Condor 3238, 4248, 4248LC Operation Maintenance & Parts Manual PN 92154 - PDF DOWNLOAD

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

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.

11= CAL.INVAIR CORPORATION

Model Serial No. Date Delivered CUSTOMER

Note: Additional copies of this Manual (Part No. 92154) may be obtained through the Parts Department at Calavar.

Series II (Serial Nos. 2187-2276)

CALAVAR CORPORATION 13750 E. Firestone Blvd.

Santa Fe Springs, CA 90670

SELF PROPELLED CONDOR 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, operating instructions, recommended lubrication procedures.

OPERATING INSTRUCTIONS AND ILLUSTRATED PARTS MANUAL FOR YOUR CALAVAR SELF-PROPELLED CONDOR MODELS 3238S-4248S-4248LC

Model Serial No. Order No. Date Delivered Customer

001 - 2276

INTRODUCTION

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

THE OPERATOR'S MANUAL MUST BE RETAINED ON THE

CONDOR® AT ALL TIMES.

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

It is YOUR RESPONSIBILITY to follow procedures while operating the CONDOR®. The manufacturer of this CONDOR® cannot control the wide range of applications that may be used in carrying out a variety of jobs. Therefore, it is THE USER'S RESPONSIBILITY to consider all personnel when making decisions regarding the CONDOR®'s intended use.

It is also YOUR RESPONSIBILITY to understand and obey all federal, state, and local regulations regarding the operation and use of aerial work platforms. A copy ofthe ANSI/SIA Manual of Responsibilities is attached for your use: ANSI/SIA A92.5-1992 is provided for Boom-Supported Elevating Work Platforms, and ANSI/ SIA A92.6-1990 is provided for Self-Propelled Elevating Work Platforms.

TIME CONDOR Corporation reserves the rightto 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 THE TIME CONDOR Corporation.

SERVICE & MAINTENANCE

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

NOTE:

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

CCIIINEVOR TIME CONDOR Corporation

CONDOR® SERVICE INFORMATION

1. Ifyou need assistance orhave any service or maintenance questions, TIME CONDOR Corporation 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 MaintenanceProcedures available for this machine. These procedures are available through the TIME CONDOR Corporation S ervic e Department to anyone who requests them.

3. Service and maintenance are not a substitute fortrained, qualified service technicians. TIME CONDOR Corporation conducts services chools on a continuing b asis. Call any of our s ervice or sales persons for a schedule. Remember, training of mechanics is the responsibility of their employer, but TIME CONDOR Corporation. Service Schools help you provide this training.

4. TIME CONDOR Corporation Service School Training Manuals are available forpurchase through the parts department. Thepart numbers forthesemanuals are: #92333 fors elf-propelled models; and #92334 fortruck-mounted models .

TIME CONDOR Corporation

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

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 Corporation 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 Corporation part number(s) for the part(s) you require, and always provide a complete description of all parts.

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

4.

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

5.

TIME CONDOR Corporation 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 Corporation 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 (1) week.

7

TIME CONDOR Corporation 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 Corporation 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.

CONDOR PARTS DEPARTMENT FAX ORDER FORM FAX NO. 800-443-5803

C U S T 0 M E R

I N F 0 R M A T I

SALES ORDER #

PURCHASER

ACCOUNT #

NAME

NAME ADDRESS CITY

ZIP

STATE

PHONE

STATE

PHONE

FAX

) N ( CUST. PURCHASE ORDER NO.

S ADDRESS HT I 0 p CITY

( ) ORDER DATE

) ( REQUEST DATE

ZIP

FAX ( ) SPECIAL MARKS & NUMBERS

SHIPPING INSTRUCTIONS

DESCRIPTION

QTY.

PART NUMBER

...

FOR ORDER STATUS PLEASE CHECK APPROPRIATE BOX BELOW EMERGENCY STOCK

NOTES

VAR COR PORATION

ICALII‘ 9200 SORENSEN AVE. • SANTA FE SPRINGS, CALIFORNIA 90670-2645 • (213) 946-6561 • TELEX 69-8378 • TELECOPIER (213) 946-2265

Self-Propelled Booms and Scissors WARRANTY Calavar Corporation ("Calavar") warrants each new aerial work platform made by Calavar and bearing the trademark -Condor" to be free from defects in material and workmanship.

The obligation and liability under this Warranty is expressly limited to repairing or, at Calavar's option, replacing free of charge at its factory in Santa Fe Springs, California or at an authorized repair facility as designated by Calavar, any part proving defective under normal use and service within 180 days after said aerial work platform is first placed in service or within one year after the original shipment of said aerial work platform from Calavar's plant, whichever first occurs.

Parts claimed to be defective and for which repair or replacement is desired shall be, if requested by Calavar, returned transportation prepaid to Calavar's factory for inspection. Replacement parts provided under the terms of this Warranty are for the remainder of the Warranty period applicable to the aerial work platform in which they are installed as if such parts were original components of the aerial work platform.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTIES OF MERCHANTABILITY AND FITNESS FOR ANY PARTICULAR PURPOSE, AND THE OBLIGATION AND LIABILITY OF CALAVAR UNDER THIS WARRANTY SHALL NOT INCLUDE ANY TRANSPORTATION OR OTHER CHARGES OR THE COST OF INSTALLATION OR ANY LIABILITY FOR DIRECT, INDIRECT OR CONSEQUENTIAL DAMAGES OR DELAY RESULTING FROM THE DEFECT. Any operation beyond rated capacity or the improper use or application of equipment or the substitution upon it of parts not approved by Calavar or any alteration or repair by others in such manner as, in Calavar's judgment, to affect the equipment materially and adversely shall void this Warranty. No representative of Calavar is authorized to change this Warranty in any way, and no attempt, effort or promise to repair equipment of Calavar either by Calavar or by any representative of Calavar at any time shall change or extend this Warranty in any way. This Warranty covers only new and unused aerial work platforms manufactured by Calavar. Products or parts manufactured by others are covered only by such warranties as are extended to Calavar by its suppliers.

FORM NO. 280 1M-587

Printed in U.S.A.

CALAVAR CORPORATION WARRANTY CALAVAR EQUIPMENT

CALAVAR CORPORATION WARRANTS EACH UNIT OF NEW EQUIPMENT SOLD BY IT FOR A 90 DAY WARRANTY PERIOD AS FOLLOWS: 1.

The equipment sold will be free of defects in material and workman ship which might arise from normal usage of the equipment for its intended function and in accordance with Calavar Operating Instruc tions.

2.

If during the 90 day warranty period, which peroid commenced upon delivery of the equipment to the buyer or delivery at a place of delivery designated by the buyer, whichever date is earlier, the equipment develops such a defect in material or workmanship arising from such usage, then upon return of the component, freight prepaid by the buyer, to the Calavar Plant at Santa Fe Springs, California, Calavar will at its cost, expend the necessary labor and furnish the necessary materials to correct such defects, and will return the component to buyer or to a place designated by the buyer, with the return transportation cost to be borne by buyer. In the event of such defect or defects in material or workmanship, Calavar may, at its election, send an employee to the site.

3.

The warranty with respect to materials and workmanship set forth herin does not apply to standard shelf type items such as tires, batteries, and similar accessories which are standard items manufac tured by national companies who furnish their own warranties with respect therto. For these items Calavar hereby assigns to the buyer such warranty rights as it might have against the manufacturer thereof.

4.

The warranty and warranty obligations of Calavar Corporation as set forth above are nullified in all respects in the event that the equipment is subjected to non-approval alterations which are not in accordance with Calavar Corporation Operating instructions for the equipment and which, in the sole discretion of Calavar, have so materially affected the structural or operating elements of the equipment as to impair the functioning of the equipment.

5.

The foregoing warranty and the warranty obligations of Calavar Cor poration are nullified in every respect, if, during the warranty peroid, the equipment is subjected to usage other than normal usage which is contrary to the Calavar Operating Instructions for the equipment.

6.

The foregoing warranty, and warranty obligations of Calavar Corpora tion apply only in favor of the original buyer of the equipment and do not apply in favor of any subsequent owner or user of the equip ment or in favor of any third party in any manner whatsoever.

CALAVAR CORPORATION--WARRANTY OF NEW EQUIPMENT (Continued) The warranty set forth hereinabove and the responsibilities of Calavar Corporation thet. eunder as set forth herein above is in lieu of any and all other warranties, oral or written, and Calavar shall have no further responsibility to the buyer or anyone else with respect to the design or materials or workmanship of said equipment. Without limiting the foregoing Calavar Corporation specifically shall in no way be responsible to the buyer or any one else on account of so-called consequential damages.

Upon approval and by request of Calavar, Dealer agrees to perform the service required under the above Warranty with respect to all units sold

by Dealer at a compensation to Dealer of $7.00 per hour.

co

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 Corp. 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 the plant of TIME CONDOR Corp.; 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 the plant of TIME CONDOR Corp., whichever comes first.

The obligation and liability under this Warranty is expressly limited to repairing or, at TIME CONDOR Corp.'s option, replacing free of charge at its factory in Waco, Texas or at an authorized repair facility designated by TIME CONDOR Corp., the defective part. In no event shall TIME CONDOR Corp. 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 Corp., 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 the CONDOR 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 Corp. or alteration or repair of the equipment by any person not authorized by TIME CONDOR Corp. shall, at TIME CONDOR's option, void this Warranty. TIME CONDOR Corp. shall have no liability or responsibility for damages resulting from accident or the malfunction of equipment and components not supplied by TIME CONDOR Corp.

No agent, employee, distributor, dealer, or other representative of TIME CONDOR Corp. 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 Corp. and should not be relied upon as limited warranties of TIME CONDOR Corp., and no attempt, effort, or promise to repair equipment by TIME CONDOR Corp. 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 by TIME CONDOR Corp. This Warranty covers only new and unused aerial work platforms manufactured by TIME CONDOR Corp. 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.

TIME CONDOR Corp.

8300 Imperial Drive P.O. Box 21447 Waco, Texas 76702-1447

Phone: (254) 420-5200 Fax: (800) 443-5803

Printed in the USA 06/98

Effective August 27, 1996 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 certain period of time following purchase by a customer.

TIME CONDOR Corporation's warranty states, in general, the TIME CONDOR Corporation will replace free of charge, any components found to be defective within the time frame of the warranty period. There are exceptions to some components which are not the responsibility of TIME CONDOR Corporation. These will be outlined in other paragraphs.

The warranty policy and description are depicted on the attached printed policy. For your reference, the following is offered: A.

NOTE:

WARRANTY PERIOD

1.

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

2.

The truck mounted unit warranty is one (1) year from shipment of the unit from TIME CONDOR' s plant.

3.

For parts sold thru the Parts Department, the warranty peroid 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 CONDOR® shipment still under warranty. No labor is paid under parts warranty.

4.

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

5.

In addition to covering the parts replaced undeiCOND OR® warranty, TIME CONDOR will pay a dealer warranty labor rate, which is based on a percentage of your standard shop labor rate.

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 aCONDOR® to have in stock, but may not use it. After three months, theCOND OR® 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 CONDOR® constitutes it as being "in service", initiating the warranty period.

B.

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

1.

Each Self-Propelled Boom or ScissorCONDOR® 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 theCONDOR® from TIME CONDOR, whether it will be the dealer or the end user, to complete this form and return it to TIME CONDOR's facility within 45 days from the date of receipt to setup the Warranty Account.

3.

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

NOTE:

C.

The form mustbe filled out completely, giving the name ofthe dealer, address, model number, serial number, person inspecting theCONDOR® signature, and date of inspection.

(The date of inspection does not constitute the "In Service" date.)

ITEMS NOT COVERED

Some components are used on the machine 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 Corporation can advise you if you need assistance locating a dealer.

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. NOTE: For international dealers where tires or batteries are not obtainable from a local in-country supplier, locally supplied tires or batteres can be used.

Components mustme et or exceed originally-supplied items. Copies ofinvoices for said items MUST accompany any Warranty Claims to receive parts credit.

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 Corporation by its suppliers.

5.

Freight and Charges: The warranty does not include any freight, 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 CLAIM

During the Warranty Period, should a component failure be encountered within the guidelines of the TIME CONDOR Warranty Policy, the following procedure is to be followed: 1.

Upon identifying the defective component, the replacement can be obtained by: a.

Issuing an orderto our Parts Departmentthrough normal channels, which entails your company being invoiced.

You may have prevoiusly 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 onthe claim the TIME CONDOR invoice number to substantiate the parts purchase and the amount to be credited.

2.

NOTE:

c.

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

d.

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

Complete the Warranty Claim as noted in the "Warranty Claim Procedure" section. Provide as much information as possible to enable TIME CONDOR to thoroughly evaluate the claim and process it in the shortest amount of time possible.

CLAIMS NOT RECEIVED BY TIME CONDOR WITHIN 45 DAYS OF FAILURE WILL BE DENIED

3.

Provided no return parts are required and all the information has been verified, the claim will be processed and credit will be issued against your account.

E. RETURN AUTHORIZATION

1.

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

2.

It will be necessary for you to call the TIME CONDOR Service Department and request a Return Authorization (R/A) number. You will be asked for a Dealer Claim Number. As noted in Section 2, Item A, ofthe 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 RiA number issued must be logged in the appropriate section ofthe 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.

NOTE:

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 Warrranty will be required to be shipped back to TIME CONDOR Corporation FREIGHT PREPAID. No freight collect shipments will be accepted.

Due to shipping charges and impart duties imposed on INTERNATIONAL DEALERS, these dealers will not be required to automatically return all parts.

TIME CONDOR Corporation requires that all parts claimed on a Warranty Form be retained by the international dealer for a period of no less than 180 days. After this period, if no instructions have been received form TIME CONDOR Corporation, the parts may be scrapped.

Should TIME CONDOR Corporation request any part be reurned, it will be shipped to our factory in Waco, Texas, frieght prepaid.

WARRANTY CLAIM PROCEDURE INTRODUCTION

This procedure is offered to assist our Dealers in properly completing our Warranty Claim Forms. The more information supplied, the better TIME CONDOR Corporation can evaluate the problem and expedite processing the claim.

The form should be TYPED or completed LEGIBLY in ink. Several copies are utilized.

Ensure that sufficient pressure is applied to make all copies legible.

PROCEDURE NOTE:

THE NUMBERS NOTED BELOW CORRESPOND TO THE BLOCK NUMBERS ON THE CLAIM FORM

1

Where to mail: P.O. Box for mailing claim, street address for R/A parts returns.

2.

Claim information: a.

Dealer's Claim Number: This assigned number is necessary for Dealer and TIME CONDOR Corporation tracking purposes, since there may be more than one claim for the same unit.

b.

TIME CONDOR Corporation Warranty Number: Do not write in this section. It is for Condor Div. use only.

c.

Return Authorization Number: All parts replaced under Warranty MU S Tbe returned to TIME CONDOR Corporation freight prepaid. Call the TIME CONDOR Corporation Service Department for Return Authorization Number. Parts returned without proper authorization and gold packing slip will not be accepted.

d.

All dates pertinent to the claim and/or R/A are to be entered in the proper locations.

3.

Dealer information: Supply the name of the company, address and name of the person submitting the claim. This person will be the contact if a discrepancy occurs, and will be referred to on all correspondence.

4.

This section is provide dto identifythe unit: The date of delivery (date unit was received at your facility); In Service date (date sold to end user or date put into operation); Model and Serial numbers; type of Warranty, (A) Aerial Lift Warranty on a specific unit or (B) Parts Replacement, Warranty on a new part ordered and found to be defective.

5.

Owner Information: Supply end user company name and address. If it is the same as the dealer's, write "Same".

6.

This area is for part number(s) and description(s). It is VERY important that the TIME CONDOR Corporation invoice number(s) for which the part(s) were purchased be provided along with the amounts in order to properly process the claim. NO'lE: All dollar amounts are to be in U.S. currency.

7

Labor Description: A detailed description of the failure along with the work performed is required in order to fully evaluate the hours of your claim and the amount TIME CONDOR Corporation will approve.

8.

TIME CONDOR Corporation remarks: This area is completed by TIME CONDOR Corporation A brief explanation and steps taken in the determination of approval or denial is provided here.

Upon completion ofthe form, remove the YELLOW copy for your records. Remove the GOLD copy (packing slip) and send it, along with the parts being returned under warranty. The GOLD copy MUST have the R/A number in the proper location and must be packed in with the parts sent back to Condor Div..

Mailthe remaining copies to theTIME CONDOR Corporation P.O. Box block# I forTIMECONDORCorporation evaluation.

NOTE:

CLAIMS NOT RECEIVED WITHIN 45 DAYS OF FAILURE WILL BE DENIED.

15'7"

DIMENSIONS SUBJECT TO CHANGE WITHOUT NOTICE

4' 23' 7" 6'

TO WORK HEIGHT

42'

CONDOR 4248,

25'8"

/

1

/

/

/ /

/ / / /

I

8'11"

__ _

3'6"

30'1 2 2 34'

CALAVAR CORPORATION CALAVAR CORP.

13750 E. FIRESTONE BLVD.

■

SANTA FE SPRINGS, CALIF. 90670

■

(213) 921-5521

■

TELEX 65-7341 II CABLE: CALACORP

REACH ---, 75°1

ROTATION CA;

DIMENSIONS SUBJECT TO CHANGE • WITHOUT NOTICE ;

CONDOR 4248:

HEIGHT

T"'"•

'-r----1 I 1 1 . I

- - .1-•

DEGREE

0°

15°

30°

....• • •••

45°

f10 ,

w1

.., _,- -..-/ `'' - -• " j L..... .... J

60°

75°

REACH (From Rotation CA)

33' 6"

32'-6"

28' 6"

24' 0"

17' 3"

8' on

HEIGHT (From Ground Level)

7' 6"

16' 3"

25' 0

32' 0"

38' a"

42' 0

CALAVAR CORPORATION CALAVAR CORP.

13750 E. FIRESTONE BLVD.

■

SANTA FE SPRINGS, CALIF. 90670

■

(213) 921-5521 II TELEX 65-7341

■

CABLE: CALACORP

TO THE CALAVAR DEALER This instruction manual includes a step by step procedure for checking out your new CONDOR and at the same time acquainting you with its operation. This whole procedure will not take over a half an hour and it would be well for each of your sales and service people to have an opportunity to personally follow through on this procedure. In this half hour each becomes and "expert" and, therefore, will be in a position to sell, rent, or demonstrate the CONDOR. GENERAL INFORMATION A.

Emergency control panel is located at the engine and counterweight end of turret.

It is just inside the small latch door of engine cover.

B.

All hydraulic valves are located on panel inside turret and these are fully exposed by removing six bolts and the opposing side cover.

C.

Entire engine cover can be removed for any major engine service.

D.

All engine, tire and battery service is to be done at local dealer for each item.

E.

Manual includes the following: 1.

2.

3.

4.

Check out procedure of new machine.

Parts illustration and lists.

Lubrication instructions.

Trouble shooting chart.

F.

Only assigned operators should be permitted to use the CONDOR. Op erators should undergo a training period with their supervisors in an open area.

G.

Operators should be familiar with check out procedures.

H.

Safety precautions should be rigidly adhered to as to height, lift ing capacity, operating no closer than 10 feet to overhead wires and other warning posted on unit.

I.

Repairs and adjustments should only be made by qualified mechanics.

No modifications should be make to machine without prior consent from manufacturer. No extra weights of any kind such as generators or compressors should be "hung" on counterweight end.

J.

Anyone working on or near the machine should wear hard hats.

K.

It is good practice to visually inspect all of the unit before starting operation each day. All aerial equipment should be so checked.

CALAVAR CONDOR INSTRUCTIONS TO DEALER Prior to putting the Calavar Condor in service, a full checkout of unit should be made. Shipping can do strange things to any equipment, and the Calavar Corporation wants your CONDOR to be in good working order for you and your customer.

An unloading instruction sheet was mailed to your office with the invoice. If you have not received this in your department, please ask for it.

To better understand the following we refer to three different parts of the CONDOR chassis. CHASSIS: This is based on the unit. TURRET: This is part of unit that rotates on the chassis; BOOM: Is the telescoping section that raises and lowers the platform.

CHECKING PROCEDURE 1.

Visually inspect all parts of the unit that is exposed. Check for loose nuts, bolts or structural damage. Check for oil leaks, low tire pressure (90 lbs.) etc.

2.

Check oil level in engine. Add 30 weight non-detergent if needed.

3.

Check hydraulic tank oil level. Add EP-15 hydraulic oil if needed.

4.

Check and fill gasoline tank with regular grade gasoline.

5.

Turn on ignition key at platform or ground station, then start engine at the emergency control station located inside latch door at counterweight end of machine. Set controls for ground operation before pressing start button. A choke for engine is located just below emergency panel. It may be necessary to choke when starting first time of day. Stop button on both consoles will "kill" engine with a momentary torch only. It is necessary to turn off ignition switch between running operations.

6.

Be certain you unit is standing in an open area to allow for operation.

7.

Be certain your unit is standing in an open area to allow for operation.

8.

When operating be sure no one has stepped into the area of movement where they could be injured by boom and platform movements.

9.

In following, make certain all movements are smooth and without unusual mechanical or hydraulic hoses. Should malfunction occur, stop operation at once and refer to trouble shooting section of manual.

10.

Press switch to lift boom until it automatically stops at top.

11.

Press switch to rotate full turn each direction. It will be neces sary to be cautious as counterweight end passes over and close to wheels.

12.

Press switch to extend telescoping section UP. This too, automati cally stops at maximum platform height. You may notice a hydraulic notice a hydraulic "squeal' at end of travel height. This is the automatic hydraulic bypass.

13.

Lower boom to parallel with ground. Retract telescoping sections.

Lower platform to ground. Boom rest in turret may be pivoted down to allow boom to be lowered to its maximum.

14.

Now place selector switch to AERIAL operation and continue check out from platform operation control panel.

Activation of any control at the platform will automatically cause the engine to run at governor speed and bring the hydraulic pump on stroke (pressure).

15.

Lift platform to approximately two feet from ground.

16.

To get "feel" of tilt operation, pull tilt switch toward you. Then return forward until platform is again level. This switch is for manually correcting the automatic leveling of platform. This manual leveling is at times necessary to compensate for different weights on platform.

17.

Until you are more oriented to operation, place platform to rear of machine (by use of rotating control).

This puts your "steering" wheels ahead of you and drive wheels near platform.

18.

Press DRIVE button and more oriented to operation. Acquainting yourself with this operation and getting the feel of steering and driving.

19.

With telescoping sections retracted, raise boom to top position.

Drive unit forward and reverse until you feel comfortable.

Now extend telescoping sections and again drive until you get the "feel" of this operation.

20.

At full height, press button and move control to rotate full circle, then left full circle until comfortable.

21.

Return platform to position just above ground, and if the unit has the platform swing option, try this in both directions.

22.

Positraction is manual control, the hand control valve is located between two drive wheels. Positraction should only be used on rough, soft or uneven ground conditions.

Performing the above operations will have purged the system of any air that might have been in any cylinder such as platform swing which you may have thought was spongy.

OPERATING INSTRUCTIONS FOR CALAVAR CONDOR MODELS 3238S, 4248S, 4248LC

Prior to starting the CONDOR a general observation should be made of the machine to determine that there are no oil leaks or structural damage, flat tires, or visual damage to the controls.

The following checks should be made: 1.

2.

3.

Fuel Level Engine Oil Level Hydraulic Oil Level

.

The Calavar Self-Propelled Condor has been designed as a one man operated unit with the standard controls in the platform to start and stop and to perform all operational modes of the unit with the operator standing in the platform. An optional remote basket control is available for the operator to stand on the ground and operate the boom and plaform tilting to facilitate loading the pipe pick up brackets. (Condor cannot be started, stopped, or driven from the remote basket control).

A ground control panel is standard and is located on the turret (these controls are for functional testing and emergency use only). This panel is limited to lifting and lowering the boom, extending and retracting the boom and rotating the machine on its base.

For the ground, the engine can be started or stopped and there is a selector switch to isolate the controls either to the ground panel or to the platform panel. An optional remote ground control is available and provides the ability to drive and steer the unit for loading on or off a truck or trailer.

Controls are electric toggle switches. Power source is gas, diesel or LP gas engines driving a hydrualic pump, which delivers oil through a series of valves that, when activated by the lever switches, direct oil under pressure to perform the function asked for by the operator.

STARTING AND OPERATING Calavar Self-Propelled Condor The ignition key switch is located on the side of the PLATFORM Control Panel, or GROUND Control box. Press the start button to start the engine. Choke control will be at engine or on turret close to Ground Control Panel. Use Ground Panel Start Button while choke is used.

All control panels are adequately marked for all functions. The lever or switches electrically activate valves to produce the function as marked on the face of the panel adjacent to the switch.

OPERATOR PROCEDURE Calavar Self-Propelled Condor The Calavar Self-Propelled Condor Aerial Platform is a personnel lifting device and it is essential that it be properly maintained and operated in order to perform its functions with safety and efficiency. Operation of new and relatively unfamiliar equipment can be hazardous in the hands of untrained operators.

For this reason, it is suggested the PERSONNEL assigns to the self-propelled Calavar Condor undergo a thorough check-out or training period to familiarize himself with operating characteristics of the unit. Only a minimum of practice will be necessary for a person of average abilities to become proficient and safe in the operation of this equipment. The initial phase of training should include a comprehensive study of this manual; the last phase should include practice of operation under simulated conditions which may be encountered in actual work.

The following rules should be observed at all times during operation of the Calavar Self-Propelled Condor aerial platform.

1.

Only "Assigned Operators" should be permitted to operated the equipment.

2.

Operators should undergo a thorough training peroid with a trained operator in an open area before operating at job site.

3.

Operators must be thoroughly familiar with Operating Instructions and the Operator's Maintenance Instructions.

4.

All safety precautions must be strictly adhered to, especially--DO NOT EXCEED MACHINE PLACARD MAXIMUM PLATFORM LOAD.

5.

Repair and adjustments, outside of those described in the Operator's Manual, should be made only qualified, trained mechanics. NO modifications should be made to this equipment without prior consent from the original manufacturer.

A knowledge of the operating characteristics and limitations of the Calavar Self-Propelled Aerial Platform is always advantageous to the new operator.

Several of the important points to remember during operation are provided at the control station through warning and caution placards, or stenciled in an area convenient for the operator to observe. These placards or stenciled warnings are placed at this station for the express purpose of assuring that the operator is informed of certain potential hazards.

The following information is provided as an aid for efficient operation and as preparation to avoid these hazards.

When operating the Calavar Self-Propelled Condor Aerial Platform from the upper controls, care should be taken to prevents lowering or rotating the booms into building, electrical wires, vehicles, or any other obstructions.

All load capacity ratings on this equipment are given on this basis that the unit is operating on firm level ground, and with proper tire pressures.

DO NOT EXCEED MACHINE PLACARD MAXIMUM PLATFORM LOAD All preparation necessary to place the equipment in a ready status should be the responsibility of one member of the operating personnel. Most preparatory operations are relatively simple and usually involve little more than a series of visual inspections.

Before a new unit is put in operation, it should be inspected for any damage incurred during shipment and periodically thereafter. The equipment should be thoroughly checked for hydraulic leaks during the initial running. Leaks usually develop at fittings. Since all of these fitting are of the pip thread or straight thread (0-Ring) design, almost any leak that would develop can be stopped by tightening the fitting further. If the leak cannot be stopped in this manner, further inspections may reveal a bad thread, broken fitting, or a defective 0-Ring. In such cases, the damaged part must be replaced or repaired as necessary.

The operating,maintenance and supervisor personnel responsible for the operation and work performance of the equipment should become thoroughly familiar with the operating functions of the Calavar Self-Propelled Aerial Platform and the entire manual, especially the safety section, before actual job operation.

WARNING PERSONNEL MUST BE EXTREMELY CAUTIOUS WHEN OPERATING THIS EQUIPMENT AROUND HIGH TENSION LINES OR ANY ELECTRICAL INSTALLATION. ALWAYS REMEMBER THE AERIAL PLATFORM HAS NO INSULATION PROVISIONS AND MAY CARRY ANY ELECTRICAL CHARGE ON CONTACT. It is advantageous to distribute load uniformly over or about work platform. Extremely uneven sloping or soft terrain is hazardous and should be avoided whenever possible.

WARNING PLATFORM CAPACITY MUST BE DE-RATED FOR TOOLS AND ACCESSORIES.

Start the engine and allow a short warm-up.

CAUTION Always remember the manual drive lever will automatically return to neutral (spring loaded) and will automatically set and hold your brakes if the unit has been moving forward or reversed.

Study the controls to be positive the lever or switch activated will produce the function desired. Check the operation of the aerial platform boom-lift and turnable rotation from the platform controls. If operation is satisfactory, operate the condition at once. DO NOT CONTINUE TO OPERATE. Defective components jeopardizes the safety of the crew and may cause extensive damage to unit.

Board the platform and check the response of platform controls by operating each control lever or switch. If control performance is satisfactory, proceed to job operation.

Personnel assigned to work on or around the aerial platform should become familiar with this and any sections of this manual that point out safety hazards. This section is provided to augment any established safety practices set up by the customer and to establish safety practices especially for the Calavar-Self-Propelled Condor Aerial Platform. The personnel should consider it important to their personal safety to review this section often.

PRECAUTIONS IN USE OF TOOLS AND EOUIPMENT Safety head gear should be worn by all operating personnel, especially those on the ground during operation.

Since no insulation features are provided on the self-propelled aerial platform, caution should be used to prevent the operator from being energized by phase to phase contact or phase to some external ground such as guy wire, ground cable, etc.

DO NOT secure any line, wire, cable or any other such equipment directly to the platform.

BEFORE OPERATING the Calavar Self-Propelled Condor Aerial Platform, the operator must have read and become familiar with this and the following sections of this manual.

The operating and supervisory personnel responsible for the operation and performance of the equipment should set up a check-off list to guarantee the readiness of the equipment for a safe operation. This schedule should be checked every day before beginning operating and should include the following: 1.

Thorough inspection for visible worn, damaged or loose components.

2.

Check the fuel supply.

3.

Check the operating performance of all functions from the control station. If trouble is detected, do not proceed job operation until corrected.

4.

Check the unit to assure proper operating condition. Tires should be properly inflated, brakes in good conditon and operating prop erly. Wheel chocks may be used where ever practical as an added safety measure.

CALAVAR SELF-PROPELLED CONDOR LOAD CAPACITY DATA

Model

6 ft. basket

12 ft. basket

Fork Lift

3238S

1,750 lbs.

1,600 lbs.

2,000 lbs.

4248S

750 lbs.

600 lbs.

1,000 lbs.

1,000 lbs.

750 lbs.

1,250 lbs.

4248 LC

CALAVAR SELF-PROPELLED CONDOR TROUBLE SHOOTING

ENGINE WILL NOT START

Be certain ignition key is in ON position--Check battery connection--check battery terminals and both ends of cables. Short out across ignition key terminals. Check engine manufacturer's manual. Check circuit breaker on emergency panel.

ENGINE TURNS OVER, BUT WILL NOT START

May need to be choked (at emergency control panel).

Check gasoline supply. See engine manufacturer's manual.

Check for badly contaminated fuel filter.

ANY SWITCH NOT OPERATING ON PLATFORM CONTROL

a) Check emergency control to make sure switch is set for aerial control. ) Open control box lid (at platform) check for loose wires. c)

Check for moisture in switch.

d)

Check for loose wires at emergency control box.

e)

Check continuity for wires from platform to emergency control box.

Locate solenoid valve for this function (see valve location chart). At either end of valve there is a small end of a shaft. Press in either direction with small diameter screw driver or rod. With motor running, this should manually operate valve for action desired. At times small foreign particles can be forced on through the valve in this manner and if this is the case, the switch will then operate the valve.

g) A weak battery can be the cause of solenoid valve malfunctioning. Check battery for condition.

ANY SWITCH THAT OPERATES IN ONE DIRECTION BUT NOT THE OTHER

a)

Locate solenoid valve of this operation (see valve location chart). Switch the two wires leading into top and bottom of valve. If unit then goes in opposite direction but then won't go in original direction, check for voltage when switch is applied both at switch and at solenoid.

b)

Check battery condition. A weak battery will cause this action at times.

c)

Manually push on solenoid valve ends as in F above.

BASKET LEVELING

Condor has automatic leveling of platform, however, the amount of weight lifted and position of telescoping may make manual correction necessary during work day.

POSITIVE TRACTION DRIVE

This manual control is located between the drive wheels.

Positive Traction Drive should only be used on soft sand, rough or uneven ground surfaces.

LOSS OF TORQUE TO DRIVE WHEELS

a)

Highest torque for travelling on uneven ground is found by using the high speed. Platform must be in position close to ground to enable high speed to be in effect.

b)

Remove cover from motors (at drive end). Check for broken drive chain.

c)

Check for broken motor shaft. If broken, do not continue use of machine as metal parts can work their way into hydraulic system.

Greatest traction can be found by placing turret counterweight end over drive wheels.

ROUGH BOOM EXTENSION AND RETRACTION

Most likely to find foreign matter has built up on roller under boom or on the underneath surface of booms.

Scrape clean.

BRAKES

The brakes set automatically when drive switch is released.

Important: There is a thumbscrew adjustment that is a time delay which slowly applies brake. This is very important when boom is in raised position. When adjusting this delay, unit should "roll" 3 to4 feet to a stop -- to keep from jolting the operator on the platform. Turning thumbscrew to right eases the application of brakes, turning to left causes quicker stops..

Brakes holding capacity is not reduced when set, so it comes gently to a stop. The setscrew merely "times" the application of brakes.

STEERING

It is natural for steering to be faster in one direction than the other due to natural limitations of hydraulic cylinders.

Unit will not normally steer both directions unless unit is moving (brakes released).

BROKEN PARTS ON LEVELING CYLINDER OR ITS CONNECTIONS

Probably caused by lifting of machine with boom. Condor places platform cylinder so it pushes to lift platform for safety sake.

HYDRAULIC OIL

A.T.F. Dexron B

CONTINUAL BURINING OF POINTS ON ENGINE

Probable cause is leaving ignition key in ON position after engine has stopped due to any cause other than depressing "stop" button.

M inimum Oil Specifications for Condor Model 4248-3238 with Racine TRW Drive Morors

Adherance to these specifications from any oil company are necessary to lessen the slippage factor through the drive motors.

•

Oil Company

Number

Gulf Harmony

Chevron Teknifax

54AW

EMS

Shell Trilas

#33

Mobil DTE

#26 ,

Viscosity, SUS @ 100° F SUS @ 210°F

Viscosity Index, Mimimum

300 53.4

315 54

95

107

304 48.8

97

300 53

95 .

_ Flash Point,

455°

400°

400°

Pour Point, °F

-20

-20

-30

-5

Corrosion Protection ASTM D665

Pass

Pass

Pass

Pass

June 25, 1974

MAINTENANCE CHECK SHEET

,

Item

Daily

Weekly

Monthly ,

.,

--.

X

Engine Fuel Level

.

