Replaces July 2009 REPAIR PART S MANUAL

Transcription

1 Replaces July 2009 REPAIR PART S MANUAL Part Number December 2011

2 The aerial platform is not electrically insulated. Death or serious injury will result from contact with, or inadequate clearance from, an energized conductor. Do not go closer than the Minimum Safe Approach Distance as defined by ANSI standards. Regard all conductors as energized. Allow for electrical wire sag and aerial platform sway. If the platform, boom structure, or any part of the aerial platform contacts a high-voltage electrical conductor, the entire machine can become electrically charged. If that happens, remain on the machine and do not contact any other structure or object. This includes the ground, adjacent buildings, poles, and any other objects that are not part of the aerial platform. Such contact could make your body a conductor to the other object, creating an electrical shock hazard resulting in death or serious injury. If an aerial platform is in contact with an energized conductor the platform operator must warn ground personnel in the vicinity to stay away. Their bodies can conduct electricity creating an electrical shock hazard resulting in death or serious injury. Do not approach or leave the aerial platform until the electricity has been turned off. Do not attempt to operate the lower controls when the platform, boom structure, or any part of the aerial platform is in contact with a high-voltage electrical conductor or if there is an immediate danger of such contact. Personnel on or near an aerial platform must be continuously aware of electrical hazards, recognizing that death or serious injury can result from contact with an energized conductor. California Proposition 65 Warning Battery posts, terminals and related accessories contain lead and lead components, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. Snorkel International, Inc. all rights reserved Printed in the U.S.A.

3 Table of Contents Electrical Hazard... Inside front cover California Proposition Inside front cover General Information About This Manual... i Repairs and Maintenance... i Abbreviations... i Additional Information... i Service and Parts Information Ordering Parts... ii ANSI and OSHA Compliance... ii Manuals... ii Machine Information... ii Parts Order Form... iii Section 1 Repair Parts Chassis Assembly... 3 Tires and Wheels... 7 Steering Spindle Assembly Right Side...9 Steering Spindle Assembly Left Side Front Hub Assembly...13 Chassis Cover Assembly...15 Battery Tray Cover Assembly...17 Turntable Assembly Riser Boom Assembly Main Boom Assembly Wear Pad Assembly Jib Boom Assembly Platform Assembly...37 Placards and Decals Section 2 Hydraulics Hydraulic Power Unit Assembly... 3 Emergency Power Unit Assembly...5 Hydraulic Oil Return Filter Assembly...7 Brake Valve Assembly...9 Boom Function Control Valve Assembly Dual Proportional Control Valve Accumulator Assembly Steer Cylinder Hydratech Riser Boom Cylinder Hydratech Main Boom Lift Cylinder Hydratech Main Boom Extend Cylinder Hydratech Jib Cylinder Hydratech Master Level Cylinder Hydratech...27 Slave Level Cylinder Hydratech Platform Rotator Assembly...31 Hydraulic Plumbing...33 Hydraulic Hose Kit...37 Section 3 Electrical Chassis Wiring... 3 Electrical Panel Assembly...7 Contactor Assembly 48 V...9 Converter Assembly 48 VDC to 12 VDC Battery Charger Assembly 48 V Global Input...13 Battery Disconnect Panel Assembly...15 Level Sensor Assembly...17 Platform Foot Switch...19 Lower Control Panel Upper Control Panel Platform AC Power...33 Chassis Wiring Harness...35 Lower Controls to Drive Controller Wiring Harness...37 Lower Controls to Boom Controller Wiring Harness..39 Lower Controls to Brake Release Valve Wiring Harness...41 Lower Controls to Level Sensor Wiring Harness...43 Lower Controls to Boom Function Valve Wiring Harness...45 Lower Controls to Upper Controls Wiring Harness...47 Lower Controls to Upper Controls Wiring Harness 12/8 Conductor...49 Lower Controls to Upper Controls Wiring Harness 18/19 Conductor...51 Down Limit Switch Wiring Harness Boom Extend Limit Switch Wiring Harness Horn Wiring Harness Motion Alarm Wiring Harness...59 Amber Beacon Wiring Harness...61 Platform Foot Switch Wiring Harness Section 4 Options Dual Amber Beacon... 3 Motion Alarm... 5 Tow Package... 7 Airline to Platform CSA Package...15 Section 5 Maintenance Maintenance... 3 Daily Prestart Inspection... 5 Frequent Inspection and Maintenance... 7 Annual Maintenance Major Repairs Lubrication Points Batteries...16 Fastener Torque Chart Appendix Electrical Schematic Hydraulic Schematic Limited Warranty A46JE/AB46JE

4 A46JE/AB46JE

5 General Information About This Manual This manual covers AB46JE aerial platform. Information is included for machines that have been manufactured to conform to all applicable requirements of the following organizations: American National Standards Institute (ANSI) Canadian Standards Association (CSA) Part pages include a drawing and a bill of material. The bill of material lists the item number that is on the drawing, the Snorkel part number, quantity used and a description of the item. Some callouts in the drawings may have a balloon with two numbers. The top number is the item number and the bottom number is the quantity of the item at that location. While Snorkel has attempted in every way to confirm that all information in this manual is correct, improvements are being constantly made to the machine that may not be reflected in this manual. If you find information in this manual that is not correct or is confusing, you are urged to report your findings to Snorkel for our evaluation. Your input is important to us and will be used in future printings of this manual. This machine is covered by a limited warranty that specifically identifies items warrantied by Snorkel and those items covered by original manufacturer's warranty. A copy of the Snorkel Limited Warranty is located on the inside of the back cover of this manual. Repairs and Maintenance Every person who maintains, inspects, tests or repairs the machine must be qualified and authorized to do so. Caution Do not modify this aerial platform without prior written consent of Snorkel Engineering Department. Modification may void the warranty, adversely affect stability or affect the operational characteristics of the aerial platform. Abbreviations The following abbreviations may be used in this manual. AC ANSI AR CCA cm DC ft GFCI in lbs mm no NPT psi qty rpm UL alternating current American National Standards Institute as required cold cranking amps centimeter direct current feet ground fault circuit interruptor inch pounds millimeter number national pipe thread pounds per square inch quantity revolutions per minute Underwriters Laboratories Inc. Additional Information All correspondence relative to this machine, such as field reports, discrepancy reports, requests for information, etc., should be directed to: Snorkel International, Inc. P.O. Box 1160 St. Joseph, MO USA Phone: A46JE/AB46JE i

