Condor 46EN Calavar Self-Propelled Operation Maintenance & Parts Manual - PDF DOWNLOAD

OPERATION/MAINIENANCE AND ILLUSTRATED PARTS MANUAL FOR YOUR CAL/WAR SELF-PROPELLED CONDOR INDUSTRIAL MODEL 46EN Calavar Corporation provides this Manual for the guidance of all owners, operators, and servicing personnel in order to obtain the longest possible trouble-free service. It contains general data; specifications; operating instructions; recommended lubrication procedures; vendor information and specifications; illustrated parts breakdown; and a special section on safety.

CA L.P.VA IR

tr.

CORPORATION

Serial Number Date Delivered CUSTOMER

Note: Additional copies of this manual (Part No. 92182) can be obtained through the Parts Department at Calavar.

46EN/10-83: Series I

CALAVAR SELF-PROPELLED CONDOR INDUSTRIAL MODEL 46EN

INDEX Introduction • . . .•••••••.••.... . Page 1 Unloading Instructions . . . . 0 • 2 Factory Recommended Transportation Diagram . • ..... • . . • • • . . • . . 4 • • • • . • . . . . . 5 Check-Out Instructions .

Calavar Warranty• . • ......

• . . . . • 8 Conversion Table, Degrees to Percentages . • • . 0 . . . 8(a) General Information: General Specifications .•••••• 9 Hydraulic System . . . . • • . . . 12 Electrical System. • . . • • • • • . 14 Presetting Controllers . . . . . . 16 Battery Charger Operation. . • • • . • . . • 17 Operation Procedures . . . • • . . . 18 Troubleshooting Guide. . . • ... • • • 0 • . . . 19 20 Starter Failure Analysis . • • Checks to Make on Starter 21 Electrical Check of Starter. .. • . 22 D.C. Motor Controller Block Diagram 23 Oil Specification Sheet. . . 0 0 0 . 24 Lubrication Chart. . . . . . • • . .25 Tightening of Torque Valves. ... • • • . . 28 . .

Industrial Battery Operating Instructions . . 29 Recommended Battery Maintenance. ... . .30 Battery Inspection Report. . • • • . . 34 Central Control Record • • . . . .35 Battery Capacity Test ... • • • . . . . .36 • • • • . . . .37 Preventative Maintenance . . .

Vendor Section: Racine Solenoid Control Valves W.S.I. Drive Motor Fairfield Torque-Hubs H.P.I. Proportional Valve Sundstrand Load-Sensing Pump Sundstrand/Honeywell Control Consoles Sundstrand/Honeywell Multi-Axis Slope Sensor Return Line Spin-A-Filter 180° Rotary Actuator Hydraulic Rotary Coupling Electrical Rotary Slip Ring Synchro-Start D.C. Solenoids Cylinder Holding Valves 46EN/10-83

CALAVAR SELF-PROPELLED CONDOR INDUSTRIAL MODEL 46EN

INDEX--CONTINUED Parts Section: Parts Breakdown Hydraulic Schematic #32873 Electrical Schematic #32885 Condor Operation and Safety Section

46EN/10-83

INDUSTRIAL SELF-PROPELLED CONDOR PARTS AND MAINTENANCE MANUAL

INTRODUCTION The function of the Parts and Maintenance Manual is to first provide the Customer with a complete and up-to-date Parts Manual covering models presently in production and second, to aid in ordering correct parts. If used properly it will provide the customer with a source of information that will aid in solving quickly and inexpensively the bulk of maintenance problems.

Under the various sections called out in the index, Calavar has included all of the specification sheets from the manufacturers of component parts that make up the Condor, as well as a general troubleshooting guide directed solely to the Condor as a completed unit: Throughout this manual reference is made to unit serial numbers, and the use of this number when ordering parts will assist our parts department in giving you prompt and accurate service. The use of correct serial numbers and part numbers will also expedite completion of warranty claims sent to Calavar. Serial numbers should also be used at all times in phone conversations to Calavar's service personnel.

This manual has been produced as a valuable tool for our customer. It 'is in your best interest that time be spent to read and understand all the sections in the manual.

Calavar has included a special section that deals with the safe operation of the Self-Propelled Condor, as well as information about certain items that must be inspected periodically to ensure a safe operating unit.

-o0o-

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IMPORTANT UNLOADING INSTRUCTIONS FOR THE SELF-PROPELLED CONDOR, INDUSTRIAL MODEL 46EN BEFORE UNLOADING THE CONDOR, INSPECT FOR ANY PHYSICAL DAMAGE. NOTE ANY SUCH DAMAGE ON THE FREIGHT BILL AND REPORT SAME TO CARRIER.

CAUTION The Self-Propelled Condor, Industrial Model 46EN, weighs approximately 17,500 lbs., and must be unloaded on a sturdy ramp.

If possible, select a site for unloading the unit that is suitable for making the installation check-out and inspection. A procedure form has been provided and must be completed before putting the CONDOR into service.

Operating instructions are located on a placard on the inside of access door to ground controls. Before starting the electric motor, check out the items as instructed on the placard and then proceed to operate the CONDOR following the Check-Out Instructions in this manual.

NOTE: Grasp the control handle knob as if it were a ball; squeezing the fingers will lift the bottom side of the control knob. This unlocks the control handle so that it can be moved in either direction.

When released and brought back to neutral position, it will again lock.

CAUTION The lift controls are proportional type, with the speed of movement dependent on the position of the control lever. Controls should always be moved gradually. The normal driving position for the CONDOR is with the counterweight over the drive wheels, and the decal for controller movement is based on this configuration. When the counterweight is positioned over the steering axle, the drive and steering controls will be reversed. Try each control momentarily to orient yourself on the direction of operation. the unit down the ramp, test the automatic braking system by moving the CONDOR slightly back and forth and see that the brakes apply each time the drive controller goes back to neutral position. Move the unit on the truck or trailer and down the ramp approximately a foot at a time, allowing for steering correcitons to be made. Keep unit in alignment with the carrier and ramp during the unloading procedure.

It may be necessary to elevate the boom slightly to clear the ground as you proceed down the ramp.

CAUTION Before driving

All CONDOR models are equipped with a slope sensing device which has been incoporated into the system to indicate a 5° out-of-level condition. This device will automatically cancel all boom functions at both control stations when the CONDOR is subjected to an out-of level condition of 5° or more. An indicator light located in the aerial control console will also warn of this condition.

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Once CONDOR has reached an out-of-level condition of 5° and boom functions are inoperable, the operator may at his option, correct the situation normally by reversing drive direction, or by selecting an alternate route.

The slope sensing device is a safety system and must not be disconnected. Should this system be found inoperative, the CONDOR must be grounded and must not be used until this system has been repaired.

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FACTORY RECOMMENDED TRANSPORTING DIAGRAM

•0

0E4

:0

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4

INDUSTRIAL CONDOR MODEL 46EN CHECK-OUT INSTRUCTIONS The following instructions are a step-by-step procedure for checking out the Self-Propelled Industrial Condor while at the same time acquainting operating personnel with its operation. The procedure will not take over an hour and is time well spent to give both operator and maintenance personnel a better understanding of the operation of the CONDOR, and also to provide an opportunity to acquire experience in the operation of the Self-Propelled Condor.

Prior to placing the Self-Propelled Condor, Industrial Model, into

service, a full check-out of the unit should be made and the Installation Inspection Report completed and returned to the factory. Each unit has undergone a thorough Quality Control Inspection and each unit leaves Calavar in a first-class condition. Unfortunately, transport-

tation damages may occur, and you should be aware of such damages and make a note on the consignee copy of the freight bill. Calavar Corporation is not responsible for damages to units in transit.

1.

Visually inspect all parts of the CONDOR that are exposed.

Check for loose nuts, bolts, damaged hydraulic lines, broken wires or structural damages.

2.

IMPORTANT! Check tire for cuts, etc. They were foam-filled by the vendor.

3.

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

4.

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

5.

All hydraulic valves are located on a panel inside turret cover and are exposed by opening the inspection cover. Close this door, after visual inspection of turret compartment, before placing unit in service.

6.

Turn on master switch at ground station located inside turret door. Momentarily engage the start switch; this activates the CONDOR electrical control circuit. With Ground/Aerial selector switch in Ground position, the unit can now be operated by activating switches marked in universal symbols for BOOM UP, BOOM DOWN, TURRET ROTATION LEFT OR RIGHT, and BOOM EXTEND OR RETRACT. The STOP switch will deactivate the control circuit with a momentary touch only. It is not necessary to turn the master switch off between running operations. This switch only provides the operator with a means of electrically locking CONDOR. NOTE: The CONDOR cannot be driven from the Ground Control console. Move the selector switch to Aerial position, close the access door, and proceed to the platform.

46EN/10-83

NOTE UNIVERSAL SYMBOLS FOR AERIAL AND GROUND CONTROL CONSOLES 7.

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

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

8.

The Self-Propelled Industrial 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.

9.

A modular valve is located on the base between drive wheels.

It contains several features -- a flow divider cartridge, two diverter cartridges, a two-speed solenoid cartridge, a flow control and check valve cartridge, and counterbalance valve.

This modular valve performs the necessary functions of dividing the oil for slow speed travel with adjustable differential action to round corners, as well as diverting the oil flow for high speed travel. The counterbalance valve softens the brake release and application, efficiently without an accumulator.

10. The wheel drive has the following features: A.

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

B.

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

C.

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

D.

In LOW speed mode, the vehicle has 0 - 1.5 mph speed capability (fully proportional).

E.

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

F.

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

11.

Operate boom at HORIZONTAL position until you have familiarized yourself with the operation and how the controllers feel. The smoother you are with the controller, the smoother the unit will respond.

12.

Gradually operate unit up to maximum elevation and extension.

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13. All Self-Propelled Industrial Condor Models are equipped with a slope sensing device which has been incorporated into the system to sense a 5° out-of-level condition. This device will automatically cancel all boom functions at both control stations when unit is subjected to an out-of-plumb condition of 5° or more. An indicator light located in the aerial control console will also warn of this condition. Once unit has reached an outof-level condition of 5° or more and boom functions are inoperable, the operator may at his option, correct the situation normally by reversing drive direction, or by selecting an alternate route. Even though this is a safety device, it must not be considered as a fail-safe system. The operator must use normal safety precautions when operating this equipment.

The slope sensing device is a safety system and must not be disconnected. Should this system be found inoperative, the unit must be grounded and must not be used until this system has been repaired.

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AL.IWA CORPORATION

9200 SO. SORENSEN AVE. • SANTA FE SPRINGS, CALIFORNIA 90670 • 213/921-5521 • TELEX 69-8378 • CABLE: CALACORP

WARRANTY

Calavar Corporation ("Calavar") warrants each new aerial work platform made by Calavar and bearing the trademark "Condo " to be free from defects in material and workmanship.

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

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

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTIES OF MERCHANTABILITY AND FITNESS FOR ANY PARTICULAR PURPOSE, AND THE OBLIGATION AND LIABILITY OF CALAVAR UNDER THIS WARRANTY SHALL NOT INCLUDE ANY TRANSPORTATION OR OTHER CHARGES OR THE COST OF INSTALLATION OR ANY LIABILITY FOR DIRECT, INDIRECT OR CONSEQUENTIAL DAMAGES OR DELAY RESULTING FROM THE DEFECT.

Any operation beyond rated capacity or the improper use or application of equipment or the substitution upon it of parts not approved by Calavar or any alteration or repair by others in such manner as, in Calavar's judgment, to affect the equipment materially and adversely shall void this Warranty. No representative of Calavar is authorized to change this Warranty in any way, and no attempt, effort or promise to repair equipment of Calavar either by Calavar or by any representative of Calavar at any time shall change or extend this Warranty in any way. This Warranty covers only new and unused aerial work platforms manufactured by Calavar. Products or parts manufactured by others are covered only by such warranties as are extended to Calavar by its suppliers.

Form No. 280-2500-181

Printed in U.S.A.

CONVERSION TABLE DEGREES TO PERCENTAGE

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

l00% 95% 9o% 85% 8o% 75% 7o% 65% 60% 55% 5o% 45% 4o% 35% 30% 25% 2o% 15%

lo% 5% - 100 ft. ---

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8(a)

INDUSTRIAL CONDOR MODEL 46EN GENERAL SPECIFICATIONS AND INFORMATION 1. Electic Motor and Starter A. Horsepower (Continuous Duty): 25 H.P. B. Speed: 2600 RPM C. Voltage: 72V, D.C. D. Housing: Open, drip-proof type E. D.C. Motor Starter: Operating Voltage: Nominal: 72 V D.C. Low: 63 V D.C. (Self Protecting) Maximum Operating Current Limit: (Adjustable) Average: 350 Amperes Peak: 375 Amperes Operating Duration: (50 Celsius Amb.) Continuous: 300 Amperes (Thermally Protected) Control: Pilot Relay Contacts Closed--Full Speed Contacts Open--Stopped Acceleration Ramp: 3 to 4 Seconds Size: 6 in. x 9 in. x 10 in.

2. Batteries A. B. C. D. E. F. G. H. 3. Pump

A. B. C.

Quantity Required: 2 Connected in Series Each Battery: 36 V D.C., 525 Amp-Hour Total Capacity: 36.2 Kilowatt-Hours (6-Hour Rate) Battery Housing: Steel with Forklift Pockets Length: 27 in. (0.69 m) Width: 19 in. (0.48 m) Height: 34 in. (0.86 m) Weight: 1850 lbs. (839 kg) each Sundstrand Series 18 Compensator Pressure Setting 2500 PSI Load Sensing Differential 350 PSI

4. Proportional Control Valve A. H.P.I. B. Main System Relief 3200 PSI C. Operating Voltage 0 12 Volts -

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5. Solenoid Control Valve A. Racine Valve B. Operating Voltage--12 Volt C. Operating Flow 2 GPM 6. Holding Valves (set and sealed at factory) A. Platform Leveling (pilot operated check valve) B. Boom Lift Holding Valve 2900 PSI C. Boom Extension Holding Valve 2900 PSI D. Platform Rotation (pilot operated check valve) 7. Ring Gear Bolts A. Base to Ring Gear, 105 ft-lbs.

B. Turret to Ring Gear, 205 ft-lbs.

8. Weight (approximate only) A. Model 46 EN--17,500 lbs.

9. Tires

A. Foam-Filled

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INDUSTRIAL CONDOR MODEL 46EN FUNCTION TIME TABLE (4. 10%)

FUNCTION

MODEL

Boom Extension

31 Seconds

Boom Retraction

28 Seconds

Topping - Up

32 Seconds

Topping - Down

30 Seconds

Turret Rotation - CW

100 Seconds

Turret Rotation - CCW

100 Seconds

200 ft. drive forward - high

45 Seconds

200 ft. drive reverse - high

45 Seconds

200 ft. drive forward - low

86 Seconds

200 ft. drive reverse - low

86 Seconds

Turning Radius (outside)

14 ft. 6 in.

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HYDRAULIC SYSTEM The hydraulic system for the Self-Propelled Condor Industrial Model 46EN uses a Sundstrand Series 18 flow and pressure compensated piston pump driven directly from the engine shaft.

Flow from the pump is connected to the H.P.I. Proportional Control Valve Assembly. The pump has a sensing port that is connected to the control valve assembly so as to measure pressure drop across an orifice and automatically adjusts the pump displacement to match the size of the orifice (or valve spool opening). Maximum pressure is 2,500 psi and is set and maintained by the pump pressure compensator. Load sensing differential pressure is 350 psi and is set and maintained by the pump flow compensator.

At idle, with the valve spool in neutral, no pump flow exists. The pump stand-by pressure will equal the selected load sensing differential (350 PSI).

The H.P.I. Valve Assembly is a load sensing type 4-way directional and proportional control system, operated by a variable DC electrical signal (0 - 12 V DC).

The valve assembly is composed of a manifold, drilled and ported to accommodate four solenoid valves, four cartridge compensators, various orifices, shuttle valves and a solenoid operated auxiliary function module, making it possible to perform one or more independent or simultaneous operations of load (drive, boom up or down, boom extension or retraction, and/or turret rotation).

When all valves are in the neutral position, the pump at zero flow and at bias pressure (350 psi), and one or more controller is moved, an electrical signal causes the directional valve spools to move proportionately to the controller lever movements. Small controller lever movement results in small spool movement in the directional valve, maximum controller lever movement results in maximum spool movement in directional valve.

The valve compensator controls flow to its respective 4-way valve. The internal shuttle valve system senses the highest load pressure and directs it to the pump control. The pump then strokes to the total flow requirements of the 4-way valves at a pressure equal to its highest load plus bias pressure.

The auxiliary function module has a built-in solenoid valve. When energized, flow from the pump will be directed to the auxiliary functions of platform leveling, steering, and platform rotation, if option is installed. Because there is not a compensator in this system to establish the load sensing back to the pump upon energizing the solenoid, flow going to the auxiliary functions will see maximum system pressure.

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The pressure fitting at the H.P.I. Valve Assembly is fitted with a pressure test port. Using a 0 - 5,000 psi gauge, the system pressure can be checked. With engine running at a prescribed high rpm, the pump will go to full stroke when the steering is activated to a cramp angle. Pump compensator pressure setting is 2,500 psi. As the steering control is returned to neutral allowing the engine to idle, the bias pressure of 350 psi should appear on the pressure gauge.

Condor cylinders have built-in holding. valves.

▪

Topping has a single holding valve set at 2,900 psi.

▪

Boom extension and retraction has double holding valves set at 2,900 psi and relief valve set at 1,400 psi.

• Slave leveling has double pilot operated check valves.

EMERGENCY POWER SYSTEM Industrial Condors are equipped with a small emergency (12V D.C.) electric driven pump. This system can lower the boom, retract the boom, and rotate the turret; one function at a time.

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ELECTRICAL CONTROL SYSTEM (12 VOLT D.C.)

Electrical Schematic Drawings are located at the back of the Parts and Maintenance Manual and should be referred to for a better understanding of the Condor electrical system.

The Self-Propelled Condor, Industrial Model 46EN utilizes a 12 volt direct current system with a negative ground. All electrical components with the exception of the proportional control valves, operate directly from the 12 V DC source. The proportional control valves are energized at the ground control station through toggle switches which have a resistor on the supply terminal. The resistor drops the voltage to a level for continuous operation. The Aerial Control Station contains lever type proportional controllers which are designed to deliver the required proportional voltage to the valves through the entire movement of the controller handles.

To prevent early problems and to aid in troubleshooting the electrical system, the use of a hydrometer will determine the condition of the battery. If at times it may not have adequate capacity to operate the H.P.I. valve, check the specific gravity of the battery. An acceptable reading on a fully charged battery will read approximately 1.200 on a hydrometer.

The Ground Control Station is primarily an emergency control station.

Anyone on the ground can transfer operation from the operator in the platform by switching the aerial ground toggle switch to the ground position. When in the ground position, lift, rotation, extension and retraction are controlled with momentary bi-directional toggle switches.

(Speed is controlled with rotary potentiometer at the ground panel.)

Each of the ground toggle switches, when activated, electrically energizes the electric motor. The function selected is now hydraulically and electrically energized and operational.

Proportional Speed Controllers used to control drive, lift, turret rotation, boom extension/retraction, are located at the aerial station.

Bi-directional toggle switches are used for steering, tilt and platform rotation.

NOTE See Sundstrand/Honeywell Literature, Vendor's Section, for details of operation and adjustment.

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Electric motor start and stop at the aerial station and ground station are independent circuits. The Condor can be started or stopped at any time from either position. After the master switch has been turned on, pull the start button. To stop takes only a momentary touch of the stop button.

NOTE The electric motor stop circuit is considered a safety feature and must be maintained as a safety item.

To perform electrical checks, turn master switch on. Pull the start button momentarily. This resets the main latching relay and will energize the entire electrical system.

See troubleshooting procedures of Sundstrand/Honeywell literature in Vendor Section.

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PRESETTING PROPORTIONAL CONTROLLERS FOR CONDOR MODEL 46EN Controlled settings must be made with a fully-charged battery on the CONDOR machine.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

Turn key on.

Ground/Aerial switch to Aerial.

Pull start button to turn on power to aerial box. Remove wire #8 at the pilot control relay.

Take a Volt-Ohm Meter (VOM); set scale to read maximum 10 volt D.C. Place common (-) lead of VOM on ground (-) or black wire.

Place (±) lead of VOM on either green (Forward) or white (Reverse) wire on the controller to be set.

Move controller handle in direction of terminal selected ("F" or "R") until voltage registers on the VOM. Adjust threshold screw on the controller until VOM reads threshold volts on chart.

Move controller handle in the direction of terminal selected to full handle position.

Set Output Adjustment for terminal selected "F" output (Forward) green wire, "R" output (Reverse) white wire to the proper setting.

Repeat steps 9 and 10 for the other terminal, check that threshold voltage is turning on at specified volts in this direction also. If reading is lower than specified, adjust until it reads approximately the specified settings.

Readings taken while electric motor is running will be slightly higher that settings made with electric motor off.

A low battery condition will change settings.

PRESETTINGS FOR MODEL 46EN CONTROLLERS

FUNCTION

OUTPUT FULL HANDLE POSITION THRESHOLD

Topping--Up 7.4 VOLTS 4 Topping--Down 8.3 VOLTS 4 Boom Extend 9.0 VOLTS 4 Boom Retract 9.0 VOLTS 4

VOLTS VOLTS VOLTS VOLTS

Rotation CW (L)

6.6 VOLTS

4 VOLTS

Rotation CCW (R)

6.4 VOLTS

4 VOLTS

Drive Forward

9.0 VOLTS

4 VOLTS

Drive Reverse

9.0

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VOLTS 4 VOLTS 16

CONDOR MODEL 46EN BATTERY CHARGER OPERATION 1. Disconnect both batteries at the quick disconnects.

2. Check the battery charger to insure that it is turned off.

3. There are 2 charging leads on the battery charger. Connect one to each battery. Do not connect charging leads to the electrical connectors mounted on the carriage.

4. Position dial #1 on 8 hours. Position dial #2 on 8 hours. The battery charger will charge battery #1 for 8 hours and then switch automatically and charge battery #2 for 8 hours. Both batteries will fully charge in 16 hours.

NOTE If battery #1 is set for too long of a time span, battery #2 may not be fully charged.

••

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CONDOR MODEL 46EN OPERATION PROCEDURES 1.

Check both battery connectors (main batteries) for full engagement.

2.

Turn key on at Ground Control Console.

3.

Momentarily engage the starter switch. This energized the CONDOR control circuit.

4.

Select "Ground" station on the Aerial/Ground control switch.

5.

Select and operate a function. Adjust the speed control to the desired speed.

6.

The electric motor will start to rotate at a low RPM and increase to full RPM in a 3 to 4 second time span. The electric motor will continue to run as long as a function is being performed. If a function is not operated for approximately 6 minutes, the electric motor will stop. The motor is restarted by performing any function (moving the controller handle/lever).

7.

Select "Aerial" station on the Aerial/Ground control switch. Now the machine can be operated from the platform.

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TROUBLE SHOOTING THE STARTER IN THE MACHINE

POSSIBLE CAUSE CORRECTIVE ACTION SYMPTOM 1. MACHINE STOPS

LOW BATTERY VOLTAGE

CHARGE BATTERIES

BLOWN FUSE

CHECK AND REPLACE .

LOOSE WIRING

CHECK AND REPAIR

STARTER IS CURRENT LIMITING (WHINING)

MECHANICALLY SEIZED

LOW BATTERY VOLTAGE CHARGE BATTERIES.

2. MACHINE RUNS SLOWLY.

STARTER OVERHEATED ALLOW TO COOL 3. NO CONTROL

HAND CONTROL WIRING CHECK AND REPAIR STARTER FAILURE * CHECK STARTER

4. FUSE CONTINUES TO BLOW.

CHECK AND REPLACE.

CHECK AND REPLACE. FAILED CONTACTOR

* CHECK STARTER. FAILED STARTER

FAILED MOTOR

* SEE STARTER FAILURE ANALYSIS.

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STARTER FAILURE ANALYSIS IT IS HIGHLY UNLIKELY FOR THIS STARTER TO FAIL UNDER NORMAL OPERATING CONDITIONS, AS THE COMPONENTS USED IN THE MANUFACTURE OF THE UNIT ARE RATED WELL IN EXCESS OF THE EXPECTED OPERATING LEVELS. HOWEVER, DUE TO AN EXTERNAL FAULT, SUCH AS INCORRECT CONNECTION, OR MOTOR FAILURE) IT IS POSSIBLE THAT ONE OR MORE OF THE POWER COMPONENTS COULD BE OVERLOADED AND FAIL, CAUSING CONTINUED BLOWING OF THE FUSE IN THE HIGH CURRENT LINE, OR ERRATIC OPERATION OF THE STARTER. TO CHECK THE STARTER, IT IS FIRST NECESSARY TO BE SURE OF THE FAILURE MODE WHAT DOES THE STARTER DO?, OR NOT DO?).

FOR EXAMPLE, IF THE FUSE CONTINUES TO BLOW, THIS COULD BE BECAUSE THE STARTER TRIES TO START THE MOTOR ABRUPTLY, INSTEAD OF BEING CAUSED BY SHORTED POWER COMPONENTS. SYMPTOM

POSSIBLE CAUSE CORRECTIVE ACTION.

CHECK AND REPLACE

CHECK AND REPLACE. FAILURE OF POWER TRANSISTOR

DOESN'T RUN FAILURE OF CIRCUIT BOARD

2. BLOWS FUSES

FAILURE OF CIRCUIT BOARD

CHECK AND REPLACE

FAILURE OF POWER TRANSISTOR

CHECK AND REPLACE.

FAILURE OF POWER DIODES

CHECK AND REPLACE.

FAILURE ON LARGE CAPACITOR

CHECK AND REPLACE.

3. RUNS SLOW WHEN FAILURE OF CIRCUIT BOARD COOL

CHECK AND REPLACE.

4. STARTS ABRUPTLY

READJUST

INCORRECT ADJUSTMENT OF CONTROL RANGE

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20

FIRST CHECKS TO MAKE ON THE STARTER AFTER REMOVING FROM THE MACHINE. 1. A PHYSICAL INSPECTION SHOULD BE MADE OF THE STARTER CONNECTIONS TO BE SURE THEY HAVE NOT COME LOOSE OR BEEN DAMAGED IN ANY WAY. IF NO DAMAGE IS APPARENT, CONTINUE WITH THIS CHECK-OUT ROUTINE. IF DAMAGE APPEARS EVIDENT, REPAIR OR REPLACE THE DAMAGED COMPONENTS BEFORE CONTINUING THIS TEST PROCEDURE. IT WILL BE NECESSARY TO REMOVE THE STARTER COVER TO REPAIR ANY DAMAGE. THE PRELIMINARY ELECTRICAL TESTS BELOW, CAN BE DONE WITHOUT REMOVING THE COVER. 2. A CHECK CAN BE MADE WITH A CONTINUITY CHECKER, TO DETERMINE IF ANY SHORTS EXIST IN THE STARTER POWER COMPONENTS WHICH COULD CAUSE INCORRECT OPERATION. MAKE A SIMPLE CONTINUITY CHECKER WITH A 12V LAMP AND A 12V BATTERY AS SHOWN BELOW. (AN OHMMETER CAN BE USED BUT SOMETIMES THE TESTS ARE INCONCLUSIVE SINCE THE TEST THIS WAY IS MADE WITH VERY LITTLE CURRENT)

SIMPLE CONTINUITY CHECKER SINCE DIODES ARE BEING CHECKED, IT IS NECESSARY TO USE THE CONTINUITY CHECKER WITH THE CORRECT POLARITY TO ASSURE CORRECT ANALYSIS. 3. CHECK THE BRAKING DIODE BY CONNECTING THE CONTIUNITY CHECKER TO TERMINALS "ARM-PUS" AND "ARM-FIELD", WITH PLUS TO "ARM-PUS". NO CONTINUITY SHOULD BE NOTED. REVERSE THE POLARITY OF THE CONNECTIONS, AND CONTINUITY SHOULD OCCUR. 4. THE FREE WHEELING DIODE SHOULD BE CHECKED BY CONNECTING FROM "ARM -POS" TO "FIELD" WITH PLUS ON "ARM-PUS". NO CONTINUITY SHOULD SHOW. REVERSE THE CONNECTIONS AND CONTINUITY SHOULD SHOW. 5. THE POWER TRANSISTOR CAN BE. CHECKED BY CONNECTING THE CHECKER FROM "FIELD" TO "NEG" WITH PLUS ON "FIELD". NO CONTINUTY SHOULD SHOW. REVERSE CONNECTIONS TO SHOW CONTINUITY. 6. ISOLATION FROM THE CHASSIS CAN ALSO BE CHECKED BY CONNECTING THE CHECKER TO "NEG" AND THE THE METAL CASE, WITH PLUS TO "NEG". NO CONTINUITY SHOULD SHOW WITH EITHER POLARITY CONNECTION. IF THESE TESTS PROVE 0.K., THE STARTER CAN THEN BE ELECTRICRLY CHECKED BEFORE

RE-INSTALLING IN THE MACHINE. OF COURSE IF ONE OR.MORE CONTINUITY CHECK PROVES FAULTY,

THE SUSPECT COMPONENT SHOULD BE REPLACED OR REPAIRED, AND THE CHECKS RE-RUN BEFORE DOING

THE ELECTRICAL CHECKS OR REPLACING THE STARTER IN THE MACHINE.

