Upright AB46 I Guide

AB46 I/C
Service &
Parts Manual
Service &
Parts Manual
2 WHEEL DRIVE
WORK PLATFORMS

Call Toll Free in U.S.A.
1-800-926-LIFT
UpRight, Inc.
1775 Park Street
Selma, California 93662
TEL: [phone]
FAX: [phone]
PARTS: 1-888-UR-PARTS
PARTSFAX: 209/896-9244
SERVICE & PARTS
MANUAL
AB46
2WD - I/C Models
Serial Numbers 1000 to current
When contacting UpRight for service or parts
information, be sure to include the MODEL
and SERIAL NUMBERS from the equipment
nameplate. Should the nameplate be missing
the SERIAL NUMBER is also stamped on top of
the chassis above the front axle pivot.
068343-001
068343-001 9805 .5 D
Stamped
Serial Number

Foreword
AB46 Work Platform i
i
1.0
2.0
3.0
4.0
5.0
6.0
Introduction &
Specifications
General description and machine specifications.
Operation
Operating instructions and safety rules.
Maintenance
Preventative maintenance and service information.
Troubleshooting
Causes and solutions to typical problems.
Schematics
Schematics and valve block diagram with
description and location of components.
Illustrated Parts
Breakdown
Complete parts lists with illustrations.
Introduction
HOW TO USE THIS MANUAL
This manual is divided into 6 sections. The right hand
pages of each section is marked with a black tab that lines
up with one of the thumb index tabs on the right side of
this page. You can quickly find each section without
looking through the table of contents which follows this
page. The section number printed at the top corner of each
page can also be used as a quick reference guide.
SPECIAL INFORMATION
Indicates the hazard or unsafe practice will
result in severe injury or death.
Indicates the hazard or unsafe practice
could result in severe injury or death.
Indicates the hazard or unsafe practice could
result in minor injury or property damage.
NOTES: Give helpful information.
WORKSHOP PROCEDURES
CAUTION: Detailed descriptions of standard workshop
procedures, safety principles and service operations are not
included. Please note that this manual does contain warn-
ings and cautions against some specific service methods
which could cause personal injury, or could damage a
machine or make it unsafe. Please understand that these
warnings cannot cover all conceivable ways in which service,
whether or not recommended by UpRight, Inc., might be
done, or of the possible hazardous consequences of each
conceivable way, nor could UpRight Inc. investigate all such
ways. Anyone using service procedures or tools, whether or
not recommended by UpRight Inc., must satisfy themselves
thoroughly that neither personal safety nor machine safety
will be jeopardized.
All information contained in this manual is based on the latest
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 may be reproduced, stored in
retrieval system, or transmitted, in any form by any means,
electronic, mechanical, photocopying, recording, or otherwise,
without the prior written permission of the publisher. This
includes text, figures and tables.

AB46 Work Platformii
Foreword
NOTES

Section
i
Contents
AB46 Work Platform I
3.0 Maintenance
3.0 Introduction .......................................................... 3-1
Terminology ................................................... 3-1
General Procedures........................................ 3-1
Special Tools .................................................. 3-1
3.1 Preventative Maintenance..................................... 3-1
Preventative Maintenance Table Key........... 3-2
3.2 Blocking Elevating Assembly ................................. 3-3
Installation ................................................... 3-3
Removal....................................................... 3-3
3.3 Battery Maintenance............................................. 3-4
Battery Inspection and Cleaning..................... 3-4
Battery Charging............................................. 3-4
3.4 Lubrication............................................................ 3-5
Grease Fittings ................................................ 3-5
Hydraulic Oil and Filter.................................. 3-5
Fluid Level ................................................... 3-5
Oil and Filter Replacement.......................... 3-5
3.5 Proportional Controller......................................... 3-6
Joystick Handle............................................... 3-6
Proportional Control Adjustment ................... 3-6
Rotary Control for Boom Functions............. 3-6
Drive Control............................................... 3-7
3.6 Platform Down Limit Switch............................... 3-7
3.7 Tilt Sensor ........................................................... 3-8
3.8 Hydraulic Manifold............................................... 3-8
Removal ......................................................... 3-8
Disassembly.................................................... 3-8
Cleaning and Inspection................................. 3-8
Assembly ........................................................ 3-8
Installation ...................................................... 3-8
3.9 Hydraulic Brakes................................................... 3-10
Removal....................................................... 3-10
Seal Replacement ........................................ 3-11
Installation ................................................... 3-11
3.10 Drive Pump Settings ........................................... 3-12
Pressure Override........................................... 3-12
Main Reliefs.................................................... 3-12
Pump Removal and Installation...................... 3-12
3.11 Front Wheel Bearings ......................................... 3-13
Removal ......................................................... 3-13
Installation ...................................................... 3-13
3.12 Drive Motor Removal ......................................... 3.14
Drive Motor Seal Replacement ...................... 3-14
Disassrmbly .................................................... 3-14
Assembly ........................................................ 3-15
3.13 Torque Hub ........................................................ 3-15
Removal ......................................................... 3-16
Installation ...................................................... 3-16
Seal Replacement........................................... 3-17
Roll Test....................................................... 3-17
Leak Test...................................................... 3-17
Roll and Leak Testing ..................................... 3-17
Disassembly.................................................... 3-17
Assembly ........................................................ 3-17
Main Assembly ............................................... 3-18
Pressing Tools .............................................. 3-20
Table of Contents
Section Page
No. No. Section Page No. No.
1.0 Introduction & Specifications
1.0 Introduction .......................................................... 1-1
Purpose .......................................................... 1-1
Scope.............................................................. 1-1
1.1 General Description.............................................. 1-1
Platform ....................................................... 1-1
Controller .................................................... 1-1
Elevating Assembly....................................... 1-1
Chassis ......................................................... 1-1
Purpose of Equipment .................................... 1-1
Special Limitations.......................................... 1-1
1.2 Specifications ........................................................ 1-2
2.0 Operation
Safety Rules................................................................. 2-1
2.1 Introduction ........................................................ 2-2
Pre-Operation and Safety Inspection.................. 2-2
System Function Inspection............................ 2-2
Controls and Indicators....................................... 2-3
Operation ........................................................... 2-3
Emergency Stop.............................................. 2-3
Service Horn................................................... 2-3
Starting the Engine.......................................... 2-4
Driving............................................................ 2-4
With Boom Lowered................................. 2-4
With Boom Elevated ................................. 2-4
Steering ..................................................... 2-4
Positioning The Platform..................................... 2-4
Multifunction Controls .............................. 2-4
Lower Controls Operation ........................ 2-4
Leveling the Platform...................................... 2-5
Rotating the Turret ......................................... 2-5
Elevating the Riser .......................................... 2-5
Elevating the Upper Boom ............................. 2-5
Extending the Upper Boom............................ 2-6
Elevating the Jib .............................................. 2-5
Rotating the Platform...................................... 2-5
Emergency Operation ......................................... 2-6
Lowering Elevating Assembly.......................... 2-6
Rotating Turret ............................................... 2-6
Emergency Towing.............................................. 2-6
After Use Each Day............................................. 2-6
Transportation.......................................................... 2-7
By Crane............................................................. 2-7
By Truck or Trailer .............................................. 2-7
Maintenance ............................................................ 2-8
Fueling ................................................................ 2-8
Gasoline ......................................................... 2-8
Diesel ............................................................. 2-8
Hydraulic Oil ...................................................... 2-8
Lubrication.......................................................... 2-8
Battery Maintenance........................................... 2-8
Tires .................................................................... 2-8