6 Service and Parts Information Ordering Parts When placing an order for service or repair parts, please have the following machine information readily available. Model number Serial number Snorkel part number Description of part Quantity of parts required Your purchase order number Address for order to ship to The desired shipment method The parts order form on the following page may be mailed or faxed to the attention of the Parts Department at the following location: Snorkel International, Inc. P.O. Box 1160 St. Joseph, MO USA Phone: Parts Fax: Attention: Parts Department For your convenience, our electronic on-line ordering system is available at the following Internet location: ANSI and OSHA Compliance All owners and users of the aerial platform must read, understand and comply with all applicable regulations. Ultimate compliance to OSHA regulations is the responsibility of the user and their employer. ANSI publications clearly identify the responsibilities of all personnel who may be involved with the aerial platform. A reprint of the Manual of Responsibilities for Dealers, Owners, Users, Operators, Lessors and Lessees of ANSI/SIA A Boom-Supported Elevating Work Platforms is available from Snorkel dealers or from the factory upon request. Copies are also available from: Manuals Manuals are available from Snorkel to support any of the machines that we produce. The specific manuals for A46JE and AB46JE aerial platforms are as follows: A46JE Operator s Manual ANSI Snorkel part number A46JE Operator s Manual CE Snorkel part number AB46JE Operator s Manual ANSI Snorkel part number July 2008 AB46JE Operator s Manual CE Snorkel part number August 2008 A46JE/AB46JE Repair Parts Manual Snorkel part number ANSI Manual of Respobsibilities ANSI/SIA A Snorkel part number Machine Information Model Number: Serial Number: Date of Purchase: Purchased From: Snorkel Dealer or Distributor: Scaffold Industry Association, Inc. P.O. Box Phoenix, AZ USA ii A46JE/AB46JE

7 Parts Order Form Fill out completely and fax to , attention Parts Department. Date: Company: Address: Account Number: Purchase Order Number: Model Number: Serial Number: Ship To: Contact Name: Phone Number: Fax Number: Shipping Method: Part Number Description Quantity Note: Backordered parts will be shipped as soon as available using the same shipping method as the original order unless otherwise indicated below. Ship complete order only. Do not backorder parts. Ship all available parts and disposition of backordered parts. Other instructions as specified: A46JE/AB46JE iii

8 A46JE/AB46JE

9 Repair Parts A46JE/AB46JE Repair Parts 1

10 Repair Parts 2 A46JE/AB46JE

11 Chassis Assembly Repair Parts 3

12 Repair Parts 4 Chassis Assembly

13 Item Part No. Qty. Description Chassis Assembly CHASSIS WELDMENT AB46JE STEERING CYLINDER ASSEMBLY (refer to hydraulics 17) STEERING SPINDLE ASSY, RH (refer to repair parts 9) STEERING ARM FRONT HUB ASSY (refer to repair parts 13) ELECTRICAL PANEL ASSEMBLY (refer to electrical 7) STEERING SPINDLE ASSY, LH (refer to repair parts 11) ROTATION BEARING BATTERY TRAY WELDMENT CONVERTER ASSEMBLY (refer to electrical 11) battery CHARGER ASSEMBLY (refer to electrical 13) PUMP ASSEMBLY EM POWER, 48V (refer to hydraulics 5) Battery disconnect panel ASSEMBLY (refer to electrical 15) BRAKE VALVE ASSEMBLY (refer to hydraulics 9) hydraulic POWER UNIT ASSEMBLY (refer to hydraulics 3) BEARING SLEEVE STEERING PIN-LONG STEERING PIN - SHORT BLT HEXHD M MM WSHR FLAT M NUT HEX LKG M BLT SKTHD SHLDR HEX NUT HEX LKG BEARING SLEEVE SEAL GARLOCK #71X THRUST WASHER GARLOC SEAL PARKER STEERING PIN CAP WSHR LOCK M BLT HEXHD M MM WSHR, FLAT HARD.653 SP BLT, FLGHD M MM 12PT ANGLE BATTERY TRAY MOUNT WSHR FLAT 1 x 1.5 x PIN COT.125DIA 2.00LG NUT LUG 5/ WSHR FLAT HARD.625 SP BLT HEXHD GR RING-INNER MOTOR ELEC 48VDC DRIVE XP O-RING 4.75ID 4.94OD D HUB-PLANETARY LEVELING SENSOR ASSEMBLY (refer to electrical 17) chassis COVER ASSEMBLY (refer to repair parts 15) battery tray COVER ASSEMBLY (refer to repair parts 17) BATTERY US #L NUT HEX CASTLE BLT HEXHD WSHR FLAT BLT HEXHD GR CONTACTOR 48V N0 ASSEMBLY (refer to electrical 9) O-RING.250 ID.375 od.063 AS Chassis Assembly A46JE/AB46JE Repair Parts

14 Repair Parts 6 A46JE/AB46JE

15 Item Part No. Qty. Description Tires and Wheels tire and wheel, nonmarking foam filled assembly Decal, danger foam filled tires Not shown tire and wheel, nonmarking foam filled left/right side assembly wheel, left/right side tire, nonmarking Tires and Wheels ABETW A46JE/AB46JE Repair Parts 7

16 Repair Parts 8 A46JE/AB46JE

17 Item Part No. Qty. Description Steering Spindle Assembly Right Side STEERING SPINDLE PIN, STEERING PIVOT CHROME PL BLT HEXHD M MM WSHR FLAT HARD.625 SP NUT HEX M Steering Spindle Assembly Right Side A46JE/AB46JE Repair Parts 9