46EN/10-83

21

ELECTRICAL CHECK OF THE STARTER OUT OF THE MACHINE

TO CHECK THE OPERATION OF THE STARTER OUT OF THE MACHINE, IT SHOULD BE CONNECTED AS SHOWN BELOW: 100

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cow

4

P u se, I /1 4

A4110

too 0004 So v.)

cf‘ +12/96

Ft.1)

tl

VB.

To -8

I 41 4, 0 0 \ 0

0

0

CONNECTIONS FOR TESTING THE STARTER A VOLTMETER CAN BE USED TO DETERMINE IF THE STARTER IS FUNCTIONING CORRECTLY BY MEASURING THE RESPONSE TO VARIOUS OPERATING CONDITIONS. SOME DIGITAL VOLTMETERS MAY NOT RESPOND CORRECTLY TO THE TYPE OF WAVEFORM THAT THE STARTER PUTS OUT, THEREFORE IT IS BETTER TO USE A MECHANICAL (NEEDLE POINTER) METER TYPE OF UNIT. CONNECT THE VOLTMETER FROM TERMINALS "ARM-PADS" TO "ARM-FIELD", WITH THE PLUS ON "ARM-POS".

TURN ON SW-1, THEN SW-2. IF THE 5AMP. FUSE BLOWS, PERFORM THE FULL SERIES OF CONTINUITY CHECKS, BEFORE CONTINUING. APPROXIMATELY 18 VOLTS SHOULD BE READ ACROSS THE OPEN PILOT RELAY CONTACTS CONNECTED TO TERMINALS I AND 2. 72V /96V SHOULD BE MEASURED ACROSS THE OTHER SET OF N. O. PILOT RELAY CONTACTS. WHEN THE PILOT RELAY IS ACTUATED THE VOLTAGES WILL BE ZERO. IF THIS TEST PROVES SATISFACTORY, THE BASIC OPERATION OF THE STARTER HAS BEEN VERIFIED. TO CHECK CURRENT LIMIT, LOW VOLTAGE CUTOFF, ETC., REQUIRES TEST EQUIPMENT NOT NORMALLY FOUND IN THE FIELD. SHOULD THE STARTER PERFORM ERRATICALLY, YET PASS THESE PRELIINARY CHECK, THE CIRCUIT BOARD CAN BE REPLACED WITH A SUBSTITUTE UNIT, AND THE CHECKS CAN BE MADE AGAIN. IF ERRATIC PERFORMANCE IS STILL NOTED AFTER PERFORMING THESE FIELD CHECKS, THE STARTER SHOULD BE RETURNED TO THE FACTORY FOR SERVICE. ■■•

46EN/10-83

22

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1)444C.,

7:1210 LOC. Pgir

t1Th( -

Di A a) sli alkAN. APPROVED BY:

SCALE: DATE:

4 71)

DRAWN BY REVISED

erNt

NE114C t2-P

DRAWING NUMBER

?.113133

HYDRAULIC OIL SPECIFICATIONS for CA LAVAR AERIAL WORK PLATFORMS

OIL COMPANY Chevron

Gulf

ATF ATF Dextron II Dexron II D Series

Brand Name

Shell I Union 1 Mobil

ATF Donax T6 Dexron

ATF 220

Conoco

Dexron

it

Viscosity, SUS @ 100° F 205 SUS @ 210° F 50.1

195 50.4

175 49

200 187 52,3 50

170 50

Viscosity Index Typical 150

155

160

172 I 159

145

390°

395° 320°

365°

-45°

-45°

Flash Point ° F

350°

Pour Point ° F

46EN/10-83

-50°

24

Ph

0 oo

LUBRICATION CHART FOR MODEL 46EN

INTERVAL SYMBOL

LII

50 HOURS or SEMI-MONTHLY 100 HOURS or MONTHLY

(Sheet 1 of 2)

MASTER LEVELING CYLINDER 2 - PLACES

Check Speed Reducer®

500 HOURS or ANNUALLY

Speed Reducer-Change Oil TYPE OF LUBRICANT CG - CHASSIS GREASE: SHELL DARNA AX 70330, or EQUAL SL - SPRAY LUBE: CROWN 7045 HEAVY DUTY OPEN GEAR AND WIRE ROPE LUBE, or EQUAL GO - GEAR OIL : SAE 90 WEIGHT EP

TORQUE HUB RING GEAR 2 - PLACES

N.) oh

(Rotate Turret While Lubing) WHEEL BEARINGS WHEEL BEARING GREASE PLATFORM PIVOT PIN 2 PLACES

PLATFORM LEVELING CYLINDER 1 PLACE

1-fl

INTERVAL SYMBOL

LUBRICATION CHART FOR MODEL 46EN ( Sheet 2 of 2)

0 50 HOURS or SEMI-MONTHLY E; i 03 100 HOURS or MONTHLY G.) Ell

0

BOOM PIVOT PIN 2 PLACES

500 HOURS or ANNUALLY

TYPE OF LUBRICANT CG - CHASSIS GREASE: SHELL DARNA AX 70330, or EQUAL SL - SPRAY LUBE: CROWN 7045 HEAVY DUT Y OPEN GEAR AND WIRE ROPE LUBE, or EQUAL GO - GEAR OIL : SAE 90 WEIGHT EP STEERING KNUCKLE

Hydraulic Tank Oil (ATF Dextron II)

2- EACH SIDE

Hydraul ic Line Filter

TIE RODS I - EACH SIDE

TOPPING CYLINDER 2- PLACES

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

46EN/10-83

27

TIGHTENING TORQUE VALUES

1/4 - 20 1/4 - 28

Tightening Dry

Torque Lub

Ft. Lbs. N/M

Ft. Lbs.

5.5 6.3

7.5 8.5

SAE GRADE 8

SAE GRADE 5

SAE GRADE 2

4.08 4.66

N/M

Tightening Dry

Torque Lub

Ft. Lbs. N/M

Ft. Lbs.

5.5 6:2

8 10•

10.8 13.6

6.2S 7.2

N/M

Tightening Dry

Torque Lub

Ft. Lbs. N/M

Ft. Lbs.

N/M

8.5 9.8

12 14

16.3 19.8

9 10

12.2 13.6

5/16 - 18 5/16 - 24 3/8 - 16 3/8 - 24 7/16 - 14

11 12 20 23 30

15 16.3 27.1 31.2 40.7

9 15 17 24

10.8 12.2 20.3 23 32.5

17 19 30 35 SO

23 25.8 40.7 47.S 67.8

13 14 23 2S 35

17.6 19.0 31.9 33.9 47.5

25 25 45 SO 70

33.9 33.9 61.0 67.8 95.0

18 20 35 35 55

24.4 27.1 47.5

7/16 - 20 1/2 - 13 1/2 - 20 9/16 - 12

3S SO SS 70

47.5 67.8 74.6 95.0

ZS 3S 40 SS

33.9 47.S 54.2 74.6

SS 75 90 110

74.6 •101.7 122.

149.1

40 SS 6S 80

54.2 74.6 88.1 108.5

80 110 120

108.5 149.1 162.7

60 80 90

81.3 108.5 122.0

9/16 - 18

80

108.5

60

81.3

120

162.7

90

122.0

150 170

203.4 230.5

110 130

149.1 176.3

5/8 - 11 5/8 - 18 3/4 - 10 3/4 - 16 7/8 - 9

100 110 175 195 165

135.6 149.1 - 237.3 264.4 223.7

75 85 130 145 125

101.7 ' 115.2 176.3 196.6 169.5

150 170 260 300 430

203.4 238.5

110 130 200 220 320

149.1 176.3 271.2 298.3

220 240 380 420 600

298.3 325.4 515.2 569.4 813.5

170

180 280 320 460

230.5 244.o 379.6 433.9 623.7

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

185 250 270 350 400

250.8 339.0 366.1 474.5 542.3

140

190

189.8 257.6

•474.5 650.8 718.6

660 900 1000 1280 1440

894.8 1220.2

271.2 366.1 406.7

637.2 867.7 949.0 1084.6 1193.1

350 480

200 270 300

470 640 700 800 880

500 680 740 960 1080

678.0 922.0 1003.3 1301.6 1464.3

1-1/4 - 7 1-1/4 - 12 1-3/8 - 61-3/8 - 12 1-1/2 - 6

500 550 660 740 870

678.0 745.69 694.8 1003.3 1179.5

380 420 490 560 650

515.2 569.4 664.3

1518.5 1681.2

759.2 881.3

1120 1240 1460 1680 1940

2467.6 2711.6 3226.8 3687.8 4284.3

1780 2040 2360

1-1/2 - 12

980

1328.7

730

989.7

2200

4826.6

2660

FOOTNOTE: Foot/Pounds to Newton/deters

;4 1.3558

352.5 406.7 583.0

•

530 600 66o

433.9

813.5 894.8

1979.5 2277.7 2630.3

840 920 1100 1260 1460

1979.5

1820 2000 2380 2720 3160

2982.8

1640

2223.5

3560

1138., 1247.3 1491.4 1708.3

1355.8 1735.4 1952.4

•

1360 1500

47.5 74.6

1843.9 2033.7 2413.3 2765.8 3199.7 3606.4

OPERATINGINSTRUCTIONS INDUSTRIAL BATTERIES RECEIVING BATTERY: It is extremely important to examine the exterior of the packing case upon receipt of the battery. Examine for wet spots on sides and bottom.

Wet spots may indicate leaking cell jars broken in shipment due . to rough handling by the carrier. If any damage is observed mark the receiving slip accordingly, file-a claim with the transportation company and contact the battery company. Complete receiving inspectionshould be accomplished as soon as possible and appropriate action taken in the event of shipping damage.

PLACING THE BATTERY INTO SERVICE : 1. Give battery a thorough external inspection, including the type number ordered, tray, cover, sealing, cable and connector.

2. If the new battery is dry charged, follow the special dry charge instructions, otherwise remove all cell caps and water as required - DO NOT OVERFILL. The electrolyte level should not be higher than the bottom of the fill tube or approximately 1/2" above the moss shield.

3. Check that the respective charger is compatable with the new battery.

Place the battery on.a freshening charge for approximately three hours.

4.

The specific gravity at the end of the charge should be approximately 5.

1.280 (temp. corrected).

6. Paint the assigned I.D. numbers on each end of battery and prepare it's maintenance record file._ 7. During the first week of service, extra attention should be given to the new battery in order to confirm that it is receiving proper charging and that it is capable of performing the required work load; This is accomplished by checking the specific gravity of a Tew.pilot cells at the end of the work shift (before re-charge). The reading should be no less than 1.140. At the end of the re-charge period the specific gravity should be no less than. 1.270.

STORING BATTERY: If the new battery is not put into service immediately, it should be stored in a cool dry area. It should be given a re-charge every 60 days.

NORMAL MAINTENANCE: Battery should be given a daily re-charge imMediately following an . accumulative 6 hour work period. Battery should be given an equalizing charge at least once per month. The top of the battery must be kept clean and diy and the electrolyte must be kept at the proper level. Use only approved water. Record specific gravity and open cell voltages periodically in order to determine when a cell is starting to fail. Maximum voltage variation. (open cell) is .03V and maximum specific gravity variation is 20 points.

46EN/10-83

29

RECOMMENDED BATTERY MAINTENANCE

Record Keeping Two sources of record keeping is recommended. One source would be used

primarily for inventory, cost and performance; the other would contain all activity documentation.

Central Control

This record should be maintained by the person in charge of all batteries regardless of location. Its useful purpose is to provide information for inventory, depreciation, warranty, operational expenses and periodic maintenance requirements. The attached example is offered for your consideration.

Chronologically recorded information should include, location or duty change, periodic capacity test percentages and specific repair cost.

Local Control A separate file . folder should be kept on each battery. It should contain complete documentation of all activity, such as weekly and monthly inspection reports, required repairs, change of location or duty and any abnormal operating condition, such as excessive water requirements, running out of charge before the end of the work shift, excessive operating or charging temperatures, etc.

New Battery When a new battery is placed in service, it should be given special attention during the first week of operation. The following suggestions are recommended: 1.

Upon receiving, give battery a thorough external inspection, including the type number ordered, tray, cover, sealing, cables and connector.

2. Check that the respective charger is compatable with the battery.

3. Remove all cell caps and add water if required. Replace cell caps.

4. Place on freshening charge for approximately three hours.

5. Check output of charger. When charger is first turned on it will show a high rate.

After three or four minutes the charge rate should

stabilize at a lower rate. At the end of three hours of charging,

46EN/10-83

30

check the specific gravity of the electrolyte. It should be approximately 1.280 and the charger output should be at the low end of the scale. (5% of the A.H. rating of the battery or less).

6.

Paint the assigned user number on each end of the battery.

7.

Set up the file on the subject battery and enter the required documentation.

8.

Place the battery in service.

9.

During the first week of service, 'extra attention should be given

to the new battery in order to confirm that it is receiving proper charging and capable of performing the required workload. This can be accomplished by checking the specific gravity of a few pilot cells at the end of the workshift and at the end of the charge period.

The respective Trojan battery reading should be 1.270 or mere at the end of charge period and no less than 1.140 at the end of the workshift.

Daily Maintenance 1.

Prior to the commencement of the workshift install the battery which

has had a cooling period following the recharge.

2.

Check pilot cells for temperature; specific gravity; and electrolyte level.

3.

Observe cable and connector conditions.

4.

If all checks are satisfactory, no entry need be made in log.

5.

At the end of the workshift, exchange batteries and release truck after performing 2, 3 and 4 above.

6.

Before placing the discharged battery on charge,

check the

temperature; specific gravity and electrolyte level.

7.

Connect charger and turn switch to normal position. Observe charger output.

The output should be within the upper quarter

of maximum.

Weekly Maintenance

1.

Check cables and connector condition.

2.

Check all cells for water. Fill as required.

46EN/10-83

31

3.

Place on charge and set timer to equalize position.

4. Since watering may be required the supervisor may want a log entry as to the amount of water required.

Monthly Maintenance 1.

Check cleanliness of battery. Wash if necessary.

2.

Check all cells for water. Fill as required.

3.

Place on charge and set timer to equalizing position.

4.

At the finish of the equalizing charge, complete all the information required on the "Battery Inspection Report". If other service or repairs are made enter such information under #6 ofthe report.

Bi-Annual Maintenance 1.

Wash battery if necessary.

2.

Check all cells for water. Fill as required.

3.

Check cables, connector, seal and paint. Service as required.

4.

Place on charge and set timer to the equalize position.

5.

Following the completion of the equalizing charge and cooling period, the battery will be given a capacity test.

6.

Complete all requirements listed on the "Battery Capacity Test" report.

7.

Recharge battery and return to service.

8.

Forward of copy of the report to Central Control.

CHARGERS One of the most important assurances of maximum battery life is a properly operating charger. Therefore, a great amount of emphasis is placed on periodic charger inspection. Any unusual charger performance should be investigated without delay. Do not assume that a problem is the battery - it could very well be a malfunctioning charger. If there is a responsible person who charges the batteries, he would recognize a malfunctioning charger immediately if he observed

46EN/10-83

32

the following listed items on a daily basis.

1. When a charger is operating beyond its normal period it would indicate that the timer was improperly set or the timer had failed..

2. Before connecting the charger to the battery to be charges, check the timer switch to be off; check the charger cables and connector.

3. After connecting the battery and turning the timer to the correct position notice the charger current meter. When first turned on it should show maximum current and after about 2 or 3 minutes it should

stablize to a steady current. If the battery is low on charge, the meter will remain high for about 5 hours and thereafter will gradually taper down as the battery becomes fully charged. After 6 hours

of charging, the charge rate should be down to, or less than, the finishing rate. The finishing rate is 5% of the A.H. rating of the

battery: e.g. if the battery is rated 600 A.H., the finish charge rate would be: .05 X 600 = 30 Amps. Most chargers taper down to much less.

4. The above listed items, if checked on a daily basis by the maintenance person, would practically eliminate charger problems where resulting battery damage could occur. However, additional charger service is recommended as outlined in paragraph 5 following: 5.

Once a year a complete charger check should be performed. This would include a thorough internal check and cleaning of the charger.

The meter, timer, cables and connector would be checked. A plot of the charge curve would be made - this not only includes the maximum and minimum current output, but also includes the existing current taper qualities which is very important.

46EN/10-83

33

DATE

BATTERY IASPECTION RPPORT MFR.

USER NO. uELL NO. . SPEC. GR .

SER. #

TYPE BATTERY WAS ON

VOLTS

OR OFF

CHARGE

1

CONDITIONS:

2

1. Readings must be taken following an equalizing charge.

3

5

2. If off-charge voltage readings are taken, the float voltage must be removed.

Tolerance = .03 volts Max-

6

3. On charge tolerance = .15 volts Max.

7

INSPECTION:

14

8

1.

9

Battery cleanliness

2. Cables

10

3. Connector 4,

12

Seal

5. Water (Circle cell Ps when added)

13

6. Other Remarks:

14 15

16 17 18

i9 20 21 22

23 24 25

31 32

SIGNATURE

46EN/10 83 -

LI

CENTRAL CONTROL RECORD OF INDUSTRIAL BATTERIES

USER NO. LTL .111,1114;

MFR. COST A CTIV ITY

TYPE NO. LOCATION

A H. SER. NO.

DUTY DATE

ACTIVITY

7

1•.

BATTERY CAPACITY TEST DATE

USER NO; MFR. TYPE NO. SER.NO. .:ITY A.H. ° 6 HOUR DISCHARGE RATE

AMPS

CONDITIONS: BATTERY MUST BE FULLY CHARGED, ELECTROLYTE ADJUSTED TO MANUFACTURERS SPECIFICATION AND. GIVEN SUFFICIENT COOLING TIME AFTER CHARGE. . PILOT CELL TEM.

• START

ON CHARGE READING AT FINISH RATE ELL 1

FINISH

3 HOUR DISCHARGE

SP. GR. VOLTS

SP. GR. VOLTS

VOLTS SP. GR. VOLTS

5 HOUR DISCHARGE VOLTS

VOLTS

0

3 4 MATERIAL USED:

EQUALIZING CHARGE

AVG. OF RATED CAP. RESEALED

REPAINTED

ha. COMMENT:

46EN/10-83

1111

ADJUSTED ELECTROLYTE

6 HOUR DISCHARGE

36

RATED CAPACI PER CELL

NOTE

The "Preventative Maintenance" Section and the "Trouble Shooting Guide" Section are written for the Standard Condor units that use internal combustion engine. For battery-powered Condor Model 46EN, please neglect the portions that are applicable to gasoline or diesel engines only.

11

CAILIWAqt CORPORATION

PREVENTATIVE MAINTEN,4ACE SELF-PROPELLED AERIAL WORK PLATFORMS GENERAL The finest equipment manufacturered is only as good as it is maintained.

Many times costly repairs and loss of revenue can be avoided by planning ahead, setting a regular schedule and peorming preventative maii. enance.

You can do preventative maintenance NOW or costly repairs LATER. This section is devoted to the PREVENTIVIiVE MAINTENANCE PROGRAM of the CONDOR and is broken down into two (2) phases; an INSPECTION mainenance and LUBRICATION maintenance. A lubrication chart and a complete preventative maintenance interval check list is provided.

The preventative INSPECTION maintenance is generally, but not limited to, the responsibility of .he operator. It is to his best interest that the inspection maintenance be carried out as it directly effects his safety. The preventative LUBRICATION maintenance is the responsibility of the serviceman or mechanic as in some instances shop time will be r - quired to perform the maintenance tasks.

Many of the suggestions for preventative mainv,eiliAce described id noted herein may sound time consuming and expensive. This is not the case. The program has been carefully layed out and if closely followed, it will result in an extended life expectancy of the unit as w(211 as the reCuction in downtime and costly repairs.

The inspections and checks listed are not intended to replace any local or regional regulations which may pertain to t h is type of cquipment, nor should the list and schedule be considered all inclusive. Variances in interval times may occur due to climate and/or conditions depending on the location and use of the machine.

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

PREVENTATIVE I. NS PECT I ON MAI i!TErAECE This field inspection list provides for a systemancic inspec;,:on of the CONDOR. The items listed to be inspected or checked daily basically insure a good safe unit performance prior to start-up work operation. By accomplishing these inspections on a daily basis any potential mahunction will be identified and detected before it results in a major problem. The fifty (50) hour inspection will

ea

,ect any defective, damaged or improperly

secured part.

The 50-hour time interval is for normal operation. Should they unit be subjected to extensive use or if the application invol‘! ,2s operation in abnormal environmental conditions, then the inspections should be made more oft2n.

It is suggested that a maintenance log be kept and ady conditions or items found to be abnormal should be recorded.

DAILY NSPECT I OP NTENANCE A.

VISUAL 1.

Overall Condition

Inspect platform, boom, turret and carriage that no physical damage is evident. Look for missing components, loose parts, etc.

2.

Tire Condition

Inspect tires for wear, cuts and proper pressure (pnzumatic filled only)

3.

Battery Cable Connections Inspect for looseness and corrosion of terminals.

4.

! vdraulic Fluid Leaks Inspect that there is no evidence of fittings or hoses leaking.

5.

Main Electrical Connections Inspect harness connections at rear of ground box and at platform console to assure they are tight.

B.

FLUID LEVEL CHECK 1.

Engine Oil Level

If low, Ad as reccIllended by engine mmufacturer in quantity as required.

B.

FLUID LEVEL CHECK (Continued) 2.

3.

4.

5.

C.

Engine Coolant Level Add as required (water cooled engine only)

Fuel Tank Level Check level

Hydraulic Tank Level If low, add ATF De-ron II as required.

Battery Electrolyte Level Add as required.

OPERATIONAL TEST NOTE:

1.

Instrument Check A. B. C.

2.

Start engine and follow all inst ctions and proced es.

Be observant of all inst ents and controls for proper operation as well as each function of the unit. Pay particular attention to any unus .1 noises or jerky operation.

Hourmeter Is it recording properly?

Ammeter Is baCcery being charged?

Oil Pressure Gauge (Diesel Engine) Is pressure indicating?

Ground Control Console Operation Check A. Toggle Switches

With engine off, check that 11 momentary switches return to neutral when actuated and released.

B.

Boom Functions

Start engine and operate fuocijons through one complete cycle.

C.

Emergency Controls

Stop engine and operate emergency controls.

3. Platform Control Console 0 eration Check A.

Toggle Switches

With engine off, check that all momentary switches return to neutral when actuated and released.

B.

Controllers

Check that lever cannot be moved without pulling knob. Ch2ck tivt lever returns to center position when actuated & released.

C.

Boom Functions

Start engine and operate all aerial functions one complete cycle.

D.

Drive Functions

Operate drive and steeri4 functions and check bra::ing.

E.

Emergency Control

Stop engine and operate emergency controls.

F.

Slope Sensor

For procedure, refer to vendor data in operation manual, Honeywell Section.

PREVENTATIVE MATPTENANCE INSPECTION EVERY FIFTY (50) HOURS OF OPERATION A.

CARRIAGE 1.

Visual Damage

Inspect weld cracks, dents, or bends.

2.

Steering Cylinder

Check cylinder and pins holding cylinder in place for proper installtion.

3.

Steering Tie Rods

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

4.

Steering Yokes

Check instJlation, pins, caps, and steering stop.

5.

Wheels

Check for loos or missing lug nuts, loose or worn spindle, damayed or cracked rims.

6.

Torque Hubs & Motors

Check hub avid motor connecmv aid disc brake for leakage.

7.

Hydraulic Fittings

Chc.:k or l&rks and t;ghtness

8.

Hydraulic Hoses

Cho' for leaks, cuts, abrasions

9.

Tire Pressure

(Pneumatic filled) Check for proper pressure.

10.

Tire Damge

Check for wear & cuts

11.

Rotation Gear

Chest bolts securing ring gear to chassis for tightness and that all locf: tabs Li'e in pluce.

B. TURRET 1.

Visible Damage

Inspect ?or weld cracks, dents or bends

2.

Rotation Gear

Check bolts scxur:ng gear to turret for tightness.

3.

Rotation Gear Box

Check oil level. Check mounting bolts.

Inspect motor and coupling and pLiion installation.

4.

Rotary Coupling

Inspect for leakage and check mounng bolt F and bracket.

5.

Hydraulic Valves

Check mountiog bolts and inspect for damage or leakage.

6.

Hydraulic Hoses

Check for leaks, cuts, abrasions

7.

Hydraulic Fittillas

Check for leaks and tightness

8.

Electrical Wiring

Inspect for fraying ci-acked iosulLtioo

9.

Electrical Connections

Check for corrosion, looseness and insure good contc,ct.

B. TURRET (Continued) 10.

Lift Cylinder

Inspect for damage aid leakage. Check pin installation and retainers.

11.

Master Leveling Cylinder

Inspect for damage and leakage. Check pin installation and retainers.

12.

Counterweight

Check mounting bolts for tightness.

13.

Shrouding, Covers

Check for loose, damaged or missing parts and fasteners.

C. MAIN POWER SOURCE 1.

Engine

See engi -ae manufacturer's "Operation & Maintneance Aanual" for maintenance check list (Wisconsin, Deutz, Ford).

2.

Air Cleaner

Check oil level, mouning and connection.

3.

Muffler

Check shrouding, connection and mounting.

4.

Exhaust Tube

Check for rust, leaks and imallation.

5.

Engine Mounts

Check bolts for tightness.

6.

Throttle Solenoid and Linkage Check mounting, operatiod and connecting parts.

7.

Fuel System

Check tank, mounting, fuel line and connections.

8.

Battery

Check electrolyte level, mounting and hold down.

9.

Battery Cables

Check connections for tightness, corrosion and frayed insulation.

10.

Hydraulic Pump

Inspect pump damage, check mounting bolts and connection to engine.

11.

Emergency Motor/Pump

Inspect pump and motor for damage. Check mounting bolts & electrical connection.

12.

Hydraulic Hoses

Check for leaks, arcs and abrasions.

13.

Electrical Wiring

Inspect for fraying, cracked insula .,ion.

14.

Electrical Connections Check for corrosion, looseness and insure good contact.

B. BOOM ASSEMBLY 1.

Visible Damage

Inspect for weld cracks, dents or bends.

2.

Pivot Pin

Check pin installation and retainer.

3.

Extension Cylinder

Inspect for damage & leakage. Check pin installation & retainer.

B. BOOM ASSEMBLY (Continued) 4. Hose & Cable Routing

Chec"; routing of hydraulic hose & electrical cable from turret to boom. Inspect for chafing, broken tyes or overly tight routing.

5.

Mechanical Cables (3-Section Boom)

Insdect Lables for fraying or damage and tightness (torque). Inspect for proper installation cn sheave.

6.

Wear Pads

Inspect for clearance, excessive wear.

Check mountiog bolts and adkistment. .

7.

Slave Leveling Cylinder

Inspect for damage and leakage. Check pin installation and ratainer.

8.

Tie Down Ring

Check or

9.

