Condor 3238, 4046, 4248, 4248E, 5056, 6066 Operation Maintenance & Parts Manual - PDF DOWNLOAD by www.heydownloads.com

OPERATION/MAINTENANCE AND ILLUSTRATED PARTS MANUAL FOR CALAVAR SELF-PROPELLED CONDOR MODELS 3238, 4046, 4248, 4248E, 5056, 6066

Calavar Corporation provides this Manual for the guidance of all owners, operators, and servicing personnel in order to obtain the longest possible trouble-free service. It contains general data; specifications; operating instructions; recommended lubrication procedures; vendor information and specifications; illustrated parts breakdown and a special section on safety.

111MAL.11WAIIR

CORPORATION

Model Serial No. Date Delivered CUSTOMER

Note: Additional copies of this Manual (Part No. 92149) may be obtained through the Parts Department at Calavar. Series VII (Serial Nos. 4464-4800)

NOTES

CONDOR OPERATION AND SAFETY MANUAL

It shall be the responsibility of all users to read and comply with the following common sense rules that are designed to promote safety and aid in better understanding the operation of the Self-Propelled Condor. These .rules do not purport to be all inclusive, nor to supplant or replace other additional safety and precautionary measures to cover usual or unusual conditions. If these rules conflict in any way with any state, local or federal statute or regulations, said statute or regulation shall supersede these rules and it shall be the responsibility of each user to comply therewith. UNLOADING 1)

If the use of a loading ramp is necessary to unload the Condor, select a sturdy ramp. The Condor Model 4248 weighs approximately 15,000 lbs. and the Condor Model 6066 weighs approximately 21,200 .lbs.

If the work platform was removed for shipment, it must be replaced prior to unloading. Do not unload unit by standing on fork assembly.

OPERATING 1)

Operating instructions are located on a placard on the ground control side of counterweight. Before operating unit, check out items as instructed on the placard and in this booklet.

Start unit and allow engine to warm up. If it is necessary to reposition boom, this can be done from the ground control station. Switch Aerial/Ground Selector Switch to Ground, and by activating toggle switches, the boom can be placed in a position that would be safe for unloading. If possible unload the Condor boom first.

By switching Aerial/Ground Selector Switch to the Aerial Position, ground position controls are inoperative. Unit can now be operated from Aerial Position.

Aerial Controllers are proportional, except for steering, platform tilt and platform rotation, which are bi-directional toggle switches. Each controller has a deadman lock-out mechanism that must be depressed before the controller can be activated. By depressing the deadman button not only is the controller free to be activated, but also will bring the pump from a stand-by position to a working position, while increasing engine R.P.M. from idle to operating R.P.M. Normal driving position for the Condor is with the counterweight over the driving wheels. Controller movement is based on this configuration. With counterweight over steering, the drive and steering control will react reversed.

6) Try each controller momentarily to orient yourself on its operation. The controller should always be moved gradually to obtain the smoothest possible operation:

Before unloading Condor, test the automatic braking system by moving forward and reverse to see that the brakes apply when the drive controller returns to the neutral position.

Located between the dri ■ie motors is the two speed valve. Handle up indicates high speed, minimum torque. Handle down indicates minimum speed, maximum torque. Unit should be loaded and unloaded in low---handle down.

INSPECTION

••■•■•■ 1=1•111 ,11•111•14•IMO MIND MN.. Mo. 411•111••■ =Noe

Once unit has been unloaded, give the unit a visual inspection paying special attention to items listed below. This inspection should become part of a daily inspection performed at the beginning of a work shift by the assigned operator. A) B) C) D) E) F) G) H) I)

Check tire pressure Check for cut or damaged tires Check electrolyte level Check engine oil Check hydraulic oil level (use A .T.F. oil only) Check oil cooler for damage and cleanliness Check air cleaner oil level and cleanliness Check stop and start circuit from ground and aerial position Visual inspection for hydraulic leaks

NOTE: Condor models equipped with 54 to 1 torque hubs. Check operation of slope sensor device. If possible, place unit on slope of 5° or more, indicator light should come on and all boom functions will be inoperative. The Condor Model 6066 is also equipped with limit switches. One located inside the boom and another located outside of boom at the boom to turret hinge pin. When either switch is activated, they automatically shift drive to low speed when boom is extended or raised to horizontal. OPERATOR TRAINING 1)

In order for an operator to thoroughly understand the operation of a Condor and to become a qualified operator, it is recommended that after having been checked out by a trained, qualified operator, the trainee operator should move the unit to an area free of any overhead obstruction. The surface upon which the unit will be operated should be level with no hazardous irregularities or accumulation of debris.

Models equipped with manual two-speed shift---shift to high speed (handle up), drive unit to become familiar with the speed and braking characteristics. Shift unit to low speed (handle down) and repeat driving exercise. NOTE: Condors equipped with automatic shift—this is done automatically when boom is extended or reaches horizontal.

Elevate boom to approximately 60°, at this angle the operator will have a clear field of vision over the area below. Repeat low speed driving exercise. 4)

With boom at 60°, extend boom approximately half way and repeat driving exercise.

With boom at 60° and half extension, rotate counterweight between drive wheels and repeat driving unit.

Extend boom to maximum and raise boom to 75°, rotate turret. Turret rotation is continuous. By gradually operating rotation controller giving full signal to rotation, and by gradually returning controller to neutral, the operator will learn how the rotation can be controlled to place unit along side a building smoothly. Place counterweight over drive wheels, with unit at 75° and maximum extension. Repeat driving exercise. NOTE: Extreme care must be taken when driving in this position, as ground vision has been reduced. The operator must watch for objects or personnel that may be in the area. At the end of this exercise, the operator will have driven the Condor in both high speed and low speed; with extended and retracted boom; and will have driven the Condor with boom off to the side, and will have practiced placing Condor in imaginary work positions.

SAFETY Listed below are items pertaining to safety that the operator must know and follow. 1) The Calavar Self-Propelled Condor is a personnel lifting device and it is essential that it is properly maintained and operated to perform all functions with maximum safety and efficiency. The operation of any new and unfamiliar equipment can be hazardous in the hands of untrained operators. Only trained operators should be assigned to operate the Condor. 3) It is the responsibility of the operator to be familiar with the manufacturer's manual and to follow all recommendations made. Never exceed mamufacturer's recommended load. It is the reponsibility of the owner to instruct the operator with the safety requirements made not only by Calavar, but by various safety boards in your area, as well as requirements set down by OSHA and ANSI. (Note: See ANSI 92.2-6.1.1 and 6.1.2 1969 Appendix A2.1 and A2.2.)

Do not operate Condor in excess of rated load specification.

The Condor is a non-insulated unit and must not be operated near high voltage lines.

Do not lean over platform railings to perform work.

Do not use ladder or makeshift devices on the platform to obtain greater heights.

Care must be taken to prevent raising or lowering boom into objects.

10)

The platform capacity must be derated for all tools, accessories and operators.

11)

Always distribute load evenly over work platform.

12)

The Condor is equipped with Safety "D" Rings. A body belt must be worn with a safety strap attached.

13)

Safety head gear should be worn by personnel in work platform.

14)

Care must be taken in storing loose material in work platform such as pipe, rope, wire and miscellaneous boxes. If it is necessary to store such items in platform they must be stored in such a way as to prevent walking or fripping over such items.

15)

Do not alter equipment.

16)

.Do not over ride safety devices.

17)

Slope control devices should be checked periodically for proper operation on Condor Models 6066. - Immediate repairs are mandatory on this device should it be found inoperative or disconnected.

18)

Extremely uneven, sloping, or soft terrain is hazardous and must be avoided. The Condor must not be operated on terrain with more than a 5° slope.

19)

The Condor boom is not to be used to push unit along ground.

20)

The .Condor boom is not to be used to lift wheels off ground.

21)

Visual inspection of turret rotation ring gear bolts in turret and inside base assembly must be accomplished periodically, and if found loose, re-torqued to 80 foot pounds on base bolts and 140 foot pounds on turret bolts.

22)

Visually inspect tires. Tires that have been severly cut to the cord are dangerous and should be replaced. Tire pressure is • 75 P.S .1. and must not be over inflated.

23)

Visual inspection of inner boom extension/retraction cables must be accomplished periodically to determine any damage. Damaged cables must be replaced immediately. Failure to do so will result in a dangerous condition to both operator and equipment.

24)

Under no circumstances should horseplay by tolerated. Report any foolishness or misuse of equipment to proper personnel.

25)

Never take chances. Do not work on platform if your physical condition is such that you feel dizzy or unsteady in any way.

26)

The Condor is not to be used as a ground for welding. Disconnect both positive and negative ground leads from battery before welding on Condor.

REMOTE CONTROL FOR PIPE HANDLING ATTACHMENT

EMERGENCY OR GROUND CONTROL AERIAL CONTROL

REMOTE DRIVING CONTROL PLUG-IN FOR LOADING AND UNLOADING FROM TRANSPORT TRUCK

INTRODUCTION

The primary purpose of this manual is to provide the user with a thorough understanding of the proper operating procedures necessary to comply with the intended use of the CONDOR®, and to provide the information necessary to maintain and service the CONDOR®.

THE OPERATOR'S MANUAL MUST BE RETAINED ON THE CONDOR® AT ALL TIMES.

Do not attempt to operate or service the CONDOR® until you have read and understood all information provided in this manual. Familiarize yourself with the functions and operations of the upper and lower controls. A good understanding of the controls, their limitations, and their capabilities will maximize operating efficiency. The various decals attached to this CONDOR® also contain vital operational instructions. Read the decals before operating this CONDOR®.

It is YOUR RESPONSIBILITY to follow procedures while operating the CONDOR®. The manufacturer of this CONDOR® cannot control the wide range of applications that may be used in carrying out a variety of jobs. Therefore, it is THE USER'S RESPONSIBILITY to consider all personnel when making decisions regarding the CONDOR®'s intended use. It is also YOUR RESPONSIBILITY to understand and obey all federal, state, and local regulations regarding the operation and use of aerial work platforms. A copy of the ANSI/SIA Manual of Responsibilities is attached for your use: ANSI/SIA A92.5-1992 is provided for BoomSupported Elevating Work Platforms, and ANSI/SIA A92.6-1990 is provided for Self-Propelled Elevating Work Platforms. Calavar Corporation reserves the right to modify, improve, add, and/or delete certain design features of its products without any obligation to incorporate new features into products previously sold. Our manuals are continually updated to reflect these changes.

DO NOT ALTER OR MODIFY THIS CONDOR® WITHOUT PRIOR WRITTEN APPROVAL FROM THE MANAGEMENT OF CALA VAR CORPORATION

SERVICE & MAINTENANCE Many of the parts used in the manufacture of the CONDOR® have specific properties, and the manufacturer recommends that replacement parts be purchased through Calavar Corporation in order to ensure the original integrity of the product. Repairs and adjustments should only be made by trained and qualified personnel. Please refer to the maintenance and parts sections of the Calavar Operation, Maintenance, & Parts Manual for information on service and maintenance of the CONDOR®.

NOTE: Please refer to the Calavar Parts section of the Operation, Maintenance, & Parts Manual for information pertaining to your CONDOR®.

NOTES

SELF-PROPELLED CONDOR PARTS AND MAINTENANCE MANUAL INTRODUCTION

The function of the Parts and Maintenance Manual is to first provide the Customer with a complete and up-to-date Parts Manual covering all models presently in production and second, to aid in ordering the correct parts. If used properly, it will provide the customer with a source of information that will aid in solving quickly and inexpensively the bulk of maintenance problems. Under the various sections called out in the index, Calavar has included all the specification sheets from the manufacturers of component parts that make up the Condor, as well as a general trouble shooting guide directed solely to the Condor as a completed unit. Throughout this manual reference is made to unit serial numbers, and the use of this number when ordering parts will assist our parts department in giving you prompt and accurate service. The use of correct serial numbers and part numbers will also expedite completion of warranty claims sent to Calavar. Serial numbers should also be used at all times in phone conversations to Calavar's service personnel. This manual has been produced as a valuable tool for our customers. It is in your best interest that time be spent to read and understand all the sections in this manual Calavar has included a special section that deals with the safe operation of the self-propel led Condor, as well as information about certain items that must be inspected periodically to ensure a safe operating unit.

.9/12/79 , S P4200

CALAVAR SELF-PROPELLED CONDOR MODELS 3238; 4046; 4248 and 6066 INDEX

SECTION 1 - CALAVAR

Page

Unloading Instructions 1 Factory Recommended Tie Down and Transportation Diagram 2 Check-out Instructions to Calavar Customer 3 Calavar Warranty 5 Conversion Tables, Degrees to Percentage 6 General Information 7 Hydraulic System 7 Electrical System 10 Mechanical Electric Adjustment 12 Spare Parts List - Hydraulic and Electrical 13 Lubrication Chart 15 Oil Specification Sheet 18 Troubleshooting Guide 19 Part 1, Wisconsin Engine 19 Part II, Electrical System 20 Part III, Hydraulic System 20 Part IV, Drive 21 Part V, Boom Operation 22 Part VI, Turret 22 Preventative Maintenance 24 General Specifications and Information 26 SECTION II Waterman Fluid Power Systems Michigan Fluid Power SECTION III W.S.I. Drive Motor Torque Hub Braden Gear Box SECTION IV Char-Lynn Hunter Hydro Throttle Control

SPC 480

SECTION V Rotary Coupling Synchro Start (Diesel only) Honeywell Sensor Device

SECTION VI John Deere

SECTION VII Bertea , 0. E. M.

SECTION VIII Wisconsin Engine

SECTION IX Parts Breakdown SECTION X Wiring Diagram Hydraulic Schematic

SECTION XI Condor Operation and Safety

SPC 480

iii

IMPORTANT

UNLOADING INSTRUCTIONS FOR THE SELF-PROPELLED CALAVAR CONDOR

BEFORE UNLOADING THE CONDOR, INSPECT FOR ANY PHYSICAL DAMAGE. NOTE ANY SUCH DAMAGE ON THE FREIGHT BILL AND REPORT SAME TO CARRIER.

CAUTION: The Condor Model 4046 weighs approximately 12,000 lbs., Model 4248 weighs approximately 15,000 lbs. and the Model 6066 approximately 22,000 lbs. and must be unloaded on a sturdy ramp. If possible, select a site for unloading the unit that is suitable for making the installation check-out and inspection. A procedure form has been provided and must be completed before putting the Condor into service.

Operating instructions are located on a placard on the ground control side of counterweight, Before starting the engine, check out the items as instructed on the placard and then proceed to operate the unit following the Check Out Instructions.

4, If the work platform was removed for shipment, it should be replaced prior to unloading. This provides a safe place from which to operate the Condor. It may require moving the unit and repositioning the boom slightly, which can be accomplished with the controls at the top of the fork assembly. NOTE: Grasp the control handle knob as if it were a ball, squeezing the fingers the bottom side of the control knob. This unlocks the control handle so that it can be moved in either direction, When released and brought back to neutral position, it will again lock.

70111Tt

CAUTION: The lift controls are proportional type, with the speed of movement dependent on the position of the control lever. Controls should always be moved gradually. The normal driving position for the Condor is the counterweight over the drive wheels, and the controller movement is based on this configuration. When the boom is positioned over the steering end of the unit the drive and steering controls will be reversed. Try each control momentarily to orient your self on the direction of operation. 5. CAUTION: Before driving the unit down the ramp, test the automatic braking s7sTenTgTmoving the unit slightly back and forth and see that the brakes apply each time the drive control goes back to neutral position. Move the unit on the truck or trailer and down the ramp approximately a foot at a time allowing for steering corrections to be made. Keep unit in alignment with the carrier and the ramp during the unloading procedure. It may be necessary to elevate the boom slightly to clear the ground as you proceed down the ramp.

6. Some Condor Models equipped with a slope sensing device which has been incorporated into the system to indicate a 5° out of level condition. This safety system is operational only when the boom is above horizontal or at minimum extension. This device will automatically cancel all boom functions at both control stations when the unit is subjected to an out of level condition of 5 0 or more. An indicator light located in the aerial control console will also warn of this condition. Once unit has reached an out of level condition of 5° and boom functions are inoperable, the operator may at his option, correct the situation normally by reversing drive direction, or by selecting an alt er nate route. The slope sensing device is a safety system and must not be disconnected. Should this sytem be found inoperative, the unit must be grounded and must not be used until this sytem has been repaired.

SP.4200/9-12-79

FACTORY RECOVVENDED TRANSPORT! \G DIAGRAV

Le.

ALTERNATE PLATFORM HOLD- DOWN

NO PALLETS

PLATFORM PALLETS CARRIAGE 0

21055

CALAVAR CORPORATION SELF-PROPELLED TELESCOPIC AERIAL WORK PLATFORM CONDOR INSTALLATION AND INSPECTION REPORT Dealer's Name Address Serial Number Model

Date

This CONDOR was inspected and tested before leaving CALAVAR. Due to environmental conditions, loading, transporting and unloading the unit, it will be necessary for you to check the following items to assure the user of a first clas , product. This report, when completed, must be returned to Calavar Corp., 9200 Sorensen Ave., Santa Fe Springs, CA 90670.

Item No. Description of Inspection or Test

Initial If O.K.

1 GENERAL APPEARANCE A Visual Damage to unit B Visual fluid leaks C Paint damage

2 ENGINE SERVICING A Engine oil level B Battery condition 1 Electrolyte level 2 Terminal security

3 GROUND CONTROL STATION A Engine start B Choke operation C Starter operation D Governor operation E Alternator operation F Station selection G Boom lifting H Boom extension I Turret rotation J Engine stop K Speed control L Emergency

4 TIRE CONDITION A Tire pressure (Note Decal on Base) B Lug nuts

Remarks

• Item

Initial If

No.

Description of Inspection or Test

AERIAL CONTROL STATION A Engine start B Boom lifting control C Boom extension D Turret rotation E Platform rotation F Platform tilt G Drive high H Drive low I Steering J Brakes K 2-speed shift L Engine stop M 5° slope light

Up Out CW Left Left Forward Forward Left Forward Low

Remarks

Down In CCW Right Right Reverse Reverse Right Reverse High

HYDRAULIC COMPONENTS A Platform swin actuator B Pin retainer C Boom lift c linder D Pin retainer E Master leveling cylinder F Pin retainer G Slave leveling cylinder H Pin retainer I Boom extension cylinder J Pin retainer K Steering cylinder L Pin retainer Left M Drive motors Left N Brake assembly 0 Drive block P Positive traction Q Turret rotation gear box R Turret rotation motor S Hydraulic pump T Hydraulic tank U Hydraulic filter V Valve Panel (Proportional) W Valve (Solenoid)

O.K.

Right Right

ELECTRICAL COMPONENTS A Moving warning horn B Two-speed limit switch C Deadman foot switch D Hour meter

GENERAL SERVICING A Hydraulic oil level B Air cleaner oil level C Turret lube points D Chassis lube points E Boom Lube points

Inspection performed by Name

Title

Date

CHECK-OUT INSTRUCTIONS The following instructions are a step by step procedure for checking out the self-propelled Condor, while at the same time, acquainting operating personnel with its operation. This procedure will not take over an hour and is time well spent to give both operating and maintenance personnel a better understanding of the operation of the Condor and also to provide an opportunity to acquire experience in the operation of the self-propelled Condor. Prior to placing the self-propelled Condor into service, a full check-out of the unit should be made and the Installation Inspection Report completed and returned to the factory. Each unit has undergone a thorough Quality Control Inspection and each unit leaves Calavar in a first class condition. Unfortunately, damage in transportation may occur and you should be aware of such damage and make a note on the consignee copy of the freight bill. Calavar Corporation is not responsible for damage to units in transit. 1.

Visually inspect all parts of unit that are exposed. Check for loose nuts, bolts, damaged hydraulic lines, broken wires or structural damage.

IMPORTANT! Check tire pressure. Pressure must be correct before operating. Do not over inflate. Correct PSI is stenciled on both sides of the carriage.

Check hydraulic oil level---add Dexron II A.T.F. oil if required.

Fill gas tank, use regular gasoline only.

Check battery with an hydrometer. Battery must have a full charge.

All hydraulic valves are located on panel inside turret and are exposed by removing the inspection panel. Remove and replace this panel for visual inspection of turret compartment before placing unit into service.

Turn on master switch at ground station located inside locking access door. Depress Start Button and allow engine to warm up at idle. After unit has warmed up and with Ground/Aerial Selector Switch in ground position, unit can now be operated by activating switches marked BOOM UP, BOOM DOWN, TURRET ROT - LEFT OR RIGHT, and BOOM EXTEND OR RETRACT. Stop button will kill engine with a momentary touch only. It is not necessary to turn master switch off between running operations. This switch only provides the operator with a means of electrically locking unit.

With Master Switch ON, switch AERIAL POSITION. Unit can be started or stopped from AERIAL POSITION. Position unit in an area that is free from any overhead obstruction. Lift bottom of Controller Knob for BOOM UP, push slowly to the UP position and raise boom about six (6) feet. When released, the controller will return to neutral position automatically. Learn to operate controller slowly to obtain the smoothest possible operation.

SP-C/4-20-80

9. The Condor has been designed to drive with the counterweight over the drive wheels. This configuration will provide the best traction and a familiar driving position. 10. The Posi-Traction Valve is located on the base between drive wheels. This valve must be turned clockwise completely to place unit in posi-traction. Posi-Traction should be engaged when unit is used on rough terrain. By turning Posi-Traction Valve counter-clockwise, unit will operate at its best on smooth level terrain. 11. The wheel drive has the following features: A.

There is a HIGH/LOW speed selection (toggle switch) on the aerial control box.

In HIGH speed mode, the vehicle in stowed position has 0 - 3 MPH speed capability (fully proportional).

In HIGH speed mode, no aerial functions can be operated (even if operator activates the controllers for aerial functions).

In LOW speed mode, the vehicle as 0 - 1.0 MPH speed capability (fully proportional).

All aerial functions can be operated only in LOW speed mode.

At no time can the operator shift from HIGH to LOW on-the-go. (i.e.: HIGH/LOW toggle switch can only be functional when controller for drive function is in the neutral position). .

12. Operate boom at HORIZONTAL position until you have familiarized yourself with the operation and how the controllers feel. The smoother you are with the controller, the smoother the unit will respond. 13. Gradually operate unit up to maximum elevation and extension. 14. Some Condor models are equipped with an optional slope sensing device which has been incorporated into the system to sense a 5° out-of-level condition. This safety system is operational only when the boom is above horizontal or at minimum extension. This device will automatically cancel all boom functions at both control stations when unit is subjected to an out-of-plumb condition of 5° or more. An indicator light located in the aerial control console will also warn of this condition. Once unit has reached an out-of-level condition of 5° or more and boom functions are inoperable, the operator may at his option, correct the situation normally by reversing drive direction, or by selecting an alternate route. Evehthough this is a safety device, it must not be considered as a failsafe system. The operator must use normal safety precautions when operating this equipment. The slope sensing device is a safety system and must not be disconnected. Should this system be found inoperative, the unit must be grounded and must not be used until this system has been repaired.

SP-C/4-20-80

CALAVAR CORPORATION

Self Propelled Booms and Scissors

WARRANTY Calavar Corporation ("Calavar") warrants to the purchaser that each new aerial work platform made by Calavar is free from defects in material and workmanship arising under normal use and service, in the case of major weldments (chassis, turret and booms), for a period of 5 years after the original shipment of the aerial work platform from Calavar's plant; and in the case of all other parts, for a period of 1 year after the aerial work platform is first placed in service or two years after the original shipment of the aerial work platform from Calavar's plant, whichever occurs first. The obligation and liability under this Warranty is expressly limited to repairing or, at Calavar's option, replacing free of charge, at its factory in Waco, Texas or at an authorized repair facility designated by Calavar, the defective part. In no event shall Calavar or its suppliers be liable to the purchaser or any other person for transportation charges or for any incidental, collateral, special or consequential damages, including without limitation damages for loss of profits, loss of customers, loss of goodwill or work stoppage, claims by any party other than the purchaser, or any other similar damages or loss even if Calavar, its suppliers or its representatives have been advised of the possibility of such damages. Parts claimed to be defective and for which repair or replacement is desired shall be returned transportation prepaid to Calavar's factory for inspection. This Warranty applies to replacement parts provided under the terms of this Warranty only for the remainder of the Warranty period applicable to the original purchase. Any operation of the equipment beyond rated capacity, improper use or application of the equipment, substitution upon it of parts not approved by Calavar or alteration or repair of the equipment by any person not authorized by Calavar shall, at Calavar's option, void this Warranty. Calavar shall have no liability or responsibility for damages resulting from accident or the malfunction of equipment and components not supplied by Calavar. No agent, employee, distributor, dealer or other representative of Calavar is authorized to modify this Warranty in any way. Accordingly, additional statements or presentations by any such representative, whether oral or written, do not constitute warranties by Calavar and should not be relied upon as limited warranties of Calavar, and no attempt, effort or promise to repair equipment by Calavar or any such representative at any time shall modify or extend this Warranty in any way. If the purchaser has used its own order form, no additional or different warranty terms contained in purchaser's form will be honored by Calavar. This Warranty covers only new and unused aerial work platforms manufactured by Calavar. Products or parts manufactured by others are covered only by such warranties as are extended to the purchaser by Calavar's suppliers. This Warranty is in lieu of all other warranties, expressed or implied, including but not limited to warranties of merchantability and fitness for a particular purpose. Any applicable implied warranty shall be limited in duration to the warranty period. 8300 Imperial Drive, P.O. Box 21447, Waco, Texas 76702-1447 • 817-666-4545, 817-666-4544 FAX Form No. 513-1M-495

Printed in U.S.A.

CONVERSION TABLE DEGREES TO PERCENTAGE

Since the conversion of gradeability is often referred to in percentages and then on the other hand often referred to in degrees, this chart is being provided for your convenience to quickly convert percents to degrees.

100 %

95% 90% 85% 80% 75% 70% 65% 60% 55% 50%

45%

40% 35% 30% 25%

20% 15% 10%

5% --- 100 ft. ---

HYDRAULIC SYSTEM The hydraulic system for the CONDOR uses a John Deere pressure-compensated piston pump which is driven directly from the engine shaft. Flow from the John Deere piston pump is directly connected to the electrically-controlled hydraulic valves. These control valves, in their neutral or center position, have inlet flow passages internally closed-off to the cylinder ports as well as to the tank port. Because of this, when the unit is started, the system reaches the maximum pressure and causes the compensator to de-stroke the pump. Then the pump only delivers enough oil to make up for system slippage, and maintains the maximum pressure throughout the high-pressure system. The maximum system pressure thus depends on the compensator setting of the pump. To avoid wasted horsepower, the John Deere piston pump remains at minimum pressure and minimum flow condition whenever all the controls are not being operated. This is achieved by use of the normally-open two-way solenoid valve (Figure 13B, View A, Item 53). When the ground RUN-IDLE Switch is in the RUN position or when any of the controllers are activated, the solenoid valve is energized causing the pump to go on stroke. The pump then delivers oil to the control valves building maximum system pressure immediately. The following procedure will provide the mechanic with the necessary pressure settings and a step-by-step method to test and troubleshoot the hydraulic system and obtain the best possible performance from the self-propelled Condor. It is recommended that two properly calibrated pressure gauges (0-600 PSI range and 0-5000 PSI range) be used to set pressures. Table 1 gives the basic information on the self-propelled Condor hydraulic system (pump, speed pressure, flow, and wheel drive components). In order to make the proper hydraulic adjustments on the various Condor Models, it is necessary to refer to Table 1. The Condor Parts Manual, supplied with each vehicle, has service information on the Wisconsin Gas Engine (or Deutz Diesel Engine), John Deere Pumps, Bertea Proportional Control Valves, Racine On-off Solenoid Valves, Char-Lynn Motors, Fairfield Torq-Hubs (or Borg-Warner Power Wheels) and W.S.I. Hydraulic Drive Motors. This information along with the complete component specifications should be referred to for a thorough understanding of how the various system components work. To check main pump pressure, place 0-5000 PSI gauge on the system pressure test port (Figure 11, Item 79). Start Unit. Switch to ground control and switch to RUN on the RUN-IDLE Switch. Hydraulic pressure should read 2150 PSI. If pressure is somewhat higher or lower than 2150 PSI, use the following procedure for making adjustment: Loosen pump compensator (Figure 13, Item 65) and turn adjustment screw counterclockwise to lower pressure. Turn adjustment screw clockwise to raise pressure. Once the pressure has been properly set, secure locknut on adjustment screw. The main proportional control valve assembly (Figure 11, Item 25) is a Bertea four-spool valve bank. The spool valve functions, from left to right, are boom extension; turret rotation; boom lift and wheel drive.

SP-C/4-20-80

There are two relief valves located in the Bertea valve inlet section. The main relief valve (Figure 3, Bertea Service Manual, Item 5) is set at 2750 PSI, and the control pressure relief valve (Figure 3, Bertea Service Manual, Item 10) is set at 300 PSI. Both relief valves have been set at the factory, and these settings MUST NOT BE CHANGED. Control pressure for the Bertea valve is taken from the pressure inlet port through a flow control valve (Figure 11, Item 16), having a fixed setting of 3.0 GPM at 300 - 500 PSI. The pressure can be checked by installing a 0 - 600 PSI gauge in the control system test port (Figure 11, Item 15). Located above the Bertea valve bank is the MFP 10 micron filter (Figure 11, Item 11) for the control oil. Care must be taken when changing the filter element.

CAUTION After a new element has been installed, fill the filter can with oil before replacing can and starting unit. This will prevent any possible damage to the filter element. p•■••••

44.1■1■

Located on the inlet cap on the Bertea valve is the control pressure inlet port (Figure 3, Bertea Service Manual, Item 14). This is an in-line filter, to provide additional filtration for the control oil. This filter should be removed, inspected and cleaned with the MFP Filter is replaced.

Located to the left of the Bertea valve bank is the two-spool Racine valve assembly (Figure 11, Item 36) for control of the steering and platform tilt functions. Three-spool assembly is used with platform rotation option. Inlet flow to the Racine valve assembly is controlled by a needle valve (Figure 11, Item 20) located on the inlet pressure line of the Bertea valve. This needle valve is set to deliver three to four GPM to the Racine solenoid valve bank assembly. To adjust needle valve, follow these steps: 1.

Loosen lock nut, turn valve counter-clockwise to open valve wide open.

Turn valve clockwise one turn, giving full signal to drive, unit should turn left or right on any surface the unit would be driven on. If oil flow is too little, unit will have a very slow steering response. If oil flow is too great, steering will react too quickly, resulting in possible damage to steering components as well as to the valve.

Once steering has been set, secure lock nut.

The drive and brake assembly are shown in Figure 4, Item 6. The W.S.I. Drive Motor (Figure 4, Item 6) includes a spring activated and hydraulic released disc brake package that is automatically released while driving. The drive motors are coupled to a planetary gear box (Figure 4, Item 1).

SP-C/4-20-80

CAUTION 1=4

Care should be taken when checking and servicing of theA7 components. Read vendor information pertaining to servicing. Figures 4 and 4A show a Modular Valve, located in the carriage between the drive motors. It contains several features---a flow divider cartridge, a two speed feature, a flow control and check valve cartridge, another adjustable flow control valve cartridge, and an internal shuttle valve. This Modular Valve Performs the necessary function of dividing the oil for slow speed travel with adjustable differential action to round corner, as well as diverting the oil flow for high speed. The shuttle valve (with check valve and flow control valve) provide brake release and application efficiently without an accumulator. The standard self-propelled Condor is NOT BUILT TO BE TOWED. However, if it should become necessary to move the unit, and it cannot be done so under its own power, torque hub literature shows the reversible plates making the unit free-wheeling.

CAUTION 4-,

During free wheeling, there are no wheel brakes. All necessary precautions must be taken to avoid accidents. [4,

Because there are two separate hydraulic system pressures being supplied by the John Deere Pump, it is possible to trace which system is not working. (MAIN SYSTEM or CONTROL PRESSURE SYSTEM.) By placing pressure gauge on the main test port, (Figure 11, Item 79) a reading of 2150 PSI should be noted. If by checking the pressure setting no reading is obtained, check the pump stroke solenoid valve, (Figure 13, View A, Item 42) to be sure it is electrically energized. (Refer to the "Electrical System Specification.") If solenoid functions electrically, the valve should then be checked hydraulically. This valve is s normally open and is closed electrically. If the LIFT; TURRET ROTATION: EXTENSION: STEERING: TILT and PLATFORM ROTATION are inoperative and the pump pressures are properly set, use the following steps to isolate the problem: 1.

Place 0 - 600 PSI gauge on test port (Figure 11, Item 15).

There should be a pressure reading of 300 PSI minimum (OIL HOT), 400 PSI maximum (OIL COLD). If this pressure is too high, possible damage may occur to pilot valve assembly. If this pressure is low, functions will have a slow response. However, if control pressure is too low (150 to 200 PSI), the Bertea valves will not function.

Valve, Part Number Waterman 190-2-3, non-adjustable. Replace valve.

SP-C/4-20-80

If unit should lose STEERING, TILT, and PLATFORM ROTATION, check needle valve (Figure 11, Item 20). Should only one function be inoperable, check electrical portion of manual.

SP-C/4-20-80

TABLE 1: HYDRAULIC SYSTEM DATA

Pump Displ. Cu. In./Rev.

Maximum System Pressure PSI, or Compensator Setting PSI

W.S.I. Drive Motor. Cu. In./Rev.

Wheel Gear Reduction

Condor Model

Pump Model

3238

PR-24

2.4

19.5 GPM @ 2100 RPM

2150

FAIRFIELD Torq-Hub 35:1

4046

PR-24

2.4

19.5 GPM @ 2100 RPM

2150

BORG-WARNER Power Wheel 29:1

4248

PR-24

2.4

19.5 GPM @ 2100 RPM

2150

FAIRFIELD Torq-Hub 35:1

5056 and 6066

PR-24

2.4

19.5 GPM @ 2100 RPM

2150

FAIRFIELD Torq-Hub 54:1

PR-24

2.4

19.5 GPM @ 2100 RPM

2150

OPTIONS: #21066 #21433 (Diesel w/spec. drive)

SP-C/4-20-80

Pump Flow/Pump Speed

FAIRFIELD Torq-Hub 54:1

ELECTRICAL SYSTEM Electrical Schematic Drawings are located in Section X of the Parts and Maintenance Manual and should be referred to for a better understanding of the Condor electrical system. The Condor utilizes a 12-volt direct current system with a negative ground. All electrical components with the exception of the Proportional Control Valves operate directly from the 12 VDC source. The proportional control valves are energized at the ground control station through toggle switches which have a resistor on the supply terminal. The resistor drops the voltage to a level for continuous operation. The Aerial Control Station contains lever type proportional controllers capable of delivering the required proportional voltage to the valves through the entire movement of the controller handles.

NOTE:

Refer to Section VII for troubleshooting the Electrical System and for a thorough explanation of the system.

T) prevent early problems and to aid in troubleshooting the electrical system, the use of an hydrometer will determine the condition of the battery. Although the battery may have enough charge to start the Wisconsin Engine, it may not have adequate capacity to operate the Bertea System. Check the specific gravity of the battery. An acceptable reading on a fully charged battery will read approximately 1,200 on an hydrometer. The Ground Control Station is primarily an emergency control station. Anyone on the ground can transfer operation from the operator in the platform by switching the aerial ground toggle switch to the ground position. When in the ground position, lift, rotation, extension and retraction are controlled with momentary bi-directional toggle switches. Each of the ground toggle switches, when activated, electrically energizes the pump solenoid valve which advances the pump from standby to a working position. With hydraulic pressure, the engine RPM is increased to 2,100. The function selected is now hydraulically and electrically energized and operational. Proportional Speed Controllers used to control drive, lift, turret rotation,boom extension/retraction, are located at the aerial station. Bi-directional toggle switches are used for steering, tilt and platform rotation.

NOTE: See O.E.M. Literature, Section VII, for details of operation and adjustment for deadband (threshold). Engine start and stop at the aerial station and ground station are independent circuits. The Condor can be started or stopped at any time from either position. After the master switch has been turned on, depress start button. To stop takes only a momentary touch of the stop button.

NOTE:

The engine stop circuit is considered a safety feature and must be maintained as a safety item.

SP-C/4-20-80

To perform electrical checks, turn master switch on. Remove engine coil wire from coil and depress engine start button momentarily. This resets the main latching relay and will energize the entire electrical system.

NOTE: Watch ammeter for a discharge condition. Should a discharge reading occur, momentarily depress start button again, and continue this procedure until a no discharge condition prevails. Install a volt ammeter in series on turret rotation, wire #21 or wire #22 at the pilot valve. Activating the ground control turret rotation switch will result in energizing the pump solenoid valve and send an electrical signal to the pilot valve through the volt ammeter. A reading of between 40 to 60 milliamperes would register. If there is no reading, reverse direction of the switch or controller. If still no reading, then check for voltage into switch or controller. Should there be voltage into switch and no voltage into pilot valve, then check for damaged or broken wire or connection. The above example can be used to quickly troubleshoot any of the functions on the Self-Propelled Condor.

SP-C/4-20-80

MECHANICAL AND ELECTRICAL CABLE ADJUSTMENT To properly torque and adjust mechanical cables, completely retract boom and remove cover on back of boom. Refer to Figure 2. Remove cotter pins from Cables A and B and loosen jam nut. Torque Cable A to 60 foot pounds. Care must be taken to prevent cable from turning. Use vise grips to hold cable. Torque Cable A to 60 foot pounds first, then Cable B to 60 foot pounds. After mechanical cables have been properly torqued, check adjustment. Figure 1, Item C, Spring must measure 1-1/8 plus or minus 1/8. This measurement can be checked through the inspection hole located in Item D Cover Plate. Should it be necessary to adjust electrical cable, remove cover plate to make correction. By extending and retracting boom a couple of time, re-check torque on mechanical cables and measurement on electrical cable. Adjust if necessary. Replace lock nut, cotter pins and cover plate.

F 1 G.1

SP-C/4-20-80

FIG. 2

SELF-PROPELLED CONDOR SPARE PARTS LIST Stock will vary depending on units in inventory and type of use. 8512-K-2, or 8511-K-2, or 8502-K-4, or 8500-K-9, or A3N 9518 Key KB-17D-1-12V SW-3 E3OJT 109-220-101 10-040

8502-K2 8501-K2 8512-K4 8510-K9

Switch Switch Switch Switch (for Model 6066) Limit Switch Lever (for Model 6066) Key Switch Latching Relay Solenoid Stop, Start Switch Circuit Breaker Flasher

WISCONSIN ENGINE PARTS VJ-68 Rectifier Module VJ-59 Regulator Module DJ-16J Champion Spark Plug 1GS -2224LB Point Set Condensor 1BB-204255

O.E.M. PARTS MS3M836 MS3M983

O.E.M. Std. Controller O.E.M. Drive Controller

BERTEA PARTS 234912

Pilot Valve

HYDRAULIC SPARE PARTS S-29 C-68 RU-40-S4 2950-34 3489-34 2672-34 4382-34 4381-34 4394-34 4395-34 4366-34 4366-34 3489-34 SX-1-3/8

SP-C/4-20-80

Oil Filter (System Return) Oil Filter (Control Pressure) Oil Filter (Engine) Steering Cylinder Seal Kit Master Leveling Cylinder Seal Kit Topping Cylinder Seal Kit (Model 4046) Topping Cylinder Seal Kit (Models 5056-6066) Topping Cylinder Seal Kit (Models 3238-4248) Extension Cylinder Seal Kit (Model 4248) Extension Cylinder Seal Kit (Model 6066) Extension Cylinder Seal Kit (Model 3238) Extension Cylinder Seal Kit (Model 4046) Leveling Cylinder Seal Kit Pillow Block

INTERVAL SYMBOL

SEMI-MONTHLY

A MONTHLY 0 ANNUALLY

TYPE OF LUBRICANT CG- SHELL DARNA AX70330 or EQUIVALENT EO- S.A.E. 30 WEIGHT GO - SAE 90 WEIGHT EP SL- CROWN 7045 HEAVY DUTY OPEN GEAR AND WIRE ROPE LUBE OR EQUIVALENT

CG - CHASSIS GREASE

NYLATRON BEARINGS (BothSides

EO - ENGINE OIL GO - GEAR OIL

SL - SPRAY LUBE

SHEAVE PIN AIR A CLEANER LA OIL BATH

NOTE:

* WARNING LUBRICANT MUST 1121 CONTAIN

CRANK CASE DRAIN

LITHIUM

CRANK CASE FILL

SELF-PROPELLED CONDOR LUBRICATION

❑

4 MONTHS or 100 HOURS

LUBRICANT

OIL FILTER CHANGE

G SPEED REDUCER TIE RODS (Two Places Each Side) STEERING KNUCKLE (Two Places each side)

GO TORQUE HUB

RING GEAR (4 Places) ROTATE WHILE LUBING RE-PACK WHEEL BEARINGS (Wheel Bearing Grease)

INTERMEDIATE BOOM CABLE SHEAVE (One place underneath)

INNER BOOM SKIRT LEVELING CYLINDER PIN

INTERMEDIATE BOOM CABLE SHEAVES TOPPING CYLINDER (Two Places) STEERING CYLINDER PIN

PLATFORM ROTATION CYLINDER PIVOT POINTS

DIP STICKS

SKIRT (Two places) AND TOP PIVOT BRACKET AND BOTTOM PILLOW BLOCK

HYDRAULIC TANK FILTER CHANGE

STEERING CYLINDER PIVOT POINTS (Both. Sides)

S ELF-PROPELLED C ONDORLUBRICATI ON

PLATFORM LEVELING SLAVE CYLINDER (Two Places)

MASTER LEVELING CYLINDER (Two Places)

Lubrication Type EP 90 Oil Temperature • Continuous —160°F • Intermittent — 200°F Oil Change • Initial — After 50 hours of operation • Subsequent — 1000 hours or one year which ever comes first Oil Fill Level • Unit mounted horizontal — half-full

• Shaft or spindle mounted down — lubrication must be as high as top of cluster bearings per chart

S P 4200/9-12-79

HYDRAULIC OIL SPECIFICATIONS for CALAVAR AERIAL WORK PLATFORMS

OIL COMPANY

BRAND NAME

CHEVRON

GULF

SHELL

ATF ATF Dextron II Dexron I] Donax D Series

UNION

ATF Dexron

MOBIL

ATF 220

CONOCO

Dexron II

VISCOSITY, SUS @ 100° F SUS @ 210° F

205 50.1

195 50.4

175 49

200 52.3

187 50

170 50

VISCOSITY INDEX TYPICAL

150

155

160

172

159

145

FLASH POINT ° F

350°

405°

390°

395°

320°

365°

POUR POINT ° F

-45°

-50°

_450

-45°

-50°

-45°

SP-C/4-20-80

TROUBLESHOOTING GUIDE In the following section are possible problems and their solutions. This section will save down time and provide a starting point for the mechanic to troubleshoot and isolate the cause for malfunction.

PART 1 - WISCONSIN ENGINE 1. ENGINE WILL NOT START (will not turn over) A. B. C. D. E.

Check Check Check Check Check

battery and connection starter solenoid master switch latching relay starter

2. ENGINE WILL NOT RUN (engine turns over) A. B. C. D. E.

Check Check Check Check Check

gas ignition coil and points fuel pump and fuel line choke and air cleaner fuel filter

3. ENGINE WILL NOT START - LP GAS A. B. C. D. E.

L.P. bottle opened too fast Fuel line connection to bottle loose Fuel flow to carburetor (lock off filter & vacuum switches) Fuel storage tank empty Regulator or carburetor

4. LOSS OF POWER (engine) A. B. C. D.

Timing Governor setting (refer to Wisconsin Engine Manual) Engine RPM too low Wrong fuel (regular gasoline only)

5. UNIT WILL NOT START (electrical) A. B. C. D.

Battery dead Battery connection Solenoid bad Check battery alternator

SP-C/4-20-80

PART II - ELECTRICAL 1. BATTERY DEAD A. B. C.

Master switch left on with start circuit energized Alternator inoperative (regulator or rectifier module) Battery not to full charge a. b.

Dead battery Condor battery used to jump start other equipment

2. FUNCTION INOPERATIVE FROM GROUND AND AERIAL A. B. C. D.

Check Check Check Check

controller and toggle switch wiring for continuity pilot valves for voltage into circuit

3. FUNCTION INOPERATIVE FROM EITHER GROUND OR AERIAL (Bertea) A. Refer to Item 2 above 4. FUNCTION INOPERATIVE (Solenoid valve assembly) A. B. C.

Check coil on solenoid valve Refer to Items 2 and 3 Check toggle switch

5. NO HYDRAULIC PRESSURE (Engine running, no high RPM) A. B. C.

Check circuit to pump solenoid Check coil on pump solenoid (magnetic field if energized) Open hydraulic tank gate valve

6. FUNCTION WILL CREEP WHEN NOT IN USE (Pump on stroke, high engine RPM) A. B. C.

Check controller for null Check for voltage crossing over into another circuit Air in end cap

PART III- HYDRAULIC 1. FUNCTION INOPERATIVE (Engine running high RPM, hydraulic pressure at 2,100 or 2,200 PSI) A. B. C.

Check for control pressure (350 to 370 PSI) Check for plugged control pressure oil filter Check in-line filter into main valve

2. NO CONTROL PRESSURE A. Flow control valve (replace)

SP-C/4-20-80

3. LOW OR NO HYDRAULIC PRESSURE A. B. C.

Refer to Item 5 - Electrical Check compensator on John Deere Pump (set too low) Check oil tank gate valve

PART IV - DRIVE 1. LOSS OF DRIVE POWER A. B. C. D. E. F.

Pump pressure set too low Driving unit in high gear Engine RPM too low Flow divider valve Posi-Traction Valve (open) Bad drive motor

2. UNIT WILL NOT MOVE FORWARD OR REVERSE A. B.

Check torque hub (may be out of gear) Refer to Item 2 - Electrical Section

3. UNIT WILL NOT SHIFT TO LOW OR HIGH (Model 6066 only) A. B. C. D.

Check limit switch (boom elevation and extension) Check two speed toggle switch and wiring Check hydraulic shift cylinder Check hydraulic two-speed solenoid valve (Hydraulic pane Figure 11, Item 123.

4. NO STEERING A. B. C. D.

Needle valve controlling oil flow to solenoid valve bank Check toggle switch and wiring Check coil on Waterman Valve Damaged steering cylinder, or broken hydraulic line

NOTE: Above would apply to Platform Rotation and Tilt 5. BRAKES APPLY TOO FAST A. B.

Alter brake adjustment valve (close slightly and reseal) "0" Ring on brake release piston damaged (W.S.I.)

6. BRAKES APPLY TOO SOON A. Alter brake adjustment valve (open slightly and reseal)

PART V - BOOM OPERATION 1. NO LIFTING POWER A. B.

Internal leak (cylinder) Check system hydraulic pressure. Refer to specification page for applicable unit.

SP-C/4-20-80

2. BOOM BLEEDS DOWN

A. B. C.

Check emergency bleed down valve (may be open) Holding valve topping cylinder Internal leak (cylinder)

3. BOOM RETRACTS (bleeds in or out) A. B.

Check holding valve Internal leak (cylinder)

4. ELECTRICAL CABLE MOVING IN AND OUT WITH BOOM (at platform) A. B.

Check electrical cable adjustment. NOTE: This adjustment can be seen on bottom of boom at turn-around bracket cover, and should be 1-1/8" from spring end to housing. Boom mechanical cables loose (re-torque to 60 lbs.)

5. EXCESSIVE BOOM PLAY A. Missing or worn wear pads

PART VI - TURRET

1. EXCESSIVE TURRET ROTATION BACKLASH (turret rotation) A. B. C.

Check rotation gear box (loose) Check brake in gear box (tighten) Check ring gear bolts for torque (140 lbs. turret, 80 base)

2. BROKEN PIN RETAINERS BOTH TURRET AND BOOM A. Lack of lubrication

SP-C/4-20-80

PREVENTIVE MAINTENANCE This section is devoted strictly to preventive maintenance. By using the Condor Installation Inspection Report as a guide line, the owner has a starting point from which a successful preventive maintenance program can begin. Located under "Lubrication" in the Calavar Section of the Part Manual is the Lubrication Chart showing the location of all the lube points. The specifications for lubrication and general inspection referred to in this section may have to be changed due to the application or environmental conditions the Condor is subjected to. For example: The air cleaner may have to be checked and serviced more frequently when the Condor is used in a sand blast operation than would normally be done if the unit was being used for assembly of fire sprinkler system. The following items should be checked and followed depending on the type of use to ensure the unit is in top mechanical condition. A. GENERAL APPEARANCE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Clean unit (free of oil and dirt) Operation and safety decals in place and legible Tire pressure - see stencil on carriage Tire condition (free of serious cuts or defects) Proper engine oil level Proper hydraulic oil level Air cleaner oil level Battery electrolyte level Battery fully charged Fuel level Check and lube, if necessary (Check lube chart for locations). Check ring gear bolts for proper torque, 140 top, 80 bottom with Nordic lockwasher. Proper engine RPM Proper brake operation Hour meter reading

B. SEMI-MONTHLY 1. 2.

Check and lube, if necessary Check battery electrolyte level

C. MONTHLY, OR FIRST 50 HOURS 1. 2. 3. 4. 5. 6. 7.

Check and lube, if necessary Check condition of battery Check air cleaner Change engine oil filter Change hydraulic return oil filter Check boom cables for torque Check ring gear bolt for torque

SP-C/4-20-80

D. SIX MONTHS, OR 100 HOURS 1. 2. 3. 4. 5. 6.

Check and lube, if necessary Change control pressure oil filter Change engine oil filter Change hydraulic return oil filter Check ring gear bolts for torque Safety inspection (return form to Calavar)

E. ANNUALLY 1. 2. 3. 4. 5. 6. 7.

Repack all wheel bearings Check oil level---speed reducer, turret rotation Change hydraulic oil (if unit has been used in sand blast operation regularly) Check torque hub oil level Check condition of boom cables Safety inspection Refer to lubrication chart

SP-C/4-20-80

IC CALR

VAR

CORPORATION

LOWER RING-GEAR BOLTS AND LOCKSTRIPS: TYPICAL INSTALLATION

4; .;

II= MO •IMM

.1=0

Lockstrip

7rP /

/ /- /

...vim,.

ku■ esamilhwakIneklar rT gni 1. Install lockstrips as shown. • Use Kit #58004 for Condor Models 76, 68, 58, 56, 50, 6066, 5056, 4248. • Use Kit #58005 for Condor Models 60N, 46N, 36N, 4046N. • Use Kit #58006 for Condor Models 48, 4046, 3036N. 2. Bolts are special (grade, strength & length) for the Condor machines. DO NOT USE ANY OTHER BOLTS. 3. Do not use lockwashers. 4. Torque lower ring-gear bolts to 105 ft-#s ± 5 ft-#s, using conventional criss-cross torque sequence. 5. Bend-up ears (ends of lockstrips) on flat of bolt hex head as shown. Bend two places for each lockstrip.

Note: BE CERTAIN THE LOWER RING-GEAR BOLTS ARE CHECKED DURING THE NORMAL INSPECTION/SERVICING, AFTER EVERY 50-HOUR OPERATION OF YOUR CONDOR MACHINE(S).

CIllftwira a CORPORATION

LOWER RING GEAR-BOLTS & LOCKSTRIPS: BILL OF MATERIAL

1. Kit #58004 for Condor Models 76, 68, 58, 56, 50, 6066, 5056, 4248, and 3238. Consists of: •

Lockstrip Calavar Part #68237; Qty = 9 Special Hex Head Capscrews; 1/2-13 UNC x 1-3/4 long Calavar Part #BOW36107; 18

Qty -

Kit #58005 for Condor Models 60N, 46N, 36N, and 4046N. Consists of:

•

Lockstrip Calavar Part #68226; Qty = 9

•

Special Hex Head Capscrews; 1/2-13 UNC x 2-3/4 long Calavar Part #BOW36111; Qty = 18

Kit #58006 for Condor Models 48, 4046, and 3036N. Consists of: •

Lockstrip Calavar Part #68226; Qty = 9

•

Special Hex Head Capscrews; 1/2-13 UNC x 1-3/4 long Calavar Part #BOW36107; Qty = 18

Note: Bolts are special (grade, strength and length) for the Condor machines. Use only Calavar supplied bolts in the above kits. DO NOT USE ANY OTHER BOLTS.

GENERAL SPECIFICATIONS AND INFORMATION 1. ENGINE A. B. C. D. E.

Wisconsin VG4D Operating speed 2100 RPM Idle speed, 1250 RPM Battery, 12 volt, 83 amp. hr . External Alternator, 37 amp. at 2100 RPM engine speed

2. PUMP A. B.

John Deere, PR-24 For pressures and flow, see Table 1 on Page

3. MAIN VALVE A. B. C. D. E.

Bertea System Relief, 2750 PSI Control Relief, 300 PSI Control Pressure, 350 to 370 PSI Operating Voltage,. 4.2 volts, 60 milliamperes (max.)

4. SOLENOID VALVE A. B. C.

Racine Valve Operative Voltage - 12 volt Operating Flow, 3 GPM

5. HOLDING VALVES (set and sealed at factory) A. B. C.

Platform leveling holding valve, 3200 PSI Boom lift holding valve, 3200 PSI Boom extension relief valve, 1200 PSI

6. BOOM- MECHANICAL CABLES Torque bottom (retraction) cable first at 60 ft. lbs., then torque top (extension) cable to 60 ft. lbs. 7. ELECTRICAL CABLE ADJUSTMENT A. 1-1/8 plus or minus 1/8 from end of spring to spring housing 8. TIRE PRESSURE A. 65 PSI - Model 4046 • 70 PSI - Models 3238, 4248 75 PSI - Models 5056, 6066 9. RING GEAR BOLTS A. B.

Base to ring gear, 80 ft. lbs. (Bowmalock bolts) Turret to ring gear, 140 ft. lbs. (Special bolts and nuts)

SP-C/4-20-80

10. WEIGHT (approximate only) A. B. C. D. E.

Model Model Model Model Model

3238 4046 4248 5056 6066

15,000 12,000 15,000 22,000 22,000

lbs. lbs. lbs. lbs. lbs.

11. FUNCTION TIME TABLE, plus or minus 10%

FUNCTION

Model 4046

Boom Extension

41 sec..

24 sec.

25 sec.

.47 sec.

Boom Retraction

.44

Topping - Up

Topping - Down

117

104

112

110

Turret Rotation - CCW 114

110

115

105

100 ft. drive forward - high

100 ft. drive reverse - high

Turret Rotation - CW

SP-C/4-20-80

Models 3238/4248

Model 5056

Model 6066

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Iar\VAR

CALAVAR CORPORATION

CONDOR® SERVICE INFORMATION

1. If you need assistance or have any service or maintenance questions, Calavar service and parts personnel are always available by phone or fax. The telephone numbers are: (817) 666-4545 Telephone (817) 666-5125 Voice Mail (800) 443-5803 FAX 2. There are numerous written Maintenance Procedures available for this machine. These procedures are available through the Calavar Service Department to anyone who requests them. 3. Service and maintenance are not a substitute for trained, qualified service technicians. Calavar conducts service schools on a continuing basis. Call any of our service or sales persons for a schedule. Remember, training of mechanics is the responsibility of their employer, but Calavar Service Schools help you provide this training. 4. Calavar Service School Training Manuals are available for purchase through the parts department. The part numbers for these manuals are: #92333 for self-propelled models; and #92334 for truck-mounted models.

CALAVAR CORPORATION

8300 IMPERIAL DRIVE, P.O. Box 21447, WACO, TEXAS 76702-1447 • 817-666-4545, 817-666-4544 FAX

INTRODUCTION

THE OPERATOR'S MANUAL MUST BE RETAINED ON THE CONDOR® AT ALL TIMES.

DO NOT ALTER OR MODIFY THIS CONDOR® WITHOUT PRIOR WRITTEN APPROVAL FROM THE MANAGEMENT OF CALA VAR CORPORATION

NOTE: Please refer to the Calavar Parts section of the Operation, Maintenance, & Parts Manual for information pertaining to your CONDOR®.

CALAVAR CORPORATION

Self Propelled Booms and Scissors

WARRANTY Calavar Corporation ("Calavar") warrants to the purchaser that each new aerial work platform made by Calavar is free from defects in material and workmanship arising under normal use and service, in the case of major weidments (chassis, turret and booms), for a period of 5 years after the original shipment of the aerial work platform from Calavar's plant; and in the case of all other parts, for a period of 1 year after the aerial work platform is first placed in service or two years after the original shipment of the aerial work platform from Calavar's plant, whichever occurs first. The obligation and liability under this Warranty is expressly limited to repairing or, at Calavar's option, replacing free of charge, at its factory in Waco, Texas or at an authorized repair facility designated by Calavar, the defective part. In no event shall Calavar or its suppliers be liable to the purchaser or any other person for transportation charges or for any incidental, collateral, special or consequential damages, including without limitation damages for loss of profits, loss of customers, loss of goodwill or work stoppage, claims by any party other than the purchaser, or any other similar damages or loss even if Calavar, its suppliers or its representatives have been advised of the possibility of such damages. Parts claimed to be defective and for which repair or replacement is desired shall be returned transportation prepaid to Calavar's factory for inspection. This Warranty applies to replacement parts provided under the terms of this Warranty only for the remainder of the Warranty period applicable to the original purchase. Any operation of the equipment beyond rated capacity, improper use or application of the equipment, substitution upon it of parts not approved by Calavar or alteration or repair of the equipment by any person not authorized by Calavar shall, at Calavar's option, void this Warranty. Calavar shall have no liability or responsibility for damages resulting from accident or the malfunction of equipment and components not supplied by Calavar. No agent, employee, distributor, dealer or other representative of Calavar is authorized to modify this Warranty in any way. Accordingly, additional statements or presentations by any such representative, whether oral or written, do not constitute warranties by Calavar and should not be relied upon as limited warranties of Calavar, and no attempt, effort or promise to repair equipment by Calavar or any such representative at any time shall modify or extend this Warranty in any way. If the purchaser has used its own order form, no additional or different warranty terms contained in purchaser's form will be honored by Calavar. This Warranty covers only new and unused aerial work platforms manufactured by Calavar. Products or parts manufactured by others are covered only by such warranties as are extended to the purchaser by Calavar's suppliers. This Warranty is in lieu of all other warranties, expressed or implied, including but not limited to warranties of merchantability and fitness for a particular purpose. Any applicable implied warranty shall be limited in duration to the warranty period. 8300 Imperial Drive, P.O. Box 21447, Waco, Texas 76702-1447 • 817-666-4545, 817-666-4544 FAX Form No. 513-1M-495

Printed in U.S.A.

Effective January 1. 1993 WARRANTY PROGRAM Warranty is a function of a manufacturing company to back up the product it manufactures. It is a guarantee against defects in design and workmanship of components utilized in the product, and is offered for a fixed period of time following the purchase of the product by a customer. Calavar Warranty states, in general, that Calavar will replace free of charge any components found to be defective within the time frame of the warranty period. There are exceptions to some components which are not the responsibility of Calavar. These will be outlined in subsequent paragraphs. A. WARRANTY PERIOD 1.

The Self-Propelled Boom and Scissor Warranty is one (1) year from placing the CONDOR® in service or two (2) years following shipment from Calavar, whichever comes first. In the case of major weldments (chassis, turret, and booms), the Warranty Period is five (5) years following shipment from Calavar.

The Truck-Mounted CONDOR® Warranty Period is one (1) year from shipment of the CONDOR® from Calavar's plant.

For parts sold through the Parts Department, the Warranty Period is six (6) months from utilizing the component or placing it in service, or twelve (12) months following shipment from Calavar, whichever comes first, unless the part is furnished to correct a defective part on the original shipment still under Warranty.

Replacement parts provided under the terms of the Warranty are for the Warranty Period applicable to the unit in which they were installed as if such parts were original components of the aerial work platform.

During the Warranty Period, in addition to covering the parts replaced under Warranty, Calavar will pay a Dealer Warranty Labor Rate which is based on a percentage of your standard shop labor rate. NOTE: The term "IN SERVICE" means that the Warranty starts at the time the CONDOR® is first used for any purpose. An example: The dealer may have purchased a CONDOR® to have in stock, but may not use it. After three months, theCONDOR® is sold or the dealer decides to put the CONDOR® into its rental fleet. In this situation, the Warranty Period begins the day the dealer puts the CONDOR® into the fleet or when the CONDOR® is delivered to the end user.

The submittal of a warranty claim against a stock machine constitutes it as being "in service," initiating the warranty period.

B. PRE-DELIVERY INSPECTION SHEET (P.D.I.) 1.

Each Self-Propelled Boom or Scissor CONDOR® shipped from Calavar's facility will have a Pre-Delivery Inspection (P.D.I.) sheet enclosed in the Safety Manual holder tube.

It will be the responsibility of the original recipient of the CONDOR® from Calavar, whether it will be the dealer or the end user, to complete this form and return it to Calavar's facility within 45 days from the date of receipt to set up the Warranty Account.

Failure to complete the P.D.I. sheet and return it to Calavar within the time frame given will result in voiding the Warranty on the CONDOR® .

NOTE: The form must be filled out completely, giving the name of the dealer, address, model number, serial number, person inspecting the CONDOR® 's, signature, and date of inspection. (The date of inspection does not constitute the "In Service" date.) C.

ITEMS NOT COVERED UNDER WARRANTY Some components are used on the CONDOR® which are not warranted by Calavar. However, these are warranted by the component manufacturer. Some of these are:

Engine: Manufacturers used include Wisconsin, Ford, Deutz, Isuzu, Kubota, Onan, Cummins, John Deere, and others. To apply for warranty on the engine, contact should be made with the engine manufacturer's dealer in your area. Calavar can advise you who the dealer is if unknown to you.

Tires and Batteries: These are normal wear items and are considered normal maintenance items. However, if they are found to be defective, contact can be made with the manufacturer's local dealer.

Hydraulic Filters and Fluid: These are considered general maintenance and service items, and are not covered by warranty.

Other components: Products or parts manufactured by others are covered only by such warranties as are extended to Calavar by its suppliers.

Freight and Charges: The warranty does not include any transportation, other charges, or the cost of installation or any liability for direct, indirect, or consequential damages or delay resulting from the defect.

Travel Time / Mileage: Travel time and the mileage to and from dealer facilities to CONDOR® location are not covered or reimbursable.

Troubleshooting: Troubleshooting is not covered or reimbursable. However, Calavar Warranty will cover reasonable labor charges for the removal and replacement of defective components.

PROCESSING OF WARRANTY CLAIM During the Warranty Period, should a component failure be encountered within the guidelines of the Calavar Warranty Policy, the following procedure is to be followed: 1. Upon identifying the defective component, the replacement can be obtained by: a.

Issuing an order to our Parts Department through normal channels, which entails your being invoiced.

You may have previously purchased the part from Calavar for your stock and will utilize it for this replacement.

The above two methods will enable you to indicate on the claim the Calavar invoice number to substantiate the parts purchase and the amount to be credited. c.

Although not recommended, you may purchase the part locally. When this is done, a copy of the purchase order or receipt MUST accompany the claim. Calavar has the option to ship a replacement part at no charge if the local cost would be greater, in lieu of issuing credit for locally purchased parts.

When parts are puchased from Calavar, part numbers with invoice numbers MUST be referenced in the appropriate section of the claim form.

2. Complete the Warranty Claim as noted in the "Warranty Claim Procedure" section. Provide as much information as possible to enable Calavar to thoroughly evaluate the claim and process it in the shortest amount of time possible. NOTE: WARRANTY CLAIMS NOT RECEIVED BY CALAVAR WITHIN 45 DAYS OF FAILURE WILL BE DENIED 3. Provided no return parts are required and all the information has been verified, the claim will be processed and credit will be issued against your account. E.

RETURN AUTHORIZATION 1.

If a component is found to be defective within the normal guidelines of the Warranty, a Warranty Claim Form must be completed.

It will be necessary for you to call the Calavar Service Department and ask to be issued a Return Authorization (R/A) number. You will be asked for a Dealer Claim Number. As noted in Section 2, Item A, of the Warranty Claim Procedure, this is a number assigned by the dealer for the purpose of tracking the claim, as there may be more than one claim for the same CONDOR® . The R/A number issued must be logged in the appropriate section of the claim form, and the gold copy (R/A) of the form must be returned with the parts being returned.

NOTE: DO NOT SHIP ANY RETURN PARTS WITHOUT A RETURN AUTHORIZATION (R/A) NUMBER Doing so may result in parts getting lost in the system and may delay processing the claim, or may cause denial due to the time element of the claim. 3.

All R/A parts must be received at Calavar within 45 days from the date the R/A number was issued. Failure to do so will cause the claim to be denied.

All parts claimed under Warrranty will be required to be shipped back to Calavar FREIGHT PREPAID. No freight collect shipments will be accepted.

APPENDIX B

CALAVAR CORPORATION

BOLT TORQUE CHART FOR METRIC HEX HEAD CAP SCREWS • RECOMMENDED ASSEMBLY TORQUES IN FOOT-POUNDS (*VALUES IN LB-IN, OTHERS ARE LB-FT.)

•THE TORQUE VALUES FOR EACH DIAMETER ARE ACCEPTABLE FOR ANY THREAD PITCH IN THAT DIAMETER.

PROPERTY CLASS 8.8 PROPERTY CLASS 9.8 PROPERTY CLASS 10.9 PROPERTY CLASS 12.9 DIAMETER

DRY LUBRICATED THREADS THREADS

DRY THREADS

LUBRICATED THREADS

DRY THREADS

LUBRICATED THREADS

DRY THREADS

LUBRICATED THREADS

27.5*

17*

30*

18*

38.5*

24*

53*

32.5*

56.5*

33.5*

61*

37*

78*

47*

107*

65*

95*

57.5*

103*

61*

132*

79*

180*

109*

M10

M12

127

M14

107

116

146

203

122

M16

167

100

181

108

230

138

316

190

M20

325

195

352

211

449

269

617

370

M24

562

337

609

386

775

465

1066

640

M30

1117

670

1210

726

1540

924

2188

1271

APPENDIX A

N....... CAL,AVAR CORPORATION

BOLT TORQUE CHART BASIC STRESS MAJOR AREA NOMINAL DIA SQ. IN THREADS INCH

TENSILE STRENGTH (T) MIN

4-40 .1120 4-48 .1120 6-32 .1380 6-40 .1380 .1640 8-32 .1640 8-36 10 - 24 .1900 .1900 10 - 32 .2500 1/4- 20 .2500 1/4- 28 5/16 - 18 .3125 5/16 - 24 .3125 3/8 - 16 .3750 .3750 3/8 - 24 .4375 7/17 - 14 7/16 -20 .4375 1/2 - 13 .5000 1/2 - 20 .5000 9/16 - 12 -.. .5625 9/16 - 18 .5625 5/8 - 11 ,.. .6250 5/8 - 18 .6250 .7500 3/4 - 10 3/4- 16 . .7500 7/8 - 9 .8750 7/8 - 14 .8750 1.000 1 -8 1 - 12 1.000 1.1250 1 1/8-7 1 1/8 - 12 1.1250 1.2500 1 1/4-7 1.2500 1 1/4 - 12 1.3750 1 3/8-6 1 3/8- 12 ..., 1.3750 1.5000 1 1/2-6 1 1/2- 12 1.5000

.00604 .00661 .00909 .01015 .01400 .01474 .01750 .0200 .03180 .03640 .05240 .05800 .07750 .08780 .10630 .11670 .14190 .15990 .18200 .20300 .22600 .25600 .33400 .37300 .46200 .50900 .60600 .66300 .76300 .85600 .96900 1.0730 1.1550 1.3150 1.4050 1.5800

SAE GRADE 5

PROOF LOAD (P) SAE GRADE (1957) GRADE 5 GRADE 8 120KSI 120K 5 I 120KSI 120KSI 120KSI 120KSI 120KSI 120KSI 120KSI 120KSI 120KSI

P 85KSI 85KSI 85KSI 85KSI 85KSI '85KSI 85KSI 85KSI 85KSI 85KSI 85KSI

120KSI 85KSI 120KSI 85KSI 120KSI 85KSI 120KSI 85KSI 120 KS I 85K S I 120 KS I 85KSI 120 KS I 85K S I 120KSI 85K S I 120KSI 85KSI 120KSI 85KSI 120KSI 85KSI 120KSI 85KSI 120KSI 285KSI 120KSI 85KSI 120KSI 85KSI 120KSI 85KSI 120KSI 85KSI 105KSI 74KSI ,„ 105KSI 74KSI 105KSI 74KSI 105KSI 1051(51 105KSI 105K51

741(51 74KSI 74KSI 74KS1 105KSI 74KSI

T 150KSI 150KSI 150KSI 150KSI 150KSI 150KSI 150KSI 150K51 150KSI 150KSI 1501(S1 150KSI 150KSI 150KSI

P 120KSI 120KSI 120KSI 120KSI 120KSI 120KSI 120KSI 120KSI 120KSI 120KSI 120KSI 120KSI 120KSI 120KSI

150KSI 120KSI 150KSI 120KSI 150KSI 120KSI 150KSI 120KSI 150KSI 120KSI 150KSI 120KSI 150KSI 120KSI 150KSI 120KSI 150KSI 120KSI 150KSI 120KSI 150KSI 120KSI 150KSI 120KSI 150KSI 120KSI 150KSI 120KSI 150KSI ,., 120KSI 150KSI ,., 120KSI 150KSI 120KSI 150KSI 120KSI 150KSI 120KSI 150KSI 120KSI 150KSI ' 120KSI 150KSI 120KSI

CLAMP LOAD LBS. 380 420 580 640 900 940 1120 1285 2020 2320 3340

ASSEMBLY TORQUE R=.200 DRY R=.150 LUB 8LB-IN 9LB-IN 16LB-IN 18LB-IN 30LB-IN 31LB-IN 43LB-IN 49LB-IN 8LB-FT 101.3-FT 17LB-FT

3700 4940 5600

19LB-FT 30LB-FT 35LB-FT

6800 7550 9050 10700 11600 12950 14400 16950 21300 23800 29500 32400

50LB-FT 55LB-FT 75LB-FT 90LB-FT 1101.8-FT 120LB-FT 150LB-FT 180LB-FT 260LB-FT 300LB-FT 520LB-FT 570LB-FT

38600 42300 42300 47500 53800 59600 64100 73000 78000 87700

770LB-FT 850LB-FT 800LB-FT 880LB-FT 1120LB-FT

6LB-IN 7LB-IN 12LB-IN 13LB-IN 22LB-IN 23LB-IN 32LB- IN 36LB-IN 751.13-IN 86LB-IN 13L13-FT 14LB-FT 23LB-FT 25LB-FT 35LB-FT 40LB-FT 551.3-FT 65LB-FT 80LB-FT 90LB-FT 110LB-FT 130LB-FT 200LB-FT 220LB -FT 390LB-FT 430LB-FT 5801.13-FT 630LB -FT 600LB-FT 660LB-FT 840LB-FT

1248LB-FT 920LB-FT 1468LB-FT 1100LB-FT 1680LB-FT 1260LB-FT 1940LB-FT 1460LB-FT 2200LB-FT 16401.13-FT

SAE GRADE 8 CLAMP ASSEMBLY TORQUE LOAD R=.200 DRY R=.150 LUB LBS. 540 12LB-IN 9LB-IN 600 13LB-IN 10LB-IN 820 23 LB-IN 17LB-IN 920 25LB-IN 19LB-IN 1260 41LB-IN 31LB-IN 1320 43LB-IN 32LB-IN 1580 6 OLB-IN 45LB-IN 1800 68LB-IN 51LB-IN 2860 121.13-FT 9LB-FT 3280 14LB-FT 1 oLB-Fr 4720 25LB-FT 181.13 FT 5220 25LB-FT 20LB-FT 7000 45LB-FT 35LB-FT 7900 50LB-FT 35LB-FT 9550 70LB-FT 55LB-FT 10700 80LB-FT 6OLF3-FT 12750 110LB-FT 801,B-FT 14400 120LB-FT 90LB-FT 16400 ' 150LB-FT 110LB-FT 18250 170LB-FT 130LB-FT 20350 220LB -FT 170LF3-FT 23000 240LB-FT 180LB-FT 30100 380LB-FT 280LB-FT .,, 33600 420LB-FT 320LB-FT 41600 600LB-FT 460LB-FT 45800 660LB-FT 500LB-FT 54500 900LB-FT 680LB-FT 1000LB-FT 7401.13-FT , 59700 , 68700 1280LB-FT 960LB-FT , 77000 1440LB-FT 1080LB-FT 87200 1820LB-FT 1360LB-FT 96600 2000LB-FT 1500LB-FT , 104000 2380LB-FT 1780LB-FT 118400 2720LB- FT 2040LB-FT 126500 3160LB-FT 2360LB-FT 142200 3560LB- FT 2660LB-FT

NOTES: 1.THIS CHART SHOWS RECOMMENDED BOLT TORQUES. 2.TORQUE =RXDXT R = .150 FOR LUB CONDITIONS R = .200 FOR DRY CONDITIONS TO ASSURE CONSISTENCY IN TORQUE, LUBRICATE FASTENERS WITH ENGINE OIL (MAY BE USED OIL) D = NOMINAL DIAMETER IN INCHES T = DESIRED CLAMP LOAD IN POUNDS = 75% PROOFLOAD X STRESS AREA

....

Page of 2

CA LA VAR SELF-PROPELLED CONDOR ILLUSTRATED PARTS LIST

Figure Number

IA IB IC ID 2 3 3A 3C -

3D 4 4A 5 5A 6 6A 7 8 9 10

12 13 I3A

14 15 16 17 18 19 I9A 20 21

SPC 480

Title

Model

Final Assembly Final Assembly Final Assembly Final Assembly Safety Decals and Placards Carriage Weldment Carriage Assembly Carriage Assembly Four Wheel Drive Option

3238, 4248 5056, 6066 4248 E 4046

Four Wheel Drive Steering Assembly Torque brive Assembly W/Modular Valve Modular Valve Hub, Spindle and Stub Axle Assembly Hub, Spindle and Stub Axle Assembly Tire-Wheel Assembly Tire Wheel Assembly Steering Assembly Steering Cylinder Rotary Coupling Turret Assembly (all models except Battery Powered) Turret Proportioncl Valve System Installation Turret Proportional Control Valve Assembly Turret Pump and Emergency Bleed Down Installation Turret Pump and Emergency Bleed Down Installation (Battery Powered) Fuel Tank Assembly Hydraulic Tank Assembly Ground Control Box Assembly Turret Rotation Speed Reducer Instal lation Muffler Installation Air Cleaner and Automatic Choke Instal lation Duel Fuel Does not apply Boom Assembly

3238, 4248, 5056, 6066 4046 4248, 6066

3238, 4248, 5056, 6066 4046 3238, 4248, 5056, 6066 4046

4248, 5056, 6066

iii

NOTES

Page 2 of 2

CALAVAR SELF-PROPELLED CONDOR ILLUSTRATED PARTS LIST

Figure Number 2IA 2IB 22 23 24 25 25A 26 26A 26B 26C 26D 27 27A 28 28A 28B 29 29A 30 31 32

SPC 480

Title

Model

Boom Assembly Boom Assembly Platform Slave Leveling Cylinder Assembly Slave Leveling Cylinder Master Leveling Cylinder Boom Extension Cylinder Assembly Boom Extension Cylinder Assembly Boom Extension Cylinder Boom Extension Cylinder Boom Extension Cylinder Boom Extension Cylinder Boom Extension Cylinder Topping Cylinder Assembly Topping Cylinder Assembly Topping Cylinder Topping Cylinder Topping Cylinder Rotating Fork Assembly Non-Rotating Fork Assembly Platform Rotation Cylinder Platform Control Console Assembly Platform Weldment

4046 3238

4248, 3238, 3238 4046 4248 5056 6066 3238, 4046 3238, 5056, 4046 6066 3238, 6066

5056, 6066 4046

4248, 5056, 6066 4248 6066

4046, 4248, 5056

ILLUSTRATED PARTS LIST LIST OF OPTIONS SELF-PROPELLED CONDOR OPTION NUMBER TITLE

FIGURE NUMBER

21013 6 Ft. X 42 In. X 42 In. Platform 42 21050 Pipe Handling Attachment 33 21051 Platform Rotation, Power Operated 29 21052 Auxiliary Control Receptacle at Plat- 34 form and Console 21053 Auxiliary Control Receptacle at Base 35 and Console 21057 Air Line

21058 110 V. Electric Line Inside Boom with 37 Receptacle at Base and Platform 21059 Rotating Beacon

21060 Headlight and Tail-Light for In-Plant 39 Operation 21062 Platform Work Light

21063 Foam Filled Tire

21064 Solid Tires

21065 12 Ft. Platform

21066 Diesel Engine Assembly 43 21069 LP Gas Assembly

21071 Descent Horn

21072 Automobile Type Horn in Platform 47 21156 Special Paint (One Color) **

OPTION NUMBER TITLE

FIGURE NUMBER

21211 4' X 42" X 42" Platform 42 21292 Platform - Deadman Switch 46 21315 Platform Weldment - 8' 42 21385 Spark Arrestor

21400 Emergency Turret Rotation ** 21431 Bumper Installation 21433 Special Wheel Drive - Diesel ** 21440 In-Plant Towing

A A

21647 110 V. Shaft Driven Alternator Installa- 48 tion 21648 Auxiliary Hydraulic Power Pack Installa- 49 tion - Gas Engine 21650 Auxiliary Hydraulic Power Pack Installa- 49 tion - Diesel Engine 21651 Lifting Eyes

21659 Platform Emergency Descent 51 21704-1 Fiberglass Platform 42" X 42" X 48" 53 21704-2 Fiberglass Platform 42" X 42" X 60" 53 21751 Rotating Fork Assembly 41 21844 5

Automatic Slope Control Assembly 50

21921 Platform Weldment - 5' 42 21943 Emergency Boom Retraction 55

** Not Illustrated

3/30/79

INTRODUCTION

THE OPERATOR'S MANUAL MUST BE RETAINED ON THE UNIT AT ALL TIMES. Do not attempt to operate or service the CONDOR® until you have read and understood all information provided in this manual. Familiarize yourself with the functions and operations of the upper and lower controls. A good understanding of the controls, their limitations, and their capabilities will maximize operating efficiency and safety. The various decals attached to this machine also contain vital safety and operational instructions. Read the decals before operating this machine.

It is YOUR RESPONIBILITY to follow safe procedures while operating the CONDOR®. The manufacturer of this unit cannot control the wide range of applications that may be used in carrying out a variety of jobs. Therefore, it is THE USER'S RESPONSIBILITY to consider the safety of all personnel when making decisions regarding the unit's intended use. It is also YOUR RESPONSIBILITY to understand and obey all federal, state, and local regulations regarding the safe operation and use of aerial work platforms. A copy of the ANSI/ SIA 92.5-1992 Manual of Responsibilities is attached for your use. Calavar Corporation reserves the right to modify, improve, add, and/or delete certain design features of its products without any obligation to incorporate new features into products previously sold. Our manuals are continually updated to reflect these changes.

DO NOT ALTER OR MODIFY THIS UNIT WITHOUT PRIOR WRITTEN APPROVAL FROM THE MANAGEMENT OF CALA VAR CORPORATION

NOTE: Please refer to the Calavar Parts section of the Operation, Maintenance, & Parts Manual for information pertaining to your machine.

CALAVAR CORPORATION

Self Propelled Booms and Scissors

WARRANTY Calavar Corporation ("Calavar") warrants to the purchaser that each new aerial work platform made by Calavar is free from defects in material and workmanship arising under normal use and service, in the case of major weldments (chassis, turret and booms), for a period of 5 years after the original shipment of the aerial work platform from Calavar's plant; and in the case of all other parts, for a period of 1 year after the aerial work platform is first placed in service or two years after the original shipment of the aerial work platform from Calavar's plant, whichever occurs first. The obligation and liability under this Warranty is expressly limited to repairing or, at Calavar's option, replacing free of charge, at its factory in Waco, Texas or at an authorized repair facility designated by Calavar, the defective part. In no event shall Calavar or its suppliers be liable to the purchaser or any other person for transportation charges or for any incidental, collateral, special or consequential damages, including without limitation damages for loss of profits, loss of customers, loss of goodwill or work stoppage, claims by any party other than the purchaser, or any other similar damages or loss even if Calavar, its suppliers or its representatives have been advised of the possibility of such damages. Parts claimed to be defective and for which repair or replacement is desired shall be returned transportation prepaid to Calavar's factory for inspection. This Warranty applies to replacement parts provided under the terms of this Warranty only for the remainder of the Warranty period applicable to the original purchase. Any operation of the equipment beyond rated capacity, improper use or application of the equipment, substitution upon it of parts not approved by Calavar or alteration or repair of the equipment by any person not authorized by Calavar shall, at Calavar's option, void this Warranty. Calavar shall have no liability or responsibility for damages resulting from accident or the malfunction of equipment and components not supplied by Calavar. No agent, employee, distributor, dealer or other representative of Calavar is authorized to modify this Warranty in any way. Accordingly, additional statements or presentations by any such representative, whether oral or written, do not constitute warranties by Calavar and should not be relied upon as limited warranties of Calavar, and no attempt, effort or promise to repair equipment by Calavar or any such representative at any time shall modify or extend this Warranty in any way. If the purchaser has used its own order form, no additional or different warranty terms contained in purchaser's form will be honored by Calavar. This Warranty covers only new and unused aerial work platforms manufactured by Calavar. Products or parts manufactured by others are covered only by such warranties as are extended to the purchaser by Calavar's suppliers. This Warranty is in lieu of all other warranties, expressed or implied, including but not limited to warranties of merchantability and fitness for a particular purpose. Any applicable implied warranty shall be limited in duration to the warranty period. 8300 Imperial Drive, P.O. Box 21447, Waco, Texas 76702-1447.817-666-4545, 817-666-4544 FAX Form No. 513-1M-495

Printed in U.S.A.

How to Order Parts

When ordering parts for your CONDOR®, ensure that you are able to give the model and serial numbers of all units for which parts are needed. The serial number(s) will assist the Calavar Parts Department in providing the correct parts for your machine(s). Please refer to FIGURE A for Serial Number Location on this model.

If known, please specify the Calavar part number(s) for the part(s) you require, and always provide a complete description of all parts.

Fax orders are preferable, though parts may also be ordered by mail and telephone. A sample parts order (with fax number) follows this page.

Parts needed for a warranty repair must be purchased through the Calavar Parts Department. Credit will be authorized through the Service Department after a Warranty Claim has been submitted to Calavar. A Warranty Claim is to be filed for any part received as "defective".

Calavar will ship parts as per our customers' request at the time of the order—i.e., UPS, Federal Express, or preferred truck line. When shipping Federal Express, your customer account must be given at the time of the order.

Calavar classifies its orders in the following ways: Emergency (unit out of service) - Top priority. Shipping deadline for emer-

gency orders to ship same day is 2:00 p.m. Central Standard Time. Any emergency order received after 2:00 p.m. will be shipped the following day. Stock Order to be shipped within (1) week.

Calavar has a $25.00 Net Minimum Billing charge per order.

All price quotations will be valid for 90 days.

