Snorkel TL49J Manual

PARTS & SERVICES
MANUAL
Serial Number TL49-01-008562 and after
Part Number 513868-200
June 2016
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TL49J
ENGLISH
When contacting Snorkel for service or parts information, be sure to include the model and serial
numbers from the equipment name plate. Should the name plate be missing, the serial number
is also stamped on top of the chassis above the front axle pivot.
MANUFACTURER
TANFIELD POWERED ACCESS LTD.
SNORKEL IS A TRADING DIVISION OF:
TANFIELD POWERED ACCESS LTD.
VIGO CENTRE, BIRTLEY ROAD,
WASHINGTON,
TYNE & WEAR, U.K.
T: +44 (0)845 1550 057
TYPE APPROVAL e11*2007/46*0879
VIN
Kg
TYPE
0-
Kg
VARIANT
1-
Kg
SER NR
MAX GROSS WT
MAX AXLE WT
YEAR
PART No: 508945-004
Snorkel,
Vigo Centre, Birtley Road,
Washington, Tyne & Wear,
NE38 9DA, U.K.
MODEL
NUMBER
SERIAL
NUMBER
MONTH / YEAR
OF MANUFACTURE
SLOPE SENSOR ALARM SETTING
NON-LOADED
MACHINE
WEIGHT
lbs
kg
ENGINE
POWERED
MODELS
hp
kW
MAXIMUM
OUTRIGGER
LOAD
lbs
kg
MAXIMUM
GRADEABILITY
%
Indoors
MAXIMUM
ALLOWABLE
MANUAL FORCE
(SIDE PULL)
Outdoors
lbs
N
MAXIMUM
PLATFORM
HEIGHT
ft
m
Indoors
Outdoors
RATED NUMBER
OF OCCUPANTS
FRONT
TO BACK
SIDE
deg
deg TO SIDE
MAXIMUM
WHEEL
LOAD
lbs
kg
BATTERY
POWERED
MODELS
DRIVE
MOTORS
V
V
Ah
BATTERIES
CHARGER
INPUT
V
MAXIMUM
ALLOWABLE
WIND SPEED
mph
m/s
MAXIMUM
PLATFORM
REACH
ft
m
MAXIMUM
DRIVE
HEIGHT
ft
m
MAXIMUM
PLATFORM
LOAD
ASSEMBLED IN
CAUTION
ONLY trained and authorised personnel may operate this machine.Consult the Operation Manual before using this machine.
DO NOT make any changes to this machine, any changes made will invalidate the manufactures warranty and
may contravene legislation.
Axle weights with machine in the stowed position.
lbs
STEER AXLE
kg
DRIVE AXLE
lbs
The serial number is stamped on the
chassis behind the toe hitch and above
the vehicle identification number plate.
kg
511039-300
USA
Europe
TEL: +1 (559)443 6600
FAX: +1 (559)268 2433
TEL: +44 (0) 1952 200
FAX: +44 (0) 1952 229
www.snorkellifts.com
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TL49J SERVICE AND PARTS MANUAL
FOREWORD
This manual is divided into six sections namely;
SECTION 1: INTRODUCTION
General description and machine specifications.
SECTION 2: OPERATION AND SPECIFICATION
Information on how to operate the work platform
and how to prepare it for operation.
SECTION 3: SERVICE AND REPAIR
Preventative maintenance and service information.
SECTION 4: TROUBLESHOOTING
Causes and solutions to typical problems.
SECTION 5: SCHEMATICS
Schematics and valve block diagrams with
description and location of components.
SECTION 6: ILLUSTRATED PARTS BREAKDOWN
Complete parts list with illustrations.
SPECIAL INFORMATION
! D A N G E R !
Indicates an imminently hazardous situation which if not avoided, will result in
death or serious injury.
! W A R N I N G !
Indicates a potentially hazardous situation which if not avoided, could
result in death or serious injury.
! C A U T I O N !
Indicates a potentially hazardous situation which if not avoided,
may result in minor or moderate injury.
NOTE: Provides helpful information.
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WORKSHOP PROCEDURES
All information contained in this manual is based on the latest product information available at the
time of printing. We reserve the right to make changes at any time without notice.
No part of this publication may be reproduced, stored in retrieval system or transmitted in any
form by any means whether electronic, mechanical, photocopying, recording or otherwise without the prior written permission of the publisher. This also includes text, figures and tables.
! C A U T I O N !
Detailed prescriptions of standard workshop procedures, safety
principles and service operations are not included.
Please note that this manual contains warnings and cautions
against some specific service methods which could cause personal
injury or could damage a machine or make it unsafe.
Please understand that these warnings cannot cover all conceivable
ways in which service, whether or not recommended by Snorkel,
might be carried out, or of the possible hazardous consequences of
each conceivable way, nor could snorkel investigate all such ways.
Anyone using service procedures or tools whether or not recommended by Snorkel must satisfy themselves thoroughly that neither
personal saftey nor machine safety will be jeopardized.
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INTRODUCTION
INTRODUCTION
PURPOSE
The purpose of this service and parts manual is to provide instructions and illustrations for
the operation and maintenance of this work platform manufactured by Snorkel.
SCOPE
The manual includes procedures for proper operation, specifications, service and repair of
this product as well as recommended maintenance schedules, troubleshooting, schematics
and illustrated parts breakdown.
GENERAL DESCRIPTION
The work platform consists of the platform, upper and lower controls, elevating assembly,
outriggers and a chassis.
! W A R N I N G !
DO NOT use the work platform without guardrails properly assembled and
in place.
Features of the TL49J is shown in Figure 1-1.
1.
2.
3.
4.
5.
6.
Platform
Upper controls
Elevating assembly
Lower controls
Outriggers
Chassis
2
3
1
4
6
5
Figure 1-1: Work platform
TL49J
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INTRODUCTION
PLATFORM
The platform consists of guardrails which prevents personnel from falling of the platform. The
guardrail system consists of the top rail, mid rail, lock rail strap and toeboards around the sides
of the platform.
UPPER & LOWER CONTROLS
These are controls located on the chassis and platform and used to operate the machine. A
complete explanation of control functions can be found in section 2.
ELEVATING ASSEMBLY
The platform is raised and lowered by the elevating assembly. The hydraulic pump driven by
the engine, powers the 3 - stage lift cylinders.
CHASSIS
The chassis is a structural frame that supports all the components of the TL49J work platform.
PURPOSE OF EQUIPMENT
The objective of the work platform is to provide a quickly deployable, variable height work
platform to elevate personnel and materials to overhead work areas.
SPECIAL LIMITATIONS
Elevating of the work platform is limited to firm, even surfaces only.
! D A N G E R
!
The elevating function shall ONLY be used when the work platform is level and on a
a firm surface.
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TL49J
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OPERATION AND SPECIFICATION
TL49J
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SAFETY RULES
WARNING
All personnel shall carefully read, understand and follow all safety rules and operating instructions before operating or
performing maintenance on any SNORKEL aerial work platform.
E L E C T R O C U T I O N TIP OVER HAZARD COLLISION HAZARD
HAZARD
THIS MACHINE IS NOT
INSULATED
NEVER ELEVATE THE
PLATFORM OR DRIVE
THE MACHINE WHILE
ELEVATED UNLESS THE
MACHINE IS ON A FIRM
LEVEL SURFACE
NEVER POSITION THE
PLATFORM WITHOUT
FIRST CHECKING
FOR OVERHEAD
OBSTRUCTIONS OR
OTHER HAZARDS
FALL HAZARD
NEVER CLIMB, STAND
OR SIT ON PLATFORM
GUARDRAILS OR MID
RAIL
TRAPPING/CRUSHING
HAZARD
BEWARE OF CRUSHING
HAZARD WHEN HOLDING
HANDRAILS WHILE THE
PLATFORM IS MOVING
IN CLOSE PROXIMITY TO
OTHER OBJECTS
USE OF THE AERIAL WORK PLATFORM: This aerial work platform is intended to lift a person or persons and their tools including material needed for a job. The work platform is designed to be used for repair and assembly jobs ONLY at overhead work
places (ceilings, cranes, roof structures, buildings, etc.).
The use and operation of the aerial work platform as a lifting tool or a crane is prohibited!
Climbing up the railing of the platform, standing on or stepping from the platform unto buildings, steel or prefab concrete structures
etc is prohibited!
NEVER use the machine if damaged, not functioning properly, has damaged or missing decals.
NEVER attach notice boards etc. to the platform as this will increase the wind loading.
INSULATION: The aerial work platform is not insulated. It is imperative to keep a safe distance from live parts or electrical
equipment. DO NOT get closer than the minimum distance recommended by the “National Regulations”.
PLATFORM CAPACITY: Exceeding the specified permissible maximum load is prohibited! Refer to platform capacity on page 24
for details.
MANUAL FORCE: NEVER exceed the manual force allowed for this machine. Refer to special limitations on page 9 for details.
LOAD DISTRIBUTION: Ensure that all loads are distributed evenly on the platform.
SURVEILLANCE: NEVER operate the machine without first surveying the work area for surface hazards such as holes, drop-offs,
bumps, curbs or debris and avoiding them.
WHEEL LOAD: OPERATE the machine only on surfaces capable of supporting wheel load.
WIND SPEED: NEVER operate the machine when the wind speed exceeds the machine’s wind speed rating. Refer to the Beaufort
scale for details.
EMERGENCY STOP: In case of an emergency, push the EMERGENCY STOP switch to de-activate all powered functions.
ALARM: If the alarm sounds while the platform is elevated, STOP operation immediately and carefully lower the platform. Move the
machine to a firm, level surface.
SWING GATE: Dismantling the entry gate or other railing components is prohibited! Always make certain that the entry gate is
closed and securely locked.
It is prohibited to keep the entry gate in an open position when the platform is raised.
Extending the height of the platform by placing ladders, scaffolds or similar devices on the platform is prohibited!
SERVICING: NEVER perform service on machine while platform is elevated without blocking the elevating assembly. Refer to
“maintenance” for details.
INSPECT: the machine thoroughly for cracked welds, loose or missing hardware, hydraulic leaks, loose wire connections and
damaged cables or hoses before usage.
DECALS: VERIFY that all labels are in place and legible before using the machine.
BATTERIES: NEVER charge batteries near sparks or open flame. Charging batteries emit explosive hydrogen gas.
STORAGE: AFTER USE, secure the work platform from unauthorised use by turning the key switch off and removing the key.
HARNESS: Harness attachment points are provided on the platform and the manufacturer recommends the usage of a fall restraint
harness especially where required by national safety regulations.
Modifications to the aerial work platform are prohibited or permissible only at the approval of the manufacturer.
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SAFETY NOTICE
Harness attachment points are provided in the platform and the manufacturer recommends the usage of a fall
restraint harness, especially where required by national safety regulations.
All harness attachment points on SNORKEL vehicles have been tested with a force of 3,650 lbs (16.3 KN)
per person.
See below examples of harness attachment points used on SNORKEL vehicles with their corrosponding rating;
Harness attachment point Type 1. is rated for one
lanyard attachment per loop as shown in the
illustrations depending upon platform occupancy rating
(see operators manual & decals).
Type 1.
Top View
Top View
2 lanyard
attachments
1 lanyard
attachment
Harness attachment point Type 2. is rated for two
lanyard attachments per loop as shown in the
illustrations depending upon platform occupancy rating
(see operators manual & decals).
Type 2.
Top View
Top View
2 lanyard
attachments
1 lanyard
attachment
Harness attachment point Type 3. is rated for one
lanyard attachment per loop as shown in the
illustrations depending upon platform occupancy rating
(see operators manual & decals).
Front View
1 lanyard
attachment
Type 3.
Harness attachment point Type 4. is rated for one
lanyard attachment per loop as shown in the
illustrations depending upon platform occupancy rating
(see operators manual & decals).
1 lanyard
attachment
Type 4.
NOTE: There can be more harness attachment points per machine than the
maximum number of occupants allowed in a platform. Refer to
the platform decal & specifications table listed in the operators
manual for the correct occupancy rating before use.
TL49J
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SAFETY NOTICE
NOTE:
1. To bypass any safety equipment is prohibited and presents a danger for the person/persons on
the aerial work platform and in its working range.
2. Modification to the aerial work platform is prohibited or permissible only at the approval of Snorkel.
3. The driving of MEWP’S on the public highway is subject to national traffic regulations.
4. It is important to ensure that the machine meets the requirements of stability during use, transportation, assembly, dismantling when out of service, testing or foreseeable breakdowns.
5. Never use a machine that is damaged or not functioning properly. Verify that all labels are in
place and legible before using.
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TL49J
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TL49J
Model
Modell
Modele
Modelo
Modello
Verticaal model
Malli
Serial number
Matricola
Sarajanumero
Serienummer
Numero de serie
Matricola
Holder of Technical File
Inhaber des technischen Dossiers
Titulaire du dossier technique
Titular del expediente técnico
Houder van een technisch dossier
Innehavaren av technichal fil
Voer tekst in om hier te vertalen
Haltija technichal tiedosto
Titolare del fascicolo technichal
Innehaveren av technichal fil
TL49J
TL49J-01-008577
Snorkel
Vigo centre
Washington
Tyne and Wear
NE38 9DA
England
Manufacturer
Hersteller
Fabrikant
Produsent
Tillverkare
Valmistaja
Fabbricante
Fabricante
Fabricant
Snorkel
Vigo Centre, Washington
Tyne and Wear, England , NE38 9DA
TEL:+44(0)845 1557 755
FAX:+44(0)845 1557 756
Authorized Representative
Autorisierte Vertretung
Representant autorise
Representante autorizado
Mandatario
Erkend vertegenwoordiger
Auktoriserad representant
Autorisert representant
Represenentant
Valtuutettu edustaja
Signed for Snorkel
Jan-16
Manufacturing Quality Manager
EC Declaration of Conformity of Machinery 2006/42/EC
EC-Konformitätserklärung für Maschinen 2006/42/EC
Declaration De Conformite CE pour les Machines 2006/42/EC
Declaracion De Conformidad CE Para Maquinaria 2006/42/EC
Dichiarazione Di Conformità CE Per Le Macchine 2006/42/EC
CE Conformiteitsverklaring voor Machinerie 2006/42/EC
EU Deklaration Avseende Överensstammelse För Maskinutrustning
2006/42/EC
EF-Samsvarserklaering For Maskiner 2006/42/EC
EF-Overensstemmelseserklaering for Maskiner 2006/42/EC
EU Vaatimustenmukaisuusvakuutus 2006/42/EC
Date
Page 2 - 5
Datum
Fecha
Data
Dato
Paivamaara
Stuart Campbell (Design Manager)
Vigo Centre, Washington
Tyne and Wear, England
Tel: +44 (0) 845 1557 755
FAX: +44 (0) 845 1557 756
Description .....................................Aerial Work Platform
Bezeichnung ....................................Arbeitsbühne
Description .......................................Plate-forme elevatrice de personnel
Descripcion ......................................Platforma aerea de trabajo con motor
Descrizione ......................................Piattaforma di sollevamento motorizzata
Beschrijving .....................................Mechanisch aangedreven werkplatform
Beskrivning ......................................Höj-och sänkbar arbetsplattform
Beskrivelse ......................................Selvgående arbetsplattform
Beskrivelse ......................................Motordrevet lofteplatform
Kuvaus .............................................Konevoimalla toimiva nostolava
Selvgående personarbetslift
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CONTENTS
INTRODUCTION
2-7 TRANSPORTATION
SPECIAL LIMITATIONS
2-8
GENERAL DESCRIPTION
PLATFORM CAPACITY
MANUAL FORCE
BEAUFORT SCALE
PLATFORM OVERLOAD ALARM
CONTROLS/PRE-OPERATION
PLATFORM CONTROLS
AND INDICATORS
CHASSIS CONTROLS
AND INDICATORS
PRE-OPERATION SAFETY
INSPECTION
OPERATOR’S MANUAL
ELECTRICAL SYSTEM
BATTERY TERMINALS
BATTERY FLUID LEVEL
SAFETY SWITCHES
BATTERY CHARGER
DAMAGED OR LOOSE FITTINGS
WHEELS
CABLE AND WIRING HARNESS
HYDRAULIC SYSTEM
FLUID LEVEL
HOSES, TUBES AND FITTINGS
LOWER CONTROL STATION
OPERATING CONTROLS
EMERGENCY SLEW
EMERGENCY LOWERING VALVES
EMERGENCY STOP
EMERGENCY LOWERING SWITCH
EMERGENCY HAND PUMP
STRUCTURES
WELDMENTS
FASTENERS
UPPER CONTROL STATION
GUARDRAIL SYSTEM
EMERGENCY LOWERING SWITCH
EMERGENCY STOP
2-7
2-8
2-8
2-8
2-9
2-31
2-32
2-10 WASTE REMOVAL AND DISPOSAL
2-34
2-11
2-11
2-11
2-12
2-12
2-12
2-13
2-13
2-13
2-13
2-14
2-14
2-15
2-15
2-15
2-16
2-16
2-16
2-16
2-16
2-17
2-17
2-17
2-17
2-17
2-18
2-18
EMERGENCY PROCEDURE
2-22
Page 2 - 6
2-25
2-25
2-26
2-26
2-27
2-28
SCHEDULE
2-10 SPECIFICATIONS
2-19
EMERGENCY SLEW
EMERGENCY LOWERING VALVES
EMERGENCY LOWERING
HANDPUMPS
EMERGENCY LOWERING SWITCH
PLATFORM OVERLOAD SWITCH
2-25
INSPECTION AND MAINTENANCE
2-30
2-10 DAILY PREVENTATIVE MAINTENANCE
OPERATION
PREPARING FOR OPERATION
LOWER CONTROLS
UPPER CONTROLS
PLATFORM
SIDE TRAY COVERS
STOWING
TRANSPORTATION
SECURING FOR TRANSPORT
HOISTING
TOWING
FRICTION DRIVE ASSIST PACKAGE
2-19
2-19
2-20
2-21
2-21
2-22
2-22
2-23
2-23
2-24
TL49J
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INTRODUCTION
INTRODUCTION
This manual covers the operation of the TL49J work platform. This manual must be stored on the
machine at all times.
GENERAL DESCRIPTION
Boom structure
Upper Controls
Platform
Lower/Ground
Controls
Toeboards
Outriggers
Wheels
Emergency
Lowering Valve
Identification
Number Plate
Right Side
Emergency
Hand Pump
Manual
Holder
Chassis
Jockey Wheel
Battery
Disconnect
Plug
Safety Harness
Attachment
Point
Rear
Lights
Left Side
Figure 2-1: Work platform
TL49J
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SPECIAL LIMITATIONS
SPECIAL LIMITATIONS
Elevating the work platform is limited to firm surfaces only. The aerial platform can tip over if it
becomes unstable.
! D A N G E R !
The elevating function shall ONLY be used when the work platform is
levelled and on a firm surface.
PLATFORM CAPACITY
The platform capacity for the machine including occupants is determined by model and options.
This is listed under “specifications” on page 2-32.
! D A N G E R !
DO NOT exceed the maximum platform capacity or the platform occupancy
limits for this machine.
MANUAL FORCE
Manual force is the force applied by the occupants to objects such as walls or other structures outside the work platform.The maximum allowable manual force is limited to 200N (45 lbs.) of force
per occupant with a maximum of 400N (90 lbs.) for two or more occupants.
! D A N G E R !
DO NOT exceed the maximum amount of manual force for this machine.
BEAUFORT SCALE
Beaufort
Scale
m/Sec
3
3.5-5
Ground Conditions
4
6-8
5
9-10
6
11-13
7
14-17
Whole trees in motion; inconvenience felt when walking against wind.
8
18-21
Breaks twigs off trees; generally impedes progress.
9
22-24
Slight structural damage occurs (chimney pots and slates removed)
Raises dust and loose paper; small branches are moved
Small trees in leaf begin to sway; crested wavelets on inland waterways.
.
Table 2-1: Beaufort scale
Never operate the machine when wind speed exceeds 12.5 m/s (28 mph) as indicated on the
Beaufort scale 6.
