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Snorkel A38E, Parts And Service Manual

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Snorkel A38E Parts And Service Manual Download Page 120

   

Maintenance

 Process

Section

4-16

A38E Work Platform

4.11

Figure 4-13:   Electric Motor Assembly

1.

Pump

2.

Bearing

3.

Pulley End Cover

4.

Pulley End Bearing

5.

Armature

6.

Commutator

7.

Bearing

8.

Stator Housing

9.

Brush Housing Support

10.

Commutator End Cover

11.

Inspection Cover

12.

Brush Holders

13.

Brush Retaining Spring

14.

Brushes

15.

Retaining Bolt

16.

Coupling

10

9

8

7

6

5

9

12

1

3

11

10

2

4

13

14

15

16

Summary of Contents for A38E

Page 1: ...A38E PARTS MANUAL S N 00715 AND AFTER ...

Page 2: ...KIT INTERNATIONAL CE 2 12 CONTACT SNORKEL 2 13 HYDRAULICS HOSE KIT 3 1 HOSE KIT ADDITIONAL 3 2 LOWER LIFT CYLINDER 3 3 UPPER LIFT CYLINDER ASSEMBLY 3 4 TELESCOPIC CYLINDER ASSEMBLY 3 5 STEERING CYLINDER ASSEMBLY 3 6 MASTER SLAVE CYLINDER ASSEMBLY 3 7 PLATFORM ROTATE CYLINDER ASSEMBLY 3 8 MOTOR PUMP ASSEMBLY 3 9 MANIFOLD BLOCK ASSEMBLY Hydraulic Platform Rotate 3 10 ELECTRICAL A38E LOWER CONTROL BO...

Page 3: ...SCHEMATICS 7 1 Appendix A Pages Index A Appendix B Parts Index B ...

Page 4: ...PARTS AND SERVICE AUG 2018 Serial Number 01 00715 Part number 514252 201 ...

Page 5: ...l shock hazard resulting in death or serious injury If an aerial platform is in contact with an energized conductor the platform operator must warn ground personnel in the vicinity to stay away Their bodies can conduct electricity creating an electrical shock hazard resulting in death or serious injury Do not approach or leave the aerial platform until the electricity has been turned off Do not at...

Page 6: ...is covered by a limited warranty that spe cifically identifies items warrantied by Snorkel and those items covered by original manufacturer s warranty A copy of the Snorkel Limited Warranty is located on the inside of the back cover of this manual Repairs and Maintenance Every person who maintains inspects tests or repairs the machine must be qualified and authorized to do so Caution Do not modify...

Page 7: ...umber of the Work Platform is also stamped on the inside of the Chassis close to the Steering Cylinder The A38E work platform meets and exceeds the requirements of both En280 2013 A1 2015 and ANSI A92 5 1992 SERVICE PARTS MANUAL A38E 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 ...

Page 8: ... Lugs Electrical Power Outlet Optional Hydraulic Tray Pump Reservoir Fluid Filter Freewheeling Brake Release Valve Entry Step Toeboards Lower Controls Operator s Manual Battery Charger LED Charge Indicators Tie Down Lifting Lugs Emergency Lowering Lever Serial Number Battery Disconnect Battery Charger Receptacle Battery Tray Freewheeling Brake Release Valve Component Identification ...

Page 9: ...ulations Refer back the the Operators Manual for more information on safe use TheA38E work platform meets and exceeds the require ments of En280 2013 A1 2015 ANSI and OSHA Compliance All owners users of the aerial platform must read un derstand and comply with all applicable regulations Ultimate compliance to OSHAregulations is the respon sibility of the user and their employer ANSI publications c...

Page 10: ...Backordered parts will be shipped as soon as available using the same shipping method as the original order unless otherwise indicated below Ship complete order only Do not backorder parts Ship all available parts and disposition of backordered parts Other instructions as specified Fill out completely and fax attention Parts Department to Snorkel USA 1 785 989 3077 Snorkel Europe 44 0 1952 607 678...

Page 11: ...s fitted permanently within this platform A W A R N I N G A DO NOT begin using the machine until the platform entrance drop bar is in the fully lowered position CONTROL BOX The control box is permanently fitted at the front centre of the platform It features a Joystick which will provide proportional control for raising or lowering either of the two booms extending or retracting the Telescopic Boo...

Page 12: ... frame designed to support all the components of the A38E Work Platform A38E PURPOSE LIMITATIONS The purpose of the A38E work platform is to provide a quickly deployable variable height work platform It is capable of lifting two people with work tools up to an upper limit of 215 kg ANSI 475 lbs in total The unit will provide the ability to reach over obstacles but must be used on firm level ground...

Page 13: ...8V DC 4kW 8 X 6V 210Ah Batteries 48V DC 5 4HP 8 X 6V 210Ah Batteries System Voltage Control 12V 12V Battery Charger Auto Dual AC input 100 240V 50 60Hz 15A Output 48V 35A Auto Dual AC input 100 240V 50 60Hz 15A Output 48V 35A Hydraulic Oil Tank Capacity 25 Litres 6 5 Gallons US Max Hydraulic Pressure 145 bar 2105 psi Hydraulic Oil Grade ISO 46 ISO 46 Cylinder Types 2 Double Acting Lift Cylinders W...

Page 14: ...Page 6 A38E Work Platform Section 1 3 Introduction Specifications NOTES ...

Page 15: ...ee specifications Section 1 2 for the weight of the work platform and be certain that lifting apparatus is of adequate capacity to lift the platform The A38E may be lifted by an overhead hoist crane in the following manner Four lifting straps capable of safely supporting the total weight of the A38E 3 795 Kg and at least 250 cm 8 ft long are required This minimum length is important to ensure the ...

Page 16: ...heels and using a 6 mm Allen key turn each one clockwise to its full extent The machine is now in freewheel mode A W A R N I N G A DO NOT leave the machine unattended or attempt to operate the A38E Work Platform until the Brake Release Screws have been re engaged 4 When towing is completed turn both Allen head socket screws in a counter clockwise direction until they rest firmly against the lockin...

Page 17: ... preferred Fully charged batteries perform best The deeper the discharge the fewer number of Battery Disconnect Switch cycles a battery will deliver Deep discharges deteriorate the battery quicker than light shallow cycles An overly discharged battery may need to be cycled a few times before it can fully recover If a battery begins to heat before becoming fully charged it may be necessary to recha...

Page 18: ...harger is plugged in after the charge cycle is complete Do not leave the battery charger on for more than 48 hours 7 After the charge cycle is complete unplug the extension cord from the battery charger and allow the batteries to cool 8 Remove the cover on each side of the chassis to access the batteries Remove the caps from each battery Note Machines can also be supplied with maintenance free bat...

Page 19: ...REPAIR PARTS A38E PARTS MANUAL S N 00715 AND AFTER FINAL ASSEMBLY FINAL ASSEMBLY Fri Jul 05 12 03 39 UTC 2019 2 1 ...

Page 20: ... 1 EA 500261 000 A38E MANIFOLD BLOCK Manual No Platform rotate 1 EA 504504 002 Lower Lift Cylinder Assembly 1 EA 504505 000 UPPER CYLINDER ASSEMBLY 1 EA 058461 000 TELE CYLINDER ASSEMBLY 1 EA 058463 000 STEERING CYLINDER ASSEMBLY 1 EA 058734 000 MASTER LEVEL CYLINDER ASSEMBLY 1 EA 058735 000 SLAVE CYLINDER 1 EA 12330 Cylinder Rotator 1 1 EA 6 515044 000 Lower Control Box Assembly 1 EA 7 515039 000...

Page 21: ...REPAIR PARTS A38E PARTS MANUAL S N 00715 AND AFTER CHASSIS ASSEMBLY A38E CHASSIS ASSEMBLY A38E Fri Jul 05 12 03 39 UTC 2019 2 2 ...

Page 22: ...0A 058074 000 FILTER WASHER SPRING ASSEMBLY Part of item 10 1 EA 11 057534 000 FILLER BREATHER CAP 1 EA 12 514274 000 DRIVE MOTOR 2 EA 13 238396 PLUGMALE STR 15AMP 125V NYLON 1 EA 14 3069521 INLET FLANGE ANSI 1 EA 15 515611 000 BEACON ASSEMBLY AMBER 1 EA 17 515652 000 CB2A F6C1F BI DIR PUMP MOTOR 1 EA Not Shown 514767 000 Fitting Pump Elbow BK 1 2 x 35 PUMP MOTOR 1 EA Not Shown 514768 000 Fitting ...