Contents
i
Section
II AB46 Work Platform
Table of Contents (cont.)
Section Page
No. No. Section Page No. No.
3.14 Setting Hydraulic Pressures................................. 3-23
High Relief Valve............................................ 3-23
Low Relief Valve............................................. 3-23
Counterbalance Relief Valves ......................... 3-23
3.15 Master Cylinder .................................................. 3-24
Removal ......................................................... 3-24
Disassembly.................................................... 3-24
Assembly ........................................................ 3-24
Installation ...................................................... 3-24
3.16 Slave Cylinder..................................................... 3-25
Removal ......................................................... 3-25
Disassembly.................................................... 3-25
Assembly ........................................................ 3-25
Installation ...................................................... 3-25
3.17 Cage Rotate Cylinder.......................................... 3-26
Removal ......................................................... 3-26
Disassembly.................................................... 3-26
Assembly ........................................................ 3-26
Installation ...................................................... 3-26
3.18 Steering Cylinder ................................................ 3-27
Removal ......................................................... 3-27
Disassembly.................................................... 3-27
Assembly ........................................................ 3-27
Installation ...................................................... 3-27
3-19 Jib Cylinder......................................................... 3-28
Removal ......................................................... 3-28
Disassembly.................................................... 3-28
Assembly ........................................................ 3-28
Installation ...................................................... 3-28
3-20 Boom Raise and Boom Riser Cylinders .............. 3-29
Removal ......................................................... 3-29
Disassembly.................................................... 3-29
Assembly ........................................................ 3-29
Installation ...................................................... 3-29
3-21 Boom Extend Cylinder ....................................... 3-30
Removal ......................................................... 3-30
Disassembly.................................................... 3-30
Assembly ........................................................ 3-30
Installation ...................................................... 3-31
3.22 Long Term Storage.............................................. 3-32
Preservation.................................................... 3-32
3.23 Torque Specifications.......................................... 3-32
Fasteners......................................................... 3-32
Hydraulic Components .................................. 3-32
4.0 Troubleshooting
4.0 Introduction .......................................................... 4-1
General Procedure ......................................... 4-1
4.1 Hydraulic Troubleshooting Guide......................... 4-2
4.2 Electrical Trouble Shooting Guide ........................ 4-4
5.0 Schematics
5.0 Introduction .......................................................... 5-1
5.1 Electrical Schematics............................................. 5-2
5.2 Hydraulic Schematics ........................................... 5-8
5.3 Boom Valve Block Assembly................................. 5-10
5.4 Drive Valve Block Assembly ................................. 5-13
5.5 Upper Control Box Component Location............. 5-14
5.4 Lower Control Box Component Location............. 5-16
6.0 Illustrated Parts Breakdown
6.0 Introduction .......................................................... 6-1
6.1 Index..................................................................... 6-1
6.2 Illustrated Parts Breakdown .................................. 6-2
Final Assembly, AB46 Gas
068301-000................................................................ 6-2
Final Assembly, AB46 Diesel
068302-000................................................................ 6-8
Basic Assembly, AB46 Gas
068304-000................................................................ 6-14
Basic Assembly, AB46 Diesel
068305-000................................................................ 6-14
Chassis Assembly, Gas
068320-001................................................................ 6-16
Chassis Assembly, Diesel
068320-002................................................................ 6-17
Lower Boom Linkage Assembly, AB46
068323-000................................................................ 6-20
Upper Boom Linkage Assembly, AB46
068322-000................................................................ 6-22
Turret Assembly, Gas
068330-001................................................................ 6-24
Turret Assembly, Diesel
068330-002................................................................ 6-24
Engine Assembly, Kubota Gas
068661-000................................................................ 6-26
Fuel Tank Assembly, Kubota Gas
068710-000................................................................ 6-30

