Snorkel A38E Parts & Service Manual
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Snorkel A38E Parts & Service Manual

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May 2011

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  • Page 1 May 2011...
  • Page 3 SERVICE & PARTS MANUAL AB38 Aerial Work Platform Nameplate The Serial Number of the Work Platform is also stamped on the inside of the Chassis, close to the Steering Cylinder. AB38 Work Platform AB38 Work Platform...
  • Page 4 NOTES: AB38 Work Platform...
  • Page 5 Foreword Introduction Introduction & Specifications HOW TO USE THIS MANUAL This manual is divided into 7 Sections, one of which is in a General Description & Machine Specifications. loose leaf format. The right hand pages of each Section is marked with a black tab that line up with one of the thumb index tabs on the right side of this page.
  • Page 6 Foreword NOTES: AB38 Work Platform...

  • Page 7: Table Of Contents

    Contents Section Table of Contents Section Page Section Page Introduction & Specifications Maintenance Introduction ............1-1 Introduction ............4-1 Purpose ............1-1 Tools Required ..........4-1 Scope ..............1-1 Preventative Maintenance ....... 4-1 General Information .......... 1-1 Preventative Maintenance Platform ............1-1 Table Key ............4-2 Control Box ............1-1 Preventative Maintenance...
  • Page 8 Section Contents Table of Contents Section Page Section Page Installation .............4-20 Illustrated Parts Breakdown 4.15 Upper Lift Cylinder ..........4-21 Removal ............4-21 Introduction ............7-1 Disassembly ..........4-21 Index ..............7-1 Cleaning & Inspection .........4-21 Illustrated Parts Breakdown ......7-2 Reassembly/Seal Replacement ....
  • Page 9 Contents Section List of Illustrations List of Tables Figure Title Page Table Title Page AB38 Work Platform ........1-1 AB38 Work Platform Specifications ....1-3 Forklifting & Lifting The AB38 ....2-1 Controls & Indicators ........3-4 Manual Brake Release ........2-2 Preventative Maintenance ......4-2 Controls &...
  • Page 10 Section Contents NOTES: AB38 Work Platform...

  • Page 11: Introduction & Specifications

    Introduction & Specifications Section CONTROL BOX 1.0 Introduction The control box is permanently fitted at the front centre of the platform. It features a Joystick which PURPOSE will provide proportional control for raising or The purpose of this Service & Parts Manual is to lowering either of the two booms, extending or provide instructions and illustrations for the operation retracting the Telescopic Boom, rotating (slewing)

  • Page 12: Drive & Steer Systems

    Introduction & Specifications Section DRIVE & STEER SYSTEMS AB38 PURPOSE & LIMITATIONS The AB38 Work Platform is restricted to low speed The purpose of the AB38 work platform is to provide a drive when the Platform is raised above the Boom quickly deployable variable height work platform.

  • Page 13: Specifications

    Introduction & Specifications Section 1.2 Specifications Table 1-1: Specifications ITEM METRIC IMPERIAL (ANSI) Duty Cycle 45% of 8 hour shift 45% of 8 hour shift Platform Size 0.7 m x 1.3 m (inside gaurdrails) 2.3 ft x 4.3 ft (inside gaurdrails) Max.

  • Page 14: Notes

    Section Introduction & Specifications NOTES: AB38 Work Platform...

  • Page 15: Machine Preparation

    Machine Preparation Section 2.1 Preparation for use CAUTION Read, understand and follow all operating instructions before attempting to operate the machine. 2.2 Preparation for Shipment Lubricate machine per lubrication instructions in Section 4.4, Maintenance. Fully lower the platform and make sure the machine is stowed securely.

  • Page 16: Manual Brake Release

    Section Machine Preparation When the AB38 is on the Truck it should then be When towing is completed, turn both Allen head made secure. socket screws in a counter clockwise direction until they rest firmly against the locking circlip. Chock the wheels of the AB38. Secure the work platform to the transport vehicle with chains or straps of adequate load capacity attached to the lifting lugs on the...

  • Page 17: Notes

    Machine Preparation Section NOTES: AB38 Work Platform...
  • Page 18 Section Machine Preparation NOTES: AB38 Work Platform...

  • Page 19: Operation

    Operation Section Joystick Interlock Switch is depressed. The speed 3.0 Introduction range within which the machine will drive is deter- mined by whether or not the booms are raised. If a GENERAL FUNCTIONING boom is raised off the Boom Rest Limit Switch the current to the drive motors will be reduced leading to WARNING a significantly slower drive speed.

  • Page 20: Design Features

    Section Operation It will be noticed that on the Upper Control Box a set HOUR METER of buttons are used to alternate functions. Each The AB38 Series Work Platform is equiped with an function will have it’s corresponding graphic. This hourmeter as standard.

