CONDOR Scissor Lift 2032,3146,3154, & 3160 Operator's Manual - PDF DOWNLOAD

( CALAVAR CORPORATI ON

AERIAL WORK PLATFORM

MODELS 2032,3146,3154, AND 3160

OPERATOR'S MANUAL

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CALAVAR CORPORATION 8300 IMPERIAL DRIVE

W ACO, TExAs 76712 (817) 666-4545

MANUAl. 1l227HlOl SEPTEMBER 1993

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INTRODUCTION

The primary purpose of this manual is to provid 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 AERIAL WORK PLA TFORM A T ALL TIMES .

Do not attempt to operate the CONDOJl® until you have read and

understood all information provided inthis manual.

Familiarize

yourself with the functions and operations of the upper and lower controls. A good understanding of the controls, their limitations, Bnd their capabilities will maximize operating efficiency Bnd safety. The various decals attached to this machine are NOT for decoration. Theycontain vita/information. Read the decals before

operating this machine.

It is your responsibility to follow safe procedures w hile operating the CONDORi!l. The manufacturer of this unit does not control the wide range of applications that may be used in ca rrying 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.

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It is also YOUR RESPON SIBILITY to understand and obey all federal. state. and local regulations regardi ng the safe operation and use of aerial work platforms. A copy of the ANSI/ SIA A92 Manual of Responsibilities is attached for your use.

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

DO NOT ALTER DR MODIFY THIS UNIT WITHOUT PRIOR WRITTEN APPROVAL FROM THEMANAGEMENTOF CALAVAR CORPORATION.

SERVICE & MAINTENANCE Many of the parts used in the manufacture of the CONDOR4D have specific properties, and the manufacturer recommends that replacement parts be purchased through CALAVAR CORPORATION in order to ensure the original integrity of the product. Repa irs and adjustments should only be made by trained and qualified personnel. Please refer to the Owner's Service Manual f or information on service and maintenance of the CONDORi!l.

MANUAl. 9227NlO l SEPTEMBER 1993

TABLE OF CONTENTS

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INTROOUCTION ........ .......•••.••.• .•.•••.•.•.•.•.••.• .•..... .... .. ....... ...•..•.•..•..•.• .•.•..• .•. .•.•.•..••. .•.•. i TABLE OF CONTENTS .•.••• .•.•.•. •.•. •.••.•.••...• .•.•.••.•.•.•..•.•.•..•..•.•• .•..•..•.•..•.•...•..•.•.•.•...••••. ii

I. PREPARATION. INSPECTION. ANO MAINTENANCE .. ........... ............ ....................... . 1 A. B. C. D. E.

OVERALL CONDITION ... ..•.. ........ ........ ....•.. .. ..... •............. ..... ....• .•.. •.•.•.•.•... ..

LOWER CONTROL STATION .•.•..•.• .•.• .•.. •.•..• .•.•.••.•..•. .•.•• .••.•.• ...... •. .•.....•.......

PLATFORM & UPPER CONTROL STATION ................ •• .•..• .... •.•.•.•..••.•.•• .•.•••.• HYDRAULIC SYSTEM •.•.•.•.••• ••. •...•.•.••.•. •.. •. ••.•. •.......... ...... ..... .. ......... .... ......

BATTERIES & CHARGER .... ... .... ... ............•... .... .... ..... •.••.••.• .•••..•.•..•.•.••.• ... •.

1 1 1 2 2

II. MACHINE OPERATION .... .. .. ............ ...................................... •.•. .•.••.•.• .•. .•.• .•.••• .•..• 2

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A . RATED WORK LOAD .•.•.• .•... ..• .•. •. .. .•.• .•.•• .•...... •.••..•.•..•.•..•..•.• .•. •..• .•.•.•.• .•••.• 2 B. LOWER CONTROLS ..................... •........ ..... ... .... ...... .... .... •.•..•........ •... .... •. .•. 2 C. PLATFORM CONTROLS .••••.•.••.•••.•.•.•.•..•.•..•.•.•....••.••.• ... .•........... .... .... ...... .. 3 III. OPTIONAL EQUIPMENT .. ... ....•.•. •.•.•.••• .•.•.••• .....•••.•.• •••...... .... .... ... ...... ........ ... ..... .. .. 3 IV. EMERGENCY LOWERING .••.•.• .•.•.•.•.•.•.•.•.• .•.••. •.••.• .•.•.••.•..•. .•.... •..• .•.... •.•................. 4 V . MOVING FROM JOB SITE TO JOB SITE .•.. .• .. •.• ....•..... ......... .... .... ..... ....•.•..•.•.•.•.•.•..• 4 A. B. C. D.

LOADING AND UNLOADING •.. ••.•.........•.. •.... ..•....................•••.• .. •.•....•..•.•.•.• RAMP METHOD .•.•..••..•...•.•.• .•.•..••.•.•• .•.•. .•. : ....•..•.••.•....•..• ... ...... .. ......•...... ..

FORKLIFT LOADING/UNLOADING METHOD ................ ••.... •.•.•••• .•.•..•.• .•.••.•••.

TRANSPORTING •••.•.•.• .•.•.•••••..•• .•.•.•.• .•.••.•••..•.•.•. .•. .... ............ .....................

4 4 4 5

VI. FREEWHEEL OPERATION ...............•........ ...•.•.•• ....•.•.•.•• .••.••.•.••.•..•.• .•.• ..•.•. .•...... .. ... 5 APPENDIX: ANSI/SIA 92.6 - 1992 MANUAL OF RESPONSIBILITIES

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IMPORTANT: A COpy OF THE ANSlfSIA 92.6 - 1990 MANUAL OF RESPONSIBILITIES IS ATTACHEO TO THIS OPERATOR'S MANUAL. IT CONTAINS IMPORTANT OPERATING INFORMATION FOR THIS MACHINE. READ BEFORE OPERATING THIS MACHINE. I.

PREPARATION, INSPECTION, AND MAINTENANCE

THE CONDITION OF THE UNIT IS VERY IMPORTANT, AS IT DIRECTLY AFFECTS THE OPERATOR'S SAFETY AS WELL AS THE SAFETY OF OTHERS. THE OPERATOR MUST PERFORM A THOROUGH WALK-AROUND INSPECTION EACH DAY PRIOR TO OPERATING THE MACHINE. ANY DAMAGE OR FAULTY OPERATION SHOULD BE REPORTED IMMEDIATELY. A DO NOT OPERATE TAG OUTLINING THE PROBLEM SHOULD BE ATTACHED TO THE LOWER CONTROL STATION KEY SWITCH AND ANY DISCREPANCIES SHOULD BE CORRECTED BEFORE OPERATING THE CONDOR®.

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KNOW THE UNIT AND ITS CAPABILITIES. REPORT ANY UNUSUAL OPERATION, SUCH AS ERRATIC SWAY OR MOTION OF THE ARMS OR PLATFORM.

CAUTION : DEFECTIVE COMPONENTS , STRUCTURAL DAMAGE, MISSING PARTS, AND EQUIPMENT MALFUNCTION JEOPARDIZE THE SAFETY OF THE OPERATOR AND OTHER PERSONNEL A ND MAY CAUSE EXCESSIVE DAMAGE TO THE UNIT. A POORLY MAINTAINED MACHINE COULD BECOME THE GREATEST OPERATIONAL HAZARD YOU MAY ENCOUNTER. B. LOWER CONTROL STATION CHECK ELECTRICAL WIRES AND CABLES FOR LOOSE, BROKEN, OR FRAYED WIRES. ALL FUNCTIONS OPERATE PROPERLY, CONTROL RETURNS FREELY TO NEUTRAL, CENTER POSITION. DO NOT OPERATE T HE UNIT W ITH STICKING CONTROLS. C. PLATFORM AND UPPER CONTROL STATION CHECK ELECTRICAL WIRES AND CABLES FOR LOOSE, BROKEN, OR FRAYED W IRES.

A. OVERALL MACHINE CONDITION. TIRES AND WHEELS: CHECK FOR CRACKS, TEARS, CUTS, OR MISSING OR LOOSE LUG NUTS (A RUST LINE RUNNING DOWN THE RIM FROM THE LUG NUT INDICATES A LOOSE LUG NUT).

MISSING, BROKEN, OR DAMAGED PARTS: CHECK CYLINDER MOUNTING PINS, PIVOT PINS, PIN RETAINERS, BOLTS, AND NUTS. STRUCTURAL: CHECK FOR DAMAGED OR CRACKED WELDS ON STRUCTURAL COMPONENTS-ARMS, PLATFORM, CHASSIS. STEERING: CHECK TIE ROD ENDS AND STEERING CYLINDER FOR PROPER AND SECURE MOUNTING .

DECALS: ALL DECALS AND WARNING SIGNS ARE IN PLACE AND ARE CLEARLY LEGIBLE.

ENTRY POINT BARS AND CHAINS ARE FUNCTIONAL AND SECURE, FOOTSWITCH OPERATES PROPERLY, GUARDIS IN PLACE. RE-CHECK THE STRUCTURAL CONDITION OF THE PLATFORM - PINS , RAILINGS , FLOOR. CHECK RED BUTTON: DISCONNECTS POWER TO THE CONTROLS AND STOPS THE OPERATION OF ALL FUNCTIONS. CHECK THAT ALL CONTROL LEVERS RETURN FREELY TO THEIR NEUTRAL POSITIONS. CHECK AUXILIARY LOW ERING VALVES ON ARM LIFT CYLINDERS.

1 MANUAl 92277-00 1 SEPTEMBER 1993

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D. HYDRAULIC SYSTEM

B.

CHECK THE HYDRAULIC TANK FLUID LEVEL WITH THE ARMS LOWERED. MAINTAIN FULL FLUID LEVEL - DEPENDING ON THE UNIT. THIS WILL BE TO THE MARK ON THE SIGHT GLASS, TO THE MARK ON THE DIPSTICK, OR TO WITHIN ONE INCH FROM THE TOPOFTHETANK. ADD SHELL TELLUST32 HYDRAULIC OIL TO THE SYSTEM. ENSURE THE BREATHER CAP IS CLEAN AND IN PLACE ON THE TANK .

MODEL 2032

CHECK FOR HYDRAULIC LEAKS AT FITTINGS, VALVES, AND CONTROLS. CHECK ALL HYDRAULIC HOSES AND TUBES FOR DAMAGE, KINKS, AND PROPER ROUTING TO AVOID PINCH POINTS. E. BATTERIES & CHARGER

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LOWER CONTROLS

AT THE LOWER CONTROL STATION THERE IS A SELECTOR SWITCH, A TOGGLE SWITCH, AND CONTROL LEVER. TO OPERATE THE LOWER CONTROLS, TURN THE SELECTOR SWITCH TO THE LOWER POSITION. TO RAISE THE PLATFORM, PUSH THE TOGGLE SWITCH TO THE UP POSITION .

THEN MOVE THE CONTROL LEVER IN THE UP POSITION .

TO LOWER THE PLATFORM, PUSH THE TOGGLE SWITCH TO THE DOWN POSITION. THEN MOVE THE CONTROL LEVER IN THE DOWN DIRECTION.

CHECK BATTERY ELECTROLYTE LEVEL AND ENSURE THAT ALL CAPS ARE PRESENT AND TIGHT ON THE BATTERIES. ALL BATTERY CABLE CONNECTIONS SHOULD BE TIGHT AND CLEAN.

MODEL 3160

MAKE SURE THE BATTERY CHARGER IS IN GOOD CONDITION AND THE ELECTRICAL PLUG AND METER ARE NOT DAMAGED.

THE MAIN KEY SWITCH IS ALSO LOCATED AT THE LOWER CONTROL STATION. WITH THE KEY IN THE CENTER (STRAIGHT UP) POSITION, THE UNIT IS OFF AND POWER IS DISCONNECTED. WITH THE KEY IN THE FAR RIGHT POSITION, THE CONTROL CIRCUIT IS ENERGIZED FOR OPERATION.

II. MACHINE OPERATION A. RATED WORK LOAD THESE PLATFORMS WILL SUPPORT A COMBINED WEIGHT EQUAL TO THE UNIT'S RATED WORK LOAD- INCLUDING PERSONNEL, TOOLS , AND EQUIPMENT -THROUGHOUT THE WORKING ENVELOPE OFTHE MACHINE. MODEL 2032 3146 3154 3160

LBS.

KG.

# OCCUPANTS

500 750 750 1500

227 340 340 6B1

2 3 3 6

AT THE LOWER CONTROL STATION, THERE ISA "PUMP " SWITCH, A "PUSH TO LOWER" SWITCH, AND CONTROL LEVER.

MODELS 3146 AND 3154 AT THE LOWER CONTROL STATION THERE IS AN OPERATOR ' S SELECTOR SWITCH WHICH SHIFTS THE OPERATIONAL CONTROLS BETWEEN " PLATFORM" AND "GROUND " MODES. NEXTTOTHISSWITCH IS A TOGGLE SWITCH LABELED "UP" AND "DOWN" . FOR OPERATION OF LOWER CON TROLS, THE OPERATOR SWITCH SHOULD BE SWITCHED TO GROUND. THE TOGGLE SWITCH MAY BE HELD EITHER IN THE UP OR DOWN POSITION WHILE HOLDING CON TROL LEVER IN POSITION DESIRED.

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TO OPERATE THE UNIT FROM EITHER CONTROL STATION, TURN THE KEY SELECTOR SWITCH ON. TO RAISE THE PLATFORM. OEPRESS THE "PUMP" SWITCH. THEN MOVE THE CONTROL LEVER IN THE UP OIRECTION. TO LOWER THE PLATFORM, DEPRESS THE "PUSH TO LOWER" SWITCH, THEN MOVE THE CONTROL LEVER IN THE DOWN DIRECTION. C. PLATFORM CONTROLS NOTE: AT LOWER CONTROL STATION. THE OPERATOR S.ELECTOR SWITCH MUST BE SWITCHED TO THE PLATFORM TO ENERGIZE THE UPPER CONTROLS. EMERGENCY POWER BUnON PULL TO TURN ON AND PUSH TO TURN OFF .

NOTE : THIS IS ALSO AN EMERGENCY STOP SWITCH. PUSH TO CEASE ALL FUNCTIONS.

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THE CONTROLS ARE ENERGIZED ONLY WHEN THE FOOTSWITCH IS DEPRESSED. THE PLATFORM CONTROL BOX CONTAINS THE FOLLOWING CONTROLS: DRIVE/STEER CONTROL THIS FOUR-WAY CONTROL LEVER OPERATES THE DRIVE AND STEER FUNCTION S. DRIVE " FORWARD" MOTION IS DETERMINED W ITH THE STEERING WHEELS LEADING THE WAY. AND " REVERSE " MOTION IS DETERMINED WITH THE DRIVE WHEELS LEADING THE WAY . MOVING THE DRIVE/STEER CONTROL LEVER TO THE FORWARD OR REVERSE DIRECTION WILL CAUSE THE UNIT TO DRIVE IN THOSE RESPECTIVE DIRECTIONS . MOVING THE SAME CONTROL LEVER TO THE RIGHT OR LEFT WILL CAUSE THE UNIT TO STEER RIGHT OR LEFT RESPECTIVELY. THE FOOTSWITCH MUST BE DEPRESSED WHILE OPERATING THESE FUNCTIONS. THE CONDOR~ SCISSOR LIFTS HAVE THREE (3) DRIVE SPEEDS: LOW. HIGH. AND CREEP. LOW SPEED IS ACCOMPLISHED WITH THE SCISSOR ARMS COMPLETELY

LOWERED. THIS ALLOWS THE GREATEST POSSIBLE TORQUE FOR DRIVING UP MAXIMUM INCLINES. HIGH SPEED IS AVAILABLE WITH THE PLATFORM RAISED JUST A FEW INCHES SO THE ARMS JUST CLEAR THE TRANSMISSION VALVE ACTUATOR. THIS ALLOWS THE FASTEST DRIVE SPEED. BUT HAS REDUCED TORQUE. CREEP SPEED IS ACCOMPLISHED BY RAISING THE SCISSOR ARMS FURTHER. APPROX IM ATELY 12 INCHES. TO CLEAR THE CREEP VALVE ACTUATOR. THIS ALLOWS THE MINIMUM DRIVE SPEED AND GREATLY REDUCED TORQUE WHILE DRIVING AT INCREASED PLATFORM HEIGHTS. LIFT UP/DOWN CONTROL LEVER TO RAISE THE UNIT. MOVE THE CONTROL LEVER TO THE "UP " POSITION. TO LOWER THE UNIT. MOVE THE CONTROL LEVER TO THE "DOWN " POSITION . THE FOOTSWITCH MUST BE DEPRESSED FOR BOTH "UP" AND "DOWN " OPERATIONS; HOWEVER. THE HYDRAULIC PUMP WILL NOT BE OPERATING DURING THE " DOWN " FUNCTION .

GRAVITY LOWERING IS ACCOMPLISHED .

III. OPTIONAL EQUIPMENT THE FOLLOWING OPTIONS ARE AVAILABLE ON THE CONDOR~ AERIAL WORK PLATFORM: -DECK EXTENSION -TRAVEL WARNING HORN -5 0 MULTI-AXIS SLOPE SENSOR -110V LINE TO PLATFORM -SELF-CLOSING GATE -HOUR METER -3154 OPTION

3 MA~U"'l

92277-00 1 SEPTEMBER 1993

IV. EMERGENCY LOWERING

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THE CONDOfl® IS EQUIPPED WITH EMER· GENCY LOWERING VALVE(S) LOCATED AT THE HOLDING VALVE ON THE LIFT CYLINDER(S)' TO OPERATE THE EMER· GENCY LOWERING VALVE(S). DEPRESS THE RED·KNURLED KNOB AND TURN COUNTER· CLOCKWISE UNTIL IT POPS OUT SLIGHTLY (1 /8 " . 1/4 "). THE LIFT/LOWER CONTROL LEVER .AT THE LOWER CONTOL STATION CAN NOW BE MOVED TO THE "LOWER " POSITION AND THE PLATFORM WILL LOWER. (NO ELECTRICAL ACTIVATION IS NECES· SARY) V. MOVING FROM JOBSITE TO JOBSITE

THE RAMP SHOULD BE SET AT AN ANGLE NO STEEPER THAN THE MACHINE'S RATED GRADE·A81L1TY, MODELS 2032 AND 3146: 11 ' OR 21 % , OR A RISE OF 25 INCHES IN 10 FEET, MODELS 3154 AND 3160: 15 ' OR 26 %, OR A RISE OF 32 INCHES IN 10 FEET. BEFORE DRIVING THE UNIT ON THE RAMP, LOWER THE PLATFORM COMPLETELY, TEST THE DRIVE/STEER CONTROLS AND THE BRAKE SYSTEM, AND 8EWARE OF FREE· WHEELING CONDITIONS. DRIVE UP OR DOWN THE RAMP SLOWLY, ALLOWING FOR STEERING CORRECTIONS TO BE MADE, KEEP UNIT IN ALIGNMENT WITH THE CARRIER AND RAMP DURING LOADING AND UNLOADING PROCEDURES.

A. LOADING AND UNLOADING

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ALTHOUGH THE .CONDOR" IS SOMEWHAT SMALL COMPARED WITH LARGER CON· STRUCTION EQUIPMENT, IT REQUIRES THE SAME CARE AND ATTENTION IN LOADING, TRANSPORTING, AND UNLOADING AS DOES LARGER EQUIPMENT. AT NO TIME SHOULD ITS SIZE BE UNDERESTIMATED. BEFORE LOADING OR UNLOADING, INSPECT THE UNIT FOR ANY PHYSICAL DAMAGE OR DE· FECTS. THE MEANS 8Y WHICH YOU LOAD OR UN· LOAD THE UNIT SHOULD BE OF SUFFICIENT STRENGTH TO WITHSTAND THE WEIGHT OF THE CONDOR".

MODEL 2032 3146 3154 3160

WEIGHT(#) 2, 120 4,640 5,780 4,960

WEIGHT (KG) 962 2, 105 2,622 2,250

C, FORKLIFT LOADING AND UNLOADING METHOD ENSURE THAT THE FORKLIFT HAS SUFFI· CIENT CAPACITY TO HANDLE THE WEIGHT OF THE CONDOR", (SEE PAGE 4) MODELS 2032, 3146, AND 3154 SHOULD ONLY 8E LIFTED FROM THE SIDE, POSITION· ING THE FORKS UNDERNEATH THE CHAS· SIS. FORKS SHOULD BE LONG ENOUGH TO GO ACROSS THE WIDTH OF THE FRAME AND SHOULD 8E POSITIONED AS CLOSE TO THE INSIDE OF THE TIRES AS POSSIBLE .

NOTE: DO NOT ATTEMPT TO LIFT THESE MODELS FROM EITHER END. MODEL 3160 SHOULD ONLY BE LIFTED FROM THE FRONT OR REAR, USING THE FORKLIFT BOOTS PROVIDED. THE CONDOR" SHOULD ONLY BE RAISED TO A HEIGHT SUFFICIENT TO CLEAR ANY OBSTRUCTIONS.

B. RAMP METHOD ENSURE THAT THE RAMP BEING USED IS SUFFICIENTLY STRONG TO HANDLE THE WEIGHT OF THE UNIT.

KEEP FORKLIFT TRAVEL TO A MINIMUM, AND SET GENTLY DOWNTOGROUND LEVEL.

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stl'rEMGEA 1993

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D. TRANSPORTING THE CONDOR. CAN BE EASILY AND SAFELY TRANSPORTED FROM THE JOBSITE IF THE FOLLOWING RULES AND PROCEDURES ARE FOLLOWED: BLOCK ALL WHEELS TO PREVENT FORWARD AND REVERSE MOTION. TIE DOWN THE CONDOR$ WITH CHAINS OR CABLES, RUNNING THEM THROUGH THE TIE-DOWN BRACKETS ONLY. DO NOT CHAIN OR STRAP OVER THE GUARD RAILS. SEVERE DAMAGE TO THE SCISSOR ARMS MAY RESULT FROM SECURING THE UNIT OVER THE TOPOF THE PLATFORM, DUE TO EXCESS PRESSURE. ALWAYS TURN THE POWER OFF AT THE GROUND CONTROL STATION. VI. FREEWHEEL OPERATION

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CAUTION: WHEN USING THE FREEWHEEL VALVE, THE CONDOR. MUST BE ON LEVEL GROUND. TURN VALVE KNOB CLOCKWISE UNTIL CLOSED AND DRIVE THE CONDOR. APPROX IMATELY 3 FEET. THIS W ILL DISABLE THE BRAKE, ALLOWING THE CONDOR. TO BE MOVED .

THE VALVE KNOB MUST BE TURNED FULLY COUNTERCLOCKWISE (OPEN) FOR NORMAL OP,ERATION . .

NEVER EXCEED 5MPH WHEN MOVING THE CONDOR. IN THE FREEWHEEL MODE.

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ATTENTION MANUAL OF RESPONSIBILITIES for Dealers, Owners, Users, Operators, Lessors and Lessees of

ANSIISIA A92.6-1990 Self-Propelled Elevating Work Platforms

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WARNING (

FAILURE TO COMPLY with your REQUIRED RESPONSmlLITIES in the use and operation of the Aerial Platform could result in DEATH OR SERIOUS INJURY.

IMPORTANT

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You are required by ANSI/SIA A92.6-1990 to read and understand YOUR RFSPONSmILITIES before you use or operate this Aerial Platform.

This Manual and the manufacturer's operation and safety manuals are considered integral parts of the Aerial Platform and are VITAL TO COMMUNICATE NECFSSARY SAFETY INFORMATION to users and operators. They MUST BE KEPT ON TIlE AERIAL PLATFORM in the storage compartment.

The operation of any aerial platform is subject to certain HAZARDS that can be protected against only by the exercise of INTELLIGENCE, CARE, AND COMMON SENSE. It is essential to have COMPETENT, CAREFUL PERSONNEL, TRAINED in the INTENDED USE, SAFE OPERATION, MAINTENANCE AND SERVICE of this type of equipment.

The USER and OPERATOR MUST MAKE DECISIONS on the maintenance, use and operation of the Aerial Platform with due consideration for the fact that the SAFETY OF THE OPERA TOR AND OTIlER PERSONNEL is dependent on those decisions.

FAILURE TO COMPLY with your REQUIRED RFSPONSmILITIES in the use and operation of the Aerial Platform could result in DEATH OR SERIOUS INJURY. Refer to the manufacturer' s operation and safety manual for the INTENDED USE of the aerial platform and for further INFORMATION ON SAFE USE AND OPERATION.

The ANSIISIA A92.6-1990 standard for Self-PropeUed Elevating Work Platforms became effective January 2, 1992 . This Manual incorporates sections from that standard as follows: Definitions Responsibilities Responsibilities Responsibilities Responsibilities

Section

3 5

Section Section Section Section

6 7 8 9

Section

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Section of Dealers of Owners of Users of Operators

Responsibilities of Lessors Responsibilities of Lessees Typical Examples of Equipment Covered Minimum Safe Approach Distance Published by

Scaffold Industry Association, Inc. 14039 Sherman Way, Va n Nuys, California 91405·2599 Copyright c 1992 by Scaffold Industry Association, Inc. All rights reserved .

No part of thi s publication may be reproduced in any fo rm, in an electro nic retrieval system or o therwise, without the prior written permission of the publisher.

Printed in tbe United States of America

Figure Figure

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Page Page Page Page Page Page Page Page Page

1 1 2

3 6 8 8 9

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Single copy list price ........ $ 4.95

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IRESPONsmn.lTIES MAN UAL

Reprint from ANSI/S IA A92.6-J990

( 3. Definitions

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aeria l plutfoTm. A mobile device that has lin adjustable position platform. supported from ground level

by II structure.

Il ut hori zed personnel (u ulhori zed person). Personnel approved as assigned to perform a specific type of duly or dulies al a specific location or locations al a work sile. bnse. The relevant contact points of the aerial platform that Conn the stability fulc rum (e.g. wheels. casters, outriggers, stabiliz.crs). chassis. TIle integral part of the aerial platform Ibal provides mobility and support for the elevating assembly. conng urntion. All positions in which an aerial platform or any part thereof can be placed within its intended operating limits. denier. A person or entity who buys from a manufacturer or distributor and who generally sells. rents. and services aerial platforms. deli ve ry. Transfer o f care. control. and custody of the aerial platform from one person or entity to anothe r person or entity. directional controls. Controls that initiate functions that affect movement of the platform or the aerial platform. eleva tin g a ssembl y. The mechanisms used to position the platform relative to the ae rial platform chassis. gua rdra il system. A ve rtical barrier erected to prevent personnel from falling to lower levels. ha7.Drd ous location. Any location that contains. or has the potcntial to contain. an cxplosivc or nammable atmosphcre as defined by ANSIINA'A 505. instability. A condition o f an aerial platfonn in which the sum of the moments that tend to overturn the unit exceeds the sum of the moments tending to resist overturning. insula ted platCorm. A platform designed and tested to meet the specifi c electrical insulation ratings consistent with the ma nufacturer's identification plate. interlock. A contro l or mechanism that. under specified cond itions. automatically allows or prevents the operation of another control or mechanism. ma nuCacturer. A person or entity who makes. builds, or produces an ae rial platform. maximum travel hcight. The maximum platform heigh t or the most adverse configuration(s) with respect to stability in which travel is permitted by the manu factu rer. modlnelltion. Modification. modifie s: To make a change(s) to an aerial platfonn that affects the operation. stabi lity. safety factors. rated load or safety of the aerial platfonn in any way. operator. A qualified person who controls the movemen t of the aerial platform. outriggers. Devices that increase the stability of the ae rial platfonn and that arc capable of lifting and leveling the aerial platform.

overri de. To take over aeri3l p!3tform movcmcnt control functions at the upper control station by those at the lowcr control station. owner. A person or cntity who has possession of an aeri3l platform by virtue of proof of purchase. passive. Automatically performed and not rcquiring any specific operator action to accomplish. plat form. The portion of an aerial platform intended to be occupied by personnel with their necessary tools and ma terials. pla trorm height. The vertical distance measured from the noor of the platform to the surface upon which the machine is being supported. powe red fun ctions. '{bose which control motion o f the platform or the aerial platform and arc caused by clectromechanical. hydraulic or pncum:l\ie forces. qUlllifle d p('rson. A person, who by reason of knowledge. expericllce. or training is familiar with the operation to be performed and the hazards involved. rllted wo rk load. 111e designed carrying capacity of the aerial platform as specified by the manufacturcr. s hllii. The word "shall" is to be undcrstood as being mandatory. s tllbilit y/s tnble. A condition of an aerial platform in which thc sum of the moments that tend to overturn the unit is Icss than or equal to the sum of the moments tending to resist overturning. stabili-,;ers . Devices that increase the stability of the aerial platform but are not capable o f lifting or leveling the aerial platform. unintend ed motion o r motion unintend ed by opera tor. Motion of the acrial platform or platform without activation or any control. unrest r icted rllted work lond. 111e maximum designed carrying capacity of thc aerial platform allowed by the manufacturer in all operating configurations. user. A person(s) or cntity who has care. control and custody of the aerial platform. This person or entity may also be a de(ller. owner. lessor. lessee. or operator.

NOTE: Operating and maintenance manuals covered in Section 4 of ANSVSIA A92.6, and referred to in this document, should be obtained from the manufacturer of the ae ri al platfor m.

15. Responsibilities of Dealers 5.1 Bas ic Principles. Sound principles of safety. training, inspection. maintenance. application. and operation consistent with all data available regarding the parameters of intended use and expected environment shall be ap plied in the training of operators. in mainten(lnce. application. safety provisions and operation

IRESPONSIBILITIES MANUAL of the aerial platform with due consideration of the knowledge that the aerial platform will be carrying personnel.

5.2 Mn nunls. Dealers shall keep and maintain a copyOts) of the operating and maintenance manual(s) required in 4.16.1. l be operating manual(s) shalt be provided with each rental, lease or sale delivery. The manual(s) shall be slored in the location required by 4. 16.2. The manual(s) is considered an integral part of the aerial platform and is vital to communicate necessary safety information 10 users and operators. In addition. parts and maintenance manuals shall be provided with each sale delivery.

5.3 Prcdcli vcry P reparat io n. Aerial platforms shall be inspected. serviced and adjusted to manufacturer's requircments prior to each dclivcry by sale, lease or rental.

