CONDOR 38AG 47AG & 47AE Articulating Operator's Manual - PDF DOWNLOAD

BOOM-SUPPORTED ELEVATING WORK PLATFORM

MODEL 38AG ARTICULATING

OPERATION, PARTS & MAINTENANCE MANUAL

THIS MANUAL APPLIES ONLY TO CONDOR® MODEL 38AG GASOLINE AND DIESEL ENGINES BEGINNING WITH SERIAL NUMBER 1563

CALAVAR CORPORATION 8300 IMPERIAL DRIVE WACO, TEXAS 76712 (817) 666-4545 MANUAL 92323 SEPTEMBER 1994

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

It is YOUR RESPONIBILITY to follow safe procedures while operating the CONDOR®.

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

It is also YOUR RESPONSIBILITY to understand and obey all federal, ai id local regulations regarding the safe operation and use of aerial work platforms. A copy of the ANSI/SIA 92.5-1992 Manual of Responsibilities is attached for your use Calavar Corporation reserves the right to modify, improve, add, and/or delete certain design features of its products without any obligation to incorporate new features into products previously sold. Our manuals are continually updated to reflect these changes.

•

•.•

DO NOT ALTER OR MODIFY THIS UNIT WITHOUT PRIOR WRITTEN APPROVAL FROM THE MANAGEMENT OF CALA VAR CORPOR4770N 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 fieoduct. Repairs and adjustments should only be made by trained and qualified personne:. 'lease 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, Maritenance, & Parts Manual for information pertaining to your machine.

MANUAL 92323 SEPTEMBER 1994

LAWAR CALAVAR CORPORATION

Condor® Self-Propelled Aerial Work Platforms 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 five (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 one (1) year after the aerial work platform is placed in service or two (2) years after the original shipment of the aerial work platform from Calavar's plant, whichever comes 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 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 damage or loss even if Calavar, its suppliers, or its representatives have been advised of the possibility of such damages.

Parts cla,tos 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 lit 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 the 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 parchas;ar by Calavar's suppliers.

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

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

817-666-4545, FAX 817-666-4544 Printed in

MANUAL 92323 SEPTEMBER 1994

CALAVAR CORPORATION

BOOM-SUPPORTED ELEVATING WORK PLATFORM

MODELS 38AG, 47AG, AND 47AE ARTICULATING

OPERATOR'S MANUAL

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

MANUAL 92265-001 SEPTEMBER 1994

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 UNIT AT ALL TIMES.

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

It is YOUR RESPONIBILITY to follow safe procedures while operating the CONDOR®.

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

It is also YOUR RESPONSIBILITY to understand and obey all federal, state, and local regulations regarding the safe operation and use of aerial work platforms. A copy of the ANSI/SIA 92.5-1992 Manual of Responsibilities is attached for your use.

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

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

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 machine.

MANUAL 92265-001 SEPTEMBER 1994

TABLE OF CONTENTS

INTRODUCTION

ii

TABLE OF CONTENTS I. PREPARATION, INSPECTION, AND MAINTENANCE A. B. C. D. E. F.

Overall Machine Condition Lower Control Station Platform and Upper Control Station Hydraulic System Multi-Axis Slope Sensor Batteries/Charger

1 1 2 2 2 2 2

II. MACHINE OPERATION A. B. C. D. E. F.

1

Rated Work Load Upper Controls, Gas & Diesel Power Lower Controls, Gas & Diesel Power Upper Controls, Electric Power Lower Controls, Electric Power Travel

2 3 3 5 5 7

III. OPTIONAL EQUIPMENT

7

IV. AUXILIARY LOWERING

7

V. MOVING FROM JOB SITE TO JOB SITE

8

A. TOWING B. TRANSPORTING

8 8

VI. EMERGENCY STOPPING

8

APPENDIX: DECALS ILLUSTRATION

9

INSPECTION REPORT

ANSI/SIA 92.5-1992 MANUAL OF RESPONSIBILITIES

MANUAL 92265-001 SEPTEMBER 1994

IMPORTANT: A COPY OF THE ANSI/SIA 92.5-1992 MANUAL OF RESPONSIBILITIES IS ATTACHED TO THIS OPERATOR'S MANUAL. IT CONTAINS IMPORTANT OPERATING INFORMATION FOR THIS MACHINE. READ BEFORE OPERATING THIS MACHINE. I. PREPARATION, INSPECTION, AND MAINTENANCE

STEERING:

El

The condition of this unit is very impor- tant, as it directly affects the operator's safety as well as the safety of others.

The operator must perform a thorough walk-around inspection each day prior to operating the machine. 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®.

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

SWING BEARING: Check that all mounting bolts are securely in place.

DECALS:

Check that all decals and warning KNOW THE UNIT AND ITS CAPABILITIES. signs are in place and are clearly legible.

REPORT ANY UNUSUAL OPERATION, SUCH AS ERRATIC SWAY OR MOTION OF THE BOOM, ARM, OR PLATFORM. CAUTION: Defective components, structural damage, missing Some major areas to check daily are: parts, and equipment malfunction jeopardize the A. OVERALL MACHINE CONDITION safety of the operator and other personnel and may TIRES AND WHEELS: cause excessive damage to the unit. A poorly mainCheck for proper tire pressure, tained machine could becracks, tears, cuts, or missing or come the greatest operaloose lug nuts (a rust line running tional hazard you may down the rim from the lug nut encounter. indicates a loose lug nut).

MISSING, BROKEN, OR DAMAGED B. LOWER CONTROL STATION PARTS: Check electrical installations for loose, broken, or frayed wires and Check cylinder mounting pins, cables. pivot pins, retainers/fasteners, bearing pads, bolts, and nuts.

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

STRUCTURAL: Check for damaged or cracked welds on structural components-boom, arm, platform, skirt, chassis, and turret.

1

MANUAL 92265-001 SEPTEMBER 1994

C. PLATFORM AND UPPER CONTROL STATION

The slope sensor is located adjacent to the lower controls (see illustration).

Check electrical installations for loose, broken, or frayed wires and cables. Re-check the structural condition of the platform, pivot points, pins, railings, and floor.

Check to see that slide bar is in place and moves freely at access opening. See that footswitch operates properly, and that guard is secured and in its proper place on the platform floor.

LII El

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

Ei

Check the general condition of the slope sensor, inspect for loose or damaged wires, and ensure that mounting is secure and that housing is not cracked or broken.

F. BATTERIES/CHARGER

LI LI

Check electrolyte level and ensure that all caps are present and installed properly. Cable connections should be tight and clean.

(Electric models) Ensure that charger is operating properly, and inspect charger, plug, and meter for damage.

Check the operation of the auxiliary lowering pump.

G. MOTORS/ENGINE

D. HYDRAULIC SYSTEM El Check the hydraulic tank fluid level with the arms lowered and the boom lowered and retracted.

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

LI LI

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

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

E. MULTI -AXIS SLOPE SENSOR The CONDOR® is equipped with a slope sensor to warn the operator of an out-oflevel operating condition.

LI

Check to see that power units are operating properly. Inspect for loose cables or fasteners.

(Gas/diesel models) Check all fluid LI levels—oil, fuel, and coolant.

Inspect air cleaner and muffler operation and mounting, and perform routine maintenance as recommended in engine manual.

II. MACHINE OPERATION A. RATED WORK LOAD

The CONDOR® Models 38A and 47A have an rated work load of 500 lbs. (226.8 kg), or two occupants. This means that the platform will support a 500-1b. combined weight (including personnel and their tools and equipment) throughout the working envelope of the machine.

MANUAL 92265-001 SEPTEMBER 1994

2

Models 38AG, 47AG —Gas & Diesel Power

UPPER CONTROLS

DRIVE/STEER BOOM LIFT

EMERGENCY STOP ENGINE START

TURRET ROTATE

LP/GAS (OPTION)

PLATFORM TILT

CHOKE/GLOWPLUGS BOOM EXTEND

DRIVE SPEED SELECTOR

ARM LIFT

AUX. LOWERING (OPTION)

LOWER CONTROLS

ENGINE START EMERGENCY STOP CHOKE/GLOWPLUGS AUX. LOWERING (OPTION)

ARM LIFT

THROTTLE

BOOM EXTEND

KEY SWITCH & UPPER/LOWER CONTROL STATION SELECTOR

3

TURRET ROTATE BOOM LIFT

MANUAL 92265-001 SEPTEMBER 1994

B. UPPER CONTROLS, GAS & DIESEL POWER

C. LOWER CONTROLS, GAS & DIESEL POWER

The upper control station provides for complete operation of the machine. As a safety precaution, the footswitch mounted on the platform floor must be depressed and held during all functions.

The upper control console is equipped with a red EMERGENCY STOP switch that will cease all movement and (on gas and diesel models) stop the engine.

The lower control station is located on the turret of the machine. The DRIVE/STEER functions are not operable from the lower controls; all other functions may be operated from the lower control station.

On engine-powered units, the upper control console will contain an engine START switch and either a CHOKE (gas engines) or GLOWPLUGS switch (diesel engines). If the CONDOR® is equipped with an optional dual fuel system, the console will also contain an LP/GAS switch for selecting the mode of fuel consumption.

The upper control console also contains a drive speed selector switch, which allows the operator to select either FAST or SLOW speed, and a DRIVE/STEER controller. The steering control is a spring-loaded, return-to-center rocker switch located on top of the drive control handle. With the coun-

terweight over the steer wheels, the steering control moves the unit in the direction in which the rocker switch is actuated.

Directly in front of the control console are five (5) handles that control the following functions: ARM LIFT, BOOM EXTEND,

PLATFORM TILT, TURRET ROTATION, and BOOM LIFT. The aerial functions correspond directly to the movement of the control levers in the directions indicated on the control valve decal.

When set properly, the platform on Models 38A and 47A will remain level throughout the operational envelope of the machine.

The CONDOR® is also equipped with a hand-operated rotating platform. To rotate the platform, turn the handle located on the right side of the skirt, just below the control station.

The main key switch is located on the lower control console. With the key in the center (OFF) position, power is disengaged. With the key in the left (LOWER) position, the lower controls are energized for operation. With the key in the right (UPPER) position, the upper controls are energized for operation.

The THROTTLE switch must be depressed continuously in order to operate the functions from the lower control station.

On engine-powered units, the control console contains an engine START switch and either a CHOKE (gas engines) or GLOWPLUGS (diesel engines) switch to assist in starting the engine.

Also located on the lower control console is the optional auxiliary lowering switch.

This switch is used to energize the auxiliary pump and motor, which may be used to lower the platform in the case of primary power failure.

Adjacent to the lower control console are four (4) handles that control the following functions: ARM LIFT, BOOM EXTEND, TURRET ROTATION, and BOOM LIFT. The lift functions correspond directly to the movement of the control levers in the directions indicated on the control valve decal.

NOTE: The CONDOR® is not equipped with continuous turret rotation. With the counterweight over the drive wheels, the turret may be rotated 179° in either direction until the stop is reached.

MANUAL 92265-001 SEPTEMBER 1994

4

Model 47AE —Electric Power

UPPER CONTROLS

DRIVE/STEER POWER ON/OFF TURRET ROTATE

BATTERY CONDITION INDICATOR

BOOM LIFT DRIVE SPEED SELECTOR BOOM EXTEND PLATFORM TILT ARM LIFT

LOWER CONTROLS

PUMP ARM LIFT KEY SWITCH & UPPER/LOWER CONTROL STATION SELECTOR

BOOM EXTEND

HOUR METER

TURRET ROTATE

BOOM LIFT

5

MANUAL 92265-001 SEPTEMBER 1994

B. UPPER CONTROLS, ELECTRIC POWER

C. LOWER CONTROLS, ELECTRIC POWER

The upper control station provides for complete operation of the machine. As a safety precaution, the footswitch mounted on the platform floor must be depressed and held during all functions.

The upper control console is equipped with a red POWER switch that will cease all movement and disengage the power unit.

The lower control station is located on the turret of the machine. The DRIVE/STEER functions are not operable from the lower controls; all other functions may be operated from the lower control station.

The upper control console contains a drive SPEED selector switch, which allows the operator to select either FAST or SLOW speed, and a DRIVE/STEER controller. The steering control is a springloaded, return-to-center rocker switch located on top of the drive control handle.

With the counterweight over the steer wheels, the steering control moves the unit in the direction in which the rocker switch is actuated.

The console also contains five (5) handles that control the following functions: ARM LIFT, BOOM EXTEND, PLATFORM TILT, TURRET ROTATION, and BOOM LIFT. The aerial functions correspond directly to the movement of the control handles; the direction of operation for each function is indicated on the upper control console decal.

When set properly, the platform on Models 38A and 47A will remain level throughout the operational envelope of the machine.

The CONDOR® is also equipped with a hand-operated rotating platform. To rotate the platform, turn the handle located on the right side of the skirt, just below the control station.

Electric models may be equipped with an optional battery condition indicator at the upper control station.

The key switch is located on the lower control console. With the key in the center (OFF) position, power is disengaged. With the key in the left (GROUND) position, the lower controls are energized for operation. With the key in the right (PLATFORM) position, the upper controls are energized for operation.

The PUMP switch must be depressed continuously in order to operate the functions from the lower control station.

Also located on the lower control console is the optional auxiliary lowering switch.

This switch is used to energize the optional auxiliary pump and motor, which may be used to lower the platform in the case of primary power failure.

The lower control console contains four (4) handles that control the following functions: ARM LIFT, BOOM EXTEND, TURRET ROTATION, and BOOM LIFT. The lift functions correspond directly to the movement of the control handles in the directions indicated on the control console.

All models are equipped with an hour meter at the lower control station.

NOTE: The CONDOR® is not equipped with continuous turret rotation. With the counterweight over the drive wheels, the turret may be rotated 179° in either direction until the stop is reached.

MANUAL 92265-001 SEPTEMBER 1994

6

D. TRAVEL Driving the machine may only be accomplished from the upper control station, with the boom in raised or lowered (stowed) position. Even thought the gradeability of the unit is 14° (25%), such a grade should only be negotiated with the boom in the fully lowered (stowed) position and in SLOW drive speed. The CONDOR® is designed to travel with the platform elevated only when on firm, level ground.

The CONDOR® is designed to be driven with the counterweight positioned over the drive wheels. In this configuration, the direction of travel corresponds directly to the direction of movement of the drive controller. Moving the controller away from the operator drives the unit forward; moving the controller toward the operator moves the unit in reverse.

The steering control is a spring-loaded return-to-center rocker switch located on top of the drive controller handle. With the counterweight over the drive wheels, the steering direction corresponds directly to the direction in which the rocker switch is activated. Pushing the rocker switch to the left turns the unit to the left, and pushing the rocker switch to the right moves the unit to the right. When the rocker switch is released and returns to center, the sterring wheels remain in the last directed line of travel and do not return to a straight line of travel; steering is not self-centering.

When the machine is driven with the counterweight in a position other than as described above, the relationship of the drive and steer functions to the movement of the controller will change. The operator should move the unit slowly until familiar with this change in movement.

Always look in the direction of travel and maintain a clear field of view, paying particular attention to overhead obstructions.

7

Avoid erratic movement of the controller by moving smoothly into and out of travel. Come to a complete stop before changing directions.

The brakes on the unit are spring-applied and hydraulically released. The brakes are automatically released when the drive controller is returned to the neutral position.

The upper control console is equipped with a maintained two-position toggle switch to select either FAST or SLOW travel speed. However, when the boom or arms are raised sufficiently to open the boom limit switch (approximately horizontal), both drive speeds are automatically reduced by one half.

III. OPTIONAL EQUIPMENT The following options are available on the CONDOR® Models 38A and 47A: • • • • • • • • • •

110-Volt Line to Platform Foam-Filled Tires Motion/Travel Warning Horn Low Voltage Warning (electric models) Strobe Light/Rotating Beacon Larger Platform Air Line to Platform Platform Work Lights Diesel Engine Dual Fuel (liquid, vapor)

IV. AUXILIARY LOWERING Provisions are made to return the operator to the ground in the event of primary power loss.

The boom and arm lift cylinders on electric units are equipped with (manual) gravity lowering cartridges on the holding valves. To lower the boom or arm manually, depress the red button and turn counter-clockwise. The lowering process may be halted at any time by depressing the red button and turning clockwise.

MANUAL 92265-001 SEPTEMBER 1994

On electric models, the turret may be rotated manually by placing the ROTATION TOOL provided (located directly below the rotation gearbox) over the hex head shaft of the rotation gearbox.

Optional on engine-powered units is an auxiliary power unit which is operated from both control stations. This option allows the lift functions to be operated in case of engine or main pump failure.

Push and hold the AUXILIARY LOWERING switch while operating the desired function.

V. MOVING FROM JOB SITE TO JOB SITE A. TOWING The brakes on the CONDOR® are automatically applied when the drive controller is returned to neutral. However, for towing purposes the drive hubs may be disengaged by removing the two (2) bolts (.25" - 20UNC x .75" long) that secure the disconnect cap, removing the disconnect cap and reinstalling with the nipple facing inward, and resecuring the cap using the two bolts.

making sure that the controls return to center smoothly when released. Move the CONDOR® slowly back and forth to ensure that the brakes apply each time the drive controller is released.

It may be necessary to elevate the boom or lift the arms to clear the ramp during loading. The unit is equipped with a slope sensor that will warn the operator of an out-of-level condition of 5° or greater.

Move the unit up or down the ramp slowly, allowing time for steering corrections to be made, and keep the unit in alignment with the ramp and carrier during loading and unloading operations.

The. CONDOR® may be transported easily and safely to and from the work site by completing the following procedures: block all wheels to prevent forward and reverse movement during transportation; tie down the CONDOR® using chains, straps, or cables of sufficient strength; set the platform on wooden pallets and tie the boom down near the skirt; turn off the power at the key switch and remove the key. [See diagram below] FACTORY RECOMMENDED • TRANSPORTATION DIAGRAM

B. TRANSPORTING The CONDOR® Model 47A weighs approximately 12,500 lbs.; Model 38A weighs approximately 11,500 lbs. The means of loading or unloading must be of sufficient strength to withstand the weight of these machines.

When using a ramp, it should be set at an angle no greater than 14° or 25% (30" rise in 10 feet).

Remember that the normal driving position of the CONDOR® is with the counterweight over the drive wheels, and that any other position will change the operation of the drive and steer functions.

Before driving the unit onto the ramp, test each of the controls and the brakes,

[Decal located on chassis—both sides]

VI. EMERGENCY STOPPING As stated previously, the EMERGENCY STOP button may be used in an emergency to stop movement from both the upper and lower control stations. However, the foot may be taken off of the footswitch to 'panic stop' any function, including drive and steer.

MANUAL 92265-001 SEPTEMBER 1994

8

APPENDIX: DECALS ILLUSTRATION [Model 47AG Shown]

21

15

19 1

7

110.MAINIJICIRI

0 0

26 35

9

MANUAL 92265-001 SEPTEMBER 1994

APPENDIX: DECALS ILLUSTRATION

ITEM PART NUMBER DESCRIPTION

47AG 47AD 47A 38AG 38AD QTY QTY QTY QTY QTY

2 2 2 N/A N/A 1 34271 Decal, 47A N/A N/A N/A 2 2 37290 Decal, 38A 2 2 2 2 2 2 50172 Decal, CONDOR® 3 35366 Decal, Gen. Op. Instructions 1 1 1 1 1 4 21882-001 Decal, Electrocution Hazard 2 2 2 2 2 5 21882-002 Decal, This Unit Not Insulated 2 2 2 2 2 6 21882-003 Decal, Danger: Qual. Operator 1 1 2 1 1 7 52759 Decal, Stand Clear/Operating 2 2 2 2 2 8 37348 Decal, Lower Valves (see NOTE 1) 1 1 1 1 1 1 1 1 1 1 9 34270 Decal, Upper Valves 1 1 2 2 2 10 21850 Decal, Hydraulic Fluid 1 1 2 1 1 11 50070 Decal, Battery Service 12 37354 Decal, Aux. Lwrg. (see NOTE 2) 1 1 N/A 1 1 67880 Decal, Emergency Lowering (47A) N/A N/A 1 N/A N/A 1 1 1 1 1 13 35042 Decal, Forward (Arrow) 1 1 1 1 1 14 35043 Decal, Forward 15 67938-100 Decal, Tire Press. 100 PSI (47AG) 4 4 N/A N/A N/A 34523 Decal, Tire Pr. 60 PSI (38AG/47A) N/A N/A 4 4 4 1 N/A N/A 1 N/A 16 21849 Decal, Gas 1 1 N/A N/A 1 15376-012 Decal, Diesel 17 21971-002 Decal, Do Not Lift Wheels w/Boom 2 2 2 2 2 18 37784 Decal, Transportation Diagram 2 2 2 2 2 19 35656 Decal, Made in U S A —6 00" 1 1 1 1 1 1 1 N/A 1 1 20 68859 Decal, Oil Dipstick Inside 1 1 1 1 1 21 81417 Decal, Rated Work Load 1 1 1 1 1 22 36885 Decal, 500 LBS 23 54416 Decal, Caution: Tie-Down Ring 3 3 3 3 3 24 37419 Decal, Panic Stop/Ramping Control 1 1 1 1 1 25 58419 Tape, Orange/Red 5.00" (linear ft.) 39 39 39 39 39 26 38176 Decal, Manual Lowering Procedure 2 2 N/A 2 2 27 32200 Decal, Warning Power Lines 1 1 1 1 1 28 37958-500 Decal, Rated Work Load 500 LBS 1 1 1 1 1 Nameplate, Booms Identification 1 1 1 1 1 29 30 38072 Decal, Lower Control Console 1 N/A N/A 1 N/A 37365 Decal, Lower Control Console N/A 1 N/A N/A 1 37024 Decal, Pump (electric models) 1 N/A 1 N/A N/A 31 37969 Decal, Key Switch—Upper/Lower 1 1 N/A 1 1 37025 Decal, Key Switch—Ground/Plat. N/A N/A 1 N/A N/A 32 38144 Decal, Upper Control Console 1 1 N/A 1 1 37080 Decal, Upper Control Console N/A N/A 1 N/A N/A 33 67812 Decal, Glowplugs (diesel models) N/A 2 N/A N/A 2 option .. option ...option .. option . option 34 52735 Decal, 110 Volts 35 15376-024 Decal, 110V Power To Platform option .. option ...option .. option . option 36 67881 Decal, Rotation Tool Inside 1 1 1 1 1 37 34767 Decal, Aux. Lowering (plat. cntrl.) .... option .. option ...option .. option . option (see NOTE 2)

- Indicates Items Not Shown NOTE: 1. Decal #37348, showing lower control valve operation, replaces decal #34502.

2. Decal #34767 is used to indicate the pushbutton control for Auxiliary Lowering on units equipped with an optional auxiliary power unit. Decal #37354 contains the instructions for auxiliary lowering on units equipped with the optional power unit.

MANUAL 92265-001 SEPTEMBER 1994

10

NOTES

MANUAL 92265-001 SEPTEMBER 1994

CA la R.VA R CALAVAR CORPORATION

Condor® Self-Propelled Aerial Work Platforms 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 five (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 one (1 ) year after the aerial work platform is placed in service or two (2) years after the original shipment of the aerial work platform from Calavar's plant, whichever comes 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 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 damage 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 the 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 merchantibility and fitness for a particular purpose. Any applicable implied warranty shall be limited in duration to the warranty period.

8300 Imperial Drive, P.O. Box 21447, Waco, Texas 76702-1447 817-666-4545, FAX 817-666-4544 Printed in U.S.A.

MANUAL 92265-001 SEPTEMBER 1994

NOTES

MANUAL 92265-001 SEPTEMBER 1994

CALAVAR CORPORATION

BOOM-SUPPORTED ELEVATING WORK PLATFORM

MODEL 38AG ARTICULATING

MAINTENANCE MANUAL

THIS MANUAL APPLIES ONLY TO CONDOR® MODEL 38AG GASOLINE AND DIESEL ENGINES BEGINNING WITH SERIAL NUMBER 1563

CALAVAR CORPORATION 8300 IMPERIAL DRIVE WACO, TEXAS 76712 (817) 666-4545 MANUAL 92323-002 SEPTEMBER 1994

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 UNIT AT ALL TIMES. Do not attempt to operate or service the CONDOR® until you have read and understood all information provided in this manual. Familiarize yourself with the functions and operations of the upper and lower controls. A good understanding of the controls, their limitations, and their capabilities will maximize operating efficiency and safety. The various decals attached to this machine also contain vital safety and operational instructions. Read the decals before operating this machine. The parts and maintenance sections of this manual will serve as a tool to be used in servicing the machine and in ordering parts. When referring to this manual, please note the publication date and any Serial Number information pertaining to this manual and its corresponding model(s).