  • Page 21: Safety Rules & Precautions

    Operation Section 3.1 Safety Rules and Precautions DO NOT use in winds exceeding 12.5 m/s (28 mph - Beaufort Force 6) WARNING NEVER change or modify operating or safety systems. Before using the AB38 Work Platform it is imperative to read, understand and follow the INSPECT the machine thoroughly for cracked welds, following Safety Rules and Precautions.

  • Page 22: Controls & Indicators

    Section Operation 3.2 Controls and Indicators The controls and indicators for operation of the AB38 Work Platform are shown in Figures 3-1 & 3-2. The name and function of each control and indicator are listed in Tables 3-1. The index numbers in the figure correspond to the index numbers in the table.

  • Page 23: Controls & Indicators

    Operation Section 6 7 8 Figure 3-1: Controls & Indicators AB38 Work Platform...

  • Page 24: Pre-Operation Inspection

    Section Operation Operate the manual telescopic retraction 3.3 Pre-Operation Inspection system using the Handpump to test that it will WARNING work. (Not required on ANSI machines). LOWER each boom until the Elevating Assembly is fully stowed. Climb into the Carefully read, understand and follow all Platform and check that the Platform is level.

  • Page 25: Elevating & Lowering The Ab38 Work Platform

    Operation Section the Joystick. Slowly move the Joystick forward 3.4 Operation to ELEVATE Boom 1. The further the joystick is moved, the faster the boom will move. NOTE: Before operating the AB38 Work Platform Pressure must be applied to the Interlock at it is imperative that the Pre-Operation Inspection all times while operation is required.

  • Page 26: Elevated

    Section Operation To “STEER” the AB38 activate the Interlock The platform can be levelled from the Upper controls Switch while pushing the Steering Switch LEFT using the levelling function, depress and hold the or RIGHT to turn the wheels. Observe the tyres levelling button on the upper control box (see fig3-1) while manoeuvring to ensure proper direction.

  • Page 27: Control From Ground Level

    Operation Section ensure a slow controlled rate of descent at all times. Descent can be halted at any time by removing MANUAL ROTATION pressure from the red knob. Repeat the operation if necessary for the upper boom Ensure booms are lowered as far as possible when cylinder is in reach of the ground.
  • Page 28 Section Operation Hand Pump Hydraulic Valve Tank Valve Block Hand Pump Handle Figure 3-4: Manual Telescopic Retraction 3-10 AB38 Work Platform...

  • Page 29: Notes

    Operation Section NOTES: AB38 Work Platform 3-11...
  • Page 30 Section Operation NOTES: 3-12 AB38 Work Platform...

  • Page 31: Maintenance

    Maintenance Section 4.0 Introduction 4.1 Preventative Maintenance (Table 4-1) WARNING The complete inspection consists of periodic visual Be sure to read, understand and follow all and operational checks, together with all necessary Operation Section information in the minor adjustments to assure proper performance. this manual before attempting to operate or Daily inspection will prevent abnormal wear and prolong the life of all systems.

  • Page 32: Preventative Maintenance Table Key

    Section Maintenance Preventative Maintenance Table Key COMPONENT INSPECTION OR SERVICES INTERVAL Steering Check Steering Cylinder for leaks. 50h/30d Interval Assembly Lubricate all pivot pins. 250h/6m Daily each shift or every day Check Links and Hubs. 250h/6m 10h/7d every 10 hours or 7 days Drive Check for operation.

  • Page 33: Battery Maintenance

    Maintenance Section Basic Rule for maximum duty cycle of deep cycle 4.2 Battery Maintenance traction batteries Electrical energy for the motor is supplied by eight 6 Use the machine until it shows signs of weak / volt batteries wired in series to give a 48 volts DC slow performance.

  • Page 34: Battery Cell Equalization

    Section Maintenance All UpRight battery operated Work Platforms, including 4.3 Temperature correction for the AB38 can operate at ambient Electrolyte readings temperatures to a value of -20ºC (-4ºF). However for this there are two provisions which must be met. The ISO#46 grade of hydraulic oil normally used in UpRight Work Platforms must be replaced with a SPECIFIC GRAVITY CONVERSION CHART grade suitable for these low temperature conditions.

  • Page 35: Lubrication

    Maintenance Section 4.4 Lubrication PIVOT PINS Apply grease liberally to the Pivot Pin and Pin Lock Plate locations using a brush or cloth. Force as much Refer to Table 4-1 and Figure 4-1 for location and grease as possible between the Pins & Pin Lock lubrication intervals required for the items that Plates and the Weldments.

  • Page 36: Setting Hydraulic Pressures

    Section Maintenance Provide a suitable container to catch the 4.5 Setting Hydraulic Pressures drained oil. Hydraulic tank has a capacity of 25 (Figure 4-3) Litres (6.5 Gallons US). Remove the drain plug on the lower side and allow all oil to drain. Check the hydraulic pressures whenever the pump, Clean the magnetic drain plug and reinstall.

