CONDOR Scissor Lift 1528 1535 1552 2035 2052 Parts Manual - PDF DOWNLOAD

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OPERATION/MAINTENANCE

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AND ILLUSTRATED PARTS MANUAL FOR·YOUR CALAVAR SELF-PROPELLED CONDOR SCISSORS MODELS 1528; 1535; 1552; 2035; 2052 Calavar Corporation provides this manual for the guidance of all owners, operators, and servicing personnel in order to obtain the longest possible trouble-free service. It contains general data; specifications; operating instructions; recommended lubrication procedures; vendor information and speCifications; illustrated parts breakdown and a - special section on safety.

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Model _________________________________ Serial Number __________________ Date Del ivered __________________

CUSTOMER _ _ _ _ _ _ _ _ _ _ _ _ _ __ Note:

Additional copies of this manual can be obtained through the Parts Department at Calavar.

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OPERATION/MAINTENANCE AND ILLUSTRATED PARTS MANUAL SELF-PROPELLED CONDOR SCISSORS INDEX Warranty Statement • • Unloading Instructions Check-Out Instructions .

D~scription . . • • . • Specifications • Operation. • • . .

Hydraulic System •. . .

Electric System ..

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· . Page · • Page • Page · Page · • Page · • Page • Page · . Page

2 3 4 7 9 10 10 15

· . Page Page . · Page · Page Page Page Page

5 6 12 14 16 & 17 18 19

ILLUSTRATIONS Walk-Along Control . . . • .

Forklift Transport Photo. ...

Hydraulic Schematic #50 •.

Free Wheeling Valve Illustration.

Electric Circuit Schematic . . . .

Safety Bar Installation Illustration.

Battery Service Access Illustration. .

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( SELF-PROPELLED CONDOR SCISSORS OPERATION, MAINTENANCE AND PARTS MANUAL INTRODUCTION The function of the Operation, Maintenance and Parts Manual is to first provide the Customer with a complete and up-to-date manual covering models presently in production and second, to aid in training operators and mechanics. If used properly, it will provide the customer with a source of information that will aid in solving quickly and inexpensively the bulk of maintenance problems.

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Throughout this manual, reference is made to unit serial number, and the use of this number when ordering parts will assist our parts department in giving you prompt and accurate service., The use of correct serial number and part numbers will also expedite completion of warranty claims sent to Calavar. Serial number should also be used at all times in phone conversations to Calavar's service personnel.

This manual has been produced as a valuable tool for our customer.

It is in your best interest that time be spent to read and understand all the sections in the manual.

Calavar has included a special section that deals with the safe operation of the sel f-propell ed Condor Sci s'sors, as well as . information about certain items that must be inspected periodically to ensure a safe operating units.

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INTRODUCTION

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

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

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

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

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

TIME CONDO R Corporation reserves the rightto 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 CONDOR® WITHOUT PRIOR WRITTEN APPROVAL FROM THE MANAGEMENT OF THE TIME CONDOR Corporation.

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

NOTE:

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

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SAFETY FIRST!

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It is the responsibility of all users to read and comply with the following rules and information designed to promote safety and understanding of the Self-Propelled Condor. A thorough knowledge of the operating characteristics and limitations of the Condor machine is always the first requirement for any user, regardless of his prior experience with similar types of equipment,

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Only authorized and trained personnel (who have read the included manual entitled "Self-Propelled Condor Operation and Safety Manual," and are thoroughly familiar with the operating characteristics and limitations of the machine) must be allowed to operate the Condor.

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The Operation and Safety Manual work platform at all times.

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Know and follow all cautions, warnings and operating instructions on the machine.

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Understand and obey all federal, state and local statutes and regulations applying to safe operation and use of an aerial work platform.

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must be retained on the Condor

Caution: The following are rated platform capacities for standard Scissors models. Do not exceed these capacities!

Condor Model 1528 1535 1552 2035 2052 2565 RT2065 RT2565 RT3788 RT4388

Platform Capacity 750 lbs.

1000 lbs.

1000 lbs.

750 lbs.

1000 lbs.

1250 lbs.

1250 lbs.

1250 1bs.

2000 lbs.

1000 1bs.

Pl atform Width 28 in.

35 in.

52 in.

35 in.

52 in.65 in.

65 in.

65 in.

88 in.

88 in.

Working Height 21 ft.

21 ft.

21 ft.

26 ft.

26 ft.

31 ft.

26 ft.

31 ft.

37 ft.

43 ft.

The following are a few additional precautions that, if adhered to, will help assure the safe operation of your Condor: 1.

Only authorized and trained operators must operate the Condor.

2.

Do not overload the platform, know the rated capacity.

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3.

For units equipped with outriggers or the optional stabilizers, do not elevate platform without outriggers or stabilizers in their extended work position.

4.

Do not operate the Condor on soft or uneven surfaces.

5.

Do not operate the Condor when the wind velocity exceeds 25 mph.

6.

Do not tow the Condor Scissors unless equipped with option for in-plant towing (5 mph maximum).

7.

Do not jerk controls. out of movements.

8.

Do not sit or climb on platform railing. platform floor at all times.

9.

Do not allow overhanging loads on the work platform.

Operate smoothly and deliberately into and Keep both feet on the

10. Do not use ladders, planks, or other devices to extend or increase work position from platform.

11. Do not operate a machine that is malfunctioning.

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12. Do not perform maintenance on fully extended scissors without the safety bar in place.

13. Do not make any modifications to the Condor without prior written consent of the Calavar Corporation Engineering Department.

14. Do not operate near energized electrical conductors. This is a non-insulated aerial work platform. You must maintain a clearance of at least 10 ft. between any part of the machine or its load and any electrical power line.

15. Do not use the Condor for any other purpose than to position personnel and their tools or equipment. The Condor is not designed for use as a crane.

16. Monitor batteries during charging. over-charge or boil.

DO NOT allow batteries to

17. Battery's sulfuric acid can cause a serious burn. acid away from skin and clothing with water.

Quickly flush

18. Hydrogen and oxygen gases are produced during normal battery operation. This gas mixture can explode if flame or sparks are near battery vents.

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19. Take adequate measures to protect batteries from sparks if welding, or burning operations, are performed from or near the Condor Scissors platform.

A.N.S.I. SPECIFICATIONS

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The following excerpts from American National Standard Institute Specification No. A92.6-1979 are listed to help promote your safe use of the Condor Aerial Work Platform.

12. Inspection and Maintenance 12.1 Each work platform shall be inspected and maintained in proper working order in accordance with the manufacturer1s operating/maintenance manual.

12.2 Any work platform not in safe operating condition shall be removed from service until it is repaired. All repairs shall be made by a qualified service person in conformance with the manufacturer1s operating/maintenance manual.

13. Training Only trained and authorized personnel shall the work platform.

be permitted to operate

14. Operation 14.1 Before Operation 14.1.1 Before using the work platform, the operator shall have: (1) Read and understood the manufacturer1s operating instructions and safety rules, or been trained by a qualified person on the contents of the manufacturer1s instructions and safety rules.

(2) Read and understood all decals, warnings, and instructions on the work platform.

14.1.2 On a daily basis, before the work platform is used, it shall be given a thorough inspection, which shall include: (1) Inspection for defects such as cracked welds, hydraulic leaks, damaged control cable, loose wire connections~ and tire damage.

(2) Inspection of functional controls for proper operation.

14.1.3 Any suspect items discovered through inspection in accordance with 14.1.2 shall be carefully examined and a determination made by a qualified service person as to whether they constitute a safety hazard. All unsafe items shall be corrected before further use of the work platform.

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14.1.4 Before the work platform is used, the operator shall survey the area for hazards such as: Untapped earth fills Ditches .

Dropoffs or holes Bumps and floor obstructions Debris Overhead obstructions and high-voltage conductors Other possible hazardous conditions 14.2 Restrictions and Requirements. The work platform shall be used only in accordance with the manufacturer's operating instructions and safety rules and this standard.

14.2.1 Only trained and authorized personnel shall be permitted to operate the work platform.

14.2.2 Before each elevation of the work platform, the operator shall:

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(I) Check for overhead obstructions and high-voltage conductors. A minimum distance of 10 feet from energized high-voltage conductors shall be maintained at all times between the conductors and the operator or platform, whichever is closer.

(2) Ensure that the work platform is on a firm and level surface.

(3) Ensure that the load and its distribution on the platform are in accordance with the manufacturer's rated capacity. The manufacturer's recommended load limits shall never be exceeded.

(4) Ensure that outriggers and stabilizers are used if the manufacturer's instructions require their use.

(5) Ensure that guardrails are properly installed, and gates or openings are closed.

14.2.3 Before and during driving, while the platform is elevated, the operator shall: (1) Be required to look in the direction of, and keep a clear view of, the path of travel and assure that the path of travel is firm and level.

(2) Maintain a safe distance from obstacles, debris, dropoffs, holes, depressions, ramps or other hazards to safe elevated travel.

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(3) Maintain a safe distance from overhead obstacles.

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14.2.4 Under all travel conditions, the operator shall limit travel speed in accordance with conditions of ground surface, congestion, slope, location of personnel, and other factors affecting hazard of collision of injury to personnel.

