Maintenance

TB80/TB85J/TB86J – Fixed Axle Maintenance – 1

Maintenance – 2 TB80/TB85J/TB86J – Fixed Axle
Maintenance AWarning
Every person who maintains, inspects, tests or repairs the The potential for accident increases when operating
aerial platform must be qualified to do so. Maintenance an aerial platform that is damaged or malfunction-
functions must be performed by maintenance personnel ing. Death or serious injury can result from such
who are qualified to work on the aerial platform. accidents. Do not operate the aerial platform if it is
damaged or malfunctioning.
ACaution Repair all defects before returning the machine to
Welding current can be very intense. Damage to
electronic components can result. Connect the service.
ground clamp as close as possible to the area be-
ing welded. Disconnect the battery cables and any General Information
microprocessors and engine control modules before The parts drawings located in the Repair Parts section
welding on the machine. are designed for use as a guide for proper disassembly
of the machine and components, as well as, for parts
If it becomes necessary to weld aerial platform com- replacement.
ponents as a method of repair, take all precautions to
prevent damage to electronic circuitry and devices on
the machine. This includes, but may not be limited to,
ADanger
Hydraulic fluid escaping under pressure can have
disconnecting battery cables and electronic devices. enough force to inject fluid into the flesh. Serious
infection or reaction will result if medical treatment
Do not modify this aerial platform without prior writ- is not given immediately. In case of injury by escap-
ten consent of the Snorkel Engineering Department. ing hydraulic fluid, seek medical attention at once.
Modification may void the warranty, adversely affect
stability or affect the operational characteristics of the Always refer to the hydraulic system installation draw-
aerial platform. ings and the electrical wiring diagram before removing
or disassembling associated parts.
Maintenance Schedules
Snorkel has established a preventative maintenance When disassembling or reassembling components,
schedule to detect any defective, damaged or improperly complete the procedural step in sequence. Do not par-
secured parts and provide information regarding lubrica- tially disassemble or assemble one part, then start on
tion and other minor maintenance items. another. Always check your work to assure that nothing
has been overlooked.
This schedule includes the following:
Keep the following in mind when disassembling or as-
yy Daily Prestart Inspection sembling the machine.
yy Frequent Inspection and Maintenance – Every 90 yy Always be conscious of weight.
Days or 150 Hours
yy Never attempt to lift heavy objects without the aid
yy Annual Maintenance – Every 500 Hours of a mechanical device.
The Daily Prestart Inspection must be performed by a yy Do not allow heavy object to rest in an unstable
trained operation. All other maintenance and inspection condition.
must be performed by a trained service technician only.
Retain a copy of these forms for your records. yy Always make sure the work platform is in the
stowed position, blocked or the weight removed
All placards and decals on the machine must be in place by a suitable lifting device before removing any
and legible. Use the Placards and Decals parts page in components from the machine.
the Repair Parts section of this manual to check these
placards and decals. yy When raising a portion of the machine, be sure
that adequate blocking is properly positioned. Do
Snorkel recommends that you make additional copies of not depend solely on the lifting device to hold and
the preventative inspection and maintenance checklists secure weight.
for your use in performing these inspections.
yy If a part resists removal, check to see if all fasten-
ers, electrical wiring, hydraulic lines, etc., have
been removed or that other parts are not interfering.

