Condor 3238 4248 4248LC 4248T Operation & Maintenance & Parts Manual - PDF DOWNLOAD

OPERATION/MAINTENANCE AND ILLUSTRATED PARTS MANUAL FOR CALAVAR SELF-PROPELLED CONDOR MODELS 3238, 4248, 4248LC, 4248T

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.

CAILIWAR CORPORATION

Model Serial No. Date Delivered CUSTOMER

Note: Additional copies of this Manual (Part No. 92152) may be obtained through the Parts Department at Calavar.

Series IV Serial Nos. 2392-2544)

DEC 1 3 19a9 STYLE

MAKE

PART #

QTY DESCRIPTION

OLD M-V1833XL-01-02-03,

NEW

MAKE

OLD

V-2033XL-01

OLD

NEW

55646 55645 55639 55625

2

SIDE HANDRAIL WELDMENT LIFT UP GATE HANDRAIL WELDMENT EXT.DECK

56462 56592 56588 56461 56569 56453

1 1 1 1 1 1

LH SIDE HANDRAIL WELDMENT RH SIDE HANDRAIL WELDMENT LH SIDE HANDRAIL WELDMENT EXT.DECK RH SIDE HANDRAIL WELDMENT EXT.DECK FRONT RAIL WELDMENT REAR GATE

M-V1833XL-04

STYLE

PRINT NO# LIST PRICE

$ 91.00 $ 35.00 359.00 56521

PART #

QTY DESCRIPTION

$ 140.00 $ 140.00 $ 190.00 $ 190.00 $ 140.00 $ 81.00

PRINT NO# LIST PRICE 55478

55267 55473 55470

1 HANDRAIL WELDMENT EXT. DECK 2 SIDE HANDRAIL WELDMENT LIFT UP GATE

55970 55473 55470

1 HANDRAIL WELDMENT EXT. DECK 2 SIDE HANDRAIL WELDMENT 1 LIFT UP GATE

V-2033XL-02

$ 687.00 $ 153.00 $ 65.00 55971

V-2033XL-03

$ 493.00 $ 153.00 $ 65.00 56664

56519-001 56519-002 56588 56461 56569 56453

1 LH SIDE HANDRAIL WELDMENT 1 RH SIDE HANDRAIL WELDMENT 1 LH SIDE HANDRAIL WELDMENT EXT.DECK 1 RH SIDE HANDRAIL WELDMENT EXT.DECK 1 FRONT RAIL WELDMENT REAR GATE

$ 345.00 $ 345.00 $ 190.00 $ 190.00 $ 140.00 $ 81.00

, STYLE OLD

MAKE

PART #

V2648XL-01

V2648XL-02 BILL NOT COMPLETE

STYLE

MAKE

OLD

V2570G-01 (EXT) 39'_

NEW

PRINT NO# LIST PRICE 55663

55567 55607 55612 NEW

QTY DESCRIPTION

PART #

1 2 1

HANDRAIL WELDMENT EXT. DECK SIDE HANDRAIL WELDMENT LIFT UP GATE

1 1 1 1 1 1

LH SIDE HANDRAIL WELDMENT RH SIDE HANDRAIL WELDMENT LH SIDE HANDRAIL WELDMENT EXT.DECK RH SIDE HANDRAIL WELDMENT EXT.DECK FRONT RAIL WELDMENT REAR GATE

■■■

QTY DESCRIPTION

$ 477.00 $ 153.00

91.00 $

PRINT NO# LIST PRICE 84080

84035 84060 84058 84057 84016 84021

1 HANDRAIL EXT. 1 LH FRONT HANDRAIL 1 RH FRONT HANDRAIL 1 LH REAR HANDRAIL 1 RH REAR HANDRAIL 1 REAR GATE WELDMENT

84208 84202 84201 84199 84198 84179

1 HANDRAIL EXT. 1 LH FRONT HANDRAIL 1 RH FRONT HANDRAIL 1 LH REAR HANDRAIL 1 RH REAR HANDRAIL 1 REAR GATE WELDMENT

$ 689.00 $ 121.00 $ 121.00 $ 140.00 $ 193.00 $ 246.00 84192

V2570G-01 (EXT)

$ 682.00 $ 400.00 $ 121.00 $ 140.00 $ 190.00 $ 235.00

STYLE

MAKE

NEW

V2570G-02 (STD)

PART #

QTY DESCRIPTION

PRINT NO#

LIST PRICE

84176 84185 84190 84191 84171 84172 84179

HANDRAIL FRONT 1 LH FRONT HANDRAIL 1 RH FRONT HANDRAIL 1 LH REAR HANDRAIL 1 RH REAR HANDRAIL 1 REAR GATE

...

$ 319.00 $ 237.00 $ 254.00 $ 194.00 $ 194.00 $ 235.00

TIME CONDOR Corporation

SELF-PROPELLED ELEVATING WORK PLATFORM

MODEL V2546 OPERATOR'S, MAINTENANCE, AND PARTS MANUAL

SHIPPING ADDRESS

MAILING ADDRESS

CONDOR

CONDOR

TIME CONDOR Corporation

TIME CONDOR Corporation

8300

P.O. Box 21447 76702-1447 (254) 420-5200

IMPERIAL DRIVE

76712 (254) 420-5200

WACO, TEXAS

WACO, TEXAS

MANUAL 92361 JUNE 1997

TIME CONDOR Corporation

SELF-PROPELLED ELEVATING WORK PLATFORM

MODEL V2546 OPERATOR'S MANUAL

SHIPPING ADDRESS

MAILING ADDRESS

CONDOR

CONDOR

TIME CONDOR Corporation

TIME CONDOR Corporation

8300

P.O. Box 21447 76702-1447 (254) 420-5200

IMPERIAL DRIVE

76712 (254) 420-5200

WACO, TEXAS

WACO, TEXAS

MANUAL 92361-001 June 1997

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 of the 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 92.6-1990 Manual of Responsibilities is attached for your use.

TIME CONDOR 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 TIME CONDOR 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 TIME CONDOR 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 TIME CONDOR Corporation, Maintenance, & Parts Manual for information on service and maintenance of the CONDOR®.

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

O

CONDOR® Model V2546 OPERATOR'S MANUAL TABLE OF CONTENTS

INTRODUCTION

TABLE OF CONTENTS

1

I. PREPARATION, INSPECTION, AND MAINTENANCE

3

A. B. C. D. E.

Overall Condition Lower Controls Platform & Upper Controls Hydraulic System Batteries & Charger

II. MACHINE OPERATION

3 3 3 4 4 4

A. RATED WORK LOAD B. LOWER CONTROLS C. PLATFORM CONTROLS

4 4 4

III. OPTIONS

6

IV. EMERGENCY LOWERING

6

V. MOVING FROM JOB SITE TO JOB SITE

6

A. B. C. D.

Loading & Unloading Ramp Method Forklift Loading & Unloading Method Transporting

6 6 7 7

VI. FREEWHEEL OPERATION

7

APPENDIX: DECALS ILLUSTRATION

8

ANSI/SIA 92.6 - 1990 MANUAL OF RESPONSIBILITIES

MANUAL 92361-001 June 1997

IMPORTANT: A COPY OF THE ANSUSIA 92.6-1990 MANUAL OF RESPONSIBILITIES IS ATTACHED TO THIS OPERATOR'S MANUAL. IT CONTAINS IMPORTANT OPERATING INFORMATION FOR THIS CONDOR®. READ BEFORE OPERATING THIS CONDOR®.

CAUTION:

I. PREPARATION, INSPECTION, AND MAINTENANCE The condition of this unit is very important, as it directly affects the operator as well as other personal. The operator must perform a thorough walk-around inspection each day prior to operating the CONDOR®. Any damage or faulty operation should be reported immediately.

A DO NOT OPERATE tag outlining the problem should be attached to the lower control station and any discrepancies should be corrected before operating.

Defective components, structural damage, missing parts, and equipment malfunction jeopardize the operator and other personnel and may cause excessive damage to the CONDOR®. A poorly maintained CONDOR® could become the greatest operational hazard you may encounter.

B. LOWER CONTROL STATION Check electrical installations for loose, broken, or frayed wires and cables.

KNOW THE CONDOR® AND ITS CAPABILITIES. REPORT ANY UNUSUAL OPERATION, SUCH AS ERRATIC SWAY OR MOTION.

Check that all functions operate properly, and that all controls return freely to center (neutral).

Some major areas to check daily are: C. PLATFORM AND UPPER CONTROL STATION

A. OVERALL MACHINE CONDITION TIRES & WHEELS: Check for proper tire pressure, cracks, tears, cuts, or missing or loose lug nuts (a rust line running down the rim from the lug nut indicates a loose lug nut).

MISSING, BROKEN, DAMAGED PARTS: Check cylinder mounting pins, pivot pins, retainers/fasteners, bearing pads, bolts, and nuts.

STRUCTURAL: Check for damaged or cracked welds on structural components—chassis, armstack, and platform.

S TEERING: Check tie rod ends and steering cylinder for proper and secure mounting.

11

DECALS: Check that all decals and warning signs are in place and are clearly legible.

MANUAL 92361-001 June 1997

Check electrical installations for loose, broken, or frayed wires and cables.

Re-check the structural condition of the platform, pivot points, pins, railings, and floor.

Check to see that entry chain is in place and latches securely at access opening.

Check the red EMERGENCY STOP button; this button disconnects power to the controls and stops all powered functions.

See that footswitch operates properly, and that guard is secured and in its proper place on the platform floor, and that no functions work unless depressed.

HYDRAULIC SYSTEM

El

Check the hydraulic tank fluid level with the arms and platform lowered. Maintain fluid level at the full mark on the sight glass. Add only Shell Tellus T-32 Hydraulic Oil (or equivalent) to the system. Ensure that the breather cap is clean and in place on the tank.

El

Check for hydraulic oil leaks at all fittings, valves, and controls, and check hydraulic hoses and tubes for damage and kinks.

Any leaks or damage should be corrected before use.

Ensure that hydraulic lines are routed properly to avoid pinch points.

Check that all control levers return freely to their neutral positions when actuated and released.

Ensure that manual lowering valves on cylinders are functioning properly. See section IV.

E. BATTERIES/CHARGER Check electrolyte level and ensure that all caps are present and installed properly.

Cable connections should be tight and clean. Always wear protective equipment when working with batteries. Only add water when the batteries are fully charged.

Protect batteries from sparks and open flame.

Ensure that charger is operating properly, and inspect charger, plug, and meter for damage.

This means that the platform is rated for a 750-lb. combined weight (including personnel and their tools and equipment) throughout the working envelope of the CONDOR®. If equipped, the extension deck has a rated work load of 250 lbs.The combined total weight on platform and extension deck must not exceed 7501bs. DO NOT overload the platform; know the rated capacity.

DO NOT sit or climb on platform railing. Keep both feet on the platform floor at all times.

DO NOT use ladders, planks or other devices on the aerial platform for achieving additional height or reach. DO NOT use the CONDOR® for any other purpose than to position personnel and their tools or equipment. The CONDOR® is not designed for use as a crane.

B. LOWER CONTROLS At the lower control station there is a selector switch which shifts the operational controls between "Platform" and "Ground" modes. Next to this switch is a toggle switch labeled "Up" and "Down". For operation of lower controls, the selector switch should be switched to "Lower".

The toggle switch may be held either in the up or down position while holding the control valve lever in position desired.

To raise the Platform, push up on the toggle switch and lift the "Lower Control Valve" lever.

To lower, push down on the toggle switch and push down on the same lever.

C. PLATFORM CONTROLS NOTE: At lower control station, the operator selector switch must be switched to the "Upper position" to energize the upper controls.

EMERGENCY POWER BUTTON

II. MACHINE OPERATION CAUTION: OPERATE ON FIRM, LEVEL GROUND.

NOTE: This is also an emergency stop switch.

Pull to turn on and push to turn off. Push to cease all functions.

A. RATED WORK LOAD

The controls are energized only when the footswitch is depressed. The platform control box contains the following controls:

The CONDOR® Model V2546 has a rated work load of750 lbs. (340 kg), including two occupants.

MANUAL 92361-001 June 1997

LOWER CONTROL STATION

PUMP SWITCH

UPPER/LOWER SELECTOR SWITCH

LOWER CONTROL VALVE

CONTROL VALVE HANDLE

UPPER CONTROL STATION EMERGENCY STOP BUTTON 110 VOLT OUTLET OPTION

SLOPE ALARM (OPTIONAL)

LIFT HANDLE CONTROL LEVER GUARD

DRIVE/STEER HANDLE EMERGENCY STOP BUTTON LIFT HA DLE

SLOPE ALARM (OPTIONAL)

C=1

N CONTROL LEVER GUARD

MANUAL 92361-001 June 1997

110 VOLT OUTLET OPTION

DRIVE/STEER CONTROL

IV. EMERGENCY LOWERING

This four-way control lever operates the drive and steer functions moving the Drive/Steer control lever to the forward or reverse direction will cause the CONDOR® to drive in those respective directions. Moving the same control lever to the right or left will cause the CONDOR® to steer right or left respectively.

The footswitch must be depressed while operating these functions The CONDOR® Scissor lifts have three (3) drive speeds: Low, High, and Creep. Low speed is accomplished with the scissor arms completely lowered. This allows the greatest possible torqure for driving up maximum inclines. High speed is available with the platform raised just a few inches so the arms just clear the transmission valve actuator. This allows the fastest drive speed, but has reduced torque. Creep speed is accomplished by raising the scissor arms further, approximately 12 inches, to clear the creep valve actuator. This allows the minimum drive speed and greatly reduced torque while driving at increased platform heights.

The CONDOR® is equipped with an emergency lowering valve located at the holding valve on the lift cylinder. To operate the emergency lowering valve, depress the red knob and turn counterclockwise until it pops out slightly (1/8"-1/4"). The lift/ lower control lever at the lower control station can now be moved to the "Lower" position and the platform will lower. (No electrical activation is necessary). To reset holding valve, depress the red knob and turn clockwise.

LIFT UP/DOWN CONTROL LEVER

The means by which you load or unload the CONDOR® should be of sufficient strength to withstand the weight of the CONDOR®.

To raise the CONDOR®, move the control lever to the "Up" position. To lower the unit, move the control lever to the "Down" position.

The footswitch must be depressed for both "Up" and "Down" operations; however, the hydraulic pump will not be operating during the "Down" function. Gravity lowering is accomplished.

III. OPTIONS Battery Condition Indicator Strobe Light Travel Alarm 110V Line to Platform Hour Meter Non Marking Tires (V2546) Motion Alarm Deck Extension 5° Multi-Axis Slope Alarm Special Paint

V. MOVING FROM JOBSITE TO JOBSITE A. LOADING AND UNLOADING Although the CONDOR® is some what small compared with the larger construction equipment, it requires the same care and attention in loading, transporting, and unloading as does larger equipment. At no time should its size be underestimated. Before loading or unloading, inspect the CONDOR® for any physical damage or defects.

MODEL WEIGHT (#) WEIGHT (KG) V2546 4,640 2,105

B. RAMP METHOD Ensure that the ramp being used is sufficiently strong to handle the weight of the CONDOR® The ramp should be set at an angle no steeper than the machine's rated grade-ability, 11° or 21%, or a rise of 25 inches in 10 feet.

Before driving the CONDORID on the ramp, lower the platform completely, test the Drive/Steer controls and brake system, and beware of freewheeling conditions.

MANUAL 92361-001 June 1997

Drive up and down the ramp slowly, allowing for steering corrections to be made. Keep CONDOR® in alignment with the carrier and ramp during loading and unloading procedures.

VI. FREEWHEEL OPERATION

C. FORKLIFT LOADING AND UNLOADING METHOD

CAUTION: When using the freewheel valve, the CONDOR@ must be on level ground. Turn valve clockwise until closed and drive the CONDOR® approximately 3 feet. This will disable the brake, allowing the CONDOR® to be moved.

Ensure that the forklift has sufficient capacity to handle the weight of the CONDOR®.

The valve knob must be turned fully counterclockwise (open) for normal operation.

The Model V2546 should be lifted from the side, positioning the forks underneath the chassis. Forks should be long enough to go across the width of the frame and should be positioned as close to the inside of the tires as possible.

NOTE: DO NOT ATTEMPT TO LIFT THIS MODEL FROM EITHER END.

Never exceed 5 MPH when moving the CONDOR® in the freewheel mode.

DO NOT tow the CONDOR®.

NOTE: IN FREEWHEEL MODE THE BRAKES ARE INOPERABLE, USE EXTREME CAUTION.

The CONDOR® should only be raised to a height sufficient to clear any obstructions.

Keep forklift travel to a minimum, and set CONDOR® gently down on trailer or on ground level.

D. TRANSPORTING The CONDOR® can be easily transported from the jobsite if the following rules and procedures are followed: Block all wheels to prevent forward and reverse motion.

Tie down the CONDOR® with chains or cables, running them through the tie-down brackets only.

Do not chain or strap over the guard rails. Severe damage to the scissor arms may result from securing the CONDOR® over the top of the platform.

Always turn the power off at the ground control station.

MANUAL 92361-001 June 1997

0

Decal Installation

20

MANUAL 92361-001 June 1997

PARTIAL VIEW "A-A"

Decal Installation ITEM PART NUMBER DESCRIPTION

Ref. 55114 Decal V2546 Set 1 54749 Replaced By 55894 2 55894 Decal, V General Caution 3 54183 Decal, Danger Arm Stand 4 54288 Decal, Lower Control Valve 5 21882-002 Decal, Danger Not Insulated 6 21882-001 Decal, Keep Clear Decal, Battery Charger Plug 7 54182 8 50070 Decal, Battery Service 9 54301 Decal, Lower Control Operator's Instruction Decal, Caution Tie Down Ring 10 54416 11 54300 Decal, Upper Control Operator's Instruction 12 13 69473-002 Decal, Condor 14 15 55008 Decal, Caution Emergency Lowering 16 54652-003 Decal, Guardrail/Chain Caution Decal, Tire Replacement Solid 17 58399 18 21850 Replaced By 54984-007 19 54984-007 Decal, Hydraulic Fluid Tape, 6" W Non-Skid Black 20 53259 21 54280 Decal, Caution 22 54291 Decal, Free-Wheel Instruction Decal, Free-Wheel Valve 23 54320 24 55160 Decal, Emergency Lower Instruction 25 54338 Decal, Rated Load 250/750LBS 26 54348 Decal, Control Station - Indicates Item Not Shown

MANUAL 92361-001 June 1997

QTY

Ref. 1 1 2 1 2 2 1 2 1 4 1 4 1 1 4 1 1 1LF. 1 1 1 1 1 1

Decal Installation

0

0

PARTIAL VIEW "B-B"

INSIDE VIEW OF PARTIAL VIEW "B-B"

PARTIAL VIEW "C-C"

MANUAL 92361-001 June 1997

Decal Installation0 ITEM PART NUMBER DESCRIPTION

Ref. 55114 Decal V2546 Set 1 54749 Replaced By 55894 2 55894 Decal, V General Caution 3 54183 Decal, Danger Arm Stand 4 54288 Decal, Lower Control Valve 5 21882-002 Decal, Danger Not Insulated 6 21882-001 Decal, Keep Clear 7 54182 Decal, Battery Charger Plug 8 50070 Decal, Battery Service 9 54301 Decal, Lower Control Operator's Instruction 10 54416 Decal, Caution Tie Down Ring 11 54300 Decal, Upper Control Operator's Instruction 12 13 69473-002 Decal, Condor 14 15 55008 Decal, Caution Emergency Lowering 16 54652-003 Decal, Guardrail/Chain Caution 17 58399 Decal, Tire Replacement Solid 18 21850 Replaced By 54984-007 19 54984-007 Decal, Hydraulic Fluid 20 53259 Tape, 6" W Non-Skid Black 21 54280 Decal, Caution 22 54291 Decal, Free-Wheel Instruction 23 54320 Decal, Free-Wheel Valve 24 55160 Decal, Emergency Lower Instruction 25 54338 Decal, Rated Load 250/750LBS 26 54348 Decal, Control Station - Indicates Item Not Shown

MANUAL 92361-001 June 1997

QTY

Ref. 1 1 2 1 2 2 1 2 1 4 1 4 1 1 4 1 1 1LF. 1 1 1 1 1 1

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.

TIME CONDOR Corporation

SELF-PROPELLED ELEVATING WORK PLATFORM

MODEL V2546 MAINTENANCE MANUAL

SHIPPING ADDRESS

MAILING ADDRESS

CONDOR

CONDOR

TIME CONDOR Corporation

TIME CONDOR Corporation

8300 IMPERIAL DRIVE WACO, TEXAS 76712 (254) 420-5200

P.O. Box 21447 WACO, TEXAS 76702-1447 (254) 420-5200

MANUAL 92361-002 JUNE 1997

INTRODUCTION The primary purpose of this manual is to provide the user with a thorough understanding ofthe 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 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. The various decals attached to this machine also contain vital operational instructions. Read the decals before operating this machine.

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 of the 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 92.6-1990 Manual of Responsibilities is attached for your use.

TIME CONDOR 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 TIME CONDOR 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 TIME CONDOR 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 ofthe TIME CONDOR Operation, Maintenance, & Parts Manual for information on service and maintenance ofthe CONDOR®.

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

TIME CONDOR Corporation

CONDOR® SERVICE INFORMATION

1. Ifyou need assistance or have any service or maintenance questions, TIME CONDOR service and parts personnel are always available by phone or fax. The telephone numbers are: (254) 420-5200 Telephone (254) 420-5298 Voice Mail (800) 443-5803 FAX 2. There are numerous written Maintenance Procedures available for this machine.

These procedures are available through the TIME CONDOR Service Department to anyone who requests them.

3. Service and maintenance are not a substitute for trained, qualified service technicians.

TIME CONDOR 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 TIME CONDOR Service Schools help you provide this training.

4. TIME CONDOR 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.

TIME CONDOR Corporation

8300 IMPERIAL DRIVE, P.O. Box 21447, WACO, TEXAS 76702-1447 • 254-420-5200, 817-666-4544 FAX

TIME CONDOR Corporation

Condor® Self-Propelled Booms and Scissors WARRANTY TIME CONDOR Corporation warrants to the purchaser that each new aerial work platform made by TIME CONDOR 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 five (5) years after the original shipment of the aerial work platform from TIME CONDOR's plant; and in the case of all other parts, for a period of one (1) year after the aerial work platform is placed in service or two (2) years after the original shipment of the aerial work platform from TIME CONDOR's plant, whichever comes first.

The obligation and liability under this Warranty is expressly limited to repairing or, at TIME CONDOR's option, replacing free of charge at its factory in Waco, Texas or at an authorized repair facility designated by TIME CONDOR, the defective part. In no event shall TIME CONDOR 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 damage or loss even if TIME CONDOR, 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 TIME CONDOR'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 TIME CONDOR or alteration or repair of the equipment by any person not authorized by TIME CONDOR shall, at TIME CONDOR's option, void this Warranty.

TIME CONDOR shall have no liability or responsibility for damages resulting from accident or the malfunction of equipment and components not supplied by TIME CONDOR. No agent, employee, distributor, dealer, or other representative of TIME CONDOR 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 TIME CONDOR and should not be relied upon as limited warranties of TIME CONDOR, and no attempt, effort, or promise to repair equipment by TIME CONDOR 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 the purchaser's form will be honored byTIME CONDOR. This Warranty covers only new and unused aerial work platforms manufactured by TIME CONDOR. Products or parts manufactured by others are covered only by such warranties as are extended to the purchaser by TIME CONDOR's suppliers.

This Warranty is in lieu of all other warranties, expressed or implied, including but not limited to warranties of merchantibility 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•254-420-5200,800-877-5544,817-666-4544 FAX E 1 7 /12 2"

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.

TIME CONDOR Corporation Warranty states, in general, that TIME CONDOR Corporation will replace free of charge any components found to be defective within the time frame ofthe warranty period. There are exceptions to some components which are not the responsibility of TIME CONDOR Corporation.

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 TIME CONDOR Corporation, whichever comes first. In the case ofmaj or weldments (chassis, turret, and booms), the Warranty Period is five (5) years following shipment from TIME CONDOR Corporation.

2.

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

3 . 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 TIME CONDOR, whichever comes first, unless the part is furnished to correct a defective part on the original shipment still under Warranty.

4. Replacement parts provided under the terms ofthe 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.

5 . During the Warranty Period, in addition to covering the parts replaced under Warranty, TIME CONDOR Corporation 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, the CONDOR® 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 TIME CONDOR' s facility will have a Pre-Delivery Inspection (P.D.I.) sheet enclosed in the Safety Manual holder tube.

2.

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

3.

Failure to complete the P.D.I. sheet and return it to TIME CONDOR Corporation 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 TIME CONDOR Corporation. However, these are warranted by the component manufacturer. Some of these are: 1.

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. TIME CONDOR can advise you who the dealer is if unknown to you.

2.

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.

3.

Hydraulic Filters and Fluid: These are considered general maintenance and service

items, and are not covered by warranty.

4.

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

5.

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.

6.

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

7.

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

D.

PROCESSING OF WARRANTY CLAIM

During the Warranty Period, should a component failure be encountered within the guidelines of the TIME CONDOR Corporation 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.

b.

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

The above two methods will enable you to indicate on the claim the TIME CONDOR 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 ofthe purchase order or receipt MUST accompany the claim. TIME CONDOR Corporation 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.

d.

When parts are puchased from TIME CONDOR Corporation, 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 TIME CONDOR Corporation to thoroughly evaluate the claim and process it in the shortest amount of time possible.

NOTE: WARRANTY CLAIMS WILL NOT BE ACCEPTED BY TIME CONDOR CORPORATION AFTER 45 DAYS AFTER FAILURE

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.

2.

It will be necessary for you to call the TIME CONDOR 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 TIME CONDOR Corporation within 45 days from the date the R/A number was issued. Failure to do so will cause the claim to be denied.

4.

All parts claimed under Warranty will be required to be shipped back to TIME CONDOR Corporation FREIGHT PREPAID. No freight collect shipments will be accepted.

CONDOR® MODEL V2648/53 & V2648/53XL ILLUSTRATED PARTS MANUAL TABLE OF CONTENTS INTRODUCTION SERVICE INFORMATION SERIAL NUMBER TO MODEL DESIGNATION TABLE OF CONTENTS FIGURE DESCRIPTION A B C 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

Serial Number Location Recommended Spare Parts List How to Order Parts Final Installation Decal Installation Chassis Assembly -Hose Kit -Steer Cylinder -Brake Cylinder -Hub Motor Assembly - Rear Hub Assembly Belly Pan Assembly Motor & Pump Assembly Pump Assembly Motor 24VDC Assembly Valve Assembly Charger 115V/60Hz-25A/24VDC Wiring Installation Lower Control Box Assembly Armstack Assembly Platform Installation Upper Control Box Assembly 110 Volt Extension To Platform Travel Alarm (Option) Motion Alarm (Option) Strobe Light (Option) Descend Alarm (Option) Slope Alarm (Option) Hour Meter (XL-Option) Battery Condition Indicator (XL-Option) Low-Voltage Warning Interrupt (XL-Option) Larger Batteries IPOS (XL-Option)

MANUAL 92356-003 May 1997

ii iii

1 PAGE 2 3 4,5 6 8 10 14 16 17 18 19 20 22 23 24 26 28 32 36 44 50 52 56 57 58 59 60 61 62 63 64 65

NOTES

MANUAL 92361-002 June 1997

SPECIFICATIONS SPECIFICATIONS

V2546

Maximum Working Height Platform Height Stowed Platform. Height Overall Length Overall Width Inside Platform Size Platform Capacity Gross Weight Power System Battery Capacity Number ofBatteries Battery Voltage Battery Charger Toe Plate Wheel Base Tires

31 ft.

25 ft.

4 ft. 7 in.

10 ft.

3 ft. 10 in.

43.5 x 110 in.

750 lbs.

4,750 lbs.

36 volt electric 250 amp hour 6 6 volt 40 amp 6 in.

7 ft. 2 in.

18 x 255 x 315 (Solid Rubber) 8 ft. 11 in.

27/24 sec.

0-2.75 mph

Inside Turning Radius Lift/Lower Speed Drive Speed

OPTIONS * * * * *

Battery Condition Indicator Strobe Light Travel Alarm 110V Line to Platform Hour Meter

* * * * *

Non Marking Tires Motion Alarm Deck Extension 5° Multi-Axis Slope Alarm Special Paint

The CONDOR® Model V2546 is designed and built to conform to Condor's understanding and interpretation of all applicable OSHA rules and regulations as well as ANSI standards:

ANSI Standard A92.6 - 1990

SelfPropelled Elevating Work Platform

CAUTION It is imperative that all owners and operators ofthe CONDOR® read, understand and conform to these regulations. Ultimate compliance to prevailing OSHA regulations is the RESPONSIBILITY ofthe employer utilizing the equipment.

MANUAL 92361-002 June 1997

RECOMMENDED TOOL LIST The following is a list of tools that you will find helpful when performing service, maintenance or troubleshooting the CONDOR® equipment.

1 each Volt/Ohm Test Meter 1 each Hydraulic Flow Meter, 0-10 GPM 1 each Hydraulic Flow Meter, 0-50 GPM 1 each Hydraulic Quad Meter Pressure Gauge 1 each Battery Hydrometer 1 each Battery Load Tester 1 each 1/2" Drive Torque Wrench, 0-250 ft/lbs 1 each Photo Tachometer (gasoline/diesel engines) 1 each Pry Bar 1 each Strap Type Filter Wrench 1 each Grease Gun 1 each Hammer, 24 oz.