Limit Switches

Inspect for damage. Check electrical connection.

E. PLATFORM AND SKIRT 1.

Visible Damage

Inspect for weld cracks, dents or bends.

2.

Platform Mount

Check platform to skirt mounting bolts for tightness.

3.

Hydraulic Hose & Electrical Check routing from boom to skirt. Inspect for chafing broker yes or overly tight Cable Routing routing.

4.

Platform Slide Bar

Check that it slides freely.

ON UNITS EQUIPPED WITH OPTIONAL 180° PLATFORM ROTATION- Inspect for damage, leaks and mounting 5. Rotary Actuator bolts for tightness. Check hydraulic hoses for cuts and abrasions.

F. GROUND CONTROL CONSOLE 1.

Visible Damage

Inspect for weld crEcs, dents or bends.

2.

Mounting

Check that bolts are secure.

3.

External Electrical Connection Insure connection is firmly made.

4.

Instruments

Inspect for damage.

5.

Internal Wiring

Inspec; for fraying broken insulation.

Check that connections are tight.

6.

Slope Sensor

Inspect for damage and check mounting bolts for tiyhtness.

7.

Enclosure

Check for any moistm2, inspect cover seal.

Insure cover is firmly secure.

F. GROUND CONTROL PANEL Continued 8.

Toggle Switches

Check thLt momentary type eturn to center position when actuated dud released.

9.

Speed Control

Insure knob is firmly secured to shaft.

Check tha . 1, speed control rotates freely.

G. PLATFORM CONTROL CONSOLE 1.

Visible Damage

Inspect for dents, etc.

2.

Mounting

Check that bolts are secur2 and tight.

3.

External Electrical Connection Ihsure connections are firm.

4.

Controllers

A.

Check mounting screws for tight -Bess.

B. Check that handle cannot be moved without first lifting o ':ob.

C.

Inspect rubber bellcis for d muf,;e.

D.

Check that handle returns to center when actuated and released.

5.

Toggle Switches

. ,urn to Check thai, momentary switches re c center position when actuated & released.

6.

Engine Stop-Start

Check that switch when actuated stays in "ON" or "OFF" position.

7.

Electrical 110-V Rece t4cle Inspect for damage.

H. OPERATIONAL SYSTEM

1.

Operation with ground panel controls A. Start engine and listen and/or observe: 1.

Unusual noise reun engine or pump.

2.

Excessive engine vibration.

3.

Operation of hourmeter and amm,er.

B. Actuate boom "raise" control switch and observe: 1.

Increase in engine RPM (gasoline engines)

2. Bt;3M raises smoothly.

3.

Hydraulic hoses &_lectrical cable at rear of boom are properly moving.

A.

Proper platform leveling.

5.

At full travel release control, switch returns to center.

6.

Inspect lift cylinder rod for dimLge to chrome.

7.

Platform stays elevated, is lot lowering under its own power.

H.

OPERATIONAL SYSTEM (Continued) 8. With speed control in "slaw" actuate boom "lower". Rotate speed control slowly to "fast" and observe change in speed.

C. With boom horizontal, actuate boom "EXTEND" and observe: 1.

Any unusual noise in telescoping

2.

Boom telescopes smoothly

3.

At full extension, release control, switch returns to center.

4.

Visually inspect inner boom sections for weld cracks, dents or scouring.

D. Actuate boom rotate control and observe: 1.

Any unusual noise during rotation

2.

Release control, switch returns to center

E. Actuate emergency power switch (engine OFF) and any of the boom function controls, observe: 1. Any unusual noise 2. Function operates normally 2. Place speed selector switch in "FAST". Actuate drive controller and observe: A.

Travel starts smoothly and stops smoothly when control is released.

B.

Travel speed is in high range.

3. With speed selector in "FAST" actuate boom extension and drive controller travel speed should automatically switch to slow range.

Retract boom.

4. With speed selector in "FAST" actuate boom "Raise" until above horizontal and actuate drive controller. Travel speed should automatically switch to slow range.

5. Actuate steering control right and left, observe: A.

Steering wheels turn smoothly

B.

Steering continues until stops are reached.

LUBRI CATI ON

LUBRI CATI ON Refer to Self-Propelled Condor Lubrication Chart for location of items requiring lubrication and service. Recommended lubricating intervals are based on normal use in normal environmental conditions. User is cautioned to adjust the lubricating interval accordingly to meet each individual condition and usage.

Specific lubricants as recommended by the component manufacturers are generally the best choice. Should their lubricant not be available in your area, consult your local supplier for an equivalent. Under no circumstances should lubricant containing "LITHIUM" be used.

1.

PRESSURE GUN LUBE POINTS Lubricant Chassis Grease

Shell Darna AX70330 or equal

Time Interval

50 Hours of Operation

Procedure

Service all fittings as indicated in chart. Clean lube fitting and apply pressure gun. Wipe away all excess lubricant from exposed surfaces. Over lubrication can collect dirt and foreign matter which acts as an abrasive.

When lubricating turret rotation bearing, it is recommended that turret be rotated.

2.

3.

AIR CLEANER (OIL BATH) Lubricant

S.A.E. 30 weight engine oil

Time Interval

50 Hours of operation

Procedure

Remove oil cup from bottom of air cleaner and clean thoroughly.

Fill to level line indicated on the oil cup.

STEERING CYLINDER PIVOT POINTS Lubricant

S.A.E. 30 weight engine oil

Time Interval

50 Hours of operation

Procedure

Apply with oil can to both sides of pivot.

8. HYDRAULIC SYSTEM (Continued) C.

D.

Tank Breather

Clean every 50 hours of operation

Procedure

Remove from tank and clean with solvent, air blow dry

Hydraulic Tank Procedure

Change every 500 hours or yearly, whichever comes first. Drain oil from tank and replace filter element. Add oil to tank required level.

Use only ATE Dexron II or equal. Do not mix hydraulic oil.

9. ENGINE Refer to engine manufacturer's recommended maintenance and service procedure for lubricant and time interval.

LUBRICATION (Continued) 4. ROTAFION GEAR TEETH & PINION Lubricant

Crown 7045 heavy duty open gear oil or equal.

Time Interval

500 Hours of operation, or yearly whichever comes first.

Procedure

Wipe clean gear teeth on rotation ring and pinion. Spray on lubricant.

5. ROTATION GEAR BOX Lubricant

S.P.E. 90 weight EP oil

Time Interval

Check every 50 hours. Change every 500 hours of operation or yearly, whichever comes first.

Procedure

Remove drain plug on side. Refill until lever reaches about 1 in. from top of fill.

6. DRIVE TORQUE HUBS Lubricant

S.A.E. 90 weight EP oil

Time Interval

Check periodically & fill as required. Change every 500 hours, or yearly, whichever comes first.

Procedure

To check level, rotate wheel so that level plug is horizontal.

Remove plug if steady flow of oil runs out, unit is sufficiently full.

To add oil, remove fill plug on top of gear hub and level plug (horizontally). Fill until oil runs out of level plug.

7. WHEEL BEARINGS Lubricant

Wheel-bearing grease

Time Interval

500 Hours or yearly, whichever comes first or upon reassembly

Procedure

Remove hub cap, clean out old lubricant and repack.

8. HYDRAULIC SYSTEM A. Fluid Level

Check level daily. Maintain fluid level at full mark or dipstick with the boom fully retracted and in stowed position.

B.

Hydraulic Oil Filter

Replace filter element every 100 hours of operation.

C.

Procedure

Unscrew elemen, and replace with new element.

Ill

IC AIL.1%1 A .I

CORPORATION

PREVENTATIVE MAINTENANCE INTERVAL CHECK LIST --Operational Hours Or Yearly, Whichever Comes First-ITEM REQUIRING ATTENTION A) Carria9e Assembly.

1 - Visible Damage--Weld Cracks, Dents 2 - Steering Cylinder and Pins

3 - Steering Tie Rods and Connections 4 - Steering Yokes 5 - Lubricate Steering Points 6 - Repack Wheel Bearings 7 - Visually Inspect Torque Hubs, Motors 8 - Check Torque Hub Oil Level 9 - Change Torque Hub Oil 10- Inspect Wheel Mtg., Lugs, Rims 11- Inspect Tires for Cuts and Damages 12- Check Tire Pressure (Pneumatic) 13- Check Hydraulic Fittings and Hoses 14- Check Rotation Gear Bolts B) Turret Assembly 1 - Visible Damage--Weld Cracks, Dents 2 - Check Rotation Gear Bolts 3 - Check Rotary Coupling Mounting Bolts 4 - Check Rotation Gear Box Mounting 5 - Check Rotation Gear Box Oil Level 6 - Change Rotation Gear Box Oil 7 - Check Rotation Drive Motor and Pinion 8 - Check Hydraulic Valve Mounting 9 - Check Hydraulic Hoses and Fittings 10- Check Wiring and Electrical Connections 11- Inspect Lift Cylinder 12- Inspect Lift Cylinder Pins 13- Inspect Master Level Cylinder 14- Lubricate Lift and Level Cylinder Pins 15- Check Counterweight Mounting Bolts 16- Inspect Shrouding, Covers

PREVENTATIVE MAINTENANCE CHECV, LIST

ITEM REQUIRING ATTENTION

DAILY

C Main Power Source 1 - Engine (Refer to Engine Manufacturer's Manual 2 - Inspect Air Cleaner Connection 3 - Change Air Cleaner Oil 4 - Check Exhaust Tubing Connections 5 - Inspect Muffler, Shrouding, Mounting 6 - Check Engine Mounting 7 - Check Throttle Solenoid and Linkage 8 - Check Fuel Tank Level 9 - Check Fuel Tank Mounting Bolts 10- Check Fuel Line Connections 11- Check Battery Electrolyte Level 12- Check Battery Mounting and Hold Down 13- Check Battery Cable and Connection 14- Check Hydraulic Pump Mounting 15- Check Emergency Pump/Motor Mounting 16- Inspect Hydraulic Fittings and Hoses 17- Check Wiring and Electrical Connections Boom Assembly 1 - Visible Damage--Weld Cracks, Dents 2 - Inspect Installation Boom Pivot Pin 3 - Inspect Installation Master Level Pin 4 - Inspect Installation Ext. Cylinder Pin 5 - Lubricate Pins 6 - Inspect Extension-Retraction Cables (3 Section Boom) 7 - Check Cables for Torque (3 Section Boom) 8 - Check Boom Wear Pads Mounting Bolts 9 - Check Boom Wear Pads Clearance, Wear 10- Inspect Installation Boom to Skirt Pin 11- Inspect Installation Slave Cylinder Pin 12- Inspect Slave Cylinder

50 100 HOURS HOURS

500 HOURS

1,000 HOURS

YEARLY

PREVENTATIVE MAINTENANCE CHECK LIST

ITEM REQUIRING ATTENTION

DAILY

D) Boom Assembly (continued) 13- Lubricate Slave Cylinder and Skirt Pins 14- Inspect Hydraulic Hose and Electrical Cable Routing 15- Check Boom Tie Down Ring 16- Inspect Interlock Limit Switches E) Platform and Skirt 1 - Visible Damage--Weld Cracks, Dents 2 - Check Platform to Skirt Mounting Bolts For Units With 180° Platform Rotation 1 - Inspect Rotary Actuator for Damage 2 - Check Mounting Bolts 3 - Check Hydraulic Fittings and Hoses F) Ground Control Box 1 - Check Mounting of Enclosure 2 - Check External Electrical Connection 3 - Check Hour Meter and Ammeter for Damage 4 - Check Internal Wiring and Connections 5 - Check Seal on Enclosure Cover 6 - Check Slope Sensor Mounting Bolts 7 - Check Toggle Switch's Return to Center 8 - Check Speed Control Knob is Secure 9 - Check Speed Control Operates Freely X G) Platform Control Console 1 - Check Console is Securely Mounted 2 - Check External Electrical Connections 3 - Inspect Console for Damage

X

4 - Check Controller Mounting Screws 5 - Inspect Controller Rubber Bellows 6 - Check Control Does Not Move Without Raising Knob

X

506— HOURS

1,000 HOURS

PREVENTATIVE MAINTENANCE CHECK LIST

ITEM REQUIRING ATTENTION G) Platform Control Console (continued) 7 - Check Control Lever Returns to Center 8 - Check Toggle Switches Return to Center 9 - Engine "Stop-Start" Retains Position 10- Inspect 110 Volt Outlet for Damage H) Hydraulic System 1 - Check Hydraulic Tank Fluid Level 2 - Clean Hydraulic Tank Breather 3 - Change Hydraulic Filter 4 - Change Hydraulic Fluid in Tank 5 - Check Hydraulic Fittings and Hoses

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

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

battery and connection starter solenoid master switch latching relay starter

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

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

3. ENGINE WILL NOT START - LP GAS A L.P. bottle opened too fast B Fuel line connection to bottle loose C Fuel flow to carburetor (lock off filter & vacuum switches) D Fuel storage tank empty E Regulator or carburetor frozen. Fuel tank too full (drawing 1 iquid) 4. LOSS OF POWER (engine) A Timing B Governor setting (refer to Wisconsin engine manual) C Engine rpm too low D Wrong fuel (regular gas only) 5. UNIT WILL NOT START (electrical) A Battery dead B Battery connection C Solenoid bad D Check battery alternator

46N/4-83

E.

3 5-30

.

I

3-25 - Lax3

391

LEFT---TURRET

RETRACT

DOWN BOOM

10

BOOM

F la 60--

EXTEND

I

0

up

LR2 13

LR I ,

J

2

7• WH/BLK

40 0

C

(0

6

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31

64-1

0

_60-2,\ W

5

R2

4

3

GRD. STOP

1 —,

t I

57A (c)

D3

in (0

I 2 WM

, N AER. START ENGINE

1 1 1 I I 3 3551311415116:21 2425;26

4218 , /5\ ' (NJ co

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AERIAL—GROUND

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NOT E5 1. MARK THE ENOS OF ALL WIRES AT 'TERMINALS AND

SPLICES Kir' WIRE NotARKERS 5HOWtNG TH E WIRE. NUMBER. OF E AC H WIRE. 2. DIODE 05 -• IN

UNLESS OTHERWISE SPECIF.E0 0;44EN5iONs AE IN INCHES, TO LE ANCSS ON: MACTICOIS OIC IMAL3 a • *1/i. sax • 0,11 010

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A,poIROVS0 4011 4.400t...CT, ON

SANTA FE SPRINGS. C.ALIFORNIA

ELECTRICAL WIRIN3 DIAGRAM GROUND CONTROL BOX H.P. 5E5-PROPELLED

SIZE "WING '0

3C-ALE

40179 1 VD '4E ET

PART II - ELECTRICAL 1. BATTERY DEAD A Master switch left on with start circuit energized B Alternator inoperative (regulator or rectifier module) C Batter not to full charge a Dead Battery b Condor battery used to jump start other equipment 2. FUNCTION INOPERATIVE FROM GROUND AND AERIAL A Check controller and toggle switch B Check wiring for continuity C Check solenoid coils D Check for voltage into circuit 3. FUNCTION INOPERATIVE FROM EITHER GROUND OR AERIAL A Refer to Item 2 above 4. FUNCTION INOPERATIVE (Solenoid valve assembly) A Check coil on solenoid valve B Refer to Items 2 and 3 C Check toggle switch 5. NO HYDRAULIC PRESSURE (engine running no high rpm) - A Check oil level in hydraulic tank B Test operate the manual override of any function C Open hydraulic tank gate valve 6. FUNCTION WILL CREEP WHEN NOT IN USE (high engine rpm) A Check controller for null B Check for voltage crossing over into another circuit C Air in end cap PART III - HYDRAULIC 1. FUNCTION INOPERATIVE (engine running high rpm, hydraulic pressure at 2,500 psi).

A Check if auxiliary function solenoid energized B Check for stuck spool in auxiliary function valve module

46N/4-83

2.

NO LOAD SENSING DIFFERENTIAL PRESSURE A Flow compensator spool stuck

3.

LOW OR NO HYDRAULIC PRESSURE A Refer to Item 5 - Electrical B Check compensator on pump C Check oil tank gate valve

PART IV - DRIVE 1. LOSS OF DRIVE POWER A Pump pressure set too low B Driving unit in high gear C Engine rpm too low D Bad drive motor 2. UNIT WILL NOT MOVE FORWARD OR REVERSE A Check torque hub (may be out of gear) B Refer to Item 2 - Electrical Section 3. UNIT WILL NOT SHIFT TO LOW OR HIGH A Check limit switch (boom elevation and extension) B Check two-speed toggle switch and wiring C Check hydraulic tow-speed solenoid valve cartridge in modular valve 4. NO STEERING A Check toggle switch and wiring B Check coil on Waterman valve C Damaged steering cylinder or broken hydraulic line NOTE: Above would apply to platform rotation and tilt

46N/4-83

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

Internal leak (cylinder).

Check system hydraulic pressure. Refer to specification page for applicable unit.

2. BOOM BLEEDS DOWN A. B.

Holding valve topping cylinder.

Internal leak (cylinder).

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

Check holding valve.

Internal leak (cylinder).

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

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

Check rotation gear box (loose).

Check brake in gear box (tighten).

Check ring gear bolts for torque (205 ft-lbs. turret, 105 ft-lbs. base)

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

46N/4-83

1E1111 PARTS

• • • • • • • • • • • • -,- • • • •'• • • C • • •

•

DIRECTIONAL CONTROL VALVES FOUR WAY VALVE

3000 PSI SLEEVELESS STACKABLE

WHEN ORDERING PARTS, FURNISH: 1. COMPLETE CODE NUMBER 2. PARTS REQUIRED 3. SHIPPING INSTRUCTIONS WRITE FACTORY FOR NEAREST AUTHORIZED PARTS AND SERVICE CENTER.

C IIIMIN11118117-:

-

P--PARALLEL S--SERIES

C--SPRING CENTERED A--SPRING OFFSET PRESSURE TO CYL. PORT A B--SPRING OFFSET PRESSURE TO CYL. PORT B

D--4 WAY VALVE B--3 WAY VALVE

H--SPRING CENTERED SINGLE SOLENOID *X--SPECIAL

T--MANIFOLD W/ BLOCKED SPOOL

DNC

-

AA

-

*VDC

AB

A--STANDARD

(1 C)

-DOUBLE RESTRICTOR FIXED W/FF CHECK

vai

C--DOUBLE CYL. PORT RELIEF VALVE W/ANTI-CAVITATION CHECK D--DOUBLE CYL. PORT RELIEF VALVE

J

E--SINGLE CYL. PORT RELIEF VALVE

M

G--DOUBLE ADJ. RESTRICTOR W/FF CHECK H--DOUBLE HOLDING VALVE

12 VDC

(3 C)

24 VDC

1111111 (7C) 114111

100 VDC

PT

R--SINGLE CYL. LOCK VALVE

6 VDC

(2C)

115 VAC EXPLOS ION PROOF SOLENOID

S--DOUBLE CYL. LOCK VALVE T--SINGLE CYL. LOCK VALVE W/THERMAL RELIEF D--DIRECT SOLENOID OPERATED R--SEQUENCE HEAD OPERATED

For engineering data see Bulletin ED 2.06

U--DOUBLE CYL. LOCK VALVE W/DOUBLE THERMAL RELIEF *X--SPECIAL

*CONSULT FACTORY AUGUST 1979 Copyright@ 1979 by Rexnord Inc.

PARIAH VALUE SINGLE D.C. SOLENOID -

0

A

ErI

ffilimp aRNL ittiottNNIIIIIIIIIIIIIIII iiiimiviiiisiv Ammi

MN 0 II

®

NOTE: USED ONLY WITH "M" SPOOL FOR SPRING OFFSET

SEUS !ILVE DOUBLE A.C. SOLENOID -

SD 2.06 Page 2

limy

Ref. No. 1 1 1 1 1 1 *2 3 *4

5

_5 6 6 7 8 8 —9 9 [10

TABLE # 1 Part No. 253207 253209 253127 253129 253128 253130 407342 See Spool Chart 408870 355296 355491 355671 355674 Table #2 355341 355478 355281 355280 493459

10

493460

11 _ 11 _ 12 13 _ 13 * 14 15 16 * 17 18 19 20 — 20 —21 21 22

355275 355277 355290 405964 306769 407362 493745 355292 406460 355293 493428 355274 355276 493829 493483 493526

L22 23 24 25 26 27 28 29 30 31 F32 L32 33

355841 355414 400995 355415 493543 Table #1 Table #1 491028 493543 355714 493474 493467 405914

Description

AC SOLENOID

Qty.

Series Body, 6 SAE Series Body, 6 SAE (Accessory Body) Parallel Body, 6 SAE Parallel Body, 6 SAE (Accessory Body) Parallel Body, 1/4 " NPTF Parallel Body, 1/4 " NPTF (Accessory Body) 0 - ring, 1/16 x 11/16 x 13/16 Spool 0 - ring, 1/16 x 5/8 x 3/4 Push Pin, DC Solenoid Push Pin, AC Solenoid Female Cone, DC Solenoid Female Cone, AC Solenoid Coil, DC Plunger, DC Solenoid Plunger, AC Solenoid Guide Tube, DC Solenoid Guide Tube, AC Solenoid Screw, Fillister Hd., #10 -24 UNC x 2 -15/16 (D.C. Solenoid Only) Screw, Fillister Hd., #10 -24 UNC x 3 -7/8 (A. C. Solenoid Only) Outer Flux Sleeve, DC Solenoid Outer Flux Sleeve, AC Solenoid External Push Pin Guide Actuator Pin, Standard Actuator Pin, Extended Quad Ring, 1/16 x 1/8 x 114 Nameplate (Blank) End Plate 0 - ring, 1/16 x 9/16 x 11/16 Solenoid Case Spring Inner Flux Sleeve, DC Solenoid Inner Flux Sleeve, AC Solenoid Spring, Parallel Body Spring, Series Body Washer, (All Except Spring Offset) Series Only Hat Washer, Parallel Only Plug Seal Screw, Fillister Hd., #10 -24 UNC x5/8 End Plate Wiring Enclosure, AC Solenoid Rectifier Coil, AC Screw, Pan Hd. , #6 -32 x 1/4 Cover, Enclosure Spacer (Spring Offset Only) 4 " Lead Wire W/1/4 " Spade Connector 24" Lead Wire W/1/4 " Spade Connector Hubbard Washer (AC Only)

1 1 1 1 1 1

Rectifier No.

Coil No.

AC Voltage

Watts

493539 493539

493418 493523

115 VAC 115 VAC

30 55

TABLE #2

1/2 1

SERIES 6 D. C. SOLENOID

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

Solenoid Assy. No.

Coil No.

Voltage

707562 707563 707564 707565 706255 708256 708257

493519 493482 493596 493522 493519 493482 493596

6 VDC 12 VDC 24 VDC 100 VDC 6 VDC 12 VDC 24 VDC

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

Spool Only

SPOOL CHART

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

'M '

PARALLEL BODY

* OLD

* NEW mmememamm,

1C

355588

1C

355866

2C

355678

2C

355867

7C

355589

7C

355868

1 355713

M

SChL6 _AV

2C

35 601

*Included in Seal Kit 708268 3C * NOTE:

3ELIE VALVE CODING k...

- 04 - LF.1

04 --6 SAE R -- RELIEF

M -- MOBILE

355599

New Spool Design uses Hat Washer No. 355841 Old Spool Design uses Washer No. 493526

R SERIES BODY EXTERNAL PORT FOR RELIEF EXHAUST B -- PARALLEL BODY (NORMALLY OPEN) J -- PAR. BODY TWO EXTERNAL PORTS C -- PARALLEL BODY SD 2.06 (NORMALLY CLOSED) Page 3

F -- TWO STAGE D TWO STAGE SOLENOID OPR. (PARALLEL ONLY)

B -- 250 C -- 500 D -- 750 E -- 1000 F -- 1250 G -- 1500 H -- 1750 J -- 2000 K -- 2250 L -- 2500 M -- 2750 N -- 3000

BELIEF VALVES PARALLEL RELIEF VALVF AC OPERATED—NORMALLY OPEN Ref. No.

1 2 3 —3 4 5 6 7 8 *_ 9

13 14 _14 15 15 [16

493543 355675 355374 355480 400925 355626 400922 405420 404463 253406 253407 407342 355463 355481 355274 35527 6 355293 355341 355478 355275 355277 493459

16

493460

17 18 19 20 21 21 *22 23 24 25 *26 27 28 29 30 31 32 33 34 35 36 *37 58

355292 306769 403057 493541 493482 493418 406460 401272 355624 493851 405688 355622 355547 493850 355625 493477 355675 355390 406484 493428 355290 407362 355281 355290 403446 401296 253496 493127 405411 355511 401273 490438 401279 355508 493743 355503 402455 401014 493742 355547 355509 493779 355504 407347 707869 405914

—

_9 10 11 11 12

11=111 1.1. 2 11 1 1 1

0

0

oc)

12

PARALLEL RELIEF VALVE DC OPERATED—NORMALLY 1:1

-

33

O ® PARALLEL RELIEF VALVE INTERNAL! ,Y :.ntIUSTABLE

40

38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 *58 59 60

SERIES RELIEF VALVE EXTERNALLY AL HATA E

c!

SD 2.06 Page 4

Part No.

Description Enclosure, Wiring Rectifier Push Pin, DC Solenoid Push Pin, AC Solenoid Plug, 1/16 N. P. T. F. Plug, #10 SAE Plug, 1/8 N. P. T. F. Plug, Orifice, 0.040" 0-ring, 1/16 x 1/2 x 5/8 Body, Electrically Operated Body, Internally Adjustable 0-ring, 1/16 x 11/16 x 13/16 Female Cone, DC Solenoid Female Cone, AC Solenoid Inner Flux Sleeve, DC Solenoid Inner Flux Sleeve, AC Solenoid Solenoid Case Plunger, DC Solenoid Plunger, AC Solenoid Outer Flux Sleeve, DC Solenoid Outer Flux Sleeve, AC Solenoid Screw, Fillister Hd. , #10-24 UNC x 2-15/16 (DC Solenoid) Screw, Fillister Hd., #10-24 UNC x 3-7/8 (AC Solenoid) End Plate Actuator Pin Screw, Slotted Hd. , #6-32 UNC x 1/4" Cover, Enclosure Coil, 12 VDC Coil, 115 VDC 0-ring, 1/16 x 9/16 x 11/16 0-ring, 1/16 x 3/8 x 1/2 Poppet, Ma in Spring 0-ring, 0.097 x 0.755 x 0.949 Adjustment Seat Poppet Spring Seat Spring Poppet Poppet Guide 0-ring, 1/16 x 1/2 x 5/8 Spring External Push Pin Guide 0-ring, 1/16 x 1/8 x 1/4 Guide Tube, DC Solenoid Guide Tube, AC Solenoid Nameplate Screw, Self Tapping Body 0-ring, 1/16 x 13/16 x 15/16 0-ring, 0.116 x 0.924 x 1.156 Body Cartridge 0-ring, 1/16 x 1/4 x 3/8 Glyd Ring 0-ring, 1/16 x 3/16 x 5/16 Body, 1st Stage Thread Seal Adjustment Screw Spring Lock Nut Washer Poppet, 1st Stage Balance Piston Spring Balance Piston 0-ring, 1/16 x 15/16 x 1-1/16 Relief Valve Cartridge Ass'y.

Hubbard Washer (AC Only)

*Included in Relief Valve Seal Kit 708274

Qty. 1 1 1 1 4 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 4

4

1 1 1 1

ELECTRICAL OPTIONS SOLENU1D

O

HEAVY DUTY PROTECTIVE HOSE CLAMPED ONTO TUBE TO PROTECT WIRING. REFER TO SPECIFICATIONS FOR PERMISSIBLE EQUIPMENT WIRING.

TORQUE TO 80 -100 IN. LBS. (9 -11.3 NM) ASSEMBLE WITH CHAMFER AS SHOWN

Ref. No. Part Number 1 2 3 4 5 6 7 7 [88 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

355813 355814 See Chart 784190 408195 494067 494064 494068 494065 494069 494066 355826 407520 355816 355817 494056 355812 355818 707331 355819 355815 406460 778290 784191 355821 355822 408870 407672 494073 401296

Description

Qty.

