Snorkel A38E Service Manual

006001 +

Part number 514252-200

PARTS & SERVICE

December 2014

iA38E Work Platform

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.

When contacting Snorkel for service or parts information, sure to include the MODEL and SERIAL
NUMBERS from the equipment nameplate.

The A38E work platform meets and exceeds the requirements of both:
En280:2001 and ANSI A92.5 (1992)

ii A38E Work Platform

WARNING

All personnel shall carefully read, understand and follow all safety rules and operating

instructions before operating or performing maintenance on any Snorkel aerial work platform.

Safety Rules

USE OF THE AERIAL WORK PLATFORM: This aerial work platform is intended to lift persons and his tools as well as the material
used for the job. It is designed for repair and assembly jobs and assignments at overhead workplaces (ceilings, cranes, roof struc­tures, buildings etc.). All other uses of the aerial work platform are prohibited!

THIS AERIAL WORK PLATFORM IS NOT INSULATED! For this reason it is imperative to keep a

safe distance from live parts of

electrical equipment!

Exceeding the specified permissible maximum load is prohibited! See “Platform Capacity” for details.

The use and operation of the aerial work platform as a lifting tool or a crane is prohibited!

NEVER exceed the manual force allowed for this machine. See “Manual Force” for details.

DISTRIBUTE all platform loads evenly on the platform.

NEVER operate the machine without first surveying the work area for surface hazards such as holes, drop-offs, bumps, curbs, or

debris; and avoiding them.

OPERATE machine only on surfaces capable of

supporting wheel loads.

NEVER operate the machine when wind speeds exceed this machine’s wind rating. “Beaufort Scale” for details.

IN CASE OF EMERGENCY push EMERGENCY STOP switch to deactivate all powered functions.

IF ALARM SOUNDS while platform is elevated, STOP, carefully lower platform. Move machine to a firm, level surface.

Climbing up the railing of the platform, standing on or stepping from the platform onto buildings, steel or prefab concrete structures,
etc., is prohibited!

Dismantling the entry gate or other railing components is prohibited! Always make certain that the entry gate is closed and securely
locked!

It is prohibited to keep the entry gate in an open position when the platform is raised!

To extend the height or the range by placing of ladders, scaffolds or similar devices on

the platform is prohibited!

NEVER perform service on machine while platform is elevated without blocking elevating assembly.

INSPECT the machine thoroughly for cracked welds, loose or missing hardware, hydraulic leaks, loose wire connections, and dam-

aged cables or hoses before using.

VERIFY that all labels are in place and legible before using.

NEVER use a machine that is damaged, not functioning properly, or has damaged or missing labels.

To bypass any safety equipment is prohibited and presents a danger for the persons on the aerial work platform and in its working
range.

NEVER charge batteries near sparks or open flame. Charging batteries emit explosive hydrogen

gas.

Modifications to the aerial work platform are prohibited or permissible only at the approval by Snorkel .

AFTER USE, secure the work platform from unauthorized use by turning the keyswitch off and removing key.

The driving of MEWP’s on the public highway is subject to regulations made under the Road Traffic Acts.

ALWAYS use a full body harness, prior to raising the platform, as recommended by the Health and Safety Executive (H1/05/05)

U

p

R

i

g

h

t

A

B

3

8

NEVER elevate the platform or drive

the machine while elevated unless

the machine is on a firm, level

surface.

NEVER climb, stand, or sit on

platform guardrails or midrail.

NEVER position the platform

without first checking for overhead

obstructions or other hazards.

Electrocution Hazard Tip Over Hazard

C

ollision Hazard Fall Hazard

THIS MACHINE IS NOT

INSULATED!

NEVER get closer than the minimum distance recommended by your National Regulations.

iiiA38E Work Platform

Harness attachment points are provided in the platform and the manufacturer recommends the usage of a fall

restraint harness, especially where required by national safety regulations.
All harness attachment points on SNORKEL vehicles have been tested with a force of 3,650 lbs (16.3 KN)

per person.
See below examples of harness attachment points used on SNORKEL vehicles with their corrosponding rating;

Type 1.

Harness attachment point Type 1. is rated for one
lanyard attachment per loop as shown in the
illustrations depending upon platform occupancy rating

(see operators manual & decals).

Type 2.

Harness attachment point Type 2. is rated for two
lanyard attachments per loop as shown in the
illustrations depending upon platform occupancy rating

(see operators manual & decals).

Type 3.

Harness attachment point Type 3. is rated for one
lanyard attachment per loop as shown in the
illustrations depending upon platform occupancy rating

(see operators manual & decals).

Top View Top View

2 lanyard

attachments

Top View

1 lanyard

attachment

Top View

2 lanyard

attachments

1 lanyard

attachment

1 lanyard

attachment

Top View

Front View

Type 4.

Harness attachment point Type 4. is rated for one
lanyard attachment per loop as shown in the
illustrations depending upon platform occupancy rating

(see operators manual & decals).

1 lanyard

attachment

NOTE: There can be more harness attachment points per machine than the

maximum number of occupants allowed in a platform. Refer to

the platform decal & specifications table listed in the operators

manual for the correct occupancy rating before use.

Safety Rules

iv A38E Work Platform

NOTES:

vA38E Work Platform

General Description & Machine Specifications.

Foreword

Introduction &

Specifications

1.0

Machine Preparation

2.0

Information on the preparation for use, shipment,

forklifting, transporting and storage.

Operation

3.0

Operating Instructions & Safety Rules.

Maintenance

4.0

Preventative Maintenance & Service Intervals.

Troubleshooting

5.0

Causes of and Solutions to typical problems.

Schematics

6.0

Schematics and Valve Block Diagram with

description and location of components.

Illustrated Parts

Breakdown

7.0

Complete parts lists with illustrations.

Introduction

HOW TO USE THIS MANUAL

This manual is divided into 7 Sections,
The right hand pages of each Section is marked with a black
section number printed at the top corner of each page which

can be used as a quick guide.

SPECIAL INFORMATION

Notes: Give helpful information.

All information contained in this manual is based on the
lates

t product information available at the time of printing.
We reserve the right to make changes at any time without
notice. No part of this publication ma

y be reproduced,
stored in retrieval system, or transmitted, in any form by
any means, electronic, mechanical, photocopying,
recording, or otherwise, without prior written permission of
the publisher. This includes text, figures and tables.

WORKSHOP PROCEDURES

Detailed descriptions of standard workshop
procedures, safety principles and service operations
are not included. Please note that this manual does
contain warnings and cautions against some specific
service methods which could cause personal inju

ry,

could damage a machine and make it unsafe.
Please understand that these warnings cannot cover
all conceivable ways in which service, whether or not
recommended by Snorkel, can be done, or the possible

hazardous consequences of each conceivable way,
nor could Snorkel investigate all ways. Anyone using
service procedures or tools, whether or not recom-

mended by Snorkel, must satisfy themselves

thoroughly that neither personal safety no

r machine

safety will beorjeopardised.

Indicates a potentially hazardous situation which, if not avoided, could
result in severe injury or death.

W A R N I N G

Indicates an imminently hazardous situation which, if not avoided, will
result in severe injury or death.

D A N G E R

Indicates a potentially hazardous sit uation which, if not avoided, may
result in minor or moderate injury.

C A U T I O N

C A U T I O N

vi A38E Work Platform

NOTES:

Foreword

Contents

Section

IA38E 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

A38E 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

A38E 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

Section

No.

Page

No.

Section

No.

Page

No.

Table of Contents

Contents

Section

II A38E Work Platform

i

Installation .....................................................4-20

4.15 Upper Lift Cylinder ............................................4-21

Removal ......................................................... 4-21

Disassembly ..................................................4-21

Cleaning & Inspection .................................4-21

Reassembly/Seal Replacement ................... 4-21

Installation ........................

.............................4-22

4.16 Telescopic Cylinder ........................................... 4-22

Removal ......................................................... 4-22

Disassembly ..................................................4-23

Cleaning & Inspection .................................4-23

Reassembly/Seal Replacement ................... 4-23

Installation .....................................................4-23

4.17 Steering Cylinder ........

.......................................4-23

Removal ......................................................... 4-23

Disassembly ..................................................4-23

Cleaning & Inspection .................................4-24

Reassembly/Seal Replacement ................... 4-24

Installation .....................................................4-24

4.18 Master Levelling Cylinder ............................... 4-25

Removal ..............................

........................... 4-25

Disassembly ..................................................4-25

Cleaning & Inspection .................................4-25

Reassembly/Seal Replacement ................... 4-25

Installation .....................................................4-25

4.19 Slave Levelling Cylinder ..................................4-26

Removal ......................................................... 4-26

Disassembly .............................

.....................4-26

Cleaning & Inspection .................................4-26

Reassembly/Seal Replacement ................... 4-26

Installation .....................................................4-27

Bleeding the Master/Slave

5.0 Troubleshooting

5.0 Introduction ........................................................5-1

General Procedure ........................................ 5-1

5.1 Troubleshooting Guides ....... .................... 5-4

5.2

6.0 Schematics

6.0 Introduction ........................................................6-1

6.1 Electrical Schematics ........................................6-3

6.2 Hydraulic Schematics ....................................... 6-6

7.0 Illustrated Parts Breakdown

Sect ion

No.

Page

No.

Sect ion

No.

Page

No.

Table of Contents

Special Tools .... ............................................ 5-2

Adjustment Procedures .......... ..................... 5-2

Checking Pump Preasure...............................5-2

Diagnostics using Ezcal display......... .......... 5-2

I/O Matrix ..................................................... 5-3

GP400 I/O Allocations...............................

5-8

Replacing the GP400 Control module ....... 5-6

5-7

Notes ........................................................

7.0 Introduction ........................................................ 7-1

7.1 Index ..............

....................................................... 7-1

7.2 Illustrated Parts Breakdown .......................... 7-2

F inal Assembly A38E .... ............. ........ ........................ 7-2

Chassis Ass embly .......................................................... 7-4

Booms and Posts Assembly .......... ................. .. ............. 7-8

Cage and Cradle Assembly.................................................... 7-

Cage and Cradle Assembly (Rotator) ................................... 7-

10

Wheel Hub Assembly .......................................................... 7-

12

Drive Reduction Gear box Assembly .................................. 7-

14

Traction Motor Assembly (512944-000).............................

16

Motor / Pump Assembly..................................................

7-

18

Re ar & Front Wheel Kit .................................................

7-

20

Worm Drive Unit & Slew Bearing .......................................

7-

22

Manifold

Block Assem

bly ...............................................

7-

24

Lower Lift Cylinde r Assembly.............................................

7-

26

Upper Lift Cylinder Assembly ............................................

7-

28

Telescopic Cylinder Assembly.............................................

7-

30

St eeri ng Cylinder Assembly................................................

7-

32

Master / Slave Cylinder Assembly......................................

7-

34

7-

36

Lower Control Box Assembly ............................................ 7-

38

Upper Control Box Assembly (CE)..................................... 7-

40

Cables & Electrical Components..........................................

7-

42

Hose Assembly...................................................................

7-

44

Decal Kit - ANSI Version ...............................................

7-

46

Decal Kit - CE Version ....................................................

7-

48

7-52

50

Options List ..........................................................................

A38 PG Parts Assembly ......................... ....... ....... ........ 7-6

Traction Motor Assembly (514274-000)............................. 7-

Upper Control Box Assembly (ANSI).................................

7-54

Levelling Circuit ........................................4-27

4.20 Adjustment Of Overcentre Valves .................... 4-28

4.21 Replacing GP400 control module ....................4-29

4.22 Calibration of load cell ...................................4-30

Contents

Section

IIIA38E Work Platform

i

NOTES:

Contents

Section

IV A38E Work Platform

i

NOTES:

Introduction & Specifications

Section

1-1A38E Work Platform

1.0 Introduction

SCOPE

The manual includes the procedures and
responsibilities which must be strictly adhered to for
proper operation, maintenance, adjustment, and
repair of this product. The Maintenance Section
further covers preventative maintenance and trouble
shooting.

1.1 General Information

PLATFORM

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 Boom, rotating (slewing)
the entire Booms & Posts Assembly or driving.

A safety feature which is incorporated into the
Joystick’s operation is the Interlock Switch. This
must be activated at all times while operation is
required. This allows for one-handed operation. A
complete explanation of control functions can be
found in Section 3.

ELEVATING ASSEMBLY

The platform is raised and lowered by a combination
of two steel lift booms and one telescopic boo

m,
each of which is operated by a hydraulic cylinder
which in turn is actuated by hydraulic power from the
motor driven pump. Solenoid operated valves control
to which cylinder the hydraulic oil is directed. Each
cylinder features an integral holding valve to prevent
uncontrolled descent in the case of a hose burst.

ROTATION GEAR

The Booms & Posts Assembly can be rotated to
provide up to 5.6 m (18.4 ft.) of side outreach,
measured from the centreline of rotation to the front

of the Platform. This is do

ne by means of an integral
hydraulic motor driving a Worm Drive Unit, around a
large diameter Slew Gear.

1.0

Figure 1-1: A38E Work Platform

1. Platform

2. Elevating Assembly

3. Chassis

4. Power Module

5. Control M odul e

6. Platform Control Box

7. Lower Control Box

1.

2.

3.4.

5.

6.

7.

PURPOSE

The purpose of this Service & Parts Manual is to
provide instructions and illustrations for the operation
and maintenance of the A38E Work Platform
manufactured by Snorkel. (See Figure 1-1).

DO NOT begin using the machine until the
platform entrance drop bar is in the fully
lowered position.

W A R N I N G

The A38E is a quickly deployable self propelled aerial
work platform, designed to raise a specified number
of operators with hand tools to a work height of up
to 13.45 m (44.12ft.) i.e. a platform floor height of

11.45 m (37.56 ft.). It is designed to provide mobility
with the Platform in the raised or lowered position,
although travel with the Platform raised is limited to
a low speed. The boom assembly and telescope
functions are operated by a hydraulic pump driven
by a DC electric motor. Two DC electric traction
motors coupled to two braked gearboxes regulate
the drive function.

The platform is large enough for a specified number
of operators and has a free-draining perforated floor
with 150 mm (5.9inches) toe boards. Hand rails are
constructed from steel tubing and a safety drop-bar is
provided at the entrance. Safety harness anchor points
are also fitted in the floor of the platform. The primary
Control Box is fitted permanently within this platform.

Introduction & Specifications

Section

1-2 A38E Work Platform

1.1

A38E PURPOSE & LIMITATIONS

NOTE: It should be recognised that if the tilt
switch senses a degree of slope greater than
3º the elevating circuits will lockout and
sound a warning alarm. The Emergency
Override should then be used, to lower the
Elevating Assembly.

DRIVE & STEER SYSTEMS

The A38E Work Platform is restricted to low speed
drive when the Platform is raised above the Boom
Rest Limit Switch. The Traction controller controls the
application of drive from the Joystick by means of two
Tra

ction Motors, which are assembled to the drive

wheels via a Drive Reduction Gearbox.

POWER SYSTEM

The power system incorporates eight 6V batteries
driving the drive traction motors, or the 4kW (5.4HP)
electric motor which in turn drives the hydraulic
pump. The application of this hydraulic pressure is
performed by the Control System.

CONTROL SYSTEM

The machine is provided with fully proportional
controls by means of the interaction between a
P600, electron tor om ci contro l a dna rel proportional
joystick. The P600 and motor controller regulate the
drive motor/pump speed and hence the flow of oil
reaching the cylinders, the Worm Drive Unit or the
Drive Reduction Gearbox. It regulates the direction of
flow of the hydraulic oil via the solenoid valves located
on the manifold block, and it also monitors the opera­tion of all switches on the machine via the machine
harness system.
The motor control units are located, in the left hand
chassis mo

dule. The manifold block is located on the
hydraulic tank. This is accessible by removing the
main cover.

CHASSIS

The chassis is a structural frame designed to support
all the components of the A38E Work Platform.

DANGER

Steering of the A38E Work Platform is controlled by
a double acting cylinder. An Operator can Steer left
or right by depressing the Rocker Switches on top of
the Joystick, while activating the Interlock Switch.

The purpose of the A38E work platform is to provide a
quickly deployable variable height work platform. It is
capable of lifting a specified number of 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.
See Specification table on page 1-3.

The platform must only be used on firm level or slightly
uneven ground capable of supporting the maximum load
generated under the four wheels. Do not use on soft or
severely sloping ground.

Introduction & Specifications

Section

1-3A38E Work Platform

1.2 Specifications

1.2

Table 1-1: Specifications

ITEM METRIC IMPERIAL (ANSI)

Duty Cycle 45% of 8 hour shift 45% of 8 hour shift

Platform Size

0.58 m x 1.3 m (inside gaurdrails) 1.77 ft x 4.3 ft (inside gaurdrails)

Max. Platform Capacity 2

15 kg 475 lbs

2 People 2 People

Min. Platform Floor Height

13.45 m

11.45 m

0.65 m

44.12 ft

37.56 ft

2.13ft

6.10 m 20.00 ft

Platform Height At
Maximum Outreach

5.40 m 17.72 ft

Stowed Dimensions

Length
Width
Height

4.04 m

1.50 m

2.00 m

13.25 ft

4.92 ft

6.56 ft

Ground Clearance 0.12 m 0.39 ft

W

heel Base x Gauge 2.00 m x 1.27 m 6.56 ft x 4.16 ft

Rotation

362 degrees non-continuous 362 degrees non-continuous

3,770 kg 7

,826 lbs

3,985kg 8,840 lbs

Drive Speed Stowed 0 - 4 km/h 0 - 2.49 mph

Drive Speed Elevated

0 - 0.4 km/h 0 - 0.25 mph

Maximum Gradeability 36% 36%

Inside Turning Radius

0.40 m 1.31 ft

Outside Turning Radius 2.40 m 7.87 ft

Power Source

48V 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 18A
Output 48V, 25A

25 Litres 6.5 Gallons US

Max. Hydraulic Pressure

145 bar 2105 psi

ISO #46 ISO #46

2 Double Acting Lift Cylinders With

Lock Valves And Manual Emergency

Lowering Facility.

1 Double ActingTelescopic Cylinder

2 Double Acting Lift Cylinders With

Lock Valves And Manual Emergency

Lowering Facility.

1 Double ActingTelescopic Cylinder

Refer to Section 5 of the Service &

Parts Manual

Refer to Section 5 of the Service &

Parts Manual

Control System

One handed Proportional Joystick

Operating Energy Efficient Motor

Control System

One handed Proportional Joystick

Operatin

g Energy Efficient Motor

Control System

Wheels/Tyres

400 mm Diameter Steel Disc Wheel

With Solid All Surface Tyres

15.75 inch Diameter Steel Disc Wheel
With Solid All Surface Tyres

Braking

Automatic Spring Applied

Hydraulic Release

Automatic Spring Applied

Hydraulic Release

69.5 dB(A) 69.5 dB(A)

Indoors

Outdoors

Unloaded Weight

With Load/ Max Weight

Max Noise Level

Auto Dual AC input 100-240V ~ 50/60Hz 18A
Output 48V, 25A

Hydraulic Oil Tank Capacity

Hydraulic Oil Grade

Cylinder Types

2 People

1 People

Max. Working Outreach

Maximum Working Height
Maximum Platform Height

Introduction & Specifications

Section

1-4 A38E Work Platform

NOTES:

1.3

Machine Preparation

Section

2.1

2-1A38E Work Platform

2.1 Preparation for use

Read, understand and follow all operating
instructions before attempting to operate the
machine.