14.2.5 Stunt driving and horseplay shall not be permitted.

14.2.6 Personnel shall maintain a firm footing on the platform while working thereon unless they are secured by safety harness/lanyard devices fixed to manufacturer approved hard points. Use of railings or planks, ladders or any other device on the work platform not conforming to 14.3.3 for achieving additional height shall be prohibited.

14.2.7 The operator shall immediately report any defects or malfunctions which become evident during operation and shall discontinue use of the work platform until correction has been made.

14.2.8 Altering or disabling of safety devices or interlocks shall be prohibited.

14.2.9 Care shall be taken to prevent ropes, electric cords, hoses, etc. from becoming entangled in the work platform when the platform is being elevated, lowered, or moved.

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14.2.10 Work platform rated capacities shall not be exceeded when loads are transferred to the platform at elevated heights.

14.2.11 The operator shall ensure that the area surrounding the work platform is clear of personnel and equipment before lowering the platform.

14.3 Additional Requirements 14.3.1 Fuel Tanks. Fuel tanks shall not be filled while the engine is running. Spillage shall be avoided.

14.3.2 Battery Charging. Batteries shall not be charged except in an open, well-ventilated area, free of flame, smoking, spark, or fire.

14.3.3 Modification or Alteration. All modifications and alterations to work platforms shall be certified in writing by the manufacturer or by any other equivalent entity, such as a nationally recognized testing laboratory, as being in conformance with all applicable provisions of this standard, and as not impairing the safety of the equipment.

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~ Caution and Warning Decals are designed for your protection. Know and adhere to the information they provide.

CAUTION DO NOT PERFORM ANY MAINTENANCE WITH MACHINE IN RAISED POSITION UNLESS SAFm BAR IS ENGAGED. SII21

ELEmOCUTIOI HAZARD KEEP CLEAR IUIIIMI_ _ Y C M _ ' _ (0lIl10 WIllI , . 1_ _ 01 YlIIOI Iftf _ _ lUClllCalrC_ , _

CAUTION (

WARNING FOR NORMAL OPERATION, POWER WHEELS

STANO CLEAR WHILE OPERATING OUTRIGGER ...,

YOU MUST NOT O'IUTE THIS MACHINE UIUII " ' . . . . . . .,. ~_ araua

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MUST BE PROPERLY ENGAGED TO THE DRIVE MOTORS. ALSO. TOWING SELECTOR VALVE MUST BE IN NORMAL POSITION (HANDLE UP!.

OTHERWISE. CONDOR WILL NOT HAVE STEERING.

FOR TOWING, DISENGAGE POWER WHEELS FROM DRIVE MOTORS AND MOVE TOWING SELECTOR VALVE TO TOW POSITION (HANDLE DOWN). IN·PLANT TOWING ONLY. CAUTION: CONDOR DOES NOT HAVE BRAKES DURING TOWING. lUst

TIllS MletlIN' IS NIT INSUlAm

ELECTROCUTION HAZARD IAlITI.. WI! CWlllCO FI.. fucmc.tL U...

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CWIIICl II 1E1II_ Fli 1ft" AlIITIIII... lUll IIUI II Uill aUTI II SI..... 111./1.,. IIIU au.., , ... ealTin o. luftllAn CWUIICI.

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I EMERGENCY \ LOWERING

OPEN

CLOSE

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OPEN TO LOWER .

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TIME CONDOR Corporation

CONDOR® SERVICE INFORMAnON

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

2. There are numerous written MaintenancePro cedures available for this machine. Theseprocedures are available through the TIME CONDOR Corporation ServiceDepartmentto anyone who requests them.

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

4. TIME CONDOR Corporation Service School TrainingManuals are available forpurchasethrough the parts department. The part numbers forthes e manuals are: #92333 forself-propelled models; and #92334 fortruck-mountedmodels.

TllvIE CONDOR Corporation

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&300 IMPERIAL DRIVE, P.O. Box 21447, WACO, TEXAS 76702-1447· 254-420-5200, 254-666-4544 FAX

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CORPORATION

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

Self·Propelled Booml aDd Scillorl WARRANTY Calavar Corporation ("Calavar") warrants each new aerial work platfonn made by Calavar and bearing the trademark "Condor" to be free from defects in material and workmanship.

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

Pans claimed to be defective and for which repair or replacement is desired shall be, if requested by Calavar, returned transportation prepaid to Calavar's factory for inspection. Replacement parts provided under the tenns of this Warranty are for the remainder of the Warranty period applicable to the aerial work

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platfonn in which they are installed as if such parts were original components of the aerial work platfonn.

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

FORM NO. 280 lM-587

1'nnIIcI .. US.A.

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WARRANTY PROGRAM

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Warranty is a function of a manufacturing company to back up the product it manufactures. It is a guarantee against defects in design, and workmanship of components utilized in the product, and is offered for a certain period of time following purchase by a customer.

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

The warranty policy and description is depicted on the attached printed policy. For your information and ready reference the following is offered~ A.

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WARRANTY PERIOD

1.

The Self Propelled Boom and Scissors warranty period. is six months from placing unit in service or 12 months following shipment from Calavar, whichever comes first.

2.

The Truck Mounted unit warranty period is 12 months from placing unit in service or 18 months following shipment from Calavar, whichever comes first.

3.

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

4.

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

The term IIIN SERVICE II means that the warranty starts at the time the unit is first used for any purpose. In example: The dealer may have purchased a unit for his stock and does not use it.

After three months the unit is sold or he decides to put it in his rental fleet. In this situation the warranty period starts the day he puts it into his fleet or when the unit is delivered to the end user.

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

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B.

ITEMS NOT COVERED Some components are used on the machine which are not warranteed by Calavar. However, these are warranteed by the component manufacturer.

Some of these are: 1.

Engine - Manufacturers Wisconsin, Ford, Oeutz, Isuzu, Cummins, John Deere, and others are used. To apply for warranty on the engine, contact should be made with the local engine manufacturer dealer in your area. We can advise you who this is if unknown to you.

2.

Tires I Batteries - These are normal wear items and considered normal maintenance items. However. if they are found to be defective contact can be made with the manufacturer or with Calavar.

3.

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

4.

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

5.

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

6.

Travel Time/Mileage - Travel time and the mileage to and from dealer facilities to machine location is not covered or reimburseable.

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C.

,PROCESSING OF CLAIM

During the warranty period should a component failure be encountered within the guidelines of theCalavar Warranty Policy, the following procedure is to be fo 11 owed: 1.

Upon determination of the defective component the replacement can be obtained by: A.

Issuing an order to our parts department through normal channels which entails your being invoiced.

B.

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

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

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C.

D.

Although not recommended, you may choose to purchase the part locally. However, when this is done or when no Calavar invoice can be provided, Calavar will in lieu of issuing credit, ship a repl acement part at no charge, but you are responsible for shipping cost.

2.

Complete the warranty claim as noted on "Warranty Claim Procedure". Provide as much information as possible to enable Calavar to thoroughly evaluate the claim.

3.

Provided no return parts are required, the claim will be processed and credit issued against your account.

4.

A warranty labor rate conducive to your charge out will be set by Calavar.

RETURN AUTHORIZATION

1.

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Depending on the component and situation, Calavar from time to time may request that the defective component be returned to Calavar. The purpose of our requesting the return part is: •

In some instances the part can be returned to our vendor for warranty credit.

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It could help us to determine the cause of failure.

2.

Normally, parts with values less than $100 are not asked to be returned unless for the purpose of assisting us in analyzing the fail ure.

3.

The request for the return of the part will be made at time your warranty claim is received. A special form, "RETURN AUTHORIZATION" will be issued and will contain the authorization number, shipping slip, and identification tag.

4.

The part, once return authorization is issued, must be returned to Calavar within 45 days from date of authorization. A reminder will be sent ct 30 days if part has not been received at Calavar.

·5.

If part is not returned within the 45 day period it could cause your claim to be denied.

6.

All parts are to be shipped prepaid. ments will be accepted.

NO FREIGHT COLLECT ship-

7.

Calavar is obligated to issue a return authorization within a 14 day period following receipt of claim. If the authorization is not issued within this time, Calavar loses its right to have the parts returned and must approve the warranty claim without part being returned.

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Special forms and tags will be sent to you with authorization.

(Copy enclosed)

NOTE: DO NOT SHIP ANY RETURN PART WITHOUT RETURN AUTHORIZATION. part will get lost in the system and delay approval of claim.

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Doing so

TIME CONDOR Corporation

CONDOR Self Propelled Booms and Scissors

WARRANTY TIME CONDOR Corporation warrants to the purchaser that each new aerial work platform made by TIME CONDOR Corp. is free from defects in material and workmanship arising under normal use and service in the case of major weldments, (chassis, turret, and booms), for a period of five (5) years after the original shipment of the aerial work platform from the plant of TIME CONDOR Corp.; and in the case of all other parts, for a period of one (1) year after the aerial work platform is placed in service or two (2) years after the original shipment of the aerial work platform from the plant of TIME CONDOR Corp., whichever comes first.

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

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

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

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

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

TIME CONDOR Corp.

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

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

Printed in the USA 06/98

Effective August 27, 1996

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WARRANTY PROGRAM Warran:ty is a function of a manufacturing company to back up the product it manufactures. It is a guarantee against defects in design and workmanship of components utilized in the product, and is offered for a certain period of time following purchase by a customer.

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

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

A.

