial platform on soft, uneven, or sloping surfaces. Do not drive the machine on grades that exceed 30 percent.

For operation on grades up to 30 percent, it is recommended that the main boom be near horizontal and the

The blue and yellow arrows on the chassis indicate the direction the chassis will move when the drive or steer control is moved toward the corresponding color.

When the machine is in the stowed position, with the booms centered between the rear wheels, the direction of drive and steer control movement corresponds with the direction of chassis movement.

When the turntable is rotated from the stowed position, with the booms to either side of or in front of the chassis, the direction of control movement does not correspond with the direction of chassis movement.

To avoid confusion, always drive to the work area or move between work areas with the turntable and booms in the stowed position. After arriving at the work area, the booms may be positioned to the side or the front of the chassis for final positioning. Always look in the direction of movement as indicated by the directional arrows on the chassis.

Use the following procedure to operate the drive and steer functions.

1. Determine the desired drive range for the specific driving conditions. Place the switch in the appropriate position to achieve the desired drive wheel operation.

• Use high range (two wheel drive) when traveling

across firm, flat, level surfaces. High range can only be activated when the booms are stowed. High range is for high speed, low torque operation.

50 AB80J/AB85J – 0420453

Chapter 8 – Operation

• Use mid range (four wheel drive) when traveling across soft surfaces or those with small inclines. Mid range can only be activated when the booms are stowed. Mid range is for medium speed, high torque operation.

• Use low range (four wheel drive) for driving on loading ramps or other steep grades and when safety considerations demand slow deliberate machine movement. Low range is for low speed, high torque operation.

2. Determine the desired steer mode for the specific driving conditions. Place the switch in the four wheel coordinated, two wheel, or crab steer mode position to achieve the desired machine movement. Refer to Figure 8.5

Steer Modes

Four Wheel

Coordinated

• Front wheels turn

in steer direction

• Rear wheels turn

in the opposite direction

Two Wheel

• Front wheels turn in steer direction

• Rear wheels do not turn

Crab

• Front and rear wheels turn in steer direction

Figure 8.5 – Steer Modes

5. To stop drive motion, return the joystick to neutral.

6. Push the drive joystick to the right to steer to the right, the direction of the yellow arrow. Push the joystick to the left to steer to the left, the direction of the blue arrow. The wheels will steer only when the drive joystick is in the forward or reverse drive position, or when the booms are stowed.

Note The steering wheels are not self-centering. Set the steering wheels straight ahead after completing a turn.

7. After driving to the desired location, release the foot switch, or push the emergency stop button to apply the parking brakes.

Drive Speeds

The drive speed is proportional to the joystick position. The farther the joystick is moved, the faster the travel speed.

Always slow down and shift the drive system to low range before traveling over rough terrain or any sloped surface.

Drive speed ranges are interlocked through limit switches that sense the main and riser boom position. When either boom is elevated or extended, only the slowest drive speed will work regardless of the drive range switch position. To avoid a sudden speed change from high to low elevated boom speed, always bring the machine to a stop before raising the booms from the stowed position.

• Use two wheel steer for most machine operation such as travel between jobs and to position the machine near the job location.

• Use four wheel coordinated steer when a tight turning radius is desired for positioning the machine.

• Use crab steer to travel in a diagonal motion in the direction of the wheels.

Note The steering wheels are not self-centering. Set the steering wheels straight ahead after completing a turn and before switching from one steer mode to another.

3. Step down on the platform foot switch.

4. Push the drive joystick forward to move the chassis forward, the direction of the blue arrow. Pull the joystick backward to move the chassis backward, the direction of the yellow arrow. The drive speed is proportional to the joystick position.

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.

Do not use the aerial platform if it drives faster than 0.6 miles per hour (26 feet in 30 seconds) when any of the booms are out of the stowed position.

Motion Warning Alarm

The motion warning alarm sounds loud intermittent beeps when the drive joystick is in the forward or reverse position.

Gradeability

Machine gradeability refers to the maximum slope that the aerial platform is capable of travel under practical conditions. It is based on mathematical calculation, but it also takes into account the practical application.

At any given moment when driving the machine on a slope, at least one, if not all, of the factors contributing to achieving theoretical gradeabilty will not be at optimal performance. For example, tire contact may not be the same at each drive wheel or the slope conditions may not be optimal, which would then allow for loss of traction.

AB80J/AB85J – 0420453 51

Chapter 8 – Operation

Percent vs. Degree of Slope

Gradeability is most often referenced as a percentage. That value is based on a slope angle of 45° representing 100% grade.

Angle indicators, or inclinometers, often measure the angle of the slope in degrees not the percent slope. Because of that, it may be useful to understand the relationship between percent slope and the degree of the slope angle as shown in Figure 8.6.

Driving on a Slope

The machine should only be driven on a slope or loading ramp in the stowed position with the platform on the downhill side.

Angle of Slope

in Degrees

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 on slopes that exceed 30 percent grade, or where conditions of the slope could cause driving to be hazardous.

Place the drive range switch in the low position before attempting to drive the machine on a slope.

Drive the aerial platform only on slopes, or loading ramps that are within the 30 percent grade capability of the aerial platform.

Calculate the percent grade:

• before attempting to climb an unknown grade

• if it is believed that there is a malfunction to determine if the slope is within the actual grade capability of the aerial platform.

100%

95%

90%

85%

80%

75%

45°

40°

35°

30°

25°

20°

15°

10°

5°

70%

65%

60%

55%

50%

45%

40%

35%

30%

25%

20%

15%

10%

Percent of

Grade

Figure 8.6 – Slope Percent/Degree Conversion

52 AB80J/AB85J – 0420453

Chapter 8 – Operation

Length

Height

Length

Height

% of Grade

100

Length

Height

Ground Slope

Calculating Percent Grade

The percent grade equals the height (rise) of the slope divided by the length (run) times 100. Refer to Figure 8.7.

Figure 8.7 – Percent Grade Formula

The grade can be measured with an inclinometer or by using a tape measure, a level, and a straight 2x4. If using an inclinometer, refer to the conversion diagram if necessary.

To measure the grade without an inclinometer, use the following procedure.