2.2 Preparation for Shipment

1. Lubricate machine per lubrication instructions in
Section 4.4, Maintenance.

2. Fully lower the platform and make sure the

machine is stowed securely.

3. Check that the hydraulic oil level is adequate

and that it is not over filled.
Check that the batteries are charged and disconnect
the batteries usin

g the Battery Disconnect Plug.
This prevents excessive power drain prior to next
using the machine.

2.3 Forklifting the Work Platform

The A38E is not designed to be consistently
forklifted. This operation can be used for very
short distances only.

Forklift from the side by lifting under the chassis
modules as per Figure 2-1. When lifting the A38E
with a forklift, great care should be taken not to
damage the right or left hand modules as these

contain sensitive equipment.

2.4 Lifting the Work Platform

See specifications (Section 1.2) for the
weight of the work platform and be certain
tha

t 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 ( (3,770 Kg /7,430 lbs CE

Version & 4,010 Kg /8,840 lbs ANSI Version) and at
least 250 cm (8 ft.) long are required. This minimum
length is important to ensure the correct lifting an

gle.

The straps should be positioned at the Lifting/Tie

Down Lugs as shown in Figure 2-1. Great care must
be taken to avoid damage to any of the components
of the machine.

2.5 Transport by Truck

The A38E is normally carried upon a suitably rated

transportation vehicle. Because of the high

gradeability of the A38E it will be capable of driving

directly on to most vehicles. If however the loading

slope is greater than the gradeability or the batteries

have been depleted sufficiently a winch sho

uld be
used. The procedure when using a winch is to
disengage the gearbox from the drive wheels using
the Allen key release, and then winch the machine on
to the vehicle in its freewheel state.

Refer to Section 2.6 which follows.

Figure 2-1: Forklifting & Lifting the A38E

Front Lifting /

Tie-down Lug

Rear Lifting /

Tie-down Lug

FORKLIFT

HERE

CAUTION

CAUTION

CAUTION

Machine Preparation

Section

2-2 A38E Work Platform

2.6

2.7 Storage

No preparation is required for storage when the Work
Platform is in regular use. Regular maintenance per
Table 4-1 should be performed.
If the work platform is to be placed in long term
storage (dead storage) use the following preservation
procedure.

PRESERVATION

1. Clean painted surfaces. If the painted surface is

damaged, repaint.

2. Fill the hydraulic tank to operating level with the

platform fully lowered. Fluid should be visible
on the Di

p Stick. It is not recommended that the

hydraulic fluid be drained.

3. Coat exposed portions of cylinder rods with a

preservative such as multipurpose grease and
wrap with barrier material.

4. Coat all exposed unpainted metal surfaces with

preservative.

BATTERIES

1. Disconnect the batteries.

2. Disconnect the battery leads and secure to the

chassis.

Care should be taken, while disconnecting the
battery leads, that a short circuit does not occur.
i.e. grounding to the chassis with a

spanner.

3. Remove the batteries and place in alternate

service. Battery efficiencies are best realised
when used consistently.

When the A38E is on the Truck it should then be
made secure.

1. Chock the wheels of the A38E.

2. Secure the work platform to the transport
vehicle with chains or straps of adequate load
capacity attached to the lifting lugs on the
chassis.

Overtightening of the chains or straps through
tie down lugs may result in damage to the
Work Platform.

2.6 Manual Brake Release

Perform this operation only when the machine
will not operate under its own power and it is
necessary to move the mach

ine, or for
winching onto a trailer for transportation.
Ensure the machine is on level ground before
commencing this operation and use wheel
chocks as appropriate to prevent the machine
from rolling inadvertently.
Do not exceed 3 mph. Faster speeds will
damage drive components and void warranty.

1. Ensure that the Platform is fully lowered and
that the Elevating Assembly is slewed (rotated)
such that the platform is stowed above the drive
wheels. Turn the Upper Control Box to the OFF
posi

tion and remove the key.

2. Attach a chain/cable of sufficient capacity for
towing the machine to the front or rear lifting/tie
down lugs. Take up the slack in the chain/cable.

3. Locate the Allen head socket screws located in
the centre of the two drive (rear) wheels and
using a 6 mm Allen key, turn each one
clockwise to its full extent. The machine is now
in freewheel mode.

DO NOT leave the machine unattended or
attempt to operate the A38E Work Platform
until the Brake Rele

ase Screws

have bee

n

re-engaged.

4. When towing is completed, turn both Allen head
socket screws in a counter clockwise direction
until they rest firmly against the locking circlip.

Figure 2-2 : Manual Brake Release

CAUTION

CAUTION

WARNING

WARNING

Machine Preparation

Section

2-3A38E Work Platform

NOTES:

2.7

Machine Preparation

Section

2-4 A38E Work Platform

2.7

NOTES:

Operation

Section

3-1A38E Work Platform

3.0

3.0 Introduction

GENERAL FUNCTIONING

The Drive function is operated by utilising two drive
motors which

are controlled by a Electronic Traction

Motor Controller.

NOTE :

An Interlock Trigger Switch is an integral part of the
Joystick. This must be depressed for the functions to
operate. This will energise the Line Contactor and enable
electrical control. (This safety feature prevents
inadvertent activation of all powered functions, in the
case of accidental movement of the Joystick.)

DRIVING

Platform controls provide variable speeds for the
drive function through the use of a Joystick. This is
achieved using a motor control unit which varies the
speed of the two DC electric traction motors. To drive
the A38E there are a number of steps which need be
taken. First the operator should ensure that neither of
the Emergency Stop Buttons are pressed, then the
Keyswitch on the ground control panel should be

‘PLATFORM CONTROL’ position.

function switch and

The machin

e will then drive at a speed proportional

to the angle of the Joy-

stick

from the neutral (centre)

If a boom is raised off the Boom Rest Limit Switch
the current to the drive motors will be reduced leading
to a significantly slower drive speed. This is a safety
feature. The drive wheels are driven by two DC
electric traction motors coupled to two braked
gearboxes. When the Joystick is in the neutral
position the brake chamber is free of oil and the
internal spring within the gearbox maintains the
braking pressure. Upon moving the Joystick the
brake chambers will receive a flow of pressurised
oil which will release the brakes.

STEERING

Platform controls also provide a steering function
through the use of ‘Rocker’ activated Steering
Switches in the Joystick. This is achieved by using the

tla yb wolf ciluardyh eht seirav hci 006P wh ering
the voltage to the pump. To steer the A38E there are
a number of steps which need be

taken.

First the operator should ensure that neither of the

NOTE:

Steering is not self-centring. The wheels must be
returned to the straight ah

ead position by operating the

Steering Switch.

OPERATING THE BOOMS

Boom functions, including the telescopic and slewing
functions, can be operated either from the Platform
Controls or the Chassis Controls.
The Platform controls provide variable speeds for the
boom functions through the use of a Joystick. This is

deeps eht seirav hcihw 006P na gnisu deveihca

of the motor/pump unit and increases

or decreases
the flow of oil to the different functions. This control
uni

t receives a control signal from the Joystick on the
upper controls, the speed of the motor will increase
as the Joystick is pushed further away from the
neutral (centre) position.

position, while the

turned to the
Momentarily operate the drive

the A38E will be able to drive.

WARNING

Emergency Stop Buttons are pressed, then the
Keyswitch ground control Panel should be turned to

‘PLATFORM CONTROL’ position.

the

Before beginning to operate the machine it is a
mandatory requirement to read, fully understand
and follow the Operators Manual.

Joystick Interlock Switch is
depressed. The speed range within which the machine
will drive is deter-mined by whether or not the booms
are raised.

The A38E Lift and Steer functions are operated by
utilising a battery powered electric motor which
drives a hydraulic pump. The pump supplies oil
under pressure to the various platform functions.

electrically activated solenoid valves (the control
of which solenoid valve activates and the rate at

electrical circuit, and its components).

Momentarily operate the drive function switch to drive
and the A38E will also be able to steer. To steer the
machine the Rocker should be pushed to the left or
the right, while the Joystick Interlock Switch is
depressed. Steering left or right will energise the
steering coils and allow oil to enter the full bore side
or annular side of the steering cylinder, there by
turning the wheels in the chosen direction. The
orientation of the Platform to the Chassis will
determine the direction the machine will travel when
the Joystick is engaged.

Operation

Section

3-2 A38E Work Platform

3.0

It will be noticed that on the Upper Control Box a set
of switches are used to alternate functions. Each
function will have it’s corresponding graphicand lamp.
This selector switch indicates to the Controller which
function is required and by using the Joystick the
speed of this selected function can be adjusted.

The boom functions on the chassis controls provide
proportional control for each function by way of an
analog rocker switch, the desired function can be
activated by holding on

one of four switches on the

controls and and operating the analog rocker, the

The use of these functions is further explained
throughout this Section.

DESIGN FEATURES

The A38E Series Work Platform has the following
features:

The drive speed is limited to a ‘creep speed’ when
operating the Work Platform while the machine is
elevated.

The energy-efficient motor control units provides
long battery life and smooth proportional control of
the boom and drive functions.
All cylinders are fitted with hydraulic hose-burst
protection interlocks.
The on-board charger is fully automatic and
charges the batteries efficiently and economically.
If the work platform starts to become unstable and
the Tilt Sensor is activated an alarm will sound in

the upper control box. In this situation power is
partially cut to the upper controls to prevent any
boom movements (i.e. UP, TELE OUT) that might
increase instability. An emergency override switch
is fitted to allow the booms to be lowered at a
controlled speed to bring the machine back to a
stable position.

In the event of a power loss the two Boom Lift
Cylinders are fitted with emergency lowering

valves which allow the booms to be lowered at a
controlled speed by an operator on the ground.

A Master Cylinder/Slave Cylinder levelling system
ensures that the Platform remains level throughout
the entire working cycle of the machine.
A manual rotation facility is fitted to allow rotation of
the Elevating Assembly in the event of power loss.

the four switchs act as both selector & enable

switches.

HOUR METER & BATTERY CHARGE
INDICATOR.

The A38E Series Work Platform is equiped with a

display in the chassis control panel which displays

charge.

total hours run & an Indication of remaining battery

LOAD SENSI NG

The A38E is fitted with a load sensing system de­signed to comply with the requirements of :
BS EN 280 : 2001

If a load equivelent to 99% of safe working load is
lifted an overload lamp will illuminate on the platform

control box.

If a load which is greater than the safe working load by

is present in the basket all machine functions will

cease to operateand an acoustic warning will sound.

In order to return
les

to normal operation a load equal to or

s than the safe working load must be present in the

the power must be re-cycled, power can be

re-cycled by pushing the emergency stop button and

releasing it again.

basket and

10%

Operation

Section

3-3A38E Work Platform

3.1

3.1 Safety Rules and Precautions

Before using the A38E Work Platform it is
imperative to read, understand and follow the
following Safety Rules and Precautions.

NEVER operate the machine unless you have been
fully trained in its safe use, are medically fit and have
read and fully understood these instructions.

NEVER leave the A38E unattended with the Platform
in the raised position.

ALWAYS position the machine on firm level ground
with a minimum bearing capacity of 78 kg /cm

2

(1109 psi).

CHECK that no

overhead obstructions exist within

the machines range of movement.

DO NOT work within 3 metres (10 feet) of live
overhead cables. Set up warning tape barrier at the
safe distance.

(THIS MACHINE IS NOT INSULATED).

DO NOT exceed the safe working load of 215 kg,

CE=max. 1 persons Outdoor + Tools 135Kg
2 person Indoor + Tools 55Kg

See specification table on page 1-3 .

NEVER sit, stand or climb on guard rail or midrail of

the platform.

NEVER use ladders or scaffolding on the platform.

DO NOT use the ma

chine as a crane or for any other
application involving additional loads or forces. The
maximum side force must not exceed 200N

Outdoors / 400N Indoors, (ANSI = 90 ft. lbs).

DO NOT increase wind loadings by fitting items such

as sign boards, flags etc. to the cage or boom.

DISTRIBUTE all loads evenly on the platform. See
Table 1-1 for maximum platform load.

NEVER use damaged equipment. (Contact Snorkel
Ltd. for instructions).

NEVER attach overhanging loads or increase the
size

of the working platform.

DO NOT use in winds exceeding 12.5 m/s (28 mph ­Beaufort Force 6)

NEVER change or modify operating or safety
systems.

INSPECT the machine thoroughly for cracked welds,
loose hardware, hydraulic leaks, damaged control
cable, loose wire connections and wheel bolts.

NEVER climb down an elevating assembly with
platform elevated.

NEVER perform service on or in the elevating
assembly while the platform is elevated without first
blocking the elevating assembly.

NEVER recharge batterie

s near sparks or open
flame; batteries under charge emit highly explosive
hydrogen gas.

SECURE the work platform against unauthorised use
by turning Keyswitch off and removing key from
switch.

NEVER replace any component or part with anything
other than original Snorkel replacement parts without
Snorkel’s consent.

NEVER leave the machine unattended while the
Gearbox Drive is disengaged.

(ANSI 475 lbs)

(ANSI=max. 2 person Indoor/Outdoor)

WARNING

Operation

Section

3-4 A38E Work Platform

3.2

3.2 Controls and Indicators

The controls and indicators for operation of the A38E
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. The

operator should know the location of each
control and indicator and have a thorough

knowledge of the function and operation of each
before attempting to operate the unit.

Table 3-1: Controls and Indicators

Platform Controller*

Chassis Control

INDEX NO. NAME FUNCTION

1 Emergency Stop Cuts all Platform control functions when pushed, twist to release.

2 Platform Level Operate switch and hold while using joystick to level the platform.

3 Upper Boom Operate switch to engage Upper Boom lift functions (Up & Down)

4

Low Boom

Operate switch to engage Lower Boom lift functions (Up & Down)

5 Drive Operate switch to engage Drive functions (Forward & Reverse)

6 Horn Operate switch and hold to sound

the horn.

7 Slew (Rotate) Operate switch to engage Slew functions (Clockwise & Counter Clockwise)

8 Display In normal operation displays battery life and hour run. Can also be used to display

diagnostics.

9 Telescope Operate switch to engage Telescope functions (Extend & Retract)

10

11

Joystick Depress deadman switch and select joystick forward or reverse to enable a selected

function.

Key Switch Turns the machine OFF/ON and selects Platform or Chassis controls

INDEX NO. N

AME FUNCTION

1

E

mergen

cy Stop

Cuts

all m

achine functions

2 Upper Boom Operate switch and hold to engage and enable Upper Boom lift functions (up & down)

3 Lower Boom Operate switch and hold to engage and enable Lower Boom lift functions (up & down)

4

Slew (Rotate) Operate switch and hold to engage and enable Slew functions (clockwise & counter

Clockwise.

5 Telescope Operate switch and hold to engage and enable Telescope functions (extend & retract)

6

Rocker Switch Use with “enable” switches to activate the selected fun

ction7

8 Warning Lamp Low battery warning lamp. Machine must be charged.

Overload warning lampWarning Lamp

Note: Platform Cylinders will keep the platform level during normal operation, if the
Platform goes out of level over time this function will return the platform to level.

Note:

Yellow and Blue direction arrows are included on the Control Panel to show the operator which way each
function will move when the joystick is moved in a particular direction.

Operation

Section

3-5A38E Work Platform

3.2

Figure 3-1: Controls & Indicators

2

23

3

4 4

5 109

9

1

2

3

4

512937-000

6

6

1

1

7

512940-000

0

CUTOUT

CUTOUT

CUTOUT

CUTOUT

CUTOUT

CUTOUT

6

8

11 8

7

5

(CE)

(ANSI)

8

7 5 10

Operation

Section

3-6 A38E Work Platform

3.3

3.3 Pre-Operation Inspection

Carefully read, understand and follow all
safety rules and operating instructions.
Perform the following steps each day before
use. DO NOT perform service on Work
Platform with the platform elevated unless the
elevating assembly is properly supported.

1. Remove module covers and inspect for
damage, oil leaks or missing parts.

2. Check the level of the hydraulic oil with the
platform fully lowered and the Telescopic Boom
fully retracted. Oil should be visible on the filler
cap dip stick. If ne

cessary top-up using ISO

No. 46 hydraulic oil.

3. Check that the electrolyte level in the batteries
is correct. (Battery Maintenance, Section 4.3)

4. Verify batteries are charged.

5. Check that the A.C. extension cord has been
disconnected from charger.

6. Carefully inspect the entire machine for
damage such as cracked welds or structural
members, loose or missing parts, oil leaks,
damaged cables or hoses, loose connections
and tyre damage.

7. Move machine, if necessary, to unobstructed
are

a where machine can be fully elevat

ed.

8. Visually inspect the cylinders, hoses and cables
for damage. Check for missing or loose parts.

SYSTEM FUNCTION INSPECTION

9. Turn both Chassis and Platform Emergency
Stop switches ON (rotate clockwise).

10. Turn Keyswitch on the Lower Control box to
the ‘LOWER CONTROL SELECTION’.

11. Using the chassis control switches, fully
ELEVATE Booms no. 1 & 2 and EXTEND the
Telescope.

12. SLEW the Elevating Assembly through 180
degrees in both directions.

13. Visually inspec

t the elevating assembly and
cage mounting/structure, lift cylinders, cables
and hoses for leaks, damage or erratic
operation. Check for missing or loose parts
such as nuts, bolts and circlips.

14. Test that the Emergency Lowering Valves on
each of the Lift Cylinders is operating correctly
as detailed in Section 3.4. PUSH the
Emergency Stop Button to identify that
functions will indeed cease when depressed.

15. Operate the manual telescopic retraction
system using the Handpump to test that it will
work. (Not required on

ANSI machines).

16. LOWER each boom until the Elevating
is fully stowed. Turn Keyswitch on the Lower

Platform and check that the

If not adjust as shown in

the Platform Levelling
Section of this manual. Repeat all the above
tests from the Platform Controls. Push the
Emergency Stop Button to identify that
functions will indeed cease when depressed.
Bring the machine back to the stowed position
and retract the Telescopic Cylinder.

17. PRESS the Service Horn to see that it is
operational

. Select the DRIVE function. While

pressing the Joystick Interlock Switch slowly

PUSH the Joystick to DRIVE FORWARD, and
then PULL to DRIVE REVERSE, to check for
speed and proportional control. The farther you
push or pull the Joystick the faster the machine
will travel.

18. PUSH the Steering Switch RIGHT and then

LEFT to check for steering control.

