Condor A38 42J Operation, Service & Parts Manual - PDF DOWNLOAD

OPERATOR'S, SERVICE AND PARTS MANUAL ARTICULATING

MODEL

A38/42J

BOOM-SUPPORTED ELEVATING WORK PLATFORM

o

MANUAL92379-001 July 1998

i INTRODUCTION

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

THIS MANUAL MUST BE RETAINED ON THE UNIT AT ALL TIMES.

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

Read the decals before operating this machine.

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

It is also YOUR RESPONSIBILITY to understand and obey all federal, state, and local regulations regarding the safe operation and use of aerial work platforms. A copy of the ANSI/SIA A92.5-1992 Manual of Responsibilities is attached for your use.

TIME CONDOR Corporation reserves the right to modifY, improve, add, andlor delete certain design features of its products without any obligation to incorporate new features into products previously sold. Our manuals are continually updated to reflect these changes.

DO NOT ALTER OR MODIFY THIS UNIT WITHOUT PRIOR WRITTEN APPROVAL FROM THE MANAGEMENT OF TIME CONDOR Corporation

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

MANUAL92379-002 May1998

Revised11198

CONDOR® SERVICE INFORMATION

1. Ifyou need assistance or have any service or maintenance questions, TIME CONDOR Corporation service and parts personnel are always available by phone or fax. Thetelephone numbers are: (254)420-5200 Telephone (817)420-5298 Voice Mail (800) 443-5803 FAX

2. TherearenumerouswrittenMaintenanceProceduresavailableforthismachine. Theseprocedures are availab Ie through the TIME CONDOR Corporation ServiceDepartmentto anyone who requests them.

3. Service and maintenance are not a substitute for trained, qualified service technicians . TIME CONDOR Corporation conducts service schools ona continuing basis. Call any ofour service or sales persons for a schedule. Remember, training ofmechanics is the responsibility of their employer, butTlME CONDOR Corporation. Service Schools help you provide this training.

4. TII\1E CONDOR Corporation Service School TrainingManuals are availableforpurchasethrough the parts department. Thepartnumbers for thes e manuals are: #92333 forself-propelled models; and #92334 fortruck -mounted models.

TIME CONDOR Corporation

8300 IMPERIAL DRIVE, P.O. Box21447, WACD, TEXAS 76702-1447' 817-666-4545, 817-666-4544 FAX

Condor® Self-Propelled Booms and Scissors

WARRANTY TIME CONDOR Corporation warrants to the purchaser that each new aerial work platform made by TIME CONDOR is free from defects in material and workmanship arising under normal use and service in the case of major weldments, (chassis, turret, and booms), for a period of five (5) years after the original shipment of the aerial workplatformfrom TIME CONDOR's plant; and in the case of all otherparts, for a period of one (1) year aftertheaerialworkplatformisplacedinseIViceortwo(~yearsaftertheoriginalshipmentoftheaerialworkplatform

from TIME CONDOR's plant, whichever comes first.

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

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

Any operation of the equipment beyond rated capacity, improperuse or application of the equipment, substitution upon it of parts not approved by TIME CONDOR or alteration or repair of the equipment by any person notauthorizedbyTIMECONDORshall,atTIMECONDOR'soption,voidthisWarranty. TIME CONDOR shall have no liability or responsibility for damages resulting from accident or the malfunction of equipment and components not supplied by TIME CONDOR. No agent, employee, distributor, dealer, or other representative of TIME CONDOR is authorized to modify this Warranty in anyway. Accordingly, additional statements orpresentations by any such representative, whether oral or written, do not constitute warranties by TIME CONDOR and should not berelied upon as limited warranties of TIME CONDOR, and no attempt, effort, or promise to repair equipment by TIME CONDOR or any such representative at anytime shall modify or extend this Warranty in any way. If the purchaser has used its own order fonn, no additional or different warranty terms contained in the purchaser's form will behonoredby TIME CONDOR This Warranty covers only new and unused aerial work platforms manufactured by TIME CONDOR. Products or parts manufactured by others are covered only by such warranties as are extended to the purchaser by TIME CONDOR's suppliers.

This Warranty is in lieu of all other warranties, expressed or implied, including but not limited to warranties ofmerchantibilityandfitnessforaparticularpurpose. Any applicable implied warranty shallbe limited induration to the warranty period.

8300 ImperialDrive, P.O. Box21447, Waco, Texas76702-1447'254-420-5200,254-666-4544FAX FormNo.513-3M-392

Effective Date 9/1/90 Printed in U.S.A.

TIME CONDOR Corporation

OPERATOR'S MANUAL ARTICULATING

MODEL

A38/42J

BOOM-SUPPORTED ELEVATING WORK PLATFORM

MANUAL92379-001 July1998

TABLE OF CONTENTS

•

INTRODUCTION .....................................................................................................................

i

TABLE OF CONTENTS ...........................................................................................................

1

I. SAFETY ................................................................................................................................

3

A Safety Symbols ...........................................................................................................

B. Safety Rules ...............................................................................................................

C. Safety Decals ....... .... ........ .................. ............................ .......... ...... ................ ........ ....

3 4 8

II. MACHINE OPERATION ................................................................................................

A B. C. D.

Primary Machine Components ............. .......................................... ...... .... ...... ...... .....

Ground Controls ..... ........ ........ .................................. .......... ............ .... .............. .......

Platform Controls ... .... ........ .................. .............. ...... ........ .......... ...... ........................

StartUp Procedures .................................................................................................

1. Shift Check ......... .......... .................. ...... .................. .... ................ ...... ............ .......

2. Machine Start Up .................................................................................................

3. Ground Operation and Checks ..................................... ................................ ........

4. Platform Operation and Checks ..................................... .......... ...... .......... ............

5. Cold Weather Operation ......................................................................................

E. General Operation . ........ ........ ............ .... ................................ .......... ........ ............ ....

1. Drivers and Steering ............... .......... ........................... ....... ........ .......... ................

2. Braking ................. ...... ........ .............. ............ ................ ...... .... ............................

3. Booms, Turret and Platform .................................................................................

F. ShutDown Procedures .............................................................................................

12 13 14 16 19 19 19 20 22 25 26 26 26 27 28

III. MOVING FROM JOB SITE TO JOB SITE ..................................................................... 28 A B. C. D.

Unloading ............. ...................... .................... .... ...... .... .... ........ ........ ........ ...... .... .....

Loading ....... ........ .... ...... ........ ........ .... ...... ...... ...... ...... ...... .... ...... ........ ........ .... ..........

Tie Down ....... ...... ...... ...... .......... .... ........ .................... ...................... ............ ........ ...

TowingProcedure....................................................................................................

28 28 28 30

IV. EMERGENCY PROCEDURES .......................................................................................

31

V.

MAINTENANCE ........................................................................................................... .

VI.

MACHINE SPECIFICATIONS ...................................................................................

34

VII.

MACHINEDIAGRAM .................................................................................................

35

ANSIISIA 92.5-1992 MANUAL OF RESPONSIBILITIES

MANUAl92379-001 July 1998

•

SAFETY SYMBOLS

This manual contains imponant information on the safe use ofyour COND OR A Series. Your failure to read, understand and follow all safety rules, warnings and instructions will unnecessarily expose you and others to dangerous situations. For your safety and the safety of those around you, you must operate your aerial platform as instructed in this manual.

You the operator, are the single most imp on ant factor for safety when usinganypieceof equipment. Learn to operate your work platform in a safe manner.

To help you recognize imponant safety information, we have identified warnings and instructions that directly impact on safety with following signals:

A DANGER "DANGER" INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH,IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY. THIS SIGNAL WORD IS LIMITED TO THE MOSTEXTREME SITUATIONS.

AWARNING "WARNING" INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN DEA TH OR SERIOUS INJURY.

A CAUTION "CAUTION" INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT IS ALSO USED TO ALERT AGAINST UNSAFE PRACTICES, AND FOR PROPERTYDAMAGE-ONLYSITUATIONS.

One final note: The best method to protect yourself and others from injury or death is to use common sense. If you are unsure of any operation, don't stan until you are satisfied that it is safe to proceed.

MANUAL92379-001 July 1998

.SAFETY RULES AND PRECAUTIONS

A DANGER • ELECTROCUTION HAZARD!! THIS MACHINE IS NOT INSULATED!!

Maintain safe clearance from electrical lines and apparatus. You must allow for machine sway (side to side movement) when elevated, and electrical line movement. This machine does not provide protection from contact with or proximity to an e1ectricallychargedconductor.

You must AVOID CONTACT between any pan of the machine, or its load, and any electrical line or apparatus carrying up to 300 volts.

You must maintain CLEARANCE OF AT LEAST 10 FEET (3.05 M) between any pan ofthe machine, or its load, and any electrical line or apparatus carrying over 300volts up to 50,000 volts. One foot (30.5 cm) additional clearance is required for every additional 30,000 volts.

DEATH OR SERIOUS INJURY will result from contact with, or inadequate clearance from, any e1ectricallychargedconductor.

• Read and understand all safety and control information found on the machine and in this manual before operating the unit.

• Only trained, competent personnel should operate the aerial work platform.

• Be aware of all Government and Local rules which may apply to this machine and its safe operation.

• Approved safety belts must be worn at all times when operating the unit from the platform. In addition, approved headgear and other protective equipment must be worn as required. (In the U.S.A., OSHA approved equipment is required. For other countries, the appropriate equivalent government body should be consulted.)

• NEVER fasten safety belt to an adjacent structure while on the work platform.

• Make sure that entry gate to platform is secured before operating unit from the platform.

• DO NOT block the foot switch or anyfunctioncontrolin the operating position.

• DO NOT exceed the platform capacity of the unit in any configuration. Review the section titled "MACHINE SPECIFICATIONS", later in this manual, regarding this model's capacities and dimensions.

MANUAL92379-001 July 1998

SAFETY RULES AND PRECAUTIONS (Continued)

A DANGER • SECURE all tools and other loose items to prevent injury to persons working on or below the work platform.

• DO NOT use scaffolding, ladders or similar items to extend your reach while on the work platform.

• DO NOT attempt to climb down the boom assembly if the unit fails while the operator's platform is raised or extended.

• Since the machine may be operated from the ground controls, precautions should be taken to prevent unauthorized personnel from operating the work platform with the ground controls while the platform is in use.

• The "UNPOWERED EMERGENCY MOVEMENT" procedure (described later in this manual) requires releasing the brakes, which results in there being no means to stop the unit's travel. TIME CONDOR recommends using this procedure only in cases of emergency, and onlyfor a short distance. Be on guard against unit runaway on sloping surfaces. Movement speed shall not exceed 1M.P.H. (1.6K.P.H.).

• DO NOT attempt to open any hydraulicline orcomponent without first relieving all system pressures and shutting off fluid flow from the tank.

• DONOTallowanyonetotamperwith,serviceoroperatethemachinefrom the ground control station while personnel are on the platform, except in an emergency.

• DO NOT alter, modify or disable any safety devices or interlocks.

• DO NOT use the aerial work platform outdoors in electrical storms or high wind situations.

• DO NOT raise the aerial work platform unless the unit is on a firm, level surface.

MANUAL92379-001 July1998

•

•

SAFETY RULES AND PRECAUTIONS (Continued)

A. DANGER • Use caution to prevent ropes, cords, hoses, etc. from becoming entangled in the unit's boom sections when being raised, lowered or repositioned.

• Ensure that the area surrounding the mo bile platform is clear of personnel and equipment before: driving the unit; or raising, lowering or extendingthe boom; or swinging the turret; or, rotating or tilting the platform.

• Maintain a safe distance from overhead and ground obstacles, debris, drop-off, holes, depressions, electrical wires and other hazards to travel.

• Limit travel speed according to conditions of the ground surface, congestion, slope, location of personnel or any other factors that could cause hazard of collision or injury to personnel.

• DO NOT sit, stand or climb on platform rails.

• DO NOT operate this machine while under the influence of any drugs or alcohol.

• DO NOT operate this machine if you are bothered by heights, seizures, or dizzy spells.

• DO NOT indulge in stunt driving or horseplay while operating this machine.

AWARNING • Complete the "Operational Checklists" found in this manual (see Table of Contents) at designated intervals.

• Ensure that the machine is in "CREEP" drive speed while unloading from a truck onrailer.

• Always attach the unit to a winch when loading or unloading from a truck ortrailer.

TIME CONDOR does not recommend unassisted loading or unloading of any aerial work platform.

• With the turret swung away from the stowed position, use caution when selecting travel or steering direction. Travel and steer direction will be opposite switch or lever movement. Refer to the large "FORWARD" arrows on the chassis.

MANUAL92379-001 July 1998

SAFETY RULES AND PRECAUTIONS (Continued)

AWARNING • Actuation of the red "EMERGENCY STOP" button will apply brakes immediately, causing unexp ected platform movement as the machine comes to a sudden stop. Brace yourself.

• Whenever disengaging the brakes or before disconnecting from towing vehicle, ensurethatthe unit cannot roll.

• Immediately report any erratic noises, vibrations or malfunctions of the unit to supervisor. Machine must be removed from service until diagnosis and any necessary repairs have been comp leted.

• Operating this equipment without all safety and control decals in place can be hazardous.

A CAUTION • Fortransportingthe machine, the platform must not be tied to the trailer bed.

• Be sure to turn all hydraulic valves back "ON" before starting the machine, or extensive pump damage will occur.

• DONaT exceed the maximum platform horizontal pulloflOOlbs. (45.4 kg).

• DO NOT use the boom or platform as a crane to lift oversized or hanging loads.

• DO NOT raise, extend, retract, tilt, rotate, or lowerthe platform or booms into stationary objects, as this will cause damage to mechanical and hydraulic components.

• DO NOT use the platform or boom functions to push ortowthe unit or another vehicle.

• Avoid sudden braking or steering, go slowly and leave more maneuvering room during cold weather operation until the machine is warm.

MANUAL92379-001 July1998

•

•

SAFETY RELATED DECALS

ELECTROCUTION HAZARD KEEP CLEAR DEATH OR SERIOUS INJURY CAN RESULT FROM CONTACT WITH TIllS EQUIPMENT OR VEHICLE IF IT SHOULD BE ELECTRICALLY CHARGED 21882-001

21882-001 - Decal, Electrocution Danger

• DO NOT OPERATE THIS CONDOR ® UNTIL YOU HAVE BEEN PROPERLY TRAINED AND HAVE COMPLETELY READ AND UNDERSTOOD THE OPERATOR'S MANUAL LOCATED ON THIS CONDOR, ® • PRIOR TO EACH DAY'S USE, CHECK TO MAKE SURE ALL FUNCTIONS ARE OPERATING PROPERLY PERFORM ALL INSPECTIONS REQUIRED BY SECTIONS 6,5, 6.6 AND 7.3.3 OF THE ANSI 92.5 STANDARD. •

DO NOT USE THIS CONDOR® IF IT IS MALFUNCTIONING OR DAMAGED IN ANY WAY, OR If THE WIND BLOWS OVER 25 MPH.

•

RAISE PLATFORM ONLY WHEN CONDOR ® IS ON FIRM, LEVEL GROUND.

•

AL WA YS LOOK IN THE DIRECTION IN WHICH THE PLATFORM IS MOVING, WATCH FOR AND AVOID OVERHEAD OBSTRUCTIONS AND ANYTHING ELSE THAT MAY STRIKE PLATFORM, PERSONNEL, CONTROLS OR CONDOR ®,

•

THIS CONDOR ' IS NOT ELECTRICALL Y INSULATED. SEE OPERATOR'S MANUAL FOR SAFE APPROACH DISTANCES TO ENERGIZED POWER LINES,

•

DO NOT MAKE ANY MODIFICATIONS TO THIS CONDOR@ WITHOUT WRITTEN APPROVAL FROM CONDOR'S MANAGEMENT.

•

IN CASE OF EMERGENCY, PUSH RED "EMERGENCY STOP" BUTTON,

@

:3853.}

38533 - Decal, Lower Boom Caution MANL!AL92379-001 July 1998

•

SAFETY RELATED DECALS

Ii ·

ILh CAUr~ON I

~~;

BEFORE OPERATING CONDOR®, ALL PERSONS IN PLA TFORM MUST HAVE APPROVED FALL

}

PROTECTION SYSTEMS ATTACHED..

"f .~

•

i~.

:;.

THIS CONDOR® IS NOT ELECTRICALLY INSULATED. SEE OPERA TOR'S MANUAL FOR MINIMUM SAFE' APPROACH DISTANCES TO ENERGIZED POWER LINES.

t •

RAISE PLATFORM ONLY WHEN CONDOR® IS ON FIRM, LEVEL GROUND.

i •

ALWAYS LOOK IN THE DIRECTION IN WHICH THE' PLATFORM IS MOVING. WATCH FOR, AND AVOID, f; OVERHEAD OBSTRUCTIONS AND ANYTHING ELSE THAT MAY STRIKE PLATFORM, PERSONNEL, CONTROLS. OR CONDOR.®

Ii " ';

, "

•

NORMAL TRAVEL POSITION IS WITH BOOM POSITIONED OVER FIXED (REAR) AXLE. DIRECTION OF TRAVEL AND STEERING REVERSES IN RELATION TO CONTROL MOTION WHEN BOOM IS OVER STEER (FRONT) AXLE. DO NOT DRIVE ON A SLOPE UNLESS BOOM IS FULLY RETRACTED AND LEVEL OR LOWER.

{ M ~

•

i

I 1•

~

IF SLOPE ALARM SOUNDS, CONDOR@> lS OUT OF 1 x LEVEl. REVERSE DIRECTION OF TRAVEL AND'" REPOSITION CONDOR® ON FIRM, LEVEL GROUND. i.'

t

IN CASE OF EMERGENCY, PUSH RED "EMERGENCY STOP" BUTTON.

6957~

69573 - Decal, Upper Boom Caution

RATED WORK LOAD

500 LB 37958-500 37958-500 - Decal, Rated Work Load

MANUAL92379-OO1 Ju1y1998

8) SAFETY AND CONTROL DECAL LOCATIONS

AWARNING OPERATING THIS EQUIPMENT WITHOUT ALL SAFETY AND CONTROL DECALS IN PLACE CAN BE HAZARDOUS. If any of these items are damaged or missing, replace them immediately.

Decals are shown for standards machine. Optional equipment may change the decal locations.

6

8

Rear

Front

20

Right Hand Side

5

Rear

Front

8

1----+1--1+- 21

3

Left Hand Side

MANUAL92379-001 July 1998

CD

SAFETY AND CONTROL DECAL DESCRIPTIONS

DESCRIPTION

QTY

ITEM

PART NUMBER

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

76412-A38/A42J ......... DecalInstallationM-A38-01M-A42J-Ol ................................. Ref. 76412-DWG ............... Decal Installation Drawing .......................................................... 1 76105 .......................... Decal; Turret Control Box .......................................................... 1 21882-001 .................... Decal; ElectroocutionDanger ..................................................... 2 37958-500 .................... Decal-500 lb Rated Work Load .................................................. 1 38176 .......................... Decal-AuxHydraulic Valve Lowering .......................................... 3 38533 .......................... Decal-LowerCautionBoom ....................................................... 1 38550 .......................... Decal-PlatformFallArrest .......................................................... 2 52759 .......................... Decal-Stand Clear ....................................................................... 2 54182 .......................... Decal-BatteryChargerPlug ......................................................... 1 54652-005 .................... Decal, BatteryService Caution ..................................................... 2 55940-023 .................... Decal-3.50x23.33 Gray Condor ................................................ 2 54984-004 .................... Decal-Lift and Tie Down ........................................................... 4 54984-006 .................... Decal-ll0 Volt Ext To Platform ................................................ 1 54984-007 .................... Decal-HydraulicFluid ................................................................. 1 56024 .......................... Decal-Forward2.5x17Gray ....................................................... 2 56023 .......................... Decal-Arrow7x6.1 Gray .......................................................... 2 56033 .......................... Decal-Twin Stripe 3.5 Gray .............................................. 12.23LF 56034-500 ................... Decal; Rtd Work LD 3.5 x 13.7 Gray .......................................... 1 55941-017 .................... Decal-"Bird" 2.5 x 17 Gray ......................................................... 1 58399 .......................... Decal-Tire Replacement Solid ...................................................... 4 69573 .......................... Decal-Boom Upper Caution ...................................................... 1 71615 .......................... Decal;PanicStop ........................................................................ 1 76102 .......................... Decal;PlatfromControlBox ...................................................... 1 76407 .......................... Decal; A38 ................................................................................. 2 76408 .......................... Decal;A42J ................................................................................ 2

- Indicates Items Not Shown

MANUAL92379-001 July1998

G) PRIMARY MACHINE COMPONENTS PLATFORM

----~

,..-,11------ PLA TFORM CONTROLS

\'\¢&,¥----------

JIB BOOM

\ "'~------ JIB CYLINDER

UPPER BOOM

LIFT CYLINDER - - - - - - - - - - - - \ -

-1-----------

LOWER BOOM

--------------1

1-------------

GROUND CONTROLS

, - - - - - TURRET

MANUAl92379-001 Ju1y1998

LIFT CYLINDER

MID-BOOM

OPERATOR CONTROLS DESCRIPTION (GROUND CONTROLS)

2

3

6

8

~

RIGHT

5

'-r-r---=-' ~

t

BOOM UP

~'----"'---'

L

)18

"

DOWN BOOM

7

UP

+

PLATFORM LEVEL

4 9

LOWER CONTROL

OFF

UPPER CONTROL 10

1 MANUAL92379-001 July 1998

OPERATOR CONTROLS DESCRIPTION (GROUND CONTROLS) Item

Control

Location

Description

1.

Main Power Key Switch

On Ground Console Panel

Three position main power "ON/OFF" switch.

Straight up position is "OFF".

Turn key left (counterclockwise) one position to turn power"ON" for ground control operation. Turn key right (clockwise) one position to turn power "ON" for platform control operation.

With key switch "OFF", the key may be removed to prevent unauthorized operation.

2.

Hour/VoltMeter

On Ground Console Panel

Indicates that elapsed time that the unit has been operated in hours and tenths. Also LED Lights indicate the electrical system voltage.

3.

EmergencyStop Button

On Ground Console Panel

Used to stop all functions in an emergency. Push for emergency stop. Pull or rotate clockwise to reset, depending on style used.

4.

Lower Boom Lift On Ground Console Panel

Push switch up to raise Lower Boom. Pull switch down to lower Lower Boom. (Boom speed will be controlled byProportional Control Knob.)

5.

Upper Boom Lift

On Ground Console Panel

Push switch up to raise Upper boom. Pull switch down to lower Upper boom. (Boom speed will be controlled

by Proportional Control Knob.)

6.

Boom Extend!

Retract

On Ground Console Panel

Switch Control the Boom/Retract Function. Push left to Extend Boom. Push right to Retract Boom.

7.

Jib Boom Switch

On Ground Console Panel

Push switch up to raise Jib Boom. Pull switch down to lower Jib Boom.

8.

Platform Rotate Toggle

On Ground Console Panel

Push and hold switch to the left to rotate platform to the left (counterclockwise). Push and hold switch to the right to rotate platformto the right (clockwise).

9.

Platform Levelling On Ground Console Panel Toggle

Push and hold switch to the left to tilt the platform backwards. Push and hold switch to the right to tilt the platform forwards.

10.

Swing Switch

On Ground Console Panel

Push switch to right to swing turret to right (counterclockwise). Push switch to left to swing left (clockwise).

Turret can rotate 355° non-continuous. (Swing speed will be proportional to Proportional Control Knob.)

MANUAL92379-001 July 1998

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS)

1

6

13

10 11

5 4

8

BOOM UP

+ JIB

DOWN

DOWN

BOOM'"

'---t------.J'

UP

T

o

+

DRIVE FORWARD

~ORIVE T

REVERSE

3

12

7

9

MANUAL 92379·001

July 1998

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS) Item

Control

Location

Description

1.

Emergency Stop Button

On Platform Console Panel

Used to stop all functions in an emergency. Push for emergency stop. Pull or rotate clockwise to reset, depending onstyle used.

Circuit Breaker

On Platform Console Panel

Pops out when the 48 Volt electrical circuit is overloaded. Push in to reset.

Lower Boom Lift

OnPlatfrom Console Panel

Push switch up to raise Lower Boom. Pull switch down to lower LowerBoom. Boom speed will be controlled by Proportional Control Knob.

Upper Boom Lift

OnPlatfrom Console Panel

Push switch up to raise Upper boom. Pull switch down to lower Upper boom. Boom speed will be controlled

by ProportlOnal Control Knob.

Boom Extend/ Retract

OnPlatform Console Panel

Switch controls the Boom Extend/Retract function.

Push Left to Extend Boom. Push Right to Retract Boom.

Jib Boom Switch

On Platform Console Panel

Push switch up to raise Jib Boom. Pull switch down to lower Jib Boom. Boom speed will be controlled by Proportional Control Knob.

7.

Platform Leveling Toggle

On Platform Console Panel

Push and hold switch to the left to tilt the Platform backwards. Push and hold switch to the right to tilt the Platform forwards.

8.

Platform Rotate Toggle

On Platform Console Panel

Push and hold switch to the left to rotate Platform to the left (counterclockwise).Push andholdswitch to the right to rotate Platfo rm to the right (clockwise).

9.

Swing Switch

On Platform Console Panel

Push switch to right to swing Turret to right (counterclockwise). Push switch to left to swingleft (clockwise).

Turret can rotate 355 0 non-continuous. Swmg speed will be proportional to Proportional Control Knob

10.

Drive Lever

On Platform Console Panel

2.

3.

4.

s.

6.

Lever controls forward and reverse travel of machine at aspeedproportional to handle movement.

A. WARNING

I

WITH PLATFORM SWUNG OVER STEERING WHEELS, USE CAUTION WHEN SELECTING THE TRAVEL DIRECTION. TRAVEL DIRECTION WILL BE OPPOSITE DRIVE LEVER MOVEMENT.