Page 23: ...48V GLOBAL CE BEFORE sn01 00975 1 EA 27 515622 000 CHARGER 48V GLOBAL CE Without remote display AFTER sn 01 00976 1 EA 28 501868 001 HORN 1 EA 29 500234 002 A38E CHASSIS SIDE DROP PANEL WITH SLOTS CE BEFORE sn01 00975 1 EA 29 515606 000 A38E CHASSIS SIDE DROP PANEL WITH SLOTS CE AFTER sn 01 00976 1 EA 29 500234 003 A38E CHASSIS SIDE DROP PANEL WITH SLOTS ANSI BEFORE sn01 00975 1 EA 29 515607 000 A...

Page 24: ...OP PANEL WITHOUT SLOTS 1 EA 34 057580 000 DRIVE GEARBOX 2 EA 35 514331 000 CAPACITOR ASSEMBLY 1 EA 36 514867 000 CRASH BAR 1 EA 37 514450 000 DIODE ASSY 1 EA 38 3020061 BATTERY DISCONNECT SWITCH EA A38E PARTS MANUAL S N 00715 AND AFTER CHASSIS ASSEMBLY A38E CHASSIS ASSEMBLY A38E Fri Jul 05 12 03 39 UTC 2019 2 2 ...

Page 25: ...REPAIR PARTS A38E PARTS MANUAL S N 00715 AND AFTER PG PART ASSEMBLY A38E PG PART ASSEMBLY A38E Fri Jul 05 12 03 39 UTC 2019 2 3 ...

Page 26: ... 3 502588 000 ALARM ECCO BEEPING 6 28VDC 1 EA 3 512684 000 ALARM BRACKET 1 EA 4 513550 000 CONTACTOR SPDT 200A 12VDC 1 EA 5 067387 022 FUSE 1 EA 6 512942 000 SEM 600 PGT 21 510 611 1 EA A38E PARTS MANUAL S N 00715 AND AFTER PG PART ASSEMBLY A38E PG PART ASSEMBLY A38E Fri Jul 05 12 03 39 UTC 2019 2 3 ...

Page 27: ...REPAIR PARTS A38E PARTS MANUAL S N 00715 AND AFTER BOOMS POSTS ASSEMBLY BOOMS POSTS ASSEMBLY Fri Jul 05 12 03 40 UTC 2019 2 4 ...

Page 28: ... FASTNER 2 EA 10 500266 000 ENERGY CHAIN SUPPORT CHANNEL 1 EA 11 500468 000 ENERGY CHAIN COMPLETE 1 EA Not Shown 500468 002 ENERGY CHAIN 1 UNIT OF 24 24 EA Not Shown 500468 001 MOUNTING ELEMENTS 1 EA 12 057975 000 INNER TELESCOPIC BOOM WEAR PAD 2 EA Not Shown 058510 016 M8 X 16 CSK 6 EA Not Shown 058510 025 BLT FLSKTHD M8 1 25 25MM 2 EA 13 514799 000 OUTER TELESCOPIC 2 EA Not Shown 058491 010 M6 X...

Page 29: ...A 21 058054 001 PIN TENSION BARS 4 EA 22 058066 001 PIN 1 EA 23 058066 007 PIN 1 EA 24 058053 004 PIN 1 EA 25 058053 005 PIN 1 EA 26 058065 006 PIN 1 EA 27 500254 000 PIN 1 EA 28 058053 001 PIN 1 EA 29 058065 005 PIN SLAVE CYLINDER ROD END 1 EA 30 058066 001 PIN 1 EA 31 057033 000 CIRCLIP 30mm 4 EA 32 057047 000 BUSH 8 EA 33 057054 000 BUSH 12 EA 34 057046 000 BUSH 8 EA 35 057034 000 CIRCLIP 25mm ...

Page 30: ...REPAIR PARTS A38E PARTS MANUAL S N 00715 AND AFTER CAGE HYDRAULIC ROTATOR ASSEMBLY CAGE HYDRAULIC ROTATOR ASSEMBLY Fri Jul 05 12 03 41 UTC 2019 2 5 ...

Page 31: ...3 EA 15 12468 22 PIN CYLINDER ROTATE 1 EA 16 8628 Pin Keeper Rolled Eye 6mm 1 EA 17 056058 016 HHD BLT M6 1 0 X 16 MM 8 8 1 EA 19 503101 040 M16 x 40 HEX HD SCREW x1 5 P 8 EA 20 515501 000 TILT QUADRANT ASSY ROTATE 1 EA 21 11492 1 Tab Washer 1 EA 22 058491 050 M6 x 50 HEX HD BOLT 8 8 1 EA 24 056066 008 Nut NylockNut DIN985 M8 8 0 Zi 6 EA 26 056687 055 M16 x 55 HEX HD BOLT 8 8 2 EA 27 515541 000 PL...

Page 32: ...A 37 260839 HINGE COVER RH 1 EA Not Shown 513767 006 Drop Bar Assy 1 EA 38 513767 010 Drop Bar 1 EA 39 508932 000 U Bracket 2 EA 40 510566 055 M8 x 55 SOCKET HD CAP SCREW ST STEEL 4 EA 41 510561 008 M8 washer ST ST 8 EA 42 058557 000 END CAP 2 EA 43 260852 Spring 1 EA 44 11492 1 Tab Washer 1 EA A38E PARTS MANUAL S N 00715 AND AFTER CAGE HYDRAULIC ROTATOR ASSEMBLY CAGE HYDRAULIC ROTATOR ASSEMBLY Fr...

Page 33: ...REPAIR PARTS A38E PARTS MANUAL S N 00715 AND AFTER WHEEL HUB ASSEMBLY WHEEL HUB ASSEMBLY Fri Jul 05 12 03 41 UTC 2019 2 6 ...

Page 34: ...057664 000 THRUST BEARING 1 EA 3 057662 000 PIVOT BOSS 1 EA 4 057663 000 PIVOT PIN 1 EA 5 057585 000 COVER PLATE 1 EA 6 057584 000 OUTER HUB BEARING 1 EA 7 057583 000 INNER HUB BEARING 1 EA 8 057582 000 STUD 5 EA 9 057661 000 PIVOT BUSHING 30 38 x 30 long 2 EA A38E PARTS MANUAL S N 00715 AND AFTER WHEEL HUB ASSEMBLY WHEEL HUB ASSEMBLY Fri Jul 05 12 03 41 UTC 2019 2 6 ...

Page 35: ...REPAIR PARTS A38E PARTS MANUAL S N 00715 AND AFTER DRIVE REDUCTION GEARBOX ASSEMBLY DRIVE REDUCTION GEARBOX ASSEMBLY Fri Jul 05 12 03 41 UTC 2019 2 7 ...

Page 36: ...EAL 1 EA 14 REF END PLATE 1 EA 15 REF O RING 1 EA 16 REF CIRCLIP 1 EA 17 REF HUB 1 EA 18 REF BEARING 1 EA 19 REF CIRCLIP 1 EA 20 REF PLANET SHAFT 1 EA 21 REF PLANET CARRIER 1 EA 22 REF CIRCLIP 1 EA 23 REF THRUST WASHER 3 EA 24 REF NEEDLE ROLLER 84 EA 25 REF PLANET GEAR 3 EA 26 REF THRUST WASHER 3 EA 27 REF CIRCLIP 3 EA 28 REF SUN PINION 1 EA 29 REF O RING 1 EA A38E PARTS MANUAL S N 00715 AND AFTER...

Page 37: ...EF CIRCLIP 1 EA 44 REF O RING 1 EA 45 REF THRUST WASHER 1 EA 46 REF O RING 1 EA 47 REF RING BEARING 1 EA 48 REF PLANET SHAFT 3 EA 49 REF SPINDLE 1 EA 50 REF THRUST WASHER 3 EA 51 REF THRUST WASHER 3 EA 52 REF NEEDLE ROLLER 75 EA 53 REF SPACER 3 EA 54 REF PLANET GEAR 3 EA 55 REF NEEDLE ROLLER 75 EA 56 REF THRUST WASHER 3 EA 57 REF THRUST WASHER 3 EA 58 REF WASHER 2 EA A38E PARTS MANUAL S N 00715 AN...

Page 38: ...REF PLUG 2 EA 60 REF STUD M15 X 1 5 5 EA 61 REF PIN 1 EA 62 REF SCREW 1 EA 63 REF CIRCLIP 1 EA A38E PARTS MANUAL S N 00715 AND AFTER DRIVE REDUCTION GEARBOX ASSEMBLY DRIVE REDUCTION GEARBOX ASSEMBLY Fri Jul 05 12 03 41 UTC 2019 2 7 ...

