| Snorkontt cou ee no eens Guide asGENERAL INFORMATION This manual contains procedures for locating and correcting the majority of problems which may develop on the “Snorkelif’ TB60 and PROS6 aerial platforms. Since the majority of maifunctions experienced on equipment in the aerial platform industry are associated with the hydraulic and electrical systems, great effort has been made to develop a guide hich insures that procedures regarding these areas are given the fullest possible attention and detail As a result of these efforts, the aerial piatform has been divided into thirteen distinct groups with each group covered by an individual section. The Sections are as follows: 4.) Engine Diagnostics 8.) Platform Leveling System Diagnostics 2.) Hydraulic Pump Diagnostics 9.) Boom Elevation System Diagnostios 3)) Steering System Diagnostics 10.) Telescope System Diagnostics 4.) Drive System Diagnostics 11.) Control Valve System Diagnostics 5.) Emergency Power System Diagnostics 12.) Fuel System Diagnostics 6) Swing System Diagnostics 13.) Accessories Diagnostics 7,) Platform Rotation System Diagnostics NOTES, CAUTIONS AND DANGERS The terms NOTE, CAUTION, and DANGER appear throughout this manual and have specific meanings ‘A NOTE provides addtional or special information to make a step or procedure easier or clearer. Disregarding a NOTE might cause inconvenience, but would not cause equipment damage or personal injury. ‘A CAUTION is provided in a procedure wherever minor personal injury or equipment damage could result. Disregarding a CAUTION could cause damage to the machine; however serious personal injury is unlikely. DANGER 's tne most serious and emphasizes areas where personnel injury and even death could resutt from negigence. Permanent mechanical damage is also highly probable. DANGER ‘signs are to be taken seriously. In some cases, serious injury or death has resulted from disregarding a DANGER. NOTE: Engine maintenance and troubleshooting information not contained in this manual may be found in the engine maintenance manual originally provided with the machine. It should be recognized that every person who performs testing and diagnostic procedures and every person supervising any of these functions must be properly trained and qualified. Ifa problem should ‘occur which is not covered by this manual or which cannot be corrected using the listed corrective actions, technically qualified guidance from the Service Department of Snorkel International Inc., should be obtained prior to proceeding further. NOTE: biagnostic procedures basically consist of a logical process of elimination. For this reason, itis very important that the steps be performed in the order in which they are presented, Always begin by localizing the problem and defining the symptoms as accurately as possible. When the problem has been localized, make sure to completely read and comprehend the appropriate flow chart. Do not attempt to make shortcuts.MANUAL DESIGN Each symptom described is followed by a list of inspections to be performed. Each inspection is in the form of a flowchart. A set of detailed checks are then performed at the component andior related areas which confirm or decline the outcome. Ifthe inspection is declined the flowchart will refer to the Next step to be performed unti the problem is confirmed. The diagnosis then enables a determination (of the appropriate action or remedy. Example: Problem Solving Procedure Step 1 Problem Inspect Ly coto Page l Step2 2 Inspect t+} Goto Page Example: Flowchart Procedure Inspect L____] + Troubleshoot (identify Problem) }-vee Goto step + Replace or perform repair EQUIPMENT NEEDED: Multimeter: A meter designed to read both voltage and resistance, Pressure Test Gauge: A pressure gauge designed for 5000 psi ‘Tachometer: A meter designed to measure engine RPM. Flowmeter: A