TB80/TB85J/TB86J – Fixed Axle Maintenance – 3

Parts should be thoroughly inspected before restoring Clean surrounding areas, as well as the opening and
to service at the time of reassembly. Burrs, nicks or fittings before disconnecting air or oil lines. As soon as a
scratches may be removed from machines surfaces by line or component is disconnected, cap or cover all open-
honing or polishing with a #600 crocus cloth, followed by ings to prevent the entry of dirt or foreign materials.
a thorough cleaning with an approved cleaning solvent,
and blown dry with compressed air. Do not alter the New parts should remain in their container until they are
contour of any part. If this operation does not restore the ready to be used.
part to a serviceable condition, replace the part.
Clearly mark or tag hydraulic lines and electrical wiring
Replace all o-rings, seals and gaskets at reassembly. connections when disconnecting or removing them from
Use new roll pins or cotter pins. Dip all packing rings and the machine. This will assure that they are correctly
seals in hydraulic oil before reassembling in cylinder and reinstalled.
manifolds. Replace any part having imperfect threads. In
general, machines that have been disassembled can be Proper assembly is critical to the successful rebuilding
reassembled by reversing the order of disassembly. of any machine. Carefully, inspect any parts which are
to be reused. If in doubt, replace.
The service life of a machine can be increased by keep-
ing dirt and foreign materials out of the vital components. “Safety First” is a good slogan.
Shields, covers, seals and filters help to keep air and oil
supplies clean. However, these items must be maintained Replace any guards and protective devices that have been
on a scheduled basis in order to function properly. removed to carry out maintenance and repair work.

Maintenance – 4 TB80/TB85J/TB86J – Fixed Axle

 Daily Prestart Inspection
Item Inspect For Ok
Operator’s Manual In manual holder
Engine
Oil level Between full and add marks
Coolant Proper fluid level
Radiator Cap tight, good condition and clean
Air cooled engines Air intake and fan free of obstructions
Belt in good condition
Fuel tank and line Tank full, cap in place and tight/no leaks
Air filter Green indicator
Charging system Proper operation
Cold weather start kit No damage or deformation
Electrical System
Emergency power battery Condition and charged for proper operation
Battery fluid level and terminals Proper level/clean, connectors tight
Cables and wiring harness No wear or physical damage
Hydraulic System
Fluid level Between full and add marks
Fluid filter Verify operation in the green zone
Hoses, tubes and fittings No leaks
Cold weather warm-up kit Proper operation
Tires and Wheels Good condition, all wheel lug nuts present and tight
Lower Control System
Operation controls Proper operation
Emergency stop and emergency power Shuts off lower controls/proper operation
Emergency Lowering Proper operation
Level Sensor Sounds tilt alarm
Flashing Light Proper operation
Sandblast Protection Kit In place and proper operation
Structures
Weldments – Chassis, turntable, booms, platform, etc. Welds intact, no damage or deformation
Slide Pads In place, no damage or deformation
Fasteners In place and tight
Upper Control System
Guardrail system and lanyard anchors Welds intact, no damage or deformation
All fasteners in place, no loose or missing parts
Operating controls Proper operation
Emergency stop and emergency power Shuts off upper controls/proper operation
Horn Sounds when activated
Electrical power outlet Proper operation
Drive motion alarm Sounds when aerial platform moves
Driving and work lights Proper operation
Platform control cover In place and proper operation
Air Line Good condition, proper operation
Placards and Decals In place and readable

Performed by: Date:

TB80/TB85J/TB86J – Fixed Axle Maintenance – 5
Maintenance – 6 TB80/TB85J/TB86J – Fixed Axle
 Frequent Inspection and Maintenance – Every 90 Days or 150 Hours
Item Procedure Information OK
Chassis
Structural Check for damage and cracked welds
Steering cylinder snap rings Verify that all fasteners are in place
and are tight
Steering linkage Check for proper operation
Tires Check for wear and damage
Hydraulic tubes and hoses Check for leaks, wear, and damage
Drive motor brake Check for proper operation
Torque drive and steer wheel Torque lug bolts/nuts to proper value Front: 450 to 500 ft lb
lug nuts per placard on wheel on machine placard Rear: 450 to 500 ft lb
Right drive motors Check for leaks
Left drive motors Check for leaks
Tie-down and lifting lugs Check for damage and cracked welds
Decals and placards Check for damage and readability
Order replacements as necessary
Turntable
Structural Check for damage and cracked welds
Torque turntable top bolts Torque to proper value 475 to 525 ft lbs
Torque turntable bottom bolts Torque to proper value 350 to 400 ft lbs
Hydraulic tubes and hoses Check for leaks, wear, and damage
Centerpost Check for leaks, wear, and damage
Centerpost mounting bolts Verify that all fasteners are in place
and are tight
Lift cylinder pin caps and tie Verify that all fasteners are in place
wire and are tight
Lift cylinder and holding valve Check for leaks, wear, damage, and
for proper operation
Master level cylinder pin caps Verify that all fasteners are in place
and tie wire and are tight
Master level cylinder and Check for leaks, wear, damage, and
holding valves for proper operation
Emergency bleed down valve Check for proper operation
Cowling Check for wear/damage and that
fasteners are in place and are tight
Wire harness Check for wear/damage and that
fasteners are in place and are tight
Rotation brake Check for proper operation
Rotation backlash Check for wear and damage
Operator’s Manual Proper manual in document holder
System pressure Check maximum system pressure 2,750 – 2,850 psi
Decals and placards Check for damage and readability
Order replacements as necessary

TB80/TB85J/TB86J – Fixed Axle Maintenance – 7

 Frequent Inspection and Maintenance – Every 90 Days or 150 Hours
Item Procedure Information OK
Lower Controls
Control switch in the lower controls Check for proper operation With selector in the lower
position controls position, upper
controls do not work
Station selector switch in the upper Check for proper operation With selector in the upper
controls position controls position, lower
controls do not work
Engine Start – Stop Check for proper operation
Throttle High – Low Check for proper operation
Turntable CW – CCW Check for proper operation
Boom elevation Up – Down Check for proper operation
Boom Extend – Retract Check for proper operation
Jib Up – Down Check for proper operation
Jib rotation CW – CCW Check for proper operation
Platform level Up – Down Check for proper operation
Platform rotation CW – CCW Check for proper operation
Emergency power, all functions Check for proper operation
Emergency stop Check for proper operation
Booms
Structural Check for damage and cracked
welds
Lift cylinder pin caps and tie wire Verify that all fasteners are in place
and are tight
Hydraulic tubes and hoses Check for leaks, wear, and damage
Extension cylinder pin caps and Verify that all fasteners are in place
tie wire and are tight
Extension cylinder and holding valve Check for leaks, wear, damage, and
for proper operation
Jib boom pin caps and snap rings Verify that all fasteners are in place
and properly installed
Jib cylinder pin caps and snap rings Verify that all fasteners are in place
and properly installed
Jib cylinder and holding valve Check for leaks, wear, damage, and
for proper operation
Slave level cylinder pin caps and tie Verify that all fasteners are in place
wire and are tight
Slave level cylinder and holding Check for leaks, wear, damage, and
valves for proper operation
Hose carrier tube and support Check for residue buildup/proper
operation
Plastic hose track Check for wear and damage
Electrical wires Check for wear and damage
Decals and placards Check for damage and readability
Order replacements as necessary

