Condor 3887G 4887G Operator’s, Maintenance Vendor & Parts Manual – PDF DOWNLOAD

SELF-PROPELLED ELEVATING WORK PLATFORM

MODELS 3887G/4887G OPERATOR'S, MAINTENANCE, ILLUSTRATED PARTS, AND VENDOR MANUAL

3887G

4887G

SHIPPING ADDRESS

MAILING ADDRESS

CALAVAR CORPORATION 8300 IMPERIAL DRIVE WACO, TEXAS 76712 (817) 666-4545

CALAVAR CORPORATION P. O. Box 21447 WACO, TEXAS 76702-1447 (817) 666-4545 MANUAL 92328 SEPTEM8ER 1995

SELF-PROPELLED ELEVATING WORK PLATFORM

MODELS 3887G/4887G OPERATOR'S MANUAL

3887G

4887G

SHIPPING ADDRESS

MAILING ADDRESS

CALAVAR CORPORATION 8300 IMPERIAL DRIVE WACO, TEXAS 76712 (817) 666-4545

CALAVAR CORPORATION P. O. Box 21447 WACO, TEXAS 76702-1447 (817) 666-4545 MANUAL 92328-001 SEPTEMBER 1995

INTRODUCTION

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

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

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

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

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

Calavar Corporation reserves the right to modify, improve, add, and/or delete certain design features of its products without any obligation to incorporate new features into products previously sold. Our manuals are continually updated to reflect these changes.

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

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

NOTE:

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

MANUAL 92328-001 SEPTEMBER 1995

CONDOR® SERVICE INFORMATION

1. If you need assistance or have any service or maintenance questions, Calavar service and parts personnel are always available by phone or fax. The telephone numbers are: (817) 666-4545 Telephone (817) 666-5125 Voice Mail (800) 443-5803 FAX

2. There are numerous written Maintenance Procedures available for this machine. These procedures are available through the Calavar Service Department to anyone who requests . them.

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

Calavar conducts service schools on a continuing basis. Call any of our service or sales persons for a schedule. Remember, training of mechanics is the responsibility of their employer, but Calavar Service Schools help you provide this training.

4. Calavar Service School Training Manuals are available for purchase through the parts department. The part numbers for these manuals are: #92333 for self-propelled models; and #92334 for truck-mounted models.

CALAVAR CORPORATION

8300

ii

IMPERIAL DRIVE.

P.o. Box 21447,

WACO. TEXAS

76702-1447- 817-666-4545, 817-666-4544 FAX

CONDOR® MODELS 3887G/4887G

OPERATOR'S MANUAL TABLE OF CONTENTS

INTRODUCTION ......•.....................•...•..•.................................•................................... i SERVICE INFORMATION .....••......•..•..•..••.••.....•..........•..•..•.......................................... ii

TABLE OF CONTENTS •.......•......••..••.......•.•....•.............••........•.................................. 1

I.

PREPARATION. INSPECTION. AND MAINTENANCE ................................................ 2 A. B. C. D. E.

Overall Machine Condition ..........................................................................

Lower Control Station ..................... ; ..........................................................

Platform & Upper Control Station ................................................................

Hydraulic System ......................................................................................

Batteries ...................................................................................................

2 2 3 3 3

II.

RATED WORK LOAD .........••.••....•...•..............•................................................ 3

III.

OPTIONAL EQUIPMENT ..••.••.••••.•.••.•••.....•...........••.....••..................•................ 3

IV.

LOWER CONTROLS ....•...•.•..•..••••.••.•......•..•...................•..............•.................. 4

V.

UPPER CONTROLS ......................................................................................... 5

VI.

EMERGENCY LOWERING PROCEDURE .............................................................. 6

VII.

MOVING FROM JOB SITE TO JOB SITE ............................................................ 6 A. B. C. D.

Loading & Unloading ..................................................................................

Ramp Method ............................................................................................

Forklift Loading/Unloading Method ...............................................................

Transporting .............................................................................................

ANSI/SIA 92.6 - 1990 MANUAL OF RESPONSIBILITIES

MANUAL 92328-001 SEPTEMBER 1996

6 6 7 7

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

I.

PREPARATION, INSPECTION, AND MAINTENANCE

A. OVERALL MACHINE CONDITION TIRES AND WHEELS:

Before putting the CONDOR® into service, all personnel must receive proper training and instruction regarding the operation, service, and maintenance of the CONDOR®. All operators and maintenance personnel should read and understand all portions of the operator's manual and should follow all procedures for the proper operation of all functions and controls.

The condition of the CONDOR® is very important, as it directly affects the operator as well as others.

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

The operator must perform a thorough walkaround inspection each day prior to operating the CONDOR®. Any damage or faulty operation should be reported immediately. A DO NOT OPERATE tag outlining the problem should be attached to the lower control station and any discrepancies should be corrected before operating the CONDOR®.

More detailed inspections should be performed at the intervals specified in this Operator's Manual, and after any components have been repaired or replaced.

KNOW THE CONDOR® AND ITS CAPABILITIES. REPORT ANY UNUSUAL OPERATION, SUCH AS ERRATIC SWAY OR MOTION OF THE ARMS OR PLATFORM. The daily inspection of the CONDOR® should include the following:

2

D

Inspect for proper tire pressure, cracks, tears, cuts, or missing or loose lug nuts (a rust line running down the rim from the lug nut indicates a loose lug nut.

MISSING, BROKEN, OR DAMAGED PARTS:

D

Inspect cylinder mounting pins, pivot pins, pin retainers, wear pads, bolts, nuts, and washers.

STRUCTURAL CONDITION:

D

Inspect for structural damage or cracked welds on all structural components, paying particular attention to major structuralgroups (arms, platform, chassis).

STEERING:

D

Inspect tie rod ends and steering cylinder for proper and secure mounting.

DECALS:

D

Be sure that all instructional and cautionary decals are in place and are clearly legible.

B. LOWER CONTROL STATION

D

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

D

Verify that all functions operate properly and that controls return freely to center (neutral position) when actuated and released.

MANUAL 92328-001 SEPTEM8ER 1995

C. PLATFORM & UPPER CONTROL STATION

D

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

D

Verify that entry point bars and chains are functional and secure.

D D

Verify that footswitch operates properly and that guard is in place.

Re-check the structural condition of the platform, paying close attention to pins, railings, and floor.

D

Check the red stop button-its purpose is to disconnect power to the controls in an emergency.

D

Verify that all control levers return freely to center (neutral position) when actuated and released.

II. RATED WORK LOAD The rated work loads of the CONDOR® are as follows: Models 3887G-2,000 Ibs. (908 kg.); Model 4887G -1,500 Ibs. (681 kg.).

The platform will support a combined weight equal to the CONDOR®'s rated work load, which includes personnel, tools, and equipment, throughout the working envelope of the CONDOR®.

III. OPTIONAL EQUIPMENT The following options are available on CONDOR® Models 3887G, and 4887G:

D. HYDRAULIC SYSTEM

D

Check the hydraulic tank fluid level with the arms lowered. Maintain a full level of fluid-to the mark on the dipstick or sight glass (if equipped), or within one inch of the top of the tank. Add Shell Tellus T-32 Hydraulic Oil if required.

D

Verify that the breather cap is clean, undamaged, and properly installed on the hydraulic tank.

D

Check for leaks at all fittings, valves, and controls.

D

Check all hydraulic hoses and tubes for damage or kinks, and ensure proper routing to avoid pinch points.

E. BATTERIES

D

Check battery electrolyte level, and ensure that all caps are present and tight on batteries.

D

Inspect all battery cable connections for security and cleanliness.

MANUAL 92328-001 SEPTEMBER 1995

•

FORWARD-REVERSE DRIVE ALARM

•

MOTION/MOVEMENT ALARM

•

STROBE LIGHT

•

50 MULTI-AXIS SLOPE ALARM

•

HYDRAULIC STABILIZERS (3887G)

•

110-V EXTENSION TO PLATFORM

•

DIESEL ENGINE (HATZ 2M40Z)

•

LP/GAS DUAL FUEL (VAPOR)

•

LP/GAS DUAL FUEL (LIQUID)

•

SINGLE SPCL PAINT COLOR-ENAMEL

•

FOAM-FILLED TIRES

•

4-WHEEL DRIVE

•

HOUR METER

•

ADDITIONAL OPR/SVC/PRTS MANUAL

3

IV. LOWER CONTROLS The lower controls are located on the chassis, adjacent to the engine, to operate all functions except DRIVE and STEER. The lower controls are as follows:

OPERATING INSTRUCTIONS • TURN KEY TO LOWER POSIllON TO OPERATE FROM GROUND. • START ENGINE. • DEPRESS AND HOLD -THROTlLE BUnON WHILE MOVING PLATFORM UP OR DOWN. • TURN KEY TO UPPER POSITION TO OPERATE FROM PLATFORM. • TURN ENGINE OFF WITH KEY. • IN AN EMERGENCY, PUSH RED BUnON. TO OPERATE, BUnON MUST BE PULLED OUT.

LP

THROTTLE

EMERGENCY PUSH TO STOP

H

RAISE

0@~ o

SWITCH TO MOVE PLATFORM

LOWER CHOKE

START UPPER

OFF LOWER GAS

[CIRCUIT BREAKER]

•

THROTTLE:

This pushbutton switch brings the engine to operating speed, and must be depressed and held in order to raise or lower the platform.

•

EMERGENCY STOP:

This red push-pull switch must be pulled out (ON) prior to operating the controls. This switch will stop all powered motion in an emergency.

•

RAISE/LOWER:

This toggle switch is used to raise and lower the platform. The switch will return to neutral (center position) when released.

•

CIRCUIT BREAKER:

A resettable 20-amp circuit breaker serves all control circuits. It may be pulled out to de-energize all controls.

•

LP/GAS (OPTIONAL): If the CONDOR® is equipped with an optional dual fuel system, then this twoposition toggle switch is provided to select either gasoline or propane as the fuel source.

•

CHOKE:

This switch may be engaged, while starting the engine, after long periods of non-use or when the engine is difficult to start.

•

START:

Depress this pushbutton switch to start the engine.

•

KEY SWITCH:

This 3-position (UPPER/OFF/LOWER) key switch allows the operator to select either the lower or upper controls for the operation of the CONDOR®.

4

MANUAL 92328-001 SEPTEMBER 1995

V. UPPER CONTROLS The upper controls allow operation of all functions of the CONDOR®. The FOOTSWITCH must be depressed and held while operating functions from the upper control station. The upper controls are as follows:

EMERGENCY STEERING

PLATFORM

JACKS

START

CHOKE

DRIVE CONTROLS--

~®®o©o~~~ - - SPEED - - -

PUSH TO STOP

•

STEERING (LlR): This switch is used to turn the steering wheels. Move the switch to the right and the CONDOR® will steer to the right, move the switch to the left and the CONDOR® will steer to the left, both, in forward and reverse. The switch will return to neutral (center position) when released; however, the steering wheels are not automatically self-centering. Therefore, to go straight again after a turn, move the switch in the opposite direction. Release the switch when the CONDOR® steers in the desired direction.

•

PLATFORM RAISE/LOWER: This toggle switch is used to raise and lower the platform. The switch will return to neutral (center position) when released.

•

JACKS-UP/DOWN (OPTIONAL): When the CONDOR® is equipped with optional outriggers and jacks, then this two-position toggle switch is provided to raise and to lower the jacks. The switch will return to netural (center position) when released.

•

START:

•

EMERGENCY STOP: This red push-pull switch must be pulled out (ON) prior to operating the controls. This switch will stop all powered motion in an emergency.

•

CHOKE: This switch may be engaged, while starting the engine, after long periods of non-use or when the engine is difficult to start.

•

HIGH/LOW (OPTIONAL WITH FOUR-WHEEL DRIVE): select HIGH or LOW drive speed range.

•

FAST/CREEP: This two-position toggle switch is used to select FAST or CREEP speed. If the CONDOR® is equipped with optional four-wheel drive, then a three-position switch is provided to select a medium speed in conjunction with the optional HIGH/LOW speed switch.

•

FORWARD/REVERSE: This toggle switch is used to select the direction of drive travel. FORWARD and REVERSE relate to the orientation of the operator while facing the control panel.

Depress this pushbutton switch to start the engine.

This two-position toggle switch is used to

OPERA TING INSTRUCTIONS •

TURN KEY, ON LOWER CONTROL PANEL. TO ·UPPER" POSITION TO OPERATE FROM PLATFORM.

• IN AN EMERGENCY, PUSH RED BUTTON. TO OPERATE FROM PLATfORM, BOTH RED BUTTONS, ON LOVt{:R AND ON UPPER CONTROLS. MUST BE PULLED OUT. •

START ENGINE. USE CHOKE OR GLOWPLUGS AS REOUIRED. KEEP FOOl OFF SWITCH WHEN STARTING

•

PUT FOOT ON SWITCH TO MOVE CONDOR. TAKING FOOT orF SIMTCH. STOPS ALL POWERED MOVEMENT.

•

ALL MOVEMENT IS CONTROLLED BY TOGGLE SWITCHES THAT RETURN TO NEUTRAL WHEN LET GO.

•

STEERING IS NOT AUTOMA nCALLY SELF -CENTERING. BE SURE THE STEERING WHEELS POINT IN THE DIREcnON YOU WANT BEFORE LETTING GO OF THE STEER SWITCH.

•

DRIVE SPEED IS SELECTED BY A TWO-POSiTiON "HIGH/LOw" S'NITCH. THE FOUR-WHEEL DRIVE OPTION HAS AN ADDITIONAL THREE POSlTlON "FAST/NEUTRAL/CREEP~ S'MTCH, ALLOWING SIX SPEEDS.

•

LIMIT SWITCHES AUTOMATICALLY CUT BACK THE SPEED, AS THE PLATFORM IS RAISED.

•

BRAKES ARE NORIwlAU Y SPRING-APPLIED AND ARE AUTOMAnCALLY RELEASED 'M-iENEVER THE DRIVE SWITCH IS PUSHED.

•

ON CONDORS WITH JACKS. LIMIT SWITCHES ALLOW THE PLATFORM TO BE RAISED ALL THE WAY UP ONLY 'NHEN THE JACKS ARE DOWN.

•

TURN ENGINE OFF WITH KEY ON LOWER CONTROL PANEl.

~710

MANUAL 92328-001 SEPTEMBER 1995

5

VI. EMERGENCY LOWERING

Before loading and unloading, inspect the CONDOR® for any physical damage or defects.

The EMERGENCY LOWERING SYSTEM should only be used if the battery (ies) is (are) totally discharged or if there is an "OPEN" failure in the wiring from the battery to lower controls and on to the lowering valves. There are three valves, one on each cylinder and one lowering in the main valve.

The means used to load and unload should be of sufficient strength to withstand the weight of the CONDOR®: 3887G

8,2851bs

(3,758 kg.)

4887G

9,1501bs

(4,150 kg.)

To operate the Emergency System, follow the instructions on decals 55007 and 55008, shown below: B. RAMP METHOD

EMERGENCY LOWERING 1. CHECK THAT NEEDLE VALVE, IN MAIN VALVE, IS COMPLETELY CLOSED,

BY TURNING ITS HANDLE CW 2. PUSH RED KNURLED KNOB AND TWIST CCW O. KNOB IS ON VALVE AT UPPER LIFT CYLINDER. 3. PUSH RED KNURLED KNOB AND TWIST CCW 0 .

KNOB IS ON VALVE AT LOWER LIFT CYLINDER. 4. ONLY AFTER DOING STEPS 1,2,&3, IN SEQUENCE, OPEN NEEDLE VALVE, TURNING HANDLE CCW 0 , TO LOWER PLATFORM. 5. WHEN PLATFORM IS DOWN, RESET VALVES AT CYLINDERS BY TWISTING RED KNOBS CW 0 AND CLOSE NEEDLE VALVE.

o.

Ensure that the ramp being used is capable of handling the weight of the CONDOR®. The ramp should be set at an angle no steeper than the machine's rated gradeability (SEE CHART BELOW):

MODEL

05007

[~C~Ul~ON[ FOLLOW INSTRUCTIONS, ON DECAL AT VALVE IN CHASSIS, FOR EMERGENCY LOWERING.

(0)

(%)

3887G (2WD) 3887G (4WD)

14 14

26 26

4887G (2WD) 4887G (4WD)

14 14

26 26

Before driving the CONDOR® on the ramp, be sure that the CONDOR® is in LOW speed by lowering the platform completely. (NOTE:Raising the platform slightly will put the CONDOR® into HIGH speed, and raising the platform completely will result in CREEP speed.) Test the DRIVE/STEER control and the brake system.

55008

Drive up or down on the ramp slowly, allowing for steering corrections to be made. Keep the CONDO~ in alignment with the ramp and the carrier throughout loading and unloading procedures.

VII. MOVING FROM JOB SITE TO JOB SITE A. LOADING AND UNLOADING Although the CONDOR® is small compared with larger construction equipment, it requires the same level of care and attention in loading and unloading as does larger, heavier equipment. At no time should the CONDOR®'s weight be underestimated.

6

GRADEABILITY

MANUAL 9232B-ool SEPTEMBER 1995

C. FORKLIFT LOADING/UNLOADING METHOD Ensure that the forklift has sufficient capacity to handle the weight of the CONDOR® (as specified above). The forks should be long enough to extend across the full width of the frame, and should be positioned as close to the tires as is possible. DO NOT ATTEMPT TO LIFT THE CONDOR® FROM EITHER END. The CONDOR® should only be raised to a height sufficient to clear any obstructions. With the forklift carrying the CONDOR@, keep travel to a minimum and always set the CONDOR@ down gently.

D. TRANSPORTING The CONDOR@ may be transported easily and safely to and from the job site if the following procedures are observed: •

Block all wheels to prevent forward and reverse motion.

•

Tie down the CONDOR@ with chains or cables threaded through the tie-down holes only. DO NOT CHAIN OR STRAP OVER THE PLATFORM OR GUARD RAILS. Severe damage may result from securing the CONDOR@ improperly .

•

ALWAYS TURN OFF THE POWER AT THE LOWER CONTROL STATION.

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

MANUAL 92328-001 SEPTEMBER 1995

7

SELF-PROPELLED ELEVATING WORK PLATFORM

MODEL 3887G/4887G MAINTENANCE MANUAL

3887G

4887G

SHIPPING ADDRESS

MAILING ADDRESS

CALAVAR CORPORATION 8300 IMPERIAL DRIVE' WACO, TEXAS 76712 (817) 666-4545

CALAVAR CORPORATION P. O. Box 21447 WACO, TEXAS 76702-1447 (817) 666-4545

MANUAL 92328-002 SEPTEMBER 1995

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 CONDORs, and to provide the information necessary to maintain and service the CONDOR®.

THE OPERA TOR'S MANUAL MUST BE RETAINED ON THE CONDORS AT ALL TIMES.

Do not attempt to operate or service the CONDORs 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 CONDORs also contain vital operational instructions. Read the decals before operating this CONDORs.

It is YOUR RESPONSIBILITY to follow procedures while operating the CONDORs. The manufacturer of this CONDORs 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 CONDORS's intended use.

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

Calavar Corporation reserves the right to modify, improve, add, andlor 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 CONDORS WITHOUT PRIOR WRITTEN APPROVAL FROM THE MANAGEMENT OF CALA VAR CORPORATION

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

NOTE:

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

CONDOR~

SERVICE INFORMATION

1. H you need assistance or have any service or maintenance questions, Calavar service and parts personnel are always available by phone or fax. The telephone numbers are: (817) 666-4545 Telephone (817) 666-5125 Voice Mail (800) 443-5803 FAX

2. There are numerous written Maintenance Procedures available for this machine. These procedures are available through the Calavar Service Department to anyone who requests them.

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

Calavar conducts service schools on a continuing basis. Call any of our service or sales persons for a schedule. Remember, training of mechariics is the responsibility of their employer, but Calavar Service Schools help you provide this training.

4. Calavar Service School Training Manuals are available for purchase through the parts department. The part numbers for these manuals ar.e: #92333 for self-propelled models; and #92334 for truck-mounted models.

CALAVAR CORPORAnON

8300 lMPmuAL DRIVB, P.O. Box 21447, WACO, TEXAS 76702-1447.817-666-4545,817-666-4544 FAX

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 Galavar.

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 Fonn No. 513-1M-495

Printed in U.S.A.

Effective January 1. 1993 WARRANTY PROGRAM Warranty is a function of a manufacturing company to back up the product it manufactures.

It is a guarantee against defects in design and workmanship of components utilized in the product, and is offered for a fixed period of time following the purchase of the product by a customer.

Calavar Warranty states, in general, that Calavar will replace free of charge any components found to be defective within the time frame of the warranty period. There are exceptions to some components which are not the responsibility of Calavar. These will be outlined in subsequent paragraphs.

A.

NOTE:

WARRANTY PERIOD

1.

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

2.

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

3.

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

4.

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

5.

During the Warranty Period, in addition to covering the parts replaced under Warranty, Calavar will pay a Dealer Warranty Labor Rate which is based on a percentage of your standard shop labor rate.

The term "IN SERVICE" means that the Warranty starts at the time the CONDOR® is first used for any purpose. An example: The dealer may have purchased a CONDOR® to have in stock, but may not use it. After three months, the CONDOR® is sold or the dealer decides to put the CONDOR® into its rental fleet. In this situation, the Warranty Period begins the day the dealer puts the CONDOR® into the fleet or when the CONDOR® is delivered to the end user.

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

2

MANUAL 92328-002 SEPTEMBER 1996

B.

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

1.

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

2.

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

3.

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

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

NOTE:

C.

ITEMS NOT COVERED UNDER WARRANTY Some components are used on the CONDOR® which are not warranted by Calavar.

However, these are warranted by the component manufacturer. Some of these are: 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. Calavar can advise you who the dealer is if unknown to you.

2.

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

3.

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

4.

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

5.

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

6.

Travel Time I 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, Calavar Warranty will cover reasonable labor charges for the removal and replacement of defective components.

MANUAl 92328-002 SEPTEMBER 1995

3

D.

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

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

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

b.

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

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

2.

NOTE:

4

Although not recommended, you may purchase the part locally.

When this is done, a copy of the purchase order or receipt MUST accompany the claim. Calavar has the option to ship a replacement part at no charge if the local cost would be greater, in lieu of issuing credit for locally purchased parts.

d.

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

WARRANTY CLAIMS NOT RECEIVED BY CALAVAR WITHIN 45 DAYS OF FAILURE WILL BE DENIED

3.

E.

c.

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.

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

MANUAL 92328-002 SEPTEMBER 1995

NOTE:

DO NOT SHIP ANY RETURN PARTS WITHOUT A RETURN AUTHORIZATION (RIA) NUMBER Doing so may result in parts getting lost in the system and may delay proce.ssing the claim, or may cause denial due to the time element of the claim.

3.

All RIA parts must be received at Calavar within 45 days from the date the RIA 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 Calavar FREIGHT PREPAID. No freight collect shipments will be accepted.

MANUAL 9232Il-002 SEPTEMBER 1996

5

CHECK-OUT INSTRUCTION The following instructions are a step-by step procedure for checking out the self-propelled CONDOR®, as well as for acquainting operating personnel with the CONDOR®'s operation.

This procedure will not take more than one hour and is time well-spent, as it will give both operating and maintenance personnel preliminary experience and a better understanding of the operation of the self-propelled CONDOR®.

Prior to placing the CONDOR® into service, a full check-out of the CONDOR® should be made and the Installation Inspection Report should be completed and returned to Calavar.

Each CONDOR® has undergone a thorough Quality Control Inspection, and each CONDOR® leaves Calavar in first-class condition. Unfortunately, some CONDOR®'s may be damaged in transportation; all such damage should be recorded on the consignee copy of the freight bill. Calavar Corporation is not responsible for damage to CONDOR's in transit.

1. Visually inspect all exposed components. Check for loose nuts and bolts, damaged hydraulic lines, broken wires, and structural damage.

2. IMPORTANT: Check tire pressure. Tires must be properly inflated before operating the CONDOR®. Do not over-inflate. Proper P.S.1. rating appears on decals applied to both sides of the carriage.

3. Check hydraulic oil level and add Shell Tellus T-32 hydraulic oil, if required.

4. Fill fuel tank using unleaded gasoline or diesel fuel.

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

6. Inspect all hydraulic valves located in the front carriage compartment before putting the CONDOR® into service.

7. Turn on the key switch at the lower control station; IF DIESEL-POWERED, first activate glowplugs and allow 30 seconds before starting engine. Depress the start button and allow engine to warm up at idle. After the CONDOR® has warmed up, and with the UPPER/LOWER control station selector switch in the LOWER position, the CONDOR® may be operated by activating the control handles on the lower control valve. Activate each control lever to check operation and ensure that when released, the control levers return to center (neutral). While wheel drive is not available from the lower control station, the engine may be started and stopped from both control stations.

8. With the key switch ON, switch to the UPPER control station. Position the CONDOR® in an area that is free from any overhead obstruction. At the upper control station, engage the footswitch and activate a control lever while maintaining pressure on the footswitch. Ensure that when released, the control levers return to center (neutral).

Learn to operate the controller slowly to obtain the smoothest possible operation.

6

MANUAL 923211-Cl02 SEPTEMBER 1995

9.

The CONDOR® has been designed to drive with the counterweight over the drive wheels. This configuration will provide the best traction and a familiar driving position.

10.

A series/parallel drive valve is located in the front carriage compartment between the drive wheels. This valve performs the necessary functions of dividing the hydraulic oil for slow speed travel with adjustable differential action to round corners, and diverting the oil flow for high speed travel. The counterbalance valve softens the brake release and application efficiently without an accumulator.

11 .

The wheel drive has the following features: A.

There is a FAST/SLOW speed selector (toggle switch) on the upper control box.

B.

FAST speed is only available in stowed position.

c.

In FAST speed mode, no aerial functions may be operated, even if the controllers are activated.

12.

Gradually operate the unit up to its maximum elevation and extension.

13.

All CONDOR® models are equipped with a slope-sensing device which senses a 50 out-of-Ievel condition. This safety system is operational when the ignition circuit is on and the boom is above horizontal. When the unit is subjected to an out-of-plumb condition of 50 or more, the system will sound an audible alarm at both control stations. The operator should correct the condition by reversing the drive direction or by selecting an alternate path, observing normal safety precautions when operating the equipment. The slope-sensing device is a safety system and must not be disconnected. Should the system be found inoperable, the unit must be taken out of service and must not be used until the system has been repaired.

MANUAl 92328-002 SEPTEMBER 1995

7

PREVENTIVE MAINTENANCE

GENERAL The finest equipment manufactured is only as good as it is maintained. Costly repairs and loss of revenue can often be avoided by planning ahead, setting a regular schedule and exercising preventative maintenance NOW or costly repairs LATER. A good preventative maintenance program will enhance a properly operating CONDOR®.

The preventative maintenance inspection is generally, but not exclusively, the responsibility of the operator. Since it directly affects him, it is in his best intrest that the inspection maintenance be carried out. The lubrication and service is the RESPONSIBILITY of the serviceman or mechanic since shop time will be required to perform the maintenance tasks in some instances.

Many of the suggestions for preventative maintenance described and noted herein may sound time consuming and expensive. THIS IS NOT THE CASE. The program has been carefully structured and, if followed closely, will result in an extended life expectancy of the unit, as well as a REDUCTION in down time and costly repairs.

NOTE The inspections and checks listed are not intended to replace any local or regional regulations which may pertain to this type of equipment, nor should the list and schedule be considered all-inclusive. Interval times may vary due to climate and/or conditions, depending on the location and use of the CONDOR®.

CAUTION Always ensure that applicable precautions are strictly observed when performing the maintenance inspections and checks. Make certain that damaged components, or those in need of adjustment, repair, or replacement are corrected before operation.

8

MANUAL 92328-002 SEPTEMBER 1995

LUBRICATION The CONDOR8 Model 3887 and 4887 are equipped with bushings at the majority of pivots, tie-rod and cylinder areas that requres attention and service. CONDOR8 that hasbeen stored or exposed to environmental conditions of extreme low humidity and high dust level, elevated temperatures of heavy rainfall, lubrication of components may be required more frequently than under normal conditions. External, non bearing surface shall be wiped clean of extruded or spilled surplus grease with a clean lint free cloth, to prevent damaging dust and abrasive accumulation on lubricant wet surfaces.

ENGINE OIL FILTER AIR CLEANER OIL BASE CRANK CASE DRAIN AND REFILL EO

RETURN LINE FILTER AND IUGH PRESSURE FILTER

INTERVAL SYMBOL EO ENGINE OIL: SAE 30 WEIGHT

o

D

o

50 HOURS or SEMI - MONTHLY 100 HOURS or MONTHLY 500 HOURS or ANNUALLY MANUAL 92328-002 SEPTEMBER 1995

9

,.

SERVICE TOOLS To property and efficiently service your CONDORf>, several basic tols are required. The following list of tools should be available.

A. Volt/OHM meter.

B. Hydraulic pressure gauge (0-3,00 psi).

C. '6 JIC swivel run tee and proper hose connection to gauge and run tee.

D. Battery hydrometer.

E. Battery load tester.

F. Standard mechanics hand tools.

G. Electrical test light.

2.

HYDRAULIC SYSTEM The CONDORf> SCISSORS hydraulics are used to power the various operational functions.

As with any operational system, it is only as good as it is maintained. This section is offered to alert you and guide you in maintaining the hydraulic system. CAUTION - One of the major contributors leading to malfunctions in a hydraulic system is CONTAMINATION. Care must be exercised to prevent dirt from entering the system. ALWAYS CAP or PLUG OPEN PORTS AND HYDRAULIC LINES.

A. FLUID LEVEL - Check level daily. Maintain fluid level at full mark on side gauge with the CONDOR® in fully retracted position.

B. OIL FILTER - Change return line filter located on hydraulic tank after the first 30 days or 50 hours of operation. Therafter, change the filter every 3 months or 300 hours of operation.

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

D. HYDRAULIC TANK - Drain oil from tank every 500 hours of operation or yearly, which ever comes first, and replace filter element. Add oil to tank to required level.

CAUTION

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

10

MANUAl 92328-002 SEPTEMBER 1995

3.

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

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

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

D. NEVER let the batteries stay completely DISCHARGED. Batteries should be charged at the end of each work day with the charger time set to accommodate overnight charging. A fully charged battery will have an electrolyte specific gravity of 1.265 to 1 .285 at electrolyte temperature of 77.

CAUTION

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

4.

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

B. Operate charger in accordance with the battery charging instructions.

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

D. Avoid arcing battery conditions. DO NOT smoke or INTRODUCE a FLAME or SPARK in the CHARGING AREA. E. Use protective face and eye equipment when checking the condition of charging batteries.

DANGER Lead acid batteries generate highly explosive hydrogen gas especially during the charging cycle.