Parts shown as shipped on the Calavar packing list and subsequent invoice but not received by the dealer/customer MUST be reported within 10 days after the date of shipment. If the parts are still required, a NEW parts order must be submitted. Shortages and discrepancies will be reviewed on an individual basis by the Parts staff and adjustments will be made accordingly.

10.

Invoice discrepancies regarding incorrect prices or discounts should be reported immediately to the Parts Department. Report the Sales Order number, Purchase Order number, and Invoice number. Your request will be reviewed and adjustments will be made accordingly.

CALAVAR PARTS DEPARTMENT FAX ORDER FORM FAX NO. 800-443-5803 PURCHASER

ACCOUNT# I c N U F S 0 T R 0 M M A E T R I

NAME

NAME ADDRESS CITY PHONE

N ( ) CUST. PURCHASE ORDER NO.

SALES ORDER #

STATE ZIP

S ADDRESS H T I 0 p CITY STATE ZIP PHONE

FAX ( ) ORDER DATE

FAX ( ) ( ) REQUEST DATE SPECIAL MARKS & NUMBERS

SHIPPING INSTRUCTIONS

PART NUMBER

QTY.

DESCRIPTION

FOR ORDER STATUS PLEASE CHECK APPROPRIATE BOX BELOW EMERGENCY STOCK

NOTES

21 22 23 24

11,.. ITAVAIR

r L

45 25

VIEW B ...

■••■••■

18 17 11 16 15 14 tIl F."

49 50 51 32

LA) N.) LA) 00

N.) 00

FIGURE 1 - FINAL ASSEMBLY (3238, 4248)

Final Assembly

PART NUMBER

DESCRIPTION

REF

1 2 3 4 5 6

- 7 - 8 - 9 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25 -26 -27 -28 -29 -30 -31 -32 -33 -34 -35 -36 -37 -38 -39 -40 -41 -42 -43

Carriage Weldment Carriage Assembly Turret Assembly Door - Left Door - Right "Do Not Lift Wheels with Decal Boom" (inside of both doors & Decal - "lithe Fitting" Lower Hinge Block Upper Hinge 0 Hex Head Capscrew Lockwasher Nameplate - Operation Instructions Decal - Hazard & Accident Prevention Decal - Hazard & Accident Prevention Decal - Hazard & Accident Prevention Nameplate - Caution Hex Head Capscrew Engine Hood Rotating Beacon (Option 21059) Decal - Hazard & Accident Prevention Nameplate -Hydraulic Fluid (Nearside) Nameplate - Gas (Farside) Hex Head Capscrew Lockwasher Turret Side Plate Boom Assembly -

Decal - Condor Nameplate - Caution & Warning Nameplate - Transportation Rotating Fork Assembly Platform Control Console 6 Ft. Platform Weldment Nameplate - Platform Capacity Nameplate - Fork Caution & Warning Decal - "FWD" Decal - "Tire Pressure 70 PSI" Hex Head Capscrew Lockwasher Hex Nut Flat Washer Decal - "FWD" Decal - "Close for Positraction" Decal - "Position Lever Up for High Speed"

QTY

40026 (3238) 1 40028 (4248) 1 (See Fig. 2) 1 (See Fig. 3) 1 (See Fig. 10) 1 40068 1 40067 1 21971-2 4' both _sides of inner bo3m) 21079 (4248) i 21790 • 2 21795 2 3/4-18 UNF X 1 4 1 14 4 1 21415 2. 21882-2 21882-3 2 21882-4 2 .1 21854 10 3/4-28UNC X k 40066 1 1 (See Fig. 38) 21882-1 3 21850 1 1 21849 3/8-18 UNF X k 6 3/8 6 1 21794 (See Fig. 21) (4248) 1 (See Fig. 21B)(3238) 1 21834 2 1 21416 21658(3238)21055(4248) 2 (See Fig. 29) 1 (See Fig. 31) 1 1 (See Fig. 32) 1 21577 1 • 21837 1 21873-2 2 21971-6 4 7/16-14 UNC X 3-k 4 7/16 4 7/16 - 14 UNC 8 7/16 1 21873-1 1 21971-4 1 21971-1

,s Immo,

N.)

(I) CD

A 'IgNHSSVrIVNI,1

FIGURE 1 - FINAL ASSEMBLY (3238 & 4248 DESCRIPTION

REF

-44 -45 -46 -47 -48 -49 -50 -51

Decal - "Calavar Corporation" Nameplate- Serial Number (Farside) Nameplate - Emergency Bleed Down Decal -"Battery Replacement!' Decal - "Operation and Safety Manual" (on holder inside compartment) Safety Belt Assembly Lanyard Belt

PART NUMBER

15430 15843 21264 21399 21384 21280 21281 21238•

QTY 1 1 1 11 1 1 1 -1

3/30/79

FIGURE lA - FINAL ASSEMBLY, (5056 , 6066) 43

Inet cl

FIGURE lA - FINAL ASSEMBLY5056 6066

DESCRIPTION

REF

1 2 3 4 5 - 6

- 7 - 8 - 9 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25 - -26 -27 -28 -29 -30 -31 -32 -33 -34 -35 -36 -37 -38 -39 -40 -41 -42 -43 -44

(NIcNi ••■1* 00 1-1 r-4 0 r4 Cr) I-1 ra r-I r-I N 1-1 r-I 1-11-4 r-I r-4 1-4 *-1 1-4 T-4 r-1 1-4 CNI CN1 0 *-1 CN1 CNI (NI

40029 (5056) 40030 (6066) (See Fig. 2) Carriage Weldment (See Fig. 3) Carriage Assembly (See Fig. 10) Turret Assembly 40068 Door - Left 40067 Right Door 21971-2 Decal "Do Not Lift Wheels with Boom" (inside of Both Doors and both sides of inner boom) 21079 Decal "Lube Fitting" 21790 Lower Hinge Block 21795 Upper Hinge 1/4-28 UNF X 1 Hex Head Capscrew 1/4 Lockwasher 21415 Nameplate-Operation Instructions 21882-2 Decal-Hazard & Accident Prevention 21882-3 Decal-Hazard & Accident Prevention 21882-4 Decal-Hazard & Accident Prevention 21854 Nameplate-Caution 1/4-28 UNC X 1/2 Hex Head Capscrew 40066 Engine Hood (See Fig.38) Rotating Beacon (option 21059) 21882-1 Decal-Hazard & Accident Prevention 21850 Nameplate-Hydraulic Fluid (Nearside) 21849 Nameplate-Gas (Farside) 3/8-18 UNF X 1/2 Hex Head Capscrew 3/8Lockwasher 21794 . Turret Side Plate (See Fig. 21) Boom Assembly 21834 Decal "Condor" 21416 Nameplate-Caution & Warning 21658 Nameplate-Transportation (See Fig. 29) Rotating Fork Assembly (See Fig. 31) Platform Control Console (See Fig. 32) 6 FT. Platform Weldment 21766 (6066) Nameplate-Platform Capacity 21364 (5056) 21837 Nameplate-Fork Caution & Warning 21873-2 Deed1-"FWD" 21971-51 Decal-"Tire Pressure 75PSI" 7/16-14 UNC X 3-1/2 Hex Head Capscrew 7/16 Lockwasher 7/16-14 UNC Hex Nut 7/16 Flat Washer 21873-1 Decal-"FWD" 21971-4 Decal"Close For Positraction" 21971-1 Decal"Position Lever Up for High Speed" 15430 Decal-"Calavar Corporation" Final Assembly

IA-

PART NUMBER

1 2

'IVNI 3-VT

47 4 48 5 11 6 51

53 54 55 32

ximsla s s v

- FINAL ASSEMBLY (5056 1 6066 REF

-45 -46 -47 -48 -49 -50 -51 -52 -53 -54 -55

DESCRIPTION

Nameplate-Serial Number (Farside) Nameplate-Emergency Bleed Down Door Stop Hex Head Capscrew Decal - "Battery Replacement" Nameplate - Caution (5 ° Automatic Slope Control) Decal - "Operation and Safety Manual" (on holder inside compartment) Front counterweight Safety Belt Assembly Lanyard Belt

PART NUMBER

QTY

15843 21881 21868 1/4-28 UNF X 1/2 21399 21880 (6066)

1 1 2 6 1 1

21384

21738 21280 21281 21238

11 1 1

1 6 c=r. 1 IC Mi. INWER LOAPGRADON

42— VIEW B

79 tri F-4

KIEDE S S V 'I VNI 3

N.) Co CrJ

FIGURE 1B - FINAL ASSEMBLY 04248E REF

Final Assembly 21897 Carriage Weldment (See Fig. 2) Carriage Assembly (See Fig. 3) Turret Assembly (See Fig. 10A) Nameplate-Caution 21854 Decal-Hazard & Accident Prevention 21882-2 Decal-Hazard & Accident Prevention 21882-3 Decal-Hazard & Accident Prevention 21882-4 Nameplate-Operation Instructions 21415 21426 Door-Right 21795 Hinge Hinge Block 21790 Hex Head Capscrew 1/4-28 UNF X 1 Lockwasher 1/4 21971-2 Decal "Do Not Lift Wheels With Boom" (Inside of Door and both sides ofinner boom) Decal - 'Ube Fitting" 21079 Decal-Hazard & Accident Prevention 21882-1 Rotating Beacon Option 21059) (See Fig. 38) Nameplate-"Hydraulic Fluid" 21850 Hex Head Capscrew 3/8-18 UNF X 1/2 Lockwasher 3/8 21794 Turret Side Plate (See Fig. 21) Boom Assembly 21834 Decal "Condor" 21416 Nameplate=Caution & Warning 21658 Nameplate-Transportation (See Fig. 31) Platform Control Console 1/4-28 UNF X 1/2 Hex Head Capscrew (See Fig. 29) Rotating Fork Assembly (See Fig. 32) 6 Ft. Platform Weldment 21873-1 Decal-"FWD" 21971-4 Decal-"Close for Positraction" 21971-1 Decal-"Position Lever For High Speed" 21577 Nameplate-Platform Capacity 21837 Nameplate-Fork Cuation & Warning 21873-2 Decal-"FWD" 21971-6 Decal-"Tire Pressure 70 PSI" • 7/15 4 UNC X 3-1/2 Hex Head Capscrew 7/16 Lockwasher 7/16 X 14 UNC Hex Nut 7/16 Flat Washer 15430 Decal-"Calavar Corporation" Nameplate-Serial Number (Far Side) 21264 Nameplate-"Emergency Bleed Down" 21384 Decal - "Operation and Safety Manual" (on holder inside compartment)

art,

CNI r.4 1_4 r.4 r.4r_i

-15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25 -26 -27 -28 -29 -30 -31 -32 -33 -34 -35 -36 -37 -38 -39 -40 -41 -42 -43 44

PART NUMBER

1 r-I 1-4 1-4 1-'4 1-1 CNI CN C■1r-4 rlr-4 C12 r-4 N r.4 %,0

1113- 1 - 2 - 3 - 4 - 5 - 6 - 7 - 8 - 9 -10 -11 -12 -13 -14

DESCRIPTION

-13

IC/31.-INVIIIR CORPGRAWN

42 41/ I A'IMAIISSVrIVNI3 - g i 31111013

VIEW B

VIEW C 5 6 7 8

-a 9

10 11 13 12 14 44

FIGURE 1B - FINAL ASSEMBLY (4248E) REF

DESCRIPTION

PART NUMBER ,

-45 -46 -47

Safety Belt Assembly Lanyard Belt

QTY .

21280 21281 21238

1 1 1

FIGURE 1C - FINAL ASSEMBLY (4046) 00 I.% P...

*0 in

3 3o79

FIGURE 1C FINAL ASSEMBLY (4046 REF

1C-

1 2 3 4 5 6

- 7 - 8 - 9 -10 i -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25 -26 -27 -28 -29 -30 -31 -32 -33 -34 -35 -36 -37 -38 -39 -40 -41 -42 -43 -44 -45

DESCRIPTION

PART NUMBER

QTY

Final Assembly 1 40027 Carriage Weldment (See Fig. 2) 1 1 Carriage Assembly (See Fig. 3A) (See Fig. 10B) Turret Assembly 1 40068 Door-Left 1 40069 Door-Right 1 Decal-"Do Not Lift Wheels with Boom" 21971-2 4 (Inside of Both Doors Ond both sides of inner boom) 48 Rivet 4-356 5 Lower Hinge Block 21790 2 21795 Upper Hinge 2 Hex Head Capscrew 1/4-28 UNF X 1 4 Lockwasher 1/4 14 Nameplate-Operation Instructions 1 21415 Decal-Hazard & Accident Prevention 21882-2 2 Decal-Hazard & Accident Prevention 21882-3 2 DeCal-Hazard & Accident Prevention 21882-4 2 Nameplate-Caution 1 21854 Hex Head Capscrew 1/4-28 UNC X 1/2 10 40066 1 Engine Hood Rotating Beacon (option 21059) (See Fig. 38) 1 21882-1 Decal-Hazard & Accident Prevention 3 1 21850 Nameplate-Hydraulic Fluid (Nearside) Nameplate-Gas (Farside) 21849 1 3/8-18 UNF X 1/2 6 Hex Head Capscrew 3/8 6 Lockwasher . 1 21794 ' Turret Side Plate (See Fig. 21A) 1 Boom Assembly 2 21834 Decal "Condor" 1 21416 Nameplate-Caution & Warning 21658 Nameplate-Transportation 2 1 (See Fig. 29A) Non-Rotating Fork Assembly(See Fig. 31) 1 Platform Control Console 1 (See Fig. 32) 48 X 42 Platform Weldment 1 21970 Nameplate-Platform Capacity 1 21837 Nameplate-Fork Caution & Warning 1 21837-2 Decal-"FWD" 21971-3 2 Decal-"Tire Pressure 65 PSI" 7/16-14 UNC X 3-1/2 4 Hex Head Capscrew 7/16 4 Lockwasher 7/16-14 UNC 4 Hex Nut 7/16 8 Flat Washer 21873-1 1 Decal-"FWD" 1 21971-4 Decal "Close For Positraction" 1 21971-1 Decal-"Position Lever Up for High Speed" 15430 1 ' Decal-"Calavar Corporation" Nameplate-Serial Number (Farside) 15843 1 1/1n/79

ATillAla SS V'I VNI 3

N1111."--.•

O'N

FIGURE 1C - FINAL ASSEMBLY (4046) REF

-46 -47 -48 -49 -50 -51

DESCRIPTION

Nameplate - Emergency Bleed Down Decal - "Battery Replacement" Decal - "Operation and Safety Manual" (on holder inside compartment) Safety Belt Assembly Lanyard Belt

PART NUMBER

QTY

21264 21399 21384

1 1 1

21280 21281 21238

1 1 1

3/30/79

FIGURE ID SELF-PROPELLED CONDOR SAFETY DECALS & PLACARDS

( 1 of 6)

SELF - PROPELLED CONDOR SAFETY DECALS & PLACARDS ( 2 of 6

4046

SELF - PROPELLED CONDOR SAFETY DECALS & PLACARDS 2

CALAVAR CONDOR

3 of 6)

FACTORY RECOMMENDED TRANSPORTING DIAGRAM

CAUTION DO NOT OPERATE THE AERIAL LIFE WITH THE VEHICLE ON SLOPES IN EXCESS OF 5 DEGREES IN COMPLIANCE WITH ANSI BULLETIN A92.2 - 1969. TRAVEL CONFIGURATION NORMAL TRAVEL POSITION THE BOOM SHALL BE RETRACTED, POSITIONED OVER THE DRIVING AXLE AND ELEVATED TO PROVIDE ADEQUATE GROUND CLEARANCE FOR THE PLATFORM. WARNING SEVERE DAMAGE TO BOOM CABLE ASSEMBLIES WILL BE CAUSED BYA) DRIVING EXTENDED BOOM INTO STATIONARY OBJECTS. 13) DRIVING OBJECTS INTO STATIONARY BOOM. VISUAL INSPECTION OF BOOM EXTENSION CABLES MUST BE ACCOMPLISHED PERIODICALLY TO DETERMINE ANY DAMAGE. DAMAGED CABLES MUST BE REPLACED IMMEDIATELY. FAILURE TO DO SO WILL RESULT IN A DANGEROUS CONDITION TO OPERATOR AND EQUIPMENT.

21658 2- Also located opposite side and on rear of carriage.

21414

21416

DO NOT LIFT WHEELS WITH BOOM

29„2

21971-2 3- Also located on opposite side and inside of both doors.

OFF

115 VAC

• 21WIP

BEFORE ENERGIZING 115 VAC, ALLOW A 2 MINUTE DELAY AFTER ENGINE SHUT OFF. DO NOT ATTEMPT TO START ENGINE WITH THIS SWITCH ON.

4- Option 21647

21769

21879 21980 21877 5- Option 21844 (STDon6066) 6- Option 21943 (Also 7- Option 21659 indicated (STD on 6066) O on Grnd. Box Panel) CAUTIO N THIS SELF-PROPELLED CONDOR IS EQUIPPED WITH SLOPE SENSORS AND INDICATOR LIGHT. WHEN BOOM IS ABOVE HORIZONTAL AND THE MACHINE IS BEING DRIVEN UP, DOWN, OR ON A SIDE GRADE AT 5° OUT OF LEVEL, THE INDICATOR LIGHT WILL COME ON AND ALL BOOM FUNCTIONS WILL BE INOPERABLE. TO CORRECT CONDITION---(DO NOT LOWER BOOM WITH EMERGENCY LOWERING), REVERSE DIRECTION OF GROUND TRAVEL UNTIL LIGHT GOES OUT INDICATING THE CONDOR IS AGAIN LESS THAN 5 ° OUT OF LEVEL AND THE BOOM FUNCTIONS ARE AGAIN OPERABLE,

21880 .

8- Option 21844 (STD on 6066)

SELF - PROPELLED

4248LC LOAD CAPACITY PLATFORM SIZE CAPACITY PLATFORM SIZE CAPACITY NONE 1250 LBS

12 FT 750 LBS

6 FT 1000 LBS 8 FT 900 LBS CAPACITIES INCLUDE PERSONNEL & EQUIPMENT

ELECTROCUTION HAZARD

DEDUCT: 60 LBS FOR PIPE HANDLING FIXTURE risr?

THIS MACHINE IS NOT INSULATED

21577

•

MAINTAIN SAFE CLEARANCES FROM ELECTRICAL POWER LINES AND APPARATUS. YOU MUST ALLOW FOR PLATFORM SWAY, ROCK, OR SAG.

•

THIS AERIAL DEVICE DOES NOT PROVIDE PROTECTION FROM CONTACT WITH OR PROXIMITY TO AN ELECTRICALLY CHARGED CONDUCTOR.

4046 LOAD CAPACITY PLATFORM SIZE CAPACITY NONE 665 LBS 4 FT 500 LBS 5 FT 460 LBS 6 FT 425 LBS

•

DEATH OR SERIOUS INJURY WILL RESULT FROM SUCH CONTACT OR INADEQUATE CLEARANCE. 3751006 •

CAPACITIES INCLUDE PERSONNEL & EQUIPMENT DEDUCT 60 LBS FOR PIPE HANDLING FIXTURE

•

21882-2 (3751006A)

21970

•

6066 LOAD CAPACITY

PLATFORM SIZE

217••

750

LBS

500

LBS

400 LBS CAPACITIES INCLUDE PERSONNEL EQUIPMENT.... DEDUCT: 60 LBS FOR PIPE HANDLING FIXTURE O 8

CAPACITY

NONE 6

•

YOU MUST NOT OPERATE THIS DEVICE UNLESS:

21766

3238 LOAD CAPACITY

PLATFORM SIZE CAPACITY NONE 2100 8 FT 1750 4 FT 1950 12 FT 1600 6 FT 1850

1.YOU HAVE BEEN TRAINED IN THE SAFE OPERATION OF THIS DEVICE, AND 2.YOU KNOW AND FOLLOW THE SAFETY AND OPERATING RECOMMENDATIONS CONTAINED IN THE MANUFACTURER'S MANUALS, YOUR EMPLOYER'S WORK RULES AND APPUCABLE GOVERNMENTAL REGULATIONS.

21423°

AN UNTRAINED OPERATOR SUBJECTS HIMSELF AND OTHERS TO

DEATH OR SERIOUS INJURY.

CAPACITIES INCLUDE PERSONNEL & EQUIPMENT DEDUCT 60LBS FOR PIPE HANDLING FIXTURE Oa 0

012•

21882-3 (3751012A)

21423

9D •—

4350 LOAD CAPACITY PLATFORM SIZE

31691

OUTRIGGERS UP

OUTRIGGERS DWN

850 600 500 350

1250 1000 900 750

NONE 6 FOOT 8 FOOT 12 FOOT

•CAPACITIES INCLUDE PERSONNEL & EQUIPMENT •DEDUCT 60 LBS. FOR PIPE HANDLING FIXTURE

21692

WARNING

THIS UNIT IS NOT INSULATED AND MUST NOT BE OPERATED NEAR ENERGIZED POWER LINEL r,

21837

SELF - PROPELLED CONDOR SAFETY DECALS & PLACARDS

( 5 of 6)

CAUTION

•

EMERGENCY ONLY BOOM LOWERING VALVE

I. INSPECT VEHICLE AND AERIAL DEVICE, INCLUDING OPERATION, PRIOR TO USE, DAILY. 2.

FOR STATIONARY OPERATION VEHICLE MUST BE SECURELY PARKED AND STABILIZED FOR THE WORK TO BE PERFORMED BEFORE AERIAL DEVICE IS OPERATED.

OUTRIGGERS WHEN REQUIRED MUST BE ON SOLID FOOTING.

OPERATORS SHALL WEAR A BODY BELT, AND ATTACH WITH A LANYARD TO BOOM OR PLATFORM.

OPERATE ALL CONTROLS SLOWLY FOR SMOOTH PLATFORM MOTION.

DO NOT LOAD BEYOND RATED CAPACITY.

KEEP CLOSED WHEN NOT IN USE

4248 & 4046

21264

14A

21882-4 (7761010A) 6066 CA LAVAR SELF-PROPELLED CONDOR . WARNINGBEFORE OPERATING UNIT, READ AND UNDERSTAND ALL OPERATING AND SAFETY INFORMATION IN THE MANUAL AND ON ALL PLACARDS. REFER 10 INDIVIDUAL PLACARDS FOR SPECIFIC INSTRUCTIONS AT EACH CONTROL STAI ION. GENERAL INSPECTIONDAILY12345-

CHECK HYDRAULIC FLUID LEVEL. CHECK BATTERY WATER LEVEL. ROUTINE INSPECTION FOR STRUCTURAL DEFECTS. INSPECT FOR DETERIORATION (A) FLUID LINES, (B) ELECTRICAL CIRCUITS, (C) BOOM EXTENSION CABLES. CHECK ENGINE •OIL AND FUEL LEVEL.

MAXIMUM INTERVALS OF 50 HOURS-

CHECK GEAR BOX TUBE LEVELS.

23456-

GREASE ALL PRESSURE GUN FITTINGS. INSPECT WHEEL DRIVE COMPONENTS. INSPECT STEERING COMPONENTS, AND WHEEL NUTS. INSPECT BRAKE COMPONENTS, AND FLUID LEVEL. VISUALLY INSPECT ALL MECHANICAL BOOM CABLES FOR ANY SIGNS OF DAMAGE. REPLACE IMMEDIATELY ANY DAMAGED CABLE. CONTINUED USE OF CONDOR WILL RESULT IN A DANGEROUS CONDITION TO OPERATOR AND EOUIPMENT.

GENERAL OPERATING INSTRUCTIONS1TURN MASTER SWITCH ON AT GROUND CONTROL STATION. 2POSITION SELECTOR SWITCH TO GROUND CONTROL, AND TEST OPERATE ALL AERIAL FUNCTIONS FROM THE GROUND CONTROL STATION. 3POSITION SELECTOR SWITCH TO AERIAL POSITION. 45-

REFER TO WORK PLAT FORM INSTRUCTION PLACARDS FOR ALL OPERATIONS IN THE PLATFORM. REFER TO THE PLACARD ON THE REMOTE CONTROL BOX FOR OPERATIONS FROM THE REMOTE STATION.

21415

21881

SELF-PROPELLED CONDOR SAFETY DECALS & PLACARDS

6 of 6 )

19 CAUTION

TRAVEL SPEED

DO NOT USE CONDOR AS A WELDING GROUND DO NOT WELD ON CONDOR

HIGH SPEED WORKS ONLY WITH • SELECTOR SWITCH IN uHl• • BOOM BELOW HORIZONTAL • BOOM FULLY RETRACTED

WITHOUT DISCONNECTING BOTH POSITIVE AND NEGATIVE BATTERY LEADS REFER TO MAINTANCE MANUAL FOR ALL WELDING PROCEDURES

NOTE • AERIAL FUNCTIONS DO NOT OPERATE IN HIGH SPEED 4,313o

DO NOT JUMP START OTHER VEHICLES WITH BATTERY CONNECTED TO CONDOR 0

21854

#19 - On top of center crossmember of fork assembly

ELECTROCUTION HAZARD KEEP CLEAR DEATH OR SERIOUS INJURY CAN RESULT FROM CONTACT WITH THIS EQUIPMENT OR VEHICLE IF IT SHOULD BE ELECTRICALLY CHARGED.

21882-1(3751002)

WARNING FOR NORMAL OPERATION, POWER WHEELS MUST BE PROPERLY ENGAGED TO THE DRIVE MOTORS. ALSO, TOWING SELECTOR VALVE MUST BE IN NORMAL POSITION (HANDLE UP). OTHERWISE CONDOR WILL NOT HAVE STEERING. FOR TOWING, DISENGAGE POWER WHEELS FROM DRIVE MOTORS AND MOVE TOWING SELECTOR VALVE TO TOW POSITION (HANDLE DOWN). IN-PLANT TOWING ONLY CAUTION: CONDOR DOES NOT HAVE BRAKES DURING TOWING. 21499 18-Option 21440 (also located inside Engine Compartment Door)

20 #20 - Two p laces, fron t s ide of bo th con tro lboxes.

17- Also located on opposite side and on rear of counterweight.

FIGURE 2 - CARRIAGE WELDMENT (ALL MODELS)

FIGURE 2 - CARRIAGE WELDMENT (ALL MODELS) REF 2-

DESCRIPTION Carriage Weldment

PART NUMBER 21632 (4248, 3238) 21871 (6066, 5056) 21916 (4046)

QTY 1 1 1

FIGURE 3 - CARRIAGE ASSEMBLY (3238 , 4248, 5056,, 6066)

FIGURE 3 - CARRIAGE ASSEMBLY (3238. 4248_ 5056 6066) DESCRIPTION

REF

NOTE: Unless otherwise stated,parts for 3238, 4248, 5056, & 6066 Carriage Assembly

Carriage Hydraulic Hose & Fitting Assembly Torgue Drive Assembly Wheel Assembly Adapter Hose Assembly-Case Drain Adapter Adapter Hose Assembly

1 2 3 4 5 6 7

- 8 - 9

90 0 Elbow Hex Head Capscrew

-10

Hose Assembly

-11 -12 -13 -14 -15 -16 -17 -18 -19

Adapter Tube Assembly (3/4) Tube Assembly (3/4) Adapter Rotary Coupling Bracket Hex Head Capscrew Lockwasher Rotary Coupling (See Fig. 9) Hex Head Capscrew

-20 -21 -22

Ring Gear Hex Locknut Hex Head Capscrew

-23 -24 -25 -26 -27 -28 -29 -30 -31 -32 - 33

Hex Head Capscrew Lockwasher Turret Floor Hex Nut Hub, Spindle/Knuckle and Stub Axle Assembly, Steering Assembly Hose Assembly-To Turret Hydraulic Panel Solenoid Valve (See Fig. 11) Hose Assembly-To 2-Speed Valve Shifter Cylinder (See Fig. 4A) Speed Reducer Mounting Plate Lockwasher Lockwasher

PART NUMBER

QTY

are common 40061 (5056)(6066) ,40060 (3238)(4248)

1 1 1

21836 (See Fig. 4) (See Fig. 6) 202702-4-4 6 CIT-6FJX-6JX-60 2021-4-6 202702-12-12 D7-EAO4NJ- X 04NJ72 2024-4-4 5/8-11UNC X 1-1/2 Grade 8 Hl-EC12-12NJX-90T -27 2027-12-12 21799-22 21799-23 2021-12-12 21627 3/8-16 UNC-7/8 3/8 21562 41027 (1/2-13 UNC X 1-3/4) 21770 36786 (5/8-11 UNC) 36149 (5/8-11 UNC X 2) 5/16-18 UNF X 1-3/4 5/16

1 1 1 2 1 1 2

5/16-18 UNF (See Fig. 5) (See Fig. 7) FG1012-GGG-0217 (6066) FA-7229-GGG-0730 (6066) (See Fig. 17) 5/8 5/8 Dia. - Nordic

2 2 1 2 2 1 1 1 1 2 2 1 18 .1 15 15 4 4 1 4 1 1 1 1 1 1 1

3/30/79

FIGURE 3A — CARRIAGE ASSEMBLY (4046)

00 P-1 /

\\ vl CI) \\

04\ \t.

:".78 Y‘cy

\ 0

\"..

IJlII

N /

01 0%

/\ //// / \//, /

/ / / / / /

</1 /

(4/7P1 578

FIGURE 3A - CARRIAGE ASSEMBLY 0 6 DESCRIPTION

REF 3A-

- 1 -2

- 3 -

4 5 6 7 8 9

-10 -11 -12 -13 -14 -15

• 40059

Carriage Assembly Carriage Hydraulic Hose & Fitting Assembly Torgue Drive Assembly Wheel Assembly 90 ° 0-Ring Elbow Hose Assembly-Case Drain

40022

(See Fig. 4) (See Fig. 6A) 2062-4-4 6CIT-6FJX-6JX-60 2021-4-6 202702-12-12 FG1012-EEE-0720R 2024-4-4

Adapter

Adapter Hose Assembly 90 ° Elbow Hex Head Capscrew, Grade 8 Hose Assembly

-17 -18 -19

Adapter Tube Assembly (3/4) Tube Assembly (3/4) Adapter Rotary Coupling Bracket Hex Head Capscrew Lockwasher Rotary Coupling (See Fig. 9) Hex Head Capscrew

-20 -21

Ring Gear Hex Head Capscrew

-22 -23 -24 -25 -26: -27 -28 -29 -30

Flat Washer Hex Head Capscrew Lockwasher Turret Floor Hex Nut Hub, Spindle/Knuckle and Stub Axle Assembly, Steering Assembly Speed Reducer Mounting Plate

-16

PART NUMBER

QTY

1 •1

1 1 2 1 1 2 2

5/8-11UNC X 1-1/8 11

FG1556-KKK-0270

2027-12-12 • 21799-22 21799-23 2021-12-12 21627 • 3/8-16 UNC-7/8 3/8 21562 41027(1/2-13 UNC X • 1-3/4 Grade 8) . 21922 5/8-11UNC X 1-1/4

Grade 8 .• 5/8 • 5/16-18UNC X 1-3/4 5/16

Lockwasher

(Reference) 5/16-18 UNF (See Fig. 5A) (See Fig. 7) 21779 5/8 DIA - NORDIC

2 2 1 .1 1 1 2 2 1 18 1

11 12 '4

4 1

•1 1 1 1

(Grind Flush with Turret Floor before installing. speed reducer mounting plate)

9/17/79

9 10 12 13 14

40 ..■•■

..■ „

15 ••■

••■

16 17 18

3 2 19 20

29 33

34 27

26 22

24 25 2

31 35

37 38 39

FAR SIDE VIEW

F I GUR E 3C F O UR W HE E L DR I VE OPTI O N

5 ii to*

FIGURE 3C FOUR WHEEL DRIVE OPTION (ON 6066 BASE)

REF

DESCRIPTION

1 Hose Assembly, 51" LG 2 Hose Assembly, 91" LG 3 Hose Assembly, 91" LG 4 Hose Assembly, 44" LG 5 Hose Assembly, 15" LG 6 Hose Assembly, 22" LG 7 Hose Assembly, .98" LG 8 Hose Assembly, 17" LG 9 Tubing 10 Tubing Hose Assembly, 27" LG 12 Hose Assembly, 71" LG 13- Hose Assembly, 71" LG 14 Hose Assembly, 99" LG 15 Tubing 16 Hose Assembly, 36" LG 17— Tubing 18 Hose Assembly, 36" LG 19 Hose Assembly, 35" LG 20— Hose Assembly, 26" LG 21 Hose Assembly, 34" LG 22 Hose Assembly, 26" LG 23 Hose Assembly, 64" LG 24 — Hose Assembly, 91" LG 25— Hose Assembly, 91" LG 26 Hose Assembly, 88" LG 27 Hose Assembly, 88" LG 28 Hose Assembly, 15" LG 29 Hose Assembly, 32" LG 30— Flow Control Valves (set at 4 GPM 31 Selector Valve (for Mudhog) 32 Flow Divider 33 Hose Assembly, 32" LG 34 Pressure Reducing Valve 35 Mudhog Assembly 36 Pins, I" x 3" LG Cap Screw 37 Cover 38 Steering Cylinder 39— 2 Cubic Inch Drive Motor 40-6 Port Manifold 41 Collector Block 42 Tie Rod 43— End Bearing 44 Pins, 3/4" x 3 1/2" LG Cap Screw

PART NUMBER J406-06NJ J408 -08 N J J408-08NJ J404-04N J J404-04N J J406-06NJ J406-06NJ HAl2-12NJ

QTY

J406 06NJ J408-08NJ J408-08NJ J404-04N J .J404-04NJ J406-06NJ J406-06NJ HAl2-12NJ

HAl2-12NJ HAl2-12NJ 90cT— 1 HAl2-12NJ HAl2-12NJ 1 HAl2-12NJ HAl2-12NJ 1 _1406-06N J J406-06NJ 90°TL -1

1- I HAl2-12NJ

HAI2-I2NJ 90°T-1

HAl2-12NJ HA 12-12NJ 90°T — 1 J408-08NJ J408-08N J J408-08N J J408-08N J J404-04N J J404 04NJ J404-04NJ J404-04NJ J401 -04N J J401 -04N J J408 08NJ J408 08NJ J408-08NJ J408-08NJ J404-04N J J404-04N J J404-04N J J404-04N J J404 04NJ J404-04N J J406 -06N J J406-06NJ 2 PC5-4-4 I01318-CPP 2V13-41-3-6 5 J406-06N J J406-06N J 1PD11-FZ-6 S 2 40588 2 36517 40576 32545 2 40583 21562 6400-0 str 6-6 .1 40570 2 40589 2 36178

8/80

FIGURE 3C-I FOUR WHEEL DRIVE

8/80

FIGURE 3C -1 FOUR WHEEL DRIVE

A 2 3 4 5 6 7 8 9

B C 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17

6 Port Manifold (21652) 2406-STR 6-4/reducer 6602 Tee 6-6 2501 90° 6-4 6801 - NWD 90° 12-12 680! - NWD 90° 4-4 6801 - NWD 90° 4-4 6801 - NWD 90° 12-12 6500 - 90° 6-6 2404 - STR 6-4

G 2 3

Collector Block 2404 - 6-4 2406 - STR 6-4/reducer 6500 - 90 6-6 Hyflex fittings

Selector Valve Flow Divider 2406 - STR 8-4/reducer 2506 - Tee 8-8 pr 6804 NWD - Tee 8-8 5404 - STR 8-8 Flow Control Valve PCS - 4 - 4 2404 - STR 8-6 6405 - 0 - STR 8-8 6400 - 0 - STR 8-8 6500 - 90° 8-8 6405 STR 4-4 5404 - STR 4-4 Valve CP2013 2501 - 90° 4-4 5404 - STR 8-8 Flow Divider 2VI3-4-3-6S Selector Valve I01318-CPP 6801 - NWD - 90° 4-4 6400 -0 - STR 4-4 Bulkhead Fittings • Bulkhead fittings 2704-LN 12-12 2406 - STR I2-8/reducer

E 2 3

F 2 3 4 5 6 7

Mudhog Assembly (650I45-CPP) 6801 - NWD - 90° 6-6 2406 - STR 1:2-8/reducer 6500 -,90° 6-6 Pressure Reducing Valve (IPDII-EZ-6S) 2501 - 90° 4-4 2501 - 90± 4-4 5404 - STR 4-4 2404 - STR 4-4 2605 - Tee 4-4 304-6 Cap Nut #4 CPZOB Shuttle Valve

8/80

FIGURE 3C-I FOUR WHEEL DRIVE

8/80

FIGURE 3C -1 FOUR WHEEL DRIVE

6 Port Manifold (21652) 2406-STR 6-4/reducer 2 6602 Tee 6-6 3 2501 90° 6-4 4 6801 - NWD 90° 12-12 5 6801 - NWD 90° 4-4 6 6801 - NWD 90° 4-4 7 6801 - NWD 90° 12-12 8 6500 - 90° 6-6 2404 - STR 6-4 9 A

Collector Block 2404 - 6-4 2 2406 - STR 6-4/reducer 3 6500 - 90 6-6 Hyflex fittings

B Selector Valve C Flow Divider 2406 - STR 8-4/reducer 2 2506 - Tee 8-8 ,or 6804 NWD - Tee 8-8 3 5404 - STR 8-8 4 Flow Control Valve PCS - 4 - 4 5 2404 - STR 8-6 6 6405 - 0 - STR 8-8 7 6400 - 0 - STR 8-8 8 6500 - 90° 8-8 9 6405 - STR 4-4 5404 - STR 4-4 To Valve CP2013 12 2501 - 90° 4-4 13 5404 - STR 8-8 14 Flow Divider 2VI3-4-3-6S 15 Selector Valve I01318-CPP 6801 - NWD - 90° 4-4 16 17 6400 - 0 - STR 4-4 Bulkhead Fittings • Bulkhead fittings 2704-LN 12-12 2406 - STR 12-8/reducer

Mudhog Assembly (650I45-CPP) 6801 - NWD - 90° 6-6 2 2406 - STR 12-8/reducer 3 6500 -90° 6-6 F

Pressure Reducing Valve (I PDII-EZ-6S) 2501 - 90° 4-4 2 2501 - 90± 4-4 3 5404 - STR 4-4 4 2404 - STR 4-4 5 2605 - Tee 4-4 6 304-6 Cap Nut #4 7 CPZOB Shuttle Valve

8/80

FIGURE 3D FOUR WHEEL DRIVE STEERING ASSEMBLY (40588)

Hydraulic Motor

8/80

FIGURE 3D FOUR WHEEL DRIVE STEERING ASSEMBLY (40588)

REF

DESCRIPTION 1 ---C-Frame Assembly

2 ---Pivot Pin 3 ---Spherical Bearing 4 ---Grease Fitting 5 ---Spacer

6 --- Thrust Washer 7 ---Thrust Washer -

Nylatron

8 ---1 5/8 Jam Nut

9 ---90 ° Elbow (High Pressure Swivel) 0 ---90° Elbow (08 ORB -M X 06 JIC-M)

--Plug (08 ORB -M) 2 ---Box Frame Assembly 3 --- 5/8 X 2 UNC Gr. 8 Hex Head Bolt 4 --- 5/8 Jam Nut 5---Planetary Gear Box 6 ---5/8 Flat Washer 7 --- 5/8 X 1 1/2 UNC Gr. 8 Hex Head Bolt 8 ---5/8 UNF Wheel Lug Nut

PART NUMBER 500272-M1 101302-M1 101119-P1 101127-P1101298-M1 101332 -P1 101301-P1 100901-M1 200071 P1 200078 -P1 208000-P1

500273-M1 100275-P1 100276-P1 100871-P1 100073-P1 100075-P1 100321 -P1

QTY 1 2 2 --2

1 2 1 2 2 1

1 1 2 2

1 6 6 9

FIGURE 4 TORQUE DRIVE ASSEMBLY

REF

Torque Drive Hub Hex Head Capscrew Lockwasher Nordic Hex Head Capscrew Lockwasher Hydraulic Motor with Disc Brake 0-Ring, Elbow Tube Assembly 0-Ring, Elbow Tube Assembly Tube Assembly 0-Ring Adapter Tube Assembly Wheel Drive Valve Assembly (Module) 90° Swivel 0-Ring Elbow (Long) 0-Ring Adapter Tube Assembly Tube Assembly Tube Assembly Tube Assembly Hose Assembly Hose Assembly Hose Assembly

PART NUMBER

QTY

21568 5/8-11 UNC x 1-3/45/8 1/2-13 UNCx 1-1/41/2 21568 206209 12-12 40183 2062 6-6 40186 2062 12 -12 2062 6-6 40180-2 40099 2062 12-12 2062 6-6 202702 6-6 2062 6-6 2062 6-6 40180 4 40180 7 40180-6 40180-5 40180-3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

DESCRIPTION

3/18/80

FIGURE 4A WHEEL DRIVE VALVE ASSEMBLY

REF

DESCRIPTION

PART NUMBER

Flow Control Valve (Cartridge) Directional Valve, 3-Way (Cartridge) Special Plug W/SAE 6 Port Flow Control Valve, (Cartridge) Flow Divider, Combiner Valve (Cartridge) Manifold

FCV1-10-S-0 PTS 1-16-0-80 SK 1-10-3 FCV3-10-S-0 FDC1-16-0-66 40108

2 3 4 5 6

QTY 1 2

3/ its/du

FIGURE 5 - HUB SPINDLE KNUCKLE AND STUB AXLE ASSEMBLY (3238, 4248, 5056, 6066)

REF. 5-

2 3 4 5 6 7 8 9 -10 -11 -12 -13 -14 -15 -16 -17 -18 IMO

-19 -20 -21

DESCRIPTION Hub, Spindle/Knuckle and Stub Axle Assy.

King Pin Roll Pin Bushing Thrust Washer Spindle/Knuckle Grease Seal Inner Cone Hub Outer Cone Key Washer Spindle Nut Cotter Pin Gasket Grease Cap Washer Hex Head Screw

PART NUMBER Part Part Part Part

of 21485 of 21485 of 21485 of 21485

(3238)

(4248) (5056) (6066) 5 22 2 or 3

13 2-LH-3RH 11 9 4 8 23 24 25 14 12 18 16 21

Stud Stub Axle Weldment 1 Note: Above items are part of Kit No. 214435 Port of 21485 End Cover No. 10 Lockwasher No. 10-24UNC X .50 Hex Head Capscrew

Y. 1 1 1 1 2 2 4 4 1 2 2 2 2 2 2 2 2 2 6 6 12 2 4 8 8 11-80

FIGURE 5A - HUB, SPINDLE KNUCKLE AND STUB AXLE ASSEMBLY (4046)

REF DESCRIPTION 5A- 1 - 2 - 3 - 4 - 5 - 6 - 7 - 8 - 9 -10 -11 -12 -13 -14 -15 -16 -17 -18

Hub, Spindle/Knuckle and Stub Axle Assy. King Pin Roll Pin Bushing Thrust Washer Spindle/Knuckle Grease Seal Inner Cone Hub Outer Cone Key Washer Spindle Nut Cotter Pin Gasket Grease Cap Washer Hex Head Screw

Stud Stub Axle Weldment Note: Above items are part of Kit No. 21456.

PART NUMBER Part of 21456

5 22 2 or 3 13 2LH-3RH 11 I0 4 8 27 28 23 14 12 21 19 16 1

QTY 1 2 2 4 4 2 2 2 2 2 2 2 2 2 8 8 12 2

FIGURE 5A - HUB, SPINDLE KNUCKLE AND STUB AXLE ASSEMBLY (4046)

REF -19 -20 -21

DESCRIPTION End Cover Lockwa sher Hex Head Capscrew .

PART NUMBER 6 No. 10 20 No . 10 -24UNC X 18

QTY 4 8 8

11-80

FIGURE 6 - TIRE-WHEEL ASSEMBLY (3238, 4248, 5056, 6066)

REF.

DESCRIPTION

Tire-Wheel Assy. (Front) Tire-Wheel Assy. (Rear) Steering Assy.. 10-Ply Super All Traction Hi-Flotation Tire Wheel Assy. (Front)

- 4 - 5

Wheel Nut Wheel Assy. (Rear)

- 6

Torque Drive Assembly

PART NUMBER

21339 (3238, 21989 (5056, 21338 (3238, 21983 (5056, See Fig. 7 21487 (3238, 21494 (5056, 21948 (3238, 21952 (5056, 30288 21734 (3238, 21950 (5056, See Fig. 4

NOTE: Unless otherwise stated, parts are common for 3238, 4248, 5056, 6066.

QTY. 1

4248) 6066) 4248) 6066)

4 4 2 2 32 2 2

4248) 6066)

2 2 2

FIGURE 6A - TIRE-WHEEL ASSEMBLY (4046)

DESCRIPTION

REF. 6A-

3 4 5 6 7 8

PART NUMBER

Tire-Wheel Assy. (Front) 21497 Tire-Wheel Assy. (Rear) 21496 Steering Assembly See Fig. 7 8-Ply Super All-Traction Hi-Flotation Tire 21459 12.00 X 16.5 Wheel Assy. (Front) 21947 Wheel Nut 30288 Wheel Assy. (Rear) 21949 Torque Drive Assy. See Fig. 4 Stud 14-00-183-005 Wheel Nut 9/16-18UNF

QTY.

2 2 1 4 2 12 2 1

16 16

FIGURE 7 - STEERING ASSEMBLY (ALL MODELS)

15 14

FIGURE 7 - STEERING ASSEMBLY (NLL MODELS)

REF

- DESCRIPTION

Steering Assembly

- 1 - 2 - 3 - 4 - 5 - 6 - 7 - 8 - 9 -10 -11 -12 -13

Steering Center Arm Pin Lube Fitting Hex Head Capscrew Lockwasher Clevis Pin Washer Steering Cylinder (See Figure 8) Cotter Pin Elbow Yoke Pin* Lube Fitting* Carriage Weldment Tie Rod*

..-14

Nut and Cotter Pin

-15 -16 -17

Steering Center Arm Weldment Yoke Pin* Yoke* Jam Nut* Bushing Bushing Hex Nut Hex Head Capscrew Yoke*

-18

-19 -20 -21 -22 -23

PART NUMBER

Part of 21485 (3238) Part of 21485 (4248) Part of 21485 (4046) Part of 21485 (5056) Part of 21485 (6066) 21136 1610BL 3/8-16UNC X 3/4 3/8 C-46 3/4 40002 1/8 X 2 2024-4-4 T1 33 II 32 (See Fig. 2) It

QTY

1 1 1 1 1 1 1 2 2 2 4 1 2 2 2 4 1 2

" 36 & 37

1 2

21148 11 II

II 31

4 1 1 2 2 2

M1218-8 21148-5 3/4-10 UNC 3/4-10 UNC .X 2-k II 27

* These items are part of Kit No. 21485 (The dash numbers are listed in Steering Assembly Drawings)

P-0

FIGURE 8 - STEERING CYLINDER (ALL MODELS)

4 5 HD 11 12 123 67 g 9 13 ._ -.MAWAVAIMIIIIIYAIPA

41611 %/111///11111%■111/AIL._-_Z■Fp70 / Mar, id All

1111P . it ro 311 " As

8-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14

DESCRIPTION Steering Cylinder (L) Locknut - Self - Locking Wear Ring Piston Piston Seal 0-Ring Rod Static Seal Barrel Assembly Rod Assembly Gland Static Seal . Gland Rod Seal Collar Rod Wiper Seal Kit

PART NUMBER

40002 50935 52101 3120-06 50916 50915 50103 4379-02 4379-18 50003 105-05 50024 248-11 50082 2950-34

OTY

I-, 1-4 I-, I-,

REF

I-1 I-a1-,

111

•

3 3079

FIGURE 9 - ROTARY COUPLING (ALL MODELS)

REF 91 - 2 - 3 - 4 - 5 - 6 - 7 - 8 - 9 - 10 -11 - 12 - 13 - 14

DESCRIPTION

PART NUMBER

Rotary Coupling Spool Adapter Adapter Socket Capscrew Seal Kit Mounting Plate Socket Capscrew Lockwasher Keeper Plate 0-Ring Housing Spacer Adapter Adapter

21562 5393-0001 202702-4-4 202702-12-12 0000-2028 0000-9000 5033-0005 0000-2030 0000-2601 5033-0004, 0000-3238 5393-0002 5033-0003 2021-2-4 2021-4-6

1 1

4 4 1

6 1 4 4 1 1 1 1 1 1

FIGURE 10 - TURRET ASSEMBLY (ALL MODELS EXCEPT BATTERY POWERED)

/\7 __

Go 0% 0 in in 44

co OtO 04 elen; %

in It WI el MC*

In pit%1 (*Me 01044401

0 II. et et

011 et

■0 NCO et qii'Vr

.3 -2.77 fa

FIGURE 10 - TURRET ASSEMBLY (ALL MODELS, EXCEPT 4248E)

REF 10

DESCRIPTION • Turret Assembly

Turret Proportional Valve System Gas Tank Assembly Decal - "Gas" Decal - "Hydraulic Fluid" 90° Elbow Rod - Throttle Control Cap - Rotation Pin Assembly Anti Control Hydro-Throttle Brace 90° Elbow Pressure Hose - Hydraulic To Throttle Hex Head Capscrew Lockwasher Hydro-Throttle Control Mounting Plate Engine Self-Tapping Screw Pan Head Warning Horn Control Mounting Bracket Ground Box Counter Weight Bracket Hex Head Capscrew Lockwasher Hex Nut Item 20) (Other of Hex Head Capscrew End Counterweight

-26 -27 -28 -29 -30 -31 -32 -33 -34 -35 -36 -37 -38 -39 -40 -41 -42 -43

Decal - "Manufacture" Ground Control Console Box Assembly Striker Plate Hex Head Capscrew Flat Washer Lockwasher Spacer Hex Head Capscrew Hex Nut Lockwasher Gas Engine Adapter Hydraulic Tank Assembly Turret Rotation Speed Reducer Hex Head Capscrew Ring Gear Hex Locknut Gas Engine Assembly

QTY

40083 (3238) 40069(4046) 40071 (6066) 40025 (4248) 40071 (5056) (See Figure 11) (See Figure 14) 21849 21850 2103-4 5 40165 FNXT 40169 40015 2024 4-4 FG 1012 EEE-0240 1/4-28 UNC 1-3/4 x 1/4 21462 21780 21082 No. 7 3/4 x SP-30 40018 40063 3/4 10 - x UNC 2 -1/4 3/4 3/4 10 - UNC 3/4-16 UNC 1-1/2 X 40084 (3238) 40064 (4046)40065 (4248) 40073 (6066)(5056) 15834 (See Figure 16) ° 21793 7/16 14 x x UNC 3/4 7/16 7/16 21797 9/16-12 UNC 2-1/2 x -12 9/16UNC 9/16 40017 0102 -6-4 (See Figure 15) (See Figure 17) (5/8-11 36149 UNC) 21770 36786 (5/8-11 UNC)

-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22-23 -24 -25

PART NUMBER

40016

4/ 2/ 80

FIGURE 10 - TURRET ASSEMBLY (ALL MODELS EXCEPT BATTERY POWERED)

3-277 fro

FIGURE 10 - TURRET ASSEMBLY (ALL MODELS, EXCEPT 4248E)

REF

DESCRIPTION

-44—Rotary Coupling -45—Turret Weldment

-46—Hex Head Capscrew -47— Lockwasher -48—Hex Nut -49-5 Degree Automatic Slope Control Box Assembly (Option 21844) (Std. on 6066) -50—Level Controller -51—Delay Relay -52—Delay Relay Socket -53—Relay -54—Hex Head Capscrew (Grade 8) -55—Lockwasher -56— Decal - "Battery Replacement" -57—Operation and Safety Manual Holder -58—Round Head Capscrew -59— Flatwasher "Operation and Safety Manual" -60— Decal - -61—Belt -62-110 Volt Boom Electrical Line

PART NUMBER

QTY

21562 40074 (4248) (3238) 40070 (4046) 4072 (6066) (5056) 5/16 18 UNC 5/16 5/16 18 UNC 21903

1 1 1 1 4 —4 4 1

21347 12NO2 SL-608 KUP14D55 5/8-11 UNC 1/2 xl 5/8 21399 21383 No. 10-32 UNF x 1-1/2 No. 10 21384 Goodyear M H 184-A See Figure 37

2 1 1 —1 1 1 —1 1 2 2 —1 1 1

4/2/80

FIGURE 10A - TURRET ASSEMBLY

(BATTERY POWERED MODELS)

0 0 0

1/2/80

FIGURE 10A-TURRET ASSEMBLY (BATTERY POWERED MODELS

-17

Turret Assembly Battery Charger & Terminal Connection Assembly • Charger Cable Ring Tongue Terminal Connector-For Disconnect Use Only Turret Proportional Valve System Installation Battery Pack Hose Assembly-To Topping Cylinder . Adapter Emergency Bleed Down Valve Bleed Down Bracket Hex Head Capscrew Lockwasher Hose Assembly-To Hydraulic. Tank Terminal Connector-For Disconnect Use Only Terminal Connector Mounting Half Assembly Cable

-18 -19 -20 -21

Ring Tongue Electric Motor Jumper Cable Cable-To Electric Motor Terminal F2

-22

Cable-To Electric Motor Terminal A2

-23 -24 -25 -26 -27 -28 -29 -30 -31 -32 - 33 -34 -35 -36 -37 -38

Power Relay-500 Amp With 12 VDC Coil Hex Head Capscrew Nameplate-Emergency Bleed Down Ground Control Console Flat Washer Battery Indicator Hour Meter Striker Plate Hex Head Capscrew Flat Washer Lockwasher

10A-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16

PART NUMBER

DESCRIPTION

REF

Spacer

Door-Right Hex Head Capscrew Lockwasher Flat Washer

QTY

21930 21746 A35-180-18L 2/0 Industrial Welding x 10 Ft. 5816B-EC

1 2 2 1

(See Fig.11)

21675 FG1005-EEER-0300 2021-6-4 21466 21722 k-20UNC x 11/2 if1 FA-4407-EBE-0280 (Part of 21675 Batter Pack) 21931

1 1 2 1 1 2 18 1 1

2/0 Industrial Welding x 7 In. 2/0-5/16 21747 2/0 x 101/2 In. 2/0 Industrial Welding x 22 In. 2/0 Industrial Welding x 13 In. 1119841 3/4-20UNC x 3/4 21881 (See Fig. 16)

20-3006392 MS15002-12VDC 21793 7/16 x 14UNC x 3/4 7/16 7/16 21797

21426 5/8-18UNC x 23/4 5/8 5/8

9 1 2 1 1 1 16 1 1 4 1 1 1 2 2 2 A/R 1 4 4 4

1/2/80

FIGURE 10A - TURRET ASSEMBLY (BATTERY POWERED MODELS)

1/2/80

FIGURE 10A REF -39 -40

TURRET ASSEMBLY (BATTERY POWERED MODELS)

DESCRIPTION

-42 -43 -44

Hex Nut Hydraulic Tank Assembly Decal - Hydraulic Fluid Turret Rotation Speed Reducer Lockwasher Hex Head Capscrew

-45

Hex Head Capscrew

-46 -47 -48 -49 -50 -51 -52

Ring Gear Hex Lock Nut -36786 Rotary Coupling Turret Weldment Hex Head Capscrew Lockwasher Hex Nut

-41

PART NUMBER 5/8-18UNC

(See Fig. 15)

21850

(See Fig. 17)

5/8 5/8-11UNC X 1-1/2, Grade 8 36149 (5/8-11UNC X2 21770 5/8-11UNC X 2 (See Fig. 9) 21789 5/16-18UNC X 1-3/4 5/16 5/16-18UNC

QTY 4

1 1

1 1 2 15 1 15

1 1 4 4 4

1 2/80

FIGURE 11 - TURRET PROPORTIONAL VALVE SYSTEM INSTALLATION (ALL MODELS)

3 4

7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 9 80 1 24

38 39 40 41 37 31 36 35 34 33 78 76 27 26 25 28,8 77 28,8

VIEWA

BULKHEADS

MASTER LEVELING CYLINDER

TOPPING CYLINDER

HOLDING VALVE

SOLENOID VALVES PROPORTIONAL VALVES

HYDRAULIC TANK

ENGINE THROTTLE

71 (O 65 72 I ROTARY COUPLING / I

SPEED REDUCER

VIEW B

-ZtIRRFT PROPORTIONALVALVE SYSTEM INSTALLA ,

DESCRIPTION'

REF

1 2 3 4 5

Hex Head Cepscrew Lockwasher Mounting Clip Hydraulic Panel Cover Hydraulic Valve Plate Assembly

Adapter Nipple Needle Valve 90 ° Elbow (Modified) Tee Adapter (Modified) 0-Ring Elbow Proportional Control Valve Assembly (See Figure 12) 0-Ring Adapter Hex Head Capscrew Hex Nut Tee Tube End Reducer 0- Ring Elbow Holding Valve 3000 PSI Hex Head Capscrew Tube Assembly 90 ° 0-Ring Elbow Solenoid Control Valve Pack (3Section) 90 ° 0-Ring Elbow Hex Head Capscrew Hex Nut '

-26 -27 -28 -29 -30 -31 -32 -33 -34 -35 -36 -37 -38 -39

r•4 r-4 r-1 CV T-4 kr) Cf) U1 r•Ir-I Nr-i CN11-4 r-I C•I

-18 -19 -20 -21 -22 -23 -24 -25

r-1 CNI ON CV CN1 r-♦ r-4 r4

Mounting Plate Hex Head Capscrew Lockwasher Reducer 90° Elbow Filter . Hose Assembly Tube Assembly Tee Cap Flow Control Valve Adapter (with Filter)

- 6 - 7 - 8 - 9 -10 -11 -12 -13 -14 -15 -16 -17

21969 (4046) 21363 (5056) 21380 (3238) 21748 (4248) 21863 (6066) 1/4 X 28 UNC X 3/4 1/4 21564 21565 40038 (6066)(5056) 40054 (3238,4046, 4248) • 21551 3/8-16 UNC X 3/4 3/8 2081-12-6 2024-6-6 21475 FG1556-GGG-U-0160 21799-3 2028-4-6 210292-6 21516 or 21517 Furnished with proportional Control Valve Pack 2021-4-4 2083-4-4 . 21479 21570 2091-4-4 21569 206209-12-12 40053

QTY r-4r-Ir-1r-i 1` ON

Turret Proportional Valve System Installation

11-

PART NUMBER

202702-12-8 3/8-16 UNC X 6 3/8-16 UNC 203003-12-12 12-8S-TRBTX 2062-6-6 21461 3/8-16 UNC x 3-1/2 21799-6 2062-6-8 21460 2062-6-4 1/4-20 UNC X 3/4 1/4-20 UNC h(

RE 11 - TURRET PROPORTIONAL VALVE SYSTEM INSTALLATION (ALL MODELS DESCRIPTION

REF

-40 -41 -42 -43 -44 -45 -46 -47 -48 -49

Flat Washer Lockwasher 90 ° 0-Ring Elbow Hose Assembly Tube Assembly 0-Ring Adapter Tube Assembly Swivel. Elbow Adapter Turret Hydraulic Hose Assembly

-50 -51 -52 -53 -54 -55 -56

Hose Hose Hose Hose Hose Hose Hose

-57 -58 -59 -60 -61 -62 -63 -64 -65 -66 -67 -68 -69 -70 -71 -72 -73 -74 -75 -76 -77 -78 -79 -80 -81

Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose

Assembly Assembly Assembly Assembly Assembly Assembly Assembly Assembly Assembly Assembly Assembly Assembly Assembly Assembly Assembly Assembly Assembly

PART NUMBER

QTY

1/4 1/4 2062-6-6 FG1005-GEE-R-0450 21799-5 202702-6-6 21799-4 2071-8-8 2021-4-8 • 21838 .(4248,3238) 21890 (5056,6066) FG1012-GGG-0217 FG1005-EEER-0300 FA7229-GGG-0730 FG101-GGG-0610 FG1012-EEE-0480 FC120-EBE-0170 3634 (J.D. Furnished) FA4407-EBE-0280 FG1556-KKK-0270 FG1011-HHH-0660 FG1005-GGG-0430 FG1011-HHH-0296 FG1011-KKK-0360 FG1012-KKK-0360 , FG1012-EEE-0840 FG1012-HHH-0200 FG1012-HHH-1050

4 4 1 I 1 6 1. 1 1 1 1 2 1 2 2 2 2

FG1556-KKK-0270 FG1012-GGG-0480 FG1005-EEE-0274. FG1012-GGG-0217 (6066) FG1012-GGG-0480 (6066) FA4407-EBE-0280 (6066) 21491 (6066) 2024-6-4 (6066) 1/4-20 UNC-1-1/2 1/4 2024-6-6 (6066) 1/4 MRO (6066) 0103-4-4 (6066) RTX-4-4

2 2 2

1 1 2 2 2 1 1 1 1 1 1

1 Hose Hose Hose Hose

Assembly Assembly Assembly Assembly

Hose Assembly Hose Assembly Solenoid 90° Elbow Hex Head Capscrew Lockwasher 90 ° Elbow Tee Adapter Tee

1 I 1 1 1 2 2 2 1 1

NOTES

III III I)

■ !..z.

12" 18 AWG 2 Cond. S.O. Cable Typ.

PART NUMBER

7ci rri

MFRS. Module Part Nos Typ.

See Note 3

40053 - A

1-3

NOTES:

1-3

Spool #4

Spool #1

Spool #3

Spool #2

Sub. Assem. Inlet

Part No. 269381-7

Spool

2A05-21

Spool 2 Spool 3 Spool 4 Outlet

1A04-2 2A04-2 1A05-3 269362=9

Function

Type

77)w---"" rave

I.D.

• Drive

Motor

9 G PM

. 320'

700266

Comments Relief Valve 100% 2750 PSI Open.

Lift Rotate Extend

Cyl. Motor Cyl.

2.5GPM 4 GPM 5 GPM

.320 .320 .280

248507 248507 248508

2 2 3

Blkd. Blkd. Open

C2 Pori

Port

Power beyond w/ separate P.V. drain

PROPO RTIONAL CONTROL VA LVE A SSEMBLY(ALL MODELS )

Inlet

Outlet

1. Valve Assembly to operate at 2150 PSI & 160° F. Hydr. oil to be Dexiion II or equal 2. Completed Assembly to be thoroughly tested prior to ship3. Valve Assembly to be supplied with Bertea part number 250825-101 R stamped in 7/32"high characters as shown. 4. Valve Assembly to be supplied complete with 1/2"NFT plug installed internally in power beyond port and 1/4" NPT plug installed in port 'D' of outlet section.. 5. Pilot pressure relief valve setting to be 300 PSI

FIGURE 13 - TURRET PUMP AND EMERGENCY BLEED-DOWN INSTALLATION (ALL MODELS)

REF 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

DESCRIPTION Hex Hex Head Capscrew Pump Adapter Gas Engine Hex Head Capscrew Hex Head Capscrew Spacer 0 Ring Elbow Hex Head Capscrew Hose Assembly Hose Assembly Engine Rubber Mount 0-Ring Adapter 90° Swivel Elbow 0-Ring Elbow Hose Assembly 90° 0-Ring Elbow Hose Assembly 45° 0- Ring Elbow Hose Assembly Assembly To Hydraulic Panel Hose Assembly To Rotary Coupling Hose Hose Assembly - To Hydraulic Panel Reducer Hose Assembly Tee 90° Elbow Filter -Adapter Tube Assembly 90° Elbow Adapter Bracket, "T" 90° Elbow Spacer Allen Head Set Screw Spider Coupling Hex Head Capscrew Lockwasher 45° 0- Ring Swivel Elbow Pump Solenoid Valve 90° 0 - Ring Elbow Hose Assembly - To Topping Cylinder 90° 0-Ring Elbow 0- Ring Adapter Emergency Bleed Down Valve Bracket •

PART NUMBER

QTY

1-1/2 3/8 x x 3/8 (Filed) 5/8 x 1-3/4 Grade 8 40171 21082 2 5/8 x 5/16 1 x 40231 2062 6-4 1/2 x 2-1/2 FG1005-EEER-0300 FG1012-EEE-0480 40163 400B RMD 202702 10-12 2071 12-12 3/8 3-4 3C1T-3FJX-4FJX-36 2026 20-20 FG1011-KKK-0360 2023 20-20 FG1556-KKK-0270 1012 FG -KKK-0360 FG1012-GGG -048 FG1012 GGG-0480 1290-8 FG1011-HHH-0296 203102 8 8 - "T " 2024 16-12 21474 2021 16-16 21799-7 2024 4-4 2021 6-4 32089 2024 16-16 40232 1/4 40233 40187 1/4 1 x -3/4 1/4 2023 20-20 21465 202413 4-4 FG 1005 EEER 0300 2024 4-4 2021 4-4 21466 21722

1 4 1 1 8 8 2 1 4 1 1 4 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 4 1 1 4 41 1 1 1 1 2 1 1

3/28/80

FIGURE 13 - TURRET PUMP AND EMERGENCY BLEED-DOWN INSTALLATION (ALL MODELS)

REF 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65

DESCRIPTION Hex Head Capscrew Lockwasher Emergency Bleed-Down Solenoid Valve Lockwasher Reducer Close Pipe Nipple Hex Head Capscrew Lockwasher Swivel Tee Lockwasher • Lockwasher Lockwasher Hose Assembly - To Emergency Bleed Down Valve Solenoid Bracket Lockwasher Reducer Pump Compensator Adjustment

PART NUMBER 1/4 x 1/4 21493 5/8 2081 24-20 13404 1-1/2 P.T. 1/4 1/2 x 1/4 203102 8-8 "T" 5/8 5/16 5/16 FA 4407 EBE 0280 21046 5/16 221501 TRTX 6-4 Reference Only

QTY

2 1 4 1 1 2 2 1 4 8 4 1 1 8

•

3/28/80

(BATTERY

FIGURE 13A-TURRET PUMP AND EMERGENCY BLEED DOWN INSTALLATION POWERED)

(BATTERY

FIGURE 13A - TURRET PUMP AND EMERGENCY BLEED DOWN INSTALLATION POWERED) DESCRIPTION

REF

13A- 1

-2 - 3 - 4 - 5 - 6 - 7 - 8 - 9 - 10 - 11 -12 - 13 - 14 - 15 -16 -17 - 18 - 19 - 20 - 21 -22 - 23 - 24 - 25 - 26 - 27 - 28 - 29 - 30 - 31 - 32 -33 - 34 -35 - 36 -37 - 38

-39

-40 - 41 - 42 - 43 - 44

Turret Pump and Electric Motor Electric Motor Pump Drive Assembly Hex Head Capscrew Flat Washer Lockwasher Electric Motor Socket Head Capscrew Chain Coupling Cover Chain Coupling Drive Line Hex Head Capscrew Lockwasher Flat Washer 0-Ring Boss Adapter 90° Elbow 0-Ring Elbow Reducer Hose Assembly - To Pump Solenoid Pump 0-Ring Boss Adapter 90° Swivel Elbow 90° 0-Ring Elbow Hose Assembly Hose Assembly - To Proportional Control Valve 90° Elbow (J.D. Furnished) Hose Assembly (J.D. Furnished) Hose Assembly - To Hyd. Panel Hose Assembly - To Rotary Coupling Reducer Hose Assembly - To Proportional Control Valve Tee Tee Reducer 90° Elbow

Filter Gate Valve Compensator Adjustment Plug Hose Assembly - To Emergency Bleed Down Valve 90° Elbow Hose Assembly - To Topping Cylinder Adapter Emergency Bleed Down Valve Hex Head Capscrew Lockwasher Bracket Pump Solenoid Valve

PART NUMBER

QTY

21930 21649 3/8-16UNC X 1-1/2 3/8 3/8 21747 3/8-24UNC X 1/2 5016 21898 X 13UNC X 2-3/4 1/2 1/2 0503-5-4 2071-4-4 2062-8-6 TRTX-6-4 FG1012-EEE-0480 21852 202702-8-12 2071-12-12 2062-12-12 FG 1556-KKK-0270 FG 1011-KKK-0360

1 1 4 4 4 1

AR26746 3634 FG 1012-KKK- 0360, FG 1012-GGG-0480 2215-8-6 FG 1011-HHH-0296

1 1

2028-8-8 1-1/2 B.P. 2021-24-12 2023-16-12 21474 1-1/2 Bronze FA-4407-EBE-0280

1 1 2 1 1 1 1 1

2024-4-4 FG 1005-EEER-0300 2021-6-4 21466 1/4 X 20UNC X 1-1/2 1/4 21722 21465

2 1 2 1 4 4 1 1

1 1 4 4 4

2 1 1 1 2 2 1

1 1 1

3/13/80

(BATTERY

FIGURE 13A-TURRET PUMP AND EMERGENCY BLEED DOWN INSTALLATION POWERED)

FIGURE 13A.

REF -45 -46

(BATTERY TURRET PUMP AND EMERGENCY BLEED DOWN INSTALLATION POWERED)

PART NUMBER

DESCRIPTION

2062-6-4 202702-6-4

90 ° 0-Ring Elbow Adapter

QTY 1 1

,.., ,,„„

FIGURE 14 - FUEL TANK ASSEMBLY (ALL MODELS)

FIGURE 14 - FUEL TANK ASSEMBLY (ALL MODELS ) REF 14 -1 -2 -3 -4 -5 -6 -7 -8 -9 -10

DESCRIPTION Fuel Tank Assembly

90° Brass Elbow Copper Tube Assembly Fuel Tank Weldment Pipe Plug Filler Cap Fuel Gauge Pipe Plug Pipe Plug Valve Engine Sediment Bowl

PART NUMBER

21743 69 x 4 1/4 x 20 21236 3/8 NPT FC1.5-S GA-VE-FA-26 1" NPT 1/8 NPT A555 (Reference)

QTY

1 1 1 1 1 1 1 I 1 1 1

FIGURE 15 - HYDRAULIC TANK ASSEMBLY (ALL MODELS )

FIGURE 15 - HYDRAULIC TANK ASSEMBLY (ALL MODELS) REF

- 4 - 5 - 6 - 7 - 8 - 9 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24

Hydraulic Tank Assembly Hydraulic Tank Weldment Gasket No. 12 Type-C, Self-Tapping Screw X Long Cover Filler Breather Unit (Tank Cap) Dip Stick Sump Strainer Close Pipe Nipple Hex Head Capscrew Tee Reducer . Lockwasher Allen Head Pipe Plug Bronze Gate Valve Reducer Tee 90 ° Elbow Filter Adapter Tube Assembly Pipe Plug (1" NPT) 90 ° Elbow Swivel Tee 90° Elbow

21742 21237 Part of 21237 Part of 21237 Part of 21937 Part of 21237 21192 21473 1-1/2 NPT 3/4-20 UNC X 5/8 2028-8-8 2215-8-6 (4248,6066) 1/4 Part of 21237 1-%, 2021-24-12 1-%, SCHD 40 B.P. 2024-16-12 21474 2021-16-16 21799-7 Part of 21237 2024-4-4 203102-8-8 (6066) 2024-16-16

r—I r—I r—I00r—i r-1 r 1r—ICr) C\1r—I C\1 r—I C\1 r—I 1-1 r—I r—I Cs's!

15- 1 - 2 - 3

PART NUMBER

DESCRIPTION

•

FIGURE 16 GROUND CONTROL BOX ASSEMBLY (ALL MODELS)

2.28-80

FIGURE 16 GROUND CONTROL BOX ASSEMBLY (ALL MODELS)

REF

DESCRIPTION

1 Socket Base Relay 2 3 Latching Relay 4 Box, Machining 5—Circuit Breaker Micro-Switch Boom Turret Retract 6 7 Micro-Switch Selector 8 Push Button 9—Ciamp Channel Mounting Channel 10 Terminal Block 11 Switch Start/Stop 12 13 Hour Meter 14 --Ammeter 15 Key Switch 16 Connector Assembly 17—Connector Assembly 18—Placard Assembly 19—Mounting Plate 20- -Wobulator 21----- Sending Unit for Wobulator--------------- -- -

PART NUMBER

QTY

27E122 1 KRP-11DG 2 KB170-12VDC 1 40075 3 109 -220-101 4 ATLI 7 ATL1-3 2 1 W191P6R 4 #11 2 #12 X 9" Lg 40 P-625 1 8510-K2 1 56288 1 1 Assy.) 2 (Engine YE 1 LS61-ATC 2 2522 1 2535 1 21422 1 40018 PS-30 -- - -- ----- --- --- - 1 1 GR2 12VDC -

2/ 2 8/8 0

FIGURE 17 - TURRET ROTATION SPEED REDUCER INSTALLATION (ALL MODELS)

REF

DESCRIPTION

17-

Turret Rotation Speed Reducer Installation

- 1

Turret Speed Reducer

Key

2 3 4 5 6 7

- 8 - 9 -10

Connector Motor Hydraulic Lockwasher Hex Head Capscrew Turret Rotation Pinion

Lockwasher Hex Socket Head Capscrew Base Plate (21437) -11 Turret Base Plate -12 Adjustable Speed Reducer Mbunting Assy. -13 Mounting Plate -14 Hex Head Capscrew

PART NUMBER QTY Part .of 21006(3238) 1 Part of 21005(4046) 1 Part of 21004(4248) 1 Part of 21007(5056) 1 Part of 21003(6066) 1 21739 1/4 Sq. X 1 202702-10-8 21442 3/8 3/8-16 UNC X 1 21740 21906 (4046) 5/8 5/8-11 UNC X 1-1/2

1 1 2 1 2 2 1 1 4 4

(Reference) (See Fig. 13B)

1 1

21435 21436 5/8-11 UNC X 14-

1 1 3 121578

FIGURE 17 - TURRET ROTATION SPEED REDUCER INSTALLATION (ALL MODELS) DESCRIPTION

REF

-15 -16 -17

Lockwasher Flat Washer Flat Washer

-18 -19

Hex Nut Square Head Capscrew

•

PART NUMBER

5/8 5/8 SAE STD. 2 OD X 11/16 X 'T., THR 3/4 X 10 UNC 3/4 X 10 UNC X 4

** See Vendor Section for Further Breakdown.

•

QTY

3 2 1

1 1

FIGURE 18 - MUFFLER INSTALLATION (ALL MODELS)

REF

DESCRIPTION Muffler Installation

18-

1 - 2 - 3

4 5 6 7 8

Rain Cap Muffler Hole for 110V Boom Electrical Line Receptacle (Option 21058) 90° Street Elbow Engine Manifold Flexible Exhaust Tube Assembly Hex Head Capscrew Lockwasher

PART NUMBER

QTY

Part of 21380 (3238) Part of 21969 (4046) Part of 21748 (4248) Part of 21363 (5056) Part of 21863 (6066) 21563 21515 (See Fig. 13B)

1 1 1 1 1 1 1 1

1-1/4 NPT Part of 21082 40087 5/16-18 UNC X 3/4 5/16

1 1 1 8 8 6/29/79

FIGURE 18 - MUFFLER INSTALLATION (ALL MODELS)

REF - 9 -10

DESCRIPTION Flatwasher Muffler Guard

PART NUMBER 5/16 21826

•

QTY 4 1

FIGURE 19 - AIR CLEANER, AUTOMATIC CHOKE, AND BATTERY INSTALLATION

QTY.

DESCRIPTION

PART NUMBER

Air Cleaner, Automatic Choke and Battery Installation

Part of 21380 (3238) 1 Part of 21969 (4046) Part of 21748 (4248) 1 Part of 21363 (5056) 1 Part of 21863 (6066) 1 FM127-2 X 33 4 7907 2 LJ 120 X 6 LK 8 1/4 X 20 UNC X 1/2 4 1/4 4 LO 157-1 51 40021 1 5/16 - 18 UNC X 10-1/2-- 2 5/16 2 5/16 - 18 UNC 2 2 21725 1 21518 1 21342 , 2 7244

1 Flex Hose 2 Hose Clamp - 3 Air Intake Tube - 4 Hose Clamp - 5 'Hex Head Cap Screw - 6 Lock Washer 7 Air Cleaner - 8 Air Cleaner Baffle Plate - 9--I "J" Bolt -10 Flat Washer -11--1--Hex Nut -12--1-Battery Clamp -13 --Battery (Exide ) -14----Solenoid -15--1—Self Tapping Screw

FIGURE 19.- AIR CLEANER, AUTOMATIC CHOKE, AND BATTERY INSTALLATION PART NUMBER DESCRIPTION QTY REF 19-16----Cable - 17 ----Cable - 18----Automatic Choke Assembly (Wisconsin)

PBL-19 2 372 2 VF 62B 1

FIGURE 19A - DUAL FUEL INSTALLATION

FIGURE 19A - DUAL FUEL INSTALLATION REF

DESCRIPTION

PART NUMBER

QTY

, 19A- 1 - 2 - 3 - 4 - 5 - 6 - 7 - 8 - 9 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25 -26

Solenoid Valve Vacuum Switch Carburetor Adapter Load Block Bracket Regulator Model S2 Fitting Fitting Elbow Hose Assembly Hose, Fuel Tank to Sediment Bowl Wisconsin Engine Fuel Bowl Wisconsin Engine Pump Hose Hose, Vacuum - 100 WP Tank Bracket Hose, Vacuum - 100 WP Hose - 200 WP Valve Tank (Vapor withdrawal) Hose End for Items 10 and 14 Hose End for Items 10 and 14 Tee 1/4" Pipe Thread Quick Disconnectors Quick Disconnectors Adapter, Straight

330-03 350-02 201-11-28 140-08 520-01 074-1321 401-09 400-06 1582 X 4 (Weatherhead) FC 321-06-5/16" X 105" 801-4 X 30 FC 321-06-5/15" X 105" 5/8" X 9-1/2" TB-3 3" - 5/8" 1/4" X 18" 6600 (Weatherhead) 33.5 Lbs. 411-6S 412-6S 3700 X 4 7141 M 7141 F 48 X 6

2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 2 2 2 1 3 3 1

FIGURE 21 - BOOM ASSEMBLY (4248, 5056, 6066)

77 78 79 2 3 5 56 55 56

./N.,

./ I I ..'

.0." • ''s .

. ./.