18 Repair Parts 10 A46JE/AB46JE

19 Item Part No. Qty. Description Steering Spindle Assembly Left Side STEERING SPINDLE PIN, STEERING PIVOT CHROME PL WSHR FLAT HARD.625 SP BLT HEXHD M MM NUT HEX M Steering Spindle Assembly Left Side A46JE/AB46JE Repair Parts 11

20 Repair Parts 12 A46JE/AB46JE

21 Item Part No. Qty. Description Front Hub Assembly FRONT HUB BRG. TAPER ROLLER WHEEL BEARING GREASE CAP WHEEL BeARING GREASE SEAL BRG. TAPER ROLLER Front Hub Assembly A46JE/AB46JE Repair Parts 13

22 Repair Parts 14 A46JE/AB46JE

23 Item Part No. Qty. Description Chassis Cover Assembly COVER LATCHDRAW BLT HEXHD M MM WSHR FLAT M NUT LKG M Chassis Cover Assembly A46JE/AB46JE Repair Parts 15

24 Repair Parts 16 A46JE/AB46JE

25 Item Part No. Qty. Description Battery Tray Cover Assembly COVER, BATTERY TRAY LATCHDRAW WSHR FLAT M BLT HEXHD M MM NUT LKG M Battery Tray Cover Assembly A46JE/AB46JE Repair Parts 17

26 Repair Parts 18 A46JE/AB46JE

27 Turntable Assembly Repair Parts 19

28 Repair Parts 20 Turntable Assembly

29 Item Part No. Qty. Description Turntable Assembly grease fitting bracket, hydraulic filter weldment turntable cover hinge bar Boom function control valve assembly (refer to hydraulics 11) swing drive guard weldment, pinion gear shim, rest pad 1.5 mm shim, rest pad 3 mm spacer tube stop weldment counterweight, rear counterweight, left side counterweight, right side turntable cover, left turntable cover, right rest pad rest pad, long tubing, nylon fitting bulkhead spring cylinder, poly latch hinge, turntable cover bracket bracket bracket cap plug ww turntable post weldment mounting plate Hydraulic oil return filter assembly (refer to hydraulics 7) Bolt, hexhd x.625 gr bolt, hexhd x 1.00 gr5 plated bolt, hexhd m x 18 mm nut, hex m washer, flat washer, flat washer, flat washer, flat washer, lock washer, lock horn 12 vdc adapter, male pipe fitting elbow 90 strthd -12b -8s stl fitting elbow 45 swvl -8s -8s stl fitting adaptor strthd -12b-8s stl filter condition gauge Bolt, hexhd x 2.50 gr Bolt, hexhd M x 25 MM washer, flat M washer, lock M washer, FLAT M washer, FLAT 12 MM nut, hex LKG m Bolt, hexhd M x 120 MM nut, hex LKG m washer, flat M Bolt, hexhd M x 140 MM Bolt, hexhd M x 12 MM Continued on next page Turntable Assembly A46JE/AB46JE Repair Parts 21

30 Item Part No. Qty. Description Turntable Assembly Bolt, hexhd M x 12 MM lg bolt, hexhd m x 20 mm bolt, hexhd m x 35 mm bolt, hexhd m x 60 mm mounting plate valve block washer, flat hard.653 sp bolt, flgd m mm hex sp clip, cushion 2.25 vinyl coated accumulator assembly (refer to hydraulics 15) hexhd capscrew unc stl gr lg nut, hex lkg unc washer, flat.375 standard plated lower control Panel (refer to electrical 21) Turntable Assembly Repair Parts 22 A46JE/AB46JE

31 Riser Boom Assembly Repair Parts 23

32 Repair Parts 24 Riser Boom Assembly

33 Item Part No. Qty. Description Riser Boom Assembly Pin roll.375 dia rod end 3/8 x rod end 1/2 x 3 1/ riser post weldment tension link weldment st tension rail front riser weldment nd riser boom weldment st riser boom weldment pin 1.75 dia pin 1.75 dia pin 1.75 dia pin 1.75 dia pin 1.75 dia pin 1.75 dia nd tension rail weldment lever switch rest pad hose guard pin 1.75 dia pin 1.75 dia pin 1.75 dia 38 mm pin 1.75 dia cylinder, riser boom (refer to hydraulics 19) cylinder, main boom lift (refer to hydraulics 21) cylinder, master level (refer to hydraulics 27) Nut, hex lkg m washer, flat m nut lkg.500 hub electrical strain relief ft grommet edge cover (sold by the foot) ft grommet edge cover (sold by the foot) washer, lock m Bolt, hexhd M x 25 MM washer, flat M Bolt, hexhd M x 30 MM Bolt, hexhd M10 85 MM nut, hex LKG m screw, rd hd m5 x 30 mm Bolt, hexhd M MM bearing sleeve bearing sleeve bearing sleeve bearing sleeve nut, hex m hose guard clamp, hose retainer Riser Boom Assembly A46JE/AB46JE Repair Parts 25

34 Repair Parts 26 A46JE/AB46JE

35 Main Boom Assembly Repair Parts 27

36 Repair Parts 28 Main Boom Assembly

37 Item Part No. Qty. Description Main Boom Assembly tip boom weldment main boom weldment snap ring, external shim wear strip, polyethylene wear strip, polyethylene wear pad wear pad retainer plate wear pad 2 x 4 x 3/8" retainer, puck wear pad wear pad, puck wear pad, cassette wear pad, retainer bar bar, cat track retainer Boom Extend limit switch wear pad, top tip boom hose -4-4s90-4s r assembly, wear pad (refer to repair parts 31) shim, dia shim, bearing sleeve bearing sleeve rod end 3/8 x pin 1.25 dia pin 1.75 dia extension tube weldment extension tube mounting bar support bracket cat track hose guard clamp, hose retaining pin 1.5 dia pin 1.25 dia cylinder, Main boom extend (refer to hydraulics 23) Bolt, hexhd M x 20 MM nut, hex m fitting, elb90 blhd -4s-4s stl nut, hex LKG m washer, lck m washer, flat m Bolt, hexhd M x 30 MM Bolt, hexhd M x 35 MM nut, hex LKG M screw, button head m8 x bolt, skthd screw, flat head m x16 mm Bolt, hexhd M x 20 MM stud, m x 20 mm stud, m5-0.8 x 40 mm screw, button head m x 16 mm nut, hex lkg m screw, hex skt set m6-1.0 x 10 mm bolt, fshcs m mm bolt, hexhd m mm bolt, hexhd m6-1.0 x 20 mm Main Boom Assembly A46JE/AB46JE Repair Parts 29