5.4 Mllintenll nce Sllrety Preca utions.

Before adjustments and repairs arc started on an aerial platform, the following precautions shall be taken as applicable: ( I) Powerplant slopped and starting means rendered inoperative (2) All controls in the "Ofr position and all operating systems secured from inadvcrtent motion by brakcs, blocks or other means (3) Elevating assembly and platform lowered down to thc full down position, if possible, or otherwise secured by blocking or cribbing to prevent dropping (4) Hydraulic oil pressurc rclieved from all hydraulic circuits before looscning or rcmoving hydraulic componcnts (5) Safety props or latehcs installcd whcrc applicable as prescribed by the manufacturer 5.5 Replacement Parts, Whcn parts or components arc rcplaced, they shall be identical or equivalent to original aerial platform parts or components.

5.6 T ra ining. Whenevc r a dcaler dirccts or authorizcs an individual to operate an aerial platform, the dealer shall ensure that the individual has been trained unde r the direction of a qualified person in accordance with the manufacturer's operating manual and requireme nts listed in Section 8 of this standard before operating the aerial platform.

5.6.1 Training on Delivery. Manufacturer's operating instruction and rcquired training of the proper use and operation of the aerial platform shall be provided upon each delivery by sale, lease, or rental.

5.7 Opera tion. When a dealer operates an aerial platform in sales demonstrations or for other beneficial use, the dealer shall assume the responsibilities of users as specified in Section 7 and the operating personnel shall assume the responsibili ties of operators as specified in Section 8 of this standard.

S.S Assistance to Owners li nd Users. If a dealer is unable to answer an owner's or user's question(s) relating to rated capacity, intended use, maintcnance, repai r, inspection, or operation of the aerial platform, the dealer

Reprint from ANSIISlA An.6-J990

( shall obtain the proper information from the manufacturer and provide that information to the owner or user.

5.9 Record Reten tion. Dealer(s) shall retain the following records for at least 3 years: (I) Name and address of the purehascr of each aerial platform by serial number and datc of delivery (2) Records of the pcrson(s) trained upon each delivery of an aerial platform (3) Records of the predelivery preparation performed prior to each delivery 5. 10 Modifications. Modification or alteration of an aerial platform shall be made only with prior wrillen permission of the manufacturer.

5.1 1 Man ufllclu rer's Safely Bulletins. The dealer shall comply with safety-related bulletins as reeeivcd from the manufacturer.

6, Responsibilities of Owners 6.1 Basic Principles. Sound principles of safety, training, inspection, maintenance, application, and operation consistent with all data available regarding the parameters of intended usc and expected environment shall be applied in the performance of the responsibilities of owners with due consideration of the knowledge tha t the aerial platform will be carrying personnel.

6.2 Man ua ls. Owners shall keep and maintain a eopy(ies) of the operating and maintenance manual(s) required in 4.16.1 of this standard. The operating manual(s) shall be provided with each rental, lease or sale delivcry and shall be stored in the weather resistant stor.lge compartment required by 4.16.2 of this standard.

-lbese manual(s) are considered an integral part of the aerial work platform and arc vital to communicate necessary safety information to users and operators. In addition, parts and maintenance manuals shall be provided with each sale delivery.

6.3 Mllintenance. The owner of an aerial platform shall arrange that the maintenance specified in this standard is properly performed on a timely basis. The owner shall establish a preventive maintenance program in accordance with the manufacturer's recommendations and based on the environment and severity of usc of the aerial platform. The owner shall arrange that frequent and annual inspections arc performed. All malfunctions and problems identified shall be corrceted before the aerial platform is returned to service.

6.4 Predeli ve ry Preparnt ion. Aerial platforms shall be inspected, serviced, and adjusted to manufacturer's requirements prior to each delivery by sale, lease or rental.

The owner of an aerial 6.5 F requent Inspection. platform shall cause a frc:quent inspection to be performed on an aerial platform: (I) lbat has been in service for three (3) months or 150 hours whichever comes first:

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IRESPONSmILITIES MANUA L (2) TIlal bas been out o f service for a peri od longer than three months; The inspection shall be made by a person qualified as a mechanic on the specific make and model of the aerial platform. The inspection shall include all items specified by the manufact urer for a frequent inspection and sha n include but not be limited to the following: (3) All func tions and their controls for speed(s). smoothness, and limits o f motion; (4) Lower controls including the provisions for overriding o f upper controls; (5) All c hain and cable mechanisms for adjustment and

worn or damaged parIs;

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(6) All emergency and safety devices; (7) Lubrication of all moving parts, inspection of filter clement(s), hydraulic oil, engine oil, and coolant as specified by the manufacture r; (8) Visual inspection o f structural components and o ther critical components such as fasteners, pins, shafts and locking dev ices; (9) Placard, warnings and control markings; (1 0) Additional items specified by the manufacturer.

The owner shall not place the aerial platform into service until all malfunctions and problems have been corrected.

6.6 AnnuIII Inspection. The owner of an aerial platform shall cause an annual inspection to be performed on the aerial platfonn no later thall 13 months from the date of the prior annual inspection. The inspection shall be performed by a person(s) qualified as a mechanic on the specific make and model o f the aerial platform. The inspection shall include all itcms specificd by thc manufacture r for an annual inspection.

6.7 Mllintenance Safety Precautio ns .

Before adjustments and repairs arc started on an aerial platform, the fo llowing precautions shall be taken as applicable: (I ) Powerplant stopped and starti ng means rendered inoperative (2) All controls in the "ofr position and all operating systems secured from inadvertcnt motion by brakes, blocks, or other means (3) Elevating assembly and platfonn lowered to the full down position, if possible, or otherwise secured by blocking or cribbing 10 prevent dropping (4) Hydra ulic o il pressure relieved from all hydraulic circuits before looscning or n:movi ng hydraulic components (5) Safety props or latches installed where applicable as prescri bed by the manufacturer 6.8 Replacemen t Parts. When paris or components arc replaced, they shall be identical or equivalent to original aerial platform parts or components.

6.9 Maintenpnce Trlllning. The owners shall train their maintenance personnel in inspection and maintcnance of the aerial platform in accordance with 6.3, 6.4,6.5,6.6,6.7,6.8 and 6.1 0 of th is standard. and with the manufacture r's recom mendations.

Reprint from ANSIISJA A92.6-1990 6.10 Operator TTIlining. An owner who directs or authorizes an individual to operate an aerial platfonn shall ensure that the individual has been trained in accordance with lhe manufacturer's operating manual and requirements listed in Section 8 of this standard before operating the aerial platform.

Manufacturer's opcrating instructions and required training on the proper usc and operatio n of the acrial platform shall be pro vided upon each delivery by sale. lease or rcnta\.

6.11 Opcrtllion. When an owncr operates an aerial platform . the owner shall have the responsibilities o f users as specified in Section 7 of this standard and his operating personncl shall have responsibilities of operators as specified in Sectio n 8 of this standard.

6.12 Assis ta nce to Use rs and Operators. If an owner is unable to answer a user's or operator's question(s) relating to rated capacity, intended usc, maintenance, repair. inspection. or operation of the acrial platform. the owner shall obtain the proper information from the dealer or manufacturer and provide that information to the user or operator.

6.13 Record Retention. 111e owner shall retain the following records for at least 3 years: (I) Name and address of the purchaser of each aerial platform by serial number and date of delivery; (2) Rccords of the person(s) trained upon each delivcry of an acrial platform; (3) WriU<;'n records o f the frequent and annual inspections performed by the owner. The record shall include deficiencies found. corrective action and identification of the perso n(s) performing the inspection and repairs.

(4) Records of the predelivcry preparation performed prior to each delivery.

6. 14 Modifications . Modification or altera tion of an aerial platform shall be made only with prior written permission of the manufacturer.

6.15 Manufacturer 's Sa fety Bulletins. 'Ille owner shall comply wilh safety-related bulletins as received from the manufacturer or dealer.

7. Responsibilities of Users 7.1 Basic Prin ciples. 'Ibe information in this standard must be supplemcntcd by good job managcmcnt, safcty control. and the application of sound principles of safety. training. inspection, maintenance, application, and operation, consistent with all data available regarding the parametcrs of intcndcd usc and expected environment.

Since the user has direct control over the application and operation of aerial platforms, conformance with good safety practiecs in this area is the responsibility of the user and the operating personnel, including the operator.

Decisions on the use and operation o f the aerial platform must always be made with due considcration for the fact

IRESPONSmILITIES MANUAL thai the aeri al platform will be carrying pcrsonnd whose safety is dependent on those decisions.

7.2 l\1ta nuu ls.

Users shall keep and maintain a copy(ies) of the operating and maintenance manual(s) required in 4 .16. 1 of this standard. The operating manual(s) shall be provided wit h each ren tal. lease or sale delivery and shall be stored in tbe weather resistant Slorage compartment required by 4.16.2 of tbis standard.

The manual is considered an integral part of the: aerial platfonn and is vital to communicate ne<:essary safety infonnation to users and operators. In addition, parts and maintenance manuals shall be: provided with each sale de li very.

7.3 [nspcct ion a nd Maintenance. Users shall inspect and maintain the aeri al platform as required to ensure proper operation, The frequency o f inspection and maintenance shall be determined by the manufacturer's recommendations and be compatible with operating conditions and the severity o f the operating environment.

Aerial platforms that are not in proper operating condition shall be im mediately removed form service until repaired, Repairs shall be made by a qualified person and the repairs shall be in conformance with the ma nufacturer's recommendations, 7.3.1 F r eq uent Ins pectio n , An inspection as outlined in section 6.5 of this standard shall be conducted.

7.3.2 Annun l lnspec tion , An inspection as outlined in section 6,6 of this standard shall be conducted, 7.3.3 Prestart Inspection. Before use each d ay or at the beginning of each shi ft. the aerial platform shall be given a visual inspecti on and functional test including but not limited to the following: ( I ) Operating and emerge ncy controls (2) Safety dev ices (3) Personal protective devices (4) Air, hydraulic and fue l ~yste m leaks (5) Cables and wiring harness (6) Loose or missing parts (7) Tires and wheels (8) Placards. warn ings, eontrol markings, and operating manual(s) (9) Outriggers, stabilizers, and other structures (10) Guardrail system ( II) Items specified by the manufac ture r Before 7.3.4 Mnintenunce Surety Preca utions. adjustments and repairs are started on an aerial platform, the following precautions shall be taken as applicable: (I ) Powerplant stopped and starting means rendered inoperati ve (2) All controls in the "Ofr position and all operating systcms secured from inadvcrtent motion by brakes. blocks. or o ther means (3) Elevating assembly and platform lowered to the full down position, if possible, or otherwise secured by blocking or cri bbing to prevent dropping

Reprint from ANSlfSIA An.6-J990 (4) Hydraulic oi l pressu re relieved from all hydraulic circuits before loosening or removing hydraulic components (5) Safety props or latches installed whe re ap plicable as prescribed by the manufacturer 7.4 Replace men t I'a r ts. When parts or components are replaced. they shall be ide ntical or equivalent to the original aerial platform parts or components.

7.5 l\'iPintennnce Training. l oe use r shall train the maintenance personnel in inspection and maintenance o f the aerial platform in accordance with sections 7.3, 7.3. 1, 7.3.2. 7.3,3, and 7.3.4 of Ihis standard and wit h the manufacturer's recommendations, 7.6 O perator Trai ning. Wheneve r a user directs or authorizes an individual to operate an aerial platform the user shall ensure that the individual has been trained in accord ance with th e manufacturer's operating and maintenance manual, the user's work instructions, and the requirements listed in Section 8 of this standard before operating the aerial platform , 7.6. 1 Model Training. l oe operator shall be trained either on the same model of aerial platform or one having operating characteristics and controls consistent with the one to be used duri ng actual work site operation. Under the direction of a qualified person, the trainee shall operate th e aerial platform for a sufficient period of lime to demonstrate proficiency and kn owledge in the actual operation of the aerial platform, Care shall be taken to ensure the area o f such operation has a minimum of obstacles and is conducive to training. Only properly trained and authorized personnel shall be pcrmilled to operate the aerial platform.

7.6.2 Trainee Uecords. 1\ record of the trainee's aerial platform instruction shall be maintained by the uscr for at least 3 years.

7.7 Befor e O per a tio n. Before authorizing an operator to operate an aerial platform, the user shall ensure that the operator has: (I) Been instructed by a qualified person in the intended purpose and function of each control (2) Read and understood the manufacturer's operating instruction(s) and user's safety rules, or been trained by a qualified person on the contents of the manufacturer's operating instruction(s) and user's safety rules (3) Understood by reading or having a qualified person explain all decals, warnings. and instructions displayed on the aerial platform (4) Been informed Lhat the purpose for wh ic h the acrial platform is to be used is within th e scope of lhe intended applications defined by the manufacturer 7,8 Wo rkpla ce Inspecti on. Before th e aeria l platform is used and during usc, the user shall check the area in which the aerial platform is to be used for pouible hazards such as, but not limited to: (I) Drop-offs or holes (2) Bumps and n oor obstructions (3) Debris

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IRESPO NSIBILITIES MANUAL (4) Overhead obstructions and high voltage conductors (5) Hazardous locations (6) Inadequate surface and support to withstand all load forces imposed by the aerial platform in all operating configurations (7) Wind and weather conditions (8) Presence o f unauthorized persons (9) Other possible unsafe conditions 7.9 Durin g Opcrntion. The aerial platform shall be used in accordance with Ihis standard. The user shalt direct his operating personnel and supervise their operation \0 ensure that the following is adhered to prior to each movement o f the aerial platform and each rCp:>Sitioning of the platform: (I) The aerial platform is operated on a surface within the limits specified by the manufacturer (2) The outriggers, stabi lizers, extendable axles, or other stability enhancing means, are used as required by the manufac turer (3) The guardrails are installed and access gates or openings arc closed per manufacturcr's instructions (4) The load and its distribution on the platform and any platform extension arc in accordancc with the manufacturc r's ratcd capacity for that specific configurati on (5) There is adequate clearance from overhead obstructions (6) The min imum safe approach distanccs (MSAD) to e nergized power lines and parts, as listed in T able One o f Figure 3 are maintained. See page ( lO) (7) The precautio ns defined in sections 7.3.3, 7.7, 7.8.

7.9, 7.10 and 7. 11 of this standard are foll owed during operatio n of the aerial platform 7.10 Dete rmina tion or HaUlrdous Locations . It shall be tbe rcsponsibility of the user to detennine the hazard class ification o f any particular atmosphere or location according to ANSIIN Fl)A 505- 1987.

Aerial Platforms operated in hazardous locatio ns shall be approved in accord ance with, and o f the type required,

by ANSIINFPA 505-1987.

1.11 Warnings and Ins truetions. The user shall di rect his operating personnel and supervise their work to ensure operation of the aerial platform in compliance with this standard.

7.11.1 Personnel Footin g. Personnel shall maintain a firm footing on the platform floor while working thereon.

Use o f planks, ladders, or any othcr dev ice on the acrial platform for achieving additional height or reach shall be prohi bited.

1.11.2 Other Mo ving Eq uipment.

When other mo ving equipme nt and vehicles are present, special precautions shall be taken to comply with local ordinances or safety standards established for the workplace. Warnings such as, but not Iimitcd to, fl ags, roped-off areas, fl ashi ng lights, and barricades shall be used.

Reprint from ANSl/SIA A92.6-1990 7.1 1.3 Ueportin g Problems or Ma lfu nct ions. 111c operator shall immediately report to the supervisor lWy problems or malfunctio ns that become evident du ring operation. Any problems or malfunctions that affect the safcty of opcr.ltions shall be rcpaircd prior to continued use.

7. 11.4 Altering Safety Devices. Altcring or disabling of intcrlocks or othcr safcty deviccs shall be prohibited.

7. 11 .5 Ent3 11glement. Care shall be taken to prcvcnt rope, electri c cords and hoses from becoming entangled in the aerial platform.

7.1 1.6 Ca paci ty Limitutio ns. Rated capacities shall not be exceeded when loads are transferred to the platform at any height.

7. 11.7 Wo rk Area. 'l1le operator shall ensure that the area surrounding the aerial plat form is clear of personncl and equipment before lowering the platform.

7. 11.8 Fueling. The engine shall be shut down while fuel tanks arc being filled. Fueling shall be donc in a well-venti lated area fre e of flame, sparks. or other hazards that may cause fire or explosion.

7.11.9 Hatte r y Chargi ng. Batteries shall be charged in a well-ventilated area free of flame, sparks. or other hazards that may cause fire or explosion.

7. 11 .10 1mp roper Platform Sta bili1.ration. '111e acrial platform shall no t be positioned against another Object to steady the platform .

7.1 1.1 1 !\"lisuse as a Crane. The aerial platform shall not be used as a crane.

7.11.12 Un us u;! 1 O pera ting Su ppo rt Conditions. l be aerial platform shall not be operated from a position on trucks, trailers, railway cars, floating vessels, scaffolds. or similar equipment unless the application is approvcd in writing by the manufacturer.

7.11.13 T r;l\'eI S peeds. Under all travel conditions, the operator shall limit travcl speed according to conditions of ground surface, congestion. visibility, slope, location of personnel, and other factors causing hazards o f collision or injury to personnel.

7.11.14 Elevnted Dri ving Requirements. Bcfore and during driving while the platform is elevated, the operator shall: ( I ) Maintain a clcar view of the path of travel (2) Maintain a safe distancc from obstaclcs, debris, drop-offs, holes, depressions. ramps, and other hazards to ensure safe elevated travel (3) Maintain a safe dis tance from overhead obstacles 7.11.1 5 St unt Driving. Stunt driving and horseplay shall not be permitted.

7.11.16 Unnuthorized Usc. Means shall be used to protect against use by unauthorized pcrson(s).

7.12 Opera tion of t he Acri nl Pla tform. If a user is also the operator of an aerial platform, the user shall have the responsibilitics of operators specified in Section 8 of Ihis standard as well as responsibilities o f users as specified in Section 7 o f this standard.

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IRESPONSmlLITTES MANUAL 7.13 Assista nce to O pe ra to r. If a user is unable to answer an operator's qucstion(s) relating to rated capacity, intended use, main tenance. condi tion. or safety of operation of the aerial platform, the user shall obtain the proper information from the dealer, owner. or manufacture r and provide that informatio n to the opera tor before use o f the aerial platform in the application of concern.

7.14 S hutdown or Aeria l Platfor m. The user shall authorize and direct the operating personnel 10 cease operatio n of the aerial platform in case of any suspected mal fu nctions of the ae rial platform. or any ha7.ard or poten tially unsafe condition that may be e ncoun tered. and to req ues t further in formation as \0 safe operation from tbe o wner. dealer, or manufac turer before furthcr operation of the acrial pl atform .

1. ]5 Record Reten tio n. lbe user shall reta in the following records for at least 3 ycars : ( I) Records of the o perator(s) trained on each model of an aerial platform: (2) Written records of the frequcnt and annual inspection shall be kept by the uscr whcn performing thc inspections. The rccords shall include the datc of inspection. any dcficicncics found. the corrcc tive ac tion recommended and idcn tification of the person(s) performing the inspection.

(3) Written records of all rcpairs accomplished on the aerial platfo rm, ind uding the date of an y such repair, a description of the work accomplished and the identification of the person(s) performing the repai r.

7,]6 Modificatio ns, Modification or alteration of an aerial platform shall be made only wit h prior wri tte n permission of the manufac turer.

7.17 Ma nufneturer 's Safety Bulletins. The user shall comply with safety-related bulleti ns as received from the manufacturer, dealer or owner.

8, Responsibilities of Operators 8.1 Basic Principles. The info mlation in this standard shall be supplemented by good judgme nt, safety co ntro l, and caution in e valuating each situation. Since the operator is in direct control of the aerial platform, conformance wit h good safety practices in this area is the responsibility of the operator. The operator shall make decisions on the use and operatio n of the aerial platform wit h due consideration for the fact that his or her own safety as well as the safety of other personnel on the platform is dependent on those decisio ns.

8.2 Manuals. The operator shall ensure that the the operating and safcty man uals delineating responsibilities of dealers, owncrs, lessors, lessces. users. and operators, arc storcd on the aerial platform in the weather resistant storage compartment provided. lbe operator shall be familiar with the manuals and consult

Reprin t frolll ANSVSIA A92.6-1990

( them whcn questions arise with respect 10 the aerial platform.

8.3 P restnrt I ns pectio n. Before usc cach day or at the beginning of each shift. the acrial platform shall be givcn a visual inspection and functional test including but not limitcd to the following: ( I ) Operating and emergency controls (2) Safet y dev ices (3) Personal protective dcvices (4) Ai r. hydraulic. and fuel system lcaks (5) Cables and wiring harness (6) Loosc or missing parts (7) Tires and whccls (8) Placards, warnings, control markings, and operating manual(s) (9) Outriggers, stabilizers and o ther structures (10) Guardrail system (I I) Items specified by the manufacturer 8,4 P roblems or Mal functions. Any problems or mal func tions tha t affcct the safcty of operations shall be rcpaired prior to the usc of the acrial platform.

8.5 T ra ining. 'Ibc operator shall be trained either on the same model of aerial platform or one having operating characteristics and controls consistent with the one to be used duri ng ac tual work site operation. Under the dircction of a qualified perso n. the trainee shall operatc the aerial platform for a sufficient period of time to demonstrate proficicncy and knowledge in thc actual operation of the aerial platform. Care shall be taken to ensure thc area of such operation has a minimum of obstaclcs and is conducivc to training. Only properly trained and authorizcd perso nncl shall be pcrmitted to operate the acrial platform.

8.6 Befo re Operation. Before being authorized to operate the acrial platform. the operator shall have: ( I) Becn instructed by a qualificd person in the intended purpose and function of cach of the controls (2) Read and unde rstood the manufacturcr's operating instruction(s) and user's safcty rules, or been trained by a qualified person on the contcnts of the manufacture r's operat ing instruction(s) and user's safety rulcs.

(3) Understood by reading or by having a qualified person explain all decals, warnings, and instructions displayed on the aerial platform 8.7 Wor k place Inspection. Bcfore the acrial platform is uscd and during usc. the operator shall chcck the area in whic h thc aerial platform is to be uscd for !X'ssible hazards such as, but not limitcd to: ( 1) Drop-offs or holcs (2) Bumps and floor obstructions (3) Debris (4 ) Ovcrhead obstructions and high voltage conductors (5) Hazardous locations (6) Inadcquatc surface and support to withs tand all load forces imposcd by thc acrial platform in all operating configU rations

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IRESPONSIBILITIES MANUAL (7) W ind and weather conditions (8) Other possible unsafe conditions 8.8 Duri ng O pera tion. 'Ibe ae rial platform shall be used in accordance with Ihis standard. Before eac h elevation of the platform, the operator shall ensure: (1) The aerial platform is operated on a surface withi n the limits specified by the manufacturer (2) Outriggers. stabilizers, extendable axles, or other stability enhancing means, are used as required by tbe manufacturer (3) Guardrails are installed and access gales or openings are closed per manufacturer's instructions (4) The load and its distribution on the platform and any platform extension(s) are in accordance with the manufacturer's rated capacity (or that specific configuration (5) There is adequate c1caranee from overhead obstructions (6) The minimum safe approach distanccs (MSAD) to energized power lines and parts. as listed in Table I of Figure 3. arc maintained. Sec page {101 (7) All personnel on the platform are wearing safcty gear as required at all times S.9 Determi na tion of Hazardo us Locations. It shall be the responsibility of the user to determine thc hazard classification of any particular atmosphe re or location according to ANSIINfPA 505 .

S.9.1 Haza rdous Location Ope rating Requirements.

Aerial platfonns operated in hazardous locations shall be approved and of the type required by ANSIIN FPA 505.

8.10 Ope rator Wa rnings a nd Instructions. The operator shall ensure the operation of the aerial platfonn in compliance with the following: 8.10.1 Personnel Footing. Personnel sball maintain a finn footing of the platform floor while working thereon.

Usc of planks. ladders, or any other devices on the platfonn for achieving additional height or reach shall be prohi bited.

S. 10.2 Precaution for Other Moving Equipmen t.

When other moving equipment and vehicles are prcscnt, special precautions shall be taken to comply with local ordinances or safety standards established for the workplace. Warni ngs such as, but not limited to flags. roped off areas, flashing lights. and barricades shall be used.

8.10.3 Reporting Problems o r Malrunct ions, l be operator shall immediately reJXIrt to a supervisor any problems or malfunc tions thai become evident during operation. Any problems or malfunctions that affect the safety of operations shall be rcpaired prior 10 continued usc.

8. 10.4 Repo rting I~ote nti ll ll y Haza rdous Locations.

The operator shall immediately reJXIrt to a supervisor any JXItentially hazardous location(s) (environment) that become evident during operation.

S, I O,S Hazardous Location O pera tio n. Operation of aerial platfonns that are not approved and marked for

Reprint from ANS]JSIA A92.6·1990 operation in a hazardous location shall be prohibited.

8.10.6 Enta nglemen t, Care shaJl be taken to prevcnt rope. c1ectric cords. and hoses, etc .. from becoming entangled ill the aerial platform.

8.10.7 Capacity Li mitations. Ratcd capacities shall not be exceeded whcn loads are transferred to the platform at any height.

8,10,8 Work Area, The operator shall ensure that the area surrounding the aerial platform is clear of personnel and equipment before lowering the platform.

8. 10,9 Fueling. The engine shall be shut down while fuel tanks are being filled. Fueling shall be done in a well-ventilated area free of flame, sparks. or other bazards tbat may cause fire or explosion.

S.l O. l O Ha ttery Cha rging. Batteries shall be charged in a well-venti lated area free of flame. sparks. or other hazards that may cause fire or ellplosion.

8,10,11 Impro per Pl atform S tabilizat ion, The aerial platform shall nOI be positioncd against another object to steady the platform.

8. 10.12 Mis use as a Crane. 'Ibe acrial platform shall not be uscd as a crane.

8.10. 13 Unusual Operating S uppo rt Condi tions. The acrial platform shall not be operaled from a JXIsition on trucks. trailers. railway cars. floating vessels, scaffolds. or similar equipment unless the application is approved in writing by the manufacturer.

8.10,14 Travel S peeds. Under all travel conditions, the operator shall limit travel speed according to conditions of ground surface. congestion, visibility, slope. location of personnel, and olhcr factors causing hazards of collision or injury to personncl.

8.10. 15 Ele va ted Driv ing Requi rc ments. Bcfore and during driving while the platform is elevated. the operator shall: (1) Maintain a clear view of the path of travel (2) Maintain a safe distance from obstacles. debris. drop-offs. holes. depressions, ramps, and other hazards to ensure safe elevated travel (3) Maintain a safe distance from overhead obstacles 8. 10.16 Stunt Dr iving, Stunt driving and horseplay shall not be permitted.

8. 10. 17 Securit y. '111e operator shall implement means provided to protect against use by unauthorized person(s).

8. 10. IS Altering Sa fety Devices. Altcring or disabling of interlocks or other safety devices shall be prohibited.

8.10.19 Driving on S lo pes. '111e acrial platform shall not be driven on grades, side slopes or ramps exceeding thosc for which the aerial platform is rated by the manufacturer.

8. 10.20 Snagged I'la tfonn. If the platformlbasket or supporting assembly becomes caught. snagged. or otherwise prevented from normal motion by adjacent structures or other obstacles such that control reversal does not free the platform, all personnel shall be removed from the platformlbasket before attempts arc made to free the platform using chassis controls.

PAGE 7

IRESPONSmILlTIES MANUAL 8.11 As.s istonce t o Opcrlltor.

If an operator encounters any suspected malfunction of the aerial platform, or any hazard or potentially unsafe cond ition rel ating to capacity, in tended use or safe operation of thc aerial platform, the operator shall cease operation of the aerial platform and request further information as to safe operation from management, or from the owner, dealer, or manufacturer. before further operation.

S. 12 Modificntions. Modification or alteration of an aeri al platform shall be made only wi th pri or written perm ission of Ihe manufacturer.

9. Responsibilities of Lessors 9.1 Basic Principles. Sound princ iples of safety, train ing, inspections. ma intenance, application. and operation consistent with all data available regarding the parameters of intended usc and expected environment shall be applied in the performance of responsibilities of lessors with due consideration of tbe knowledge that the aerial platfonn will be carrying personnel.

9.2 Lesso r. A lessor is a person(s) or entity who leases. rents. loans, or otherwise provides an aerial platform to anothe r party for the beneficial use of that party (the user). A lessor may also be a dealer, owner, lessee, user, or operator.

9.2.1 Lessor as a Dealer. When a lessor uses the aerial platform as a dealer, the lessor shall have the responsibilities of dealers as specified in Section 5 of this standard .

9.2.2 l essor as a ll Owner. When a lessor uses the aerial platform as an owner, the lessor shall have the responsibilities of owners as specifi ed in Section 6 of this standard.

9.2.3 Lessor as a User. When a lessor uses the aerial platform as a user. the lessor shall have the responsibilities of users as specified in Section 7 of th is standard.

9.2.4 Lessor as a n Operator, Whcn a lessor uses the aerial platform as an operator, he shall have the responsibilities of operators as specified in Section 8 of this standard.

Reprint from ANSI/SIA A92.6-1990

( 10. Responsibilities of Lessees 10.1 Has le l'ri nci])les. Sound principles of safety. training, inspections. maintenance. application, and operation consistent with all data available regarding the parameters of intended use and expected environme nt shall be app licd in the performance of responsibilities of lessees with due consideration of the knowledge that the acrial platform will be carrying personnel.

10,2 Lessee. A lessee is a person(s) or entity to whom an aerial platform is provided by lease, rental. loan. or other arrangement. A lessee may also be a dealer, owner, user or operator.

10.2.1 Lessee as a Dealer. When a lessee uses the aerial platform as a dealer. he shall have the responsibilities of dealers as specified in Section 5 of this standard.

10.2.2 Lessee as an Owner. When a lessee uses the aerial platform as an owner, he shall have the responsibilities of owners as specified in Section 6 of this standard.

10.2.3 Lessee as a Use r. When a lessee uses the aerial platform as a use r, he shall have the responsibilities of users as specified in Section 7 of this standard.

10.2.4 Lessee as a n Operator. When a lessee uses the aerial platform as an operator, he shall have the responsibilities of operators as speci fi ed in Sect ion 8 of th is standard.

c

(

IRESPO NSmILlTIES MANUAL

Reprint from ANSIISIA A92.6-1990

Figure 1 - Typical Examples of Equipment Covered

l PAGE 9

IRESPONsmn.ITIES MANUAL

Reprint from ANSIISIA A92.6-1990

(

Figure 3

~

::.

( M.S.A.D. = MINIMt:M SAFE APPROACH DISTANCE (SEE TABLE BELOW)

~

DENOTES PROHIBITED ZONE

DANGER: • DO NOT ALLOW MACHINE, PERSONNEL OR CON D UCTIVE MATERIALS INSIDE PROHIBITED ZONE .