1. With the 2x4 laying parallel with the slope, lay the level lengthwise on the 2 x 4.

2. Holding the downhill end, raise the 2x4 until the level indicates that the board is level (refer to Figure

8.8).

Electrical Power Outlet

The electrical outlet at the platform has 2, 3-prong, 125 volt AC electrical connectors. Their combined output is limited by a 15 amp circuit breaker.

Power may be supplied to the outlet using an external power source or by operating the optional AC generator.

To use the outlet, plug a source of power into the powerinput connector on the left side of the turntable (refer to Figure 8.9). Unplug the source of power before moving the aerial platform.

Power-Input

Connector

Figure 8.9 – Power-Input Connector

AC Generator

The generator supplies power to the electrical outlet only when the engine is running and the machine is stationary. The machine functions will not operate when the machine/ generator selector switch is in the generator position.

Caution

Cold hydraulic oil does not flow well and may produce improper generator output voltage. Improper outlet voltage can damage some electrical power tools and equipment. Warm the hydraulic oil before operating the generator.

Do not operate the generator unless the hydraulic oil tem-

Figure 8.8 – Percent Grade Calculation

3. Use the tape measure to measure the distance (height) from the end of the 2x4 to the ground. Record the height distance.

4. Measure the length of the 2x4 and record this measurement.

5. Use the formula in Figure 9.2 to calculate the percent of the grade.

Machine Gradeability

The gradeability specification for the AB80J/A80J and AB85J/A85JRT aerial platforms is 20%. An actual gradeability of 20%, indicates that in most normal working conditions the machine can be driven on a slope with an angle of 11.3 degrees.

AB80J/AB85J – 0420453 53

perature is at least 100°F (38°C). Refer to Cold Weather Start-Up for a hydraulic oil warm-up procedure.

Use the following procedure to supply power to the electrical power outlet if the machine is equipped with the optional generator.

1. Plug the generator cord into the outlet on the left side of the turntable (refer to Figure 8.9).

Start the engine and place the machine/generator switch (refer to Figure 8.10) in the generator position.

Chapter 8 – Operation

Use the following procedure to drain the air line.

1. Close the input connector on the chassis.

Machine/Generator Switch

Figure 8.10 – Upper Control Panel Front

The engine will run at high idle while the generator is operating. The generator will continue to operate as long as the engine is running and the switch is in the generator position.

Dual Fuel

The dual fuel switch is located on the front of the lower control panel.

Before starting the engine, place the fuel switch in the gasoline or the LPG position. Open the shut-off valve on the LPG gas tank if using LPG. Always keep the LPG tank shut-off valve closed when not using LPG.

2. Open the output connector at the platform.

3. Raise the riser and main booms slightly above horizontal.

4. Open the input connector on the chassis.

5. Allow the fluid to drain from the line.

6. Lower the boom and close both connections.

Driving Lights

The optional driving lights are for use in dimly lit areas and are not intended for driving on public roadways. There are two headlights at the front of the chassis and two blinking taillights at the rear of the chassis.

The lights are operational when the machine is set up for operation from the upper controls and the light switch is turned on (refer to Figure 8.11).

To switch from gasoline to LPG with the engine running:

1. Open the shut-off valve on the LPG tank.

2. Place the fuel switch in the LPG position.

To switch from LPG to gasoline with the engine running:

1. Place the fuel switch in the gasoline position.

2. Close the shut-off valve on the LPG tank.

Air Line

The optional air line may be used to conduct air for tool operation at the platform. The input connector is at the rear of the chassis and the output connector is at the platform on the rotator guard. The maximum working pressure of the line is 250 psi (1,723 kPa).

The air line may be used to conduct fluids such as water or antifreeze. Contact Snorkel for compatibility information before using the air line to conduct other fluids.

Caution

Fluid in the air line can damage some air tools or freeze and damage the line. Drain and blow out the air line after using it to conduct fluids.

Light Switch

Figure 8.11 – Upper Controls

If the engine is running, the idle speed increases when the driving lights are turned on.

Note Working with the driving or platform work lights on, while the engine is off, can discharge the batteries enough that the engine will not start or the emergency power system will not operate. If the engine cannot be left running while the lights are on, start and run the engine for at least 15 minutes each hour.

54 AB80J/AB85J – 0420453

Chapter 8 – Operation

Platform Work Lights

The optional platform work lights are located on the top rail of the platform next to the upper controls (refer to Figure

8.12). The direction a light points can be adjusted by using two 1/2″ wrenches to loosen the clamp below the light.

Figure 8.12 – Upper Controls

The lights are operational when the machine is set up for operation from the upper controls.

Glazier Package

The glazier package allows the platform operator to position glass at the work place. Refer to the Glazier Package manual (Snorkel Part Number 0421269) for information on proper use of the glazier package.

The package includes two lined trays with keeper pins, platform rail padding, and tie-down straps with protectors (refer to Figure 8.13)

Platform Welder

The platform welder package allows the platform operator to perform continuous duty stick and TIG welding from the platform. Refer to the Platform Welder Package manual (Snorkel Part Number 0083991) for information on proper operation of the welder package.

The package includes a Lincoln® V275-S welder mounted in the platform the welder by a hydraulically driven generator mounted on the turntable.

Platform Welder

The welder package includes the following features.

• Lincoln® V275-S welder

• 208 VAC 3-phase generator

• Circuit protection (overcurrent and ground fault)

• Fire extinguisher mounted at the platform

(refer to Figure 8.14)

Figure 8.14 – Platform Welder

. Power is supplied to

Tie-Down Straps

Figure 8.13 – Glazier Package

Platform Capacity

The platform rated work load is the total weight of the personnel and equipment that may be lifted in the platform. The work load is stated on the platform rating placard mounted on the toeboard at the rear of the platform.

The maximum total load carried by the glazier trays must not exceed 250 lb (113 kg). The weight of the load in the trays reduces the platform capacity by the amount of the load.

Rail Padding

Tray

Platform Capacity

The welder and its associated accessories are considered as equipment and reduces the platform capacity by 110 lb (50 kg).