''''' /

15 . >t....._ . - . . . . „.. . .-Vi i. .. 1 ..- '..e.. I‹.--- 7 ./. / / .....,

108 109

I / -4-7

14 2 13

FIGURE 21 - BOOM ASSEMBLY (4248, 5056, 6066) REF

DESCRIPTION

PART NUMBER

QTY

NOTE: Unless otherwise stated parts are common for 4248, 5056, 6066. 21-

Boom Assembly Platform Leveling Slave Cylinder Assembly Inner Boom Assembly Inner Boom Weldment Inner to Intermediate Boom Assembly

- 6 - 7 - 8 - 9 -10

Wear Pad Allen Flat Head Socket Machine Screw Wear Pad Wear Pad Allen Flat Head Socket Machine Screw Electrical Cable Assembly

- 11

Hydraulic Hoses Assembly

-12

Retraction Cable Assembly

-13 -14 -15

Clevis Pin Cotter Pin Extension Cable Assembly

-16 -17 -18 -19 -20 -21 -22 -23 -24 -25 -26 -27 -28

Allen Head Set Screw Leveling Cylinder Pin Punch Lock Clamp Support Grip Spring Hose Fitting Bulkhead Union Adapter 90° Swivel Elbow Hose Assembly Rotating Fork Assembly Boom Extension Cylinder Assembly g e ar Pad Allen Flat Head Socket Machine Screw Intermediate Boom Assembly

-29

Intermediate Boom Weldment

-30

Trunion Pin

1 1 1

40049 (5056) 40048 (4248) 40051 (6066) (See Fig. 22) 40056 (4248) 40058 (6066, 21762 (4248) 21765 (5056, 40057 (4248) 40062 (6066, 21775 3/8 - 24 UNF 21787 21822 3/8 - 24 UNF 21817 (4248) 21875 (6066 21818 (4248) 21876 (6066, 21820 (4248) 21828 (6066,

5056) 6066) 5056) X 3/4

1 1 1 1 1 1 1

6 2

X 1

5056) or 5056) or 5056)

1 1 1 1 1 1

x 1-3/4 1/8 X 1 21819 (4248) 21827 (6066 5056) 3/8 - 16 UNC X 3/8 21896 1-k 022-11-003 21489 FC9200- 04035 2041-4-4 2071-4-4 G1055-EEE-0234 (See Fig. 25) 21802 10-32 UNF X 3/4 21757 (4248) 21886 (6066, 5056) 21761 (4248) 21764 (6066, 5056) 21810

2 2

3 2

8 2 2 2 1

2 4 1 1 1 1

3/30/79

FIGURE 21 - BOOM ASSEMBLY (4248, 5056, 6066) REF

DESCRIPTION

-31 -32 -33 -34 -35 -36 -37 -38 -39 -40 -41 -42 -43 -44 -45 -46 -47 -48 -49 -50 -51 -52 -53 -54 -55 -56 -57 -58 -59 -60

Allen Head Set Screw Wear Pad Allen Flathead Socket Machine Screw Sheave Pin Lube Fitting Hex Head Capscrew Lockwasher Sheave Pin Extension Cable Sheave Hydraulic Hoses Assembly Sheave Electric Cable Sheave Wear Pad Wear Pad Lockwasher Hex Head Capscrew Cap Plate Sheave Bracket Weldment Cable Sheave Sheave Spacer Wear Pad Back-Up Plate Set Screw Jam Nut Wear Pad Hex Head Capscrew • . Lockwasher Wear Pad Allen Flat Head Socket Wear Pad Bracket Outer Boom Weldment

-61 -62 -63 -64

Bracket Shaft Back-Up Plate Lockwasher Hex Head Capscrew

-65 -66 -67 -68 -69 -70 -71 -72

Hose Cover Guard Hex Head Capscrew Lockwasher Turn-Around Bracket Clevis Pin Cotter Pin Pressure Spring Flat Washer

773 -74

Hex Head Nut Threaded Rod Assembly

PART NUMBER

3/8 - 24 UNC X 3/4 21787 3/8 - 24 UNC X 1 21785 1/4 NPT 1/4 - 28 UNF X k ' • 4 21925 21774 21784 21783 21772 21807 3/8 3/8 - 24 UNF X 3/4 21761-6 21771 . 21774 21776 21812 21813 li - 20 UNF X 3/4 k - 20 UNF 21812 k - 28 UNF X li ;-4 21805 3/8 - 24 UNF X 1 21804 21760 (4248) 21763 (5056, 6066) 21806 21813 5/8 5/8 X 11 UNC X 1-1/2 (Grade 5) 21788 3/8 -24 UNF X 3/4 3/8 21706 C7 1/8 X 1 21488 7/16 I.D. X 10.D (Type A) 3/8 - 24 UNF 21861

12TY

2 3 10 1 3 11 11 2 1 1 1 2 1 8 8 1 1 1 1 2 1 8 8 2 15 15 2 4 1 1 1 1 2 2 2 1 4 4 1 1 1 1 1 2 1 n/i-7

/7Q

FIGURE 21 - BOOM ASSEMBLY (4248, 5056, 6066 DESCRIPTION

REF

- 75 - 76 - 77 - 78 -79 - 80 -81 -82 - 83 - 84 -85 - 86 -87 - 88 - 89 - 90 -91 - 92 - 93 - 94 - 95 - 96 - 97 -98 - 99 - 100' - 101 -102 - 103

Relief Valve 90 ° 0-Ring Elbow Hex Head Capscrew Lockwasher Hex Nut Hose Assembly Adapter • Outer Boom Rear Cover Rear Cover Brace 90 ° Bulkhead Elbow Swivel Tee Cotter Pin Hex Nut Internal Tooth Lockwasher Boom Extension Cylinder Pin Socket Head Cap Screw Eccentric Socket Head Cap Screw 90 Elbow Master Leveling Pin 90 ° 0-Ring Boss Elbow Master Leveling Cylinder (See Fig. 24) Topping Cylinder Boom Pin Topping Cylinder Assembly 90 ° 0-Ring Boss Elbow Hose Assembly Bualead Adapter Hose Assembly - To Turret Proportional Control Valve Pack Hose Assembly - To Turret Solenoid Control Valve Pack Hose Assembly - To Turret Holding Valve Hose Assembly Hose Assembly - To Turret Proportional Control Valve Pack 90° Bulkhead Elbow Hose Assembly Limit Switch * 1c Boom To Turret Pivot Pin Lube Fitting Lockwasher Hex Head Cap Screw Master Leveling Cylinder Pin Topping Cylinder Pin Lockwasher Hex Head Cap Screw Tube End Reducer Support Grip Hose Assembly - To Emergency Bleed Down

PART NUMBER

QTY

21892 2062-8-8 5/6 - 18 UNC X 3 5/16 5/16 - 18 UNC FG 1012-HHH-0150R 202702-8-8 21755 21754 2043-8-8 203102-8-8 1/8 X 1-1/2 3/4 - 10 UNC 3/4 21808 3/8 - 24 UNC X 21809 3/8 - 24 UNC X 1 2003-8-8 21847 2062-4-4 40003 21845 (See Fig. 27) 2062-6-6 FG1012-GGG-0217 2041-6-6 FG1005-GGG- 0430

FA7229-GGG-0730

FG101-GGG-0610 FC120-EBE-0660 FG1011-HHH-0660

2 2 2

2043-8-8 FG1011-HHH-0350 40208 21791 1/8 NPT 3/8 3/8-24UNC X k21131 21645 5/16 5/16-18UNC X 3/4 6-4-TRBTX 022-01-1467 FG1005-EEE-R-300

2 2

2 2 2 1 4 1 1 1

2 1 2 4 2 1

4 2 3 1

2 2 2 2

- 104 - 105 - 106 -107 - 108 - 109 - 110 - 111 - 112 -113 - 114 - 115 -116 -117 -118 - 119 - 120

3 3 3

1 1

2 2 4 1 3/30/7-c

FIGURE 21 - BOOM ASSEMBLY (4248, 5056, 6066)

REF -121 -122 -123 -124 -125 -126 -127 -128 -129 -130

DESCRIPTION Socket Set Screw Spacer Bulkhead Tee Bulkhead Adapter Limit Switch ** Washer Tube Spacer • Washer Pivot Pin Bushing Limit Switch Bracket

PART NUMBER

QTY

5/16 - 18 UNC X 1 3/4 X 1-1/4 B.P. 203008-6-6 2041-6-6 40207 32570 15/16 X 7/32 21040-2 4- 2 0.D. X 2-* I.D. 21773 40226

4 1 2 2 1 1 1 A/R 2 1

** Part of Automatic Shift to low gear system - (See Figure 4A)

•

FTC,ITR P, 21A - BOOM ASSEMBLY ( 4 04 6

35 , 5 36 \ 27 6 x_ u in .34333129 23 1 3 'we..16 3230 28 24 17 25 26

16 14 17 0 19 1

FIGURE 21A - BOOM ASSEMBLY (4046)

12i578

FIGURE 21A - BOOM ASSEMBLY (4046) REF

21A-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25 -26 -27 -28 -29 -30 -31 -32 -33 -34 -35 -36 -37 -38 -39 -40 -41 -42

DESCRIPTION

Boom Assembly Platform Leveling Slave Cylinder Assembly (See Fig. 22) Inner Boom Assembly Inner Boom Weldment Outer Boom Weldment Electrical Cable Assembly Boom Control Cable Boom Extension Cylinder Assembly (See Fig. 25A) Retraction Cable Assembly Hydraulic Hoses Assembly Hydraulic Hose Support Grip-Closed Off-Set Eye Punch Lock Clamp Support Grip-Conduit Riser Spring ' Turn-Around Bracket Lockwasher Hex Head Capscrew Socket Head Set Screw Leveling Cylinder Pin Spring Locknut Flat Washer . Rod Assembly Threaded Rod Clevis Clevis Pin Turn Around Bracket Cover Hex Head Self Tapping Screw Hex Head Jam Nut Hex Socket Head Set Screw Hex Head Capscrew Lockwasher Back-Up Plate Wear Pad Bracket Wear Pad Flat Socket Head Capscrew Hose Fitting Bulkhead Union Adapter 90° Swivel Elbow Hose Assembly-To Rotating Fork Assembly (Option 21751) Wear Pad Cable Sheave

PART NUMBER

QTY

40047 40052

1 1

40055 21918 21917 21914 21937 4004 2

1 1 1 1 1 1

21951 21913 FC120-03022-01-039 1 k 022-11-003 21489 21904 3/8 3/8-16UNCX1 3/8-24UNF x k 21896 21488 3/8-16UNC 7/16 21861 3/8-24UNC x 8 Y4 C7 21962 No. 10-24 x k 1/2-20UNF 1 x 20 UNF x 3/4 1/4-28 UNF x k3-4 21813 21961 21787 3/8-24 UNF FC9200-04035 2041-4-4 2071-4-4 G1055-EEE-0234

1 1 4 2 4 2 1 1 10 10 4 1 1 2 1 1 1 1 1 1 4 4 4 8 8 1 1 1 2 8 2 2 2 2 3

21812 21946

_ ___

FIGURE 21A - BOOM ASSEMBLY (4046) REF

-83

2062-6-6 FG1005-EEE-R-0300 FG1012-GGG-0217 FG1005-GGG-0430 2041-6-6 FG1011-GGG-0610 FC120-EBE-0170

CA CV CV CV CA CV

-81 -82

90 ° 0-Ring Boss Elbow Hose Assembly-To Emergency Bleed Down Hose Assembly Hose Assembly-Turret PropOrtional Control Valve Pack Bulkhead Adapter Hose Assembly-To Turret Holding Valve Hose Assembly

2062-4-4 1/8 NPT (See Fig. 27A)

♦ CV

-79 -80

5/16-24 UNF x lk 5/16 21941 21939 5100-100 21958 3/8-24UNF x 3/4 1 in. Type B Ser. N 21938 21944 FG1012-HHH-0150 2041-8-8 2071-8-8 21923 21924 k-28UNF x 1.4 3/8-16UNC 21847 3/8-24UNC x 1 21809 21956 5/16-18UNC x 1 3/8-24UNC x k SA155-6 5/16-24UNF x 13/4 21960 21772 21959 ' 21957 40003

CV r4 r4CV C4 r4 r4 CV CV r

-77 -78

Hex Head Capscrew Flatwasher Retraction Cable Bracket Hydraulic Hose Sheave Retaining Ring Wear Pad Flat Socket Head Capscrew Thrust Washer Electrical Cable Sheave Sheave Pin Hose Assembly Bulkhead Adapter 90° Swivel Elbow Boom Brace Boom Cover Hex Head Capscrew . Lockwasher Hex Nut Master Leveling Cylinder Pin Socket Head Capscrew Eccentric Extension Cylinder Pin Socket Head Set Screw Socket Head Set Screw Threaded Terminal Hex Socket Head Capscrew Cylinder Trunion Pin Wear Pad Wear Pad Boom Lift Cylinder Pin Master Levleing Cylinder (See Fig. 24) 90 ° 0-Ring Boss Elbow Lube Fitting Topping Cylinder Assembly

QTY

■t

-74 -75 -76

PART NUMBER

CV CVCV r4 CV r-( 00 CV r4 rA CV CV C4 1-4 moCV r-1 CV c4 r4

-43 -44 -45 -46 -47 -48 -49 -50 -51 -52' -53 -54 -55 -56 -57 -58 -59 -60 -61 -62 -63 -64 -65 -66 -67 -68 -69 -70 -71 -72 -73

DESCRIPTION

FIGURE 21A - BOOM ASSEMBLY (4046) DESCRIPTION

PART NUMBER

QTY

FG1011-HHH-0350 40208 203008-6-6 6-4-TRBTX 2041-6-6 FG1011-HHH-0660

2 1 2 4 2 2

-90 -91 -92 -93 -94 -95 -96 -97 -98 -99 -100 -101

Hose Assembly Limit Switch Bulkhead Tee Tube End Reducer Bulkhead Adapter Hose Assembly-To Turret Proportional Control Valve Pack 90° Bulkhead Elbow Boom to Turret Pivot Pin Lockwasher Hex Head Capscrew Master Leveling Cylinder Pin Topping Cylinder Pin Lockwasher Hex Head Capscrew Cable Sleeve Terminal Tube Spacer Washer

102 -103 104

Pivot Pin Bushing Limit Switch Cover Limit Switch**

REF

-84 -85 -86 -87 -88 -89

Washer

105 •

2043-8-8 21791 3/8 3/8-24UNC x 1/2 21131 21645 5/16 5/16-18UNC x 3/4 3/16 7 x 9 SA157-6 21040-1 4-1/2 0. D. x 2-1/4 I. D. 21773 40226 40207

2 1 3 3 1 1 2 2 1 1 1 A/R

32570 15/16 X 7/21

2 1 1

Part of Automatic Shift to Low Gear System (See Figure 4A)

/:n /73

NOTES

FIGURE 21B - BOOM ASSEMBLY (3238)

8 9 98 10

40 39 11

16 X14 1 17 220 i91

35 36 27 44333129 23 Cf 3 104 10516 3230 24 17 28 25 26

33079

FIGURE 21B - BOOM ASSEMBLY (3238)

21B- 1 - 2 - 3 - 4 - 5 - 6 - 7 - 8 - 9 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25 -26 -27 -28 -29 -30 -31 -32 -33 -34 -35 -36 -37 -38 -39 -40 -41 -42 -43 -44 -45 -46

• PART NUMBER

DESCRIPTION

REF

QTY

. Boom Assembly Platform Leveling Slave Cylinder Assembly Inner Boom Assembly Inner Boom Weldment Outer Boom Weldment Electrical Cable Assembly Boom Control Cable Boom Extension Cylinder Assembly Retraction Cable Assembly Hydraulic Hoses Assembly Hydraulic Hose Support Grip-Closed Off-Set Eye Punch Lock Clamp Support Grip-Conduit Riser Spring Turn-Around Bracket Lockwasher Hex Head Capscrew Socket Head Set Screw Leveling Cylinder Pin Spring Locknut Flat Washer Rod Assembly Threaded Rod Clevis Clevis Pin Turn-Around Bracket Cover Hex Head Self-Tapping Screw Hex Head Jam Nut Hex Socket Head Set Screw Hex Head Capscrew Lockwasher Back-Up Plate Wear Pad Bracket Wear Pad Flat Socket Head Capscrew Hose Fitting Bulkhead Union Adapter 90° Swivel Elbow Hose Assembly - To Rotating Fork Assembly (Option 21751) Wear Pad Cable Sheave Hex Head Capscrew Flatwasher Retraction Cable Bracket Hydraulic Hose Sheave

40046 (See Fig. 22)

1 1

40050 21999 21998 21448 21937 (See Fig. 25A) 21326 21449 FC120-03-0684 022-01-039 1-k 022-11-003 21489 21373 3/8 3/8-16 UNC X 1 3/8-24 UNF X k 21896 21488 3/8-16 UNC 7/16 21861 3/8-24 UNC X 8 Y4 C7 21788 No. 10-24 X k 1/2-20 UNF k X 20 UNF X 3/4 k-28 UNF x li 1/4 21813 21804 21805 3/8-24 UNF FC9200-04035 2041-4-4 2071-4-4 G1055-EEE-0234

1 1 1 1 1 1 1 1 4 1 4 2 1 1 10 10 4 1 1 2 1 1 1 1 1 1 4 4 4 8 8 1 1 1 2 8 2 2 2

21812 21946 5/16-24 UNF X 1-4 5/16 21941 21939

3 /30 /79

2 2 2 2 2 1

FIGURE 21B - BOOM ASSEMBLY (3238) REF

5100-100

Flat Socket Head Capscrew Thrust Washer Electrical Cable Sheave Sheave Pin Hose Assembly Bulkhead Adapter 90° Swivel Elbow Boom Brace Boom Cover Hex Head Capscrew Lockwasher Hex Nut Master Leveling Cylinder Pin Socket Head Capscrew Eccentric Extension Cylinder Pin Socket Head Set Screw Socket Head Set Screw Threaded Terminal Hex Socket Head Capscrew Cylinder Trunion Pin Wear Pad Wear Pad Boom Lift Cylinder Pin Master Leveling Cylinder (See Fig. 24) o 90 0-Ring Boss Elbow Lube Fitting Togping Cylinder Assembly 90 0-Ring Boss Elbow Hose Assy. - To Emergency Bleed Down Hose Assy. Hose Assy. - Turret Proportional Control Valve Pack Bulkhead Adapter Hose Assy. - To Turret Holding Valve Hose Assy. Hose Assy. Limit Switch Bulkhead Tee Tube End Reducer Bulkhead Adapter Hose Assy. - To Turret Proportional Control Valve Pack 90° Bulkhead Elbow Boom to Turret Pivot Pin Lockwasher Hex Head Capscrew

3/8-24UNF X 3/4 1", Type B, Ser. N 21938 21944 FG1012-HHH-0150 2041-8-8 2071-8-8 21754 21755 k-28 UNF X k 1/4 3/8-16 UNC 21847 3/8-24 UNC X 1 21809 21956 5/16-18 UNC X 1 3/8 - 24 UNC X k SA155-6 5/16-24 UNF X 1-k 21810 21787 21446 21845 40003 2062-4-4 1/8 NPT (See Fig. 27) 2062-6-6 FG1005-EEE-R-0300 FG1012-GGG-0217 FG1005-GGG-0430 2041-6-6 FG1011-GGG-0610 FC120-EBE-0170 FG1011-HHH-0350 40208 203008-6-6 6-4-TRBTX 2041-6-6 FG1011-HHH-0660 2043-8-8 21791 3/8 3/8-24UNC x k

-90 -91 -92 -93

Retaining Ring

QTY

-81 -82 -83 -84 -85 -86 -87 -88 -89

PART NUMBER

N CONT-4 T-1 NNNr-1 r--1 1/401/40N T-I CAN r-4 ...3* NT-1 r--1 N NIr-i r-1 r-I N Nr-I NI N N N NNN NT-1N-4 N N Nr-1 Cr) CO

-47 -48 -49 -50 -51 -52 -53 -54 -55 -56 -57 -58 -59 -60 -61 -62 -63 -64 -65 -66 -67 -68 -69 -70 -71 -72 -73 -74 -75 -76 -77 -78 -79 -80

DESCRIPTION

•

3/30/79

FIGURE 21B - BOOM ASSEMBLY (3238) DESCRIPTION

REF

-94 -95 -96 -97 -98 -99 -100 -101 -102 -103 -104 105 -

PART NUMBER

Master Leveling Cylinder Pin Topping Cylinder Pin Lockwasher Hex Head Capscrew Cable Sleeve Terminal Tube Spacer Washer Pivot Pin Bushing Limit Switch Cover Limit Switch **

21131 21645 5/16 5/16-18UNC X 3/4 3/16 7 X 9 SA157-6 21040-2 4-1/2 0.D. X 2-k I.D. 21773

Washer

32570 15/16 X 7/21

40226

40207

QTY 1 1 2 2 1 1 1 A/R 2 1 1 1

**Part of Automatic Shift to Low Gear System (See Figure 4A)

3/30/79

NOTES

FIGURE 21C - BOOM ASSEMBLY (4248 - Two Cable System)

4/81

FIGURE 21C- BOOM ASSEMBLY (4248 - Two Cable System)

FIGURE REF

-4248 - Two 61 ____ ASSEMBLY .

DESCRIPTION

, t

PART NUMBER

QTY

Boom Assembly

40048

(See Fig. 22)

- 2

Platform Leveling Slave Cylinder Assembly Inner Boom Assembly

40056

- 3

Inner Boom Weldment

21762

- 4

Inner to Intermediate Boom Assembly

40057

- 5 - 6 - 7 - 8 - 9 -10

Wear Pad Allen Flat Head Socket Machine Screw Wear Pad Wear Pad Allen Flat Head Socket Machine Screw Electrical Cable Assembly

21775 3/8 - 24 UNF X 3/4 21787 21822 3/8 - 24 UNF X 1 21817

-11

Hydraulic Hoses Assembly

21818.

-12

Retraction Cable Assembly

21820

-13 -14 -15

Clevis Pin Cotter Pin Extension Cable Assembly

1/2 X 1 k 1/8 X 1 21827

3 3 2

-16 -17 -18 -19 -20 -21 -22 -23 -24 -25 -26 -27 -28

Allen Head Set Screw Leveling Cylinder Pin Punch Lock Clamp Support Grip Spring Hose Fitting Bulkhead Union Adapter 90 ° Swivel Elbow Hose Assembly Rotating Fork Assembly Boom Extension Cylinder Assembly Wear Pad Alien Flat Head Socket Machine Screw Intermediate Boom Assembly

3/8 - 16 UNC X 3/8 21896 1 -2 022 11 003 21489 FC9200-04035 2041-4-4 2071-4-4 G1055-EEE-0234 (See Fig. 25) 21802 10-32 UNF X 3/4 21757

1 1 3 2 1 8 2 2 2 1 2 4 1

-29

Intermediate Boom Weldment

21761

-30

Trunion Pin

21810

21- 1

1 6 2

1 2 1

4/81

•FIGURE 21C- BOOM ASSEMBLY (4248 - Two Cable System) DESCRIPTION

REF

- 31 - 32 -33 -34 - 35 - 36 - 37 - 38 - 39 -40 - 41 -42 - 43 - 44 -45 - 46 - 47 - 48 - 49 - 50 - 51 - 52 - 53 -54 - 55 - 56 -57 -58 - 59 - 60

Set Screw Jam Nut Wear Pad Hex Head Capscrew Lockwasher Wear Pad Allen Flat Head Socket Wear Pad Bracket Outer Boom Weldment

-61 - 62 - 63 - 64

Bracket Shaft Back-Up Plate Lockwas her Hex Head Capscrew

- 65 - 66 -67 - 68 -69 - 70 - 71 - 72

Hose Cover Guard Hex Head Capscrew Lockwasher Turn-Around Bracket Clevis Pin Cotter Pin Pressure Spring Flat Washer

Allen Head Set Screw Wear Pad Allen Flathead Socket Machine Screw Sheave Pin Lube Fitting Hex Head Capscrew, 1/2" 13 UNC x 3/4" LG. Lockwasher, 1/2" Roller Bearing Extension Cable Sheave Hydraulic Hoses Assembly Sheave Electric Cable Sheave Wear Pad Wear Pad

PART NUMBER

QTY

3/8 - 24 UNC X 3/4 21787 3/8 - 2.4 UNC X 1 21785 1/4 NPT

2 3 10 1

Lockwasher , 3/8" Hex Head Capscrew, 3/8" - 24UNF x 3/4" LG, Bracket Retainer Cable Sheave and Bracket Assembly Retainer

Wear Pad Sheave

-73 Hex Head Nut - 74 Threaded Rod Assembly

40212 or 21447

21774 21784 21783 21772 21807 3/8" 3/8" 40209 40213 40211 40214 21812

8 8 1

1 1 1

40210 2 - 20 UNF X 3/4

- 20 UNF 21812 k 28- UNF X -

21805 3/8 - 24 UNF X 1 21804 21760 21806 21813 5/8 5/8 X 11 UNC X (Grade 5) 21788 3/8 -24 UNF X 3/4 3/8 21706 C7 1/8 X 1 21488 7/16 I.D. X 10.D (Type A) 3/8 - 24 UNF 21861

2 1 8 8 2 15 15 2 4 1 1 1 1 2 2 2 1 4

4 1 1 1 1 1

4/81

FIGURE 22 - PLATFORM SLAVE LEVELING CYLINDER ASSEMBLY (ALL MODELS)

REF.

DESCRIPTION

PART NUMBER

22-

Platform Leveling Slave Cylinder Assy.

40052

- 1

- 2 - 3 - 4 - 5 - 6 - 7 - 8 - 9 -10 -11 -12 -13 -14 -15 -16 -17 -18

Leveling Cylinder (See Fig. 23) Hose Clamp Lube Fitting Adapter Tube Assy. (k) 0-Ring Boss Tee Tube Assy. (k) Pilot Valve Bracket Lockwasher Hex Head Capscrew 90 0 Swivel Elbow 90° Elbow 90° 0-Ring Boss Elbow Hex Head Capscrew Lockwasher Pilot Check Valve 90° 0-Ring Boss Elbow Tube Assembly NOTE: Unless otherwise stated, parts are common for all models.

40004 4-1219 1/8 NPT 2027-4-4 21799-11 203003-4-4 21799-10 21752 4-20 UNC X 3/4 2071-4-4 2024-6-4 2062-6-4 3/8-24 UNC X 143/8 21470 2062-4-4 21799-12

QTY. 1 1 1

2 2

1 1 1 1 1

2 2 1

2 1 2 2 1 1 1

3/30/79

FIGURE 23 - SLAVE LEVELING CYLINDER (ALL MODELS) . ,

1 2

8 910 11

__, ...._ ■AMPAmm,...........,...

...m..........,.....

-- , • .

N11

4muiRg

4mnaD:44 1

1110

Allik

. REF

DESCRIPTION

CD Cq 1 r-4 CN1 M .1-inMD oo r-4 r-I CN1 1 1 1 1 1 1 1 1 1 1 1 1

Slave Leveling Cylinder (L) Locknut - Self - Locking Piston Seal - U - Cup Piston Rod Static Seal Barrel Assembly Rod Assembly Gland Static Seal Gland Rod Seal . Rod Wiper Bronze Bushing Seal Kit

. PART NUMBER 40004 50935 50043 3489-06 50103 4377-02 4377-18 50005 4377.;.05 50024 50082 51490 3489-34

QTY 1 1 2 1 1 1 I 1 1 1 1 1 1

FIGURE 24 - MASTER LEVELING CYLINDER (ALL MODELS)

10 2 4 5 8 9 3 6 7 Zdri.E.411MIVIIMMI, /21MI/AM VIIIIMMICAIUM16114 03.-----Jill=wuwa CC i

■

14p

214

REF 24-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11

DESCRIPTION Master Leveling Cylinder (L) Locknut - Self - Locking Piston Seal - U-Cup Piston Rod Static Seal Barrel Assembly Rod Assembly Gland Static Seal Gland Rod Seal Rod Wiper Seal Kit

PART NUMBER 40003 50935 50043 4378-06 50103 4378-02 4378-18 50005 4377-05 50024 50082 3489-34

QTY 1 1 2 1 1 1 1 1 1 1 1 1

FIGURE 25 - BOOM EXTENSION CYLINDER ASSEMBLY (4248, 5056, 6066)

DESCRIPTION

REF

NOTE: Unless otherwise stated, parts ar common for 4248, 5056, 6066. Boom Extension Cylinder Assembly

25- 1

2 3 4 5 6 7

- 9 -10 -11 -12 -13 -14 -15

Boom Extension Cylinder Adapter Tube Assebmly (1/2) 90 Swivel Elbow Holding Valve Hex Head Capscrew Lockwasher Adapter Tube Assembly Wear Pad Allen Flat Head Socket Machine Screw Allen Flat Head Socket Machine Screw Wear Pad Tube Assembly (1/2) Tube Assembly (1/2)

PART NUMBER

40043 (4248) 40044 (5056) 40045 (6066) (See Fig. 26B,C,orD) 2103-12-8 21799-29 2071-8-8 40104 3/8-24UNC X 3-3/4 3/8 0503-8-8

21799-3.0 21801 I0-32UNF X 1 10-32UNF X 3/4 21802 21799-32 21799-31

1 1

1 2

4 1 2 2 2 2 4 2 1 1 9/17/7c

FIGURE 25A - BOOM EXTENSION CYLINDER ASSEMBLY (3238, 4046)

, REF .25A-

• DESCRIPTION Boom Extension Cylinder Assembly

- 1

Boom Extension Cylinder

- 2

Electrical Cable Sheave

3 4 5 6

Sheave Pin Retaining Ring Thrust Washer Hydraulic Hose Sheave

- 7 - 8

Holding Valve Bracket Holding'Valve

Q17,

PART NUMBER 40089 (3238) 40042 (4046) (See Fig. 26)(3238) (See Fig. 26A)(4046) (4046) 21938-1 Nylon -2 Aluminum 21944 5100-100 1" Type B Series N 21939- 1 Nylon - 2 Aluminum —7----Th 21953 `2_ I 9 -11 -401.02

1 1 1 1 1 1 2 2. 1 . / 1

9/ 1 7/7c

FIGURE 25A - BOOM EXTENSION CYLINDER ASSEMBLY (3238, 4046) REF

9 -10 -11 -12 -13 -14 -15 -16 -17

DESCRIPTION

Hex Head Capscrew LoS kwasher 90 u 0-Ring Elbow Tube Assembly 450 0-Ring Elbow Tube Assembly Bar Retraction Sheave Bracket Weldment Retraction Sheave Bracket Bushing

PART NUMBER

3/8-24 UNF X 3-3/4 3/8 2062-6-8 21799-33 2061-8-8 21799-34 lk X 7k. A1S1M1OZO 21920 (3238) 21932 (3238)

QTY

2 2 2 1 4 1 1 1

FIGURE 26 - BOOM EXTENSION CYLINDER (3238)

2)3 14 , 10 '

/* '

^ A

A A

.. ,

.......

J. g A A A A A A

DESCRIPTION

REF 26-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16

Boom Extension Cylinder (L) Rod Assembly Barrel Assembly Gland Static Seal Wear Ring Gland Rod Seal Rod Wiper Sheave Bracket Plug - 1/8 NPT Locknut - Self - Locking

Piston Seal Wear Ring Rod Static Seal Spacer

Piston Seal Kit

PART NUMBER 40008 4366-06 4366-02 50005 51070 4366-05 50028 50087 4366-53 50377 50066 50043 50563 50107 4366-23 4366-06 4366-34

QTY 1 1 1 1 4 1 3

1 1 2 1 1 1 1

FIGURE 26A - BOOM EXTENSION CYLINDER (4046)

REF 26A-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16

DESCRIPTION Boom Extension Cylinder (L) Rod Assembly Barrel Assembly Gland Static Seal Wear Ring Gland Rod Seal Rod Wiper Sheave Bracket Plug - 1/8 NPT Locknut - Self - Locking Piston Seal Wear Ring Rod Static Seal Spacer Piston Seal Kit

PART NUMBER

QTY

40009 4393-18 4393-02 50005 51070 4393-05 50028 50087 4366-53 50377 50066 50043 50563 50107 4393-23 4366-06 4366-34

1 1 1 1 4 1 1 3 1 1 1 2 1 1 1 1

3.507(

FIGURE 26B - BOOM EXTESNION CYLINDER (4248)

9 1011 12 13 14

n ir4 /1I FAIII I f! IMII! 2W.d il I I 1 1 I I FAfir eA11011dArAllIAIMIsa AV W ,a; I,w It AJF

REF 26B-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15

DESCRIPTION Boom Extension Cylinder (L) Rod Assembly Barrel Assembly Gland Static Seal Wear Strip Rod Seal Gland Rod Wiper Plug 1/8 NPT Locknut - Self -Locking Piston Seal Wear Strip Piston Rod Static Seal Spacer Seal Kit

PART NUMBER OTY 40011 1 4366-18 1 4366-02 1 50005 1 51070 2 50028 1 4366-05 1 50087 1 50377 1 50066 1 50043 2 50563 1 4366-06 1 50107 1 4366-23 1 4394-34 1

FIGURE 26C - BOOM EXTENSION CYLINDER (5056)

UWAIWAIWAMMUMMONMMWMMMMWMMIIMMWWW

DESCRIPTION

REF 26C-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15

Boom Extension Cylinder (L) Rod Assembly Gland Static Seal

Wear Strip Barrel Assembly Rod Seal Gland Rod Wiper Plug - 1/8 NPT Locknut - Self - Locking

Piston Seal Wear Strip Piston

Rod Static Seal Spacer Seal Kit

PART NUMBER 40007 4394-18 50005 51070 4394-02 50028 4366-05 50087 50377 50066 50043 50563 4366-06 50107 4366-23 4394-34

QTY

1 1 1 2 1 1 1 1 1 1 2 1 1 1 1 1

FIGURE 26D - BOOM EXTENSION CYLINDER (6066)

910111213 14 //

Ammagammommemmummummummememmur

Mg - /iez/, .4.nePIIIIIIIRM \ AMMEMMERImm Ell

; 11211k A A A !

-4

1 i

REF 26D-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15

MMMUMO/ . //

i 1111WAIMWMKAIPTINIIMINFAIIVANNUNIMIMINV741115 din

ri "

i A A

e\ /IN 01 A4 ii

DESCRIPTION Boom Extension Cylinder (L) Rod Assembly Barrel Assembly Gland Static Seal Wear Ring Rod Seal Gland Rod Wiper Plug - 1/8 NPT Locknut - Self - Locking Piston Seal Wear Ring Piston Rod Static Seal Spacer Seal Kit

PART NUMBER 40006 4395-18 4395-02 51032 51071 51499 — 4395-05 51503

552 67 67 51497 51498 4395-06 50107 4395-23 4395-34

QTY

1 1 1 1 1 1 1 1 1 2 1 1 1 1

33079

FIGURE 27 - TOPPING CYLINDER ASSEMBLY (3238, 4248, 5056, 6066)

P.I.,

5 ..), 4#1 15 d'Ar., 8

6066

iki.

k It .. .

f4 14 ‘ -46,,, 41, Lis'410. 4 11 / -4* 12 9 13 10 8 6 7

REF

DESCRIPTION

27-

NOTE: Unless otherwise stated parts are common for 3238, 4248. 5056, 6066. Topping Cylinder Assembly

- 1 - 2 - 3 - 4 - 5 - 6 - 7 - 8 - 9 -10 -11 -12 -13 -14 -15

Topping Cylinder (3ee Fig. 28) (See Fig. 28A) Hose Clamp Tube End Reducer and Restrictor . B-Nut 90° 0-Ring Boss Elbow 0-Ring Boss Tee Tube Assembly (3/8) 90° 0-Ring Boss Elbow Double Holding Valve Valve Mounting Plate Hex Head Capscrew Flat Washer Lockwasher Tube Assembly (3/8) Tube Assembly

PART NUMBER

40040 (3238, 4248) 40041 (5056, 6066) 40012 (3238, 4248) 40005 (5056, 6066) 4-1219 21798 6-BTX 2062-8-6 203003-6-6 21799-8 2062-6-6 40104 21168 3/8-24UNF X 3 3/8 3/8 21799-9 3/8 (6066)

QTY

1 1 1 1 2 1 1 2 1 1 3 1 1 2 2 2 1 1 .

, 9/17/79

FIGURE 27A - TOPPING CYLINDER ASSEMBLY (4046) •

ELI REF 27A-1 -2 -3 -4 -5

-6 -7 -8 -9 -10 -11 -12 -13

DESCRIPTION Topping Cylinder Assembly Topping Cylinder Hose Clamp 90 ° 0-Ring Boss Elbow Tube Assembly Double Holding Valve .0-Ring Boss Tee -Mounting Plate B-Nut Hex Head Capscrew Flat Washer Lockwasher Tube Assembly Tube End Reducer & Restrictor

PART NUMBER 40039 (See Fig. 28B) 4-1219 2062-6-6 21799-B 40104' 203003-6-6 21168 BTX- 6 5/16-24 UNF X 3 5/16 5/16 21799-9 21798

QTY .

2 5 1 1 1 1 2 2 2

9/17/79

FIGURE 28 - TOPPING CYLINDER (3238, 4248)

____ o

9 4 5 6 7 ..._— ■ M .1. . ,

iffigirrm I L *VINE 1 li

...

........:Tm.m2

.41

10 11 12 13 .

0- 1- ...: 1

A .. A Is

40 "

2 .,

REF

DESCRIPTION

PART NUMBER

QTY

28-1

Topping Cylinder (L) Set Screw - With Nylon Insert Hex Nut Piston Seal Piston Rod Static Seal Spacer Barrel Assembly Rod Assembly Gland Static Seal Gland Collar Rod Seal Rod Wiper Bronze Bushing Seal Kit

40012 54701 2623-41 51032 4381-06 50109 3644-23 4381-02 4381-18 51004 4381-05 3201-11 50028 50087 51491 4381-34

1 1 1 2 1 1 1 1 1 1 1 1 1 1 4 1

-2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15

3 50 79

FIGURE 28A - TOPPING CYLINDER 5056,6066)

3 45 6 7 9 10 11 12 8 13 IG , -, .... 1.-....iN Ara cri i 14 Wilmid

1111/trall:VIIMOVAIIIIIP/ANIVAII7., 41Iarc

,,...

(, 0

A,-,

REF 28A-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15

DESCRIPTION Topping Cylinder (L) Bronze Bushing Set Screw - With Nylon Insert Hex Nut Piston Seal Piston Rod Static Seal Spacer Barrel Assembly Rod Assembly Gland Static Seal Gland Collar Rod Seal Rod Wiper Seal Kit

PART NUMBER 40005 51491 54701 2623-41 51492 4382-06 50109 3644-23 4382-02 4382-18 51493 4382-05 4382-11 50028 50087 4382-34

QTY 1 4 1 1 2 1 1 1 1 1 1 1 1 1 1 1

33079

FIGURE 28B - TOPPING CYLINDER (4046)

REF

DESCRIPTION

Topping Cylinder (L) 28B -1 Bronze Bushing -2 Hex Nut 3 Piston Seal -4 Piston Seal -5 Rod Static -6 Spacer -7 Barrel Assembly -8 Rod Assembly -9 Gland Gland Static Seal -10 -11 Collar -12 Rod Seal -13 Rod Wiper - With Nylon Insert -14 Set Screw -15 Seal Kit

PART NUMBER

QTY

40010 1 51491 4 263-41 1. 50046 2 234-06 1 50109 1 3644-23 1 4383-02 1 4383.-18 1 134-05 1 50008 1 2224-11 1 50028 1 50087 1 54701 1 2671-34 1

3307S

FIGURE 29 180° PLATFORM ROTATION ASSEMBLY

-xik -

........wimaaa \'■' . WaqI v---NT.1%, -,1.. .1 --(caw- „--\\ ■wiLC -- - \ *...7 we ' Iwo.

-.11:-\\-• --

___- \TILL:

■, .:11Wair1 5 VIEN* 71 1 itfai Ii■ \■‘ 7-IlaWita - ■Klik\liktjk■\__ v- V--

5/81

FIGURE 29 180° PLATFORM ROTATION ASSEMBLY (Prior to Ser.#242)

REF 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28. 29 30 31 32 33 34 35 36 37 38

DESCRIPTION Platform Assembly Roll Pin, 3/8" Pin, Platform Pivot Bushing, Platform Rotation Cylinder, Platform Rotation UNF 1/2 LG. Capscrew, Hex Head, 1/4" 20 - x Lockwasher, 1/4" Zerk Fitting, 45° Bushing, Platform Rotation Pin Nut, Hex Head 3/4" - -10 UNC, Nylon Insert Cotter Pin, 1/8 " 1 x 1/2" Bracket Plate, Rotation Leveling Cylinder, Skirt Pin Skirt, Leveling Main Leveling, Skirt Pin Double Check Valve Capscrew, Hex Head 1/4" - x NCX 13/4" LG. 20 End Plate, Boom Pin Lockwasher, 1/2" Capscrew, Hex Head 1/2" - x 13 UNC 3/4" LG. Zerk Fitting, 1/8" NPT Lockwasher, 5/16" Capscrew, 24 NF 3/4'.1 LG. Hex Head - 5/16" - x Capscrew, Hex Head 3/8" - 25 NFX 3/4" LG. Lockwasher, 3/8" Hose Assembly, Holding Valve to Platform Rot. Hose Assembly, Holding Valve to Platform Rot. Hose Assembly, Holding Valve to Platform Rot. Hose Assembly, Holding Valve Platform to Rot. Hose Assembly, Bulkhead to 90° Swivel to Rot. Holding Val ve Hose Assembly Holding , Valve to Platform Rot. Bulkhead Adaptor 90° Elbow Lockwasher, 1/4" Tee Pin, Steering Cylinder Clevis Pipe, STR

PART NUMBER

QTY

32104

32075 32073 32072

1 2 2 2 2 2 I 1 1 1 1 1 1 1 2 I 1 1 2 I 1 1 I I 1 I

1610L (Alemite) 32073 21291

32070 21126 32060 21127 21480 32189

D7 EA04-04NJ-16" D7 04-04N -EA J 28" D7-EA04-04NJ-32" D7-EA 04-04N J-22" D7_,EA04-04NJ-19 1/2 1 — D7-EA04-04NJ-21" 204IT,4 6-6 2024 6-6 2028TH 6-6 21139 2021 6-6

I I 2 2 2 2 2

2/81

FIGURE 29 - ROTATING FORK ASSEMBLY (6066)

121578

FIGURE 29 - ROTATING FORK ASSEMBLY (6066) REF

DESCRIPTION

PART NUMBER

QTY

40037 Rotating Fork Assembly 2921766 Platform Capacity Nameplate - 1 21837- 2---Nameplate - Fork Caution & Warning 21976 Weldment - 3---Fork 21291 Cylinder to Fork Pin - 4 G1055-EEE-0234 Assembly - 5---Hose 21479 - 6---Needle Valve 2089-4-4 Elbow 90° - 7 21480 Holding Valve - 8 4-12-19 Strap Clamp - 9 2024-4-4 -10_90° Elbow 4-ME-4FX -11---Elbow --21799-1 -12---Tube Assembly (1/4) 21799 -2 Assembly (1/4) -13--Tube 2UNF -28 X -14---Hex Head Capscrew 1/4 Lockwasher -15 1/8 1-k X -16---Cotter Pin 1610-L Grease Fitting -17 21139 Cylinder to Skirt Pin -18 -19---Platform Rotation Cylinder (See Fig.30)-40001 21282 -20---Leveling Skirt Weldment -21 Hex Head Capscrew 2--13 UNC X 2-1/2 1/2 Lockwasher -22 1/2 -23 Flat Washer 21495 -24 Pillow Block 5/16-24 UNF X k -25 Hex Head Capscrew 5/16— -26 Lockwasher 21126 -27 Main Leveling Skirt Pin 21127 Leveling Cylinder Skirt Pin -28 3/8 -29---Lockwasher 3/8 -24UNF X k -30---Hex Head Capscrew -31—Platform Slave Leveling Cylinder Assy.---(See Fig. 22) 2041-4-4 -32---Bulkhead Union Adapter 2071-4-4 -33-90 ° Swivel Elbow 21817 (4248) Assembly Electrical Cable -34 21875 (6066)

3/30/79

1 1 1 1 1 2 1 2 1 1 4 1 1 1 1 1 1 2 1 1 2 2 2 2 1 1 1 1 1 1 1 1 2 2 1 1

FIGURE 29A - NON-ROTATING FORK ASSEMBLY (3238, 4046,4248,5056)

1 2 ! 5 78

FIGURE 29A - NON-ROTATING FORK ASSEMBLY (3238, 4046, 4248, 5056) REF

DESCRIPTION

Coalr-I Er,.1) ON r-IN (N 1 1 1 1 I 1 I I I I I

Non-Rotating Fork

Platform Control Console Guard Name Plate - Platform Capacity Name Plate - Fork Caution & Warning Leveling Cylinder Skirt Pin Lockwasher Hex Head Capscrew

Main Leveling Skirt Pin Lockwasher

Hex Head Capscrew Platform Slave Leveling Cylinder Inner Boom

PART NUMBER 21977 (Reference) 21970 21837 21127 3/8 3/8-24 UNF x

21126 5/16 5/16 24 UNF x -

QTY

1 1 1 1 1 1

k k

(Reference) (Reference)

3/30/79

1 1 1 1 1 1

FIGURE 30

PLATFORM. ROTATION CYLINDER (6066

FIGURE 30 - PLATFORM ROTATION CYLINDER t6066)

REF

30-1

-2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14

DESCRIPTION

Platform Rotation Cylinder (L) Locknut - Self - Locking Wear Ring Piston Piston Seal 0-Ring Rod Static Seal Rod Assembly Barrel Assembly Gland Static Seal Gland Rod Seal

Collar Rod Wiper Seal Kit

PART NUMBER

QTY

40001

50935 52101 4380-06 50916 50915 50103 4380-18 4380-02 50003 4380-05 50024 248-11 50082 2950-34

1 1 1 1 1 1 1 1 1 1 1 1 1 1

3 3079

n 0 C

C.J

P LATFOR M C ONTRO L C O NS O LE ASSEMB L Y

FIGURE 31 PLATFORM CONTROL CONSOLE ASSEMBLY

REF

DESCRIPTION

2- 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Platform Control Console Assembly Control Box Machining Control Box Nameplate Controller (0.E.M.) Connector Seal Locknut Terminal Block Mounting Channel Channel Clamp End Section Hex Head Capscrew Lockwasher Connector Indicator Light Push Button Toggle Switch Toggle Switch "Horn" Placard (OPtion 21071) Button Switch (Option 21071) "Light" Placard (Option 21060) "110V" Placard (Option 21647) Button Switch (Option 21659 & 21943) "Emergency Descent" Placard (Option 21659) "Emergency Descent" Placard (Option 21943) Circuit Breaker Outlet and Plate (Option 21058)

27 28 29 30 31 32

Contact Block Start Button Stop Button Boot Drive Controller, O.E.M. Switch Gaurd

PART NUMBER QTY. 21547 21708 1 21707 1 - 3 21546 4 2546 STC-100 1 143 1 32 P625 Buchanan #12 1 Buchanan #11 2 P630 1 4 No. 6-32 UNC X 3/8 4 No. 6 2522 2 PL26-12V —1 40236 1 8510K9 3 851IK2 3 21874 1 BA2RQ1-AZ 2 21978 1 21425 1 BA2R Ql-AZ 2 21877 1 21980 1 44 100-P20 1 5214 (Consists of 1 5262 and 5210) 2 E30-KLA 1 1 E3u-KB-180E30-KB-231 1 E30 -K T-3" 1 40129 1 1 40603

12/80

FIGURE 33 - PLATFORM PIPE HANDLING ATTACHMENT (Option 21050)

REF

DESCRIPTION

PART NUMBER

QTY

33-1 -2 -3 -4 -5

Platform Pipe Handling Attachment Cargo Belt Assembly Quick Release Pin Platform Rail 1-1/2 Ton Hydraulic Utility Jack Quick Release Self-Lock Pin

21050 490388-36 98320D-369 (Reference) 91-238 98320A-380

1 1 1 2 1 2

FIGURE 34 - PLATFORM AUXILIARY CONTROL (OPTION 21052)

l C "

cf 13 ff 1

.,(.. 4

I -.

,,,

)

0 15

........

40....1!..

-t. i.

;1/..4,. .

3 -40

i . *_ . .

.t..-,

Per

L /..' 5

6 7,8

gfel

DESCRIPTION

PART NUMBER

-4. M

Platform Auxiliary Control Receptacle Platform Auxiliary Control Box Assy. Control Box

Part of 21985 21830 21166 (Part of 21830 (Re ference) 4TL-7 21076 MS3106A-24-20P MS25042-24D AN3420-12A. MS3057-16A 21093 2522 MS3102A-24-20S 6-32NF X k 6-32NF No. 6 MS25043-24P

r—I C•1Cr) ....1* Lr)1/40r-coONo1--1 CV Cr)-4" Lei r—Ir—I r—I 1--1 I—I r—I I I 1 1 II 1 I I I I I I I I I 1

REF

Platform Control Console (21985) Toggle Switch Decal Connector Cap Sleeve Cable Clamp Control Cable Connector Receptacle Round Head Screw Hex Nut Lockwasher Cap

QTY 1 1 1 1 4 1 1 1 1 1 1 1 1 4 4 4 1

FIGURE 35 - BASE AUXILIARY CONTROL (Option 21053)

FIGURE 35 - BASE AUXILIARY CONTROL (Option 21053) REF

35-

ONO

-12 -13 -14 -15

DESCRIPTION

Base Auxiliary Control Receptacle Base Auxiliary Control Box Assy. Control Toggle Switch Rubber Boot Toggle Switch Decal 7 Pin Connector Control Cable Connector Receptacle Hex Head Capscrew Flat Washer Lock Washer Hex Nut Ground Control Box (21982) Mounting Bracket (21821)

PART NUMBER

Part of 21842 21831 21165 2TL1-7 77S11 4TL1-7 21075 77P 21094 2521 77S 4-20 UNC X 3/4 1/4 1/4 1/4-20 UNC (Reference) (Reference)

QTY

1 1 1 1 1 1 1 1 1 1 1 2 2 2 2

FIGURE 36 - AIRLINE (OPTION 21057)

(

FIGURE 36 - AIRLINE (OPTION 21057) • REF

DESCRIPTION

36- 1 - 2 - 3 - 4 - 5 - 6 - 7 - 8 - 9 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21

Airline Platform Bracket Mounting Plate Roller Guide Hex Head Capscrew Lockwasher Air Hose Reel Assembly Plug 90° Elbow Socket Plug 450 Elbow Hose Assembly Hex Head Capscrew Lockwasher Boom Bracket Roller Guide Hose Guide Bracket Slotted Round Head Screw Hex Nut Lockwasher Air Hose

-22

90° Elbow

PART NUMBER

QTY

21057 21382-1 21984 77-2A k-28 UNF X 5/8 1/4 21394 80 2103-8-8 8300 85 3103-8-8 FG1060-HHH-0520 3/8-16 UNC X k 3/8 21382-2 77-1A 21382-3 No. 10-24 UNC X 5/8 No. 10-24 UNC No. 10 k I.D. 200 X A/R PSI W.P. 2102-8-8

1 1 1 1 4 4 1 2 1 3 1 1 1 4 4 1 1 2 8 8 8 1

•

FIGURE 37 - 110 VOLT BOOM ELECTRICAL LINE (STANDARD)

4 /'

. c) ,(// ) *•--!

L it

1 1 3 t'E 4z-.. .,.

1.•

VI_IM

■ PA

4.10 z,-PLATFORM CONSOLE

TURRET BASE 5.

REF

DESCRIPTION

PART NUMBER

37- 1

110 Volt Boom Electrical Line Cable to Ground Control Box Pre-Assembled Nut and Lockwasher Flat Washer

Part of 21748

(Reference) No. 10-32 UNF

1 4 4 4

- 2 - 3 4 - 5

—

- 6 - 7 - 8

No. 10

Round Head Screw 110 Volt Receptacle Rubber Boot

10-32 UNF X 1-k

Outlet with Lift Cover Decal "110 Volts"

5214 15376-24

7600

7531

QTY

1 2

9 17/ 79

FIGURE 38 - ROTATING BEACON (OPTION 21059)

„ ....,

•

0/•,/

71146 4 OW

rEF 8- 1 - 2 3 - 4 - 5 -

%.%

DESCRIPTION

PART NUMBER

Rotating Beacon Mounting Bracket Sheet Metal Screw Hex Head Capscrew Lockwasher Wire Tube

21344 21642 Part of 21344 4-20 UNC X 3/4 1/4 (Reference)

QTY 1 1 3 4 4 1

FIGURE 39 - HEAD LIGHTS AND TAIL LIGHTS FOR IN-PLANT OPERATION (OPTION21060) "WINNII '1141/

•

4‘

•.

5 6 7 8

4248

a 6 7 8

REF

39-

1 2 3 4 5 - 6 - 7 - 8 - 9 -10 -11 -12 -

-6-,k oh.-

IMO

6066

DESCRIPTION

PART NUMBER

Head Lights and Tail Lights for In-Plant 21060 Operation Stud (?") (Reference) Hex Nut 1/2-20UNF X 1-1/8 Head Light Assembly 009-45601 Mounting Bracket Assembly Part of 009-45601 Tail Light Assembly 3701-DOT Lamp 1157 Red Lens SAE-ST164 Body 37ST Mounting Bracket 21933 Switch* 8500 Placard "LIGHTS"* 21978 Relay* 1116969 * Located in Platform Control Console

QTY

1 2 2 2 2 2 2 2 2 2 1 1 1

FIGURE 40 - 12 VOLT ATFORM WORK LIGHT OPTION 21062)

- _

C \

,..,0

• :•• •-..

%4:i

REF

40-I -2

DESCRIPTION

12 Volt Platform Work Light Work Light Assembly Mounting Bracket Assembly

PART NUMBER

21062 009-50202 Part of 009-50202

• 1 1

FIGURE .42 - PLATFORMS (OPTIONS 21013, 21065, 21211, 21315, 21921)

FIGURE 42 - PLATFORMS (OPTIONS 21013, 21065, 21211, 21315, 21921) REF

42-

1 2 3 4 5

DESCRIPTION

Platforms 42" X 42" X 42" Weldment 5 Ft. Weldment 6 Ft. X 42" X 42" Weldment' 8 Ft. Weldment .12 Ft. Weldment

PART NUMBER

QTY

21211 21921 21013 21315 2192 1

1 1 1 1 1

FIGURE 43 DIESEL ENGINE ASSEMBLY (OPTION 21066)

5/81

FIGURE 43 DIESEL ENGINE ASSEMBLY (OPTION 21066)

REF I

DESCRIPTION Counterweight Assembly

2— Counterweight Bracket 3 = Ground Control Box Mounting Bracket4 Starter Solenoid (Motorcraft) Ground Control Box 5 6 Engine Mount Bracket- Front) (Left 7 Hex Head Capscrew 8 Engine Mount 9 Engine Mount Plate 0 Capscrew, Hex Head I Capscrew, Hex Head 2 Circuit Breaker AMP) (20 3 Lockwasher 4 Solenoid 5— Spring 6 Bracket, Spring Attaching7 Kill Link Alternator 8 9 Hose Assembly 20 Reducer 21.-0-Ring Elbow 22--,--Capscrew, Hex Head 23 --,--Hose Assembly 24 0Adapter -Ring 25—Hose Assembly 26 Hose Assembly 27-90° Swivel Elbow 28 90° 0-Ring Elbow 29 ---- 0 -Ring Elbow 30 —Hex Bolt 31 Hose Assembly 32—Diesel Engine 33 Exhaust Pipe 34 —90° 0-Ring Elbow 35 90 Ring El bow 36 Pump Solenoid Valve 37 Stop Relay 38 Engine Mount Bracket (Rear) 39 Pump 40 Engine Mount Bracket Front) (Right 41—, Oil Pressure Guage Assembly, Engine 42 43

Capscrew, Hex Head Lockwasher

44 45

Throttle Bracket

Bracket, Solenoid MountingJam Nut, 1/4" 28 46—*UNF 0-Ring Elbow 47

PART NUMBER

QTY

40085 (3238) 40086 (4056) 40087 (4248) 40088 (6066) (Reference) (Reference) 21342 (Reference) 21856 1/2" 13 UNC 1" x 4 520-RMD 4 21857 2 1/2" 13 UNC 3/4" x 8 (Furnished with Engine) 8 109-220-101 3 1/2" 12 21450 21659 40764 21929 Mark I, 110 Volt FG 1012 EEE-0480 22150ITRTX 6-4 2062 6-4 1/21k 2 -1/2" FG 1556 kkk 9270 202702 10-12 FG 1011-KKK-0360 FG 1005-EEER-0300 2071 12-12 2026 20-20 3/8" 3-4 MIO 30 x LG 3 CIT - 3FJX - 4FJX-36 —1 21340 21694 2024 4-4 202413 4-4 21465 1116969 40747 21478 • 21853 Reference MI0 40 x LG.

7/16" (Furnished with Engine) 40762 . 3/8" 3-4 4

FIGURE 43 DIESEL ENGINE ASSEMBLY (OPTION 21066)

REF

DESCRIPTION

Base, Shut-Off Solenoid Bracket 48 3/4" 49 -Capscrew, Hex Head 5/16" -18 UNC x LG. x LG. Capscrew, Hex Head 5/16" 18 UNC 5/8" 50 Lockwasher, 5/16" 51 5/16" UNC 52 Nut, Hex -18 Fuel Shut-Off Lever, 53 54- Lockwasher, 3/8" 55-Mounting Bolt Nut, Hex 3/8" -18 UNC 56 " LG. -18 x Capscrew, Hex Head 5/16" UNC 57 58 Nut, Hex 5/16" -18 59 -Washer, 5A6" Lockwasher, 5/16" 60 61 Double Pulley Bracket, Fuel Shut-Off 62 Bracket, Spring Attaching 63

PART NUMBER

QTY

40763

- I Reference

AG43 40761 40764

5/81

FIGURE 44 - WISCONSIN ENGINE WITH LP GAS (OPTION 21069)

RE 44 - WISCONSIN ENGINE WITH LP GAS (OPTION 21069 1

REF 44

- 1 - 2 - 3 - 4 - 5 - 6 - 7 - 8 - 9 -10 -11 -12 -13 -14 -15 -16 -17 -18

DESCRIPTION

Wisconsin Engine with LP Gas Street Elbow and Hose to Muffler Existing Hex Head Capscrew and Lockwasher Existing Gasket Elbow and Hose to Air Cleaner LP Gas Vapor with Drawal Fuel System Carburator Brass Nipple Primary Regulator Fuel Filter 90 0 Brass Elbow Adapter Piston Pump Drive Line Assembly Pump (PR14) (21852) Hose and Fitting Conversion Kit Vapor Tank Tank Bracket Hex Head Capscrew Lockwasher

PART NUMBER

QTY

21069 (Reference) (Reference)

1 1 2 •

(Reference) (Reference) 21398 21398 21398 21398 21398 21398 2021-4-6 (Reference) (Reference) C2002-A 33.5 Lb TB-3 3/8-18 UNC X 1 3/8

1 1 1 1 1 1 1 1 1 1 1 1 2 2 8 8

FIGURE 45 - DESCENT HORN (OPTION 21071)

1 tie •LIO)

_._ _._„7„:

e::3

I 1 '1 %4411I

s4..... -.....—

I iveraRs eu

"''...........,

al .

..,,,

DESCRIPTION

REF 45-1

-2 -3 -4 -5

Descent Horn

Horn Ground Control Box (21981) Diode Flat Washer Hex Head Capscrew

PART NUMBER

QTY

21071

GR-2

(Reference) 1N4719 3-4 4-20UNC x 3/4

1 1 1 1

FIGURE 46 - PLATFORM DEADMAN SWITCH (OPTION 21292) ,

.Lf;•

'■

,,,

, 1

i -

. .

, 1 1 1 ,1 ,. ,`t1W soll■ , . WEIPP14° ,..e \, ...--

•

3 4 5

REF

+6- 1 - 2 - 3

- 4 - 5 - 6

" : ► LA ■ i,

DESCRIPTION

Platform Deadman Switch Foot Switch Hex Head Capscrew Lockwasher Hex Nut Connector Cable

21292 9002AW-17 5/16-18UNC X 1 5/16 5/16-18UNC 2535 10-2 P123-MESA 600V 6' LG (Glen Air)

•

1 1 3 3 3 1 1

FIGURE 47 PLATFORM AUTOMOBILE TYPE HORN (OPTION 21072) -

FIGURE 47-PLATFORM AUTOMOBILE TYPE HORN (OPTION 21072)

REF

47-1 -2 -3 -4 -5 -6 -7

DESCRIPTION

Platform Automobile Type Horn Horn Ground Control Box Flat Washer (k) Hex Head Capscrew (k-20UNC X 3/4) Platform Control Console Decal "HORN" "PUSH TO SIGNAL" Push Button Switch

PART NUMBER

21072 28-12VDC (reference) (reference) (reference) (reference) 21874 M525089-1C

QTY

1 1 1 1 1 1 1 1

FIGURE 48 - 110 VOLT SHAFT DRIVEN ALTERNATOR (OPTION 21647)

FIGURE 48 - 110 VOLT SHAFT DRIVEN ALTERNATOR (OPTION 21647) REF 48

1 2 3 4 5 6

. DESCRIPTION

110 Volt Shaft Driven Alternator Arm Bracket Hex Head Capscrew Hex Nut Lockwasher Arm Alternator

- 7 - 8 - 9 -10 -11 -12 -13

Double Pulley Hex Head Capscrew Hex Nut Washer Lockwasher Drive Belt Pulley (Two Groove)

-15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25 -26 -27 -28 -29

Engine Shaft Taperlock Bushing Key Seat Mounting Bolt Hex Nut Mounting Bracket Hex Head Capscrew Lockwasher Engine Flywheel Shroud Mbunting Bracket Circuit Breaker Regulator Hex.Head Capscrew Relay Outlet and Plate

PART NUMBER

QTY

21647 21900 3/8-24 UNF X 1-k 3/8-24 UNF 3/8 21899 Mark I, 120 Vac 2500 Watt AG43 5/16-18 UNC X 1 5/16 -18 UNC 5/16 5/16 A38 8.2A. Pitch (Furnished w/Taperlock Pulley (Reference) 2517 w/1-7/16 Bore 3/8 X 3/16 3/8-18 UNC X4 3/8 - 18 UNC 21901 3/4-20 UNC X 3/4 1/4 (Reference) 21902 109220-101 RST-2 10-32 UNF X k 1116969 5214

1 1 2 3 4 1 1 1 1 1 1 1 2 3 1 1 1 1 1 1 . 4 4 1 1 1 -

1 4 1 1

(OSTEZ OM MOIL:10) . MOVd UHMOd OrInNUCIAH AUVIMMW - aanola

FIGURE 49 - AUXILIARY HYDRAULIC POWER PACK INSTALLATION (OPTION 21648 & 21650) I VIEW B

119 78

FIGURE 49 - AUXILIARY HYDRAULIC POWER PACK INSTALLATION (OPTION 21648 & 21650) REF

DESCRIPTION

-42 -43

Auxiliary Hydraulic Power Pack Installation Gas Engine Diesel Engine Cover Piston Pump Drive Line Assembly End Yoke Journal Assembly Kit Flange Yoke Companion Flange Companion Flange Companion Flange Hose Assembly - Suction Hose Assembly - Pressure Swivel Elbow Adapter Pump Case Drain Hose Assembly 90° Degree Elbow Engine Base Engine Mount Hex Head Capscrew Lockwasher Hex Head Capscrew Engine Support Bracket Pump Bracket Tube Assembly , 90° Elbow 0-Ring Adapter Adapter Adapter Female Tee Relay 0-Ring Adapter 0-Ring Adapter 90° Swivel Elbow Tube Assembly Tube Assembly Solenoid Valve (FPS) Solenoid Valve (FC) Adapter (for FPS) Adapter (for FC) • Fuel Filter (Cartridge C-1110PB) Filter Mounting Bracket Hex Head Capscrew

-44

Socket Head Capscrew

9- 1 - lA - 2 - 3 - 4 - 5 - 6 - 7 - 8 - 9 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25 -26 -27 -28 -29 -30 -31 -32 -33 -34 -35 -36 -37 -38 -39 -40 -

PART NUMBER

QTY

21648 (Gas) or 1 21650\ (Diesel) 1 21377 1 21618 1 18788 1 21782 1 2-4-453 1 5-153 2 6-73-316 1 2-2-329 1 2-1-293 * 1 2-2-329 1 2-2-389 1 FG 1060-KKK 1 FG 1059-KKK 1 3903-12-12 1 0503-8-12 1 21345 1 (J.D. Furnished) I (J.D. Furnished) 1 21392 1 RMD-520 4 3 -13 UNC X 14 1 4 1/2 12 1/2-13 UNC X 1 8 21391 2 21393 1 3/4 1 2103-12-12 2 0502-12-12 2 0103-12-12 1 0101-12-12 1 02J02-12 1 1116969 1 202702-8-4 1 202702-6-4 1 2071-4-4 2 1/4 1 1/4 1 5-06AA-2A 1 7W31-16T-12 1 0103-4-4 2 0503-4-4 2 Nbdel FBM 1110-PBM 1 25219 1 2 (Furnished w/fuel filter) (Furnished w/diesel 2 engine)

1(9 78

FIGURE 49 - AUXILIARY HYDRAULIC POWER PACK INSTALLATION (OPTION 21648 & 21650)

REF

DESCRIPTION

PART NUMBER

* 2-1-293 Replaces W27-1-7/17 when drive line assembly 21782 used for emergency power packs.

QTY

•

. . . .

1E9 78

FIGURE 50 - 5 ° AUTOMATIC SLOPE CONTROL (OPTION 21844)

1 2 3 4 HYDRAULIC PANEL

PLATFORM CONSOLE

TURRET

REF

DESCRIPTION

PART NUMBER

50- 1 - 2 - 3

5 0 Automatic Slope Control

Level Controller Hex Head Capscrew Hex Nut

21844 32583. 4-20 UNC X 1-k 3/4-20 UNC 1/4 1 X 1 X 3/16 X1 0 ASTMA .36 21346 5/16 X 5/16 X 3-1/2 21880 21903 PL-26 Clear 5/16-24 UNF X %-2C2T-JK-01T XJ4N A3N No.10-32 UNF X 2

Lockwasher Angle

6 7 8

9 -1a -11 7 12 -13 - 14 -1 c

Mounting Plate Machined Key Bar Stock Name Plate"Caution"

5 ° Automatic Slope Control Indicator Light Hex Head Capscrew

Limit Limit Limit Round

Switch Switch Arm Switch Arm Head Screw

..;

6 6 6 1

1 1 1 1 1 4 2 1 1 4 12/80

FIGURE

51-PLATFORM EMERGENCY DESCENT (OPTION 21659)

fi°

s.. g

It ;Pr' ‘00

•

■%.

Viiiti fAi■ 4114

....

;;

TURRET

_ REF

51- 3 - 5 - 6

DESCRIPTION Platform Emergency Descent (Standard on 6066) Push Button Switch Decal-"For Platform Emergency Descent' Valve Adapter Hex Head Capscrew Lockwasher

. PART NUMBER

QTY

21659

SA401-CR2 21877 21493 0103-4-4 k X 20 UNC X 1-k 1/4

1 1 1 2 2 2

•

FIGURE 53-48 & 60 IN. FIBERGLASS PLATFORMS.SOPTIONS 21704-1 & ?)

REF 53-

DESCRIPTION 48 In. Fiberglass Platform 60 In. Fiberglass Platform

PART NUMBER 21704-1 21704-2

QTY 1 1

FIGURE 54 - LIFTING EYES (OPTION 21651)

a o

o a a

REF 54-1 -2

DESCRIPTION Lifting Eyes Front Eye Rear Eye

----_____ o o

411-1

PART NUMBER 21651 21651-1 21651-2

QTY 4

2 2

FIGURE 55 - EMERGENCY BOOM RETRACTION (OPTION 21943)

FIGURE 55 - EMERGENCY BOOM RETRACTION (OPTION 21943) REF

56- 1 - 2 - 3 - 4 - 5 - 6 - 7 - 8 - 9 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25 -26 -27 -28

DESCRIPTION

Emergency Boom Retraction Pump Solenoid Hose Assembly 90° Elbow Check Valve Bulkhead Bracket Stop Switch (SA-401-CR2) Hex Head Capscrew Adapter Adapter Tee Hose Assembly Push Button Switch Placard "Emergency Retract" "Push to Retract Boom II Connector Hose Assembly- From Boom Retraction Hose Assembly - From Gear Pump Hose Assembly - From Boom Extension Hose Assembly - From Bulkhead Bracket Hose Assembly - From Bertea Valve Mounting Bracket Hex Head Capscrew Lockwasher Tee Reducer Battery Starter Cable ' Valve Pack

PART NUMBER

QTY

21943 21341 21342 FG1556-GGG-0160 2024-4-6 21379 (Reference) (Reference) 5/16-18 UNC X 1-3/4 2021-8-6 2021-8-4 8R6X FG1005-GGG-0430 SA401-CR2 21980

1 1 1 1 2 1 1 1 2 1 1 1 1 1 1

2522 (Reference) (Reference) (Reference) (Reference) (Reference) 21990 3/8-16 UNC X 1 3/8 2028-6-8 221502-8-6 TC-12(140 AMP) 7244 (Reference)

1 2 1 1 1 1 1 4 4 1 1 1 1 1

FIGURE 56 - SPARK ARRESTER (OPTION 21385)

REF

DESCRIPTION

PART NUMBER

56- 1 2 - 3 - 4 - 5 - 6 - 7 - 8

Spark Arrester Rain Cap Muffler Muffler Mounting Bracket Hex Head Capscrew Lockwasher Flexible Exhaust Tube Assembly (21824 Bank, Clamps & Shims Tube Section

21385 35226 21390 21825 5/16-18UNC X 3/4 5/16 (Reference) Part of 21390 1-3/4 O.D. X GA 12 X 44- ASTMA513

QTY 1 1 1 1 2 2 1 A/R 1

£6681 3

060 0

0.4

NOI-V711ridY

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WIRE NUMBER. OF EACH WI R E. — 2. DIODE -• IN•4-719.

UNLESS OTHERWISE SPECIFIED:

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DECIMALS J• .43 t

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TITLE

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37 AM PERE BELT-DRIVEN ALTERNATOR_

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• CONDOR MODELS 4046, 4248, 5056 -,.6066._,WITH NO OPTIONS uNLESS OT44(411.56 SPECIF411D, .03,.., D4444=cit .411E 114 1140113. .,

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Bulletin No. 5-2350-2

multi- pak valves SOLENOID OPERATED

maximum flow rate 45L/min (12 gpm) i direct solenoid operated working pressures to 172 BAR (2500 PSI) stackable in two directions field stackable

AMBAC Industries Incorporated FLUID POWER SYSTEMS DIVISION

multi-pak adenoid valve features FPS Multi-Pak Solenoid Valves offer a new concept in valve assembly allowing greater circuit flexibility in less space than with conventional valves. This modular banking design concept eliminates costly fittings, potential leak points and simplifies factory and field installations. In addition to banking directional control valves, you can also stack the main system relief valve. Attachment valves such as cross over reliefs, restrictors, single and double pilot operated check valves and anti-cavitation checks can be banked on the cylinder ports. Maximum flow rate 45 L/min (12 GPM). Operating pressures to 172 BAR (2500 PSI). Construction features include hardened steel spools, precision fit into a high strength alloy cast body. Solenoid actuator construction utilizes the proven wet plunger design.

• New Circuit Versatility • Either Series or Parallel Circuits • Low Pressure Drop • Low Current Consumption • Direct Operated • Manual Over-rides • 10 Standard Spool Variations • Single or Double Solenoids • Weather Resistant Solenoids, Continuous Duty at Rated Voltage • AC and DC Service • Stackable Relief Valve • 19 Accessory Attachment Valve Options • Field Stackable • Various Coil Terminations

ATTACHMENT VALVE

SOLENOID VALVE

ELECTRICAL RACEWAY FOR AC APPLICATIONS. WITH KNOCKOUTS FOR 1/2" OD CONDUIT. (2 EACH END)

314.3

12.38

NOM.

• Two Position and Three Position Spools Available - See Table I, Page 4. • One or More Cylinder Attach ment Valves Can Be Stacked See Table II, Page 4.

157.1 NOM. 6.19

22.2 2.2 .88 X NO. VALV ESINBAN K+ R ELIE F VALV E+44. 4

CYLINDER PORTS SAE #8 ( 1/2" OD TUBE)

• Rated Pressure 172 BAR (2500 PSI). • Rated Oil Temperature 82 ° C (180 ° F).

• Available Voltages 12, 24 and 36 VDC - 115 and 220 VAC.

57.1 2.25

• Current Consumption 3.8 amps., at 12 VDC at 21 ° C (70 ° F). At 115 VAC, .30 amp. at 21 ° C (70 ° F) Inrush and Holding. • All Ports Can Be Pressurized. • Can Be Mounted In Any Position. • Recommended 25 Micron Filtration.

22.2

kr)

.44

INCH

28.6 57.1 1 1.13 2.25

9.6 DIA. MOUNTING .38 HOLES RELIEF VALVE OPTION

50 8 2.00

150

22.2 .88

a. 2 •

.44

FLOW L/MIN

PRESSURE DROP P-Ci, C 2 -T BAR

PRESSURE DROP P-T BAR

3.8

3.8 P to CI or C2 to T

100 50

P to T

9 .5

DIA. MOUNTING .38 HOLES (2 PLACES)

57.1 2.25

= MM/INCH.

2 4 6 8 10 12 14 16 Flow Rate (GPM) Oil-SAE #10 @ 38 ° C (100 ° F)

ATTACHMENT VALVE OPTION 19.1 .75

RACEWAY IS SUPPLIED FOR AC ONLY AS STANDARD 184.2 7.25 A

42.1 1.66

27.7

457.2 LONG 18.00 LEADS ..... ••• •

■■■ ■

36.6 1.44

122.3 4.81 65.1 2.56

Pressure drop data for valve Model 4013 (Tandem center 3 position 4 -way, pressure to tank open - C, and C2 blocked.) Maximum flow rate 45 l/min (12 GPM). Consult factory for specific recommenda tion.

Available options (consult factory).

TANK PORT SAE #8 ( 1/2" OD TUBE)

INLET PORT SAE #8 ( 1/2" OD TUBE)

IP all--

57 1

2.25

Check with factory for price and delivery.

For spools and attachment valves not shown consult factory.

Three bank valve assembly for AC service with system relief valve and one cylinder attachment valve. °11

Three bank valve assembly

for DC service with system relief valve and two cylinder attachment valves,

spool type (flow pattern) —table I A.S.A. Symbol c,

Model No.

: ini

- 4812-XX

c,, cz 1 I !1 I . 11 ;IplAi

4813-XX 4843-XX*

P 'T

Stan dard Sp oo ls

cylinder attachment valves—table II Type

A.S.A. Symbol

Open Center

S a

Tandem Center Type I

4814-XX

Illin

Tandem Center Type II

4815-XX

c,. ez 7' I .AI p 3 T I

■

Closed Center Type I

4816-XX

c, i,',11-j_it d

Closed Center

,Cs

01"3 ■T

P T

c, ct r7--, rt--- -71--1

4817-XX

.j4r4jj co,cz 7--r----- ,-7--1 ! '

4818-XX

L....._;____L_I; P T

CICO,

4819 - XX .

,--- r5-•

--:,---,

,.. , L _;, -L. 1 P T C, C z

4830-XX

7-,-/-1

-' ,Ii\I ' ' '

74-yrt- tr--.7

Tier---,,iri; P"T

Code

Lock Valve

Cross Over Relief

- -7-`." "a ,.,_:,-,

Description

Without Thermal Reliefs

One Thermal Relief

Two Thermal Reliefs

241 BAR (3500 PSI)

Specify Pressure Settings

Pilot

Without Thermal Reliefs

Operated

One Thermal Relief

Two Thermal Reliefs

Check

,Type II Closed Center

Type III Closed Center Type IV Closed Center Type V

Motor Spool

Code 1

P j- T

4832-XX

Valve Type

-r-

Code ,

Description

I Palm Button Manual Over-ride

Tandem Center

Relief Valve

Type III

Series Banking

P IGS

Description Parallel Banking

Internally Grounded Spade Connector Coil

4843-XX High Flow Spool (tandem center) For spool configurations other than shown consult factory.

ordering information

example of three bank assembly 48 — 13A — 12 — 13F1500 — S

48 —

Basic Model No. Basic Mod-T I No. 1st Bank Valve Spool Designation See Table I

Coil Voltage Second Valve in Bank

— 1st Bank Valve Attachment Valve See Table II

_ Relief Valve Show Crack Pressure Series or Parallel Banking (Specify "S" or "P")

1st Valve in Bank Tandem Center Spool Double Lock Valve in Cyl. Ports 2nd Valve in Bank Open Center Spool

Series Type Banking 3rd Valve in Bank Tandem Center Spool Cross Over Relief Set for 103 BAR (1500 PSI)

R2000 — 12 VDC 12 Volt DC Solenoid Coils Relief Valve at Inlet Set for 138 BAR (2000 PSI) Crack Pressure

•Customer variation where specified

AM BAC Industries Incorporated FLUID POWER SYSTEMS DIVISION

511 South Glenn Avenue • Wheeling, Illinois 60090 Phone: 312-541 -3000 FO - LC - 5M - 3,78

Printed in U.S.A.

Fluid Power Systems SU GLENN AVENUE, WHEELING, ILL, 60090 • 312-641.1000 Title 211.2509

SERVICE BULLETIN No. 4000-4-SB2

MULTI - PAK VALVES March 1975 Revision 1

DISASSEMBLY OF SPRING CENTERED VALVE Before starting disassembly, prepare an oil bath of clean SAE-10 oil to receive parts as described in the following procedures. Refer to figure 1 and disassemble the valve as follows: 1. Remove attachments, 0-rings, and mylar shims. 2. Remove nut (1). Slide sleeve (2) and solenoid cod off tube subassembly (3). Use proper tools to avoid damaging tube subassembly. Do not use monkey wrench or visegrip pliers. 3.

Use proper spanner wrench to loosen tube assembly.

NOTE

Spring and spring retainer may fall from valve body when tube subassembly is removed.

4. Remove tube subassembly by hand. 5. Remove spring (10) and spring retainer (11) from valve body (12). Place spring and retainer in oil bath. 6. Slide pin (9), plug (8), and plunger (7) out open end of tube subassembly. Place pin. plug, and plunger in oil bath. 7. Using a small screwdriver or punch, gently push button (6) into tube subassembly until it is free and falls out. Remove and discard 0-ring (5), and place button in oil bath.

8. Remove 0-ring (4) from tube subassembly, place tube subassembly in oil bath, and discard 0-ring. 9. Repeat steps 2 through 8 to remove and disassemble the second tube subassembly. Handle spool with extreme care. Damage to the surface of the spool will prevent it from functioning properly. Note spool position in relation to valve body. Do not turn spool around. 10. Gently slide spool from valve body. Valve body and spool are a matched pair. If either one is damaged, both must be replaced. To order replace. ment: specify valve assembly part number (see nameplate) and state position of valve in relation to the inlet 11. Remove plugs (13, 16) and discard 0-rings. 12. Inspect all parts for damage. Replace all 0-rings and any part suspected of being damaged. Place new parts in oil bath.

ASSEMBLY OF SPRING CENTERED VALVE 4. Place new 0-ring (4) into groove on tube subassembly Refer to figure 1 for identification and orientation of parts. (3). Before proceeding, check that both 5. Place new 0-ring (5) into groove on button (6). Drop spool and valve body are thoroughly button into tube and, using a screwdriver, push into place. dry. Residual cleaning agent may 6. Insert plunger (7), plug (8), and pin (9) in tube subdamage 0-rings. assembly. 7. Place spring retainer (11) and spring (10) over spool 1. Wash all parts with a cleaning solvent such as triend into valve body (12). chloroethane and dry with a low pressure air hose. 8. Reinstall tube subassembly into body and band tighten. Handle spool with extreme care. 9. Repeat steps 4 through 8 for second tube subassembly. Contamination or damage to sur10. Using a spanner wrench, tighten each tube subassembly. face of the spool will prevent it 11. Place new 0-rings in grooves on valve body. from functioning properly. 12. Install plugs. 13. Use mylar shims (14) between each section on each tie 2. Dip spool and valve body (12) in clean SAE-10 oil and slide spool into valve body be sure spool has not been turned rod, reinstall attachments. around. U spool does not slide freely into valve body, in14. Use a torque wrench and tighten tie rods to 125-inchspect for buns. Remove burrs with stiff wire brush and repounds, in 3 steps: 75 in. lbs, 100 in. lbs, 125 in. lbs. peat steps 1 and 2. 15. Reinstall solenoid coils and sleeves (2). Tighten nuts (1). 3. Place all disassembled parts in oil bath. ,

MULTI -PAk VALVES

SOLENOID COIL

Figure I

SPRING CENTERED VALVE.PARTS LIST MISCELLANEOUS SERVICE PARTS AND KITS Index Part No. No. Description ---' Vaive Assembly, flush button __, Valve Assembly, extended button= 1 1006024 Nut 2 4014550 Sleeve 3 6006090. Tube Subassembly 4 0102916 0-ring 5 0101008 0-ring 6 4014130 Button, flush, std. 4014131 Button, extended, option -I7 4019950 Plunger 8 4019960 Plug 9 4020051 Pin Spring 10 4015410 * 6002880 11 Retainer, Spring 12 ---" • Spool and Body (matched set) 13 1004005 Plug 14 4023150 Myiar Shim 15 0102908 0-ring 16 4022030 Series Plug 17 4014041 Plug (Single Solenoid Valve Assy)

SingIs Double

Solenoid Solenoid Qty City

Coils 12 VDC 24 VDC 115 VAC 220 VAC

6002790 6002800 6009840 6002870

1 1 1 2 1 1 1 1 1 1 2 2 1 I 6

2 2 2 2 2 2 2 2 2 2

Inlet relief 6003580 plus Setting: Example (60035802000 psi)

2 1 1 6

1 1

1 —

Sections with Relief 1 6008750 2 6003092 3 6008751 4 6008752 • 5 6008753 6 6003097 7 6008754

'To order valve assembly, use part number as listed on the nameplate. "To order body and spool, specify valve assembly part number and position of valve in relation to inlet.

Seal Kit: (0-rings only) Single section valve any. 6008840 Inlet relief 6009290 Banking Kit Banking kit includes: nut, washers. mylar shims, tie rods, mounting brackets, 0-rings, and series plugs. Sections without Relief 1 6003090 2 6003091 6003092 3 4 6003093 6003095 5 6003096 6 6003097 7

Tube Kit Items 3 thru 9 6013080 18 0101118 0-Ring (between sections and attachments) DIVIStON OF 10* 4015430 Spring for spools #15 thru 20, 24, thru 31, and 35. INCIUSTRIMIS

PRESSURE COMPENSATED

Fixed FLOW CONTROL VALVES A simple, compact unit to control hydraulic

MAXIMUM RECOMMENDED SYSTEM PRESSURE

3000 or 5000 psi

This type of valve is available in small "cartridge" or "plug" type units.

Advantageous in applications where their use can save space, eliminate external plumbing, or make a more compact, neater installation. Contact factory, giving your approximate size and flow rate needed.

power by limiting outlet flow in the direction indicated by the arrow. Optimum flow rate can be selected for the job conditions. This valve will maintain the flow selected regardless of varying system pressures created by different loads. In the controlled flow direction the valves are pressure compensated over all of the specified differential pressure range. Differential pressure changes affect the internal control area, which in turn limits flow to the required rate. (See information sheet G1 for more detailed information on the principle of operation.) Flow in the reverse direction is uncontrolled. If it is necessary to control flow in both directions, at either the same or different flow rates, the Series 1420 valves shown on Sheet FF9 can be used. Installation in one of the lines of the hydraulic circuit is fast and easy, and the valve is just slightly larger than the line itself. This product is available in a very wide variety of flow capacities, port sizes and pressure ranges. Details and specifications are shown on the inner pages.

FLOW CONTROLS-FIXED

••••4•WATERMAN HYDRAULICS A COMPONETROL COMPANY 00

FF REPLACES FF1 ANDTr2

6565 WEST HOWARD STREET, CHICAGO, ILLINOIS 60648 / PHONE 312/792-2450 / TELEX: 7:

Series 190

CUTAWAY VIEW OF BASIC SERIES 190 Slight internal parts changes are made to give performance changes for some of the models listed. All valves are individually calibrated and tested to assure conformance to published data for the specific model.

Materials MODEL SERIES

BODY

ALL 190 MODELS EXCEPT THOSE WITH AN "SS" CODE

ANODIZED ALUMINUM ALLOY

ANY 190 MODELS WITH AN "SS" CODE

TYPE 303 STAINLESS

1908

STEEL

1477

ANODIZED ALUMINUM ALLOY

Reverse Pressure Drop (100 ssu OIL)

PISTON ALUMINUM ALLOY

1 ,

SLEEVE CADMIUM PLATED STEEL

REMARKS

GENERAL PURPOSE.

TYPE 316 STAINLESS

ADAPTABLE FOR MILDLY CORROSIVE CONDITIONS.

STEEL

CADMIUM PLATED STEEL

HIGH PRESSURE GENERAL PURPOSE. TEFLON BACK-UP RINGS.

ALUMINUM . ALLOY

ANODIZED ALUMINUM ALLOY

HAS MIL-SPEC. ANODIZE MEETING SALT SPRAY TEST REQUIREMENTS. INCLUDES TEFLON BACK-UP RINGS.

TYPE 316 STAINLESS CHROME PLATED

Pressure drop at up to controlled flow rate in the mately 160 psi for the 70 to 3000 psi differential reverse flow direction is approximately the same as in pressure range. If flow in reverse direction will be near the controlled flow direction. At 11/2 times the con- or above this rate, we recommend Series 194 Flow trolled flow rate, reverse pressure drop will be approxi- Controls, Sheet FF3. AMINMINE111111111•10111•1111111MNIF

Flow Tolerances

NOMINAL CONTROLLED FLOW RATE, GPM

0.1 to 0.49 0.5 to 1.49 1.5 and up -± 20% ±15% ±10%

TOLERANCE

Arrows show controlled flow direction thru flow control. Reverse direction for different circuit. Meter-in circuit gives precise control for extension of single-acting cylinder; excess flow dumped at relief valve setting. If retraction is more important, reverse the flow control direction for meter-out.

Typical Circuits

Valves 1 and 2 control speed of cylinders when extending; valves 3 and 4 control cylinder speed when retracting.

MUST BE A NONTHROTTLING TYPE

Tolerances are maximums over the full differential pressure range; will be less if pressure range is less. Can be made to closer tolerances for specific applications.

Pump works at pressure the actuator requires, with best efficiency, since only work resistance need be overcome. Flow is regulated by diverting portion of pump output thru flow control valve rather than relief valve. Accuracy changes if pump output changes since fluid bled off remains constant.

Combined flow of valves 1 and 2, or 3 and 4, must be less than pump output.

SPECIALISTS IN FLUID POWER CONTROL FOR VIRTUALLY ALL INDUSTRIES • REPRESENTATIVES IN ALL PRINCIPAL CITIES

WATERMAN 3701-AC

Printed in U.S.A.

PRESSURE COMPENSATED

RMA

Piked FLOW CONTROL VALVES DIFFERENTIAL PRESSURE RANGE, PSI

. 25 to 250 (lilailmum Sjotsa Pressure 3000 PSI) . , ,,,..

The bask model for low pressure appli. cations.

SIZE

FORTS

PIPE

TYPE

Use in sets of two I or more for extra :Lc': iT IA:artt

synchronization Is ' . within ±.. 2%. I

70 to 3000

Varies from basic model only in type used in construction, as of ddetailed led in table.

i Use in sets of two more for extra The basic model for : or precise control. Tolmedium pressure , erance on actuator i applications. I synchronization Is , within 4. 2% . .

counteracts uneven loading WO might cause instability. Can also prevent "hunting" or oscillotion sometimes caused by fluid motors.