It is YOUR RESPONIBILITY to follow safe procedures while operating the CONDOR®.

The manufacturer of this unit cannot control the wide range of applications that may be used in carrying out a variety of jobs. Therefore, it is YOUR RESPONSIBILITY to consider the safety of all personnel when making decisions regarding the unit's intended use. It is also YOUR RESPONSIBILITY to understand and obey all federal, state, and local regulations regarding the safe operation and use of aerial work platforms. The ANSI/SIA Manual of Responsibilities pertaining to this model is attached for your use.

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

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

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 Manal for information pertaining to optional parts.

MANUAL 92323-002 SEPTEMBER 1994

CONDOR® MODEL 38AG BEGINNING WITH SERIAL NUMBER 1563

MAINTENANCE MANUAL

TABLE OF CONTENTS

CONDOR® SERVICE INFORMATION CHECK-OUT INSTRUCTION

1

WARRANTY PROGRAM

3

A. WARRANTY PERIOD

5

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

6

C. ITEMS NOT COVERED

6

D. PROCESSING OF CLAIM

7

E. RETURN AUTHORIZATION

7

SERIAL NUMBER LOCATION

MANUAL 92323-002 SEPTEMBER 1994

9

CA IL. INVII 14 CALAVAR CORPORATION

CONDOR® SERVICE INFORMATION

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

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

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

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

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

CALAVAR CORPORATION

8300 IMPERIAL DRIVE, P.O. Box 21447,

WACO, TEXAS

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

MANUAL 92323-002 SEPTEMBER 1994

CHECK-OUT INSTRUCTION The following instructions are a step-by step procedure for checking out the selfpropelled CONDOR®, as well as for acquainting operating personnel with the unit'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 unit into service, a full check-out of the unit should be made and the Installation Inspection Report should be completed and returned to Calavar.

Each unit has undergone a thorough Quality Control Inspection, and each unit leaves Calavar in first-class condition. Unfortunately, some units may be damaged in transportation; all such damage should be recorded on the consignee copy of the freight bill. Calaver Corporation is not responsible for damage to units 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 unit. Do not over-inflate. Proper P.S.I. 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 unit into service.

7.

Turn on the key switch at the lower control station; IF D1ESEL-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 unit has warmed up, and with the UPPER/LOWER control station selector switch in the LOWER position, the unit may be operated by activating the control handles on the lower control valve. 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 unit 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. Learn to operate the controller slowly to obtain the smoothest possible operation.

MANUAL 92323-002 SEPTEMBER 1994

1

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.

1 1 . 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. When the boom is elevated off of the turret, HIGH speed is not available and boom functions become operable.

D.

A CREEP speed mode is automatically engaged when the lift arm is raised or the boom is elevated out of its stowed position.

1 2. Operate the boom at a horizontal position until you are familiar with the operation and feel of the controls. The unit will respond more smoothly to the controls when they are activated properly.

1 2. 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 5° out-of-level 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 5° 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.

2

MANUAL 92323-002 SEPTEMBER 1994

CA EWA 14 CALAVAR CORPORATION

Condor® Self-Propelled Aerial Work Platforms 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 five (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 one (1) year after the aerial work platform is placed in service or two (2) years after the original shipment of the aerial work platform from Calavar's plant, whichever comes 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 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 damage 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 the 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 merchantibility and fitness for a particular purpose. Any applicable implied warranty shall be limited in duration to the warranty period.

8300 Imperial Drive, P.O. Box 21447, Waco, Texas 76702-1447 817-666-4545, FAX 817-666-4544 Printed in U.S.A.

MANUAL 92323-002 SEPTEMBER 1994

3

NOTES

4

MANUAL 92323-002 SEPTEMB E R 1994

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

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

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

A. WARRANTY PERIOD 1 . The Self-Propelled Boom and Scissor Warranty is one (1 ) year from placing the unit 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 unit Warranty Period is one (1 ) year from shipment of the unit 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 (1 2) 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.

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

MANUAL 92323-002 SEPTEMBER 1994

5

B. PRE-DELIVERY INSPECTION SHEET (P.D.I.) 1 . Each Self-Propelled Boom or Scissor unit shipped from Calavar's facility will have a Pre-Delivery Inspection (P.D.I.) sheet enclosed in the Safety Manual holder tube.

NOTE:

2.

It will be the responsibility of the original recipient of the unit 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 unit.

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

C. ITEMS NOT COVERED Some components are used on the machine 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.

6

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 machine 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 92323-002 SEPTEMBER 1994

D. PROCESSING OF 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.

C. Although not recommended, you may purchase the part locally.

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

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

NOTE: CLAIMS NOT RECEIVED BY CALAVAR WITHIN 45 DAYS OF FAILURE WILL BE DENIED 3. Provided no return parts are required and all the information has been verified, the claim will be processed and credit will be issued against your account.

E. RETURN AUTHORIZATION 1 . If a component is found to be defective within the normal guidelines of the Warranty, a Warranty Claim Form must be completed.

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

MANUAL 92323-002 SEPTEMBER 1994

7

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

8

3.

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

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 92323-002 SEPTEMBER 1994

CONDOR® Model 38AG Serial Number Location

STAMP ON TURRET PLATE

STAMP ON STEER AXLE

STAMP ON DATA PLATE

The CONDOR® Model 38AG Serial Number is stamped in three locations on the machine.

1.

The first place to find the serial number stamp is on the data plate affixed to the chassis, as indicated on the illustration above.

2.

Another serial number stamp is located on the steer axle, as shown above.

3.

The third serial number stamp is located on the turret plate, near the lower control console, as shown above.

MANUAL 92323-002 SEPTEMBER 1994

9

NOTES

10

MANUAL 92323-002 AUGUST 1994

OEM Drive Controller Adjustment Procedure

CAUTION: Have another person in the platform to assure safe driving during this procedure.

1. Turn 'RAMP RATE' all the down counterclockwise.

2. Threshold Adjustment: • Put arm and boom all the way down.

• Switch to fast drive speed.

• Move handle slowly off center until LED comes on and hold it there.

• Adjust 'THRESHOLD' until unit will just start to creep with control handle moved 1" to 2" after LED has come on. Also, unit should slow and stop just prior to LED turning off.

NOTE: Move handle slowly to allow system to respond.

3. High Range Adjustment: • Turn 'HIGH RANGE' all the way down counterclockwise.

• Push handle all the way to drive forward and hold it in maximum position.

• Turn 'HIGH RANGE' up clockwise and 1/2-turn at a time. Each time you will feel unit accelerate. After several turns, there will be no further acceleration. Stop adjustment and driving at this point.

• While driving forward at maximum, move control handle slowly toward neutral a few degrees. There should be a definite sensation of slowing. If not, then HIGH RANGE is set too high and needs to be slowed by turning counterclockwise about 1/4-turn to 1/2-turn.

4. Low Range Adjustment (see NOTE at 'Fine Tune" below): • Lift boom off limit switch. (This will de-energize terminal 'R' on the controller.)

• Switch to slow drive speed.

• Adjust 'LO RANGE' to a speed of .75 mph. (This is 80 sec in 88 feet.)

5. Ramp Rate Adjustment: • Put arm and boom all the way down.

• Switch to FAST drive speed.

• Turn 'RAMP RATE all the way up clockwise.

• Turn 'RAMP RATE' down counterclockwise 6 turns.

• Check ramp rate performance. While driving at maximum speed, pull handle rapidly and fully in opposite direction. Unit should stop and reverse its direction in approximately 3 feet. If stopping distance is excessive, turn ramp rate down, counterclockwise, one to two turns, and recheck.

6. Fine Tune: • Repeat Threshold Adjustment.

• Check High Range setting.

NOTE: Low Range may not be functional on units shipped prior to August 1991.

If not, then skip this step.

MANUAL 92323-002 AUGUST 1994

NOTES

12

MANUAL 92323-002 SEPTEMBER 1994

• BC rRENOTH ( T I OF LOAD IN STRESS GRADE (195,) SIZE BASIC AREA MAJOR Mal28 01A 1)54-40 1120 . 006 12 151‘4 1150M 11201 4 - 48 ..20 0064 120h4 85h4;150M112011/1 6-32 HI380 00909 120M1f — 1150M1120M u 4 ®4 .1380 ® 01015 120M1 50M1120Mi 8-32 I 1640 rtthnIA

GRADE 5 ■ 33E1v3LY TORQUE

LOAD c00 DRY R 150 LUB R-.200 DRY 1831 540 8 1N/L83 6 1N/L83 IN/L83 7 IN/LBS 1 0 IN/L133 12 IN/LBS s 13 IN/1_83 920 Z5 IN/L83 19 IN/LBS 1260 41 IN/1.33 31 IN/LBS 30 IN/LBS 22 IN/L133 120 43 IN/LBS 32 IN/LBS 31 IN/LEIS 23 !NABS zUMIJMI 944.t

1580 80 IN/LBS 45 IN/LBS 43 IN/L83 32 IN/L83 19 150,A 120M 1120 0 I ZO M 1800 88 INIUM 51 IN/LBS 49 IN/LBS 38 IN/LBS 01.41120M! 1265 1900 02000 12mAl Z880 12 FT/L113 9 FT/LBS 8 FT/LBS 75 IN/LBS 1/4-20 OM I1ZOMI 2020 2500 $. 0316C 88 IN/LBS 3280 14 FT/LBS 10 FT/LBS 10 FT/LBS I OM11ZOMI 20 1/4-28 2.500 1. 038 13 FT /LBS 4720 16 FT/LBS 17 FT/LBS 5 FT/L153 5/18 i8 2125 I.Q5Z )5M 1150/41120W, 33 ,-.0 14 FT/LBS 5220 ZO FT/LBS 19 FT/LBS 5/16-24 .3125 r.-6.7100 tI4V1641 d5M 1150L411201 7000 43 T/L133 35 FT /LBS Z3 FT/LBS 30 FT/LBS 3/8-16 . 2750 .0775011ZOM1 85M 1150M1120M t 40 7900 50 FT/1153 35 FT/LBS 35 FT/LBS I 25 FT 3/8-2-1 .3750 .08780 120M 85M 1150M11ZOM 5800 35 FT/LBS 9550 70 FT/LBS 55 FT/LBS 50 FT/LBS 7/17-14 1 .4375 10630 120M 85M 1150M1120M1 6800 40 FT/LBS 0700 80 FT/LBS 60 FT /LBS 55 FT/LBS 7/18-20 I .4375 11870 120M 85M 1150M1120M1 7550 2750 110 FT/LBS 75 FT/L83 1/Z-13 .5000 120M$851.4 1150141120M 9050 4400 65 FT/LBS 120 FT/LBS 90 FT/LBS 1 / Z- 2 0 . 5000 15990 85M 1150).41120M 10700 90 FT/LBS 80 FT/LBS 8400 150 FT/LBS 110 FT/LBS 110 FT/LBS 85M 15014 120M 1 11800 8250 90 FT /L8S 170 FT/LBS 130 FT/LBS 120 FT/LBS 9/ 1111- 18 . 56z5 .z0300 120M 85k4 150M 120M 12950 110 FT/LBS 20350 170 FT/1.83 220 FT/LBS 150 FT/LBS U 8-11 IIMNUEZ 4 85M 150/441120M 14400 180 FT/LBS 130 FT/LBS 180 FT/LBS .6250 . 25800 MEM 85M 1501441120M1 16950 ZOO FT/LBS 0100 380 FT/ILM 280 FT /LBS 280 FT/L83 220 FT/LBS 33600 1420 FT/LBS 320 FT/LBS 390 FT/LBS 41800 ' ZS 460 FT/LBS 430 FT/LBS 45800 I 860 I 580 FT/LBS 54500 1 900 FT/L153 880 FT/LBS 630 FT/LBS 1 59700 11000 FT/LBS 740 FT/LBS 66700 280 FT/LBS 960 FT/LBS 600 FT/LBS 770001 440 FT/LBS 1080 FT/LBS 680 FT/LBS 1/8 - 12 11.1250 1 851500 105M 1 74M 115nu Ii7oh4 47500 880 FT/LBS 87200 1820 FT/L83 1350 FT/LBS 1 120 FT/LB 1/4-7.25001 969001105M1 74M 115 -.

96800 2000 FT/LBS 1500 FT/LBS FT/L83 420 FT/LBS m 11248 1/4 - 1211 . 2500I 0730 t105M 74h4 t1501411ZOM nri 468 FT/LBS 100 FT/LBS 104000 2380 FT/LB., 1 Jim •A 11.3 7 " v . ,j474)4 i15014i1ZOM Jew FT/L83 1250 FT/LBS 118400 !ZO FT/L113 2040 FT/LBS UUU 105M 74M 115 - 1ZOM 000 1 940 FT/LBS 460 FT/LBS 126500 3160 FT/LBS 2360 FT/LBS 1 / 2-6 .A , 150 105M 74M 115 1120M T &BS 142200 3560 FT/LBS 2660 FT/LBS Ii. 5%Mn 1105M 1 74M 115- 4120k41 &In 1111111111111111IL

-

OTES:

1 . THIS CHART SHOWS STANDARD BnLT TORQUES TO E3 'F LIED UNLESS OTHER' IE SPECIFIED a. CLAMP LOAD = 7h X PROOF X STkESS AR_ 3 . TORQUE (FL) = R 0 T R = . ZOO FOR DRY CONDITIONS R = . 130 FOR LUB CONDITIONS LUB CONDITIONS a NCLUDES LUBRICANTS, LUBRIZING, PLATING AND H/V.L.)ENEE) WASHERS .

D = NOMINAL 2IAMETEER IN INCHES T DESIRED CLAMP LOAD IN pouNo

APPENDIX E

IAILSO/011111

CALAVAR CORPORATION

T( RC I

C7 3

, Suggested assembly torques in 7eat-. ounci. (* Values in Inch-Pounds) ri

The tai_r_ for an

Property Class 8.8 Property Class 9.8 DIAMETER

Dry Lubricated Threads Threads

Dry Lubricated Threads Threads

M4

PropAy Class 10.C..'

.-)roperty C ass 12.9

Dry Lubricated Threads Threads

Dry Lubricated Threads Threads

38.5k 24*

53* 32.5

180* 109*

M6

`L 37 22

M8 M10

92 55 127 76

i4:12 L.;

116 69 146 89 203 122

16

18u 08 230 38 316 190 167 617 370

35L-, M24

562 .237 609 38f 775 465 `.06 '40

M30 1111

1210 726 1E0 =IL

1271

CALAVAR CORPORATION

BOOM-SUPPORTED ELEVATING WORK PLATFORM

MODEL 38AG ARTICULATING

VENDOR INFORMATION

THIS MANUAL APPLIES ONLY TO CONDOR® MODEL 38AG GASOLINE AND DIESEL ENGINES BEGINNING WITH SERIAL NUMBER 1563

CALAVAR CORPORATION 8300 IMPERIAL DRIVE WACO, TEXAS 76712 (817) 666-4545 MANUAL 92323-004 SEPTEMBER 1994

NOTES

MANUAL 92323-004 SEPTEMBER 1994

This catalog covers:

FD620D-[1S03

PARTS CATALOG 4-STROKE AIR-COOLED ENGINE

FE)62013 PRODUCT CODE

NOTE

FD620D-AS03

111-1C Kawasaki Motors Corp., US A ENGINE DIVISION P/N 99910-2831

P.O. BOX 388285 GRAND RAPIDS, MI 49588-8285

Printed in U.S.A.

900APC-4/92

GRI D NO. This grid covers: NUivi ERI CAL PARTS Ii4DE; ,',

This catalog covers: FD620D LI S03 Firts No. Grid No.

Parts No. Grid No. Parts Jo. Grid No. Ptr ts No. G- d No. Parts No. Grid N o.

11004-2107.. ....... B-03 11008-2087.. ....... B-03 11008-6015.. ....... B-03 11009-2546.. ....... 8-03 11009-2566.. ....... B-06 11009-2766.. ....... B-09 11009-3028... ...... B-03 11011-222.. ...... B-12 11011-2239.. ....... B-12 11013-2114.. ....... B-12

8-08 130G0845 130G0860.. .. .... ..8-03 B-03 130G0865 B-08 130G0870 130H0665...........13-08 13001-2136.........8-04 13002-1013.... ..... B-04 13008-6025.........8-04 13024-6004.........8-04 13025-6007.........8-04

180B0616 B-10 49078-2063 49085-2052.. .....

18080635.... . .....8-10 21039-2059 B-14 49103-2123 21040-2052 B-14 49110-2073 49113-2102.. ....

21066-2070.........13-09

.........

21080-2054 ..... .... B-14 49118-2082.. . ..

8-09 49119-2130 21119-2120 B-09 49120-6059 21121-2064 49120-6075 21130-2060.. ... ...B-09 B-14 21163-2101 510A5100

B-05 8-07 8-10 B-10 8-10 8-05 B-04 B-03 B-03 B-09

92033-2081.........13-14 92036-021..........8-04 92037-2209.........8-10 92037-2210.........8-07 92042-014..........13-06 92043-1037.........8-03 92043-2196... ...... 8-11 92045-2191.........8-07 92049-2097 ......... B-03 92049-2109.........8-05

11013-2139 ...... ...B-12 11022-2056.........8-03 11022-2063 ..... ....8-03 11029-2005.........8-12 110'.7-2036-9H......B - 09 11047-2056-9H......B - 07 1107-2057-9H......B-12 1107-2111-9H......B - 12 11047-2112-9H......B - 07 11047-2113-9H......B-07

B-04 13025-6008 8-04 13027-2064...

13029-2108... . ..B-04 8-04 13029-2109 13045-2051 B-06 B-07 13070-2093 13081-2108.. ..B-14 B-14 13091-2068 13107-2097.. . ..... B-07 13107-2099.. ....B-06

21169-2055. ........ B-09 21169-2055.... ..... B-13 21188-2006 ...... ...B-11 B-09 21193-2115 B-06 21480512 B-09 225B0414 23480525 . ..... .. ..B-12 241B0406 B-09 8-12 242 8 0516 26030-2073 . ..... . .. B-09

52005-2108.........8-06 551A0314 B-08 55140408 B-04 55140416.... ....... B-08 56032-6060 C-03 59011-2056 B-07 59026-2054 B-09 59031-2096.. .. . ... B-09 59041-2063 B-07 59051-2112 . .... .. B-04

920.9-2110.. ...... .B-03 920-39-2111.........8-07 92055-2086 ......... B-06 92055-2175.........B-11 92063-2241.........B-11 92064-2093.... ..... B-11 92066-2099.........B-06 92070 - 2072.........B-09 92093-2092.........B-11 92093-2093.........8-11

11047-2114-9H......B - 07 11047-2115-9H......B - 07 B-11 11060-2072 11060-2073.........B - 11 11060-2079.........B - 12 11060-2080.........B - 03 11060-2081. ...... ..B-07 11060-2082.........B - 07 11060-2084. ......... ... ..... B-07 11060-2084 11060-2087.........8 - 11

13107-2246... ...... B-07 13116-2057 ...... ...B-05 B-14 13168-2131 13183-2120... ...... B-03 B-06 13183-2419 13251-6022.........B - 04 13251-6026... ...... B-04 13304-6005.. ..... ..B-07 14024-2113.........B-06 B-14 14024-2205

26030-2081 ...... ...B-09 27010-2122.........B-14 27010-2170 ......... B-09 B-09 27010-2182 31180600 B-10 B-12 311G0600 311509-3595-00 B-10 314401-5121B ..... B-10 B-08 315B1000 315601-32454........B-04

59051-2113 B-07 59051-2114 B-06 59076-2056 B-11 59091-2052-9H B-07 59091-2053-9H.. ...B-07 59221-2099 B-09 59221-2156.. . ..8-13 59256-2051 B-07 B-07 59336-2052 B-06 600A1300

92141-2110.........B-03 92143-2010.........B-03 92143-2178.........B-12 92143-2187.........B-06 92143-2189.........B-12 92143-2191.........B-11 92143-2192 ...... ...B-11 9214 .-2052.........B-10 92144-2053.........B-06 9214 , ;-2287.........6-10

11060-2088.........B - 11 .........

11060-2089.. ....... B - 03 11060-2089 11060-2090.........B - 11 12004-2094.........B-05 12005-2083... ..... .8-05 12009-2061.........B - 05 12016-2056... ..... .B-05 12020-2059.........B-05 12032-2064.. ....... B-05 130B0520...........B - 09

B-03 14024-2292 B-07 14024-2293 ....... B-07 14037-2128..

14083-2051.. ....... B-09 15003-2243... ...... B-11 16004-2051.. ....... B-11 16014-2066.... ..... B-11 B-11 16025-2163 16030-2085'. ..... ...B-11 16031-2071.........B - 11

316644-8577A 316691-8577A 317B0800 317472-5332A 32085-2066 32085-2089 32150-2076-9H 352101-1349A

39003-2064... .

39061-2056

B-09 B-09 B-14 B-10 B-14 B-11 B-03 B-07 B-10 B-07

670B1507 . ..... . ..B-08 670B2010 B-03 670B2011 .. .. . ... B-06 92002-220.. . .. ...B-12 B-04 92002-2263 92002-2269 ..... ....B-10 92002-2277 B-14 92009-1109. ..... ..B-05 92009-2273 ..... ....B-09 92009-2308 B-03

92144-2306... ... ..B-11 92144-2307 B-11 92150-2182.........B-10 92150-2230.........B-07 92150-2231 ...... ...B-07 92150-2254.........B-03 92150-2255.........B-02 92160-2034.........B-03 92170-2002.........B-03 92170-2056. ...... ..B-09

1308061 ,4 .. ..... ...B-06 130B0614...........B - 09 130B0616...........B-08 130B0616 .. ... ... ...B-09 130B0620...........B - 11 130B0625...........B - 03 130B0635.. ...... ...B-08 13080645.. ..... ....B-11 13080816.. ...... ... B-03 13080816...........8-12

16035-2073 ..... ....B-11 B-11 16035-2074 16041-2218.........B-11 16041-2219... ...... B-11 16060-2173.........B - 12 B-14 16073-2098 B-0-6 16115-2090 16126-2146.........8-03 B-11 16126-2185 16142-2066.........8-07

39062-2051... ...... B-07 B-07 39062-2062 39062-2063... ...... B-07 B-05 39108-2057 B-10 39129-2043 410B0800.. ...... ...B-03 41081000....'.......8-08 41180600...........13-10 461F0600 B-12 461F0800..... ...... B-14

92009-2330 B-11 92009-2331 B-11 92009-2332......

B-11 92009-2333...... ..B-11 92009-2334.........B-11 92015-1014...... ..B-07 92015-1137 ..... . ..8-05 92015-1143 8-07 B-11 92015-1143 92015-2146 . .... .

8-14

92170-2075.........B-12 92180-2013 .........

92180-2013... ...... B-08 92180-2014.........B-08 92190-2064.........B-12 92190-2086.........B-03 92200-2036.........B-10 92200-2044 B-08 92200-2059-9H......8-12

...... B-06 13080820... . .

13080820... . . ...... B-08 130n0825... .. ..... B-08 13080830... . . ...... 8-08 13080830... ...... B-14 130808.".0. . . . ...... B-08 13000812.. . ...... B-03 B-08 130G0645 130G0-675.. ......... B-08 130G0845.. .. ...... . 8-03

16146-2186.. . . ..8-14 B-14 16146-2187 16154-2053.. . . ..8-06 16154-2054.. . . . ..8-06 B-10 16169-2092 16171-2065.........8-10 171G0818...-........8-08 B-11 171G0880 172G0616.. ....... ..8-03 172G0618...........8-03

480J1200...........8-05 B-08 481J2800 49015-6130.........8-03 49040-2065 ...... ...8-13 B-07 49044-2055 49054-2054.........8-07 49063-2056.........8-07 49065-2071 8-06 49065-2072......