1 each Vice Grip Pliers 1 each Combination Wrench Set, 1/4" to 1-1/2" 1 each 3/8" Drive Socket Set, 1/4" to 3/4" 1 each 1/2" Drive Socket Set, 3/8" to 1-1/2" 1 each Hex Key (allen wrench) Set, up to 1/2" 1 each Screwdriver Set, Phillips Tip & Slot Tip 1 each Punch Set; Drift, Lineup and Straight 1 pair Wire Stripping Pliers 1 pair Wire Crimping Pliers 1 pair Wire Cutting Pliers 1 pair Needle Nose Pliers 2 pair Jumper Wires with Alligator Clips NOTE: This list is not intended to be all inclusive of the tools required to perform every maintenance function that may be required on this specific CONDOR® model. However, these tools will greatly assist in troubleshooting problems and conducting routine maintenance on the equipment.

MANUAL 92361-002 June 1997

Serial Number Location

STAMP ON DATA PLATE

STAMP ON DRIVE AXLE

The CONDOR® Model V2546 Serial Number is stamped in two locations on the machine.

1.

The first place to find the serial number is on the data plate affixed to the chassis, above ground controls.

2.

The second serial number is located at the left rear (drive) axle.

MANUAL 92361-002 June 1997

•

CONTROL DESCRIPTION AND OPERATING PROCEDURE It is important from an operational standpoint that you, the operator, know the function of each control, its limitations, as well as that of the CONDOR®. A good understanding of the controls, limitations and capabilities will enhance operation and assure maximum operating efficiency.

1. PLATFORM CAPACITY

The rated platform capacity of the CONDOR® SCISSOR is unrestricted and is applicable within the operational envelope/positions when operated on a firm level surface. DO NOT overload the platform beyond the RATED CAPACITY. MODEL V2546 PLATFORM CAPACITY 750 lbs.

The platform capacity noted above is the COMBINED WEIGHT of all personnel, their tools and any other equipment or materials carried by the platform. Larger platforms require de-rating the capacity.

Proper stability of the CONDOR® is based and tested on the standard CONDOR® and all of it's components as supplied by Condor Division.

Any modifications of the CONDOR®, either by the addition or removal of parts and/or weight can greatly affect the CONDOR'S® STABILITY. 2. TRAVEL

Travel can be accomplished from both the stowed position or with the platform elevated. Although the gradeability of the CONDOR® is 12 degrees or 21%, this should only be negotiated with the platform in its stowed position. The CONDOR® is designed to travel with the platform elevated on FIRM LEVEL surfaces. The parking brake is spring applied and hydraulically released. This brake releases when the drive circuit is energized.

Maximum travel speed is 2.75 MPH for the MODEL V2546 CONDOR® SCISSORS. This speed is only attained under certain conditions which also result in less drive torque. When the CONDOR® is placed in LOW speed drive torque is increased while drive speed is reduced to approximately one-half of the maximum speed. There is a third or CREEP speed which is automatically activated when the platform deck is raised to or above approximately 7 feet. The drive speed selections are accomplished in two seperate methods dependant upon the date of manufacture.

Driving and steering is done with the control handle in the center of the platform control. Steering is accomplished through a tie rod and hydraulic cylinder arrangement. Although the control handle is momentary and returns to the center position, the steering system itself is not self-centering. Therefore, the control handle direction must be reversed when the turn is completed in order to return to straight line travel.

MANUAL 92361-002 June 1997

CAUTION Prior to making any attempt to operate the CONDOR® SCISSOR, it is essential that the operator be thoroughly familiar with the location and function of each control. The following will assist in accomplishing this required understanding.

3. LOWER CONTROLS The lower controls are located in access holes in the left battery compartment cover (See Figure 1). Driving is not possible from this location.

SOLENOID

FIG.-1

UPPER

UP PUSH TO MOVE

DOWN

CONTROL STATION SELECTOR

OFF LOWER

PUMP MOTOR GEAR PUMP

PUMP SWITCH

UPPER/LOWER SELECTOR SWITCH

UPPER/LOWER SELECTOR SWITCH The lower controls include a three-position rotary switch. With the knob in its center or horizontal position, the CONDOR® is "OFF" and the power is disconnected. Turn the knob clockwise to the "LOWER" position and the electrical circuits are energized for the ground controls only. Turn the knob counterclockwise to the "UPPER" position and the electrical circuits are energized for the platform controls only.

PUMP SWITCH On the same panel there is a two-position, momentary toggle switch. This switch enables RAISING or LOWERING of the scissor arm stack, however the "UPPER/LOWER SELECTOR SWITCH" must be in the "LOWER" position. Pushing the toggle switch UP while raising the lower control valve handle will raise the CONDOR®. Likewise, pushing the toggle switch DOWN while pushing downward on the lower control valve handle will lower the CONDOR®.

LOWER CONTROL VALVE The lower control valve is located inside the left battery compartment cover and is mounted at the end nearest the footsteps. It is a momentary, return to center, lever type controller used to raise or lower the scissor in conjunction with the "PUMP SWITCH". The amount of handle travel from its center position will determine the speed at which the lift function operates.

MANUAL 92361-002 June 1997

4. UPPER CONTROLS The upper controls are located on the right hand side of the top railing at the steering axle end of the CONDOR® (See Figure2), thus giving the best control advantage for the operator. The platform contol box contains controls for the complete operation of the CONDOR®. In order to enable the platform controls, the "UPPER/LOWER SELECTOR SWITCH" at the lower control station must first be placed in the "UPPER" control position. At this point the foot switch must be depressed to allow any ofthe upper control functions to operate.

EMERGENCY STOP BUTTON 110 VOLT OUTLET OPTION

SLOPE ALARM (OPTIONAL)

LIFT HANDLE CONTROL LEVER GUARD

FIG.-2

DRIVE/STEER HANDLE EMERGENCY STOP BUTTON

SELECTOR SPEED SWITC CONTACT BLOCK 2NO

SLOPE ALARM (OPTIONAL)

V NNCONTROL LEVER GUARD 110 VOLT OUTLET OPTION

PUS H T O S TOP PU LLTOOPE RAT E

SELECTOR SPEED SWITCH CONTACT BLOCK 2NO

0

rTh CC W >

LL_U

MANUAL 92361-002 June 1997

EMERGENCY STOP BUTTON At the upper controls is a large red "Emergency Stop Button". This button mut be pulled out to allow the upper controls to operate. Pushing the button IN will only disengage power to the upper controls.

DRIVE AND STEERING CONTROLLER The lever-type four-way controller is momentary and returns to its center position when released.

While depressing the foot switch, moving the handle forward towards the front railing will produce forward travel. Likewise, moving the handle towards the footstep end of the CONDOR® will produce reverse travel. Moving the handle to the left or right of its center line of travel will steer the front wheels left or right respectively. When the handle is returned to center after steering, the wheels will still be pointing in the "steered" direction. They will NOT return to straight line travel. The control handle must be moved to the opposite direction until the wheels are pointing in a straight line of travel, or in the direction necessary. Drive and steering can be accomplished simultaneously by "bumping" the handle to the left or right while traveling. Note: the speed at which the function operates is dependant on the amount of handle travel from its center position.

LIFT - UP/DOWN The upper lift control valve works identical to the lower control valve. The foot switch must be depressed to raise or lower the CONDOR®. Raise the handle upward to lift the platform, push the handle downward to lower the platform.

110 VOLT RECEPTACLE (OPTIONAL) Just to the right of the lift control valve is a 110 VOLT RECEPTACLE outlet. Between the lower control box and the footstep, secured to the chassis, is the male plug end of the 110 Volt line to the platform.

When the CONDOR® will not be driven, this "pigtail" can be connected to an external 110 Volt source, thus supplying voltage to the platform to run small hand tools, lights, etc..

14111111111111

■11111111■1/

CAUTION Prior to the operation of the CONDOR® it is your RESPONSIBILITY to ensure that the CONDOR® is in proper working condition and the PRE-OPERATION INSPECTION has been performed.

OBSERVE ALL PRECAUTIONS WHILE OPERATING THE CONDOR®. Before attempting to operate the CONDOR®, disconnect the external power source from the machine's battery charger.

MANUAL 92361-002 June 1997

Your head and shoulders are above the platform railings. Be sure sufficient OVERHEAD clearance exists before raising the platform. When lowering the platform, make sure the area is clear of personnel and obstructions in the path of the platform.

1. SHUT DOWN/CHARGING At the end of operation, turn the "SELECTOR SWITCH" to the OFF position at the LOWER CONTROLS. If there is to be no further use of the CONDOR® for a period of time, reconnect power source to the battery charger. Batteries must be recharged after each work shift. When the CONDOR® is not being used on a daily basis, the batteries should be charged at least once a week.

2. BRAKE RELEASE/FREE WHEELING The brake is a dry friction disc type and is released by hydraulic pressure (approximately 200psi), which is applied to the piston to compress the internal springs. The brake is self-applying with zero pressure producing maximum torque.

To set the CONDOR® in freewheel mode, close the free wheeling valve located inside the left side battery compartment cover, then energize drive in either FORWARD or REVERSE to produce hydraulic pressure to unlock the brake. This maintains oil in the brake, preventing it from releasing.

WARNING: WITH THE BRAKE LOCKED OPEN, THE CONDOR® CAN ROLL ON UNLEVEL SURFACES. To re-activate the brake to normal operation, simply open the freewheeling valve.

PREVENTIVE MAINTENANCE In conjunction with the PRE-OPERATIONAL INSPECTION, a good preventive maintenance program will enhance a properly operating CONDOR® for those operating and using the equipment. This section of the manual is directed to those items of maintenance of which the operator should be aware of, and which can be accomplished by, or for him/her prior to the operation of the CONDOR®. Refer to the SERVICE MANUAL for a more detailed breakdown and recommended time interval of PREVENTIVE MAINTENANCE.

CAUTION DO NOT perform any maintenance or repair on the CONDOR® unless the arm stand is used to hold the armstack in the elevated position.

1. SERVICE TOOLS See page 4 for the recommended tool list.

2. HYDRAULIC SYSTEM The CONDOR® SCISSOR hydraulics are used to power the various operational functions. As with ANY operational system, it is only as good as it is maintained. This section is offered to alert you and guide you in maintaining the hydraulic system.

MANUAL 92361-002 June 1997

CAUTION One of the major contributors leading to malfunctions in a hydraulic system is CONTAMINATION. Care must be exercised to prevent dirt from entering the system. ALWAYS CAP or PLUG OPEN PORTS AND HYDRAULIC LINES.

A.

FLUID LEVEL — Check daily. Maintain full fluid level with the CONDOR® in the stowed position.

B.

OIL FILTER — Change the return line filter after the first 30 days or 50 hours of operation. Thereafter, change the filter every 3 months or 300 hours of operation.

C.

TANK BREATHER Clean every 50 hours of operation. Remove from tank and clean with solvent. Air blow dry.

D.

HYDRAULIC TANK — Drain oil from tank after every 500 hours of operation or yearly, whichever comes first and replace filter element. Add oil to tank to required level.

CAUTION Use only Shell TELLUS T-32 or Mobil DTE-13M. DO NOT MIX different brands of hydraulic oil. DO NOT MIX hydraulic oil with automatic transmission fluid. It may be necessary to lubricate or service the hydraulic system more frequently when operating the CONDOR® SCISSOR in severe environments, such as dusty conditions.

3. BATTERIES A.

Check electrolyte (water) level in batteries once a week and fill to the proper level using distilled water. CAUTION — Add water only when batteries are fully charged to reduce the possibility of over filling.

B.

Check battery connections for corrosion and condition at least once a week.

C.

Periodically wash the batteries off with clean water to reduce current leakage across a dirty battery surface.

D.

NEVER let the batteries stay completely DISCHARGED. Batteries should be charged at the end of each work day with the charger time set to accomodate overnight charging. A fully charged battery will have an electrolyte specific gravity of 1.265 to 1.285 at an electrolyte temperature of 77 degrees F.

CAUTION Low battery voltage (discharged) requires higher current draw to do the same work. This high current draw WILL DAMAGE the electric motor, relay contacts and the batteries. DO NOT OPERATE the CONDOR® with a battery DISCHARGED or that has a specific gravity of 1.130 or LESS. MANUAL 92361-002 June 1997

0

4. BATTERY CHARGING A.

DO NOT charge batteries unless the electrolyte level has been checked.

B.

Operate charger in accordance with the battery charging instructions.

C.

Make sure the charger INPUT A.C. VOLTAGE is the same as the voltage rating of the battery charger.

D.

Avoid ARCING battery conditions. Protect batteries from sparks or open flame.

E.

Use protective face and eye equipment when checking the condition of charging batteries.

CAUTION Lead acid batteries generate highly explosive hydrogen gas especially during the charging cycle. To AVOID the possibility of an explosion, charge batteries ONLY in a well VENTILATED AREA. Keep fire, sparks and burning material away from the charging area. Do not smoke near a battery, and always shield the eyes when working near a battery.

IMPORTANT

CHECK BATTERY WATER LEVEL AT LEAST ONCE A WEEK

MANUAL 92361-002 June 1997

PREVENTIVE MAINTENANCE INSPECTION EVERY 50 HOURS of OPERATION

CARRIAGE

VISUAL DAMAGE

Inspect for weld cracks, dents or bends

STEERING CYLINDER

Check cylinder and pins holding cylinder in place for proper installation

STEERING TIE RODS

Check pin installation and connections for loose, binding, worn or missing parts

STEERING YOKES

Check installation and connection of pins, bushings and steering stops

WHEELS

Check for loose or missing lug nuts, loose or worn spindles, and damaged or cracked rims

MOTORS & BRAKE

Check motor to brake connection for loose bolts and leaks, check fittings for leaks

HYDRAULIC HOSES

Check for leaks, cuts, abrasions

HYDRAULIC FITTINGS

Check for leaks and tightness

TIRE DAMAGE

Check for wear and cuts

HYDRAULIC TANK

Check for cracked welds, leaks, and check fluid level. At the first 50 hour inspection replace the hydraulic filter.

SLOPE SENSOR (Option)

Check mounting and cable condition

GROUND CONTROL CONSOLE VISIBLE DAMAGE

Inspect for cracks or dents

MOUNTING

Check that all components are in place and secure

WIRING

Inspect for broken insulation, pinched or broken wires, and security of wires. Check all connections for tightness and corrosion

MANUAL 92361-002 June 1997

.

• SWITCHES

Inspect for secure mounting; momentary switches return to normal/off position when released

POWER SOURCE

BATTERIES

Check electrolyte level. Check mounting and security

BATTERY CABLES

Check connections for tightness and corrosion.

Inspect cables for cut or damaged insulation

HYDRAULIC PUMP

Inspect pump for damage. Check mounting bolts and connections to motors, and fittings/ hoses

ELECTRIC MOTOR

Check mounting bolts for tightness, inspect security of components

ELECTRICAL WIRING

Inspect for cracked or broken insulation, check for pinched or damaged wires, ensure good tight connections SCISSOR STACK ASSEMBLY

VISIBLE DAMAGE

Inspect for cracked welds, dents or bends, and structural damage

PIVOT PINS

Check pin installations and retainers

LIFT CYLINDER

Inspect for damage or leaks, check pin installations and retainers. Check security of emergency lowering valve

-

,

MANUAL 92361-002 June 1997

Check routing of hydraulic hoses and electrical cables through the armstack. Inspect for chafing, pinching, broken ties or overly tight routing

HOSE AND CABLE ROUTING

PLATFORM

Inspect for cracked welds, dents or bends, and structural cracks

VISIBLE DAMAGE

i PLATFORM MOUNT

Check platform mounting bolts for tightness

PLATFORM SAFETY CHAIN

Inspect for defects. Check that it latches securely

.

PLATFORM SUB-FLOOR

, Inspect for cracked welds and other structural damage. Inspect plywood floor for cracks or rotting.

PLATFORM CONTROL CONSOLE

VISIBLE DAMAGE

Inspect for cracks and dents

MOUNTING

Check that all bolts are secure and tight

DRIVE CONTROLLER

Check mounting screws for tightness; inspect rubber bellows for damage if equipped; ensure that handle returns to center/neutral position when re leased

SWITCHES

Inspect for security of mounting; check that all momentary switches return to center/off position when released

BATTERY/CONDITION INDICATOR (OPTION)

Check for moisture; inspect for security of mounting, damage, tightness of wiring connections

INTERNAL WIRING

Inspect for cracked or broken insulation, pinched or broken wires; all connections are tight and free of corrosion

ENCLOSURE

Inspect cover seal, ensure cover is firmly secure, and all latching screws are in place

i

MANUAL 92361-002 June 1997

OPERATION FROM LOWER CONTROL STATION

Start Pump And Listen/Observe; Note Any: Unusual noise from motor or pump Unusual noise from hydraulic system Excessive motor/pump vibration Actuate Platform Raise Lever and Observe: Platform raises/lowers smoothly Hydraulic hoses and electrical cables move properly without binding or pinching Actuate Slope Sensor and check for proper operation (Option) Check Motion Alarm for proper operation (Option) Switch returns to center/off position when released There is no damage to chrome on lift cylinder rod Boom stays elevated and does not creep down under its own weight Emergency lowering valve on lift cylinder operates properly OPERATION FROM PLATFORM CONTROL STATION

With the Platform Fully Lowered, Actuate Drive Controller And Be Sure That: Travel starts and stops smoothly Travel speed is truly LOW SPEED Travel Alarm works properly (Option)

Raise the Platform Approximately 6 Inches. Check That: Travel speed automatically switches to HIGH SPEED Travel starts and stops smoothly Travel Alarm works properly (Option) Raise the Platform 6 to 7 Feet. Check That: Travel speed automatically switches to CREEP SPEED Travel starts and stops smoothly Travel Alarm works properly (Option) Actuate The Steering Control Left and Right. Check That: Steering turns freely in both directions Steering turns fully to stops in both directions Steering "Drift" is minimal while driving Repeat All Aerial Function Tests Performed At The Ground Control Station From The Platform Control Station

MANUAL 92361-002 June 1997

0

HYDRAULIC SYSTEM DESCRIPTION

The following is a detailed description of the hydraulic system used on the CONDOR® model V2546 , and how it is designed to operate. To assist in understanding the system, this description should be used in conjunction with the Hydraulic Schematic 55056 which can be found at the end ofthis hydraulic section, see page 23.

GENERAL The hydraulic system of the CONDOR® model V2546 are the open center type, meaning that when the pump is running and the control valves are in the neutral or center position, the oil will flow freely through the entire system and back to the hydraulic reservoir. Additionally, because this is an open center system, the valve nearest the pump will have priority over the other valves. At the upper controls, the steering and drive have priority. For example, if steering or drive were commanded while lifting the platform, the platform would slow down or even stop lifting. The lower control valve only provides lifting and lowering of the platform. Driving or steering cannot be accomplished at the lower controls. The system is designed to operate at a maximum system pressure of 2400 PSI. HYDRAULIC RESERVOIR Located in the chassis on the right side, when viewed from the platform entrance end(See Figure 3), is a hydraulic reservoir having a capacity of5 U.S. gallons. Filtration is provided by a 10 micron spin on canister filter, located in the return line at the hydraulic tank, to filter oil before it returns to the reservoir. The hydraulic fluid is Shell Tellus T-32, or Mobil DTE-13M. Only these fluids, or their equivalents should be used. DO NOT MIX HYDRAULIC FLUIDS.

PUMP/MOTOR

RETURN FILTER

FIG.-3

HYDRAULIC RESERVOIR

MANUAL 92361-002 June 1997

The hydraulic pump used on these models is a Gear Type pump which draws fluid directly from the hydraulic reservoir, and discharges oil at a fixed, constant flow rate of 4.26 GPM. Powering the pump is a 36 volt DC motor rated at 6 HP at 2500 RPM. The pump/motor assembly is mounted to the chassis base near the lower control valve, on the left side of the CONDOR® (See Figure 4).

FIG.-4

LOWER CONTROL VALVE The lower control valve is of the closed center working port, open center pressure port, manually operated directional control type. Having a closed center working port means that the ports are blocked when the spool is in its center or neutral position. This assists, but is not the only means used, in holding the lift cylinder in the desired position. An open center pressure port means the oil flows directly through the valve when the spool is in its center or neutral position. Function speed can be controlled by the amount of handle movement. The lower control valve is located on the inside wall of the chassis compartment nearest the left rear wheel (See Figure 5). It also contains a system relief valve which is adjusted to 2400 PSI to protect the system components.

FREE WHEELING VALVE

SHUTTLE VALVE SYSTEM RELIEF VALVE (2400 PSI)

FIG.-5 CONTROL VALVE HANDLE

LOWER CONTROL VALVE

MANUAL 92361-002 June 1997

UPPER CONTROL VALVE The upper control valve is mounted at the front right hand corner of the platform(See Fig.6). This valve manipulates three functions, lift, steer and drive, with the lift and steering sections being identical in operation to the lower control valve. The difference in the drive section lies in the working ports. The drive uses a motor spool instead of a closed center working port. This allows the working ports to flow back to the reservoir, thus reducing dynamic shock in the drive circuit.

EMERGENCY STOP BUTTON 110 VOLT OUTLET (OPTION) CONTROL LEVER GUARD LIFT HANDLE EMERGENCY STOP BUTTON

SLOPE ALARM OPTION

FIG.-6

DRIVE/STEER HANDLE

LIFT HANDLE SPEED SELECTOR SWITCH

MICRO-SWITCH MOUNTED INSIDE BOX ASSEMBLY

110 VOLT OUTLET (OPTION)

CONTROL LEVER GUARD

110 VOLT OUTLET (OPTION)

STEERING SYSTEM When the foot switch is depressed, the pump motor turns on, thus pumping oil through the lower control valve to the upper control valve and then returning to the reservoir. With the pump running, the drive/steer control handle can be moved to the left or right from its vertical position to direct oil to the steering base end for left, and oil to the rod end for right. Once the wheels are in the desired direction, the cylinder becomes "locked" by the closed center working ports of the upper control valve, and therefore cylinder drifting is prevented. Steering can not be accomplished at the lower controls.

LIFT SYSTEM The lift system can be accomplished at both control locations. To lift the platform from the ground, push the lift toggle switch to the "UP" position to turn the pump on, then raise the lower control valve handle.

To lower the platform, push the lift toggle switch to the "DOWN" position to open the holding valve, then push the valve handle downward to let oil in the cylinder flow back to the reservoir. To operate lift from the platform, depress the foot switch to turn the pump on, then raise the lift handle. To lower the platform, depress the foot switch and push the lift handle downward. When the handle is pushed downward the pump turns off and the holding valve opens. Further handle movement allows oil to flow from the cylinder through the control valve spool and back to the reservoir. These electrical functions are accomplished by a micro-switch which is activated by the upper lift handle downward movement (see Fig 6).

MANUAL 92361-002 June 1997

HOLDING VALVE The primary means of maintaining the platform in any position other than stowed is employed by a solenoid operated/manual override control valve, or holding valve, located at the cylinder base port (See Figure 7). This valve allows oil to flow unrestricted to the cylinder and becomes closed or "locked" when oil tries to flow out of the cylinder. Lowering the platform requires oil to pass back through this holding valve. This is accomplished by applying 24 volts to the solenoid via the upper control lift handle, or the lower control lift toggle switch. The holding valve can be manually opened in the event the solenoid/ electrical system becomes inoperative. To lower,depress and turn the small red knob on the holding valve counter-clockwise then push the lower control valve handle downward. To reset the holding valve push the red knob "in" and turn clockwise.

FIG.-7

LIFT CYLINDER HOLDING VALVE

BRAKE SYSTEM

MANUAL RELEASE

BRAKE HYDRAULIC LINE

Located on the left rear wheel is a dry friction disc brake that is spring applied and hydraulically released(See Fig 7). The wheel hub is mounted directly to the brake shaft. Brake activation is accomplished by a drive pressure "signal" produced when drive is commanded. To receive a "signal" regardless of drive direction, a shuttle valve is employed in the drive circuit. The shuttle valve is located on the inside compartment wall near the lower control valve(See Fig.5), and allows oil to flow from its center port in both forward or reverse drive. Hydraulic pressure from the shuttle valve flows directly to the brake assembly and unlocks the brake at approximately 200 PSI. In the brake circuit is an adjustable check/choke valve otherwise referred to as a "free-wheeling" valve(See Fig 5). Its function is to provide a means for adjusting the rate at which the brake applies. Turning the thumb wheel clockwise will restrict the oil flow from the brake when released thus reducing the amount of shock the brake receives from applying while the CONDOR® is still rolling. To activate the free-wheeling mode, turn the thumb wheel fully clockwise and energize drive for about 3' of travel. This maintains the brake in its pressurized or unlocked state and allows the CONDOR® to be pushed or towed. To return the brake to normal operation, turn the thumb wheel counter-clockwise to release the brake. In addition to the free-wheeling valve, there is also a normally open pressure switch in the brake circuit to sense brake pressure and activate the travel alarm (option) through a dedicated electrical circuit.

MANUAL 92361-002 June 1997

DRIVE SYSTEM This section will cover both types of drive systems, mainly pertaining to the speed control selection methods --- electric over hydraulic for current production models. The electric over hydraulic system utilizes a rotary speed selector switch at the upper controls for operator control of the Series/Parallel Valve located in the center of the chassis. The mechanical method, however, relies upon the position of the platform. Fully stowed, the armstack depresses a plunger on the transmission valve (See Figure 8) which therefore places the drive system into LOW speed. Raising the platform up a few inches allows the plunger to release thus changing the drive system to HIGH speed.

LOW speed is a situation whereas the hydraulic fluid is directed to both drive motors at the same time and providing a LOW speed/high torque drive condition. This condition provides the best gradeability.

HIGH speed, on the other hand, is a condition whereas the hydraulic fluid is first directed to one drive motor, back to the manifold, then on to the second drive motor. This condition provides a faster drive speed but at the expense of reduced gradeability and is best suited for travel on level surfaces. LOW drive speed is commonly referred to as "Parallel Drive" while HIGH drive speed is commonly called "Series Drive".

The V2546 drive motors each have an 18.9 cubic inch per revolution displacement. The left and right motors, in both applications, are not identical due to differences in the output shafts. The left motor shaft is splined for mounting to the brake assembly while the right motor utilizes a tapered shaft for direct wheel hub mounting.

FIG.-8 PLUNGER

7/

SERIES/PARALLEL VALVE FLOW DIVIDER/COMBINER

M3

M1

TRANSMISSION VALVE

M2

MANUAL 92361-002 June 1997

CREEP VALVE The CONDOROV2546 model utilizes a creep speed valve to limit the amount of drive speed and drive torque at platform heights above approximately 7 feet. The current production machines activate creep speed by means ofa limit switch, located just above the battery charger, (See Figure 10) and an electrically operated solenoid valve, located next to the lower control valve. Previous machines (Serial Nos. 3899 and below) utilized a mechanical valve system (See Figure 9). The two systems basically perform the same function which is to allow some of the drive pressure (hydraulic fluid) to be directed back to the reservoir when the platform is at a height of 7 feet or above. In the electric over hydraulic system the armstack actuates a limit switch which, in turn, operates the creep valve. The same goal is achieved with the mechanical system. The armstack manually depresses or releases a plunger on the creep valve. Either creep valve bypasses drive fluid back to tank. The amount of fluid returning to tank is determined by an orifice installed in one of the fittings of the creep valve and is therefore non-adjustable.

PLUNGER CREEP VALVE

FIG.-9

FIG.-10

Limit Switch

MANUAL 92361-002 June 1997

MDL3146: MOTOR 18.9 CIPR 54754-001

UPPER CONTROL VALVE 315-00034-00

TRAVEL ALARM OPTION 54371

MDL3154: MOTOR 29.1 TIPS 321-00005-00 D606 S703

S703

BRAKE 126-10005-00

0703

X

52661

S703

0703

B

54477

B2 A2 61

Al 0703

M3 0606

PB

STEER CYL. 162-96440— 00 BORE: 1.5 ROD: .75 STROKE: 5.25

5703

7

A

21479—SEE NOTE 3

21481

LIFT CYL 162-96443-00 BORE: 6.0 ROD: 2.50 STROKE: 21.75

D606

0704 MAN

TRANSMISSION VALVE

Mff r1 DIA

315-00027—TO

D606

MDL3146: MOTOR 18.9 CIPR 54754-002

D606

.106

S704 52733

MDL3154: MOTOR 29.1 CIPR 321-00002-00

MOTOR M 322-00015-00 2500 RPM

394

HYD. FILTER 33430

D606

0606

P

r-

1

PUMP 54286-394

LOWER CONTROL VALVE 315-00036-00

2400 PSI

SERIAL #3900 AND ABOVE

HYDRAULIC TANK 020—R0060-00

nii,...

PRas 0PDER,IE.TADERTYA„INDF.,040N MA s. TTI.OENRAN,E, AND

NOTES: 1. THIS SCHEMATIC SUPERCEDES 54995.

2. THIS SCHEMATIC REFLECTS IMPROVED "CREEP" PERFORMANCE. 3. ADJUST CREEP SPEED TO 80-100 SEC/88 FEET, ON FIRM, LEVEL GROUND (REF. .75/.6 MPH).