X

Fuel Filter

Change

X

Engine Oil Level

Yearly

6 Months

Change

Engine Oil Filter Engine Air Cleaner

X

Battery Water Level

X

Tire Pressure

X Change

X

Hydraulic Oil Level

Change

Hydraulic Oil Filter Hydraulic Oil Leaks

X

Hoses &Wiring

X

Unusual Noises

X

.

-

_.

X

Wheel Brakes

X

Lubrication

N

,

Speed Reducer Oil Levels

41

X

(See lubrication chart for recommended components to be serviced.)

.

SEMI-MONTHLY

A MONTHLY 0-TURS°r 1VFS

I

ANNUALLY

TYPE OF LUBRICANT CG- SHELL DARNA AX70330 or EQUIVALENT E0- S.A.E. 30 WEIGHT GO - SAE 90 WEIGHT EP SL- CROWN 7045 HEAVY DUTY OPEN GEAR AND WIRE ROPE LUBE OR EQUIVALENT

L

CG - CHASSIS GREASE EO -ENGINE OIL

GO WINCH ( Capacit y 12 oz)

• WINCH FLANGE BEARING A • CABLE DRUM L NYLATRON BEARINGS (BothSides )

LUBRICANT

..

SHEAVE PIN CG AIR A CLEANER c.E__0.

OIL BATH

. GO -GEAR OIL SL -SPRAY LUBE NOTES: * VAJLNILIQ LUBRICANT MUST U.Q1 CONTAIN LITHIUM ** ROTATING PLATFORM OPTION COMPONENTS

CRANK CASE DRAIN CRANK CASE FILL

FLANGE BEARING ( One Place Each Side GO SPEED REDUCER TIE RODS (Two Places Each Side) STEERING KNUCKLE CG (Two Places each side)

OIL FILTER CHANGE

AXLE FLANGE BEARING (Two Places each side)

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

DIV HD N O .I.VD Ig ill 8t Z17

INTERVAL SYMBOL

PLATFORM ROTATION CYLINDER PIVOT POINTS ** SKIRT (Two places) AND TOP PIVOT BRACKET AND BOTTOM PILLOW BLOCK

STEERING CYLINDER PIN

OUTER BOOM CABLE SHEAVES (Two Places Underneath)

DIP STICKS A

EO\ DRIVE CHAIN (Both Sides)

rrl 2 +, 7 +7

INNER BOOM SKIRT LEVELING CYLINDER PIN

TOPPING CYLINDER • (Two Places)

nIt `,;fll

PLATFORM LEVELING SLAVE CYLINDER (Two Places)

MASTER LEVELING CYLINDER (Two Places)

>iH P ') NJ

INTERMEDIATE BOOM CABLE SHEAVE (One place underneath)

HYDRAULIC TANK OIL (SSU315 at 100° F Chevron EP15 or Equivalent) HYDRAULIC TANK FILTER CHANGE BRAKE RELEASE CYLINDER PIVOT POINTS (Two Places each) INTERMEDIATE BOOM ROLLER (Both Sides)

STEERING CYLINDER PIVOT POINTS (Both Sides)

MASTER BRAKE CYLINDER FLUID

ADJUSTMENTS HYDRAULICS In order for a mechanic to make adjustments, he should have a working knowledge of the hydraulic system. The schematic drawing is Figure 43. The system incorporates a single pump being of the gear design and will deliver approximately 14 to 16 gallons of oil when operated at 1800 to 2000 RPM. The oil flow from the tank passes through a screen strainer element which is inside of the hydraulic reservoir. This element is a washable element and is accessible by removing the top from the hydraulic tank unscrewing the element and is accessible removing the top from the hydraulic tank and unscrewing the element from the bulkhead fitting (refer to Figure 19 in your Parts manual). The pump then discharges the oil to one of two priority valves indicated on the hydraulic schematic.

This priority valve is adjustable to provide a portion of the flow through the regulated port to the 4-bank solenoid valve. This valve controls tilt, lift, steering and rotation. This oil also control platform swing via the power beyond port on the 4-bank valve. This priority valve should be adjusted to the point that movement of these functions are reasonable (not to slow and not too fast).

The oil passing over the by-pass port of the first priority valve goes directly to a second priority valve, which is adjustable for oil flow through the regulated port to the extension valve. This again should be adjusted to obtain the desired speed of extension and retraction. By following the schematic, you will note that the oil flowing through the extension valve goes through a tee, one side of the tee going to a dump valve and one side going to a check valve. The check valve is a one way passage valve having a spring tension that, if the dump valve is open, the oil will go in the direction of the tank. The dump valve is normally open to tank and is operated with an electric solenoid. Therefore, oil from extend valve is normally routed to the tank when the solenoid is de-energized. When the dump valve solenoid is energized, the dump portion is closed and diverts oil through the check to one of the pressure ports of the drive solenoid valve. This portion of oil is combined with the by-pass flow of the second priority valve producing faster DRIVE speed or 2nd gear.

When the dump valve is not energized, by-pass oil coming from the second priority valve port will go to the drive. This is first speed drive. The terminology of speed must be considered in this way--that first speed does not create the greatest torque. Quite often to negotiate rougher terrain, it is necessary to use the second speed for greater torque.

The above adjustments can be varied, depending upon the service the equipment is in. However, after some experience, a setting will be established and not varied again. For example, if the machine was going to be used primarily as a lifting and placing device, and only with very little driving involved, and all of these load were of near maximum capacity of the machine, it may be necessary to open the first priority valve, allowing a greater flow of oil through the regulated port to the 4-bank of valves. Greater flow again will create more torque in the lifting capabilities of the boom.

CAUTION-- this will also cause the rotation of the turret to be more rapid and severe.

It must be remembered that originally the pump was delivering 14 gallons, and if 5 gallons is taken at this point through the 4-bank valve and optionally, the work platform rotation, this oil goes back to tank.

It is not usable for any other function.

Assuming now that 5 gallons are being used through this regulated flow, 5 from 14 will leave us 9 gallons of oil across the by-pass port to the second priority valve. If we were to adjust the second priority valve so that the extension would move rapidly, and carry a load near or at the capacity of the machine, we will assume that 6 gallons would be needed to flow across the regulated flow to the extension valve. This leaves 3 gallons from the by-pass port to the ground drive valve. Then perhaps, due to the terrain, temperature of the oil, etc., 3 gallons would not drive the machine in the first speed. If shifted to second speed, there will now be 9 gallons available to drive the machine.

Let us review the system one more time. At the first priority, if the adjustment was made to use only 3 gallons of oil to the 4-bank valve, the motions would be slower and smoother in rotation. 11 gallons of oil going across the by-pass port the input port of the second priority valve, the second priority valve then adjusted to pass approximately 5 gallons of oil to the extension valve will result in a nice smooth operation. Then with 6 gallons of oil going across the by-pass port to the ground drive, will undoubtedly drive the machine over reasonable terrain.

In second speed, it would have 11 gallons to the ground drive valve which would, of course, create greater second gear speed and greater torque capabilities. At this point it should be recognized that these adjustments then are compromises.

During any checking of the hydraulic system, it is quite important to note what pressure is created under loaded conditions for each function. Figure 16--Fitting 61, 62, and 63--61 being an elbow, 62 being the test fitting, and 63 being a cap. If the cap is removed, a gauge with a hose and a end fitting of 1/4" JIC female will screw directly on to the test fitting. Since this is the pressure line directly from the pump, any function actuated will produce the reading on the gauge necessary to operate that function. For example, the 4-bank valve, having its own relief valve preset at the factory at 2250 P.S.I., can be checked by lifting the boom to its maximum cylinder stroke and a reading of 2250

should be obtained on the gauge. Obviously, if needed, this same pressure is available at all 4 functions of lift, tilt, steering and rotation. However, rotation is continuous and requires very little pressure, so you must not expect to see that high a pressure at any time at rotation, and only at full stroke or position or all the three banks; tilt, lift, and steering. In the upper right hand corner of Figure 16 is the platform swing valve which has its own relief valve and is set at 1500 P.S.I. In the same area of Figure 16, Fitting 38, is a power beyond fitting, which screws into the outlet casting on the 4-bank as shown. The power beyond fitting, just as the name implies, carries the oil beyond the 4-bank valve to the single bank for platform swing. When the oil passes through the platform swing valve, it is plumbed to a common return line to the tank, passing_ through a replaceable filter element, again shown on Figure 19, item 11.

Again, in Figure 16, near the center of the page toward the top, Item 10 is the boom extension valve. It has its own relief valve and this valve is set at 1800 P.S.I. Item 33 indicates the drive directional valve. It has its own relief valve set at 2000 P.S.I. Item #4 is dump valve normally open and is solenoid operated to close, which also has a relief section originally set 2000 P.S.I. However, in the current design, it is no longer needed. Future units will have the relief feature.

In the present configuration, it is suggested that this relief valve be screwed shut so that it will not leak or lose oil back to tank during second speed operation.

Return oil from the extension valve will also join a common return line and pass through the same filter previously mentioned in Figure 19 and return to the tank. This element should be changed 30 days after the machine is put in operation, and then at regular intervals thereafter, depending upon the type of service and atmospheric conditions in which the machine is being used.

ADJUSTMENTS ELECTRICAL Electrical schematic drawings are in the Parts Manual, Figures 41, 41A and 41B. All of the functions of the 4248 are electrically operated, with toggle switches at the control stations to energize solenoid hydraulic valves. The switches are, of course, two directional and the solenoid valves are two direction valves. It will be noted on Figure 41 that this drawing covers the ground control station and the connections for the ground control remote box. The stationary ground control box gives control of lift, extension and rotation and the selector switch for ground or aerial control. Further, there is a receptacle to plug in the remote ground control box which then provides ground drive and steering.

When the selector switch is on ground, the platform controls are inoperative. Figure 41A is the schematic for the platform controls. There is an optional remote control which can be plugged into the platform controls and will provide turret rotation, lift the boom, tilt the platform and extend the boom. Figure 41B shows the electrical circuitry to switch No. 7 in the platform for first and second gear and third gear is optional high speed machine is purchased. The turret switch is wired in series with the speed switch for first, second and third gear so that a point below horizontal of the boom the machine is operable in first, second, and third gear. Up and above horizontal, second or third gear is electrically elimated. The machine will then only operate in first gear.

If any function from any location does not operate, a systematic trouble shooting procedure should be followed, for example, take the ground drive functions. Assuming for a moment that the platform controls, the unit will not steer in one or both directions. A first step may well be to move the selector switch to ground control, and if optional ground remote control box is available, test the steer switch there.

By operating the steer switch results in moving the front wheels, the problem may be in the switch in the platform control. This can be checked again by switching the selector to aerial control and opening the cover of the platform control box. Using a test wire, connect the middle terminal to one of the end terminals on the back of the switch. If the switch is bad, this jumper wire does not cause the unit steer. If the switch proves to be all right, and the jumper wire does not cause the unit to steer, a jumper wire may be brought from the battery terminal directly to the solenoid valve.

Reference to Figure 16, Item 33, is the steering valve. If coil has two wires, one being ground, the other will be connected to a wire running through a loom back to the control station. If the jumper wire from the battery was briefly connected to the lead coming out of the loom, and this effort would cause the unit to steer, it would then indicate there was a broken or loose wire somewhere in the circuitry.

It should be noted on the schematic drawing Figure 41 that the steer solenoid wires are #15 and #16. In the ground control box, Figure 18, there is a terminal board, Index 20. Systematically using the jumper wire checking off wire 15 and 16 with either a jumper wire or with a test lamp and following the curcuits indicated in the electrical schematic, one should arrive at a point where continuity would be lost and certainly the trouble would be found.

There is an intermediate step in this procedure that should be taken; assuming electrical ground was evident at the solenoid valve, when the toggle switch was applied, and still no hydraulic activity took place, one or both of the solenoid coils may be burned out. In the top and bottom of all of the valves in the center of the retaining rod that holds the coil in place will be found ,a manual override plunger.

With the engine running, using a screw driver or small driver or small rod, these plungers may be pushed in to operate the valve.

CAUTION: If this is being done to the travel valve, that the wheels are going to drive and the machine is going to move. Prior to activating this valve manually, the area must be for the machine to move and the man performing this function must be ready to step back quickly and release the plungers. When pushing the control button on one coil, it will cause the machine to travel in one direction and pushing the button on the coil will cause the machine to travel in the opposite direction.

If the spool were stuck, it may be possible to work it loose and then the electrical system may take care of further operation. However, it is also possible that any large particle of foreign matter might jam the valve, and this, of course, would be known in attempting to move these plungers manually, it would take extreme effort pushing on the plunger with no result. This would then necessitate total disassembly of the valve for cleaning or perhaps its placement in the circuit.

If it is evident that the valve does function manually very well, and there is electrically to the coils; but there is no activity, it is then suggested that a meter be used to determine continuity of the coil.

If the coil is bad, it can be removed from the valve and a new coil installed. Generally, if the coil is energized either by its switch on the control box or a temporary jumper from the battery, a small metallic object such as a washer or screw driver will be magnetically attracted to the coil. This will indicated if the electrically circuitry is complete.

The same general principle may be applied to all solenoid valves mounted on the hyraulic assembly mounting plate.

It might be well to explain the use of the latching relay located in the ground control box. Normally when a man arrives at his destination in the air and expects to work there some period of time, the engine should be shut off. Pushing the stop button energizes the latching relay and the contacts are opened shutting off ignition. There would then be no current drawn off of the battery and no danger of running the battery down or burning distributor points. Upon restarting (push starter button), the latching relay will latch in the opposite direction automatically completing circuit to the engine coil. This particular feature is helpful in trouble shooting a unit.

If one is trouble shooting electrical problems, one may start the machine and allow it to run and turn off the ignition key switch. Do not push the stop button if the engine has stopped, turn the ignition key on.

Do not start the engine. All circuits are now alive and depending upon the position of the selector switch, if for example, on aerial, the aerial switches could be applied forward, reverse, up, down, right or left. With an ammeter hooked into the circuit at the solenoids, reading then could be obtained assuring the mechanic that switches do work and you do get proper amperage at the coil and proper volts, if a volt meter were connected at that point. Normal amperage is 2.2 at 12 VDC. The solenoid valves should shift with 9.8 volts. Of course, if the battery is up to 12 volts, the volt meter reading should read 12 volts, but as stated, the solenoid valve should shift with something less than 12 volts, such as 9.8.

If one were checking switches and wiring from the ground station, the selector switch must be in the ground station position.

It is suggested that the maintenance mechanic make himself familiar with the schematic in Figures 41, 41A and 41B and also of the respective locations of components and wiring of the machine. A mechanic with a fair knowledge of electricity should not have difficulty in trouble shooting the electrical system.

WHEEL BRAKE SYSTEM - CONDOR- MODEL 4248-3238 Parts book figure #11 shows the components of the Wagner Hydraulic, single wheel cylinder, two shoe brake system and deserves the normal attention for adjustment and maintenance afforded any hydraulic brake system.

Parts book figure #9 shows the components for the automatic application and the power release feature. The master cylinder is a conventional Wagner product, automotive brake fluid is used and should be checked and maintained by being kept clean and full to the proper level.

Part #21189-spring, Index #26-figure #3 applies the necessary tension to the lever arm and master cylinder linkage as shown in figure #9. This should produce a minimum of 1200 PSI to a maximum of 1500 PSI to the wheel cylinder. (This can be checked by teeing pressure gauge at either wheel cylinder line). Release is activated at any item the wheel travel switch is applied for forward or reverse. Hydraulic pressure to the travel motors is fed through part #FPS22-lA2 shuttle valve, index #15, figure #9, releasing the master cylinder pressure to the wheel cylinder.

The adjustment of part #FMF20-B is approximately 1-1/2 turns open-and is to be further adjusted to slow down or speed up the brake application.

This means that when the operator releases the switch for either forward or reverse travel the brakes apply smoothly and the machine may roll one or two feet (close valve slightly for longer interval before brakes apply).

This is particularly important when traveling while the operator is riding the platform in elevated altitudes. Conversely if the machine is being driven on grades of up to 8° to 8-1/2° maximum it would be desirable for the brakes to apply sooner, (which will be abrupt) by opening the valve slightly. The above adjustly only controls timing. Shoe and tension spring (part #21189) adjustment, hydraulic brake fluid level and of course maintained condition of all components resulting in the 1200 PSI necessary for good dependable brakes which are then adequate to hold the Condor safely for extended period of time.

Weather or job site working conditions vary considerably-therefore, maintenance schedules will necessarily vary. Calavar, in the interest of safety, highly recommends a minimum semi annual inspection be performed.

INSTRUCTIONS FOR SELF PROPELLED BOOM REMOVAL AND DISASSEMBLY (All drawing numbers indicated refer to Figure 25 and 25A in your parts book)

1.

Remove basket and control box from fork. Wire control box to inner boom section.

2.

Extend boom out far enough to remove pin (21128, item 12). Pull cylinder (21015, item 1) far enough out to remove and cap hydraulic lines. (If boom cannot be run, above step can be done later).

3.

Remove side wear pads (21198, item 27) and upper wear pad (22018, item 27B) lower wear pad is removed by pulling pin (21119, item 144).

4.

Remove pin (21120, item 52) to remove roller.

5.

Raise boom to horizontal position and place sling before and after of in (21132, item 129) apply pressure and remove pin. Lower top ping cylinder down and out of the way.

6.

Remove pin (21131, item 134) from bottom end of master leveling cylinder.

7.

Disconnect hydraulic lines from Tulsa Winch motor hydraulic lines from bulkhead fitting located inside turret. Disconnect two lines from master leveling cylinder and two lines from basket rotation.

8.

Remove electrical cable from master control panel and cut tie raps freeing cable from any other line it may be connected to. Pull out turret.

9.

Remove main boom pivot pin (21129, item 148).

10.

Lift boom up to free turret.

11.

Lay boom upside down. Pull pin (21130, item 121). Remove master leveling cylinder.

12.

As a reference point to aid in speed of assembly, measure threads showing after removing jam nuts on cables and also on thread showing inside turnbuckle.

SELF PROPELLED CONDOR BOOM REMOVAL AND DISASSEMBLY (CONTINUED) pg 2 13.

Remove spring from turnbuckle (21262, item 161). Remove turnbuckle (G-228). Unwind cable from around winch drum.

14.

Loosen and remove cables from anchor brackets (21111-1, item 83 and 21111-2, item 84). Look down inside boom to be sure cables have not fallen down between sections.

15.

Remove springs (Fig. 26, items 1 and 2) to remove tension from hydraulic lines and electrical cable.

16.

Remove end cover from channel on bottom of boom and feed hydraulic lines and electrical cable back to this point.

17.

Remove grease fittings (item 36) and four bolts holding turnaround bracket (21261, item 45A) to main boom.

18.

Using U-bolt shaped tool, hook on to turn around bracket and secure to intermediate boom (21101, item 17). When out far enough, mark on boom where bracket goes as a reference.

19.

Secure main boom and hook on to intermediate boom and start to pull apart. Watch cables to see that they don't fall between boom sections and guide hydraulic lines and electrical cable to be sure they don't get hung up. When intermediate section reaches end of main boom, lift up on intermediate section to clear stops.

20.

To remove inner boom from intermediate section it is necessary to cut tie raps to free cable from turnaround bracket or from control box. Before separating electrical cable and hydraulic lines, measure how far kellum grips are up on cables, mark for reassembly.

When these are free, tension will be off turnaround bracket.

21.

Remove set screw holding pin (2118, item 76) to remove the three vertical sheaves (21210, item 58, 21110, item 59, and 21202, item 70).

22.

Remove bolts holding retraction bracket (21262, item 71).

23.

Remove pin (C12, item 9) holding cable in. Pull inner boom out back and at intermediate section. Watch cable to be sure it doesn't fall down sides of boom.

24.

Pull pin (21049, item 20) to remove intermediate boom sheave. You can remove leveling cylinder after boom is out.

25.

To reassembly boom, work backward from above steps.

26.

When you reach step 19, it helps to use masking tape to keep cable and lines laying on boom while putting sections back together.

27.

When you reach a point where you have secured all the cables, you can run them up to reach the amount of thread you measured. At this point you can look down boom to be sure you don't have any cables twisted or have not lost any from around sheaves.

28.

Replace boom on unit and follow procedure for boom cable adjustment.

PROCEDURE FOR BOOM CABLE ADJUSTMENT 1.

Attach snubber cable to inner and intermediate booms as shown in Figure 1.

2.

Reconnect hydraulic line to Tulsa Winch motor, extend booms against the snubber cable until relief valve dumps at 1800 PSI.

3.

Tighten turnbuckle by hand until slack on retraction cable is elimi nated. Secure both locknuts. See Figure 2.

4.

Attach spring as shown in figure 2 from turnbuckle to intermediate boom.

5.

With snubber cable still attached and under tension, tighten inner boom extension cable at bracket to 50 inch pounds. See figure 3.

Secure locknut.

6.

Release tension by retracting booms. Remove snubber cable.

7.

Extend booms against their stops until relief valve dumps at 1800 PSI.

8.

Tighten inner boom retraction cable at bracket to 50 inch pounds.

See figure 3. Secure locknut.

NOTE: 1.

DO NOT lubricate cable threads.

2.

DO NOT allow cable to rotate while torgeing nuts.

PROCEDURE FOR BOOM CABLE ADJUSTMENT

INTERMEDIATE BOOM

FIG.2

SPRING

CciP

-40 1

LOCKNUT WINCH DRUM

CABLE PLUG

F10.3 LOCK NUT DOUBLE BRACKET INNER BOOM RETRACTION CABLE

OUTER BOOM

SINGLE BRACKET

INNER BOOM EXTENSION CABLE//

LOCK NUT INNER BOOM RETRACTION CABLE

OUTER BOOM TORCAIE II

INNER BOOM EXTENSION CABLE \e" •

I I I 3.

I I R CORPORATION

LOWER RING-GEAR BOLTS AND LOCKSTRIPS: TYPICAL INSTALLATION

1. Install lockstrips as shown.

• Use Kit #58004 for Condor Models 76, 68, 58, 56, 50, 6066, 5056, 4248.

• Use Kit #58005 for Condor Models 60N, 46N, 36N, 4046N. • Use Kit #58006 for Condor Models 48, 4046, 3036N. 2. Bolts are special (grade, strength & length) for the Condor machines. DO NOT USE ANY OTHER BOLTS. 3. Do not use lockwashers.

4. Torque lower ring-gear bolts to 105 ft-#s ± 5 ft4s, using conventional criss-cross torque sequence.

5. Bend-up ears (ends of lockstrips) on flat of bolt hex head as shown. Bend two places for each lockstrip.

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

1113.

/I I RI CORPORATION

LOWER RING GEAR-BOLTS & LOCKSTRIPS: BILL OF MATERIAL

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

Consists of:

2.

•

Lockstrip Calavar Part #68237; Qty = 9

•

Special Hex Head Capscrews; 1/2-13 UNC x 1-3/4 long Calavar Part #801436107; Qty - 18

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

Lockstrip Calavar Part #68226; Qty = 9 Special Hex Head Capscrews; 1/2-13 UNC x 2-3/4 long Calavar Part #BOW36111; Qty = 18

3.

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

Lockstrip Calavar Part #68226; Qty = 9 Special Hex Head Capscrews; 1/2-13 UNC x 1-3/4 long Calavar Part #BOW36107; Qty = 18

Note:

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

ICOINIVER TIME CONDOR Corporation

CONDOR® SERVICE INFORMATION

1. Ifyou need assistance orhave any service or maintenance questions, TIME CONDOR Corporation 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 MaintenancePro cedures available for this machine. These procedures are availab le through the TIME CONDOR Corporation S ervice D epartment to anyone who requests them.

3. Service and maintenance are not a substitute fortrained, qualified service technicians. TIME CONDOR Corporation conducts service schools on a continuing b asis. Call any of our service or sales persons for a schedule. Remember, training ofmechanics is the responsibility of their employer, but TIME CONDOR Corporation. Service Schools help you provide this training.

4. TIME CONDOR Corporation Service School Training Manuals are available forpurchase through the parts department. Thepart numbers for thesemanuals 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, 254-666-4544 FAX

INTRODUCTION

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

THE OPERATOR'S MANUAL MUST BE RETAINED ON THE

CONDOR® AT ALL TIMES.

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

It is YOUR RESPONSIBILITY to follow procedures while operating the CONDOR®. The manufacturer of this CONDOR® cannot control the wide range of applications that may be used in carrying out a variety of jobs. Therefore, it is THE USER'S RESPONSIBILITY to consider all personnel when making decisions regarding the CONDOR®'s intended use.

It is also YOUR RESPONSIBILITY to understand and obey all federal, state, and local regulations regarding the operation and use of aerial work platforms. A copy ofthe ANSI/SIA Manual of Responsibilities is attached for your use: ANSI/SIA A92.5-1992 is provided for Boom-Supported Elevating Work Platforms, and ANSI/ SIA A92.6-1990 is provided for Self-Propelled Elevating Work Platforms.

TIME CONDOR Corporation reserves the rightto 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 THE TIME CONDOR Corporation.

SERVICE & MAINTENANCE

Many ofthe parts used in the manufacture of the CONDOR® have specific properties, and the manufacturer recommends that replacement parts be purchased throughthe TIME CONDOR Corporation in orderto ensure the original integrity of the product. Repairs and adjustments should only be made by trained and qualified personnel. Please referto the maintenance and parts sections ofthe TIME CONDOR Corporation Operation, Maintenance, & Parts Manual for information on service and maintenance of the CONDOR®.

NOTE:

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

CALAVAR CORPORATION

Self Propelled Booms and Scissors

WARRANTY Calavar Corporation ("Calavar") warrants to the purchaser that each new aerial work platform made by Calavar is free from defects in material and workmanship arising under normal use and service, in the case of major weldments (chassis, turret and booms), for a period of 5 years after the original shipment of the aerial work platform from Calavar's plant; and in the case of all other parts, for a period of 1 year after the aerial work platform is first placed in service or two years after the original shipment of the aerial work platform from Calavar's plant, whichever occurs first.

The obligation and liability under this Warranty is expressly limited to repairing or, at Calavar's option, replacing free of charge, at its factory in Waco, Texas or at an authorized repair facility designated by Calavar, the defective part. In no event shall Calavar or its suppliers be liable to the purchaser or any other person for transportation charges or for any incidental, collateral, special or consequential damages, including without limitation damages for loss of profits, loss of customers, loss of goodwill or work stoppage, claims by any party other than the purchaser, or any other similar damages or loss even if Calavar, its suppliers or its representatives have been advised of the possibility of such damages.

Parts claimed to be defective and for which repair or replacement is desired shall be returned transportation prepaid to Calavar's factory for inspection. This Warranty applies to replacement parts provided under the terms of this Warranty only for the remainder of the Warranty period applicable to the original purchase.

Any operation of the equipment beyond rated capacity, improper use or application of the equipment, substitution upon it of parts not approved by Calavar or alteration or repair of the equipment by any person not authorized by Calavar shall, at Calavar's option, void this Warranty. Calavar shall have no liability or responsibility for damages resulting from accident or the malfunction of equipment and components not supplied by Calavar.

No agent, employee, distributor, dealer or other representative of Calavar is authorized to modify this Warranty in any way. Accordingly, additional statements or presentations by any such representative, whether oral or written, do not constitute warranties by Calavar and should not be relied upon as limited warranties of Calavar, and no attempt, effort or promise to repair equipment by Calavar or any such representative at any time shall modify or extend this Warranty in any way. If the purchaser has used its own order form, no additional or different warranty terms contained in purchaser's form will be honored by Calavar. This Warranty covers only new and unused aerial work platforms manufactured by Calavar.

Products or parts manufactured by others are covered only by such warranties as are extended to the purchaser by Calavar's suppliers.

This Warranty is in lieu of all other warranties, expressed or implied, including but not limited to warranties of merchantability and fitness for a particular purpose. Any applicable implied warranty shall be limited in duration to the warranty period.

8300 Imperial Drive, P.O. Box 21447, Waco, Texas 76702-1447.817-666-4545, 817-666-4544 FAX Form No. 513-1M-495

Printed in U.S.A.

co

TIME CONDOR Corporation

arad

CONDOR Self Propelled Booms and Scissors

WARRANTY TIME CONDOR Corporation warrants to the purchaser that each new aerial work platform made by TIME CONDOR Corp. 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 the plant of TIME CONDOR Corp.; 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 the plant of TIME CONDOR Corp., whichever comes first.

The obligation and liability under this Warranty is expressly limited to repairing or, at TIME CONDOR Corp.'s option, replacing free of charge at its factory in Waco, Texas or at an authorized repair facility designated by TIME CONDOR Corp., the defective part. In no event shall TIME CONDOR Corp. 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 Corp., 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 the CONDOR 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 Corp. or alteration or repair of the equipment by any person not authorized by TIME CONDOR Corp. shall, at TIME CONDOR's option, void this Warranty. TIME CONDOR Corp. shall have no liability or responsibility for damages resulting from accident or the malfunction of equipment and components not supplied by TIME CONDOR Corp.

No agent, employee, distributor, dealer, or other representative of TIME CONDOR Corp. 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 Corp. and should not be relied upon as limited warranties of TIME CONDOR Corp., and no attempt, effort, or promise to repair equipment by TIME CONDOR Corp. 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 by TIME CONDOR Corp. This Warranty covers only new and unused aerial work platforms manufactured by TIME CONDOR Corp. 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.

TIME CONDOR Corp.

8300 Imperial Drive P.O. Box 21447 Waco, Texas 76702-1447

Phone: (254) 420-5200 Fax: (800) 443-5803

Printed in the USA 06/98

APPENDIXA

CCIIIIKIII TIME CONDOR Corporation BOLT TORQUE CHART BASIC STRESS NOMINAL THREADS

MAJOR AREA DIA SQ. IN INCH

TENSILE STRENGTH (T) MIN PROOF LOAD (P) SAE GRADE (1957 GRAZE 5 GRADE 8

SAE GRADE 8 _

CLAMP LOAD LBS. 380

.1120

.00604

120KSI

85KSI

150KSI

120KSI

8LB-IN

6LB-IN

CLAMP LOAD LBS. 540

12LB-IN

9LB-IN

.1120

.00661

120KSI

85KSI

150KSI

120KSI

420

9LB-IN

7LB-IN

600

13LB-IN

10LB-IN

.1380

.00909

120KSI

85KSI

150KSI

120KSI

580

16LB-IN

12LB-IN

820

23LB-IN

17LB-IN

.1380

.01015

120KSI

85KSI

150KSI

120KSI

640

18LB-IN

13LB-IN

920

25LB-IN

19LB-IN

.1640

.01400

120KSI

85KSI

150KSI

120KSI

900

3 OLB-IN

22LB-IN

1260

41LB-IN

31LB-IN

.1640

.01474

120KSI

85KSI

150KSI

120KSI

940

31LB-IN

23LB-IN

1320

43LB-IN

32LB-IN

.1900

.01750

120KSI

85KSI

150KSI

120KSI

1120

43LB-IN

32LB-IN

1580

60LB-IN

45LB-IN

.1900

.0200

120KSI

85KSI

150KSI

120KSI

1285

49LB-IN

36LB-IN

1800

68LB-IN

51LB-IN

.2500

.03180

120KSI

85KSI

150KSI

120KSI

2020

8LB-FT

75LB-IN

2860

12LB-FT

9LB-FT

.2500

.03640

120KSI

85KSI

150KSI

120KSI

2320

10LB-FT

86LB-IN

3280

14LB-FT

10LB-FT

.3125

.05240

120KSI

85KSI

150KSI

120KSI

3340

17LB-FT

13LB-FF

4720

25LB-FT

18LB-FT

.3125

.05800

120KSI

85KSI

150KSI

120KSI

3700

19LB-FT

14LB-FT

5220

25LB-FT

20LB-FT

.3750

.07750

120KSI

85KSI

150KSI

120KSI

4940

30LB-FT

23LB-FT

7000

45LB-FT

35LB-FT

.3750

.08780

120KSI

85KSI

150KSI

120KSI

5600

35LB-FT

25LB-FT

7900

50LB-FT

35LB-FT

.4375

.10630

120KSI

85KSI

150KSI

120KSI

6800

50LB-FT

35LB-FT

9550

70LB-FT

55LB-FT

.4375

.11670

120KSI

85KSI

150KSI

120KSI

7550

55LB-FT

40LB-FT

10700

80L13-FT

60LB-FT

.5000

.14190

120KSI

85KSI

150KSI

120KSI

9050

75LB-FT

55LB-FT

12750

110LB-FT

80LB-FT

.5000

.15990

120KSI

85KSI

150KSI

120KSI

10700

90LB-FT

65LB-FT

14400

120LB-FT

90LB-FT

.5625

.18200

120KSI

85KSI

150KSI

120KSI

11600

110LB-FT

80LB-FT

16400

150LB-FT

110LB-FT

.5625

.20300

120KSI

85KSI

150KSI

120KSI

12950

120LB-FT

90LB-FT

18250

170LB-FT

130LB-FT

.6250

.22600

120KSI

85KSI

150KSI

120KSI

14400

150LB-FT

110LB-FT

20350

220LB-FT

170LB-FT

.6250

.25600

120KSI

85KSI

150KSI

120KSI

16950

180LB-FT

130LB-FT

23000

240LB-FT

180LB-FT

.7500

.33400

120KSI

851(51

150KSI

120KSI

21300

260LB-FT

200LB-FT

30100

380LB-FT

280LB-FT

.7500

.37300

1201(51

85KSI

150KSI

120KSI

23800

300LB-FT

220LB-FT

33600

420LB-FT

320LB-FT

.8750

.46200

120KSI

85KSI

150KSI

120KSI

29500

520LB-FT

390LB-FT

41600

600LB-FT

460LB-FT

.8750

.50900

120KSI

85KSI

150KSI

120KSI

32400

570LB-FT

430LB-FT

45800

660LB-FT

500LB-FT

1.000

.60600

120KSI

85KSI

150KSI

120KSI

38600

770LB-FT

580LB-FT

54500

900LB-FT

680LB-FT

1.000

.66300

1201(8I

85KSI

150KSI

120KSI

42300

850LB-FT

630LB-FT

59700

1000LB-FT

740LB-FT

1.1250

.76300

105KSI

74KSI

150KSI

120KSI

42300

800LB-FT

600LB-FT

68700

1280LB-FT

960LB-FT

1.1250

.85600

105KSI

74KSI

150KSI

120KSI

47500

880LB-FT

660LB-FT

77000

1440LB-FT

1080LB-FT

1.2500

.96900

105KSI

74KSI

1501(51

120KSI

53800

1120LB-FT

840LB-FT

87200

1820LB-FT

1360LB-FT

1.2500

1.0730

105KSI

74KSI

150KSI

120KSI

59600

1248LB-FT

920LB-FT

96600

2000LB-FT

1500LB-FT

13750

1.1550

105KSI

74KSI

150KSI

120KSI

64100

1468LB-FT

11001,13-FT

104000

2380LB-FT

1780LB-FT

1.3750

1.3150

105KSI

74KSI

150KSI

120KSI

73000

1680LB-FT

1260LB-FT

118400

2720LB-FT

2040LB-FT

1.5000

1.4050

105KSI

74KSI

150KSI

120KSI

78000

1940LB-FT

1460LB-FT

126500

3160LB-FT

2360LB-FT

1.5000

1.5800

105KSI

74KSI

150KSI

120KSI

87700

2200LB-FT

1640LB-FT

142200

3560L13-FT

2660LB-FT

T

4-40 4-48 6-32 6-40 8-32 8-36 10-24 10-32 1/4-20 1/4-28 5/16-18 5/16-24 3/8-16 3/8-24 7/17-14 7/16-20 1/2-13 1/2-20 9/16-12 9/16-18 5/8-11 5/8-18 3/4-10 3/4-16 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

SAE GRADE 5

P

,

T

P

ASSEMBL' TOROUE R=.200 DRY R=.150 LUB

ASSEMBLY OROUE R=.200 DRY R=.150 LUB

NOTES: L'THIS CHART SHOWS RECOMMENDED BOLT TORQUES. 2.TORQUE =RXD 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 X STRESS AREA

APPENDIX B

TIME CONDOR Corporation

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

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

PROPERTY CLASS 8.8

PROPERTY CLASS 9.8

PROPERTY CLASS 10.9

PROPERTY CLASS 12.9

DIAMETER

DRY LUBRICATED THREADS THREADS

DRY THREADS

LUBRICATED THREADS

DRY THREADS

LUBRICATED THREADS

DRY THREADS

LUBRICATED THREADS

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

PARTS MANUAL

FOR CALAVAR 42-48 CONDOR

Serial *NO.