Plate Spacer Coil Outer Tube Screw, Socket Hd. , 114-20UNC x 1 Hose Clamp Hose Tube (3/4") Hose Tube (5/8") Control Cable Nut (314") Control Calbe Nut (5/81 Packing Adaptor (5/8" Control Cable Only) Lockwasher Cover Guide Screw. Hex Hd. , 1/4-20 UNC x 6-1/2 Plate Spacer Pin & Quad Ring Assembly Washer Washer 0-ring, 1/16 x 9/16 x 11/16 Plunger Guide Tube Cone Pin 0-ring, 1/16 x 518 x 314 Screw, Socket Hd. , #10-24UNC x 112 Nameplate (Not Shown) Self-Tapping Screw (Not Shown)

Solenoid Ass'y. No.

Coil No.

Voltage

994479 994480 994409

494057 494058 491685

12 VDC 24 VDC 100 VDC

3/4" Tube Kit - 708346 5/8" Tube Kit - 708347

SD 2.06 Page 5

OPTIONS DOUBLE CYLINDER RELIEF & ANTI-CAVITATIOM Ref. No.

Part No.

Description

Qty.

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

408526 401024 356950 407480 404463 401066 356949 407808 408522 405688 407807 407229 356951 356491 408544 407548 401296

Adjusting Screw Lock Nut Plug Back-up Ring 0-ring, 1/16 x 1/2 x 5/8 Ball Poppet Spring Rivet 0-ring, 0.097 x 0.755 x 0.949 Spring 0-ring, #3 SAE Plug Body Thread Seal Name Plate (Not Shown) Screws (Not Shown)

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

Seal Kit No. 708307

CYLINFIL VOLI BELIEF VAL!: Ref. No.

Part No.

Description

Qty.

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

408526 356494 490423 401296 407483 356819 408544 401024 407808 401273 784900 356853 407466 405393 408522 404463

Adjusting Screw Body Plug Screw, Self Tapping Nameplate Plug Thread Seal Lock Nut Spring 0-ring, 1116 x 114 x 3/8 Piston Assembly Piston (Not Shown) Roll Pin (Not Shown) 0-ring, 0.087 x 0.644 x 0.818 Rivet (Spring End) 0-ring, 1/16 x 1/2 x 5/8

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

C'LEULEI LUC. Vi7IVE 11-1EIMAL RELIEF VALVE Seal Kit No. 708307

THERMAL RELIEF CARTRIDGE

Ref. No.

Part No.

Description

Qty.

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

356460 307737 401065 407832 407186 307739 356159 404463 360342 407814 405393 360101 360873 491638 711121

Body Piston Ball Spring Spring Plug Poppet 0-ring, 1/16 x 1/2 x 5/8 Plug Spring 0-ring, 0.087 x 0.644 x 0.818 Poppet Orifice Set Screw Thermal Relief Valve Ass'y.

1 1 2 2 2 2 2 2 1/2 1/2 1/2 1/2 1/2 112 1

401296

Screw, Self Tapping (Not Shown)

2

407548

Nameplate (Not Shown)

1

Seal Kit No. 708314 SD 2.06 Page 6

OPTIONS DOUBLE FIXEPI 7 7.3TRICTUE FEEL CHECK Ref. No. 1 2 3 4 5 6

Part No.

Description

407186 307739 405393 784931 404463 356456 401296 407548

Spring Plug 0-ring, 0.087 x 0.644 x 0.818 Poppet Sub-Assembly 0-ring, 1/16 x 1/2 x 518 Body Drive Screw (Not Shown) Nameplate (Not Shown)

Qty 2 2 2 2 2 1 2 1

0 RECIFhaCATING SEQUENCE VALVE

Ref. No.

Part No.

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

707120 355457 355456 253188 490917 707791 404972 405612 405291 707199 490560 403446 401296 406484 408870 355543 355544 707124 400925 493456

Description Plug, #6 SAE Seat Poppet Body Set Screw Seat Assembly Spring, Outer Spring, Inner Push Pin Sequence Valve Head Screw, Pan Hd. , 10-24 UNC x 7/8 Nameplate Screw, Self Tapping 0-ring, 1/16 x 1/2 x 5/8 0-ring, 1/16 x 5/8 x 3/4 Cone, Female Detent Plug, #5 SAE Plug, 1/16 N. P. T. F. (Not Shown) Spring, Detent (Not Shown)

ACCESSORIES STACKING (ITS PARALLEL VALVES Sections

Stacking Kit No.

1

707671

2

707672

3

707673

4

707674

5

707675

6

707676

7

707677

8

707678

9

707679

10

707680

SERIES VALVES

NOTE: Torque Tie Rods to 250 in-lbs. (28.2 N-m).

SD 2.06 Page 7

Sections

Stacking Kit w/o Relief Valve

Stacking Kit w/ Relief Valve

1

707871

2

707872

708162

3

707873

708163

4

707874

708164

5

707875

708155

6

707876

708156

7

707877

708157

8

707878

708158

9

707879

708159

10

707870

708160

Qty. 2 2 2 2 2 2 2 2 2 2 8 1 2 2 2 2 2 4 4 4

/law Manufacturing. Company

INSTALLATION AND OPERATING INSTRUCTIONS FOR THE MODEL A-45 RECHARJER

The La Marche Automatic Recharjer is designed to operate on a specific type of battery with a specified number of cells. The name-plate on the charger indicates the type and the number of cells required. Binding posts with wire lug connectors are provided on a terminal board within the unit.

When connecting the D.C. output cables to the battery, be certain the positive terminal of the charger is connected to the positive battery terminal and the negative terminal is connected to the negative of the battery. A grounding connection is also provided for complete protection. Once properly installed, the rectifier should automatically complete its charge cycle every time it is connected to a discharged battery. Install the rectifier so that the flow of air through the ventilators is vertical and not obstructed.

Before connecting the A.C. input cable, check the line power with that specified on the name-plate of the unit. Chargers furnished for 208 and 240 volt power lines are dual input voltage units. Taps within the unit must be set on the 208 volt setting for 208 volt power lines and 240 volt tap for 240 volt power system. Chargers designed for 120 volt and 480 volt power systems are single input voltage chargers and therefore do not have any taps. The A.C. input current specified on the name-plate is for rated output. A.C. line breakers must be sized for the overload or current limiting point of the charger, which is 135% of the rated name-plate value.

Input and output wiring may be connected to wire lugs provided on the input and output terminals. The tool used to secure the wire to the lug is T & B Sta-KonWT-130A (lugs 10 through 18), and WT-115 (lugs 3 through 8).

To operate the charger, it is only necessary to turn on the time switch which supplements for an on off switch. The charger will automatically start to charge the battery at some rate up to its maximum capacity depending upon the state of charge of the battery and charge the battery to full charge and shut down to a trickle charge-preserving-charge. The charger will continue the trickle rate until the time switch turns the unit completely off.

This charger accomplishes its charge cycle completely automatically without the use of any moving parts. The only moving part in the charger is the time switch which has no other function except to turn the unit off at some time after the charge has been completed.

A saturable reactor regulator controls the charge rate so that the charger puts out near maximum output current up to the gassing point of the battery, then automatically reduces the output current down to a trickle

charge on a taper curve as the battery comes up to full charge. The charger's battery EMF sensing circuit continuously samples the battery voltage during the complete charge cycle and controls the saturation of the reactor which in turn controls the power output of the charger.

The charger provides automatic power line compensation. This eliminates the need for adjusting taps to match the input line voltage. The automatic compensation also eliminates charging problems that arise from a varying line when charging continually day and night or for two or three shift operations.

The unit is self protecting when subjected to abnormal overloading conditions. The current limiting feature limits the output current to not more than 1405 of the output rating of the charger.

The charger is factory tested and pre-set such that no field adjustments are necessary. If field adjustments must be made, the taper and shut-down point may be adjusted. This adjustment may be made by moving the red slider band on the voltage reference variable resistor RVI. Moving this slider band toward the series connected resistor RV2 raises the shut down point which allows the battery voltage to rise to a higher point before shutting down to a trickle charge. Moving the red slider band away from the series connected RV2 lowers the shut-down point.

It should not be necessary to make any adjustments to this charger and should any adjustments be necessary extreme care should be taken in making the adjustment. An accurate D.C. voltmeter should be used and the D.C. voltage at the charger and battery terminals should be measured.

The battery voltage should not exceed 2.5 volts per cell on a fully charged battery. Settings above this point may cause excessive (gassing) use of water and battery heating.

Because of the stability of design the unit needs no periodic adjustment.

This along with the rugged construction and conservatively rated components insure long life and trouble free operation.

EJZ/jw 2-7-74

MANUFACTURERS AND ORIGINATORS OF THE WORLD'S MOST COMPLETE LINE OF MAG-AMP. REGULATED AUTOMATIC BATTERY CHARGERS

106 Bradrock Drive, Des Plaines, Illinois 60018 Phone: 299-1188 (A.C. 312) Telex: 282526

Manufacturing Company

Printed in U.S.A.

TYPICAL SCHEMATICS FOR SINGLE PHASE CHARGERS 120 V.A.C.

208/240 V.A.C.

PT

00

•

0 N C L A T U ACF

AC FUSE

ZO

ZENER DIODE

TM

TIMECLOCK

RZ

ZENER RESISTOR

PT

POWER TRANSFORMER

RC

COLLECTOR RESISTOR

RV

VOLTAGE DIVIDER RESISTOR

C

CAPACITOR

SR

SATURABLE REACTOR

SP

SURGE PROTECTOR

SD

SILICON DIODE TRANSISTOR

DCF

DC FUSE

A

AMMETER

208 VAC .01

1,0{

NANVIIILIM e^; A.

DWG. NO.

E 208 — I

1-4,

240VAC la Stii. I Ma

MIN

771-Z7:ER''

UMW ;11,7 !!!

IZiW

E507-I

2Evf.0

DC '

AK-

OUTPUT

AK-

OM E C L . A TUFE TPA ,t'itT")}1 VOI TAaF tiIrM R I RZ ZENER 2CF] Fur., ZENE.P. CIOCE AC RC COLLECTOc: kEIITci A A:v.IFTR PT POWER TRANF,FORi,Cri cp SIP PCIiICP PA TJALE iPDTIP c CAPAC;TJR Cii

ACF

CT In

0 ME NC L A T U

4

AC FUSE

CJtD.. AN SI OP.PIE'.

DWG. NO.

E 8I9—I

120 or 480 or 550 V.A.C. Bridge

ZD ZENER DIODE

TIMECLOCK POWER TRANSFORMER

ZENER RESISTOR COLLECTOR RESISTOR

SATURABLE RE ACTOR

VOLTAGE DIVIDER RESISTOR

SURGE PROTECTOR SILICON DIODE

AC CONTACTOR

TRANSISTOR

CONTROL TRANSFORMER

DC FUSE

208/240 V.A.C. Bridge

PT

ACF 0-11 11—%, — ,

AC INPUT

SR

C A PT

SR SP SD

1S E _CLOCK POWER TRANSFORMER

L A

T U

ZENER DIODE ZENER RESISTOR COLLECTOR RESISTOR

SAT uPAKE REACTOR SURGE PROTECTOR

'WAGE DIVIDER RESISTOR

SILICON UODE

DC

TRANSISTOR

AMMETER

CAPACITOR FUSE DWG. NO.

E 209 —I

L-571-45

TYPICAL SCHEMATICS FOR 3 PHASE CHARGERS

TM

INPUT II1CF

AK-1

6 T

0 •

c • • •

•

IMIIMIN••••••••••

TemENENEENE.

SR —2

SR — I

PM-Mr

p1-2

SR-3

ACF AC FUSE TM TIMECLOCK AK AC CONTACTOR SDI

208/240 V.A.C.

502

sc) , iEsp

PT POWER TRANSFORMER

- -J

SR SATURABLE REACTOR SP SURGE PROTECTOR

sP SO2

0

T 1"'""1" r r

SDI

SILICON DIODE

SD

T TRANSISTOR

ZO

ZENER DIODE

R RESISTOR

14

rTs2 t;Ti : TT oTt-

, •

RZ ZENER RESISTOR

RV VOLTAGE DIVIDER RESISTOR RC COLLECTOR RESISTOR C CAPACITOR

A AMMETER DCF DC FUSE

504

NOMENCLATURE

iCF

DC OUTPUT

VOLTAGE CONTROL TAPS 240V 208V PT 1(F) 3(Gf I(F) 3( SR 5(A W 71C 0) 4 ( A,81 810,0

ACF

ACF

ACF

AK-3

AK-2

AK-I

Mfirrnr SR-3

r

P T -2

DWG. NO.

Tn-rM SR -2

P-Trirrr PT-I

/-6-TIMM SR- I CT

CONTROL TRANSFORMER

ACF TM

AC FUSE TIMECLOCK AC CONTACTOR POWER TRANSFORMER SATURABLE REACTOR SURGE PROTECTOR SILICON DIODE TRANSISTOR ZENER DIODE RESISTOR ZENER RESISTOR VOLTAGE DIVIDER RESISTOR COLLECTOR RESISTOR CAPACITOR AMMETER DC FUSE

AK

480 or

SDI

E316

TM - I

INPUT

30 AC

'Tnnirr PT-3

(:),

PT

502

SR SP SD T

550 V.A.C.

ZD R RZ RV

RC C

4

DCF V

NOMENCLATURE

ICF

DC OUTPUT

9 DWG'

NO.

1885

CR CONTROL RELAY CT CONTROL TRANSFORMER ACF AC F USE TM TIMECLOCK AK AC CONTACTOR PT

POWER TRANSFORMER

SR SATURABLE REAC TOR SP

SURGE PROTECTOR

SD T

SILICON DIODE TRANSISTOR

ZD

ZENER DIODE

R RESISTOR RZ ZENER RESISTOR RV VOLTAGE DIVIDER RESISTOR RC COLLECTOR RESISTOR C CAPACITOR A AMMETER DCF DC FUSE

NOMENCLATURE SCHEMATIC WIRING DIAGRAM OF MODEL A45 3 0 STANDARD

LA MARCHE MFG. CO .

06 8RADROCK DR., DES PLAINES, ILL. DATE REV

ISS, 5-2 1- 79

REV

4-28-75 s CALE .21-79

DRAY/ G

'Aim pp. • DWG. Pitt). E 885- 3 CH. BY

sY

TROUBLE SHOOTING AND REPLACING SILICON DIODES

he silicon diode may be a source of trouble. The function of the diode Ls to allow the flow of current through it in one direction only. If the polarity of the conducting current is reversed, the diode will block the current flaw. Thus, the diode has a low resistance to current flow in one direction, and a high resistance to current flow in the other direction.

Therefore, a simple ohmmeter may be used to test the diode. The proceedure for checking the silicon diode is as follows: 1.

Isolate one end of the diode by disconnecting the wires attached to the nipple (or pig-tail) end of the diode (only one end of the diode must be disconnected).

2.

Clip one lead of the ohmmeter to the nipple (or pig-tail) lead of the diode. Clip the other ohmmeter lead to the aluminum heat sink. (If a portable multimeter is used, set the switches on ohms, DC and scale RX100).

3.

Note the ohmmeter reading. Then reverse the leads to the diode. Again, note the ohmmeter reading. If the diode is good, the meter will indi7 cate a high resistance in one direction, and a low resistance with the leads reversed. If the diode is shorted, the meter will read full scale, or "0" resistance with the leads in either direction. If the diode is "open", the ohmmeter needle will not indicate or show infinite resistance indicating an open circuit with the ohmmeter leads in either direction.

• -

4.

All diodes must be checked in the event that more than one diode is defective.

5.

If the diode is defective, remove the defective diode from the heat sink and replace with a new diode. When installing a new diode, be sure to note if the old diode was insulated from the heat sink. If the diode should be insulated from the heat sink, care should be taken so that the mica insulating washer is placed properly on each side of the heat sink with the insulating bushing between the diode mounting stud and the aluminum heat sink.

7/30/63 ez

WHEN ORDERING REPLACEMENT PARTS, DRAWINGS OR SCHEMATICS OR REQUESTING SERVICE INFORMATION, ALWAYS GIVE MODEL NUMBER, SERIAL NUMBER, AND A. C. INPUT VOLTAGE.

Manufacturing Company

MANUFACTURER'S WARRANTY All La Marche Mfg. Co. equipment has been thoroughly tested and found to be in proper operating condition upon shipment from the factory and is guaranteed to be free from any defect in workmanship and material that may develop within a period of one year from date of purchase.

Any part or parts of the equipment that prove defective within a one year period shall be replaced without charge when subjected to examination at our factory, providing such defect, in our opinion, is due to faulty material or workmanship and not caused by tampering, abuse or misapplication. All such adjustments are made F.O.B. Des Plaines, Illinois.

Contact your local sales representative for minor parts replacement or equipment adjustments.

Should a piece of equipment require major component replacement or repair, these can be handled in one of two ways: 1. The equipment can be returned to the La Marche factory to have the inspections, parts, replacements and testing performed by factory person-id. Should it be necessary to return a piece of equipment or parts to the factory, the dealer from whom the equipment was purchased will obtain authorization from the factory. If, upon inspection at the factory, the defect was due to faulty material or workmanship, all repairs will be made at no cost to the customer.

2. If the purchaser elects not to return the equipment to the factory and wishes a factory service representative to make adjustments and repairs at the equipment location, field service rates will apply.

A purchase order to cover such service must be issued.

In accepting delivery of the equipment, the purchaser assumes full responsibility for proper installation, installation adjustments and service arrangements. Should minor adjustments be required, the local La Marche Sales Office should be contacted to provide this service.

All sales are final. Only standard La Marche units will he considered for return. A 10% restocking fee is charged when return is factory authorized. Special units are not returnable.

In no event shall La Marche Mfg. Co. have any liability for consequential damages, or for loss, damage or expense directly or indirectly arising from the use of the products, or any inability to use them either separately or in combination with other equipment or materials, or from any other cause. In addition, any altera tions of equipment made by anyone other than La Marche Mfg. Co. renders this warranty null and void.

La Marche Mfg. Co. reserves the privilege of making revisions in current production of equipment, and assumes no obligation to incorporate these revisions in earlier models.

The failure of La Marche Mf g. C o . t o o bj ect t o provisions contained in customers' purchase orders or other communications shall not be deemed a waiver of the terms or conditions hereof, nor acceptance of such provisions.

The above warranty supersedes and is in lieu of all other warranties. expressed or implied, and no person. agent or dealer is authorized t o g ive any warran ties on behalf of the Manufacturer, nor to assume for the Manufacturer any other liability in connection with any of its products unless made in writing and signed by an official of the Manufacturer.

La Marche Mfg. Co. 3/1/78

Des Plaines, Illinois

THE ENERGY INDICATOR By DARONICS, SANTA ANA, CALIFORNIA

This instrument is used on electrically operated equipment such as forklifts, golf cars, parts carriers and electric cranes to provide information

of the state of charge of the vehicle's batteries. The model for electric forklifts has an additional cost saving feature where the required charge time is indicated. Simply set the charger time control to the indicated time and the battery will be returned to a fully charged condition. This feature is used when the eight hour charger is matched to the battery.

When ordering the Energy Indicator, the intended use must be stated, such as crane, golf car, forklift, etc., and the number of battery cells or voltage must be specified. Example - 24 volt forklift or 36 volt golf car, etc.

Installation 1.

Select the location. It generally is located with the group of other instruments such as the hour meter, ignition switch, etc. Be sure that there is adequate depth clearance. Select a place where the meter will be in plain sight and also where

it will not get damaged. .

2.

Use a punch or a hole saw 2 1/16" diameter in the location selected.

3.

Install the instrument using the provided "U" clamp and hardware.

4.

Install the provided connectors to lengths. of #22 or larger stranded wire using a crimping tool.

5.

Connect the black and red wires from the instrument to the respective positive and negative leads from the battery.

The black lead goes directly to the battery negative and the red lead goes directly to the battery positive with only the ignition switch between. Polarity must be observed.

When properly installed and maintained the Energy Indicator carries a 90 day warranty against failure resulting from defective material or workmanship.

CONDOR MODEL 60N

a4

ff

ELECTRICAL SLIP RING (Calavar Part No. 6779)

The electrical slip (collector) ring assembly is mounted at the center of rotation of the turret. Its purpose is to provide electrical current between the turret, which can rotate continuously, and the carriage, which is stationary. Without the slip ring, the wire harness from one to the other would twist off, and electrical current would be lost.

The slip ring assembly is designed for maximum efficiency with a minimum of maintenance. It is of a compact design, which allows for stacking many circuits in a small space. The brushes used are a self cleaning type, which in normal use will last the life of the machine. In circuits requiring up to 20 amp capacity, one pair is used per circuit. For circuits requiring up to 30 amp capacity, two pair are used per circuit. These ride on a 3/16" wide brass ring. For 40 amp capacity, a 3/8" wide brass ring and a single pair of wider brushes is used, and on 60 amp capacity, two pair of wide brushes are used. The brushes are riveted to a nylon brush arm. The rivet concept allows the brush to pivot slightly on the arm. This assures complete contact at all times between the brush and the brass ring. This is especially important as the equipment ages, and an orbiting condition arises. The brushes are normally attached to the upper wire harness with knife disconnect terminals. This allows for quick disconnect of the terminals should removal of the ring be required. The terminal connection of this type is protected by a plastic sleeve. When installing the ring assembly, care should be taken to insure complete coverage of the terminals by this sleeve. Some rings use multiple circuit plugs. These should be removed and replaced carefully to avoid damaging the contacts.

The center harness is normally connected to the core leads on the ring by set screw type connectors. These connectors have proven to be superior to the twist on type, especially in field installations, because they are a positive type termination.

The brass sleeve is slipped over the stripped wire endss, and the set screw tightened with a straight screwdriver. The nylon cover is then screwed down over the sleeve for protection. Care should be taken to keep the center leads as short as possible when connecting the center harness. This is to prevent the wires from catching on any portion of the upper.

Some slip rings are prewired during manufacture, and the center core leads are permanently fastened to the center harness with machine crimped terminals. If it becomes necessary to remove these, the set screw type connectors should be used for replacement.

In some conditions, the slip ring will have a tendency to collect fine silt, or a salt atmosphere will cause corrosion.

If this happens, swing the upper several timess. This should clean the surfaces. If it does not, it may be necessary to use a standard non-residue solvent to clean the ring. Then lightly sand the brushes and rings with a fine grade of sandpaper. They can then be blown off with compressed air.

To replace a brush and arm assembly, remove the hex nut and washer at the top of the brush stud. This will allow the brush assemblies to be removed. Be sure when replacing the brush and arm assemblies that all assemblies are located on the corresponding circuit, which is identifiable by number. And be sure that all springs are hooked at the brush arms.

There is a nylon bearing in the base of the assembly, eliminating the need for lubrication of the ring base bearing.

If it should become necessary to remove the slip ring from the machine, do so by loosening the socket screws at the base of the ring. This will allow the ring to be lifted off the mounting tube. When replacing it, make sure these set screws are again tightened, as they hold the core in a stationary position. If the set screws are not tight, the core can turn, and twist off the wires. The mounting tube should be 1.492-1.496 inches, maximum outside diameter, and 14 gauge thickness. This allows for proper fit, along with maximum inside clearance, while maintaining necessary strength. Care should be taken to abide by these tolerances if mounting tube replacement is required.

The slip ring drive pins, which are located on the rotating member, should be 1/8" smaller in diameter than the 3/4" diameter holes in the base bracket of the ring. This base bracket should not be bolted down tightly.

Make centre harness connections as short as possible to prevent rubbing on the slip-ring cover.

Make brush harness connections similar to the 'Christmas tree' type assembly shown. The terminal connection must be completely covered by the sleeve.

TIGHTEN SETSCREWS SECURELY to the drive tube

ON drive pins recommended to turn base. Do not fasten base down tightly.

ICITS111111(311ii . 111111111a "1

i I I% i

I

a ..* a is 1111111111011111111 ■ 11. 11111111.111111111611, 11)111■ 111,1111111111Aralli114,.3,.

wilimmaim singtwainamswalevamesswasvows a

1.500 I.D. nylon bearing accepts a mounting tube of 1.496 Diameter.

1.492

S.'

a........ vs

•

SLIP RING GENERAL CASE

ELECTRICAL SLIP RING

INSTALLATION

CALAVAR NO. 67979

GROUND ST 0 T ON COIF T

AUGU 'T 19 BULLETIN 95'89

1 SUNDSTRAND

ono

Stat on

BULLETIN 95-8961

‘.0 The MCP102A Aerial Lift Ground Station Control Console is designed exclusively for use on the Calavar selfpropelled Condor aerial lift. The panel switches actuate the functions controlled by seven-ohm HPI valves.

The panel provides electrical output for the following machine functions: ignition on/off engine start engine stop boom raise and lower boom rotate boom extend and retract emergency boom descend • emergency boom rotate • emergency boom retract

di • • •

• • •

aerial/ground selector machine function speed machine run time ammeter 12 Vdc circuit breaker (2) 110 Vac circuit breaker choke

See Figure 1 for locations.

(1 ) (2)

BOOM RAISE AND LOWER

(3)

(8)

AC CIRCUIT BREAKER DC CIRCUIT BREAKER (2)

BOOM EXTEND AND

(9 ) (10)

RETRACT

(11)

CHOKE

(4)

EMERGENCY FUNCTION

(12)

MACHINE FUNCTION

(5) (6)

ENGINE START/STOP

(7)

AMMETER

BOOM ROTATE

IGNITION ON/OFF

FIGURE 1. Front IVICP102A.

SPECIFICATIONS-

MACHINE RUN TIME

-34° to 66° C (-30° to 150° F)

SPEED (13)

AERIAL/GROUND SELECTOR 1067

r.imponent locn - ici fo

HUN-11131TV After being placed in a controlled atmosphere of 95% humidity at 49° C for 10 days, the Console will perform within specification limits.

SPECIFICATIONS (continued page 3) Sundstrand [",c')ile Controls

156 mm (6.14)

330 mm (13.0)

203,00 mm — 2 PL. (8.0) 15 mm (.59)

1,5 mm (.06)

30 mm (1.18)

25 mm (.98)

305 mm (12.0)

324,00 mm (12.750)

343 mm (13 50)

11111111111•:-_ ,_ _ _11111MIIMIM

8,0 mm DIA. — 4 PL. (.312) 230 mm (9.06) 140 mm (5.51) 42 mm — 3 PL.

(1.65)

50 mm (1.96)

1 0

90 mm — 2 PL. (3.54) 105 mm (4.13)

VIEW FIGURE 2. Dimension driiifar the MCP102A in millimeL-r: (inc1713).

2

Sundstrand Mobile Controls

95-U961

WIRING

SPECIFICATIONS (continued from page 1) VIBRATION Withstands a vibration test designed for mobile equipment controls consisting of two parts: 1. Cycling from 5 to 2000 Hz in each of the three axes.

2. Resonance dwell for one million cycles for each resonant point in each of the three axes.

Run ,from one g to three g's. Acceleration level varies with frequency.

SHOCK

External wiring connections are made with three separate plugs to the back of the console. The plugs are key , ed and cannot be connected incorrectly. See Figures 3 and 4 for connector pin locations as well as pin locations of other components. Point-to-point connections between pins are given in Table 1.

Components shown in Figures 3 and 4 Wiring schematics are identified by location in Figure 5. These parts can be ordered as spares or replacements through the corresponding Sundstrand numbers listed in Figure 5. See the Ordering Information section for ordering details.

50 g for 11 milliseconds. Three shocks in both directions of the three mutually perpendicular axes for a total of 18 shocks.

After being showered from all directions by a highpressure hose down, the Console will perform within specificntion limits. This test fulfills NEMA 4 specifications.

11 to 15 Vdc.

O 2. Level the base of the alarm by tightening the three flange nuts with a screwdriver-type socket wrench. Each nut should be tightened through approximately one half of its spring's travel. During the remainder of the procedure do not adjust the nut on the 90 ° corner.

01,.1Er.:L10 1 ,7 See Figure 2.