WEIGHT Lgs. ALUMINUM MODELS

NPTF

1901-2- *

190AL-2- *

1908L-2- *

190LSS-2- *

190-2- * 190A-2- *

190S S-2- *

3/4"

190L-3- *

190AL-3- *

1908L-3- *

NPTF NPTF

190LSS-3- *

190-3- * I 190A-3- *

190SS-3- *

190D-3- *

1908-3- * 1908A-3-*

0.4

190L-4- *

190AL-4- *

19081-4- *

190LSS-4- *

190-4- * 190A-4- *

190S S-4- *

1900-4- *

1908-4- * 1908A-4- *

0.9

NPTF

1901-6- *

1908-6- * l 1908A-6-*

1.3

190L-8- *

190-6- * 190A-6- * 190-8- * 190A-8- *

190D-6- *

NPTF NPTF

190AL-6- * 190AL-8- *

190SS-6- *

1900-8- *

190L-12- *

190SS-8- * -

1908-8- * 1908A-8-* - -

SAE

190LT-4- ?h

2.0 7.3 0.3

1477L-4- *

SAE MS

14" Vs"

SAE

3/4" 3/4 " 3/4 "

ii'

19081-6- *

190LS S-6- *

190AL-12- *

,1908L-8- * -

190LSS-8- * -

190ALT-4- 90

1908LT-4 *

190LS ST-4 - 4

190LM SS-4- u

190LT-6- *

1477AL-4- * 190ALT-6-*

1908LT-6- At

190LSST-6- *

1477L-6- *

1477AL-6- *

190LT-8- oit •

190ALT-8-*

1477L-8- * '

1477AL-8-*

SAE

190L1-10- * ,

190ALT-10-*

MS SAE

1477L-10- * ' I 19011-12- * •

MS •

TUBE

190LM SS-6- At

190M SS-6- *

14770-6- *

19081T-8- 8F

190LSST-8- *

190T-8-* 190AT-8- *

190SST-8-* '

190DT-8- *

1908T-8- *

AU. MODELS WITHOUT L"

0.1 to 2.5 0.1 to

-3 44" -8 i V2" 0.1 to 4.5 ; 0.1 to 9.0 • . -4 1/2" -10 T5 0.5 to 7.5 0.5 to 15.0 • -6 3/4" -12 ' 4/4" 1.0 to 15.0 , 1.0 to 30.0 -8 1" -16 2.0 to 25.0 : 2.0 to 50.0 -12 1% -24 11/2" 5.0 to 50.0 5.0 to 100.0 lo IOW eases tom fluid can be controlled by UN valve If o eaerlHoli io pressen *op and/or tolotanet it permissible. , . . •

1908AT-6- * I 1908AT-8- *

0.3 0.4 0.4 0.4

190MSS-8-*

14770-8- * 190DT-10- *

1908130- * 1908AT-10-*

0.9

1477A1-10- *

1901.M SS-10- *

190ALT-12-*

1908LT-12- *

190LSST-12- 44

1477-10- * 1477A-10- * 1901-12-* 190AT-12- *

190MSS-10-* 190SST-12-*

14770-10- * 19001-12- *

- I 19081-12- * 1908AT-12-*

0.9 1.3

190L M SS-12-*

1477-12- * 1477A-12- *

190811-16- 4,,

190LSST-16-* 190LMSS-16-*

1901-16- * i 190AT-16- * ! - I '

i 190MSS-12-dB 1 I 190SST-16- * 1 190MSS-16-* !

1477D-12.*

1908T-16- * 1908AT-16- * - i- _ ...m... For all valves with "A" in model number, specify quantity in a working set, minimum and maximum Inlet and outlet pressures, in addition to controlled flow rate.

O r,___, ' 4111\ . . .01) 1.k.. ,■„.„,../1

190DT-16- * -

0 ._)

DIMENSIONS

. e

ANY MODELI

19081-6- *

190S ST-6- *

190SST-10-*

1477AL-12- *

1901-6- * 190AT-6- * 1477-6- * 1477A-6- * 1477-8- * i 1477A-8- *

190ALT-16- * I

LINE SIZE RECOMMENDED CAPACITY GPM

1908T-4- 9e1908AT-4-* f -

190MSS-4-*

1901-10- * I 190AT-10- 9E

1477L-12- * 1

*, ., • y , , .,.. :.‘.. !.: , :;.L1

0.3

190LSST-10• *

1901T-16- * 1

190SST-4- die

1908-2- * 1908A-2-*

190LM SS-8- *

- !

190-12- * 190A-12- * 1901-4-* 190AT-4- * 1477-4- * 1477A-4- 9e

190811-10- * -

SAE

DS* hi idadal Numibera shwa intst Iiii mined , 1 with a last dash matt to deftest* YO lift DE,: SKID FIXED CUNT/MUD FLOW PAU 1W GPD . within the radowaiwahwiiipacity let tieCtiza elcm. .., , .

•-2 Vs" 11 VA:.

Varies from basic model only in type of materials used in construction, as de. , tailed in table. .

The basic model for high pressure spoil- : Use in sets of two or cations. : more for extra precise control. TolerVaries from basic . once on actuator model only in type , synchronization is of materials used in within a' 2%. Conconstruction, as de- I strutted of steel. tailed in table.

1/4"

1 V2"

PIPE TUNE

70 to 5 . 000. - ''' . "Dashpot" piston

'7.•':7J-7:7"7277 . 7777,?5.7 PIPE THREAD MODELS PIPE 1 SIZE DASH 1 THREAD SIZE j NUMBER ; SIZE Y4', -2 , %a

.- r

-3 %-18 1/2" i -4 1/2-14 ' 3/4" -6 3/4-14

1" -8 1.11% 1% -12 1%•11/2

1W.21781!.(titOttfil=321.E. 190A 19CAL 19013 1" 190L 190SS I 901SS 1908 19080 19081. DIMENSIONS A HEX. j R C DIA. 1 3.50 0.81 1.00 0.88 ; 4.16 1.13 1.25 1.50 1.75 2.50( 1 )

5.00 5.38 I 6.63 . 8.50 i

1.50 1.75 2.00 315

(I) DISTANCE ACROSS mutton FLATS

- -

7.77.7f..77;717177Irr I .. z'.44-,...i -,,..e. - 71tAtIttiltt...7..7 .7.7.601SERIOIlmonsgtorrea 1901 190AT 190ALT 190DT 190MSS 1477 1477A 1477AL TUBE THREAD MODELS 190LT 190SST 190LSST 19081 1901.1ASS 147711 147n 1908AT 1909LT TUBE SIZE DASH -1 THREAD DIMENSIONS DIMENSIONS SIZE NUMBER .! SIZE A HEX. ' 11 C 1118. A HEX. B C DIA. Vs" -4 ; 0t-20 0.88 3.19 1.00 - I -6 i Tft•18 -8 3/4-16 -10 . %-14 114-12 3/4" -12 1" -16 134-12 if)" 1/2" %"

0.88 I 3.81 1.13 1.06 4.13 125 1.25 5.25 1.50 1.50 - 5.88 1.75 1.75 6.88 2.00

0.88 1.06 1.25 1.50 -

3.81 1 4.13 5.25 5.88 -

1.00 1.31 - 1.38 1.69 -

0.4

1.3

2.0 2.0

RACINE®

BRIIIR PR.'S

• • • • ••••••••• • • • ••••••• • •• • ••

DIRECTIONAL CONTROL VALVES FOUR WAY VALVE 1/4" 3000 PSI SLEEVELESS STACKABLE

WHEN ORDERING PARTS, FURNISH: 1. COMPLETE CODE NUMBER 2. PARTS REQUIRED 3. SHIPPING INSTRUCTIONS WRITE FACTORY FOR NEAREST AUTHORIZED PARTS AND SERVICE CENTER.

VALVE CODING MD04 - P DNC - AA -*VDC

A--STANDARD P-- PARALLEL

C--SPRINGCENTERED

S--SERIES

A--SPRING OFFSET PRESSURE TO CYL. PORT A B--SPRING OFFSET PRESSURE TO CYL. PORT B

D--4 WAY VALVE

H--SPRINGCENTERED SINGLE SOLENOID °X--SPECIAL

(1C)

6 VDC

(2C)

12 VDC

(3C)

24 VDC

(7C)

C--DOUBLE CYL. PORT RELIEF VALVE W/ANTI -CAVITATION CHECK D--DOUBLE CYL. PORT RELIEF VALVE E--SINGLE CYL. PORT RELIEF VALVE H--DOUBLE HOLDING VALVE

R--SINGLE CYL. LOCK VALVE

M PT

S--DOUBLE CYL. LOCK VALVE T--SINGLE CYL. LOCK VALVE W/THERMAL RELIEF

100 VDC 115 VAC EX PLOS ION PROOF SOLENOID

U--DOUBLE CYL. LOCK VALVE W/DOUBLE THERMAL RELIEF D--DIRECT SOLENOID OPERATED

°X--SPECIAL

SD 2.06

For engineering data see Bulletin ED 2.06

*CONSULT FACTORY AUGUST 1979

PARALLEL VALVE SINGLE D.C. SOLENOID -

0 0

INEMEML IFIrarAPr IV/

MIIIIIIIMII11111 --+Illk 1 .1 a=1. 141:2 la I I 1 11 P / TrOMMIO Tel I I

NOTE: USED ONLY WITH "M" SPOOL FOR SPRING OFFSET

SERIES VALVE DOUBLE A.C. SOLENOID

SD 2.06 Page 2

0 0

° 0 0

TABLE # 1

Ref. No.

Part No.

1 1 1 1 1 _1

253207 253209 253127 253129 253128 253130

'2 3

407342 See Spool Chart 408870 355296 355491 355671 355674 Table #2 355341 355478 355281 355280 493459

*4 5 L5 [6 6 7 8 8 9

_10

493460

r 11 L 11 12 13 13 *14 15 16 *17 18 19 20 ' L 20 [21 1_21 r22

355275 355277 355290 405964 306769 407362 493745 355292 406460 355293 493428 355274 355276 493829 493483 493526

[

1_22 23 24 25 26 27 28 29 30 31 F32 L32 33

355841 355414 400995 355415 493543 Table #1 Table #1 491028 493543 355714 493474 493467 405914

Description

AC SOLENOID

Qty.

Series Body, 6 SAE Series Body, 6 SAE (Accessory Body) Parallel Body, 6 SAE Parallel Body, 6 SAE (Accessory Body) Parallel Body, 114" NPTF Parallel Body, 114" NPTF (Accessory Body) 0-ring, 1116 x 11/16 x 13/16 Spool 0-ring, 1/16 x 5/8 x 3/4 Push Pin, DC Solenoid Push Pin, AC Solenoid Female Cone, DC Solenoid Female Cone, AC Solenoid Coil, DC Plunger, DC Solenoid Plunger, AC Solenoid Guide Tube, DC Solenoid Guide Tube, AC Solenoid Screw, Fillister Hd., #10-24 UNC x 2-15/16 (D. C. Solenoid Only) Screw, FillisterHd., #10-24 UNC x 3-7/8 (A. C. Solenoid Only) Outer Flux Sleeve, DC Solenoid Outer Flux Sleeve, AC Solenoid External Push Pin Guide Actuator Pin, Standard Actuator Pin, Extended Quad Ring, 1/16 x 1/8 x 1/4 Nameplate (Blank) End Plate 0-ring, 1/16 x 9/16 x 11/16 Solenoid Case Spring Inner Flux Sleeve, DC Solenoid Inner Flux Sleeve, AC Solenoid Spring, Parallel Body Spring, Series Body Washer, (All Except Spring Offset) Series Only Hat Washer, Parallel Only Plug Seal Screw, Fill ister Hd. , #10-24 UNC x 5/8 End Plate Wiring Enclosure, AC Solenoid Rectifier Coil, AC Screw, Pan Hd., #6-32 x 1/4 Cover, Enclosure Spacer (Spring Offset Only) 4" Lead Wire W/1/4" Spade Connector 24" Lead Wire W/114" Spade Connector Hubbard Washer (AC Only)

1 1 1 1 1 1

Rectifier No.

Coil No.

AC Voltage

Watts

493539 493539

493418 493523

115 VAC 115 VAC

30 55

TABLE #2

1/2 1

SERIES 6 D.C. SOLENOID

1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 4/8

Solenoid Assy. No.

Coil No.

Voltage

707562 707563 707564 707565 706255 708256 708257

493519 493482 493596 493522 493519 493482 493596

6 VDC 12 VDC 24 VDC 100 VDC 6 VDC 12 VDC 24 VDC

'M' Spool Only

SPOOL CHART

4/8

PARALLEL BODY

1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 2/4 1/2 1/2 1/2 1/2 1/2 1/2 2

*OLD

*NEW

3 E 1C

•••••1110111.11Wr

••••••••■■••

355866

355588 1C

El= 2C

355867

3 E

2 1 4 1 1/2 1/2 1/2 4/8 1/2 1 1/2 1/2 1/2

355678

355589 7C

355713

355868

SERIES BODY •■■

•••••

355601

* I ncluded in Seal Kit 708268 3C

355599

*NOTE: New Spool Design uses Hat Washer No. 355841 Old Spool Design uses Washer No. 493526

RELIEF VALVE CODING

MR - 04 - FN u

04--6 SAE -- RELIEF

M -- MOBILE

R SERIES BODY EXTERNAL PORT FOR RELIEF EXHAUST B-- PARALLEL BODY (NORMALLY OPEN) J -- PAR. BODY TWO EXTERNAL PORTS C--PARALLEL BODY SD 2.06 (NORMALLY CLOSED) Page 3

F -- TWO STAGE D -- TWO STAGE SOLENOID OPR. (PARALLEL ONLY)

B -- 250 C -- 500 D 750 E -- 1000 F -- 1250 G -- 1500 H -- 1750 J -- 2000 K 2250 L -- 2500 M -- 2750 N -- 3000

RELIEF VALVES PARALLEL RELIEF VALVE AC OPERATED-NORMALLY OPEN Ref. No. 1 2 3 L3 4 5 6 7 *8 9 1_9 10 ril L11 [12 L12 13 F14 L14 P155 16

493543 355675 355374 355480 400925 355626 400922 405420 404463 253406 253407 407342 355463 355481 355274 355276 355293 355341 355478 355275 355277 493459

493460

17 18 19 20 [21 121 *22 23 24 25 *26 27 28 29 30 31 32 33 34 35 36 *37

355292 306769 403057 493541 493482 493418 406460 401272 355624 493851 405688 355622 355547 493850 355625 493477 355675 355390 406484 493428 355290 407362 355281 355290 403446 401296 253496 493127 405411 355511 401273 490438 401279 355508 493743 355503 402455 401014 493742 355547 355509 493779 355504 407347 707869 405914

PARALLEL RELIEF VALVE DC OPERATED-NORMALLY CLOSED

® PARALLEL RELIEF VALVE INTERNALLY ADJUSTABLE

38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 *58 59 60

SERIES RELIEF VALVE EXTERNALLY ADJUSTABLE

SD 2.06 Page 4

Part No.

Description Enclosure, Wiring Rectifier Push Pin, DC Solenoid Push Pin, AC Solenoid Plug, 1116 N. P. T. F. Plug, #10 SAE Plug, 1/8 N. P. T. F. Plug, Orifice, 0.040" 0-ring, 1/16 x 1/2 x 5/8 Body, Electrically Operated Body, Internally Adjustable 0-ring, 1/16 x 11/16 x 13/16 Female Cone, DC Solenoid Female Cone, AC Solenoid Inner Flux Sleeve, DC Solenoid Inner Flux Sleeve, AC Solenoid Solenoid Case Plunger, DC Solenoid Plunger, AC Solenoid Outer Flux Sleeve, DC Solenoid Outer Flux Sleeve, AC Solenoid Screw, FillisterHd., #10-24 UNC x 2-15/16 (DC Solenoid) Screw, FillisterHd., #10-24 UNC x 3-718 (AC Solenoid) End Plate Actuator Pin Screw, Slotted Hd., #6-32 UNC x 1/4" Cover, Enclosure Coil, 12 VDC Coil, 115 VDC 0-ring, 1/16 x 9/16 x 11/16 0-ring, 1/16 x 3/8 x 1/2 Poppet, Main Spring 0-ring, 0.097 x 0.755 x 0.949 Adjustment Seat Poppet Spring Seat Spring Poppet Poppet Guide 0-ring, 1/16 x 1/2 x 518 Spring External Push Pin Guide 0-ring, 1/16 x 1/8 x 1/4 Guide Tube, DC Solenoid Guide Tube, AC Solenoid Nameplate Screw, Self Tapping Body 0-ring, 1/16 x 13/16 x 15/16 0-ring, 0.116 x 0.924 x 1.156 Body Cartridge 0-ring, 1/16 x 1/4 x 3/8 Glyd Ring 0-ring, 1/16 x 3/16 x 5/16 Body, 1st Stage Thread Seal Adjustment Screw Spring Lock Nut Washer Poppet, 1st Stage Balance Piston Spring Balance Piston 0-ring, 1/16 x 15/16 x 1-1/16 Relief Valve Cartridge Ass'y. Hubbard Washer (AC Only)

*Included in Relief Valve Seal Kit 708274

Qty. 1 1 1 1 4 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 4 4 1 1 4 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

ELECTRICAL OPTIONS EXPLOSION PROOF SOLENOID

u in ii

HEAVY DUTY PROTECTIVE HOSE CLAMPED ONTO TUBE TO PROTECT WIRING. REFER TO SPECIFICATIONS FOR PERMISSIBLE EQUIPMENT WIRING.

laci

4111•11111111

TORQUE TO 80 - 100 IN. LB S. (9 -11.3 NM)

ASSEMBLE WITH CHAMFER AS SHOWN

Ref. No. 1 2 3 4 5 6 7 L7 r8

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 — —

Part Number 355813 355814 See Chart 784190 408195 494067 494064 494068 494065 494069 494066 355826 407520 355816 355817 494056 355812 355818 707331 355819 355815 406460 778290 784191 355821 355822 408870 407672 494073 401296

Description Plate Spacer Coil Outer Tube Screw, Socket Hd., 1/4-20UNC x 1 Hose Clamp Hose Tube (3/4") Hose Tube (5/8") Control Cable Nut (3/4") Control Calbe Nut (5/8") Packing Adaptor (5/8" Control Cable Only) Lockwasher Cover Guide Screw. Hex Hd., 1/4-20 UNC x 6-1/2 Plate Spacer Pin & Quad Ring Assembly Washer Washer 0-ring, 1/16 x 9/16 x 11/16 Plunger Guide Tube Cone Pin 0-ring, 1116 x 5/8 x 3/4 Screw, Socket Hd., #10-24UNC x 1/2 Nameplate (Not Shown) Self-Tapping Screw (Not Shown)

Qty. 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 4 1 1 1 1 1 2 1 1 1 1 1 4 1 2

Solenoid Ass'y. No.

Coil No.

Voltage

994479 994480 994409

494057 494058 491685

12 VDC 24 VDC 100 VDC

3/4" Tube Kit - 708346 5/8" Tube Kit - 708347

SD 2.06 Page 5

OPTIONS DOUBLE CYLINDER RELIEF & ANTI-CAVITATION Ref. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part No.

Description

Qty.

408526 401024 356950 407480 404463 401066 356949 407808 408522 405688 407807 407229 356951 356491 408544 407548 401296

Adjusting Screw Lock Nut Plug Back-up Ring 0-ring, 1/16 x 1/2 x 5/8 Ball Poppet Spring Rivet 0-ring, 0.097 x 0.755 x 0.949 Spring 0-ring, #3 SAE Plug Body Thread Seal Name Plate (Not Shown) Screws (Not Shown)

2 2 2 4 2 2 2 2 2 2 2 2 2 1 2 1 4

Seal Kit No. 708307

CYLINDER PORT RELIEF VALVE

1 2 3 4 5 6 7 8 9 10 11 11 _11 12 13 14

408526 356494 490423 401296 407483 356819 408544 401024 407808 401273 784900 356853 407466 405393 408522 404463

Description Adjusting Screw Body Plug Screw, Self Tapping Nameplate Plug Thread Seal Lock Nut Spring 0-ring, 1/16 x 1/4 x 3/8 Piston Assembly Piston (Not Shown) Roll Pin (Not Shown) 0-ring, 0.087 x 0.644 x 0.818 Rivet (Spring End) 0-ring, 1/16 x 1/2 x 5/8

Qty. N)N)

Part No.

Nj N.) N N.)N.) N N.)

Ref. No.

CYLINDER LOCK VALVE & THERMAL RELIEF VALVE Seal Kit No. 708307

THERMAL RELIEF CARTRIDGE

Ref. No.

Part No.

Description

Qty.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

356460 307737 401065 407832 407186 307739 356159 404463 360342 407814 405393 360101 360873 491638 711121

Body Piston Ball Spring Spring Plug Poppet 0-ring, 1/16 x 1/2 x 5/8 Plug Spring 0-ring, 0.087 x 0.644 x 0.818 Poppet Orifice Set Screw Thermal Relief Valve Ass'y.

1 1 2 2 2 2 2 2 1/2 1/2 1/2 1/2 1/2 1/2 1

—

401296

Screw, Self Tapping (Not Shown)

—

407548

Nameplate (Not Shown)

Seal Kit No. 708314 SD 2.06 Page 6

OPTIONS DOUBLE FIXED RESTRICTOR WITH FREE FLOW CHECK Ref. No. 1 2 3 4 5 6 — —

Part No.

Description

407186 307739 405393 784931 404463 356456 401296 407548

Spring Plug 0-ring, 0.087 x 0.644 x 0.818 Poppet Sub-Assembly 0-ring, 1/16 x 1/2 x 5/8 Body Drive Screw (Not Shown) Nameplate (Not Shown)

Qty 2 2 2 2 2 1 2 1

RECIPROCATING SEQUENCE VALVE Ref. No.

Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 — —

707120 355457 355456 253188 490917 707791 404972 405612 405291 707199 490560 403446 401296 406484 408870 355543 355544 707124 400925 493456

Description Plug, #6 SAE Seat Poppet Body Set Screw Seat Assembly Spring, Outer Spring, Inner Push Pin Sequence Valve Head Screw, Pan Hd., 10-24 UNC x 7/8 Nameplate Screw, Self Tapping 0-ring, 1116 x 1/2 x 5/8 0-ring, 1116 x 518 x 314 Cone, Female Detent Plug, #5 SAE Plug, 1/16 N. P. T. F. (Not Shown) Spring, Detent (Not Shown)

ACCESSORIES STACKING KITS SERIES VALVES

PARALLEL VALVES Sections

Stacking Kit No.

707671

707672

707673

707674

707675

707676

707677

707678

707679

707680

NOTE: Torque Tie Rods to 250 in-lbs. (28.2 N-m).

SD 2.06 Page 7

Sections

Stacking Kit wfo Relief Valve

Stacking Kit w/ Relief Valve

707871

707872

708162

707873

708163

707874

708164

707875

708155

707876

708156

707877

708157

707878

708158

707879

708159

707870

708160

Qty. 2 2 2 2 2 2 2 2 2 2 8 1 2 2 2 2 2 4 4 4

ACCESSORIES STACKING KITS PARALLEL VALVES Sections

Stacking Kit No.

707671

707672

707673

707674

707675

707676

707677

707678

707679

707680

NOTE: Torque Tie Rods to 250 in-lbs. (28.2 N-m).

SERIES VALVES Sections

Stacking Kit wlo Relief Valve

707871

707872

708162

707873

708163

Stacking Kit w/ Relief Valve

707874

708164

707875

708155

707876

708156

707877

708157

707878

708158

707879

708159

707870

708160

RACINE HYDRAULICS DIVISION, DANA CORPORATION RACINE, WISCONSIN 53401 PRINTED IN U.S.A.

MIVMM

°Transportation Equipment

Power Wheel

gear reduction drive for farm, industrial and off-road equipment

Warner Gear Division of Borg-Warner Corporation

0cVARNER

Warner Gear

°Transportation Equipment

Division of Borg-Warner Corporation

Let Borg-Warners expertise in power transmission design work for you through Warner Gear's unique Power Wheel. •

Quality gearing throughout

•

Tapered roller bearings

•

Choice of ratios

•

Compatible with all popular hydraulic motors

•

Highly efficient

•

Completely reversible

•

Input speeds to 5000 rpm

•

Output torque to 180,000 lb. in. (2073 kgm)

=MO •011•1111111•11•111•11MMINIIIMINENINEMMININIIIIIMIIIIIIMMIUMMUNIIIMIIIMIIMINN

CONTENTS Introduction

2-4

Application Data

5-6 .

Table 1-Known values from vehicle and performance parameters Table 2-Road Rolling Resistance (rr) and % grade equivalents (RR%) Table 3-Values to be calculated Table 4-Power Wheel general specifications Model 6 Installation drawing

7 8

Model 8 Installation drawing

Model 10 Installation drawing

420 Kit

Work sheet

-47

11Y74.4"-:7..;-4■4■0401*

„ '

tziai

v'Sz-vett •

Mobile Applications Slip form pavers Crop sprayers Straddle carriers Coal carriers Tunneling machines Trenchers Front-end loaders Crop harvesters Loader back hoes Airport tow tractors;

Stationary Applications Seeders Log loaders Windrowers Concrete mixers Asphalt pavers Cherry pickers Compactors Combines Swathers Forage harvesters —3—

Conveyors Mixers Pile drivers Auger drives Lifts Loaders Winches Turret drives Rotary actuators

Borg-Warner's Power Wheel delivers torque anywhere you can run a hydraulic line.

ENGINE

4011 MMD MOM MM. ME. ••••••■

•■•■•••■•■•

POWER WHEELS

Great design freedom. No longer does your design for farm, industrial and off-road equipment (mobile or stationary) need to be locked in by the constraints of conventional power train design. The Power Wheel simply eliminates the need for conventional drive-shafts, clutches, transmissions, axles, and differentials. Mechanical, pneumatic or electric power sources may also be used. In any application where you need to increase torque or reduce speed to achieve useable power, the BorgWarner Power Wheel can provide an efficient solution. The schematic shows how. Hydrostatic power operating through a central variable-flow pump to fixed or variable hydraulic motors at each wheel provides the power transmission. The Power Wheel supplies the gear reduction and wheel rotation to achieve desired performance.

Responsive performance. The Borg-Warner Power Wheel delivers infinitely variable power. It provides smooth power even at "crawl" speeds for remarkably precise control of heavy equipment. Performance can be equally as precise in forward or reverse. Reverse power is obtained by simply reversing rotation of the hydraulic motor. The positive traction provided by individually powered wheels results in superior maneuverability. Borg-Warner's high-ratio multi-planetary reduction assemblies permit utilization of relatively inexpensive high speed/low torque drive motors. Most makes of motors can be accommodated. Power Wheel models are available with bolt circles that generally match standard U.S. industrial wheels. Equipment towing speeds of up to 40 mph (64 km/hr) are made possible by the uniquely efficient planetary gearing arrangement and "quick disconnect" feature.

APPLYING THE POWER WHEEL

Atypical application adapts the Power Wheel to a hydrostatically-driven vehicle; however the basic formulas apply to other uses as well. For mobile equipment, identify parameters for the vehicle and its desired performance. They are listed in Table 1. Determine the road rolling resistance (rr) in pounds per 1,000 lbs. (kg per 1,000 kg) of gross vehicle weight and the percent grade equivalent (RR%) from Table 2. Calculate the road rolling resistance (RR) in pounds (kg): GVW x rr ER(kg)= RR= 1000

GVW(kg) x rr (k 1000

Calculate the Power Wheel input speed necessary to obtain the desired maximum vehicle ground speed: 0

Ni _ 168 x V x Ra r

2652 x V(km/hr) x Ra r (mm)

This value should not exceed 5,000 rpri. The Power Wheel ratio (Ra) may be used to adjust the input speed to the desired level while maintaining the required ground speed. The output torque required for gradeability (G) and wheel slip can now be calculated: 0

Tog - GVW x r x (G + RR%) (kgm) - GVW(kg) x r (mm) x (G + RR2 100 100,000

Tos=VWxmxr Es(kgm) - VW(kg) xmxr (mm) 1,000 Select the correct Power Wheel from the general specifications contained in Table 4. Consider the maximum intermittent output torque to be a conservative ultimate value at which the Power Wheel would be expected to fail should it be operated at this level continuously. Intermittent torque peaks of short duration at this level should not damage the Power Wheel. A torque value of 50% of the maximum intermittent value may be considered safe for continuous operation. The net force available to drive the vehicle, termed the "drawbar pull," is the difference between the tractive effort (Tos/r) produced by the Power Wheel output torque and the road rolling resistance: DPos = Tos — R R DPos(kg) os(kg)

1000 x Tos(k gm) R R(k R(kg) r (mm)

After selecting the appropriate Power Wheel verify that the unit will provide satisfactory bearing life and still support the anticipated radial load. Refer to the appropriate bearing load curve, and read the allowable radial load (R) at the appropriate distance of the load centerline from the wheel mounting face. This value, the anticipated load at the location from the mounting flange (R') and the bearing speed factor (SF, determined from the chart adjacent to the bearing load curve) can be used to determine the life factor (LF) and the hours of B-10 bearing life expected (read the B-10 hours from the chart adjacent to the bearing load curve). The bearing capacity of each Power Wheel is matched to that unit's torque capacity so the same Power Wheel will provide both adequate torque and bearing life for a specific range of vehicle sizes and weights. After selection of the appropriate Power Wheel refer to the legend on the appropriate installation drawing to determine the assembly number that will give the desired ratio, wheel stud, mounting flange and drive shaft combination.

The above information is provided as a guide in applying the Power Wheel. The Power Wheel group is available to assist in the application procedure. The application data sheet in this brochure may be used to supply information to Warner Gear for free application recommendations. A typical Power Wheel application: Self propelled windrower

Maximum percent gradeability desired, 25%

Two front wheels driving Gross vehicle weight, 6,000 lbs. (2,721 kg)

Maximum vehicle ground speed desired, 10 mph (16.21 km/hr) Coefficient of friction 0.6

Weight on driving tires, 3,600 lbs. (1,633 kg)

Operation on smooth dirt

Weight distribution 60% front, 40% rear

Rolling radius of driving tires, 16" (406.4 mm) From Table 2: rr =25 lbs. (kg) per 1,000 lb. (kg) gross vehicle weight RR%=2.5% Calculate the road rolling resistance (RR) from equation 0:

RR -

(6,000) (25) - 150 lbs. 1000

(2721) (25)=

1000

- 68.03

Calculate the Power Wheel input speed necessary to obtain the desired maximum vehicle ground speed:

(168) (10) (24.5)

Ni =

=2572.5 rpm Ni -

(2652 ) (1 6 .09) (24.5) - 2572.5 rpm 40 6 .4

From equation Cs, calculate the Power Wheel output torque required to obtain the desired gradability: Tog -

(6,000) (16) (25 + 2.5) (2721) (406.4) (25 + 2.5) - 26,400 lb. in. Tog - 304.1 kgrr 100 100,000

Calaculate the Power Wheel output torque required to obtain wheel slip from equation Q: Tos = (3600) (0.6) (16) = 34,560 lb. in. Tos = (1633) (0.6) (406.4) = 398.1 kgr] 1000 From Table 4 the Model 6 Power Wheel would be most suitable for this application in terms of torque capacity, and the maximum input speed of 2572.5 rpm is well within the speed limitation of the Power Wheel. Determine the drawbar pull from equation Cs: DPos =

34, 560

— 150 = 2010 lbs.

lEpos -

(1000) (398.1) — 68.03 = 911.5 kg 406.4

The gross force available to drive the vehicle, termed the tractive effort, is 2160 lbs. (34,560/16) or 979.6 kg (398,100/406.4). Now that the Model 6 has been determined as the most suitable unit, determine the B-10 bearing life to confirm the application. Assuming the centerline of the 1800 lb. (816.3 kg) load (R') is located 1" (25.4 mm) rearward of the wheel mounting flange, the allowable radial load for 3000 hours B-10 at 100 rpm (R) is 5500 lbs. (2494 kg). For an output speed of 105 rpm (Ni/Ra = 2572.5/24.5), the speed factor (SF) is approximately 1.00. Now the life factor (LF) can be calculated: LF

5 500

x 1 00 = 3.05 LF 1 800

2494 816.3

x 1.00 = 3.05

which will give a B-10 life in excess of 10,000 hours and confirms that the Model 6 is the most appropriate Power Wheel for this application. Assuming an SAE B mounting flange with a 13 tooth, 16/32 pitch drive shaft without wheel studs is required, obtain assembly no. 14-02-000-005 from the legend on the Model 6 installation drawing for ordering. —6—

TABLE 1—KNOWN VALUES FROM VEHICLE AND PERFORMANCE PARAMETERS

TABLE 3 VALUES TO BE CALCULATED —

RR Road Rolling Resistance (lbs.) (kg) Ni Input speed to Power Wheel (rpm) Tog Power Wheel output torque required to obtain desired gradeability (lb. in.) (kgm) Tos Power Wheel output torque required to obtain wheel slip (lb. in.) (kgm) Drawbar pull available at wheel slip DPos (lbs.) (kg)

GVW Gross vehicle weight (lbs.) (kg) VW Weight on driving tires (lbs.) (kg) r Rolling radius (static, loaded) of driving

tires (in.) (mm) G Percent gradeability (maximum desired)

V Vehicle speed (maximum desired, mph) (km/hr) m Coefficient of friction

TABLE 2—ROAD ROLLING RESISTANCE (rt. ) , AND % GRADE EQUIVALENTS (RR%) —rr—SURFACE—

Pounds (kg) per 1,000 lb. (kg) GVW

TABLE 4—POWER WHEEL GENERAL SPECIFICATIONS

—RR%— Equivalent % Grade

Ratio Model 6 28.4, 24.5, 21.7, 19.6, 15.9 Model 8 39.96, 30.89, 22.0 Model 10 36.82

Concrete, Excellent

(10)

Concrete, Good

(15)

1.5

Concrete, Poor

(20)

Asphalt, Good

Nimax Maximum input speed to Power Wheel-5,000 rpm all models

(12)

1.2

Asphalt, Fair

TM Maximum intermittent output torque

(17)

1.7

Asphalt, Poor

(22)

2.2

Model 6 50,000 lb. in. (576 kgm) Model 8 100,000 lb. in. (1152 kgm) Model 10 180,000 lb. in. (2073 kgm)

Macadam, Good

(15)

1.5

Macadam, Fair

(22)

2.2

Macadam, Poor

(37)

3.7

(55)

5.5

Cobbles, Ordinary

Cobbles, Poor

(85)

8.5

Snow, Two Inch

(25)

2.5

Snow, Four Inch

(37)

3.7

Dirt, Smooth

(25)

2.5

Dirt, Sandy

(37)

3.7

Mud

37-150

(37-150)

3.7-15.0

Sand, Level & Soft

60-150

(60-150)

6.0-15.0

Sand, Dune

TC Maximum continuous output torque (1/2 TM)

160-300 (160-300) 16.0-30.0 —7—

MODEL 6 OPTIONAL

9T 16/32 KEYED 13T 16/32 1,2,3,4,5,6,7 15T 16/32 8

8-.646-.666 116,41-16,92) DIA. THRU HOLES EQ. SPACED ON 8.501215,90) B.C. DIA.

8-.50-13 UNC 26 1.00 (25,40)" DEEP HOLES EQ. SPACED ON 6.75 (171,45) B.C. DIA. FOR DISC BRAKE INSTALLATION

OPTIMAL

SAE A 5 SAE 8 1,2,3,4,6,7,8

9-.604-.611 (15,34-15,60) DIA. THRU HOLES EQ. SPACED ON 9.50 (241,30) B.C. DIA. 88 122.351 FOR .50.20 UNF 1. 00 (25,40) FOR 562-18 UNF

OPTIONAL .562 18 UNF. R.H. THD. 5020 UNF. R.H. THD . NONE

2.5 1,3,6,7.8

5.50-5.49 DIA. (139,70-139.45)

10.06-9.97 DIA. (255,52.253,24)

7.88 DIA. MAX. 1200,15)

6.885-6.865 DIA. (174,88 174,37)

REMOVE & REVERSE TO DISCONNECT DIA. X-

2.87 (72,90)

41 .47 (10,4111,94) FILLER-DRAIN PLUG

SAE B MTG. 1.0661.161 (27,0849.49) AIRG. EFF. SPREAD 1.922 148,82) MIN. DISENGAGED 2.549164,74) MIN. ENGAGED

.88 122,35) 2.31 158,67) PREFERRED CENTER OF WHEEL OR LOAD

PARENTHETICAL DIMENSIONS ARE EXPRESSED METRICALLY

1.07 (27,2) -1.

.57(14,48).-0..

3.135-3.115 79,63-79,12)

"11-. (

5.88 (149,35) 11.59 (294,39)

5.14 (130,56)

11.094.10.906 DIA. (281,79.277,01) -

OPTIONAL RATIO 28.37 24.53 1, 2, 4, 5, 8 21.7 3 19.62 7 15.88 6

ALLOWABLE RADIAL LOAD VS. DISTANCE FROM WHEEL MTG. FLANGE

ALLOWABL ERADIAL LOAE/ - LBS. (kg )

R=R' x (LF÷SF)

BRG. LIFE CURVE BASED ON:

10000 (4535)

LIFE - 3000 HRS. 8-10

R= Allowable radial load for 3000 hrs.

SPEED - 100 RPM OUTPUT

8000 (3628) I

6000 12721)

LOAD, LIFE. & SPEED RELATIONSHIPS

1•111,.

B-10 @ 100 RPM for given location from mounting flange.

WHEEL MOUNTING FLANGE

R'= Anticipated load at location from mounting flange.

BEARING LIFE

LF= Life factor from tabulation, 4000 (1814

SF= Speed factor from tabulation. ...

POSITION FOR MAXIMUM BEARING LOAD 2000 (907)

•••■■-

NOTE: These curves apply for radial load

OUTPUT (REED PM) M)

2.456

.584

560

1.994

.719

1000

1.620

.812

1500

30 40

1.435

.886

2000

1.316 1.231

.947

2500

1.000

3000

1.165

1.047

3500

1.113

1.090

4000

80 90

1.069

1.130

4500

1.032

1.166

5000

100

1.000

1.231

6000

200

.812

1.289

7000

300

.719

1.342

8000

400

.659 .617

1.390

9000

1.435

10000

500

only. For other load combinations contact

2.31 I (58,67) i

Warner Gear engineering.

4.0" 3.0" 2.0" 1.0" 0" (101,60) 176,20) (50.80) 125,40) (0,0) (-25.40) 1-50,80) 1-76.20) DISTANCE FROM WHEEL MOUNTING TO RADIAL LOAD - IN./MM

TORQUE OUTPUT UP TO 50,000 LB. IN. (576 kgm) MOTOR MTG. DIMENSIONS SAE A

SAE B

2 - .375-16 UNC 26 THRU HOLES ON 4.187 (106,35) B.C. DIA.

2 - .50-13 UNC 28 THRU HOLES ON 5.75 (146,05) B.C. DIA.

LEGEND

DIA. X 3.251-3.256 (82.58-82.70)

4.001-4.006 (101,62.101,75)

14-02-000-005 2

14-02-000-009

14.02-000-010

14.02-000-011

14-02.000.013

14-02.000-014

14-02000-015

14-02.000-016

INPUT SPEED

APPROX. WEIGHT

HOURS B-10 LIFE

UP TO 5,000 RPM 103 LBS. (46.7 kg.)

Parenthetical dimensions are expressed metrically. NOTE: All specifications and descriptive data shown are nominal and subject to change without notice. Specific applications should be referred to Warner Gear for assistance.

MODEL 8 OPTIONAL 8--.848-.668116,41-18,92) DIA. THRU HOLES Ea. SPACED ON E 01A. B.C.

13T 18/32 1, 2, 3, 21T 18/32 141 12/24 4 , 6 8-.825-11 UNC 28 1.25 131,75r DEEP HOLES Ea SPACED ON 8.75 (222,25) B.C. DIA. FOR DISC BRAKE INSTALLATION

OPTIONAL SAE 8 it 2, 3, SAE C 4,6

13.53-13.47 DIA. (343,66-342,14)

3.00 178,20)

7.25-7.24 DIA. (184.15.183.90)

DIA. F

10.635 DIA. MAX. (270,13)

•

1111•1,1•1.0,11, sit-Nourasl-,

3.04 (77,22) BRG. EFF. SPREAD

FILLER PLUG

-DRAIN PLUG

C .76 (1%30) 1.31 (33,27) -

241 (61,21)

PREFERRED CENTER - OF WHEEL OR LOAD

PARENTHETICAL DIMENSIONS ARE EXPRESSED METRICALLY

3.88

198,55) 5.82 (142,75)

6.34 (136,84)

.62113.21)

11.48 (291,52)

OPTIONAL 30.89 2, 6 22.00 3 8-.804-.811 (15,3415,80) DIA. THRU HOLES EQ. SPACED ON 12.375 (314,32) B.C. DIA.

LOAD, LIFE & SPEED RELATIONSHIPS

ALLOWABLE RADIAL LOAD VS. DISTANCE FROM WHEEL MTG. FLANGE 20000 190701

BRG. LIFE CURVE BASED ON: LIFE - 3000 HRS. 810

Ty.

SPEED - 100 RPM OUTPUT SPEED

!I 16 000 172561

4 0

Q 12000 (54421 4

■

3 8000 13628)

2.456

.584

500

B-10 @ 100 RPM for given location

1.994

.719

1000

from mounting flange.

1.620

.812

1500

1.435

.886

2000

1.316

.947

2500

1.231

1.000

3000

1.165

1.047

3500 4000

LF= Life factor from tabulation.

SF= Speed factor from tabulation,

....

R= Allowable radial load for 3000 hrs.

mounting flange.

POSITION FOR MAXIMUM BEARING LOAD

R'= Anticipated load at location from

41 III

BEARING LIFE

4000 (1814)

WHEEL MOUNTING FLANGE

HOURS B-10 LIFE

OUTPUT SPEED (RPM)

R=R' x (LFSF)

1.113

1.090

1.069

1.130

4500

1.032

1.166

5000 6000

100

1.000

1.231

200

.812

1.289

7000

300

.719

1.342

8000 9000 10000

NOTE: These curves apply for radial load

400

.659

1.390

only. For other load combinations contact

500

.617

1.435

Warner Gear engineering.

241 161,211

4.0" 3.0•• 2.0•• 1.0" 0" -1 0" 1101,601 176,301 150.801 (25,40) 10,01 (-25,40) (-50.801

DISTANCE FROM WHEEL MOUNTING TO RADIAL LOAD - IN (MM)

ANGLE D

DIA. E

DIA. F

SAE B 2- .50 13 UNC 2B THRU HOLES ON 6.761146,05) B.C. WA,

.40.46 110,1611,681

1.105 1.120 128,0728,451

1.68 142,611 MIN.

22° 30'

8.50 1215,901

9.96 (252,981

SAE C 4- 50 13 UNC 28 HOLES 1 00 125,41 DEEP ON 6.3751161.931 B.C. DIA. EO. SPACED

42.48 110,6712,19/

2.24 156,901 MIN.

90°

9.75 1234,95 ►

10.71 1272,031

MOTOR MOUNTING DIMENSIONS

1 378 1.491 135,00 37,871

LEGEND

DIA. 0

TORQUE OUTPUT UP TO 100,000 LB. IN. (1,152 kgm)

DIA. H

6 878 6.872 4 001 4.006 1174,70174,55) 1101,62101,75!

INPUT SPEED- APPROX. WEIGHT

5.001 5.006 7.645 7.815 1194.18 193,4211127,02-127,151

Parenthetical dimensions are expressed metrically.

14-05-000-007 2 14-05-000-008 3 14-05-000-009 4 14-05-000-010 5 14-05-000-011

NOTE: All specifications and descriptive data shown are nominal and subject to change without notice. Specific applications should be referred to Warner Gear for assistance.

UP TO 5,000 RPM 186 LBS. (84.4 kg.)

MODEL 10 12-.604•.611 (15,34-15,60) DIA. THRU HOLES EQ. SPACED ON 1450 (388,30) B.C. DIA.

OPTIONAL SAE C 1, 3 SAE D 2

12-50-13 UNC 28 1.00 (25,4)" DEEP HOLES EQ. SPACED ON 11.50 (292,10) B.C. DIA. FOR DISC BRAKE INSTALLATION

OPTIONAL

RATIO 36.82:1

14T 12/24 3 23T 16/32 1 21T 12/24 131" 8/16 271 16/32 2

12.76 DIA. MAX. 1324,101 DIA. X -•- ■

8.29 (210,57) BRG. EFF. SPREAD

FILLER PLUG

.16 (4,06) 16.28.16.22 DIA. (413,51411,99) d.—DRAIN

SAE C MTG. .352•.578 18,94-14,68) 2.238 (56,84) MIN.

1.25 131,75)

1.00 (25,4)

3.935 199,95) PREFERRED CENTER OF WHEEL OR LOAD 5.53 1140,46) PARENTHETICAL DIMENSIONS ARE EXPRESSED METRICALLY

10.25 1260,351 16.69 (423,93)

6.44 1163,58)

PLUG

ALLOWABLE RADIAL LOAD VS. DISTANCE FROM WHEEL MTG. FLANGE

ALLOWABL ERADIAL LOAD - L BS.

25000 (11338)

R= Allowable radial load for 3000 hrs. B-10 @ 100 RPM for given location from mounting flange.

BRG. LIFE CURVE BASED ON: LIFE - 3000 HRS. B-10 SPEED - 100 RPM OUTPUT

20000 (9070)

R'.= Anticipated load at location from mounting flange.

I ...-. WHEEL MOUNTING FLANGE

15000 (6803)

LOAD, LIFE & SPEED RELATIONSHIPS R=R' x (LF4SF)

BEARING LIFE

LF= Life factor from tabulation.

SF= Speed factor from tabulation. 10000 (4535)

POSITION FOR MAXIMUM BEARING LOAD

5000 12268 ►

NOTE: These curves apply for radial load only. For other load combinations contact Warner Gear engineering.

.-...... -

....

OUTPUT SPEED (RPM) 5 10 20 30 40 50 60 70 80 90 100 200 300 400 500

HOURS B-10 LIFE

2.456 1.994 1.620 1.435 1.316 1.231 1.165 1.113 1.069 1.032 1.000 .812 .719 .659 .617

.584 .719 .812 .886 .947 1.000 1.047 1.090 1.130 1.166 1.231 1.289 1.342 1.390 1.435

500 1000 1500 2000 2500 3000 3500 4000 4500 5000 6000 7000 8000 9000 10000

3.935 199,95) -4P. I 8.0" (203,20)

6.0" (152,40)

4.0" (101,60)

2.0" (90.80)

0" 10,01

-2.0" (-50,80)

-4.0" ( -101,80)

DISTANCE FROM WHEEL MOUNTING TO RADIAL LOAD - IN (MM)

MOTOR MOUNTING DIMENSIONS SAE C

4-.50-13 UNC 28 1.25 (31,75) DEEP HOLES ON 8.375 (181,92) B.C. DIA.

DIA. X • 5.001-5.008 (127,02-127,151

LEGEND 1 14.01-000-001 2 14-01400-002

TORQUE OUTPUT UP TO 180,000 LB. IN. (2,074 kgm) INPUT SPEED APPROX. WEIGHT

UP TO 5,000 RPM 390 LBS. (176.9 kg.)

3 14-01-000-004 SAE D

4-.75-10 UNC 28 1.25 (31,75) DEEP HOLES ON 9.00 1228,80) B.C. DIA.

8.0014.008 (152,42.152,55)

420 KIT Borg-Warner also offers a special Power Wheel subassembly--the "420 Kit:" a high-ratio compound planetary gear set that is adaptable to a wide variety of tasks. Where space or design limitations preclude the use of the Power Wheel assembly, the 420 Kit allows the designer to retain the advantages of the Power Wheel while meeting his other design criteria. The 420 Kit is available in the same sizes and ratios as the Power Wheel. Typical applications include industrial crane winches, and road roller drum drives. DIMENSION

MODEL 6

MODEL 8

7.88 (200,15) max.

10.63 (270,00) max.

12.76 (324,10) max.

7.31 (185,67)

9.88 (250,95)

11.75 (298,45)

5.18 (131,57) approx.

5.47 (238,94) approx.

5.72 (145,29) approx.

MODEL 10

No. Holes Dia.

8 .344 (8,74)

12 .41 (10,41)

12 .531 (13,49)

'No. Teeth Pitch Pitch Dia.

13 8/16 1.625 (41,275)

21 8/16 2.625 (66,675)

No. Teeth Pitch Pitch Dia.

13 16/32 .8125 (20,638)

14 16/32 .875 (22,225)

oi 54117%/i/ZdFAININPaltIRW/IPAIAPV4P5,41/4/4•MMI N,

sao■■■•■■■•∎∎amea. % AI/0~A ‘■

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4AI 110EIDI .IP

1(% 1:11•11114111111:1M Wei: ■• • AZ \-- '

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—14—

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Alee'm

TALK TO THE POWER WHEEL GROUP

The Power Wheel group at Warner Gear and your Power Wheel distributor are ready to discuss your specific power transmission requirements. Special reduction ratios can often be provided for quantity orders. Tell us about your application and we will quickly respond with a recommendation.

Contact

Title

Customer Address Phone Vehicle Data Type of vehicle

Function

Engine, Type

Rated HP

Gross vehicle weight. (GVW)

lbs. (kg); Number of driving tires

Weight per driving tire

lbs. (kg).

Rolling Radius of Driving Tires (r)

in. (mm):

coefficient of friction (m)

working surface

Hydraulic motor, type

Displacement

Continuous Operating Pressure

cu. in./rev (cu. cm/rev)

psi (bar); maximum relief valve setting

Operating Conditions: No. 1 Torque level

lb. in. (kgm), length of time

No. 2 Torque level

lb. in. (kgm), length of time

No. 3 Torque level

lb. in. (kgm), length of time

No. 4 Torque level

lb. in. (kgm), length of time

Performance Data Vehicle speed required (V), maximum working

RPM

mph (km/hr ► ;

mph (km/hr).

Gradeability Required (G)

Drawbar Pull Required (DP), maximum

average lbs. (kg); minimum

lbs. (kg); lbs. (kg).

Estimated Annual Production (vehicles)

Additional combinations of product options available if production quantities warrant.

—15—

psi (bar).

Transportation Equipment

Warner Gear Division of Borg-Warner Corporation P.O. Box 2688, Muncie, Indiana 47302 Telephone: 317/286-6100 Telex: 027-491

September 15, 1977

INSTALLATION & SERVICE BULLETIN SUBJECT: GASKETS AT EACH END OF RING GEAR REPLACED BY SILASTIC 732 RTV ADHESIVE/SEALANT AND REMOVAL OF THE OIL LEVEL PLUG IN THE SMALL COVER. The large gaskets used at both ends of the ring gear have been removed and Silastic 732 RTV adhesive/sealant is now used at these two locations on all Power Wheels. The Silastic material is much thinner than the gaskets which were removed, therefore, two additional (three) gaskets are required under the small cover to compensate for the reduction in end play of the gear sets in these assemblies. The changes just described may be used when older units are serviced. No gaskets are required under the small cover on Model 6 Power Wheels which have the quick disconnect. The 1/2-14 pipe plug part number 03-04-101-01 has been removed from the small cover and the dimensions of the cover have been changed to permit a single gasket to be used when Silastic 732 is used at each end of the ring gear. The cover without the pipe plug should never be used when gaskets are used at each end of the ring gear.

The oil level should be maintained at the level of the horizontal center line of the Power Wheel, therefore, it is necessary to rotate the wheel to a position where the plug in the large cover is on the horizontal center line of the wheel. The hole is used to fill the wheel and check the oil level. To summarize: 1. Power Wheels with a large gasket at each end of ring . gear should use the small cover with a pipe plug and a single gasket. 2. Power Wheels without large gaskets but using Silastic 732 RTV may use the small cover with the filler plug and three small gaskets or the small cover without the filler plug and one small gasket. 3. Never use the small cover without the filler plug when two large gaskets are used at ends of ring gear.

HORIZONTAL CENTER LINE

IB112

Bulletin No. 2-3310-4

it flui er

T-line filters for low-pressure systems Choice of models with Twin-Life® patented wire cloth dual element or polymer-coated "throw-away" paper element. For 20.69 BAR (300 psi) operating pressure.

.011114;apiw

f-A '',

(

r( i s. i. i'• 1 s.

! 4

tl ); to 04 :::: i t I .1 I I) , I 4 t) ' 0 1I I , ' 1,.. 1 , I t) I' it i

:4);,

I) I.

i- i' 4111 f) , 1 t) I) f, r t

• i 4

i):

l• • , ,)

NATIONAL

nano mu ASSOCIATION

'If

g !! i d

f) ( r‘

IOU II I ° Ph 1 4 ;i1 ) % 4) I) (I. r* , t Pl ' ‘ ‘1,1 41 1 0 4) I , ; P i i' I ' 4/ )

AM BAC Industries Incorporated FLUID POWER SYSTEMS DIVISION 511 South Glenn Avenue • Wheeling, Illinois 60090 Phone: 312-541-3000

Michigan' T-line filter assemblies . . . your best protection against damage by contaminants. Choice of precision "throwaway" paper element or "Twin-Life" wire cloth dual-element—each designed to keep your fluid system clean longer for top performance. With up to 20.69 BAR (300 psi) operating pressure, lowmaintenance T-Line filters are rated at up to 114 Liter/Min. (30 gpm) flow, depending on allowable pressure drop. In compact installations, less than 25.4 mm (1") disassembly clearance is required to replace or clean the dirty element. Many accessories and options offer added convenience and protection: precisiongrade by-pass valve . . . protective magnet . . . vacuum indicators ... compound pressure gauge ... Viton seals ... and top mounting holes.

Maximum protection for hydraulic, lubrication and other fluid systems

TC SERIES

Polymer-coated paper "throw-away" element assures fine filtration down to 10 microns

TC Series filters have a high-grade pleated paper element, designed for use with petroleum and most water-base fluids. Element is constructed with corrosion-resistant metal end-caps, protective exterior perforated metal support, and integral gasket for leak-proof sealing. Replacement elements are easily installed for low-cost maintenance.

Port (Out)

Port (In)

2903 sq. cm 450 sq. in.

TC68

TC69

2903 sq. cm 450 sq. in.

C68

C69

Pressure differential/flow characteristics' (average)

Flow data shown below was taken from laboratory tests using petroleum-base 225 SSU hydraulic oil at 29.4°C (85°F). Pressure differentials were measured across 25.4 mm (1") filter inlet and outlet ports.

in BAR psi ,-

IIIIIIIMIIIMIIIIIIMIMIIIO

.83 12 .69 10

• settin ,i „(,,4111111.17; . 0. Miltraillill mo i =.----

ill By-pas valve cu ► e 1.03

.97 14

BY.P :AR (10

Efffflinall_alleinam

.55 8

See ordering information on page four for complete order number, by-pass valve setting, connector line size, accessories, and dimensions. By-pass valve is optional.

.41 6

.....-

.28 4 .14 2 FLOW: GPM L/Min.

10 38

20 30 40 50 76 114 152 189

ug i Vacuum indicator shows element condition_ at a.glance Visual signal or remote signal vacuum indicators monitor changing system conditions when mounted on MichiganT T-Line filters — lets you know when to clean or change the element. Write for indicator Bulletin *2.5300-1, covering complete specifications. Compound pressure gauge indicates psi increment vacuum conditions in inches Hg. and pressure conditions in two psi increments up to 6.9 BAR (100 psi).

ORDERING INFORMATION .

T-Line filter with Red-Alert° visual indicator

T-Line filter with compound pressure gauge

Typical ordering number: TC68GA2OGV

For T-Line filter-assembly order number, fill-in boxes below...

10 micron, paper element 1.72 BAR (25 psid) by-pass valve, pressure taps, (2), 1 1/4 NPTF, compound pressure gauge, and Viton seals.

OPTIONAL BY-PASS VALVE -

Wire Cloth:

(130 sq. in.) 839 sq. cm 40 Micron 74 Micron 150 Micron 262 Micron (230 sq. in.) 1484 sq. cm 40 Micron 74 Micron 150 Micron 262 Micron

"Floater" Vacuum Indicator

No Valve

f22 With Valve: F2a. BAR PSID ,

.10 1.5 .21 3

Compound Pressure Gauge

.34 5 .69 10 1.03 15 1.72 25

(See drawing below)

Top Mounting Holes "Locker" Vacuum Indicator

Paper:

(450 sq. in.) 2903 sq. cm 10 Micron 25 Micron

Viton Seals

To order replacement elements, use numbers shown above, i.e. "F22" and "C68."

Protective Magnet (for use with TF Series only)

111

Ordering Number (Specifications subject to change without notice.) 107 4.22

Optional 1/4 - 18 taps: (2 provided) A for pressure indicator; B for vacuum indicator

AMBAC Industries Incorporated

66 04 (2.6) Inlet A !On)

Port

- Outlet II (Out) — 19.05

32.5

'317

(1.28) 107 Port (4.22) Port (Out) R., dia. `'")

206 (8.13) 839 sq. cm . (130 sq. in.)

FLUID POWER SYSTEMS DIVISION

257

(10.13) 1484 sq. cm . (230 sq. in.)

Outlet 8 Init. A -

5/6

FO-LC-5M-6147

(Optional 3/8 16 mounting holes)

20.69 BAR (300 psi) operating pressure, housings are aluminum castings with 82.76 BAR (1200 psi) burst strength rating.

511 South Glenn Avenue • Wheeling, Illinois 60090 Phone: 312-541-3000

Rugged M ichiganT T-Line filters provide outstanding performance in critical fluid power and lubrication systems. A wide choice of micron retention ratings meet demanding filtration needs. Choice of port sizes and mounting holes aid easy installation. Precision die-cast construction and advanced design assure economy and convenience. T-Line filters are specified to protect automotive, agricultural, construction, industrial, material handling, chemical, petroleum, machine tool, processing, and automation equipment fluid systems.

To guard your system components against washing of collected contaminants downstream, Michigan'. filters feature an all metal by-pass valve. Self-contained in the filter head, this optional by-pass valve provides straightthrough flow. Available standard valve settings range from pressure differential of .10 BAR (1.5 PSID) to 1.72 BAR (25 PSID).

"Twin-Life" wire cloth dual-element has

TFSERIES

up to 50% more dirt-holding capacity

TF Series filters feature the patented "Twin-Life" wire cloth dual-element—actually two elements mounted coaxially in a single assembly. This unique dualelement provides 50% longer life between cleanings, because element area is 50% larger than comparable single-edge elements. Take-apart construction allows easy maintenance cleaning with less downtime.

MI A

Port (In)

40 Micron 325 Mesh (.0016") (.040 MM)

Port (Out)

•

74 Micron 150 Micron 200 MeSh 100 Mesh. (.0029") (.00601 (.074 MIA)

839 sq.cm 130 sq. in

TF22

TF23

TF25

TF27

1484 sq. cm 230 sq. in.

TF42

TF43

TF45

TF47

Pressure-differential/flow characteristics (average) Flow data shown below was taken from laboratory tests of a 140 micron element using petroleum-base 225 SSU hydraulic oil at 29.4°C (85°F). Pressure differentials were measured across 25.4 MM (1") filter inlet and outlet ports.

L.13 In

BAR

Psi

.28 4 .21 3 .14 2

See ordering information on page four for complete order number, by-pass valve setting, connector line size, protective magnet, other accessories, and dimensions. By-pass valve is optional.

.07 1

FLOW: GPM L/Min.

10 38

20 76

30 114

AMBAC Industries Incorporated FLUID POWER SYSTEMS DIVISION

40 152

T-LINE FILTER REPLACEMENT PARTS LIST for TC Series (Paper Element) and TF Series (Wire Cloth Element)

DESCRIPTION

A. HEAD ASSEMBLY Specify if required: 1. By-pass valve setting 2. Vacuum or pressure taps *Special Order . BY-PASS VALVE ASSEMBLY (Factory installed; please specify head assembly part number.) C. BOWL

SPECIFICATION

le-14- N?TF %"-14 NPTF 1.11% 11PTF 1 14-111/2 NIPTF *1-1/16 Straight Thd. * 1-3/16 Straight Thd. * 1-5/16 Straight Thd. 1% psid 3 psid 5 psid 10 psid 15 psid 25 iasid 8.13" x 4.22" (inc. head) 10.13" x 4.22" (inc. head)

PART NUMBER

SERIES

ALL

200500 200165 200166 200167 200168 200169 20C i 70

ALL "B' "C" "E" "F" "G" 200147 200148

TF20 TF40/All TC

D . BOWL SEAL

Buna-N Buzyl Viton

20.35r.:0 201832 231831

ALL

E . BOLT

5/16" x 1 1h" bolts (4) 5/16" lock washers (4)

900478 901007

ALL

F22 F23 F25 127

TF22 TF23 TF25 TF27

F42 F43 F45 F47

TF42 TF43 TF45 1F47

C68 C69

TC68 TC69

Buna-N seal

201651

ALL TC

1 - Element spring

200070 200475 20010 Std.

ALL TF ALL TC ALL TF ALL ALL ALL ALL

F . ELEMENT

Wire cloth (145 sq. in.): 40 rr.::ron 74 micron 140 micron 262 micron Wire clo7,.h ;250 sq. in.): 40 micron 74 micron 140 micron 262 micron Paper (450 sq. in.,: 10 micron 25 micron

LIST PRICE

set (4)

2 - "X" magnet 3 -'J''" drain plug 4 - LP Indicator 5 • "Floater" vacuum indicator MF 360 6 - "Locker" vacuum indicator ML 360

(Specifications subject to change without notice.)

Michigan Fluid Power 511 GLENN AVENUE, WHEELING, ILL 60090 • 312-541-3000 • Tolax 28.2509

Bulletin 317 June 1976

MICHIGAN ® T-LINE FILTER REPLACEMENT PARTS LIST for TC Series (Paper Element) and TF Series (Wire Cloth Element)

KEY

DESCRIPTION

Head assembly

, B

By-pass vat% assembly (not shown)

Bowl

Bowl seal

Bolt

Element

1 • Element spring 2 -"X" magnet (not shown) 3 - %" drain piug 6 - "Floater" vacuum indicator 6 - "Locker" vacuum indicator

INDUSTRIES

spin-a-filter SAF 20 SERIES

wist off the old element. Twist on the new. No bolts to remove. No time-consuming cleaning operations. Takes less than a minute to change a Spin-A-Filter element. Disposable filter element pays for itself with lower maintenance and downtime costs. Designed for most return line applications up to 76 L/Min. (20 GPM). Also for low flow, critical suction line applications. For use with petroleumbased oils in industrial and mobile equipment operations. Isolated by-pass valve in the cast aluminum housing head protects element against line surges. 10 and 25 micron elements available as standard. 3/4" and 1" NPTF port sizes. Two other series available: (SAF50 and TAF50).

DOWE R 4GAN FLUID • -A vE, .SOUTH GLENN ,— "tELING, !WNW , ,- -

, I

SAF-29

Please consult manufacturer for details: Michigan Fluid Power 511 South Glenn Avenue Wheeling, Illinois 60090. Phone: (312) 541-3000

AMBAC Industries Incorporated FLUID POWER SYSTEMS DIVISION 511 South Glenn Avenue • Wheeling, Illinois 60090 Phone: 312-541-3000

dimensional data

Imo.*

1 1MIIDLO

"q141111111■

engineering data 3/4" and 1" NPTF Port sizes *By-pass valve setting, factory set . . . 1.7 BAR (25 PSID) Nominal size particle retention rating 10 & 25 MICRON 6 9 BAR (100 PSI) MAX. Operating pressure Operating temperature 121°C (+250° F) MAX. Performance 160 SSU @ 37.8°C (100°F) *Optional By-pass valve settings 3 PSID 5 PSID 15 PSID

FLOW L/MIN

AVERAGE PRESSURE DROP

GPM

19 . 5 38 10 57 15 76 20

25 MICRON

.04 BAR .23 BAR .43 BAR .69 BAR

.6 PSI 3.4 PSI 6.3 PSI 10.0 PSI

10 MICRON

.14 BAR .38 BAR .68 BAR 1.01 BAR

2.0 PSI 5.5 PSI 9.9 PSI 14.7 PSI

ordering information 25 MICRON

10 MICRON

Filter Assembly Model SAF29G12 for 3/4" NPTF

Filter Assembly Model SAF28G12 for 3/4" NPTF

Filter Assembly Model SAF29G16 for 1" NPTF

Filter Assembly Model SAF28G16 for 1" NPTF

Replacement element model S-29

Replacement element model S-28

3 PSI D replace "G"w/"B" 5 PSID replace "G"w/"C" 15 PSID replace "G"w/"F"

AMBAC Industries Incorporated FLUID POWER SYSTEMS DIVISION 511 South Glenn Avenue • Wheeling, Illinois 60090 Phone: 312-541-3000

HD - LC - 5M - 8/75

Printed In U.S.A.

ROL-SEAL® MOTOR ROLLING ABUTMENT TYPE WASHINGTON SCIENTIFIC INDUSTRIES, INC. POWER COMPONENTS DIVISION 2605 West Wayzata Blvd. PO Box 340 Long Lake, Minnesota 55356 Telephone: (612) 473-1271 TWX: 910-576-2742

MODELS RSA, RSB AND RSC

MAINTENANCE AND PARTS MANUAL

NOTE ONLY FACTORY OR QUALIFIED DISTRIBUTORS ARE AUTHORIZED TO OVER HAUL AND REPAIR WSI EQUIPMENT. ALL FACTORY WARRANTY IS CANCELLED UPON DISASSEMBLY BY UNAUTHORIZED PERSONNEL.

FORM 201FM

MODELS RSA, RSB AND RSC

ROL-SEAL MOTOR

TABLE OF CONTENTS TITLE INTRODUCTION

PAGE

HOW TO AVOID REPAIRS

TOOLS FOR DISASSEMBLY DISASSEMBLY

1 2

REASSEMBLY

SEAL REPLACEMENT

TROUBLE SHOOTING

ROL-SEAL MOTOR EXPLODED VIEW REPLACEMENT PARTS LIST

8 9

MODELS RSA, RSB AND RSC

ROL-SEAL MOTOR

INSTRUCTION MANUAL

INTRODUCTION The ROL-SEAL® Motor was designed to give both high volumetric and high torque efficiencies. It is manufactured with good quality workmanship and a design concept that allows it to be mass produced. Because of its low breakaway and low leakage characteristics it is understandable why this motor is desired in this energy conservation time.

Remove the key. Carefully remove all burrs from the shaft. Make sure there are no sharp corners around the keyway, to prevent the shaft seal from being cut upon removal of the end cap. If there is any rust present, remove using 180 grit emery cloth.

The tools that are recommended for a successful repair job are as follows:

"A" AND "B" FRAME MOTORS HOW TO AVOID REPAIRS Maintain cleanliness in your system. Be careful when adding to the reservoir that clean oil is added and the container being used is clean. Proper filtration does not guarantee a contaminate-free system if the filters aren't serviced at regular intervals. Make sure that proper care is taken when installing the motor. If a flexible coupling is used, alignment must be within the coupling range. Do not exceed radial or thrust load ratings of the shaft. For hydraulic surge pressures applied to or by the motor, a close-coupled direct-acting relief valve must be provided in the circuit. The motor must be protected from any pressure surges that exceed twice the pressure rating of the motor.

1. Soft face hammer or mallet. 2. Torque wrench with at least 50 ft. lbs. capacity. 3. 5 116 " Allen wrench adaptable to torque wrench. 4. No. 03 internal snap ring pliers. 5. 3/ i ," Allen wrench for gear cover.

"C" FRAME MOTOR 1. Soft face hammer or mallet. 2. Torque wrench with at least 175 ft. lb. capacity. 3. 1 /2" Allen wrench adaptable to torque wrench. 4. No. 06 external snap ring pliers.

DISASSEMBLY 5. No. 05 internal snap ring pliers. Cleanliness is extremely important when repairing the ROL-SEAL Motor. Before you remove the motor from the system, clean as much debris off of the exterior as possible. The area around the ports is most important. Upon disconnecting use something to plug the ends of the hydraulic lines to prevent contamination of the system.

6. 3116" Allen wrench for gear cover. A bench vise is very helpful in the disassembly and assembly of the ROL-SEAL Motor. Our instructions will be based on the assumption that this item is available.

PAGE 1

ROL-SEAL MOTOR

MODELS RSA, RSB AND RSC

DISASSEMBLY 3.) Using the soft-faced hammer or mallet, tap upward on the ear of the SAE mounting flange. (Fig. 2.) By putting the heel of your hand over the output shaft and your fingers on the opposite ear you can keep the front end cap from falling back down after each successive rap.

When you get beyond the dowel pin engagement there should be no further requirement for the hammer. Simply lift the end cap off of the assembly.

FIGURE 1 1.) Place motor in vise as shown in Fig. 1, tightening vise enough to prevent motor from rocking out. Excessive clamping pressure could damage the inlet and outlet ports. Normally the standard jaws will not contact spotface of ports. 2.) Unfasten the nine cap screws holding the end caps and housing together. (Fig. 1.) Remove the cap screws completely from the assembly.

FIGURE 3

4.) Removal of the displacement housing, (Fig. 3) the dark center portion of the assembly, is carried out similar to step 3. There are two scallops in the rear end cap. It is this area that you tap to remove the housing. (Fig. 3.) Do not ever use any screwdriver or pinch bar to remove this part. It is extremely easy to damage the end cap faces. The dowel pins will remain in the displacement housing. Unless you are replacing the housing, leave them intact. The dowels are a press fit.

NOTE FIGURE 2 PAGE 2

The remaining steps can be performed on a bench.

ROL-SEAL MOTOR

MODELS RSA, RSB AND RSC

DISASSEMBLY 7.) Unfasten the seven socket head cap screws which hold the Model Code and Serial No. plate on the rear end cap.

FIGURE 4 FIGURE 6 5.) Remove seal plates (Fig. 4). 8.) The previous step exposed a set of timing gears. Before removing these parts you must mark them (Fig. 6). The two small gears should also be marked left and right.

FIGURE 5 6.) Remove seal rollers (Fig. 5). The motors have two sizes. The seal rollers in the rotor tip are about 1132nd dia. larger than those behind the seal plates.

FIGURE 7 9.) Remove the snap rings that retain the gears, (Fig, 7) and remove the gears. PAGE 3

ROL-SEAL MOTOR

MODELS RSA, RSB AND RSC

DISASSEMBLY

FIGURE 8 10.) By positioning the rotor as in Figure 8, you can lift one of the abutment valves out. Rotate the shaft and remaining abutment until the paddle of the rotor leaves the abutment cavity. You now can remove this abutment.

FIGURE 9 11.) Lift the rotor up, which will expose the drive key. Remove the drive key. (Fig. 9.) PAGE 4

FIGURE 10

12.) Remove the snap ring which retains the shaft and thrust bearing. (Fig. 10.)

FIGURE 11 13.) Remove the shaft from the rear end cap. (Fig. 11.)

ROL-SEAL MOTOR

MODELS RSA, RSB AND RSC

DISASSEMBLY 14.) The step bearing that remains in the front end cap should be taken out and inspected. There is an 0-ring and Teflon back-up ring under this part. (Fig. 12.)

15.) Check all mating metal-to-metal parts for scratches or burrs which could cause leakage. Replace all parts on which excessive damage is found. Use the following procedure to be sure that all these surfaces are perfectly smooth: Place a piece of 240 grit paper on a flat, smooth surface.

Place the part on the grit paper and stroke gently in a figure eight motion several times. Excessive removal of material should not be done as the parts may not reassemble with proper clearances.

16.) Clean all parts in solvent and let them air-dry. All 0-rings and shaft seals should be replaced. If conditions are such that you have to use the old seals they should be washed in a mild soap and water solution.

FIGURE 12

REASSEMBLY 1.) Install shaft with thrust bearing and races through the back of the rear end cap.

9.) Proceed to assemble the snap rings to retain the gears assembled in the previous step.

2.) Install snap ring to retain shaft.

10.) Set the assembly back on the rear cover face. Install the seal plates and the seal pins in the rotor.

3.) Put spacer over shaft end, and assemble the large timing gear to the shaft. 4.) Assemble snap ring to retain gear. 5.) Turning this subassembly and setting it on the rear cover face, you can install one abutment valve. Install new back-up ring and 0-ring first. A light film of oil should be applied to all new seals. 6.) Reassemble the round drive key in the key seat and slip rotor over key. 7.) Set the subassembly on its side and proceed with the alignment and timing of the abutment and rotor. Either one of the abutments can be assembled.

8.) Rotate the shaft so the second abutment can be installed. Align the timing marks. If the shaft can be rotated one complete revolution, it is likely that the proper assembly has been carried out. NOTE: When properly timed, the rotor tip will pass directly through the center of the abutment cavity.

11.) Place the new 0-ring in the groove of the end cap. A light film of gun grease will help keep the 0-ring from slipping out of the groove. 12.) Install the housing. If binding occurs take a soft faced hammer and tap on the housing to free it. 13.) Install new 0-rings and back-up rings in the front end cap. Put the step bearings in place. Apply a light film of gun grease to the large static seal, and place it in the groove. 14.) Install the front end cap by slipping it over the shaft and watching the static seal to make sure it stays in place. Tapping lightly with a soft face hammer may be required to seat the front end cap. 15.) Set the body cap screws in place and tighten to recommended torque values using a crisscross pattern. Torque settings are for lubricated threads. (see chart on following page)

PAGE 5

ROL-SEAL MOTOR

MODELS RSA, RSB AND RSC

REASSEMBLY FRAME SIZE

16.) Assemble Model Code and Serial No. plate to back of the motor along with new static seal. DISPLACEMENT

TORQUE

"A" and "B"

500 in # (56 N-M)

"A" and "B"

500 in # (56 N-M)

"A" and "B"

500 in # (56 N-M)

"C"

150 ft # (203 N-M)

"C"

150 ft # (203 N-M)

"C"

175 ft # (237 N-M)

SERIAL COVER PLATE

ALL

125 in # (14 N-M)

17.) Before installing new shaft seal, make sure that shaft turns. Then proceed to install new seal and replace snap ring. NOTE: Remove any burrs or raised edges from shaft keyway as not to damage seal lip. 18.) Replace motor in the system and run unit through normal operating cycle.

SEAL REPLACEMENT 1.) Clamp the motor in a vise. Remove the key and all burrs or sharp edges which may have developed. Use 400 grit emery cloth to remove all rust from the shaft. 2.) Remove the snap ring. 3.) Remove front end cap as in steps 1-3 of the disassembly procedure. 4.) Turn end cap with sealing face up. Use a large screwdriver blade inserted between the seal lip and shell. Proceed to pound out seal alternating from side to side so as not to damage the end cap bore. 5.) Replace end cap and torque body bolts to recommended torque, (see chart above.)

PAGE 6

6.) Apply a thin film of grease to the lip of the new seal. Slide over shaft to face of end cap.

7.) The seal must be installed without cocking it. The best procedure is to obtain a short piece of tubing or pipe which is square on the ends and will contact the outer shell of the seal. If the tubing is too small it will damage the seal.

8.) Press seal in just far enough so the snap ring will stay in the seal bore. Using the snap ring to seat the seal will prevent you from pressing the seal in too deep. When the snap ring pops into the groove the seal is properly seated.

ROL-SEAL MOTOR

MODELS RSA, RSR AND RSC

TROUBLE SHOOTING The following chart lists the possible troubles that may be encountered, the probable cause and the remedial action recommended.

TROUBLE SHOOTING CHART -

Trouble

Probable Cause

Remedy

1.) Loose coupling.

1.) Repair or replace coupling.

2.) System relief open.

2.) Clean, adjust, or replace if necessary.

1.) Cavitation at pump.

1.) Check for inlet air leaks. Check pump inlet for restriction.

2.) Reservoir low.

2.) Fill to recommended level.

1.) System relief unloading.

1.) Disassemble, clean, adjust.

2.) Worn out.

2.) Repair or replace.

3.) High temperature operation.

3.) Change to fluid with higher viscosity index.

1.) Drain restriction.

1.) Drain directly to tank.

2.) High case drain.

2.) Repair motor.

Leakage around shaft.

1.) Shaft seal worn out.

1.) Replace.

Motor turns in wrong direction.

1.) Hose connection wrong.

1.) Reverse connections.

No pressure

Noisy system

Motor will not develop torque.

Blown rear cover

PAGE 7

ROL-SEAL MOTOR

PAGE 8

MODELS RSA, RSB AND RSC

FIGURE 13. ROL -SEAL MOTOR EXPLODED VIEW

ROL-SEAL MOTOR

MODELS RSA, RSB AND RSC

PARTS LIST REPLACEMENT PARTS LIST - ROL-SEAL@ MOTOR NOTE When Ordering Replacement Parts, Give Model Number, Serial Number, Item Number, Description and Quantity.

Item

Description

Quantity

1 2 3

Key, Woodruff Pin, Drive Ring, Retaining

3 1 2

4 5 6

Gear, Drive Spacer Ring, Retaining

1 1

7 8 9

Race, Bearing Thrust Bearing, Thrust Bearing, Roller

2 1 2

Seal, 0-Ring Cap, Rear

3 1 3

10 11 12 12A 13 14 15

Pin, Rotor Tip Pin, Seal Plate Rotor Plate, Seal Valve, Rotary Abutment

18 1 3 2

16 17 18

Bearing, Needle Bearing, Step Seal, 0-Ring

4 4 4

19 20 21

Ring, Teflon Backup Pin, Dowel Screw, Cap

4 2 9

23 24

Seal, Shaft Cap, Front

1 1

25 26 27

Housing, Displacement Ring, Retaining Gear, Timing

1 4 2

28 29 30 31 32

Shift, Power Cover, Gear Screw, Cap Ring, Retaining 0-Ring, Front Cap Seal

1 1 7 1 1

PAGE 9

ROL-SEAL MOTOR

PAGE 10

MODELS RSA, RSB AND RSC

PRINTED IN U.S.A.

FORM 201FM

ROL-SEAL® BRAKE REAR-MOUNTED, MULTI-DISC TYPE FOR RSA AND RSC MOTORS WASHINGTON SCIENTIFIC INDUSTRIES, INC. POWER COMPONENTS DIVISION Long Lake, Minnesota 55356 Telephone: (612) 473-1271 TWX: 910-576-2742

MAINTENANCE AND PARTS MANUAL

NOTE ONLY FACTORY OR QUALIFIED DISTRIBUTORS ARE AUTHORIZED TO OVERHAUL AND REPAIR WSI EQUIPMENT. ALL FACTORY WARRANTY IS CANCELLED UPON DISASSEMBLY BY UNAUTHORIZED PERSONNEL.

10/84

FORM 304FP

304 FP 10/84

ROL-SEAL® BRAKE

TABLE OF CONTENTS PAGE

TITLE

INTRODUCTION

HOW TO AVOID REPAIRS

REAR MOUNTED BRAKE ASSEMBLY

TOOLS REQUIRED

DISASSEMBLY

REASSEMBLY

PARTS LIST

304 FP 10/84

ROL-SEAL® BRAKE

INSTRUCTION MANUAL

INTRODUCTION

CASE DRAIN

This Wet Disc Type Brake was designed to fit on the W.S.I. Rol-Seal®Motor to provide either dynamic braking, or as a mechanical means of locking the motor shaft to prevent motor drift due to overhanging loads. The number of disc brake sets provide for a higher static torque loading than the dynamic torque rating of the hydraulic motor.

These units are provided with a case drain connection. A line must be provided to return case drain flow to the reservoir at no more than 250 PSI surge pressure. Cross port check valves are optional for internal drain but should not be used where instantaneous shock pressures occur, such as in dynamic braking.

HOW TO AVOID REPAIRS

OTHER BRAKE SPECIFICATIONS

Maintain cleanliness in your hydraulic system. Be careful when adding to the reservoir that clean oil is added and the container being used is clean. Proper filtration does not guarantee a contaminate-free system if the filters aren't serviced at regular intervals. Caution should be used when connecting the brake release pressure port to the brake housing inasmuch as the drain port is adjacent to the pressure port.

WK2 of brake 2 6 lb. in. 2 Volume of oil to release brake 0 6 in. 3 Torque holding capacity 2 in. 3 3 in. 3 4 in. 3 940 lb. in. 1410 lb. in. 1880 lb. in.

PAGE 1

304 FP 10/84

ROL-SEAL© BRAKE

DISASSEMBLY

FIGURE 1. SECTIONAL VIEW, ROL-SEAL® BRAKE REAR MOUNTED BRAKE ASSEMBLY

TOOLS REQUIRED: 1/4 alien wrench NOTE: If it is necessary to remove adapter plate (8), a %, alien wrench and centering fixture (available from factory) will be required.

4. Remove remaining brake components. (To remove brake piston (10), it may be necessary to inject shop air (80 PSI max.) into pressure port "P". PLEASE NOTE: If air is used, precautions must be taken to retain piston so as to eliminate the possibility of injury!)

DISASSEMBLY (Figure 1)

5. Remove the back-up rings (11, 15), and 0-rings (12, 14) from the housing (1).

1. Thoroughly clean the exterior of the assembly and hydraulic lines before attempting removal.

6. If it's necessary to remove the adapter plate (8) from the motor, remove the seven cap screws (7).

2. Disconnect hydraulic lines and cap them to prevent loss and contamination of fluid.

7. Clean all components in solvent and dry.

3. Remove the eight cap screws (13), and separate the brake housing (1) from the adapter plate (8). Discard 0-ring (5).

PAGE 2

8. Inspect all components for wear and damage. Replace components unfit for service. Note quantities of friction discs (3) and drive plates (4) in parts lists on following pages.

304 FP 10/84

ROL-SEAL® BRAKE

REASSEMBLY (See Figure 2) 3. Lubricate all components with clean hydraulic fluid. 4. Position the spacer rings (2) in the housing (1). NOTE: Spacer ring thickness varies with motor size. See parts list. 5. Locate friction disc (3) in the housing; then a driver plate (4); then another friction disc (3); and so on depending on model, making sure driver plate splines are aligned. 6. Carefully install the pressure plate (10) in the housing so as not to damage the 0-rings (12, 14). Place the eight die springs (9) in the pressure plate. FIGURE 2. CENTERING FIXTURE 7. Position a new 0-ring (5) in the housing using a little grease to hold it in place. 1. If adapter plate (8) is removed, reassemble on the motor using a centering fixture available from factory. Install capscrews (7) with washers (6) including 0-rings (16) for RSC brake and torque to 150 in. lb. 2. Install new 0-rings (12, 14) and back-up rings (11, 15) in the housing (1). Make sure the ends of the back-up rings are flush and not overlapped.

8. To assemble motor to brake, carefully drop shaft while engaging the plate drivers (4) with the splined motor shaft. 9. Secure the housing to the adapter plate with the eight cap screws (13). Tighten and torque the cap screws to 300 in. lbs. 10. Connect the hydraulic lines.

NOTE: Backup rings (11, 15) must be in position as shown in sectional view.

11. Test the brake for operation and leaks.

PAGE 3

304 FP 10/84

ROL-SEAL® BRAKE

PARTS LIST REPLACEMENT PARTS LIST—REAR MOUNTED BRAKE ASSEMBLY MODELS RSA02, RSA03, RSA04, RSB02, RSB03, RSB04, BRAKE NOTE When ordering replacement parts, give model number, serial number, item number, part number, description and quantity.