• MAINTAIN M.S.A.D. FROM ALL ENERGIZED LINES AND PARTS AS WELL AS THOSE S HOWN .

• ASSUI\1EALL ELECTRICAL PARTS AND WIRES ARE ENERGIZED UNLESS KNOWN OTHERWISE. CAUTION : • DIAGRAMS SHOWN ARE ONLY FOR PURPOSES OFILLUSTRAT!KG M.S .A .O . WORK POSITIONS, NOT ALL WORK POSITIONS.

Table I M INIMUM SAFE APPROACH DISTANCE (M.S.A.D.) \0 energized (exposed or insulated) power lines and partS. MINIMUM SAFE APPROACH DISTANCE

VOLTAGE RANGE

IF!!!t)

(Ph ase \0 Phase)

o 10 JOOV

(Meters)

AVO ID CONTACT

""

O~l'r

Joe v \0 50KV Over 50KV to 200KV Over 200KV !o 3S0KV

25

6.10 7.62

3S

10.61

"

13.72

20

Over 350KV !o 500 KV Over SOOKV to 1S0KV Over 7S0KV !o 1000KV

PAGE 10

3.05 4.60

(

( CONDOR® SERVICE INFORMATION

1. If you need assistance or have any service or maintenance questions, Calavar service and parts personnel are always available by phone or fax. The telephone numbers are:

(817) 666-454 5 Telephone (817) 666-5125 Voice Mail (800) 443-5803 FAX

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

c

requests them.

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

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

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

CALAVAR CORPORATION

( 8300 iMPERlAL DRIVE, P.O. Box 21447, WACO, TI!XAS 76702·1447 • 817-6664545, 817-U6-4544 FAX

( CALAVAR CORPORATION

Condor® Self-Propelled Aerial Work Platforms WARRANTY

Cal,Yer Corporation ('Calavar') warrants to the purchaser that each naw aerial work platform made by Calave, is fre8 from defects in materialaoo workmanship arising under normal use and service-in the case of major weldmants, (chassis, turret, and booms), for a period of five (5) years after the original shipment of the aerial work platform from Calavar's plant; and in the case of all other parts. for a period of one (1) year after the aerial work platform is placed in service (H' two (2) years after the original shipment of the aerial work platform from Calaver's plant. whichever comes first.

c

The obligation and liability under this Warranty is expressly limited to repairing or, at Calavar's option, replacing free of charge at its factory or at an authorized repair fac ility designated by Calavar, the defective pan. In no event shall Calavar or its suppliers be liable to the purchaser or any other person for transportation charges or for any incidental, collateral, special, or consequential damages, including without limitation damages for loss of profits, loss of customers, loss of goodwill or woric stoppage, claims by any party other t han the purchaser, or any other similar damage or loss even if Calavar, its suppliers, or its representatives have been advised of the possibility of such damages.

Parts claimed to be defective and for which repair or replacement is desired shall be returned transportation prepaid to Calavar' 5 factory for inspection. This Warranty applies to replacement parts provided under the terms of this Warranty only for the remainder of the Warranty period applicable to the original purchase.

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

No agent, employee, distributor, dealer, or other representative of Calavar is authorized to modify this Warranty In any way. Accordingly, additional statements or presentations by any such representative, whether oral or written, do not constitute warranties by Calavar and should not be relied upon as limited warranties of Calavar, and no attempt, effort, or promise to repair equipment by Catavar or any such representative at any time shall modify or extend this Warranty in any way. If the purchaser has used its own order form, no additional or different warranty terms contained in the purchaser's form will be honored

by Calavar. This Warranty covers only new and unused aerial work platforms manufactured by Cafavar.

Products or parts manuf actured by others are covered only by such warranties as are extended to the purchaser by Calavar's suppliers.

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

(

8300 Imperial Ori..... P.O. 80)( 21447. Waco. TUII 76702· 1447.817-666-4545, FAX 817·666-4544 """'!Old In U.S.A.

( CALAVAR CORPORATION

BOLT TORQUE CHART

c

NOTES: 1. THIS CHART SHOWS STANDARD BOLT TORQUES TO BE i' PPUED UNLESS OTHERWISE SPECIFIED.

Z. CLAMP 3.

l

~OAD

= 751

X PROOF X STR ESS AREA .

TOROUE iPLI = ROT R = . ZOO F·JR DRY CONDITIONS R = . : SO FOR LUB CONDITIONS ' LUB CONDITiONS ' 'NCLUDES LUBRICANTS. ?LA TING ;'ND ,'-'AR DENED WASHERS .

D = NOMINAL :::IAMET::" iN INCHES T ~ DESIRED CLAMP LOAD IN POUNDS

LUBRIZ ING.

APPENDIX B

( CALAVAR CORPORATION

BOLT TORQUE CHART METRIC HEX HEAD CAP SCREWS (REGULAR PITCH) • Suggestad assembly torque. in Foot -Pounds (e Value. in Inch·Pounds) • The torque value. for Bach diameter are acceptable for any thread pitch in that diameter

Propeny Cia•• 8.8

Property Cia.. 9 .8

Property Cia•• 10.9

Property Clus 12.9

D~

Lubricatea

Th. _

~

M4

27.5*

17'

30'

-

T......

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

M10

39

23

42

25

53

32

73

44

M12

67

40

73

44

92

55

127

78

M1.

107

64

116

69

146

89

203

122

M16

,67

'00

,8,

,08

230

,38

3,6

190

M20

325

,95

352

21,

449

269

617

370

M2.

562

337

609

386

775

4 65

,066

640

M30

1117

670

12 10

726

1540

924

2188

,271

DIAMETER

Th,D~ __

Lubr\elltMl

D~

l ubric.ltll(l Th_

D~

Th_

,....... ........"

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(

TABLE OF CONTENTS

C

3160

FIGURE 10 21 22 30 31 50 51

52 70 71

72 73

74 75

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(

76 77

TITLB Final Installation Electrical Diagram Hydraulic Schematic

Platform Installation Platform Control Box Assembly Lift Installation Lift Cylinder Assembly Arm Stand Assembly

Chassis Installation Drive and Brake Installation Brake Assembly Hydraulic Tank Assembly steering Installation Battery Installation Pump Assembly Ground Control Assembly

FIGURE 10 FINAL INSTALLATION

(

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1

1 REF

, :

~

3

'~~45

, '

I~ .. t'.".

2

~ ()

-

®

6

74 STEERING INSTALLATION

(

1 2

C 9

16 17

18

15

11

16

14\ 13 12

10

~

, 17

l

18

-/

®

FIGURE 74 STEERING INSTALLATION I

CALAVAR PART NUMBER

T

E

W

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

(

14 15 16 17 18 19 20 21 22

289-00002-0U Hub Drive 396-00003-00 stud, Wheel BOW30160-3 Bolt, Hex BOW30160-2 Bolt, Hex BOW34278 Nut, Elastic Stop 119-00012-00 End, Male Rod BOW32278 Nut, Jam 663-54151-00 Rod, Tie 010-54009-00 Weldment, Spindle Left 010-54010-00 Weldment, Spindle Right 350-00017-00 Set, King Pin • Shim • Bearing, Sealed BOW40541 • Screw, Set • Pin 124-00028-00 Bushing 475-00062-00 Shim 124-00033 - 00 Bushing 020-R0055-00 Assembly, Steering CYlinder 253-96659-00 • Elbow, 90 162-96440-00 • CYlinder, steering • • Kit, Seal

.

(

DESCRIPTlON

QUANliTY

1 2345 2 10 1 1 2 2 2 1 1 1 2 2 1 1 1 3 2 2 1 2 1 1

FIGURE 10 FINAL INSTALLATION

(

I

T E W

CALAYAR PART NUMBER

1 34354 2 92272 3 67793 4 BOW31444 5 BOW36725 6 BOW31201 -7 FIGURE 21 -8 FIGURE 22 9 001-04000-1A 10 030-A4000-00 11 001-04000-2A 12 001-A4000-3B -13 58276 1467470-001 15 287-96491-00

(

DESCRIPTlON

Q(JANllTY

1 2345 Holder, Safety Manual Manual, Operation and Safety Clamp Washer, Flat Washer, SPL Lock Nut, Hex Diagram, Electrical (See Fig . 21) Schematic, Hydraulic (See Fig. 22) Installation, Platform (See Fig. 30) Kit, 3160 Decal Installation, Lift (See Fig. 50) Installation, Chassis (See Fig 70) Paint Yellow Oil, Hydraulic Kit, Hose

1 1 1 1 1 1

1 1 1 1 1 1 1 1 1

.---------------------~~-------------------SOL ENO I D

rl

k>

BLI .C K

1,IH !

re

,

L

MOTOR

-

I , I

i

0 PUSH

I

\

/ -

KE Y Sw[1 CH

,

BU T TON

MAS TE R DI SCOI'JI'l EC'

5 \.J J rC H

~

,,

~~

~

...

",

--1

"'HI TE

-

'"

EMERGENCY

'-=

STOP

BLACK

FOOT Sld TCH

BAT TERy CHARGER

.-.:

..BATTERIES

-

,

-.

BRAKE LINE

[

UPPER CONTROL VALVE

IAIB

LEFT DRIVE MOTOR & BRAKE

v

•a ,

~

~

a•

RIGHT DRIVE MOTOR

~

J

, , , ~

0 0 C

B AI

~

I

GREEN

~

0

~

~

0

&SlSl

0

~ ~

0

CO CO

z

I

PURPlE YEllOII

~-'j3

La"

SPEED VALVE

r®o-

...

""_t •• <>.c, ...

I

~y

~

JI-

0

•,•<

2

!

N

• • m

N

m

IN HYDRAUL Ie TANK

T'

'" 0

OUT

r-

ROD END

LOIJER CONTROL VALVE

r

~ ~

,"c •

TO U.C,v . .

l=rt ROO END

MOTOR

PUMP

I

M

6~ I

~

Z

UfT

0

m

CAP E"D

ClIP END

STEER CYLINDER

'"

n -< r

•

~

I a OI'!"NGE

""

FIGURE 30 PlATFORM INSTALlATION 4

2

19

II

•

3

18

~I 17

,

22

~/' 16

15

®

FIGURE 30 PIATFORM INSTALLATION

(

I

T E W

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

CALAVAR PART

DESCRIPTION

NUMBER

1 2345

010-A4028-00 010-54034-00 010-54031-00 010-54030-00 010-54029-00 FIGURE 31 570-A4003-00 570-A4004-00 392-00031-00

Weldment, Weldment, Weldment, Weldment,

Platform Frame

Right Side Rear Guardrail Left Side Rear Guardrail Side Guardrail Weldment, Front Guardrail Assembly, Platform Control (See Fig. 31) Guard, Deck Hose Guard, 4" Deck Hose Switch, Foot Clipper Assembly, Platform Floor Decal, capacity 1,500 LBS Decal, 3160 Decal, CONDOR Tape, Orange and Red 31LF

52963 37515 50277 58419 164-00013-00 Chain 010-A4028-00 Weldment, Platform Frame 533-00001-00 Link, Chain Weldment, Rear Movable Guardrail BOW30006 Bolt, Hex BOW31401 Washer, Flat BOW34272 Nut, Lock BOW34113 Rivet, Pop 245-00008-00 Pin, Lanyard Hitch

QUANllTY

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

AIR AIR

FIGURE 31 PLATFORM CONlROL BOX ASSEMBLY

(

-+--++---18 1

19 5

!'. . . .

I

2 ___ ,

3

',-, &

12

0

0

~

I

0

5

lJ :J.

•

:=

7

6

I

(

D

®

4

FIGURE 31 PLATFORM CONTROL BOX ASSEMBLY

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I

T E W

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

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l

CALAVAR PART NUMBER 020-R2047-00 010-R1013-00 529-R1083-00 620-R1078-00 128-00009-00 475-00070-00 BOW34272 310-00219-00 275-00002-00 392-00009-00 020-A4025-00 315-00034-00 253-96632-00 253-96662-00 253-96670-00 310-00159-00 310-00214-00 310-00151-00

DESCRIPTION

QUANllTY

1 2345

Assembly Control Box • Weldment, control Box Handle • Cover, Control Box

• Panel, Control Box Side • Bolt, Hex • Washer, F1at • Nut, Hex Lock Decal, Control Cover Knob, Emergency stop Plastic Switch, Emergency On-Off Assembly, Platform Control Valve • Valve, Platform control

• Fitting • Fitting • Fitting Decal, caution Volt Lines Decal, Operation Sheet Decal, Lift control

Decal, Read Instructions

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

FIG URE 32 UPPER CONTROL BOX INSTALLATION

( "

"

"

(

...

,

_____ j~ __ j_Oh!:j===CD o \,

,

" '"

"

o

o

o •

( 92 277-003

•

(

lITEM Ref. I 2 3 4 5 6 7 8 9 10 II 12 13 14 15 16 17 18

FIGURE 32 UPPER CONTROL BOX INSTALLAT ION PART NUMBER DESCR IPTION 55151 54060 5406 1 0 10-RIOI3-00 54498 020-M I035-00 51913 5 191 4 67872 BOW34273 BOW30037 BOW33848 52672 BOW3 11 27 54192 54193-00 1 52028 54187 551 09

QTY

Upper Control Box Installation .... ............................................. I Cover, Control Box ............................................................ .. ....... 1

Panel, Side Control Box ..... ........................................... ..... .. ...... 1

Handle, Control Box ..................................... ,............................. 1 Spacer, Upper Control Valve ...................................................... 3 Valve Assembly. Upper Control ................................................. 1 Sw itch, Emergency Shut Off ........................................ .............. 1 Con lact Block, NC ......................................................... ............. 6 Switch-Short Arm ....................................................................... 1 Nut, Stop, 5/16- 18UNC ........ .......................................... .. .......... 3 Bolt, Hex .3 1"-1 8UNC x 3.00" ....................................... ..... .. .... . 3 Screw, Self-Tap .25" x 1.00" ..... ..... ........... ............... ...... ........... . 8 Base + INO Contact ZB2-BZIO I ............................................... 1 Screw Grade 5, #6-32 .................................................. ............... 2 Plug, Hole 1.25" Dia................................................................... 1 Plug, Hole 1.1 25" Dia ................................................................. 1 Operator, 2 Pos. Rot. ZB2-BD2 .................................................. 1 Decal, Li ft Control ........................................................ .............. I Decal, 3146/60 Upper Control Top ............................................ 1

C

( 92271-003

FIGURE 50 LIFT INSTALIATION

( 1

3 ~-------,~

4

5___

~

13 14 15

7

8

9

1

3 4

12

11

\,,_

1 3 4

13 14 15

10

1

2 3

_ _ 10

c

FIGURE 50 LIFT INSTALLATION I

T E

Y

CALAVAR PART NUMBER

DESCRIPTION

QlJANllTY

1 2345

.

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16

(

l

124-00028-00 124-00032-00 128-00013-00 BOW34278 010-54020-00 010-54025-00 010-54026-00 020-H5015-00 010-54022-00 010-54024-00 010-54027-00 010-54018-00 124-00030-00 167-00002-00 BOW40541 524-00006-00

Bushing Cam, 2" Flower Bolt, Hex Nut, 5top Weldment, Upper Outer Arm. Weldment, Upper Inner Arm Weldment, Middle Inner Arm Assembly, Lift CYlinder (See Fig. 51) Weldment, Middle Outer Arm Weldment, Lower Outer Arm Weldment, Lower Inner Arm Weldment, Arm S tand (See Fig. 52) Bushing Collar, 5haft Screw, 5et Cable, Arm

16 4 16 12 2 1 1 2 2 2 1 1 6 6 6 1

FIGURE 51 LIFT CYIlNDER ASSEMBLY (

2

3

~I

~----;

7

8 ~ I

T E

.

1 2 3 4 5 6 7

(

q

CALAVAR PART NUMBER 621-G9131-00 128-00026-00 331-00098-00 162-96438-00 253-96618-00 154-00007-00 257-00001-00 253-96609-00

DESCRIPTION

-9 QUANllTY

12345 Pin, Lift Cylinder Bolt, Hex Nut, Esna Assembly, Lift Cylinder • Kit, Seal Fitting Clamp, Hose FUse, Velcty

Fitting, Adapter

4 4 4

1 1 1 1 1 1

FIGURE 52 ARM STAND ASSEMBLY

(

2 3

6 1

2 3

4

c

5

I

T E W

1 2 J 4 5 6

CALAVAR PART NUMBER 5J1-G9125-00 BOWJ6055 BOWJ4274 010-54018-00 BOWJ411J 245-00008-00

DESCRIPT10N

QUANnTY

1 2345 Bracket, Arm Stand Pivot Bolt, Hex Nut, Lock Weldment, Arm stand Rivet, Pop Pin, Lanyard Hitch

2 8 8 1 1 1

FIGURE 70 CHASSIS INSTALLATION

c

5

6

El OB 4

4

9

10 11

I

T E W

CALAVAR PART NUMBER

8

DESCRIPllON

QUAN~TY

12345

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

010-04000-3A 315-00035-00 FIGURE 71 476-00022-00 315-00037-00 020-M049-00 FIGURE 74 FIGURE 75 355-00006-00 355-00016-00 322-00015-00 020-S4042-00 396-00003-00 289-00007-00 321-00002-00 FIGURE 77

Weldment, 3160 Chassis

Valve, Creep Installation, Drive and Brake (See Fig. 71) Assembly, Tire Valve, Transmission Assembly, Hydraulic Tank (See Fig. 73) Installation, steering (See Fig . 74) Installation, Battery (See Fig. 75) Assembly, Battery Charger Assembly, Pump (See Fig . 76) Assembly, Electric Motor Assembly, Motor Hub • stud, Wheel • Drive, Hub • Assembly, Motor Assembly, Ground control (See Fig. 77)

1 1 1

4

1 1 1 1 1 1 1

1 5 1 1 1

FIGURE 71 DRIVE AND BRAKE INSTALLATION

(

2

6

6

3

5

4

I,

® I T

CALAVAR PART

II

NUMBER

1 2 3 4 5 6

396-00003-00 289-00007-00 126-10007-00 253-96506-00 321-10005-00 253-9 6 610-00

E

DESCRIPTlON

QUANllTY

12345 S·t ud , Wheel Drive, Hub Brake, Eskridge (See Fig. 72) Elbow, 90 Motor, Brake Wheel Elbow, 90

5

1 1 1 1

2

FIGURE 72 BRAKE ASSEMBLY

( 9

5 4

o

r

r\

,

I

1 10

~G

~~

~G(l

~G

12

,

~(l

' 9 21 / \ 20

16

23

22

FIGURE 72 BRAKE ASSEMBLY

(

I

T E W

1 2 3 4 5 6 7 8 9 10 11

C

12 13 14 15 16 -17 18 19 20 21 22 23

CALAVAR PART NUMBER

DRJ01034 DRJ01035 DRJ01036 DRJ01037 DRJ01038 DRJ01039 DRJ01040 DRJ01041 DRJ01042 DRJ01043 DRJ01044 DRJ01045 DRJ01047 DRJ01048 DRJ01049 DRJ01050 DRJ01051

DESCRIPTION 1 2345

Nut, slotted Jam Screw, Socket Head Cap Plug, Hollow Hex Case, Brake Bearing, output

Key Shaft Spacer Plate, Separate

Plate, Bronze Friction Piston Spring, Blue Cover, Brake Bearing, Input Ring, Snap Ring, Snap Kit, Seal • Ring, Piston Backup • O-Ring, Piston • O-Ring, Piston • Ring, Piston Backup

• a-Ring, Case Seal • Gasket Mounting

S c;61 \ - \ Dd--

~U-

(

1 4 1 1 1 1 1 1 9 8 1 12 1 1 1 1 1 1 1 1 1 1 1

FIGURE 73 HYDRAULIC TANK ASSEMBLY

( 11

4 10

r:

" 15

16

17

14

.

O.

9

19

8--~

,

OJ

7

~ 6--r'~ 4

~3

5 --j---

J0~U--22

23

B'

2

FIGURE 73 HYDRAULIC TANK ASSEMBLY

(

I

T E \I

c

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

CALAVAR PART

NUMBER

010 - 84012-00 254-96611-00 450-00051-00 253-96612-00 260-00001-00 310-00160-00 254-00051-00 253-96618-00 259-00001-00 529-81076-00 152-00008-00 BOW36002 BOW36725 253-96596-00 253-96597-00 253-96616-00 33430 67408 254-00042-00 254-00009-00 254-00008-00 254-00041-00 254-00084-00

DESCRIPTION

QUANTlTY

1 2345 Weldment, Hydraulic Tank Elbow, street Valve, Ball Shut Off Fitting, Adapter Gauge, oil Level Decal, Hydraulic Fluid Plug, Black Steel

Elbow, 90 Gasket , Tank Cover, Hydraulic Tank Cap, Breather Bolt, Hex Washer, SPL Lock Fitting Reducer Elbow, 90 Filter, Return • Element, Filter Elbow, Steel Nipple, Close Pipe Nipple, Close Pipe Elbow, Steel Plug, Pipe

1

1 1

1 1 1 1

1 1

1 1 8 8

1 1 1 1 1

1 1 1 1

1

FIGURE 75 BATTERY INSTALLATION

(

(

I T

E Y

CALAVAR PART NUMBER

1 010-84013-00 2 121-00004-00 3 010-84016-00 4 122-00014-00 5 122-00015-00 6 122-00017-00 7 122-00020-00 8 010-84017-00 9 50070 10 010-84015-00

(

DESCRIPTION

QUANnTY

1 2345 Weldment, Right Side Cover Battery, 6 Volt Weldment, Battery Box Mount

Cable, Battery 7 . 25LG Cable, Battery 22LG Cable, Battery 59LG Cable, Battery 28LG Weldment, Battery Hold Down Decal, Battery Service Weldment, Battery Tray

1 6 1 6 2 2 2 2 2

1

FIGURE 76 PUMP ASSEMBLY

(

( I

T E

w

CALAVAR PART NUMBER

DESCRIPll0N

1 018-00110-00 Cover, Back -2 018-00053-00 Kit, Seal 3 • O-Ring 4 • Plate, Thrust 5 • Plate, Wear 6 • Shield, Heat 7 • Gasket 8 • V-Seal 9 • Seal, Shift 10 018-00114-00 Gear, Driven 11 018-00113-00 Gear, Drive 12 018-00112-00 Section, center 13

(

QUANTITY

1 2345

Pin, Dowel

14 018-00111-00 Cover, Front 15 Washer, SPL Lock 16 Screw, Cap 17 Screw, Hex

1 1 2 1 1 1 1 1 1 1 1 1 2 1 8 6 2

FIGURE 77 GROUND CONTROL ASSEMBLY

(

10

11

14

19 16

~20 21

5

4 23

20 3

24 22 25

~

18

./

~

® 17

®

A

~6

2

16

0

7

FIGURE 77 GROUND CONIROL ASSEMBLY

(

c

(

I T

E

CALAVAR PART

W

NUMBER

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

020-A4020-00 253-96662-00 253-96667-00 315-00036-00 253-96626-00 253-96605-00 253-96631-00 310-00153-00 394-00009-00 010-54014-00 310-00161-00 392-00021-00 310-00157-00 392-00008-00 020-A4030-00 02335 315-00047-00 315-00048-00 253-96516-00 253-96605-00 315-00052-00 020-A4015-00 253-95538-00 450-00072-00 253-96614-00

DESCRIPTION

QUANliTY

1 2345 Assembly, Lower Control • Fitting • Fitting • Valve, Lower Control/ Lift • Elbow, 90 • Elbow, 90 • Tee Decal, Warning Arm Stand

Solenoid, 36 Volt Weldment, Left Side Cover Decal, Free Wheeling Valve Switch, Push Button Decal, Master Disconnect Switch Switch, Master Disconnect Assembly, P/R Valve

1

1 1 1 1 1 1 1 1 1 1 1

1 1 1

• Elbow, 90

2

• • • • • •

1 1

Valve, Cartridge Valve, Body Connector, STR Fitting Valve, Shuttle Assembly, Freewheel Valve

• • Elbow, 90

• • Valve, . Freewheel • • Elbow, 90

2 2 1 1 1

1 1

VENDAA COMPANY NO : Sel

(

VENDOR PART NUMBER LOOKUP PARTS FOR LIFTS , INC

001

Vendor Item

Name

Vendor Part Number Description

000000 NO VENDOR ON FILE SVI-IO-3-12DW 450 - 00067 - 00 VALVE- 3 WAY P : SVI-IO-3-12 >

05/10/1996

2.

000468 BERENDS EN FLurD POWER 93017 SOLENOID VALVE

SVI - 10-30-12DL 2 POSITION

07/29/1998

3.

000586 WOMACK MACHINE SUPPLY CO 450-00054-00 VALVE-DUMP >

SVIO-20-0 -N- 12DS(NOTYETA

06/11/1997

4.

000586 WOMACK MACHINE SUPPLY CO 50085 VALVE SOLENOID

SV10-20-6T-N-12DS(NOTYET

06/11/1997

5.

000586 WOMACK MACHINE SUPPLY CO SV10-20-0N-12-DG 66637-102 VALVE - SOLENOID BLOCKING Enter to Continue ,

(

Date: 01/09/02

* , CTL-III

to restart , CTL-IV to Exit . . .

05/10/1996

!--{JB~E~A~C20N~/ZS~T~R~0~BIE~0~P~T~10~NQ----------11I'

d

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EMERGENCY STOP

R3 A

',-;:::

~

~

A"

R3-8 ,

,

20A

+24VOC TAP

---------~~-----~~~~t CIRCUIT

"

BREAKER

CHARGING LI GHT

G

POS ~

I I

'"a.a.w

=>

HOUR METER OPTION

J-POS ROTARY

~

36 VDC BATTERY

NEG

R1 ~UP~

4

II

'"

R1

3

CHARGER

MOllON ALARM OPTION

HORN

DESCEND ALARM OPTION

+--- - ------1 GAGE FUEl f---+

SEE NOTE 5

7

I

WHT

HORN

RED

5·

SLOPE ALARM OP"nON

8LK

SLOPE SENSOR OPTION

L_--<

SEE NOTE 4 0

GRN WHT

SEE NOTE 4 A

lOW VOLT WARNING

36VOC CONTROL

R2

I~ELA Y

COIL FOR OPTIONS

OPTIONAL SA TTERY CONOITION INDICATOR

SEE NOTE 4

SEE NOTE 2

1

BATTERY

3A CIRCUIT BREAKER

R2

I~

2

f-8"'L"K'--_ _

SEE NOTE J

HORN

0'

HYO PUMP

-+

RED

PLATFORM LOWERING

~

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PLATfORM RAISING

"OOWN"

(

IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII

+----1

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LO'NER

EMERGENCY

GROUND

®

6

LO W VOLT SENSOR

:.DW VOLT OVERRIOE

115 VAC PLUG

8LK

R3

OPTIO,~AL CHARGING CUT-OU T RELAY COIL

SEE NOTE 6

K

HORN

TRAVEL ALARM OPTION

= GROUND

NQTES, ' "<) ,,"-\

1. THIS SCHEMATIC IS STANDARD FOR MDU146, MDU154, AND MDU160 SCISSOR LIFTS. REFER TO DIAGRAM 54356.

2. SWITCH ACTIVATED BY VALVE LEVER IN PLATFORM. 3. ~COND HOj,QING VALVE, ON MDU160 ONLY. 4.

THRU REPRESENT TER MINALS OF OPTIONAL LOW VOLTAGE WARNING/INTERRUPT SENSOR/SWITCH. 5. LIFT LIMIT SWITCH IS SHOWN WITH PLATFORM ALL THE WAY DOWN. 6. PRESSURE SWITCH SENSES BRAKE RELEASE PRESSURE.

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0

3146/60 ELECTRICAL

54355

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MOLJ146: MOTOR-BRAKE 115A-189-AS- O 18.9 CIPR 54754-001

126-10005- 00

321-00005-00

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PRESSURE S'NITCH

:

VAL~61

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54371

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-

315-00034- 00

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BORE: 1.5 ROO:.75 STROKE: 5.25

SHUTTLE VALVE 21481

-

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HOLDINC VALVE 52733

TRANSMISSION VALVE ASSY 315-00037 - 00

MOTOR 322-00015-00 M

MDL3146: MOTOR 114A-189-HS-O 18.9 CIPR 54754-002 MOL3154 &: M0L.3160; MOTOR-P: MJ290231 -AAAB 29.1 CIPR 321-00002-00

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FILTER 33430 r - --

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315-00036-00

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p::; ""::>

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SERIES/PARALILEL VALVES

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CREEP SPEED VALVE SLOPE ALARM OPTION

BLK

I

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7

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0

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1

RELAY FOR 36V OPTIONS

B

I

LOW VOLT ALARM OP TION

HORN HORN

I

11

6

®

115 VAC PLUG

WHT BLK R3

LOW VOLT SENSOR

SEE NOTE 4 LOW VOLT OVERRIDE

GRN

BLK

1

WHT

OPTIONAL CHARGING CUT-OUT RELAY

SIGNAL HORN OPTION

1 1

A

BATTERY CHARGER

SEE NOTE 4

FASTjSLOW DRIVE SPEED

TRA VEL ALARM OPTION

SEE NOTE 5

17

HYD PUMP

OPTIONAL BATTERY FUEL" GAGE )----'; CONDI1l0N INDICA TOR

SEE NOTE 4

p-----0--1

BLK

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WHT

HORN

1

MOTOR

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,

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FUSE

R3-B

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0\.9 24

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14-WHT::::tNEUTRAL

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GROUND

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TO PLATFORM OPTION

"3\ \.QCJ -

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C3PI'9.,- '-"{'") - OS "-<'-oJ\ ~ WACO, TEXAS

NOTES: I. THIS SCHEMATIC SUPER CEDES 54996.

2. Sv.1TCH ACTI VATED BY VALVE LEVER IN PLA1lFORM. 3. LIMIT Sv.1TCH SHOWN v.1TH PLA 1lFORM BELOW T. 4. G) THRU REPRESENT TERMINALS OF OPTIONAL LOW VOLTAGE WARNING/INTERRU PT SENSOR/Sv.1TCH. 5. PRESSURE Sv.1 TCH SENSES BRAKE RELEASE PRESSURE.

3146/60 ELECTRICAL

CD

55060 =

TRAVEL

t'

UPPER CONTROl VALVE 315-00034-00

ALARM

MOTOR

OPTION

321-00005-00 BRAKE 126-10007-00

54371

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TRANSM ISSION VALve:

315-00027-00

VALVE 2 PL

go MOTOR 322-00015-00 M

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MOTOR 321-00002-00

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5704

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54286-394

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HYORAUUC TANK OlO-R0060-CO

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1. THIS SCHEMA TIC SUPERCEDES 54284.