meter designed to measure fluid flow.SYMPTOM PAGE NUMBER Section One - Engine Diagnostics Engine starter fails to operate (No Electrical) Starter disengages before engine starts Engine cranks over but will not start Engine starts then shuts down after 30 seconds Engine will not accelerate Engine over accelerates Engine will not start from ground control Engine will not start from platform control Engine starts while cranking, then dies when key switch is released Section Two - Hydraulic Diagnostics Hydraulic system functions on emergency power only Non-proportional hydraulic functions not operating under engine power Proportional hydraulic functions not operating under engine power Hydraulic pump stays on stroke Hydraulic oil overheats while idling Hydraulic oil overheats during operation Hydraulic functions are sluggish Hydraulic pump will not build pressure Hydraulic pump will not build enough pressure Flow from hydraulic pump is too low Flow from hydraulic pump is too high (kills engine) Section Three - Steering System Diagnostics Machine will not steer 10 10 4 14 1 12 12 13 39 39 39 39 40 40 40 41 4a a a1 53SYMPTOM PAGE NUMBER Section Four - Drive System Diagnostics Drive system is not operational with controller in either direction No forward drive (Reverse OK) No reverse drive (Forward Ok) High speed range allows only 1.5 mph Drive high range not operating Machine drives at full speed with platform raised andfor extended Brakes will nt release ‘Only one whee! turns (2 wheel drive) ‘One wheel turns faster than other (2 wheel drive) (Only two wheels turn (4 wheel drive) ‘Two wheels turn faster than other two (4 wheel drive) Section Five - Emergency Power System Diagnostics Emergency pump motor non-operational No proportional functions on hydraulic power No functions when on emergency power Section Six - Swing System Diagnostics ‘Swings only in one direction No response from swing when platform controls are activated No response from swing when ground controls are activated Will not swing from platform control, (Ground control is Ok) Will not swing from ground control, (Platform control is Ok) ‘Swings erratically in either direction ‘Swings faster one way than other Swings too slow ‘Swing brake will not hold 59 60 60 60 61 61 61 62 62 63 63 89 89 89 95 95 96 96 97 97 98 98SYMPTOM PAGE NUMBER Section Seven - Platform Rotation System Diagnostics Platform rotate does not operate 119 Platform rotates too fast 119 Platform rotates too slow 119 Platform rotates itself 120 Section Eight - Platform Leveling System Diagnostics Platform will not level as boom raises or lowers 127 Platform will not maintain level 127 No response when platform level switch is activated (Electrical Related) 127 No response when platform level switch is activated (Hydraulic Related) 128 Platform bleeds down 128 Platform level will not work from ground control 128 Platform level will not work from platform control 128 Platform level up function is inoperative 129 Platform level down function is inoperative 129 Section Nine - Boom Elevation System Diagnostics Boom raises but will not stay elevated 143 Boom will not raise from platform control 143 Boom will not raise from ground contro! 143 Boom raises slow from platform 144 Section Ten - Telescope System Diagnostics Boom will nt retract from ground control 153 Boom will not retract from platform control 153 Boom will nt extend from ground control 153 Boom will nt extend from platform control 154SYMPTOM PAGE NUMBER Section Eleven - Control Valve System Diagnostics Can not override 165 Section Twelve - Fuel System Diagnostics Engine will not start on gasoline, but will start on L.P. 169 Engine will not start on L.P., but will start on gasoline 169 Section Thirteen - Accessory Diagnostics AC Generator will not function 177 AC Generator has low voltage 177SECTION ONE: ENGINE