B-06 49070-2593-9Y 8-12

B-14 92015-2147 92015-2167 B-09 B-09 92022-1517 8-04 92022-2194 B-14 92022-2218 8-09 92022-2245.. . . . .

B-07 92026-2311.. .

92027-1568.. . . ...B-09 92027-2096.. .. ...B-09 92027-271... . .. ..8-07

GR I L This grid cover s:

This catalog covers: FD620D- fl so3

PART NAME INDEX AIR—FILTER ... . ....... .

CAMSHAFT ..... . .. .

0

019

2

SIDS

.....

...

BOOBOO S.S.19.1.6 0.80 a ••

CARBURETOR . .. . . . . . .

.0

0

0

0

88

2.88

CONTROL—EQUIPMENT.. . .....a ...

COOLING—EQUIPMENT ...

a

0.0

a

....

.00....8

0 BO a 0 a 0. .0 8 802. 08.

B-12 PISTON ........ .. ...... . .

80.

CRANKSHAFT ...

88.09

CYLINDER ........

000.8.

0

00

8.0

0.0.8....

0

ELECTRIC—EQUIPMENT ....

9.8...

9

FUEL—TANK . .. 0.. ........

8.8

a

0

8 .8 0

LUBRICATION—EQUIPMENT ....

.8.

OS.

00.0..0

0000.0.0

00

9

IS

8.008....

0 0 0 0.0800

a

••

200018

0 0 9 8.020

. .. . .

FUEL—VALVE ... .0. . .

LABEL ....... .

.0.0.008.0M

0.208.9

• .

a

B-05 STARTER ......... .... .. B-14 . ..... .. . . . .... .

B-11 VALVE ................................. B-05 B-10 B-07

B-08 COOLING—EQUIPMENT..... .. . ............ .

CRANKCASE ....... ..

. . .. B-04

08..0.

B-03 B-04 B-03 B-09 B-13 B-13 C-03

... B-06

MUFFLER .... ......... ... ......... B-12

3R1 D NO.

I B

This catalog covers: _'D620D- 11 S03

EOM) -2291A -C 130 92143 11022 11009

130 9243 11022A 11009

92150

cee

410

92190 130E

4

92150 ---92170

130E

92009 130A 13183 1,024 3126 11060A

IT

11000 92043 11004 L—'1 11008A

130E

9204:3

11004 92049A 49015 92141 11308 11009A 49120.A

(,.‘>

C;) 92043

11060 '

92049A

13C -

0\ , 00

130D

32150

670

CYLINDER/CRANKCASE Ref. ND. Parts No. Description

Quantity

A

11004 11008 11008A 11009 11009A

11004-2107 11008-2087 11008-6015 11009-2546 11009-3028

GASKET-HEAD 2 HEAD-001:.?-CYLINDER 1 HEAD-COMP-CYLINDER I GASKET,ROCKER CASE 2 GASKET 2

11022 11022A 11060 11060A 13183

11022-2056 11022-2063 11060-2080 11060-2089 13183-2120

CASE - ROCKER 1 CASE-ROCKER 1 GASKET,CRANKCASE COVER 1 GASKET 1 PLATE 1

1402', 16126 32150 49015 49120

14024-2292 16126-2146 32150-2076-9H 49015-6130 49120-6059

COVER 1 VALVE 1 PIPE 1 COVER-CRANKCASE 1 CRANKCASE-COMP 1

( - FD620-001309) 49120A 49120-6075 CRANKCASE-COMP 1 ( FD620-001310 - ) 92009 92009-2308 SCREW 1 92043 92043-1037 PIN 6

172A

q!)

Thi s grid covers:

92049 92049-2097 SEAL-OIL 92049A 92029-2110 SEAL-OIL 92141 92141-2110 BEARING-PLANE 92143 92143-2010 COLLAR 92150 92150-2254 BOLT

1 2 1 8 2

92170 92170-2002 CLAMP 92190 92190-2086 TUBE 130 130B0625 BOLT-FLANGED 130A 13060816 BOLT-FLANGED 130B 13000812 BOLT-FLANGED

1 1 8 4 2

130C 13000845 BOLT-FLANGED 130D 13000860 BOLT-FLANGED 130E 13000L65 BOLT-FLANGED 172 17200616 BOLT-STUD 172A 172G0618 BOLT-STUD

6 2 8 2 2

410 410B0800 W - PLAIN - S 670 670B2010 0 RING

2 1

GRID

Thi s grid covers:

This catalog covers: SO3

PISTON/CRANKSF:AF

E0120-2223A-C

92036 13002 r2036 13008 13024 13025•A

C) 13251.A

13251.A

13001 13027 13029.A

92002 92036

92002 13001 13027 13029.A

13002 92036 551

to' 92022 92002A

59051 49119

13008 13024 13025.A

Quantity

Ref. No. arts No.

Description

A

13001 13002 13008 13024 13025

13001-2136 13002-1013 13008-6025 13024-6004 13025-6007

PISTON-ENGINE PIN-PISTON RING-SET-PISTON RING-SET - PISTON LL,0.75 RING-SET-PISTON L,0.25

2 2 2 AR AR

13025A 13027 13029 13029A 13251

13025-6008 13027-2064 13029-2108 13029-2109 13251-6022

RING-SET-PISTON L,0.50 PISTON-ENGINE LL,0.75 PISTON-ENGINE L,0.25 PISTON-ENGINE L,0.50 ROD-ASSY-CONNECTING

AR AR AR AR 2

13251A 49119 59051 92002 92002A

13251-6026 49119-2130 59051-2112 315601-3245A 92002-2263

ROD-ASSY-CONNECTING,U/S=0.50 CRANKSHAFT-ASSY GEAR-SPUR BOLT BOLT,10X28

AR 1 1 4 1

92022 92036 551

92022-2194 92036-021 55140408

WASHER RING-SNAP PIN-DOWEL

1 4 1

(iR1 U NU. This grid covers:

Thi s catalog covers: :D620D-

LI S03

,

B-05

E0130-2081A-C

VALVE/CAMSHAFT

Ref. No. Par ts No. 12004 12004-2094 12005 12005-2083 12009 12009-2061 12016 12016-2056 12020 12020-2059

13116

Descr iption

Quanti ty

A

VALVE-INTAKE 2 VALVE-EXHAUST 2 RETAINER-VALVE SPRING 4 4 ARM-ROCKER SHAFT-ROCKER 2

12032 12032-2064 TAPPET 4 13116 13116-2057 ROD-PUSH 4 39108 39108-2057 RETAINER-SPRING 4 49078 49078-2063 SPRING-ENGINE VALVE 4 49118 49118 - 2082 CAMSHAFT - COMP

13116

1

92009 92009-1109 SCREW 92015 92015-1137 NUT 92049 92049-2109 SEAL - OIL 480 480J1200 CIRCLIP

13116 12032 12032 480 12016 92009 92015 92015 92009

12009 \N 49078 39108 92049 12004 N

12016 12009 12020 480 49078

39108 92049 12005

12020 480

480 12016 92015 92009 12016 *---92015 92009 0-12009 49078

12009 --CD 1-61 —39 108 49078 92049 39108 92049

rn

12005 12004

-

4 4 4 4

GRID Thi s grid covers:

Thi s catalog covers:

LUBRICATION -EQUIPMENT

FD620D- Q 203

E0140-2146A 49065

luso,

16115

52005

130 92055 670 92144 600

92042 92042

59051

13045

14024 13107 16154 214 13183 11009 92066 49065A

130A

Ref. No.

Quant i ty

Parts No.

Description

11009 13045 13107 13183 14024

11009-2566 13045-2051 13107-2099 13183-2419 14024-2113

GASKET,DRAIN PLUG RECEIVER - OIL SHAFT PLATE COVER

16115 16154 16154A 49065 49065A

16115-2090 16154-2053 16154-2054 49065-2071 49065 - 2072

CAP-OIL FILLER ROTOR-PUMP,IN ROTOR-PUMP,OUT FILTER-OIL FILTER-OIL

52005 59051 92042 92055 92066

52005 - 2108 59051-2114 92042-014 92055-2086 92066-2099

GAUGE,OIL GEAR-SPUR PIN RING-0 PLUG,DRAIN

1 1 2 1 1

92143 92144 130 130A 214

92143-2187 92144 - 2053 130B0614 130B0820 214B0512

COLLAR,8.2X10X10 SPRING BOLT-FLANGED BOLT-FLANGED SCREW-PAN+ -

2 1 3 2 2

60041300 670B2011

BALL - STEEL 0 RING

1 1

600 670

GRI D NO.

Thi s gri d covers:

Thi s catalog covers:

B-07

FD620D- [11 S03

E0150-2374A-C 39061 49085 14037

11047C

92150B 130C

13070 92027

92015 11047A

4 130D

13304

92160

1

- 1 92045 92026 481 92045 130 59041

92037A

410 13107A 130A

39062A 110470 92015

5905i 130E 92200 59336 92180.A 920A9 13 07 59091A 551A 92037A 551 )70 130J 490U3 39062B 5925T I 11060A 39062 92037 92037A 130G liC20 1301 16142 130F

92037A 92150 92150A 14024 110608 49054

COOLING-EQUIPMENT

Ref. No. ?art s No.

Descr i pt i on

Quant i ty

A

11047 11047A 11047B 11047C 11047D

11047-2056-9H 11047-2112-9H 11047-2113-9H 11047-2114-9H 11047-2115-9H

BRACKET BRACKET BRACKET BRACKET BRACKET

11060 11060A 110608 13070 13107

11060-2081 11060-2082 11060-2084 13070-2093 13107-2097

GASKET,PUPE COVER GASKET,PUPE CASE GASKET, THERMOSTAT COVER GUIDE SHAFT,IMPELLER

13107A 13304 14024 14037 16142

13107-2246 13304-6005 14024-2293 14037-2128 16142-2066

SHAFT,PULLEY HOUSING-ASSY COVER, THERMOSTAT SCREEN COVER-PUMP

39061 39062 39062A 39062B 49044

39061-2056 39062-2051 39062-2062 39062-2063 49044-2055

RADIATOR-ASSY HOSE-COOLING HOSE-COOLING HOSE-COOLING PUMP-WATER

49054 49063 49085 59011 59041

49054-2054 49063-2056 49085-2052 59011-2056 59041-2063

THERMOSTAT SEAL-MECHANICAL CAP-ASSY-PRESSURE BELT,FAN FAN

59051 59091 59091A 59256 59336

59051-2113 59091-2052-9H 59091-2053-9H 59256-2051 59336-2052

GEAR-SPUR PULLEY PULLEY IMPELLER CASE-PUMP

92015 92015A 92026 92027 92037

92015-1014 92015-1143 92026-2311 92027-271 352101-1349A

NUT NUT SPACER,12X18X1.4 COLLAR CLAMP

2 3 1 4 2

92037A 92045 92049 92150 92150A

92037-2210 92045-2191 92049-2111 92150-2230 92150-2231

CLAMP BEARING-BALL,6001DDUC3 SEAL-OIL BOLT,6X40 BOLT,6X20

4 2 1 1 1

130F 11047

GRI D Nu. This grid covers:

This catalog covers:

COOLING-EQUIPMENT

F0620D- LI S03

E0150-2374A-C 39061 49085 14037

110470

Ref. ro.

Parts No.

92150B 92160 92180 92180A 92200

92150-2255 92160-2034 92180 - 2013 92180 - 2014 92200-2044

BOLT DAMPER SHIM,T=0.6 SHIM,T=1.2 WASHER

130 130A 130B 130C 130D

130B0616 130B0635 130B0820 130B0825 130B0830

BOLT-FLANGED BOLT-FLANGED BOLT - FLANGED BOLT-FLANGED BOLT-FLANGED

4 2 1 4 1

130E 130F 130G 130H 1301

130B0840 130G0645 130G0675 130G0845 130G0870

BOLT - FLANGED BOLT-FLANGED BOLT-FLANGED BOLT-FLANGED BOLT-FLANGED

1 3 1 1 1

130J 171 315 410 481

130H0665 171G0818 315B1000 410B1000 481J2800

BOLT-FLANGED BOLT-STUD NUT-HEX-FINE W-PLAIN-S CIRCLIP

1 3 1 1 1

551 551A 670

551A0314 551A0416 670B1507

PIN - DOWEL PIN-DOWEL 0 RING

1 1 1

Quantity Description

A 1 4 AR AR 1

92015 11047A

.04

13304

92045

(56 410 315

59051 92200 59336 92049 107

59091A 92037A 130J 390628

11060A 39062 92037 92037A 130G 11060 1301 16142 130F

130F 11047

92037A A45---92150 AP---92150A 14024 11060B 49054

GRI D NO.

Thi s gr i d covers:

This catalog covers:

B-09

FDG2OD - LI S03 E0160-2734A-C 21130

21130 27010A 11009

59026

92027 21121

225 14083 92170 225

130 21066

920 5 92022A

1308

27010 92022 92027: 92072 26030

Ref. No. Par t s No.

26030A 92072A 59221 21169

21119

130A

Descr i pt i on

Quant i t y

A

11009 11047 14083 21066 21119

11009-2766 11047 - 2036 - 9H 14083-2051 21066-2070 21119-2120

GASKET BRACKET COVER-FLYWHEEL REGULATOR-VOLTAGE IGNITER

21121 21130 21169 21193 26030

21121-2064 21130 - 2060 21169-2055 21193 - 2115 26030 - 2073

COIL-IGNITION CAP - SPARK PLUG

26030A 27010 27010A 59026 59031

26030-2081 27010-2170 27010 - 2182 59026 - 2054 59031-2096

HARNESS SWITCH SWITCH COIL-PULSING COIL-CHARGING

59221 92009 92015 92022 92022A

59221 - 2099 92009 - 2273 92015-2167 92022-1517 92022 - 2245

CONNECTOR-CORD SCREW NUT WASHER WASHER

1 4 1 2 1

92027 92027A 92070 92072 92072A

92027-1568 92027 - 2096 92070-2072 316644-8577A 316691-8577A

COLLAR COLLAR,6.2X7.8X5 PLUG-SPARK,BMR4A(NGK) BAND BAND

2 2 2 2 2

92170 130 130A 130B 225

92170 - 2056 130B0520 13080614 130B0616 225B0414

CLAMP BOLT-FLANGED BOLT-FLANGED BOLT-FLANGED SCREW-PAN-WSP-CROS

1 4 4 2 4

241B0406 51045100

SCREW-PAN-WP+KEY-WOODRUFF

241 510

59031

ELECTRIC -EQUIPMENT

TERMINAL FLYWHEEL-ASSY HARNESS

2 2 6 1 1

GRI D This catalog

FD620D-

11

covers: SO3

B-10 E0170-2301B 180

92022 92150 49113

nu.

-92037

160A 92022 16169

16171 92027

92144:.

92144

49103 311 411 39129 92002 V. 39003

42036

This grid covers: COrTEOL-7ECWIPMEN'T

Ref. No. PEr t s No.

Quantity Description

A

16169 16171 39003 39129 42036

16169-2092 16171-2065 39003-2064 39129-2043 314401-5121B

LINK-CHOKE LINK ARM-PIVOT SPRING-GOVERNOR SLEEVE

49103 49110 49113 92002 92022

49103-2123 49110-2073 49113-2102 92002-2269 311509-3595-00

ARM-GOVERNOR GOVERNOR-ASSY PANEL-COMP-CONTROL BOLT WASHER

1 1 1 1 2

92027 92037 92144 92144A 92150

317472-5332A 92037-2209 92144-2052 92144-2287 92150-2182

COLLAR CLAMP SPRING SPRING BOLT,5X18

1 2 1 1 2

92200 180 180A 311 411

92200-2036 180B0616 180B0635 311B0600 411B0600

WASHER BOLT-UPSET-WS BOLT - UPSET-WS NUT-HEX WASHER-PLAIN

GKl D NU.

Thi s' catalog covers: FD620D

Thi s gri d covers:

[1] S03

CARBURETOR E0180-2A05A

Quantity

Description

16126 16041

92009 92055 16035A-1 920098 \

92093A 92143A 92143

16031 11060 1E003

Ref. No. Par t s No.

92009A 32085 X92064 92093 16041A

X12015

11060 11060A 11060B 11060C 11060D

11060-2072 11060-2073 11060-2087 11060-2088 11060-2090

GASKET GASKET GASKET,INTAKE MANIFOLD GASKET,INTAKE MANIFOLD GASKET, CARBURETOR

15003 16004 16014 16025 16030

15003-2243 16004-2051 16014-2066 16025-2163 16030-2085

CARBURETOR-ASSY. CAP-CHAMBER SCREW-PILOT AIR VALVE-THROTTLE VALVE-FLOAT

16031 16035 16035A 16041 16041A

16031-2071 16035 - 2073 16035-2074 16041-2218 16041-2219

FLOAT JET-AIR,#1.8 JET-AIR,#0.9 SHAFT-CARBURETOR, CHOKE SHAFT-CARBURETOR, THROTTLE

16126 21188 32085 59076 92009

16126-2185 21188-2006 32085-2089 59076-2056 92009-2330

VALVE,CHOKE SOLENOID STOPPER MANIFOLD-INTAKE SCREW

1 1 1 1 3

92009A 92009B 92009C 92009D 92015

92009-2331 92009-2332 92009-2333 92009-2334 92015-1143

SCREW SCREW SCREW SCREW NUT

1 4 1 1 2

92043 92055 92063 92064 92093

92043 - 2196 92055-2175 92063-2241 92064-2093 92093-2092

PIN RING-0 JET-MAIN,#112 JET-PILOT,#58 SEAL

92093A 92143 92143A 92144 92144A

92093-2093 92143-2191 92143-2192 92144-2306 92144-2307

SEAL COLLAR COLLAR SPRING SPRING

1 1 1 2 1

130B0620 130B0645 171G0880

BOLT-FLANGED BOLT-FLANGED BOLT-STUD

5 3 2

92009C

92063 11060A 21188 16025_7 92144A 92009

16014 92009D

171 110600 130A

11060C 11060B 59076

130 130A 171

GRI D Nu. This grid covers:

This catalog covers:

FD62OD jIJSO

AIR-FILTER/MUFFLER

B

IL_

E0190-2i96A-C

16060

92170

--11013A

Quantity

Ref. No.

Parts No.

11011 11011.4 11013110134 11029•

11011-2224 11011-2239 11013-2114 11013-2139 11029-2005

CASE-AIR FILTER CASE-AIR FILTER ELELENT-AIR FILTER ELEMENT-AIR FILTER ELEMENT-ASSY-AIR FILTER

11047 11047A 11060 16060 49070

11047-2057-9H 11047-2111-9H 11060-2079 16060-2173 49070-2593-9Y

BRACKET BRACKET GASKET,MUFFLRT PIPE-INTAKE MUFFLER-COMP

2

92002 92143 92143A 92170 92190

92002-2230 92143-2178 92143-2189 92170-2075 92190-2064

BOLT COLLAr1,5.1X6.3X1/1 COLLAR,6.2X7.8X7.5 CLAMP TUBE

2 3 4 1 1

92200 130 234 242 311

92200-2059-9H 130B0816 234B0525 242B0516 311G0600

WASHER BOLT-FLANGED SCREW-PAN-WSP+SCREW-PAN-WSP+NUT-HEX

2 2 3 4 4

461F0600

WASHER-SPRING

4

Description

A

1 1

1 1

11013 242 92143A

461

130 311

11047 61

GRI D NO.

This grid covers:

This catalog covers:

FUEL -TANK/FUEL -VALVE

FD620D- LI S03

E0200-2434A-C 59221

Ref. No. Part s No. 21169 49040 59221

21169

49040

21169-2055 49040-2065 59221-2156

Quantity Description

TERMINAL PUMP-FUEL CONNECTOR-CORD

A 2 1 1

GRI D NO.

This catalog covers: FD620D Eli S03

Thi s grid covers: 14 STARTER EQ210-21126

Ref. No. rar t s No.

130 461 317 14024

A

13091 13168 • 14024 16073

13081-2108 13091-2068 13168-2131 14024-2205 16073-2098

CLUTCH-ASSY HOLDER,BRUSH LEVER,SHIFT COVER INSULATOR

16146 16146A 21039 21040 21080

16146-2186 16146-2187 21039-2059 21040-2052 21080-2054

COVER-ASSY COVER-ASSY BRUSH SPRING - BRUSH ARMATURE

1 1 4 1 1

21163 27010 32085 92002 92015

21163-2101 27010-2122 32085-2066 92002-2277 92015-2146

STARTER-ELECTRIC SWITCH STOPPER BOLT NUT

1 1 2 2 2

92015A 92022 92033 130 317

92015-2147 92022-2218 92033-2081 130B0830 317B0800

NUT WASHER RING-SNAP BOLT-FLANGED NUT-HEX-SMALL

1 1 1 2 2

461 461F0800 WASHER-SPRING

2

13081

21163

Quantity Description

GRI D NO. This grid covers: C-03 LABEL

This catalog covers: FD620D- Eli S03 F0290-2809A

Ref. No. Parts No.

Quantity Description

56032 56032-6060 LABEL - SET

56032

DUAL ELEMENT AIR CLEANER MAINTENANCE BEFORE STARTING FILL CIANICASE VITN OIL USE CLASS . SO.SE.SE/CC.IF .

1111:1111IIMIEZ:111111 01:11131110111311311 E=130111111X111 *CONSULT OPERATOR'S MANUAL

FOAM ELEMENT:CLEAN EVERY 26 HRS. AWASH IN DETERGENT ANO WATER. AND ORY THOROUGHLY. 2.OATURATE IN ENGINE OIL ANO 1000000 OUT EXCESS. PAPER ELEMENT CLEAN EVERY 100 HRS. S. IF PAPER ELEMENT IS DIRTY. TAP GENTLY ON YCUR HAND ED REMOVE OUST. 2. IF PAPER ELEMENT EXTREMELY DIRTY. INSTTALL NEW ELEMENT. OPERATING IN DUETY CONDITIONS MAY REQUIRE DAILY MAINTENANCE.

LIQUID COOLED V-TWIN

13

A 1

CALAVAR CORPORATION

BOOM-SUPPORTED ELEVATING WORK PLATFORM

MODEL 38AG ARTICULATING

ILLSTRATED PARTS MANUAL

THIS MANUAL APPLIES ONLY TO CONDOR® MODEL 38AG GASOLINE AND DIESEL ENGINES BEGINNING WITH SERIAL NUMBER 1563

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

MANUAL 92323-003 SEPTEMBER 1994

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 UNIT AT ALL TIMES. Do not attempt to operate or service the CONDOR® until you have read and understood all information provided in this manual. Familiarize yourself with the functions and operations of the upper and lower controls. A good understanding of the controls, their limitations, and their capabilities will maximize operating efficiency and safety. The various decals attached to this machine also contain vital safety and operational instructions. Read the decals before operating this machine. The parts and maintenance sections of this manual will serve as a tool to be used in servicing the machine and in ordering parts. When referring to this manual, please note the publication date and any Serial Number information pertaining to this manual and its corresponding model(s).

It is YOUR RESPONIBILITY to follow safe procedures while operating the CONDOR®.

The manufacturer of this unit cannot control the wide range of applications that may be used in carrying out a variety of jobs. Therefore, it is YOUR RESPONSIBILITY to consider the safety of all personnel when making decisions regarding the unit's intended use. It is also YOUR RESPONSIBILITY to understand and obey all federal, state, and local regulations regarding the safe operation and use of aerial work platforms. The ANSI/SIA Manual of Responsibilities pertaining to this model is attached for your use.

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

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

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 Manal for information pertaining to optional parts.