Section
i
Contents
AB46 Work Platform III
Engine Assembly, Kubota Diesel
068666-000................................................................ 6-32
Fuel Tank Assembly, Kubota Diesel
068710-001................................................................ 6-36
Dual Fuel Conversion Kit
068296-000................................................................ 6-38
Valve Block Assembly
068348-001................................................................ 6-40
Drive Valve Block Assembly
068347-000................................................................ 6-42
Hydraulic Tank Assembly
068709-000................................................................ 6-44
Ground Control Box Asembly
068328-001 Gas........................................................ 6-46
068328-002 Diesel.................................................... 6-46
Controller Inststallation, Gas
068339-002................................................................ 6-52
Controller Inststallation, Diesel
068339-003................................................................ 6-53
Controller Assembly - Platform, Gas
068329-001................................................................ 6-54
Controller Assembly - Platform, Diesel
068329-002................................................................ 6-58
Hose Kit, AB46 Gas/Diesel
068336-001................................................................ 6-62
Tire & Wheel Assembly
067664-000/001 ....................................................... 6-64
Tire & Wheel Assembly - Ploy Filled
067664-002/003 ....................................................... 6-64
Cage "B" Assembly
068325-001................................................................ 6-66
Cage "A"
068500-000................................................................ 6-68
4 FT. Cage
068500-003................................................................ 6-69
Label Kit, Gas
068335-001................................................................ 6-70
Label Kit, Diesel
068335-002................................................................ 6-70
Motion Alarm/Flashing Beacon - Option
068294-000................................................................ 6-72
Section Page
No. No.
Table of Contents (cont.)

Contents
i
Section
IV AB46 Work Platform
List of Tables
Figure Page
No. Title No.
1-1 Specifications............................................................ 1-2
3-1 Preventative Maintenance Checklist .................... 3-2
3-3 Bolt Torque ............................................................... 3-32
3-4 Hydraulic Component Torque.............................. 3-32
4-1 Troubleshooting Guide-Hydraulics ..................... 4-2
4-2 Troubleshooting Guide-Electrical......................... 4-4
5-1 Electrical Schematic Legend, Gasoline Model.... 5-2
5-2 Electrical Schematic Legend, Dual Fuel............... 5-4
5-3 Electrical Schematic Legend, Diesel ..................... 5-6
5-4 Hydraulic Schematic Legend................................. 5-8
5-5 Upper Controller Components ............................. 5-14
5-6 Lower Controller Components ............................. 5-16
1-1: AB46 Work Platform............................................... 1-1
2-1: Chassis Controls ...................................................... 2-3
2-2: Platform Controls .................................................... 2-3
2-3: Fall Restraint Ancorage Point................................ 2-3
2-4: Emergency Control Operation .............................. 2-6
2-5: Manual Turret Rotation.......................................... 2-6
2-6: Securing the Machine for Transportation............ 2-7
2-7: Fuel Fill Pipe/Level Gauge .................................... 2-8
2-9: Hydraulic Oil Filler ................................................. 2-8
3-1: Blocking Elevating Assembly ................................ 3-3
3-2: Lubrication Chart .................................................... 3-5
3-3: Proportional Controller .......................................... 3-6
3-4: Rotary Control Adjustment ................................... 3-6
3-5: Proportional Control Adjustment......................... 3-7
3-6: Platform Down Limit Switch................................. 3-7
3-7: Tilt Sensor ................................................................. 3-8
3-8: Hydraulic Manifold, Exploded View................... 3-9
3-10: Rear Axle Assembly................................................ 3-10
3-11: Brake Assembly ....................................................... 3-11
3-12: Pressure Override Valve ........................................ 3-12
3-13: Hydraulic Pump ...................................................... 3-12
3-14: Front Axle Assembly .............................................. 3-13
3-15: Drive Motor.............................................................. 3-14
3-16: Torque Hub .............................................................. 3-15
3-17: Torque Hub Assembly............................................ 3-16
3-18: Measuring Hub End Play....................................... 3-18
3-19: Torque Hub .............................................................. 3-19
3-20: Seal Pressing Tool.................................................... 3-20
3-21: Bearing Cone Pressing Tool ................................... 3-21
3-22: Bearing Cup Pressing Tool..................................... 3-22
3-23: Valve Manifold ........................................................ 3-23
3-24: Master Cylinder ....................................................... 2-24
3-25: Slave Cylinder .......................................................... 3-25
3-26: Cage Rotate Cylinder.............................................. 3-26
3-27: Steering Cylinder..................................................... 3-27
3-28: Jib Cylinder............................................................... 3-28
3-29: Boom Raise Cylinder .............................................. 3-29
3-30: Removing Boom Extend Cylinder........................ 3-30
3-31: Boom extend Cylinder............................................ 3-31
List of Illustrations
Table Page
No. Title No.
5-1: Electrical Schematic, Gas Model ........................... 5-3
5-2: Electrical Schematic, Dual Fuel ............................. 5-5
5-3: Electrical Schematic, Diesel.................................... 5-7
5-4: Hydraulic Schematic ............................................... 5-9
5-5: Valve Block Assembly ............................................ 5-10
5-6: Hydraulic Valve Ports ............................................ 5-11
5-7: Check Ports............................................................... 5-12
5-8: Drive Valve Block.................................................... 5-13
5-9: Upper Controller ..................................................... 5-14
5-10: Electrical Diagram, Upper Control Box, Gas...... 5-15
5-11: Electrical Diagram, Upper Control Box, Diesel.. 5-15
5-12: Lower Control Box Cover ...................................... 5-16
5-13: Terminal Strip, Relay Identification ..................... 5-16
5-14: Electrical Diagram - Lower Control Box, Gas .... 5-18
5-16: Electrical Diagram - Lower Control Box, Diesel 5-19
Figure Page
No. Title No.
List of Illustrations (continued)