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NOTE:

WARRANTY PERIOD 1.

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

2.

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

3.

For parts sold thru the Parts Department, the warrantyperoid is six (6) months from utilizing the component or placing it in service, or twelve (12) months following shipment from TIME CONDOR, whichever comes first, unless the part is furnished to correct a defective part on the original CONDOR® shipment still under warranty. No laboris paid underparts warranty.

4.

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

5.

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

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

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

B.

(

PRE-DELIVERY INSPECTION SHEET (P.D.I.) 1.

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

2.

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

3.

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

NOTE:

C.

The form must be filled out completely, giving the name ofthe dealer, address, model number, serial number, person inspectingtheCONDOR® signature, and date of inspection.

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

ITEMS NOT COVERED Some components are used on the machine which are not warranted by TIME CONDOR COIporation. However, these are warranted by the component manufacturer. Some of these are: 1.

Engine: Manufacturers usedinc1ude Wisconsin, Ford, Deutz, Isuzu, Kubota, Onan, Cummins, John Deere, and others. To apply for warranty on the engine, contact should be made with the engine manufacturer's dealer in your area. TIME CONDOR COIporation can advise you if you need assistance locating a dealer.

2.

Tires and Batteries: These are normal wear items and are considered normal maintenance items. However, if they are found to be defective, contact can be made with the manufacturer's local dealer. NOTE: For international dealers where tires or batteries are not obtainable from a local in-country supplier, locally supplied tires or batteres can be used.

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

3.

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

4.

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

5.

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

6.

Travel Time / Mileage: Travel time and the mileage to and from dealer facilities to CONDOR® location are not covered or reimbursable.

7.

Troubleshooting: Troubleshooting is not covered or reimbursable. However, TIME CONDOR Corporation warranty will cover reasonable labor charges for the removal and replacement of defective components.

(

D.

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

(

1.

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

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

b.

You may have prevoiusly purchased the part from TIME CONDOR for your stock and will utilize it for this replacement.

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

2.

( NOTE:

(

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

d.

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

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

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

3.

E.

c.

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

RETURN AUTHORIZATION 1.

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

2.

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

DO NOT SHIP ANY RETURN PARTS WITHOUT A RETURN AUTHORIZATION (RIA) NUMBER

NOTE:

(

Doing so may result in parts getting lost in the system and may delay processing the claim, or may cause denial due to the time element of the claim.

NOTE:

3.

All RIA parts must be received at TIME CONDOR Corporation within 45 days from the date the RIA number was issued. Failure to do so will cause the claim to be denied.

4.

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

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

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

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

c

WARRANTY CLAIM PROCEDURE

(

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

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

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

PROCEDURE NOTE:

THE NUMBERS NOTED BELOW CORRESPOND NUMBERS ON THE CLAIM FORM

TO THE

1.

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

2.

Claim infonnation:

(

BLOCK

a.

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

b.

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

c.

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

d.

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

3.

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

4.

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

(

5.

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

6.

This area is for part number(s) and description(s}. It is VERY important that the TIME CONDOR Corporation invoice number(s} for which the part(s} were purchased be provided along with the amounts in order to properly process the claim. NOTE: All dollar amounts are to be in U.S. currency.

7.

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

8.

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

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

MailtheremainingcopiestotheTIMECONDORCorporationP.O.Boxblock#lforTIMECONDORCorporation evaluation.

NOTE:

(

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

( IMP 0 R TAN T

!

UNLOADING INSTRUCTIONS FOR THE SELF-PROPELLED SCISSORS MODELS 1528; 1535; 1552; 2035; 2052 1.

·2.

Before unloading the Condor, inspect for any physical damage, note any damage on the freight bill and report same to the carrier. (The carrier is responsible for damage in transit.)

CAUTION! The Self-Propelled Condor Scissors will weigh from 2,700 lbs. to 3,700 lbs. depending on which model you have ordered.

The smaller scissors are designed with forkl ift pockets so that they can be safely and conveniently loaded or unloaded with an adequate size forklift.

(

3.

If the Condor Scissors is to be safely unloaded under its own power, the dock or ramp must be adequate (strong and sturdy).

~ 4.

NOTE: CONDOR SCISSORS ARE NOT DESIGNED TO BE TOWED.

Before driving the Condor Scissors down the ramp, test the controls to be sure that if the control is returned to neutral the automatic hydraulic braking is effective. If the ramp is quite steep, a safety winchline should be attached to the Condor Scissors to ensure safe control during loading or unloading. Move the unit slowly, allowing time for corrective steering as,necessary to keep alignment on carrier or ramp during loading or unloading.

-000-

Scs/3-81

SELF-PROPELLED CONDOR SCISSORS CHECK-OUT INSTRUCTIONS

(

Prior to placing the Condor Scissors into service, a full check-out of the unit should be made, and the Installation Inspection Report completed and mailed to the factory.

Each Condor Scissors has undergone a thorough Quality Control Inspection at the factory, so each unit leaves Calavar in the best possible condition.

Transportation damage does sometime occur, and you must be aware of such damage and make note on the consignee copy of the freight bill, followed by your claim for repairs to the carrier.

CALAVAR IS NOT RESPONSIBLE FOR DAMAGE TO PRODUCTS WHILE IN TRANSIT. However, Calavar does want to know the condition in which the product was when it arrived.

1.

Visually inspect all parts of the Condor Scissors. From the slightest paint scratch to evidence of spilled or leaking battery acid, all deserve your attention.

2.

Check for loose bolts, nuts, damaged or leaking hydraulic lines, hoses and fittings, broken wires or structural damage.

3.

Check the tires for cuts or abrasions. are sol i d.)

4.

Check hydraulic oil level and cleanliness of oil. Add Dexron II, ATF (Automatic Transmission Fluid) if required.

5.

Check batteries (all one,~ four or eight) with hydrometer. Batteries must have a full charge for Condor Sci ssors to perform to perfection.

6.

Check battery terminal connections for tightness and cleanliness (loose or corroded terminal, lose continuity).

7.

Ground control of Power Shut-off and Lift toggle switches must be checked for use and serviceability.

8.

Check platform control box---condition of box, and all toggle switches for use and serviceability.

9.

Check drive wheels, freewheeling valve. drive operation.)

(Note: Small scissor tires

(Valve must be closed for

10.

Check emergency lowering valve. operations.

(Must be closed during normal

11.

Make out the Install at ion Inspection Report and ma'i 1 to Ca lavar.

( Scs/3-81

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SELF-PROPELLED CONDOR SCISSORS DESCRIPTION The Condor Scissors are self-propelled and operator controlled through the hand control box from the work platform.

The design intent is that the Condor Scissors is to operate on hard, flat, smooth, and level surfaces with outriggers extended, jacks lowered to . within 1/2" of the ground. This condition allows some movement of travel while operator is elevated to full heights. Unit will travel at slow speed above half its maximum platform height.

All five models covered by this manual can be transported short distances in a fully retracted (lowered) position by the operator in the platform, or by removing the platform control box from its holder on the guard rail and pass the control box to the ground operator, who may walk along side of the Condor Scissors controlling the drive and steering modes. This is known as the "walk along" mode.

Please study the specifications of all five models and specifically know the capacities and limitation of the model you are now planning to operate, keeping in mind the following safety precautions.

C

1.

DO NOT attempt to lift a load of more than the rated capacity of the work pl atform.

2.

The work platform has been designed to operate on smooth and level surfaces only.

3.

DO NOT modify or change the design in any way.

4.

Work platform must not be raised unless outriggers are extended and lowered to 1/2" from floor.

5.

DO NOT tow the Condor Scissors. The unit should be transported by truck or trailer.

6.

Monitor batteries during charging. DO NOT allow batteries to overcharge or boil.

7.

Battery's sulphuric acid can cause a serious burn. Quickly flush acid away from skin and clothing with water.

8.

Hydrogen and oxygen gases are produced during normal battery operation.

This gas mixture can explode if flame or sparks are near battery vents.

9.

Take adequate measures to protect batteries from sparks if welding, or burning operatons, are peformed from or near the Condor Scissors platform.

( Scs/3-80

(

10. DO NOT allow overhanging loads outside the work platform.

11. DO NOT alter the working height by using scaffolding or ladders on the platform.

12. DO NOT perform any maintenance on the Condor Scissors while the platform is raised, unless the SAFETY BAR is installed. (See picture. )

(

Scs/3-80

CALAVAR CORPORATION SELF-PROPELLED CONDOR SCISSORS SPECIFICATIONS Model 1528

Model 1535

Model 1552

Model 2035

Model 2052

9.

10.

11.

12.

13.

14.

15.

Working Height Platform Raised Platform Lowered Base Width Base Length Capacity Travel Speed Tires Guard Rail Height Toe Board Shipping Weight Lifting Time Power Supply Brakes Steering

21 1 141 9" 39" 28-1/2" 79" 750 lbs. .75 - 1. 5 mph 400 X 8, Solid 42" 4" 2700 lbs.

50 sec.

12 V DC Hydraulic Electro-Hydraulic

211 141 9" 39" 35" 79" 1000 lbs. .75 '"'- 1.: mph 400 X 8, Solid 42" 4" 2765 lbs.

50 sec.

12 V DC Hydraulic Electro-Hydraulic

211 14' 9" 39" 52" 79" 1000 lbs. .75 - 1. 5 mph 400 X 8, Solid 42" 4" 2885 lbs.