FIGURE 3. EXPLODED VIEW RSA AND RSB SERIES BRAKE

PAGE 4

Item

Part No.

1 2 2 2 3

C-63086 A-63095 A-63096 A-63120 B-62308

B-63100

5 6 7 8 9 10 11 12 13 14 15

A-63097 A-60709 A-60955 C-63087 A-62298 B-63093 B-62303 B-62301 A-61716 B-62302 B-62304

Description Housing Spacer Ring 2 Cubic Inch Spacer Ring 3 Cubic Inch Spacer Ring 4 Cubic Inch Friction Disc 2 Cubic Inch 3 Cubic Inch 4 Cubic Inch Plate Driver 2 Cubic Inch 3 Cubic Inch 4 Cubic Inch 0-Ring Brass Washer Cap Screw—Socket Head Adapter Plate Die Spring Pressure Plate Back-Up Ring 0-Ring Cap Screw—Socket Head 0-Ring Back-Up Ring

Quantity 1 1 1 1 3 4 5 2 3 4 1 7 7 1 8 1 1 1 8 1 1

304 FP 10/84

ROL-SEAL® BRAKE

PARTS LIST REPLACEMENT PARTS LIST RSC MODEL ROL-SEAL® BRAKE NOTE When ordering replacement parts, give model number, serial number, item number, part number, description and quantity.

FIGURE 4. EXPLODED VIEW

14 Item

Part No.

1 2 2 2 3

C-63086 A-63118 A-63119 A-63079 B-62308

B-63099

5 6 7 8 9 10 11 12 13 14 15 16

A-63097 A-60709 A-60500 C-63089 A-62298 B-63093 B-62303 B-62301 A-61716 B-62302 B-62304 A-60846

15 RSC SERIES BRAKE Description Quantity Housing Spacer Ring 6 Cubic Inch Spacer Ring 8 Cubic Inch Spacer Ring 10 Cubic Inch Friction Disc 6 Cubic Inch 8 Cubic Inch 10 Cubic Inch Driver Plate 6 Cubic Inch 8 Cubic Inch 10 Cubic Inch 0-Ring Brass Washer Cap Screw—Socket Head Adapter Plate Die Spring Pressure Plate Back-Up Ring 0-Ring Cap Screw—Socket Head 0-Ring Back-Up Ring 0-Ring

1 1 1 1 7 9 12 6 8 11 1 6 6 1 8 1 1 1 8 1 1 2 PAGE 5

304 FP 10/84

PRINTED IN U.S.A.

ROL-SEAL® BRAKE

FORM 304FP

Torque-Hub Final Drives Service Manual W1 ‘13' DRIVE

Fairfield Manufacturing Company, Inc.

Fa. l ief l e l

South Concord Road, Lafayette, Indiana 47902, U.S.A. 317/474-3474

Introduction This Service Manual is a step-by-step guide designed for the customer or shop mechanic who is servicing or repairing a particular model of Torque-Hub Final Drive. (The model covered by this copy of the Manual is specified on the Manual cover.) Included are — 1. assembly and exploded view drawings 2. disassembly procedure 3. main assembly procedure (assuming all sub-assemblies to be intact) 4. sub-assembly procedures. At the time of printing, this Manual was complete for the specific Torque-Hub model designated. However, Fairfield Manufacturing Co., Inc., reserves the right to update and improve its products at any time. All specifications and procedures are therefore subject to change without notice.

Safety Standard safety practices should be followed during the disassembly and assembly procedures described. Safety glasses and safety shoes should be worn; heavy, heat resistant gloves should be used when heated components are handled. Be especially alert when you see a caution symbol (A). This symbol indicates that a particular operation could cause personal injury if not, performed properly or if certain safety procedures are not followed.

W1 A-W1 B Disassembly Procedure 1. Loosen all 16 Cover Bolts and drain the oil from the unit. 2. Remove the 16 Cover Bolts and lift off the Cover Sub-Assembly. Discard the '0' ring Seal from the Cover counterbore. 3. Lift out the Carrier Sub-Assembly and the top Thrust Washer. The Thrust Washer may stick inside the Cover. 4. Pry the Ring Gear loose and remove it. Discard the '0' ring Seal from the Hub counterbore. 5. Remove the Input Shaft, Input Gear, and the Thrust Spacers that are on the Input Shaft. 6. Lift out the internal Gear and Thrust Washer. The Thrust Washer may stick to the bottom of the Carrier. 7. Remove the Retaining Ring from the Spindle and discard; then lift the hub off the Spindle. 8. The inside Bearing Cone and the Bearing Shim can now be removed. 9. The Seal can be pried out of the Hub with a screw driver or pry bar. This will also allow the outside Bearing to be removed. Note: If bearing replacement is necessary, the Bearing Cups can be removed with a "slide hammer puller" or driven out with a punch.

10.To remove the Cluster Gears from the Carrier, drive the anti-roll pin into the Planet Shaft of the Cluster Gear. After the Planet Shaft is removed the roll pin should be driven out of the Planet Shaft. WARNING: When rebuilding the unit, the '0' rings and Retaining Rings should always be replaced.

Main Assembly Procedure 1. Using an arbor type press if available, press Bearing Cups with large inside diameters facing out, into Hub counterbores. Cup #JLM506810 will go into small end of Hub, and Cup #JM2051 10 will go into large end of Hub. If Studs are being used, they can be pressed in at this time. Solid support must be used in this operation.

2. Place Bearing cone #JLM506849 into Bearing Cup in small end of Hub.

3. Press Seal into Hub counterbore with flat metal side facing in. Use a flat object to assure that Seal is pressed evenly and is flush with Hub face.

4. Lower Hub onto Spindle with large open end up.

5. Place Bearing Cone #JM205149 over end of Spindle and into Bearing cup.

6. Place Bearing Shim over end of Spindle and against Bearing Cone.

7. Secure Retaining Ring completely into Spindle groove and against Bearing Shim. Be sure that Retaining Ring is entirely in groove. LEye protection should be worn during Retaining Ring installation.

8. Place Internal Gear onto end of Spindle.

41,

9. Place Input Shaft Assembly into Spindle bore with unsplined end facing out.

10.Place narrow Thrust Spacer over Input Shaft with counterbore side facing Spindle.

11.Place '0' Ring into Hub counterbore. Use petroleum jelly or grease to hold '0' Ring in place. Slight stretching of the '0' Ring may be necessary to insure proper seating.

\ position punchmarks at 12 o'clock

12.Place Carrier Assembly on a flat surface with the large gears up and positioned as shown. Find the punch marked tooth on each large gear and locate at 12 o'clock (straight-up) from each planet pin. Marked tooth will be located just under the Carrier on upper two gears.

13.With shoulder side of Ring Gear facing down, place Ring Gear over (into mesh with) large gears. Be sure that punch marks remain in correct location during Ring Gear installation.

14. Turn over Carrier Assembly and Ring Gear while keeping gears in mesh. Place Thrust Washer into Carrier counterbore. Use petroleum jelly or grease to hold washer in place.

15. While holding Ring Gear, Input Gear and Cluster Gears in mesh, place small side of Cluster Gears into mesh with the Internal Gear. On the Ring Gear locate the hole marked "X" over one of the counterbored holes in Hub. Mark these holes on outside diameter for later use.

Note If gears do not mesh easily or Carrier Assembly does not rotate freely, then remove the Carrier and Ring Gear and check the Cluster Gear timing.

16. Place Thrust Washer into Carrier counterbore.

17. The Input Gear is now installed into the carrier meshing with the large diameter cluster gear. The counterbore in the bore of the Input Gear must be to the inside of this assembly.

19.Place '0' Ring into Cover Assembly counterbore. Use petroleum jelly or grease to hold '0' Ring in place.

20.Place Cover Assembly over Ring Gear with oil level check plug in Cover located approximately 90° from oil fill plug in Hub.

21.Locate four Shoulder Bolts with flat washers, 90° apart into counterbored holes in Hub marked in step 16. Torque Shoulder Bolts to 23-27 ft. lbs.

22.Use standard grade 8-5/16-18x2 1/4 bolts with flat washers in remaining holes. Torque to 23-27 ft. lbs.

23.Place Coupling into Spindle and onto Input Shaft.

■

This completes the Torque-Hub Assembly. The unit must be filled onehalf full of EP90 lubricant before operation.

4s se r,r, ,,

Assembly Procedure For Sub-Assemblies Input Shaft Sub-Assembly 1. Place Washer, Spring and Washer, in that order, onto Input Shaft.

2. Install Retaining Ring into Input Shaft groove to secure Spacers and Spring to shaft. Z._\ Eye protection should be worn during Retaining Ring installation.

Carrier Sub-Assembly 1. Apply a coat of grease or petroleum jelly to Cluster Gear bore.

2. Place sixteen Needle Rollers into Cluster Gear bore.

3. Place Spacer washer into opposite side of Cluster Gear and against Needle Rollers.

4. Place second set of sixteen Needle Rollers into Cluster Gear.

5. Apply grease or petroleum jelly to the tang side of two Thrust Washers. Place Thrust Washers against bosses in Carrier with washer tang fitting into slot in Carrier outside diameter. Note: Some old style Carriers will not have slots and tangs should be located inside boss relief.

6. While keeping Thrust Washers in place, slide Cluster Gear into Carrier with the larger gear on the side with the small pin hole.

7. Line up Cluster Gear and thrust Washers with hole in Carrier and slide Planet Shaft through. Line up chamfered side of hole in Planet Shaft with pin hole in Carrier.

VIMMEN=OMI

8. Drive Anti-Roll Pin flush into Carrier hole, thereby locking Planet Shaft into place. Repeat these steps for remaining two Cluster Gears to complete Carrier Sub Assembly.

Cover Sub-Assembly 1. Screw Pipe Plug into Cover.

2. Slip '0' Ring over Cover Cap and against face.

3. Place '0' Ring into Cover Cap internal groove. The Disconnect Rod may be used to push '0' Ring into groove.

4. Place Cover Cap into Cover with large hole located over Pipe Plug. Secure Cover Cap to Cover with two 1/4-20x 3/4 bolts. Torque bolts to 70-80 in. lbs.

5. Place Disconnect Cap over Cover Cap with nipple facing out. Secure Disconnect Cap to Cover with two 1/4-20x 3/4 bolts. Torque bolts 70-80 in. lbs.

6. Turn Cover over and push Disconnect Rod into Cover Cap. Rod will be held in place by friction from the '0' Ring.

Cover Sub-Assembly

3B f7B

bpi

'6F; 6E) bD'

■

,, ,- , - ii: ".`, - • '9 ` ..,%.•• )

TORQUE '13)

Fakfieid 8 THE OR, VE 0 EOPL E

DRIVE b,

LAFAYET,, INP.A

CONDOR MODEL 46N 36N, 481 TORQUE HUB, CALAVAR PART NO. 32084 ITEM

QTY.

PART NO.

DESCRIPTION

W18140

Hub-Spindle Sub-Assembly

1400703

Spindle

1501301

Seal

1500803

Brg. Cup (JLM506810)

1500804

Brg. Cone (JLM506849)

1500805

Brg. Cup (JM205110)

1500806

Brg. Cone (JM205149)

1500603

Hub

1900904

Spacer

910006

Retaining Ring

950002

Pipe Plug

970004

Stud

1400066

Internal Gear

1200028

Carrier Assembly

1200503

Carrier

1200310

Thrust Washer

1200803

Needle Roller

1201002

Spacer

1200101

Planet Shaft

1300028

Cluster Gear

920002

Roll Pin

1500073

Ring Gear

1940001

"0" Ring

1500406A

Cover Assembly

1500406

Cover

1900402

Cover Cap

930004

Bolt

1900401

Disconnect Cap

.6E

1900101

Disconnect Rod

940001

"0" Ring

940002

"0" Ring

950001

Pipe Plug

901201

ID Plate

Condor Model 46N 36N, 48 Torque Hub, Calavar Part No. 32084 - continued:

ITEM

PART NO.

1100104A

QTY.

DESCRIPTION

Input Shaft Assembly

1100104

Input Shaft

910007

Retaining Ring

1901501

Spring

1201002

Spacer

1100017

Input Gear

1901001

Thrust Spacer

1200301

Thrust Washer

930101

1930201

Shoulder Bolt

1100203

Coupling

960201

Bolt

Flat Washer

Torque-Hub Final Drives Service Manual W3

B DRIVE

Fairfield Manufacturing Company, Inc.

Fai l ief l el South Concord Road, Lafayette. Indiana 47902, U.S.A. 317/474-3474

Safety Standard safety practices should be followed during the disassembly and assembly procedures described. Safety glasses and safety shoes should be worn; heavy, heat resistant gloves should be used when heated components are handled. Be especially alert when you see a caution symbol (A). This symbol indicates that a particular operation could cause personal injury if not performed properly or if certain safety procedures are not followed.

W3B-W3C Disassembly Procedure 1. Loosen all 12 Cover Bolts and drain the oil from the unit. 2. Remove the 12 Cover Bolts and lift off the Cover Sub-Assembly. Discard the '0' ring Seal from the Cover counterbore. 3. Lift out the Carrier Sub-Assembly and *Thrust Bearing Set. A Thrust Washer may stick inside the Cover. 4. Pry the Ring Gear loose and remove it. Discard the '0' ring Seal from the Hub counterbore. 5. Remove the Input Shaft, Input Gear, and the Thrust Spacers that are on the Input Shaft. 6. Lift out the Internal Gear and Thrust *Bearing Set. A Thrust Washer may stick to the bottom of the Carrier. 7. Remove the Retaining Ring from the Spindle and discard; then lift the hub off the Spindle. Eye protection should be worn during Retaining Ring removal. 8. The inside Bearing Cone and the Bearing Shim can now be removed. 9. The Seal can be pried out of the Hub with a screw driver or pry bar. This will also allow the outside Bearing to be removed. Note: If bearing replacement is necessary, the Bearing Cups can be removed with a "slide hammer puller" or driven out with a punch.

Main Assembly Procedure 1. Using an arbor type press if available, (if not, a hammer may be used), install the wheel studs. The hub flange should be supported from the underside during this operation. Note: Wheel studs are optional.

2. Using an arbor type press if available, press Bearing Cups with large inside diameters facing out, into Hub counterbores. Cup #JM716610 will go into small end of Hub, and Cup #JM515610 will go into large end of Hub.

3. Place Bearing cone #JM716649 into Bearing Cup in small end of Hub.

4. Press Seal into Hub counterbore with flat metal side facing in. Use a flat object to assure that Seal is pressed evenly and is flush with Hub face.

5. Lower Hub onto Spindle with large open end up.

6. Place Bearing cone #JM515649 over end of Spindle and into Bearing Cone.

7. Place Bearing Shim over end of Spindle and against Bearing Cone.

8. Secure Retaining Ring completely into Spindle groove and against Bearing Shim. Be sure that Retaining Ring is entirely in groove. L. Eye protection should be worn during Retaining Ring installation.

9. The pipe plugs are installed in the Hub. The use of lub-seal is recommended on the pipe plug.

10. The disengage spacer and spring are installed into the co'bore of the Spindle.

11. Another spacer and the correct Retaining Ring are installed into the Spindle co'bore and Retaining Ring groove provided. Eye protection should be worn during Retaining Ring installation.

12. The internal gear is installed matching the Bore Spline to the Spindle Spline.

13. The thrust washer/thrust bearing set is installed on the portion of the Spindle which extends into the internal gear.

14. The O'Ring is placed into the counterbore provided in the Hub. Slight stretching may be necessary. Use sufficient grease or petroleum jelly to hold in place.

15.1nstall retaining ring into input shaft retaining ring groove.

16.The input shaft is installed into the spindle. The action of the spring should be checked at this point.

17.The thrust spacer is installed on the input shaft.

18.Locating the four counter reamed holes in the face of the hub, mark them for later identification. These holes are reamed to accept the shoulder bolts.

position punchmarks at 12 o'clock

19.Place Carrier Assembly on a flat surface with the large gears up and positioned as shown. Find the punch marked tooth on each large gear and locate at 12 o'clock (straight-up) from each planet pin. Marked tooth will be located just under the Carrier on upper two gears.

20.With shoulder side of Ring Gear facing down, place Ring Gear over (into mesh with) large gears. Be sure that punch marks remain in correct location during Ring Gear installation. The side of the Ring Gear with an "X" stamped on it should be up.

21 .While holding Ring Gear and Cluster Gears in mesh, place small side of Cluster Gears into mesh with the Internal Gear. On the Ring Gear locate the hole marked "X" over one of the marked counterbored holes in Hub.

Note:

If gears do not mesh easily or Carrier Assembly does not rotate freely, then remove the Carrier and Ring Gear and check the Cluster Gear timing.

22.The Input Gear is installed into this assembly meshing with the larger diameter Cluster Gear. The counterbored side of the Input Gear is installed down or to the inside of the unit.

23.After inserting at least one Shoulder Bolt in the proper location, rotate the Carrier. This is to check freedom of rotation and recheck the timing.

24.Another thrust washer/thrust bearing set is now installed into the counterbore in the face of the carrier.

25.Place O'Ring into cover assembly counterbore. Slight stretching may be necessary. Use sufficient grease or petroleum jelly to hold in place.

26.Place cover assembly on Ring Gear with oil level, check plug in cover located approximately 90° from oil fill plug in Hub.

27.Locate four shoulder bolts 90° apart into counterbored hole in Hub which were marked in step 17. Torque each bolt to 47 ft. lbs.

28.Install grade eight bolts into the remaining eight holes and torque all bolts to 47 ft. lbs. Use the 180° to 90° method in torqueing all bolts.

29.Place Coupling into the Spindle and onto the Input Shaft. Note: W3C units must have one external and one internal Snap Ring installed. All units with a "X" on the end of the model number must have two internal Snap Rings with a spacer between them installed in the Coupling.

This completes the assembly. The unit must be filled one-half full of EP 90 lubricant before operation.

Carrier Sub-Assembly 1. Apply a coat of grease or petroleum jelly to Cluster Gear bore.

2. Place fourteen Needle Rollers into Cluster Gear bore.

3. Place Spacer washer into opposite side of Cluster Gear and against Needle Rollers.

4. Place second set of fourteen Needle Rollers into Cluster Gear.

6. While keeping Thrust Washers in place, slide Cluster Gear into Carrier with the larger gear on the side with the small pin hole.

7. Line up Cluster Gear and thrust Washers with hole in Carrier and slide Planet Shaft through. Line up chamfered side of hole in Planet Shaft with pin hole in Carrier.

8 Drive Anti-Roll Pin flush into Carrier hole, thereby locking Planet Shaft into place. Repeat these steps for remaining two Cluster Gears to complete Carrier Sub Assembly.

Cover Sub-Assembly 1. Screw Pipe Plug into Cover.

2. Place '0' Ring into Cover Cap internal groove. The Disconnect Rod may be used to push '0' Ring into groove. Rod will be held in place by friction from the '0' Ring.

3. Slip '0' Ring over Cover Cap and against face.

4. Place Cover Cap into Cover with large hole located over Pipe Plug.

5. Install two 1/4 x 20 x 3/4 bolts 180° apart and torque to 70 - 80 in. lbs.

6. Place disconnect cap over cover cap with nipple facing out and align with two open holes. Secure disconnect cap to cover with two 1/4 x 20 x 3/4 and 70 - 80 in. lbs.

3C ,

61)

(3G

TORQUE W3

(A) HUB

Fairfield

DRIVE Me Calif PE°Fte LAFAYETTE, NOUAA

FOR MATERIAL HANDLING EQUIPMENT, FARM MACHINERY, ROAD EQUIPMENT, MINING MACHINERY, ETC.

Fairfield Manufacturing Company, Inc.

Fa iten lel South Concord Road, Lafayette, Indiana 47902, U.S.A. 317/474-3474

Lubrication Type — EP 90 Oil Temperature • Continuous — 160°F • Intermittent — 200•F Oil Change • initial — After 50 hours of operation • Subsequent — 1000 hours or one year which ever comes first Oil Fill Level • Unit mounted horizontal — half-full

• Shaft or spindle mounted down — lubrication must be as high as top of cluster bearings per chart

CONDOR MODELS 50 & 56 TORQUE HUB - CALAVAR PART NO. 21486

REF

1lA 1B 1C 1D 1E 1F 1G 1H 1I 1J 1N 233A 3B 3C 3D 3E 3F 3G 4566A 6B 6C 6D 6E 6F 6G 6H 6J 6K 789101112131516171819-

DESCRIPTION Hub-Spindle Sub-Assembly Spindle Seal Bearing Cup (JM71661C) Bearing Cone (3M716649) Bearing Cup (3M515610) Bearing Cone (JM515649) Hub Spacer Retaining Ring Pipe Plug Stud Internal Gear Carrier Assembly Carrier Thrust Washer Needle Roller Spacer Planet Shaft Cluster Gear Roll Pin Ring Gear 0-Ring Cover Assembly Cover Cover Cap Bolt Disconnect Cap Disconnect Rod 0-Ring 0-Ring Pipe Plug ID Plate Drive Screw Washer Spring Retaining Ring Retaining Ring Input Shaft Thrust Spacer Input Gear Thrust Washer Thrust Bearing Bolt Shoulder Bolt Coupling

PART NUMBER W3B110 3400702 3501301 3500803 3500804 3500805 3500806 3500601 3900904 910002 950003 970001 3400079 3200031 3200505 3200305 3200801 3201001 3200101 3300031 920001 3500085 3940001 3500402A 3500402 3900402 930004 3900401 3900101 940001 940003 950001 901201 930301 3901004 3901501 910003 910016 3100109 3901001 3100023 3200306 3200307 930102 3930201 3100205

QTY 1 1 1 1 1 1 1 1 1 5 2 10 1 1 1 6 84 3 3 3 3 1 2 1 1 1 4 1 1 1 1 2 1 4 2 1 1 1 1 1 1 4 2 8 4 1

CONDOR MODELS 58, 68 AND 76 TORQUE HUB, CALAVAR PART NO. 21492 PART NO.

ITEM 1

QTY.

W3B110

DESCRIPTION

HUB-SPINDLE SUB-ASSEMBLY

3400702

Spindle

3501301

Seal

3500803

Brg. Cup (JM716610)

3500804

Brg. Cone (JM716649)

3500805

Brg. Cup (JM515610)

3500806

Brg. Cone (JM515649)

3500601

Hub

3900904

Spacer

910002

Retaining Ring

950003

Pipe Plug

970001

Stud

3400081

INTERNAL GEAR

3200001

CARRIER ASSEMBLY

3200505

Carrier

3200305

Thrust Washer

3200801

Needle Roller

3201001

Spacer

3200101

Planet Shaft

3300001

Cluster Gear

920001

Roll Pin

3500085

RING GEAR

3940001

"0" RING

3500402A

COVER ASSEMBLY

3500402

Cover

3900402

Cover Cap

930004

Bolt

3900401

Disconnect Cap

3900101

Disconnect Rod

940001

"0" Ring

940003

"0" Ring

950001

Pipe Plug

CONDOR MODELS 58, 68 AND 76

TORQUE HUB, CALAVAR PART NO. 21492 ITEM

PART NO.

QTY.

DESCRIPTION

901201

ID Plate

930301

3901004

Drive Screw WASHER

3901501

SPRING

910003 910016

1 1

RETAINING RING RETAINING RING

3100109

13 15 16

3901001 3100023 3200306 3200307

1 1 4 2

17 18 19

930102 3930201 3100205

8 4 1

INPUT SHAFT THRUST SPACER INPUT GEAR THRUST WASHER THRUST BEARING BOLT

7 8 9 10 11 12

SHOULDER BOLT COUPLING

ACW1 1 2A,D

SUNDSTRAND SAUER

ACW112A,D Level Controller BULLETIN 95 - 8952 - 3

APPLICATION The ACW112 Level Controller measures deviation from a gravity reference for mobile equipment such as hillside combines and aerial lifts. Its sensing and amplifying components are contained within a single compact housing and are powered by either a 12 or 24 volt dc electrical system. The controller senses level through the interaction of a bearing-suspended magnetic pendulum and Hall proximity sensors. Signals from the Hall sensors drive the amplifier, which provides ON-OFF electric output totwo solenoid valves. The switching signal is instantaneous on the ACW112A and is delayed either one quarter or one half second on the ACW112D to allow it to disregard momentary slope deviations. Additionally, the ACW112D has short circuit protection. Both have instantaneous turn-off.

VOLTAGE DROP 2.3 Vdc for A 2.5 Vdc for D

LOAD CURRENT 4 amperes maximum

FEATURES •

Capable of operation under severe dust and moisture conditions

•

Solid state circuitry

•

Rugged aluminum housing

•

Specially damped to resist response to normal machine oscillations

•

Capable of driving solenoid valves directly, with out additional signal amplification

TIME DELAY One quarter and one half second turn-on delays available on the ACW112D.

AVERAGE SHORT CIRCUIT CURRENT (ACW112D ONLY) .7 amp maximum with .5 ohm maximum from output to ground.

SETPOINT Fixed ±1 ° , ±1%° , and ±5 ° models available. Consult Sundstrand-Sauer for other options.

DIFFERENTIAL Typically less than % degree, turn-on to turn-off.

SPECIFICATIONS INPUT VOLTAGE 11 to 15 volts dc for 12 volt models; 22 to 30 volts dc for 24 volt models.

When the Level Controller is used as a switch to a tip alarm in rechargable battery-operated electrical systems, the warning device will not sound if the system voltage drops below the input voltage rating for the relay to the alarm.

VIBRATION Withstands a vibration test designed for mobile equipment controls that includes two parts: 1. Cycling from 5 to 2000 Hz over a range of ±1.5 g's to ±3.0 g's for a period of one hour (if there are four resonant points), for two hours (if there are two or three resonant points) and for three hours (if there is one or no resonant point). Cycling test performed on each of the three major axes. 2. Resonance dwell for one million cycles over a range of ±1.5 g's to ±3.0 g's for each of the four most severe resonant points on each of the three major axes.

SPECIFICATIONS (continued page 2)

▪▪

STORAGE TEMPERATURE -40° to +77° C (-40° to +170° F)

SPECIFICATIONS (continued from page 1) SHOCK 50 g for 11 milliseconds. Three shocks in both directions of the three major axes, totaling 18.

WEIGHT 3 pounds, 1 ounce (1.4 kg).

OPERATING TEMPERATURE -18° to +60° C (0° to 140° F). The ACW112 will operate from -40° to +66° C (-40° to +150 ° F) with more liberal specifications.

DIMENSIONS Refer to Figure 1.

95,2 mm (3.75) 47,6 mm (1.875)

LEARANCE HOLES FOR 1/4 INCH BOLTS ( 3)

138 mm (5.44) 119 mm (4.69)

9,52 mm (.375)

GAUGE POINTS FOR LEVELING

76,2 mm (3.0) 301A

4 LEADWIRES, 610 mm (24.0)

FIGURE 1. Approximate mounting dimension of the ACW112 in millimeters (inches).

THEORY OF OPERATION The ACW112 houses a pendulum suspended from two ball bearings on a horizontal fixed shaft. The pendulum acts as the system's gravity reference for vertical. Four permanent magnets assembled in an arc on the lower portion of the pendulum activate two solid state Hall Effect switches. Refer to Figure 2. When the sensitive area of the switch is exposed to magnetic flux from the magnet's north pole, the switch is held in the OFF position, the opposite being true for the south poles. When leveled, both north poles are above both switches, which are consequently OFF. When the unit is tilted to the right, as in Figure 3, the switches rotate such that the right switch is exposed to a south pole and the left to a north pole. Thus the right switch is ON and the left switch if OFF. In the ACW112D, the Hall Effect switch turns ON, discharging a capacitor

through a series resistor to start the time delay. When the voltage drops below the quarter of the reference voltage, one half of the dual comparator switches on the low state. Its output is amplified by a Darlington power transistor. In the ACW112, the Darlington transistor amplifies the Hall Effect switch's output directly. When driven to saturation, the transistor operates the solenoid valve load. A diode interlock circuit allows an external manual switch to override the controller. When short circuit current reaches 5 amps in the D model, a currentsensing resistor triggers a uni-junction transistor to charge the timing capacitor on the hot side. This turns the Darlington transistor OFF. A short time delay follows until the Darlington turns ON again and the cycle repeats. The components are kept from burning because the ratio of time ON to time OFF is low.

95-8952-3

FIGURE 2. ACW112 at level.

FIGURE 3. ACW112 off-level.

POWER SWITCH

5 AMP \...100-- +12 VDC JOG SWITCH

RED ORANGE

WERED ONCCW E RR O

ACW112 LEVEL CONTROLLER

WERED ON C W ERRO

CCW

SOLENOID VALVE

YELLOW BLACK FRAME GROUND

284-a

/I\ ROTATION AS VIEWED FROM COVERSIDE OF LEVEL CONTROLLER.

FIGURE 4. Typical wiring to the ACW112.

INSTALLATION MOUNTING

WIRING

Before tighting down the mounting screws, the controller must be leveled. Be sure the machine is level too. Use washers on the screws to make leveling easier. Place a small bubble level against the gauge points on the right side edge of the base. Tighten the mounting screws firmly after the controller is level.

A suggested wiring scheme is given in Figure 4, utilizing a power switch, JOG switch and a fuse. These are additional, optional components and are not supplied with the ACW112 Level Controller. Be sure the black leadwire is grounded to the machine frame (minus side of the electrical system). A poor ground connection will

damage the controller.

95-8952-3

ADJUSTMENT The turn-on points of the Level Controller are factory set to order specification. Field adjustment is not recommended. However, in new applications, it may be necessary to change the setting for a particular type of machine. Should the turn-on points need adjustment, use the following procedure. ❑ 1. Turn power OFF and remove the ACW112 from the machine. Wipe off as much dirt as possible, particularly from the gasket edge. The controller contains 200 cc's damping fluid and care must be exercised when removing the cover to retain this fluid. The fluid can be captured in the cover when the controller is taken apart by positioning the controller with the cover down while removing the cover screws. Separate the base assembly from the cover and allow most of the oil to drain off.

It should be noted that this adjustment procedure is for the right blade; for small changes, the right blade only need be changed. If we assume that the controller initially was factory adjusted to give switch turn-on points of ±1'/2° setting with an additional ±1/22 added to this for a total of 2° switch turn-on points. In the example just given, since the right blade only was moved, it will be necessary to mount the controller 1/2° off the vertical on the machine in order to maintain the same level position that was established prior to the switch change.

❑ 2. Measure the distance from the edge of the right blade to its mounting boss and record this dimension. See Figure 5. Loosen the right blade locking screw. To widen the turn-on point, adjust the right blade outward. A change in the right blade position to its mounting boss of .048 inch will change the switch point a total of 1 ° . Changes of less than 1/2° are not recommended. • ❑ 3. Hold the blade in its new position and tighten the blade locking screw. ❑ 4. Hold the base assembly upright and rotate it side to side to be sure that the pendulum swings freely. Some stickiness due to the oil will be observed when the pendulum touches the stop post. ❑ 5. Place the base assembly on the cover and install the cover screws. Mount the control on the machine and check for proper operation.

FIGURE 5. ACW112 internal assembly with adjustment scale.

ORDERING INFORMATION See Table I for listing of preferred models. Consult Sundstrand-Sauer for other options.

SPECIFY 1. Model number (ACW112A, or D Level Controller). Two controllers must be ordered for controling two axes. 2. Voltage (12 or 24 Vdc). 3. Setpoint desired. 4. Time delay (when ordering the ACW1120).

REPLACEMENT PARTS 1. Refill kits containing the correct amount of silicon fluid (200 cc) for refilling one controller. Order with Part Number 24400106-001 for 1000 cs or 24400106-005 for 5000 cs. 2. Replacement Hall Effect switch. Order Part Number 240011511-001. 4

ORDER FROM SUNDSTRAND-SAUER 3900 Annapolis Lane North Minneapolis, Minnesota 55447 (612) 559-2121

DEVICE REPAIR For devices in need of repair, include a description of the problem, a copy of the purchase order and your name and address,

RETURN TO SUNDSTRAND-SAUER Return Goods Department 3900 Annapolis Lane North Minneapolis, Minnesota 55447

95-8952-3

TABLE I. PREFERRED MODELS

95-8952-3

O.S. NUMBER

VOLTAGE

ACW112A1106 ACW112A1130 ACW112A1171 ACW112A1189 ACW112A1197

12 Vdc 12 Vdc 24 Vdc 24 Vdc 12 Vdc

ACW112D1004 ACW112D1020 ACW112D1038 ACW112D1061

12 Vdc 12 Vdc 24 Vdc 24 Vdc

TIME DELAY

SWITCH POINTS

VISCOSITY

NONE NONE NONE NONE NONE

±11/2° ±1 ° ±1 1/2° ±1 ° ±4%°

5,000 CS 5,000 CS 5,000 CS 5,000 CS 5,000 CS

1/2 SEC. 1/2 SEC. 1/2 SEC. 1/2 SEC.

±1 ° ±1 1/2° ±1Y2° ±1 °

1,000 CS 1,000 CS 1,000 CS 1,000 CS

3. 3 3134 33 37 39

0171I 11:1606111finm. 0

Ne119 1.11 ri■

11 is

.0117.11 11

himma ■-40i

43 32 3. 2224 811130I7

•

15 11 1 4412 13 B2 41

28 B2

N3D 110321 0 33dS

BR30-1 SPEED REDUCER ::F

-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25 -26 -27 -28 -29 -30 -31 -32 -33 -34 -35 -36 -37 -38 -39 -40 -41 -42 -43 -44 -45 -46 -47

DESCEZIPTION

PART Nu:....zza

CTY

Housing Worm Assy Cover-Housing Assy 23476 Worm Gear Worm-Right Hand Shaft-Output 22585 Cup-Brg 22584 Cone-Brg

81548 81549 23476 23644 23645 22585 22584

1 1 1 1 1 2 2

Thrust Ring Retainer Spacer-Bearing MU7-502DG Shield Dust 23482 Key E050T Pipe Plug 23483 Seal-Shaft 5025-12AN Capscrew MU7-45DG Gasket MU7-402R Snap Ring 1885002 0-Ring S043-15PH5 Capscrew S043-15A Capscrew S031-08PH5 Capscrew A043 Lockwasher 7/16 ' A031 Lockwasher 5/16 2558001 Relief Valve 58-RD6-1 Reducer BSHG ED121 Pipe Plug MU7-134J Plug Expn Coupling - Brake Shaft Brake MU7-450 Cover Brk Plate Brake End MU7-148-7 Friction Disc 23480 Brake Rotor MU7-153 Pressure Plate MU7-156-0 Spring-Assy MU5-151A Woodruff Key M5-157 Wm Brk Adj Nut Coupling-Motor Adaptor-Motor 22471 Dowel Pin 45-TED-2 0-Ring Gasket 23108 Gasket-Motor S050-05PH5 Capscrew A050 Lockwasher

23648 23649 23650 21959 23482 18010 23483 23857 21640 11454 21033 21253 21135 11766 11025 11024 10074 18066 18009 11412 23651 23652 21591 23653 11426 23480 11431 81081 11385 11599 23654 23655 22471 12465 23669 23108 10009 11026

2 2 2 1 2 2 1 2 2 2 1 4 4 6 8 6 1 1 2 1 1 1 1 1 2 1 1 1 2 1 1 1 2 1 1 1 2 2

CHAR-LYNN ® HYDRAULIC MOTOR "H" SERIES PARTS INFORMATION NO. 6-110

Char-Lynn Motor Parts Information PRODUCT NUMBER 101-1001-005 THROUGH 101-1088-005 (FORMERLY - X5X) (AND M-200-B)

PARTS DRAWING

Chart 1 Displacement **cu. in./rev. 2.89 4.34 6.04 10.04 11.64 14.56 17.47 23.31

Drive

Gerotor

602 602 616 616 616 616 616 616

5387-1 5387-2 5387-3 5387-4 5387-5 5387-6 5387-7 5387-8

G er o t o r

W i dth .25 .38 .52 .86 1.00 1.25 1.50 2.00

Spacer

Cap-Screws— Length

NON E NONE NONE 6901-2 6901-3 6901-5 6901-6 6901-8

5389-1-1.50" 5389-2-1.62" 5389-3-1.75" 5389-4-2.12" 5389-5-2.25" 5389-6-2.50" 5389-7-2.75" 5389-8-3.25"

**See Page 4 for Product Number Cross Reference List

Complete Kit

Base Block Mounting Kit

PARTS LIST

Ref. No.

Part No.

1 X2 3 4 X5 X6 X7 8 9

5777 844 843 6296 6796 20599 15048 7462 7537

10 11 12 13

14193 5367 5367-12 6305-1 6305-2 6305-3 15007 20817 5662 * 5414 * * 6481 6049 *

X 14 15 16 17 18 19 20 21 X 22 23 24

123-1007-001

123-1008-001

X 25 26 27 X

15058 21046-2 NSS 60038

Description Screw, Cap 12 pt. Dr. 5/16-24 NF x 7/8 Seal, Dust Flange, Mounting (4 Bolt) ** Flange, Mounting (2 Bolt) ** Washer, Backup (Replaces and is Interchangeable with 5799) Seal, Quad Seal, 0-Ring Race, Bearing (Replaces and is Interchangeable with 866) Bearing,Thrust Needle (Replaces and is Interchangeable with 867) Key, Woodruff Shaft, Output ( Keyed,Includes Spacer 5662) Shaft, Output ( Splined,Includes Spacer 5662) , Housing 7/8" 14 Str. Thd. Ports 1/2" NPTF Ports Manifold Mount Seal, 0-Ring Plug, Housing Spacer — ( Included with Shaft P/N 5367 or 5367-12 1 Drive Plate, Spacer Gerotor Set Spacer Cap, End Washer, Seal Screw, Cap 12 pt. Dr. 5/16-24 NF. Base Block Kit (1/2-NPTF) Optional on motors with manifold mount only. Base Block Kit (7/8-14 Str. Thd.). Optional on motors with manifold mount only. Seal, 0-Ring Screw, Cap 5/16-18 NC x 1-1/2 Port Block Seal Kit — For all motors (contains parts indicated by X)

X— Seal Kit (See 60038)

5534-1

city. Per Unit 4 1 1 1 1 1 1 1 2 1 1 1

Recommended Spare Parts Per 100 Units 1 Multi Kit #60517 3 3

5 5 3 3 3 2 1 2

1 1 1 1 1 1 1 1 7 7 1

3 3 3 3 5 ea. displ. size 3 ea. displ. size 3 1 Multi Kit ea. displ. size

1 2 4 1 10

*—See Chart 1 on opposite page for part NSS—Not Sold Separately. numbers of specific models

Seal Kit, Butyl, includes two (2) seals for port block For use with certain fire resistant synthetic fluids. CAUTION: Check for compatability with fluids before using.

** Previously manufactured with roll pins, reassemble without roll pins, instructions with Seal Kit 60042.

CHAR-LYNN ® HYDRAULIC MOTOR "H" SERIES PARTS INFORMATION NO. 6-110

HOW TO ORDER REPLACEMENT PARTS

**Product Number Cross Reference List

Each Order Must Include the Following Information: 1. Product Number 2. Date Code 3. Part Name 4. Part Number 5. Quantity of Parts

* Available on Special Order Only-Consult Factory.

Displacement (Cu. in./rev) Mtg. sha“ Hydraulic Pros. '‘ Connections 2.89 4.34 6.04 10.04 11.64 14.56 17.47 23.31 . . KA(M-201.8) ACM-2024) AC(M-283-11) AE(14204-11) AG(M.205-8) AK(M-206-B) AM IK4.207-81 APIM-2011-11) ModelOldNumbers 454 ASO ASC ASE ASG, ASK ASM ASP 1/2 NPTF Product Alum*. 101-100140S 181.1002-COS 101.1003-001 101-1004.005 101-1005-005 101.1006401 101.1007-00S 101-1088.005' Old x 14 "Iwo Number 854 858 BSC BSE SSG 85K 8SM OSP Straight 7/8SAE Keyed Product Number 101.1009-COS 101.1014-00S 101.101140S 101.101240S 101.101340S 101.1014-00S 101-101S-005 101.1010401 4 Bolt Old Flange Manifold Model Number cSA C58 CSC CSE CSC COO CSM OP Mount Product Number 101.1011-4WS 101.1018-001 101.101S-02S 101-1020401 101.1021-00S 101-1022-005 101.1023-005 101.102440S ModelOldNumber ASA.9 458.9 IOC 9 ASE•9 ASG•9 ASK-9 ASM-9 ASP-11 . 1/2 NPTF Product Number 181-1049.005 101.101040S 101.101140S 101.1012-00S 101-1053-005 101.1014-00S 101.1010-801 101-1011.885 Old OSE-9 850.9 19541-1 IISP4 1 7/8 x 14 Model Number... Stained SAE 101.1010-005 * 101.101240S 101-101340S 101-101440 ' * * Product Number * ■ Old C511-9 CSP-11 Manifold Model Number --., , Mount Product Number * * * * 101.1070-000 * 101-1072.005 DSC 175E DOG DSK NM OSP ModelOldNumber OSA DOS .1/2 NPTF Product Alum*. 101-102540S 101-1021-000 181.1027-000 101-1021-000 101.1021140S 101-1030.005 101.103141S 101-1032405 Old G5t OE GSG GOO GSM GOP GSA all x 14 Model "ember Straight 7/8SAE Keyed Product /dumber 101.103340S 101-1034.00S 101.103S-00S 1014034-40S 101.103740S 101-1031140S 101-1031140S 101-1040.00S 2 Bolt Flange Manifold, $4441OldNumber NSA MSC MSC 051 HOG 1450 MOM MOP Mount Product Number 101.1041-00S 101.1012-005 101.10113-00S 101.10woos 101.104140S 101.1041400 101-1047400 101-1048400 05E -9 OSG-I DSK-9 DSM-9 DSP•9 ModelOldNumber . 1/2 NPTF Product Number * * 4140714es 101.1077-00S 181.1078-COS 101.10711-00S 101.108040S, Old G5K-9 GSM-9 CSP-I 7/8 x 14 Model Number G54•9 G58.9 GSC•9 Splined SAE Product Number 101.1011-00S 101.100240S 101.1083-000 * * 101-1080005 101-1017405 101.1088405 Manifold * * * * * * * * _ Mount Oate Code

Motors manufactured prior to March 1974 have product identification and serial number stamped on port face area.

Week of Year 1 Thru 52

Product Number t - t

Product Identification Number

0000

Last Number of Year 197

I - , 000

Non-Significant Number

Engineering Change Code

Eaton Corporation Fluid Power Operations Minneapolis Division 15151 Highway 5 Eden Prairie, MN. 55343 Telephone (612) 941-2800

E 1T• N Fluid Power

REVISED JUNE, 1977 p KA ben A - 1

INSTALLATION INSTRUCTIONS

()HUNTER

HYDROTHROTTLE CONTROL MUNCIE PARTS MFG..-00_, INC_ GENERAL OFFICES

ATLANTA DIVISION

CHICAGO DIVISION

P.O. Box 548 • Muncie, Indiana 47305 Phone (317) 284-7721

P.O. Box 43468 • Atlanta, Georgia 30336 Phone (404) 349-4402

P.O. Box 66151 • AM F, O'Hare 60666 Phone (312) 298-6860

SEATTLE

TOLEDO DIVISION

MUNCIE CANADA LIMITED

Subsidiary of Muncie Parts Mfg. Co. Inc.

P.O. Box 6593 • Toledo, Ohio 43612 Phone (419) 729-3861

P.O. Box 113, Malton Station Mississauga, Ontario L4T 3B5 Phone (416) 677-9852 'Telex No. 06-968841

The Blackler Company • 317 So. Bennett St. Seattle, Wash. 98108 • Ph. (206) 763-2230

PARTS LIST SERIES 90 THROTTLE CONTROL

1 2

3 4 0,77- PRESSURE SENSING PORT

YOUR THROTTLE ROD (SIMULATED)

D 6

)

SectionAA

°. A

Model 1 9010 -

Item 1 2 3 4 5 6 7 8 9 10 11

Description

Part No. 2-8124 2-9002 5322 5050 9004 2-9007 5049 8118 1-170211 2-170212 180960

MUNCIE PARTS MFG_ CO_, INC_

Bracket and Bolt Assembly Piston Assembly Nut, Jam 3/8 - 16 Screw 3/8 - 16 x 1-1/4 Spring Tension Adjusting Screw, Fulcrum Housing and Liner Assembly Screw 3/8 - 16 x 3/4 Speed Adjusting Spring, Leaf (3 required) Rod, Actuating, with Nuts and Set Screws Cable Assembly Clamp

MUNCIE • ATLANTA • CHICAGO • SEATTLE • TOLEDO • TORONTO

-2-

I. INSTALLATION OF THE THROTTLE CONTROL A. Introduction Refer to sketch shown with parts list, included on page 2. One Throttle Control can operate an unlimited number of circuits, that are driven by the same pump discharge line in the hydraulic system. The Throttle Control piston (2) senses the pump discharge line pressure. The pressure increases, and pulls the throttle open, when you operate a circuit to move a load. The pump by-passes, and allows the throttle to close when the valve circuit lever is returned to neutral. The pressure must increase, above by-passing pressure, at least 15 PSI for each pound of throttle pull, plus the amount your by-passing pressure will vary, due to oil viscosity changes, over your oil operating temperature range. Highly loaded circuits usually increase the pressure to a level far above the pump by-passing pressure, and produce a motivating force far beyond the minimum required to open the throttle. Lightly loaded circuits, such as, when the boom is lowering, swing circuits, outriggers lowering, etc., produce the least pressure. The plumbing flow restrictions must be revised in these circuits if the load cannot increase the circuit pressure sufficiently above by-passing pressure to produce the motivating force needed to open the throttle. The pressure will increase at a greater rate as the engine speed increases because the plumbing relating to the circuits usually contain greater restrictions. A lightly loaded circuit may then become operable at a higher engine speed, if it did not operate at idle. The motivating force can be increased by revising your plumbing, downstream of the throttle control connection, as follows: Restrict the plumbing relating to the circuits. (1) Add an orifice. (2) Reduce diameter and/or lengthen line size. (3) Add a two-way check valve with a heavier spring in the direction of flow. This will increase pressure more at idle speed where needed most. It, therefore, is the best type of restriction. Decrease your by-passing pressure. (1) Remove "bottle necks", and elbows. (2) Increase diameter and/or shorten line size.

MUNCIE PARTS MFG_ CO..,N&

MUNCIE • ATLANTA • CHICAGO • SEATTLE • TOLEDO • TORONTO

-3-

Mounting Bracket One is furnished in the kit. Modify it to fit if necessary. Make the bracket rigid and mount it to your engine rather than another surface to prevent erratic operation due to flexing and/or movement. Position the Throttle Control so the connecting cable is in line with the accelerator rod and pulls in the same direction.

Pressure Connection to Pump Discharge Line Use a 1/4" minimum sized high pressure tube or hose. Make the connection at the control valve inlet rather than the pump discharge so it will sense the lowest pressure. The pressure will then change by a smaller amount when the oil viscosity changes. The spring tension will also be_come more effective. For cold climates, consider whether you need to add a heater to your reservoir and/ or shut off valve in this pressure connection to prevent high speed operation of your hydraulic components with cold oil. An oil temperature sensing switch would make them automatic.

Engine Throttle Linkage Check Start the engine. Engage PTO to load the idling engine with by-passing oil pressure. Try to reduce the engine throttle pull to a minimum. Make sure it is well oiled and in good repair. Check with the engine manufacturer whether the return spring load can be reduced if it appears to be excessive for its application. When the engine has warmed up, make sure it is capable of returning to its proper idle speed after operating the accelerator. Make necessary adjustments now before the connecting cable is applied.

Cable Slack Adjustment Refer to the sketch on page 2. Make sure the actuating rod (9) is still located in hole 4 as shipped. Secure the clamp ( 1 1) to the throttle rod. Engage the cable (10) eyelet to one of the clamp studs. Thread the cable through the hole in the rod, remove almost all slack, and secure it with the set screws. Finalize the cable slack adjustment with the nuts provided on the actuating rod (9). The cable should have some slack but not excessive. Check to make sure the engine returns to idle after operating the accelerator.

MUNCIE PARTS MFG_ CO_, INC_

MUNCIE • ATLANTA • CHICAGO • SEATTLE • TOLEDO • TORONTO

-4-

F. Adjusting Procedure The spring rate is adjustable by moving the fulcrum screw (5) and changing the number of leaf springs (8). See table below for the possible variations. The spring rate increases as the variation number decreases. For instance, the table indicates the spring will be three (3) times stiffer with variation No. 2 than No. 3.

Variation Number 1 2 3 4 5

No. of Springs

Fulcrum Hole

3 3 3 2 2

A B C C D

*Turns 3 3 2-1/2 2 5/8

Spring Tension *Pressure 1100 780 640 370 300

Rate 11X 3X Normal 3/4X 1/4X

Actuating Rod Hole Location 4 4 4 4 4

* Note: Apply turns from when the screw (4) just begins to deflect the spring at zero load. Pressure is approximate when piston will begin to move. The control was shipped with variation 3. Try it first. The adjusting procedure will direct you to another variation, if another is needed. 1.

Disengage PTO. Turn in speed screw (7) until it touches spring (8). Then turn out one turn, temporarily, to limit stroke and prevent accidental racing of engine.

Engage PTO. Air bleed sensing line by cracking fitting at Throttle Control. Proceed after oil warms up to within normal operating temperature range.

Operate a highly loaded circuit valve lever. Bottom out a cylinder to obtain system relief valve pressure if this is easier. The throttle will open.

Make speed adjustment. Turn speed screw (7) in or out with the circuit loaded. Use the nut (3) to lock it when it regulates your desired speed. Move actuating rod from hole 4 to hole 3 only if the spring should stop ,

on the housing instead of the screw. 5.

Return lever to neutral. The throttle must close and the engine must return to idle. Check Trouble Shooting section, Part II, Section C. If unsuccessful, increase the spring rate, see table above. Repeat entire procedure.

MUNCIE PARTS MFG_ CO_, INC_

MUNCIE • ATLANTA • CHICAGO • SEATTLE • TOLEDO • TORONTO

-5-

Adjusting Procedure (Continued) 6. Determine which of the circuits produce the lowest pressure. Operate it and decide which of the following applies, paragraph 6a, 6b, or 6c. a. Throttle Opens and Closes Properly From Idle (1)

Finalize engine speed screw (7) adjustment by alternately operating the lowest and the highest loaded circuits. Lock nut (3) securely.

(2)

Operate and check all other circuits. They should operate because they are loaded between the highest and lowest circuits used for adjustments.

(3)

Installation is now complete.

b. Throttle Does Not Open From Idle Speed, but Will at Higher Speed Check if it will open at higher engine speeds. (1)

Operate a higher pressure circuit lever to open the throttle and bring the engine up to speed, then operate the lowest pressure circuit lever.

(2)

If it stays open, after the higher pressure lever is returned, decide whether the required sequence of operation is acceptable. It usually is acceptable. It now contains the highest spring setting.

(3)

If not acceptable, or if it did not stay open, proceed with step (c) below.

c. Throttle Will Not Open at All Make spring tension adjustment. Proceed as follows: (1)

Disengage PTO. Turn out screw (4) until leaf spring (8) is loose. Then turn it in until the spring just begins to deflect and is at zero load.

(2)

Engage PTO. The throttle will open.

(3)

Turn screw (4) in gradually. Count turns, and record as "B", until the throttle just closes. Do not overshoot and leave the screw at this point. Note how the throttle closed. If it closed suddenly, increase the spring rate, see table above. Repeat adjustment from paragraph c (1).

MUNCIE PARTS MFG_ CO_, INC_

MUNCIE • ATLANTA • CHICAGO • SEATTLE • TOLEDO • TORONTO

-6--

6c. (Continued) (4) Operate the lowest pressure circuit. The throttle must open. If it opened, proceed directly to step 5. Otherwise, choose between (a) and (b) below. (a) I'f it did not open, the motivating force is below zero. Revise the plumbing to increase the amount the pressure will increase when the circuit is operated. See Section A. (b)

Operate the next higher loaded circuit, etc. until you find a circuit that does operate from idle. Use this circuit for the adjustments specified in paragraph 5 below. You will find out later whether the lower pressure circuits, that did not operate from idle, will become operable at a higher speed.

(5 ) Turn in on screw (4) in small increments equal to approximately 10% of the total turns given in the table above. After each increment, operate the lowest pressure circuit lever from neutral to fully open the throttle, and then return it to neutral to fully close the throttle. Wait for the engine to idle before repeating. Count, and record as "C", the number of turns to exactly when the throttle no longer opens from idle. Note: Increase the spring rate, see table above, if the total turns counted (B plus C), exceeds by more than 20% the number of turns noted in the table above. Decrease your spring rate if you observed the throttle will no longer fully open. Repeat adjustment from paragraph c(1), if spring rate was changed. (6) Turn screw (4) out 1/8 turn or 1/4 times "C" turns whichever is greater to provide an operating margin between the lowest circuit pressure and the final spring tension. (7 ) Check operation as per paragraph F6a or F6b. If the lighter loaded circuits do not operate, revise the plumbing to increase the amount the pressure will increase when these circuits are operated. See Section A.

MUNCIE PARTS MFG_ CO.., INC_

MUNCIE • ATLANTA • CHICAGO • SEATTLE • TOLEDO • TORONTO

II. TROUBLE SHOOTING HINTS A. Problem: Engine Does Not Idle But Speeds Up When PTO Is Engaged Probable Cause

Remedy

1. Control lever stuck open. 2. Low leaf spring tension. 3. Cold Oil.

1. Return all valves to neutral. 2. Repeat calibration. 3. Warm oil. Also check Part I, Section "C".

B. Problem:

Engine Does Not Speed Up When Light Load Is Applied

Probable Cause

Remedy

1. PTO not engaged. 2. Air in sensing line. 3. Connecting cable. 4. Stops on speed screw. 5. Hot oil. 6. Your engine throttle linkage. 7.

Circuit pressure is too low.

8. 9.

Excessive leaf spring tension. Excessive leaf spring rate.

1. 2. 3. 4. 5. 6.

Engage PTO. Bleed line. Crack fitting at control. Reduce slack to minimum. Adjust screw. Allow oil to cool. Oil and repair. Check manufacturer for lighter spring if it is excessive. 7. Revise plumbing to increase spread between your circuit and by-passing pressures. See Part I, Section "A". 8. Repeat calibration. 9. Reduce spring rate. See table in Part I, Section "F".

C. Problem: Engine Does Not Return To Idle After A Load Is Applied Probable Cause

Remedy

1. Engine speed excessive. 2. Your engine. 3. Connecting cable. 4. Low leaf spring rate.

1. Reset speed screw adjustment. 2. Make sure it can idle. 3. Check for slack. 4. Increase spring rate. See table in Part I, Section "F". 5. Repeat calibration. 6. Remove "bottlenecks" or increase line size downstream of the control connection.

5. Low leaf spring rate. 6. Excessive by-passing pressure.

MUNCIE PARTS MFG_ CO_, INC_ Printed In U.S.A.

MUNCIE • ATLANTA • CHICAGO • SEATTLE • TOLEDO • TORONTO

-8-

INSTALLATION PROCEDURE FOR TEFLON RINGS

EQUIPMENT NEEDED: 1.

Heating container (NESCO oven or equivalent).

One (1) pair of heat resistant gloves.

OPERATION: 1.

Insure coupling is free of foreign matter.

Place teflon rings in oven until 300°-350° is reached. CAUTION-Do not exceed 500°. (Rings should turn dark in color and become elastic.)

Grasp a ring (using gloves) and slip over end of coupling to groove. CAUTION-- Do not stretch rings as they will not return to size. Speed is essential before contracting occurs.

Insure ring is not twisted when installed in groove.

NOTE: Rings that are loose on coupling can be sized by compressing with suitable hose clamp.

SP•4/15/77

Y CAJUPLING

8 9 0 I

10/1 2/79

k• .39 r

, :1 ' „. - ••- r:4

•

Zr"Inik

f:is• • ,41

p ia

•kVi•v•*,

1. 2. 3. 4. 5. 6. 10. 11. 12. 13. 14. 15. 16. 17. 18.

Dust Seal Wire Ring Shim Seal Housing Seal Carrier Assy. Thrust Bearing Shaft Drive Link Wear Plate Seal (3) Roller Stator Pin End Cover Bolt (4)

14 *NOTE: Earlier models have a leather backup in seal carrier. Leather and old shaft seal should be replaced by new shaft seal and spring.

16 Figure 1

SERVICE PROCEDURE Disassembly Procedure . . . Prior to removing roller stator motor from unit, clean off all dirt. Disconnect hydraulic connections and plug ports. Remove the motor from unit. After removal, wash the motor with solvent to remove all excess dirt from outside of the motor. Remove the woodruff key from shaft (11), place the motor in a vise as shown in Fig. 2 taking care to clamp at port area of housing (see Fig. 2). Place newspapers or a sheet of cardboard on top of bench to obtain a clean work area.

6. Assemble the drive link (12) into shaft (11). Care

8. 9. DISASSEMBLY OF ROLLER STATOR (reference Fig. 1) 1. Remove four bolts (18) [9/16 socket or boxed end] and end cover (17). 2. Shift wear plate to clear end of drive link and lift group [rotor assembly (15) and wear plate (13)] from housing assembly (5). 3. Remove shaft (11) and drive link (12) from housing by pushing up on shaft end with palm of one hand and lifting shaft with the other hand. Items 6, 10, 11, 12 and 16 usually will come out from assembly. 4. Remove housing (5) from vise and place upside down on work bench. This allows thrust bearing (10) to fall free. Next place fingers through dust seal (1) of housing and push seal carrier (6) out the opposite end from the dust seal. Care should be taken to keep the seal carrier from marring the housing bore, This procedure will remove items 6 and 10 from housing. 5. Mount housing assembly (5) in vise, using the grip end of a large screw driver, tap dust seal (1) until it falls free, With small screw driver remove retaining ring (2), seal (4) and shim (3).

10.

must be taken to align mark at root of drive link tooth with mark on cupped end of shaft. See Fig, 3. Fill drive link end with grease. Note, if markings are indistinguishable the root of the drive link tooth should be placed with the deeper slot of the output shaft to the right and 1/4" thru hole to the left. (Mark alignment as described on drive link end with soft pencil if no marks appear.) Slide output shaft assembly (6, 10, 11 and 12) into housing Fig. 4. (Shaft must be flush or slightly below housing.) Place lightly oiled seal (14) in groove of housing. Place wear plate (13) on top of drilled end of housing, insuring alignment of seven feed holes. See Fig. 5. Note alignment groove of wear plate to be in direction of ports. Install lightly oiled seal (14) into groove of roller stator (15). With seal side down place roller stator (15) over drive link with mark on drive link root in line with rotor valley (min. diameter). See Fig. 6. Mark on stator must be in line with slot in wear plate. Note alignment of seven feed holes with wear plate and housing. See Fig. 7. Align four bolt holes with housing. Care must be taken to insure that seal stays in place. Note: Counterbore on rotor is away from housing.

LONG MILLED OR ANGLE DRILLED SLOT

Fig. 2

Fig. 3

ASSEMBLY PROCEDURE (reference Fig. 1) IMPORTANT Before assembling, wash all parts off in clean solvent. It is advisable to use a new seal kit containing items 1, 3, 4 and 14 (3 seals). 1. Place housing with mounting flange end up on newspaper, install seal (4) in groove. 2. Install shim (3) into groove next to seal. 3. Push retaining ring (2) into position. 4. Place housing (5) in vise as shown in Fig. 4 with groove side up clamping at ports. 5. Place thrust bearing (10) on shaft (11) followed by the seal carrier assembly (6) with large diameter of seal carrier towards thrust bearing.

Fig. 4

Fig. 5

16. Place assembly on side (ports up) in vise and rotate shaft with key in place and check to insure the suction port is In the same direction of rotation.

11. Place lightly oiled seal (14) into end cover (17). 12. Place grease in recessed center of end cover face. Install pin (18) Into greased recess if recess Is filled with oil, wipe clean before loading with grease. End cover of new models (built after March, 1983) contains a pressed steel ball and a pin (16) with a concave end. Make sure concave end of pin is inserted into end cover (17) in these models. 13. Carefully Invert end cover assembly (17, 16 and 14) and place into position on top of roller stator assembly. Take care not to dislodge seal or pin from end cover. 14. Check sides for seals that may be out of place. 15. Insert four bolts (18) and torque to 50 foot pounds.

Fig, 7

Fig. 6 elielfo U MOUNTING IGLER

of =TWA

43*

aft

22'30

MS SPOIVOINDEOD-ROG 32511C 1 : 3 LEO

MANIFOLD PORT

-16 UNC X 22 DEEP 4 HOLES EQUALLY SPACED AND LOCATED ON A 3250 DIA. B.C.

J499)

6-B SPLINE (SAE

PILOT DIA.

PILOT DIA. UNC

■VOOORLIFF KEY

loo0tA.x 14wim

TD WOODRUFF KEY

11111111e11111.7= *A.„ 1:2 ■..7.41N.:1 UNC K.50 MIN DEEP t Mounting Holm MANIFOLD PORTING * Available with 2 Hole or 4Holo Flange Housing

WHITE HYDRAULICS, INC. TELEPHONE 502485-1110 P.O. BOX 1127 HOPKINSVILLE, KY 42240 TWX 757176 Attn: White Co.

LIMP •11111111.

Mounting Dimensions MOTOR SERIES

YDRAULIC MOTOR

DISPLACEMENT Cu.ln./Rev.

Cu.Cm./Rev.

RS-AA-1

RS-AB-1

4.5

50 74

RS-AC-1

6.8

110

RS-AE-1

164

RS-AG-1

200

RS-AK-1

14.6

268

RS-AM-1

RS-AP-1

295 393

. .....„ DIMENSION "A" 4 Hole Flange 2 Hole Flange ... mm In. In. mm 137,41 5.41 137:41 5.41 137,41

137,41

5.53

137,41— 5.53 137,41 • . 155,45 5.87 155,4 6A

5.87 —

5.41

6-12 15574i 6.12

155,45\

169,16 6.66 169,16 6.66

169,16

7.3 7 187.20 7.37

1$7,20

6.66 6.66

169,16

WHITE HYDRAULICS, INC. Bill Bryan Boulevard Box 1127, Hopkinsville, KY 42240 502-885-1110 / TWX 757176 FAX 502-886-8462

SERVICE BULLETIN

JULY 11, 1988

HS & RS SERIES SERVICE AND SEAL KIT INSTALLATION THESE INSTRUCTIONS COVER BOTH THE HS & RS SERIES MOTORS. NOTE CAREFULLY THE DIFFERENT TIMING PROCEDURES FOR EACH SERIES. PRIOR TO DISASSEMBLY, CLEAN OFF THE EXTERIOR OF THE MOTOR IF NECESSARY AND MARK A VERTICAL LINE UP ONE SIDE OF THE MOTOR WITH A FELT MARKER FOR LOCATION REFERENCE WHEN REASSEMBLING. HAVE A CLEAN WORK BENCH AVAILABLE. DISASSEMBLY 1. PLACE MOTOR IN VISE AROUND PORT AREA. 2. REMOVE 4 BOLTS AND END COVER. 3. SLIDE WEAR PLACE OFF CENTER AS NECESSARY TO CLEAR THE DRIVE LINK SPLINES AND REMOVE THE ROTOR SET AND WEAR PLATE AS ONE PIECE TO PREVENT ROLLS FROM FALLING OUT. 4. REMOVE DRIVE LINK AND PIN. 5. REMOVE SHAFT UP THROUGH HOUSING. BE CAREFUL NOT TO LOSE THE COOLING PLUG LOCATED INSIDE THE SHAFT. 6. REMOVE HOUSING FROM VISE AND PLACE WITH MOUNTING FLANGE UP ON WORK BENCH. THIS ALLOWS THRUST BEARING (AND THRUST WASHER IN MAY, 1988 AND NEWER MODELS) TO FALL FREE. CAREFULLY INSERT A SCREWDRIVER BETWEEN DUST SEAL AND SEAL CARRIER AND PRY OUT DUST SEAL. 7. PRESS THE SEAL CARRIER BACK THROUGH THE HOUSING, BEING CAREFUL NOT TO SCORE THE HOUSING BORE. 8. REMOVE RETAINING RING, BACK UP SHIM AND LATHE CUT SEAL FROM GROOVE IN HOUSING WITH A SMALL SCREWDRIVER. REASSEMBLY AND SEAL KIT ASSEMBLY THIS COVERS REASSEMBLY USING SEAL KIT NUMBER PS222001, WITH VITON SEAL AND THRUST WASHER. PS222001 IS A UNIVERSAL KIT COVERING BOTH HS & RS SERIES MOTORS SO THERE WILL BE 2 EXTRA BODY SEALS LEFT WHEN REASSEMBLY IS FINISHED. EACH PART SHOULD BE WASHED IN CLEAN SOLVENT PRIOR TO REASSEMBLY. INTERNAL WORKINGS OF MOTOR MUST BE TOTALLY FREE OF DIRT OR DEBRIS. ALL SEALS SHOULD BE LIGHTLY OILED PRIOR TO INSTALLATION.

1. PLACE HOUSING IN VISE WITH MOUNTING FLANGE UP. 2. INSTALL 1.735" I.D. LATHE CUT SEAL 3. INSTALL BACK-UP SHIM. THIS SHIM MUST BE FOLDED AND BENT SLIGHTLY AND THEN WORKED INTO PLACE WITH A SMALL SCREWDRIVER. 4. INSTALL WIRE RING AND TURN HOUSING OVER SO IT IS IN VISE WITH FLANGE DOWN. 5. SEE ATTACHED DRAWING C10014 FOR INSTALLATION OF SEAL CARRIER COMPONENTS. 6. CAREFULLY SLIDE SHAFT ASSEMBLY INTO HOUSING. BE SURE THE COOLING PLUG IS STILL PROPERLY PLACE IN HOLE IN BOTTOM OF THE SHAFT. IMPORTANT - TIMING INSTRUCTIONS (STEPS 7-10) FOR HS MOTOR 7. USE TIMING DOT ON DRIVE LINK END AS A REFERENCE OR MARK ANY SPLINE ROOT WITH A PENCIL. CAREFULLY LOWER DRIVE LINK INTO SHAFT WITH REFERENCE MARK DIRECTLY IN LINE WITH THE CENTER OF ANY OF FOUR THROUGH HOLES IN SHAFT. AS DRIVE LINK SPLINES CONTACT THE SHAFT SPLINES, SLOWLY TURN DRIVE LINKS, COUNTERCLOCKWISE UNTIL SPLINES ENGAGE IN SHAFT SPLINE. TAPLIGHTLY ON DRIVE LINK END TO SEAT THE SHAFT ASSEMBLY INTOTHE WIRE SNAP RING. SHAFT END SHOULD BE SLIGHTLY ABOVE FLUSH FLUSH WITH HOUSING SURFACE. (APPROXIMATELY .010"-.020") BUT WILL SEAT AS MOTOR IS BOLTED TOGETHER. 8. INSTALL BODY SEAL INTO GROOVE IN HOUSING. 9. INSTALL BODY SEAL INTO GROOVE IN ROTOR SET. 10. PLACE WEAR PLATE ONTO SEAL SIDE OF ROTOR SET WITH THE CENTER HOLE OF WEAR PLATE DIRECTLY CENTERED ON ROTOR SPLINES. (BE SURE THE WEAR PLATE IS LOCATED SUCH THAT THE NOTCH ON ONE SIDE OF WEAR PLATE PERIMETER WILL LINE UP WITH TAB ON ROTOR SET PERIMETER WHEN BOLT HOLES ARE AUGNED). LOCATE ANY ONE OF THE FOUR ROTOR SPLINES THAT ARE DIRECTLY ON A CENTER LINEWITH THE HIGH (CONVEX) LOBE OR ROTOR. PLACE THE WEAR PLATE AND ROTOR SET ONTO DRIVE LINK SPLINE AS ONE PIECE WITH THE HIGH LOBE SPLINE ENGAGING THE PREVIOUSLY DETERMINED DRIVE SPLINE. WEAR PLATE SHOULD BE BETWEEN HOUSING AND ROTOR SET. ALIGN PLATE AND ROTOR SET BOLT HOLES WITH HOUSING BOLT HOLES. THE WEAR PLATE NOTCH AND ROTOR SET TAB MUST BE IN LINE AND MUST BE LOCATED ON THE PORT SIDE OF THE HOUSING.

ANIM1111111=1111111 ■.

IMPORTANT - RS SERIES TIMING INSTRUCTIONS SEE STEPS 7-10 FOR HS SERIES TIMING 11. USE TIMING DOT ON DRIVE LINK END AS A REFERENCE OR MARK ANY SPLINE ROOT WITH A PENCIL. CAREFULLY LOWER THE DRIVE LINK INTO THE SHAFT WITH REFERENCE MARK DIRECTLY IN LINE WITH THE CENTER OF ANY OF THE 6 THROUGH HOLES IN SHAFT. AS DRIVE LINK SPLINES CONTACT THE SHAFT SPLINES, SLOWLY ROTATE THE DRIVE LINK CLOCKWISE UNTIL SPLINES ENGAGE IN SHAFT SPLINES. (NOTE: THIS APPLIES TO TIMING PROCEDURE FOR MOTORS WITH STANDARD CW ROTATION CODE '0'. FOR REVERSE CCW ROTATION CODE 'I' ROTATE THE DRIVE LINK CCW UNTIL SPLINE ENGAGES. ROTATION CODE IS SEVENTH DIGIT OF SPEC. NUMBER). TAP LIGHTLY ON DRIVE LINK END TO SEAT THE SHAFT ASSEMBLY INTO THE WIRE RING. SHAFT END SHOULD BE SLIGHTLY ABOVE FLUSH WITH HOUSING SURFACE, BUT WILL SEAT AS MOTOR IS BOLTED TOGETHER. 12. INSTALL BODY SEAL INTO GROOVE IN HOUSING. 13. INSTALL BODY SEAL INTO GROOVE IN ROTOR SET. 14. PLACE WEAR PLATE ONTO SEAL SIDE OF ROTOR SET WITH THE CENTER HOLE OF WEAR PLATE DIRECTLY CENTERED ON ROTOR SPLINES. (BE SURE THE WEAR PLATE IS LOCATED SUCH THAT THE NOTCH ON ONE SIDE OF WEAR PLATE PERIMETER WILL UNE UP WITH TAP PROTRUDING ON ONE SIDE OF ROTOR SET PERIMETER WHEN BOLT HOLES ARE ALIGNED). LOCATE ANY ONE OF THE 6 ROTOR SPLINES THAT ARE DIRECTLY ON A CENTER LINE WITH ANY OF THE 6 ROTOR VALLEYS (MINOR DIAMETER OF ROTOR). PLACE THE WEAR PLATE AND ROTOR SET ONTO THE DRIVE LINK AS ONE PIECE WITH THE ROTOR VALLEY SPLINE ENGAGING THE PREVIOUSLY MARKED DRIVE LINK SPLINE. WEAR PLATE MUST BE BETWEEN HOUSING AND ROTOR SET. ALIGN WEAR PLATE AND ROTOR SET BOLT HOLES WITH HOUSING BOLT HOLES. THE WEAR PLATE NOTCH AND ROTOR SET TAB MUST BE IN LINE AND MUST BE LOCATED ON THE PORT SIDE OF THE HOUSING. 15. PLACE PIN IN DRIVE LINK. NOTE THAT PIN HAS ONE CONVEX END AND ONE CONCAVE END. CONVEX END MUST GO INTO THE DRIVE LINK. 16. INSTALL BODY SEAL INTO END COVER GROOVE AND PLACE THE END COVER ON THE MOTOR SO THAT CONCAVE END OF PIN ENGAGES INTO THE HOLE IN CENTER OF END COVER. ALIGN BOLT HOLES. 17. INSTALL BOLTS AND TORQUE DOWN TO 50 FT. LBS. 18. CHECK TO SEE THAT REF. LINE YOU MARKED ON THE EXTERIOR OF THE MOTOR PRIOR TO DISASSEMBLY, MATCHES UP THROUGH ALL THE PARTS.

C1 OM 4 SERVICE PROCEDURE SUPPLEMENT FOR SEAL KIT PS222001 W/VITON SEAL AND THRUST WASHER.

SERVICE PROCEDURE SUPPLEMENT FOR SEAL KIT P5222001 W/VITON SEAL AND THRUST WASHER. 1. PLACE THRUST BEARING ON SHAFT.

2. PLACE THRUST WASHER (5) ON SHAFT. 3. INSTALL SHAFT SEAL (4) ONTO SHAFT AND DOWN AGAINST THRUST WASHER (5) ORIENTED AS SHOWN. (NOTE: TAKE CARE NOT TO DAMAGE SEAL WHEN SLIDING OVER SHAFT SLINES OR KEYSLOT.) 4. INSTALL TEFLON BACK-UP (3) ONTO SHAFT ORIENTED AS SHOWN. THE LIP ON THE TEFLON BACK-UP (3) SHOULD ENGAGE WITH SHAFT SEAL I.D. (4) 5. INSTALL BACK-UP SHIM (2) ONTO SHAFT AND DOWN AGAINST TEFLON BACK-UP (3) 6. CAREFULLY PUSH THE SEAL CARRIER (1) STRAIGHT DOWN OVER SHAFT SEAL ASSEMBLY, ORIENTED AS SHOWN, TAKING CARE NOT TO COCK THE CARRIER WHILE INSTALLING. 7. RETURN TO STEP 6 OF REASSEMBLY SECTION OF SERVICE PROCEDURE.

SEAL CARRIER RS018991 BACKUP SHIM R5018020 TEFLON BACKUP R5018058 SHAFT SEAL RS018053 THRUST WASHER 85018059

SOLENOID CARTRIDGE

luicl II Controls, inc.

PILOT OPERATED, POPPET STYLE, TWO WAY VALVE NORMALLY OPEN, NORMALLY CLOSED FOR OIL - TO 2 G.P.M. (7.5 L/MIN), 3000 P.S.I. (210 bar)

CARTRIDGE CONSTRUCTION NORMALLY CLOSED FREE REVERSE FLOW WHEN DE-ENERGIZED Normally open (unidirectional only)

NORMALLY OPEN INLET

(unidirectional when energized) OUTLET

7W30-1

USE

To be used as a two-way directional control in any hydraulic system with less than 2 GPM flow. Also can be used to remotely operate or pilot large pilot operated valves requiring up to 2 GPM pilot flow.

NORMALLY CLOSED INLET

OPERATION Normally Open Spring tension holds the pilot poppet away from the orifice seat on the main poppet. An axial groove on the O.D. of the main poppet allows pilot flow to pass, through the poppet nose.This flow pattern creates a pressure imbalance on the main poppet and causes the poppet to shift open allowing complete flow to pass through the outlet port. When the solenoid coil is energized, the armature is magnetically forced to slide the push pin and pilot poppet forward. The poppet blocks pilot flow and the main poppet shifts to a completely closed position.

OUTLET

OPTIONAL APPLICATION REVERSE FLOW PATH

FEATURES Reliable, excellent performance. Cartridge construction for use in your own cavity or complete in body. Hardened steel working parts. Replaceable weather resistant coil.

Normally Closed Spring tension holds the pilot poppet against the main poppet and both pilot and main flow through the valve is blocked. When the solenoid coil is energized the armature is magnetically forced to pull the pilot poppet from the orifice seat and pilot flow occurs. The pilot flow creates a pressure imbalance on the main poppet and the valve shifts open. Optional Application

SPECIFICATIONS WORKING PRESSURE: Rated to 3000 P.S.I. (210 bar) VOLTAGE: 12, 24,36 VDC, 12 Watts 115 VAC ( ±10% ) .12 amps. 50-60 hz. 230 VAC ( -±10%) .07 amps. 50-60 hz. All coils rated for continuous operation. AC coils use an internal AC/DC rectifier.

For Pilot Operated Normally Closed only - By reversing the normal porting arrangement the valve allows free flow through the main poppet. When flow is stopped, the main poppet blocks return flow and will lock an actuator in stationary position. To release the actuatpr the solenoid is energized and the main poppet opens allowing return flow to pass through the cartridge.

PLEASE NOTE:

Coils contain a full wave bridge rectifier rated for reverse voltage peaks of 1000 Volts Maximum. This is adequate for most systems. If voltage transients in your system are

PR E SS UR ED R OP - P.S. I.

300 250

P/'

greater than 1000 Volts P.I.V., voltage transient suppressors such as metal oxide varistors should be added in parallel with the coil.

SUPPRESSOR 115 VAC - USE G.E. MOV-VP130A10 OR EQUAL AC 230 VAC - USE G.E. MOV-VP250A20 OR EQUAL

200

■

150

100 50

ei ,,.

‘!\---/:vest

0 0.5 1 0

COIL ASSEMBLY

LEAKAGE:

In closed position — Inlet to Outlet @ 3000 psi. 5 drops per minute maximum with 135 s.s.u. oil @ 100° F.

MATERIALS: Cartridge housing, steel.

15 2.0 25 3.0 35 40

Valve body, hi strength wrought aluminum. Internal parts, hardened steel, stainless steel.

FLOW — G.P.M.

4/79

7W30-2

20.03

1p had

SOLENOID CARTRIDGE PILOT OPERATED,POPPET STYLE, TWO WAY VALVE NORMALLY OPEN, NORMALLY CLOSED FOR OIL - TO .2 G.P.M. (.75 L/MIN), 3000 P.S.I. (210 bar)

ontrols, Inc.

PART NUMBER EXAMPLE: HOW TO ORDER

EXPLOSION PROOF MODELS AVAILABLE ON SPECIAL ORDER Certified for use on U.S. Bureau of Mines approved equipment (meets schedule 2G)

7W31 - 12 - L 12S

0 7W30

Cartridge Only

7W3 1 Complete valve

WEIGHT — 8 OZ. (.23 Kg)

.288 (7.1mm) DIA. THRU 2 MTG. HOLES

2, l'*--- I 32 .-- 1 i6- —.1 C COILS , s "

% ( 1 6 M M )- —1 1/4

CI -7-

(OUT)

irs

1011°

2 (51mm)

.498

_16 3

I .496 t

3/4

(19mm)

APPROX.

1/4 (6mm) ---f 1

CAVITY DIMENSIONS

-T ,3 -16 UNF - 213. THD. FULL THD. i MIN. DR - 8 SAE MACHINING 1.025 .500 SPOTF ACE.5. I

UNF - 2A THO

-110-

/4 (6mm)

r ) .,.../1...

% (16mm)

i L-r

. 10

(32mm)-.-

7/8

(

IN) WEIGHT — 1 LB. (.45 Kg)

(22mm) -. (51mm) 2

►

if M IN .+

8 718

I I■ im.

li Iitsmiinir11

4 Y32 (102.4mm) OUTLET AREA ( 0 UT)

INLET AREA

It=

O Oil

Refer to coil catalog page for

Note: Please obtain certified

dimensions of available coils.

cavity and tool drawings

1 Normally Open 2 Normally Closed

0 VOLTAGE

2 14" NPTF 3 ,/, " NPTF 6T 34," SAE 3W 3/8 " BSPPL 2W 'A" BSPPL

1 2 1 2 VOLT D.C. Black

2 (51 mm)

e PORT SIZE

WIRE COLOR

(IN)

before machining.

e VALVE CONFIGURATION

COIL TERMINATIONS Refer to coil catalog page for dimensions of available coils.

_ Pigtails

C Conduit D Double Screw H DIN S Double Spade _ B Heavy Cord L Heavy Lead G Single Screw M Military Standard

0 SEALS

S Buna N

24 24 VOLT D.C. Yellow 36 36 VOLT D.C. Red 115 115 VOLT A.C. White

Sif Viton

230 230 VCLT A.C. Blue 3/80

2 Y32 (51.6mm)

20.04

Consul t factory for absolute seal compatibi I i ty.

.11W11 R CORPORATION

COUNTERBALANCE VALVE CARTRIDGE CALAVAR PART NO. 32585

•

Low leakage load holding ( 0 to 5 drops per minute, max. )

•

Built-in free-flow check valve; cracking pressure = 4 psi

•

Manual emergency load release

•

Pilot ratio 3:1

•

Seals : Buna-N

•

Pressure adjustment range : 1000 - 4000 psi

•

Standard setting : 2900 psi (stamped on cartridge hex )

•

Installation torque : 40- 45 ft-lbs.

Locating shoulder 2.38 MAX.

1.12

HEX

1.38

or Air = NW.WWIEWWwww.sg

liV

WM lig1 1( SCREW OUT To INCREASE PRESSURE SETTING. SCREW PILOT

IN TO

PILOT

RELEASE LOAD. 300

C4WITY IN FREE F LOW (VALVE)

PRESSURE DROP

-20 0 vS

vALYE

loo PILOTED OPEN — FREE FLOW CYL .

Symbol

IN COUNTERBALANCE (CYLINDER)

10 20 30 G.F.' M.

CALAVAR PART NO. 32585 COUNTERBALANCE VALVE CARTRIDGE SERVICE INSTRUCTIONS Calavar #32585 cartridges are basic service items in themselves. They are easily removed from their mounting for cleaning or replacement, but are not designed to be disassembled or repaired in the field. It is not necessary to remove an entire holding valve from the circuit plumbing. Simply unscrew the cartridge from its body for troubleshooting (below) or replacement. If, for any reason, a cartridge does not perform as required, the troubleshooting steps given below may be taken. Following this, if the cartridge still does not function, it should be replaced with a new factory-tested cartridge. The non-functioning cartridge may be returned to Calavar through your local dealer/distributor for evaluation if desired. A full report of our findings will be issued on request.

TROUBLE SHOOTING The most common cause of a cartridge failing to operate is dirt in the hydraulic fluid - dirt which lodges in the working parts and interferes with their operation. Cartridges can be cleaned without altering their pressure setting. To check and clean a cartridge which is not functionin • I) Remove the cartridge from the cavity. 2) Inspect for visible contaminants and carefully remove obvious particles. 3) Through the nose of the cartridge, manually operate the inner working parts several times. Use a wooden or plastic dowel to avoid damaging soft seats, sharp edges or finished surfaces. All parts should move freely. If possible, do this with the cartridge submerged in clean mineral spirits. 4) After "flushing", blow dry with clean filtered air. 5) Replace seals if indicated, using the appropriate service kit. 6) Reinstall cartridge, tighten to specified torque, and retest. 7) If this procedure does not eliminate the problem, replace with a new factory-tested cartridge.

CARTRIDGE SEAL KIT:

Calavar Part No. 93067

SE A LS

Kit contains quantity = 3 seals and quantity = 3 back-up rings. Install nose end back-up ring seal as

shown.

L SEAL

NOSE ENO BACK-UP RING

When replacing spiral back-up rings, take special care that the SPIRAL IS WOUND LIKE A LEFT-HANDED THREAD, so that the back-up ring will follow the cartridge into the cavity properly when being assembled.

INSTALLATION TORQUE:

40 to 45 ft. lbs.