Page 39: ...TS A38E PARTS MANUAL S N 00715 AND AFTER TRACTION MOTOR ASSEMBLY SERIAL BREAK SN 006001 006204 006800 Current TRACTION MOTOR ASSEMBLY SERIAL BREAK SN 006001 006204 006800 Current Fri Jul 05 12 03 41 UTC 2019 2 8 ...

Page 40: ...6 SHEATHING 1 EA 7 514274 007 FRONT ENDSHIELD 1 EA 8 514274 008 FRONT BEARING 1 EA 9 514274 009 ARMATURE 1 EA 10 514274 010 REAR BEARING 1 EA 11 514274 011 HOUSING 1 EA 12 514274 012 REAR ENDSHIELD 1 EA A38E PARTS MANUAL S N 00715 AND AFTER TRACTION MOTOR ASSEMBLY SERIAL BREAK SN 006001 006204 006800 Current TRACTION MOTOR ASSEMBLY SERIAL BREAK SN 006001 006204 006800 Current Fri Jul 05 12 03 41 U...

Page 41: ...REPAIR PARTS A38E PARTS MANUAL S N 00715 AND AFTER REAR FRONT WHEEL KIT NON MARKING REAR FRONT WHEEL KIT NON MARKING Fri Jul 05 12 03 41 UTC 2019 2 9 ...

Page 42: ...EAR WHEEL NUT M14 10 EA 2 513429 000 FRONT WHEEL TYRE RIM ASSEMBLY sn 004939 current 2 EA 3 057666 000 WHEEL NUT M16 10 EA 4 513430 000 REAR WHEEL TYRE RIM ASSEMBLY sn 004939 current 2 EA A38E PARTS MANUAL S N 00715 AND AFTER REAR FRONT WHEEL KIT NON MARKING REAR FRONT WHEEL KIT NON MARKING Fri Jul 05 12 03 41 UTC 2019 2 9 ...

Page 43: ...REPAIR PARTS A38E PARTS MANUAL S N 00715 AND AFTER SLEW MOTOR WORM DRIVE UNIT SLEW BEARING ASSEMBLY SLEW MOTOR WORM DRIVE UNIT SLEW BEARING ASSEMBLY Fri Jul 05 12 03 41 UTC 2019 2 10 ...

Page 44: ...t Shown 500281 000 Washer HardenedWasher M16 Da 32 EA 2 500285 000 SLEW MOTOR 1 EA Not Shown 500285 001 SEAL KIT 1 EA Not Shown 500282 000 BOLT 1 2 13 UNC X 1 2 EA Not Shown 056021 012 WASHER LOCK M12 DIN 127 2 EA A38E PARTS MANUAL S N 00715 AND AFTER SLEW MOTOR WORM DRIVE UNIT SLEW BEARING ASSEMBLY SLEW MOTOR WORM DRIVE UNIT SLEW BEARING ASSEMBLY Fri Jul 05 12 03 41 UTC 2019 2 10 ...

Page 45: ...REPAIR PARTS A38E PARTS MANUAL S N 00715 AND AFTER DECAL KIT ENGLISH ANSI DECAL KIT ENGLISH ANSI Fri Jul 05 12 03 42 UTC 2019 2 11 ...

Page 46: ...E 2 EA 13 7030161 DECAL SORKEL GUARD SWITCH 1 EA 15 508772 000 DECAL WARNING RESPONSIBILITIES 1 EA 16 515086 002 DECAL UPPER CONTROL BOX 1 EA 17 058538 000 DECAL DANGER HAZARDS INSTR 1 EA 18 0181562 27522 DECAL MACH COMPLIES WITH ANSI 1 EA 19 058534 000 DECAL BATTERIES 2 EA 20 514698 000 DECAL SNORKEL GUARD OPERATION 2 EA 21 058761 000 DECAL S W L LARGE ANSI 1 EA 22 057434 001 DECAL GENUINE REPLAC...

Page 47: ...070540 DECAL YELLOW ARROW 2 EA 35 0070541 DECAL BLUE ARROW 2 EA 36 514252 200 SERVICE AND PARTS MANUAL 1 EA 37 511028 001 NAMEPLATE ANSI 1 EA 38 0070921 Placard 125 volts 15 amps 1 EA 39 0150606 DECAL 125V 15AMP PWR TO PLATF 1 EA 40 416836 DECAL BTRY CHARGE 115V ONLY 1 EA 41 515591 000 MANUAL OF RESPONSIBILITY A92 20 ANSI 1 EA 42 515843 000 DECAL OIL TYPE 1 EA 43 515335 000 QR DECAL 1 EA 44 058660...

Page 48: ...REPAIR PARTS A38E PARTS MANUAL S N 00715 AND AFTER DECAL KIT INTERNATIONAL CE DECAL KIT INTERNATIONAL CE Fri Jul 05 12 03 42 UTC 2019 2 12 ...

Page 49: ...5843 000 DECAL OIL TYPE 1 EA 12 514698 000 DE DECAL SNORKEL GUARD PROCEDURE 1 1 EA 13 7030161 DE DECAL SNORKEL GUARD SWITCH 1 1 EA 15 514252 001 DE OPERATORS MANUAL CE 1 1 EA 16 7030162 DE DECAL SNORKEL GUARD OVERIDE 1 1 EA 17 058181 002 DECAL 3 POINT 1 1 EA 18 504199 005 DECAL S W L LARGE 1 1 EA 19 058860 000 DECAL PINCH POINT 2 2 EA 20 500438 002 DECAL LOWER CONTROL COVER 1 1 EA 21 514252 201 SE...

Page 50: ... DECAL EXPLOSION HAZARD 2 EA 9 508852 001 DECAL IMPORTANT BEFORE USING 1 1 EA 10 511027 003 NAMEPLATE CE 1 1 EA 11 515843 000 DECAL OIL TYPE 1 EA 12 514698 000 FR DECAL SNORKEL GUARD PROCEDURE 1 1 EA 13 7030161 FR DECAL SNORKEL GUARD SWITCH 1 1 EA 15 514252 001 FR OPERATORS MANUAL CE 1 1 EA 16 7030162 FR DECAL SNORKEL GUARD OVERIDE 1 1 EA 17 508853 000 DECAL 3 POINT 1 1 EA 18 504199 005 DECAL S W ...

Page 51: ...LOWERING 2 2 EA 6 511099 000 Decal Snorkel 2 EA 7 509944 000 DECAL BATTERY FLUID LEVEL 2 2 EA 8 057430 002 DECAL EXPLOSION HAZARD 2 EA 9 510014 001 DECAL IMPORTANT BEFORE USING 1 1 EA 10 511027 003 NAMEPLATE CE 1 1 EA 11 515843 000 DECAL OIL TYPE 1 EA 12 514698 000 ES DECAL SNORKEL GUARD PROCEDURE 1 1 EA 13 7030161 ES DECAL SNORKEL GUARD OVERRIDE 1 EA 15 514252 001 ES OPERATORS MANUAL CE 1 1 EA 16...

Page 52: ...DECAL SNORKEL LOGO 75mm 1 EA 4 511067 000 Decal www snorkellifts com 1 EA 5 510280 100 DECAL EMERGENCY LOWERING 2 2 EA 6 511099 000 Decal Snorkel 2 EA 7 510848 000 DECAL BATTERY FLUID LEVEL 2 2 EA 8 057430 002 DECAL EXPLOSION HAZARD 2 EA 9 512236 000 DECAL IMPORTANT BEFORE USING 1 1 EA 10 511027 003 NAMEPLATE CE 1 1 EA 11 515843 000 DECAL OIL TYPE 1 EA 12 514698 000 IT DECAL SNORKEL GUARD PROCEDUR...

Page 53: ... COMPLETE DUTCH 1 EA 1 511069 000 DECAL SNORKEL A38E BOOM 2 EA 2 512940 000 OVERLAY 1 EA 3 512224 000 DECAL SNORKEL LOGO 75mm 1 EA 4 511067 000 Decal www snorkellifts com 1 EA 5 510280 100 DECAL EMERGENCY LOWERING 2 2 EA 6 511099 000 Decal Snorkel 2 EA 7 510215 000 DECAL BATTERY FLUID LEVEL 2 2 EA 8 057430 002 DECAL EXPLOSION HAZARD 2 EA 9 510220 001 DECAL IMPORTANT BEFORE USING 1 1 EA 10 511027 0...