MANUAL92379-001 July 1998

CD

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS, CONTINUED) Item

Control

Location

Description

11.

Steer Switch

On end of Drive Lever

Move switch left and hold to turn Steer Wheels to left, and right to turn Steer Wheels to right. Push and hold in opposite direction to straighten Wheels.

~ WARNING WITH PLATFORM SWUNG OVER THE STEERING WHEELS, USE CAUTION WHEN SELECTING THE STEERING DIRECTION. STEERING DIRECTION WILL BE OPPOSITE STEER SWITCH MOVEMENT.

12.

Proportional Control Knob

On Platform Console Panel

The Proportional Control Knob controls the speed of all hydraulicfunctions except steering (upper boom, lower boom, jib, and swing). To increase the speed of a h ydraulicfunction, rotate the Control Knob to the right (counterclockwise). To decrease the speed of a boom function, rotate the Control Knob to the left (clockwise).

13.

Horn Button

On Platform Console Panel

Press button to sound warning horn.

MANUAL 92379-001

July 1998

START-UP PROCEDURES SHIff CHECKS

Before the CONDOR A-Series is put into use each shift, the following checks should be completed to make sure that the machine is safe and in good condition.

Referto check lists at back of this manual for periodic maintenance requirements and additional procedures for severe duty applications: Visually inspect all machine components, i.e. missing parts, torn or loose hoses, hydraulic fluid leaks, torn or disconnected wires, flat or damaged tires, etc. Both compartment doors can be opened to inspect components inside.

Check volt meter on ground controls for battery condition and wire connections.

Check hydraulic fluid level with booms fully retracted end lowered.

Check wheellug nuts tightness. Check tire pressure (see Machine Specifications).

Check hoses and cables for worn areas.

Check platform rails and safety gate latch for damage.

Check pivot pins for security.

Check that all warning and instructional labels are legible and secure.

MACHINE START-UP

.. DANGER ALL OPERATORS MUST THOROUGHLY READ AND UNDERSTAND THE "SAFETY RULES AND PRECAUTIONS" SECTION OF THIS MANUAL PRIOR TO OPERATING THE MACHINE.

A COMPLETE VISUAL INSPECTION OF THE MACHINE MUST BE PERFORMED PRIOR TO OPERATIONAL CHECKS.

•

Ensure that "EMERGENCY STOP" buttons on ground control panel and platform control console panel are disengaged. Pull out ortwist to reset, depending on style.

MANUAL92379-001 July1998

GROUND OPERATION AND CHECKS

A

WARNING

BE SURE BOOM TRAVEL AREA IS CLEAR OF OBSTRUCTIONS. DO NOT OPERATE THE MACHINE IF THE FOLLOWING CHECKS REVEAL A DEFECT.

•

Select "GROUND CONTROLS" with the " GROUND IPLA TFORM" key switch.

•

Press and hold the upper "BOOM" toggle to the "UP" position to raise the upper boom to the horizontal position or slightly above. Release the "BOOM" toggle.

•

Press and hold the "JIB BOOM" toggle on the ground controls to the "UP" position to raise the jib boom to the end of its travel. Release the "JIB BOOM" toggle.

Listen for any unusual noises.

Check foranyvibration while the boom travels up.

Check for uneven or jerky operation.

Check for hydraulic leaks.

Check pivot pin security. Make sure that all retaining bolts and rings are in place on the pin locking point.

•

Press and hold the "JIB BOOM" toggle on the ground controls to the "DOWN" position to lower the jib boom to the end of its travel. Release the "JIB BOOM" toggle.

•

Inspectthe boom sections visuallyfor any damage along their entire lengths.

•

Push down on each of the three fastened corners of the tilt alarm located in the D rive Axle. The alarm should sound as each corner is pressed beyond 5 degrees.

•

Press and hold the upper "BOOM" toggle to the "UP" position. Raise the upper boom to the end of its travel. Then, release the "BOOM" toggle.

Listen for any unusual noises.

Checkforanyvibration while the boom travels up.

Check for uneven or jerky operation.

Check for hydraulic leaks.

Check pivot pin security. Make sure that all securing bolts are in place on the pin locking point.

Visually confirm that the platform has remained level duringboomt ravel.

Report to supervisor and repair anyproblem.

MANUAL92379-001 July 1998

GROUND OPERATION AND CHECKS (Continued)

•

Press and hold the "BOOM" toggle to lower the boom slightly.

•

Press the "EMERGENCY STOP" button. All machine functions must stop. Then, check to see if the auxiliary lowering valve on the upper lift cylinder works. After the valve on the upper lift cylinder is closed, pull the "EMERGENCY STOP" button out to reset. Fully lower the upper boom and repeat the procedure for the lower boom.

•

Return the booms to their stowed positions byusing the appropriate toggles for "DOWN".

Listen for any unusual noises.

Checkforanyvibration while the booms lower.

Check for uneven or jerky operation.

Check for hydraulic leaks.

Report to supervisor and repair any problem.

•

Operate the "SWING" toggle in each direction.

Listen for anyunusual noises.

Check for anyvibration while the turret swings up.

Check for uneven or jerky operation.

Check for hydraulic leaks.

Report to supervisor and repair any problem.

•

Release the "SWING" toggle.

•

Press the "EMERGEN CY STOP" button. AIHunctions must stop immediately. Pull the button out or twist to reset.

•

Return the machine to the stowed position by pressing appropriate toggle switches correspondingly.

MANUAL92379-001 July1998

PLATFORM OPERATION AND CHECKS •

Complete Ground Operation Checks before p erforming Platform Operation Checks.

•

Select "PLATFORM CONTROLS" with the "GROUND/PLATFORM" Key switch.

•

Entertheplatform. Close gate securely.

•

Ensurethatthe "EMERGENCY STOP" button is released.

A WARNING BE SURE BOOM TRAVEL AREA IS CLEAR OF OBSTRUCTIONS. DO NOT OPERATE MACHINE IF THESE CHECKS REVEAL ANY DEFECT OR ABNORMALITY.

•

Depress the foot switch mounted on the floor of the platform. (Activate foot switch to operate any of the machine functions.)

•

Move the "JIB BOOM" switch up to the "JIB UP" position. The jib boom will start to rise.

Function speed is controlled by the proportional control knob. Raise the jib boom to the fully raised position. Slowly return the leverto the center position.

•

Move the "UPPER BOOM" switch up to the "UP" position. The upper boom will start to rise. Function speed is controlled by the Proportional Control Knob.

Listen for any unusual noises.

Check for anyvibration while the upper boom travelsup.

Checkforunevenorjerkyoperation.

Check for hydraulic leaks.

Report to supervisor and repair any problem.

•

Move the "LOWER BOOM" switch up to the "UP" position. The upper boom will start to rise. Function speed is controlled by the Proportional Control Knob.

Listen for any unusual noises.

Checkfor anyvibration while the lower boom travels up.

Check for uneven or jerkyoperation.

Checkfor hydraulicleaks.

Report to supervisor and repair any problem.

MANUAL92379-001 July 1998

PLATFORM OPERATION AND CHECKS (Continued)

•

Return the booms to the travel position by operating the "LOWER BOOM" and "UPPER BOOM" switches down to the "DOWN" position. Function speed is controlled by the Proportional Control Knob.

Listen for any unusual noises.

Check for any vibration while the upper and lower booms are lowered.

Check for uneven or jerky operation.

Check for hydraulic leaks.

Report to supervisor and repair any problem.

•

Move the "SWING" switch right to swing right (counterclockwise) and left to swing left (clockwise). Swing speed is controlled by the Proportional ControlKnob.

Listen for any unusual noises.

Check for anyvibration while the unit rotates.

Check for uneven or jerky operation.

Check for hydraulic leaks.

Report to supervisor and repair any problem.

IMPORTANT: JIB BOOM SHOULD BE RAISED FOR SUFFICIENT GROUND CLEARANCE.

A

WARNING

WITH THE PLATFORM SWUNG OVER THE STEERING WHEELS, USE CAUTION WHEN SELECTING THE TRAVEL DIRECTION. TRAVEL AND STEERING DIRECTION WILL BE OPPOSITE CONTROL OPERATION.

•

Slowly move the "D RNE" lever forward"The machine should smoothly accelerate in the forward direction.

Listen for any unusual noises.

Check for anyvibration while the unit travels.

Check for uneven or jerky operation.

Checkfor hydraulicleaks.

Report to supervisor and repair any problem.

MANUAL 92379-001

July1998

PLATFORM OPERATION AND CHECKS (Continued) •

Operate the "STEER" rocker switch and check for proper steering control. Note position of the platform to the steering wheels.

•

Return the wheels to the straight ahead position.

•

Slowly move the"D RIVE" lever backward. The machine will smoothly accelerate in the reverse direction.

•

Press "EMERGENCY STOP" button. All functions must stop immediately.

A.

WARNING

BRACE YOURSELF FOR UNEXPECTED PLATFORM MOVEMENT BECAUSE THE MACHINE COMES TO A SUDDEN STOP. ACTUATION OF THE "EMERGENCY STOP" BUTTON WILL APPLY BRAKES IMMEDIATELYl •

Reset "EMERGENCY STOP" button by turning or pulling.

•

Raise the upper or lower boom to above horizontal, and repeat the drive tests. Machine should travel a maximum ofO.s M.P.H (0.8 K.P.H.). This condition is referred to as "creep speed", and is the maximum rate of travel with the upper or lower boom raised.

•

Return the machine to the straight ahead position, with the upper and lower boom in the stowed position. Position jib boom for adequate ground clearancefortravel.

•

Move all switches back to their neutral positions. Release the foot switch.

NOTE: All machine motion should stop upon release of the foot switch.

MANUAL92379-001 July 1998

COLD WEATHER OPERATION

•

In below zero weather, the hydraulic fluid should be allowed to warm before full

operation of the unit.

•

Check for water contamination of the fluid.

•

Check for and remove ice on the platform, swing gear teeth and steering linkage(s) prior to operation.

•

Check that all switches operate smoothly, and return freely to the neutral position.

A

CAUTION

Avoid sudden braking or steering, go slow and leave more maneuvering room during cold weather operation.

MANUAL92379-001 July 1998

DRIVING AND STEERING

it.. WARNING ENSURE THAT THE ROUTE OF TRAVEL IS CLEAR OF PERSONNEL AND DE· BRIS. Depress the foot switch. Slowly push the "DRNE" lever forward to provide forward travel, or pull the lever backward for reverse travel.

NOTE: The speed of the unit will be proportional to handle movement.

To steer, press "STEER" rocker switch on the end of the drive lever to the left or right as required.

Although the unit can be driven with the platform positioned at either end of the unit, the operator may find driving easier when the platform is overt he non-steering axle.

The stowed position can be identified by the large "FORWARD" arrows on the chassis.

When driving with the platform overthe opposite axle, rememberthat all directions given to the steer and drive controls will be reversed.

When descending a ramp (incline), it is necessary to control the travel speed. To slowthe unit, move the drive lever slowly towards the center "neutral" position.

BRAKING For parking, the brakes are automatically applied when the drive lever is in the center "neutral" position.

it.. WARNING RELEASE OF THE DRIVE LEVER OR ACTUATION OF THE RED "EMERGENCY STOP" WILL APPLY BRAKES IMMEDIATELY! BRACE YOURSELF FOR UNEXPECTED PLATFORM MOVEMENT AS THE MACHINE COMES TO A SUDDEN STOP.

MANUAl92379-001 July 1998

BOOMS, TURRET AND PLATFORM Depress the foot switch, then select the required function. A vailablefunctions are: •

Lower boom UP or DOWN

•

Upper boom UP or DOWN

•

Jib boom UP or DOWN

•

TurretswingLEFTorRIGHT

Each function can be selected by moving the appropriate lever or toggle in the proper direction.

NOTE: Function speeds will be proportional to the position of the Proportional Control Knob.

MANUAL92379-Q01 July 1998

SHUT -DOWN PROCEDURES

•

When finished with the machine, placethe booms in the stowed position.

•

Park the unit on a level surface.

•

Turn "OFF" the "GROUND/PLATFORM" key switch. Remove key to prevent unauthorized operation.

MOVING JOB SITE TO JOB SITE

•

Inspectthe outside of the unit for damage (including the underside).

Inspect all hoses,and boom sections for chafing or road damage.

Confirm that all wheel lug nuts and swing bearing bolts are tight (refer to specifications).

UNLOADING PROCEDURES

•

Remove all machine tie downs. Remove wheel chocks, if used. Switch the "GROUNDIPLATFORM" key switc h to "PLATFORM".

•

Enterthe platform, and test all platform functions.

•

Raise the boom and the jib so that the platform will clear any obstacles as the machine is driven down the loading ramp.

•

Carefully drive the unit off the truck ortrailer .

•

Before placing the unit into service, all operators must read and understand the contents ofthis Operator'sManual.

Upon initial unloading of the machine the "Prede1ivery InspectionReport" must be completed and returned in order to activate the Time Condor LimitedWarranty.

MANUAl92379-001 July 1998

Thispage intentionallyleft blank

MANUAL92379-001 July1998

TRUCK OR TRAILER TRANSPORT UNASSISTED LOADING OR UNLOADING OF ANY MOBILE PLATFORM IS NOT RECOMMENDED.

1.

Enter the platform, secure the safety gate.

2.

Raise the main and jib booms to allow greater ground clearance so that the platform will clear any obstacles as the machine goes up the loading ramp.

3.

Carefully drive the unit onto the truckonrailer.

4.

Ensure that the lower boom is fully lowered and that the upper boom is stowed in the boom rest.

S.

Tie down locations are located on all four corners of the chassis and on the platform's skirt. Use four (4) 1/2 inch, "Grade 7" chains from each of the tie down lugs.

Ratchet type load binders are recommended. Ifusing lever type load binders, wire or strap them shut, or wrap chains around them to prevent <?pening.

TRANSPORTING THE UNIT

TOWING PROCEDURES

•

If optional towing package is not installed, refer to "UNPOWERED EMERGENCY MOVEMENT" in this section.

MANUAl92379-001 July 1998

EMERGENCY SYSTEM AND PROCEDURES UNPOWERED EMERGENCY MOVEMENT •

Every attempt should be made to restore powerto the unit before using this procedure.

.. DANGER THIS PROCEDURE REQUIRES RELEASING THE VEHICLE BRAKES, WHICH RESULTS IN NO MEANS TO STOP THE UNIT'S TRAVEL. TIME CONDOR RECOMMENDS USING THIS PROCEDURE ONLY IN CASE OF EMERGENCY, AND ONLY A SHORT DISTANCE. BE AWARE OF UNIT RUNAWAY ON SLOPING SURFACES. MOVEMENT SPEED SHALL NOT EXCEED 1 M.P.H. (1.6 K.P.H.).

MANUAL92379-001 July19ga

•

UNPOWERED EMERGENCY MOVEMENT 1.

Secure the unit with chains or ropes.

The A38/42J is equipped with tie down lugs (front and rear of chassis) that can beused fonowingtheunit. The chains or ropes must be of sufficient capacity to move the unit.

A. WARNING ALWAYS CHOCK THE WHEELS BEFORE YOU RELEASE THE BRAKES TO PREVENT UNEXPECTED UNIT MOVEMENT ON SLOPES. 2

Chock wheels.

3.

Disengage brakes.

A. WARNING WHENEVER DISENGAGING THE BRAKES OR BEFORE DISCONNECTION FROM TOWING VEHICLE, ENSURE THAT THE UNIT CANNOT ROLL. 4.

Disconnect steer cylinder.

5.

Disconnect batteries.

After unchocking the wheels, the unit will be ready to be moved.

After power has been restored to the machine, engage brakes, reconnect batteries, and connect the steer cylinder. The machine is now ready for normal operation.

MANUAL 92379-001 July 1998

EMERGENCY LOWERING

In case of total power loss, the upper and lower booms can be lowered manually usingtheauxiliaryvalveslocatedontheboom'sliftcylinder. Tolowerthebooms using auxiliary valves, follow the following procedures:

1. Open auxiliary valve on the lower boom lift cylinder (counterclockwise) and allow boom to lower until it stops. Control boom speed by opening and closing valve.

2.

Close auxiliary valve (clockwise) to resume normal operation.

3.

Open auxiliary valve on upper boom lift cylinder (counterclockwise) and allow boom to lower until it stops. Control boom speed by opening and closing valve.

4.

Close auxiliary valve (clockwise) to resume normal operation.

It is not possible for us to foresee every emergency situation that could arise during operation of this machine.

When faced with an emergency,above all please remember: •

Staycalm.

•

Think through the situation before operating the machine.

•

Get help if necessary.

IMPORTANT: Any incident involving personal injury must be immediately reported to the local Time Condor Corporation.

MANUAL9Z379-0D1 July 1998

MACHINE SPECIFICATIONS

A42J

A38

Working Hght.

13.40m 14.60m 11.60m Platfonn Hght. . .··38' 12.80m ..........

1 .6. 9'1 . 2.06m Stow. Height {)'$">. 2.03 m Stow. Length 5.49m 4.78 m ·"1&'" .. 15'8" ....... ....

Overall Width 5'~)'!<. 1.75 m<5'9" 1.75 m Platfonn Cap. /SOrlbs 225 kg~(}Oib~ . •• 225 kg Platfonn Size 6()'1x':19 IJ 1.5OXO.8m6Qi' x.3p f' l.50x0 .8m Up/Over .<~()t19tt 6.53 mQ.QiIQrt. 6.35 m Horiz. Reach 19'/ 5.80m23'9" 7.25 m ZERO-_ ..... •. ZERO <ZERO ZERO Tail Swing .. ..... ..........

In. Tum Rad. 4'(i~1I 1.38 m A~?~'1 1.38 m Out.Tum Rad. :.: ....10'2,,'·· 3.10m >1<)'2"'.

3.10m . .... . .... :::: .. ::" .... ::: ...

Gradeability '·30%> 30% .·• •• 25%.

25% 3.8 kmh Travel Speed 2.4mph. 3.8kmh Ground Clear. ... 5',< 12.7 em ·.·S'.< 12.7 em Tire Size 6.()Ox9 6.00 x 96;O()x.9 6.00 x 9 ONJAd N/A4'< 1.20m Jib Length Jib Rotation N/l\.

NIA <• .I3tjO 1300 0 Turret Rotat.

360°·N/C 360 N/C $(J()"}NiC360° N/C 0 Plat. Rot.l~P6If 120 Hl~Oo.l-I. 1200 H Power Source 4,8VJl)O 48 VDC4-8YPC< 48 VDC Gross Weight lO,5001bs 4763kg12;50qlbs 5670kg Wheel Base ..·.·6'3/t 1.90 mG')"> 1.90 m .........

Hyd. Tank Cap. 55gal. 20.821 J.5gal 20.821 Tire PressureqQp$i 120ttO . 120 (pneumatic tire option) :: :

-

:::

:

-.-

"

-

·.2.,4fuPh .'.

MANUAL 92379·001 July 1998

MACHINE DIAGRAM ... - ............ - .... - "',--- --- ............ , ..................... -- - r" .............. _ .. - .. -,- _ ................... --. .. _ .. - -_ ............ r" _ .. __ ....... _ .. --r

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A381A42J Working Range Diagram

MANUAL92379-001 July1998

.',

,.

------ .. --- ---_ .. _-- .. ---1 ..... --------_ .. "'"

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SERVICE MANUAL

ARTICULATING MODEL A38/42J BOOM-SUPPORTED ELEVATING WORK PLATFORM ~===========r

MANUAL92379-002 May1998 Revised 11198

·

TABLE OF CONTENTS Introduction '" ............................................................................................................................ .

Service Information ... .... ........ ...... ...... .... .......... ...... ...... .... ............ .... ........ ............ ............ ........ ...

WaITanty ............... .......................................................................................................... .......

ii iii

Introduction ............................................................................................................................................ 3 MachineSpecifications .............................................................................................................................. 5 Machine Component Locator .................................................................................................................. 7 Lubrication Chart ..................................................................................................................................... 8

Section 1: Transporting and Emergency Procedures Transportingthe Unit .............................................................................................................................

TruckandTrailerTransport ...................................................................................................................

Unloading Procedure .............................................................................................................................

UnpoweredEmergencyMovement .......................................................................................................

Emergency Lowering ..................•..........................................................................................................

13 13 14 14 16

Section 2: Hydraulic System HydraulicFluid ...................................................................................................................................... 20 HandlingPrecautions ........................................................................................................................ 20 FluidRecommendations ................................................................................................................... 20 Fluid Contamination Checks ................................................................................................................... 21 Main Hydraulic Pump ....................................................................................................................... 22 MainHydraulicControl Valve ........................................................................................................... 24 BoomLiftSystem ............................................................................................................................ 26 Boom Lift Valve Segment ......................................................................................................... 26 Lift Cylinder .............................................................................................................................. 26 Boom Telescope (Extend) System ..................................................................................................... 26 Boom Extend Valve Segment .................................................................................................... 26 Pressure Relief Valve .................................................................................................................. 26 Telescope (Extend) Cylinder ...................................................................................................... 26 JibBoomSystem ............................................................................................................................. 26 Jib Boom Valve Segment ........................................................................................................... 27 JibCylinder ............................................................................................................................... 27 PlatformRotateSystem .................................................................................................................... 27 Rotary Actuator ........................................................................................................................ 27 Platform Levelling System ................................................................................................................. 27 Master Levelling Cylinder ........................................................................................................... 27 Slave LevellingCylinder ............................................................................................................. 28 Steer System ..................................................................................................................................... 28 Selector Valve Segment .............................................................................................................. 28 Steer Cylinder ............................................................................................................................ 28 SteerSystemMaintenance .......................................................................................................... 28

MANUAL92379-002

May 1998 Revised 11198

•

TABLE OF CONTENTS

Section 3: Electrical System Battery Charger ...................................................................................................................................... 32 Battery Service ...................................................................................................................................... 42 Cable Wiring Diagram ........................................................................................................................... 50 LimitSwitches ....................................................................................................................................... 51 5° Slope Alarm ...................................................................................................................................... 52 DriveSystem-SevconBoomController ................................................................................................ 53 General .......................................................................................................................................... 53 Inputs/Outputs ................................................................................................................................ 53 Brake .......................................................................................................................................... 54 Modes of Operation ........................................................................................................................ 54 TractionMode .......................................................................................................................... 54 Pump Mode ............................................................................................................................. 55 FeaturesinPumpMode ............................................................................................................ 55 Features in Traction Mode ......................................................................................................... 55 TroubleshootingwithFlashCodes ............................................................................................. 57 Sevconcontroller -Handheldcalibrator .......................................................................................... 58 Featuresandlliustration ............................................................................................................. 58 Condorfactorysettings .............................................................................................................. 59 TroubleshootingwithSevconcontroller ..................................................................................... 60 Sevcon to Drive Motors power wiring .............................................................................................. 61 Drive Controller ........................................................................................................................ 63 Section 4: Maintenance Maintenance ......................................................................................... '" .............................................. 66 General Maintenance Tips ...................................................................................................................... 66 First Three Months of Operation ............................................................................................................ 67 RoutingServicing ................................................................................................................................... 67 Shift Operational Checklist ..................................................................................................................... 70 Weekly Operational Checklist ................................................................................................................. 73 MonthlyOperational Checklist ................................................................................................................ 74 Semi -Annual Operational Checklist ....................................................................................................... 76 BoltTorqueChart(Standard) ................................................................................................................. 78 Bolt Torque Chart (tv1etric) ..................................................................................................................... 79

MANUAL92379-002 May 1998 Revised 11/98

INTRODUCTION This Service Manual is designed to provide you with the instructions needed to properly maintain the Time Condor Corporation A28/32J A38/24J. When used in conjunction with the Operators and Parts manuals (provided separately) this Service Manual will Assist you in making necessary adjustments or repaIrs. Time Condor Aerial Platforms are designed and built to provide many years of safe, dependable service. To obtain full benefits from your A28/32J A38/42J, always follow the proper operating and maintenance procedures. Only trained, authorized personnel should be allowed to operate or service this machine. Service personnel should read and study the Operators, Service and Parts Manuals in order to gain a thorough understanding of the unit prior to making any repairs. Exercise all necessary safety precautions when performing maintenance not covered in this manual.

To help you recognize important safety information, we have identified warnings and instructions that directly impact on safety with the following signals:

A. DA.NGER "DANGER" INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY. THIS SIGNAL WORD IS TO BE APPLIED TO THE MOST EXTREME SITUATIONS.

A. WARNING "WARNING" INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY.

A.

CAUTION

"CAUTION" indicates a potentially hazardous situation which, if not avoided, may result in minor moderate injury. It is also used to alert against unsafe practices which could lead to property-dam age-only accidents.

MANUAL92379-002 May 1998 Revised 11/98

Service personnel and machine operators must understand and comply with all warnings and instructional decals on the body of the machine, and at the ground controls and platfonn control console.

A. DANGER MODIFICATIONS OF THIS MACHINE FROM THE ORIGINAL DESIGN AND SPECIFICATION WITHOUT WRITTEN PERMISSION FROM CONDOR ARE STRICTLY FORBIDDEN. A MODIFICATION MAY COMPROMISE THE SAFETY OF THE MACHINE, SUBJECTING USERS TO SERIOUS INJURY OR DEATH. ANY SUCH MODIFICATION WILL VOID ANY REMAINING WARRANTY. Condor reserves the right to change, improve, modify or expand features of its equipment at any time. Specifications, models or equipment are subject to change without notice, and without incurring any obligations to change, improve, modify or expand features of previously delivered equipment.

Any procedures not found within this manual must be evaluated by the individual to assure himself that they are "proper and safe", because all possible procedures cannot be covered.

All Condor manuals are periodically updated to reflect changes that occur in the equipment.

Please contact the factory with any questions you may have regarding your machine, or the availability of more recent manuals.

MANUAL92379-002 May 1998

Revised 11198

•

MACHINE SPECIFICATIONS

A28 •.•• .34L ... . . - ..... , .......

A32J

.

WorkingHght.

PlatformHght.<2S! ::::::::::,: ::::::>-: .