To AVOID the possibility of an explosion, charge batteries ONLY in a well VENTILATED AREA. Keep fire, sparks, and burning material away from the charging area. Do Not smoke near a battery, and always shield the eyes when working near a battery.

MANUAL 92328-002 SEPTEMBER 1995

11

5. ENGINE Refer to engine manufacturers recommended maintenance and service procedure for lubricant and time interval.

ENGINE MAINTENANCE SCHEDULE

DAILY

WEEKLY OR 50 HRS.

100HRS

25OHRS.

SEASONALLY OR 500 HRS

• •

CHECK OIL LEVEL. Add to full mark • DO NOT overfill.

CHECK AIR CLEANER. Shake out accumulated dirt from dry element cleaner· Maintain oil level in oil bath type cleaner.

CLEAN AIR INTAKE SCREEN. Clean cooling fins if neceS88ry.

•

CHANGE CRANKCASE OIL. CLEAN AIR FILTER ELEMENT. Dry element and oil bath types.

CLEAN CRANKCASE BREATHER CAP. GREASE CLUTCH HOUSING BEARING (VG4D,V4650).

REPLACE OIL FILTER. In adverse conditions replace every oil change.

• • • • •

LUBRICATE DISTRIBUTOR SHAFT.

•

CHECK COMMPRESSION. Pressure should not very more than 10 p.s.i. between cylinders. Remove head· clean out carbon deposits. Reseat valvea if necessary.

•

INSPECT SRARK PLUGS. and BREAKER POINTS. Replace if necessary and regap to specification.

• • •

INSPECT FUEL FILTER. Clean filter screen and glasl bowl.

LUBRICATE DISTRIBUTOR CAM and breaker arm pivot.

INSPECT COOLING SYSTEM. Remove shrouding and screpe

•

off dirt from between fins, around cylinders and from shrouding.

INSPECT STARTING MOTOR. Check for loose mounting and cable connections.

CHANGE OIL IN CLUTCH and REDUCTION GEAR HOUSINGS.

12

MANUAL 9232Il-002 SEPTEM9ER 1996

• •

NOTES:

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HOLDING VALVE 37171 4 PL

OUTRIGGER CYL 2.00 DIA BORE 1.25 DIA ROD 15.00 SROKE 162-96449-00 4 PL

STEERING CYLINDER 2.00 DIA BORE .75 DIA ROD 10.00 STROKE 54548

1. KAWASAKI ENGINE 20HPOJ,600 RPM PUMP 54604-003 .61CIPR 2. FOR BATTERY POWERED CONDORS, SEE SCHEMA TIC BELOW. 3. REPLACE RV3 Ie RV3. WITH PLUGS, PARKER Pl0-2, OR, SET AT 3000 PSI. 4. THE DRIVE SPOOL IS PARKER 697604.

5. HYD HOSE DIA IS IDENTIFIED BY IMPERIAL-EASTMAN PART NUMBER. 6. THIS SCHEMATIC SUPERCEDES 54522.

LIFT CYLINDERS FIRST STAGE-5.5 DIA X 20.56 STROKE SECOND STAGE-4.25 DIA X 21.69 STROKE 55085 2 PL

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MANUAL 92328-002 SEPTEMBER 1995

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118 Il6A

27

''''

29

lIB

116A

r

c:::.

I

r:-~-' :

:

I I

L_~.:.J

~~_--------------------_---6=3~A

. I I I

I I

6"

OUTRIGGERS

VOLT METER OPTION CHOKE SOlENOID

64

++

..:c..___ r..:c...,.....;;;.;.:..~__ l:;

:

PUMP

BEACON/STROBE OPTION

________________________________

B3A

17/BLANK

FU~

HIGH TEMP SHUTOFF

START

17/BLANK

IGNITION COIL

~.~2:...&6~1f_.~:tr.~'S:!---------------------------__<;~ 'CJ'

SA

CHOKE

OIL S..,TCH

HOUR METER OPTION

84

IIA

STARTER SOLENOID START RELAY

~.!!2~-------------------------p_;:::_------'2;:J2:!..·.!.F--4' L.!!2~

ilIA

STARTER MOTOR

I

I

L~ J

t: :

r.=!1~:...-----------~V~~:>~.4-11--_+--+_~~.2~~I~.~2r~-o.

7

CR2

-un

UP

"052" VALVE -LOWER HOLDING VALVES ON un cns

DESCEND ALARM OPTION DUMP RELAY JACKS UP RELAY UP "DCV2" VALVE -JACKS DO""'"

BRAKE/SPEED RELAY

29

14

I 55/62

13

DRIVE

"

29

rQRWARD "DRIVE" VALVE REVERSE

13 :

UMIT SWITCH SHOWN WITH JACK UP

.~.:.J 16 --,--,

.1

o---------------------------------------~~I-~rt--~

t:17~~/.B=LA==N=K~____~~-------~~~S~~:E~RI~N:G_______________________________~~~:~~i!·--_1' NOTES: 1. THIS SCHEMATIC SUPERCEOES 54509.

2. 31 .. 66 ARE ISOLA TED SPARES l. SPADE TERMINALS AT ENGINE ARE SHOWN AS:

.'•

--7>

MANUAL 82328-002 SEPTEMBER 1886

RI~T

"S~ER"VALVE

.:.J _ '-- LEFT

54672 17

....00 NOTES: LIFT CYLINDERS FIRST STAGE 5 DIA X 20.56 STROKE SECOND STAGE 3.75 DIA X 21.69 STROKE 162-96448-00 2 PL

STEERING CYLINDER 2.0 DIA BORE .75 DIA ROD 10.0 STROKE 54548

1. WISCONSIN ENGINE 30HP02.400 RPM PUMP 355-00014-00 .91CIPR 2. KAWASAKI ENGINE 20HP@3.600 RPM PUMP 54604-003 .61CIPR 3. FOR BATTERY POWERED CONDORS. SEE SCHEMATIC BELOW. 4. REPLACE CROSS-RELIEF VALVES 51616. 2 PL. WITH PLUGS. PARKER P10-2. OR SET AT 3000 PSI. 5. THE DRIVE SPOOL IS PARKER 697605.

6. HYD HOSE DIA IS IDENTIFIED BY IMPERIAL-EASTh4AN PART NUMBER.

A

Sl

0608

FRONT MOTORS 321-00010-00 CHECK VALVES 450-00062-00 D6<l8

'.120 '.106

F01

0608

F02

1.44

F SAHR BRAKES 126-10007-00 REAR AXLE

G MANIFOLD ASSY 315-00025-00

2 0

.., N

'"

5103 CHECK VALVE 50068 FILTER 250-00012-00

5703

5703

FREE WHEEL 52661

g•.

5703

5103

BRAKE 58079 N

~

PUMP FILTER 33430

HYDRAULIC TANK 23.27 GALLONS

.. _ PROPRIETARY ... _ _1Nf000Al1ON ___ ~ WACO. TEXAS ~-I----I--+---I~~~~·"~~~~==~-------------------------i ='::"'~o:-~,..~-= liRE ~-I---f--+---I

8209

lTft

E.C.N. NO.

4935 l 'JR. E.R.N. NO.

UNl.ESS OKftWI$[ sPttF1EO: bIMEMSION5 AM .. INCH[S

6/26}15 RAK

~-l-='5=12=-+'::1/'='3"'/9::'5-+R;;:-A"'K:-t OAT[ 10

0 ... Tt

TClI.£IWaS ON,

:r:: _i:ii

MDA3887 HYDRAULIC

~ REV.

APPR. DR"" 4

RAK

B

CHECIW)

APPR. APPROI.m

SHEET

1 OF 2

LIFT CYLINDERS FIRST STAGE 5 DIA X 20.56 STROKE SECOND STAGE 3.75 DIA X 21.69 STROKE 162-96448-00 2 PL

STEERING CYLINDER 2.0 DIA BORE .75 DIA ROO 10.0 STROKE 54548

BRAKES-4 PL 126-10007-00 MOTORS-4 PL 321-00011-00

21479 2 PL

1.43 I I

SIP

_-=1'-' FRONT

•. 120

FOI

•. 106

F02

1.14 I

SIP

_m.-_ _ _ _ _ _ _ _ _ _ _ _ _ _ _

.--J

MANIFOLD 315-00025-00

I

'----'1'-- _ _ _ _ ~E~ PA 315-00027-00 2 PL

I I

FREE WHEEL 52661

CHECK VALVE 50068 BRAKE 58079 NOTE: SEE SHEET 1 FOR HOSE PART NUMBERS.

ri:i:l__

PllClPRETNtt INFlRMftCN

BALL VALVE 450-00052-00 HYDRAULIC TANK 23.27 GALLONS

~+----+----+-~~~~~~,~~r===~------W-A-C--O-.-T-E-X-A-S------~ :-..:-=:-.:r.,...w:.,..~= mat

..... -=......... _

~+_--_+----+~ ~s '"' ::: Llft. E.C.N. NO.

DATt

49.35 lTft. E.R.N. NO.

10 DATE

APPR. DftA...

APPR._

m "':;:"'

A.HITTLE

/23/M

SCHEMATIC. MDA3887 HYDRAULIC (4WO- SEE SHEET 1 FOR 2WO) REV.

54806

""'T

B 2OF2

SELF-PROPELLED ELEVATING WORK PLATFORM

MODELS 3887G/4887G ILLUSTRATED P ARTS MANUAL

3887G

4887G

SHIPPING ADDRESS

MAILING ADDRESS

CALAVAR CORPORATION 8300 IMPERIAL DRIVE WACO, TEXAS 76712 (817) 666-4545

CALAVAR CORPORATION P. O. Box 21447 WACO, TEXAS 76702-1447 (817) 666-4545

MANUAL 92328-003 SEPTEMBER 1995

INTRODUCTION

The primary purpose of this manual is to provide the user with a thorough understand ing 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 UNIT AT ALL TIMES.

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

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

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

Calavar Corporation reserves the right to modify, improve, add, and/or delete certain design features of its products without any obligation to incorporate new features into products previously sold. Our manuals are continually updated to reflect these changes.

DO NOT AL TER OR MODIFY THIS CONDOJ1® WITHOUT PRIOR WRITTEN APPROVAL FROM THE MANAGEMENT OF CALAVAR CORPORATION

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

NOTE:

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

MANUAL 92328-003 SEPTEMBER 1995

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 of5 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, Texas76702-1447- 817-666-4545,817-666-4544FAX Form No.

ii

513-1M~5

Printed in U.S.A.

MANUAL 12328-003

1EPTEMlER111&

CONDORII SERVICE INFORMAnON

1. If you need assistance or have any service or maintenance questions, Calavar service and parts personnel are always available by phone or fax. The telephone numbers are: (817) 666-4545 Telephone (817) 666-5125 Voice Mail (800) 443-5803 FAX

2. There are numerous written Maintenance Procedures available for this machine. These procedures are available through the Calavar Service Department to anyone who requests them.

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

Calavar conducts service schools on a continuing basis. Call any of our service or sales persons for a schedule. Remember, training of mechanics is the responsibility of their employer, but Calavar Service Schools help you provide this training.

4. Calavar Service School Training Manuals are available for purchase through the parts department. The part numbers for these manuals are: #92333 for self-propelled models; and #92334 for truck-mounted models.

CALAV AR CORPORATION

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

iii

NOTES

CONDOR® MODEL 3887G/4887G ILLUSTRATED PARTS MANUAL

TABLE OF CONTENTS

INTRODUCTION ............................................................................................................ i WARRANTY ................................................................................................................ ii SERVICE INFORMATION ............................................................................................... iii

FIGURE

DESCRIPTION

PAGE

A B C

............................... Serial Number Location .................................................... 2 ............................... Recommended Spare Parts List ......................................... 3 ............................... How To Order Parts ........................................................ 4

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

............................... Final Installation ............................................................. 6 ............................... Decals Installation ......................................................... 10 ............................... Chassis Installation ....................................................... 14 ............................... Outrigger Installation ..................................................... 18 ............................... Cover Installation .......................................................... 20 ............................... Steer Installation .......................................................... 22 ............................... Steer Cylinder Assembly ................................................ 24 ............................... Hydraulic Installation ..................................................... 26 ............................... Brake/Hub Assembly ..................................................... 28 ............................... Brake Assembly ............................................................ 30 ............................... Lift Cylinder Assembly ................................................... 32 ............................... Hydraulic Tank Assembly ............................................... 36 ............................... Engine Assembly .......................................................... 38 ............................... Lower Control Assembly ................................................ 40 ............................... Limit Switch Assembly .................................................. 54 ............................... Arm Stack Assembly ..................................................... 56 ............................... Platform Assembly ........................................................ 60 ............................... Upper Control' Box Assembly .......................................... 64

OPTIONS

18 19 20 21 22 23 24 25 26 27 28

............................... 110 Volt Line to Platform .............................................. ............................... 4-Wheel Drive .............................................................. ............................... Spark Arrestor ............................................................... ............................... Slope Alarm 5-Degree Multi-Axis .................................... ............................... Dual Fuel Carb-Vapor Kit ............................................... ............................... LP/Gas Dual Fuel (Liquid) ............................................... ............................... Tires, Foam Filled ......................................................... ............................... Hour Meter .................................................................. ......'......................... Decend Alarm ............................................................... ............................... Engine, Hatz Diesel ....................................................... ............................... Generator, Hydraulic Driven ...........................................

MANUAL 92328-003 SEPTEMBER 1995

68 69 70 71 72 73 74 75 76 77 78

1

FIGURE A-Serial Number Location

4887G

3887G

2 2

The CONDO~ Model 3887G/4887G Serial Number is stamped in two locations on the machine.

2

1.

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

2.

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

MANUAL 92328-003 SEPTEMBER 1995

FIGURE B-Recommended Spare Parts List Models 3887G & 4887G (1 Unit-1 Year Operation)

PART NO.

DESCRIPTION

QTY

34354 .................................... . Holder, Saftey Manual .................................................. 1 92328-001 .............................. Manual, Operator's 3887G/4887G ................................. 1 67821-002 .............................. Rod End, 5/8 Male ....................................................... 1 355-00014-00 .......................... Pump, Hydraulic .......................................................... 1 52671 ..................................... Operator, 3Pos. Rot. Key .............................................. 1 206-00001-00 .......................... Diode ......................................................................... 9 5191 3 .................................... . Operator, Red Push-Pull ................................................ 1 50077 ..................................... Switch ....................................................................... 1 50075 ..................................... Switch ....................................................................... 2 67758 ..................................... Switch, Toggle ............................................................ 1 36083 ..................................... Switch, Foot ............................................................... 1 40808 ..................................... Solenoid, Throttle ........................................................ 1 32111 ..................................... Solenoid, Choke .......................................................... 1 394-00006-00 ...... .................... Solenoid, Essex ........................................................... 1 67408 ..................................... Element Hyd. Filter - PIN 33430 ..................................... 5 5031 6 ..................................... Breather Filler .............................................................. 1 250-00012-00 .......................... Filter, High Pressure ..................................................... 2 030-G7000-00 ......................... Decal Installation 3887G ............................................... 1 030-G9000-00 ......................... Decal Installation 4887G ............................................... 1 392-00011-00 .......................... Switch, Limit ............................... (4887 Only) ............. 1 52773 ..................................... Lever, Actuating Arm 5" ............... (4887 Only) ............. 1 105-00003-00 .......................... Actuator Arm .............................. (4887 Only) ............. 1 392-00010-00 .......................... Switch, High Speed ...................... (4887 Only) ............. 1

MANUAl 92328-003 SEPTEMBER 1995

3

FIGURE C - How to Order Parts

1.

When ordering parts for your CONDOR®, ensure that you are able to give the model and serial numbers of all units for which parts are needed. The serial number(s) will assist the Calavar 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 Calavar part number(s) for the partes) 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 Calavar Parts Department. Credit will be authorized through the Service Department after a Warranty Claim has been submitted to Calavar. A Warranty Claim is to be filed for any part received as "defective".

5.

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

6.

Calavar classifies its orders in the following ways: Emergency

(unit out of service) - Top priority. Shipping deadline for emergency orders to ship same day is 2:00 p.m. Central Standard Time. Any emergency order received after 2:00 p.m. will be shipped the following day.

Stock

Order to be shipped within one (1) week.

7.

Calavar 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 Calavar packing list and subsequent invoice but not received by the dealer/customer MUST be reported within 10 days after the date of shipment. If the parts are still required, a NEW parts order must be submitted.

Shortages and discrepancies will be reviewed on an individual basis by the Parts staff and adjustments will be made accordingly.

10.

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

4

MANUAl 92328-003

SEPTEMBER 1995

FIGURE C - How to Order Parts

CALAVAR PARTS DEPARTMENT FAX ORDER FORM FAX NO. 800·443·5803

I

ACCOUNT # C U

S T 0 M E R

I N

PURCHASER

SALES ORDER # NAME

NAME

F 0

ADDRESS

R M A T I

CITY

PHONE 0 ( ) N CUST. PURCHASE ORDER NO.

STATE

S IADDRESS H T I 0 ICITY P

ZIP

FAX ( )

STATE

FAX ( )

IPHONE

(

I ORDERDATE

I

)

REQUEST DATE

I

I

ZIP

SPECIAL MARKS It NUMBERS

SHIPPING INSTRUcnONS

PART NUMBER

DESCRIPTION

QTY.

NOTES

FOR ORDER STATUS PLEASE CHECK. APPROPRIATE BOX BELOW EMERGENCY STOCK MANUAL 92328-003

SEPTEMBER 1996

5

FIGURE 1-Finallnstallation (3887G)

1

3

6

MANUAL 92328-003 SEPTEMBER 1995

FIGURE 1-Final Installation (3887G)

ITEM

PART NUMBER

DESCRIPTION

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

MDA3887G .............. Model 3887G Scissor .................................................. Ref. 001-G7000-1A .......... Deck/Rails Weldment ...................................................... 1 55081 ...................... Armstack Weldment, MDA3887 ....................................... 1 55079 ......•............... Chassis Installation, 3887G .............................................. 1 54741 ...................... Wiring Assembly 3887G Electrical .................................... 1 54507 ....................•. Hydraulic Installation - 3887 .........................•.................. 1 030-G7000-00 .......... Decal Installation - 3887G ............................................... 1 54671 ...................... Schematic, 3887G Electrical ............................................ 1 54806 .........•............ Schematic, MDA3887 Hydraulic ....................................... 1 53259 ........•..........•.. Tape, Non-Skid 6"W Black ....................................... 5.91LF 55179 ...................... Hose Kit - 3887G 2WD Kawasaki ..................................... 1

QTY

- Indicates Items Not Shown

MANUAl 92328-003 SEPTEMBER 1995

7

FIGURE 1 -Final Installation (4887G)

1

3

6

8

MANUAL 92328-003 SEPTEMBER 1996

FIGURE 1 -Final Installation (4887G)

DESCRIPTION

ITEM

PART NUMBER

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

MDA4887G .............. Model 4887G Scissor .................................................. Ref. 001-G9000-1A .......... Deck/Rails Weldment MDL4887 ....................................... 1 55117 ...................... Armstack Weldment, 4887 .............................................. 1 55080 ...................... Chassis Installation, 4887G .............................................. 1 54670 ...................... Wiring Assembly 4887G Electrical .................................... 1 55104 ...................... Hydraulic Installation - 4887 ............................................ 1 020-G9030-o0 .......... Assembly - Outrigger ...................................................... 4 53259 ...................... Tape, Non-Skid 6"W Black ....................................... 7.58LF 030-G9000-00 .......... Decal Installation - 4887G ............................................... 1 55096 ...................... Schematic, MDA4887 Hydraulic ....................................... 1 54523 ...................... Diagram, 38/4887 Hydraulic ............................................ 1 54672 ...................... Schematic, 4887G Electrical ............................................ 1 55180 ...................... Hose Kit - 4887G 2WD Kawasaki ..................................... 1

QTY

- Indicates Items Not Shown

MANUAL 92328-003 SEPTEMBER 1995

9

FIGURE 2-Decallnstallation (3887G)

3

7

10

MANUAl 92328-003 SEPTEMBER 1995

FIGURE 2-Decallnstallation (3887G) 10

15 4

ITEM

PART NUMBER

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

030-G7000-00 .......... Decal Installation - 3887G ........•..........•.•..•.................. Ref. 54186 ...................... Decal, Caution Guard Rail Use .......................................... 1 54183 ...................... Decal, Danger Arm Stand ................................................ 2 54190 ...................... Decal, Stop .................................................................... 1 52735 ...................... Decal, 110 Volts ............................................................ 2 21882-002 ............... Decal, Danger Not Insulated ............................................. 2 21850 ...................... Decal, Hydraulic Fluid ...................................................... 1 54125 ...................... Decal, Free Wheel Valve .................................................. 1 276-R 1046-00 .......... Latch, Rubber Hold Down ................................................ 4 50070 ...................... Decal, Battery Service ..................................................... 1 54749 ...................... Decal, Operator Warning ................................................. 2 52964 ...................... Decal, Platform Capacity 2,000 Ibs ................................... 2 55007 ...................... Decal, Emergency Lowering ............................................. 2 54293 ...................... Decal, Tie Down ............................................................. 2 310-00191-00 .......... Decal, Gasoline .............................................................. 1 54710 ...................... 4887G Operating Instructions .......................................... 1 58419 ...................... Tape Orn/Red 5" ....................................................... 39LF 55008 ...................... Decal, Caution Emergency Lowering .................................. 2 37515-002 ............... Decal, Model 3887 ......................................................... 2

DESCRIPTION

QTY

- Indicates Items Not Shown

MANUAL 92328-003 SEPTEMBER 1995

11

FIGURE 2-Decallnstallation (4887G)

3

19

7

--------"'~,&..:'

17

2

18

12

MANUAL 92328-003 SEPTEMBER 1995

FIGURE 2-Qecallnstallation (4887G)

16

DESCRIPTION

5

QTY

ITEM

PART NUMBER

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

030-G9000-00 .......... Decal Installation - 4887G ........................................... Ref. 54183 ...................... Decal, Danger Arm Stand ................................................ 2 54186 ...................... Decal, Caution Guard Rail Use .......................................... 1 54190 ...................... Decal, Stop .................................................................... 1 21882-001 ............... Decal, Keep Clear ........................................................... 4 52735 ...................... Decal 110 Volts ............................................................. 2 55007 ...................... Decal, Emergency Lowering ........................... ~ ................. 1 69473-002 ............... Decal, Die-Cut, CONDORs 3.45 x 23 ................................. 4 50070 ...................... Decal, Battery Service ..................................................... 1 -52759 ...................... Decal, Stand Clear .......................................................... 4 21850 ...................... Decal, Hydraulic Fluid ...................................................... 1 55008 ...................... Decal, Caution Emergency Lowering .................................. 2 54088 ...................... Deca'l, Tie Down ............................................................. 2 310-00191-00 .......... Decal, Gasoline .............................................................. 1 54749 ...................... Decal, Operator Warning ................................................. 2 276-R 1046-00 .......... Latch - Rubber Hold Down ............................................... 4 54710 ...................... 4887G Operating Instructions .......................................... 1 37515-001 ............... Decal, Model 4887 ......................................................... 1 54291 ...................... Decal, Free-Wheel Instruction ........................................... 1 58419 ...................... Tape Orn/Red 5- ....................................................... 39LF 52963 ...................... Decal Platform Cap 1,500 Ibs ........................................... 2

- Indicates Items Not Shown

MANUAL 92328-003 SEPTEMBER 1995

13

FIGURE 3-Chassis Installation

2

17

7

1

11

14

6

MANUAL 92328-003 SEPTEMBER 1995

FIGURE 3-Chassis Installation

DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. 1 2 3

55079 ............................ Chassis Installation. 38/4887G ................................................. Ref. 54643 •..•.•••.•••.••...•.••.•.•.• Chassis Weldment. 38/4887 .......................................................... 1 55074 ....••••.••••...••..•....•.• Engine Installation. 38/4887 Kawasaki .......................................... 1 51306 ............................ Tank. Fuel. 12 Gallons ................................................................... 1 51307 ............................ Bracket Set. Fuel Tank Mtg ........................................................... 1 54551 ............................ Tie Rod - 38/4887 Steering ............................................................ 1 02O-G9001-00 ............... Assembly. Rim & Tire. Right .......................................................... 2 476-00025-00 ............... -Tire ............................................................................................... 1 4n-00002-00 ............... -Rim ............................................................................................... 1 020-G9001-10 ............... Assembly. Rim & Tire. Left ............................................................ 2 46-00025-00 ................. -Tire ............................................................................................... 1 4n-00002-oo ............... -Rim ............................................................................................... 1 67821-002 ..................... Rod End. 518' Male ......................................................................... 2 BOW34287 ................... Nut. Hex Lock .63 - 18UNF ............................................................ 2 54567 ............................ Weldment. 4887 LH Yoke .............................................................. 1 54568 ............................ Weldment. 4887 RH Yoke ........................................................;.... 1 010-G5062-00 ............... Weldment. King Pin ....................................................................... 4 54074 ............................ Bushing Flange .............................................................................. 4 55197 ............................ Cover Installation - 4887G ............................................................. 1 55123 ............................ Step Weldment. 4887 .................................................................... 1 54793 ............................ Mnt. Kaw. Lower Elec. Box ........................................................... 2 55162 ............................ Mnt. Lower Elec. Box .................................................................... 2 55224 ............................ Fuel Line. 38/4887G ...................................................................... 1 55225 ............................ Fuel Line. 38/4887G Tank ............................................................. 1

-4 -5 6

7

-8 -9 10 11 -12 -13 -14 15 16 17 -18 -19

- Indicates Items Not Shown

MANUAL 92328'()()3 SEPTEMBER 1995

15

FIGURE 3-Chassis Installation

2

17

7

1

6

11

16

MANUAl 92328-003 SEPTEMBER 1996

FIGURE 3-Chassis Installation

ITEM

PART NUMBER

Ref. 1 2 3

55080 .....•................ Chassis Installation, 38/4887G ..................................... Ref. 54643 .....•...........••... Chassis Weldment, 38/4887 ............................................ 1 55074 ......•.......••...... Engine Installation, 38/4887 Kawasaki .............................. 1 51306 .......•............. ; Tank, Fuel, 12 Gallons .................................................... 1 51307 ...........•.......... Bracket Set, Fuel Tank Mtg .............................................. 1 54551 ..•..•................ Tie Rod - 38/4887 Steering .............................................. 1 020-G9001-00 .......... Assembly, Rim & Tire, Right .. ~ .......................................... 2 476-00025-00 ......•... -Tire ..........•..............•.....................•.........•................... 1 477-00002-00 .......... -Rim ............................................................................. 1 020-G900 1-10 .......... Assembly, Rim & Tire, Left .............................................. 2 476-00025-00 .......... -Tire ............................................................................. 1 477-00002-00 .......... -Rim ................•...............•...........................................• 1 67821-002 ............... Rod End, 5/8 Male .......................................................... 2 BOW34287 .............. Nut, Hex Lock .63 - 18UNF ............................................. 2 54567 ...................... Weldment, 4887 LH yoke ................................................ 1 54568 ........••............ Weldment, 4887 RH yoke ............................................... 1 010-G5062-00 .......... Weldment, King Pin ........................................................ 4 54074 ......•............... Bushing Flange ............................................................... 4 55197 ..................•... Cover Installation - 4887G ............................................... 1 55123 ...................... Step Weldment, 4887 ..................................................... 1 54793 ...................... Mnt. Kaw. Lower Elec. Box .............................................. 2 55162 .........•............ Mnt. Lower Elec. Box .......•.............................................. 2 55224 ...................... Fuel Line, 38/4887G ....................................................... 1 55225 ...................... Fuel Line, 38/4887G Tank ............................................... 1

-4 -5 6

7

-8 -9 10 11 -12 -13 14 15 16 17 -18 -19

DESCRIPTION

QTY

- Indicates Items Not Shown

MANUAl 92328-003 SEPTEMBER 1995

17

FIGURE 4-0utrigger Installation

8

I I

7

4

0

6

9

3

o

o 5

2

18

MANUAL 92328-003 SEPTEMBER 1995

FIGURE 4-0utrigger Installation (4887G Only)

ITEM

PART NUMBER

Ref. 1 2 3 4 5 6 7 8 9 10

020-G9030-00 •....•.... Assembly, Outrigger •••••••.•.........•..••...•••...•.••.......•....... Ref. 010-G9035-oo .......... Outrigger Weldment, 4887 .............................................. 1 010-G9135-00 .......... Foot Weldment, 4887 Outrigger ....................................... 1 010-G9140-00 .......... Weldment, Inner Tube ..................................................... 1 245-00008-00 .......... Pin, 3/4 x 4-1/4 Hitch ..................................................... 1 350-00019-00 .......... Pin, Pivot ....................................................................... 1 164-00014-00 .......... Chain #4 Straight Link ................................................ 18LF 621-G9113-00 .......... Pin - Cylinder ................................................................. 1 54490 ...................... Cover Weldment, Outrigger .............................................. 1 162-96449-00 .......... Cylinder MDL4887 Outrigger ............................................ 1 020-G9050-oo .......... Assembly, Limit Switch Outrigger .. ; .................................. 1 392-00011-00 .......... -Switch, Limit ................................................................ 1 67114-003 ............... -Strain Relief 1/2NPT .37/.5 ............................................. 1 52773 ...................... -Lever, Actuating Arm-5· ................................................. 1

DESCRIPTION

QTY

- Indicates Items Not Shown

MANUAL 82328-003

SEPTEMBER 1811&

19

FIGURE 5-Cover Installation (3887G/4887G)

5 4

7

B

20

MANUAL 92328'()()3

SEPTEMBER 1995

FIGURE 5-Cover Installation (3887G/4887G)

ITEM

PART NUMBER

Ref. 1 2 -3 4 5 -6 7 8

55197 ...................... Cover Installation ........................................................ Ref. 55238 ...................... Cover Weldment - RH ...................................................... 1 55195 ...................... Cover Weldment - LH ...................................................... 1 529-G9085 ............... Cover, Inside Angle ......................................................... 2 020-G9401-00 .......... Assy, Deck Floor ............................................................ 1 34354 ...................... Holder Safety Manual - Black Caps .................................... 1 67793 ...................... Clamp Cable 2 3/4 .......................................................... 1 55198 ...................... Cover - MDA38/4887G Engine ......................................... 1 55014 ...................... Cover, Kawasaki Front ................................................... 1

DESCRIPTION

QTY

- Indicates Items Not Shown

MANUAL 82328-003 SEPTEMBER 1896

21

FIGURE 6 -Steering Installation

2 6

3 4

5

8

23

1 18 15

I

7

,

i I

~~ l

~27

>~ !!