Page 54: ...17 000 DECAL LOWER CONTROL COVER 1 1 EA 21 514252 201 SERVICE PARTS MANUAL 1 1 EA 22 058531 200 DECAL TIE DOWN LIFT POINT 4 4 EA 23 068635 001 Harness anchor point 1 EA 24 010076 901 DECAL DOCUMENT BOX 1 EA 25 060197 001 DECAL HYDRAULIC FLUID 1 EA 26 0070540 DECAL YELLOW ARROW 2 EA 27 0070541 DECAL BLUE ARROW 2 EA A38E PARTS MANUAL S N 00715 AND AFTER DECAL KIT INTERNATIONAL CE DECAL KIT INTERNATI...

Page 55: ...ll Distributore locale EUROPE MIDDLE EAST AFRICA ASIA PHONE 44 0 845 1550 058 FAX 44 0 845 1557 756 NORTH SOUTH AMERICA PHONE 1 785 989 3000 TOLL FREE 1 800 255 0317 FAX 1 785 989 3070 AUSTRALIA PHONE 611300 700 450 FAX 61 2 9609 3057 NEW ZEALAND PHONE 64 6 3689 168 FAX 64 6 3689 164 ...

Page 56: ... 4 BSP MALE END C 1 4 BSP MALE 057376 000 1 1 2 BONDED SEAL 3 8 BSP MALE 3 8 BSP MALE 057121 000 2 1 4 BSP MALE 500356 000 MANIFOLD TO STEERING CYLINDER MACHINE DESCRIPTION AB 38 THIS DRAWING IS COPYRIGHT AND THE PROPERTY OF UpRight LTD IT MUST NOT BE COPIED OR RE ISSUED WITHOUT THEIR WRITTEN CONSENT 1 4 1 4 BOF SWEPT 90 1 2 500351 000 6690mm HOSE SIZE 3 8 HYDRAULIC KIT UpRight POWERED ACCESS VIGO...

Page 57: ...Illustrated Parts Breakdown Section 7 44 A38E Work Platform 7 2 2 2 12 4 4 8 8 7 7 11 1 10 9 9 3 3 6 6 5 5 13 14 Non Hydraulic Platform Rotate ...

Page 58: ...INGTON TYNE WEAR NE38 PART NUMBER WORKING PRESSURE END FITTINGS QUANTITY OFF HOSE SIZE LOCATION ON MACHINE END A MACHINE DESCRIPTION A38E HYD ROT THIS DRAWING IS COPYRIGHT AND THE PROPERTY OF UPRIGHT LTD IT MUST NOT BE COPIED OR RE ISSUED WITHOUT THEIR WRITTEN CONSENT HYDRAULIC KIT 1 4 BSP FEMALE STRAIGHT spiral wrap for 1 meter starting from straight end 514357 000 1 1 4 R17 514356 000 2 1 4 BSP ...

Page 59: ...Illustrated Parts Breakdown Section 7 46 A38E Work Platform 7 2 2 2 12 4 4 8 8 7 7 11 1 10 9 9 3 3 6 6 5 5 13 14 Platform Rotate Hydraulic Platform Rotate 15 16 17 15 ...

Page 60: ...HYDRAULICS A38E PARTS MANUAL S N 00715 AND AFTER LOWER LIFT CYLINDER LOWER LIFT CYLINDER Fri Jul 05 12 03 44 UTC 2019 3 3 ...

Page 61: ...CK4 1 EA 21 515886 000 OVERCENTRE VALVE 1 EA 20 515887 000 LOWERING VALVE 1 EA 19 515888 000 1 4 BSP PLUG 2 EA 18 515889 000 1 4 BSP PLUG 1 EA 17 515890 000 1 8 BSP PLUG 1 EA 16 515891 000 O RING 1 EA 15 515892 000 O RING 1 EA 14 515893 000 TAB WASHER 1 EA 13 515894 000 WIPER 1 EA 12 515895 000 U RING 1 EA 11 515896 000 Ø45xØ50 BUSH 1 EA 10 515897 000 BACK UP RING 1 EA 9 515898 000 X8600 O RING 1 ...

Page 62: ...03 000 VALVE BLOCK 1 EA 3 515904 000 TRUNNION 1 EA 2 515905 000 CYL END Ø85xØ100x1 1 EA 1 515906 000 TUBE 3A08092C 01 1 EA A38E PARTS MANUAL S N 00715 AND AFTER LOWER LIFT CYLINDER LOWER LIFT CYLINDER Fri Jul 05 12 03 44 UTC 2019 3 3 ...

Page 63: ...HYDRAULICS A38E PARTS MANUAL S N 00715 AND AFTER UPPER LIFT CYLINDER ASSEMBLY UPPER LIFT CYLINDER ASSEMBLY Fri Jul 05 12 03 44 UTC 2019 3 4 ...

Page 64: ...8 000 SEAL KIT 1 EA 6 KIT ITEM O RING 1 EA 7 KIT ITEM O RING 1 EA 8 KIT ITEM O RING 1 EA 9 KIT ITEM O RING 1 EA 10 KIT ITEM O RING 1 EA 11 REF SPACER 1 EA 12 KIT ITEM O RING 1 EA 13 REF PISTON HEAD 1 EA 14 KIT ITEM PISTON SEAL 1 EA 15 REF PISTON LOCKNUT 1 EA 16 REF WASHER 1 EA 17 501964 001 GREASE NIPPLE 2 EA A38E PARTS MANUAL S N 00715 AND AFTER UPPER LIFT CYLINDER ASSEMBLY UPPER LIFT CYLINDER AS...

Page 65: ...HYDRAULICS A38E PARTS MANUAL S N 00715 AND AFTER TELESCOPIC CYLINDER ASSEMBLY TELESCOPIC CYLINDER ASSEMBLY Fri Jul 05 12 03 44 UTC 2019 3 5 ...

Page 66: ...L KIT 6 THRU 9 INCLUDING 12 AND 14 1 EA 6 KIT ITEM O RING 1 EA 7 KIT ITEM O RING 1 EA 8 KIT ITEM O RING 1 EA 9 KIT ITEM O RING 1 EA 10 057048 000 GREASE NIPPLE EA 11 REF SPACER 1 EA 12 KIT ITEM O RING 1 EA 13 REF PISTON HEAD 1 EA 14 KIT ITEM WEARBAND 1 EA 15 057121 000 PISTON LOCKNUT 1 EA 16 501964 000 WASHER 1 EA A38E PARTS MANUAL S N 00715 AND AFTER TELESCOPIC CYLINDER ASSEMBLY TELESCOPIC CYLIND...

Page 67: ...HYDRAULICS A38E PARTS MANUAL S N 00715 AND AFTER STEERING CYLINDER ASSEMBLY STEERING CYLINDER ASSEMBLY Fri Jul 05 12 03 45 UTC 2019 3 6 ...

Page 68: ... 1 EA 500460 000 SEAL KIT CONTAINS 3 5 6 AND 7 1 EA 3 KIT ITEM WEARBAND 1 EA 4 REF END CAP 1 EA 5 KIT ITEM O RING 1 EA 6 KIT ITEM O RING 1 EA 7 KIT ITEM O RING 1 EA 8 057048 000 GREASE NIPPLE 3 EA A38E PARTS MANUAL S N 00715 AND AFTER STEERING CYLINDER ASSEMBLY STEERING CYLINDER ASSEMBLY Fri Jul 05 12 03 45 UTC 2019 3 6 ...

Page 69: ...HYDRAULICS A38E PARTS MANUAL S N 00715 AND AFTER MASTER SLAVE CYLINDER ASSEMBLY MASTER SLAVE CYLINDER ASSEMBLY Fri Jul 05 12 03 45 UTC 2019 3 7 ...

Page 70: ...IVOT 1 EA 058750 000 SEAL KIT 1 EA 6 KIT ITEM O RING 1 EA 7 KIT ITEM O RING 1 EA 8 KIT ITEM O RING 1 EA 9 KIT ITEM O RING 1 EA 10 KIT ITEM O RING 1 EA 11 REF SPACER 1 EA 12 KIT ITEM O RING 1 EA 13 REF PISTON HEAD 1 EA 14 KIT ITEM WEARBAND 1 EA 15 REF PISTON LOCKOUT 1 EA 16 REF WASHER 1 EA 17 057048 000 GREASE NIPPLE 2 EA A38E PARTS MANUAL S N 00715 AND AFTER MASTER SLAVE CYLINDER ASSEMBLY MASTER S...

Page 71: ...HYDRAULICS A38E PARTS MANUAL S N 00715 AND AFTER PLATFORM ROTATE CYLINDER ASSEMBLY PLATFORM ROTATE CYLINDER ASSEMBLY Fri Jul 05 12 03 45 UTC 2019 3 8 ...

