Upright AB38, Service & Parts Manual

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Contents Section
I AB38 Work Platform
i
1.0 Introduction & Specifications
1.0 Introduction ........................................................ 1-1
Purpose .......................................................... 1-1
Scope ..............................................................1-1
1.1 General Information .......................................... 1-1
Platform .......................................................... 1-1
Control Box ....................................................1-1
Elevating Assembly ..................................... 1-1
Rotation Gear ................................................ 1-1
Drive & Steer Systems .................................1-2
Power System ................................................1-2
Control System ............................................. 1-2
Chassis ...........................................................1-2
AB38 Purpose & Limitations ...................... 1-2
1.2 Specifications ..................................................... 1-3
1.3 Notes .....................................................................1-4
2.0 Machine Preparation
2.1 Preparation For Use ......................................... 2-1
2.2 Preparation For Shipment ............................... 2-1
2.3 Forklifting The Work Platform ........................ 2-1
2.4 Lifting The Work Platform ................................ 2-1
2.5 Transport by Truck .............................................2-1
2.6 Manual Brake Release ......................................2-2
2.7 Storage .................................................................2-2
2.8 Notes .....................................................................2-3
3.0 Operation
3.0 Introduction ........................................................ 3-1
General Functioning .....................................3-1
Driving ........................................................... 3-1
Steering .......................................................... 3-1
Operating the Booms ................................... 3-1
Design Features ............................................3-2
3.1 Safety Rules & Precautions ............................. 3-3
3.2 Controls & Indicators .......................................3-4
3.3 Pre-Operation Inspection .................................3-6
System Function Inspection .......................3-6
3.4 Opertaion ............................................................ 3-7
Elevating & Lowering The
AB38 Work Platform ................................. 3-7
Travel With The Work Platform
Lowered ..................................................... 3-7
Travel With The Work Platform
Elevated ..................................................... 3-8
Levelling ........................................................ 3-8
Emergency Situations &
Emergency Override .................................3-8
Emergency Lowering ......................3-8
Control From Ground Level ........................ 3-9
After Use Each Day ..................................... 3-9
Manual Rotation ...........................................3-9
Manual Telescopic Retraction ....................3-9
3.5 Notes .....................................................................3-11
4.0 Maintenance
4.0 Introduction ........................................................ 4-1
Tools Required ..............................................4-1
4.1 Preventative Maintenance ............................... 4-1
Preventative Maintenance
Table Key ....................................................4-2
Preventative Maintenance
Report ..........................................................4-2
4.2 Battery Maintenance .........................................4-3
Battery Inspection & Cleaning ...................4-3
Battery Charging .......................................... 4-3
Battery Cell Equalization ............................. 4-4
4.3 Temperature Correction For
Electrolyte Readings
...................................... 4-4
4.4 Lubrication ......................................................... 4-5
Grease Fittings .............................................. 4-5
Slew Ring ....................................................... 4-5
Pivot Pins .......................................................4-5
Hydraulic Oil Tank & Filter ......................... 4-5
4.5 Setting Hydraulic Pressures ............................ 4-6
Main Relief Valve ..........................................4-6
Slew Cross-Line Relief Valve ...................... 4-7
4.6 Maintenance on Elevating Assembly ............. 4-7
Installation of Elevating Assembly
Support ....................................................... 4-7
Removal of Elevating Assembly
Support ....................................................... 4-7
4.7 Switch Adjustments ............................................ 4-8
Tilt Sensor ..................................................... 4-8
Boom Rest Limit Switch ... ...........................4-8
4.8 Hydraulic Manifold ........................................... 4-10
Removal ......................................................... 4-10
Disassembly .................................................. 4-10
Cleaning & Inspection .................................4-10
Assembly .......................................................4-10
Installation .....................................................4-10
4.9 Hydraulic Pump ................................................. 4-12
Removal ......................................................... 4-12
Installation .....................................................4-12
4.10 Traction Motor Maintenance .......................... 4-12
Inspecting the Drive Motor ........................ 4-12
4.11 Electric Motor .................................................... 4-14
Troubleshooting ...........................................4-14
Disassembley ................................................ 4-14
Inspection ......................................................4-14
Reassembley ................................................. 4-14
Maintenance Intervals & Procedures ....... 4-15
4.12 Drive Reduction Gearbox .................................4-17
Changing the Oil ...........................................4-18
4.13 Torque Specifications ........................................4-18
4.14 Lower Lift Cylinder ............................................4-19
Removal ......................................................... 4-19
Disassembly .................................................. 4-19
Cleaning & Inspection .................................4-19
Reassembly/Seal Replacement ................... 4-20
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