AB80J/AB85J – 0420453 55

Chapter 8 – Operation

56 AB80J/AB85J – 0420453

Chapter 9 – Stowing and Transporting

To prevent unauthorized use and damage, properly stow the aerial platform at the end of each work day. It must also be properly stowed while transporting.

Stowing

The properly stowed position is shown in Figure 9.1.

AB80J

AB85J

Figure 9.1 – Stowed Position

Tucked Stow – AB80J

The platform may be tucked underneath the main boom to reduce the overall length of the machine when it is stowed for an extended period of time or for transporting.

The tucked stow position is shown in Figure 9.2.

Figure 9.2 – Tucked Stowed Position

Use the following procedure to stow the platform in the tucked position using the lower controls.

1. Rotate the platform so it is perpendicular to the end of the boom.

2. Fully retract the tip boom and then raise the main boom slightly above horizontal.

Use the following procedure to properly stow the aerial platform.

1. Rotate the platform so it is perpendicular to the end of the boom.

2. Fully retract the tip boom and then fully lower the riser and main booms.

3. Lower the jib boom until the foot on the jib is near the ground to allow for exiting the platform.

4. Center the booms between the rear wheels.

5. If the engine has just been under load and is hot, set the throttle switch to low and let the engine idle for five minutes.

6. Turn the start switch off and place the platform control cover over the upper controls if the machine is equipped with that option.

7. Push the lower controls emergency stop button inward. Place the start switch in the off position and remove the key.

8. Turn the battery disconnect switch off.

3. Operate the platform level switch in the down position to tuck the platform beneath the main boom. Watch the position of the platform to make sure it does not contact the ground surface. It may be necessary to slightly raise the main boom to prevent the platform from contacting the ground

4. Center the booms between the rear wheels.

5. If the engine has just been under load and is hot, set the throttle switch to low and let the engine idle for five minutes.

6. Push the lower controls emergency stop button inward. Place the start switch in the off position and remove the key.

7. Turn the battery disconnect switch off.

8. Close and latch the cowling doors.

Transporting

The aerial platform may be moved on a transport vehicle. Depending on the particular situation, the aerial platform may be driven, winched, or hoisted onto a vehicle such as a truck or trailer. Driving is the preferred method.

9. On dual fuel machines, close the shut-off valve on the LPG tank.

10. Close and latch the cowling doors.

AB80J/AB85J – 0420453 57

Chapter 9 – Stowing and Transporting

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 on ramps that exceed 30 percent grade, or where conditions of the ramp could cause driving to be hazardous.

Drive the aerial platform onto the transport vehicle if the ramp incline is within the 30 percent grade capability of the aerial platform.

A 30 percent grade is a 36″ (0.91 m) vertical rise in 10′ (3.05 m) horizontal length.

Use a winch to load and unload the aerial platform on ramps that exceed the grade capability of the machine. A winch may also be used when conditions of the ramp could cause driving to be hazardous.

The equipment used to load, unload, and transport the aerial platform must have adequate capacity. Refer to Chapter 2 to determine the approximate weight of the aerial platform.

The user assumes all responsibility for choosing the proper method of transportation, and the proper selection and use of transportation and tie-down devices, making sure the equipment used is capable of supporting the weight of the aerial platform and that all manufacturer’s instructions and warnings, regulations and safety rules of their employer, the DOT and/or any other state or federal law are followed.

Danger

The aerial platform can tip over if it becomes unstable. Death or serious injury can result from a tip-over accident. Set the drive range to low before driving up or down a grade.

9. Place the drive range switch in the low position.

10. Drive the aerial platform onto the transport vehicle in a straight line through the grade transitions with minimal turning.

11. Rotate the turntable to align the main boom between the rear wheels.

12. When driving down the ramp, always back the machine with the platform on the downhill side only.

Winching

Use the following procedure to winch the aerial platform onto the transport vehicle.

1. Locate the transport vehicle so the aerial platform will not roll forward after it is loaded.

2. Remove any unnecessary tools, materials, or other loose objects from the platform.

3. Drive the machine to the foot of the loading ramp with the front wheels nearest the ramp. Make sure the machine is centered with the ramps and that the steering wheels are straight.

Driving

Use the following procedure to drive the aerial platform onto the transport vehicle.

1. Locate the transport vehicle so it is in a straight line with the loading ramp.

2. Chock the vehicle wheels so it cannot roll away from the ramp while the machine is loaded.

3. Remove any unnecessary tools, materials, or other loose objects from the platform.

4. Drive the machine to the foot of the loading ramp with the front wheels nearest the ramp. Make sure the machine is centered with the ramps and that the steering wheels are straight.

Rotate the platform so it is perpendicular to the boom.

6. Retract the tip boom and raise the main boom or jib so it is horizontal.

7. Rotate the turntable slightly to the side so you can see the front wheels.

8. Verify that the machine wheels, loading ramps, and transport vehicle are aligned.

Fully retract the booms. Lower the main boom as much as possible making sure there is adequate ground clearance between the platform and the ramp.

5. Attach the winch to the tie-down lugs (refer to Figure

9.3) on the front of the chassis.

Tie-Down/Lifting

Lugs

Figure 9.3 – Front Tie-Down/Lifting Lugs

6. At each drive wheel, remove the two bolts from the disconnect plate (refer to Figure 9.4). Turn the plate over so the nipple points inward. Reinstall the two bolts.

58 AB80J/AB85J – 0420453

Chapter 9 – Stowing and Transporting

Use the following procedure to hoist the aerial platform onto the transport vehicle.

1. Properly stow the aerial platform.

Bolt

Figure 9.4 – Drive Wheel

7. Use the winch to position the aerial platform on the transport vehicle.

Disconnect Plate

Warning

The aerial platform is free to move when the drive hubs are disabled. Death or serious injury can result. Re-enable the drive hubs before operating the aerial platform.

8. At each drive wheel, remove the two bolts and return the plate to its original position as shown in Figure

9.4.

9. Start the engine and operate the drive control in forward and reverse several times to engage the drive hubs.

Hoisting

Use a four point sling arrangement attached to the lifting lugs when hoisting the aerial platform. Machine damage can occur if the sling is attached to the booms, turntable, or platform.

Warning

The potential for an accident increases when the aerial platform is lifted using improper equipment and/or lifting techniques. Death or serious injury can result from such accidents. Use proper equipment and lifting techniques when lifting the aerial platform.