19. RAISE the Elevating Assembly until the Boom
Rest Limit Switch is no longer activated and
then repeat the Drive Fun

ction test. Only low

speed (‘CREEP SPEED’) should be available.

The System Function Inspection is then complete.

If there are any concerns about the safe use
or operation of the A38E following this
Pre-Ope

ration Inspection DO NOT USE
THE A38E WORK PLATFORM. Contact your
supplier or Snorkel’s Product Support
Department.

Assembly

Control box to the ‘LOWER CONTROL SELECTION’.

Climb into the
Platform is level.

W A R N I N G

W A R N I N G

Operation

Section

3-7A38E Work Platform

3.4

3.4 Operation

NOTE: Before operating the A38E Work Platform
it is imperative that the Pre-Operation Inspection
(Section 3.3) has been completed and any
deficiencies have been corrected. The operator
must also understand the functions of all the
controls before operating the machine.

ELEVATING & LOWERING THE A38E
WORK PLATFORM

Before beginning any operation involving the Elevating
Assembly the following checks should be carried out.
When the A38E has been thoroughly inspected the
elevating assembly can then be used.

NOTE: Chas

sis controls are for service use only.

Enter Platform through the entrance at the side

of the A38E and ensure that the drop bar is in
the lowered position. Lock the Entry Step in the

raised position.

3. Before using the machine all local Safety
Regulations involving helmets and restraining
devices should be observed. Safety harness

lanyards, not exceeding 1 m (3 ft.) in length,
should be attached to anchor points in cage

floor.

1. Ensure the ‘CONTROL SELECTION KEYSWITCH’
is selected to ‘UPPER CONTROL’ and

both

emergency stop buttons are released (twisted clock­wise).

4. Select “ LOWER BOOM ” on function selector
switch.Check for overhead obstructions and when
when satisfied squeeze the Joystick Interlock

Slowly move the Joystick forwardto ELEVATE
the lower boom.
The further the joystick is moved, the faster.

Pressure must be applied

to

the boom will move.

all times while operation is

required.

the Interlock at

5. Select “UPPER BOOM ”, “TELESCOPE” or
“ROTATE” as required using the ‘Function
Selector Switches’ and operate as described
above. For boom functions the controls will
again be forward for UP and backward for
DOWN.

6. To rotate (SLEW) RIGHT the Controller
Joystick should be moved forward. Conversel

y
to rotate (SLEW) LEFT move the Controller
Joystick backward.

7. To ”TELESCOPE” IN the Controller Joystick
should be moved forward. Conversely to
”TELESCOPE” OUT move the Controller
Joystick backward.

8. Before lowering, check beneath the cage floor
for obstructions, operate as described above,
moving the Joystick back to lower the Booms.

TRAVEL WITH WORK PLATFORM
LOWERED

1. Verify that the chassis Emergency Stop Button
is in the

‘ON’ position (turn clockwise)

and that the Keyswitch is turned to the

2. Climb into the Platform and check that the
Platform Emergency Stop Button is in the ‘ON’
position,

‘UPPER CONTROL’position.

and that the Drive function button is

depressed. Ensure that the

position.

drop bar is in the

3. Check that the route is clear of persons,
obstructions, pot holes or ledges and is capable
of supporting the wheel loads. Also, check that
the clearances above, below and to the side of
the Work Platform are sufficient.

4. Grasp the Joystick so that the Interlock Switch
is depressed (releasing this Interlock Switch will
cut power to the Joystick). Slowly push or pull
the Joystick to FORWARD or REVERSE to
travel in the desired direction. The farther you
push or pull the Joystick from the centre the
faster the machine will travel.

control on.

2.

LOOK up and around for obstructions before
performing the lift function.
ENSURE that the Elevating Assembly is
clear of the Chassis before engaging the
Slew operation.
DO NOT overload the platform
DO NOT operate within 3 metres (10 feet) of
any electrical power cables. THIS WORK
PLATFORM IS NOT INSULATED.
Cordon off the area within the platform’s
working area to keep passers-by clear of
the booms.

W A R N I N G

lowered

Operation

Section

3-8 A38E Work Platform

3.4

5. To “STEER” the A38E activate the Interlock
Switch while pushing the Steering Switch LEFT
or RIGHT to turn the wheels. Observe the tyres
while manoeuvring to ensure proper direction.

NOTE:

Steering is not self-centring. The wheels must be
returned to the straight ahead position by operating
the Steering Switch.

TRAVEL WITH WORK PLATFORM
ELEVATED

Travel with platform elevated ONLY on firm
and level surfaces. Platform motion is
exaggerated whil

e travelling on uneven

surfaces.

NOTE:

The Work Platform will travel at reduced speed when
in the elevated position.

1. Check that the route is clear of persons,
obstructions, pot holes or ledges and is capable
of supporting the wheel loads. Also, check that
the clearances above, below and to the side of
the Work Platform are sufficient.

2. Operate the Drive function switch.

3. Grasp the Joystick so that the Interlock Switch
is depressed (releasing this Interlock Switc

h will
cut power to the Joystick). Slowly push or pull
the Joystick to FORWARD or REVERSE to
travel in the desired direction. The farther you
push or pull the Joystick from the center the
faster the machine will travel.

If the machine comes to a halt and the Tilt
Alarm sounds, immediately lower the
Platform and move the machine to a level
location before re-elevating the Platform.

PLATFORM LEVELLING

NOTE:

The Levelling function will only

work when the Boom
Rest Limit Switch has been activated i.e. when the
Booms are stowed.

The platform can be levelled from the Upper controls
using the levelling function, oper d oh ld thena eta

levelling switchon the upper control box (see fig3-1)
while moving the joystick forward or back to level the
platform. The switch should be operated in short
bursts to level the platform slowly.

EMERGENCY SITUATIONS &
EMERGENCY OVERRIDE

In any emergency situation, the first action to be taken
should be to hit the red “Emergency Stop”
button for instant cutout of all functions. It will then be
required to twist the button clockwise, this releases
the cutout and the machine can be operated again.
If the audible Tilt warning alarm sounds, normal
control functions will cease to operate. This will

be

due to the following problem ;

the machine is out of level i.e. Tilt Sensor has
been activated.

In this situation the only machine

functions that will
operate are descent functions, descend to the ground
in a controlled manner and cycle the power (push and
release the emergency stop) to restore all functions,
move the machine to a level surface and continue
with normal operation.

Note that during emergency operation, controls
will operate at a fixed, slow speed and will not
allow the raising or extending of the Booms.
The Booms can be lowered or retracted.

When operating this function, extreme care
must be taken to ensur

e that the person
carrying out the task does not become
trapped by the structure. DO NOT climb
down the Elevating Assembly to operate
these valves.

Should the machine become inoperable when
elevated, request a person on the ground to lower the
platform using the emergency lowering valves.
These are red knobs (push type) mounted at the
base of the 2 Main Hydraulic Lift Cylinders (See
Figure 3-2).
Operate the lower boom first by pushing slowly.
The boom will descend slowly. The speed

of descent

is controlled by retaining pressure on the valve -

W A R N I N G

C A U T I O N

C A U T I O N

EMERGENCY LOWERING

Operation

Section

3-9A38E Work Platform

3.4

Figure 3-2: Emergency Lowering

Before operating the Emergency
Lowering Valves the surrounding
area should first be cleared of any
potential obstructions. It is also
important that when the valve is
pushed, it is initially done slowly.
This is so that sudden movement
will not occur in the Elevating
Assembly, leading to a potentially
unstable machine.

CONTROL FROM GROUND LEVEL

1. Chassis Controls are fitted at the base of the
Elevating Assembly. These should be used
when no operator is in the platform (for
maintenance/ service or inspection purposes),
or if the operator has become incapacitated.
For further information see Table 3-1.

2. Use the appropriate switch to raise or lower
Boom 1, Boom 2, Telescope or rotate as
required.

AFTER USE EACH DAY

1. Ensure that the platform is fully lowered.

2. Park the machine on level ground, preferably
undercover, secure against vandals, children or
unauthorised operation.

3. Turn key switch to OFF and remove key to
prevent unauthorised ope

ration.

4. Recharge batteries in accordance with

the

instructions in section 4.2.

Figure 3-3: Manual Rotation

To rotate the Elevating Assembly first apply a 7/8”
socket wrench to the shaft and turn to rotate the
Elevating Assembly. When finished remove the wrench.

MANUAL ROTATION

1. Ensure booms are lowered as far as possible
using the emergency lowering valves, and that
the Emergency Stop Button is pressed to
prevent any accidental powered operation.

2. Apply a 7/8” socket wrench to shaft and turn to
rotate elevating assembly.

3. Remove wrench.

MANUAL TELESCOPIC RETRACTION
(SEE FIGURE 3-4)

NOTE:

Manual Tele Retraction is not required, and

hence is

not provided for ANSI machines.

In the event of loss of electrical power the Telescopic
Cylinder can be retracted as follows:

1. Remove the cover from the chassis body.

2. The Handpump is attached to the Main Manifold
Block. Remove the Handpump Handle from the
clips on the side of the Chassis and insert into
the Handpump Valve as shown in Figure 3-4.

3. Operate handpump to retract

the tele cylinder.

4. After use replace the Handpump Handle in the
clips provided.

5. Reposition the cover on Chassis.

ens

ure a slow controlled rate of descent at all times.
Descent can be halted at any time by removing
pressure from the red knob.
Repeat the operation if necessary for the upper boom
when cylinder is in reach of the ground.
With both main booms lowered fully it should then be
possible to leave the platform safely.

Operation

Section

3-10 A38E Work Platform

3.4

Figure 3-4: Manual Telescopic Retraction

Valve Block

Hydraulic

Tank

Hand Pump

Valve

Hand Pump

Handle

Operation

Section

3-11A38E Work Platform

NOTES:

3.5

Operation

Section

3-12 A38E Work Platform

NOTES:

3.5

Maintenance

Section

4-1A38E Work Platform

4.0 Introduction

Be sure to read, understand and follow all
information in the

Operation Section of

this manual before attempting to operate or
perform service on any A38E Work Platform.

This section contains instructions for the

maintenance of the A38E Series Work Platform.
Procedures for scheduled maintenance and repair/
removal are included.

Referring to Section 3.0 and Section 6.0 will aid in
understanding the operation and function of the
various com

ponents and systems of the A38E Work
Platform and help in diagnosing and repair of the
machine.

Refer to Table 4-1, the Preventative Maintenance
Checklist for the recommended Maintenance
intervals.

TOOLS REQUIRED

The following is a list of items which may be required
to perform certain maintenance & repair procedures
on the A38E Work Platform.

1 x Multi-meter capable of reading Voltage, Ohms

and Amps.

1 x Hydraulic Pressure Gauge

- Range (0 - 3000 PSI)

4.1 Preventative Maintenance
(Table 4-1)

The complete inspection consists of periodic visual
and operational checks, together with all necessary
minor adjustments to assure proper performance.
Daily inspection will prevent abnormal wear and
prolong the life of all

systems. The inspection and

maintenance schedule is to be performed at regular
intervals.
Inspection and maintenance shall be performed by
personnel who are trained and familiar with
mechanical and electrical procedures. Complete
de

scriptions of the procedures are in the text

following the table.

The Preventative Maintenance table has been

designed primarily to be used for machine service
and maintenance repair.

Please copy the following page and use this
table as a checklist when inspecting a machine

for service.

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 the elevated
position.

4.0

1 x

Calibrator EZcal (Snorkel Part No: 504560-001)

!

!

W A R N I N GW A R N I N G

!

!

W A R N I N GW A R N I N G

Note:
EZcal Display can be used in place of the above

Calibrator, the calibrator may only be necessary
when working in the Platform as the EZ Display
is located within the ground Controls.

Maintenance

Section

4-2 A38E Work Platform

Steering Check Steering Cylinder for leaks. 50h/30d
Assembly Lubricate all pivot pins. 250h/6m

Check Links and Hubs. 250h/6m
Drive Check for operation. Daily
Motors Check for any foreign bodies. Daily

Check for wear of brushes. 500h/1y

Check that commutator or springs 500h/1y

are undamaged.

Check bearings for operation. 1000h/2y

Platform Check welds for cracks. Daily
Deck and Check condition of floor. Daily
Guardrails Check that securing bolts are Daily

tightened.

Check drop bar on cage entrance. Daily
Slew Grease slew gear. 10h/7d
System Check slew motor for leaks and 50h/30d

mounting bolts for proper torque.

Check hardware and fittings for 250h/6m

proper torque.
Slew Check torque on all bolts, 15 outer 50h/30d

System/ ring and 20 inner ring.
First Post Retorque to 220 Nm (160 ft. lbs).

Elevating Inspect for structural cracks. Daily
Assembly Check hoses for pinch or rubbing Daily

points.

Check pivot pins for damage. 50h/30d

Check pivot pin retaining rings. 50h/30d

Check elevating assembly for 250h/6m

bending.

Check component mounting for 250h/6m

proper torque.

Check fasteners for proper torque. 250h/6m
Lift Check cylinder rod for wear. 50h/30d
Cylinders Check pivot pin retaining rings. 50h/30d

Grease all fittings as section 4.4. 50h/30d
Chassis
Assembly Daily

points.

Entire Unit Function check Emergency stop Daily

switches at control boxes.

Perform pre-operation inspection. Daily

Check for and repair collision Daily

damage.

Check for peeling, missing or Daily

unreadable decals. Replace.

Lubricate. 50h/30d

Grease all fittings. 50h/30d

Check for corrosion - Remove and 250h/6m

repaint.

NOTE:

Recommend Bolt Torques are shown in Table 4-3,
Section 4.13.

Preventative Maintenance Table Key

Interval

Daily = each shift or every day
10h/7d = every 10 hours or 7 days
50h/30d = every 50 hours or 30 days
250h/6m = every 250 hours or 6 months
500h/1y = every 500 hours or 1 year

1000h/2y = every 1000 hours or 2 years
Y=Yes/Acceptable
N=No/Not Acceptable
R=Repaired/Acceptable

Preventative Maintenance Report

Signature of Service Engineer

_____________________________

4.1

Battery Check electrolyte level. Daily
System Check battery cable condition. Daily

Charge batteries. Daily
Check Charger condition &
operation. Daily
Check specific gravity. 50h/30d
Clean exterior. 250h/6m

Clean terminals. 250h/6m
Hydraulic Check oil level. Daily
Oil Drain and replace oil. 500h/1y

(ISO #46).
Hydrau e clean piWcil
Pump Check for hose fitting leaks. 50h/30d

Check for leaks at mating surfaces. 50h/30d

Check mounting bolts for proper 50h/30d

torque.
Hydraulic Check for leaks. Daily
System Check hose connections. 50h/30d

Check for exterior wear. 50h/30d

Change filter. 250h/6m
Emer. Open the emergency lowering Daily
Hydraulic valves and check for proper
System operation.
Control Check switch operation. Daily
Cable Check the exterior of cable for Daily

pinching, binding or cable wear.
Tyres / Check for damage. Daily
Wheels Check/torque nuts - 50h/30d

Front: 200 Nm (150 ft. lbs)

Rear: 130 Nm (95 ft. lbs)

COMPONENT INSPECTION OR SERVICES INTERVAL Y N R

Date : _______________________________
Owner : ______________________________
Model No : ____________________________

V.I.N No : _____________________________
Serial No :____________________________
Serviced By :__________________________
Service Interval :________________________

COMPONENT INSPECTION OR SERVICES INTERVAL Y N R

Overload
System

Check/torque nuts - 220 Nm
(162 ft. lbs)

Calibrate system

50h/30d

500h/1y

50h/30d

Change oil in drive reduction
gearbox.(ref: sec 4.12)

500h/1y

DailyInspect for structural cracks

Check hoses for pinch or rubbing

Maintenance

Section

4-3A38E Work Platform

4.2

4.2 Battery Maintenance

Electrical energy for the motor is supplied by eight 6
volt batteries wired in series to give a 48 volts DC
supply. Each of these batteries consist of three cells
which can supply a maximum voltage of 2.1V ea
=>6.3V per battery =>50.4V per battery pack. Proper
care and maintenance of the batteries and motor will
ensure maximum performance from the work
platform.

Hazard of explosive gas mixture. Keep
sparks, flames and smoking materials away
from batteries
Always wear

safety glasses when working
with batteries.
Battery fluid is highly corrosive. Rinse away
any spilled fluid thoroughly with clean water.

BATTERY INSPECTION AND
CLEANING

Check battery fluid level daily, especially if work
platform is being used in a warm, dry climate. If
required, add distilled water; use of tap water with a
high mineral content will shorten battery life.

If battery water level is not maintained,
batteries will not fully charge, creating a low
di

scharge rate which will damage Motor/Pump

unit and void warranty.

Batteries should be inspected periodically for signs of
cracks in the cases, electrolyte leakage and
corrosion of the terminals. Inspect cables for worn
spots or breaks in the insulation and for broken cable
terminals.

Clean batteries that show signs of corrosion at the
terminals or onto which electrolyte has overflowed
during charging. Use a baking soda solution to clean
the batteries, takin

g care not to get the solution inside
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 do not reach full potential until they have
been through 50 charge/discharge cycles (however
the rate at which the potential

increases is exponen­tial, and the batteries will normally have 95% potential
after 15 charge/discharge cycles). Hence do not use
a new battery in a battery pack that already has more
than 15 cycles Charge batteries at the end of each
work shift or sooner if batteries have been
discharged. A battery is conside

red to have a faulty
cell if it has less than 80% of the potential of the other
batteries in the pack while

measured under load.

DO charge batteries in a well-ventilated area.
DO NOT charge batteries in the vicinity of
sparks or flames.
NEVER leave charger operating unattended
for more than two days.
NEVER disconnect cables from batteries
when charger is operating.
Permanent damage to batteries will result if
they are not immediately recharged after
discharging.
Keep charger dry.

To ensure a proper charge several items must first be
checked.

1. Correct voltage and current are avai

lable to the

charger.

2. Extension cord in good condition, is no longer

than 8 m (26 ft.) and is 1.5 mm (12g a) or
larger.

3. Charger will have an adequate time to allow a

full charge i.e. ensure that power supply will not
be switched off overnight.

W A R N I N G

W A R N I N G

W A R N I N G

Maintenance

Section

4-4 A38E Work Platform

Temperature Corrected

Electrolyte Temperature Specific Gravity, Fully

Charged

Fahrenheit Celsius USA Euro

120 48.9 1291 1.29

110 43.3 1287 1.29

100 37.8 1283 1.28

90 32.2 1275 1.28
80 26.7 1275 1.28
70 21.1 1275 1.28
60 15.6 1267 1.27
50 10.0 1263 1.26
40 4.4 1259 1.26
30 -1.1 1255 1.26
20 -6.7 1251 1.25
10 -12.2 1247 1.25

5 -15.0 1245 1.25
0 -17.8 1243 1.24

-5 -20.6 1241 1.24

-10 -23.3 1239 1.24

-15 -26.1 1237 1.24

-20 -28.9 1235 1.24

-25 -31.7 1233 1.23

-30 -34.4 1231 1.23

All Snorkel battery operated Work Platforms,
including the A38E can operate at ambient
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
Snorkel Work Platforms must be replaced with a
grade suitable for these low temperature conditions.