Maintenance – 8 TB80/TB85J/TB86J – Fixed Axle

 Frequent Inspection and Maintenance – Every 90 Days or 150 Hours
Item Procedure Information OK
Platform
Structural Check for damage and cracked welds
Entry Gate Check for proper operation
Hydraulic tubes and hoses Check for leaks, wear, and damage
Slave level cylinder pin caps and Verify that all fasteners are in place
tie wire and are tight
Slave level cylinder holding valves Check for leaks, wear, damage, and
for proper operation
Decals and placards Check for damage and readability
Order replacements as necessary
Upper Control Station
Foot switch Check for proper operation With the foot switch
engaged the engine should
not start. Functions should
be operational when foot
switch is engaged
Engine Start – Stop Check for proper operation
Throttle High – Low Check for proper operation
Turntable CW – CCW Check for proper operation
Boom elevation Up – Down Check for proper operation
Boom Extend – Retract Check for proper operation
Jib Up – Down Check for proper operation
Platform level Up – Down Check for proper operation
Platform rotation CW – CCW Check for proper operation
Drive speed Boom up and/or extended 1 mph = 100 ft in 65 to 75 sec
Low – 1.0 mph
Boom down and retracted 3 mph = 100 ft in 22 to 28 sec
High – 3.0 mph
Drive range – boom stowed Check for proper operation Slow speed only with boom
raised
Engine choke – gas engine only Check for proper operation
Emergency power, all functions Check for proper operation
Emergency stop Check for proper operation
Horn Check for proper operation
Gradual start to stop lift/swing/ Check for proper operation
drive controls
Speed limit switch Check for proper operation
Tilt alarm Check for proper operation 5° NonCE/3.5° CE
110 volt AC power to platform Check for proper operation
Hydraulic Oil Reservoir
Filler/breather cap and tank Check for wear/securely fasten
Hydraulic fluid level Check for proper level Above 10°F (-13°C)
ISO VG32
Below 10°F (-13°C)
ISO VG15
Hydraulic filter Replace after the first 50 hours, every
90 days or 150 hours thereafter
Inspect filter for foreign matter that
could indicate component wear

TB80/TB85J/TB86J – Fixed Axle Maintenance – 9

 Frequent Inspection and Maintenance – Every 90 Days or 150 Hours
Item Procedure Information OK
Engine
Charging system Check for proper operation
Air filter Check for wear and damage
Hour meter Check for proper operation
Belts and hoses Check for wear and damage
Hydraulic pump Check for proper operation
Battery terminals Clean terminals and check cable
condition
Battery electrolyte Check electrolyte levels Add distilled water if
necessary
Indicator gauges Check for wear/damage and proper
operation
Engine oil Check for wear and damage/level Between add and full
Engine coolant Check level Between add and full
Engine Start – Stop Check for proper operation
Electric throttle Check for proper operation
Electric choke, if equipped Check for proper operation
Engine governor setting Check for proper operation
Platform Rotator
Structural Check for damage and cracked welds
Hydraulic rotator actuator Check for leaks, wear, and damage
Platform rotation holding valve Check for proper operation
Mounting bolts and pin caps Verify that all fasteners are in place
and are tight
Options
110 volt AC generator Check for proper operation
220 volt AC generator Check for proper operation
Dual fuel system Check condition and for proper operation
LP gas system and control Check condition and for proper operation
Drive motion alarm Check for proper operation
Flashing light Check for proper operation
Cold weather start kit – diesel only Check for proper operation
Hydraulic system cold weather warm Check for proper operation
up kit
Driving lights Check for proper operation
Platform work lights Check for proper operation
Platform control cover Check condition and for proper operation
Sandblast protection kit Check for proper operation
Airline to platform Check for proper operation
Spark arrestor muffler – Deutz only Check for wear and damage
Platform welder Check condition and for proper operation
Platform glazier package Check condition and for proper operation
Optional platform Verify that all fasteners are in place
and are tight

Maintenance – 10 TB80/TB85J/TB86J – Fixed Axle

 Frequent Maintenance – Every 90 Days or 150 Hours
Item Procedure Information OK
Daily maintenance Perform maintenance as per schedule Retain copy of checklist
Preventive inspection Perform inspection, complete form Retain copy of checklist
maintenance checklist
Placards and decals Inspect using drawing and parts listing in Replace any missing or
inspection Section 1 – Repair Parts Manual unreadable decals/placards
Door hinges and latches Lubricate SAE 10W oil or spray lubricant
Rotation bearing Lubricate Conoco Super Sta #2
Above 32° F Mobilgrease CM-P
Below 32° F Mobilgrease CM-L
Rotation bearing teeth Lubricate Mobil Mobiltac 375NC
and pinion
Tie rods Lubricate Conoco Super Sta #2
Above 32° F Mobilgrease CM-P
Below 32° F Mobilgrease CM-L
Gear hubs Check fluid level, fill if low Mobil Mobilube HD 80W-90
Swing drive Check fluid level, fill if low Mobil Mobilube HD 80W-90
Platform rotator Refill if disassembled for repairs Consult factory
Platform controller Check smooth operation/speeds
Batteries Check specific gravity 1.260/1.275 at 80° F (26° C)
Hydraulic return filter Check condition Replace if dirty
Engine rpm Check for proper engine rpm See engine owner’s manual
Engine oil and filter Replace per engine owner’s manual See engine owner’s manual
Engine fuel filter Check condition Replace every 6 months or if dirty