4. LINE SIZES SHOWN ARE MIN I.D. FOR HYD HOSE.

:scc'ArtzRAR,,ex,rozz c4-411zTuit=tnircv(A)Rw.A.. ...„ RESERVED

WACO, TEXAS TI TLE

UNLESS OTHERWISPECIFIED: ES DIMENSIONS ARE IN INCHES

TOLERANCES ON:

A 8209

LTR. E.C.N. NO. DATE APPR. DRAWN -

5351

4/25/95

RAK

SCHEMATIC, 3146/54 HYDRAULIC

E:Tio

WHITTLE

04/05/95

B .,ZE

()RA.'

CHECKED

LTR. E.R.N. NO. DATE APPR. APPROVED

RAK _04/07/95 SCALE

FULL

NO.

REV A

55 056 SHEET 1

OF 1

•

ELECTRICAL SYSTEM DESCRIPTION The following is a detailed description ofthe electrical system used on the CONDOR® model V2546, and how it is designed to operate. To assist in understanding the system, this description should be used in conjunction with the Electrical Schematics 54355, 54996,55060 and diagrams 54356,55062 which can be found at the end of this electrical section, see pages 31 thru 36.

GENERAL The electrical system ofthe CONDOR® model V2546 is a 36 Volt D.C. (Direct Current) negative ground system, which is made up of six, 6 Volt Deep Cycle batteries connected in series to each other. The pump motor, optional low volt interrupt (LVI) and the optional battery condition indicator are the only circuits operating on the full 36 Volt battery source while all other electrical circuits use only 24 Volts and are isolated from the batteries by a 10 Amp circuit breaker. The 24 Volt supply is achieved by using the same negative ground and by making the positive lead connection at the positive terminal ofthe fourth battery's positive terminal. This separate "grouping" of batteries, although they are still in the 36 Volt "total" system, yields the necessary 24 Volts to power other machine functions which have a 24 Volt maximum capacity.

BATTERIES The batteries have a 250 Amp hour capacity and are located on the chassis plate closest to the steering axle with three batteries on each side ofthe machine (See Fig 11). They are filled with electrolyte and have a "wet" weight of 78 lbs each. If filling is needed during routine maintenance, distilled water can be used to bring the level up to the indicator in all cells. DO NOT OVERFILL ANY CELL. BATTERY CHARGER The battery charger has a 36 Volt, 40 Amp maximum output, and operates on a 115 Volt A.C. (Alternating Current)input. The charger is located on the right side chassis base nearest the fixed axle (See Fig 11).

A more detailed description of the charger is covered in the Battery Charger Troubleshooting Guide on page 44.

FIG-11

BATTER CHARGER

BATTERY

MANUAL 92361-002 June 1997

MDL3146: MOTOR

18.9 CIPR 54754-001

UPPER CONTROL VALVE 315-00034-00

TRAVEL ALARM

MDL3154: MOTOR 29.1 CIPR 321-00005-00

OPTION 54371

D606 5703

S703

BRAKE 126-10005-00

P

5703

X

52661

S703

5703

B3

54477

B

A2 B1

S703

M3 D606 M4

Al

PB

0606

D606 M2

STEER CYL. 162-96440-00 BORE: 1.5 ROD: .75 STROKE: 5.25

S703

;./• .). ," 21479-SEE / NOTE 3

- 21481

LIFT CYL 162-96443-00 BORE: 6.0 ROD: 2.50 STROKE: 21.75

D606

D606 M1

5704

MAN

TRANSMISSION VALVE 315-00027-00 D606

MDL3146: MOTOR 18.9 CIPR 54754-002

D606

S704 52733

8

MDL3154: MOTOR 29.1 CIPR 321-00002-00

MD`

DIA .106

OMOTOR 322-00015-00 2500 RPM

) 4

D606

0606

P

r- HYD. FILTER 33430

PUMP 54286-394

2400 PSI

1

LOWER CONTROL VALVE 315-00036-00

SERIAL #3900 AND ABOVE

HYDRAULIC TANK 020-R0060-00

PROPRIETARY INFORMATION THIS DRAWING ITS DESIGN, DElAIL, DIMENSONS,E TOLERANCES ENO

NOTES: 1.

2.

3, 4.

THIS SCHEMATIC SUPERCEDES 54995.

THIS SCHEMATIC REFLECTS IMPROVED "CREEP" PERFORMANCE. ADJUST CREEP SPEED TO 80-100 SEC/88 FEET, ON FIRM, LEVEL GROUND (REF. .75/.6 MPH).

LINE SIZES SHOWN ARE MIN I.D. FOR HYD HOSE.

frodlleM

DO' F CrAaRARCEINTORCATIOrA: IrArNMEIA:::'PRZUC7D7i

WACO, TEXAS

VIVIZORNZirCSATAIPARIORMPNA."AINcrTils

c'IXF'" RESEW.

UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN INC,HES TOLERANCES ON: :v.; ETA

L11-2. E.C.N. NO. DATE APPR. DRAWN

- 5351 4/25/95 RAK

A.HITTLE

SCHEMATIC, 3146/54 HYDRAULIC

FRVANAL

A 8209 04/05/95

sizE B

DRAWING NA. 5

CHECKED

LTR. E.R.N. NO. DATE APPR. APPROVED

RAK 04/07/9s scALE FULL

RE,

5056

I

SHEET 1

A

OF 1

ELECTRICAL SYSTEM DESCRIPTION The following is a detailed description ofthe electrical system used on the CONDOR® model V2546, and how it is designed to operate. To assist in understanding the system, this description should be used in conjunction with the Electrical Schematics 54355, 54996,55060 and diagrams 54356,55062 which can be found at the end of this electrical section, see pages 31 thru 36.

GENERAL The electrical system ofthe CONDOR® model V2546 is a 36 Volt D.C. (Direct Current) negative ground system, which is made up of six, 6 Volt Deep Cycle batteries connected in series to each other. The pump motor, optional low volt interrupt (LVI) and the optional battery condition indicator are the only circuits operating on the full 36 Volt battery source while all other electrical circuits use only 24 Volts and are isolated from the batteries by a 10 Amp circuit breaker. The 24 Volt supply is achieved by using the same negative ground and by making the positive lead connection at the positive terminal ofthe fourth battery's positive terminal. This separate "grouping" of batteries, although they are still in the 36 Volt "total" system, yields the necessary 24 Volts to power other machine functions which have a 24 Volt maximum capacity.

BATTERIES The batteries have a 250 Amp hour capacity and are located on the chassis plate closest to the steering axle with three batteries on each side ofthe machine (See Fig 11). They are filled with electrolyte and have a "wet" weight of 78 lbs each. If filling is needed during routine maintenance, distilled water can be used to bring the level up to the indicator in all cells. DO NOT OVERFILL ANY CELL. BATTERY CHARGER The battery charger has a 36 Volt, 40 Amp maximum output, and operates on a 115 Volt A.C. (Alternating Current)input. The charger is located on the right side chassis base nearest the fixed axle (See Fig 11).

A more detailed description of the charger is covered in the Battery Charger Troubleshooting Guide on page 44.

FIG-11

BATTER CHARGER

BATTERY

MANUAL 92361-002 June 1997

SLOPE SENSOR (OPTION) The optional slope sensor system consists of a multi-axis level sensor, a slope alarm (or buzzer)(See Fig 13), and a limit switch. The system's purpose is to notify the operator of an out of level condition by means of sounding an alarm. The functions are NOT inhibited during an out of level condition which allows the operator to reverse the direction of travel to bring the CONDOR® back to a level condition. The sensor is mounted on the chassis plate and is adjusted to "level" when the chassis is on a level surface, and the alarm is mounted at the upper controls. The sensor is supplied a 24 Volt signal once the platform is raised above six feet, which is determined by the limit switch, which is located under the arm stack near the transmission valve in such a manner that the arm stack will activate (open) the switch upon lowering of the platform. When the CONDOR® is driven to an out of level condition of 5 degrees or more, the sensor turns on and grounds the alarm completing its circuit and activating it. When the platform is below six feet or stowed, the limit switch opens, disconnecting power to the sensor and disabling the system. This allows loading and unloading of the unit using ramps that exceed 5 degrees. The sensor is attached to its mounting plate with three spring loaded studs. This permits testing of the system by raising the platform above six feet and pressing on the sensor (against the spring tension) to put it at a 5 degree or more out of level condition to verify that the alarm will sound.

110 VOLT RECEPTACLE IN PLATFORM (OPTION) The CONDOR® V2546 can be equipped with a 110 Volt A.C. receptacle at the upper control station for powering small electric hand tools, lights, etc.(See Fig 12). The male plug end is located on the chassis and is intended to be connected to a suitable A.C. power supply. This addition allows electric tool use at various heights without danger of hanging cords from the platform. While lifting/lowering of the CONDOR® is permissible, driving of the CONDOR® while the supply line is connected to the chassis is not recommended to prevent damage to the cord or components.

BATTERY CONDITION INDICATOR (OPTION) The optional battery condition indicator is located at the upper control station(See Fig 13) and measures the voltage of the 36 Volt system providing a "state of charge" reading for the operator. This indicator is connected directly to the batteries and is not "switchable" since its amp draw is relatively low and not a concern for battery drain.

EMERGENCY STOP BUTTON

FIG-13

110 VOLT OUTLET(OPTION) LIFT HANDLE CONTROL LEVER GUARD DRIVE/STEER HANDLE

SLOPE ALARM OPTION

EMERGENCY ,STOP BUTTO

-1 I

Li

LIFT HANDLE SPEED SELECTOR SWITCH

O BATTERY CONDITION INDICATOR OPTION CONTROL LEVER GUARD 110 VOLT OUTLET(OPTION) MANUAL 92361-002 June 1997

110 VOLT OUTLET(OPTION)

FUSES/CIRCUIT BREAKERS

The CONDOR® V2546 are equipped with a 20 Amp 32 Volt in-line fuse in the 24 VDC "tap" circuit thus protecting all of the 24 Volt circuits from damage. The optional battery condition indicator, Low Voltage Interrupt (LVI) module, and LVI override circuits are protected by a 3 Amp circuit breaker, located near the LVI, which is only added when these options are installed. The 110 Volt line to platform option includes a 15 Amp circuit breaker, located at the upper controls. The circuit breakers are the manual reset type and must be pushed in to reset once tripped, while the fuse must be replaced once it has blown.

MANUAL 92361-002 June 1997

"---

BEACON/STROBE OPTION

I D

II EMERGENCY STOP

R3- A

97,

,I717

R3- B CHARGING LIGHT

0

SWITCH

RD

3

0

•

>1

o-,1,-o

• PLATFORM LOWERING

c-1,-o

• SEE NOTE 3

1 HORN 1

•

oi SEE NOTE 5 cx,...

MOTOR • HYD PUMP

RED

BLK

•

I

RED 5. BLK

•

• SLOPE SENSOR OPTION

LOW VOLT SENSOR

SEE NOTE 4

GRN

-__:-- 115 VAC PLUG

WHT • LOW VOLT WARNING . 36VDC CONTROL RELAY COIL FOR OPTIONS

R2

SEE NOTE 6 cr

0

0 ® LOW VOLT OVERRIDE

SEE NOTE 4

•

CONDITION INDICATOR

SEE NOTE 4

_1_ SLOPE ALARM OPTION

• OPTIONAL BATTERY

"FUEL" GAGE

• DESCEND ALARM OPTION

0

WHT

I

HORN 1

BATTERY CHARGER

TA CIRCUIT BREAKER

SEE NOTE 2

HORN 1

•

•

R2 0

• BATTERY 36 VDC

NEC

• PLATFORM RAISING

-• MOTION ALARM OPTION •--->1—•--1 HORN EMERGENCY STOP

111111111111111W

II

R1

SEE NOTE 4

"UP"

' "DOWN"

•

P05

0

LOWER

GROUND

+24VDC TAP

•• HOUR METER OPTION TION

, 3-POS b ROTARY c, Ld a_ a_ D

20A ..•.., CIRCUIT BREAKER

•

BLK

0

OPTIONAL CHARGING

CUT-OUT RELAY COIL

• TRAVEL ALARM OPTION 7,-- GROUND

NOTES: 1. THIS SCHEMATIC IS STANDARD FOR MDL3146, MDL3154, AND MDL3160 SCISSOR LIFTS. REFER TO DIAGRAM 54356.

2. SWITCH ACTIVATED BY VALVE LEVER IN PLATFORM. 3 SECOND HOLDING VALVE, ON MDL3160 ONLY. 4.

1 THRU 0 REPRESENT TERMINALS OF OPTIONAL LOW VOLTAGE WARNING/INTERRUPT SENSOR/SWITCH. 5. LIFT LIMIT SWITCH IS SHOWN WITH PLATFORM ALL THE WAY DOWN. 6. PRESSURE SWITCH SENSES BRAKE RELEASE PRESSURE.

SERIAL #3799 AND BELOW PROPRIETARY INFORMATION MOS DRAMANG ITS DESICNIETAIL DIMSICAMS.E TOLERANCES AND IIB,CFSZA,CIRI WACO, TEXAS n.'-'01S6 ""ATZ:DIZ:w4A,M= D 6846 re7R,I,A=TrAreWag.= TI TLE RESEINED. 3/28/95 R AK 7888 C uwasS OTHERWISESPECIFIED: IT SCHEMATIC 3146/60 , ELECTRICAL .71-1Es .4.. .N . ARE 6/15/94 RAK ToLERA 0 B 6691 Nc•E, ; In rftViANAL 7/9/93 RAK 5547 A REV. L TR. E.C.N. NO. DATE APPR. DRAWN J. CARMICAL 6/30/93 SAE DRAWING NT. 3998 — 7/6/93 RAK CHECKED L TR. E.R.N. NO. DATE APPR. APPROVED SCALE i/1.5 RAK 7/6/93 I SHEET 1 OF 1

, xi.:1, 0

B

54.355

D

1

BEACON/STROBE OPTION EMERGENCY STOP

R3-A 2A

1--•-----

III

2B

Oro

2A

R3-B

1

20 A

GROUND I

+24VDC Tap

,C-

3, FUSE

CHARGING LIGHT OPTION POS

2 3-POS L•

11

HOUR METER OPTION

SWITCH

CC

1.,

0

SEE NOTE 4

"UP"

LOWER

•

' DOWN"

7

•

RED

• PLATFORM LOWERING • MOTION ALARM OPTION

HORN

• HYD PUMP

1

PLATFORM RAISING

0-1,-0 7A

MOTOR

5

6A 3 R1

4

0._

36 VDC • BATTERY

R1

ROTARY

•

NEG

1

BLK

BATTERY CHARGER

• 3A CIRCUIT BREAKER

EMERGENCY

0(.5 STOP 70 3A

N

• p — —

—

7A 5A

—I

°c)-> 7 SEE NOTE 2]

HORN

HORN 1

o--1,--o

R2

SEE NOTE 4 G.) 0 13

SEE NOTE 3 3 • •

4111

0

5B

SLOPE ALARM OPTION

1 RED . BLK

15

• .

SLOPE SENSOR OPTION

GRN

----- 115 VAC PLUG

BLK

RELAY FOR 36V OPTIONS BLK

• LOW VOLT ALARM OPTION

0

HORN 1 • TRAVEL ALARM OPTION

SERIAL #3800 TO #3899 PROPRIETARY IN THIS DRArANC ITS DES.. DETAIL °DAMON, TOLERANCES AND

niAmmilara =r.Atry 7,,"

NOTES: THIS SCHEMATIC IS STANDARD FOR MDL3146 & MDL3154.

SWITCH ACTIVATED BY VALVE LEVER IN PLATFORM. PRESSURE SWITCH SENSES BRAKE RELEASE PRESSURE. 0 THRU 0 REPRESENT TERMINALS OF OPTIONAL LOW VOLTAGE WARNING/INTERRUPT SENSOR/SWITCH.

OPTIONAL CHARGING CUT-OUT RELAY

WHT

--.7.,-. GROUND 1.

2.

3.

4.

LOW VOLT SENSOR

, SEE NOTE 4 L5,) LOW VOLT OVERRIDE

WHT

1•

OPTIONAL BATTERY CONDITION INDICATOR

SEE NOTE 4

CREEP SPEED

WHT

3

3

• DESCEND ALARM OPTION

•

"FUEL" GAGE

,

5B

8A o—c5 3

1

rAV:Z,Vgin:ialAgRANCORVglimmiril; RESERVED.

1,,27,Z,.n;`,InN7Or

, 113(..p.

WACO, TEXAS

TITLE

SCHEMATIC, 3146 ELECTRICAL

TOLERANCES ON: lg.); icy.TE FRTANA,

LTR.

E.C.N. NO.

DATE

APPR.

LTR.

E.R.N. NO.

DRAWN JUDY LANSFORD CHECKED

5238 DATE

APPR.

APPROVED

1/27/95

SIZE DRAWING NO.

B 54996 SCALE FULL

I SHEET 1 OF 1

REV.

SEE NOTE 5 0 TRAVEL ALARM OPTION

PLATFORM

GROuND GROUND OROUND

K

SEE NOTE 2 WHT BLK

.5• SLOPE

D WHT

SPARE

C

uPPER

0

SEE NOTE 1

SPARE

RED

EMERGENCY STOP

OVERRIDE LOW VOLT

OPTION

oc000cal

SLOPE

I SENSOR HOUR METER OPTION

OPTIONAL LOW VOLT WARNING/ INTERRUPT

BLK

RED

UPPER DOwH

PU P

ORN BLU

SEE NOTE 4 0±0 WHT

BLK

FOOT

HOLD VALVE

RUT

ce

DESCEND WARNING OPTION

0

"UP"

CIRCUIT BREAKER

UPPER

R.3 RELAY

0 LOWER "DOWN"

BE

tr)

\STROBE

IL

CONTACTOR R1

SIC

OPTIONAL CHARGING CUT—OUT EMERGENCY 111111 STOP 10A

OPTION

+24VDC TAP

CIRCUIT BREAKER RED

0 6V

BATTERY CHARGER

0

d

6V

0

0

6V

0

0

6V

0

6V

0

6V

0

BLK 0

SERIAL #3799 AND BELOW NOTES:

1. SWITCH ACTIVATED BY VALVE LEVER. 2. LIFT LIMIT SWITCH SHOWN WITH PLATFORM ALL THE WAY DOWN. 3. THIS DIAGRAM IS STANDARD FOR MODELS 3146, 3154 & 3160.

REFER TO SCHEMATIC 54355.

4. ONE VALVE COIL SHOWN FOR MDL3146 & MDL3154; MDL3160 HAS TWO HOLDING VALVES, 5. PRESSURE SWITCH SENSES BRAKE RELEASE PRESSURE.

PROPRIETARY INFORMATION THIS DRAWING ITS DESIGN, DETAIL, DIMENSIONS, TOLERANCES AND

TIEZ: i'sf,c,,,I.u ,TorKA cfco'.=,Proc'; TO NIIHOUT Of

OD'F fYLTaRARE(NiP"OR(■:\ TRAE CCPIED IN ANY MANNER NOR DISaosto ANY OUTSCE PARTY 111E PRIOR WRITTEN CONSENT CALAVAR CORPORATION. ALL RIGHTS RESER ,.

UNLESS OTHERWISE SPECIFIED: DIMENSiONS ARE iN INCHES

B

6691

A

5547

7/9/93

RAK

LTR.

E.C.N. NO.

DATE

APPR.

DRAWN

RAK

CHECKED

APPR.

APPROVED

— 3998 7/6 /93 LTR. E.R.N. NO. DATE

CMGIOGL.ERSYGODU

WACO, TEXAS

TITLE

DIAGRAM, 3146/60 ELECTRICAL

TOLERANCES ON: ANGLE DECIMALS FRACTIONAL

J. CARMICAL

6/30 /93

SIZE

DRAWING NO

C

RAK 7/6/93 SCALE FULL

REV .

54356 I SHEET

1 OF 1

CABLE BETWEEN UPPER & LOWER CONTROLS #

41

11=BLU/BLK

EMERGENCY STOP SWITCH SEE NOTE 2 LOWERING SWITCH SEE NOTE 2

3 4

Ak

0 3-RED

A 20 21 19

8=RED/BLK

0

GAGE

5A = WH T

BATTERY CONDITION INDICATOR OPTION SLOPE ALARM OPTION

1= GRN

• =GRN/BLK

FOOT SWITCH

7= WH T/BLK

3A=BLK

BLK

4=BLK

A =ORN

2= WH T

SPEED LIMIT SWITCH

ORN BLU

UP (PUMP "ON")

7

WHT/BLK

DOWN (HOLD VALVES)

8

RED/BLK

B 10

GRN/BLK ORN/BLK

SPARE, OR GAGE OPTION SLOPE ALARM OPTION

11

BLU/BLK

12

BLK/WHT

14

WHT

15 16 17

BLK GRN

LOW VOLT O'RIDE OPTION LOW VOLT ALARM OPTION

STROBE LIGHT OPTION

HON

Ct<( SLOW/FAST .)

ROT SWITCH 56 54247-42

/1

1.00 EA

1.00

55 54247-62.5 54247-14.75 54247-47.5

41

• • • •

CONTROL CABLE TO TERMINAL BOARD ON CHASSIS /

2

GRN WHT

RED BLK ORN

3 4 5

BLU 6 WHT/BLK 7 RED/BLK 8 GRN/BLK 9 ORN/BLK 10 BLU/BLK 1 BLK/WHT 1 2

CABLE ASSY, 15 1/8" BATTERY CABLE ASSY, 62 1/2" BATTERY

EA

CABLE ASSY, 19 3/4" BATTERY

1.00 EA

CABLE ASSY, 75 1/2" BATTERY

1.00 EA

CABLE ASSY, 37 1/2" BATTERY

1.00

CABLE ASSY, 47 1/2" BATTERY

54247-37.5 53 54247-47.5

CABLE ASSY, 42" BATTERY

EA 1.00 EA

1.00

54 54247-75.5

SEE NOTE 3

2

*

NOT USED NEUTRAL LIVE (HOT) GROUND POWER TO LOWER CONTROLS

54247-15.12

GRN WHT

*

SIGNAL (HORN/SWITCH) OPTION

18

10=ORN/BLK

5A= WH T

POWER TO UPPER CONTROLS CREEP (SWITCH/VALVE)

13

CB)

*

SPARE, OR GROUND FOR OPTIONS FAST (S-P VALVES)

WHT RED

5 6

=BLU

1 H/1, 1 V2:11 (13 N =t7

0

12=BLK/WHT

GRN

2

OPTIONAL LOW VOLT O'RIDE

DESCRIPTION OF CIRCUIT

COLOR

1

SIGNAL HORN OPTION

1.00

EA

CABLE ASSY, 47 1/2" BATTERY

52 54247-5.75

1.00

1.00 EA

CABLE ASSY, 5 3/4" BATTERY

51 54247-6.5

5.00

5.00 EA

CABLE ASSY 6 1/2" BATTERY

41

REF

REF

110 VOLT EXT OPTION

1.00

1.00 EA

RED B N BLU WHT/BLK

23 55062

41

RED/BLK GRN/BLK ORN/BLK BLU/BLK BLK/WHT

CONTINUED ON SHEET 2 lEaLT-1124 WHT BLK 15 GRN GRN 16

OPTIONAL 110 VOLT EXTENSION CORD

15=LIVE=BLK 16= GROUND=GRN

22 55062-002 55062-001 21 67295-004 20 36084 36083 18 34552-016 17 67295-035 16 50089 15 67123-001 14 67114-002

14=NEUTRAL=WHT

ram

TERM IN STRIP ON 9 TOEBOARD OF PLTFRM

SEE NOTE 3 {

3

5.00 1.00 1.00 1.00

5.00 1.00 EA 1.00 EA 1.00 EA

CABLE KIT, 3160 BATTERY

3.41

CABLE, 16GAGE/2 CONDUCTOR SJO GUARD, FOOT SWITCH SWITCH, FOOT STRIP, TERMINAL

3.41 LF 1.00 EA

CABLE, 16GAGE/8 CONDUCTOR SJO

1.00 1.00

1.00 EA

SEAL, CONNECTOR ELECT 1/2"

1.00

1.00 EA

STRAIN RELIEF 1/2 NPT .25/.:58

FUSE HOLDER

1.00

1.00 EA

1.00

1.00

11 51036

1.00

10 34552-012

1.00 1.00 1.00 1.00

EA 1.00 EA 1.00 EA 1.00 EA 1.00 EA

MOTOR ELECTRIC BALDOR 36V

1.00

1.00 EA

SOLENOID 24V

5 52029

EA

1.00

1.00

EA

1.00

ARM ADJUSTABLE LIMIT SWITCH OFFSET HEAD LIMIT SWITCH SWITCH LIMIT BODY ONLY STRIP, TERMINAL GUARD TOGGLE SWITCH MICRO SWITCH (REF P/N 67760)

BASE +2 NO CONTACTS ZE32-8Z103

4 52670

1.00

1.00

EA

OPERATOR, 3POS ROT Z62-803

3 121-00004-00 67295-023 2 67295-023

6.00

6.00

EA

BATTERY, 6V TROJAN J250-UT CABLE, 6GA/8 CONDUCTOR CABLE, 16GA/8 CONDUCTOR

1 34037 ITEM PART NUMBER

60.00

1.00 OTT

65.00 LF LF 1.00 EA QTY

xtutrnPaT,AR Y I R MiRANzi

NOTES: 1. THIS DIAGRAM SUPERCEDES 54:556.

2. LOWERING SWITCH AND EMERGENCY STOP SWITCH ARE PART OF UPPER CONTROL BOX ASSY, 3. ITEM 22 CONSISTS OF ITEMS 51- 56.

WIRING DWG, 3146/60 ELECTRICAL CABLE KIT, 3146 BATTERY

13 51039 12 51037

9 40880 8 50075 7 322-00015-00 6 52138

SERIAL #3900 AND ABOVE

1.00 EA 1.00

CHARGER, BATTERY 36VDC/40A DESCRIPTION

110 =14

WACO, TEXAS

Vlor.‘1,7,1 m.

WIRING DWG, 3146/60 ELECTRICAL IgS1WAVER=T

8280

RAK

TOLERANCES ON:

A

8198

06/27/95

LTR.

E.C.N. NO.

DATE

APPR. DRAWN

LTR.

E.R.N. NO.

DATE

APPR. APPROVED

5351

CHECKED

r=m.

A.HITTLE 04/06/R5

DRAWING NO

C

REV

55062

SCALE NONE

I SHEET 1

OF 2

B

FIGURE: Y

BATTERY TESTING CHART STEP 1

VISUAL INSPECTION CHECK FOR OBVIOUS DAMAGE SUCH AS CRACKED OR BROKEN CASE THAT SHOWS LOSS OF ELECTROLYTE. ALSO CHECK FOR TERMINAL DAMAGE.

OBVIOUS DAMAGE I

NO OBVIOUS DAMAGE I

REPLACE BATTERY I

CHECK ELECTROLYTE LEVEL. ADD WATER IF NECESSARY. PROCEED TO STEP 2.

I FIXED

STEP 2

LOAD TEST

. ATTACH TESTER CLAMPS TO BATTERY TERMINALS INCORRECT POLAITY - USUALLY RED TO POSITIVE (+) AND BLACK TO NEGATIVE (-).

2. SET SELECTORSWITCH ON LOAD TESTERTO 1/2 CRANKING AMPERAGE RATING OF BATTERY (AT 0°F, -18°C).

3. I F TESTER DOES NOT HAVE AN AUTOMATIC BATTERY TEMPERATURE COMPENSATOR, PLACEATHERMOMETER IN CELL, READ AND SETTEMPERATURE DIAL ON TESTER. WITHOUTANY TEMPERATURE CORRECTION, MAKE LOAD TESTS ONLY ON BATTERIES ABOVE 60°F (16°C).

4. APPLY LOAD FOR 15 SECONDS AND READ LOAD TESTER JUST BEFORE RELEASING THE LOAD.

BATTERY PASSES LOAD TEST RETURN TO SERVICE.

BATTERY FAILS LOAD TEST PROCEEDTO STEP 3 I

STEP 3

I OPEN CIRCUITVOLTAGE TEST I . ALLOW 10 MINUTES FOR BATTERY VOLTAGE TO STABILIZE AFTER LOAD TEXT. . READ OPEN CI RUITVOLTAGE.

UNDER 12.4 VOLTS-BATTERY SHOULD BE CHARGED AND LOAD TESTED AGAI N (REPEAT STEP2). IF BATTERY AGAIN FAILS THE LOADTEST, REPLACE IT. IF IT PASSES, RETURN TO SERVICEAFTER PROCEEDING TO STEP 4.

STEP 4

12.4 VOLTS OR ABOVE- IF BATTERY DID NOT PASS THE LOADTEST, IT SHOULD BE REPLACED-THEN PROCEED TO STEP 4.

CAUSES OF BATTERY FAILURE: 1. CORRODED BATTERY POSTS OR CONNECTORS -ALWAYS CLEAN THE BATTERY POSTS OR SIDE TERMINALS AND THE BATTERY CABLE CONNECTIONS WHEN CHARGING OR REPLACING A BATTERY. 2. ELECTRICAL LEAKAGE - CHECK FOR ELECTRICAL LEAKAGE WITH ALLACCESORI ES TURNED OFF: A) DISCONNECTTHE BATTERY GROUND CABLEAND CONNECTA SUITABLE VOLTMETER BETWEEN DISCONNECTED BATTERY POSTAND GROUND (A READING OVER 6 VOLTS INDICATES AN EXCESSIVE LEAK).