Stow.Height?'g"> Stow. Length .:.:":"':::::;;";':::;:;:;" 15,U ii n

1O.36m ................ 11.58m 8.53 m32.'

9.75 m ":. ::.; .... : ":.:: 2.06m()I~IIC 2.06m i 4.85mI8 (j1l 5.64m : :.: : : :.

L 1 OverallWidth5:!~!tH 1.75 m Si9 ! . 1.75 m PlatformCap.$QQI~$ 226.8kg?OQI6s. 226.8 kg Platform Size 48"%$0'1 1.2xO.8m4-$~'~39" l.2xO.8m Up/OveriS'9" 4.80mL$t9'~ 4.80m "::':-':':':::.::;.::::::::> .. ::.::: ... ;::::;:;.,.: ...... .

Ii Horiz.Reachiri'su/ 4.17m ··ls'2 5.54m ':;:-::::"::'.:::::.:::.::' TaiISwing~l£l{Q ZERO?;ER.() ZERO In. TumRad.~'?~~' 1.38m41.!§~" I.38m Out. TumRad.l0'2,i'H 3.1 0 m)()I~'~ 3.10 m Gradeability~Q%.< 30%.~$~ 25% Travel Speed~.@~p~ 5.15 kmh3.2-#lpg 5.15 kmh t GroundClear.5 '?. 12.70cm > 5'!· · ·• • ··12.70cm TireSize6:QQ*Q 6.00 x 96.0Qx9 6.00x 9 Jib Length.'NfA NIA/4' . 1.22 m Jib Rotation ·N/A N/A . 13()?

130° ... .....

.. .. ..

TurretRotat.360~N/C360° N/C 36()~N)C360° N/C Plat. Rot. >hO~M 130° Mi36 M BooM 0

Power Source 48V.DC Gross W eight ~,3QQlbs . •• 6'311 WheelBase Hyd. Tank Cap.?5ga.l

48 VDC48vDC 2404 kg (),900)bs 1.91 m.6'3" . .

20.821 5,5 gal

MANUAL 92379-002

May 1998 Revised 11198

48 VDC 3 13 0 kg 1.91 m 20.821

•

MACHINE DIAGRAM

40'

·· ·

---------~----,---~----------~r--------------~--------------r-----------~--,---------------r--------------1 I I I I I I I

.

I

35'

··

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MANUAL92379-002 May 1998 Revised 11198

10'

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•

PRIMARY MACHINE COMPONENTS PLATFORM

PLA TFORM CONTROLS

JIB BOOM

JIB CYLINDER

UPPER BOOM

LIFT CYLINDER

MID-800M

LOWER 800M

LIFT CYLINDER GROUND CONTROLS

TURRET

CHASSIS

MANUAL92379-002 May 1998 Revised 11/98

LUBRICATION CHART

SPECIFICATION AND QUANTITY

FREQUENCY OF LUBRICA TION Check level & condition each shift.

Analye 6 months or 500 hours.*+ Change yearly or 1000 hours. *+ Change after first 50 hours then every 6 months or 500 hours. *+

NO.

ITEM

l.

Hydraulic Reservoir

Texaco Rando HDZ32 to "Full" mark with all cYlinders retracted.

2.

Hydraulic Filters

Filter elements.

3.

Swing Bearing (standard open style)

Lithium N.L.G.I. #2 EP. Purge old grease.

Weekly or every 25 hours.*+

4.

Exposed Swing Bearing Gear Teeth

Dry moly lube spray.

Every six (6) months or 500 hours.*+

5.

Swing Drive Gear Box

Fill to plug. SAE 140 EP or N.L.G.I. #00 EP oil.

Check monthly or every 100 hours.*+ Change every two (2) years or 2,000 hours.*

6

Wheel Bearings

Lithium N.L.G.I. #2 EP. Clean and repair.

Change every six (6) months or 500 hours.*+

7

Drive Wheel Power Hubs

SAE 90, half full.

Change after first 50 hours. Check monthly or every 100 hours.*+ Change yearly or 1,000 hours.*+

* Whichever occurs first. + Different requirements for severe duty applications. See check list.

MANUAL92379-002 May 1998 Revised 11!98

LUBRICATION DIAGRAM

1 2

3 4 5

MANUAl92379-Q02 May 1998 Revised 11/96

SECTION 1: TRANSPORTATION AND EMERGENCY PROCEDURES

MANUAL92379-002 May 1998 Revised 11198

TABLE OF CONTENTS, SECTION 1 Transponingthe Unit ............................................................................................................................. 13 TruckorTrailerTranspon ..................................................................................................................... 13 Unloading Procedures ............................................................................................................................ 14 UnpoweredEmergencyMovement ....................................................................................................... 14 Emergency Lowering ............................................................................................................................. 16

MANUAL92379-002 May 1998 Revised 11198

FACTORY RECOMMENDED TRANSPORTATION DIAGRAM

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MANUAL92379-002 May 1998 Revised11198

TRANSPORTING THE UNIT TRUCK OR TRAILER TRANSPORT

A WARNING UNASSISTED LOADING OR UNLOADING OF ANY MOBILE PLATFORM IS NOT RECOMMENDED.

1. Enter the platfmm, secure the safety gate.

2. Raise the main and jib booms(if so equipped) to allow greater ground clearance so that the platform will clear any obstacles as the machine goes up the loading ramp.

3. Carefully drive the unit onto the truck or trailer.

4. Ensure that the lower boom is fully lowered and that the upper boom is stowed in the boom rest.

5. Tie down locations are located on all four comers of the chassis and on the platform's skirt. Use four (4) 112 inch, "Grade 7" chains from each of the tie down lugs.

Ratchet type load binders are recommended. Ifusing lever type load binders, wire or strap them shut, or wrap chains around them to prevent opening.

TOWING PROCEDURES •

If optional towing package is not installed, refer to "UNPOWERED EMERGENCY MOVEMENT" in this section.

MANUAL92379-002 May 1998 Revised 11198

•

MOVING JOB SITE TO JOB SITE

•

Inspect the outside of the unit for damage (including the underside).

Inspect all hoses, boom sections and cables for chafing or road damage.

Confirm that all wheel lug nuts and swing bearing bolts are tight (refer to specifications).

UNLOADING PROCEDURES Remove all machine tie downs. Remove wheel chocks, ifused. Switch the "GROUNDIPLATFORM" key switch to "PLATFORM".

Enter the platform, and test all platform functions.

Raise the boom and the jib so that the platform will clear any obstacles as the machine is driven down the loading ramp.

Carefully drive the unit off the truck or trailer.

Before placing the unit into service, all operators must read and understand the contents of this Operator's Manual.

Upon initial unloading of the machine the "Pre delivery Inspection Report" must be completed and returned in order to activate the Time Condor Limited Warranty.

EMERGENCY SYSTEM AND PROCEDURES UNPOWERED EMERGENCY MOVEMENT •

Every attempt should be made to restore power to the unit before using this procedure.

A.

DANGER

THIS PROCEDURE REQUIRES RELEASING THE VEHICLE BRAKES, WHICH RESULTS IN NO MEANS TO STOP THE UNIT'S TRAVEL. TIME CONDOR RECOMMENDS USING THIS PROCEDURE ONLY IN CASE OF EMERGENCY, AND ONLY A SHORT DISTANCE. BE AWARE OF UNIT RUNAWAY ON SLOPING SURFACES. MOVEMENT SPEED SHALL NOT EXCEED 1 M.P.H. (1.6 KP.H.).

MANUAL92379·002 May 1998 Revised 11198

UNPOWERED EMERGENCY MOVEMENT l.

Secure the unit with chains or ropes.

The A28/32J -A38/42J is equipped with tie down lugs (front and rear of chassis) that can be used for towing the unit. The chains or ropes must be of sufficient capacity to move the unit.

A

WARNING

ALWAYS CHOCK THE WHEELS BEFORE YOU RELEASE THE BRAKES TO PREVENT UNEXPECTED UNIT MOVEMENT ON SLOPES. 2.

Chock wheels.

3.

Disengage brakes by tightening the three sets of nuts against brake. See below.

Brake release nut

A

WARNING

WHENEVER DISENGAGING THE BRAKES OR BEFORE DISCONNECTION FROM TOWING VEHICLE, ENSURE THAT THE UNIT CANNOT ROLL. 4. Disconnect steer cylinder.

5. Disconnect batteries.

After unchocking the wheels, the unit will be ready to be moved.

After power has been restored to the machine, engage brakes, reconnect batteries, and connect the steer cylinder. The machine is now ready for normal operation.

MANUAL9Z379·002 May 1998

Revised 11198

EMERGENCY LOWERING In case oftotal power loss, the upper and lower booms can be lowered manually using the auxiliary valves located on the boom's lift cylinder. To lower the booms using auxiliary valves, follow the following procedures: 1. Open auxiliary valve on the lower boom lift cylinder (counterclockwise) and allow boom to lower until it stops. Control boom speed by opening and closing valve.

2. Close auxiliary valve (clockwise) to resume normal operation.

3. Open auxiliary valve on upper boom lift cylinder (counterclockwise) and allow boom to lower until it stops. Control boom speed by opening and closing valve.

4. Close auxiliary valve (clockwise) to resume normal operation.

It is not possible for us to foresee every emergency situation that could arise during operation of this machine.

When faced with an emergency, above all please remember: Stay calm.

Think through the situation before operating the machine.

Get help if necessary.

IMPORTANT: Any incident involving personal injury must be immediately reported to Time Condor Corporation.

MA NUAL 9Z379-002

May 1998 Revised 11198

SECTION 2: HYDRAULIC SYSTEM

MANUAL92379-002 May 1998 Revised 11198

TABLE OF CONTENTS, SECTION 2: HydraulicFluid ...................................................................................................................................... 20 HandlingPrecautions ........................................................................................................................ 20 FluidRecommendations ................................................................................................................... 20 Fluid Contamination Checks ................................................................................................................... 21 Main Hydraulic Pump ....................................................................................................................... 22 Main Hydraulic Control Valve ........................................................................................................... 24 BoomLiftSystem ............................................................................................................................ 26 Boom Lift Valve Segment ......................................................................................................... 26 Lift Cylinder .............................................................................................................................. 26 Boom Telescope (Extend) System ..................................................................................................... 26 Boom Extend Valve Segment .................................................................................................... 26 Pressure Relief Valve .................................................................................................................. 26 Telescope (Extend) Cylinder ...................................................................................................... 26 JibBoomSystem ............................................................................................................................. 26 Jib Boom Valve Segment ........................................................................................................... 27 JibCylinder ............................................................................................................................... 27 Platform Rotate System .................................................................................................................... 27 Rotary Actuator ........................................................................................................................ 27 Platform Levelling System ................................................................................................................. 27 Master Levelling Cylinder ........................................................................................................... 27 SlaveLevellingCylinder ............................................................................................................. 28 Steer System ..................................................................................................................................... 28 Selector Valve Segment .............................................................................................................. 28 Steer Cylinder ............................................................................................................................ 28 Steer System Maintenance .......................................................................................................... 28

MANUAL92379-002

May 1998 Revised11198

HYDRAULIC FLUID HANDLING PRECAUTIONS

A WARNING PERSONS IN REGULAR CONTACT WITH MINERAL - BASED HYDRAULIC FLUID NEED TO BE AWARE OF THE IMPORTANCE OF THOROUGH HYGIENE, AND THE PROPER METHODS FOR HANDLING MINERAL OILS IN ORDER TO AVOID POTENTIAL HAZARDS TO HEALTH.

Ifmineral-based hydraulic fluid is SPLASHED INTO THEEYES, it must be WASHED OUTlliOROUGHLYusing abundant quantities ofwater.

If irritation persists, medical advice should be sought Mineral oils act as solvents on the natural oils in the skin. FREQUENT AND PROLONGED SKIN CONTACT CAN CAUSE DERMATITIS OR SEVERE IRRITATION. Mineral-basedhydraulicfluidsnormallypresent no health hazard when used properly. Protective clothing and proper washing facilities should be provided or be accessible.

A

WARNING

HYDRAULIC FLUID UNDER PRESSURE CAN PENETRATE AND BURN THE SKIN, DAMAGE EYES, AND MAY CAUSE SERIOUS INJURY, BLINDNESS, AND EVEN DEATH. FLUID LEAKS UNDER PRESSURE MAY NOT ALWAYS BE VISIBLE. IF MINERAL - BASED HYDRAULIC FLUID HAS PENETRATED THE SKIN, IT MUST BE MEDICALLY TREATED, BY A DOCTOR FAMILIAR WITH THIS TYPE OF INJURY, WITHIN A FEW HOURS. FLUID RECOMMENDATIONS We strongly recommend the use of TEXACO RANDO HDZ32 HYDRAULIC FLUID. An EQUIVALENT substitute can be used if absolutely necessary. Mineral - based hydraulic fluids produced by different companies will USUALLY mix with each other satisfactorily, but this IS NOT RECOMMENDED. When in doubt, consult your supplier.

MANUAl92379-002 May 1998 Revised11!98

FLffin CONTAMINATION CHECKS Use the following as a guide to determine when analysis of the hydraulic fluid is necessary.

Any time the hydraulic pump is replaced.

If fluid discoloration is noticed in the hydraulic reservoir sight tube.

If, after the first 50 hours of operation, the hydraulic filter elements are plugged.

Any time the hydraulic filter elements show signs of metal content.

•

Once every six months, under normal operating conditions.

•

Every 3 months, in extremely dusty or dirty operating conditions.

The hydraulic fluid analysis must be done by a qualified laboratory. To ensure that you receive accurate recommendations about the fluid being analyzed, always provide the following information with the test sample.

Type of hydraulic fluid. (See Lubrication Chart) •

Model and serial number of unit from which sample was taken.

Purpose of analysis: i.e. pump failure, discoloration, etc.

Type of analysis: i.e. complete to show additive breakdown, acid buildup, viscosity, type and percent of contaminants. Comparison to new fluid and recommendations.

Comply with contamination analysis and recommendations to achieve a clean, contamination free hydraulic system.

Following the above guide will prevent premature failure of pumps, cylinder seals and drive motors, and unnecessary down time.

MANUAL92379-002 May 1998 Revised 11198

Hydraulic Pump The hydraulic pump is a fixed displacement type pump. The speed, or rate ofthe hydraulic functions are controlled by the speed of the electric motor driving the pump. The control of this speed is done with the "Pump Mode" of the Sevcon controller. The rheostat on the platform control box sets the speed from the platform. The speed is 100% from the ground control box using the ramping feature to smooth the operations.

The pump pressure can be checked by adding a 0-3000 PSI gauge to test port gauge. Now bottom-out lower boom function from lower control box and adjust for 2500PSL For more detailed information on the pump control see page 58 of the Electrical System, Section Three.

MANUAL92379-002 May 1998 Revised 11/98

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MANUAL92379-002 May 1998 Revised 11/98

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BOOM LIFT SYSTEM The boom lift system consists of a hydraulic valve segment on the ground valve bank, a lift cylinder with a counterbalance valve, a lift toggle switch on the ground control and a toggle switch on the platform console.

BOOM LIFT VALVE SEGMENT When the boom control lever on the platform console or the boom control toggle switch on the ground control is activated, an electrical signal is transmitted to the valve cartridge in the boom lift valve segment. This allows hydraulic fluid at the correct pressure to be sent to the proper end of the lift cylinder to raise or lower the boom.

LIFT CYLINDER The boom lift function is controlled by a double acting cylinder. The cylinder contains a counterbalance valve, which will prevent unintended movement of the cylinder should a hose or fitting develop a leak. When the boom is lowered, fluid flows to the rod end cylinder port and to the counterbalance valve, and allowing fluid in the base end of the cylinder to flow back to the hydraulic reservoir. When the boom section is raised, fluid flows to the base end cylinder port and to the counterbalance valve, opening this valve and allowing fluid in the rod end of the cylinder to flow back to the hydraulic reservoir.

BOOM TELESCOPE SYSTEM ( A381 A42J) The boom telescope system consists of a hydraulic valve segment on the ground valve bank, a pressure relief valve, a double telescope cylinder with two counterbalance valves, an extend toggle switch on the ground control and a toggle switch on the platform console.

BOOM TELESCOPE VALVE SEGMENT When the boom telescope control lever on the platform console or the boom telescope control toggle switch on the remote control pendant is activated, an electrical signal is transmitted to the valve cartridge in the boom telescope valve segment. This allows hydraulic fluid at the correct pressure to be sent to the proper end of the telescope cylinder to extend or retract the boom.

PRESSURE RELIEF VALVE The pressure relief valve limits the pressure on the base end ofthe cylinder to 2000 PSI to prevent the cylinder rod from buckling. The pressure relief valve is factory set and needs no adjustment.

TELESCOPE CYLINDER The telescope cylinders control the extending and retracting of the boom.

JIB BOOM SYSTEM ( A32JI A42J) The jib boom system consists of a hydraulic valve segment on the ground valve bank, a cylinder with a counterbalance valve, and a toggle switch on the platform console and a toggle switch on the ground control.

MANUAL92379-002

May 1998 Revised 11/98

JIB BOOM VALVE SEGMENT When the jib boom control lever on the platform console or ground control station is activated, an electrical signal is transmitted to the valve cartridge in the jib boom valve segment. This allows hydraulic fluid at the selected flow to be sent to the proper end of the cylinder to raise or lower jib boom.

JIB ARTICULATION CYLINDER The jib boom function is controlled by a double acting cylinder. The cylinder contains a counterbalance valve, which will prevent unintended movement of the cylinder should a hose or fitting develop a leak. When the boom is lowered, fluid flows to the rod end cylinder port and the counterbalance valve, opening this valve and allowing fluid in the base end ofthe cylinder to flow back to the hydraulic reservoir. When the jib boom section is raised, fluid flows to the base end cylinder port and to the counterbalance valve, opening this valve and allowing fluid in the rod end of the cylinder to flow back to the hydraulic reservoir.

PLATFORM ROTATE SYSTEM The platform rotate system consists of a platform rotate toggle switch and valve, a double pilot operated check valve, a rotary actuator and a platform rotator manifold. The platform rotate system can onlybe operated from platform console.

ROTARY ACTUATOR The rotary actuator is a helical gear type. Hydraulic fluid enters the actuator from either side depending on the control valve direction, and moves the rack which causes the pinion shaft to rotate.

PLATFORM LEVELLING SYSTEM The platform levelling system automatically keeps the platform level, using a master/slave cylinder arrangement. As the boom is raised or lowered, fluid is forced from one cylinder to the other in a closed loop, which keeps the platform parallel to the ground in any boom position. Due to slight internal leakage, there is a manual override that controls fluid through the platform level control valve.

The platform levelling system in only controlled from the platform console.

MASTER LEVELLING CYLINDER The master levelling cylinder is a double acting cylinder located between the upper frame of the superstructure and the boom. Whenever the boom is raised or lowered, the master cylinder is forced to extend or retract. The fluid displacement from the master cylinder is in tum sent up the boom to the slave cylinder. This forces the slave cylinder to move the same distance as the master levelling cylinder; thereby keeping the platform level.

MANUAL92379-002 May 1998 Revised 11 /98

SLAVE LEVELLING CYLINDER The slave levelling cylinder is a double acting cylinder located between the jib boom and the platform. This cylinder controls the position of the platform relative to the tip boom.

The slave levelling cylinder contains two counterbalance valves. The counterbalance valves prevent platform movement in the event of hose failure.

STEER SYSTEM The steering system consists of a steer valve segment, in the ground valve bank, a steer cylinder, a steer rocker switch on the drive lever atthe platform console. Refer to "Component Locators" in the introduction of this manual.

STEER VALVE SEGMENT When the steer control lever on the platform console is activated, an electrical signal is transmitted to the valve cartridge in the steer valve segment. This allows hydraulic fluid to be sent to the steer cylinder.

STEER CYLINDER The cylinder is double acting and is directly connected to the steering linkage assembly. This cylinder powers all steering movements.

STEER SYSTEM MAINTENANCE Check all pins on steering linkage and steer cylinder for excessive play, and ensure that all retaining rings are in place and secure.

Lubricate linkage as required (see Lubrication Chart).

MANUAL92379-002 May 1998 Revised11t98

SECTION 3: ELECTRICAL SYSTEM

MANUAL92379-002 May 1998 Revised 11198

TABLE OF CONTENTS, SECTION 3 BatteryCharger ...................................................................................................................................... 32 Battery Service ...................................................................................................................................... 42 Cable Wiring Diagram ........................................................................................................................... 50 Limit Switches ....................................................................................................................................... 51 SO Slope Alarm ...................................................................................................................................... 52 DriveSystem-SevconBoomController ................................................................................................ 53 General .......................................................................................................................................... 53 Inputs!Outputs ................................................................................................................................ 53 Brake .......................................................................................................................................... 54 Modes of Operation ........................................................................................................................ 54 TractionMode .......................................................................................................................... 54 Pump Mode ............................................................................................................................. 55 Features in Pump Mode ............................................................................................................ 55 Features in TractionMode ......................................................................................................... 55 Troubleshooting with Flash Codes ............................................................................................. 57 Sevconcontroller -Handheld calibrator .......................................................................................... 58 Featuresandlliustration ............................................................................................................. 58 Condor factory settings ............................................................................................................. 59 T roubleshootingwith Sevcon controller ..................................................................................... 60 Sevcon to Drive Motors power wiring .............................................................................................. 61 DriveController ........................................................................................................................ 63

MANUAL92379-0D2 May 1998

Revised 11198

115VACBATTERYCHARGER TROUBLESHOOTING GUIDE To be able to use the troubleshooting guide effectively, itis importantto read this guide completely before beginning any tests.

CAUTION REPAIRS BY QUALIFIED PERSONNEL ONLY.

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

CAUTION DO NOT DISASSEMBLE THE CHARGER. TAKE IT TO A QUALIFIED SERVICEMAN WHEN SERVICE OR REPAIR IS REQUIRED. Incorrect assembly may result in a risk of electric shock or fire.

SECTION 1 - CHARGER DOES NOT TURN ON In normal operation the charger DC output must be connected to the batteries in order to tum the charger on. A time delay of 2 to 5 seconds is provided to allow adequate time to make a secure connection before the charger turns on. After this time delay the power relay closes and an audible "click" should be heard. When the relay closes, AC power is supplied to the transformer primary coil.

If operating properly, the transformer should hum and the ammeter should indi cate the charge rate.

If the charger does not turn on properly, refer to Part A, B, or C for specific test procedures.

Do not operate the charger if it is malfunctioning. Personal injury or property damage could result.

MANUAL92379'()02

May 1998 Revised 11198

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

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

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

Dis connect the power supply cord from its outlet. With the DC output connector still connected to the battery connector, measure the voltage at the battery connector using a suitable DC voltmeter. The voltage reading shouldbe the same as the battery terminal voltage and mustbe between 24 and 5ovolts DC in order to close the relay. Ifthe DC voltage is within the above limits, remove the charger cover and verify that the charger is properly wired and you read the same voltage (24 to 5ovolts DC) inside the charger where the white and black wires ofthe DC cord attach. Ifthe battery DC voltage measured inside the charger is now below the above limits ornotpresent, the DC plug or cordsethas an internal break and must be replaced. If the charger is wired correctly and a satisfactory battery DC vol tage is measured inside the charger, a malfunction in the Electronic TimerKithasprobablyoccurred. Due to its complexity, do not attempt to make field repairs to any part of the Electronic Timer Ki t. If a malfunction exists, simply remove the entire Electronic Timer Kit andreplaceitwithanewone. Refer to Part D - "Electronic Timer Kit Replacement" - for correct procedure.

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

The Electronic Timer Kit may be bypassed in order to verify that amalfunction exists. First disconnect the charger power supply cord from its outlet and the DC output from the battery. Place aj umper wire between terminals #1 and #3 to bypass the Electronic Timer Kit. The power supply cord is now connected directly to the primary transformer coil and the transformer should hum when the power supply cordis connected to alive outlet. The charger operation may be checked by first connecting the DC output connector to the battery connector, and then connecting the power supply cord to an outlet. Ifnormal charging currentis indicated on the ammeter the Electronic Timer Kit is defective and must be replaced.

MANUAL92379-002 May 1998

Revised 11198

CAUTION DO NOT charge batteries with the Electronic Timer Kit bypassed. The charger will remain on as long as the power supply cord is connected to an outlet.

Severe overcharging and eventual damage to batteries will result.

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

PART B - RELAY CLOSES BUT NO TRANSFORMER HUM AND AMMETER DOES NOT REGISTER Check to be sure the power supply cord is securely connected to a live AC outlet. When three-prong to two-prong adapters are used, they tend to work loose resulting in a poor connection. Check the AC line fuse or circuit breaker and, if possible, measure the AC line voltage at the outlet to be sure AC power is present. If necessary, connect a functioning charger, utility light or other electrical appliance to the outlet to verify the presence of AC power.

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

PART C - RELAY CLOSES AND TRANSFORMER HUMS BUT AMMETER DOES NOT REGISTER If the relay closes and the transformer hums, the charger AC circuit and Electronic Timer Kit are functioning properly. If the ammeter does not register, a fault in the charger DC circuit exists and a continuity check must be performed. Disconnect the power supply cord from its outlet and the DC output connector from the battery connector, and check the charger fuse. If a fuse link is blown, referto Section 2 - "Charger Fuse Blows" for further tests. If the fuse checks good, use a low voltage continuity tester to perform the following tests: 1.

Connect the tester leads to the charger DC output connector and note the reading. Reverse the tester leads and check the output connector again. The circuit should be complete in only one direction. If the circuit does not conduct in either direction and the fuse is good, individually check the continuity of the DC output cord, ammeter, diodes and all connections. Ifthe circuit conducts in both directions, a "short" exists in the charger DC circuit. First check the DC output cord for a "short" between the two wires.

It is more likely that one or both diodes have "shorted." Refer to Section 2 - "Charger Fuse Blows" for continuity test of diodes.

MANUAL92379-002 May 1998 Revised 11198

6) 2.