2. THIS SCHEMATIC REFLECTS IMPROVED "CREEP~ PERFORMANCE.

J. ADJUST CREEP SPEED TO 80-100 SEC/Ba FEET, ON FIRM, LEVEL GROUND (REF .. 75/.6 MPH).

4. LINE SIZES SHOWN ARE MIN 1.0. FOR HYO HOSE.

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111IS SCHEMAnc IS STANDARD FOR MOL3146. MDL3154.

AND MOLJI60 SCISSOR REFER TO DIAGRAM :\4356 SIII1 TCH AcnVAT£D BY VAlVE LEVER IN PLATFORM ~COND H~ING VAlVE. ON 1010\.3160 ONLY. l!J THRU QJ REPRESENT T£R MIN ALS Of' OP"'ON~L LOW VOLTAGE WARNINGj\ NT£RRUPT SENSOR/SIII1 TCH UMIT S'M TCH IS SHO\\N III1TH PLATFORM ALL 111E W ~Y DOWN PRESSURE S'MTCH SENS£S BR~K [ RELE~SE PRESSURE

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SI!lQl<L2U~

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THRU 7 REPRESENT TERMINALS OF OPTIONAL lOW TAGE W RNINGjlNT[RRUPT S£NSOR/SWI TCH. 5. un UlillT SWITCH 15 SHO~ WI TH PLA TFORM ALL THE WAY DOWN .

6 . PRESSURE SWI TCH SENSES BRAKE RELEASE PRESSURE.

WACO, TEXAS

1

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5 4355

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WACO, TEX AS

J. THIS OIAGRAr.I 15 STANDARD FOR Moons 3 1.6, 3154 .. J 160.

REFER TO SCHE MA nc 5·U5S. 4. ONE VALVE COIL SHOIm FOR toI DLJ 146 &: 1040LJ15 4: MDLJ160 HAS TWO HOLOING VALVES.

5. PRESSURE SWI TCH SENSES BRAKE RELEASE PRESSURE.

3146/60 ELEC TRICAL

I

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t:lQTES;

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LIFT CYLINDERS 4.0 OIA BORE

2.0 DIA ROD STROKE 551162 PL

1. REPLACE CROSS-RELIEF VALVES 51616, 2 PL, WITH PLUGS, PARKER Pl0-2, OR SET AT 3000 PSI. 2. THE DRIVE SPOOL IS PARKER 697604.

3. FOR BATTERY POWERED CONDORS. SEE SCHEMA nc BELOW. 4. HYD HOSE DIA IS IDENTIFIED BY IMPERIAL-EASTMAN PART NUMBER.

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THIS SCHEMA TlC SUPERCEDES 54284.

THIS SCHEMATlC REFLECTS IMPROVED ·CREEp· PERFORMANCE. ADJUST CREEP SPEED TO 80-100 SEC/BS FEET, ON FIRM, LEVEL GROUND (REF. . 75/.6 MPH).

UNE SIZES SHOWN ARE MIN 1.0. FOR HYD HOSE.

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Note: 'lhls is a Ventilated Motor; for totally enclosed version use SP-6058 (7D-42)Enclosfn; Kit.

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MMG

Smart

FULLY AUTOMATIC

CHARGERS

FERRO-RESONANT

(

AERIALIFT SERIES SEVERE SERVICE

(

MODELS

(110 VAC - 60 Hz)

12 VOLT

24 VOLT

MMG 12135

MMG 24/40

Each model is a COmpletely solid state-fully automatic, self regulating and self adjusting AC to DC charger/converter that provides up to rated amps when needed-automatically.

(

FEATURES & BENEFITS

c •

IMPERVIOUS TO ELEMENTS AND PRESSURE WASHERS

. ,' FULLY AUTOMATIC - NO ADJUSTMENTS NEEDED ON INSTALLATION

(

•

IGNITION PROOF - (USCG Elect Sid 33 CFR 183.410)

•

SELF LIMITING - (USCG Elect Sid 33 CFR 183.460[b])

•

AUTOMATIC RESET OVERLOAD PROTECTION (AC & DC)

•

NO DELICATE CIRCUITRY (NO TUBES, RELAYS, TRANSISTORS, SCR's, elc.)

•

CAN BE INSTALLED IN MULTIBLES TO MULTIPLY PERFORMANCE

•

CONTINUES TO MONITOR BATTERIES AFTER FULL CHARGE AND REPLACES ONLY THE AMOUNT OF CURRENT NORMALLY DISSIPATING (COUNTER VOLTAGE)

•

POWER SUPPLY (CHARGER/CONVERTER) WHEN BATTERIES ARE LOW -PLUG IN AC AND CONTINUE OPERATING

•

CAN BE DEAD SHORTED WITHOUT ILL EFFECT

•

VISUAL LED INDICATOR LIGHTS - GREEN: (charger Is functioning), reached 90'10+ charge) ,

•

CHARGES AUTOMATICALLY OVER A WIDE RANGE OF AC INPUT VOLTAGES (85 10 140V)

•

CANNOT OVERCHARGE YOUR BATTERIES (physically Impossible by design) MOST PRECISE FINISHING CHARGE IN THE INDUSTRY (13.8 - 12 VDC • 27.S -24 VDC • 55.2 - 48 VDC) NOTE: GASSING ,THRESHOLD IS 14.1, 28.2 and 56.4 RESPECTIVELY

•

RED: (batteries have

SHIPPEDCOMPLETEWITHRECESSEDMALEPLUGANDSFTOFSGa.DCWIREWITH

3/8" TERMINAL EYES •

COMPACT SIZE MMG 12/20 (S" X S" X 9'1 ALL OTHERS (8" X 8" X 12'1

•

IDIOT PROOF (PLUG IT IN.. pHECK BATTERY WATER EVERY TWO WEEKS -FORGET tTl

-Each charger Is guaranfeed against defects In material and wotkmanshlp fa 'the original consumer In nonnal usage for one full year after purchase af no charge ""capt shipping-

NOTES ON YOUR 12 & 24 VOLT D.C. ELECTRICAL SYSTEM

(

Check battery water level. Check each 2 weeks while charging.

Read D.C. Voltage at batteries with an accurate voltmeter before turning on A.C. to charger.

Any increase in voltage when unit is activated means charger is functioning P'lrfectly. Each unit will supply adequate voltage up to rated capacity and under a nO'load condition will finish at 13.8 volts (12 VDC) and 27.6 volts (24 VDC) nominal (correct full charge while charging voltage even though Input A.C. voltage varies from 85 to 140 V. r

MMG ferro-resonant Smart Chargers can be used as both a battery charger and a conver.ter/powersource over the batteries at the same time, supplying necessaryVDC and keeping batteries charged.

CORRESPONDNG VOLTAGES 12V 9.0 11.0

12.2 12.8 12.8+

24V 18.0 22.0 24.4 25.6 25.6+

= = = = =

STATUS 'dead' battery 'low' battery 'medium' battery

'full' battery full charge on charger (no load)

Any rapid boiling under 14.1 volts (12 VDC) 28.2 volts (24 VDC) while on a charger means your battery Is probably defective.

(

Our ferro-resonant Smart Chargers continue to hum even though voltage has peaked at finishing charge, The charger monitors and replaces the amount of current normally dissipating (counter-voltage), TROUBLESHOOTING YOUR CHARGER Check voltages of batteries after 24 hours of charging. Should any voltage be under 13.4 (12 VDC) 26.8 (24 VDC) (no load), exceed 14,1 (12 VDC) 28.2 (24 VDC) or after charger Is shut down, voltage drops under 12V or24V within 15 minutes: (1) check your voltmeter (2) check your batteries.

Troubleshooting Is simple. A failure of any component causes D.C. output to drop Y.z or less.

(1) NO OUTPUT WITH PROPER CONNECTIONS, INPUT VOLTAGES AND CYCLES (a) The A.C, thermal breaker has failed (Cyctes off more than 5% could cause overheatIng and charger shut down) (b) A diode has shorted and blown safety fuse Inside charger.

(2) 112 OUTPUT (a) The capacitor has failed.

( NOTE: In event of charger failure, ship unit to factory for repair, (ONE YEAR-NO CHARGE EXCEPT SHIPPING)

TROUBLESHOOTING YOUR CHARGER BENCH TEST SPECIFICATIONS A

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A voltage reading of 13.3 + .3 (12V Charger) 26.6 + .3 (24V Charger) without a battery in line means the charger is functioning correctly. (A quality voltmeter might have spurious readings - place fingers across D.C. positive and negative.) If the battery voltage Increases when AC.ls applied means the charger is functioning perfectly and the finished charge will be a nominal 13.8 on a 12VDC (no load), 27.6 on a 24VDC system (no load).

Transformer unloaded should read less than one amp AC. draw.

If transformer does not hum; (a) check A.C. In (b) check internal wiring to transformer (c) by-pass Internal thermal breaker (loop at point A).

A failure of any component causes output to drop to 10V or less (12 VDC) 20V or less (24 VDC).

Read AC. output - Approximately 29.5 VAC ·betweentips of 2 diodes on same heat sink 81 -82. Approximately 14.8 VAC from tip of one diode and circuit breaker or fuse. 8 to D. Read AC. capacitor - Should be over 400 VAC (DON'T TOUCH - discharge with a screwdriver after A.C. Is off).

Check capacitor with one lead disconnected. Analog V.O.M. or R x 10,000 should jump to full scale and then drop back to Infinity.

",

With A.C. off, batteries disconnected, and VoltOhmMeter on Rx1 - Read from diode tip to heat sink. Leads one way should read 0 and the other approximately 60% of scale. 0 both ways or full scale both ways - Replace diode. •.

MMG .

P.D- BOX 105 Sl Joseph, MI 49085 (616) 849-3000

2368 EASTMAN AVE.

#6

VENTURA, CA. 93003

(805) 644-1886

SALES AND TROUBLESHOOTING GUIDE

(

FERRO-RESONANT CHA.RGERS PROFESSIONAL MARINER MU/.TI·BA7TERY CHARGER/CONVERTER/POWER SUPPLY/ENGINE START BOOSTER All ferro-resonant (fR) units ronsist of a transformer with built·in A.C. thermal breaker, an A.C. Cap.ll.Cilor. diode pairs on heat sinks and a circuit breaker.

All F'R units are n.t~ 'Ignition Proor (U.S. Coast Guard Electrical Standard 33CFRI83 ..clO).

AU FR units can ~ dead shorted without ill effect and can Voltage .....mnot rise

p.s

~

used in conjunction with the batteries to help SUlrt an engine.

on an ordinary transfonner to hurt your a1tem.at.or or electronics.

All fR units are power supplies and will supply D.C. current without. battery in line up to rated capacity.

All FR units art' ('tJnverters and will supply current to 'house' plus

k~p

the batteries charged.

All F'R uOlt1\ can lIE' installed in multiples til multiply performance.

All FR units are rated self limiting and do not n«"d. La be circuit breaker~ on the output D.C. wiring (We have a lener frum thE- Coast Guard affirming this). (C.S. Coast Guard Electrical Standard 33CFRl83.460 Ib~) All F'R units Art' completely automatic between 85VACand HOVAC 60 HZ or 240 t 15% 50 HZ. Higher and lower input \'oluge-5 art' tolerat~ by the unique ferro-resonant tnnsfonner but the finishing yoltages are higher and water will be boiled out (If the batteries with the resulting excessive voltage it left unmonitored.

On 60 HZ unils . .t 5% HZ will cause overheating at tull output and will (unction well at 50 HZ if a circuit breaker ..... ith 314 (If power supply rating is installed in negative line but finishing voltages will be2O'W! lower. A 240VAC :: 15% unit can be uperated on 60 HZ as a non·automatic or fast c~r. .

The finishing (or full charge while charging) voltage is set by the definite relationship between an exact number of wind· ings of the 3 coils to an exact amount of core and cannot be adjusud. Resist.ance in the circuit or an in·line diode will drop volt..age. (A diodt: tquals approximately .6V drop) or 10 La 12 amps on an output stud with no battery in line will raise voltagc to hattery on other studs. No voltage increasing mtthod is recommended by the facLary.

(

Our ferru·re-sonant charger continues to hum even though voltage has peaked at finishing charge. The charger replaces tM amount of current normal dissipating. (Counter Vol~.)

TROUBLESHOOTING YOUR CHARGER Che-ck voltage of batteries after 24 hours of charging. Should any voltage be under 13.4 (no load). exreed 14 .1 or after charger is shut do ..... n. voltage drops under 12V within 15 minutt'$: (I) Check your voltmeter (2) Check your batteries.

On·board Testing I. Does unit hum when A.C. is activated!

Yes - Go to step 2

2.

No - If A.C. La charger.

ro to step 4

~ D.C. Voltage rise when charger is activated!

Yes - Charger is perfect No - Go to step 3

3. Disconnect nep.tive lead trom charger stud. ActivaLe A.C. to charger. Measure D.C. Voltage' between plus studs and negative stud. (Place fingers across ... &: - studs to reduce tipsoC sqU&I"'e wave.) Voltage reads 13.1 to 13.6-unit is perfect. Less than 12 volts-go to step 4.

4_ Ship unit to factory. (One year. no ch1r&"e except shipping plus lifetime repair polky. Read back of hf()('hure.)

Any boiling under 14.2 V.D.C.. while on a charger muns)'04Jr bAttery is probably detective.

Tut bench specificatinns A voIt.ae:e reading of 13.3 :t .3 (l2V charger) without a battery in line means !.he charger is functionin, correctly. (A quality voltmeter might have spurious rtadings. ptacfo nngers across D.C. positive and negative.) If the battery voltage increa.sa when A.C. is applied means the charger is tunctioNng perfect.ly and the finished charge will be a nominaJ 13.8 un a 12VOC (no load). 27.6 on a 2.f. VDC ayt'tem (no load). or 36.8 on a 32 VOC system (no luad).

Tnan:ofonner unloaded shouJd read less than one amp A.C. draw.

I( tnns(onner does nut hum; (a) check A.C. in (b) check inLemal wiring to transtOtllK"f (c) hy.paM inttomal tht:rmal breaker (loop at point A)..

A (.,lure o( any component c:ausn output to drop La 10V Of" less.

Read A.C. output. Approx. 29.5 volts A.C. between 2 110 studs on plastic or between tipso(2 diodf'S on same ~at link.

81·82. Approx. 14.8 A.C. bdwt'flJ one 110 stud on plastic La neptive post ot ~ror (rom tipo( ont' diode and circuit breaker or (use. B to D.

(

CHARCER/PO\JER SUPPLY INSTALLATION

(

Units .are 8 5 to

1~0

+ YAC 60 cycle or 230-20% 50 cycle to 12V, 24Y o r J2V neg.ative ground .

Choose a dry, safe location and through bolt or screw securely. Mount small rubber spacers between charger and mounting surface. Units mounted on a light surface-toward the cabin could accent or mildy ampliry transfonner hum . There should be a minimum of 6" space around unit for ventilation . .

Unit can be mounted in any position.

..'6 10,,-

Mini. .. um "Hr t! sil.es 05-C ( 161-n or higher r .. tcd

80AKl' 60AHl'

40AHP 20AKl'

'8

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Monitor vo ltage in operation t o check wire size. Should b. less than .J vo l ts differe nce betve~n battery and charger or battery and equipment .

All conn e c tio ns shou ld be tight, viring routed t o escape injury, nonmetalic con nections or plastic grommets used at wiring ho l es in case, and proper vire terminal s used a t studs and battery terminals.

(A) Wire directly {rom pllJS .studs on charger to plus terminals on batteries (or battery main switch if closer or easier). (One Of" more studs can be lelt unattached if desired.)

(8) \.lire dire c tly rrom negattve stud to negative terainal on battery. (Only one g round vire is necessary if battery grounds are cOlll4lOn) . (el Wire {rom A.C. circuit breaker box to A.C. ~ire on charge r (10 t o 15 amps A. C. breaker ). \.Ie r~co_nd A.C. ground t o case.

c

Check b.attery water level . Check each two weeks while charging.

Read D.C. vol tage at battt!ries before turn i ng on A. C. to charger. (Our 'Elec trical System Honitor' i s an excellent companion unit to charger). Any increase i n vo lta ge when un i t is activated means charger is functioning perf ectly.

Each unit will supply adequate voltage up to rated capacity and under a no load condition will finish at 13.8 nocaina!. (Correct lull charge (while charging) voltaRe).

Another check is [0 disconnect ne gative wire and read voltage acros s 12V posit ive and negative (Plac~ fingers across positive nad nega tive if using+a sensitive non-RHS Deter). Yo ltage without a battery in line should be 1).)- . ).

Check voltage of batteries after 24 hours of charging. Should any voltage ~~ under 1).4 ( no load) , exceed 14.1 (except No Haintenance batteries), or after charger is shut dovn, voltage drop ~ under 12V wi thin 15 minutes (1) Che ck your voltmeter (2) Check your batteries.

Note: New batteries, severely discharged batteries or b.a tt e ries that have bee n sittina uncharged over a month should be charged for 12+ hours (or to 13.4+V) individually . Check with hydrometer for any radical difference in float reading O/S") between cells .

Our ferro-resonant charger continues to hum e ven though voltage has peaked at finishing charge. The charger replaces the amount of current normally dissipating. (Counter Voltage).

Any rapid boiling or vater loss under 14.2 volts D. C. while on a charger means your ba ttery is probably defective.

Professional H.riner ferro-resonant units can be used as both a battery charger and converter at the same time. supplying necessary 12VDC .and keeping batteries charged. This feature . . kes expensive A.C . fixture. and wiring unneces s ary , probably saving the boat builder more than the cost of our unit.

Conault factory for specifications or specialty applications.

Caution: Disconnect batteries from converter when usln& one or more .tuds as s power supply only. A resistive load on one stud without a battery in line rsises voltage to batteries on other stud • •

R.e.ad A.C. cap.aciLor· should be over 0(00 V.A.C. (Don't touch· di.scb.arge with a screwdriver alter A.C. is off).

Check capacitor with

OM

lead disconnected. Analog V.O.M. on Rx 10,000 should jump up and then fall back to infinity.

(

With A.C. 0((, baueries disconnected, and VoltOhmMeter on Rxl . Read from diode tip to heat sink. Leads one way should head 0 and the other approx. 60'" of scale. 0 both ways or full scale both ways 'N!ptace diode.

Rxl across

r~

or cin:uit breaker should read full scale.

To open the charger. drill out the pop rivets around the base and the two Lop pop rivets on the plastic face inside door.

Remove A.C. gTound bolt and lift off cage.

On 12V models with 2 extra studs in upper left comer of plastic paMl marked '28V AC Secondary Test Termina.ls' , one can connect a 'trans(onner OK' or 'charger functioning' indicator light.. Maximum 15 watt (28V range) bulb. Test read· ings should be: 27·30 VAC between these two termina.ls and approx. 14.5 VAC between either terminal and the D.C. negative tenninal.

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12V CIURGER TO UV (voids wananty . consult !actory • we manuf.a.cture 24 V units) By remo\'ing the two diodes (rom one heat sink and replacing with two reverse diodes, this heat sink is 24V nt:galive.

This charger can charge either 12V or 20(V but 12 and 20(V negatives grounded in the same system will dead short inside of charger. (AU units except Pro Mite 15.)

LEAD-CALCIUM BATTERIES ffighe.r finishing voltages are seen because of the much reduced internal resi.stance of lead<alcium (Maintenance Fr~ ·No fLlILops). We do not recommend using lea.d<alcium batteries (or deep cycle or heavy duty ~ and recommend that ....ith '00 Load' or no current usage situations that the ~r be turned off. Lead calcium will ait (or 6 months ta a yar v.ith little charge loss. Several weeks at 14.3 to 14.5 has not visibly deteriorated test batteries. Leaving a 12V bulb on will nor· mally keep \'oltage below 100V which should not harm any battery ovu extended charging periods.

(

TRANSFORMER NOISE SUPPRESSION With • bat~ry in the system there should be no apparent noise in your ndio. Using the unit a.s a power supply with m.. batter)' in line for an A.M. or SSB radio, there will be a slight audible hum which can be elimina~ with an 18,000 MfD· Z5Veap.acitor.

AMMETERS We do not believe an ammeter tells much on a multi~tput charger and also a charger is normaJly located where it can not be easily monitored. A 6 passenger boat for hire is required by Coast Guard regulations to have an ammeter in the charging system. To comply with r~tions or a slrippus desirc, an ammeter can be installed in any convenient loca· tion by extending the negative wire o( the charger and placing an ammeter in the line. The total output of the charger can be observed.

VOLTMETERS An accurate voltmeter, preferably expanded sc:ale (Professional Mariner ElectriCal System Monitor) is an ucellent means of monitoring your electrical system.. Besides an a.ccurate means o( detennining full charge (rom a battery charger. one can also watch (or problems with the alternator systems or when charging systems an! shut down, the condition o( the batteries.

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corner of pl •• tic panel ~rked 'tran.fon.er OK' or 'charier range) bulb. Telt reading • 13.5 to 15YAC "between either

On 12V .odel. with 2 extra .tud. in upper left '2eVAC Secondary Test Te~in.I.·. one can connect I functionin,' indLcator liCht. Kaximu. 15 watt (2ev • hould be: 27-l0VAC between the Ie two terminal. and ter.inal and the D.C. negative ter.in.l.

Service depart.ent - C,ll (805) 644-1886

CORRESPONDING VOLTAGES

32V

2.V 16

I1V 8 11.2 12.2 12.5

22

22.'

29.~

24.4

32.fl 33.:1

2.-

12V 12.8 13.2

24V 25."

26.4

35.2

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29."

39.5

I"

32V 34.1

<2

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WI RING SCHEMATIC

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~" Center Section

Assembl y

Front Cover Assembly

Driven Shaft

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Quick Reference Data Chart Pump Series

Displacement IN'/REV .

@ 1000 RPM In GPM

Weight In Pounds

D

.11 . .63

.5 - 2.7

2-3

H

.47 - 2. 15

2.0 - 9.3

5-7

M

2.08 - 3.25

9.0-14.1

11 - 13

Pump Delivery

Fluid Compatibility All data based on Petroleum • Water Base Fluids Water Glycols Waler Emulsions • Pressure ratings reduced to 1/2 specified ratings of model • RPM reduced by 1000 from specified rating of model • Always use "OU" bushings • Use Nitrile (Buna "N") seals

• Synthetic/Special Fluids TransmiSSion Fluid Brake Fluid Diesel Fluid Mineral Oil Fluids • May need to de-rate based on viscosity • Use Nitrile (Buna "N") seals

• Phosphate Ester Fluids Pydrauls, Skydrols, Cellulubes (Fyrquel), etc.

• Use pump as rated • Use Viton seals • Quintrolubic Fluids reqUire "OU" bushings

Fluidpower Pump Division Otsego. MI 49078

( .~l.I.oiW Fluidpower

D/H/M Series Pumps, Fixed Gear

Features

• • •

Efficient, simple design -

few moving parts

Exceptionally compact and lightweight for their capacity Efficient al high pressure operation

• • •

Resistant to cavitation effects High tolerance to system contamination Reliable under cold weather operation

Specifications

)

•

185°F, Maximum operating temperature

• • • •

10" Mercury maximum vacuum (at 1800 RPM) 5" Mercury maximum vacuum (at maximum rated RPM)

20 PSI maximum positive pressure Pressure to 2500 PSI

Fluid Viscosity

• •

BO-1000 SSU Operating viscosity range 4,000 SSU Maximum start-up viscosity

Filtration And Installation For maximum pump and system component life, the system should be protected from contamination at a level nol to exceed 214 particles greater than 10 microns per milliliter of fluid.

Pump and motor shaft alignment must be within 0.007 inches total indicator reading using a standard float coupling. Please follow coupling manufacturer's recommended installation instructions to prevent end thrust on pump shaft Turn pump by hand to assure freedom of rotation. Pump and motor must be on a rigid base.

The coupling should be sized to absorb the peak horsepower developed.

) Fluidpower Pump Division Otsego, M I 49078

Parker Fluidpower 5

D/H/M Series Pumps, Fixed Gear

Instructions for Reversing Gear Pump Rotation The basic tools needed are a vise, preferably with soft jaws. a torque wrench, a thin screwdriver, a small hone stone, a ratchet, and a paper clip. The "0" series will require a 1/2" socket, the "H" series an additional 1/4" hex head driver, and the "M" series a 5/16" hex head driver. It is

also recommended that you have on hand a few extra heat shields and gaskets. Part numbers are 655287 and 655288 for the "0" series, 656942 and 656943 for "H" series, and 656026 and 656025 for the "M" series.

To change rotation, hold the pump by the rear cover with the drive shaft pointing up. Remove all the bolts. The "0" series will have four hex head, the "H" series will have six hex and two allen head, and the .oM" series will have eight allen head bolts. At this time. it would be helpful to scribe a line down the outlet side of the pump. If not marked, the outlet port is usually the smallest.

If the pump has a key type shaft, remove the key and hone down any burrs that may be on the shaft. This is important as the next step will be to lift off the front cover and any sharp edges could possibly damage the front seal or bearing.

After the front cover is off, note the position of the little vent hole in the bronze wear plate, which should have come off with the front cover. The parts underneath also have a similar vent hole.

Remove in order, the wear plate , the heat shield, gasket. and V-seal. To facilitate this. make a little hook with a paper clip and lift up the part high enough to slip a screwdriver under and carefully pry up. Please note. the heat shield. in particular, is very brittle and may crack if bent.

After removing these four parts, reinstall the V-seal with the lips down in the front cover so that the vent hole is on the opposite side across from the reference mark. Use the screwdriver to seat it completely. Next install the gasket, heat shield, and wear plate: again with the vent hole in line with that of the V-seal. The wear plate should be almost flush with the surface of the front cover. You may have to go back and tuck in, here or there, so that it is flush.

Remove the center section and note the notch cut on the inside. This will be installed in line and next to the vent hole in the wear plate. The dowel pins used to locate the center section may be removed temporarily to facilitate sliding the center section over the gear assemblies. Be careful not to pinch the O-ring between the front cover and center section. If it doesn 't want to stay in place, it can be "glued" using heavy grease.

Fluidpower Pump Division Otsego, MI 49078 6

Shaft Seal Cap Screws Hex Screws Washers 5. Front Cover 6. V·Seal 7. Dowel Pins S. Gasket 9. Heat Shield 10. Wear Plate 11. " 0 " Rings 12. Center Section 13. Drive Gear Assembly

1.

2.

3.

4.

14. Driven Gear Assembly 15 . Flow Control (" H" Flow Divider Pump only) 16. Relief Valve (" H" Flow Divider Pump Only) 17. Back Cover 18. Thrust Plate (H&M only) 19. Key (Where Required)

)

If the pump is an "H" or "M" series. install the bronze thrust plate into the center section orienting the side with the bar in line with the vent hole.

The rear cover is installed with the outlet side in line with the vent hole. The outlet side will be marked or can be iden· tified by the smaller cavity internally. As when installing the center section, be careful not to pinch the O·ring seal.

To check your work, the line that was originally scribed on the side should now be located 180 0 on the rear cover and center section from that on the front cover.

Install the bolts and snug them down by hand. Then torque to the proper setting, alternating from side to side. The correct torque specifications are 355-375" Ibs. for the "M" series. and 190·210" Ibs. for the "0" and "H" series respectively.

Testing Procedure After pump has been reinstalled. run for 2-3 minutes before pressurizing. Try to apply pressure graduaUy for an additional five minutes, but do not pressurize for longer than 5 seconds at a time.

Pilrker Fluidpower

)

~ )

-

.---/ ,

...

- -

-

-

-

~

~

-

~

-

Model95W )

Multiple Disc Brake Service & Repair Manua};-

Part Number & Technical Information

.53 tlA lHR\I W11:. H<US (4) PLCS.

.....,sa

, "-'JlOC-2B

(1S!~~~u.

PlDT DIA..

t 88 CIA. D.C.

N'UT 00

~

,.

,.

~

1.500 DlA SHAFT 1.500 TAPER/FOOT

1.25-1_-' (9..0TTED !-EX JAJ,t i":-.-

)

HUT INO.lIDED)

Waxmum release pressure

3000 PSI

vrr

Woximum op4I'"ClUlg lrrnpllf'"crtun

F

Ua.hum conthuOUI preMUrI 3000 PSI Volume of oa to rdcaac broke .5 aJ.".

Uaxmum speed 250 RPt.I Approxmote .1I~ht ...... [bl.

Shaft. SpIne ;W ~wluto. ftot root. aid, fit PO! ~SI 892.1-1970 "'tarnai-doli 7, mct.nal-daa 5.

Breckawo)' torque mo)' wry ±lOX from apoclfiod ratings. UN eny mneral bcS8 h)drw[ic: DO to releoae brake.

OPTIONS AND ORDER INFORMATION

f 951 I

MODEL

•

Whe~

=

Rel.Press.(lnitiol/Full)

BooO Ib-ins = 9000 Ib-ins = 10000 Ib-In. = 12000 Ib-In. = 14000 Ib-in. = 16000 Ib-in.

Torque. r..ted en "drf and at

Mount

OUTPUT SHAFT B -

Torque Code

806B 80B7 8097 B09B 8127 812B

OUTPUT PLOT

w-

TORQUE

i

1.500 Dia X 1.500 Taper

240/300 310/390 350/435 350/435 455/570 455/570

pSi

PSI PSI PSI PSI PSI

(0) PSI bock pn!IIIUre. Other torque. and release pressures ore oYCInoble.

Per Foot

VoluN WlOWTI are ,laIdcrd unIts.

INPUT PLOT (s.. p,,. 10) A

-

SAE "A" 2 80lt and Modified 4 801t

INPUT SHAFT 3 4 -

SAE 1"-68 Spline 14T 12/24 Spline

)

Model 9SW Service Manual The Model 95W series EskJ-idge brake is a spring applied, hydraulically released, multiple disc, failsafe parking brake with side load carrying capability. The 95W is designed with dry bronze friction linings and as Ii .. failsafe" type operation.

All brakes are individually tested at ttle factory for (unction. leaks and static breakaway torque. Failsafe type brakes are tested to be assure<.! they are in excess of 110% of the failsafe torque rating for the unit. A failsafe brake should be used when the only requirement is a minimum static holding torque.