50 sec.

12 V DC Hydraulic Electro-Hydraulic

26 1 19' 6" 44" 39" 79" 750 lbs. .75 - 1. 5 mph 400 X 8, Solid 42" 4" 3100 lbs.

50 sec.

12 V DC Hydraulic Electro-Hydraulic

3300 lbs.

50 sec.

12 V DC Hydraulic Electro-Hydraulic

16.

17.

18.

19.

20.

21.

Outriggers Platform Size Drive Method Stowed Length Stowed Width Stowed Height

Manual 28" X 79" Dual Hyd. Mtr. 79" 28 II 81"

Manual 35" X 79" Dual Hyd. Mtr. 79" 35" 81 11

Manual 52" X 79" Dual Hyd. Mtr. 79" 52 11 81"

Manual 35" X 79" Dual Hyd. Mtr. 79" 39" 86"

Manual 52" X 86" Dual Hyd. Mtr. 86" 52 11 86"

1.

2.

3.

4.

5.

6.

7.

8.

26 19' 6" 44" 52" 86" 1000 lbs. .75 - 1. 5 mph 400 X 8, Soli d 42" 1

4"

(

SELF-PROPELLED CONDOR SCISSORS OPERATION Condor Scissors models are work platforms enclosed with guard rails. They can be raised and lowered by hydraul it cylinders and a" four-section sci ssor arm mechanism supported by a frame base. The frame base has two fixed heavy-duty rear drive wheels and two steerable heavy-duty front wheels.

The frame base, constructed of heavy-duty reinforced steel, is equipped with locking type stabilizing outriggers which are employed when the work platform is raised. The lower compartment in the frame is used to house the battery, battery charger, and hydraulic motor and pump.

Each work platform is driven by a +12 V DC (four 6-volt batteries connected in a series-parallel configuration) 500 ampere hour battery power source (which includes a built-in battery charger) and is controlled by means of two control panels. A frame control panel is installed on the frame base and an operator's control box is accessible from the work platform.

(

The platform is elevated by a 12 volt DC motor and hydraulic pump equipped with relief and check valves. Cylinders in the hydraulic loop are equipped with close-coupled, flow regulators. Additionally, a flow control valve is provided as an emergency measure to effect controlled lowering of the platform if a hydraulic line failure occurs.

The steerable front wheels use standard type automotive bearings and are operated by a double-acting hydraulic cylinder which is powered by the main hydraulic pump. Each rear wheel is driven by a hydraulic motor which also functions in conjunction with the main hydraulic pump. Rollers on the base frame and platform are equipped with self-lubricated bearing which track on steel raceways allowing smooth elevation and lowering of the work platform.

HYDRAULIC SYSTEM The hydraulic system consists of hydraulic fluid reservoir, suction strainer, pump with drive motor, inline filter, three directional solenoid valves.

The solenoid valves are stacked together with a single pressure in and return oil out back to tank. In neutral, delivery and return ports are blocked.

Delivery ports are plumbed one valve to lift, one valve to steering and one valve to drive.

When a directional switch is actuated, the motor driven pump starts and simultaneously the directional solenoid valve for that function selected opens, directing the oil flow to perform lift, steer, or drive.

Scs/3-80

(

The lift valve, when energized electrically by control switch, for LIFT directs oil from motor driven pump to the kick and lift cylinders to raise the platform until the control switch is returned to neutral. A check valve then holds the oil in the cylinder, holding the platform at the established height. When the control switch is moved to DOWN, the motor driven pump does not start, only a solenoid valve is opened allowing oil out of the lift and kick cylinders and directs the oil through small orifices to the res·ervoir. The platform lowers slowly by gravity.

The steering valve when energized electrically by control switch, for LEFT or RIGHT directs oil from the motor driven pump to steering cylinders to steer the front wheels left or right. When the control switch is moved to neutral the pump motor stops, and the valve closes locking the oil in the steering cylinder.

The drive valve, when energized electrically by the control switch for DRIVE FORWARD or DRIVE REVERSE directs oil from the motor driven pump to the drive wheel motors. A cushion cylinder is provided to reduce surge in the drive system, during starting and stopping.

When the control switch is in neutral, the valve spool blocks the delivery or motor ports, thereby stopping the oil creating a hydrostatic brake system.

(

When the two speed control switch is in the SLOW speed position, some of the motor driven pump oil is directed back to the reservoir. When the control switch is in the FAST position, drive speed will be FAST on1y---if the platform is below 1/2 max. height. (This is accomplished with an electric limit switch that senses a pre-set dimension of the scissors arms.)

All normal Condor Scissors aerial operations are to be performed by the platform operator. The ground controls are emergency controls and are used only in case of emergency or only with the permission of the platform operator. Further, emergency control without electric power is provided by the manual emergency lowering valve located adjacent to the frame panel and battery charger.

In the event of total loss of power, the Condor Scissors may be rolled on its wheels without power by opening the free wheeling valve, located at the rear of the machine in the lower frame. This bypasses the hydraulic motor.

When free wheeling is completed, close the free wheeling valve (to re-establish the hydrostatic brake system).

Scs/3-80

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SELF-PROPELLED CONDOR SCISSORS ELECTRIC SYSTEM The primary battery power system is supplied by four six-volt DC batteries housed below the main frame. The batteries are wired in a series-parallel circuit providing a total system supply of twelve (12) volts DC at 500 ampere hours.

The Condor Sci ssors is equipped with a battery charger permanently installed along with the batteries. The charger may be connected to any 115 Volt AC, 60 Hz power source. (Export machines require 220 Volt, 50 Hz power source.)

The electrical system is a negative ground, 12 volt DC network. There are two POWER SHUT-OFF switches. One in the frame panel, which when in the POWER position, establishes the control circuit ground. The POWER SHUT-OFF switch in the hand-held conso'le when in the POWER position connects 12 volts to the function toggle switches, UP-DOWN, RIGHT-LEFT, FORWARD and REVERSE in the hand-held console and UP-DOWN toggle switch in the frame panel.

During transportation, (platform lowered), the Condor Scissors can be operated from either the platform or walk-along carrying the hand-held console.

(~

BATTERY CHECK OFF LIST 1.

Brand new batteries should be given a 12 hour charge before first use.

2.

Limit use of brand new batteries to 3 hours between charges for first 5 cycles.

3.

During the first month of new batteries, particularly when night-time temperatures are below 60° F, give them an extra 12 hour charge once a week.

4.

All batteries that still taper down into the green area of the ammeter toward end of charge should be given the full 12 hours of charge.

5.

When batteries age to the point where charge rate no longer tapers into the lower 10% of the ammeter, reduce the hours of charge progressively to 10 hours, 8 hours, and finally down to 6 hours near the end of useful life.

6.

Turn on timers of all chargers first thing in the morning and send out first those whose ammeter needles jump up smartly to 15 amps or more and taper into the green area within 15 minutes.

7.

Add water carefully to proper level in cells as required after they have been fully charged. Do not fill them so high that they bubble over while charging.

Scs/10-81

15.

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8.

Keep tops of batteries and battery hold-downs clean and dry.

9.

Charge fuses should be screwed in at maximum hand tightness.

(

( Scs/l0-81

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OPERATOR CONTROL BOX

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SAFETY BAR Do NOT PERFORM ANY MAINTENANCE ON SCISSORS IN A RAISED POSITION UNLESS THE SAFETY BAR IS INSTALLED.

(

BATTERY SERVICE ACCESS

SELF-PROPELLED CONDOR SCISSORS TROUBLESHOOTING - ELECTRICAL SYSTEM ALL CONTROLS INOPERATIVE:

(

1.

Control box pendant cable plug. and locking collar is tight.

Check if plug is mating with receptacle

2.

Power Shut-off switch on control panel OFF. continuity.

3.

Power Shut-off switch on control box OFF. Turn switch ON. continuity.

4.

Battery weak. Check each cell with hydrometer; should indicate specific gravity of 1.275 (full charge). Recharge if low. NOTE: replace battery if a 0.050 specific gravity difference between any cells.

5.

Battery connections. connections.

6.

Defective 20 ampere fuse.

7.

Defective wire in control cable. Jumper from (+) battery terminal to RED lead on fuse block. If platform operates, check control cable continuity.

Turn switch ON. Check switch Check switch

Clean if corroded. Tighten loose electrical Replace if defective.

Jumper from ground to relay terminal (DARK GREEN) lead. If unit operates, check continuity between POWER SHUT-OFF switch and relay terminal (DARK green) lead.

Jumper from ground to relay terminal (WHITE and BLACK) lead. If work platform operates, check continuity between POWER SHUT-OFF switch and relay terminal (WHITE and BLACK) lead.

UP CIRCUIT INOPERATIVE: 1.

Same steps as in IIAll Controls Inoperative

2.

Defective Up section of UP-DOWN Switch. Replace switch if defective.

Check conti nu ity between termi na 1 block poi nts (1 eads WHITE to WHITE/BLACK).

If pump motor operates, check continuity between BLUE lead on terminal block and point on lead between relay and terminal block.

3.

Defective UP hydraulic solenoid. Same as Step 2 above. Check continuity through coil. Replace if defective. Check continuity between DARK GREEN lead of solenoid and POWER SHUT-OFF switch.