I

23

Q-16 24

9

15

25

26_-l.-~t.t1

®

16 15

25

25

22

~UAL 92328-003

PTEMBER 1995

FIGURE 6-Steering Installation

ITEM

PART NUMBER

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 -14 15 16 17 18 -19 -20 -21 -22 23 24 25 26 27

.. ............................. Steering Installation .................................................... Ref. 020-G9042-00 .......... Assembly, Motor/Hub #3 ................................................. 1 289-00006-00 .......... -Hub-Drive ................................................................... 1 321-00010-00 .......... -Motor, Hydraulic Wheel (Ref 54751) .............................. 1 BOW36111 .............. -Bolt, Hex .50"-13UNC x 2.75" ..................................... 4 BOW36729 .............. -Washer, Split Lock .50" ............................................... 4 396-00003-00 .......... -Stud Wheel .50"-20 x 1.75" ......................................... 5 54551-001 ............... Tie Rod, Steer ................................................................ 1 BOW32278 .............. Nut, Jam .75"-10 ........................................................... 2 67821-002 ............... Rod End, .625" Male ....................................................... 2 ............................... Assembly, Steer Clyinder ................................................. 1 54548 ...................... -Cylinder, Steer 2 x 6 .................................................... 1 253-96590-00 .......... -Fitting, Adapter ........................................................... 2 54548-100 ............... -Seal Kit ...................................................................... 1 67821-003 ............... -Rod End, .75" Female .................................................. 1 01 0-G5062-00 .......... Weldment, King Pin ........................................................ 4 124-00033-00 .......... Bushing, 1.25" x 1.00· x 1.25"-.125"FL .......................... .4 ............................... Not Used ........................................................................ .

020-G9041-00 .......... Assembly, Brake/Hub ...................................................... 1 126-10007-00 .......... -Brake, Eskridge ........................................................... 1 289-00006-00 .......... -Hub-Drive ................................................................... 1 396-00003-00 .......... -Stud, Wheel .50"-20 x 1.75· ........................................ 5 529-G5060-00 .......... -Plate, Brake Cover ....................................................... 1 BOW30160-350 ........ Bolt, Hex. 75"-10UNC x 3.50· ......................................... 3 BOW34278 .............. Nut, Stop Elastic .75"-10 ................................................ 3 BOW36834 .............. Bolt, Socket Flat Head .38"-16UNC x 1.00· ....................... 8 54568 ...................... Weldment, Right Hand Yoke ........................................... 1 54567 ...................... Weldment, Left Hand Yoke ............................................. 1

DESCRIPTION

OTY

- Indicates Items Not Shown

MANUAl 92328-003 SEPTEMBER 1995

23

FIGURE 7 -Steer Cylinder Assembly

o

wui

:::>ID

(Xl 0-'

0:.

Off-lL.

I/)

"oI

<D

24

MANUAL 92328-003 SEPTEMBER 1995

FIGURE 7 -Steer Cylinder Assembly

DESCRIPTION

ITEM

PART NUMBER

Ref.

54548 ...................... Steer Cylinder Assembly .............................................. Ref. 54548-100 .............. : Seal Kit ......................................................................... 1 ..... ;......................... O-Ring .......................................................................... 1 ............................... Crown Seal .................................................................... 1 ............................... Back-Up ........................................................................ 2 ............................... O-Ring .......................................................................... 1 ............................... Back-Up ........................................................................ 1 ............................... U-Cup (Dual Lip) ............................................................. 1 ............................... Wiper ............................................................................ 1 ............................... Lock-Nut ....................................................................... 1

1 2 3 4 5 6 7 8

OTY

- Indicates Items Not Shown

MANUAL 92328-003 SEPTEMBER 1996

25

FIGURE a-Hydraulic Installation

3

12

17

~~.:.---+---

10

26

MANUAL 92328-003 SEPTEMBER 1995

20

FIGURE 8-Hydraulic Installation ITEM

PART NUMBER

Ref. 1

54507 ...................... Hydraulic Installation ................................................... Ref. 020-G9041-OO .......... Assembly - Brake/Hub #3 ................................................ 2 126-10007-00 .......... -Brake, Eskridge ............................................................. 1 396-00003-00 .......... -Stud Wheel ................................................................... 5 529-G5060-00 .......... -Plate, Brake Cover ......................................................... 1 289-00006-00 .........• -Hub, ............................................................................ 1 020-G9042-00 .......... Assembly - Motor/Hub #3 ................................................ 2 289-00006-00 .......•.• -Hub ............................................................................. 1 321-00003-00 .......... -Motor, Hyd. Wheel (Ref. 54751) ..................................... 1 396-00003-00 ...•.••.•• -Stud Wheel .•...•.••..•.............••.....•...••............••....•..•....... 5 020-G9049-00 .......... Assembly - Hydraulic Tank 4887 ...................................... 1 54506 ...................... Cylinder Assembly, 3887 Lift ........................................... 2 55092 ...................... Cylinder Assembly, 4887 Lift ........................................... 2 54548 ...................... Cylinder, Steer .............................................................. 1 250-00012-00 .......... Filter, High Pressure ........................................................ 1 51921 ...................... Valve, Solenoid .............................................................. 2 315-00025-00 .......... Valve, Lift Control .......................................................... 1 392-00025-00 .......... Switch - Limit Pressure .................................................... 1 51616 ...................... Valve Relief Cart 1500-3000 ............................................ 2 450-00061-00 .......... Valve, Flow Control (Ref. 66418) ..................................... 3 54574 ...................... Tube Assembly, Lift on Man/Blkhd .................................... 1 020-G9OO3-00 .......... Assembly - Dump Valve ................................................... 1 450-00054-00 .......... -Valve-Dump .................................................................. 1 450-00056-00 .......... -Valve-Body Dump .......................................................... 1 54579 ...................... Tube Assembly, HP Filter/P Prt Man .................................. 1 54580 ...................... Tube Assembly, T to Return Filter ..................................... 1 54577 ...................... Tube Assembly, S1 Man/Strg. Blkhd ................................. 1 54578 ...................... Tube Assembly, S2 Man/Strg. Blkhd ................................. 1 54575 ...................... Tube Assembly, LT Man/Tp Tee Blkhd ............................... 1 54576 ...................... Tube Assembly, L2 Man/Bm Tee Blkhd .............................. 1 67821-003 ............... Rod End, 3/4 Female ....................................................... 1 BOW32288 .............. Nut Jam .75-16UNF ........................................................ 1 50068 ...................... Check Valve .................................................................. 1

2

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

14 15 16 17 18 19 20 21 22

DESCRIPTION

QTY

- Indicates Items Not Shown

MANUAL 9232f1.OO3 SEPTEMBER 1996

27

FIGURE 8A-Brake/Hub Assembly

3

4

28

MANUAL 92328'()()3 SEPTEMBER 1995

FIGURE 8A-Brake/Hub Assembly

ITEM

PART NUMBER

Ref. 1 -2 3 4

020-G9041-Q0 126-10007-00 396-00003-00 529-G5060-00 289-00006-00

DESCRIPTION

QTY

.......... Brake/Hub Assembly #3 .............................................. Ref. .......... Brake, Eskridge .............................................................. 1 .......... Stud Wheel 1/2 - 20 x 1 3/4 ............................................ 5 .......... Plate, Brake Cover .......................................................... 1 .......... Hub, 1.5 Taper 38/4887 Wheel ........................................ 1

- Indicates Items Not Shown

MANUAL 92328-003 SEPTEMBER 1995

29

FIGURE 9-Brake Assembly

21",

1&

22

30

MANUAL 92328-003 SEPTEMBER 1995

FIGURE 9-Brake Assembly

ITEM

PART NUMBER

Ref. 1 2 3 4

126-10007-00 .......... Assembly, Brake ......................................................... Ref. ............................... Nut, Slotted Jam ............................................................ 1 ............................... Screw, Socket Head Cap ................................................. 4 ............................... Plug, Hollow Hex ............................................................ 1 .......

Case, Brake ................................................................... 1

5

••........•.•........•......... Bearing, Output .............................................................. 1

6 7 8

............................... Key .............................................................................. 1 ............................... Shaft ............................................................................ 1 ............................... Spacer .......................................................................... 1

9 10

.............................. ; Plate, Sera rate ............................................................... 9 ............................... Plate, Bronze Friction ...................................................... 8

11

12

............................... Piston ........................................................................... 1 ............................... Spring, Blue................................................................. 12

13 14 15 16 -17 -18 -19 -20 -21 -22 -23

............................... Cover, Brake .................................................................. 1 ............................... Bearing, Input ................................................................ 1 ............................... Ring, Snap ..................................................................... 1 ............................... Ring, Snap ..................................................................... 1 ............................... Kit, Seal (includes items 18-23) ........................................ 1 ............................... Ring, Piston Backup ........................................................ 1 ............................... O-Ring, Piston ................................................................ 1 ............................... O-Ring Piston ................................................................. 1 ............................... Ring, Piston Backup ........................................................ 1 ............................... O-Ring, Case Seal ........................................................... 1 ............................... Gasket, Mounting ........................................................... 1

DESCRIPTION

QTY

>. . . . . . . . . . . . . . . . . . . . . . . .

- Indicates Items Not Shown

MANUAL 92328-003 SEPTEMBER 1996

31

FIGURE 10-Lift Cylinder Assembly 3887G

vi

.D

I

32

MANUAL 92328-003 SEPTEMBER 1995

FIGURE 1O-Lift Cylinder Assembly 3887G

PART NUMBER

Ref.

54506 .•.•.•••.•.•••..•..•.•••••.• Lift Cylinder Assembly 3887G ................................................... Ref. SBW9056 .........•.•••.•.•••.• Seal Kit .......................................................................................... 1 ...................................... Wear Ring ...................................................................................... 2 ...................................... O-Ring ........................................................................................... 1 ...................................... Back-Up ......................................................................................... 1 ...................................... O-Ring ........................................................................................... 1 ...................................... Wear Ring ...................................................................................... 2 ...................................... U-Cup. Loaded .............................................................................. 1 ...................................... Wiper. AN ...................................................................................... 1 ...................................... Wear Ring ......................................................................................2 ...................................... O-Ring ........................................................................................... 1 ...................................... Back-Up ......................................................................................... 1 ...................................... O-Ring ........................................................................................... 1 ...................................... Wear Ring ......................................................................................2 ...................................... U-CuP. Dual Up ............................................................................. 1 ...................................... Wiper. AN ...................................................................................... 1 ...................................... Bushing ..........................................................................................4 154-00007-00 ................ Clamp. 31/8 x 5 Hose ................................................................... 1 162-96448-00 ................ Cylinder, 3887 Arm Lift .................................................................. 1 253-96609-00 ................ Fitting. Adapter .............................................................................. 1 54505 ............................ SVC1 0-22 Poppet. 2-Way. NC .......................................................1 621-G9031-00 ............... Pin-Lift Cylinder 45/16 x 1/8 .........................................................4 55093 ............................ Pin. Lift Cylinder ............................................................................. 4 81368-006 ..................... Bearing. 1.5010 x 1~25L x 1/8W .....................................................4

1

2 3 4 5 6

7 8 9 10 11 12 13 14 15 -16 -17 -18 -19 -20 -21 -22

DESCRIPTION

QTY

ITEM

- Indicates Items Not Shown

MANUAL 92328-003 SEPTEMBER 1995

33

~----------------------30.50

SAE #8 PORT

RETRACTED------------------------t

FIRST STAGE- 5.50 0.0. x 4.75 1.0.

SECOND STAGE- 4.25 0.0. x 3.50 1.0.

5

6

1

2 BLEED PORT

"

C5

C

JJ

m II! 1.7500

1.7505 x 1.25 DEEP 4 PLACES

8

,

I,

I, - - - I. - I,

I, I,

FIGURE 10-Lift Cylinder Assembly 4887G

oTY

ITEM

PART NUMBER

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

55092 ............................ Lift Cylinder Assembly 4887G ................................................... Ref. 55085 ............................ Cylinder .......................................................................................... 1 55085-101 ..................... Head. Gland. 2nd Stage ................................................................ 1 55085-102 ..................... Weld Assembly Second Stage ....................................................... 1 55085-103 ..................... Piston. 2nd Stage .......................................................................... 1 55085-104 ..................... 1st Stage ........................................................................................ 1 55085-105 ..................... Head. Gland. 1st Stage ................................................................. 1 55085-106 ..................... Barrel Weld Assembly 1st Stage ................................................... 1 55085-107 ..................... O-Ring ........................................................................................... 1 55085-100 ..................... Seal Kit (2Stage) ............................................................................ 1 154-00007-00 ................ Clamp. 31/8 x 5 Hose ................................................................... 1 253-96609-00 ................ Fitting. Adapter .............................................................................. 1 54505 ............................ SVC10-22 Poppet. 2-Way, NC ...................................................... 1 81368-006 ..................... Bearing. 1.501D x 1.25L x 1/8W .....................................................4 621-G9031-00 ............... Pin Lift Cylinder 4 5/16 x 1/8 .......................................................... 4 55093 ............................ Pin. Cylinder .................................................................................. 4

DESCRIPTION

- Indicates Items Not Shown

MANUAL 92328-003 SEPTEMBER 1995

35

FIGURE 11-Hydraulic Tank Assembly

5 4

j

r

11

8

g

10

6

2 3

5

6

36

MANUAL 92328-003 SEPTEMBER 1995

FIGURE 11-Hydraulic Tank Assembly

ITEM

PART NUMBER

Ref. 1 2 3 4

020-G9049-00 .......... Assembly, Hydraulic Tank ............................................ Ref. 01 0-G90 12-00 .......... Weldment, Hydraulic Tank ............................................... 1 33430 ...................... Filter (67408 Element) ..................................................... 1 254-00009-00 .......... Nipple-Pipe. 75" x Close .................................................. 2 254-00009-20 .......... Nipple-Pipe. 75" x 8 Black ............................................... 1 254-00038-00 .......... Fitting, Elbow Street 90° .75" ......................................... 2 254-00042-00 .......... Plug, Steel Black .75" IPS ................................................ 2 254-00051-00 .......... Gauge-Oil Level P:FSA 1.50" ............................................ 1 260-00004-00 .......... Valve, shut Off .50" Ball ................................................. 1 450-00052-00 .......... Cover, Hydraulic Tank ..................................................... 1 529-G4076-00 .......... Gasket, Hydraulic Fuel Tank ............................................. 1 50316 ...................... Breather Filler ................................................................. 1 259-00001-00 .......... Gasket Hydraulic & Fuel Tank ........................................... 1

5 6 7

8 9 10 11 12

DESCRIPTION

QTY

- Indicates Items Not Shown

MANUAL 92328-003 SEPTEMBER 1995

37

FIGURE 12-Engine Assembly 3887G/4887G

27 25

14

26

18 17 13

21

20 19

24

23 22 15

TOP VIEW

12 11

7

28

29 30 31

38

MANUAL 92328-003 SEPTEM8ER 1995

3

FIGURE 12 - Engine Assembly 3887G/4887G QTY

ITEM

PART NUMBER

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

55074 ...................... Engine Installation, 38/4887 Kawasaki .......................... Ref. 55078 ...................... Engine Assembly, 38/4887 Kawasaki ................................ 1 38169 ...................... Engine Modification ........................................................ 1 38033 ...................... -Plate, Engine Mounting ................................................ 1 54609 ...................... -Adapter Mod., 3172G ................................................. 1 BOW36056 .............. -Bolt, Hex .38-16UNC x 1.50 ...................................... 4 BOW31433 .............. -Washer, Flat 3/8 SAE .................................................. 4 54604-007 ............... -Pump, .61CIPR JSB900 Gear ....................................... 1 38118-001 ............. .. -Coupling Assembly ..................................................... 1 BOW46055 .............. -Bolt, Hex .38-16UNC x 1.250 .................................... 2 BOW31433 .............. -Washer, Flat 3/8 SAE .................................................. 2 38102...................... -Tail Pipe, Kawasaki ..................................................... 1 67169-001 ............... -Clamp, Muffler 1.25" .................................................. 1 38100 ...................... -Choke, Remote Assembly ............................................ 1 32111 ...................... -Solenoid .................................................................... 1 38282 ...................... -Plate- Kawasaki Throttle/Choke ................................... 1 38281 ...................... -Clevis Mod-l/4 Rod .................................................. 1 38290 ...................... -Solenoid Mod-47AG-K Choke ................................... 1 BOW31829 .............. -Screw, Self-Tapping .................................................. 2 BOW2120 ................ -Pin Clevis .250 Oia. x .75 ............................................ 1 BOW31233 .............. -Nut, Hex Keps #10-32 .............................................. 1 BOW38217 .............. -Cotter Pin, 3/32 x 1 Lg ................................................ 1 BOW30000 .............. -Bolt Hex .25-20UNC x .50 ......................................... 2 BOW31201 .......... " .. -Nut Hex .25-20UNC .................................................. 2 BOW31431 .............. -Washer Flat .25 10 x .63 00 ........................................ 2 BOW31430 .............. -Washer, Flat #10 10 .................................................... 3 BOW32281 .............. -Nut, Hex Jam - 1/4-28UNF ...................................... 2 BOW31146 .............. -Screw, Slotted, Round #10-32UNF x 1.00 ................... 2 04673 ...................... -Adapter, 10MM Male - 1/8 NPT .................................. 1 67957 ...................... -Filter Fuel In Line Bubble .............................................. 1 37987 ...................... Engine Mount - Center Bonded ......................................... 4 BOW39058 .............. Hex Hd Bold 3/8-16 x 2 Gr8 ............................................ 4 BOW31327 .............. Washer Split Lock 3/8" 10 ............................................... 4 BOW31413 .............. Washer, Flat .38 10 x 1.0000 ......................................... 4

DESCRIPTION

- Indicates Items Not Shown * Units With SIN 3952-xxxx to have Pump 54604-003 and 38118-001 Coupling

MANUAL 92328-003 SEPTEMBER 1995

39

FIGURE 13-Lower Control AssemblylWiring 3887G

42T WHT/BLK

1 GRN

CABLE TO LOWER CONTROL BOX SEE SHEET 3

1 GRN/BLK STARTER IGNITION COil

5 BlK

5

5

BlK/WHT

25B

RED

5 YEl TEMP SWITCH

VOL TAGE REGULATOR

~i=~==~~

____________~8~5~~~ ORN/BlK 42TS RED/BlK

2B 4 PSI PRESSURE SWITCH

2A 25B RED 31 WHT

8A ORN

SEE NOTE 4

24 SWITCH

BlU

:------------l

i t :I , FUEL PUMP

i

BREF

~

®

SEE NOTE 2

50 BlU/WHT

:

56 BlU/BlK SEE NOTE 3 NOTES:

1. ITEMS 39-46 ARE NOT ILLUSTRATED. 2. ITEMS 71-74 ARE PART OF DUAL FUEL OPTION. 3. BlU/BlK CONDUCTOR IS SPARE UNLESS DUAL FUEL OPTION IS ORDERED. THEN RED/WHT. GRN/WHT & BlK/RED ARE SPARES. 4. VACUUM SWITCH IS ONLY USED WHEN DUAL FUEL OPTION IS ORDERED. CONNECT CIRCUIT 31. INSTEAD OF 31A. TO 4PSI SWITCH ON STANDARD INSTAllATION.

40

MANUAL 9232B-003 SEPTEMBER 1995

FIGURE 13-Lower Control AssemblylWiring 3887G

aTY

ITEM

PART NUMBER

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

54741 ...................... Wiring Assembly, 3887G Electrical ............................... Ref. 54673 ..........•........... Electric Box, 3172G/3887G Lower .................................... 1 BOW34376 .............. Screw, Rd Hd Sit 1/4-20 x 1/2 ....................................... 2 BOW31288 .............. Nut, Hex # 10-32 ............................................................ 2 BOW31529 .............. Button, Plug .50Dia ........................................................ 1 69146 ...................... Operator, Green Pushbutton ............................................. 1 52672 .....•................ Base + 1 NO Contact ........................ ; ............................ 2 34836 ...................... Operator White Pushbutton .............................................. 1 52669 ...................... Operator Black Pushbutton ............................................... 1 52029 ...................... Base + 2 NO Contacts .................................................... 2 51913 ...................... Operator, Red Push-Pull ................................................. 1 51914 ...................... Base + 1 NC Contact ..................................................... 1 50075 ...................... Switch (Ref PIN 67760) .................................................. 1 52671 ...................... Operator, 3 Pos. Rot. Key .........................................•...... 1 34383 .............•........ Contact Block, NO ............................................•............. 4 67280 ...................... Relay Bosch ...............•................................................... 5 BOW31105 .............. Slotted Pan Head 10-32 x .75 ........................................ 5 BOW31233 .............. Nut, Hex Keps #10-32 .................................................. 5 80025 ...................... Circuit Breaker 20 AMPS ................................................. 1 206-00001-00 .......... Diode ............................................................................ 5 34552-016 ............... Terminal Strip ................................................................ 4 BOW31132 .............. Screw, Round Head #8-32UNC x 3/4 Lg .......................... 8 BOW31232 .............. Nut, Hex Keps #8-32UNC .............................................. 7 34542 ...................... Jumper ......................................................................... 5 51325 ...................... Cable 24 Conductor 16 Gage ...................................... 77LF 67114-008 ............... Connector, Strain Relief ................................................... 1 67123-002 ............... Seal, Connector, Electric 3/4" .......................................... 3 67124-002 ............... Locknut, Connector. 75 ................................................... 3 21342 ...................... Solenoid Starter 12VDC .................................................. 1 67114-003 ............... Strain Relief 1/2NPT .37/.5 .............................................. 1 67123-001 ............... Seal, Connector Electric 1/2" ........................................... 5 67124-001 ............... Locknut, 1/2 NPT Strain Relief ......................................... 5 80024 ...................... Relay 2 PDT-12 Volt R#67588 ......................................... 1 80049 ...................... Socket, 8-Pin Octal ......................................................... 1 67114-002 ............... Strain, Relief 1/2NPT .25/.38 ........................................... 4 67295-004 ............... Cable, 12 Conductor 16 Gage ....................................... 8LF 67114-009 ............... Strain, Relief 3/4NPT .62/.75 ........................................... 2 54521 ...................... Decal, 4887 Lower Control .............................................. 1 67295-035 ............... Cable, 16 Gage/2 Conductor SJO ................................ 40LF 020-G9048-00 .......... Assembly, Upper Control Box ........................................... 1 020-S1050-00 .......... Assembly, Limit Switch ................................................... 3 121-96822-00 .......... Battery, 12 Volt 24C 85AN .............................................. 1 122-00015-00 .......... Cable, Battery 22"Long ................................................... 1 122-00025-00 .......... Cable, Battery 13'6"Long ................................................ 1 52040 ...................... Bracket, Limit Switch 3" .................................................. 1 51036 ...................... Switch Limit Body Only ................................................... 1 52619 ...................... Head Limit Switch .......................................................... 1 67295-004 ............... Cable, 12 Conductor 16 Gage ..................................... 15LF 67295-035 ............... Cable, 16 Gage/2 Conductor SJO ................................ 10LF 67295-037 ............... Cable, 16 Gage/4 Conductor SJO ................................ 15LF 67295-022 ............... Cable, 3 Conductor 12 AWG ....................................... 15LF

DESCRIPTION

- Indicates Items Not Shown MANUAL 92328-003 SEPTEMBER 1995

41

FIGURE 13-Lower Control AssemblylWiring 3887G

=

CABLE TO HYD VALVES CIRCUIT NUMBER 1 13 14 15 16 18A 19 28A 20 60B 63 64

MISCELLANEOUS CABLES

ITEM 35 CIRCUIT NUMBER

CONNECTED TO:

COLOR

GROUND AT VALVES

GRN RED

H

DRIVE REVERSE RED/BLK FORWARD VALVE DCV1 ORN LEFT STEER ORN/BLK RIGHT BLK DS4 - SERIES GRN/BLK DS5 - CREEP DS3 - DUMP VALVE BLU WHT BRAKE VALVE BLK/WHT 4 VALVES ON 2 "SP" MANIFOLDS BLU/BLK DS1 - PLATFORM UP WHT/BLK DS2 - PL TFRM DOWN

COLOR

17/BLANK 55/62

BLK WHT

20 19 60 60A 18 18A

BLK WHT RED GRN BLK WHT

64

WHT

I

BLK

~

ITEM

FUNcnON OF CIRCUIT LIMIT SWTCH PLA TFORM IS 25' OR HIGHER

50 12 GA

LIMIT SWITCH PLTFRM 11'-6" OR HIGHER

49

LIMIT SWITCH PL TFRM 7'-6" & UP

48

VALVE ON LIFT CYL - THEN BUTTSPLICE & CONTINUE TO OTHER CYL WITH 2C/16GA

38

r--------------------------~

I I I I

• TURH kEY TO LO'II£R POSInON

TO OPERA T£ FROM GROUND.

• START DlGltfE. • D[PIiIESS AHD HOU) -'I1-IROTl\..£"

BUnoH "'IL£ WO'oIINC

PLA l"ORU tP OR DOWN.

• TURN kEY TO \JIPPf:R POSIfIOH TO oP£JtA'It: FJItOU PI.'\ TrOAhI -1'URNENGlfEOFT'MTI1KEY. • IN o\N EMERGENCY, PVSH litEO

BUtTON. to OPERATE, 9JTTON Must BE puu.m OUT.

I I I I I I I I I I I I I LOWER .___---+--7tt----1 5

REF

6

UPPER

LOv.£R

l----II!+---"' 37

'----------~---~ 6

I I I I

I I I I I I I

I

l ___________________________ ~

TO TERMINAL 80ARDS SEE SHEET 3 WIRE 8UNDLE CONSISTS OF:

17 1 5 - 12 GA 5A - 12 GA 58 - 12 GA

78

8 17 21 -

12 GA

22 - 12 GA 24

42

5

58

5A

12GA

25 25A 25T

12 GA

31 42 - 12 GA 50 55

53 54 ALL WIRES 15 GA EXCEPT

AS NOTED

5A

42

MANUAL 92328-003 SEPTEMBER 1995

25T

31

FIGURE 13-Lower Control AssemblylWiring 3887G ITEM

PART NUMBER

DESCRIPTION

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 .13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

54741 ...................... Wiring Assembly, 3887G Electrical ............................... Ref. 54673 ...................... Electric Box, 3172G/3887G Lower .................................... 1 BOW34376 .............. Screw, Rd Hd Sit 1/4-20 x 1/2 ....................................... 2 BOW31288 .............. Nut, Hex # 10-32 ............................................................ 2 BOW31529 .............. Button, Plug .50Dia ........................................................ 1 69146 ...................... Operator, Green Pushbutton ............................................. 1 52672 ...................... Base + 1 NO Contact ..................................................... 2 34836 ...................... Operator White Pushbutton .............................................. 1 52669 ...................... Operator Black Pushbutton ............................................... 1 52029 ...................... Base + 2 NO Contacts .................................................... 2 51913 ...................... Operator, Red Push-Pull ................................................. 1 51914 ...................... Base + 1 NC Contact ..................................................... 1 50075 ...................... Switch (Ref PIN 67760) .................................................. 1 52671 ...................... Operator, 3 Pos. Rot. Key ................................................ 1 34383 ...................... Contact Block, NO .......................................................... 4 67280 ...................... Relay Bosch ................................................................... 5 BOW31105 .............. Slotted Pan Head 10-32 x .75 ........................................ 5 BOW31233 .............. Nut, Hex Keps # 10-32 .................................................. 5 80025 ...................... Circuit Breaker 20 AMPS ................................................. 1 206-00001-00 .......... Diode ............................................................................ 5 34552-016 ............... Terminal Strip ................................................................ 4 BOW31132 .............. Screw, Round Head #8-32UNC x 3/4 Lg .......................... 8 BOW31232 .............. Nut, Hex Keps #8-32UNC .............................................. 7 34542 ...................... Jumper ......................................................................... 5 51325 ...................... Cable 24 Conductor 16 Gage ...................................... 77LF 67114-008 ............... Connector, Strain Relief ................................................... 1 67123-002 ............... Seal, Connector, Electric 3/4" .......................................... 3 67124-002 ............... Locknut, Connector .75 ................................................... 3 21342 ...................... Solenoid Starter 12VDC .................................................. 1 67114-003 ............... Strain Relief 1/2NPT .37/.5 .............................................. 1 67123-001 ............... Seal, Connector Electric 1/2" ........................................... 5 67124-001 ............... Locknut, 1/2 NPT Strain Relief ......................................... 5 80024 ...................... Relay 2 PDT-12 Volt R#67588 ......................................... 1 80049 ...................... Socket, 8-Pin Octal ......................................................... 1 67114-002 ............... Strain, Relief 1/2NPT .25/.38 ........................................... 4 67295-004 ............... Cable, 12 Conductor 16 Gage ....................................... 8LF 67114-009 ............... Strain, Relief 3/4NPT .62/.75 ........................................... 2 54521 ...................... Decal, 4887 Lower Control .............................................. 1 67295-035 ............... Cable, 16 Gage/2 Conductor SJO ................................ 40LF 020-G9048-00 .......... Assembly, Upper Control Box ........................................... 1 020-S 1050-00 .......... Assembly, Limit Switch ................................................... 3 121-96822-00 .......... Battery, 12 Volt 24C 85AN .............................................. 1 122-00015-00 .......... Cable, Battery 22"Long ................................................... 1 122-00025-00 .......... Cable, Battery 13'6"Long ................................................ 1 52040 ... ~ .................. Bracket, Limit Switch 3" .................................................. 1 51036 ...................... Switch Limit Body Only ................................................... 1 52619 ...................... Head Limit Switch .......................................................... 1 67295-004 ............... Cable, 12 Conductor 16 Gage ..................................... 15LF 67295-035 ............... Cable, 16 Gage/2 Conductor SJO ................................ 10LF 67295-037 ............... Cable, 16 Gage/4 Conductor SJO ................................ 15LF 67295-022 ............... Cable, 3 Conductor 12 AWG ....................................... 15LF

QTY

- Indicates Items Not Shown MANUAL 92328-003 SEPTEMBER 1995

43

FIGURE 13-Lower Control AssemblylWiring 3887G

CONDUCTOR 22 OR 23

61

IN CABLE

CABLE TO LOWER CONTROLS CIRCUIT NUMBER 13 14 15 16 17 BLANK 18 19 20 60 21 22 23 24 25 55 62 59 63 64 26 27 31 65

"'ERE 22/23 IS SHOWN.

REV FWD LEFT RIGHT

DRIVE

REF. SLOPE ALAR", OPTION REOUIRES 1.125 OIA ....OUNTING HOLE.