Of course, temperature. wear and contamination of the friction plate surfaces may effect the perlonnance of the brake and should be taken into consideration when specifying a required torque rating. Care should be taken to avoid damaging the splines or mounting surfaces during installation

Installation NOTE: Before beginning instatlotion procedures. visually inspect broke mounting (Jonges and shaft splines for damage due do not use broke.

to poor handling during shipping. t( damage is excessive,

I. The 95W brake is supplied with the necessary o-rings or gaskets for mounting the brake to a motor. Use the gasket when mounting the hydraulic motor to the brake. The 95W is also supplied with a slotted jam nut and key for the tapered shaft.

The tapered output shaft confonns to SAE J501 standards.

The 95W brake is designed as a "thru bolting" (4) bolt assembly. The mounting bolts must be long enough to go thru the bra\. and into the mounting tube or plate. The hydraulic motor can be mounted directly to the input side of the brake using either the 2 or 4 bolt SAE "A" bolt patterns.

NOTE: I. Use only grade 5 or better mounting bolts or hardware for mounting the brake and or motor.

2. Allow a minimum of 112" thread engagement when sizing assembly bolts 3. Torque all 112-13 bolts to 75 ft-tbs.

4. The brake can be rotated to orient the bleed and release ports as required.

5. Some installations may require that the brake be released so it can be rotated to align bolt holes (see step 4 of installation instructions) for mounting.

3. Remove plastic protective plug from pressure port of brake and attach a pressure line with a 7/ 16-20UNF-2B straight thread o-ring fitting.

4. Apply low pressure (20-30 PSI) to brake release port. Loosen hollo w hex plug opposite of pressure port, just enough to allow hydraulic fluid to bleed from piston cavity. After air has been bled from brake, tighten plug.

1lI'.AK£

MOTOR

) GlISKIT OR O-RING

Disassembly: I. Place brake on a stable work platfonn. input shaft down. Use assembly/disassembly tool number ESK - 95002. A drawing is available for use in manufacturing your own.

2. Remove Snap Ring (ITEM 17).

3 .. "mOve the (4) Socket Head Cap Screws (ITEM 18) from output end of brake.

)

... Remove Cover (ITEM 1<4). This will expose the intemal components of the brake. The Case Seal C-Ring (ITEM I J ), Input Bearing (I TEM IS) and Snap Ring (ITEM 16) will be attadTed to the Cover. Note the color. number and spacing of the Springs (ITEM 10) before removal from Piston (ITEM 7). Inspect springs for breakage, discoloration and spring rate. ( Blue colored springs have a spring load of 250 Lbs. @ .780" compressed heigl'lt.).

5. Removal of the Piston (ITEM 7) will require the use of an air pressure source, air gun with a small nozzle tip and erring port plugs. Procedure is as follo~

* Remove any plugs in the release and drain ports of the brake Case (ITEM

"'). Using the air gun, blow all excess hydraulic oil from piston cavity. ( This will keep excess oil from blowing down into the friction plate cavity when piston is removed.)

II< Place one o-ring port plug in either brake release port. Place cloth shop rag over piston cavity and brake. Using the air gun and small nozzle tip. blow air into the open release port. The air pressure will blow the piston up and out of the piston bore in the Case (ITEM '" ).

6. Remove and inspect the O-Rings and Back-Up Rings (ITEMS 8. 9 • I I • 12 )for wear and or damage. Note seal o rientation before removal. Seals must be replaced rr abnonnal wear or damage is evident.

7. Remove Brake Shaft (ITEM I). Inspect splines and bearing journals for abnonnaJ wear or damage.

8. Turn brake assembty over. which will facilitate the removal of the friction Plates (ITEM 5). Spacer (ITEM 3) and Separator Plates (ITEM 6) . friction plates should be replaced if oil soaked and or excessively worn (dry brakes only).

9

unaged. the Bearing (ITEM 2) can be removed and replaced. Check for wear spots and or nicks on the sealing lips of the ... ..aring seals.

NOTE; All major components should be washed in plates!

0

degreasing solution with a (lnal de<Jnsing rinse in alcohol. Do not rinse friction

)

Assembly: Parts must be clean and dry before assembly. Visually inspect components for damage and abnormal wear. Brake operation should be tested during normal service operation. Service or inspection to the brake should be part of the normal service and maintenance schedule of the equipment or vehicle.. Any loss of holding torque requires the removal. inspection and replacement of suspect components.

Assembly should be in reverse order of disassembly with the following additional Instructions • I. Place brake Case (ITEM 4) on a stable work platform. output end down. If the Bearing (ITEM 2) has been removed, press new bearing into the Case (ITEM 4). Lubricate the bearing and seals with a light coat of lithium grease..

2. Using the assembly/disassembly tool number ESK-95002 to properly space the Case (ITEM 4) off the work surface, install the Brake Shaft (ITEM I). Push shaft downward thru bearing until end of shaft bottoms OUt in the assembly/disassembly tool.

3. Install Spacer (ITEM J), Separator Plate (ITEM 6) and Friction Plate (ITEM 5) in exactly the same order as they were removed. There must always be a Separator Plate (ITEM 6) on top and bottom of the friction stack of plates. If a Friction Plate (ITEM 5) is placed next to the Piston (ITEM 8) or a Spacer, the unit will overheat and seize up. Be rorefU/ not to contaminate the friction plate surfaces with dirt, grease. or fluid of any kind.

cam

-4. I( replacing Piston D -Rings (ITEMS 9 & II) and Piston Back-up Rings (ITEMS 8 & 12). be sure a-rings are nearest other with back-up rings to the outside after installing onto Piston (ITEM 7). Lightly lubricate piston bores. Take care not to get lubriamt onto friction pad<.. Gently slide piston into Case (ITEM ") until larger o-ring touches case. Using a light to medium duty press, install piston completely into bore. This will squeeze the o-rings and back-up rings and set piston against friction pack.

S. Place the Springs (ITEM 10) into the spring pockets in the Piston (ITEM 7).

6. If removed, install Input Bearing (ITEM 15) and Snap Ring (ITEM 16) into Cover (ITEM 14).

7. Install the Case Seal C-Ring (ITEM 13) onto pilot of the Cover (ITEM 14).

8. Set Cover (ITEM 14) on top of the piston, springs and input end of the brake shaft. Start four Assembly Bolts (112-13 x 1.50) (ITEM 18) thru the Case (ITEM ") and into the Cover (ITEM I") with your fingers. A light to medium duty press can be used to push the cover down on to the case so the cover bofts can be installed more easily. Alternately tighten assembly bolts 112 tum at a time until cover is tight against the case. Tighten bolts to 110 ft-tbs of torque.

9. Install Snap Ring (ITEM 17) on to the Brake Shaft (ITEM I). If snap ring will not fit, lightly tap the opposite end of the brake shaft with a brass hammer. This will help seat the shaft onto the Input Bearing (ITEM 15).

10. The brake is now ready (or minor testing o( fit, (unction and release pressure. Due to the complex equipment required, you will not be oble to test the holding torque of the brake. To test release pressure, place the o-ring port plug in one o( the brake release ports.

Using a hydraulic power source either a hand pump or port -a-power, pressurize the brake slowly to the advertised release pressure both initial and (ull. DO NOT EXCEED 1000 PSI WITHOUT THE BRAKE BEING BOLTED TO THE GEARBOX OR A TEST FIXTURE. As you pressurize the brake, rotate the brake shaft at the output end. The brake shaft should begin to tum at the advertised initial release pressure (+ or - 25 PSI). There will be drag on the shaft. Increase the pressure slowly until the shaft spins (reely, this is the full release pressure. As you pressurize the brake, look (or signs o( leaks which would indicate that the o-rings or back-up rings were damaged during assembly.

)

II. Use only mineral based hydraulic oil to test and operate Eskridge multiple disc brakes.

Repair Kits, 95W Repair kits listed below are for use with the model 95W multiple disc brake.

None Due [0 the many combinations of torques and release pressures ovailable (or the 95W, it is impossible to detail e<lch style and supply (] rcpoir kit (or each individual model. The information listed in this manual is represetltotive of all95W brakes. The repair kits listed below will worlc: with all combinations of torque vs. release pressure, input mountings and friction plates. h is entirely pOSSible to have "extra" parts left over from the repair kits after you have completed the repair or maintenance. If you ore not wre about whot is required (or your broke and its configuration, ploose contoct Eskridge, Inc soles or engineering deportment.

)

"MASTER REBUILD KIT. 95W

'~_r~ "'''c/'

'-"-' ::'1,'

_ 95-016-2491 - 95-016-1181 0':' 00'9231

F.,,~n()N

I"105.iP"90

<¥ii,

)

WARRANTY MULTIPLE DISC - FAILSAFE BRAKES ESKRIDGE, inc. ("Eskridge") warrants to its original purchaser ("Custome r") that new component parts sold by Eskridge ("unit (s)", at the time of delivery

by Eskridge to the customer will be free of defects in material and workmanship and will conform to standard specifications set fo rth in current Eskridge sales literature and to any C\lstom specifications of the customer acknowledged in writing by Eskridge, subject to the (ollowing qualifications and limitations.

)

I.

Prior to placing warranted units in service, the customer shall provide proper storage such that foreign objects (e.g., rain or debris) cannot enter any unit via entry ports which are nonnalty closed during operation.

2.

The customer must notify Eskridge in writing of any claim for breach of this warranty prompdy after discovery of a defect and in any event prior to the termination of the warranty period, which shall commence when a unit is shipped to the customer by EWidge and shall expire twelve (12) months thereafter.

3.

This warranty shall not apply with respect to units which, upon inspection

by Eskridge, mow signs of disassembly. rework. modification pr imprope r installation, mounting use or maintenance.

4.

Claims under this warranty will be satisfied only by repair of any defect(s) or, if repair is determined by Eskridge in its sole, absolute and uncontrolled discretion to be impossible or impractical. by replacement of the unit or any defective part thereof. No cash payment or credit will be made for defective materials or

worl<man"'lp.IN NO EVENT SHALL ESKRIDGE BE LIABLE FOR INCIDENTAL OR CONSEQUENllAL DAMAGES OF ANY KIND OR NATURE.

)

s.

From time to time, Eskridge may make design changes in the component parts manufactured by it without incorporating such changes in units previously shipped.

6.

All freight charges in units returned for warranty service are the responsibilty of the C\Jstomer.

THE FOREGOING WARRAN1Y IS THE SOLE WARRAN1Y MADE BY ESKRIDGE WITH RESPKTTO ANY UNIT, AND IS IN LIEU OF ANY AND ALL OTHER WAR· RANllES, EXPRESSED OR IMPLIED. WITHOUT L1MIllNG THE GENERALI1Y OF THE FOREGOING, ESKRIDGE EXPRESSLY DISCLAIMS ANY IMPLIED WARRAN1Y OR MERCHANTABILl1Y OR FllNESS FOR ANY PARTICUlAR PURPOSE, REGARD· LESS OF ANY KNOWLEDGE ESKRIDGE MAY HAVE OF ANY PARllCUlAR USE OR APPLICAllON INTENDED BY THE PURCHASER. THE SUITABILl1Y OR FITNESS OF THE UNIT FOR THE CUSTOMERS INTENDED USE, APPLIcAllON OR PURPOSE AND THE PROPfR METHOD OF INSTALLAllON OR MOUNllNG MUST BE DETERMINED BY THE CUSTOMER.

95W SERVICE MANUAL VER. · 319 1

)

ESKRIDGE

1900 KANSAS CITY RD .

OLATHE, KS 66061 (913) 782-1238 (913) 782-4206 FAX

)

II~• •

orqmotor

TM

MAR and MAE Series Service Procedure

)

TRW Ross Gear Division ) Price $3.00

Table of Contents Page Trouble Shooting Guide ................ . .................. . .. . ... . .. . ......... 1A

Exploded Assembly View Fold OUI. . . . . . . . . . . .. . .............................. IB.l C Trouble Shooting Checklist . .. .

. .... . ..... . . ... ... . ... . . .. ........... 10

Seal Installation Tools ....... .

. .... 2

. ............. 3

MAB Service Parts List Chart . .......... .

11 V. Inch. 31.8 mm. Seal Oia. Coupling Shaltl MAE IStandardl Service Parts list Chart . .......... '.' .......... .

. . . .... . . . . . . . . .4

11 'f, Inch. 31.8 mm. Seal Oia. Coupling Shaltl

MAE Service Parts list Chart ....................... . . . . . ...................... . . 5 1Yz Inch, 38. 1 mm, Seal Dia. Coupling Shaltl Disassembly & Inspection . ................... ................ ................... 6

Assembly .................... .... ......... .

. . .................... 8

)

. .. 10

Final Checks ...... .

Hydraulic Fluids .................... .. . . . .

Filtration, Operating Temperawre .......... . ... . . .. . . . . . .

Tips for Maintaining the System . .

. 10 .. 10 . ..... ..... . . . ...... 11

) © TRW 1988

Troubleshooting Guide NOTE: Before troubleshooting any system problem, check service literature published by the equipment and/or component manufacturers. Follow their instructions, if given, "') for checking any component other than the MAB or MAE Torqrnotorrll unit.

Preparation

Hydraulic Components

Make your troubleshooting easier by preparing as follows:

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

• work in a clean, well-lighted place; • have proper tools and materials nearby; • have an adequate supply of clean petroleum-based solvent.

WARNING: SIN CE THEY AR E FLAM MABLE, BE EXTREMElY CAREFUL WHEN USING ANY SOLVENT. EVEN A SMALL EXPLOSION OR fiRE CO ULO CAUSE INJURY OR DEATH. WA RNING: WEAR EYE PROTECTION AN O BE SURE TO COM PLY WITH OSHA OR OTHER MAXIMUM AI R , RESSURE REQUI REMENTS.

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

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

Next, go to the reservoir and filter or filters. Check fluid level

and look for air bubbles. Check the filterls!. A filter with a maximum 50 micron filtration is recommended for the MAS and MAE system.

Visually check other components to see if they are loosely f11ounted, show signs of leaks, or other damage or wear.

Excessive heat in a hydraulic system can create problems that can easily be overlooked. Every system has its limitation for the maximum amount of temperature. After the temperature is attained and passed, the following can occur:

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

• oil seal leaks

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

• pump loss of efficiency

• improper replacement parts used in previous servicing

• pump failure

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

• loss of efficiency such as speed and torque

• hoses become hard and brittle • hose failure A normal temperature range means an efficient hydraulic 'System. Consult the manuals published by equipment and/or component manufacturers for maximum allowable temperatures and hydraulic tests that may be necessary to run on the performance of the hydraulic components. The MAS and MAE are not recommended for hydraulic systems with maximum

temperatures above 200"1' 193.3"C1.

) 1A

1.

MAB/MAE Torqmotor™ Exploded Assembly View-Typical

'Not used on all units .

all' CJo /// " 3

, f".- ,. 'ii _SET) &~,

/

~W

•

°0

VII. ,/ "_~O<ED / " " ~:> /

lb.C

Matcl1ed Sel lor MA8 TOIQmotors

,,,I ".. ,;,.

NOTE, A",mbl.

Dol " 'h.we ;" '"',,,., View 01 Sectioned Segments 01 Items Number 19 and 20.

/

B

18

/

19

V /

V

/

20

118 \

2.

J. 4.

••

II

Back-Up Washer

16. lSA. 168.

Dllve link Wear P\a1e AolOl Sel AolOl Vane m

15.

Washer

Seal

6.

1.

•7. 1 B. BA. 9.

10.

11 .

HO~lng

1SC.

Slaw

Seal Ring 12) Back Up Ring 121 Thrust Washer ThrUSI Washer Th rUSI Beaung Bearing Coupling Shah

17.

lie '

N", Washer

Ma mlold Plate Manilold Commutator Seal Ring Commutator Ring Sleeve End Cover Assemhly ~et:ial Bult 171

I1A 118.

110 11£.

IlF 12. ~

Seal Aetalnlng Ring

13

18.

19.

20.

21 .

22 23.

24 25.

26.

21..

29.

2BA

K.,

Bull Lock Washer Relaln lng Ring Bearing ThrUS1 Beanng

,0

"9

a·Rmg Spnng 121 Valve IShulllel Re~ef Valve QI ITwtI plecel

~

SA

00o / / ~

~ •• ~('

~

/

21

I1C

--

10

~.

llA

,1A I1F

"

~/12 ~.//3 !70

'("

N•.

:1.

11Dk

9

/

~® V. tt ' ...

hem

-6

11E

.

p ...

'

~

~1'

MA.TCHEO

" //.~ 16~6A

.

25

~~26 'All.,..,. Con.'Rlction

/21

R,lief V.I .... £lid COft, AllelOate ConSlruction" shuttle valve end cover

V

NOTE: "Alternate Construction" is far Torqmo\Orsno/lisled in charts plOvided in this manual.

28

-~

21 ' " /26

0

/25

•

u MAB/MAE TorqmotopM Exploded Assembly View-Typical

/1. , 0/

(Identical to page 1B)

v ///'

A ' fI / ~~d.'>D //

16~b. A

/ lbC

Matched Set for

MAB Torqmolols

NOTE: Assemble Seal flat Side Out as Shown in Enlarged

View of Sectioned Segments of 'terns Number 19 and 20.

IIJil

"-6

5

°0

,;:; 1·

s".t;

11°k o · 11E

9

.

,1 ~ ~PrCHEO 18

8A

\

()

/0

~"A

/

\

.

/

2.

3.

4.

5.

6.

7.

'7.1 B. BA.

,.

10.

11 . llA. llB,

lle.

Seal Retaining Ring

Back-UP Washer Washer

Seal HOUSing

Seal Ring 121 Back Up Ring 121 Thrust Washer ThlllSt Washer Thrust Bearing Bearing Coupling Shalt

"j N",

Washer

110.

Boh

llF.

lock Washer Retaining Ring Bearing

m.

11.

13.

Thrust Bearing

14.

15.

16. \SA. 168.

16C. 17.

lB. 19.

20.

21 .

22.

13.

14.

25.

26.

27.

2B. 2eA.

Dnve link Wear Plale RolOf Set ROIO!

Vane 171

Stalor Manifold Plate Manifold

25

~q'26

Commutator Seal Ring CommulalOr Ri~g Sleew t nd Covel Assembly Special 8Qll 171

""'

O-Ring Spring 121 Valve IShulllel Renel Valve (21 )Two piecel

" AIt,r.," ConttrlctiOR R,11e1 V.I .... hel CO'IIr

llA llF

11

::10

21

No.

:1.

___ "C

~/" ~.//3

~~''"

/

118

//

O~ ~-

v ~:> / "'" ~®~//q -xl V. ~~ I ..

Item

3

CJ

16

15

• Not used on all units.

/ 21

V

Alremate Construction" 28 shuttle valve end cover -~ '2.7 NOTE: "Alternate Construction" is lor Torqmowsnot listed in .... / /26 charts provided in ll1is manual. , 0 /25

•

'<'

Troubleshooting Checklist Trouble

Cause

Oil l eakage

1_ Hose fittings loose, worn or damaged

Check & replace damaged fittings or "0" Rings. Torque 10 manufacturers specifications.

2 Oil seal rings mdeteriorated by excess heat 3_ Special bolt (24) loose or its sealing area deteriorated by corrosion

Replace oil seal rings by disassembling Torqmotor1l. unit.

Remedy

lal Loosen then tighten single bolt to 45-55 ft.lbs_ 160-76 N ml Ibl Replace bolt.

4_ Internal shaft seal (51 worn or damaged 5_ Worn coupling shaft 1111 and internal seal 151 Significant loss of speed under load

1. lack of sufficient oil supply

Replace seal. Oisassembly of TorQffiotorll. unit not necessary.

Replace coupling shaft and seal by disassembling TorQffiotorUoI unit.

lal Check for faulty reiief va lve and adjust or replace as required.

Ibl Check for and repair worn pump. lei Check for and use corract oil for temperature of operation.

2_ High internal mOlOr leakage

lal Replace worn ro tOf set by disassembling

3_ Severely worn or damaged internal splines

Low mechanical efficiency or undue high pressure required to operate Torqmotorr.. unit

To rqmolOr'~

unit.

)

Replace rolOr set, drive link and coupling shaft by disassembling Torqmoto rl~ unit.

4_ Excessive heat

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

1. Line blockage

Loca te blockage source and repair or replace.

2_ Internal interference

Disassemble Torq motor'~ unit, identify and remedy cause and repair, replacing pans as necessary.

3_ Lack of pumping pressure 4_ Excessive binding Of loading in system

Check for and repair worn pump.

Locate source and eliminate cause.

external to MAB/MAE unit.

CAUTION: If the hydraulic system fluid becomes overheated lin excess of 200 "F (93.3OCll. seals in the system can shrink. harden or crack. thus losing their sealing

ability.

Patents Ross Gear Division products and systems described in this manual are protected by one or more of the following United

States patents: 3,289,602; 3.288.034; 3,452.680 and 3,606,601_ In addition, patent applications have been liled in 8razil, Canada, Denmark, France, Italy, Japan, Sweden, the United Kingdom, and West Germany.

10

)

Seal Installation Tools 1.185 1.175

.760 .740

!

'C ODIA

'AoO IA 'BoOlA

20

30±S·Y L._ F'OLISH TO REMOVE SHARP EDGE ONL V

POLISH TO REMOVE SHARP EDGE ONLY

Dimensions Shown in Inches

Oimem:iGns Shown in Inches Shaft

Shafl

Tool No. J26751 JJ3074·'

Seal Oia.

Dim. "Au

I~

1.25211.256 1.50211.508

'" Seal Thimble

Dim. "8" 1.20011.280 1.54011.530

Tool No.

Seal Dia.

J26753 J33074·3

1',

lY,

CONVERSIONS 1.240 1.260

=n

"A001A "9"OIA

""'~ .740 .700 1.175 1.185

1.240 1.252 1.258 1.200

1.180 1.290 1.300

1.350 1.498

1.500

Dimensions Shawn in Inches Shalt Seal Dia.

"

1%

Dim. "C" 1.590/1.61(1 1.640/1.860

3.00 3.10

Tool No. J26752 J33074-2

Dim. "8"

1.13511.715 1.985/1.965

Seal Compression Ring Figure 3.

Figure 1.

4. 10 4.00

Dim. "Au 1.50211.504 1.75111.753

1.502 Dim. "A" 1.ID1.350 1.55011.600

Dim. "B" 1.50011.498 1.747/1.745

Dim. "e" 1.800/1.600 2.400rl.200

Seal Driver Figure 2.

1.504 1.508

1.530 1.540 1.550 1.590

1.600

mm

Irches

mm

18.80 19.30 29.85 30,10 31.50 31.80 3\.95 32.00 32.51 32.77 33.02 34.29 38.05 38.10 38.15 38.20 38.30 38.B7 39.12 39.37 40.39 40.46

1.610

40.89

1.715 1.135

1.745

43.55

44.07 44.32

1.860

44.37 44.48 44.53 45.72 46.14 47.24

2.052 2.057

52.12 52.25

2.200

5S.BB

2.240

56.00 57.40 59.94 00.20 60.96 76.2 7B.7 101.6 104.1

1.747

1.151 1.753

1.800 1.840

2.180 2.360 2.370

2.400 3.00 3.10 4.00 4.10

NOTE: Tool Kit J26905 for 114 inch 132 mml seal diameter coupling shaft includes tools J26751, J26752 and J26753.

)

Tool Kit J33074 for 1% inch 138 mml seal diameter coupling shaft includes tools J33074·1 , J33074·2 and J33074·3.

Tool Kits available from: Kent·Moore, 29784 little Mack. Roseville, Michigan 46066, Phone 13131 774·9500.

2

~

MAB Service Parts List Chart (1 % Inch. 31.8 mm. Seal Dia. Coupling Shaft) CHART USE EXAMPlE: MABOSOO2 TDROMOTORTM INCLUDES PART NUMBERS LISTED TO THE RIGHT OF MAS, 06· AND -002 SHOWN IN LEFT HAND COtUMN OF CHART. CAUTION: THE CHARTED COMPONENT SERVICE INFORMATION IS FOR THE TORQMOTORS LISTED ONLY. REfER TO THE ORIGINAL EQUIPMENT MANUFACTURER OF THE EOUIPMENT USING THE TOROMOTOR FOR ASSEMBLY NUMBERS NOT LISTED BELOW.

EXPlOOEO VIEW

MAS

06081014-

1624-

32-

·002 ·003

-004 ·005 ·008

-008 ·0 10 ·011 ·014 ·015 ·016 ·017

-041

I

l'

'"

EXPlODED VIEW ITEMI

8 &8A"

g""

EXPlODED VIEW ITEM/ DeSCRIPTION SERVICE PART I EXPlODED VIEW

SERVICE PART I SERVICE PART I SERVICE PART I SERVICE PART I SERVICE PART I SERVICE PI\RT I EXPLOOEO VIEW

J"

'"

5"

12"

I"

15

" 11 ·1 8

19·21 Commutator

~.

20"

2J

Seal Ar.o

MAB01800OS1

032435

Elld COYI!f ksy.

MABOI6000Al

16

22

24

MAB083001

MAB087000A2

MAB103000

MAB107000AI

MA8143000 MAB163DOl MAB243001 MI\B323001

MABI47000Al

099025 099091 099104 099026 099024 099085

021271 021 272 021273

K.,

'"

N",

039027 039027

025126 025126

Manifold Plene • Manifold MA8D15003Xl

MAB167000A2 MAB241000A3 MAB321005A1

ITEM ...

6

11

DESCRIPTION SERVICf PART I SERVICE PART I SERVICE pm I SERVICE PMT I SERVICE PART I SERVICE PART I SERVICE PART I SERVICE PART I SERVICE PART I SERVICE PART I SERVlct: PAAT I SERVlct: PART I SERVICE PART I

Housing MAB012000Al MABOl2002Al MAB012000AI MAB01 2002AI MABOI2000Al MAB012002Al MABOI2000Al MABOI2002Al MABOI 2002AI MABOI2000Al MABOI2000Al MABOI2002Al MABOI2000Al

toupling Shah 091399 09 1404 09 1404 091399 091405 091405 091416 091416 091462 091931 091462 091431 091435

039028 039028

021 270 021 326

liS'"

m Washer

e110.,

lock Washer

028413 028413 028413

6223734 G223734 G223734

6103325 GI03325 Gl03325

028413

G223734

61 03325

NOUS: 'Ind1Hled in MAB500003-standald seal kit. Other kits: MAB500004- vitoo, synthetic I\uJd appiatlOllS, MAB500005-cokl temperatUle applications. " Induded with iltm /6, Service Housing Assembly, "'hem 1118 nut secvice paft number isted is fill TorqmolQl" assembly pan numbers with an Al sumx crit.

Ite.m 1118 11\11 sefVir:e pall numbel fO! TOI"qmotOf assembly pan numbers wilh an A4 sulfix is 025113. ham 1118 nut service pall number !of TOfqmotlH" assembly parI numbers with an A1 sulfix is 025 132.

11E

11F Rela1"1tllg RlIlg

401333 401333

MAE (Standard) Service Parts List Chart (1% Inch. 31.8 mm. Seal Dia. Coupling Shaft) CHART USE EXAMPLE: MAE·l0002 TOROMOTOA TII INCLUDES PART NUMBERS LISTED TO THE RIGHT OF MAE, 10· AND ·002 SHOWN IN LEfT HAND COLUMN OF CHART.

CAUTION; THE CHARTED COMPONENT SERVICE INFORMATION IS FOR THE tOAOMOTDRS LISTED ONLY. REfER TO THE ORIGINAL EOUIPMENT MANUFACTURER OF THE EQUIPMENT USING THE TORQMQTOR FOR ASSEMBLY NUMBERS NOT LISTED BElOW.

,.

EXPlQom VIEW

4·

I

10· 14·

20· 24· 34· 68·

EXPLODED VIEW ITEM I DESCRIPTION SERVICE PART I SERVICE PART I SERVICE PART I SERVICE PART I SERVICE PART I SERVICE PART I

14 Drive lilk

15

16

Wear PlaIS

HOIO! Sel

MAElO3000 MAE143000 MAE203000

417259 477259 417259

MAE107000

MAE243000 MAE343000 MAE683000

477259 477257 477257

MAB012002Al MAB012000A 1 MAB012002Al MABOI2000Al MAB012002AI MAB012000AI MABO I 2002Al MABOI2002Al MABOI2000Al MABOI2000Al MABOl2002Al MAB012007AZ''''

091442 091442 091443 091445 091445 091441 091441 091453 091452 091453 091452 09 1460

MAE141000 MAE2070DO MAE247000 MAE347000 MAE687000

11 Manifold Plale 417260 477260

Manifold

Sleeve

23 End Cover Msy.

MAE015000 MAEOI5000

099082 099096

MAEOI6000AI MAEOI6000Al

477260

MA£OI5DOO

477260

MAEOI5000 MABOI5003 MAB015003

099092 099066 099064 099079

MAE016000AI MAEOl6OOOAI MABOl6OOOAl MABOl6OOOAl

02 1340 021273 021273 021329

028413 028413 028413

G223734 G223734 G223734

Gl03325 G103325 G103325

40 1333

028413

G223734

Gl03325

477256 477256

18

"

"

Special Bolt171 021271

021352

EXPtODEO VIEW

·002 ·003

·004 ·005 ·008

·009 ·010 ~1l

·0 14 ·015 ·016 ·0 17 ·029

SERVICE PART SERVICE PART SERVICE PART SERVICE PART SERVICE PART SERVICE PART SERVICE PART SERVICE PART SERVICE PART SERVICE PART SERVICE PART SERVICE PART

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

039027 039027

025 126 025126

039028 039028

039027

025126

NOTES: ' lrduded ., MAB500003-s!andard seal kit. Olhef kits: MA8500004-vitOO, synthetic I1uid applications; MA8500005--co1d temperallJ(e 8pj1licalions. willi item iii, 5efva Housilg Assembly. "'hem 1118 nut service part number isted is for Torqmo!OI" assembly part numbers willi an Al suffIX ~.

Item 1118 nut servCe part numbllr fur Torqmotor assernlt( pan I1\JlIber witll en 44 suffix is 025113.

Item 1118 nut S8fVite part IllI1lber for Torqmolor membIy part number with an A1 suffix is 025 132. · ·· ·Housmg MABOI2007A2 uses chamlered washer 1400 135 101" ilem SA" the exploded assemlt( view.

"1ncIo.Jjejj

4013~

~

MAE Service Parts List Chart (1% Inch. 3B.1 mm. Seal Dia. Coupling Shaft) CHART USE EXAMPLE: MAE10031 TOROMOTOATM INCLUDES PART NUMBERS LISTED TO TllE RIGHT OF MAE, lG- and ·037 SHOWN IN LEFT HAND COLUMN OF CHART.