Know the weight of the aerial platform and the capacity of the lifting devices before hoisting. Lifting devices include the hoist or crane, chains, straps, cables, hooks, sheaves, shackles, slings, and other hardware used to support the machine. The empty vehicle weight is stamped on the serial number placard and is listed in Chapter 2.

The user assumes all responsibility for making sure the equipment used is capable of supporting the weight of the aerial platform and that all manufacturer’s instructions and warnings, regulations and safety rules of their employer and/or any state or federal law are followed.

2. Inspect the front lifting lugs (refer to Figure 9.3) and the rear lifting lugs (refer to Figure 9.5) to make sure they are free of cracks and are in good condition. Have any damage repaired by a qualified service technician before attempting to hoist the machine.

Tie-Down/Lifting

Lugs

Figure 9.5 – Rear Tie-Down/Lifting Lugs

3. Remove all personnel, tools, materials, or other loose objects from the platform.

4. Connect the chains or straps to the lifting lugs using bolted shackles. Hooks that fit properly in the lugs and that have latching mechanisms to prevent them from falling out under a slack line condition may also be used.

Do not run the sling cable through the lifting lugs.

Cable damage and/or failure can result from the cable contacting the sharp corners of the lug. There is no effective way of putting a corner protector in the hole of the lifting lug.

5. Use spreader bars of sufficient length to keep the chains, straps, or cables from contacting the turntable, booms, and steer cylinders. When using cables, use rigid corner protectors at any point where the cable contacts sharp corners to prevent damaging the cable. Careful rigging of the spreaders is required to prevent machine damage.

6. Adjust the length of each chain or strap so the aerial platform remains level when raised off the ground.

7. Use the hoist or crane to carefully raise and position the aerial platform onto the transport vehicle.

Securing for Transport

Use the following procedure to secure the aerial platform on the transport vehicle.

1. Chock the wheels.

AB80J/AB85J – 0420453 59

Chapter 9 – Stowing and Transporting

2. Raise the main boom about 1′ (0.3m).

3. Place a large wood block under the jib foot. Lower the platform so the foot rests on the wood block.

4. Remove all personnel, tools, materials, or other loose objects from the platform.

5. Turn the start switch off and place the platform control cover over the upper controls if the machine is equipped with that option.

6. Place the lower controls emergency stop switch in the off position. Turn the start switch off and remove the key.

7. Turn the battery disconnect switch off.

Figure 9.6 – Platform

8. Close the shut-off valve on the LPG tank on LPG.

9. Close and latch the cowling doors.

10. Use wire-ties to fasten the platform gate to the guardrails to prevent the gate from bouncing. Also, use wire-ties to fasten the platform foot switch to the platform floor.

11. Use a nylon strap to securely fasten the platform against the wood block. On steel platforms, thread the strap over the toeboard as shown in Figure 9.6.

Caution

Ratchets, winches, and come-alongs can produce enough force to damage machine components. Do not over tighten the straps or chains when securing the aerial platform to the transport vehicle.

12. Use chains or straps to securely fasten the aerial platform to the transport vehicle using the tie-down lugs as attachment points. Proper tie-down and hauling are the responsibility of the carrier.

60 AB80J/AB85J – 0420453

Chapter 10 – Emergency Operation

If the main hydraulic system fails, the aerial platform may be lowered and stowed using the emergency power system. The main and riser booms may be lowered using the emergency lowering pump. The machine may be towed if the drive system fails. Refer to Emergency Power System, Emergency Lowering, or Towing for the appropriate procedure.

Emergency Power System

The emergency power system can be used to operate the machine from the lower or upper controls.

Caution

The emergency power system is for emergency lowering and stowing only. The length of time the pump can be operated depends on the capacity of the battery. Do not use this system for normal operation.

Engine/Emergency

Power Switch

Ground

Operation Switch

Control Selector Switch

Start Switch

Only use the emergency power system if the main power system fails.

Lower Controls

Use the following procedure to operate the machine using the emergency power system from the lower controls.

1. Place the battery disconnect switch in the on position (refer to Figure 10.1).

Battery Disconnect Switch

Figure 10.1 – Battery Disconnect Switch

2. Place the key in the start switch (refer to Figure 10.2) and turn the start switch on.

3. Pull the emergency stop button outward.

Emergency

Stop Button

Figure 10.2 – Lower Controls

4. Place the controls switch in the lower control position.

5. Hold the ground operation switch in the on position while holding the engine/emergency power switch in the emergency power position.

6. Hold the appropriate function toggle switch in the desired direction.

Upper Controls

For the upper controls to be operational:

• the battery disconnect switch must be in the on position.

• the start switch at the lower controls must be turned on.

• the emergency stop button at the lower controls must be in the on position.

• the control selector switch at the lower controls must be in the platform position.

Use the following procedure to operate the machine using the emergency power system from the upper controls.

1. Pull the emergency stop button outward (refer to Figure 10.3).

2. Turn the start switch on.

AB80J/AB85J – 0420453 61

Chapter 10 – Emergency Operation

Engine/Emergency

Power

Emergency Stop Button

Top

Figure 10.3 – Upper Controls

3. Step down on the platform foot switch (refer to Figure

10.4).

Start Switch

Front

1. The pump handle is mounted next to the Operator’s Manual holder. Insert the handle into the pump (refer to Figure 10.5).

Pump

Manual Emergency

Lowering Pump

Platform Foot

Switch

Figure 10.4 – Platform Foot Switch

4. Hold the engine/emergency power switch in the emergency power position.

5. Hold the appropriate function toggle switch in the desired direction.

Emergency Lowering Pump

The emergency lowering pump allows the riser and main booms to be lowered only. Only use this method if the engine will not start and the emergency power system will not work.

Use the following procedure to manually lower the riser and/or main boom.

Danger

Pinch points may exist between boom components and between the booms and turntable. Death or serious injury can result if the booms or platform lowers onto personnel. Make sure all personnel stand clear while lowering the booms.

Riser Boom KnobMain Boom Knob

Figure 10.5 – Behind Left Cowling Door

2. Pull and hold the riser boom knob outward while pumping to lower the riser booms. Stop pumping and release the knob to stop descent of the booms.