Introduction & Specifications Section
AB46 Work Platform 1-1
1.0 Introduction
PURPOSE
The purpose of this service and parts manual is to
provide instructions and illustrations for the operation
and maintenance of the AB 46 Work Platform manufac-
tured by UpRight, Inc. of Selma, California.
SCOPE
The manual includes procedures for proper operation,
maintenance, adjustment, and repair of this product as well as
recommended maintenance schedules and troubleshooting.
1.1 General Description
The AB46 Work Platform consists of the platform,
controller, elevating assembly, power module, control
module, and chassis.
Platform
The platform has a reinforced steel floor, 43.5 inch (1.11 m)
high guardrails with midrail, 6 inch (152 mm) toeboards
and an entrance gate at the side of the platform.
DO NOT use the maintenance platform
without guardrails properly assembled and
in place.
Platform Controller
The platform controller contains the controls to operate
the machine. It is located at the front of the platform
cage. The foot switch must be depressed to operate any
function from the platform. A complete explanation of
control functions can be found in
Section 2 .
Elevating Assembly
The platform is raised and lowered by the elevating
assembly; an articulated boom powered by two single
stage lift cylinders. The hydraulic pump, driven by the
engine, powers the cylinders. Solenoid operated valves
control raising and lowering.
Chassis
The chassis is a structural frame that supports all the
components of the AB46 Work Platform. It contains the
engine, battery, hydraulic pump, and drive motors.
PURPOSE OF EQUIPMENT
The objective of the AB46 Work Platform is to provide a
quickly deployable, self propelled, variable height work
platform to elevate personnel and materials to overhead
work areas.
SPECIAL LIMITATIONS
Travel with the platform raised is limited to a creep
speed range.
Elevating of the Work Platform is limited to firm, level
surfaces only. Any degree of slope greater than 5owill
sound a warning alarm when machine is elevated. If
machine is lowered, a light will illuminate on platform
control box.
The elevating function shall ONLY be used
when the work platform is level and on a
firm surface. The work platform is NOT
intended to be driven over uneven, rough
or soft terrain when elevated.
Figure 1-1: AB46 Work Platform
1.0
2
1
4
3
6
5
4. Boom
5. Chassis Control Module
6. Chassis
1. Platform
2. Platform Controller Assembly
3. Elevating Assembly

Introduction & Specifications
1-2
Section
AB46 Work Platform
1.2
1.2 Specifications
Table 1-1: Specifications
REACH ENVELOPE DIAGRAM
DIMENSIONS IN FEET
* Specifications subject to change without notice.
Meets or exceeds all applicable requirements of OSHA and ANSI A92.5-1992
ITEM SPECIFICATION
Height
Working height maximum 52 ft.
Platform height maximum 46 ft.
Platform step in height 9 in.
Up and over height 25 ft.
Drivable height 46 ft.
Horizontal outreach 24 ft. 6 in.
Turret rotation 360 deg. noncontinuous
Platform rotation 160 deg.
Tail swing None
Jib length 5 ft.
Jibarc 140 deg.
Inside turning radius 2 ft.
Outside turningradius 9 ft. 10 in.
Drive speed (lowered) 3.5 mph
Drive speed (elevated) .34 mph
Gradability 30% - 16.7 Degrees
Dimensions (boom stowed)
Platform Size 69 in. x 39 in.
Guardrail height 431/2in.
Toeboards 6 in.
Maximum platform capacity 500 lbs.
Maximum no. of occupants 2
Weight 14,140 lbs.
Overall height 6 ft. 6 in.
Overall length 17 ft. 10 in.
Overall width 5 ft. 9 in.
Wheelbase 73 in.
Wheeltrack 59 in.
Ground Clearance 6 in.
Power source Kubota WG750 or D905
System voltage 12VDC
Maximum Hyd. Pressure 4400 psi
Controls Electric Proportional
Tires 10x16.5 8 ply lug tread

AB46 Work Platform 2-1
NEVERoperatethemachine
withinten(10)feetofpower
lines. THISMACHINEIS
NOT
INSULATED.
NEVERoperatethe
boom or drive with
platform elevated
unless on firm level
surface.
NEVERpositionthe
platform without first
checking for overhead
obstructions or other
hazards.
NEVERclimb,standorsit
onplatformguardrailsor
midrail.
ElectrocutionHazard TipOverHazard CollisionHazard FallHazard
AB-46 I/C
WARNING
All personnel shall carefully read, understand and follow all safety rules, operating
instructions, and the Scaffold Industry Association’s MANUAL OF RESPONSIBILITIES
(ANSI A92.5) before operating or performing maintenance on any UpRight boom supported
aerial work platform.
ALLoccupantsmustwearanapprovedfallrestraintproperlyattachedtodesignatedplatformanchoragepoint. Attach
onlyonefallrestrainttoeachanchoragepoint.
NEVERexceedmaximumplatformloadof500lbs.(225kg)andtwo(2)occupants.
NEVERexceed45lbs.(200N)ofsideforceperoccupant.
DISTRIBUTEallplatformloadsevenlyontheplatform.
NEVERoperatethemachinewithoutfirstsurveyingtheworkareaforsurfacehazardssuchasholes,drop-offs,bumps,
curbs,ordebris;andavoidingthem.
OPERATEmachineonlyonsurfacescapableofsupportingwheelloads.
NEVERelevatethemachinewhenwindspeedsexceed28mph(12.5m/sec.).
INCASEOFEMERGENCYpushemergencystopbuttontocutpowertoallmachinefunctions.
ALWAYScloseandsecuregateafterenteringplatform.
NEVERexitorenterplatformwhileelevated.
NEVERuseladders,scaffolding,orotheritemstogainheight;workonlyfromtheplatformfloor.
NEVERclimbdownelevatingassemblywhileplatformiselevated.
INSPECTthemachinethoroughlyforcrackedwelds,looseormissinghardware,hydraulicleaks,loosewireconnections,
anddamagedcablesorhosesbeforeusing.
VERIFYthatalllabelsareinplaceandlegiblebeforeusing.Refertopages6-66 &6-67forlabelidentification.
NEVERuseamachinethatisdamaged,notfunctioningproperly,orhasdamagedormissinglabels.
IFALARMSOUNDSwhileboomiselevated,STOP,carefullyretractboomandlowerplatformwithoutrotating. Move
machinetoafirm,levelsurface.
NEVERattachoverhangingloadsoruseboomasacrane.
NEVERalteroperatingorsafetysystemswithoutmanufacturerswrittenconsent.
NEVERchargebatterynearsparksoropenflame. Chargingbatteriesemitexplosivehydrogengas.
NEVERreplaceanycomponentorpartwithanythingotherthanoriginalUpRightreplacementpartswithoutthe
manufacturer'swrittenconsent.
NEVERtowthemachine.Transportbytruckortraileronly.
AFTERUSE,securetheworkplatformfromunauthorizedusebyturningbothkeyswitchesoffandremovingallkeys.
SAFETY RULES
Section
2.1
Safety Rules and Operating Instructions
Safety Rules and Operating Instructions
Operation

