SAFETY RELATED MANDATORY OUTRIGGER CYLINDER INSPECTION AND REPAIR

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1 An ISO 9001 Registered Company June 10, 1999 SERVICE BULLETIN SL-158 This Service Bulletin should be read and understood by all Service Technicians who are trained to service the units affected by this bulletin. SAFETY RELATED MANDATORY OUTRIGGER CYLINDER INSPECTION AND REPAIR To: All Current and Past Snorkel Dealers, Branches and National Accounts Attention: Service Manager Unit's Affected: ALL SLH series units with Outriggers (either standard or optional) Subject: Mandatory Inspection and Repair of the Outrigger Cylinders This Service Bulletin is being issued to advise you a MANDATORY REPAIR of all four Outriggers cylinders on the above stated units. This required repairs must be done immediately. We have received field reports about the outrigger cylinders bleeding down. In extreme cases, this can lead to the unit tipping to one side or the other. These field failures have been linked to contamination being found in the outrigger cylinders and their components. We are providing a field replacement kit (P/N SRV) for this modification. This kit will have all related parts required to repair all four-outrigger cylinders, as required by this bulletin. The cylinder repair kits will be provided to you at no charge. Please verify the Serial Numbers listed for your company and branches to insure we ship the correct quantity of kits. After the campaign has been performed, the Information Sheet must be returned before any credit will be issued. Due to the nature of this campaign, it must be completed on a priority basis. See page 2 of this bulletin for the address of where to return the Information Sheets, and for the phone number where you can contact us if needed. Also, the attached pages of this Service Bulletin include an Installation Procedure, cylinder re-packing procedures, a required response form, and a required order form for the field service kits. Caution: Do not perform any of the procedures of this Service Bulletin if you do not know how to safely operate the affected models. Safe operating procedures are listed in the Operating Manual in the document holder attached to each unit. SL-158 (1) 6/10/99

2 DEALER NOTE: If you have sold any of the affected units to new owners in you area, please give a copy of this Service Bulletin to the new owners and schedule a time when the modification can be performed. If you have sold any of the affected units to new owners outside of your area, please advise us of the Model and Serial Numbers of the units and the names, address, telephone number and contact name(s) of the new owners. All paperwork and claims must be returned to this address: Snorkel Warranty Dept. P.O. Box 1160 St. Joseph, MO Ref. SL-158 Fax Number for returning the Order Forms and the Information Sheets: (816) For questions regarding this bulletin, call the Snorkel Service Dept. at: (800) between 8:00am and 5:00pm SL-158 (2) 6/10/99

3 An ISO 9001 Registered Company INSTALLATION PROCEDURE IP /10/99 Machines Affected: SLH's with Outriggers Installation Procedures for the Mandatory Outrigger Recall Parts List: Kit Part Number: SRV Quantity Part Number Description Pressure Switch Return Filter Element Roll Pin (.375 x 1.5) Outrigger Cylinder Seal Kit Pinch Point Danger Decal Pilot Operated Check Valve Cable Tie 1. Make sure the outriggers are fully retracted. 2. Make sure the unit's platform is in its stowed position. 3. Turn off the unit's main power switch. 4. Remove the 2 hoses that attach to the outrigger cylinder assy. 5. Disconnect the pressure switch wiring at the outrigger cylinder assy. 6. Remove the roll pin securing the footpad-attaching pin. (This will require the use of a hammer and punch.) 7. Remove the footpad attachment pin. 8. Remove the roll pin in the inner sleeve attachment pin. (This will require the use of a hammer and punch.) 9. Remove the inner sleeve attachment pin. Caution: When removing the inner pin, you must take measures to block and support the inner sleeve. This will prevent the sleeve from dropping straight down and possibly causing physical injury. 10. Lift the outrigger cylinder assembly straight up out of the housing. (Note that the cylinder assembly weighs approximately lbs.) 11. Remove the pressure switch. 12. Remove the pilot operated check valve. 13. Disassemble the cylinder for repacking. (Note: Take care not to damage the rod, piston or the barrel while taking apart.) Reassemble the cylinder using the supplied seal kit. (P/N ) SL-158 (3) 6/10/99