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SPECIAL LIMITATIONS
PLATFORM OVERLOAD ALARM
If a load greater than 100% of safe working load is lifted, the overload alarm on the platform will
sound. All machine functions will cease to operate.
To operate the machine, a load equal to or less than the safe working load must be placed on
the platform. To re-start the machine functions, the excess load must be first removed to stop the
alarm from sounding.
! D A N G E R !
Never operate the machine with a platform load greater than the rated
capacity.
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CONTROLS/PRE-OPERATION
PLATFORM CONTROLS AND INDICATORS
1.
2.
3.
4.
Emergency lowering switch
Platform raise/lower button
Platform raise/lower lever
Emergency stop button
1
3
2
Platform
Level Up
Platform
Rotate Anticlockwise
Raise
Dropnose
Retract Tele
Boom
Raise Top
Boom
Platform
Level Down
Platform
Rotate
Clockwise
Lower
Dropnose
Extend Tele
Boom
Lower Top
Boom
Slew
Anti-clockwise
Raise Lower
Boom
Slew
Clockwise
Lower Lower
Boom
4
Figure 2-2: Platform controls and indicator locations
CHASSIS CONTROLS AND INDICATORS
1. Emergency stop button
2. Upper controls
3. OFF position
4. Lower controls
5. Emergency lowering switch
6. Control select/Ground operation switch
7. Outrigger LED display
8. Outrigger raise/lower enable button
9. Platform raise/lower enable button
10. Outrigger raise/lower levers
11. Platform raise/lower levers
1
5
2
3
11
7
4
10
6
8
9
Raise
Dropnose
Retract Tele
Boom
Lower
Dropnose
Extend Tele
Boom
Raise Top
Boom
Lower Top
Boom
Slew
Anti-clockwise
Raise Lower
Boom
Slew
Clockwise
Lower Lower
Boom
Figure 2-3: Chassis controls and indicator
locations
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CONTROLS/PRE-OPERATION
PRE-OPERATION SAFETY INSPECTION
Perform a pre start 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.
! W A R N I N G !
DO NOT operate the aerial platform if it is damaged or malfunctioning
OPERATOR’S MANUAL
The manual holder is located underneath the platform controls on the platform (refer to Figure 2-4).
Manual Holder
Figure 2-4 – Operator’s Manual Holder
To inspect the operator’s manual and manual holder:
1. Make certain the Operator’s Manual holder is securely fastened in place.
2. Check to see that the proper Operator’s Manual is in the holder.
3. Check to see that the manual is complete with all pages intact and in readable condition.
ELECTRICAL SYSTEM
Electrical power is supplied from four, 6 volt batteries. The batteries supply 24 volt DC electrical power
to operate the aerial platform control system. The battery tray is located on the left side of the aerial
platform.
! W A R N I N G !
DO NOT not smoke or permit open flames or sparks when checking the
batteries.
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CONTROLS/PRE-OPERATION
! C A UT I O N !
Electric shock or component damage may result from contact with energised conductors.
Use caution when working with any electrical device.
For optimal battery performance, the battery fluid level must be maintained and the battery connections
must be kept clean.
BATTERY TERMINALS
To inspect the battery terminals:
1. Check the top of the battery, the terminals and cable ends (refer to Figure 2-5). They should be
clean and free of corrosion.
2. If necessary, clean the top of the battery. Clean the terminals and cable ends with a wire brush
or terminal cleaning tool.
3. Make sure all cable ends are securely fastened to the terminals.
BATTERY FLUID LEVEL
To inspect the battery fluid level:
1. Remove the caps from the batteries (refer to Figure 2-5).
Terminals
Caps
Caps
Terminals
Figure 2-5 – Battery tray
2. Visually check the battery fluid level making sure the level is ¼″ (6 mm) above the plates.
3. If necessary, add distilled water.
Note
Use only distilled water when refilling the battery. Tap water may contain metallic solids such as iron
which can reduce the life of the battery.
4. Replace the caps on the battery. The caps must be in place and tight during machine operation
and battery charging.
SAFETY SWITCHES
To inspect the safety switches:
1. Visually check that the platform overload switch is free from damage.
2. Check all limit switch arms are fee from damage and move easily.
3. Check to make sure the platform does not extend when outriggers are raised.
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CONTROLS/PRE-OPERATION
4. Check to make sure outrigger controls do not work when the outriggers are deployed under
load and the top or bottom boom is raised approximately 2” (50 mm).
BATTERY CHARGER
Inspect the battery charger (refer to Figure 2-6) to ensure that it is operating properly.
1. Plug the charger into a source of power.
2. Observe the LED’s on the charger to determine the charger status. If necessary, refer to the
charger decal or to the battery charge indicator in chapter 5 to determine when the batteries are
fully charged.
Figure 2-6 – LED Charge Indicator
3.
Unplug the charger
DAMAGED OR LOOSE FITTINGS
Visually inspect the machine for signs of wear and tear, damage, loose or missing parts.
WHEELS
Check tyres are at the correct pressure of 76 psi(5.25 bar) and that the wheel nuts are tightened
using the correct torque settings 147.5 ft lbs(200 Nm).
CABLES AND WIRING HARNESS
To inspect the cables and wiring harness:
1. Visually inspect all cables and wiring for wear and/or physical damage such as loose connections,
broken wires, and frayed insulation.
2. Check the wiring in areas where a change in routing direction may cause them to become pinched.
3. Make sure the cables and wires are properly routed to avoid sharp edges, pinching, and scuffing.
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CONTROLS/PRE-OPERATION
HYDRAULIC SYSTEM
Hydraulic power is supplied from three stage hydraulic pumps.
! D A N G E R !
Hydraulic fluid escaping under pressure can have enough force to inject fluid into the
flesh. Serious infection or reaction will result if medical treatment is not given
immediatley. In the event of injury from escaping hydraulic fluid, seek medical
attention at once.
The hydraulic reservoir, pump, and filter are located in the hydraulic tray on the left side of the chassis.
Open the cover to inspect the hydraulic components.
FLUID LEVEL
To inspect the fluid level:
1. Make sure the aerial platform is fully stowed on a level surface. Open the hydraulic tray cover and
visually check the fluid level using the hydraulic level indicator attached to the hydraulic tank (refer
to Figure 2-7). Some machines may have a fill cap with a dipstick. The fluid must be visible on the
dipstick.
Hydraulic Tank
Hydraulic Level
Figure 2-7 – Hydraulic Tank
!
C A U T I O N
!
Not all hydraulic fluid is suitable to use in the hydraulic system. Some have poor lubricating characteristics and may increase component wear.
Only use hydraulic fluid as
recommended.
2. If necessary, add fluid of the proper type.
Note
Refer to specifications on page 2-32 for the proper type and grade of hydraulic fluid to use. The need
to regularly add fluid indicates a leak that should be corrected.
3. Replace the cap making sure it is secured in place.
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CONTROLS/PRE-OPERATION
HOSES, TUBES AND FITTINGS
To inspect the hoses, tubes and fittings:
1. Inspect all hydraulic hoses, tubes, and fittings for wear, leakage, or damage.
2. Make sure the hoses are properly routed to avoid sharp edges, kinking, and scuffing.
3. Inspect the tubes for dents or other damage that may restrict fluid flow.
4. Make sure all hoses and tubes are held firmly in their support brackets.
5. Check under the chassis for fluid that has leaked. Hydraulic fluid leaks are easily visible on the
ground.
LOWER CONTROL STATION
With no personnel or materials on the platform, test the operation of each control from the lower
controls (refer to Figure 2-8)
Emergency
Stop Button
Upper
Controls
Emergency
Lower Switch
Lower
Controls
Outrigger LED
Lights
Platform Raise/
Lower Button
Off
Control Select/
Ground Operation
Switch
Outrigger Raise/
Lower Button
Figure 2-8 – Lower Control Station
OPERATING CONTROLS
Use the following procedure to operate and test the machine from the lower controls:
1. Plug the battery disconnect (refer to Figure 2-9).
2. At the lower controls, twist and pull the emergency stop switch outwards to the ON position.
3. Turn the control select switch to lower controls (turn to the right).
Figure 2-9 – Battery Disconnect
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CONTROLS/PRE-OPERATION
! W A R N I N G !
The potential for an accident increases when operating an aerial platform that is damaged or maifunctioning. Death or serious injury could
result from such accidents. Do not operate the aerial platform if it is
damaged or malfunctioning.
1. Pressing down on the platform raise/lower button, test the operation of the platform raise/lower
levers in both directions.
2. Unplug the battery disconnect. The platform should not raise or lower with the disconnect in this
position.
EMERGENCY SLEW
Use the following procedure to test the emergency lowering.
With the top and bottom booms each raised approximately 20”(500 mm) and the unit switched off,
check:
•
The emergency slew can be operated using a 17mm socket or spanner together with a lever.
EMERGENCY LOWERING VALVES
Use the following procedure to test the emergency lowering.
With the top and bottom booms each raised approximately 20”(500 mm) and the unit switched off,
check:
•
The emergency lowering valves located on the lift cylinders lower the boom when pushed in a
slow and controlled manner and the boom movement is stopped on releasing the valve.
EMERGENCY STOP
To test the emergency stop button from the lower controls:
1. Push the emergency stop button inward to turn off electrical power.
2. Test the lower control functions to make sure they do not operate with the emergency stop in this
position.
EMERGENCY LOWERING SWITCH
To test the Emergency Lowering Switch from the lower controls:
Note
The emergency lowering switch relies on the electrical system. The switch will not function if the electrical system is faulty.
• Turn the switch clockwise to lower the top boom.
• Turn the switch anti-clockwise to lower the lower boom.
• Check that the Emergency Lowering Switch does not work with the battery disconnect plug unplugged.
EMERGENCY HAND PUMP
With the outriggers down, under load, the machine level with the wheels clear of the ground, turn the
control select switch to the lower controls (turn switch to the right).
• Insert the hand pump lever into the pump shaft.
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CONTROLS/PRE-OPERATION
• Move the platform raise/lower levers to the required direction of movement and operate the hand
pump.
• Continue pressing down on the platform raise/lower lever when the machine starts to lower.
Platform Raise/
Lower Levers
Hand Pump(Rest Hold)
Figure 2-10 – Emergency hand pump operation
STRUCTURES
Visually inspect all weldments and related components. It is important to inspect the fasteners that
connect the components.
WELDMENTS
To inspect weldments:
1. Visually inspect all weldments for abnormal wear, abrasion or deformation that could cause
interference between moving parts.
2. Inspect the welds on the structural components. The area to be inspected should be clean and
free of dirt and grease.
3. Look for visible cracks in the welds and at the weld to parent material joints. A bright light may
be used to provide adequate visibility of the inspection area.
4. Pay close attention to welds in areas where changes in cross section takes place near the attachment points of highly loaded components.
FASTENERS
To inspect the fasteners:
1. Visually inspect all fasteners to see that none are missing or loose.
2. Inspect all of the bolts, nuts, rollpins, collars, and snap rings. They should all be present, tight, and
not damaged in any way.
UPPER CONTROL STATION
Inspect the platform and upper controls only if all functions operated properly from the lower controls.
GUARDRAIL SYSTEM
The guardrail system includes (refer to Figure 2-11):
y
y
y
y
A top rail
A mid rail
Drop bar
Toeboards around the sides of the platform
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CONTROLS/PRE-OPERATION
Top Rail
Mid Rail
Drop bar
Toeboard
Figure 2-11 – Guardrail System
The lock rail allows for access to the platform. The lock rail must be securely closed except when
personnel are entering or leaving the platform.
To inspect the guardrail system:
1. Visually inspect all components of the guardrail system. Make sure the rails and toeboards are all
in place and free of any damage or deformation.
2. Visually check the rail and toeboard welds for cracks.
3. Visually check all bolts and nuts fastening the platform and guardrails are in place. They must be
present and not show any signs of looseness.
4. Inspect the entry doors to see that they swing freely and are not deformed in any way. Make sure
the doors are secure when they are closed.
EMERGENCY LOWERING SWITCH
To test the Emergency Lowering Switch from the Upper controls:
Note
The emergency lowering switch relies on the electrical system. The switch will not function if the electrical system is faulty.
• Turn the switch clockwise to lower the top boom.
• Turn the switch anti-clockwise to lower the lower boom.
• Check that the Emergency Lowering Switch does not work with the battery disconnect plug unplugged.
EMERGENCY STOP
To test the emergency stop button from the upper controls:
1. Push the emergency stop button inward to turn off electrical power.
2. Test the upper control functions to make sure they do not operate with the emergency stop in
this position.
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OPERATION
The aerial platform may be operated from either the lower or upper controls.
The platform rated work load is the total weight of the personnel and equipment that may be lifted in
the platform. The work loads are stated on the platform rating placard at the entrance to the platform.
! D A N G E R !
The aerial platform can tip over if it becomes unstable. Death or serious injury will
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 but 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.
PREPARING FOR OPERATION
Use the following procedure to prepare the aerial platform for operation:
1. Perform a prestart inspection.
2. Connect the battery disconnect plug.
3. Close and latch the swing-out tray cover.
LOWER CONTROLS
The lower controls may be used for initial set up of the aerial platform and for testing and inspection.
The lower controls can also be used to raise and lower both the outriggers and platform.
Use the following procedure to raise or lower the platform using the lower controls.
1. Twist and pull the emergency stop button outward (refer to Figure 2-12).
1
5
2
3
7
11
4
10
6
8
9
Figure 2-12 – Lower Control Station
1
2
3
4
5
6
TL49J
Emergency Stop
Button
Upper Controls
Off Position
Lower Controls
Emergency
Lowering Switch
Control Select/
Ground Operation Switch
7
Outrigger LED Display
8
9
10
11
Outrigger Raise/Lower Button
Platform Raise/Lower Button
Outrigger Raise/Lower Levers
Platform Raise/Lower Levers
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OPERATION
2. Hold down on the platform raise/lower button.
3. Still holding the platform raise/lower button down, use the platform raise/lower control levers to
raise/lower the platform.
4. Release either button to stop movement.
Use the following procedure to raise or lower the outriggers using the lower controls.
1. Hold down on the outrigger raise/lower button (refer to Figure 2-12).
2. Still holding the outrigger raise/lower button down, use the outrigger raise/lower levers to raise/
lower the outriggers.
3. An alarm sounds as the outriggers lower or raise.
UPPER CONTROLS
The upper controls may be used for driving and positioning the aerial platform while on the job.
Before operating the upper controls, properly set up the aerial platform as described under Pre - operation.
Use the following procedure to operate the aerial platform from the upper controls:
1. From the lower controls, twist and pull the emergency stop button outward (refer to Figure 2-12).
2. Switch the control select/ground operation switch to the upper controls position.
Note
The upper controls will not operate while the control selector is in the lower position.
3. Enter the platform and secure the lock rail.
4. From the upper controls, twist and pull the emergency stop button outward (refer to Figure 2-13).
Platform Overload Switch
Emergency Lowering
Switch
Platform Raise/
Lower Levers
Platform Raise/
Lower Button
Emergency
Stop Button
Figure 2-13 – Upper Controls
5. The aerial platform may be driven and the platform may be raised and lowered from the upper
controls.
6. Hold down on the platform raise lower button.
7. Still holding the platform raise/lower button down, use the platform raise/lower levers to raise/
lower the platform.
8. Release either the button or levers to stop movement.
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OPERATION
Platform
Level Up
Platform
Rotate Anticlockwise
Raise
Dropnose
Retract Tele
Boom
Raise Top
Boom
Platform
Level Down
Platform
Rotate
Clockwise
Lower
Dropnose
Extend Tele
Boom
Lower Top
Boom
Slew
Anti-clockwise
Raise Lower
Boom
Slew
Clockwise
Lower Lower
Boom
Figure 2-14 – Upper Controls Raise/Lower Levers
PLATFORM
Use care when entering and exiting the platform to avoid slipping and/or falling. Securely close the lock
rail when the platform is occupied.
SIDE TRAY COVERS
Batteries and hydraulic components are enclosed in trays covered by a swing out cover (refer to Figure
2-15) on each side of the chassis.
Side Tray Covers
Latch
Figure 2-15 – Side Tray cover
y
The battery tray is on the left side and contains four batteries.
y
The right side of the chassis contains the battery charge indicator. The diagnostic center LCD display
is also on this tray.
y
The hydraulic tray on the right side of the chassis contains the hydraulic pump, reservoir and fluid filter.
y
To open the tray, pull upward on the latch (step 1) and open the cover (step 2)(refer to Figure 15).
y
The latched tray cover must be opened first to enable access to the battery tray.
y
When closing the tray cover, reverse the process to lock it in place.
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EMERGENCY PROCEDURE
The aerial platform may be lowered using the emergency lowering slew, hand pump or switch.
Use the following procedure to operate the emergency lowering system.
1. Immediately push the emergency stop button inward to disable the control system in the event of
an emergency.
2. Locate the emergency lowering control.
3. Make sure there is nothing in the way to obstruct the platform when it lowers.
4. Stand clear of the boom structure.
EMERGENCY SLEW
A 17 mm socket together with a lever or spanner may be used to move the platform if there is a
malfunction in the hydraulic or electrical system.
In the event of a failure, the machine can be manually slewed by moving the slew platform clockwise or anticlockwise by inserting the slew lever and rotating the gearbox by moving upwards and
downwards.
Slew Lever Insert
Figure 2-16 – Slew Lever Insert
EMERGENCY LOWERING VALVES
In the event of a power failure, the emergency lower valve on the ram can be used to lower the
booms.
This process involves assistance from the ground.
• Operate the lower ram valve first because it is closer to the ground
• Press on the lowering valve button to initiate lowering and facilitate access to the top ram valve.
Note
Each emergency ram valve will automatically close when the button is released.
Figure 2-17 – Emergency Valve Location
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Courtesy of Crane.Market
EMERGENCY PROCEDURE
! DANGER !
If the emergency lower is used due to a machine defect, do not use the machine.
Contact your local Snorkel representative.
! W A R N I N G !
If the emergency lower is used, the top and bottom booms must be fully
extended then fully lowered before work can continue.
After emergency lowering, any further powered lowering could cause an
airlock in the hydraulic system. This could cause the hydraulic operation
to fail.
All booms must be fully extended/raised, then lowered before work can
recommence.
EMERGENCY LOWERING HAND PUMP
The emergency hand pump lowering procedure is available from the lower control station. In the
event of a power failure, the hand pump procedure to use is as follows:
• Insert the hand pump lever into the pump shaft (refer to Figure 2-18).
• Move the platform raise/lower lever to the required direction of movement and operate the hand
pump.
• Continue pressing down on the platform raise/lower lever when the machine starts to lower.
Platform Raise/
Lower Levers
Hand Pump(Rest Hold)
Figure 18 – Hand Pump Emergency Lowering Procedure
EMERGENCY LOWERING SWITCH
The Emergency lowering switch can be used to lower the platform from the lower controls in situations where the boom levers malfunction (refer to Figure 2-19).
Note
The emergency lowering switch relies on the electrical system. The switch will not function if the electrical system is faulty.
• Turn the switch clockwise to lower the top boom.
• Turn the switch anti-clockwise to lower the lower boom.
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EMERGENCY PROCEDURE
• Releasing the switch will stop the lowering procedure.
Emergency
Stop Button
Upper
Controls
Emergency
Lower Switch
Lower
Controls
Off
Control Select/
Ground Operation
Switch
Outrigger LED
Lights
Platform Raise/
Lower Button
Outrigger Raise/
Lower Button
Figure 2-19 – Lower Control Station
PLATFORM OVERLOAD
In the event of the platform being overloaded, an audible alarm will sound and the platform controls will stop working.
To re-start the machine, the excess load must first be removed to stop the alarm from sounding.
In a situation where the excess load cannot be removed immediately then the platform overload
switch (refer to Figure 2-13) can be used to move the platform to a safe position so that the excess
load can be removed safely.
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TRANSPORTATION
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
Use the following procedure to properly stow the aerial platform.