3. Pull and hold the riser boom knob outward while pumping to lower the main boom. Stop pumping and release the knob to stop descent of the booms.

4. Place the pump handle back in its holder.

62 AB80J/AB85J – 0420453

Chapter 11 – Troubleshooting

The troubleshooting chart may be used to locate and eliminate situations where machine operation may be interrupted. If the problem cannot be corrected with the

Troubleshooting Chart

Symptom

Engine will not start from lower or upper controls.

Possible Cause

Out of fuel. The engine will crank, but will not start.

Engine is cold.

High engine temperature.

action listed, stow the machine and remove it from service. Repairs must be made by qualified maintenance personnel.

Corrective Action

Add correct type of fuel. Try starting the engine for 20 seconds and then let the starter motor cool for 60 seconds. Repeat as necessary.

Cummins or GM engine – plug the block heater into a 125 Volt AC, 600 watt source eight hours before starting the engine.

Deutz engine – hold the manifold heater switch on for about a minute before starting the engine. Hold the switch on until the engine starts.

Let engine cool. Do not restart the engine until the cause of overheating has been corrected.

Low oil pressure.

Dual fuel machines. The fuel switch on the lower control panel is set incorrectly. The engine cranks, but will not start.

Do not try to start the engine until the cause of low oil pressure has been corrected. The engine can be restarted with low oil pressure, but it will only run a few seconds before it shuts off again.

• Place the fuel switch on the lower control panel in the proper position for the fuel being used.

• Make certain there is fuel in the fuel tank.

• If using LPG make certain that the fuel shutoff valve is open.

• Try starting the engine for 20 seconds and then let the starter motor cool for 60 seconds. Repeat as necessary.

AB80J/AB85J – 0420453 63

Chapter 11 – Troubleshooting

Symptom

Engin e will not star t from lower controls.

Engine will no t st art fr om upper controls.

Possible Cause

Switches are set wrong. The engine will not crank.

The master start switch was left in the on position for 30 seconds or longer before turning it to start.

The main system circuit breaker on the lower control panel has tripped. The engine will not crank.

Switches are set wrong. The engine will not crank.

Corrective Action

Turn the battery disconnect switch on and then at the lower controls:

• Turn the master start switch off.

• Pull emergency stop button outward.

• Place the controls switch in the lower control position.

• Place the master start switch in the on position for 5 seconds and then turn the switch to start.

Turn the start switch back to off, then to start within 30 seconds.

Push the main system circuit breaker button back in. If the button pops back out, refer the problem to a qualified service technician.

Turn the battery disconnect switch on and then at the lower controls:

Continued on next page...

Platform foot switch is activated.

The master start switch was left in the on position for 30 seconds or longer before turning it to start.

• Turn the master start switch off.

• Pull the emergency stop button outward.

• Place the controls switch in the upper control position.

• Place the master start switch in the on position.

From the upper controls:

• Turn the master start switch off.

• Pull the emergency stop button outward.

• Place the master start switch in the on position for 5 seconds and the then turn the switch to start.

Do not step on foot switch while starting the engine.

Turn the master start switch back to off, then to start within 30 seconds.

64 AB80J/AB85J – 0420453

Chapter 11 – Troubleshooting

Symptom

Engin e will not sta rt from upper controls.

Engine starts from the upper controls but no boom functions work – machines with AC generator option only.

Engine dies when the control selector switch at the lower controls is placed in the upper control position.

After starting the engine, it will not throttle up and dies when a function is operated – GM 2.4 engines only.

Constant tone alarm sounds while the engine is running.

Possible Cause

The main system circuit breaker on the lower or upper control panel has tripped. The engine will not crank.

The machine/generator switch is in the generator position.

Upper controls are not set-up properly.

Function is operated within a few seconds after starting the engine.

High engine temperature.

Corrective Action

Push the main system circuit breaker button back in. If the button pops back out, refer the problem to a qualified service technician.

Place the switch in the machine position to operate machine functions.

At the upper controls, pull the emergency stop button upward and turn the anti-restart master switch on.

Normal operation for GM 2.4 engine. There is a 7 to 10 second delay after each engine start before the throttle will go to mid or high to prevent an engine overspeed under certain starting conditions.

Lower the platform and reduce the engine speed to idle for five minutes. Turn the engine off and let it cool. Do not restart the engine until the cause of overheating has been corrected.

Constant tone alarm sounds and engine shuts off.

All functions stop working.

Low oil pressure.

No alternator current/broken fan belt.

High engine temperature.

Low oil pressure.

Low fluid level in reservoir.

Engine or pump failure.

Lower the platform and turn the engine off. Do not restart the engine until the cause of low oil pressure has been corrected.

Turn the engine off. Do not restart the engine until the cause of no alternator current has been corrected or the fan belt is replaced.

Let the engine cool. Do not restart the engine until the cause of overheating has been corrected.

Do not restart the engine until the cause of low oil pressure has been corrected. The engine can be restarted with low oil pressure, but it will only run a few seconds before it shuts off again.

Check fluid level. Add correct type of fluid if necessary.

Manually stow the machine using the emergency power system or the emergency lowering knob.

Circuit breaker is tripped.

Continued on next page...

AB80J/AB85J – 0420453 65

Push circuit breaker button in to reset.

Chapter 11 – Troubleshooting

Symptom

All functions stop working.

Lower controls do not work.

Upper controls do not work.

Possible Cause

Electrical system malfunction.

Battery disconnect switch turned off.

Emergency stop button at lower controls is pushed in to the off position.

Controls switch is in the upper control position.

Ground operation switch not held in the on position.

Battery disconnect switch turned off.

Emergency stop button at lower and upper controls is in the off position.

Control selector switch at lower controls is in the lower control position.

Platform foot switch not engaged.

Corrective Action

Manually lower the boom using the emergency lowering pump.

Place switch in the on position.

Pull the emergency stop button outward.

Place the switch in the lower control position.

Hold the ground operation switch in the on position while operating the control toggle switches.

Place switch in the on position.

Pull the emergency stop buttons outward.

Place switch in the upper controls position.