2-2 AB46 Work Platform
2. Turn chassis key switch to chassis, and turn on
(rotate clockwise) emergency stop switches at
the chassis control panel and at the platform
control panel.
3. Press the engine start button to crank the
engine; release when engine starts. If engine is
cold: press and hold the choke button while
starting gasoline / propane models; press the
glow plug button and hold for six seconds prior
to starting diesel models.
4. Push in the chassis emergency stop button
engine should stop. Repeat for platform emer-
gency stop button. Return both emergency stop
buttons to the on position, and start engine.
5. Operate each function switch to raise / lower,
extend / retract, rotate left / right, each section of
the elevating assembly and observe the opera-
tion of the machine. All functions should operate
through full cycle smoothly.
6. Turn chassis key switch to platform.
7. Mount the platform, close and latch the gate, and
attach approved fall restraint to designated plat-
form anchorage point. Attach only one fall
restraint to each point.
8. Start the engine.
9. Without depressing the foot switch, move the
drive control handle, machine should not function.
10.Depress the foot switch and move the drive
control handle forward and reverse. Observe
that proportional functions operate smoothly,
and that brakes apply quickly after control is
released.
11.While depressing foot switch, operate steer
switch to left and right. Observe that steering
wheels turn properly.
12.While depressing foot switch, turn function
speed control knob to desired setting, and
operate boom controls. Observe that boom
operates smoothly, and that upper boom, jib,
turret rotation, platform level, and platform
rotation controls operate proportionally in con-
junction with function speed control knob.
Observe that platform maintains level when
boom is elevated.
13.With the upper boom elevated one foot, operate
drive control handle. Observe that drive speed
is limited to creep (1/2 foot [.15m] per second).
Lower upper boom to stowed position.
14.Press the service horn button. Observe that
horn is audible.
DO NOT use a machine that is damaged or
malfunctioning. Tag and remove the unit
from service until it is repaired.
Introduction
This manual covers the operation of internal com-
bustion powered models of the AB-46 Articulated
Boom.
Pre-Operation and Safety
Inspection
Carefully read, understand and follow all safety
rules, labels, and operating instructions, then
perform the following steps each day before
use.
Perform a complete visual inspection of the entire
unit prior to operating. Check the following areas
for discrepancies:
1. Open panels and check hydraulic components /
hoses for damage or leaks. Check electrical
components / wiring for damage or loose connec-
tions.
2. Inspect chassis, axles, hubs, and steering
linkage for damage, deformation, buckled paint,
loose or missing hardware, and cracked welds.
3. Check tires for damage, punctures, and infla-
tion; tire pressure must be 65 psi.
4. Check all hoses / cables for wear.
5. Inspect elevating assembly for damage, defor-
mation, buckled paint, loose or missing
hardware, and cracked welds.
6. Inspect platform and guardrails for damage,
deformation, buckled paint, loose or missing
hardware, and cracked welds. Insure that gate
operates freely and latches securely.
7. Check Hydraulic fluid level with platform fully
lowered.
8. Check battery fluid level (see battery mainte-
nance, page 2-8).
9. Check fuel level, add fuel if necessary (see
fueling, page 2-8).
10.Ensure that radiator is cold, check coolant level.
Add if necessary.
NEVER remove the cap from a hot radiator.
Hot coolant can cause severe burns.
SYSTEM FUNCTION INSPECTION
Note: Refer to figures 2-1 and 2-2 for chassis
and platform control locations.
1. Before performing the following tests, check
area around machine and overhead for obstruc-
tions, holes, drop-offs, and debris.

AB46 Work Platform 2-3
Controls and Indicators
Figure 2-3: Typical Fall Restraint Anchorage
Point
Operation
Before operating work platform insure that:
Pre-operation and safety inspection has been
completed, and any discrepancies have been
corrected.
The operator has been thoroughly trained on
the operation of the machine.
The work area is clear of all obstructions,
holes, drop-offs, or persons in the route of
travel.
The surface is capable of supporting wheel loads.
Refer to figures one and two for control locations.
Emergency Stop
At any time during operation, press the emergency
stop button to stop all functions in an emergency.
Service Horn
At any time during operation, press the service
horn button to sound an audible warning if neces-
sary.
Always wear an approved fall restraint
properly attached to designated platform
anchorage point when driving or elevating
the machine (see figure 2-3).
Attach only one fall restraint to each anchor-
age point.
Figure 2-2: Platform Controls
Figure 2-1: Chassis Controls
Note: The following list corresponds to the
numbered items in figures one and two.
1. Emergency stop.
2. Engine start.
3. Choke / glow plug button.
4. Keyswitch
5. Control fuses.
6. Riser control.
7. Upper boom control.
8. Boom extension control.
9. Jib control.
10.Turret rotation control.
11.Platform rotation control.
12.Platform level control.
13.Hourmeter.
14.Service horn button.
15.Drive control handle.
16.Function speed control.
17.Fuel selector.
18.Foot switch (located on platform floor).
19.Out of level indicator.
16 4
5
17
3
14
1
10
11
19
678912
15
12
9
8
5
4
3
2
1
6
7
10 13 11