CONDOR® MODEL 38AG—Serial Number 1563 and Following ILLUSTRATED PARTS MANUAL

TABLE OF CONTENTS FIGURE

DESCRIPTION

PAGE

GENERAL INFORMATION A B C D

Serial Number Location Recommended Spare Parts List How to Order Parts Parts Groups Breakdown

3 4 6 8

FINAL INSTALLATION 1.1 1.2 1.3

Final Assembly Decals Installation Cover Installation

9 10 12

CARRIAGE INSTALLATION 2.1 2.2 2.3 2.3A 2.3B 2.3C 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12

Carriage Assembly Steering Installation Drive Installation (Two-Wheel Drive) Torque Hub Assembly Drive Motor Assembly Brake Assembly Wheels Installation Fuel Tank & Battery Installation Carriage Hydraulic Installation Hydraulic Tank Assembly Lift/Steer Manifold Assembly Series/Parallel Drive Valve Assembly Proportional Drive Valve Assembly Speed Control (2-Position/3-Way) Valve Assembly Kawasaki Gasoline Engine Assembly

14 16 18 20 22 23 24 25 26 28 29 30 31 32 34

TURRET INSTALLATION 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8

Turret Installation Rotation Installation Rotation Gearbox Assembly Rotation Motor Assembly Turret Hydraulic Installation Turret Electrical Installation Lower Control Box Assembly Electrical Box Assembly, Kawasaki Engine

36 38 40 41 42 46 48 50

LIFT INSTALLATION 4.1 4.2

Lift Installation Arm Lift Cylinder Assembly

52 53

(Continued Next Page) MANUAL 92323-003 SEPTEMBER 1994

1

TABLE OF CONTENTS (Continued)

FIGURE

DESCRIPTION BOOM INSTALLATION

5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11

Boom Installation Aluminum Boom Assembly Boom Extension Cylinder Assembly Boom Extension Cylinder Parts Breakdown Master Leveling Cylinder Parts Breakdown Slave Leveling Cylinder Assembly Slave Leveling Cylinder Parts Breakdown Holding Valve Assembly Boom Hydraulic Installation Hose Installation Diagram Track Assembly

55 56 58 60 62 64 66 68 70 72 74

PLATFORM/SKIRT INSTALLATION 6.1 6.2 6.3 6.4

Platform Installation Platform Assembly Platform Wiring Platform Hydraulic Installation

76 78 81 83

OPTIONS INSTALLATION 7.1 7.1A 7.1B 7.1C 7.1D 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 7.13 7.14 7.15

Kubota Diesel Engine Installation (Option) ........ ........ .... ...... ...84 86 Diesel Engine Electrical Installation 87 Kubota D850-B2 Diesel Engine 88

Radiator Installation, Diesel Engine 89

Electrical Box Assembly, Diesel Engine 91

Auxiliary Lowering Power Unit Assembly (Option) 92 Strobe Light Assembly (Option)

93 Dual Fuel Carburetor Assembly-Liquid (Option) 94

Dual Fuel Tank Assembly-Liquid (Option) 95

Dual Fuel Carburetor Assembly-Vapor (Option) 96

Dual Fuel Tank Assembly-Vapor (Option) 97

Travel Alarm Assembly (Option)' 98

Motion Alarm Assembly (Option) 99

Air Line to Platform Assembly (Option) 100 110-Volt Line to Platform Assembly (Option) 101 Foam-Filled Tires Assembly (Option) 102 Self-Closing Platform Gate Assembly (Option) 103 Five-Foot Wide Platform Assembly (Option) 104 Platform-Mounted Work Light (Option)

SCHEMATICS & DIAGRAMS 8.0

2

List of Schematics/Diagrams Appearing in This Section 105

MANUAL 92323-003 SEPTEMBER 1994

FIGURE A—Serial Number Location

STAMP ON TURRET PLATE

STAMP ON STEER AXLE

STAMP ON DATA PLATE

The CONDOR® Model 38AG Serial Number is stamped in three locations on the machine.

1.

The first place to find the serial number stamp is on the data plate affixed to the chassis, as indicated on the illustration above.

2.

Find another serial number stamp on the steer axle, as indicated on the illustration above.

3.

The third serial number stamp is located on the turret plate, near the lower control console.

MANUAL 92323-003 ° SEPTEMBER 1994

3

FIGURE B—Recommended Spare Parts List CONDOR® MODEL 38AG (1 UNIT-1 YEAR OPERATION) BEGINNING WITH SERIAL NUMBER 1563

QTY PART NUMBER

DESCRIPTION

2-Position/3-Way (Solenoid) Valve 1 58079 Shuttle Valve 1 36841 Torque Hub Vent, 5 PSI 1 58425 NC Logic Cartridge 1 36287 NO Logic Cartridge 1 36285 Counterbalance Cartridge 1 36286 Cartridge, Flow Divider Combiner 1 67401 Hydraulic Filter Cap 1 50316 Element, Hydraulic Filter 4 67408 Relay 1 80377 Circuit Breaker, 10 AMP Auto-Reset 1 67947-010 Relay 2 67280 2 BVQ01004 Dust Cover, Steering Control Handle Kit, Lower Controls 1 34890 Control Handle Kit, Upper Controls 1 34818 Contact Block, NO/NC 2 34464 Key Switch 1 36878 Contact Block, NC 2 51914 Relay 1 67593 Body, Limit Switch 1 51036 Offset Head, Limit Switch 1 51037 Adjustable Arm, Limit Switch 1 51039 Slope Sensor, 2-Axis 5° 1 32002 Logic Cartridge, NO 1 34369 Cartridge, Counterbalance Valve 1 35033 Cartridge, Relief 1 32586 Repair Link, Hose/Cable Track 6 67865 Mounting Bracket Set, Hose/Cable Track 1 37809 Alarm

1 34644 Operator, Pushbutton—White 1 34836 Contact Block, NO 1 34383 Toggle Switch 1 80305 Toggle Switch 1 50077 Guard, Toggle Switch 2 40880 Controller, Drive/Steer 1 37165 Footswitch 1 36083 Service Kit, Footswitch (includes internal switch, fasteners) 1 36083-100 Pin, Grooved

4 36847-024 4 36847-034 Pin, Grooved 4 36847-053 Pin, Grooved 4 92265-001 Operator's Manual, Models 38/47AG (including diesel), 47AE Holder, Operator's Manual 1 34354 Latch

2 34527 Solenoid, Throttle (Kawasaki gasoline engine)

1 32111 Solenoid Assembly, Choke (Kawasaki gasoline engine) 1 38100 Relay (Kawasaki gasoline engine)

1 67280

NOTE: For ordering replacement decals, please refer to Decals Installation in your Operator's Manual or in the Illustrated Parts section of your CONDOR® Operation, Parts, & Maintenance Manual.

MANUAL 92323-003 4 SEPTEMBER 1994

FIGURE B—Recommended Spare Parts List CONDOR® MODEL 38AG (1 UNIT-1 YEAR OPERATION) BEGINNING WITH SERIAL NUMBER 1563

Units Equipped with Kubota D850 Diesel Engine (Option) QTY PART NUMBER

1 34999 2 80303 1 37395 1 40808 1 NNV01008 1 67947-010 1 67280

DESCRIPTION

Solenoid Module Motor Mount Solenoid, Shut-Off Solenoid, Throttle Throttle Rod End Circuit Breaker, 10 AMP Auto-Reset Relay

MANUAL 92323-003 SEPTEMBER 1994

5

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

3.

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

4.

Parts needed for a warranty repair must be purchased through the 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 orderi.e., UPS, Federal Express, or preferred truck line. When shipping Federal Express, your customer account must be given at the time of the order.

6.

Calavar classifies its orders in the following ways: Emergency Top priority. All efforts are made to ship the order the day the order is received; when possible, parts may be pulled off of the assembly line.

Standard Order to be shipped within a 48 hour period.

-

Stock Order to be shipped within 2 weeks.

7.

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

8.

All price quotations will be valid for 30 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.

6

MANUAL 92323-003 SEPTEMBER 1994

FIGURE C—How to Order Parts

CALAVAR PARTS DEPARTMENT Fax Order Fax No. 800-443-5803 iL3iccount # 'Purchaser I Sales Order #

A City State Zip IE T iR

OlPhone Fax

Name S H T Address 0 I

City State Zip P Phone Fax

Cust.Purchase Order No Order Date

Request Date Special Marks & Numbers

I Name

I C NI

'U !

(

1

Address

7

10 M

1m

Shipping Instructions

PART NUMBER

QTY. DESCRIPTION . NOTES

FOR ORDER STATUS PLEASE CHECK APPROPRIATE BOX BELOW EMERGENCY ROUTINE STOCK 7 MANUAL 92320-003 AUGUST 1994

CONDOR® MODEL 38AG —Serial Number 1563 and Following PARTS GROUPS BREAKDOWN

5

1

ITEM PART NUMBER DESCRIPTION 1 38229 2 38230 3 37314 4 37316 5 34046 -

8

Carriage Installation (see Fig. 2.1) Turret Installation (see Fig. 3 1) Lift Installation (see Fig. 4.1) Boom Installation (see Fig. 5.1) Platform Installation (see Fig. 6 1)

Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

QTY 1 1 1 1 1

FIGURE 1.1—Final Assembly

7 6 5 4 3 2

ITEM PART NUMBER

DESCRIPTION

QTY

1 Holder, Operator's Manual 1 34354 2 2 67793 Clamp, 2.75" 2 3 BOW30029 Bolt, Hex .3125" - 18UNC x 1.00" long 2 4 BOW31432 Washer, Flat .3125" ID x 6875" OD 2 5 BOW36726 Washer, Split Lock .3125" ID 2 6 BOW31202 Nut, Hex .3125" - 18UNC 1 7 92265-001 Operator's Manual-38AG, 47AG, 47AE Service Manual, Kawasaki FD620D V-Twin Engine 1 -8 66126 - Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

9

FIGURE 1.2—Decals Installation

21

15

19 2

: INGO CIIR I U. =I

38A

00

26 35

NOTE: Model 47AG Shown

10

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 1.2—Decals Installation ITEM PART NUMBER DESCRIPTION

QTY

1 Ref. 37564 Decal Kit, 38AG (does not include * items) 2 1 37290 Decal, 38A 2 2 50172 Decal, CONDOR® 3 35366 Decal, Self-Propelled CONDOR® Operating Instructions 1 2 4 21882-001 Decal, Danger: Electrocution Hazard 2 5 21882-002 Decal, Danger: This Unit Not Insulated 1 6 21882-003 Decal, Danger: Training/Safe Operation 2 7 52759 Decal, Stand Clear While Operating 1 8 37348 Decal, Lower Control Valves (see NOTE 1) 1 9 34270 Decal, Upper Control Valves 2 10 21850 Decal, Hydraulic Fluid 1 11 50070 Decal, Battery Service 12 37354 Decal, Aux. Lowering Instructions (Option; see NOTE 2) 1 1 67880 Decal, Emergency Lowering (47A) 1

13 35042 Decal, Forward (Arrow) 1

14 35043 Decal, Forward 4 15 34523 Decal, Tire Pressure-60 PSI 1 16 21849 Decal, Gas 1 15376-012* Decal, Diesel (option) 2 17 21971-002 Decal, Do Not Lift Wheels w/Boom 2 18 37784 Decal, Transportation Diagram 1 19 35656 Decal, Made in U S A —6 00" 1 20 68859 Decal, Oil Dipstick Inside 1 21 81417 Decal, Rated Work Load 1 22 36885 Decal, 500 LBS

3 23 54416 Decal, Caution: Tie-Down Ring 1 24 37419 Decal, Panic Stop/Ramping Control 39L.F. 25 58419 Tape, Orange/Red 5.00" 2 26 38176 Decal, Manual Lowering Procedure 1 27 32200 Decal, Warning Power Lines 1 28 37958-500 Decal, Rated Work Load 500 LBS 1 Nameplate, Booms Identification 29 * 1 30 38072* Decal, Lower Control Console (gas units) 1

37365* Decal, Lower Control Console (diesel units) 1

31 37969* Decal, Key Switch—Upper/Lower 1

32 38144* Decal, Upper Control Console 2 33 67812* Decal, Glowplugs (diesel models) 1 34 52735* Decal, 110 Volts (option) 1 35 15376-024* Decal, 110V Power To Platform (option) 1 36 67881 Decal, Rotation Tool Inside 37 34767* Decal, Auxiliary Lowering—Platform Control (see NOTE 2) 1 - Indicates Items Not Shown

NOTE: 1 .

Decal #37348, showing lower control valve operation, replaces decal #34502.

2. Decal #34767 is used to indicate the pushbutton control for Auxiliary Lowering on units equipped with an optional auxiliary power unit. Decal #37354 contains the instructions for auxiliary lowering on units equipped with the optional power unit.

MANUAL 92323-003 SEPTEMBER 1994

11

FIGURE 1.3—Cover Installation

3 REF

12

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 1.3—Cover Installation

20

21

19

ITEM PART NUMBER DESCRIPTION Ref. 37355 Cover Installation 1 Ref. Carriage Weldment Wear Pad, Sliding Cover 2 37113 Cover, Engine Compartment—Top 3 37115 Cover, Engine Compartment 4 37116 Door, Side (right-hand) 5 37118 Cover, Front 6 37126 7 LBL00210 Latch, Vertical Mounting 8 LBL00256 Bracket 9 BOW30000 Bolt, Hex .25" - 20UNC x .50" long 10 BOW30002 Bolt, Hex .25" - 20UNC x 75" long 11 BOW30004 Bolt, Hex .25" - 20UNC x 1.00" long 12 BOW30009 Bolt, Hex .25" - 20UNC x 2.25" long 13 BOW36725 Washer, Split Lock .25" ID 14 BOW31444 Washer, Flat .25" ID x 625" OD 15 BOW34272 Nut, Hex Lock 25" - 20UNC 16 37117 Door, Side (left-hand) 17 34527 Spring Latch Cover, Pump/Engine 18 38164 Cover, Lower Control Valves (top plate only) 19 37351 Cover, Boom 20 34394 Cover, Boom 21 34454 -22 BOW36726 Washer, Split Lock .3125" ID -23 BOW30200 Bolt, Hex .3125" - 24UNF x .50" long -24 BOW31412 Washer, Flat .3125" ID

QTY 1 1 2 1 1 1 1 2 2 16 8 8 4 30 24 12 1 2 1 1 1 1 5 5 5

- Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

13

FIGURE 2.1 —Carriage Assembly

5

7 (INSIDE COVER) 8

1

NOTE: Model 47AG Shown

14

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 2.1—Carriage Assembly

ITEM PART NUMBER DESCRIPTION Ref. 38229 1 38159 2 34213 3 38086 -4 38081 5 34388 6 37573 7 38079 8 38205

Carriage Assembly Carriage Weldment Steering Installation (see Fig. 2.2) Drive Installation (see Fig. 2.3) Hydraulic Installation (see Fig. 2.6 Fuel Tank & Battery Installation (see Fig. 2.5) Wheel Installation (see Fig. 2.4) Engine Installation (see Fig. 2.12) Tube, Fuel

QTY 1 1 1 1 1 1 1 1 1

- Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

15

11.1.1141

CD

REF. CARRIAGE WELDMENT

.

20 .

12

,

/

12 13

FIGURE 2 .2 —Steeri n g I nstall ati on

19

FIGURE 2.2—Steering Installation ITEM PART NUMBER DESCRIPTION

QTY

Ref. 34213 Steering Installation 1 34877 Knuckle, Left-Hand 2 34876 Knuckle, Right-Hand 3 34350 Tie Rod, 43.50" 4 51170 Cylinder, Steering (Hy Power; Seal Kit #91109) 4A 51170-100 Clevis, Threaded (see item 20 for pin) 5 37009 Pin Weldment, Steering 6 34145 Bushing, Self-Lube 7 34336 Bearing, Thrust 8 34342 Bushing, Self-Lube 9 34341 Rod End, Male 10 36924 Washer, Flat 11 BOW36475 Bolt, Hex .75" - 16UNF x 2.75" long 12 BOW36066 Bolt, Hex .375" - 16UNC x 4.00" long 13 36847-073 Pin, Grooved .25" x 2.50" 14 BOW32288 Nut, Jam .75" - 16UNF 15 BOW34274 Nut, Hex Lock .375" - 16UNC 16 BOW36720 Washer, Flat 1 00" ID 17 02793 Straight, MJ04 MPO6 18 BOW34288-1 Nut, Hex Lock (Flex) .75" - 16UNF 19 BOW34991 Pin, Spiro! .25" x 2.00" 20 51170-101 Pin, Clevis for Steering Cylinder #51170

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

- Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

17

FIGURE 2.3—Drive Installation (Two-Wheel Drive)

18

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 2.3—Drive Installation (Two-Wheel Drive)

ITEM PART NUMBER

DESCRIPTION

QTY

Ref. 38086 Drive Installation (Two-Wheel Drive) 1 Torque Hub, 18.25:1 Ratio (see Fig. 2.3A) 2 1 35317 Vent, 5 PSI .25" NPT Relief (used on torque hubs) 2 2 58425 2 Brake, B-Mount Modular (see Fig. 2.3C) 3 34460 2 4 34883 0-Ring 1 Motor, Hydraulic 5.4 cu. in. (see Fig. 2.3B) 5 38085 12 6 BOW31331 Washer, Split Lock .625" ID 12 7 BOW36149 Bolt, Hex .625" - 11UNC x 2.00" long 4 8 BOW36729 Washer, Split Lock 50" ID 9 BOW33675 Bolt, Socket Head .50" - 13UNC x 4.50" long 4 4 10 BOW31413 Washer, Flat .375" ID x 1.00" OD 4 11 BOW36727 Washer, Split Lock .375" ID 4 12 BOW36054 Bolt, Hex .375" - 16UNC x 1.00" long 4 Straight, MJO8 M010 13 00560 Elbow, 90° MJ04 M004 (used only on left side) 2 14 02236 - Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

19

FIGURE 2.3A—Torque Hub Assembly

3

5

25 32 33

21 33 45

20

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 2.3A—Torque Hub Assembly ITEM PART NUMBER DESCRIPTION

QTY

2 Torque Hub, 18.25:1 Ratio -1 35317 1

2 EQE01037 Coupling 1 -3 EQE01069 Assembly, Hub-Spindle (includes items 4-14) 1

—Spindle 4 EQE01070 1

5 EQE01071 —Seal 1

—Cone Bearing 6 EQE01073 1

—Cup Bearing 7 EQE01072 1 —Hub

8 EQE01074 9

—Stud 9 EQE01014 2 —Pipe Plug

10 EQE01013 1

—Cup Bearing 11 EQE01008 1 12 EQE01009 —Cone Bearing 1

—Spacer 13 EQE01011 1

—Retaining Ring 14 EQE01012 1

Internal Gear 15 EQE01015 1 Assembly, Input Shaft (includes items 17-20)

16 E QE01055 1

—Input Shaft 17 EQE01075 2

—Spacer 18 EQE01020 1

—Spring

19 EQE01032 1 20 EQE01031 —Retaining Ring 2 21 EQE01036 Thrust Washer 1 22 EQE01057 Thrust Spacer 1 23 EQE01054 Input Gear 1 -24 EQE01016 Carrier Assembly (includes items 25-31) 1 25 EQE01017 —Carrier 3

—Planet Shaft

26 EQE01021 3 27 EQE01023 —Roll Pin 6 28 EQE01018 —Thrust Washer 3 29 EQE01022 —Cluster Gear 96 -30 EQE01019 —Roller, Needle 3 31 EQE01020 —Spacer 1 32 EQE01053 Thrust Spacer 2 33 EQE02300 0-Ring 1

Ring Gear

34 EQE01024 1 -35 EQE01025 Cover Assembly (includes items 36-46) 12 —Bolt, Hex

36 EQE01590 4 37 EQE02310 —Bolt, Shoulder 16

—Washer, Flat

38 EQE01038 1 39 EQE02000 —Cover, Hub 1 40 EQE01632 —0-Ring 1 41 EQE01026 —Cap, Cover 1 42 EQE01628 —0-Ring 1 43 EQE01028 —Rod, Disconnect 1 44 EQE01027 —Cap, Disconnect 45 BOW39002 —Bolt, Hex .25" - 20UNC x .75" long (Grade 8) 4 1 46 EQE01595 —Pipe Plug .

- Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

21

FIGURE 2.3B—Drive Motor Assembly

ITEM PART NUMBER DESCRIPTION

QTY

Hydraulic Motor, 5.4 cu in. displacement 2 (2WD) Ref. 38085 1 1 (see item 28) Seal, Dust 1 2 (see item 28) Ring, Wire 1 3 (see item 28) Shim, Back-Up 1 4 (see item 28) Seal, High-Pressure 1 5 (see item 28) Shim, Back-Up 1 6 (see item 28) Seal, Teflon 1 7 (see item 28) Seal, Shaft 4 8 (see item 28) Seal, Body 1 9 (see item 28) Seal, Commutator 1 10 (see item 28) Seal, 0-Ring 1 11 (see item 28) Seal, Teflon 1 12 38085-001 Carrier, Seal 2 13 38085-002 Washer, Thrust 2 14 38085-003 Bearing, Thrust 2 15 38085-004 Bearing, Shaft 1 16 38085-005 Plate, Wear 1 17 38085-006 Manifold 1 18 38085-007 Commutator Assembly 1 19 38085-008 Piston, Endcover 1 20 38085-009 Spring, Piston 1 21 38085-010 Endcover, 875"-14 Rear Ports 1 Nameplate, HB-05565070 Identification

22 4 23 B0W36065 Bolt, Hex .375" - 24UNF x 3.75" long 1 24 38085-011 Housing, SAE 'A'-Style, 2-Bolt Flange 1 25 38085-012 Link, Drive 1 26 38085-013 Rotor Assembly 1 27 38085-014 Shaft, 13-Tooth Spline 28 38085-015 Seal Kit, #38085 Hydraulic Motor (includes items 1-11) 1 - Indicates Items Not Shown 22

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 2.3C—Brake Assembly

ITEM PART NUMBER

DESCRIPTION

-1 34460 Brake 2 LHB01002 Bearing 3 LHB01003 Bolt, Flat Head 4 LHB01004 Cover Plate 5 LHB01005 Shaft 6 LHB01006 Outer Spline 7 LHB01007 Bolt, Socket Head Shoulder 8 LHB01008 Disc, Primary 9 LHB01009 Disc, Rotor 10 LHB01010 Disc, Stator 11 LHB01011 Bolt, Socket Head 12 LHB01012 Plate, Spring 13 LHB01013 Spring, Red 14 LHB01014 Spring, Blue 15 LHB01015 Piston 16 LHB01016 Plate, Pressure 17 LHB01017 Screw, Bleeder -18 93156 Seal Kit (includes items 19-26)

—Retaining Ring 19

—Snap Ring 20

—Seal, Oil 21

—Gasket, Case 22

—Ring, Back-Up 23

—0-Ring 24

—Ring, Back-Up 25

—0-Ring 26

QTY

2 (2WD) 1 2 1 1 4 1 2 1 2 1 2 4 1 1 1 1 1 1 1 2 1 1 1 1

- Indicates Items Not Shown MANUAL 92323-003 SEPTEMBER 1994

23

FIGURE 2.4—Wheels Installation

ITEM PART NUMBER

DESCRIPTION

QTY

1 Wheels Installation (2WD) 2

Tire & Wheel Assembly, Drive includes qty two (2) item 7 tire, qty two (2) item 5 rim 2 Tire & Wheel Assembly, Steer 3 34545 Includes qty two (2) item 7 tire, qty two (2) item 6 wheel 4 a ^ t -104,4 Nut, Wheel •50" - 20UNF (6/steer hub, 9/drive hub) 30 2 Drive Wheel 5 34332 2

Steer Wheel 6 34015 4 7 34531

Tire, 7.50 R16-60 PSI Steer Hub (each includes shown qty of items 11-17) 2 8 34017 2 Washer, Keyed 9 34749 alb 2 Nut, Castle

10 345 1 ....: .::‘,..