38 Repair Parts 30 A46JE/AB46JE

39 Item Part No. Qty. Description Wear Pad Assembly extend cylinder pad weldment wear pad 2 x 4 x 3/ upper wear pad bolt, flskthd m nut, hex lkg m bolt, flskthd m bolt, skthd m nut, hex lkg m Wear Pad Assembly A46JE/AB46JE Repair Parts 31

40 Repair Parts 32 A46JE/AB46JE

41 Jib Boom Assembly Jib Boom Assembly A46JE/AB46JE Repair Parts 33

42 Repair Parts 34 A46JE/AB46JE

43 Item Part No. Qty. Description Jib Boom Assembly Bearing sleeve Bearing sleeve Bearing sleeve Bearing sleeve rod end 3/8 x rod end 1/2 x 3 1/ swinging frame weldment jib boom weldment leveling tube weldment pin 1.25 dia pin 1.25 dia pin 1.25 dia hose guard, jib hose clamp, jib Platform rotator assembly (refer to hydraulics 31) pin, lower jib pin, stepped pin 1.75 dia jib cylinder (refer to hydraulics 25) slave cylinder (refer to hydraulics 29) bolt, skthd 1/4-20 x 1 3/ Nut, hex lkg m Nut, hex lkg m fitting elbow 90 strthd -4b -4s stl fitting elbow 90 strthd -6b -4s stl adapter 90 deg elbow swivel -4 jic fitting adapter strthd -6b-4s stl washer, lock m bolt, hexhd m mm washer flat m bolt, hexhd m10 65mm Jib Boom Assembly A46JE/AB46JE Repair Parts 35

44 Repair Parts 36 A46JE/AB46JE

45 Platform Assembly Repair Parts 37

46 Repair Parts 38 Platform Assembly

47 Item Part No. Qty. Description Platform Assembly WELDMENT PLATFORM 6FT CAGE MOUNT grip strut LIFT GATE PANEL, DECAL MOUNT ROLLER TUBE, GATE BRACKET CHAIN TIE DOWN anchor plate rotator adaptor plate upper control panel ASSmbly, (refer to electrical 27) LIFT GATE ANGLE BRACKET DIAMOND WASHER platform foot SWITCH, (refer to electrical 19) WIRE HARNESS, FOOT SWITCH, (refer to electrical 63) WaSHeR, LOCK M BoLT, HEXHD M MM WaSHeR, LOCK M BoLT, SKTHD BoLT, HEXHD M MM GR NUT, HEX LKG M NUT, HEX LKG M BoLT, HEXHD M MM WASHER SPRING LOCK M NUT, HEX M WaSHeR, FLAT M WaSHeR, FLAT NUT LKG BoLT, Carriage X NUT HEX LKG BoLT, HEXHD M MM BoLT HEXHD M X 35MM BoLT, HEXHD M X 120MM WaSHeR, FLAT M NUT, HEX LKG M ft HOSE GUIDE.125 RUBBER EDGE cover platform AC POWER, (refer to electrical 33) harness, 110V cable not shown LITERATURE COMPARTMENT WaSHeR, FLAT 1 x 1.5 x Australia platform included items 1 through toeboard cage entry item not shown screw slftpg type b item not shown Platform Assembly A46JE/AB46JE Repair Parts 39

48 Repair Parts 40 A46JE/AB46JE

49 Placards and Decals L e ft S id e R ig h t S id e U p p e r C o n tro l B o x 3 5 Placards and Decals P la tfo rm AB46JE Decals A46JE/AB46JE Repair Parts 41

50 Repair Parts 42 A46JE/AB46JE

51 Item Part No. Qty. Description Placards and Decals DECAL AB46JE LOGO 5" DECAL snorkel 5" DECAL DaNGeR DO NOT ALTER SWitch DECAL battery charger plug DECAL HYDRAULIC OIL DECAL ASSEMBLED IN THE USA DECAL snorkel 4" DECAL DaNGeR DESCENDING BOOM DECAL danger ELECtrical HAZARD DECAL, AB46JE LOGO 3.5" DECAL DaNGeR CYLINDER FAILURE one per cylinder DECAL LIFT/TIE DOWN DECAL DIRectional ARROWS FR MT FWD/RVS DECAL power to platform DECAL danger ELECtrocution HAZARD DECAL circuit breaker DECAL prestart instructions DECAL ROTATE WHILE GREASING DECAL battery charging instructions DECAL side load DECAL danger ELECtrocution HAZARD DECAl DECAL snorkel 5" DECAL DANGER DO NOT OPERATE DECAL DIRECTION ARROWS FWD/RVS PLACard CAUTioN SERIAL NUMBER DECAL CAUTioN PLATform CONTROLS PLACard PLATForm IDENTIFICATION DECAL NOTICE MANUAL RE-ORDER COMPARTMENT LITERATURE 8.5X DECAL MANUAL HOLDER DECAL danger ELECtrocution HAZARD DECAL DaNGeR HI AMP/ELEC DECAL danger you must not operate PLACard turn key off E 4 placard 227 kg 2 person capacity decal danger foam/solid tires decal attach fall restraint placard lower control box placard upper control box front placard upper control box top Decal danger electrical/tipping hazard decal battery service instructions placard battery disconnect Placards and Decals AB46E Decals A46JE/AB46JE Repair Parts 43