001 -

JL

CALAVAR CORPORATION 13750 E. Firestone Blvd Santa Fe Springs, California 90670

IC101114Vrill TIME CONDOR Corporation

CONDOR® SERVICE INFORMATION

1. Ifyou need assistance orhave any service or maintenance questions, TIME CONDOR Corporation 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 Corporation S ervice D epartment to anyone who requests them.

3. Service and maintenance are not a substitute fortrained, qualified service technicians. TIME CONDOR Corporation conducts service schools on a continuing b asis. Call any of our s ervice or sales persons fora schedule. Remember, training of mechanics is the responsibility of their employer, but TIME COND OR Corporation. Service Schools help you provide this training.

4. TIME CONDOR C orporation Service School Training Manuals are available forpurchase through the parts department. The part numbers forthes e manuals are: #92333 for s elf-propelled models; and #92334 fortruck-mounted models .

TIME CONDOR Corporation

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

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

5.

TIME CONDOR Corporation 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 Corporation 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 (1) week.

7.

TIME CONDOR Corporation 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 Corporation 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.

CONDOR PARTS DEPARTMENT FAX ORDER FORM FAX NO. 800-443-5803 ACCOUNT # C U S T 0 M E R

I N F 0 R M A

PURCHASER

SALES ORDER # NAME

NAME ADDRESS

CITY

T I PHONE 0 N ( ) CUST. PURCHASE ORDER NO.

S II I STATE

ZIP

p

ADDRESS T 0 CITY

STATE

PHONE

FAX ( ) ORDER DATE

( ) REQUEST DATE

ZIP

FAX (

)

SPECIAL MARKS & NUMBERS

SHIPPING INSTRUCTIONS

PART NUMBER

QTY.

DESCRIPTION

FOR ORDER STATUS PLEASE CHECK APPROPRIATE BOX BELOW EMERGENCY STOCK

NOTES

12 13

# (SER. NO. 0001-0050) ## (SER. NO. 0051-2266)

11 ###(SER. NO. 2267 - ON)

8t7 Z17 2IO G NOD

v.

CONDOR 42 48

FIGURE 1

DESCRIPTION

REF

1

-

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

PART NUMBER.

Condor 42 48 Carriage Weidment Carriage Assembly Turret Assembly Decal Plate "OPERATION" Hood Rotating Beacon Boom Assembly Basket (6 FT.) Non-Rotating Fork Assembly (Option) Rotating Fork Assembly Basket Control Panel Assembly Turret Cover Hex Head Cap Screw Lockwasher Decal "Condor" Decal Plate "Operation" Decal "Travel Configuration Self Propelled CONDOR" Platform Proportional Valve System Controls NOTE:

_

# #1.7

(Serial No. 0001-0050) (Serial No . 0051-2266)

###

(Serial No. 2267 - ON)

QTY

(See Figure 2) (See Figure 3) (See Figure 15) 21186 21144 Or 21249 7-460 A (See Figure 25) .

(See Figure 37) (See Figure 34) (See Figure 35) (See Figure 38)

1 1 1 1 1 1 1 1 1 1 1 6 6 2 1

21239 ;

1 1

*15647 (See Fig. 53)

• ,,.

.

•

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,. .

............_-

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i.

9 /4"., 7-/

IN3 W0 13 M 3 0 VI U VD

-n

0

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m

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• CARRIAGE ASSEMBLY

FIGURE 3

ad

od

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/Jr' --

N

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\

/

yr 11.•

•

• I.

/

/

I

I

/

/

/

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/

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/ / / /, / ' I.

ii

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7/h. 2.7'

FIGURE 3

CARRIAGE ASSEMBLY

varlormwm,•• ■■•■•••••••■•■••■•■•■■•■■■■•■■•■■••■■•■■••■•••

REF.

DESCMPTION

PART NC ti ES E

Carriage Assembly Ring Gear -1 -2 -3 Drive Motor Plumbing Assem.

-4 Drive Motor Plumbing Assem. (3 Speed 0-5 MPH) -5 Drive Motor Assembly -6 Drive Motor Assembly (3 Speed 0-5 MPH) -7 - 8 Wheel Assembly Tube Assembly -9 - 10 Adapter -11 Shuttle Valve - 12 Elbow - 13 TubeAssembly - 14 Hose Assembly - 15 Brake Assembly - 16 Hose Assembly -17 Hex Head Cap Screw - 18 Lockwasher - 19 Tee - 20 Elbow - 21 Hose Assembly - 22 Hub, Drum, Spindle/Knuckle & Stub Axle Assy.

I -23 *Steering Assembly -24 Male Connector • - 25 Tube Assembly - 26 Brake Spring -27 Brake Extension Arm -28 Hex Head Cap Screw -29 Lockwasher -30 Hose Assembly -31 Hex Head Cap Screw -32 Lockwasher -33 Rotary' Coupling Bracket -34 Hose Assembly -35 Hex Head Cap Screw (Grade 5) - 36 Lockwasher - 37 5 Port Rotary Coupling Assembly - 38 s Tee -39 Reducer -40 Nut -41 Tube Assembly -42 Tee p ug -43

CI T Ir. 1

10650001

(See FIG. 4) (See FIG. 5) (See Fig. 6) (See Fig. 7) (See Fig. 8) 1 21218-1 .

1 0103-4-4 1 FPS22-1A-2 1 2103-4-4 1 21218-2.

1 D7EA04-04MBX04NJ-20 (See Fig. 9) 1 D7EA04-04NJX04NJ-72 2 1/2-13 UNC x 1-1/4 LG 2 1/2 1 752X3 ' 1 2102-2-2 2 10876544 (See Fig. 11) (See Fig. 12) 1 200 x 3 1 S-340 1 21189 21160 1 2 1/2-13 UNC x 1 2 1/2 HIEC12 12NJx12NJ90Tx27 2 3/8-16 UNC x7/8 3/8 21176 1 D7EA04-04NJX04NJ-84 18 1 1/2-13 UNC x 1-.3/4 Lg 1/2 18 (See Fig . 14) 2 12JTX-S 2 12-4TRTX-S 2 12-BTX-S 1 5-351 r 1 1/BMMS-S 1 1/8 .

1 i I orrurvt.o.,............:-.

...e■amirr

os......

•., ...,•. . , Ai..

DRIVE MOTOR PLUMBING ASSEMBLY (5 MPH)

FIGURE 4

19

(

or -.

18 17--

c-

4

5

tt

0

6)11 41.

4.

, ,„,„„ 0

15

WOt 2 ."

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16

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.

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11

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R1.4 ••

.

.

•

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

DESCRIPTION Drive Motor Plumbing Assembly (5 MPH) Valve 0 Reducer Tube Assembly Tube Assembly Male Connector Tube Assembly Tube Assembly Tube Assembly Union Tee Tube Assembly Tube Assembly Male Elbow Mounting Bracket Reducer Fluid Control Valve Union Tee Flat Washer Lockwasher Hex Head Cap Screw

PART NUMBER

10M015T 0103-6-10 21218-3 21218-4 3103-12-12 21218-5 21218-6 21218-7 10JTX-S 21218-8 21218-9 2103-8-10 21169 12-10TRTX-S 2V14-6-4-25S 12JTX-5 3/8 3/8 3/8-24 UNF x 3-3/4

QTY

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

FIGURE 4A DRIVE MOTOR PLUMBING ASSEMBLY - FLUID CONTROL

1

1 l'="t

o

19

I (

o

' 1 11

46 18 . 17 il-0 16 20

4

5

IP

13

.A

tipr

.

.

1

22 9 23

12

4::,,

10

, --

.

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

0

0

•

.

DESCRIPTION Drive Motor Plumbing Assembly Fluid Control Valve Elbow Tube Assembly Tube Assembly 45° Elbow Tube Assembly Tube Assembly Tube Assembly Elbow Tube Assembly Tube Assembly Male Elbow Mounting Bracket Reducer Fluid Control Valve Union Tee Flat Washer Lockwasher Hex Head Cap Screw Union Tee Tube Assembly Adapter Cross Over Relief Valve

— ,

....

0

PART NUMBER

QTY.

10M015T 2103-6-10 21218-42 21218-4 3103-12-12 21218-5 21218-43 21218-44 2103-12-10 21218-45 21218-46 2103-8-10 21169 12-10TRTX-S 2V14-6-4-25S 12JTX-S 3/8 3/8 3/8-24 UNF x 3-3/4 10JTX-S 21218-47

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

0103-12-10 1LL23-F6-40S

1

DRIVE MOTOR PLUMBING ASSEMBLY (3 SPEED 0-5 MPH)

FIGURE 5 0% 0 II et

co M

A

et

Sri

4.)

14.

•

rl r■• 1,0'\ in g•04

• / "e•

41Y

-

FIGURE 5

DRIVE MOTOR PLUMBING ASSEMBLY (3 SPEED 0-5 MPH) PART tZLIMBER

DESCPAPTION

QTY. ■1110•17

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

-4 44 -45 -46 -47

Drive Motor Plumbing Assembly (3 SPEED 0-5 MPH) Tube Assembly Tube Assembly Tube Assembly Male Branch Tee Tube Assembly Tube Assembly Reducer Tube Assembly Tube Assembly Male Connector Control Valve Hex Head Cap Screw Flat Washer Mounting Bracket Flat Washer Lockwasher Hex Nut Fluid Control Valve Mounting Bracket Tube Assembly Tube Assembly Male Elbow Flat Washer Lock Washer Hex Head Cap Screw Male Connector Male Branch Tee Tube Assembly Control Valve Tee Tube Assembly Tube Assembly Elbow 45° Elbow Tube Assembly Tube Assembly Tee Hose Assembly Reducer Nut Tube Assembly Check Valve Adapter Tube Assembly Tube Assembly Tube Assembly Tube Assembly

••

21218-10 21218-11 21218-12 12JTX-S 21218-13 21218-14 12-10TRTX-S 21218-15 21218-16 0503-8-12 FPS4030-12VDC/ET 5/16-18-3-1/4 5/16 • 21170 5/16 5/16 5/16-18 2V14-6-4-25S 21169 21218-17 21218-18 2103-8-10 3/8 3/8 3/8-24UNF x 3-3/4 0503-8-10 12JTX-S • 21218-19 FPS 4017-12VDC/ET 4JTX-S 21218-19A 21218-19B 2103-4-4 3103-12-12 21218-49 21218-1 12JTX-S HIEC12-12NJx12NJ90T -27 12-4TRTX-S 12-BTX-S 21218-50 C2OS 0103-4-4 21218-51 21218-52 21218-53 21218-2

1 1 1 1 1 1 1 1 1 6.

1 6 6 1 6 6 6 1 1 1 2 2 2 2 1 1 1 4 1 1 4 1 2 2 2 2 2 1 2 3 1 1 1

1

FIGURE 5 DRIVE MOTOR PLUMBING ASSEMBLY (3 SPEED 0-5 MPH)

MET -48 -49

PART NUMBER

DESCEZIPTION

QTY

Hose Assembly 04NJ-20 FPS 22-1A-2

Shuttle Valve

.

.

.

• •

.

,... ...

... .

'

.

'

1

FIGURE 5A

REF

-1 -2 -3 -4 -5 -6 -7 -8 -9

ELECTRICAL COLLECTION RING INSTALLATION (3 SPEED 0-5 DRIVE MOTOR)

DESCRIPTION Electrical Collection Ring Installation (3 Speed 0-5 MPH) (4) Port Rotary Coupling Assembly (5392-0000) Electrical Slip Ring Bracket Electrical Collection Ring Assembly Electrical Ring Anti-Rotation . Bracket Hex Head Cap Screw Lockwasher Rotary Coupling Bracket Carriage Weldment (21030) Hex Head Cap Screw

PART NUMBER

Reference 21185 2944 21188 3/8-16 UNC x 7/8 3/8 21176 Reference 3/8-16 UNC x 1-1/4

QTY

2 2

FIGURE 6

DRIVE MOTOR ASSEMBLY (5 MPH)

33 31-7=-7-

28

1

29

,

/

'

20 25

5 10,34 11 1822 0,34

12

21

13

# (SER. NO, 0001-0050)

24 27 ## (SER, NO, 0051-ON)

REF. 6-

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

DESCRIPTION Drive Motor Assembly (5 MPH) Sprocket Drive Chain Set Screw Cross Over Relief Valve Bearing Adapter Block Male Connector Drive Motor Hex Head Cap Screw Grease Fitting (Used with Ref. 21 Axle Spacer) Flange Bearing Hex Head Cap Screw Set Screw Axle Weidment Wheel Stud Key 45° Grease Fitting Lockwasher Lockwasher Hex Nut

1823 . 72

14

.

PART NUMBER

21201 56 Links 50-2 3/8-16 UNC x 3/8 1381-SAE-10 21402-2 0503-10-10 MAB40-010 1/2-20 UNF x 1-3/4 1610BL SCM-2-1/4 5/8-11 UNF x 2 5/16-18 x 5/16 21031 59364 1/2 x 1-7/8 75-80 1/2 5/8 5/8-11 UNF

QTY.

1 1 2

1 2 2

1 4 2 2 4 3

1 6

1 4 16 4

9A

FIGURE 6 DRIVE MOTOR ASSEMBLY (5MPH)

tzur 6-20 -21 -22 -23 # -24 - 25 -26 -27 - 28 - 29 -30 -31 - 32 -33 -34

DESCP..1P7i0';'.9

PART

Drive Motor Assembly (Continued) Keyed Sprocket Axle Spacer Hex Head Cap Screw Hex Nut Chain Guard (RH) Chain Guard (LH) Self Tapping Screw (Type F) Bearing Housing Chain Guard ( L.H .)

Chain Guard (R.H.) Bearing Inner Race Spacer Flat Washer Lockwasher Hex Head Capscrew Flange Bearing (Ser. No. 2187-0n) (Ref. 21 Axle Spacer Length is shortened to 3-1/4)

Nur.mr.rz.

21403 21206 5/8-18 UNF x 1 5/8-11 UNC 21404-2 21404-1 No. 12 x 3/8 21246 221232 21232-2 NCS 2416 P1202416 21252 5/8 5/8 5/8-20 UNF x 1-1/2 FY204

1 1 4 8 1 1 3

1 1 1 1 1 1 1 1 1

(Serial No. 0001-0050) (Serial No . 0051- ON)

••

■•••••••••■arorwear•ra

mommorwmiramoomorwri

resmormari■Ows•

.1% Is

a//7.../

FIGURE 6A HI-TORQUE DRIVE MOTOR ASSEMBLY (OPTION)

10

12,26 15 1 1 14

1

20

25

16

..•

•

•

■ ' \ .1.--4IG' ,,- tr-), --• ...... ..„.• s, //,

• ---- •••'' ••..0.

• •• .....

• • • • ••....• • • • • ,,.-• •• •• • • • ,„...

• 40.

■-,Zrt , -',..if f

/// 17

/

1/ WI,'

44 ,

N., /

11 ,P

/,

24

//

/ z/ / /, / z , / / / / "/ / /,' // /d z/

z

23 22

18

19

20

ell 711

FIGURE 6A - HI-TORQUE DRIVE MOTOR ASSEMBLY (OPTION)

1:a1

DESCUIPTiON

6A-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

HI-Torque Drive Motor Assembly (Option) , Drive Motor Hex Head Cap Screw Lockwasher Cross Over Relief Valve Male Connector Hex Nut Lockwasher . .

- Motor Mounging Plate Hex Head Jack Screw Hex Head Cap Screw Hex Head Cap Screw Flange Bearing (Used with Ref. 22 Axle Spacer) •, .._ .

Lockwasher . . .

Hex Nut .• Set Screw ,.

Grease Fitting . , .

• Spacer Drive Chain (158 Links) Sprocket (95 Tooth) Key Wheel Stud Axle Speer Axle Weldment , Sprocket Set Screw Flange Bearing (Ser. No. 2187-ON) (Ref. 22 Axle Spacer is shortened to 3-1/4

PAnT

+\-.11,./ Mr, ;7: a

21401 MA840-010 1/2-20 UNF x 1-1/4 1/2 1381-SAE-10 0503-10-10 1/2-13 UNC 1/2 1/2-13 . UNC x 5 1/2-13 UNC x 1-1/2 5/8-11 UNF x 2 SCM-2-1/4 5/8 5/8-11 UNF 5/16-18 UNC x 5/16 1610BL 21401-2 50-2 21401-1 1/2- x 2 59364 21206 21400 21201 • 3/8-16 U NC x 3/8 FY204

Orr 1 1 4 .

4 1 2 4 4 1 2 4 4 2 8 • 8 4 2 1 1 1 3 6 1 1 1 2 1-

,..

.

.

• .- ..

3/. 7

DRIVE MOTOR ASSEMBLY - V FLUID CONTROL (5 MPH)

FIGURE 6B 35 34 33

- ..„...._--:--..

.

.„ ...„ „. ,.. ... '''.. // ,',.. / sz ,, , ..,„,-- ,..,, .

`

,•

i,„

--

•

-, „-—"

26 7

i!/„1 1//, ' , ,...-.:,., >.,.----', -i' .....,.\' _,./...,....,,,-,

„--/ / --...,, ' ../„„„/

20 25-1

1822 10,36

12 21 13

4

18

24

0

14

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

PART NUMBER

DESCRIPTION Drive Motor Assembly Sprocket Drive Chain Set Screw

QTY,

V Fluid Control (5 MPH)

21201 56 Links 50-2 3/8-16 UNC x 3/8

1 1 2

Bearing Adapter Block Male Connector Drive Motor Socket Head Cap Screw Grease Fitting Flange Bearing (Used with Ref. 21 Axle Spacer) Hex Head Cap Screw Set Screw Axle Weldment Wheel Stud Ke y

21402-2 0503-10-10 MAB40-010 1/2-20 UNF x 1-1/4 1610BL SCM-2-1/4 5/8-11 UNF x 2 5/16-18 x 5/16 • 21031 59364 1/2-1-7/8

2 2 1 2 2 2 4 3 1 6 1

Lockwasher Lockwasher Hex Nut Keyed Sprocket

1/2 5/8 5/8-11 UNF 21403

4 16 4 1

FIGURE 6B

DRIVE MOTOR ASSEMBLY - FLUID CONTROL (5 MPH)

D4 ELF Car,..?71CH

- 25 -26 -27 - 28 -29 -30 -31 - 32 -33 - 34 -35 -36

Drive Motor Assembly (Contunued) Axle Spacer Hex Head Cap Screw Hex Nut Chain Guard (RH) Chain Guard (LH) Self Tapping Screw (Type F) Hex Head Cap Screw Grease Fitting Bearing Housing Bearing Inner Race Spacer Flat Washer Lock Washer Hex Head Cap Screw Flange Bearing (Ser. No. 2187-On) (Ref. 21 Axle Spacer is shortened to 3-1/4)

Pf:ErZT.

mit.matz.rz

21206 5/8-18 UNF x 1 5/8-11 UNC 21404-2 21404-1 No. 12 x 3/8 1/2-20 UNF x 1-1/4 7580 21246 NCS2416 P1202416

1 4 8 1 1 3 2 1 1 1 1

21252 5/8 5/8 5/8-20 UNF x 1-1/2 ' FY204

1 1 1 1 1

.5//

7.

FIGURE 6C

DRIVE MOTOR ASSEMBLY - FLUID CONTROL

REF.

DESCRIPTION

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

Drive Motor Assembly V Fluid Control Sprocket Drive Chain Set Screw

PART NUMBER (Ser. No. 55 -ON) 21201 56 Links 50-2 3/8-16 UNC x 3/8

Male Connectcr Drive Motor Socket Head Cap Screw Grease Fitting Flange Bearing (Used with Ref. 21 Axle Spacer) Hex Head Cao Screw Set Screw Axle Weidment Wheel Stud Key Key Lockwasher Lockwasher Hex Nut Keyed Sprocket

0503-10-10 MAB40- 010 1/2-20 UNF x 1-1/4 1610BL SCM-2-1/4 5/8-11 UNF x 2 5/16-18 x 5/16 21031 59364 1/2-1-7/8 21253 1/2 5/8 5/8-11 UNF 21403

QTY. 1 1 2

2 1 2 2 2 4 3 1 6 1 1 4 8 4 1 4-1-5

74'

DRIVE MOTOR ASSEMBLY -Fluid Control

FIGURE 6C Ofp•••••■■•••■•■■••■■•

DESCRIPTION

REF

PART NUMBER 41■11■1■11111.1•■•11,

C,

-21 - 22 - 23 -24 -25 -26 - 27 -28 - 29 - 30 - 31 -32 -33 -34 - 35

Drive Motor Assembly (Continued) Axle Spacer Hex Head Cap Screw Chain Guard (RH) Chain Guard (LH) Self Tapping Screw (Type F) 45° Hex Head Cap Screw Grease Fitting Bearing Housing Bearing Inner Race Spacer Flat Washer Lock Washer Hex Head Cap Screw Flange Bearing (Ser. No. 2187-ON) (Ref. 21 Axle Spacer is Shortened to 3-1/4)

21206 5/8-18 UNF x 1

1 4

21232-2 21232-1 No. 12 x 3/8 1/2-20 UNF x 1-1/4 7580 21246 NCS2416 P1202416 21252 5/8 5/8 5/8-20 UNF x 1-1/2 FY204

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

••

WSY■■•

■•■ •

■ •■.■■■

•

,••••NINOMOrnINM

S•11

11••

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FIGURE 7

DRIVE MOTOR ASSEMBLY

DESCRIPTION 7

Drive Motor Assembly (3 Speed 0-5 MPH) Sprocket Drive Chain -4 -5 -6 -7 -8 -9 - 10 - 11 - 12 - 13 - 14 -15 - 16 -17 - 18 - 19 -.20 -21

3 SPEED 0-5 MPH)

PART NUMBER

QTY.

Set Screw Male Connector (Right Hand) Drive Motor Lockwasher Hex Head Cap Screw Fitting Flange Bearing (Used with Ref. 21 Axle Spacer) .

Hex Head Cap Screw Set Screw Axle Weldment Wheel Stud Keyed Sprocket Key

21201 56 Links 50-2 1 Connecting 50-2 3/8-16 UNC x 3/8 0503-10-12 MS03018A021A RH 7/16 7/16-20UNF x 2 1610BL SCM-2-1/4 5/8-11 UNF x 2 5/16-18 x 5/16 21031 59364 21403 1/2 x 1-7/8

Lockwasher Hex Nut Drive Motor (Left Hand) ref. item 5 Axle Spacer

8 8• MS03018A021A L.H. 1 2 21206 5/8 5/8 11 UNC

DRIVE MOTOR ASSEMBLY (3 SPEED 0-5 MPH)

FIGURE 7

REF -22 -23 -24 -26 --27 -28 -29 -30 -31

PART NUMBER

DESCrelPTION

QTY

7580 21246-1 NCS2416 21246-2 5/8 .

5/8 3/8-16UNC x 1-1/2 21246-3

45° Grease Fitting Bearing Housing Bearing Spacer Flat Washer Lock Washer Hex Head Cap Screw Spacer Flange Bearing (Ser. No. 2187-ON) (Ref. 21 Axle Spacer Length is shortened to 3-1/4)

1 1 1 1 1 1 1 .

FY204

.,.

.-

.

.

•

.

. .

;7/

WHEEL ASSEMBLY

FIGURE 8

-,.

10R 4

, . . / •

, \

.

71:

/

......-----/

•.%

(i.

3

/ ee •

•

4• PART NUMBER

DESCRIPTION

REF. 8-1 -2 -3 -4

.

Wheel Assembly 10 Ply Super All Traction Hi Flotation Tire 17.5 x 10.5 Rim Wheel Nut 14 PLY Non-Directional Cross Country Duplex

14.00 x 17.5 27114 37888 14.00 x 17.5

QTY.

.

1 6 1

,.. .

..

.. .

/5

4,1

.11

FIGURE 9

BRAKE RELEASE ASSEMBLY

. ,

„c 01'

13

ilk 12

(1 -

# .•

-..., /

.0

1

N....( .%.

C) ,, •••■■•........„,......

0

''''..........k '7

' .044." ' 010

18

PART NUMBER

DESCRIPTION Brake Release Assembly Bracket Weldment Cotter Pin Clevis • Clevis Pin Hex Nut Master Brake Cylinder Actuator Master Cylinder Reducing Connector Washer Hex Head Cap Screw

/

,,..■

i

,

0

-11 -12 -13 -14 -15 -16 -17 -18 -19 -20

Z

,

-..

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

b 3

•-•'”

1

20

,.,-. /4., *

t

19

REF.

14

Ark

i, .

21137 21159 1/8 Dia. x 1-1/4 LG Y6 C17 1/2-20 UNF Galv.

21162 BC1050 7817 CG1 1/4-20 UNC x 1 LG. 7/16 Spring 21218-20 2103-4-4 1/4 MMS-S FMF-20-B 0103-4-4 C48 21048 2103-2-4 2102-4-4

_

Lockwasher Tube Assembly Elbow Male Branch Tee Valve Male Connector Clevis Pin Brake Release Cylinder (See Fig. 10) Elbow Elbow

QTY.

.

1 1 3 1 1 1 1 1 1 1 4 4 1 1 1 1 1 1 1 1 1

... ‘

/c J.,/ 7 ?=/

FIGURE 9A -

DUAL BRAKE RELEASE ASSEMBLY(3 SPEED 0-5 MPH)

15

16 7

17

18

REF. 9A-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22

DESCRIPTION Dual Brake Release Assembly 3 Speed 0-5 MPH Brake Release Bracket Weldment Master Brake Cylinder Lockwasher Hex Head Cap Screw Master Brake Cylinder Actuator Hex Nut Cotter Pin Clevis Clevis Pin Actuator Bracket Pin Tube Assembly Elbow Male Branch Tee Valve Male Connector Clevis Pin Brake Release Cylinder (See Figure 10) Elbow Elbow Reducing Connector Washer

PART NUMBER 21229 21226 1050 1/4 1/4-20UNC x 1 21162 1/2-20 UNF 1/8 x 1-1/4 Y-6 C17 21227 21228 21218-20 2103-4-4 1/4 MMS-S FMF-20-B 0103-4-4 C48 21048 2103-2-4 2102-4-4 7817 CG I

QTY.

1 2 8 8 2 2 6 2 2

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

FIGURE 10 - BRAKE RELEASE CYLINDER

DESCRIPTION

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

Brake Release Cylinder Rod Wiper Backup Gland Retainer Retainer Ring Gland Backtip 0-Ring Rod Assembly 0-Ring Piston Backup 0-Ring Piston Nut Body Assembly - Pin Assembly Breather Seal Kit

PART NUMBER 21048 631-9 646-19 13-010 627-19 650-200 7-009 644-2 630-2 27-4017 627-11 16-005 646-29 627-29 671-10 26-4017 25-4017 674-22 K21048

QTY. 1 1 1 1 1 1 1 1 1 1 1 i 1 1 1 1 1 1 1 1

•-•

/0?

FIGURE 11

HUB, DRUM, SPINDLE/KNUCKLE, AND STUB AXLE ASSEMBLY

FIGURE 11

HUB, DRUM, SPINDLE/KNUCKLE, AND STUB AXLE ASSEMBLY

NONBA.......,• ■•••■••••••■•■■•••■•••••111011•••■■•■•■■•■•••••1111111■411.1=1•

LIEF. [11-1 -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 i -27 -28 1 - 29 -30 -31 -32 -33 -34 -35 -36 -37 -38 -39 -40 -41 -42 -43 I -44 t 45 -

D scru PT I ON Hub, Drum, Spindle/Knuckle and Stub Axle Assem.

Round Head Screw Washer Grease Cap Gasket Spindle Nut Key Washer Outer Cone Outer Cup Hub Inner Cup Inner Cone Grease Seal Brake Drum Adjusting Lever (Left Hand) Adjusting Lever (Right Hand) Adjuster Spring Automatic Adjuster Assembly (Left Hand) Automatic Adjuster Assembly (Right Hand) Retainer Spring Primer and Brake Shoe Assembly Hex Head Cap Screw Shoo Actuator Wheel Cylinder Assembly (Left Hand) Wheel Cylinder Assembly (Right Hand) Hook Spring Mounting Plate Assembly (Left Hand) Mounting Plate Assembly (Right Hand) Shoe Keeper Pin Brake Adjustment Access Plug Hex Head Cap Screw & Lockwasher Assembly Hex Nut Washer Plate Anchor Pin Anchor Pin Plate Anchor Cable Assembly Primary - Brake Shoe Assembly Cable Guide Stud Bushing Lockwasher b Hex Nut Thrust Washer Stub Axle Weldment Roll Pin King Pin iSpi ndle/Knuckle Assembly (Left Hand) g -

2 x 100D 3 12 x 134 3 26-100 1 7-1004 1 5-409 1 11-914 1 17-111 1 17-194 1 1 18-628 17-110 1 1 17-134 16-1000 1 1 K189-2* 1 320872 320873 1 1 311309 1 323548 1 323549 2 23969 1 23960 321277 1 1/2-20 UNF x 1-1/2 LG, 4 1 47865 1 617485 617486 1 33786 321093 1 321094 1 1 25831 2 301055 2111 47708 901631-K6 901035 49599 1 323534 1 32594 1 .321149 1 321277 1 309992 6 35-806 2 10-901 4 1/2 1/2-20 UNF 4 2 11-150 1 K189-197 1 20-400 1 41-800 1 17-1211 -----. 1 97-163 .

I

I ...1

STEERING ASSEMBLY

FIGURE 12

\`,

•

20 15 14

/0? 6/ 711/

FIGURE 12

STEERING ASSEMBLY

DESCRIPTION

V.:1F

PART KILIfiliM11

-

7'.,'

•

Steering Assembly 12-1 Steering Center Arm Pin -1 -2 Fitting Hex Head Cap Screw -3 Lockwasher -4 Clevis Pin -5 -6 Washer 'Steering Cylinder (See Fig. 13) -7 Cotter Pin -8 -9 Elbow -10 Lockwasher -11 Hex Nut -12 Hex Head Cap Screw -13 Tie Rod -14 Cotter Pin -15 Steering Center Arm Weldment -16 Clevis Pin -17 Clevis -18 Jam Nut -19 Bushing -20 Bushing

.

•

•

1 1 2 2 2

21136 1610BL 3/8-16 UNC x 3/4 LG 3/8 C-46 3/4 21047 1/8 x 2 2103-4 -. 4 7/8 7/8-12 UNF 7/8-12 UNF x 3-1/4 21224 1/8 x 2 21148 ' 6-801 516 . 1-1/8-12 UNF M1218-8 21148-5

4 1 6 2 2 2 2 2 2 1 2 2 2 1 1

•

.•• •

.

-

•

•

011•111YOVIIMIMP • ■•••■ 0.•(••• ■.1=1.10.

/c2

.,

FIGURE 13 - STEERING CYLINDER

DESCRIPTION

REF. 13-

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

Steering Cylinder Rod Wiper Polypak Lock Ring Retainer Ring Gland Backup 0-Ring Rod Assembly Body Assembly 0-Ring Piston T-Ring Piston Nut Seal Kit

PART NUMBER

QTY.

21047 631-11 694-11 13-013 650-250 7-4015 644-6 630-6 27-4015 26-4015 630-13 16-009 616-28 627-5 K21047

■111•1111■11•••

1/ 4)2%771/

FIGURE 14 - 4 PORT ROTARY COUPLING

REF. 141 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12

DESCRIPTION 4 Port Rotary Coupling Spool Male Connector Male Connector Socket Cap Screw Seal Kit Mounting Plate Socket Cap Screw Lock Washer Keeper Plate 0-Ring Housing Spacer

PART NUMBER 5392-0000 5393-0001 0503-4-4 0503-12-12 0000-2028 0000-9000 5033-0005 0000-2030 0000-2601 5033-0004 0000-3248 5393-0002 5033-0003

QTY.

1 1 4 4 1 6 1 4 4 1 1 1

FIGURE 15

TURRET ASSEMBLY

FIGURE 15

TURRET ASSEMBLY

DESCRIPTION 15-1 -2 -3 -4

Turret Assembly Turret Weldment Tube Assembly Tube Assembly Hose Assembly

-5

Hose Assembly

-6 -7 -8 -9 - 10

Mounting Plate Hydraulic Assem Tube Assembly Tube Assembly Gas Tank Assembly Hose Assembly

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

Tube Assembly Decal Plate "GAS" Tube Assembly Decal Plate "HYDRAULIC FLUID" Limit Switch Solenoid Hex Head Bolt Lock Washer Hex Nut Choke Cable Warning Horn Decal Plate "MANUFACTURE" Ground Control Box Battery Cable (Postive) Battery Hold Down Frame Battery, "J" Bolt Lockwasher Hex Nut Battery Cable (Negative) Hydraulic Tank Assembly Hydraulic Pump Mounting Assembly Hose Hose Clamp Tube Assembly Tube Assembly Turret Rotation Speed Reducer Assembly Hex Head Bolt (Grade 5) Ring Gear, L7-33N12 Lockwasher Hex Nut (4) Port Rotary Coupling

-46

Hose Assembly Tube Assembl

PAIZT NtLIPAGER

CITY

21022 21218-21 21218-22 HIEC-08-08NJ-08NJ -66 HIEC-08-08NJ-08NJ -66 (See Figure 16) 21218-23 21218-24 (See Figure 17) D7EA06-06NJ-06N_IX 06NJ-90TX43 21218-27 15376-13 21218-39 15376-7 (See Figure 25) 24059 1/4-20 UNC x 1/2 1/4 .