Step down on platform foot switch while operating controls.

Boom and drive functions seem sluggish.

Turntable and main boom functions do not work from the upper controls.

Riser and/or main boom drifts down.

Drive functions do not work.

Can not reach maximum drive speed of 3 mph (4.8 km/h).

Hydraulic oil is cold and thick.

Boom speed knob set too slow.

Hydraulic system malfunction.

Load capacity exceeded.

Machine on too steep a grade.

Drive hubs are disengaged.

Low hydraulic system pressure.

Booms are not retracted and lowered.

Drive range switch is in LO or MID.

Use cold weather hydraulic oil as recommended for weather conditions. Warm oil before operating the machine.

Turn knob toward fast.

Stow the machine and do not operate until repairs are made.

Remove load from platform. Refer to platform capacity placard for maximum capacity.

Lower the booms and drive to a level surface.

Turn drive wheel disconnect plates around so nipples point outward.

Stow the machine and do not operate until repairs are made.

Fully retract and lower the boom.

Place the switch in the HI position.

Wheels will not turn when

Drive hubs are engaged.

winching.

66 AB80J/AB85J – 0420453

Turn drive wheel disconnect plates around so nipples point inward.

Chapter 11 – Troubleshooting

Symptom

Steer wheels do not turn when the drive joystick is moved to the right or to the left.

Tilt alarm does not work.

Circuit breaker will not reset.

Electrical outlet does not work.

Possible Cause

The drive joystick must be in the forward or reverse position for the steering wheels to turn or the main boom must be stowed.

Booms are stowed.

Electrical circuit has not had time to cool.

Electrical system malfunction.

Power supply not plugged in.

GFCI is tripped.

Machine/generator switch not in the generator position.

Corrective Action

Push the drive joystick slightly forward or backward when operating steer right or left.

Normal operation. The tilt alarm is operational when the booms are near horizontal.

Wait a minute or two for circuit to cool, then push circuit breaker button in to reset.

Do not operate machine until repairs are made.

Plug a source of power into the power-input connector on the wiring box.

Push reset button on outlet.

With engine running, place the machine/generator switch in the generator position.

Improper AC generator output voltage.

Hydraulic fluid temperature 200°F (93°C) or more.

Severe hydraulic leak.

Power cord to platform is not plugged into the AC generator.

Hydraulic oil is cold and thick.

Prolonged boom operation or driving.

High pressure fluid return to reservoir caused by kinked or twisted hose.

Hydraulic system component failure.

Failure of hose, tube, fitting, seal, etc.

Plug power cord into the outlet on the left side of the lower control panel.

Use cold weather hydraulic oil as recommended for weather conditions. Warm oil before operating the machine.

Stop operation until fluid cools.

Remove the kink or twist from the hose. Let fluid cool before operating.

Stow the machine and do not operate until repairs are made.

Do not operate machine until repairs are made.

AB80J/AB85J – 0420453 67

Chapter 11 – Troubleshooting

68 AB80J/AB85J – 0420453

Appendix A – Glossary

aerial platform – a mobile device that has an adjustable position platform,

supported from ground level by a structure.

ambient temperature – the air temperature of the immediate environment.

ammeter – an instrument for measuring the strength of an electric current in amperes.

authorized personnel – personnel approved as assigned to perform specific duties at a specific location.

base – the relevant contact points of the aerial platform that form the stability support (e.g. wheels, casters, outriggers, stabilizers).

boom – a movable cantilever beam which supports the platform.

center of gravity – the point in the aerial platform around which its weight

is evenly balanced.

chassis – the integral part of the aerial platform that provides mobility and support for the booms.

fall restraint – a system that is used while working on a boom lift within the boundaries of platform guardrails to provide restraint from being projected upward from the platform. This system includes a harness or belt, lanyard, and a lanyard anchor. Federal OSHA, ANSI, and Snorkel require the use of additional fall protection beyond the platform guardrails on boom supported aerial platforms.

floor or ground pressure – the maximum pressure, expressed in pounds per square inch, a single wheel concentrates on the floor or ground.

gradeability – the maximum slope that the aerial platform is capable of travel.

ground fault circuit interrupter (GFCI) – a fast-acting circuit breaker that opens to stop electrical circuit flow if it senses a very small current leakage to ground. The GFCI is used to protect personnel against a potential shock hazard from defective electrical tools or wiring.

guardrail system – a vertical barrier around the platform to prevent personnel from falling.

maximum wheel load – the load or weight that can be transmitted through a single wheel to the floor or ground.

Minimum Safe Approach Distance – the minimum safe distance that electrical conductors may be approached when using the aerial platform. Also called M.S.A.D.

operation – the performance of any aerial platform functions within the scope of its specifications and in accordance with the manufacturer’s instructions, the users work rules, and all applicable governmental regulations.

operator – a qualified person who controls the movement of an aerial platform.

personal fall arrest system – a fall protection system that is used while working on an unprotected edge (such as a roof top with no guardrail). This system includes a harness, lanyard or other connecting device, a fall arrestor, an energy absorber or decelerator, an anchorage connector, and a secure anchorage such as a building beam, girders or columns. An aerial platform is not a fall arrest anchorage.

platform – the portion of an aerial platform intended to be occupied by personnel with their tools and materials.

platform height – the vertical distance measured from the floor of the platform to the surface upon which the chassis is being supported.

prestart inspection – a required safety inspection routine that is performed daily before operating the aerial platform.

qualified person – a person, who by reason of knowledge, experience, or training is familiar with the operation to be performed and the hazards involved.

rated work load – the designed carrying capacity of the aerial platform as specified by the manufacturer.

riser – the structure that connects the riser boom to the main boom.

riser boom – an articulating boom section. The riser boom is between the

turntable and the main boom.

stow – to place a component, such as the platform, in its rest position.

hazardous location – any location that contains, or has the potential to

contain, an explosive or flammable atmosphere as defined by ANSI/NFPA

505.

interactive link – the structure connecting the extend cylinder assembly to the turntable, increasing the reach of the tip boom.

jib – an articulating boom attached to the tip boom which increases the overall boom reach.

level sensor – a device that detects a preset degree of variation from perfect level. The level sensor is used to sound an alarm if operating on a slope greater than the preset value.