DIAGNOSTICS, a AXRPVIFVIPVOVIVDIIAVVIIPIIMIIIAIIIIIIIIIYDSECTION ONE ENGINE DIAGNOSTICS Chart 1 Engine starter as 3 Inspect 9 te Page fails to operate Battery and Cable Connections ta (No Electrical) Step 2 = inapect PowerCasesand |_) Goto Page Battery Disconnect Switch * Sup = — inspect Ground Control he Goto Page Circuit Breaker (25 Amp) 18 | supé = inspect Goto Page Emergency Stop Switch [4 15 ses Inepect Got Page ‘Ground Master (Key) Switch [—*) 16 Step 6 z Tnapect Goto Page orton Est gen | | Bowen Sich 6 Step? ¢ Trapect ‘Ground/Platform Ky (Gaile Paw ‘Selector Switch 7 ten 6 = Inspect Goto Page Engine Ants Restart Relay 17 9 = Inspect Goto Page Engine Stor Rey | 4} 18 sep10 = ina Goto Page starter Seienog | 18 Troubleshooting Guide 9 TB 60, PRO 66SECTION ONE ENGINE DIAGNOSTICS Chart 2 Starter pet disengages before Engine AnteRestat Relay [>| CO1apae engine starts Chart 3 Engine cranks peat a ws to as over but Grouna master Key) Switcn |-—>} 20 will not start sep? z Inspect Got Pape Ground/Platform Selector Switch 20 * Sep z Trepect Goto Pape Ignition/Emergency Power Switch 21 * Step 4 ¢ Inspec Goto Page Run ty 21 Steps z Goto Page Murphy (ages) Swich and [of uae omen 2 Sip6 : ‘Murphy is ast) ‘Switch | om (Go te Page (Ford only) ccd Siep7 g Goto Pape Hot Stat Relay Ford ony) 3 * tep 8 = Inspec Goto Pape Engine Col trerdony) |} 3 step si Got Page ‘+1 nition mete Ferd ony) | >} me Troubleshooting Guide: 10 ‘TB 60, PRO 66,SECTION ONE ENGINE DIAGNOSTICS Chart 4 Engine starts Step 1 then shuts down Engine Temporaure Gauge oon after 30 seconds sep2 rome Gove Pave Engine Of PRES Sten Ss Chart 5 sep Engine will not Inspect Go to Page poerinily Tote Cell BAe (15 Ame) eo supe i cour. Medium Tivotle Relay 28 Step 3 s Inspect Gola Poe igh TENS Relay r supa inoect Goto Page Tote ASSES contoter a Step 5 = inspect Cote Pose homed, us Chart 6 sip Engine over Inspect Go to Page one Twotle AEBS contoter 29 sip2 insect Cote Page Raiser 8 Troubleshooting Guide Ww TB 60, PRO 66SECTION ONE ENGINE DIAGNOSTICS Chart 7 ne wi wot Engine will not = a start from ce 3 Cont f—+ Sete Page ground contel co Broker 25 Ane) Step 2 : Inspect Goto Page Emergency Stop Switch 30 Step 3 + Inspect af Goto Page Ground Master (Key) Switch [—~* uM Step 4 : Ins Go 10 P GrounsPtattors Selector Switch | —] on Step 5 ¥ Inspect Goto Page Ignion/émergency Power Switch _—4 32 Chart 8 i Step + Engine will not = ; a inspect 0 to Page start from GrounayPlattarm Selector Switch | —* 3 platform control step? = Piao Control [| GetaPage Circuit Breaker (25 Amp) a3 Step 3 £ Inspect Goto Page Emergency Stop Switzn > ue Sep 4 ¢ Ins Goto Page Foot Snitch ry 4 Step 5 = in |_ [Goto page Platform Stat Sitch 36 Sup 6 = Inspect Goto Page Igntionrémergency Power Switcn | —% 35 Troubleshooting Guide 12 TB 60, PRO 66SECTION ONE ENGINE DIAGNOSTICS Chart 9 Engine starts while cranking, then dies when key switch is released Inspect ‘Vacuum Sitch Troubleshooting Guide TB60, PRO 66SECTION ONE ENGINE DIAGNOSTICS Engine starter fails to operate (No Electrical) Recharge or replace battery(s) = ow rf vege Inspect Using a meter | sa. Batteries set to read ¥ voltage, check Check battery each battery for connections 12 volts while T undertoad | " . Clean all | Tighten all connections connections Step 1 Step 2 Inspect Power Cables and Using a meter set to read voltage, measure voltage entering Battery Disconnect Switch ‘Should read 12 volts 4 wpe Battery Disconnect Using a meter set to Switch in Off Tead voltage, turn Position Battery Disconnect Switch — to On position, measure Tren voltage coming out of + Battery Disconnect Switch Reset Battery Should read 12 volts Disconnect Switch | || _—________ toOnPosition | sy sooo reaang Repair orreplace | Battery Disconnect Switch and/or Gotostep3 le Battery Bicone Switeh Troubleshooting Guide 14 TB 60, PRO 66SECTION ONE ENGINE DIAGNOSTICS inspect Using @ meter set to read ~ Ground Control voltage, tum Battery - Circuit Breaker [——?