Ifthe charger DC circuit test is good, a check ofthe capacitoris necessary. Disconnect the power supply cord from its outlet and the DC output connector from the battery connector. Then disconnect both transformer coil leads from the capacitor terminals. Use care when disconnecting the capacitor leads so the wires do not break. Using an ohmmeter, setthe scale to R X 10K ohms and testthe capacitor as follows:

DANGER HIGH VOLTAGE: With the charger operating, the charger capacitor voltage is approximately 650 volts AC. Use extreme caution when working near the capacitor terminal

GOOD CAPACITOR - When the ohmmeter leads are connected to the capacitor terminals, the meter needle jumps to mid-scale and rapidly moves to high resistance.

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

SHORTED CAPACITOR - When the ohmmeter leads are connected to the capacitor terminals, the meter needle jumps immediately to zero ohms and remains there.If the capacitor is open or shorted, it must be replaced.

CAUTION Use only a 6 Mfd, 660 volt AC rated capacitor for replacement (Part No. 02390S).

The use of a different value capacitor may result in improper charging, capacitor failure, transformer burnout and/or battery damage.

3.

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

PART D -

ELECTRONIC TIMER KIT REPLACEMENT

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

1.

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

2.

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

3.

Install the replacement Electronic Timer Kit by reversing the disassembly procedures described in Step 2. When reconnecting the wires to the Electronic Timer Kit terminal tabs, support the terminal board to prevent damage to the electronic circuit board. Connect either transformer primary lead to terminal #2 and the remaining primary I lead to terminal #3.

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•

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

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

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

4.

Replace the charger cover and check the Electronic Timer Kit for proper operation as follows:

A.

With the DC output connector disconnected from the battery connector, insert the power supply cord into an outlet. The relay on the Electroni c Timer Kit should not close. A DC voltmeter connected across the DC output connector should indicate zero volts.

B.

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

C.

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

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

SECfION 2- CHARGER FUSE BLOWS The charger fuse assembly consists of a dual element fuse link under a transparent cover mounted on the charger front panel. Each fuse element is electrically connected in series with a rectifier diode to provide protection for the transformer in the event of a diode failure. Visually inspect and electricall y test the fuse to determine if one or both fuse links are blown and refer to Part A or Part B for test procedures. LOCATE AND CORRECT CAUSE OF TROUBLE BEFORE REPLACING BLOWN FUSE. DO NOT attempt to repair the fuse link as inadequate protection will result.

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•

PART A-SINGLE FUSE LINK BLOWS

This conditionisnonnally caused by a short circuit failure ofone diode. The fuse link will blow when the charger DC output connector is connected to the battery connector, regardless of whether the power supply cord is connected to an outlet To check the diodes, disconnect the power supply cord from its outlet and the DC output connector from the battery connector, and then disconnect one transformer secondary coil lead from the diode terminaL Using alowvoltage continuity tester, connect one tester lead to the diode mounting plate and the other tester lead to a diode tenninaL Note the reading and then reverse the tester leads and check each diode again. If a diode conducts current in both directions, it is "shorted" and the complete Heat Sink Ass embly with Diodes (Part No. 09653 S) must be replaced.

On rare occasions a single fuse link may melt due to excessive heat. This can be caused by a loose internal fuse connection. Check all three fuse connections inside the charger to be sure they are clean and tight The proper torque on the fuse connector nuts is 20 Inch-Pounds (23 Cm-Kg).

PART B -

BOTH FUSE LINKS BLOW

This isnonnally caused by areversepolarity connection between the charger DC output connector and the battery connector. Check the battery pack and battery connector to be sure they are wired in the correct polarity. Ifpossible, check the voltage and polarity at the battery connector with aDC voltmeter. Also, check the charger DC output connector for the correct polarity. The white wire should be connected to the positive (+) contact, and the black wire to the negative (-) contact. If a reverse polari ty connection is made between the charger and batteries, both fuse links will blow, regardless of whether the power supply cord is connected to an outlet.

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

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.SECfION 3 -

AMMETER READS 30 AMPS FOR MORE THAN 30 MINUTES

This high output condition is caused by misuse, connecting the charger to an incorrect battery system which is lower than 24 volts. A common error is to install one or more of the 6 volt batteri es in a 24 volt batterypackreversepolarity. Using asuitableDCvoltmeter, testto be sure all batteries ina battery pack are correctly wired and also test the battery pack voltage at the charging connector. After charging for 3 0 minutes atthis excessive rate, the measured on charge voltage should rise to 22 to 26 volts DC for a 24 volt system. Voltage measurements, while charging, lower than this indicate an incorrect or failed battery pack that must be corrected before using the charger.

CAUTION DO NOT connect the charger to battery packs which are not 24 volt systems.This misuse will cause overheating and transformer burnout will result.

SECfION 4 -

CHARGER OUTPUT IS LOW

The most probable cause oflow output is a single fuse link blowing as the result ofa short circuit failure of one diode. Refer to Section 2 - "Charger Fuse Blows" for troubleshooting procedures. On rare occasions a short circuit failure ofthe transformer coils may cause the 0 utputto be low. Refertosection 7 - "Transformer Short or Burn Out" for test procedures.

CAUTION Do not use the charger if the output is low. Batteries will not reach full charge, thereby increasing the possibility of a harmful deep discharge during their next use.

SECfION 5 -

CHARGER TURN OFF MALFUNCTIONS

The Electronic Timer Kittums the charger off as well as on. Proper charge time is determined by many factors, butthe main elements are: (1) battery size, (2) depth ofbattery discharge and (3) finish charge rate. Large severely discharged batteries require more time to reach full charge than do smaller lightly discharged batteries.

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

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

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

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PARTA-CHARGERTURNSOFFTOOSOON

Checkto be sure the power supply cordis securely connected to alive outlet. Ifthe power supply outlet is live, proceed with the next step.

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

1.

Theammeterneedlejumps smartly to between 20 and 25 amps and then tapers below 14 amps within 15 minutes. This indicates that the batteries were truly charged. The apparent short charging time is in response to the batteries' ability to accept charge and the electronic timer is performing properly.

2.

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

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

As batteries age, individual cells may weaken, causing areductionin battery capacity. This condition normally results in a finish charge higher than 10 Amps and less time is required to fully charge the batteries. Do notinterput this shorter charging time and reduced battery capacity as being caused by the charger turning offtoo soon. The battery is aging naturally and the charger is working properly.

When the batteries will no longer perform as required, they should be replaced.

PART B - CHARGER DOES NOT TURN OFF

New batterieswith all good cells should rise to atleast2. 5volts per cell. This will allow the finish charge rate to taper below 8 amperes. As batteries age, individual cells may weaken and these cells may not reach 2.5 volts. This will result in finish charge rates greater than 8 amperes, and less time will be required for the batteries to reach full charge. At a fmish charge rate of8 amperes or less the charge time should not exceed 18 hours. At a finish charge rate greater than 8 amperes the charge time should not exceed 14 hours.

If the charger remains on longer than the specified maximum time, check to see ifthe charger turns on immediately when the DC output cord is connected withoutthe normal two to five second delay.

If the charger turns on instantly without the two to five second delay the Electronic Timer Kit has probably failed. This type ofmalfunction generally results in the chargernotturning off and the complete Electronic Timer Kit must be replaced. Refer to Section 1, PartD - "Electronic Timer Kit Replacement" for correct procedures.

MANUAL92379-002 May 1998 Revised 11/98

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

If a precision digital type DC vol tmeter is available, a test to verify that the Electronic Timer has malfunctioned can be made. Connect the charger to the batteries and allowto charge normally. After the charge rate has tapered to its lowest point, measure the battery terminal voltage using a DC voltmeter capable of reading in increments of. 00 1 volts. Continue charging and check the battery voltage reading every hour. Ifthe battery voltage increases less than .0 12 volts, or ifthe battery vol tage decreases between successive hourly readings, the charger should tum off. If the charger does not tum off, the Electronic Timer has malfunctioned and the complete Electronic Timer Kit must be replaced.

PART C- CHARGER RUNS TOO LONG BUT DOES TURN OFF In the event ofAC power interruption when the charger is on, the charger will automatically restart when AC power is restored. This power outage can make the apparent charge time seem longer than the actual charge time. TocheckforACpowerinterruptions,pluganelectricclockintothesameoutlet to which the AC cord is connected. Charge normally and note any time difference between the test clock time and the actual time.

SECTION 6 - AC LINE FUSE OR CIRCUIT BREAKER BLOWS If this occurs when the charger power supply cord is connected to an outlet, without the DC output connector connected to the battery connector, the charger power supply cord may be shorted.

Disconnect the power supply cord from its outlet and the DC output connector from the battery connector, then check to be sure the Electronic Timer Kit is NOT bypassed With a suitable continuity tester, check the circuit across the power supply cord prongs as shown. THE CIRCUIT SHOULD NOT BE COMPLETE. If the circuit is complete, check the relay contacts to be sure they are open and have notwelded closed. Ifthe relay contacts are open, the power supply cord is shorted and must be replaced. Ifthe power supply checks good, the transformer coils may be shorted. Referto Section 7 - "Transformer Short or Burnout" for test procedures.

SECTION 7 - TRANSFORMER SHORT OR BURNOUT Failure ofthe transformer can be the result ofnatural aging, premature shorting ofadj acent coil turns or overheating damage. The most common cause of transformer overheating and premature burnout is the result of misuse, connecting the charger to a battery system oflowervoltage than specified on the charger (See Section3). Darkening ofall the transformer secondary coil windings is anindication ofpossible overheating damage. Aloworcomplete lack ofoutput would be observed on the ammeter, however, the transformer may hum ortheAC line fuse or circuit breaker may blow when the charger is turned on. To test the transformer, disconnect the power supply cored from its outlet and the DC output connector from the battery connector. Then disconnect the transformer secondary coil leads #1 and #4 from the diode terminals and disconnectthe transformer capacitor coil leads from the capacitor terminals. Use care when disconnecting the capacitor lead so the wires do not break.

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DANGER HIGH VOLTAGE: With the charger operating, the charger capacitor voltage is approximately 650 volts AC. Use extreme caution when working near the capacitor terminals.

In order to apply AC power directly to the transformer primary coil, the Electronic Timer Kit must be bypassed. Refer to Section 1, Part Afor by-pass procedures. With the Electronic Timer Kit bypassed take caution in connecting the power supply cord to an outlet. If the AC line fuse or circuit breaker blows, the transformer is shorted internall y and must be replaced. If this does not occur, check the transformer secondary and capacitor coil voltages as shown in Figure 6, using asuitableACvoltmeter.

Ifthe measured voltages are substantially lower than those shown, the transformer is shorted internally and must be replaced.

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

The correct voltage reading is shown in Figure 7. Ifthe transformer secondary voltage reading is the same as measured with the capacitor disconnected, from Figure 6, the capacitor may be open, the capacitor coil may be open orthe capacitor coil terminals may not be making proper electrical contact.

Refer to Section 1, Part C, Item 2 for capacitor test procedures. If the voltage readings are correct, both the transformer and capacitor are good, refer to Section 1, Part C, Item 1 for further tests of the DC circuit.

Ifitshould become necessary to replace a terminal on one of the transformer leads, the new terminal must be crimped AND soldered. N01E: Some transformer leads may be aluminum wire and a solder mustbeusedonthesewiresthatisintendedforuseonaluminum,suchasAlcoa#807solderwithAlcoa #69 flux. Ifthese materials are not available locally, contact the Lester factory.

MANUAL92379-002 May 1998 Revised11198

BATTERY SERVICE

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

BATTERY CHARGING A.

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

B.

Operate charger in accordance with the battery charging instructions.

C.

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

D.

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

E.

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

BATTERY SERVICING TOOLS Use proper tools when performing battery service to prevent damage to battery, cables, terminals and hold-downs, and to save time and energy. Suggested battery tools and their use are described below.

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

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

BA TTERY CARRIER A battery carrier should not place any undue strain on the battery terminals or the container. An excellent carrier for plastic - cased batteries is a clamp ("ice tong") type carrier with rubber pads which grip the SIDE WALLS of the container just below the lip of the cover. It is used on the side

MANUAL92379-002 May 1998 Revised 11198

walls rather than the end walls, since the side walls have additional strength from the inner cell partitions. Gripping the flexible end walls of plastic containers could cause electrolyte to spew from some of the cells.

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

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

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

If corrosion is found on the terminal posts, remove the cable terminals from the battery (ground cable first), using the proper end wrench. A wire cleaning brush can be used to clean the posts and the mating surfaces of the cable clamps. Connect the cables to the terminal posts (ground cable last).

Coat the terminal connections with a spray corrosion inhibitor or high temperature grease.

The second item in routine servicing of conventional batteries is to check the electrolyte level in all cells. If necessary, add clear, odorless, mineral free water to bring the liquid level to the level indicator in all cells. If the battery does not have a level indicator, bring the level to 112" (l3mm) above the tops of the separators. Do not overfill any cell. When a cell is overfilled, the excess electrolyte may be forced from the cell by the gas formed in the battery. This will cause excessive corrosion of adjacent metal parts, reduced performance and shorter life.

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

STEP 1 -

VISUAL INSPECTION

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

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STEP 2 -

HYDROMETER TEST

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

The average state of charge of the cells in a battery can be determined by measuring the stabilized voltage of the battery. The voltage is stabilized if the battery has been on open circuit overnight or for a period of several hours. A voltage reading of 12.4 (6.2 on a 6-volt battery) is equivalent to a specific gravity of 1.225. The disadvantage of measuring the open circuit voltage is that a lower voltage cell can be masked by the remaining cells. If the cell connectors are accessible for voltage measurements, a range of 0.05 volts between the highest and lowest cells corresponds to a 50 point variation in specific gravity. A cell voltage of2.07 is equivalent to a specific gravity of 1.225.

STEP 3 -

ADJUSTABLE LOAD TEST

The following instructions are intended as guidelines. When available, the instrument manufacturer's instructions should be followed. Follow all precautions.

A.

Disconnect battery cables starting with ground cable.

B.

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

C.

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

D.

Connect current transducer (if necessary) to appropriate lead.

E.

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

F.

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

G.

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

H.

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

I.

If test voltage is below minimum, replace battery.

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

STEP 1 -

VISUAL INSPECTION

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

STEP 2 -

FIXED LOAD TEST

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

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

A.

Disconnect battery cables starting with ground cable.

B.

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

C.

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

D.

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

E.

Apply test load for 15 seconds.

F.

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

G.

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

H.

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

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STEP 3 -

OPEN CIRCUIT VOLTAGE TEST

If the battery failed the load test, the state of charge must be checked. If a hydrometer is not available, the stabilized open circuit voltage can be used to indicate the state of charge. Allow at least 10 minutes after the load test for the voltage to stabilize, then measure and record the open circuit voltage. Determine the approximate state of charge from the following chart (Battery temperature 60-100 degrees F.) OPEN CIRCUIT VOLTS 12.6 or greater 12.4 - 12.6 12.2 - 12.4 12.0 - 12.2 11.7 - 12.0 11.70rless

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

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

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DETERMINING CAUSES OF BATTERY FAILURE Whether the battery passes or fails either of the above tests, the result must be delivered.

If the battery passed the load test only after a recharge, the cause of the discharge condition should be determined. If the battery has been returned previously or is otherwise still questionable, one final test should be made. Fully charge the battery and place it on open circuit stand for three days. If the loss in specific gravity of any cell is greater than 35 points or the open circuit voltage drops by more than discharge condition. The following should be checked: 1.

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

2.

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

A.

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

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

B.

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

C.

Voltmeter -Disconnect the ground cable (negative) at the battery. Connect a low resistance voltmeter (100 ohms -see Note I) between the disconnected battery post and the chassis. A voltage measurement of 6 volts or more indicates a leak of 0.1 amp or more and the equipment electrical should be tested and repaired.

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

3.

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

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FIGURE: X

SA TTERY TESTING CHART STEP1

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

I NO OBVIOUS DAMAGE I

IOBVIOUS DAMAGE I I REPLACE BATTERY I

I

I

BELOW TOP OF PLATES IN ONE OR I MORE CELLS

CHECKELECTROLYTE LEVEL

I

ELECTROLYTE LEVEL ABOVE TOP OF PLATES INALLCELLS-PROCEDTO STEP 2

ADD WATER TO JUST ABOVE SEPARATORS. CHARGE FOR lSMINUTESAT lS-2SAMPS. PROCEEDTOSTEP2

I HYDROMETER TEST J

STEP2 I

I

SPECIFIC GRAVITY LESS THAN 1.22S OR CELL VARIATION SO POINTS OR GREATER.

SPECIFIC GRAVITY 1.225 OR GREATER ORCELLVARlAllONLESSTHAN50POINTS.

I

I

I RECHARGE I

I

DISCHARGE AT 150 AMPS FOR 151 SECONDS

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

I

I CONTINUETOSTEP3

I

I

I REPLACE BATTERY I I LOAD TEST I

STEP 3

I 1. PLACE THERMOMETER IN CENTER CELL. COVER BATTERY WITH A DAMP CLOTH. 2. CONNECTVOLTMETERANDAMPERELOAD EQUAL TO 1/2THE COLD CRANKING AMPERES ATO°F (-18°C) RATING OFTHE BATTERY FOR 15SECONDS. 3. OBSERVE VOLTAGE AT 15 SECONDS WITH LOAD ON. 4. REFERTOVOLTAGECHARTBELOW.

I I VOLTAGE BELOW CHART VALUE

I

I

I

I

VOLTAGE EQUAL TO OR ABOVE CHARTI VALUE-RETURN TO SERVICE

I

I REPLACE BATTERY I

I

VOLTAGE CHART ESTIMATEDELECTROLYTE TEMPERATURE

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

70°F (21°C) & ABOVE 60°F (16°C) SO°F (10°C) 40° F{4° C) 30°F(-1°C) 20° F(-7" C) 10°F (-12°C) OaF (-18°C)

9.6 9.S 9.4 9.3 9.1 8.9 8.7 8.S MANUAl92379-002 May 1998 Revised 11/98

FIGURE: Y

BATTERY TESTING CHART STEP 1

VISUAL INSPECTION CHECK FOR OBVIOUS DAMAGE SUCH AS CRACKED OR BROKEN CASETHATSHOWS LOSS OF ELECTROLYTE. ALSOCHECKFOR TERMI NAL DAMAGE.

I I

I

IOBVIOUS DAMAGE I

NO OBVIOUS DAMAGE

I

I

I

IREPLACE BATTERY I

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

I FIXED LOAD TEST I

STEP 2

I 1. ATTACH TESTER CLAMPS TO BATTERY TERMINALS INCORRECT POLAITY - USUALLY RED TO POSITIVE (+) AND BLACK TO NEGATIVE (-).

2. SET SELECTOR SWITCH ON LOAD TESTER TO 1/2CRANKING AMPERAGE RA TI NG OF BATTERY (AT O'F, -18'C).

3. IFTESTERDOESNOTHAVEANAUTOMATlCBATTERYTEMPERATURE COMPENSATOR, PLACEA THERMOMETER IN CELL, READ ANDSETTEMPERATURE DIAL ON TESTER. WITHOUT ANYTEMPERATURE CORRECTION, MAKE LOAD TESTS ONLY ON BATTERIES ABOVE 60·F (16'C).

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

I

I

I

I BATTERY FAILS LOAD TEST I

I

BATTERY PASSES LOAD TEST RETURN TO SERVICE.

I

I PROCEEDTOSTEP3 I STEP 3

I I

I OPENCIRCUITVOLTAGETEST I I 1. ALLOW 10 MI NUTES FOR BA TTERY VOLTAGE TO STABI LlZE AFTER LOAD TEXT. 2. READ OPEN CIRUITVOLTAGE.

I 12.4VOLTSORABOVE-IFBATTERYDID NOTPASSTHE LOAD TEST, ITSHOULD BE REPLACED- THEN PROCEED TO STEP 4.

UNDER 12.4VOLTS-BATTERYSHOULD BE CHARGED AND LOAD TESTED AGAIN (REPEAT STEP2).IF BATTERY AGAIN FAILS THE LOAD TEST, REPLACE IT. IF IT PASSES, RETURNTOSERVICEAFTERPROCEEDING TOSTEP4.

STEP 4

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

OR B) DISCONNECTTHE BATTERY CABLE THATGOESTO THE STARTER AND CONNECT AN OHMMETERBETWEENTHECABLEANDTHEGOUND(ARESISTANCEOFUNDER1000HMS WILL DRAIN THE BA TTERY).

3. CHARGING SYSTEM SHOULD ALWAYS BE CHECKED AFTER CHARGING OR REPLACING A BATTERY. MANUAL92379-002

May 1998 Revised 11198

.WIRING DIAGRAM

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MANUAL92379-002 May 1998

Revised11J98

I

LIMIT SWITCH The lower elevation limit switch should be adjusted to change state when the boom is 4' to 6' high.

The upper elevation limit switch should be adjusted to change state when the boom is horizontal or just above.

Upper Elevation Limit Switch

Lower Elevation Limit Switch

MANUAL92379-002 May 1998 Revised 11/98

•

TILT ALARM The tilt alarm gives an audible warning when the machine is 4-1/2° or more out oflevel. It is located in the platform control console. To replace the tilt alarm, open the platform control console, disconnect the wires and remove it from the platform control console.

TIL T ALARM TEST The alarm can be tested by manually tipping the alarm sensor. This "Push-to Test" feature enables tilt alarm to be tested without losing its adjustment. Select "Platform" at the ground key (selector) switch.

With the boom raised above horizontal, individually push down on each of the three fastened corners of the tilt alarm. On the tilt alarm, there are three LED's. The green LED indicates the unit has power. The red LED indicates the sensor is tilted beyond 4-1/2°. The yellow LED indicates the sensor is tilted beyond 41/2° and the 3 second delay has expired (tilt alarm should sound at the platform).

TIL T ALARM ADJUSTMENT The tilt alarm can be adjusted. Before attempting to adjust the alarm, park the machine on a flat, level surface.Level the base of the alarm by adjusting each of the three flange nuts until the level bubble is centered.

CIRCUIT BREAKER There is one 20 amp circuit breaker mounted on the face of the ground control box.

If the breaker is tripped, reset it by pushing in the button. If the breaker trips again, the cause of the high current draw must be corrected prior to further operation.

LIMIT SWITCH There are limit switches for the boom telescope and boom lift. The (boom telescope) limit switch is located on the lower left side of the base boom. The boom lift limit switch is located on the center post of the turret. Unless the boom lift and (telescope) limit switches are closed as shown on the machine electrical schematic at the end of this manual, the machine will only be able to travel at creep speed from platform.

EMERGENCY STOP BUTTON There is an emergency stop button on the ground control console and on the platform control console.

When the emergency stop buttons are pressed, all functions stop immediately and the wheel brakes are automatically applied. To replace the emergency stop button, open the ground control console or platform control console to gain access for button removal. Remove the appropriate button mounting screws and Wires.

MANUAL9237~02

May 1998 Revised11i98

DRIVE SYSTEM SEVCON BOOM CONTROLLER General Comments/Scope A boom controller is a device which will provide TRACTION and PUMP control to a boom lift vehicle, operating at 24 to 48 volts. The TRACTION and PUMP control functions are incorporated into the device such that either mode of operation can be selected by an advantage ofthis system being that both TRACTION and PUMP drives can be incorporated into a single controller.

The FORWARD and REVERSE contactors are wired to enable PLUG-BRAKING. A tachometer is present to measure speed and is used in a closed loop fashion to provide CONSTANT SPEED CONTROL (CSC).

The accelerator input is used to select a 'cruise' speed, which the controller will attempt to maintain by varying the percentage on and/or utilizing PLUG-BRAKING. The controller remains in CSC at all speeds.

This specification outlines the modes of operation, inputs and outputs, and essential features proposed for the boom controller.

Inputs and Outputs The following sections define the required 110 forthe boom controller.

Power Inputs and Outputs The following power connections shall be provided: Battery positive Battery negative 2 Motor connections

Control Inputs The following control inputs shall be provided: OnJOffEmergency SW in series with Foot SW, applying battery voltage to controller.

TRACTION Acc. 5K to OK, min to max speed or 3.5+ 0.05 to <0.2v.

PUMP Acc. same as above with external pull up resistor.

FORWARD select REVERSE select PUMP select TRACTION Speed cutback 1 (interlock with boom extension)* TRACTION Speed cutback 2 (interlock with off-level switch)* Tachometer input * Speed cutback is: SW close = no cutback SW open = speed cutback applies Lowest selected speed has priority.

Control Outputs The following control outputs shall be provided: FORWARD contactor drive REVERSE contactor drive PUMP/TRACTION select contactor drive PUMP (STEER) motor override direct battery connection contactor

MANUAL92379-002 May 1998 Revised 11198

DRIVE SYSTEM SEVCON BOOM CONTROLLER Cont.

Electric Brake The ELECTRIC BRAKE will be supplied from the positive side through the emergency switch and from the negative side through the FWD and REV driver. Therefore, the ELECTRIC BRAKE will be applied when no DIRECTION contactoris energized (i.e. in NEUTRAL, during PUMP mode, or if a fault condition is forcing neutral).

The brake time constant should be slow enough that it will not operate during direction contactor changeover (of the order of 0.25 Seconds).

The ELECTRIC BRAKE must be rated at the same voltage as the contactor coils. The current consumption of the brake should be such that the 3 amp overcurrent limit is not exceeded by the contactor coil and brake current, combined. If the combined current consumption ofthe coil and brake will exceed 3 amps, an auxiliary relay will be needed to drive the brake.

Modes of Operation The following sections define the required modes of operation:

TRACTION Motor Drive Drive in either FORWARD or REVERSE will start only if the following conditions are satisfied: PUMP switch off.

No procedure or diagnostic faults present.

FWD or REV selected as appropriate.

Once in TRACTION mode activating the PUMP switch shall not cause TRACTION mode to be exited, the PUMPITRACTION contactor drive shall not be energized (shall be left at the TRACTION position). If the PUMP switch is selected during TRACTION, a procedure fault will occur when NEUTRAL is selected, remaining until the PUMP switch and both DIRECTIONS are no longer selected.