1/4-20 UNC (See Figure 18) (See Figure 18) 15834 (See Figure 18) PBL-19 3-4486 H-29NF 598 5/16 5/16 x 18 UNC PBC-38 (See Figure 19) (See Figure 20 & 21) SAE100 R4-1-1/2 4-4557 21218-28 21218-29 (See Figure 22) 5/8-11 UNC x 2 (REFERENCE) 5/8 5/8-11 UNC (See Figure 14) HIEC-12NJX12N1 90TX27 21218-32 ■■■••■

•0•MMOO•ft.,MO

111

arteftaMe.i.1.

1 1 1 1

1 1 1 1 1 2 1 1 1

I 2 2 2 1

1 1 1 1 2 2 2 1 1 1 2 1 1 1 18 18 18 1 2 1

0MMftlt•M..1,.

FIGURE 15

TURRET ASSEMBLY

TURRET ASSEMBLY

FIGURE 15

DESCEIIPTION

REF 15– –47

PAEZT Nurni3ER

Turret Assembly (cont.) .

Tube Assembly

21218-33

.

CITY 1

.

.

. . .

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.. ... ..

-

.

.

. .

.

.

t

.

'

—......14111•14111.111,!..11a1M.N.

.11.•••••••,111.11 -

58

1

45 6 47

9 5

O

z

7 46

6

19 18

13

17

12

110

27 29

28

4 IN

[ 000'O N*H S

54

tit

24

22 23

P LATE HYD RAULIC AS S EMBLY

""•

BASKET ROTATION OPTION 51

FIGURE 16 MOUNTING PLATE HYDRAULIC ASSEMBLY

(SER. NO, 0001-0050)

PART MUMBER 16-1 -2 -3 -4 -5 -6 -7 -8 -9 - 10 - 11 - 12 - 13 - 14 - 15 -16 -17 -18 -19 - 20 - 21 -22 -23 - 24 - 25 - 26 - 27 - 28 - 29 -30 -31 - 32 -33

Mounting Plate Hydraulic Assembly(Ser. No. Tube Assembly (0001-0050) Tee Tube Assembly Relief Valve Hex Head Bolt Elbow Tube Assembly Male Connector Mounting Plate Operataing Value

Lock Washer Hex Nut Flow Regulator Male Connector Male Connector 1 Tube Assembly Tee Tube Assembly Connector Male Connector Elbow Male Connector Tube Assembly Adapter Operating Valve Reducer Tee Tube Assembly Male Connector Check Valve Male Connector Operating Valve

21146 21146-10 12STX- S 21146-9 FPS-9-15N0-6-200 12VDC-ET 1/4-20UNC x 1 LG 2103-12-12 21146-11 0503-8-12 21117 FPS-4013-R180012VDC-ET

TV I

1 1 1 2 1 1 6 1

1

1/4 1/4-20 UNC 13-15F-4 0103-8-8 0103-8-6 21146-13 8-STX-S 21146-14 0502-10-4 0503-6-4 2103-4-4 0503-6-6 21146-34 12BTX-S FPS 0 7106546 12-8TRTX-S 12JTX-S 21146-12 0103-12-12 EC-35S 21146-31 FPS-4012-R200012VDC-ET

14 14 2 5 1 1

21051 21146-51 21146-8 FPS-4014280 FPS-5110-12VDC-PB-ET 1/4 1/4-20 UNC 21146-16 0503-6-6 0503-6-8

1 1 1 1 1 2 2 1 1 1

1 1 2 1 5 1 1 1 1 1 1 1 1 1

-34 -35 Basket Rotation Option

L36 -37 -38 -39 -40 -41 -42 -43 -44

Tube Assembly Tube Assembly (Remove Existing Plug) Adapter Plug Operating Valve Lockwasher Hex Nut Tube Assembly Male Connector Male Connector ■■••■•■•■••••••■■ MINDOMMOMIN■ twoosem•••• ■•••■••••••1.1MaMMIIMM............*

•• •••••••■••••••■■

T1 -

rn

0'

0

.Z

0 P LATE HYD RA U LI C AS S EMB LY

(SE R . NO . 0001

U)

0

FIGURE 16

MOUNTING PLATE HYDRAULIC ASSEMBLY (SER NO.0001-0050•

DESCRIPTION 16-45 -46 -47 -48 -49 -50 -51 -52 -53 -54 -55 -56 -57 -58 -59 -60 -61 -62 -63

PART NumsErt

Mounting Plate Hydraulic Assembly Elbow Elbow Tee Tube Assembly Reducer

(Continued) 2503-6-6 6C5X 8RTX-S 21146-15 6-4TRBTX

Reducer Male Connector Male Connector Swivel Tee Male Connector Elbow Elbow Tube Assembly Tube Assembly Tube Assembly Elbow (45°) Test Fitting Cap

TRTX-8-4 0502-10-6 0503-6-8 R6X-8-8 0103-6-8 2503-8-8 2502-8-6 21146-7 21146-50 21146-64 21231 0103-4-6 6 FNTX

al••••••••■■■■•••■■••

2

1 1 1 1

1 1 1 1 1 1 1 1 1 1 1

16

15 14

r 7

9 26 27 BASKET ROTATION OPTION

53

23 29

51

30 /

31 32 33

55

3 3 42 43

3

43 45 -44

•

M O UNTI N GP LATE H YD RA ULI C A S SEM B LY ___ _

10

FIGURE 16A MOUNTING PLATE HYDRAULIC ASSEMBLY (SER. NO. 0051-2186) L is

16A-

DESCP.IPTIOr.:3

PART NurActin

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

Mounting Plate Hydraulic Assembly (SER. NO. 0051-ON) Tube Assembly Male Branch Tee Tube Assembly Relief Valve Hex Head Capscrew Elbow Tube Assembly Connector Mounting Plate Priority Flow Regulator Elbow Tube Assembly Male Connector

- 14 - 15 - 16

Male Connector Priority Flow Regulator Modified Elbow

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

Solenoid Valve Lockwasher Hex Nut Tube NeumtbRiyun Tee Swive l Elbow Power Beyond Adapter Connector Tube Assembly Tube End Reducer Elbow

FPS-5110-12VDC-PB-ET 1/4 1/4-20 UNC 21234-54 8-R6X- S 2062-6-8S 4014280 0503-6-8 21234-55 6-4TRTX-S 2503-6-6

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

Tube Assembly Male Branch Tee Swivel Nut Elbow ' Connector Mini-Pak Valve Rework Assembly Connector Connector Tube Assembly Swivel Nut Run-Tee Elbow Adapter Elbow Hex Nut Lockwasher Tube Assembly Tube End Reducer

21234-52 8-STX-S 8-C6X-S 0503-6-8 21222 0503-6-6 0503-6-4 21234-53 8-R6X-S 2103-6-8 0502-10-6 2060-6-4S 1/4-20 UNC 1/4 21234-47 12-8-TRTX-S

21234 1 21234-41 1 12-STX-S 1 21234-42 1 FPS9-15N0-6-2000=12VDC T 4 5/16-18 UNC x 1 2103-12-12 1 1 21234-43 5 0503-8-12 1 21117 13-15F-4 1 1 2103-8-10 21234-51 1 0103-12-10

0103-8-8 21235

1 1 1

BASKET ROTATION OPTION 1 2 2

1 1 1 1 2 1 2 2

1 1 1 3 1 4 2

1 1 1 2 2 12 12

1 2

16

15

20

17 18

14

--,

19 --,.

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, 'Y 6, i

I

i

1

w,

1

r-

25

& .,

li _V

i9

26 27 BASKET ROTATION OPTION 23 99 30/

53

31 32 33

34 3 42 43

►

39 .)8 37

43 45

-44

\,?

i

22

123

,

MO UNTI NG P LATE H YD R A UL IC AS SE MB LY

`

I

t- s

35

FIGURE 16A MOUNTING PLATE HYDRAULIC ASSEMBLY (SER. NO. 0051-2186) 1-•;.T.

DESC 11 E.-=. 7 i 0 N

16A -44 -45 -46 -47 -48 -49 -50 -51

Mounting Plate Hydraulic Assembly (Continued) Union Tee " Tube Assembly Tube Assembly Tube Assembly Male Connector Check Valve Connector Assembly Solenoid Valve

PART Euiral-,-.:R

Connector Tube Assembly Male Connector Lockwasher Hex Nut Tube Assembly Tube Assembly Elbow Male Connector Female Elbow Solenoid Valve .

-52 -53 -54 -55 -56 -57 -58 -59 -60 -61 -62

•

-

_ -

.

C7Y —.4.--

12-JTX-S 21234-45 21234-48 21234-44 0103-12-12 EC-35S 21197 FPS-4012-R210012VDC-ET 0503-8-10 21234-46 0103-8-10 5/16 5/16-18 UNC .

21234-49 21234-50 2503-8-8 , 0103-6-8 2502-8-6 FPS-4013-R190012VDC-ET

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

.

.

-

w

. .

.•. .

.

.

•

-■.....■■ ---

-

-

. .

4111.1. 4.. PO SO.

--

15

20

17 18

14

19 -n

13

0

12

rn

11

CP

27 BASKET ROTATION OPTION 58 30

28 29

31 32 33

.-ge •

di

48 .

6 RELIEF VALVE & RELATED ITEMS USED ON (SER.NO. 2187-ON)

34 3 42

46 43

43 45

47

40 3

44

44

35

MO UN TI NG P LATE H YD RA ULI C A S SEM B LY(SER .NO . 2 18 7-O N )

26

FIGURE 16B MOUNTING PLATE HYDRAULIC ASSEMBLY

REF

PART

DESUMPT1ON

an 4D

Or—oi e401 "at41401".00 0% 11 1 11 11 1 11 11

Mounting Plate Hydraulic Assembly (Ser. No. 2 87-0n) Tube Assembly Male Branch Tee • Tube Assembly

Nt %0

1111

2103-12-12 21288-43 0503-8-12 21117 13-15F-4 2103-8-10 21288-51 0103+12-10 0108-8-8 13-A-32-F-6 21235

•

FPS-5110-12VDC-PB-ET 1/4 1/4-20 UNC 2-288-54 8-R6X-S 2062-6-8S 4014280 .0503-6-8 21288-55 .

6-4TRTX-S 2503-6-6

'

!M

IMI) Ci?

CI

? "I 1.

'

1. in 1 .1 .'

0

. 21288-52 8-STX-S 8-C6X-S 0503-6-8 21222 0503-6-6 0503-6-4 21288-53 8-R6X-S 2103-6-8 0502-10-6 2060-6-45 1/4-20 UNC 1/4 21288-47 12-8-TRTX-S 12-JTX-S 21288-45 21288-48

.

11.1•11111.

111111

co0, 0 cvcoNI- tr)NoN.cosa, 0 e— •0 COoa, 0 c•1 CVCV CV CV CV CV CV CV CV04 OD OD OD OD OD CD

111111

Tube Assembly Male Branch Tee Swivel Nut Elbow Connector • Mini-Pack Valve Rework Assembly Connecotr Connector Tube Assembly • Swivel Nut Run - tee Elbow Adapter Elbow Hex Nut Lockwasher Tube Assembly Tube End Reducer Union Tee Tube Assembly Tube Assembly

mum=

21288 21288-41 12-STX-S 21288-42

Elbow Tube Assembly Connector Mounting Plate Priority Flow Regulator Elbow Tube Assembly Male Connector Male Connector Proirity Flow Regulator Mo ified Elbow BASKET ROTATION OPTION Solenoid Valve Lockwasher Hex Nut Tube Assembly Swivel Nut Run Tee Elbow Power Beyond Adapter Connector Tube Assembly Tube End Reducer Elbow

(SER.NO. 2187-ON)

15

20

17 18

14

19

- 4.11 _ v..yi J) 1. _ I1,i, )i-

2-

,

13 a , ' I1 „ i (.--,.0 _1):A

11

0.),,i

i

I '1

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r-rt''

25

0 ji

I. ,

I

MO UNTI N G P LA TE H YD RA ULI C AS SEM B LY

tj 1

I

22

1I 23

/'

26 27

BASKET ROTATION OPTION 58 30

28 29

31 1\%

32 33

34 3 42

3

43 45 47

44

44

35

(SER . NO . 21 87-O N )

RELIEF VALVE & RELATED ITEMS USED ON (SER.NO. 2187—ON)

48 .

99t

fr , ri.Jy- i -iir 'N`:- -:)

12

FIGURE 16B MOUNTING PLATE HYDRAULIC ASSEMBLY

REF -16B-47 -48 -49 -50 -51 -52 -53 -54 -55 -56 -57 -58 -59 -60 -61 -62

PART NULVILIEE1

DESCRIPTION Continued Tube Assembly Male Connector• Check Valve Connector Assembly Solenoid Valve Connector Tube Assembly Male Connector •

.

Tube Assembly Tube Assembly Elbow Male Monnector Female Elbow Solenoid Valve

21234-44 0103-12-12 EC-35S 21197 FPS-4012-R210012VDC-ET 0503-8-10 21288-46 0103-8-10

Reducer Rel ief Valve Hex Nut .

Spacer Hex Head Cap Screw

CITY

1 1 1 1

•

21288-49 21288-50 2503-8-8 0103-6-8 2502-8-6 FPS-4013-R190012VDC-ET

•

. .

RELIEF VALVE & RELATED ITEMS USED ON . (2187-ON) -63 -64 -65 -66 -67

(SER.NO . 2187-ON)

1 2 1 2

1 1 1 1 1 1

.

3/4 x 1/2 FG-S FPS 5-039-4-12VDC 1/4-28 UNF 1/2 x .049 Wall x 1/2 1/4-28 UNF x 3

.

.

.

1 1 2 2 2

.

•

G. 7 774-

SL 9L

(NO-1500 'ON • 2135)#

GR OU N DC ONT R OL B OXASSEMBLY

FIGURE 18 1110.111.••••••,

fral.

GROUND CONTROL BOX ASSEMBLY

•••••■• • PWIN.M.MIMII.......

DESCRIPTION

PART NUMBER

18-1 -2 -3 -4 -5

Ground Control Box Assembly Warning Horn Hex Head Cap Screw Washer Mounting Bracket Connector Assembly, Bottom Connector Assembly, Top -6 Hex Nut Receptacle -7 Round Head Screw . .

-8 -9 Truse Head Screw -10 Lockwasher -11 Machined "J" Box • -12 Flasher Toggle Switch -13 -14 Toggle Switch Toggle Switch -15 -16 Circuit Breaker Circuit Breaker (Option) -17 Push Button Switch -18 Push Button Switch -19 Decal Terminal Block -20 -21 t End Section • -22 Channel Clamp Mounting Channel -23 Hex Head Cap Screw -24 Hex Head Nut -25 -26 Hex Head Lock Nut Lockwasher -27 Hex Head Cap Screw -28 -29 Washer Connector Assembly -30 Connector Assembly -31 RHeocuerptectieer (Opt ion) -32

-33 -34 -35 -36 -37 -38 -39 -40 -41 i # -42

21182 28-12VDC 1/4-28 x 3/4 1/4 21150 2522 2522 6-32 7600 6-32 x 3/4 10-32 UNF A 3/8 No. 6 21167 550 8511K2 • 8510 K4 8510K2 109-220-101 109-220-101 _SA401CR SA401CB2 21077 P625 P630 No. 11 No. 12 x 8 LG. 6 x 32 UNC x 3/8 . 6-32 UNC 10-32 UNF .

No. 10 1/4-20 x 3/4 1/4 2546 2522 MS5601-3-12VDC 77-S 1/4-20 . YE-2 1/4 32001 35RC 21092 KB17D-1 2V DC 1116969

-

-

.

• -

. '

Hex Nut Ammeter Lockwasher Clamp • Choke Assembly Hydraulic Valve Control Cable Relay Relay

1 1 • 2 2 1 1 1 4 1 4 4 • 3 1 1 1 •1 2 1 1 1 1 1 18 2 2 1 3 3 4 4 4 4 1 1 1 1 4 1 4 1 11

1

9518

Master Switch

# (Serial No. 0051-ON)

Cri Y. -....,—

1

i

I

FIGURE 19 - HYDRAULIC TANK ASSEMBLY

FIGURE 19

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

.

HYDRAULIC TANK ASSEMBLY

DESCRIPTION

PART NUMBER

Hydraulic Tank Assembly Hydraulic Tank Weldment Gasket No. 12 Type C Self-Tapping Screw x 1/2" Lg. .

Cover Filler Breather Unit • Sump Strainer Pipe Nipple Hex Head Bolt Lock Washer Bushing Filter Assembly Male Connector Tube Assembly Street Elebow Reducing Bushing Hose Nipple Gate Valve Street Elbow Elbow

21237-1 21237-15

.

.

QTY

21237-12 Sp-113C P-50-1-1/2"-100-RV3 Close 1-1/2" NPT 1/4-20 UNC x 1-1/2Ig 3/8 I.D. x 11/16 OD 0102-16-12 SAF29G16 0103-16-16 21218-48 1" NPT x 90° 0102-24-16 Ch-261-1/2 1-1/2" Bronze 1-1/2 NPT x 90° 2103-12-12

1 1 1 18 1 1 1 2 2 1 1 2 1 1 1 1 1 1 1

.

1

21192 •

Dip• Stick

.

.

. .

•

.

•

%

. .

.

.

.

. .

• .

_

• •s/..i'o

FIGURE 20 - HYDRAULIC PUMP MOUNTING AS -, EM3LY (3 SPEED 0-5 MPH)

FIGURE 20

REF. 20-

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

.....ilsoffiftwasiar

HYDRAULIC PUMP MOUNTING ASSEMBLY (3 SPEED 0-5 MPH)

DESCmPTION

PART NUMEIER QTY

Hydraulic Pump Mounting Assembly (3 Speed 0-5 MPH Reference 21082 Engine (Reference) 3/8 Sq. x 1-1/2 Lg. Key FB 5016 Coupling Pump Adaptor 21123 7/16 Lock Washer 7/16-14UNC X 1-1/2 LO Cap Screw 3/16 Sq. X 1-1/2 LG. Key Male Connector 0503-8-8 Pump (Vickers) V2010—IF-8555-1AA10 1-1/2 Hose Barb Street Elbow 1-1/2 NPT X 90° Flange Assembly FL1-12-12P-10 0503-12-12 Male Connector 1/2-13UNC X 1-1/4 LG Cap Screw Lock Washer 1/2

Ar.....••••••••••■■•..Gramsw • .1111PIPIMMEIIIIIIMN•• ■■•••••••■■■•■••■■•■•••MORIO../

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

-.---.-.--

/7/ /o? 4/ 7*V

FIGURE 21 - HYDRAULIC PUMP MOUNTING ASSEMBLY

3

ffyrrei0 8 19 9

6

18

(

15

Sitimmumo

.,

**

10 TWO STAGE

1

rio•

25

11411 ft44,, 21 20

fit.

,

24 11

23 24

11

22 23

FIGURE 21

REF 21-1 -2 -3 -4 -5 -6 -7 # -8 #-9 -

10

-11 -12 -13 -14 -15 #-16 # -17 -18 -19 -20

HYDRAULIC PUMP MOUNTING ASSEMBLY

PART NUMBER

DESCMPTION Hydraulic Pump Mounting Assembly ..

Engine (Reference Key Coupling Pump Adapter Lockwasher Cap Screw Key Elbow Male Connector Pump (One Stage) Hose Barb Street Elbow .

Bushing Hex Head Screw Lockwasher Check Valve Male Connector Hose Assembly

QTY

'

Elbow 90° "J"•Ring Elbow (Used with Ref. No 10 One Spare Pump) Street Elbow (Used with Modified Ref. No. 25 two to one stage pump.)

Close Nipple Black Pipe Bushing (One Stage Pump) Black Pipe Bushing (Two Stage Pump) Black Pipe Coupling Pump (Two Stage

1

21082 3/8 SQ. x 1-1/2 Lg. FB5016 . .

21123 7/16 7/16-14 UNC x 1-1/2 lg .

1/4 SQ. x 1 Lg. 2502-12-12 0101-12-12 P30A197BEEJ10-30

1 1 1 4 1 1 1

1 1

1 1/2

1

-

1 1 2 2 1 1

1-1/2 x 90° 24-1,1/2 :'F5OGS 1/2-13 UNC x 1-1/4 - 1/2 C35 0103-12-12 HEIC12-12NJ x 12 NJ x 29' 2503-12-12 .

1 1

.

'

-21 -22 -23 -

-24 -25

T•

one .

1 1

1 Inch 1-1/2 x 1 1-1/2 x 1

2 1

1 1/2 -

P30A197BIED1030FJABO5

S. # Used only when unit has Emergency Power Pump

•

.

•

-I

ll 7 vi/

rivutcc z i — rITUIV\ULIL. t'UNIV MOUN1 INC.

I

ASLIvitiLY t mt 11 )

FIGURE 21

HYDRAULIC PUMP MOUNTING ASSEMBLY (5 MPH)

REF

DESCRIPTION

21-

Hydraulic Pump Mounting Assembly (5 MPH)

PART NUMBER

QTY

-1

Engine (Reference)

-2

Key, 3/8" Sq. x 1-1/2" Lg.

-3

Coupling

FB5016

1

-4

Pump Adaptor

21123

1

-5

Lockwasher, 7/16"

4

-6

Cap Screw, 7/16" - 14 UNC x 1-1/2" Long

4

-7

Key, 1/4" Sq. x 1 Lg.

1

-8

Elbow

2502-12-12

1

-9

Male Connector

0101-12-12

1

-10

Pump (Commercial Shearing & Stamping Co.)

P30A 197 BEEJ 10-30

1

-11

Hose Barb, 1-1/2"

1

-12

Street Elbow, 1-1/2" x 90°

1

-13

Bushing, 24-1-1/2

-14

Hex Head Screw, 1/2" - 13 UNC x 1-1/4"

2

-15

Lockwasher, 1/2"

2

-16

Check Valve

C35

1

-17

Male Connector

0103-12-12

1

-18

Hose Assembly

NJ-29

1

21082

1 1

F5OGS

1

FIGURE 21 A - HYDRAULIC PUMP TO TANK INSTALLATION (Ser. No. 2104-ON)

kr

**,

ter

-

eilk

WA

,. . . . ./ 5.

fe 414 0 PIPE THREAD REF. 21A-1 -2 -3 -4 -5 -6 -7

• ,dir

It4176 .11"-°°

illIlilit glir

(

6.

/ (

lie

STRAIGHT THREAD PART NUMBER

DESCRIPTION Hydraulic Pump to Tank Installation (Ser. No. 2104-ON Single Stage Pump (With Pipe Threaded port) ' C ..

Single Stage Pump (With straight threaded port) 0-Ring Adapter 90° Street Elbow Hose Barb Hose Clamp Radiator Hose

QTY

)

P30A197BEEJ10-30 P30A197BEEJ10-30 1x1 1 -1/2 1-1/2 1-3/4 to 2-1/2 1-1/2 I.D. x 7

1 1 1 1 1 2 1

3.

42 274-

FIGURE 2IB

DIESEL HYDRAULIC PUMP MOUNTING ASSEMBLY

HYDRAULIC TANK

FIGURE 21B

DIESEL HYDRAULIC PUMP MOUNTING ASSEMBLY

21B-1 -2 -3 -4 -5 -6 -7 0 -8 -9 4 -10 . #-11 4 12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23

PART mums En

DESCRIPTION

•REF

Diesel Hydraulic Pump Mounting Assembly Diesel Engine Key Chain Coupling Pump Adapter * Metric .Split Washer Hex Head Metric Cap Screw Key Elbow Elbow Male ConnectOr Check Valve Male Connector Hose Assembly Pump (One Stage) Hex Head Cap Screw Lockwasher "0" Ring Adapter 90° Street Elbow Hose Barb ' Hose Clamp .

Radiator Hose Gate Vafve Pipe Nipple

(Reference) 3/16 x 3/8 x 1-1/2 21297 21279 M10 M10-17 x 30 1/4 Sq. x 1 2502-12-12 2503-12-12 0101-12-12 C35 0103-12012 HEIC12-12NJ x 12NJ x 29 P30A197BEEJ10-30 1/2-13 UNC x 1-1/4 1/2 • 1x1 .1 -1/2 1-1/2 1-3/4 to 2-1/2 ' 1.1/2 I.D. x 7 1-1/2 Bronze Close 1-1/2

. .

.

.

.

• .

.

# Used only when unit has emergency power pump.

• ,

.-

-

_

.

..

• • •

OTT

1 1

1 1 8 8 1 1 1 1 1 1 1 1 2 2 1 2 '2 2 1 1 1

FIGURE 22 - TURRET ROTATION SPEED REDUCER ASSEMBLY

REF. 22 -1 -2 -3 -4 -5 -6 -7 -8 -9 - 10 -11 - 12 - 13 -14 -15

DESCRIPTION Turret Rotation Speed Reducer Assembly Turret Speed Reducer (See Figure 23) Key Coupling Coupling Connector Orbit Motor Key Lock Washer Hex Head Cap Screw Turret Rotation Pinion Set Screw Key Lock Washer Hex Nut Roll Pin Coupling (Ser. No. 2187..ON)

PART NUMBER Figure 21083 1/4 SQ. X 1 LG. FB4016 6-10BCO B-E 1/4 SQ. X 1 LG. 3/8 3/8-16UNCX1 21080 5/8 -18UNCX1/2 LG. 3/8 SQ. X 3 LG 3/8 /8-11 UNC 3/8 x 1-1/2 21213

QTY

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

FIGURE 23

REF. 23 -

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

SPEED REDUCER ASSEMBLY (TURRET)

DESCRIPTION Speed Reducer Assembly Slow Speed Cover - Closed Slow Speed Worm Gear - Bronze Roller Bearing - Slow Speed Slow Speed Spacer - Short Housing .Slow Speed Spacer - Long Slow Speed Oil Seal Slow Speed Shaft - Bottom Extension High Speed Oil Seal High Speed Cap - Open High Speed Worm Shaft Roller Bearing - High Speed High Speed Cap - Closed

PART NUMBER (ORDER BY REFERENCE NUMBER AND DESCRIPTION)

QTY.

'1 1 2 1 1 1 1

1 ,1 2 1

Li 7

FIGURE 24

REF. 24-1 -2 -3 -4 -5 -6

EXHAUST ASSEMBLY

DESCRIPTION Exhaust Assembly Elbow Pipe Elbow Muffler Muffler Cage (Option) Pipe

PART NUMBER

1-1/4 NPT x 90° 8 NIPPLE x 1-1/4 1W4 NPT x 90° WD-86 21180 9 Nipple x 1 1-1/4

QTY

1 1 1 1 1

FIGURE 25

BOOM ASSEMBLY 21006

(SER. NO. 0001 - 2186)

14

15 16 46&47

17 48

18

45 _

52 50 49 51

19 20 21 22 23

44

24

43 42 41 40

- erg LI, 25 /` 26

27 27A 2

/294130 / 34 28 31 32 33 35 36 37 38 39

FIGURE 25

REF

BOOM ASSEMBLY

21006 (CONT 'D) (0001-2186)

DE SCRIPT! ON

25Boom Assembly -1 Beskef-Levetihg-S-1-crve-Cylinder (See Figure 29) -2 Wear Pad -3 Allen Flat Head Socket Machine Screw -4 Inner Boom Weldment -5 Allen Flat Head Socket Machine Screw -6 Gable-Assembly (See figure 27) -7 Wear Pad -8 Wear Pad -9 Clevis Pin 7/16 x 1 - 10 Allen Flat Head Socket Machine Screw -11 Cotter Pin -12 Leveling - Cyril-rider Boom Pin - 13 Electrical Cable (See figure 26) -14 Hydraulic Hose Assemblies -15 Allen Flat Head Socket Machine Screw - 16 Wear Pad - 17 Intermediate Boom Weldment - 18 Sheave - 19 Intermediate Boom Roller -20 Intermediate Boom Sheave Pin - 21 Grease Fitting - 22 Hex Head Cap Screw - 23 Allen Flat Head Socket Machine Screw - 24 Wear Pad - 25 Outer Boom Wear Pad Bracket - 26 Lockwasher -27 Wear Pad Retainer -27A Wear Pad -27B Wear Pad - 28 Outer Boom Weldment - 29 Lockwasher -30 Washer - 31 Hex Head Cap Screw - 32 Outer Boom Sheave Pin - 33 Grease Fitting - 34 Hex Head Cap Screw - 35 Lockwasher -36 Grease Fitting -37 I Hex Head Cap Screw -38 Lockwasher -39 Outer Boom Sheave Pin -40 Hex Head Cap Screw -41 Outer Boom Bracket Pin - 42 Hex Head Cap Screw Lockwasher -43 - 44 i Hose Cover Guard -45 I Outer Boom Sheave Bracket r

PART NUMBER CITY 21006 21015 21108 3/8-24 x 1-1/2 21102 3/8-24 x 1-1/2 21086 21107-1 21107-1 C12 3/8-24 x 1-1/2 7/64 x 1 21128 21095 (See Figure 26) 3/8-24 x 1-1/2 21107-1 21101 21202 21115 .21049 1/8-28 3/8-24 x 1/2 3/8-24 x 1-1/2 21194 21194 3/8 21198 21107 21108 21100 3/8 3/8 3/8.-24 x 3/4 Grade 8 21116-1 1/8-28 3/8-24 x 1/2 3/8 1/8-28 3/8-24-x 1/2 Grade 8 3/8 21116-2 3/8-24 x 1/2 21119 1/4-20 - 1-11/16 1/4 21171 21103

1 1 4 1 4 2

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

abiairomp.o.owslm.........11•■•■•••••••••••1•1.1'

,.•"' 7 4/

FIGURE 25

57 5

BOOM ASSEMBLY 21006 (CONT'D) (S ER. NO. 0001-2186)

59

64 65 66

63

158

159

.

160

60 62 61

69 64 161

92

98C

3 94 98 95

17

98A 99

77 8 76 79

100 101 • 102

28 103 104 fi2r

105 106 107

119 12 114

149 ••• 750 149 148

129

138

130

# (SER. NO, 0051 ON) -

131

I

133

134 135 136

145 144 143 142

137 7'/

FIGURE 25

BOOM ASSEMBLY 21006 (CONT'D) (SER. NO. 0001-2186)

TY .

RAF

DESCRIPTION

PART NUMBER

-46 - 47 - 48 -.49 - 50 - 51 -52 - 53 - 54 -55 - 56 - 57 -58 - 59 - 60 -61 -62 -63 - 64 -65 - 66 - 67 - 68 -69 - 70 - 71 -72 - 73 -74 - 75 - 76 - 77 - 78 -79 - 80 -81 - 82 - 83 - 84 - 85 -86 - 87 -88 -89 - 90 -91 - 92 -93

Sheave Sheave Bracket Spacer Sheave Lockwasher Hex Head Cap Screw Hex Head Cap Screw Intermediate Boom Roller Pin Lockwasher Hex Head Cap Screw Lockwasher Cable Assembly (See Figure 27) Fitting Electrical Cable Sheave Hydraulic Hose Sheave Allen Flat Head Socket Machine Screw Wear Pad Cable Anchor Bracket Cottwr Pin Washer Clevis Hex Nut Tur'n Buckle Cable Assembly (See Figure 27) Clevis Pin Sheave Retraction Sheave Bracket Weldment Hex Head Cap Screw Allen Flat Head Socket Machine Screw `Near Pad Allen Flat Head Socket Machine Screw Hose Drums and Sheave Pin Tab Lockwasher Hex Head Elastic Stop Nut Allen Flat Head Socket Machine Screw Wear Pad Hex Head Cap Screw Cable Tensioner Bracket Weldment (Right Hand) Cable Tensioner Bracket Weldment (Left Hand) Hex Nut Lockwasher Washer Hex Head Cap Screw Flange Bearing Lockwasher Hex Nut Set Screw Winch Drum Weldment

21199 21200 21098-2 3/83/8-24 x 1/2 3/8-24 x 1/2 21120 3/8 3/8-24 x 1/2 3/8 21087 1/8-28 21210 21110 3/8-24 x 1 21108-2 21113 Part of item 67 Part of item 67 Part of item 67 5/8-11 UNC Left Hand G-228 21024 Part of item 67 21202 21109 3/8-24 x 1-1/8 3/8-24 x 1-1/4 21107-2 1/4-28 x 3/8 21118 21209 3/8 3/8=24 3/8-24 21107-1 3/8-16 x 5/8 Grade 8 21111-1 21111-2 3/8-16 3/8 3/8 9/16-18 x 1-1/2 131072-SX 1-3/4 9/16 9/16-18

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

3/8-16 x 1/2 21025

1 1

•■•■•■■■•1AVAIllwiall..

1111.110.11111111•111.0.011 .4111.1•44

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

.

FIGURE 25

BOOM ASSEMBLY 21006 (CONT'D) (SER. NO. 0001-2186)

## (SER. NO. 0001-0050)

100 28

101 102 103 104 105 12

106 107 155## 154## 153##

122

148 147## 146

zr,P7'5/

DESCRIPTION

REF -94 -95 -96 -97 -98 -98A -98B -98C -99 -100 -101 -102 -103 -104 -105 -106 -107 #-108 # -109 #-110 -111 -112 #-113 #-114 -115 -116 -117 -118 -119 -120 -122 -123 -124 -125 -126 -127 1 = -129 -130 -131 -

Set Screw Collar Hex Nut Lockwasher Boom Brace Boom Brace Cover Lockwasher Hex Head Cap Screw Hex Head Cap Screw Hex Head Cap Screw Hex Nut Lockwasher Breather Bushing • Street Elbow (See Figure 28) Speed Reducer Pipe Plug Bushing Housing Coupling Key Key Hex Head Cap Screw Hex Head Cap Screw Hex Nut Lockwasher Washer Hex Head Cap Screw Cable Clip Key -Woodruff Master Leveling Cylinder Boom Pin Orbit Motor

PAT

• -

. ' ,

.

. .

MIRMAMMINEMENIM.1

14.

-

2503-10-8 2102-4-4 21089 2102-4-4 21014 21132 H1-GA08-08NJX08NJ22

.

CZT If ......................, 1 2 4 4 ,1 1 2 2 4 4 4 4 1 1 1 1 2 2 1 1 1 4 1 I 6 1 4 1 1.

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

• 11

..

Male Connector Master Leveling Cylinder Turret Pin Retaining Ring Cable Assembly

-

•

NUMBER

3/8-16 x 3/8 1-3/4 1/4-20 1/4 21190 21191 1/4 1/4-28 x 1/2 1/4-20 x 3/4 1/2-16 x 1-1/2 1/2-16 1/2 674-22 1/8-1/2 1/2 21074 1/8 21240 21212 21213 5/16 SQ x 1-1/4 1/2 SQ. x 4" 3/8-UNC x 2 3/8-16 UNC x 1 • 1/4-20 1/4 1/4 1/4- 2 0 x 1/2 32606 1/2 x 1 21130 BE

-

. . .