BOOM RAISE LOWER

BOOM EXTEND BOOM ROTATE RETRACT

0 00 100 CD 0 ®O® CD® ®0 O 0 00 S2

O 3. With the electrical connections complete, slowly tighten the nut on one of the two corners adjacent to the 90° corner until the circuit is closed, i.e., when the LED on the underside of the housing turns on.

S3

EMERGENCY SPEED CONTROL AERIAL/GROUND BOOM POSITION SELECTOR PUMP

0 0 C • ®®

®® ® S4

S7

® 0 ®C) S6

R1 12 V 12 V 110 VC CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER

61

O 4. Note the angular position of the socket. Loosen the nut, counting the number of turns until the circuit is closed again.

O 5. Divide this number in half. Tighten the nut by this many turns. The line determined by this nut and the nut on the 90° corner is now parallel to the ground.

O 6. Repeat steps 3 through 5 for the remaining nut.

The alarm is now level.

-

CB1 CLi2 CB3 IGNITION ON/ OFF

sole is ready for use. Use the following procedure to do so.

O 1. Park the aerial lift on a flat surface. Be sure it is as level as possible, with tires filled to rated pressure.

I . G VOLTAGE

ENGINE START/ STOP

The Tilt Alarm (device number 14 in Figure 5) must be brought into gravitational null before the Control Con-

AMMETER

HOUR METER

CHOKE

M1

M2

S8

O 7. Individually push down on one corner at a time; there should be enough travel to cause the alarm to trip. If the alarm does not trip in all three tests, the flange nuts have been tightened too far.

Loosen the nut on the 90 ° corner and repeat steps 3 through 6. This push-to-test feature enables the operator to test the alarm without losing the alarm adjustment.

As a safety precaution, the alarm should be field tested for proper working condition every day before the ma

FIGUFE 3. MCP102/ Dir -ir-m (cover).

S5-0_ 1

chine is run.

Sundstrand Mobile Contra s

3

J7

0 C)403 0 CD 0®001

oc)cp@o J6

J5

A B

01 00 090 0a0 070 060 060 00 030 020 010

AB

I

[01 00 0 0 080 070 060 0 50 040 030 0.0 010

4

TB1

RELAY

0® 0'0 1 ® ® K 1 ®® ®® RELAY

TB2 TILT ALARM

LATCHING RELAY

LATCHING RELAY

11

11

I

0 CD@ C) 0® U LK 2

TA

I

LK 1

1070

GND. TERMINAL IS LOWER LEFT PANEL TO BOX MTG. SCREW.

FIGURE 4. MCF iO2A Wiring Diagrrcm (irnide).

4 Sundstrand Mobile Controls

U1-.;-8961

.1 ABLE 1. Point-to-poirrt " ,Ja_ctions for the MCP107A. "To" ;- nd "From" are shown in Figures 3 rid 4. Wire identification numkrr- rirr! stamped on each wire.

CWZBEfft

I.D. NO.

LINE NO.

M1-2

5

46

J7-2

18

SG-11

8

J7-4

60

2

J7-7 J7'12

19

J7- 3

26

LINE NO. 1 2

J1-3

3

J1-5

4 5

J1-7 TB1-9B TB - -7B

6

J1-11 K2O

TO

I.D. NO.

21 T82-9B

7 8

15

42 95

FROM

55

13-9

56

S3-3

17

J7-10

50

S2-6

22

TB2-10B

51

TB2-8A

J7-23

J4-1

J5-11

So-1O

10

J4-2

TB2-1OB CE1-2

S1-3

10 10

TB1-73

0

J4-9 TB ,-G3

10

JE-9 J4-11

57

10

101

40 40 40

20

J3-3 J7-3

23

21

J3-5 J6-2 J3-6 J7-6

E

66

22

14

67

23

J3-7 S1-6

G

68

24

69

25

61

26

C

71

A

F

J3-14 J3-19 S4-1

S4-3

27

J3-11

J;11

15

72

S4-5

28

J3-12

S7-4

20

73

29

16

30

21

74 75

S4-6 S6-5 LK1A-6

31

76

LK2A-12

77

M1-1

32

J3-20

J7-16

49 27

33

J3-21

S3-3

17 B-14

K1-3 TB2-1B 38

26 2

CB2-1

74

22 249

CB2-1

CB3-1

74

C-3-2

LK2A-9

4

CB2-2

TB2-1A

TB2-2A

82

TB2-4A

40

144

S5-1

6

39

55

69 TB2-3B

S8-2

3

83

S7-2

3

84

S4-2

3

85

TB2-2A

3

86

S6-12

67

K1-4

H

155 3

LK2A-10 87 LK2A-10 LK2B-4 88 S1-5 TB1-3A

43

J6-4

44

J6-6

TB2-7B

89

45

J6-7

TB2-8B

90

TB1-4A TB1-4A

3 3 260

R1-2

60

S4-6

60

TABLE 1. (continued pc.9: 6)

9E 961

Su trani ___obile r",citr( 1.

5

TABLE 1. (continued from page 5)

I.D. NO.

91

TO

LK1B-13

LK2B-13

LK2B-13

LK2A-11

S2-5

TB1-5A 260A

92

TB1-6A

S3-2 260B

93

TB1-7A

M2-2 42

114

TB2-5A

94

TB1-7A

115

J6-8

31

95

TB1-8A

TA-3 t2 LK2B-9 42

116

J7-5

65

96

TB1-9A

K1-A 42

117

J7-9

62

97

TB1-9A

K1-7 42

118

J7-15

98

TB1-2A

R1-1

60

119

TB2-7A

59 25

99

T81-2A

S6-1

| 60

120

TB2-7A

25

60

1

100

TB1-1A

LK1A-12

121

TB2-8A

68

101

TB1-2B

TB1-1B

122

TB2-9A

55

102

TB1-3B

T 1-4B

123

TB2-1 OA S9-3

51

TA-2 TB1-10A

103

TB1-4B

TB1-5B

124

104

TB1-4B

TB1-6B

125

TB2-9B

55

105

TB1-7B

TB1-8B

126

TA-1|TB2-3A

106

TB1-8B

TB1-9B

127

K2-2 L,K1 B-9

1 35

TB2-2B

128

L K2A-3

107

129

108 109

1 kk -10

34 244

130 LK1A-11 1 LK1 B-13

110 111

131

12000436-001 12000255-002

AMMETER

SWITCH

(9) (10)

12000500-001

(2)

12000498-001

CIRCUIT BREAKER

(3)

12000497-001

POTENTIOMETER

(11)

12000501-001

HOUR METER

(4)

12000256-003

SWITCH

(12)

12000255-001

SWITCH

(5)

12000418-001

PANEL

(13)

12000495-001

(6)

12000496-001

RELAY

(7)

12000502-001

RELAY

on MCA100A1012 (15) 12499784-001

(8)

12000499-001

KEY SWITCH

(1)

LABEL

FICU.1.1 5. t.;oLnponent locatio.. and spar,. pz. -

RELAY TI LT ALARM ENCLOSURE

list fc -.- t::: JCP102A.

7,181MNBIV,IMINNIEM991:-

6

SuriclAn TIL.J CoLJtrols

361

OR1E

I FOH

I

)L 1. MCP102A Aerial Lift Ground Station Control Console.

:VI - E. REPAIR For devices in need of repair, include a description of the problem, a copy of the purchase order and your name and address.

2. Spare parts needed (see Figure 5).

ORDER 6-- O.

•t I

SUNDSTRAND MOBILE CONTROLS 3900 Annapolis Lane North Minneapolis, MN 55441 (612) 559-2121

SUNDSTRAND MOBILE CONTROLS Return Goods Department 3900 Annapolis Lane North Minneapolis, MN 55441

Surtd7trand Mcbf ontroln

7

%NM

D

SMLES, SERVICE

al

RELTM CONTACT:

SUNDSTRAND MOBILE CONTROLS 3900 Annapolis Lane North Minneapolis, Minnesota 55441 (612) 559-2121

TELEX: 9105762716

Contro MINNEAPOLIS, MINNESOTA 55441 unit of Sundstrand Corporation

SUNDgifflal

SUNDSTRAND

SAUER MCHXXX

AA

1171;AktirL7fft$604,

Wr,=.43itt

--

The MCHXXX Control Handle is intended for use in open loop systems or as a setpoint for analog or microprocessor closed loop systems for controlling position, speed, pressure, horsepower or other dynamic parameters.

The Control Handle is designed to provide remote electrical actuation of the MCV101 Pressure Control Pilot Valve or other pilots for pressure and flow control servovalves as well as directly controlling main spool valves. It may also be used to power the V7058 Hydrotransmission Valve for SundstrandSauer pumps/motors, or other electrically-actuated pump strokers such as the MCV104 Electrical Displacement Control.

▪:eatures •

Shock and vibration resistant Choice of three mounting styles, with or without watertight case Rugged components designed for the construction environment High-torque handle actuation gives sure feel Simple to install Mechanical options include center-!ock, springreturn, friction drag uni/bi-directionality and Packard connector

•

SWITCH CURRENT CAPABILITY 3 amps inductive at 28 Vdc.

echanical HANDLE STROKE ± 30° (± .52 radians) SPRING TORQUE 11 ± 4 in-lbs. (1 .2 ± .4 N-m) at center breakaway 18 ± 6 in-lbs. (2.0 ± .7 N-m) at full stroke DETENT TORQUE (OVER AND ABOVE ERICTIC:.! DRAG) 10 in - lbs. (1.1 N-m) FRICTION DRAG 13.5 ± 3 in-lbs. (1.5 ± .3 N-m). Friction is adjusted at the brake with a 5/32 English Allen wrench and 3/8 open end wrench.

ELctrical characteristics customized to the ap-ilcation

ki,cif cations Elecisical OPERATING VOLTAGE 11 - 15 Vdc (12 volt models) 22 - 30 Vdc (24 volt models) POWER See Ordering Information LOAD RESISTANCE Customer specified. See Ordering Information.

TEMPERATURE - 40° to 170° F (- 40 0 to 77° C) operating - 30° to 150° F (- 34° to 66° C) storage HUMIDITY After being placed in a controlled atmosphere of 95% humidity at 38° C (100° F) for 10 days, the Control Handle will perform within specification limits.

RAIN After being showered from all directions by a high pressure hose down, the Control Handle will perform within specification limits (applied to cased models only). This test fulfills NEMA 4 specifications.

-

VIBRATION Withstands a vibration test designed for mobile equipment controls consisting of two parts:

r „„, formeirec NULL CURRENT ± 5 ma maximum if not switched (12 Vdc models) ± 8 ma maximum if not switched (24 Vdc models)

1. Cycling from 5 to 2000 Hz in each of the 3 axes.

2. Resonance dwell for one million cycles for each resonance point in each of the 3 axes.

CENTER DEADZONE (OPTIONAL) ± 3° nominal

SHOCK 50 g for 11 milliseconds. Three shocks in both directions of the 3 mutually perpendicular axes for a total of 18 shocks.

FULL STROKE CURRENT CAPABILITY Customer specified. See Ordering Information.

LIFE Greater than 1,000,000 cycles excluding potentiometers. Potentiometers with greater than 1,000,000 cycles available for most applications.

STEP CURRENT Customer specified. See Ordering Information.

Step current occurs at end of deadzone.

DIMENSIONS See Figure 1.

PArEL CUTOUT AN!) MOUNTING PLATE

149,1 mm (5.87) MAX.

31,75 mm (1.25)

PiL CUTOUT .1c-n

)

138,0 mm (5.43) 7 (1771

A

66,6 mm (2.62)

50,8 mm (2.00)

6,2 mm (.245) 4-PL

\REMOVE BURRS FROM BOTH SIDES OF PANEL TO AVOID DAMAGING BOOT

(1 4248,:‘ m m 150,5 (5.93) MAX.

-at

MOUNTING PLATE

LOCKED

UNLOCKED POSITION

REMOVE COLLAR THAT RETAINS BOOT AND DISCARD

POSITION

269,2 mm (10.6) MAX.

143,5 mm (5.65 MAX.

IL

CUSTOMER PANEL

A 54,0 mm (2.12)

33,3 mm (1.31)

85,5 mm (3.37) MAX.

25,4 mm (1.00)

25,4 mm (1.00)

TAPPING SCREWS (2)

120,0 mm (4.72) MAX.

147,3 mm (5.8) MAX.

CUSTOMER PANEL

97,6 mm (3,84) MAX.

96,0 mm (3.78) MAX.

Z■ ■A,

27,0 mm (1.06)

1111

CUSTOMER PANEL

14,2 mm (.56) 2-PL

113,0 mm (4,45) MAX.

121,0 mm (4.76) MAX.

26,1 mm (1.03)

26,1 mm (1.03) MAX. 121,3 mm (2.38) MAX.

SURFACE MOUEIT •

DIMENSIONS FOR REF. ONLY UNLESS OTHERWISE SPECIFIED

•

INDICATES MAX. DIMENSION WITH CASE OMITTED

TOP MOUFT

111.Nrilm i..4111-151 4-) r •

1

26,1 mm (1.03)

slam WMP 60,4 mm (2.38) 121,3 mm (4.78) MAX.

PANEL MOUE1T

114,6 mm (4.51) MAX.

44,4 mm (1.75) 64,1 mm (2.52) MAX.

SIDE VIEW OF ALL PANEL MOUNT

FIGURE 1. Dimensions of the MCHXXX Control Handle in millimeters (inches).

2

If no external cabling is ordered, ocess to power, ground and the potentiometer(s) is gained through a barrier terminal strip int . :de he handle's case. The customer hould run a cable from the strip through the connector on the sice or bottom of the case. See Figure 2. A clockwise handle movement causes a current fow from terminal b to A when the terminal strip is facing you.

A failure may cause an output which could activate the valve or pump. If this occurs, the apparatus may move, possibly endangering people or equipment. It is strongly recommended that handles be equipped with a neutral OFF switch to prevent this eventuality.

For cases in which an active neutral is necessary, an emergency shut down and/or braking system sufficient to stop the system or vehicle immediately should be provided.

In most applications, auxiliary switches must be customer-wired, as shown in Figure 2. When the switch is used as a center-off, power is connected

j

TORQUE MOTOR 11111 ---

FROM POTENTIOMETER + FROM +

+ 12 VDC 1223A

GND

FIGURE 2. Center-off switch assembly and wiring connections foii the Control Handle. If no center-off switch is used the power lead should be wired to the " terminal on the terminal strip. Ground and A, B wires are attached thr ugh the connector, at right. The terminal strip can also be accessed from the other (potentiometer) side of the handle. Connectin the centeroff switch necessitates wrapping wires f. Jill one side to the othr.

3

from the external 12 volt supply to the terminal labeled "common". The switch terminals are 3/16" quick-connect. Figure 3 shows a pre-wired Control Handle with center-off switch and Packard connector, exhibiting the handle phasing and color coding of the wires.

posed of six sockets and one plastic connector body.

Figure 5 shows the location of the three trim potentiometers on the "L" handle. See the "Electrical Characteristics" section of the Ordering Information.

In order to avoid damaging the Control Handle, a 1 amp fuse wired in series is recommended for applications with low current-drawing requirements.

Figure 4 demonstrates how to assemble the mating Packard connector (male shell, female sockets) shown in Figure 3. The necessary parts are shipped in a bag assembly (Part Number K03370) com-

REVERSE

FORWARD

Cs

BLUE — POWERED WHEN HANDLE IS CENTERED RED — 12 VDC SUPPLY YELLOW — POWERED WHEN HANDLE IS OFF CENTER GREEN — VALVE DRIVE, HANDLE FORWARD WHITE — VALVE DRIVE, HANDLE REVERSE BLACK — GROUND

c

-

1- 1 Z\ TOTAL LENGTH: 1 FOOT (WITH CONNECTOR) OR 5 FOOT (WITHOUT CONNECTOR) aL

FUNCTIONS PROVIDED BY THE BLUE AND YELLOW WIRES ARE OPTIONAL.

FIGURE 3. Phasing color ch - riie for hEinde with cable aird corioector.

4

TERMINALS (6) (REF)

TRIM TERMINAL AS SHOWN (2)

A wide range of options to the basic Control Handle allows it to be custom-tailored to each application.

See Ordering Specification chart on page 9. Other options are possible; consult Sundstrand-Sauer with further questions.

SHROUD (REF)

C

I. iihountii tg (See Figure 1)

INSULATION CRIMP LEADWIRE CRIMP

1. BASE OR SURFACE MOUNT Connection is via four screws to the flanges on the bottom of the metal case.

2. TOP MOUNT WITH CASE Connection is via two screws to an enlarged mounting plate. Top mounting allows the entire handle to be removed from above the panel.

The case is made of black nylon plastic.

1137B

Z\, CRIMP BEFORE INSERTING TERMINAL INTO BODY

3. TOP MOUNT WITHOUT CASE Same as 2, but without case.

FIGURE 4. Unsealed, Packard mating connector asaembly.

4.

PANEL MOUNT WITH CASE Connection is via four screws to the top plate that holds the boot in place. The case is made of black nylon plastic.

5.

PANEL MOUNT WITHOUT CASE Same as 4, but without case.

II. Typo Of Control Knob (See Figure 1) 1. NON-LOCKING The non-locking handle has a standard ball knob. The friction-held handle detents with a spring-loaded ball to indicate null, while the spring-return handle has a spring-preload indicating null.

TIVIVAINAIONAVAIMAIIIINIAPAIIKWARIMIAVIVAI

STEP CURRENT ADJUST V

FORWARD

•

REVERSE

SPAN ADJUST, OR FULL CURRENT OUTPUT

2. CENTER-LOCK The center-lock handle has a cylindrical knob and provides a positive center-lock that unlatches when the operator pulls up on the knob.

3.

1138A

NON-LOCKING, AUXILIARY SWITCH This knob is teardrop shaped, with an auxiliary momentary push-button switch on top. The switch is wired through the handle shaft to the body with three wires (common, normally open and normally closed).

5. NON-LOCKING, NO KNOB The customer provides his own customized knob.

FIGURE 5. Location of trim potentiometers on "L" Control Handles.

5

6. THREE POSITION MAINTAINED ROCKER SWITCH IN KNOB The cylindrical knob has a boot covering the three position switch in the knob. The switch, wired through the handle, is used for auxiliary functions.

9. THREE POSITION MOMENTARY ROCKER SWITCH IN KNOB This is the samo as 11.6, but the switch returns to the center position when released.

III. Handle AuEtin A. SPRING-RETURN, BI-DIRECTIONAL This har dle uses a torsion spring to return to the mechanical center position, and has 30 degrees of handle throw on either side of center.

B. FRICTION-HELD, BI-DIRECTIONAL This handle has an adjustable drag, set with a clamp-type brake, that holds the :i&fdle at the set position, and has 30 degrees of handle throw on either sida of the center detent.

FIE !ME 6. Proportorial ontrol Handle O. pia C•Ariient vs. Clntrol Handle Travel.

OUTPUT CURRENT

C. FRICTION-HELD, UNI-DIRECTIONAL This handle has a high-resolution 60 degrees of handle throw, rotating on only one side of mechanical null, which is at full stroke. It has no detent mechanism.

30°

IV.

I:

tricci

HANDLE STROKE 30°

A. PROPORTIONAL, NO SWITCHES, 12 VOLT BI-POLAR This handle's output curve is fairly linear (see Figure 6), with output voltages a function of handle stroke. The supply voltage is 12 volts, and there are no auxiliary function switches.

1140

B. PROPORTIONAL, CENTER-OFF SWITCH, 12 VOLT, BI-POLAR This handle has a center-off switch that ensures zero output voltage over + 3 degrees handle throw.

FIGURE 7.

Handle.

roourtional CGitol

C. PROPORTIONAL, CENTER-OFF SWITCH, 24 VOLT, BI-POLAR This handle runs on a supply voltage of 24 volts.

E. PROPORTIONAL, CENTER-OFF SWITCH, 12 VOLT, UNI-POLAR This handle maintains a single direction of current or voltage flow at all handle angles.

D. PROPORTIONAL, CENTER-OFF SWITCH, AUXILIARY SWITCH, 12 VOLT, BI-POLAR This handle has a second switch that actuates at + 2 or - 2 degrees.

F. STEP-PLUS-PROPORTIONAL, 12 VOLT, BIPOLAR This handle uses two switches to give the step-

V. Coi-inector

plus-proportional output current on either side of null. This is used to overcome deadbands in spool valves. See Figure 7. Current beyond this step output is proportional through the rest of the handle throw. Full current output at 30 degrees handle stroke is maximum of 250 ma. Step current is a maximum of 50% of full current output.

1. TERMINAL STRIP Electrical connections are made to a set of four internal screw terminals.

G. STEP-PLUS-PROPORTIONAL, 24 VOLT, BIPOLAR Same as F, but 24 volt.

H. SWITCHING This handle is non-proportional. Moving the handle off null activates switches that power ON/ OFF devices (e.g., solenoid valves).

J.

STEP-PLUS-PROPORTIONAL, FULL AUXILIARY SWITCHING, 12 VOLT, BI-POLAR This handle uses the step switches for additional secondary funcf:A... Full current output at 30 degrees handle stroke is a maximum of 250 ma.

Step current is a maximum of 50% of full current output.

2.

PIGTAIL WITHOUT CONNECTOR Four wires extend from the handle case. See Figure 3 for lengths.

3.

PIGTAIL WITH CONNECTOR The wires from the case terminate in a Packard environmental connector. See Figure 3.

4.

PIGTAIL WITH BOTH HALVES OF UNSEALED PACKARD CONNECTOR Both halves of the unmounted connector are included. Unsealed connectors are generally used inside a sealed panel.

5.

SEALED PACKARD CONNECTOR WITH MATING HALF A weather-sealed Packard connector and unassembled mate. See Figure 8.

6. SEALED PACKARD CONNECTOR (FOUR PIN MALE AND FEMALE) These are two separate connectors, each connected to a separate potentiometer.

K. PROPORTIONAL, UNWIRED SWITCH The customer provides an auxiliary function, such as a neutral start interlock, with the unwired center switch.

7.

L. STEP-PLUS-PROPORTIONAL, FULL AUXILIARY SWITCHING, 12 VOLT, BI-POLAR ELECTRONIC, PULSE WIDTH MODULATED This handle uses a printed circuit board that makes the step height and output current fu!!' adjustable, accomodating high current applica-tionr. It also has pulsc width modulation, which "dithers" the load to avoid stiction. Full current output at 30 degrees har dle stroke is a maximum of 2 arts into a 5 ohm load. Step current is a maximum 50% of full curren/ output. Typical dither frequencies (dependent on resistance of the load, specified in the suffix nu! ober) are: 60 Hz for the HPI solenoid actuator, approximately 400 Hz for the V7058 Hydrotransmissior. Valve and approximately 1000 Hz for the MCV101A Pressure Control Pilot Valve.

PIGTAIL SEALED PACKARD CONNECTOR Same as V.5 with no unassembled mate.

VI. Suffi:: !ura:yir These final three numbers are factory-generated.

To create the suffix number, the following information must be supplied: number of additional switches needed ard actuation angle of each with respect to null, full current output, resistance of the driven !,ad and step current needed (if necessary).

M. PROPORTIONAL, THREE SWITCHES The three switches are: a wired centerswitch, one unwired switch in forward and one unwired switch in reverse.

7

FICUAL: 3.S&Ied Seale Lakad connector

eig Infoiation Orcie SUNDSTRAND-SAUER 3900 Annapolis Lane North Minneapolis, Minnesota 55447 (612) 559-2121

Drvice Repair For devices in need of repair, include a description of the problem, a copy of the purchase order and your name and address.

Return To SUNDSTRAND-SAUER Return Gocds Department 3900 Annapolis Lane North Minneapolis, Minnesota 55447

8

MCHXXY Orecring Specification Chant

CH

MOUNTING

FACTORY CONNECTOR ELECTRICAL TYPE OF HANDLE ASSIGNED CHARACTERISTICS CONTROL KNOB ACTUATION

MOULTING

ELECTRICAL CHARAOTERI TICS

1 BASE (SURFACE) MOUNT ALUANUM CASE 2 TOP MOUNT (DROP IN) WITH PLASTIC CASE 3 TOP MOUNT (DROP IN) WITHOUT CASE PANEL MOUNT WITH PLASTIC CASE 5 PANEL MOUNT WITHOUT CASE

A PROPORTIONAL, NO SWITCHES B PROPORTIONAL, 12 VDC CENTER OFF SWITCH C PROPORTIONAL, 24 VDC CENTER OFF SWITCH D PROPORTIONAL, CENTER OFF AND AUX SWITCH E PROPORTIONAL, SET-POINT POTENTIOMETER F STEP PLUS PROPORTIONAL, 12 VDC G STEP PLUS PROPORTIONAL, 24 VDC SWITCHING J STEP PLUS PROPORTIONAL, AUX SWITCHING K PROPORIIONAL, UNWIRED SWITCH L ELECTRONIC PWM AUX SWITCHING M 3 SWITCHES X SPECIAL Y SPECIAL Z SPECIAL

TYPE OF CONTROL KNOB 1 NON LOCKING 2 CENTER LOCK 3 PUSH BUTTON IN KNOB 4 TRON MAINTAINED ROCKER SWITCH 5 NON-LOCKING NO KNOB 6 3 POSITION MAINTAINED ROCKER SWITCH IN KNOB 7 TRON MOMENTARY ROCKER SWITCH 8 SPECIAL (NO HANDLE OR KNOB) 9 3 POSITION MOMENTARY ROCKER SWITCH IN KNOB

rfiONNECTOR

HANDL E A A B D

1 TERMINAL STRIP INTERNAL 2 PIGTAIL 60 INCH WITH NO CONNECTOR 3 PIGTAIL WITH UNSEALED PACKARD CONNECTOR 4 PIGTAIL WITH BOTH HALVES OF UNSEALED PACKARD CONNECTOR 5 SEALED PACKARD CONNECTOR WITH MATING HALF 6 SEALED PACKARD CONNECTOR 4 PIN MALE AND FEMALE

SPRING RETURN, BI-DIRECTIONAL FRICTION HELD, BI-DIRECTIONAL FRICTION HELD, UNI-DIRECTIONAL SPECIAL (FRICTION HELD, CEN) ER DETENT ONLY, NO BRAKE)

9

undstrand-Sauer Hydraulic Power Systems—Market Leaders Worldwide SUNDSTRPb-SAUER is a world leader and your source for hydri- ulic power system technology, utilizing both North Americ an and European resources in design and manuiacturing. SUNDSTRAND-SAUER

specializes in integrating a full range of system components including closed circuit hydrostatic transmissions, electrohydraulic controls, open circuit pumps, and gear pimps and motors.

• H3Rvy Duty PU111;3:; and Motors

Open Circuit Pumps

Variable Motors

—4,

Series 40 Pumps and ■tiotors

Bantam Duty Transmissions

Electrohydraulic Controls

..Staftatta.

Light Duty Pumps and Motors

Microcontrollers

Gear Pumps and Motors

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Power Wheel Planetary Gear Drive Service Manual Model 6 Wheel Drive

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(219) 92S-3200 TEL 888859 FAX: (214) 9254125

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ROL SEAL® MO ROLLING ABUTMENT TYPE WASHINGTON SCIENTIFIC NDUSTRIES,

POWER COMPONENTS DIVISION 2605 West Wayzata Blvd. PO Box 340 Long Lake, Minnesota 55356 Telephone: (612) 473-1271 TWX: 910-576-2742

MODELS RSA, RSB AND RSC

miuNTENANcE

AND PARTS MANUAL

NOTE ONLY FACTORY OR QUALIFIED DISTRIBUTORS ARE AUTHORIZED TO OVERHAUL AND REPAIR WSI EQUIPMENT. ALL FACTORY WARRANTY IS CANCELLED UPON DISASSEMBLY BY UNAUTHORIZED PERSONNEL.

FORM 201FM

•▪

▪

MODELS RSA, RSB AND RSC

ROL-SEAL MOTOR

TABLE OF CONTENTS TITLE

PAGE

INTRODUCTION

1

HOW TO AVOID REPAIRS ..

• • • • . ... .. • • ..... • • • ........ ...

TOOLS FOR DISASSEMBLY ......... . ............. . . . . 1 DISASSEMBLY . .......

• • • ........ • •

.