lower controls – the controls located at ground level for operating some or all of the functions of the aerial platform.

main boom – a boom assembly located between the riser and the jib.

manufacturer – a person or entity who makes, builds or produces an

aerial platform.

maximum travel height – the maximum platform height or the most adverse configuration(s) with respect to stability in which travel is permitted by the manufacturer.

tip boom – a telescopic boom section that extends and retracts from within the main boom. The tip boom is nearest the platform.

turning radius – the radius of the circle created by the wheel during a 360° turn with the steering wheels turned to maximum. Inside turning radius is the wheel closest to the center and outside turning radius is the wheel farthest from the center.

turntable – the structure above the rotation bearing which supports the booms. The turntable rotates about the centerline of rotation.

unrestricted rated work load – the maximum designed carrying capacity of the aerial platform allowed by the manufacturer in all operating configurations.

upper controls – the controls located on or beside the platform used for operating some or all of the functions of the aerial platform.

wheelbase – the distance from the center of the rear wheel to the center of the front wheel.

working envelope – the area defined by the horizontal and vertical limits

of boom travel that the platform may be positioned in.

working height – platform height plus six feet.

AB80J/AB85J – 0420453

Appendix A – Glossary

AB80J/AB85J – 0420453

Product Warranty

1. Snorkel warrants each new machine manufactured and sold by it to be free from defects in material and workmanship for a period of one (1) year from date of delivery to a Customer. The warranty will

apply subject to the machine being operated in accordance with the rules, precauons, instrucons

and maintenance requirements outlined in the Snorkel Operator's and Repair Parts Manuals.

2. Snorkel further warrants the structural components, specically the mainframe chassis, turntable,

booms and/or scissor arms of each new machine manufactured by it to be free from defects in

material and workmanship for an addional period of four (4) years. Any such part or parts which, upon examinaon by the Snorkel Warranty Department, are found to be defecve will be replaced or repaired by Snorkel through its local Authorised Dealer. The structural warranty specically excludes adverse aects on the machine structure arising from damage, abuse or misuse of the equipment.

3. Machines may be held in an authorised Distributor stock for a maximum of six (6) months from the date of shipment from Snorkel, before the warranty period is automacally iniated.

4. It is the responsibility of the Distributor to complete and return a Predelivery/Warranty registraon, before the act of rental/loan/demonstraon of the machine or delivery to an end user.

5. The Customer and Dealer shall not be entled to the benets of this warranty and Snorkel shall have no obligaons here under unless the “Predelivery and Inspecon Record” has been properly completed and returned to the Snorkel Warranty department within een (15) days aer delivery of the Snorkel product to the Customer or Dealer’s demonstraon/rental eet. Snorkel must be noed, in wring, within ten (10) days, of any machine sold to a Customer from a Dealer’s rental eet during

the warranty period.

6. Any part or parts which upon examinaon by the Snorkel Product Support Department are found to be defecve within the specied warranty period, will be replaced or repaired at the sole discreon of Snorkel, through Snorkel directly or an authorised Distributor, at no charge. Any parts replaced under warranty must be original Snorkel parts obtained through Snorkel directly or an authorised Distributor, unless expressly agreed otherwise in wring and in advance by Snorkel’s Warranty Department.

7. All parts being claimed under warranty must be held available for return and inspecon upon request for a period of 90 days from date of claim submission, it is necessary that all parts are individually tagged or marked with their part number and the warranty claim number. Aer 90 days all parts

replaced under warranty which have not been returned to Snorkel should be destroyed. Failure to

produce parts requested by the Warranty Administrator for inspecon within a period of 14 days will result in the claim being automacally rejected in full. Materials returned for warranty inspecon

must have the following procedure:

Carefully packaged to prevent additional damage during shipping



Drained of all contents and all open ports capped or plugged



Shipped in a container tagged or marked with the RMA number



Shipped PREPAID. Any item(s) returned for warranty by any other means maybe refused and returned,



unless prior approval is agreed with Snorkel.

Product Warranty

8. At the direcon of the Snorkel Warranty Department, any component part(s) of Snorkel products to be replaced or repaired under this warranty program must be returned freight prepaid for inspecon. An RMA (Returns Material Authorisaon) must be requested from Snorkel Warranty Department, a

copy to be placed with the returning component part(s).

9. All warranty replacement parts will be shipped freight prepaid (standard charge) from the Snorkel Parts/Service Department or from the Vendor to Dealer or Customer.

10. All warranty claims are subject to approval by Snorkel Service Department. Snorkel reserves the right to limit or adjust claims with regard to defecve parts, labor or travel me based on usual and cus-

tomary guidelines.

REPLACEMENT PARTS WARRANTY

Any part replaced under this limited warranty is not subject to further warranty cover beyond the normal



warranty period of the machine upon which the part was installed. Any replacement parts sold (not delivered under a warranty claim) will be subject to a warranty period of



(6) six months from the date of invoice. Parts held by a Distributor are covered under warranty for a period of (12) twelve months from the date



of invoice, provided that those parts have been subject to appropriate storage to prevent damage and deterioration.

CLAIM PROCEDURE

The Snorkel Warranty Department must be notied within (48) forty-eight hours of any possible warranty situation

during the applicable warranty period. Personnel performing major warranty repair or parts replacement must obtain

specic approval by the Snorkel Warranty Department prior to performing the warranty repair or replacement.

When a Distributor/Customer perceive a warranty issue to exist the following steps must be adhered to:

All warranty claims must be submitted within 30 days of the date of the machine repair



All correspondence in respect of the claim to be on an ofcial Snorkel warranty claim form as supplied by



Snorkel’s Warranty Department Allocate a warranty claim number to the repair



Place a purchase order for genuine Snorkel replacement parts



Snorkel to dispatch parts via the requested method (in line with the required response time)



Conrmation that a qualied technician is available to replace the part and that this person has been ac-



cepted by Snorkel to carry out such work under the warranty of the machine. Failure to do this may nullify the warranty.

FREIGHT DAMAGE

If a machine is received in a damaged condition, then the damage must be noted on the bill of lading and/or delivery documents and if possible photographs taken, prior to signing acceptance of the consignment. The freight company must be contacted by the Distributor and a damage claim registered immediately.