Elbow Elbow Master Leveling Cylinder (See Figure 31) .

Elbow (See Figure 32) inder • Topping-Cylinder Boom Pin Elbow Hose Assembly

-132 -133 -434 -135 -136

(CONT'D) (SER. No. 0001 - 2186)

21006

BOOM ASSEMBLY

FIGURE 25

1

.

0

6WTX-S 21131 5100-125 16GA-4 Cond. x 6 ft.

2 1 1 1

FIGURE 25 REF -137 -138 -139 -140

BOOM ASSEMBLY 21006 (CONT'D) (SER. NO. 0001-2186)

DESCRIPTION

PART NUMBER

QTY

21133 2532 4WJJTX-S HI-GA06-06NJ x 06 NJ-17

1 1 2

4 1 1 1 1 1 1

Elbow

10-20 x 1-15/16 C4T-JDOIT 14667 DN 3/8-16 x 1/2 1/8-28 21129 H I EC-08-08N J 08NJ-29-3/4 SWETX-S

2 2

Hex Head Cap Screw Spacer Coupling Chain Coupling Lockwasher Hex Head Cap Screw Internal Star Lockwasher Hex Nut Spring Anchor Tab Spring Set Screw

3/8-24 x 5/8 21240 FB5016 21175 3/8 3/8-16 UNC x 7/8 5/8 5/8-11 UNC 21209 2262 5/16-18 UNC x 3/8

1 1 1 1 4 4 2 1 1 1 1

Topping Cylinder Turret Pin Connector (T & B) Tee Hose Assembly

2

-141 -142 -143 -144 -145 -146 ##-147 -148 -149 -150 -151 -152 ##_153 -154 -155 -156 ##_157 -158 -159 -160 -161 #.162

Round Head Screw Limit Switch 'Switch Plate Limit Switch Arm Set Screw Grease Fitting Main Boom Turret Pivot Pin Hose Assembly

#(Serial No. 0051-2186) ## (Serial No. 0001-0050)

FIGURE 25A BOOM ASSEMBLY 21006

(SER. NO. 2187-ON)

14

75

53 16 30 17

46&47 168

18 95

167

5

19 20 21 22

23-

44

24-

43 42 41 35,40

0

25'

' '2' „)

26

27 271

/ / 34 276 23 2 ' 31 32 33 35 36 37 38 39 7/ -'r

„!

FIGURE 25A

REF

BOOM ASSEMBLY 21006

DESCRIPTION

(CONT'D) SER. NO. 2187-ON)

PART

•

Boom Assembly • 25ABasket Leveling Slave Cylinder (See figure 29) -1 -2 Wear Pad Allen Flat Head Socket Machine Screw -3 Inner Boom Weldment -4 -5 •Allen Flat Head Socket Machine Screw Cable Assembly (See Figure 27A) -6 Wear Pad -7 -8 -9 Clevis Pin 7/16 x 1 • Allen Flat Head Socket Machine Screw -10 Cotter Pin -11 Leveling Cylinder Boom Pin -12 Electrical Cable (See Figure 26) -13 Hydraulic Hose Assemblies • -14 Hex Head Cap Screw -15 -16 Wear Pad Intermediate Boom Weldment -17 Sheave -18 ' Intermediate Boom Roller -19 Intermediate Boom Sheave Pin -20 Grease Fitting -21 Hex Head Cop Screw -22 Allen Flat Head Socket Machine Screw -23 -24 Wear Pad .

Outer Boom Wear Pad Bracket -25 Lockwasher -26 -27 Wear Pad Retainer -27A Wear Pad -27B Wear Pad Outer Boom Weldment -28 -29 Lockwasher _ Retainer -30 Hex Head Cap Screw -31 Outer Boom Sheave Pin -32 Grease Fitting -33 Hex Head Cap ScreW -34 Lockwasher -35 Grease Fitting -36 Hex Head Cap Screw -37 Lockwasher -38 Outer Boom Sheave Pin -39 Hex Head Cap Screw . -40 -41 Outer Boom Bracket Pin • -42 Hex Head Cap Screw Lockwasher * -43 -44 Hose Cover Guard -45 -45A Sheave Housing Weldment

21006 21015 21108 -1 3/8-24 UNF x 21102 3/8-24 UNF x 21267 21107-1

•

,

.

•

QTY

reQumocrt

1

1 1 1/2

4 1 4

1/2

1 6

1

•• C12 1/2 3/8-24 UNF x 7/64 x 1 21128 21095 See Figure 26 1/2 3/8-24 UNF x 21287-2 21101 • 21202 .21115 21049 1/8-28 3/8-24 UNF x 1/2 3/8-24 UNF x 1-1/2 21194-4 21194-1 .3/8 21198 2:1107.4 21108 21270 -* 7/16 21287-1 7/16-20 UNF x 3/4 gr 8 21116-1 1/8-28 UNF 3/8-24 UNF x 1/2 gr 8 3/8 1/8-28 3/8-24 UNF x 1/2 Gr 8 3/8 21116-2 3/8-24 UNF x 1/2 21119 3/8-24 UNF x 5/8 3/8 21294

6

1 1 1 4 6 2 1 1 1 ' 1 1 8 4 1 1 8 4 4 1 1 4 2 4 1 1 4 2 1 1 1 1 1 1 6 6 . 1

21261 ///'

....., ;;/'

FI GURE 25A 57

BOOM ASSEMBLY 21006 (CONT'D) (SER.NO. 2187-ON)

59 79 63 60 62 61

158 .

—159 160

6,4 65 66

4

— 64

161

92

98C

93

17

94

98

98A 98C

28 103 104 105 106 107

149 121

128

150

12 1 24 157 156 125 126

149 140-; cv 1394 '" /'/;'

127

146 145 -144 143 '—i42

129 130

I

4'7 131

133

N(/`. 2),/,)

• C,L, 1 134156 136

137

FIGURE 25 A

LIEF - 46 -47 - 48 -49 -50 - 51 -52 - 53 - 54 -55 -56 -57 -58 - 59 -60 -61 -62 -63 -64 -65 -66 -67 -68 -69 - 70 - 71 - 72 -73 - 74 - 75 - 76 - 77 -78 - 79 - 80 - 81 -82 - 83 -84 - 85 - 86 - 87 - 88 - 89 - 90 - 91 -92 -93

BOOM ASSEMBLY

DESMIPTION

21006(CONT'D) (SER. NO. 2187-ON)

PART NUMBER

Sheave Sheave Bracket Spacer Sheave Lockwasher Hex Head Cap Screw Hex Head Cap Screw Intermediate Boom Roller Pin Lockwasher Hex Head Cap Screw Clevis Pin Cable Assembly (See Figure 27A) Fitting Electrical Cable Sheave Hydraulic Hcise Sheave Allen Flat Head Socket Machine Screw Wear Pad Cable Anchor Bracket Cotter Pin Washer Clevis Hex Nut (Left Hand Thread) Turn Buckle (See Figure 27A) Cable Assembly Clevis Pin Sheave Retraction Sheave Bratket . Weldment Hex Head Cap Screw Allen Flat Head Socket Machine Screw Wear Pad Allen Flat Head Socket Machine Screw Hose Drums and Sheave Pin Tab

21251 21200 21098-2 3/8 3/8-24 UNF x 1/2 3/8-24 UNF x 1/2 21120 3/8 3/8-24 UNF x 1/2 7916-1 21268 1/8-28 21210 21110 3/8-28 UNF x 1-1/2 21108-1 21113 Part of item 67 Part of item 67 Part of item 67 3/4-10 UNC L.H. Thd. G-228 (3/4 x 6) 21266 Part of item 67 21202 21262 3/8-24 UNF x 1-1/4 3/8-24 UNF x 1-1/4 21107-1 1/4-28 UNF x 3/8 21118 21209

Hex Head Elastic Stop Nut Allen Flat Head Socket Machine Screw Wear Pad Hex Head Cap Screw Cable Anchor Weldment Boom Pivot Pin Spacer Hex Nut Lockwasher Cotter Pin Hex Head Cap screw Flange Bearing Lockwasher Hex Nut Set Screw Boom Cable Drum Weldment

3/8-24 UNF 3/8-24 UNF x 5/8 • 21107-1 3/8-16 UNC x 5/8 gr.8 21272 21278 3/8-16 UNC 3/8 1/8 x 3/8 9/16-18 UNF x 1-1/2 FY112 9/16 9/16-18 UNF 3/8-16 UNC 21269

BOOM ASSEMBLY 21006 (CONT'D) (SER. NO. 2187-ON)

FIGURE 25A

DESCRIPTION

REF

-

-94 -95 -96 -97 -98 -98A -98B -98C -99.

-100 -101 -102 -103 -104 -105 -106 -107 -108 -109 -110 -111 -112 -113 -114 -115 -116 -117 -118 - -119 -120 -121 -122 -123 -124 -125 -126 -127 -128 -129 -130 -131

PART NUMBER

QTY

3/8-16 UNC x 3/8

Set Screw .

Hex Nut Lockwasher Boom Brace Boom Brace Cover Lockwasher Hex Head Cap Screw .

Hex Head Cap Screw Hex Head Cap Screw Hex Nut Lockwasher Breather Bushing Street Elbow (See Figure 28) Speed Reducer Pipe Plug Bushing .

Housing 1' • .

Coupling Key Key • Hex Head Cap Screw Hex Head Cap Screw Hex Nut Lockwasher .

Washer Hex Head Cap Screw Cable Clip Key - Woodruff Master Leveling Cylinder Boom Pin Orbit Motor

.

• •

.

.

•

•

4.

4 ,1 1 8 6 4 4 4 4 1 1 1 1 21

.

-

,

.

Elbow .

Elbow Master Leveling Cylinder (See Figure 31) Elbow (See Figure 32A) Topping Cylinder Topping Cylinder Boom Pin Elbow Hose Assembly

• 1/4-20 UNF 1/4 .

21190 21191 1/4 1/4-28 UNF x 1/2 1/4-20 UNC x 3/4 1/2-13 UNC x 1-3/4 1/2-13 UNC .

1/2 .674-22 1/8-1/2 1/2 • 21074 1/8 21240 21212 21213 .5/16 SQ x 1 1/4 1/2 SQ. x 4" 3/8-UNC x 2 3/8-16 UNC x 1 . 1/4-20 UNF , 1/4 1/4 .

1/4- 2 0 UNC 32606 1/2 x 1 21130 BE

. .

2503-10-8 2102-4-4 21089 2102-4-4 21241 21132

1 1 6 4 1 1.

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

H1-GA08-08NJ x 08NJ -22

12

6WTX-S 21131

2.

1

16GA-4 Cond. x 6 ft.

1

-132 -133 -134 -135 -136

Male Connector Master Leveling Cylinder Turret Pin Cable Assembly

•

Niumpart

PADS

DESMIPTION

!US -137 -138 -139 -140

21006 (SER. NO. 2187-ON)

BOOM ASSEMBLY

FIGURE 25A

Topping Cylinder Turret Pin Connector (T & B) Tee Hose Assembly

CT?

21133 2532 4WIJTX-S HI-GA06-06NJx06NJ x17

1 1 2

10-20 UNF x 1-15/16 .

C4T-JDO1T • 14667 DN 3/8-16 UNC x 1/2

4 1 1 1 1

21129 HIEC-08-08NJ-08NJ 29-3/4 8WETX-S .

1

2

-141 -142 -143 -144 -145 -146 -147 -148 -149

Round Head Screw Limit Switch • Switch Plate Limit Switch Arm Set Screw

.

. .

•

Main Boom Turret Pivot Pin Hose Assembly

-150 -151 -152 -153 -154 -155 -156 -157 -158 -159 -160 -161 -162 -163 -164

Elbow

-165 -166 -167 -168

Hex Head Cap Screw LockwasherSpiro! Pin Socket Head Sholder Bolt

2 2

.

Roll Pin Roll Pin • Bearing Stop Hex Head Cap Screw Lockwasher Internal Star Lockwasher (Left Hand Thread) .

Hex Nut Spring Anchor Tab Spring Set Screw Retainer Cam

. ..

.

;

1 .1 1 2 2 2.

1 1 1 1 1 1 1 2 2 2 1

7/16 x 3/4 7/16 x 1-1/2 .

21293 3/8-24 UNF x 1/2 3/8 3/4 3/8-11 UNC 21209 21193 .

5/16-18 UNC x 3/8 21225 21207 or ' 21208 (5 mph Option) 1/4-20 UNC x 1/2 1/4 34991 3/8 x 1-1/2

•

.

'

'

.

%/

yam

•

FIGURE 26

BOOM HYDRAULIC HOSE AND ELECTRICAL CABLE ASSEMBLY (PART OF 21006)

\ %\ \ \ ,\‘• \ \\\\

.fk‘ \

D ‘ k‘\

\ \\ \ \ s , \N . \ \\\

\\ \\

\

\

'

\ \\‘, 0 ., ‘‘

\\‘‘‘ \\ 0 \

FIGURE 26

BOOM HYDRAULIC HOSE AND ELECTRICAL CABLE ASSEMBLY (PART of 21006)

FIEF 26#

-1 -2 -3 -4

-5 -6 -7 -8

DESCPaPTiON

PART NUMBER

CITY

Boom Hydraulic Hose and Electrical Cable Assemblies (Part of Boom Assembly 21006) NOTE: Booms shown in up-side down position in order to clarify hydraulic hose and electrical cable routing.

Kellum Grip Hook Assembly Retraction Cable Tensioner Spring Hose Assembly • Platform Rotation Hose Assembly (Option) Kellum Grip * (Ser. No. 0001 to 2186) Kellum Grip * (Ser. No. 2187 - ON) Kellum Grip **(Ser. No. 0001- .0N) Sheave Housing Weldment, 21103 Electrical Cable

21177 21193 K4CTO4NJx04NJ-564

2 2 2

K4CTO4NJx04NJ-564

2

022-03-014 022-01-014 022-01-039 (See Fig. 25) 21095

1 1 2 1 1

•

-

.

• * For (2) Hose Hook-Up ** For Electrical Cable or (4) Hose Hook-Up ‘..

•

• •

.

. //,

•

FIGURE 27

BOOM CABLE ASSEMBLIES

Part of 21006) (SER. No. 0001-2186)

/'

■

..'

...." '''''

i'il rt - ? '1 4:4:1 )' .4 .4. `t.-.' ,r.-r s N ■ :1 ',:i ) ",. )

..eft. ,...' ,:;:',

,;..,

■

...

'

.

../...."...

..0",./

.0.'

.■ ../ ..." / ,./

• .0 ,,,,

,. de"

.-

•

.," ,..■ ...."

• '...; ''''' .„,---".

40' r.... ..... ,....... ./ -'. .../ ii ..e"

1 i

,..".....---

-

■

.."

/-

""

...." •''''. ,,

REF.

-1 -2 -3 G.4 -5

./ .." .."'

..." "e

6'■

.

....7

4

i/

,• -

■

s--

.

% 1 ■•

-

3

1

1".

---...4.,,...-

......"'"

IL ,./ --.;-... , ,...... ....

1 C'

...-.—

...-- ., • ....- -' i ...... .....

II

..-

../.

..-.7

...4i'

..., .. *

1..;=-*-

■

..'

t ,o,'-' 'I

...--• 4&5

I1 0 )

."::„..1„,/

.i

CP 1! ✓ ,,..." r.... ..... r ti )1 I 0 )

DESCRIPTION Boom Cable Assemblies (Part of Boom Assembly 21006) Cable Assembly - Inner Boom Extension Cable Assembly - Inner Boom Retraction Cable Assembly— Intermediate Retraction & Extension Hex Nut Conical Washer

PART NUMBER

21087 21086 '‘ 21024 5/8-11 5/8

-6 8 74/

FIGURE 27 A BOOM CABLE ASSEMBLIES (Part of 21006) (SER.NO. 2187-ON)

REF. 27-A

-1 -2 -3

DESCRIPTION Boom Cable Assemblies (Part of Boom Assembly 21006) Cable Assembly - Inner Boom Extension Cable Assembly- - tnner Boom Retraction Cable Assembly - Intermediate Retraction & Extension

PART NUMBER

21268 21267 21266

QTY.

1

FIGURE 28

SPEED REDUCER (OUTER BOOM)

/

FIGURE 28

wrzx NO 28-1 -2 -3 -4 -5 -6 -7 -8 -9 - 10 - 11 - 12 - 13 -14 - 15 - 16 -17 - 18 -19 - 20 - 21 -22 - 23 -24 -25 - 26 -27 - 28 - 29 - 30 -31 -32 -33 -34 -35 -36 -37 - 38 - 39 -40 -41 - 42 - 43 - 44 - 45 -46

SPEED REDUCER (OUTER BOOM)

DESCRIPTION

I

Speed Reducer - Outer Boom Cover Grease Fitting Shaft Gear Carrier Dowel Pin Key Pin Bushing Cap Screw Lock Washer Nut Housing Pipe Plug Cap Screw Brake Shoe Assembly Screw, Cap Washer Cap Screw Cam Cap Housing NOTE: Actual Housing Used is Rotated 180° Drum Key Lockwasher Nut Bearing Worm Gasket Cap Screw Gasket Key Cap Screw Washer Grease Retainer Cap Drive Screw Name Plate Cap Screw Instruction Plate Drive Screw Breather 0-Ring Oilers Cap Screw Nut

1 PART NUAIBER 21074 20706 21128 17485 SP 20812 22411 20517 21526 21527 12101 23885 20526 20271 20828 20286 20523 SA3317 28578 20617 20522 23875 23878 23872 29503 20279 2011 5 20114 20732 20809 20731 20270 20730 20105 20278 20092 20232 20815 21775 24042 20325 23676 23046 26799 12102 12077 12078 21723 .

lorwrailm•■••1 1,••■11•■••■•■••nr. .4111•1.••••■•■••■■■••1111•1110.11111•01111111111101014.0.••• ■■•■■•••1111••••

QTY 1 2 1 1 1 2 2 1 2 12 25 20 3 82 4 2 2 1 1 1 1 1 1 1 2 1 2 4 2

1 1 1 2 1 2 1 4 1 3 1 2 2 4 41

BASKET LEVELING SLAVE CYLINDER ASSEMBLY

FIGURE 29

11

001100

1

4

I . ..>

, ‘,.. 3

Ad

3

'W

L

•

.40

...

•

,••0° -.I 5

ti.os"

..

4

4-0

.

• 1

REF. 29-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11

DESCRIPTION Basket Leveling Slave Cylinder Assembly Cylinder - Levering (See Figure 30) Hose Clamp Reducer Male Elbow Tube Assembly Tube Assembly Hex Head. Cap Screw Lockwasher Flat Washer Fluid Control Valve Tube Assembly

PART NUMBER

21015 4-4565 0102-8-4 2103-4-4 21218-35 21218-36 1/4-20 UNC x 1-3/4 Long 1/4 1/4 4KK33-N2-S 21218-40

QTY.

1 1 2 6 2 1 2 2 2 1 1

FIGURE 30 - LEVELING CYLINDER

30-2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16

PART NUMBER

DESCRIPTION

REF.

21015 27-3993 631-13 696-9 657-312 654-36 644-16 630-16 7-3993 627-19 16-3993 610-23 671-6 26-3993 674-13 2-3993 K21015

Leveling Cylinder Rod Assembly Rod Wiper Polypak Retaining Ring Key Lock Backup 0-Ring Gland 0-Ring Piston Polypak Piston Nut Body Assembly Fitting Bushing Seal Kit

Y.

QTY. 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 1 1

/,)_ 4./ 7

FIGURE 31 - MASTER LEVELING CYLINDER

31-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16

PART NUMBER

DESCRIPTION

REF.

Master Leveling Cylinder Rod Wiper Polypak Retainer Ring Key Lock Gland Backup 0-Ring Rod Assembly Body Assembly 0-Ring Piston T-Ring Piston Nut Fitting Seal Kit

•■

••••••■••••■•••■

QTY.

21089 631-13 696-9 657-312 654-31 7-131 644-14 630-14 27-4016 26-4016 627-19 16-4016 616-35 671-6 674-13 .

1 1 1 1 1 1 1

K21089

1

1 1 1 1 1 1 2

FIGURE 32

TOPPING CYLINDER ASSEMBLY (SER, NO. 0001 - 2186)

DESCRIPTION 32-1 -2 -3 -4 -5 -6 -7 -8 -9 - 10 - 11 - 12

Topping Cylinder Assembly ( See Fig 33) Topping Cylinder Hose Clamp Male Elbow Reducer Tube Assembly Hex Head Cap Screw Lockwasher Flat Washer Tube Assembly Lock Valve Mounting Plate Male Elbow

PART NUMBER 21014 4-1218 2503-6-6 0102-12-6 21218-37 1/4 x 2-1/2 Lg. 1/4 1/4 21218-38 25720-6SAE 21168 2103-6-6

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

•

547-r=

/ /

FIGURE 32A

REF. 32-1

-2 -3 -4

-5 -6 -7 -8 -9 -10 - 11 - 12 - 13

TOPPING CYLINDER ASSEMBLY (SER. NO. 2187-ON)

DESCRLPTION Topping Cylinder Assembly Topping Cylinder ( See Fig. 33A) Hose Clamp Male Elbow Reducer Tube Assemblj, Hex. Head Cap Screw Lockwasher Flat Washer Tube Assembly Lock Valve Mounting Plate Male Elbow Tee

PART NUMBER 21241 4-1218 2503-6-6 0102-12-6 21218-37 1/4 x 2-;1/2 1/4 1/4 21218-38 25720-6SA E 21168 2103-6-6 RTX-4-6

QTY.

-

2 4 2 1 2 2 2 1 1 1 1

7%' 71

FIGURE 33 - TOPPING CYLINDER

REF. 33-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16 -17

DESCRIPTION Topping Cylinder Rod Wiper Pelypak Retainer Ring Key Lock Gland Backup 0-Ring Rod Assembly Body Assembly 0-Ring Piston Polypak Piston Nut Fittings Internal Stop Bushing Seal Kit'

(SER. NO. 0001-2186)

PART NUMBER 21014 631-25 697-19 657-450 654-44 7-4014 644-26 630-26 27-4014 26-4014 627-27 16-4014 610-38 671-19 674-12 9-4014 2-4014 K21014

QTY

I 1

2 1 2 4 1

FIGURE #33A

REF. 33A-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16 -17

DESCRIPTION Topping Cylinder Rod Wiper Polypak Retainer Ring Key Lock Gland Backup O Ring Rod Assembly Body Assembly O Ring Piston Polypak Piston Nut Fittings Internal Stop Bushing Seal Kit

TOPPING CYLINDER

(SER. NO. 2187- ON)

PART NUMBER 21241 631-25 697-19 RS-500 904160 7-4160 6244-30 630-30 27-4014 26-4160 627-27 6-4160 25005000-562 671-19 674-12 9-4014 2-4014 4160

QTY.

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

3 874/

FIGURE 34

NON-ROTATING FORK ASSEMBLY

NON-ROTATING FORK ASSEMBLY

FIGURE 34

REF

DESCRIPTION Non-Rotating Fork Assembly Non-Rotation Fork Weldment Decal Plate - 'Warning" Leveling Cylinder Skirt Pin Main Leveling Skirt Pin Basket Levleing Slave Cylinder Work Light Assembly (Option) • LAMP Basket Control Box Guard Hex Head Cap Screw Lockwasher Decal " PLATFORM CAPACITY MUST BE DE-RATED. FOR TOOLS AND ACCESS ORIES" Hex Head Cap Screw Lockwasher Hex Head Cap Screw Lockwasher

34-1 -2 -3 -4 -5 -6 -7 -8 • --9 -10

-11 -12 -13 -14

-

• ,

•.

, ,

-

PART NUMBER 21088 21127 21126 (See Figure 9-502-4435 4435 21223 1/4-28 UNF x 3/8

QTY 1 1 1

1/4

1 1 1 1 2 2

15376-45 5/16-24 UNF x 1/2 5/16 3/8-24 UNF x 1/2 3/8

1 ' 1 1 1 1

FIGURE 35

ROTATING FORK ASSEMBLY (OPTION) (SER. NO. 0001-076)

/

FIGURt 35

ROTATING FORK ASSEMBLY

(Option) (SER. NO. 0001-0076)

levElammohogesmownrmamilweda,

DESCruPTECE1

RE F. 35-

-1 -2 -3 -4 -5

(Option) Rotating Fork Assembly Rotating Fork Weldment Platform Rotation Cylinder Pin Cotter Pin Platform Rotation Cylinder (See Fig. 36) Hose Assembly

Elbow Fitting -7 - 8 Valve -9 Hose Assembly -6

- 10 Swivel Elbow (45°) - 11 Holding Valve -12 Elbow - 13 Hex Nut - 14 Lockwasher -15 Washer.

- 16 Elbow (45°) -17 Elbow - 18 Hose Assembly - 19 Hose Assembly - 20 1 Basket Leveling Slave Cylinder -21 ;Main Leveling Skirt Pin -22 Leveling Cylinder Skirt Piri - 23 Skirt - 24 Hex Head Bolt - 25 Hex Head Bolt - 26 Lockwasher - 27 Washer -28 Pillow Block - 29 Elbow (45°) -30 Decal Plate "Warning" -31 Decal " Platform Capacity must be De-Rated for tools and accessories" -32. Hex Head Cap Screw -33 Lockwasher -34 Hex Head Cap Screw - 35 Lockwasher

PART NUr-.1BF.P.

21036 21406 1/8 x 1-1/4 21097 D7EA04-04MBX 04NJ-17-1/2 2103-4-4 1610-L NMF-20B D7EA04-04MBX 04NJ-23-1/2 3107-4-4 1606-2 4ME-4FX 1/4-20 1/4 1/4 3103-4-4 2103-4-4 K-403 K-403 (See Fig. 29) 21126 21127 21012 1/4-20 x 1-1/2 1/2-13 NC x 2-1/2 1/2 1/2 SX-1-3/8 3102-4-4

1 2 2 1 1 2 1 1

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

15376-43 5/16-24 UNF x 1/2 5/16 .3/8-24 UNF x 1/2 3/8

1 11 1 1

FIGURE 35A

ROTATING FORK ASSEMBLY

(OPTION) (SER.NO. 2126-2266)

31

---

27

26 32 25 33 23

07" "1.

FIGURE 35A

ROTATING FORK ASSEMBLY

(OPTION) (SER.NO. 2126-2266)

v

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

(Option) Rotating Fork Assembly Rotating Fork Weldment Platform Rotation Cylinder Pin Cotter Pin Platform Rotation Cylinder (See Fig. 36) Hose Assembly Elbow Fitting Valve Elbow Elbow Holding Valve Strap Clamp Tube Assembly Male Connector Bulkhead Elbow (45°) Swivel Elbow (45°) Elbow (90°) Hose Assembly Bulkhead Connector Basket Leveling Slave Cylinder Leveling Cylinder Skirt Pin Main Leveling Skirt Pin Skirt Swivel Elbow Hex Head Bolt Lockwasher Washer Pillow Block Decal Plate 'Warning" Decal "Platform capacity must be de-rated for tools and accessories" Hex Head Cap Screw Lockwasher Hex Head Cap Screw Lockwasher

1

21036 21406 1/8 x 1-1/4 21097 D7EA04-04MBX 04NJ-23-1/2 2103-4-4 1610-1 NMF-20B 4-M E-4FX 2102-4-4 1606-2 4-121921218-41

2 2 1 2 2

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

0103-4-4 4WNTX 4V6X 4WETX K4CT-04NJx04NJ-564 4WLN (See Fig. 29) 21127 21126 21012 3903-4 1/2-13 NC x 2-1/2 1/2 1/2 SYP106

1

1 1 1 1 1

15376-45 5/16-24 UNF x 172 5/16 3/8-24 UNF x 1/2 3/8

7

FIGURE 35B ROTATING FORK ASSEMBLY (OPTION) (SER. NO. 2267-ON)

FIGURE 35B ROTATING FORK ASSEMBLY (OPTION) (Ser..No. 2267-ON)

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

.

PART NU m.4

DESCRIPTION

Rotating Fork Assembly (Option) Decal "Platform Must be De-Rated for Tools and Accessories" Decal 'Warning" Fork Weldment Pin - Cylinder to Fork .

Hose Assembly Valve Elbow Holding Valve Strap Clamp Male Connector Elbow Tube Assembly Elbow Hex Head Cap Screw Lockwasher Cotter Pin .

Grease Fitting Pin - Cylindar to Skirt Platform Rotation Cylinder (See Fig. 36A) Leveling Skirt Weldment Hex Head Cap Screw Lockwasher .

Washer Pillow Block Hex Head Cap Screw ..

Lockwasher Main Leveling Skirt Pin Leveling Cylinder Skirt Pin Lockwasher Hex Head Cap Screw Basket Leveling Slave Cylinder .

Bulkhead Union Swivel Elbow Hex Head Cap Screw Lockwasher .

Cable Clip Electrical Cable Assembly

.

.

QTY 1

15376-45

1

1 21285 21291 D7EA04-04MBX-04NJx23-1t2 NMF-20-B 2102-4-4 • 1606-2 4-12-19 0103-4-4 4-ME-4FX 21218-41 2103-4-4.

1/4-28 UNF x 1/2 1/4 1/8 x 1-1/2 1610-L 21139 • 21271 21282 1/2-13 UNC x 2-1/2 1/2 1/2 SYP106 5/16-24 UNF x 1/2 5/16 21126 21127 3/8 3/8-24 UNF x 1/2 (See Fig. 29) WETX-4 3903-4-4

(Reference)

1 1 2 1 2 1

1 2 1 2 2 1 1 1 2 1 1

1 2

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

FIGURE 36 - PLATFORM ROTATION CYLINDER (SER; NO. 0001-22)

REF. 36-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 - 11 - 12 -13 -14 - 15

DESCRIPTION Platform Rotation Cylinder Rod Assembly Rod Wiper Backup 0-Ring Retaining Ring Retaining Ring Gland 0-Ring Body Assembly 0-Ring Backup 0-Ring Piston Piston Nut Seal Kit

PART NUMBER (Option)

21097 27-4031 631-9 646-19 627-19 657-175 658-200 7-006 630-2 26-4031 627-11 646-29 627-29 16-005 671-4 K21097

QTY.

FIGURE 36A PLATFORM RATATION CYLINDER (SER. NO. 2267- ON)

REF. 36A-1 -2 -3 -4 -5 %-6 -7 -8 -9 -10 -11 -12 -13 -14

DESCRIPTION Platform Rotation Cylinder (Option) Rod Assembly L ck Ring Wiper Poly Pak Retainer Ring Gland Back-Up 0-Ring 0-Ring T-Ring Piston Lock Nut Body Assembly Seal Kit

PART NUMBER 21271 27-4227 13-013 6231-11 12501125-250B 5000-250 7-4015 6244-6 6230..6 6227-13 TP-028 160009 LN-087-14 26-4227 K21271

QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 1

FIGURE 37

REF. 37-1 -2 -3

DESCRIPTION Basket (6 ft ) Basket (-1/2 ft. Option) Basket (12 ft. Option) Basket (8 ft.) (Used with Condor 3238)

BASKET (6 FT)

PART NUMBER 21013 21211 21145 21315

• QTY, 1 1 1

.

1

/,)J-,/ 7 ci

FIGURE 38

# (SER. NO. 0001-0050) \

BASKET CONTROL PANEL ASSEMBLY

FIGURE 38 REF.

BASKET CONTROL PANEL ASSEMBLY

DESCRIPTION

PART

MusncErt

- 10

Basket Control Panel Assembly Toggle Switch (Option) Toggle Switch Toggle Switch Toggle Switch Basket Control Junction Box Decal Plate Push Button Switch Push Button Switch Master Switch Decal Plate "Operation"

21173 8510K9 8511 K2 8511 K14 8510K2 21164 21078 SA401CR2 SA401CB2 9518 21187

- 11 - 12 - 13 - 14 - 15 - 16 - 17 - 18 - 19 -20

Connector Cap (Option) Round Head Screw (Option) Locknut Connector (Option) Hex Nut (Option) Lockwasher (Option) 110 Volt Outlet (Option) Decal Plate "110 Volts" Lift Cover Plate (Option) Connector Assembly

MS25043-22D No. 6-32NC x 1/2 Ig 143 MS3102A22-17 No. 6-32 NC No. 6 5262 15376-24 5210 2546

38-1 -2 -4 -5 -6 -7 -8

(Serial No. 0001-0050)

QTY. 1 2 1 5 1 1 1 1 1 1

1 4 •1 1 4 4 1 1 1 1

.

FIGURE 38A

BASKET CONTROL BOX

(BERTEA CONTROLLERS)

/.0/P74

FIGURE 38A

BASKET CONTROL BOX

DEscrurnioN

RAF 38A- .

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

(BERTEA CONTROLLERS)

PART NUMBER

Basket Control Box (Bertea Controllers) Controller • Basket Control Box Decal Plate Toggle Switch Decal Plate Push Button Switch Push Button Switch Connector Cap (Option) Round Head Screw 1 - 7'C Locknut Connector (Option Hex Nut Lockwasher • 110 Volt Outlet (Option) Decal Plate "110 Volts" Lift Cover Plate (Option) Connector Assembly

QTY 1 4 1 • 1 3 1 1 1 1 4 1 1 4 4 1 1 1 1

•

242900 21585 21587 8511K2 21597 SA401CR2 SA401CB2 MS25043-22D No. 6-32NC x 1/2 Ig 143 MS3102A22-17 No. 6-32 NC No. 6 5262

15376 24 -

5210 2546

•

.

•

• •

.4

.

•

•

.

.

/0

REMOTE BASKET CONTROL BOX ASSEMBLY

FIGURE 39

,

0

1

.............,,

Awaver

•

Ik4fr

kl.

.

6

REF. 39-1 -2 -3 -4.

-5 -6

.

, Jo.

...

4i

,

. , V

1 1

/7

PART NUMBER

DESCRIPTION Remote Basket Control Box Assembly Junction Box Toggle Switch Decal Plate Plug Control Cable Connector Assembly

21184 21166 8510K2 21076 MS3106A-22-17-P 21093 2522

,

QTY. 1 1 4 1 1 1 1

4.

•

c41-307.1

FIGURE 40

REMOTE GROUND CONTROL BOX ASSEMBLY 0

1

0

•

.

•

...,„/ 3

11100

0%1#

eill.

SO

44.

I,

.

,

REF. 40 -1 -2 -3 -4 -5 -6 -7

DESCRIPTION

PART NUMBER

Remote Ground Control Box Assembly Junction Box Toggle Switch Decal Plate Plug Control Cable Connector Assembly .

Toggle Switch

--

QTY

21181 21165 8510K2, 21075 77P 21094 2522 8511K2

.

-

, .

1 1 1 1 1 1 1 1

•

.

.

.

.

4.9o7a--

FIGURE 41

L.P. GAS (OPTION)

FIGURE 41

L. P. GAS (OPT ION)

, REF

•

PART NuriDER

DESCrZIPT1ON

CITY •

41-

L.P. Gas(Option) Elbow Vapor Hose Carburetor Vacuum Switch Bushing Vapor Cylinder Strap Valve Valve Elbow H.P. Hose Assembly Nipple .