. ...... . .......... 2

REASSEMBLY . ............ .......... . . ...... . . . . .. 5 SEAL REPLACEMENT

6

TROUBLE SHOOTING . ..... . ............. .........

7

ROL-SEAL MOTOR EXPLODED VIEW . .. . • ..... . ........ . 8 REPLACEMENT PARTS LIST ..... .

• • • • • • .. ....... • •

MODELS RSA, RSB AND RSC

ROL-SEAL MOTOR

INSTRUCTION MANUAL

ir TEODUCTION The ROL-SEAL® Motor was designed to give both high volumetric and high torque efficiencies. It is manufactured with good quality workmanship and a design concept that allows it to be mass produced. Because of its low breakaway and low leakage characteristics it is understandable why this motor is desired in this energy conservation time.

Remove the key. Carefully remove all burrs from the shaft. Make sure there are no sharp corners around the keyway, to prevent the shaft seal from being cut upon removal of the end cap. If there is any rust present, remove using 180 grit emery cloth.

The tools that are recommended for a successful repair job are as follows:

"A" AVM "B" FRAME MOTORS HOW TO AVOID REPAIRS Maintain cleanliness in your system. Be careful when adding to the reservoir that clean oil is added and the container being used is clean. Proper filtration does not guarantee a contaminate-free system if the filters aren't serviced at regular intervals. Make sure that proper care is taken when installing the motor. If a flexible coupling is used, alignment must be within the coupling range. Do not exceed radial or thrust load ratings of the shaft.

For hydraulic surge pressures applied to or by the motor, a close-coupled direct-acting relief valve must be provided in the circuit. The motor must be protected from any pressure surges that exceed twice the pressure rating of the motor.

1. Soft face hammer or mallet.

2. Torque wrench with at least 50 ft. lbs. capacity.

3. 5/1 ," Allen wrench adaptable to torque wrench.

4. No. 03 internal snap ring pliers.

5. 3 /16 " Allen wrench for gear cover.

"C" MOTOR 1. Soft face hammer or mallet.

2. Torque wrench with at least 175 ft. lb. capacity.

3. 1 /2 " Allen wrench adaptable to torque wrench.

4. No. 06 external snap ring pliers.

5. No. 05 internal snap ring pliers.

Cleanliness is extremely important when repairing the ROL-SEAL Motor. Before you remove the motor from the system, clean as much debris off of the exterior as possible. The area around the ports is most important.

Upon disconnecting use something to plug the ends of the hydraulic lines to prevent contamination of the system.

6. 3 /16 " Allen wrench for gear cover.

A bench vise is very helpful in the disassembly and assembly of the ROL-SEAL Motor. Our instructions will be based on the assumption that this item is available.

PAGE 1

ROL-SEAL MOTOR

MODELS RSA, RSB AND RSC

DISASSEMBI Y 3.) Using the soft-faced hammer or mallet, tap upward on the ear of the SAE mounting flange. (Fig. 2.) By putting the heel of your hand over the output shaft and your fingers on the opposite ear you can keep the front end cap from falling back down after each successive rap.

When you get beyond the dowel pin engagement there should be no further requirement for the hammer. Simply lift the end cap off of the assembly.

FIGURE 1 1.) Place motor in vise as shown in Fig. 1, tightening vise enough to prevent motor from rocking out. Excessive clamping pressure could damage the inlet and outlet ports. Normally the standard jaws will not contact spotface of ports.

2.) Unfasten the nine cap screws holding the end caps and housing together. (Fig. 1.) Remove the cap screws completely from the assembly.

FIGURE 3

4.) Removal of the displacement housing, (Fig. 3) the dark center portion of the assembly, is carried out similar to step 3. There are two scallops in the rear end cap. It is this area that you tap to remove the housing. (Fig. 3.) Do not ever use any screwdriver or pinch bar to remove this part. It is extremely easy to damage the end cap faces.

The dowel pins will remain in the displacement housing.

Unless you are replacing the housing, leave them intact.

The dowels are a press fit.

NOTE 45,g;t4,0,

FIGURE 2 PAGE 2

The remaining steps can be performed on a bench.

MODELS RSA, RSB AND RSC

ROL-SEAL MOTOR

DISASSEMBLY 7.) Unfasten the seven socket head cap screws which hold the Model Code and Serial No. plate on the rear end cap.

FIGURE 4 FIGURE 5.) Remove seal plates (Fig. 4).

8.) The previous step exposed a set of timing gears.

Before removing these parts you must mark them (Fig. 6). The two small gears should also be marked left and right.

FI(.3 , [17 5 FIGURE 7 6.) Remove seal rollers (Fig. 5). The motors have two sizes. The seal rollers in the rotor tip are about 1/32nd dia. larger than those behind the seal plates.

9.) Remove the snap rings that retain the gears, (Fig. 7) and remove the gears.

PAGE 3

MODELS RSA, RSB AND RSC

ROL-SEAL MOTOR

DISASSEMBLY

Or'

FIGURE' 8 10.) By positioning the rotor as in Figure 8, you can lift one of the abutment valves out. Rotate the shaft and remaining abutment until the paddle of the rotor leaves the abutment cavity. You now can remove this abutment.

,

FIGURE 10

12.) Remove the snap ring which retains the shaft and thrust bearing. (Fig. 10.)

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)4,

FIGURE 9 11.) Lift the rotor up, which will expose the drive key.

Remove the drive key. (Fig. 9.)

PAGE 4

FIGURE 13.) Remove the shaft from the rear end cap. (Fig. 11.)

MODELS RSA, RSB AND RSC

ROL-SEAL MOTOR

SEMBLY 14.) The step bearing that remains in the front end cap should be taken out and inspected. There is an 0-ring and Teflon b?ck-up ring under this part. (Fig. 12.)

15.) Check P !I mating metal-to-metal parts for scratches or burrs which could cause leakage. Replace all parts on which excessive damage is found. Use the following procedure to be sure that all these surfaces are perfectly s moot h: Place a piece of 2. -.0 grit paper on a flat, smooth surface.

Place the part on the grit paper and stroke gcitly in a figure eight motion several times. Excessive removal of material should not be done as the parts may not reassemble with proper clearances.

'IGURE 12

16.) Clean all parts in solvent and let them air-dry. All 0-rings and shaft seals should be replaced. If conditions are such that you have to use the old seals they should be washed in a mild soap and water solution.

1.) Install shaft with thrust bearing and races through the back of the rear end cap.

9.) Proceed to assemble the snap rings to retain the gears assembled in the previous step.

2.) Install snap ring to retain shaft.

10.) Set the assembly back on the rear cover face. Install the seal plates and the seal pins in the rotor.

3.) Put spacer over shaft end, and assemble the large timing gear to the shaft.

4.) Assemble snap ring to retain gear.

5.) Turning this subassembly and setting it on the rear cover face, you can install one abutment valve. Install new back-up ring and 0-ring first. A light film of oil should be applied to all new seals.

6.) Reassemble the round drive key in the key seat and slip rotor over key.

7.) Set the subassembly on its side and proceed with the alignment and timing of the abutment and rotor. Either one of the abutments can be assembled.

8.) Rotate the shaft so the second abutment can be installed.

Align the timing marks. If the shaft can be rotated one complete revolution, it is likely that the proper assembly has been carried out. NOTE: When properly timed, the rotor tip will pass directly through the center of the abutment cavity.

11.) Place the new 0-ring in the groove of the end cap. A light film of gun grease will help keep the 0-ring from slipping out of the groove.

12.) Install the housing. If binding occurs take a soft faced hammer and tap on the housing to free it.

13.) Install new 0-rings and back-up rings in the front end cap.

Put the step bearings in place. Apply a light film of gun grease to the large static seal, and place it in the groove.

14.) Install the front end cap by slipping it over the shaft and watching the static seal to make sure it stays in place. Tapping lightly with a soft face hammer may be required to seat the front end cap.

15.) Set the body cap screws in place and tighten to recommended torque values using a crisscross pattern. Torque settings are for lubricated threads. (see chart on following page)

PAGE 5

MODELS RSA, RSB AND RSC

ROL-SEAL MOTOR

FRAME SIZE

16.) Assumble Model Code and Serial No. plata to back of the motor along with new static seal.

DISFL, CEr E:!T

TORQUE

"A" and "B"

2

500 in # (56 N-M)

"A" ar.J "B"

3

500 in # (E3 M)

"A" and "B"

4

500 in # (56 N-M)

"C"

6

150 ft # (203 N-M)

"C"

8

150 ft # (203 N-M)

"C"

10

175 ft # (237 N-M)

SERIAL COVER PLATE

ALL

125 in # (14 N-M)

1.) Clamp the motor in a vise. Remove the key and all burrs or sharp eciges which may have developed. Use 400 grit emery cloth to remove all rust from the shaft.

2.) Remove the snap ring.

3.) Remove front end cap as in steps 1-3 of the disassembly procedure.

4.) Turn end cap with sealing face up. Use a large screwdriver blade inserted between the seal lip and shell.

Proceed to pound out seal alternating from side to side so as not to damage the end cap bore.

5.) Replace end cap and torque body bolts to recommended torque, (see chart above.)

PAGE 6

17.) Before installing new shaft seal, make sure that shaft turns. Then proceed to install new seal and replace snap ring.

NOTE: Remove nny burrs or raised edges from shaft keyway as not to damage seal lip.

18.) Replace motor in the system and run unit through normal operating cycle.

6.) Apply a thin film of grease to the lip of the new seal.

Slide over shaft to face of end cap.

7.) The seal must be installed without cocking it. The best procedure is to obtain a short piece of tubing or pipe which is square on the ends and will contact the outer shell of the seal. If the tubing is too small it will damage the seal.

8.) Press seal in just far enough so the snap ring will stay in the seal bore. Using the snap ring to net the seal will prevent you from pressing the seal in too deep. When the snap ring pops into the groove the seal is properly seated.

MODELS RSA, RSB AND RSC

ROL-SEAL MOTOR

JBLE SHOC '11-..a following chart lists the possible troubles that may be encountered, the probable cause and the remedial action recommended.

I.7.01.11.,LLE c OOTI C".]

-

Trouble

No pressure

Noisy system

Motor will not develop torque.

Blown rear cover

—

Probable Cause

Remedy

Repair or replace coupling.

1.)

Loose coupling.

1.)

2.)

System relief open.

2.) Clean, adjust, or replace if necessary.

1.)

Cavitation at pump.

1.) Check for inlet air leaks.

Check pump inlet for restriction.

2.)

Reservoir low.

2.) Fill to recommended level.

1.)

System relief unloading.

1.)

Disassemble, clean, adjust.

2.)

Worn out.

2.)

Repair or replace.

3.)

High temperature operation.

3.) Change to fluid with higher viscosity index.

1.)

Drain restriction.

1.) Drain directly to tank.

2.)

High case drain.

2.) Repair motor.

Leakage around shaft.

1.) Shaft seal worn out.

1.) Replace.

Motor turns in wrong direction.

1.) Hose connection wrong.

1.) Reverse connections.

PAGE 7

ROL-SEAL MOTOR

MODELS RSA, RSB AND RSC

FIGURE 13. R0 1 ..-CEAL MOTOR EXPLODED VIEW PAGE 8

ROL-SEAL MOTOR

MODELS RSA, RSB AND RSC

PARTS LIST MEILP.C1" "- '-'413TS LIST - .10L-SEAL® MOTOR MOTE When Ordering Replacement Parts, Give Model NumVer, Serial Number, Item Number, Description and Quantity.

Item

Description

Quantity

1 2 3

Key, Woodruff Pin, Drive Ring, Retaining

3 1 2

4 5 6

Gear, Drive Spacer Ring, Retaining

1 1 1

7 8 9

Race, Bearing Thrust Bearing, Thrust Bearing, Roller

2 1 2

10 11 12 12A 13 14 15

Seal, 0-Ring Cap, Rear Pin, Rotor Tip Pin, Seal Plate Rotor Plate, Seal Valve, Rotary Abutment

3

16 17 18

Bearing, Needle Bearing, Step Seal, 0-Ring

4 4 4

19 20 21

Ring, Teflon Backup Pin, Dowel Screw, Cap

4 2 9

23 24

Seal, Shaft Cap, Front

1 1

25 26 27

Housing, Displacement Ring, Retaining Gear, Timing

1 4 2

28 29 30 31 32

Sh'aft, Power Cover, Gear Screw, Cap Ring, Retaining 0-Ring, Front Cap Seal

1 1 7 1 1

1 3

18 1 3 2

PAGE 9

ROL-SEAL MOTOR

PAGE 10

MODELS RSA, RSB AND RSC

PRINTED IN U.S.A.

FORM 201FM

ROL-SEAL® BRAKE REAR•MOUNTED, MULTI•DISC TYPE FOR RSA AND RSC MOTORS WASHINGTON SCIENTIFIC INDUSTRIES, INC. POWER COMPONENTS DIVISION 2605 W. Wayzata Blvd. • P.O. Box 340 Long Lake, MN 55356 Phone (612) 473-1271 • TWX 910-576-2742

MAINTENANCE AND P RTS MANUAL

NOTE ONLY FACTORY OR QUALIFIED DISTRIBUTORS ARE AUTHORIZED TO OVERHAUL AND REPAIR WSI EQUIPMENT. ALL FACTORY WARRANTY IS CANCELLED UPON DISASSEMBLY BY UNAUTHORIZED PERSONNEL.

10/84

FORM 304FP

•

•

304 FP 10/84

ROL-SEAL® BRAKE

TABLE OF CONTENTS PAGE

TITLE

1

INTRODUCTION

1

HOW TO AVOID REPAIRS

1

REAR MOUNTED BRAKE ASSEMBLY

2

TOOLS REQUIRED ......... . ............ ....... . . . 2 DISASSEMBLY

2

REASSEMBLY

3

PARTS LIST

4

304 FP 10/84

ROL-SEAL® BRAKE

INSTRUCTION MANUAL

INTRODUCTION

CASE DRAIN

This Wet Disc Type Brake was designed to fit on the W.S.I. Rol-Seal®Motor to provide either dynamic braking, or as a mechanical means of locking the motor shaft to prevent motor drift due to overhanging loads. The number of disc brake sets provide for a higher static torque loading than the dynamic torque rating of the hydraulic motor.

These units are provided with a case drain connection. A line must be provided to return case drain flow to the reservoir at no more than 250 PSI surge pressure. Cross port check valves are optional for internal drain but should not be used where instantaneous shock pressures occur, such as in dynamic braking.

HOW TO AVOID REPAIRS

OTHER BRAKE SPECIFICATIONS

Maintain cleanliness in your hydraulic system. Be careful when adding to the reservoir that clean oil is added and the container being used is clean.

Proper filtration does not guarantee a contaminate-free system if the filters aren't serviced at regular intervals. Caution should be used when connecting the brake release pressure port to the brake housing inasmuch as the drain port is adjacent to the pressure port.

WK2 of brake 2 6 lb. in. 2 Volume of oil to release brake 0 6 in. 3 Torque holding capacity 2 in. 3 3 in. 3 4 in. 3 940 lb. in. 1410 lb. in. 1880 lb. in.

PAGE 1

304 FP 10/84

ROL-SEAL® BRAKE

DISASSEMBLY

FIGURE 1. SECTIONAL VIEW, ROL-SEAL® BRAKE REAR MOUNTED BRAKE ASSEMBLY

TOOLS REQUIRED: 1/4 alien wrench NOTE: If it is necessary to remove adapter plate (8), a 3/1 , allen wrench and centering fixture (available from factory) will be required.

4. Remove remaining brake components.

(To remove brake piston (10), it may be necessary to inject shop air (80 PSI max.) into pressure port "P". PLEASE NOTE: If air is used, precautions must be taken to retain piston so as to eliminate the possibility of injury!)

DISASSEMBLY (Figure 1)

5. Remove the back-up rings (11, 15), and 0-rings (12, 14) from the housing (1).

1. Thoroughly clean the exterior of the assembly and hydraulic lines before attempting removal.

6. If it's necessary to remove the adapter plate (8) from the motor, remove the seven cap screws (7).

2. Disconnect hydraulic lines and cap them to prevent loss and contamination of fluid.

7. Clean all components in solvent and dry.

3. Remove the eight cap screws (13), and separate the brake housing (1) from the adapter plate (8).

Discard 0-ring (5).

PAGE 2

8. Inspect all components for wear and damage.

Replace components unfit for service. Note quantities of friction discs (3) and drive plates (4) in parts lists on following pages.

304 FP 10/84

ROL-SEAL® BRAKE

REASSEMBLY (See Figure 2)

3. Lubricate all components with clean hydraulic fluid.

4. Position the spacer rings (2) in the housing (1).

NOTE: Spacer ring thickness varies with motor size. See parts list.

5. Locate friction disc (3) in the housing; then a driver plate (4); then another friction disc (3); and so on depending on model, making sure driver plate splines are aligned.

6. Carefully install the pressure plate (10) in the housing so as not to damage the 0-rings (12, 14). Place the eight die springs (9) in the pressure plate.

FIGURE 2. CENTERING FIXTURE 7. Position a new 0-ring (5) in the housing using a little grease to hold it in place.

1. If adapter plate (8) is removed, reassemble on the motor using a centering fixture available from factory. Install capscrews (7) with washers (6) including 0-rings (16) for RSC brake and torque to 150 in. lb.

2. Install new 0-rings (12, 14) and back-up rings (11, 15) in the housing (1). Make sure the ends of the back-up rings are flush and not overlapped.

8. To assemble motor to brake, carefully drop shaft while engaging the plate drivers (4) with the splined motor shaft.

9. Secure the housing to the adapter plate with the eight cap screws (13). Tighten and torque the cap screws to 300 in. lbs.

10. Connect the hydraulic lines.

NOTE: Backup rings (11, 15) must be in position as shown in sectional view.

11. Test the brake for operation and leaks.

PAGE 3

304 FP 10/84

ROL-SEAL® BRAKE

PARTS LIST REPLACEMENT PARTS LIST—REAR MOUNTED BRAKE ASSEMBLY MODELS RSA02, RSA03, RSA04, RSB02, RSB03, RSB04, BRAKE NOTE When ordering replacement parts, give model number, serial number, item number, part number, description and quantity.

3

FIGURE 3. EXPLODED VIEW RSA AND RSB SERIES BRAKE

PAGE 4

Item

Part No.

1 2 2 2 3

C-63086 A-63095 A-63096 A-63120 B-62308

4

B-63100

5 6 7 8 9 10 11 12 13 14 15

A-63097 A-60709 A-60955 C-63087 A-62298 B-63093 B-62303 B-62301 A-61716 B-62302 B-62304

Description

Housing

Spacer Ring 2 Cubic Inch Spacer Ring 3 Cubic Inch Spacer Ring 4 Cubic Inch Friction Disc 2 Cubic Inch 3 Cubic Inch 4 Cubic Inch Plate Driver 2 Cubic Inch 3 Cubic Inch 4 Cubic Inch 0-Ring Brass Washer Cap Screw—Socket Head Adapter Plate Die Spring Pressure Plate Back-Up Ring 0-Ring Cap Screw—Socket Head 0-Ring Back-Up Ring

Quantity 1 1 1 1 3 4 5 2 3 4 1 7 7 1 8 1 1 1 8 1 1

304 FP 10/84

ROL-SEAL® BRAKE

PARTS LIST REPLACEMENT PARTS LIST RSC MODEL ROL-SEAL® BRAKE NOTE When ordering replacement parts, give model number, serial number, item number, part number, description and quantity.

FIGURE 4. EXPLODED VIEW RSC SERIES BRAKE Item

Part No.

1 2 2 2 3

C-63086 A-63118 A-63119 A-63079 B-62308

4

B-63099

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

A-63097 A-60709 A-60500 C-63089 A-62298 B-63093 B-62303 B-62301 A-61716 B-62302 B-62304 A-60846

Description Housing Spacer Ring Spacer Ring Spacer Ring Friction Disc

6 Cubic Inch 8 Cubic Inch 10 Cubic Inch 6 Cubic Inch 8 Cubic Inch 10 Cubic Inch Driver Plate 6 Cubic Inch 8 Cubic Inch 10 Cubic Inch 0-Ring Brass Washer Cap Screw—Socket Head Adapter Plate Die Spring Pressure Plate Back-Up Ring 0-Ring Cap Screw—Socket Head 0-Ring Back-Up Ring 0-Ring

Quantity 1 1 1 1 7 9 12 6 8 11 1 6 6 1 8 1 1 1 8 1 1 2 PAGE 5

304 FP 10/84

PRINTED IN U.S.A.

ROL-SEAL® BRAKE

FORM 304FP

100A MuItLAxk lit Alarm

SUNDSTRAND

BU LLE1 1 N 95 8P51—')

•

I ICATIOV

1111111111M.11111111,-

The MCA100A Multi-Axis Tilt Alarm provides a signal to the operator of self-propelled aerial lifts, cherry pickers, truck cranes, etc. that warns when the base vehicle is off level. When the alarm is tilted 4.5 ° from null the output signal activates both medium and high current alarms, sirens, bells or lights. The warning alarm indicates an imminent danger that must be rectified before work continues.

The Mult-Axis Tilt Alarm is easily mounted in a convenient location on the machine frame. It can be wired and leveled quickly and will provide years of trouble-free servi ce.

FEATURES 3 Complies with ANSI aerial lift standard A 92.5

Alarms used in rechargeable battery-operated electrical systems will not sound if the system voltage drops below the input voltage rating for the relay to the alarm.

High reliability with solid state load switching Easy to install •

LED simplifies leveling of time delayed alarms

•

Damped response ignores normal machine vibrations

-

Operates in either 12, 24 or 36 volt systems

OUTPUT CURR:AT .2 amps, nominal; .5 amps, maximum OUIPUI LOAD INDUCIANCE .5 henries, maximum SHORT CIRCUIT 7ROTECTION Indefinite (output to ground or output to power supply).

- Time delay option available Reverse polarity and short circuit protected Tough housing withstands the elements •

VIAD SWIICAING RATE 60 cps maximum at rated inductance and current TIE DELAYED 2.5 ±.5 seconds

( r)

Spring-loaded base allows for operational tests

EN v iIJbENTA I

SPECIFICATIONS' ELECTRI POWER SUPPLY 11 to 30 Vdc (12/24 volt model) 24 to 40 Vdc (36 volt model)

OPERAT1, 1 0 i'EMPF.:44TURI: -34° to +71 ° C (-30 ° to +160° F) STORAGE TEIV1 Erb-. FURE -34° to +66° C (-30 ° to +150 ° F) SPECIFICATIONS (continued page 2)

Sundstrand Mobile Controls

EM,/NF. Radiated fields of 10 volts per meter from 30 MHz o 200 MHz.

SPECIFICATIONS (continued from page 1) VIBRATION Withstands a vibration test designed for mobile equipment controls that includes two parts: 1. Cycling from 5 to 2000 cycles in each of the three major axes.

2. Resonance dwell for one million Hz for each resonance point in each of the three major axes.

SHOCK 50 g for 11 milliseconds, Three shocks in both directions of the three major axes for a total of 18 shocks.

HUMIDITY After being placed in a controlled atmosphere of 95% humidity at 120° F for 10 days the alarm will perform within specification limits.

RAIN After being showered from all directions by a high pressure hose down the alarm will perform within specification limits.

MECHANICAL LIFE 10,000 operations at a single alarm point DI FE:ERE:it-11AL +1 9 -1.5 ° differential between diametrically opposite switch-on points.

For non-time delayed units, a maximum of 2.5 seconds and a minimum of .15 seconds from null to 6° tilt angle over a temperature range of -30 ° to 160 ° F. For time delayed units, 2.5 -±.5 seconds (0° to 160° F) and 5.0 seconds or less (-30 ° to 0 ° F) from null to 6° tilt angle.

GENER DIMENSIONS See Figure 1.

F

56,00 men 2.20 28,0 mm 1.10 12,0 mm .47

12,0 mm .47

80 i0,5 mm 3.15

./4 -28 ADJUSTING NUTS -3PL

50 ,0,5 mm -2PL 1.97

28,0 mm 1.10 56,00 mm 2.20

80 mm 115

7,0 mm -4PL .28

OPTIONAL MOUNTING HOLES IN BASE

300 mm MIN 11.81

POWER (RED)

"=(BLACK)

SIGNAL (WHITE)

83,18 mm MAX 3.27

A

LED ONLY ON TIME DELAYED UNITS.

BASE

4,8 mm .19

FIGURE 1. Dimensions of th MCA100A in millinytors (inches).

2

Sundstrand Mobile Controls

95-8953-3

THEORY )F E:

1111111111.1111111■11

The Mult-Axis Tilt Alarm functions as a switch. It consists of a molded nylon housing containing a steel ball bearing, an incandescent lamp, a photo detector and a printed circuit board. The ball bearing is free to roll in a clear silicone damping fluid on a transparent, spherical basin. The bearing normally acts as an interruption between the lamp and the photo detector, but when the alarm is tilted 4.5 ° from horizontal the ball no longer blocks the light. The detector then receives the light and switches a VMOS transistor from a high impedence (OFF) to a low impedence (ON) state, activating the alarm. If the unit is time-delayed, an RC timing circuit is allowed to charge towards a threshold voltage before the transistor switches to the ON state. The timer is reset when the alarm is releveled back to less than 4,5° . Should the filament break, the circuit will close to warn the operator.

INSTALLATION

In everyday use, some shaking of the machine's frame is to be expected. To prevent an intermittent alarm that would normally sound during use, the Tilt Alarm response is damped with silicone fluid. The resulting lag can be several seconds. Therefore, the alarm should not and can not be expected to give the operator sufficient warning time in dynamic movement situations.

Angular boom and ground velocities should be kept to reasonable rates to ensure operator safety.

Nor should the alarm be expected to warn the operator in the event of machine lurches due to untamped earth fills, ditches, drop-offs, holes, etc.

Good safety practices demand a thorough inspection of the ground surrounding the vehicle base.

When properly performed, this inspection should preclude possibilities of unforeseen machine movements.

111111=11111111111111111r

71 1 RIMC Three wires must be connected to put the Tilt Alarm in the alarm circuit. The red wire is the high (positive) side of the alarm, the black wire is the chassis ground and the white wire is the output lead. The Tilt Alarm and load are powered by 12, 24 or 36 volts.

In a very few applications, machinery equipped with the Tilt Alarm will be subjected to the high accelerations and decelerations associated with quick stops, starts and turns. Since its sensing principle responds to gravity, the alarm will also respond to these accelerations and trip the horn or light. In order to avoid annoying the operator with false alarms, the owners of tight-cornering and/ or high-grounded-speed vehicles should interlock the operation of the Tilt Alarm with the work (as opposed to travel) mode. If the alarm has the time delay feature, this precaution is necessary.

Two typical wiring schemes are illustrated in Figures 2 and 3. Figure 3 uses a separate remote horn as the load.

The horn should be a solid state device such as the Mallory SC616N with a volume of 80 db or better. It should draw no more than one-half amp. Figure 3 uses the vehicle's own alarm system (generally the horn) as the load. The horn relay should typically be from 200 to 600 ohms. Also pictured is the interlock switch.

tern on the base (see Figure 1). If the device is welded, the base should be detached from the housing and the alarm assembled subsequent to the mounting. This will avoid accidentally overheating the housing. Since the alarm is leveled after mounting, a smooth, flat weld is not critical for correct operation.

The location of the mounting will vary from machine to machine. In all cases it should be on a level, horizontal area of the main frame. It should also be isolated from the operator (outside of the cab) but accessible for day-to-day use, since the -I-nuld be field tested for proper working condition every day before the machine is run.

RED

11 to 40 V Mt1.11111KU

TILT ALARM

WHITE

REMOTE HORN

MOUNTING Three welds, one on each corner, are sufficient to mount the base for the Multi-Axis Tilt Alarm. Or the device can be bolted to the frame through the four-bolt pat£5-8953-3

IRLACK 1002

FIGURE 2. Wiring schum:, rJrnote horn.

INSTALLATION (continued page 4) Sundstrani Controls 3

O 2. Level the base of the alarm by tightening the three flange nuts with a screwdriver-type socket wrench.