} Disconnect Switch to (25 Amp) On position, ues measure voltage entering i Emergency Stop Switch Circuit breaker is Should read 12 pon ow off rena ee Check for voltage * between Reset Circuit 1, Battery Disconnect breaker 1 | Switch and Ammeter (+) ¥ av 2. Ammeter (-) and Circuit fe Breaker wire (1A) 3. Circuit Breaker wire (14) land Emergency Stop Switch Wow argo reading Repair or replace Circuit Breaker Goto step 4 andlor Circuit Breaker wiring Step 3 Step 4 Inspect Using a meter Emergency Stop |—+| set to read voltage, pull Switch Emergency Stop Switch T out and measure * voltage between Emergency Stop Emergency Stop Switch 7 Switch is off and Battery side of (pushed in) Ground Master 7 (Key) Switch, 7 ‘Should read 12 volts PullEmergency |" ‘Stop Switch (out) | "7° Wow or ra reading to the On position ——— - oo Replace Emergency Stop Switch and/or 7 Gomes Emergency Stop Switch wiring - Troubleshooting Guide 5 TB 60, PRO 66SECTION ONE ENGINE DIAGNOSTICS Step 5 Step 6 Inspect Ground Master (Key) Switch Using a meter set to read voltage, activate engine starter and measure voltage between Battery post side of Ground Master Switch and start side of Ground Goto step 6 : Master Switch 1277] Should read 12 volts Inspect Ignition/Emergency Power Switch T ower no reading Repair or replace Ground Master Switch and/or Ground Master Switch wiring Using a meter set to read voltage, activate engine starter and measure voltage between Ground Master Switch and Goto step 7 Ignition/Emergency Power | ‘Switch "|__ Should read 12 volts iow Fn e8dng 4 Replace Ignition/Emergency Power Switch and/or Ignition/Emergency Power Switch wiring Troubleshooting Guide 16 TB 60, PRO 66SECTION ONE ENGINE DIAGNOSTICS Step 7 Step 8 Inspect Ground/Platform |—»| Selector Switch ¥ Ground/Platform Selector Switch is in Platform position Set Selector Switch to Ground position. Using a meter set to read voltage, activate starter and measure voltage between Ignition/Emergency Power ‘Switch and Ground! Platform Selector Switch ‘Should read 12 volts Then ¥ Return Ground/ Platform Selector | ‘Switch to Ground | 1% Goto step 8 Replace Ground/Platform Selector ‘Switch and/or Ground/Platform Selector Switch wiring Inspect Engine Anti- | —+! Restart Relay Measure voltage atwire #5C. |_| Should read 12 [1 volts Wom ono resin Using a meter set to read voltage, activate engine starter and measure voltage between wire #5C and Anti-Restart Relay. Should read 12 volts tom ono reacing L Replace x Replace Engine Anti- Engine Anti- Restart Relay Restart Relay wiring Goto step 9 Troubleshooting Guide 7 TB 60, PRO 66SECTION ONE ENGINE DIAGNOSTICS Inspect Using a meter set to Engine Starter -—* read voltage, activate Relay ‘engine starter and measure voltage from 1, wire #58 to Starter : Relay 2. wire from Starter Relay to Ground Check ground |, y | continuity frwV~] Should read 12 vots T 1 7 i neconsy apes : Replace Replace contruiy| Engine Starter Engine Starter Relay Relay wiring Ll Gotostep 10 Step 9 - Step 10 : inspect Using a meter set to - Starter Solenoid read voltage, activate ty enaine starter and measure voltage from 1. wire #54 to Starter Solenoid 2, Starter Solenoid to 7 Ground u Check ground |, | continuity v7] Should read 12 volts Nocona, Ww mang : : Replace Replace Conmaty Starter Solenoid Starter Solenoid ne {4 Go back to step 1 Troubleshooting Guide 18 TB 60, PRO 66SECTION ONE ENGINE DIAGNOSTICS Starter disengages before engine starts Inspect Engine Anti- Restart Relay Open field in alternator I Disconnect battery wire from Alternator output terminal. Check continuity between post and alternator case. a ‘Adjust resistor for longer cranking time. (approx. 