1. Fully lower all the booms.
2. Engage the Transit Pins and lock in place using an ‘R’ clip (refer to Figure 2-20).
Lower Boom
Upper Boom
Figure 2-20 - Transport Pin Locations.
3. Set the platform keyswitch to ‘Ground’.
4. Raise the outriggers by simultaneously pressing down on the ‘Outrigger raise/lower button’
and using the appropriate control levers, two at a time until the road wheels are in contact with
the ground (refer to Figure 2-21).
Outrigger
Raise/Lower
Button
Boom Control
Outrigger
Control
Figure 2-21 – Outrigger Operation
5. Only when the road wheels are in contact with the ground should the unit be lowered further
until the jockey wheel makes contact with the supporting surface.
6. Fully raise the outriggers until they are in the stowed position.
7. Switch off the platform and ensure all loose items/covers are secure.
TRANSPORTATION
The aerial platform may be moved on a transport vehicle or towed. Depending on the particular situation,
the aerial platform may be lifted with a forklift, driven, winched, or hoisted onto a vehicle such as a truck.
The equipment used to load, unload, and transport the aerial platform must have adequate capacity.
The empty vehicle weight is listed in Chapter 2 and is stamped on the serial number placard.
The user assumes all responsibility for:
y
Choosing the proper method of transportation.
y
Choosing the proper selection and use of transportation and tie-down devices.
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TRANSPORTATION
y
Making sure the equipment used is capable of supporting the weight of the aerial platform.
y
Making sure all manufacturer’s instructions and warnings, regulations and safety rules of their employer and federal law are followed.
SECURING FOR TRANSPORT
Use the following procedure to secure the aerial platform on the transport vehicle.
1. Chock the wheels.
2. Remove all personell, tools, materials or other loose objects from the platform.
3. Properly stow the aerial platform.
4. Place the lower controls emergency stop switch in the off position.
5. Unplug the battery disconnect.
!
C A U T I O N
!
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.
6. Use chains or straps to securely fasten the aerial platform to the transport vehicle using the
front and rear tie-down lugs (refer to Figure 22) as attachment points. Proper tie-down and
hauling is the responsibility of the carrier.
Tie Down/Lifting Lugs
Chassis Front
Chassis Rear
Figure 2-22 – Tie Down Lug Locations
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 anywhere else.
! W A R N I N G !
The potential for an accident increases when the aerial platform is lifted
using improper equipment and/or lifting techniques. Death or serious
injury could 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.
y
Lifting devices include the hoist or crane, chains, straps, cables, hooks, sheaves, shackles, slings,
and other hardware used to support the machine.
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TRANSPORTATION
y
The empty vehicle weight is stamped on the serial number placard and is listed in specifications.
The user assumes all responsibility for:
y
Making sure the equipment used is capable of supporting the weight of the aerial platform.
y
Making sure all manufacturer’s instructions and warnings, regulations and safety rules of their employer and/or any state or federal law are followed.
Use the following procedure to hoist the aerial platform onto the transport vehicle:
1. Properly stow the aerial platform.
2. Inspect the front and the rear lifting lugs (refer to Figure 2-22) to make sure they are free of cracks
and are in good condition. There are two lugs on the front and rear of the chassis. Have any damage
repaired by a qualified service technician before attempting to hoist the machine.
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.
y
Cable damage and/or failure can result from the cable contacting the sharp corners of the lug.
y
There is no effective way of putting a corner protector in the hole of the lug.
5. Use spreader bars of sufficient length to keep the chains, straps, or cables from contacting the
structure or platform.
y
When using cables, use rigid corner protectors at any point where the cable contacts on sharp
corners to prevent damaging the cable.
y
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.
TOWING
Trailer mounted machines may be safely towed behind a vehicle at a speed set by state traffic
regulation or up to 50 mph (80 km/h), whichever is the lowest.
1. Before towing, check the capacity of the vehicle being used. Machine weight will increase if
optional extras are fitted.
2. Ensure that the road tyres and brakes are in good serviceable condition.
3. Ensure that all booms are fully lowered and both the transit pins are fitted through the loops
and secured with the “R” clip on the end of the chain.
4. Ensure that all outriggers are fully raised.
5. Use the jockey wheel to raise or lower the tow bar coupling to position the machine above the
50 mm ball hitch on the towing vehicle (refer to Figure 2-23).
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TRANSPORTATION
Tow Bar
Tow Bar
Coupling
Coupling
Breakaway
13 Pin
Cable
Light
HandHandBrake
brake
Plug in
Jockey
Wheel
Jockey
Wheel
Breakaway
Breakaway
Cable
Cable
Figure 2-23 - Illustration Of A Jockey Wheel.
1. Apply the handbrake.
2. Lower the tow bar coupling down onto the ball hitch using the jockey wheel.
3. Secure the breakaway cable, (Ensure correct engagement of 50 mm ball).
4. Fully raise the jockey wheel and lock in position.
5. Release the handbrake.
6. Plug in the trailer lights (13 pin) plug and check that both vehicle and trailer lights operate correctly.
FRICTION DRIVE ASSIST PACKAGE
The friction drive assist package is an option to have attached to the aerial platform. It allows for the
aerial platform to be moved over short distances with ease.
Use the following procedure to operate the friction drive:
1. Ensure that the booms are fully lowered and all outriggers are fully raised.
2. Push down on the friction drive hand lever to engage the drive cylinders against the tyres until
they lock over centre (refer to Figure 2-24).
Figure 2-24 – Friction Drive Hand Lever
3. Turn the Control select/ground operation switch to lower controls.
4. Disengage the handbrake and ensure that the locking pin stopping the tow bar coupling from
rotation is removed to enable the jockey wheel to be lowered.
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TRANSPORTATION
Figure 2-25 – Locking Pin Disengaged
5. Using the 2 hydraulic cylinders on the right side of the chassis (refer to Figure 26);
•
•
•
•
Push both levers forward to move the aerial platform in a straight direction.
Push both levers backwards to reverse the aerial platform in a straight direction.
Push the left lever only forwards or backwards to turn the machine to the right.
Push the right lever only forwards or backwards to turn the machine to the left.
Figure 2-26 – Hydraulic Levers
6. Ensure the hand brake is engaged when the machine is in position
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INSPECTION AND MAINTENANCE
The complete inspection consists of periodic visual and operational checks along with periodic minor adjustments that assure proper performance. Daily inspection will prevent abnormal wear and
prolong the life of all systems. The inspection and maintenance schedule should be performed by
personnel who are trained and familiar with mechanical and electrical procedures.
! W A R N I N G !
Before performing preventative maintenance, familiarize
yourself with the operation of the machine. Always block
the elevating assembly whenever it is nessecary to perform maintenance while the platform is elevated.
The daily preventative maintenance checklist has been designed for machine service and maintenance. Photocopy the checklist page and use the checklist when inspecting the machine.
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INSPECTION AND MAINTENANCE
DAILY PREVENTATIVE MAINTENANCE SCHEDULE
MAINTENANCE TABLE KEY
PREVENTATIVE MAINTENANCE REPORT
Y = Yes/Acceptable
N = No/Not Acceptable
R = Repaired/Acceptable
Date: ______________________________
Owner: _____________________________
Model #: ____________________________
Serial #: ____________________________
Serviced by: _________________________
COMPONENT
INSPECTION OR SERVICES
Operator’s
Manual
Check that the operators manual is in
the manual holder and all pages are
intact and readable
Labels &
Decals
Check that labels and decals are in
place, intact and readable
Entire Unit
Y
N
R
COMPONENT
Elevating
assembly
Chassis
Battery
System
Check electrolyte level
Check battery cable condition
Check terminals are clean and connectors are tight
Check charger condition and operation
Charge batteries
Hydraulic
fluid (*)
Check oil level
Hydraulic
system
Check all fittings are tight and there are
no leaks
Hydraulic
pump
Check fittings are secure and there are
no leaks
Emergency
lowering
Check emergency lowering correctly
(See emergency lowering procedure)
Controller
Check condition and operation
Platform
deck and
rails
Check fasteners are in place, correctly
tightened and not damaged
Check the structure and welds for damage, deformation, corrosion and cracks
R
Inspect for external damage, dents, loose
rivets or cracks.
Check cables for pinch or rubbing points
Check the structure and welds for damage, deformation, corrosion and cracks
Check for and repair any damage
Check cables and wiring harness condition (No wear or physical damage)
Y N
Check the structure and welds for damage, deformation, corrosion and cracks
Perform pre-operation inspection
Electrical
system
INSPECTION OR SERVICES
Lift Cylinders
Wheels
Check for leaks
Check for loose components
Check for damage to tyres
Harness
anchor point
Check fasteners are secure
System function inspection
Conduct system function inspection (see
pre-start operation pocedure)
Emergency
stops
Check that the emergency stop button on
the basket panels opertates correctly
Check for damage, deformation, corrosion
and cracks
Check that the emergency stop button
on the ground control panel operates
correctly
Brakes
Check that the brakes operate correctly
Controller
and Sensors
Check that the level sensor and controller
functions correctly.
* NOTE: Use ISO #22 hydraulic fluid.
Check condition of deck (no damage,
deformation, corrosion or cracks
Check entry gate closure functions
correcly
Table 2-2: Daily preventative maintenance
checklist
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SPECIFICATIONS
ITEM
Operating Dimensions
Maximum platform height
Guardrail height
Maximum working height
Platform length
Platform width
Platform height
Maximum outreach (from center of rotation)
Travel Dimensions
Towing length
Towing width
Stowed height
Weight
Weight (battery model) UN-LADEN
Weight (battery model +friction drive) UN-LADEN
Weight (bi-fuel model)
Operating parameters
Safe working load
Maximum horizontal pull
Maximum wind speed
Rotation
Control system
Outrigger raise
Outrigger lower
Platform raise
Platform lower
Maximum ground slope
Stabilizer feet to accommodate ground uneveness
of at least 10°
Tyres
Brakes
Hydraulic system
Hydraulic reservoir capacity
Maximum hydraulic system pressure
Hydraulic fluid temperature normal above 32° F
(0°C)
Electrical system
Energy source
System voltage
Battery duty cycle
Page 2 - 32
TL49J
48' (14.7 m)
3.61' (1.10 m)
54.8' (16.7 m)
47" (1.2 m)
31.5" (0.8 m)
6.3" (0.16 m)
27' (8.23 m)
23.3' (7.10 m)
5.6' (1.72 m)
7.1' (2.16 m)
5027 lb (2280 kg)
5291 lb (2400 kg)
5159 lb (2340 kg)
441 lb (200 kg)
89.9 lbs (400 N)
28 mph (12.5 m/s)
680°
Hydraulic proportional
112 s
84 s
136 s
101 s
5°
+/-5°
205/75R16
Hand brake )spring release)
3.96 US gal (15 L)
3045.79 psi (210 bar)
ISO #22
24 V battery x 6 V
195 Ampere hour/230 V mains power
24 DC/230 V AC
89.6% in 192.2 minutes
TL49J
Courtesy of Crane.Market
SPECIFICATIONS
Battery charger
Maximum wind speed
Table 2-3: TL49J Specification
Auto selectable dual input:
AC input 100 - 240 V 50 - 60 Hz
8 A output: 24 V - 18 A
28 mph (12.5 m/s)
NOTE: Specifications are subject to change without notice. Hot weather or heavy use may affect
performance. Refer to the service manual for complete parts and service information. This machine meets or exceeds all applicable OSHA and ANSI A92.6 - 1999.
TL49J
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No
Your waste can't be recycled as scrap metal.
No
Is the waste: A solid metal ?
Is the metal:
Aluminum,
Copper,
Iron,
Lead,
Steel, or Zinc?
Yes
Yes
should be RECYCLED according to the universal
No
Your waste is a HAZARDOUS WASTE Follow your
RECYCLED according to
Yes
IIs the waste: A used
Yes
HAZARDOUS WASTE
Is your waste (not Leaking / damaged)?
Is your waste (Leaking / damaged)?
No
These are non-hazardous and can be
placed in regular trash, however, in an
No
Yes
Yes
friendly you may chouse to collect
RECYCLING purposes.
Your waste should be RECYCLED following your
Is your waste?
*Any type of oil contaminated with a hazardous chemical
No
Is your waste:
* Motor Oil
Yes
Yes
Is the waste: an
* Degreasing solvents
Your waste is a HAZARDOUS WASTE
Is your waste?
Yes
* Power Steering Fluid
* Diesel Fuel
* Gear Oil
* Hydraulic Oil
* Kerosene (#3,#4, & #6)
Oils can NOT be disposed down the drain
(even if they are not hazardous waste).
No
* Coolant from chillers/HAVC systems
No
* Naptha
* Transformer oil
* Brake Fluid
* Radiator Flush
* Deicers
* Oily Water
Yes
HAZARDOUS
WASTE DISPOSAL AND REMOVAL
Page 2 - 34
End of Life Waste Advice Chart :
WASTE
No
Is the waste: an electrical component
or wiring ?
Is your waste:
Yes
* Armer cable
* Electrical Components
* Electrical circuit boards
Your waste is a HAZARDOUS WASTE Follow your
HAZARDOUS WASTE
No
Is the waste: a Polymer, Tyre or Hose ?
Your End of life waste is a HAZARDOUS WASTE
Yes
Is your waste:
Polymer wear pads
Tyres
Hydraulic hoses
disposal of HAZARDOUS WASTE
been depoluted
TL49J
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SERVICE AND REPAIR
CONTENTS
INTRODUCTION
CONSTRUCTION STANDARD
TECHNICAL CHARACTERISTICS
TRAILER/STRUCTURE
/OUTRIGGERS
POWER PACK - BATTERY POWER
OR MAINS POWER
POWER PACK ENGINE
SAFETY SYSTEMS
EMERGENCY STOP BUTTONS
EMEREGENCY LOWERING
SWITCH
OUTRIGGER INDICATORS
EMERGENCY SLEW
EMERGENCY LOWERING
VALVES
EMERGENCY LOWERING
HANDPUMPS
GUARDRAILS
OPERATING SPEEDS AND
NOISE LEVEL
DUTY CYCLES
BATTERY
MAINTENANCE SCHEDULE
GENERAL
OPERATOR’S RESPONSIBILTY
MAINTENANCE PROCEDURE
POWER PACK
CORRECT OIL LEVEL
DC MOTOR & PUMP
SOL 1
GROUND CONTROL VALVE
SLEW MOTOR
PLATFORM CONTROLS
HAND PUMP
PLATFORM SLEW
ALL OTHER BOOM CYLINDERS
STABILIZER CONTROL VALVE
TOP & BOTTOM RAM
RAM NOT HOLDING UNDER
LOAD
DROPNOSE RAM
OUTRIGGER RAM
PLATFORM CONTROL VALVE
GROUND CONTROL VALVE
DIVERTER VALVE
OUTRIGGER CONTROL VALVE
RESTRICTORS
SLEW MOTOR
GENERAL TESTS OF LOAD
HOLDING VALVES
SLEWING PLATFORM RAM
BLEEDING
HYDRAULIC PUMP
ENGINE SETTINGS
ELECTRICAL START/STOP
LEVEL GAUGE
TL49J
3-2
3-2
3-2
3-2
3-3
3-3
3-3
3-3
3-3
3-3
3-3
3-4
3-4
3-4
3-4
3-4
3-4
3-5
3-5
3-5
3-8
3-8
3-8
3-8
3-9
3-9
3-10
3-10
3-10
3-10
3-10
3-10
3-10
PHYSICAL DAMAGE
NUTS & BOLTS
LOCKING PEG
LOCKING PINS
TIE DOWN LUGS
BATTERY & CHARGING
OPERATION
ERROR CODES
CHARGING TIMES
PRACTICAL APPLICATIONS
BATTERY & CHARGING
CHECKLIST
BATTERY & SAFETY
PRECAUTIONS
BATTERY CHARGING USING
A GENERATOR
EMERGENCY STOP
ELECTRICAL SYSTEM
OUTRIGGER SAFETY &
MAINTENANCE
EMERGENCY LOWERING
SAFETY & MAINTENANCE
WHEELS
BRAKES
AXLE
WHEEL BEARINGS
TL49 REAR LIGHTS
GENERAL GREASE POINTS
LUBRICATION SPECIFICATIONS
SLEW DRIVE
SLEW DRIVE GEAR
SLEW STOP
3-18
3-18
3-19
3-19
3-20
3-20
3-20
3-21
3-21
3-21
3-21
3-21
3-22
3-22
3-22
3-22
3-23
3-23
3-23
3-24
3-25
3-26
3-27
3-27
3-27
3-27
3-28
3-11
3-11
3-12
3-12
3-13
3-13
3-14
3-14
3-14
3-15
3-15
3-15
3-15
3-16
3-17
3-17
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SERVICE AND REPAIR
INTRODUCTION
The Snorkel TL49J is a versatile means of gaining access in difficult locations.
The access platform is safe in operation providing that basic rules are observed in the setting up of
the machine. This manual focuses on the maintenance and repair of the machine. Please read the
operators manual available from Snorkel or from your local distributor prior to operating the machine.
All operator’s and service personnel should have read and understood the operator’s manual and
received full training in the safe use of the machine before attempting to use it or carrying out repairs.
Always quote your machine serial number and date of manufacture when ordering spare parts.
The part number for this manual is found on the front cover.
CONSTRUCTION STANDARDS
The TL49J machine complies fully with the requirements of European standard EN280:2013.
TECHNICAL CHARACTERISTICS
TRAILER/ STRUCTURE/OUTRIGGERS
This consists of a variety of welded and folded fabrications which where necessary, contain bushed
stainless steel pivots with grease nipples. The main components are shot blasted and then powder
coated. The cylinders are wet painted. The machine also includes a fully automatic running gear
with auto reverse and an integrated trailer lighting. At the towing end of the machine, there is a heavy
duty coupling head as well as a pneumatic jockey wheel. The maximum allowable load on the outriggers is 10.3 kN and the allowable sideway inclination is 5 degrees.
EQUIPMENT
Bottom ram
INFORMATION
Double acting: Bore Ø 60.0 mm
Rod Ø 40.0 mm
Top ram
Double acting: Bore Ø 60.0 mm
Rod Ø 40.0 mm
Dropnose ram
Double acting: Bore Ø 60.0 mm
Rod Ø 40.0 mm
Stabilizer ram
Double acting: Bore Ø 70.0 mm
Rod Ø 40.0 mm
Basket levelling ram
Double acting: Bore Ø 40.0 mm
Rod Ø 20.0 mm
Bottom & Top ram lock valves
Pilot operated over centre valves
Control valve (Platform)
Monoblock unit consisting of five double acting
spools
Control valve (Ground)
Monoblock unit consisting of four double acting
spools
Control valve (Stabilizer)
Monoblock unit consisting of four double acting
spools
Bushes
Acetol resin polymer with sintered bronze base
(DX)
Pivot pins
Stainless steel bright bar
to grade BS970 303 S31 CW
Tyres
205/75R16
Table 3-1: A list of equipment on the trailer and its associated features.
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SERVICE AND REPAIR
POWER PACK - BATTERY POWER OR MAINS POWER
This is a fully integrated power pack consisting of a motor, pump, relief valve, non-return check valve
and a return filter with a dip stick for checking oil level. The pump is fitted with an internal suction
strainer. The return filter is fitted with a breather and is used for topping up oil if required. The tank is
fitted with a drain plug on the bottom face. A quick release coupling for checking oil pressure is also
fitted on top of the pressure port.
POWER PACK - ENGINE
The engine is fitted with a separate pump which is fitted with a return filter and dipstick. The return
filter is fitted with a breather and is used for topping up oil if required. The tank is fitted with a drain
plug on the bottom face. The relief valve is mounted independently in close proximity to the pump
together with a quick release coupling for checking hydraulic pressure.
The engine is fitted with an electric starter with its own independent starter battery. The engine can
be started from the engine’s start/stop key switch and from the remote start/stop push button from
the platform.
SAFETY SYSTEMS
This is a full fail-safe hydraulic and electric system as required by EN280 and the machinery directive.