When ambient temperatures fall below 18ºC
(65ºF) batteries cannot deliver 210 Ampere hours and
so should be placed on charge as soon after use as
possible. Under such conditions a 4 hour equalize
charge once a week in the early afternoon will

improve state of charge and battery life.

Charging

1. Check battery fluid level. If electrolyte level is
lower than 10 mm (3/8 in) above plates add
distilled water only.

2. Connect battery charger lead

to properly

earthed outlet of correct voltage and frequency.

3. The Charger will turn on automatically after
going t

hrough 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
temperature corrected reading should be about 1.28.
The specific gravity of the electrolyte in the battery
cells should be equalized monthly, or weekly when
used in low temperature conditions. To do this,
charge batteries as described above. After this initial

charge, check the electrolyte level in all cells and add
distilled water as necessary, and turn the charger on
until a full charge is again indicated. During this time,
the charging current will be low (four Am

ps) as cells
are equalizing.
After equalization, the specific gravity of each cell
should be checked with a hydrometer. The
temperature corrected specific gravity in this state
should be 1.28. If any corrected readings are below

1.23, the batteries contain bad cells and therefore the

battery should

be replaced.
Do not check the specific gravity in a cell to which
water has just been added. If there is not enough
electrolyte in a fully charged cell to obtain a sample
for the hydrometer, add water and continue charging
for one to two hours before checking again.

4.3 Temperature correction for
Electrolyte readings

SPECIFIC GRAVITY CONVERSION CHART

4.3

Table 4-2: Specific Gravity Conversion

Chart

Maintenance

Section

4.4

4-5A38E Work Platform

4.4 Lubrication

Refer to Table 4-1 and Figure 4-1 for location and
lubrication intervals required for the items that
necessitate lubrication service. Refer to the
appropriate sections for lubrication information on the
Hydraulic Oil Tank and Filter.

Figure 4-1: Lubrication Points

GREASE FITTINGS

Wipe each grease fitting before and after greasing.
Using multipurpose grease in a grease gun, pump the
grease into the fitting until grease just begins to
appear at the edges of the pivot, then wipe of any
excess grease.

Grease Fitting Locations

2
1
1

Lower Cylinder (including Trunnions) 3

2
1
2
2
2
4

Pinion Gearbox & Slew Bearing Assembly 3

SLEW RING

Grease Slew Ring evenly and sparingly every 10
hours or 7 days as per the intervals in Table 4-1.
DO NOT subject this area to powerwashing.

HYDRAULIC OIL TANK AND FILTER

(Figure 4-2)

Fluid Level

With platform fully 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 when
handling hot oil (hydraulic oil can be a skin
irritant). The hydraulic oil may be of sufficient
temperature to cause burns.

PIVOT PINS

Apply grease liberally to the Pivot Pin and Pin Lock
Plate locations using a brush or cloth. Force as much
grease as possible between the Pins & Pin Lock
Plates and the Weldments. Wipe away all excess
grease.

Grease Fitting (Grease Type - Lithium Sulphate, Water Resistant, ISO220 Oil + NLG#2 Thickness e.g. Mobil HP222)

Note: oil grades may vary depending on machine
specification. Contact Snorkel Product Support for
further advice.

Lower Boom
Upper Boom
Telescopic Boom

Upper Cylinder
Telescopic Cylinder

Master Cylinder
Slave Cylinder
Steering Cylinder
Torque Arms

Total

23

C A U T I O N

Maintenance

Section

4-6 A38E Work Platform

4.5

2. Provide a suitable container to catch the
drained oil. Hydraulic tank has a capacity of 25
Litres (6.5 Gallons US).

3. Remove the drain plug on the lower side and

allow all oil to drain.

4. Clean the magnetic drain plug and reinstall.

5. Disconnect the return hose and hose fitting
from inlet port of the hydraulic return filter.
Loosen and remove the filter cover retaining
bolts. Remove filter (10 micron) assembly.
Replace with

a new filter.

6. Fill the hydraulic reservoir with hydraulic oil
(see Section 1-2) checking level with dipstick.

7. Recycle used oil as per local environmental
regulations.

Figure 4-2: Oil and Filter Replacement

4.5 Setting Hydraulic Pressures
(Figure 4-3)

Check the hydraulic pressures whenever the pump,
manifold or relief valve have been serviced or
replaced.

The hydraulic oil may be of sufficient
temperature to cause burns. Wear safety
gloves and sa

fety glasses when handling hot
oil. The oil in the hydraulic system is under
very high pressure which can easily 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
using a 4 mm Allen key.

5. Operate the Telescope RETRACT function

switch from lower controls and keep it
activated.

6. Slowly turn the main relief valve adjusting screw

clockwise until the pressure gauge reads 175
Bar (2538 p.s.i.) pressure.

7. Release the Telescope RETRACT switch.

8. Tighten locknut on main relief valve while

holdin

g the adjusting screw in position.

Figure 4-3: Manifold Block

Figure 4-4: Setting Main Relief Pressures

Filler Cap W ith
Dipstick

Filter Housing
Cover

Filter
Element

Filter
Housing

DRAIN
PLUG

Main Relie f

Valve

Slew Cross
Line Relief

Valve

Pressure

Test Point

W A R N I N G

Maintenance

Section

4-7A38E Work Platform

4.6

4.6 Maintenance on Elevating

Assembly (Figure 4-6)

The only time the Elevating Assembly needs to be
elevated is to allow service work to be carried out on
the lower parts of the Elevating Assembly, the Lower
Lift Cylinder or the Slewing mechanisms.
All other work (Bearings, Cylinders, Booms & Tension
Bars) can and must be performed with the Elevating
Assembly in the stowed position.

BEFORE entering Elevating Assembly, to
perform maintenance on the Work Platform
while elevated, ensure that Elevating
Assembly is properly supported by suitable
cran

age of adequate capacity.
(Recommended 1 tonne capacity crane and
sling.)

INSTALLATION OF ELEVATING
ASSEMBLY SUPPORT

1. Park the work platform on firm level ground.

2. Verify Platform Emergency Stop Switch is ON.

3. Hold the Chassis/Platform Selector Switch on the
Lower Control Box to the ‘Chassis’ position.

4. Select Lower Control Boom 1 Switch and
elevate until the lower boom is slightly above
horizontal.

5. Place a sling of 1 Tonne load capacity at the end of
the

lower boom and second post. Ensure sling is

secured so that it

will not slip up along the boom.

6. Gradually lower the platform 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 screws anticlockwise
two full turns.

3. Operate slew function from lower controls and

rotate the Elevating Assembly until the slew
stop prevents further rotation.

4. Slowly turn the cross-line relief valve adjusting
screw clockwise using a 4 mm Allen key until
the pressure gauge reads 50 Bar (725 p.s.i.)
pressure.

5. Now operate the slew function in the opposite
direction throu

gh approximately 360

o

until the

Slew Stop prevents further rotation.

6. Slowly turn the remaining cross-line relief valve
adjusting screw clockwise until the pressure
gauge reads 50 Bar (725 p.s.i.) pressure.

7. Tighten the locknuts on both cross-line relief

valves while holding the adjusting screws in
position.

Figure 4-5: Setting Cross-Line Relief

Pressures

Figure 4-6: Supporting Elevating Assy.

1 Tonne Capacity

Crane/Winch

Sling

W A R N I N G

Maintenance

Section

4-8 A38E Work Platform

4.7 Switch Adjustments
(Figure 4-7 & 4-8)

4.7

BOOM REST LIMIT SWITCH

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
Rest is located on the side of the First Post on the
A38E Work Platform. The high speed drive can only
be operated when this switch is activated. When the
boom leaves the boom rest the Normally Open con­tacts of the limit switch open and power is cut to the
high speed drive function.

Location: The switch is located on the side

of the
First
(see fig 4-8)

Post on the Boom Rest Weldment.

Adjustment:The switch should be activated when the

boom sits in the boom rest. The lever is

adjustable and should be adjusted so that the

switch’s activation/deactivation point occurs just as
Boom 2 leaves the Boom Rest. To adjust the switch
loosen the lever clamping nut and rotate the lever.
Tighten the lever clamping nut. The switch should
periodically be checked for freedom of movement and

be kept clean from dirt and other contaminants tha

t

might affect its free movement.

TILT SENSOR

Function: This limit switch is activated when the

internal sensor in the ‘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.

S

ETTINGTHETILTSENSORTOZERO

If the EZ230 control modual is replaced and/of moved within the
machine for any reason the tilt sensor must be reset for zero°
using the following procedure. Failure to do so could result in serious
injury or death.

To follow this procedure you need to switch the Ezcal
display in the Upper Control Box into “Calibration mode”.

1. Place the machine on a firm level surface , ≤ 0.25 °
2 Use a Gauge to confirm that the front and rear of the

chassis are level to within +/- 0.25 ° in both directions

3. Switch the machine on, press and hold Esc for 5 seconds
.sraeppA ”uneM tfilzE“ litnu

4. Scroll to access level.(Enter)

5. Enter code 2222 for access level 2 .(Enter)

6. Scroll to setups.(Enter)

7. Scroll to tilt setups . (Enter)

8. Calibrate level. (Enter)

9. Enter for yes.

To confirm calibration has worked switch the machine of then
back on again.

10. Scroll to Diagnostics. (Enter)

11. System. (Enter)

12. Scroll to tilt, both readings should be below 0.2 ° if not

repeat from 3.

ESC

ENTER

Esc to leave
Sub-Menu
without saving.

Display

Enter to Save
Entry

Scroll
Left/Right

Change Entry
Up / Down

W A R N I N G

Maintenance

Section

4-9A38E Work Platform

4.7

Figure 4-8: Boom Rest Limit Switch

Elevating Assembly

Switch Head

Switch Body

Lower Boom

Upper Boom

Maintenance

Section

4-10 A38E Work Platform

4.8 Hydraulic Manifold
(Figure 4-9)

Though it is not necessary to remove the manifold to
perform all maintenance procedures, a determination
should be made as to whether or not the manifold
should be removed before maintenance procedures
begin.

REMOVAL

1. Disconnect the Battery Disconnect Plug.

2. Remove the cover from the Chassis body.

3. Tag and disconnect the solenoid valve leads
from the solenoids.

4. Tag, disconnect and plug hydraulic hoses.

5. Remove securing bolts that hold manifold block
to hydraulic resevoir.

6. Remove the mani

fold block.

DISASSEMBLY

NOTE: Mark all components as they are
removed so as not to confuse their location
during assembly. Refer to Figure 4-9 often to
aid in disassembly and assembly.

1. Remove coils from solenoid valves.

2. Remove solenoid valves and the relief valves.

3. Remove fittings and bonded washers.

CLEANING AND INSPECTION

1. Wash the manifold in cleaning 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 w

here 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 O-rings before installation
to prevent damage to O-rings.

1. Install fittings, plugs and bonded seals.

2. Install the solenoid valves and tighten the coils
on to the valves.

3. Install the Main Relief Valve and the Slew
Cross- Line Relief Valves .

Note: Torque relief valves to 45 Nm (33 ft. lbs).

Torque solenoid spool cartridges to

20 Nm
(14.75 ft. lbs)
Torque coil retaining nuts to 1.5 Nm (1.01 ft. lbs)

INSTALLATION

1. Attach manifold assembly to the Hydraulic Tank
with bolts and washers.

2. Connect hydraulic hoses to their destinations
on the manifold block.

3. Connect solenoid leads to their correct coils.

4. Operate each hydraulic function and check for
proper function and leaks.

5. Re-secure cover to Chassis body.

4.8

C A U T I O N

C A U T I O N

Maintenance

Section

4-11A38E Work Platform

Figure 4-9: Manifold Block Components

1. Valve Block

2. Solenoid Valve

3. Coil

4. Locking Nut

5. Fitting, 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

Refer to Page 7-20 for part numbers

1

2

3

4

5

6

6

5

5
6

56

9

67

8

10

11

Maintenance

Section

4-12 A38E Work Platform

4.9

4.9 Hydraulic Pump
(Figure 4-10)

If the hydraulic reservoir has not been
drained, suitable means for plugging the
hoses should be provided to prevent
excessive fluid loss.

REMOVAL

1. Mark, disconnect and plug hose assemblies.

2. Loosen the capscrews and remove the pump
assembly from the motor.

INSTALLATION

1. Lubricate the pump shaft with general purpose
grease and attach the pump to the motor with
the capscrews.

2. Using a crisscross pattern torque each
capscrew a little at a time until all the
capscrews are torque

d to 27 Nm (20 ft. lbs).

3. Unplug and reconnect the hydraulic hoses.

4. Check the oil level in the hydraulic tank before
operating the work platform.

1. Pressure Hose

2. Suction Hose

3. Capscrew

4. Pump Assembly

5. Electric Motor

5

1

2

4

3

Figure 4-10: Hydraulic Pump

4.10 Traction Motor Maintenance
( )

Before carrying out any maintenance
procedures on the Drive 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 eht morf )6n metI (g iht rear
section of the motor and examine the brushes for
excessive wear.
If required

the brushes may need to be changed as

follows:

1. Lift the spring (Item 3)

2. Release the brushes and unscrew the bolts
(Item 2) from the brush box (Item 5)

3. Remove the brushes by pulling the electric
leads.

During these operations take care that
screws, washers or other materials do not
fall inside the motor.

4. After thoroughly cleaning the brush boxes,
insertthe new brushes and check that they slide
correctly inside the seat (Item 5).

5. Tighten and lock the bolts (Item 2).

6. Push

the springs back in

place. Check the
constant pressure on all the brushes, and the
correct contact with the commutator.

7. Replace the inspection/ventilation covers.

CAUTION

CAUTION

WARNING

See 7-19

6

6. Non return valve

- 514274-000

Maintenance

Section

A38E Work Platform

4.10

Every 500 working hours, or annually

Brushes - Check the wear, the correct seating,

and the regularity of the working
surface.

Springs - They should not be burned or

damaged, and they must apply a
constant and equal pressure on the
brushes.

Commutator - The surface must be clean and

regular without grooving or burning.

Every 1000 working hours, or every two years

Bearings- All the bearings are fitted with a

double shield and lubricated with
high temperature grease.
Check for leaks, vibration and noise.
If necessary repla

ce with bearings

of identical type.

Screws - Check that all nuts, particularly the

cable nuts and screws are tight.

General - Check that foreign bodies or dirt

have not entered the motor.
Check that the ventilation holes are
clean and not obstructed.

4.10 Traction Motor Maintenance

-512944-000 ( See 7-21)

Figure 1. Exploded view of Drive End Locked Motor

1. Pull back the brush springs and latch them on the
holders in the open position (or if the brush box
assembley has no holders, pull the springs out,
pull the brush back and rest the springs on the
side of the brush). See Figure 1. The brushes
should move freely within the holders.

2. Check the brush springs for correct alignment on
the back of the brush. A brush spring that 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 below their usable

length, show signs of uneven wear or signs of over

heating, such as discoloured brush shunts and
brush springs.

4. Make sure the brush box assembley is tight on the
commutator end head. Replace brush box

assemblies in the commutator end head if they are

physically damaged or brush holders are loose on

on the brush plate.

5. Brushes should always be replaced in complete

sets of four or eight. Use identical replacement
parts; do not substitute brush grades as the
are matched to the motor type and application to
provide the best service. Substituting brushes of

the

wrong grade can cause premature

commutator failure and excessive brush wear.

6. Carefully release the brush springs allowing the
brushes to contact the commutator.
Brushes should be checked for proper tention
using the following procedure:

a. Place paper strip between brush face and

commutators. See Figure 8.

b. Hook spring scale as shown.

c. Pull spring scale on a line directly opposite the line of

force exerted. When the paper strip begins to move
freely read the spring tention on the scale.

Maintenance

Section

4-14 A38E Work Platform

4.11 Electric Pump Motor
(Figure 4-13)

Before carrying out any maintenance
procedures on the electric motor 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.

TROUBLESHOOTING

1. Read the nameplate to become familiar with the

motor, especially the rated voltage.

2. Try to turn the shaft by hand. Keep motor lea

ds

separated while doing this. If the shaft turns

freely go to step 3. If the shaft won’t turn,
proceed to step 2A.

2A. The shaft could be tight for a number of

reasons , this check is to determine if the
tightness is of a temporary nature only. Obtain
power to produce the nameplate voltage. Do
not make a permanent connection.
First touch the motor leads quickly to the power
supply just long enough to observe if the shaft
runs. If it does turn, then hold the motor le

ads

on the power

supply for a longer time. If the
motor sounds normal , go to step 3.
If the motor is noisy it should be taken apart as
described in the DISASSEMBLY section.

3. If the motor turned freely, connect an ammeter
in the circuit as shown in Figure 4-12. With
rated voltage applied and the shaft running free,
the ammeter should read less than 20% of 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 operation.
Permanent distortion or other damage will
result.

INSPECTION

Once the motor has been disassembled, go through
the following check list steps to determine where the
problem lies.

1. Bearings should spin smoothly and easily and
have ample lubr

ication and be free of corrosion.

2. Armature should be checked for grounds and
shorted Windings. Refinish commutator
surface if pitted or excessively worn.

3. Brushes should be checked for wear and to
ensure that they are free in the brush holders.
NOTE: Observe how the brushes are
assembled in brush holders and position of
brush lead. New brushes must be installed in
same manner. Brushes should be removed as
follows:

mounting on brush assembly.

reversing the above procedure.

4. Inspect wire harness and

all connections for

signs of damage due to overheating.

5. Check stator to see if it is securely mounted.

REASSEMBLY

1. Install new brushes and be sure they are free in
the holder. Install brush with the lead wires
positioned as when received.

2. Place commutator cover on a work bench with
brush assembly facing upward.

Figure 4-12: Electrical Test Circuit

4.11

AMP METER

A

V

VOLTMETER

D.C.

Power

Supply

D.C.

Motor

WARNING

CAUTION

Maintenance

Section

4-15A38E Work Platform

3. Place the bearing spring into the bearing bore.

4. Take a complete armature assembly, including
bearings, and insert commutator end bearing
into the bearing bore.
Note: Do not reuse bearings which have been
removed from armature shaft. Keep assembly

in a vertical position. Use extreme care not to
damage armature with bearing pullers. New
bearings should be installed by pressing inner
race of bearing onto proper position on
armature shaft.

5. Set the brushes to final position and lock with
springs.

6. Place the complete stator down over the
vertical armature, and into position on the
commutator cover.

7. The stator assembly must be placed in a
definite relationship with the commutator covers
in order to obtain a neutral brush setting. There
is a match-mark on both items. These two
marks must line up exactly.
Rotate until they do.

8. Assemble the pulley end cover in the proper
relationship. Insert mounting bolts and tighten
alternately to ensure a good mechanical
alignment.