( Scs/3-80

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4.

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Relay clicks, but pump motor inoperative. If motor operates, check continuity between a point on the WHITE/BLACK lead to the relay and a point on pump motor coil (WHITE/BLACK lead). Jumper across the PM contacts. If pump motor operates, replace pump motor solenoid. Check pump motor brushes. Replace if defective. Jumper from negative battery terminal to negative terminal side on pump motor and actuate UP switch.

If motor operates, check continuity of line from negative battery side to negative motor side.

DOWN CIRCUIT INOPERATIVE: 1.

Same steps as in "All Controls Inoperative".

2.

Defective DOWN section of UP-DOWN switch. Replace switch if defective.

Jumper between LIGHT GREEN lead and WHITE/BLACK lead on terminal block.

If work platform lowers, check continuity of LIGHT GREEN lead.

3;

Defective down hydraulic solenoid. Same steps as in "All Controls Inoperative. Same steps as 2 above. Check continuity through coil.

Replace if defective. Check continuity of DARK GREEN lead.

II

RIGHT STEERING CIRCUIT INOPERATIVE:

(

1.

Same steps as in "All Controls Inoperative.

2.

Defective RIGHT section of RIGHT-LEFT switch. Replace switch if defective. Jumper between terminal block RED/BLACK and WHITE/BLACK leads. If platform steers right, check RED/BLACK lead continuity. Same as Step 2 in IIUp Circuit Inoperative.

II

1I

3.

Defective right hydraulic solenoid. Same as steps 1 and 2 in IIUp Circuit Inoperative." Check continuity through coil. Replace if defective. Check continuity of DARK GREEN lead. Same step as #4 in IIUp Circuit Inoperative.

LEFT STEERING CIRCUIT INOPERATIVE: 1.

Same steps as in IIAll Control s Inoperative.

2.

Defective LEFT section of RIGHT-LEFT switch. Replace switch if defective.

Jumper between terminal block BLACK and WHITE/BLACK leads. If platform steers left, check BLACK continuity. Same step as #2 in "Up Circuit Inoperative.

II

II

FORWARD DIRECTION CIRCUIT INOPERATIVE: 1.

Same steps as in "All Controls Inoperative."

2.

Defective FORWARD section of FORWARD-REVERSE switch. Replace switch if defective. Jumper between terminal block BLUE and WHITE/BLACK leads. If platform drives forward, check BLUE lead continuity. Same step as in #2 of IIUp Circuit Inoperative."

( Scs/3-80

1I

(

REVERSE DIRECTION CIRCUIT INOPERATIVE: 1.

Same steps as in "All Controls Inoperative."

2.

Defective REVERSE section of FORWARD-REVERSE switch. Replace switch if defective. Jumper between terminal block ORANGE and WHITE/BLACK. If platform drives in reverse, check ORANGE lead continuity.

c

Scs/3-80

c

SELF-PROPELLED CONDOR SCISSORS TROUBLESHOOTING - HYDRAULIC SYSTEM PLATFORM DRIFT DOWN: 1.

Worn, nicked, or defective cylinder packing. Check return line. If hydraulic fluid is present, packing is worn, nicked, or cut. Install new packing. .

2.

Leaking check valve or release valve. reinstall. Replace if defective.

3.

Emergency lowering valve open.

Clean to remoVe contamination and

Close valve.

PLATFORM DOES NOT LIFT; MOTOR AND PUMP OPERATE:

C

1.

Emergency lowering valve open.

Close valve.

2.

Oil reservoir low.

3.

Hydraulic system overloaded. Lighten load on platform, if excessive.

Check for obstructions in guide system.

4.

Clogged filter.

5.

Broken gear of shear pin.

6.

Leaking check valve or release valve. Clean to remove contamination and reinstall. Replace if defective.

7.

Directional valve spool scratched.

8.

Valve spool sticking. Use manual override on each valve. free spool or replace valve.

9.

Valve coil burned out.

Fill to within 1/2" of reservoir top.

Clean filter and/or check oil contamination.

Replace pump.

Return to factory for repair.

Replace valve.

If unit rises,

Check coil and replace if necessary.

PLATFORM WILL NOT LOWER: 1.

Faulty lowering valve.

2.

Defective electrical circuit(s).

3.

Obstruction in guide system.

4.

Obstruction in hose.

( Scs/3-80

Check and replace if necessary.

Refer to "Up Circuit Inoperative."

Clean and inspect.

Remove and inspect.

Replace if necessary.

(

WORK PLATFORM WILL NOT STEER: 1.

Directional valve spool scratched.

Replace valve.

2.

Defective electrical circuit(s).

3.

Faulty packing in steering Replace if necessary.

4.

Valve spool sticking. Use manual override on each valve. free" spool or replace val vee

5.

Valve coil burned out.

6.

Closed speed control.

Refer to "Up Circuit Inoperative.

1I

Remove cylinder and inspect packing.

If unit rises,

Check valve coil and replace if defective.

Open valve and adjust.

WORK PLATFORM WILL NOT DRIVE IN FORWARD OR REVERSE DIRECTION:

C

1.

Closed speed control.

Open valve and adjust.

2.

Valve spool sticking. Use manual override on each valve. free spool or replace valve.

3.

Valve coil burned out.

4.

Defective drive motors.

5.

Cushion accumulator defective. leaking.

Remove and check for leakage. Replace if

6.

Defective electric circuit(s).

Refer to "Up Circuit Inoperative."

7.

Faulty pump and/or motor. Check motor brushes and replace if necessary.

Check pump for broken gear or shear pin. Replace if necessary and return defective pump to factory.

If unit rises,

Check valve coil and replace if necessary.

Replace motor. Send defective motor to factory.

ALL SYSTEM SLUGGISH: 1.

Contamination buildup.

Flush or replace filters. replace with ATFDexron" II only.

2.

Defective hydraulic pump.

Scs/3-80

Replace if worn.

Flush system, then

( SELF-PROPELLED CONDOR SCISSORS MAINTENANCE PRACTICES GENERAL: Maintenance should be performed by competent personnel who are familiar with mechanical and electrical procedures. Due caution should be exercised since most mechanical and electrical guards will be removed during removal, installation, adjustment, and test.

WAR N I N G Do NOT PERFORM ANY MAINTENANCE ON CONDOR SCISSORS IN A RAISED POSITION UNLESS THE SAFETY BAR IS INSTALLED. Before attempting any repair work, set POWER SHUT -OFF switches to OFF position and disconnect charger cable from 120 volt AC source. Disconnect positive cable from final battery terminal to prevent accidental "shorts."

c

SAFETY BAR INSTALLATION: Raise work platform, then position the Safety Bar between the low and middle arm bearing shafts. Lower the work platform until the weight of the work platform rests on the Safety Bar. NOTE: This Safety Bar may be ordered from the manufacturer, or can be fabricated.

REMOVAL, INSTALLATION, ADJUSTMENT, AND TEST: The removal, installation, adjustment, and test of the electrical system and hydraulic system is covered respectively. Each major part is identified for the maintenance procedure. See Parts List for the particular part number, description and quanity.

PARTS REMOVAL, INSTALLATION, ADJUSTMENT, AND TEST: See attached charts for Electrical and Hydraulic Systems.

Scs/3-80

SELF-PROPELLED CONDOR SCISSORS ELECTRICAL SYSTEM - PARTS REMOVAL, INSTALLATION, ADJUSTMENT, AND TEST PART

REMOVAL

INSTALLATION

ADJUSTMENT

TEST

Power Shut-off Switch

Machine DOWN and OFF. Open control box or frame control panel.

Disconnect wires and remove fau 1ty swi tch .

Opposite of removal.

None

Power Shut-off switch ON.- Operate directonal switch.

Machine DOWN and OFF. Open conDirectional Switch; UP-DOWN, trol box or frame control panel FORWARD-REVERSE, for UP-DOWN only. Disconnect wires and remove faulty switch.

LEFT-RIGHT

Opposite of removal.

None

Power Shut-off switch ON. Operate directional switch.

Diode

Machine DOWN and OFF .• Open frame access cover. Locate diode on terminal board. Disconnect wires.

When removed, check with a continuity test.

Opposite of removal.

None

Power Shut-off switch ON. Operate associated directional switch.

Relay

Machine DOWN and OFF. Open frame access cover. Remove relay from socket. When removed, check with a Volt-Ohm meter.

Opposite of removal.

None

Power Shut-off switch On. Operate a directional switch.

Scs/3-80

SELF-PROPELLED CONDOR SCISSORS HYDRAULIC SYSTEM - PARTS REMOVAL, INSTALLATION, ADJUSTMENT, AND TEST PART

REMOVAL

INSTALLATION

ADJUSTMENT

TEST

Hydraulic Pump

Machine DOWN and OFF •. Back off nuts, loosen hoses and remove pump.

Opposite of removal. .

Bleed hydraulic Line to remove air.

Turn Machine ON. for leaks.

Opposite of removal.

Bleed hydraulic Line to remove air.

Turn Machine ON. Check for leaks. Operate proper working condition.

Lift Cylinder(s} Machine UP and OFF. Place Safety Bar between low and middle arm shafts. Loosen hos~s. Remove pin(s} at top, unbolt mounting blocks. Rotate cylinder 90°.