1MLAVAIR 1111

COMOOAT1401■4

WATERPROOF LIMIT SWITCHES Calavar Part No. 40207 (All Boom Machines) Calavar Part No. 40208 (Model 86 and Truck Mounts)

Condor self-propelled aerial work platforms use waterproof limit switches manufactured by Control Products, Inc. They are designed for rugged military and mobile equipment applications. These switches are really WATER-PROOF. They are designed to operate reliably under exposure to water, oil, humidity, sand, dirt, vibration and shock. They do not rely on gaskets, 0-rings, or diaphrams. The neoprene jacket is bonded to the neoprene insulation on the leads, to withstand temperatures from -65°F to +I65°F. The CPI waterproof switches meet or exceed Military Specifications with exact ratings shown in Table I.

Large area actuating button accurately locates actuation point on snap action spring.

Plated steel switch case and cover.

Riveted snap action blade mounting points.

Flexible waterproof neoprene jacket molded to lead wires. Eccentric adjustment for precise tensioning of blade.

Rigid insulator and contact support. Contact - Carrying extension lever

REQUIREMENT

CPI MEETS OR EXCEEDS MU.. SPEC.

Construction

MS 39058

Material: Rubber Jacket Wire

MS 39058, Mil-R-3065 MS 39058, Ord. :7-7722204

Corrosion Resistance Fungus Resistance

Mil-Std. 202 Method 101 A 200 hrs., Salt Spray Mil-F-13927 90 Days

Water Proofness

Mil-S-13484 B 6 psi internal pressure, 30 min. 6 psi internal vacuum, 30 min. Immersed in Salt Water Solution

Extreme Temp. Res.

Mil-S-13484 B 24 hrs. at —65°-_L- 5'F 24 hrs. at 165° -±5°F Operated 1000 cycles 28 V.D.C. 15 amp load

Shock Resistance

202A Mil-Std 202A 100 gravity units "g's" 28 V.D.C. 15 amp (resistive) load during test.

Vibration Resistance

Lead Connections

201A Mil-Std 202A 1 hr. of vibration 3 major axes repeated in open position. (Not less than 6 hrs. in vibration.) .06 inch double amplitude frequency 10 and 55 CPS return to 10 CPS 28 V.D.C. 15 amp resistive load during test. Subjected to a tensile force of 25 pounds along axis of lead and perpendicular to axis of leads.

REQUIREMENT

CPI MEETS OR EXCEEDS MIL. SPEC.

Mechanical Actuation

Actuating Force — 1 to 2 pounds Release Force -- 6 oz. minimum Release Time — 1/4 sec. maximum at —65°F Pretravel — .015 minimum Overtravel — .015 minimum Differential — .005 maximum

Contact Voltage Drop

Mil-S-13484 B 28 V.D.C. 15 amp (resistive) load Voltage drop shall not exceed 150 millivolts

Overload

Mil-S-13484 B 28 V.D.C. 22-1/2 amp (resistive) 100 "make" and "break"

High Voltage

Mil-S-13484 B 440 Volts (RMS) at 60 CPS 1 min. between leads

Open Circuit Resistance

Mil-S-13484 B Open contacts not less than 1 megohm

Endurance

Mil-S-13484 B 28 V.D.C. 7-1/2 amp inductive) load 7-1/2 amp (lamp) load 25,000 "make" and "break" cycles (

115 V.A.C. 60 Hz 1/3 H.P. motor load 5 amp. lamp. 10 amp. resistive 25,000 "make" and "break" cycles -

115 V.A.C. 60 Hz 4 amp. inductive L/R = .049 8 amp. resistive 100,000 "make" and "break" cycles

CPI Waterproof Switches

PR24, PR30, PR40 HYDRAULIC PUMPS GENERAL DESCRIPTION Type Radial piston Displacement 2 4, 3.0, and 4.0 cu. in./rev. Approximate weight 60 lb.

FEATURES Variable displacement Pressure-compensated discharge Rapid response High power-to-weight ratio High volumetric and overall efficiency Exceptional reliability Low cost Three sizes, 2.40-, 3.00-, and 4.00-cu.-in./rev., with various shut-off-control and port-size options are available. Deactivation permits torque reduction as a starting aid. All ports are straight-thread 0-ring openings (SAE J514d). The pumps are provided with either two or three inlet ports which may be used in various combinations.

PERFORMANCE PR40 r,„, 40

30 11.1 2 30 con. cr

ii. I PR 30 PR24

00 20

(2500 RPM)

(2 10 O

The discharge characteristics of the pumps are nearly constant over a broad pressure range. Variable displacement is accomplished by hydraulic rather than mechanical means and is responsive to discharge line pressure. Discharge is infinitely variable between the point of inflection on the constant-discharge portion of the curve and zero flow.

0 500 1000 1500 2000 0

500 1000 1500 2000 2500 3000

DISCHARGE PRESSURE - PSI

PUMP SPEED - RPM

OVERALL (2000 PSI)

2500

With their rapid response characteristics, these pumps perform exceptionally well as the power source for closed-center systems, as well as for open-center systems.

Adjacent Curves: Average performance at 190° F (87.8° C) inlet temperature, 25 psi (1,76 Kg/cm 2 I charge pressure, using SAE 10W20

VOLUMETRIC

0 500 1000 1500 2000

2500

PUMP SPEED - RPM

Litho in U S A 12-73 OEM (Replaces pages dated 10-72)

2-PR234-1

SPECIFICATIONS: (Specifications and design subject to change without notice.)

Discharge Flow-GPM 2500 Displacement 1800 RPM RPM Control

Pump Displacement 1200 Series Cu-In/Rev RPM

Shut-Off Option Available

Shut-Off Ports Control

PR24 2.4 (39,3cm 3) 11.2

16.7

23.3 Variable

B Optional

Manual

PR30 3.0 (49,2cm 3) 14.5

21.8

30.2 Variable

B Optional

Manual, Electric

TR40 4.0 (65,5cm 3) 19.0

28.5

39.5 Variable

E Optional

Manual, Electric

JDT 841 (SAE J514d) "0" Ring Port Sizes Discharge Al Code '/8- 14 A '/a-14 B 1-V18-12 E

Inlet B2

B1 1416-12 1- 1/18-12 1- 5/18-12

Max. Pressure at Max. flow-2000 PSI Max. Zero Flow Pressure-2400 PSI Max. Speed-2500 RPM (Loaded); 2650 RPM (Zero Flow) *Requires AR 46054 Accumulator in Discharge Line

Cl V8-14 7/8-14 V e- 14

1- 5/8-12 1- 5/e-12

SHAFT SPLINE DATA NUMBER OF TEETH._ _ t114A 1/44 1 PITCH DIAMETER _ 1.1667 129.6341 CIRCULAR TOOTH THICKNESS AT 'PCs .1309 13.3251 W/RELATION GAGE MIN. ACTUAL .1251 13.1781 PRESSURE ANGLE 30° MINOR DIAMETER.._ 1.0400 126.4161 MAJOR DIAMETER 1.25 - 1.225 131.75 - 31.121

3.43 187 11 3.88 198.61---I

1.12 128.51

.531 113.491 DIA 4 HOLES

OPTIONAL INLET

DRAIN

1 1081 1.250 HEX 4.25 1221 1 86 DIA 1215.91 r8.50

176.144 -± 0.0251 2.9978 _t .0010 DIA 1"---1 1.38 135.11

♦-4E INLET

1 CLEARANCE TO SERVICE FILTER EVERY 1200 HRS

SHUT-OFF SCREW

1.50 1381 DIA

PRESSURE ADJUSTING SCREW

147.21 1.86 :75 1191

CLEARANCE FOR SHUT-OFF SCREW OPERATION

5 . 78 1146.81

1101.51 4.00-

4.361110.7) 4F 1.75 144.51 1-3.50 188.91-4

2-PR234

.47 1121 FULL DEPTH SPLINE

1121.41 4.78 1100.11 3.94

I 1321

L I91 .35 1.12 128.51 OPTIONAL INLET t: 44 136.61 2.86 172,61 9.02 12291

130.841 t0.131 1.2142 4._ 0050 DIA

JOHN DEERE

PR24,30,40 and 60 Series Hydraulic Pumps Technical Manual As the pistons move toward the race a partial vacuum is created at the outer or spring end of the pistons. This partial vacuum plus inlet oil pressure, opens the inlet valves (6) of the pistons, allowing oil to enter and fill the spring area of the pistons. At the end of the intake stroke, the partial vacuum no longer exists and the inlet valve spring closes the inlet valve against the inlet oil pressure.

OPERATION The pump shaft (4, Figure 1) has a cam (3) machined as an integral part of the shaft. A race (2) mounted on needle bearings is positioned around the cam for actuating the eight pistons (9) located radially around the race. The crankcase area (1) of the pump in which the pump shaft, cam, and race are located contains oil under pressure to hold the pistons away from the race. The pistons are held in this "standby" position until a demand for oil is placed on the pump by the operation of one or more of the hydraulic functions. All eight pistons are connected together by two separate annular passages which serve as inlet (7) and outlet (12) galleries for the pistons. Each piston is connected to the annular passages by individual inlet (6) and discharge (11) valves. Operation of one or more of the hydraulic functions reduces pressure in the outlet gallery of the pump and crankcase outlet valve (15) assembly. This pressure reduction causes the crankcase outlet valve spring (16) to move the valve up, permitting oil from the pump crankcase to enter the inlet gallery of the pump. Reducing oil pressure in the pump crankcase permits the spring loaded pistons (9) to move toward the race.

FPD (7-74)

Further rotation of the pump shaft, cam, and race causes the pistons to move out, forcing the trapped oil through the discharge valve (11) into the outlet gallery. At the end of the pressure stroke the discharge valve spring (10) closes the discharge valve. This sequence of operation continues until the combined effort of all the pistons increases oil pressure in the outlet gallery. This increased pressure also takes place in the center and upper area of the crankcase outlet valve (15). The upper part of the valve is larger than the bottom, giving the increased pressure oil more surface to work against. This forces the valve down, overcoming resistance of the crankcase outlet valve spring. The valve moving down stops oil flow from the pump crankcase to the inlet gallery of the pump. The increased pressure oil in the upper area of the crankcase outlet valve enters the stroke control valve (13) assembly, forcing the stroke control valve open. This allows pressure oil to enter the pump crankcase, increasing crankcase pressure. The race moves the pistons out and the increased crankcase pressure holds the pistons away from the race in "standby" position. The stroke control valve (13) can be adjusted to give more or less pressure in the outlet gallery and pump crankcase. By controlling oil pressure in the pump crankcase, the amount the piston springs move each piston toward the race can be controlled, thereby controlling the stroke. Any oil leakage past the pistons and stroke control valve re-enters the inlet gallery of the pump. This is accomplished by a 0.060-inch bleed hole (14) from the area below the stroke control valve to the inlet gallery of the pump. This oil circulation also provides cooling for the pump.

60-10-1

60-10-2

PR-24, 30, 40 and 60 Series Hydraulic Pumps

GENERAL INFORMATION

HIGH PRESSURE OIL LOW PRESSURE CRANKCASE OIL LOW PRESSURE OIL FROM CHARGE PUMP

1—Pump Crankcase 2—Race 3—Cam 4—Pump Shaft

5—Inlet Valve Spring 6—Inlet Valve 7—Inlet Gallery 8—Piston Spring

9—Piston 10—Discharge Valve Spring 11—Discharge Valve 12—Outlet Gallery

Fig. 1-Oil Flow Through Hydraulic Pump

FPD (7-74)

7-74 (Replaces page dated 8-72)

13—Stroke Control Valve. 14-0.060 Inch Bleed Hole 15—Crankcase Outlet Valve 16—Crankcase Outlet Valve Spring 17—Stroke Control Valve Solenoid 18—Manual Destroke Screw

PR-24, 30, 40 and 60 Series Hydraulic Pumps

60-10-3

DIAGNOSING PUMP MALFUNCTIONS Pump Noise Or Squeal Stroke control valve spring guide binding. Dress down sharp bottom edge. Reset system pressure.

No Pump Output Pump out of stroke. Check pump shutoff screw. Reset pump stroke control valve. Stroke control valve stuck open. Pump shaft broken.

Loose drive coupling cap screws. Tighten to specified torque.

Erratic Pump Operation

Air trapped in stroke control valve oil cavity. Relieve tension on stroke control valve adjusting screw, bleed air through threads, and reset system pressure.

Stroke control valve not seating properly. Check for foreign material or damaged seat.

Pump Slow Going Out of Stroke

Leaking inlet or discharge valve, defective 0-rings. Replace inlet and discharge valve; replace 0rings in stroke control valve housing.

Wear at quad ring seal groove causes crankcase oil leakage. Replace pump housing and seal.

Piston springs not balanced. Check for broken springs or springs at unequal tension.

Standby Pressure Does Not Remain Constant

Pump piston sticking in bore. Clean pump and check for damaged piston.

FPD (7-74)

Stroke control valve piston sticking in bore. Replace piston or remove burrs with fine crocus cloth.

7-74 (Replaces page dated 8-72)

60 10 4 -

PR-24, 30, 40 and 60 Series Hydraulic Pumps

3. Drive inlet valve assemblies from housing with tool made from old R27157 Discharge Valve Guide (with chamfer ground off) and a driver with shoulder ground to fit guide (Fig. 5) (see Special Tools).

Disassembly Before disassembling pump, check shaft for end play. Steel shims are located in the stroke control valve housing for making this adjustment. End play should be from 0.002 to 0.006 in. Excessive shaft end play may be an indication of worn thrust washers. Disassemble pump as follows: 1. Remove stroke control valve housing. (Note the number of adjusting shims.) Remove discharge valve guides and valve springs (Fig. 6) and, using a magnetic pick up tool, remove discharge valves. Keep pistons, inlet valves, discharge valves and plugs sorted so they may be returned to their original positions. Pump parts tray JDH-21 can be used for this purpose. 2. Remove piston plugs and 0-rings (Fig. 6); pull piston springs and pistons from housing.

4. Drive discharge valve seats from the housing with JDE-54 Tool (see Special Tools). After discharge valve seats have been removed, drive out pump shaft assembly while supporting machined surface of pump housing on wooden blocks. 5. Remove pump shaft bearing race from the end opposite splined end of pump shaft. Then remove needle bearing from around pump shaft cam and press bearing off splined end of shaft. 6. Remove crankcase outlet valve and stroke control valve assemblies from stroke control valve housing. 7. Remove pump shut-off screw and crankcase outlet valve adjusting plug from the stroke control valve housing.

Inspection See Specifications and compare pump parts with dimensions given. Check all parts for excessive wear, scored or pitted surfaces, or other damage. Check for looseness of inlet valve stem in valve guide. This fit should be tight. When roller bearings have been removed from pump shaft, always use new thrust washers.

1—Inlet Valve 2—Pump Housing

Inspect stroke control valve and crankcase outlet valve for foreign material or varnish buildup. Remove varnish build-up with crocus cloth. Never use lapping compound to remove varnish.

3—Modified Guide 4—Modified Driver

Fig. 5—Driving Out Inlet Valve Assembly

FPD (7-74)

Thoroughly clean filter screen below the crankcase outlet valve.

7-74 (Replaces page dated 8-72)

PR-24, 30, 40 and 60 Series Hydraulic Pumps

17 21

18 8----10 37 16 17 11 1 3 j4 ;1 546/ q.(

60-10-5

S \rriN

22 - "

CD ° \23 22 21 26

1246f4

1—Plug (8 used) 14—Spring (8 used) 2-0-Ring (8 used) 15—Guide (8 used) 3—Inlet Valve (8 used) 16—Packing (8 used) 4—Plug 17—Thrust Washer (2 used) . 5-0-Ring 18—Pump Shaft 6—Sealing Washer 19—Roller Bearing (36 used) 7—Hose Connector 20—Race 8—Piston Plug (8 used) 21—Spacer (2 used) 9-0-Ring (8 used) 22—Cone (2 used) 10—Spring (8 used) 23—Bearing Cup (2 used) 11-e-Piston (8 used) 24—Shim 12—Discharge Valve Seat (8 used) 25—Cap Screw (4 used) 13—Discharge Valve (8 used)

26-0-Ring 27—Connector 28-0-Ring 29—Elbow 30—Elbow 31-0-Ring 32—Housing 33—Quad-Ring Packing 34—Oil Seal 35—Snap Ring 36—Discharge Valve Stop (8 used) 37—Discharge Valve Assembly (8 used)

Fig. 6 — Assembly View

Assembly NOTE: Always install new 0-rings, packings, and oil seals. Use overhaul kit available (see parts catalogue). Dip all parts in clean Type 303 SpecialPurpose Oil before assembly.

Install pump shaft bearing race in housing bore until it seats. Place pump shaft 0-ring in housing, coat sealing lips of pump shaft oil seal with lubriplate and install seal (lettered side out) using JDH-18 driver (see Special Tools). Drive in seal only far enough to allow snap ring to snap in place. If oil seal is installed beyond snap ring groove, the oil relief outlet will be restricted and oil seal failure will result.

Fig. 7 — instaiimq Od Seal cInd Snap Ring

FPD (7-74)

7-74 (Replaces page dated 8-72)

60 10 6 -

PR-24, 30, 40 and 60 Series Hydraulic Pumps

28-41' 27 26-0 0-28 25_1 c•--26 0-31 24 32

-3°

33 23 21 \

(9-316

18 1-0-Ring 2-0-Ring 3—Gasket 4—Steel Ball 5—Spring Pin 6—Bushing 7-0-Ring 8-0-Ring 9—Shut-Off Screw 10—Shut-Off Screw Assembly 11—Plug with Pin 12-0-Ring

13—Housing 14—Cap Screw (4 used) 15-0-Ring 16—Plug 17—Adjusting Screw with Washer and Nut 18—Plug with Pin 19-0-Ring 20—Bushing 21-0-Ring (2 used) 22—Special Washer 23—Spring 24—Spring Guide

25—Stroke Control Valve 26-0-Ring (2 used) 27—Sleeve 28-0-Ring (2 used) 29—Crankcase Outlet Valve 30—Sleeve 31—Packing (2 used) 32—Spring Guide 33—Filter 34—Spring 35—Special Washer (3 used) 36—Washer (2 used) 37—Solenoid Valve 38—Plug, Solenoid Test 39—O-ring 40-0-ring

Fig. 8 — Stroke Control Valve

Using Discharge Valve Seat Installation Tool (see Special Tools), drive on shoulder of seats with no more than 850 lbs. of force until they are bottomed in bore. Distance from pump housing surface to the discharge valve seat shoulder must be at least 0.870 in. Install thrust washer and bearing spacer on pump shaft. Press tapered roller bearing on splined end of shaft. Turn shaft over, place needle bearing race over pump shaft cam, and insert needle bearings. Install thrust washer and other bearing spacer. Press on tapered roller bearing.

Install inlet valve assemblies in pump housing and replace inlet valve plugs. Tightening the plugs will press inlet valves into place. Install pistons, springs, and piston plugs. Apply Loctite to plugs and tighten to 100 ft-lbs. For easier assembly, turn pump shaft until the piston assembly being installed is on the low part of the cam. Assemble and install stroke control and crankcase outlet valves in stroke control valve housing. Use Fig. 4, page 60-10-5 as reference in assembling zero/max flow pump stroke control valve.

Install assembled pump shaft in housing carefully so as not to damage oil seal. Install bearing and bearing race in pump housing.

FPD (7 74) -

7-74 (Replaces page dated 8-72)

PR-24, 30, 40 and 60 Series Hydraulic Pumps

SCRIBE LINE N1/4

SPECIFIED "CLEARANCE

CRANKCASE OUTLET VALVE ADJUSTING TOOL

60-10-7

After correct end play has been determined, remove stroke control valve housing. Install discharge valves, springs, and guides in main pump housing. Replace packings in stroke control valve housing and install control valve housing, using 85 ft-lbs on each cap screw. Add oil to seal cavity through bleed line connector to provide initial lubrication for shaft seal.

ADJUSTING WASHERS

T24243

1—Scribe Line 3—Adjusting Tool 2—Specified Clearance 4—Adjusting Washers

Fig. 9 — Cutaway of Stroke Control Housing with JOH-19 Too/ Installed

NOTE: Test JDH-19 Tool before using it to adjust crankcase outlet valve. Scribe line on plunger must align with top of plug when 35-.± 1/2 lbs. of force is applied. Add or remove shims (No. 10815 and/or No. 10816*) to obtain correct adjustment. If desired, standard SAE 1/4 in. steel washers (1/4" x 7/16" x 3/64") may be used instead of shims.

Adjust crankcase outlet valve using tool JDH-19. Install tool in housing leaving 1/8 in. clearance between flat surface of nut and housing (Fig. 9). Add adjusting washers as indicated. When the valve is adjusted properly, the scribe line will be flush with top of nut on the tool. This procedure is not used when assembling zero/max flow pump. Before installing discharge valves, springs, and guides, place stroke control valve housing, with adjusting shims, on pump housing. Tighten cap screws to 85 ft-lbs. Check pump shaft for end play. Add or deduct adjusting shims in the stroke control valve housing to obtain 0.0020 to 0.0060 in. end play.

FPD (7-74)

7-74 (Replaces page dated 8-72)

60-10-8

PR-24, 30, 40 and 60 Series Hydraulic Pumps

SPECIFICATIONS 24, 30 and 60

Pump Series

I.D. of housing at pump shaft 0-ring I.D. of housing at pump shaft oil seal I.D. bearing bores for pump shaft I.D. of piston bore O.D. of piston I.D. of inlet valve bore O.D. of inlet valve assembly Lift of inlet valve I.D. of discharge valve bore O.D. of pump shaft cam I.D. of cam race O.D. of cam race Thickness of drive shaft thrust washer Stroke control valve housing, flat within I.D. of stroke control valve bore in housing O.D. of stroke control valve I.D. of stroke control valve sleeve, lower section O.D. of stroke control valve sleeve O.D. of crankcase outlet valve, upper end O.D. of crankcase outlet valve, lower end I.D. of crankcase outlet valve sleeve, upper end

I.D. of crankcase outlet valve sleeve, lower end O.D. of crankcase outlet valve sleeve I.D. of crankcase outlet valve bore in housing Discharge valve spring free length test strength Clearance between flat surface of nut on Tool JDH-19 and pump housing

Pump shaft end play Thickness of adjusting shim, stroke control housing Standby hydraulic pressure

1.3850 to 1.3870 in. 2.0110 to 2.0210 in. 3.3745 to 3.3755 in. 0.8747 to 0.8753 in. 0.8740 to 0.8744 in. 0.9995 to 1.0005 in. 1.0010 to 1.0020 in. 0.0600 to 0.0820 in. 0.6245 to 0.6255 in. 1.9632 to 1.9638 in. 2.3400 to 2.3406 in. 2.8700 to 2.8800 in. 0.1230 to 0.1270 in. 0.0030 in. 0.7485 to 0.7495 in. 0.2661 to 0.2665 in. 0.3756 to 0.3762 in. 0.7481 to 0.7485 in. 0.4368 to 0.4372 in. 0.4678 to 0.4682 in. 0.4374 to 0.4380 in. 0.4684 to 0.4690 in. 0.7481 to 0.7485 in. 0.7485 to 0.7495 in. 1/2 in. 1-1/2 pounds at 5/32

0.9637 to 0.9643 0.9630 to 0.9634

1.7442 to 1.7448 2.2457 to 2.2465 2.8140 to 2.8160 0.0422 to 0.0452

1/8 (0.125) in. 0.0020 to 0.0060 in. 0.0060 to 0.0100 in. 2200 to 2300 psi

Piston Springs Compressed to Color code-yellow green blue red

FPD (7-74)

1% in. 34.0 to 35.5 to 37.0 to 38.5 to

7-74 (Replaces page dated 8-72)

35.5 lbs. 37.0 lbs. 38.5 lbs. 40.0 lbs.

1 3/4 in. 47.0 to 48.5 to 50.0 to 51.5 to

48.5 lbs. 50.0 lbs. 51.5 lbs. 53.0 lbs.

PR-24, 30, 40 and 60 Series Hydraulic Pumps

60-10-9

TORQUE VALUES Torque (ft-lbs.) 3.01 cu. in. 0.69 and 1.38 cu. in.

Item

100

100 36 35 20 85 32 25 25

Pump piston plugs Pump cover to body cap screws Pump drive special screws to crankshaft pulley Pump drive special screws to pump drive shaft Pump to pump support Pump drive shaft retaining screw(s) Pump drive coupler cap screws Coupler screw locknuts Stroke control housing to main pump cap screws

• • •

35 35 85 32 25 85

SPECIAL TOOLS No.

Essential Tools JDH-18* JDH-19* JDE-54*

Use

Name

Driver Crankcase outlet valve adjusting tool Driver

To install oil seal To adjust crankcase outlet valve Remove discharge valve seat

Time Saving Tools Contain parts during disassembly Install discharge valve seat Remove inlet valve assembly

JDH-21* Pump parts tray Fig. 12** Installation tool Fig. 13** Removal tool

I f

T23736

1—Tubing 2-2 to 4 in.

3—O.D. - 0.625 In. 4 - I.D. - 0.500 in.

Fig. t2-Ditcharge Valve Seat Installation Tool

1—Grind Off Chamfer 2—Driver Rod

3—R27157 Guide

Fig. 13-Inlet Valve Romovaligool

*Order from Service Tools Inc., 1901 Indiana Ave., Chicago, Ill. 60616. **Make in dealer's shop.

FPD (7-74)

7-74 (Replaces page dated 8-72)

PR 24 AR 39088 HYDRAULIC PUMP (2.41 Cubic Inch)

V-10 37 17 18 6 14 X536 11 1 2 13 / / A\-\

2 19 20

21 22

23 22 21 —25 26

T 29311

Key

Model or Serial No.

Part No. R 51912 R 27149 HR 53301

(

8 9 10

45438 R 495 R* R AR 55186

( ( (

11 12 13

R R R

27150 39067 49297

( (

4PP3 . 4PP3 -

14 15 16 17 18 19 20 21 22 23 24

39228 48738 56754 42467 39843 27145 45874 34349 8192 8223 27478 27479 1805 26906 *

( ( ( ( ( ( t ( ( ( ( ( ( (

4PP3 4PP3 -

25 26

R R R R R R R R JD JD R R 19H R

33 34 35 36 37

R AR R R AR

1 2 3

47580

) Plug (8 used) ) 0-ring (8 used) ) Valve, inlet (8 used)

4PP3 -

39729 * 52224 *

26137 49298 52785

Description

4PP3 4PP3 -

) Plug, hydraulic pump piston (8 used 1 0-ring (8 used) ) Spring, hydraulic pump piston (8 used) (set of 8 matched) ) Piston, hydraulic pump (8 used) ) Seat, pump discharge valve (8 used) ) Valve, pump discharge (also order one R49298) (8 used) ) Spring (8 used) ) Guide, pump discharge valve (8 used) ) Packing, discharge valve guide (8 used) ) Washer. thrust (2 used) ) Shaft, hydraulic pump ) Bearing, roller (36 used) ) Race ) Spacer (2 used) ) Cone, with rollers (2 used) ) Cup. bearing (2 used) ) Shim, .006" steel (3 used) ) Shim. .010" steel (2 used) ) Screw, cap, 1/2" x 2-1/4" (4 used) ) 0-ring

Housing. pump, with inlet valves. plugs. packings and seats (marked R45228) Packing. quad ring Seal. oil Ring. snap Stop. outlet valve (also order one R49297)(8 used) Valve. outlet assembly (8 used)

AR 39088 Pump assembly. hydraulic. complete * Kit listed below contains all parts followed by an asterisk O. AR 52223 ( 1 Kit. overhaul

FPD (7-74) (Replaces page dated 8-72)

30-4

PR 24 AR 39088 HYDRAULIC PUMP STROKE CONTROL VALVE (2.41 Cubic Inch Pump) 1 28 co 27— 26—o 0---.28 25 V30 dr o-26 24 •-31 0 -32

— 10

33 23-1 11 22--0 F34

21 - 0

20—

qii---31

19—' •-35 37—i C--21 17-8 ir.--36

Key

Part No

Description

Serial No.

R 56755 R 56756 R 56757 R 26552

0-ring 0-ring Gasket Ball. 5/16 -

7 8

R 26448 R 30903

0-ring 0-ring

10 11 12

AR 33249 AR 51745 R 26906

Plug. with pin 0-ring

13 14 15 16 17 18 19 20 21

AR 19H R R 14H AR R R F R R R R R R R R R R R R R R 24H AR AR R

1 2 3

22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

Screw assembly. pump shut-off

Housing (R426631. stroke control valve, with ball Screw, cap. 1/2" x 3-1/4" (4 used)

38714 1945 26287 31631 1021

0-ring Plug Nut, 7/16"

Screw, adjusting, hex head (Optional socket head, use AR 52254 and 14141021)

51929 28782 28781 3171 R* 48808 31781 32344 27472 27166 27471 27564 27172 2 74 76 27174 27167 27173 27159 27170 1298 26646 52254 27218

0-ring Bushing. adjusting screw 0-ring (2 used)

Washer, special Spring

Guide, spring Valve. pump stroke control 0-ring (2 used) Sleeve. pump stroke control valve 0-ring (2 used) Valve, pump crankcase outlet Sleeve. pump crankcase outlet valve PaCking (2 used) Guide. spring Fitter Spring Washer. special (3 used)

Washer, 3/8" x 5/8" x .030" (2 used) Plug with pin

•

Screw, adjusting, socket head (Optional hex head, use AR51929) Plug

Kit listed below contains all parts followed by an asterisk (* )

AR 52223

FPD (7-74) (Replaces page dated 8-72)

1 Kit. overhaul

JULY 1977

SERVICE MANUAL LOAD SENSING PRESSURE COMPENSATING PROPORTIONAL DIRECTIONAL VALVE

MODEL NO. 269300 BERTER I IPFZEurra*

SERVICE

MANUAL

MODEL 269300 SERIES

PAGE NO. I Introduction

II System Description

III Operation Load Sensing - Pressure Compensating ---- 3 6 Remote Electro-Hydraulic Control 9 Remote Pilot Oil Control IV Assembly & Service 9 Dual Port Inlet Directional Valve Spool Section 13 Single Port Inlet 13 14 Pilot Valve 16 Shuttles Purge Manifold 17 V Installation

VI Start Up & Trouble Shooting 21 VII Specifications

FIGURE

IDENTIFICATION

Figure #1 - Module Assembly Figure #2 - Circuit Schematic Figure #3 - Remote Electro-Hydraulic Control Schematic Figure #4 - Remote Pilot Oil Control Schematic Figure #5 - Dual Port Inlet Manifold Figure #6 - Directional Valve Manifold Figure #7 - Manual Override End Cap Figure #8 - Single Port Inlet Manifold Figure #9 - Basic Shuttle Figure #10 - Adjustable Shuttle Figure #11 - Purge Manifold Assembly Figure #12 - Bertea Valve Installation Figure #13 - Remote Purge System Schematic Figure #14 - Installation Drawing 269300 Figure #15 - Pilot Valve Installation

BERTEA

INDUSTRIAL PROOUL. I

SERVICE MANUAL MODEL 269300

BERTEA LOAD SENSING - PRESSURE COMPENSATING PROPORTIONAL DIRECTIONAL VALVE WORK PORTS (CYLINDER) TYP.

SINGLE PORT INLET

DIRECTIONAL VALVE MANIFOLD (TYP)

PILOT VALVE SYSTEM RELIEF VALVE

SHUTTLE VALVES PILOT CONTROL FLUID INLET

PRESSURE SPOOL END REDUCER CAP TYP SYSTEM, RELIEF VALVE

DUAL PORT INLET

BY-PASS COMPENSATOR & UNLOADER

- COMPENSATOR CONTROL PORT

MODULE ASSEMBLY FIGURE 1

INTRODUCTION The Bertea Load Sensing Pressure Compensating directional valve module, Figure #1, provides a means of sensing the highest "work cylinder port" pressure and then adjust a by-pass compensator or variable pump compensator to provide a pump pressure of 150 psi above this value. Since the pump pressure is always held at only 150 psi above the highest load pressure, this system reduces the energy requirements

BERTER / INDUSTIRIAL PROOUL.

SERVICE MANUAL MODEL 269300

and heat generation. Additional features are provided; such as, unloading the pump to 50 psi when the valves are not in use; providing constant rate control for multiple function operation, and providing a single module for dual pump application. In order to provide control of the directional valve spools under various system configurations and operating modes, the module is designed to contain two separate hydraulic circuits. The main power pump circuit is configured in the normal manner to provide power oil to the working cylinder ports. The control circuit used to position the directional valve spool is independent of the power oil circuit and operates at approximately 300 to 400 psi. This circuit separation, also, provides the capability to control the module from a remote location with electro hydraulic controls or by a remote pilot oil system with variable pressure capability. The method used to port the Pressure Compensating Control Circuit to tank when not in use requires all directional valve spools to be open cylinder port configuration. Therefore, external controls will be required for load holding capability. II

SYSTEM DESCRIPTION

The Bertea pressure compensating valve module consists of (5) basic sub-systems as noted: (Ref: Figure 1) A. The shuttle valves, within the spool sections, sense the highest cylinder port pressure within each spool section manifold assembly and, also, select the highest load pressure among all of the spool sections in the complete module, and port this signal to the by-pass compensator. These shuttles, also, connect the pressure compensation control circuit to tank thru the open cylinder port type directional valve spools. B. The by-pass compensator, within the inlet manifold, is controlled by the highest load pressure and it will by-pass all excess pump flow at 150 psi above the highest load pressure. C. The optional pressure reducer, within the spool section manifold, is controlled by the highest cylinder port pressure of that spool section and maintains 100 psi pressure drop across the directional valve spool regardless of supply pressure. D. The directional valve spool directs and meters the fluid to the function as specified by the amount of spool travel from its neutral or shut off position. This travel is determined by the difference in pressure established in the two spool end caps by the external control source. Since the pressure reducer holds 100 psi pressure drop across this spool, then for any fixed spool position the flow to the

BERTER

INDUSTRIAL PPODUC,

SERVICE MANUAL MODEL 269300

function thru the spool metering notch will be constant regardless of load. This provides constant rate for the function. E. The remote control system determines the directional valve spool position by varying the pressure in each spool end cap. The two commonly used control systems are: 1) Remote pilot control oil ported to each end cap thru external tubing from a remote pressure reducing valve. 2) Electro-hydraulic pilot valves, manifold to the spool section, and controlled electrically from a remote location. This pilot valve obtains its pilot supply oil from the module and ports it to the spool end cap at various pressure levels proportional to the electrical command. Figure 1 & 2 shows a typical 4 spool section module of the following configuration in sequence, starting with the dual port inlet: Dual Port Inlet Manifold Assembl with a by-pass compensator, un oa•er, system re ie va ve an• an optional pilot control circuit relief valve. Directional Valve Manifold Assemblies with shuttles and pressure reducers. Plugs in the pressure compensation control line and main pump line between directional valve manifold #3 and #4. Directional Valve Manifold with one shuttle and a blank spool in the pressure reducer cavity. Single Port Inlet Manifold Assembly with a by-pass compensator, unloader, and system relief valve. This module is supplied by one 20 gpm pump ported into the dual port inlet for directional valves #1, #2, & #3, and one 30 gpm pump ported into the single port inlet for directional valve #4. The remote control configuration can be electro-hydraulic using the Bertea pilot valve and electrical controllers or it can be the remote pilot oil system using lever operated pressure reducing valves to provide control oil from 0 to 200 psi into either spool end cap. III OPERATION (Figure #2) A. LOAD SENSING & PRESSURE COMPENSATING

When the system is not in use and the directional valve spools are in the center position, the pressure compensating (P.C.)

BERTER I

IAL PRODUCTS

SERVICE MANUAL MODEL 269300

control circuit is connected to tank thru the shuttles and open cylinder port spools! Since this connects the large area of the unloading piston (Item 4) to tank allowing the piston to move away from the compensator and the spring to relax its preload; the pump output is by-passed to tank at 50 psi, rather than the 150 psi control level. This results in lower stand by heat generation. The directional valve spool (Item 9) is spring caged to the center position with a 19# preload. As the remote control system builds up a differential pressure across the spool - ie increases the pressure in one end cap and lowers the pressure in the other end cap - the spool will move out of center detent at about 40 psi differential pressure. Increasing the differential pressure will move the spool thru its 0.100 inch over lap length to the initial metering area and, also, with this movement, close off the open path across the spool from the cylinder port to the tank port. (Additional increase in differential pressure, up to 200 psi, will move the spool thru the metering notch area to full stroke of .350 travel and maximum flow.) The shuttle system of spool section #1 is now connected to the cylinder load instead of the tank port. Shuttle "A" (Item 8 Large Shuttle) senses this load pressure and passes it thru shuttle "B" (Item 7 - Small Shuttle) to the P.C. control circuit. This pressure moves the unloading piston (Item 4) into the operating position which preloads the spring (Item 2) to the 150 psi operating position. The compensator spool (Item 1) will now vary the metering notch opening from pump supply to tank return, holding pump pressure at 150 psi above the cylinder port load pressure. If the directional valve spool #1 is set to flow 5 gpm, the remaining 15 gpm of the pump will be by-passed. The pressure reducer spool (Item 6), also receives a load pressure signal from shuttle "A", and begins to reduce its meter notch area to hold a 100 psi pressure drop across the directional valve spool. It is this feature that provides constant flow regardless of changes in load pressure or pump pressure. Logically if only one spool section were to be used this reducer would not be required, since the by-pass compensator always holds the pump at 150 psi above the load. Assume that the load pressure of directional valve spool #1 is 500 psi and the pump pressure is 150 psi higher or 650 psi! Then the directional valve spool, of section #3, is moved to operate its function at 7 gpm. The load pressure of #3 is 1500 psi.

[BERTER

SERVICE MANUAL MODEL 269300

P.C. CONTROL CIRCUIT °SHUTTLE "B"

SHUTTLE " A"

DUAL PORT SPOOL SPOOL INLET SECT ION SECTION 1 2 REMOTE CONTROL MANIFOLD BLOCK CIRCUIT OR PUMP PI LOT VALVE

SPOOL '- SPOOL SECTION SECTION 3 # 4

SINGLE PORT INLET LJ

LOAD SENSING - PRESSURE COMPENSATING CIRCUIT SCHEMATIC FIGURE 2 5

BERTER / ,

N.10cguIR

SERVICE MANUAL MODEL 269300

Shuttle "A" of spool section #3 senses this 1500 psi load and ports it to the pressure reducer (Item 6) of this spool section and, also, on to the P.C. control circuit. Shuttle "B" is omitted in this manifold since the P.C. circuit of #4 is blocked from this #3 spool section system. This 1500 psi load signal is transmitted thru the "B" shuttles of the P.C. control circuit to the by-pass compensator which in turn increases pump pressure to 1650 psi. Now the pressure reducer (Item 6) of spool section #1 must operate to reduce the 1650 psi pump pressure to 600 psi in order to maintain the 100 psi differential across the directional valve spool and thus hold constant rate. The system relief valve (Item 3) limits maximum pump pressure by bleeding off the P.C. control circuit at the pre-set level. The flow limiting orifice (Item 5) permits the small poppet of the relief valve to control the pressure level in the spring cavity of the compensator. This results in the pump output being by-passed to tank at relief setting. Since the 30 gpm pump supplies fluid to only spool section #4, it is not required to use a pressure reducer spool in the manifold, because the by-pass compensator (Item 1) of the single port inlet will hold 150 psi differential pressure across the directional valve spool. This 150 psi will maintain constant rate of the function for any directional valve spool position. A simple blocking spool (Item 10) is used in place of a pressure reducer spool. B. REMOTE CONTROL OF DIRECTIONAL VALVE SPOOL The two basic systems used to control the position of the directional valve spool, and thus control the speed or position of the function are (1) Electro-Hydraulic or (2) Remote Pilot Oil. Each system varies the differential pressure in the end caps to position the spool proportional to input command! Power system output flow will be provided from the cylinder port adjacent to the end cap with the highest pressure. The Remote Electro-Hydraulic system uses the pilot valve and remote electrical controller as shown on figure 3. The operation starts with a manual input to the remote electrical controller that provides an output signal(0 to 3.6 volts) proportional to handle position. This signal is conducted to the pilot valve where it is converted to a differential control pressure by the movement of the jet diverter wand. The pilot valve operates on a 300 psi differential pressure across its supply to tank ports and will provide a maximum differential output control pressure between its Cl and C2 output ports of 240 psi. (ie - minimum pressure recovery of 80%) Each pilot valve requires a continous flow of 0.5 to 0.6 gpm

BERTER I INDUSTRIAL

SERVICE MANUAL MODEL 269300

PROOUL.

RETURN D.C. POWER INPUT

PRESSURE WAND

MANUAL INPUT HANDLE

• iri;•

MI i 1 111 , la...

. ii illilriling lis 11—ht . NM

1 SECT ION

A-A

1 5wi

1 Irmo , pm i

\II g orge

\ \ III 1111-1 1 El1!fe

REMOTE ELECTRICAL CONTROLLER

- l ige 40 ambrOi .

L1 .

A PILOT VALVE C

DIRECTIONAL VALVE

LOAD

\\\\\\\\\ OUTPUT ACTUATOR

REMOTE ELECTRO-HYDRAULIC CONTROL FIGURE 3

BERTER I INDUSTRIAL PROOUL,

SERVICE MANUAL MODEL 269300

MANUAL LEVER REMOTE PRESSURE REGULATING VALVE

•

DIRECTIONAL VALVE

\\\

LOAD

\\\ OUTPUT ACTUATOR

REMOTE PILOT OIL CONTROL FIGURE 4

NDUSTRIAL BEF?TER / I'PROD

SERVICE MANUAL MODEL 269300

at 300 psi differential pressure. An isolated source of control fluid is required as shown on figure 12: A positive polarity of the red wire of the pilot valve coil will provide flow from the cylinder port adjacent to the pilot valve. The Remote Pilot Oil Control system, Figure #4, starts with a remote pressure regulating valve that will provide an output pressure (0 to 200 psi) that is proportional to valve lever position. When the pressure regulating spool is in the neutral position, both control ports (C1 and C2) are connected to tank. As the spool is moved with manual lever travel, the pressure will increase in the selected control port, overcoming the 19# directional valve spool spring detent. Additional pressure increase with the remote pressure regulating valve operation will position the directional valve spool in proportion to command. An optional purge manifold assembly is discussed in section IV, and figure #11. IV ASSEMBLY & SERVICE The Bertea module is a stack type valve that permits the use of multiple spool sections and various options of controls in the inlets or directional valve manifolds. Dual Port Inlet Manifold Assembly Figure #5 The dual port manifold assembly provides inlet porting for both the power fluid circuit and, also, the pilot valve control fluid circuit. The power fluid circuit contains both inlet and outlet porting, but the control fluid circuit is inlet porting only. The system relief valve (Item 21 thru 26) is adjustable up to 3000 psi. The orifice (Item 18) limits the flow into the compensator spring cavity, permitting the relief valve to limit system pressure by porting this fluid to tank. The compensator unloader (Item 9) is a selected fit of the piston to the housing and, therefore, must be changed as an assembly. When electro-hydraulic pilot valves are used for directional valve spool control, the dual port inlet should contain a pilot pressure relief valve (Item 33) to maintain the required 300 psi control pressure. All other inlets may use the optional port plug (Item 30).

BERTEA

ITEM NO.

QTY.

SERVICE MANUAL MODEL 269300

PART NUMBER

DESCRIPTION

1 1 1 1 1 1 1 1 1 1 AS REQ'D

269342-20 3-920N552-90 261895-5 2-122N674-70 259341-3 3-916N552-90 8-922N300-90 2-822N674-70 269388-1 259337-1 249899-11

HEX. PLUG "0" RING GLYD RING "0" RING ORIFICE PLUG "0" RING BACKUP RING "0" RING UNLOADER ASSY. SPRING SHIM

12 13 14 15 16 17 18 19 20 21 22 23 24

1 1 1 1 1 1 1 1 1 1 1 1 AS REQ' D

269336-1 3/8-24 UNF 5/8x1/4x3/8-24 UNF 269343-1 MS28774-006 2-006N674-70 269374-1 269376-3 3-903N552-90 1x5/16x3/4-16UNF 269316-1 2-014N674-70 249899-12

SPOOL ACORN NUT HEX. NUT THROTTLE BACKUP RING "0" RING ORIFICE PLUG HEX. HD. PLUG "0" RING HEX. NUT PLUG "0" RING SHIM

25 26 27 28 29 30 31 32 33

1 1 1 1 1 1 1 1 1

269318-1 269317-1 234950-1 3-908N552-90 269307-1 242925 3-912N552-90 2-014N674-70 231852-1

2 2 2 1 1

3-912N552-90 2-014N674-70 2-117N674-70 24854-3 2-112N674-70 2-122N674-70 2-107N674-70

SPRING POPPET FILTER "0" RING INLET MANIFOLD PLUG ASSY. "0" RING "0" RING PILOT PRESS. RELIEF VALVE "0" RING "0" RING "0" RING BACKUP RING "0" RING "0" RING "0" RING

2 3 4 5 6 7 8 9 10 11

34 35 36 37 38 39 40

22 24 26 25 23

0 269344-1 "0" RING KIT

DUAL PORT INLET MANIFOLD FIGURE 5

BERTER

ITEM NO.

A A A A A

QTY

3 4

5 6 7 8 9 10 11 12 13 14 15 16 17 18

4 4 4

19 20 21 22 23 24 25 26 27 28 29 30

2 2 8 2

1 1 1 1 1 1 4 2 2 2 2

1 1 1 2 2 2

1 1

SERVICE MANUAL MODEL 269300

PART NUMBER 10-24x1 3/4 269357-1 10-24x1 1/2 269327-1 #6-32x1/2 234980 234959 249896 242933 242907 234912 225931-1 269305-1 234927-1 234953-1 231830-1 234932-1 234931-1 -3 -9 225989-1 269315-1 #10-24x3/4 1/8-27 NPT AS REQ'D 261850-3 3-912N300-90 2-112N674-70 2-114N674-70 248584-3 2-122N674-/0 2-107N674-70

DESCRIPTION SCREW-SOC. HEAD MANIFILD ASSY.-PURGE SHUTTLE VALVE SCREW-SOC. HEAD MANIFOLD ASSY.PURGE CIRCUIT SCREW-PHILLIPS HD. SCREW-SOC. HEAD . WASHER SEAL KIT COVER GASKET PILOT VALVE GASKET BODY SPRING GUIDE SHIM SPRING PIVOT PIN .350 SPOOL TRVL PIN .300 SPOOL TRVL PIN .250 SPOOL TRVL GASKET END CAP SCREW-SOC. HEAD PLUG SOC. HEAD SPOOL PLUG ASSY. "0" RING "0" RING "0" RING BACKUP RING "0" RING "0" RING

& 22

269344-1 "0" RING KIT

DIRECTIONAL VALVE MANIFOLD (SHEET 1 OF 2) FIGURE 6

SERVICE MANUAL MODEL 269300

(BERTER

ITEM NO.

QTY.

269360-1

32 33 34 35

1 1 1

8-014 2-014 N64-70 269370-012 269364-1

269330-1

37 38 39 40

1 1 1 1

8-010 2-010N64-70 269379-009 269359-1

41 42a

1 1

3-916N552-90 269335-1

PART NUMBER

269340-1

42B 43 44 45 46

1 2 1 1

47 48 49

1 1

269347-1 249899-11 269375-1 269333-1 269349-1 269345-1 2-115 269394-1

DESCRIPTION SHUTTLE BY-PASS VALVE ASSY. BACKUP RING "0" RING "0" RING SHUTTLE VALVE ASSY. (1/4 BALL) SHUTTLE VALVE ASSY. (5/32 BALL) BACKUP RING "0" RING "0" RING PLUG ASSY. (SHUTTLE VALVE) "0" RING PLUG, PRESSURE REDUCER (USE WITH ITEM 35) PLUG, PRESSURE REDUCER (USE WITH ITEM 31) RETAINER SHIM SPRING SPOOL-PRESSURE REDUCER SPOOL-BLANK PLUG O'RING PLUG

42 A 428

38 31

O 38 37 36

DIRECTIONAL VALVE MANIFOLD (SHEET 2 OF 2) FIGURE 6

BERTER

INIDUSTRtAL .4=100UL. ,

SERVICE MANUAL MODEL 269300

Directional Valve Manifold Assembly Figure #6 Each directional valve assembly consists of the directional valve spool (Item 23); a means to position the spool by either the electro-hydraulic pilot valve (Item 11) or a remote pilot oil system (Item 2 or 4); a shuttle to sense highest working cylinder port pressure (Item 31 or 35); and a shuttle (Item 36) to transmit the highest pressure with in the total module to the inlet compensator. An optional pressure reducer spool (Item 46) is provided when constant rate for the function is required in multiple spool section stacks. When only single functions are operated at one time, a blank spool is provided in order to simplify the system. The standard end cap (Item 20) with various length pins (Item 18) determine the maximum spool travel and hence the maximum flow rate for any specific spool. This selction of spool and pins provide field adjustment of desired function speeds.

The optional manual override assembly for a remote controlled spool is shown in Figure #7. This assembly will provide direct manual control of the spool in the event of a failure in the remote controller, the electrical power supply, or a malfunction of the pilot valve. The hand knob is held in the thread disengaged position by a light spring to prevent inadvertent operation. Press the knob inward while rotating to engage the threads in the cap and the drive screw. Continued rotation clockwise will move the spool from center and will provide flow from the cylinder port adjacent to this end cap. The knob must be rotated outward and disengaged prior to operating the manual override on the opposite end cap. A plug is provided, as shown, to bleed the air from each end cap after initial assembly and operation. Air trapped in the spool end cap will reduce the response of the valve assembly. Single Port Inlet Manifold Assembly Figure #8 The single port manifold provides inlet porting for the power system fluid only. The tank return porting has an optional configuration of joining the pilot valve control fluid tank return, to the power fluid return for common porting to tank or separating the two return circuits for independent tank lines. When the h NPTF pipe plug (Item 29) is installed, it will block the pilot control return fluid from the power system tank line! With this configuration the pilot fluid must be connected to tank from port 28A. Without the h NPTF plug installed, both fluid return circuits are common.

BERTER INDUSTRIAL PRODUC,

SERVICE MANUAL MODEL 269300

irmaima.am

MANUAL OVERRIDE END CAP ASSEMBLY NO. 234955 FIGURE 7

The system relief valve (21 thru 26) is adjustable up to 3000 psi. The orifice (Item 18) limits the flow into the compensator spring cavity, permitting the relief valve to limit system pressure by porting this fluid to tank. The compensator unloader (Item 9) is a selected fit assembly of the piston to the housing and, therefore, must be changed as an assembly.

Pilot Valve Assembly The electro-hydraulic pilot valve is a separate, replaceable assembly as shown on Figure #6 and #15. Each valve has 150 micron filter, installed beneath the roll pin that is used for installation orientation.

BERTER

ITEM NO.

QTY.

SERVICE MANUAL MODEL 269300

PART NUMBER

DESCRIPTION

1 1 1 1 1 1 1 1 1 1 AS REQ'D

269342-20 3-920N552-90 261895-5 2-122N674-70 269341-3 3-916N 552-90 8-022N300-90 2-022N784-70 269388-1 269337-1 249899-11

HEX. PLUG "0" RING GLYD RING "0" RING ORIFICE PLUG "0" RING BACKUP RING "0" RING UNLOADER ASSY. SPRING SHIM

12 13 14 15 16 17 18 19 20 21 22 23 24

1 1 1 1 1 1 1 1 1 1 1 1 AS REQ'D

269336-1 3/8-24 UNF 5/8x1/4x3/8-24UNF 269343-1 MS28774-006 2-006N674-70 269374-1 269376-3 3-903N552-90 1"x5/16x3/4-16 UNF 269316-1 2-014N674-70 249899-12

SPOOL ACORN NUT HEX. NUT THROTTLE BACKUP RING "0" RING ORIFICE PLUG HEX. HD. PLUG "0" RING HEX NUT PLUG "0" RING SHIM

25 26 27 28 29

269318-1 1 269317-1 1 269310-1 1 3/8-18 NPT 1 AS 1/4-18 NPT REQ'D

1 2 3 4 5 6 7 8 9 10 11

SPRING POPPET OUTLET MANIFOLD PIPE PLUG SOCKET HD. PIPE PLUG SOCKET HD.

SINGLE PORT INLET MANIFOLD FIGURE 8

288

, BERTER / . ,

N O USTR I ODUG b

SERVICE MANUAL MODEL 269300

BASIC SHUTTLE FIGURE 9

Shuttle Assemblies Two types of shuttle assemblies are used in the P.C. control circuit. The basic shuttle shown in Figure #9, is a single ball unit that seals in either position. This type is the standard configuration for shuttle "B" (Ref: Figure #2), and is optional for shuttle "A" usage. There are no adjustments in this shuttle. Figure #10 shows the second shuttle configuration used as shuttle "A", and it provides an adjustable by-pass bleed from cylinder port "B" to cylinder port "A", as shown on Figure #2. This is used to smooth the operation of a holding valve in a topping cylinder application. Therefore, cylinder port "B", which is adjacent to the pilot valve or purge manifold mounting face must be connected to lower the function.

BY-PASS BLEED ADJUSTMENT

ADJUSTABLE BY-PASS SHUTTLE FIGURE 10

BERTER

PRODUCTS

SERVICE MANUAL MODEL 269300

PURGE MANIFOLD ASSEMBLY FIGURE 11

Purge Manifold Assembly The purge manifold assembly, shown in Figure #11, provides the interface porting for the Remote Pilot Oil applications. The manifold is ported to receive control oil from the remote valve into the h" tube ports on the top surface, and, also, to provide porting into the directional valve spool section for Cl, C2, R (return), and P c (control pressure). This control pressure (P c ) is received internally from the inlet manifold and is not from the remote pressure reducer valve. The external circuit is shown on Figure #13. When 200 psi pressure is applied at P c , the poppets are held in the position shown, which isolates C1 and C, from R (return). This is the normal operating configuration for the system. In order to purge cold oil from the lines connecting the purge manifold to the remote pressure reducing valve, the Pc port is connected to tank. Now the 100 to 200 psi pressure in the control lines C1 and C2 will unseat the poppets, and the oil will flow into the return port (R), and back to tank.

BERTER /

SERVICE MANUAL MODEL 269300

INSTALLATION

A. FILTRATION & HYDRAULIC SYSTEM PREPARATION

The life of any hydraulic system is sensitive to the cleanliness of the fluid stream. It is recommended that good cleaning and flushing procedures be followed in the assembly and test of the system. The filtration configuration recommended for the Bertea system is shown on Figure #12. A power system filter of 10 micron rating is to be used either as a return line unit or a full flow high pressure filter on the power system pump discharge. The non by-pass filter for the pilot fluid line should be as large a flow rating as possible and of a 25 or 40 micron rating. Since this pilot circuit is a constant flow, if the filter is the same micron size as the system filter, it will have a short life. The small tube type filter in the inlet manifold (234950, Figure #5) is 100 micron rating and is only intended for coarse material. Each pilot valve has a 150 micron filter on its inlet port as a protection while replacing units on a manifold. B. PILOT FLUID CIRCUIT

The separate pilot fluid circuit options, as shown on Figure #12 and #13, provide capability of controlling the directional valve spool under any operating mode. When using electro-hydraulic pilot valves, (Ref: Figure #12), a differential pressure of 300 to 350 psi is required across the module. If the return line pressure is 50 psi, an inlet pressure of 350 psi would be required. Each standard pilot valve requires a continous flow of 0.5 to 0.6 gpm and the pilot pressure relief valve is set to flow 0.5 gpm at 300 psi Lip. Therefore, a (4) spool section module would require 4 x 0.5 gpm plus 1.0 gpm for the relief valve (plus flow tolerance) or 3 gpm total constant flow. If a remote pilot oil system is used as shown on Figure #13, the method of obtaining the pilot oil can be the same, but the required flow rate and pressure will be lower. Since the manual pressure reducer valves are blocked center, they only flow oil when actuated. Therefore, a flow rate of 2 to 3 gpm is adequate for control and, also, for the purge mode. The required pressure is 250 psi.

BERTER

SERVICE MANUAL MODEL 269300

PUMP OPTIONS

••

oo#1

•

40 •

■'

RETURN FLOW 10 MICRON FILTRATION #111, RECOMMENDED

...1 1 . I 1

FLOW DIVIDER

10I _,t0

PILOT VALVE

410

1. OPEN CENTER OPERATION A FIXED DISPLACEMENT PUMP USED WITH A FLOW DIVIDER 2 OPEN CENTER OPERATION

pII

DUAL FIXED DISPLACEMENT PUMP

3 CLOSED CENTER OPERATION A VARIABLE DISPLACEMENT PUMP CAN BE USED WITH EITHER A FLOW CONTROL VALVE OR SEPARATE PUMP

•

'III •• I

•••

• II • ••

FLOW CONTROL VALVE

.•••

BERTEA PROPORTIONAL CONTROL VALVE

•)if

HAND CONTROLLER

VARIABLE POTENTIOMETER

TEE FOR PRESSURE GAGE CONTROL FLUID FILTER 40 MICRON NON BY-PASS

LOW FLOW FIXED DISPLACEMENT PUMP

12V BATTERY

BERTER

SERVICE MANUAL MODEL 269300

PURGE "ON DEMAND" SYSTEM OPERATION CONTROL LINES

NORMAL OPERATING MODE 1.

PRESSURE REDUCER VALVE BANK

PURGE MANIFOLD

2. 3.

Purge mode selector valve connects the tank line of the pressure reducer valve bank (Port B) to the reservoir. Module pilot pressure line (Port A) is connected to 250 psi. Shuttles in purge manifold seal the control lines from tank port as shown.

PURGE MODE OPERATION 1.

2. 3. DIRECTIONAL VALVE MODULE PILOT PRESSURE LINE

CONTROL PRESSURE PORT

Purge mode selector valve connects tank line of pressure reducer valve bank (Port B) to 250 psi supply. Module pilot pressure line (Port A) is connected to reservoir. The 250 psi is ported thru pressure reducer valve bank; thru control lines to purge manifold! Shuttles unseat and connect control lines to tank port in module. This removes the cold oil in the control lines.

250 PSI RELIEF VALVE

PURGE MODE SELECTOR VALVE SHUTTLE TANK PORT

PILOT PRESSURE PORT

PURGE MANIFOLD REMOTE PURGE SYSTEM SCHEMATIC FIGURE 13 20

BERTER

lgulr IrtL

IN Dc

SERVICE MANUAL MODEL 269300

C. REMOTE PILOT OIL WITH PURGE OPTION The remote pilot oil system uses manually operated pressure reducers to vary the control pressure in the directional valve spool end caps from 0 to 200 psi. Spool position is proportional to the differential pressure in the end caps. The addition of a manually selected purge system that will flow oil from the pressure reducers, thru the control lines, then thru the purge manifold and into the tank return line of the module is, also, shown qn Figure #13. This is a demand system that is energized by putting the selector valve in the purge mode. This applies pressure to port (B) and connects port (A) to tank and causes the purge flow as noted. Normal control operation is resumed when the lever is returned to the operating mode by connecting (B) to tank and control pressure to port (A). Do MODULE INSTALLATION The Bertea proportional control valve module can be mounted in any position or attitude, except in the case where in a severe shock load would be imposed parallel to the axis of movement of the directional valve spool. For example, with a scoop loader impacting into a material pile, the module should be installed with the spool axis 90° to the direction of impact. Figure #14 shows the installation dimensions of the module. It should be noted that when using the electro-hydraulic pilot valves, the 11/2" air gap should be maintained as shown. VI START-UP AND TROUBLE SHOOTING (Figure #2) PROBLEM POSSIBLE CAUSES REMEDY A. Functions will not move and pump is at full system pressure. 1) Inlet and outlet plumbing are reversed. a. Reverse plumbing. 2) Inlet spool is stuck. a. Remove spool (1) and check for burrs, and/or foreign material. B. Functions gill not move and pump is at low press. (approximately 100 psi)

BERTEIR

INDOUSTRIAL PROUL.

SERVICE MANUAL MODEL 269300

1) No pilot pressure to spool section spool. a. Apply pilot pressure

AP across spool and to pilot inlet.

2) Small shuttle plugged. a. Clean shuttle (7). 3) Orifice in inlet plugged. a. Clean orifice (5). C. First function speeds up when a second function is operated. 1) Small shuttle in first function is plugged. a. Clean shuttle (7). 2) Pressure reducer spool in first function is stuck. a. Remove spool (6) and check for burrs and/or foreign material. D. Function operates in one direction only. 1) Large shuttle stuck. a. Clean shuttle (8). 2) Directional valve spool stuck. a. Remove spool (9) and check for burrs and/or foreign material. 3) Pilot pressure to spool section spool in one direction only. a. Check AP across spool in both directions: See paragraph 8 for remote pilot oil applications. See paragraph 9 for electro-hydraulic pilot valve applications. E. Function continues to move with no input command. 1) Directional valve spool stuck. a. Remove spool (9) and check for burrs and/or foreign material. Pilot pressure to spool section spool is unbalanced. a. Check 2P across spool in both directions: See paragraph 8 for remote pilot oil applications. See paragraph 9 for electro-hydraulic pilot valve applications.

BERTERiPOD

UCTS

SERVICE MANUAL MODEL 269300

F. Can Not obtain full system pressure. 1) System relief valves adjusted too low. a. Increase relief valve setting (3) by adjusting the cap clockwise. 2) Inlet control orifice plugged. a. clean orifice (5). 3) Foreign material on relief valve seat. Remove relief valve cap (3), spring, and poppet. Flush the cavity. 4) Damaged "o" ring on unloader. Remove unloader body (4) and replace "o" ring. G. By-pass pressure too high. 1) Excessive flow. a. Reduce pump output. 2) Excessive return pressure. a. Remove return line restriction. 3) Unloader piston stuck in the "in" position. a. Remove unloader (4) and clean orifice. 4) Directional valve spool stuck. a. Remove spool (9) and check for burrs and/or foreign material. H. Remote Pilot Oil Applications Control problems with remote pilot oil systems are usually caused by a mal-function of either the pressure reducer or purge manifold assembly. Disconnect the control lines at the purge manifold and attach pressure gages to the lines. With the manual lever in the center position the pressure in the lines should be equal. Movement of the lever should increase the pressure proportionally in one line to at least 200 psi greater than the other line pressure. Opposite lever travel should reverse the pressure differential.

BERTEA I INDUSTRIAL RRODUL I

SERVICE MANUAL MODEL 269300

Stuck poppets in the purge manifold block normally occur in the sealed or non purge mode! This mal-function is demonstrated by a function operating in one direction when switching to the purge mode, but stopping when returning to the operating mode. Remove poppet and deburr or replace purge manifold assembly. I. Electro-Hydraulic Pilot Valve Applications The pilot valve converts an electrical input signal of 0 to 3.6 volts into a pressure unbalance across the directional valve spool. At the factory setting of 300 psi differential pressure across the pilot valve, the directional valve spool deadband will be a minimum of 20%. Increasing the differential pressure across the pilot valve will reduce the deadband significantly. Control problems are usually either electrical, hydraulic or mechanical! Electrical problems are isolated by disconnecting the wires from the pilot valve to determine if the problem is caused by the remote electrical controller or the pilot valve. Hydraulic control problems, such as poor feathering, can be caused by very high or very low differential pressure across the pilot valve. Hydraulic mal-function problems, such as unwanted motion or non operation, can be caused by contamination failures. Check the control system filter and the inlet manifold filter lItem 27, Figure #5) for plugging or failure. Replace the pilot valve with a spare unit or one from another function to check for a plugged valve. Mechanical failure, such as a broken part or mechanical null shift, can be checked by replacing the pilot valve. VII

SPECIFICATIONS

A. POWER OIL SYSTEM Rated Flow - 30 gpm Rated Pressure - 2500 psi By-Pass Compensator - 150 psi setting Pressure Reducer - 100 psi setting Recommended Filtration - 10 micron

B. PILOT VALVE OIL SYSTEM REQUIRED Pressure - 300 psi AP REQUIRED Flow - 0.6 gpm per valve Plus - 1.0 gpm for relief valve REQUIRED Filtration - 40 micron

BERTER / INDUS IAL PRODUL. I 5

SERVICE MANUAL MODEL 269300

C. PORT SIZES Inlet - 1 5/16-12 (1" Tube) Cylinder - 1 1/16-12 (3/4" Tube) Outlet - 1 5/16-12 (1" Tube) Pilot Control - 3/8 Flared Tube Male Purge Manifolds - 7/16-20 (1/4" Tube) D. BOLT TORQUES 3/8-16 Clamping Studs - 23 lb-ft Lube 30 lb-ft Dry 10-24 Screws - 30 in lb Lube 40 in lb Dry E. HYDRAULIC OIL The recommended viscosity range is 50 to 4000 SSU which is typical for most pumps! Operating temperature range is -40 °F to 200°F. Extreme cold weather operation will require fluids simular to automatic transmission fluids in order to minimize pump cavitation and excessive pressure loss in lines during start-up and initial warm-up.

BERTER

SERVICE MANUAL MODEL 269300

The pilot valve is mounted on the directional valve in a location to provide the easiest access for wiring and field replacement. This mounting configuration does present restraints when installing the complete valve module on a vehicle because of the permanent magnet in the pilot valve. A large mass of magnetic metal adjacent to the magnet will offset the flux field and may cause a null shift in the valve. Therefore, the recommended mounting is shown in Figure 1 and 2 in order to provide at least 1-1/2 inches air gap beneath the magnet of the pilot valve.

If the mounting plate does not extend beneath the pilot valve, as shown, the module may be mounted directly to the plate.

PILOT VALVE MAGNET AREA

MOUNTING PLATE

FIGURE 1

2.1" MAX. FROM CENTER LINE OF MOUNTING HOLE TO END OF MOUNTING PLATE PILOT VALVE

CAUTION: NO MAGNETIC METAL WITHIN 1.5 OF PILOT VALVE AS SHOWN. NUMBER OF SPOOL SECTIONS

1 2 3 4 5

DIMENSION "A"

8.62!10.94'13.26115.58 17.90 20.22

DIMENSION "B"

7.62 9.94 12.26 14.58 16.90 19.22 I-6 -4 -5 -3 -1 -2

CLAMPING KIT P/N 269350 DASH NO.

If the mounting plate extends underneath the pilot valve magnet the module must be raised at least one (1) inch in order to provide an air gap of 1-1/2 inch beneath the pilot valve.

FIGURE 2

1" SPACER

MOUNTING PLATE

1 1/2" AIR GAP

INSTALLATION FIGURE 14 26

SERVICE MANUAL MODEL 269300

BEFITER

KIM PROPRIETARY RAMPS ME INCLUDED IN ME Hoop..H. MODS. HOKIN. MESMER MIS COCUSIDET NOR ME 11RPoUMATRIR OPICLOMXI HERON SHALL EE REPRODUCED OR MAMSFIRRED TO Oh. COCUSSEN711 OR USED OR

OncLCM0 m OTHERS FOR

SEE E 0

MANUFACTURING OR FOR ANY OTHER PURPOSE

6-32 SCREW 4 PLCS TORQUE TO 5 -7 IN-LB

MOT AS SPUMONIS AOMORI= IN MOM. VI ROMA CORPORATKM.

187 DIA 3 PLCS / 250 .1- Lea; BSC • 844 BSC/

TANK

-r

DIA x.55 DEEP

TAP •10-24 UNC-3B THO x .35 MIN EEP C'SINK i X.210 DIA

,PLCS 1010 DIA 1

•••,.-375

1 344 BSC

TERMINAL LEAD FROM PILOT VALVE (REF) BEND DOWN AS REO'D (2 PLCS)

EXISTING

.i4

CABLE 0.0.

200 TO .345 (2 CONDUCTORS 16 TO 20 GA.)

BSC TERMINAL BLOCK (REF)

.650 .560

CYI Ti .

.312 DIA X.300 DEEP MIN

PRESS0RE

MOUNTING

,ACE

NOTES: 1.

TECHNICAL DATA DIFFERENTIAL PRESSURE 300 PSI

60 M

PETROLEUM OIL

WEIGHT

.a5 LB/385 EM

TOOL: AMP SPEC. IND. NO. 29564 VACO CORP. NO. 1902

TANK

FOR MOUNTING. USE BERTEA SCREW P/N 234980 110-24 A 1 - 1/2 SOC HEAD CAP SCFEW -

p.134aLleg .

PIN 225931 TORQUE TO 18 -42 IN- LBS DRY N PLC. USE BERTEA WASHER P/71 234959 UNDER READ OF

NO. H2A

CAUTION: NO MACHETIC MATERIAL ALLOWED WITHIN

OR EQUIV. TOOL

AREA SHOW..

150 MICRON FILTER

NO. OF COND

SJO

18 AWG

16 AWG .330

SJO SON SDN

SECTION

WIRE SIZE O.D. ,REFI i

TYPE

TERMINAL (REF)

SOLDERLESS TERMINAL CO

SCREW.

TABLE OF ELECTRICAL CABLES REF .

248502-3

THOMAS & BETTS NO. WT1000 HOLLINGSWORTH

®" ---1

NON MAGNETIC CIES/. AND BERTEA GASKET

.000 .250

THE FOLLOWING CRIMPING

CYL

WHEN RED WIRE IS POSITIVE. PRESSURE AT CYL 02 IS GREATER THAN CYL 01.

MAX CABLE DIA) 242996 SLEEVE (FOR CABLE 0.0. .200 TO .290)

P/N 327043 BEFORE BEND). STRIP INSULATION AS SHOWN AND CRIMP WITH ONE OF

■

RATED OLTAGE Y 60 MA 3.6 VOLTS X FLUID

249875 WASHER FOR .200

48502 -3 TERMINAL 2 RECT'D (BERTEA FURNISHED) (AMP SPECIAL IND.

COIL RESISTANCE 60 90 25 MICRON

(FOR CABLE 0.0..300 TO.345

QUIESCENT FLOW .5 TO .6 602 RATED CURRENT

242971 SLEEVE

-.2F

fILTRAT ION

'150 .19 2.0 .25

2.1 (REF)

(REQD FOR MOUNTING MANIFOLD)

.300 i

A-A

CYL

I I 1

r.LBRILINBL

22C

CUSTOMER'S CABLE PMT ND. • NAME UNLESS OTHEIMASE SPECIFIED, ALL DIMENSIONS ME IN INCHES TOLEAMICE 011. UNEAR DIMENSIONS ANGLES

00 — 2.16 OuAmYTTY PREMARED rQR ROTS° ASSLIAM.

1 (8 AWG .278 ! 16 AWG .292 HaT msv comPLErE

AMY

mATEICAL

MATERIAL SPEC. ; HEAT TREATMENT

L.LimeEkr 2p16 -14

Accv

_sox ± Hico AUDI t cur

DIO IOUI M t Sir DRAWING SYMOOLS • TOLERANCE PEA USASI 19' MM. SURFACE ROuGHNESS PEA USA-SI STRAIGHT THREADS PER MILS-!79 NFU polAcnc. P. BAAF sia3

CONNECTIONS

sia

9149

BEATER

SHE

CORPORATION mime • CALIFORNIA

INSTALLAT ION DRAWING - FOR 234912 PILOT VALVE fIa

,710;: t!-. 24298 0

SOLL E:

I / I NOTED I SHEET I 0, I

PILOT VALVE INSTALLATION FIGURE 15 27

Bertea Industrial Division July 1980

Service Manual

Remote Controller Model No. 264360

Fluidpower

SERVICE MANUAL MODEL 264360

TABLE OF CONTENTS

INTRODUCTION . • •

II.

TECHNICAL DATA . •

III.

IV.

OPERATION

INSTALLATION • 0

ELECTRICAL CIRCUITS

TROUBLE SHOOTING

VI.

SERVICE . . • •

Bertea Industrial Division Costa Mesa, California 92626

E!!!!!Fluidpower

di Ili L. AZ

nile-% lid 4.4,-1 4- 'VI Li CL. G

O-FJOU

Page 1

INTRODUCTION

The model 264360 single axis controller provides a remote control station for Bertea electrohydraulic proportional valves. The unit operates from any 12 volt DC power supply and is wired directly to the pilot valve. This manual describes the configurations for single station control and multiple station control of one pilot valve.

II.

TECHNICAL DATA

Supply Voltage Supply Power

12 volt DC 0.0 watts @ lever center with microswitch 2.8 watts @ maximum command position

3 • volts @ 60 ma Output . • • 6 (With controller connected to the 60 ohm coil) Micro Switch Rating. . • • • 5 amp @ 12 volt DC

Bertea Industrial Division Costa Mesa, California 92626

FI idpower

Page 2

III OPERATION A Center position look feature is incorporated in the lever to prevent accidental operation of the controller. By depressing the center lock button (see Figure 3), the lever is free to move in either direction. This depression of the button also actuates a microswitch that applies battery power to the electrical circuit of the controller. When the switch is not actuated, the controller is electrically off.

Movement of the lever from the center position will rotate the potentiometer thru a gear drive to provide an output command as shown in Figure 2.

60 50 40 CURRENT FLOW 30 IN MA WITH 6052 COIL 20 10

30° 20° 10° 10° 20° 30 ° 10

HANDLE ROTATION 20 (DEGREES) 30 40 50 60

REMOTE CONTROLLER OUTPUT FIGURE 2

The micro switch provides not only the zero current flow configuration at the center position of the lever but also the capability of triggering secondary function when that controller is used. Secondary functions such as warning horns, solenoids, lights, etc., are activated when the button is depressed and are held on whenever the lever is out of the center position.

Bertea Industrial Division Costa Mesa, California 92626

Er!

Fluidpower

SERVICE MANUAL MODEL 264360

Page 3

CENTER LOCK PUSH TO RELEASE

INSTALLATION The basic controller (without case or top cover) will attach under the top surface of the vehicle console if the cutout shown in Fi g . 3G is provided. The 1.312" diameter permits passing the controller knob and boot throu g h the mountin g panel without disassembl y .

4 7 UNDERSIDE OF MOUNTING PANEL REF.

ELECTRICAL WIRING The size of the connectin g wire should be selected so that the total wire resistance does not exceed 3 ohms (5% of the coil resistance). Resistances for common wire sizes of stranded copper wire include the following .

The outside diameters of the cable should not exceed .500" as noted. Smaller size g rommets for the cable strain relief are available. (Consult factory)

2.6

CABLE COUPLING

AWG RESISTANCE POT WIRE

WIRE GAGE OHMS / 1000 FT TERMINAL COLOR

8.2

REF

FUNCTION

REF

FIGURE 3E

FIGURE 3D

20 10.54 $1 Red Batter y +12V DC 18 6.64 15 Black Batter y -12V DC 16 4.17 $2 White Pilot Valve Coil 14 2.62 $4 Green Pilot Valve Coil 12 1.65 Oran g e Micro Switch Function 10 1.04

5.875

.218 DIA 4 HOLES

5.250

1.125-.1 r

—

I 3.31 2.500

INSTALLATION FOR CASE ASSEMBLY UNIT 1. 2. 3. 4. 5. 6.

Lubricate cable O.D. with a silicone base lubricant in area of strain relief fittin g to facilitate feedin g cable throu g h fitting . Feed wire leads throu g h strain relief fitting as shown in Fi g . 38 prior to crimpin g terminals. Strip cable j acket and cut wires to len g ths noted in Fi g . 3A or 38. Attach 1248502 terminals (AMP 1327043) to wires and connect to terminal board. Insert controller assembl y into the case with the orientation shown in Fi g . 3D. Secure g asket and cover with four (4) 8-32 x .38 lon g screws.

SW r COIL

+ 601 I AUX

4.125 3.5 3.25 r.-3.125

. I

BASE PLATE OF HAND CONTROLLER CASE FIGURE 3F

0 3

0 0 Q

0 3 3

TERMINAL BLOCK L CIRCUIT BOARD FIGURE 3A

Bertea Industrial Division Costa Mesa, California 92626

GREEN WHITE-1

1.625

-1 .188 DIA 6 HOLES

TYP

FIGURE

4.718 .406

AS RE Q 'D

.1 TYP 4111. BLACK

(7 1) ✓ t♦

.750

3.906

11-125

DUAL

1.312 DIA

.06 R

5.0

ATTACH TERMINALS THIS SIDE

RED

---/- I CABLE 0.D. .375 TO .500 2.500 I 3.312 — FIVE (5)

STRAIN RELIEF CONDUCTORS 18 GA. ORANGE (MICRO SWITCH) AND CABLE SEAL FIGURE 38

1 TOP COVER .406 HAND CONTROLLER CASE FIGURE 3C

FluidPower

il/10061. 264360

Page 4

NC NO i

1 + 1 _ I

20052

I AUX o.-----eN I I SW c 1 I I 0____,-N I COIL r

852 852

_ 11 1 .'. ;-.1 IDUAL FP:: L

•

JUMPER SINGLE STATION CONTROLLER FIGURE 4 IV • INSTALLATION ELECTRICAL CIRCUITS In order to provide sing le or dual station control with one controller, the circuit board contains diodes for circuit isolation plus an open circuit to provide the optional confi g urations. Fi g ure 4 shows the use of a jumper strip required to complete the circuit for sin g le station control. The external hookup to the terminal block for the (2) batter y wires, (2) pilot valve wires and auxilar y functions for the standard controller with a micro switch is shown in Fi g ure 5. When installin g the controller into the 264399 case, the wire terminals should be attached to the terminal block on the same side as the letters as shown in Fi g ure 3A.

FROM SWITCH

■

- AUX

CO Ll DUAL

110

fta

JUMPER

P.V. COIL __/ P.V. COIL

BATTERY (-1)=

lor AUXILIARY FUNCTION

BATTERY (+)

WIRING FOR CONTROLLER WITH MICROSWITCH FIGURE 5

Bertea Industrial Division Costa Mesa, California 92626

Fludpower

Page 5

If for some reason, the microswitch is not desired, the required connections are shown in Figure 6. This will eliminate the electrical off feature' when the lever is in the center position and will result in a power drain of approximately 130 ma.

AUX SW r(01 Li DUAL

JUMPER BATTERY (-)

4 P.V. COIL

BATTERY (+)

' P.V. COIL WIRING FOR CONTROLLER W/O MICROSWITCH FIGURE 6

When multiple station control for one pilot valve is required, an optional circuit board with diodes is used to isolate the multiple controllers without adding selector switches to the circuit. This circuit board contains the (2) fixed resistors plus (3) diodes as noted. The electrical schematic is shown in Figure 7. The external hookup to the terminal block for multiple station control requires one controller to be the prime unit and the others to be slave units as shown in Figure 8. The slave unit has the ground connection and jumper removed. It is noted that the Model 242900 controllers should not be used as the prime unit in combination with the Model 264360 units.

NC •NO

- I +

I AUX

2°00

. I SW

85Z 852

1COIL IDUAL JUMPER FOR PRIME UNIT (Remove for slave units) MULTIPLE STATION CONTROLLER FIGURE 7

Bertea Industrial Division Costa Mesa, California 92626

Fluidpower

MODEL 264360 CONTROLLER #1 /2 ♦ FROM SWITCH

- AUX

FROM SWITCH

DUAL

- AUX

r COI Li DUAL

U JUMPER

0 =.111ral

()

P.V. COIL

.1.11■•■■•■

NOTE: JUMPER MUST BE REMOVED ON CONTROLLER #2. b- TO AUX. FUNCTION

(600)

TO AUX. FUNCTION

12 VDC BATTERY (OR) MODEL 242900 CONTROLLER #2 (OPTIONAL) DO NOT INSTALL AS PRIME UNIT MULTIPLE STATION FIGURE 8

A Model 264360 controller for the prime unit usage contains a jumper between the "DUAL" terminal and "COIL" terminal. This jumper is removed for the slave unit. The Model 242900 controller for the slave unit is wired as noted.

SERVICEMANUAL MODEL264360

MODEL 264360 CONTROLLER #2

Page 7 V. TROUBLE SHOOTING Electrical circuit trouble shooting, with the standard single station controllers, checks the battery voltage, microswitch operation, and potentiometer circuit output to the pilot valve. Figure 9 shows the typical connections required to use a volt/ammeter to check the circuits.

+ BAT. -- AUX SW

99a

COIL--

9 g

DUAL

METER IN SERIES

METER IN PARALLEL

BAT. VOLTS

PILOT VALVE

11■■

.1■1

rTh

••■•■ •••••■•■

MICROSWITCH

CIRCUIT CHECKOUT FIGURE 9

Correct supply voltage (12 volts is checked by connecting the volt meter in parallel to the (+) and (-) terminals as s-own.

The micro switch is wired to operate as a normally open switch. Connect the voltmeter in parallel to terminal (+) and (SW) as shown. The micro switch is actuated by depressing the button in the lever knob, which in turn moves the lock pin against the actuation leaf of the switch. Button depressed should provide 12 volts and button released (with lever in center position) should open the circuit to zero volts. Switch adjustment is shown on Figure 10.

Bertea Industrial Division Costa Mesa, California 92626

Fluidpower

SERVICE MANUAL MODEL 264360

Page 8

V. TROUBLE SHOOTING (Continued)

SWITCH CLOSES --AFTER 0.140 TRAVEL

MICRO SWITCH ACTUATION ADJUSTMENT FIGURE 10

The switch should be open in the button up (or released) position and should be closed at 0.140" travel of the lock pin. The switch should always be closed prior to the lock pin clearing the detent slot that is provided in the mounting plate. Adjust the switch actuation by loosening the #4-40 cap screws and moving the switch bracket assembly left or right as required. After proper switch actuation is obtained, torque cap screws to 4-5 in-lbs. C. Connecting the ammeter in series with one pilot valve wire from the "COIL" terminal board connection as shown in Figure 9 will check the output command of the potentiometer circuit. With the control lever in the center position and the lock button depressed to close the micro switch, the ammeter should show a 0 to + 3 ma reading. Then as the lever is moved from the center position, the command signal should increase on a curve as shown on Figure 2 to a maximum command position of 55 ma to 65 ma. If the test shows no output command with lever rotation and it is confirmed that the pilot valve is good, then the potentiometer assembly will have to be changed.

Bertea Industrial Division Costa Mesa, California 92626

Fluidpower

Page 9

TROUBLE SHOOTING (Continued)

Since the gear is attached to the potentiometer shaft with adhesive, adjustments and potentiometer replacements must be made as a complete assembly, including the mounting bracket. This assembly Part Number 272357 is shown on Figure 11. A failure of the diodes in the multiple station controller circuit board will result in the test showing a significant reduction in output command versus lever rotation. This results from the additional resistance being added to the circuit. The failed circuit will be in the unit not being operated during the test.

Figure 11 VI.

SERVICE MODEL #264360 CONTROLLER (See Figure 12) ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 *16 17 18

PART NUMBER 249868 249824 242982 242956 8-32 x .5 lg 8-32 x .5 lg 249867 242954 242955 242961 272357 249821-7 249869-3 249838-5 264399-13 249886 264363-1 264363-3

Bertea Industrial Division Costa Mesa, California 92626

DESCRIPTION Cover, Knob Plunger Assembly Spring Knob Screw, Pan Head Slotted (4 req'd) Screw, Pan Head Slotted (6 req'd) Cover Plate, Flat Gasket, Cover Boot Clamping Plate Potentiometer & Gear Assembly Lockpin Cap Screw, Soc. Hd. Micro Switch & Bracket Assembly Case Cover Flanged Circuit Board - Single Station Circuit Board-Multiple Station

Fluidpower

Page 10 SERVICE MANUAL MODEL 264360

SERVICE

Boot Replacement - In order to replace the boot, the plunger assembly and the knob must be removed in the following manner. 1.