STEERING

THROTTLE FROM FOOTSWITCH FAST CREEP LOW HIGH IGNITION POWER POWER CHOKE START

DRIVE SPEEDS

REF 54528 DECAL, 4887 UPPER CONTROL

EMERGENCY STEERING

SLOPE UP DOWN SPARE SPARE SPARE SPARE

ALARM OPTON

~ -

PLATFORM

PLATFORM

REF

".., N

00

<ON

N N

17 21A

BLANK 12GA JUMPER

~

}

w

RED

ISOLATED REF

12GA CABLE

44

0

a:: rOQTSWITCH

) SPARES

65

z

<.:)

a::

...J

[IJ

27

CHOKE

PUSH TO STOP

L{)

31

START

ISOLATED ISOLATED ISOLATED ISOLATED

N

26

JACKS

- - DRIVE CONTROLS - -

q 1.:II~IOOOI:IO[j

DRIVE BELOW 25'

24

17

CONDUCTOR 59 IN C

16 GA 'MRE TO EMERGENCY SToP SYt'lTCH TO TERlIIlNAl

FUNCTION OF CIRCUIT

I

GRN

LB~

21A 17

~ 21 I

~

MANUAL 92328-003 SEPTEM8ER 1995

--SPEED-_

FIGURE 13-Lower Control AssemblylWiring 3887G ITEM

PART NUMBER

DESCRIPTION

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

54741 ...................... Wiring Assembly, 3887G Electrical ............................... Ref. 54673 ...................... Electric Box, 3172G/3887G Lower .................................... 1 BOW34376 .............. Screw, Rd Hd Sit 1/4-20 x 1/2 ....................................... 2 BOW31288 .............. Nut, Hex # 10-32 ............................................................ 2 BOW31529 .............. Button, Plug .50Dia ........................................................ 1 69146 ...................... Operator, Green Pushbutton ............................................. 1 52672 ...................... Base + 1 NO Contact ..................................................... 2 34836 ...................... Operator White Pushbutton .............................................. 1 52669 ...................... Operator Black Pushbutton ............................................... 1 52029 ...................... Base + 2 NO Contacts .................................................... 2 51913 ...................... Operator, Red Push - Pull ................................................. 1 51914 ...................... Base + 1 NC Contact ..................................................... 1 50075 ...................... Switch (Ref PIN 67760) .................................................. 1 52671 ...................... Operator, 3 Pos. Rot. Key ................................................ 1 34383 ...................... Contact Block, NO .......................................................... 4 67280 ...................... Relay Bosch ................................................................... 5 BOW31105 .............. Slotted Pan Head 10-32 x .75 ........................................ 5 BOW31233 .............. Nut, Hex Keps #10-32 .................................................. 5 80025 ...................... Circuit Breaker 20 AMPS ................................................. 1 206-00001-00 .......... Diode ............................................................................ 5 34552-016 ............... Terminal Strip ................................................................ 4 BOW31132 .............. Screw, Round Head #8-32UNC x 3/4 Lg .......................... 8 BOW31232 .............. Nut, Hex Keps #8-32UNC .............................................. 7 34542 ...................... Jumper ......................................................................... 5 51325 ...................... Cable 24 Conductor 16 Gage ...................................... 77LF 67114-008 ............... Connector, Strain Relief ................................................... 1 67123-002 ............... Seal, Connector, Electric 3/4" .......................................... 3 67124-002 ............... Locknut, Connector. 75 ................................................... 3 21 342 ...................... Solenoid Starter 12VDC .................................................. 1 67114-003 ............... Strain Relief 1/2NPT .37/.5 .............................................. 1 67123-001 ............... Seal, Connector Electric 1/2" ........................................... 5 67124-001 ............... Locknut, 1/2 NPT Strain Relief ......................................... 5 80024 ...................... Relay 2 PDT-12 Volt R#67588 ......................................... 1 80049 ...................... Socket, 8-Pin Octal ......................................................... 1 67114-002 ............... Strain, Relief 1/2NPT .25/.38 ........................................... 4 67295-004 ............... Cable, 12 Conductor 16 Gage ....................................... 8LF 67114-009 ............... Strain, Relief 3/4NPT .62/.75 ........................................... 2 54521 ...................... Decal, 4887 Lower Control .............................................. 1 67295-035 ............... Cable, 16 Gage/2 Conductor SJO ................................ 40LF 020-G9048-00 .......... Assembly, Upper Control Box ........................................... 1 020-S 1050-00 .......... Assembly, Limit Switch ................................................... 3 121-96822-00 .......... Battery, 12 Volt 24C 85AN .............................................. 1 122-00015-00 .......... Cable, Battery 22" Long ................................................... 1 122-00025-00 .......... Cable, Battery 13'6" Long ................................................ 1 52040 ...................... Bracket, Limit Switch 3" .................................................. 1 51036 ...................... Switch Limit Body Only ................................................... 1 52619 ...................... Head Limit Switch .......................................................... 1 67295-004 ............... Cable, 12 Conductor 16 Gage ..................................... 15LF 67295-035 ............... Cable, 16 Gage/2 Conductor SJO ................................ 10LF 67295-037 ............... Cable, 16 Gage/4 Conductor SJO ................................ 15LF 67295-022 ............... Cable, 3 Conductor 12 AWG ....................................... 15LF

QTY

- Indicates Items Not Shown

MANUAL 92328-003 SEPTEM8ER 1995

45

FIGURE 13-Lower Control AssemblylWiring 3887G

THROTTLE CR3

~ 8

r-

421

r-=-o ,~? '!=====? !===== ? ~ 5 I--i.---

Z t":-o --<

~ I--

;:::z

-0",

~

o() ~--<

'---

z" "'::0

Vl8

@--

VIZ

5 PL

I» or :;:0

j=== [ , - - 8LANK

~ I---

:== 18

'18A

I--

F-

v----; ~~ :== [ , - - 22

14

~~ 13 t1===

T3t--' v----: 1== (r--

~

..QQ

t::

'F===?

85

,-1-----

l=Qo

;:::

r-----; r-

~ 42TS I - 'f===

1===

12GA

1 k

Lr-7~

Lr-;===

..QQ

To F ~F

'6oB

!===== 62 t--f=== 1===

,------: F==?

31 r== ~~ f:-----'F== Lr-~ ~

b-

, 59

TsA F

~,.-I---

ZZ

55

r=== 56 I-r===

~ F==P

r===

1===

To'

63 28

~

24 t---t-- '25

h

J

'f===? '~ ? 'r=== ~ '!=====? ,

I--

L.,

ISOLA TED SPAR E

~I--

~

lJ 6";

"" ~

r-oo '!=====?

, F==P

~ i=--~

15 16

19

SEE NOTE

5 PL

-~I)

20 I-v---; F==

'---

z~

+

~

25T

_«

r=== I--

-

I-I--I--~ 8A 1===

1-1--

--<::0 ::0'" c r "'» -< --<VI 0--< VlO () »--< r'" ",::0

17

~

;===

1===

~

~

1==

>==

'"

CR4

'00'

=5B5B ~

'" o§{

()()VI

»Z ::00 --< z'" 0::0 --<!;;

~

~ ~

~

® -1

4 PL 20 22 21 8 Pl

-

@ii" C

~

60A

~A 25A

32 33

58

58 28

2#

'---..

SIP VALVES CR7

CR5

-

20

~

DUMP

258 85

58

~ ~ WIRE BUNDLE TO COMPONENTS ON INSIDE OF DOOR OF BOX SEE SHEET 2

START LOCKOUT CR2

BRAKE/ SPEED CR6

at-

r-;;:: ~ b.

64

OPTIONAL DESCEND ALARM OPTION

'Ts !===== r ?

J t::+~ roo ~

23

5 PL

» Or ::0 0"" "'~ :::0:;: --<:::; OI VI-

-00

;:::" ~»

24 SEE SHEET

<4-

~~

27 26 25

~I

47 SEE SHEET 1

-u'"

~111

~

36 27 26

ENGINE

"'-u

:-

48 34 31 .30

LS 7'-6"

LS 11'-6"

(4SY3,XJ1XJO

46

18 GY LS 25'

~

MANUAL 92328-003 SEPTEMBER 1995

~~

LIFT CYL VALVE

35

SEE TABLE ON SHEET 2

SLOPE ALARM OPTION

61

~

FIGURE 13-Lower Control AssemblylWiring 3887G ITEM

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 "28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

PART NUMBER

DESCRIPTION

QTY

54741 ...................... Wiring Assembly, 3887G Electrical ............................... Ref. 54673 ...................... Electric Box, 3172G/3887G Lower .................................... 1 BOW34376 .............. Screw, Rd Hd Sit 1/4-20 x 1/2 ....................................... 2 BOW31288 .............. Nut, Hex #10-32 ............................................................ 2 BOW31529 .............. Button, Plug .50Dia ........................................................ 1 69146 ...................... Operator, Green Pushbutton ............................................. 1 52672 ...................... Base + 1 NO Contact ..................................................... 2 34836 ...................... Operator White Pushbutton .............................................. 1 52669 ...................... Operator Black Pushbutton ............................................... 1 52029 ...................... Base + 2 NO Contacts .................................................... 2 51913 ...................... 0perator, Red Push-Pull ................................................. 1 51914 ...................... Base + 1 NC Contact ..................................................... 1 50075 ...................... Switch (Ref PIN 67760) .................................................. 1 52671 ...................... Operator, 3 Pos. Rot. Key ................................................ 1 "34383 ...................... Contact Block, NO .......................................................... 4 67280 ...................... Relay Bosch ................................................................... 5 BOW31105 .............. Slotted Pan Head 10-32 x .75 ........................................ 5 BOW31233 .............. Nut, Hex Keps # 10-32 .................................................. 5 80025 ...................... Circuit Breaker 20 AMPS ................................................. 1 206-00001-00 .......... Diode ............................................................................ 5 34552-016 ............... Terminal Strip ................................................................ 4 BOW31132 .............. Screw, Round Head #8-32UNC x 3/4 19 .......................... 8 BOW31232 .............. Nut, Hex Keps #8-32UNC .............................................. 7 34542 ...................... Jumper ......................................................................... 5 51325 ...................... Cable 24 Conductor 16 Gage ...................................... 77LF 67114-008 ............... Connector, Strain Relief ................................................... 1 67123-002 ............... Seal, Connector, Electric 3/4" .......................................... 3 67124-002 ............... locknut, Connector. 75 ................................................... 3 21342 ...................... Solenoid Starter 12VDC .................................................. 1 67114-003 ............... Strain Relief 1/2NPT .37/.5 .............................................. 1 67123-001 ............... Seal, Connector Electric 1/2" ........................................... 5 67124-001 ............... locknut, 1/2 NPT Strain Relief ......................................... 5 80024 ...................... Relay 2 PDT-12 Volt R#67588 ......................................... 1 80049 ...................... Socket, 8-Pin Octal ......................................................... 1 67114-002 ............... Strain, Relief 1/2NPT .25/.38 ........................................... 4 67295-004 ............... Cable, 12 Conductor 16 Gage ....................................... 8lF 67114-009 ............... Strain, Relief 3/4NPT .62/.75 ........................................... 2 54521 ...................... Decal, 4887 Lower Control .............................................. 1 67295-035 ............... Cable, 16 Gage/2 Conductor SJO ................................ 40lF 020-G9048-00 .......... Assembly, Upper Control Box ........................................... 1 020-S1050-00 .......... Assembly, Limit Switch ................................................... 3 121-96822-00 .......... Battery, "12 Volt 24C 85AN .............................................. 1 122-00015-00 .......... Cable, Battery 22"long ................................................... 1 122-00025-00 .......... Cable, Battery 13'6"Long ................................................ 1 52040 ...................... Bracket, Limit Switch 3" .................................................. 1 51036 ...................... Switch Limit Body Only ................................................... 1 52619 ...................... Head Limit Switch .......................................................... 1 67295-004 ............... Cable, 12 Conductor 16 Gage ..................................... 15LF 67295-035 ............... Cable, 16 Gage/2 Conductor SJO ................................ 10lF 67295-037 ............... Cable, 16 Gage/4 Conductor SJO ................................ 15lF 67295-022 ............... Cable, 3 Conductor 12 AWG ....................................... 15LF