Remove cylinder(s}.

Check

Kick Cylinder

Machine UP and OFF. Ensure Safety Bar installed. Remove cylinder body mounting bolts.

Loosen hoses. Remove cylinder.

OpPosite of removal.

Bleed hydraulic Line to remove air. '

Repeat test for lift cylinder.

Steering Cylinder

Machine DOWN and OFF. Remove clevis pins from both ends.

Loosen hoses. Remove cylinder.

OpPosite of removal.

Bleed hydraulic Line to remove air.

Repeat test for lift cylinder.

Drive Motor(s}

Machine DOWN and OFF. Elevate rear end. Remove wheel and rear drive hub. Loosen bolts and hoses. Extract drive motor(s}

Opposite of removal.

Bleed hydraulic Line to remove air.

Repeat test for lift cy1 inder.

Directional Valve, LIFTSTEER

Machine UP and OFF. Safety bar installed. Disconnect electrical leads from solenoids. Disconnect hydraulic lines. Extract Allen bolts. Remove valve manifold block.

Opposite of removal.

Bleed hydraulic Line to remove air.

Repeat test for lift cylinder.

Scs/3-80

i~.

PART

REMOVAL

INSTALLATION

ADJUSTMENT

TEST

Manifold block

Machine UP and OFF. Safety bar installed. Remove directional valves as above. Disconnect hydraul ic lines. Remove manifold block.

Opposite of removal.

Bleed hydraulic Line to remove air.

Repeat test for 1ift cyl inder.

Cushion Valve

Machine DOWN and OFF. Disconnect hydraulic lines. Remove clamps, take out valve.

Opposite of removal.

Bleed hydraulic Line to remove , air.

Turn machine ON. Activate valve.

Check for leaks.

Scs/3-80

( SELF-PROPELLED CONDOR SCISSORS INSPECTION/CHECK PART

CHECK

MAINTENANCE

Lug Nuts

Tightness, especially after first two hours of operation.

Torque to standard foot lbs.

Hydraul ic Tank

Level of fluid. fluid.

Fluid visible in tank. clear and clean.

Hydraulic Hoses

Connections and lines.

Keep connections tight. Allow no leaks or kinks in hoses. Make sure hoses do not rub or get caught in 1ift.

Electrical Wires

Terminals and wires.

Keep terminals tight. Keep wires free from being caught in lift.

Replace cracked or frayed wires.

Val ves

Free movement. Check for dents or leaks.

Ensure hose connections tight.

Replace if defective.

Batteries

Fluid. Terminals.

Sump Filter in Hydraul ic Tank

Debris in filter

Remove, clean, and replace filter every six months.

Pressure Valve Fi 1ter

Debris

Remove, clean and replace every six month.

Color of

(

Scs/3-80

Hydrometer.

Red ATF

Keep full. Clean terminals and tighten periodically.

(

SERVICING The Self-Propelled Condor Scissors require a minimum of servicing. The bearings in the work platform arms are oi1ite bushings, impregnated with oil, and will provide years of service with no lubrication.

LUBRICATION POINTS Grease fittings are found on the lift cylinders and steering cylinder. These should be greased once every six months.

The wheel hubs should be packed with grease, and the front axle spindles lubricated once a year.

Apply silicon lubricant sparingly as needed, to eliminate any binding conditions on: 1.

Frame access cover hinges

2. Outriggers and stabilizing jack splines 3. Platform and frame rollers 4.

(

Kick cylinders pillow

BATTERY CARE Periodically service the batteries by removing the battery tray bolt and nut and sliding the tray and batteries out of the frame compartment. The battery weight is supported by the tray leg while pulled out. Ensure that all battery cells have water covering the plates. Add distilled water if needed.

Batteries should be re-charged after each working period. This is accomplished by plugging the charger into a 115 V AC outlet, and setting the timer. The Christie Electric Charger, Model 2440LC will charge at decreasing rates until the batteries are charged. The charger will then keep a trickle-charge on the batteries. Monitoring the charging operation is advised to keep from overcharging and boiling the batteries. Refer to Inspection/Check for battery checks.

HYDRAULI C FLUID The hydraulic system has been designed for long life and trouble-free operation.

The hydraulic oil needs no routine service except if it should be unusually dirty (very dark in color) or the reservoir level is low because of line leaks, cr water is cvid2nt due to cond~nsation. Ensure it is clean and fill the tank to,within tHO i:lches of the top usin~ o;,ly ''-TF (:'\utor.1iltic Transr.1ission Fluid) Dexran II hydrill:l ic oil.

Scs/3-80

ILLUSTRATED PARTS INDEX Calavar Self-Propelled Condor Scissors Models 1528, 1535, 1552, 2035, 2052

( FIGURE NO.

DESCRIPTION General Arrangement & Decal Identification

2

C

3

Base Assem b Iy

4

Drive Motor and Hub Assembly

4A

Drive Motor - Cushion Cylinder

5

Steering Assembly

5A

Steering Cylinder

6

Steering Hub Assembly

7

Tire and Wheel Assembly

8

Hydraulic Tank Assembly

9

Pump and Motor Assembly

10

Kick Cylinder

11

Hydraulic Plumbing

llA

Electrical Wiring

12

Battery Charger

13

Directional Control Valve Assembly

13A

2

14

Scissor Assembly, 15 Ft. Machines

14A

Scissor Assembl y, 20 Ft. Machines

15

lift Cylinder

16

Pla.tform Assembly

17

Control Box Assembly

Speed Valve

How to Order Parts

(

l.

When ordering parts for yourCONDOR®, ensure that you are able to give the model and serial numbers of all units for which parts are needed. The serial number(s) will assist the TIME CONDOR Corporation Parts Department in providing the correct parts for your machine(s). Please refer to FIGURE A for Serial Number Location on this model.

2.

Ifknown, please specify the TIME CONDOR Corporation partnumber(s) for the part(s) you require, and always provide a complete description of all parts.

3.

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

4.

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

5.

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

6.

TIME CONDOR Corporation classifies its orders in the following ways:

'.

c

Emergency

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

Stock

Order to be shipped within (I) week.

7.

TIME CONDOR Corporation has a $25.00 Net Minimum Billing charge per order.

8.

All price quotations will be valid for 90 days.

9.

Parts shown as shipped on the TIME CONDOR Corporation packing list and subsequent invoice but not received by the dealer/customer MUST be reported within 10 days after the date of shipment. If the parts are still required, a NEW parts order must be submitted.

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

10.

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

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

(

I

CCOUNT# I NAME N C F U ADDRESS 0 S R T M 0 CITY A M T E I R PHONE 0 ( ) N CUST. PURCHASE ORDER NO.

PURCHASER

SALES ORDER # NAME

STATE

S H I P

ZIP

FAX

(

)

I ORDERDATE

I

I

I

T 0

~DRESS

CITY

STATE

HONE

FAX

(

(

)

REQUEST DATE

ZIP

)

SPECIAL MARKS & NUMBERS

SIDPPING INSTRUCTIONS

PART NUMBER

QTY.

DESCRIPTION

NOTES

"

(

FOR ORDER STATUS PLEASE CHECK APPROPRIATE BOX BELOW

C

EMERGENCY

STOCK

FIGURE I GENERAL ARRANGEMENT & DECAL JDENTrFfCATION ;

i !

~

:;..

',,;;,

: .i

~

Ii :; '" :i ~ ,:1

:

CONTROL BOX

(

FIGURE 17 ,

-----

M ~

i

!

~

"\i1.,~fIV".

if

1•

8

"" (

PLATFORM ASSEMBLY FIGURE 16

SC ISSORS ASSEMBly ..........

FIGURE 14

,1

FIGURE 1 GENERAL ARRANGEMENT & DECAL IDE~TtFICA TION i

(

PART NUMBER

DESCRIPTION

REF 1

"Load Capacity"

Mode I (1528,2035)

(1535,1552,2052) 2 '. Forklift Boot" 3- "Power & Platform Controls" 4 "Baftery Service" IIMaximum Travel Height" (1528, 1535, 1552) 5 6 1 - - " Danger - Electrocution Hazard" 7- II Danger Keep Clear"

8-

Danger - Qualified Operator" 9 "Emergency Lowering" -"Condor" !O Model (1528) 11 "Model Number" -

II

(1535) (1552) (2035) (2052) 12 I - - - "Scissors"

13 I--- "-Nameplate 14 -

(

II

II Freewhee ling II

Jd-I

QTY

50054 50055 50057 50672 50070 50062 21882-2 21882-1 21882-3 50058 50172 50166 50167 50168 .

50170 50171 50173 50064 50553

2 2 2 1 2 1 1 2 2 1 2 2 ·2 2 2 2 2 1 1

/5c18- 990/~

( 10/81

FIGURE IA

GENERAL ARRANGEMENT & DECAL IDENTIF ICA TlON

LOAD CAPACITY 750 LBS.

(EVENL Y DISTRIBUTED LOAD) LOAD CAPACITY 1000 LBS.

(EVENL Y DISTRIBUTED LOAD)

IMPORTANT CHECK BATTERY WATER LEVEL AT LEAST ONCE A WEEK.

50070

50055

tFORKLIFTt

BOOT

300'7

I

MAXIMUM TRAVEL HEIGHT 15 Fa::J

I

MAXIMUM TRAVEL HEIGHT 20

~.1

I EMERGENCY LOWER..G VALVE I t OPEN VAtVE TO LOWER PlATFORM t 50058

POWER

o

(.