Remove the micro switch bracket assembly if one is included. (14)

Remove the knob cover. (1)

The plunger assembly (2) is held into the lock pin (12) by the 116-32 screw (13). Loosen this screw and pull the plunger assembly clear of the knob. (4)

Remove the knob (4) by rotating it counter clockwist to unscrew it from the shaft.

Remove the M8-32 screws that clamp the boot (9) to the case cover. (7)

Pull the flanged portion of the boot (9) through the slot in the case cover (7) and off the end of the shaft.

Installation of a new boot is accomplished in the reverse sequence. 1.

Lube shaft with a compatible lube.

Install the boot (9) over the end of the shaft and pull the flanged portion through the slot of the case cover.

Note: The top surface of the small portion of the boot should be 1-3/4 inches from the top of the case cover. The boot shape should be free and not distorted. 3.

Replace the 48-32 screws to clamp the boot (9) flange between the case cover (7) and clamping plate. (10)

Replace the knob. (4)

Place the button return spring (3) into the hole in the knob (4) and insert the plunger wire assembly (2) through the knob. (4)

Place the lock pin (12) into the slot with the threaded end opposite to the potentiometer. Feed the plunger wire (2) through the hole in the lock pin.

With the plunger wire (2) extended approximately 1/16" through the lock pin, (12) tighten the 116-32 screw (13) to clamp the wire in place. The slot on the opposite end of the lock pin (12) is for a screw driver to resist the torquing load on the M6-32 screw (13)

Check the assembly by depressing the button rotating the lever.

9. 10.

Replace the micro switch assembly (14) and adjust as required. Replace the knob cover. (1)

Bertea Industrial Division Costa Mesa, California 92626

BOOT REPLACEMENT FIGURE 12

r5f.iB Fluidpower

Engr. Bulletin 6011 1-25-79 BERTEA INDUSTRIAL PRODUCTS

HYDRAULIC OIL SELECTION PARAMETERS

The low temperature operating limitation of the Bertea valve modules is determined by the oil viscosity and pilot valve circuit configuration. Generally, a low viscosity fluid with a high viscosity index is required in order to minimize the pressure drop in the small control fluid passages of the pilot valve. The maximum operating oil viscosities for the standard flow and high flow pilot valves versus pressure drop across the control circuit are shown below. #234912-23 Pilot Valve 1100 SSU @ 300 P (Standard Flow) 1800 SSU 400L P 234912-25 Pilot Valve 1800 SSU @ 3000 P 2400 SSU @ 400L P (High Flow) The normal procedure for cold weather operation is to run the engine for a short warming period prior to operating a load. This will also warm the hydraulic fluid and provide time to push the cold slug of oil out of the small nozzles in the pilot valves. In order to purge the pilot valves, it is important that the pump does provide oil to the pilot circuit during the engine warming period. Open center circuits usually warm up rapidly since full pump flow is ported through the system continuously. Closed center circuits produce flow only upon demand and,therefore,.may require a manual means to bypass pump flow to tank during extreme cold warm-up cycles. It is noted that the 400 psi pilot supply pressure provides a higher viscosity tolerance since it is able to force a higher flow through the pilot valve. This higher pilot pressure is a normal occurence during cold starts because of the increased resistance to flow of the fluid. Logically, the oil selection versus anticipated oil operating temperature is very important. Ambient temperature determines the cold soak and hence the initial start viscosity parameters of the circuit. The initial operating oil temperature and viscosity is determined by the warm up period and is usually considerably higher than the ambient. The attached Viscosity-Temperature chart shows the affect of temperature on typical oils. The high VI and lower viscosity oils are required for cold temperature operation. An automatic transmission type fluid (ATF), similar to fluid B on the chart, will normally provide year around service.

BERTEA INDUSTRIAL PRODUCTS

ENG. BULLETIN NO. 6009 9-1-78

264360 CONTROLLER CIRCUIT BOARD CHANGE In order to provide single or dual station control with one controller,

Bertea has standardized on the circuit board containing the diodes as described on page 5 of the 264360 Service Manual. Therefore, Figure 5 and Figure 6 should be modified as shown to use the jumper in order to complete the circuit for single station control applications. All future controllers will be provided in this configuration and will show

code letter "D" for Diode by the date stamp data.

WIRING FOR CONTROLLER WITH MICROSWITCH FIGURE 5

JUMPER BATTERY (-)

P.V. COIL

BATTERY (+) 4 WIRING FOR CONTROLLER W/O MICROSWITCH FIGURE 6

P.V. COIL

BERTER

CORPORATION IRVINE • CALIFORNIA

SERVICE MANUAL

REMOTE CONTROL PROPORTIONAL DIRECTIONAL VALVE For Open Center Circuits

SERIES 225900-3

ANIEMCAN •.t, a. oo

thl IC 80 la HO 170 130 944 !SI 1Sil

STANDARD

t --- ,

A.S.T.M. STANDARD VISCOSITY-TEMPERATURE CHARTS FOR LIQUID PETROLEUM PRODUCTS (D 341)

54 549

CHART 8: SAYBOLT UNIVERSAL VISCOSITY, ABRIDGED

MEE

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TEMPERATURE, DEGREES FAHRENHEIT MALAY:AR SOCIETY FOR TES1ING MATERIALS 1,11,TTAL!

ISERTER /

SERVICE MANUAL SERIES 225900

TABLE OF CONTENTS

INTRODUCTION OPERATION

FILTRATION AND ASSEMBLY AND -SERVICE A

•

• • • .

1,%

INLET SECTION

DIRECTIONAL VALVE SECTION OUTLET SECTION

6 9

OPEN CENTER CIRCUITS - , CLOSED CENTER _ CIRCUITS PILOT. _VALVE - r TROUBLE SHOOTING TROUBLE SHOOTING -.CHART7'71

10 11 . 12

INSTALLATION •-- MODULE -' PILOT VALVE

EETER

Irs, (21_,STPIA1—

CAS

SERVICE MANUAL SERIES 225900 BERTEA PROPORTIONAL CONTROL VALVE FOR OPEN CENTER CIRCUITS SYSTEM OUTLET PORT

SYSTEM - - RELIEF ._ VALVE

OUTLET SECTION

DIRECTIONAL VALVE SECTION INLET SECTION _

•

PILOT VALVE

SYSTEM INLET PORTS •-- CONTROL PRESSURE RELIEF VALVE CONTROL PRESSURE INLET FIGURE 'I -

The Bertea proportional electrohydraulic control valv -e is a stack configuration to provide remote control for - open center systems. The basic module consists of an inlet manifold assembly, a number of directional valve section assemblies_ with pilot valves, plus an outlet manifold assembly as shown in - Figure 1. In order to provide control for an open center system when the main power.pump is ported to tank at minimum pressure, the module design contains two separate hydraulic circuits. These include the main power pump circuit in the normal manner for cylinder port control plus a 300 psi control pressure circuit for the pilot valves. The control pressure is to be-supplied by a separate pump or fluid source operating continuously at 300 to 400 psi. Each pilot valve reauires continuous flow of .5 to .6 gpm. The valve is designed for open loop, visual feedback control of hydraulic circuits at supply pressures up to 2500 psi and flow rates to 30 gpm. The recommended viscosity range is 52 to 4000 0 SSU for continuous operation. Operating temperature -30 F to 200 F.

Page 1

ERTEIR

SERVICE MANUAL SERIES 225900

RETURN D.C. POWER INPUT

PRESSURE

MANUAL INPUT HANDLE

WAND

•C1

SECT ION

REMOTE ELECTRICAL CONTROLLER

A - - P I LOT VALVE L. 2

DIRECTIONAL VALVE

LOAD

OUTPUT ACTUATOR

SCHEMATIC

SINGLE FUNCTION OPEN CENTER REMOTE CONTROL VALVE FIGURE 2 Page 2

E'ER -TEA /

SERVICE MANUAL SERIES 225900

OPERATION (Reference Figure 2) The Bertea valve system converts a low power electrical signal into a high hydraulic power output. The signal generation can be from a remote hand controller that is connected to the module by wires or can be a remote radio control unit without direct wire connections. The remote hand controller provides a signal that is porportional to lever position and operates on 12 VDC. The power draw in the controller is approximately 2.0 watts. The pilot valve is a jet diverter configuration of a transfer valve that provides proportional pressure control by moving the jet diverter in the fluid stream. The valve operates on 300 psi differential pressure and requires a continuous flow of .5 to .6 gpm. The output of the valve is proportional to command since the movement of the diverter wand is proportional to the voltage applied to the torque motor. :

The diverter wand is located in a manner to partially block the flow of the fluid from the pressure port to each cylinder port. When the wand'is in the neutral position, the pressure in each control port (C 1 and C 2 ) will be equal. As the wand is moved in response to the commana signal it will interrupt the flow to one control port more than the other. This creates a differential pressure between the two control ports that is proportional to the command signal. The output of the pilot valve is ported to each end of the spool of the directional valve. This valve is an open center design with the pressure beyond porting as a parallel circuit. The spool is spring caged to neutral which provides 19# detent force . . In addition, the spool design contains .100 inch overlap travel prior to metering the cylinder ports. As a pilot valve varies the control pressure on each end of the spool, creating a pressure unbalance, the spool will move to a position proportional to the signal. The spool position is determined by the balance of differential pressure versus spring load. It should be noted that open center type valves contain two flow paths for the main power circuit. The open center porting connects the pump to tank when the spool is in the center positon plus the pressure beyond porting that supplies the cylinder ports with power fluid. The spool movement must close off the open center porting in a manner to provide a smooth rise in pump pressure. This will permit the slow operation of a cylinder with the pump pressure slightly above load pressure rather than relief valve setting.

Page 3

BERTER

ITEM NO. 1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

INCt_.:571=1,4_

Cow, 5

PART QTY NUMBER 1 269322 2-020 1 1 8-020 3-914 1 234905 1 225946 1 1 231856 1 3-912 1 2-014 231852 1 2-117 3 2-128 1 2 2-112 1 234950 1 3-908 3 248584-3

SERVICE MANUAL SERIES 225900

DESCRIPTION Manifold "0" Ring Backup Ring "0" Ring System Relief Valve Plug - System Relief Plug - Pilot Pressure "0" Ring "0" Ring Pilot Pressure Relief "0" Ring "0" Ring "0" Ring Filter Assembly "0" Ring Backup Ring

234911 "0" Ring Kit

MANIFOLD ASSEMBLY, PART NO. 269381 FIGURE 3

Page 4

EERTEP9It

SERVICE MANUAL SERIES 225900

FILTRATION AND HYDRAULIC SYSTEM PREPARATION The life of any hydraulic system is sensitive to the cleanliness of the fluid stream. It is recommended that good cleaning and flushing procedures be followed in the assembly and test of the system. The purposeof separating the control pressue fluid from the • main power circuit fluid as shown on -7 is to 'assure continuous filtration of the fluid supply to Valves.' A 40 micron full flow, non bypass filteris,requiredfor the control pressure circuit. The minimum flow .rate_will:be Eased_on _the number of pilot valves used, it is recommended that a unit as .. large as poSsible . be = Used to - - _ . The main power fluid circuit filt -r -a-tiOn shOuld be -1 n 0 micros a . _ shown on Figure - 7. - A suction strainer-'on the pump -and magneti agnetcc tank . unit are benefiCal to =filter A secondary _filter is installed in each inlet section (see Figure .e . . 3) to provide pilot - valve protection-from contamination generated i between the main cOntr-ol / fluidfilte:and the valve.'' ASSEMBLY AND SERVICE _ . . . The Bertea p .ropOrtiOn-al . electrohidraulic . contrOl Talve - module can be mounted in any position or attitude. It is not sensitive to vibration or shock. The stack configuration permits the use of multiple - -spool sections *and the optional tandem outlet facil itates the use of dual pumps .. -

•

A. INLET MANIFOLD ASSEMBLY (Figure 3) The inlet manifold provides the inlet porting for the main power fluid circuit and the pilot valve fluid circuit. An optional 30 gpm system relief valve cartridge (Item 5) is available to replace the standard plug assembly (Item 6) for the power fluid circuit. Each vehicle installation requires only one control pressure relief valve (Item 10), to maintain the 300 psi control pressure, regardless of the number of modules used. This valve should be installed in the module that is the greatest distance from the pump in order to assure a minimum of 300 psi pilot valve supply pressure to all units. The other inlet sections would use the standard plug assembly (Item 7). This pressure relief valve will provide 300 psi differential pressure for the pilot valve supply regardless of tank pressure. Therefore, if the vehicle return line has 100 psi back pressure the inlet to the pilot valves will be 400 psi.

Page 5

8ERTER

SERVICE MANUAL SERIES 225900

All inlet sections contain the pilot_ valve filter assembly(Item 14) regardless of the location - of the pressure - relief valve. The replacement schedule of this filter .will be- determined by the system usage_and the quality of filtration of the power Circuits.-- The "0" ring face seals are the same as the ones used in the directional. valve_ section _(Figure 4).,Care _should. be taken to assure .that each ring is" n itsrespectiv- e groove when clamping a module together. . _

B DIRECTIONAL VALVE SECTION ASSEABLY. (Figure : 4)-. 2n t±fli: - -f-a. -si5Ool,.v.a.le-, Each directional valve section ,conSist .s. o assembly:plus the pilot -valve. ---.The .spool7section bodyi8 a 30 gpm configuration optional .spools rates. lower-flow _• ,• _• The.majority :,pf,the.components are_,basic .with variations available in manuaroverride_of aremote .controlled. - spool_plus a standard lever operated spool. . . OSF - r The load -drop dEeckviivejltemsa.2, -Z.13,-, standard cOiripOnenhtipreVentsfl -orom_the . . - :.This prevents the higher back to the pressure beyond loaded cylinder from dropping in the event.a. second..spool -is actuated to a lower pressure load: poppet - and - spring - maY be removed_- for - functions.that_require_flow back into ._the .supply _•• _ .

- :The manual override asseiribiy_for a remote controlled spool is shown in Figure 5. This assembly will provide direct manual control of the spool in the event of a failure in the remote controller, the electrical power. supply, or-a malfunction of the pilot valve. The hand knob.is held in the thread : disengaged position by a light spring to prevent . inadvertent_operation. Press the knob while rotating to - engage engage the_threadsin the cap and the drive screw. Continued rotation clockwise will move the spool from center and will provide flow from the cylinder port adjacent to this end cap. _The knob must be rotated outward and disengaged prior to operating the manual override on the opposite end cap. A plug is provided, as shown, to bleed the air from each end cap after initial-assembly and operation. Air trapped in the spool end cap will reduce the response of the valve assembly.

Page 6

(BERTER

A A A

ITEM NO.

QTY

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

1 1 1 1 2 3

1 1 1 1 1 1 1 1 4 2 2 2 2 2 2 2 8 4 3

PART NUMBER

SERVICE MANUAL SERIES 225900

IVINE • CAL/I'ZRNIA

DESCRIPTION

234980 249896 #6-32 x 1/2 242933 242907 234912-3 225931 2-112 2-117 2-128 234924 225940 225941 3-912 225942 242966 AS REQ'D 234927 234953 231830 234932 234931 225989 269315 1/8 - 27 NPTF #10-24 x 3/4 234959 248584-3

SCREW - SOC. HEAD SEAL KIT SCREW-PHILLIPS HD. COVER GASKET PILOT VALVE GASKET "0" RING "0" RING "0" RING BODY POPPET SPRING "0" RING CAP NAMEPLATE SPOOL SPRING GUIDE SHIM SPRING PIVOT PIN GASKET END CAP PLUG SOC. HD. SCREW - SOC. HD. WASHER BACKUP RING

10 18

234911 "0" RING KIT

19 20 18

21 23 24

QT 26

DIRECTIONAL VALVE ASSEMBLY 231863-5 & FIGURE 4A

Paye 7

(BERTER W'

ITEM NO.

QTY

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

4 1 1 1 1 2 3 1 1 1 1 1 1 1 1 4 2 2 2 2 2 2 2 2 2 4 2 2 2 2 8 4 3

PART NUMBER 234980 249896 #6-32 x 1/2 242933 242907 2349L 225931 2-112 2-117 2-128 269319 225940 234947 3-912 225942 242966 AS REQ'D 234927 234953 231830 234928 234949 234932 225989 2-012 269385 1/8 - 27 NPTF 234936 234935 234946 234934 3/32 DIA. x 1/2 #10-24 x 3/4 234959 248584-3

SERVICE MANUAL SERIES 225900

DESCRIPTION SCREW - SOC. HEAD SEAL KIT SCREW-PHILLIPS HD. COVER GASKET PILOT VALVE GASKET "0" RING "0" RING "0" RING BODY POPPET SPRING "0" RING CAP NAMEPLATE SPOOL SPRING GUIDE SHIM SPRING DRIVE SCREW SPACER PIVOT GASKET "0" RING END CAP PLUG SOC. HD. WASHER SPRING FELT HANDLE SPRING PIN SCREW SOC. HD. WASHER BACKUP RING

A 234911 "0" RING KIT

DIRECTIONAL VALVE ASSEMBLY FIGURE 4B Page 8

BERTER

alrg,t`

SERVICE MANUAL SERIES 225900

END CAP AIR BLEED PLUG

""0"--

DISENGAGED

DRIVE SCREW HAND KNOB '17

MANUAL OVERRIDE FIGURE 5

OUTLET MANIFOLD-(Figure 6) : --- -_ The outlet manifold provides a dual function - of being the - end section with connections to tank for the standard module plus providing pressure beyond.capability as a tandem outlet.

The Bertea outlet manifolds contain two optional plumbing . configurations. One option relates to the main system fluid and use of the 1/2 NPTF pipe plug inserted through port "A". When an outlet manifold is used without the internal pipe plug, either port can be connected to the reservoir line. The tandem outlet configuration is created when a pipe plug is inserted through the port labeled "A" which thus separates the normal tank lines of the valve stack from the open center porting. In this configuration, the "A" port must be connected to tank and the "B" port used to carry the fluid to the next valve stack for the power beyond configuration. When operating as a closed center _circuit, the plug is installed; port "A" is connected to tank and port "B" is plugged.

Page 9

BERTER /

SERVICE MANUAL SERIES 225900

3/8 NPTF PIPE PLUG (OPTIONAL) OUTLET MANIFOLD FIGURE 6

C OUTLET MANIFOLD (Continued)

The other option relates to the method of connecting the pilot valve drain line to tank which is determined by the location of the optional 1/4 pipeplugs.:If the.main system return line pressure does not exceed 100 psi, the pilot valve drain can be ported to this circuit within the manifold by inserting the plug into port "E". (Omit 1/4 NPTF plug at "D"). _-= If high system back pressure is anticipated, the 1/4 NPTF plug should be inserted into port "D" and the pilot valve drain connected to the 'tank through port "E". The 3/8 NPTF plug is only for access to port "D".

PILOT VALVE The pilot valve ratings include'the following: Coil 60 ohm resistance Operating Current . . 60 ma Operating Voltage . . . 3.6 volts Maximum Current . 100 ma rated .5 to .6 gpm at 300 psi differential Required Flow

Page 10

BERTERIML-

SERVICE MANUAL SERIES 225900

VALVE_JContinued)_ The correct mounting orientation - of the - pilot va:l.ve is determined by the locating pin in the pilot valve body. Care must be exercised to assure correct matching of the gasket between the two faces. A positive pOlarity of the red wire of the pilot valve will provide .flow from the cylinder,port adjacent . to the pilot valve. • for the pilot valve• nor mech ,• .__ • are,no,eXternal:adjustments _anical,connections to' the spool. HIf a problem related to the pilot •valve2develops the unit - should be replaced-andreturned to the factory: = TROUBLE SHOOTING -•

- df The modular the'valve provides simple',field trouble shoot _ . . ."design . .ing and se i e. 4 .Thefirst step shddld be to isOlate the problem to . . a specific component.if possible. For Change . the remote controller leads-from one:pilot - valves:to-another:to checkA.f,,.the problem follows the remote controller.-:=1

rv c

The same procedure can then be used tOcche -ck:thelpilot valves by interchanging -Care - shOUid:bekeili --EO - avoid introaUeing dirt into .the . system _when - .removing -pilot.-.-valves:;: The pilot valve converts an electrical:input signal of 0 to .3.6 volts into a pressure unbalance.across the directional valve spool. At the factory setting of 300 psi differential.pressure across the the pilot valve; the:directional valve spool deadband will be'a minimum of 20%.: .. Increasing the - differential . presure across the pilot yalve will - reduce the deadband significantly. Control problems are usually either electrical, hydraulic or mechanical. Electrical problems are isolated by disconnecting the wires from the pilot valve to determine if the problem is caused by the remote electrical controller or the pilot valve: Hydraulic control problems, such as poor feathering, can be caused by very high or very low differential pressure across the pilot valve. Hydraulic mal-function problems, such as unwanted motion or non operation, can be caused by contamination failures. Check the control system filter and the inlet manifold filter (Item 14, Figure 3) for plugging or failure. Replace the pilot valve with a spare unit or one from another function to check for a plugged valve. Mechanical failure, such as a broken part or mechanical null shift, can be checked by replacing the pilot valve.

Page 11

ER TEA I ';',.c."-g,Tia-t-

SERVICE MANUAL SERIES 225900 TROUBLE SHOOTING CHART

POTENTIAL TROUBLE ' .. .. _. . . ..... Control valve does not respond to command __ ...

- -

PROBABLE CAUSE

REMEDY

- - - - - - . - l: Controller_does not _ provide signal (60 ma max recd) 2. Open wire in control _cable. . - -...•••

- •-- _ • - - - , - - . :_-_ Replace Controller 2. , Replace cable _ -

3. • Shorted Terminal -- --- 3: - Check for -terminal .' connection. • 'end: contacting case - -" . _ .. 1'::: • —I a= -* -':- . --.==; -orpoor claMoinj =Of _ .-::,i, :2z.?:'Ll_r_f.:? -1 -i-,-)1c-i :: "="..... -:j_cc ,-z - !:E.:-:: -ji- . -=Hire - ends- bn ter- , :-. , .. ;.--..sL7I -2.`:±al-,.. f.',;;I: b:1-:.".: L•:-.7::.i:f.e::: b.,r_:11::::-=1 fifIa : e-.-: 2 ---i;:m-inal:::strip.'Y f- p_t.:-..;..1 4. •- Pilot valve mounted 4 . • .Check fo_r-.;.matching j. incorrectly. :porting of .pilot • .valve to ,spool% '77 7,-..---- 7--:. -, -: section. _ .. ... „ . • -. Failed _ pilot v alve. ___: 7Replace:pilot_ valve, .:;i: , i-co..lz.: ,:_ic'fi '.1.-)1.91 ?._E ,-,.--Jammed -spool - -1. -._ -. -"-' Remo ve 'end . - and _____ ...._cap irtf-..1do -.7q . ,,-.-,r.:'::1 ---E,...tz.1.. 3 J-. r.::: r:: , :.;_ .L-., .... .L.L!ci-_ ;- c e :Li a , .-i.: . _ ch eck spool freedom. -2' .E.;IDLIZ3f: E.UC..:;1.11..:: -2:.C.''`'_: ::..:::.C.:_::.;?.?... S 44i , :7 ".... =_:_::.:::1::::::7:..: 7.-2.:.:_:.:_: • , High 'null: bias .:-.,:-..-.., _oz 1 :=1 ,-!.:Failedz- controller C , 1:C Replaces:controller ..'..7 _:. (Actuator - drifts resulting :-in - a -com-_- • .:',-;:--:-.--a-:. ,:: - - . - .7. __ _ ,.: : --.: f.,. ---or hydraulic - - mand at neutral motor slowly.- - -,,-- r 1 - -: -L position.: .:- -....- .- - -- — - --- - - -- --- ----- *rotates ,when Failed „pilot : valve . _ -r- , - ._ 2. . , ):-.72. 2. ..: Replate -pilot valve controlle*r -returns 3: -- Sticking•,-spool --du-e ., . 3 :-.. "--_..TRemove - end tap and to neutral) -. to contamination. i-f" -- --'''-' - check 'spool freedom. --

‘.

,. Low flow -rate >'-Directional valve spool ='. 7 --7 :"-z- 7 - .. - 7 ":-::: from cylinder . -:-_::.-.:-. is not traveling far — - : - --. ' - _-_ .. _ port, - motor :turns I. -: enough: -.....:-_-.- :-..:. = i; _ . slowly or cylinder . : 1. :.:. Caused by low ,..:1:-,.:: :. -, 1. --;Check filter in the moves slowly -at 1 .. - .-- , pressure gain of -... - . ._ -, r inlet section for -_ maximum command. _ .. pilot valve. : . . _ . __plugging. . .. . _ . 2; - Caused by low control 2. - Replace *pressure repressure supply. . _ gulator if necessary. - - 3. - Plugged pilot valve - 3. - Change pilot valve -Poor response, function shuts off slowly when command is removed.

Restricted tank 1. . .. - return - line. 2. Low spool spring preload. . .

3. 4.

• ■•

Page 12

Sticking spool due to contamination. Air in end caps.

1. 2.

Check for restrictions - in tank return line. Check for correct spring and shims in

end caps. . Remove end cap and check spool freedom. 4. Bleed air from end caps

(BERTER I =-A ' = SERVICE MANUAL SERIES 225900

PUMP OPTIONS loA

o ■ oo # o

••• I A 1 1 A -I '

4 •oi 1

40 10° FLOW DIVIDER

A' 4.

RETURN FLOW 10 MICRON FILTRATION RECOMMENDED

•

4°

i°

PILOT VALVE

1 OPEN

CENTER OPERATION

A FIXED DISPLACEMENT PUMP USED WITH A FLOW DIVIDER

2 OPEN

c or_

CENTER OPERATION

DUAL FIXED DISPLACEMENT PUMP

•

3 CLOSED CENTER OPERATION

A VARIABLE DISPLACEMENT PUMP CAN BE USED WITH EITHER A FLOW CONTROL VALVE OR SEPARATE PUMP

HAND CONTROLLER

TEE FOR PRESSURE GAGE

•••

FLOW CONTROL VALVE

BERTEA PROPORTIONAL CONTROL VALVE

4•11,

POTENTIOMETER

CONTROL FLUID FILTER 40 MICRON NON BY-PASS

LOW FLOW FIXED DISPLACEMENT PUMP

12V BATTERY

BERTEA VALVE INSTALLATION FIGURE 7

.BERTEA

SERVICE MANUAL SERIES 225900

.INSTALLATION .

MODULE ASSEMBLY

Insert the "0" rings into the respective groves-of the inlet manifold and spool sections. Assemble the required number of spool sections between the inlet and outlet manifolds with the pilot valve porting on the right hand side as shown In Figure 8. Use a flat surface for support in order to - align thd inlet and outlet manifolds. Torque the clamping bolts as noted on Page 15. .

)

1 1/16-12 PORTS TYP

1 5/16-12 PORT •

Al CAU'T'ION:

NO MAGNETIC METAL WITHIN .62 OF PILOT VALVE AS SHOWN.

NUMBER OF SPOOL SECTIONS

DIMENSION "A"

6.83

8.72

10.61 12.50 14.39 16.28

DIMENSION "B"

5.96

7.85

9.74

-1

-2

-3

STACKING KIT P/N 242902 DASH NO.

11.63 13.52 13.41 -4

-5

-6

INSTALLATION FIGURE 8

Page 14

SERTEA

SERVICE MANUAL SERIES 225900

The valves are not sensitive to attitude and therefore may be installed in any reasonable manner on the vehicle. Caution should be exercised to avoid placing steel tubing or magnetic material within 1.5 inches of the pilot valve as shown in Figure 8. Magnetic material will affect the flux field of the pilot valve permanent magnet and will cause a major shift in the valve null position. The optional configurations of the inlet manifold assembly are shown in Figure 3. - If the-234905 system relief valve is not required, the 225946 - plug must . be used in _the - portTin order to provide the correct seals ...for the internal lands. PORT SIZES - _ 1-1/16 - 12 (3/4 tube) Cylinders -Inlet1-1/16 - 12 (3/4 tube) Outlet Control -Pressure Flared tube-male ... • : --. BOLT TORQUES 3/8 - 16 Clamping_Studs 10 - 24 Sci. e%.77

•

.•

23 30 30 40

lb-ft lb-ft in-lb in-lb

Lube Dry

Lube -Dry'

The-_231852 pilot pressure relief valve establishes the=300 psi differential pressure for the _pilot valve circuit. Only one pilot pressure relief valve is required per vehicle and therefore when two or more modules are - used, this port must be closed with a 231856 plug in the extra modules. Each pilot valve requires a continuous flow of .5 to .6 GPM at 300 psi P. A four spool section installation would require four times .5 GPM plus 1.0 GPM for assurance or a .30 GPM supply. - Figure 9 shows typical-installations of a separate pump for pilot fluid supply and a circuit using a priority flow divider. A 40u filter is required as shown for this pilot fluid circuit.

-PILOT CIRCUIT

PILOT FLUID CIRCUITS FIGURE 9

Page 15

(BERTEF1

I '"ekuSTAucti

SERVICE MANUAL SERIES 225900

N AM MIOPRIETMY RIGHTS ARE INCLUDED IN THE INFORMATION DISCLOSED

REVIIMOIM

HUMUS NEITHER THIS DOCUMENT NOR THE INFORMATION DISCLOSED HEREIN

0111.1110/710,1

SMALL SE REPRODUCED OR TRANSFERRED TO OTHER LOCUM/MT{ 0. USED OR DISCLOGED TO OTHERS FDA MANUFACTURING OR FOR ANY OTHER PURPOSE

6-32 SCREW 4 PLCS TORQUE TO 5-7 IN-LB

MGM M SPECIFICALLY AUTHORIZED IN WRITING SY RENTER CORPCSIATION.

TANK

—187 DIA 3 PLCS 50

Vi CYL

I5 DIA X .55 DEEP TAP •10-24 -3B THD EEP X .35 MIN C' SINK I X .210 DIA

1.688 (3SC 844 BSC/ .375

1.75 //

1 344 BSC

TERMINAL BLOCK (REF) .312 DIA X.300 DEEP MIN ellf.UBE

1 09

MOUNTING FACE

2.I (REF) .19 2.0 .t

(REQ. () FOR MOUNTING MANIFOLD) NOTES: 1. TECHNICAL DATA

2 2 2

18 AWG 16 AWG 18 AWG

.300 .330 .278

16 AWG

.292

242971 SLEEVE (FOR CABLE 0.0. .300 T0.345

125

-44L

CYL TANK

ISO MICRON F ILTER

.50

REF

DIFFERENTIAL PRESSURE 300 PSI QUIESCENT FLOW .5 TO .6 6PM COIL FESISTANCL 60 OHM RATED CURRENT 60 MA FILTRATION 25 MICRON RATED VOLTAGE i 60 MA 3.6 VOLTS DC FLUID PETROLEUM OIL WEIGHT .85 LB/385 GM 2. WHEN RED WIRE IS POSITIVE, PRESSURE AT CYL 02 IS GREATER THAN CYL 01. 3. FOR MOUNTING. USE HERTEA SCREW P/N 234980 (10-24 0 1-1/2 SOC HEAD CAP SCREW NON MAGNETIC CRESS, AND BERTEA GASKET P/N 225931 TORQUE TO 38-42 IN -LBS DRY 4 PLC. USE BERTEA WASHER P/N 234959 UNDER HEAD Of SCREW. 40 CAUTION: NO MAGNETIC MATERIAL ALLOWED WITHIN AREA SHOW,

.SJO SJO SON SON

OAMOVIL

Atuf---

CABLE 0.0. .200 TO .345 (2 CONDUCTORS 16 TO 20 GA.)

672 BSC t

TABLE OF ELECTRICAL CABLES REF. TYPE NO. OF COND. WIRE. SIZE 0.0. IREF1

•6.7

EXISTING TERMINAL LEAD FROM PILOT VALVE (REF) BEND DOWN AS REQ'D (2 PLCS)

.2501

.560

an I

CI SEE E 0

,SECTION

A-A

248502 -3 TERMINAL 2 REM) (BERTEA FURNISHED) (AMP SPECIAL IND. P/N 327043 BEFORE BEND). STRIP INSULATION AS SHOWN AND CRIMP WITH ONE OF THE FOLLOWING CRIMPING TOOL: AMP SPEC. IND. NO. 29564 VACO CORP. NO. 1902 THOMAS & BETTS NO. WT 1000 HOLLINGSWORTH SOLDERLESS TERMINAL CO NO. H2A OR EQUIV. TOOL TERMINAI CONNECTIONS 2.X. SIZE CUSTOMER'S CABLE

CYL 112 PART NO. & NAME

2.00 2.16

MATERIAL

UNLESS OTHFJIWISE SPECIFIED, ALL DIMENSIONS ME IN INCHES TOLERANCE OK UNEAR DIMENSIONS ANGLES

► MOW. POI NOTED ABSDNA.

XX( ••• ± .010 =TX 030• .X( ••• t .040 XXX LOY S .100

MAX. SURFACE ROUGHNESS PER USASI STRAIGHT THREADS PER MIL-S41179

COMPLETE ASSY.

ACILI

.000

.250

248502-3 TERMINAL (REF)

HEAT TREATMENT

MATERIAL SPEC.

7-2-74 81614.

BERTER

FINISH

SHY

CORPORATION IRVINE • CALIFORNIA

INSTALLATION DRAWING- FOR 234912 PILOT VALVE

± STY'

DRAWING SYMBOLS A TOLERANCE PER WAN VMS

tzy

--J

L .LAMBERT

*TIMM

249875 WASHER (FOR .200 MAX CABLE DIA) 242996 SLEEVE (FOR CABLE 0.0. .200 TO .290)

MFG. PRACTICES PER IMF 5I83

Fla

72O:

SCALE: I / I

2 2 9 110

e NOTED

I SHEET I OF I

PILOT VALVE INSTALLATION FIGURE 10 16

CIO

coritrols,iric.

OPERATIONS AND MAINTENANCE MANUAL Single Axis Controller MS3M836. Bertea proportional valve.

To operate one 12 VDC

Single Axis Controller MS3M983. To operate one 12 VDC Bertea proportional valve. Includes threshold adjustment and maximum output adjustment. Electrical Assembly Kit 980-AE. For multiple station operation of one Bertea 12 VDC proportional valve. Single Axis Controller MS4M2040. To operate one 12VDC Bertea proportional valve. Single Axis Controller MS4M2041. To operate one 12 VDC Bertea proportional valve. Includes threshold adjust ment and maximum output adjustment.

OEM CONTROLS, INC 10 Controls Drive Shelton, Conn.

o6484.

ADDENDUM This addendum covers the MS4M2040, which replaces the MS3M836, and the MS4M2041 which replaces the MS3M983. The differences consist solely of mechanical changes which do not affect the mechanical interchangeability or the electrical hook-up function or adjustment. The new controllers do not utilize a knurled retaining ring, but do use a different neoprene boot, a different boot retaining clamp, and in the case of the MS4M2040, a different pot plate which is smaller. SPARE

PARTS

LIST

Part Number Description 1187AM-1

Circuit Board CB 145 with potentiometer #801AE, completion resistors and one microswitch for Bertea valve control to retro fit MS4M2040.

1187AM-2

SST CB111 circuit board complete with 10K potentiometer and three V-3L-139-D8 microswitches for Bertea valve control to retro fit MS4M2041.

1187AM-3 Upper Handle 1187AM-4 Gasket 1187AM-5 Lower Handle Assembly 1187AM-6 Handle Spring 1187AM-7 Boot 1187AM-8 Retaining Ring for Boot 1187AM-9 Mounting Screw and Washer 1187AM-10 V-3L-139-D8 microswitch with insulator, switch spacer, mounting screws, and washers.

6/6/80

The OEM Type MS3 Single Axis Controller is a remote control station for the control of electro-hydraulic valves. It is available with a friction held or spring return handle, with or without a safety mechanical interlock. The Type MS3 controller can be equipped with a variety of Micro Switch/Potentiometer combinations to tailor its application to many different porportional and non-porportional electro-hydraulic valves. This manual describes the configurations for single and multiple station control of one pilot valve.

Operation The optional center position lock feature is incorporated in the lever to prevent accidental operation of the controller. By raising the bottom section of the handle the lever is free to move in either direction. The movement of the handle bottom can also actuate a Micro Switch if the controller was supplied with this option. This switch can be wired as a "dead man" device to prevent the unintentional operation of the electrohydraulic circuitry. Movement of the lever from the center position will rotate a potentiometer through a gear drive. It will also rotate cams to actuate micro switches if the unit is so equipped.

6/2/79

TECHNICAL DATA Operating shaft deflection 37 degrees. Microswitches PN V3L-139-D8, Contact rating 24 Spring return handle Handle-operated mechanical interlock. Field replaceable electrical assembly kits.

I7 Tb )

6/2/79

PANEL MOUNT

vnc-5

amps.

Foreword

Before Commissioning Your New Engine: Surely you expect top service from your DEUTZ engine ... So please give this manual your top attention!

Safety and dependability result from superior technology, correct operation, plus proper care and maintenance

All necessary safety precautions and regulations have been observed in the design, choice of material and manufacture of your engine, and before the engine left our factory, it stood up satisfactorily to the severest tests and trials. Maximum engine performance is however not possible without a minimum of upkeep. Remember that even simple household appliances need some care and attention once in a while. So be sure to maintain your engine as scheduled herein and to use the fuels and lube oils recommended. You will get a lot in return: a long lifespan of your DEUTZ engine, high power output and reliability, plus low consumption rates and exhaust emissions.

K HD

DEUTZ Genuine Spare Parts

When reading through this manual, you will find the above symbol marking all important safety instructions. Give particular heed to these instructions and proceed with special care. Pass on these safety instructions to your operating personnel.

General Safety Rules Apart from the safety instructions given in this manual, it is also necessary to observe the official safety rules, which may vary from country to country.

Care and Maintenance

For ordering such spares, please always refer to the relevant Parts Catalogue. Otherwise ask your local DEUTZ distributor. By the way, you will agree with us that "Safety first" is a good slogan. So please be sure to refit any guards and protective devices that should have been removed for carrying out work on the engine. To prevent pollution of the environment, please let old fuel and oil run into a special receptacle.

Reliability of the engine largely depends on close observance of the Maintenance Schedule (page 89).

The Right Work Clothing

Never attempt to rectify faults or carry out repairs for which you do not have the necessary experience and special tools. Entrust the job to your DEUTZ Service Station, where DEUTZtrained personnel will give your engine expert attention.

Work clothing should be closely fitting, so that it cannot be caught by rotating or projecting parts.

Beware of Running Engine Always stop the engine before refuelling. Always stop the engine before carrying out maintenance or repair work.

Note: In view of the constant improvements to our engines, the specification data as well as other information included in this manual are subject to change without notice 64

NO1103 S21 OG N3 A

3NI9N3 73S3I0

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Should, on the other hand, any trouble arise on engine calling for overhaul or repair, do not tamper with it but entrust the job to a workshop of the worldwide DEUTZ organization, where you will find a staff of DEUTZ-trained mechanics, the latest special tools and facilities, and a full stock of

Description of Engine

Description of Engine (Air intake side) Cylinder Numbers Description of Engine (service side) (shown: F2L 912 -- with Deutz fuel-injection pump) 1 Exhaust manifold 2 Air intake manifold 3 Injection lines 4 Vertical plate, front 5 Cooling air blower 6 Hydraulic pump connection 7 V-belt 8 Deutz fuel-injection pump 9 Fuel feed pump 10 V-belt pulley

11 Lube oil filter 12 Speed control lever 13 Lube oil cooler 14 Oil filler cap 15 Shutdown lever 16 Oil dipstick 17 Fuel filter 18 Crankcase breather 19 Waste air box 20 Pushrod with cover tube

21 Air cowling 22 Injector 23 Rocker chamber covers 24 Vertical plate, rear 25 Adapter housing 26 Flywheel 27 Crankcase 28 Starter motor 29 Alternator

NO11 33 S bOON3A

3NI9N3 13S310zima

Description of Engine

Description of Engine Combustion Method FL 912 W Two-stage Combustion

FL 912 Direct Injection

Fig. 5

Note: This instruction Manual applies both to F2L 912 engines using direct injection and to F2L 912 W engines using two-stage combustion. The difference in the two systems is dealt with in the sections ”Specification Data-, ' , Starting. and -Operation in Winter.. Direct-injection engines are used where high power output and compact construction are more important than high exhaust-gas quality, while.two-stage combustion engines are designed for applications where low exhaust emissions are of prime importance.

0 a

O I

Lube Oil Circuit 1 Oi sump 2 Suction pipe 3 Oi pump 4 Delivery pipe 5 Oi filter with cartridge (full-flow) 6 Oi bore to 3rd main bearing 7 Oi pipe to oil cooler 8 Oi cooler (version optional) 9 Oi bore to 2nd main bearing, valve drive and piston cooling 10 Oi bore to 1st main bearing 11 Main bearing 12 Big-end bearing 13 Spray nozzle for piston cooling 14 Camshaft bearing 15 Oil duct to tappets 16 Tappet (with groove for pulse-fed rocker arm lubrication)

17 Pushrod (hollow, supplying oil to rocker arms) 18 Rocker arm bearing 19 Pushrod cover tube (surplus oil returning from rocker arm chamber to sump) 20 Oil pressure gauge 21 Oil drain plug, for lube oil filter housing 22 Main oil drain plug 23 Injection pump (connected to engine lube oil circuit (on version with Bosch injection pump)

N01103Sb Oa N 3 A

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Description of Engine

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1 C/1

Fig. 6

Fig. 7

Layout of Fuel System (here with Deutz injection pump)

Layout of Fuel System (here with Bosch injection pump)

1 Fuel tank 2 Fuel supply line 3 Fuel feed pump 4 Fuel filter 5 Injection pump 6 Injection lines 7 Injector 8 Backleakage line 9 Overflow line 10 Fuel return line

1 Fuel tank 2 Fuel supply line 3 Fuel feed pump 4 Fuel filter 5 Injection pump 6 Injection lines 7 Injector 8 Backleakage line 9 Overflow line 10 Overflow valve 11 Fuel return line

1-11 CI

N011 33 S 11 00 N3 A

3NI9N3 13S3Ia ZIA3a

Description of Engine

Engine Model and Engine Serial No.

Specification Data

The model designation A and the engine serial No. B are given on the rating plate (Fig. 8).

Model

Description of Engine F2L 912

F2L 912 W

The rating plate is attached to the crankcase below air cowling (Fig. 9). Number of cylinders Bore Stroke Piston displacement Direction of rotation (facing flywheel) Working principle

mm mm cm

Weight (depending on version) approx. kg Power output' kW (HP) Speed' rev ./min Lubrication system Oil capacity initial fill approx. ltr. refill approx. Hr. Valve clearance (engine cold) mm

10.4

Mtl

Fig. 8

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Valve timing: with Deutz injection pump Inlet opens bTDC Inlet closes aBDC Exhaust opens bBDC Exhaust closes aTDC with Bosch injection pump Inlet opens bTDC Inlet closes aBDC Exhaust opens bBDC aTDC Exhaust closes Piston crown clearance (measured with lead wire) mm Injection release pressure (during operation) . . bar Commencement of Delivery Deutz injection pump up to 2300/min above 2301/min Bosch injection pump with advance unit without advance unit up to 1800/min from 1801 - 2300/min above 2301/min

forced lubrication 6 4.5 0.15

26" 67" 73'' 30"

175 8

32" 60" 70" 32 ' 1.0 1.2 115 1 8

bTDC 32" + 1" bTDC 38" 1"

25" t 1" 25" + 1"

bTDC 22" 1" bTDC 26" t 1" bTDC 30" 1" bTDC 32" + 1" 1-2

Firing order

2 100 120 1884 counter-clockwise four-stroke diesel with direct two-stage injection combustion 255 see rating plate see rating plate

Fig. 9

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Fig. 10 72

' The power output and speed of the engine are stamped on the nameplate. 73

NO1103 S I OG N3 A

The serial No. is also stamped into the crankcase, see Fig. 10.

Engine Operation

Starting up a new engine for the first time involves a number of preparatory jobs, some of which must also be carried out later on in the course of routine maintenance (see Maintenance Schedule on page 89).

1. Fuel 1.1 Grade Always use a reputable branded grade of gas oil, the sulphur content of which should be below 0 5 %, and observe strict cleanliness when filling in. Higher sulphur contents affect the oil-change intervals (page 98). Al low ambient temperatures use winter-grade fuel only (see hints on page 83) The fuel must be replenished promptly to prevent the tank from running dry, otherwise fuel filter and injection lines will need air-bleeding. The following fuel specifications are approved: DIN 51601; NATO Codes F 54, F 75, F 76; BS 2869: A 1 and A 2"; ASTM D 975-78: 1-D and 2-D; VV-F-800 a: DF-A, DF-1 and DF-2. 1.2 Air-bleeding Never let the tank run dry! Any air which has found its way into the fuel system can cause irregular running of the engine and decrease its performance, even leading to stopping of the engine and preventing its restarting. Not only when the fuel tank has been run dry, but also after changing the fuel filter or working on the fuel line system, is it therefore necessary to air-bleed the system as follows:

3N ISN313S3 Ia zima

Note: When operating the priming lever, the distinctly perceivable "pressure point",i. e. the commencement of the lifting movement of the diaphragm, must occur in the first quarter of its total travel. Failing this, turn engine over a little by hand.

Fig. 11

Caution: Stop engine before filling fuel tank! Observe strict cleanliness! Do not spill any fuel!

C:3

• Observe sulphur content!

•

Fig . 12

(When operated by hand, the feed pump will only work if the camshaft of the injection pump is in such position that the diaphragm of the feed pump is not lifted.)

1.2.1 Version with Deutz Injection Pump (Fig. 11) • Loosen bleed screw 1 by 2 • 3 turns. • Actuate priming lever 2 by pressing repeatedly upwards against spring force until fuel emerges free of air bubbles at the loosened bleed screw 1. • Tighten bleed screw securely, while still pumping. • Loosen banjo bolt 3 at smaller hexagon by 2 3 turns. • Actuate priming lever 2 by pressing repeatedly upwards against spring force until fuel emerges free of air bubbles at the loosened banjo bolt 3. • Tighten banjo bolt securely, while still pumping.

• Loosen banjo bolt 1 by 2 3 turns. • Actuate priming lever 2 by pressing repeatedly until fuel emerges free of air bubbles at the loosened banjo bolt 1. • Tighten banjo bolt securely, while still pumping. • Loosen overflow valve 3 (Fig. 12) at the lower (larger) hexagon by 2 -• 3 turns. • Actuate priming lever 2 by pressing repeatedly downwards against spring force until fuel emerges free of air bubbles at the loosened overflow valve 3. • Tighten overflow valve securely, while still pumping.

N011 03S 1OON 3 A

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1.2.2 Version with Bosch Injection Pump (Fig. 12)

Engine Operation

Engine Operation 2.4 Oil Viscosity

2. Motor Oil 2.2 Checking Oil Level (Fig. 14) - see page 93 -

2.1 Filling In Oil (Fig. 13)

The viscosity of the oil being greatly influenced by the ambient temperature, the choice of the SAE-grade should be governed by the ambient temperature at engine site (see diagram). If temperatures temporarily fall below the limit of the SAE-grade selected, this will merely affect the starting performance but cause no engine damage.

SAE 10 W SAE 20 W/20 SAE 10 W/40 SAE 10 W/30 SAE 5 W/30 (Synthetic) -40 -30 - 20 -10 0 +10 +20 +30 I 1 / I I I I I -49 -40 -31 -22 -13 -4 5 14 23 32 41 50 59 68 77 86 1: SAE 5 W/30 (Synthetic) SAE 10 W/30 SAE 10 W/40

F-4

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SAE 15 W/40 SAE 20 W/20

2.3 Oil Quality By preference, use oils of the API quality grade CD/SE or CD/SF. You will thus attain the longest possible oil change intervals. Oils of the API quality grade CC/SE and CC/SF can be used when halving the length of oil intervals (see page 98).

Note: During operation of the engine, not only part of the oil lubricating the pistons is burnt but the thermal stress and the combustion residues mixing with the oil also entail a deterioration of the oil and in particular of its chemical additives. Therefore, a complete change of the oil should be carried out at the recommended intervals. As this deterioration is greatly influenced by the operating conditions as well as by the quality of the fuel and oil used, the oil change intervals differ accordingly. Be sure, therefore, strictly to observe the specifications given on page 98. Do not mix different oil grades.

Fig. 15 * Only with engine oil preheating. Since a too viscous oil causes starting difficulties, the choice of the viscosity grade during winter operation should be governed by the ambient temperature prevailing at the time of starting the engine. Oil changes as a function of ambient temperatures can be avoided by using multigrade oils, which are again subject to the oil change intervals recommended on page 98. The required oil capacities are given under "Specification Data" on page 73.

Note: For manually started engines, other viscosity grades are prescribed than for electrically started engines. The upper part of Fig. 15 therefore shows the viscosity grades for the manually started engine, while the lower part shows the grades for the electrically started engine.

O ••1

SAE 40

N011 03 S 21 00N3 A

3N I9N3 13S310Zif1313

SAE 15 W/30

Engine Operation

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5. Starting

3. Oil Bath Air Cleaner (if mounted)

5.1 Starting with Electric Starter • Disengage clutch to disconnect engine from driven equipment, where possible. • Move speed control lever 1 or 2 (Fig. 17) to about quarter speed by hand or fool

The air cleaner bowl 1, Fig. 16, must be filled with oil before starting up (use the same grade of motor oil as for the engine).

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5.1.1 Version F2L 912 (Direct Injection) without Heating Tube • Insert starter key 1 (Fig. 18), turn clockwise to detent.

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• Check that charging pilot lamp 2 lights up. • Push in starter key 1 deeper and turn farther clockwise against spring pressure. • Starter motor turns engine; as soon as the engine starts firing, release starter key 1.

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Fig. 16

4. Important for your Engine's Power Output

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111

3N I9N3 13 S310

Power output, temperature level and exhaust gas qualtity of any diesel engine are governed by careful matching of combustion air and fuel injection volumes, and since the density of the combustion air taken in varies with the atmospheric pressure and the ambient temperature, full rated power is obtained only at standard reference conditions in respect of atmospheric pressure (altitude of engine site) and ambient temperature. Standard reference conditions are as follows: (a) 101.3 kPa = 1013 mbar (sea level) and 20 "C (68 "F) for automotive engines to DIN 70020 (b) 100 kPa - - 1000 mbar (100 m above sea level) and 27 "C (81"F) for industrial and marine engines to DIN 6271. Where engines are operated at greater altitudes and/or higher ambient temperatures, they must be de-rated (reduced fuel injection and hence engine loading) in accordance with special Tables available.

Note: Therefore, never run your DEUTZ diesel in "thin air" under heavy-duty conditions unless your engine has been de-rated accordingly, otherwise the engine's lifespan, reliability and exhaust emissions may be affected, especially at altitudes above 1000 m and/or temperatures above 30 "C. Be sure to contact us or your equipment supplier in good time!

Fig. 17

5.1.2 Version F2L 912 (Direct Injection) with Heating Tube (Item 1, Fig. 19) • Insert starter key 3 (Fig. 18), "Stage 0". • Turn clockwise, "Stage 1". • Check that charging pilot lamp 2 lights up. • To start, push in starter key deeper and turn farther clockwise against spring pressure through "Stage 2" to "Stage 3". • Starter motor turns engine; as soon as the engine starts firing, release starter key 3. 5.1.3 Version F2L 912 W (Two-stage Combustion) • Insert starter key 3 (Fig. 18), "Stage 0". • Turn clockwise, "Stage 1".

Fig. 18

• Check that charging pilot lamp 2 lights up. • To preheat, push in starter key deeper and turn farther clockwise against spring pressure to "Stage 2", and hold. • Preheat for about 30 to 60 seconds, while observing that heater plug indicator 4 glows up. • To start, turn key farther clockwise to "Stage 3" • Starter motor turns engine; as soon as the engine starts firing, release starter key 3. Note: Do not actuate the starter for more than 20 seconds at a time. You will protect your battery if you wait for 1 minute between each starting attempt.

NO1103 SbOON3 A

• c2

•

Engine Operation

Engine Operation 5.2 Starting Manually

6. Attendance in Service

5.2A Version F2L 912 (Direct injection) Possible down to about 5 "C. • Disengage clutch to disconnect engine from driven equipment, where possible. • Set speed control lever 1 or 2 (Fig. 20) by hand or foot about quarter speed in the direction of the arrow.

6.1 Motor Oil Pressure At idling speed, • the green oil pressure pilot light should have gone out or • the pointer of oil pressure gauge 1 (Fig. 23) - if mounted -- should be in the green sector, or • the pointer of the oil pressure gauge 2 (Fig. 23) if mounted - should indicate about 1.0 bar.

• Move decompression lever 1 (Fig. 21) from stop to stop (see arrows) and then back into the initial position. This is important for safety reasons!

Note: Fig. 20

O I N

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3NI9N3 13S3 10 Zinn

Caution! Do not actuate the decompression device while the engine is running. • Grasp crank handle 1 (Fig. 22) with both hands, all fingers and thumbs up, and turn handle briskly until decompression shuts off automatically (after some 6 camshaft revolutions) and the engine starts firing. • As soon as the engine runs smoothly, cut back the speed. When a moderate load is applied and the speed is varied, the engine will warm up to its working temperature in a short time.

Fig. 23

6.2 Temperature (Fig. 24) Through the window of the temperature indicator*, the pointer is to be seen in the yellowish-green sector when the engine is at normal working temperature. If the pointer is in the orange sector, this means that the engine Is overheated and must be shut down immediately. In this case the cause of the overheating must be traced on the lines indicated in the Trouble Chart (see pages 116 and 117). 6.3 Fan Drive

5.3 Starting at Low Ambient Temperatures

If a mechanical V-belt breakage monitoring system* (Fig. 25) is provided, the engine is shut down by the action of the tensioning pulley 1 in the case of V-belt breakage.

See "Operation in Winter", pages 83 85.

Caution! Before starting, make sure that no one is standing in the close vicinity of the engine or driven machine. After carrying out repairs: Check that all safety guards have been refitted and all tools have been removed from engine.

* Not mounted on all engine versions. Fig. 22 80

NOLI MS HO0N3 A

-n

Lighting up of the warning lamp at low idling speed (engine warm) or a drop of the gauge indicator into the red sector is still permissible if, when speed is increased, the lamp goes out again or the indicator moves back into the green sector. The minimum oil pressure is 1.0 bar at 750 + 50/min., low idling. Where a continuous monitoring of the oil pressure is desired also within the engine's working speed range, this will require optional extras.

Engine Operation

7. Stopping

8. Operation in Winter

• Set speed control lever 1 or 3 (Fig. 26)10 idling position. • Operate stopping lever 2 or 4 (Fig. 26) on the injection pump until the engine stops, whereupon the pilot lamp 2 (Fig. 26a) should light up again. • Turn starter key 1 or 3 (Fig. 26a) fully anticlockwise and pull out; this will cause the pilot lamp to go out.

8.1 Use winter-grade motor oil

CLI

To ensure satisfactory cold starting, the choice of the viscosity grade (SAE-grades page 77) should be governed by the ambient temperature prevailing at the time of starting. As to the oil change intervals, it should be borne in mind that operation below 10 "C requires shorter oil change intervals (see page 98, "Changing Motor Oil"). 8.2 Fuel

Note:

Fig. 26

IS3

+ 32

3N19N313S31 0z1n30

Fig 27

I I Summer diesel fuel-

23 + 14 10 5 -15

Winter diesel fuel— - 4 - 20 - 13 -25

Fig. 26a

- 22 -30 Caution!

0 —10 30 40 50 60 "C % 1 Ambient temperature Percentage by volume in

(I)

Use winter-grade fuel in winter because with ordinary fuel, waxing. may occur at low temperatures and clog the fuel filter. At excessively low temperatures, even winter-grade fuel may tend to wax. Therefore, if only summer-grade fuel is available, or if winter-grade fuel is used at excessively low temperatures, we recommend the following percentages (see diagram) for mixtures of diesel fuel and kerosene or regulargrade gasoline'. Admixture of the latter is however permissible for a short period only, but never for permanent operation.

Prepare the blend in the tank itself: fill in the gasoline" first, then add diesel fuel. The blend is as easily inflammable as pure gasoline.

ap.iii

Maximum admixture of regular-grade gasoline" 30 %; when admixing more than 30 %, use kerosene only.

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For using a commercial additive, please consult your DEUTZ Service Station.

' Never use premium fuel.

NO11 03 S bOGN3A

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Like all internal combustion engines, the aircooled DEUTZ diesel engine should not be shut down suddenly from full-load running. It is better to let the engine idle for 1 2 minutes to allow for temperature balance.

Engine Operation

8.3 Additional Maintenance Jobs

8.5 Starting

• The grade of oil in the oil bath air cleaner - if fitted - should preferably suit the ambient

8.5.1 Starting with Electric Starter: Version F2L 912 with Heating Tube or Version F2L 912 W (Two-stage combustion)

temperature just like the engine oil.

8.4 Cold Starting Aids

• Prior to starting, preheat for about 2 minu tes, then start as per 5.1.2 or 5.1.3 respect ively. • Should the engine not fire smoothly or emit grey - white smoke, do not attempt to accel erate with the speed control lever 1 or 2 (Fig. 29), but • Afterheat for not more than 3 minutes in the preheating stage.

8.4.1 Heating Tube (Item 1, Fig. 28)

The heating tube should be used at ambient temperatures near or below freezing point. It not only lowers the starting limit temperat ure, but proves also useful at temperatures normally not requiring a starting aid. Located at the inlet of the air intake pipe 3, the heating tube 1 contains an electric glow coil 2 for preheating the combustion air.

Note: Continue starting attempt for not more than 20 seconds if no firing occurs. Intervals between starting attempts should be 1 minute or so, enabling the battery to recover. The next starting attempt has to begin again in preheating position ( 1 minute).

1 G ~~ pp

8.5.2 Starting Manually

Cold starling of a Diesel engine depends, among other things, on the capacity of the starter motor and that of the battery, as well as the turning resistance offered by the transmission and driven machine. Since the starting equipment of the engine may differ according to its application, no data on limit temperatures for cold starting are given in this Manual. Any DEUTZ distributor, however, will furnish you with the desired information on this subject. The viscosity specification for lube oils should by all means be observed. Cold starting requires satisfactory condition of the battery. Lowering the limit temperatures by 4 - 5 "Cis possible by raising the battery temperature to about + 20 ° C. This is done by removing the battery with the engine stopped and storing it in a warm room. When installing the battery, ensure satisfactory terminal contact by keeping contact surfaces clean and bright. To avoid distortion of terminal cones, be sure to tighten screws only moderately. At very low temperatures (below - 30 "C) In the case of extremely low temperatures, the engine is to be warmed up to ensure satisfactory starting and lube oil supply. Parts for connecting preheating units, however, are provided only on engines intended for operation in very cold regions.

Manually Started Engines: at very low temp eratures it is advisible to cut in the decompres sion device and then merely turn the engine before starting with speed lever in idling posit ion. Starting procedure as per 5.2.1. 8.5.3 With Start Pilot

During starting operation, the start pilot sprays fuel of very high ignition quality into the intake pipe. Assist starting operation by actuating the pump until the engine fires smoothly. Closely ob serve special instructions for VISO F 27 pilots.

Caution! Do not inject an excessive amount of fuel. Excessive quantities of fuel injected before starting can lead to engine damage. For safety reasons, never use start pilot simultaneously with preheating systems.

mod

NO1103S bOON3 A

3NI9N3 13S3IG Z11130

Note:

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Fig. 29

Maintenance

Maintenance Maintenance Chart* IMPORTANT! The Maintenance Chart displayed below is supplied as a selfadhesive label along with each engine. Check that this label is stuck at a convenient location on the engine or driven equipment.

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Note: Valid for routine maintenance work is the Maintenance Schedule on page 89.

h Std.

Z= c7 m H m

ca 0156

250 1000

1/4

F 2 L 912 IKHOTI111111111111111110 297 3629

DEUTZ

N0I103 S i OGN 3A

Stop engine before carrying out any maintenance work

If necessary, ask for a fresh supply of labels.

Maintenance

Maintenance Schedule

Engine Maintenance

•

Maintenance

•

Every

Long life

Engine reliability

Starting performance

0 0 0

0 0

Engine noise

Exhaust emissions

Bearing clearances

Specific oil consumption

Specific fuel consumption

Engine power

by servicing

OIL.. ft O

PZI

3N I 9N313S3 I0 Z11130

AIR CD

0 FUEL

,q4 0 *,

. .

0 0

0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

0 0

1 24 866 88

94-96

•

ery Ev00 5 hours

98/99

100/101

•

f ,,,, ,

15.m ,.),,,, i,... , Az--,

--'..4. , 1 :

See page

•

Job

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i".,, i iiie 404 4/.1(

•

See page Job

103/104

4*'t 2

4. 1:.:x '1

,;.,.. , ._

).*1.*: 14,̀ ,1_ V,

ii ,

Job

♦

x i*

Maintenance point

105

106/107

See page

Job

.. ,sicisy

6 'A ,1 ki,

106/107

Maintenance point

See page

410 F21_ 912 w

F2L 912

Maintenance point

102

..A fi ,

N .

98/99

Every 1000 hours

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•

, P. .c

•

0 0

Maintenance point : pt 4":i.,; ii

98/99

0 0 0

0 0

Every 250 hours

Job

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rria;vir...,,

Ort_ ,

Every 125 hours

•

• el.—.

-./\,,k .

10 hours

Improvement of

\\Ir t See Note

Check • Clean • Change

The maintenance jobs described on the following pages ensure ready engine availability at all times and long life span.

108

Cie

109-111

Maintenance point

See page

Workshop Maintenance Every 1000

•

Air intake and exhaust manifolds

hours

•

Cylinder-head temperature indicator

112

Every 1500

•

Alternator

113

hours

•

Starter motor

113

Every 3000 hours

•

Injectors

114

112

Maintenance

The maintenance jobs duly completed can be recorded and certified in the schedule below.

Completed Maintenance Jobs

• 50

Hours Date j Signature

Date Signature

Hours

375

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pz• I

U) U) C,

3N I9N313S3 1 0 Zlfl3a

Signature

Hours 6250

6375

6500

250 1

6750

500

6875

7000 7250 7500

750

7125

875

1000

7375

1125

1250

7625

7750

1375

1500

7875

8000 8250

625

Date

6125

6625

125

Hours

■

1625

1750

8125

1875

2000

8375

8500

2125

2250

8625

8750

2375

2500

8875

9000

2625

2750

9125

9250

3000

9375

9500

2875

3250

9625

9750

3375

3500

9875

10000

3625

3750

10125

10250

4000

10375

10500

4125

4250

10625

10750

4375

4500

3125

3875

4625

10875

11000

11125

11250

5000

11375

11500

5250

11625

11750

4750

4875

5125

5500

11875

12000

5625

5750

12125

12250

5875

6000

12375

12500

5375

Date

Signature

NO11 03 S I OGN3A

The maintenance jobs duly completed can be recorded and certified in the schedule below.

• See instructions on page 92 90

•

• u) oi 0

-4 D ti) it -n

P. o

Maintenance

Important: Commissioning New or Overhauled Engines

Routine Maintenance

At the end of 15 minutes' running: O

Check Oil Level in Engine

• Retension V-belts (Fig. 30). See pages 103/104.

03 -.1

Maintenance

10 N

• Engine must be in horizontal position and shut down. • Pull out dipstick 1 (Fig. 33), • wipe with clean, non-fraying rag, • reinsert as far as it will go, and then • withdraw again. The oil level should be between the marks 2 and 3 (Fig. 33). If the level is only up to or even below the lower mark 3, top up with oil immediately, preferably up to the upper mark 2, in order to prevent serious damage being caused to engine.

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At the end of 50 hours' running: • Change oil. See pages 98/99. At the first oil change, the following jobs are due in addition:

Note: Checking the oil level prior to starting the engine ensures a sufficient engine oil level for the start. To check the oil level accurately, it is necessary to shut down the engine after about one minute of operation. The entire oil system will then be filled. The immediate oil level check will then show the oil sump filling volume actually available during operation of the engine.

3NI9N313S3Ia

• Clean lube oil filter (item 1, Fig. 31). See page 105.

Fig. 33

Note: With a view to matching the intervals for subsequent oil changes and maintenance jobs to the total running time of the engine, we recommend, after the initial maintenance work at the end of 50 running hours, that the ensuing maintenance jobs be carried out after 125, 250 and 500 hours, etc.

We strongly recommend to carry out this double check of the oil level before any prolonged engine operation, particularly if the check prior to the engine start discloses an oil level in the vicinity of the lower or minimum mark on the dipstick.

Fig. 31

Normally, new engines have a higher oil consumption. During the running-in period (about 200 running hours) it is therefore essential to check the oil level twice a day. After the running-in period, one check per day is sufficient. Where engines are inclined, oil level should reach top mark of dipstick.

• Retighten engine mounting bolts. • Retighten bolts securing air intake and exhaust manifolds to the cylinder heads (item 2, Fig. 32). See page 112. • Check valve clearance readjusting if necessary. See page 106/107.

Fig. 32 92

N01103 Sb OGN3A

Maintenance

Maintenance 2. Dry-type Air Cleaner (if mounted)

Checking and Cleaning Air Cleaners

The life of the expendable paper cartridges in dry-type air cleaners depends on dust collector 2 (Fig. 35) being emptied in good time. Failing this, the cartridge will clog up fast. Be sure, therefore, to empty the collector not later than when filled half-way. Where the air is very dust-laden, this may require daily servicing.

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Dust in the combustion air can cause premature wear of the engine. Maintenance of the air cleaners is therefore essential to ensure long life It is also necesary to check unions and connections of the intake manifold regularly. The maintenance intervals for air cleaners depend on the amount of dust fall-out. No fixed intervals can therefore be given.

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If a special dust ejector 8 is provided, it is only necessary to clear the discharge slot from time to time. 2.1 Emptying the Dust Collector • Stop engine. • Release clip 1 (Fig. 35) and remove dust collector 2 along with cover 3.

-n Fig. 34

1. Oil Bath Air Cleaner (if mounted, otherwise see page 95) N)

• Before checking, wait at least one hour after stopping the engine, so that the oil has had time to drip down from the cleaner element. • Release the snap clips 3 (Fig. 34) and remove oil bowl 2.

3N 1914313S3 10z1n30

• Remove element 4 by sidewise tapping with the hand or by inserting a screwdriver. Do not damage rubber gasket! • Renew oil in bowl 2 (for motor oil viscosity, see page 76). Note oil level mark (arrow). • Rinse filter element 4 in diesel fuel (never in gasoline!) and allow to drip-dry thoroughly. • Once or twice a year (depending on amount of dust), remove also the filter upper part 1 and likewise rinse in diesel fuel. Allow to drip-dry thoroughly. • Following reassembly, check all connections for leaks.

Fig. 35

• Refit assembly, making sure that recess on cover mates with lug on collector (see arrows, Fig. 35). • When cleaner is installed in horizontal position, check that the "Top" mark is actually at top.

2.2 Servicing the Cartridge Where a service gauge (Fig. 36) is fitted and keeps displaying the red warning signal 1 when the engine is stopped, or where a yellow warning light goes on with the engine running, the cartridge is due for servicing. (Also indicated by smoking exhaust and decreasing engine output.) It is not advisable to service the cartridge more frequently, as this may affect seal 7 (Fig. 35) between cartridge 5 and housing 6. Replace cartridge not later than at the end of 12 months or when soiled by soot. If no new cartridge is to hand for replacement, the existing cartridge can also be cleaned for reuse (see Section 2.2.1), but should then be replaced at the earliest opportunity.

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• Take off cover 3 and empty collector.

• Proceed by taking down dust collector 2 (Fig. 35) as described under 2.1. (Where a dust ejector 8 is provided, unscrew wing nut 9 and remove cover.)

Fig. 36

Fig. 36 94

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Maintenance

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Maintenance

• Unscrew hex. nut 4 and remove soiled cartridge 5.

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Checking Water Separator on Two-stage Fuel Filter

• Renew or clean cartridge.

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(if mounted)

• After having serviced cartridge 5 five times, or after two years at the latest, renew together with safety cartridge 11 (secured to body 6 by nut 10). Enter the number of servicings of cartridge 5 in the spaces provided on safety cartridge 11.

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• Safety cartridge 11 may not be cleaned and reused.

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• Renewal of cartridge 11 is also required when cartridge 5 is renewed because of defects, etc., or when warning signal reappears although cartridge 5 has been serviced.

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Some engine versions use a two-stage fuel filter with water separator for protection of the injection system. The water collects in bowls 2 and 3 (Fig. 37). In the transparent bowl 2, the water is distinguished from the fuel above by its lighter shade. Make sure that water level will not exceed the lower rim of bead 4. The maintenance intervals for the water separator depend on the amount of water contained in the fuel and cannot be stated definitely. Initially, therefore, check daily whether there are indications of water in the transparent bowl 2.

• Make sure that only genuine cartridges are used as supplied by the air cleaner manufacturer. Cartridges of other make usually do not fit and are a hazard to the engine.

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3N19N3 13S310 Z1030

Fig. 35

2.2.1 Cleaning the cartridge: a) by tapping (provisional): Tap cartridge 5

with its front end gently against the palm of your hand or on a soft surface, to shake off the dust. Take care not to damage the front end of the cartridge. b)with air: Apply air blast of max. 5 bar from inside to outside until no more dust is coming out. Do not blow out housing 6.

Fig. 37

Note: Catch fuel in special receptacle to prevent pollution of the environment.

Fig. 36

3. Checking:

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Draining off the water:

• Loosen knurled screws 5 and bowls 2 and 3 through one or two turns. • Observe the flow of draining liquid and the transition from water to diesel fuel. • Gently retighten knurled screws 5.

Prior to reassembly, introduce a lighted bulb into filter cartridge 5 to see whether it suffered damage (damaged cartridges must definitely be renewed). Also make sure that gasket 7 is not defective. If a service gauge with visual signal is fitted (Fig. 36), press push button 2; this causes the red signal to disappear from the window.

Caution: In no event use gasoline or hot liquids for cleaning the cartridge!

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Maintenance

Maintenance Change Oil

Changing the Motor Oil

Important: Should the engine run less than the hours stated in the following Table, the oil must be changed in any case once a year. Oil Chan ge Periods

Engine Application

A CD U)

Oil Grade API: CC/SE or CC/SE

Oil Grade API: CD/SE or CD/SF

250

500

125

250

3NI9N3 num zima

Fig. 38

Oil capacity at refill approx. 4.5 litres.

Caution: Danger of scalding when draining off the hot oil!

(FL 912 W)

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Oil Change Intervals (running hours)

Important: The above intervals are based on the use of a diesel fuel containing max. 0.5 % b.w. of sulphur and ambient temperatures above — 10 "C. Periods between oil chan ges should be cut b y half • when using fuels containing more than 0.5 % up to 1 % sulphur or • if the ambient temperatures are permanently below • 10 "C. In the case of fuels containing more than 1 % up to 1.5 % sulphur, the motor oil should have a TBN' of about 12 x % S-content, with the periods between oil changes being halved.

Catch old oil in suitable receptacle to prevent pollution of the environment!

Note: Upon changing over to a higher grade of oil following a prolonged period of operation, change oil at the end of 20 hours and clean oil filter element.

Typical examples: 1) Tropical climate, oil stressing category A, fuel containing 0.8 % sulphur, lube oil grade CD/SE: Change oil every 250 hours. 2) Tropical climate, oil stressing category A, fuel containing 1.2 % sulphur: Change oil every 250 hours, using CD/SE or CD/SF oil having a TBN' of about 14 mg KOH/g. Oil Grades The responsibility for the grading of his particular oil product to API Specification is borne by the supplier.

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"Total Base Number", expresses the neutralising capacity of the oil. TBN Ask your supplier to quote TBN. 98

N011 0 3 S bOO N3A

Tractors, Lift trucks, Cranes, Construction machinery, Rail traction units, Ships, Base-load gensets, Pumps Farm equipment (seasonal) Underground mining, Road sweepers, Winter service, Emergency gensets, Emergency pumps Engines with two-stage combustion

Category of Oil Stressing

while the engine is still hot, since the old oil will run more easily in this condition. • Shut down engine. • Unscrew drain plugs 1 (Fig. 38), after placing suitable receptacle underneath. • When all old oil has run off, refit drain plugs 1 complete with new sealing rings 2. • Fill in fresh oil through filler neck 3 (Fig. 39) up to the upper dipstick mark (Max., Fig. 40). • Following a short trial run, check oil level again, topping up to the upper mark (Max.) if necessary.

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Maintenance

Cleaning methods:

Cleaning the cooling system is most important since accumulation of dust on the cooling air blower blading 1, on the cooling fins of the cylinder heads 2, cylinders 3 (Fig. 41) or oil cooler 4 (Fig. 42) is liable to reduce cooling efficiency substantially, especially where the dust is retained by a film of fuel or oil.

11.4

• Dry cleaning by means of compressed air. Start blowing through from the exhaust-air side (Fig. 44). Any dirt blown into the air cowling space (Fig. 45) must be removed afterwards, of course.

Check the cooling system regularly for contamination in accordance with the following table, and clean if necessary. Please note that the inspection intervals can only be given as guide figures based on normal operating conditions, and that in the case of abnormally contaminated cooling air check mounted cooling air sieve boxes for correct seating and good condition - the inspection and cleaning intervals may have to be substantially shortened accordingly.

• Use of cold cleansing agent (e.g. P 3 or Nalfleet). After allowing an adequate soaking-in period, wash the engine with a powerful water jet. • If a high-pressure jet is available, this method of cleaning is preferable to any other.

Note: When cleaning the vehicle or engine by means of cold cleansing agent or steam, cover up the injection pump, alternator, voltage regulator and starter motor as protection against direct application of the jet.

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After wet-cleaning, let the engine run until warm so that any water left behind will be evaporated before rust can form.

3NI9N3 13S3Ia ZIA30

For inspecting and cleaning, proceed by undoing the hex. bolt 1 (Fig. 43) securing the air cowling hood 2 on the alternator side, and removing the hood.

Inspecting/Cleaning the Cooling System

Maintenance

Caution: Always stop the engine before cleaning! Fig. 42

Inspection Interval (guide figures only) Running hours 2000 1000 500 250 125

Engine Application

Ships, Gensets in closed rooms, Pumps Vehicles on paved roads Tractors, Litt trucks, Mobile gensets Vehicles on building sites and unpaved roads, Construction machinery, Compressors, Underground mine units Farm equipment, Tractors doing harvesting work 100

101

N011 03 S b O0N3A

K.,

Maintenance

Maintenance r

Checking Electrolyte in Battery

c 15mm Ofu

Checking V-belt/ V-belt Tension

, .

• Remove cell caps 1 (Fig. 46).

• Inspect V-hell over whole length for damage or cracks. Renew damaged or cracked V-belts.

• In some cases, electrolyte level testers 2 are provided: the level should be high enough to wet the bottom of these.

• Check by pressing with the thumb (Fig. 47) midway between the pulleys to see whether the V'-belt deflects inwards by max. 10 15 mm (0.4 • 0.6 in.).

• An alternative method is to insert a clean wooden stick 3 into the cell until it touches the top of the plates. The electrolyte should wet the stick over a length of about 10 - 15 mm.

-n

Retensioning V-belt with Alternator:

• If the electrolyte level is low, top up with distilled water only. • Replace cell caps.

Fig. 46

• For hints on battery care in winter, see page 84.

Retensioning V belt with Idler Pulley: -

• Slacken hex. bolts 1 and 2 (Fig. 49). • Pull idler pulley 3 in direction A until the correct belt tension is obtained. • Then securely retighten hex. bolts 1 and 2.

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3NI9N3 13S3 10 ZIA30

• Slacken hex. bolts 1, 2 and 3 (Fig. 48). • Pull alternator 4 in direction A until the correct belt tension is obtained. • Then securely retighten hex. bolts 1, 2 and 3.

Caution: When working on the battery, keep naked lights away, do not smoke!

• Slacken hex. bolts 1, 2 and 3 (Fig. 48) or 1 and 2 (Fig. 49).

Do not allow acid to come into contact with the skin or clothing! Wear protective goggles!

• Push alternator 4 or idler pulley 3 in direction B against the engine. In this position, it is easy to fit the new V-belt.

Do not place tools on battery!

• Tension V-belt as described above.

Renewing the V belt: -

Note: Retension new V-belts after running for 15 minutes. (Not applicable to cooling blower drive with automatic tensioning pulley 1 (Fig. 50). When two V-belts are provided, always renew both belts when only one is worn or damaged. The difference in length of the new V-belts may not exceed 0. 15 %.

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102

103

NOI1 03 S HOO N3A

O m O

Maintenance

Checking V-belt Tension on Version equipped with Mechanical Shutdown system upon V-belt Breakage

Maintenance

Cleaning the Oil Filter

(Fig. 50)

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On this version, it has to be ensured that the V-belt has the correct tension, since otherwise the shut-down device 2 will be actuated by the swing movement of the idler pulley 1. It is therefore essential to tension the V-belt by swinging out the alternator so that distance A between V-belt pulley 5 (Fig. 51) and idler pulley 1 measures 10 mm. At every oil change, apply a drop of motor oil to pin 3. The shut-down device 2 must be so adjusted that the shut-down lever 4 can be moved about 3" further until reaching the stop.

Cleaning the Oil Filter (Wash-filter)

• Unscrew hex. bolt 1 (Fig. 52). • Remove cover 2 with gasket 3 and filter element 4. • Unscrew hex. nut 5 of hex. bolt 1, and take off element 4. • Wash element 4 in clean diesel fuel and allow to drip-dry thoroughly.

• When reassembling, ensure correct positioning of gasket 3 for cover 2 and gasket 6 of element 4. Fig. 50

• To clean, turn handle 2 of plate-pack 1 (Fig. 53) once or twice. • The deposited sludge is thus carried outwards and sinks into the sludge chamber of filter body 3. • Drain off the sludge from time to time by loosening filter body 3.

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Cleaning the Oil Filter (Edge Filter)

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3NI 9N3 13S3113

Note: During trial run following reassembly, check oil pressure and tightness of filter mountings.

Caution! A small amount of oil runs out when screwing off the oil filter.

Fig. 53

Danger of scalding in case of hot oil! Catch old oil in suitable receptacle to prevent pollution of the environment!

• If mounted. 104

105

NOI103S i OGN3A

Maintenance

Maintenance Checking Decompression Clearance (manually started engine)

Checking Valve Clearance

Whenever checking valve clearance, be sure also to check the adjustment of thrust screw 1 (Fig. 55) located on the rocker arm and designed for determining the clearance of the decompression device, where provided. Proceed as follows:

• Valve clearance to be checked with engine cold. Note: The valve clearance is the requisite gap 1 between the pads of rocker arms 2 and valves 3 (Fig. 54). Good engine performance and power output depend on its correct setting which may be carried out by a skilled mechanic according to the following instructions, but preferably by a specialist.

• Check valve clearance: Valve clearance 1 is correct when a 0.15 mm feeler gauge can be inserted with a slight drag between rocker arm 2 and valve 3. • Failing this, the valve clearance must be readjusted.

3NI9N3 13S3 10win

• First remove rocker chamber covers. • Turn crankshaft at front end until the valves of the cylinder in question are "overlapping" Fig. 54 (exhaust valve about to close, inlet valve about to open). • Then continue turning the crankshaft through 360".

• Readjust as follows: Loosen locknut 4 by two to three turns. Adjust setscrew 5 with screwdriver so that, when locknut is retightened, the feeler gauge can be inserted and withdrawn with slight drag. • Check the valve clearances of each of the remaining cylinders and readjust if necessary. • Do not change the setting of oil nozzle 6 unless required. With hot engine running at idling, an oil flow to pad of rocker arm 2 must be just noticeable. An excessive oil flow can lead to higher oil consumption.

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• Remove rocker chamber cover. • With valves closed, i. e. piston in compression TDC, press thrust pad 2 by hand against the valve stem end. • In this position of the rocker arm, the setting dimension "a" should be 59.7 + 0.2 mm. • Setting the thrust screw 1: Loosen hex. nut 3 (Fig. 55) by 2 3 turns with a 13 mm spanner. • Adjust thrust screw 1 with a screwdriver so that the setting "a" stated above is obtained when hex. nut 3 is tightened. • Refit rocker chamber cover 1 (Fig. 56). • After tightening the cover fastening bolts, check that the decompression shafts 2 can be turned easily through some 10".

106

107

Fig. 55

N01133S bOGN3A

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Maintenance

Cleaning Strainer of Fuel Feed Pump

Renewing the Fuel Filter Cartridge

• In case of high-level tank, close fuel cock. • Remove hex. bolt 1 (Fig. 57). • Take off cover 2. • Take out gasket 3 and strainer 4. • Clean strainer in diesel fuel.

• In case of high-level tank, close fuel cock. • Place receptacle in position to catch escaping fuel.

Note: Falling-off engine performance can be due to contamination of this strainer.

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3N I9N313S3Iazin3a

• Screw off fuel filter cartridge 1 (Fig. 58), using special tool if necessary. • Clean sealing surface. • Apply a light film of oil to rubber gasket 2 of the new filler cartridge.

• Following reassembly, check unit for tightness.

Fig. 57

.1;

• Screw new cartridge in place by hand until gasket is evenly seated. • Give cartridge a final half turn. • Air-bleed fuel system (see page 74).

Fig. 58

Note: Falling-off engine performance can be due to clogged filter cartridge. If the filter cartridge clogs up too quickly, check fuel for contamination, clean tank, check sealing of filler cap.

Caution: When working on the fuel system, keep naked lights away, do not smoke! Do not spill any fuel!

108

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109

N01103 S 21 OO N3A

Maintenance

Renewing the Two-stage Fuel Filter Cartridge (2nd stage)

Renewing the Two-stage Fuel Filter Cartridge (1st stage)

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• In case of high-level tank, close fuel cock. • Place receptacle in position to catch escaping fuel.

• In case of high-level tank, close fuel cock. • Place receptacle in position to catch draining-off fuel. • Unscrew drain plug 2 (Fig. 59).

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• Unscrew filter cartridge 1 (Fig. 60) complete with drain plug by means of hexagon 2 at the bottom. • Clean sealing surface.

• Release clamping pin 3. • Remove water bowl 5 and the two seals 4 and 6. • Unscrew cartridge 1 from bracket and replace by new cartridge. • Refit water bowl in reverse sequence, taking care that seals 4 and 6 are properly seated.

(\.)

• Apply a light film of oil to the rubber gasket of the new filter cartridge and screw new cartridge in place by hand until gasket is evenly seated, then give cartridge a final half-turn. • Air-bleed fuel system (see page 74).

• Air-bleed fuel system (see page 74).

Fig. 60

Fig. 59 Note:

Falling-off engine performance can be due to clogged filter cartridges. If the filter cartridges clog up too quickly, check fuel for contamination, clean tank, check sealing of filler cap. m

Caution: When working on the fuel system, keep naked lights away, do not smoke! Do not spill any fuel!

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NOI103S J OO N3 A

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Workshop Maintenance

Inspecting Air Intake and Exhaust Manifolds

Testing Alternator It is advisable to have the alternator 1 (Fig. 63) tested in a specialized workshop.