When NEUTRAL is selected the controller will control smooth stopping of the vehicle, using PLUG BRAKING, before the ELECTRIC BRAKE is allowed to operate.

If the PUMP switch is activated in NEUTRAL, when the vehicle has stopped and the BRAKE is applied, then PUMP mode will become operational.

PUMP Motor Drive PUMP motor drive will start only if the following conditions are satisfied: FWD and REV switch off.

Traction mode off (brake applied) No procedure or diagnostic faults present.

PUMP switch selected.

MANUAL92379-002 May 1998 Revised 11198

PUMP drive shall only be enabled when the DIRECTION selector inputs in NEUTRAL and the truck is stationary. Once PUMP drive mode has been entered then the status of the DIRECTION selector inputs shall no longer interlock PUMP operation. If a DIRECTION switch is selected during PUMP drive, a procedure fault will occur when the PUMP switch is no longer selected, remaining until both DIRECTIONS and the PUMP switch are no longer selected.

Features in PUMP Mode • Proportional control of PUMP motor speed when upper control is selected.

The PUMP motor speed shall be controlled by varying the percentage on of the switching element in relation to a separate PUMP accelerator input. The accelerator input is wire number 60 from the speed control potentiometer. When PUMP mode is enabled a variable offset speed shall be applied to the PUMP motor at zero demand. This shall be adjustable in the range of 0% ON to 30% ON using the handheld calibrator. Displacement ofthe accelerator input shall result in a linear increase in percentage on from the offset speed to 100% ON over the full range of accelerator input. When lower control is selected, the input is connected to ground for 100% output through wire #60 any time a function is activated.

• Wire off detect In the event ofthe accelerator input becoming detached, the fitted external pull up resistor will cause pulsing in PUMP mode at the offset speed. No fault diagnostic will be reported.

• Pump Accell The PUMP motor speed control shall incorporate a "soft start" facility by applying acceleration delay to changes in the applied percentage on of the switching element. The duration of the acceleration delay shall be variable between 0.5 seconds and 5 seconds with a resolution of 0.1 seconds, using the hand held calibrator.

• Pump Decel The PUMP motor speed control shall incorporate a "soft stop" facility by applying deceleration delay to changes in the applied percentage on of the switching element. The duration of the deceleration delay shall be variable between 0.5 seconds and 5 seconds with a resolution of 0.1 seconds, using the hand held calibrator.

NOTE: Both Soft Start and Soft Stop share a common adjustable parameter.

Features in Traction Mode Maximum speed control The controller shall incorporate a function to limit the maximum possible speed. This function shall operate in such a manner as to control vehicle speed by limiting the percentage on of the switching device to keepthe vehicle speed below the maximum permitted valve or, if required, to apply variable PLUG BRAKING to restrict vehicle speed when traveling down a gradient.

In any case maximum permitted valve should not be exceeded by more than 15%.

The maximum permitted speed shall be computed from the accelerator input percentage such as that the maximum acceleratorinputpercentageis equivalenttothe maximum allowed speed.

The maximum permitted speed shall vary linearly with accelerator input percentage according to the following relationship.

MANUAL 92379-002 May 1998

Revised 11198

•

MAX SPEED = Percentage speed as defined by calibrator personality (0% to 100%).

ACCEL. SPEED = MAX. SPEED * Accelerator input percentage.

Where control speed is the speed at which the controller will drive the truck, in the manner described above.

NOTE: Minimum control speed is set by the speed personality.

The actual vehicle speed shall be measured using a suitable tachometer, to be agreed with Sevcon, which shall supply 20V DC for 1000 RPM with a maximum speed of 2500 RPM (50V). The polarity indicates the vehicle direction.

If the actual vehicle speed is greater than the CONTROL SPEED the controller shall employ an algorithm which will limit the percentage of the switching device or, if necessary, initiate PLUG BRAKING to ensure that the CONTROL SPEED is not exceeded by more than the specified tolerance.

The SPEED CONTROL function shall also compensate (to an accuracy of 15910) for positive gradients by increasing the percentage ofthe switching device, to alimitoffull battery voltage.

Speed Cutbacks If either speed cutback is selected, the MAX SPEED above is reduced to the appropriate cutback (provided that it is lower), and the accelerator input is rescaled to the new MAX SPEED. A four second lag is applied to the off-level switch when it is de-selected to compensate for switch bounce.

Off-Level Control When the off-level cutback is selected, in addition to reducing the MAX. SPEED, various algorithms are activated to give greater vehicle control on a hill.

The TRACTION acceleration delay is reduced to a very short delay, so that it is possible to quickly compensate for roll-back when the vehicle is going up hill.

The Plugging level range increases to 400A versus 200A when on-level.

Accelerator Input The TRACTION accelerator is controlled with wire #45 from the Drive Joystick Control.

Direction in controlled as follows, wire #43 is Forward and wire #44 is Reverse.

Wire Off Detect In the event of the accelerator input becoming detached, pushing in TRACTION mode will occur so that the vehicle drives at minimum speed. A 6-flash fault diagnostic will also be reported.

MANVAL92379·002 May 1998 Revised11198

TractionlBraking Hysteresis So that the vehicle behavior is smooth, a hysteresis curve will be implemented on changeover between pulsing of the switching device to drive the vehicle, and PLUG BRAKING. When pulsing, the braking requirement must be high enough to justify changeover to PLUG BRAKING. When braking, the pulsing requirement must be high enough to justify changeover from PLUG BRAKING.

Troubleshooting With Flash Codes The following is a list of flash codes that are displayed on the Sevcon unit. The number of flashes identify one of several conditions possible in a fault condition.

LED on - Controller operational LED off - Internal fault 2 flash - Procedure fault This includes DIRECTION os PUMP selected at power on, or DIRECTION and PUMP selected together.

3 flash - Motor permanently low.

This includes MOSFET short circuit. This fault only shuts down TRACTION mode, not PUMP mode, though PUMP mode cannot be selected if this fault occurs during TRACTION mode.

4 flash - Motor permenently high.

This includes DIRECTION or PUMPffRACTION contactor welded. This fault only shuts down TRACTION mode, not PUMP mode, though PUMP mode cannot be selected if this fault occurs during TRACTION mode.

5 flash - Motor neither low nor high.

This includes DIRECTION or PUMPffRACTION contactor open circuit, MOSFET open circuit and hardware failsafe trip. This fault onlt shuts down TRACTION mode, not PUMP mode.

6 flash - Faulty TRACTION accelerator.

This includes TRACTION accelerator greater than 30% at power on, and wire off. Note that the PUMP accelerator in not fault detected.

NOTE: 6 Flash is normal when lower control is selected 7 flash - Low battery voltage.

This includes battery voltage below 13 volts.

8 flash - Thermal cutback.

This includes MOSFET temperature above 80°.

10 flash - Tachometer fault detected.

11 flash - Tachometer input out of range.

MANUAL9237g.002 May 1998

Revised 11198

The Sevcontrolleris a hand held unit that plugs directly into the Sevcon Boom Controller through a seven pin connector. It can be used to view and change system parameters as well as for troubleshooting.

,

/

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AMP SEC SEC % % % % SEC %

Max Plug Current Traction Aceel Delay Traction Decel Delay Creep Speed Max Speed Elevation Cutback Speed Slope Cutback Speed Pump Delay Pump Threshold

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Calibrator

Sevcontrol

MANUAL 92379-002 May 1998 Revised 11198

CONDOR FACTORY SEVCON SETTINGS

MODEL A28/A32J

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9.

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amps sec sec % % % % sec % amps

1)

MAX CONTROLLER CURRENT a.

50 Amps to 400 Amps DEFAULT 270A b.

50 Amps to 600 Amps DEFAULT 600A

2)

ACCELERATION DELAY l.0 Seconds to 3.0 Seconds DEFAULT 2.0 Seconds

3)

DECELERATION DELAY 0.5 Seconds to 3.0 Seconds DEFAULT l.5 Seconds

4)

TRACTION CREEP 0% to 10% DEFAULT 0%

5)

MAX ALLOWED SPEED 0% to 100% DEFAULT 70%

6)

CUTBACK SPEED 15% to 20% (Boom Up) DEFAULT 10%

7)

CUTBACK SPEED 25% TO 60% (Off-Level) DEFAULT 50%

8)

PUMP SOFT START DELAY 0.5 Seconds to 5.0 Seconds DEFAULT 3.0 Seconds

9)

PUMP CREEP SPEED % on 0% -> 30% DEFAULT 10%

10)

ON LEVEL PLUGGING CURRENT a.

50 to 400 Amps b.

50 to 750 Amps

MANUAL92379-0OZ May 1998 Revised 11 198

600 2.0 .50 10 100 10 50 3.0 10 750

Troubleshooting

,

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Diagnostics using hand held calibrator

GRAPHIC OF HAND CALIBRATOR

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6

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16

7

Actual Direction

2

8

Not Used

9

Not Used

10

Not Used

Sequence No.

NOTE: CL = Switch CLOSED OP = Switch OPEN

MANUAL92379-002 May 1998 Revised 11/98

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SECTION4: MAINTENANCE

MANUAL92379-002 May 1998

Revised 11 /98

Table of Contents, Section 4 Maintenance .......................................................................................................................................... 66 General Maintenance Tips ...................................................................................................................... 66 First!hree~~nthsofOperation ............................................................................................................ 67 RoutlngServlclng ................................................................................................................................... 67 Shift Operational Checklist ..................................................................................................................... 70 Weekly Operational Checklist ................................................................................................................. 73 MonthlyOperational Checklist ................................................................................................................ 74 Semi-Annual Operational Checklist ....................................................................................................... 76 Bolt Torque Chart (Standard) ................................................................................................................. 78 BoltTorqueChart~etric) ..................................................................................................................... 79

MANUAL92379-002 May 1998 RevSed 11198

•

MAINTENANCE The A28/32J is designed to require a minimum amount of maintenance. However, it is essential thathe specified services be performed at the indicated intervals, and that instructions contained in this manual are followed to ensure safety and reliability.

~

DANGER

DEATH OR SERIOUS INJURY MAY RESULT IF MACHINE IS OPERATED IN AN UNSAFE CONDITION. DO NOT OPERATE ANY MACHINE IF IN UNSAFE OPERATING CONDITION. GENERAL MAINTENANCE TIPS •

ALWAYS clean the surrounding area before opening hydraulic components.

Never open a hydraulic system when there are contaminants in the air.

Never leave components or hoses open. They must be protected from contamination (including rain) at all times.

Use only recommended lubricants. Improper lubricants or incompatible lubricants may be as harmful as no lubrication.

Watch for makeshift "fixes", which can jeopardize safety as well as lead to more costly repairs.

Any work platform found not to be in safe operating condition should be removed from service until repaired. All repairs should be made by authorized personnel in conformance with the manufacturer's operating, maintenance, and repair manuals.

MANUAl92379-002 May 1998 Revised 11/98

FIRST THREE MONTHS OF OPERATION As with any new machine, minor fluid leaks may occur until the various hydraulic components and pipe fittings are fully seated.

It is particularly important that, for the first three months of operation, all hydraulic components, hoses and pipe fittings be checked regularly for leaks and tightness, and corrective action taken as required.

The hydraulic pump, electric motor, cylinders and pressure valves are self-lubricating.

ROUTINE SERVICING NOTE: The following recommendations are based on advice of our component suppliers, and the requirements of various safety regulations. They should be followed with discretion based on factors such as amount and type of machine usage, environmental conditions, and local safety regulations.

IMPORTANT: Make certain that the unit is inspected per the operational checklist at the end of this section.

SHIFT SERVICE Hydraulic System Before checking the hydraulic fluid level, ensure that the machine booms are stowed in the traveling position, and the machine is standing on level ground. Fluid level must be to full mark on dipstick, located under filler cap. Refer to Lubrication Chart for correct grade of hydraulic fluid. Ensure that the filler cap is secure to prevent entry of water or other impurities into the tank.

Tire Condition Check that the tires are not damaged.

Platform Rails and Safety Gate Check security of platform and safety gate.

Steering Check the steer cylinder for fluid leakage. Inspect steering linkage for signs of wear.

Batteries Check the electrolyte level in battery cells. Replenish with distilled water, ifnecessary.

Pivot Pins Examine all pivot pins on booms and cylinders to ensure that they are positively secured in position.

Test All Machine Systems Test the operation of the drive assembly, including drive motor and steering. Test the operation of all machine boom functions.

MANUAl92379-002 May 1998 Revised 11198

Checklist Perform all items on the Shift Checklist found later in this section.

WEEKLY SERVICE Swing Bearing and Drive Pinion Gear Lubricate standard open swing bearing and drive pinion gear.

Checklist Perform all items on the Weekly Checklist found later in this section.

MONTHLY SERVICE Hydraulic System Pressurize the hydraulic circuit and inspect the system for any signs of leakage, particularly at flexible hoses, connections and hydraulic components. Check hydraulic fluid color. If the hydraulic fluid does not appear clear amber, but has a cloudy appearance, it is usually an indication that water is present.

A dark brown color, accompanied by a strong ''burnt'' smell, indicates that the fluid has overheated. If either condition occurs, a complete hydraulic fluid and filter change will be necessary.

Chassis Bolts Check all bolts for signs oflooseness. Refer to individual items in the Monthly Checklist.

Cylinders Check all cylinders for hydraulic fluid leakage.

Pivot Pins and Grease Fittings Lubricate all pivot pins and grease fittings.

Platform Mounting Check that platform weldments and platform frame members are in good condition.

Checklist Perform all items on the Monthly Checklist found later in this section.

SEMI-ANNUAL SERVICE Boom Cylinders Fully retract, then extend the boom lift cylinder. After each extreme position, check that there is no movement between cylinder rod and bearing housing, or between cylinder cap and tube.

MANUAL9237~002

May 1998

Revised 11/98

Hydraulic Filter Change the return filter element.

In severe use applications, more frequent filter changes will be necessary.

Checklist Perform all items on the Semi-Annual Checklist found later in this section.

ANNUAL SERVICE Note: Machine Annual Inspection Report Forms are available from TIME CONDOR. Flexible Hoses Inspect all hoses over their complete length. Replace any hoses showing looseness or corrosion at the end fittings. Replace hoses with cracking, blistering or excessive wear of outer protective covering.

Hydraulic Fluid If the hydraulic system has been properly maintained, the fluid should only need to be changed once each year. This, of course, will depend on machine application, amount of use, temperature, atmospheric conditions and other factors.

Hydraulic Fluid Tank Carefully check the condition of the fluid inside the tank to ensure that it flows easily and is of clear, amber color. In cases of gross contamination, it will be necessary to completely drain and refill the entire hydraulic system.

Structural Examination A thorough examination of the machine should be carried out for signs of corrosion, misalignment, material fractures, and other damage. Particular attention should be given to the condition of welded joints.

FOUR YEAR INTERVAL SERVICE Pivot Pins and Bearings Remove the pivot pins for examination. Check the pivot pin bearings with the pivot pins removed.

Replace with the correct type of pins and bearings, as necessary.

MA NUAl 92379·002 May 1998 Revised 11/98

SHIFT OPERATIONAL CHECKLIST All checks must be completed before operation of the unit.

These checklists can be copied as needed to aid in performing these inspections.

DATE:

INSPECTED BY: - - - - - - - - - -

MODEL NUMBER: ____________ SERIAL NUMBER: GENERAL INFORMATION

1.

2.

3.

Keep inspection records up-to-date.

Record and report all discrepancies to your supervisor.

A dirty machine cannot be properly inspected.

KEEP YOUR CONDOR MACHINE CLEAN!!!

A WARNING THIS CHECKLIST MUST BE USED AT DAILY INTERVALS OR AFTER EVERY 6 TO 8 HOURS OF USE, WHICHEVER IS SOONER. FAILURE TO DO SO COULD ENDANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS. INITIAL

DESCRIPTION 1. Check unit for any prior-shift or transportation damage, i.e. missing parts, torn or loose hoses, hydraulic fluid leaks, torn or disconnected wires, flat or damaged tires etc.

2. Check for machine damage, broken welds, improper or makeshift repaus.

3. Check hydraulic system for leaks, examine hoses for signs of excessive wear, chafing or twisting.

MANUAL9237S-002 May 1998 Revised11198

SHIFT OPERATIONAL CHECKLIST (Continued) INITIAL

DESCRIPTION 6. Check battery electrolyte leveL Check battery terminals for tight connections and cleanliness.

7. Check hydraulic fluid level. The level should be at the line marked on the sight gauge with the unit in stowed position. Inspect condition of hydraulic fluid in the reservoir. Fluid should be a clear amber color.

8. Check tires proper inflation pressure.

9. Check if wheel lug nuts are tight.

10. Inspect safety equipment as required by OSHA, government and local rules.

11. Inspect the work platform and boom structure for signs of damage and broken welds. Check platform gate latch for damage.

12. Check pivot pins for security.

13. Check that no attempt had been made to override the drive interlock system by a previous operator.

14. Check that all warning and instructional decals are legible and secure.

15. Check that the tilt alarm is working properly.

16. When all pre-inspection checks have been completed, test the ground controls for proper operation.

MANUAL92379·002 May 1998 Revised 11198

•

SHIFT OPERATIONAL CHECKLIST (Continued)

INITIAL

DESCRIPTION

21. With the main boom raised, check for the smooth operation of drive, creep speed.

ADDITIONAL MAINTENANCE REQUIREMENTS FOR HARSH ENVIRONMENTS

INITIAL

DESCRIPTION Inspect cylinder bolts, valve spool boots, etc., for cuts or other damage after every eight (8) hours of service. Repair if necessary.

Check hydraulic system for leakage after every eight (8) hours of operation.

MANUAL92379-Q02 May 1998 Revised 11198

WEEKLY OPERATIONAL CHECKLIST DATE:--------------

INSPECTED BY:

MODEL NUMBER: - - - - - - - -

SERIAL NUMBER: _ _ _ _ _ _ __

These checklists can be copied as needed to aid in performing these inspections.

GENERAL INFORMATION 1.

2.

3.

Keep inspection records up- to-date.

Record and report all discrepancies to your supervisor.

A dirty machine cannot be properly inspected.

Keep your Condor machine clean!!

A. WARNING THIS CHECKLIST MUST BE USED AT WEEKLY INTERVALS OR EVERY 25 HOURS, WHICHEVER OCCURS FIRST. FAILURE TO DO SO COULD ENDANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS. INITIAL

DESCRIPTION 1. Perform all checks listed on Shift Operational Checklist.

2. Check wheel lug nut torque.

3. Check hydraulic connections for leaks, corrosion and wear.

4. Lubricate swing bearing and drive pinion gear.

5. Apply lubricant swing to exposed swing bearing and drive pinion gear .

Check lubricant in optional oil bath swing bearing case, if so equipped, for proper level, and check for dirt or mental contamination.

MANUAL92379-002 May 1998 Revised 11198

MONTHLY OPERATIONAL CHECKLIST DATE:--------------------

INSPECTED BY:

MODEL NUMBER: -------------

SERIAL NUMBER: - - - - - - - - -

These checklists can be copied as needed to aid in performing these inspections.

GENERAL INFORMATION 1.

2.

3.

Keep inspection records up- to-date.

Record and report all discrepancies to your supervisor.

A dirty machine cannot be properly inspected.

Keep your Condor machine clean!!

A

WARNING

THIS CHECKLIST MUST BE USED AT MONTHLY INTERVALS OR EVERY 100 HOURS, WHICHEVER OCCURS FIRST. FAILURE TO DO SO COULD ENDANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS.

INITIAL

DESCRIPTION 1. Perform all checks listed on Shift and Weekly Operational Checklists.

2. Lubricate all grease fittings.

3. Lubricate all hydraulic valve spool linkages .

4. Check hose and electrical wire routed from the main boom, through the jib boom and to the platform for any damage.

5. Check torque of swing bearing bolts.

MANUAL92379-002 May 1998 Revised 11 /98

MONTHLY OPERATIONAL CHECKLIST (CONTINUED)

INITIAL

DESCRIPTION 8. Check adjustment and security of swing drive motor assembly.

There should be a slight amount of backlash between the turret and chassis when properly adjusted. Check torque of mounting bolts.

9. Check oil level in swing drive gear box.

10. Check oil level in power hubs.

11. Check that tires are not leaning in or out.

12. Check that wheel spindles turn freely, with no end play.

13. Check drive wheel power hub mounting bolt torque.

14. Check that neither the main boom nor jib boom drift with a full load, when there is no hydraulic pressure.

15. Check to make sure boom sections are not dented or bent.

16. Check that all adjustable flow valves are locked. Check settings if any are not locked.

MANUAL92379.002 May 1998

Revised 11198

•

SEMI-ANNUAL OPERATIONAL CHECKLIST DATE:--------------------

INSPECTED BY:

MODEL NUMBER: -------------

SERIAL NUMBER: - - - - - - - - -

These checklists can be copied as needed to aid in performing these inspections.

GENERAL INFORMATION 1.

2.

3.

Keep inspection records up- to-date.

Record and report all discrepancies to your supervisor.

A dirty machine cannot be properly inspected.

Keep your Condor machine clean!!

A WARNING THIS CHECKLIST MUST BE USED AT SIX MONTH INTERVALS OR EVERY 500 HOURS, WHICHEVER IS SOONER. FAILURE TO DO SO COULD ENDANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS. INITIAL

DESCRIPTION 1. Perform all checks listed on Shift and Weekly Operational Checklists .

2. Have hydraulic fluid sample analyzed at a test laboratory.

Comply with test results and recommendations to ensure long, trouble free operation.

NOTE: Ifhydraulic fluid has been regularly maintained, it should only require changing once every year, depending on maintenance, temperature, application, duty cycle, and atmospheric conditions.

3. Inspect the entire machine for signs of structural damage and broken welds, and worn or damaged components. Replace as necessary.

4. Clean and lubricate all electrical switches with an electrical contact cleaner and ensure that the switches operate freely in all positions.

5. Check the electrical mounting and hardware connections for security.

MANUAl92379·Q02 May 1998 Revised 11/98

SEMI-ANNUAL OPERATIONAL CHECKLIST (CONTINUED)

INITIAL

DESCRIPTION 6. Replace retum filter element.

7. Clean and lubricate the exposed swing bearing gear teeth with dry moly lube spray (not required for oil bath swing bearing option).

8. Repack front wheel bearings.

EVERY YEAR 9. Drain and replace fluid from hydraulic reservoir. Drain and replace fluid from drive wheel power hubs. Ifbadly contaminated, it may be necessary to disassemble and inspect components.

EVERY TWO YEARS 10. Drain and replace fluid from swing drive motor assembly. Ifbadly contaminated, it may be necessary to disassemble and inspect components.

MANUAL 92379-002 May 1998 Revised 11/98

•

APPENDIXA

BASIC STRESS

SAE GRADE 8

MAJOR AREA NOMINAL lllREADS

DlA INCH

SQ. IN

NOTES: I.TIllS CHART SHOWS RECOMMENDED BOLT TORQUES. 2.TORQUE =RX DXT R = .150 FOR UJB CONDITIONS R = .200 FOR DRY CONDITIONS TO ASSURE CONSISTENCY IN TORQUE, LUBRICATE FASTENERS WITH ENGINE OIL (MAY BE USED OIL) D = NOMINAL DIAMETER IN INCHES T = DESIRED CLAMP LOAD IN POUNDS = 75% PROOFLOAD X STRESS AREA MANUAL92379-002

May 1998 Revised 11198

APPENDIXB

TIME CONDOR Corporation

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

-THE TORQUE VALUES FOR EACH DIAMETER ARE ACCEPT ABLE FOR ANY THREAD PITCH IN THAT DIAMETER

DIAMETER

LUBRICATED DRY THREADS THREADS

DRY THREADS

LUBRICATED THREADS

DRY THREADS

LUBRICATED THREADS

DRY THREADS

LUBRICATED THREADS

M4

27.5*

17*

30*

18*

38.5*

24*

53*

32.5*

M5

56.5*

33.5*

61*

37*

78*

47*

107*

65*

M6

95*

57.5*

103*

61*

132*

79*

180*

109*

M8

19

12

21

13

27

16

37

22

MIO

39

23

42

25

53

32

73

44

M12

67

40

73

44

92

55

127

76

M14

107

64

116

69

146

89

203

122

M16

167

100

181

108

230

138

316

190

M20

325

195

352

211

449

269

617

370

M24

562

337

609

386

775

465

1066

640

M30

1117

670

1210

726

1540

924

2188

1271

MANUAL92379-002 May 1998 Revised 11/98

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BOOM-SUPPORTED ELEVATING AERIAL WORK PLATFORM

MODEL A38/42J SERIAL NUMBER 425980 19 AND UP

ILLUSTRATED PARTS MANUAL

MANUAL 92379-003 July 1998

•

CONDOR® Model A38/42J ILLUSTRATED PARTS BREAKDOWN CONTENTS FIGURE NO.

DESCRIPTION

PAGE

A ....................................... SERIALNUMBERLOCA TION ...................................... 2 B ........................................ HOW TO ORDER PARTS ............................................... 3 C ....................................... RECOMMENED SPARE PARTS LIST ............................ 5 1.1 ..................................... FINALASSEMBLY .......................................................... 6 21 2.2 2.3 2.4 25 2.6

..................................... CHASSIS INSTALLATION .............................................. ..................................... STEERIN"GINSTALLATION ......................................... ..................................... BATTERY BOX INSTALLATION .................................. ..................................... BATTERY CABLE KIT .................................................... ..................................... ELECTRIC MOTOR ........................................................ ..................................... WfIEELDRIVE ...............................................................

8 10 12 14 16 17

3.1 ..................................... HOSE KIT ........................................................................ 18 4.1 4.2 4.3 4.4 4.5

..................................... TURRET INSTALLATION .............................................. ..................................... HYDRAULIC FILTER ASSEMBLY ................................. ..................................... TURRET WIRING ASSEMBLY ....................................... ..................................... TURRET BOX ASSEMBLY .............................................. ..................................... UPPER-LOWER BOX CABLE ASSEMBLY ....................