  • Page 37: Slew Cross-Line Relief Valve

    Maintenance Section SLEW CROSS-LINE RELIEF VALVES 4.6 Maintenance on Elevating Assembly (Figure 4-6) Repeat steps 1-3 as outlined above Loosen Locknuts on both cross-line relief valves and turn adjusting screws anticlockwise The only time the Elevating Assembly needs to be two full turns.

  • Page 38: Switch Adjustments

    Section Maintenance BOOM REST LIMIT SWITCH 4.7 Switch Adjustments (Figure 4-7 & 4-8) Function: This limit switch is activated when the Elevating Assembly is fully stowed and the upper boom is sitting in the boom rest. The Boom TILT SENSOR Rest is located on the side of the First Post on the AB38 Work Platform.

  • Page 39: Tilt Sensor

    Maintenance Section Figure 4-7: Tilt Sensor Elevating Assembly Lower Boom Upper Boom Switch Body Switch Head Figure 4-8: Boom Rest Limit Switch AB38 Work Platform...

  • Page 40: Hydraulic Manifold

    Section Maintenance ASSEMBLY 4.8 Hydraulic Manifold (Figure 4-9) CAUTION Though it is not necessary to remove the manifold to Note: Lubricate all O-rings before installation perform all maintenance procedures, a determination to prevent damage to O-rings. should be made as to whether or not the manifold should be removed before maintenance procedures begin.

  • Page 41: Manifold Block Components

    Maintenance Section Valve Block Solenoid Valve Coil Locking Nut Fitting, straight Bonded Washer Pressure Reduction Valve Main Relief Valve Pressure Test Point Telescopic Retraction Valve Cross Line Relief Valves Refer to Page 7-20 for part numbers Figure 4-9: Manifold Block Components AB38 Work Platform 4-11...

  • Page 42: Hydraulic Pump

    Section Maintenance 4.9 Hydraulic Pump 4.10 Traction Motor Maintenance (Figure 4-10) (Figure 4-11) CAUTION CAUTION If the hydraulic reservoir has not been Before carrying out any maintenance drained, suitable means for plugging the procedures on the Drive Motors ensure that hoses should be provided to prevent the electric circuit is disconnected i.e.
  • Page 43 Maintenance Section 4.10 Every 500 working hours, or annually Every 1000 working hours, or every two years Brushes - Check the wear, the correct seating, Bearings- All the bearings are fitted with a and the regularity of the working double shield and lubricated with surface.

  • Page 44: Electric Motor

    Section Maintenance 4.11 DISASSEMBLY 4.11 Electric Motor (Figure 4-13) Remove through bolts. WARNING Remove pulley end cover Pull the armature out of the assembly in one Before carrying out any maintenance swift motion. procedures on the electric motor ensure that Remove commutator end cover.

  • Page 45: Maintenance Intervals & Procedures

    Maintenance Section 4.11 Place the bearing spring into the bearing bore. MAINTENANCE INTERVALS & Take a complete armature assembly, including PROCEDURES bearings, and insert commutator end bearing into the bearing bore. Every 500 working hours, or annually Note: Do not reuse bearings which have been removed from armature shaft.

  • Page 46: Electric Motor Assembly

    Section Maintenance 4.11 Pump Bearing Pulley End Cover Pulley End Bearing Armature Commutator Bearing Stator Housing Brush Housing Support Commutator End Cover Inspection Cover Brush Holders Brush Retaining Spring Brushes Retaining Bolt Coupling Figure 4-13: Electric Motor Assembly 4-16 AB38 Work Platform...

  • Page 47: Drive Reduction Gearbox

    Maintenance Section 4.12 During oil change, we recommend that the inside of 4.12 Drive Reduction Gearbox the Gearcase is flushed out with flushing fluid (Figure 4-14) recommended by the lubricant manufacturer. Oil should be changed when hot to prevent a build up of sludge deposit.

  • Page 48: Changing The Oil

    Section Maintenance 4.13 Reattach the brake hose to the brake port. CHANGING THE OIL Reattach the Wheel Assembly to the Gearbox using the five M14 nuts. Unless an oil suction system can be used, it is necessary to remove the gearbox to fully drain the oil. CAUTION The AB38 should be driven for five minutes in order to bring the oil up to working temperature.

  • Page 49: Lower Lift Cylinder

    Maintenance Section 4.14 4.14 Lower Lift Cylinder (Figure 4-15) REMOVAL CAUTION The Lower Lift Cylinder is heavy, so utilise appropriate lifting equipment to support the unit before removing pins. Ensure that the AB38 is on firm level ground, the Elevating Assembly is completely stowed, the Keyswitch is to the ‘OFF’...

  • Page 50: Reassembly/Seal Replacement

    Section Maintenance 4.14 with filtered compressed air. Lubricate the piston seal and install the piston Check all threaded parts for stripped or and rod assembly in the barrel tube. damaged threads. Thread headcap onto barrel tube and hand Check the bearing surfaces inside of the tighten, then turn 1/4 turn further.