Check the connections of air intake manifold 1 (Fig. 61) and exhaust manifold 2 to the cylinder heads for tightness and retighten if necessary.

Fig. 61

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3NI9N313S310 Z.U130

Testing Temperature Indicator/Pilot Light Unscrew sensor or switch 1, as provided (Fig. 62), from cylinder head 2 and immerse in oil heated to 150 - 155 "C (302 311 "F). This should cause the red sector to appear in the window of the indicator or the lamp, if provided, to light up.

Note: The temperature elements 1 (sensor or switch) are always screwed into the head of the No. 1 cylinder.

Fig 63

Testing Starter Motor It is advisable to have the starter motor 1 (Fig. 64) tested in a specialized workshop.

Fig. 62 Caution:

Note: Cover up starter motor before washing engine.

Heat the oil in a container on a hot-plate (not with welding torch). Do not exceed the specified temperature range. Danger of burns.

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Fig. 64 112

113

N01103S 21 00 N3 A

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Notes on three-phase system: • When the engine is running, never disconnect the leads between battery, alternator and regulator. Where it is however necessary to operate the engine without battery, disconnect, before starting, the alternator from the regulator. • Never interchange the battery leads. • Renew a defective charging pilot light bulb immediately. • Before washing the engine, fit covers to protect the alternator and regulator. • The common practice on a DC-system of touching a lead against earth for checking whether the lead is live must under no circumstances be adopted on a three-phase current system. • In case of electric welding, connect the earth terminal of the welding unit direct to the piece to be welded.

Workshop Maintenance 8

Trouble Shooting

Testing Injectors

If troubles should occur, these will be frequently due to incorrect operation, lubrication or maintenance of the engine. In such a case, therefore, make a point of thoroughly re-reading the Sections on pages 74 to 114.

• Remove injectors. • Have the injectors tested in a specialized workshop. For specified injection pressure, see Specification Data, page 73. • When refitting the injectors, observe tightening torque (see page 119)!

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If you cannot identify the cause of the trouble or are unable to put it right yourself, the best plan is to contact your local DEUTZ distributor.

Note: inspection of the injectors between the times stated on page 89 is unnecessary unless the engine displays unusual symptoms (e.g. black exhaust smoke, harsh combustion noises).

See Trouble Charts on pages 116 and 117.

n Fig. 65

Caution! To prevent personal injury, do not allow the pressurized spray-jet to come into contact with the skin!

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Battery defective and/or flat Cable connections of starter motor circuit loose or oxidized Starter motor defective or pinion does not engage Starting aid defective Oil pressure switch/oil pressure gauge defective Valve clearance incorrect/valves worn Compression pressure loo low Cylinders and/or piston rings worn Plugs in cylinder heads leaky Oil metering screw for rocker arm lubrication incorrectly set Piston crown clearance excessive Valve guides worn Main and/or big-end bearings defective Engine suspension defective and/or incorrect Flexible engine coupling defective

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Commencement of delivery setting incorrect Nozzle backleakage line clogged Amount of fuel injected excessive

Cooling fins soiled Air cowling plates loose, cracked or missing Blower V-belt loose or broken Lube oil cooler soiled Heating-up of cooling air/Recycling of heat

• • • • •

•

• • •

Fuel tank empty and/or fuel cock closed Tank breather clogged Air in fuel system Fuel filter and/or lines fouled Fuel feed pump defective (diaphragm) ' Injector defective

Oil suction pipe strainer clogged Suction line leaky Control valve defective Lube oil pump defective

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Driven machine not declutched (where possible) Below start limit temperature - Cold-start procedure unobserved Oil level too low Oil level too high Engine shut-down lever not in operating position _. Speed control lever not in correct starting position Speed control lever not reaching full-load stop Excessive inclination of engine Engine run mainly at low load Wrong SAE-grade of motor oil and machine lube oil aE; Fuel temperature too high Air cleaner contaminated Exhaust back pressure excessive

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Workshop Information

The Workshop Manual dealing with the

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Workshop Information Tightening Table for Bolts and Nuts

engines described in this Operation Manual bears the number 291 1842 and can be ordered from our headquarters in Cologne, Depart ment MZA.

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Tightening Heavy-duty Bolts and Nuts

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To prevent faulty assembly, the following information includes instructions on the tighten ing of heavy -duty bolts, because the procedure differs from that normally employed. The tightening angle is particularly important and, for this reason, Fig. 66 indicates how various angles can be readily obtained by comparison with a clock face.

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210 1681

Connecting rod

M 12 x 1.5

Bearing cap

M 14 x 110

Rocker bracket

M 8 x 55

Balance weight

M 12

x 70

positioned ready for pre - loading. 3. Pre-load the bolts to the value stated in the "Tightening Table for Bolts and Nuts " on page 119. Fig. 66 4 Tighten the bolts according to the Table, if necessary in stages, in conformity with the tightening angles specified.

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45 45 45 30- ' 165

30" 60'

45' 60"

105

30"

90"

90'

28 Ni;; 60 180 25 Nm (FL 912)

Injectors

M 10

V- belt pulley

M 35 x 1.5

140

Cooling blower

M 12

Adapter housing

216 4062

Oil filter cover

337 1962

60"

30"

60"

60•

90" 90"

60 90' 240

I 1 35 Nm

Note: When renewing main and big-end bearings or after piston seizures, be sure to renew the bearing bolts as well.

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I 118

119

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3NI9N3 13S310un30

Cylinder head

Flywheel

1.Wet threads and seatings with motor oil before fitting. 2. Screw the bolts in until they are uniformly

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Designation

Engine Preservation

Workshop Information

It your engine is to be shut clown for a major period (e g over the winter), we recommend the following preservation measures against rust formation. 1 Clean the engine. including the cooling system, with commercial detergent and a water jet or better, a high-pressure jet (see page 101) 2 Run engine up to working temperature and then shut down 3 Drain the motor oil from the sunup when still hot and fill in anti-corrosive oil 4. Pour the oil out of the bowl of the oil bath air cleaner, clean bowl and fill up with anti-corrosive oil 5 Drain fuel from tank, mix well with 10 'X, anti-corrosive and fill hack into tank Instead of adding anti-corrosive oil to the fuel, the tank can be filled up with injection pump testing oil having corrosion inhibiting properties (e. g. Calibration Fluid B). 6 Run engine for about 10 minutes, so that pipes, filler, pump and nozzles are filled with the preservative mixture and the mixture is distributed to all parts.

Fitting Valve Springs Be sure the close-coil end is at the bottom (Fig. 67).

Fig. 67

Rtl

7. After this run, detach the rocker chamber covers and spray the rocker chambers with a mixture of diesel fuel arid 10 % anti-corrosive or with injection pump testing oil. After this, refit the covers. 8 Now turn the engine over several times without firing in order to spray the mixture into the combustion chambers. 9 Remove V-belts and spray the grooves of the V-belt pulleys with anti-corrosive. Before revs ing the engine, wipe off the anti-corrosive. 10. Close intake opening of air cleaner and exhaust opening tightly,

FL 912 (Direct Injection) When fitting a new piston, make sure that the stamped-in arrow points to the exhaust-air side of the engine (Fig. 68).

Fig. 68

125041i

Fig. 70 Note: These preset vative measures will give the engine a protection; of 6 to 12 months, depending on weather effects. Before reusing the engine, replace the preserving mixture by regular motor oil" to API Specifica tions. The anti -corrosive oils used should conform to MIL -L -21260 B or TL 9150-037/2 specifications (;1 NATO Code C 640/642.

r.)

FL 912 W (Two - stage Combustion) When fitting a new piston, make sure that the stamped-in arrow points to the exhaust-air -ode the engine (Fig 69).

' See page 98

120

NO113 3Sb OON3 A

3N1 9N313S3 10 Z1030

SYNCHRO-START D.C. SOLENOIDS GENERAL INFORMATION Because of the dual coil design, Synchro-Start D.C. Solenoids may be energized continuously without any duty cycle derating. This is an advantage over single coil solenoids. The dual coils, one low resistance, the other high resistance, permit safe operation even in high ambient temperatures.

THE DUAL COIL GIVES GREATER PULLING POWER AND PERMITS CONTINUOUS OPERATION AT HIGHER AMBIENT TEMPERATURES

The low resistance coil provides a high pulling force. Upon completion of the plunger stroke, the heavy duty double break self contained switch automatically disconnects the high current pull winding within .040 seconds of energization. This means that Synchro-Start D.C. Solenoids pack more power in a smaller space at lower cost. All D.C. solenoids using dual coils must be installed and adjusted so that the plunger always completes its stroke, ie., the plunger must bottom, disconnecting the low resistance coil. If this does not occur, excessive heat ensues, which in time (over 30 sec.), does irreparable damage.

Contacts Must Open With Plunger Bottomed

Synchro-Start Heavy Duty Solenoids are Rugged and Performance Tested.

WARRANTY Proper installation is extremely important. Plunger must bottom properly

to operate pull coil disconnect switch. If contacts fail to open and circuit is not protected against overload, the pull coil will burn out in 50 seconds. Damage of this type is due to faulty installation and is not covered by Synchro-Start's normal warranty.

SYNCHRO-START D.C. SOLENOIDS

1. GENERAL •

Condor uses the Synchro-Start D.C. Solenoids for choke and throttle control on the gasoline engines, and for fuel on/off and throttle control on the diesel engines. (See Table "A" for the list of Condor Models and the solenoids used.)

•

The solenoids used have the dual coil design, and may be energized continuously without any duty cycle de-rating. They have an extremely high work output for their size, because of the high amperage "pull" winding and a separate low amperage "hold" winding. These dual coils (one low resistance, the other high resistance) permit safe operation even in high ambient temperatures.

•

The low resistance coil provides a high pulling force. Upon completion of the plunger stroke, the heavy duty double break self-contained switch automatically disconnects the high current pull winding within .040 seconds of energization.

•

All D. C. solenoids using dual coils must be installed and adjusted so that the plunger always completes its stroke, i.e., the plunger must bottom, disconnecting the low resistance coil. If this does not occur, excessive heat ensues, which in time (over 30 sec.), does irreparable damage.

• -CAUTION: Proper installation is extremely important. Plunger must "bottom" properly (i.e., complete its stroke) to actuate the pull-coil disconnect switch. If contacts fail to open and circuit is not protected against overload, the pull-coil will burn out in 30 to 50 seconds. Damage of this type is due to faulty installation and is not covered by normal warranty.

2. ELECTRICAL DATA: SYNCHRO-START D.C. SOLENOIDS

SOLENOID PART NO.

LENGTH OF STROKE

RATED D.C. VOLTS

PULL AMPERES

HOLD AMPERES

32111

1 IN.

0.5

40808

1 IN.

0.6

32239

1i IN.

0.6

#32111

#40808

Contacts must Open with Plunger Bottomed

#32239

SYNCHRO-START D.C. SOLENOIDS - continued:

TEST PROCEDURE TO DETERMINE PLUNGER HAS BOTTOMED •

On units with an auxiliary terminal, connect a voltmeter or appropriate light (voltage rating) between auxiliary and "+" terminals. When the solenoid is energized and the plunger bottoms, the voltmeter will indicate the battery voltage or the light is energized.

•

Visual Method - Push the plunger to the full bottomed position and measure the plunger extension length from the solenoid body before the linkage is connected. Connect linkage and energize the solenoid. If the plunger has fully bottomed, the plunger extension lengths should be the same.

4. TEST •

PROCEDURE TO DETERMINE ADEQUATE VOLTAGE

Connect a D. C. Voltmeter across the solenoid terminals and manually hold the plunger so that it cannot bottom. Energize the solenoid just long enough to obtain a voltmeter reading, then connect the same voltmeter across the power source and manually hold the plunger so that it cannot pull in just long enough to obtain a voltmeter reading. The difference between the two voltmeter readings is the voltage reduction due to wiring which should normally be less than 7% of rated voltage.

5. CORRECTIVE •

ACTION

If the power source voltage is low, check for partially discharged battery, etc. If the solenoid voltage is low, check for undersized hookup wire, high resistance connections and underrated control device contacts.

TABLE "A" LIST OF CONDOR MODELS & SYNCHRO-START D.C. SOLENOIDS USED

CONDOR MODEL

ENGINE

36N

Wisconsin Gasoline

46N

Model VH4D, 30 HP

36N 46N

Deutz Diesel Model F2L511

60N 48 50 56 58 68 76 46Q8 60N 48 50 56 58 68 76 46Q8

CONTROL FUNCTION

Choke

SOLENOID PART NO.

32111

Throttle

32111

Fuel Shut Off

32239

Wisconsin Gasoline

Choke

32111

Model VG4D, 37 HP

Throttle

40808

Fuel On

40808

Deutz Diesel _ F2L912

TABLE "B" SYNCHRO-START SOLENOIDS USED ON CONDOR MODEL 86

CONDOR MODEL

ENGINE

Ford Gasoline

Wisconsin Emergency Gas Engine

Ford Diesel

Deutz Diesel F4L912

CONTROL FUNCTION

SOLENOID PART NO.

Choke

32111

Throttle

32239

Choke

32111

Fuel Shut-Off

32111

Throttle

32239

Fuel On

40808

Throttle

40808

C /I L.INV/ift

VENDOR SECTION

Operation Manual DEUTZ

F2L 91211N Contents Page

Foreword Before Commissioning Your New Engine Safety Precautions

64 65

Description of Engine Description of Engine

Numbering of Cylinders Lube Oil Circuit Combustion Method Layout of Fuel System (Deutz Injection Pump) Layout of Fuel System (Bosch Injection Pump) Engine Model and Engine Serial No. Specification Data

66 67 68 69 70 71

Operation of Engine Fuel (Filling-up/Air-bleeding)

Motor Oil Starting Stopping Winter Operation

74 76 79 82 83

Maintenance Maintenance Schedule Important: Commissioning New or

Overhauled Engines Checking Oil Level in Engine Checking and Cleaning Air Cleaners Checking Water Separator on Two-stage Fuel Filter Changing Motor Oil Inspecting/Cleaning the Cooling System Checking Electrolyte in Battery Checking V-belt/V-belt Tension Cleaning Lube Oil Filter Checking Valve Clearance/Decompression Clearance Cleaning Strainer of Fuel Feed Pump Renewing Fuel Filter Cartridge Renewing Two-stage Fuel Filter Cartridge (1st stage) Renewing Two-stage Fuel Filter Cartridge (2nd stage)

89 92 93 94 97 98 100 102 103 105 106 108 109 110 111

Workshop Maintenance Checking Fastenings of Intake and Exhaust Manifolds 112 Checking Cylinder Head Temperature Monitoring System 112 113 Testing Alternator/Starter Motor 114 Testing Injectors

Trouble Shooting Workshop Information Engine Preservation

FIGURE 02 In

Min 11 coRPoRAT,oN

9200 Sorensen. Santa Fe Springs CA 90670-2645 (213) 946-6561 • Telex 69-8378 • Fax 213-946-2265

DEUTZ DIESEL ENGINE

115 118 121

VENDOR -02- 00

1501-PA VACUUM SAFETY SWITCH KIT INSTALLATION INSTRUCTIONS 1. This switch kit was intended for use • with Beam "E" style regulators: 50-E 60-E 100A-E 202ABP-E 52-E 60-HE 120A-E 202ANL-E ZOZANP-E 2. A 10-32 thread x 1/8" hose fitting is first installed in the Carburetor, below the throttle valve. All Beam Carburetors have a 10-32 thread or an 1/8" pipe opening for this vacuum connection. a.

Check to see if a satisfactory vacuum connection is available at the base of the gasoline carburetor or in the intake manifold. If not, remove the gasoline carburetor and prepare to drill and tap it for the necessary vacuum connection in the area between the throttle valve and the manifold flange. Select an area of the carburetor where the metal is strong enough to support a 10-32 thread nipple. Be sure nipple will not interfere with throttle. Carefully drill the carburetor with a number 2.1 drill. Tap this hole using a 10-32 thread tap. Blow out any metal chips and install the 10-32 thread by 3/16 inch hose nipple.

3. Select a 1/8" female pipe opening to mount the 1501-L vacuum switch. The air cleaner elbow of the Wisconsin S-10D, S-12D and S-14D have 1/8" pipe openings. Other engines have 1/8" pipe openings in the intake manifold. a.

If an opening is not available close to the Carburetor, the 1/8" vacuum connector at the Beam regulator can be used. It is plugged in all "E" style regulators. When a satisfactory 1/8" pipe opening is selected, install the plugged 1/8" hex pipe nipple (note one end of this nipple is plugged) using a good grade of pipe seal on all thread connections. The 1/8" street tee is installed next, so the vacuum switch can be installed on the male end of the 1/8" street tee.

BEAM PROGUM MFG. ED.

Install the vacuum switch and the 1/8" hose x 1/8" pipe hose fitting.

4. Install the 1/8" vacuum hose between the connection at the carburetor and the connection at the 1501-L switch. Cut the 1/8" hose to correct length for a proper fit. 5. Review the wiring instructions on the backside of Form F-397 or 78-006. Install one circuit at a time. 6. The switch is now ready to operate. When the starter is engaged, the starter circuit will open the fuel solenoid to supply starting fuel requirements. 7. Beam idle fuel mixture adjustments are preset at the factory to allow the engine to start. If more fuel is required, screw the mixture adjustment in about 1/4 turn at a time until the correct amount of fuel is being released. 8. When the engine starts, allow a few minutes to warm up before adjusting the main power adjustment at the Carburetor or Carburetor Adapter.

Power adjustment is in for lean and out for rich.

When the engine has warmed up, load the engine and adjust the power screw for correct setting.

When the power adjustment has been set and the lock nut is tightened, slow the engine to an idle speed and adjust the idle mixture at the regulator for a smooth idle. a.

The idle mixture adjustment is the opposite of the power adjustment. Idle mixture is out for lean and in for rich.

Turn the idle mixture screw a small amount at a time. After each turn, speed up the engine and return to idle until you have a smooth idle. This will give you a correct starting mixture. Printed in U.S.A. May 1979, Form H-8932D

FUEL MIXTURE ADJUSTMENTS WITH BEAM

1. The idle fuel mixture is adjusted at the Regulator. Z. Power adjustment is made at the carburetor or carburetor adapter. 3. The dry-gas hose between regulator and carburetor provides the starting, idling and main fuel supply. 4.

Most Beam regulators will start with an open or closed throttle. An exception, especially when starting a cold engine, are regulators having Beam's vacuum-lock system. These require a closed throttle position, or a pumping action that allows the throttle to close for a moment while the starter is turning the engine.

5. The idle mixture adjustment screw (at the regulator) is preset at the factory to allow the engine to start. If more or less fuel is required, move the screw about 1/4 turn at a time until the correct amount of fuel is being released.

After the engine starts, allow a few minutes for it to warm up before adjusting the power screw at the carburetor or carburetor adapter.

The power mixture adjustment screw is set in for lean and out for rich.

After the engine has reached operating temperature, place it under load and adjust the power screw for correct setting.

7. When the power adjustment has been set and locknut tightened, adjust the idle fuel mixture and idle speed as required.

Form

The idle mixture adjustment screw is set out for lean and in for rich.

Idle speed and/or emission standards should comply with engine manufacturers' specifications and local emission standards.

Turn idle mixture screw a little at a time. After each turn, speed up engine and return to idle until you obtain the results required. This setting will also furnish the correct starting fuel mixture.

T4-147A Paco.

PROPER INSTALLATION OF CARBURETOR THROTTLE LINKAGE

A common complaint on governor control override systems is short life of carburetor throttle shaft and throttle levers. This is not necessarily the fault of the equipment. It is in a great part due to improper installation of throttle and governor control rods.

PROCEED AS SHOWN BELOW. EACH POINT IS IMPORTANT.

1. Prior to removal of the gasoline carburetor, study and note connections to the throttle and governor levers. Remember which is the throttle and which is the governor, where the throttle stops are, what angles the levers move through, etc._ This will greatly simplify connection of the LP-gas carburetor. 2. Remove the control lever connections; then the gasoline carburetor. 3. Install the LP-gas carburetor and prepare to connect the governor and throttle control rods. 4. Be sure you know which is the throttle rod and which is the governor rod. 5. Control rods must be free from binding in all directions and must not be in a sidewise bind (coming in from an angle). 6. Manually, move the carburetor throttle lever from closed to full open position. Set the carburetor levers so that the various control rods cross the levers at close to 90° at the half open position. This will permit the levers to travel approximately 40° past center to

idle or 40° past center to wide open position. This relieves most of the strain on the various pivot points. 7. Connect control rods to the carburetor. You should then be able to easily open the throttle by hand which would indicate no bind or twist in the rods. 8. The foot throttle must be set to stop on the floor board and not use the carburetor as the throttle stop. This will greatly reduce throttle shaft torque and breakage. However, be sure that the carburetor butterfly opens completely. 9. Check for possible excessive tension of the throttle return spring. Many pull much too

heavily. In many instances, we have reduced this return spring tension as much as 30% after first carefully aligning the throttle control mechanism. The main purpose of the throttle control spring is to return the throttle to an idle position, not an attempt to pull the carburetor off the intake manzlold. Reducing tension of this spring so that it still returns the carburetor to idle (but no more) will relieve excessive shaft wear, carburetor linkage wear and also makes the vehicle easier to operate.

REAM PRODUCTS MFG. CD.

November 1980, Form H-347A

PRIMARY PRESSURE TEST

MODEL 50 DRY-GAS REGULATOR, CROSS SECTION, PARTS LIST

Nil so - ggt.11

E0DI

occonzil REGULATOR OPERATION

Order by Part No., NOT by Reference No. Ref. No. No. Req. • 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 NS

1 1 1 1 1 1 1 1 1 2 1 1 10 1 1 1 1 1 4 1 1 1 1 1 1 1 2 1 1 1

Part No.

Description i

3152 x 1 • 50-1 *; ZG-150 *4 60-10 A, • 60-7 4 60-8 • 60-9 4 60-4 • -A 60-2A • .,4 103205-F • 60-5 4 60-3 • * •' 6 103208-FS • 60-29 4 60-154 • *# 4 60-14 • *4 60-22 A • 60-23 103206-P • * ; 60-16 A 60-17 • 4 60-18 • *,Z 60-19A • 60-28 • # 400-21 • PS-20A • 4 103205-P • #4

•

60-RBK 60-RCK • 60-RK

, Plug-1/8" pipe, hex head Casting—regulator body Gasket—diaphragm Diaphragm--primary Cover—primary Spring—primary pressure Retainer—spring Spring—primary lever Lever—primary, with valve Screw—machine Bridge--primary lever Pin—primary pivot Sc rew —machine/ lockwasher Orifice—primary regulator Diaphragm—vacuum-lock Spring —vacuum-lock Diaphragm—secondary Cover—secondary regulator Screw—machine Ring—vacuum-lock cover Spring—secondary lever Pin—secondary pivot Lever--secondary, with valve Orifice—secondary regulator Spring---idle adjustment Screw—idle adjustment Screw—machine (not shown) Kit—Rebuilding (marked .fr) Kit—Complete (marked • ) Kit—Repair (parts marked *)

(6) 4 screws only in Repair Kit. (#) Secondary pivot screws.

Form B-350, page 2

LP-gas Vapor enters at point (A), then passes into primary area (C) at point (28), where pressure is reduced from up to 250 p.s.i. at the tank to 4 p.s.i. in area (C). Fuel pressure against diaphragm (4) overcomes spring (6) and as movement increases, spring (8) will close lever (9). The primary diaphragm breather (not shown in drawing), is vented to secondary chamber so that rupture of this diaphragm would direct fuel into the carburetor. Fuel now moves through passage (E), past secondary valve (29) into secondary area (F). As negative pressure (vacuum) is created at carburetor venturi and is transmitted through dry-gas hose to chamber (F), atmospheric pressure, exerted through vent hole (G), forces down secondary diaphragm (17), secondary lever (23) and spring (21). Fuel will flow in proportion to air velocity through carburetor venturi, insuring an ideal mixture at all engine speeds. Whenever engine is operating, vacuum diaphragm (15) is down against floor (H) and spring (16) is collapsed. The idle and starting adjustment is made with tapered screw (26) which regulates the whisker wire system (not shown), opening up secondary orifice slightly (but only when vacuum diaphragm is drawn down). Very little vacuum is needed to start this vacuum diaphragm travel; 0.2" Mercury to start and 0.5" Mercury for full travel. The instant engine stops rotating, loss of vacuum in section (J) releases diaphragm (15), causing bumper (K) to push against secondary lever (23), overcoming action of whisker wire and insuring 100% lockoff. This patented Beam design will lock off primary pressures up to five times in excess of normal, permits starting without priming or choking, and does not require a fuel shutoff valve for positive fuel lockoff.

BEAM MODEL 50

* DRY-GAS REGULATOR LP-GAS VAPOR WITHDRAWAL AT TANK PRESSURE Contains both primary and secondary chambers. Unit available in several variations as shown below. A Fuel Filter Recommended. U.L. Listed All parts except main body casting are interchangeable with the Model 60 Vaporizer Regulator. Optional Back Cover with Primer is part number 60-23A

* SPECIFY MODEL NO. DESIRED

For factory and field conversions to LP-Gas using vapor withdrawal to units capacity: Approximately 125 cu. in. engine (or equivalent of a 28 venturi)

SPECIFICATIONS Capacity Up to 40 h.p. Up to 28 venturi Type

Vapor Withdrawal

Mounting Position Vertical Fuel Lockoff

INDUSTRIAL TRUCKS — FARM TRACTORS SMALL INDUSTRIAL ENGINES Operating Pumps, Generators, Cranes, Mixers, etc. Built-in vacuum controlled lockoff. 100% shutoff when engine stops. No separate idle line. Manual primer on back cover is optional. Finished in Golden Beamalite. Pat. No. 2,775,981. Others pending.

MODEL*

1/8" diameter

Primary Pressure 4 p.s.i.g. Secondary Orifice ... 3/16" diameter Fuel Inlet

1/4" pipe

Fuel Outlet

3/8" pipe

Vacuum Connection 1/8" pipe Dimensions .... 4" O.D. x 3" thick Weight

DESCRIPTION SHOWING VARIATIONS AVAILABLE

Standard Dry-gas Regulator. With idle. No primer.

50-A

Dry-gas Regulator. Less idle screw. Add primer.

50-B

Dry-gas Regulator. Manual primer on back cover.

50-C

Dry-gas Regulator.

50-D

Dry-gas Regulator. Less idle. Less vacuum-lockoff.

50-E

Dry-gas Regulator. Less vacuum-lockoff assembly.

BERM PRODUCTS MFG. CO. otOtTlro

Primary Orifice

Built-in

22 ounces

LIST

Less idle, less vacu-lock. Add primer.

Form B-350

MICROVAC MODEL 1501-L VACUUM SAFETY SWITCH

Ref. No.

No. Req.

103208-FS 1501-6 1501-24 1501-25

2 3 3

063207-B • 044003-RB W04-T

8A 8B 9 10 NS NS NS

MAGNETO IGNITION

Description of Part

6 2 3 4 5 6 7

Part Number

BEAN otato

CIUMPOSTIOU EQUIPMENT

1501-26 Kit---switch replacement 1501-27 Kit---adapter

Screw--- machine w/lockwasher Diaphragm-- Microvac Shim-- microswitch Adapter--- terminal Screw--Screw--Washer---

machine 6-32 x 7/15' machine 4-40 x 3/16' external star #4

1501-28A 1501-5 1501-23 1501-21

Microswitch---(includes spring 1501-5) Spring--- matched to microswitch Cover--- front Cover--- back

103210-FS 2E-101 1C-Z10

Screw--Terminal-Clamp--

machine solderless neoprene

2 3 3

3 3

0 STARTER SWITCH

BATTERY IGNITION

ELECTRICAL CONNECTIONS 1. Install Microvac at any convenient source of manifold vacuum, away from the heat of the exhaust system. 2. Use 16-gauge primary automotive wire. Insulated terminals are provided. To avoid mistakes, connect one circuit at a time as follows: 3. Connect "SOL" (Solenoid) terminal of Microvac to electric solenoid valve or Filterlock. 4. Connect "IGN" (Ignition) terminal of Microvac to coil side terminal of ignition switch. If there is no bypass resistor in the ignition circuit, this wire may be connected to the battery terminal of the ignition coil. For use as a 2-wire switch, simply do not connect the center terminal; use the two outside terminals only. Proceed to step 6. For use as a 3-wire switch, proceed with steps 5 and 6.

Form

F-397, Page 2

13 " 16

SCREW NOT SHOWN

0 0

5" 2 16

0 5. Connect center 'STR" (Starter) terminal of Microvac to terminal on starter switch which goes to starter. Engaging starter will complete circuit to solenoid valve only while the starter is energized. 6. Secure all the electrical wires to the Microvac. After installation, remove one screw at the most convenient location, replace it with the longer screw and clamp provided. Run all wires through the clamp and tighten. This will avoid vibration at the terminals and extend their life.

STARTING THE ENGINE 2-wire Installation: Start engine on a closed throttle or use a pumping action to allow the throttle to close momentarily to build up manifold vacuum to close the normally open circuit ("IGN" to "SOL"). Solenoid valve will remain open as long as manifold vacuum is present. 3-wire Installation: Normally, the engine will start at any throttle position. The normally closed circuit (step 5, "STR" to "SOL") will automatically open to avoid current feedback after the engine starts.

BEAM MICROVAC MODEL 15014 VACUUM SAFETY SWITCH 6 OR 12 VOLT D.C.

• Total Weight 5-Ounces. • Housing is Die Cast Aluminium. • Furnished with Terminals and Electrical Harness Clamp, as Pictured. • Enclosed Points: Positive Snap Action; No Arcing. • Instant Closing of Precision Points at Starting Vacuum. • Vacuum Connection is On Side Opposite Terminals for Accessibility to Wiring. • Set to Close Between 2-Inches and 2 1/2 Inches of Water, Vacuum. • Large Diaphragm: Switch Stays Closed Whenever Engine is Running; Remains Closed Down to Ph Inches Water Column. SPECIFICATIONS Working Pressure: Maximum 30-Inches Mercury, Vacuum Electrical Rating: 6-Volt D.C. 4-Amperes 12-Volt D.C. 2-Amperes Vacuum Connection: Ye Inch Female Pipe Features a subminiature microswitch. A switch of this type is required on most fork lift installations as a safety measure to open the solenoid valve circuit and prevent fuel flow should the engine stop (even with ignition switch still on.) Switch will remain closed on small one or two-cylinder engines.

Microvac has an insulated terminal block with three screw type terminals, well marked so that one model can be used as either a two-wire or three-wire switch. The sturdy terminal block (1501-25) fits securely over the 3-spade terminals and can be installed on the earlier 1501-K3 switches in the field; order kit 1501-27.

Installation: Since the Microvac is generally used with

Repairs: Two holes in the body are offset so that the diaphragm cannot be installed upside down. Note the small register line on each casting and the corresponding tip on the diaphragm. All three marks must line up when the switch is assembled.

Beam regulator models 120A, 100A, 60 or 50, the same vacuum line which operates the vacuum-lock in the regulator can also accommodate the switch. Use a street tee at the regulator and make a single vacuum connection. The Microvac is a precision unit and will not stand heavy surges of current which bypass the solenoid valve circuit.

Springs and switches are matched; keep them together. To insure the vacuum spring being inserted on the correct side of the diaphragm, casting is marked in the spring depression area. Be sure that the microswitch is installed with red operator button in the center so that it will properly contact the rivet in the

See Form F-145 for use with 450B Regulator

diaphragm.

Never short the Microvac terminals to ground.

BEAM PRODUCTS MFG. CO .

March 1980, Form F-39:

FILTERLOCK MODEL FL-418 REPLACEMENT PARTS

SHOWN FULL SIZE

Do not tighten male outlet from this end of unit

17 19 20

To install or remove a fitting from this end, place a one inch wrench on this filter inlet

■

Maximum torque this end 35 ft. lbs.

mmati

Use a 3/4 inch wrench on this hex brass outlet to install or remove Filterlock from regulator

„

lojrimeam

Brass body at 0-ring ® will not stand over 18 ft. lbs. of torque

e to 4f4mmieni.nwei Aftemonsiannt MOW

6 7

I I 12 13 14 15 16

Part of Coil Operation Liquid LP-gas enters as indicated by arrow,

passes through the center bolt (1) and exits at cross-drilled hole (A). It is not permitted to pass between the bolt and retainer cup (3), therefore it must pass around to the outside of filter element (5). Dirt particles are dropped out in section (B). Fuel then passes through chamber (C)

to cross-drilled hole (D), down through center (E) of center plate (8), on through spring (12) and plunger (14), out through cross-drilled hole (F). Fuel then passes around the outside of the smaller outlet end of plunger (14). When the valve is in the open position (shown closed) fuel passes on through the center outlet orifice (G) and into the fuel system.

* * * * * * * * * * Part No.

Ref. N*. ! r . No. ;Req. 1 ' 1 ' 1 2 1 3 1 1 4 1 1 ! 5 1 6 7 1 8 1 -9,- 1 10 1

FL-4734 ' Bolt—filter inlet /- 4S-108 * Seal—"0" ring (inlet) FL-4703 Cup—filter retainer FL-4704 Spring—filter retainer FL-4735 * Filter—Microbon

11 I 1

Description of Part

FL-4706 Bowl—filter FL-4737B* Casket—filter bowl FL-4708 Plate—filterlock center FL 4707 Gasket—coil (between plate) Seal—"O" ring (body to plate) 4S-107 Coil— 6 volt Coil-12 volt Coil-24 volt Coil-32 volt Spring —plunger return Housing—coil

12 1 13 i 1

4 3B-620A 6 3B-623A o 3B-62.5A 4 3B-627 # L-4210 FL-4736

14 1 15 1 16 1 . 17 1

Plunger—valve, with spring # L-4212 FL-47 13 Plate—outlet end FL-4714 Body—valve A FL-47 15 * Seal—filter element (top)

18 19

Washer—marcel # 3W-101 4 2E-101 Terminal--solderless 063202-P Screw—machine 4 FL-4740 Grommet

■

2 1

20 i 1 21 2 1 Kits:

/- FL-4747 Kit—filter gasket FL-4748 *1 Kit—element and gasket # FL-4732. Kit—valve plunger # FL-4749 Kit—Filterlock repair

gi Coils furnished with terminal and grommet. # Plunger includes return spring part L-4210. Part No. FL-4750 is a new Rebuilding Kit. Includes ref. nos. 2, 5, 7, 10, 14, 17 and 18.

FORM D•2600-2

GENERAL SERVICING Filterlock may be completely disassembled without use of special tools. Either filter or solenoid section may be disassembled separately by the clamping of hex center plate (8) in a vise. Do not pinch it too tightly. CLEANING CR REPLACING FILTER ELEMENT FL-4735 Hold hex center plate (8) in a vise and unscrew fuel inlet bolt (1). The spring (4) holds retainer cup (3) down against filter element (5). Seals are provided at (7) and (17). Remove any deposits from section (B) and blow out filter element from the inside. Gaskets (7) and (17) and "0" ring seal (2) should be replaced and are included in Kit No. FL-4747. FILTER SECTION GASKET KIT Kit No. FL-4747 includes gaskets and seals which should be replaced when cleaning the filter section. Parts include reference numbers (2), (7) and (17). FILTER SECTION REPLACEMENT KIT The filter element (5) must be ordered separately, Part No. FL-4735. Kit No. FL-4748 includes the Microbon element, gaskets and seals. SOLENOID SECTION REPAIR To disassemble, hold center plate (8) in a vise and unscrew the 3/4" hex brass valve body (16). When loose, the entire solenoid section may be removed. New coils (11) are furnished with grommets and ground wire terminal. The valve plunger (14) is easily replaced if the neoprene valve seat becomes damaged or indented. When reassembling, be sure to replace the small spring (12). The marcel washers (18) allow for machine tolerances and insure tightness between valve body and center plate and also prevent a loose coil housing. SOLENOID SECTION REPAIR KIT Repair parts for the solenoid section include reference numbers (12), (14) and (18), in Kit No. FL-4732. The solenoid coil, if burned out or damaged, must be ordered separately. See parts list for voltage that is desired. Coil is assembled with ground wire terminal (19) and two grommets (21). FILTERLOCK REPAIR KIT Kit No. FL-4749 includes parts in both filter section gasket kit and the solenoid section repair kit. The filter element (5) and coil (11) must be ordered separately.

BEAN me EL FL-4111 . 4aP Ser/OCk A REAL TIME SAVER SPACE SAVER

FEATURES

MONEY SAVER

Two "0" Ring Seals

PAT. NO. 3.004.670

All Units pressure tested Filter or Solenoid may be

SHOWN ACTUAL SIZE

Disassembled Separately Heavy Duty Coil, grounded externally Impregnated Phenolic Element Traps Particles as small as .001

a compact, efficient combination of

LP-GAS FILTER and SOLENOID VALVE ADDITIONALDATA DATA J

SPECIFICATIONS

Use with every LP-Gas Carburetor Installation

if Operates in any position

•

20% Weight Saving over Separate Filter and Solenoid Straight Through Design

Port Size 1/8" Diameter

•

Hycar Vulcanized Seat

Requires Only Two Connections

Eliminates Need of Extra Fittings and Connectors

Weight 22 oz. 1/4 " Female Pipe Inlet 1/4

" Male Pipe Outlet

Available 6, 12 or 24 Volt

Parts are of Brass, Stainless Steel, Copper and Cadmium Plated Steel

BEAM PRODUCTS MFG. (0.

Jan. 1982, FORM D-260D

VENDOR SECTION

Limited Engine Warranty TELEDYNE WISCONSIN MOTOR, herein referred to as ' Teledyne Wisconsin ', warrants each new Wisconsin 4-cycle air-cooled engine sold by Teledyne Total Power to be free from defects in material and workmanship, under normal Use and service, for a period of one (1) year (except in the case of an engine used on any recreational type vehicle the period shall be ninety (90) days) after the date of delivery to the original retail purchaser, and Teledyne Wisconsin will, at its option, replace or repair, at one of Teledyne Wisconsin's factories, or at a point designated by Teledyne Wisconsin, any part or parts which shall appear to the satisfaction of Teledyne Wisconsin upon inspection at such point, to have been defective in material or workmanship. This warranty does not obligate Teledyne Wisconsin to bear any transportation charges in connection with the replacement or repair of defective parts. This Warranty shall not apply to any engine which shall have been installed or used in a manner not recommended by Teledyne Wisconsin, nor to any engine which shall have been repaired, altered, used in any type of competition, nor operated other than within Teledyne Wisconsin Motor specified limits, neglected or used in any way which, in Teledyne Wisconsin's opinion, adversely affects its performance: nor to any engine in which parts not approved by Teledyne Wisconsin have been used: nor to any accessories installed on the engine where the accessory manufacturer has its own warranty: nor to normal maintenance services or replacement of normal service items. Teledyne Wisconsin reserves the right to modify, alter, and improve any engine or parts without incurring any obligation to replace any engine or parts previously sold with such modified, altered, or improved engine or parts. THIS WARRANTY, AND TELEDYNE WISCONSIN'S OBLIGATION HEREUNDER, IS IN LI EU OF ALL OTHER WARRANTIES, EXPRESS, IMPLIED, OR STATUTORY, INCLUDING ANY WARRANTIES OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE, AND ALL OTHER OBLIGATIONS OR LIABILITIES, INCLUDING SPECIAL OR CONSEQUENTIAL DAMAGES OR CONTINGENT LIABILITIES ARISING OUT OF THE FAILURE OF ANY ENGINE OR PART TO OPERATE PROPERLY. No person is authorized to give any other warranty or to assume any additional obligation on Teledyne Wisconsin's behalf unless made in writing and signed by an officer of Teledyne Wisconsin.

leTELEDYNE WISCONSIN MOTOR

cut along dotted line

return to TELEDYNE TOTAL POWER 3409 DEMOCRAT ROAD MEMPHIS, TENNESSEE 38118

Individual INSTRUCTION and SERVICE PARTS MANUAL available from all Wisconsin Distributors,

Dear Customer: If you would like to receive a free copy of a list of Authorized Teledyne Wisconsin Motor DISTRIBUTORS and SERVICE CENTERS in your area, please complete the following;

NAME STREET STATE ZIP

CITY ENGINE MODEL

LEI

FIGURE 01

!WA 2ORPORAT , ON

9200 Sorensen. Santa Fe Springs. CA 90670-2645 12131946-6561 • Telex 69-8378 • Fax 213-946-2265

SERIAL NO

WISCONSIN GASOLINE ENGINE

VENDOR - 01-10

C/IL.11V/111P

VENDOR SECTION

TROUBLE SHOOTING

continues to drip from carburetor with engine standing idle.

The three prime requisites essential to starting and maintaining satisfactory operation of internal combustion engines are:

COMPRESSION

Poor compression. See 'Compression'. Sticky valves.

Damaged cylinder head gasket or loose cylinder head. This will likewise cause hissing noise on compression stroke.

If all three of these conditions do not exist the engine cannot be started. As a guide to locating some of the difficulties in starting, causes are listed under the three main headings of: Fuel Mixture, Compression, and Ignition. No fuel in tank or fuel valve closed. Plugged vent hole in fuel tank cap. Fuel line clogged. Fuel pump diaphragm worn or punctured. Anti-diesel solenoid valve at carburetor inoperative (model V465D). Check for disconnected, loose or broken wire. Carburetor not choked sufficiently, especially if engine is cold. Water, dirt, or gum in gasoline interfering with free flow of fuel to carburetor. Poor grade, stale or out-of-season gasoline. Carburetor flooded, caused by too much choking especially if engine is hot. Carburetor float needle valve stuck open. This condition would be indicated if fuel

Spark plug gap incorrect. Worn, leaking or loose ignition cables. Weak spark. See 'Ignition' test for spark. Breaker points pitted or worn. Water in gasoline.

Cylinders dry due to engine having been out of use. Pour one fluid ounce of crankcase oil through spark plug holes. Loose or broken spark plug. A hissing noise will be heard in cranking due to escaping gas mixture on compression stroke.

1. A proper fuel mixture in the cylinder. 2. Good compression in the cylinder. 3. Good spark, properly timed, to ignite the mixture.

FU EL MI XTUR E

ENGINE MISSES

ENGINE STOPS

Valve stuck open.Piston rings stuck or worn. Valves adjusted with insufficient clearance.

Fuel tank empty. Water, dirt or gum in gasoline. Gasoline vaporized in fuel lines, due to excessive heat around engine (Vapor Lock). See 'Stopping Engine'. Vapor lock in fuel lines due to using winter gas (too volatile) in hot weather. Air vent hole in fuel tank cap plugged. Ignition troubles. See 'Ignition'.

IGNITION Test for spark by removing spark plugs and observe spark at plug gap while turning engine over, No spark or weak spark may be attributed to the following: Ignition wires loose or disconnected at magneto, spark plug, distributor or coil. Broken or frayed ignition wires. Spark plug insulator broken. Spark plugs wet or dirty. Spark plug gap incorrect. Condensation on spark plug electrodes.

OVERHEATING Crankcase oil supply low.

Breaker point gap incorrect. Breaker points pitted or fused. Breaker arm sticking. Condenser leaking or grounded.

Ignition timing wrong. Low grade of gasoline. Engine overloaded. Restricted cooling air circulation. Part of air shroud removed from engine. Dirt between cooling fins.

Spark timing wrong. Weak battery. Faulty ignition coil.

Intake or rotating screen clogged with dirt. Restricted exhaust.

ENGINE MAINTENANCE SCHEDULE

Page Weekly Seasonally Ref. Daily or 50 hrs. 100 hrs. 250 hrs. or 500 hrs.

CHECK OIL LEVEL. Add to full mark - Do not overfill.

•

CHECK AIR CLEANER. Shake out accumulated dirt from

•

CLEAN AIR INTAKE SCREEN. Clean cooling fins if necessary.

•

GREASE CLUTCH THROWOUT BEARING (VG4D, V465D).

•

dry element cleaner - Maintain oil level in oil bath type cleaner.

CHANGE CRANKCASE OIL.

•

CLEAN AIR FILTER ELEMENT. DRY Element and OIL Both types.

•

CLEAN CRANKCASE BREATHER CAP.

•

GREASE CLUTCH HOUSING BEARING (VG4D, V465D).

•

REPLACE OIL FILTER. In adverse conditions replace every oil change.

LUBRICATE DISTRIBUTOR SHAFT.

•

CHECK COMPRESSION. Pressure should not vary more than 10 p.s.i. between

—

•

INSPECT SPARK PLUGS and BREAKER POINTS. Replace if necessary and regap to specification.

•

INSPECT FUEL FILTER. Clean filter screen and glass bowl.

•

LUBRICATE DISTRIBUTOR CAM and breaker arm pivot.

•

INSPECT COOLING SYSTEM. Remove shrouding and scrape off dirt from between fins, around cylinders and from shrouding.

•

INSPECT STARTING MOTOR. Check for loose mounting and cable connections.

•

CHANGE OIL IN CLUTCH and REDUCTION GEAR HOUSINGS.

cylinders. Remove head - clean out carbon deposits. Reseat valves if necessary.

•

FIGURE 01 WISCONSIN GASOLINE ENGINE

11 L. 11W/1114 :oRPoRA-,oN

9200 Sorensen. Santa Fe Springs. CA 90670.2645 (213) 946-6561 • Telex 69-8378 • Fax 213-946-2265

VENDOR - 01

crie...nvrira

VENDOR SECTION

SHIFTER LEVER

ADJUSTING,: LOCK PIN •

PRECAUTIONS to be exercised in the use of this flywheel alternator: 1. Do not reverse battery connections. This is a negative ground system only. 2. Connect booster batteries — positive to positive and negative to negative. 3. Do not polarize the alternator. 4. Do not ground any wires from stator or modules which terminate at connectors. 5. Do not operate engine with battery disconnected from system.

6. Disconnect at least one battery lead if a battery charger is used.

GENERATOR — WIRING CIRCUIT, Fig. 24 The model V465D engine is equipped with a 12 volt-17 amp generator in a negative ground electrical system. Do not reverse polarity-damage to both generator and regulator will occur. Engine will not operate with carburetor antidiesel solenoid wire disconnected. REGULATOR MODULE

RECT IFIER M DULE

Fig. 21, VG4D, V465D TWIN DISC CLUTCH ADJUSTMENT as shown, or wedge a screw driver into the adjusting yoke and against the side of the inspection hole openings to keep the yoke from turning, then turn the take-off shaft counter-clockwise to adjust yoke enough so that the shifter lever requires a distinct pressure to engage. Remove wire from lockpin and turn adjusting yoke slightly, to allow lockpin to snap into hole in floating plate. A new clutch generally requires several adjustments until the friction surfaces are worn in. Do Not let a new clutch slip, this will ruin the friction surfaces.

)3-:1-1% STATOR

12 VOLT BATTERY

IGNITION SWITCH

AMMETER

Make Connections for Lights, etc., at Charge Side of Ammeter. AUTOMATIC CHOKE (optional)

----- Connect Equipment Solenoids Here

SPARK PLUGS 4 2

START SWITCH (optional)

FLYWHEEL ALTERNATOR Fig. 22 and Fig. 23 12 Volt - 10 Amp or 25 AmpFlywheel Alternator, consisting of a flywheel with Magnetic Rotor, Stator and Rectifier- Regulator modules, is optional equipment on models VH4D and VG4D-furnished when battery ignition is required. There are no brushes, commutator or belts to contend with and no adjustments are necessary. Since the physical appearance of both 10 amp and 25 amp alternator systems are very similar, they can be distinguished from each other by the ammeter calibrations; 0 to 15 amps for the 10 amp circuit and 0 to 30 amps for the 25 amp circuit.

SOLENOID SWITCH (optional) DISTRIBUTOR DRIVE IGNITION COIL

HI-TEMP SWITCH (optional)

STARTING MOTOR

Fig. 23, WIRING DIAGRAM,Flywheel Alternator and Battery Ignition, Models VH4D, VG4D BATTERY

STARTING SOLENOID

*t.

Of S C. 44 E

STARTING MOTOR

RECTIFIER MODULE

02,

SPARK PLUGS

STATOR

IGNITION-STARTING SWITCH Rotation CARBURETOR HI-TEMPERATURE SAFETY SWITCH

MAGNETIC ROTOR

ANTI-DIESEL SOLENOID

10 AMP - 16 GA. RED WIRE 25 AMP - 14 GA. GREEN WIRE

DISTRIBUTOR AND ACCESSORY DRIVE

'PRESTOLITE' REGULATOR GENERATOR

CONNECT TO CHARGE SIDE OF AMMETER

Fig. 24, WIRING DIAGRAM,Generator and Battery Ignition, Model V465D

Fig. 22, FLYWHEEL ALTERNATOR

FIGURE 01 10/11...11W/1

OP POP A nON

9200 Sorensen. Santa Fe Springs. CA 90670-2645 1213) 946.6561 • Telex 69-8378 • Fax 213-946-2265

WISCONSIN GASOLINE ENGINE

VENDOR - 01

IOW

C /i11-111-AIR

gauge as shown. By means of a 1/2 inch tappet wrench, turn the ackusting screw clockwise to decrease valve clearance and counter-clockwise to increase the clearance. The sequence in which the tappets are adjusted is determined by the 1-3-4-2 firing order. Start by adjusting No. 1 inlet valve clearance first, then by just a short turn of the crank, No. 3 inlet can be adjusted. Return to No. 1 cylinder and adjust the exhaust clearance, then adjust the No. 3 exhaust. The same procedure applies to the No. 2 and No. 4 bank of cylinders, starting with No. 4 inlet valve. Mark each rocker arm with chalk as adjustment is completed, to prevent repetition.

TIMING

VENDOR SECTION screw driver. Connect the other two wires of the timing light; one to the positive side of the battery, the other to ground. Chalk or paint the end of the 'X' marked vane of the flywheel, white. Then, with the engine operating at 2000 r.p.m. or over, allow the flash from the timing light to illuminate the white vane. At the time of the flash the leading edge of the vane should line up with the running spark advance timing hole in the front face of the flywheel shroud. Note: Timing can be checked without removing flywheel shroud screen (Fig. 17 shows screen removed), by illuminating leading edge of white vane with timing light thru the 3/8" diameter hole in rim face of flywheel screen.

SHIFTER LEVER (Released Position) ADJUSTING PLUG ADJUSTING LOCK

ADJUSTMENT LOCKSCREW

NOTCHES ON ADJUSTING RING

Timing Adjustment for either battery or magneto ignition: Refer to the INSTRUCTION and PARTS MANUAL of the specific engine model for adjustment procedure.

FIRING ORDER The firing order of the cylinders is 1-3.4-2, and the magneto or distributor rotor turns at one-half engine speed, as is the case with conventional 'In Line' engines. The intervals between the firing of the cylinders is 180°. No. 1 cylinder is the one nearest to the flywheel in the left bank of cylinders, when viewed from the flywheel end of the engine. No. 3 cylinder is the other cylinder in this bank. No. 2 cylinder is the one nearest to the flywheel in the right bank of cylinders and No. 4 is the other cylinder in this bank. The cylinders are numbered on the head covers. Note: When disconnecting ignition wires, mark cap, and tag wires for correct re-assembly. TIMING CHECK, Fig. 17 The running spark advance for both magneto and battery ignition, is 23°, and timing must be checked with the engine running at 2000 R.P.M. or over.

CLUTCH ADJUSTMENT If the clutch begins to slip, it should be readjusted to prevent it from becoming overheated and damaged. First, remove inspection plate to expose the adjusting ring. Release clutch by pushing shifter lever forward (toward engine). VH4D Clutch, Fig. 18

VH4D CLUTCH REDUCTION, Fig. 19 The clutch in the clutch reduction unit is the same as used in the power take-off unit and is adjusted thru two pipe tap openings; one for the adjustment lockscrew and the other for turning the adjusting ring. If one of the taps is inaccessible, adjustment can be made thru just one opening by rotating clutch slightly after adjustment lockscrew

CTRLINE of #1 and 3 CYL. BANKS WHITE VANE #1 TERM. TOWER

ADJUSTMENT SHIFTER LEVER LOCKSCREW (released position)

etd

Fig. 19, VH4D CLUTCH REDUCTION ADJUSTMENT is loosened. Follow adjustment procedures as outlined in preceding paragraph. VG4D, V465D CLUTCH ADJUSTMENT

Turn engine over by means of the starting crank until clutch adjustment lock is visible thru the inspection opening. Loosen adjustment lockscrew one full turn. Keep clutch from turning by securing the crank_ shaft at cranking end. Then, by means of a screw driver, turn adjusting ring one notch at a time in a clockwise direction, until a very firm pressure is required when engaging the clutch shifter lever, and as the clutch snaps into engaged position. Securely tighten adjustment lockscrew.

Insert a small screw driver into the No. 1 terminal tower on the distributor cap, making contact with the ignition wire terminal. Connect the red terminal clip, from an automotive Timing Light to the metal part of the

Rockford Clutch Fig. 20: After removing the inspection cover and disengaging clutch with the shifter lever, turn engine over by means of the hand crank, until the clutch adjustment lock is visible thru the in spection opening in the clutch housing. Pre vent take-off shaft from turning by means of a drift punch wedged in place as shown. Then, loosen the lockscrew holding the adjustment lock in place. Insert a screwdriver in one of the notches and turn the adjusting ring, in a counter-clockwise direction, one notch at a time, until a very firm pressure is required to engage the clutch with the shifter lever. Tighten adjusting lockscrew and mount inspection cover. TWIN DISC CLUTCH, Fig. 21: Pull adjusting lockpin out and insert a piece of 1/16" diameter wire into the hole on the side of the lockpin to keep pin in outer position. Turn the adjusting yoke in a clockwise direction SHIFTER LEVER ADJUSTMENT LOCK

(.4

ADJUSTMENT LOCK

RUNNING SPARK RED to..---fr ADVANCE TIMING DISTRIBUTOR HOLE IN SHROUD to BATTERY to GROUND

ADJUSTING RING (turn clockwise) Fig. 18, VH4D CLUTCH ADJUSTMENT

Fig. 17

FIGURE 01 ORPOR TION

9200 Sorensen. Santa Fe Springs. CA 90670-2645 (213) 946-6561 • Teiex 69-8378 • Fax 213-946-2265

DRIFT ADJUSTING RING PUNCH (turn counter-clockwise) Fig. 20, VG4D, V465D ROCKFORD CLUTCH ADJUSTMENT

WISCONSIN GASOLINE ENGINE

VENDOR - 01 07

CAL.rW/in IM

CR'

VENDOR SECTION utor breaker arm RUBBING BLOCK is on a high point of the CAM. Loosen the stationary contact LOCKSCREW slightly and insert a feeler gauge between the points. By means of a screw driver, turn ADJUSTING SCREW until correct gap is obtained. Tighten lockscrew and recheck gap. Points that are badly pitted or worn should be replaced. VALVE TAPPET ADJUSTMENT Models VH4D, VG4D, Fig, 15 With the tappets in their lowest position (valves completely closed) and engine cold, the clearance between valve stem and tappet adjusting screw should be:

Fig. 12 A FULL-FLOW oil filter is furnished on model V465D engines as standard equipment. Since all of the circulated oil passes thru the filter, it is very important that it be serviced regularly. The oil filtering cartridge should be replaced after EVERY OTHER OIL CHANGE. If operating conditions are extremely dusty, replace cartridge after every oil change. Use only Wisconsin Micro-Fine or Full-Flo oil filter cartridges from your nearby Teledyne Wisconsin Motor Service Center.

Inlet - .008" Exhaust - .016" Fig. 13 so that no immediate adjustment is necessary. The IDLE ADJUSTMENT is for smooth low speed operation and this adjustment, if necessary, must be made with the carburetor throttle lever closed. Initial setting is approximately 11/2 turns open. MAGNETO BREAKER POINTS, Fig. 13

SPARK PLUGS, Fig. 12

At least once each season or when ignition spark becomes weak, remove magneto end cover, inspect points and check gap opening. If there is evidence of pitting or pyramiding and it becomes necessary to resurface or replace points, it will also be necessary to readjust the gap clearance. The BREAKER POINT GAP should be: .015 inch at full separation.

Incorrect gap, fouled or worn spark plug electrodes, will have an adverse affect on engine operation. Remove spark plugs periodically — clean, regap or replace if necessary. Spark plug gap - .030 inch. Use new spark plugs at the beginning of a new season. Replacement plug must be of the correct heat range, equal to:

Turn engine crankshaft over until breaker points are at their maximum opening. Loosen the two lockscrews on breaker plate just enough so that plate can be moved. Place a 0.015 inch feeler gauge between points. Insert end of small screw driver into adjusting slot at bottom of breaker plate and open or close the contacts by moving plate until a slight drag is felt when sliding the feeler gauge from between the points. Tighten lockscrews and recheck point gap. Before placing end cover on frame, clean contact surfaces, coat with gasket cement and mount new gasket. Assemble cover, rotor and end cap.

Model Thread Size Make VH4D 18mm Champion D-16J (Wisconsin YD-6) VG4D V465D 14mm Champion N-12Y Wisconsin YD-301 Torque spark plugs 25 to 30 foot pounds for Models VH4D, VG4D, and to 22 foot pounds for Model V465D. STARTING MOTOR, Fig. 1, Ref. 19 No maintenance is required other than keeping the outside of the starting motor clean, and periodic inspection for insecure mounting and loose or corroded cable connections. In extreme dust and dirt conditions it may be necessary to occasionally remove the starter from the engine and clean the Bendix by brushing with Kerosene. Do not oil Bendix.

DISTRIBUTOR (Battery Ignition), Fig. 14 The breaker point gap should be: .020 inch at full separation. To readjust point gap, turn engine over by means of the hand crank until the distrib-

The inlet valves are to the inside of the cylinder block, the exhaust valves are toward the outside. Place feeler gauge between valve stem and tappet screw, and adjust clearance by means of two 1/2 inch tappet wrenches. Model V465D, Fig. 16 The clearance between the valve and rocher arm, with the tappet in its lowest position (valve completely closed) and the engine cold. Inlet - .008" Exhaust - .014" The rocker arms can be identified as follows: When facing toward the sideof the engine, the Exhaust Rocker Arm is to the right in the cylinder head and the inlet rocker arm to the left. Measure clearance between the top of the valve and nose of rocker arm with a feeler

... .... INLET .̀.ADJUSTING •• • • ,',..1 SCREW . . . . . . . . Fig. 15, VH4D, VG4D VALVE. TAPPET ADJUSTMENT

ADJUSTMENTS CARBURETOR The carburetor MAIN METERING JET is of the fixed type and therefore no adjustment is necessary. The correct amount of throttle plate opening for the proper low idle speed is obtained by means of the THROTTLE STOP SCREW. However, this is set at the factory

Fig. 14

FIGURE 01

111-11W/1111P

ORP OR A T,ON

9200 Sorensen. Santa Fe Springs CA 90670-2645 (213) 946-6561 • Telex 69-8378 • Fax 213-946-2265

Fig. 16, V465D VALVE TAPPET ADJUSTMENT

WISCONSIN GASOLINE ENGINE

VENDOR - 01

ER'

C/IL.INVAIR

6a. Release choke button to open position after engine starts, but rechoke if it tends to stop. EVEN A HOT ENGINE REQUIRES MOMENTARY CHOKING WHEN STARTING. When engine starts release switch to 'RUN' position. If flooding should occur, continue cranking with the starting motor, but with the choke open (choke button in).

VENDOR SECTION

COLLECTOR TYPE PRE-CLEANER 401r.1.%

PRE-CLEANER The collector type pre-cleaner, mounted to the top of the air cleaner as illustrated in Fig. 9, removes the larger dirt and dust particles before the air reaches the main air cleaner. Clean bowl regularly of accumulated dust and dirt. Do not put oil or water in precleaner, this must be kept dry.

WARM-UP

BREATHER CAP, Fig. 1, Ref.3

If all conditions are right, engine will start promptly in one or two attempts. After engine starts, allow it to warm up a few minutes before applying load. Do not race or gun engine to hurry WARM-UP. The proper oil film on various surfaces of the pistons, cylinders, bearings, etc., cannot be established until the oil has warmed up and become sufficiently fluid. Break-in new engine per instructions on page 1.

The crankcase is ventilated thru a breather cap mounted of the top of the oil filler tube. At every oil change, it is recommended that the cap be cleaned by washing in kerosene.

TO STOP ENGINE

Fig. 9 OIL BATH AIR CLEANER

Magneto ignition (open engines) have a lever type ground switch on the side of the magneto. DEPRESS AND HOLD DOWN UNTIL ENGINE STOPS. See Fig. 1, Ref. 21 Power units and battery ignition, Fig. 7, are furnished with an ignition switch, "TO STOP PUSH IN".

high melting point grease to the breaker arm rubbing block.

Avoid excessive lubrication. Oil on the contact points will cause them to burn.

Model V465D; turn IGNITION-STARTING SWITCH to OFF position. See Fig. 8.

GENERATOR - Belt Driver, Fig. 1, Ref 13 Every 50 hours of operation; add 3 to 5

drops of medium engine oil into the oil cups at both ends of the generator.

If engine has been running hard and is hot, do not stop it abruptly from full load. Remove the load and allow the engine to run. idle (1000 to 1200 R.P.M.), for 3 to 5 minutes. Air circulation from the flywheel will reduce the temperature of the engine much faster and minimize valve warping.

FUEL FILTER, Fig. 11 .4-- DUST UNLOADER

MAINTENANCE

Fig. 10, DRY TYPE AIR CLEANER

AIR CLEANERS

from the engine and the element, which is not removable, should be washed in a solvent to clean out accumulated dust and dirt.

The air cleaner is an essential accessory, filtering the air entering the carburetor and preventing abrasive dirt from entering the engine and wearing out valves and piston rings in a very short time. The air cleaner must be serviced frequently, depending on the dust conditions in which the engine is operated. Check hose connections for leaks or breaks and replace all broken or damaged hose clamps. Excessive smoke or loss of power are good indications that the air cleaner requires attention. OIL BATH AIR CLEANER, Fig. 9 Service daily; or twice a day if engine is operating in very dusty conditions. Once each week; in comparatively clean conditions. Remove oil cup from bottom of air cleaner and clean thoroughly. Add the same grade of oil, as used in the engine crankcase, to the LEVEL LINE indicated on the oil cup. Operating the engine under dusty conditions without oil in the air cleaner or with dirty oil, may wear out cylinders, pistons, rings and bearings in just a few days time.

It is very important that the fuel be filtereu to prevent sediment, dirt and water from entering the carburetor and causing trouble or even complete stoppage of the engine. The glass filter bowl should be inspected frequently, and cleaned if dirt or water are present. To remove sediment bowl, loosen nut below bowl, swing bail to one side and twist bowl as it is being removed. Clean screen and bowl thoroughly — replace gasket if it is damaged or hardened.

DRY TYPE AIR CLEANER, Fig. 10

OIL FILTER, Fig. 1, Ref. 17

Service daily; squeeze rubber dust unloader once or twice a day to check for possible obstruction. If engine is operating in very dusty conditions, remove cartridge and shake out the accumulated dirt (do not tap or strike element — it may become damaged). Wipe out dirt from inside cover and bowl, after removing baffle and dumping out dust. Once each week; the filtering cartridge should be taken out and rinsed under a faucet with cold water, then wash by repeated dippings for several minutes in a solution of lukewarm water and a mild, NON-SUDSING detergent. Rinse in cold water from the inside out, and allow to dry overnight before re-installing. In cold weather, protect element from freezing until dry.

A BY-PASS type oil filter is furnished on all Model VH4D and VG4D engines, except where the use of other accessories prevent mounting an oil filter.

DO NOT USE GASOLINE, KEROSENE OR SOLVENT — DO NOT OIL ELEMENT. After ten washings or one year of service, replace cartridge. New cartridges are available at your TELEDYNE WISCONSIN MOTOR Service Center.

Once a year; or oftener if conditions are severe, the air cleaner should be removed

110

DISTRIBUTOR, Fig. 1, Ref. 8 If engine is equipped with battery ignition distributor Every 250 hours of operation; add 3 to 5 drops of medium engine oil to the oiler on side of distributor base. Every 250 hours, apply 3 to 5 drops of light engine oil (10W), to the felt in the to of the cam sleeve, and 1 or 2 drops to the breaker arm pivot. Every 250 hours, add a small amount of

Fig. 11, FUEL FILTER

FIGURE 01 WISCONSIN GASOLINE ENGINE 2oRPoRATioN

9200 Sorensen. Santa Fe Springs CA 90670.2645 (213i 946-6561 • Telex 69-8378 • Fax 213-946-2265

VENDOR

01 - 05

IC AL.11■411111

IND

VENDOR SECTION

STARTER SWITCH

AMMETER

CHOKE BUTTON

IGNITION SWITCH

VARIABLE SPEED GOVERNOR CONTROL Fig. 7, VH4D, VG4D CONTROL PANEL

Fig. 2, VH4D CLUTCH LUBRICATION

Fig. 5, VG4D, V465D CLUTCH REDUCTION LUBRICATION high grade transmission oil, S.A.E. No.90

to No. 110 viscosity. Change oil every 500 hours of service, while unit is warm.

STARTING With reference to Fig. 1: Engines enclosed in a sheet metal house are referred to as Power Units, whereas those without a house are called Open Engines.

Fig. 3, VH4D CLUTCH REDUCTION LUBRICATION

Power Unit side doors should always be removed when operating.

Models VG4D and V465, Fig. 4 and Fig. 5:

The clutch in both the power take-off and clutch reduction units is of the dry disc type, therefore NO OIL should be put into the clutch housing. Grease fittings are provided for periodic lubrication of the bearings. The HOUSING BEARING should be greased every 50 hours of operation, and the THROWOUT BEARING every day before starting. use Mobil Gargoyle grease BRB No3, Sinclair AF-1 grease, or equal.

STARTING PROCEDURE Fig.'s 6,7,8

1. Check crankcase oil level and gasoline supply. Open shut-off valve in fuel strainer. OIL BURNING engines must be started on gasoline and run for 2 or 3 minutes before switching to oil. Special instructions are available for starting L.P.G. and NATURAL GAS burning engines.

The PILOT BEARING is sealed and requires no external lubrication.

2. Disengage clutch, if furnished. 3. Prime new engine — if necessary, see Fig. 6. Hand primer lever at fuel pump (available option), should be workedback and forth until strainer bowl is full — then an additional 5 or 10 strokes to fill carburetor bowl. If primer does not function — turn crankshaft one complete revolution. Gravity feed (power units), and electric start engines do not require priming.

The SHIFTER SHAFT should be lubricated periodically if external oil fittings are provided. THE REDUCTION UNIT IS OPERATED IN OIL and the gear case oil level must be maintained to the oil DIPSTICK mark or PLUG opening, which ever is applicable. In ROCKFORD units use No. 30 S.A.E. crankcase oil, for TWIN DISC units use

4. Set throttle about 1/2 open if variable speed governor control is furnished. With a two speed control, start in full load position — idle after engine starts.

THROWOUT BEARING GREASE FITTING

OIL PRESSURE VARIABLE SPEED GAUGE GOVERNOR CONTROL

IGNITION-STARTER SWITCH Fig. 8, V465D CONTROL PANEL Models VH4D and VG4D only, Fig. 7 5. Pull out ignition switch, if applicable (tag reads "TO STOP PUSH IN - ). Magneto ignition engines ( less ignition switch), have a lever type ground switch on side of magneto which is always in the ON or running position, except when depressed for stopping. 5a. Close choke by pulling choke button to extreme out position. b. Turn engine over slowly one or two revolutions. CAUTION: Be sure that crank does not bind — apply oil to the crank jaw and crank nut extension for ease of engagement and release. Push choke control button in about halfway and then pull up rapidly on the starting crank. Do not attempt to spin the engine with the starting crank. If engine does not start on the first pull up of the crank, re-engage the crank and repeat the operation. With electric starting motor; depress starter switch button in place of hand cranking. See Fig. 7. 5c. After engine starts, push choke button in as required for smooth running. Choke should be completely open (button in), when engine is warmed up.

Less choking is necessary in warm weather or when engine is warm, than when cold. Should flooding occur, open choke fully and continue cranking. Model V4650 only, Fig. 8 6. After setting throttle as per paragraph

r'. HOUSING BEARING

INSPECTION PLATE GREASE FITTING Fig. 4, VG4D, V4650 CLUTCH LUBRICATION

Fig. 6, FUEL PUMP PRIMER

FIGURE 01 1 MV/M

3RP ,oRAT oN

9200 Sorensen. Santa Fe Springs. CA 90670-2645 (213) 946-6561 • Telex 69-8378 • Fax 213-946-2265

Turn IGNITION-STARTING SWITCH to 'Start' position and at the same time pull out choke button only sufficient to start the engine.

WISCONSIN GASOLINE ENGINE

VENDOR - 01- 04

VENDOR SECTION

STARTING AND OPERATING INSTRUCTIONS 4 11 3 6 10 7 21

1 AIR CLEANER 2 PRE-CLEANER 3 BREATHER CAP and OIL FILLER

15 17

4 CARBURETOR 5 CHOKE BUTTON

6 CYLINDER NUMBERS 7 DIP STICK 8 DISTRIBUTOR 9 EXHAUST MUFFLER 10 FUEL FILTER 11 FUEL PUMP 12 FUEL TANK 13 GENERATOR 14 IGNITION COIL 15 MAGNETO 16 OIL DRAIN PLUG 17 OIL FILTER 18 ROCKER ARM COVERS 19 STARTING MOTOR 20 STARTING SOLENOID 21 STOP SWITCH 22 VARIABLE SPEED GOVERNOR CONTROL 23 VENT HOLE 24 ANTI-DIESEL VALVE

MODELS VH4D and VG4D

18 3

7 14 13

Fig. 1, REFERENCE VIEWS

GENERAL INFORMATION These engines are of the four cycle type, in which each of the four operations of suc-

1. Fill tank with Regular grade gasoline. OIL BURNING engine has letter '0' suffixed to model designation — use 35 minimum octane fuel oil.

tion, compression, expansion and exhaust constitutes a complete stroke. This gives one power stroke per cylinder for each two revolutions of the crankshaft.

L.P.G. BURNING engine has letter 'G' added to model designation — use propane HD5.

COOLING

Cooling is accomplished by a flow of air circulated over the cylinders and heads of the engine from a combination fan-flywheel encased in a sheet metal shroud. The air is divided and directed by ducts and baffles to insure uniform cooling of all parts. NEVER OPERATE AN ENGINE WITH ANY PART OF THE SHROUDING REMOVED this will retard air cooling. —

NATURAL GAS burning engines require a B.T.U. content of at least 1000. 2 Fill crankcase base with the proper grade of engine oil as specified in "GRADE OF OIL" chart. Fill through the breather tube opening to the level indicated by the FULL mark on DIPSTICK.

IGNITION

For run-in of new engines, use same oil as recommended in GRADE OF OIL chart.

The spark for ignition of the fuel mixture is

furnished by a high tension magneto driven by the timing gears at crankshaft speed (models VH4D and VG4D).

Check crankcase oil level every 8 hours, change oil every 50 hours of operation.

Battery ignition (12 volt) distributor, is furnished in place of magneto on engines equipped with flywheel alternator, or as optional ignition (Std. on model V-465D).

To change oil, remove drain plug from oil pan. Oil should be drained while engine is hot; it will flow more freely.

ROTATION The rotation of the crankshaft is clockwise when viewing from the flywheel or front end of the engine, and counterclockwise rotation of the power takeoff or rear end of the engine.

3. Clutch and gear reduction unit lubrication differs between the various engine models. All units operating in oil are furnished with oil filler, level and drain plugs, suitable for any take-off shaft position.

111311

GRADE OF OIL

BEFORE STARTING NEW ENGINE

FIGURE 01 0//11R

CORP O R A T I ON

9200 Sorensen. Santa Fe Sonngs CA 90670-2645 (213) 946 - 6561 • Telex 69-8378 • Fax 213-946-2265

SEASON OR TEMPERATURE

GRADE OF OIL

Spring, Summer or Autumn +120°F to +40°F

SAE 30

Winter . +40°F to +15°F +15°F to 0°F Below 0°F

SAE 20-20W SAE lOW SAE 5W-20

Use oils classified as Service MS, SDorSE

Crankcase Capacity New Engine Oil and filter change Less — oil filter or filter change

VH4D

VG4D V4650

31/2 qts. 41/2 qts. 4 qts.

5 qts.

31/2 qts. 41/2 qts.

6 qts. 7qts., 6 qts.

Model VH4D, Fig 2 and Fig. 3: Fill clutch and gear reduction units to the height of the oil level plug opening Use same grade oil as used in engine crankcase. Add sufficient oil between changes to keep oil up to the level plug opening. Change oil in clutch and reduction units at least every 500 hours of operation.

WISCONSIN GASOLINE ENGINE

VENDOR - 01 03

Clit-AVAIR

VENDOR SECTION

NEW ENGINE Instructions • LUBRICATION

Operating without oil will ruin engine.

I MPORTANT Refer to GRADE OF OIL chart (page 2) and fill with proper oil before starting engine.

There is NO OIL in this unit. Fill crankcase to proper oil level, also clutch or gear box if furnished, and oil bath air cleaner.

• AIR CLEANER

Oil bath type Add same grade oil as used in crankcase to the level line indicated on cleaner bowl. Maintain oil level or dirt will be drawn in and damage engine. —

Dry element type, optional equipment - DO NOT OIL - Follow instructions on cleaner body.

• FUEL

Use 'REGULAR' grade gasoline. Engines built to operate on FUEL OIL, KEROSENE, L.P.G. or NATURAL GAS are so identified in the model designation. Refer to 'FUEL' paragraphs of instructions. Buy fresh fuel. Do not use out-of-season gasoline.

• NEGATIVE GROUND CIRCUIT , ,sof

if engine is equipped with STARTING MOTOR, DISTRIBUTOR IGNITION and FLYWHEEL ALTERNATOR, or GENERATOR.

GROUND ENGINE TO NEGATIVE TERMINAL ON BATTERY. CAUTION: Be absolutely sure of proper connection or damage to the Alternator or Generator circuits will result.

• PREVENT OVERHEATING T emperature Safety Switch Do not disconnect wire or allow terminal to touch head fins or shrouding. Optional accessory mounted to cylinder head bolt near spark plug — TO PROTECT ENGINE

AGAINST OVERHEATING. If engine stops, check first to see if engine is overheated. Other conditions may have caused the engine to stop. Clean air cleaner, air intake screen, fins, and check oil level, spark plugs and wiring. Let engine cool at least 10 minutes before restarting.

Keep Engine Clean

External dirt restricts cooling and internal dirt causes wear.

BREATHER CAP Clean at every oil change

CYLINDER and HEAD COVERS Remove and scrape dirt from cylinder and head fins. (7\

AIR CLEANER OIL FILTER

Service daily if necessary

Replace at least every other oil change.

VEE AREA Remove dirt and chaff from manifold ports and space between CYL. blocks.

AIR INTAKE Remove screen and brush clean.

• NEW ENGINE BREAK-IN Proper break-in will lead to trouble-free operation and increased engine life. The factory test given to a new engine is not sufficient to establish the polished bearing surfaces which are so necessary for good performance and long engine life. There is no quick way to force the establishment of good bearing surfaces, and these can only be obtained by running a new engine carefully and under reduced

FIGURE 01 AkSain 9200 Sorensen. Santa Fe Springs. CA 90670.2645 (213 1 946-6561 • Telex 69-8378 • Fax 213-946-2265

speeds and loads for a short period of time. Run the engine for a half hour without load at low idle speed (1000 to 1200 R.P.M.). The speed should then be increased gradually, to engine operating r.p.m. still without load, for an additional two hours. If at all possible, operate the engine at light loads for a period totaling about eight hours, before maximum load is applied.

WISCONSIN GASOLINE ENGINE

VENDOR- 01- 02

CAL,

CFI

VENDOR SECTION

INTRODUCTION WISCONSIN heavy duty air cooled engines are of the

Teledyne Wisconsin Motor is backed by over 65 years of engineering experience in the design of internalcombustion engines for every conceivable type of service. The performance of these engines is proof of the long satisfactory service you too can expect from your engine.

most advanced design and are built in a modern factory, equipped with the latest machinery available. Only the best materials, most suitable for the particular part, are used. During production, every part is subjected to rigid inspection, as are also the completely assembled engines. After assembly, every engine is operated on its own power and all adjustments are carefully made so that each engine will be in perfect operating condition when it leaves the factory.

Like all fine machinery, the engine must be given regular care and be operated in accordance with the instructions.

SPECIFICATIONS MODEL VH4D

MODEL VG4D

MODEL V-465D

Bore 3 1/4" Stroke 3 1/4" Piston Displacement — cu. in. 107.7 Horsepower — 1400 R.P.M. ... 17.2 1600 R.P.M. ... 20.0 1800 R.P.M. ... 22.5 2000 R.P.M. ... 24.7 2200 R.P.M. ... 26.5 2400 R.P.M. ... 28.0 2600 R.P.M. ... 29.2 2800 R.P.M. ... 30.0

Bore a1/2" 4 Stroke Piston Displacement — cu. in. 154 Horsepower — 1400 R.P.M. ... 25 1600 R.P.M. ... 29 1800 R. P. M. ... 32 2000 R.P.M. ... 34 36 2200 R.P.M. ... 2400 R.P.M. ... 37

Bore Stroke Piston Displacement — cu. in. Horsepower — 1600 R.P.M. 1800 R.P.M. 2000 R.P.M. 2200 R.P.M. 2400 R.P.M. 2600 R.P.M. 2800 R.P.M. 3000 R.P.M.

Note:

3 3/4" 4 " 177 41.6 47.5 52.4 56.7 60.0 63.0 64.5 65.9

For continuous operation, allow 20% of horsepower shown, as a safety factor.

SAFETY PRECAUTIONS

•

Never fill fuel tank while engine is running or hot; avoid the possibility of spilled fuel causing a fire.

•

Always refuel slowly to avoid spillage.

•

When starting engine, maintain a safe distance from moving parts of equipment.

•

Do not start engine with clutch engaged.

•

Do not spin hand crank when starting. Keep cranking components clean and free from conditions which might cause the crank jaw to bind and not release properly. Oil periodically to prevent rust.

•

Never run engine with governor disconnected, or operate at load speeds in excess of: 2800 R.P.M. for

FIGURE 01 Ira

a !WA CORPORATION

9200 Sorensen. Santa Fe Springs. CA 90670 - 2645 (213) 946 - 6561 • Telex 69-8378 • Fax 213-946-2265

model VH4D, 2400 R.P.M. for model VG4D and 3000 R.P.M. for model V-465D.

•

Do not operate engine in a closed building unless the exhaust is piped outside. This exhaust contains carbon monoxide, a poisonous, odorless and invisible gas, which if breathed causes serious illness and possible death. Never make adjustments on machinery while it is connected to the engine without first removing the ignition cables from the spark plugs. Turning the machinery over by hand during adjusting or cleaning might start the engine and machinery with it, causing serious injury to the operator.

•

Precaution is the best insurance against accidents.

•

WISCONSIN GASOLINE ENGINE

VENDOR- 01-01

CAL.f1VAIR 1140

eRr

VENDOR SECTION

STARTING and OPERATING INSTRUCTIONS

SCONSIN

/1eiz=--ea-aeed Engines OIL BATH AIR CLEANER EXHAUST MUFFLER CONTROL PANEL so

OIL FILLER AND BREATHER CAP

VARIABLE SPEED GOVERNOR CONTROL

FUEL PUMP

CYLINDER NUMBERS

OIL DIP STICK FUEL STRAINER - OPTIONAL BATTERY IGNITION DISTRIBUTOR FLYWHEEL SHROUD OIL FILTER IGNITION COIL OIL DRAIN PLUG

OPEN ENGINE - TAKE-OFF VIEW

Four Cylinder Engine Models VH4D • VG4D • V-465D leTELEDYNE WISCONSIN MOTOR WORLD'S FOREMOST SOURCE FOR HEAVY DUTY AIR COOLED ENGINES

FIGURE 01 111 101..11WAR zoRpoRArioN 9200 Sorensen. Santa Fe Springs CA 90670-2645 (213) 946 - 6561 • Telex 69-8378 • Fax 213-946-2265

WISCONSIN GASOLINE ENGINE

VENDOR - 01 - 00

ELECTRICAL SCHEMATIC FOR BERTEA 12 VDC OPERATOR MULTIPLE STATION

COIL

2ESI51A NICE VALUE 5 SAME A5 Of SINGLE VALVE ope 2AT 012 1)100E: IN 4005, lam P, 600 V

122

AUX COIL jukiPgRN DUAL

p NC

L-

When multiple station control for one pilot valve is required, a special electrical assembly with diodes is used to isolate the multiple operators without adding selector switches to the circuit. The electrical schematic is shown above. The external wiring to the terminal blocks requires one operator to be the Master and the other to be the Slave as shown below. The slave has the ground connection (E) and the jumper removed.

LANE

MASTER

A B C D H E L AUX) COIL. r*N JUMpER.

g2/79

CD H E L AUX

JUNIPER REMOVED

ELECTRICAL SCHEMATIC FOR BERTEA 12VDC OPERATOR

Ref

Mfg

Control Circuit Resistance Values Model Catalog # [Res 'Watts Rol . 2 EJAIN056P2OIU +10% EJ 200

Clarostat

■ .

VC3D

3.25

+5% .

A Ea• AUX

C NO

COIL

37°

E MASTER SWITCH AND ELECTRICAL ASSEMBLY COMPONENTS

t3 c 9

3. 4. 5. 6. 7. 8. 9. 10.

1. 2.

JET 5c12EW AT 6.00

Electrical assembly complete. Screw fastener for electrical assembly. Lock washer. Fastening nut fixed to plate. Potentiometer coupling. Potentiometer & cam drive gear. Master switch complete. Main drive gear. Adjustable cam segments. Pot nuts.

5 4L7 L6

ELECTRICAL ASSEMBLY INSTALLATION PROCEDURES 1. Turn potentiometer coupling #5 to vertical position, set screw location to 6 o'clock. 2. Insert complete electrical assembly into MS3, aligning coupling with drive gear #6. 3. Install (2) screw fasteners and lock washers. Tighten snug. 4. Check for free operation, if needed loosen screws and adjust plate accordingly. THE ABOVE ELECTRICAL DIAGRAM AND VALUES ARE FOR THE OPERATION OF THE VALVES AT 12 VDC ONLY.

6/2/79

Installation Instructions

The controller will attach under the top surface of the vehicle cut-out. Before attempting to install the controller the following parts must be removed. The cap handle top is removed by unscrewing it counter clockwise. The top assembly including the spring will then come off.

Grasp the bottom of the neoprene boot and by rotating counter clockwise the boot with the knurled retaining ring under it can be unscrewed from the controller. The boot, retaining ring, phenolic tube, and lower handle can then be removed as an assembly from the controller. The controller can then be inserted up through the panel bottom with the gasket between the controller mounting plate and the panel bottom surface. Insert the mounting screws through the panel thread into the mounting plate of the controller. The boot assembly including the knurled ring, and the other handle parts can then be reinstalled.

6/2/79

Dimensional Outline Drawing MS3M983

142/9

Dimensional Outline Drawing MS3M836 1V:2/79