20 22 23 24 26

5.1 5.1 5.2 5.3 5.4

..................................... BOOMINSTALLATION ................................................. ..................................... BOOMINSTALLATIONS/N 42598019 &UP ............... ..................................... CYLINDER ASSEMBLY ................................................. ..................................... REGENERATIVE MANIFOLD ASSEMBLY ................. ..................................... HOSE CARRIER INSTALLATION .................................

28 32 34 35 36

6.1 ..................................... JIB INSTALLATION ........................................................ 38 7.1 ..................................... PLATFORM INSTALLATION ........................................

7.2 ..................................... PLATFORM BOXASSEMBLY A38 .................................

7.3 ..................................... PLATFORM BOX ASSEMBLY A42J ................................

7.4" ..................................... 110VOLTLINETOPLATFORM ...................................

41 42 46 51

8.1 ..................................... DECAL KIT ..................................................................... 52

MANUAL 92379-003 July 1998 Revised 11f98

•

FIGUREA:SERIALNUMBERLOCATION

o

. ·.

O

TheCONDOR®ModelA38/42] Serial Number is stamped in two locations on the machine.

1.

Thefirst place the serial number is located is on the right hand side, stamped on the top of the rear axle housing.

2

The second place the serial number is located is on the right hand side at the rear of the turret.

The Data Plate is located at the right hand side in front of the axle.

MANUAL 92379-003 July 1998 Revi<edlll98

o

FIGUREC-RecornrnendedSparePartsList • CONDOR®MODELA38/42J (1 UNIT-1 YEAROPERATION)

QIY

PARTNUMBER

DESCRIPTION

Electricallnstallation 11 2060000100 ........ Diode 2 51913 .................. OperatorRedPIPuIl 2 51914 .................. Base + 1 NC Contact 12 40880 .................. Toggle Switch Guard 6 40874 .................. Switch, Toggle 50075 .................. Switch, Toggle 6 I 52671 .................. Operator 3 Pos Keyed 1 52029 .................. Base + 2 NO Contact 3 34383 .................. ContactBlockNO 6 34542 .................. Jumper 3 76386 .................. DiodeJumper 1 65355 .................. Resistor2.2KOHMS 67939-003 ........... Fuse Bussman 1 65360 .................. Level Sensor 1 2 81164 .................. LimitSwitchAssembly 51036 .................. LimitSwitchBodyOnly 1 51037 .................. OffsetHeadLimit Switch 1 51039 .................. Ann Adjustable 1 76011 .................. PotentiometerCOntrol 1 76012 .................. JoystickDrive Control 1 65356 .................. Relay SPDT 48VD C Fig. Mt. 2 65354-005 ........... Circuit Breaker Ther. 5A 1 34644-648 ........... Alann 1 1 34552-010 ........... TenninalStrip 2 67869 .................. Socket Relay 1 66751 .................. Foot Switch 4 76346 .................. QuickDisconnect48110 1 76013 .................. Charger,Battery48V 1 76363 .................. PlatfonnCOntrolBoxA38 1 76362 .................. PlatformCOntroIBoxA42J 1 76006 .................. SevconController

QIY

PARTNUMBER

DESCRIPTION

Hydraulic lnstallation 33430 .................. Filter Assembly 1 1 110-1 .................. Element-Filter 110-2 .................. FilterHead-Return 1 50316-OO1 ........... FilterBreather/Dipstick 1 1 76021 .................. Pump/Motor Assy DC 1 76021-104 ........... Motor Assembly 1 76021-101 ........... Pump Assembly 34814 .................. Regenerative Manifold 1 1 34799 .................. RegManifoldOnly 2 34369 .................. CartridgeLogicNO 2 35033 .................. Counterbalance Cart.

1 38167 .................. CavityBlockingPlug Decal Installation 1 76412-A38 .......... DecalKit 1 76105 .................. ControlBoxDecaIGround 76102 .................. ControlBoxDecalPlatform 1 Manual Installation 1 A630-A38-1 ....... Opr,Parts, Service Manual 1 92379-001 ........... Operator's Manual 1 76393 .................. Electric Schematic 1 76493 .................. Hydraulic Schematic

Drive Installation 76003 .................. Motor,Electric6HP 2 2 76004 .................. Brake, 37LB Saer 2 76018 .................. DrWheeIPlanetary 2 76019 .................. Torque Hub 4 76397 .................. CompressionRing Steering lnstallation 1 76036 .................. Knuckle WeldmentLH 1 76037 .................. Knuckle WeldmentRH 4 76081-001 ........... Pin We1dment 1.25 Dia 4 813680532 .......... Bearing1.25x1.50x2"L 76047 .................. Tie Rod 1 34341 .................. RodEnd-Male.75RH 2 34342 .................. Bushing Self Lube 4 2 66770-125 ........... Bearing, Thrustl-1I4 1 76502 .................. Cylinder, Steering 2 76017 .................. Hub Assembly, 6 Bolts 6" Dia. 4 76016 .................. Tire Assembly, 600-9x4.00 MANUAL 92379·003 July 1998 Revised 11198

•

FIGURE 1.1: Final Assernbly

0 I

(X)

1'0

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U~

~

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MANUAL 92379-003 July 1998 Revised 11/98

(fl--' _w 0 ZO

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FIGURE 1.1: Final Assembly • ITEM Ref. -1 2 3 4 5 6

-7 -8 -9 -10 11

PART Nl JMBER

DESCRIPTION

QTY

M-A38/42J-Ol ............. CondorModeIA38/42J-01 .................................................... Ref. 76369 .......................... FinalAssemblyDWG;M-A38-01 ............................................... 1 76370 .......................... FinaIAssemblyDWG;M-42J-01 ................................................. 1 76413 .......................... ChassisInstallation;A38/42J ....................................................... 1 A38-Turret ................... TurretInstallation ........................................................................ 1 A42J-Turret ................. TurretInstallation ........................................................................ 1 76483 .......................... BoomInstallation ....................................................................... 1 76484 .......................... BoomInstallation ....................................................................... 1 A42J-Jib ...................... Jib Installation ............................................................................. 1 A38-Platform ............... Platform Installation .................................................................... 1 A42J-Platform ............. Platform Installation .................................................................... 1 76412-A38/42J ............ DecalInstallation ........................................................................ 1 76393 .......................... ElectricSchematic ....................................................................... 1 92379-001 .................... Operator'sManuaIM-A38/42J-01 .............................................. 1 A630-A38-01 ............... Operator/Service/PartsManualA38/42J .................................... 1 76465-001 .................... HoseKit,A38 ............................................................................ 1 76465-002 .................... HoseKit,A42J ........................................................................... 1

- Indicates Items Not Shown

MANUAL 92379-003 July 1998 Revised 11/98

•

FIGURE 2.1 :Chassis Installation; A38/42J

3

18

MANUAL 92379-003 July 1998 Revised 11/98

FIGURE 2.1 :ChassisInstallation;A38/421 • DESCRIPTION

QIY

ITEM

PARTNlJMBER

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

76413 .......................... ChassisInstallation;A38/42J ................................................... Ref. 76413-DWG ............... InstallationDWG,A38/42JChassis .............................................. 1 76078 .......................... MainChassisWeldment;A38/42J ............................................... 1 76359 .......................... SteeringInstallation,A28/32J ...................................................... 1 76414 .......................... BatteryBoxlnstallation,A38/42J ................................................ 2 76487 .......................... Angle, Battery Box ...................................................................... 2 BOW30054 .................. Bolt .38-16UNC x 1.00" GR5 Hex ............................................. 4 BOW31433 .................. Washer,Flat3/8SAE ................................................................. 4 76358-002 .................... CableKit;A38/42JBattery ......................................................... 1 76358-DWG ............... DWG,A38/42JBatteryCableInstallation ................................... 1 ~ ... ~.ttQ.H.f....... TireAssembly,600-9x4.00 ........................................................ 4 76001 .......................... Tachometer Kit, DC ElecMotor ................................................ 1 65009-001 .................... Bolt .63-11UNCx 4.50 GR9 Hex ............................................. 16 76003 .......................... ElecDrive Motor, 6 HP ............................................................. 2 BOW30054 .................. Bolt .38-16UNC x 1.00" GRS Hex ............................................ 8 76004 .......................... Brake, 37LB Static Torque ......................................................... 2 BOW30105 .................. Bolt .50-13UNCx 1.25 Hex ....................................................... 4 76006 .......................... Controller ................................................................................... 1 BOW30281 .................. Bolt, Hex .50-20UNF x 1.500 ................................................... 24 76017 .......................... HubAssembly,6BoltsOn6" DIA ............................................. 2 76019 .......................... TorqueHub,50.29:1 ................................................................... 2 76397 .......................... CompressionRing,ITL .............................................................. 4 BOW36615 .................. NutHex.50-20UNF ................................................................ 18 76334 .......................... Strap, Static ................................................................................. 1 76346 .......................... Quick Disconnect, 48V 1/0AWG .............................................. 4 BOW30007 .................. Bolt .25-20UN C x 1.75" Hex ...................................................... 8 76345 .......................... CoverWeldment,DriveTube ..................................................... 1 CLY020000-001 .......... Trim-Seal,.56wx.0620pening101"L .......................................... 1 67928-240 .................... O-Ring 11.75 ID x 4.03 OD ....................................................... 1 65409-021 .................... Bumper, Rubber 1" OD x 1/2 H ............................................... 1 BOW36717-HD .......... Washer,Flat.63IDHeavyDuty ................................................. 18 76498 .......................... Stop Bracket, Turret .................................................................... 1

- Indicates Items Not Shown

MANUAL 92379-003 July 1998

Revised 11198

•

FIGURE 2.2 :Steering Installation; A28/38

4 5 6

15

3------+t-

8

9 11

8

MANUAL 92379·003 July 1998 Revised 11198

FIGURE 2.2 :Steering Installation; A28/38 . , DESCRIPTION

QTY

ITEM

PART NIJMBER

Ref. -1

76359 .......................... SteeringInstallation;A28/38 ................................................... Ref. 76359-DWG ............... SteeringlnstaliationDWG;A38/42J ............................................ 1 76036 .......................... KnuckleWeldment;A38/42JLH ................................................ l 76037 .......................... Knuckle Weldment;A38/42J RJI ............................................... 1 76081-001 .................... Pin Weldment; l.25"DIA ........................................................... 4 BOW30052 .................. Bolt .38-16 x .75 GR5 Hex ......................................................... 4 BOW31433 .................. Washer Flat, 3/8 SAE ................................................................. 4 76047 .......................... TieRod;A28/38 ........................................................................ 1 34341 .......................... Rod End - Male .75 RJI R#67821 .............................................. 2 BOW36176 .................. Bolt .75-10UNCx3.00GR8 Hex ............................................... 2 BOW31438 .................. Washer .75x 1.50D GRS SAEFlat ............................................. 2 BOW34278 .................. Nut - 3/4-10 Elastic Stop ........................... ;.r ............................ 2 76502 .......................... Cylinder; ArticulatedSteering ..m~.~f..l~.§UJ.Q........... 1 34342 .......................... Bushing,SelfLub ........................................................................ 4 81368-05-32 ................ Bearing; 1.25ID x 1.500D x 2"L ................................................ 4 66770-125 .................... Bearing - Thrust 11/4 ................................................................ 2 76489 .......................... Washer, Modified ....................................................................... 1 BOW2506 ................... Hitch Pin, 3/16 x 35/8 .............................................................. 1

2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17

- Indicates Items Not Shown

MANUAL 92379-003 July 1998

Revised 11198

fa

FIGURE2.3:Battery Box Installation; A38/42J

5

2

12

10

MANUAL 92379-003 July 1998

Revised Ui98

FIGURE 2.3 :Battery Box Installation; A38/421 DESCRIPTION

QTY

ITEM

PARTNUMBER

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

76414 .......................... BatteryBoxlnstallation;A38/42J ............................................ Ref. 76414-DWG ............... DWG;BatteryBoxInstallation ................................................... 1 76064 .......................... BoxWeldment,Battery ............................................................... 1 76065 .......................... Cover,Battery ............................................................................ 1 76347 .......................... Insulation;BatteryCover ............................................................. 1 54048 .......................... Latch - Door .............................................................................. 1 BOW30004 .................. Bolt .25-20UNC x 1.00" GR5 Hex ............................................. 2 BOW31431 .................. Washer.25IDx.630DFlat ........................................................ 4 50554 .......................... J- Bolt 5/16 x 13 114 - Battery ................................................... 2 BOW34324 .................. Nut-5/16-18UNCWing ........................................................... 2 52793 .......................... Battery;6V305AH165RCM ....................................................... 4 BOW34272 .................. Nut-25-20UN"CNylonLock ................................................... 2 76470 .......................... Angle, A38/42J Battery Clamp .................................................... 1

- Indicates Items Not Shown

MANUAL 92379-003 July 1998 Revised 11198

fJ)

•

FIGURE2.4:BatteryCableKit

7

5 6

+

CHASSIS

@

2 PL POWER UNIT

TURRET

MANUAL 92379-003 July 1998

Revised 11198

FIGURE 2.4: Battery Cable Kit . ,

QTY

ITEM

PART NUMBER

DESCRIPTION

Ref. 1 2 3 _-- 4

76358-002 ....................

76358-DWG ...............

76356-043.00 ...............

76356-038.00 ...............

54247-007.00 ...............

54247-016.00 ...............

54247-082.00 ...............

54247-035.00 ...............

76356-055.00 ...............

76361-030.00 ...............

76361-033.00 ...............

76361-040.00 ...............

76361-025.00 ...............

76361-026.00 ...............

54247-100.00 ...............

BatteryCableKit ..................................................................... Ref InstallationDWG,A38BatteryKit .............................................. 1 Cable Assembly-43.0" Large Battery ........................................... 2 Cable Assembly-38.0" Large Battery ............................................ 2 CableAssembly-6.5" LargeBattery ............................................. 6 Cable Assembly-16.0"LGBattery ................................................ 6 CableAssembly-16.0" Large Battery ........................................... 1 Cable Assembly-35.0" Large Battery ........................................... 1 CableAssembly-55.0" Large Battery ........................................... 1 CableAssembly-30.0" Large Battery ........................................... 1 CableAssembly-33.0" Large Battery ........................................... 1 Cable Assembly-40.0" Large Battery ........................................... 1 CableAssembly-25.0" Large Battery ........................................... 2 CableAssembly-26.0" Large BAttery .......................................... 1 CableAssembly-100.00" Large Battery ....................................... 2

5 6 7 8 9 10 11 12 13

-Indicates Items Not Shown

rr====jjm=========nn

S2 51

A1 A2

A2 A1

~E VCON

/cON TROLLER Sl S2

CHi\SSIS DRIVE

TUBE

MANUAL 92379-003 July 1998

Revised 11198

FIGURE 2.5:Motor, Elec6HP DESCRIPTION

QTY

ITEM

PART NUMBER

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

76003 .......................... Motor, Elec 6 Hp ................................................................... Ref. 76003-101 .................... DriveEndhead ........................................................................... 1 76003-102 .................... Bearing ....................................................................................... 1 76003-103 .................... RetainingRing ............................................................................. 1 76003-104 .................... Fan ............................................................................................. 1 76003-105 .................... Armature & Fan Assembly .......................................................... 1 76003-106 .................... Field Coil Kit .............................................................................. 1 76003-107 .................... Brush ......................................................................................... 2 76003-108 .................... Brush Spring ............................................................................... 2 76003-109 .................... Brush Box Assembly ................................................................... 1 76003-110 .................... Brush Lead Assemb ly Kit ............................................................ 1 76003-111 .................... Bearing ....................................................................................... 1 76003-112 .................... WavyWasher .............................................................................. 1 76003-113 .................... CommutatorEndhead ................................................................ 1 76003-114 .................... HeadbandAssembly(M:) ................................................ _............ 1

- Indicates Items Not Shown Drawing not available at this time

MANUAL 92379-003 July 1998 Revised II (98

., NIlTEI

DlN ELECTRICAl ctlHHECTQR" TYPE EHPM ME. MANJFACruREJ)

IN UL APPRIlVElI CSA HIli! TEMPERAl'IH: MATERIAl.

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lEB40-14

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lEB4G-40D4 lE11-4O-4OO3 8001113 8001301

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113 II 8 7 II

1£840-1707 lEB+O-2II01

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1.00 1.00 A 3.00 1.00 1.00 1.00 11.00 3.00 3.00 2.00 3.00 1.00

1.00 1.00 1.00 QTY

7Il004-1111 7Il004-115 7Il004-114 7Il004-113 7Il004-112 7Il004-111 7Il004-1113 7Il004-109 7Il004-108 7Il004-107 7Il004-1011 7Il004-105 7Il004-104 7Il004-103 7Il004-102 7Il004-101 CCIIlCft saNCI£ P

o-RING o-RING

SHIW IWIUAL. R£l. SUB-ASSY 1N1ERHAL. aJP EXTERNAL aJP CALL. IlEMlNG COIiIPRESSICIII SPf!IHQ soa<ET lID eN!' SCREW SPACER CJU1EIII PLATE FRlCllON PI.ATE - SOlID NOOfI1\NG PLATE SHAfT

ARMAlIlRE UAGNET " cat. ASSDIlI.Y DESaaP1lON

VENDOR: MATRIX ENGINEERING

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BRAKE, 37 LB SAER

....

76004

8 1 Ql'1

·

16

S001430

15

1.00

76004-116

O-RING

1.00

76004-115

O-RING

14

1E840-4004

AIR

76004-114

SHIM

13

1EB40-4003

3.00

76004-113

MANUAL REL SUB-ASSY

12

S001113

1.00

76004-112

INTERNAL CLIP

11

S001301

1.00

76004-111

EXTERNAL CLIP

10

S001901

1.00

76004-110

CALL BEARING

9 8

S009364

6.00

76004-109

COMPRESSION SPRING

S008895

3.00

76004-108

SOCKET HD C,A,P SCREW

7

1E840-1707

3.00

76004-107

SPACER

6

1E840-2501

2.00

76004-106

OUTER PLATE

5

1E840-1305

3.00

76004-105

FRICTION PLATE -

4

1EB40-21 06

1.00

76004-104

3

1E840-11 08

1.00

76004-103

MOUNTING PLATE SHAFT

2

1EB40-1209

1.00

76004-102

ARMATURE

1

1E840-1812

1.00

76004-101

MAGNET & COIL ASSEMBLY

ITEM

MATRIX PIN

QTY

CONDOR SERVICE PIN

DESCRIPTION

SOLID

= ;

~

J )

J j

,j j j ) ~

J J

,] )

J j

J

FIGURE 2.6:WheeIDrive, 33.79: 1 Planetary •

p

X·

RETAINING RING SELECTION RING THICKNESS

PART NO

.107-.105 .112-.110 .117-.115

14-00-139-042

.107-.111 112-.116 .117-.121 .12 -.1 .. 1 132-.136

.132- 130

14-00-139-043 14-00-139-044 14-00-1 9-045 14-00-139-046

.137-.141

.137-.135

14-00-139-047

.12.2-.126

.122-.120 12 -.125

C

14-00-139-041

15-45 LB

n

16-21 l6

n

15-45 LB

n

21

STAMP COVER ON GROUND SURFACE f'ROVlDED

?

LEGIBLY STAMP FINAL ASSEMBLER'S NAME

0/'1 MACHINED SURFACE Of fLANGE CODe

6J01166

II

L

DAY Of /¥IONTH

>EAR (LAST O<01T)

MONTH (SEE $TO-l02 fOR

ITEM

PARTNUMBER

Ref. 1 2 3 4 5

76018 ..........................

6171101 .......................

14-00-044-010 .............

04-01-101-35 ...............

04-01-102-12 ...............

04-01-101-17 ...............

6

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

DESCRIPTION

QTY

WheelDrive,33.79:1Planetary ................................................ Ref. Shaft-Output .............................................................................. 1 Seal-Oil ...................................................................................... 1 Bearing-Cone ............................................................................. 1 Bearing-Cup ............................................................................... 2 Bearing-Cone ............................................................................ 1 *** ............................... Ring-Retaining ............................................................................ 1 10-00-041-002 ............. Compound-Sealing ............................................................ 2PLCS 14-14-165-001 ............. Cover ......................................................................................... 1 03-04-101-01 ............... Plug-Pipe .................................................................................... 1 14-14-165-001 ............. Gear-PriSun .............................................................................. 1 95-04-115-01 ............... Washer-Thrust ............................................................................ 1 14-00-191-003 ............. Plug-Shipping ............................................................................. 1 0000179820 ................. Bolt-HexHead ........................................................................... 8 6659122 ....................... Assembly-Pri Carrier ................................................................... 1 616226 ......................... Gear-Ring .................................................................................. 1 665952 ......................... Assembly-SecCarrier .................................................................. 1 14-00-183-006 ............. Bolt-Wheel ................................................................................. 9 617946 ......................... Hub ........................................................................................... 1 14-00-047-002 ............. Washer-Flat .............................................................................. 12 6188315 ....................... Bolt-HexHead ......................................................................... 12 14-00-052-002 ............. Plug-Pipe .................................................................................... 1

- Indicates Items Not Shown MANUAL 92379-003

July 1998 Remed 11198

coor)

FIGURE 3.1 :HoseKit, A38/42J

~!

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-----------------------------_.-/

o..............

MANUAL 92379·003 July 1998

Revised 11198

....................·

~

FIGURE3.1:HoseKit,A38/42J • DESCRIPTION

QTY

ITEM

PART NUMBER

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

76465 .......................... Hose Kit, A38/ 42J ................................................................. Ref. 76465-DWG ............... HoseKitlnstallationDWG;A38/42J .......................................... 1 66044-276.00 ............... Hose Assembly #04 67685 J37 ST-ST ......................................... 1 66044-276.00 ............... Hose Assembly #04 67685 J37 ST-ST ......................................... 1 66848-087.00 ............... Hose Assembly #04 67685 J37 ST-90L ....................................... 1 66848-087.00 ............... Hose Assembly #0467685 J37 ST-90L ....................................... 1 66044-100.00 ............... Hose Assembly #04 67685 J37 ST-ST ......................................... 1 66044-100.00 ............... Hose Assembly #04 67685 J37 ST-ST ......................................... 1 66044-041.00 ............... Hose Assembly #0467685 J37 ST-ST ........................................• 1 66044-041.00 ............... Hose Assembly #0467685 J37 ST-ST ......................................... 1 66698-046.00 ............... Hose Assembly #0666645 J37 ST-ST ......................................... 1 66698-043.00 ............... Hose Assembly #0666645 J37 ST-ST ......................................... 1 66698-043.00 ............... Hose Assembly #0666645 J37 ST-ST ......................................... 1 66044-312.00 ............... Hose Assembly #0467685 J37 ST-ST ......................................... 1 66044-312.00 ............... Hose Assembly #04 67685 J37 ST-ST ......................................... 1 66044-300.00 ............... Hose Assembly #0467685 J37 ST-ST ......................................... 1 66044-300.00 ............... Hose Assembly #04 67685 J37 ST-ST ......................................... 1 66044-246.00 ............... Hose Assembly #04 67685 J37 ST-ST ......................................... 1 66044-246.00 ............... Hose Assembly #0467685 J37 ST-ST ......................................... 1 66044-012.00 ............... Hose Assembly #04 67685 J37 ST-ST ......................................... 1 66044-012.00 ............... Hose Assembly #0467685 J37 ST-ST ......................................... 1 66044-600.00 ............... Hose Assembly #04 67685 J37 ST-ST ......................................... 1 66044-612.00 ............... Hose Assembly #04 67685]37 ST-ST ......................................... 1 66044-600.00 ............... Hose Assembly #04 67685 J37 ST-ST ......................................... 1 66044-612.00 ............... Hose Assembly #04 67685 J37 ST-ST ......................................... 1 66044-576.00 ............... Hose Assembly #0467685]37 ST-ST ......................................... 1 66044-576.00 ............... Hose Assembly #04 67685 J37 ST-ST ......................................... 1

22 23 24

- Indicates Items Not Shown

MANUAL 92379·003 July 1998 Revised 11/98

•

FIGURE4.1 :Turret Installation

8 6

4

7

10 11

3

12

9

MANUAL 92379-003

July 1998 Revised 11/98

FIGURE 4.1 :Turret Installation . , DESCRIPTION

QTY

ITEM

PARTNUMBER

Ref. Ref. 1 2

A38-Turret ................... TurretInstallation .................................................................... Ref. A42J-Turret ................. Turret Installation .................................................................... Ref. 76000 .......................... Motor,Hydraulicl0CIPR(R#68697) .......................................... 1 76009 .......................... HydraulicControlValve .............................................................. 1 76010 .......................... Hydraulic Control Valve .............................................................. 1 76013 .......................... Charger;48VBattery .................................................................. 1 76021 .......................... Pump/Motor Assembly; DC ...................................................... 1 76046" .......................... SwingGear;A38/42J ................................................................. 1 76108-001 .................... Cover;A38/42JTurretLH ......................................................... 1 76108-002 .................... Cover; A38/42J Turret RH ......................................................... 1 76109 .......................... Cover;A38/42JCounterweight .................................................. 1 76398 .......................... HydraulicTank;A38/42J ............................................................ 1 33430 .......................... FilterAssembly-Hydraulic ......................................................... 1 50316-001 .................... Filter Breather W/Dipstick .......................................................... 1 76259 .......................... TurretWeldment ........................................................................ 1 76267-001 .................... Pin Weldment;2"DIAx 11.68"LG.............................................. 3 76480 .......................... Pin Cap; For2" Pin ..................................................................... 3 76392-003 .................... Turret WiringAssembly;A38 ....................................................... 1 76392-004 .................... Turret WiringAssembly,A42J ..................................................... 1 76371 .......................... Closeout;A38/42JCenter ........................................................... 1 76259-A42J .................. Turret Weldment;A42J .......................:;;.('i1;:: ....:;......,s,O/, ........ 1 65009-001 .................... Bolt .63-11 UNC x 4.50 GR9 Hex .......f:b.ij;, ... ( .... /.... :.7 ......... 22 65009-003 .................... Bolt .63-11 UNC x 5.50 GR9 Hex ....c..s.. ....f€.::... !..~-:I:::l............ 2 76486 .......................... Stop,A38/42JTurret ................................................................. 1 BOW36717-HD .......... Washer,Flat.631DHeavyDuty ................................................. 24

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

- Indicates Items Not Shown

MANUAL 92379-003 July 1998 Revised 11/98

•

FIGURE 4.2:Filter Assembly-Hydraulic

DESCRIPTION

QTY

ITEM

PARTNUMBER

Ref. 1 2

33430 .......................... Filter Assembly-Hydraulic ..................................................... Ref. 110-2 ........................... FilterHead-ReturnLine ............................................................. 1 110-1 ........................... Element-Filter ........................................................................... 1

- Indicates Items Not Shown

MANUAL 92379-003 July 1998

Revised 11198

FIGURE 4.3 :Turret WiringAssembly; A38/42J

ITEM

PART NUMBER

Ref. -1

76392-003/004 ............ TurretWiringAssembly;A38/42J ........................................... Ref. 76374 .......................... Box Assembly; A38 Turret .......................................................... 1 76373 .......................... BoxAssembly;A42JTurret ......................................................... 1 76386 .......................... DiodeJumper; 12" ..................................................................... 1 76385 .......................... DiodeJumper; 8" ....................................................................... 1 76384 .......................... DiodeJumper; 6" ....................................................................... 6 76377-003 .................... CableAssembly;A38Upper-LowerBox .................................. 1 76377-004 .................... CableAssembly;A42JUpper-LowerBox ................................... 1 76378-003 .................... Cable;A38 Upper Box To Chassis .............................................. 1 76378-004 .................... Cable;A28/42JChassis ............................................................... 1 76380 .......................... Cable;A28/42JChassis ............................................................... 1 65360 .......................... Level Sensor; 48 VDC ................................................................ 1 54910-105 .................... StrainRelief-ST-21 .................................................................... 1 66992 .......................... Plug-l0Contact ........................................................................ 1 65358 .......................... Hood; Top Entry ....................................................................... 1 81164 .......................... Limit Switch Assembly ......