9. Spin the shaft by hand to see if it is free.

Be

sure

motor leads (if used) are not touching
together. If the leads are touching, a generator
action will give the effect of friction in the motor.
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 been connected the wrong way. To solve
this disassemble and reconnect in the
proper way. Reversing the polarity will not
solve this problem as this is a series wound
motor.

MAINTENANCE INTERVALS &
PROCEDURES

Every 500 working hours, or annually

Brushes - Check the wear, the correct seating,

and the regularity of the working
surface.

Springs - They should not be burned or

damaged, and they must apply a
constant and equal pressure on the
brushes

.

Commu

tator - The surface must be clean and

regular without grooving or burning.

Every 1000 working hours, every two years

Bearings- All the bearings are fitted with a

double shield and lubricated with
high temperature grease.
Check for leaks, vibration and noise.
If necessary replace with bearings
of Identical type.

Seals - Check that hydraulic seals are in

perfect condition.

Screws - Check that all nuts, particularly the

cable nuts and screws are tight.

General - Check that foreign bodies or dirt

have not entered the motor.
Check that the ventilation holes are
clean and not obstructed.

4.11

Maintenance

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

Maintenance

Section

4-17A38E Work Platform

4.12

Figure 4-14: Drive Reduction Gearbox

4.12 Drive Reduction Gearbox
(Figure 4-14)

As with most gearboxes oil changes must be carried
out at regular intervals. Initially this should be done
after the first 50/100 working hours and then
subsequently every 500 working hours or at least
every 12 months.

For this gearbox the minimum recommended
viscosity index is 95. Depending on the ambient
temperature of the work place the viscosity index
should vary as follows:

Ambient Temperature Viscosity Index

(ISO 3448)

-20

o

C (-4oF) / 5oC (41oF) VG 100

5

o

C (41oF) / 30oC (86oF) VG 150

30

o

C (86oF) / 50oC (122oF)

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 of the same
make.
Never mix mineral and synthetic oi

ls.

Service Engineers must be aware of the
dangers during an oil change involving hot
oil i.e. scalding. The Service Engineer must
also be responsible when disposing of the
discarded oil. This should be done in
accordance with local environmental

regulations.

Traction Motor

Drive

Reduction

Gearbox

Rear

Wheel

3 O’Clock

12 O’Clock

Filling

Plug Hole

Level

Plug Hole

CAUTION

Maintenance

Section

4-18 A38E Work Platform

CHANGING THE OIL

Unless an oil suction system can be used, it is
necessary to remove the gearbox to fully drain the oil.

1. The A38E should be driven for five minutes in
order to bring the oil up to working temperature.

2. The Electric Traction Motor must be
disconnected from the Gearbox.

Disconnect the batteries when working near
the traction motors.

3. Unscrew the four bolts that hold the traction
motor to the Gearbox and pull the Motor away
from the rear face of the Gear

box.

4. Disconnect the brake hose from the brake port
on the Gearbox and plug to avoid excessive oil
spillage and contamination.

5. Loosen the five wheel nuts securing the Wheel
Assembly to the Gearbox studs.

6. Jack up the rear of the A38E and chock the
front wheels to prevent the machine from
moving during the service.

7. Remove the Wheel Assembly by unscrewing
the five wheel nuts

8. Unscrew the eight securing bolts that hold the
Gearbox to the Chassis, and remove th

e

Gearbox, noting its orientation on the ch

assis

before removal.

9. Remove the oil filler and drain plugs from the
front (stud) face of the Gearbox.

10. Stand the Gearbox vertically (studs facing
down) in a suitable oil disposal container and
allow the oil to drain fully.

11. The Gearbox needs to be half filled which
requires 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 gearbox.

13. Reattach the Gearbox to the Chassis in its
original position with the eight securing bolts.

The Gearbox Securing Bolts must be torqued
to 130 Nm (96 ft. lbs).

14. Reattach the brake hose to the brake port.

15. Reattach the Wheel Assembly to the Gearbox
using the five M14

nuts.

The Wheel Assembly Nuts must be torqued
as per values given in Table 4-1.

16. Reattach the Electric Traction Motor to the
Gearbox.

The Electric Traction Motor Bolts must be
torqued to 74 Nm (55 ft. lbs).

Repeat this procedure for the other Drive

Gearbox.

4.13

4.13 Torque Specifications

RETAINING BOLTS

Use the following values to torque bolts used on
Snorkel A38E Work Platform unless a specific torque
value is called out for the part being installed.

Table 4-3: Bolt Torques

Torque

Thread Size Location

Metric Imp

erial

M4 SPIRIT 3 Nm 2 Ft/Lbs

LEVEL
M6 VARIOUS 10 Nm 7 Ft/Lbs
M8 TRUNNION 25 Nm 18 Ft/Lbs

M10 PIN LOCK 45 Nm 33 Ft/Lbs

PLATES

M12 TORQUE 90 Nm 67 Ft/Lbs

ARMS

5/8” -11 UNC SLEW 220 Nm 165 Ft/Lbs

x 3 1/2” BEARING

(ISO 10.9)

(US Grade 8)

NOTE: All Bolts are ISO Grade 8.8 unless

otherwise stated

WARNING

CAUTION

CAUTION

CAUTION

Maintenance

Section

4-19A38E Work Platform

Figure 4-15: Lower Lift Cylinder

1. Rod End Pivot Pin

2. Bushings

3. Pin Lock Plate

4. Lower Boom

5. First Post

6. Lower Lift Cylinder

7. Trunnion

8. Trunnion Screw

4.14

1

2

3

4

5

7

6

8

4.14 Lower Lift Cylinder
(Figure 4-15)

REMOVAL

The Lower Lift Cylinder is heavy, so utilise
appropriate lifting equipment to support the
unit before removing pins.

1. Ensure that the A38E is on firm level ground,

the Elevating Assembly is completely stowed,
the Keyswitch is to the ‘OFF’ position and the
Emergency Stop Button is pressed.

2. Provide a suitable container to collect the

hydraulic fluid, then disconnect the hydraulic
hoses. Immediately plug hoses to prevent
foreign material from entering.

3. Remove securing bolts and pin lock plates from

the cylinder pins.

4. Suppor

t rod end of cylinder and 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
components are sensitive to

contamination.

DISASSEMBLY

1. Unscrew the headcap and withdraw the rod and
piston assembly from the barrel tube.

2. Uns

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 maintenance.

CLEANING AND INSPECTION

1. Clean all metal parts in solvent and blow dry

CAUTION

Maintenance

Section

4-20 A38E Work Platform

Figure 4-16: Hydraulic Cylinder Component Breakdown

2

7

8

13

12

11

10

15

45

6

3

14

2

1

1. Cylinder Body

2. Grease Nipple

3. Overcentre Cartridge

4. End Cap

5. Rod And Pivot

6. Rod Seal

7. O-Ring

8. Wiper

9. Piston O-Ring

10. Piston Head

11. Piston Seal

12. Piston Locknut

13. Washer

14. Emergency Lowering
Valve

15. Spacer

4.14

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 shaft 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

Note: During seal replacement do not use sharp
edged tools to avoid cutting the seals, and allow
at least one hour for the seals to elastically
restore to their original shape before assembly.

1. Lubricate and install new rod seal, rod wiper
and static seal on the headcap.
NOTE: Multi-purpose lubricant 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 Illustrated Parts
Breakdown.

5. Lubricate the piston seal and install the piston
and rod assembly in the barrel tube.

6. Thread headcap onto barrel tube and hand
tighten, then turn 1/4 turn further.

7. Install the lower cylinder Overcentre Valve.

INSTALLATION

NOTE: Before installing Lift Cylinder check cylinder
pins, bearings and Trunnion Pivot for wear and
replace if necessary.

1. Locate the Trunnion Pivot on the cylinder
and place the lift cylinder against the first post.

2. Maintaining the Trunnion Pivot in place put the
first Allen Bolt in one turn. Repeat for all of the
bolts. When all bolts are in place tighten fully.
NOTE: Take care in alig

ning the holes so that
the bolts can be made turn by hand. If holes are
not properly aligned the Trunnion Pivot will be
positioned incorrectly.

3. Install rod end bearings (if removed).

4. Lift rod end

of cylinder into place and insert pin.

Install pin lock plate. Fix pin lock plate with bolt.

5. Test with weight at rated platform load to check
system operation.

Maintenance

Section

4-21A38E Work Platform

Figure 4-17: Upper Lift Cylinder

1. Second Post

2. Upper Boom

3. Pin Lock Plate

4. Lower Boom

5. Upper Lift Cylinder

6. Bushings

7. Rod End Pivot Pin

8. Barrel End Pivot Pin

2

4.15

4.15 Upper Lift Cylinder
(Figure 4-17)

REMOVAL

The Upper Lift Cylinder is heavy, so utilise
appropriate lifting equipment to support the
unit before removing pins.

1. Ensure that the A38E is on firm level ground,

the Elevating Assembly is completely stowed,
the Keyswitch is to the ‘OFF’ position and the
Emergency Stop Button is pressed.

2. Provide a suitable container to collect the
hydraulic fluid, then disconnect the hydraulic
hoses. Immediately plug hoses to prevent
foreign material from entering.

3. Remove securing bolts and the pin lock plates
from the cylinde

r pins.

4. Support rod end of cylinder and remove rod end
pivot pin. Let cylinder down to hang freely.

5. Support the cylinder so that the barrel end
cylinder pin can be removed, then 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
components are highly sensitive to
contamination.

DISASSEMBLY (Refer to Figure 4-16)

1. Unscrew the headcap and withdraw the rod and
piston assembly from the barrel tube.

2. Unscrew the piston nu

t 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 maintenance.

CLEANING AND INSPECTION

1. Clean all metal parts in solvent and blow dry

with filtered compressed ai

r.

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 shaft 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: Mul

ti-purpose lubricant 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

1

5

4

6

3

8

7

3

Note: During seal replacement do not use sharp
edged tools to avoid cutting the seals, and allow
at least one hour for the seals to elastically
restore to their original shape before assembly.

CAUTION

Maintenance

Section

4-22 A38E Work Platform

4.16 Telescopic Cylinder
(Figure 4-18)

REMOVAL

1. Ensure that the A38E is on firm level ground,

the Elevating Assembly is completely stowed,
the Keyswitch is to the ‘OFF’ position and the
Emergency Stop Button is pressed.

2. From Chassis Controls extend the Telescope

until the Rod End Pin is just visible. This will
leave a small amount of clearance between the
ground and the Telescopic Boom.

3. Support the Telescopic Boom & Platform

Assembly to avoid any damage while removing
the Telescopic Cylinder.

4. Provide a suitable container to collect the

hydraulic fluid, then disconnect the hydraulic
hoses. Immediately plug hoses to prevent
foreign material from entering.

5. Remove securing bolts and pin lock plates from

the barrel end cylinder pin.

6. Remove the Telescopic Cylinder rod end circlip

and then push the rod end pin out.

7. Support the cylinder so that

the barrel end
cylinder pin can be removed, then remove the
cylinder from the machine. This is done by
pulling the cylinder forward through the gap
provided in Boom 2 at the 2

nd

post end.

8. Move the cylinder to a prepared work area. It is
important that clean assembly practices are
observed. Seals and other cylinder components
are highly sensitive to contamination.

DISASSEMBLY (Refer to Figure 4-16)

1. Unscrew the headcap and withdraw the rod and
piston assembly from the barrel tube.

2. Unscrew 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 hav

e been
deemed serviceable following the cleaning and
inspection phase of maintenance.

4.16

Figure 4-18: Telescopic Cylinder

end of thread and secure with circlip.

5. Lubricate the piston seal and install the piston
and rod assembly in the barrel tube.

6. Thread headcap onto barrel tube and hand
tighten, then turn 1/4 turn further.

7. Install the upper cylinder Overcentre valve.

INSTALLATION

NOTE: Before installing Lift Cylinder check cylinder
pins and bearings for wear and replace if necessary.

1. Install barrel end bearing (if removed)

2. Lift the barrel end of the cylinder into place and
push the cylinder pin in.

NOTE: Take care in aligning the holes so that the pin
can be pushed in by hand. Bearings will be damaged
if holes are not properly aligned and the pin is forced.

3. Align pin lock plate on cylinder pin with hole in
the mast and push the cylinder pin completely
in. Fix pin lock plate with bolt.

4. Install rod end bearings (if removed).

5. Lift rod end of cylinder into place and insert pin.
Install pin lo

ck

plate. Fix pin lock plate with bolt.

6. Test with weight at rated platform load to check
system operation.

1. Upper Boom

2. Pin Lock Plate

3. Circlip

4. Telescopic Cylinder

5. Barrel End Pivot Pin

6. Rod End Pivot Pin

7. Telescopic Boom

7

4

3

6

1

2

5

Maintenance

Section

4-23A38E Work Platform

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 shaft 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: Multi-purpose lubricant 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.

5. Lubricate the piston seal and install the piston
and rod assembly in the barrel tube.

6. Thread headcap onto barrel tube and hand
tighten, then turn 1/4 turn further.

7. Install the telescopic cylinder’s Overcentre and
Check Valves.

INSTALLATION

NOTE: Before installing Telescopic Cylinder check
cylinder pins and bearings for wear and replace if
necessary.

1. Lift the Telescopic Cylinder so that it will be able
to slide down Boom 2.

2. While maintaining a positive hold on the cylinder
position the barrel end of the cylinder into place.
Push the cylinder pin in.
NOTE: Take care in aligning the holes so that
the pin can be pushed in by hand. If holes are
not properly aligned and the pin is forced in, the
bearings will be damaged.

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 Steering Cylinder
(Figure 4-19)

REMOVAL

1. Ensure that the A38E is on firm level ground,
the Elevating Assembly is completely stowed
but slewed away from centre, the Keyswitch is
to the ‘OFF’ position and the Emergency Stop
Button is pressed.

2. Straighten the drive wheels.

3. Provide a suitable container to collect the
hydraulic fluid, then disconnect the hydraulic
hoses. Immediately plug hoses to prevent
foreign material from entering.

4. Remove the circlips from each steering pivot
pin. Push the steering pivot pins out and rotate
the steering link arm away from the rod.

5. While supporting the cylinder remove the four
bolts from the front panel of the A38E’s
chassis.

6. Move the cylinder to a prepared work area. It is
important

that

clean assembly practices are
observed as seals and other hydraulic cylinder
components are highly sensitive to
contamination.

DISASSEMBLY (Refer to Figure 4-16)

1. Unscrew both of the headcaps and withdraw
the rod piston assembly (this is one unit) from
the barrel tube.

2. Remove the piston static O-ring from the
cylinder rod.

3. Remove the piston seal from the piston.

4. Remove the rod seal, rod wiper and static seal
from the headcap.

5. 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.

4.17

Note: During seal replacement do not use sharp
edged tools to avoid cutting the seals, and allow
at least one hour for the seals to elastically
restore to their original shape before assembly.

Maintenance

Section

4-24 A38E Work Platform

4.17

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 rod & piston
assembly or inside of the cylinder barrel and the
shaft 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: Multi-purpose lubricant should be used.

2. Install a new piston seal on the piston.

3. Install the headcap on one end of the cylinder
barrel.

4. Lubricate the piston seal and install the rod &

Figure 4-19: Steer Cylinder

piston assembly in the barrel tube.

6. Thread the headcap onto the free end of the
barrel tube and hand tighten, 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 the
circlips are attached properly.
NOTE: Take care in aligning the holes so that
the pin can be pushed in by hand. If holes are
not properly aligned and the pin is forced in, the
bearings will be damaged.
Torque these four bolts to 90 Nm (66 ft. lbs).

3. Reconnect the hydraulic hoses.

4. Test system operation by carrying out

a ‘figure
of eight’ driving pattern for 5 cycles. This should
be sufficient to prove proper function.

Figure 4-20: Master Levelling Cylinder

1. Steering Cylinder

2. Steering Link Arm

3. Torque Arms

4. Steering Pivot Pins

5. Circlip

3

2

4

5

1

1. Bushings

2. Circlip

3. Barrel End Pivot Pin

2

3

5

4

6

4. Master Levelling
Cylinder

5. Pin Lock Plate

6. Rod End Pivot Pin

1

Note: During seal replacement do not use sharp
edged tools to avoid cutting the seals, and allow
at least one hour for the seals to elastically
restore to their original shape before assembly.

Maintenance

Section

4-25A38E Work Platform

4.18

4.18 Master Levelling Cylinder
(Figure 4-20)

REMOVAL

1. Ensure that the A38E is on firm level ground,

the Elevating Assembly is completely stowed,
the Keyswitch is to the ‘OFF’ position and the
Emergency Stop Button is pressed.

2. Provide a suitable container to collect the

hydraulic fluid, then disconnect the hydraulic
hoses. Immediately plug hoses to prevent

foreign material from entering.

3. Remove securing bolts and pin lock plates from
the rod end cylinder pin. Remove the circlip
from the barrel end of the cylinder

4. Support barrel end of cylinder and remove rod
end pivot pin. Move cylinder backwards and
allow to hang freely.

5. Support the cylinder so that the barrel end
cylinder pin can be removed, then 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
components are highly sensitive to
contamination.

DISASSEMBLY (Refer to Figure 4-16)

1. Unscrew the headcap and withdraw the rod and
piston assembly from the barrel tube.

2. Unscrew 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 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 shaft 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: Multi-purpose lubricant 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.

5. Lubricate the piston seal and install the piston
and rod assembly in the barrel tube.

6. Thread headcap onto barrel tube and hand
tighten, then turn 1/4 turn further.

7. Install the Master Cylinders Overcentre Valves.

INSTALLATION

NOTE: Before installing the Master Cylinder check
cylinder pins and bearings for wear and replace if
necessary.

1. Install barrel end bearing (if removed).

2. Lift the barrel end of the cylinder into place and
push the barrel end pivot pin in until the circlip
grooves are exposed, then

attach the

circlip.

NOTE: Take care in aligning the holes so that
the pin can be pushed in by hand. If holes are
not properly aligned and the pin is forced in, the
bearings will be damaged.

3. Align pin lock plate on cylinder pin with hole in
the 2

nd

Post and push the cylinder pin

completely in and fix pin lock plate with bolt.

4. Install rod end bearings (if removed).

5. Lift rod end of cylinder into place and insert the
rod end pivot pin until the circlip grooves are
exposed, then attach the circlip. Install the pin
lock plate.

6. Fix pin lock plate with bolt.

7. Test with weight at rated platform load to check
system operation.

Note: During seal replacement do not use sharp
edged tools to avoid cutting the seals, and allow
at least one hour for the seals to elastically
restore to their original shape before assembly.

Maintenance

Section

4-26 A38E Work Platform

4.19 Slave Levelling Cylinder
(Figure 4-21)

REMOVAL

1. Ensure that the A38E is on firm level ground,

the Elevating Assembly is completely stowed,
the Keyswitch is to the ‘OFF’ position and the
Emergency Stop Button is pressed.