  • Page 51: Upper Lift Cylinder

    Maintenance Section 4.15 4.15 Upper Lift Cylinder (Figure 4-17) REMOVAL CAUTION The Upper Lift Cylinder is heavy, so utilise appropriate lifting equipment to support the unit before removing pins. Ensure that the AB38 is on firm level ground, the Elevating Assembly is completely stowed, the Keyswitch is to the ‘OFF’...

  • Page 52: Installation

    Section Maintenance 4.16 end of thread and secure with circlip. 4.16 Telescopic Cylinder Lubricate the piston seal and install the piston (Figure 4-18) and rod assembly in the barrel tube. Thread headcap onto barrel tube and hand tighten, then turn 1/4 turn further. REMOVAL Install the upper cylinder Overcentre valve.

  • Page 53: Cleaning & Inspection

    Maintenance Section 4.17 Boom 2 and push the cylinder pin completely in CLEANING AND INSPECTION and fix pin lock plate with bolt. Position the rod end of cylinder into place and Clean all metal parts in solvent and blow dry insert the pin until the circlip groove is exposed.

  • Page 54: Cleaning & Inspection

    Section Maintenance 4.17 piston assembly in the barrel tube. CLEANING AND INSPECTION Thread the headcap onto the free end of the barrel tube and hand tighten, then turn 1/4 turn Clean all metal parts in solvent and blow dry further. with filtered compressed air.

  • Page 55: Master Levelling Cylinder

    Maintenance Section 4.18 inside of the cylinder barrel and the shaft for 4.18 Master Levelling Cylinder signs of scoring, pits, excessive wear or (Figure 4-20) polishing. Scratches or pits deep enough to catch a fingernail are unacceptable. Polishing is a sign of uneven loading and if sufficiently REMOVAL polished the affected parts should be replaced.

  • Page 56: Slave Levelling Cylinder

    Section Maintenance 4.19 DISASSEMBLY (Refer to Figure 4-16) 4.19 Slave Levelling Cylinder (Figure 4-21) Unscrew the headcap and withdraw the rod and piston assembly from the barrel tube. Unscrew the piston nut and remove piston and REMOVAL headcap from the cylinder rod. Remove the piston static O-ring from the Ensure that the AB38 is on firm level ground, cylinder rod.

  • Page 57: Installation

    Maintenance Section 4.19 Switch while a colleague holds a cloth at the INSTALLATION fitting ‘B’. Air will be expelled through this fitting. Activate the Switch slowly in both directions NOTE: Before installing the Slave Cylinder check until all air is expelled and hydraulic fluid begins cylinder pins and bearings for wear and replace if to appear.

  • Page 58: Adjustment Of Overcentre Valves

    Section Maintenance 4.20 4.20 Adjustment of Overcentre Valves on AB38 Lift Cylinders (Figure 4-22) The valve supplier delivers the Overcentre valve preset to specification and SHOULD NOT be adjusted by the user. In the event of the valve having been tampered with the advisable course of action is to fit a replacement cartridge.

  • Page 59: Notes

    Maintenance Section 4.21 NOTES: AB38 Work Platform 4-29...
  • Page 60 Section Maintenance 4.21 NOTES: 4-30 AB38 Work Platform...

  • Page 61: Troubleshooting

    Troubleshooting Section 5.0 Introduction GENERAL PROCEDURE As all problems which require troubleshooting will to The following section on troubleshooting provides some extent be unique, the Service Engineer will guidelines on the types of problems users may need to evaluate the steps to follow for each individual encounter in the field, helps determine the cause of case.
  • Page 62 Section Troubleshooting PROBLEM PROBABLE CAUSE REMEDY PROBLEM PROBABLE CAUSE REMEDY All functions 1. Blown Electric Check fuses, 4. Platform Remove excess weight. inoperable. Fuse. Replace if blown. Overloaded. Electric 2. Faulty Battery Check the voltage output of Machine 1. The Elevating Raise the Elevating motor does Charger.
  • Page 63 Troubleshooting Section PROBLEM PROBABLE CAUSE REMEDY PROBLEM PROBABLE CAUSE REMEDY prime the brake drive is selected. If no 4. Tacho faulty. Repair or replace. lines. current is being fed to this Machine 1. The AB38 is not Lower the Elevating coil then replace the cable will not in the stowed...

  • Page 64: Fault Codes

    Section Troubleshooting 5.2 Fault Codes. The AB38 is equipped with a fault detection system, if you have a faulty component, bad electrical connection or start up error a fault code will be displayed on the read out located on the upper control box. For fault codes 01 - 39 the following procedure should be followed.
  • Page 65 Troubleshooting Section FAULT CODE SYSTEM INITIALIZATION ERROR SYSTEM COMMUNICATION ERROR Platform STEER left switch ON at power-up (rocker switch on top of joystick) Platform STEER right switch ON at power-up (rocker switch on top of joystick) Platform SLEW switch ON at power-up (rotate function) Platform DRIVE switch ON at power-up Platform TELESCOPE switch ON at power-up Platform LOWER BOOM switch ON at power-up...
  • Page 66 Section Troubleshooting NOTES: AB38 Work Platform...