Page 72: ...linder Rotator 1 1 EA 2 12330K SEAL KIT 1 EA 3 514352 000 ADAPTER 6ORB 1 4 BSP MALE MALE STRAIGHT 1 EA 4 514352 000 ADAPTER 6ORB 1 4 BSP MALE MALE STRAIGHT 1 EA A38E PARTS MANUAL S N 00715 AND AFTER PLATFORM ROTATE CYLINDER ASSEMBLY PLATFORM ROTATE CYLINDER ASSEMBLY Fri Jul 05 12 03 45 UTC 2019 3 8 ...

Page 73: ...HYDRAULICS A38E PARTS MANUAL S N 00715 AND AFTER MOTOR PUMP ASSEMBLY MOTOR PUMP ASSEMBLY Fri Jul 05 12 03 45 UTC 2019 3 9 ...

Page 74: ...M S2 15Min 1 EA 2 515652 100 Pump CB2A F6C1F 6 37cc r 20Mpa 1 EA 3 515923 000 Screw M10X25 2 EA 4 515924 000 Spring Washer Ø10 2 EA 5 515925 000 Flat washer Ø10 2 EA 6 515652 010 PUMP SEAL KIT 1 EA A38E PARTS MANUAL S N 00715 AND AFTER MOTOR PUMP ASSEMBLY MOTOR PUMP ASSEMBLY Fri Jul 05 12 03 45 UTC 2019 3 9 ...

Page 75: ...HYDRAULICS A38E PARTS MANUAL S N 00715 AND AFTER MANIFOLD BLOCK ASSEMBLY Hydraulic Platform Rotate MANIFOLD BLOCK ASSEMBLY Hydraulic Platform Rotate Fri Jul 05 12 03 45 UTC 2019 3 10 ...

Page 76: ...A 6 12 3149 PRESSURE TEST POINT FITTING 1 EA 7 514525 000 PRESSURE REDUCING VALVE 1 EA 8 514524 000 MAINRELIEF VALVE 1 EA 9 500261 002 MANUAL TELE RETRACTIONVALVE 1 EA 10 500261 004 TELE RETRACTIONVALVE LEVER 1 EA 11 514527 000 CROSS LINE RELIEF VALVE 2 EA 13 514353 000 ADAPTER 6ORB 3 8 BSP M M STR 2 EA 14 512251 000 ADAPTER 4ORB 1 4 BSP M M STR 11 EA 15 514354 000 ADAPTER 4ORB 3 8 BSP M M STR 4 E...

Page 77: ...S MANUAL S N 00715 AND AFTER A38E LOWER CONTROL BOX ASSEMBLY CE ASSY Harnesses are not part of this assembly A38E LOWER CONTROL BOX ASSEMBLY CE ASSY Harnesses are not part of this assembly Fri Jul 05 12 03 46 UTC 2019 4 1 ...

Page 78: ...114020 90 1 EA 10 514604 000 LOCKWASHER DEUTSCH 114021 1 EA 11 056057 012 HEX HEAD M5 x 16mm 2 EA 12 056069 005 WASHER STEELFLATWASHER M5 DIN125A 2 EA Not Shown 100338 013 CRIMP PIN DEUTSCH 0460 202 16141 16 EA 14 512366 000 4 WAY PANEL PLUG 1 EA 15 509755 000 Mate N lock socket contact 4 EA 16 515087 002 OVERLAY 1 EA Not Shown 514450 001 DIODE 3 AMP 600V 2 EA A38E PARTS MANUAL S N 00715 AND AFTER...

Page 79: ...LECTRICAL A38E PARTS MANUAL S N 00715 AND AFTER UPPER CONTROL BOX ASSEMBLY ANSI CE Hydraulic Platform Rotate UPPER CONTROL BOX ASSEMBLY ANSI CE Hydraulic Platform Rotate Fri Jul 05 12 03 46 UTC 2019 4 2 ...

Page 80: ...ATWASHER M5 DIN125A 2 EA 14 056069 004 M4 FLAT WASHER DIN 125 8 EA 15 056066 004 Nut NylockNut DIN985 M4 8 0 Z 8 EA 16 058500 025 M4 x 25 SHCS 12 9 8 EA 17 515086 002 DECAL UPPER CONTROL BOX 1 EA 18 3028933 Joystick I Axis Deadman Guard 1 EA 19 3028844 IFS241 IFM PROXY 1 EA 20 514627 000 CONN DEUTSCH DT06 8SA 1 EA 21 514629 000 LOCK WEDGE W8P 1 EA 22 058501 016 M5 x 16 S H C S GR 12 9 2 EA 23 1003...

Page 81: ...154 000 6WAY PANEL PLUG 1 EA 28 509755 000 Mate N lock socket contact 32 EA A38E PARTS MANUAL S N 00715 AND AFTER UPPER CONTROL BOX ASSEMBLY ANSI CE Hydraulic Platform Rotate UPPER CONTROL BOX ASSEMBLY ANSI CE Hydraulic Platform Rotate Fri Jul 05 12 03 46 UTC 2019 4 2 ...

Page 82: ...ELECTRICAL A38E PARTS MANUAL S N 00715 AND AFTER CABLES ELECTRICAL COMPONENT LEGEND CABLES ELECTRICAL COMPONENT LEGEND Fri Jul 05 12 03 47 UTC 2019 4 3 ...

Page 83: ...S BATTERY DISCONNECT SW 1 EA 10 515502 003 BATTERY DISCONNECT SW VE EARTH STUD 1 EA 11 513542 005 BATTERY BATTERY 1 EA 12 513542 008 FUSE 300A CONTACTOR N O 1 EA 13 513542 010 P600 PUMP 1 EA 14 513542 012 P600 EARTH STUD 1 EA 15 513542 014 SEM600 LEFT MOTOR 1 EA 16 513542 016 SEM600 RIGHT MOTOR 1 EA 17 513542 018 SEM600 CONTACTOR OUT N O 1 EA 18 513542 006 BATTERY BATTERY 1 EA 19 513542 009 CONTAC...

Page 84: ...OPTIONS A38E PARTS MANUAL S N 00715 AND AFTER OPTION LIST OPTION LIST Fri Jul 05 12 03 47 UTC 2019 5 1 ...

Page 85: ...OPTIONS A38E PARTS MANUAL S N 00715 AND AFTER OPTION SNORKEL GUARD OPTION SNORKEL GUARD Fri Jul 05 12 03 48 UTC 2019 5 2 ...

Page 86: ...r RH 1 EA 9 3028844 IFS241 IFM PROXY 1 EA 10 301403 BOLT SHOULDER 375 500 GR5 1 EA 11 0260857 PIN 1 EA 12 5560123 375 16UNC THIN HEX LOCK NUT 2 EA 13 0260852 SPRING GUARD ACTUATOR 1 EA 14 510521 000 GROUND OP SWITCH ENABLE 1 EA 15 514404 001 FLASHING BEACON BLUE 1 EA 16 7030161 Decal Snorkel Guard Override 1 EA 17 7030162 Decal Warning Snorkel Guard 1 EA 18 514698 000 Decal Snorkel Guard Override ...

Page 87: ...OPTIONS A38E PARTS MANUAL S N 00715 AND AFTER ADDITIONAL OPTIONS A38E ADDITIONAL OPTIONS A38E Fri Jul 05 12 03 48 UTC 2019 5 3 ...

Page 88: ...e placards and decals Snorkel recommends that you make additional copies of the preventative inspection and maintenance checklists for your use in performing these inspections AWarning The potential for accident increases when operating an aerial platform that is damaged or malfunction ing Death or serious injury can result from such accidents Do not operate the aerial platform if it is damaged or...

Page 89: ...ne can be increased by keep ing dirt and foreign materials out of the vital components Shields covers seals and filters help to keep air and oil supplies clean However these items must be maintained on a scheduled basis in order to function properly Clean surrounding areas as well as the opening and fittings before disconnecting air or oil lines As soon as a line or component is disconnected cap o...

Page 90: ...d properly torqued Lower Control Station Operating controls Proper operation Emergency stop and emergency power Shuts off lower controls proper operation Level Sensor Sounds tilt alarm Flashing Light Proper operation All Motion Alarm Sounds when machine is operated and or driven Structures Weldments Chassis turntable booms platform etc Slide pads In place no damage or deformation Fasteners In plac...

Page 91: ...Maintenance 4 A38E ...

Page 92: ... 175 Nm 130 lb ft Rear 145 Nm 107 lb ft Overload System Check torque nuts 220Nm 162 ft lbs Steering Assembly CheckSteering Cylinder for Leaks Turtable Slew System Check slew motor fo leaks and mounting bolts for proper torque Slew System First post Check torque on all bolts 15 outer ring and 20 inner ring Re torque Bolts 220Nm 160 ft lbs Elevating Assembly Check pivot pins for damage Check pivot p...