SHUT OFF

FREE-WHEELING VALVE

UP

o

OPEN ONLY FOR TOWING - .

SO!!~3

. DOWN 50672

ELECTROCUTION HAZARD THIS MACHINE IS NOT INSUUTED ".'AIII SAf£ CWIAICU fIIIIM

1lSTIICAI. _ IllES MIl UI'lIAlUS. IOU MUST ALLOW fOI PUlfOlll SWAY. ROCK. OR SA&.

TIllS _ DIYIC£ DIllS NDl PR1I¥IIIl PROllC1IIIII FItIII CIIIIlACT WITH OIIPRt1X111IlY 'I' III WClIICALI.Y CllAIIElI CONDUClGI.

_

YOU

(OIIIA(! WITH I1IIS _ If

n~ •

_fllflmn_IllUl.II1._. .

_-"'-_...-, lI8UUllIOS. ... _ACIHU'S ...... ... SIIII1'~IILAIM"1111

..

""-1

SUCH CINTACT OR INADEQUATE ClEAIAIICl 51l1li_ 2

21882-2

THIS MACHINE

_ _ _ COIPIlIt _ .. fJIlSIROPUAtIIII.TIIS . ._ . . .1f

GIl VDIICII

DKtllUU.y CIIAIUI.

NOT

UOUSS ... U l _ n _ ... _

ELEaROCUTION HAZARD KEEP CLEAR 1U1II _ _ _ UIIIfSIl'_

21882-1

~SlRUIL

.-"

DEATH OR SERIOUS INJURY.

21882-3

10/81

FI GURE 3

BASE AS SEMBL Y

(

(

10/81

FIGURE 3 BASE ASSEMBLY

I (

REF

Base Weldment

1 Electric Motor with Pump 2- Hydraulic Tank Assembly Kick Cylinder 3 4 Directional Control Valve 5-1 - - - Drive Motor 7 2-Speed Directional Control Valve 8 I - - - Battery 9 Battery Tray 10 Battery Charger 11 ~Junction I30x (Not required on 1528)

c

PART NUMBER

DESCRIPTION (1528) (1535, 2035) (1552, 2052)

50709 50707 50690 (Ref. Fig. . (Ref. Fig. (Ref. Fig. (Ref. Fig. (Ref. Fig. (Ref. Fig. 50046 50635 (Ref. Fig. 50670

QTY

9) 8) 10) 13) 4) 13A)

1 1 1 1

2 1 4 1 1 1

12)

12 r-- Cam Follower 50638 13 r--Stop Tab 50669 50069 14 r-- Metering Valve 15 -Bracket, Metering Valve 50427 16 -Battery' Compartment Cover (1528)- -50719 (1535, 1552, 2035, 2052) 50663 18 (Ref. Fig .4A) Cushion Cylinder 19 ~ Limit Switch-2· Speed 50082 50671 20 r-- Limit Switch-Height 21 I--- Toggle Switch-on/off 50077 50075 22 -Toggle Switch-up/down 50078 23 -Relay 50079 24 Relay Socket

10 2 2 2 1 I 2 1

1 1 1 1

1

10/81

FIGURE 4 DRIVE MOTOR AND HUB ASSEMBLY DESCRIPTION

REF

(

PART NUMBER

QTY

+1

1 Drive Motor - - - - - - - - - - - - - + - - 50042 - - - - - r - - - 2 2 Drive Key 5/16" SO. x 3/4" lG. 2 1/2-13 x 2 1/2 lG. 8 3 - C a p Screw Drive Hub 50096 2 4 I 5 $ Slotted Nut 1"-20 Thd 2 Cotter Pin 3/16" x 2" lG. 2 6 7· 2 - Speed Valve (See Fig 13A) 1 8 Washer 1-1/8 Type B 2

C~

10/81

FIGURE 4A DRIVE MOTOR CUSHION

REF

( 1 2 3 4 5

6-

DESCRIPTION

I.

R PART NUMBER

Drive Motor Cushion Cyl inder .

50033

End Plug "0" Ring End Plug Cyl inder Tube Spring Piston Piston Seal (Quad Ring)

91016 91017 91018 91019 91020 91021

\ QTY

2 2 1 2

1 1

c-

10/81

F! GURE 5

STEER! NG ASSEMBl Y

(

12

~ I

:i

7

(,

9 17

J t3

13

/

5 .

3

17

Tie Rod Arrangement

Model 1528

( 17

10/81

FIGURE 5 STEERING ASSEMBLY

PART NUMBER

DESCRIPTION

REF

QTY

( Steering Assembly Steering Cylinder

(1528) (1535,2035) (1552,2052)

50034 (Ref. Fig. 5A) 50044· 50032 50230 2 Clevis Pin 3 - r- Washers (1/8) 1" 3/16 zerk 5 - f- Lube Fitting (1528) 6 Tie Rod 50365 50174· (1535,2035) 50224 (1552,2052) 1/2"-13 UNC-2" LG. 7 Hex Head Cap Screw 1/2"-13 UNC 8 -f- Lock Nut 50527· 9 - t- Rod End Bearing 1/2-20 UNF lO- t- Nut 50679 11-~ King Pin 3/16" x 1-1/2 LG. 12-t- Cotter Pin 50373 (1528) 13-- Spindle Assembly (Left) (1535, 1552,2035,2052)- f-50227 50372 (1528) 14-- Spindle Assembly (Right) (1535,1552,2035,2052)- f-50226 50048 15-- Bushing, Bronze 1" 16- ~Washer (1/32) 50047 17- i- Thrust Washer 1

,

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

1 4 2 4

10/81

NDER

DESCRIPTION

REF

PART NUMBER

QTY

Model 1552/2052-1---50032 Model 1528 50034 Model 1535/2035 50044 Piston Lock-Nut------------I---91034------+-1 Piston 91035 1 Steel Washer 91036 1 Head Gland 91037 1 Head Gland Lock Ring 91038 1 Rod Assembly Model 1528 91040 1 /Yodel 1535/2035-+--91041 1 Model 1552/2052 91039 1 91043 AR Cylinder Seal K i t - - - (Includes 8 thru 12) Piston Seal 1 Rod Seal 1 -Head Gland Seal 1 Piston/Rod Seal 1 Rod Wiper 1 Steering Cyl inder

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

9/81

FIGURE 6 STEERING HUB ASSEMBLY

REF

DESCRIPTION

(

Steering Hub Assembly 1---"-- Washer 2 + 0 i l Seal 3 Searing Cone 4 Bearing Cup 5 Slotted Nut Cotter Pin 6 7 -,-- Hub Cap

=f= -r-

8 fHUb Solt Lug Nut 9

PART NUMBER

QTY

50095

2

111 91022 91023 91024 111-14 UNF 3/16" x 211 91027 91028 91029

1 1 2 2 1 1 1 5 5

i

10/81

REF

( 1 2

3 4

5

DESCRIPTION

PART NUMBER

I QTY

Tire and Wheel Assembly

50090

4

Tire 400 x 8, Solid Wheel Lug Nut Hub Front Drive Hub, Rear

50092 50091 91029 50095 (See Fig 6) 50096 (See Fig 4)

4 4 20

2 2

(

2

10/81

FI GURE 8 HYDRAULIC TANK ASS EMBL Y

DESCRIPTION

REF

(

I 2 3 4 5 6 7 8 9 10

II

PART NUMBER

QTY I I I I I

50633 S0634 50304 50684 50686

Hydraulic Tank Assembly Tank Wetdment Breather Cap Gasket lid Tapping Screw

-1/4" x 3/4" [G.

Sight Guage 90° Adapter Sump Strainer Pipe 90° Adapter

50067 Hyflex 5502-4-4 50074 50685 Parker 2-103-8-8

12

~~1--_;----7

8 I---t--

10

11

10/81

FIGURE 9

DESCRIPTION

REF

(

PUMPANDMOTORASSEM~LY

I.

PART NUMBER

I QTY

I Pump and Motor Assembly I 50021 -1±Pump - - - - - - - - - - - - - t · - 5 0 4 5 1 - - - - - + - ·-2 Motor 50476-----3 Solenoid It:,; 50152·----_+_-4 - L Bracket, Solenoid Mounting 50699 - - - - - + - -

1I'

+

(DRo/ocR fumf fDlZo ja:/i/ Coup/inj 5'0/t/1 hlltr 51('3'1

hlf:ey E/embt

13

(' --+--3

4

10/81

FIGURE 10 KICK CYLINDER

REF

(

DESCRIPTION

It'

Kick Cyl inder

PART NUMBER

I

QTY

50031

Piston Lock Nut 91001 2 Piston ----------------t-- 91002 - - - - - - + - - 1 3 Steel Washer 91003 - - - - - - + - - 1 4 Head Gland 91004 .

1 Head G land Lock Ring 91005 1 5 6 Rod 91006 1 7--r-Cylinder Seal Kit (Includes items 8 thru 12) 91007 AR 8 Piston Seal - - - - - - - - - - - - + - 9 Rod Seal 10 Gland S e a l - - - - - - - - - - - - + - - 11 Rod Seal 12 Rod Wiper

-t1

(

10/81

FIGURE 12

BATTERY CHARG ER I

(

Charger Cable Assembly

50520 50521 50531

Cable, 14/3 Plug (Not Included For Export) Connector

50429 50530

12 Y DC Battery Charger

2 3 4

PART NUMBER

DESCRIPTION

REF

mDL -d(035

115 YAC, 60 Hz 220 YAC, 50 Hz

I QTY

6 ft.