2. Provide a suitable container to collect the

hydraulic fluid, then disconnect the hydraulic
hoses. Immediately plug hoses to prevent
foreign material from entering. Support the
Platform

3. Remove securing bolts and pin lock plates from

the cylinder pins.

4. Support barrel end of cylinder and remove rod

end pivot pin. Move cylinder backwards allowing
it to hang freely. Rotate the cylinder backwards.

5. Support the cylinder so that the barrel end
cylinder pin can be removed, then 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
components are highly sensitive to

contamination.

Figure 4-21: Slave Levelling Cylinder

DISASSEMBLY (Refer to Figure 4-16)

1. Unscrew the headcap and withdraw the rod and
piston assembly from the barrel tube.

2. Unscrew 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 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 shaft 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: Multi-purpose lubricant 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.

5. Lubricate the piston seal and install the piston
and rod assembly in the barrel tube.

6. Thread headcap onto barrel tube and hand
tighten, then tur

n 1/4 turn further.

7. Install the upper cylinder valve block. Check
O-rings.

4.19

1. Circlip

2. Barrel End Pivot Pin

3. Bushings

4. Pin Lock Plate

5. Rod End Pivot Pin

6. Slave Levelling Cylinder

1

2

3

4

6

5

Note: During seal replacement do not use sharp
edged tools to avoid cutting the seals, and allow
at least one hour for the seals to elastically
restore to their original shape before assembly.

Maintenance

Section

4-27A38E Work Platform

INSTALLATION

NOTE: Before installing the Slave Cylinder check
cylinder pins and bearings for wear and replace if
necessary.

1. Install barrel end bearing (if removed)

2. Lift the barrel end of the cylinder into place.

NOTE: Take care in aligning the holes so that
the barrel end pivot pin can be pushed in by
hand. If holes are not properly aligned and the
pin is forced in, the bearings will be damaged.

3. Align pin lock plate on cylinder pin with hole in
the bracket, push the cylinder pin completely in
and fix pin lock plate with bolt. Attach the circlip
inside the Telescopic Boom.

4. Install rod end bearings (if removed).

5. Lift rod end of cylinder into place and insert rod
end pivot pin. Install pin lock plate.

6. Fix pin lock plate with bolt.

7. Test with weight at rated platform load to check
system operation.

BLEEDING THE MASTER/SLAVE
LEVELLING CIRCUIT

When air enters the Master/Slave Levelling circuit the
Slave Levelling Cylinder is prevented from following
the master cylinder precisely. If it seems there may
be air in the system the following procedures should
be followed.

1. While outside the Platform activate the Levelling
Switch function and level the cage in the for­ward direction. Continue this until, and for 30

seconds after, the Platform comes to a stop.

2. Activate the Levelling function in the backward
direction. Continue this until, and for 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
and the booms are in their rest position.

4. Remove securing bolts and pin lock plates from
the rod end cylinder pin of the Master Cylinder.

5. Remove the rod end pivot pin. Move cylinder
backwards and allow to hang

freely.

6. Loosen, but do not fully disconnect, the hose
fitting at ‘B’. Prepare to activate the Levelling

4.19

Switch while a colleague holds a cloth at the
fitting ‘B’. Air will be expelled through this fitting.

7. Activate the Switch slowly in both directions
until all air is expelled and hydraulic fluid begins
to appear.

8. Repeat the above procedure for fitting ‘A’. Lift
the rod end of the cylinder into place and insert
the pin until the circlip grooves are exposed,
then attach the circlip. Install the pin lock plate.

9. Fix the pin lock plate with the bolt.

10. Support the Platform before removing the
securing bolts and pin lock plates from the
Slave Cylinders rod end pivot pin.

11. Remove the rod end pivot pin. Move the cylinder
backwards allowing it to hang freely. Rotate the
cylinder backwards.

12. Repeat the procedures outlined in Items 6, 7 &
8 for the Slave Cylinder.

13. Lift rod end of cylinder into place and insert pin.
Install pin lock plate.

14. Fix pin lock plate with bolt.

Maintenance

Section

4-28 A38E Work Platform

4.20

4.20 Adjustment of Overcentre
Valves on A38E 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.

A short term solution is to temporarily adjust the
valve as follows :­a) Place the max. SWL (Safe Working Load),

evenly distributed, in the cage.

b) Raise the boom to 50 mm stroke on the

cylinder.

c) First loosen the Locknu

t, then using an Allen
Key adjust the spring setting screw on the valve
cartridge. Turning the screw clockwise
increases the 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 following:-

Cylinder drifts down under load less than the
SWL (Safe Working Load).
Jerky motion in cylinder & boom when lowering.
Pump under high load when lowering.
Valve does not hold load if hose connections
are loosened or broken.
Damaged seals in cylinders due to high
ambient temperature rise.
High pitched sound from hydraulic system when
lowering.

Figure 4-22: Overcentre Valve

The Overcentre Valves are located towards the Rod End
of the Lower Lift and Upper Lift Cylinders.

CAUTION

Maintenance

Section

4-29

A38E Work Platform

4.21

Section

4.21

4.21 REPLACEING THE GP400
CONTROL MODULE

If for any reason you have to replace the GP400 control
moduale it is important that you complete the following
procedures:

If the GP400 control module is replaced and /or moved
with the machine for any reason the tilt sensor must be
result for zero º and the loadcell re-calibrated using the
following procedure.
Failure to do so could result in serious injury or death.

W A R N I N G

To follow this procedure you need to switch the Ezcal
display in the lower control box into “Calibration mode”.
To zero the tilt sensor :-

≤ 0.25°

2. Use a Gauge to Confirm that the front and rear

of the chassis are level to within +/- 0.25° in both
directions.

3. Switch the machine on and press and hold Esc
for 5 Seconds until “Ezlift Menu” is displayed.

4. Scroll to access level.(Enter)

5. Enter 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 below 0.2° if
not repeat from 5.

Now Re-Calibrate the loadcell:-

17. Scroll to setups. (Enter)

18. Scoll to load setups. (Enter)

19. Scoll to Calibrate load (Enter)

20. Redo loaded? Press up arrow for yes, place SWL
in basket and press enter twice.

21. Redo empty? Press up arrow for yes, remove
load from platform and press enter twice.

22. Use arrow to enter calabration date and press
Enter.

23. Place 120% of SWL in the platform and verify
that the lift function cuts out automatically when
raised off the boom switch.

ESC

ENTER

Esc to leave
Sub-Menu
without saving.

Display

Enter to Save
Entry

Scroll
Left/Right

Change Entry
Up / Down

1. Place the machine on firm level surface,

Maintenance

Section

4-30

A38E Work Platform

4.22

4.22 CALLIBRATION OF
THE LOAD CELL

If for any reason you have to replace the LOAD CELL
it is important that you complete the following
procedures:

If the LOAD CELL is replaced and /or tampered with

for any reason the loadcell must be re-calibrated

using the

following procedure.

Failure to do so could result in serious injury or death.

W A R N I N G

To follow this procedure you need to switch the Ezcal
display in the lower control box into “Calibration mode”.

2. Scroll 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 the boom switch.

ESC

ENTER

Esc to leave
Sub-Menu
without saving.

Display

Enter to Save
Entry

Scroll
Left/Right

Change Entry
Up / Down

1. Switch the machine on and press and hold Esc

for 5 seconds until “Ezlift Menu” is displayed.

SWL in basket and press enter twice.

load from platform and press enter twice.

Troubleshooting

Section

5-1A38E Work Platform

5.0

5.0 Introduction

The following section provides troubleshooting
guidelines to be used to locate and correct most of
the operational problems which may occur.
Problems which arise and which are not solved by
following corrective actions should be referred to a
technically qualified person, as there is no
substitute for a thorough knowledge of and practical
experience in the servicing and repair of related

equipment and machines.

For further assistance contact the local distributor
and if warranted the Snorkel product support at:

Referrin

g to Operators Manual and to Section 3.0
and Section 6.0 will aid in understanding the
operation and function of the verious components
and systems of the A38E Work Platform and help
diagnosing and repair of the machine.

When troubleshooting, ensure that the work
platform is resting on a firm, level surface.
Disconnect the batteries when replacing or
testing the continuity of any electrical
component.
When performing any service on or in the
elevating

assembly area, which requires the
platform to be raised, the elevating assembly
must be securely supported by overhead
cranes, or equivalent, of suitable capacity.

GENERAL PROCEDURE

EUROPE, MIDDLE EAS T
AFRICA & ASI A
PHONE: [phone]

FAX: +44 ( 0) 845 155 7 756

NORTH & S OUT H AM ERIC A

PHONE: + 1 785 989 3 000

TOLL FR EE: [phone]

FAX: [phone]

AUSTRA LIA

PHONE: [phone]

FAX: [phone]

NEW ZEAL AND
PHONE: [phone]

FAX: [phone]

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 following tables.

Note that the majority of problems will be related
to the electrical and hydraulic systems.
For this reason much attention has been paid to
these areas in the troubleshooting charts.
The lists are not guarenteed to include all possible
causes and remedies. The immediately obvious
causes and remedies are not necessarily listed.

1. Verify your problem.

• Do a full function test from both the platform
and chassis controls, and note all functions that
are not operating correctly.

2. Narrow the possible causes of the malfunction.

• Use the troubleshooting guide to determine
which components are common to all circuits that
are not functioning correctly.

3. Identify the problem component.

• Test components that are common to all circuits
that are not functioning correctly. Remember to
check wires and terminals between suspect
components, be sure to check connections to
battery negative.

4. Repair or replace any component found to be

faulty.

5. Verify that repair is complete.

• Do a full function test from both the platform and
the chasssis controls to verify that all fun

ctions are

operating correctly and that the machine is

Troubleshooting

Section

5.0

SPECIAL TOOLS

Remove hose from pump port and connect
pressure gauge.

Hydraulic settings must be checked whenever a
component is repaired or replaced.
Remove counterbalance valves and “bench test”
them if they are suspect.
Connect a pressure guage of appropriate range to
the test port located on the hydraulic manifold.
Correct pressure settings are listed in the hydraulic
schematic.

The following is a list of tools which may be required
to perform certain maintenance procedures on the
AB38.

• Flow Meter with Pressure Gauge
(Snorkel P/N: 067040-000).

• 0-69 bar (0-1000 psi) Hydraulic Pressure Gauge with
Adapter Fittings (Snorkel P/N: 014124-010).

• 0-207 bar (0-3000 psi) Hydraulic Pressure Guage
with Adapter Fittings ( Snorkel P/N: 014124-030).

• Adapter Fitting ( Snorkel P/N: 063965-002).

• Inclinometer ( Snorkel P/N: 010119-000)

• Crimping Tool (Snorkel P/N: 028800-009)

• Terminal Removal Tool ( Snorkel P/N: 028800-006)

• Calibrator EZcal ( Snorkel P/N: 504560-001)

ADJUSTMENT PROCEDURES

CHECKING PUMP PRESSURES

DIAGNOSTICS USING EZCAL
DISPLAY

The EZcal 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. FUNCTIONS- DRIVE

STEER

LL (LOWER LIFT)

UL (UPPER LIFT)

JIB (N/A)

BASKET

TELE

SLEW

INTERLOCK

3.

DIGITALS

4.

5.

VERIOUS

VERIOUS

VERIOUS

ANALOG

OUTPUT

Displays the condition of all digital inputs to the relevant controller & matrix, refer
to the following table and the circuit diagram on page 6.1 for full list of I/O’s.

Demand ON or OFF, Armature & Field Current and SEM600 controller
Temperature.

Displays Battery Voltage

Pump Motor Voltage and Current and P600 Controller Tempreture

Displays tilt angle of the machine in X and Y, bothshould be less than 3 degrees

N/A

Displays load as a percentage of SWL

Yes or No

Yes or No

These display the percentage demand for each function.

Displays the condition of all analogue inputs to relevant controller & matrix.

Displays the condition of all outputs from the relevant controller & matrix.

5-2 A38E Work Platform

Troubleshooting

Section

5-3A38E Work Platform

5.0

TROUBLESHOOTING TABLES

The next step is to refer to the Troubleshooting charts in tables.

Refer to Hydraulics section for detailed 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.

MATRIX I/O

Sch. 15 500 410

AB 38 Rev 1

MP1-1 B+ supply

B+ s upply

P1-2 B+ supply
P1-3 CANH

CANH

P1-4 GND

GND

P1-5 GND
P1-6 CANL CANL

P2-1 B+ Digital Input
P2-2 B+ Digital Input
P2-3 B+ Digital Input

Steer Left Sw.

P2-4 B+ Digital Input

Steer Right Sw.

P2-5 B+ Digital Input Trigger Sw.
P2-6 Analog Input

Joystick Hall effect output Direction & proportional control of selected function

P2-7 Analog Input
P2-8 B- protected Supply P2-8 & P2-11 share

the same PTC

P2-9 B+ protected Supply P2-10 & P2-12 share

the same PTC

P2-10 5V protected Supply (PTC 140mA) Joystick Hall effect supply
P2-11 B- protected Supply P2-8 & P2-11 share

the same PTC

Joystick Hall effect gnd

P2-12 B+ protected S upply P2-10 & P2-12 share

the same PTC

Joystick Sw's supply

P3-1 Mux digital input

Connect to commun of all function Sw's

P3-2 Mux digital input Moba Alarm output High when Overload
P3-3 Mux digital input

Overload Sw. 0V when overload

P3-4 Mux High side output Lower Boom function s elect

Sw.

P3-5 Mux High side output Upper Boom function select

Sw.

P3-6 Mux High side output

Tel Boom function select Sw.

P3-7 Mux High side output

Slew Boom function select
Sw.

P3-8 Mux High side output Basket Boom function select

Sw.

momentary SW's, funct ion not latching, function activated if Sw.

closed and elevation Sw. closed

P3-9 Mux High side output Drive function select Sw.
P3-10 Mux High side output
P3-11 Mux High side output
P3-12 Mux digital input Moba lamp output pulse 1s ON, 1s OFF when 80% overload

P4-1 Low side 1A output

Buzzer ON when overloaded (P3-3 @ 0V)

P4-2 Low side 1A output
P4-3 Low side 1A output Overload lamp mimic P3-12 + flash quicker when overloaded (P3-3 @ 0V)
P4-4 Low side 1A output

Lower boom selected ON when function latc hed

P4-5 Low side 1A output

Upper boom selected ON when function latched

P4-6 Low side 1A output Tele boom selected ON when function latched
P4-7 Low side 1A output

Slew boom selected ON when function latched

P4-8 Low side 1A output

Drive boom select ed ON when function latched

P4-9 N/C

momentary SW's, latching function, & turning ON selected
functions lamps

Ensure that the work platform is resting on firm, level surface.

Troubleshooting

Section

5-4 A38E Work Platform

5.1

P

ROBLEM

C

AUSE

A

CTION

All functions inoperable.
Electric motor does not start.

1. Blown main fuse Check the 300A fuse and replace if necessary

2. Faulty Battery Charger Connect charger to batteries and check the output voltage. If less than
48v, repair or replace.

Check input voltage to charger. Check the internal charger protection
fuse.

3. Faulty Battery Charge batteries overnight. Check individual cell voltage. Replace as
necessary.

4. Loose or broken battery leads Check resistance and continuity of each individual lead. Replace as
required.

5. Emergency Stop butt

ons

contacts failed

Check resistance and continuity of each individual lead. Replace as
required.

7. Loose Upper Control Box

Terminal

Unscrew connector, align locating tabs and reconnect

8. Battery Disconnect plug loose Check and reconnect. Check the internal steel points for pitting or
damage

Electric motor starts but all
functions are inoperable

1. Low hydraulic oil Check and top up using ISO VG 46 hydraulic oil.

2. Faulty hydraulic pump Insert a pressure gauge in the G1 port of the valve block. Operate a
function to the limit of stroke. Check that relief valve pressure
de

velops. Repair or replace.

3. Faulty controller Check the 10mm cable terminals for tightness.

Electric motor continues to
run when action has ceased

1. Line contactor 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. Fault

y lift valve solenoids Test the voltage to the mast and jib solenoids. Swap around solenoids

to isolate the problem. Solenoids are not serviceable.

3. Platform overloaded Remove excessive load.

Check the pressure setting of the hydraulic ‘lift limit’ relief valve (CT11)
on the block. This may only be reset at 215 kg payload in the platform.

level yrettaB 4. Low Check the battery cell voltages after recharging. Total battery pack

voltage should exceed 18v.
Charge the batteries or replace faulty

battery unit.

Platform drifts down
uncontrollably

1. Leaking emergency lowering /

hose burst valves

Check the operating levers and cables.
Check contamination within the valve.

Check closure of the control knob (CT14) at the base of the control
valve block.

Remove and replace the cylinder-mounted valves as necessary.

2. Cylinder piston seal internal
leakage

Switch off all power functions. Disconnect the hose from the annular
side of the cylinder and check for small oil flow. Oil flow indicates a
faulty cylinder piston seal. Remove and repair the cylinde

r.

3. Platform is overloaded Remove excessive weight.
The Safe Working Load is 215 kg for A38

5.1 G

ENERAL TROUBLESHOOTING

Troubleshooting

Section

5-5A38E Work Platform

5.1

Platform assembly will not
slew

1. Faulty controller Check the I/O's Using EZcal diagnostics

2. Faulty slew solenoid Check voltage at the solenoid electrical connections.

Use a screw driver or similar component to check the magnetic effect
of solenoid.

3. Incorrect cross-line relief
setting

Insert a pressure gauge in the TP port of the valve block.

Operate a slew function and measure the pressure.

Provided the main relief pressure has been preset properly, the gauge
should register 20-50 bar.

Reset or replace CLRV valves thus preventing bypassing of oil.

4. Faulty slew select switch Replace the complete switch assembly.

Platform assembly wi

ll not

descend

1. Faulty controller

Check the programmed mast speed settings.
Check the continuity of mast speed enabling cables to the
controller.
Repair as necessary.

2. Faulty mast or jib solenoids Check the voltage to the solenoids V7 & V8 for the mast functions.
Swap solenoids to confirm fault and replace if necessary.

P

ROBLEM

C

AUSE

A

CTION

Check the I/O’s using EZcal diagnostics.

Machine will not steer 1. Malfunction of joystick toggle Check I/O’s using EZcal diagnostics.

switch Remove and service the switch &/or joystick.

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 eht fo ytiunitnoc eht kcehC ..scitsongaid lacZE gnisu s’O/I kcehC

steer speed enabling cable to the contr

oller. Repair or repla

ce as

necessary.

4. Steer cylinder malfunction Check the hose connections to the cylinder.
Check the cylinder rod-end pins and the cylinder mounting bolts.

5. Seized wheel mounting frame
pivot(s)

Refer to the maintenance section for assembly and repair of the pivot
and associated parts.

6. Damaged steering link plates Replace the steering link plates, associated pins and lock plates.

Machine will not drive 1. Temp Reset system and allow the system to cool down.

2.

Towing valve open Locate the towing valve CT 21 on the valve block. Ensure that it is fully

closed by turning clockwise.