Emergency Stop Buttons
Emergency stop buttons are fitted on the machine to stop operation in an emergency. There are two
emergency stop buttons; one on the upper control panel and the other on the lower control panel
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.
Emergency Lowering Switch
The Emergency lowering switch can be used to lower the platform in situations where the boom
levers malfunction.
Note
The emergency lowering switch relies on the electrical system. The switch will not function if the electrical system is faulty.
Outrigger Indicators
The LED lights at the lower control station are indicators for outrigger stability. The outriggers are
pressure sensitive to prevent operating of the booms until the outriggers are in full contact with the
ground. It is not possible to raise the outriggers when the booms are extended.
Emergency Slew
A 17 mm socket together with a lever or spanner may be used to move the platform if there is a
malfunction in the hydraulic or electrical system.
In the event of a failure, the machine can be manually slewed by moving the slew platform clockwise or anticlockwise by inserting the slew lever and rotating the gearbox by moving upwards and
downwards.
TL49J
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SERVICE AND REPAIR
Emergency Lowering Valves
In the event of a power failure, the emergency lowering valve on the ram can be used to lower the
booms.
Emergency Lowering Hand Pump
The emergency hand pump lowering procedure is available from the lower control station.
Guardrails
The guardrails help protect personnel from falling off the platform.
OPERATING SPEEDS AND NOISE LEVEL
Due to oil viscosity and the fluctuating supply of power on a machine fitted with batteries and/or an
engine as its power source, the following nominal operating speeds reached are indicated on table
3-2. All speeds have been taken with fully charged batteries and at an ambient temperature of +10
degrees. Significant speed differences will be experienced if operating in cold climates with batteries
in a semi discharged state or if the engine is poorly maintained. All speeds have been taken from the
platform with 1 person on board.
Note
Mains power powered machines have different speeds.
FUNCTION
SPEED TIME/SECONDS
Bottom boom - up
32
Bottom boom - down
17
Top boom - up
41
Top boom - down
26
Dropnose boom - up
14
Dropnose boom - down
8
Slew - clockwise 180
73
degrees
Slew - counter clockwise
73
180 degrees
Platform rotation
8
Emergency decent - top
87
boom
Table 3-2: A list of functions and their associated speed times.
TOLERANCE/SECONDS
+/- 5
+/- 5
+/-5
+/- 5
+/-1
+/-1
+/-10
+/-10
+/- 2
+/- 2
DUTY CYCLES
The mains power pack and the engine are both continuously rated. The engine speed is fixed and
must not be altered.
BATTERY
With well maintained batteries, you will be able to get the following operations from one full charge in
a simulated working environment. For one cycle, lifting to full elevation and lowering can take place
10 times with a 5 minutes break. The cycle also includes lifting and lowering the outrigger at ground
level once. A total of four cycles can be achieved from one full charge.
This will provide the operator under normal circumstances, a full days work. The charger can also
be connected to the mains supply if re-charging is needed. The machine cannot be run directly from
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TL49J
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SERVICE AND REPAIR
the charger as the current drawn from the motor is higher than the output from the charger. It is important to cool the machine for 5 minutes to prevent the motor from being overloaded.
MAINTENANCE SCHEDULE
GENERAL
A well maintained machine will provide years of trouble free operation. It is important to carry out set
out checks of the machine’s structure and component prior to use or when set up for transportation.
Note
All machines operated in the UK must have a thorough inspection carried out every 6 months in accordance with LOLER regulations 1998 and a Certificate of Thorough Inspection produced by a competent person. Contact Snorkel for further details.
OPERATOR’S RESPONSIBILITY
It is the responsibility of the operator to ensure that the machine is safe to use. To do so, all the daily
checks provided should be performed prior to operating the machine. The weekly and 6 monthly
period checks should be performed for maintenance purposes.
The information on the maintenance schedule are set to cover most eventualities. If further advice
is needed, contact Snorkel or its local representative.
Note
If this manual was not issued with the machine, check for updates and revisions from Snorkel or its
local representative. Failure to maintain the machine as specified will invalidate the warranty.
! W A R N I N G !
Always ensure the machine is in good, sound and undamaged condition.
When carrying out maintenance and repairs. Always clean the machine
thoroughly. Take care not to steam the batteries or the electrical
components.
TL49J
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SERVICE AND REPAIR
DAILY CHECKS
ACTION
NOTES
Ensure the machine is on level
ground.
Top up the oil using the return
Hydraulic system
SHF22 oil or equivalent.
line filter on top of the tank. Oil Use
Change
oil and filter every 6
must be at the bottom mark on
months.
the dipstick.
Check out for oil leaks.
Check oil, filter and fuel.
Check for leaks.
Engine
Refer to OEM manual for more
information.
Check battery.
Top up with distilled water only
6 mm above plates
Level gauge
Check that the level gauge is
present and secure
Check for physical damage to
the booms, tie bars, basket,
Physical damage
slew and the chassis.
Do not use a damaged
machine.
Check that all warning labels
are legible and in place.
Nuts, bolts & fittings
Check for missing and loose
Replace immediately
nut and bolts.
Check that all locking pegs are
Locking pegs
present.
Broken peg = seized shaft.
Check that no shafts are
seized.
Check that all transport lock
Transport locks & lifting points
pins are present.
Do not transport machine
without locking pin.
Check for damaged lifting
points.
If fitted, check the operation of
the charger.
Record specific gravity of each
Battery & Charging
cell.
Clean top of the battery.
Clean and check terminals.
Emergency stop
Check that all emergency stop
Turn to release.
switches are working.
Electrical system
Check for correct operation of
the complete electrical system.
Check that the booms cannot
be operated until the outriggers
are down and in contact with
Electrical safety system
the ground.
Check that the outriggers cannot be raised with the top or
bottom boom elevated.
Hydraulic safety system
Check that all emergency lowering valves work.
Check emergency slew
Check emergency hand pump.
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SERVICE AND REPAIR
Wheels
Running gear
Trailer lights
Check tyres for damage.
Check wheel nuts and tyre
pressures
Check parking brake.
Check overrun device.
Check for damage.
Check for correct operation if
towing.
55 PSI 3.8 Bar
Table 3-3: Daily checklist.
WEEKLY CHECKS
Lubrication
Slew gear
ACTION
All grease nipples. Depending
on machine use and operating
condition, different intervals
may be acceptable.
Check slew gear for excessive
wear. Grease, if needed.
NOTES
ACTION
Check and replace motor
brushes if the machine is used
very frequently.
Check for wear - Perform
checks after every 3000 miles
NOTES
If 2/3 worn out, replace
ACTION
Contact Snorkel or its local
representative.
NOTES
Change oil and filter.
Table 3-4: Weekly checklist.
MONTHLY CHECKS
DC motor
Wheel bearings
Table 3-5: Monthly checklist.
6 MONTHLY CHECKS
Thorough Inspection
Table 3-6: 6 Monthly checklist.
TL49J
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SERVICE AND REPAIR
MAINTENANCE PROCEDURE
POWER PACK
The power pack consists of a fully integrated pump,
tank, preset relief valve and a return filter. The biggest
cause of hydraulic problems is due to contaminated
oil and filter. The oil and filter needs changing at least
every 6 months even though the hydraulic system is
a closed system. The only access for external dirt is
through the filter breather. Contamination will occur
due to seal kit wear (black sludge in the bottom of the
tank, mechanical wear from the gear pump, valve block
and cartridges in addition to water contamination due
to tank condensation). Refer to the power pack section
for more details.
The hydraulic system is fully self contained. Oil tank
capacity is 15 litres. When operating above 0°C,
ISO22 grade hydraulic mineral oil (refer to health &
safety guidelines supplied with the oil prior to
handling) is recommended.
Filter Breather
Figure 3-1: Filter breather location.
The main cause of hydraulic issues, sticking valves and leaking cylinders is due to contaminated oil.
There is no need to replace the oil in the hose. Replace the oil in the tank and filter every 6 months.
Oil is not discharged from the system and as a result, if oil is required, this would indicate an oil leak
which must be investigated prior to using the machine.
CORRECT OIL LEVEL
It is critical that the correct oil level is maintained. Too little oil will cause cavitation and failure of the
pump. Too much oil will lead to oil leak through the return filter breather or a massive oil leak when
using the emergency lower valves on the top and bottom boom. When using the emergency lower
valves, enough space is required in the tank to accommodate oil which normally would be pumped
into the annular side of the cylinder. If this should happen, clean up the oil spillage. Fully extend all
rams and then close up all the rams to check for the amount of free space in the tank using the dip
stick. The correct level expected is that at the bottom mark of the dipstick.
DC MOTOR & PUMP
The hydraulic pump is submerged in the tank. Oil
is drawn in through a suction strainer protecting the
pump. The DC motor is directly coupled to the pump
shaft. On the AC motor, a small adaptor coupling is
used between the motor and pump shaft. To replace
the pump;
1. Remove the tank by removing the 4 bolts securing it in place.
2. Remove the power pack from the machine.
DC Motor
3. Remove the 4 fixing bolts securing the pump to
the aluminium block.
Pump Shaft
4. With the pump removed, inspect the gears for
wear.
5. If the gears are worn out or broken, replace the
complete pump. The replacement pump is a unit
consisting of the gears but without the strainer. Figure 3-2: DC motor coupled to the pump
6. Torque the 4-5/16 hex fixing bolts evenly to
17.63 Nm (13 ft/lbs) to ensure correct operation shaft.
of the pump. Do not overtighten.
7. Before re-fitting, thoroughly clean the tank and the magnet found inside.
8. De-grease and replace the large “O” ring and apply a small amount of silicone around the
circumference of the de-greased tank neck.
9. Place the tank back on and secure with the 4 bolts removed earlier.
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SERVICE AND REPAIR
Note
The relief valve is factory set to 210 bar.
The DC motor can be removed without worrying about oil spillage.
1. Remove the 2 bolts shown in Figure 3-3 at the end of the motor.
2. Withdraw the motor taking care not to strain the wires.
3. For optimum performance of the DC motor, replace the motor brushes when they are 2/3 worn
out. If the machine is used extensively, changes must be made at least every 6 months.
4. Fully remove the motor from the power pack to be able to replace the brushes.
5. Blow out dust on the brushes using compressed air before re-assembling the motor.
6. Check the motor shaft bearing and replace if worn out. Replacing the contactor is recommended at the same time as replacing the brushes. The unit is fully sealed and contains no
serviceable parts.
7. Press on the platform raise/lower button. If the motor carries on running and there’s no power
at the contactor coil, the contactor needs replacing. To stop the motor in this situation, use the
battery disconnect plug or lightly tap the contactor on its end with the handle of a large screw
driver to free the internal contact points.
Note
The main relief valve is factory set to 210 bar and should not need adjusting. Breaking the seal during
the warranty period will invalidate the warranty.
+
+
Contactor
-
Bolt
Bolt
Figure 3-3: DC motor showing contactor
and bolt location.
Seal
Figure 3-4: A view of the seal location.
SOL 1
The SOL 1 valve diverts oil from the outrigger control valve firstly to the ground control valve and
then to the platform control valve. Never operate the coil unless it is on the valve cartridge. This risks
burning out the coil.
GROUND CONTROL VALVE
The ground control valve provides full control over all functions apart from the platform slew. The
adjustable relief valve is preset at the factory to approximately 190 bar. This setting is put in place
to ensure only the safe working load (SWL) is lifted. The centre position is closed to prevent oil back
feeding into the tank when operating the platform controls.
TL49J
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SERVICE AND REPAIR
PLATFORM CONTROLS
The platform controls is identical to the ground controls apart from the extra valve blank needed to
control the slewing platform ram. The orifice in the platform slew fitting is there to prevent the platform from turning too quickly.
HAND PUMP
The hand pump enables lowering and operates the slew in case of an emergency. The pump is fed
from the general return line. It is theoretically possible to extend the cylinder with the hand pump but
the force required is excessive and the fixing bracket for the hand pump is not designed to take such
a load. If no resistance is felt when operating the hand pump, try to operate the platform slew or the
drop nose to prime the pump.
PLATFORM SLEW
The cylinder has no lock valve. It relies on the closed centre of the spool to prevent it from moving.
ALL OTHER BOOM CYLINDERS
Lock valves are fitted to prevent uncontrolled movement in case of hose failure.
STABILIZER CONTROL VALVE
In the centre position, this block has the B port connected to the tank. This is to ensure that the outrigger cylinder check valve closes quickly when setting up the machine. The 4 restrictors are there
to prevent cylinder juddering caused by the check valves fitted to the outrigger cylinders.
The TL49J can be fitted with a variety of power options. The battery powered machine has only
one solenoid valve fitted (SOL 1). Both the engine and the mains powered version have a separate
dump valve fitted (SOL 2). This is because oil is in circulation all the time and not just when a cylinder movement is required as on the battery version. Having oil circulating through the different valve
blocks may lead to uncontrolled movements should the controls be accidentally operated. By fitting
the dump valve, the oil will always flow to tank unless the dump valve is activated.
Refer to the relevant circuit diagram under schematics or contact Snorkel or its local representative
for further information if required.
TOP & BOTTOM RAM
Each ram is fitted with a manual release to enable lowering of the boom in case of an emergency.
Press down on the red button as shown in Figure 3-5 and hold. When released, the red button will
spring out and the movement should stop.
If the cylinder is operating erratically (jamming at odd intervals with the motor running), check that
the little restrictor disc fitted at the nose of the cartridge is not loose. The disc is held in place with a
Restrictor Disc
small circlip. Replace cartridge.
The O/C valve enables the oil to flow freely into the
cylinder but will not let any oil flow out until a pilot
signal is received when pumping oil into the annular
side of the ram. The O/C valve will then open up and
let oil flow out in a controlled manner.
Red Button
The O/C valve is also fitted with an adjustable
relief valve which must be set to 1.25 times the
maximum pressure inside the cylinder. If the
cartridge is marked with CBBA, the adjusting
screw is turned CCW to increase pressure.
If screwed fully CW, the cartridge is now fully
open and does not hold any load. The O/C valve
must be set correctly to ensure safe operation.
Figure 3-5: A view of the manual release
valve and restrictor disc.
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SERVICE AND REPAIR
RAM NOT HOLDING UNDER LOAD
Releasing the controls must stop the cylinder movements.
•
•
It is not advisable to leave an extended machine unattended to for a lengthy period of
time.
It is normal to expect slight creep over time
however during normal operating conditions,
the ram should hold the load and not move
once the lock valve cartridge has closed. This
may take between 1-2 seconds after the directional valve has been returned to the centre
position. The pilot pressure holding the valve
open must be allowed to drain back into the
tank to allow the lock valve to seat fully.
When a cylinder is not holding the load in place, it is
critical to know which part from the following list has
failed.
•
•
•
3
2
Cylinder piston seal.
O/C valve (check valve)
Emergency lowering cartridge (if fitted)
2
The efficient way of establishing where the failure is,
is by removing all the hoses to determine where oil
is leaking out from.
•
•
•
1
If leakage is from the emergency lowering
cartridge, clean or replace (#3).
If leakage is from the O/C valve, clean and
adjust the relief valve or replace (Check
valves are non adjustable and can only be
cleaned or replaced) (#1).
If the leakage is from the piston seal kit, replace. The leakage is possibly through
annular port which has no lock valve (#2).
DROPNOSE RAM
The dropnose ram is fitted with two O/C valves.
There are two ways to determine which component
has failed.
2
1
1
3
Figure 3-6: For clarity, the drawing shows
only one hose to each service. In reality,
there are two hoses. One for the platform
controls and one for the ground controls. Only
the emergency lower has one hose.
1. Remove all hoses to determine where the oil
is escaping from.
2. If the oil is escaping from the full bore side,
the full bore O/C valve must be faulty.
3. Slowly open the adjusting screw for the O/C
relief valve on the annular side.
4. The piston seals have failed if oil starts to flow
out from the annular side and the cylinder is
starting to close up at an increased speed.
Replace the piston seals.
Figure 3-7: Dropnose cylinder with welded
on block containing 2 adjustable O/C valves.
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SERVICE AND REPAIR
OUTRIGGER RAM
The outrigger ram is fitted with two check valves. They require no adjustment. If the outrigger is not
holding under load, it is most likely that the check valve for the full bore side is leaking. The check
valves are difficult to get to as the block is tucked away on the underside of the ram.
•
•
•
With the outrigger retracted, remove the rod pin.
Swing down the outrigger to remove the cylinder.
Both check valves are identical. Swap them over to determine if the cylinder stops moving.
The full bore check is performed to ensure that the outriggers stay down when the booms have been
lifted (#2).
The annular side checks are performed to enure that the outrigger remains vertical when towing the
machine (#1).
The restrictor is critical to prevent the outrigger from juddering when raising the outrigger to the
transport position. Do not replace with a non restricted hose adapter (#3).
2
1
3
Figure 3-8: Outrigger cylinder with welded on block containing the two check valves. The
restrictor shown is the hose adaptor fitted in the outrigger control valve.
PLATFORM CONTROL VALVE
The in-line check valve is found below the manual hand pump. The valve prevents the oil from flowing back down the pressure line when operating the hand pump. The relief valve is set at 190 bar
and should be adjusted in accordance with the set up procedure.
To adjust the pressure, remove the cap of the relief valve and screw the adjusting screw inwards to
increase pressure and outwards to decrease pressure. Place the cap back after adjusting.
The spools are all the same and are closed centred in the neutral position. It is critical that the valve
block does not leak internally when in the neutral position. Note that there are two valve blocks with
each connected together at the lift cylinders. If the ground valve is not leak free with the spool in the
neutral position when operating the platform valve, the oil will not flow into the cylinder but leak out
through the ground valve. The same scenario applies for operating the ground controls when the
platform valve is leaking internally. This can also occur if the spool is not properly centralised by the
spring at the end of the spool.
In a situation where the ground controls function well but the operation of the boom from the platform
controls does not work, then the valve responsible for making the booms lift/lower is the faulty valve.
Page 3 - 12
TL49J
Courtesy of Crane.Market
SERVICE AND REPAIR
Figure 3-9: A view of the platform controls and check valve location.
GROUND CONTROL VALVE
This valve is identical to the platform control valve
except
•
•
It is not possible to operate the platform slew
from the ground controls. On the ground control valve schematic shown in Figure 3-10, the
last spool is that of the platform slew.
A high pressure carry over plug has been
fitted to the ground control valve to allow oil
under full system pressure to pass through
it. Without the internal plug, it is impossible
to operate the platform valve as all the oil will
flow directly back to the tank.
If it is necessary to operate the ground control valve,
make sure the carry over plug is fitted. The plug is
found inside the valve under the fitting for the return
line. Shine a light down the port to make the Allen
Figure 3-10: Ground control valve.
head grub screw visible. If not in place, use the
head grub screw fitted to the replacement valve.
Incase of an oil leak from the valve block, it is most likely to be from the end cap. This refers to either
the end where the lever is or at the opposite end where the return spring is. Never fully withdraw
the spool. Push it out opposite to where the leak is coming from with sufficient space to clear the
“O” ring which can now be observed with a small screw driver. Apply plenty of grease and keep well
lubricated when pushing the spool back in. If the spool is not centring, check that the return spring
and the end cap is well secured.
DIVERTER VALVE
When the diverter valve is not activated (no power on
the coil), the oil will flow to the outrigger control valve.
When activated, the oil flows to the ground control
valve. Incase of a reduced flow and a high pressure drop over the valve, the valve could be sticking.
Remove the cartridge from the aluminium body and
clean. Also look for contamination in the valve or
valve cavity.
To check that power is reaching the coil, hold a
screw driver against the end of the coil. When the
TL49J
Figure 3-11: Diverter valve schematic.
Page 3 - 13
Courtesy of Crane.Market
SERVICE AND REPAIR
coil is activated, a strong magnetic force is felt pulling the screwdriver towards the nut securing the
coil to the cartridge.
Do not use great force when securing the coil to the cartridge as the casing can easily crack due to
thermal expansion when heated up during use. The coil will fail if water gets through the crack.