  • Page 67: Introduction

    Schematics Section 6.0 Introduction This section contains electrical and hydraulic power schematics and associated information for maintenance purposes. INDEX Page Electrical Assy, J1 Harness Electrical Assy, J2 Harness Electrical Assy, J1 Harness & Connections Hydraulic Legend Hydraulic Schematic 6.11 AB38 Work Platform...
  • Page 68 Schematics Section NOTES: AB38 Work Platform...

  • Page 69: Electrical Schematics

    Schematics Section 6.1. Electrical Schematics J1 Harness AB38 Work Platform...
  • Page 70 Schematics Section 6.1. Electrical Schematics AB38 Work Platform...
  • Page 71 Schematics Section 6.1. Electrical Schematics J1 Harness & Connections AB38 Work Platform...
  • Page 72 Schematics Section NOTES: AB38 Work Platform...
  • Page 73 Schematics Section AB38 Work Platform Electrical Schematic...
  • Page 74 Schematics Section TOP VIEW Electrical Schematic AB38 Work Platform...

  • Page 75: Hydraulic Schematics

    Schematics Section 6.2. Hydraulic Schematics Table 6-2: Hydraulic Schematic Legend REFERENCE NAME FUNCTION LOCATION REFERENCE NAME FUNCTION LOCATION Brake. Spring applied - hydraulically On front end of V10 (RV) Main relief Sets max system pressure to On main released brakes to stop wheel drive valve.
  • Page 76 Section Schematics NOTES: 6-10 AB38 Work Platform...

  • Page 77: Main Manifold Block

    Schematics Section CYL1- BOOM1 CYL6 - SLAVE CYL2- BOOM2 CYL5 - MASTER CYL3- TELE MOT1 B2 A3 B3 A4 B4 A5 BRAKE CLRV CLRV (RV) BOOM1 TELE SLEW STEER BOOM2 F L1 Main Manifold Block MMB - RESEVOIR / HYDRAULIC TANK AB38 Work Platform Figure 6-3, 4 : Hydraulic Schematic 6-11...
  • Page 78 Schematics Section NOTES: 6-12 AB38 Work Platform...

  • Page 79: Index

    Section Illustrated Parts Breakdown Section 7.0 Introduction 7.1 Index Assembly Page This section lists and illustrates the replaceable assemblies and parts of the AB38 Work Platform as inal Assembly AB38 ..........7-2 manufactured by UpRight UK. Chassis Assembly ............7-4 Each parts list contains the component parts for that assembly indented to show relationship where Booms and Posts Assembly ........

  • Page 80: Final Assembly Ab38

    Section Illustrated Parts Breakdown FINAL ASSEMBLY AB38 - 500200-001 (ANSI Version) 500200-000 (CE Version) ITEM PART NO. DESCRIPTION QTY. 500202-000 Chassis Assembly 500201-000 Booms and Posts Assembly 057603-000 Cage and Cradle Assembly 057580-000 Drive Reduction Gearbox Assembly 057568-000 Traction Motor Assembly - Right Hand 058834-000 Traction Motor Assembly - Left Hand 057530-000...
  • Page 81 Illustrated Parts Breakdown Section AB38 Work Platform...
  • Page 82 Illustrated Parts Breakdown Section CHASSIS ASSEMBLY AB38 - 500202-000 ITEM PART NO. DESCRIPTION QTY. 500210-000 AB38 CHASSIS WELDMENT 500232-000 AB38 DRIVE MOTOR COVER 500233-000 AB38 CHASSIS BODY COVER 500231-000 AB38 MODULE COVER 500052-000 GRAB HANDLE 057727-000 TWIST SCREW FASTENER 500259-000 AB38 COVER GRIP LATCH 500261-000 AB38 MANIFOLD BLOCK...
  • Page 83 Illustrated Parts Breakdown Section AB38 Work Platform...
  • Page 84 Illustrated Parts Breakdown Section BOOMS & POSTS ASSEMBLY 500201-000 ITEM PART NO. DESCRIPTION QTY. 058412-000 AB38 FIRST POST WELDMENT 058431-001 BALLAST COVER (ANSI / Wide Only) BALLAST (Inc Cover)CE Narrow ONLY See manufacturer 058417-000 AB38 TENSION BAR WELDMENT 058416-000 AB38 SECOND POST WELDMENT 058413-000 AB38 LOWER BOOM WELDMENT 058414-001...
  • Page 85 Illustrated Parts Breakdown Section AB38 Work Platform...
  • Page 86 Illustrated Parts Breakdown Section CAGE & CRADLE ASSEMBLY(STANDARD) 057603-000 (501864-000 is not included as part of this assembly) (ANSI is Without Overload) ITEM PART NO. DESCRIPTION QTY. 057521-003 CAGE RAIL ASSY. 057524-000 DROP BAR ASSY. 057523-000 CONTROL BOX MOUNTING PLATE 501864-000 AB38 UPPER CONTROL BOX 010076-000...
  • Page 87 Illustrated Parts Breakdown Section AB38 Work Platform...
  • Page 88 Section Illustrated Parts Breakdown CAGE ROTATOR ASSEMBLY(OPTION) 500905-000 (501864-000 is not included as part of this assembly) (ANSI is Without Overload) ITEM PART NO. DESCRIPTION QTY. 501864-000 UPPER CONTROL BOX. 500973-000 MOUNTING PLATE. 500985-000 ROTATING HANDLE 500922-000 GEARBOX 500905-034 HANDLE 500905-030 DRIVE SHAFT 508930-000...
  • Page 89 Illustrated Parts Breakdown Section AB38 Work Platform 7-11...