2

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

DESCRIPTION

OTY

00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Indicates Items Not Shown Drawing not available at this time

MANUAL 92379-003

July 1998 Revised 11198

8)

•

FIGURE4.4:BoxAssembly,A38/42JTurret

o

o

o

o

o

P

D

000

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e

MANUAL 92379-003 July 1998 Revised 11/98

I l--0i

FIGURE4.4:BoxAssembly,A38/42JTurret . , ITEM

PART NUMBER

DESCRIPTION

QTY

Ref. 76373 .......................... BoxAssembly,A38 Turret ...................................................... Ref. Ref. 76374 .......................... Box Assembly, A42J Turret ..................................................... Ref. 1 76268 .......................... Box, Lower Control-Machined ................................................. 1 2 34552-012 .................... TerminalStrip-12Position ......................................................... 1 3 76075 .......................... Diode Circuit Board ................................................................... 1 4 76382 .......................... Decal,LowerBoxTags .............................................................. 1 5 76379 .......................... CableAssembly,LowerBoxToChassis ...................................... 1 6 Jr~ .1'~1~...... BatteryCondition/HourMeter ................................................... 1 7 51913 .......................... Operator, RedP-Pull ZB2-BT4 .................................................. 1 8 51914 .......................... Base + 1 NC Contact ZB2-BZI02 .............................................. 1 9 40874 .......................... ToggleSwitch-DPDT (A38) ..................................................... 3 40874 .......................... ToggleSwitch-DPDT (A42J) .................................................... 4 10 40880 .......................... Guard, Toggle Switch (A38) ....................................................... 3 40880 .......................... Guard, Toggle Switch (A42J) ...................................................... 4 11 52671 .......................... Operator,3POSRotkyZB2BG3 ............................................... 1 12 52029 .......................... Base + 2NO ContactsZB2-BZ103 ............................................ 1 13 34383 .......................... ContactBlock,NOZB2-BE101 ................................................. 3 14 67114-009 .................... Strain Relief 3/4NPT (.63-.75) ................................................... 1 15 67123-002 .................... Seal, Connector Elect. 3/4" ......................................................... 1 16 67124-002 .................... Locknut-3/4NPTConduit ....................................................... 1 17 BOW31231 .................. Nut #6-32 Hex Keps ................................................................. 2 18 34542 .......................... Jumper ....................................................................................... 1 19 65355 .......................... Resistor, 2.2K OHMS 2Watt ................................................... 1 20 206-00001-00 ............... Diode ........................................................................................ 1 21 BOW31071 .................. Mach ScrewFH #6-32NC x 1/2 ................................................ 2 22 BOW31070 .................. Mach ScrewFH #6-32NC x 1/4 ................................................ 4 23 BOW31529 .................. PlugButton.50DIA(A38) ......................................................... 4

30 31

76377-003 .................... Cable Assembly, Upper To Lower Box .................................. Ref. 76377-004 .................... Cable Assembly, Upper To Lower Box .................................. Ref. 76105 .......................... Decal, TurretControlBox ...................................................... Ref.

- Indicates Items Not Shown

MANUAL 92379-003 July 1998

Revised 11198

flit FIGURE4.5:CableAssembly;A38/42JUpper-LowerBox

4

C1

MANUAL 92379·003

JulyJ998 Revised 11198

FIGURE 4.5:CableAssembly; A38/42JUpper-LowerBox •

ITEM

PARTNUMBER

DESCRIPTION

Ref. Ref. 1 2 3

76377-003 ....................

76377-004 ....................

51325 ..........................

66652-002 ....................

66655-010 ....................

66655-011 ....................

54910-105 ....................

76377-DWG ...............

Cable Assembly; A38/42J Upper - Lower Box ...................... Ref. Cable Assembly; A38/42J Upper -Lower Box ...................... Ref. Cable 24 Conductor 16GA ......................................................... ..

Plug, Male 24 Contacts #1-24 ..................................................... 1 Hood; Top E ntry 24 Contacts .................................................... 1 Hood, Side Entry24 Contacts ..................................................... 1 StrainRelief,ST21 ....................................................................... 1 CableAssemblyDWG;UpperToLowerBox ............................ l

4 5

- Indicates Items Not Shown

MANUAL 92379-003 July 1998 Revised 11198 .

OTY

•

FIGURE 5. l:BoomInstallation; A38/42JtoSN#42598019

MANUAL 92379-003 July 1998 Revised 11/98

FIGURE 5.1 :Boom Installation; A38 to SN #42598019 . ,

DESCRIPTION

QTY

ITEM

PARTNUMBER

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

76483 .......................... BoomInstallation;A38 ........................................................... Ref. 76066-006 .................... PinWe1dment; Slave Cylinder Base End ....................................... 1 76069 .......................... Pin Cap; l"DIAPin .................................................................... 1 76066-007 .................... Pin Weldment;MasterCylinder Rod End .................................... 1 76069 .......................... Pin Cap; l"DIAPin .................................................................... 1 76066-008 .................... PinWe1dment;MasterCylinderBaseEnd .................................... 1 76069 .......................... Pin Cap; l"DIAPin .................................................................... 1 76129 .......................... Lift Cylinder, Lower Boom ........................................................ 1 76130 .......................... Lift Cylinder, Upper Boom ......................................................... 1 76464 .......................... Cylinder Assembly;A38BoomExt .............................................. 1 76208 .......................... Bearing Pad; AD] 11/4-7 UNC ................................................. 4 76256 .......................... Base Boom Weldment; A38 ........................................................ 1 76267-001 .................... Pin Weldment,2"DIAx 11.68"LG .............................................. 2 76269 .......................... Pin Cap; 2" Pin ........................................................................... 2 76267-002 .................... Pin Weldment;2"DIAx 11.12"LG ............................................. 4 71983 .......................... RubberPad,S"x5 x1/4" ............................................................ 5 76267-003 .................... Pin Weldment;2 DIAx7.18"LG .............................................. 2 37398-002 .................... Wrap-Track/Boom .................................................................... 1 76274 .......................... Boom We1dment;A38 Lower ..................................................... 1 76275 .......................... Tension Link We1dment; Lower Boom ....................................... 1 76282 .......................... WearPad;A38 Tip/Base Top ..................................................... 1 76283 .......................... Wear Pad; A38 Tip/Base Bottom ............................................... 1 76294 .......................... Wear Pad; Base/Mid Boom Bottom ........................................... 1 76295 .......................... Wear Pad; Base/Mid Top ........................................................... 1 76308-001 .................... Pin; Ext CylinderRodEnd ......................................................... 1 76308-002 .................... Pin Ext Cylinder BaseEnd .......................................................... 1 76311 .......................... Wear Pad; .50 x 1.00 x 2.50 ......................................................... 2 76312 .......................... Mid-PostWeldmentA38 ............................................................ 1 76337 .......................... HoseCarrierInstallation;A38 ...................................................... 1 76127 .......................... Master Cylinder; Upper Boom .................................................... 1 76128 .......................... Slave Cylinder; Upper Boom ....................................................... 1 76257 .......................... Boom Weldment;A38 Tip .......................................................... 1 81494-002 .................... Cover - 86A Arm Hose 77112"LG ............................................ 1 76427 .......................... Retainer;A38HydraulicHose ...................................................... 1 BOW36835 .................. Bolt.38-16UNCx 1.25 Flat SOC ............................................... 2 BOW34272 .................. Nut-25-20UNC Nylon Lock .................................................... 6 76267-004 .................... Pin Weldment;2"DIAx 10.56"LG .............................................. 2 76471 .......................... CableClamp;A38 ...................................................................... 1 76472 .......................... Cover Base Boom, A38 .............................................................. 2 BOW36000 .................. Screw .25-20UNC .50"HD Cap Hex .......................................... 4 BOW36701 .................. Washer-l/4Flat ....................................................................... 4 BOW31325 .................. Washer-.25IDSplitLock ............................................................ 4 BOW36818 .................. Screw, Cap Flat Head .2S-20UNC 2L ......................................... 2 37398-004 .................... Wrap-Track3146/54 .................................................................. 3 I

I

- Indicates Items Not Shown

MANUAL 92379-003 July 1998 Revised 11/98

•

FIGURE 5.l:BoomInstallation;A42JtoSN#42598019

MANUAL 92379·003 July 1998 Revised 11/98

FIGURE 5.1:BoomInstallation;A38toSN#42598019 • DESCRIPTION

QTY

ITEM

PARTNUMBER

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

76483 .......................... BoomInstallation;A38 ........................................................... Ref. 76066-006 .................... Pin Weldment; Slave Cylinder Base End ....................................... 1 76069 .......................... Pin Cap; l"DIAPin .................................................................... 1 76066-007 .................... Pin Weldment; Master Cylinder Rod End .................................... 1 76069 .......................... Pin Cap; l"DIAPin .................................................................... 1 76066-008 .................... Pin Weldment;MasterCylinder Base End .................................... 1 76069 .......................... Pin Cap; l"DIAPin .................................................................... 1 76129 .......................... LiftCylinder,LowerBoom ........................................................ 1 76130 .......................... Lift Cylinder, Upper Boom ......................................................... 1 76464 .......................... CylinderAssembly;A38BoomExt .............................................. 1 76208 .......................... Bearing Pad; AD] 11/4-7UNC ................................................. 4 76256 .......................... Base Boom Weldment;A38 ........................................................ 1 76267-001 .................... Pin Weldment,2"DIAxl1.68"LG .............................................. 2 76269 .......................... PinCap;2"Pin ........................................................................... 2 76267-002 .................... Pin Weldment;2" DIAx 11.12"LG ............................................. 4 71983 .......................... Rubber Pad,5"x5"x1/4" ............................................................ 5 76267-003 .................... PinWeldment;2"DIAx7.18"LG .............................................. 2 37398-002 .................... Wrap-Track/Boom .................................................................... 1 76274 .......................... Boom Weldment; A38 Lower ..................................................... 1 76275 .......................... TensionLinkWeldment;LowerBoom ....................................... 1 76282 .......................... Wear Pad; A38Tip/BaseTop ..................................................... 1 76283 .......................... WearPad;A38 Tip/Base Bottom ............................................... 1 76294 .......................... Wear Pad; Base/Mid Boom Bottom ........................................... 1 76295 .......................... WearPad;Base/MidTop ........................................................... 1 76308-001 .................... Pin; Ext Cylinder Rod End ......................................................... 1 76308-002 .................... Pin Ext Cylinder Base End .......................................................... 1 76311 .......................... WearPad;.50x1.00x2.50 ......................................................... 2 76312 .......................... Mid-PostWeldmentA38 ............................................................ 1 76337 .......................... HoseCarrierInstallation;A38 ...................................................... 1 76127 .......................... Master Cylinder; Upper Boom .................................................... 1 76128 .......................... Slave Cylinder; Upper Boom ....................................................... 1 76257 .......................... BoomWeldment;A38Tip .......................................................... l 81494-002 .................... Cover _86A Arm Hose 77 112"LG ............................................ 1 76427 .......................... Retainer;A38 Hydraulic Hose ...................................................... 1 BOW36835 .................. Bolt.38-16UNCx 1.25 Flat SOC ............................................... 2 BOW34272 .................. Nut-25-20UNCNylonLock .................................................... 6 76267-004 .................... Pin Weldment;2"DIAx 10.56"LG .............................................. 2 76471 .......................... CableClamp;A38 ...................................................................... 1 76472 .......................... Cover Base Boom, A38 .............................................................. 2 BOW36000 .................. Screw .25-20UNC .50"HD Cap Hex .......................................... 4 BOW36701 .................. Washer-l/4Flat ....................................................................... 4 BOW31325 .................. Washer-.25IDSplitLock ............................................................ 4 BOW36818 .................. Screw, Cap FlatHead .2S-20UNC 2L ......................................... 2 37398-004 .................... Wrap-Track3146/54 .................................................................. 3

- Indicates Items Not Shown

MANUAL 92379·003 July 1998 Revised 11/98

•

FIGURE 5.1:Boomlnstallation;A38/42J SN#42598019andabove

35

37

3' 3J

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of! il

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.'~------r--------L------',ii

!(§~~J~~)

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MANUAL 92379-003 July 1998

Revised II 198

FI GURE 5.1 :Boom Installation; A3 8/42J SN #425980 19 and above DESCRIPTION

QTY

ITEM

PARTNUMBER

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

76525 .......................... Boomlnstallation;A38-02 ...................................................... Ref. 76066-006 .................... Pin Weldment; Slave Cylinder Base End ....................................... 1 76069 .......................... PinCap;l"DIAPin .................................................................... 1 76066-007 .................... Pin Weldment;MasterCylinderRodEnd .................................... 1 76069 .......................... Pin Cap; l"DIAPin .................................................................... 1 76066-008 .................... Pin Weldment;MasterCylinderBaseEnd .................................... 1 76069 .......................... Pin Cap; l"DIAPin .................................................................... 1 76129 .......................... Lift Cylinder, Lower Boom ........................................................ 1 76130 .......................... Lift Cylinder, Upper Boom ......................................................... 1 76464 .......................... Cylinder Assembly;A38BoomExt .............................................. 1 76208 .......................... Bearing Pad; ADJ 11/4-7 UN C ................................................. 4 76508 .......................... Base Boom Weldment;A38 ........................................................ 1 76267-001 .................... Pin Weldment,2"DIAx 11.68"LG .............................................. 2 76269 .......................... Pin Cap; 2" Pin ........................................................................... 2 76267-002 .................... Pin Weldment;2"DIAx 11.12"LG ............................................. 4 71983 .......................... RubberPad,5"x5"xl/4" ............................................................. 5 76267-003 .................... Pin Weldment;2" DIAx7.18"LG .............................................. 2 37398-002 .................... Wrap-Track/Boom .................................................................... 1 76274 .......................... Boom Weldment;A38Lower ..................................................... 1 76275 .......................... TensionLinkWeldment;LowerBoom ....................................... 1 76282 .......................... Wear Pad; A38 Tip/Base Top ..................................................... 1 76283 .......................... WearPad;A38 Tip/BaseBottom ................................................ 1 76294 .......................... Wear Pad; Base/Mid Boom Bottom ........................................... 1 76295 .......................... WearPad;Base/MidTop ........................................................... 1 76308-001 .................... Pin; ExtCylinderRodEnd ......................................................... 1 76308-002 .................... Pin Ext Cylinder Base End .......................................................... 1 76311 .......................... Wear Pad; .50 x 1.00 x 2.50 ......................................................... 2 76509 .......................... Mid-PostWeldmentA38 ............................................................ 1 76337 .......................... HoseCarrierInstallation;A38 ...................................................... 1 76127 .......................... Master Cylinder; Upper Boom .................................................... 1 76128 .......................... Slave Cylinder; Upper Boom ....................................................... 1 76257 .......................... Boom Weldment;A38 Tip .......................................................... 1 81494-002 .................... Cover-86AArmHose77112"LG ............................................ 1 76427 .......................... Retainer; A38 Hydraulic Hose ...................................................... 1 BOW36835 .................. Bolt .38-16UNC x 1.25 Flat SOC ................................................ 2 BOW34272 .................. Nut-25-20UNCNylonLock .................................................... 6 76267-004 .................... PinWeldment;2"DIAx10.56"LG .............................................. 2 76471 .......................... CableClamp;A38 ...................................................................... 1 76472 .......................... Cover Base Boom, A38 .............................................................. 2 BOW36000 .................. Screw.25-20UNC.50"HDCapHex .......................................... 4 BOW36701 .................. Washer - 1/4 Flat ....................................................................... 4 BOW31325 .................. Washer-.25IDSplitLock ............................................................. 4 BOW36818 .................. Screw, Cap Flat Head .25-20UNC 2L ......................................... 2 37398-004 .................... Wrap-Track3146/54 .................................................................. 3

- Indicates Items Not Shown

MANUAL 92379·003 July 1998

Revised 11/98

e

•

FIGURE 5.2:Cylinder Assembly DESCRIPTION

QIY

ITEM

PARI NUMBER

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

76464 .......................... Cylinder Assembly .................................................................. Ref. 76131 .......................... Extension Cylinder-Upper Boom ............................................... 1 34814 .......................... ManifoldAssembly,Regenerative ................................................ 1 76310 .......................... Wear Pad ................................................................................... 2 BOW36815 .................. Bolt, Soc. Flat .25-20 UNC x 1.0 ................................................. 4 02448 .......................... Straight,M]06M006 ................................................................. 2 02298 .......................... Elbow, 90° M]06 F]06 ............................................................... 2

- Indicates Items Not Shown Drawing not available at this time

MANUAL 92379-003 July 1998

Revised 11(98

FIGURE 5.3:RegenerativeManifoldAssembly

I

e

I CYL RETR

VALVE RETR

l 4

(

X

3

5

CYL EXT

VALVE EXT

C

z

ITEM Ref. 1 2 3 4 5

-

~

PARTNUMBER

DESCRIPTION

34814 34799 34369 35033 38167 02662

ManifoldAssembly,Regenerative ............................................ Ref. Manifold,Regenerative ................................................................ 1 Cartridge, Logic NO .................................................................. 2 Cartridge, Counterbalance ........................................................... 2 Plug,SUNCavaityBlocking ........................................................ 1 Elbow, 90° MJ06 M006 ............................................................ 2

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

- Indicates Items Not Shown

MANUAL 92379-003 July 1998 Revised 11/98

QTY

•

FIGURE 5.4:HoseCarrier Installation

QIY

ITEM

PART NUMBER

DESCRIPTION

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

76337 ..........................

76337-DWG ...............

76335 ..........................

76338 ..........................

76318 ..........................

71402 ..........................

71403 ..........................

71404 ..........................

71471 ..........................

Hose Carrier Installation .......................................................... Ref. HoseCarrierInstallationDrawing ............................................... 1 TubeWeldment,HoseCarrierTip .............................................. 1 HoseCarrierTrack ..................................................................... 1 Bracket, Hose Carrier Wear Pad .................................................. 1 Wear Pad, Hose Tube Base Lower .............................................. 1 Wear Pad, Hose Tube Base Upper .............................................. 1 Retainer, Wear Pad ...................................................................... 1 Spacer, CatrackMounting ........................................................... 1

- Indicates Items Not Shown

MANUAL 92379-003 July 1998 Revised 11198

•

This page intentionally left blank

MANUAL 92379·003 July 1998 Revised 11/98

•

FIGURE 8.1 :Jib Installation

o 11

3,4

9

o o

5,6

10

7,8

MANUAL 92379-003 July 1998 Revised 11/98

FIGURE 8.1 :Jib Installation ITEM

PARTNUMBER

Ref.

A42J-Jib ...................... Jib Installation ......................................................................... Ref.

1 2 3 4

5 6 7 8 9

10

11

DESCRIPTION

QTY

76040 .......................... LiftCylinder;Jib ......................................................................... 1 76066-003 .................... Pin Weldment;Jib Adapter .......................................................... 3 76069 .......................... Pin Cap; l"DIAPin .................................................................... 3 76066-004 .................... Pin Weldment;Jib Cylinder Rod .................................................. 1 76069 .......................... Pin Cap; l"DIAPin .................................................................... 1 76066-005 .................... PinWeldment;JibToBoom ....................................................... 1 76069 .......................... Pin Cap; l"DIAPin .................................................................... 1 76230 .......................... Jib Weldment; Upper .................................................................. 1 76237 .......................... Jib Weldment;Lower ................................................................. 1 76296 .......................... AdapterWeldment;Jib ............................................................... 1

MANUAL 92379-003 July 1998

Revised 11198

e

•

This Page Intentionally Left Blank

MANUAL 92379-003 July 1998 Revised 11198,.

FIGURE 6.1 :Platfonn Installation • ITEM Ref. -1 -2

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

PART NUMBER

DESCRIPTION

QTY

A38/42J-Platform ........ Platform Installation ................................................................ Ref.

76363 ..........................

76362 ..........................

81368-36-16 ................

76348 ..........................

76066-002 ....................

76069 ..........................

BoxAssembly,A38Platform ...................................................... 1 Box Assembly, A42J Platform ..................................................... 1 Gar-Max, 2.00 II) x 2.50 OD x 1" L .......................................... 1 MountingPlate,Relay&Breaker ................................................. 1 Pin Weldment ............................................................................. 2 Pin Cap, 1" DiaPin ..................................................................... 2

76205 35460 76211 76252 76284 66751 38335

30 x 60 Platform Weldment ........................................................

Actuator .....................................................................................

SkirtWeldrnent ...........................................................................

LowerSkirtBracketWeldment ...................................................

Bracket Weldment, UpperSkirt ...................................................

FootSwitchw/Guard + Cable ...................................................

110VLinetoPlatformAssembly .................................................

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

- Indicates Items Not Shown

MANUAL 92379-003 July 1998 Revised Ilf98

1 1 1 1 1 1 1

BOX COMPONENT ASSEMBLY

2XI9J§ /-------,,,"

(l) M4 X ,07 X !6mrn Le.

o

~

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VIEW FROM TOP OF BOX LIP

'A'

CONDOR PjN 76378-001 76378-002 76378-003 76378-004

...

TO LIM. SW. CABLE ASSY

iliM'T 528"

'57r"

-64r 696"

4

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TO CHASSIS CABLE ASSY

CUb=;:e;;=="LJ }

DO NOT STRIP THIS END

TO UPPER CONTROL BOX

PIN 1 2 3 4 5 6 7 8 9 10

WIRE NO. BLU WHT GRN ORG WHT/BU< BU< RED/BU< GRN/BU< REO ORG/BU<

CONNECTOR Cl (10 PIN) FUNCTION LIMIT SW. OUlPUT TO PUMP SP. CONT. INPUT FROM UMIT SWITCH DRIVE FORWARD DRIVE REVERSE TRACllON ACCELERATE GROUND GROUND GROUND INPUT FROM LEVEL SENSOR WHEN LEVEL SPARE

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65358 66992 54910-105

65351-010 65351-134 65351-042 65351-044 65351-048 1 67295-023 ITEM PART NUMBER 6 5 4 3 2

r

I

I I

I

I

1.00 EA 1.00 EA 1.00 EA

1.00 1.00 1.00

1.00 1.00 1.00

1.00 1.00 1.00

11.00 11.00 1.00 1.00 1.00 58.00

11.00 11.00 1.00 1.00 1.00 54.00

11.00 11.00 1.00 1.00 1.00 48.00

11.00 11.00 1.00 1.00 1.00 44.00

On'

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EA EA EA EA EA LF UM

HOOD, 10 CONTACT PLUG, 10 CONTACT STRAIN RELIEF, ST21

CABLE SEAL, GREEN TERMINAl, 16-14GA MALE CONNNECTOR. SHROUD 2 C( CONNNECTOR. SHROUD 3 C( CONNNECTOR, SHROUD 6 C( CABLE. 16GA/l0C DESCRIPTION

~

m£OONOtll 00

8300 IYf'£RIAl. 0 WACO. TEXAS .,.

FIGURE 6.2:BoxAssemblY,A38 Platform •

DESCRIPTION

QTY

ITEM

PART NUMBER

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

76363 .......................... BoxAssembly,A38Platform .................................................. Ref. 76253 .......................... Box, Upper Control-Machined ................................................... 1 76011 .......................... Speed Control Potentiometer ...................................................... 1 76012 .......................... DriveControlJoystick ................................................................ 1 67964-002 .................... Butt Connector, 16/14GA .......................................................... 2 51913 .......................... Operator,RedP-PullZB2-BT4 ................................................... 1 BOW31529 .................. Plug Button .50DIA ................................................................... 1 51914 .......................... Base + 1NC Contact ZB2-BZ102 ............................................... 1 50075 .......................... Toggle SwitchSPDT ................................................................. 6 40880 .......................... Guard, Toggle Switch ................................................................. 6 65356 .......................... Relay,SPDT48VDCW/Diode .................................................. 2 65354-005 .................... CircwtBreaker5A-50VDC ......................................................... 2 34644-648 .................... Alarm,48VDC ........................................................................... 1 34552-010 .................... Strip, Terminal10Position ......................................................... 1 66993 .......................... Receptacle, Female 10 Con 1-10 ................................................. 1 66995 .......................... Base,PanelMounted10Contacts ................................................ 1 76390 .......................... Decal, Upper Box Tags .............................................................. 1 66653-002 .................... Receptacle, Female 24 Contacts 1-24 ........................................... 1 66654-024 .................... Base, Panel Mounted 24 Contacts ............................................... 1 67869 .......................... Socket,Relay .............................................................................. 2 65353-004 .................... Connector Plug-6Pin ................................................................. 1 65353-006 .................... Connector Plug-9Pin ............................................................... 1 65353-052 .................... Pin For AMP Plug .................................................................... 13 67114-003 .................... Strain Relief -1I2NPT .371.5 .................................................... 1 67123-001 .................... Seal, Connector Elect 1/2" .......................................................... 1 67124-001 .................... Locknut-1/2NPTConduit ....................................................... 1 34542 .......................... Jumper ....................................................................................... 5 BOW31145 .................. Machine Screw RH #10-32 x 3/4 .............................................. 2 BOW43602 .................. Machine ScrewRH4Mx 0.7 x 1Smm ......................................... 2 BOW31127-1 .............. Machine Screw RH #6-32 x 11/4 ............................................. 4 BOW31126 .................. Machine Screw RH #6-32 x 3/4 ................................................ 2 BOW31132 .................. Machine Screw RH #8-32 x 3/4 ................................................ 8 BOW31231 .................. Nut, #6-32 ................................................................................ 6 BOW31232 .................. Nut, #8-32 ................................................................................ 8 BOW31428 .................. Washer,Flat #6 ......................................................................... 4 BOW31429 .................. Washer,Flat #8 ......................................................................... 1 206-00001-00 ............... Diode ........................................................................................ 4

45 46 47 48

(Optional) 76102 .......................... Decal, Platform Control Box .................................................. Ref. 34836 .......................... Operator, WhiteP-ButtonZB2-BAl ....................................... Ref. 52672 .......................... Base + 1 NO Contact ZB2-BZ101 ......................................... Ref. 65354-005 .................... CircuitBreaker5A-50VDC ..................................................... Ref.