3. Incorrect hose connections Refer to the hydraulic diagram for correct connections of valve ports

to the motor ports. Incorrect connection may result in locking of

wheels.

4. Fail-safe brake-circuit

malfunction

Blocked brake line to either motor. Clear blockage and/or replace
hoses and fittings.

Check the correct function of the check valves V1 and V2 on
the valve block. These valve should open to allow brake chamber
evacuation.

Troubleshooting

Section

5-6 A38E Work Platform

5.2

NOTES:

Troubleshooting

Section

5-7A38E Work Platform

5.3

R

EPLACING THE

GP

400 CONTROL MODULE

If for any reason you have to replace the GP400 control
module it is

important that you complete the following

If the GP 400 control module is replaced and/or

moved within

t

he machine for any reason the tilt

sensor must be reset for zero ° using

t

he

following procedure.

Failure to do so could result in serious injury or death.

To follow this procedure you need to switch the Ezcal display in the upper Control box into “calibration mode”.

1.2.Place the machine on a firm level surface , ≤ 0.25 °

Use a Gauge to confirm that the front and rear of the chassis are level to within +/- 0.25 ° in both directions.

3. Switch the machine on and press and hold Esc for 5 Seconds until “Ezlift Menu” is displayed.

Scroll 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

Enter to Save
Entry

Scroll
Left/Right

Change Entry
Up / Down

6.

7.

8.

9.

10.

11.

12.

Now re-calibrate the load cell:-

17.

18.

Scroll to setups. (Enter)

Scroll to load setups. (Enter)

19. Scroll to Calibrate load (Enter)

Redo Loaded? Press up arrow for yes, place SWL in basket and press enter twice.

21.

20.

Redo empty? Press up arrow for yes, remove load from platform and press enter twice.

Use arrow to enter calabration date and press Enter.

Place 120% of SWL in the platform and verify that the lift function cuts out automatically when raised

off the boom switch.

22.

23.

procedures:

W A R N I N G

Troubleshooting

Section

5-6 A38E Work Platform

5.7

GP400 I/O allocations

Sch. 15 500 430

AB 38 Rev 1

U# PCB 59 100 026

same hardware as 21 510 436
P4-12 J6-12 23 Safe High side output 48V protect ed S ee Note 1 Line contactor
P4-13 J6-13 23 Safe High side output Brake unlock

P4-14 J6-14 23 Safe High side output Brake unlock
P4-15 J6-15 23 Safe High side output 48V protect ed

P5-1 J5-1 17 High side PWM output
P5-2 J5-2 16 High side 2A output
P5-3 J5-3 16 High side 2A output
P

5-4 J5-4 17 High s ide P WM output
P5-5 J5-5 17 High side 2A output
P5-6 J5-6 16 High side 2A output
P5-7 J5-7 18 High side PWM output

P5-8 J5-8 18 High side PWM output
P5-9 J5-9 16 High side 2A output
P5-10 J5-10 18 High side PWM output
P5-11 J5-11 18 High side PWM output
P5-12 J5-12 15 High side 2A output
P5-13 J5-13 B+ protect ed S upply (PTC 140mA)
P5-14 J5-14 19 High side 2A output
P5-15 J5-15 17 High side PWM output

P6-1 J4-1 14 High side 2A ou

tput Lower Boom up

V8

P6-2 J4-2 13 High side 2A output Lower Boom down
P6-3 J4-3 13 High side 2A output Upper boom up

V7

P6-4 J4-4 14 High side 2A output Upper boom down
P6-5 J4-5 13 High side 2A output Tele out

V6

P6-6 J4-6 13 High side 2A output Tele in
P6-7 J4-7 14 High side 2A output Steer left

V5

P6-8 J4-8 12 High side 2A output Steer right
P6-9 J4-9 12 High side 2A output Turntable CW

V4

P6-10 J4-10 14 High side 2A output Turntable CCW
P6-11 J4-11 12 High side 2A output Bask et level up
P6-12 J4-12 12 High side 2A output Bask et level down
P6-13 J4-13 15 High side 2A output

P6-14 J4-14 15 High side 2A output
P6-15 J4-15 15 High side 2A output Buzz er

P7-1 J3-1 B+ Digital Input Valve s upply

from P600

P7-2 J3-2 B+ Digital Input Valve & Logic supply (ground mode) K ey sw grnd mode

also to P600

P7-3 J3-3 B+ Digital Input Elevation sw.
P7-4 J3-4 B+ Digital Input Logic supply (platform mode) Key sw platform mode

also to P600

P7-5 J3-5 B+ Digital Input Lower boom sw.
P7-6 J3-6 B+ Digital Input Upper boom sw.
P7-7 J3-7 B+ Digital Input Tele sw.
P7-8 J3-8 B+ Digital Input Turntable sw.
P7-9 J3-9 B+ Digital Input
P7-10 J3-10 B+ Digit al Input
P7-11 J3-11 B+ Digit al Input

P7-12 J3-12 B+ Digit al Input
P7-13 J3-13 B- Digital Input
P7-14 J3-14 B- Digital Input
P7-15 J3-15 B- Digital Input

P8-1 J2-1 Analog Input gnd finger joy stick Ground control; direction and propor

tional control of

gnd control selected function St d 0. 5V/ 2.5V/4.5V

P8-2 J2-2 Safe Analog Input
P8-3 J2-3 Analog Input

P8-4 J2-4 Analog Input
P8-5 J2-5 Analog Input
P8-6 J2-6 Safe Analog Input

P8-7 J2-7 Analog Input
P8-8 J2-8 Analog Input
P8-9 J2-9 Analog Input

P8-10 J2-10 No connect

P8-11 J2-11 +5V protect ed S upply
P8-12 J2-12 +5V protect ed S upply
P8-13 J2-13 GND gnd finger joy stick
P8-14 J2-14 GND
P8-15 J2-15 GND

P15-1 J10-1 B+ Digit al Input

P15-2 J10-2 B+ Digit al Input
P15-3 J10-3 B+ Digit al Input
P15-4 J10-4 B+ Digit al Input
P15-5 J10-5 B+ Digit al Input
P15-6 J10-6 B+ Digit al Input
P15-7 J10-7 B+ Digit al Input
P15-8 J10-8 B+ Digit al Input
P15-9 J10-9 B+ Digit al Input
P15-10 J10-10 B+ protected Supply 140mA PTC shared wit h 11, 12
P15-11 J10-11 B+ protected Supply 140mA PTC shared wit h 10, 12

P15-12 J10-12 B+ protected Supply 140mA PTC shared wit h 10, 11

V9; basket leve

ling only operates when the booms

are fully stowed, elevati on s w. closed (B+)

Ground control; enable funct ion, direct ion and
proport ional c ontrol from gnd fingerjoystick (P8-1),
need to hold while function

V1 & V2; both powered when driving

Schematics

Section

6-1A38E Work Platform

6.0 Introduction

This section contains electrical and hydraulic power
schematics and associated information for
maintenance purposes.

6.0

Schematics

Section

6-2 A38E Work Platform

6.0

A38E CE Electric Kit Parts

Circuit Diagram: 512819- 002

DESCRIPTION PART No.

PLATFORM CONTROL BOX 513433-002

Enclosure(cut-out) 512936-002 -

Joys

ck 510471-000 1

Matrix Board 510472-000 1

Overload I/F Board

13468-01

1

Alarm 502588-000 1

Twist& Release E/stop c/w 1 N/C contact block 510524-000 1

Black Flush Push Bu

on c/w 1 N/O contact block 510542-000 2

Toggle Switch, on-(on) IP65 510521-000 6

Boot 514132-000 6

Red LED 512934-000 2

Green LED 512935-000 5

Pl

a

orm Control Box Overlay 512937-002 1

9-way Chassis Socket 513949-000 1

6-way Panel Plug 510154-000 1
9-way Panel Plug 510156-000 1

12-way Panel Plug 510157-000 2

4-way Panel Plug 512366-000 2

3-way Panel Plug 510155-000 1

2-way Panel Plug 512816-000 1

Mate-N-Lock Socket Contact 510145-000 42

9-way Bulkhead Connector 512938-000 1

DIN Rail 512368-000 0.4

GROUND CONTROL PANEL 513434-000

Ground Control Panel 512939-001 1

Ground Control Panel Overlay 512940-000 1

Ezcal Display 3087803 1

Twist& Release E/stop c/w 1 N/C contact block 510524-000 1

3 posn. Stayput Key Switch (key remove able only in

off posi on) c/w/2 N/O contact blocks 512543-000 1

Analogue Rocker 514131-000 1

Deadman Toggle Switch, on-(on) IP65 510521-000 4

Boot 514132-000 4

19-Way Cable Clamp Socket 513951-000 1

4-way Panel Plug 512366-000 1

Mate-N-Lock Socket Contact 510145-000 4

3 amp diode. 510150-000 2

External Components

12v Solenoid coil 505555-016 14

Alarm 502588-000 1

Alarm bracket 512684-000 1

Fuse 300Amp 067387-022 1

Fuse holder 501877-000 1

Contactor 513550-000 1

GP400 512941-000 1

SEM600 512942-000 1

P600 512943-000 1

Load Cell

513160-000

1

Load Cell Cable Harness

513161-000

1

Trac

on motors 512944-000 2

Eleva

on Switch 058864-000 1

Horn 501868-001 1

Ferrite 510437-000 5

Cable Assemblies

A38E Wire Harness PG Tr

ionics 513539-000 1

A38E Valve Cable 513540-001 1

A38E Addi

onal Cable Kit 513541-000 1

A38E Power Cable Kit 513542-000 1

QTY.

Schematics

Section

6-3A38E Work Platform

6.1. Electrical Schematics

6.1

512819-002

Schematics

Section

6-4

A38E Work Platform

6.1

A 38E ANSI Electric Kit Parts

Circuit Diagram: 512819-003

DESCRIPTION PART No. QTY
PLATFORM CONTROL BOX 513433-003

Enclosure(cut-out) 512936-003 -

Joys

ck 510471-000 1

Matrix Board 510472-000 1

Alarm 502588-000 1

Twist& Release E/stop c/w 1 N/C contact block 510524-000 1

Black Flush Push Bu

on c/w 1 N/O contact block 510542-000 2

Toggle Switch, on-(on) IP65 510521-000 7

Boot 514132-000 6

Red LED 512934-000 1

Green LED 512935-000 6

Pla

orm Control Box Overlay 51

2937-003 1

9-way Chassis Socket 513949-000 1

6-way Panel Plug 510154-000 1
9-way Panel Plug 510156-000 1

12-way Panel Plug 510157-000 2

Mate-N-Lock Socket Contact 510145-000 30

DIN Rail 512368-000 0.4

GROUND CONTROL PANEL 513434-001

Ground Control Panel 512939-001 1

Ground Control Panel Overlay 512940-000 1

Ezcal Display 3087803 1

Twist& Release E/stop c/w 1 N/C contact block 510524-000 1

3 posn. Stayput Key Switch (key removeable in any

posi

on) c/w/2 N/O contact blocks 510526-000 1

Analogue Rocker 514131-000 1

Deadman Toggle Switch, on-(on) IP65 510521-000 4

Boot 514132-000 6

19-Way Cable Clamp Socket 513951-000 1

4-way Panel Plug 512366-000 1

Mate-N-Lock Socket Contact 510145-000 4

3 amp diode. 510150-000 2

External Components

12v Solenoid coil 505555-016 14

Alarm 502588-000 1

Alarm bracket 512684-000 1

Fuse 300Amp 067387-022 1

Fuse holder 501877-000 1

Contactor, 200Amp 12vdc SPDT 513550-000 1

GP400 512941-000 1

SEM600 512942-000 1

P600 512943-000 1

Trac

on motors 512944-000 2

Eleva

on Switch 058864-000 1

Horn 501868-001 1

Ferrite 510437-000 5

Cable Assemblies

A38E Wire Harness PG Trionics 513539-000 1

A38E Valve Cable 513540-001 1

A38E Addi

onal Cable Kit 513541-000 1

A38E Power Cable Kit 513542-000 1

Schematics

Section

6-5A38E Work Platform

6.1

6.1. Electrical Schematics

Schematics

Section

6-10 A38E Work Platform

6.2

6.2. Hydraulic Schematics

REFERENCE NAME FUNCTION LOCATION

V10 (RV) Main relief Sets max system pressure t o On main

valve. 175 Bar manifold block.

V11 Single Prevents back flow and On base of

Overcentre provides a hydraulic lock on upper, lower &
valve.

the cylinder. tele cylinders.

V12 Emergency Allows upper and lower boom On base of

lowering valve. to be manually lowered. upper and lower

cylinders .

V13 Pilot operated Holds tele cylinder in position On base of

che ck va lve. after controls are released tele cylinder.

V14 Dual Holds pressure in On base of

Overcentre master/slave closed circuit master cylinder.
valve . and provides hose burst

protection. (Set 160 Bar).

V15

Dual Holds pressure in slave On base of
Overcen tre cylinder and prov ides host slave cylinder.

valve.

burst protection.
(Set 120 Bar).

Table 6-2: Hydraulic Schematic Legend

REFERENCE NAME FUNCTION LOCATION

BRK Brake. Spring applied - hydraulically On front end of

released brakes to stop w heel drive
rotation of drive wheels. motors on
(Set at 100 Bar). chassis.

CLRV Cross-line To limit the max. operating On main

relief valve. pressure of the slew motor. manifold block.

(Set at 50 Bar).

CV Check Valve. To prevent oil pressure in the On main

brake line from b eing lost manifold block.
through the main pressure
line.

CYL1 Lower boom lift Provides t he force to lift the Foward of first

cylind er. lower boom - Boom1. post

CYL2 Upper boom lift Provide the force to lift the Behind second

cylind er. upper boom - Boom2. post

CYL3 Tlelscopic Provides the fo rce to Inside Boom2

cylind er. push/pull the tele-boom & Tele boom.

- Boom3.

CYL4 Steering Provides the force to Inside front of

cylind er. push/pull the steering torque chassis.

arms .

CYL5 Ma ster levelling Provid es the pr essure to the Behind the

cylinder. slave cylinder for cage second post

levelling.

CYL6 Slave levelling Pr ovides the f orce to level Close to cage

cylind er. the cage up/down. pivot at inner

Tele boom.

FL1 Return line Continuously filters hydraulic On top of the

filter. return oil. hydraulic
(10 Micron) reservoir.

HP Handpump. U sed for retraction of tele On side of

boom in the case of power manifold block.
failure. Delivers 15cc/stroke.

MMB Main manifold Contains the directional On hydraulic

block. cont rol 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 el ectric motor. Provides

pressurised oil flow for all
hydraulic functions.

V1 Brake oil This valve is energised to On main

sup ply v alve. allow oil into the brake manifold blo ck

release chamber.

V2 Brake valve. When energised th is valve On main

prevents the pressurised manifold block.
brake oil from venting back
to tank. When the machine is
stationar y this v alve
de-energises and the brake
oil vents to tank and the
brake springs apply
themselves a nd keep t he
machine sta tionary.

V3 Pressure Prevents pressures i n On main

reduc tion valve. excess of 100 Bar entering mani fold block.

the brake chambers.

V4 Slew Directional Send oil to the left or right On main

Control Valve. side of the slew motor. manifold block.

V5 Steer Send oil to the annular or full- On main

Directional bore side of the steering manif old block.
Control Valve. cylinder.

V6 Tele Send oil to the annular or full- On main

Directional bore side of the telescopic manifold block.
Control Valve. cylinder.

V7 Boom2 Send oil to the annular or full- On main

Directional bore side of the Boom2 manifold block.
Control Valve. cylinder.

V8 Boom1 Send oil to the annular or full- On main

Directional bore side of the Boom1 manifold block.
Control Valve. cylinder.

V9 Levelling Send oil to the annular or full- On main

Directional bore side of the levelling manifold block.
Control Valve. cylinders.

Notes:

1. All of the Overcentre Valves represented within
this schematic have a 5:1 Pilot Ratio.

2. The P/O Check Valve represented has a 3:1
Pilot Ratio.

3. The maximum flow rate of the Pump/Motor Unit
is limited to 15 L/min @ 100% speed. Although
it should be noted that the actual flow rate will
depend on the applied load and the D.C. Motor
speed.

4. The maximum ‘Return’ flow rates for each of
the functions are restricted to the following
values;
Slew... 4 L/min
Boom1... 8 L/min

Boom2... 5 L/min
Tele... 5 L/min
Steering... 6 L/min.

Section

6.2

Schematics

6-11A38E Work Platform

Figure 6-3, 4 : Hydraulic Schematic

MMB

SLEW

RESEVOIR / HYDRAULIC TANK

MP

F L1

M

CYL1- BOOM1

V11

A

B

V12

CYL2- BOOM2

V11

A

B

V12

CYL3- TELE

V11

A

B

V13

V10

(RV)

MOT1

TP A 6 B6 A2 B2 A 3 B3 A4 B4 A5 B5 A 1 B1 BRAKE

CYL4 - STEER

A

B

BRK

BRK

CYL6 - SLAVE

A

V15

B

F C

EF

CYL5 - MASTER

A

V14

B

F C

EF

V9 V8 V7 V6 V5 V4 V3 V2 V1

HP

P

T1

STEER

BOOM2

BOOM1 TELE

CLRV

CLRV

V10 (RV)

V8

CLRV

V7

V4

CLRV

V1

V2

V9
V5
V6

HP

TP

A1

B1

A2

B2

A3

B3

A4

B4

A5

B5

A6

B6

T1

BRAKE

V3

P

MMB -

Main Manifold Block

CV

dedda evlav kcehc enilnI

JUNE 2013

Illustrated Parts Breakdown

Section

6-12 A38E Work Platform

6.2

“This Page Intentionally Left Blank”

Illustrated Parts Breakdown

Section

7-1A38E Work Platform

7.2

7.1

Section

7.0 Introduction

This section lists and illustrates the replaceable
assemblies and parts of the A38E Work Platform as
manufactured by Snorkel UK.

Each parts list contains the component parts for that
assembly indented to show relationship where
applicable.

7.1 Index

Assembly Page

F

inal Assembly A38E ..................................................7-2

Chassis Assembly ...................................................... 7-4

Booms and Posts Assembly ........................................7-8

Cage and Cradle Assembly .......................................... 7-10

Cage and Cradle Assembly (Rotator) .............................7-12

Wheel Hub Assembly .................................................. 7-14

Drive Reduction Gearbox Assembly .............................. 7-16

Traction Motor Assembly (514274-000) ..................... 7-18

Motor / Pump Assembly .................................

............ 7-22

Rear & Front Wheel Kit ............................................... 7-24

Worm Drive Unit & Slew Bearing Assembly ............ ...... 7-26

Manifold Block Assembly ............................................. 7-28

Lower Lift Cylinder Assembly ....................................... 7-30

Upper Lift Cylinder Assembly ....................................... 7-32

Telescopic Cylinder Assembly ...................................... 7-34

Steering Cylinder Assembly ......................................... 7-36

Master / Slave Cylinder Assembly ................................ 7-38

Lower Control Box Assembly ... ........................