  • Page 90: Wheel Hub Assembly

    Section Illustrated Parts Breakdown WHEEL HUB ASSEMBLY 057669-000 ITEM PART NO. DESCRIPTION QTY. 057665-000 WHEEL HUB 057664-000 THRUST BEARING 057662-000 PIVOT BOSS 057663-000 PIVOT PIN 057585-000 COVER PLATE 057584-000 OUTER HUB BEARING 057583-000 INNER HUB BEARING 057582-000 STUD 057669-002 PLASTIC BUSHING 7-12 AB38 Work Platform...
  • Page 91 Illustrated Parts Breakdown Section AB38 Work Platform 7-13...

  • Page 92: Drive Reduction Gearbox Assembly

    Section Illustrated Parts Breakdown DRIVE REDUCTION GEARBOX ASSEMBLY 057580-000 ITEM PART NO. DESCRIPTION QTY. ITEM PART NO. DESCRIPTION QTY. COUPLING INPUT FLANGE EXPANSION PLUG SCREW STEEL DISC SPACER BRONZE DISC CIRCLIP O-RING BEARING SPACER COUPLING O-RING BEARING ANTI-EXTRUS. RING PISTON SPRING SPRING SUN PINION...
  • Page 93 Illustrated Parts Breakdown Section AB38 Work Platform 7-15...

  • Page 94: Traction Motor Assembly

    Section Illustrated Parts Breakdown TRACTION MOTOR ASSEMBLY 057568-000 : RIGHT HAND MOTOR 058834-000 : LEFT HAND MOTOR ITEM PART NO. DESCRIPTION QTY. MOTOR MOUNTING FACE SEAL CIRCLIP BEARING COOLING FAN COMMUTATOR BEARING FIELD WINDINGS COMMUTATOR COVER BRUSH BOXES SUPPORT END FACE VENT / INSPECTION CAP 057698-000 BRUSH...
  • Page 95 Illustrated Parts Breakdown Section AB38 Work Platform 7-17...

  • Page 96: Motor/Pump Assembly

    Section Illustrated Parts Breakdown MOTOR/PUMP ASSEMBLY 057530-000 ITEM PART NO. DESCRIPTION QTY. 058862-000 HYDRAULIC PUMP 058862-001 SEAL KIT 058847-000 COUPLING OIL SEAL PUMP MOUNTING FACE CIRCLIP BEARING CIRCLIP CIRCLIP COOLING FAN COMMUTATOR BEARING COMMUTATOR COVER BRUSH HOUSING SUPPORT 058863-000 BRUSH END HOUSING TERMINAL BLOCK VENT / INSPECTION CAP...
  • Page 97 Illustrated Parts Breakdown Section AB38 Work Platform 7-19...

  • Page 98: Rear & Front Wheel Kit

    Section Illustrated Parts Breakdown REAR & FRONT WHEEL KIT (WHITE - NON MARKING) SERIAL 1297 TO CURRENT 500494-000 ITEM PART NO. DESCRIPTION QTY. 057578-000 WHEEL NUT - M14 057668-001 REAR WHEEL TYRE & RIM ASSY. 057666-000 WHEEL NUT - M16 057667-003 FRONT WHEEL TYRE &...
  • Page 99 Illustrated Parts Breakdown Section AB38 Work Platform 7-21...
  • Page 100 Section Illustrated Parts Breakdown SLEW MOTOR, WORM DRIVE UNIT & SLEW BEARING ASSEMBLY 500284-001 ITEM PART NO. DESCRIPTION QTY. 500284-000 AB38 WORM DRIVE UNIT & SLEW BEARING ASSEMBLY 500280-000 BOLT 5/8” -11 UNC x 3 1/2” 500281-000 WASHER M16 HARDENED 500285-000 AB38 SLEW MOTOR 500285-001...
  • Page 101 Illustrated Parts Breakdown Section AB38 Work Platform 7-23...