OUTRIGGER CONTROL VALVE
This valve is not interchangeable with the ground control valve even tough it is a 4 bank valve block
with a relief valve and looks identical to the ground controls.
When the spool is in the neutral position, the
annular side of the ram is attached to the tank
line. This is done to ensure that the pilot pressure
holding the check valve on the full bore open is
drained of quickly to tank so that the check valve
closes quickly.
If the valve block is replaced, make sure that
the piping is done exactly as shown. Rely on the
closed port as back up for the check on the full
bore side.
Note that earlier versions might not have this type
of spool. This type can easily be identified as it
has a “DIN - Oil” stamped on the end cap. This
type used a standard closed centre valve block.
The leakage rate across the closed centre spool
is high enough to ensure that the deck would
Figure 3-12: Schematic view of outrigger
close.
control valve.
Each A port has a restrictive hose adaptor fitted in the valve block. If the restrictor gets blocked, the
cylinder will not operate correctly.
When looking for a fault relating to cylinders and valve blocks, swapping hose connections can easily provide a good pointer to where the fault is. If the fault position doesn’t change, then the fault is
in the valve block. If the fault position moves, then the fault is in the cylinder.
Do not overtighten the hose fittings. Overtightening can lead to leakages due to deformation of the
adaptor cone.
RESTRICTORS
All valve blocks have restrictors fitted at different locations. The current versions (2002) of the TL49J
uses a hose adapter with a drilled hole. Other types which have been in use (and currently are on
other machines) are a simple copper washer with a sized hole. The copper washer is squashed
between the hose fitting and the adapter screwed into the valve block.
It is easy to observe that a copper washer type restrictor has been used as it looks like the hose
fitting is not screwed fully down onto the adapter in comparism to the hose fitting next to it. A large
force is needed when tightening the hose fitting to prevent leaks.
Figure 3-13: Hose adaptor shown here with
drilled hole. If cylinder movement is erratic,
check for contamination.
Page 3 - 14
Figure 3-14: Copper restrictor fitted
loose in the hose adaptor. Hose end
requires more torque to prevent oil
leak when securing hose.
TL49J
Courtesy of Crane.Market
SERVICE AND REPAIR
SLEW MOTOR
The slew motor is a high torque low speed hydraulic motor.
The slew motor is bolted directly on the slew gear. Apart from
greasing and checking for oil leaks, no maintenance is required.
The motor can be unbolted from the slew drive to check for
leakage. A full seal kit is available with overhaul instructions.
Location 3 and 4 on figure 3-15 indicates the hoses going to
the platform controls.
GENERAL TESTS OF LOAD HOLDING VALVES
All critical movements rely on 2 components for safety namely:
•
•
The lock valve on the cylinder
The closed centre on the valve block
The valve blocks used have very low leakage rate. This is ideal
Figure 3-15: Hose connections to
for the slewing platform ram which has no lock valve.
the platform controls.
To determine which load holding valve is in use be it the
valve block or cylinder lock valve, perform the procedure
below.
•
•
•
With the pump not running, operate the valve blocks which leads to closing the ram up.
If there is cylinder movement, then there is a leaking load holding valve on the cylinder.
Do not use a machine with a failed load holding valve.
SLEWING PLATFORM RAM
Do not operate the slewing platform ram valve lever without the pump turning. If operated, the valve
lever can push the platform from side to side. This allows air to enter the system and the platform
will not stay put during transportation.
If this occurs, move the valve lever with the pump running. Moving the platform from side to side will
fill the cylinder with oil and the platform will lock in place when the lever is released.
BLEEDING
The hydraulic system needs no special bleeding. If a cylinder is stripped down or hoses for repair
removed, operate the cylinder fully in and fully out for the system to be operational.
Note
•
•
•
•
•
•
•
•
Replace filter and oil regularly.
Make sure the oil in the tank is clean.
Never use dirty cans when filling up the tank with oil.
In situations where oil replacement is needed, the system must be leaking.
Use the right oil for the right temperature:
Below 0° C - use low viscosity oil.
Above 0° C - use regular grade oil.
Keep a log of relief valve settings to monitor pump performance.
HYDRAULIC PUMP
The engine drives a hydraulic pump via a spider type coupling.
If there is a loss of oil pressure experienced and the motor is running correctly, use the check procedures stated below.
•
•
TL49J
First check that the hydraulic system is working correctly by checking that the dump valve is
activated. If the dump valve is working and there is still no oil flow, the issue is most likely to
be a failed pump or that the coupling is spinning on the motor or pump shaft.
Remove the bell housing to check that each coupling half is secured on the shaft. Then remove the pump and check the internal gears.
Page 3 - 15
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SERVICE AND REPAIR
•
The stop/run/start key switch is located on the right
hand side of the engine. Also available is a separate
start/stop push button on the platform controls.
Some engines are equipped with an automatic electrical
choke (Figure 3-16) to facilitate remote cold start. For the
engine to start remotely, the key switch on the engine must
be in the run position. If not, the engine will turn over on the
starter but will fail to ignite.
The platform’s control circuit is powered by the engine’s
start battery. The built in heavy duty 10 A alternator will recharge the battery during use. If the engine is not turning
over when trying to start, the most likely cause is a discharged battery. Jump start using another 12 V battery or
use the manual recoil fitted on all engines.
Terminals
Caps
Caps
Terminals
Figure 3-16: Check battery weekly
and top up with distilled water if
required.
Always switch the keyswitch on the engine position when
not in use to isolate the circuit. Should the engine turnover without starting, check the fuel level
first and then look at the electrical circuits for faults.
Note
Always let the engine reach operating temperature before loading the hydraulic circuit.
Some engines are fitted with a low oil level safety cut out which will stop the engine and prevents
starting if the oil level is low.
Note
The engine Stop/Run/Start key switch must be in the run position even when starting the engine manually.
Check the battery level weekly and top up with distilled water if required.
ENGINE SETTINGS
The throttle is locked and must not be tampered with. If the boom speeds are not in accordance with
the time test sheet, the engine speed may have to be adjusted. Set the engine speed by adjusting
the throttle to give required pump flow which in turn governs boom speed. Then set the throttle end
stop and secure the throttle from turning using a lock nut on the throttle spindle. Use fuel cut-off
when moving the machine over long distances.
Electrical
Choke
Throttle
Dump Valve
Pump Relief valve
Fuel Cut-off
Figure 3-17: Engine settings.
Battery Earth
Terminal
Page 3 - 16
Engine Oil
SAE 10-40
TL49J
Courtesy of Crane.Market
SERVICE AND REPAIR
ELECTRICAL START/STOP
The full engine electrical diagram shown below is not integrated in the main electrical diagram for
the machine. The engine is stopped by letting the signal to the ignition coil go to earth.
Figure 3-18: Engine engine schematics.
LEVEL GAUGE
The level gauge used for setting up the machine is located next to the outrigger control valve block.
If the level is damaged or has been removed, do not use the machine until a new level has been
fitted.
Level Gauge
Figure 3-19: Level gauge location.
TL49J
Page 3 - 17
Courtesy of Crane.Market
SERVICE AND REPAIR
PHYSICAL DAMAGE
When looking for physical damage, it is important that the machine is clean. Large dents in the
boom from operators hitting obstacles are generally easy to see. Crack in welds or corrosion damage can be harder to spot. The biggest wear and tear is due to the constant vibration from towing
the machine. Curbs and speed bumps passed at high speed can also cause severe damage to the
tow bar or the axle.
On machines fitted with the optional sliding axle, inspect the underside of the axle carrier and the
sliding box suspension.
On machines fitted with the fixed axle, check the fixing bolts and the main chassis member.
Check the area just behind the coupling where the vertical boom is secured to the tow bar. Incase
the vertical boom is not secured to the tow bar and the machine is towed over a long distance on
poor roads, damage may have occurred due to the constant banging of the vertical boom against
the towbar. Also check the top boom rest. The top boom must be locked in place during transport.
Note
Forgetting to lower the boom leads to damage occurring to the underside of the top boom due to movement in its rest position during transportation. Fitting the top boom lock would greatly reduce the need
for top boom repairs or possible replacement.
Another area prone to damage is the drop nose. When reversing, the basket may hit a low wall or a
post. The impact may not be easy to spot on an already battered basket however may bend the bottom of the drop nose. Check the straightness of the top tie bar. A slight dip is acceptable but a kink or
sideways bend is unacceptable. Check both booms for creases in the steel next to the main bosses
which is next to the slew post and the vertical boom. Hoses and cables are prone to damage, wear and
tear. If the outer sheathing on the hydraulic hose is a slightly frayed fitting, a temporary outer sleeve
may be adequate depending on the size of the damage.
Note
If in doubt, replace or ask Snorkel or its local representative for advice.
NUTS & BOLTS
Replace any missing bolts immediately. The main pivot shafts and pivot pins are secured with one or
two locking pegs. The locking peg not only secures the shafts from falling out but also stops them from
turning.
Most nuts used are nyloc nuts which are superior to the normal full nut and spring washer. Never use
plain nuts and spring washers unless originally fitted. Always torque fixings.
MAXIMUM TIGHTENING TORQUES
THREAD SIZE
UNPLATED
PLATED
Nm
Lbf.in.
Nm
Lbf.in.
M4
4.6
40.7
3.5
31
M5
9.5
84.1
7.1
62.8
M6
16.0
142.0
12.0
106.0
M8
39.0
345.0
29.0
257.0
M10
77.0
682.0
58.0
513.0
M12
135.0
1200.0
101.0
894.0
M14
215.0
1900.0
161.0
1420.0
M16
330.0
2920.0
248.0
2190.0
M20
650.0
5750.0
488.0
4320.0
Table 3-7: Torque table for nuts & bolts.
Page 3 - 18
TL49J
Courtesy of Crane.Market
SERVICE AND REPAIR
LOCKING PEG
Each shaft is secured with a locking peg. If a peg is broken or the
bolt and peg is missing then this could be down to a seized shaft
as a result of no lubrication. If a seized shaft is suspected, check
that the x-drilling for the locking peg lines up with the bolt for the
locking peg. Fit a new peg. Carefully operate the boom to determine if the shaft is trying to turn.
If a grease nipple is fitted, apply grease. If the shaft has seized, it
is recommended to drive the shaft 1/2 way out. Clean and apply
new grease. If the shaft is badly worn or scoured, replace both
shaft and the bush. Depending on which shaft is causing the problem, the structure might need support to prevent jamming when
extracting the shaft.
LOCKING PINS
Figure 3-20: Locking peg.
It is important that the boom locking pins are used when the machine
is transported. Never transport a machine if the pin is missing. The fixing clips fitted on machines have
been provided to prevent paint damage by the pin hitting the structure during use.
When towing, insert the pin and lock in place with the “R” clip provided. During inspection, look for
indication of the machine being moved without the pin. Signs of damage include dents in the top boom
and crack lines below the vertical boom. Contact Snorkel or its local representative for repairs.
Fixing Clips
R Clips
Figure 3-21: Level gauge location.
TL49J
Page 3 - 19
Courtesy of Crane.Market
SERVICE AND REPAIR
TIE DOWN LUGS
Check for wear and tear. Also check for damage. There are two lugs on each side attached to the towbar and two other lugs on each side of the rear outriggers. Current machines have a single box towbar.
Earlier models had an “A” frame towbar with one individual lug welded to each side of the towbar.
Note
The lugs are used to secure the platform when being stowed or transported. They are not designed
for lifting the access platform.
Tie Down
Lugs
Figure 3-22: Tie down lugs location.
BATTERY & CHARGING
If the machine is fitted with a fully automatic charger,
refer to the information provided here. If the machine
is fitted with a different type of charger, refer to documentation included with the unit.
The fully automatic charger is
•
•
•
•
•
•
•
Waterproof.
Capable of charging batteries when the motor is
running.
Dual voltage with auto select and indicator light
to show voltage selected.
Short circuit protection.
Designed to withstand heavy vibration.
Modular design. The black box will control 12 V,
Figure 3-23: The charger (black box) shown
24 V and 48 V at 30 A outputs with the
has a 110 V plug. To operate on 240 V, reappropriate transformer.
place plug.
Auto-boost to enable batteries to be kept in
optimum condition when machine is in storage
with the charger connected.
OPERATION
The LED’s are visible on the battery charger.
• 50% green LED blinking – indicates that the batteries are 0% to 50% charged.
• 50% solid green LED light and 75% green LED blinking – indicates that the batteries are 50% to
75% charged.
• 50% solid green LED light, 75% solid green LED light and green LED blinking – indicates that the
batteries are 75% to 100% charged.
• 50% solid green LED light, 75% solid green LED light and a 100% solid green LED light – indicates
that the charge cycle is complete.
The fuse used is a 24 V (15 A) fuse.
Page 3 - 20
TL49J
Courtesy of Crane.Market
SERVICE AND REPAIR
ERROR CODES
If the display panel on the box is flickering between -1 and 2, then there is a fault in the transformer or
the black box. Check the two output fuses under the terminal cover. The black box or the transformer
contains no user replaceable parts. Opening the black box apart from the terminal cover shown will
invalidate the warranty.
If the “time out light” comes on, there is a possibility of a faulty battery. Check each cell with a hydrometer.
The “time out light” will come on and the charger will switch off if gassing level has not been reached in
24 hours. The “reverse polarity light” will light if the output cables to the battery are reversed. The red
cable must go to the positive terminal and the black cable goes to the negative terminal.
CHARGING TIMES
The charger will recharge 2/3’s of discharged batteries in 8 to 10 hours. In reality, batteries are often
discharged more than 2/3’s when used on an access platform. The operator tends to use the machine
until the motor stops (This causes arcing of the motor contactor and severe heat rise in the motor; both
of which shortens the components life considerably.). After which it is easy to forget to put the machine
back on charge after using it. This results in the battery being as much as 95% discharged before the
charger is connected (this causes severe reduction in battery life).
If the battery cell voltage is below 1 V, the charger may not start. In this case, hold down the low voltage start button for several seconds. This will bypass the charger safety system and cause it to start
irrespective of battery voltage. After the voltage has increased sufficiently for the controller to take over,
the button can be let go off.
If gassing level is not reached in 24 hours, the charger will switch off and the “time out light” will come
on. Disconnecting the input lead will automatically re-set the timer. Take care not to disconnect the
charger during a charging cycle. Always let the charger reach “Charge complete” or “Time out” to prevent overcharging.
PRACTICAL APPLICATIONS
The machine will not work if the batteries are run down fully. This is still the case even if the charger is
connected. The electric motor requires as much as 3 times the charger output. The charger will float
on 30 A maximum and the motor will not turn (This results in damage to the motor and contactor). If the
user has a very hectic work schedule, it is easy to run out of battery power before work is completed. In
this case, the charger can be connected to the mains supply before the batteries are 50% discharged.
This will provide enough time for the charger to keep topping up the batteries and extend the duty cycle
of the machine considerably. The battery life may be slightly reduced as the optimum charging cycle
for any battery is “fully charged - 2/3’s discharged and then fully charged.
To check if a charger works, connect the voltmeter to the same battery terminals as the charger. Take
a note of the reading. The next step is to connect the charger to a mains voltage. There should be a
marked increase in voltage. Check the display on the charger. An in-line anmeter (or use a clamp on
type) can also be connected to check that the charger output display matches the current going into
the batteries.
BATTERY & CHARGING CHECKLIST
•
•
•
•
Check that the fuses are secured in the fuse holder.
Check that all wires are secure on the terminal block and on the battery terminal.
Check that the multi pin plug is secure on the pcb.
Check for damage to cables and wiring.
BATTERY SAFETY PRECAUTION
When charging the battery, explosive hydrogen gas will be given off. Keep away from open flames.
Always wear appropriate personal safety equipment such as eye goggles and rubber gloves to prevent
injury incase of spillage. Keep the top of the batteries clean and free from dirt. It is very easy for the
battery to be contaminated when topping up with distilled water. Regular topping up with distilled water
will be required from time to time.
TL49J
Page 3 - 21
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SERVICE AND REPAIR
BATTERY CHARGING USING A GENERATOR
The charger can only be connected to a generator fitted with a full AVR (Automatic voltage regulator)
and spike filtering system. Large voltage fluctuations and spikes will damage the electronic components in the charger. It has been noted that the Honda generator set offers the best and most reliable
voltage supply. This applies only to the fully integrated Honda generator sets and not the cheaper
options using a Honda engine fitted with a non-Honda generator unit.
EMERGENCY STOP
Two emergency stops are fitted; one at the lower controls and the other at the upper controls. When
pressed down on, they must stop all movements immediately. To release, pull up the emergency stop.
The switch head is not physically attached to the switch mechanism behind the head. If the head is
released and the machine will not start, check that the switch has not seized in the off position.
ELECTRICAL SYSTEM
The electrical system is quite simple and requires minimal maintenance. The biggest problem is
loose connections which is caused by vibration during towing and secondly moisture or condensation caused by high humidity and temperature fluctuations.
Erratic running of the motor when pressing down on the platform raise/lower button and moving the
booms can be caused by an intermittent internal cable failure. The failure can be hard to locate. The
best way is to lower the relevant boom. If the motor has stopped permanently, use the emergency
lower system. Try raising the boom again to determine if the fault occurs roughly in the same place. If
it does, it is highly likely there is an internal cable failure and the complete cable should be replaced.
On mains powered machines, the control circuit is almost identical apart from voltage variants and
the use of an isolation transformer on the control circuit. The bolt on motor contactor used on the
DC pack is replaced by a combined thermal overload and motor contactor mounted inside its own
junction box. On engine powered machines, the boom circuit is the same as for the DC powered
machines apart from the electrical start/stop circuit needed for the engine.
OUTRIGGER SAFETY & MAINTENANCE
•
•
•
It should not be possible to raise the outriggers with the booms up in the air. If this occurs, immediately check the boom limit switch and the diverter valve. If it is not possible to lift up the
outriggers after lowering the booms, check the same components.
It should not be possible to lift the booms up in the air unless the outriggers are all down and
in full contact with the ground. If this occurs, adjust the outrigger limit switch immediately. If
lifting is performed without having the outrigger correctly set, the operator will fall over. In any
case of instability, the machine will stop and the audible alarm mounted on the underside of the
platform control box will sound. The hand pump must be used for dropping down and re-setting
the outriggers. Check that the LED on the ground control panel is working correctly. Each LED
should only come on when the outrigger is in contact with the ground.
Check that the audible alarm is working. It should sound when the outriggers are unstable.
Figure 3-24: Boom limit switch.
Page 3 - 22
Figure 3-25: Diverter valve.
TL49J
Courtesy of Crane.Market
SERVICE AND REPAIR
Figure 3-26: Audible alarm.
Figure 3-27: Outrigger limit switch.
EMERGENCY LOWERING SAFETY & MAINTENANCE
•
When using the emergency lowering valve on the top or bottom ram, it is important to fully extend
the cylinder to fill the ram up with oil. There is a delay if it is the first time powering the cylinder
down because it has to fill up with oil. If the oil tank is overflowing, clean up the oil spillage immediately. The spillage is due to the tank being overfilled.
The emergency slew handle and the slew valve handle must be operated at the same time to
allow oil to circulate. When the hydraulic motor is turned, it becomes a pump leading to the oil
being moved elsewhere.
•
Figure 3-28: Emergency slew.
Figure 3-29: Emergency lowering valve.
WHEELS
Check for damage to the tyre/tyres. Replace if tread pattern is worn below 3 mm. On machines with
sliding axle, increased wear will be noticed on the inside part of the tyre/tyres compared to the outside
part. It is important that correct tyre pressure is maintained at all times. The correct pressure is 3.8 bar
(55 PSI) and not what may be indicated on the tyre. Refer to the tyre pressure sticker fitted on the top
of the mudguard. Tyre size is 205/75R16.
Note
For full service and maintenance information on the running gear, contact Snorkel to request a copy of
the running gear OEM service handbook.
BRAKES
Check Bowden cable for damage - Replace if inner steel core is visible. Sticking brakes can be down
to seized cables. The inner steel wire must run freely inside the cable.