Performed by: Date:

TB80/TB85J/TB86J – Fixed Axle Maintenance – 11

Maintenance – 12 TB80/TB85J/TB86J – Fixed Axle
 Annual Maintenance – Every 500 Hours
Item Procedure Information OK
90 day or 150 hour Perform maintenance per Retain copy of checklist
maintenance schedule
Hydraulic oil reservoir Clean and replace fluid Above 10° F (-13° C)
ISO VG32
Below 10° F (-13° C)
ISO VG15
Hydraulic return filter Replace After first 50 hours, then at
recommended interval
Hydraulic reservoir Clean and reinstall
suction filter
Hydraulic pressures Pump setting Standby pressure:
350-375 psi
Function pressures Boom up:
2,450-2,550 psi
Boom down:
800-900 psi
Steer: 2,800-3,000 psi
Level: 3,000 psi
Extend: 1,450-1,550 psi
Retract: 2,450-2,550 psi
Swing: 1,250-1,350 psi
Gear hubs Replace fluid Mobil Mobilube HD 80W-90
Swing drive Replace fluid Mobil Mobilube HD 80W-90
Engine coolant Check condition See engine owner’s manual

Performed by: Date:

TB80/TB85J/TB86J – Fixed Axle Maintenance – 13

Maintenance – 14 TB80/TB85J/TB86J – Fixed Axle
 Major Repairs
Date Part Number Part Description Repair Performed

TB80/TB85J/TB86J – Fixed Axle Maintenance – 15

Maintenance – 16 TB80/TB85J/TB86J – Fixed Axle
 Lubrication Points

7
11 8 10 9 4 1

12

12
13 5
5 5 6
3 2 3
3

Lubrication 3. Fill until lubricant is level with bottom of fill hole.

Specific lubricants as recommended by Snorkel, should
be used in maintaining the unit. If in doubt regarding Note
the use of lubricants other than those listed, contact Do not overfill gear hubs as they are not vented and need
Snorkel Customer Service Department for evaluation air space for expansion of oil to prevent damage to hubs.
and recommendation.
Platform Rotator
Refer to the above lubrication illustration to locate com- Platform Rotator – Item 6. Platform rotators will require
ponent item numbers. lubrication only if disassembled for repairs. Consult
factory for proper lubricant if replacement of platform
Service all fittings as indicated on the Frequent Mainte- rotator is required.
nance schedule and lubrication illustration. Wipe away all
excess lubricant from exposed surfaces. Over lubrication Hydraulic Oil Reservoir
can collect dirt and foreign matter which acts as an abra- Hydraulic oil reservoir – Item 7. The fluid level should
sive. Lubrication of accessory equipment should be in be kept between the full and add marks on the sight
accordance with the manufacturer's recommendations. gauge and should be checked with the machine in the
stowed position.
Rotation Bearing
Rotation bearing – Item 1. Pressure gun lubricate bear- The interior of the reservoir should be wiped out and
ing at recommended interval using lubricant as outlined cleaned each time the hydraulic oil is changed. The
in the maintenance schedule. Rotate while lubricating. reservoir filler/breather cap should be removed and the
The lubrication fitting is located on the turntable below cap strainer cleaned with Kerosene, fuel oil, or other
the lower controls. solvent at this time.