52 Repair Parts 44 A46JE/AB46JE

53 Hydraulics A46JE/AB46JE Hydraulics 1

54 Hydraulics 2 A46JE/AB46JE

55 Item Part No. Qty. Description Hydraulic Power Unit Assembly POWER UNIT WaSHeR, FLAT HARD WaSHeR, LOCK M BoLT, HEXHD GR NUT HEX LKG FTG TEE SWVL RUN-6S-6S STL FTG ELB90SWVL-6S-6S STL FTG NIP DIGN-6S FEM FTG ELB90SWVL-8S-8S STL FTG RDCR-8S-6S W/O NUT STL FTG NUT-8S STL FTG ADPTR STRTHD-6B-6S STL-PH FTG ADPTR MALE-8N-8S STL FTG ADPTR MALE-12N-8S STL FTG TEE SWVL BR-8S-8S STL SIGHT GAGE Hydraulic Power Unit Assembly A46JE/AB46JE Hydraulics

56 Hydraulics 4 A46JE/AB46JE

57 Item Part No. Qty. Description Emergency Power Unit Assembly EMergency POWER PUMP, 48V FTG ELB90STRTHD-8B-8S STL FTG ELB90SWVL-6S-6S STL FTG ADPTR STRTHD-8B-6S STL BLT HEXHD M MM WaSHeR, FLAT M NUT HEX LKG M Emergency Power Unit Assembly A46JE/AB46JE Hydraulics 5

58 Hydraulics 6 A46JE/AB46JE

59 Item Part No. Qty. Description Hydraulic Oil Return Filter Assembly Hydraulic Oil Return Assembly (Includes Items 1 through 5) Return Oil filter (Includes Item 5) ftg elb90strthd -12b-8s stl adapter straight -12 sae to -8 jic ftg elb 45 swvl -8s-8s stl filter element, spin on filter condition gauge Hydraulic Oil Return Filter Assembly A46JE/AB46JE Hydraulics 7

60 Hydraulics 8 A46JE/AB46JE

61 Item Part No. Qty. Description Brake Valve Assembly Brake VALVE ASSemblY, E-DRIVE BoLT HEXHD GR5-GRA WaSHeR LOCK WaSHeR FLAT FTG TEE STRTHD RUN-4B-4S STL FTG ELB90STRTHD-4B-4S STL FTG ELB90STRTHD-4B-6S STL FTG NIP DIGN-6S FEM FTG ADPTR STRTHD-4B-4S STL FTG ELB90SWVL-4S-4S STL Brake Valve Assembly A46JE/AB46JE Hydraulics 9

62 Hydraulics 10 A46JE/AB46JE

63 Item Part No. Qty. Description Boom Function Control Valve Assembly DUAL PROPORTIONAL CONTROL valve assy (refer to hydraulics 13) FTG ELB90STRTHD-4B-4S STL FTG ELB45STRTHD-4B-4S STL FTG ELB45STRTHD-6B-6S STL-PH FTG TEE SWVL RUN-8S-8S STL FTG ELB45SWVL-4S-4S STL FTG ELB90SWVL-4S-4S STL FTG ADPTR STRTHD-4B-4S STL FTG ADPTR STRTHD-6B-4S STL FTG ADPTR STRTHD-12B-8S STL FTG NIP DIGN-4S FEM ORIFICE ORIFICE DRIVER MOD, EVDR1, PROGRAMED DRIVER MOD, EVDR1, PROGRAMED FTG TEE TEE SWVL RUN-4-4F jic Boom Function Control Valve Assembly A46JE/AB46JE Hydraulics 11

64 Hydraulics 12 A46JE/AB46JE

65 Item Part No. Qty. Description Dual Propotional Control Valve VALVE, SOLENOID CART 3-POS 4WAY CC SOLENOID VALVE SOLENOID VALVE SOLENOID VALVE ELECTRO-PROPORTIONAL VALVE RELIEF VALVE RELIEF VALVE RELIEF VALVE SHUTTLE VALVE ORIFICE PLATE COIL COIL LOGIC ELEMENT VALVE, PILOTED CHECK VALVE VALVE CART CHECK 1 Dual Propotional Control Valve A46JE/AB46JE Hydraulics 13

66 Hydraulics 14 A46JE/AB46JE

67 Item Part No. Qty. Description Accumulator Assembly ACCUMULATOR 300 psi seal kit item not shown FTG RDCR-8S-4S W/O NUT STL FTG NUT-8S STL FTG ELB90SWVL-4S-4S STL FTG ADPTR STRTHD-12B-8S STL Accumulator Assembly A46JE/AB46JE Hydraulics 15

68 Hydraulics 16 A46JE/AB46JE

69 Item Part No. Qty. Description Steer Cylinder Hydratech STEERING CYLINDER seal kit BLT HEXHD GR WSHR FLAT NUT HEX LKG GR8 Steer Cylinder Hydratech A46JE/AB46JE Hydraulics 17

70 Hydraulics 18 A46JE/AB46JE

71 Item Part No. Qty. Description Riser Boom Cylinder Hydratech CYLINDER, riser boom seal kit counterbalance holding valve Riser Boom Cylinder Hydratech A46JE/AB46JE Hydraulics 19

72 Hydraulics 20 A46JE/AB46JE

73 Item Part No. Qty. Description Main Boom Lift Cylinder Hydratech CYLINDER, main boom lift seal kit Main Boom Lift Cylinder Hydratech A46JE/AB46JE Hydraulics 21

74 Hydraulics 22 A46JE/AB46JE

75 Item Part No. Qty. Description Main Boom Extend Cylinder Hydratech CYLINDER, main boom extend seal kit counterbalance holding valve shuttle valve Main Boom Extend Cylinder Hydratech A46JE/AB46JE Hydraulics 23

76 Hydraulics 24 A46JE/AB46JE

77 Item Part No. Qty. Description Jib Cylinder Hydratech CYLINDER, jib seal kit counterbalance holding valve Jib Cylinder Hydratech A46JE/AB46JE Hydraulics 25