- Indicates Items Not Shown

MANUAL 92328-003 SEPTEM8ER 1995

47

FIGURE 13-Lower Control Assembly/Wiring 4887G

42T WHT/BLK

CABLE TO LOWER CONTROL BOX SEE SHEET 3

GRN 1 GRN/BLK STARTER

5 BLK

5

5

BLK/WHT

25B

RED

5 YEL TEMP SWITCH

VOLTAGE REGULATOR

~~~~~~__________~~8~5~~ ORN/BLK 42TS RED/BLK

2B 4 PSI PRESSURE SWITCH

2A 25B RED 31 WHT

811.

ORN

SEE NOTE 4

24 SWITCH

REF

BLU SEE NOTE 2

!-----------l FUEL PUMP

i t :I , i : I

50 BLU/WHT

c:!::=,~~~~~~11

56

It, L ___________ J

BLU/BLK SEE NOTE 3 NOTES: 1. ITEMS 39-46 ARE NOT ILLUSTRATED. 2. ITEMS 71- 74 ARE PART OF DUAL FUEL OPTION. 3. BLU/BLK CONDUCTOR IS SPARE UNLESS DUAL FUEL OPTION IS ORDERED, THEN RED/WHT, GRN/WHT & BLK/RED ARE SPARES. 4. VACUUM SWITCH IS ONLY USED WHEN DUAL FUEL OPTION IS ORDERED. CONNECT CIRCUIT 31, INSTEAD OF 31A, TO 4PSI SWITCH ON STANDARD INSTALLATION.

48

MANUAL 92328-003 SEPTEMBER 1995

FIGURE 13-Lower Control AssemblylWiring 4887G CABLE TO HYD VALVES = ITEM 35 CIRCUIT NUMBER 1 13 14 15 16 18A 19 28A 20 60B 63 64

CIRCUIT NUMBER

CONNECTED TO:

COLOR GRN RED RED/BlK ORN

MISCEllANEOUS CABLES

GROUND AT VALVES REVERSE FORWARD LEFT RIGHT DS4 - SERIES

n ~

DRIVE VALVE DCVl STEER

ORN/BlK BlK GRN/BlK DSS - CREEP DS3 - DUMP VALVE BlU WHT BRAKE VALVE BlK/WHT 4 VALVES ON 2 "sp" MANIFOLDS BLU/BlK DSl - PLATFORM UP WHT/BlK DS2 - PL TFRM DOWN

FUNCTION OF CIRCUIT

COLOR

17/BlANK 55/62

BlK WHT

20 19 60 60A 18 18A

BlK WHT RED GRN BlK WHT

64

WHT

1

BlK

ITEM

LIMIT SWTCH PLATFORM IS 25' OR HIGHER

50 12 GA

LIMIT SWITCH PLTFRM 11'-6" OR HIGHER

49

L1MI T SWITCH Pl TFRM 7'-6" & UP

48

VALVE ON LIFT CYl - THEN BUTTSPLICE & CONTINUE TO OTHER CYl WITH 2C/16GA

38

r--------------------------~

I

I

I

I

I I I I

I I I I

I I I I I I I I I I I I I I I I I I I I I I I I I I

I I

• lUltN KE'( TO lOIll{:R POSITION • i~. .rrE~~i~ ~OUND • ~~s ~ ~ ~THRonL.(· • ~~~~~~~n~ • ~~~E~:i:~~ • ~f~wi£~;~~~~

=E . . . .

T~*~g~

LOWER

CHOKE

PL~rr~~

START

LP

uPPER

I I I I I I I I

REF

OfF LOWER

l-_ffi_--,37

'---=::---------Itt-------j6

REF

2 PL

I

l ___________________________ ~

TO TERMINAL BOARDS SEE SHEET 3

78

WIRE BUNDLE CONSISTS OF, 17 1

5 - 12 GA

7B

5A -

12 GA

5B - 12 GA 8 17 21 -

12 GA

22 - 12 GA 24 25 25A - 12 GA 25T 31 42 - 12 GA

42

5B

SA 12GA

50 56 63

64 ALL WIRES 16 GA EXCEPT AS NOTED

SA

MANUAL 9232B-003 SEPTEMBER 1995

25T

31

49

FIGURE 13-Lower Control AssemblylWiring 4887G

CABLE TO LOWER CONTROLS CIRCUIT NUMBER 13 14 15 16 17 BLANK

18 19

20 60 21

22 23 24 25

FUNCTION OF CIRCUIT REV FWD LEFT RIGHT

DRIVE STEERING

THROTTLE FROM FOOTSWI TCH FAST CREEP LOW HIGH IGNITION POWER POWER CHOKE START

DRIVE SPEEDS

REF 54528 DECAL, 4887 UPPER CONTROL

EMERGENCY STEERING

55 62 59

DRIVE BELOW 25'

64

DOWN

26 27 31 65

SPARE SPARE SP ARE SPARE -

l

5

JACKS

START

PLATFORM

PUSH TO STOP

<D

N

N

"'N

00

N

<.ON

17 21A

BLANK 12GA JUMPER

z

0<:

0

w et:

et:

-l

m

()

26

50

FOOTSWITCH

~l

- - SP(ED---

ISOLATED SPARES

RED REF 12GA CABLE

I

GRN

LB~

21A 17

co

N <.0 <D <D

N

65

DRIVE CONTROLS - -

REF

n

31

~-

ISOLA TED ISOLATED ISOLA TED ISOLATED 24

27

CHOKE

q 1,:II,:IOOOI:IO[

SLOPE ALARM OPTON

~~63~-b_U~P~__

PLA rrORM

~ 21

I

~

MANUAL 92328-003 SEPTEMBER 1995

FIGURE 13-Lower Control AssemblylWiring 4887G

THROTTLE

START LOCKOUT

BRAKE/ SPEED CR6

CR3

VALVES CR5

CR2

258 85

5B

29

Ti

SIP

DUMP

CR7

58 28

2~

SEE NOTE'

'----..

'"

25A

WIRE BUNDLE TO COMPONENTS ON INSIDE OF DOOR OF BOX SEE SHEET 2

ISOLATEO SPARE

J 50 t:---'- 55 h

(5()

:== 5

1----'N-t--r----c-4=~1:;7=i=-~---I--I-~

5A I----'

58 58

8

v---

18

I-'

~

I----'

56 1-_1--59 1-__

8LANK

r---: v--:

'--

27

18A

60

608

r-

19

20 r--

8A

1-__

'-- 60A

h

62

V---cf=='i'>1--,----- 28A

v---

21

r

63 b~ ~

31

rr-

42

r;:::

T~=F-~I2G~A-l--fJr r=1

~

1

Cl

UPPER

(48X34X31XJO).

LS

7'-6"

LS

'1'-6"

MA~UAL

9232S-003

~ TEMSER 1995

1

~

1

~h

lQQ

5pe

r:::Y V

SEE SHEET I

ENGINE

c-----

~

~: :E~~HE~ET~4~-----------r-------r--~~i8 362726)---------11---1

i:-'I

23

....-~

~

47

64 65

~

[..- 42TS~

85

P

'T1=~6;:;4==*1--";-II-r-r-

~

[..- 42T

28

LS 25'

/"

~ S£~~~BLE

;~~~~

ON

SHEET 261

OPTION

LIFT CYL VALVE

51

OPll0NA OESCENt ALARM OPTION

FIGURE 13-Lower Control AssemblylWiring 4887G DESCRIPTION

QTV

ITEM

PART NUMBER

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

54670 ...................... Wiring Assembly, 3887G Electrical ............................... Ref. 54662 ...................... Electric Box, 4887 Lower ................................................ 1 BOW34376 .............. Screw, Rd Hd Sit 1/4-20 x 1/2 ....................................... 2 BOW31288 .............. Nut, Hex # 10-32 ............................................................ 2 BOW31529 .............. Button, Plug .50Dia ........................................................ 1 69146 ...................... Operator, Green Pushbutton ............................................. 1 52672 ...................... Base + 1 NO Contact ..................................................... 2 34836 ...................... Operator White Pushbutton .............................................. 1 52669 ...................... Operator Black Pushbutton ............................................... 1 52029 ...................... Base + 2 NO Contacts .................................................... 2 51913 ...................... Operator, Red Push-Pull ................................................. 1 51914 ...................... Base + 1 NC Contact ..................................................... 1 50075 ...................... Switch (Ref PIN 67760) .................................................. 1 52671 ...................... Operator, 3 Pos. Rot. Key ................................................ 1 34383 ...................... Contact Block, NO .......................................................... 4 67280 ...................... Relay Bosch ................................................................... 5 BOW31105 .............. Slotted Pan Head 10-32 x .75 ........................................ 5 BOW31233 .............. Nut, Hex Keps #10-32 .................................................. 5 80025 ...................... Circuit Breaker 20 AMPS ................................................. 1 206-00001-00 .......... Diode ............................................................................ 5 34552-016 ............... Terminal Strip ................................................................ 4 BOW31132 .............. Screw, Round Head #8-32UNC x 3/4 Lg .......................... 8 BOW31232 .............. Nut, Hex Keps #8-32UNC .............................................. 7 34542 ...................... Jumper ......................................................................... 5 51325 ...................... Cable 24 Conductor 16 Gage ...................................... 77LF 67114-008 ............... Connector, Strain Relief ................................................... 1 67123-002 ............... Seal, Connector, Electric 3/4" .......................................... 3 67124-002 ............... Locknut, Connector. 75 ................................................... 3 21 342 ...................... Solenoid Starter 1 2VDC .................................................. 1 67114-003 ............... Strain Relief 1/2NPT .37/.5 .............................................. 1 67123-001 ............... Seal, Connector Electric 1/2" ........................................... 5 67124-001 ............... Locknut, 1/2 NPT Strain Relief ......................................... 5 80024 ...................... Relay 2 PDT-12 Volt R#67588 ............................ ; ............ 1 80049 ...................... Socket, 8-Pin Octal ......................................................... 1 67114-002 ............... Strain, Relief 1/2NPT .25/.38 ........................................... 4 67295-004 ............... Cable, 12 Conductor 16 Gage ....................................... 8LF 67114-009 ............... Strain, Relief 3/4NPT .62/.75 ........................................... 2 54521 ...................... Decal, 4887 Lower Control .............................................. 1 67295-035 ............... Cable, 16 Gage/2 Conductor SJO ................................ 40LF 020-G9048-00 .......... Assembly, Upper Control Box ........................................... 1 020-S 1050-00 .......... Assembly, Limit Switch ................................................... 3 121-96822-00 .......... Battery, 12 Volt 24C 85AN .............................................. 1 54247-022.00 .......... Cable Assy, 22" LG Battery ............................................. 1 54247-162.00 .. ; ....... Cable, Battery 162"Long ................................................. 1 52040 ...................... Bracket, Limit Switch 3" .................................................. 1 51036 ...................... Switch Limit Body Only ................................................... 1 52619 ...................... Head Limit Switch .......................................................... 1 67295-004 ............... Cable, 12 Conductor 16 Gage ..................................... 15LF 67295-035 ............... Cable, 16 Gage/2 Conductor SJO ................................ 10LF 67295-037 ............... Cable, 16 Gage/4 Conductor SJO ................................ 15LF 67295-037 ............... Cable, 16 Gage/4 Conductor SJO ................................ 15LF

• Indicates Items Not Shown

52

MANUAL 92328-003 SEPTEM8ER 1995

FIGURE 13-Lower Control AssemblylWiring 4887G ITEM

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

PART NUMBER

DESCRIPTION

OTY

67295-035 ............... Cable, 16 Gage/2 Conductor SJO ................................ 25LF 67295-035 ............... Cable, 16 Gage/2 Conductor SJO ................................ 20LF 67295-035 ............... Cable, 16 Gage/2 Conductor SJO ................................ 20LF 67295-035 ............... Cable, 16 Gage/2 Conductor SJO ................................ 15LF 64295-030 ............... Cable, 12 Gage/4 Conductor SJO ................................ 15LF 0201-G9050-00 ........ Assy, Limit Switch Outrigger ............................................ 1

- Indicates Items Not Shown

MANUAL 92328-003 SEPTEMBER 1995

53

FIGURE 14-Limit Switch Assembly

54

MANUAL 92328-003 SEPTEMBER 1995

FIGURE 14-Limit Switch Assembly QTY

ITEM

PART NUMBER

Ref. 1 2 3

020-S1050-00 .......... Limit Switch Assembly ................................................ Ref. 105-00003-00 .......... Actuator Arm ................................................................. 1 67114-003 ............... Strain Relief 1/2NPT .37/.5 .............................................. 1 392-00010-00 .......... Switch High Speed ......................................................... 1

DESCRIPTION

- Indicates Items Not Shown

MANUAL 92328-003 SEPTEM8ER 1995

55

FIGURE 15-Arm Stack Assembly 3887G

5 2

PL

4 8

2 PL

10

2 PL

10 2

2

20, 32

10

56

8 PL

PL

17 2 PL

MANUAL 9232B-003 SEPTEMBER 1995

16

FAR SIDE

FIGURE 15-Arm Stack Assembly 3887G DESCRIPTION

QTY

ITEM

PART NUMBER

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

55081 ...................... Arm Stack Assy ......................................................... Ref. 55148 ...................... Armstand Weldment ....................................................... 1 55081-002 ............... Arm Weldment - Lower Outer Arm .................................... 2 55081-003 ............... Arm Weldment - Lower Inner Arm ..................................... 1 55081-004 ............... Arm Weldment - Middle Inner Arm .................................... 1 55081-005 ............... Arm Weldment - Middle Outer Arm ................................... 2 55081-006 ............... Arm Weldment - Upper Outer Arm .................................... 2 55081-007 ............... Arm Weldment - Upper Inner Arm ..................................... 1 50142 ...................... Bushing (R#66513) ...................................................... 12 50141 ...................... Bushing ....................................................................... 12 531-G9125-00 .......... Pivot Bracket Arm Stand ................................................. 2 128-00121-00 .......... Bolt, Modified .............................................................. 16 331-00099-00 .......... Nut Stover 1-8 ............................................................. 16 BOW31202 .............. Nut Hex .31 - 18UNC ...................................................... 8 BOW30011 .............. Bolt, Hex .25 - 20UNC .................................................... 8 BOW36780 .............. Nut Hex Lock .25 - 20UNC x 2.75 .................................... 8 632-G9004-00 .......... Roller Vee 5· Machine ..................................................... 2 632-G9003-00 .......... Roller Flat 5" Machine ..................................................... 2 BOW36780 .............. Nut Hex Lock .25 - 20UNC .............................................. 8 BOW31432 .............. Washer, Flat .3110 x .6800 ........................................... 30 BOW30031 .............. Bolt, Hex .31 - 18UNC x 1.50 ......................................... 8

- Indicates Items Not Shown

MANUAL 92328-003 SEPTEMBER 1995

57

FIGURE 15-Arm Stack Assembly 4887G

19 FAR

SIDE

NEAR SIDE FAR SIDE

8 12

2 PL

8 PL

6 11

11

2 PL

4 PL

12

2 PL

5

2 PL

4 25

11 2 PL

12

2 PL

2 PL

27, 28

16 PL

3

2

21,22sPL

2 PL

18 12

2

PL

11 2 PL

58

MANUAL 92328-003 SEPTEMBER 1995

19FAR

SIDE

FIGURE 15-Arm Stack Assembly 4887G

ITEM

PART NUMBER

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

55117 ...................... Arm Stack Assembly ................................................... Ref. 55148 ...................... Armstand Weldment, 38/4887 ......................................... 1 55117-002 ............... Arm Weldment - Lower Outer Arm .................................... 2 55117 -003 ............... Arm Weldment - Lower Inner Arm ..................................... 1 55117-004 ............... Arm Weldment - Lower Middle Inner Arm ........................... 1 55117-005 ............... Arm Weldment - Lower Middle Outer Arm .......................... 2 55117 -006 ............... Arm Weldment - Upper Middle Inner Arm ........................... 1 55117-007 ............... Arm Weldment - Upper Middle Outer Arm .......................... 2 55117-008 ............... Arm Weldment - Upper Inner Arm ..................................... 1 55117 -009 ............... Arm Weldment - Upper Outer Arm .................................... 2 50142 ...................... Bushing (R#66513) ...................................................... 16 50141 ...................... Bushing ....................................................................... 18 531-G91 25-00 .......... Pivot Bracket Arm Stand ................................................. 2 128-00121-00 .......... Bolt, Modified .............................................................. 16 331-00099-00 .......... Nut Stover 1-8 ............................................................. 16 BOW31202 .............. Nut Hex .31 - 18UNC ...................................................... 8 BOW30011 .............. Bolt, Hex .25 - 20UNC x 2.75 .......................................... 8 BOW36780 .............. Nut Hex Lock .25 - 20UNC .............................................. 8 632-G9004-00 .......... Roller Vee 5" Machine ..................................................... 2 632-G9003-00 .......... Roller Flat 5" Machine ..................................................... 2 BOW31432 .............. Washer, Flat .311D x .680D ............................................. 8 BOW36780 .............. Nut Hex Lock .25 - 20UNC ............................................ 40 BOW30031 .............. Bolt, Hex .31 - 18UNC x 1.50 ......................................... 8

DESCRIPTION

QTY

- Indicates Items Not Shown

MANUAL 92328-003 SEPTEMBER 1995

59

FIGURE 16-Platform Installation 3887G

6 2

7 4

A

A

60

MANUAL 92328-003 SEPTEMBER 1995

8

FIGURE 16-Platform Installation 3887G

ITEM

PART NUMBER

Ref. 1 2 3

001-G7000-1 A .......... Deck/Rails Weldment .................................................. Ref. 01 0-G7028-00 .......... Deck Frame Weldment .................................................... 1 010-G9030-00 .......... Weldment. Front Guard Rail ............................................. 1 010-G9034-00 .......... Weldment. Grd Rail Rt Frnt Side ....................................... 1 010-G99055-00 ........ Weldment. Grd Rail Rt Rear Side ....................................... 1 01 0-G9057-00 .......... Weldment. Grd Rail Left Frnt Side ..................................... 1 010-G9056-00 .......... Weldment. Grd Rail Left Rear Side .................................... 1 55015-001 ............... Weldment. 4887 Rear Guard Rail ...................................... 1 245-00008-00 .......... Pin. 3/4 x 4-1/4 Hitch ..................................................... 6

4 5 6 7 8

DESCRIPTION

QTY

- Indicates Items Not Shown

MANUAL 92328-003 SEPTEMBER 1995

61

FIGURE 16-Platform Installation 4887G 2

6

5

4 7

A

3

A 8

62

MANUAL 92328-003 SEPTEMBER 1995

FIGURE 16-Platform Installation 4887G

DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. 1 2 3 4 5 6 7 8

001-G9000-1A .......... Deck/Rails Weldment .................................................. Ref. 010-G9028-00 .......... Deck Frame Weldment .................................................... 1 010-G9030-00 .......... Weldment, Front Guard Rail ............................................. 1 010-G9034-00 .......... Weldment, Grd Rail Rt Frnt Side ....................................... 1 010-G99055-00 ........ Weldment, Grd Rail Rt Rear Side ....................................... 1 01 0-G9057-00 .......... Weldment, Grd Rail Left Frnt Side ..................................... 1 01 0-G9056-00 .......... Weldment, Grd Rail Left Rear Side .................................... 1 55015-001 ............... Weldment, 4887 Rear Guard Rail ...................................... 1 245-00008-00 .......... Pin, 3/4 x 4-1/4 Hitch ..................................................... 6

- Indicates Items Not Shown

MANUAL 9232B-003 SEPTEMBER 1995

63

FIGURE 17 - Upper Control Box Assembly 3887G

15

6

18

13

13

---++-~~~

13

4 2

9

5 2

17 16

64

MANUAL 92328-003 SEPTEMBER 1995

FIGURE 17-Upper Control Box Assembly 3887G ITEM

PART NUMBER

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

020-G7048-00 .......... Assembly, Upper Control Box ....................................... Ref. 010-G4013-00 .......... Weldment, Upper Control Box .......................................... 1 161-00001-00 .......... Cover, Weatherproof/Single-Gang Receptacle ..................... 1 51 91 3 ...................... Operator-Push Pull .......................................................... 1 67114-003 ............... Strain Relief .50"NPT .37"/.50· ........................................ 1 67114-009 ............... Strain Relief .75"NPT .62"/.75" ........................................ 1 324-00023-00 .......... Plug Button 1.25 ............................................................ 1 67114-015 ............... Strain Relief 1NPT .87"/.99" ............................................ 1 BOW17351 .............. Nut, .50" Conduit Connector ............................................ 1 67124-002 ............... locknut, Connector. 75" ................................................. 1 67124-003 ............... locknut, Connector 1.00" ............................................... 1 52672 ...................... Contact Block 1NO ......................................................... 3 50075 ...................... Switch (Ref PIN 67760) .................................................. 4 69146 ...................... Operator, Green Pushbutton ............................................. 1 34836 ...................... Operator, White Pushbutton ............................................. 1 36083 ...................... Switch Foot .................................................................... 1 36083-100 ............... Switch Foot - Service Kit ................................................ 1 ............................... Switch (BA-2R-A4 or Equivalent ...................................... 1 ............................... 8-32 x .218 Ref. Binder Hd. Term. Sew. & liplss Cupwasher3 36084 ...................... Guard, Foot Switch ......................................................... 1 40880 ...................... Guard, Toggle Switch Micro ............................................. 6 67758 ...................... Toggle Switch-R # 67760 ................................................ 1 54528 ...................... Decal, 4887 Upper Control .............................................. 1 67295-022 ............... Cable, 3 Conductor 12 AWG ......................................... 6lF

16 17 18 19 20

DESCRIPTION

QTY

- Indicates Items Not Shown

MANUAL 9232B-003 SEPTEMBER 1995

65

FIGURE 17 -Upper Control Box Assemby 4887G

15

6

18 13

13

---H_--=::\~~

13

4 2

9

5 2

17

16

66

MANUAL 92328-003 SEPTEMBER 1995

FIGURE 17-Upper Control Box Assemby 4887G DESCRIPTION

aTY

ITEM

PART NUMBER

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

020-G9048-00 .......... Assembly, Upper Control Box ....................................... Ref. 01 0-G4013-00 .......... Weldment, Upper Control Box .......................................... 1 161-00001-00 .......... Cover, Weatherproof/Single-Gang Receptacle ..................... 1 51913 ...................... Operator-Push Pull .......................................................... 1 67114-003 ............... Strain Relief .50"NPT .37"/.50" ........................................ 1 67114-009 ............... Strain Relief .75"NPT .62"/.75" ........................................ 1 324-00023-00 .......... Plug Button 1.25 ............................................................ 1 67114-015 ............... Strain Relief 1NPT .87"/.99" ............................................ 1 BOW17351 .............. Nut, .50· Conduit Connector ............................................ 1 671 24-002 ............... locknut, Connector .75" ................................................. 1 67124-003 ............... locknut, Connector 1.00· ............................................... 1 52672 ...................... Contact Block 1NO ......................................................... 3 50075 ...................... Switch (Ref PIN 67760) .................................................. 4 69146 ...................... Operator, Green Pushbutton ............................................. 1 34836 ...................... Operator, White Pushbutton ............................................. 1 36083 ...................... Switch Foot ................................................................... 1 36083-100 ............... Switch Foot - Service Kit ................................................ 1 ............................... Switch (BA-2R-A4 or Equivalent ...................................... 1 ............................... 8-32 x .218 Ref. Binder Hd. Term. Sew. & Liplss Cupwasher3 36084 ...................... Guard, Foot Switch ......................................................... 1 40880 ...................... Guard, Toggle Switch Micro ............................................. 6 67758 ...................... Toggle Switch-R # 67760 ................................................ 1 54528 ...................... Decal, 4887 Upper Control .............................................. 1 67295-022 ............... Cable, 3 Conductor 12 AWG ......................................... 6lF

16 17 18 19 20

- Indicates Items Not Shown

MANUAL 92328-003 SEPTEMBER 1995

67

FIGURE 18-11 OV Line To Platform (Option A407) QTY

ITEM

PART NUMBER

DESCRIPTION

Ref. Ref. 1 2 3 4 5 6 7 8 9 10 11

A407-3887 ............... 11 OV Line To Platform ................................................ Ref. A407-4887 ............... 110V Line To Platform ................................................ Ref. 52710 ...................... Plug, 110 Volt ................................................................ 1 29161 ...................... Cover Weatherproof - Duplex ........................................... 1 80361 ...................... Receptacle 15 Amp/125V ................................................ 1 53226 ...................... J Box, 11 OV Modified ..................................................... 1 BOW31834 .............. Scr, Selftap #12-24 x .50 ................................................ 2 52735 ...................... Decal 110 Volts ............................................................. 2 67295-022 ............... Cable 3 Conductor 12 AWG ........................................ 75LF 29163 ...................... Circuit Breaker 15 Amp ................................................... 1 67114-003 ............... Strain Relief 1/2NPT .37/.5 .............................................. 1 67123-001 ............... Seal, Connector Elect. 1/2" .............................................. 1 67124-001 ............... Locknut, 1/2NPT Strain Relief .......................................... 1

- Indicates Items Not Shown

7

1

9 10 11

68

MANUAL 92328·003 SEPTEMBER 1995

6

FIGURE 19-4-Wheel Drive (Option A604) ITEM

PART NUMBER

Ref. 1 2 3 4 5 6

A604-4887 ............... Drive - 4-Wheel .......................................................... Ref. 55227 ...................... Vlv (Assy); Ser/Parallel 12VDC ......................................... 2 321-00011-00 .......... Motor, Hyd. Wheel (Ref. 54750) ...................................... 4 126-10007-00 .......... Brake, Eskridge .............................................................. 2 54549 ...................... Weldment, 4887 LH yoke ................................................ 1 54550 ...................... Weldment, 4887 RH Yoke ............................................... 1 54556-001 ............... Rim & Tire (Assy.) - Right ................................................ 1

7

54556-002 ............... Rim & Tire (Assy.) - Left .................................................. 1

8 9 10 11 12 13

DESCRIPTION

QTY

50077 ...................... Switch R#67760 ............................................................

55246 ...................... Tube (Assy) - 38/4887 PB-M3 ..........................................

55247 ...................... Tube (Assy) - 38/4887 PA-M4 .........................................

55248 ...................... Tube (Assy) - 38/4887 PB-M 1 ..........................................

55249 ...................... Tube (Assy) - 38/4887 PA-M2 .........................................

55206 ...................... Hose Kit - 4887G 4WD Kawasaki .....................................

1 1 1 1 1 1

7

- Indicates Items Not Shown

6

5

9 1

2 MANUAL 92328-003 SEPTEMBER 1995

69

FIGURE 20-Spark Arrestor (Option A305) ITEM

PART NUMBER

Ref. 1 2 3 4

A305-3172 ............... Spark Arrestor ............................................................ Ref. 66451 ...................... Arrestor, Spark ............................................................... 1 54841 ...................... Shield, 3172 Spark Arrestor (includes items 3-5) ................ 1 38169 ...................... - Engine Modified, Kawasaki Muffler ................................. 1 54719 ...................... -Shield, Spark Arrestor .................................................. 1 54816 ...................... -Gusset, Spark Arrestor ................................................. 1

5

DESCRIPTION

- Indicates Items Not Shown

70

MANUAL 92328-003 SEPTEM8ER 1995

QTY

FIGURE 21-Slope Alarm, 5 Degree Multi-Axis (Option A353) ITEM

PART NUMBER

Ref. 1 2

A353-3172 ............... Slope Alarm, 5 Degree Multi-Axis ................................. Ref. 32002 ...................... Slope Sensor 2-Axis ........................................................ 1 34644 ...................... Alarm ............................................................................ 1

DESCRIPTION

QTY

- Indicates Items Not Shown

MANUAL 92328-003 SEPTEMBER 1995

71

FIGURE

22~LP/Gas

Dual Fuel (Vapor) Wisc. (Option A505)

DESCRIPTION

QTY

ITEM

PART NUMBER

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

A505-4887/38 .......... LP/Gas Dual Fuel Vapor Wisc ....................................... Ref. 32790 ...................... Dual Fuel 30HP .............................................................. 1 51630 ...................... -Filterlock FL-218 LP-Gas ................................................. 1 68095 ...................... -Regulator LP Fuel ........................................................... 1 68096 ...................... -Switch Vacuum Dual Fuel ............................................... 1 68097 ...................... -Valve Gasoline Shut Off ................................................. 1 68098 ...................... -Dual Fuel Carb Adapter 30HP .......................................... 1 BOW36004 .............. -Bolt, Hex .25"-20UNC x 1.00" ........................................ 2 BOW36725 .............. -Washer, Split Lock .25"ID .............................................. 4 BOW36001 .............. -Bolt, Hex .25"-20UNC x .630" ........................................ 2 BOW24113 .............. -Clamp, Hose 5/8"-3/4" - 1 1/4" ....................................... 2 BOW7836 ................ -Fitting 3/8" Pipe x 5/8" Hose .......................................... 2 BOW11101-X ........... -Elbow, Street 90° 3/8" Pipe ........................................... 2 BOW10838 .............. -Elbow, 45 ° . 125NPT Street Brass .................................... 1 BOW11 099-2 ............ -Nipple, .125NPT x 2.00" Brass ........................................ 2 BOW11024 .............. -Elbow, 90° 3/16" Tube 1/8" Pipe .................................... 1 BOW11027 .............. -Elbow, 90° 3/8" Tube x 1/4" Pipe ................................... 1 BOW11101 .............. -Elbow, 90° .125" Street Brass ........................................ 1 BOW10702-1 ............ Hose Dry Gas x 18" Lg .................................................... 1 50077 ...................... Switch R#67760 ............................................................ 1 392-00021-00 .......... Switch, Push Button ....................................................... 2 67075-002 ............... Coupling- Quick Disconnect ............................................. 1 67104 ...................... Bracket, LP Mount Horizontal ........................................... 1 67103-001 ............... Tank, LP Fuel Vapor 33.5LB ............................................. 1

- Indicates Items Not Shown

72

MANUAL 92328-003 SEPTEMBER 1995

FIGURE 23-LP/Gas Dual Fuel (Liquid) Wisc. (Option A506) QTY

ITEM

PART NUMBER

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

A506-4887/38 .......... LP/Gas Dual Fuel (Liquid) ............................................. Ref. 32790 ...................... Dual Fuel, 30HP ............................................................. 1 51630 ...................... -Filterlock FL-218 LP-Gas .............................................. 1 68095 ...................... -Regulator LP Fuel ........................................................ 1 68096...................... -Switch Vacuum Dual Fuel ............................................ 1 68097 ...................... -Valve Gasoline Shut Off .............................................. 1 68098 ...................... -Dual Fuel Carbo Adapter-30HP ...................................... 1 BOW36004 .............. -Bolt Hex .25-20UNC x 1.000 ....................................... 2 BOW36725 .............. -Washer Split Lock .2510 .............................................. 4 BOW36001 .............. -Bolt Hex .25-20UNC x .630 ......................................... 2 BOW24113 .............. -Clamp Hose 5/8 - 3/4 - 1-1/4· ...................................... 2 BOW7836 ................ -Fitting 3/8 Pipe x 5/8 Hose .......................................... 2 BOW111 01-X ........... -Elbow Street 90 3/8 Pipe ............................................. 2 BOW10838 .............. -Elbow 45 .125NPT Street Brass ................................... 1 BOW11099-2 ............ -Nipple .125NPT x 2.00 Brass ....................................... 2 BOW11024 .............. -Elbow, 903/16 Tube x 1/8 Pipe ................................... 1 BOW11027 .............. - Elbow, 90 3/8 Tube x 1/4 Pipe ..................................... 1 BOW11101 .............. -Elbow, 90 .125 Street Brass ........................................ 1 BOW10702-1 ............ -Hose Dry Gas x 18·Lg ................................................. 1 58045 ...................... Convertor Algas For Wisconsin ......................................... 1 68097 ...................... Valve Gasoline Shut Off .................................................. 1 017-00060-00 .......... Propane, Vapor Bracket ................................................... 1 392-00021-00 .......... Switch Push Button ........................................................ 2 50077 ...................... Switch R#67760 ............................................................ 1 67075-002 ............... Coupling - Quick Disconnect ............................................ 1 67104 ...................... Bracket, LP Mount Horizontal ........................................... 1 67586-002 ............... Tank, LP Fuel Liquid 43.51b .............................................. 1

DESCRIPTION

- Indicates Items Not Shown

MANUAL 92328-003 SEPTEMBER 1995

73

FIGURE 24-Tires, Foam Filled (Option A602) ITEM

PART NUMBER

Ref. 1

A602-4887/38 .......... Tires, Foam Filled ....................................................... Ref. 020-G9005-00 .......... Assembly, Tire/Rim/Foam Filled ........................................ 4

DESCRIPTION

- Indicates Items Not Shown

74

MANUAL 92328-003 SEPTEMBER 1995

QTY

FIGURE 25-Hour Meter (Option A619) DESCRIPTION

QTY

ITEM

PART NUMBER

Ref. 1 2

A619-3172G ............ Hour Meter ................................................................ Ref. 80027 ...................... Meter Hour, 8/50V DC .................................................... 1 67840-001 ............... Bracket, Gauge Mounting ................................................ 1

- Indicates Items Not Shown

MANUAL 92328-003 SEPTEMBER 1995

75

FIGURE 26-Decend Alarm (Option A312) ITEM

PART NUMBER

DESCRIPTION

OTY

Ref. 1 2 3

A312-3172G ............ Decend Alarm ............................................................ Ref. 80188-024 ............... Wobbulator And Speaker 24V .......................................... 1 BOW31147 .............. Screw, Slotted Round #10-32UNF x 1.50" ........................ 4 BOW31144 .............. Screw, Slotted Round #10-32UNF x .50" .......................... 3

- Indicates Items Not Shown

1

2

WOBBULATOR

TRAVEL

DESCEND

GROUND SEE NOTE 2

NOTES: 1. IF TRAVEL. THEN PULSING TONE. IF DESCEND. THEN STEADY TONE. IF BOTH. THEN PULSING. 2. FOR CIRCUIT NUMBERS. SEE ELECTRICAL SCHEMA TIC.

76

MANUAL 92328-003 SEPTEMBER 1995

FIGURE 27-Engine, Hatz Diesel (Option A502) QTY

ITEM

PART NUMBER

Ref. 1 2

A502-38/4887 .......... Engine, Hatz Diesel ..................................................... Ref.

3 4 5 6

DESCRIPTION

54470 ...................... Engine - Hatz Diesel 2M40 ...............................................

54604-004 ............... Pump, .854 Cipr JSB 900 Gear ........................................

54470-001 ............... Pump Mnt, SAE 'A' 2-Bolt ...............................................

54470-002 ............... Coupling, Hyd. Pump Drv 9-Tooth .....................................

54514 ...................... Tailpipe, Hatz Diesel ........................................................

54956 ...................... Schematic, 4887 Hatz Elec ..............................................

1 1 1 1 1 1

- Indicates Items Not Shown

MANUAL 92328-003 SEPTEMBER 1995

77

FIGURE 28-Generator, Hydraulic Driven (Option A411)

EXISTING PUMP & FILTER

)---------,- - - - fxi~~~~c - - - , - - - - - - - - - - - - - - - j

"P" PORT OF EXISTING MANIFOLD

0. --, I j

3000 PSI

<;)

SEE NOTE 3.

,.

13 12 11 10

EXISTING RETURN FILTER EXISTING RETURN LINE

54866 52710

67990 67989 66357

9

67295-022

8 7

80025

NEW 3/4·' TEE 2

67280 67762 37171

1.00 1.00 1.00 1.00 1.00 70.00 1.00 1.00 1.00

1.00

70077

2.00

70076 70078

2.00 1.00

21 JUMPER

10

NEW JUMPER "'.,,,7/:-iB"Lc.A~N;=K,~""'TH"'R;;;O~T"T"'LE"""~t__-A'cr 21

I I a-=cI

~iL~C~fN~O~UT~~~RS

TERMINAL

~~1~2~1_F------~r

" hE",XI."S,cTI",N",G:::-C",I",R",C",U,::,'T:-:JL U,2=-''::-::--,---__ IN UPPER CONTROL BOX

"-'<~r

EXISTING CIRCUIT #,7/BLANK-REMOVE CONDUCTORS 17 & BLANK FROM THIS CIRCUIT AND RE-LABEL THIS CIRCUIT #17A

EXIS TI NG FOOT SWITCH

-----<D

USE SPARE NEW SWITCH CONDUCTOR IN UPPER CONTROL BOX "',N=C"O"'N"'T=R"'O-'-L-'C"'A'-B=-L"""Ec------l NEW DECAL ,

~ INCLUDED WITH GENERATOR EXISTING CIRCUIT

5

IN LOWER CONTROL BOX NEW DECAL 67989 ,~

\0

II

I'

----0 -----0

REF

13 REF

1 REF

FUSE

NEW 20A CIRCUIT BREAKER NEW GENERATOR

NEW RELAY ~

78

RED BLK WHT GRN

B U

MANUAL 92328-003 SEPTEMBER 1995

PLUG

EA EA EA EA EA

INST OWG,

PLUG DECAL DECAL RECEPTACL

LF EA

CABLE .3 C

EA EA

RELAY, BO!

CIRCUIT BR

SWITCH, RII

EA EA

BODY, SUN

EA

CARTRIDGE,

EA

VALVE, 2W,

VALVE. 2W,

FIGURE 28-Generator, Hydraulic Driven (Option A411)

DESCRIPTION

QTY

ITEM

PARTNUMBER

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

A411-3172 ............... Generator, Hydraulic Driven ......................................... Ref. 66490 ...................... Gen-11 OV 2KW Hyd Driven ............................................. 1 70078 ...................... Valve, 2Way NO 12 VDC ................................................ 1 70076 ...................... Cartridge, RDDA-Lan Relief .............................................. 2 70077 ...................... Body, Sun FAJ Cartridge Valve ......................................... 2 37171 ...................... Valve, 2-Way NC 12 VDC ................................................ 1 67762 ...................... Switch, R #67760 .......................................................... 1 67280 ...................... Relay Bosch ................................................................... 1 80025 ...................... Circuit Breaker 20AMPS .................................................. 1 67295-022 ............... Cable 3 Conductor 12AWG ........................................ 70LF. 66357 ...................... Receptacle, Ground Fault ................................................. 1 67989 ...................... Decal, Switch Must Be In Aerial ........................................ 1 67990 ...................... Decal, On/Off Generator .................................................. 1 52710 ...................... Plug, 110 Volt ................................................................ 1

- Indicates Items Not Shown

MANUAL 92328-003 SEPTEMBER 1995

79

SELF-PROPELLED ELEVATING WORK PLATFORM

MODELS 3887G/4887G VENDOR SECTION

3887G

4887G

SHIPPING ADDRESS

MAILING ADDRESS

CALAVAR CORPORATION 8300 IMPERIAL DRIVE WACO, TEXAS 76712 (817) 666-4545

CALAVAR CORPORATION P. O. Box 21447 WACO, TEXAS 76702-1447 (817) 666-4545 MANUAL 92328-<lO4 SEPTEMBER 1995

UUIlCUI I '-oJVV-"" I V- III

August, 1990 '.1.

'

Parker Pressure Filters Models 15p, 30P and 30PD

. • Pressure ratings to 3000 psi (204 bar) • Flow rates to 45 gpm (174 Ipm)

Parkar Filtration

~n

rUlers Models 15P, 30P and 30PD ~~ure

Applications for Parker Pressure Filters • Saw Mills • Aircraft ground support equipment • Asphalt pavers • Hydraulic fan drives • Power steering circuits • Waste trucks • Cement trucks • Servo control protection • Logging equipment • Metal presses • Plastic machinery These application examples have one thing in common ... the need for clean hydraulic fluid.