Each nut should be tightened through approximately one half of its spring's travel. During the remainder of the procedure do not adjust the nut on the 90 ° corner.

INSTALLATION (continued from page 3)

INTERLOCK SWITCH

661.1IMMIMS

HORN RELAY

RED

OM, -IMEN 1

1 TO 40 V -

For non-time delayed units, the alarm will sound.

For time delayed units, the LED on the underside of the housing will turn on.

WHI E

TILT ALARM

O 3. With the electrical connections complete, slowly tighten the nut on one of the two corners adjacent to the 90° corner until the circuit is closed.

VEHICLE HORN

BLACK

L'1 13th

HORN BUTTON

scheme using ',111iL;lc, Lorn.

O 4. Note the angular position of the socket, Loosen the nut, counting the number of turns until the circuit is closed again.

O 5. Divide this number in half. Tighten the nut by this many turns. The line determined by this nut and the nut on the 90 ° corner is now parallel to the ground.

0 6. Repeat steps 3 through 5 for the remaining nut.

The alarm is now level.

Use the following procedure to bring the Tilt Alarm into gravitational null: 0 1. Park the vehicle on a flat surface. Be sure it is as level as possible, with tires filled to rated pressure.

O 7. Individually push down on one corner at a time; there should be enough travel to cause the alarm to trip. If the alarm does not trip in all three tests, the flange nuts have been tightened too far.

Loosen the nut on the 90 ° corner and repeat steps 3 through 6. This push-to-test feature enables the operator to test the alarm without losing the alarm adjustment.

ORDERING DEVICE AIR Model name (MCA100A) Input voltage (12, 24 or 36) Instantaneous or time-delayed turn-on For non-standard trip angles, or different trip angles in the X and Y axes, consult the Customer Service Department.

ORDER FROM SUNDSTRAND MOBILE CONTROLS 3900 Annapolis Lane North Minneapolis, Minnesota 55441 (612) 559-2121

4 Sundstrand Mane Controls

For devices in need of repair, include a description of the problem, a copy of the purchase order and your name and address.

RETURN TO SUNSTRAND MOBILE CONTROLS Return Goods Department 3900 Annapolis Lane North Minneapolis, Minnesota 55441

95-84253--3

ILLUSTRATED PARTS INDEX Industrial Self-Propelled Condor Model 46EN

FIGURE NO. 1

2

3

4

4A

5

6

7

8

9

9A

10

11

DESCRIPTION Final Assembly Safety Decal & Placard Location Carriage Assembly Torque Drive Assembly Wheel Drive Valve Assembly (Showing Cartridges)

Front Hub Assembly Tire-Wheel Assembly Steering Assembly Steering Cylinder Electric Slip Ring Rotary Coupling Turret Assembly Hydraulic Routing Diagram e•

12

Load Sensing Pump & Drive Assy.

15

16

17

17A

20

21

Hydraulic Tank Assembly

46EN/10-83

Ground Control Box Assembly Turret Rotation Speed Reducer Installation Speed Reducer Parts Break Down Pump and Motor Assy., for Emergency System Boom Assembly

Illustrated Parts Index - continued:

FIGURE NO.

DESCRIPTION

23

Slave Leveling Cylinder Assembly

23A

Slave Leveling Cylinder

24

Master Leveling Cylinder

26

Boom Extension Cylinder

28

Topping Cylinder

30

Skirt Weldment, Non-Rotation

31

Platform Control Console Assembly

32

Platform Weldment

34

180 0 Platform Rotation Assembly (Option)

46EN/10-83

FIGURE 1 FINAL ASSEMBLY

1n/R:

FIGURE 1 FINAL ASSEMBLY

REF

DESCRIPTION

1 Strobe Light 2 —Cover, Turret - RH Side 3 Latch 4 —Bracket 5 Tie-Down Ring 6 Door, Turret LH Side 7 Cover, Turret-LH Side 8 —Hinge, Piano 9 Door, Turret-RH Side

PART NUMBER 68459 —1 32867 1 LBL 00200 —2 LBL 00256 2 32536 —4 32865 32869 1 LBL 00300 2 32864

10/ 83

FIGURE 2 SAFTY DECAL & PLACARD LOCATION

10/83

FIGURE 2 SAFETY DECAL & PLACARD LOCATION

REF

DESCRIPTION

1 Decal - Condor (Trade Mark) 2 Decal 110V 3 Decal - 46 4 Decal - N 5 Decal Lube Fitting 6 -Decal - Danger 7 Decal Danger 8 Decal - Emergency Bleed Down 9 Decal - Danger (Electrocution Hazard) 10 Decal - Posi traction 11 Decal - Serial No. 12 - Decal - Caution (No Wleding Ground) 13 Decal - Turret Lock Pin 14 Placard - Transporting Diagram 15 Decal - Forward Direction Arrow 16 Placard - Hydraulic Fluid 17 Decal - Do Not Lift Wheels with Boom 18 Decal Warning 19 Decal - Forward Direction Arrow 20 Decal - Condor 21 Decal - Warning 22 Decal - Travel Speed 23 -Placard - Platform Capacity 24 Placard - Caution 25 Decal - Danger 26 Decal Danger 27 Decal - Danger 28 Decal Caution & Warning

PART NUMBER Qin( 21834 -2 15376-024G 40791-0 02 -2 32563 2 21079 -2 21882-004 -1 21882-003 3 40122 1 21882-001 2 21971-004 1 15843 21854 2 40191 2 32508 2 21873-002 1 21850 21971-002 32200 21873 -001 1 50277 1 32200 1 40130 -1 32617 -1 21880 -1 21882 -002 -1 21882-003 21882-004 1 21 41 6

10/83

FIGURE 3

CARRIAGE ASSEMBLY

10/83

FIGURE 3 CARRIAGE ASSEMBLY

REF

DESCRIPTION

1 Cover , Engine 2 —Pinion, Turret Rotation 3 Electric Battery Pack W/Cover 4 —Cover, Electric Battery Pack 5 Cover Pin, Electric Battery Pack 6 —Torque Hub 7 —Cover, Rear Body 8 Heat Exhuast Panel, Rear 9 Motor, Wheel 10 Relay, Starter 11 Lockstrip 12 Ring Gear 13 Tire and Wheel Assembly, Front 14 Starter, Electronic 15 Carriage Weldment 16 Tire and Wheel Assembly, Rear

PART NUMBER

CITY

32676 1

21906 1

3286 1 —2

32865 2

67337 4

32084 2

32175 1

32721 1

21424 2 2887 1

68226 9

21922 1

32519 2

32856 1

32719 1

32520 2 —

10/83

FIGURE 4 TORQUE DRIVE ASSEMBLY

V 119 C.4 C4

.

8/82

FIGURE 4 TORQUE DRIVE ASSEMBLY

REF

DESCRIPTION

PART NUMBER

1 Hose Assy, 3/8" I. D. x 75" Lg., #6 JIC x #6 JIC 40180-34 2 Hose Assy, 3/4" I. D. x 79" Lg., #12 JIC x #12 JIC 40180-35 Tube Assy, 3/4" Dia. x 16-1/4" Lg., #12 JIC x 3 #12 JIC 4 Tube Assy, 3/4" Dia. x 17-1/2" Lg., #12 JIC x #12 JIC 5 Tube Assy, 1/4" Dia. x 11-7/8" Lg., #6 JIC x #6 JIC 6 Tube Assy, 1/4" Dia. x 18-5/8" Lg., #6 JIC x #6 JIC 7 Tube Assy, 3/4" Dia. x 17-1/2" Lg., #12 JIC x #12 JIC 8 Tube Assy, 1/4" Dia. x 17-7/8" Lg., #6 JIC x #6 JIC 9 Tube Assy, 1/4" Dia. x 12-1/8" Lg., #6 JIC x #6 JIC 10 Tube Assy, 3/4" Dia. x 20-1/4" Lg., #12 JIC x #12 JIC 11 Elbow, 90° Adj. 6801-4-6 NWO 12 Elbow, 90° Ell. 13 Elbow, 90° - #12 M. JIC x #12 SAE 0-Ring w/ Nut 14 Capscrew, Hex Hd. 3/8" - 16 UNC x 1-1/2" Lg. 15 Adapter, STR - #6 M. JIC x #6 SAE 0-Ring 16 Adapter, STR - 1 12 M. JIC x /12 SAE 0-Ring 17 Valve, Solenoid - 2 position 93017 18 Elbow, 45° 6502-12-12 19 Torque Drive Hub 32084 20 Lockwasher, 3/8" 21 Hydraulic Motor w/ Disc Brake 21424 22 Capscrew, Hex Hd., 1/2" - 13 UNC x 1-1/4" Lg. 23 Lockwasher, 1/2" 24 Capscrew, Hex Hd. 5/8" 11 UNC x 1-3/4" 25 Lockwasher (Nordic), 5/8" 26 Modular Control Drive Valve 32800

QTY 2 2 1 1 1

1

,

1 1 7 2 2 3 4 1 1 2 3 2 4 4 12 12 1

FIGURE 4A DRIVE VALVE ASSEMBLY

Drive Valve Assembly 1-- Valve, Check 2 Valve, Solenoid - 2 position 3-Valve, Positive Traction 4 Valve, Flow Divider/Combiner 5 Valve, Ccunterbalance

32800 -67406 93017 -92069 p67401 -67405

8/82

FIGURE 5 FRONT HUB ASSEMBLY

REF

DESCRIPTION

Hub Assembly 1 Oil Seal 2 Bolt 3 Nut 4 Nut, 1" - 14 Th. Dustcap 6 Cotter Pin, 1/8" x 1-1/2" 7 Special Washer, 1" Cone 9 Cup 10 Hub Machining 11 Cup 12 Cone

PART NUMBER QTY 32819 32527-008 32820-001 32820-002 32528-004 32527-009 32528-003 32528-002 32527-005 32820-003 32819 32527-006 32527-007

1 1 6 6 1 1 1 1 —1 1 1 —1

10/83

FIGURE 6 TIRE, WHEEL ASSEMBLY

REF

DESCRIPTION

Tie Rod 2 Steering Knuckle Assembly, L. H. 3 Wheel Assembly, Steering 4 5 Torque Drive Hub 6 Wheel Assembly, Drive 7 Lug Nut Front Hub Assembly 8 Steering Knuckle Assembly, R.H. (Not Shown)

PART NUMBER 32516

QTY

32740 32519

2 1 2

32084 32520 91068 32527 32734

2 2 30 2 1

10/83

3- 1

)

FIGURE 7 STEERING ASSEMBLY

3/83

•

FIGURE 7 STEERING ASSEMBLY

REF

DESCRIPTION

King Pin Bushing, King Pin 2 Steering Knuckle Assembly-RH 3 4- Cotter Pin, 1/4" Diameter x 2 1/4" Long Thrust Washer 5 Nut, King Pin, I 1/4" 7 UNC, Hex Locknut 7 Bolt, Hex Head I" - 8 UNC x 4" Long 8 Bolt, Hex Head I - 8 UNC x 5" Long 9 10 Hex Jam Nut, 1/4" -12 UNF-RH 11 Lube Fitting (Zerk) Steering Cylinder 12 Tie Rod 13 14 Bolt, Hex Head I" - 8 UNC x 6" Long Steering Knuckle Assembly- LH 15 16 Tie Rod End, LH 17- Lock nut; I" -8 UNC 18 Hex Jam Nut, I 1/4" -12 UNF Tie Rod End RH 19 20 Capscrew, Hex Head 1/4" 20 UNC x 1/2" LG. 21 Lockwasher, 1/4"

3 I

es

PART NUMBER QTY

32514 32541

ADe

4

32736

2 4

Grade 5 Grade 5

2 1 1 1

2 32725 3272 7 Grade 5 Oc..13 .4. I 32738

32737

1 1 1 1 3 1 1 2 2

FIGURE 8 STEERING CYLINDER

REF

DESCRIPTION

Cylinder 1-Gland 2 • Collar 3 Piston 4-Barrel Assembly 5--- Rod 6 Rod Mount 7- Locknut, Self-Locking 8------.Jam Nut, 1"-14 UN 9-Gland Static Seal 10 - Rod Seal 11Rod Wiper 12Rod Static Seal 13-Piston Seal * Seal Kit (Includes Items 9-13)

PART NUMBER QTY

Calavar 32725 92035 92036 .93012 93013 93014 93015 92027 93016 * * * * * S 32637

1 1 1 S1 1 1 1 1 1 1 1 1 2 1

10/81

ON 11 dl lS D lnD3 13 6

Ri ne

10

A

Make centre harness connections as short as possible to prevent rubbing on the slip-ring cover.

brush harness connections similar El Make to the 'Christmas tree' type assembly ehown. The terminal connection must be completely covered by the sleeve.

C

TIGHTEN SETSCREWS SECURELY to the drive tube, NC 8015 or equivalent.

1/2" drive pine recommended to turn D '1' base. Do not fasten base down tightly.

E

1.500 I.D. nylon bearing accepts a mounting tube of 1,112§ Diameter.

1.492

FIGURE 9 ELECTRIC SLIP RING

REF

2 3 4 5 .6 7 , 8 9 10

II

DESCRIPTION

PART NUMBER

Slip Ring Assembly 67262 RC8010

Brush Holding Stud r 5/16" -18 Th. Both Ends 6" LG. RC8082 Brush Spring Brush and Arm Assembly, 20 AMP, Capacity -1/8" RC8004 Brush RC8021 Disconnect Terminal, Large Knife RC8023 Large Plastic Sleeve, 1/4" I .D RC8I30 Wire Connector, Crimp Type Core Assembly, Collector Ring -10 Circuits, RC86I -10-20 20 AMPS RC8207 Base Bracket, Round. Aluminum RC 8706-2 Slip Ring Mounting Tube 12119-5.50 Cover Connector, 90° Liquid Tight RC13158-0.375/0,500

QTY

2 10 10 10 10 10

10/83

FIGURE 9A: ROTARY COUPLING

10/81

FIGURE 9,4; ROTARY COUPLING

REF

DESCRIPTION

PART NUMBER QTY

12 13 14

Spacer 0-Ring Keeper Plate Lockwasher Capscrew, Socket Head Mountings Plate Reducer, Male to Female JIC Tee Adapter, 90° Union Male MC to Male JIC, Female Swivel Seal Kit 90° 0-Ring to JIC 90° 0-Ring to JIC 0-Ring to JIC STR NPT to NPT 0- Ring Elbow to Female NPT

15 16 17 18 19 20

Elbow, 90° - NPT to JIC Check Valve Adapter, 0-Ring to Pipe Parker Adapter, STR - Pipe to JIC Adapter, STR - Pipe to JIC Adapter, 0-Ring

Aeroquip 2D3102T-I2-12-S —1 92079 8 Aeroquip 2062-4-45 3 Aeroquip 2062-12-125 Aeroquip 202702-12 2 Aeroquip 2083-12-12 1 Aeroquip 2502-12-125,-1 Modified Aeroquip 2024-4-6 1 21368 1 Parker 0502-4-4 —3 Aeroquip 2021-4-45 .3 Aeroquip 2021-12-I2S Parker 0502-12-12 4

Rotary Coupling (7 Port Manifold)

32554

2 3 4 5 6 7 8 '

9 10

'

92072 92079 92073 92074 92075' 92076 Aeroquip TRSTXX12-45—

1 4 4 1 I

FIGURE 10 TURRET ASSEMBLY

Lei

0 1— C•41 Men en en Ct) MaCN

•0 NCO CsICNCNICNCsi

0

r--AIA

4orie 7701

I Col

YIEM,

FIGURE 10 TURRET ASSEMBLY

REF

DESCRIPTION

I. Master Leveling Cylinder 2 Pin, Master Leveiing Cylinder 3 Counterweight, Right - Rear 4 , 'Turret Weldment 5 Wobbulator Sending Unit and Horn 6 Control Box Assembly 7 Limit Switch 8 Cushion Pad 9 Slip Ring 10 Pin, Topping Cylinder II Topping Cylinder Assembly 12 ecepticle 13 Shield w/Cable Clamp 14 Solenoid Valve Pack 15 'Holding Valve lo I-IPI Control Valve Assembly 17 Pin, Turret Locking 18 Counterweight, Rear Left 19 Speed Reducer 20 Rotary Coupling 21 Capscrew, Hex Hd. 1/4" - 20 UNC x 3/4" Lg. 22 Nut, Hex, 1/4" - 20 UNC 23 Lockwasher, 1/4" 24 Harness, Boom Cable 25 Plug, G3 26 Shield, G3 27 Module, 23 Pin 28 Module, 11 Pin 29 Harness, Valve Cable 30--Harness, Power Cable 31 Receptacle, G2 32 Module, 11 Socket 33-Socket 34 Lockwasher, 3/8" 35 Pin, Main Boom Pivot 36-End Plate, Boom Pin 37. Capscrew, Hex Hd. 3/8"-13 UNC x 1" Lg. 38Grease Fitting, 90 0 1/8- NPT Grease Fitting, 1/4" - NPT x 1 1/8" Lg. 3940 Capscrew, Hex Hd. 3/8"- 13UNC x 3/4" Lg.

PART NUMBER QTY 32891 32137 32888-001 32551 80188 32552 40207 32890 32659 32136 32562.

80333 67217 40077 40104 32560 32201 32888-002 32557 32554

2

4 4 4 Reference 67220 67221 80356 1 80355 2 32546 Reference 1 67216 •1 80369 80367 10 6 32094 2 32148 2 4 BOW13250 2 BOW7595 2 2

10/ 8 3

FIGURE 12 PUMP AND DRIVE ASSEMBLY

REF

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

DESCRIPTION Pump and Drive Assembly Motor, Electric 72V DC Belt, V 3/8" x 33-1/4" O.D. x 3/8 x 38° Sheave Assembly Coupling Pump, Model 18 Connector Elbow, 90 Hose Assembly Elbow, 90° Bushing, Reducer Hose Assembly, Pressure Pump/Motor Assembly, Emergency Arm, Belt Tensioner Plate, 1/2" x 26" x 31" Alternator, 37 AMP Hose Assembly Hose Assembly, Case Drain

PART NUMBER QTY 328 76 32854 1

1 32882 1 32881 32524 04076 02679 Ref. Fig. , Item 21 1 02675 1 00386 32566-1 1 32199 32850 1 A-36 32218 1 Ref. Fig. , Item 13 32566-5

14

1 o/R2

FIGURE 15

HYDRAULIC TANK ASSEMBLY

10/83

FIGURE 15 HYDRAULIC TANK ASSEMBLY

REF

DESCRIPTION

1 Cover, Hydraulic Tank 2 Gasket, Hydraulic Tank Cover 3 Strainer, Hydraulic Tank 4 Tee, Run 282 5602-16-16 5 Nipple, 1" P.T. x 2" (Bowman) 6 Filter 7 Elbow, 00404 12-16 8 Reducer, 00386-20-12 9 Reducer, 02804-6-12 10 Hose Assembly, 90° 6-STR 11 Reducer, 02655 16-6 12 Hose Assembly, 12-STR 71" Lg. 13 Hose Assembly 14 Tee, Run 15 Hose Assembly 16 Elbow, 90° 1-1/4" 17 Nipple, 1-1/4" x 2" 18 Cap, Filler (Paul Monroe) 19 Valve, Gate 20 Nipple, 1-1/4" x 21 Hose Assembly 22 Elbow, 90° 23 Gauge, Fluid Level 24 -Screen, 3" 30 Mech. (Paul Monroe) 25 .Flange, Bolt-in Type w/gasket (Paul Monroe) 26 Quick Disconnect

PART NUMBER 32883 32883-006 67413

QTY

1 1 1 1 1 1

13466 32522

1 1 1 40180-003 40180-041 02694-6-6 4018-028 13256 13477 Type A 67414 13478 40180-063 Airway 2501-12-16 80126-001 Type W Type 100 67051

10/83

1 1 1 1 1 1 1 1 1 1 1

FIGURE 16 GROUND CONTROL BOX ASSEMBLY 8=MNIIM,M'

10/83

FIGURE 16 GROUND CONTROL BOX ASSEMBLY

REF

DESCRIPTION

Ground Control Box Assembly 1 Guard Switch Decal, Ground Control Panel 2 3 Circuit Breaker, 20 AMP 4 Lock Switch, Ignition 5 Ammeter, * 30 AMP 6 Alarm, Multiaxis 7- Potentiometer 8 Hour Meter 9 Switch, Toggle 10 Switch, Toggle 11 Locking Latch Assembly 12 11 Pin Module, AMP 13 • Plug G2, AMP Special Ind. 14 Recepticai G3 15 23 Pin Module 16 Boom Cable Assemble 17 Engine Cable Assembly 18 Valve Cable Harness 19 Switch, Toggle 20 Knob 21 Meter, Battery Indicator

PART NUMBER QTY 40921 40880 67222 80025 80043 (Engine Assy) YEZ 32002 67203 80027

12 7

80026 80360 80355 80374 80370 80356 Ref. Ref. Ref. 40874 67204 32886-001

1 7 1 3 1 1 1 1 1

2 1 3 5 2

1 —2

1 1 1 4

1 1

C

1 0/83

FIGURE 17 TURRET ROTATION SPEED REDUCER INSTALLATION

FIGURE 17 TURRET ROTATION SPEED REDUCER INSTALLATION

REF 1 2 3 ' 4 5 6 7 .

8 910 11 12 13 14 15 16 17 18

DESCRIPTION Gear Box Assembly Mounting Plate Turret Rotation Pinion Turret Speed Reducer Hydraulic Motor Capscrew, Hex Head 3/8" - 16 UNC x 1" Lockwasher 3/8" Nut, Hex 3/4" x 10 UNC Capscrew, Square Head 3/4" x 10 UNC x 4" Capscrew, Hex Head 1" x 2" LG. - 8 N.C. Th. Capacrew, Hex Head 5/8" - 11 UNC x 1-1/4" Lockwasher, 5/8" Flat Washer 2" O.D. x 11/16 " x 1/4" Lockwasher 3/4" Capscrew, Hex Head Gr.8 -3/8"x 6" LG-18 N.C. Nut, Hex 3/8" N.C. Th. Lockwasher 3/8" Cross Port Relief Valve Spacer

PART NUMBER QTY 32571 32066 21906 32557 32798

1 1 -1

2 2 1 1 1 2 2 2 Th.

32763 32573

4 4 4 1 1

10/81

FIGURE 17A: SPEED REDUCER PARTS BREAKDOWN

FIGURE 17A: SPEED REDUCER PARTS BREAKDOWN

REF

DESCRIPTION

PART NUMBER QTY

Speed Reducer Assembly

32557

Worm Housing Half Worm Housing Half 2 Gear, Worm L. H. 3 Gasket, Worm Housing 4 Seal (Boretite on 0 .D .)

5 Plug, Pipe 3/4" Sq. 6 Gasket, Worm Housing 7 Bearing Cone 8 9 ' Bearing Cup 10 Worm, L. H .

0 Ring 3-1/2 x 3-11/16" 12 Shaft, Worm 13 Container, Bearing 14 Grease Seal Capscrew 15 16 Pipe Plug Shim, Worm Housing 17 18 Worm Housing Gasket 19 Output Shaft 20 Pilot Bushing 21 Spacer, Worm 22 Retainer Washer 23 Quad Ring 24 0-Ring 25 Dust Shield 26 Adapter, Motor 27 Couplings, Half-Winch 28 Couplings, Half-Motor 29 Spacer, Constant 30 Chain, RLR 31 Spacer 32 Capscrew 33 Lockwasher 34 Lockwasher 35 Spacer 36 Capscrew 37 Spring, Spacer 38 Bolt 39 Nut, Hex 3/8-16 NC 40 Vent Plug 41 Worm Key 42 K ey 43 Capscrew 44 Key 45 Bearing Constant Gasket 46 Drive Screw

24010 24140 23535 23428 23421 23378 23429 18015 18016 23534 23422 23461 23303 18026 22703 22374 23670 23671 B058 B 24276 23415 24275 24224 22586 21959 23079 23081 23083 23078 13424 22704 10009 18003 11026 23085 23420 23353 13796 11780 10074 18030 18020 24274 18044 18027 11842

47 48

23310 18024

'

'

'

Warning Plate Bearing Constant Gasket

2 2 2 2 2 2 2 2 4

-

1 18 2

10

_2 4 2 4 4 2 1n /511

FIGURE 20 ELEC. MOTOR - PUMP ASSEMBLY FOR EMERGENCY SYSTEM

DESCRIPTION Pump and Motor Assembly I — Pump 2 Motor Solenoid

PART NUMBER 32199 32644 32645 21342

FIGURE 21

BOOM ASSEMBLY (46N)