4 Take the appropriate precautions to prevent any ingested contamination while reassembling the cylinder. (See pages 5 and 6 for the cylinder re-pack procedures.) 14. Install a new pressure switch. (P/N supplied in the kit.) 15. Install a pilot operated check valve. (P/N supplied in the kit.) 16. Reinstall the outrigger cylinder assembly into the unit by reversing steps 4 through 10 of these instructions. 17. Complete these steps for all four-outrigger cylinders. 18. Replace the unit's return line filter element using one of the supplied elements (Snorkel P/N ), after approximately 2 hours of use replace it again with the other supplied filter element. 19. The final step of this procedure is to test all of the outrigger cylinders for any bleed down. Completely extend all four of the outrigger cylinders. Measure and record the distance from the floor pad to the housing of the outrigger assembly of all four outriggers. Let the unit stand for at least one hour. Re-measure the distance for all four cylinders again. If ANY bleed down is detected, contact the Snorkel Service Department before continuing. 20. Complete the attached paperwork for each unit modified. Submit the paperwork and proper warranty claim forms, to the Snorkel Warranty Department. These must be completed and submitted in order to receive warranty reimbursement. This modification should take approximately 7 man-hours to complete for each unit affected. Should you have any questions concerning this Service Bulletin or its procedures, please contact the Snorkel Service Department at (800) SL-158 (4) 6/10/99

5 Outrigger Cylinder Re-Pack Procedures This procedure outlines the requirements to install a new packing kit in the Prince outrigger cylinder. Tools Required: "Face Style" Adjustable Spanner Wrench, with 1/4 pins adjustable to2" center distance 1/8" Allen Wrench 1 1/8" Hex Socket Torque Wrench with 130 Ft-lb. capacity Suitable holding device for piston rod to prevent damage to chrome surface while torquing piston nut to 130 Ft-lb. 7/16" Hex Wrench for #2 SAE plugs Material Required: One SLH Outrigger packing kit (Snorkel P/N ) Procedure: 1. This procedure assumes that the pilot operated check valve and pressure sensing switch located in the base block have already been removed. 2. Refer to drawing " Cylinder Configuration". 3. Loosen gland locking set screw using 1/8" Allen wrench 4. Unscrew gland completely using spanner wrench. 5. Remove piston rod assembly. 6. Remove four SAE #2 plugs from the base block. 7. Thoroughly clean the inside of the tube and all oil passageways in the base block. Blow compressed air through the manifold to help insure no contamination is present. 8. Examine the inside of the tube for any evidence of scoring. If any scoring is present the cylinder needs to be replaced. 9. Remove the cotter pin, piston nut, and piston from the rod. Remove the rod from the gland. 10. Remove all of the old packing, being careful not damage any seal grooves with the removal tools. 11. Thoroughly clean the piston, gland, and rod. Install the new packing kit. Insure that the rod seal U-cup is oriented correctly (open portion of the "U" towards the inside of the cylinder) when installing the gland packing. Refer to "Piston Seal Detail" when installing the piston seal. Note the orientation of the radius surface on the anti-extrusion rings. 12. Apply clean oil to the inside surface of the gland and install on the rod. Install the piston on the rod, noting the position of the static O-ring (item #4). Install the piston nut and torque to 130 Ftlb. Install the cotter pin (item#1). 13. Oil the outside of the piston and CAREFULLY insert the rod assembly into the tube. The piston should not be allowed to contact the threaded portion of the tube during this step, as the anti-extrusion rings may be "rolled" in the seal groove. 14. Thread the gland into the tube and tighten securely. Tighten the locking screw in the face of the gland. 15. Replace the four SAE #2 plugs in the base block. SL-158 (5) 6/10/99

6 SL-158 (6) 6/10/99

7 SL-158 Mandatory SLH OutRigger Recall Information Please Note: For warranty reimbursement, the following information MUST be completed for each unit modified and submitted with the Warranty Claim Form, before any credit will be issued. From: Unit Model Number: Unit Serial Number: Hour Meter Reading: Contact: Phone Number: Note: To determine the front and rear of this unit, the platform control box is always in the front and the engine is in the rear. Original Equipment Information: Left Front Outrigger Cylinder Right Front Outrigger Cylinder Cylinder ID #: Cylinder ID #: PO CK Valve ID #: PO CK Valve ID #: PO CK Valve Date Code: PO CK Valve Date Code: Left Rear Outrigger Cylinder Right Rear Outrigger Cylinder Cylinder ID #: Cylinder ID #: PO CK Valve ID #: PO CK Valve ID #: PO CK Valve Date Code: PO CK Valve Date Code: CC: Unit File SL-158 (7) 6/10/99

8 Service Bulletin SL-158 Outrigger Recall Order Form SRV Mandatory SLH Outrigger Kit (This kit will be provided at NO CHARGE) Dealer/ Owner: Ship To: Ordered By: Date: Reference: Received: (a) Please list the Serial Number of each machine that requires the Mandatory Outrigger recall kit. (b) Fax a copy of this sheet to the Snorkel Service Department. Fax Number: (816) ) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) SL-158 (8) 6/10/99

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