  • Page 102: Manifold Block Assembly

    Section Illustrated Parts Breakdown MANIFOLD BLOCK ASSEMBLY 500261-000 ITEM PART NO. DESCRIPTION QTY. MAIN MANIFOLD BLOCK ONLY 501960-000 SOLENOID VALVE & COILS 501961-000 SOLENOID VALVE & COILS 501962-000 SOLENOID VALVE & COILS 501963-000 SOLENOID VALVE & COILS 057106-000 PRESSURE TEST POINT FITTING 057540-000 PRESSURE REDUCING VALVE 057536-000...
  • Page 103 Illustrated Parts Breakdown Section AB38 Work Platform 7-25...

  • Page 104: Lower Lift Cylinder Assembly

    Section Illustrated Parts Breakdown LOWER LIFT CYLINDER ASSEMBLY 058460-000 ITEM PART NO. DESCRIPTION QTY. CYLINDER BODY 058887-000 EMERGENCY LOWERING VALVE SERIAL NUMBERS #1501-1522 500397-000 EMERGENCY LOWERING VALVE SERIAL NUMBERS #1523-CURRENT 058728-000 SINGLE OVERCENTRE VALVE END CAP ROD AND END PIVOT SEE NOTE U-RING ROD SEAL SEE NOTE...
  • Page 105 Illustrated Parts Breakdown Section AB38 Work Platform 7-27...

  • Page 106: Upper Lift Cylinder Assembly

    Section Illustrated Parts Breakdown UPPER LIFT CYLINDER ASSEMBLY 058462-000 ITEM PART NO. DESCRIPTION QTY. CYLINDER BODY 058887-000 EMERGENCY LOWERING VALVE SERIAL NUMBERS #1501-1522 500397-000 EMERGENCY LOWERING VALVE SERIAL NUMBERS #1523-CURRENT 058728-000 SINGLE OVERCENTRE VALVE END CAP ROD AND END PIVOT SEE NOTE U-RING ROD SEAL SEE NOTE...
  • Page 107 Illustrated Parts Breakdown Section AB38 Work Platform 7-29...

  • Page 108: Telescopic Cylinder Assembly

    Section Illustrated Parts Breakdown TELESCOPIC CYLINDER ASSEMBLY 058461-000 ITEM PART NO. DESCRIPTION QTY. CYLINDER BODY 058728-000 SINGLE OVERCENTRE VALVE 058714-000 SINGLE P.O. CHECK VALVE END CAP ROD AND END PIVOT SEE NOTE U-RING ROD SEAL SEE NOTE ROD SEAL SEE NOTE WIPER SEE NOTE 0-RING...
  • Page 109 Illustrated Parts Breakdown Section AB38 Work Platform 7-31...

  • Page 110: Steering Cylinder Assembly

    Section Illustrated Parts Breakdown STEERING CYLINDER ASSEMBLY 058463-000 ITEM PART NO. DESCRIPTION QTY. CYLINDER BODY CYLINDER ROD SEE NOTE PISTON SEAL END CAP SEE NOTE WIPER SEE NOTE ROD SEAL SEE NOTE O-RING 057048-000 GREASE NIPPLE NOTE:ITEMS 3, 5, 6 & 7 FORM THE SEAL KIT FOR THE AB38 STEERING CYLINDER.
  • Page 111 Illustrated Parts Breakdown Section AB38 Work Platform 7-33...

  • Page 112: Master/Slave Cylinder Assembly

    Section Illustrated Parts Breakdown MASTER/SLAVE CYLINDER ASSEMBLY MASTER CYLINDER 058734-000 SLAVE CYLINDER 058735-000 ITEM PART NO. DESCRIPTION QTY. CYLINDER BODY VALVE BLOCK BODY 058728-000 SINGLE OVERCENTRE VALVE END CAP ROD AND END PIVOT SEE NOTE U-RING ROD SEAL SEE NOTE ROD SEAL SEE NOTE WIPER...
  • Page 113 Illustrated Parts Breakdown Section AB38 Work Platform 7-35...
  • Page 114 Section Illustrated Parts Breakdown PUMP & TRACTION MOTOR CONTROL UNIT ASSEMBLY 501862-000 ITEM PART NO. DESCRIPTION QTY. 501863-000 ECU BOX WITH PC BOARD 501873-000 LINE CONTACTOR 501874-000 PUMP CONTACTOR 501875-000 MOTOR CONTACTOR 501876-000 MOTOR CONTROLLER 501877-000 FUSE BLOCK 501878-000 FUSE HARNESSES ITEM PART NO.
  • Page 115 Illustrated Parts Breakdown Section AB38 Work Platform 7-37...

  • Page 116: Lower Control Box Assembly

    Section Illustrated Parts Breakdown AB38 LOWER CONTROL BOX ASSEMBLY 500490-000 (Harnesses are not part of this assembly) ITEM PART NO. DESCRIPTION QTY. 501867-000 E-STOP SWITCH C/W CONTACT BLOCK 501872-000 ANALOG ROCKER 501870-000 OVERLAY (DECAL) NOTE: THE PART NUMBER FOR THE CABLE-BOX CONNECTOR IS 501880-000 7-38...
  • Page 117 Illustrated Parts Breakdown Section AB38 Work Platform 7-39...