Modern high pressure hydraulic systems are demanding. Better controls and long component life are expected. To deliver the high standards of performance, hydraulic components are built with tighter firs and tolerances, which increase sensitivity to contamination.

That's where Parker pressure filters come into play. They stop ingressed dirt before it jams a valve or scores a cylinder. They block pump generated debris before it gets to servo or control valves. Parker pressure filters are a key ingredient in meeting the demand of today's systems.

Engineered to be a better filter.

Right to the last detail, Parker has designed and built the 15P/30P family of filters to be rugged, compact and economical. The result is a family with one of the highest fatigue pressure ratings in aluminum filters; 2000 psi (138 bar), per the NFPA/T3.10.5.1Category 2/90 specification.

Depend on Parker pressure filters for system protection.

Put your hydraulic systems in the care of Parker Hydraulic Filter Division. We are committed to designing and building the best filters available to industry.

Manifold Ports

Indicators

• Optional mounting for reduced piping

• Both visual pop-up style and dual indicator visual! electrical style available to suit your application.

New patented design resists false signaling due to vibration.

Bowl Construction • Formed of high grade 6061-T6 aluminum • Black anodized. corrosion resistant finish • Knurled for easier gripping when removing and re-assembling

Straight Thread Ports • SAE straight thread for positive sealing

Bowl Configurations

Bypass Valve (Not Shown)

• Single and double length bowls available to cover a wide range of flows • 30P available in a duplex version.

See page 4

• May be blocked for critical applications

Hex servicing • Lets you drain bowl before element changes

Hydraulic Filter Division Metamora. OH 43540

2

• Hex formed at base of bowl for easy removal

Parker Filtration

Pressure Filters Models 15P, 30P and 30PD Inside each Parker Filter... a quality Parker Element \

}

The important item in a filter assembly ... is the element. It has to stop and hold contaminants that can damage or stop a machine ... while at the same time allowing the required flow of clean fluid to perform its function.

There are many ways to design and build an element, and, it's easy to design a low cost element. However, cost is not a good selection criteria ... especially when the risk is loss of critical performance.

For instance, wire mesh reinforcement. Not all filter elements have it. It's used in Parker elements to keep the pleats from collapsing or bunching.

If pleats bunch, the effective surface area of the element is reduced, excessive pressure drop develops, and the filter assembly may go into the bypass mode. This condition wastes energy, allows unfiltered fluid flow back into the system and effectively shortens filter life.

Price-Per-Gram Another reason why cost is a poor selection criteria for elements, is that it ignores dirt holding capacity.

If two elements of the same size and equal stated efficiency have prices of $20.00 and $30.00, many people would automatically select the $20.00 element. This could prove to be the wrong choice.

Features Wire reinforced microglass elements.

"0" Ring Seal

Engineered Element Design

• Positive sealing for optimum element efficiency

Wire Reinforced Media • Prevents pleat bunching • Helps prevent media migration • Maintains media efficiency

Elements for Every Application

Hydraulic Filter Division Metamora, OH 43540

• Standard microglass media for long life and excellent system protection.

• Extended life microglass elements for severe applications

Epoxy Treated End Caps • Excellent corrosion protection • Strong adhesion means no element separation

The correct comparison is "priceper-gram" of dirt holding capacity ... not just price!

Here is an example: • Element "A" at $20.00 only holds 10 grams of dirt for a price-per-gram of $2.00.

• Element "B" is $30.00 ... but contains 20 grams ... for a priceper-gram advantage at only $1.50.

It's easy to see, that with Element "B" you have a better price-pergram value which equates to longer working life for the filter, less maintenance downtime, less maintenance labor.

Advantages

Benefits

Rugged construction stands up to abuse of cyclic flows without performance loss.

The reliable filtration provided assures equipment protection, reduces downtime, maximizes element life, and allows the hydraulic system to operate properly.

Wire support reduces pleat bunching, keeps pressure drops consistent.

Multipass tested elements (per ANSI/B93.31-1973 modified for fine filtration).

Complete element performance data disclosure.

• The right combination of pleat depth and number of pleats means lower pressure losses (longer life) • Dirt holding capability is maximized for less frequent element change-out • Parker elements last longer and perform better (see performance information), saving you time and money.

Filter performance backed by recognized and accepted laboratory test standards.

Filters you select have known performance levels.

All pertinent information is provided in an easy-to-compare format.

Provides an easy guide to proper filter selection.

3

Parkar Filtration

Pressure Filters Models 15P, 30P and 30PD 30PD Duplex Filter for continuous filtration The Parker 30PD duplex pressure filter provides uninterrupted filtration for equipment that canl be shut down for servicing.

By simply switching the diverter valve, you can service one filter element while the other one is still in use.

Pressure balancing valves and check valves are all neatly assembled in a compact manifold head that makes the operation smooth and easy.

Parker reliability The Parker 30PD pressure duplex makes use of industry proven components. All elements are mUlti-pass tested in accordance with ANSI/B93.31-1973, modified for silt control filters. Bowls and housings are subjected to rigorous fatigue testing for millions of cycles. And every filter assembly is static tested before shipment.

Get the best-get Parker Reliable, field proven components.

Accurate and complete testing. Full performance data disclosure. We give our best ... so you can do your best.

Uninterrupted hydraulic pressure line filtration for sensitive components Balance Valve • Safety valve equalizes pressure between the two bowls

Diverter Valve • Low torque for easy servicing • Detent for valve handle prevents accidental switching • Valve indicates which filter is in use

Instructions and Identification • Name tag and operating instructions riveted to manifold Ports • SAE straight threa(J-_ ports for positive sealing

• %-27 NPT drain port, both sides

---Bowls • 30PO unit uses standard 30P bowls and elements

Vents • Valved vents allow for r.nn"pnIPnt purging of trapped air

Installation Information

1"SAE-16 (1.312-12 UN-2B) STRAIGHT THREAD BOSS BOTH PORTS

4.00 MIN. ELEMENT REMOVAL CLEARANCE

1.12 HEX TYP.

--..--t

Valve Manifold Flow/Pressure Loss 30PD

~2 5

a: 1.6

~

1.4

20

1.2 1.0

~ 15 w a:

0.8

tt

'V

is 1 0

0.6 0.4 0.2

us "-

o ~ o

------

~

/

./'

20

10

AGPM

25

Hydraulic Filter Division Metamora, OH 43540

r ",,"3

Q.

For the total pressure loss through the 30PD at a specific flow, add the valve manifold pressure loss to the pressure loss of the selected filter assembly.

See pages 7 and 8 for 30P assembly pressure loss data.

/

I /

40

30

50 LPM ....

FLOW

I

50

75

100

125

150

175

4

Parkar Filtration

Pressure Fitters Models 15p, 30P and 30PD

'''11.

Element Performance

Media Code

Filter Media

Time Averaged + Beta xly/z=2120175 Where xly/z is:

Dirt Capacity (Grams)

40W 25W 40SA 20C 10C 03C 10B

Woven Wire Woven Wire Synthetic Cellulose Cellulose Cellulose Microglass

0.0016' 0.001' 40 Micron Nominai2 20 Micron Nominai2 7.6/18.4/21 Micron 2/4.5/6.4 Micron <2/5.4/7.2 Micron

* * 2 1.5 5

+ Multipass test run @ 10 gpm to 100 psid (235 psid, H and X

J

0.2

o

ie

~

) o

V /y

V/

20B 03B 10BH 03BH 10BX 03BX

Microglass Microglass Microglass Microglass Microglass Microglass

4/15/20 Micron <2/2.4/3.2 Micron 2.8/5.6/7.4 Micron <2/2/2.6 Micron 2/5/7 Micron <2/2/2.6 Micron

4 2 3 2.5 3 4.5

/

/

/

/

1.6

«

In

Q.

1.0

iiI 5

"

~

./ V

~10

Q.

0.6

10

12.5

15

17.5

22.5

20

FLOW

5

ie

~

25

!

!

!

I

!

20

30

40

50

60

70

80

/'

40SA

V

~~ ~

o

2.5

/

7.5

90

./

~V 12.5

10

... GPM

LPM"I'

/

V

V/ "

0

W II:

0.8

'/

/

1.2

0.4

7.5

/

0

1.4

0.2

2.5

20 C

5

II:

/

10

Dirt Capacity (Grams)

<l1li 2

/

... GPM

o

Time Averaged + Beta xly/z=2/20175 Where xly/z Is:

03B

/ V /

Filter Media

1. Not multipass tested. Number shown is actual pore size in inches.

2. Not multipass tested.

elements) ANSIIB93.31-1973 w/50 ppm anti-static additive. * Not Applicable.

03C

Media Code

15

17.5

20

22.5

FLOW

10

I

I

20

30

40

25

LPM"I'

50

60

70

90

80

20B

/

V

0.4 0.2

0.2

7.5

10

12.5

15

17.5

22.5

20

FLOW

o

10

I

!

20

30

40

Hydraulic Filter Division Metamora, OH 43540

50

o

25

70

80

~

o

2.5

7.5

10

90

/

/

V

10

12.5

15

17.5

20

22.5

FLOW 20

30

40W

/"

... GPM

LPM"I'

60

V i.-::::: ~

ie

. /~

V /

VY

40

50

25

LPM"I' 60

70

80

90

5

Parkar Filtration

Pressure Filters Models 15P, 30P and 30PD

'le1li'

Element Performance

Media Code

Filter Media

40W 25W 40SA 20C 10C 03C 108

Woven Wire Woven Wire Synthetic Cellulose Cellulose Cellulose Microglass

Dirt .

Capacity (Grams)

Time Averaged + Beta xly/z=2/20175 Where xly/z is: 0.0016 1 0.0011 40 Micron Nominal2 20 Micron NominaF 6/16/19 Micron 2/6/8.7 Micron <2/5.8/7.5 Micron

3 4 11

+ Multipass test run @ 15 gpm to 100 psid (235 psid, H and X

'" 0 "-

fj11 5

0

w

a: 0.8

ffl "-

0.4 0.2

V ,,/

5 1i!

~

208 038 108H 038H 108X 038X

Microglass Microglass Microglass Microglass Microglass Microglass

4/15/20 Micron <2/2.7/3.6 Micron 3.4/6.5/8.1 Micron <2/2.1/3.6 Micron 2/5/7 Micron <2/2/2.6 Micron

8 6 9 5 6 9

25W

/

V V/ V VV V

V

~

...---..e:::::. ~

o

2.5

/'

V

./

V

0.2

7.5

10

... GPM

17.5

15

22.5

20

FLOW

10

!

!

20

(j)

~;::::::::

"-

12.5

30

40

o

25

70

60

80

~

o

~

r:::

7.5

2.5

/' V

10

10

90

15

20

17.5

22.5

FLOW

20

30

40

V

V

o

~V

2.5

/ ",

7.5

V

V

/

~

50

70

60

80

90

10

10C

V ......-:

~

~~ v

V

10

20

30

40

Hydraulic Filter Division Metamora, OH 43540

/

~

V

V V ...---~

12.5

17.5

15

20

22.5

50

..?2.5

25

o

LPM ....

60

70

80

7.5

10

/

!

20

I

30

40

40SA

/

V

12.5

,

15

17.5

20

22.5

FLOW

10

90

V

/

./

/'

... GPM

/

V V V '"

V

./'

FLOW

... GPM

25

LPM ....

03C

/

40W

'"

~V

12.5

... GPM

LPM ....

50

/ 20C

/ / / / ./ /"

./

~10

0.6

/

V

1.2 1.0

Dirt Capacity (Grams)

/

«

1.4

Time Averaged + Beta xly/z=2/20175 Where xly/z is:

03B

5

a:

1.6

Filter Media

1. Not multipass tested. Number shown is actual pore size in inches.

2. Not multipass tested.

elements) ANSI/893.31-1973 w/50 ppm anti-static additive. * Not Applicable.

.... 2

Media Code

50

25

LPM ....

60

70

80

90

6

Parkar Filtration

Pressure Filters Models 15P, 30P and 30PD

letl'l' Element Performance

-, ;;

Media Code

Filter Media

Time Averaged + Beta x/y/z=2/20/75 Where x/y/z is:

40W 25W 40SA 20C 10C 03C

Woven Wire Woven Wire Synthetic Cellulose Cellulose Cellulose

0.0016' 0.001' 40 Micron Nominal2 20 Micron Nominal 2 4/12/17 Micron 2/4.8/7 Micron

Dirt Capacity (Grams)

Media Code

Filter Media

Time Averaged + Beta x/y/z=2/20175 Where Xly/z is:

Dirt Capacity (Grams)

3 5.5

10B 03B 10BH 03BH 10BX 03BX

Microglass Microglass Microglass Microglass Microglass Microglass

<2/5.8/7.8 Micron <2/2.5/3.3 Micron 3.1/5.2/7.2 Micron <2/2.2/3.7 Micron 2.6/7/8 Micron <2/2.2/3.5 Micron

11 6.5 12 8 6 9

+ Multipass test run @ 20 gpm to 100 psid (235 psid, H and X *

elements) ANSI/B93.31-1973 w/50 ppm anti-static additive.

1. Not multipass tested. Number shown is actual pore size in inches.

Not Applicable.

2. Not multipass tested.

03B

II /

/

I

V

en

"-

o ~

/

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10

20

30

40

50

70

60

90

80

FLOW

J

I

I

50

75

I

!!

100

125 150 175

VI

200

o 10 .... GPM

100

LPM,.I!

225

10B

250

275

I

I

300

325

I

I

350 375

20

30

40

/

0.4

I'

/

o:t: L / o

10

I

/

!

I

I

!

25

50

75

100

!

V

20

!

25

50

75

100

125 150 175

Hydraulic Filter Division Metamora, OH 43540

200

100

t

I

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!

200

225

250

t.J

I!

275

300

325

350 375

--

/

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70

90

80

o

100

10 .... GPM

LPM,.-

225

90

Vj /

60

I t !

80

LPM,.-

1/1

FLOW

50

70

20C 25W

/~

40

30

60

175

40W

/

.... GPM

I

125 150

V

/

50 FLOW

/ V /

/

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.... GPM

25

/

/ / II /

V

l(Y o

10C

/

/

V/

0.2

03C

40SA

J

I

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250

275

300

325

I

'-

/ ._-

20

30

......."._--

-----

40

60

50

70

'--

80

-----

90

100

FLOW LPM,.'---:'::---::L----:':---c'c::---:'::~':_:__~'=__ _L ____.1- __ L. __ J. ..... __L .. _.-L _____ 1 ____ ... 1

I

350 375

25

50

75

100

125 1 50

175

200

225

250

275

300

325

350 375

7

Parkar Filtration

Pressure Filters Models 15P, 30P and 30PO

lle1#f4 Element Performance Code

Filter Media

Time Averaged + Beta xIy/z=2/20115 Where xIy/z Is:

40W 25W 40SA 20C 10C 03C

Woven Wire Woven Wire Synthetic Cellulose Cellulose Cellulose

0.00161 0.0011 40 Micron Nominal 2 20 Micron Nominal 2 6/17/20 Micron 2.5/6.5/8.8 Micron

Media

Dirt Capacity (Grams) * * * 10 12

+ Multipass test run @30gpm to 100 psid (235 psid, H and X *

2.8/6.6/8.6 Micron <2/2.8/3.6 Micron 3.1/6fT.9 Micron <2/2.7/3.7 Micron 2.6fT/8 Micron <2/2.2/3.5 Micron

26 15 26 15 15 23

2. Not multipass tested.

20C

li/

o ~ o

GPM

I

!

o

/

V

0.8

~

~10

Q.

0.4

ii!

~ 20

30

40

1

!

I

50

75

100

!

50

!

60

I

70

80

90

100

LPM ...

I!

200

125 150 175

225

I!

250

275

300

I

!

325

350 375

~1 5 c w a:

ffl

~1 0 Q.

0.6

5

u; Q.

.L:.

o ~ o

A

~

10

GPM

I

,

I

!

I

o

25

50

75

100

w

~

~10

0.4

5

V ~ ~

u; Q.

GPM

90

80

FLOW

I

!

I

[

I

o

25

50

75

100

!

I

I

125 150 175

Hydraulic Filter Division Metamora, OH 43540

o

100

LPM'"

I

!

I

I

!

I

200

225

250

275

300

325

I

I

350 375

~

60

70

80

90

125 150 175

100

LPM 'f'

I

!

!

I

!

I

200

225

250

275

300

325

1

350 375

V

0.6

70

50 I

V/ V / v~

~1 5

C

Q.

60

I

VV

a:

50

,

108 40W

:;,

0.8

0.2

40

40

FLOW

Q.

1.0

V

30

30

1.2

II II VV

20

20

0

1.4

IIII

Q.

?

10

5

VV

1.2

~

V ~ /

o A

I

10C 40 SA

20

0.4

1.0

~15 c w a: :;,

0.6

5

1.4

VV V[7

Q.

FLOW

25

20

1.2

0.2

10

A

/

)VJV

a: ~

1.4

/

V/

ii!

1.6

,.-,

03B 25W

<11125

V

I y

/

/

0.2

Microglass Microglass Microglass Microglass Microglass Microglass

Not Applicable.

/

0.8

10B 03B 10BH 03BH 10BX 03BX

1. Not multipass tested. Number shown is actual pore size in inches.

II

1.0

Filter Media

Dirt Capacity (Grams)

elements) ANSI/B93.31-1973 w/50 ppm anti-static additive.

D3C

0.2

Media Code

Time Averaged + Beta x/y/z=2/20115 Where x/y/z Is:

o A

GPM

I

1

I

!

I

o

25

50

75

100

10

20

40

30

70

60

50

80

90

FLOW I

I

I

125 150 175

100

LPM'f'

I

!

I

I

I

200

225

250

275

300

I

325

I

350 375

8

Parkar Filtration

Pressure Filters Models 15P, 30P and 30PD Installation and Specification Data

o and RFP. Also, limitations on fittings Model 15P

Visual Indicator (optional): Differential pressure type.

Rated Fatigue Pressure: 2,000 psi (138 bar) per NFPA!T3.10.5.1Category 2/90

may restrict operating pressure to less than rated static pressure (RSP) of 3,000 psi. Refer to SAE J1065, Table 2 for fitting recommendations. Please consult Parker Hydraulic Filter Division if you have questions about your application.

Electrical Indicator (optional): Electrical Switch rated 5A at 115/230 VAC, 5A resistive and 3A inductive at 28VDC. Color Coding: White (N.C.), Red (N.O.), Black (common)

Operating Temperatures: 225 OF to -40°F (1 OTC to -40°C)

Filter Housing: Anodized 6061-T6 Aluminum.

Warning: Maximum absolute system

Element Collapse Rating: 150 psi (10 bar).03B, 10B-350 psi (24 bar)

Weights (approximate): 15P-1 3.5 lb. (1.6 kg) 15P-2 4.6 lb. (2.1 kg)

Specifications Maximum Allowable Operating Pressure (MAOP): 3,000 psi (207 bar) Design Safety Factor: 3 to 1

pressure must not exceed filter's rated fatigue pressure (RFP) of 2,000 psi if the system frequently cycles between

High Collapse: 03BH, 1DBH-2,000 psi (138 bar). 03BX, 10BX-3,000 psi (209 bar)

Optional Visual Rotary Indicator Torque 55-70 Ft Lbs

% SAE·12 (1· \\0-12 UN-2B) Straight Thd Boss Port Torque 75-90 Ft Lbs (Ref to SAE J-514) _80.9

Standard Pop-up Indicators

Visual Indicator

ElectricallVisual Indicator

rt~

/

Rotates 360°

Max

,.

SAE-10 Torque 15-20 Ft Lbs

268.7 ±2.3 10.58±.09 15P.2

I

I

50.8

2:00

Optional 0/,0 SAE-5 (\>-20 UNF-2B) Straight Thread Drain Port Torque 15-20 Ft Lbs

Minimum Cartridge

I

Removal Clearance

I Bottom View

344 Thru

TOLERANCES (ALL MODELS) TO ONE DECIMAL PLACE· 2.3mm ·0.09 TO TWO DECIMAL PLACES. 1.5mm ·0.06 TO THREE DECIMAL PLACES· OAmm ·0.D15 LINEAR MEASURE MILLIMETER INCH

Plugs Supplied With Bypass Only

Inlet 69 Dia. 2-117 O-ring Boss

Hydraulic Filter Division Metamora, OH 43540

Outlet .69Dia 2-117 O-ring Boss

9

Parkar Filtration

Pressure Filters Models 15P, 30P and 30PD Installation and Specification Data

may restrict operating pressure to less than rated static pressure (RSP) of 3,000 psi. Refer to SAE J1065, Table 2 for fitting recommendations. Please consult Parker Hydraulic Filter Division if you have questions about your application.

Model 30P

Specifications Maximum Allowable Operating Pressure (MAOP): 3,000 psi (207 bar) Design Safety Factor: 3 to 1

Operating Temperatures: 225°F to -40°F (10TC to-40°C)

Rated Fatigue Pressure: 2,000 psi (138 bar) per NFPM3.10.5.1Category 2/90

Element Collapse Rating: 150 psi (10 bar). 03B, 108-350 psi (24 bar)

Warning: Maximum absolute system

High Collapse: 03BH, 10BH-2,OOO psi (138 bar). 03BX, 10BX-3,OOO psi (209 bar)

pressure must not exceed filter's rated fatigue pressure (RFP) of 2,000 psi if the system frequently cycles between and RFP. Also, limitations on fittings

o

Electrical Indicator (optional): Electrical Switch rated 5A at 115/230 VAC, 5A resistive and 3A inductive at 28VDC. Color Coding: White (N.C.), Red (N.O.), Black (common) Filter Housing: Anodized 6061-T6 Aluminum.

Weights (approximate): 30P-1 6.4 lb. (2.9 kg) 30P-2 8.7 lb. (3.9 kg) 30PD-1 36 lb. (16.3 kg) 30PD-2 40 lb. (18.1 kg)

Visual Indicator (optional): Differential pressure type.

~

-16 UNC

1.~i Deep Min.

4 Total Torque 30-40

Ft Lbs

Standard Pop-up Indicators Visual Indicators

SAE-10

I

30P-2

.~DiaThru

Str Thd Boss Port 1" SAE-16 (1-';;'.-12 UN-2B) Torque 120-140 Ft Lbs Or Optional SAE-12 (1\1,.·12 UN·2B) Torque 75-90 Ft Lbs

3"

338.8 13.34 I

4-Total

Torque 25-30

Ft TOLERANCES (ALL MODELS)

t 101.6 4.00 Cartridge Removal Clearance

!

TO TWO DECIMAL PLACES 0 1.5mm 00.06

'A.

-M

TO THREE DECIMAL PLACES 0 OAmm 00.Q15 LINEAR MEASURE MILLIMETER INCH

2750 9

349 1375

104.8 Dia 4.13

TO ONE DECIMAL PLACE 0 2.3mm 00.09

Optional Str Thd Drain Port SAE-5 ('/.,-20 UNF-2B) Torque 15-20 Ft Lbs

Minimum

9

,-

-

.~~~ Dia Th ru

2 Total

I

Hex

31.8 1.25 Optional Mounting Brackel (925562)

Hydraulic Filter Division Metamora, OH 43540

10

Parkar Filtration

t'ressure t"lIlers Models 15p, 30P and 30PD Filter Service When servicing a filter, use the following procedure: A. Stop the system's power unit.

B. Relieve pressure in filter line.

C. Rotate bowl counter-clockwise and remove.

D. Remove element from housing.

Discard all disposable elements.

These elements are not cleanable.

E. Place new, clean element in housing, centering it in the head.

F. Inspect the o-ring seal and replace if necessary.

G. Replace bowl. Rotate clockwise and tighten to specified torque (see pgs. 9 and 10).

Parts List INDEX DESCRIPTION HEAD ...... .

INLINE Porting Bypass, indicator port.. .................. .

No Bypass, indicator port ..... .

MANIFOLD Porting Bypass, indicator port No bypass, indicator port ....................... .

2 BYPASS VALVE ASSEMBLY. 50 psid ............... .. ......................................... ..

No bypass.. ............................ ..

3 ELEMENTS ................. ..

(See Chart Below) 4 BOWL O-RING .......

Buna N (Nitrile) .

Viton 5 BOWL ............................ ..

Standard, Single .... ..

Standard, Dou ble .

W/Drain, Single ..

W/Drain, Double ....... ..

DRAIN PLUG ..... .

6 W/Buna N (Nitrile) o-ring WNiton o-ring NAMEPLATE ..................... ..

7 DRIVE SCREWS ..

8 9 TUBE, Spacer ......................... ..

10 MOUNTING BRACKET KIT .................. .

11 BLANK KIT, Indicator ..

INDICATOR KIT (Includes a-ring) .

Visual, rotary dial ............................. ..

12 13 Visual, pop-up 13 Visual, pop-up w/thermallockout ..................... ..

ElectricalNisual WI'/2 -14 NPT connection and 12' leads ..

14 ElectricalNisual w/12" only 14 MANIFOLD MOUNTING KIT .:.

QUANTITY ....... 1

........ 1

........ 1 .. 1

........ 1

......... Optional

......... 1 ......... 2 ........ Optional ......... Optional .......... Optional .. ....... Optional

........... Optional

"Does not include bypass assembly.

Replacement Element Part Numbers Filter Type

Media 25W 40W 40SA 20C 10C 03C 20B lOB 03B 10BH 03BH 10BX 03BX

15P-1

15-P2

30P-1

30P-2

925574 925572 925584 925576 925385 925578 930369 925580 925582 925666 925664 928642 927725

925594 925592 925604 925596 925394 925598 930370 925600 925602 925671 925669 928643 927723

922627 922628 922960 922625 922624 922623 N/A 922622 922621 924423 923544 927712 927963

925832 925831 925833 925834 925835 925836 N/A 925837 925838 925839 925840 927965 927964

~--9 I 3

8

3

--'~-6

Hydraulic Filter Division Metamora, OH 43540

11

Parkar Filtration

fuWARNING

~

FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. This document and other information from Parker Hannifin Corporation, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application and review the information concerning the product or system in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met.

The products described herein,.including without limitation, product features, speCifications, designs, availability and pricing, are subject to change by Parker Hannifin Corporation and its subsidiaries at any time without notice.

Parkar Filtration

Parker Hannifin Corporation Hydraulic Filter Division 16810 Fulton County Road #2 Metamora, OH 43540 (419) 644-4311 FACSIMILE: 419644-6205

I

• To rqrnotor™ MG, MF, MB, ME, MJ Series Service Procedure

Service Manual 2704

Torqrnotor™ Design Features

COUPUNG SHAfT ... HIIIIH PRESSURE SEAL NEEDLE THRUST BEARING

DIRT a. WATER SEAL

MATCHED ROTOR SET MATCHED COMMUTATOR SET

COUPUNG SHAFT HI8H PRESSURE SEAL NEEDLE THRUST BEARING DRIVEUNk12-TOOTH SPLINES

DIRT a. WATER

SEAL

NEEDLE RADIAL BEARING MATCHED ROTOR SET MATCHED COMMUTATOR SET

Torqmotor™ MG Series features includes • The roller vane rotor set design offers a low-friction, wear compensation which maximizes the useful performance life of the motor.

• Zero leak commutation valve provides greater, more consistent volumetric efficiency.

• Design flexibility - MG offers the widest selection of shaft options, displacements and mounting flanges in the industry.

• Patented 60-40 spline member arrangement transmits more torque with less weight.

Full flow lubrication maximizes cooling and may provide up to 50% longer life than motors not having this feature.

• Higher pressure rating provide greater torque than competitive brands.

• Full interchangeability with other motors which are designed according to industry standards.

• Compatible with most hydraulic systems with regard to pressure, torque and speed.

• A unique high-pressure shaft seal that eliminates the need for case drains.

• Up to 13 horse power output.

Torqmotor™ MF Series features include: • Roller vanes to reduce friction and internal leakage and to maintain efficiency.

• Zero leak commutation valve provides greater, more consistent volumetric efficiency.

• Wheel mount version available.

• More starting torque than competitive motors in applications where the shaft is side loaded. ICompetitive brands require more pressure to start the motor.)

• A needle-roller mounted coupling shaft and steel-caged thrust bearing which can withstand 1000-pound thrust loads.

• Side load capacity is 1600 Ibs.1727.3 kg) maximum at center of output shaft.

• A unique high-pressure shaft seal that eliminates the need for case drains, check valves and extra plumbing.

• Up to 17 horsepower output.

• Greater durability due to superior lubrication and minimum drive spline ( . wear. ,,--.

• Patented 60-40 spline member arrangement transmits more torque with less weight.

•

Torqmotor™ Design Features

..

"'.'

_1I111t1i

PRESSURE SEAL NEEDlE THRUST BEARING

DIRT a WATER SEAL NEEDlE RADIAL BEARI.

MATCHED ROTOR SET MATCHED COMMUTATOR SET

COUPLING SHAFT

HIGH PRESSURE SEAL AIEEIIILE THRUST BEARING DRIVE LlNK14-TOOTH SPLINES

,.~~," ~

(-

DIRT a WATER SEAL NEEDLE RADIAL BEARING MATCHED ROTOR SET MATCHED COMMUTATOR SET

Torqmotor™ MB Series features includes • Heavy-duty thrust and roller bearings for up to twice side-load capacity to the previous motor.

• Roller vanes to reduce friction and internal leakage, and to maintain efficiency.

• A patented orbiting commutation system for less wear and longer life.

• A patented 60:40 arrangement of internal and external spline members to transmit more torque with less weight.

• A unique high-pressure shaft seal that eliminates the need for case drains, check valves and extra plumbing.

• A unique manifold designed to improve operating efficiency.

• Up to 1000 Ibs. (453.6 kg) end-thrust capacity in either direction.

• A design that is less sensitive to contamination than competitive motors.

• Up to 36 horsepower output.

• Greater durability because of superior lubrication and minimum drive spline wear.

• Superior low speed performance.

• Zero leak commutation valve provides greater, more consistent volumetric efficiency.

Torqmotor™ ME & MJ Series features include: • Roller vanes to reduce friction and internal leakage and to maintain efficiency.

• A patented orbiting commutation system for less wear and longer life.

• A patented 60:40 arrangement of internal and external spline members to transmit more torque with less weight.

• A unique high-pressure shaft seal that eliminates the need for case drains, check valves and extra plumbing.

• A manifold designed to improve operating efficiency.

• Heavy-duty thrust and roller bearings for up to twice the side-load capacity to the previous motor.

• Up to 1000 Ibs. (453.6 kg) end-thrust capacity in either direction.

• A design that is less sensitive to contamination than competitive motors.

• Up to 49 horsepower output.

• Greater durability because of superior lubrication and minimum drive spline wear.

• Zero leak commutation valve provides greater, more consistent volumetric efficiency.

2

Definitions NOTE:

A NOTE provides key information to make a procedure easier or quicker to complete.

CAUTION:

A CAUTION refers to procedure that must be followed to avoid damaging the Torqmotor™ OJ other system components.

WARNING:

A WARNING REFERS TO PROCEDURE THAT MUST BE FOLLOWED FOR THE SAFETY OF THE EQUIPMENT OPERATOR AND THE PERSON INSPECTING OR REPAIRING THE TORQMOTORTM.

Disclaimer This Service Manual has been prepared by Ross Operation for reference and use by mechanics who have been trained to repair and service hydraulic motors and systems' on commercial and non-commercial equipment applications. Ross Operation has exercised reasonable care and diligence to present accurate, clear and complete information and instructions regarding the techniques and tools required for maintaining, repairing and servicing the complete line of Ross MG, MF, MB, ME, & MJ Torqmotor™ Units.

However, despite the care and effort taken in preparing this general Service Manual, Ross makes no warranties that (a) the Service Manual or any explanations, illustrations, information, techniques or tools described herein are either accurate, complete or correct as applied to a specific Torqmotor™ unit, or (b) any repairs or service of a particular Torqmotor™ unit will result in a properly functioning Torqmotor™ unit.

If inspection or testing reveals evidence of abnormal wear or damage to the Torqmotor™ unit or if you encounter circumstances not covered in the Manual, STOP - CONSULT THE EQUIPMENT MANUFACTURER'S SERVICE MANUAL AND WARRANTY. DO NOT TRY TO REPAIR OR SERVICE A TORQMOTORTM UNIT WHICH HAS BEEN DAMAGED OR INCLUDES ANY PART THAT SHOWS EXCESSIVE WEAR UNLESS THE DAMAGED AND WORN PARTS ARE REPLACED WITH ORIGINAL ROSS REPLACEMENT AND SERVICE PARTS AND THE UNIT IS RESTORED TO ROSS SPECIFICATIONS FOR THE TORQMOTORTM UNIT. It is the responsibility of the mechanic performing the maintenance, repairs or service on a particular Torqmotor™ unit to (a) inspect the unit for abnormal wear and damage, (b) choose a repair procedure which will not endanger his/her safety, the safety of others, the equipment, or the safe operation of the Torqmotor™, and (c) fully inspect and test the Torqmotor™ unit and the hydraulic system to insure that the repair or service of the Torqmotor™ unit has been properly performed and that the Torqmotor™ and hydraulic system will function properly.

3

• Table of Contents

Page

Design Features ............................................. .Inside Front Cover Definitions .......................................•.........................3 Introduction ................................................................5 Troubleshooting Guide .......................................................6 Troubleshooting Check List .................................................. .7 Tools and Material Required for Servicing .......................................8 Bolt Torque .................................................................9 Exploded Assembly View ................................•...............10 & 11 MG Service Parts List Chart ........ , .........................................12 MF Service Parts List Chart ..................................................13 MB Service Parts List Chart ..................................................14 ME Service Parts List Chart ................................. " .. '" .......... 15 MJ Service Parts List Chart ..................................................16 Disassembly &Inspection ...................................................17 Assembly .................................................................25 Rotor Set Component Assembly Procedure (One Piece Stator) ....................35 Rotor Set Component Assembly Procedure (Two Piece Stator) ....................36 Final Checks ...............................................................38 Hydraulic Fluids ............................................................38 Filtration, Operating Temperature .............................................38 lips for Maintaining the System ..............................................39

4

Introduction Service Manual for Series MG, MF, MB, ME, MJ This service manual has one purpose: to guide you in maintaining, troubleshooting, and servicing the MG, MF, MB, ME, & MJ Torqmotor™ (low-speed, high-torque hydraulic motor).

Material in this manual is organized so you can work on the Torqmotor™ and get results without wasting time or being confused. To get these results, you should read this entire manual before you begin any work on the Torqmotor™.

This manual also contains troubleshooting information and checklist. If you must service the Torqmotor™, the checklist will help you to determine where the problem may be.

The three-column format of the Disassembly and Inspection, and Assembly sections will make it easier for you to conduct major work on the Torqmotor™. Column 1 gives a brief key for each procedure. Column 2 explains in detail the procedure you should follow.

Column 3 illustrates this procedure with photographs. Read all material carefully and pay special attention to the notes, cautions, and warnings.

A page with the Torqmotor™ exploded assembly view is provided several places in this manual. The component part names and item numbers assigned on this exploded assembly view correspond with names and item numbers (in parentheses) used in the disassembly and assembly procedures set forth in this manual.

Service part list charts are also provided in this manual with the part names and exploded view item numbers cross referenced to Ross service part numbers.

Service parts are available through the Original Equipment Manufacturer or Ross approved MG, MF, MB, ME, & MJ Distributors.

As you gain experience in servicing the Torqmotor™, you may find that some information in this manual could be clearer or more complete. If so, let us know about it. Do not try to second guess the manual. If you are stuck, contact us. Servicing the Torqmotor™ should be a safe and productive procedure, in order for the unit to deliver the reliable, long-life operation engineered into it.

5

Troubleshooting Guide

A

U

NOTE: Before trouble.shooting any system problem, check service literatu!e published by the equipment andlor component manufacturers. Follow their . instructions, if given, for checking any component other than the Torqmotor™ umt.

Preparation

Hydraulic Components

Make your troubleshooting easier by preparing as follows:

If you think the problem is caused by a hydraulic component, start by checking the easy-to-reach items.

• work in a clean, well-lighted place;

Check all hoses and lines for cracks, hardening, or other signs of wear. Reroute any useable hoses that are kinked, severely bent, or that rest against hot engine parts. Look for leaks, especially at couplings and fittings. Replace any hoses or lines that don't meet system flow and pressure ratings.

• have proper tools and materials nearby; • have an adequate supply of clean petroleum-based solvent.

WARNING: SINCE SOLVENTS ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT, EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH.

(J

WARNING: WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA AND OTHER MAXIMUM AIR PRESSURE REOUIREMENTS.

Preliminary Checks Hydraulic systems are often trouble-free. Hence, the problem an operator complains of could be cause by something other than the hydraulic components.

Thus, once you have determined that a problem exists, start with the easy-to-check items, such as:

Next, go to the reservoir and filter or filters. Check fluid level and look for air bubbles. Check the filter(s). A filter with a maximum 50 micron filtration is recommended for the Torqmotor system.

Visually check other components to see if they are loosely mounted, show signs of leaks, or other damage or wear.

Excessive heat in a hydraulic system can create problems that can easily be overlooked. Every system has its limitation for the maximum amount of temperature. After the temperature is attained and passed, the following can occur: • oil seal leaks • loss of efficiency such as speed and torque

• parts damaged from impact that were not properly repaired, or that should have been replaced; and

• pump loss of efficiency

• improper replacement parts used in previous servicing

• pump failure

• mechanical linkage problems such as binding, broken, or loose parts or slipping belts

• hoses become hard and brittle • hose failure A normal temperature range means an efficient hydraulic system. Consult the manuals published by equipment and/or component manufacturers for maximum allowable temperature and hydraulic tests that may be necessary to run on the performance of the hydraulic components. The Torqmotor™ is not recommended for hydraulic systems with maximum temperatures above 200°F (93.3°C).

6

Troubleshooting Checklist Remedy

Trouble

Cause

Oil Leakage

1. Hose fittings loose, worn or damaged.

Check & replace damaged fittings or "0" Rings. Torque to manufacturers specifications.

2. Oil seal rings (4) deteriorated by excess heat.

Replace oil seal rings by disassembling Torqmotor™ unit.

3. Special bolt (1, lA, lB or lC) loose or its sealing area deteriorated by corrosion.

Significant loss of speed under load

(a) Loosen then tighten single bolt to torque specification. (b) Replace bolt.

4. Internal shaft seal (16) worn or damaged.

Replace seal. Disassemblyof Torqmotor™ unit necessary.

5. Worn coupling shaft (12) and

Replace coupling shaft and seal by disassembling Torqmotor™ unit.

internal seal (16).

1. Lack of sufficient oil supply

c'.

(a) Check for faulty relief valve and adjust or replace as required. (b) Check for and repair worn pump. (c) Check for and use correct oil for temperature of operation.

2. High internal motor leakage

Low mechanical efficiency or undue high pressure required to operate Torqmotor™ unit

(a) Replace worn rotor set by disassembling Torqmotor™ unit.

3. Severely worn or damaged internal splines.

Replace rotor set, drive link and coupling shaft by disassembling Torqmotor™ unit.

4. Excessive heat.

Locate excessive heat source (usually a restriction) in the system and correct the condition.

1. Line blockage

Locate blockage source and repair or replace.

2. Internal interference

Disassemble Torqmotor™ unit, identify and remedy cause and repair, replacing parts as necessary.

3. Lack of pumping pressure

Check for and repair worn pump.

4. Excessive binding or loading in system external to Torqmotor™ unit.

Located source and eliminate cause.

CAUTION: If the hydraulic system fluid becomes overheated [in excess of 200°F (93.3°C)], seals in the system can shrink, harden or crack, thus losing their sealing ability.

7

(

"-,,

,.

\.'''''''/

Tools and Materials Required for Servicing MG, MF, MB, ME,MJ Series Service Manual (()

Clean, petroleum-based solvent Emery paper Vise with soft jaws Air pressure source Arbor press Screw driver Masking tape Breaker bar Torque wrench-ft. Ibs. (N m) Sockets: 1/2 or 9/16 inch thin wall, 1 inch Allen Sockets: 3/16,3/8 inch Adjustable crescent wrench or hose fitting wrenches SAE 10W40 SE or SF oil Special bearing mandrel for MG & MF Torqmotors (SEE FIGURE 1) Special bearing mandrel for MJ Torqmotors (consult factory) Special bearing mandrel for MB & ME Torqmotors (SEE FIGURE 2) Feeler gage .005 inch (.13 mm) MG & MF Torqmotors require blind hole bearing puller for 1.06 inch (26.9) mm) and 1.62 inch (41.1 mm) diameter bearing/ bushing.

MJ Torqmotors require blind hole bearing puller for a 1.575 inch dia. (40.0 mm) and 2.130 inch dia. (54.1 mm) bearings.

MB & ME Torqmotors require blind hole bearing pullerfor 1.400 inch dia. (35.6 mm) and 2.130 inch dia. (54.1 mm) bearings.

Clean corrosion resistant grease.

Recommended grease is Ross Specification #045236 or Mobil Mobilith SHC® 460 NOTE: The available service seal kits include the recommended grease as a grease pack #406018 CAUTION: Mixing greases that have different bases can be detrimental to bearing life.

i'·:~.

~.

8

CONVERSIONS INCHES

mm

INCHES

mm

.020 .021 .029 .030 .111 .119 .152 .160 .296 .304 .460 .470 .500 .585 .595 .660 .675 1.058

.51 .53 .74 .76 2.81 3.02 3.86 4.06 7.52 7.72 11.68 11.94 12.70 14.86 15.11 16.76 17.15 26.87

1.060 1.295 1.297 1.396 1.398 1.620 1.622 1.983 1.985 2.120 2.122 2.233 2.235 2.483 2.485 2.500 2.88

26.92 32.89 32.94 35.46 35.51 41.15 41.20 50.37 50.42 53.85 53.90 56.72 56.77 63.07 63.12 63.5 73.2

/--"":

\

Torque Chart Part Name

Item Number

Torque

bolt 5/16 24 UNF 2A bolt 3/8 24 UNF 2A bolt 5/8 18 UNF 2A nut 3/4 16 UNF 2B nut 1-20 UNEF 2B nut 1-1/818 UNEF 2B

1, lA, lBorlC 1, lA, lB or lC 120 12B (MG, MF) 12B (MB, ME) 12B (ME)

22-26 ft. Ibs. (30-35 N m) 45-55 ft. Ibs. (60-76 N m) 140-180ft.lbs. (190-244 N m) 175-255 ft. Ibs. (237-305 N m) 300-400 ft. Ibs. (407-542 N m) 300-400 ft. Ibs. (407-542 N m)

{'

IFabricate if considered necessary) FIGURE l-MG & MF

9

IFabricate if considered necessary) FIGURE 2-MB & ME

·_ Torqmotor'M Exploded Assembly View - Typical

:~(t

cD-~'BA

. ,

,

_

~

..

/

..,/~~.

@

•

~

~--

This Component Included in MB & ME - - - - - , Torqmotors Only,

,'~/"U,

/ ... _,"l

1M

//~~ ~'7~'O,

20

19

/ ~ --/

lS

12E

0,/\

/ v' 17 25 / -

12C

1\\~::: ~2~_ ~

J,

tJ

~_ i\J

:

"

J 0l)"~ '~,J'

16/ II 15 14 /

i

tJ~

/~~t?0

12