Tee

-1 -2 -3

4

-

-5 -6 -7 -8 -9 -10 -11 -12 -13 • -14 -15 -16 -17

• •

' '

.

-

H.P. Hose Assembly Solenoid Fuelock Converter

•

.

PH305E 1/2 DG-20 503UC24Q2L-102 1501K 3325x2 33-1CC Vert.

TB-3 7141M 7141F 49 x 6 1533-14 48 x 6 3700 x 4 1533-56 F201 L-416-12V 50C

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

.

. .

i .

.

%

.

• .

-

,

.

.

• .

. .

•

,

..

FIGURE 44

REF. 44-2 -3 -4 -5 -6

AIR HOSE AND REEL ASSEMBLY (OPTION)

DESCRIPTION Mr Hose and Reel Assembly Socket Male Connector Roller Guide Air Hose Outer Boom Hose Reel

PART NUMBER

I QTY

1 8800 85 77-IA 3/8 x 250 PSI x 35 ft.

(Reference) S D -4A2-03

2 2

FIGURE 45D

L.P. GAS OPTION

(SER. NO. 2205-ON)

FIGURE 45D

I nu 45D-1 -2 -3 -4 -5 -6 -7 -8 -9 - 10 - 11 - 12 - 13 - 14 - 15 - 16 -17

L.P. GAS OPTION (SER. NO. 2205 - ON)

DESCMPTION L.P. Gas Option (Ser. No. 2205 - ON) Elbow Vapor Hose Carburetor Vacuum Switch Bushing Vapor Cylinder Strap Valve Valve Elbow H.P. Hose Assembly Nipple Tee H.P. Hose Assembly Solenoid Fuelock Converter

I

PART ilMIZER

PH305E 1/2 DG-20 503UC24Q2L-102 1501K 3325x2 33-1CC Vert.

TB-3 7141M 7141F 49 x 6 1533-14 48 x 6 3700 x 4 1533-56 F201 L-416-12V 50C

QTY 2 1 1 1 1 2 2 2 2 3 2 3

•

FIGURE 46 - AUXILIARY POWER SUPPLY - OPTION

3 *" ■ / • 441 N

Cll;

)

k,

,.S. ‘ I ■

c Or

■ (

'''

0■42 ,

...4.

I 4I %.y.. %.........

... .°.

%0•/N /'.J 1'

I' e..i.

,

/

I's , ..V.i...

I .„‹ , I:' ‘.,....,../ '1, -I , , i 27 G I i , t1 F l- . -1 1: 14I I I I i I 1 I Q.,., 1 II 11 1 l' • 1 l.,

26

25

1 .

-_ I

I

..,

,>i

-1 1

I I J

I

■4.• \

• 1

„..

`I -If I r•tri

t,

24 1 Ice- /1':-'11 . ., t : ':.-' 11 23 11

.-

19

20

■.„...

l. _ /

22

40 41

4. , \\

'j

21

30

-10..

1 \ \ ,* : .v\ \ \ \\ \ \ BASKET CONTROL BOX

31

II 11 II 41

1

I I

GROUND CONTROL BOX

5 13

air q yl

FIGURE 46 - AUXILIARY POWER SUPPLY - OPTION

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

DESCIZIPTION

PArZT NUF:IBER

Auxiliary Power Supply Option Tube Assembly Mounting Plate (21117) Priority Flow Regulator (13-A-32-F-6) Female Connector Check Valve Reducer Elbow Three Way Solenoid Valve Lockwasher Hex Nut Male Run Tee Reducer Elbow Check Valve Female Connector Reducer Tube Assembly Tube Assembly Mini-Pak Valve Rework Assembly (21222) Tube Assembly Solenoid Valve (FPS-4013-R1800-12VDC-ET) Female Elbow Check Valva Male Branch Tee Female Adapter Connector Male Connector • Priority Flow Regulator (13-15-4) Turret Weldment (21022) Tube Assembly Male Elbow Hydraulic Pump Hex Head Cap Screw Lockwcsher Male Elbow Tube Assembly Tube End Reducer Male Branch Tee Plug Decal "Auxiliary Hydraulic Power" Toggle Switch Battery Cover Battery Hex Nut Lockwasher Hex Nut Lockwasher

21243 21234-74 Reference Reference 8-8GTX-S CMM305 0201-8-6 2103-6-6 8-3-3-12VDC

1 1 1

1/4

2 2

1/4-20UNC 8 RTX-S 0201-12-8 3/4CD CMM355 12-GTX-S ' 12-8TRTX-S 21234-76 21234-75 Reference 21234-77 Reference 2203-8-10 . • 3CM13-4-3 1/2MMS-S 0502-88 0503-6-8 0103-8-10 Reference Reference 21243-9 2103-6-8 53-0304101 3/8-24U N FX 1 3/8 2103-8-8 21243-8 12-8TRTX-S 12-STX-S 06C-12 21230 8834 K5 21259 759 5116-18 UNC 5/16 1/4-20 UNC 1/4 •

C1TV

1 1

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

1 1 1 1 1 2 2

1 1 2 2 2 2 0/275/

/

FIGURE 46 AUXILIARY POWER SUPPLY - OPTION

(Cont'd)

FIGURE 46 - AUXILIARY POWER SUPPLY - OPTION (CONT'D)

REF .

-48 -49 -50 -51 -52 -53 -54

DE$UZ1PTI©N

PART NUMBER

!'..1" Bolt Battery Hold Down Battery Cable (Negative) Battery Cable (Positive) Solenoid Battery Cable (Positive) (To Engine Solenoid) Hydraulic Tank

5/16-18 UNC x 10 ' 1/4 x.1-1/4 x 1-1/2 x 23 A-19-1 A-53-1 24059 A-32-1L (Reference)

•

QTY 2 1 1 1.

1

1 1

• -

' •

.

.

.

• '

.

•

•

4

•

'

.

dworrim,

A

3//

75/

FIGURE 47 OIL COOLER

,

.

.

v

1

....---3

,10 1,,,.,t--, , 4106..

2

„

•

/

O

•••

12 ,

ii

...

13 14 /

*V-40' 111„, -.!

-.0.4

...-

%\

---..) ,

■

illh ill,1 pi: 0" 1

.... .... ..

.....

■

i `1

....

1

\

,,- ,,-\ e'ANINIL-

il

10

r

1

.

,....,

•

i {

, ''.

t

.

ce► ,, .

:

i

... ..... ....

.,..

!!

•

:. -

'

.

.

- :IP ;:l

'11214' " 6

•

•

11 REF. -1 -2 -3 -4 -5 -6 -7 -8

DESCRIPTION

-

V

Oil Cooler ' Baffle Shroud Hex Head CapscreW Lockwasher Mounting Kit Oil Cooler 45° Elbow Hose Assembly

• V ,

-9 -10

Filter Assembly (SAF29G 16) Hose Assembly

-11 -12 -13 -14

• Union Tee (12-JTX-S) Mini-Pak Valve Rework Assembly (21222) 90° Elbow .

• Bushing (0102-16-12) . .

-

••

PART NUMBER

.

.

. .

.

21238 .

21248 21247 1/4-20 UNC x 1/4 1/4 K-103 10424-R1 2023-12-12 A1HAl2-12NJ x 12NJ -64 (Reference) A1HAl2-12NJx 12NJ 53-1/2 (Reference) (Reference) 2103-12-12 (Reference)

QTY 1 1 1 4 4 1 1 2 1 1

1 1 1 . 1 • 1 1

-

.

• 94;' 7 4

FIGURE 48

REF.

-2 -3 -4 -5 -6 -7 -8

AIR CLEANER RELOCATION

DESCRIPTION

PART NUMBER

Air Cleaner Relocation Flex Hose Hose Clamp Air Intake Tube (Modified) Hose Clamp Hex Head Cap Screw Lock Washer Air Cleaner Lock Washer Hex Head Cap Screw Air Cleaner Baffle Plate Original Air Cleaner Mount Location

FM-15x24" 4-7907 U-120 x 6" L K-8 5/16-20 UNF x 3/4 5/16 LO-157-151 1/4 1/4 x 20 UNF x 1/2 21263 (Reference)

QTY

2 1 1 3 3 4 4 1

FIGURE 49

HAND EMERGENCY BLEED DOWN INSTALLATION

20

18 11 •

9 8

INSTALLATION WHEN COMBINED WITH AUXILIARY POWER SUPPLY OPTION

15

■

1 •••*"

-•

OR 11

13 14 //

17

its

// //

11

REF 49-

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

I/

DESCRIPTION Emergency Bleed Down Installation Bushing Tee Tube Assembly (21218-37) Topping Cylinder (21014) Hose Assembly Decal "Emergency Only - Boom Lowering Valve - Keep closed when not in use Round Head Screw Star Lock Nut Elbow Valve Hose Assembly Male Connector

PART NUMBER

QTY

0102-6-4 RTX-6-6-4 Reference Reference HI-EC06-06Nix06N..121

1 1

21264 10-32 x 2-1/2 10-32 2103-6-6 10M015T D7-EA04-04Nix04 NJ-36 0103-4-4 /// 7 :

1 1 1 1 2 2

1 1 1 1

HAND EMERGENCY BLEED DOWN INSTALLATION

FIGURE 49

REF

DESCrZIPTION Bushing Elbow Bracket 90° Swivel Elbow Union Tube Assembly Female Elbow Elbow

-13 -14 -15 -16 -17 -18 -19 -20

PART NUMBER 0102-12-4 2103-4-4 21265 3903-6-6 0303-6-6 21218-57 2103-4-4 3103-6-6

•

.

• '

.

•

. . ,

.

, • .

.

4.

.

1 1 1.

1 1 1 1 1

.

.

.

•

QTY

.

• FIGURE 5)

.:1.;00tv't SAFTTY STO) AND CAN..E SENSOR INSTALLATION (SOLENOID VALVE SYSTEM)

FIGURE 50 BOOM SAFETY STOP AND CABLE SENSOR INSTALLATION (SOLENOID VALVE SYSTEM)

.

REF 50-

1

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

•

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

.

DESCRIPTION

Boom Safety Stop and Cable Sensor Installation Toggle Switch - Reset Decal "Sensor-Reset" Switch Bracket Relay ' Lockwasher F lat Washer Round Head Machine Screw Stop Plate Bushing Grease Fitting Ratchet Shaft Side Plate Spring Arm Spring Guide Spring Side Plate Ratchet Shaft Lever Clevis Solenoid Outer Boom Hex Head Cap Screw • • Lockwasher Intermediate Boom , Stop-Lug Hex Head Cap Screw •Lockwasher Cable Sensor Assembly Micro Switch Spiro! Pin Spring Spiro! Pin ...

Locknut • Hex Head Cap Screw Bearing • Cotter Pin • Flat Washer Roller Swing Arm Bracket Solenoid Switch Push Switch - Reset Toggle Switch - Throttle

•

PART NUMBER

8828K13 21411 21410 KUP11055 No. 632 No. 632 No. 632 21508-3 .21508-6 7600 21508-5 21508-2 21508-7 21508-8 21685-1 21508-1 21508-4 21511 SA841-12 (Reference) 1/4-20 UNC x1/2 1/4 (Reference 21101-9 5/16-18 UNC x 3/4 5/16 21209 BZE-2RN 34992-6 21692 34992 1/4-28 UNV 1/4-28 UNF x 3/4 FB-812-6 34462 1/2 21507 21506 21505 24059 SA21WDx1 8510K9

QTY

1 1 1 1 4 4 4

1

2 2 1 1 1

1 1 1

1 1 1 1 4 4 4 19 2 2 1

1 1 1 1 1 1 2

1 1 1 1 1 1 1

DIESEL ENGINE INSTALLATION

FIGURE 51

____....

51-1 -2 -3 -4 -

5

-6 -7 -8 -9 -

-

10 11

-12 -13 -

-

14 15

-16 -17 -18 -

19

-20 -21 -22 -23 -24 -25 -26 -27 -28 -29 -30

-31 32

-

-33 -34

-35 -36 -37 -38 -39 -40 -41 -42 -43

PART NUMBER.

D ESCR 1PT 10 N

REF

Diesel Engine Installation (Reference) Counter Weight 1/2-20 UNF x 2 Hex Head Cap Screw Support Bar Mounting Bracket 1/2 Lockwasher 1/2-20 UNF Hex Nut (Furn. with eng.)

Hex Head Cap Screw (fum. with engine) Lockwasher • Rear Engine Mount Bracket 5/8-18 UNF x 1-3/4 Hex Head Cap Screw Lockwasher 5/8 Counter Weight Mount Bracket Control Box Support Bar 3/8 Lockwasher 3/8-24 UNF x 1 Hex Head Cap Screw (Fum. with engine) ' Hex Head Cap Screw (Furnished with engine) Lockwasher (Furnished with engine) Flat Washer Side Engine Mount Bracket (Reference) Hand Emergency Bleed Down Installation (See Fig 49) 21180 Muffler Cage WD-86 Muffler 9 inch Nipple x 1-1/4 Pipe 0155-41-03.12 MI Manifold Assembly 21299 Upper Blower Duct 10-32 X 3/4 Machine Screw 21298 Lower Blower Duct 1/4-20 UNC Hex Nut 21249 Hood 1/4-20 UNC x 3/4 Hex Head Cap Screw Solenoid Kill Switch Installation Solenoid Mount Bracket Hex Nut Engine Kill Switch Arm Lockwasher

OTY

1 2 1

1 2 2 4 4

1 4 4 2

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

12 1 4 1 4 1

1

' 1/4-20 UNC (Reference)

5 1

1/4 1/4-20 UNC x 3/4 SA-841-12 5/16-18 UNC

5 5 1 2

Clevis

5/16

1 1

Flat Washer Clevis Pin Cotter Pin Tab Link

5/16 5/16 1/8 x 1

Hex Head Cap Screw Solenoid Hex Nut Extension Tube

.

.

.

3 1 1 1

1

FIGURE 52

.)

TUI7,ET PORPORTIONAL VALVE SYSTEM INSTALLATION

4 • \ 71 1/\ 1 1-

1---- (+'4-..1. -:::,7-77-7 ,, , --, ,/ \\,7 -, ',:": :, , 7-7, . :- 1. :.-. . c---, , ,,, 4 j...---/\,., If. "\, \: 1- ..F4fl• r'Ll ,i . ._''\• N .., ,LL, 0 Lil l q . .

..---;"'---

,.,... `•

INC14

\

_.„.

1

);

N N ........."-

C

-.—•,:ts, \N.

1;4'./7

1 -, .,

---',....,.., ''‹.4. / /

_

I

'---, , /— 1' , ,,

::

7

CY

‘

441/2

Olt 1

,', VI C9/ _.

/

(7 -

I ii

t •C;71.1

il'At gt''',.. ...............

..,......„,... \

ii -.. ..,

- :,

• ,,,,---,... , , '

3! . . ', 1; ; .: ' ' •1 \

Cl

11

- • -...-; ' 1 : • ,,

,•

.

,

.---

•

-

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,._'

—•

- '-_,'

. - '-'''' \ ...„, ' .,.... s ..••• • Pow ...., -*.• „y , '.;

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/ i' - - 0

- , . ,

_ .:• / i.,,,..--------- ,

..,...._..., -... . .2:N -

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r., '26.....

P.,

, .

7"-'----- . ,:''-:-•%--<:,

cp

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it) el

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)

'.'-,; •:•\ : -1' ___..---:j

elP..

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OZ.

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It)

Nl:____ /1 „L—.--/

_ .„..7- ,•• , 'R. XV"14

-

\ (? .

NO

-.;-'

IF) /,-,' CI rf) \ co \ /

--...- ..--../tf, ),„, ,-.-/:,------, - :2;.-T-. .r.: -7 r="", Le'

,.

\

,0

-., - .- — ..,. ,fi. q)

,.

•, , , Cl \ .--'22-• 2 -- --- / \%. .....Z..........................4;;T) \N: :lit .i• --..:., , ,•,--.1? ' 1 .L.."- -- .‘ --7.1 - V

•,, 177

Li _

„

/

• C4 r-

\''.

FIGURE 52 TURRET PROPORTIONAL VALVE SYSTEM INSTALLATION

REF 52-

, PART NUMBER

DESCRIPTCON 1

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

Proportional Valve Styem Installation Hose Assembly - To Operating Valve Hose Assembly - To. Operating Valve Hose Assembly - to Master Leveling Cylinder Hose Assembly - To Basket Leveling Slave Cylinder Bulkhead Tee Bulkhead Union (with platform rotation Option only) Hose Assembly - To Holding Valve Hose Assembly - To Holding Valve • Hex Head Cap Screw Washer Hydraulic Panel Extension Tab Hydraulic Panel Extension Cover Hydraulic Panel Hose Assembly Solenoid Control Valve Holding Valve •• 0-Ring Elbow .

Tube Assembly Elbow •• Reducer • •• Filter .

Reducer Elbow Hose Assembly - To Charge Pump Hose Assembly - Extension Hose Assembly - Topping -Swivel Elbow Valve •• 0-Ring Elbow Hose Assembly - To Pump Adapter with Filter Adapter 0-Ring Adapter Proportional Control Valve 0-Ring Adapter Gap 0-Ring Elbow Hose Assembly Adapter Tube Assembly Tube End Reducer

.

1/2-20 UNC x 1/2 1/4

Tee

..

.

'•

2103-6-6 0102-12-6 TC68GK12 0102-1208 2103-8-8 No. 6 x 39 No. 8 x 66 No. 6• • x 43 2103-4-6 NMF-20B 2503-12-12

1e.

Adapter ,_(,S .edepends

:

-

port

size)

1 2 2 1 1 3 1

TRTX-12-8

1 2 6 4 5 1 2 2 2 1 1

JTX 12 12

1

-

.

.:c)ls,a___ 1 I co..t21_11g

1 1 3 1 4 1 1 1 1 1

1

(Furnished with Prop.

Contr. Valve) TRTX-8-6 0503-12-8 242998 0503-6-6 R771-S 2503-6-4 No. 4 x 20 0503-6-8

-

Tube Assembly Tube Assembly Tube Assembly Tee Adapter

4 4 3

1 21551 No. 6 x 39 5116-16C-16-12VDCETAGb 257206-SAE 2506-6-6

-

..

1 1 2 2 2 2 1

(Reference) (Reference) WJJTX-6-6 WTX-6-6

i -32 -33 -34 -35 -36 -37 -38 -39 -40 -41 -42 -43 -44 -45 -46 -47 -48

CITY

0503-4-4 0503-12-12 or -8-12

1 1 1 1 2' 2

NOI1V11V1SNI WRSAS 3A1VA 1VN011A0cql0d nani

Zg Hfleld

FIGURE 52 TURRET PORPORTIONAL VALVE SYSTEM INSTALLATION

REF -49 - 51 - 52 -53 -54 - 55 - 56 - 57 - 58 - 59 - 60 - 61 -62 - 63 -64 - 65 - 66 - 67 - 68 - 69 - 70 -71 -72

7 73

.-74 7 75 - 77 - 78 -79 - 80 -81 - 82 -83 .-84 -85 -86 -87 - 88 -89 -90* - 91 -92 7 93 -94 -95

DESCMPTCON Adapter Hose Assembly Tube Assembly Adapter Hose Assembly - To cooler (No. 12 x 27) Elbow (2103-12-12) Reducer (0102-16-12) Tube As Adapter Pressure Cap PI ug Pipe Plug Plug 0-Ring Elbow Swivel Elbow Hex Nut Lockwasher Bracket Hex Head Cap Screw Elbow Charge Pump Elbow Chain Coupling Half

Key Sheave Belt Hose Assembly Sheave Key Pump Adaptor Hex Nut Lockwasher Adaptor Plate Spacer Pump Elbow Hex Head Cap Screw Hose Assembly Adapter Reducer Elbow 0.-Ring Elbow • Hose Assembly Adapter Bushing Street E I bow

PART NUMBER 0303-12-12 No. 12 x 27 0503-10-8 (Reference) (Reference) (Reference) (Reference) No. 4 P5ON-12 1/2 Flush P5ON-12 (MOD) 2503-12-12 3903-6-6

C7TZ10145-A 2103-8-12 P-46 2103-8-12 6015 6015 (with 2-4-1741 Splined End Yoke Section Insert)

38 IN.

21123

PR-24 2503-6-4 No. 4 x 45 0103-2-4 0503-10-12 3903-12-12 2503-20-20 No. 20 x 16-1/2 0103-20-20 1-1/2 to - 1-1/4 1-1/2

QTY 1 2 1 2 1 1 1 1

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

1 1 1 1 1 1 1 1 4 4 1 2 1 1 4 2 2 1 1 1 1 1 1 7-7

FIGURE 52 TURRET PORPORTIONAL VALVE SYSTEM INSTALLATION

DESCMPTION Gate Valve -96 Close Nipple - 97 Hose Assembly -98 Reducer -99 - 100 Elbow Elbow - 101 - 102 Tube Assembly -103 Valve - 104 Tube Assembly - 105 Elbow Solenoid • - 106 - 107 Hex Head Cap Screw -108 Lockwasher

PMT NUMBER

M-208

FIGURE 53

PLATFORM PROPORTIONAL VALVE SYSTEM CONTROLS

PLATFORM PROPORTIONAL VALVE SYSTEM CONTROLS

FIGURE 53

PART NUMBER

DEESCE1IPTION

EF

QTY

....,....

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

Platform Proportional Valve System Controls Screw • Lockwasher Control Box Cover Toggle Switch Push Button Switch - Start Push Button Switch - Stop Connector Assembly Hex Nut • Lockwasher Flat Washer Connector Assembly Cable Assembly Hex Head Cap Screw Receptacle Box Mount • Plate Receptacle Box Mount Bracket Decal "Boom-Up-Down" Decal "Boom - CW-CCW" Extend - Retract" Decal "Boom Decal "Drive-Forward - Reverse" Bolt Controller Pack End Bracket Hex Head Cap Screw LOckwasher Flat Washer Moog 'Control ler Electrical Cable - To Inner Boom Cable Assembly - To Receptacle Box Receptacle Box 11-0 Volt (Option) Junction Control Box Fork Weldment Hex Head Cap Screw 4.

Control Box Guard

1032 x 1/2 1032 8511 K2 . MS25039-ICB MS25039-ICR 2546 114-20 UNC 1/4 1/4 CGB-193 063-60695-3 1/4-20 UNC x 1/2

21514-4 21514-1 21514-3 21514-2 1/4-20 UNC x 20 3/8-24 UNF x 3/4 3/8 3/8 86A126H 21095 18-4 FSA-1 (Reference) 1/4-28 UNF x 3/8 21563

.

. .

.

.

•

• .

.

•

.

.

.

1 8 8 1 3 1 1 1 2 11 15 6 4 5 1 1 1 1 1 1 • 2 1 2 2 2 4 1 1 1 1 1 2 1

OQ1VE

.T1 LT :3)

raj

FLOM) Cea NI can PC) C,ISocK 4 K '5 ii5.• tJ 5.5

STEE

SLAVE

MILS-

2-k-1

BRAKE RELEASE CYLINDER

•

(OPT ► ON1 21051)

m F.2o.

TU12. QaT.

LI

EXTE t\ISIOW .

r L

• Ce,,T

PLAT. 20T.

egt

t2b.C,,47. 1-11t7.. I

-J

r

-

I

211C 1 L..1 %=!CI W.! tCC,

CV1AnLYN1.l 1,Ac•jores

s°' 2 '4 ..4.-C..4-2!!...3

7-"Z 41.-rr .2210•2.

-

gr.

ROTARY COUPLING •

L

„,AF .2 a 15

.2 GPM

I ROTARY COUPLING.

if PA.L.,..)

I 13 1.E C DOWN

ill-TI

I

r

-1

L- 1

71-11-11 1 F..`'tEa

L F

P24-)1;:t=)Cc.TtO1JA.t_

r'' L- 1

"U11111111141"

T czc)L. Vt LVE 24 a 99 8

Vt,k.

HAY cL1-1,1 cont.c2,

2r

NOG 2 41, R

• ■.:.•AF

25P31.

eie. %C•..

MFP *TC 68G14

V.10 E GGA21Om p

I)

MFP TC GeGK 16

.1C>,• ►4 tOwe,raze pomp 1•12 PC2.- 24 •

ct.c; "

laV

1

tzp, .. 4. 114..216c -16_;:v4vr-,c- ETZ..!9_s

4o.LvV.: 4 01 ?..0.4 54,

r

r

7, 71

fa pm • P44.

41

X. I 1

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Bertea Industrial Division July 1980

Service Manual

Remote Controller Model No. 264360

M!!!!!

Fluidpower

SERVICE MANUAL MODEL 264360

TABLE OF CONTENTS

I.

INTRODUCTION

II.

TECHNICAL DATA •

III.

OPERATION

IV.

INSTALLATION

1

2

ELECTRICAL CIRCUITS

V.

TROUBLE SHOOTING

VI.

SERVICE

Bertea Industrial Division Costa Mesa, California 92626

.

4

7

.

9

Fluidpower

SERVICE MANUAL MODEL 264360

I.

Page 1

INTRODUCTION

The model 264360 single axis controller provides a remote control station for Bertea electrohydraulic proportional valves. The unit operates from any 12 volt DC power supply and is wired directly to the pilot valve. This manual describes the configurations for single station control and multiple station control of one pilot valve.

•

II.

TECHNICAL DATA

Supply Voltage Supply Power

12 volt DC 0.0 watts @ lever center with microswitch 2.8 watts @ maximum command position

Output ..... . • ± 3.6 volts @ 60 ma (With controller connected to the 60 ohm coil) Micro Switch Rating

Bertea Industrial Division Costa Mesa, California 92626

5 amp @ 12 volt DC

Fluidpower

Page 2 III

OPERATION

A Center position loOk feature is incorporated in the lever to prevent accidental operation of the controller. By depressing the center lock button (see Figure 3), the lever is free to move in either direction. This depression of the button also actuates a microswitch that applies battery power to the electrical circuit of the controller. When the switch is not actuated, the controller is electrically off.

Movement of the lever from the center position will rotate the potentiometer thru a gear drive to provide an output command as shown in Figure 2.

60 50 40 CURRENT FLOW IN MA WITH 60Q COIL

30 20

10 30°

20°

10° 10°

20°

30 °

10 20

HANDLE ROTATION (DEGREES)

30

40 50 60

REMOTE CONTROLLER OUTPUT FIGURE 2

The micro switch provides not only the zero current flow configuration at the center position of the lever but also the capability of triggering secondary function when that controller is used. Secondary functions such as warning horns, solenoids, lights, etc., are activated when the button is depressed and are held on whenever the lever is out of the center position.

Bertea Industrial Division Costa Mesa, California 92626

EIEM

Fluidpower

Page 2

III

OPERATION

A Center position loOk feature is incorporated in the lever to prevent accidental operation of the controller. By depressing the center lock button (see Figure 3), the lever is free to move in either direction. This depression of the button also actuates a microswitch that applies battery power to the electrical circuit of the controller. When the switch is not actuated, the controller is electrically off.

Movement of the lever from the center position will rotate the potentiometer thru a gear drive to provide an output command as shown in Figure 2.

60 50 40 CURRENT FLOW 30 IN MA WITH 600 COIL 20 10 30°

20°

10°

10°

20°

30 °

10 20

HANDLE ROTATION (DEGREES)

30 40 50 60

REMOTE CONTROLLER OUTPUT FIGURE 2

The micro switch provides not only the zero current flow configuration at the center position of the lever but also the capability of triggering secondary function when that controller is used. Secondary functions such as warning horns, solenoids, lights, etc., are activated when the button is depressed and are held on whenever the lever is out of the center position.

Bertea Industrial Division Costa Mesa, California 92626

Fluidpower

SERVICE MANUAL MODEL 264360

Page 3

CENTER LOCK PUSH TO RELEASE

INSTALLATION The basic controller (without case or top cover) will attach under the top surface of the vehicle console if the cutout shown in Fig. 3G is provided. The 1.312" diameter permits passing the controller knob and boot through the mounting panel without disassembly.

UNDERSIDE OF MOUNTING PANEL REF.

ELECTRICAL WIRING The size of the connecting wire should be selected so that the total wire resistance does not exceed 3 ohms (5% of the coil resistance). Resistances for common wire sizes of stranded copper wire include the following.

The outside diameters of the cable should not exceed .500" as noted. Smaller size grommets for the cable strain relief are available.

(Consult factory)

8.2

CABLE COUPLING H"'i- 1.4

AWG

RESISTANCE

WIRE GAGE

OHMS/1000 FT

POT

WIRE

TERMINAL COLOR

REF

FUNCTION

REF

FIGURE 3E

FIGURE 3D 20 18 16 14 12 10

10.54 6.64 4.17 2.62 1.65 1.04

Red Black White Green Orange

#1 #5 #2 #4

Battery +12V DC Battery -12V DC Pilot Valve Coil Pilot Valve Coil Micro Switch Function

.218 DIA 4 HOLES

1.125 -.1 of

r...?/ - 1.312

i . 4,,--1",./ 4,1

____, 1\750

DIA

1.25 6

INSTALLATION FOR CASE ASSEMBLY UNIT 1.

2.

3.

4.

5.

6.

Lubricate cable O.D. with a silicone base lubricant in area of strain relief fitting to facilitate feeding cable through fitting.

Feed wire leads through strain relief fitting as shown in Fig. 3B prior to crimping terminals.

Strip cable jacket and cut wires to lengths noted in Fig. 3A or 3B. Attach #248502 terminals (AMP #327043) to wires and connect to terminal board.

Insert controller assembly into the case with the orientation shown in Fig. 3D. Secure gasket and cover with four (4) 8-32 x .38 long screws.

. 06 R ---*/'-- L._ '-.- 32 58 :17 8 0-1j TYP

.188 DIA 6 HOLES

FIGURE 3G

BASE PLATE OF HAND CONTROLLER CASE FIGURE 3F

4.718 5.0

•••••

r

4.125 3.5

3.906 .406

AS REQ'D

ATTACH TERMINALS THIS SIDE r COI L SW

CABLE O.D. .375 TO .500

H 25 TYP

DUAL

--ir

LACK GREEN

0

0

0

O

O

3 0

0

0

TERMINAL BLOCK & CIRCUIT BOARD FIGURE 3A

Bertea Industrial Division Costa Mesa, California 92626

WHITE

11

2.500 3.312 II

RED ORANGE (MICRO SWITCH)

3

FIGURE 3B

STRAIN RELIEF AND CABLE SEAL

—FIVE (5) CONDUCTORS 18 GA. TOP COVER .406 HAND CONTROLLER CASE FIGURE 3C

EIMI

Fkidpower

Page 10 SERVICE MANUAL MODEL 264360

SERVICE Boot Replacement - In order to replace the boot, the plunger assembly and the knob must be removed in the following manner.

1.

Remove the micro switch bracket assembly if one is included. (14)

2.

Remove the knob cover. (1)

3.

The plunger assembly (2) is held into the lock pin (12) by the #6-32 screw (13).

Loosen this screw and pull the plunger assembly clear of the knob. (4)

4.

Remove the knob (4) by rotating it counter clockwist to unscrew it from the shaft.

5.

Remove the #8-32 screws that clamp the boot (9) to the case cover. (7)

6.

Pull the flanged portion of the boot (9) through the slot in the case cover (7) and off the end of the shaft.

Installation of a new boot is accomplished in the reverse sequence.

1.

Lube shaft with a compatible lube.

2.

Install the boot (9) over the end of the shaft and pull the flanged portion through the slot of the case cover.

Note: The top surface of the small portion of the boot should be 1-3/4 inches from the top of the case cover. The boot shape should be free and not distorted.

3.

Replace the #8-32 screws to clamp the boot (9) flange between the case cover (7) and clamping plate. (10)

4.

Replace the knob. (4)

5.

Place the button return spring (3) into the hole in the knob (4) and insert the plunger wire assembly (2) through the knob. (4)

6.

Place the lock pin (12) into the slot with the threaded end opposite to the potentiometer. Feed the plunger wire (2) through the hole in the lock pin.

7.

With the plunger wire (2) extended approximately 1/16" through the lock pin, (12) tighten the #6-32 screw (13) to clamp the wire in place. The slot on the opposite end of the lock pin (12) is for a screw driver to resist the torquing load on the #6-32 screw (13)

8.

Check the assembly by depressing the button rotating the lever.

9.

Replace the micro switch assembly (14) and adjust as required.

10.

16

15

Replace the knob cover. (1)

Bertea Industrial Division Costa Mesa, California 92626

BOOT REPLACEMENT FIGURE 12

MI

Fluidpower

SERVICE MANUAL MODEL 264360

Page 4

SINGLE STATION CONTROLLER FIGURE 4 IV INSTALLATION ELECTRICAL CIRCUITS In order to provide single or dual station control with one controller, the circuit board contains diodes for circuit isolation plus an open circuit to provide the optional configurations. Figure 4 shows the use of a jumper strip required to complete the circuit for single station control.

The external hookup to the terminal block for the (2) battery wires, (2) pilot valve wires and auxilary functions for the standard controller with a micro switch is shown in Figure 5. When installing the controller into the 264399 case, the wire terminals should be attached to the terminal block on the same side as the letters as shown in Figure 3A.

WIRING FOR CONTROLLER WITH MICROSWITCH FIGURE 5

Bertea Industrial Division Costa Mesa, California 92626

Fluidpower

Page 5

If for some reason, the microswitch is not desired, the required connections are shown in Figure 6. This will eliminate the electrical off feature when the lever is in the center position and will result in a power drain of approximately 130 ma.

WIRING FOR CONTROLLER W/O MICROSWITCH FIGURE 6

When multiple station control for one pilot valve is required, an optional circuit board with diodes is used to isolate the multiple controllers without adding selector switches to the circuit. This circuit board contains the (2) fixed resistors plus (3) diodes as noted. The electrical schematic is shown in Figure 7. The external hookup to the terminal block for multiple station control requires one controller to be the prime unit and the others to be slave units as shown in Figure 8. The slave unit has the ground connection and jumper removed.

It is noted that the Model 242900 controllers should not be used as the prime unit in combination with the Model 264360 units.

C

NO

I- --I + 1 I AUX SW

2000 e-•-"AAr--9-Wr--•

85/ 85/ 1COIL

F-

IDUAL L _

JUMPER FOR PRIME UNIT (Remove for slave units) MULTIPLE STATION CONTROLLER FIGURE 7

Bertea Industrial Division Costa Mesa, California 92626

ElEn

Fluidpower

MODEL 264360 CONTROLLER #1

MODEL 264360 CONTROLLER #2 FROM SWITCH

- AUX

■

FROM SWITCH

U NCO L 1 D UAL

N CO

AUX

L1 DUAL

O

0

■ NOTE: JUMPER MUST BE REMOVED ON CONTROLLER #2.