OR B) DISCONNECT THE BATTERY CABLE THAT GOES TO THE STARTERAND CONNECTAN OHMMETER BETWEEN THE CABLE AND THE GOUND (A RESISTANCE OF UNDER 100 OHMS WILL DRAIN THE BATTERY).

3. CHARGING SYSTEM SHOULDALWAYS BE CHECKED AFTER CHARGING OR REPLACING A BATTERY.

MANUAL 92361-002 June 1997

115 VAC BATTERY CHARGER TROUBLESHOOTING GUIDE To be able to use the troubleshooting guide effectively, it is important to read this guide completely before beginning any tests.

CAUTION REPAIRS BY QUALIFIED PERSONNEL ONLY.

NOTE:

Modifying this charger for use other than that for which it was intended, repairs by persons not qualified, or not using original equipment replacement parts will void the warranty and Lester liability.

CAUTION DO NOT DISASSEMBLE THE CHARGER. TAKE IT TO A QUALIFIED SERVICEMAN WHEN SERVICE OR REPAIR IS REQUIRED. Incorrect assembly may

result in a risk of electric shock or fire.

HIGH VOLTAGE — With the charger on, the internal charger capacitor voltage is approximately 650 volts.

CAUTION ALWAYS UNPLUG THE ELECTRICAL CORDS FROM THE AC OUTLET AND THE BATTERIES BEFORE ATTEMPTING ANY REPAIRS TO THE CHARGER.

Do not operate the charger if it is malfunctioning.

Personal injury or property damage could result.

SECTION 1 — CHARGER DOES NOT TURN ON

In normal operation the charger DC output connector must be connected to the batteries in order to turn the charger on. A time delay of 2 to 5 seconds is provided to allow adequate time to make a secure connection before the charger turns on. After this time delay the power relay closes and an audible "click" should be heard. When the relay closes, AC power is supplied to the transformer primary coil. If operating properly, the transformer should hum and the ammeter should indicate the charge rate. If the charger does not turn on properly, refer to Part A, B, or C for specific test procedures.

MANUAL 92361-002 June 1997

PART A — RELAY DOES NOT CLOSE, NO TRANSFORMER HUM AND AMMETER DOES NOT REGISTER.

Check to be sure the power supply cord is securely connected to a live outlet. Check the DC output connector and the battery connector for damage, dirt or corrosion that would prevent a good electrical connection.

If the plug or receptacle is broken, twisted, bent or loose and does not make good electrical contact, have it replaced by a qualified serviceman immediately. DO NOT USE THE CHARGER IN THIS CONDITION AS FIRE OR PERSONAL INJURY CAN RESULT.

Then disconnect the power supply cord from its outlet. with the DC output connector still connected to the battery connector, measure the voltage at the battery connector using a suitable DC voltmeter. The voltage reading should be the same as the battery terminal voltage and must be between 24 and 50 volts DC in order to close the relay. If the DC voltage is within the above limits, remove the charger cover and verify that the charger is properly wired and you read the same voltage (24 to 50 VDC) inside the charger where the white and black wires of the DC cord attach. If the battery DC voltage measured inside the charger is now below the above limits or not present, the DC plug or cordset has an internal break and must be replaced. If the charger is wired correctly and a satisfactory battery DC voltage is measured inside the charger, a malfunction in the Electronic Timer Kit has probably occurred. Due to its complexity, do not attempt to make field repairs to any part of the Electronic Timer Kit. If a malfunction exists, simply remove the entire Electronic Timer Kit and replace it with a new one. Refer to Part D - "Electronic Timer Kit Replacement" - for correct procedure.

The Electronic Timer Kit may be bypassed in order to verify that a malfunction exists. First disconnect the charger power supply cord from its outlet and the DC output connector from the battery connector.

Place a jumper wire between terminals #1 and #3 to bypass the Electronic Timer Kit. The power supply cord is now connected directly to the primary transformer coil and the transformer should hum when the power supply cord is connected to a live outlet. The charger operation may be checked by first connecting the DC output connector to the battery connector, and then connecting the power supply cord to an outlet. If normal charging current is indicated on the ammeter the Electronic Timer Kit is defective and must be replaced.

CAUTION DO NOT charge batteries with the Electronic Timer Kit bypassed.

The charger will remain on as long as the power supply cord is connected to an outlet. Severe overcharging and eventual damage to batteries will result.

If the transformer does not hum and the ammeter still does not register with the Electronic Timer Kit bypassed, a continuity check of the charger AC circuit is necessary. Disconnect the power supply from its outlet and the DC output connector from the battery connector and, with a suitable continuity tester, check the circuit across the power supply cord prongs. With the Electronic Timer Kit bypassed, the CIRCUIT SHOULD BE COMPLETE. If the circuit is not complete, individually check the continuity of the power supply cord, primary transformer coil and all connections.

MANUAL 92361-002 June 1997

PART B — RELAY CLOSES BUT NO TRANSFORMER HUM AND AMMETER DOES NOT REGISTER

Check to be sure the power supply cord is securely connected to a live AC outlet. When three-prong to two-prong adapters are used, they tend to work loose resulting in a poor connection. Check the AC line fuse or circuit breaker and, if possible, measure the AC line voltage at the outlet to be sure AC power is present. If necessary, connect a functioning charger, utility light or other electrical appliance to the outlet to verify the presence of AC power.

If AC power is present, disconnect the power supply cord from its outlet and the DC output connector from the battery connector. Bypass the Electronic Timer Kit as described in Section 1, Part A, and with a suitable continuity tester check the circuit across the power supply cord prongs. With the Electronic Timer Kit bypassed, the CIRCUIT SHOULD BE COMPLETE. Ifthe circuit is complete, refer to the wiring diagram and check the relay wiring and all connections. Ifthe circuit is not complete, check the wiring ofthe power supply cord, transformer primary coil leads and the Electronic Timer Kit. Ifthe charger is wired correctly, individually check the continuity of the power supply cord, transformer primary coil and relay.

PART C — RELAY CLOSES AND TRANSFORMER HUMS BUT AMMETER DOES NOT REGISTER

If the relay closes and the transformer hums, the charger AC circuit and Electronic Timer Kit are functioning properly. If the ammeter does not register, a fault in the charger DC circuit exists and a continuity check must be performed. Disconnect the power supply cord from its outlet and the DC output connector from the battery connector, and check the charger fuse. If a fuse link is blown, refer to Section 2 - "Charger Fuse Blows" for further tests. If the fuse checks good, use a low voltage continuity tester to perform the following tests: 1. Connect the tester leads to the charger DC output connector and note the reading. Reverse the tester leads and check the output connector again. The circuit should be complete in only one direction. If the circuit does not conduct in either direction and the fuse is good, individually check the continuity ofthe DC output cord, ammeter, diodes and all connections. Ifthe circuit conducts in both directions, a "short" exists in the charger DC circuit. First check the DC output cord for a "short" between the two wires. It is more likely that one or both diodes have "shorted." Refer to Section 2 - "Charger Fuse Blows" for continuity test of diodes.

2.

If the charger DC circuit test is good, a check of the capacitor is necessary. Disconnect the power supply cord from its outlet and the DC output connector from the battery connector. Then disconnect both transformer coil leads from the capacitor terminals. Use care when disconnecting the capacitor leads so the wires do not break. Using an ohmmeter, set the scale to R X 10K ohms and test the capacitor as follows: GOOD CAPACITOR When the ohmmeter leads are connected to the capacitor terminals, the meter needle jumps to mid-scale and rapidly moves to high resistance (symbol here).

OPEN CAPACITOR — When the ohmmeter leads are connected to the capacitor terminals, the meter needle does not move and stays at high resistance (symbol here). A bulge in the top of the capacitor may be visible if the capacitor has failed "Open."

SHORTED CAPACITOR — When the ohmmeter leads are connected to the capacitor terminals, the meter needle jumps immediately to zero ohms and remains there.

If the capacitor is open or shorted, it must be replaced.

MANUAL 92361-002 June 1997

CAUTION

Use only a 6 Mfd, 660 volt AC rated capacitor for replacement (Part No. 02390S). The use of a different value capacitor may result in improper charging, capacitor failure, transformer burnout and/or battery damage.

3. If the charger DC circuit and capacitor check good, a test of the transformer is necessary. Refer to Section 7 - "Transformer Short or Burnout" or test procedures.

PART D - ELECTRONIC TIMER KIT REPLACEMENT

The Electronic Timer Kit should always be replaced as a complete assembly. The tools required a Phillips head screwdriver, 3/8" and 11/32" wrenches and pliers. No soldering is required. To replace the kit, follow the step-by-step procedures listed below.

Disconnect the charger power supply cord from its outlet and the DC output connector from the 1. battery connector and remove the charger cover.

Disconnect the green, black and red wires of the Electronic Timer Kit. Then remove the black and 2. white leads of the power supply cord and both primary transformer coil leads from the Electronic Timer Kit terminal tabs. The Kit can be removed by removing the three mounting screws on the charger front panel. Save all hardware for reassembly.

Install the replacement Electronic Timer Kit by reversing the disassembly procedures described in 3.

Step 2. When reconnecting the wires to the Electronic Timer Kit terminal tabs, support the terminal board to prevent damage to the electronic circuit board. Connect either transformer primary lead to terminal #2 and the remaining primary 1 lead to terminal #3.

Connect the black lead of the power supply cord to terminal #1 on the Electronic Timer Kit and the white lead of the power supply cord to terminal #2.

Connect the red wire ofthe Electronic Timer Kit along with the white lead ofthe DC cord to the Heat Sink Assembly. Connect the black wire of the Electronic Timer Kit along with the black lead of the DC cord to the ammeter post. Do not allow the ammeter post to turn when tightening the nut. Reconnect the green wire of the Electronic Timer Kit along with the transformer secondary lead to the diode lead terminal.

CAUTION

Be sure all connections are clean and tight. Also check to be sure all wires and terminals are positioned so they do not short together or to the charger case.

4.

Replace the charger cover and check the Electronic Timer Kit for proper operation as follows: A . With the DC output connector disconnected from the battery connector, insert the power supply cord into an outlet. The relay on the Electronic Timer Kit should not close.

A DC voltmeter connected across the DC output connector should indicate zero volts.

MANUAL 92361-002 June 1997

B . Disconnect the power supply cord from its outlet and connect the DC output connector to the battery connector. The relay on the Electronic Timer Kit should close with an audible "click" after a two to five second delay.

C. If the Electronic Timer Kit does not operate as (a) and (b) above, refer to the wiring diagram and check to be sure the charger is wired correctly. If the Electronic Timer Kit operates properly, the charger is ready for use. Always monitor the first charge cycle to verify that the charger is turning off properly.

SECTION 2 — CHARGER FUSE BLOWS

The charger fuse assembly consists of a dual element fuse link under a transparent cover mounted on the charger front panel. Each fuse element is electrically connected in series with a rectifier diode to provide protection for the transformer in the event of a diode failure. Visually inspect and electrically test the fuse to determine if one or both fuse links are blown and refer to Part A or Part B for test procedures. LOCATE AND CORRECT CAUSE OF TROUBLE BEFORE REPLACING BLOWN FUSE. DO NOT

attempt to repair the fuse link as inadequate protection will result.

PART A — SINGLE FUSE LINK BLOWS

This condition is normally caused by a short circuit failure of one diode. The fuse link will blow when the charger DC output connector is connected to the battery connector, regardless of whether the power supply cord is connected to an outlet. To check the diodes, disconnect the power supply cord from its outlet and the DC output connector from the battery connector, and then disconnect one transformer secondary coil lead from the diode terminal. Using a low voltage continuity tester, connect one tester lead to the diode mounting plate and the other tester lead to a diode terminal.

Note the reading and then reverse the tester leads and check each diode again. If a diode conducts current in both directions, it is "shorted" and the complete Heat Sink Assembly with Diodes (Part No. 09653 S) must be replaced.

On rare occasions a single fuse link may melt due to excessive heat. This can be caused by a loose internal fuse connection. Check all three fuse connections inside the charger to be sure they are clean and tight.

The proper torque on the fuse connector nuts is 20 Inch-Pounds (23 Cm-Kg).

PART B — BOTH FUSE LINKS BLOW

This is normally caused by a reverse polarity connection between the charger DC output connector and the battery connector. Check the battery pack and battery connector to be sure they are wired in the correct polarity. If possible, check the voltage and polarity at the battery connector with a DC voltmeter.

Also, check the charger DC output connector for the correct polarity. The white wire should be connected to the positive (+) contact, and the black wire to the negative (-) contact. If a reverse polarity connection is made between the charger and batteries, both fuse links will blow, regardless of whether the power supply cord is connected to an outlet.

Another cause for both fuse links blowing is the short circuit failure of both diodes. Although this is rare, it may occur as the result of a lightning strike at the charging location. Excessive heat due to a loose connection may also cause both fuse links to melt. Refer to Part A - "Single Fuse Link Blows" for troubleshooting procedures.

MANUAL 92361-002 June 1997

SECTION 3 - AMMETER READS 30 AMPS FOR MORE THAN 30 MINUTES This high output condition is caused by misuse, connecting the charger to an incorrect battery system which is lower than 36 volts. A common error is to install one or more of the 6 volt batteries in a 36 volt battery pack reverse polarity. Using a suitable DC voltmeter, test to be sure all batteries in a battery pack are correctly wired and also test the battery pack voltage at the charging connector. After charging for 30 minutes at this excessive rate, the measured on charge voltage should rise to 34 to 38 volts DC for a 36 volt system. Voltage measurements, while charging, lower than this indicate an incorrect or failed battery pack that must be corrected before using the charger.

CAUTION DO NOT connect the charger to battery packs which are not 36 volt systems. This misuse will cause overheating and transformer burnout will result.

SECTION 4 - CHARGER OUTPUT IS LOW The most probable cause of low output is a single fuse link blowing as the result of a short circuit failure of one diode. Refer to Section 2 - "Charger Fuse Blows" for troubleshooting procedures. On rare occasions a short circuit failure of the transformer coils may cause the output to be low. Refer to section 7 - "Transformer Short or Burn Out" for test procedures.

CAUTION Do not use the charger if the output is low.

Batteries will not reach full charge, thereby increasing the possibility of a harmful deep discharge during their next use.

SECTION 5 - CHARGER TURN OFF MALFUNCTIONS The Electronic Timer Kit turns the charger off as well as on. Proper charge time is determined by many factors, but the main elements are: (1) Battery size, (2) Depth of battery discharge and (3) Finish charge rate. Large severely discharged batteries require more time to reach full charge than do smaller lightly discharged batteries.

The charge rate, as indicated by current flow in amperes on the panel meter, is controlled by the batteries' rising voltage during charge. The higher the on charge voltage will rise, the lower the finish charge will be before the Electronic Timer terminates charging.

The following timer malfunctions are occasionally due to factors other than the charger's performance.

To help isolate the problem, it is often necessary to use the charger on a different set of batteries and the original set of batteries on another charger.

MANUAL 92361-002 June 1997

PART A — CHARGER TURNS OFF TOO SOON Check to be sure the power supply cord is securely connected to a live outlet. If the power supply outlet is live, proceed with the next step.

To determine if the charger did shut off too soon, disconnect and reconnect the charger DC output connector. This will restart the charger. Observe charger output on the ammeter.

1.

The ammeter needle jumps smartly to between 20 and 25 amps and then tapers below 14 amps within 15 minutes. This indicates that the batteries were truly charged.

The apparent short charging time is in response to the batteries' ability to accept charge and the electronic timer is performing properly.

2.

The ammeter needle jumps smartly to between 20 and 25 amps, but does not taper below 14 amps within 15 minutes. If the batteries have been properly maintained and charged regularly, this generally indicates that the batteries were not fully charged. If possible, use a hydrometer to check the specific gravity of several battery cells. If the specific gravity readings are more than 30 points (.030) lower than normal full charge readings, the electronic timer has malfunctioned and the complete Electronic Timer Kit must be replaced. Refer to Section 1, Part D - "Electronic Timer Kit Replacement" for correct procedures.

If the batteries have not been used or charged regularly, they may be sulfated and will not produce their full capacity. Repeated cycles (at least 5) of a light discharge followed by a full charge will generally result in the recovery of most of the battery's capacity. Do not interpret this reduced battery capacity as being caused by the charger turning offtoo soon. The charger is working properly if, after several charge cycles, the battery capacity increases to near normal. Sulfation occurs most often when the batteries have been stored without weekly charging. New batteries may also be sulfated due to extended shipment or storage time prior to sale.

As batteries age, individual cells may weaken, causing a reduction in battery capacity. This condition normally results in a finish charge higher than 10 Amps and less time is required to fully charge the batteries.

Do not interput this shorter charging time and reduced battery capacity as being caused by the charger turning offtoo soon. The battery is aging naturally and the charger is working properly. When the batteries will no longer perform as required, they should be replaced.

PART B — CHARGER DOES NOT TURN OFF New batteries with all good cells should rise to at least 2.5 volts per cell. This will allow the finish charge rate to taper below 8 amperes. As batteries age, individual cells may weaken and these cells may not reach 2.5 volts. This will result in finish charge rates greater than 8 amperes, and less time will be required for the batteries to reach full charge. At a finish charge rate of 8 amperes or less the charge time should not exceed 18 hours. At a finish charge rate greater than 8 amperes the charge time should not exceed 14 hours.

If the charger remains on longer than the specified maximum time, check to see if the charger turns on immediately when the DC output cord is connected without the normal two to five second delay. If the charger turns on instantly without the two to five second delay the Electronic Timer Kit has probably failed.

This type of malfunction generally results in the charger not turning off and the complete Electronic Timer Kit must be replaced. Refer to Section 1, Part D - "Electronic Timer Kit Replacement" for correct procedures.

MANUAL 92361-002 June 1997

If the charger remains on longer than the maximum time specified and the two to five second delay is present, verify that the green wire from the Electronic Timer Kit and the secondary transformer coil lead are securely connected to the diode lead as shown. The charger will NOT turn off if the green wire is loose or disconnected. If the green wire is securely connected, the Electronic Timer has malfunctioned and the complete Electronic Timer Kit must be replaced.

If a precision digital type DC voltmeter is available, a test to verify that the Electronic Timer has malfunctioned can be made. Connect the charger to the batteries and allow to charge normally. After the charge rate has tapered to its lowest point, measure the battery terminal voltage using a DC voltmeter capable of reading in increments of .001 volts. Continue charging and check the battery voltage reading every hour. If the battery voltage increases less than .012 volts, or if the battery voltage decreases between successive hourly readings, the charger should turn off. If the charger does not turn off, the Electronic Timer has malfunctioned and the complete Electronic Timer Kit must be replaced.

PART C — CHARGER RUNS TOO LONG BUT DOES TURN OFF

In the event of AC power interruption when the charger is on, the charger will automatically restart when AC power is restored. This power outage can make the apparent charge time seem longer than the actual charge time. To check for AC power interruptions, plug an electric clock into the same outlet to which the AC cord is connected. Charge normally and note any time difference between the test clock time and the actual time.

SECTION 6 — AC LINE FUSE OR CIRCUIT BREAKER BLOWS

If this occurs when the charger power supply cord is connected to an outlet, without the DC output connector connected to the battery connector, the charger power supply cord may be shorted. Disconnect the power supply cord from its outlet and the DC output connector from the battery connector, then check to be sure the Electronic Timer Kit is NOT bypassed. With a suitable continuity tester, check the circuit across the power supply cord prongs as shown. THE CIRCUIT SHOULD NOT BE COMPLETE. If the circuit is complete, check the relay contacts to be sure they are open and have not welded closed. If the relay contacts are open, the power supply cord is shorted and must be replaced. If the power supply checks good, the transformer coils may be shorted. Refer to Section 7 - "Transformer Short or Burnout" for test procedures.

SECTION 7 — TRANSFORMER SHORT OR BURNOUT

Failure of the transformer can be the result of natural aging, premature shorting of adjacent coil turns or overheating damage. The most common cause of transformer overheating and premature burnout is the result of misuse, connecting the charger to a battery system of lower voltage than specified on the charger.

(See Section 3) Darkening of all the transformer secondary coil windings is an indication of possible overheating damage. A low or complete lack of output would be observed on the ammeter, however, the transformer may hum or the AC line fuse or circuit breaker may blow when the charger is turned on. To test the transformer, disconnect the power supply cored from its outlet and the DC output connector from the battery connector. Then disconnect the transformer secondary coil leads #1 and #4 from the diode terminals and disconnect the transformer capacitor coil leads from the capacitor terminals. Use care when disconnecting the capacitor lead so the wires do not break.

MANUAL 92361-002 June 1997

With the charger operating, the charger capacitor voltage is approximately 650 volts AC. Use extreme caution when working near the ca • acitor terminals.

In order to apply AC power directly to the transformer primary coil, the Electronic Timer Kit must be bypassed. Refer to Section 1, Part A for bypass procedures. With the Electronic Timer Kit bypassed take caution in connecting the power supply cord to an outlet. If the AC line fuse or circuit breaker blows, the transformer is shorted internally and must be replaced. If this does not occur, check the transformer secondary and capacitor coil voltages as shown in Figure 6, using a suitable AC voltmeter. Ifthe measured voltages are substantially lower than those shown, the transformer is shorted internally and must be replaced.

If the transformer secondary coil voltage and capacitor coil voltage check good, disconnect the power supply cord from its outlet. Check the capacitor to be sure its rating is 6 Mfd. 660 volts AC, and then carefully reconnect the capacitor coil leads to the capacitor terminals. Then, take caution when reconnecting the power supply cord to an outlet and measure the transformer secondary voltage again.

The correct voltage reading is shown in Figure 7. Ifthe transformer secondary voltage reading is the same as measured with the capacitor disconnected, from Figure 6, the capacitor may be open, the capacitor coil may be open or the capacitor coil terminals may not be making proper electrical contact. Refer to Section 1, Part C, Item 2 for capacitor test procedures. If the voltage readings are correct, both the transformer and capacitor are good, refer to Section 1, Part C, Item 1 for further tests of the DC circuit.

IF it should become necessary to replace a terminal on one of the transformer leads, the new terminal must be crimped AND soldered.

NOTE:

Some transformer leads may be aluminum wire and a solder must be used on these wires that is intended for use on aluminum, such as Alcoa #807 solder with Alcoa #69 flux. If these materials are not available locally, contact the Lester factory.

ELECTRONIC TIMER BLACK

RED OR WHITE

WHITE

TO BATTERIES BLACK BLACK AMMETER

110 VAC INPUT PLUG

4 *GREEN WIRE NOTE USED ON SOME MODELS.

NATURAL

CAPACITOR

NOTE: SOME TRANSFORMER LEADS MAY BE ALUMINUM WIRE AND A SOLDER MUST BE USED ON THESE WIRES THAT IS INTENDED FOR USE ON ALUMINUM, SUCH AS ALCOA #807 SOLDER WITH ALCOA #69 FLUX. IF THESE MATERIALS ARE NOT AVAILABLE LOCALLY, CONTACT THE LESTER FACTORY. MANUAL 92361-002 June 1997

11 8

WARNING: ALL ELECTRICAL REPAIRS MUST BE PERFORMED BY QUALIFIED PERSONNEL ONLY. INCORRECT ASSEMBLY MAY RESULT IN A RISK OF ELECTRICAL SHOCK OR FIRE.

PARTS LIST FOR LESTERONIC II CHARGER MODEL 07850 TYPE 36LC25-8ET FOR USE ON 115 VAC 60HZ ITEM PART NUNIBER DESCRIPTION

CASEASSEMBLY 1

2

TRANSFORMERASSEMBLY ELECTRONIC TIMERKIT 3

3A > RELAY, TIMERKIT, 36 VDC i— 4 z :5-• CAPACITOR, 6MFD 660 VAC 5

'Lnt 'al HEATSINK ASSEMBLY WITH DIODES 6 .E— Q. AMMETER, 0-30 AMPS w— 7 4 cr. FUSE ASSEMBLY, DC OUTPUT a. > 8 -111 < BUSHING, 7W-2, FORAC CORDSETS AND 12/2 DC en la BUSHING, 8P-2, FOR10/2 CORDS 8 u)

i— AC CORD SET, 6 FT 9 cc < 9 < to AC CORDSET, 9 FT. CL 10 -CC 5 DC CORDSET, 12/2, 108", NO PLUG .4 — DC CORDSET, 12/2, 108" MOLDEDNEOPRENEPLUG 11 > i x 11 < CL DC CORDS SET, 10/2, 144" MOLDED NEOPRENE PLUG .....1 I 4 X, DC CORDSET, 10/2, 240", MOLDED NEOPRENE PLUG I1 o< 12

_l a, DC CORDS SET 12/2, 108", W/SB-50 AMP PLUG, GRAY --I CC 12 < 0 DC CORDSET, 12/2, 130", W/SB-50 AMP PLUG, GRAY 13 0 U- DC CORDSET, 12/2, 108" W/SB-175 AMP PLUG, GRAY

14 DC CORDSET, 12/2, 108" LESTERYELLOWPLUG

PLUG ASSEMBLY, SB-50 AMP, GRAY 15

PLUG ASSEMBLY, SB-175 AMP, GRAY 16

DC RECEPTACLE, FORLES'IERYELLOW OR MOLDED 17

NEOPRENEPLUG NOT

1 EST AND INSPECTION KIT FOT 08045S RECEPTACLE SHOWN - Indicates Items Not Shown MANUAL 92361-002 June 1997

'6

A div. of TIME Manufacturing Company

BOLT TOR IJE CHART BASIC STRESS TENSILE STRENGTH (T) MIN NOMINAL THREADS

MAJOR AREA PROOF LOAD (P) AE GEJ.DE 5 SAE GRADE (1957) DIA SQ. IN GRADE 5 GRADE 8 CLAMP 5.5p 413T LTS2PQMP, CLAMP INCH

4-40 4-48 6-32

.1120 .1120 .1380

6-40

.1380

.1640 .1640 10-24 .1900 .1900 1 0-32 .2500 1/4-20 .2500 1/4-28 .3125 5/16-18 .3125 5/16-24 .3750 3/8-16 .3750 3/8-24 .4375 7/17-14 .4375 7/16-20 .500 0 1/2-13 500 0 1/2-20 9/16-12 .5625 9/16-18 .5625 5/8-11 .6250 625 0 5/8-18 .7500 3/4-10 7500 3/4-16

8-32

8 36 -

7/8-9 7/8-14 1-8 1 12

1 1/8-7 1 1/8-12 1 1/4-7 1 1/4-12 1 3/8-6 1 3/8-12 1 1/2-6 1 1/2-12

.8750 .8750 1.000 1.000 1 1250 1 1250 1.2500 1.2500 1.3750 1.3750 1.5000 1.5000

'PADE 8 ASSEMBLY TORQUE

T P T P LOAD R=.200 DRY R=.150 LUB LOAD R=.200 DRY R=.150 LUB LBS. LBS. 9LB-IN 6LB-IN 540 12LB-IN 120KSI 380 8LB-IN 150KSI .00604 120KSI 85KS 10LB-IN 7LB-IN 600 13LB-IN 120KSI 420 9LB-IN 150KSI .00661 120KSI 85KS 17LB-IN 12LB-IN 820 23LB-IN 120KSI 580 16LB-IN .00909 120KSI 85KSI 150KSI 19LB-IN 13LB-IN 920 25LB-IN 8LB-IN 120KSI 640 .01015 120KSI 85KSI 150KSI 31LB-IN 22LB-IN 1260 41LB-IN 120KSI 900 30LB-IN .01400 120KSI 85KSI 150KSI 32LB-IN 23LB-IN 1320 43LB-IN 120KSI 940 3 LB- N 50KSI 120KSI 85KSI .01474 45LB-IN 32LB-IN 1580 60LB-IN 120KSI 1120 43LB-IN 120KSI 85KSI 150KSI .01750 51LB-IN 36LB-IN 1800 68LB-IN 120KSI 1285 49LB-IN 120KSI 85KSI 150KSI .0200 9LB-FT 75LB-IN 2860 12LB-FT 120KSI 2020 8LB-FT 120KSI 85KSI 150KSI .03180 10LB-FT 86LB-IN 3280 14LB-FT 120KSI 2320 1O LB-VF 120KSI 85KSI 150KSI .03640 18LB-FT 3LB-FT 4720 25LB-FT 12OKSI 3340 17LWV1 120KSI 85KSI 150KSI .05240 14LB-FT 5220 25LB-FT 23LB-FT 7000 45LB-FT 25LB-FT 7900 50LB-FT 35LB-FT 9550 70LB-FT

120KSI 85KSI 150KSI .05800 120KSI 85KSI 150KSI .07750 120KSI 85KSI 150KSI .08780 120KSI 85KSI 150KSI .10630 120KSI 85KSI 150KSI .11670 50KSI 120KSI 85KSI .14190 120KSI 85KSI 150KSI .15990 120KSI 85KSI 150KSI .18200 120KSI 85KSI 150KSI .20300 120KSI 85KSI 150KSI .22600 120KSI 85KSI 150KSI .25600 120KSI 85KSI 150KSI .33400 .37300 120KSI 85KSI 150KSI

1207.SI 3700 19LB-FT 120KSI 4940 30LB120KSI 5600 35LB120KSI 6800 50LB-FT 120KSI 7550 55LB-FT 120KSI 9050 75LB-FT 120KSI 10700 90LB-FT 120KSI 11600 OLB-FT 120KSI 12950 120LB-FT 120KSI 14400 150LB-FT 120KSI 16950 180LB-FT 120KSI 21300 260LB-FT 120KSI 23800 300LB-FT