78 Hydraulics 26 A46JE/AB46JE

79 Item Part No. Qty. Description Master Level Cylinder Hydratech CYLINDER, master level seal kit counterbalance holding valve Master Level Cylinder Hydratech A46JE/AB46JE Hydraulics 27

80 Hydraulics 28 A46JE/AB46JE

81 Item Part No. Qty. Description Slave Level Cylinder Hydratech CYLINDER, slave level seal kit counterbalance holding valve Slave Level Cylinder Hydratech A46JE/AB46JE Hydraulics 29

82 Hydraulics 30 A46JE/AB46JE

83 Item Part No. Qty. Description Platform Rotator Assembly platform rotator assembly Platform Rotator Assembly A46JE/AB46JE Hydraulics 31

84 Hydraulics 32 A46JE/AB46JE

85 A26011B Hydraulic Plumbing Hydraulics 33

86 Hydraulics 34 Hydraulic Plumbing A26011B

87 Item Part No. Qty. Description Hydraulic Plumbing HOSE-6-6S-6S R HOSE-4-4S-4S HOSE-6-6S-6S R HOSE-4-4S-4S R HOSE-4-4S-4S R HOSE-8-8S-8S R HOSE-8-8S-8S R HOSE-6-6S-6S R HOSE-8-8S-8S 72 SP HOSE-4-4S-4S R HOSE -4-4S-4S R HOSE -4-4S-4S R HOSE -4-4S-4S R HOSE -4-4S-4S R HOSE -4-4S-4S R HOSE -4-4S-4S R HOSE -4-4S-4S R HOSE-6-6S-6S R2 Hydraulic Plumbing A26011B A46JE/AB46JE Hydraulics 35

88 Hydraulics 36 A46JE/AB46JE

89 Item Part No. Qty. Description Hydraulic Hose Kit HOSE-6-6S-6S R HOSE-4-4S-4S HOSE-6-6S-6S R HOSE-4-4S-4S R HOSE-4-4S-4S R HOSE-8-8S-8S R HOSE-8-8S-8S R HOSE-6-6S-6S R HOSE-8-8S-8S 72 SP HOSE-4-4S-4S R HOSE -4-4S-4S R HOSE -4-4S-4S R HOSE -4-4S-4S R HOSE -4-4S-4S R HOSE -4-4S-4S R HOSE -4-4S-4S R HOSE -4-4S-4S R HOSE -4-4S90-4S R HOSE-6-6S-6S R2 Hydraulic Hose Kit A46JE/AB46JE Hydraulics 37

90 Hydraulics 38 A46JE/AB46JE

91 Electrical A46JE/AB46JE Electrical 1

92 Electrical 2 A46JE/AB46JE

93 L e ve l S e n sor B a tte rie s L o w e r C o n tro l P a n e l B a tte rie s E le ctrica l P a n e l A sse m b ly E m e rg e n cy P u m p C o n ta cto r E m e rg e n cy P o w e r U n it B ra ke Va lve H yd ra u lic P o w e r U n it-b o o m P u m p D rive M o to r D rive M o to r C o n ve rte r 4 8 V D C to 1 2 V D C B a tte ry C h a rg e r B a tte ry D isco n n e ct P a n e l A26008C Chassis Wiring Electrical 3

94 Electrical 4 Chassis Wiring A26008C

95 Item Part No. Qty. Description Chassis Wiring diode assembly r101 r battery wire right side battery wire left side battery wire center wire 2 r312i r312i 36 blk wire 2/0 r375 r blk wire 10 r313i r250i 48 wht sp wire 2 r313i r313i 66 red wire 10 r313i r250i 24 wht sp wire 2/0 r375 r red wire 2 r312 r red wire 4 r313i r375i wire 2 r313i r313i 10 blk wire 2 r375i r375i 26 blk wire 2 r375 r375 9 blk boot battery cable end blk 4ga boot battery cable end blk 1/ boot battery cable end y-type cover battery terminal wire harness, e chassis (refer to electrical 35) wire harness, drive controller (refer to electrical 37) wire harness, boom controller (refer to electrical 39) wire harness, level sensor (refer to electrical 43) wire harness, brake valve (refer to electrical 41) terminal male 250fi 22/18 Chassis Wiring A26008C A46JE/AB46JE Electrical

96 Electrical 6 A46JE/AB46JE

97 Item Part No. Qty. Description Electrical Panel Assembly FUSE BUSS 350 AMP FUSE BUSS 125 AMP FUSE BUSS BLOCK # PUMP CONTROLLER, 48V 600A MTG PLATE, CONTROLLER CONTACTOR 48V N0 ASSEMBLY, (refer to electrical 9) MOTOR CONTROLLER BUS BAR, CU, 2 CIRCUIT BUS BAR, CU, 2 CIRCUIT, 90DEG WaSHeR, LOCK M SCRew SKTBTNHD M6-1.0 X SCRew SKTBTNHD M6 X 1. X SCRew FLH SKT CP M5 -.8 X NUT, HEX LKG M BoLT HEXHD M10 40MM Drive contactor Drive controller Boom contactor Boom controller Electrical Panel Assembly A46JE/AB46JE Electrical 7

98 Electrical 8 A46JE/AB46JE

99 Item Part No. Qty. Description Contactor Assembly 48 V CONTACTOR 48V NO DIODE ASSY NUT HEX NUT HEX WaSHeR LOCK.250 split washer lock #10 split Contactor Assembly 48 V A46JE/AB46JE Electrical 9

100 Electrical 10 A46JE/AB46JE

101 Item Part No. Qty. Description Converter Assembly 48 VDC to 12 VDC CONVERTER, 48VDC TO 12VDC WaSHeR FLAT M BoLT HEXHD M MM NUT HEX M Converter Assembly 48 VDC to 12 VDC A46JE/AB46JE Electrical 11