CAUTION: THE CHARTED COMPONENT SERVICE INFORMATION IS fOR THE TDROMOTORS LISTED ONLY. REFER TO THE ORIGINAL EDUIPMENT MANUFACTURER OF THE EQUIPMENT USING THE TDAOMOTOR FOR ASSEMBLY NUMBERS NOT tlSTED BELOW.

,.

EXPLODED VIEW

r

3·

;

II

MA'

EXPLODED VIEW

ITEM I MA'

DESCRIPTION SERVICE PART I

8· · Thrust Washer 400136

".

DA" ThrlJSt Washer

9· ·

10&12"

13"

19+21

Thrust Bearing

Thrust Bearing

Commutator Assy.

400138

069011

Bearingl21 071017

068024

MAB018000S1

032435

15

16

17

"

22

23

14

021352

477260

MAE016000A 1

477260 477256 477256

MAE015000 MAE015000 MAB015003 MAB015003

099096 099rJ92

MAEOl6000Al

MAE207000 MAE247000 MAE347000 MAE687000

099066 099064 099079

MAE016ODOA 1 MABOl6000Al MAB016000Al

021340 021273 021273 021329

Seal Ring

EXPLODED VIEW

10·

14· '0·

'34·4-

68·

·037 ·038 ·039 ·040 ·048

I SERVICEPART I SERVICE PART I SERVICE PART I SERVICE PART I SERVICE PART I EXPLOOED VIEW

SERVICE PART SERVICE PART SERVICE PART SERVICE PART

I I I I

MAE143000 MAE203000 MAE243000 MAE343DOO MAE683DOO

477259 477259 477259 477257 477256

,

11

'"

11B'" For AI

11B' " FOf A4 Assys.

118' " For A1 Assys.

MAB012013Al MAB012014Al MAB012014Al MAB012015A 1

091466 091466 091468 091466

039027 039027 039039 039027

025126 025126 025131 025126

025113 025113 025133 025113

025132

NOTES: "Included i1 MAE500003-Standard seal kit. " Included with item /6, SMVice Housilg Assembly. ·· ·ltem 1118 nui service part number varies as shown tor TorqmolOr assembly part numbers listed that have an A1, A4 or A7 suffix.

Disassembly and Inspection Procedures PREPARATION BEFORE DISASSEMBLY Before disconnecting hoses, thoroughly clean off all outside dirt around fittings. IAfter disconnecting hoses and before removing Irom vehicle, IMMEOIATELY plug ponholes.! Orain fluid and finish cleaning and drying assembly before placing on a clean work surface. IA piece of clean paper makes an excellent disposable top.1 All disassembled pans should be cleaned separately in clean petroleum-based solvent and blown dry with air to avoid nicks and burrs. Discard all seal and seal rings as they are removed from Torqmotor. Use Ross Gear Division or OEM approved service parts.

WARNING: SINCE THEY ARE FLAMMABLE, BE EXTREMElY CAREFUL WHEN USING ANY SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULO CAUSE INJURY OR OEATH.

two retaining rings to select from.1 Apply a small amount of clean grease to the back side of new seal 111 and assemble into housing ~61 if required.

TOROMOTOR DISASSEMBLY IRelerenee Exploded Assembly Viewl 1.

WARNING: IF THE TOROMOTOR IS NOT FIRMLY HELO IN THE VISE, IT COULO BE DlSLOOGED OURING THE SERVICE PROCEOURES, CAUSING INJURY. 2.

"the end cover assembly 1231 has a shuttle valve 1281, scribe a line on housing 161 in some manner in line with the port in the end cover for reassembly orientation.

Loosen the two plugs 1251 with a 3/16 or 3/8 inch Allen wrench, for later disassembly. Remove the seven special bolts (241 using a 9/16 inch thin wall socket. Inspect bolts for damaged threads, or the sealing ring under the bolt head. Replace damaged bolts.

3.

Remove end cover assembly (23) and seal ring !7J and back up ring (7.1) if included by insening screwdriver between end cover assembly and sleeve (22), Pry up end cover assembly and lift from unit with rings attached. Oiscard seal ring and back up ring. It may be necessary to use a chisel and hammer to break the end cover loose.

4.

"the end cover 1231 has shuttle valve'1281 or reliel valve 128AI and the previously loosened plugs 1251, remove the two plugs and o·rings 1261.

WARN ING: WEAR EYE PROTECTION AN O BE SURE TO COMPLY WITH OSHA OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS . .

CAUTION: Never steam Dr high pressure wash hydraulic

components. 00 not force or abuse closely fitted parts.

REPLACEMENT OF HIGH PRESSURE SEAL 151 WITHOUT COMPLETE TOROMOTOR" DISASSEMBLY IRelerenee Exploded Assembly Viewl

1. Remove and discard dirt seal III and retaining ring 121 from Torqmotor. [Some applications may not require dirt seal 111.1

) 2.

3.

Completely lill Torqmotor with oil. Plug "A" and "8" pons and set Torqmotof in a clean pan. Place a clean rag around the coupling shaft seal area of the housing to prevent oil spray. Carefully grip coupling shaft with appropriate wrench and rotate coupling shaft rapidly in a counter-clockwise direction. Oil pressure generated by Torqmotor will eject backup washer 131, washer (4) and seal 151.

4.

)

CAUTION: Be ready to catch two springs 1271 and shuttle valve 1281 or reliel valve 12BAI that will lall out of the end cover valve cavity when the plug assemblies are removed.

Select the proper seal assembly tools for the 1V4 inch 131.8 mm) or 1Y2 inch 138.1 mm) seal diameter coupling shaft involved . See Figures 1, 2 and 3, page 2.

Insert the selected seal compression ring tool lFigure 31, with chamfered end inward, into housing (6) until it bottoms out. Assemble the selected seal thimble tool IFigure 1I over coupling shah 1111. Coat new seal 151 with clean grease and assemble over seal thimble with lip side inward. Push new seal {51 into housing 161 with the appropriate seal driver tool IFigure 21. Remove seal driver, thimble and compression tools.

Hold washer (4) between thumb and index finger and slightly collapse washer and assemble into housing (61.

Assemble back.up washer 131 tab side out, and retaining ring 121. Be sure rounded edge of retaining ring is faced inward, and that back.up washer tab is between ends of retaining ring. Be sure the new retaining ring 121 is the same thickness as the one removed. (Seal kit contains

Place Torqmotor in a vise, clamping down on the housing 161 port bosses with the coupling shaft 111) pointed down.

Thoroughly wash cover in proper solvent and blow dry.

Be sure the cover valve apertures, including the internal orifice plug, are free of contamination. Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces. Replace cover as necessary.

NOTE: O·ring 1261 is not included in seal kits but is serviced separately if required.

5.

Remove commutator ring (21), commutator 11 9), seal ring 1201, and manilold 1181by using two 01 the special bolts (24) as a lifting tool-insert the two special bolts into two holes and lift out the previously mentioned pans.

6.

Remove seal ring (201 from commutator 1191. using an air hose to blow air into ring groove until seal ring is lifted out and discard seal ring. Inspect commutator and commutator ring 1211 for cracks or burrs. Inspect commutator for wear, scoring, spalling or brinelling. If

6

any of these conditions exist, replace commutator and commutator ring as a matched sel.

15.

Remove housing (6)lrom vise, turn over and reclamp in vise with dirt seal !1l end pointed up.

7.

Remove manifold plate (17) by again using two special bolts 1241 as a lifting tool. Inspect manifold 1181 and manifold plate (17) for cracks, surface scoring, brinelling or spalling. Replace manifold or manifold plate that exhibits any of these conditions. A polished pattern on the ground surfaces from commutator or rotor rotation is normal.

16.

Remove dirt seal Ill, retaining ring 121, back-up washer 131, washer (4), and seal 151 from housing 161. Discard seals and washers but keep retaining ring 121 for comparison when selecting new retaining ring from seal kit. If burr exists on retaining ring groove, remove with a scraping tool.

8.

Remove rotor set 1161 and wear plate 1151. by again using the two bolts as a lifting tool. Retain rotor set in its assembled form, if possible, to maintain the same rotor vane to stator contact surfaces. Inspect the rotor set in its assembled form for nicks, scoring, or spalling, on any surface and broken or worn rotor splines. If any rotor set component requires replacement, the complete rotor set must be replaced as it is a matched sel.

Inspect the wear plate for cracks, brineliing, or scoring.

17.

Inspect housing (6) assembly lor cracks, the machined surfaces for nicks, burrs, brinelling or corrosion. Remove burrs that can be removed without changing dimensional characteristics. Inspect tapped holes for thread damage.

If the housing is defective in these areas, discard the housing assembly and the disassembly of the Torqmotor is complete.

1B.

If the housing assembly (5) has passed inspection to this point, inspect the bearings 191. 1101, 1121 and thrust washers !Bl and IBAI. The bearing rollers must be firmly retained in the bearing cages, but must rotate and orbit freely. All rollers and the thrust washers must be free of brinelling and corrosion. If the housing has passed this inspection the disassembly of the TorQmotor is completed.

9.

10.

Place rotor set on a flat surface and center rotor 115A) in stator (1 6C) such that two rotor lobes !1 BO 0 apart) and a roller vane 116B) centerline are on the same stator centerline. Check the rotor lobe to roller vane clearance with a feeler gage at this common centerline.

If there is more than .005 inches m.13 mmJ of clearance, replace rotor set.

Remove drive link (141 from coupling shaft 1111 if it was not removed with rotor set and wear plate. Inspect drivelink for cracks and for worn or damaged splines. No perceptible lash Iplayl should be noted between mating spline pans.

11.

Remove thrust bearing (131 and inspect for wear, brinelling, corrosion, and a full complement of retained rollers.

12.

Remove coupling shaft (111 by pushing on the output end of shaft. Inspect coupling shaft bearing and seal surfaces for spalling, nicks, grooves, sevSre wear or corrosion and discoloration. Inspect for damaged or wern internal and external splines or keyway. Replace coupling shaft if any of these conditions exist.

NOTE: Minor shaft wear in seal area is permissible.

If wear exceeds .020 inches (0.51 mm) diametrically, replace coupling shaft.

A slight "polish" is permissible in the shaft bearing area.

Anything more would require coupling shaft replacement.

13.

7

20.

If bearing 1101 requires replacement, use a 1.488 inch 137.BOmm} maximum diameter shaft or a 1.745 inch \44.32 mm) maximum diameter shaft based on the internal seal 15) bore diameter and press out thrust washers IBI. IBAI. thrust bearing 191. and bearings 1101 and 1121. The housing wearplate face should be placed on a block of wood during the pressing operation to protect it. Discard thrust washers IBI and IBAI, thrust bearings 191. and bearings 1101 and 1121 and replace with new pans, as parts will have been damaged when being pressed out.

)

NOTE: The depth or location of bearings 11 OJ and (12) in relation to the housing wearplate face should be measured and noted before pressing the bearing s out. This will facilitate the correct reassembly of new bearings.

The disassembly of Torqmotor is completed.

Remove sleeve 122) by inserting screwdriver between sleeve and housing 151 and pry up. Inspect sleeve for deformation from the original cylindrical shape to a "barrel" or "hour glass" shape. Inspect sleeve ends for severe nicks, burrs or corrosion. Replace sleeve if any 01 these conditions exist.

NOTE: Minor burrs and corrision that would damage new seal rings during assembly can be removed from sleeve ends.

14.

19. If only the outer bearing 1121 requires replacement, carefully use a suitable bearing puller to remove bearing so the housing is not damaged.

Remove seal ring l7! and back up ring 17.11 if included from housing (6) and discard seal and back up ring.

)

TOROMOTOR ASSEMBLY PROCEOURES (Reference Exploded Assembly View) Replace all seals and seal rings with new ones each time you reassemble the Torqmotor unit. Lubricate all seals and seal rings with SAE 10W40 oil or clean grease before assembly.

NOTE: Individual seals and seal rings as well as a complete seal kit are available. The parts should be

available through most OEM parts distributors or Ross approved Torqmotor distributors. (Contact your local dealer for availability.)

TOROMOTOR ASSEMBLY If the sealing diameter of the coupling shaft 1111 is larger than any. other diameter on the output end of th~ coupling shaft, begin the TOfQmOlor assembly procedures with Slep 1 below.

If there is a diameter on the output end of the coupling shaft equal to the sealing diameter of the coupling shaft begin the procedures with Step 6 below.

1.

Place housing 161 in a vise and clamp down on housing port bosses with small bore end, pointed up. Apply clean grease to new seal (5) and assemble into housing with seal lip poimed inward.

parts before assembly.

2.

Wash all parts in clean petroleum-based solvents before assembly. Blow them dry with compressed air. Remove any paint chips from mating surfaces at the end cover, sleeve, and housing and from port and sealing areas.

Hold washer (4) between thumb and index finger and slightly collapse to facilitate assembly into housing 161.

3.

Assemble back·up washer 131 into housing !61 with the anti·rotation tab facing out.

4.

Select a new retaining ring (2) from the seal kit, that is the same thickness as the retaining ring removed.

Assemble the new retaining ring into housing 161. Be sure rounded edge of retaining ring is faced inward and that back-up washer tab is between ends of retaining ring.

5.

Apply a small amount of clean grease to back side of new seal 11 J and assemble into housing 161, if a seal 11) is required.

6.

Invert housing 16) in vise so that the large bore end is up.

7.

Apply cellophane tape around splines or keyway on coupling shah (11 ) to prevent damaging seals.

NOTE: Unless otherwise indicated, do not oil or grease

HOUSING BEARING REPLACEMENT PROCEDURES 1.

If bearing components were removed for replacement, assemble new thrust washer 181, new thrust bearing (9) and new thrust washer (8A! in that order into housing (61 bearing cavity. If thrust washer tEAl has a chamfer on the inside diameter, the chamfered side must face away from thrust bearing (91.

NOTE: Thrust washer IBA) will be identical to thrust washer (8) unless a chamfered inside diameter is required because of coupling shaft design.

)

NOTE: An appropriate size piloted bearing mandrel is required to press in housing bearings.

2.

If bearings 1101 and 1121 required are for a 2.25 inch 157.2 mml diameter InominaU housing bearing bore, press in new bearing (101 which is 1.0 inch 125.4 mml long, into housing (6) bearing bore to a depth of 2.410 ± .010 inch 161.2 ± 0.254 mml, measured from the . housing wear plate contact surface. Then, press in new bearing 1121 which is .5 inch 112.7 mml long into housing bearing bore to a depth of .115 ± .010 inch 12.92 ± 0.254 mm) measured from the housing wear plate contact surface.

NOTE: Press against the lettered end of bearing cage when pressing in a roller bearing assembly.

3.

)

If the bearings 11 01 and 1121 required are for a 2.50 inch 163.5 mm) diameter Inominall bearing bore, press in new bearing (10) which is 1.0 inch (25.4 mmJ long into housing 161 bearing bore to a depth of 2.379 ± .0lD inch 160.43 ± 0.254 mm) measured from housing wear plate contact surface. Press new bearing 1121 which is identical to bearing 11 0) into housing bearing bore to a depth of .115 ± .0lD inch 12.92 ± 0.254 mml measured from the housing wear plate contact surface.

NOTE: The bearings 1101 and 1121 must be assembled to the correct depths to assure the necessary clearance for thrust washer (SA) and thrust bearing (131 and to assure required bearing support.

S. 'l lubricate and assemble coupling shah Ill), firmly seating it against thrust washer (SAL 9.

Assemble thrust bearing 11 3) onto end of coupling shaft

1111.

10.

Assemble dr.e link 1141 into coupling shaft 1111 with their splines in mesh. IAlign hole in drive link with hole in coupling shaft 1111. if applicable.!

NOTE: Two alignment studs screwed finger tight into housing 161 bolt holes, approximately 1BO 0 apart, will facilitate the assembly and alignment of components as required in the following procedures. The studs can be made by cutting off Ihe heads of 31B·24 UNF 2A bolts that are over .5 inch 112.7 mmllonger than the bolts 1241 used in the Torqmotor. . .,. ". . '''''.-. ..

'.,

.' ,.

"

~,

.

.,1'

11 . . Assemble. wear plate 11 51 over dr.e link 1141 ',nd studs onto housing 161. . '::':; ..

12.

13.

Install assembled rotor set 1161 wittJ counterbore in rotor 116A) down, if applicable, and splines in mesh with drive link splines.

NOTE: If necessary, go to " Rotor, Stator, Vane Assembly" procedures on page 9.

Assemble manifold plate 1171. manifold I1BI and then the commutator ring 121) over the drive link 1141 onto rotor set (16) per the exploded assembly view. Be sure swirls in manifold and manifold plate are faced together.

B

14.

Assemble a new seal ring 1201, flat side up, into commutator 1191 and assemble commutator over end of drive link 1141 onto manifold 1181with seal side up.

15.

Assembly new back up ring (7.11 if required and new seal ring (71 on housing (61, apply a generous amount of SAE 10W40 to both ends of sleeve 1221 and assemble onto housing. Make sure sleeve is sitting in a non· cocked position.

16.

Turn a plug 1251with a new O-ring 1261 loosely onto each end of cover 1231 valve cavity if shuttle valve 12S1 is required.

17.

Then insert a spring 1271, the valve (28) and another spring (27) into the other end of the valve cavity. Turn another plug 1251 with new O-ring 1261 loosely into cover valve cavity.

21.

If seal 151. washer 141. back-up washer 131, snap ring 121 and seal (1) have not yet been assembled, invert housing in vise so the coupling shaft 111) is pointing up and follow procedures #3 and #4 under "Replacement of High Pressure Seal" on page 6 to assemble these components.

)

The assembly of Torqmotor is now complete except for woodruff key I11AI, nut I11BI. washer 111el, bolt 11101, lock washer l1lE) or retaining ring (11F) if applicable at Torqmotor installation. See final checks. All ports should be plugged until Torqmolor is installed in system.

ROTOR, STATOR. VANE ASSEMBLY PROCEOURE

If relief valve 128A) components were removed from the end cover, assemble new O·ring 1261 onto the relief valve plugs 125l. Assemble the two piece relief valve 128A1 with large end of conical spring into the plug first and the small nut of the other valve piece in the small end of the conical spring. Turn these plug and relief valve assemblies into the end cover loosely to be torqued laler.

18.

Assemble a new back up ring (] .1 1if required and a new seal ring monto end cover and assemble end cover onto sleeve 1221in a non-cocked position.

A disassembled rotor 116AI. stator 116CI and vanes 116BI that cannot be readily assembled by hand can be assembled by the following procedures.

1.

Place stator 11 6C ) onto wear plate 11 5) after following Torqmotor assembly procedures 1 through 11.

2.

If assembly alignment studs are not being utilized, align stator bolt holes with wear plate bolt holes and turn twO bolts 1241 finger tight into bolt holes 180 0 apart to retain stator and wear plate stationary.

3.

Assemble six vanes 11661 into the stator vane pockets.

4.

Assemble rotor 116A1, counterbore down, if applicable, into stator 116CI and onto wear plate 115) with rotor splines in mesh with drive link splines.

5.

Grasp the output end of coupling shaft Ill) with locking pliers or other appropriate turning devices and rotate coupling shah, drive link and rotor to seat the rotor and assembled vanes into stator, creating necessary clearance to assemble seventh vane. Assemble the seven vanes using minimum force .

NOTE: If the end cover has a valve (281 or 128A1 use the line you previously scribed on the housing (6) to radially align the end cover port into its original position.

19.

Assemble seven special bolts 1241 and screw in finger tight. Removal of the two alignment studs should be made after at least two bolts have been assembled.

Alternately and progressively tighten the bolts to pull end cover assembly 123) and sleeve 1221 into place with a final torque of 50 ± 5 ItJbs. 168 ± 8 N mJ. Tightening sequence:

0

6.

)

Remove the two assembled bolts if used to retain stator and wear plate.

,' 3

4

5

7

NOTE: The special bolt (241 required for use with the shuttle valve 1281 end cover assembly (231 is longer than the bolt required with the standard end cover assembly. Refer to the individual service parts list for correct service part number.

20.

Torque the two shuttle plug valve assemblies 1251 into a end cover assemble to 12-19 hJbs. 116-26 N mi. Torque the relief valve plug assemblies 125) into an end cover assembly to 45-55 It.lbs_ 161-75 N mJ.

)

9

Final Checks

Final Chacks •

Pressurize the Torqmotor'1ot with 100 p.s.i. {6.S BAAl dry nitrogen and submerge in solvent to check for external leaks.

•

Check Torqmotor ll for rotation. Torque required 10 rotate coupling shaft should not be more than 50 ft.lbs. 168 N ml

•

Pressure port with "A" cast under it on housing 161 is for counter-clockwise coupling shaft rotation as viewed from the Output end of coupling shalt. Pressure port with "B" cast under it is for clockwise coupling shaft rotation.

•

Use test stand if available, to check operation of the Torqrnotor'IoI ,

Hydraulic Fluid.

Keep the hydraulic system filled with one of the following:

)

•

10W40 SE or SF manufacturers suggested oil.

•

Hydraulic fluid as recommended by equipment manufacturer, but the viscosity should not drop below 50 SSU or contain Jess than .t 25% zinc anti-wear additives.

CAUTION: 00 not mix oil types. Any mixture, or em unapproved oil, could deteriorate the seals. Maintain the proper fluid level in the reservoir. When changing fluid, completely drain old oil from the system. It is suggested also that you flush the system with clean oil.

Filtration Recommended filtration 20-50 micron.

Oil Temperature Maximum operating temperature 200'f (93.3OCI.

) 10

Tips for Maintaining the Torqmotor" Hydraulic System

•

Adjust fluid level in reservoir as necessary.

•

Encourage all operators to report any malfunction or accident that may have damaged the hydraulic system or component:

•

00 not attempt to weld any broken Torqrnotoril component. Replace the component

with original equipment only.

• •

Do not cold straighten, hot straighten, or bend any Torqmotor'M part.

Prevent dirt or other foreign matter from entering the hydraulic system. Clean the area around and the filler caps before checking oil level.

•

Investigate and correct any external leak in the hydraulic system, no matter how minor the leak.

•

Comply with manufacturer's specifications for cleaning or replacing the filter.

CAUTION: 00 not weld, braze, solder or any way alter any TorqmotorTlo! component.

CAUTION: Maximum operating pressure must not exceed recommended Torqmotor™ pressure capacity.

CAUTION: Always carefully inspect any system component that may have been struck or damaged during operation or in an accident. Replace any component that is damaged or that is questionable.

)

CAUTION: Do not force any coupling onto the Torqmotor'M coupling shaft as this could damage the unit internally.

Ross Gear extends close technical cooperation and assistance. If problems occur which you cannot solve, please contact our Ross Service Department or local Ross approved Distributor.

Our phone number and telex number and address are on the back cover of this manual.

)

11

Disclaimer This Service Manual has been prepared by TAW Ross Gear Division for reference and use by mechanics who have been trained to repair and service hydraulic mOtors and systems on commercial and non·commercial equipment applications. TAW Ross Gear Division has exercised reasonable care and diligence to present accurate, clear and complete information and instructions regarding the techniques and tools required for maintaining, repairing and servicing the complete line of TAW Ross Gear MAB & MAE Torqmotor Units. However, despite the care and effort taken in preparing this general Service Manual, TRW makes no warranties that lal the Service Manual or any explanations, illustrations, information, techniques or IDols described herein are either accurate, complete or correct as applied to a specific Torqmotor unit, or fbi any repairs or service of a particular Torqmotor unit will result in a properly functioning Torqmotor unit.

")

If inspection or testing reveals evidence of abnormal wear or damage to the Torqmotor unit or if you encounter circumstances not covered in the Manual, STOP - CONSULT THE EQUIPMENT MANUFACTURER'S SERVICE MANUAL ANO WARRANTY. 00 NOT TRY TO REPAIR OR SERVICE A TOROMOTOR UNIT WHICH HAS BEEN OAMAGED OR INCLUOES ANY PART THAT SHOWS EXCESSIVE WEAR UNLESS THE OAMAGEO ANO WORN PARTS ARE REPLACEO WITH ORIGINAL TRW REPLACEMENT ANO SERVICE PARTS ANO THE UNIT IS RESTOREO TO TRW'S SPECIFICATIONS FOR THE TOROMOTOR UNIT. It is the responsibility of the mechanic performing the maintenance, repairs or service on a particular Torqmotor unit to lal inspect the unit for abnormal wear and damage, fbi choose a repair procedure which will not endanger his/her safety, the safety of others, the equipment, or the safe operation of the TOfqmOlor, and Icl fully inspect and test the Torqmotor unit and the hydraulic system to insure that the repair or service of the Torqmotor unit has been properly performed and that the TOfqmotor and hydraulic system will function properly.

)

MAB and MAE Series Service Procedure

)

Write or call for information and added details concerning your installation and applications:

Phone: Telex:

317.413.5371 179413

Write:

TRW Ross Gear Division

800 Heath Street lalayette, Indiana 47901

)

I

")

Torqmoto(M MG, MF, MB, ME Series Service Procedure

)

)

TRW Ross Gear Division PRICE: $3.00

Torqrnotor'· Design Features

Torqmotor!1I MG Series features include: - The roller vane rotor set design offers a low-friction, wear compensation which maximiles the useful performance life of the motor.

COUPLING SHAFT

-Zero leak commutation valve provides

greater, more consistent volumetric

... HIGH PRESSURE SEAL ,--- NIEEOI_E THRUST BEARING

,.OIUVE lINK12-TOOTH SPLINES

efficiency.

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

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

- Full flow lubrication maximizes cooling and may provide up to 50% longer life than motors nOI having this feature.

- Higher pressure ratings provide greater

torque than competitive brands.

DIRT & WATER SEAL

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

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

- A unique high-pressure shaft seal that elimina tes the need for case drains.

- Up to 13 horse power output.

MATCHEO ROTOR SET MATCHED COMMUTATOR SET

COUPLING SHAFT HIGH PRESSURE SEAL NEEDLE THRUST BEARING

DRIVE lINK12-TOOTH SPLINES

Torqmotor1M MF Series features include: - RoUer vanes to reduce friction and internal leakage and to maintain efficiency.

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

- Wheel mount 'Jersion available.

- More starting torque than competitive motors in applications where the shah is side loaded. ICompetitive brands require more pressure to start the motoLl - A needle·roller mounted coupling shah and steel-caged thrust bearing which can withstand 1000-pound thrust loads.

)

- Side load capacity is 1600 Ibs 1727.3 kgl

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

maximum at center of ou tput shaft.

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

- Up to 17 horsepower output.

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

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

)

I

Torqmotor" Design Features

TorqmotorlM MB Series features include: - Heavy-duty thrust and roller bearings for up [Q twice Side-load capacity to the previous mOior.

• Roller vanes to reduce friction and

\""COUF'L1 NG SHAFT

imernalleakage, and to maintain

... HIGH PRESSURE SEAL "N'EEDLE THRUST BEARING

efficiency.

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

- A patented 60:40 arrangement of

DRIVE L1NK12-TOOTH SPLINES

internal and ex.ternal spline members 10 transmit more IOfQue with less weight. · A unique high-pressure shalt seal that eliminates the need for case drains, check valves and extra plumbing .

• A unique manifold designed to improve

operating efficiency. · Up 10 1000 Ib, 1453.6 kgl end-thrust capacity in Bither direction.

DIRT & WATER SEAL NEEDLE RADIAL BEARING

)

MATCHED ROTOR SET MATCHED COMMUTATOR SET

COUPLING SHAFT

HIGH PRESSURE SEAL THRUST BEARING L1NK14-TOOTH SPLINES

DIRT & WATER SEAL NEEDLE RADIAL BEARING

)

MATCHED ROTOR SET MATCHED COMMUTATOR SET

- A deSign that is less sensitive 10 contamination than competitive mOlors.

- Up to 36 horsepower output.

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

- Superior low speed performance.

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

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

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

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

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

- A manifold designed to improve operating efficiency.

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

·Up 10 1000 Ib, 1453.6 kgl end-thrust capacity in. either direction.

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

- Up to 49 horsepower output.

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

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

Definitions NOTE:

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

to complete.

CAUTION:

A CAUTION refers to procedure that must be followed to avoid damaging th e Torqmotor™ or other system components .

- .~ :

• , ~: , . ~ ,,~:= :: ::'3 ~ = ::~OS ~: 'J.1E::: . -: "A UST 3E FOLL;: .~: ruR _. "T :" ",( T L!~ :n l_IH) M~ i'r: r:=, ;OR J:..'JO r~E F:RSON

I~:: ':- - "

' . ' .. : ' ~ :iQMOTO iFI

Disclaimer This Service Manual has been prepared by TAW Ross Gear Division for reference and use by mechanics who have been trained to repair and service hydraulic motors and systems on commercia! and non-commercial equipment applications. TAW Ross Gear Division has exercised reasonable care and diligence to present accurate, clear and complete information and instructions regarding the techniques and tools required for maintaining, repairing and servicing the complete line of TRW Ross Gear MG, MF, MB & ME TorqmolOr Units. However, despite the care and effort taken in preparing this general Service Manual, TRW makes no warranties that lal the Service Manual or any explanations, illustrations, information, techniques or 100is described herein are either accurate, complete or correct as applied 10 a specific TorqmolOr unit, or Ibl any repairs or service of a particular TorqmolOr unit will result in a properly functioning TorqmOlOr unit.

)

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

Patents Ross Gear Division products and systems described in this manual are protected by one or more of the following United States patents: 3,606,601. In addition, foreign patents have been issued in Canada, the United Kingdom , and West Germany.

2

TRW 1988

)

Table of Contents

Page

Design Features . .. . .. . . . .. .. ..... . .. . . . ........ . . . . . .. .

. .. . Inside front Cover

........ 2

Definitions .......... . .... .. . .

Introduction ... .

4

Troubleshooting Guide ..................... .

5

Troubleshooting Check list .

6 Tools and Material Required for Servicing . .......... . .. .

7 Bolt Torque . ................. . ...... . .............. 7 Exploded Assembly View Fold Out . ................ . ....................... . 7A & 7B

)

MG Service Parts list Chart . . . ....... .. ... . ... .

B MF Service Parts list Chart. .. . . .............. .. . . ....................... . .. 9 MB Service Parts list Chart . . . . ............. 10 ME Service Pans list Chart ... . .... . .... . ... . ...... . . . . . ..... . .... . . . .......... 11 Oissassembly & Inspection .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .............. 12

Assembly .......... . .. ....... .... . ...................... . ......... .. ..

Rotor Set Component Assembly Procedure !One Piece Statorl . ....

ADlor Set Component Assembly Procedure ITwo Piece Statorl ..... . ..... .

Final Checks . . ........ . . ... ..... .