2-4 AB46 Work Platform
Starting the engine
From the lower controls
1. Turn the chassis key switch to chassis position.
2. Press the start button to crank the engine.
Release when the engine starts.
3. When the engine is cold: press and hold the
choke button while starting gasoline / propane
engines; press and hold the glow plug button for
six seconds prior to starting diesel engines.
From the platform controls
1. Turn the chassis key switch to platform con-
trols.
2. Turn the platform keyswitch fully clockwise to
crank the engine. Release when engine starts.
3. When the engine is cold: Press and hold the
choke button while starting gasoline / propane
engines. Press and hold the glow plug button
for six seconds prior to starting the diesel
engine.
Driving
With Boom Lowered
1. Turn chassis key switch to platform, and turn on
(turn clockwise) the chassis emergency stop switch.
2. Mount the platform, close and latch the gate.
3. Attach approved fall restraint to designated
platform anchorage point. Attach only one fall
restraint to each point.
4. Start engine.
5. Check that the area around and above the work
platform is clear of obstructions, holes, drop-
offs, persons in the route of travel, and the
surface is capable of supporting wheel loads.
6. Depress the foot switch and move the drive
control handle forward to travel forward and
reverse to travel in the reverse direction.
7. While driving, press the differential lock button,
located on the front of the drive control handle,
as necessary for improved traction.
Note: When the boom is rotated to the front of
the chassis (steering wheels aft) directions of
travel and steering will be reversed. Observe
the color coded arrows on the control panel
near the drive control handle, and on the chas-
sis. They will indicate the direction of travel
when the drive control handle is moved.
With Boom Elevated
Travel with boom elevated is restricted to firm
level surfaces only.
When driving elevated, the machine will travel at
creep speed (1/2 foot [.15 m] per second).
Steering
1. While depressing the foot switch, push the
steering switch (located on top of the control
handle) to the left to turn left, and right to turn
right.
Note: Steering is not self centering. Wheels
must be returned to the straight ahead position
by operating the steering switch.
POSITIONING THE PLATFORM
Positioning the platform as close as possible to the
work area requires some planning. First, you must
survey the work site to find a suitable place to park
the machine. This must be a firm level area as
close as possible to the work area. Take into
consideration all obstructions on the ground and
overhead and avoid them.
Once you have moved the machine to a firm level
surface as near as possible to the work area, follow
the instructions on page five to position the platform
as close to the work area as possible.
Always, before operating any function, check the
area around and overhead for any obstructions or
electrical conductors.
NEVER exit the platform while the boom is
elevated. Keep both feet firmly planted on
the platform floor at all times.
Multifunction Controls
The UpRight AB-46 employs the use of
multifunction controls. This means that riser or
boom extension will function at full speed while
simultaneously operating upper boom, jib, turret, or
rotating the platform.
The turret may be rotated while driving if necessary
to make turns in tight areas. All other boom func-
tions will not operate while driving.
Lower Control Operation
All boom functions will operate at fixed speed.
1. Turn chassis keyswitch to chassis controls.
2. With engine running, operate boom control
switches to position the platform.

AB46 Work Platform 2-5
Elevating the Upper
Boom
1. Set the function speed control dial to the desired
setting. Rotate the dial clockwise to increase
speed, counterclockwise to decrease. If you are
not sure what speed to use, start out slow; the
speed can be varied while operating the function.
2.
While depressing the foot switch, push the upper
boom control lever forward to elevate the upper
boom, rearward to lower the upper boom. Re-
lease the control lever to stop elevating / lowering.
Extending the Upper
Boom
1. While depressing the foot switch, push the
boom extension control lever rearward to extend
the boom, forward to retract the boom. Release
the control lever to stop extending / retracting.
The boom extension will function at a constant
speed, function speed control setting is not
necessary.
Elevating the Jib
1. Set the function speed control dial to the desired
setting. Rotate the dial clockwise to increase
speed, counterclockwise to decrease. If you are
not sure what speed to use, start out slow; the
speed can be varied while operating the function.
2. While depressing the foot switch, push the jib
control lever forward to elevate the jib, rearward
to lower the jib. Release the control lever to
stop elevating / lowering.
Rotating the Platform
1. Set the function speed control dial to the desired
setting. Rotate the dial clockwise to increase
speed, counterclockwise to decrease. If you are
not sure what speed to use, start out slow; the
speed can be varied while operating the function.
2. While depressing the foot switch, turn the
platform rotation control switch counterclock-
wise to rotate left, clockwise to rotate right.
Release the switch to stop rotation.
Leveling the Platform
DO NOT operate the machine if the
platform does not maintain level when
elevated.
Note: Platform leveling can be performed only
with the boom stowed and should be done only
to calibrate the automatic leveling system.
1. Set the function speed control dial to the desired
setting. Rotate the dial clockwise to increase
speed, counterclockwise to decrease. If you are
not sure what speed to use, start out slow; the
speed can be varied while operating the function.
2. While depressing the foot switch, push the
platform level control switch forward to swing
the platform upward, rearward to swing the
platform downward. Release the switch to stop
leveling.
Rotating the Turret
1. Set the function speed control dial to the desired
setting. Rotate the dial clockwise to increase
speed, counterclockwise to decrease. If you are
not sure what speed to use, start out slow; the
speed can be varied while operating the function.
2. While depressing the foot switch, turn the turret
rotation control switch counterclockwise to
rotate left, clockwise to rotate right. Release the
switch to stop rotation. Observe the area
around the boom when rotating the turret to
avoid any obstructions.
Elevating the Riser
1. While depressing the foot switch, push the riser
control lever forward to elevate the riser, rear-
ward to lower the riser. Release the control
lever to stop elevating / lowering. The riser will
function at a constant speed, function speed
control setting is not necessary.