102 Electrical 12 A46JE/AB46JE

103 Battery Charger Assembly 48 V Global Input Item Part No. Qty. Description CHARGER 48V, GLOBAL INPUT BoLT HEXHD M MM WSHR FLAT M NUT HEX LKG M nut lkg m hhcs m4 x 0.7 x 10 g CHARGE INDICATOR light Battery Charger Assembly 48 V Global Input A46JE/AB46JE Electrical 13

104 Electrical 14 A46JE/AB46JE

105 Item Part No. Qty. Description Battery Disconnect Panel Assembly DISCONNECT SWitch PANEL SWitch BATTERY DISCONNECT flange inlet 15a 125v BoLT HEXHD M MM WaSHeR FLAT M NUT HEX LKG M nut lkg m bolt hexhd m mm washer flat m4 Battery Disconnect Panel Assembly A46JE/AB46JE Electrical 15

106 Electrical 16 A46JE/AB46JE

107 Item Part No. Qty. Description Level Sensor Assembly LEVEL SENSOR 5 DEGREE BoLT HEXHD M MM WaSHeR FLAT M NUT HEX M Level Sensor Assembly A46JE/AB46JE Electrical 17

108 Electrical 18 A46JE/AB46JE

109 Item Part No. Qty. Description Platform Foot Switch foot switch replacement switch, square d switch, 4 pole NOT SHOWN Replacement switch, Square D switch, 8 pole wire harness, platform foot switch (refer to electrical 63) connector connector locknut corrosion inhibitor jumper strap - (used on Square D switch only ) B 1A 2A 2B Platform Foot Switch AW A46JE/AB46JE Electrical 19

110 Electrical 20 A46JE/AB46JE

111 Lower Control Panel Electrical 21

112 Electrical 22 Lower Control Panel

113 Connector Connects To Part # Page # J7 BOOM FUNCTION VALVE Electrical 45 J8 BOOM FUNCTION VALVE Electrical 45 J9 UPPER CONTROLS - J Electrical 47 J10 UPPER CONTROLS - J Electrical 47 J11 UPPER CONTROLS - J Electrical 51 J12 UPPER CONTROLS - J Electrical 51 J13 CHASSIS WIRE HARNESS Electrical 35 J14 UPPER CONTROLS - J Electrical 49 J15 LEVEL SENSOR Electrical 43 J17 BRAKE RELEASE VALVE Electrical 41 J18 DOWN LIMIT SWITCH Electrical 53 J19 BOOM EXTEND LIMIT SWITCH Electrical 55 J20 HORN Electrical 57 J21 DRIVE CONTROLLER Electrical 37 J22 BOOM CONTROLLER Electrical 39 J23 MOTION ALARM Electrical 59 J24 AMBER BEACON Electrical Lower Control Panel Electrical 23

114 Electrical 24 Lower Control Panel

115 Item Part No. Qty. Description Lower Control Panel WeLDMenT, lower CONTROL BOX e drive DIN RAIL, 14" LG CORD GRIP 3/4" RELAY, 48VDC, 1 POLE RELAY SOCKET, 1 POLE, DIN JUMPER, 2 PIN end cap terminal block RELAY SPST, 12 VOLT DC BLOCK TERMINAL ORANGE BLOCK TERMINAL TAN PANEL NUT, RECEPTACLE RELAY, 48VDC, 2 POLE BLOCK TERMINAL BLUE RELAY SOCKET, 2 POLE, DIN END BLOCK TERMINAL DIN RAIL, 4" LG RETAINER CLIP, 1 POLE RELAY RELAY SPRING CLIP, 2 POLE JUMPER, 4 PIN CONNECTOR 12-PIN LOCK WEDGE 12-PIN DEUTSCH 8-PIN BLKHD RCPT CONN LOCK WEDGE 8-PIN CONNECTOR, 4-PIN 16GA RECPT, BLKHD LOCK WEDGE 4-PIN CONNECTOR, 3-PIN BHD LOCK WEDGE 3-PIN CONNECTOR DEUTSCH 8PIN 12GA RECP CONNECTOR DEUTSCH 8SCKT 12GA RECEP PANEL WeLDMenT, CONTROL BOX emergency stop button PLACard, lower CONTROL E-DRIVE HOURMETER SWitch TGL SPDT (M/ON) SWitch TGL DPDT (M/OFF/M) CIRCUIT BREAKER 10 AMP CIRCUIT BREAKER 25 AMP switch contact blk n.c. and mount switch tgl dpdt (mom/on) sealed switch tgl dpdt (on/on) sealed key switch LIGHT, RED LED 12V.69DIA MTG a/r wire single conductor 16ga wht diode 3 amp 600v a/r wire single conductor 16ga blk pin contact size 12 deutsch pin contact size 16 deutsch CONN DEUTSCH RECEP 2 pin a/r wire single conductor 16ga blk a/r wire single conductor 16ga wht socket contact 12 deutsch lock wedge 2 pin deutsch Lower Control Panel A46JE/AB46JE Electrical 25

116 Electrical 26 A46JE/AB46JE

117 Upper Control Panel Electrical 27

118 Connector Connects To Part # Page # J1 LOWER CONTROLS - J Electrical 47 J2 LOWER CONTROLS - J Electrical 47 J3 LOWER CONTROLS - J Electrical 51 J4 LOWER CONTROLS - J Electrical 51 J5 LOWER CONTROLS - J Electrical 49 Electrical 28 Upper Control Panel J6 FOOT SWITCH Electrical 63

119 Upper Control Panel Electrical 29

120 Electrical 30 Upper Control Panel

121 Item Part No. Qty. Description Upper Control Panel weldment platform control box placard upper control box top placard front platform control box switch contact blk n.c. and mount alarm 97 dba dual tone 12/24 v switch toggle spst on off sealed switch toggle spst (on) off sealed switch toggle dpdt (on/off/on) switch toggle SPDT (on/off/on) sealed rheostat assembly rheostat knob terminal strip.188 tab 12 circuit connector 12 pin bhd deutsch connector 8 pin blkhd rcpt deutsch circuit breaker 10 amp connector 8 pin pnd 12ga rcpt deutsch connector 4 pin blkhd weldment hand support controller single axis w/tog two position push/pull switch relay spdt 12v 30 amp battery indicator pin contact size 16 16/18 ga pin contact -12 deutsch lock wedge 12-pin deutsch rec lock wedge 8-pin rec lock wedge 4-pin deutsch a/r wire 12ga single conductor wht a/r wire 12ga single conductor blk diode assembly terminal strip strap a/r wire 18ga single conductor blk a/r wire 18ga single conductor wht Upper Control Panel A46JE/AB46JE Electrical 31