  • Page 118: Upper Control Box Assembly

    Illustrated Parts Breakdown Section UPPER CONTROL BOX ASSEMBLY 501864-000 ITEM PART NO. DESCRIPTION QTY. 501864-001 PLATFORM CONTROLLER 501865-000 PC BOARD ASSY 501866-000 KEY SWITCH 2WAY Before SN 04310 510366-000 KEY SWITCH 3WAY After SN 04310 501867-000 E-STOP SWITCH C/W CONTACT BLOCK 501869-000 OVERLAY (DECAL) 501881-000...
  • Page 119 Illustrated Parts Breakdown Section AB38 Work Platform 7-41...
  • Page 120 Illustrated Parts Breakdown Section CABLES & ELECTRICAL COMPONENT LEGEND QTY. ITEM PART NO. DESCRIPTION 058834-000 DRIVE MOTOR, LH 057568-000 DRIVE MOTOR, RH 501864-000 UPPER CONTROL BOX ASSY. 502597-000 LOWER CONTROL PANEL 501074-000 BATTERY 0260021 CHARGER 057530-000 PUMP MOTOR 501879-000 HARNESS - J1 501880-000 HARNESS - J2 502588-000...
  • Page 121 Illustrated Parts Breakdown Section AB38 Work Platform 7-43...

  • Page 122: Hose Assembly

    Section Illustrated Parts Breakdown HOSE ASSEMBLY 500262-000 EXPLANATION OF HYDRAULIC TERMINOLOGY ITEM PART NO. DESCRIPTION QTY. 500357-000 HOSE ASSY, 1/2” M1T 267 mm B90-B90 STRAIGHT FEMALE FITTING PUMP TO MANIFOLD SWEPT 90º FITTING 500353-000 HOSE ASSY, 1/4” M1T 6630 mm MEGAFLEX HOSE B90-B90 MANIFOLD TO MASTER CYLINDER...
  • Page 123 Illustrated Parts Breakdown Section AB38 Work Platform 7-45...
  • Page 124 Illustrated Parts Breakdown Section DECAL KIT American English (ANSI) 500206-001 ITEM PART NO. DESCRIPTION QTY. 500264-000 DECAL - ‘UpRight AB38N’ BOOM 501870-000 DECAL - LOWER CONTROL BOX 500257-001 DECAL - AB38N LOGO 057695-000 DECAL - BALLAST STRIP 510280-000 DECAL - EMERGENCY LOWERING 057696-000 DECAL - ‘UpRight’...
  • Page 125 Illustrated Parts Breakdown Section AB38 Work Platform 7-47...
  • Page 126 Illustrated Parts Breakdown Section DECAL KIT International English (CE) 500206-000 ITEM PART NO. DESCRIPTION QTY. 500264-000 DECAL - ‘UpRight AB38’ BOOM 501870-000 DECAL - LOWER CONTROL BOX 500257-000 DECAL - AB38 LOGO 057695-000 DECAL - BALLAST STRIP 502480-000 DECAL - EMERGENCY LOWERING 057696-000 DECAL - ‘UpRight’...
  • Page 127 Illustrated Parts Breakdown Section AB38 Work Platform 7-49...
  • Page 128 Illustrated Parts Breakdown Section DECAL KIT DECAL KIT French (CE) German (CE) 500206-003 500206-002 ITEM PART NO. DESCRIPTION QTY. ITEM PART NO. DESCRIPTION QTY. 500264-000 DECAL - ‘UpRight AB38’ BOOM 500264-000 DECAL - ‘UpRight AB38’ BOOM 501870-000 DECAL - LOWER CONTROL BOX 501870-000 DECAL - LOWER CONTROL BOX 500257-000...
  • Page 129 Illustrated Parts Breakdown Section AB38 Work Platform 7-51...

  • Page 130: Options List

    Section Illustrated Parts Breakdown OPTION LIST The options outlined opposite are available ITEM PART NO. DESCRIPTION 058191-000 AB38 OPTION, POWER TO PLATFORM 110V from UpRight when ordering a new 058191-001 AB38 OPTION, POWER TO PLATFORM 220V 500123-000 AB38 OPTION, DESCENT ALARM machine or as a spare part to be 058286-001 AB38 OPTION, HOURMETER...
  • Page 131 Illustrated Parts Breakdown Section NOTES: AB38 Work Platform 7-53...
  • Page 133 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 & SOUTH AMERICA PHONE: +1 785 989 3000 TOLL FREE: +1 800 225 0317 FAX: +1 785 989 3070 AUSTRALIA...

  • Page 134: Ab38 Work Platform

    Technician’s Print AB38 Work Platform Electrical Schematic...

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