Page 93: ...Tuntable Slew Structural Check for damage and cracked welds Torque turntable top bolts Torque to proper value 220 Nm 162 lb ft Torque turntable bottom bolts Torque to proper value 220 Nm 162 lb ft 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 Lower cylinder pin caps...

Page 94: ...nd damage Platform Rotate cylinder pin caps and bolt retainer Verify that all fasteners are in place and are tight Telescopic Boom cylinder Check for leaks wear damage and for proper operation Master cylinder and pin caps Verify that all fasteners are in place and are tight check for leaks wear damage and for proper operation Master level cylinder and holding valves Check for leaks wear damage and...

Page 95: ...r to platform Check for proper operation Hydraulic Oil Resevoir Filler breather cap and tank Check for wear securely fasten Hydraulic fluid level Check for proper level Q8 Hydraulic filter Replace after the first 50 hours every 180 days or 250 hours thereafter Inspect filter for foreign matter that could indicate component wear Platform Rotator Structural Check for damage and cracked welds Hydraul...

Page 96: ...arts Manual Replace any missing or unreadable decals placards Door hinges and latches Lubricate Spray lubricant Interflon EP Rotation bearing Lubricate EP 2 Lithium Grease Rotation bearing teeth and pinion Lubricate Interflon LS 1 2 Tie rods Lubricate Interflon LS 1 2 Gear hubs Check fluid level fill if low Swing drive Check fluid level fill if low EP 2 Lithium Grease Platform rotator Refill if di...

Page 97: ...filter Replace After first 50 hours then at recommended interval Hydraulic high pressure filter Clean and reinstall Hydraulic pressures Pump setting Standby pressure 300 psi Function pressure Boom up max 180Bar 2610psi 190Bar 2755 psi Gear hubs Replace fluid Overload Calibrate System Drive motors Check for wear of brushes Check that commutator or springs are undamaged Change oil in drive reduction...

Page 98: ...A38E Maintenance 11 Major Repairs Date Part Number Part Description Repair Performed ...

Page 99: ... Plates and the Weldments Wipe away all excess grease Gear Hubs Gear hubs Item 4 To check and fill Gear hubs 1 Rotate the Gearbox into the horizontal position with one of the filler drain plug holes in the 3 O Clock position and the other plug hole above it 2 Remove plug bolts with drive ratchet and extension 3 Fill until half full 0 9 Litres 0 23 Gallons oil will just start to trickle out the plu...

Page 100: ...n 1 New batteries need to be cycled several times before reaching full capacity 20 50 cycles depending on type Usage should be limited during this period 2 Always recharge batteries fully immediately after use Batteries perform best when they are fully charged More capacity and longer life will result from this practice 3 The deeper the discharge the fewer number of cycles a lead acid battery will...

Page 101: ...der batteries need to be watered more often and their capacity decreases 16 Opportunity charging a short partial charge during an extended duty cycle is a controversial subject Generally the practice is a crutch to make up for undersized batteries The correct approach is to install adequate battery capacity If this is impossible because of lack of space in the battery compartment or extreme operat...

Page 102: ...A38E Maintenance 15 ...

Page 103: ...iplying by 12 Bolt Grade SAE Grade 1 or 2 SAE Grade 5 SAE Grade 6 SAE Grade 8 Marking Minimum Tensile Strength 64 000 psi 105 000 psi 133 000 psi 150 000 psi Material Definition Low Carbon Steel Medium Carbon Steel Tempered Medium Carbon Steel Quenched and Tempered Medium Carbon Alloy Steel Quenched and Tempered Indeterminate Quality Minimum Commercial Quality Medium Commercial Quality Bolt Size 1...

Page 104: ...lamp Load lb M4 0 7 27 20 861 36 24 1 173 M5 0 8 55 41 1 394 72 60 1 895 M6 1 0 93 70 1 971 132 96 2 686 M8 1 25 228 168 19 14 3 591 312 228 4 889 M8 1 0 240 180 20 15 3 844 336 252 5 232 M10 1 5 37 28 5 693 51 38 7 744 M10 1 25 39 30 6 008 54 41 8 171 M12 1 75 65 49 8 273 89 66 11 257 M12 1 25 71 53 9 037 96 72 12 297 M14 2 0 103 77 11 285 140 107 15 354 M14 1 5 114 85 12 263 155 114 16 691 M16 2...

Page 105: ...pection and maintenance shall be performed by personnel who are trained and familiar with mechanical and electrical procedures Complete descriptions of the procedures are in the text following this page Before performing preventative maintenance familiarise yourself with the operation of the machine Ensure that the machine is fully secured and supported when carrying out maintenance procedures in ...

Page 106: ...Section 4 2 4 1 Notes ...

Page 107: ...side the cells Rinse thoroughly with clean warm water Clean battery and cable contact surfaces to a bright metal finish whenever a cable is removed Basic Rule for maximum duty cycle of deep cycle traction batteries Always recharge Battery as soon as possible after the low Battery L E D illuminates Allow the charger to charge the batteries until it automatically shuts off BATTERY CHARGING Batteries...

Page 108: ... 3 The Charger will turn on automatically after going through a self test sequence LED s will indicate the status of charging 4 The Charger indicates that the charge is complete when the batteries are fully charged BATTERY CELL EQUALIZATION Specific Gravity is a measurement of the strength of the electrolyte in a battery and is measured using a hydrometer For a fully charged battery the temperatur...

Page 109: ... lowered i e stowed oil should be visible on the dipstick If the oil is NOT visible fill the tank until oil ISO 46 is then visible on the dipstick DO NOT fill above the upper line on the dipstick or when the platform is elevated Oil and Filter Replacement 1 Operate the platform for 10 15 minutes to bring the hydraulic oil up to normal operating temperature Wear safety gloves and safety glasses whe...

Page 110: ...ily cause severe cuts Obtain medical assistance immediately if cut by hydraulic oil MAIN RELIEF VALVE Figure 4 3 4 1 Operate the hydraulic system for 10 15 minutes to warm the oil 2 Remove the cover from the Chassis body 3 Insert pressure gauge into the high pressure gauge port TP on the Manifold Block 4 Loosen locknut on main relief valve and turn adjusting screw anticlockwise two full turns usin...

Page 111: ...latform until Lower Boom is supported by the sling REMOVAL OF ELEVATING ASSEMBLY SUPPORT 1 Select Lower Control Boom 1 Switch and gradually raise the platform until the sling can be removed 2 Remove the sling 3 Completely lower platform 4 Turn Key Switch to OFF SLEW CROSS LINE RELIEF VALVES 1 Repeat steps 1 3 as outlined above 2 Loosen Locknuts on both cross line relief valves and turn adjusting s...

Page 112: ... Tilt Sensor is tilted 3 or more factory set at this value When the Tilt Sensor activates the elevating and telescope extend functions will be locked out and an audible warning alarm will sound It will activate if the Chassis tilts 3 in any direction The Tilt Sensor is incorporated in the GP400 control module SETTING THE TILT SENSOR TO ZERO If the EZ230 control modual is replaced and of moved with...

Page 113: ...Maintenance Process Section 4 9 A38E Work Platform 4 7 Figure 4 8 Boom Rest Limit Switch Elevating Assembly Switch Head Switch Body Lower Boom Upper Boom ...

Page 114: ...eaning solvent to remove built up contaminants and then blow out all passages with clean compressed air 2 Inspect the manifold for cracks thread damage and scoring where O rings seal against internal and external surfaces 3 Wash and dry each component and check for thread damage torn or cracked O rings and proper operation 4 Replace parts and O rings found unserviceable ASSEMBLY Note Lubricate all...

Page 115: ...ting straight 6 Bonded Washer 7 Pressure Reduction Valve 8 Main Relief Valve 9 Pressure Test Point 10 Telescopic Retraction Valve 11 Cross Line Relief Valves 4 8 1 2 3 4 5 6 6 5 5 6 5 6 9 6 7 8 10 11 Refer to page 7 31 7 33 for partnumbers Only one valve on Hydraulic Platform Rotate manifold for Hydraulic Platform Rotate manifold for see page 4 6 ...

Page 116: ... Motors ensure that the electric circuit is disconnected i e disconnect the batteries and unplug the charger It is also important that when dealing with batteries the proper safety precautions are adhered to There is always a hazard of sparks or explosive gas INSPECTING THE DRIVE MOTORS Remove the Sea e h t m o r f 6 n m e t I g i h t rear section of the motor and examine the brushes for excessive...