122 Electrical 32 A46JE/AB46JE

123 Item Part No. Qty. Description Platform AC Power wire r10i r8si ELECTRICAL BOX DRILLED PLATE OUTLET BOX MTG NUT LKG HUB CONN CIRCUIT BREAKER 15 AMP RECEPTaCAL GFCI OUTLET 20AMP COVER GFCI OUTLET WEATHERPRooF WSHR FLAT M NUT HEX LKG M BoLT HEXHD M MM SCR HEXHD THD CTG Platform AC Power A46JE/AB46JE Electrical 33

124 Electrical 34 A46JE/AB46JE

125 Item Part No. Qty. Description Chassis Wiring Harness wiring harness, e chassis 48VDC to 12VDC Converter Assembly J13 Location Lower Control Panel Battery Charger Drive Controller Boom Contactor Emergency Pump Contactor Connector J17 Pin ID Pin Wire # A 82 B 1C C 82D D 6A E 3 F 83D G 3 H 3 Chassis Wiring Harness A46JE/AB46JE Electrical 35

126 Electrical 36 A46JE/AB46JE

127 Lower Controls to Drive Controller Wiring Harness Item Part No. Qty. Description wiring harness, drive controller J21 Location Lower Control Panel Drive Controller Drive Contactor Connector J21 and J23 Pin ID Pin # Wire # Description 1 82D 48V INPUT 2 17 FORWARD 3 18 REVERSE 4 83A FOOT SW INPUT 5 34 CUT BACK SP # CUT BACK SP # BRAKE RELEASE 8 82D LINE CONTACTOR 9 3D LED FAULT LIGHT ACCEL POT INPUT 11 NOT USED 12 NOT USED Lower Controls to Drive Controller Wiring Harness A46JE/AB46JE Electrical 37

128 Electrical 38 A46JE/AB46JE

129 Lower Controls to Boom Controller Wiring Harness Item Part No. Qty. Description wiring harness, boom controller J22 Location Lower Control Panel Boom Controller Connector J22 Pin ID Pin # Wire # Description 1 82D 48V INPUT 2 3D FAULT SIGNAL FLOW A FLOW "C" SIGNAL FLOW "B" SIGNAL FLOW "D" SIGNAL FLOW "E" SIGNAL 8 16A ACCEL POT INPUT 9 NOT USED 10 NOT USED 11 NOT USED 12 NOT USED Connector J24 Pin ID Pin # Wire # Description 1 82D 48V INPUT FLOW A FLOW "C" SIGNAL FLOW "B" SIGNAL FLOW "D" SIGNAL FLOW "E" SIGNAL 7 NOT USED 8 3D FAULT SIGNAL 9 NOT USED 10 16A ACCEL POT INPUT 11 NOT USED 12 NOT USED Lower Controls to Boom Controller Wiring Harness A46JE/AB46JE Electrical 39

130 Electrical 40 A46JE/AB46JE

131 Lower Controls to Brake Release Valve Wiring Harness Item Part No. Qty. Description wiring harness, brake release valve Brake Release Valve J17 Location Lower Control Panel Connector J17 Pin ID Pin # Wire # A Lower Controls to Brake Release Valve Wiring Harness A46JE/AB46JE Electrical 41

132 Electrical 42 A46JE/AB46JE

133 Lower Controls to Level Sensor Wiring Harness Item Part No. Qty. Description wiring harness level sensor J15 Location Lower Control Panel Level Sensor Connector J15 and Level Sensor Pin ID Pin # Wire # Description A 1D AUX CIRCUIT B 73 TILT ALARM SIGNAL C 3 GROUND Lower Controls to Level Sensor Wiring Harness A46JE/AB46JE Electrical 43

134 Electrical 44 A46JE/AB46JE

135 Lower Controls to Boom Function Valve Wiring Harness Item Part No. Qty. Description wiring harness, valve block Location A Lower Control Panel Location B Boom Function Valve Pin # Wire # Description Location J STEER RIGHT J STEER LEFT J7-9 J7-8 J7-1 J LEVEL UP J LEVEL DOWN J8-2 22C JIB UP J8-3 21C JIB DOWN J7-4 22B MAIN BOOM UP A and B J7-5 21B MAIN BOOM DOWN J BOOM EXTEND J BOOM RETRACT J A RISER UP J A RISER DOWN J PLATF ROTATE CCW J PLATF ROTATE CW J SWING CCW J SWING CW J GROUND Lower Controls to Boom Function Valve Wiring Harness A46JE/AB46JE Electrical 45

136 Electrical 46 A46JE/AB46JE

137 Lower Controls to Upper Controls Wiring Harness Item Part No. Qty. Description wiring harness, upper Control functions J1 and J2 Location Upper Control Panel J9 and J10 Location Lower Control Panel Connector J1 and J9 Pin ID Pin # Wire # Rex # Rex Color BLACK/RED BROWN/BLACK BLACK/BLUE 4 22B 7 RED/BLACK 5 21B 19 ORANGE/BLUE YELLOW/RED BROWN 8 16A 3 BLUE 9 16B 4 ORANGE 10 22A 2 RED 11 21A 5 YELLOW 12 NONE NONE - Connector J2 and J10 Pin ID Pin # Wire # Rex # Rex Color BROWN/RED 2 22C 9 ORANGE/BLACK 3 21C 18 RED/BLUE BROWN BLACK ORANGE/RED BLUE/RED BLUE/BLACK Lower Controls to Upper Controls Wiring Harness A46JE/AB46JE Electrical 47