30 seconds) |_Seren Seer Locate the adjustable (Note a resistance reading means an internal grounding condition exists ‘and the alternator may be resistor between terminals 164# and 164B#, remove the plastic covering, While activating the starter, defective) slowly slide adjuster until ——\oaduniy «faking time is sufficient z for starting engine. Repair or replace Replace the plastic ‘Alternator covering Step1 Troubleshooting Guide 9 TB 60, PRO 66SECTION ONE ENGINE DIAGNOSTICS Engine cranks over but will not start Step 1 Step 2 Inspect Ground Master Goto step 2 av |—+ voltage, activate engine (Key) Switch Using a meter set to read starter and measure voltage between Battery post side of Ground Master Switch and ignition side of | Ground Master Switch. | Should read 12 volts Inspect Ground/Platform Selector Switch Ground/Platform Selector Switch isin Platform position roading ng 4 Repair or replace Ground Master Switch andor Ground Master Switch wiring Check Battery Set Selector Switch to Ground position. Using a meter set to read voltage, activate starter and measure voltage between Ignition/Emergency Power Switch and Ground/ Platform Selector Switch ‘Should read 12 volts Platform Selector ‘Switch to Ground Then No redng ; t Pe Return Ground? | "7" Replace “nm Ground/Platform Selector ‘Switch and/or position GroundiPlatform Selector Switch wiring Gotostep ‘Check Battery Troubleshooting Guide 20 B60, PROOS- SECTION ONE 7 ENGINE DIAGNOSTICS Inspect Using a meter set to lgnition! read voltage, Emergency Power measure voltage Switch entering Ignition! Emergency Power Switch [—]__ Should read 12 volts w tara Gotostepa fet ee ‘Check voltage on diode wire between Ignition! Replace Emergency Power Switch - Ignition’ and Ground/Platform Emergency Power Switch. Replace diode wire Dekeh unde if faulty. Measure voltage ignition’ entering Run Relay 3 Emergency Power (wire: #44) Se teea Should read 12 volts Step 3 Tien rn etn —— Step 4 Inspect Using a meter set to ‘ead voltage, measure voltage 41, at Murphy Switch wire #164, B post of ‘Murphy Switch 2. between wire #164 at Run Relay and Murphy Switch | (B Post) < Goto step 5 ‘12v-] Should read 12 volts Ittow ee ne reading Replace Ground/Platform Selector Switch and/or Ground/Platform Selector ‘Switch wiring ° Troubleshooting Guide 24 TB 60, PRO 66SECTION ONE ENGINE DIAGNOSTICS Inspect Murphy Magnetic ‘Switch and Engine Fuel Solenoid (Deutz only) Using a meter set to read voltage, measure voltage 4. of wire #8D between post NC of Murphy Magnetic Switch and Engine Fuel Solenoid — 2. at wire #8D of Engine Fuel Solenoid [_ Goto steps | Should read 12 volts sw or rang a Replace Murphy Magnetic Switch Switch andlor Murphy Magnetic Switch wiring and/or Engine Fuel Solenoid Step 5 Step 6 Using a meter set to read voltage, measure voltage 1. on wire between Inspect Murphy Magnetic, (Ford only) Murphy Magnetic, Ford engines with ‘Switch and Hot Start an Engine Coil Relay Gotostep7 |, _| 2. atHot Start Relay wire Ford engines with [" 1") (from Murphy Magnetic an Ignition Module Switch) Goto step 9 Should read 12 volts serstlpnnity + Replace Murphy Magnetic Switch Switch and/or Murphy Hot Start Relay wiring ‘Troubleshooting Guide 22 TB 60, PRO 66SECTION ONE ENGINE DIAGNOSTICS Step 7 Step7 Step 8 Inspect Hot Start Relay (Ford only) Goto step 8 13 Using a meter set to read voltage, measure voltage 41.0n wire #808 between Hot Start Relay and Engine Coil 2.at Engine Coil (wire #808 from Hot | Start Relay) Should read 12 volts Inspect Engine Coil (Ford only) | ttn oF acing Replace Hot Start Relay andlor Engine Coil wiring (from Hot Start Relay) Check for spark at spark plugs ee wre pan a Spark plugs are not receiving spark after inspections on Magnetic ‘Switch, Hot Start Relay and related wiring have been performed a Replace Engine Coil Troubleshooting Guide 23 TB 60, PRO 66SECTION ONE ENGINE DIAGNOSTICS Inspect Refer to Ford engine Ignition Module service manual