Adjust the brakes with the wheels removed. Remove the plastic bung in the back of the brake plate.
TL49J
Page 3 - 23
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SERVICE AND REPAIR
Use a screw driver to adjust the star wheel until resistance is felt when turning the brake drum in the direction of travel. Then, slack back until the brake drum
turns freely.
Check for correct movement of the Bowden cable.
The cable should move 5 to 8 mm. Check for uniform
response when braking. All adjustments must be done
at the wheel brake and not on the brake linkage.
When removing the drum for cleaning the brake
shoes, always ensure that a new flanged nut is used.
Tighten the flange nut to between 280 - 300 Nm.
When re-fitting the wheel, tighten wheel nuts in the
N.S.W.E. sequence and to a torque of 88 Nm.
Note
Figure 3-30: Nut adjusting direction.
If the handbrake is not fully applied, there is a risk that the trailer could move backwards. The brake
rod must not be under tension or bowed when the handbrake is disengaged.
AXLE
The axle is fully maintenance free. Check the fixing bolts. If ordering replacement axle, quote all reference numbers on the oval serial number plate riveted to the axle beam.
Figure 3-31: View of the different axle positions.
En-Figure 3-32: Coupling/Overrun device. sure that the draw bar is fully extended. Screw the brake
rod into the pivot head and secure with an M10 nut. Using the M10 ball nut, connect the brake rod to
the Bowden cable via the compensating bracket. Fit and hand tighten the hex securing nut. Tighten
the M10 ball nut on the brake rod until there is no further play on the pivot head against the draw bar
(the draw bar must be fully extended).
The compensating bracket must be square on the brake rod. The current type of Bowden cables are
Page 3 - 24
TL49J
Courtesy of Crane.Market
SERVICE AND REPAIR
non adjustable. Hook the cable on to the compressor
bracket. Adjust to ensure even braking on the brake,
not on the compensator.
Check that both wheels run freely in the forward direction. Apply the handbrake; the brakes should start to
hold on at the second click. The gas strut will ensure
that the handbrake is fully applied. If the trailer is moving backwards, the handbrake will move further up.
It is imperative that the gas strut is working correctly.
Without the gas strut, the brakes will not hold the
trailer on a slope.
Adjust brakes if required and check that all nuts are
secured. Grease the coupling head (Multipurpose
grease to DIN 51825 KTA 3K), clean and oil all other
moving parts.
Figure 3-33: View of the grease nipple
locations.
WHEEL BEARINGS
The wheel bearings are sealed permanently and require no maintenance or grease. The service life for
a set of bearings is in the region of 20000 to 30000 miles depending on running conditions. It is vital
that the brakes have not been overheated as this will cause the grease in the sealed ball bearings to
evaporate and the bearings will fail. Never re-use the flanged nut when re-fitting the brake drum as the
wheel may come off when towing.
When purchasing a brake drum, the bearings are normally included fitted to the brake drum. If replacing the bearings only, contact Snorkel or its local representative for further information. Always use a
new flanged nut and torque to between 280 - 300 Nm when re-fitting the drum.
TL49J
Page 3 - 25
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SERVICE AND REPAIR
TL49 REAR LIGHTS
7 PIN PLUG
INTERIOR VIEW
YELLOW
1
RED
BLUE
2
6
BLACK
7
WHITE
3
5
4
BROWN
WHITE
GREEN
YELLOW
GREEN
BROWN
RED
RED
WHITE
WHITE
BLACK
L.H.
FLASHER
NUMBER
1
2
3
4
STOP
TAIL
REFERENCE
L
54G
31
R
FOG
LIGHT
COLOUR
YELLOW
BLUE
WHITE
GREEN
No. PLATE
LIGHT
FUNCTION
L.H. INDICATOR
REAR FOG LAMP(S)
EARTH
R.H. INDICATOR
FOG
LIGHT
NUMBER
5
6
7
REFERENCE
58R
54
58L
STOP
TAIL
COLOUR
BROWN
RED
BLACK
R.H.
FLASHER
FUNCTION
R.H.TAIL
STOP LIGHTS
L.H. TAIL & NUMBER PLATE
Figure 3-34: Colour and function table for rear lights.
Page 3 - 26
TL49J
Courtesy of Crane.Market
SERVICE AND REPAIR
GENERAL GREASE POINTS
Regular greasing greatly improves the service life of the bushes and also removes any moisture which
may cause internal corrosion on the wall of the bosses making it difficult to remove the pivot shafts for
inspection.
Figure 3-35: General grease point locations.
LUBRICATION SPECIFICATIONS
It is recommended that only premium quality grease is used. Lithium based grease offer very good
performance. For the slew ring, the “RENOLIT ARMNA G4789” from Fuchs offers extremely good lubrication and anti corrosion properties especially at very low temperatures (-30°C).
SLEW DRIVE
To grease the slew ring, the machine needs to be set up and slew around to gain access to the reassessed grease nipple fitted to the top face of the slew ring.
When greasing the worm housing, take care not to push out the oil seal on the end face. If you do, remove
excess grease from the end and drive the seal back in. Refer to the slew drive section for more details.
Figure 3-36: Location of the slew drive and
grease locations.
SLEW DRIVE GEARS
The slew drive gear is designed to be largely maintenance free. However, it is recommended that the
gear teeth be greased on a weekly/monthly basis with a high pressure grease depending on operation conditions. Always clean the gear firstly to remove any road dirt and grime. In very dusty or sandy
conditions, take care to prevent a build up of grit/sand mixed with grease which may cause pre-mature
wear on the gear.
Additionally, the ring gear and gear box should be greased on a six monthly basis. The grease nipple
TL49J
Page 3 - 27
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SERVICE AND REPAIR
for the ring gear is on the top face of the slew gear set
between the fixing bolts. It can be accessed by lifting
one of the side covers and slewing the structure appropriately.
The ring gear should be inspected on a six monthly
basis for excessive wear. It is unlikely there will be any
wear if the machine is maintained correctly.
To check the gear, place a payload of approximately
80 Kg on the platform. Elevate the lower boom to
approximately half way. Then, gently elevate the top
boom whilst observing the ring gear. Excessive wear
will be observed by noticing more than 0.5 mm movement between the inner and outer bearing rings. If
excessive wear is present, the gear ring should be
Figure 3-37: Location of the slew drive
replaced.
gears.
SLEW STOP
The slew stop mechanism is fully lubricated and should normally not require any further lubrication.
Should more lubrication be needed, this can be done in two ways;
1. When greasing the slew bearing, some grease will drop into the centre part of the slew. Keep
on greasing the slew bearing until grease escaping becomes visible from the outside sealing
lip on the slew gear. Keep on greasing as the grease will now be pushed out through the outer
and inner sealing ring of the slew bearing. Grease escaping from the inner seal will drop unto
the slew stop ring.
2. LPS-3 lubrication can also be sprayed between the slew tube and the chassis plate.
Slew Stop
Ring Tab
Slew Tube
Spray LPs-3
inbetween the
tube and the
chassis plate
Figure 3-38: Different procedures of
lubrication.
Slew Stop Ring
Chassis Stop
Figure 3-39: Critical parts of the slew stop.
The slew stop mechanism is very simple and prevents the cables and hoses getting tangled up by
continuous rotation. The slew stop ring will allow the operator to turn almost 360° in each direction from
the stowed position.
The critical parts of the slew stops are as follows:
•
•
•
•
Chassis stop
Slew stop ring
Slew stop ring tab
Slew tube stop
When slewing (rotating), the slew tube stop will pick up on the slew stop ring tab and drag it around
until the slew stop ring tab hits the chassis stop. It is possible to slew almost two turns in the opposite
direction until the slew stop ring tab hits the chassis stop again. This provides almost two turns (lock to
lock). From the parking position, this equates to one left turn or one right turn.
Page 3 - 28
TL49J
Courtesy of Crane.Market
SERVICE AND REPAIR
The mechanism is very simple and has proven reliable in the field. However, if the slew does not
stop, check that one of the 3 steel stop blocks has broken loose. If this is not rectified, the platform
can slew continually and will rip out the hoses and cables. To solve such a problem, split the machine and re-weld the slew stop.
Check hydraulic pressure. Apply plenty of lubrication to ensure that the slew stop ring has not got
jammed. Again, if the problem does not disappear contact Snorkel or its local representative for
further assistance.
Note
All machines being operated in the UK must have a thorough inspection carried out every 6 months
in accordance with LOLER regulations 1998 and a certificate of Thorough Inspection produced by a
competent person.
When the machine has passed its test, a sticker will be issued showing the certificate number and the
date of the next Examination. A copy of the certificate is available upon request.
TL49J
Page 3 - 29
Courtesy of Crane.Market
Page 3 - 30
TL49J
Courtesy of Crane.Market
TROUBLESHOOTING
CONTENTS
FAULT FINDING
FAULT FINDING MATRIX
TL49J
4-2
4-4
Page 4 - 1
Courtesy of Crane.Market
TROUBLESHOOTING
FAULT FINDING
It is recommended that fault finding is only carried out by technically competent personnel. Whilst
every effort has been made to ensure these procedures are as comprehensive as possible, they do
not cover all eventualities.
If difficulty is experienced in identifying a fault, contact Snorkel for assistance. A list of troubleshooting notes are also listed below to help with solutions to faults identified.
ISSUE
Engine will not start - if fitted.
REMEDY
Ensure there is enough fuel in the tank.
Switch off emergency stops.
Turn on the engine ignition.
Ensure the batteries are fully charged.
If the engine is cold, apply the choke manually.
Check engine blade fuse.
DC motor not turning when trying to lower the
Ensure the ground control select is turned to
outriggers.
ground controls.
Check the battery level. The battery should be
2/3 charged.
Check the motor contactor.
Check the motor brushes.
Check the motor fuse.
Ensure the emergency stop button is not
engaged.
DC motor turning but not able to operate
Ensure the top boom is lowered and the boom
outriggers.
switch is activated.
Check that the limit switch arm is secure on
the boom switch.
Ensure the diverter valve is de-activated. Refer to the hydraulic circuit.
Check the hydraulic pressure. If there’s no
pressure, check the pump.
DC motor not turning after outriggers have been Check that the key selector switch is not in the
lowered.
off position.
Ensure the emergency stop buttons are not
engaged.
If the overload alarm still sounds, check the
outrigger switches.
Boom will not raise/lower when the control lever
Ensure the right control select is in use.
is operated and DC motor running.
Check the oil level.
Ensure that the diverter valve is activated.
Check that the other control valve has all
spools in centre position.
Check the hydraulic pressure. If there’s no
pressure, check the pump.
Check that the emergency lowering valve is
not opened on the cylinder.
Check for obstructions.
Page 4 - 2
TL49J
Courtesy of Crane.Market
TROUBLESHOOTING
Audible alarm activated when outriggers are not
moving
Slew will not operate in either direction with DC
motor running
Loss of movements on the mains/engine powered machines.
Mains motor/engine stalls when trying to
operate the machine
Mains motor stalls when operating the machine
RCD on mains powered machines keeps
tripping
0.5A fuse on control circuit keeps popping
(Mains powered machines)
Burnt out mains isolating transformer (Mains
powered machines)
Check the level and limit switches on the
outriggers
Check that the machine is on level ground.
Slew will not operate if the machine is out of
level.
Check for obstructions.
Ensure the slew has not reached the slew
stop. 2002 machine specification will only
slew +/- 355 degrees from the stowed position.
Earlier machines would slew +/- 450 degrees
from the stowed position.
Check the dump valve. To enable movement,
the dump valve must pull in to stop oil going to
the tank.
Check the oil pressure.
Check the pump and coupling.
Check relief valve setting.
Check for voltage drop.
Use shorter extension lead.
If the voltage reading on the motor terminals is
below 10% of the motor rating when it is running under load, the motor will fail. Do not run
the machine.
Check for water ingress on terminal boxes.
Check motor start and run capacitors.
Check coil on selector valve and dump valve
for cracks/signs of water damage.
Check fuse.
Check coil on selector valve and dump valve
for cracks/signs of water damage.
Table 3-3: Fault finding list and possible solutions.
TL49J
Page 4 - 3
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TROUBLESHOOTING
FAULT FINDING MATRIX
Motor will not start (Petrol)
Is the Ignition Switch, turned on?
Turn ignition to ON
& Read Operators
Manual
NO
YES
Are all Emergency Stops Reset?
YES
NO
Reset Em ergency st ops
& Read Operators
Manual
Does the Engine have Oil & Fuel?
Fill up the Oil or Fuel tank
& Read Operators
Manual
NO
YES
Is the Choke On?
YES
NO
Apply t he Choke
& Read Operators
Manual
Are the Batteries Fully Charged?
Charge Batteries
& Read Operators
Manual
If further advice is
required, consult
an
Snorkel
Technician.
Page 4 - 4
NO
YES
Has the Circuit Breaker tripped?
NO
YES
Reset the Circuit Breaker
& Read Operators
Manual
TL49J
Courtesy of Crane.Market
TROUBLESHOOTING
Motor will not start (Mains)
Is the Correct Power supply Connected?
YES
NO
Connect power supply
& Read Operators
Manual
Is the Selector Switch, turned on?
Select switch posit ion
& Read Operators
Manual
NO
YES
Are all Emergency Stops Reset?
YES
If further advice is
required, consult
an
Snorkel
Technician.
NO
Reset Em ergency st ops
& Read Operators
Manual
Has the Circuit Breaker tripped?
NO
YES
Reset the Circuit Breaker
& Read Operators
Manual
Motor stalling.
Working Hard, Noisy
Check the voltage at the m otor is
230V w hen the m otor is turning?
If further advice is
required, consult
an
Snorkel
Technician.
!
TL49J
YES
NO
Voltage Drop may be
the cause, Use a shorter
Extension lead
All extensions must be a minimum of 2.5mm², and no longer than
10m, due to possible voltage drop, which will damage the motor.
Page 4 - 5
Courtesy of Crane.Market
TROUBLESHOOTING
Motor will not start (Battery)
Has the correct control sw itch
been selected? (ground/ basket)
YES
NO
Select appropriate control
& Read Operators
Manual
Are the Batteries connected?
Connect Batteries
& Read Operators
Manual
NO
YES
Are all Emergency Stops Reset?
YES
NO
Reset Em ergency st ops
& Read Operators
Manual
Are the Batteries Fully Charged?
Charge Batteries
& Read Operators
Manual
If further advice is
required, consult
an
Snorkel
Technician.
Page 4 - 6
NO
YES
Has the Circuit Breaker tripped?
NO
YES
Reset the Circuit Breaker
& Read Operators
Manual
TL49J
Courtesy of Crane.Market
TROUBLESHOOTING
Booms will not raise (Motor Running)
Has the correct control sw itch
been selected? (ground/ basket)
Select appropriate control
& Read Operators
Manual
NO
YES
Is the Motor Run / Deadman
being pressed?
YES
Press the Deadman
& Read Operators
Manual
NO
Are all the
Outriggers under load? (LEDs)
Resett he Outriggers
until all LEDs are
Illuminated
& Read Operators
Manual
NO
YES
Are the Hydraulics under pressure?
A change of motor
tone can be heard.
YES
If further advice is
required, consult
an
Snorkel
Technician.
NO
Is there enough Oil in the tank?
YES
NO
Top up Oil Level
& Read Operators
Manual
TL49J
Page 4 - 7
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TROUBLESHOOTING
Booms will not lower (Motor Running)
Is there an obstruction below ,
the basket or boom s?
Remove obstruction, or
reposition
& Read Operators
Manual
YES
NO
Is the Motor Run / Deadman
being pressed?
YES
Press the Deadman
& Read Operators
Manual
NO
Are all the
Outriggers under load? (LEDs)
Resett he Outriggers
until all LEDs are
Illuminated
& Read Operators
Manual
NO
YES
Are the Hydraulics under pressure?
A change of motor
tone can be heard.
YES
If further advice is
required, consult
an
Snorkel
Technician.
NO
Is there enough Oil in the tank?
YES
NO
Top up Oil Level
& Read Operators
Manual
Page 4 - 8
TL49J
Courtesy of Crane.Market
TROUBLESHOOTING
Outriggersw ill not extend/retract
Has the correct control sw itch
been selected? (ground/ basket)
Select appropriate control
& Read Operators
Manual
NO
YES
Is the Motor Run / Deadman
being pressed?
YES
NO
Press the Deadman
& Read Operators
Manual
Is the Boom Down Switch Made
and w orking correctly?
Lower the boom s un til the
switch is m ade
& Read Operators
Manual
NO CHANGE
TL49J
NO
YES
If further advice is
required, consult
an
Snorkel
Technician.
Page 4 - 9
Courtesy of Crane.Market
TROUBLESHOOTING
Slew will not operate (Motor Running)
Has the correct control sw itch
been selected? (ground/ basket)
Select appropriate control
& Read Operators
Manual
NO
YES
Is there an obstruction
Preventing the slewi ng action?
NO
Remove obstruction, or
reposition
& Read Operators
Manual
YES
Are all the
Outriggers under load? (LEDs)
Reset the Outriggers
until all LEDs are
Illuminated
& Read Operators
Manual
NO
YES
Has the slew reached the slew stop?
Reverse the control lever
until the slewing action returns.
& Read Operators
Manual
NO CHANGE
If further advice is
required, consult
an
Snorkel
Technician.
Page 4 - 10
YES
NO
Is there enough Oil in the tank?
NO
YES
Top up Oil Level
& Read Operators
Manual
TL49J
Courtesy of Crane.Market
SCHEMATICS
INTRODUCTION
This section contains electrical and hydraulic power schematics and associated information for
maintenance purposes.
The diagrams are to be used in conjunction with the information in section 4. The schematics provide an understanding to the makeup and functions of the systems for checking, tracing and faultfinding during troubleshooting analysis.
CONTENTS
TL49 BATTERY PG ELECTRIC SCHEMATIC - 513354-001
5-2
TL49 PETROL PG ELECTRIC SCHEMATIC - 513354-002
5-3
TL49 DIESEL PG ELECTRIC SCHEMATIC - 513354-003
5-4
TL49 BI-PETROL PG ELECTRIC SCHEMATIC - 513354-004
5-5
TL49 BI-DIESEL PG ELECTRIC SCHEMATIC - 513354-005
5-6
TL49 MAINS PG ELECTRIC SCHEMATIC - 513354-006
5-7
TL49 MAINS - GENSET PG ELECTRIC SCHEMATIC - 513354-007
5-8
TL49 BATTERY/MAINS HYDRAULICS SCHEMATIC - 515057-000
5-9
TL49 DIESEL/PETROL HYDRAULICS SCHEMATIC - 515057-001
5-10
TL49 BI-FUEL HYDRAULICS SCHEMATIC - 515057-002
5-11
TL49 BI-FUEL/FRICTION DRIVE OPTION SCHEMATIC - 515057-002
5-12
TL49J
Page 5 - 1
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SCHEMATICS
TL49 BATTERY PG ELECTRIC SCHEMATIC - 513354-001
Page 5 - 2
TL49J
Courtesy of Crane.Market
SCHEMATICS
TL49 PETROL PG ELECTRIC SCHEMATIC - 513354-002
TL49J
Page 5 - 3
Courtesy of Crane.Market
SCHEMATICS
TL49 DIESEL PG ELECTRIC SCHEMATIC - 513354-003
Page 5 - 4
TL49J
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SCHEMATICS
TL49 BI-PETROL PG ELECTRIC SCHEMATIC - 513354-004
TL49J
Page 5 - 5
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SCHEMATICS
TL49 BI-DIESEL PG ELECTRIC SCHEMATIC - 513354-005
Page 5 - 6
TL49J
Courtesy of Crane.Market
SCHEMATICS
TL49 MAINS PG ELECTRIC SCHEMATIC - 513354-006
TL49J
Page 5 - 7
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SCHEMATICS
TL49 MAINS-GENSET PG ELECTRIC SCHEMATIC - 513354-007
Page 5 - 8
TL49J
Courtesy of Crane.Market
SCHEMATICS
TL49J
June 05
TL49J Battery/Mains Power
TL49 BATTERY/MAINS HYDRAULICS SCHEMATIC - 515057-000
Page 5 - 9
Courtesy of Crane.Market
SCHEMATICS
Page 5 - 10
June 05
TL49J Diesel/Petrol Powered
TL49 DIESEL/PETROL HYDRAULICS SCHEMATIC - 515057-001
TL49J
Courtesy of Crane.Market
SCHEMATICS
TL49J
June 05
TL49J Bi-Fuel Powered
TL49 BI-FUEL HYDRAULICS SCHEMATIC - 515057-002
Page 5 - 11
Courtesy of Crane.Market
SCHEMATICS
TL49J Bi-Fuel with friction drive option
July 07
TL49 BI-FUEL/FRICTION DRIVE OPTION SCHEMATIC - 515057-002
Page 5 - 12
TL49J
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
INTRODUCTION
This section lists and illustrates the replaceable assemblies and parts of this product as manufactured by Snorkel.