2-6 AB46 Work Platform
EMERGENCY OPERATION
In the event of powered function failure, the elevat-
ing assembly may be lowered manually by the
following procedure.
NEVER climb down the elevating assembly.
If controls do not respond, ask someone on
the ground to lower the boom manually.
Lowering Elevating Assembly
1. Open the cover on the hydraulic module (opposite
side of the turret from the chassis control panel).
2. Remove the wire loop retainer from the hand
pump lever, and extend the handle upward to
gain leverage.
3. Operate the manual override (knurled knob) on the
appropriate valve (see fig. 2-4). Push in to lower /
extend, pull out to raise / retract as required.
4. While holding the appropriate valve in position,
pump the handle in and out until that section of
the elevating assembly is lowered / retracted.
5. Repeat as necessary operating each valve until
the elevating assembly is fully lowered.
Rotating Turret
1. To manually rotate the turret, remove the
manual turret crank from inside of the control
side turret cover.
2. Set ratchet direction on turret crank.
3. Place the socket of the crank onto the hex shaft
stub of the turret rotation gearbox.
4. Turn the crank clockwise to rotate the turret
counterclockwise, turn counterclockwise to
rotate the turret clockwise.
Figure 2-4: Emergency Control Operation
Figure 2-5: Manual Turret Rotation
Emergency control pump
Riser Valve
Extend Valve
Boom Valve
Jib Valve
Turret Rotation
Gear Box
7
/ 8 in. Ratcheting
Wrench
EMERGENCY TOWING
Perform the following only when the machine will
not operate under its own power and it is neces-
sary to move the machine or when winching onto a
trailer for transportation.
The batteries must be connected in order to release
the brakes.
1. Insure that the platform is fully lowered, and that
the turret is rotated so that the platform is to the
rear of the machine.
2. Attach chain / cable of sufficient strength for
towing the machine to front or rear tie down
lugs.
3. Turn the keyswitch to the parking brake release
position. Alarm will sound.
4. Operate the brake release hand pump located
on the back of the right rear bulkhead.
5. After moving the machine, return the keyswitch
to the off position and remove the key to prevent
unauthorized operation.
DO NOT move the machine faster than 3
mph. Faster speeds will damage drive
components and void warranty.
AFTER USE EACH DAY
1. Ensure that the platform is fully lowered.
2. Park the machine on level ground, preferably
under cover, secure against vandals, children or
unauthorized operation.
3. Turn the key switch to OFF and remove all keys
to prevent unauthorized operation.

AB46 Work Platform 2-7
Figure 2-6: Securing the Machine for Transportation
Transportation
BY CRANE
Stand clear of machine when lifting.
Check specifications on back page, insure
that crane and slings are of correct capacity
to lift weight of unit.
1. Insure that boom is fully lowered and retracted.
2. Attach straps to chassis lifting lugs only. Insure
that straps are adjusted properly to keep unit
level when lifting.
BY TRUCK OR TRAILER
1. Insure that boom is fully lowered and retracted.
2. Maneuver the machine onto bed of truck / trailer.
3. When winching, follow instructions for emer-
gency towing. Attach winch cable to front tie
down lugs.
Chassis Tie Down /
Lifting Lug (typ.)
Wooden Block
7.5" x 4" x 28"
Do not winch machine faster than 3 mph.
4. After winching, insure that brakes are set.
5. Secure the machine to the transport vehicle
using chains / straps of adequate load capacity
(refer to specifications, back page) attached to
chassis tie down.
6. Place a wooden block (7.5" x 4" x 28") under
platform support braces as shown.
7. Attach ratchet strap; under platform floor grating,
over support braces. Tighten securely, do not
overtighten.
NEVER elevate the machine while on a
truck or trailer.

2-8 AB46 Work Platform
Maintenance
FUELING
Gasoline
1. Open fill pipe cap located on chassis left side.
2. Fill to capacity with unleaded motor fuel only.
3. Check fuel level by lifting flap located on top of
chassis left side. Fuel tank full capacity is 25
US gallons.
Diesel
1. Open fill pipe cap located on chassis left side.
2. Fill to capacity with diesel motor fuel only, grade
#1-D, or #2-D. Use distillate fuel only, do not
use residual or blend.
3. Check fuel level by lifting flap located on top of
chassis left side. Fuel tank full capacity is 25
US gallons.
HYDRAULIC OIL
1. Check oil level at sight gauge inside engine
compartment right hand side with the platform
fully lowered.
2. If necessary, fill to capacity with clean ISO 46
compatible hydraulic oil.
3. Lift flap located on top of chassis right side.
4. Open filler / breather cap to add hydraulic oil.
5. Replace cap.
LUBRICATION
Refer to service manual for lubrication chart and
guidelines.
BATTERY MAINTENANCE
Hazard of explosive gas mixture. Keep
sparks, flame and smoking materials away
from battery.
Always wear safety glasses when working
with battery.
Battery fluid is highly corrosive. Rinse
away any spilled fluid thoroughly with clean
water.
Always replace battery with UpRight battery
or manufacturer approved replacement.
Check battery fluid level daily, especially if work
platform is being used in a warm, dry climate.
If electrolyte level is lower than 3/8 in. (10 mm)
above plates add distilled water only. DO NOT use
tap water it will shorten battery life.
Keep terminals and top of battery clean.
TIRES
Tire selection can affect the stability of the ma-
chine. Use only tires supplied by UpRight unless
approved by the manufacturer in writing.
Figure 2-7: Fuel Fill Pipe and Level Gauge
Figure 2-8: Hydraulic Oil Filler / Breather Cap
Hydraulic Oil Filler / Breather Cap
Fuel Level Gauge
Fuel Fill Pipe