THIS WARRANTY EXCLUDES AND SNORKEL DOES NOT WARRANT:

1. Engines, motors, res and baeries are manufactured by suppliers to Snorkel, who furnish their own warranty. Snorkel will, however, to the extent permied; pass through any such warranty protecon to the Distributor/Customer.

2. Any Snorkel product which has been modied or altered outside Snorkel factory without Snorkel written approval, if such modicaon or alteraon, in the sole judgment of Snorkel Engineering and/or Service Departments, adversely aects the stability, reliability or service life of the Snorkel product or

any component thereof.

Product Warranty

3. Any Snorkel product which has been subject to misuse and abuse, improper maintenance or accident. “Misuse” includes but is not limited to operaon beyond the factory-rated load capacity and speeds. “Improper maintenance” includes but is not limited to failure to follow the recommendaons con-

tained in the Snorkel Operator's and Repair Parts Manuals.

4. Normal wear of any Snorkel component part(s). Normal wear of component parts may vary with the type, applicaon or type of environment in which the machine may be used; such as, but not limited to sandblasng applicaons.

5. Roune maintenance, roune maintenance items and minor adjustments are not covered by this warranty, including but not limited to hydraulic uid, lters and lubricaon, paint and decals.

6. Any Snorkel product that has come into direct contact with any chemical or abrasive material.

7. Incidental or consequenal expenses, losses, or damages related to any part or equipment failure, including but not limited to freight cost to transport the machine to a repair facility, downme of the machine, lost me for workers, lost orders, lost rental revenue, lost prots, expenses or increased cost. This warranty is expressly in lieu of all other warranes, representaons or liabilies of Snorkel, either expressed or implied, unless otherwise amended in wring by Snorkel.

8. Snorkel Warranty policy does not cover any dues, taxes, environmental fees including without limitaon, disposal or handling of res, baeries and petrochemical items.

9. Item specically excluded are, fuel injectors, motor brushes, glow plugs, contactor ps and springs, oil lters, lamp bulbs, lamp lenses, O-rings, coolants, lubricants and cleaning material.

10.

Failure of replacement parts due to fault misdiagnosis or incorrect ng by the Distributor/Customer.

SNORKEL MAKES NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION OF THIS LIMITED WARRANTY

SNORKEL MAKES NO IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND DISCLAIMS ALL LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING BUT NOT LIMITED TO INJURY TO PERSONS OR PROPERTY.

The Customer shall make all warranty claims the

Distributor

, contact the Snorkel Service Department for further assistance.

through Snorkel directly or an Authorised Distributor

. If unable to contact

Product Warranty

APPEAL

The buyer may appeal in writing against a rejected or adjusted claim to Snorkel Warranty Department within a period of 21 days of receiving the rejection or adjustment notice. The appeal should be grounded on express reasons and supported by relevant evidence. Appeals received outside of this time limit will not be considered.

WARRANTY SCHEDULE

Limited Warranty Periods

Item

New machine materials and workmanship

Structural components (Chassis, Turntable, Booms, Scissors)

Parts held in a Distributor’s stock

Parts sold (non warranty)

Batteries

Other specically excluded parts:

Fuel injectors Motor brushes Glow plugs Contactor tips and springs Oils Filters Lamp bulbs Lamp lenses O-rings Coolants Lubricants Cleaning materials

Warranty Period

1 year parts replacement

5 years parts replacement or repair

12 months from date of invoice

6 months from date of invoice

Not covered by Warranty

Local Distributor / Lokaler Vertiebshändler / Distributeur local

El Distribuidor local / ll Distributore locale

EUROPE, MIDDLE EAST

AFRICA & ASIA

PHONE: +44 (0) 845 1550 058

FAX: +44 (0) 845 1557 756

NORTH & SOUTH AMERICA

PHONE: +1 785 989 3000

TOLL FREE: +1 800 255 0317

FAX: +1 785 989 3070

AUSTRALIA

PHONE: +61 1300 700 450

FAX: +61 2 9609 3057

NEW ZEALAND

PHONE: +64 6 3689 168

FAX: +64 6 3689 164

Snorkel AB80J User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Chapter 1 – Introduction

Aerial Platform Features

Safety Alerts

Options

Operation

Maintenance

Manual of Responsibilities

Additional Information

Working Envelope – AB80J

Engine Oil Viscosity

Chapter 3 – Safety

Electrocution Hazards

Minimum Safe Approach Distance

Prestart Inspection

Work Place Inspection and Practices

Operation

Tip-Over and Falling Hazards

Electrical System

Hydraulic System

Engine and Fuel Handling Precautions

Placards and Decals

Chapter 4 – Safety Devices

Emergency Stop Controls

Emergency Power System

Manual Emergency Lowering Pump

Ground Operation Switch

Platform Foot Switch

Lanyard Anchors

Ground Fault Circuit Interrupter

Guardrails

Tilt Alarm

Engine Protection Systems

High Engine Temperature Alarm

Horn

Drive Motion Alarm

Low Oil Pressure Alarm

Flashing Light

Driving Lights

Platform Work Lights

Chapter 5 – Gauges and Displays

Hour Meter

Ammeter

Voltmeter – GM Engines

Engine Air Filter Gauge

Engine Temperature Gauge

Fuel Gauge

Fluid Level and Temperature Gauge

Engine Oil

Hydraulic Fluid Filter Gauge

Chapter 6 – Controls

Battery Disconnect Switch

Lower Controls

Start Switch

Emergency Stop Button

Controls Selector Switch

Ground Operation Switch

Rotation Switch

Riser Switch

Boom Elevation Switch

Boom Extension Switch

Boom Speed Knob

Jib Articulation Switch

Platform Level Switch

Platform Rotation Switch

Engine/Emergency Power Switch

Engine Speed Switch

Manifold Air Inlet Heater – Deutz Only

Hydraulic System Warm-up Switch

Circuit Breaker Reset Buttons

Fuel Switch

Upper Controls

Start Switch

Boom Extend Joystick – AB80J

Emergency Stop Button

Boom Joystick

Drive Joystick