1

Grease Seal 11 91114 1 Inner Cone Bearing 12 91113 1

Inner Cup Bearing 13 91112 1 14 BVQ01005 Hub 1 Outer Bearing Cup

15 91024 1 Outer Bearing Cone

16 91023 1 17 BVQ01004 Dust Cap -1 34217 2 34536

-

-

Indicates Items Not Shown

24

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 2.5—Fuel Tank & Battery Installation

14

5

ITEM PART NUMBER DESCRIPTION

QTY

1 Fuel Tank Installation Ref. 34388 1 Fuel Tank, 12 GAL 1 51306 1 51306-001 Cap Replacement 1 51306-002 Gauge, Replacement Bracket Set, Fuel Tank Mounting 1 2 51307 3 BOW9749 Hose, Fuel Line .25" ID (from tank to fuel tube) 8L.F. 1 4 BOW24110 Hose Clamp 1 5 67624 Hose End 1 Straight, MJ04 MPO4 6 01160 7 Counterweight, Carriage (Right-Hand) NSS* Counterweight, Carriage (Left-Hand) NSS* 8 4 9 BOW30027 Bolt, Hex .3125" - 18UNC x .75" long 4 10 BOW36726 Washer, Split Lock .3125" ID Tube, Fuel Line (from fuel hose to engine compartment) 1 -11 38205 2 12 BOW31201 Nut, Hex .25" - 20UNC 2 13 BOW36725 Washer, Split Lock .25" ID Bracket, Battery Hold-Down 8.25" 1 14 37722 15 BOW32488 Threaded Rod, .25" - 20UNC x 12.00" (cut to 9") 2 2 16 BOW36780 Nut, Hex Lock .25" - 20UNC 1 17 121-96822-00 Battery, 12V DC - Indicates Items Not Shown *NSS

—

Not Sold Separately MANUAL 92323-003 SEPTEMBER 1994

25

FIGURE 2.6

—

Carriage Hydraulic Installation

32

17

28 31 29

10 30 13

AUX. LOWERING POWER UNIT (OPTION) SEE FIG. 7.2

26

5 14 (x2)

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 2.6— Carriage Hydraulic Installation

ITEM PART NUMBER DESCRIPTION

QTY

1 Carriage Hydraulic Installation Ref. 38081 1 Lift/Steer Manifold Assembly (see fig. 2.8) 1 36768 Drive Valve Assembly, Series/Parallel (see Fig. 2.9) 1 2 36707 1 Hydraulic Tank Assembly (see Fig. 2.7) -3 34219 2 Tube Assembly -4 38202 1

Spacer Plate, Pilot-Operated Check Valve (item 14) 5 38203 4 Straight, FJO8 MJ06 -6 00388 7 [Not Used] 1 Valve, Solenoid 8 37171 1 Valve, Check/Choke (see Fig. 2 11) 9 36922 Drive Valve Assembly, Proportional (see Fig. 2.10) 1 10 38148 1 Elbow, 90° Modified .375" NPT -1 1 37757 1 Straight, MJ12 M010 -12 00218 1

Valve, 2-Position/3-Way (see Fig. 2 11) 13 58079 2 Valve, Pilot-Operated Check 14 38186 1 Straight, MJ06 M008 -15 02473 1 Elbow, 45° MJ06 FJO6 -16 02319 6

Assembly, Wire Harness Connector 17 35052 2

Elbow, 90° MJ06 M008 -18 02671 2 Elbow, 90° MJ04 M006 -19 02857 4 Tee, MJ08 FJO8 MJ08 -20 00326 2 Straight, FJO8 MJ04 -21 00348 1 Elbow, 90° MJ04 FJO4 -22 02219 2

-23 BOW30037 Bolt, Hex .3125" - 18UNC x 3.00" long 2 -24 BOW36702 Washer, Flat .3125" ID 2

-25 BOW30010 Bolt, Hex 25" - 20UNC x 2.50" long 2

-26 BOW36701 Washer, Flat .25" ID 8L.F. -27 67295-019 Cable, 2 Conductor/16AWG Type SO 1 Accumulator 28 37422 1 Relief Valve 29 37421 1 Shuttle Valve 30 36841

1 31 67169-005 Clamp, 2.25u 1

Filter, Return (Replacement element #67408) 32 33430 1

Elbow, 90° MJ10 MP12 -33 02674 1

Elbow, 90° MJ12 MP12 -34 02675 - Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

27

FIGURE 2.7—Hydraulic Tank Assembly

ITEM PART NUMBER DESCRIPTION

Hydraulic Tank Assembly Ref. 34219 Filler Breather 1 37808 Gauge, Fluid Level 2 52049 Strainer, Tank 3 34209 4 BOW13402 Nipple, 1.00" NPT Ball Valve, Low Pressure 5 34212 Tee, MJ16 MP16 MJ16 6 02400 Straight, FJ16 MJ06 7 04019 8 BOW13372 Plug, 50" NPT 9 BOW13400 Nipple, 50" NPT Coupling, Quick Disconnect Male .50" 10 67051 Dust Cover, Quick Disconnect 11 67053 - Indicates Items Not Shown

28

MANUAL 92323-003 SEPTEMBER 1994

QTY 1 1 1 1 1 1 1 1 1 1 1 1

FIGURE 2.8—Lift/Steer Manifold Assembly

ITEM PART NUMBER DESCRIPTION

QTY

-1 36768 Assembly, Manifold and Fittings 1 2 36720 Lift/Steer Manifold Assembly (includes items 3-10) 1 —Cartridge, Relief Valve 1 3 51616 4 C0001007 --Seal Kit 1 5 34784 —Valve, 3-Position/4-Way DO1 2 6 BOW33596 —Capscrew, Socket Head #10 - 24UNF x 2.00' long 8 —Manifold, Lift/Steer 1 7 36721 8 BOW33627-1 —Capscrew, Socket Head .3125" - 18UNC x 3.00" long 2 —Connector, Wire Harness 9 35052 4 10 [Not Used] 11 02473 Straight, MJ06 M008 5 12 04012 Nut, Cap #8 1 1 13 00480 Plug, M008 2 14 04134 Straight, MJ04 M008 Tee, MJ06 MJ06 FJO6 2 15 00353 16 02298 1 Elbow, 90° MJ06 FJO6 1 17 04148 Straight, FJO6 MJ04 - Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

29

FIGURE 2.9—Series/Parallel Drive Valve Assembly

ITEM PART NUMBER DESCRIPTION

CITY

-1

Assembly, Series/Parallel Drive Manifold 2 00456 Straight, MJ04 M006 (P1) Plug, M006 3 02447 4 02664 Elbow, 90° MJ08 M012 (Al A2, B1, B2) Straight, MJ08 M012 (A3, B3) 5 00303 6 36707 Drive Manifold (includes items 7-14) 7 34967 —Body, Manifold 8 36287 —Cartridge, Logic Element NC 52 9 36285 —Cartridge, Logic Element NO 52 10 RTM01009 --Seal, Logic Element 11 36286 —Cartridge, Counterbalance Valve 12 RTM01011 --Seal, Counterbalance Valve 13 67401 —Cartridge, Flow Divider Combiner 14 COQ01001 --Seal, Flow Divider Combiner 15 00326 Tee, MJ08 FJO8 MJ08 ........ .............................. .............

16 00388 Straight, FJO8 MJ06 - Indicates Items Not Shown 30

MANUAL 92323-003 SEPTEMBER 1994

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

FIGURE 2.10—Proportional Drive Valve Assembly

ITEM PART NUMBER DESCRIPTION Ref. 38148 1 38132 2 00353 3 04017 4 00560 5 00327 6 00222 7 00417 8 02393

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

Assembly, Proportional Drive Valve Drive Valve, 18 GPM Tee, MJ06 MJ06 FJO6 Straight, FJ10 MJ06 Straight, MJ08 M010 Tee, MJ10 FJ10 MJ10 Straight, MJ10 M010 Plug, M004 Plug, M010

QTY 1 1 1 2 2 2 2 1 1

Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

31

FIGURE 2.11 —Speed Control (2-Position/3-Way) Valve Assembly

32

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 2.11—Speed Control (2-Position/3-Way) Valve Assembly

ITEM PART NUMBER DESCRIPTION -1 2 02793 3 02458 4 04537 5 36922 6 58079 7 35031 8 34374 9

QTY

Assembly, Speed Control Valve (2-Position/3-Way) 1 Straight, MJ04 MPO6 3 Tee, MPO4 FP04 FP04 1 Straight, MPO4 FJO4 1 Valve, Check/Choke 1 Valve, Control 1 —Cartridge, 2-Position/3-Way 1 —Coil, 12V DC 1 —Valve Body NSS*

- Indicates Items Not Shown *NSS

—

Not Sold Separately

MANUAL 92323-003 SEPTEMBER 1994

33

FIGURE 2.12—Kawasaki Gasoline Engine Installation

34

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 2.12—Kawasaki Gasoline Engine Installation ITEM PART NUMBER DESCRIPTION

QTY

1 Kawasaki Gasoline Engine Installation Ref. 38079 1 Engine Assembly -1 38082 — Kawasaki Gasoline Engine Modified (with heatshield) 1 2 38169 1 --Engine, Kawasaki FD620D 2A 38099 1 —Plate, Engine Mounting 3 38033 1 —Adapter, Pump Mounting (Modified) 4 38224 4 -5 BOW36056 —Bolt, Hex 375" - 16UNC x 1 50" long 4 -6 BOW31327 —Washer, Split Lock 375" ID 1 —Pump Triplex 7 38084 1 —Coupling Assembly 8 38118 2 -9 BOW46055 —Bolt Hex 375" - 16UNC x 1 25" long 2 -10 BOW31327 —Washer, Split Lock 375" ID 1 —Tailpipe -11 38102 1 -12 67169-001 —Clamp, Muffler 1 25" 1 —Choke Assembly Remote-Mount -13 38100 1 —Solenoid Throttle 12V DC 14 32111 1 —Support Bracket Throttle Solenoid 4 00" 15 38103 1 —Throttle Link Bellcrank-Throttle -16 38104 1 —Throttle Link Bellcrank-Solenoid 17 38105 1 —Bellcrank -18 38106 1 -19 BOW2120 —Clevis Pin, 25" x 75" long 1 -20 BOW2023 —Clevis Steel for 25" diameter rod 1 -21 BOW38217 —Cotter Pin 09375" x 1 00" long 2 -22 BOW30000 —Bolt Hex 25" - 20UNC x 50" long 2 -23 BOW31201 —Nut Hex 25" - 20UNC 2 -24 BOW31325 ......•• ...... —Washer, Split Lock .25" ID 3 -25 BOW31430 —Washer Flat #10 ID 2 -26 BOW32281 —Nut Hex Jam 25" - 28UNF -27 BOW31 146 —Screw, Slotted Round Head #10 - 32UNF x 1.00" long •••• 2 2 -28 BOW31829 —Screw, Self-Tapping 1

-29 BOW31233 —Nut Hex Keps #10 - 32UNF 4 Engine Mount -30 37987 -31 BOW39058 Bolt Hex 375" - 16UNC x 2 00" long (Grade 8) 4 4 -32 BOW31327 Washer, Split Lock 375" ID 4 -33 BOW31413 Washer, Flat 375" ID x 1 00" OD 1 34 67157-003 Oil Pressure Switch 4 PSI - Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

35

FIGURE 3.1 —Turret Installation

36

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 3.1—Turret Installation

ITEM PART NUMBER

Ref. 38230 1 37289 2 38220 3 34812 4 38080 5 34521 6 37783 -7 BOW36836

DESCRIPTION

QTY

1 Turret Installation 1 —Turret Weidment 1 —Rotation Installation (see Fig. 3.2) 1 —Turret Hydraulic Installation (see Fig. 3.5) 1 —Turret Electrical Installation (see Fig. 3.6) 1 —Pad, Arm Rest 1 —Boom Rest, 38A —Bolt, Socket Flathead 375" - 16UNC x 1 50" long 2

- Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

. 37

FIGURE 3.2 Rotation Installation

38

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 3.2 Rotation Installation ITEM PART NUMBER DESCRIPTION

QTY

Rotation Installation, 38AG 1 Ref. 38220 Ring Gear 1 1 34033 1 Rotation Gearbox (see Fig. 3.3 for assembly) 2 34034 Hydraulic Motor, Turret Rotation (see Fig. 3.4) 1 3 32762 Assembly Cross-Port Relief Valve (id. items 5, 6) 1 4 32763 1 5 RTM01004 —Valve Body 2

—Cartridge Relief Valve 1100 PSI 6 67486 24

Bolt, Hex .625" 11UNC x 3.50" long 7 BOW36155 18 8 BOW36151 Bolt, Hex .625" - 11UNC x 2.50" long 4 9 BOW36717 Washer, Flat .625" ID x 1 31" OD 46 10 BOW36717-HD Washer, Flat .625" ID (Hardened) 4 11 BOW36726 Washer, Split Lock .3125" ID 4 12 BOW36035 Bolt, Hex .3125" - 18UNC x 2.50" long 2 13 BOW36729 Washer, Split Lock .50" ID 2 14 BOW36105 Bolt, Hex .50" - 13UNC x 1.25" long 1 15 BOW32277 Nut, Jam .625" - 11UNC 16 BOW36185 Bolt, Square Head .625" - 11UNC x 2.75' long 1 2 17 BOW7588 Lube Fitting, 90° .125" NPT 2 Elbow, 90° MJ06 FJO6 18 02298 2 19 34966-401 Orifice Fitting Assembly - Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

39

FIGURE 3.3—Rotation Gearbox Assembly

15

ITEM PART NUMBER DESCRIPTION

-1 34034 2 93098 3 BOW36081 4 93097 5 93096 6 93095 7 93094 8 93099 9 BOW36080 10 93100 11 12

13

14

15

Rotation Gearbox —Retainer, Motor Shaft —Bolt —Bearing Cup —Bearing Cone —Worm Shaft —Housing, Cast —Retainer, Hex End Shaft —Bolt —Seal Kit (includes items 1 1-15) --Seal, Bearing --Seal, Shaft --Shim, Bearing .003" --Shim, Bearing .007" --Shim, Bearing .020"

- Indicates Items Not Shown

40

MANUAL 92323-003 SEPTEMBER 1994

QTY

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

FIGURE 3.4—Hydraulic Motor, Turret Rotation

11

ITEM

PART NUMBER

-1 32762 -2 33087 3 4 5 6 7 8 9 VGH01002 10 93114 11 93115 12 93113 13 CLK00011-004

14 VGH01006 15 93112 16 93111 17 93109 18 VGH01014 19 93110 20 93108 21 93107

17

DESCRIPTION

Hydraulic Motor, Turret Rotation Seal Kit (includes items 3-8) —Dust Seal —Wire Snap Ring —Seal Spacer —Shim, Back-Up —Seal, Housing —Seal, Body Thrust Washer Thrust Bearing Housing, 2-Port Manifold Shaft Key, Shaft Plug, Cooling Link, Drive Plate, Wear Pin, Drive Link Ball Rotor Set Endcover Bolt, Hex (torque to 50 ft -Ibs )

QTY 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1

- Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

41

FIGURE 3.5—Turret Hydraulic Installation

42

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 3.5—Turret Hydraulic Installation

ITEM PART NUMBER DESCRIPTION

QTY

Turret Hydraulic Installation -1 34812 1 2 [Not Used] 3 [Not Used] 4 [Not Used] 5 [Not Used] 6 [Not Used] 7 34221 Lower Control Valve Assembly (includes items 1 1-20) 1 2 8 BOW31201 Nut, Hex .25" - 20UNC 2 9 BOW36725 Washer, Split Lock .25" ID 2 10 BOW31444 Washer, Flat .25" ID x .625" OD 1 11 ENR01020 —Banking Kit 1 12 ENR01008 —Inlet Section ("PRESS") 1 13 ENR01023 —Load Check Kit 2 14 ENR01016 --Ball, Load Check 2 15 ENR01017 --Retainer, Load Check 4 16 ENR01019 —Valve Section 1 17 ENR01009 —Outlet Section ("TANK") 1 —Handle Kit, Lower Control Valve 18 34890 4 19 ENR01002 --Handle 4 20 ENR01022 --Knob 2 Tee, MJ06 FJO6 FJO6 21 00488 1 Straight 22 04038 1 Cap Nut 23 04012 4 Straight, MJ06 M006 (long) 24 04563 8 Elbow, 90° MJ06 FJO6 25 02298 4 Straight, MPO6 FJO6 26 04100 5 Elbow, 90° MJ06 M006 27 02662 4 Shuttle Valve, .375" NPT 28 36841 7 Straight, MJ06 M006 29 02448 1 Flow Control Valve 30 52661 1 Elbow, 90° M006 MPO4 31 04151 1 Elbow, 90° 32 04141 1 Plug, M006 33 02447 - Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

43

FIGURE 3.5

—

Turret Hydraulic Installation

23 31 INLET (PRESS)

22 21

25

25

BOOM LIFT/ BOOM EXTENSION

TURRET ROTATION

44

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 3.5—Turret Hydraulic Installation

25

22

33

ITEM PART NUMBER DESCRIPTION

QTY

1 Turret Hydraulic Installation -1 34812 2 [Not Used] 3 [Not Used] 4 [Not Used] 5 [Not Used] 6 [Not Used] Lower Control Valve Assembly (includes items 1 1-20) 1 7 34221 2 8 BOW31201 Nut, Hex .25" - 20UNC 2 9 BOW36725 Washer, Split Lock 25" ID 2 10 BOW31444 Washer, Flat 25" ID x .625" OD 1 11 ENR01020 —Banking Kit 1 12 ENR01008 —Inlet Section ("PRESS") 1 13 ENR01023 —Load Check Kit 2 14 ENR01016 —Ball, Load Check 2 15 ENR01017 --Retainer, Load Check 4 16 ENR01019 —Valve Section 1 17 ENR01009 —Outlet Section ("TANK") 1 —Handle Kit, Lower Control Valve 18 34890 4 19 ENR01002 --Handle 4 20 ENR01022 --Knob 2 Tee, MJ06 FJO6 FJO6 21 00488 1 Straight 22 04038 1 Cap Nut 23 04012 4 Straight, MJ06 M006 (long) 24 04563 8 Elbow, 90° MJ06 FJO6 25 02298 4 Straight, MPO6 FJO6 26 04100 5 Elbow, 90° MJ06 M006 27 02662 4 Shuttle Valve, .375" NPT 28 36841 7 Straight, MJ06 M006 29 02448 1 Flow Control Valve 30 52661 1 Elbow, 90° M006 MPO4 31 04151 1 Elbow, 90° 32 04141 1 Plug, M006 33 02447 - Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

45

FIGURE 3.6 —Turret Electrical Installation

6 (7-14)

46

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 3.6—Turret Electrical Installation ITEM

PART NUMBER DESCRIPTION

QTY

38080 1 Turret Electrical Installation Ref. 1

Slope Sensor, 2-Axis

1 32002 1 Lower Control Box Assembly 2 38071 4 BOW31444 Washer, Flat .25" ID x .625" OD -3

2 BOW36725 ......... Washer, Split Lock .25" ID -4

4 -5 BOW31201 Nut, Hex .25" - 20UNC 1 Limit Switch Assembly (includes items 7-14) 6 34509 1 Body, Limit Switch 7 51036 2 8 BOW31145 Screw, Round Head 2 9 BOW31323 Washer, Split Lock 2 10 BOW31233 Nut, Hex Keps 1 Offset Head, Limit Switch 11 51037 1 Adjustable Arm, Limit Switch 12 51039 1 13 67114-002 Strain Relief 1 Harness, Limit Switch 14 34982 1 -15 67123-001 Seal, Electrical Connector 50" 1 -16 BOW17351 Nut, Conduit Connector .50" Electrical Box Assembly, Kawasaki Engine (see Fig. 3.8) 1 17 38075 2 Bracket, Electrical Box 37553 18 - Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

47

FIGURE 3.7 - Lower Control Box Assembly

0•

SEE NOTE 3

0 CO e 00 0 4 PL

SEE NOTE 2

ct.

0 < (,)

CID ,r)

co

5

0

tairmailasaaaIN= ma

•

JOIDICIIIL AMINOC+211 rg+) Cfr L311 • 115.3 531'

parlim c+ 7iionfir -moor

/

411

11111kk k IL IS wa

i

iminu.... 1112 Or g+) • 141 itig+) g gA NI rs±) llair oo 11;+5 E3 Op

SEE NOTE 1

00 00 G O

NOTES: 1.

2.

3.

4.

48

CIRCUITS 5A, 5C AND 22/23 (INSIDE BOX) ARE TO BE 12 GAUGE (ITEM 16).

CABLE SHOWN IS FOR REFERENCE ONLY. • CONNECTORS AND DECALS ARE NOT ILLUSTRATED. SEE ELECTRICAL SCHEMATIC #38069.

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 3.7—Lower Control Box Assembly ITEM PART NUMBER DESCRIPTION

QTY

Lower Control Box Assembly Ref. 38071 1 38001 Control Box Key Switch, 3-Position 2 52671 Operator, Push-Twist (Emergency Stop) 3 52983 Operator, Pushbutton—Black 4 52669 Operator, Pushbutton—Yellow 5 69145 Operator, Pushbutton—Green 6 69146 Contact Block, 1 NO w/Base 7 52672 Contact Block, 2 NO w/Base 8 52029 Contact Block, 1 NO 9 34383 10 34552-012 Terminal Strip 11 BOW31234 Screw, Round Head #10 - 24UNC x 375" long 12 BOW31134 Nut, #10 - 24UNC 13 67114-009 Strain Relief 14 67124-002 Nut, Conduit Connector 15 67123-002 Seal, Electrical Connector Wire, 12 GA 16 58251 Wire, 16 GA 17 58292 Operator, Pushbutton—White 18 34836 Contact Block, 1 NC w/Base 19 51914 Decal Lower Control Box Electrical Tags 20 38073 Decal Upper/Lower Selector Switch 21 37969 Decal, Lower Controls 22 38072

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

- Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

49

FIGURE 3.8—Electrical Box Assembly, Kawasaki Engine

4

PL

0 CIO • 0 MB 2 P 2 PL 0 0 0

fre

003

PL

Oe

00

2 PL

0

TO UGH TS n ON

SEE NOTE 3

41116

Avi

Firlo

WOBBULATOR

REGULATOR (ID

11 S NEC (-) 4 SPK5 (ERN 5 5.. TOW .05 (Oa)

0 0

lc, TS

•

START LOCKOU T

IWG

4)

111,14

LOCKOUT DELAY

a)

12 M. X/27

000

VOLT METER OPTION

HOUR METER

St 26/27

E5

2 PL

12 AWG

*12M1 12 H. :LA

0

0

0

0 2 pt. 0

3 PL

00

6

0

PL

NOTES: (Revision 'C' Shown Above) 1.

2.

3.

4.

5.

6.

7.

50

REFER TO WIRING DIAGRAM #38076 AND TO ELECTRICAL SCHEMATIC #38069.

USE 12 GAUGE WIRE WHERE SHOWN. ALL OTHER WIRE TO BE 16 GAUGE. WIRE BETWEEN WOBBULATOR AND SPEAKER IS SUPPLIED WITH SPEAKER. ITEMS 16, 17, 52, 53, 54, 62, 63, 64, 72, 73, AND 74 NOT ILLUSTRATED. ITEMS 31 AND FOLLOWING ARE LISTED FOR REFERENCE ONLY. ITEM 41 IS A COMPONENT OF THE 110-VOLT LINE TO PLATFORM OPTION. ITEMS 51-57 ARE COMPONENTS OF THE TRAVEL/MOTION ALARM OPTIONS. (TRAVEL ALARM IS POWERED BY CIRCUIT 62; MOTION ALARM IS POWERED

BY CIRCUIT 8A) ITEMS 61-67 ARE COMPONENTS OF THE SIGNAL HORN OPTION. ITEMS 71-74 ARE COMPONENTS OF THE HEAD & TAIL LIGHTS OPTION. ITEM 81 IS A COMPONENT OF THE VOLTMETER OPTION. VOLTAGE REGULATOR (ITEM 31) IS SUPPLIED WITH KAWASAKI ENGINE. WIRES SHOWN OUT OF PLACE FOR CLARITY. .