Page 117: ...t does not apply equal pressure on the center of the brush will cause the brush to wear unevenly Check for correct clearence and freedom of brush movement in the holder Figure 8 Brush Tension Testing Motor Diameter Ounce Gram 5 5 inch New Brush 55 1540 Worn Brush 35 980 6 7 Inch 8 0 inch 9 0 Inch New Brush 65 1820 Worn Brush 40 1120 Table 2 Brush Tension Values 3 Replace brushes that are worn belo...

Page 118: ...f the nameplate full load current If the motor meets the above conditions then it can be assumed that the original problem is external to the motor DISASSEMBLY 1 Remove through bolts 2 Remove pulley end cover 3 Pull the armature out of the assembly in one swift motion 4 Remove commutator end cover NOTE Do not place the stator ring in any mechanical holding device during the disassembly or assembly...

Page 119: ... A no load test can now be performed At rated voltage observe the no load current It should be less than 20 of the nameplate full load current Anything higher will indicate Brushes are not on neutral setting check matchmarks for exact alignment Faulty armature NOTE Following assembly the electric motor may turn in the wrong direction The cause of this will be that the brush holder assembly has bee...

Page 120: ...mp 2 Bearing 3 Pulley End Cover 4 Pulley End Bearing 5 Armature 6 Commutator 7 Bearing 8 Stator Housing 9 Brush Housing Support 10 Commutator End Cover 11 Inspection Cover 12 Brush Holders 13 Brush Retaining Spring 14 Brushes 15 Retaining Bolt 16 Coupling 10 9 8 7 6 5 9 12 1 3 11 10 2 4 13 14 15 16 ...

Page 121: ...2o F VG 320 During oil change we recommend that the inside of the Gearcase is flushed out with flushing fluid recommended by the lubricant manufacturer Oil should be changed when hot to prevent a build up of sludge deposit It is advisable to check the oil level at least once per month If more than 10 of total oil capacity has to be added check for oil leaks Do not mix oils of different types even ...

Page 122: ...es approximately 0 9 Litres 0 23 Gallons US of oil To check this level rotate the Gearbox into the horizontal position with one of the filler drain plug holes in the 3 O Clock position and the other plug hole above it See fig 4 14 When the Gearbox is half full oil will just start to trickle out the plug hole in the 3 O Clock position 12 Insert and tighten both plugs and clean the surfaces of the g...

Page 123: ...nd remove rod end pivot pin Move cylinder backwards to rest against the first post 5 Support the cylinder so that the Trunnion Pivot bushings can be removed This is done by releasing the eight M8 Allen head bolts Remove the cylinder from the machine 6 Move the cylinder to a prepared work area It is important that clean assembly practices are observed as seals and other hydraulic cylinder component...

Page 124: ...should be used 2 Install a new piston seal on the piston 3 Install the headcap on the cylinder from the piston end 4 Install the piston piston nut and a new piston static O ring on the cylinder rod Screw nut to end of thread and secure with circlip 9 Note Diagram below shows a sample cylinder breakdown for the Upper Lift Cylinder Component Breakdowns of the other cylinders are shown in the Illustr...

Page 125: ... remove piston and headcap from the cylinder rod 3 Remove the piston static O ring from the cylinder rod 4 Remove the piston seal from the piston 5 Remove the rod seal rod wiper and static seal from the headcap 6 Care should be taken to save the O ring and all other seals for reassembly if they have been deemed serviceable following the cleaning and inspection phase of maintenance CLEANING AND INS...

Page 126: ...crew the piston nut and remove piston and headcap from the cylinder rod 3 Remove the piston static O ring from the cylinder rod 4 Remove the piston seal from the piston 5 Remove the rod seal rod wiper and static seal from the headcap 6 Care should be taken to save the O ring and all other seals for reassembly if they have been deemed serviceable following the cleaning and inspection phase of maint...

Page 127: ... 3 Align pin lock plate on cylinder pin with hole in Boom 2 and push the cylinder pin completely in and fix pin lock plate with bolt 4 Position the rod end of cylinder into place and insert the pin until the circlip groove is exposed Replace the circlip 5 From the Chassis Controls retract the Telescopic Cylinder fully 7 Test with weight at rated platform load to check system operation 4 17 Steerin...

Page 128: ...en then turn 1 4 turn further INSTALLATION NOTE Before installing the Steering Cylinder check cylinder pins and bearings for wear and replace if necessary 1 While supporting the cylinder replace the four washers and bolts at the front panel of the A38E s chassis 2 Move the steering arm so that the holes for positioning the pins are correct Install each of the steering pivot pins and ensure that th...

Page 129: ...t for signs of scoring pits excessive wear or polishing Scratches or pits deep enough to catch a fingernail are unacceptable Polishing is a sign of uneven loading and if sufficiently polished the affected parts should be replaced 4 Replace any parts or seals found to be unserviceable REASSEMBLY SEAL REPLACEMENT 1 Lubricate and install new rod seal rod wiper and static seal on the headcap NOTE Mult...

Page 130: ...als for reassembly if they have been deemed serviceable following the cleaning and inspection phase of maintenance CLEANING AND INSPECTION 1 Clean all metal parts in solvent and blow dry with filtered compressed air 2 Check all threaded parts for stripped or damaged threads 3 Check the bearing surfaces inside of the headcap outer edge surface of the piston inside of the cylinder barrel and the sha...

Page 131: ...r 30 seconds after the Platform comes to a stop Care must be taken that the Platform Cage does not impact on the ground Repeat this procedure until the cage becomes level when elevated The above two procedures have the effect of Priming the Levelling Circuit Test to see if the Slave Cylinder is operating correctly If not follow the procedures below 3 Ensure the Elevating Assembly is fully stowed a...

Page 132: ...e pressure setting Turning the screw anticlockwise reduces the setting and allows the boom to creep downwards Adjust the spring setting until the boom just begins to creep downwards d Screw the adjuster 1 one further turn clockwise and secure Locknut This operation should only be carried out by suitably qualified and or experienced personnel An incorrectly adjusted valve may cause one of the follo...

Page 133: ... code 2222 for access level 2 Enter 6 Scroll to setups Enter 7 Change defaults Enter 8 Select Part number 1 Enter 9 Scroll to model 10 1 code Enter followed by ESC 11 Scroll to tilt setups Enter 12 Calibrate level Enter 13 Enter for yes To confirm calibration has worked switch the machine off then back on again 14 Scroll to Diagnostics Enter 15 System Enter 16 Scroll to tilt both reading should be...

Page 134: ...oll to access level Enter 3 Enter code 2222 for access level 2 Enter 4 Scroll to setups Enter 5 Scroll to load setups Enter 6 Scroll to Calibrate load Enter 7 Redo loaded Press up arrow for yes Place 8 Redo empty Press up arrow for yes remove 9 Use arrow to enter calibration date and press Enter 10 Place 120 of SWL in the platform and verify the lift function cuts out automatically when raised off...

Page 135: ...ONE 1 785 989 3000 TOLL FREE 1 800 255 0317 FAX 1 785 989 3070 AUSTRALIA PHONE 611300 700 450 FAX 61 2 9609 3057 NEW ZEALAND PHONE 64 6 3689 168 FAX 64 6 3689 164 W A R N I N G Each malfunction is followed by a list of probable causes which will enable determination of the remedial action The Probable causes and remedial action should be followed in the order in which they are listed in the follow...

Page 136: ...Zcal Display can be switched into calibration mode to become an invaluable tool when troubleshooting on this machine Switch the machine on press and hold Esc for 5 seconds until SNORKEL EBOOM is displayed than select diagnostics the following menu s are available 1 SYSTEM Display status of joystick trigger or enable switches ENABLED B SUPPLY TRACTION PUMP TILT HEIGHT LOAD OVERLOADED ELEVATED 2 FUN...

Page 137: ...ailed troubleshooting information on the pump motor controller Read and understand the principles of operation before commencing any troubleshooting W A R N I N G RISK OF SERIOUS INJURY The elevating assembly must be supported by an overhead hoist when troubleshooting and servicing the electrical hydraulic system Ensure that the work platform is resting on firm level surface ...

Page 138: ...ctor malfunction Check the contact faces Fusing or arcing due to contamination destroys the contacts Replace the unit Pl atform elevates very slowly or not at all 1 Leaking emergency lowering valves Check the operating levers and cables Check closure of the control knob at the base of the control valve block Remove and replace the cylinder mounted valves as necessary 2 Faulty lift valve solenoids ...