available from your local Ford Dealer Step 9 Troubleshooting Guide 24 TB 60, PRO 66SECTION ONE ENGINE DIAGNOSTICS Engine starts then shuts down after 30 seconds Engine sone Temperature Check continuity on wire Gauge 4 between Murphy Switch (Black wire at S post) and Chassis ground L——__ Wresieanco\s shown ‘Allow time for Engine to cool down: Replace Murphy Engine ‘Temperature Gauge Step 1 Step 2 Inspect rene | USing 2 meter set to Engine Oil va eoaguts* read ohms, Pressure Switch Check continuity between Wire #3C and Ground wire " at Engine Oil Pressure + Switch Engine oil 1 pressure is due to he resistence shown inadequate oil level | resistance 4 CD — at Replace Then Engine Oil Pressure Switch Fillo proper level with oil Go back to step 1 Troubleshooting Guide 25 TB 60, PRO 66SECTION ONE ENGINE DIAGNOSTICS Engine Inspect Using meter set to read : Throttle Circuit voltage, measure voltage will not Breaker (15 Amp) Ford: entering either T Medium Throttle Relay accelerate * wire #55A or High Throttle Circuit breaker is Relay wire #55B open Deutz: on wire between T Medium Throttle Relay " and Actuator Module or >——*— ‘on wire between High Reset Circuit Throttle Relay and breaker Actuator Module Should read 12 volts iow of reg © Repair or replace Check continuity on wire Circuit Breaker #55 between Throttle ‘andior— lemmen-| Circuit Breaker and Circuit Breaker Medium Throttle Relay or ‘wiring High Throtle Relay Step 1 Step 2 Inspect Relay Gotostep3 fey} ‘Medium Throttle Using a meter set to read voltage, measure voltage Ford: on wire #55A to Throttle Controller Deutz: on wire #55 to Throttle Controller Should read 12 volts Wow orn0reaang Check continuity on wire between Medium Throttle Relay and Throttle Controller from Medium Throttle Relay to Throttle Controller Troubleshooting Guide TB 60, PRO 66SECTION ONE Using meter set to read voltage, measure voltage Ford: on wire #558 to Throttle Controller Deutz: on wire #55 to Throttle Controller Should read 12 volts ENGINE DIAGNOSTICS Inspect High Throttle Relay Goto step 4 . “| Step 3 Step 4 Inspect Throttle Actuator Controller Gotosteps lef-| T Itow oo reg z Check continuity on wire between High Throttle Relay and Throttle Controller Lene J ae Repair or replace wiring from High Throttle Relay to Throttle Controller Using a meter set to read voltage, measure voltage Ford: on wire #55A and +#55B going into the Electronic Governor Deutz: on red wire and on white wire going into the ‘Addco Module Should read 12 volts Wow oro easing Repair or replace Ford: wiring to Electronic Governor Deutz: wiring to ‘Addco Module Troubleshooting Guide 27 TB 60, PROGSECTION ONE ENGINE DIAGNOSTICS Using a meter set to Actuator read voltage, measure voltage Ford: on wire #A1 — and #A2 between the Repair or replace Electronic Governor Ford ‘and Actuator Electronic |, « _| Deutz: on wire between ‘Governor 1") the Addco Module and pak Addco Actuator Addco Module swatnate Repair or replace Ford: Electronic Governor and/or wiring Deutz: Addco Actuator and/or wiring Step 5 Troubleshooting Guide 28 TB 60, PRO 65SECTION ONE ENGINE DIAGNOSTICS Engine over accelerates Inspect Throttle Actuator Controller Using a meter set to read voltage, measure voltage Ford: on wire #55A and +#55B going into the Electronic Governor Goto step 2 —| Deutz: on red wire and on white wire going into the ‘Addco Module ‘Should read 12 volts r Wow orm reas ¢ Repair or replace Ford: wiring to Electronic Governor Deutz: wiring to ‘Addco Module Step 1 Step 2 r Inspect Using a meter set to Actuator read voltage, measure voltage Ford: on wire #A1 and #A2 between the Repel eene Electronic Governor Ganne | Deutz: on wire between nee the Addco Module and ‘Addco Module ‘Addo Actuator Repair or replace Ford: Electronic Governor and/or wiring Deutz: Addco Actuator | nd and/or wiring Troubleshooting Guide 29 TB 60, PRO 66