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 3.8—Electrical Box Assembly, Kawasaki Engine ITEM PART NUMBER DESCRIPTION

QTY

38075 Electrical Box Assembly, Kawasaki Engine 1 Ref. Relay Box, 47AG-Kawasaki 1 1 38087 Circuit Breaker, 15 AMP 2 29163 2 Relay, 12V DC 3 67280 2 4 [Not Used] Solenoid, Starter 12V DC 1 5 21342 Relay, 12V DC 1 6 80045 3 7 34552-016 Terminal Strip 8 BOW31 124 Screw, Slotted Round Head #6 - 32UNF x 50" long 8 8 9 BOW31231 Nut, Keps #6 - 32UNF 10 BOW33886 Screw, Slotted Pan Head .25" - 2OUNC x 50" long 4 1 1 BOW33888 Screw, Slotted Pan Head .25" - 2OUNC x 1 00" long 2 12 BOW31288 Nut, Keps .25" - 2OUNC 6 Jumper 6 13 34542 Wire, 12 GA—White 4L.F. 14 58251 20L.F. Wire, 16 GA—White 15 58292 Decal, Circuit Breaker 1 16 38092 1 Decals, J-Box 17 38093 1 Relay 18 80024 1 Socket, 8-Pin Octal 19 80049 20 BOW31127 Screw, Slotted Round Head #6 - 32UNF x 1 00" long 2 2 21 BOW31231 Nut, Keps #6 - 32UNF 1 Hour Meter 22 80027 23-30 [Not Used]

Voltage Regulator (see NOTE 6, left) NSS* 31 [Not Used]

32-40

Circuit Breaker, 15 AMP (see Note 5, left) 2 41 29163 42-50 [Not Used]

Wobbulator and Speaker (see Note 5, left) 1 51 80188 1 52 67114-001 Strain Relief, 50" NPT .1251.25" 1 53 67123-001 Seal, Electrical Connector .50" 1 54 BOW17350 Nut, Conduit Connector .50" 55 BOW31148 Screw, Slotted Pan Head #10 - 32UNF x 1 75" long 4 56 BOW31144 Screw, Slotted Pan Head #10 - 32UNF x .50" long 3 7 57 BOW31233 Nut, Keps #10 - 32UNF [Not Used] 58-60

1 Horn, Auto-Type 61 80335 1 62 67114-001 Strain Relief, .50" NPT .125"/.25" 1 63 67123-001 Seal, Electrical Connector .50" 1 64 BOW17350 Nut, Conduit Connector .50" 65 BOW31144 Screw, Slotted Pan Head #10 - 32UNF x 1 75" long 1 1 66 BOW31233 Nut, Keps #10 - 32UNF 2L.F. 67 67295-035 Cable, 2 Conductor/16 GA (bulk) 68-70 [Not Used] 1 Relay 71 67280 1 72 67114-001 Strain Relief, .50" NPT .1251.25" Seal, Electrical Connector .50" 1 73 67123-001

1 74 BOW17350 Nut, Conduit Connector .50" [Not Used]

75-80

1 Voltmeter 81 67830 - Indicates Items Not Shown *NSS—Not Sold Separately MANUAL 92323-003 SEPTEMBER 1994

51

FIGURE 4.1—Lift Installation

_5

ITEM PART NUMBER DESCRIPTION

QTY

1 Lift Installation Ref. 37314 1

Lift Hydraulic Installation (includes items 2-5) 1 37561 1

—Arm Lift Cylinder Assembly (see Fig. 4.2) 2 37002 — —Lift Cylinder (Texas Hydraulics; Seal Kit #36870-100) ...

1 3 36870 1 — —Manifold Assembly (see Fig. 4.2) 4 37485 1

—Arm Hose Kit (see Fig. 5.9)

5 38131 1

Boom Pivot Weldment •

6 37274 1 Lift Arm Weldment 7 37284 4 Bushing, Self-Lube 8 34145 2 Leveling Arm Weldment 9 37318 4

Bushing, Self-Lube

10 34672 1 Pin Weldment 11 36930 2

Washer, Flat 1.50" ID x 3.00" OD

12 BOW36724 1

Washer, Flat 13 36924 1 14 36847-073 Pin, Grooved .25" x 2.50" long 1

Pin Weldment 15 37400 2

Bolt, Hex .375" 16UNC x 75" long

16 BOW36052 2

Washer, Split Lock .375" ID

17 BOW31327 - Indicates Items Not Shown

52

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 4.2—Arm Lift Cylinder Assembly

ITEM PART NUMBER DESCRIPTION

QTY

Ref. 37002 Arm Lift Cylinder Assembly (does not include 6, 7, 8) 1 Lift Cylinder (Texas Hydraulics; Seal Kit #36870-100) 1 1 36870 Manifold Assembly 1 2 37485 —Manifold 1 3 37484 —Cartridge, Counterbalance 1 4 35033 —Needle Valve 1 5 54623 2 6 BOW9977 0-Ring, .375" ID x .50" OD 2 7 BOW31326 Washer, Split Lock .3125" ID 2 8 BOW30207 Bolt, Hex .3125" - 24UNF x 1.75" long 4 Bushing, Self-Lube (included with cylinder) 9 34145 - Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

53

NOTES

54

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 5.1—Boom Installation

ITEM PART NUMBER DESCRIPTION

Ref. 37316 1 37335 2 37385 3 51325 -4 37398-001 -5 37398-002 -6 37398-003

Boom Installation, 38A Aluminum Boom Assembly, 38AG Track Assembly, 38A Cable, 24 Conductor/16GA Hose Wrap, Skirt/Boom Hose Wrap, Track/Boom Hose Wrap, Boom/Pivot

QTY

1 1 1 50L.F. 1 1 1

- Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

55

FIGURE 5.2—Aluminum Boom Assembly

56

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 5.2—Aluminum Boom Assembly

23

ITEM PART NUMBER DESCRIPTION

QTY

Aluminum Boom Assembly 1 Ref. 37335 2 1 37678-002 Retaining Ring, 1 50" shaft diameter 1 Outer Boom Weldment 2 37334 1 Inner Boom Weldment, Aluminum 3 37758 2 4 02236 Elbow, 90° MJ04 M004 1 Master Leveling Cylinder (see Fig. 5.5) 5 34025 1 Pin Weldment 6 34184 1 Pin Weldment 7 36951 8 BOW36834 Bolt, Socket Flathead .375" - 16UNC x 1 00" long 4 2 Bushing, Self-Lube 9 34145 8 Nylon Screw, .375" x .75" long 10 37674 Boom Extension Cylinder Assembly (see Fig. 5.3) 1 11 37390 1 12 37679 Pin, Extension Cylinder 1 Pin, Slave Cylinder 13 37680 2 14 37678-001 Retaining Ring, 1.25" shaft diameter A/R 15 SQK00111 Trim, Black Bushing, Self-Lube 5 16 34147 Slave Leveling Cylinder Assembly (see Fig. 5.6) 1 17 34441 Shim, Small (only if needed) 16 18 37654 Shim (only if needed) 8 19 37264 2 20 37502-001 Bearing Pad, Top 2 21 37502-002 Bearing Pad, Bottom 8 Bearing Pad, Small 22 37653 24 Nylon Screw, .375" x 625" long 23 37503 24 [Not Used] 16 25 BOW36603 Nut, Hex .375" - 16UNC 2 Elbow, 90° MJ04 MB04 26 02317 2 Nut, Bulkhead #4 27 00334 2 -28 37040-002 Bearing Pad - Indicates Items Not Shown A/R = As required MANUAL 92323-003 SEPTEMBER 1994

57

FIGURE 5.3—Boom Extension Cylinder Assembly

Ir

-----14

4

58

MANUAL 92323-003 SEPTEMBER 1994

STARTING WITH S/N 1349

FIGURE 5.3—Boom Extension Cylinder Assembly ITEM PART NUMBER DESCRIPTION

QTY

Boom Extension Cylinder Assembly 1 -1 37390 Assembly, Regenerative Manifold (includes items 5-8) 1 2 34814 4 3 BOW36727 Washer, Split Lock .375" ID 4 4 BOW36064 Bolt, Hex .375" - 16UNC x 3.50" long 2 —Cartridge, Logic Element NO 5 34369 2 —Cartridge, Counterbalance 6 35033 1 —Plug 7 38167 1 —Manifold, Regenerative 8 34799 2 Straight MJ06 M006 9 02448 2 Elbow, 90° MJ06 FJO6 10 02298 2 11 BOW9977 0-Ring, 375" ID x 50" OD Cylinder, Boom Extension (see Fig. 5.4 for breakdown) 1 12 34884 1 Wear Pad 13 34411 14 BOW36815 Bolt, Socket Flathead .25" - 20UNC x 1.00" long 2 1 Wear Pad 15 37292 16 BOW36817 Bolt, Socket Flathead .25" - 20UNC x 1.50" long 2 - Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

59

FIGURE 5.4—Boom Extension Cylinder Parts Breakdown

60

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 5.4—Boom Extension Cylinder Parts Breakdown ITEM PART NUMBER DESCRIPTION

Boom Extension Cylinder (Texas Hydraulics) -1 34884 2 Plug, Test Port

Tube Weldment 3 4 Locknut Piston 5 Spacer 6 Head 7

Rod Weldment 8 -9 SBW01030 Seal Kit (includes items 10-18) —Wear Ring 10 11 —Seal, AQ 12 —0-Ring, Rod-Piston 13 —0-Ring, Head 14 —Ring, Back-Up 15 —Wear Ring 16 —0-Ring 17 —U-Cup, Polypak 18 —Wiper

QTY

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

- Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

61

FIGURE 5.5—Master Leveling Cylinder Parts Breakdown

15

14 13 17

12

10 11

62

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 5.5—Master Leveling Cylinder Parts Breakdown ITEM PART NUMBER DESCRIPTION

-1 34025 2 34147

3 4 5 6

7 -8 35111 9 10 11 12 13 14 15 16 17 18

Master Leveling Cylinder (Texas Hydraulics) Bushing, Self-Lube Tube Weldment Piston Head End Cap Rod Weldment Seal Kit (includes items 9-18) —Locknut —Wear Ring —Seal, AQ —0-Ring, Piston-Rod —0-Ring, Head —Back-Up Ring, Head —U-Cup, Polypak —Wiper, Rod —Set Screw —Nylon Plug

QTY

1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

- Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

63

FIGURE 5.6—Slave Leveling Cylinder Assembly

4

64

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 5.6—Slave Leveling Cylinder Assembly ITEM PART NUMBER DESCRIPTION

QTY

Slave Leveling Cylinder Assembly -1 34441 1 Slave Leveling Cylinder (Texas Hydraulics; see Fig. 5.7) 1 2 34026 Tube Assembly (left-hand) 1 3 34443 Tube Assembly (right-hand) 4 34442 1

Straight, MJ04 MPO4 2 5 01160 Holding Valve (see Fig. 5.8) 1 6 30322 3 7 BOW30181 Bolt, Hex .25" - 28UNF x 1.50" long 8 BOW36725 Washer, Split Lock .25" ID 3 9 BOW31444 Washer, Flat .25" ID x .625" OD 3 Clamp 1 10 02202 11 21479 Needle Valve 1 12 02683 1 Straight, MJ04 MJ04 - Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

65

.

FIGURE 5.7—Slave Leveling Cylinder Parts Breakdown

66

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 5.7—Slave Leveling Cylinder Parts Breakdown ITEM PART NUMBER DESCRIPTION

-1 34026 2

3 4 5

6 7 34147 -8 35111 9 10 11 12 13 14 15 16 17 18

Slave Leveling Cylinder (Texas Hydraulics) Tube Weldment Piston Head End Cap Rod Weldment Bushing, Self-Lube Seal Kit (includes items 9-18) —Locknut —Wear Ring —Seal, AQ —0-Ring, Rod-Piston —0-Ring, Head —Back-Up Ring —U-Cup, Polypak —Wiper —Nylon Plug —Set Screw

QTY

1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1

- Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

67

FIGURE 5.8—Holding Valve Assembly

4 5 6 7 8 10

68

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 5.8—Holding Valve Assembly ITEM PART NUMBER DESCRIPTION

Holding Valve, Slave Leveling Cylinder -1 30322 2 QZB01013 Body 3 QZB01015 Piston 4 QZB01016 Poppet 5 QZB01017 Ball 6 QZB01018 Spring 7 QZB01019 Spring 8 QZB01020 Plug 9 QZB01014 Seal Kit (includes items 10-12) —0-Ring, Plug 10 —0-Ring, Piston 11 —0-Ring, Body 12

QTY

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

- Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

69

FIGURE 5.9—Boom Hydraulic Installation

191

12°

18 8 1

12 13 1

14

70

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 5.9—Boom Hydraulic Installation ITEM PART NUMBER

DESCRIPTION

QTY

1 Boom Hydraulic Installation -1 37563 4 Shuttle Valve 2 36841 4 Straight, MJ06 MPO6 3 02796 7 4 00498 Elbow, 90° MJ06 MPO6 1 Straight, MJ06 MPO4 5 02795 1 Flow Control Valve 6 52661 1 Elbow, 90° 7 04597 1 Valve, Dual Counterbalance 8 34062 2 9 BOW31444 Washer, Flat .25" ID x .625" OD 2 10 BOW36725 Washer, Split Lock .25" ID 2 11 BOW30181 Bolt, Hex .25" - 28UNF x 1 50" long 1 12 RTM01005 Body, Counterbalance Valve 2 Cartridge, Counterbalance Valve 13 35033 3 14 02219 Elbow, 90° MJ04 FJO4 Elbow, 90° MJ04 M006 3 15 02857 1 16 00456 Straight, MJ04 M006 2 17 00344 Tee, MJ04 FJO4 MJ04 Boom Lift Cylinder Assembly 1 18 37002 —Lift Cylinder (Texas Hydraulics; Seal Kit #36870-100) 1 19 36870 20 37485 —Manifold Assembly (see Fig. 4.2, Lift section) 1 4 Bushing, Self-Lube (included with cylinder) -21 34145 - Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

71

FIGURE 5.10—Hose Installation Diagram

BOOM UFT CYL

A.

BU ON INNER BOOM 2P 9P

VALVE 34041 ON PLATFORM (BOTTOM

3P

7P

I

ac

®

5C

q2'®6 6p 4P TO LIFT VALVE IN BOOM TURRET PLIFIN BOOM EXT ARM UFTe4 11.T IN/OUT UP /DN ROT CARRIAGE LET

ei 11P

•

4a1 0

10P

11

2P

P e/X. C)313 C)11P ek5\P\®Se

28 €405P Gs 12F : 41

1P

r"- 1

1P 18

1

vc-vo

38

7A

3A E 989A REF COUPUNG. 6 PL

28 2A

vi 34062 12C

Cf

TO TMKN,4, CARRIME

7A v2,12B VALE 34040 ON TURRET 11C

2A

• 11A

108 1 DA

BOOM UFT UP/ON

•11R. BOOM ARM 1GC ROT. EX1D UFT LFT/R t•I /OUT UP /DN TO LIFT ti VALVE IN CARR!AGE .

I10A

• 4,4

, ::: =A J .3„ 'Ll3fr 2763 L-4R RELE SSF bL14

ARM UFT C•L FLOW CONTROL

DC

E R

EMIL 1. BUBEtE LEGEND: 0 -HOSE KIT, PLTFRM (SEE 8/14 38128 IN COMPUTER) al -HOSEKIT, BOOM (SEE 8,44 A 38129 IN COMPUTER) bx -HOSEKIT. ARM (SEE 8,44 38131 IN COMPUTER) cp -HOSE 10T CYLNOERS (SEE RIM 38130 IN COMPUTER) 2. NUMBERS NEXT TO HOSES ARE IN DINAOUAL HOSE LABELS.

72

MANUAL 92323-003 SEPTEMBER 1994

ir

8C

BB

,o

4P BP

FIGURE 5.10 ITEM

NOTE:

PART NUMBER

-

Hose Installation Diagram

DESCRIPTION

QTY

Descriptions indicate the inner diameter, length, and fittings for hose assemblies.

The description 'ST-ST indicates straight fittings at both hose ends.

The description 'ST-90' indicates one straight fitting and one 90° fitting.

ITEM PART NUMBER

DESCRIPTION

QTY

Ref. 38129 Hose Kit, Boom 1 66045-289 Hose Assembly, #5 289.00" long ST-ST 2 66045-277 Hose Assembly, #5 277.00" long ST-ST 3 66043-281 Hose Assembly, #3 281 00" long ST-ST 4 66043-273 Hose Assembly, #3 273.00" long ST-ST 5 66045-284 Hose Assembly, #5 284.00" long ST-ST 6 66045-290 Hose Assembly, #5 290.00" long ST-ST 7 66045-276 Hose Assembly, #5 276.00" long ST-ST 8 66045-288 Hose Assembly, #5 288.00" long ST-ST 9 66045-274 Hose Assembly, #5 274.00' long ST-ST 10 66045-255 Hose Assembly, #5 255.00" long ST-ST 1 1 66043-252 Hose Assembly, #5 252.00" long ST-ST 12 66043-246 Hose Assembly, #3 246.00" long ST-ST

Ref. 38130 Hose Kit, Cylinders 1 66035-023 Hose Assembly, #4 23.00" long 4/6 ST-ST 2 66035-022 Hose Assembly, #4 22.00 long 4/6 ST-ST 3 66045-051 Hose Assembly, #5 51.00" long ST-ST 4 66045-045 Hose Assembly, #5 45.00" long ST-ST 5 66045-117 Hose Assembly, #5 117 00" long ST-ST 6 66045-113 Hose Assembly, #5 113 00" long ST-ST 7 66045-057 Hose Assembly, #5 57.00" long ST-ST 8 66043-259 Hose Assembly, #3 259.00" long ST-ST 9 66043-250 Hose Assembly, #3 250.00" long ST-ST 10 66001-026 Hose Assembly, #4 26.00" long ST-90

Ref. 38128 1 66045-076 2 66045-079 3 66043-076 4 66043-079

Hose Kit, Platform Hose Assembly, #5 76.00" long ST-ST Hose Assembly, #5 79.00" long ST-ST Hose Assembly, #3 76.00" long ST-ST Hose Assembly, #3 79.00' long ST-ST

Ref. 38131 1 66045-367 2 66045-329 3 66043-329 4 66043-338 5 66045-323 6 66045-320 7 66045-337 8 66045-334 9 66045-344 10 66043-121 11 66043-128

Hose Kit, Arm Hose Assembly, #5 367.00" long ST-ST Hose Assembly, #5 329.00" long ST-ST Hose Assembly, #3 329.00" long ST-ST Hose Assembly, #3 338.00" long ST-ST Hose Assembly, #5 323.00" long ST-ST Hose Assembly, #5 320.00' long ST-ST Hose Assembly, #5 337.00" long ST-ST Hose Assembly, #5 334.00" long ST-ST Hose Assembly, #5 344.00" long ST-ST Hose Assembly, #3 121.00" long ST-ST Hose Assembly, #3 128.00' long ST-ST

-Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

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

1 1 1 1 1 1 1 1 1 1 2

1 5 3 3 1

1 1 1 1 1 1 1 1 1 1 1 1 73

FIGURE 5.1 1 —Track Assembly

4

2 5 6

74

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 5.11—Track Assembly ITEM PART NUMBER DESCRIPTION

Track Assembly Ref. 37385 Hose Support 1 38289 Channel, Track 2 38295 Link, Chain (Repair Link #67865)

3 37810 Mounting Bracket (set of two) 4 37809 Plate, Track 8.375"

5 34373

Plate, Track

6 34392 Retainer, Hose 7 38294 -8 BOW31326 Washer, Split Lock .3125" ID -9 BOW34273 Nut, Hex Lock .3125" - 18UNC -10 BOW30007 Bolt, Hex .25" - 20UNC x 1 75" long -11 BOW34272 Nut, Hex Lock .25" - 20UNC -12 BOW36726 Washer, Split Lock .3125" ID -13 BOW30200 Bolt, Hex .3125" - 24UNF x .50" long -14 BOW31444 Washer, Flat .25" ID x .625" OD -15 BOW31412 Washer, Flat 3125" ID

QTY

1 1 1 20 2 SETS 1 2 1 13 15 3 6 9 5 3 8

- Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

75

FIGURE 6.1 —Platform Installation

° lit, 1171111011 0 , ioll!lio 0 .....:.

,d

di, •

, , ,,...* V *--, • '.-- • ik•

...,.... • • • .

......•-• a i

.r.4*.••• ,... . d. , * 41■•• 0 • ' . . ' ill ., 4 ,. *tow ■dr ..- .4 4 4, • 41, Ill 4 . .

• .. • • . • # #• • • • *••' ..

'• a .• a•#••

• * • • s". , •

• #.. -

0

• • 11

••'. ••••• ji „.•

. • •-# t.'..II.' '

' 4....ar:44 ;0'.*; a•— 4 ;

76

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 6.1—Platform Installation

C

NO NC

I-

FOOTSWITCH CABLE

cc

ca

3 CONDUCTOR 16 AWG

ITEM PART NUMBER DESCRIPTION

QTY

Ref. Platform Installation -1 Ref. 1 Platform Weldment 2 34112 1 Platform Assembly (see Fig. 6.2) 3 34046 1 Plate, Upper Control Box 4 34609 Ref. Platform Wiring (see Fig. 6.3) 5 Ref. 6 6 BOW36004 Bolt, Hex 25" - 20UNC x 1.00" long 6 7 BOW31444 Washer, Flat .25" ID x .625" OD 8 BOW36725 Washer, Split Lock .25" ID ........ ........ ..... ............. . ...... ..... 6 6 9 BOW31201 Nut, Hex 25" - 20UNC Platform Hydraulic Installation (see Fig. 6.4) Ref. 10 34226 11 [Not Used] 2 12 BOW36029 Bolt, Hex 3125" - 18UNC x 1.00" long 4 13 BOW31445 Washer, Flat 3125" ID x .6875" OD 2 14 BOW36726 Washer, Split Lock .3125" ID 2 15 BOW34273 Nut, Hex Lock .3125" - 18UNC 1 Retainer, Footswitch 16 34667 1 Footswitch 17 36083 1 36083-100 Kit, Footswitch (microswitch, hardware) 1 Guard, Footswitch 18 36084 2 19 BOW36005 Bolt, Hex .25" - 20UNC x 1.00" long (USS) 2 20 BOW36701 Washer, Flat 25" ID 2 21 BOW36601 Nut, Hex .25" - 20UNC 1 Cover, Switch 22 37193 - Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

77

FIGURE 6.2—Platform Assembly

REF. PLATFORM WELDMENT

34

23 24 26

78

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 6.2—Platform Assembly 14 13 7 9 12

10

16

ITEM PART NUMBER

DESCRIPTION

QTY

1 Platform Assembly -1 34046

1 Platform Rotation Gearbox Assembly (id. items 5-16) 2 34274 4 3 BOW34276 Nut, Hex Lock .50" - 13UNC 4

4 BOW36106 Bolt, Hex 50" - 13UNC x 1.50" long 1 —Handle, Modified 5 34409 6 36847-034 —Pin, Grooved Type A 3125" dia. x 1 50" long 1 2 7 34819 —Washer, Modified 1 8 34244 .......... ........... —Worm Shaft 2 —Bushing, Flanged 9 34238 1 —Worm, Modified 10 34798 11 36847-024 —Pin, Grooved Type A 3125" dia. x 1 25" long 1 1 —Weldment, Gearbox 12 34239 1 13 BOW31208 —Nut, Hex .75" - 10UNC 1 14 BOW32278 —Nut, Hex Jam .75" - 10UNC 15 [Not Used] 1 —Platform Rotation Gear 16 36986 2 17 BOW32585-1 Clamp, Wire Loom 1.00" 4 18 BOW31201 Nut, Hex 25" - 20UNC 2 19 BOW36725 Washer, Split Lock .25" ID 6 Bushing, Self-Lube 20 34147 1 Thrust Washer, 1 26" ID x 2.50' OD 21 38284 1 Pin Weldment 22 36936 1 Pin Weldment 23 34251

4 24 BOW36705 Washer, Flat .50" ID x 1 06" OD 2 25 BOW361 14 Bolt, Hex 50" - 16UNC x 3.50" long 2 26 BOW36102 Bolt, Hex .50" - 16UNC x .75" long 1 Skirt Weldment 27 37839 28 [Not Used] 1 Pin Weldment 29 37014 1 Pin Weldment 30 37012 Washer 3 31 36934 3 32 BOW35058 Pin, Spring Rolled .25" diameter x 1 75" long 33 B0W40541 Set Screw, Socket Head .375" - 16UNC x .50" long .... ..... 4 1 34 BOW36004 Bolt, Hex .25" - 20UNC x 1 00" long 1 Hose Guard 35 37822 36 BOW36817 Bolt, Socket Flathead .25" - 20UNC x 1 50" long 2 - Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

79

NOTES

80

MANUAL 92323-003 SEPTEMBER 1994

•

°

= •1

FIGURE 6.3-Platform Wiring

EMERGENCY / STOP

22

21A

21

4-0

-110 r-A LP GAS

CHOKE

21A

21A OH 25 zO

-k0 r, START

SEE NOTE 3

22 HORN

19

59

I 28 27 I 26

BOW31231 BOW31124

4.00 4.00

34767 38144

1.00 1.00

25 ' 24

cD 18 •9 20 21

55 59 160 62 63 64

J

22 21 20 19 18 17 16 15 14 13 12

22 23

o

11 10

BLANK

0

9

e

' 1.00 I EA I CONNECTOR, LOCKNUT 3 /4 0112.),A, ; . EA SEAL CONNECTOR ELECT 3/4 67114-009 1.00 lEA STRAIN REUEF. 3/4 NPT .6254750 67124-001 1.00 I EA CONNECTOR, LOCKNUT 1/2

67124-002

67123-001 1.00 I EA 67114-003 1.00 I EA 6.00 I LF 58251 20.00 I IF 58292 67295-022 8.00 IF

40880 50077

4.00

80305 **s

2.00

2.00

WIRE, 12GA-WHITE WIRE, 16GA-WHITE CABLE. 3 CONDUCTOR 120A. SJO

EA GUARD, TOGGLE SWITCH MICRO EA SWUTCH, TOGGLE, 2-POS. MAINTAINED

5

51914 52672

4

34836

1.00

52029

1.00 I 1.00

38095

SWITCH, TOGGtE, 2-POS, MOMENTARY CONTACT BLOM 2 NO CONTACT BLOCK, 1 NC CONTACT BLOCK, 1 NO

EA OPERATOR. WHITE PUSH-BUTTON

EA EA EA ITEM PART NUMBER Q TY UM 69145 51913

NOTES: 1. ITEMS 11, 12 AND 19 THRU 26 ARE NOT ILLUSTRATED. 2. REFER TO SCHEMATIC 38069.