Section
3-1AB46 Work Platform
Maintenance
3.0 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 AB46 Work
Platform.
This section contains procedures for the operation
inspection, adjustment, scheduled maintenance, and
repair/removal of the AB46.
Section 2.0 will aid in understanding the operation and
function of the various components and systems of the
AB46 and help in diagnosing and repair of the machine.
Refer to Table 3-1, Preventative Maintenance Checklist,
for recommended maintenance intervals.
NOTE: Torque all hardware to torques listed on page
3-32 unless otherwise specified.
TERMINOLOGY
TERMINAL BLOCKS: Located in upper and lower
control boxes. Designated by TB##. (##) designates
the number of the block which is written on the termi-
nal block. "R" right or "L" may follow the number.
WIRE COLOR: Indicated by color/color. First color
refers to insulation color and second color indicates
stripe. If second color is not given there is no stripe.
FORWARD: Front of machine indicated by yellow
arrows on chassis.
AFT: Rear of machine indicated by orange arrows on
machine.
GENERAL PROCEDURES
CONTACT BLOCKS: Removed by inserting a flat
screwdriver into the slot at either end of block and
prying outward. Installed by pressing into an empty slot.
SWITCH MOUNT BASE: Assembled to back of switch
actuator. Removed by rotating the small black lever
counterclockwise and lifting off base.
TERMINAL BLOCKS: Remove wires by inserting a small
flat bladed screwdriver into square beside wire. Install
wires by stripping 1/2" of insulation, inserting screw-
driver in square and inserting wire. Be sure no strands
are bend backwards. Replace wires with same rating
and type.
3.0
SPECIAL TOOLS
The following is a list of special tools which may be
required to perform certain maintenance procedures on
the AB46 work platform.
0-1000 PSI Hydraulic Pressure Gauge
with Adapter Fittings (UpRight P/N 014124-010)
0-3000 PSI Hydraulic Pressure Gauge
with Adapter Fittings (UpRight P/N 014124-030)
0-6000 PSI Hydraulic Pressure Gauge
with Adapter Fittings (UpRight P/N 014124-060)
0-30 Gallon Hydraulic Flow Meter
With 0-3000 P.S.I. Simulated Load and Adapter
Fittings (UpRight P/N 67040-000)
Adapter Fitting (UpRight P/N 063965-002)
Inclinometer (UpRight P/N 010119-000)
Crimping Tool (UpRight P/N 028800-009
Terminal Removal Tool (P/N 028800-006)
3.1 Preventative Maintenance
(Table 3-1)
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. Inspec-
tion and maintenance shall be performed by personnel
who are trained and familiar with mechanical and
electrical procedures.
Before performing preventative mainte-
nance, familiarize yourself with the opera-
tion of the machine.
Always block the elevating assembly when-
ever it is necessary to perform mainte-
nance while the platform is elevated.

Section
3-2 AB46 Work Platform
Maintenance
3.1
Preventative Maintenance Report
Date: _______________________________________
Owner: ______________________________________
Model No: ___________________________________
Serial No: ____________________________________
Serviced By:__________________________________
Service Interval: ______________________________
Table 3-1: Preventative Maintenance Checklist
COMPONENT INSPECTION OR SERVICES INTERVAL Y N R
Battery Check electrolyte level 6 M
Check specific gravity 6 M
Clean exterior 6 M
Check battery cable condition Daily
Clean terminals 6 M
Engine Oil Check level and condition Daily
and Check for leaks Daily
Filter Change oil and filter 100 H
Engine Fuel Check fuel level Daily
System Check for leaks Daily
Replace fuel filter 6 M
Check air cleaner Daily
Engine Check coolant level (with engine cold) Daily
Coolant Replace coolant 400 H
Hydraulic Check oil level Daily
Oil Change filter 6 M
Drain and replace oil 2 Y
Hydraulic Check for leaks Daily
System Check hose connections 30 D
Check hoses for exterior wear 30 D
Emergency Operate the emergency lowering Daily
Hydraulic valve and check for serviceability
System
Controller Check switch operation Daily
Control Check the exterior of the cable Daily
Cable for pinching, binding or wear
Platform Check fasteners for proper torque Daily
Deck and Check welds for cracks Daily
Rails Check condition of deck Daily
Tires Check for damage Daily
Checkairpressure (65 psi[4.5bar]) Daily
Checklugnuts(torqueto90ft.lbs.[123Nm]) 30 D
COMPONENT INSPECTIONORSERVICES INTERVAL Y N R
Hydraulic Checkforleaksatmatingsurfaces 30 D
Pump Checkforhosefittingleaks Daily
Check mounting bolts for proper torque 30 D
Torque Check for leaks Daily
Hubs Check Oil level 250 H /6 M
Change Oil after break-in 50 H /30 D
Change Oil 1000h/2y
Steering Check hardware & fittings for proper torque 6 M
System Grease pivot pins 30 D
Oil king pins 30 D
Check steering cylinder for leaks 30 D
Elevating Inspect for structural cracks Daily
Assembly Check pivot points for wear 30 D
Check mounting pin pivot bolts 30 D
for proper torque
Check elevating arms for bending 6 M
Grease linkage pins 30 D
Chassis Check hoses for pinch or rubbing points Daily
Check component mounting 6 M
for proper torque
Check welds for cracks Daily
Lift Check the cylinder rod for wear 30 D
Cylinder Check mounting pin pivot bolts 30 D
for proper torque
Check seals for leaks 30 D
Inspect pivot points for wear 30 D
Check fittings for proper torque 30 D
Steering Check the cylinder rod for wear 30 D
Cylinder Check mounting pin pivot bolts 30 D
for proper torque
Check seals for leaks 30 D
Inspect pivot points for wear 30 D
Check fittings for proper torque 30 D
Entire Checkfor and repair collision damage Daily
Unit Check fasteners for proper torque 3 M
Check for corrosion-remove and repaint 6 M
Lubricate 30 D
Labels Check for peeling, missing, or Daily
unreadable labels & replace
Turret Lubricate teeth 30
D
C HECK BOLTS FOR TORQUE 150 HR
G REASE G EARBOX 150 HR
Table 3-1: Preventative Maintenance Checklist (cont'd.)
Preventative Maintenance Table Key
Interval
Daily=each shift or every day
50h/30d=every 50 hours or 30 days
250h/6m=every 250 hours or 6 months
1000h/2y=every 1000 hours or 2 years
Y=Yes/Acceptable
N=No/Not Acceptable
R=Repaired/Acceptable
The preventative maintenance table has been designed to be
used primarily for machine service and maintenance repair.
Please photocopy this page and use the table as a checklist
when inspecting the machine for service.