Each part list contains the component parts for that assembly.
CONTENTS
LIGHTING BOARD ASSEMBLY
6-2
OUTRIGGER ASSEMBLY
6-3
CHASSIS ASSEMBLY
6-4
SLEW - BI FUEL POWER
6-6
SLEW - MAINS POWER
6-8
SLEW - BATTERY POWER
6-10
SLEW - ENGINE POWER
6-12
LOWER BOOM
6-14
TOP BOOM
6-16
DROPNOSE
6-18
CAGE SUPPORT
6-19
STEEL CAGE
6-20
GRP BASKET
6-22
OUTRIGGER RAM
6-23
BOTTOM RAM
6-24
TOP RAM
6-25
MASTER RAM
6-26
TELESCOPIC RAM
6-27
LEVELLING RAM
6-28
DROPNOSE RAM
6-29
CAGE ROTATION RAM
6-30
TRAILER ELECTRIC KIT PARTS
6-31
STANDARD LOWER CONTROL
PANEL
BI-FUEL PLATFORM CONTROL
PANEL
6-37
MAINS MOTOR STARTER
6-38
EXTERNAL COMPONENTS
6-40
CABLE ASSEMBLIES
6-40
BASIC FITTINGS KIT
6-41
END FITTINGS KIT
6-42
TL49 FRICTION DRIVE KIT
6-44
TL49 DECAL LOCATIONS
6-45
6-31
STANDARD PLATFORM CONTROL
PANEL
6-33
BATTERY/MAINS PLATFORM
CONTROL PANEL
6-35
ENGINE PLATFORM CONTROL
PANEL
6-36
TL49J
Page 6 - 1
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ILLUSTRATED PARTS LIST
LIGHTING BOARD ASSEMBLY
1
1
4
2
3
5
4
6
7
8
Figure 6-1: Lighting board assembly.
ITEM
PART #
1
512492-000
2
513301-000
3
513302-000
4
513742-000
5
513300-000
6
058490-016
7
056069-005
8
056066-005
Table 6-1: Lighting board components.
DESCRIPTION
Amber reflector
RH Light cluster
LH Light cluster
Registration lamp mounts
Registration lamp
Set screw, M5 x 16 mm
M5 Flat washer
M5 Nylock nut
PART #
DESCRIPTION
513836-000
Harness, tow hitch to chassis
513836-001
Harness, chassis to side marker lamps
513839-000
Harness, rear light to registration lamp
513838-000
Harness, rear light to side marker lamp
513492-000
Amber marker lamp
513403-000
White reflector
512687-000
13 pin plug
512689-000
8 core cable
Table 6-2: Marker lamp kit components.
Page 6 - 2
QTY
2
1
1
2
2
4
8
8
QTY
1
1
2
2
6
2
1
10m
TL49J
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
OUTRIGGER ASSEMBLY
Figure 6-2: Outrigger assembly.
ITEM
PART #
1
10-5069
2
10-5070
3
13-3608
4
22-5179
5
15-0886
6
12-2054
7
SB-030030
8
SP-016E216
9
SP-030D171
10
SP-030D203
11
SP-030K211
12
10-2627
Table 6-3: Outrigger components.
TL49J
DESCRIPTION
Outrigger
Outrigger foot
Outrigger ram
Outrigger ram cover
Ram cover skid pad
Banjo bolt
Bush
Pin
Pin
Pin
Pin
Retaining peg
QTY
4
4
4
4
4
8
24
4
4
4
4
16
Page 6 - 3
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
2
9
10
3
8
13
11
15
16
14
7
6
24
17
25
21
4
20
22
23
19
1
5
26
27
18
28
12
CHASSIS ASSEMBLY
Figure 6-3: Chassis assembly.
Page 6 - 4
TL49J
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
ITEM
1
2
3
4
PART #
DESCRIPTION
513439-000
Chassis
508106-000
Towing coupling
508107-000
Adjustable jockey wheel
513441-000
3000 kg rubber suspension axle c/w brake cables
513443-000
215/75R16 wheel assembly (5 stud)
03-0275/01
Wheel studs
5
03-0275/02
Wheel nuts
6
24-3998
Brake rod
7
21-0855
Boom retaining pin
8
10-5068
Boom lock
9
09-1273
Inlet plug
10
09-1394
Inlet plug cap
11
513398-000
Cycle guard R/H
12
513397-000
Cycle guard L/H
13
508133-000
Bowden cable
14
508134-000
Cable bracket
15
508112-000
NATO plug
513450-000
Mudguard support bracket L/H
16
513449-000
Mudguard support bracket R/H
513416-000
Mudguard mount bracket
17
513793-000
Mudguard mount bracket (Friction drive units only)
18
IT250
Mudguard
19
11-3449
Bolt (M12 x 80 mm)
20
08-0192
Slew bearing/worm drive c/w motor
21
10-5271
Slew limiting ring
22
13-2537
Stabilizer control valve
23
25-0239
Levelling bubble
24
513403-000
White marker lamp
25
513492-000
Amber marker lamp
26
513522-002
Mudflap bracket
27
513522-000
Mudflap
28
513522-001
Mudflap support bracket
Table 6-4: Chassis components.
QTY
1
1
1
1
2
10
10
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
26
1
1
1
1
2
6
2
2
2
PART #
14305.08
DPSM 63 90 10
368A/362A
LM501349/501310
24929.03
1053 08
Table 6-5: Brake hub components.
QTY
2
2
2
2
2
2
TL49J
DESCRIPTION
Knott 300 x 60 std. Brake assembly
Oil seal
Inner Bearing cone/cup
Outer bearing cone/cup
Standard brake shoe
Load washer
Page 6 - 5
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
SLEW - BI-FUEL POWER
Figure 6-4: Slew (Bi-fuel) assembly.
Page 6 - 6
TL49J
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
SLEW - BI-FUEL POWER
ITEM
PART
DESCRIPTION
QTY
ITEM
PART
DESCRIPTION
QTY
1
10-5071
Slew platform
1
31
13-3650
Outlet elbow
1
2
16-0157
GRP cover
1
32
13-3651
Suction elbow
1
3
16-0156
GRP cover
1
33
10-5269
1
4
15-0858
Hinge
4
Engine mounting
bracket
5
24-4097
Cover stay
2
34
10-5270
Battery/Pump cover
1
6
10-5266
Power-pack tray
1
35
09-1010
Battery 12 V
1
24-4438
Ø 10mm tie bar
2
7
10-5267
Battery tray
1
36
8
22-5576
Cross Brace
1
37
24-4439
1
9
09-1185
Battery 6V
4
Battery hold down
bracket
10
513325-000
Battery cable set
1
38
13-2419
3-way valve
1
11
069199-001
Charger battery
1
39
056064-010
M10 nyloc nut
2
12
19-0154/2
Hand-pump handle
1
40
056069-010
Flat washer
2
13
19-0154/1
Hand-pump
1
41
13-0339
Suction strainer
1
14
19-0154
Power-pack
1
15
09-0998
Contactor
1
16
13-3609
Hydraulics manifold
1
17
513348-000
Electrical control box part list
1
18
22-5581
Control cover box
1
19
13-0888
Base control valve
1
20
11-3448
Bolt (M12 x 85 mm)
28
21
10-2672
Retaining peg
2
22
24-2880
Retaining peg - large
2
23
SP035D320
Pin
2
24
21-0852
Pin
4
25
22-5577
Splash guard
1
20-0055
Kubota OC60 diesel
engine c/w stop/start kit
1
20-0044
Honda petrol engine
1
27
13-0529
In-line check valve
2
28
13-1949
Bell housing
1
29
13-1950
Flexible coupling
1
30
13-3649
Pump
1
26
TL49J
Table 6-6: Slew (Bi-fuel) components.
Page 6 - 7
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
SLEW - MAINS POWER
Figure 6-5: Slew (mains) assembly.
Page 6 - 8
TL49J
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
SLEW - MAINS POWER
ITEM
PART #
1
10-5071
2
16-0157
3
16-0156
4
15-0858
5
24-4097
6
10-5266
7
10-5267
8
22-5576
9
10-5267
10
513999-000
11
19-0155
12
19-0155/2
13
19-0155/1
14
22-5516
15
09-1937
16
13-3609
17
513348-000
18
22-5581
19
13-0888
20
11-3448
21
10-2672
22
24-2880
23
SP-035D320
24
21-0852
25
22-5508
26
09-2087
Table 6-7: Slew (mains) components.
TL49J
DESCRIPTION
Slew platform
GRP cover
GRP cover
Hinge
Cover stay
Powerpack tray
Battery tray
Cross Brace
Ballast Plate
Motor starter assy mains
Tank/Powerpack
Handpump handle
Handpump
Float charger cover
Float charger
Hydraulics manifold
Ground control box
Control box cover
Base control valve
Bolt
Retaining peg
Retaining peg - Large
Pin
Pin
Emergency Battery Holder
Dry battery
QTY
1
1
1
4
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
28
2
2
2
4
1
1
Page 6 - 9
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
SLEW - BATTERY POWER
Figure 6-6: Slew (battery) assembly.
Page 6 - 10
TL49J
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
SLEW - BATTERY POWER
ITEM
PART #
1
10-5071
2
16-0157
3
16-0156
4
15-0858
5
24-4097
6
10-5266
7
10-5267
8
22-5576
9
09-1185
10
069199-001
12
19-0154
13
19-0154/2
14
19-0154/1
15
22-5577
16
09-0998
17
13-3609
18
513348-000
19
22-5581
20
13-0888
21
11-3448
22
10-2672
23
24-2880
24
SP-035D320
25
21-0852
26
24-4438
27
24-4439
Table 6-8: Slew (battery) components.
TL49J
DESCRIPTION
Slew platform
GRP cover
GRP cover
Hinge
Cover stay
Powerpack tray
Battery tray
Cross brace
Battery
Battery charger
Tank/Powerpack
Handpump handle
Handpump
Splash guard
Contactor
Hydraulics manifold
Ground control box
Control box cover
Base control valve
Bolt
Retaining peg
Retaining peg - large
Pin
Pin
Ø 10mm tie bar
Battery hold bracket
QTY
1
1
1
4
2
1
1
1
4
1
1
1
1
1
1
1
1
1
1
28
2
2
1
2
2
1
Page 6 - 11
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
SLEW - ENGINE POWER
Figure 6-7: Slew (engine) assembly.
Page 6 - 12
TL49J
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
SLEW - ENGINE POWER
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
PART #
10-5071
16-0157
16-0156
15-0858
24-4097
10-5266
10-5267
22-5576
10-5267
100287-000
10-5310
19-0154/2
19-0154/1
13-0339
13-2543
13-3609
513348-000
22-5581
13-0888
11-3448
10-2672
24-2880
SP-035D320
21-0852
22-5613
20-0044
20-0055
13-3549
13-1949
13-1950
13-3649
13-3650
13-3651
10-5269
10-5270
09-1010
DESCRIPTION
Slew platform
GRP cover
GRP cover
Hinge
Cover stay
Powerpack tray
Battery tray
Cross brace
Ballast plate
Sight gauge
Hydraulic tank
Handpump handle
Handpump
Suction strainer
Return line filter
Hydraulics manifold
Slew control box
Control box cover
Base control valve
Bolt
Retaining peg
Retaining peg - Large
Pin
Pin
Tank lid
Engine (petrol)
Engine (diesel)
In-line check valve
Bell housing
Flexible coupling
Pump
Outlet elbow
Suction elbow
Engine mounting bracket
Battery/pump cover
Battery
QTY
1
1
1
4
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
28
2
2
1
2
1
1
1
2
1
1
1
1
1
1
1
1
Table 6-9: Slew (engine) components.
TL49J
Page 6 - 13
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
LOWER BOOM
Figure 6-8: Lower boom assembly.
Page 6 - 14
TL49J
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
LOWER BOOM
ITEM
PART #
1
10-5072
2
10-5073
3
10-5263
4
13-3607
5
13-3606
6
13-3604
7
21-0852
8
SP-035D201
9
21-0850
10
SP-030D320
11
SP-035D320
13
SB-060060
14
SB-035035
15
SB-030030
16
SB-025025
17
10-2672
18
24-2880
19
15-0884
20
15-0883
Table 6-10: Lower boom components.
TL49J
DESCRIPTION
Bottom boom
Tie bar
Vertical boom
Bottom ram
Top ram
Master ram
Pin
Pin
Pin
Pin
Pin
Bush
Bush
Bush
Bush
Retaining peg
Retaining peg
Boom rest pad
Boom rest pad
QTY
1
1
1
1
1
1
2
1
1
1
1
8
6
2
2
8
2
1
1
Page 6 - 15
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
TOP BOOM
Figure 6-9: Top boom assembly.
Page 6 - 16
TL49J
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
TOP BOOM
ITEM
PART #
1
10-5075R
2
10-5076
3
13-3603
4
13-3605
5
15-0899
6
15-0881
7
15-0880
8
15-0895
9
15-0896
10
15-0882
11
24-3952
12
10-5138
13
SP-035D203
14
SP-025D200
15
SP-040D203
16
SP-025A120
17
SP-025D164
18
10-2672
19
SB-030030
20
SB-040040
21
SB-025025
22
09-2121
23
24-3909
24
15-0883
25
15-1009
Table 6-11: Top boom components.
TL49J
DESCRIPTION
Top boom
Telescopic boom
Cage levelling ram
Telescope ram
Tele ram support block
Wear pad
Wear pad
Wear pad
Wear pad
Wear pad
Pad retaining nut
Wear pad keep plate
Pin
Pin
Pin
Pin
Pin
Retaining peg
Bush
Bush
Bush
Cable tray
Hose trunking
Boom rest pad
Drag chain complete
QTY
1
1
1
1
1
1
6
1
1
2
8
4
1
1
1
1
1
8
2
2
4
1
1
1
1
Page 6 - 17
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
DROP NOSE
Figure 6-10: Drop nose assembly.
ITEM
PART #
1
10-5078
2
10-5077
3
13-3602
4
SP-025D200
5
SP-030D216
6
10-2672
7
SB-025025
Table 6-12: Drop nose components.
Page 6 - 18
DESCRIPTION
Drop nose boom
Quadrant
Drop nose ram
Pin
Pin
Retaining peg
Bush
QTY
2
1
1
3
1
6
12
TL49J
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
CAGE SUPPORT
Figure 6-11: Cage support assembly.
ITEM
1
2
3
4
PART #
10-5232
10-5231
10-5229
10-5230
SP-025D235
5
SP-025D200
6
SP-025D330
7
SP-016B108
8
10-2672
9
SB-025015
10
SB-025025
11
SB-016020
12
04-0113
13
13-2403
14
23-0031
15
11-3442
Table 6-13: Cage support components.
TL49J
DESCRIPTION
Pivot support
Cage slew pivot
See-saw bracket
Upper link bracket
Pin - CE
Pin - ANSI
Pin
Pin
Retaining peg
Bush
Bush
Bush
Thrust washer
Cage rotation ram
Spring
Bolt (M12 x 170 mm)
QTY
1
1
1
1
4
2
1
1
9
8
2
4
2
1
2
2
Page 6 - 19
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
STEEL CAGE
Figure 6-12: Steel cage assembly.
Page 6 - 20
TL49J
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
STEEL CAGE
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
PART #
10-5201
22-5065
11-3438
508932-000
508934-000
SP-016B102
10-2672
513590-000
13-0176
13-2200
22-5370
22-5601
09-1276
513321-004
513321-005
14
513321-006
513321-004
15
508140-000
16
09-2126
17
09-1939
Table 6-14: Steel cage components.
TL49J
DESCRIPTION
Steel Cgae
Cage floor
Clamp plate
U-clamp
Access bar
Pin
Retaining peg
Control support
Double over-centre valve
Control valve
Rear cover
Blanking plate
Socket (110 V)
Platform control panel (Battery)
Platform control panel (Engine)
Platform control panel (Bi-fuel)
Platform control panel (Mains)
RCD
Amber marker lamp
Swivel light
QTY
1
1
5
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
Page 6 - 21
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
GRP BASKET
Figure 6-13: GRP basket assembly.
ITEM
1
2
3
4
5
6
7
8
9
10
PART #
02-2674
22-5603
10-5317
SP-016B102
10-2672
513590-000
13-0176
13-2200
22-5370
22-5601
09-1276
11
09-1392
513321-004
513321-005
12
513321-006
513321-004
Table 6-15: GRP basket components.
Page 6 - 22
DESCRIPTION
GRP basket
Access guard
Basket support
Pin
Retaining peg
Control support
Double overcentre valve
Control valve
Rear cover
Blanking plate
Socket (110 V)
Socket (230 V)
Platform control panel (Battery)
Platform control panel (Engine)
Platform control panel (Bi-fuel)
Platform control panel (Mains)
QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
TL49J
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
OUTRIGGER RAM
Figure 6-14: Outrigger ram assembly.
ITEM
PART #
DESCRIPTION
1
13-3608-1
Tube assembly
2
13-2351
Seal kit
3
13-1004
Head bush
4
13-0604
PO Check valve
5
13-0973
Locknut
6
13-1007
Piston
7
SS-0400023
Spacer
8
13-3608-2
Rod assembly
Table 6-16: Outrigger ram components - 13-3608.
TL49J
QTY
1
1
1
2
1
1
1
1
Page 6 - 23
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
BOTTOM RAM
Figure 6-15: Bottom ram assembly.
ITEM
PART #
DESCRIPTION
1
13-3607-1
Tube assembly
2
13-0972
Seal kit
3
13-0968
Head bush
4
13-0392
Over-centre valve
5
13-2474/2
Emergency lower valve
6
09-2090
Solenoid
7
13-2425/77
Hirschmann connector
8
13-0973
Locknut
9
13-0971
Piston
10
SS-0500343
Spacer
11
13-3607-2
Rod assembly
Table 6-17: Bottom ram components - 13-3607.
Page 6 - 24
QTY
1
1
1
1
1
1
1
1
1
1
1
TL49J
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
TOP RAM
Figure 6-16: Top ram assembly.
ITEM
PART #
DESCRIPTION
1
13-3606-1
Tube assembly
2
13-0972
Seal kit
3
13-0968
Head Bush
4
13-0392
Over-centre valve
5
13-2474/2
Emergency lower valve
6
09-2090
Solenoid
7
13-2425/77
Hirschmann
8
13-0973
Locknut
9
13-0971
Piston
10
SS-0500037
Spacer
11
13-3606-2
Rod
12
13-3606-3
Bearing
Table 6-18: Top ram components - 13-3606.
TL49J
QTY
1
1
1
1
1
1
1
1
1
1
1
1
Page 6 - 25
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
MASTER RAM
Figure 6-17: Master ram assembly.
ITEM
PART #
1
13-3604-1
2
13-3603-3
3
13-1061
4
13-0973
5
13-1064
6
13-3604-2
Table 6-19: Master ram components - 13-3604.
Page 6 - 26
DESCRIPTION
Tube assembly
Seal kit
Head bush
Locknut
Piston
Rod assembly
QTY
1
1
1
1
1
1
TL49J
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
TELESCOPIC RAM
Figure 6-18: Telescopic ram assembly.