.

tr TO AUX. FUNCTION

1

P.V. COIL (60Q) TO AUX. FUNCTION

1iIiIt 12 VDC BATTERY

(OR) MODEL 242900 CONTROLLER #2 (OPTIONAL) DO NOT INSTALL AS PRIME UNIT MULTIPLE STATION FIGURE 8

A Model 264360 controller for the prime unit usage contains a jumper between the "DUAL" terminal and "COIL" terminal. This jumper is removed for the slave unit. The model 242900 controller for the slave unit is wired as noted.

SERVICE MANUAL MODEL264360

■ JUMPER

a-

-

Page 7

V.

TROUBLE SHOOTING

Electrical circuit trouble shooting, with the standard single station controllers, checks the battery voltage, microswitch operation, and potentiometer circuit output to the pilot valve. Figure 9 shows the typical connections required to use a volt/ammeter to check the circuits.

+

BAT. --

AUX

SW

COIL 7

•

DUAL

9 9 0 9_9

O

/I / 1

METER IN SERIES

( 1

1

1

BAT. VOLTS

METER IN PARALLEL1

O

PILOT VALVE

1 L

■•■••••

4111/111••

■=1■9 011.11■

.1•■■■

MICROSWITCH

O CIRCUIT CHECKOUT FIGURE 9

A.

Ccirrect supply voltage (12 volts is checked by connecting the volt meter in parallel to the (+) and (-) terminals as

B.

The micro switch is wired to operate as a normally open switch. Connect the voltmeter in parallel to terminal (+) and (SW) as shown. The micro switch is actuated by depressing the button in the lever knob, which in turn moves the • lock pin against the actuation leaf of the switch. Button depressed should provide 12 volts and button released (with lever in center position) should open the circuit to zero volts. Switch adjustment is shown on Figure 10.

Bertea Industrial Division Costa Mesa, California 92626

Fluidpower

SERVICE MANUAL MODEL 264360

V.

Page 8

TROUBLE SHOOTING (Continued)

LOCK PIN

VIEW ."A"

SWITCH CLOSES AFTER 0.140 TRAVEL

SEE VIEW "A"

MOUNTING PLATE

MICRO SWITCH ACTUATION ADJUSTMENT FIGURE 10

The switch should be open in the button up (or released) position and should be closed at 0.140" travel of the lock pin. The switch should always be closed prior to the lock pin clearing the detent slot that is provided in the mounting plate.

Adjust the switch actuation by loosening the #4-40 cap screws and moving the switch bracket assembly left or right as required. After proper switch actuation is obtained, torque cap screws to 4-5 in-lbs.

C.

Connecting the ammeter in series with one pilot valve wire from the "COIL" terminal board connection as shown in Figure 9 will check the output command of the potentiometer circuit.

With the control lever in the center position and the lock button depressed to close the micro switch, the ammeter should show a 0 to + 3 ma reading. Then as the lever is moved from the center position, the command signal should increase on a curve as shown on Figure 2 to a maximum command position of 55 ma to 65 ma. If the test shows no output command with lever rotation and it is confirmed that the pilot valve is good, then the potentiometer assembly will have to be changed.

Bertea Industrial Division Costa Mesa, California 92626

Fluidpower

Page 9

V.

TROUBLE SHOOTING (Continued) Since the gear is attached to the potentiometer shaft with adhesive, adjustments and potentiometer replacements must be made as a complete assembly, including the mounting bracket. This assembly Part Number 272357 is shown on Figure 11.

Figure 11 VI.

A failure of the diodes in the multiple station controller circuit board will result in the test showing a significant reduction in output command versus lever rotation. This results from the additional resistance being added to the circuit. The failed circuit will be in the unit not being operated during the test.

SERVICE

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

MODEL #264360 CONTROLLER (See Figure 12) .

PART NUMBER DESCRIPTION 249868 249824 242982 242956 8-32 x .5 lg 8-32 x .5 ig 249867 242954 242955 • , 242961 272357 249821-7 249869-3 249838-5 264399-13 249886 264363-1 264363-3

Bertea Industrial Division Costa Mesa, California 92626

,

Cover, Knob Plunger Assembly Spring Knob Screw, Pan Head Slotted (4 req'd) Screw, Pan Head Slotted (6 req'd) Cover Plate, Flat Gasket, Cover Boot Clamping Plate Potentiometer & Gear Assembly Lockpin Cap Screw, Soc. Hd. Micro Switch & Bracket Assembly Case Cover Flanged Circuit Board - Single Station Circuit Board-Multiple Station

Fluidpower

°Transportation Equipment

BOliciVARNER

Power Wheel Service Manual Model 6

gear reduction drive for farm, industrial and off-road equipment

Warner Gear Division of Borg-Warner Corporation

Disassembly of Power Wheel STEP 1

Slide the coupling from splines on input shaft,

(Figure 15).

STEP 2

Position the assembly upright on face of spindle.

STEP 3

Remove the disengage cover, (Figure 14).

STEP 10

Remove input shaft from spindle. Remove the snap rings, washers, and spring from input shaft only if replacement is required.

STEP 11 STEP 4

Remove bolts and large cover, (Figure 14).

Disengage plunger usually remains with cover. Remove plunger and "0" ring from cover or end of input shaft.

STEP 5

A thrust washer will usually remain in position on thrust face of cover.

STEP 6

Remove sun gear and thrust washer from end of input shaft, (Figure 12).

Remove the six bolts from hub and ring gear and remove ring gear.

STEP 12

Remove the large snap ring from in front of the tapered bearing and lift hub from spindle. If bearings are not a loose fit, it may be necessary to press spindle from hub.

STEP 13

Remove the oil seal and bearing cone from hub.

Inspect bearing cup in position and remove only if replacement is required.

STEP 7

Remove primary carrier. The sun gear may be removed from carrier assembly by expanding the snap ring located inside of carrier and sliding sun gear out of snap ring and carrier.

STEP 8

Remove the small snap ring from input shaft,

(Figure 9).

STEP 9

Remove the secondary carrier assembly. It may be necessary to remove the ring gear first, if difficulty is encountered in removing the carrier.

CARRIER ASSEMBLIES The pinion shafts were staked in position in early carrier assemblies and for this reason, disassembly of the pinion cage assemblies was not recommended. A snap ring is now used to retain the pinion shafts in the primary and secondary carrier assemblies. The new assemblies can be disassembled and individual components may be replaced as required.

Assembly of Power Wheel

A

STEP 1 Press a new bearing cup, 11 (Figure 1) in each side of the hub.

STEP 2

Assemble a bearing cone into cup at seal end of hub and press a new seal into hub, (Figure 2).

Figure 1 Press bearing cup into hub

Figure 2 Press oil seal into hub

A

Position spindle upright STEP 3 11 on bench as shown, (Figure 3).

STEP 4

Lubricate lips of seal and lower hub onto spindle. Hub should be centered as it is lowered over hub to prevent seal damage, (Figure 4).

Figure 4 Lower hub onto spindle

Figure 3 Position spindle on bench

STEP 5

Assemble bearing cone over spindle and into bearing cup.

Select the thickest snap ring that can be assembled into ring groove of shaft above bearing cone, (Figure 5). Bearing should have from .000.009 inches (.00—.29 mm) end play i when proper snap ring is installed.

STEP 6

Assemble a snap ring in one of the grooves of input shaft.

Assemble a washer, spring, a second washer and a second snap ring in the other groove of input shaft, (Figure 6). Some shafts have a shoulder and require only one snap ring.

Figure 6 Assemble disconnect spring

Figure 5 Assemble snap ring

SECONDARY CARRIER

STEP 7

Assemble the splined end of the input shaft down into spindle, (Figure 7).

STEP 8

Assemble secondary carrier splines over splined end of spindle, (Figure 7).

STEP 9

The thrust washer, (Figure 8) remains with secondary carrier and is usually not removed.

Figure 7 Assemble input shaft & secondary carrier

Figure 8 Thrust washer shown in position

STEP 10

•

Apply a bead ' of RTV compound to hub face that mates with ring gear. Assemble the end of ring gear having six bolt holes against hub with bolt holes of hub and ring gear aligned, (Figure 9).

Assemble the six 3/8-24 x 1-7/8 inch hex head bolts and tighten to specified torque.

STEP 11

Assemble the snap ring in groove of input shaft, (Figure 9).

Assemble a snap ring inSTEP 12 to innermost groove of sun war.

Assemble sun gear splines into splines in carrier, (Figure 10).

ir

Figure 10 Assemble snap ring

Figure 9 Assemble snap ring

STEP 13

4

Spread the snap ring which should be held centered as sun gear is assembled into position.

Snap ring should be seated in groove of sun gear, (Figure 11).

STEP 14

Assemble the primary carrier and sun gear into ring gear, (Figure 12). It will be necessary to rotate carrier and pinion to align sun gear teeth with secondary pinion and primary pinions with ring gear teeth. Assemble the small sun gear over input shaft. Rotate sun gear to align shaft to gear splines and gear teeth.

STEP 15

Assemble the small thrust washer over input shaft and against shoulder of shaft, (Figure 12).

Figure 12 Assemble thrust washer

Figure 11 Assemble snap ring

STEP 16

4

Assemble an "0" ring in groove of the disengage plunger.

Assemble plunger over end of input shaft and against thrust washer, (Figure 13).

COVER

DISCONNECT COVER

STEP 17

Lubricate the "0" ring in groove of disconnect plunger.

Assemble the thrust washer with tangs engaged with cover. Apply a bead of RTV compound to end face of ring gear. Assemble cover over plunger as holes of cover and ring gear are aligned, (Figure 14). Assemble the eight 5/16-18 x 1 inch hex head bolts. Tighten bolts to specified torque.

STEP 18 Figure 13 Assemble disconnect sleeve

Assemble the disengage cover as shown if wheel is to be used to drive the vehicle, (Figure 14).

Assemble and toraue the two 5/1618 x 3/4 inch bolts.

Figure 14 Assemble cover and disconnect cover(

STEP 19

Invert the Power Wheel assembly and assemble the coupling with end having splines extending to end of coupling located in as shown, (Figure 15).

TO DISCONNECT POWER WHEEL FROM SHAFT. To disconnect the wheel from input shaft, assemble the disengaged cover with the dimpled center protruding inward as shown, (Figure 16).

Figure 16 Disconnect cover in disconnect position

Figure 15 Assemble Coupling

LUBRICATION RECOMMENDATIONS

TOWING VEHICLE

Observe lubrication recommendations given by the original equipment manufacturer. When specific recommendations are not available, use mild extreme pressure lubricant SAE No. 80 or 90 for filling the Power Wheel.

The Power Wheel will not normally be damaged by towing; however the hydraulic drive components may be damaged unless the Power Wheel is disengaged from the drive motor.

Road speeds in excess of 25 MPH should be avoided unless clearly specified to be permissible by the equipment manu-

SPECIFICATIONS Approx. Weight

facturer.

103 lbs. (46.7 kg)

Oil Capacity

30 oz. (840 ml.)

RTV SEALING COMPOUND Silastic RTV 732 sealer and General Electric Silmate RTV No. 1473 are currently recommended for sealing gasket surfaces.

MODEL 6 POWER WHEEL BOLT TORQUE CHART

PART NO.

BOLT SIZE

WHERE USED

BOLT TORQUE

BOLT TORQUE

LBS. FEET

Nm

0000179816

5/16-18 x 3/4

Disconnect Cover

10-20

13.6-27.1

0000179818

5/16-18 x 1

Cover to Ring Gear

20-25

27.1-33.9

0000181378

3/8-24 x 1-7/8

Hub to Ring Gear

39-49

52.9-66.4

INDEX NUMBER

PARTS LIST FOR MODEL 6 POWER WHEEL

1 2 3

4 5 6 7 8

.... 9 10 11 12 13

14 15 16 17 18 19 20 21 22 23 N.I. 24 25 26 27 N.I.

28

29 30 31 32 33 34

35 36 37 38

39 40 41 42 43 44 45 46 47

PART NUMBER 14-02-089-003 14-02-089-006 14-02-189-002 14-02-189-004 14-02-079-004 14-02-079-005 14-02-079-006 14-02-079-007 14-00-044-010 14-00-044-012 04-01-101-35 04-01-102-12 14-00-183-005 14-00-183-006 14-02-179-004 14-02-179-005 14-02-179-006 04-01-102-12 04-01-101-17 0000181378 14-00-047-002 14-00-139-028 14-00-139-029 14-00-139-030 14-00-139-037 95-04-138-01 14-02-193-002 14-02-156-001 14-02-162-003 14-02-193-001 14-00-131-003 14-02-053-001 14-02-163-007 14-02-163-004 14-02-193-001 95-04-138-01 14-02-659-007 14-02-659-013 14-02-159-005 14-02-159-008 14-02-193-004 14-02-165-003 14-02-165-009 14-00-139-020 14-00-139-033 14-02-659-009 14-02-659-011 14-02-659-012 14-02-659-014 14-02-659-015 14-02-159-003 14-02-159-006 14-02-159-007 14-02-159-009 14-02-159-010 14-00-139-019 14-00-139-033 95-04-138-01 14-02-042-002 95-04-138-01 14-02-193-001 14-02-163-005 14-02-163-006 14-02-163-008 14-02-163-009 14-02-163-010 14-00-131-002 14-02-193-001 14-02-042-001 14-02-165-005 14-02-165-007 14-02-165-008 14-02-165-010 14-02-165-011 14-02-193-003 95-04-115-01 14-02-193-005 10-00-141-113 0000179818 14-02-052-002 14-02-039-004 14-02-039-005 0000179816

PART NAME OR DESCRIPTION Coupling — 13 teeth Coupling — 15 teeth Input shaft — 13 teeth Input shaft — 15 teeth Spindle Spindle Spindle Spindle Oil seal Oil seal Bearing cone Bearing cup Wheel bolt — 9/16" Wheel bolt — 1/2" Hub Hub Hub Bearing cup Bearing cone 3/8-24 x 1-7/8 Hex hd. bolt Flat washer Retaining ring—selective Retaining ring—selective Retaining ring—selective Retaining ring—selective Retaining ring Washer Disengage spring Ring gear Needle rollers Separating ring Planetary gear - 27 teeth Planetary gear - 29 teeth Thrust washer Retaining ring Secondary carrier assembly Secondary carrier assembly Secondary carrier Secondary carrier Thrust washer Sun gear-19 teeth Sun gear-22 teeth Retaining ring Retaining ring Primary carrier assembly Primary carrier assembly Primary carrier assembly Primary carrier assembly Primary carrier assembly Primary carrier Primary carrier Primary carrier Primary carrier Primary carrier Retaining ring Retaining ring Retaining ring Pinion shaft Retaining ring Thrust washer Planet gear — 27 teeth Planet gear — 28 teeth Planet gear — 24 teeth Planet gear — 26 teeth Planet gear — 30 teeth Needle roller Thrust washer Pinion shaft Sun gear-19 teeth Sun gear-22 teeth Sun gear-22 teeth Sun gear-25 teeth Sun gear-16 teeth Thrust washer Thrust washer -Disengage plunger "0" ring 5/16-18 x 1 Hex hd. bolt Magnetic plug Cover — large Cover — disengage 5/16-18 x 3/4 Hex hd. bolt

O'n,<). <e;-(2.

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1

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1 1 9

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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 1 1 1 1 1 1 1 1 1 1 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 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 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 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 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 1 1 1 1 1 1 1 1 1 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 102 102 102 102 102 102 102 102 102 102 102 102 102 102 102 102 102 102 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 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 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 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 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

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1 1 3 3 3 3

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51 3 3 1

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3 51 3 3

3 51 3 3

51 3 3

3 51 3 3

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51 3

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1 1 1 1 8 1 1 1 1

1 1 1 1 8 1 1 1 1

1 1 1 1 8 1 1 1 1

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1 1 1 1 8 1 1 1 1

1 1 1 1 8 1 1 1 1

1 1 1 1 8 1 1 1 1

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1 1 1 1 8 1 1 1 1

1 1 1 1 8 1 1 1 1

1 1 1 1 8 1 1 1 1

1 1 1 1 8 1 1 1 1

1 1 1 1 1 8 1 1 1 1

1 1 1 1 1 8 1 1 1 1

1 1 1 1 8 1 1 1 1

1 1 1 1 1 8 1 1 1 1

(0 s

o'V Off'

45

SUBJECT: GASKETS AT EACH END OF RING GEAR REPLACED BY SILASTIC 732 RTV ADHESIVE/SEALANT AND REMOVAL OF THE OIL LEVEL PLUG IN THE SMALL COVER. The large gaskets used at both ends of the ring gear have been removed and Silastic 732 RTV adhesive/sealant is

The oil level should be maintained at the level of the

now used at these two locations on all Power Wheels. The

necessary to rotate the wheel to a position where the plug

horizontal center line of the Power Wheel, therefore, it is

Silastic material is much thinner than the gaskets which

in the large cover is on the horizontal center line of the

were removed, therefore, two additional (three) gaskets

wheel. The hole is used to fill the wheel and check the

are required under the small cover to compensate for the

oil level.

reduction in end play of the gear sets in these assemblies.

The changes just described may be used when older units are serviced. No gaskets are required under the small

To summarize: 1. Power Wheels with a large gasket at each end of ring

cover on Model 6 Power Wheels which have the quick

gear should use the small cover with a pipe plug and a

disconnect.

single gasket.

2. Power Wheels without large gaskets but using Silastic

The 1/2-14 pipe plug part number 03-04-101-01 has

732 RTV may use the small cover with the filler plug

been removed from the small cover and the dimensions

and three small gaskets or the small cover without the

of the cover have been changed to permit a single gasket

filler plug and one small gasket.

to be used when Silastic 732 is used at each end of the ring gear. The cover without the pipe plug should never be used when gaskets are used at each end of the ring

3. Never use the small cover without the filler plug when two large gaskets are used at ends of ring gear.

gear.

HORIZONTAL CENTER LINE

FILLER PLUG

co Q

6 6.

Warner Gear

cN, e-uj

BORG

WARNER

°Transportation

Equipment

Division of Borg-Warner Corporation P.O. Box 2688, Muncie, Indiana 47302 Telephone: 317/286-6100 Telex: 027-491

cr 0 cc

BoRimunie Transportation

Warner Gear

Equipment

Division of Borg-Warner Corporation P.O. Box 2688, Muncie, Indiana 47302 Telephone: 317/286-6100 Telex: 027-491

September 15, 1977

INSTALLATION & SERVICE BULLETIN SUBJECT: GASKETS AT EACH END OF RING GEAR REPLACED BY SI LASTIC 732 RTV ADHESIVE/SEALANT AND REMOVAL OF THE OIL LEVEL PLUG IN THE SMALL COVER. The large gaskets used at both ends of the ring gear have been removed and Silastic 732 RTV adhesive/sealant is

The oil level should be maintained at the level of the horizontal center line of the Power Wheel, therefore, it is

now used at these two locations on all Power Wheels. The

necessary to rotate the wheel to a position where the plug

Silastic material is much thinner than the gaskets which

in the large cover is on the horizontal center line of the

were removed, therefore, two additional (three) gaskets

wheel. The hole is used to fill the wheel and check the

are required under the small cover to compensate for the reduction in end play of the gear sets in these assemblies.

oil level.

The changes just described may be used when older units are serviced. No gaskets are required under the small

To summarize: 1. Power Wheels with a large gasket at each end of ring

cover on Model 6 Power Wheels which have the quick

gear should use the small cover with a pipe plug and a

disconnect.

single gasket.

2. Power Wheels without large gaskets but using Silastic

The 1/2-14 pipe plug part number 03-04-101-01 has

732 RTV may use the small cover with the filler plug

been removed from the small cover and the dimensions

and three small gaskets or the small cover without the

of the cover have been changed to permit a single gasket

filler plug and one small gasket.

to be used when Silastic 732 is used at each end of the ring gear. The cover without the pipe plug should never be used when gaskets are used at each end of the ring

3. Never use the small cover without the filler plug when two large gaskets are used at ends of ring gear.

gear.

HORIZONTAL CENTER LINE

FILLER PLUG

1B112

W.S.I. BRAKE ACCUMULATOR

.

-._ .

,1 14 AA.

INIALIIIIKIIMENIM111.111111111111111 rr4:

1111111p

011111111111111111= W.11 4101111r _ _ _ IIOM '

illIlrl I

Aid

" A..N .i0:4/MEM Pi - I I li LI1,,/WA I■I I I■11 I I I RI I I I I ■■11 SI 11 I I 11 I I I Ll I MI I I I I I 1 1 I I ill .47.

7

REF.

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

-13 -14

8

9

DESCRIPTION

10

11

12 13 PART NUMBER

QTY

Brake Accumulator Retaining Ring Port Cap 0-Ring Piston Screw Retaining Ring Back-Up Ring Cylinder 0-Ring Back-Up Ring Spring Nut

B-63251 A-63284 A-63243 A-62844 13-63244 A-63285 A-63286 A-63248 B-63245 A-63253 A-63254 B-63249 B-63250

,, 1 1

Cylinder Cap Air Vent

B-63246

1

A-63486

1

1 1 1 1 1 1 1 1 1

12I

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

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

0

a)

14

0 3

15

iiui 37

46

0

39

uti=111: 1 , 1 It "aro ikorAirdsvit

24

43 32 3 22 241818 3017

•

4 15 B2

11 12 4442 13 41

113D(103 21 0 33dS

47

3 35 3134 33

BR30-1 SPEED REDUCER

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

DESCRIPTION

j

PART Nu:.=

CT Y

Housing-Worm Assy Cover-Housing Assy 23476 Worm Gear Worm-Right Hand Shaft-Output 22585 Cup-Brg 22584 Cone-Brg

81548 81549 23476 23644 23645 22585 22584

1 1 1 1 1 2 2

Thrust Ring Retainer Spacer-Bearing MU7-502DG Shield Dust 23482 Key E0501 Pipe Plug 23483 Seal-Shaft 5025-12AN Capscrew MU7-45DG Gasket MU7-402R Snap Ring 1885002 0-Ring S043-15PH5 Capscrew 5043-15A Capscrew S031-08PH5 Capscrew A043 Lockwasher 7/16 A031 Lockwasher 5/16 2558001 Relief Valve 58-RD6-1 Reducer BSHG ED121 Pipe Plug MU7-134J Plug Expn Coupling - Brake Shaft Brake MU7-450 Cover Brk Plate Brake End MU7-148-7 Friction Disc 23480 Brake Rotor MU7-153 Pressure Plate My7-156-0 Spring Assy MU5-151A Woodruff Key M5-157 Wm Brk Adi Nut Coupling-Motor Adaptor-Motor 22471 Dowel Pin 45-TED-2 0-Ring Gasket 23108 Gasket-Motor S050-05PH5 Capscrew A050 Lockwasher

23648 23649 23650 21959 23482 18010 23483 23857 21640 11454 21033 21253 21135 11766 11025 11024 10074 18066 18009 11412 23651 23652 21591 23653 11426 23480 11431 81081 11385 11599 23654 23655 22471 12465 23669 23108 10009 11026

2 2 2 1 2 2 1 2 2 2 1 4 4 6 8 6 1 1 2 1 1 1 1 1 2 1 1 1 2 1 1 1 2 1 1 1 2 2

5 PORT ROTARY COUPLING

INSTALLATION PROCEDURE FOR TEFLON RINGS

EQUIPMENT NEEDED: 1.

Heating container (NESCO oven or equivalent).

2.

One (1) pair of heat resistant gloves.

OPERATION: 1.

Insure coupling is free of foreign matter.

2.

Place teflon rings in oven until 300°-350° is reached. CAUTION-Do not exceed 500°.

(Rings should turn dark in color and become elastic.)

3

Grasp a ring (using gloves) and slip over end of coupling to groove.

CAUTION-- Do not stretch rings as they will not return to size.

Speed is essential before contracting occurs.

Insure ring is not twisted when installed in groove.

NOTE: Rings that are loose on coupling can be sized by compressing with suitable hose clamp.

SP.4/15/77

Bulletin No. 2-3310-4

michigan fluid power T-line filters for low-pressure systems Choice of models with Twin-Life' patented wire cloth dual element or polymer-coated "throw-away" paper element.

For 20.69 BAR (300 psi) operating pressure.

S

I

%,1 41 4. if ;II

'Pit 4 t 414 n n" t.'

1• 49 1, 6 0"0:''), t) 4 1, 61 0r,'f.",,Of ‘01 ,,ii • o - f. PD -1 1

NfVA

;e t ) II e n r) t - gi f ch b° 4 it i ► ri F P li t i OA a,n) . f- I rif f, !. ipt h,,

NATIONAL

FLUID POWER

Su — is i)

ASSOCIATION

r p ';

I)

1

L S ib (1 • p t "

I AM E3AC

Industries Incorporated FLUID POWER SYSTEMS DIVISION 511 South Glenn Avenue

•

Wheeling, Illinois 60090 Phone: 312-541-3000

Michigan'. T-line filter assemblies . . your best -protection against damage by contaminants. Choice of precision "throwaway" paper element or "Twin-Life" wire cloth dual-element--each designed to keep your fluid system clean longer for top performance. With up to 20.69 BAR (300 psi) operating pressure, lowmaintenance T-Line filters are rated at up to 114 Liter/Min. (30 gpm) flow, depending on allowable pressure drop. In compact installations, less than 25.4 mm (1") disassembly clearance is required to replace or clean the dirty element. Many accessories and options offer added convenience and protection: precisiongrade by-pass valve . . . protective magnet . . . vacuum indicators ... compound pressure gauge .. . Viton seals ... and top mounting holes.

TT-LINE FILTERS Maximum protection for hydraulic, lubrication and other fluid systems

, 4 t

SERIES'

Polymer-coated paper "throw-awayr element

assures. fine filtration down to 10 microns

TC Series filters have a high-grade pleated paper element,

designed for use with petroleum and most water-base fluids. Element is constructed with corrosion-resistant metal end-caps, protective exterior perforated metal support, and integral gasket for leak-proof sealing.

Replacement elements are easily installed for low-cost maintenance.

2903 sq. cm 450 sq. in.

2903 sq. cm 450 sq. in.

C69

Pressure differential/flow characteristics (average)

1.1,P in BAR psi

.97 14 .83 12

.69 10

Flow data shown below was taken from laboratory tests using petroleum-base 225 SSU hydraulic oil at 29.4°C (85°F). Pressure differentials were measured across 25,4 mm (1") filter inlet and outlet ports.

k A B •• ass valve cu • 1.03 AR (15 • setttn Asmil 11111rAllirr.

11WW0 Bypass valve Curve .69 AR (10 fleM1111 pprill

.55 8

See ordering information on page four for complete order number, by-pass valve setting, connector line size, accessories, and dimensions. By-pass valve is optional.

)pyright 8 1971. AMBAC Industries, Inc.

.41 6

,

.40°

.28 4

..-

.14 2

GPM 1./Min.

10 38

20 76

30 114

40 152

Rugged Michigan'. T-Line filters provide outstanding performance in critical fluid power and lubrication systems. A wide choice of micron retention ratings meet demanding filtration needs. Choice of port sizes and mounting holes aid easy installation.

Precision die-cast construction and advanced design assure economy and convenience. T-Line filters are specified to protect automotive, agricultural, construction, industrial, material handling, chemical, petroleum, machine tool, processing, and automation equipment fluid systems.

To guard your system components against washing of collected contaminants downstream, Michigan'. filters feature an all metal by-pass valve. Self-contained in the filter head, this optional by-pass valve provides straightthrough flow. Available standard valve settings range

from pressure differential of .10 BAR (1.5 PSID) to 1.72 BAR (25 PSID).

Twin-Life" wire cloth - dual-element has

TF SERIES "up to 50% more dirt-holding capacity TF Series filters feature the patented "Twin-Life" wire cloth dual-element—actually two elements mounted coaxially in a single assembly. This unique dualelement provides 50% longer life between cleanings, because element area is 50% larger than comparable single-edge elements. Take-apart construction allows easy maintenance cleaning with less downtime.

• 1.111,,,,,,,M,,,Vir11.1

839 sq.cm 130 sq. in 1484 sq. cm 230 sq. in.

Pressure-differential/flow characteristics

(average)

Flow data shown below was taken from laboratory tests of a 140 micron element using petroleum-base 225 SSU hydraulic oil at 29.4°C (85°F). Pressure differentials were measured across 25.4 MM (1") filter inlet and outlet ports.

.28 4

See ordering information on page four for complete order number, by-pass valve setting, connector line size, protective magnet, other accessories, and dimensions. By-pass valve is optional.

.21

3

.14

2

.07

1

so -s"'‘s° , 0 sgCtl

14,34sQco‘23° sq.

111••■al

FLOW: GPM L/Min.

10 38

20 76

30 114

I

IAMBAC industries Incorp FLUID POWER SYSTEM'

Vacuum. indicator or pressure gauges Y.

shows element conditiorr at a glance~ Visual signal or remote signal vacuum indicators

monitor changing system conditions when mounted on Michigant T-Line filters — lets you know when to clean or change the element. Write for indicator Bulletin #2.5300-1, covering complete specifications.

Compound pressure gauge indicates psi increment vacuum conditions in inches Hg. and pressure conditions in two psi increments up to 6.9 BAR (100 psi).

T-Line filter with Red-Alertr visual indicator

T-Line filter with compound pressure gauge

ORDERINGINFORMA'TIOW--

- Typical: ordering number:- TC68GA2OGV

For T-Line filter assembly,

10 micron, paper element 1.72 BAR (25 psid) by-pass valve, pressure taps, (2), 1 1/4 NPTF, compound pressure gauge, and Viton seals.

order number, fill-in boxes below...

-•

•

Wire Cloth: (130 sq. in.) 839 sq. cm 40 Micron 74 Micron 150 Micron 262 Micron (230 sq. in.) 1484 sq. cm 40 Micron 74 Micron 150 Micron 262 Micron

"Floater" Vacuum Indicator

No Valve With Valve:

BAR PSID .10 1.5 .21 3

4h,

Compound Pressure Gauge

.34 5 .69 10 1.03 15 1.72 25

Top Mounting Holes "Locker" Vacuum Indicator

Paper: (450 sq. in.) 2903 sq. cm 10 Micron 25 Micron

Viton Seals

To order replacement elements, use numbers shown above, i.e.

"F22" and "C68."

Protective Magnet (for use with TF Series only)

Ordering Number

ION

11111111

(Specifications subject to change without notice.)

107 4.22

Optional 1/4 - 18 taps: (2 provided) A for pressure indicator; B for vacuum indicator 66.04 (2.6) --"4

AM BAC Industries Incorporated FLUID POWER SYSTEMS DIVISION

—

Islet A

Port

Port

- Outlet I

32.1. I (1.28)

206

511 South Glenn Avenue

•

Wheeling, Illinois 60090 Phone: 312541-3000

7

pert Port ( . dia .(Is)

(8.13)

8.

(Out)

839 sq. cm.

(130 sq. in.)

(Out)

257 (10.13) 1484 sq. cm .

(230 sq. in.)

Outlet B Init. A - -'

(Optional 3/816 mountinp holes)

20.69 BAR (300 psi) operating pressure, 5/8 rel

T.HD-LC-5M-2/ 76

housings are aluminum castings with

82.76 BAR (1200 psi) burst strength rating.

Printed in U.S.A.

Michigan Fluid Power

Bulletin 317

June 1 9 76

511 GLENN AVENUE, WHEELING, ILL 60090 • 312-541.3000 • Telex 25-2509

MICHIGAN ® T-LINE FILTER REPLACEMENT PARTS LIST for TC Series (Paper Element) and TF Series (Wire Cloth Element)

KEY

DESCRIPTION

A

Head assembly

B

By-pass veil) assembly (not :flown)

C

Bowl Bowl seal

E

Bolt

F

Element

G

1 - Element spring 2 - "X" magnet (not olown) 3- %" drainTiug 6 - "Floater" vacuum indicator 6 • "Locker" vacuum indicator

INDUSTRIOUS

T-LINE FILTER REPLACEMENT PARTS LIST for TC Series (Paper Element) and TF Series (Wire Cloth Element)

SPECIFiCATION

DESCRIPTION

A.

B.

V-14 NPTF ii"-14 NPTF 1-1 1 'A IIPTF 1Y4-111/2 NPTF • 1-1/13 Straight Thd. • 1-3/16 Straight Thd. • 1-5/16 Straight Thd. 1 1/2 psid 3 psid 5 psid 10 psid 15 psid 25 psid

HEAD ASSEMBLY Specify if required: 1. By-pass valve setting 2. Vacuum or pressure taps *Special Order BY-PASS VALVE ASSEMBLY (Factory installed; please specify head assembly part number.)

200500 2C0165 200166 200167 200168 200169 20N 70 "ft" "B'

SERIES

ALL

"C" "E" "F" "G" TF20 TF40/All TC

Buna-N Butyl Viton

2005'n 201832 2::li 831

ALL

BOLT

5/16" x 1%" bolts (4) 5/16" lock washers (4)

900478 901007

ALL

ELEMENT

Wits cloth (145 sq. in.): 40 mi. :-on 74 micron 140 micron 262 micron Wire 001:1 ;250 sq. in.): 40 micron 74 micron 140 micron 252 micron Paper (450 sq. in.,: 1C micron 26 micron

F22 F23 F25

r27

TF22 TF23 TF25 TF27

F42 F43 F.45 F47

TF42 TP43 TF45 TF47

C68 CE9

TC68 TC69

Buna-N seal

201651

ALL TC

1 - Element spring

200070 200475 2001S9 Std.

ALL TF ALL TC ALL TF ALL ALL ALL ALL

BOWL

D.

BOWL SEAL

E. F.

8.13" x 4.22" (inc. head) 10.13" x 4.22" (inc. head)

.

2 - "X" magnet 3 - Y." drain plug 4 - LP Iiiclicatoz 5 - "Floater" vacuum indictor 6 - "Locker" vacuum indicator

LIST PRICE

ALL

200147 200148

C.

G.

PART NUMBER

MF 360 ML 360

set (4) set (4)

...

..

(Specifications subject to change without notice.)

Bulletin No. 2-3321-3

CIISTP!CLITFD CY PAI_Jk-V! '‘:?(3-: HYDRAULICS, INC. 9G:hi r,, r.)73E HILLS ROAD WliTTIER. CA. 90601 692-6912

michigan fluid power

spin-a-filter MODEL SAF 50 SERIES

New low cost Spin-a-filter for low pressure return and suction lines.

VS/410AM FLUID pow" SOUTH GLENN A VE. H EELING, ILLINOIS

SAF-58

new T type line filter featuring the "Spin-AFilter" for fast and simple maintenance. Twist off the old element. Twist on the new. No bolts to remove.

No time-consuming cleaning operations.

Disposable filter element pays for itself with lower maintenance and downtime costs. Designed for most return line applications up to 189 L/ MIN (50 GPM).

Also for low flow, critical suction line applications.

To remove the element, just twist to the left. To install a new element, insert and twist to the right. Whole operation takes less than a minute.

Spin-A-Filter assemblies are furnished standard with

a by-pass valve and are available with 10 and 25 micron elements.