3. REFER TO DRAWING 38076 FOR CIRCUIT DESCRIPTION.

SEAL, CONNECTOR ELECT 1/2 STRAIN RELIEF. 1/2 NPT .375/.500

34552-012 2.00 I EA TERMINAL STRIP 1.00 l EA ALARM 34644 37165 1.00 EA OEM DRIVE CONTROLLER EA WASHER, SEAL 4.00 38032

EA EA REF 1.00 EA EA 1.00 1.00 EA

6 I

_I EA NUT, KEPS f3-32UNF 1 EA SCR„ SLT RD #6 -32UNF X.50 1 EA DECAL EMERGENCY PUMP I EA DECAL PLATFORM CONTROL BOX

1.00

OPERATOR, YELLOW PUSH-BUTTON OPERATOR, RED PUSH-PULL CNIRL BOX, PLTFRM KAWASAKI DESCRIPTION

PROPRIETARY INFORIAATION is WOMB RIO Min IMPSWIL 10111WWWW

wAco, TEXAS

MUSK WIPSIMI. WINWAS Wb Saint AVIPart

/WM It UMW, AMMO • W MAWR OWPWW3W. Wain at MAW 11 IX MIK NOW VI*01 ara s arsor W CALAIS 1111111141110111. MIMS

1g MR MEM mos

67 17-3-7W

-

6221 5990 2.c.A.

11/24/94 IRAK

I 11/10/23 RAK

UMMIWCYMMINIEWWCWEDI OWADMCPSAWLMOKIMEW WUMMKOVOlt mlioW mmmom

NO. DATE IAPPR. DRAM

4100

i 11/21/93

ER.N. NO. I DATE

J.CARMICAL

r/7/3 a r

RAX *PPM

serows

RAK

11/21/.3

TIRE

WIRING, 47AG KAWASAKI PLTFRI DRAWS

C =Au 3/4

38097 1 OF 1

FIGURE 6.4—Platform Hydraulic Installation

1, 5

11

8, 9, 10 2 7 REF. 6

2 11

ITEM PART NUMBER

DESCRIPTION

Platform Hydraulic Installation Ref. 34226 Upper Control Valve Assembly 1 34817 Elbow, 90° 2 02337 Straight 3 00425 4 34966-402 Orifice Fitting Assembly Upper Control Valve (includes items 6 715) 5 34041 6 ENR01021 —Banking Kit 7 ENR01008 —Inlet Section ('PRESS') 8 ENR01023 —Kit, Load Check (includes items 9 and 10) 9 ENR01016 --Ball, Load Check 10 ENR01017 --Retainer, Load Check 11 ENR01019 —Valve Section 12 ENR01009 —Outlet Section ('TANK') —Handle Kit (includes items 14 and 15) 13 34818 14 ENR01022 --Knob 15 ENR01002 --Handle -16 BOW31201 Nut, Hex .25" - 20UNC -17 BOW36725 Washer, Split Lock 25" ID -18 BOW31444 Washer, Flat .25" ID x .625" OD - Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

QTY 1 1 10 2 2 1 1 1 1 2 2 5 1 1 5 5 2 2 2 83

FIGURE 7.1 —Kubota Diesel Engine Installation (Option)

21

23 19 24 18 25

/

84

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 7.1 —Kubota Diesel Engine Installation (Option) ITEM PART NUMBER DESCRIPTION

QTY

1 Diesel Engine Installation -1 37371

1 Engine Electrical Installation (see Fig. 7.1A) -2 Ref. 1

Engine/Pump Assembly -3 37297

1 —Kubota D850-B2 Diesel Engine (see Fig. 7.1B) 4 37299 1

--Bracket, Solenoid Mounting 5 37360 1

--Solenoid, Throttle 12V DC 6 40808 1

--Washer, Flat .25" ID 7 BOW36701 4

--Bolt, Hex .25" 20UNC x 1.00" long 8 BOW36004 2 9 BOW36000 --Bolt, Hex .25" - 20UNC x .50" long 6 10 BOW36725 --Washer, Split Lock .25" ID 4

--Nut, Hex Lock .25" 20UNC

11 BOW34272 1 12 BOW32281 --Nut, Hex Jam .25" - 28UNF 1 13 NNV01008 --Rod End 1

--Coupling 14 67858 2

--Set Screw, Allen Head .3125" 18UNC 15 BOW40531 1

--Plate, Pump Mounting 16 67897 1 --Gear Pump, Tandem 17 37339 6 18 BOW36727 --Washer, Split Lock .375" ID 6 19 BOW36054 --Bolt, Hex .375" - 16UNC x 1.00" long 2 --Elbow, 90° MJ16 M016 20 02216 1 --Elbow, 90° MJ10 M010 21 02214 1 --Elbow, 90° MJ06 M010 22 01397 2 23 37273/37273-001 .... —Rear Motor Mount (right-hand/left-hand) 8 24 BOW36705 —Washer, Flat .50" ID x 1.0625" OD 8 25 BOW36729 —Washer, Split Lock .50" ID 8 26 BOW36105 —Bolt, Hex .50" - 13UNC x 1 25" long 1 27 37272-001 —Front Motor Mount, left-hand 1 28 37272-002 —Front Motor Mount, right-hand 8 29 BOW42465 —Washer, Flat 10mm ID 8 30 BOW42455 —Washer, Split Lock 10mm ID 8 31 BOW42331 —Bolt, Hex 10mm - 1 25mm x 25mm long 4 —Rubber Mount 32 80303 4 33 BOW36769 —Washer, Flat .50" ID x 1.375" OD 4 34 BOW36784 —Nut, Hex Lock .50" - 13UNC 1 Module, 3-Wire Solenoid Control -35 34999 -36 37299-200 Operator's Manual, Kubota D850 (Replacement part #) ....Ref. -37 37299-201 Workshop Manual, Kubota D850 (Replacement part #) Ref. -

Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

85

FIGURE 7.1A—Diesel Engine Electrical Installation 9

15----10

8 4)

I

ITEM PART NUMBER

DESCRIPTION

QTY

Diesel Engine Electrical Installation ...... . ............ ..... . 1 -1 Ref. 1 —Plate, Wood 2 Ref. 1 3 121-96822-00 —Battery, 12V 2 4 67351-008 —Battery Cable 1

—Bracket, Battery Hold-Down 8.25" 5 37722 2 6 BOW32488 —Threaded Rod, .25" - 20UNC x 12.00" long 1

—Electrical Box Assembly, Diesel Engine (see Fig. 7 1D) 7 37940 6 8 BOW31444 —Washer, Flat 25" ID x 625" OD 6

—Washer, Split Lock 25" ID 9 BOW36725 6

—Nut, Hex 25" 2OUNC 10 BOW31201 - Indicates Items Not Shown

86

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 7.1B—Kubota D850-B2 Diesel Engine

ITEM PART NUMBER

DESCRIPTION

-1 37299 Kubota D850-B2 Diesel Engine

2 JVA01001 —Element, Oil Filter 3 JVA01002 —Fan Belt 4 37394 —Fuel Filter Kit 5 JVA01003 --Element, Fuel Filter —Kit, 90° Thermostat 6 37397 7 JVA01004 --Cover, 90° 8 JVA01005 --Gasket 9 JVA01006 —Thermostat 10 37395 —Solenoid, Shut-Down 11 JVA01007 —Glowplug 12 37396 —Gauge, Coolant Temperature 13 37392 —Kit, Air Cleaner 14 JVA01008 —-Element, Air Filter 15 BOW36725 —Washer, Split Lock .25" ID 16 BOW36002 —Bolt, Hex .25" - 20UNC x .75" long 17 BOW24116 —Hose Clamp, 2.00" 18 67099-003 —Air Hose, Inline —Muffler Kit 19 37393 20 67169-017 —Clamp, Muffler 21 37480 —Tip Muffler 22 37399 —Alternator Kit, 25 AMP -23 67157-003 —Oil Pressure Switch, 4 PSI - Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

QTY

1 1 1 1 1 1 1 1 1 1 3 1 1 1 2 2 2 1 1 1 1 1 1 87

FIGURE 7.1C—Radiator Installation, Diesel Engine

10

ITEM PART NUMBER

-1 37469 2 80175 3 BOW31431 4 BOW36725 5 BOW36001 6 37510 7 37306 8 37476 9 BOW24113 10 37350 11 BOW36727 12 BOVV36054

DESCRIPTION

Radiator Installation, Diesel Engine —Tank, Coolant Recovery —Washer, Flat 25" ID x 625" OD —Washer, Split Lock 25" ID —Bolt, Hex 25" - 2OUNC x 625" long —Radiator, Modified —Electric Fan —Radiator Hose (34 00") —Hose Clamp, 625" - 75" - 1 25" —Bracket, Radiator Mounting —Washer, Split Lock 375" ID —Bolt, Hex 375" - 16UNC x 1 00" long

- Indicates Items Not Shown

88

MANUAL 92323-003 SEPTEMBER 1994

QTY

1 1 4 2 2 1 1 5.67 4 1 2 2

. ..... • • • •

•••• 1

•

•

•

•

•

• • • • • • • •

• •. *

: ".-

FIGURE 7.1D-Electrical Box Assembly, Diesel Engine CABLE TO ENGINE (R) 51 BU< ! ENGINE MODULE + AUX 58 RED I ENGINE MODULE + HOT 8A WHT ! ENGINE - THROTTLE SOLENOID 1 t CABLE TO ENGINE (L) t BLK ENGINE STARTER 25B RED • SOLENOID 55 WHT 1 4-PSI OIL PRESSURE SWITCHi 31 WHT/BLK I OIL PRESSURE SWITCH • GRN E ALTERNATOR ORN F I BLU N RED/BLK 'SPARE CABLE TO MURPHY ELECTRICAL BOX - 37598 1 I MURPHY SWITCH 5HT BU< ;HI TEMP SHUTOFF 31 WHT

I. TO ENGINE (R)

4!)

1 25t

(.

8A

31

8

25A HIGH TEMPI CUTOFF

1T, LOCKOUT i I DELAY RELAY

TO TURRET CONTROL BOX

I

'CABLE TO TURRET CONTROL BOX 1 GRN GROUND BLK '

25/1

-

25 25C STARTER LOCKOUT 25A

TO MURPHY BOX

TO ENGINE (L) -

4 PL

FAN RELAY COIL

-- 10 GAGE WIRE 2.1 314'Sq

5A KEYSWITCH RED .

8 WHT 1 KEYSWITCH 24 ORN GLOWPLUGS _SWITCH 25 BLU I ENGINE START SWITCH 55 WHT/BLK I KEY SWITCH i RED/BLK I SPARE

19 14

TO GLOWPLUGS ON ENGINE

0 -J

25B

1.0"

10 GAGE WIRE

I 20 167295-019 19 67114-001 18 67124-002 17 67123-002 16 67114-008 15 BOW17351 14 67123-001 13 67114-002 12 BOW31431 11 B OW36725 10 BOW36002 9 BOW31126 8 BOW31429

2 PL 8 GAGE CABLE

1.00 IEA 2.00 2.00 I EA

2.00 lEA 4.00 EA 4.00 1 EA

3.00 I EA 1.00 EA 1.00 EA 1.00 EA 1.00 EA 1.00 lEA 2.00 EA 8.00 LF 2.00 EA 22.00 lIF 1.00 EA 4.00 EA 1.00 EA QTY UN

7 21342 6 67295-005

NOTES: 1. ALL WIRING TO BE 16 GAGE EXCEPT WHERE NOTED.

E'A VOLTAGE REGLL LA-TO Q.

8.00 IS

5 67947-015 4 67295-024 3 34552-016 2 67280 37586 ITEM PART NUMBER

CABLE MULT1CONDUCTOR 2C/16GA SO CONNECTOR, STRAIN RELIEF LOCKNUT CONNECTOR .75 SEAL CONNECTOR ELECT 3/4 CONNECTOR. STRAIN RELIEF NUT 1/2 CONDUIT CONNECTOR SEAL CONNECTOR ELECT 1/2 STRAIN RELIEF 1/2 NPT .25/.38 WASHER FLAT .25 ID X .63 OD WASHER SPLIT LOCK .2510

BOLT HEX .25-20UNC X .75 SCREW, RND HD #6-32 X 3/41.

WASHER #8 SOLENOID STARTER 12VDC CABLE MULT1CONDUCTOR 3C/160A SO CIRCUIT BKR AUTO RESET 15 AMPS CABLE MULTICONDUCTOR 8C/16GA SO TERMINAL STRIP RELAY BOSCH BOX, MODIFICATION

DESCRIPTION

PRDIPRIETARY INFORMATION ToRs soma MI MIK WO& 1102.02111.

-

4 •

6636

-•

•

r-11"

1.7X. C.C.* 1403864 Lilt. e..R.N. NO.

VMS IS IMAM 1 I I 1 Mgt Wit MK MINK TIE MR IWIIM UMW WOW,* MSS. UNLE. OINEAMIL 1P11.1ROM CARMOOMS ME Al NOW. TOLERANOLS Mt mom Amu. omm.Ames.

Ayr iirtri.

K ALBERTS

',A/ACO, TEXAS 171tE

DIAGRAM, ELEC BOX A524-47AG-K

4/204

AQ HO.

C

37940 1 Or 1

FIGURE 7.2—Auxiliary Lowering Power Unit (Option)

PUMP/MOTOR LOCATION IN CARRIAGE

ITEM PART NUMBER

DESCRIPTION

Ref. Ref .

Auxiliary Lowering Power Unit Assembly, Auxiliary Pump/Motor 1 35659 —Motor, Auxiliary Lowering 2 35244 3 AZP01005 —Solenoid —Pump, Auxiliary Lowering 4 35245 Inline Filter, 375" NPT 5 50148 —Element, Inline Filter 6 51634 Elbow, 90° MJ08 MPO6 7 00368 Elbow, 90° M008 MPO6 8 04155 Straight, MJ08 M008 9 00458 10 BOW36002 Bolt, Hex .25" - 20UNC x .75" long 11 BOW36701 Washer, Flat .25" ID Decal, Auxiliary Lowering .......... ..... ........

-12 34767 Contact Block, 2 NO -13 52029 Operator, Pushbutton -14 34836

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

2 2

- Indicates Items Not Shown NOTE: Items 12 14 located at platform control console.

-

MANUAL 92323-003 SEPTEMBER 1994

91

FIGURE 7.3—Strobe Light Assembly (Option)

8

BRACKET STROBE

1I

+

-,_

ITEM PART NUMBER DESCRIPTION

Ref. Ref. 1 58395 2 37751

Strobe Light Assembly (Option) Light, Amber Strobe 12-72V DC Mounting Bracket

- Indicates Items Not Shown

92

MANUAL 92323-003 SEPTEMBER 1994

QTY

1 1 1

FIGURE 7.4—Dual Fuel Carburetor Assembly, Liquid (Option)

REGULATOR LOCATION (REF - CHASSIS WELDMEN T)

CARBURETOR -

LP VAPOR LINE •-■-■111110.

C

r— r CARBURETOR ADAPTER

GASOLINE LINE SOLENOID VALVE

INTAKE MANIFOLD 6 4=GAS

APORI ZER

CIRCUIT

----\

63=LP

FILTER LOCK

REGULATOR

CIRCUIT

LIQUID LP LINE FROM LP TANK

ENGINE COOLANT LINES

3 2

WA TER JACKET

WATER PUMP

ENGINE BLOCK REFERENCE

ITEM PART NUMBER DESCRIPTION

Ref. 1 38180 2 66238 3 51630 4 68097

QTY

Dual Fuel Carburetor Assembly, Liquid (Option) Adapter Kit, Gas/LP (Kawasaki Engine) Vaporizer Regulator, Liquid Filterlock, FL-218 LP Gas Valve, Fuel Shut-Off

1 1 1 1 1

- indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

93

FIGURE 7.5—Dual Fuel Tank Assembly, Liquid (Option)

2 3 4 5 6 7

ITEM PART NUMBER DESCRIPTION

Dual Fuel Tank Assembly, Liquid (Option) -1 Ref 2 67104 Bracket, Horizontal LP Tank Mounting 3 BOW36603 Nut, Hex .375" - 16UNC 4 BOW36727 Washer, Split Lock .375" ID 5 BOW36713-HD Washer, Flat 375" ID (SAE) 6 BOW21654 Spring 7 BOW34142 Washer, Flat 8 67856-002 Tank; LP Gas (Liquid) 43.5 lb 9 67075-002 Coupling, Quick Disconnect Tee, MPO4 FP04 FP04 10 02458 11 36428 Relief Valve, Liquid LP 12 02795 Straight, MJ06 MPO4 13 ZPN01026 ...... ....... ... Hose Assembly, LP Gas - Indicates Items Not Shown

94

MANUAL 92323-003 SEPTEMBER 1994

QTY

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

FIGURE 7.6—Dual Fuel Carburetor Assembly, Vapor (Option)

REGULATOR LOCATION (REF - CHASSIS WELDMEN T)

REF CALAVAR 68097

REF CALAVAR 38180 CARBURETOR KIT

LP VAPOR LINE

GASOLINE LINE CARBURETOR ADAPTER

SOLENOID VALVE

TAKE MANIFOLD 64=GAS CIRCUIT

63=LP CIRCUI T LIQUID LP LINE FROM LP TANK REF CALAVAR 51630 FILTER -LOCK REF CALAVAR 66095 REGULATOR

ITEM PART NUMBER DESCRIPTION

Ref. 1 38180 2 66238 3 51630 4 68097

QTY

Dual Fuel Carburetor Assembly, Liquid (Option) 1 1 Adapter Kit, Gas/LP (Kawasaki Engine) Vaporizer Regulator, Liquid 1 Filterlock, FL-218 LP Gas 1 1 Valve, Fuel Shut-Off

- Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

95

FIGURE 7.7—Dual Fuel Tank Assembly, Vapor (Option)

7

11

ITEM PART NUMBER DESCRIPTION

-1 Ref. Dual Fuel Tank Assembly, Vapor (Option) 2 67104 Bracket, Horizontal LP Tank Mounting 3 BOW36603 Nut, Hex 375" - 16UNC 4 BOW36727 Washer, Split Lock 375" ID 5 BOW36713-HD Washer, Flat .375" ID (SAE) 6 BOW21654 Spring 7 BOW34142 Washer, Flat 8 67103-001 Tank, LP Gas (Vapor) 33.5 lb.

9 67075-002 Coupling, Quick Disconnect 10 02795 Straight, MJ06 MPO4 11 ZPN01026 Hose Assembly, LP Gas - Indicates Items Not Shown

96

MANUAL 92323-003 SEPTEMBER 1994

QTY

1 2 4 4 4 2 4 1 1 1 1

FIGURE 7.8—Travel Alarm Assembly (Option)

REF.

4 3 2

7

7

pi

0

41 It witiqUUtini 11111•111111111

AO

17 18 A 8A

_J.Q_.

13 , 14 , 15 , 16

c 26/1:7 7

2/

: 24 25 25B 26/27 D

.

ITEM PART NUMBER DESCRIPTION

20 21

c 222 23,

26/27

QTY

1 Travel Alarm Assembly (Option) Ref. Ref. 1 Wobbulator and Speaker, 12V 1 80188 1 2 67114-001 Connector, Strain Relief 1 3 67123-001 Seal, Electrical Connector 50" 1 4 67124-001 Locknut, 50" Strain Relief 5 BOW31148 Screw, Round Head #10 - 32UNF x 2.00" long 4 6 BOW31 144 Screw, Slotted Round Head #10 - 32UNF x .50" long 3 7 7 BOW31233 _Nut, Hex Keps #10 - 32UNF - Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

97

FIGURE 7.9—Motion Alarm Assembly (Option)

REF.

4 3

4,1

17 5

18

5A

8A

13 14 15

,c)

16 26/27 26/27

ITEM PART NUMBER DESCRIPTION

20 21 22/23 22/23

24 25 25B 26/27 26/27

QTY

1 Travel Alarm Assembly (Option) Ref. Ref. 1 Wobbulator and Speaker, 12V 1 80188 1 2 67114-001 Connector, Strain Relief 1 3 67123-001 Seal, Electrical Connector .50" 1 4 67124-001 Locknut, 50" Strain Relief 5 BOW31 148 Screw, Round Head #10 - 32UNF x 2.00" long 4 6 BOW31 144 Screw, Slotted Round Head #10 - 32UNF x .50" long 3 7 7 BOW31233 Nut, Hex Keps #10 - 32UNF - Indicates Items Not Shown

98

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 7.10—Air Line to Platform Assembly (Option) 2 3 4 5 7

ITEM PART NUMBER DESCRIPTION

Ref. Ref. 1 81389 2 67993-105 3 37176 4 02800 5 67051 6 • 67052 7 67053 8 67054

Air Line to Platform Assembly (Option) Bulk Hose, #8 Hose End Fitting, Straight J08 H08 Bracket, Coupling Straight, MJ08 M008 Coupling, Quick Disconnect Male .50" Coupling, Quick Disconnect Female Dust Cover, Quick Disconnect (for male) Cap, Quick Disconnect (for female)

QTY

1 60L.F. 2 2 2 ._ _ 1 1 1 1

- Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

99

FIGURE 7.11-110-Volt Line to Platform Assembly (Option)

1 2 (3) 4 5 6 7 8

00

9

10 13

(3) 11 12 14

ITEM PART NUMBER DESCRIPTION

QTY

1 110-Volt Line to Platform Assembly (Option) Ref. Ref. 1 Box, Rain-Tight Single Gang 1 40956 60L.F. 2 67295-017 Cable, 3-Conductor/12 GA 1 Receptacle, 15 AMP/125V 3 80361 1 Cover, Weatherproof Duplex 4 29161 1 Strain Relief, 50" NPT 5 67114-003 1 6 67123-001 Seal, Electrical Connector 50" 1 Circuit Breaker, 15 AMP 7 29163 8 BOW31 146 Screw, Slotted Round Head #10 - 32UNF x 1 00" long 8 8 9 BOW31430 Washer, Flat #10 ID 8 10 BOW31362 Washer, Split Lock #10 ID 1 Plug, 110V 11 52710 2 12 BOW23075 Butt Connector, 12-10 GA Wire 1 Decal, 110 Volts (located on box @ platform) 13 52735 14 15376-024 Decal, 110 Volts Power to Platform (located on turret) 1 - Indicates Items Not Shown

100

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 7.12—Foam-Filled Tires Assembly (Option)

ITEM PART NUMBER • DESCRIPTION

Ref. Ref. -1 34523 -2 58398 3 37817 4 37818

QTY

1 Foam-Filled Tires Assembly (Option) 4 Decal, Tire Pressure 60 PSI (see Fig. 1 2) 4

Decal, Tire Replacement (located on chassis side plates) 2 Tire & Wheel Assembly, Steer (Foam) 2 Tire & Wheel Assembly, Drive (Foam)

- Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

101

FIGURE 7.13—Self-Closing Platform Gate Assembly (Option)

c L_ L

ITEM PART NUMBER DESCRIPTION

QTY

1 Self-Closing Platform Gate Assembly (Option) Ref. Ref. 1 Gate Weldment 1 36147 1 2 CLA00310-001 Angle, 3.00" x 3.00" x .25" w x 1.50" long 2 Hinge Mounting Bracket 3 33415 1 4 CLK00719-001 Flat Bar, 1 5" x 3.0" x 3.0" long 1PAIR Hinge, Self-Closing 5 67170 6 BOW36908-5 Bolt, Socket Flathead #10 - 32UNF x .25" long 12 1 Latch, Gate 7 67171 - Indicates Items Not Shown

102

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 7.14—Five-Foot-Wide Platform Assembly (Option)

ITEM PART NUMBER DESCRIPTION

Ref. Ref. 1 34548

Five-Foot-Wide Platform Assembly (Option) Platform Weldment, 60" x 30" x 43.5"

QTY

1 1

NOTE: Replaces standard platform weldment (48" x 30" x 43.5") #34112

- Indicates Items Not Shown

MANUAL 92323-003 SEPTEMBER 1994

103

FIGURE 7.15—Platform-Mounted Work Light Assembly (Option)

REF CONTROL BOX ON PLATFORM 2 PL. 6 PL

PLATFORM CONTROL CONSOLE GUARD REF

6 PL

i 0 :SEE 1 9.TE.

i

REF CONTROL BOX

REF

PLATFORM

NOTES: 1. REFER TO ELECTRICAL SCHEMATIC FOR NUMBER OF CIRCUIT THAT FEEDS THE PLATFORM WORK LIGHT.