I

I

ext ~

rl1.art.ed c21 LC.So CVR.r PN# S-COd<:( -If C i'rcu.rt. 6r-ea.Ker 5"0 M1P - PN #: ~7~ {, .f: limp me-l:v -. ftv# J<7J~oIOO3 circu,"-I; cortb7;{ boo..Yd - PN -II:- KD(a010J(P ~ LeD f?ec/ . PN 11- J<D R 0100 (, fc

*

c

3

(

1

10/81

FIGURE 13 DIRECTIONAL CONTROL VALVE ASSEMBLY

REF

C

DESCRIPTION

PART NUMBER

QTY

Directional Control Valve 1

lA 1B

2 3 3A

4

Directional Control Valve Replacement Solenoid (DNWICK-31 Valves) Replacement Solenoid .(DNWICK-40 Valves) Sandwich Valve Dump Valve Replacement Solenoid Manifold

d157'1

~

91000 91014 50071 50085 91015 50076

3 AR AR 1 1 AR 1

c'

10/81

REF

(

1 1A 18

2

I

DESCRIPTION

Two Speed Valve Replacement Solenoid Replacement Solenoid Manifold

(DIYW8KK -31 Valve) (DNW8KK -40 Valve)

PART NUMBER

50134 910Of) 91014 50334

QTY

1 AR AR 1

c.

10/81

FIGURE 14

(

( 28

SCISSORS ASSEMBLY (15)

FJ~IJRF

~rJC:~()1)

AC:C:I=AARI'

(

Scissors Assembly

1 2 3 4 5

-

.-

11/;;\

PART NUMBER

DESCRIPTION

REF

(

14

(1528) (1535, 1552)

Collar Bushing, Flanged Upper Outer leg Bushing, Bronze Bolt, Hex Head( lH Side) Grade 5 (RH Side) Grade 5 Flanged lock Nut 7 Bushing, Bronze 8 Sleeve, Steel 9 10 I - - - Upper Inner Leg Assembly (1528) (1535, 1552)_ 11 ~Sleeve, Roller Channel -(1528) (1535,0552) 12 I---- Lower Ou ter leg 13 r-- Bottom Inner Leg Assembl y (1528) (1535, 1552) 14 I - - - Lower Inner leg Assembly (1528) (1535, 1552) Grade 5 15 Bolt, Hex Head 16 --:--Deck Roller 17 -Sleeve, Roller Limit 18 r--Washer, Type B 19 I---- Lift Cylinder 20 I---- Base Ro-ller 21 -Trunnion Block Bush ing, Bronze 22 Pin-lift Cylinder 23 r--Bushing, Bronze 24 25 t--RoII-Pin 26 r-- Trunnion 27 t - - Cyl inder Mounting Strap (Omitted on 1528) 28 r--Sway Bar 29 t--Sway Bar, Bottom (Omitted on 1528) 30 t--Bolt, Hex Hd. -(Omitted on 1528)

QTY

50710 50725 50053 6 50667 12 50707 2 50666 2 5/8"-11 UNC x 7" lG. 1 5/8-11 UNC x 6" lG. 1 5/8-11 lC 50645 14 50643 14 50704 1 50736 1 50697 2 50688 2 50644 4 50703 1 50648 1 50705 1 50646 1 3/8"-11 UNC x 3-1/4 lG --12 50655 2 50689 1 1-1/8 x 2 x 1/8 steel 2 (Ref. Fig. 15) 2 50656 2 50110 2 50928 2 50744 1 50052 2 1/4 DIA x 1-1/2 LG. 2 50109 2 5028·5 1 50793 2 1 50794 5/8" - 11 UNCx 1-1/2"Lg - - 2

1/82

FIGURE 14A SCISSORS ASSEMBLY (20) 3 1

(

L?16

~

(

8

28

9

I LI /5 ! ~; ~ 3N,' I '" I'

20 /

7

~

17

.

Cylinder Mounting

25

~22 ,

,27

F~

~ 1f 19

V/~)

~

i! /~o I/,c': ,--, I 26 ~I;

24

21~1

~~:IO/

'W~

rx:"#-, ""-J ".'~ ~

0

/ .

liB?

FIGURE 14A SCISSOR ASSEMBLY (20)

REF

Sci ssOrs Assemb Iy

( 1 2 3 4 5

PART NUMBER

DESCRIPTION

Collar Bush ing, Flanged Upper Outer leg (RH) Bush ing Bronze Bol t, Hex Head (lH Side) Grade 5 Bolt, Hex Head (RH Side) Grade 5 6- t-- Upper Outer leg (lH) 7 Flanged lock Nut 8 Bushing, Bronze 9 Sleeve-Steel 10-r--Upper Inner leg Assembly 11- -Sleeve, Roller Channel 12- -lower Outer leg 13- - Bottom Inner leg Assembly 14- -lower Inner leg Assembly 15- -Bolt, Hex Head Grade 5 16- -Deck Roller 17- -Sleev.e, Roller limit 18- -VVasher, type B 19 - -lift Cyt inder 20- -Base Roller 21- -Trunnion Block 22- - Bushing, Bronze 23- -Pin-lift Cylinder 24- - Bushing, Bronze 25~ -Rolr Pin 26- -,--Trunnion Plate 27- -.:.. Cyl inder Mounting Strap 28- -Sway Bar 29- -Sway Bar, Bottom 30- -Bolt, HexHd.

( 2035,2052)

QTY

50665 50053 8 50667 16 50680 1 50666 2 5/8 11 -11 UNC x 6 11 lG 1 11 11 5/8 -11 UNC x 5 lG 1 50653 1 5/8 11 -11 12 50645 18 50643 18 50654 1 50688 2 50644 6 50648 1 50646 2 5/8 11 -11 UNC x 31/4" lG. 1--16 50655 2 50689 1 1 1/8 x 2 x 1/8 steel 2 (Ref. Fig. 15) 2 50656 2 50110 4 50928 4 50744 2 50052 4 4 1/4 OIA x 1-1/2 lG. 50109 4 50285 2 50793 3 50794 1" 5/8 11 - 11 UNCx 1-1/2 I1 lg - - 2

.

1/82

PART NUMBER

DESCRIPTION

REF

(

Lift Cylinder

1

QTY

50517

i I

G l a n d - - - - - - - - - - - - - - - - + - - 91008 2 Piston----------------I~- 91009 3:t:Rod Assembly 91010 91011 4 I· Locknut 5 . C o l l a r - - - - - - - - - - - - - - - + - - 91012 6 I Cyl inder Seal Kit (Includes items 7 thru 13) 91013 7 Gland Static S e a l - - - - - - - - - - - - I - 8 RodSeal--------------~--9 Piston Seal 10 Back-up Ring-Piston-----------+--11 Rod Wiper 12 Rod Static S e a l - - - - - - - - - - - - - + - 13-r--Back-up Ring-Rod

1 1 1 1 1 AR 1 1 1

----------------+---

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

2

-------------+---

1 1

----------+--

1

7

(

8 12

0/81

FI GURE 16 PLATFORM ASSEMBL Y

(

(

2/82

FIGURE 16 PI ATH,)RM A<;<;!=MRI Y

!

REF

I

(

1

PART NUMBER

DESCRIPTION

QTY

Platform Assembly

1528 1535 1552 2035 2052

50723 50734 50735 50711 50662

Deck Weldment

1528 1535 1552 2035 2052

50722 50737.

50738 50702 50661

1 1 1 1 1

1528 1552/2052 2035/1535

50382 50103 50153

1 1 1

1528 1552/2052 2035/1535

50384 50104 50154

1 1 1

0

2- I-- Guard Rail-Right -

+ i

I i

3

c

Guard Rail-fran!

4-'-- Plywood Floor

1 1528 3/4" x 22" x 70" LG. 1552/2052-1-3/4" x 46" x 72-1/2" LG. I----- 1 2035/1535-1-3/4" x 29" X 72-1/2" LG. 1-----1

5-1-- Guard Rail-Left

1528 1552/2052 2035/1535

6- t-- Receptacle 6A-+--Contact Pin 7- t-- Cradle - Control Box 8 Control Box Assembly 9- I-- Chain lO- r-- Chain Snap 11- t - - Rail, Rear

1528 only

50383 50219 50169

1 1 1

50326 50328 50106 (Re.f. Fig. 17) 1/4 11 Steel 50286 50385

1 16 1

. '01 2 1

2/82

FIGURE 17

REF

(

17-I -2

-3 -4 -5 -6 -7

-8

q

DESCRIPTION Control Box Assembly Box Machining Control Cable Plug Toggle Switch Toggle Switch Decal Connector Contact Socket

-(X)!

Ca.b/~

CONTROL BOX ASSEMBLY

PART NUMBER

QTY

50234 50272 16/12 Type S.O. 50327 50077 50075 50061 2535 (Crouse Hinds) 50329

I I 6 1/2 It

I 2

3 I I 16

c

q

10/81