. .20

. ..... 30 . ...... 31

. ....... ..... . .. . ... . . . .. . ....... 33

Hydraulic Fluids . ...

. .33

Filtration, Operating Temperature . ........ . . . .............. . . . . ... . . . ... . . . ..... .33 Tips for Maintaining the System.

MG Application Data ...... . . .. .

Mf Application Data . . .

MB Application Data . .. . ....... .

ME Application Data . .

. . . .•. . ........•... . .... 34 ....... . ..

.

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

•

• . .. 37 . .... 3B

) 3

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

Material in this manual is organized so you can work on the Torqmotor and get results without wasting time or being confused. To get these results, you should read this entire manual before you begin any work on the TorqmolOr. This manual also contains troubleshooting information and checklist. If you must service the TOfqmOlor, the checklist will help you to determine where the problem may be.

The three-column format of the Disassembly and Inspection, and Assembly sections will make il easier for you to conduct major work on the TorqmolOr. Column 1 gives a brief key lor each procedure. Column 2 explains in detail the procedure you should follow. Column 3 illustrates this procedure with photographs. Read all material carefully and pay special attention to the nOles, cautions, and warnings.

A foldout page with the same Torqmotor exploded assembly view on both sides is provided in this manual. The component part names and item numbers assigned on this exploded assembly view correspond with names and item numbers lin parentheses) used in the disassembly and assembly procedures set forth in this manual. When this exploded assembly view page is folded out, you can easily identify components and locate their relative position on the exploded assembly view as you lollow the disassembly and assembly procedures.

)

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

Service pans are available through the Original Equipment Manufacturer {lr Ross approved MG, MF, MB & ME Distributors.

As you gain experience in servicing the TorqmOlor, you may find that some information in this manual could be clearer or more complete. If so, let us know about it. Do nOl try to second guess the manual. If you are stuck, contact us. Servicing the TorqmOlor should be a safe and productive procedure, in order for the unit 10 deliver the reliable, long-lile operation engineered into it.

)

4

Troubleshooting Guide NOTE: Before troubleshooting any system problem, check service literature )

published by the equi pment and/or component manufacturers. Follow their instructions, if gillen, for checking any component other than the Torqmotor1M unit.

Preparation Make your troubleshooting easier by preparing as follows:

Hydraulic Components

• work in a clean, well-lighted place;

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

• have proper tools and materials nearby;

• have an adequate supply of clean petroleum-based solvenl.

AR ~JlN G : Si NCE SOLVENTS ARE FLAMMABLE. " ,::TREivIEl Y CA REF UL WHEN USING ANY SOLVEm, ,'IEN A : '.iALL ,:,PLOSION OR FIRE COULD CAUSE ji,IJURY CR ' [ATH.

'!AR NING: '.'IEAR EYE PROTECTiON AND SE SURE 'T o J:,my '!ilTH OSHA AND OTHER MA XIMUM AiR "QtSSURE :::EQUlREMHlTS.

Next, go to the reservoir and filter or filters. Check fluid level and look for air bubbles_Check the filterlsl. A filter with a maximum 50 micron filtration is recommended for the TOTqmotor system.

Preliminary Checks

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

Hydraulic systems arl! often trouble-free. Hence, the problem an operator complains of could be caused by something other than the hydraulic components.

)

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

Thus, once you have determined that a problem exists, stan with the easy-ta.check items, such as: • parts damaged from impact that were nOi properly repaired, or that should have been replaced; and • improper replacement parts used in previous servicing • mechanical linkage problems such as binding, broken, or loose parts or slipping belts.

Excessive heat in a hydraulic system can create problems that can easily be overlooked. Every system has its limitation for the maximum amount of temperature. After the temperature is attained and passed, the following can occur: • oil seal leaks • loss of efficiency such as speed and torque • pump loss of efficiency • pump failure • hoses become hard and brinle • hose failure A normal temperature range means an efficiem hydraulic system.

Consult the manuals published by equipment and/or componem manufacturers for maximum allowable temperatures and hydraulic tests that may be necessary to run on the performance of the hydraulic components. The Torqmotor!1oI is not recommended for hydraulic systems wi th maximum temperatures

above 200"F 193.3"[1.

) 5

Troubleshooting Checklist Trouble

Cause

Oil Leakage

1.

Hose fittings loose, worn or damaged

2.

Oil seal rings 141 deteriorated by

Replace oil seal rings ·by disassembling

excess heat

TorqmotorlU unit.

3.

Special bolt 11, lA, lB or lei loose or its sealing area deteriorated by corrOSlOn

4.

5.

Significant loss of speed under load

1.

Internal shalt seal (16) worn or damaged

Worn coupling shaft 112) and internal seal 1161 Lack of sufficient oil supply

Remedy Check & replace damaged fittings or "0" Rings. Torque 10 manufacturers specifications.

)

(al Loosen then tighten single bolt 10 torque specification.

Ibl Replace bolt.

Replace seal. Disassembly of

TorqmotorU unit necessary.

Replace coupling shaft and seal by

disassembling Torqrnolor lol unit. lal Check for faulty relief valve and adiust or replace as required. (bl Check for and repair worn pump. lei Check for and use correct oil for temperature of operation.

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

2.

High internal motor leakage

3.

Severely worn or damaged internal splines

Replace rotor set, drive link and coupling shaft by disassembling Tofqmotorl,l unit.

4.

Excessive heat

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

1.

line blockage

Locate blockage source and repair or replace.

2.

Internal interference

Disassemble TorqmotorTI,I unit, identify and remedy cause and repair, replacing parts as necessary.

3.

Lack of pumping pressure

Check for and repair worn pump.

4.

Excessive binding or loading in system external to TorqmotorM unit.

Locate source and eliminate cause.

(al Replace worn rotor set by disassembling Torqmotorl,l unit.

)

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

) 6

Tools and Materials Required for Servicing MG, MF. MS, ME Series Service Manual Clean, petroleum-based solvent

")

Emery paper

Vise with soft jaws Air pressure source Arbor press Screw driver Masking tape Breaker bar

Torque wrench-ft. Ibs. IN ml Sockets: 112 or 9116 inch thin wall, 1 inch

Allen Socket': 3/16, 3/6 inch Adjustable crescent wrench or hose fitting wrenches

SAE 10W40 SE or SF oil Special bearing mandrel for MG & MF TorqmatoTs

ISEE FIGURE 11

INCHES .020 .021 .029 .030 .111 .119 .152 .160 .296 .304 .460 .470 .500 .565 .595 .660 .675 1.058

CO NVERSIONS mm INCHES .51 1.060 .53 1.295 .74 1.297 .76 1.396 2.81 1.398 3.02 1.620 1.622 3.86 1.983 4.06 7.52 1.965 7.72 2. 120 2.122 11.68 11.94 2.233 12.70 2.235 14.86 2.483 15.11 2.485 16.76 2.500 17.15 2.88 26.87

mm 26.92 32.89 32.94 35.46 35.51 41 .15 41.20 50.37 50.42 53.85 53.90 56.72 56.77 63.07 63.12 63.5 73.2

Special bearing mandrel for MB & ME Torqmolors

ISEE fiGURE 21 feeler gage .005 inch 1.13 mml

)

MG & MF Torqmotors require blind hole bearing puller for 1.06

inch 126.9 mml and 1.62 inch 141.1 mml diameter bearinglbushing.

MB & ME Torqmolors require blind hole bearing puller for 1.40

inch dia. 135.6 mml and 2.130 inch dia. 154.1 mml bearing.

Clean corrosion resistant grease. Recommended grease is ElM

Lubricant IK·70M, Ross Gear Specilication 1045236 NOTE: The available service seal kits include the recommended grease as a grease pack 8406018

IFabricate if considered necessaryl

FIGURE 1- MG & MF

CAUTION: Mixing greases that have different bases can be detrimental to bearing life.

Torque Chart Part Name

)

Item Number

bolt 5/16 24 UNF 2A 1, lA, lB bolt 3/8 24 UNF 2A 1, lA, 18 bolt 5/8 18 UNF 2A 120 nut 3/4 16 UNF 28 128 IMG, nut 1 20 UNEf 2B 12B 1MB, nut 1·1/8 18 UNEF 2B 12B IMEI

Torque

or lC 22·26 It. Ib,. 130·35 N ml or lC 45·55 It. Ib,. 160·76 N ml 140·180 It. lb,. 1190·244 N ml MFI 175·255 It. Ib,. 1237·305 N ml MEl 300-400 It. Ib,. 1407·542 N ml 300-400 It. Ib,. 1407·542 N ml

IFabricate if considered necessary I

FIGURE 2- M8 & ME 7

Torqmotor™ Exploded Assembly View- Typical )

10

-", ,

(.,

)

~.'

/ :A.. 'OTE Au.mllle s,.l FiliI Side OUI II SbowII in EnlIrgtd View ol Sectiolltd Se,_ntl of I"ml Nllmber!i.nd 3

Itam No. Description 1.

Special BoUs (5 or 7) I A. Special Bolts (7) 18.

Special Boils 17)

11 .

12.

12A.

1C. 2.

Special Bolts m End Cover

3.

4.

Seal Ring-Commutalor Seal Ring (5)

12C.

5.

6.

Commutator Commutator Ring

120.

12E.

1.

Manifold

12F.

8.

Rotor Set

13.

8A.

Rotor

14.

8B.

Stator or Stator Half

15

Be.

Vane 171

80.

BE.

Stator Hall Vane 171

16.

17 .

12B.

9.

Wear Plate

18 18A.

10.

Drive l ink

19.

Thrust Bearing Coupling Shaft

20.

Key

22.

23.

N" Washer Bolt lockwasher Retaining Ring

21.

24.

25.

Dirt & Water Seal Plug (2) a·Ring 121 Spring Valve (Shuttle or Relief)

Backup Washer

Bearing/Bushing, Inner Thrust Washer Thrust Bearing Seal Backup Washer Housing

a·Ring 121 Bearing/Bushing. Outer

)

Aher.... COII$lructiO. Relief Vi .... bel COfer

7A

Torqmotor™ Exploded Assembly View- Typical (Identical to page 7Al

--"

•

.., rJ 'I

MATCH(O SET

(~3/ 7,,~

/-

10

~.

)

~ ~f. '

/

88

/ 8C/

SA

Aiterllllle ConS lructlon ME ROIOr Set

{'l.J"-,:'

"'AltHEa S£T

-

'l" ~r~j ~

1

,{~1

~,<1A

/

6

23/ ~ 14/ 1 22 21

/~ __~.: .. "

,..

3/.-....."

~I

8E

11

/ 80

s.... e..._

Ala ..... Se.l F'-t $IH 0.1 IS In of $«UonetI .u of ttala N....... 6 ,l1li3

s.,...

Ah'fute COlurllCtioft Situ"" EIIII

v.1n

eo",

18AI'-<>

'}:i;:, / 1

~' _ ODS

Itam No. DascriptiOfl Special Bolts (5 or 7) 1. lA. Special Bolts OJ

lB. lC. 1.

3.

4.

5.

6.

11 .

11.

11'.

Seal Ring-Commutalor

128.

Seal Ring (5)

12C. 120.

12E. 12F. 13.

14.

15 16.

Commutator Commutator Ring Manifold

8.

Rotor Set

9.

10.

79

End Cover

7.

8A. 8B. 8C. 80.

8E.

)

m

Special 80lts Special Bolts 17)

Rotor Stator or Stator Half Vane 171 Stator Half Vane 17) Wear Plate Drive link

17.

18 18A. 19.

Thrust Bearing Coupling Shaft Key Nut Washer Bolt Locitwasher

Retaining Ring Bearing/Bushing, Inner Thrust Washer Thrust Bearing Seal Backup Washer Housing O-Ring 121 Bearing/Bushing. Outer

10.

11.

11.

13.

14.

25.

Dirt & Water Seal Plug 121 O-Ring (2) Spring Valve (Shuttle or Reliel) Backup Washer

~~ O'~

18

All..... C_tnIetioII I,...,oId Por1

.,"~.~~\/1 t II

8~~~

/

~ij '< (1'21::::8 A.It ..... te C_tl1letloll R..... bel eo-

y...,.

'C

MG Service Parts list Chart CHART USE EXAMPLE: MG020SD 1AAAB TORQMOTORIMINCtuDES PART NUMBERS LISTED TO THE RIGHT OF MGISER1ESI. D2(OISP.I. 06IHDUSINGI, OHSHAFTI,

AND AAAB (OPTIONI SHOWN IN lEFT HAND COLUMN OF CHART. CAUTION: THE CHARTED COMPONENT SERVICE INFORMATION IS FOR THE TOROMDTORS LISTED ONLY. REFER TO THE ORIGINAL EQUIPMENT MANUfACTURER OF THE EQUIPMENT USING THE TOROMOTOR FOR ASSEMBLY NUMBERS NOT LISTED BELOW.

EXPlODED VIEW ITEM , DESCRI PTION Service Pan I

~ ~

ffi

~

MG-

5 &6 COMMUTATOR

7

& RING ASSY

MANIFOLD MF015000

Mf01BOOO·Al

WEAR

'13 BRONZE

14 THRUST

PLATE

BUSHING

WASHER

471341

069511

028483

9

15

17

'19

20

THRUST

BACKUP

" DU"

BEARING 065066

WASHER

BEARING 065505

OIRT & WATER SEAL

028516

)

418036

EXPLODED VIEW

ITEM'

01· OJ·

c~

ffi

~

z

$i U

:3 ~

5

04· 05· 06· 08· 111· 11· 14· 16· 18· 20 .

8

DESCRIPTION

BOLT (5)

Service Pan I Servic1! Pan 1 Service Pall I Service Pall I Service Pan I Service Pan I Service Pan I SeNiee Pan I Sem Pari 1 Serw:e Pari I Service Part I Service Part I

021311 021311 021306 021382 021357 021307 1121358 021308 02135S 021310 021383 021384

EXPLODED VIEW ITEM# DESCRIPTION Service Part I Service Pari I Service Pari I Service Part I Service Part I SBIVi:e Part I

06· ~ c 09· ffi 10· ~ 1\. c;;; J2. g lJ. %

EXPLODED VIEW ITEM' DESCRIPTION Service Part I Service Part t Service Part t Service Part I Servn Pan 1 Service Part I Service Pan I Service Part I

~ ~

01· OS· ~ 10· ~ 11 · ;,g 12· ~ 13· ~ 14· g 15u

EXPLODED VIEW ITEM ' ~

c

~

~

AM.

~ MAC

:;:AAAH c

DESCRIPTION Service Part I Servn Pall I Service Part I

10 DRIVE

SET MF027003 MF037003 MF047003 MF057003 MF067D03 MF087003 MF107003 MF127003 MF1 47003 MFI67003 MF187003 MF207003

LINK MF023000 MF033000 MF04300D MF053000 MF063000 MF083000 MFI03000 MF123000 MF143000 MFI63000 MF183000 MF21l3000

'"

alBA

HOUSING SERVICE PART # MFO 12OOH2 MFOI2OOJ.A.2 MFO I2004·J2 MFOl2005·J2 MFOI2006·A2 MFOI2007·A2 11

12A

COUPLING SHAFT MF01S007 MF01S00o MFOISOO6 MF01S003 MF019004 MF019005 MF01SOO1 MFOI 9002

WOODRUFF

2

END

~

ROTOR

COVER MGD1 61101l MGD1 6000 MGOISOOJ

O,RING (21

)

032200·10 032200·10

KEY

128 NUT

G124553 GI24553 G124553

3 COMMUTATOR SEAL

032435 032435 032435

025 136

4 SEAL RING (51 032821 032821 032822

16 INNER SEAL 032377 032377 032809

aService housing ass'y ITEM11 8 with part number suffix·A2 includes ITEM113 and l IS. Service housing ass'y ITEMt 18 with part number suffix-J2 includes ITEM113, 1 19 AND two ITEM lOA. Standard seal kit SKocrooo roudes frve 1032821 seal rings, 1032435 commutator seal, 1032377 i«oer seal. / 028516 bad up washer, 1478036 dirt & water seal, 1406018 grease pack, bonetin/88l.

Special seal kit SKOOOOSI for units that use fire retardant fluids include frve 1032822 seal rings, 1032435 tommulator seal, 1Il32B09 inner seal. 1028516 bad up washer, 1478036 d~t & water seal, 14060 18 grease patk. bulletm/887.

8

)

MF Service Parts List Chart CHART USE EXAMPLE: Mf020601AAAA TOROMOTORfll INCLUDES PART NUMBERS LISTED TO THE RIGHT OF MF(SERIESI. 02(DlSP.I. 06(HOUSINGI. OHSHAFT( AND AAAA (OPTION( SHOWN IN lEFT HAND COLUMN OF CHART.

")

CAUTION: THE CHARTEO COMPONENT SERVICE INFORMATION IS FOR THE TDROMOTORS LISTED ONLY. REFER TO THE ORIGINAL EOUIPMENT MANUFACTURER OF THE EQUIPMENT USING THE TOROMOTOA FOR ASSEMBLY NUMBERS Nor USTED BELOW.

EXPlODED VIEW

5& 6

ITEM '

-ffi

DESCRIPTION Servi:e Pan I

~

~

7

MF·

& RING ASSY

MANIFOLD Mffil5000

MFOl 8000·Al

EXPlODEO VIEW ITEM'

8

DESCRIPTION Sem:e Part I

01-

OJ

Service Pan Service Pan Service Pan Service Pan S~ Pan Service Pan Service Pan Service Pan Servic:e Pan Service Pall Service Part

040506-

~ 08·

~ 10· ~ 12z ~ 14· t) 16· :5 18!!? 20· ~

0

I I I I I I I I I I I

BOLT (5)

SET

LINK

02131 1 021311 021306 021382 021 357 021307 021358 021308 021359 021310 021383 021384

MF027003 MF037003 MF047003 MF057003 MF067003 MF087003 MF107003 MF127003 Mf147003 MFI6.7003 MF187003 MF207003

MF02301Xl MF033000 MF043000

EXPLODED VIEW ITEM # DESCRIPTION Service Part I Service Part I Service Part I Servri! Part I Service Part I Service Part I

06· 5 09· ffi 10· ~ 11 · ~ 12· ~ 13· Il...

EXPLDDEO VIEW ITEM I OESCRIPTION Service Part I SeM:e Pan I Servri! Part I Service Part I Service Part I Service Part I Service Part I Service Part I

~ ~

01 · 09· :: 10· ~

11 ·

~ 12· ~

13i2 14· 51 5· u

EXPlODED VIEW ITEM ' ~

~

:;lAAAA ~

PMe

~ MAO ~

0

)

MAG

DESCRIPTION Service Part I SelVice Part I Service Part I SeMce Pan I

15

17

THRUST

BACKUP

BEARING 069512

WASHER

BEARING 065066

WASHER 028516

028483

'"

,NEEDLE BEARING 005505

20 DIRT & WATER SEAL

478036

MF083000 MFlOJOOO MF123000 MF143000 MFI63000 MFI83000 MF203000

'"

l8A

D·RING (21

0322110·10 032200·10

12

12A

COUPliNG SHAFT MF019007 MRJI9000 MRJ10006 MF01 9003 MF019004 MFOI9005 MFOI9001 MFOl9002

WOODRUFF

2 END COVER MRJI6000 MF01600J MFOI 6000 MFOI 6000

14 THRUST

MfIl53000 M_OO

a

HOUSING SERVICE PART # MF01200I·AI MF012003-AI MFOI 2004·Jl MFOI2005·Jl MF01 2006-A1 MFOI 21X!7·Al

'13 NEEDLE

10 DRIVE

ROTOR

')

9 WEAR PLATE 477341

COMMUTATOR

KEY

12.

NUT

G124553 G124553 G124553

025136

3

4

COMMUTATOR SEAL 032435 032435 032435 032435

SEAL RING (5) 032821 032821 032821 032822

16 INNER SEAL 032377 032377 032809 032809

--

3SeM:e housing ass'y ITEM liB with part number $lJffi~·Al irdudes ITEM 113 and 119. Servi:e Ilousi"9 ass'y ITEM lIB with pan number sufflx.Jl includes ITEM 113.

119 AND two ITEMlBA. Staooard seal kit SKOaoooo ;dudes fNll 1032821 seal rings,/032435 CflI'I1mUl31or seal, 1032377 h'ler seal,/02B516 back up washer,/478036 &:t & water seal, 1401Xl18 grease pack, bullelin 1881.

SJlecial seal kit SKOOOO91 lor unrlS llial use fire retardant lluids ilclude fNt! 1{)32822 seal rrogs, 1032435 commutator seal, 103281.l9 inner seal, I 028516 back up washer,/47B036 din & water seal,/406018 grease pack. bulletl1/B87.

9

MB Service Parts list Chart CHART USE EXAMPLE: MB050101AAAA TORQMOTORIMINCLUDES PART NUMBERS lISTEO TO THE RIGHT Of MB(SERIESJ. 05{DlSP.l. OHHOUSINGt Ol/SHAFT1 AND AAAA (OPTIONI SHOWN IN LEFT HAND COLUMN OF CHART.

CAUTION: THE CHARTED COMPONENT SERVICE INFORMATION IS FOR THE TOROMOTORS LISTED ONLY. REFER TO THE ORIGINAL EOUIPMENT MANUFACTURER OF THE EQUIPMENT USING THE TOROMOTDR FOR ASSEMBLY NUMBERS NOT LISTED BELOW. E!!',ODl:D VIEW

VIEW ( )

0506· 08-

Pant Pan t ServICe Partl

021326 021326 [)21171

021340 021340 021386

021386 021386 021273

r5 09·

Service Pan I

02 1390

021273

021273

~

SeJ'llCe SelVlCe Service ServICe

02 1376 021352 021272 021340

021387 021379 021391 021392

021387 021379

021392

021385

o!5

10· ... 12· § 15· ~ lB·

6

Pant Partt Part I Part I

02 1273

1.16057003 1.1 8061003 1.1 8087003

MB063000 1.18063000 MB083000

02 1379

MB09700J

M8093000

(12139 1

M81[l7003 MB127003 MB157003 M8187003

MB103000 M8123000 MB135000 MB183000

f23l· __~S~'"' ~·~'~P~.~"~/~__~OL 21~38~7~__-"Og21 13~78~____]02~1137~8____________MM~ 82~3~700m!3__~M~81~3~ 30~0~ 0 __ EXPLODED VIEW

ITEM' DESCRIPTION Service Part I Sarvice Part I

..... 01· S 02· ~ 04· ~ 05· 0;; 06· ~

Service Pan I Service Pan I Service Pan I

'IB SERVICE HOUSING ASS'Y

ME012oo1·AI ME012002·Al ME012004·AI ME012005-AI ME01200B-AI

~ ~ 07~ . __~S~ '~~ ·~ ~~ "~/:=__~M~E~01~1~ 00~ ).~Al"-_ EXPLODED VIEW

ITEM ' DESCRIPTION

12 COUPLING SHAFT

12A

128

KEY

NUT

HC WASHER

120

11E

11F

51B· 18

LOCK WASHER

RETAINING RING

BOLT

)

~

01· Service Pan I MB019001 :E 02· Service Pan I MB019002 GI24553 :::: 03SeM:e Part I MBOI9003 039028 028413 G223734 Gl03325 401333 04· Service Pan I MBOI9004 ~ 05· Service Pan I MB01901J5 028413 G223734 GI03325 ~ 06· Service Part I MB019006 ~ 07· Service Part I MB010007 8lli 08~.__~S~'~ "'~ · '~~ ~ "~/____~M~80~1~OO~OO~~G~11~'~5~ ~ ~'~0~25U12~6L-___________________________

:a

EXPLODED VIEW ITEM # bl .1A,IB,IC

§l ~

AAAA >Me >MF >MG >MH >M" >MN >MP >MT AAAU

BBBA BBBB ~ BBBC ~ BBBD

z

1

DESCRIPTION

BOLT (7)

END COVER

Servictl Part I Service Part I ServU Pan I Service Pan I Service Part I Service Part I Service Pan I Service Part I Service Pari I Service Pan I Service Part I Service Part I Service Part I Service Part I

Item II Item II ilem 11 hem 11 Item 11 Item lIB Item lIB Item lIB Ifem 11A Item 11A i1em 11C 11em IIC hem 11C Item 11C

MBOI6OQO MBOI 6000 MBOI 6000 MB01fiOOO M801 600Q ME016002 MEOIOOO2 eMEOI6001-JI IMEOI6003-Al tME016003-AI 'MEOI6004·Al 'MEOI6004·A2 'MEOI60Q4·AJ 'MEOI 6004·A4

03"2435 032435 032435 032435 032435 032435 032435 032435 032435 032435 032435 032435 032435 032435

032819 032819 032819 032620 032820 032819 032819 032819 032819 032819 032819 032819 tl32B19 032819

032817 032817 032817 032818 032818 032817 032817 032817 032817 032817 032817 032817 032817 032017

415463-A2 415463-A2 411063-AI 411063·Al 411063·Al 411063·Al

O·RING

SPRING (2)

VALVE

032200·90 032201]-00 032424 032424 032424 032424

401642 401642

41 5569 415569

m, 1000PSl 410009·71 121. 2000PSl 410009·72 12L 3OO0PSl 410009·73121, 4000PSl

41 0009·]4

aSeM:e housing ass'~ ITEM 1 18 wilh pan number wHiI·A.l n:ludes ITEM 113,/14 IWO reQ'd, 1 15 and 119. °Selecl Ille reQUled boh number ,. dW;!llilied ·OISf'lAC[MENT GROUP" under boil ITEM 11,1A.18 or Ie shown in d~lec "OPTION GROUP: cNul10251 13 1$ reqUfed If tile designated "OPTION GROUP" is AAAI. AAAfI, or AAAU. 1·20 UNEF dlTEM112 is pall of plug & 0...1'19 ass"{$ bm C&f1 be serv.::ed npara lely. eSeM:e and toVeI" MEOl fDll-Jl 'includes l'Ml / OJ2200-lO HtngS, lTfM 1M OO.,ha exploded asfy"';ew thai can also be servad separately. lEnd caver assembly ilem 12 alsll irdudes Item/21.

124 and II leQUKed item 123. AI bul Item I2ll;8n be ser.rtcf!C sep3rate/'j.

QMtQ l8001·A 1 commutatOl ass·y. 1$ requtted If tile cesqraled "OPTIO N GROUP" IS AAAM , MAN, 01 MAP. Standard seal kit SK000J92 includes rrve 1032819 seal IIllgS, 10324~ ccmmutalor seal, 1032611 inrtef seal, 1028515 and 1029118 back Wolshers. /4 JOO35 dirl & Wolter $eat 14OOJ18 grease pack. buUeI>'l/681.

Speoal seal k,t SKOO'lIS3 ItII 0011$ IlIat USE f.e retan'enl IUds ID.tdes live 1032820 .seal rl'lgs.' 032435 wnmu lattll seal, 1032818 mel .seaI,l028515 at>d Kl2911B bad ~ wWer~, 1410035 din & Woller seal, 14OOl18 grease pack. boIet... 1661

m.

10

4 16 3 COMMUTATOR SEAL INNER PLUG & O·RING RING !5) SEAL SEAL ASSEMBLY

)

ME Service Parts list Chart CHART USE EXAMPLE: ME090101AAAA TOROMOTORH,j INCLUDES PART NUMBERS LISTED TO THE RIGHT OF MEISERIES), 09(OISPJ. D1(HDUSINGl. 01lSHAFT) AND AAAA [OPTION) SHOWN IN LEFT HAND COLUMN OF CHART. CAUTION: THE CHARTED COMPONENT SERVICE INFORMATION IS FOR THE TOROMOTORS LISTED ONLY. REFER TO THE ORIGINAL EQUIPMENT MANUFACTURER OF THE EQUIPMENT USING THE TOROMOTOR FOR ASSEMBLY NUMBERS NOT liSTED BElOW.

'!!"JOEO VIEW

09· 1215~ lB· 21 · ~ 29· ~ 3], ~ 48·

~ ~

3

SeNU Panl Seriee PaM Servi:e Pan l Servi:e Pan I Service Part I Service Partt Service Part I Service Part I

021390 021352 021272 0213411 021273 021 392 021385 021395

021379 021391 021393 021385 021394 021393 021300

021379 021392 0213B5 021394 021393 021308

D2138S 021 :mJ 021395

ME097003

ME09300Q

ME127003

ME123000

ME157003 ME187003 ME217003 ME297003 ME331003 ME407003

ME153000 ME183000 ME213000 ME293QOO ME333000 ME483000

~ ~ 5B~ . __~S'~M< ~·~'~ ~~ n~ I ~__lli 01~'~ ~ 6 ____~og1~'3~B9L-__~~~'~ 3B~9__________-""~ 'S~B'~OO~3c-~"~'~ 5~ ~OO mO"-EXPLODED VIEW ITEM' a1 8 SERVICE DESCRIPTION HOUSING ASS'Y g:; 01 · Service Part I ME0120OI·AI ~

02Service Part I MEUI 2002·AI 04· Service Part I MEOI2f)04·AI ~ 05· Service Part I MEOI2005·AI ~ 06Service Part I ME012006·AI ~ .O'~.__~s~'= ""~'~~ ~ n ~'~__-"M~'O~'~ 100 ~ '.A~'L-_

<.!l

VIEW

Service Service Part Service Part Service Part Service P-drt Service Part Service Pan Service Part Service Part Service Part Service Part Service Part

I I I I I I

I I

I I I

MEOI9003 MEOI9004 ME01901J5 ME0I901J6 ME0I9007 MEOI9000 ME010008 MEOI9009 MEO I9010 MEO l90 11

EXPLODED VIEW ITEM ' bl ,IA,IB,IC DESCRIPTION

.... =>

~ ~ ~

o

)

AAAA Service Pan I MAC SelVlCe Pan I MAF Service Pan I MAG Service Part I MAM SeMCe Part I MAN Service Part I MAP Service Pan I MAT Service Pal[ I MAU Service Part I SBBA Service Part I BBBB Service Pall I BBBC Service Part I

BOLT (7) Item II

Item II Item 11 Item I I hem liB Item 118 hem lIB hem IIA hem IIA Item IIC Item I IC 11em IIC

GI24553 039028

G124554

c025126

G124554 039020

902513B 2

END COVER

ME016000 ME016000 ME016000 MEOI6000 ME{)I6002 MEOI6002

~M EO I 6001 .J l

IME01 6003.Al ,MEOI6003-AI IME01 0004-AI IME01 6004-A2 MEOI 6004·A3

02841 3

G223734

G103325

02841 3

G223734

G103325

02851 8

G223734

G103325

401333

401658

121 & 22 3 4 16 COMMUTATOR SEAL INNER PLUG & O-RING SEAL RING (5) SEAL ASSEMBLY 121 032435 032435 032435 032435 032435 032435 032435 032435 032435 032435 032435 032435

032819 032819 032819 032820 03281 9 032819 032819 0328 19 0328 19 032819 032819 032819

032817 032817 032817 032818 032817 032817 032817 032817 032817 032817 032817 032811

41546J.A2 41546J.A2 41106J.AI 411063-AI 41106J.Al

O-RING

SPRING (21

032200·90 0322(1).90 032424 032424 [)32424

401642 401642

VALVE

415569 415569 410009·74 121. I()()OPSI 41oo09·71121.2000PSI 410009·72 l2I. 3000PSI

2B~B~BO~S~'~ ,~~'~~ ~nLI-=-=~"~ 'm~I~I~C__-"'M~'~O~'O~O O ~4~~~4__~~O~ 3 1~4£ 35L--"O~3~1B~I~9-"03~1~B1~7__~4~1I~O~63~.A~'__~O~31~4~'4,-________~4~'OO~O~9~'d3~"~',~400 ~OP~S~1 3SeM:e housing 8lS'Y tTEM118 WIth pan number Sl!ffix·Al i1dWes ITEM 113. /14 tWO req'lI. I 15 and 119. tJse~l lhe r~ulled bolt number il designated "DISPlACE MENT GROUP'" under boil tTEMII,IA,IS or Ie shown II desiVlaled llPl'ION GROUP: [1·20 UNH nUl 1025113 is requ~ed il the OOsignated "OPTIO N GROUP" is /lAM. MAN, 01 AAAll. ~TEM I'll is pan 01 pklg & 0-(1:19 8SS'/'~ but can be setv'ald separately. ~SerW:e end to'Ier MEOl6001 ·Jl n1udes (WO 1032200-10 Hings.tTEMlBA Ofllhe eXlllOOed ass'V I'iew thai taO also be teIw:ed separately.