ITEM PART NUMBER

DESCRIPTION

QTY

Platform-Mounted Work Light Assembly (Option) 1 Ref. Ref. 1 1 67260-027 Work Light Assembly 3L.F. Cable, 1 Conductor/12 GA 2 58252 1 3 67114-001 Strain Relief, .50" NPT 1 4 67123-001 Seal, Electrical Connector .50" 1 5 BOW17351 Nut, Conduit Connector .50" 1 Plate, Work Light Mounting 6 69338 1 Clamp, Work Light 7 69339 2 8 BOW31201 Nut, Hex 25" - 20UNC 6 9 BOW36701 Washer, Flat .25" ID 8 10 BOW30002 Bolt, Hex .25" - 20UNC x .75" long - Indicates Items Not Shown

104

MANUAL 92323-003 SEPTEMBER 1994

FIGURE 8.1 —List of Schematics & Diagrams

U.S. Standard Schematics/Diagrams: • 38083 (REV. E) • 38069 (REV. C) • 38076 (REV. B)

Hydraulic Schematic, Kawasaki Engine Models, June 1994 Electrical Schematic, Kawasaki Engine Models, July 1994 Turret Wiring, Kawasaki Engine Models, July 1994

• 37941 (REV. A)

Electrical Schematic, Kubota Diesel Engine Models, July 1994

MANUAL 92323-003 SEPTEMBER 1994

105

so,

37171 • Li__

yI

.

5.4 CPR :.:',E .-ijBS -.... -_-.. -, —-: ,:\IE MOTORS ......---- „,,, ::-_- D85 .E..2.5 ,;. 7 ---",,,,

4--• SAHR ..›,_..../ ' :2:RAKES / ;_1-1 : < ; 34460 , 33186 `. —1

i it. • • , •,)'p•

VALVE ASSY. 34041 IN PLATFORM

DUAL 03AL

34-062 — 1=0 PSI

.029

x

•

t-4-1 ) •

•‘,._/'

5 21

! PO CHECK I VALVE

r

°•-.1..-te '

174—"t .329 .04-0 4.

DR i•

A3,

A2

C.AOKE VALVE 3692.2

;404),C

/

•

T

r r —1 3000 f

:

: t t.

I H! /LOW

0

E

SPEED VALVE 58079

DRIVE MANIFOLD ASSY. 36707

04 150

'os •

ACCUMULATOR

I PSI

4--

I400EL 38A MOOT 47A •

• ts;

_11 L'

VALVE • 37421 , 3300 PSI

A I

IraVI ■ i 1.4

I MANIFOLD ASSY. — 2 PL I 37485

• ARM CYL.

STEER CYL. 51170 3 DIA 5 STROKE L..1—

ti

; 1 ; ,._._ 4- --1 . -t4 ''—i I 1 I , 1.1 ....., I ; I --,

• 14 . ..___,

P3

: .

• : 7" i • i i!

II

1000 PSI

x

I

DRIVE VALVE 38132

TURRET ROTATE HYD. MOTOR 32762

I Ti t, AT&T

.047

,

MDL47A

r

.047

,--\ I ! -1 i rt Pti—i

1

36844(5) SAME AS 36843(T) BOOM CYL

XIiI *

(8 PL)

. P 3000 1 PSI X

I

36871(5) 36870(T)

sHuTTLE v36AL8V4E1

7

0-18 GPM

BOOM CYL.

I ,

0--1

I

RE EF

T

BOOM EXT. CYL. 34884/34815

-

FLOW CONTROL 52661 I (2 PLC S)

;AGE PORT

Et-

,J.AST ER 01. 34.025

4 4 i

— 3000

7

B !

2479I

RA

Al ;

SHUTTLE 36841 :

NEEDLE I

REGENERATIVE MANIFOLD 34-814

•

0

40--■••••••-••

51

-

SA ,E CY1.. 34026

R ; 2500 PSI

_

3032.2 _ i EL •

4-1 0-4

VALVE ASSY. 34040 ON TURRET

CROSS PORT RELIEF VALVE 32763

VALVE ASSY 36720

•

N

I\Av

NOTE: PUMP 38084

• •

FD620D ! KAWASAKI

■

1000 PSI

CI-JECKVALVE CKS01301

1. (5) MEANS SIERRA (T) MEANS TEXAS

POWER UNIT 35659 FOR AUXIUARY LOWERING (OPIION)

1

1

.3800 I RP141 I

•

BALL VALVE 34212 RETURN \ LINE FILTER 33430

SUCTION STRAINER 34209 HYDRAUUC TANK

V

PROPRIE2Ry INFORM AlION

E

6651 !VF/94I

D

6579

ti

I 5/19/94 RAK

6237 1 /26/94 I R AK

B

5990 01/20/94 I R AK

A

5841 I 10/12/93 1 RAK

LTR.

UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN INCHES TOLERANCES ON: ANC1Z

DIECIMALS * 1 /2.

o

E.C.N. NO. DATE I APPR. DRAWN

4045 8/25/93 LTR.

Daemon. Toinwas

'

S's cowstio ITS DESICA ;YET AL AC COMMIE NE THE COMM WORIIMION AND COMM PRCFERTY 7 CALAVAR CORPCRATION. AND Aell MOT BE TRACED. REACCUCED CR 07ED IM WAR kW [ZOOM 10 AO OUTSIDE MT( WTHUJT TFE MICR NIMBI =SEM OF CALAYAR CORPoRATION. Au. RIGHTS 101358,.

RAK

E.R.N. NO. DATE 1 APPR.

APPROVED

'TITLE

SCHEMATIC, 47AG—KAWASAKI HYD

±1/16

REV.

SIZE I DRAWING NO. C

RAK

WACO, TEXAS

FRAc-noNAL

COLEMAN 17/30/93

CHECKED

CaalnoMEan j...PaltATio4 ‘s.

E

3 8 0 8 3

8/25/93 SCALE NONE

I sHEET

1 OF 1

•••

cit.!, 65

22/23

5

65A

• HEAD/TAIL LIGHTS OPTION 20

AUXILIARY LOWERING OPTION

!

5

EMERGENCY STOP oto

5C

_ _

15A

--arta° —1

NEG

• YOTION ALARM OPTION

15A

PLUG ON TURRET

5B

3—POS ROTARY KEYSWITCH — 3 PL

I.-

• 12VDC BA I IERY

P05 111111111111

8A

•

I

10 -t- —

>>

17

THROTTLE SOLENOID

•

0+

• THROTTLE RELAY OPTIONAL CHARGE LAMP

•

• VOLTAGE REGULATOR 2A AUX THROTTLE

31 I

T q

•

START

i19

a- I a_ I

,

0 <

0

F-

21

N

—41 55 91 c/

Z

0

11 0 VEX TEN SI ON

0

STARTER MOTOR

RED I

STARTER SOLENOID

25A1

CHOKE I c5'4''9' • ; 24

• START RELAY

25C

START LOCKOUT RELAY •

. 25A / \‹ YEL/WHT ED 0 K R BL

31

IGNITION COIL • FUEL PUMP

4 PSI 31

0

22/23

EMERGENCY STOP

55

21

55

•

64

0

"LOWER" SEE NOTE 1 04 • CHOKE SOLENOID

A 0

AUX'

15

FOOTSWITCH

• LEFT

16

0-

E2 0

/ 27

• GROUND

14

U.11 0 0 C.)

60

• FORWARD DRIVE • REVERSE 62

62 SEE NOTE 2 18 1 62

18 •

22/23 22/23

22/23

34644

HORN o o

59

DRIVE SPEED RANGE IN CONTROI I FR • TRAVEL ALARM OPTION SERIES/PARAI FL DRIVE o SPEED PILOT VALVE 0+-0 • LOCKUP RELEASE VALVE

BLK

RED

1

STEERING

• RIGHT ,

4 -0—

® 13

f 17

"UPPER" SEE NOTE 1

04 •

....

211 21A I • ol —L __ 17

• BEACON/STROBE OPTION et, VOLT METER OPTION

10

21A: START 25

20

• HIGH TEMP SHUTOFF

<< YU232'

B

IN PLATFORM

DUAL FUEL OPTION

—04 • LP

5515

17

HOUR METER

• GAS I

-°°‘.? 63 0

55

CHOKE 21A • 24

LOCKOUT DELAY RELAY

•

31

551

31

0 E

25B

25T 31 I

0 Ct

> w

▪

11

25

P))

LOWER

-0 I

LU

5B 25A

zi

WI

• OPTIONAL OIL LAMP

11:07

20

•

ALTERNATOR

BLK

10

i 10

a1

,/

31 ,

eLK

• SLOPE SENSOR

T

SLOPE ALARM -I 803 1. 5. j

SIGNAL HORN OPTION

NOTES:

1. "UPPER" AND "LOWER" DESIGNATE COILS OF 3—POS, 4—WAY VALVE THAT DIRECTS HYDRAUUC FLUID TO UPPER OR LOWER CONTROL VALVE. 2. LIFT LIMIT SWITCH IS SHOWN WITH ARMS ALL THE WAY DOWN AND WITH BOOM LEVEL OR LOWER. 3. >> DESIGNATE CONNECTORS AT ENGINE. 4. GROUND IS DESIGNATED AS 26/27 OR 1 OR

Mtmmmytymnftwyw

la OW. Raw mirems Maras itai MUM ME 1C COND. IIMEIMMIE ND OMMMT MIME weft mimeo V MAW Carat:Mk NV Ma VW NM WWII MY tarn Ora V VW Mat MS MUM r1i IV Ma 011101.1 P.M allnalaft .11/11111

,,, Ma.

B

6741

ilimirt,

6221

I 1/26/B4

5990 .TR.

' LT&

RA

11/10/93 [RAF<

E.C.A. N0.1 DAZE

AFF

4045 i 9/23/99 RAK NO I DARE APPR.

Ewa

UNLESS 01HIERMAit SPOCIFIEDt .1.421,010 MIL 04 MCKIM

IIXERANCE3 Mal

WACO, TEXAS

/It •

SCHEMATIC, 47A KAWASAKI EL

wow. mranemora.

*vx 411111, "1"

DRAM CHECKED APPROV0)

CARUICAL

17/20,13

06A41040/40.

C

38069

RAK isets/s3 scALE NONE

zi 1 OF 1

r

CABLE TO PLATFORM - EF ONLY NO.

: 13

CABLE TO

FUNCTION

NO. i

COOR

VALVES iNCTION

-

DRIVE REVERS

10

GRN

"L.C/rtiER" VALVE

14

DRIVE FORWARD

13 I

RED

2- ,RIVE REVERSE

15

STEER LEFT

14

REO/BLK

161

STEER RIGHT

15

17

POWER FROM FOOTS'f,ITCH

I la

16 .

• 17 18 I

DRIVE SPEED. VALVE

'DRIVE FORWARD STEER LEFT

.e.111./BLK

STEER RIGHT

BUJ 7.1_,K

"UPPER" VALVE _CCKL:P RELEASE

19 .

SLOPE ALARM

20

AUXIUARY LOWERING

18

GRN/BLK

"RUN" FROM PLATFORM

20 •

CFFI

.,.:JX1UARY LOWERING

GRN/BLK

SPARE

2 22/231

POWER TO PLATFORM

24 I

RIVE SPEED PILOT

CHOKE

25

START . ENG:NE

26/271

GROUND

31

"RUN" FROM ENGINE

55

SPARE

59

SIGNAL HORN OPTION •

1. REFER TO ELECTRICAL SCHEMATIC 38069.

60

DRIVE SPEED RANGE

2. ITEMS 21, 22, 23, ARE COMPONENTS OF 110V UNE TO PLATFORM OPTION. 3. ITEMS 31, 32, 33 ARE COMPONENTS OF BEACON/STROBE OPTION.

62 I

,IOTES:

ON ?MEN DRIVING

63

LP FUEL OPTION

64. I

GAS DUAL FJEL

65

HEAD/TAIL ,..IGHTS OPTION

BLANK I

SPARE,

33

BOW17350

1.00

32

67123-001

31

67114-002

1.00 I REF I SEAL, CONNECTOR ELECT 1/2 1.00 I REF I STRAIN RELIEF, 1/2 NPT .250/.375

REF I CONNECTOR, LOCKNUT 1/2

23 I BOW17350

2.00 REF CONNECTOR, LOCKNUT 1/2

21 i 67114-003

2.00 REF I STRAIN RELIEF, 1/2 NPT .375/.500

CABLE TO Ei:IG:NE 10. I COLOR

FUNCTION/RENARKS

2A I RED/WHT F ALTERNATOR ? S' PLUG AT

BLK

28 BLU/WHT CHARGING ; ENGINE 5 RED ?S:+12\10C CONNECT TO

BLK

RED/BLK

?S

4

POWER (STARTER 8A i EL:J/BLK I THROTTLE. S..',1.2101D 24 2U</Wt-IT I CHOKE 25B BLU 26/27 GRN 31 51-11 31

2.00 I EA CONNECTOR, LOCKNUT 3/4 2.00 EA I SEAL, CONNECTOR ELECT 3/4

14 67124-003

2.001 EA I SEAL, CONNECTOR ELECT 1

13 I 67114-008 12 I BOW17350

2.00 EA STRAIN RELIEF, 3/4 NPT .500/.625 3.00 I EA I CONNECTOR, LOCKNUT 1/2

11 67123-001

3.00 I EA i SEAL, CONNECTOR ELECT 1/2

10 I 67114-003

1.00 I EA I STRAIN REUEF, 1/2 NPT .375/.500

9 67114-002

2.00 I EA I STRAIN RELIEF, 1/2 NPT .250/.375

3 i 67114-014

2.00 EA I STRAIN RELIEF, 1 NPT .750/.875 2.00 I EA i SEAL CONNECTOR ELECT 1

TO CHASSIS WLDMNT

26/271 GRN/BLK

55T •ELK

STARTER SOLENOID-PLUG AT ENGINE - RED ?C. GROUND-CONNECT

16 I 67124-002 15 I 67123-002

.

7 I 67123-003

IGNITION COL-PLUG AT ENGINE - YFL _ /WHT PSI SWITCH CR OPTIONAL VACUUM SWITCH

67295-035

4- PSI SWITCH

5515 BLK/RED I 232* F SWITCH-PLUG AT ENGINE - '(EL

63 I ORN ? DUAL ?flP

64 ORN/BLK FUEL ;) (GAS

GRN/WHT SPARE

'0.00 LE • CABLE, 2 CONDUCTOR 16 GA

= 67295-036

8.00 LF CABLE, 3 CONDUCTOR 16 GA

4 67295-035

10.00 I LF i CABLE, 2 CONDUCTOR 16 GA

3 I 67295-023

12.00 I LF I CABLE, 10 CONDUCTOR 16 GA

2 I 67295-004

12.00 a IF CABLE, 12 CONDUCTOR 16 GA 10.00 LF CABLE, 16 CONDUCTOR 16 GA

67295-003

OTY UM I DESCRIPTION

ITEM I PART NUMBER

...

inciMEMEILIMMAtnaki

342.

M. OMMMI MI MOW WM. IMMIMEMIL ittekven No mamt At se comm. maw= AM MUM POMMY au*. earamoi. is Hu. 01 II *MR MPMMOM Mt ,. '--- ,,' 01111 .11MIIM IM MOM 11 MN CAME WM IMMIM IME MS MIMMI UMW, 4:1LONt COMM . MSS mitt ItIMS.

•

B I 6823 11/alyy_i , A

-,-

at_

6221 I 1/Z6/94 IRAK

04.1M1011.10MIVEMMU

....... A. .4 WM TOURAMS OW M. arm. swallow.

. lir

at=

LTR. E.C.N. N0. I DATE I APPR. main J. CARMICAL -

- -

j: -.

4100 1 8/23/S3 I RAK E.R.H. ER

Hat DATE I

0..0

NVROMM .. . ____.

:ACO, TEXAS

WIRING, 47AG—KAWASAKI TURRET

W.

38076 :

6/1/0 s Th -TIDRAw." "9' C 1

RAK I S/23,13 SCALE

NONE

I

slim I OP 7

REY.

IQ

?A

W

1 , 5A!ei

1a

'/HT

•,:11

0

55TS

GRN

BLANK

72/231

59 60 62

258

64 65

26/27

26/27

26/27

26/27

26/27E

26/27

8A 10

0 VOLT EXTENSION OPTION

55T

5A

22/231

13 1 14 22/23

BLK RED

'

WHT WHT

•

SLOPE SENSOR

26/27 ORN BLK

'7 6;27 BLK -) BEACON STROBE O OPTION

0;-BLE _OVVER COTRCS SEE D',I;G 38071

55 WHT

CABLE 77) HYDRAULIC VALVES SEE CHART ON SHEET 1 CABLE IO ENGINE

r

SEE CHART ON PAGE 1

LIMIT SIM TCH

2 PL

26/27 BLK BLK

2 PL

31 'NHT RED

FUEL PUMP

2 PL

MMWMILAMMIna es maw na ram Kix. Norm MUSK AK X COMM DOAK MOW If W. MORM1011. /OVAL ow wawa 111.11.110

COM I NW WOO Mt MUM 11 *Of ORM NWT MON ow se MN, giro mow cMAINt UNNIPAINI. MOS ..111 3PEZIFIEDt 7,11.11110411 ARE IN INCHES TOLERANCES ONt

LTh

E.C.H. NO. I DATE I APPN. 4100

LT1 LILN. NO. I

DRAM

masa siir j.

WACO, TEXAS 1TTLE

WIRING, 47AG—KAWASAKI TURRET

maws meow.. m)

CARMIC.A.L I 8/1/93

DRAG

s/25/$3 RAK CHEOCED DATE LAMM OffitCMED

RAK

6/251,3 9CALE 3/4

38076

Isiar

2 OF 2

•••

58 65A

20 5 I

EMERGENCY 50 LTC?

NEG

A 15A1 5B

8A

12`/DC BA11ERY

51813 I • MOTION ALARM OPTION 04-0 • THROTT-E SOLENOID •

I5 I

24

24A

I

11-1 R 0 TT_E RELAY

9 9

GLOWPLUGS

g

25A

0

ORN BLK

FAN

2107 ON - 185F RESET

31

• MURPHY SWITCH

VOLTAGE REGULATOR

31

COLOR CODE A VOLTAGE REGULAISE. L

F = WHT/GRN B = WHT E = BLK L = WHT/RED = BLK/WHT N = 611T/BLK

Ct

AUX 7.-17: OTME 1

0 ''.

20

o o

10

'5

3994 V1/0 JUMPER

RUN SOLENOID

3U 0 PULLtN4 HOLD *HT 0 i REP 0 4-W 0 -44101 0 .

NI) Of

>>

>>

_105HT 51

5B 31 5B

a. a.

31 4 PSI 55

22/23

0

21

--0

f

• VOLT METER OPTIONS

15

I 17

26/27 c) I 14

AUX 0 t

• -1

117

13

QC

21 21A

FOOTSV:ITCH

>

o W

0

0

04-o

"UPPER" SEE NOTE 1

0-4%-o

"LOWER" SEE NOTE 1

c«-t-o

LEFT

o4-0 1 I

RIGHT.)

SEE NOTE 2

62 z O

18

62

oo

REVERSE j

o-+-o oo

RED BLK 11,9 34644

22/23 HORN

'3 0

WHT

GROUND FORWARD

80188 1

0

STEERING

o÷o 62

8 pm 60

22/23 22/23

HOUR METER BEACON /STROBE OPTION

...■■•■■■■■■■■•■■•■■■■■■■■■•■s);

16

20

o

RECEPTACLE IN PLATFORM

LOCKOUT DELAY RELAY

17

START 25

O

START LOCKOUT RELAY

i 55

GLOWPLUGS I 10 21Aj 24

i 21A

U

a.

START RELAY

25C

55

21 ?

•

H-

E

I ER SOLENOID STAR

25A e°

24

•

0 ><

STARTER MOTOR

25A

31

1 10 I -65

1 • HIGHTEMP SHUTOFF MURPHY SWITCH

25B RED

25 I

CHOKE

EMERGENCY STOP

>>

25A

START vc!, 25 LOWER 6

220.1:

kt

5

cc

ALTERNATOR

B

0 e

17-LUG 0;1 JRRET

AU XILJARY LOWERING OPTION •

8A 3—POS ROTARY KEYSWITCH — 3 PL + •• e 10 — + 17

HEAD/TAIL L;SHTS OPTION

——

DRIVE

DRIVE SPEED RANGE IN CONTROLLER TRAVEL ALARM OPTION SERIES/PARALLEL DRIVE SPEED PILOT VALVE LOCKUP RELEASE VALVE

NOTES: . "UPPER" AND "LOWER" DESIGNATE COILS CF 3—POS, 4—WAY VALVE THAT DIRECTS HYDRAUUC FLUID TO UPPER OR LOWER CONTROL VALVE. 2. LIFT LIMIT SWITCH IS SHOWN WITH ARMS ALL THE WAY DOWN 3.

AND WITH BOOM LEVEL OR LOWER. >>. DESIGNATE CONNECTORS AT ENGINE.

4. GROUND IS DESIGNATED AS 26/27 OR 1 OR 5. DRAWING 37941 SUPERCEDES DRAWING 37723.

• SLOPE SENSOR

mopprTANY NFORIIATIaR 0000 OS MM. MIL 00000 1010000 110 • 01. 1 • MUM al VC =POCK 00110.110 NO DOME MOM 010. 11•11001 • GUM WW2* MO W. iff WOK POW IMOR UPS • 01 MON 0000 VC OUR WM 10110f 'QUM 01,00110.. 01118 0100 L114/33 01140t010 0.031F12.

SLOPE ALARM 80335 SIGNAL HORN OPTION

6636 11/d 94 /144

CM. ECANal DATE !WM.

3.564

1 4/2f/s3

CM EJULNa DATE

RAK

01 OSWW1 .4,0101 ME TOLER.= OP& maul mums mown. at.

DRA101

K AU3ERTS

000003

1.4C8

APP00`40

RAK

4/24A3 4

II 110

'."/ACO, TEXAS

SCHEMATIC, A524-47AG—K DItA11010

scam NONE

EL •

379 41 1 OF 1