Integral by-pass valve protects element against line surges. 10 and 25 micron elements available as standard. 11/4" NPT port size. Available with pressure or vacuum taps for indicator. Two other series available (SAF20 and TAF50).

Please consult the manufacturer for details: Michigan Fluid Power, 511 South Glenn Avenue, Wheeling, Illinois 60090.

Phone: (312) 541-3000

AM BAC Industries Incorporated FLUID POWER SYSTEMS DIVISION 511 South Glenn Avenue

•

Wheeling, Illinois 60090 Phone: 312-541.3000

imensional data 137 5.38

Yi NPT INDICATOR

PORT BOTH SIDES (OPTIONAL)

METRIC METRIC/ENGLISH ENGLISH

28

24

48 1:875

114 NPT BOTH ENDS I

217 8.55**

S*

MICHIGAN FLUID POWER

*OPTIONAL 5/18-18 UNC-2B THD. —14- DEEP 2 HOLES .50

L **Add 25 (1.0) to both outside dimensions for element removal.

ineering data 11/4 NPT"

By-pass valve setting, (factory-set)... .1.72 BAR (25 PSID) Nominal size particle retention rating Operating Pressure

10/25 MICRON

.13.8 BAR (2C0 PSI MAX.)

' Optional by-pass valve settings

3 PSID 5 PSID 15 PSID

Flow UMIN

GPM

Average Pressure Drop t 25 Micron 10 Micron BAR PSIO BAR PSID

38 .08 1.2 76 .21 3.0 114 .38 5.5 152 .62 9.0 189 .90 13.0 t with 225 SSU Oil @ 29.4° C. (85° F.) (31 P Co) 0 0 0 0 0

Po rt Size

.24

.30 .48 .83 1.24

3.5 4.4 7.0 12.0 18.0

ring information STANDARD

OPTIONS

Filter assembly model SAF59G20 (25 micron) replacement element model S-59

Add "S" for vacuum taps (two provided)

Filter assembly model SAF58G20 (10 micron) replacement alement model S-58 3 PSID replace "G" w/"B" 5 PSID replace "G" w/"C" 15 PSID replace "G" w/"F"

Add "P" for pressure taps (two provided) Example: SAF59G2OP

AMBAC industries Incorporate' FLUID POWER SYSTEMS DIVIS 511 South Glenn Avenue

2/75

•

Wheeling, Illir Phone: "

ri-.

V1EW IANIS317.E.

1 5- / D - 00 77...

297Q17---4

z.

.

5TP,1-1P

10

114875-00

4 I O-RING A-11C0

10 1.1504G-00

RIVET 1\lktlEPLATE PISTON

11

9 0190(02-00 8 110491-00 116054 - 00 7 O

1145409-00

BLOCK

a

5EAT

114815-00 11456-1 -00 2

C5 Ppm 4 3 2.

I ITEM

No. PART N o.

BALL GUIDE BALL/GUIDE SUB-AWf

7003 14-00

I 14?-00 -OD 11 41g7- 00

STEEL BALL

a No. co O

SPRING PLUG PART NAME MATERIAL:

HEAT TREATMENT:

QZ, ECM 32A • ECK1 "NZ b5

NPR/ 32.1 11,11

ICIJOCIOPMA.1

II/29/73

CK

1%/2475

CK

4 -14-b re A TIC

Ak IOW

FINISH:

29NIT-G. NSSECIENLY MANIFOLD MOUNT LOCKVANLVE UNLESS OTHERWISE SPECIFIED:FRACTIONS ± .010 DECIMALS ± .005 ANGLES ± 1• ALL SURFACES

7-

RMS. MAX.

REMOVE ALL BURRS FILLETS .005 TO .010 R. BREAK CORNERS .005•010 REFERENCE POINT

@CALI

FULL DAWN

CHICAGO, ILL. MI MS

DO NOT SCALE] 72-2zit

A.XXX I CONCENTRIC TO

WITHIN .XXX T.I.R.

WATERMAN HYDRAULICS mar W. HOWARD •T.

"ICI" AIPPROVILD

7 00575-00

I

Is I (Di

DATE

1 E C-Nr11 EGA/ 4183

4-73-74 S.4-11

Act/ ACV

%I DIE rioutv-TINC, I-101E5 (4 PLACE

-NOTES

iii1:411111111

TIAD 14,.115..4r

- DELL PONTb

FOR 115 00 TOM

_2.

SEE 1E1 YOCA VALVE DANK DATA SHEET FOR. TESTING.

P

SYM1501...

Lo

o rco 5

12

1144 50- 00

11

100514-00

10

115914. - 00

6

ti4s-rtz-cio

116558

-

00

SOC NO CAP SCREW LOCK VALVE 1

PIPE PLUG.

1

ENO PLATE

is

/0/11Z1-04

0-RING .504-EN010 VALVE (4,111-

LOCKWAS14ER

5

114724- 00

8

4

114107 -00

8

HEIL JA11 taw'

5

It 1541-24

♦

TIE ROO

1151521- 00

2

FOOT

nag

1

PART PANIISIR

-n -

END PLATE

116519-00

115400-00

297T•4

18583 HALF

ASSEMBLY OUTL/IvE VALVE BANK

NAMEPLATE PART NAME

m•T•1•AL • • ►ICCAPICATION

raasH a s ► acorical1011

TOL ERANCIS tr... °maw... *PBC or Mu

DECIMALS: t .00111

=RN

(3 FRACTIONS: t V10

-

•

BANK)

*NCH- VI

t•

-

G•5

00 NOT SCALE

WATERMAN HYDRAUUCS ONO VC HOWAINP ST. CHOCA410. NJ. 'COY

[701759-P'

110.

alitvaioN 5CN 1457

yr

OMR 4-5)-74

'-9 CV

riciDEL _No.

Oo ON '4-

A

6-

5Ikb1C- MODEL No.-- I PORI SIZE- ( IN 11e Twb)

SPOoL. TYPE_ D.0 VOLTAGE.

IS

4 I

TERMINAL. (NOT SHOWN RIVET

115175-00

1 e

HEY. NO CAP 'SCREW

It 4724 -00

8

LOCIOdASHIR

701121

0514,11 - 00

2 1 1 t 2

WASHER SPOOL BLOCK 0-11114Cs TOM. Sub- ASS'

701121 -09

0 3 1110

701,21 - 00

031110 30

70n21-07

031110

2 2

COIL SNELL SPRING WASHER 0 RING

14 IS

1 15 2Z/ -00 11504(0-00 01 90ipt - 00

It 11 10

6

114335-00 114,50 8 -00

7 6,

114604-00 700557-0o

9

5 4 5

SEE TAN-E. 051105 - 00 100 t51-00 i 141572 -00 700000 - 00

2 2 2

tuditeLt.rL

MANUAL RELEA.E. AS•S1

101121 -II

bpilo -72

492+

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031110 - 60

49°1 L, -29 - rel 498 r- .0 - 29-45

45

-

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701121.06

031110.20

70,121 -05

031110 -la

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031110 .12

101 1 2i - 03

031110 -10

701121

701121

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02

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corn- Rot. No.

495T- (o 29- ro 49'31 .0-29-Z-1 4981-(0 29-20 498T - 6-29 - 19

49ST - (0 29- 1Z 4981-(0•29- ► 0 03wo-o4 4957,0 -29- 4.o 031110 -05 498T 43 - 29- 5

COIL No.

MODEL No.

NE CT /VaDY

7 0 1 1 24-00

498 T- 6 -29-X

-ASSEMBLY -

WATERMAN

l'''''' rULL MAIM Ws

D.C. IOTA•oll

Picket

SOLENOID

VALVE

(ce.Osi

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CENTER)

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00 NOR *bang 11•••

Mee Ix Newm.* R. Omemila N IM•O

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1701121 -0

CHAR-LYNN ® HYDRAULIC MOTOR "H" SERIES PARTS INFORMATION NO. 6-110

Char-Lynn Motor Parts Information PRODUCT NUMBER 101-1001-005 THROUGH 101-1088-005 (FORMERLY - X5X) (AND M-200-B)

PARTS DRAWING

Chart 1 Displacement **cu. in./rev.

2.89 4.34 6.04 10.04 11.64 14.56 17.47 23.31

Drive 602 602 616 616 616 616 616 616

Gerotor 5387-1 5387-2 5387-3 5387-4 5387-5 5387-6 5387-7 5387-8

Gerotor Width .25 .38 .52 .86 1.00 1.25 1.50 2.00

Spacer NONE NONE NONE 6901-2 6901-3 6901-5 6901-6 6901-8

Cap-Screws—Length 5389-1-1.50" 5389-2-1.62" 5389-3-1.75" 5389-4-2.12" 5389-5-2.25" 5389-6-2.50" 5389-7-2.75" 5389-8-3.25"

**See Page 4 for Product Number Cross Reference List

14 11 7

e_ 7

-I

24

Complete Kit

Base Block Mounting Kit

PARTS LIST

Part No.

Ref.

No.

Description

Screw, Cap 12 pt. Dr. 5/16-24 NF x 7/8 Seal, Dust Flange, Mounting (4 Bolt) ** 3 4 Flange, Mounting (2 Bolt) ** 6296 X5 Washer, Backup (Replaces and is Interchangeable with 5799) 6796 X6 20599 Seal, Quad X7 15048 Seal, 0-Ring 8 7462 Race, Bearing (Replaces and is Interchangeable with 866) 9 7537 Bearing,Thrust Needle (Replaces and is Interchangeable with 867) 10 14193 Key, Woodruff Shaft, Output ( Keyed,Includes Spacer 5662) 11 5367 12 ' 5367-12 Shaft, Output ( Splined,lncludes Spacer 5662) 13 Housing 6305-1 7/8" 14 Str. Thd. Ports 6305-2 1/2" NPTF Ports Manifold Mount 6305-3 X 14 15007 Seal, 0-Ring 15 Plug, Housing 20817 16 Spacer — ( Included with Shaft P/N 5367 or 5367-12 1 5662 17 * Drive 18 5414 Plate, Spacer 19 * Gerotor Set 20 * Spacer 21 6481 Cap, End X 22 6049 Washer, Seal 23 * Screw, Cap 12 pt. Dr. 5/16-24 NF. 23.1007-0W Base Block Kit (1/2-NPTF) Optional on 24 motors with manifold mount only.

23-'338.001 Base Block Kit (7/8-14 Str. Thd.). Optional on 24 motors with manifold mount only.

Seal, 0-Ring 15058 X 25 21046-2 Screw, Cap 5/16-18 NC x 1 1/2 26 NSS Port Block 27 X Seal Kit — For all motors (contains parts indicated by X) 60038 5777 844 843

1

X2

-

X— Seal Kit (See 60038)

5534 1 -

*

—

See Chart 1 on opposite page for part numbers of specific models

Seal Kit, Butyl, includes two (2) seals for port block For use with certain fire resistant synthetic fluids.

CAUTION: Check for compatability with fluids before using.

** Previously manufactured with roll pins, reassemble without roll pins, instructions with Seal Kit 60042.

Qty. Per Unit 4

Recommended Spare Parts Per 100 Units 1 Multi Kit #60517

1

1 1

3 3

1 1 1 1 2 1 1 1 1

5 3 3 3 2 1 2

1 1 1 1 1 1 1 7 7 1

3 3 3 3 5 ea. displ. size 3 ea. displ. size 3 1 Multi Kit ea. displ. size

2 4 1 10

NSS—Not Sold Separately.

CHAR-LYNN e HYDRAULIC MOTOR "H" SERIES 'ARTS INFORMATION 40. 6-110

HOW TO ORDER REPLACEMENT PARTS

**Product Number Cross Reference List

114' Prey.

Shaft

Displacement (cu.lrldrevl

04ydra u hc Connections

Old modoldunttord 1/2 NPTF

Each Order Must Include the Following Information: 1. Product Number 2. Date Code 3. Part Name 4. Part Number 5. Quantity of Parts

Straight Keyed

Pe Ode C t

7/8 x 14 SAE

4 Bolt Flange

Number

2.89

4.34

AA(M-201.8)

A8(M-202.8)

6.04

10.04

11.64

ACIPA-203-11) ACM-204-8) AG(M-2051)

ASA

AS8

ASC

AM

MG

101-1001.005

101.1002-005

101-1003-00S

101.1004-005

101.100S-00S

B51

85G

Old m.des Num"'

85A

8S8

85C

Product ftwoller

10140094105

101-1010-005

1014011-005

Ole Model homeme

GSA

C58

CSC

Product Nhoolor

1014011-005

1014018-005

101-1019-005

ASA-9

A58•9

A5C 9

1014045-005

101-1050405

101.1051-00S

101.1012-00S

ASM

ASK 101.1006-005

101-1007-005 857i

85K 1014014-005

1014013-005

C5E

17.47

14.56

23.31

AK(M-206-81 AM (M-207-8) AP(M-2011-81

101-1015-005

CSK

C5G

CSM

ASP 101.1006405 Hp 10140111-005 CSP

Manifold Mount

Old

Model Aerobe.

101.1020-005

1014021-005

AM 9

A5G•9

101.1022-00S

101-1023-005

A5K.9

AS44-9

101.1054-005

101.1055-005

1014024-005 ASP 9

1/2 NPTF Product

Old ream mums.,

7/8 x 14 Solined

Project Niewalet

.

1/2 NPTF

Flange

7/8 x 14 SAE

Product Num& rr

e508•9

8541.9

8SP 9

*

*

*

101.1060-005

*

101.1062-005

1014013-005

1014014-005

*

*

*

*

*

1014070405

OSA

058

OSC

101-1025-005

101-1026-005

101-1021-005

05E

Old MIONH Mumitou

GSA

G58

GSC

Product 4u015.

101.1033-005

101.1031-005

101.1035-005

Product mower 1

GSE

7 ,8 Splined

Available on Special Order Only-Consult Factory.

x 14

SAE

1458

CSC

1014042-005

1014043405

1014044-005 05E-9

050.9

0511.9

050•9

*

*

*

101.107i-00S

101.1077-005

101.1078-005

1014079.005

Old Model 4.05.,

G5A-9

658.9

G5C-9

Product Number

101-10111-005

101-1082-005

10140034105

*

*

Manifold

1450

14511

1450

KSA

Old Member

Product Number

101.1019-00S

1014035-005

101-1041-005

NNW 1/2 NPTF

GSM

G5K

101.1037-005

4451

05M 1014031-005

1014030-005

G5G

101-1034-005

*

0511

D5G 1014021-005

101-1022-005

1014045-005

1014047-065

101.11M4-00S

05K-9

*

*

*

*

*

.

CSP-9

CSK-9

Product Number

Old N.."(

Mount

101•054-00S

t951•9

Old Model Number

Maul

Manifold '

1014053-005

old Model Numb.'

Mount

2 Bolt

.

101.1052-005

-,

SAE

Manifold

Straight Keyed

0i01*.

GSM 9

101-1084-005

1014082-005

*

*

1014077-005 DSP 101.1032-00S GSP 101-1040-000 HSK 101-1044-005 0SP-9 101.1000-005 G5P 9 101-1088-005 *

Mount

000

Date Code

OIL LOH 1

Motors manufactured prior to March 1974 have product identification and serial number stamped on port face area.

Week of Year 1 Thru 52

Last Number of Year 197

Product Number

WOO

Product Identification Number

f-,

Non-Significant Number

000

Engineering Change Cooe

Eaton Corporation Fluid Power Operations Minneapolis Division 15151 Highway 5 Eden Prairie. MN. 55343 Telephone (612) 941-2800

Power Products FaX•N Ruid

REVISED JUNE, 1977 FORM NO. 6-110

INSTALLATION INSTRUCTIONS

OWNTER

HYDROTHROTTLE CONTROL MUNCIE PARTS MFG.. CO_, INC_ GENERAL OFFICES

ATLANTA DIVISION

CHICAGO DIVISION

P.O. Box 5.48 • Muncie, Indiana 47305 Phone (3171 284-7721

P

0 Box 43468 • Atlanta Georgia 30336 Phone (4041 349-4402

P

SEATTLE sub.:hap, 01 Man.* Pans MN Co Inc The Blackler Company • 317 So Bennett St Seattle, Wash 98108 • Ph (2061 763.2230

0 Box 66151 • AMP. 0 Hare 60666 Phone (3121298-6860

TOLEDO DIVISION

MUNCIE CANADA LIMITED

0 Box 6593 • Toledo. Ohio 43612 Phone (4191729-3861

P

P

0 Box 113. Mallon Station Mississauga. Ontario L4T 3B5 Phone (4161 677-9852 •Telex No .36.468841

PARTS LIST SERIES 90 THROTTLE CONTROL

'8

1

:10) :11,

9

2

3 4 w■I

PRESSURE SENSING PORT

•

A

—

1.11 4

B

YOUR THROTTLE ROD ,SIMULATED'

2 5

C

3

D

4

1

z

SectionAA

Mode 1-9010 Item 1 2 3 4 5 6 7 8 9 10 11

Description

Part No. 2-8124 2-9002 5322 5050 9004 2-9007 5049 8118 1-170211 2-170212 180960

MUNCIE PARTS MFG_ CO.., INC_

Bracket and Bolt Assembly Piston Assembly Nut, Jam 3/8 - 16 Screw 3/8 - 16 x 1-1/4 Spring Tension Adjusting Screw, Fulcrum Housing and Liner Assembly Screw 3/8 - 16 x 3/4 Speed Adjusting Spring, Leaf (3 required) Rod, Actuating, with Nuts and Set Screws Cable Assembly Clamp

MUNCIE • ATLANTA • CHICAGO • SEATTLE • TOLEDO • TORONTO

-2-

I. INSTALLATION OF THE THROTTLE CONTROL A. Introduction Refer to sketch shown with parts list, included on page 2.

One Throttle Control can operate an unlimited number of circuits, that are driven by the same pump discharge line in the hydraulic system.

The Throttle Control piston (2) senses the pump discharge line pressure. The pressure increases, and pulls the throttle open, when you operate a circuit to move a load. The pump by-passes, and allows the throttle to close when the valve circuit lever is returned to neutral.

The pressure must increase, above by-passing pressure, at least 15 PSI for each pound of throttle pull, plus the amount your by-passing pressure will vary, due to oil viscosity changes, over your oil operating temperature range.

Highly loaded circuits usually increase the pressure to a level far above the pump by-passing pressure, and produce a motivating force far beyond the minimum required to open the throttle.

Lightly loaded circuits, such as, when the boom is lowering, swing circuits, outriggers lowering, etc., produce the least pressure. The plumbing flow restrictions must be revised in these circuits if the load cannot increase the circuit pressure sufficiently above by-passing pressure to produce the motivating force

needed to open the throttle.

The pressure will increase at a greater rate as the engine speed increases because the plumbing relating to the circuits usually contain greater restrictions. A lightly loaded circuit may then become operable at a higher engine speed, if it did not operate at idle.

The motivating force can be increased by revising your plumbing, downstream of the throttle control connection, as follows: Restrict the plumbing relating to the circuits. (1) Add an orifice.

(2) Reduce diameter and/or lengthen line size. (3) Add a two-way check valve with a heavier spring in the direction of flow. This will increase pressure more at idle speed where needed most. It, therefore, is the best type of restriction.

Decrease your by-passing pressure. (1) Remove "bottle necks", and elbows.

(2) Increase diameter and/or shorten line size.

MUNCIE PARTS MFG_ CO_, INC_

MUNCIE • ATLANTA • CHICAGO • SEATTLE • TOLEDO • TORONTO

-3-

B.

Mounting Bracket One is furnished in the kit. Modify it to fit if necessary. Make the bracket rigid and mount it to your engine rather than another surface to prevent erratic operation due to flexing and/or movement.

Position the Throttle Control so the connecting cable is in line with the accelerator rod and pulls in the same direction.

C.

Pressure Connection to Pump Discharge Line Use a 1/4" minimum sized high pressure tube or hose.

Make the connection at the control valve inlet rather than the pump discharge so it will sense the lowest pressure. The pressure will then change by a smaller amount when the oil viscosity changes. The spring tension will also become more effective.

For cold climates, consider whether you need to add a heater to your reservoir and/ or shut off valve in this pressure connection to prevent high speed operation of your hydraulic components with cold oil. An oil temperature sensing switch would make them automatic.

D.

Engine Throttle Linkage Check Start the engine. Engage PTO to load the idling engine with by-passing oil pressure.

Try to reduce the engine throttle pull to a minimum. Make sure it is well oiled and in good repair. Check with the engine manufacturer whether the return spring load can be reduced if it appears to be excessive for its application.

When the engine has warmed up, make sure it is capable of returning to its proper idle speed after operating the accelerator. Make necessary adjustments now before the connecting cable is applied.

E.

Cable Slack Adjustment Refer to the sketch on page 2. Make sure the actuating rod (9) is still located in hole 4 as shipped.

Secure the clamp (11) to the throttle rod. -Engage the cable (10) eyelet to one of the clamp studs. Thread the cable through the hole in the rod, remove almost all slack, and secure it with the set screws.

Finalize the cable slack adjustment with the nuts provided on the actuating rod (9). The cable should have some slack but not excessive. Check to make sure the engine returns to idle after operating the accelerator.

MUNCIE PARTS MFG_ CO_, INC_

MUNCIE • ATLANTA • CHICAGO • SEATTLE • TOLEDO • TORONTO

-4-

F. Adjusting Procedure The spring rate is adjustable by moving the fulcrum screw (5) and changing the number of leaf springs (8). See table below for the possible variations. The spring rate increases as the variation number decreases. For instance, the table indicates the spring will be three (3) times stiffer with variation No. 2 than No. 3.

Variation Number

No. of Springs

Fulcrum Hole

1

3

A

3

2

3 3 2 2

B

3 2-1/2 2

3 4 5

C C D

*Turns

5/8

Spring Tension *Pressure 1100 780 640 370 300

Rate

Actuating Rod Hole Location

11X 3X Normal 3/4X 1/4X

4 4 4 4 4

* Note: Apply turns from when the screw (4) just begins to deflect the spring at zero load. Pressure is approximate when piston will begin to move.

The control was shipped with variation 3. Try it first. The adjusting procedure will direct you to another variation, if another is needed.

1, Disengage PTO. Turn in speed screw (7) until it touches spring (8). Then turn out one turn, temporarily, to limit stroke and prevent accidental racing of engine.

2.

Engage PTO. Air bleed sensing line by cracking fitting at Throttle Control. Proceed after oil warms up to within normal operating temperature range.

3.

Operate a highly loaded circuit valve lever. Bottom out a cyl inder to obtain system relief valve pressure if this is easier. The throttle will open.

4.

Make speed adjustment. Turn speed screw (7) in or out with the circuit loaded. Use the nut (3) to lock it when it regulates your desired speed.

Move actuating rod from hole 4 to hole 3, only if the spring should stop on the housing instead of the screw.

5.

Return lever to neutral. The throttle must close and the engine must return to idle. Check Trouble Shooting section, Part II, Section C. If unsuccessful, increase the spring rate, see table above,, Repeat entire procedure.

MUNCIE PARTS MFG_ CO_, INC_

MUNCIE • ATLANTA • CHICAGO • SEATTLE • TOLEDO • TORONTO

-5-

F.

Adjusting Procedure (Continued) 6. Determine which of the circuits produce the lowest pressure. Operate it and decide which of the following applies, paragraph 6a, 6b, or 6c. a. Throttle Opens and Closes Properly From Idle (1)

Finalize engine speed screw (7) adjustment by alternately operating the lowest and the highest loaded circuits. Lock nut (3) securely.

(2)

Operate and check all other circuits. They should operate because they are loaded between the highest and lowest circuits used for adjustments.

(3)

Installation is now complete.

b. Throttle Does Not Open From Idle Speed, but Will at Higher Speed Check if it will open at higher engine speeds.

(1)

Operate a higher pressure circuit lever to open the throttle and bring the engine up to speed, then operate the lowest pressure circuit lever.

(2)

If it stays open, after the higher pressure lever is returned, decide whether the required sequence of operation is acceptable.

It usually is acceptable. It now contains the highest spring setting.

(3)

If not acceptable, or if it did not stay open, proceed with step (c) below.

c. Throttle Will Not Open at All Make spring tension adjustment. Proceed as follows: (1)

Disengage PTO. Turn out screw (4) until leaf spring (8) is loose. Then turn it in until the spring just begins to deflect and is at zero load.

(2)

Engage PTO. The throttle will open.

(3)

Turn screw (4) in gradually. Count turns, and record as "B", until the throttle just closes. Do not overshoot and leave the screw at this point. Note how the throttle closed. If it closed suddenly, increase the spring rate, see table above. Repeat adjustment from

paragraph c (1).

MUNCIE PARTS MFG_ 00_, INC_

MUNCIE • ATLANTA • CHICAGO • SEATTLE • TOLEDO • TORONTO

-6-

6c. (Continued) (4) Operate the lowest pressure circuit. The throttle must open.

If it opened, proceed directly to step 5. Otherwise, choose between (a) and (b) below. (a)

If it did not open, the motivating force is below zero.

Revise the plumbing to increase the amount the pressure will increase when the circuit is operated. See Section A.

(b)

Operate the next higher loaded circuit, etc. until you find a circuit that does operate from idle. Use this circuit for the adjustments specified in paragraph 5 below. You will find out later whether the lower pressure circuits, that did not operate from idle, will become operable at a higher speed.

(5) Turn in on screw (4) in small increments equal to approximately 10% of the total turns given in the table above.

After each increment, operate the lowest pressure circuit lever from neutral to fully open the throttle, and then return it to neutral to fully close the throttle.

Wait for the engine to idle before repeating.

Count, and record as "C", the number of turns to exactly when the throttle no longer opens from idle.

Note: increase the spring rate, see table above, if the total turns counted (B plus C), exceeds by more than 20% the number of turns noted in the table above.

Decrease your spring rate if you observed the throttle longer fully open.

will no

Repeat adjustment from paragraph c(1), if spring rate was changed.

(6) Turn screw

(4) out 1/8 turn or 1/4 times "C" turns whichever is

greater to provide an operating margin between the lowest circuit pressure and the final spring tension.

(7)

Check operation as per paragraph F6a or F6b. If the lighter loaded circuits do not operate, revise the plumbing to increase the amount the pressure will increase when these circuits are operated. See Section A.

MUNCIE PARTS MFG_ C0_, INC_

MUNCIE • ATLANTA • CHICAGO • SEATTLE • TOLEDO • TORONTO

-7-

II. TROUBLE SHOOTING HINTS A. Problem: Engine Does Not Idle But Speeds Up When PTO Is Engaged Probable Cause 1.

2.

3.

Remedy

Control lever stuck open.

Low leaf spring tension.

Cold Oil.

1. Return all valves to neutral.

2. Repeat calibration.

3. Warm oil. Also check Part I, Section "C".

B. Problem: Engine Does Not Speed Up When Light Load Is Applied Probable Cause

Remedy

1. PTO not engaged.

2. Air in sensing line.

3. Connecting cable.

4. Stops on speed screw.

5. Hot oil.

6. Your engine throttle linkage.

1.

2.

3.

4.

5.

6.

7.

Circuit pressure is too low.

7.

8.

9.

Excessive leaf spring tension.

Excessive leaf spring rate.

8.

9.

C. Problem:

Engine Does Not Return To Idle After A Load Is Applied Remedy

Probable Cause

3.

4.

Engine speed excessive.

Your engine.

Connecting cable.

Low leaf spring rate.

1.

2.

3.

4.

5.

6.

Low leaf spring rate.

Excessive by-passing pressure.

5.

6.

1.

2.

MUNCIE PARTS MFG_ C0_, INC_ PfmtodInUSA

Engage PTO. Bleed line. Crack fitting at control.

Reduce slack to minimum.

Adjust screw.

Allow oil to cool.

Oil and repair. Check manufacturer for lighter spring if it is excessive.

Revise plumbing to increase spread between your circuit and by-passing pressures. See Part I, Section "A".

Repeat calibration.

Reduce spring rate. See table in Part I, Section "F".

Reset speed screw adjustment.

Make sure it can idle.

Check for slack, Increase spring rate. See table in Part I, Section "F".

Repeat calibration.

Remove "bottlenecks" or increase line size downstream of the control connection.

MUNCIE • ATLANTA • CHICAGO • SEATTLE • TOLEDO • TORONTO

-8-

Automatic remote con r0 of hydraulically operated equipment

----- _ ----------- -----

Accelerator Rod

Hydraulic Line to Throttle Control

Return Line to tank

Spring Leaf 2 1/4 "5)

• Easily Installed

Cable

• No Special Tools Needed • Compact

High-speed Screw

• Positive Action 4

• Fits All Trucks and Industrial Engines

N PT

Housing

• Mounting Bracket Furnished

Rod Clamp 4-1/8"

• Adjustable

Throttle Rod

Pivot

• 4 Optional Pivot Positions For Spring Adjustment

Low-pressure Screw

SPECIFICATIONS

11/2 Net Weight Overall Width

3 lbs. Owe. Length 2-3/1" OvarallTlidmass

• Efficient

1%"

Bracket

MUNCIE PARTS MFG_ CO_, INC_ GENERAL OFFICES

ATLANTA DIVISION

CHICAGO DIVISION

P.O. Box-.548 • Muncie. Indiana 47305 Phone (317) 284-7721

P.O. Box 43468 • Atlanta. Georgia 30336 Phone (404) 349-4402

P.O. Box 68151 • AM F, O'Hare 60666 Phone (312) 298-6860

TOLEDO DIVISION

MUNCIE CANADA LIMITED

P.O. Box 6593 • Toledo. Ohio 43612 Phone 1419) 729-3861

P.O. Box 113, Melton Station Mississauga. Ontario L4T 3B5 Phone (416) 677-9852

SEATTLE

see.s.., at Muncie Pro Mtg. Ca. inc.

The Blackler Company • 317 So. Bennett St. Seams, Wash. 96108 • Ph. (206) 763-2230

MP75-6.01

Shuttle Valve NOTES:

40

Pr es su r e Dro

1. Ports- 14-18 NPTF 2. Valve Aluminum Alloy, and Steel 3. $eprj.ce Prelsuxel 3000 PSI 4. 'ljids: S.A.E. Type 'Hydraulic Oils 5. Ersamagaj=2.1 See Table

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pi

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FLOW - G.P.M.

MODEL No. 22-IA-2

2

FLUID POWER SYSTEMS IAMBACJ WHIMING. ILLINOIS

4/7/76

CONDOR OPERATION AND SAFETY MANUAL

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

UNLOADING: 1.

If the use of loading ramp is necessary to unload the Condor, select a weighs approximately 13,000 lbs. sturdy ramp. The Condor Models

to approximately 24,000 lbs.

2.

If the work platform was removed for shipment, it must be replaced prior to unloading.

OPERATING: 1.

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

2.

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

3.

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

4.

Aerial controllers are proportional, except for steering, platform tilt and platform rotation, which are bi-directional toggle switches. Each controller has a deadman lock-out mechanism that must be lifted before the controller can be activated. By lifting the deadman button not only is the controller free to be activated, but also will bring the pump from a stand-by position to a working position, while increasing engine rpm from idle to operating rpm.

5.

Normal driving position for the Condor is with the counterweight over the driving wheels. Controller movement is based on this configuration. With counterweight over steering, the drive and steering control will react reversed.

Series IX SPC 6-82

a.

6.

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

7.

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

8.

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

INSPECTION: 1.

Once unit has been unloaded, give the unit a visual inspection paying special attention to items listed below. This inspection should become part of a daily inspection performed at the beginning of a work shift by the assigned operator.

A

B C D E F G H I

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

NOTE: Condor models equipped with 54:1 torque hubs. Check operation of slope sensor device. If possible, place unit on slope of 5° or more, indicator light should come on and all boom functions will be inoperative.

The Condor Models are also equipped with limit switches. One located inside the boom and another located outside of boom at the boom to turret hinge pin. When either switch is activated, they automatically shift drive to low speed when boom is extended or raised to horizontal.

OPERATOR TRAINING: 1.

In order for an operator to thoroughly understand the operation of a Condor and to become a qualified operator, it is recommended that after having been checked out by a trained, qualified operator, the trainee operator should move the unit to an area free of any overhead obstruction.

The surface upon which the unit will be operated should be level with no hazardous irregularities or accumulation of debris.

Series IX SPC 6 82 -

b.

2.

Condors are equipped with automatic shift to low for the drive function.

This is done automatically when boom is extended or reaches horizontal.

3.

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

4.

With boom at 60 0 , extend boom approximately half way and repeat driving exercise.

5.

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

6.

Extend boom to maximum and raise boom to 75 ° , rotate turret. Turret rotation is continuous. By gradually operating rotation controller giving full signal to rotation, and by gradually returning controller to neutral, the operator will learn how the rotation can be controlled to place unit along side a building smoothly.

Place counterweight over drive wheels, with unit at extension. Repeat driving exercise.

75°

and maximum

NOTE: Extreme care must be taken when driving in this position, as ground vision has been reduced. The operator must watch for objects or personnel that may be in the area.

8.

At the end of this exercise, the operator will have driven the Condor in both high speed and low speed; with extended and retracted boom; and will have driven the Condor with boom off to the side, and will have practiced placing Condor in imaginary work positions.

SAFETY: Listed below are items pertaining to safety that the operator must know and follow.

1.

The Calavar Self-Propelled Condor is a personnel lifting device and it is essential that it is properly maintained and operated to perform all functions with maximum safety and efficiency.

2.

The operation of any new and unfamiliar equipment can be hazardous in the hands of untrained operators. Only trained operators should be assigned to operate the Condor.

3.

It is the responsibility of the operator to be familiar with the manufacturer's manual and to follow all recommendations made. Never exceed manufacturer's recommended load.

4.

It is the responsibility of the owner to instruct the operator with the safety requirements made not only by Calavar, but by various safety boards in your area, as well as requirements set down by OSHA and ANSI. (Note: See ANSI A92.5-1980.)

Series IX SPC 6-82

c

.

5.

Do not operate Condor in excess of rated load specification.

6.

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

7.

Do not lean over platform railings to perform work.

8.

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

9.

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

10.

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

11.

Always distribute load evenly over work platform.

12.

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

13.

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

14.

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

15.

Do not alter equipment.

16.

Do not override safety devices.

17.

Slope control devices should be checked periodically for proper operation.

Immediate repairs are mandatory on this device should it be found inoperative or disconnected.

18.

Extremely uneven, sloping, or loft terrain is hazardous and must be avoided.

The Condor must not be operated on terrain with more than a 5 ° slope.

19.

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

20.

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

21.

Visual inspection of turret rotation ring gear bolts in turret and inside base assembly must be accomplished periodically and if found loose, retorqued to 80 ft. lbs. on base bolts and 140 ft. lbs. on turret bolts.

22.

Visually inspect tires. Tires that have been severly cut to the cord are dangerous and should be replaced. Recommended tire pressure must not be over inflated.

(See Section One, Page 27.)

Series IX SPC6-82

d.

23.

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

24.

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

25.

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

26.

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

Series IX SPC 6-82

e.