120KSI 85KSI 150KSI

120KSI 29500 520LB-FT

390LB-FT 41600 600LB-FT

32400 570LB-FT 770LB-FT 6

430LB-FT 45800 660LB-FT

.46200

.76300 105KSI 74KSI 150KSI .85600 105KSI 74KSI 150KSI

120KSI 12 KSI 120KSI 120KSI 120KSI

.96900 105KSI 74KSI 150KSI

120KSI

1.0730 105KSI 74KSI 150KSI 1.1550 105KSI 74KSI 150KSI 1.3150 105KSI 74KSI 150KS 1.4050 105KSI 74KSI 150KSI 1.5800 105KSI 74KSI 150KSI

120KSI 120KSI 120KSI 120KSI 12OKSI

.50900 120KSI 85KSI 150KSI .60600

1201(5185KSI 150KSI

.66300 120KSI 85KSI 150KSI

42300 850LB-FT

42300 47500 53800 59600 64100 73000 78000 87700

800LB-FT 880LB-FT 1120LB-FT

1248LB-FT 1468LB-FT 1680LB-FT 940LB-FT 2200LB-FT

40LB-FT 10700 80LB-FT

55LB-FT 12750 110LB-FT 65LB-FT 14400 20LB-FT 80LB-FT 16400 150LB-FT 90LB-FT 18250 170LB-FT 110LB-FT 20350 220LB-FT 130LB-FT 23000 240LB-FT 200LB-FT 30100 380LB-FT 220LB-FT 33600 420LB-FT

580LB-FT 45

900LB-FT

630LB-FT 59700 1000LB-FT

600LB-FT 660LB-FT 840LB-FT 920LB-FT 1100LB-FT 1260LB-FT 1460LB-FT 1640LB-FT

68700 1280LB-FT 77000 1440LB-FT

20LB-FT 35LB-FT 35LB-FT 55LB-FT 60LB-FT 80LB-FT

90LB-FT 110LB-FT 130LB-FT 170LB-FT 180LB-FT 280LB-FT 320LB-FT 460LB-FT 500LB-FT 680LB-FT 740LB-FT 960LB-FT 1080LB-FT

87200 1820LB-FT

1360LB-FT

96600 2000LB-FT 104000 2380LB-FT 118400 2720LB-VF 126500 3 60LB-FT 142200 3560LB-FT

1500LB-FT 1780LB-FT 2040LB-FT 2360LB-FT 2660LB-FT

NOTES: 1.THIS CHART SHOWS RECOMMENDED BOLT TORQUES. 2.TORQUE =R XD X T 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 Y STRESS AREA

APPEPDIX

Pm I A div. of TIME Manufacturing Company

BM.," T'

QE

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

M4

27.5*

17*

30*

18*

38.5*

24*

53*

32.5*

M5

56.5*

33.5*

61*

37*

78*

47*

107*

65*

M6

95*

57.5*

103*

61*

132*

79*

180*

109*

M8

19

12

21

13

27

16

37

22

M10

39

23

42

25

53

32

73

44

M12

67

40

73

44

92

55

127

76

M14

107

64

116

69

146

89

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

TRAVEL ALARM OPTION

3B

3

CONTROL CABLE TO TERMINAL STRIP ON PLATFORM CONTINUED ON SHEET 1

NOTE 2

HOUR METER OPTION

BLK

SLOPE

REF =BLK /WH T

TERMINAL BOARD WH T=9

= GRN/BLK 1=BLU/BLK

SENSOR OPTION

0 SEE NOTE 3

1_0

3= RED

[RED

2

®11 1, 6=BLU B=RED/BLK

8C 7A

UP

18

UPPER ° OFF LOWER 0

7A OWN

(5 .5) 20 AMP / FUSE

3 -POS ROT SELECTOR SWITCH

7 = WH T/BLK 7

5 =ORN BLK

BEACON/STROBE OPTION

WHT

WHT

ci

4= BLK

6V 6V

8A

------

n

53

WHT

CD BATTERY / CHARGER

54 6V 6V 6V BL

SERIES/PARALLEL 2

WHT

6V

51

BLK

WHT 7=WHT SIGNAL HORN OPTION

0 ©

ci BLK

=BLK

0 0 NO NC

15 14 13 12 11

GRN

BLK BLK

HOLDING VALVE ON CYLS

51 4 PL

16

WHT WHT

DESCEND ALARM OPTION

8A

10

4 5

CREEP SPEED VALVE

55

CONTACTOR

6

10

DRIVE SPEED VALVE 2 = WHT

3 6 PL

10= ORN/BLK,

SEE NOTE 1

SERIAL #3900 AND ABOVE

NOTES: PROPRIETARY INF ORMA TION

1. MDL 3146 HAS ONLY ONE HOLDING VALVE. MDL3160 HAS TWO. 2. PRESSURE SWITCH SENSES BRAKE RELEASE PRESSURE. 3.

THRU 0 REPRESENT TERMINALS ON OPTIONAL LOW VOLT SENSOR/SWITCH.

I.

iB WACO,

TEXAS

TITLE

o

W.1) Sa ZISTRI TOLERANCES ON: rA, LTR.

DATE 5351

APPR. DRA.

ri NSZ:47ES'

A.NaTLE 04,V.

WIRING DWG, 3146/60 ELECTRICAL DRAINING NO

55062

CHECKED APPR. APPROVW

SCALE NONE

SHEE T 2 OF 2

REV.

B

24C 24C 24C

EMERGENCY

R3— A

24B

24C

olho

R3—B 24D

o o

24B

0

24A

STOP

20A

32-q

CHARGING LIGHT OPTION

18

HOUR METER OPTION

„,,_,4D 6A

0

0

8A

0

SEE NOTE 4 "UP"

00

"DOWN”

GROUND

+24VOLT TAP

24

FUSE

•

PLATFORM RAISING

•

PLATFORM LOWERING

NEG R1

86

HYD PUMP

MOTOR

BLK

A

HORN

MOTION ALARM OPTION

HORN

DESCEND ALARM OPTION

36 VDC BATTERY

BATTERY CHARGER

EMERGENCY 3

3A CIRCUIT BREAKER

11 STOP :1. 3A

7

0-0 5

OPTIONAL BATTERY CONDITION INDICATOR

SEE NOTE 2 •

SEE NOTE 3

• SERIES/PARALLEL VALVES

o91)

R2

FAST/SLOW DRIVE SPEED 04-0---11 • CREEP SPEED VALVE WHT

HORN

• 3

SLOPE ALARM OPTION

RED BLK

.3

SEE NOTE 4

8C

0 0

8C

SLOPE SENSOR OPTION

BLK

• 3 C-21)

12

• 3 0 0

10 3D

• LOW VOLT ALARM OPTION

BLK

OPTIONAL CHARGING CUT—OUT RELAY

WHT j

SIGNAL HORN OPTION

HORN HORN

TRAVEL ALARM OPTION

14=WHT=NEUTRAL

SEE NOTE 5 17

115 VAC PLUG

WHT

SEE NOTE 4

3

SEE NOTE 4 LOW VOLT OVERRIDE

GRN

• RELAY FOR 36V OPTIONS

• 3

7„, ,

11

LOW VOLT SENSOR

1

•

15=BLK=LIVE

00

STROBE LIGHT OPTION

110 VOLT EXTENSION — TO PLATFORM OPTION

16=GRN=GROUND

DRA.NPGRnOs P,ER,I rE.TADR ETYA,LINFORMATION

NOTES: 1. THIS SCHEMATIC SUPERCEDES 54996.

2. SWITCH ACTIVATED BY VALVE LEVER IN PLATFORM. 3. LIMIT SWITCH SHOWN WITH PLATFORM BELOW 7'.

4. CO THRU REPRESENT TERMINALS OF OPTIONAL LOW VOLTAGE WARNING/INTERRUPT SENSOR/SWITCH. 5. PRESSURE SWITCH SENSES BRAKE RELEASE PRESSURE.

l3KS „o

girscamAIRRA,cActil-NioinA,Aito g iAN'107ATT.7710V7 warEN CONSENT OF CALAVAR

SCHEMATIC, 3146/60 ELECTRICAL

u'r',,̀-,7,Ts,°(;.,",ERAwRTETNsPuTiri's° TOLERANCES ON: l'ile/V LTR.

E.C.N. NO.

DATE

APPR.

LTR.

DRAwN

17.6. FRAi /T TAL

A.HITTLE

CHECKED

5315 DATE

APPR.

APPRoVED

WACO, TEXAS

TITLE

RAE

04/11/95

B

04/17/95 SCALE

REV. DRA'Nc

NONE

5 5 0 6 0 SHEET

1 OF 1

BATTERY SERVICE

BATTERY SERVICING TOOLS Use proper tools when performing battery service to prevent damage to battery, cables, terminals and holddowns, and to save time and energy.

Suggested battery tools and their use are described below.

FILLING DEVICES One of the most important routine battery service for conventional batteries is to maintain the correct electrolyte level. Two devices are available for this purpose, a self-levelling filler which fills the battery to a predetermined level automatically, and the syringe type. Battery cells should never be filled above the level indicator. Do not squeeze the syringe so hard that the water splashes acid from the cell opening.

SCRAPER AND WIRE BRUSH The scraper and wire brush can be used for removing dirt, corrosion and rust from various parts such as the battery posts, battery tray, the hold-down and the hold-down bolts.

BATTERY CARRIER A battery carrier should not place any undue strain on the battery terminals or the container. An excellent carrier for plastic cased batteries is a clamp ("ice tong") type carrier with rubber pads which grip the SIDE WALLS of the container just below the lip of the cover. It is used on the side walls rather than the end walls, since the side walls have additional strength from the inner cell partitions. Gripping the flexible end walls of plastic containers could cause electrolyte to spew from some of the cells.

SERVICE PROCEDURES

The user should realize that the battery is a perishable item and requires periodic attention. With a reasonable amount of care,the life of the battery can be appreciably extended. Neglect and abuse will invariably cause shorter life.

Routine servicing of the battery should proceed as follows: First, make a visual inspection for defective cables, loose connections, corrosion, cracked cases or covers, loose hold-downs and deformed or loose terminal posts. If any parts such as cables, hold-downs or the battery appear to be unserviceable, it is recommended that they be replaced.

When there is corrosion on the terminal posts or hold-down, the tray or hold-down parts are rusty, or the battery is very dirty, it is recommended that time be taken to clean the parts. A wire brush can be used to remove dirt, corrosion or rust from parts. Clean dirt from the battery top with a cloth wetted with ammonia or baking soda in water. Then wipe with a cloth with clear water. After rust is removed from a part with a wire brush, rinse with clear water, dry and paint with an acid-resistant paint.

MANUAL 92361-002 June 1997

Ifcorrosion is found on the terminal posts, remove the cable terminals from the battery (ground cable first), using the proper end wrench. A wire cleaning brush can be used to clean the posts and the mating surfaces of the cable clamps. Connect the cables to the terminal posts (ground cable last). Coat the terminal connections with a spray corrosion inhibitor or high temperature grease.

The second item in routine servicing of conventional batteries is to check the electrolyte level in all cells.

If necessary, add clear, odorless, mineral free water to bring the liquid level to the level indicator in all cells.

Ifthe battery does not have a level indicator, bring the level to 1/2" (13mm) above the tops ofthe separators.

Do not overfill any cell. When a cell is overfilled, the excess electrolyte may be forced from the cell by the gas formed in the battery. This will cause excessive corrosion of adjacent metal parts, reduced performance and shorter life.

BATTERY TESTING

Battery testing should be considered an integral part of periodic equipment maintenance and should be performed whether or not a starting problem has occurred. Servicing the battery in the equipment as described will help prevent premature battery failure from external causes and periodic battery failure from both external and internal causes or merely from the battery reaching the end of its useful life.

STEP 1 — VISUAL INSPECTION For protection, wear a face shield. First, visually inspect the battery. Check for container, cover or terminal damage that might cause leakage of electrolyte or internal damage. If serious damage is found, replace the battery. Check the electrolyte level in each cell. If below the tops ofthe plates in any cells, fill all cells with water to just above the tops ofthe separators and charge for 15 minutes at 15-25 amps to mix the water with the electrolyte. If electrolyte levels are above the tops of the plates, continue to Step 2.

STEP 2 — HYDROMETER TEST Using the hydrometer, measure and record the specific gravity, corrected to 80 degrees F (26.7 C) of the electrolyte in each cell. If the range (highest-lowest) is 50 points (0.050 sp.gr.) or greater or the lowest is less than 1.225 sp.gr., charge the battery at the recommended rate or until all cells are 1.225 sp.gr. or greater and the range is less than 50 points. Ifno amount ofcharging will achieve these conditions, replace the battery. If these conditions are achieved, apply a 150 amp load for 15 seconds to remove the surface charge on the battery and continue to Step 3.

The average state of charge ofthe cells in a battery can be determined by measuring the stabilized voltage of the battery. The voltage is stabilized if the battery has been on open circuit overnight or for a period of several hours. A voltage reading of 12.4 (6.2 on a 6-volt battery) is equivalent to a specific gravity of 1.225. The disadvantage of measuring the open circuit voltage is that a lower voltage cell can be masked by the remaining cells. If the cell connectors are accessible for voltage measurements, a range of 0.05 volts between the highest and lowest cells corresponds to a 50 point variation in specific gravity. A cell voltage of 2.07 is equivalent to a specific gravity of 1.225.

MANUAL 92361-002 June 1997

STEP 3 — ADJUSTABLE LOAD TEST The following instructions are intended as guidelines. When available, the instrument manufacturer's instructions should be followed. Follow all precautions.

A.

Disconnect battery cables starting with ground cable.

B.

Measure temperature of a center cell. If instrument has an integral temperature compensator, use attached probe.

C.

Connect voltmeter and load test leads to appropriate battery terminals, make certain terminals are free of corrosion.

D.

Connect current transducer (if necessary) to appropriate lead.

E.

Apply test load equivalent to 50% of Cranking Performance rating of battery for 15 seconds. If Cranking Performance is unavailable, use 3 times the 20 ampere-hour capacity.

F.

Read the voltage at 15 seconds, then remove the load.

G.

Determine minimum voltage required at electrolyte test temperature from chart in Figure X.

H.

If test voltage is above minimum, return battery to service.

I.

If test voltage is below minimum, replace battery.

TESTING WITH FIXED LOAD TESTER AND OPEN CIRCUIT For testing batteries with a fixed load tester and an open circuit voltmeter, refer to "Battery Testing Chart" Figure Y.

STEP 1 — VISUAL INSPECTION First, visually inspect the battery and check the electrolyte levels as described in Step 1 of "Testing with Adjustable Load Tester and Hydrometer"; take the same corrective actions. Continue to Step 2.

STEP 2 — FIXED LOAD TEST Some commercial battery testers do not have an adjustable load but measure the battery voltage under a heavy fixed load. The tester should include a selector switch or meter scale to choose among a variety of battery sizes. It should include some means of correcting for the battery temperature, either in automatic sensing circuit or a manually selectable one.

MANUAL 92361-002 June 1997

The following instructions are intended as guidelines. When available, the instrument manufacturers instructions should be followed.

A.

Disconnect battery cables starting with ground cable.

B.

Measure temperature of a center cell and set temperature dial on tester or insert automatic temperature corrector probe in center cell. Cover battery with a damp cloth.

C.

Set battery size selector to a range or select range on meter which will include 50% of the Cranking Performance rating or 3 times to 20 ampere-hour capacity of the battery.

D.

Connect voltmeter and load test leads to appropriate battery terminals, make certain terminals are free of corrosion.

E.

Apply test load for 15 seconds.

F.

Read battery performance from instrument meter at 15 seconds, then remove the load.

G.

If the battery passed the load test, return it to service.

H.

If the battery failed the load test, continue to Step 3.

STEP 3 — OPEN CIRCUIT VOLTAGE TEST

If the battery failed the load test, the state of charge must be checked. If a hydrometer is not available, the stabilized open circuit voltage can be used to indicate the state of charge. Allow at least 10 minutes after the load test for the voltage to stabilize, then measure and record the open circuit voltage. Determine the approximate state of charge from the following chart (Battery temperature 60-100 degrees F.) OPEN CIRCUIT VOLTS 12.6 or greater 12.4 - 12.6 12.2 - 12.4 12.0 - 12.2 11.7 - 12.0 11.7 or less

PERCENT CHARGE 100% 75-100% 50-75% 25-50% 0-25% 0%

The change of voltage with state of charge is small and must be measured accurately using a digital meter or an analog meter with an expanded scale. If the state of charge is 75% or greater and the battery failed the load test, it should be replaced. If the state of charge is less than 75%, the battery should be charged at the recommended rate and time, and the load test repeated. If the battery passes the load test, return it to service. If it fails the load test again, replace it and refer to the next chapter to determine the cause of failure.

MANUAL 92361-002 June 1997

DETERMINING CAUSES OF BATTERY FAILURE

Whether the battery passes or fails either of the above tests, the results must be believed. If the battery passed the load test only after a recharge, the cause of the discharge condition should be determined.

If the battery has been returned previously or is otherwise still questionable, one final test should be made.

Fully charge the battery and place it on open circuit stand for three days. If the loss in specific gravity of any cell is greater than 35 points or the open circuit voltage drops by more than 0.20 volts, replace the battery. If not, return the battery to service and determine the cause for the discharged condition.

The following should be checked: 1. Corroded Battery Terminals or Connectors

A corrosion layer between the battery terminals and the cable connectors can prevent good electrical contact even when the connectors are tight. The cables should always be removed before testing a battery and any corrosion cleaned from the terminals.

2. Electrical Circuit Leakage

There may be a fault in the equipment's electrical system that can discharge the battery even when all the accessories are turned off. To check for such leakage, turn off all accessories in the equipment. Check for leakage using one of the following methods.

A.

Ammeter - Cover battery with a damp cloth. Disconnect the ground cable.

Using a DC ammeter with a resolution of at least 0.1 amp, measure the current between the disconnected cable and the battery terminal. (DO NOT CONNECT AMMETER ACROSS BATTERY TERMINALS!) A leakage current measurement of 0.1 amp or more indicates the equipment electrical system should be tested and repaired.

B.

Ohmmeter - Disconnect the positive cable at the battery. Connect an ohmmeter to the disconnected cable end and to the chassis. A resistance measurement of under 100 ohm indicates a load of 0.1 amp or more and indicates the equipment electrical system should be tested and repaired.

C.

Voltmeter - Disconnect the ground cable (negative) at the battery. Connect

a low resistance voltmeter (100 ohms - see Note 1) between the disconnected battery post and the chassis. A voltage measurement of 6 volts or more indicates a leak of 0.1 amp or more and the equipment electrical system should be tested and repaired.

Note 1: The voltmeter test cannot be made with high resistance voltmeters.

3. Charging System

To complete the determination of the cause for the battery's discharged condition, check the equipment's charging system.

MANUAL 92361-002 June 1997

FIGURE: X

BATTERY TESTING CHART STEP 1

VISUAL INSPECTION CHECK FOR OBVIOUS DAMAGE SUCH AS CRACKED OR BROKEN CASE THAT SHOWS LOSS OF ELECTROLYTE. ALSO CHECK FOR TERMINAL DAMAGE.

I

I

OBVIOUS DAMAGE

NO OBVIOUS DAMAGE

1 CH ECK ELECTROLYTE LEVEL

REPLACE BATTERY

J

BELOW TOP OF PLATES IN ONE OR MORE CELLS

ELECTROLYTE LEVEL ABOVE TOP OF PLATES IN ALL C ELLS - PROCED TO STEP 2

ADD WATER TO JUST ABOVE SEPARATORS. CHARGE FOR 15 MINUTES AT 15-25 AMPS. PROCEED TO STEP 2 HYDROME1ERIEST

STEP 2 SPECIFIC GRAVITY LESS THAN 1.225 OR CELLVAR1ATION 50 POINTS OR GREATER.

I RECHARGE

SPECIFIC GRAVITY 1.225 OR GREATER OR CELLVARIATION LESS THAN 50 POINTS.

DISCHARGE AT 150 AMPS FOR 15 SECONDS

SPECIFIC GRAVITY LESS THAN 1.225 OR CELL VARIATION 50 POINTS OR GREATER.

I

CONTINUE TO STEP 3

REPLACE BATTERY I I LOAD TEST

STEP 3

. PLACETHERMOMETER IN CENTER CELL. COVER BATTERY WITH A DAMP CLOTH. 2. CONNECTVOLTMETERANDAMPERE LOAD EQUALTO 1/2 THE COLD CRANKING AMPERES AT OF (-18°C) RATING OF THE BATTERY FOR 15 SECONDS. 3. OBSERVE VOLTAGE AT 15 SECONDS WITH LOAD ON. 4. REFERTO VOLTAGE CHART BELOW.

I VOLTAGE BELOW CHART VALUE I

I

VOLTAGE EQUAL TO OR ABOVE CHART VALUE - RETURN TO SERVICE

1 REPLACE BATTERY

VOLTAGE CHART ESTIMATED ELECTROLYTETEMPERATU RE

MINIMUM REQUIRED VOLTAGE UNDER 15 SEC. LOAD (USE 1/2 THESE VALVES FOR 6-VOLT BATTERIES)

70°F (21°C) & ABOVE 60°F (16°C) 50°F (10°C) 40°F (4°C) 30°F (-1°C) 20°F (-7°C) 10°F (-12°C) OF (-18°C)

9.6 9.5 9.4 9.3 9.1 8.9 8.7 8.5

MANUAL 92361-002 June 1997

A DIVISION OF TIME MANUFACTURING

SELF-PROPELLED ELEVATING WORK PLATFORM

MODEL 2546 ILLUSTRATED PARTS MANUAL

SHIPPING ADDRESS

MAILING ADDRESS

CONDOR

CONDOR

A DIVISION OF TIME MANUFACTURING

A DIVISION OF TIME MANUFACTURING

8300 IMPERIAL DRIVE WACO, TEXAS 76712 (254) 420-5200

P.O. Box 21447 76702-1447 (254) 420-5200

WACO, TEXAS

MANUAL 92361-003 June 1997

A DIVISION OF TIME MANUFACTURING

CONDOR® SERVICE INFORMATION

1. If you need assistance or have any service or maintenance questions, Condor service and parts personnel are always available by phone or fax. The telephone numbers are: (254) 420-5200 Telephone (254) 420-5298 Voice Mail (800) 443-5803 FAX 2. There are numerous written Maintenance Procedures available for this machine.

These procedures are available through the Condor Service Department to anyone who requests them.

3. Service and maintenance are not a substitute for trained, qualified service technicians.

Condor 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 Condor Service Schools help you provide this training.

4. Condor 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.

CONDOR DIVISION

8300 IMPERIAL DRIVE, P.O. Box 21447, WACO, TEXAS 76702-1447 • 254-420-5200, 817-6664544 FAX

INTRODUCTION

The primary purpose of this manual is to provide the user with a thorough understanding ofthe 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 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 RESPONSIBILITY 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 ofthe ANSI/SIA 92.6-1990 Manual of Responsibilities is attached for your use.

Condor Division 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 CONDOR DIVISION

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 Condor division in order to ensure the original integrity ofthe product. Repairs and adjustments should only be made by trained and qualified personnel. Please refer to the maintenance and parts sections of the Condor Operation, Maintenance, & Parts Manual for information on service and maintenance of the CONDOR®.

NOTE: Please refer to the Condor Parts section of the Operation, Maintenance, & Parts Manual for

information pertaining to your machine.

•

CONDORO MODEL V2546 ILLUSTRATED PARTS MANUAL TABLE OF CONTENTS INTRODUCTION CONDOR() SERVICE INFORMATION

ii

TABLE OF CONTENTS

FIGURE A

DESCRIPTION Serial Number Location Recommended Spare Parts List How To Order Parts

PAGE 2 3 4,5

B C

1.1 1.2

Final Installation Decal Installation

2.1 2.2 2.3 2.4

Chassis Installation Steer Axle Assembly Brake And Drive Assembly Brake Assembly

12 14 16 18

3.1 3.2 3.3 3.4 3.5 3.6

Hydraulic Installation Hydraulic Tank Installation Lower Control Valve Assembly Lift Cylinder Valve, Creep Speed Valve, Series Parallel

20 21 22 23 24 25

4.1 4.2 4.3

Wiring Battery Installation Lower Control Assembly

26 28 29

5.1

Arm Stack Installation

30

6.1 6.2 6.3 6.4 6.5

Platform Assembly Upper Control Box Installation Holder Assembly Cover Installation Hose Kit

34 36 38 39 40

7.1 7.2

Schematic Electrical Schematic Hydraulic

42 43

8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12

Deck Extension ( Option ) 110V Line To Platform ( Option ) Hour Meter ( Option ) Travel Alarm ( Option ) Multi-Axis Slope Sensor ( Option ) Strobe Light ( Option ) Non Marking Tires ( Option ) Battery Condition Indicator ( Option ) Descend-Warning ( Option ) Low Voltage Warning Interrupt ( Option ) Key Switch ( Option ) Lifting Eyes ( Option )

44 46 48 49 50 51 52 53 54 55 56 57

MANUAL 92361-003 JUNE 1997

6 8

FIGURE A—Serial Number Location

STAMP ON DATA PLATE

STAMP ON DRIVE AXLE

The CONDOR® Model V2546 Serial Number is stamped in two locations on the machine.

1.

The first place to find the serial number is on the data plate affixed to the chassis, above ground controls.

2.

The second serial number is located at the left rear (drive) axle.

MANUAL 92361-003 JUNE 1997

FIGURE B—Recommended Spare Parts Lists CONDOR® MODEL V2546 (1 UNIT-1 YEAROPERATION)

QTY PART NUMBER DESCRIPTION

Filter, Hydraulic Return 4 33430 Switch, Hi/Lo Speed 1 54191 1 392-00008-00 Switch, Master Disconnect 1 392-00009-00 Switch, Emergency Stop 1 392-00021-00 Switch, Push Button, Lower Control 1 394-00009-00 Solenoid, 36VDC, Pump Mtr. Start Holder, Safety Manual 1 34354 4 92338-001 Manual, Operation & Safety 4 396-00003-00 Stud, Wheel 1 152-00007-00 Cap Oil Filler, HydraulicTank (up to serial #3 799) Breather Filler 1 50316

Optional

QTY PART NUMBER DESCRIPTION

1 126-10005-00 Brake Assembly 1 DRJ01051 Seal Kit For 126-10005-00 Brake 1 54286-394 Pump Assembly 1 018-00053-00 Seal Kit For 355-00016-00 Pump 1 162-96440-00 Cylinder, Steering 1 018-00076-00 Seal Kit For 162-96440-00 Cylinder 1 162-96443-00 Cylinder, Lift 1 018-00070-00 Seal Kit For 162-96443-00 Cylinder Decal Set, Model V2546 1 55114 Decal, Tire Replacement Foam 4 58398

MANUAL 92361-003 JUNE 1997

FIGURE C - How to Order Parts

1.

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 TIME CONDOR Parts Department in providing the correct parts for your machine(s). Please refer to FIGURE A for Serial Number Location on this model.

2.

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

3.

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

4.

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

5.

TIME CONDOR 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.

6.

TIME CONDOR classifies its orders in the following ways: Emergency (unit out ofservice) - Top priority. Shipping deadline for emergency 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 one (1) week.

7.

TIME CONDOR has a $25.00 Net Minimum Billing charge per order.

8.

All price quotations will be valid for 90 days.

9.

Parts shown as shipped on the TIME CONDOR 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.

MANUAL 92361-003 JUNE 1997

FIGURE C How to Order Parts,

TIME CONDOR PARTS DEPARTMENT FAX ORDER FORM FAX NO. 800-443-5803 ,CCOUNT # I NAME C N U F ADDRESS S 0 T R 0 M CITY M A E T R I PHONE 0 N ( ) CUST. PURCHASE ORDER NO.

PURCHASER

SALES ORDER # NAME

STATE

S ADDRESS HT I 0 CITY p

ZIP

PHONE

FAX

STATE ZIP

FAX

( ) ( ) REQUEST DATE SPECIAL MARKS & NUMBERS

( ) ORDER DATE

SHIPPING INSTRUCTIONS

QTY.

PART NUMBER

DESCRIPTION

..

NOTES ,

,

2

FOR ORDER STATUS PLEASE CHECK APPROPRIATE BOX BELOW

EMERGENCY STOCK JUNE 1997

FIGURE 1.1 Final Installation

3

MANUAL 92361-003 JUNE 1997

FIGURE 1.1 Final Installations

ITEM PART NUMBER DESCRIPTION Ref. M-V2546 Model V2546 Scissor Installation, Platform 1 55098 Installation Armstack

2 54961 Installation Chassis 3 55095 4 55062.3146 Installation Electrical Installation Hydraulic 5 55097 Schematic, Hydraulic -6 55056 Schematic, Electrical -7 55060 Tape, Non-Stick 6 00" Black

-8 53259 Hose Kit -9 55176 Cover Installation -10 55099 Decal Installation -11 55114 ,

,

,

,

- Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY Ref. 1 1 1 1 1 1 1 3.83LF. 1 1 1

FIGURE 1.2 Decal Installation

L. I o

i

("--N

',.