- Indicates Items Not Shown

MANUAL 92379-003 July 1998 Revised 11/98

WIRING ASSEMBLY (STEP 1)

WIRING ASSEMBLY (STEP 2) 1.

3. TILT AND ALARM RELAYS (COILS ONLY) 4, CIRCUI1 BREAKERS 5, EMERGENCY STOP AND HORN S'M1CHE'3.

IIII

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un

FUNCTION S'MTCH(S 2. TIL 1 AND ALARM RELAYS (S\\HCH SIDE ONLY) 3. TIL 1 ALARM 4, rOmS\lVlTCH

" SPEED CONTROL POTENTlOME7ER 2 DRIIi£ CONTROL JOYOTiCK

1I11

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IIII

1111

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FIGURE 6.2:BoxAssembly,A38 Platform . ,

QTY

ITEM

PARTNUMBER

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

76363 .......................... BoxAssembly,A38Platform .................................................. Ref. 76253 .......................... Box, Upper Control-Machined ................................................... 1 76011 .......................... Speed Control Potentiometer ...................................................... 1 76012 .......................... DriveControlJoystick ................................................................ 1 67964-002 .................... Butt Connector, 16/14GA .......................................................... 2 51913 .......................... Operator,RedP-PullZB2-BT4 ................................................... 1 BOW31529 .................. Plug Button .50DIA ................................................................... 1 51914 .......................... Base + INC Contact ZB2-BZI02 ............................................... 1 50075 .......................... Toggle SwitchSPDT ................................................................. 6 40880 .......................... Guard, Toggle Switch ................................................................. 6 65356 .......................... Relay, SPDT 48VDC WIDiode .................................................. 2 65354-005 .................... CircuitBreaker5A-50VDC ......................................................... 2 34644-648 .................... Alarm, 48VDC ........................................................................... 1 34552-010 .................... Strip, Terminall0Position ......................................................... 1 66993 .......................... Receptacle, Female 10Con 1-10 ................................................. 1 66995 .......................... Base,PanelMountedl0Contacts ................................................ l 76390 .......................... Decal, Upper Box Tags .............................................................. 1 66653-002 .................... Receptacle, Female 24 Contacts 1-24 ........................................... 1 66654-024 .................... Base, Panel Mounted 24 Contacts ............................................... 1 67869 .......................... Socket,Relay .............................................................................. 2 65353-004 .................... Connector Plug-6Pin ................................................................. 1 65353-006 .................... Connector Plug - 9 Pin ............................................................... 1 65353-052 .................... Pin For AMP Plug .................................................................... 13 67114-003 .................... StrainRelief-1/2NPT .371.5 .................................................... 1 67123-001 .................... Seal, Connector Elect 1/2" .......................................................... 1 67124-001 .................... Locknut-1I2NPT Conduit. ...................................................... 1 34542 .......................... Jumper ....................................................................................... 5 BOW31145 .................. Machine Screw RH #10-32 x 3/4 .............................................. 2 BOW43602 .................. Machine ScrewRH4MxO.7 x 15mm ......................................... 2 BOW31127-1 .............. Machine Screw RH #6-32 x 11/4 ............................................. 4 BOW31126 .................. Machine Screw RH #6-32 x 3/4 ................................................ 2 BOW31132 .................. Machine Screw RH #8-32 x 3/4 ................................................ 8 BOW31231 .................. Nut, #6-32 ................................................................................ 6 BOW31232 .................. Nut, #8-32 ................................................................................ 8 BOW31428 .................. Washer, Flat #6 ......................................................................... 4 BOW31429 .................. Washer,Flat #8 ......................................................................... 1 206-00001-00 ............... Diode ........................................................................................ 4

45 46 47 48

(Optional) 76102 ..........................

34836 ..........................

52672 ..........................

65354-005 ....................

DESCRIPTION

Decal, Platform Control Box .................................................. Ref. Operator, White P-Button ZB2-BA 1 ....................................... Ref. Base + 1 NO Contact ZB2-BZ101 ......................................... Ref. Circuit Breaker 5A-50VDC ..................................................... Ref.

- Indicates Items Not Shown

MANUAL 92379-003 July 1998

Revised 11198

•

FIGURE 6.3 :BoxAssembly, A42JPlatfonn BOX COMPONENT ASSEMBLY

(2) M4 X .1)7 X 16mrn lG.

(7 Plt>::.)

1 8

8 (1) (!)

, I (1) (!)

@ I'->_~_

(2 PLCS) 11

@

@

@

o

o

VIEW FROM TOP OF BOX liP

MANUAL 92379-003 July 1998 Revised 1l/98

'A'

TO LIM. SW. CONDOR PIN 76378-001 76378-002 76378-003 76378-004

CABLE ASSY

DIM 'A' 528" 576" 648" 696"

4

o

TO CHASSIS CABLE ASSY

q!b==i!5;;==d...J }

DO NOT STRIP

THIS END

TO UPPER CONTROL BOX

PIN 1 2

3 4 5 6 7 8 9 10

WIRE NO. BLU WHT GRN ORG WHT/BLK BLK RED/BLK GRN/BLK RED ORG/BLK

CONNECTOR Cl (10 PIN) FUNCTION LIMIT SW. OUTPUT TO PUMP SP. CONT. INPUT FROM LIMIT SWITCH DRIVE FORWARD DRIVE REVERSE TRACTION ACCELERATE GROUND GROUND GROUND INPUT FROM LEVEL SENSOR WHEN LEVEL SPARE

i~i~/ I

I

~') ~

R9 RB R7

65358 66992 54910-105

65351-010 65351-134 4 65351-042 3 65351-044 2 65351-048 1 67295-023 ITEM PART NUMBER 6

5

I

I

I I

L I

I

I

~') ~

1'\ '!"

;;4' ;;:, ;;~ 1'\ '!" 1'\ '!" 1'\ '!"

1.00 1.00 1.00

1.00 1.00 1.00

1.00 1.00 1.00

11.00 11.00 1.00 1.00 1.00 1.00 58.00 54.00 QTY QTY

11.00 11.00 1.00 1.00 1.00 4B.OO QTY

;;~

11.00 11.00 1.00 1.00

J IM!SS . - s E - .

1~'Jul

• +,

Il£a\IAI.S

1.00 EA 1.00 EA 1.00 EA

11.00 11.00 1.00 1.00 1.00 44.00 QTY

EA EA EA EA EA LF UM

HOOD, 10 CONTACT PLUG, 10 CONTACT STRAIN RELIEF. ST21

CABLE SEAL. GREEN TERMINAL. 16-14GA MALE CONNNECTOR, SHROUD 2 C( CONNNECTOR, SHROUD 3 C( CONNNECTOR, SHROUD 6 C( CABLE. 16GA/IOC DESCRlP1l0N _ _ 00

~

IJ300 _AlP WACO. lEXA!I 78

FIGURE 6.3 :BoxAssembly, A42J Platform •

ITEM

PART NUMBER

DESCRIPTION

QTY

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 3S

76362 .......................... Box Assembly, A42JPlatform ................................................. Ref. 76253 .......................... Box, Upper Control-Machined ................................................... 1 76011 .......................... SpeedControlPotentiometer ...................................................... 1 76012 .......................... DriveControlJoystick ................................................................ 1 206-00001-00 ............... Diode ........................................................................................ 4 51913 .......................... Operator, RedP-PullZB2-BT4 ................................................... 1 BOW18579 .................. TerminalPiggy-Back22/18GA .................................................. 2 51914 .......................... Base + lNC Contact ZB2-BZ102 ............................................... 1 50075 .......................... Toggle SwitchSPDT ................................................................. 6 40880 .......................... Guard, Toggle Switch ................................................................. 6 65356 .......................... Relay,SPDT48VDCW/Diode .................................................. 2 65354-005 .................... CircuitBreaker5A-50VDC ......................................................... 2 34644-648 .................... Alarm,48VDC ........................................................................... 1 34552-010 .................... Strip, Terminal 10 Position ......................................................... 1 66993 .......................... Receptacle, Female 10 Con 1-10 ................................................. 1 66995 .......................... Base, Panel Mounted 10 Contacts ................................................ 1 76390 .......................... Decal, Upper Box Tags .............................................................. 1 66653-002 .................... Receptacle, Female 24 Contacts 1-24 ........................................... 1 66654-024 .................... Base, Panel Mounted 24 Contacts ............................................... 1 67869 .......................... Socket,Relay .............................................................................. 2 65353-004 .................... Connector Plug-6 Pin ................................................................. 1 65353-006 .................... Connector Plug-9Pin ............................................................... l 65353-052 .................... PinFor AMP Plug .................................................................... 13 67114-003 .................... StrainRelief-1/2NPT .371.5 .................................................... 1 67123-001 .................... Seal, Connector Elect 1/2" .......................................................... 1 67124-001 .................... Locknut-1/2NPTConduit ....................................................... 1 34542 .......................... Jumper ....................................................................................... 5 BOW31145 .................. Machine Screw RH #10-32 x 3/4 .............................................. 2 BOW43602 .................. MachineScrewRH4Mx 0.7 x lSmm ......................................... 2 BOW31127-1 .............. Machine Screw RH #6-32 x 11/4 ............................................. 4 BOW31126 .................. Machine Screw RH #6-32 x 3/4 ................................................ 2 BOW31132 .................. Machine Screw RH #8-32 x 3/4 ................................................ 8 BOW31231 .................. Nut, #6-32 ................................................................................ 6 BOW31232 .................. Nut, #8-32 ................................................................................ 8 BOW31428 .................. Washer, Flat #6 ......................................................................... 4 BOW31429 .................. Washer,Flat #8 ......................................................................... 1

45 46 47 48

(Optional) 76102 .......................... Decal, Platform Control Box .................................................. Ref. 34836 .......................... Operator, WhiteP-ButtonZB2-BA1 ....................................... Ref. 52672 .......................... Base + 1 NO Contact ZB2-BZ101 ......................................... Ref. 65354-005 .................... Circuit Breaker SA-50VDC ..................................................... Ref.

. Indicates Items Not Shown

Revised August 1998 MANUAL 92379·003 July 1998

Revised 1J/98

WIRING ASSEMBLY (STEP 2)

WIRING ASSEMBLY (STEP 1) L SPEED CONTROL POTENTIOMETER 2. DRIVE CONTROL JOYS1!CK 3. lilt AND ALARM RELAYS (COILS ONLY) 4. CIRC\111 BREAKERS 5. EMERGENCY SlOP AND HORN S\\HCHE5

I. lIri fUNCTION SI'<11CHES 2. >Ill AND ALARM RELAYS (51\11CH SIDE ONLY) 3. TILT ALARM 4. [00151'<11CH

"" "

II

"

IIII IIII

IIII IIII IIII

1111 II

IIII

till

1111

Hit

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II " II II

1111

1111

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II

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cD

1111 II"

1111

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" Ol(/R

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, :·l " " "

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ALL ~RES 18 GA (~11E) PIN ,,8257 USE I\1RE MARKERS Al EACH END OF I'<1RE RUN.

lOMR t.lA$ [R S'Ml

""

LOMA IJASTER

~\'IIT()-f

~(lIanl"""

II

~

FIGURE 6.3 :BoxAssembly, A42J Platform •

DESCRIPTION

QTY

ITEM

PART NUMBER

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

76362 .......................... Box Assembly, A42J Platform ................................................. Ref. 76253 .......................... Box, Upper Control-Machined ................................................... 1 76011 .......................... Speed Control Potentiometer ...................................................... 1 76012 .......................... DriveControlJoystick ................................................................ 1 206-00001-00 ............... Diode ........................................................................................ 4 51913 .......................... Operator,RedP-PullZB2-BT4 ................................................... 1 67964-002 .................... Butt Connector, 16/14GA .......................................................... 2 51914 .......................... Base + lNC Contact ZB2-BZ102 ............................................... 1 50075 .......................... Toggle SwitchSPDT ................................................................. 6 40880 .......................... Guard, Toggle Switch ................................................................. 6 65356 .......................... Relay, SPDT 48VDC WIDiode .................................................. 2 65354-005 .................... Circuit Breaker 5A-50VDC ......................................................... 2 34644-648 .................... Alarm, 48VDC ........................................................................... 1 34552-010 .................... Strip, Terminall0Position ......................................................... 1 66993 .......................... Receptacle, Female 10 Con 1-10 ................................................. 1 66995 .......................... Base, Panel Mounted 10 Contacts ................................................ 1 76390 .......................... Decal, Upper Box Tags .............................................................. 1 66653-002 .................... Receptacle, Female 24 Contacts 1-24 ........................................... 1 66654-024 .................... Base, Panel Mounted 24 Contacts ............................................... 1 67869 .......................... Socket,Relay .............................................................................. 2 65353-004 .................... Connector Plug-6Pin ................................................................. 1 65353-006 .................... Connector Plug-9Pin ............................................................... 1 65353-052 .................... Pin For AMP Plug .................................................................... 13 67114-003 .................... StrainRelief-1/2NPT .371.5 .................................................... 1 67123-001 .................... Seal, Connector Elect 112" .......................................................... 1 67124-001 .................... Locknut-1/2NPTConduit ....................................................... l 34542 .......................... Jumper ....................................................................................... 5 BOW31145 .................. Machine Screw RH #10-32 x 314 .............................................. 2 BOW43602 .................. Machine Screw RH 4M x 0.7 x lSmm ......................................... 2 BOW31127-1 .............. Machine Screw RH #6-32 x 1114 ............................................. 4 BOW31126 .................. Machine Screw RH #6-32 x 3/4 ................................................ 2 BOW31132 .................. MachineScrewRH #8-32 x 3/4 ................................................ 8 BOW31231 .................. Nut, #6-32 ................................................................................ 6 BOW31232 .................. Nut, #8-32 ................................................................................ 8 BOW31428 .................. Washer, Flat #6 ......................................................................... 4 BOW31429 .................. Washer,Flat #8 ......................................................................... 1

45 46 47 48

(Optional) 76102 .......................... Decal, Platform Control Box .................................................. Ref. 34836 .......................... Operator, White P-Button ZB2-BAl ....................................... Ref. 52672 .......................... Base + 1 NO Contact ZB2-BZ101 ......................................... Ref. 65354-005 .................... Circuit Breaker5A-50VDC ..................................................... Ref.

- Indicates Items Not Shown

MANUAL 92379-003 July 1998

Revised 11/98

This Page Intentionally Left Blank

MANUAL 92379-003 July 1998 Revised 11/98

FIGURE 6.4: 110VoltLinetoPlatfolm •

DESCRIPTION

QTY

ITEM

PART NUMBER

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

38335 .......................... 110VoltLinetoPlatform ........................................................ Ref. 40956 .......................... Box, Rain Tight Single-Gang ....................................................... 1 67295-017 .................... Cable, 3 Conductor 12 GA .................................................. 60LF. 66357 .......................... Receptacle, GroundFault ............................................................ 1 66358 .......................... Cover, Weatherproof .................................................................. 1 67114-003 .................... StrainRelief1/2NPT .37/.5 ........................................................ 1 67123-001 .................... Seal, Connector Elect 1/2" .......................................................... 1 BOW23075 .................. Connector, 12-10GA WireButt ................................................... 2 BOW31146 .................. Screw, #10-32UNF x 1.00 Round Sit .......................................... 4 BOW31430 .................. Washer,#10IDFlat ................................................................... 8 BOW31362 .................. Washer, #10ID Split Lock ......................................................... 8 52710 .......................... Plug, 110Volt ............................................................................. 1

- Indicates Items Not Shown Drawing not available at this time

MANUAL 92379-003 July 1998 Revised 11/98

48

FIGURE 7.1:DecalKit,A38/42J

24

f

17

MANUAL 92379-003

July 1998 Revised 11/98

FIGURE 7.1:DecaIKit,A38/42J PARTNUMBER

Ref. *1

*25 26 *27 *28 29

76412-A38 ................... DecalKit,A38/42J ................................................................. Ref. 76412-DWG ............... InstallationDWG,DecalA38/42J ............................................... 1 76105 .......................... Decal, Turret Control Box .......................................................... 1 21882-001 .................... Decal, EL Hazard Keep Clear ..................................................... 2 37958-500 .................... Decal, 500LB Rated Work Load ................................................. 1 38176 .......................... Decal-AuxHydraulicValveLowering(A38) ............................... 2 38176 .......................... Decal-AuxHydraulic Valve Lowering(A42J) .............................. 3 38533 .......................... Decal, Lower Caution Boom ...................................................... 1 38550 .......................... Decal, Platform Fall Arrest .......................................................... 2 52759 .......................... Decal- Stand Clear ..................................................................... 2 54182 .......................... Decal-BatteryCharger Plug ....................................................... 1 54652-005 .................... Decal,BatteryService Caution ..................................................... 2 54940-023 .................... Decal, Time Condor Sticker ........................................................ 2 54984-004 .................... Decal, Lift And Tie Down .......................................................... 4 54984-006 .................... Decal, 110 Volt EXT To Platform .............................................. 1 54984-007 .................... Decal, Hydraulic Fluid ................................................................. 1 56024 .......................... Decal, 2.50" High" Forward" .................................................... 2 56023 .......................... Decal, 7.00" High Arrow ............................................................ 2 56033 .......................... Decal, 3.5" High Twin Stripes .......................................... 12.23LF. 56034-500 .................... Decal, 500LBS RAted Work Load .............................................. 1 55941-017 .................... Decal, 17x2.5" Condor Bird ..................................................... 1 58399 .......................... Decal- Tire Replacement Solid ................................................... 4 67938-100 .................... Decal- Tire Pressure 100 PSI .................................................. Ref. 69573 .......................... Decal, Boom Upper Caution ...................................................... 1 71615 .......................... Decal Panic Stop .................................................................... Ref. 76102 .......................... Decal, Platform Control Box ...................................................... 1 76407 .......................... Decal, A38 ................................................................................. 2 76408 .......................... Decal,A42J ................................................................................ 2 54984-003 .................... Decal, Operators Manual ............................................................ 1 55940-023-G ............... Decal, Condor ............................................................................ 1 76496 .......................... Tag,DescendingSlopeCaution ................................................... 1 76412-100 .................... DecaIKit,A38Essential .......................................................... Ref. 76412-101 .................... DecaIKit,A42JEssential ........................................................ Ref.

50

15843 .......................... Nameplate,BoomIdentification .................................................. 1

*2 ""3 *4 *5 *6

"'7 *8

""9 *10 11 *12 *13 *14 *15 *16 17 *18 19 *20 *21 *22 *23 *24

DESCRIPTION

QTY

ITEM

- Indicates Items Not Shown :}Indicates Essential Decals

MANUAL 92379·003 July 1998

Revised 11198

G

•

FIGURE 7.1:DecalKit,A38/42J

/=

to N l.()

o

o

MANUAL 92379-003 July 1998 Revised lli98

FIGURE 7.1 :Decal Kit, A38/421

PARTNUMBER

Ref. *1 ""2 *3 *4 *5

*25 *26 27

76412-A38 ................... DecaIKit,A38/42J ................................................................. Ref. 76412-DWG ............... InstallationDWG,DecalA38/42J ............................................... 1 76105 .......................... Decal, Turret Control Box .......................................................... 1 21882-001 .................... Decal, EL Hazard Keep Clear ..................................................... 2 37958-500 .................... Decal,500LBRatedWorkLoad ................................................. 1 38176 .......................... Decal-AuxHydraulic Valve Lowering(A38} ............................... 2 38176 .......................... Decal-AuxHydraulicValveLowering(A42J) .............................. 3 38533 .......................... Decal, Lower Caution Boom ...................................................... 1 38550 .......................... Decal, Platform Fall Arrest .......................................................... 2 52759 .......................... Decal- Stand Clear ..................................................................... 2 54182 .......................... Decal-BatteryChargerPlug ....................................................... 1 54652-005 .................... Decal, BatteryService Caution ..................................................... 2 54940-023 .................... Decal, Time Condor Sticker ........................................................ 2 54984-004 .................... Decal, Lift And TieDown .......................................................... 4 54984-006 .................... Decal, 110 Volt EXT To Platform .............................................. 1 54984-007 .................... Decal, Hydraulic Fluid ................................................................. 1 56024 .......................... Decal, 2.50" High" Forward" .................................................... 2 56023 .......................... Decal, 7.00" High Arrow ............................................................ 2 56033 .......................... Decal, 3.5" High TwinStripes .......................................... 12.23LF. 56034-500 .................... Decal, 500LBS RAted Work Load .............................................. 1 55941-017 .................... Decal, 17x2.5" Condor Bird ..................................................... 1 58399 .......................... Decal- Tire Replacement Solid ................................................... 4 67938-100 .................... Decal- Tire Pressure 100 PSI .................................................. Ref. 69573 .......................... Decal, Boom Upper Caution ...................................................... 1 71615 .......................... DecalPanicStop ................................................................... -.Ref. 76102 .......................... Decal, Platform Control Box ...................................................... 1 76407 .......................... Decal,A38 ................................................................................. 2 76408 .......................... Decal,A42J ................................................................................ 2 54984-003 .................... Decal, Operators Manual ............................................................ 1 76412-100 .................... Decal Kit, A38 Essential .......................................................... Ref. 76412-101 .................... Decal Kit, A42J Essential ........................................................ Ref.

50

15843 .......................... Nameplate,Boomldentification .................................................. 1

*6 >'7 *8 *9

*10 11 *12 *13 *14 ""15 *16 17 *18 19 '~20

*21 *22 >'"23 *24

DESCRIPTION

QTY

ITEM

- Indicates Items Not Shown )~Indicates Essential Decals

MANUAL 92379-003 July 1998 Revised 11/98

G

Notes

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

WARNING: Battery posts, terminals, and related accesories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

_DE_T_R_O_IT_D_IE_S_E_L_ _ CORPORATION

@ \..\....~

CALIFORNIA PROPOSITION 65 INFORMATION TO CALIFORNIA CUSTOMERS AND TO COSTOMERS SELLING DIESEL ENGINE EQUIPMENT INTO OR FOR USE IN CALIFORNIA Proposition 65, a California law, requires warnings on products which expose individuals in California to chemicals listed under the law, including certain chemicals in diesel engine exhaust.

Obligations of Manufacturers of Diesel-Powered Off-Road Equipment. The California Superior Court has approved either of the following two methods of compliance with Proposition 65 requirements by manufactures of off-road equipment containing diesel engines. (The court order containing these provisions may be furnished on request.)

1.

On-Equipment Warning. Place the warning pictured in attachment 1 on all equipment shipped by you into or for sale in California after January 1, 1996. The warning must be in a location where it is easily visible to the operator of the equipment when (s)he is operating the equipment. The warning must be secured to the equipment. If warnings or operating instructions are provided through a digital display, you may use that method of providing the warning.

2.

Operator Manual Warning. When the operator manual is next revised or by December 31, 1995, whichever is earlier, place the warning in attachment 2 in the operator manual. The warning may be either printed in the manual or a sticker.

The warning must appear in one of the following locations. * Inside the front cover

* Inside the back cover * Outside the front cover * Outside the back cover * As the first page of text

Under either alternative, the warning must appear in the same size, print and format as the attachment selected or be of equally conspicuous size and format. If the warning is provided in an on-screen display, the warning must contain the language in the attachment and must be provided at the time of or in connection with ignition in the same manner as other safety warnings electronically communicated on screen.

Obligation of Resellers of Diesel Engines. This letter must accompany any loose diesel engine sold in California.

Should you have any questions, please call Detroit Diesel Corporation, Mr. John F. Farmer on (313) 592-7111, Fax (313) 592-5014.