Rotation Gear Teeth and Pinion It is absolutely necessary that only new, clean hydraulic
Rotation gear teeth and pinion – Item 2. Gear teeth and oil is added.
gear box pinion should be lubricated with a spray-on
type open gear lubricant. Note
If it becomes necessary to add or use an oil other than
Tie Rods the recommended fluid, it is important that it be compat-
Tie rods – Item 3. Lubricate at recommended interval us- ible and equivalent to the factory fill. Local oil suppliers
ing lubricant as outlined in the maintenance schedule. can generally furnish this information.

Swing Drive If questions still remain, contact Snorkel Customer Ser-

Swing drive – Item 4. To check oil level, remove check vice Department for further information.
plug located on the side of the gear box. Unit is full if oil
is level with bottom of fill hole or just starts to run out. Engine
Engine – Item 8. Refer to the engine manufacturer’s
Gear Hubs instruction manual or consult your local engine service
Gear hubs – Item 5. To check and fill Gear hubs: representative if engine adjustments or repairs are
needed. The engine must be operated in accordance
1. Rotate wheel until bottom of filler/drain plug is with manufacturer’s instructions and serviced at recom-
about 1 inch above horizontal centerline. mended intervals.

2. Remove plug with drive ratchet and extension.

TB80/TB85J/TB86J – Fixed Axle Maintenance – 17
Hydraulic Oil Return Filter Slide Pads
Return filter – Item 9. Tthe hydraulic oil return filter is Slide pads – Item 12. Check slide pads for excessive
mounted outside of the hydraulic oil reservoir. wear and replace as required. Slide pads do not require
lubrication.
The filter element is a throw-away type filter and
should be changed after the initial break-in period Batteries
(approximately 50 hours operation time). Batteries – Item 13. Batteries will have longer life if the
water level is maintained and they are kept charged.
The filter is equipped with a hydraulic pressure gauge The engine will have better starting characteristics with a
to indicate the filter element condition. A by-pass relief fully charged battery. In cold weather the battery should
within the filter base is provided and is set to by-pass at be maintained at full charge to keep from freezing. An
25 psi. If pressure readings are above 25 psi, the filter extremely low or dead battery can freeze in cold weather.
should be changed. Make sure connections are clean and tight.

The filter condition should be checked at the 90 day or Make sure charging equipment is operating properly.
150 hour Preventive Inspection Maintenance interval or
more frequently under extreme working conditions.
ADanger
The filter condition indicator is accurate only when Lead-acid batteries produce flammable and explo-
the engine is running at maximum rpm and pump is sive gases. Never allow smoking, flames or sparks
discharging maximum flow, which occurs only during around batteries. Lead-acid batteries contain sulfu-
full speed driving. This requires that the indicator ric acid which will damage eyes or skin on contact.
be observed while the unit is in motion, booms fully When working around batteries, always wear a face
retracted and in stowed position, drive range switch shield to avoid acid in eyes.
in “LO” position, and drive controller fully forward. Oil
temperature should be at least 90° F (32° C). If acid contacts eyes, flush immediately with clear water
and get medical attention. Wear rubber gloves and
protective clothing to keep acid off skin, if acid contacts
AWarning skin, wash off immediately with clear water.
Use extreme caution while observing the condition
indicator because of the motion of the drive wheels. Battery Care and Maintenance
The condition indicator is best observed from out- The following information about battery care and main-
side of the tract of the vehicle wheels to avoid pos- tenance was supplied by Interstate Batteries and is
sible personal injury or machine damage. reprinted here with their permission.