7-----,

,

( 1 8 )

)

7-- \ /---- \ /----,

;9

) ( 1

6 ) , 2

../ /

,/---

(

Q ./ ,„,,, _.. c c.,

) 4 / ) \_

16

4

MANUAL 92361-003 JUNE 1997

R ATA Vi

7-N

(18)

FIGURE 1.2-Decal Installation ITEM PART NUMBER DESCRIPTION

Decal V2546 Set Ref. 55114 Replaced By 55894 1 54749 2 55894 Decal, V General Caution Decal, Danger Arm Stand 3 54183 Decal, Lower Control Valve 4 54288 5 21882-002 Decal, Danger Not Insulated 6 21882-001 Decal, Keep Clear Decal, Battery Charger Plug 7 54182 Decal, Battery Service 8 50070 Decal, Lower Control Operator's Instruction 9 54301 Decal, Caution Tie Down Ring 10 54416 Decal, Upper Control Operator's Instruction 11 54300 12 13 69473-002 Decal, Condor 14 Decal, Caution Emergency Lowering 15 55008 16 54652-003 Decal, Guardrail/Chain Caution Decal, Tire Replacement Solid 17 58399 Replaced By 54984-007 18 21850 19 54984-007 Decal, Hydraulic Fluid Tape, 6" W Non-Skid Black 20 53259 Decal, Caution 21 54280 Decal, Free-Wheel Instruction 22 54291 Decal, Free-Wheel Valve 23 54320 24 55160 Decal, Emergency Lower Instruction 25 54338 Decal, Rated Load 250/750LBS 26 54348 Decal, Control Station - Indicates Item Not Shown

MANUAL 92361-003 JUNE 1997

QTY

Ref. 1 1 2 1 2 2 1 2 1 4 1 4 1 1 4 1 1 1LF. 1 1 1 1 1 1

FIGURE 1.2 Decal Installation

(-2, 1z

7-, )

,

:

, ' ,;

, [

\

,z__

Li

U

oi

-

7':, '

\ ii. !----- /.-- 7-----\

'' '

---,

:

7

*\____./

\/

\ ;,

..

q- -,--

p

10 )

Lt

; • 1 i

.., T1AL

VF

NSE VIEW OF

1 •

1 1 I

RAFT AF VIEF 3-5' 232

ARTIAL V1F

MANUAL 92361-003 JUNE 1997

■-/

FIGURE 1.2-Decal Installation ITEM PART NUMBER DESCRIPTION

Decal V2546 Set Ref. 55114 Replaced By 55894 1 54749 Decal, V General Caution 2 55894 Decal, Danger Arm Stand 3 54183 Decal, Lower Control Valve 4 54288 5 21882-002 Decal, Danger Not Insulated 6 21882-001 Decal, Keep Clear Decal, Battery Charger Plug 7 54182 Decal, Battery Service 8 50070 9 54301 Decal, Lower Control Operator's Instruction Decal, Caution Tie Down Ring 10 54416 Decal, Upper Control Operator's Instruction 11 54300 12 13 69473-002 Decal, Condor 14 Decal, Caution Emergency Lowering 15 55008 16 54652-003 Decal, Guardrail/Chain Caution Decal, Tire Replacement Solid 17 58399 18 21850 Replaced By 54984-007 19 54984-007 Decal, Hydraulic Fluid Tape, 6" W Non-Skid Black 20 53259 Decal, Caution 21 54280 22 54291 Decal, Free-Wheel Instruction 23 54320 Decal, Free-Wheel Valve 24 55160 Decal, Emergency Lower Instruction 25 54338 Decal, Rated Load 250/75OLBS Decal, Control Station 26 54348 - Indicates Item Not Shown

MANUAL 92361-003 JUNE 1997

QTY

Ref. 1 1 2 1 2 2 1 2 1 4 1 4 1 1 4 1 1 1LF. 1 1 1 1 1 1

FIGURE 2.1 Chassis Installation

2

18

2C

21

MANUAL 92361-003 JUNE 1997

A DIVISION OF TIME MANUFACTURING

SELF-PROPELLED ELEVATING WORK PLATFORM

MODEL 2546 ILLUSTRATED PARTS MANUAL

SHIPPING ADDRESS

MAILING ADDRESS

CONDOR

CONDOR

A DIVISION OF TIME MANUFACTURING

A DIVISION OF TIME MANUFACTURING

8300 IMPERIAL DRIVE WACO, TEXAS 76712 (254) 420-5200

P.O. Box 21447 76702-1447 (254) 420-5200

WACO, TEXAS

MANUAL 92361-003 June 1997

A DIVISION OF TIME MANUFACTURING

CONDOR® SERVICE INFORMATION

1. If you need assistance or have any service or maintenance questions, Condor service and parts personnel are always available by phone or fax. The telephone numbers are: (254) 420-5200 Telephone (254) 420-5298 Voice Mail (800) 443-5803 FAX

2. There are numerous written Maintenance Procedures available for this machine.

These procedures are available through the Condor Service Department to anyone who requests them.

3. Service and maintenance are not a substitute for trained, qualified service technicians.

Condor 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 Condor Service Schools help you provide this training.

4. Condor 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.

CONDOR DIVISION

8300 IMPERIAL DRIVE, P.O. Box 21447, WACO, TEXAS 76702-1447 • 254-420-5200, 817-666-4544 FAX

INTRODUCTION

The primary purpose of this manual is to provide the user with a thorough understanding ofthe 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 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 RESPONSIBILITY 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 ofthe ANSI/SIA 92.6-1990 Manual of Responsibilities is attached for your use.

Condor Division 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 CONDOR DIVISION

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 Condor division in order to ensure the original integrity ofthe product. Repairs and adjustments should only be made by trained and qualified personnel. Please refer to the maintenance and parts sections of the Condor Operation, Maintenance, & Parts Manual for information on service and maintenance of the CONDOR®.

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

i

CONDOR() MODEL V2546 ILLUSTRATED PARTS MANUAL TABLE OF CONTENTS

INTRODUCTION CONDOR® SERVICE INFORMATION

ii

TABLE OF CONTENTS FIGURE

DESCRIPTION

PAGE

A

B C

Serial Number Location Recommended Spare Parts List How To Order Parts

1.1 1.2

Final Installation Decal Installation

2.1 2.2 2.3 2.4

Chassis Installation Steer Axle Assembly Brake And Drive Assembly Brake Assembly

12 14 16 18

3.1 3.2 3.3 3.4 3.5 3.6

Hydraulic Installation Hydraulic Tank Installation Lower Control Valve Assembly Lift Cylinder

Valve, Creep Speed Valve, Series Parallel

20 21 22 23 24 25

4.1 4.2 4.3

Wiring Battery Installation Lower Control Assembly

26 28 29

5.1

Arm Stack Installation

30

6.1 6.2 6.3 6.4 6.5

Platform Assembly Upper Control Box Installation Holder Assembly Cover Installation Hose Kit

34 36 38 39 40

7.1 7.2

Schematic Electrical Schematic Hydraulic

42 43

8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12

Deck Extension ( Option ) 110V Line To Platform ( Option ) Hour Meter ( Option ) Travel Alarm ( Option ) Multi-Axis Slope Sensor ( Option ) Strobe Light ( Option ) Non Marking Tires ( Option ) Battery Condition Indicator ( Option ) Descend-Warning ( Option ) Low Voltage Warning Interrupt ( Option ) Key Switch ( Option ) Lifting Eyes ( Option )

44 46 48 49 50 51 52 53 54 55 56 57

MANUAL 92361-003 JUNE 1997

2 3 4,5 6 8

FIGURE A—Serial Number Location

STAMP ON DATA PLATE

STAMP ON DRIVE AXLE

The CONDOR® Model V2546 Serial Number is stamped in two locations on the machine.

1.

The first place to find the serial number is on the data plate affixed to the chassis, above ground controls.

2.

The second serial number is located at the left rear (drive) axle.

MANUAL 92361-003 JUNE 1997

FIGURE B Recommended Spare Parts Lists CONDOR® MODEL V2546 (1 UNIT 1 YEAROPERATION)

QTY PART NUMBER DESCRIPTION

Filter, Hydraulic Return 4 33430 Switch, Hi/Lo Speed 1 54191 1 392-00008-00 Switch, Master Disconnect 1 392-00009-00 Switch, Emergency Stop 1 392-00021-00 Switch, Push Button, Lower Control 1 394-00009-00 Solenoid, 36VDC, Pump Mtr. Start Holder, Safety Manual 1 34354 4 92338-001 Manual, Operation & Safety 4 396-00003-00 Stud, Wheel Cap Oil Filler, HydraulicTank (up to serial #3799) 1 152-00007-00 Breather Filler 1 50316

Optional

QTY PART NUMBER DESCRIPTION

1 126-10005-00 Brake Assembly 1 DR.101051 Seal Kit For 126-10005-00 Brake 1 54286-394 Pump Assembly 1 018-00053-00 Seal Kit For 355-00016-00 Pump 1 162-96440-00 Cylinder, Steering 1 018-00076-00 Seal Kit For 162-96440-00 Cylinder 1 162-96443-00 Cylinder, Lift 1 018-00070-00 Seal Kit For 162-96443-00 Cylinder Decal Set, Model V2546 1 55114 Decal, Tire Replacement Foam 4 58398

MANUAL 92361-003 JUNE 1997

FIGURE C - How to Order Parts

1.

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 TIME CONDOR Parts Department in providing the correct parts for your machine(s). Please refer to FIGURE A for Serial Number Location on this model.

2.

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

3.

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

4.

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

5.

TIME CONDOR 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.

6.

TIME CONDOR classifies its orders in the following ways:

Emergency (unit out of service) - Top priority. Shipping deadline for emergency 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 one (1) week.

7.

TIME CONDOR has a $25.00 Net Minimum Billing charge per order.

8.

All price quotations will be valid for 90 days.

9.

Parts shown as shipped on the TIME CONDOR 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.

MANUAL 92361-003 JUNE 1997

FIGURE C How to Order Parts,

TIME CONDOR PARTS DEPARTMENT FAX ORDER FORM FAX NO. 800-443-5803 ,CCOUNT # I NAME C N U F ADDRESS S 0 T R 0 M CITY M A E T R I PHONE 0 ( ) N CUST. PURCHASE ORDER NO.

I

SALES ORDER #

PURCHASER NAME

STATE

ZIP

S ADDRESS HT I O CITY p PHONE

FAX ( ) ORDER DATE

STATE ZIP

FAX ( )

( ) REQUEST DATE SPECIAL MARKS & NUMBERS

SHIPPING INSTRUCTIONS

PART NUMBER

DESCRIPTION

QTY.

FOR ORDER STATUS PLEASE CHECK APPROPRIATE BOX BELOW EMERGENCY STOCK

JUNE 1997

NOTES

FIGURE 1.1 Final Installation

3

MANUAL 92361-003 JUNE 1997

FIGURE 1.1—Final Installation

ITEM PART NUMBER DESCRIPTION Ref. M-V2546 Model V2546 Scissor Installation Platform 1 55098 Installation Armstack 2 54961 Installation Chassis 3 55095 4 55062.3146 Installation Electrical Installation Hydraulic 5 55097 Schematic, Hydraulic -6 55056 Schematic, Electrical

-7 55060 Tape, Non-Stick 6.00" Black -8 53259 Hose Kit -9 55176 Cover Installation -10 55099 Decal Installation -11 55114 ,

,

,

,

,

- Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY Ref. 1 1 1 1 1 1 1 3.83LF. 1 1 1

FIGURE 1.2 Decal Installation

1:1-111 1

11,

r" , -IIIN

,

-I/

1.--, \...__./

.

L

J D

[

11

F

1

e-

L ( 18

18

,8)

MANUAL 92361-003 JUNE 1997

).

A) T

FIGURE 1.2-Decal Installation ITEM PART NUMBER DESCRIPTION

Ref. 55114 Decal V2546 Set 1 54749 Replaced By 55894 2 55894 Decal, V General Caution 3 54183 Decal, Danger Arm Stand 4 54288 Decal Lower Control Valve 5 21882-002 Decal Danger Not Insulated 6 21882-001 Decal Keep Clear 7 54182 Decal Battery Charger Plug 8 50070 Decal Battery Service 9 54301 Decal Lower Control Operator's Instruction 10 54416 Decal Caution Tie Down Ring 11 54300 Decal, Upper Control Operator's Instruction 12 13 69473-002 Decal, Condor 14 15 55008 Decal, Caution Emergency Lowering 16 54652-003 Decal, Guardrail/Chain Caution 17 58399 Decal, Tire Replacement Solid 18 21850 Replaced By 54984-007 19 54984-007 Decal, Hydraulic Fluid 20 53259 Tape, 6" W Non-Skid Black 21 54280 Decal, Caution 22 54291 Decal, Free-Wheel Instruction 23 54320 Decal, Free-Wheel Valve 24 55160 Decal, Emergency Lower Instruction 25 54338 Decal, Rated Load 250/750LBS 26 54348 Decal, Control Station ,

,

,

,

,

,

,

- Indicates Item Not Shown

MANUAL 92361-003 JUNE 1997

QTY

Ref. 1 1 2 1 2 2 1 2 1 4 1 4 1 1 4 1 1 1LF .

1 1 1 1 1 1

,

L.J

INC

a a . . .9

HJ

Decal Installation

= ,—r, Li.

C

ciYl

N N

Cl NJ ,---,

—N

N'

FIGURE 1.2-Decal Installation ITEM PART NUMBER DESCRIPTION

Decal V2546 Set Ref. 55114 Replaced By 55894 1 54749 Decal, V General Caution 2 55894

Decal, Danger Arm Stand 3 54183 4 54288 Decal, Lower Control Valve 5 21882-002 Decal, Danger Not Insulated 6 21882-001 Decal, Keep Clear Decal, Battery Charger Plug 7 54182 8 50070 Decal, Battery Service 9 54301 Decal, Lower Control Operator's Instruction Decal, Caution Tie Down Ring 10 54416 11 54300 Decal, Upper Control Operator's Instruction 12 13 69473-002 Decal, Condor 14 Decal, Caution Emergency Lowering 15 55008 16 54652-003 Decal, Guardrail/Chain Caution Decal, Tire Replacement Solid 17 58399 Replaced By 54984-007 18 21850 19 54984-007 Decal, Hydraulic Fluid 20 53259 Tape, 6" W Non-Skid Black 21 54280 Decal, Caution 22 54291 Decal, Free-Wheel Instruction 23 54320 Decal, Free-Wheel Valve 24 55160 Decal, Emergency Lower Instruction 25 54338 Decal, Rated Load 250/750LBS 26 54348 Decal, Control Station - Indicates Item Not Shown

MANUAL 92361-003 JUNE 1997

QTY

Ref. 1 1 2 1 2 2 1 2 1 4 1 4 1 1 4 1 1 1LF. 1 1 1 1 1 1

FIGURE 2.1 Chassis Installation

2

20

21

MANUAL 92361-003 JUNE 1997

FIGURE 2.1—Chassis Installation, ITEM PART NUMBER DESCRIPTION

QTY

Installation, Chassis Ref. 55095 Ref. Chassis Weldment 1 54857 1 2 010-R1456-00 Weldment, Front Bumper 1 Weldment, Battery Hold Down 3 55937 2 4 54861 Tire & Wheel Assembly 4 5 010-R1066-00 Weldment - Rear Lower Step 1 6 020-R2102-00 Axle Assembly, Steer 1 7 624-R1129-00 Cylinder Pin Lift 6.5+1/8" 1 Pin, Steering Cylinder 2 3/16+ 1/8 -8 54035 1 -9 BOW31127 Screw, Slotted Mach. 6-32 x 1 2 - 10 BOW31231 Nut, Hex Keps #6-32 2 11 54790 Plate - 3146 Charger Mount 1 12 55302 Hub, Assembly Drive w/Studs 1 Hub, Assembly Drive w/Studs - 13 55373 1 - 14 BOW39226 Hex, HD Bolt 1-8x6.5 LG 1 - 15 331-00099-00 Nut, Stover 1-8 1 16 Ref. Assembly, Hydraulic Tank

1 -17 010-R2157-00 Cover, 3146 Left Side Servie Box 1 Cover, Weldment, RH Service 18 55006 1 19 20 Ref. Assembly, Brake 1 21 Ref Assembly, Motor & Hub (includes items12,22,23) 1 22 396-00003-00 Stud, Wheel 1/2-20 x 1 3/4 5 23 321-00013-00 Assembly, Motor 1 24 Ref Assembly, Battery 1 25 37398-004 Wrap, Arm 5 - Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

FIGURE 2.2—Steer Axle Assembly

V--

C■1 CN

N

MANUAL 92361-003 JUNE 1997

Lf)

FIGURE 2.2 Steer Axle Assembly ITEM PART NUMBER DESCRIPTION

Ref. 020-R2102-00 Axle Assembly Steer 1 55380-001 Hub/Knuckle Weldment Left Hand Steer 2 55380-002 Hub/Knuckle Weldment Right Hand Steer 3 289-00002-00 Steer Hub Assembly 4 396-00003-00 Stud, Wheel 5 34341 Rod End, Male 75 RH #67821 6 124-00028-00 Bushing 1.00' x .75" x 1.00" Bushing Flanged 7 35493 8 54483 Tie Rod, 3146 25 25" + 125" -9 350-00017-00 Pin, King Kit (includes items 10-13) 10 54035 Pin, Steering Cylinder 11

Shim (included in kit) 12

Bearing (included in kit) 13 BOW40541 Screw, Set .38"-16UNC x .50" Grade5 14 BOW32278 Nut, Jam 75"-10 15 BOW34278 Nut, Stop Elastic 75"-10 16 BOW30160-3 Bolt, Hex 75"-10UNC x 3.00' 17 BOW30160-2 Bolt, Hex 75"-10UNC x 2.00" 18 124-00040-00 Bushing 1.00" x 75" x 75" Long 19 162-96440-00 Cylinder, Steer 1 1/2" x 5 1/4" 1 20 34966-408 Assembly, Orifice Fitting 024441.052 21 253-96590-00 Elbow 90° 22 BOW36708 Washer, Flat 75" Grade 12 -23 018-00036-000 Kit, Seal

- Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY

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

FIGURE 2.3 Brake And Drive Assembly n

12 14

Fl

b

13 14

NOTE:

1

1. TORQUE TO 450 FT. - LBS

2. TORQUE TO 350 FT. - LBS

MANUAL 92361-003 JUNE 1997

FIGURE 2.3—Brake And Drive Assembly ITEM PART NUMBER DESCRIPTION

Motor/Hub (includes item 3) 1 Ref 2 289-00003-01 Hub, Drive (includes 3 & 4) 3 289-0003-00 Hub 4 55363-001 Stud 5 54754-001 Motor, Hyd Brake/Motor Hub (includes items 7 & 8) 6 Ref Brake, Eskridge 7 55071 8 289-00007-01 Hub (includes 9 & 10) 9 289-0007-00 Hub 1 5 Tapered Wheel 10 55363-001 Stud, Wheel 11 54754-002 Motor, Hyd 12 BOW30111 Bolt, Hex Grade 5 50"-13UNC 2.75" Long 13 BOW30112 Bolt, Hex Grade 5 50"-13UNC 3 00" Long 14 BOW36729 Washer, Lock. 50" - Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY

Ref 1 1 5 1 1 1 1 1 5 1 4 4 8

FIGURE 2.4 Brake Assembly

22

MANUAL 92361-003 JUNE 1997

FIGURE 2.4 Brake Assembly ITEM PART NUMBER DESCRIPTION

Ref. 55071 Assembly, Brake 1 DRJ01034 Nut, Slotted Jam 2 DRJ01035 Screw, Socket Head Cap 3 DRJ01036 Plug, Hollow Hex 4 DRJ01037 Case, Brake 5 DRJ01038 Bearing, Output 6 DRJ01039 Key 7 DRJ01040 Shaft 8 DRJ01041 Spacer 9 DRJ01042 Plate, Serarate 10 DRJ01043 Plate, Bronze Friction 11 DRJO1O44 Piston 12 DRJ01045 Spring, Blue 13 DRJ01047 Cover, Brake 14 DRJ01048 Bearing, Input 15 DRJ01049 Ring, Snap 16 DRJ01050 Ring, Snap • Kit, Seal (includes items 18-23) - 17 DRJ01051 -18

Ring, Piston Backup

0-Ring, Piston - 19

-20 0-Ring Piston -21

Ring, Piston Backup -22

0-Ring, Case Seal -23

Gasket, Mounting

- Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY

1 1 4 1 1 1 1 1 1 9 8 1 12 1 1 1 1 1 1 1 1 1 1 1

20 ' FIGURE 3.1—Hydraulic Installation ITEM PART NUMBER DESCRIPTION

Ref. 55097 Hydraulic Installation - 1 020-R0030-00 Assembly, Wheel Motor Fit -1A 253-96505-00 -Fitting, P - 4-F50X-S -1B 253-96610-00 -Fitting, P - 6-10-F50X-S -2 020-R0035-00 Valve Assembly, Lower Control -3 54286-394 Pump Fixed Displ. (.394) Gear -4 020-R0045-00 Assembly, Pump Fittings -4A 253-96586-00 -Fitting, P:6-8-F5OX-S -4B 253-96653-00 -Fitting, P: #10 -5 020-R0052-00 Cylinder Assembly, Lift -5A 55208 -Cylinder, Lift -5B 52733 -Valve, 2Pos-2Way, NC

-5C 34966-414 -Orifice Fitting Assembly 04151/ 106 -6 020-R0055-00 Assembly, Steer Cylinder -6A 162-96440-00 -Cylinder, Steering -6B 34966-408 -Orifice Fitting Assembly 02444/.052 Brake, 1600LB-IN -7 55071 -8 54357 Creep Speed Valve Assembly Assembly, Hydraulic Tank -9 55005 -10 02431 • Fitting, Straight MJ06 MB06 -11 21481 Valve, Shuttle - 12 52661 Valve, Flow Control (Ref 66418) - 13 315-00027-00 Valve Assembly, Series Parallel -14 54754-001 Motor, Hyd. Wheel - 15 54754-002 Motor, Hyd Wheel - Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY

Ref. 1 1 4 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1

FIGURE 3.2—Hydraulic Tank Assembly 10 14 15

11

12 6 2

1

13

ITEM PART NUMBER DESCRIPTION

Assembly, Hydraulic Tank Ref. 55005 Filter, Return Assembly 1 33430 -Filter Head, Retuen Line 1A 110-2 -Element, Hydraulic Filter 1B 110-1 Fitting, Swivel 8x8 2 02338 Fitting, Straight MP8 MJ10 3 02802 Fitting, Elbow 90°MP4 MJ6 4 02444 5 00326 Fitting, Tee MJ8 MJ8 FJ8 6 253-96641-00 Fitting, Reducer 7 254-00009-00 Nipple, Pipe 75" x Close 8 00393 Elbow Street 90° 75"MP12 MJ8 Tank, Hydraulic Oil 1933 9 55002 10 529-G4076-00 Cover, Hydraulic Tank 11 259-00001-00 Gasket, Hydraulic & Fuel Tank Breather Filler 12 50316 Gauge, Fluid Level 13 52049 14 BOW31838 Screw, Self Tapping 25"-20 x .50" 15 BOW31431 Washer, Flat 25" - Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY

Ref. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8 8

FIGURE 3.3—Lower Control Valve Assembly

10

ITEM PART NUMBER DESCRIPTION

Ref. 020-R0035-00 Assembly, Lower Control Valve 1 315-00036-00 Valve, Lower Control/Lift 2 04523 Fitting -3 02473 Fitting Adapter -4 00458 Fitting Adapter 5 02662 Fitting Handle, Raise/Lower 6 54281 7 21481 Valve, Shuttle Elbow 90°MJ6 MP4 8 00128 9 04601 Fitting Fitting 10 00314 11 450-00072-00 Valve, Flow Control

- Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY

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

FIGURE 3.4 Lift Cylinder

3 // 4

10

5

9

Tor• ue: 780-840 Ft.Lbs.

11 1

ITEM PART NUMBER DESCRIPTION

Ref. 55208 55208-101

1

2

3

4

5

6

7

8

9

10

11

3146 Lift Cylinder Seal Kit 0-Ring Seal 0-Ring Back-Up Wear Ring Seal Wiper Lube Fitting Lock Nut Bushing Bushing

- Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY

Ref 1 1 1 1 1 1 1 1 2 1 1 2

FIGURE 3.5—Valve, Creep Speed ITEM PART NUMBER DESCRIPTION

Ref. 54357 - 1 54477 -2 00344 -3 04134 -4 04628 -5 21479

Creep Speed Valve Assembly Valve, 2 Way NO 24V Poppet Tee, MJ04 FJO4 MJ04 Straight, MJ04 M008 Elbow, 90° MJ04 M008 Valve, 1/4 NPT Needle

- Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY

Ref. 1 2 1 1 1

FIGURE 3.6—Valve, Series ParaHee 2 1 2

M3

0

M1

n

TI

'

fl-\

M3 M2

••• -7-

Mir M4 PA

ITEM PART NUMBER DESCRIPTION

PB

QTY

Ref. 315-00027-00 Assembly, Valve, Series Parallel (Creep Speed) Ref. 1 GWE01003 Flow Divider 1 2 GWE01004 Valve Cartridge 1 1 3 GWE0100 Valve Cartridge 4 GWE01005 Coil 2 5 GWE01006 Seal Kit (for GWE01003) 1 6 GWE01007 Seal Kit (for GWE01004) 1 - Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

CABLE BETWEEN UPPER & LOWER CONTROLS DESCRIPTION OF CIRCUITT

COLOR SIGNAL HORN OPTION

OPTIONAL L()W VOLT O'RIDE 1 =BLU/BLK

EMERGENCY STOP SWITCH SEE NOTE 2

0= BLU

0 3=RED

-

LOWERING SWITCH SEE NOTE 2

8 -, RLD/EiLK 1 RAT VERY CONDI TITER R' OPTION INDICATOR

SA=WHT

FOOT SWITCH

7= WH T/BLK

3A=BLK 5A= WH1 \= 5A= ORN

7 El

WHT/BEK

DOWN (HOLD VALVES)

RED/BLK

9 10

GRN/BLK ORN/BLK

SPARE, OR GAGE OPTION SLOPE ALARM OPTION SIGNAL (HORN/SWITCH) OPTION LOW VOLT O'RIDE OPTION LOW VOLT ALARM OPTION NOT USED

11

BLU/BLK

12 13 (4

BLK/WHT

15 TEl

HEW GRN

WHT

9= GRN/L-3LK

4

NEUTRALL LIVE (HOT) GROUND STROBE LIGHT OP TION POWER TO LOWER CONTROLS

SLOPE ALARM OPTION

1= GRN

-Q.

I-1 SPEED LIMIT SWITCH UP (PUMP "ON")

ORN BED

Si

4

POWER TO UPPER CONTROLS CREEP (SWITCH/VALVE)

HEW

4

5

' 0

SPARE, OR GROUND FOR OPTIONS FAST (S-P VALVES)

GRN WHT RED

2

HORN

10 =ORN/BLK 4 =LEEK 2=WH T

TX LI TTLOW/T AS I lOT SWITCH 54247-042.00

00

1.00

54247 -Dl 5.1 2

CABLE ASSY, 62 1/2" BATTERY CABLE ASSY, 19 3/4" BATTERY

EA

CABLE ASSY, 75 1/2" BATTERY

EA

CABLE ASSY, 47 /2" BATTERY

1.00

EA

CABLE ASSY, 37 1/2" BATTERY

.00

54247-0047.5 54247-0037.5

41

CABLE ASSY, 15 1/8" BATTERY

.00

54247-0075.5

SEE NOTE 3

17

CABLE ASSY, 42" BATTERY

EA EA

1.00

54247-019.75

EA EA

1.00

54247-0062.5

CABLE ASSY, 47 1/2" BATTERY

54247-0047.5

1.00

54247-005.75

1.00

1.00

EA

CABLE ASSY, 5 3/4" BATTERY

54247-007.25

5.00

5.00

EA

CABLE ASSY, 7 1/4" BATTERY

REF

REF

1.00

1.00

PET1 GRN WHT WHT 2 RED H RED

BLK BLK ORN ( ORN

EA

GRN

p, (

BLU

6 B WHT/BLK RED/BLK GRN/BLK ORN/BLK

(;ttH-1 (" (_ CONTROL CABLE TO TERMINAL BOARD ON CHASSIS

55062

CONTINUED ON SHEET 2

13 WHT OPTIONAL I N10 CVOORLDT EXTENSION

1.00

55062-002

SEE NOTE .3

BLU/BLK BLK/WHT 12 BLK/WHT

55062 001

1.00

6675

1.00

1.00

10 VOLT EXT OPTION

EA

WIRING Dwc, 3146/6C ELECTRICAL

EA

CABLE KIT, 3160 BATTERY

EA

CABLE KIT, 3146 BATTERY

EA

FOOT SWITCH W/GuARD N CABLE

34552-016

.00

1.00

EA

15=LIVE=BLK

67295-035

3.41

3.41

LF

CABLE 16GAGE/8 CONDUCTOR SJO

16 = GROUND =GRN

50089

.00

.00

EA

FUSE HOLDER

14=NEU TRAL=WHT

67123-00

1.00

67114-002

1.00

.00

EA

STRAIN RELIEF 1/2 NOT .25/.3

.00

1.00 1.00

EA

ARM ADJUSTABLE LIMIT ROTC

.00 1.0(1 1.00

EA

SWITCH LIMIT BODY ONLY

EA

STRIP, TERMINAL

EA

GUARD TOGGLE SWITCH MICRO

EA

SWITCH (REF P/N 67760)

51039

TERMINAL STRIP ON TOEBOARD OF PLTFRM

1.00

51036

.00 1.00

34552 - 012

1.00

40880

1.00

50075

1.00

1.00

322-00015-00

1.00

1.00 1.00 1.00 1.00

51037

52138

.00

52029

1.00

52071

1.00

50046

6.00

67295- 023 60.00 PART NUMBER

EA

EA

SEAL, CONNECTOR ELECT 1/2"

OFFSET HEAD LIMIT SWITCH

MOTOR ELECTRIC BALDOR 36V

EA

SOLENOID 24V

EA

BASE +2 NO CONTACTS ZB2-B2103

EA

OPERATOR, 3P05 ROT KEY ZE12-BC3

BATTERY, 6 VOLT EA 6.00 65.00 EF CABLE, 16CA/8 CONDUCTOR

67295-023

LB

EA

STRIP, TERMINAL

I F CABLE, 16(15/8 CONDuC lOR 1.00 1 A CI-TARCER, BAT EERY :56VDC/40A TY UM DESCRIP DON

(1 IT

PROPRIE TARY

NO TUT:

WACO, TEXAS

94 82 6

1, THIS DIAGRAM SUPERCEDES 54350.