/ 11

G'

1/ ~ 10

NOTE: Assemble Sael Flit Side Out IS Shown in Enlarged View of SectiaMd Sagments of Items Number 5 and 3

ltam No. Description Special Bolts (5 or 71 Special Bolts Special Bolts Special Bolts 2.

End Cover 3.

Seal Ring·Commutator 4.

Seal Ring (5) 5.

Commutator 6.

Commutator Ring 7.

Manifold 8.

Rotor Set SA. Rotor SB. Stator or Stator Half BC. Vane (7) SO. Stator Half 8E. Vanel7l 9.

Wear Plate 10.

Drive Link 1.

1A. 1B. 1C.

".

'.~~.

~

m m m

11.

12.

12A. 12B. 12C. 120.

12E. 12F. 13.

14.

15 16.

17.

18 18A. 19.

Thrust Bearing Coupling Shaft

Key

Nut Washer Bolt lockwasher Retaining Ring Bearing/Bushing, Inner Thrust Washer Thrust Bearing Seal Backup Washer Housing O·Ring (2) Bearing/Bushing, Outer

20.

Dirt & Water Seal

21.

Plug (2) O·Ring (21 Spring Valve (Shuttle or Relief) Backup Washer

22.

23.

24.

25.

A1taraate COlStruction R,lief Velvll EIIII COftr

10

Torqmotor Exploded Assembly View - Typical lM

(Identical to page 10) _<b...':::::-18A @e

o

• t!1

_0

This Component Included in MB & ME - - - - - - , Torqmotors Only.

• '

/ ·.

l~'@'<1J'~'0

12E

12\~L::

12A

I

12C

l' 17l/Vo{)~~v~' / a -, / .

19

....

'0..

~2B \

~

16/jjO_N

~o~

15 14 /

12 4 8A

/

~ ~ ~

8C

($, "iW S(

~'~~~ ~

/ 8B

4

o

I/~ j lt$!

~~:"~"''',

/

/

7

SE

/ SO

Item No. Description 1.

Special Bolts (5 or 71 1A. Special Bolts 171 1B. Special Bolts 171 1C. Special 80lts 171 2.

End Cover 3.

Seal Ring-Commutator 4.

Seal Ring (5) 5.

Commutator 6.

COlTlmutator Ring 7.

Manifold S. Rotor Set SA. Rotor SB. Stator or Stator Half SC. Vane 171 SO. Stator Half SE. Vane 171 9.

Wear Plate 10.

Drive link

11

10

MATCHED

:)

II 0. . J'~

4/IY~~~ 6 //

8[4

Alternate Construction ME Rotor Set

i/:i'

2

/~

NOTE: Assemble Seal flat Side Out as Shown in Enlarged View of Sectioned Segments of ltams Number 5 and 3

11.

12.

12A. 12B. 12C. 12D. 12E. 12F.

13.

14.

15 16.

17. lS lSA. 19.

Thrust Bearing Coupling Shaft Key Nut Washer Bolt lockwasher Retaining Ring Bearing/Bushing, Inner Thrust Washer Thrust Bearing Seal Backup Washer Housing O-Ring (2) Bearing/Bushing, Outer

20.

21.

22.

23.

24.

25.

Dirt &Water Seal Plug (21 O-Ring (21 Spring Valve (Shuttle or Reliefl Backup Washer

Alter.ata Construction Relief Valva End Coyer

Disassembly and Inspection (Preparation Before Disassembly)

•

Before you disassemble the Torqmotor™ unit or any of its components read this entire manual. It provides important information on parts and procedures you will need to know to service the Torqmotor™.

•

Determine whether the Torqmotor™ you are about to disassemble is the Small Frame Series MG or MF or the Large Frame Series MB, ME, or MJ so you can follow those procedures that pertain to that Series Torqmotor™. The first two letters of the "spec" number on the Torqmotor™ identification tag is the Series designation. Also determine the type of end construction from the alternate views shown on the exploded view.

•

The Small Frame Series MG & MF Torqmotors™ will have a 3.66 inch (92.9 mm) main body outside diameter and five 5/16-24 UNF 2A cover bolts. The Large Frame Series MB, ME, & MJ Torqmotors™ will have a 5 inch (127.9 mm) main body outside diameter and seven 3/8 24 UNF 2A cover bolts.

•

Refer to "Tools and Materials Required for Services" section for tools and other items required to service the Torqmotor™ and have them available.

•

Thoroughly clean off all outside dirt, especially from around fittings and hose connections, before disconnecting and removing the Torqmotor™. Remove rust or corrosion from coupling shaft.

•

Remove coupling shaft connections and hose fittings and immediately plug port holes and fluid lines.

•

Remove the Torqmotor™ from system, drain it of fluid and take it to a clean work surface.

•

Clean and dry the Torqmotor™ before you start to disassemble the unit.

•

As you disassemble the Torqmotor™ clean all parts, except seals, in clean petroleum-based solvent, and blow them dry.

",

WARNING: PETROLEUM-BASE SOLVENTS ARE FLAMMABLE. BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH. WARNING: WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS. CAUTION: Never steam or high pressure wash hydraulic components. Do not force or abuse closely fitted parts.

•

Keep parts separate to avoid nicks and burrs.

•

Discard all seals and seal rings as they are removed from the Torqmotor™. Replace all seals, seal rings and any damaged or worn parts with genuine Ross or OEM approved service parts.

"-C

17

Disassembly and Inspection (Reference Exploded Assembly View) Place Torqmotor in a vise

1.

WARNING: IF THE TORQMOTORTM IS NOT FIRMLY HELD IN THE VISE, IT COULD BE DISLODGED DURING THE SERVICE PROCEDURES, CAUSING INJURY.

WARNING

Scribe alignment

Place the Torqmotor™ in a soft jawed vice, with coupling shaft (12) pointed down and the vise jaws clamping firmly on the sides of the housing (18) mounting flange or port bosses.

Remove manifold port O-Rings (18A) if applicable.

2.

mark & loose valve plugs

Figure 3

Scribe an alignment mark down and across the Torqmotor™ components from end cover (2) to housing (18) to facilitate reassembly orientation where required. Loosen two shuttle or relief valve plugs (21) for disassembly later if included in end cover. 3/16 or 3/8 inch allen wrench or 1 inch hex socket Figure 4 required. SEE FIGURE 3 & 4.

Figure 5

Remove special bolts & inspect bolts

3.

Remove the five or seven special ring head bolts (1, lA, lB, or 1C) using an appropriate 1/2 or 9/16 inch size socket. SEE FIGURE 5.

Inspect bolts for damaged threads, or sealing rings, under the bolt head. Replace damaged bolts. SEE FIGURE 6.

"",' Figure 6 18

Remove end cover & inspect bolts

.4.

Remove end cover assembly (2) and seal ring (4). Discard seal ring. SEE FIGURE 7.

~"II .",

NOTE: Refer to the appropriate -alternate cover construction" on the exploded view to determine the end cover construction being serviced.

NOTE

Figure 7

Remove plugs and valves

5.

If the end cover (2) is equipped with shuttle valve or relief valve (24) components, remove the two previously loosened plugs (21) and 0rings (22). SEE FIGURE 8.

CAUTION

CAUTION: Be ready to catch the shuttle valve or relief valve components that will fall out of the end cover valve cavity when the plugs are removed.

NOTE

NOTE: O-ring (22) is not included in seal kits but serviced separately if required.

NOTE: The insert and if included the orifice plug in the end cover (2) must not be removed as they are serviced as an integral part of the end cover.

NOTE

Wash & inspect end cover

6.

NOTE

Remove & inspect commutator ring

Figure 8

Thoroughly wash end cover (2) in proper solvent and blow dry. Be sure the end cover valve apertures, including the internal orifice plug, are free of contamination. Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces. Replace end cover as necessary. SEE FIGURE 9.

(

Figure 9

NOTE: A polished pattern (not scratches) on the cover from rotation of the commutator (5) is normal. Discoloration would indicate excess fluid temperature, thermal shock, or excess speed and require system investigation for cause and close inspection of end cover, commutator. manifold. and rotor set.

7.

t

~.

Remove commutator ring (6). SEE FIGURE 10.

Inspect commutator ring for cracks, or burrs.

Figure 10

19

,

Remove & inspect commutator

S.

Remove commutator (5) and seal ring (3) Remove seal ring from commutator, using an air hose to blow air into ring groove until seal ring is lifted out and discard seal ring. Inspect commutator for cracks or burrs, wear, scoring, spalling or brinelling. If any of these conditions exist, replace commutator and commutator ring as a matched set.

SEE FIGURE 11 & 12.

Remove manifold

9.

Remove manifold (7) and inspect for cracks surface scoring, brinelling or spalling. Replace manifold if any of these conditions exist. SEE FIGURE 13. A polished pattern on the ground surface from commutator or rotor rotation is normal. Remove and discard the seal rings (4) that are on both sides of the manifold.

,>

)0/'

NOTE

Figure 11

NOTE: The manifold is constructed of plates bonded together to form an integral component not subject to further disassembly for service. Compare configuration of both sides of the manifold to ensure that same surface is reassembled against the rotor set.

Figure 12

Remove & inspect rotor set & wearplate

NOTE

..,

.

10.

Remove rotor set (S) and wearplate (9), together to retain the rotor set in its assembled form, maintaining the same rotor vane (SC) to stator (SB) contact surfaces. SEE FIGURE 14. The drive link (10) may come away from the coupling shaft (12) with the rotor set, and wearplate. You may have to shift the rotor set on the wearplate to work the drive link out of the rotor (SA) and wearplate. SEE FIGURE 15. Inspect the rotor set in its assembled form for nicks, scoring, or spalling on any surface and for broken or worn splines. If the rotor set component requires replacement, the complete rotor set must be replaced as it is a matched set. Inspect the wearplate for cracks, brinelling, or scoring. Discard seal ring (4) that is between the rotor set and wearplate.

NOTE: The rotor set (8) components may become disassembled during service procedures. Marking the surface of the rotor and stator that is facing UP, with etching ink or grease pencil before removal from Torqmotor™ will ensure correct reassembly of rotor into stator and rotor set into Torqmotor™. Marking all rotor components and mating spline components for exact repositioning at assembly will ensure maximum wear life and performance of rotor set and Torqmotor™.

Figure 13

Figure 14

20

NOTE: Series ME Torqmotors™ may have a rotor set with two stator halls (8B & 80) with a seal ring (4) between them and two sets of seven vanes (8C & 8E). Discard seal ring only if stator halls become disassembled during the service procedures.

NOTE

~.

',I

I;

NOTE: A polished pattern on the wear plate from rotor rotation is normal.

NOTE

Figure 15

Check rotor. vance clearance

11.

Place rotor set (8) and wear plate (9) on a flat surface and center rotor (8A) in stator (8B) such that two rotor lobes (180 degrees apart) and a roller vane (8C) centerline are on the same stator centerline. Check the rotor lobe to roller vane clearance with a feeler gage at this common centerline. If there is more than .005 inches (0.13 mm) of clearance, replace rotor set.

SEE FIGURE 16.

NOTE: If rotor set (8) has two stator halfs (8B Figure 16 & 80) and two sets of seven vanes (8C & 8E) as shown in the alternate construction ME rotor set assembly view, check the rotor lobe to roller vane clearance at both ends of rotor.

NOTE

Remove & inspect drive link

12.

Remove drive link (10) from coupling shaft (12) if it was not removed with rotor set and wear plate. Inspect drive link for cracks and worn or damaged splines. No perceptible lash (play) should be noted between mating spline parts.

SEE FIGURE 17. Remove and discard seal ring Figure 17 (4) from housing (18).

Remove thrust bearing

13.

Remove thrust bearing (11) from top of coupling shaft (12) if Torqmotor is a Series MB or ME. Inspect for wear, brinelling, corrosion and a full complement of retained rollers. SEE FIGURE 18.

Figure 18

21

( ,,,, r.!

'

Check coupling shaft for rust or corrosion

14.

Check exposed portion of coupling shaft (12) to be sure you have removed all signs of rust and corrosion which might prevent its withdrawal through the seal and bearing.

Crocus cloth or fine emery paper may be used. SEE FIGURE 19. Remove any key (12A), nut (128), washer (12C), bolt (120), lock washer (12E), or retaining ring (12F).

Figure 19

Remove & inspect coupling shaft

15.

NOTE

NOTE: Minor shaft wear in seal area is permissible. If wear exceeds .020 inches (0.51 mm) diametrically, replace coupling shaft.

NOTE

Remol(e.$eal ring fromhou$ing

Remove coupling shaft (12), by pushing on the output end of shaft. SEE FIGURE 20. Inspect coupling shaft bearing and seal surfaces for spalling, nicks, grooves, severe wear or corrosion and discoloration. Inspect for damaged or worn internal and external splines or keyway. SEE FIGURE 21. Replace coupling shaft if any of these conditions exist.

Figure 20

NOTE: A slight "polish" is permissible in the shaft bearing areas. Anything more would require coupling shaft replacement.

16.

Remove and discard seal ring (4) from housing (18).

Figure 21 Remove & inspect thrust washer & thrust bearing

17.

Remove thrust bearing (15) and thrust washer (14) if the unit is a Series MG or ME Inspect for wear, brinelling, corrosion and a full complement of retained rollers. SEE FIGURE 22.

NOTE NOTE: Large Frame Series MB & ME Torqmotors have a thrust bearing (15) sandwiched between two thrust washers (14) that cannot be removed from housing (18) unless bearing (13) is removed for replacement.

Figure 22

22

Remove seal & washer or washers

18.

Remove seal (16) and back up washer (17) from Small Frame, MG & MF housing (18).

Discard both. SEE FIGURE 23.

Remove seal (16), backup washer (17), and backup washer (25) from Large Frame, Series MB & ME Torqmotor™ housing by working them around unseated thrust washers (14) and thrust bearing (15) and out of the housing.

Discard seal and washers. SEE FIGURE 24.

Figure 23

NOTE: The original design units of Large Frame, Series MB & ME Torqmotors™ did not include backup washer (25), but must include backup washer (25) when reassembled for service.

NOTE

Figure 24

Remove seal

19.

Remove housing (18) from vise, invert it and remove and discard seal (20). A blind hole bearing or seal puller required. SEE FIGURE 25.

Figure 25

Inspect housing assembly

20.

Inspect housing (18) assembly for cracks, the machined surfacesfor nicks, burrs, brinelling or corrosion. Remove burrs that can be removed without changing dimensional characteristics. Inspect tapped holes for thread damage. SEE FIGURE 26. If the housing is defective in these areas, discard the housing assembly.

Figure 26

23

Inspect housing bearinglbushing

21.

NOTE

Remt;ve bearings or bushings & thrust washers

Ifthe housing (18) assembly has passed inspection to this point, inspect the housing bearings/bushings (19) and (13) and if they are captured in the housing cavity the two thrust washers (14) and thrust bearing (15). The bearing rollers must be firmly retained in the bearing cages, but must r.otate and orbit freely. All rollers and thrust washers must be free of brinelling and corrosion. SEE FIGURE 27. The MG Series bushing (19) or (13) to coupling shaft diameter clearance must not exceed .010 inch (.02~ mm). A bearing, bushing, or thrust washer that does not pass inspection must be replaced. SEE FIGURE 28.

If the housing has passed this inspection the disassembly of the Torqmotor™ is completed.

NOTE: The depth or location of bearing! bushing (13) in relation to the housing wear plate surface and the depth or location of bearing/bushing (19) in relation to the beginning of bearing/bushing counter bore should be measured and noted before removing the bearings/bushings. This will facilitate the correct reassembly of new bearingslbushings. SEE FIGURE 29.

22.

Ifthe bearings, bushing or thrust washers must be replaced use a suitable size bearing puller to remove bearing/bushings (19) and (13) from housing (18) without damaging the housing. Remove thrust washers (14) and thrust bearing (15) if they were previously retained in the housing by bearing (13). SEE FIGURES 30 &31.

Figure 27

Figure 29

Figure 30

THE DISASSEMBLY OF TORQMOTORTM IS COMPLETED.

Figure 31

24

\

TorqmotorM Assembly •

Replace all seals and seal rings with new ones each time you reassemble the Torqmotor™ unit Lubricate all seals and seal rings with SAE 10W40 oil or clean grease before assembly.

•

NOTE: Individual seals and seal rings as well as a complete seal kit are available. SEE FIGURE 32. The parts should be available through most OEM parts distributors or Ross approved Torqmotor™ distributors.

(Contact your local dealer for availability).

•

NOTE: Unless otherwise indicated, do not oil or grease parts before assembly.

•

Wash all parts in clean petroleum-based solvents before assembly. Blow them dry with compressed air. Remove any paint chips from mating surfaces of the end cover, commutator set, manifold rotor set, wear plate and housing and from port and sealing areas.

WARNING WARNING: SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH.

WARNING

Press in outer bearing/bushing

WARNING: WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS. 1.

Ifthe housing (18) bearing components were removed for replacement, thoroughly coat and pack a new outer bearing/bushing (19) with Figure 32, MD, ME seal kit clean corrosion resistant grease recommended in the material section. Press the new bearing/bushing into the counterbore at the mounting flange end of the housing, using the appropriate sized bearing mandrel such as described in figure 1 or figure 2 which will control the bearing/ bushing depth . . Small Frame Series MG and MF Torqmotor™ housings require the use of bearing mandrel shown in figure 1 to press bearing/ bushing (19) into the housing to a required depth of .151/.161 inches (3.84/4.09 mm) from the end of the bearing counterbore. SEE FIGURE 33.

Figure 33 Large Frame Series MB and ME Torqmotor™ housings require the use of the bearing mandrel shown in figure 2 to press bearing (19) into the housing to a required depth of .290/.310 inches (7.37n,87 mm) from the outside end of the bearing counterbore. SEE FIGURE 34.

Large Frame Series MJ Torqmotor housings require the use of a bearing mandrel. Consult factory for specifications.

Figure 34

25

NOTE

NOTE: Bearing mandrel must be pressed against the lettered end of bearing shell. Take care that the housing bore is square with the press base and the bearing/bushing is not cocked when pressing a bearinglbushing into the housing.

CAUTION

CAUTION: If the bearing mandrel specified in the uTools and Materials Required for Servicing" section is not available and alternate methods are used to press in bearing/bushing (13) and (19) the bearinglbushing depths specified must be achieved to insure adequate bearing support and correct relationship to adjacent components when assembled. SEE FIGURE 35.

Figure 35

CAUTION: Because the bearing/bushings (13) and (19) have a press fit into the housing they must be discarded when removed. They must not be reused.

CAUTION

Figure 36

Press in inner Bearing/bushing

2.

The Small Frame Series MG and MF Torqmotor™ inner housing bearing/bushing (13) can now be pressed into its counterbore in housing (18) flush to .03 inch (.76 mm) below the housing wear plate contact face. Use the opposite end of the bearing mandrel that was used to press in the outer bearing/bushing (19). Reference figure 1, "Tools and Materials Required for Servicing" section. SEE FIGURE 36.

The Large Frame Series MB and ME Torqmotor™ housing (18) requires that you assemble a new backup washer (25), new seal (16), with the lip facing to the inside of Torqmotor (see figure 69B), new thrust washer (14), new thrust bearing (15) and a new second thrust washer (14) in that order before pressing in the inner housing bearing (13). SEE FIGURE 37 & 38. When these components are in place, press new bearing (13) into the housing (18) to a depth of .105/.125 inches (2.67/3.18) below the housing wear plate contact face. Use the opposite end of the bearing mandrel used to press in outer bearing (19).

Reference figure 2, in the "Tools and Materials Required for Servicing" section. SEE FIGURE 39.

Figure 37

Figure 38

26

Press in dirt & water seal

3.

Press a new dirt and water seal (20) into the housing (18) outer bearing counterbore. ..~.

'1' j:

Figure 39

The Small Frame Series MG and MF Torqmotor™ dirt and water seal (20) must be pressed in until its' flange is flush against the housing. SEE FIGURE 40.

Figure 40 (~"

~~t~~;

The large Frame Series MB and ME Torqmotor™ dirt and water seal (20) must be pressed in with the lip facing out and until the seal is flush to .020 inches (.51 mm) below the end of housing. SEE FIGURE 41.

Figure 41

Place housing assembly into vice

4.

Place housing (18) assembly into a soft jawed vise with the coupling shaft bore down, clamping against the mounting flange. SEE FIGURE 42.

Figure 42

27

Assemble backup washer & seal

5.

~ . ,-pi

On Small Frame, Series MG & MF Torqmotors™ assemble a new backup washer (17) and new seal (16) with the seal lip facing toward the inside of Torqmotor™ (see Figure 69AB), into their respective counterbores in housing (18) if they were not assembled in procedure 2.

Large Frame, Series MB and ME Torqmotor™ housing (18) that did not require replacement of the bearing package will require that the two "captured" thrust washers (14) and thrust bearing (15) be unseated and vertical to the counterbore and the new backup washer (17), new backup washer (25), and new seal (16) be worked around the thrust bearing package and placed into their respective counterbores.

The seal lip must face out of the seal counterbore and toward the inside of Torqmotor™ (see figure 69A). Be sure the thrust bearing package is reseated correctly after assembly of the seal and backup washer.

SEE FIGURE 43 & 44.

CAUTION: Original design Large Frame, MB & ME Torqmotors™ that do not have backup washer (25) when disassembled must be assembled with a new backup washer (17), new backup washer (25), and new seal (16).

CAUTION

'-".

Figure 43

Figure 44

,-

Assemble thrust washer & bearing

6.

Assemble thrust washer (14) then thrust bearing (15) that was removed from the Series MG or MF Torqmotor™. SEE FIGURE 45.

NOTE: Small Frame Series MG and MF Torqmotors™ require one thrust washer (14) with thrust bearing (15). The coupling shaft will be seated directly against the thrust bearing.

NOTE

Figure 45

Apply masking tape to shaft

7.

Apply masking tape around splines or keyway on shaft (12) to prevent damage to seal.

SEE FIGURE 46.

Figure 46

28

Install coupling shaft

8.

Be sure that a generous amount of clean corrosion resistant grease has been applied to the lower (outer) housing bearing/bushing (19). Install the coupling shaft (12) into housing (18), seating it against the thrust bearing (15) in MG and MF Series housings and against the second thrust washer (14) in MB and ME Series housings.

SEE FIGURE 47.

F) .,~

CAUTION

CAUTION: The outer bearing (19) is not Figure 47 lubricated by the system's hydraulic fluid. Be sure it is thoroughly packed with the recommended grease, Ross Gear grease specification #045236, ElM Lubricant #K-70M.

NOTE

NOTE: Mobil Mobilith SHC ® 460 NOTE: A 102 Tube (P/N 406010) is included in each seal kit.

NOTE

NOTE: The coupling shaft (12) will be flush or just below the housing wear plate surface on Small Frame, Series MG and MF Torqmotors'Th'l when properly seated while the coupling shaft (12) on Large Frame, Series MB and ME Torqmotors™ will be Figure 48 approximately .10 inch (2.54 mm) below the housing wear plate surface to allow the assembly of thrust bearing (11). The coupling shaft must rotate smoothly on the thrust bearing package.

SEE FIGURE 48.

Install thrust bearing

9.

Install thrust bearing (11) onto the end of coupling shaft (12) only if you are servicing an MB or ME Series Torqmotor™. SEE FIGURE 49.

Insert seal ring

10.

Figure 49 Apply a small amount of clean grease to a new seal ring (4) and insert it into the housing (18) seal ring groove. SEE FIGURE 50.

NOTE

NOTE: One or two alignment studs screwed finger tight into housing (18) bolt holes, approximately 180 degrees apart, will facilitate the assembly and alignment of components as required in the following procedures. The studs can be made by cutting off the heads of either 3/8-24 UNF 2A or 5/1624 UNF 2A bolts as required that are over .5 inch (12.7 mm) longer than the bolts (1, 1A, 1B, or 1C) used in the Torqmotor'Th'l.

jff-"

L

'~~:4;-

.~

Figure 50

29

..,

Install drive link

11.

Install drive link (10) the long splined end down into the coupling shaft (12) and engage the drive link splines into mesh with the coupling shaft splines. SEE FIGURE 51.

NOTE: Use any alignment marks put on the coupling shaft and drive link before disassembly to assemble the drive link splines in their original position in the mating coupling shaft splines.

NOTE

Figure 51

Assemble wear plate

12.

Assemble wear plate (9) over the drive link (10) and alignment studs onto the housing (18).

SEE FIGURE 52.

Assemble seal ring

13.

Apply a small amount of clean grease to a new seal ring (4) and assemble it into the seal ring groove on the wear plate side of the rotor set stator (8B). SEE FIGURE 53.

Install the assembled rotor set

14.

Install the assembled rotor set (8) onto wear plate (9) with rotor (8A) counterbore and seal ring side down and the splines into mesh with the drive link splines. SEE FIGURE 54.

Figure 52

',,,

.'. "

--

NOTE

NOTE: It may be necessary to turn one alignment stud out of the housing (18) temporarily to assemble rotor set (8) or manifold (1) over the drive link.

NOTE

NOTE: If necessary. go to the appropriate.

"Rotor Set Component Assembly Procedure."

NOTE

NOTE: The rotor set rotor counterbore side must be down against wear plate for drive link clearance and to maintain the original rotor-drive link spline contact. A rotor set without a counterbore and that was not etched before disassembly can be reinstalled using the drive link spline pattern on the rotor splines if apparent. to determine which side was down. The rotor set seal ring groove faces toward the wear plate (9).

Figure 53

Figure 54

30

Assemble seal ring in manifold

15.

NOTE

Assemble manifold

NOTE: The manifold (1) is made up of several plates bonded together permanently to form an integral component. The manifold surface that must contact the rotor set has it's series of irregular shaped cavities on the largest circumference or circle around the inside diameter. The polished impression left on the manifold by the rotor set is another indication of which surface must contact the rotor set.

16.

\

Apply clean grease to a new seal ring (4) and assemble it in the seal ring groove in the rotor set contact side of manifold (7). SEE FIGURE 55.

Figure 55

Assemble the manifold (7) over the alignment studs and drive link (10) and onto the rotor set Be sure the correct manifold surface is against the rotor set SEE FIGURE 56.

Figure 5&

Insert a seal in manifold

17.

Apply grease to a new seal ring (4) and insert it in the seal ring groove exposed on the manifold. SEE FIGURE 57.

Figure 57

Assemble commutator ring 31

18.

Assemble the commutator ring (6) over alignment studs onto the manifold.

SEE FIGURE 58.

Figure 58

Assemble seal & commutator

19.

Assemble a new seal ring (3) flat side up, into commutator (5) and assemble commutator over the end of drive link (10) onto manifold (7) with seal ring side up. SEE FIGURE 59, 60.

Figure 59

Figure 60 ".\

Assemble shuttle valve parts into end cover

20.

If shuttle valve components items #21, #22, #23, #24 were removed from the end cover (2) turn a plug (21) with a new o-ring (22), loosely into one end of the valve cavity in the end cover. Insert a spring (23) the valve (24) and the second spring (23) into the other end of the valve cavity. Turn the second plug (21) with a new o-ring (22) loosely into the end cover valve cavity. 3/16 inch Allen wrench required. SEE FIGURE 61.

Figure 61

Assemble relief valve parts in end cover

21.

If relief valve components items #21, #22, #24 were removed from the end cover (2) assemble a new o-ring (22) on the two plugs (21).

Assemble a two piece relief valve (24) in each of the plugs, with the large end of the conical spring into the plug first and the small nut of the other valve piece in the small end of the conical spring. Turn each of the plug and relief valve assemblies into the end cover loosely to be torqued later. 3/8 inch Allen or 1 inch Hex socket required. SEE FIGURE 62.

Figure 62

32

Assemble seal ring & end cover

22.

Assemble a new seal ring (4) into end cover (2) and assemble end cover over the alignment studs and onto the commutator set.

SEE FIGURE 63, 64. If the end cover has only 5 bolt holes be sure the cover holes are aligned with the 5 threaded holes in housing (18). The correct 5 bolt end cover bolt hole relationship to housing port bosses is shown in FIGURE 65.

Figure 63

NOTE: If the end cover has a valve (24) or has five bolt holes, use the line you previously scribed on the cover to radially align the end cover into its original position.

NOTE

Figure 64

Figure 65

Assemble cover bolts

33

23.

Assemble the 5 or 7 special bolts (1, lA, 1B or 1C) and screw in finger tight. Remove and replace the two alignment studs with bolts after the other bolts are in place. Alternately and progressively tighten the bolts to pull the end cover and other components into place with a final torque of 22-26 ft. Ibs. (30-35 N m) for the five MG & MF Series 5)16 24 threaded bolts or 45-55 ft. Ibs. (61-75 N m) for the seven MB & ME Series 3/8-24 threaded bolts. SEE FIGURE 66, 67, 68.

Figure 66

NOTE: The special bolts required for use with the relief or shuttle valve (24) end cover assembly (2) are longer than the bolts required with standard and cover assembly.

Refer to the individual service parts lists or parts list charts for correct service part number if replacement is required.

NOTE

Figure 67

Figure 68

Torque the valve plugs .'\:.

24.

Torque the two shuttle valve plug assemblies (21) in end cover assembly to 9-12 ft. Ibs. (1216 N m) if cover is so equipped. SEE FIGURE 69.

Torque the two relief valve plug assemblies (21) in end cover assembly to 45-55 ft. Ibs. (6175 N m) if cover is so equipped.

Figure 69

Housing

Figure 69A

Large Frame

Housing

Figure 69AB

Small Frame

THE ASSEMBLY OF THE TORQMOTORTM IS NOW COMPLETE EXCEPT FOR WOODRUFF KEY (12A), NUT (12B), WASHER (12C), BOLT (120), LOCKWASHER (12E), RETAINER RING (12F) or PORT O-RINGS (18A) AT INSTALLATION IF APPLICABLE. PROCEED TO FINAL CHECKS SECTION. 34

Rotor Set Component Assembly Procedure One Piece Stator Construction A disassembled rotor (8A) stator (8B) and vanes (8C) that cannot be readily assembled by hand can be assembled by the following procedures.

I

~ '"

Assemble stator

1.

Place stator (8B) onto wear plate (9) with seal ring (4) side down, after following Torqmotor™ assembly procedures 1 through 13. Be sure the seal ring is in place. SEE FIGURE 70.

Insert two bolts

2.

If assembly alignment studs are not being utilized, align stator bolt holes with wear plate and housing bolt holes and turn two bolts (1) finger .tight into bolt holes approximately 180 degrees apart to retain stator and wear plate stationary.

Assemble rotor

3.

Assemble vanes

Assemble the rotor (8A), counterbore down if applicable, into stator (8B), and onto wear plate (9) with rotor splines into mesh with drive link (10) splines. SEE FIGURE 71.

NOTE: If the manifold side of the rotor was etched during Torqmotor disassembly. this side should be up. If the rotor is not etched and does not have a counterbore, use the drive link spline contact pattern apparent on the rotor splines to determine the rotor side that must be against the wear plate.

NOTE

4.

Figure 70

Figure 71

Assemble..six vanes (8C), or as many vanes that will readily assemble into the stator vane pockets. SEE FIGURE 72.

CAUTION: Excessive force used to push the rotor vanes into place could shear off the coating applied to the stator vane pockets.

CAUTION

Assemble full complement of vanes

5.

Grasp the output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes (8C) into stator (8B), creating the necessary clearance to assemble the seventh or full complement of seven vanes.

Assemble the seven vanes using minimum force. SEE FIGURE 73.

Remove two assembled bolts

6.

Remove the two assembled bolts (1) if used to retain stator and wear plate.

Figure 72

---.-/

Go to Torqmotor™ assembly procedure #15, to continue Torqmotor™ assembly.

Figure 73

35

Rotor Set Component Assembly Procedure Two Piece Stator Construction

~~ .. \

.:'

A disassembled rotor set (8) that cannot be readily assembled by hand and has a two piece stator can be assembled by the following procedures.

~ ~;.

Assemble stator halfs

1.

Place stator half (8B) onto wear plate (9) with seal ring (4) side down, after following Torqmotor™ assembly procedures 1 through 13. Be sure the seal ring is in place.

Insert two alignment studs

2.

Align stator bolt holes with wear plate and housing bolts and turn two alignment studs finger tight into bolt holes approximately 180 degrees apart to retain stator half and wear plate stationary.

Assemble rotor

3.

Assemble rotor (8A), counterbore down if applicable, into stator half (8B), and onto wear plate (9) with rotor splines into mesh with drive link (10) splines.

NOTE

()

Assemble vanes

NOTE: Use any marking you applied to rotor set components to reassemble the components in their original relationship to ensure ultimate wear life and performance.

4.

CAUTION

Assemble six vanes (8C), or as many vanes that will readily assemble into the stator vane pockets.

CAUTION: Excessive force used to push the rotor vanes into place could shear off the coating applied to the stator vane pockets.

Assemble full complement of vanes

5.

Grasp the output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes (8C) into stator half (8B), creating the necessary clearance to assemble the seventh or full complement of seven vanes. Assemble the seven vanes using minimum force.

Assemble seal ring in stator half

6.

Place second stator half (80) on a flat surface with seal ring groove up. Apply a small amount of grease to a new seal ring (4) and assemble it into stator half ring groove.

36

Assemble second stator half

7.

Assemble the second stator half (BD) over the two alignment studs and rotor (BA) with seal ring side down onto the first stator half (BB) aligning any timing marks applied for this purpose.

~

I

'""

.. ..!~,-~ ;

CAUTION: If the stator half (8B) is a different height (thickness) than stator half (80) the stator vanes (8C) or (8E) of the same length (height) as the stator half must be reassembled in their respective stator half for the rotor set to function properly.

CAUTION

Assemble vanes

B.

Assemble six vanes (BE), or as many vanes that will readily assemble into the stator vane pockets.

Assemble full complement of vanes

9.

Grasp the output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes (8E) into stator (80), creating the necessary clearance to assemble the seventh or full complement of seven vanes.

Assemble the seven vanes using minimum force.

Go to Torqmotor™ assembly procedure #15, to continue Torqmotor™ assembly.

37

,'"

'.~",

Final Checks

Final Checks •

Pressurize the Torqmotor™ with 100 p.s.i. dry air or nitrogen and submerge in solvent to check for external leaks.

•

Check Torqmotor™ for rotation. Torque required to rotate coupling shaft should not be more than 50 ft. Ibs. (68 N m)

•

On MG & MF Series Torqmotors, pressure port with "A" cast under it on housing (18) is for clockwise coupling shaft rotation as viewed from the output end of coupling shaft.

Pressure port with "8" cast under it is for counter clockwise coupling shaft rotation.

•

On M8, ME, & MJ Series Torqmotors, pressure port with "8" cast under it on housing (18) is for clockwise coupling shaft rotation as viewed from the output end of coupling shaft.

Pressure port with "A" case under it is for counter clockwise coupling shaft rotation.

•

Use test stand if available, to check operation of the Torqmotor™.

Hydraulic Fluid Keep the hydraulic system filled with one of the following: •

10W40 SE or SF manufacturers suggested oil.

•

Hydraulic fluid as recommended by equipment manufacturer, but the viscosity should not drop below 50 SSU or contain less than .125% zinc anti-wear additives.

CAUTION: Do not mix oil types. Any mixture, or an unapproved oil. could deteriorate the seals. Maintain the proper fluid level in the reservoir. When changing fluid. completely drain old oil from the system. It is suggested also that you flush the system with clean oil.

Filtration Recommended filtration 20-50 micron.

Oil Temperature Maximum operating temperature 200°F (93.3° C).

),

,.1

38

Tips for Main~aining the Torqmotor™ Hydraulic System

• •

Adjust fluid level in reservoir as necessary.

•

Encourage all operators to report any malfunction or accident that may have damaged the hydraulic system or component

•

Do not attempt to weld any broken Torqmotor™ component Replace the component with original equipment only.

•

Do not cold straighten, hot straighten, or bend any Torqmotor™ part.

•

Prevent dirt or other foreign matter from entering the hydraulic system. Clean the area around and the filler caps before checking oil level.

•

Investigate and correct any external leak in the hydraulic system, no matter how minor the leak.

•

Comply with manufacturer's specifications for cleaning or replacing the filter.

CAUTION: Do not weld, braze, solder or any way alter any Torqmotor™ component.

CAUTION: Maximum operating pressure must not exceed recommended Torqmotor™ pressure capacity.

CAUTION: Always carefully inspect any system component that may have been struck or damaged during operation or in an accident. Replace any component that is damaged or that is questionable.

CAUTION: Do not force any coupling onto the Torqmotor™ coupling shaft as this could damage the unit internally.

Ross extends close technical cooperation and assistance. If problems occur which you cannot solve, please contact your local Ross approved Distributor or Ross Technical Support. Our phone number and fax number and address are on the back cover of this manual.

39

Application Data MG Series

() ~;-;.i/

MG MG

T0!:!lmotor Series Displacement

(in'/rev) (cm'/rev)

English Metric

Pressure

Con~nuous (differen~al) 1,3

(PSI) (kg/em')

Intermittent (differential) 1,3,4

TOl1lue (In-Lbs) (kg-m)

At continuous rated pressure and flow At intermittent rated pressures and continuous rated flow Minimum starting at continuous rated pressure Minimum starting at intermittent rated pressure

Row

Continuous

(GPM) (liters/min) Speed (!I!m)

,. . .

~

'.J

Maximum At con~nuous rated flow & eressure At maximum flow and no load'

02 2.5 41 1500 105.5 2300 161.7 424 4.88 707 8.15 180 2.07 337 3.88 9 34 9 34 712 794

03 3.0 49 1500 105.5 2300 161.7 526

6.06 879 10.13 365 4.21 642 7.40 9 34 9 34 637 681

04 4.0 66 1500 105.5 2200 154.7 711 8.19 1106 12.74 378 4.36 689 7.94 9 34 9 34 497 517

10 10.0 164 1500 105.5

05

06

08

5.0 82 1500 105.5 2200 154.7 914 10.53 1387 15.96 518 5.97

6.0 98 1500 105.5 2000 140.6 1083 12.48 1501 17.29 708 8.16 1062 12.24 12 45 12 45

8.0 131 1500 105.5 2000 140.6 1488 17.14 2044 23.55 1131 13.03 1586 18.27 12 45 15 57 324

140.6 1837 21.16 2515 28.98 1414 16.29 2058 23.71 12 45 15 57 263

430

342

883

10.17 9 34 9 34 375 406

430 454

2000

12 12.0 197 1500 105.5 2000 140.6 2175 25.06 3028

34.89 1755 20.22 2418 27.86 12 45 15 57 219 284

14 14.0 229 1500 105.5 2000

140.6 2549

29.37 3495 40.27 2017 23.24 2741 31.58 12 45 15 57 189 248

16 16.0 262 1200 84.4 1500 105.5 2180 25.12 2924 33.69 1692 19.49 2294 26.43 12 45 15 57 164 212

18 18.0 295 1100 77.3 1400 96.5 2233 25.73 2993 34.48 1770 20.39 2364 27.24 12 45 15 57 149 191

20 20.0 328 1000 70.3 1400 96.5 2133 24.57 3411 39.30 1655 19.07 2676 30.83 12 45 15 57 132 169

Notes: 1. The maximum pressure at the motor inlet or outlet ports without regard to the continuous or intermittent pressure ratings is 2300 PSI (161.7 kg/cm 2), 2. For applications with rpm requirements in excess of the maximum rating contact your authorized Ross Gear representative.

3. Differential pressure is the difference between inlet and outlet port pressures.

4. Intermittent pressure applies to a maximum of 10% of every minute.

S. Operating Temperature: Recommended - 20°F to 200°F. 6. Filtration: Recommended nominal filtration is 20 to 50 micrometers.

7. Recommended fluid: 10W40 SE or SF API designation; 50 SUS minimum at maximum operating temperature; and .125% zinc antiwear by weight.

40

•

41

•

MG, MF, MB, ME, MJ Series Service Procedure

Ross Operation Snapps Ferry Road P.O. Box 1790 Greeneville, TN 37744 USA Phone: (615) 639-8151 FAX: (615) 787-2418

{

'~ MG. MF. MB. ME. MJ B&B 2500 3/95

42

DC) --

~ €K\~\ ~

CUSTOMIZED SPECIAL OPTIONS

O<':JL.»I\