When changing the filter element, the oil inside of the 1. New batteries need to be cycled several times before
filter element, should be examined for deposits of metal reaching full capacity (20-50 cycles, depending on
cuttings, which is present, could indicate excessive wear type). Usage should be limited during this period.
in some of the system components.
2. Always recharge batteries fully, immediately after
Suction Strainer use. Batteries perform best when they are fully
Suction strainer – Item 10. A 100 mesh strainer is charged. More capacity and longer life will result
located within the hydraulic oil reservoir and filters the from this practice.
pump suction flow.
3. The deeper the discharge, the fewer number of
The strainer should be cleaned at the time interval shown cycles a lead-acid battery will deliver. Deep dis-
in the maintenance schedule chart, using Kerosene, fuel charges deteriorate the battery quicker than lighter
oil or other solvent and a soft bristled brush. shallow cycles.

Inspect the filter wire cloth for damage. Holes in the filter 4. Battery cables should be intact and connectors kept
cloth leak dirt into the pump and other vital hydraulic tight at all times. Systematic inspection is recom-
components. If element is damaged, replace. mended.

When the filter has been thoroughly cleaned, reinstall 5. Vent caps should be kept in place and tight during
in suction line and tighten securely. vehicle operation and battery charging.

Door Hinges and Latches 6. Batteries should be kept clean – free of dirt and cor-
Door hinges and latches – Item 11. After lubricating, rosion – at all times. Always keep the top of batteries
remove any excess lubricant or over spray so it will not clean. A film on top of the battery can cause the
collect dirt or debris. current to migrate between the posts, accelerating
self discharge.

Maintenance – 18 TB80/TB85J/TB86J – Fixed Axle

 7. Never let the electrolyte level of a lead-acid battery fall should be equalized once per week. Manually timed
below the plates. Lack of maintaining the electrolyte chargers should have the charge time extended
in a lead-acid battery causes damage to the exposed approximately 3 hours. Automatically controlled
portion of the plate which reduces capacity. chargers should be unplugged and reconnected
after completing a charge cycle.
8. Always check electrolyte level before charging. Do
not add water to individual cells unless plates are 17. In situations where multiple batteries are connected
exposed. Batteries should be watered after charg- in series, parallel or series-parallel, a replacement
ing unless the plates are exposed before charging. battery's should be of the same size, age and usage
If exposed before charging, the plates should be level as the companion batteries. Do not put a new
covered by approximately 1/8″ of water. Check water battery in a pack that has 50 or more cycles. Either
level after charging. Water should be kept 1/4″ below replace all the batteries with new batteries or install
the bottom of the fill tube in the cell cover. a good used battery's in place of the bad. New bat-
teries should be given a full charge before use.
9. Water used to replenish batteries should be distilled
or treated to not exceed 200 T.D.S. (total dissolved 18. Periodic battery testing is an important preventa-
solids... parts per million). Particular care should be tive maintenance procedure. Hydrometer readings
taken to avoid metallic solids (iron). of each cell (fully charged) give an indication of
balance and true charge level. Imbalance could
10. A fully charged battery will give you the best and mean the need for equalizing and is often a sign
longest service. Be sure the batteries are fully of improper charging or a bad cell. Voltage checks
charged before testing or using. A fully charged bat- (open circuit, charged and discharged) can locate
tery, without a drain or load, after the surface charge a bad cell or weak battery. Load testing will pick
has dissipated, is 6.35 volts for a 6 volt battery. out a bad cell when other methods fail. The point
is to look for the abnormal. A weak cell or battery
11. Batteries should not be discharged below 20% of will cause premature failure of companion cells or
capacity (approximately 1.8 volts per cell under batteries respectively.
normal operating load; 1.98 volts open circuit; 1.145
specific gravity). Proper battery sizing will help avoid 19. As batteries age, their maintenance requirements
excessive discharge. change, Generally their specific gravity is higher and
gassing voltage goes up. This means longer charging
12. Battery chargers should be sized to fully charge time and/or higher finish rate (higher amperage at the
batteries in an eight hour period. Chargers should end of charge). Usually, older batteries need to be
be kept in proper operating condition. watered more often and their capacity decreases.