ITEM
PART #
DESCRIPTION
1
13-3605-1
Tube assembly
2
13-3605-3
Seal kit
3
13-3605-4
Head bush
4
13-0472
Over-centre valve
5
13-0659
PO check valve
6
13-3605-5
Piston
7
13-3605-6
Locknut
8
13-3605Spacer
9
13-3605-2
Rod assembly
Table 6-20: Telescopic ram components - 13-3605.
TL49J
QTY
1
1
1
1
1
1
1
1
1
Page 6 - 27
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
LEVELLING RAM
Figure 6-19: Levelling ram assembly.
ITEM
PART #
DESCRIPTION
1
13-3603-1
Tube assembly
2
13-3603-3
Seal kit
3
13-1061
Head bush
4
13-2489
Over-centre valve
5
13-1064
Piston
6
13-0973
Locknut
7
13-3603-2
Rod assembly
Table 6-21: Levelling ram components - 13-3603.
Page 6 - 28
QTY
1
1
1
2
1
1
1
TL49J
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
DROP NOSE RAM
Figure 6-20: Drop nose ram assembly.
ITEM
PART #
DESCRIPTION
1
13-3602-1
Tube assembly
2
13-3603-3
Seal Kit
3
13-1061
Head bush
4
13-2489
Over-centre valve
5
13-1064
Piston
6
13-0973
Locknut
7
13-3602-3
Spacer
8
13-3602-2
Rod assembly
Table 6-22: Drop nose ram components - 13-3602.
TL49J
QTY
1
1
1
2
1
1
1
1
Page 6 - 29
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
CAGE ROTATION RAM
Figure 6-21: Cage rotation ram assembly.
ITEM
PART #
DESCRIPTION
1
13-2403-1
Tube assembly
2
13-0993
Seal kit
3
13-0988
Head bush
4
13-0992
Piston
5
13-0994
Locknut
6
SS-0200020
Spacer
7
13-2403-2
Rod assembly
Table 6-23: Drop nose ram components - 13-2403.
Page 6 - 30
QTY
1
1
1
1
1
1
1
TL49J
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
TRAILER ELECTRIC KIT PARTS
19
18
21
38
F
E
D
28
30
32
31
27
C
31
27
B
31
27
A
31
H
G
I
27
24
31
T
J
K
L
34
12
7
14
20
2
15
13
17
29
8
3
16
9
23
4
6
5
11
1
24
STANDARD LOWER CONTROL PANEL
33
25
10
L
Figure 6-22: Standard lower control panel assembly - 513348-000.
TL49J
Page 6 - 31
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
STANDARD LOWER CONTROL PANEL
ITEM
PART
DESCRIPTION
QTY
ITEM
PART
DESCRIPTION
QTY
1
513316-000
GP450 I/F Board
1
31
508075-000
2-Core cable
5
2
512368-000
Din rail (170 mm)
1
32
513457-000
3-Core cable
1
3
510156-000
9 way panel plug
1
33
508637-000
Hirschmann connector
5
4
510154-000
6 way panel plug
1
34
513351-000
Blanking grommet
1
5
512366-000
4 way panel plug
1
35
509741-000
Fuse holder
2
6
510155-000
3 way panel plug
1
36
509740-005
Fuse 7.5 A
2
7
510524-000
SW twist release
E/stop
1
37
513349-000
Overlay
1
38
513949-000
9 way chassis socket
1
8
512935-000
LED green 12 V
4
9
512934-000
LED red 12 V
1
10
502588-000
Alarm
1
GLAND ID
LENGTH L (mm)
TAIL Length T (mm)
11
510145-000
Mate-n-lock SCKT
contact
34
A
3300
N/A
12
512543-000
Keyswitch 3 position
stayput
1
B
3300
N/A
C
3300
N/A
D
3300
N/A
E
2700
N/A
F
2700
100*
G
1600
N/A
H
1600
N/A
13
513307-000
Switch 3-way spring to
centre
1
14
513308-000
Switch push button
black mushroom
1
15
513309-000
Switch push button
green mushroom
1
16
3087803
EZcal display
1
17
513310-000
Feed through terminal
4 way
12
18
513312-000
End plate
2
19
513311-000
Feed through terminal
4 way ground
3
20
513314-000
Terminal end stop
2
21
513313-000
Jumper
2
22
513315-000
Spacer
4
23
512817-000
15 way panel plug
2
24
513319-000
Lower control box trailers
1
25
510152-000
Cable gland
12
26
510153-000
Cable gland
12
27
09-2378
Switch cable
4
28
09-2379
Switch cable
1
29
09-2326
Relay 24 V DC
1
30
513350-000
5-Core cable
1
Page 6 - 32
I
1600
N/A
J
7400
N/A
K
1600
N/A
L
1600
100*
Table 6-24: Standard lower control panel
components - 513348-000.
TL49J
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
23
22
21
18
2
3
4
12
13
19
A
14
5
6
1
20
15
17
16
7
8
GASKET SEALS ON OUTSIDE
11
10
9
10
STANDARD PLATFORM CONTROL PANEL
Figure 6-23: Standard platform control panel assembly - 513321-000.
TL49J
Page 6 - 33
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
STANDARD PLATFORM CONTROL PANEL
ITEM
PART #
DESCRIPTION
1
513327-000
Upper control panel
2
510524-000
Sw twist release E/stop
3
513309-000
Switch push button green mushroom
4
512934-000
LED red 12 V
5
512935-000
LED green 12 V
6
513318-000
Keyswitch 2 position spring return
7
510472-000
Matrix board
8
510154-000
6 way panel plug
9
510156-000
9 way panel plug
10
510157-000
12 way panel plug
11
510145-000
Mate-N-lock socket contact
12
09-2378
Switch cable
13
510152-000
Cable gland
14
510153-000
Cable gland
15
058501-025
M5 x 25 S.C.H.S. - GR 12.9
16
056066-005
M5 nylock nut - 8
17
056069-005
M5 washer - Grade 8
18
513949-000
9 way chassis socket
19
514327-000
Resistor 1 K 0.5 W 5%
20
513590-002
Cable mounting plate
21
512651-010
Socket HD capscrew - M3 x 10
22
510561-003
Flat washer - M3
23
510569-003
M3 nylock nut - stainless steel
Table 6-25: Standard Platform control panel components - 513321-000.
Page 6 - 34
QTY
1
1
1
1
1
1
1
1
1
2
14
1
1
1
2
2
2
1
1
1
4
4
4
TL49J
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
BATTERY/MAINS PLATFORM CONTROL PANEL
3
1
4
2
Figure 6-24: Battery/Mains platform control panel assembly - 513321-004.
ITEM
PART #
DESCRIPTION
1
513321-000
Platform control panel (standard)
2
512449-000
Keyswitch 2 position stayput
3
513328-004
TL49 UCP overlay bat/mains
4
513307-000
Switch 3-way spring to center
Table 6-26: Battery/Mains Platform control panel components - 513321-004.
TL49J
QTY
1
1
1
1
Page 6 - 35
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
ENGINE PLATFORM CONTROL PANEL
4
1
5
3
2
Figure 6-25: Engine platform control panel assembly - 513321-005.
ITEM
PART #
DESCRIPTION
1
513321-000
Platform control panel (standard)
2
512449-000
Keyswitch 2 position stayput
3
513317-000
Green push button
4
513328-005
TL49 UCP overlay engine
5
513307-000
Switch 3-way spring to center
Table 6-27: Engine Platform control panel components - 513321-005.
Page 6 - 36
QTY
1
1
1
1
1
TL49J
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
BI-FUEL PLATFORM CONTROL PANEL
4
1
5
3
2
Figure 6-26: Bi-fuel platform control panel assembly - 513321-006.
ITEM
PART #
DESCRIPTION
1
513321-000
Platform control panel (standard)
2
512543-000
Keyswitch 3 position stayput
3
513317-000
Green push button
4
513328-006
TL49 UCP overlay bi-fuel
5
513307-000
Switch 3-way spring to center
Table 6-28: Bi-fuel Platform control panel components - 513321-006.
TL49J
QTY
1
1
1
1
1
Page 6 - 37
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
13
MOTOR CABLE
LENGTH 1800mm
MARK 'MOTOR'
11
STRIP
50mm
10
WITH GREY BOOTLACE FERRULES
9 TERMINATE
513067-000
2
1
MAINS MOTOR STARTER
4
8
STRIP
50mm
6
7
12
5
3
MAINS IN CABLE
LENGTH 3700mm
MARK 'MAINS IN'
Figure 6-27: Mains motor starter assembly - 513999-000.
Page 6 - 38
TL49J
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
MAINS MOTOR STARTER
ITEM
PART #
DESCRIPTION
1
514000-000
Mains motor starter box
2
512368-000
Din rail (170 mm)
3
513312-000
End plate
4
514006-000
Feed through terminal 4 way ground 2.5 mm2
5
513314-000
Terminal end stop
6
509440-000
Cable gland M20
7
510146-000
Cable gland nut M20
8
514001-000
RCD 16 A- 30 mA
9
508077-000
3-core cable 2.5 CSA HO7RN-F
10
514002-000
MCB 16 A
11
514003-000
Motor starter contactor 12 V DC coil
12
514004-000
Overload relay
13
514005-000
PSU 230 V AC to 12 V DC 7.5 A
14
514007-000
Decal ‘isolate supply’
15
514008-000
Cable 2.5 mm CSA Tri-rated brown
16
514009-000
Cable 2.5 mm CSA tri-rated blue
17
514010-000
Cable 2.5 mm CSA tri rated green/yellow
18
513067-000
Grey bootlace ferrule
Table 6-29: Mains motor starter components - 513999-000.
TL49J
QTY
1
1
2
2
5
3
3
1
6m
1
1
1
1
1
0.5 m
0.5 m
0.5 m
23
Page 6 - 39
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ILLUSTRATED PARTS LIST
EXTERNAL COMPONENTS
PART #
DESCRIPTION
09-2088
Solenoid coil 12 V/22 W
09-2091
Solenoid coil 12 V/14 W
02-2639/16
Overload switch
02-2639/22
Stabilizer switch
09-1961
Elevation switch
09-2355
Elevation switch connector
09-2389
Conduit
Table 6-30: External components - All variants.
QTY
2
3
1
4
1
1
1
PART #
DESCRIPTION
502494-000
Fuse 175 A
501877-000
Fuse holder
Table 6-31: External components - All battery variants.
QTY
1
1
PART #
DESCRIPTION
502494-000
Motor starter box assembly
Table 6-32: External components - All mains variants.
QTY
1
CABLE ASSEMBLIES
PART #
513323-000
Table 6-33: Platform cable assembly.
DESCRIPTION
Platform Cable TL49
QTY
1
PART #
513325-000
Table 6-34: Battery cable assembly.
DESCRIPTION
Battery cable set TL49
QTY
1
Page 6 - 40
TL49J
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
BASIC FITTINGS KIT
PART #
DESCRIPTION
12-1008
1/4" BSP male x 7/16" JIC male straight adaptor
12-1007
3/8" BSP male x 7/16" JIC male straight adaptor
12-9005
3/8" BSP male x 7/16" JIC male staright 25th restrictor
12-9004
3/8" BSP male x 7/16" JIC male staright 40th restrictor
12-1013
3/8" BSP male x 9/16" JIC male straight adaptor
12-1017
1/2" BSP male x 9/16" JIC male straight adaptor
12-1869
1/4" BSP male x 7/16" JIC male positional elbow
12-1110
7/16" JIC equal Tee female-on-run
12-1501
1/2" Dowty washer
12-1502
3/8" Dowty washer
12-1507
1/4" Dowty washer
12-1511
1/8" Dowty washer
12-1867
9/16" JIC male/female elbow
12-2001
1/2" BSP male plug
12-2003
3/8" BSP male plug
12-2002
1/8" BSP male plug
12-0927
9/16" UNF male x 9/16" JIC male straight adaptor
12-9007
9/16" UNF male plug
5063701
7/16" (-4) JIC female cap
12-0916
1/4" BSP male x 1/4" BSP female straight adaptor
12-1001
3/8" BSP male x 1/4" BSP male straight adaptor
12-1502
3/8" Dowty washer
12-1879
1/4" BSP female x 1/4" BSP female compact 90° elbow
Table 6-35: TL49J basic fittings kit - All specifications.
TL49J
QTY
29
41
4
2
10
3
6
6
6
64
45
1
1
1
6
1
1
1
1
1
6
6
1
Page 6 - 41
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
END FITTINGS KIT
PART # QTY
G1
2
G2
2
G3
2
G4
2
G5
1
G6
1
G7
2
G8
1
G9
2
G10
1
G11
2
G12
1
G13
1
G14
2
G15
1
G16
2
G17
2
G18
2
G19
2
G20
1
G21
1
G22
1
G23
1
G24
1
Page 6 - 42
LOCATION
HOSE SIZE
Outrigger valve to
outrigger ram 1
Outrigger valve to
outrigger ram 2
Outrigger valve to
outrigger ram 3
Outrigger valve to
outrigger ram 4
Outrigger valve to
manifold P
Outrigger valve to
tank manifold
Base valve to
bottom ram
Bottom ram
emergency lower
Base valve to top
ram
Top ram emergency
lower
Base valve to
telescope ram
Telescope ram
drain
Base valve P to
manifold GP
Base valve to
manifold slew Tee
Hand-pump to
manifold HP1
Slew motor to
manifold SLA/SLB
Base valve to drop
nose ram
Basket valve to
bottom ram
Basket valve to
manifold slew tee
Basket valve P to
manifold CP
Tank manifold to
manifold T
Tank manifold to
base valve T
Pump to manifold P
1/4 R7
Tank manifold to
filter
1/4 R7
1/4 R7
1/4 R7
1/4 R7
1/4 R7
1/4 R7
1/4 R7
1/4 R7
1/4 R7
1/4 R7
1/4 R7
3/8 702
1/4 R7
1/4 R7
1/4 R7
1/4 R7
1/4 R7
1/4 R7
3/8 702
3/8 702
3/8 702
3/8 702
3/8 702
END FITTINGS
LENGTH/
mm
END ‘A’
END ‘B’
7/16 JIC female 7/16 JIC female
3000
straight
135°
7/16 JIC female 7/16 JIC female
3100
straight
135°
7/16 JIC female 7/16 JIC female
1800
straight
135°
7/16 JIC female 7/16 JIC female
1700
straight
135°
7/16 JIC female 7/16 JIC female
1700
straight
straight
7/16 JIC female 7/16 JIC female
1700
straight
straight
7/16 JIC female 7/16 JIC female
1500
straight
straight
7/16 JIC female 7/16 JIC female
1530
straight
straight
7/16 JIC female 7/16 JIC female
6700
straight
straight
7/16 JIC female 7/16 JIC female
6800
straight
straight
7/16 JIC female 7/16 JIC female
6900
straight
straight
7/16 JIC female 7/16 JIC female
6900
straight
straight
9/16 JIC female 9/16 JIC female
1200
straight
straight
7/16 JIC female 7/16 JIC female
1000
straight
straight
7/16 JIC female 7/16 JIC female
700
90°
straight
7/16 JIC female 7/16 JIC female
1200
90°
90°
7/16 JIC female 7/16 JIC female
18200
straight
straight
7/16 JIC female 7/16 JIC female
17800
straight
straight
7/16 JIC female 7/16 JIC female
18700
straight
straight
9/16 JIC female 9/16 JIC female
18700
straight
straight
9/16 JIC female 9/16 JIC female
600
straight
straight
9/16 JIC female 9/16 JIC female
370
straight
straight
9/16 JIC female 9/16 JIC female
400
straight
90°
9/16 JIC female 9/16 JIC female
1000
straight
straight
TL49J
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
END FITTINGS KIT
PART # QTY
G26
1
G27
2
G28
2
G29
2
G30
1
G31
1
G32
2
G33
2
G34
2
H1
1
H2
1
LOCATION
HOSE SIZE
Basket valve to tank
manifold
Basket valve to top
ram
Basket valve to
telescope ram
Master ram to DOC
valve
Basket valve to
slewing ram
Basket valve to
slewing ram
Basket valve to
drop nose ram
DOC valve to
basket levelling ram
Basket valve to
DOC valve
Pump to manifold
3/8 702
Engine pump to
manifold tee
H3
1
Engine pump to
tank suction port
H14
1
Pressure relief V/V
to tank
Table 6-36: TL49J end fittings kit.
TL49J
1/4 R7
1/4 R7
1/4 R7
1/4 R7
1/4 R7
1/4 R7
1/4 R7
1/4 R7
1/4 R7
1/4 R7
1/2 R1AT
1/4 R7
END FITTINGS
LENGTH/
mm
END ‘A’
END ‘B’
9/16 JIC female 9/16 JIC female
18300
straight
straight
7/16 JIC female 7/16 JIC female
12700
straight
straight
7/16 JIC female 7/16 JIC female
12000
straight
straight
7/16 JIC female 7/16 JIC female
12100
straight
straight
7/16 JIC female 7/16 JIC female
2300
straight
90°
7/16 JIC female 7/16 JIC female
2200
straight
90°
7/16 JIC female 7/16 JIC female
4100
straight
90°
7/16 JIC female 7/16 JIC female
3900
straight
90°
7/16 JIC female 7/16 JIC female
600
straight
90°
9/16 JIC female 7/16 JIC female
300
straight
90°
9/16 JIC female 9/16 JIC female
1200
straight
90°
1/2 BSP female 1/2 BSP female
1940
straight
90°
9/16 JIC female 9/16 JIC female
1060
90°
straight
Page 6 - 43
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
TL49 FRICTION DRIVE KIT
LINDEN PART #
DESCRIPTION
H4
1/4 1SN 9/16 JIC F STR x 9/16 JIC F 90 200
H5
1/4 1SN 9/16 JIC F 45 x 9/16 JIC F 90 215
H6
1/4 1SN 9/16 JIC F STR x 9/16 JIC F 90 190
H7
1/4 1SN 9/16 JIC F 45 x 9/16 F 90 250
H8
1/4 1SN 9/16 JIC F 45 x 9/16 f 90 1525
H9
1/4 1 SN 9/16 JIC F 45 x 9/16 F 90 1650
H10
3/8 1SN 9/16 JIC F STR x 9/16 JIC F 45 3275
H11
3/8 1SN 9/16 JIC F STR x 9/16 JIC F 90 3275
H12
1/4 1SN 9/16 JIC F STR x 9/16 JIC F STR 910
H13
1/4 1SN 9/16 JIC F STR x 9/16 JIC F STR 1220
Table 6-37: TL49J friction drive kit - 13-3670.
Page 6 - 44
QTY
1
1
1
1
2
2
1
1
2
1
TL49J
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
TL49 DECAL LOCATIONS
508507-000
508508-000
508521-000
508507-000
508508-000
18-0578
18-0483
508525-001
508523-000
508506-000
508507-000
508508-000
508507-000
510280-000
508508-000
508523-000
508522-000
508519-000
510280-000
508525-001
18-0071
Table 6-27: TL49J decal locations.
TL49J
Page 6 - 45
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
508523-000
510280-000
508513-000
508525-001
18-0483
18-0578
508507-000
Page 6 - 46
TL49J
Courtesy of Crane.Market
ILLUSTRATED PARTS LIST
TL49J
18-0071
508522-000
508506-000
508508-000
508521-000
508519-000
Page 6 - 47
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Courtesy of Crane.Market
Local Distributor / Lokaler Vertiebshändler / Distributeur local
El Distribuidor local / ll Distributore locale
EUROPE, MIDDLE EAST
AFRICA & ASIA
PHONE: +44 (0) 845 1550 057
FAX: +44 (0) 845 1557 756
NORTH &
PHONE:
TOLL FREE:
FAX:
SOUTH
+1 785
+1 800
+1 785
AMERICA
989 3000
225 0317
989 3070
AUSTRALIA
PHONE: +61 2 9725 4000
FAX: +61 2 9609 3057
NEW ZEALAND
PHONE: +64 6 3689 168
FAX: +64 6 3689 164
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