~~~<;. D~~ \

TO:

Ginger Sims - Parts Dept.

Rhonda Cunningham - Sales Dept.

FROM:

Nancy Castiglione - Publications -

DATE:

November , 1995

NOTE:

(:)ct %:-.'0~t~,

U

0

mCA8\.. \" c:::~

CUSTOMER:

Northridge Equipment

SALES ORDER:

3944,3945,3946,3947, 3948,3949,3950,3991, 3993

MANUAL NUMBER:

A630-3887G (92328)

MODEL #:

3887G/4887G

UNIT SHIPPED:

Various S.O. # 3946/0ctober,1995

WISCONSIN ENGINES WERE USED ON THESE UNITS FOR THE NORTHRIDGE ACCOUNT. A SUPPLEMENT PARTS MANUAL WAS CREATED FOR THIS SITUATION TO BE PLACED IN THE CUSTOM OPTION SECTION. IN THE FUTURE IF A WISCONSIN ENGINE IS USED, THE BILL OF MATERIAL WILL CALL OUT THIS SUPPLEMENT PARTS MANUAL, (PART NUMBER 92328..010).

FOR ALL THE UNITS MENTIONED ABOVE, GREG YOUNG DOES HAVE A COpy FOR EACH ONE TO BE PLACED IN THEIR MANUALS.

SELF-PROPELLED ELEVATING WORK PLATFORM

MODELS 38/4887 SUPPLEMENT PARTS MANUAL

3887G

4887G

SHIPPING ADDRESS

MAILING ADDRESS

CALAVAR CORPORATION 8300 IMPERIAL DRIVE WACO, TEXAS· 76712 (817) 666-4545

CALAVAR CORPORATION P. O. Box 21447 WACO, TEXAS 76702-1447 (817) 666-4545

MANUAL 92328-010 NOVEMBER 199&

Ground Control Panel Assembly

17 ENGINE START ~--18

/

ENGINE CHOKE

SERIES PARALLEL ________ ~-----

LOW SPEED

CREEP SPEED ~-20

DUMP VALVE

13

11

12

10

21 OPTION

6

Ground Control Panel Assembly ITEM 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

PART NUMBER

DESCRIPTION

QTY

310-00207-00 .......... Decal, Operation Sheet.. .................................................. 1 310-00206-00 .......... Decal, Lower Control Panel .............................................. 1 245-00004-00 .......... Retainer, Stainless Steel ........................

1 245-00006-00 .......... Pin, Lanyard ................................................................... 1 245-00007-00 .......... Covert, Snap Plate .......................................................... 1 392-00016-00 .......... Switch, 3-Position Ignition ............................................... 1 392-00021-00 .......... Switch, Push Button ....................................................... 1 220-00030-00 .......... Breaker, Ciruit ................................................................ 1 50075 ...................... Switch (Lift) ................................................................... 1 392-00017-00 .......... Switch, Selector ............................................................. 1 275-00002-00 .......... Knob, Emergency Stop .................................................... 1 392-00009-00 .......... Switch, Emergency On-Off .............................................. 1 370-00002-00 .......... Inlet, Flanged .................................................................. 1 010-G9033-00 .......... Weldment, Lower Control Panel ........................................ 1 80049 ...................... Base, Relay .................................................................... 7 374-00002-00 .......... Relay~ 12V .................................................................... 7 390-00007-00 .......... Spring, Relay Hold Down ................................................. 7 123-00169-00 .......... Screw, Machine ........................................................... 14 80029 ...................... Block, Terminal ............................................................ 27 80042 ...................... Section, Terminal End ..................................................... 1 123-0021 0-00 .......... Screw, Round. Head ........................................................ 2 151-00017-00 .......... Ring, Terminal .............................................................. 47 206-00001-00 .......... Diode ............................................................................ 9 150-00022-00 .......... Wire, Black 101.5 LF ...................................................... 1 150-00023-00 .......... Wire, Green 21 LF .......................................................... 1 150-00025-00 .......... Wire, 2-#18 Cable ........................................................ 38 150-00029-00 .......... Wire, 4-# 18 Cable ........................................................ 39

- Indicates Items Not Shown

i .........................

Wisconsin Engme · And Pump Installation

Wisconsin Engine And Pump Installation

ITEM 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

PART NUMBER

DESCRIPTION

QTV

02663 ...................... Elbow, 90° Out .............................................................. 1 00268 ...................... Elbow, 90° In ................................................................ 1 355-00014-00 .......... Assembly, Hydraulic Pump ............................................... 1 BOW36055 .............. Bolt, Hex """'"'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' 2 BOW36727 ............ ,. Washer, Split lock .......................................................... 2 BOW36767 ...... " ...... Washer, Flat .................................................................. 2 212-G9120-00 .......... Housing, Bell .................................................................. 1 BOW36081 .............. Bolt, Hex ....................................................................... 2 BOW36083 .............. Bolt, Hex ....................................................................... 2 BOW36728 .............. Washer, Split lock .......................................................... 4 BOW36768 .-............. Washer, Flat .................................................................. 4 020-G90 10-00 .......... Assembly, Engine-Pump Coupler ....................................... 1 160-00003-00 .......... -Coupler, Key ................................................................. 1 160-00004-00 .... ,..... -Spider, Bronze Coupler................................................... 1 160-00002-00 .......... -Coupler, Key ................................................................. 1 ClJ00901-003 .......... Key, Shaft ..................................................................... 1 150-00022-00 .......... Assembly, Black Wire 2lF ................................................ 1 151-00017-00 .......... Terminal Ring ................................................................. 7 32146 ...................... Assembly, 30HP Engine ................................................... 1 286-00007-00 .......... Hose, Fuel Line 6lF ........................................................ 1 BOW24108 .............. Clamp, Hose .................................................................. 1 58294 ...................... Weldment, Solenoid Mounting Bracket .............................. 1 32111 ...................... Solenoid, Mechanical 12VDC ........................................... 1 40808 ...................... Solenoid 12VDC ............................................................. 1 BOW36002 .............. Bolt, Hex ....................................................................... 2 BOW36004 .............. Bolt, Hex ....................................................................... 3 BOW36304 .............. Bolt, Hex ....................................................................... 1 BOW36725 .............. Washer, Split lock .......................................................... 5 BOW36701 .............. Washer, Flat ................................................................ 10 BOW34272 .............. Nut, Hex lock ................................................................ 5 BOW32281 .............. Nut, Hex Jam ................................................................. 2 BOW2023 ................ Clevis, Steel ................................................................... 3 BOW2120 ................ Pin, Clevis ........................................ , ............................ 2 BOW38209 .............. Pin, Cotter ..................................................................... 2 35184 ...................... Wire, Choke ................................................................... 1 BOW3665 ................ Clip, Carburetor Rod ....................................................... 1 21607 ...................... Rod, Throttle Wire .......................................................... 1 34704 ...................... Rod, Throttle Stop .......................................................... 1 BOW34282 .............. Nut, Hex lock ................................................................ 2

- Indicates Items Not Shown

Wisconsin Engine-Pump Assembly

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

PART NUMBER

DESCRIPTION

QTY

018-00110-00 .......... Cover, Back ................................................................... 1 018-00053-00 .......... Kit, Seal ........................................................................ 1 ............................... -O-Ring .......................................................................... 2 ............................... -Plate, Thrust ................................................................. 1 ............................... -Plate, Wear ................................................................... 1 ............................... -Shield, Heat .................................................................. 1 ............................... -Gasket ......................................................................... 1 ............................... -V-Seal .......................................................................... 1 ............................... -Seal, Shift .................................................................... 1 018-00114-00 .......... Gear, Drive .................................................................... 1 018-00113-00 .......... Gear, Drive .................................................................... 1 018-00112-00 .......... Section, Center .............................................................. 1 ............................... Pin, Dowel ..................................................................... 2 018-00111-00 .......... Cover, Front .................................................................. 1 ............................... Washer, Split Lock .......................................................... 8 ............................... Screw, Cap .................................................................... 6 ............................... Screw, Hex .................................................................... 2

- Indicates Items Not Shown

Gasoline Engine Assembly

®

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

PART NUMBER

DESCRIPTION

QTY

VH001003 ............... Element, Oil Filter ...........................................................

VH001355 ............... Gasket, Oil Filter .............................................................

VH001022 ............... Tube, Oil Filter ...............................................................

VH001531 ...........•... Kit, Fuel Pump .................................................... ~ ...........

BOW10985 .............. Elbow, 90 0 •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• VH001018 ............... Bowl, Fuel .....................................................................

VH001002 ............... Rod, Governor Control .....................................................

VH001021 ............... Spring, Governor ............................................................ ............................... Muffler ..........................................................................

VH001010 ............... Assembly, Air Cleaner .....................................................

VH001015 ............... Bracket, Air Cleaner Mounting ..........................................

35190 ...................... Strap, Adjusting .............................................................

35191 ...................... Weldment, Alternator Mounting Bracket ............................

40170 ...................... Cover, Alternator Pulley ...................................................

32218 ...................... Alternator .......................................................................

32573 ...................... V-Belt, External Alternator Drive .......................................

- Indicates Items Not Shown

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

NOTES: LIFT CYLINDERS FIRST STAGE 5 DIA X 20.56 STROKE SECOND STAGE 3.75 DIA X 21.69 STROKE 162-96448-00 2 PL

STEERING CYLINDER 2.0 DIA BORE .75 DIA ROD 10.0 STROKE 54548

1. WISCONSIN ENGINE 30HP@2,400 RPM PUMP 355-00014-00 .91CIPR 2. KAWASAKI ENGINE 20HP@3,600 RPM PUMP 54604-003 .61CIPR 3. FOR BATTERY POWERED CONDORS, SEE SCHEMATIC BELOW. 4. REPLACE CROSS-RELIEF VALVES 51616, 2 PL, WITH PLUGS, PARKER PlO-2, OR SET AT 3000 PSI. 5. THE DRIVE SPOOL IS PARKER 697605.

6. HYD HOSE DIA IS IDENTIFIED BY IMPERIAL-EASTMAN PART NUMBER.

go '--':+---':3 :3 CHECK VALVES 450-00062-00

N

;;;

*

:>

5703

CHECK VALVE 50068

$703 $703

BRAKE 58079

FILTER 250-00012-00 ;;;

:>

PUMP FILTER 33430 WACO, TEXAS HYDRAULIC TANK 23.27 GALLONS

MDA3887 HYDRAULIC jCL~1R::..f.'E~.C.::N...:N::::O.+-.:::D':::1E=---f"':..:PP-"R+==::-_ _. c.A",.H,--IT__1l=ET",--12~J/1 114 4935 LTR.

E.R.N. NO.

10 05 94 DATE

RAK APPR.

OiECKED APPROVED

RAK

B

10/05/9 SCALE

ORAMNG NO

FULL

54806 SHEET

REV

B I OF 2

LIFT CYLINDERS FIRST STAGE 5 DIA X 20.56 STROKE SECOND STAGE 3.75 DIA X 21.69 STROKE 162-96448-00 2 PL

STEERING CYLINDER 2.0 DIA BORE .75 DIA ROD 10.0 STROKE 54548

BRAKES-4 PL 126-10007-00 MOTORS-4 PL 321-00011-00

M3 I

SIP

--=-=1'--' FRONT

'.120

F01

'.106

F02

M4

SIP

I

L-_ffi-_ _ _ _ _ I!.E~

315-00027-00

2 PL

_TJf'-_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ MANIFOLD 315-00025-00 .

FREE WHEEL 52661

CHECK VALVE 50068 FILTER 250-00012-00

BRAKE 58079 NOTE: SEE SHEET 1 FOR HOSE PART NUMBERS.

8ALL VALVE 450-00052-00 HYDRAULIC TANK 23.27 GALLONS

FILTER 33430

1--1---1----1--

PROPRIETARY INFOR ..... TION

JIIS _ _ nSIJ[-..«r-.--.IIIDIMClSMO

== ....

~

WACO

TEXAS

b-~--4-_-+--~~~~:c~:::~~~==~-----------'-------nTL£

_•.

1--1-_ _+-__1--1 l TR.

[.C.N. NO.

OA T£

4935 LTR.

[.R.N. NO

~f.W. . . . . . . . . . 1U.1ICHIS

UNL£SS OTHER..Sf: SPECIFlEO: IlIWEHSIONS AII[ ... INCH(S TOLERANCES ON; MCl( 1If:0IUU 1'IIIoC\IOH.Oi.

"'IZ'

x::::::r.

SCHEMATIC, MDA3887 HYDRAULIC (4WD- SEE SHEET 1 FOR 2WD)

*1/11

DRAWING NO.

A.HITTlE

DAft

APPR.

AfPRO\I'ED

RAK 10/0$/""

REv

B

54806

RAK OtECKED seAL[

I: I

SH<ET

2 OF 2

...J

W

"-

5.)-------------------------1

22/23

~

'8 o...........:.o-_'_8A:......_ _ _1r<>_ _-1'

,FAST

~2_0_ _~_

sPEED

'9

CREEP

5B 5B

20

~~6

28A

CRI

60B

.-JL

KEY

BRAKE VALVE D53· VALVE -DUMP

-t-±++

"

EMERGENCY

:+:"'5:.:B=-----I......,~ STOP

,

12VOC BA TTERY

r~B

CB

STARTER MOTOR

I I I

START LOCKOUT RELAY

I I

5

I I

I

"

:

31

IGNI nON RELA Y

58

VACUUM

SO

I I I I

~

HOUR METER OPTON BEACON/STROBE OPTION

I

I I ~ ... 8

~~

:r,

FOOT

25

START CHOKE

"

24A :

24

"

PLATFORM

..s:.

21Al..s:.

-

-

·OSl" VALVE -UFT UP "OS2" VALVE -LOYo£R

~.

HOLDINC VA1.VES

VALVES ON

un

C'(LS

25 63

c,.

28

DUMP RELAY

'C:;7

64

'4

28

I 13 -'"'

DRIVE

U,,1T SW1TCH SHOWN W1TH PLA TFORM BELOW 25 FEET

~

28

,. , ' , ' ,

I

13 :

1

:

L"~-.J

~____________~2:9;~

L-__+-____________~2~9~~ 17/BLANK

CHOKE RELAY

-; f- OVERLOAD SY,HCH

l64

PLATF'ORM

55/62

:3: -

24 START

THROTTLE RELAY

1

6'

CHOKE

THROTTLE SOLEN010

CHOKE SOLENOID

:

r ,9.

MonON ALARM OPTION

I

R'~~----------~

SA

63 7B

17/BLANK

17/BLANK

:

~----~+--------------+{Rl~L-----------4

21A

1t7/BLANK

8:

THROTTLE

7

2I~

~ ~~

SA

..s:. l..s:.

7A

I I I I -L

GASOLINE VALVE DUAL FUEL OPTION LP VALVE C01L

31

I

7

IGNITION COIL

:

R '"

I

ALTERNATOR

,'i,

SA

~1~----~7----~2~1~~~.4_2____~~~+_~~......, IGNITION 42

17 /BLANK

VALVES PUT TWO SIP MANIFOLDS IN SERIES

20A

SA

I

EMERGENCY ["--" STOP

SIP VALVES RELAY

LIMIT SWITCH SHOWN WITH PLATFORM ABOVE 11'-6·

~~8

5B

OS5' VALVE -CREEP

'9J

HI 60 "Y 60A -@-----1 G,-,,.-,-__ ----- " G-----~CR1

O

LOWER 7 ""

054- VALVE PUTS DCV4 VALVE IN SERIES

~LO" RANGE

UPPER

"'

'9 20

22/23

SLOPE ALARM OPTION

LIM! T SWI TCH SHOWN WI TH PL TFRM ABOVE 7'-6"

<Xl <Xl

'6,", , STEERING

15 :

:

-'-26.27.31 " 65 ARE 1S0LATEO SPARES

FORWARD "DR1VE" VALVE REVERSE

TRAVEL ALAR" OPTION BRAKE/SPEED RELAY RIGHT "OCVI" VALVE -STEER LEFT

ilil! II ~

~lflll!!O 11:.111 . 1'1 ~ ".51..'I, . 'II I" i« "111'1 1 .. 11 i• !ili!! i

HI

INSTRUCTIONS

• • •

FOR:

38/4887 WITH:

WISCONSIN ENGINE = MDL3887 AND MDL4887.

EL GENERATOR OPTION = A411-38/4887 DUAL FUEL OPTION = A505-4887/38

DRILL AND TAP MNTNG HOLES PER SKETCH (ON THIS DWG)

r--

4.50~

231/4

1/4-20UNC-2B THRU 4 PL

/

()

V

C

CJ)

I I I

20.00

-i

PLAN VIEW OF RH BELLYPAN

o

s: N

m

I

o

0-0-pi-- 0 -0 - 0

CJ)

"'0

m

-+--+-

t

()

» r

3/4

o

"'0

6

55271-DWG

5

010-G9082-00

4

55238

3

020- G9035- 00

2

51307

1 ITEM

EA

CUST SPCL, 38/4887 WISC

-1.00

EA

1.00

EA

RIGHT SIDE COVER WLDMNT **87 COVER WLDMNT, 38/4887G RH

-1.00

EA

ASSY, FUEL TANK

1.00

EA

BRACKET SET, FUEL TANK MTG

51306

1.00

EA

TANK, FUEL, 12 GAL

PART NUMBER

QTY

UM

DESCRIPTION

PROPRIETARY INFORMATION THIS DRAWING ITS DESIGN, DETAIL, DIMENSIONS, TOLERANCES AN{) DISClOSURE ARE ntE C(mO(DAI. INFCRM,\TION AND [xa.uSlYE PROPERTY

CALAVAR CORPORATION, AND StW.i MOT BE tRACED, R£PROOucro OR W't€D IN ANY t.lANNER NCR OISClOSID TO ANY OOTSIDE: PARTY ""lHOOT THE PRIOR lIIRIffiN CCNSENr CF CALAVAR CORPl.mll(W. All RIGHTS

(X

R(SER\om

(§g~

LTR.

LTR.

E.C.N. NO.

5667 E.R.N. NO.

DATE

09/22/95 DATE

APPR.

RAK APPR.

DRAWN

ANGI..E

DECIMALS

:I:: 1/2'

XX= :I::.OJ XXX-±.010

FRACTIONAl ±1/16

A.HITTLE 09/18/95

CHECKEO

BFC 09/20/95

APPROVED

RAK 09/22/95

o Z

WACO, TEXAS

TITLE

CUST SPCL,

UNLESS OTHERW'lSE SPECIFIED: DIMENSIONS ARE IN INCHES

TOLERANCES ON:

-i

1.00

AI

DRAWING NO.

SCALE

NONE

38/4887G

I

REV.

55271 ISHEET

WISC

1 OF 1