13. Do not use a mismatched charger of any type; i.e., 20. “Opportunity charging”, a short partial charge during
a 12 volt charger on a 24 volt pack or a 24 volt an extended duty cycle, is a controversial subject.
charger on a 12 volt pack. An undersized charger Generally, the practice is a “crutch” to make up for
will never get the job done, no matter how long it undersized batteries. The correct approach is to
tries. An oversized charger will cause excess gas- install adequate battery capacity. If this is impossible
sing and heat that could possibly result in a battery because of lack of space in the battery compartment
meltdown and/or explosion. or extreme operating conditions (24 hour intermit-
tent use, as an example), “opportunity charging” is
14. Never charge a lead-acid battery with a sealed (gel better than excessive battery discharging. However,
cell) battery charger. The lead-acid battery needs the practice can cause batteries to overheat, require
higher voltage to finish its charge. Without it the more watering and usually will shorten battery life.
battery will never come back to 100% and sulfation “Opportunity charging” is a trade off; something to
can occur. avoid if possible. One charging cycle per day is
preferable.
15. Always allow batteries to cool off after charging.
The cooling time is very important because heat 21. Extreme temperatures can substantially affect bat-
is generated during the recharge and discharge tery performance and charging. Cold reduces bat-
cycles. Without the cooling time the heat grows, tery capacity and retards charging. Heat increases
accelerating grid corrosion which is one of the major water usage and can result in overcharging. Very
causes of battery failure. Charging practice should high temperature can cause “thermal run away”
enable batteries to cool before use. which may lead to an explosion or fire. If extreme
temperature is an unavoidable part of an application,
16. Deep cycle batteries need to be equalized peri- consult a battery/charger specialist about ways to
odically. Equalizing is an extended, low current deal with the problem.
charge performed after the normal charge cycle. It
helps keep cells in balance. Actively used batteries

TB80/TB85J/TB86J – Fixed Axle Maintenance – 19

22. An overly discharged battery might need to be cycled 24. Never store a battery in a discharged state. The
a few times before it can recover fully. If a battery sulfate that forms during discharge can make the
begins to heat before coming up to a full charge, battery impossible to recharge fully.
it might be necessary to discharge the battery and
recharge it a few times. The charge and discharge
cycle might help the current acceptance of the battery
and facilitate its recovery to a usable condition.

23. Inactivity can be harmful to deep cycle batteries. If

they sit for several months, a “boost” charge should
be given – more frequently in warm climate (about
once a month) than in cold (every 2-3 months).

Maintenance – 20 TB80/TB85J/TB86J – Fixed Axle

Fastener Torque Chart

Bolt SAE Grade SAE Grade SAE Grade SAE Grade

Grade 1 or 2 5 6 8

Marking

Minimum Medium
Indeterminate
Definition Commercial Commercial
Quality
Quality Quality

Medium Medium Carbon Medium Carbon

Low
Carbon Steel Alloy Steel
Material Carbon
Steel Quenched and Quenched and
Steel
Tempered Tempered Tempered
Minimum Tensile 64,000 psi. 105,000 psi 133,000 psi. 150,000 psi
Strength

Bolt Size Recommended Torque Value (ft lbs)

1/4 5 7 10 10.5

5/16 9 14 19 22

3/8 15 25 34 37

7/16 24 40 55 60

1/2 37 60 85 92

9/16 53 88 120 132

5/8 74 120 167 180

3/4 120 200 280 296

7/8 190 302 440 473

1 282 466 660 714

Torque chart information:

yy Consult manufacturers' specific recommendations, when available.

yy The chart may be used with both coarse and fine thread fasteners lightly lubricated.

yy Increase torque by 20% when multiple tapered tooth (shake proof) lock washers are used.

yy The torque values are given in foot-pounds.

yy Inch/pound equivalent may be obtained by multiplying by 12.

TB80/TB85J/TB86J – Fixed Axle Maintenance – 21

Maintenance – 22 TB80/TB85J/TB86J – Fixed Axle