.......... 7-40

Upper Control Box Assembly (CE) . ............................ 7-42

Cables & Electrical Components ................................ 7-46

Hose Assembly ........................................................ 7-48

Decal Kit - ANSI Version ............................................. 7-50

Decal Kit - CE Version ............................................... 7-52

Options List .............................................................. 7-54

NOTE: Any part or assembly that is not represented
by a Snorkel part number within the Illustrated
Parts Breakdown is subsequently not supported
by Snorkel. For

further advice please contact

Snorkel Product Support at:

EUROPE, M IDDLE EA ST

AFRICA & ASIA

PHONE: [phone]

FAX: [phone]

NORTH & SOUTH A MERICA
PHONE: [phone]

TOLL FREE: [phone]

FAX: [phone]

AUSTRALI A

PHONE: [phone]

FAX: [phone]

NEW ZE ALAND
PHONE: [phone]

FAX: [phone]

A38E PG Parts Assembly............................................ 7-6

Traction Motor Assembly (512944-000) ..................... 7-20

Upper Control Box Assembly (ANSI). ..

......................... 7-44

Section

7.2

7-2 A38E Work Platform

Illustrated Parts Breakdown

FINAL ASSEMBLY A38E -

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

Traction Motor Assembly

--057530-000 Motor / Pump Assembly 1

1

Front Wheel Assembly

­500284-000 Pinion Gearbox & Slew Bearing Assy.

- 500261-000 Manifold Block Assembly 1

- 504504-000 Lower Lift Cylinder Assembly 1

- 504505-000 Upper Lift Cylinder Assembly 1

- 058461-000 Telescopic Cylinder Assembly 1

- 058463-000 Steering Cylinder Assembly 1

-

-

-

-

-

-

058734-000 Master Cylinder Assembly 1

058735-00

513434-000

513433-002

513433-003

0 Slave

Lower Control Box Assembly

Upper Control Box Assembly

Upper Control Box Assembly (ANSI)

Cylinder Assembly 1

1

-

- 500

36

0-000

Hos

e Kit

W raeR hee

l

Assembl

y

-

see page 7-20

-

512944-000

-

(SN:006001 - 006281 / 006523 - ######)

Traction Motor Assembly

-

514274-000

-

1

2

(SN:006282 - 006522)

Illustrated Parts Breakdown

Section

7-3A38E Work Platform

7.2

Section

7.2

7-4 A38E Work Platform

Illustrated Parts Breakdown

CHASSIS ASSEMBLY A38E -

500202-000

ITEM PART NO. DESCRIPTION QTY.

1 514031-000 A38E CHASSIS WELDMENT 1
2 500232-000 A38E DRIVE MOTOR COVER 1
3 500233-000 A38E CHASSIS BODY COVER 1
4 500231-000 A38E MODULE COVER 2
5 500052-000 GRAB HANDLE 6
6 057727-000 TWIST SCREW FASTNER 4
7 500259-000 A38 COVER GRIP LATCH 4
8 500261-000 A38E MANIFOLD BLOCK 1
9 500260-000 A38E HYDRAULIC RESERVOIR ASSY

10 057532-000 RESERVOIR RETURN LINE FILTER ASSEMBLY(Inc Filter)

11

05

8074-000 FILTER / WASHER / SPRING ASSEMBLY (Part of item 10) 1

12

514274-000

DRIVE MOTOR (SN:006282 - 006522)

13
14
15
16
17 057530-000 MOTOR/PUMP ASSEM

BLY 1

18 057578-000 REAR WHEEL

NUT - M14 10

19 057

668-001 REAR WHEEL TYRE & RIM ASSY

20 057667

-003 FRONT WHEEL TYRE & RIM ASSY
21 056066-016 10
22 057669-000 STEERING STUB AXLE ASSY 2
23 058427-000 A38E TORQUE ARMS 2
24 500253-001 A38E STEERING LINKAGE PIN 4

* 500252-000 CIRCLIP 16mm 4

* 500408-000 BUSHINGS 2
25 500250-000 A38E STEERING LINK ARM 2
26 058463-000 A

38E STEERING CYLINDER 1

*

058494-035 MOUNTING BOLTS M12 4

* 056021-012 SPRING WASHER 4
27 0260021 CHARGER 240/100 VAC 50/60Hz
28 501868

-001 HORN 1

29 500234-002 A38E CHASSIS SIDE DROP PANEL

WITH SLOTS

30 501074-000 BATTERY 6V 210AH 8

010154-000 TERMINAL COVERS 18
31
32 ─ Please see page 7-6 ─
33 500234-001 A38E CHA

SSIS SIDE DROP PANEL

WITHOUT SLOTS

34 057580-000 DRIVE GEARBOX 2

FRONT WHEEL NUT - M16

------

512944-000

------

------

------

------

------

--------------------------------

--------------------------------

--------------------------------

12

------

--------------------------------------

DRIVE MOTOR (SN:006001 - 006281 / 006523 - ######))

------

--------------------------------------

1

1

2

2

2
2

1

1

1

057534-000 FILLER / BREATHER CAP 1

10a

Illustrated Parts Breakdown

Section

7-5A38E Work Platform

7.2

10a

Section

7.2

7-6 A38E Work Platform

Illustrated Parts Breakdown

2

1

6

4 3 5

A38E PG PART ASSEMBLY -

ITEM PART NO. DESCRIPTION QTY.

1 512941-000 GP400 ECU 1
2 512943-000 PUMP MOTOR CONTROLLER 1
3 502588-000 ALARM SOUNDER 1
3 512684-000 ALARM BRACKET 1
4 513550-000 CONTACTOR SPDT 200A 12VDC 1
5 501877-000 FUSE HOLDER 1
5 067387-000 FUSE 1
6 512942-000 SEM600 MOTOR CONTROLLER 1

Illustrated Parts Breakdown

Section

7-7A38E Work Platform

7.2

“This Page Intentionally Left Blank”

Section

7.2

7-8 A38E Work Platform

Illustrated Parts Breakdown

BOOMS & POSTS ASSEMBLY

500201-000

ITEM PART NO. DESCRIPTION QTY.

1 058412-000 A38E FIRST POST WELDMENT 1
2 512614-000 BALLAST ASSEMBLY CE 1

* 512614-001 BALLAST ASSEMBLY ANSI 1

3 058417-000 A38E TENSION BAR WELDMENT 2
4 058416-000 A38E SECOND POST WELDMENT 1
5 058413-000 A38E LOWER BOOM WELDMENT 1
6 058414-001 OUTER TELE BOOM WELDMENT 1

* 260297 WEAR PAD 1-3/4" -4 ACME THREAD 2

7 058415-001 INNER TELESCOPIC BOOM WELDMENT 1
8 058457-002 A38E HOSE CABLE COVER 1
9 500265-000 COVER FOR ENERGY CHAIN CHANNEL 1

* 057727

-000 TWIST SCREW FASTENER 2
10 500266-000 ENERGY CHAIN SUPPORT CHANNEL 1
11 500468-000 ENERGY CHAIN - COMPLETE 1

* 500468-002 ENERGY CHAIN (1 UNIT OF 24) 24
* 500468-001 MOUNTING ELEMENTS 1

12 057975-000 INNER TELESCOPIC BOOM WEAR PAD 2

* 058510-016 M8 X 16 CSK 6
* 058510-025 M8 X 25 CSK 2

13 500275-001 OUTER TELESCOPIC BOOM WEAR PAD 2

* 058491-010 M6 X 10 HEX 8
* 500519-006 1/4" T4 WASHER 8

* 057975-300 6mm INSERTS 8
14 504504-000 A38E LOW ER LIFT CYLINDER 1
15 504505-000 A38E UPPER LIFT CYLINDER 1
16 058734-000 A38E MASTER LEVELLING CYLINDER 1
17 058735-000 A38E SLAVE LEVELLING CYLINDE

R 1
18 058461-000 A38E TELESCOPIC CYLINDER 1
19 058056-000 PIN LOCK PLATE 16

056060-016 BOLT M10 X 16 mm 16
056021-010 SPRING WASHER 10 mm 16

20 058055-006 PIN-LOWER & UPPER BOOM TO FIRST 3

& S

ECOND POST
21 058054-001 PIN - TENSION BARS 4
22 058066-001 PIN - LIFT CYLINDER ROD END 1
23 058066-007 PIN - UPPER LIFT CYLINDER BODY END 1
24 058053-004 PIN - MASTER CYLINDER ROD END 1
25 058053-005 PIN - MASTER CYLINDER BODY END 1
26 058065-006 PIN - TELE CYLINDER BODY END 1
27 500254-000 PIN - TELE CYLINDER ROD END 1
28 058053-001 PIN -

SLAVE CYLINDER BODY END 1
29 058065-005 PIN - SLAVE CYLINDER ROD END 1
30 058066-001 PIN - TELE

SCOPIC BOOM TO CAGE 1
31 057033-000 CIRCLIP 30mm 4
32 057047-000 BUSHING STRAIGHT 25mm 8
33 057054-000 BUSHING FLANGED 30mm 12
34 057046-000 BUSHING FLANGED 35mm 8
35 057034-000 CIRCLIP 25mm 4
36 501085-000 BOOM REST (BOLT ON) 1

SERIAL BREAK

2890 - 3144 : Part No: 058460-000

SERIAL BREAK

2890 - 3144 : Part No: 058462-000
3145 - Current : Part No: 504505-000

Illustrated Parts Breakdown

Section

7-9A38E Work Platform

7.2

Section

7.2

7-10 A38E Work Platform

Illustrated Parts Breakdown

CAGE & CRADLE ASSEMBLY(STANDARD)

057603-000

(501864-000 is not included as part of this assembly)

Note : Ensure that items 10 (M16
screw and drilled nut with pin) remain loose,
these are safety bolts.

(ANSI is Without Overload)

ITEM PART NO. DESCRIPTION QTY.

1 057521-003 CAGE RAIL ASSY 1
2 508931-000 DROP BAR ASSY 1
3 513563-000 CONTROL BOX MOUNTING PLATE 1
4 513433-002 A38E UPPER CONTROL BOX CE 1

* 513433-003 A38E UPPER CONTROL BOX ANSI 1
5 010076-000 MANUAL HOLDER 1
6 501970-000 A38E CAGE FLOOR WELDMENT 1
7 058251-

000 LADDER LOCKING LATCH 1
8 057347-001 LADDER 1
9 513160-000 OVERLOAD UNIT CE 1

* 513161-000 LOAD CELL HARNESS 1

* 509791-000 OVERLOAD UNIT ANSI 1
10 509595 -000 M16 BOLT + NUT CROSS DRILLED 2
11 056069-016 M16 WASHER 8
12 503101-045 M16 X 45 HEX HEAD SCREW 8
13 056069-016 M16 WASHER 4
14
15 501971-000 CAGE CRADLE WELDMENT 1

###### ###### #

Illustrated Parts Breakdown

Section

7-11A38E Work Platform

7.2

3

4

5

2

1

Section

7.2

7-12 A38E Work Platform

Illustrated Parts Breakdown

CAGE ROTATOR ASSEMBLY(OPTION)

500905-000

(501864-000 is not included as part of this assembly)

Note : Ensure that items 11 (M16 screw and drilled
nut with pin) remain loose, these are safety bolts.

(ANSI is Without Overload)

ITEM PART NO. DESCRIPTION QTY.

1 513433-002 UPPER CONTROL BOX - CE 1
* 513433-003 UPPER CONTROL BOX - ANSI 1
2 500973-001 MOUNTING PLATE 1
3 500985-000 ROTATING HANDLE 1
4 500922-000 GEARBOX 1
5 500905-034 HANDLE 1
6 500905-030 DRIVE SHAFT 1
7 508931-001 DROP BAR ASSY 1
8 057521-001 CAGE RAIL ASSY 1
9 501970-000 WE

LDMENT, CAGE BASE 1

10 513160-000 OVERLOAD UNIT - CE 1

* 513161-000 LOAD CELL HARNESS - 1

* 509791-000 REPLAMENT BLOCK - ANSI 1
11 509595--000 M16 BOLT + NUT CROSS DRILLED
12 056069-016 M16 WASHER 8
13 503101-040 M16 X 40 HEX HEAD SCREW 8
14 512321-000 DISC, FRICTION 2

2

15 501971-001 CAGE CRADLE WELDMENT 1
16 500993-000 45MM BRUSHING X 30mm LONG 2
17 501972-000 WELDMENT, CAGE LINK 1

#18
19 057347-001 LADDER 1
20 058251-000 LOCKING CATCH 1
21 057405-000 LADDER BUSHING 2
22 512782-000 POLL PIN ROTATE LINK 1
23 500905-018 CAGE PIVOT PIN 1
24 504189-001 STEEL FLAT WAS

HER, M48 X 4mm 1

25 056067-545 HEX JAM NUT, M45 2

######-### ####

Illustrated Parts Breakdown

Section

7-13A38E Work Platform

7.2

22

Section

7.2

7-14 A38E Work Platform

Illustrated Parts Breakdown

WHEEL HUB ASSEMBLY

057669-000

ITEM PART NO. DESCRIPTION QTY.

1 057665-000 WHEEL HUB 1
2 057664-000 THRUST BEARING 1
3 057662-000 PIVOT BOSS 1
4 057663-000 PIVOT PIN 1
5 057585-000 COVER PLATE 1
6 057584-000 OUTER HUB BEARING 1
7 057583-000 INNER HUB BEARING 1
8 057582-000 STUD 5
9 057661-000 PIVOT BUSHING 30/38 x 30 long 2

Illustrated Parts Breakdown

Section

7-15A38E Work Platform

7.2

Section

7.2

7-16 A38E Work Platform

Illustrated Parts Breakdown

DRIVE REDUCTION GEARBOX ASSEMBLY

057580-000

ITEM PART NO. DESCRIPTIONCR N

1 - COUPLING 1
2 - EXPANSION PLUG 1
3 - STEEL DISC 1
4 - BRONZE DISC 1
5 - O-RING 1
6 - SPACER 1
7 - O-RING 1
8 - ANTI-EXTRUS. RING 1

9 - PISTON 1
10 - SPRING 12
11 - O-RING 1
12 - ANTI-EXTRUS. RING 1
13 - OIL SEAL 1
14 - END PLATE 1
15 - O-RING 1
16 - CIRCLIP 1
17 - HUB 1
18 - BEARING 1
19 - CIRCLIP 1
20 - PLANET SHAFT 1
21 - PLANET CARRIER 1
22 - CIRCLIP 1
23 - THRUST WASHER 3
24 - NEEDLE ROLLER 84
25 - PLANET GEAR 3
26 - THRUST WASHER 3
27 - CIRCLIP 3
28 - SUN PINION 1
29 - O-RING 1
30 - BEARING 1
31 - RETAINING RING 1
32 - RETAINING RING 1

NOTE: ITEMS 5,7,8,11,12,13,15,29,44 & 46 FORM

THE SEAL KIT FOR THE DRIVE
REDUCTION GEARBOX ASSEMBLY.
THE PART NUMBER FOR THE
COMPLETE SEAL KIT IS 058799-000

ITEM PART NO. DESCRIPTION

33 - INPUT FLANGE 1
34 - SCREW 8
35 - SPACER 1
36 - CIRCLIP 1
37 - BEARING 1
38 - COUPLING 1
39 - BEARING 1
40 - PIN 1
41 - SPRING 1
42 - SUN PINION 1
43 - CIRCLIP 1
44 - O-RING 1
45 - THRUST WASHER 1
46 - O-RING 1
47 - RING + BEARING 1
48 - PLANET SHAFT 3
49 - SPINDLE 1
50 - THRUST WASHER 3
51 - THRUST WASHER 3
52 - NEEDLE ROLLER 75
53 - SPACER 3
54 - PLANET GEAR 3
55 - NEEDLE ROLLER 75
56 - THRUST WASHER 3
57 - THRUST WASHER 3
58 - WASHER 2
59 - PLUG 2
60 057580-002 STUD M15 X 1.5 5
61 - PIN 1
62 - SCREW 1
63 - CIRCLIP 1

QTY. QTY.

Illustrated Parts Breakdown

Section

7-17A38E Work Platform

7.2

Section

7-18 A38E Work Platform

7.2

Illustrated Parts Breakdown

TRACTION MOTOR ASSEMBLY

512944-000

ITEM PART NO. DESCRIPTION QTY.

1 512944-001

SEAL

1

2 512944-002

DRIVE END HEAD

1

3 512944-003

WAVY WASHER

1

4 512944-004

DRIVE END BEARING

1

5 512944-005

FAN

1

6 512944-006

ARMATURE ASSEMBLY

1

7 512944-007

COMMUTATOR

1

8 512944-008

SHIM

1

9 512944-009

FRAME AND FIELD ASSEMBLY

1

10 512944-010

POLE PIECE

1

11 512944-011

FIELD COIL

1

12 512944-012

SPRING

1

13 512944-013

BUSH

1

14 512944-014

BRUSH BOX ASSEMBLY

1

15 512944-015

RETAINING RING

1

16 512944-016

COMMUTATOR END BEARING

1

17 512944-017

COMMUTATOR END HEAD

1

SERIAL BREAK: (SN:006001 - 006281 / 006523 - ######)

Section

7-19A38E Work Platform

7.2

Illustrated Parts Breakdown

Section

7.2

7-20 A38E Work Platform

Illustrated Parts Breakdown

TRACTION MOTOR ASSEMBLY

ITEM PART NO. DESCRIPTION QTY.

1 514274-001 BRUSH 1
2 514274-002 BOLT 1
3 514274-003 SPRING 1
4 514274-004 BRUSH BOX SUPPORT 1
5 514274-005 BRUSH BOX 1
6 514274-006 SHEATHING 1

514274-000

SERIAL BREAK: (SN:006282 - 006522)

Illustrated Parts Breakdown

Section

7-21A38E Work Platform

7.2

Section

7.2

7-22 A38E Work Platform

Illustrated Parts Breakdown

MOTOR/PUMP ASSEMBLY

057530-000

NOTE: THE PART NUMBER FOR THE

MOTOR ASSEMBLY (ALL ITEMS FROM
2 TO 17) IS 058861-000

ITEM PART NO. DESCRIPTION QTY.

1 058862-000 HYDRAULIC PUMP 1

* 058862-001 SEAL KIT 1
2 058847-000 COUPLING 1
3 ─ OIL SEAL 1
4 ─ PUMP MOUNTING FACE 1
5 ─ CIRCLIP 1
6 ─ BEARING 1
7 ─ CIRCLIP 1
8 ─ CIRCLIP 1
9 ─ COOLING FAN 1

10 ─ COMMUTATOR 1
11 ─ BEARING 1
12 ─ COMMUTATOR COVER 1
13 ─ BRUSH HOUSING SUPPORT 1
14 058863-000 BRUSH 4
15 ─ END HOUSING 1
16 ─ TE

RMINAL BLOCK 1

17 ─ VENT/ INSPECTION CAP 4