Page 139: ...k 2 Faulty steering solenoid valve Check that the solenoids at V5 are energised while the steering Check the cables feeding these solenoids Replace the solenoids if necessary Check the valve cartridges for contamination 3 Faulty controller e h t f o y t i u n i t n o c e h t k c e h C s c i t s o n g a i d l a c Z E g n i s u s O I k c e h C steer speed enabling cable to the controller Repair or r...

Page 140: ...Troubleshooting Section 5 6 A38E Work Platform 5 2 NOTES ...

Page 141: ...oll to access level Enter 5 4 Enter code 2222 for access level 2 Enter Scroll to setups Enter Scroll to tilt setups Enter Calibrate level Enter Enter for yes To confirm calibration has worked switch the machine of then back on again Scroll to Diagnostics Enter System Enter Scroll to tilt both readings should be below 0 2 if not repe at from 5 ESC ENTER Esc to leave Sub Menu without saving Display ...

Page 142: ...ide 2A output Basket Rotate V10 P6 14 High side 2A output Basket Rotate P6 15 High side 2A output Buzzer P7 1 B Digital Input Valve supply from P600 P7 2 B Digital Input Valve Logic supply ground mode Key sw grnd mode also to P600 P7 3 B Digital Input Elevation sw Pole 1 P7 4 B Digital Input Logic supply platform mode Key sw platform mode also to P600 P7 5 B Digital Input Lower boom sw P7 6 B Digi...

Page 143: ...Schematics Section 6 1 A38E Work Platform 6 0 Introduction This section contains electrical and hydraulic power schematics and associated information for maintenance purposes 6 0 ...

Page 144: ... PANEL PLUG 510154 000 1 Mate N Lock SCKT CONTACT 509755 000 32 GROUND COUNTROL PANEL A36E LCB ENCLOSURE 515045 000 1 1 SW PUSH PULL RELEASE E STOP 3028810 1 3 POS N KEY SWITCH STAYPUT 512543 000 1 SW TGL SPDT ON ON 3020080 6 THUMB CONTROL UNIT 514131 000 1 EZcal DISPLAY 3087803 1 LED RED 12V 512934 000 1 20PIN PANEL MOUNT RECEPTACLE DEUTSCH HDP24 18 20PN 3220275 1 LOCKNUT DEUTSCH 114020 90 514605...

Page 145: ...Schematics Section 6 3 A38E Work Platform Electrical Schematics 6 1 515490 000 Rev 0 CCT DIAG A38E CE ANSI CANbus loadcell ...

Page 146: ...RIVE LIGHT KIT LED OVAL LIGHT ASSY 0260721 2 PLAC LIGHTS ON OFF 0181376 1 CONR 2 PIN DEUTSCH RECEP 3049804 6 PIN CONTACT 3040314 16 LED RED LIGHT STOP TAIL 3069533 2 RELAY SPDT 3040469 1 CONR 2 PIN DEUTSCH PLUG 3049803 6 SKT CONTACT 3040342 16 LOCK WEDGE 3049807 6 CONR 4 PIN DEUTSCH RECEP 3049889 1 LOCK WEDGE 3049891 1 CONR 4 PIN DEUTSCH PLUG 3049888 1 LOCK WEDGE 509750 000 1 AMBER LIGHT 512492 00...

Page 147: ...directional On hydraulic block control valves and relief reservoir in valves that distribute oil to chassis the various functions and control the operating pressures MOT1 Slew Motor Drives slew bearings drive Connected to pinion drive pinion MP Motor Pump Gear pump close coupled to On chassis set D C electric motor Provides pressurised oil flow for all hydraulic functions V1 Brake oil This valve i...

Page 148: ...WER LIFT CYLINDER 3 3 MACHINE PREPARATION 1 3 MANIFOLD BLOCK ASSEMBLY Hydraulic Platform Rotate 3 10 MASTER SLAVE CYLINDER ASSEMBLY 3 7 MOTOR PUMP ASSEMBLY 3 9 OPTION LIST 5 1 OPTION SNORKEL GUARD 5 2 PG PART ASSEMBLY A38E 2 3 PLATFORM ROTATE CYLINDER ASSEMBLY 3 8 REAR FRONT WHEEL KIT NON MARKING 2 9 SCHEMATICS 7 1 SLEW MOTOR WORM DRIVE UNIT SLEW BEARING ASSEMBLY 2 10 STEERING CYLINDER ASSEMBLY 3 ...

Page 149: ...57048 000 3 5 3 6 3 7 057054 000 2 4 057121 000 3 5 057382 000 2 11 057424 001 2 11 057429 000 2 11 057430 002 2 11 2 12 2 12 2 12 2 12 2 12 057434 001 2 11 057507 024 2 12 057507 025 2 12 057532 000 2 2 057534 000 2 2 057578 000 2 2 2 9 057580 000 2 1 2 2 057582 000 2 6 057583 000 2 6 057584 000 2 6 057585 000 2 6 057661 000 2 6 057662 000 2 6 057663 000 2 6 057664 000 2 6 057665 000 2 6 057666 0...

Page 150: ...8750 000 3 7 058761 000 2 11 058860 000 2 12 2 12 2 12 2 12 2 12 058881 001 2 11 060197 001 2 11 2 12 2 12 2 12 2 12 2 12 066555 000 2 11 067387 022 2 3 068635 001 2 11 2 12 2 12 2 12 2 12 2 12 100338 013 4 1 4 2 11492 1 2 5 2 5 12 3149 3 10 12330 2 1 2 5 3 8 12330K 3 8 12468 22 2 5 12567 4 3 10 13 0176 2 5 13520 13 2 5 238396 2 2 260838 2 5 260839 2 5 260852 2 5 300699 2 11 301403 5 2 3020061 2 2...

Page 151: ... 4 500468 001 2 4 500468 002 2 4 500494 000 2 9 500519 006 2 4 501074 000 2 2 501085 000 2 4 501868 001 2 2 501964 000 3 5 501964 001 3 4 502588 000 2 3 4 2 503101 040 2 5 504120 000 2 5 504199 005 2 12 2 12 2 12 2 12 2 12 504504 001 2 4 504504 002 2 1 504505 000 2 1 2 4 3 4 508772 000 2 11 508834 000 2 12 508849 000 2 12 508852 001 2 12 508853 000 2 12 508932 000 2 5 509722 000 2 12 509755 000 4 ...

Page 152: ...3 512943 000 2 3 513429 000 2 1 2 2 2 9 513430 000 2 1 2 2 2 9 513540 001 4 3 513541 000 4 3 513542 002 4 3 513542 003 4 3 513542 004 4 3 513542 005 4 3 513542 006 4 3 513542 008 4 3 513542 009 4 3 513542 010 4 3 513542 011 4 3 513542 012 4 3 513542 013 4 3 513542 014 4 3 513542 015 4 3 513542 016 4 3 513542 017 4 3 513542 018 4 3 513550 000 2 3 513767 006 2 5 513767 010 2 5 513767 018 2 5 514131 ...

Page 153: ...9 000 4 2 514675 001 5 2 514677 000 5 2 514684 000 5 2 514685 000 5 2 514686 000 5 2 514688 000 5 2 514689 000 5 2 514698 000 2 11 514698 000 5 2 514698 000 DE 2 12 514698 000 ES 2 12 514698 000 FR 2 12 514698 000 IT 2 12 514698 000 NL 2 12 514764 000 2 5 514764 001 2 5 514764 003 2 5 514764 004 2 5 514764 008 2 5 514767 000 2 2 514768 000 2 2 514799 000 2 4 514801 000 2 4 514802 000 2 4 514867 00...

Page 154: ...15881 000 3 3 515882 000 3 3 515883 000 3 3 515884 000 3 3 515885 000 3 3 515886 000 3 3 515887 000 3 3 515888 000 3 3 515889 000 3 3 515890 000 3 3 515891 000 3 3 515892 000 3 3 515893 000 3 3 515894 000 3 3 515895 000 3 3 515896 000 3 3 515897 000 3 3 515898 000 3 3 515899 000 3 3 515900 000 3 3 515901 000 3 3 515902 000 3 3 515903 000 3 3 515904 000 3 3 515905 000 3 3 515906 000 3 3 515921 000 ...

Page 155: ...2 2 11 7030162 5 2 7030162 DE 2 12 7030162 ES 2 12 7030162 FR 2 12 7030162 IT 2 12 7030162 NL 2 12 8628 2 5 CYLINDER 12330 3 8 SEE SIDE TRAY PG ASSY 2 2 A38E PARTS MANUAL S N 00715 AND AFTER Fri Jul 05 12 03 51 UTC 2019 B 7 ...

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