IIII I I I 1 I e

3/83

3 SECTION BOOM 46N 30456 1 30420 LD 1 NT OUTER BOOM 46N(3SEC.) P N EA 1.00 N loc. prt type: M from: 000678 end bal: 0 open orders? NO 2 30460 ASSY, BOOM, INTER 46N 3SECTION N EA 1.00 Y loc: prt type: M from: end bal: 0 open orders? NO 3 30461 ASSY, BOOM, R 46N 3SECTION N EA 1.00 Y loc: prt type: M from: end bal: 0 open orders? NO 4 30563 ASSY, CYL.-EXTENSION 46N 3-SEC N EA 1.00 Y loc: prt type: M from: end bal: 0 open orders? NO 5 30428 B CKET, EVENER, 46N T N EA 1.00 N loc: prt type: M from: 000014 end bal: 0 open orders? NO 6 30204 SHEAVE (ASSY) - 46N/60N/46Q8 > T N EA 2.00 N loc: 1ST prt type: M from: 000005 end bal: 2- open orders? NO 7 30398 PIN; 46N/60N;A611-46Q8 SHEAVE> T N EA 2.00 N loc: XDA4 prt type: P from: 888001 end bal: 1 open orders? NO 8 33082-011 AERO-T C ODEL 46N(3SECT) > N EA 1.00 Y toe: prt type: M from: 000000 end bal: 0 open orders? NO 9 30374 CABLE I EXTENSION 46N T N EA 2.00 N loc: is 8 prt type: P from: 925000 end bal: 2 open orders? NO 10 30375 P ROPE ASSY RET 46N T N EA 2.00 N loc: WIC4 prt type: P from: 925000 end bal: 3 open orders? NO 11 21847 - MASTER LEVELING CYL ER T N EA 1.00 N loc: WIA4 prt type: P from: 001400 end bal: 6 open orders? NO 12 BOW32285 T 1/2-20 HEX JAM 5 N EA 8.00 N loc: T/M/V7A1 prt type: P from: 000560 end bal: 0 open orders? NO 13 21809 ECCEN C M BOOM PIN T N EA 2.00 N loc: 4 prt type: M from: 000002 end bal: 16 open orders? NO 14 32168 PIN I BOOM I EXT CYL 11 1/8 T N EA 1.00 N loc: WGC3 prt type: M from: 000002 end bal: 2 open orders? NO 15 33397 PIN, TR ON (EXT. CYL.) T N EA 2.00 N loc: prt type: P from: 001400 end bal: 0 open orders? NO 16 68223 COVER PLATE T N EA 1.00 N loc. I2 prt type: P from: 000262 end bal. 3 open orders? NO 17 30395 MO TING BRACKET AR PAD T N EA 2.00 N toe: lstArt prt type: M from: 000024 end bal: 0 open orders? NO 18 30396 AR PAD TOP & SIDES T N EA 3.00 N loc: XBB1 prt type: P from: 001400 end bal: 5 open orders? NO 19 BOW31234 T - 10-24 C 5 N EA 2.00 N loc: SUB EL 16 prt type: P from: 000560 end bal: 0 open orders? NO 20 68036 BAC PLATE AK PD 7"L T N EA 1.00 N loc: E6 prt type: M from: 000002 end bal: 2 open orders? NO 21 30387 AR PAD TOP FRT OUT BOOM 60N T N EA 1.00 N loc: WIC4 prt type: P from: 001400 end bal: 7 open orders? NO 22 BOW30029 BOLT .31-18 C X 1.00 GR5 HEX 5 N EA 8.00 N lac: A5 prt type: P from: 000560 end bal: 147 open orders? NO 23 68669 ERKT,PLASTICCK, E T N EA 1.00 N loc: XCB1 prt type: P from: 452000 end bal: 4 open orders? NO 24 68670 BRKT, PLASTIC TRACK, FELiALE T N EA 1.00 N loc: XCA1 prt type: P from: 452000 end bal: 8 open orders? NO 25 35642 SPACER, EVENER ROTATION PIN T N EA 1.00 N loc: prt type: M from: end bal: 0 open orders? NO 26 68192 PIN LEVELING CYL T N EA 1.00 N

loc: D4 prt type: P from: 001400 end bal: 7 open orders? NO 27 58366 PLUG TOP AR PAD 1/8 T N EA 8.00 N loc: AMOBS1 prt type: P from: 000869 end bal: 40 open orders? NO 28 30225 AR PAD OUTER BOOM T N EA 6.00 N loc: 1 prt type: M from: 000005 end bal: 1 open orders? NO 29 68183 PLUG T N EA 6.00 N loc: £3 prt type: P from: 000637 end bal: 26 open orders? NC 30 *** NBA .00 N prt type: P from: 000888 end bal: 0 open orders? NO 31 33447 BRACKET, AR PAD T N EA 6.00 N loc: prt type: M from: 000002 end bal: 0 open orders? NO 32 66043-522.00 HOSE ASSY #3 67684 J37 STJ-STJ T N EA 4.00 N loc. VT:FM prt type: P from: 000348 end bal: 1 open orders? NO 33 30616-011 CONTROL CABLE (SEE A PD 8) T N EA 1.00 N prt type: M from: 000007 end bal: 0 open orders? NO 34 32890 REST, BOOM STOP - 3 SECTION T N EA 2.00 N loc: prt type: M from: 000000 end bal: 0 open orders? NO 35 32536 G; TIE DO - T N EA 1.00 N loc: ZR2H prt type: P from: 000560 end bal: 0 open orders? NO 36 BOW34272 T - 25-20UNC ON LOCK 5 N EA 8.00 N be: SUB EL 12 prt type: P from: 000560 end bal. 399 open orders? NO 37 30423 PIN, BRACKET, EVENER, ROTATION T N EA 1.00 N loc: prt type: M from: 000014 end bal: 0 open orders? NO 38 30262 SPACER EVENER T N EA 2.00 N loc: pit type: M from: 000002 end bal: 0 open orders? NO 39 BOW33630 BOLT, SOC D 3/8-16 C X 1/2 5 N EA 5.00 N loc: prt type: P from: 000560 end bal: 0 open orders? NO 40 BOW32601 CL A - .25 ID LOOM 5 N EA 1.00 N loc: prt type: P from: 000560 end bal: 0 open orders? NO 41 BOW33606 BOLT 1/4-20 C X 1.50 SOC -Ii 5 N EA 4.00 N loc: TEL pit type: P from: 000560 end bal: 0 open orders? NO 42 *** N EA .00 N loc: prt type: P from: 000888 end bal: 0 open orders? NO 43 30479 COVER PL, OUTER BOOM(46N-3 SEC) T N EA 1.00 N loc: prt type: P from: 408500 end bal: 0 open orders? NO 44 30302 BUS I G BOOM PIVOT PIN T N EA 2.00 N loc: WIA2 prt type: P from: 797429 end bal: 0 open orders? NO 45 35777 PAD, AR - OUTER BOOM FRONT T N EA 1.00 N loc: D5 prt type: P from: 001400 end bal: 2 open orders? NO 46 BOW31430 WASHER - #10 ID FLAT 5 N EA 2.00 N loc: B6 prt type: P from: 000560 end bal: 0 open orders? NO 47 35775 B T, CABLE AR PAD SUPPORT T N EA 1.00 N loc: prt type: M from: 000014 end be 0 open orders? NO 48 65466-052 BOLT, HEX 130K 3/8-I6X1L N EA 2.00 N loc: T Al pit type: P from: 000560 end bal: 0 open orders? NO 49 30216 PIN CABLE E I T N EA 4.00 N OBS1D3 prt type: P from: 001400 end bal: 0 open orders? NO 50 30394 SPACER - AR P A a T N EA 1.00 N OBS1C3 pit type: M from: 000001 end bal: 0 open orders? NO 51 BOW36812 BOLT,SOC,FLT .25-20UNC X .50 > 5 N EA 8.00 N ZRID prt type: P from: 000560 end bal: 0 open orders? NO 52 30227 AR PAD INTE D BOOM T N EA 1.00 N loc: XCB4 prt type: P from: 001400 end bal: 9 open orders? NC 53 68276-01 T, 3/8 16 C 4 PRONG TEE N EA 6.00 N loc: TRK MOUNT prt type: P from: 000560 end bal: 0 open orders? NO 54 30481 PLATE COVER MODEL 46N 3-SECT T N EA 1.00 N

prt type: M from: 000002 end bal: 0 open orders? NO 55 B0W36722 WASHER 1.251D 2.50 OD FLAT 5 N EA 3.00 N ZR1B prt type: P from: 001548 end bal: 0 open orders? NO 56 BOW36607 T - .63-11 C HEX 5 N EA 8.00 N loc: TM MOVE prt type: P from: 000560 end bal: 0 open orders? NO 57 BOW36703 WASBER.37ID .810D GR8 SAE FLAT 5 N EA 4.00 N loc: WFA5 prt type: P from: 000560 end bal. 250 open orders? NO 58 B0W32606 CL 1" DIA LOOM 5 N EA 5.00 N VCC1 prt type: P from: 000560 end bal: 0 open orders? NO 59 BOW39000 BOLT 1/4-20 X 1/2 GR8 HEX HD 5 N EA 14.00 N loc. ART. prt type: P from: 000560 end bal: 0 open orders? NO 60 BOW36725 REPLACED BY BOW31325 N EA 27.00 prt type: M from: 000999 end bal: 0 open orders? NO 61 BOW31145 SCREW #10-32 3/4 RD IS SLT N EA 2.00 N loc: SUB EL 110 prt type: P from: 000560 end bal: 0 open orders? NO 62 BOW36815 BOLT .25-20 C X 1.00" FLT SOC 5 N EA 8.00 N loc: ZR3F prt type: P from: 000560 end bal: 0 open orders? NO 63 BOW7586 FITTING - .25-28 ST GHT LUBE 5 N EA 4.00 N loc: TELN2B1 prt type: P from: 000560 end bal. 0 open orders? NO 64 BOW41513 BOLT SOC FLT .31-18 C X 1.25 5 N EA 12.00 N loc: prt type: P from: 000560 end bal: 0 open orders? NO 65 B0W41085 SCR, SOC IS .625-11 C X 1.50 N EA 4.00 N prt type: P from: end bal: 0 open orders? NO 66 BOW32277 T 5/8-11 C J 5 N EA 4.00 N loc: WFB6 pit type: P from: 000560 end bal: 248 open orders? NO 67 BOW36836 BOLT 38-16 C X 1.50 FLT SOC 5 N EA 16.00 N loc: LA2B2 prt type: P from: 000560 end bal: 0 open orders? NO 68 BOW34274 T - 3/8-16 UNC HEX LOCK 5 N EA 15.00 N loc: ART/TEL prt type: P from: 000560 end bal: 0 open orders? NG 69 BOW36750 WASHER FLAT .25 ID X .75 OD 5 N EA 6.00 N prt type: P from: 000560 end bal: 0 open orders? NO 70 BOW36703 WASHER.37ID .810D GR8 SAE FLAT 5 N EA 8.00 N loc: A5 prt type: P from: 000560 end bal: 250 open orders? NO 71 BOW31329 WASHER - .50 GR5 SPLIT LOCK 5 N EA 8.00 N loc: A TE/V6B6 prt type: P from: 000560 end bal: 0 open orders? NO 72 BOW36106 REPLACED BY 65466-100 > N EA 4.00 Y loc: prt type: M from: 000999 end bal: 0 open orders? NO 73 BOW36834 BOLT .38-16 C X 1.00" FLT SOC 5 N EA 6.00 N loc: TEL/ART prt type: P from: 000560 end bal: 0 open orders? NO 74 BOW35239 E-RING FOR .438 5 A T DIA > N EA 4.00 N loc: prt type: P from: 000560 end bal: 0 open orders? NO 75 BOW46064 BOLT, HEX .375-16 C X 3.50 N EA 1.00 N loc: prt type: P from: end bat: 0 open orders? NO 76 BOW39002 BOLT 1/4-20 X 3/4 GR8 HEX IS 5 N EA 11.00 N toe: TM MOVE prt type: P from: 000560 end bal: 0 open orders? NO 77 BOW31201 - .25-20 C GR5 HEX 5 N EA 8.00 N lc: ZR1C prt type: P from: 000560 end bal: 0 open orders? NO 78 BOW46055 BOLT .38-16 C X 1.250 TIE; 5 N EA 6.00 N toe: prt type: P from: 000560 end bal: 0 open orders? NO A PAD MTG B CKET T N EA 1.00 N 79 33019 LDMT, toe: I Z/OBS2 prt type: M from: end bal: 5 open orders? NO 80 35081 CYLI JER STER LEV t > T N EA 1.00 N loc: A7 pit type: P from: 000527 end bal: 1 open orders? NO 81 30565 ASSY CYL.-SLAVE LEVELING 46N T N EA 1.00 Y toe: prt type: M from: 000000 end bat: 0 open orders? NO 82 21896 PIN - SLAVE CYL TO BOOM 6+1/8 T N EA 1.00 A

,

FGURE 21 BOOM ASSE

3,

4 59

37 63 3 5 01

96 99

55 56 c7 27

67

6 62 43

48 CO 76 „' 82 to 29 84 —50

49 67

94

75 30 .

Elise Coble F goon 3z940 - Plus IN 3021€ Oil Hord, tA5-' o,

FIGURE 21 BOOM ASSEMBLY

REF

DESCRIPTION

PART NUMBER QTY

1 Outer Boom We

30370 —1 2 Intermediate Boom Weldment —30219 —1 3 Inner Boom Weldment 30217 —1 4 Cylinder, Extension Assembly 30350 1 30428 5 Evener Bracket , Trunnion Weldment

—1 6 Sheave 30204 —4 30398 7 Pin, Sheave -4 8 Plastitrak, 122 Links 32603-010 —1 9 Wire Rope, Extension Assembly 30239 2 10 Wire Rope, Retraction Assembly 30238 2 11 Guide Bracket Assembly 68423 --1 12 Cover Plate; Rotating Light Mounting Bracket 30419 —1 13 Pin, Eccentric 30226 2 14 Pin, Extension Cylinder 1 30245 15 Pin, Extension Cylinder Trunnion 30246 —2 16 Plate, Cover 68223 1 30395 3 17 Wear Pad Mtg. Brkt.

18 Wear Pad, Top and Side 3 30396 19 Wear Pad, Top Rear 68182 1 20 Plate, Back-up 68036 —1 21— Wear Pad, Top Front —1 —30387 22 Capscrew, Hex Hd. 1/4" - 20 UN C x 1" Lg. Grade 8 —8 23 Stationary Bracket, LH 68201 1 24 Stationary Bracket, RH d68202 1 25 Wear Pad, Guide Bracket - Side 68421 2 26 Pin, Leveling Cylinder 68192 1 27 Moveable Bracket, RH 68200 1 28 Wear Pad, Outer Boom 30225 4 29 Spacer 68183 —4 30 Spacer, Wear Pad Bracket 30211 4 31 Holder, Wear Pad 68186 4 4 32 Hydraulic Hose Assembly 80143-008 33 Electrical Cable Assembly 30334- —1 34 Wear Pad, Top Rear —1 30230 35 Tie-Down Ring 1 32536 36 Capscrew, Hex Hd. Ref. Fig. 10 2

1 30423 37 Pin , Main Pivot (Evener) 30262 38 Spacer, Evener 2 Ref. Fig. 10

2

39 End Plate , Boom Pin 1 40 Cable Clamp, 1/4"

—1 40207 41 Limit Switch 68475 —1 42 Plate, Locking 68179 —2 43 Plate, Cover 44 Bushing, Pivot Pin 30302 2 —1 30229 45. Wear Pad, Bottom Front —2 30224 46 Dead-end Bracket a

10/83

FIGURE 21 BOOM ASSEMBLY

REF

DESCRIPTION

PART NUMBER

47 Spacer 30232 48 Wear Pad, Rear Bottom 68180 49 Pin, Cable End —30216 50 Spacer 30394 51 Wear Pad, Side 30231 52 Wear Pad 30227 53 Nut, Tee 68276 54 Set Screw, Socket Hd. Cup Pt. , 3/8" - 16 UNC x 1/2" Lg. 55 Star Nut, 10/24 56 Flat Washer, 10/24 57 Screw, 10/24 58 Set Screw, Socket Hd. Cup Pt. , 3/8" - 16 UNC x 3/4" Lg. 59. Pin, Main Boom Pivot Ref. Fig. 10 60 Cover, Boom 32889 61 Capscrew, Hex Hd. 3/8" 16 UNC x 1" Lg. 62 Capscrew, Ft. Hd. Socket, 1/4" - 20 UNC x 1/2" Lg. 63 SAE Flat Washer, 1-1/4" 64 Nut, Hex 5/8" - 11 UNC 65 Flat Washer, 3/8" 66 Capscrew, Hex Hd. 1/4" - 20 UNC x 1/2" Lg. Grade 8 67 Lockwasher, 1/4" 68 Capscrew, Hex Hd. Ref. Fig. 10 69 Lockwasher Ref. Fig. 10 70 Round Head Screw, 10/32 UNF x 3/4" Lg. 71 Lockwasher, 10/32 72 Capscrew, Ft. Hd. Socket, 1/4" - 20 UNC x 1" Lg. 73 Grease Fitting, STR (Zerk) 1/4" - 28 UNF 74 Capscrew, Ft. Hd. Socket 5/16" - 18 UNC x 1.-1/4"—Grade 8 75 Set Screw, Socket Hd. Cup Pt., 5/8" 11 UNC x 1 1/2" Lg. 76 Jam Nut, 5/8" - 11 UNC

16 UNC x 77 Capscrew, Ft. Hd. Socket, 3/8" 1 1/2" Lg. 78 Locknut, 3/8" 16 UNC 79 Capscrew, Ft. Hd. Socket, 3/8" - 16 UNC x 1 1/4" Lg. 16 UNC x 80 Capscrew, Ft. Hd. Socket, 3/8" 3/4" Lg. 81 SAE Flat Washer, 3/8" 82 Lockwasher, 1/2" 83 Capscrew, Hex Hcl. 1/2" 13 UNC x 1-1/2" Lg. Grade 8 84 Capscrew, Ft. Hd. Socket, 3/8" 16 UNC x 1" Lg. 85 E Clip, 7/16" Dia.

QTY 1 4 4 1 4 1 6

5 2 2 2 2 2 1

—4 3 8 4 14 27 4 4 2 2 8

4 12

-

-

4 4

-

-

-

12 19 —

6

-

-

-

8

8 4 4 — 6

4 10/83

FIGURE 23 SLAVE LEVELING CYLINDER ASSEMBLY

REF

DESCRIPTION

PART NUMBER

Slave Leveling Cylinder Assembly 1 Slave Leveling Cylinder 2 — 0-Ring Adapter 3 Grease Fitting, 45° 1/4" - 28 UNF 4 Tube Assembly

—30264 2404-4-4 32611

QTY

1 2 1 2

0

1 0/ 83

FIGURE 23A SLAVE LEVELING CYLINDER

REF

DESCRIPTION

2 3 4 5 , 6 7 , 8 9 I0 12 13 14 15 16

PART NUMBER

Cylinder

30264

Gland Piston Barret Assembly Rod. Assembl y Locknut, Self-Locking Bushing, Bronze Bolt, 1/4" - 20 Gland Static Seal Rod Seal Rod Wiper Piston Seal Rod Static Seal Dual P.O. Check Valve Washer Lockwasher Bushing, Bronz e Seal Kit (consists of Parts marked *)

93031 93032 93033 93034 W 92027 92028 92029

* S

30322 92030 92031 93035 93036

QTY

1

1

3 1 1 1 2 1 '3 3 2

13 7

15 14 16

3/83

FIGURE 24

REF

MASTER LEVELING CYLINDER

DESCRIPTION

PART NUMBER

QTY

32891

Cylinder I —Gland 2 Piston 3— Barrel Assembly 4—Rod Assembly 5— Locknut, Self-Locking 6 — Gond Static Seal 7—Rod Seal 8—Piston Seal, U-Cup 9' Rod Wiper 10 Rod Static Seal 11 'Bushing, Bronze Seal Kit (contains Parts marked *) '

93031 93032 93037 93038 92027 1111011111■11111M

*

93035 93036

10/83

FIGURE 26 BOOM EXTENSION CYLINDER

DESCRIPTION

PART NUMBER

10/83

FIGURE 28 TOPPING CYLINDER

PART NUMBER

DESCRIPTION

REF

Calavar 32562

Cylinder

l Piston

93018 93019 93020 93021 93022 93023 93024 92001 92009 92012 93025

2-Gland 3--Barrel Assembly 4 Rod Assembly 5-Manifold Assembly 6 Spacer 7° Collar 8 Bushing, Bronze 9 Bolt, Valve Assembly 10 Set Screw w/Nylon Insert II Nut, Hex Head 12 Gland Static Seal 13 'Rod Seal 14 -Piston Seal 15-Rod Wiper 16 Rod Static Seal 17 Counterbalance Valve Assembly Lockwasher 1819Plain Washer 20 • Cartridge Seal Kit

4

'

SOON

QTY

•

40707 92011 92010 32585 32636

1111111011 ■1.

MUM

ail ill'

Morn • lin 4 2111111 111111 ■

Nor

VI AKJI/AO'ZdrAIII92r/ AdrAir Min!rAlrinillrarararinin

t -i AdllWAPt IMIWAP7AlVlir PaIPZO'ZAPMPL

r

4, 4 1111,11111a 11111111111111r 7 4 X Nr, AdraIWA11111111 A I

11/82

FIGURE 30 SKIRT WELDMENT, NON-ROTATION

3/83

FIGURE 30 SKIRT WELDMENT I NON ROTATION -

REF

DESCRIPTION

PART NUMBER QTY

_1 30316 1 Skirt 30390

1 Pin, Boom to Skirt 2- 2

3 Grease Fitting (Zerk), 1/4" S 32536 4 Tie-Down Ring 7 30389

Bushing 5 2 6 Capscrew, Hex Hd. 1/4" -.28 UNF x 3/4" Lg. 1

1/4" Lockwasher, 7 .1 8 Pin, Leveling Cylinder 21126 -1 9 Capscrew, Hex Hd. 1/2" - 13 UNC x 4" Lg. Grade 8 4 10 ---L--Net, Hex 1/2" - 13 UNC 4 Lockwasher, 1/2" 11 4 12 --- Flatwasher, 1/2" 4 Platform Weiciment 13 S Ref. Fig. 32 1 ,®

3/83

FIGURE 31 PLATFORM CONTROL CONSOLE ASSEMBLY

REF

PART NUMBER

DESCRIPTION Platform Control Console Assembly

-31 1 2 3 4 5

6 7 8 10

11 12 13 14

Switch Switch Switch Switch Handle Switch Switch Panel Exterior Panek Housing Decal Label Switch Indicator Lamp Switch Guard 110 Volt Receptical

32720 40878 40877 40874 — 40876 40865 40872 40873 40867 40870 40869 40871 40879 40880 40881

11 5/82

FIGURE 32 PLATFORM WELDMENT (46N)

REF 1 2 3 4

5

DESCRIPTION

60" x 30" x 43 - 1/2" High Platform Weldment Step Weldment Capscrew, Hex Head 1/4" - 20 UNC x 1" Lg. Lockwasher, 1/4" Flat Washer, 1/4" Nut, Hex 1/4" - 20 UNC

PART NUMBER 30006 30315 Grade 5

QTY

-1 4 4 4 4

3/83

FIGURE 33

SKIRT WELDMENT, NON-ROTATION

1/83

FIGURE 33 SKIRT WELDMENT, NON-ROTATION

REF

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

DESCRIPTION

Skirt Pin, Boom to Skirt .

Grease Fitting (Zerk), 1/4" Tie Down Ring Bushing Capscrew, Hex Hd. 1/4" - 28 UNF x 3/4" Lg. Lockwasher, 1/4" Pin, Leveling Cylinder Capscrew, Hex Hd. 1/2" - 13 UNC x 4" Lg. Net, Hex 1/2" 13 UNC Lockwasher, 1/2" Flatwasher, 1/2" Platform Weldment

PART NUMBER

30316 30390 32536 30389

21126 Grade 8

QTY

1 1 2 7 2 -1 '-

1 - 4 4 4

Ref. Fig. 32

1/ 83

FIGURE 34 180° PLATFORM ROTATION ASSEMBLY (OPTION) C.)

24

FIGURE 34 180° PLATFORM ROTATION ASSEMBLY (OPTION)

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

.

,

-

DESCRIPTION

PART NUMBER al Y

Skirt 30316 1 Platform Weldment Ref. Fig. 32 Lockwasher, 1/2" Tie Down Ring 32536 Bushing 30389 2 Capscrew, Hex Hd. 1/2" 13 UNC x 1-1/4" Lg. 4 Key, 1/2" Sq. x 5" Lg. 1 Elbow, 90° 2501 6 6 2 180° Rotary Actuator 68425 1 Capscrew, Hex Hd. 1/4" - 20 UNC x 1-3/4" Lg. Lockwasher, 1/4" 2 Bearing, Thrust 68402 1 Elbow, 45° 2 2503 6 6 Step Washer 32775 1 Bushing 40976 1 Shaft, Actuator 30384 1 P.O. Check Valve 21480 1 Needle Valve 21479 2 Hose Assembly, 1/4" x 17" Lg .

2 Elbow, 90° 5500-6-6 2 Key, 1/2" Sq. x 2-1/2" Lg. 1 Lockwasher, 7/8 1 Capscrew, Hex Hd. 7/8" - 9 UNC x 2-1/2" Lg. ®1 Capscrew, Flat Hd. Socket 1/2" 13 UNC x 1" .

Elbow, 90 2501-6-10 2 -30390 Pin, Boom to Skirt 2 Grease Fitting (Zerk), 1/4" 1 Capscrew, Hex Hd. 1/4" - 28 UNF x 3/4" Lg. 1 Lockwasher, 1/4" -1 21126 Pin, Leveling Cylinder

3/83

FIGURE 35A 180° ROTARY ACTUATOR

with hollow pinion

#68425

20

4/83

FIGURE 35A 180° ROTARY ACTUATOR (with hollow pinion) #68425

REF

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

DESCRIPTION

0-Ring (Pinion) Bushing (Pinion) 0-Ring (Pinion Bushing) Snap Ring End Cap Back-up Ring (End Cap) 0-Ring (End Cap) Rack - Bolt Piston Piston Seal 0-Ring (Rack - bolt) Back-up Ring (Rack - bolt) 0-Ring (Cylinder Tube) Nut (Tie-rod) Tie Rod Cylinder Tube Rack Pinion Housing Thrust Ring Relief Valve

PART NUMBER

93049

*

93050 93051

*

93052 93053

* *

93054 93055 93056 93057 32683 93058 93060 93059

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

* Seal Kit, Calavar Part No. 93044, includes Items 1, 3, 6, 7, 10, 11, 12, & 13

4/83

SELF-PROPELLED CONDOR, INDUSTRIAL MODEL 46EN OPERATION AND SAFETY MANUAL It shall be the responsibility of all users to read and comply with the following common sense rules that are designed to promote safety and aid in better understanding the operation of the Self-Propelled Condor Industrial Models. These rules do not purport to be all inclusive, nor to supplant or replace other additional safety and precautionary measures to cover usual or unusual conditions. If these rules conflict in any way with any state, local or federal statute or regulations, said statute or regulation shall supersede these rules and it shall be the responsibility of each user to comply therewith.

UNLOADING 1.

If the use of a loading ramp is necessary to unload the Condor, select a sturdy ramp. The Self-Propelled Condor, Industrial Models weigh approximately 17,500 lbs.

2.

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

OPERATING 1.

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

2.

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

3.

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

4.

Aerial Controllers are proportional, except for steering, platform tilt and platform rotation, which are bi-directional toggle switches.

Each controller has a deadman lock-out mechanism that must be lifted before the controller can be activated. Grasp the control handle knob as if it were a ball, squeezing the fingers will lift the bottom side of the control knob. This unlocks the control handle so that it can be moved in either direction. When released and brought back to neutral position, it will again lock.

5.

Normal driving position for the Condor is with the counterweight over the driving wheels. Controller movement is based on this configuration. With counterweight over steering, the drive and steering control will react reversed.

46EN/10-83

6.

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

7.

A modular valve is located on the base between drive wheels.

It contains several features -- a flow divider cartridge, two diverter cartridges, a two-speed solenoid cartridge, a flow control and check valve cartridge, and an additional counterbalance valve in the pressure lines to the modular valve.

This modular valve performs the necessary functions of dividing the oil for slow speed travel with adjustable differential action to round corners, as well as diverting the oil flow for high speed travel. The counterbalance valve softens the brake release and application efficiently without an accumulator.

INSPECTIO N 1. Once unit has been unloaded, give the Condor a visual inspection paying special attention to items listed below. This inspection should become part of a daily inspection performed at the beginning of a work shift by the assigned operator.

A. B. C. D. E. F. G.

Check for cut or damaged tires (they are foam-filled).

Check electrolyte level.

Check hydraulic oil level (use A.T.F. oil only).

Check air cleaner oil level and cleanliness.

Check stop and start circuit from ground and aerial position.

Visual inspection for hydraulic leaks.

NOTE The Self-Propelled Condor, Industrial Models, are also equipped with limit switches. One is activated by the inner boom in the fully retracted boom position, and another located outside of the outer boom at the boom-to-turret hinge pin, which is activated when the boom is below the horizontal position. When either switch is activated (i.e., when the boom is extended or raised to horizontal) they automatically shift DRIVE to low speed.

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OPERATOR TRAINING 1.

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

2.

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

3.

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

4.

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

5.

Extend boom to maximum and raise boom to 75°, rotate turret.

Turret rotation is continuous. By gradually operating rotation controller giving full signal to rotation, and by gradually returning controller to neutral , the operator will learn how the rotation can be controlled to place unit along side a building smoothly.

6.

Place counterweight over drive wheels, with unit at 75° and maximum extension. Repeat driving exercise.

NOTE: Extreme care must be taken when driving in this position, as ground vision has been reduced. The operator must watch for objects or personnel that may be in the area.

7.

At the end of this exercise, the operator will have driven the Condor in both high speed and low speed; with extended and retracted boom; and will have driven the Condor with boom off to the side, and will have practiced placing Condor in imaginary work positions.

SAFETY Listed below are items pertaining to safety that the operator must know and follow.

1. The Self-Propelled Condor, Industrial Model 46EN, is a personnel lifting device and it is essential that it is properly maintained and operated to perform all functions with maximum safety and efficiency.

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2.

The operation of any new and unfamiliar equipment can be hazardous in the hands of untrained opeators. Only trained operators should be assigned to operate the Condor.

3.

It is the responsibility of the operator to be familiar with the manufacturer's manual and to follow all recommendations made. Never exceed manufacturer's recommended load.

4.

It is the responsibility of the owner to instruct the operator with the safety requirements made not only by Calavar, but by various safety boards in your area, as well as requirements set down by OSHA and ANSI. (Note: See ANSI 92.5 - 1980.)

5.

Do not operate Condor in excess of rated load specifications.

6.

The Condor is a non-insulated aerial work platform and MUST NOT BE OPERATED NEAR HIGH VOLTAGE LINES.

7.

Do not lean over platform railings to perform work.

8.

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

9.

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

10.

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

11.

Always distribute load evenly over work platform.

12.

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

13.

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

14.

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

15.

Do not alter equipment.

16.

Do not override safety devices.

17.

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

18.

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

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19.

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

20.

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

21.

Visually inspect tires. Tires that have been severely cut to the cord are dangerous and should be replaced.

22.

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

23.

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

24.

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

25.

The Self-Propelled Condor, Industrial Model 46EN, is NOT to be used as a ground for welding. Disconnect both positive and negative ground leads from battery before welding on Condor.

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