2. LOWERING SWI ICH AND EMERGENCY STOP SWITCH ARE PART OF UPPER CON TROL BOX ASSY. 3. ITEM 20 CONSISTS OF ITEMS 56.

12/11/90R AK

8689

10/24/95 RA

82 80

1/05/99 BAK

81.

WM/95 RAK

C C.N. NO

TI

WIRING DWG, 3146/60 ELECTRICAL 10 FIANCES (IN,

DA IC APPFT. OTTA.

A Han,

5.551 IN

E R.N. NO DATE APPR, L

RAK

04/06/95

DRAWING N

C scALE NONE

55062 1 OF 2

MOTION AL ARM OP TION

7A

TRAVEL ALARM OPTION

-

CON TROL CABLE TO TERMINAL STRIP ON PLATFORM CONTINUED ON SHEET 1

36

NOTE 2

6

HOUR ME TER OP TION

REF

12=BLK/WHT

TERMINAL BOARD

SLOPE

WH T=9

BLK

9 -.GRN /BLK 11 = BLU/BLK

SENSOR OP TION

9 SEE NOTE 3

1"-0----1 F 0 12

= RED

FRE) 3

CO-2-1

6 =BLU

55

CON TACTOR

3C

7

UPPER UP OFF TB LOWER 0

0 C

3LI

.3A _ 20 AMP FUSE

0) 3-POS ROT SELECTOR SWITCH

0

8 4 PL

(i6

B=RED/BLK

8

DOWN

MOTOR

C

E_2)

A2 S1 +

z

17

No

10

C

S2

WILT WHT

rr

NV

(-r

C-) NV NV

7= WH T/BLK 7

5= ORN 5

BEACON/STROBE OP TIC/N

BLK --NO NC

3A,

00000

WHT CREEP SPEED VALVE BLK

) (12

4=BLK 1 =GRN

BLK

1

-4- H) d) NV 6V 6V

0

5,.•

B

SERIES/PARALLEL

.1 DRIVE SPEED VALVE WH 0-0 2 .. WI I I

• 7=WH T SIGNAL HORN OPTION

HOLDING VALVE ON UOL IL SEC NOTE 1

WHT

4

(3) All

WH I 10

10= ORN/BL. K

1.3 0-

[ ..t7 MI.110L1

DESCEND ALARM OP 111)5

K

BLK

1=BLK

BR

0) I

BATTERY CHARGER

-0

NIL ICC: 1. MDL TI 46 HAS CURLY ONE HOLDING VALVE. MDL 60 HAS TWO. 2. PRESSURE TWIT CI-1 SENSES BRAKE RELEASE' PRESSURE. 1. (1) 11-1511 (7) REPRESENT TERMINALS ON OPTIONAL LOW VOL I SENSOR/SWI TCH.

=71'4 A WISAND „„..

-..."

taNVZSERAZIN' IrT■ riET

WACO,

TEXAS

TITLE

WIRING DWG, 3146/60 ELECTRICAL

rOLERANa

REV

A.fil T TLE 04,1/9 E m

Ri1;

0 fiAK

5 5 0 2

DRAWN' N' .ALC NONE

I ,I4F, II 2 OF 2

FIGURE 4.2—Battery Intstallation

12 11 10

1

7

ITEM PART NUMBER DESCRIPTION 1 121-00004-00 Battery, 6 Volt Trojan J250-VT 2 54625 Weldment, Battery Hold Down Charger, 36V/40 AMP 3 34037 4 54247-014 Assembly, Cable Battery 7.25" Long 5 54247-012 Assembly, Cable Battery 20" Long 6 54247-011 Assembly, Cable Battery 45.75" Long 7 54247-013 Assembly, Cable Battery 49" Long -8 54247-016 Assembly, Cable Battery 5.75" Long -9 54247-015 Assembly, Cable Battery 12" Long 10 51036 Switch, Limit Body Only 11 51037 Offset Head Limit Switch 12 51039 Arm Adjustable Limit Switch -14 315-00027-00 Creep Valve Assembly - Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY 6 2 1 5 1 1 1 1 1 1 1 1 1

FIGURE 4.3—Lower Control Assembly

ITEM PART NUMBER DESCRIPTION

1 52138 Solenoid 24V 2 322-00015-00 Motor, Electric Baldor 36V 3 152-00023-00 Wire-14 Gage Green -4 158-00022-00 Wire-18 TFFN Black 5 34552-010 Strip, Terminal 6 52370 Operator Selector 7 52029 Block Contact 2NO 8 50075 Switch (Ref P/N 67760) -9 50089 Fuse Holder -10 34552-016 Terminal Strip -11 54433 Coupling Pump/Motor 12 54286-394 Pump Fixed Displaced 394 Gear 13 253-96586-00 Fitting 14 253-96653-00 Fitting -Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY

1 1 1Lf 1Lf 1 1 1 1 1 1 1 1 1 1

FIGURE 5.1—Arm Stack Installation

2

10 115

MANUAL 92361-003 JUNE 1997

FIGURE 5.1— Arm Stack Assembly, ITEM PART NUMBER DESCRIPTION

QTY

Arm Stack Installation Ref. 54961 1 Arm Stack 1 54407 1 2 54407-002 Weldment, Arm Lower Inner 1 3 167-00003-00 Collar, Shaft 1.00" 2 4 124-00030-00 Bushing 2.50" x 2" x 2.50" 16 5 54407-006 Weldment, Arm Outer 4 6 54407-005 Weldment, Arm Middle Inner 1 7 54407-007 Weldment, Arm Upper Inner 1 8 54407-008 Weldment, Arm Outer 2 9 010-R2004-00 Weldment, Hose Tray Upper Left 1 10 010-R2003-00 Weldment, Hose Tray Upper Right 1 11 010-R2003-01 Weldment, Hose Tray Lower Right 1 12 010-R2004-01 Weldment„ Hose Tray Lower Left 1 13 124-00028-00 Bushing, 1" x .75" x 1" 4 - 14 54450 Pad, Chassis Side 2 15 167-00002-00 Collar, Shaft 2 00"Dia

16 -16 ZUA01001 Lanyard 1 17 54407-001 Weldment, Arm Stand 1 18 54407-003 Weldment, Arm Lower Left 1 19 54407-004 Weldment, Arm Lower Right 1 -20 54449 Pad, Deck Side 2 -21 BOW34274 Nut, Hex Lock 3/8 - 16UNC 2 -22 BOW34278 Nut, Stop-Elastic 3/4-10 1 -23 BOW36055 Bolt, Hex 38"-16UNC x 1.250" 2 -24 BOW30160-4 Bolt, Hex 75"-10UNC x 4.O0" 1 25 51476-004 Pin, Quick Release 31" x 2" Grip 1 26 286-R2002-00 Cover, Hose Tray 2 27 286-R1002-00 Cover, Hose Tray 2 -28 54925 Washer, Hose Tray 1 29 37398-004 Wrap, Arm 3146 5 30 020-R5002-00 Assembly, Lift Cylinder (includes following 4 items) 1 -31 162-96443-00 Lift Cylinder 1 -32 018-00070-00 Kit, Lift Cylinder Seal 1 -33 34966-411 Orifice Assembly 1 -34 52733 Valve 1 - Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

O

FIGURE 5.1— Arm Stack Assembly

MANUAL 92361-003 JUNE 1997

FIGURE 5.1— Arm Stack Assembly.

ITEM PART NUMBER DESCRIPTION

QTY

Arm Stack Installation Ref. 54961 1

Arm Stack

1 54407 1 2 54407-002 Weldment, Arm Lower Inner 1 3 167-00003-00 Collar, Shaft 1.00" 2 4 124-00030-00 Bushing 2.50" x 2" x 2.50" 16 5 54407-006 Weldment, Arm Outer 4 6 54407-005 Weldment, Arm Middle Inner 1

Weldment, Arm Upper Inner 7 54407-007

1 8 54407-008 Weldment, Arm Outer 2 9 010-R2004-00 Weldment, Hose Tray Upper Left 1

Weldment, Hose Tray Upper Right

10 010-R2003-00 1 11 010-R2003-01 Weldment, Hose Tray Lower Right 1 12 010-R2004-01 Weldment„ Hose Tray Lower Left 1 13 124-00028-00 Bushing, 1" x .75" x 1" 4 Pad, Chassis Side -14 54450 2 15 167-00002-00 Collar, Shaft 2 00"Dia 16 -16 ZUA01001 Lanyard 1 17 54407-001 Weldment, Arm Stand 1 18 54407-003 Weldment, Arm Lower Left 1 19 54407-004 Weldment, Arm Lower Right 1 -20 54449 Pad, Deck Side 2 -21 BOW34274 Nut, Hex Lock 3/8 - 16UNC 2 -22 BOW34278 Nut, Stop-Elastic 3/4-10 1 -23 BOW36055 Bolt, Hex .38"-16UNC x 1.250" 2 -24 BOW30160-4 Bolt, Hex 75"-10UNC x 4 .001 1 25 51476-004 Pin, Quick Release 31" x 2" Grip 1 26 286-R2002-00 Cover, Hose Tray 2 27 286-R1002-00 Cover, Hose Tray 2 -28 54925 Washer, Hose Tray 1 29 37398-004 Wrap, Arm 3146 5 30 020-R5002-00 Assembly, Lift Cylinder (includes following 4 items) 1 -31 162-96443-00 Lift Cylinder 1 -32 018-00070-00 Kit, Lift Cylinder Seal 1 1 -33 34966-411 Orifice Assembly -34 52733 Valve 1 - Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

FIGURE 6.1— Platform Assembly

11

15

MANUAL 92361-003 JUNE 1997

FIGURE 6.1 -Platform Assembly

10

ITEM PART NUMBER DESCRIPTION

QTY

Ref. 55090 Assembly, Platform 1 1 54946 Weldment, Platform 1 -2 54021 Rail Guard 1 3 54043 Plate, Toe Front, Bolt On 1 4 54349 Deck, Platform 1 5 54278 Cover, Platform Tubing 1 -6 34354 Holder, Saftey Manual- Black Caps 1 7 36084 Guard, Foot Switch 1 8 52090 Plug, Protective 12 9 51476-001 Pin, Quick Release 6 10 67295-023 Cable 10 Cond 16 AWG Type SO 4LF 11 55151 Control Box Assembly, Platform 1 12 ZUA01001 Lanyard, Quick Release Pin 6 13 BOW34113 Rivet, Pop 4 14 36083 Switch, Foot 1 36083-100 -Service Kit 1 -Switch

1

-Binder Head Terminal Screw & lipless Cupwasher 3 15 54006 Plate, Toe 2 -16 50286 Chain Snap 1 - Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

IGURE 6.2—Upper Control Box Installation

1

ni

CC III >

0 C 0

3 PL 4 FL

3 FL

5

PL

J

u-

0

0 II fl_ Fr'

3

(/.3) 2 FL

D

14

MANUAL 92361-003 JUNE 1997

FIGURE 6.2—Upper Control Box Installation ITEM PART NUMBER DESCRIPTION

Ref. 55151 Upper Control Box Installation 1 54060 Cover, Control Box 2 54061 Panel, Side Control Box 3 010-R1013-00 Handle, Control Box 4 54498 Spacer, Upper Control Valve 5 020-M1035-00 Valve Assembly, Upper Control 6 51913 Switch, Emergency Shut Off 7 51914 Contact Block, NC 8 67872 Switch-Short Arm 9 BOW34273 Nut, Stop, 5/16-18UNC 10 BOW30037 Bolt, Hex 31"-18UNC x 3.00" 11 BOW33848 Screw, Self-Tap 25" x 1.00" 12 52672 Base + 1NO Contact ZB2-BZ101 13 BOW31127 Screw Grade 5, #6-32 14 54192 Plug, Hole 1.25" Dia. 15 54193-001 Plug, Hole 1.125" Dia. 16 52028 Operator, 2 Pos. Rot. ZB2-BD2 17 54187 Decal, Lift Control 18 Decal, 2546 Upper Control Top - Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY

Ref. 1 1 1 3 1 1 6 1 3 3 8 1 2 1 1 1 1 1

FIGURE 6.3—Holder Assembly ITEM PART NUMBER DESCRIPTION

Ref. 34354 Holder Assembly -1 65158 Conduit, 2 5"ID 11 50" Grey PVC -2 65150 Cap, Safety Manual Holder Flex

- Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY

Ref. 1 2

FIGURE 6.4—Cover Installation ITEM PART NUMBER DESCRIPTION

Ref 55099 Cover Installation -1 010-R2157-00 Cover, Left SD Service Box -2 55006 Cover, Weldment, Right Service -3 54278 Cover, Platform Tubing -4 276-R1046-00 Latch-Rubber Hold Down

- Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY

Ref 1 1 1 4

UPPER CONTROL VALVE RIGHT MOTOR

5

B2 A2 I 83 B1 Al

2 M3

M4

(21

BULKHEAD

26

PB

CI\ SERIES/PARALLEL VALVE PA

I

M2

cas

M1

STEER CYLINDER

12 BRAKE

LEFT MOTOR

18

SHUTTLE SOL

LIFT CYLINDER

B

LOWER CONTROL VALVE

HYDRAULIC TANK

P1

FIGURE 6.5—Hose Kit ITEM PART NUMBER DESCRIPTION

Ref. 55176 Hose Kit 1 66712-013.50 Hose Assembly #06 66645 J37 ST-90 2 66698-046.50 Hose Assembly #06 66645 J37 ST-ST 3 66698-046.50 Hose Assembly #06 66645 J37 ST-ST 4 66698-049.50 Hose Assembly #06 66645 J37 ST-ST 5 66698-049.50 Hose Assembly #06 66645 J37 ST-ST 6 66043-033.50 Hose Assembly #3 67684 J37 STJ-STJ 7 66043-032.50 Hose Assembly #3 67684 J37 STJ-STJ 8 66043-025.50 Hose Assembly #3 67684 J37 STJ-STJ 9 66696-042.50 Hose Assembly #04 66646 J37 ST-ST 10 66712-031.50 Hose Assembly #06 66645 J3 7 ST-90 11 66698-035.50 Hose Assembly #06 66645 J37 ST-ST 12 66043-036.50 Hose Assembly #3 67684 J37 STJ-STJ 13 66702-030.50 Hose Assembly #10 66137 J37 ST-ST 14 66698-580.50 Hose Assembly #06 66645 J37 ST-ST 15 66698-578.50 Hose Assembly #06 66645 J37 ST-ST 16 66698-583.50 Hose Assembly #06 66645 J37 ST-ST 17 66698-558.50 Hose Assembly #06 66645 J37 ST-ST 18 66698-579.50 Hose Assembly #06 66645 J37 ST-ST 19 66043-629.00 Hose Assembly #3 67684 J37 STJ-STJ 20 66043-636.50 Hose Assembly #3 67684 J37 STJ-STJ 21 66698-022.00 Hose Assembly #06 66645 J37 ST-ST 22 66712-023.50 Hose Assembly #06 66645 J37 ST-90 23 66698-022.50 Hose Assembly #06 66645 J37 ST-ST 24 66698-023.00 Hose Assembly #06 66645 J37 ST-ST 25 66712-025.50 Hose Assembly #06 66645 J37 ST-90

26 66043-022.00 Hose Assembly #3 67684 J37 STJ-STJ

27 66043-024.50 Hose Assembly #3 67684 J37 STJ-STJ - Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY

Ref 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

R3 - A 24C 24C 24C 245 24C •

a

t Lu a._ a_

'

EMERGENCY 01h STOP

0

R3-B 24B 24D

cc

1

24A

20A 624 \2 F USE

CHARGING LIGHT OPTION

0

• HOUR METER OPTION

0

SEENOTE 4 •

" UP " •

18

6A •

1

•

i> 7A .

•

PLATFORM RAISING

•

PLATFORM LOWERING

•

MOTION ALARM OPTION

R1

BR

6 VDC BATTERY

N EC

11111

EIOTOR •

HYD PUMP

BLK 1. BATTERY CHARGER

TA CIRCUIT BREAKER

3A 0 0 ' 45 ----

°O'

•

7

HORN

DESCEND ALARM OPTION

' FUEL "

SEE NOTE 2

SEE NOTE 3 4

cto

R2

FAST/SLOW DRIVE SPEED

WHT

HORN I

RED

3

' SEE NOTE 4

R2)

8C • 0 •

U

GRN

LOW VOLT ALARM OPTION

HORN

•

HORN 1

------ 115 VAC PLUG

BLK OPTIONAL CHARGING CUT - OUT RELAY

BLK WHT R3

SIGNAL HORN OPTION TRAVEL ALARM OPTION

SEE NOTE 5

14=WHT=NEUTRAL 15=BLK=LIVE

•

LOW VOLT SENSOR

SEE NOTE 4 LOW VOLT OVERRIDE

11 cm ,5_)

WHT •-----•

30

1

SLOPE SENSOR OPTION

1 • RELAY FOR .36V OPTIONS

12 10

0

0

SLOPE ALARM OPTION I 1 ..)

9 .9.

0 0

SEE NOTE 4

8C

.-1,-.-1-• CREEP SPEED VALVE

,

OPTIONAL BATTERY CONDITION INDICATOR

I SERIES/PARALLEL VALVES

4

17

8A

111

•

a STOP

•

1111

8A RED

HORN

EMERGENCY 0

pos

1 I

0 1,0

"DOWN"

GROUND 1

+24VOLT TAP

00

STROBE LIGHT OPTION

= 110 VOLT EXTENSION TO PLATFORM OPTION

t 16—GRN=GROUND J

= GROUND

NOTES: 1 . THIS SCHEMATIC SUPERCEDES 54996.

2. SWITCH ACTIVATED BY VALVE LEVER IN PLATFORM. 3. LIMIT SWITCH SHOWN WITH PLATFORM BELOW 7'.

4, CD THRU C7) REPRESENT TERMINALS OF OPTIONAL LOW VOLTAGE WARNING/INTERRUPT SENSOR/SWITCH. 5. PRESSURE SWITCH SENSES BRAKE RELEASE PRESSURE.

PROPRIETARY NFORMATION MS ORMOND ITS DESIGN. DETAIL, S, ICLERANCES 0

r

....25,,,,,m2 WACO, TEXAS

"0 WIRSR70=

OR,17k7=',7 vA, coRTZIN. RESERVED.

SCHEMATIC, 3146/60 ELECTRICAL

li-T,:!LO ToLERANcEs ON: nc, DEC9AALS NAV,.

LTR.

E.C.N. NO.

-

531 5

LTR.

E.R.N. NO.

DATE

APPR.

DRAWN

DATE

APE,

APPROVED

A. HI TTLE

CHECKED

RAK

TiTLE

04/11/95

6

°RAW'.

55060

o4/17/95 SCALE NONE

1 SHEET 1 OF 1

REV.

MDL3146: MOTOR 18.9 CIPR 54754-001

1-1-,, o. 1

UPPER CONTROL VALVE 315— 00034— 00

TRAVEL ALARM OPTION 54371

MDL3154: MOTOR 29.1 CIPR 321-00005-00

:ii n

I

D606

5703

5703

P

0703

—

BRAKE

-I 1--

E 0703

S703

T 54477

82

R3

Al

A2 _

5703

tcs:, CD

M3 DATA

. . _.

XI

52661

126-10005-00

DATA

P

•

D606

e

1

, FI

„.... 21479—SEE , — NOTE 3

STEER CYL. 162-96440-00 BORE:1.5 ROD: .75 STROKE: 5.25

5703

\/ 21481

LIFT CYL 162-96443-00 BORE: 6.0 ROD: 2.50 STROKE: 21.75

-

M PA

0606 Ml

D606

5704 `,..

MAN

TRANSMISSION VALVE

11 I L ira MO

315-00027-00 0606

DATA

DATA

MDL3146: MOTOR 18.9 CIPR 54754-002

52733

C'D

--("(:)

D3

MDL3154: MOTOR 29.1 CPR 321-00002-00

MOTOR CM i g c )— OROPO,,'15 — 00

PA ,0 MN

DIA .106 ■.,

tn —

T

A6 B

*

,

9

..1

mow

I

D ATA

P

_.

D606 D

I 0

HYD. FILTER 33430

::,

PUMP 6-394

LOWER CONTROL VALVE 315-00036-00

2400 PSI

HYDRAULIC TANK 020—R0060-00

NOTES: 1. THIS SCHEMATIC SUPERCEDES 54995.

2. THIS SCHEMATIC REFLECTS IMPROVED "CREEP" PERFORMANCE, , ON FIRM, LEVEL GROUND (REF. .75/.6 MPH).

00 S E C / 8 8 3 . A D J U S T C R E E P SP EE DTO 8 4 .

LI N E S IZ E S S H O WN A R E M IN 0I—.D1. F O R H Y D HFOESEET.

0

PROPRIETARY INFORMATION NS DRAWAT., 11fiS, DE rf,7E ,,,c1,. TOLERANZZO rag11.0.01e 'AM CORPORA MO 5. Not Zgocucto cot Ta Tprg, TIi trn TITLE

9363

C

83

A

8209

LTR.

E.C.N. No.

„E,F.:

,,„, oTHER,„sE R

—

5351

LT,

E.R.N. NO.

06/26/95

RAE

DATE

APPR.

4/25/D5 DATE

RAK APPR.

DME I N SIONS ARE IN iNCHES ToLERANcEs oN,

1r/V „Ttg ..i..0

DRAWN

A.HITTLE

CH...

APPROVED

RAK

04/05/95

WACO, TEXAS

SCHEMATIC, CHEMATIC, 3146/54 HYDRAULIC

b E

DRAWING NO.

,

,

,,

D .9 U J OD

04/07/95_ScALE FULL

"SHEET 1 OF 1

REV.

D

FIGURE 8.1—Deck Extension (Option)

9 - 2 PL B - 2 PL

28-4 PL

4 - 2 PL

20-4 PL 18-2 PL

27-2 PL

\\Li°

26-12 PL CALAVAR P/N 53208 IS WELDED ON BOTTOM OF PLATFORM. 0

0

0

0

0

0

2-2 PL

13,22,23-2 PL 3 - 6 PL

/_ 5 - 2 PL

19,10-2 PL

11,17,18-2 PL

6-2 PL 17,2021,29-2 PL

7-2 PL 14,2425-4 PL

-

-

-

-

-

-

-

MANUAL 92361-003 JUNE 1997

-

FIGURE 8.1—Deck Extension (Option ITEM PART NUMBER DESCRIPTION Ref. A250-3146 Deck Extension 36" Roll-Out 1 010-R2106-00 Weldment, Extension Deck Side Out 2 53122 Slide Channel Weldment 3 52090 Plug, Protective 4 54203 Roller, Guide Slide-Out 5 54262 Pad, Button Wear 6 54495 Extension Rod Weldment Extension Deck 7 54476 Pad, Extension Deck Slide 8 BOW30160-375 Bolt, Hex 75"-10UNC x 3.75" 9 BOW34278 Nut, Stop-Elastic 3/4-10 10 54263 Pad, Slide Wear 11 54265 Roller, Extension Deck Guide 12 54189 Decal, Extension Capacity 250 LBS 13 BOW34168 Pop Rivet, 1/8 Dia. 14 68276 Nut Tee 3/8-16UNC 4 Prong 15 BOW30009 Bolt, Hex .25" - 20UNC x 2.25" 16 68276-006 Tee-Nut, 1/4-20UNC 4 Prong 17 BOW34375 Screw, Round Split Head 35"-20UNC x 375" 18 BOW31444 Washer, Flat 25"ID x 63"OD 19 BOW30008 Bolt, Hex 25"-20UNC x 2.00" 20 51476-004 Pin, Quick Release 31" x 2.00" Grip 21 ZUA01001 Lanyard Quick Release Pin 6 00"Lg 22 BOW30058 Bolt, Hex 38" -16UNC x 2.00t 23 BOW31446 Washer, Flat 38"ID x 81"OD 24 54484 Strip, 1/8 x 3 "x 40"Lg 25 BOW35191 Screw, Flat Head Wood .25" x 75"Lg 26 54500 Angle, Chick Extension Deck Stop 4"Lg. 27 54494 Pad, Slide Out Tube 28 BOW36002 Bolt, Hex .25" - 20UNC x .75" 29 54492 Pad, Slide Out Tube - Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY Ref. 1 2 10 2 2 2 2 2 2 2 2 2 2 2 2 4 2 2 2 2 2 2 2 2 12 2 2 4 2

FIGURE 8.2-110V Line To Platform (Option)

MANUAL 92361-003 TUNE 1997

FIGURE 8.2-110V Line To Platform (Option ITEM PART NUMBER DESCRIPTION

Ref. A407-3146/60 Assembly, 110V Line To Platform Option 1 53226 Junction Box, 110V Modified 2 80361 Receptacle, 15AMP/125V 3 29161 Cover, Weather Proof-Duplex -4 67114-003 Strain Relief 50NPT .371.5 -5 67123-001 Seal, Connector Electric .50 -6 29163 Breaker, Circuit 15AMP -7 BOW31146 Screw, Slotted Round #110-32UNF x 1 00" -8 BOW31362 Washer, Split Lock #10 ID 9 52710 Plug, 110 Volt 10 BOW23075 Connector, Butt 12-10Gage Wire -11 52735 Decal, 110 Volt -12 BOW31834 Screw, Self Tap #12-24 x 50"

- Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY

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

FIGURE 8.3—Hour Meter (Option) ITEM PART NUMBER DESCRIPTION

Ref. A619-3146 Hour Meter 1 80027 Meter, Hour 4/40V DC 2 67840-001 Bracket, Gauge Mounting

- Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY

Ref. 1 1

FIGURE 8.4—Travel Alarm (Option ITEM PART NUMBER DESCRIPTION

Ref. A301-SCI All TravelAlarm 1 80188-024 Wobbulator and Speaker 24V 2 54371 Switch, Pressure Limit

- Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY

Ref. 1 1

FIGURE 8.5—Multi-Axis Slope Sensor (Option)

ITEM PART NUMBER DESCRIPTION

Ref A353-SCI Degree Multi-Axis Slope Sensor 1 32002 Slope Sensor 2 Axis 2 514-G9124-00 Bracket, Filter/Slope Sensor 3 34644 Alarm

- Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY

Ref 1 1 1

FIGURE 8.6 Strobe Light(Option)0

ITEM PART NUMBER DESCRIPTION

Ref. A310-3146 Strobe Light 1 58395 Light, Amber Strobe 12-72VDC 2 58405 Plate, Top 7"Lg. 3 67295-035 Cable, 16Gage/2 Conductor SJO 4 BOW31144 Screw, Slotted Roound #10-32UNF x .50"

- Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY

Ref. 1 1

60LF. 3

OFIGURE 8.7— Non Marking Tires(Option) ITEM PART NUMBER DESCRIPTION

Ref. A609-3146A Non Marking Tires 1 54929 Tire and Wheel Assembly

- Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY

Ref. 4

FIGURE 8.8—Battery Condition Indicator (Option),

I

EXISTING

KEY CB

ADD 2.060 DIA THRU TO EXISTING COVER USE 16GA WIRE. THERE MUST BE NO SWITCH CONTACTS BETWEEN BATTERY CONDITION INDICATOR AND POS TERMINAL OF BATTERY.

1 3/16

7-

-

I

GROUND )

REAR VIEW OF BATTERY CONDITION INDICATOR 37716-012

ITEM PART NUMBER DESCRIPTION

Ref. A620-31XX Battery Condition Indicator 1 37716 Meter 36V Battery 2 37993 Meter Guard Inst.

Dwg. A620-31XX 3 54712

- Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY

Ref 1 1 1

FIGURE 8.9—Descend - Warning (Option)

ITEM PART NUMBER DESCRIPTION

Ref. A312-3146/60 Descend-Warning 1 80188-024 Wobbulator & Speaker 2 BOW31147 Screw, Slotted Round #10-32UNF x 1.50" 3 BOW31144 Screw, Slotted Round #10-32UNF x .50"

- Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY

Ref. 1 4 3

FIGURE 8.10-Low Voltage Warning Interrupt (Option)Q

ITEM PART NUMBER DESCRIPTION

Ref. A626-36V/24V Low Voltage Warning Interrupt 1 54178 Low Volt Interrupt 36V 2 67596 Relay R#67588 Socket 8-Pin Octal 3 80049 4 390-00007-00 Spring Relay Hold Down 5 52669 Operator, Black Push Button ZB2-BA2 6 52029 Base + 2 NO Contacts ZB2-B2103 7 54257-001 Light, Amber Indicator Bulb, Clear Light 24V 8 67544 9 37647-006 Decals, AE Upper Control Box

- Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY

Ref. 1 2 2 2 1 1 1 1 1

FIGURE 8.11—Key Switch (Option)

ITEM PART NUMBER DESCRIPTION

Ref. A313 1 52671

Key Switch 3 Pos Operator, 3 Pos.

- Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY

Ref. 1

FIGURE 8.12—Lifting Eyes (Option)

ITEM PART NUMBER DESCRIPTION

Ref. A603-3146 Lifting Eye 1 54718 Step Modification, Rear Lower 2 54740 Bumper Modification, Front 3 BOW36718-HD Washer, Flat 3/4 SAE 4 BOW31208 Nut, Hex 75"-10UNC - Indicates Items Not Shown

MANUAL 92361-003 JUNE 1997

QTY Ref. 1 1 16 8

TIME CONDOR Corporation

SELF-PROPELLED ELEVATING WORK PLATFORM

MODEL V2546 VENDOR SECTION

SHIPPING ADDRESS

MAILING ADDRESS

CONDOR

CONDOR

TIME CONDOR Corporation

TIME CONDOR Corporation

8300 IMPERIAL DRIVE WACO, TEXAS 76712 (254) 420-5200

P.O.

21447 76702-1447 (254) 420-5200 Box

WACO, TEXAS

MANUAL 92361 JUNE 1997

CONDOR® Model V2546

VENDOR SECTION TABLE OF CONTENTS

ELECTRIC MOTOR

BALDOR

BRAKES TORQUE MOTOR

ESKRIDGE

BATTERY CHARGER GEAR PUMP

PARKER LESTER PARKER

E3.A.1_AIDCDER. DC MOTOR MOUNTING Foot mounted machines should be mounted to a rigid foundation to prevent excessive vibration. Shims may be required if foundation is uneven.

Flange mounted machines should be properly seated and aligned.

NOTE: If improper direction of rotation is detrimental to the load, check rotation prior to connecting the motor to the load.

For V-belt drive, mount the sheave (pulley) close to the motor housing, however, allow clearance for end to end movement of shaft. Do not overtighten belts as this may cause premature bearing failure and / or shaft breakage.

Direct coupled machines should be carefully aligned and shaft should turn freely without any binding.

WIRING If the motor is part of an SCR drive system, refer to the control manufacturer's diagrams and installation data. If the motor is shunt wound and not part of an SCR control system, a proper resistance starter should be used. For protection, use a fuse or circuit breaker rated at 125% of full load amperage on the nameplate. If the motor is a series or compound wound motor, refer to the connection data tag attached to the motor. If the motor is a component part of a piece of equipment. be sure to refer to the Original Equipment Manufacturer's electrical circuit information for proper connection.

The wiring, fusing, and grounding must be in accordance with the National Electrical Code and any local codes.

When the machine is connected to the load for proper direction of rotation and started, it should start quickly and run smoothly. If this is not the case, immediately shut motor off. Investigate the cause. The cause could be; low voltage, the motor is misconnected, or the load is too great. etc.

It is recommended that the motor current be checked after it has been operating a short time and compared against nameplate current.

BRUSHES Periodically, the brushes should be inspected and the brush dust blown out of the motor. If the length has been worn down 1/2" from the original length shown in renewal parts data, the brushes should be replaced. If at this time the commutator is worn or rough, the armature shouldre removed. The commutator should be turned in a lathe, the mica recut, and commutator polished. Reassemble, and seat the new brushes using a brush seating stone. Be sure the rocker arm is set on the neutral mark.

LUBRICATION This is a double sealed ball bearing motor. The bearings have been given lubrication at the factory. No lubricant need be added.

LUBRICANT Baldor motors are pre-greased normally with Shell Oil Company's "Dolium R". Several equivalent greases which are compatible with the Baldor furnished grease are Chevron Oil's "SRI No. 2" and Texaco Inc. "Premium RB".

CE)

JJ

® (11) ;

II

Mg' *VS hAf

vhav *ICJ \,ppilarmin ihibl

;pm gwrigrwria 1117

Disassembly: I. Place brake on a stable work platform, input shaft down.

Use assembly/disassembly tool number ESK - 95002. A

drawing is available for use in manufacturing your own'.

Remove Snap Ring

3 move the (4) Socket Head Cap Screws ( ITEM 18 ) from output end of brake.

4. Kemove Cover ( ITEM (4 ). This will expose the internal components of the brake. The Case Seal 0 Ring ( ITEM 1 3 ), Input Bearing ( ITEM IS ) and Snap Ring ( ITEM 16) will be attached to the Cover. Note the color, number and spacing of the Springs ( ITEM 10) before removal from Piston ( ITEM 7 ). Inspect springs for breakage, discoloration and spring rate. ( Blue colored springs have a spring load of 2S0 Lbs. © .780* compressed height).

-

S. Removal of the Piston ( ITEM 7 ) will require the use of an air pressure source, air gun with a small nozzle tip and o-ring port plugs. Procedure is as follow= * Remove any plugs in the release and drain ports of the brake Case ( ITEM 4 ). Using the air gun, blow all excess . hydraulic oil from piston cavity. ( This will keep excess oil from blowing down into the friction plate cavity when piston is removed.) * Place one o-ring port plug in either brake release port. Place cloth shop rag over piston cavity and brake. Using the air gun and small nozzle tip, blow air into the open release port. The air pressure will blow the piston up and out of the piston bore in the Case ( ITEM 4 ).

6. Remove and inspect the 0-Rings and Back-Up Rings ( ITEMS 8 , 9 , II , 12 )for wear and or damage. Note seal orientation before removal. Seals must be replaced if abnormal wear or damage is evident 7. Remove Brake Shaft ( ITEM 1 ). Inspect splines and bearing journals for abnormal wear or damage.

8. Turn brzke assembly over, which will facilitate the removal of the Friction P!: ..t.zz ( ITEM 5 ), Spacer ( ITEM ) 11.,raz1 Separator Plates ( ITEM 6 ). Friction plates should be replaced if oil soaked and or excessively worn (dry brakes only).

-

9.

imaged, the Bearing ( ITEM 2 ) Can be removed and replaced. Check for wear spots and or nicks on the sealing lips of th bearing seals.

NOTE All major components should be washed in a degreasing solution with a final cleansing rinse in alcohol. Da not rinse friction

platesl

Assembly: Parts must be dean and dry before assembly. Visually inspect components for damage and abnormal wear. Brake operation shc tested during normal service operation. Service or inspection to the brake should be part of the normal service and maintenanz schedule of the equipment or vehicle. Any loss of holding torque requires the removal, inspection and replacement of suspect components.

Assembly should be in reverse order of disassembly with the following additional instructions 1. Place brake Case ( ITEM 4) on a stable work platform, output end down. if the Bearing ( ITEM 2) has been removed, p new bearing into the Case ( ITEM 4 ). Lubricate the bearing and seals with a light coat of lithium grease.

2. Using the assembly/disassembly tool number ESK-95002 to properly space the Case (ITEM 4) off the work surface. ins= Brake Shaft ( ITEM 1 ). Push shaft downward thru bearing until end of shaft bottoms out in the assembly/disassembly tool.

3. Install Spacer (ITEM 3 ), Separator Plate ( ITEM 6) and Friction Plate ( ITEM ) in exactly the same order as they remove There must always be a Separator Plate ( ITEM 6) on top and bottom of the friction stack of plates. if a Friction

( ITEM 5) is placed next to the Piston (ITEM 8) or a Spacer, the unit will overheat and seize up. Be careful not to con= the friction plate surfaces with dirt, grease, or fluid of any kind.

4. If replacing Piston 0-Rings ( ITEMS 9 & II ) and Piston Bade-up Rings ( ITEMS 8 & 12 ), be sure c-rings are nearest other with bade-up rings to the outside after installing onto Piston ( ITEM 7 ). Lightly lubricate piston bores. Take care not lubricant onto friction peck. Gently slide piston into Clue ( :TEM 4 ) um!! !:trzikr o-ring touches case. Using a light to mecliunpress, install piston t:ompletely into bore. This will squeeze the o-rings and hari,...-up rings and set piston against friction pack.

S. Place the Springs ( ITEM ( 0 ) into the spring podcets in the Piston (ITEM 6. If removed, install Input Bearing ( ITEM IS ) and Snap Ring ( ITEM

7 ).

16.) into Cover (ITEM 1 4 ).

7. Install the Case Seal 0-Ring ( ITEM 13) onto pilot of the Cover ( ITEM I 4 ).

14) on top of the piston, springs and input end of the brake shaft. Start four Assembly Bolts (1/2- 1 3 x I. ( ITEM 18 ) thru the Case ( ITEM 4) and into the Cover ( ITEM 14 ) with your fingers. A light to medium duty press can

8. Set Cover ( ITEM

used to push the cover down on to the case so the cover bolts can be installed more easily. Alternately tighten assembly bolts 1/2 a time until cover is tight against the case. Tighten bolts to I 10 ft-lbs of torque.

9. Install Snap Ring ( ITEM 17) on to the Brake Shaft ( ITEM I ). If snap ring will not fit, lightly tap the opposite end of the b shaft with a brass hammer. This will help seat the shaft onto the Input Bearing (ITEM I S ).

14. The brake is now ready for minor testing of fit, function and release pressure. Due to the complex equipment required, you will able to test the holding torque of the broke. To test release pressure, place the o-ring port plug in one of the brake release port Using a hydraulic power source either a hand pump or port -a-power, pressurize the brake slowly to the advertised release

pressure both initial and full DO NOT EXCEED 1000 PSI WITHOUT THE BRAKE BEING BOLTED TO THE GEARBOX OR A TEST FIXTURE. As you pressurize the brake, rotate the brake shaft at the output end. The brake sip should begin to turn at the advertised initial release pressure (+ or - 25 PSI). There will be drag on the shaft. Increase the pre slowly until the shaft spins freely, this is the full release pressure. As you pressurize the brake, look for signs of leaks which w indicate that the o-rings or back-up rings were damaged during assembly.

1 1.Use only mineral based hydraulic oil to test and operate Eskridge multiple disc brakes.

Repair Kits, 95W tir kits listed below are for use with the model 95W multiple disc brake.

14 t.J

rE:

Due to the many combinations o f torques and release pressures available for the 9SW, it is impossible to detail each sryie and supply a repair kit for each individual model. The information listed in this manual is representative of all 9SW brakes. The repair kits listed below will work with all combinations of torque vs. release pressure, input mountings and friction plates. it is entirely possible to have "extra" parts left over from the repair kits after you have completed the repair or maintenance. if you are not sure about what is required for your brake and its configuration, please contact Eskridge, inc sales or engineering department.

110A Series Low Speed High Torque Motors

OPERATING INSTRUCTIONS LESTRONIC II BATTERY CHARGER (FOR BUILT-IN OR PORTABLE CHARGERS)

A A

LOOK FOR THIS TRIANGULAR SYMBOL TO POINT OUT SAFETY PRECAUTIONS. IT MEANS BECOME ALERT -YOUR SAFETY IS INVOLVED. IF YOU DO NOT FOLLOW THESE SAFETY INSTRUCTIONS, INJURY OR PROPERTY DAMAGE CAN OCCUR. SAVE THESE IMPORTANT INSTRUCTIONS.

CAUTION - LOCATE THE IDENTIFICATION AND RATING INFORMATION. READ ALL THE INFORMATION AND INSURE THE CHARGER YOU HAVE IS CORRECT FOR THE AVAILABLE INPUT VOLTAGE, Vac, AND FREQUENCY, HERTZ or Hz, AND BATTERY SYSTEM VOLTAGE AND CAPACITY. TO REDUCE RISK OF ELECTRIC SHOCK OR FIRE, CONNECT AC SUPPLY CORD ONLY TO A PROPERLY GROUNDED SINGLE PHASE OUTLET WITH THE SPECIFIED VOLTAGE (Vac) AND FREQUENCY (HERTZ or Hz). DO NOT ATTEMPT TO OPERATE THE CHARGER ON INPUT POWER DIFFERENT, EITHER INPUT VOLTAGE (Vac) OR FREQUENCY (HERTZ or Hz), FROM SPECIFIED.

IMPORTANT SAFETY INSTRUCTIONS •. ..• 1.SAVE THESE INSTRUCTIONS - This manual contains important safety and operating instructions for your battery charger.

2. Before using battery charger, read all instructions and cautionary markings on (1) battery charger, (2) battery, and (3) product using battery.

A

CAUTION - TO REDUCE RISK OF INJURY, CHARGE ONLY LIQUID ELECTROLYTE (WET) LEAD ACID RECHARGEABLE BATTERIES. OTHER TYPES OF BATTERIES MAY BURST CAUSING PERSONAL INJURY AND DAMAGE.

3. Do not expose charger to rain or snow.

4. Use of an attachment not recommended or sold by the battery charger manufacturer may result in a risk of - fire, electric shock, or injury to persons.

5. To reduce risk of damage to electric plug and cord, pull by plug rather than cord when disconnecting charger.

6. Make sure cord is located so that it will not be stepped on, tripped over, or otherwise subjected/0 damage Of stress.

7. An extension cord should not be used unless absolutely necessary. Use of improper extension cord could • result in a risk of fire and electric shock. If extension cord must be used, make sure: a. Pins on plug of extension cord are the same number, size, and shape as those of plug on charger. b. Extension cord is properly wired and in good electrical condition. c. Wire size is large enough for AC ampere rating of charger.

8. Do not operate charger with damaged cord or plug - replace it immediately.

9. Do not operate charger if it has received a sharp blow, been dropped, or otherwise damaged in any way; take it to a qualified service center.

10. Do not disassemble charger; take it to a qualified service center when service or repair is required. Incorrect reassembly may result in a risk of electric shock or fire.

• 11. To reduce risk of electric shock, unplug charger from a live outlet or disconnect AC power to the outlet before attempting any maintenance or cleaning. Turning off controls wilinot reduce this risk.

F00377 D

INTRODUCTION This battery charger is a self reguiating charger with a minimum of moving parts, designed for long, trouble free service. Built in line voitage compensation produces a consistent output when the AC supply voltage vanes -

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by as much as 10% from nominal. The charger utilizes convection cooling which maximizes the reliability and minimizes any maintenance costs. CHARGE ONLY FLOODED, LIQUID ELECTROLYTE (WE I ) LEAD ACID BATTERIES with this charger. To ensure superior battery performance and life a patented electronic circuit turns the charger on, and off automatically when the battery has reached its maximum state of charge.

RECEIVING AND INSTALLATION When the charger is received, portable chargers should be checked for possible in-transit damage. If any damage is found, it should be reported as a claim to the carrier.

Proper installation of the charger is important in order to achieve good charger performance and to prevent damage to the charger and batteries. The charger should be located in a clean, cool, dry and well ventilated area. To permit free air flow for convection cooling, allow three inches minimum between the charger and any wall and six inches between the charger and other equipment. Position the charger on a foundation of stone, brick, concrete or grounded metal.

A

DANGER - TO REDUCE THE RISK OF FIRE, DO NOT USE THE CHARGER NEAR FLAMMABLE , MATERIALS OR VAPORS.

AC INPUT AND GROUNDING INSTRUCTIONS

This battery charger must be grounded to reduce the risk of electric shock. This charger is equipped with an electric cord having an equipment-grounding conductor with insulation having an outer surface that is green with or without yellow strpe(s). If repair or replacement of the electric cord or plug is necessary, do not connect the equipment-grounding connector to a live terminal.

Improper connection of the equipment-grounding conductor can result in a risk of A WARNING: an electric shock.

A variety of different input cord plugs and input cord lead colors are used throughout the world. Contact qualified/licensed personnel if the input plug or input cord lead colors or required charger input voltage is different than you need.

• Battery chargers equipped with a grounding plug as illustrated in figure A are used in the U.S.A., Canada, Mexico and Central America for 120Vac input voltage, and 60Hz input frequency. A temporary adapter, as illustrated in figures 8 and C may be used to connect this plug to a two-pole receptacle as shown in figure C if a properly grounded outlet is not available. The temporary adapter should be used only until a properly grounded outlet can be installed by a qualified electrician. The green-colored rigid ear or lug extending from the adapter must be connected to a permanent ground such as a properly grounded outlet box.

-A- -B- -C- • ADAPTER

COVER OF GROUND ED OUTLET BOX

ROUNDING BLADE

GROUNDING MEANS

CONNECTED TO COVER OF GROUNDED OUTLET BOX

GROUNDED OUTLET

NOTE: The use of the adapter shown In figure B and C Is not permitted in Canada. If a grounding type receptacle is not available, do not use this charger until the proper outlet is installed by a qualified electrician.

-2-

NOTE: The same plug and receptacle shown in figures A, B J C is used in Japan plus other Asian Countries for 100Vac input voltage, and 50 or 60Hz input frequenci es.

When there - is not a plug on the input cord or the input plug must be changed, identify the lead connections by the following lead color table.

Connection

Line 1, Li Neutral, N Ground, Earth,

E9

Connection

Line 1, Li Line 2,12 Ground, Faith,

ED

120V/60Hz Black White Green or Green/Yellow

100V/50-60Hz

220-240V/50Hz Brown Blue Green/ Yellow

Brown Blue Green/ Yellow

OLD BSI 220-240V/501-1z Red Black Green or Green/Yellow

240V/60Hz Black Red Green or Green/Yellow

EXTENSION CORD REQUIREMENTS Always use a three conductor No. 12 AWG heavy duty cord with ground, properly wired, in good electrical condition and keep it as short as possible. Make sure the pins on the plug of the extension cord are the same number, size and shape as the AC plug of ihe battery charger. The use of an improper extension cord could result in a risk of fire or electrical shock. Locate all cords so they will not be stepped on, tripped over or otherwise subjected to damage or stress.

OPERATING INSTRUCTIONS 1. Connect AC supply cord to a properly grounded single phase outlet of the proper voltage (Vac) and frequency (Hz) as specified on the charger. Note: The output cords of On Board or Built-In chargers are attached to the batteries. Output cord polarity, black, "-", NM: white, red, "+", POS. Verily all connections to the batteries are clean and tight. If this applies to your charger, go to step 3. If not, go to step 2.

2. Connect the DC output plug, if not already connected, by grasping the plug body and pushing it straight into the receptacle until it is fully engaged. , 3. The charger will start after a short delay as indicated by the transformer hum and the ammeter movement.

A

WARNING - LEAD ACID BATTERIES GENERATE GASES WHICH CAN BE EXPLOSIVE. CHARGE ONLY IN WELL VENTILATED AREAS. DO NOT DISCONNECT CHARGER DC OUTPUT TERMINALS FROM BATTERY WHEN CHARGER IS ON. THE RESULTING ARCING AND BURNING WILL DAMAGE THE CONNECTORS AND COULD CAUSE THE BATTERY TO EXPLODE. KEEP SPARKS, FLAME AND SMOKING MATERIALS AWAY FROM BATTERY.

If the charger must be stopped, always disconnect the input supply cord from its outlet to terminate the charge.

4. Monitor the ammeter for correct charge rate. Normal charging at the finish charge rate for the last 3 to 5 hours is important to achieve equalization of all battery cells every time the batteries are charged. New batteries or batteries charged in cold temperatures (below 50 degrees F) will require more time to achieve full charge.

5. Charger turns off automatically when battery is fully charged. Charge time varies with battery size and depth of discharge. Allow 8 hours for normal charging. Severely discharged batteries may require up to 12 hours to be properly charged and equalized. After the charger has turned off, disconnect the AC supply cord from outlet, then disconnect the DC output plug from the battery on portable chargers only.

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A

CAUTION - DO NOT LEAVE CHARGER CONNECTED WHILE UNATTENDED FOR MORE THAN TWO CONSECUTIVE DAYS. SEVERE OVERCHARGING AND POSSIBLE DAMAGE TO BATTERIES WILL RESULT IF CHARGER SHOULD FAIL TO TURN OFF.

MAINTENANCE INSTRUCTIONS The battery charger requires minimal maintenance. It should be kept clean and all connections are to be tightly securA. In the event of intermittent operation, examine and tighten, if necessary, all connections. BE SUR E THE CHASSIS IS SECURELY GROUNDED. If any problems cannot be resolved, consult a qualified service center.

Observe the following battery cycle maintenance procedures to obtain good performance and maximum cycle life.

1. Always observe the following personal safety precautions when working with lead acid batteries: a. Someone should be within range of your voice or close enough to come to your aid when you work near a battery. b. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing or eyes. c. Wear complete eye protection and clothing protection. Avoid touching eyes while working near battery. d. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eye, immediately flood eye with running cold war for at least ten minutes and get medical attention. e. NEVER smoke or allow a spark or flame in the vicinity of batteries. f. Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark or short-circuit battery or other electrical part that may cause explosion. g. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a lead acid battery. A lead acid battery can produce a short-circuit current high enough to weld a ring or the like to metal, causing a severe bum.

A

h. NEVER charge a frozen battery.

DANGER - TO REDUCE RISK OF ELECTRIC SHOCK, ALWAYS DISCONNECT THE AC SUPPLY CORD FROM RS OUTLET AND THE DC OUTPUT CORD FROM THE BATTERY BEFORE ATTEMPTING ANY MAINTENANCE (CHANGING FUSES, ETC.) OR CLEANING OF THE BATTERY CHARGER.

2. New batteries should be given a full charge before their first use because it is difficult to know how long batteries have been stored.

3. Limit use of new batteries for first five cycles. New batteries are not capable of their rated output until they have been discharged a number of times.

4. Do not excessively discharge batteries. Excessive discharge can cause polarity reversal of individual cells resulting in complete failure shortly thereafter. Limited use of new batteries will minimize the chance of cell reversal.

5. CHECK THE LEVEL OF THE ELECTROLYTE IN CONVENTIONAL LIQUID ELECTROLYTE LEAD ACID BATTERIES MONTHLY. MAINTAIN THE PROPER ELECTROLYTE LEVEL BY ADDING DISTILLED OR PURIFIED WATER WHEN NECESSARY. Electrolyte levels lower during discharge and rise during charge.

Therefore, it is mandatory that water be added to cells ONLY when they are fully charged - do not overfill.

Old batteries require more frequent additions of water than new batteries.

6. Keep tops of batteries clean and dry to prevent excessive self discharge. Keep battery terminals reasonably tight.

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FORM -00968 REVISION C ELECTRONIC TIL4ER RED GREEN • TRANSFORIAER

RED OR WHITE

NATURAL

01.

2

FU Asses' -Y

TO BATTERIES

E3LACK WHITE GREEN

AMMETER

BLACK 100 VAC INPUT PLUG NATURAL

GREEN WIRE NOT USED ON SOME MODEL&

CAPACITOR

PARTS LIST FOR LESTRONIC II CHARGER MODEL 12675 TYPE 36LC40-8ET 100 VAC 50 HZ PART NO. QTY DESCRIPTION 14724S I CASE ASSEMBLY 12690S 1 TRANSFORMER ASSEMBLY 09074S 1 HEATS INK ASSEMBLY, WITH DIODES 08849S 2 DIODE AS SEMBLY 16823S 1 AMMETER 12755S 1 ELECTRONIC TIMER ASSEMBLY 02390S 1 CAPACITOR, 6 . 0 MFD , 660 VAC 02008S 1 BUSHING, 8P -2 , INSULATOR FOR DC CORD SET 02028S 1 BUSHING, 7W-2, INSULATOR FOR AC CORD SET 14718S 1 CORDSET, AC, 12/3, 72", NO PLUG 15536S 1 CORDSET, DC, 10/2, 65", NO PLUG 08774S 1 FUSE ASSEMBLY

FORM CC653 REV A

Limited Warranty Lester Electrical warrants each new Lester Battery Charger for defects in material and workmanship for a period of two years from the date of manufacture of the complete unit.

Repairs can be made at the Lester factory. To do so send the defective unit with transportation charges prepaid to: Lester Electrical 625 West "A" Street Lincoln, NE 68522

Attention: Repair Department

For repairs made at other than the Lester factory, Lester will provide only the replacement parts.

Defective pans should be sent with transportation charges prepaid to the Lester factory at the previously mentioned address.

If the unit of parts are found in the reasonable judgement of Lester to be defective in material or workmanship, repair, or replacement will be made by Lester without charge for parts or labor. Repair or replacement will be at the discretion of Lester, with replacements being made using current models or parts performing the equivalent function. Labor charges other than those incurred at the Lester factory are not covered under this warranty. All expenses associated with delivering defective items to the Lester factory and the expense of returning repaired or replaced items from the Lester factory to the owner will be paid for by the owner. All warranty work accomplished at the Lester factory will be completed within a reasonable time after receipt of defective items.

This warranty does not cover any semiconductor parts, such as diodes, which are vulnerable to electrical overloads beyond the control of Lester. Warranty on parts not manufactured by Lester, which include, but are not limited to, timers and ammeters is limited to the period specified in the original manufacturers warranty.

This warranty does not cover any charger that has been subject to misuse, neglect, negligence,

or accident, or operated in any way contrary to instructions specified on the charger case and in the owner's manual. No claim of breach of warranty shall be cause for cancellation of the contract of sale of any Lester charger. Lester assumes no responsibility for toss of time, inconvenience, or other damage, consequential or otherwise, resulting from a defective charger. All implied warranties (including merchantability) are limited in duration to the two years from date of manufacture warranty period.

Some states do not allow the exclusion or limitation of incidental or consequential damages; or limitations on how long an implied warranty lasts, so the above limitations may not apply to you.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Lesters obligation under this warranty is strictly and exclusively limited to the repair or replacement of defective items. Lester issues this warranty in good faith and with full confidence in the workmanship and quality of Lester products.

Installation Information

Fixed Displacement Gear Pumps Series D/H/M

Instructions .for Reversing Gear Pump Rotation The basic tools needed are a vise, preferably with soft jaws, a torque wrench, a thin screwdriver, a small hone stone. a ratchet. and a paper clip. The "D" series will require a 1/2" socket. the - 1-1" series an additional 1/4" hex head driver, and the "M" series a 5/16" hex head driver. It is also recommended that you have on hand a few extra heat shields and gaskets. Part numbers are 655287 and 655288 for the "0" series, 656942 and 656943 for "H" series, and 656026 and 656025 for the "M" series.

To change rotation, hold the pump by the rear cover with the drive shaft pointing up. Remove all the bolts. The "D" series will have four hex head, the "H" series will have six hex and two alien head, and the "M" series will have eight alien head bolts. At this time. it would be helpful to scribe a line down the outlet side of the pump. If not marked. the outlet port is usually the smallest.

(iD

1. Shaft Seal 2. Cap Screws -3. Hex Screws 4. Washers 5. Front Cover 6. V-Seal 7. Dowel Pins 8. Gasket 9. Heat Shield 10. Wear Plate 11. "0" Rings 12. Center Section 13. Drive Gear Assembly

If the pump has a key type shaft. remove the key and hone down any burrs that may be on the shaft. This is important as the next step will be to lift off the front cover and any sharp edges could possibly damage the front seal or bearing.

After the front cover is off, note the position of the little vent hole in the bronze wear plate, which should have come off with the front cover. The parts underneath also have a similar vent hole.

Remove in order, the wear plate, the heat shield, gasket. and V-seal. To facilitate this, make a little hook with a paper clip and lift up the part high enough to slip a screwdriver under and carefully pry up. Please note, the heat shield, in particular. is very brittle and may crack if bent.

14. Driven Gear Assembly 15. Flow Control ("H" Flow Divider Pump only) 16. Relief Valve ("H" Flow Divider Pump Only) 17. Back Cover 18. Thrust Plate (H&M only) 19. Key (Where Required)

The rear cover is installed with the outlet side in line with the vent hole. The outlet side will be marked or can be . identified by the smaller cavity internally. As when installing the center section. be careful not to pinch the 0-ring sea'.

After removing these four parts. reinstall the V-seal with the lips down in the front cover so that the vent hole is on the opposite side across from the reference mark. Use the screwdriver to seat it completely. Next install the gasket. heat shield, and wear plate: again with the vent hole in line with that of the V-seal. The wear plate should be almost flush with the surface of the front cover. You may have to go back and tuck in. here Or there, so that it is flush.

To check your work. the line that was originally scribed on the side should now be located 180° on the rear cover and center section from that on the front cover.

Install the bolts and snug them down by hand. Then torque to the proper setting, alternating from side to side.

The correct torque specifications are 355-375" lbs. for the "M" series, and 190-210" lbs. for the "D" and "H" series. Reverse or remove the rotation arrow originally stamped on the mounting flange.

Remove the center section and note the notch cut on the inside. This will be installed in line and next to the vent hole in the wear plate. The dowel oins used to locate the center section may be removed temporarily to facilitate sliding the center section over the gear assemblies. Be careful not to pinch the 0-ring between the front cover and center section. If it doesn't want to stay in place. it can be "glued - using heavy grease.

Testing Procedure After pump has been reinstalled, run for 2-3 minutes before pressurizing. Try to apply pressure gradually for an additional five minutes, but do not pressurize for longer than 5 seconds at a time.

If the pump is an "H" or "M" series, install the thrust plate into the center section orienting the side with the bar in line with the vent hole. ensuring that the bronze side faces the gears.

Parker Hannifin Corporation

Fiuidpower Pump Division

Otsego, MI 49078

32-A

Fit licinnwPA-