End CDYef assembly Item 12 aisl:l ndodes Item / 21. m. / 24 3IId il requiled nem n3. AI 001 item 121 tan be servICed se;l3r3Ie1v. ~1 1/8·18 UNH /lUI 10251391$ reQUf ed ,t (tie designated -OPTION GROUP" is AAAf. MAN. or MAU ME01BOO1 ·Al commUiiliOf ass·y.1S reQu~ed It rhe designated ·OPTION GROUP" IS AMr.! , MAN. 01 AAM'.

Slarldard seal kn SKlXXlO92 lIlCivde5 fi\le 1032819 seat nngs. 1il324l5 commutator seal. I 032817 IfIflef seal,l 028515 and 1029118 back washels, 1418J35 II_I & watef seal. 1400018 grease pack, bU~lIn 1581 Speclat seal kit SK(I))J9J 10c ...,IS lhal use fl-e reJardenl f'oIs roudes !iw 1032820 seal rl'lQ$. iU324J5 I;OOIfOOJa!CJ seal. 1J32818 ITII!! seal, 1028515 ancIIU29118 back ~ washefs. 1410035 tillt & Wlu er seaI./4OOIl BQle<lSI! pact. bulle1., 1681.

11

Disassembly and Inspection (Preparation Before Disassembly)

• Before you disassemble the Torqffiotor unit or any 01 its components read this entire manuaL It provides important information on pans and procedures you will need to know

to service the Torqmotor.

• Determine whether the Torqmotof you are about to disassemble is the Small Frame Series MG or MF or the Large Frame Series MB or ME sa you can follow those

procedures that penain to that Series TorqmolOr. The first two letters of the "spec" number on the Torqmotor identification tag is the Series designation. Also determine the type of end cover construction from the alternate views shown on page 7A and 7B. • The Small frame Series MG & Mf TorQmotors will have a 3.66 inch 192.9 mml main body outside diameter and live 5116-24 UNf 2A cover bolts. The Large frame Series MB & ME Torqmotors will have a 5 inch 1127.0 mml main body outside diameter and seven 3/8 24 UNf 2A cover bolts.

• Refer to page 7 for tools and other items required to service the Torqmotor and have them available.

• Thoroughly clean oH all outside dirt, especially from around fittings and hose connections, before disconnecting and 'removing the Torqmotor. Remove rust or corrosion from coupling shah.

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

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

IA piece of wrapping paper makes an excellent disposable top. I

)

• Clean and dry the Torqmolor before you start to disassemble the unit.

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

WARNING: SI NCE THEY AR E fLAMMABLE. BE EXTREMELY CAR EfUL WHEN USING ANY SOLVENT. EV EN A SMALL EXPLOSION OR fiRE COULD CAUSE INJURY OR DEATH. WARNING: WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS. CAUTION: Never steam or high pressure wash hydraulic components. Do not force or abuse closely fitted parts.

• Keep pans separate to avoid nicks and burrs.

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

)

12

Disassembly and Inspection (Reference Exploded Assembly Viewl place

1.

Torqmotor

in a vise

WARNING

scribe alignment mark & loosen

valve plugs

Place the TorqmolOf in a soh jawed vice, with coupling shaft (121 pointed down and the vise jaws clamping firmly on the sides of the housing (18) mounting flange Of port bosses. Remove manifold pan O-Rings 118AI if applicable.

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

2.

Figure 3

Scribe an alignment mark down and across the Torqmotor components from end cover 121 to housing (18) to facilitate reassembly orientation where required. loosen two shuttle or relief valve plugs 121) for disassembly later if induded in end cover. 3/16 'or 3/8 inch allen wrench or 1 inch hex socket required. SEE FI GURE 3 & 4.

Figure 4

)

Figure 5

-

remove special , bolts &

)

inspect bolts

,-

."

3. :: Remove the five or seven special ring head bolts 11 , 1A, 1B, or 1CI using an appropriate 112 or _ . 9116 inch size socket. SEE FIGURE 5. Inspect ... -; bolts for damaged threads, or sealing rings, under the bolt head. Replace damaged bolts.

SEE FIGURE 6.

13

remove end

4.

cover &

Remove end cover assembly (21 and seal ring 141.

Discard seal ring_ SEE fiGURE 7_

inspect bolts

.~'

NOTE

NOTE: Refer to the appropriate "alternate cover construction" on page 7A or 78 to determine the end cover construction being serviced.

remove plugs

5.

and valves

If the end cover 121 is equipped with shuttle valve

Figure 7

or relief valve 1241 components, remove the two previously loosened plugs {2 11 and a-rings 1221.

SEE FIGURE B.

CAUTION

CAUTION: Be ready to catch the shuttle valve

or relief valve components that will fall out of the end cover valve cavity when the plugs are removed.

NOTE

NOTE: O-ring (221 is not included in seal kits but serviced sepilrately if required .

•

NOTE

NOTE: The insert and if included the orifice plug in the end cover 121 must not be removed as they are serviced as an integral part of the end cover.

• :ri<'

li:!X: C7I

Figure 8

)

wash & inspect end cover

6.

NOTE

Thoroughly wash end cover (21 in proper solvent and blow dry. Be sure the end cover valve apertures, including the internal orifice plug, are free of contamination. Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces. Replace end cover as necessary. SEE FIGURE 9_ NOTE: A polished pattern (not scratches) on the cover from rotation of the commutator (5) is normal. Discoloration would indicate excess fluid temperature, thermal shock. or excess speed and require system investigation for cause and close inspection of end cover. commutator. manifold, and rotor set.

) remove & inspect commutator ring

14

7_

Remove com mutator ring 161. SEE FIGURE 10.

Inspect commutalDr ring for cracks, or burrs.

Figure 10

remove & inspect commutator

8.

Remove com mutator (5 ) and seal ring 131.

Remove seal ring from commutator, using an air hose to blow air into ring groove until seal ring is lifted out and discard seal ring. Inspect commutator for cracks or burrs, wear, scoring, spalling or brinelling. If any of these conditions ex.ist, replace commutator and commutator ring as a matched set. SEE FIGURE 11 & 12.

remove manifold

9.

Remove manifold mand inspect for cracks surface scoring, brinelling or spalling. Replace manifold if any of these conditions ex.ist. SEE FIGURE 13. A polished pattern on the ground surfaces from commutator or rotor rotation is normal. Remove and discard the seal rings 141 that are on both sides of the manifold.

NOTE

NOTE: The manifold is constructed of plates bonded together to form an integral component not subject to further disassembly for service.

Compare configuration of both sides of the manifold to ensure that same surface is reassemble.d against the rotor set.

remove & inspect rotor set & wearplate

)

-'.

NOTE

.","

)

Figure 11

"

~

..

10.

Remove rotor set (8) and wearplate !91 together to retain the rotor set in its assembled form, maintaining the same rotor vane !SCI to stator 18BI COntact surfaces. SEE FIGURE 14. The drive link 11 01 may come away from the coupling shalt 1121 with the rotor set, and wearplate. You may have to shift the rotor set on the wearplate to work the drive link out of the rotor !SAl and wearplate. SEE FIGURE 15, Page 16. Inspect the rotor set in its assembled form for nicks, scoring, or spalling on any surface and for broken or worn splines. If the rotor set component requires replacement, the complete rotor ·set must be replaced as it is a matched set. Inspect the " wearplate for cracks, brineliing, or scoring.

Discard seal ring 141 that is between the rotor set and wearplate.

NOTE: The rotor set 181 components may "."'.. become disassembled during service procedures. Marking the surface of the rotor and stator that is facing UP, with etching ink ".or ~gfease pencil before removal from Torqmotor,wil! ensure correct reassembly of rotor into stator and rotor set into Torqmotor" ;. . Marking all rotor components and mating spline components for exact repositioning at assembly will ensure maximum wear life and performance of rotor set and Torqmotor"

Figure 12

~gure

13

.1-

Figure 14

15

NOTE

NOTE: Series ME Torqmotors may have a rotor set with two stator halls (88 & 80) with a seal ring (4) between them and two sets of seven vanes (8C & 8E). Discard seal ring only if stator halfs become disassembled during the service procedures .

)

.

..

NOTE

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

check rotor, vane clearance

II.

Place rotor set IBI and wear plate 191 on a flat surface and center rotor (BAI in stator (BBI such that two rotor lobes 1180 degrees apart) and a roller vane 18CI centerline are on the same stator centerline. Check the rotor lobe to roller vane clearance with a feeler gage at this common centerline. If there is more than .005 inches 10.13 mm) of clearance, .replace rotor set.

SEE FIGURE 16.

NOTE

NOTE: If rotor set 181 has two stator halfs IB8 & 80) and two sets of seven vanes 18C & BE) as shown in the alternate construction ME rotor set assembly view, check the rotor lobe to roller vane clearance at both ends of rotor.

,. remove & inspect drive link

12.

,

16

"i;

,

"t:·

,,'1

" Figure 16

)

.

Remove drr,e link 1101 from coupling shalt 1121 if it was not removed with rotor set and wear . plate. Inspect drive link for cracks and worn or damaged splines. No perceptible lash Iplavl should be-noted between mating spline parts.

SEE FIGURE 17. Remove and discard seal ring 141 from housing I1BI.

Figure 17

~.

•

_ 13.: Remove thrust bearing 1111 from top of coupling shah.1l21 if Torqmotor is a Series M8 or ME. Inspect for"wear, brinelling, corrosion and a full complement of retained rollers. SEE FIGURE 18.

.:'

.,

.:;

.

, remove thrust bearing

Figure 15

)'

check coupling shaft for rust or corrosion

14.

Check exposed portion of coupling shaft 11 21 to be sure you have removed aU signs of rust and corrosion which might prevent its withdrawal through the seal and bearing. Crocus cloth or fine

emery paper may be used. SEE RGURE 19.

Remove any key 112A!, nut 112BI, washer 112el. bolt 11201, lock washer 112E), or retaining ring

112fl. figure 19

remove & inspect coupling shaft

15.

Remove coupling shaft 1121, by pushing on the output end of shah. SEE fiGURE 20. Inspect coupling shaft bearing and seal surfaces for spalling, nicks, grooves, severe wear or corrosion and discoloration. Inspect for damaged or worn internal and external splines or keyway. SEE

fiGURE 21. Replace coupling shah if any of these conditions exist.

NOTE

NOTE: Minor shaft wear in seal area is permissible. If wear exceeds .020 inches (0. 51 mml diametrically, replace coupling shaft.

NOTE

remove seal ring from housing

figure 20

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

16.

.

Remove and discard seal ring 141 from housing

1181.

Rgure 21

remove & inspect thrust washer & thrust bearing

17.

" NOTE

)

Remove thrust bearing 1151 and thrust washer 1141if the unit is a Series MG or MF. Inspect for r~r; brinelling, corrosion and a full ·complement

. of retained rollers. SEE fiGURE 22.

NOTE: large frame Series MB & ME ·- Torqmotors have a thrust bearing (lSI sandwiched between two thrust washers ·(141 that cannot be removed from housing (18) unless bearing (1 3) is removed for replacement.

17

remove seal & washer or washers

18.

Remove seal 1161 and back up washer 1171 from Small Frame, MG & MF housing 1181. Discard both. SEE FIGURE 23.

)

Remove sea1116i. backup washer 1171, and backup washer 125) from large Frame, Series MB & ME Torqmotor housing by working them around unseated thrust washers 1141 and thrust bearing 115) and out of the housing. Discard seal and washers. SEE FIGURE 24.

NOTE

NOTE: The original design units of l arge Frame, Series MB & ME Tarqmotars did not include backup washer 125), but must include backup washer (25) when reassembled for service.

~gure

23

Figure 24

) remove seal

19.

Remove housing 1181 from vise, invert it and remove and discard seal (20), A blind hole bearing or seal puller required. SEE FIGURE 25.

Figure 25

inspect housing assembly

20.

Inspect housing (181assembly for cracks, the machined surfaces for nicks, burrs, brinelling or corrosion. Remove burrs that can be removed without changing dimensional characteristics.

Inspect tapped holes for thread damage. SEE FIGURE 26. If the housing is defective in these areas, discard the housing assembly.

) Figure 26

18

inspect housing bearing/bushing

21.

NOTE

If the housing 1181 assembly has passed inspection to this point. inspect the housing bearings/bushings 1191 and 1131 and if they are captured in the housing cavity the two thrust washers 1141 and thrust bearing 1151. The bearing rollers must be firmly retained in the bearing cages, but must rotate and orbit freely. All rollers and thrust washers must be free of brinelling and corrosion. SEE FIGURE 27. The MG Series bushing 1191 or 1131 to coupling shaft diametral clearance must not exceed .010 inch 1.025 mm!. A bearing, bushing, or thrust washer that does not pass inspection must be replaced. SEE FIGURE 28. If the housing has passed this inspection the disassembly of the Torqmolor is completed.

Figure 21

NOTE: The depth or location of

bearinglbushing (13) in relation to the housing

)

wear plate surface and the depth or location of bearinglbushing (191 in relation to the beginning of bearinglbushing counter bore should be measured and noted before removing the bearings[bushings. This will facilitate the correct reassembly of new bearingslbushings.

SEE FIGURE 29.

remove bearings or bushings & thrust

washers

22.

Rgure 29

If the bearings, bushing or thrust washers must be replaced USB a suitable size bearing puller to remove bearinglbushings 1191 and 1131 from housing 1181 without damaging the housing.

Remove thrust washers 1141 and thrust bearing 11 51 if they were previously retained in the housing by bearing 1131. SEE FIGUR ES 30 & 31.

THE OISASSEMBLY OF TORQM OTOR IS COMPLETEO.

-..

• •

)

'·lI. ;,I

Figure 31

19

Torqmotor" Assembly • Replace all seals and seal rings with new ones each time you reassemble the TorQffiolor unit. lubricate all seals and seal rings with SAE 10W40 oil or clean grease before assembly.

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

local dealer for availability), • NOTE: Unless otherwise indicated, do not oil or grease parts before assembly_ • Wash all parts in clean petroleum-based solvents before assembly. Blow them dry with compressed air. Remove any paint chips from mating surfaces of the

end cover, commutator set, manifold rotor set, wear plate and housing and from port and sealing areas.

WARNING

WARNING: SINCE THEY ARE flAMMABLE. BE EXTREMElY CAREFUL WHEN USING ANY SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULO CAUSE INJUR Y OR OEATH.

WARNING

WARNING: WEAR EYE PR OTECTION AN O BE SURE TO COMPLY WITH OSH A OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS.

press in outer bearing/bushing

1.

If the housing (181 bearing components were removed for replacement, thoroughly coat and pack a new outer bearinglbushing (191 with clean corrosion resistant grease recommended in the material section on page 7. Press the new bearinglbushing into the counterbore at the mounting flange end of the housing, using the appropriate sized bearing mandrel such as described in figure 1 or figure 2 on page 7 which will control the bearinglbushing depth.

Small Frame Series MG and MF Torqmotor housings require the use of bea ri ~ mandrel shown in figure 1 on page 7 to press bearing/bushing 1191 into the housing to a required depth of .1511.161 inches 13.8414.09 mml from the end of the bearing counterbore.

SEE RGURE 33.

Rgure 32 MS, ME seal kit

Rgure 33

large Frame Series MB and ME Torqmotor housings require the use of the bearing mandrel shown in figure 2 on page 7 to press bearing 1191into the housing to a required depth of .290/.310 inches 17.37n.87 mml from the outside end of the bearing counterbore. SEE FIGURE 34.

."" . . .,-.'

) Figure 34

20

NOTE

NOTE: Bearing mandrel must be pressed

against the lettered end of bearing shell. Take care that the housing bore is square with the press base and the bearing/bushing is not cocked when pressing a bearing/bushing into the housing.

CAUTION

CAUTION: If the

bearin~

mandrel specified on

page 7 is not available and alternate methods are used to press in bearing/bushing (13) and (191 the bearing/bushing depths specified must be achieved to insure adequate bearing support

Figure 35

and correct relationship to adjacent components when assembled. SEE FIGURE 35.

CAUTION

CAUTION: Because the bearing/bushings (131 and (19) have a press fit into the housing they must be discarded when removed . They must not be reused.

Fi9ure 36

) press in inner

bearing/bushing

.-r

)

2.

The Small Frame Series MG and MF Torqrnotor inner housing bearinglbushing 113) can now be pressed into its counterbore in housing 118) flush to .03 inch L76 mm) below the housing wear plate contact face. Use the opposite end of the bearing mandrel that was used to press in the outer bearinglbushing (191. Reference figure 1, page 7. SEE FIGURE 36.

The large Frame Series MB and ME Torqmotor housing n8) requires that you assemble a new backup washer 1171: new backup washer 1251, new sea) 1161, with the lip facing out, new thrust washer 1141, new thrust bearing !l5) and a new second thrust washer 114) in that order before pressing in the inner housing bearing 1131.

SEE fiGURE 37 & 38. When these components are in place, press new bearing (13) into the housing (1 81 to a depth of .105/. 125 inches 12.67/3.1 SI below the housing wear plate contact face. Use the opposite end of the bearing mandrel used to press in outer bearing 1191. Reference figure 2, page 7. SEE FIGURE 39.

Figure 38

21

press in dirt & water seal

3.

Apply a small amount of clean grease to a new dirt and water seal 1201 and press it into the housing !l81 outer bearing counterbore.

The Small Frame Series MG and MF TOfQmotor dirt and water seal (201 must be pressed in until its' flange is flush against the housing.

SEE FIGURE 40.

The Large Frame Series M8 and ME TorQmotor dirt and water seal (201 must be pressed in with the lip facing out and until the seal is flush to .020 inches (,51 mm) below the end of housing.

SEE FIGURE 41.

Figure 39

Figure 40

)

Figure 41

.

place housing assembly into vise

4.

...!· ·w "

)

Place housing (181 assembly into a soft jawed vise with the coupling shaft bore down, clamping against the mounting Ilange. SEE FIGURE 42.

Figure 42

12

assemble backup washer & seal

5.

On Small Frame, Series MG & MF TorqmOlors assemble a new backup washer (17) and new seal (161 with the seal lip facing out, into their respective counterbores in housing (181 if they were nOi assembled in procedure 2. large frame, Series MB and ME Torqmotor housing n81 that did not require replacement of the bearing package will require that the two "captured" thrust washers 1141 and thrust bearing 1151 be unseated and vertical to the counterbore and the new backup washer 117), new backup washer 1251. and new seal 1161 be worked around the thrust bearing package and placed into their respective counterbores. The seal lip must face out of the seal counterbore. Be sure the thrust bearing package is reseated correctly afteTl assembly of the seal and backup washer.

SEE FIGURE 43 & 44.

CAUTION

Figure 43

CAUTION: Original design large Frame, MB & ME Torqmotors that do not have backup washer (251 when disassembled must be assembled with a new backup washer (17), new backup washer 125), and new seal 116), Figure 44

) assemble thrust washer & bearing

6.

NOTE

Assemble thrust washer (14) then thrust bearing 1151 that was removed from the Series MG or MF TorQmotor. SEE FIGURE 45.

NOTE: Small Frame Series MG and MF Torqmotors require one thrust washer (14) with thrust bearing 115), The coupling shaft will be seated directly against the thrust bearing.

Figure 45

,

)

apply masking tape to shaft

7.

Apply masking tape around splines or keyway on shaft (121 to prevent damage to seal.

SEE FIGURE 46.

Figure 46

23

install coupling shaft

B.

Be sure that a generous amount of dean corrosion resistant grease has been applied to the lower (outer) housing bearinglbushing !1 91. Install the coupling shaft (121 into housing (1 8), seating it against the thrust bearing 115) in MG and MF Series housings and against the second thrust washer (14) in MB and ME Series housings.

SEE FIGURE 47.

CAUTION

CAUTION: The outer bearing 1191is not lubricated by the system's hydraulic fluid. Be sure it is thoroughly packed with the recommended grease, Ross Gear grease specification #045236, ElM Lubricant #K·l0M.

NOTE

NOTE: The coupling shaft 1121 will be flush or just below the housing wear plate surface on Small Frame, Series MG and MF Torqmotors when properly seated while the coupling shaft 1121 on Large Frame, Series MB and ME Torqmotors will ' be approximately .10 inch 12.54 mml below the housing wear plate surface to allow the assembly of thrust bearing (111. The coupling shaft must rotate smoothly on the thrust bearing package.

SEE FIGURE 4B.

install thrust bearing

9.

Figure 48

)

Install thrust bearing 111) onto the end of coupling shah 1121 only if you are servicing an MB or ME Series TorQmotor. SEE FIGURE 49.

Figure 49 insert seal ring

NOTE

10.

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

NOTE: One or two alignment studs screwed finger tight into housing 11 BI bolt holes, approximately 180 degrees apart, will facilitate the assembly and alignment of components as required in the following procedures. The studs can be made by cutting off the heads of either 31B·24 UNF 2A or 5116·24 UNF 2A bolts as required that are over .5 inch (12.7 mmJ longer than the bolts 11 , 1A, 1B or 1CI used in the Torqmotor.

) Figure 50

24

install drive link

")

11.

NOTE

Install drive link 11 0) the long splined end down into the coupling shalt (121 and engage the drive link splines into mesh with the coupling shaft splines. SEE FIGURE 51.

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

Figure 51

assemble wear plate

12.

Assemble wear plate (9) over the drive link [10) and alignment studs onto the housing 118), SEE FIGURE 52.

Figure 52

)

assemble seal ring

13.

ApplV a small amount of clean grease to a new seal ring 141 and assemble it into the sea! ring groove on the wear plate side of the rotor set stalOr 18BI. SEE FIGURE 53.

install the assembled rotor set

14.

Install the assembled rotor set 181 onto wear plate !9J with rotor !SAl counterbore and seal ring side down and the splines into mesh with the drive link splines. SEE FIGURE 54.

NOTE

NOTE: It may be necessary to turn one alignment stud out of the housing 11 BI temporarily to assemble rotor set (81 or manifold 171 over the drive link.

NOTE

NOTE: If necessary. go to the appropriate, "Rotor Set Component Assembly Procedure," on page 30 or 31.

NOTE

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

The rotor set has a seal ring groove on the wear plate contact side of the stator (88).

~gure

•

)

53

Figure 54

25

assemble seal ring in manifold

15.

NOTE

assemble manifold

Apply clean grease to a new seal ring 141 and assemble it in the seal ring groove in the rOior set comacl side of manifold 171. SEE fiGURE 55.

NOTE: The manifold 171 is made up of several plates bonded together permanently to form an integral component. The manifold surface that must contact the rotor set has it's series of irregular shaped cavities on the largest circumference or circle around the inside diameter. The polished impression left on the manifold by the rotor set is another indication of which surface must contact the rotor set.

16.

Figure 55

Assemble the manifold (71 over the alignment studs and drive liQk 1101 and onto the rotor set.

Be sure the correct manifold surface is against Ihe rolor sel. SEE fiGURE 56.

figure 56

)

insert a seal in manifold

17.

Apply grease to a new seal ring 14) and insert it in the seal ring groove exposed on the manifold.

SEE fiGURE 57.

Figure 57

assemble commutator ring

26

18.

Assemble the commutator ring 16) over alignment sluds onlO Ihe manifold. SEE fi GURE 58.

)

assemble seal &

19.

Assemble a new seal ring 131 flat side up, into

commutator 151 and assemble commutator over

commutator

the end of drive link 11 01 onto manifold seal ring side up. SEE FIGURE 59, 60.

mwith

Figure 59

Figure 60

) assemble shuttle valve parts into end cover

20.

II shuttle valve components items m, fl.2, fl.3 , 124 were removed from the end cover 121 turn a plug 121 I with a new o-ring 1221, loosely into one end of the valve cavity in the end cover. Insert a spring 1231 the valve 1241 and the second spring 1231into the other end of the valve cavity. Turn the second plug (21) with a new a-ring (22)

loosely into the end cover valve cavity. 3116 inch Allen wrench required. SEE FIGURE 61. ~gure

assemble relief valve parts in

end cover

)

21.

61

If relief valve components items 121, 122, 124 were removed from the end cover 121assemble a new o·ring 1221 on the two plugs 1211. Assemble a two piece relief valve 1241in each of the plugs, with the large end of Ihe conical spring into the plug first and the small nUl of the other valve piece in the small end of the conical spring. Turn each of the plug and relief valve assemblies into the end cover looselv to be torqued later. 318 inch Allen or 1 inch Hex sockel required.

SEE FIGURE 62.

"

Figure 62

27

assemble seal ring & end cover

22.

NOTE

Assemble a new seal ring 141 into end cover 121 and assemble end cover over the alignment studs and onto the commutator set. SEE FIGURE 63, 64. If the end cover has only 5 bolt holes be sure the cover holes are aligned with the 5 threaded holes in housing 1181. The correct 5 bolt end cover bolt hole relationship to housing port bosses is shown in FIGURE 65.

NOTE: If the end cover has a valve (24) or has five bolt holes, use the line you previously scribed on the cover to radially align the end cover into its original position.

,~"

..

' .'

Figure 63

Figure 64

)

assemble cover bolts

28

23.

Assemble the 5 or 7 special bolts 11, 1A, 1B or 1C) and screw in finger tight. Remove and replace the two alignment studs with baits after the other bolts are in place. Alternately and progressively tighten the bolts to pull the end cover and other components into place with a final torque of 22·26 ft. Ibs. 130-35 N ml for the five MG & MF Series 5/16 24 threaded bolts or 45-55 ft . Ibs. 161-75 N ml for the seven MB & ME Series 3/8-24 threaded bolts. SEE FIGURE 66, 67, 68.

,-

) Figure 66

NOTE

NOTE: The special bolts required for use with the relief or shuttle valve (24) end cover assembly (2) are longer than the bolts required with standard end cover assembly. Refer to the individual service parts lists or parts list charts for correct service part number if replacement is required.

Figure 68

torque the valve plugs

24.

Torque the two shultle valve plug assemblies 1211 in end cover assembly to 9·12 ft, Ib" 112·16 N ml

if cover i, so equipped. SEE FIGURE 69.

Torque the two relief valve plug assemblies 1211 in end cover assembly to 45·55 ft. Ib" 161-75 N ml if cover is so equipped.

THE ASSEMBLY OF THE TORQMOTOR IS NOW COMPLETE EXCEPT FOR WOOORUFF KEY 112A1. NUT 112BI. WASHER 112CI. BOLT 11201. LOCKWASHER 112EI. RETAINER RING 112FI or PORT O·RINGS 118A1 AT INSTALLATION IF APPLICABLE, SEE PAGE 33 FOR FINAL CHECKS.

Figure 69

) 29

Rotor Set Component Assembly Procedure One Piece Stator Construction A disassembled rotor 18A1 stator (88) and vanes 18C) that cannot be readily assembled by hand can be assembled by the following procedures. assemble stator

insert two bolts

assemble rotor

1.

2.

3.

NOTE

assemble vanes

Place stator 1881 onto wea r plate 191 with seal ring (4) side down, after following Torqmotor assembly procedures 1 through 13. 8e sure the seal ring is in place. SEE FIGURE 70.

If assembly alignment studs are not being utilized, align stator bolt holes with wear plate and housing bolt holes and turn two bolts 111 finger tight into bolt holes approximately 180 degrees apart 10 retain slator and wear plate stationary.

CAUTION

Figure 71

)

Assemble six vanes 18C)' or as many vanes that will readily assemble into the stalOr vane pockets.

SEE FIGURE 72.

CAUTION: Excessive force used to push the rotor vanes into place could shear off the coating applied to the stator vane pockets.

assemble full complement of vanes

5.

Grasp the output end of coupling shaft 1121 with locking pliers or other appropriate turning device and rO tate coupling shaft, .drive link and rotor to seat the rOior and the assembled vanes !BCI into stator 1881, creating the necessary clearance 10 assemble the seventh or full complement of seven vanes. Assemble the seven vanes using minimum lorce. SEE FIGURE 73.

remove two assembled boil s

6.

Remove the two assembled bolts 111 if used to retain stator and wear pla te.

Go 10 TorqmolOr assembly procedure 115, page 26 10 continue Torqmotor assembly.

30

Figure 70

Assemble the rotor 18AI, coumerbore down if applicable, into stator !BBI, and onto wear plate 191 wi th rOlOr splines into mesh wllh drive link 1101 splines. SEE FIGURE 71.

NOTE: If the manifold side of the rotor was etched during Torqmotor disassembly, this side should be up. If the rotor is not etched and does not have a counterbore, use the drive link spline contact pattern apparent on the rotor splines to determine the rotor side that must be against the wear plate.

4.

~ 1:'.

figure 72

)

Rotor Set Component Assembly Procedure Two Piece Stator Construction A disassembled rotor set 181 that cannOi be readily assembled by hand and has a tWO piece stator can be assembled by the following procedures. assemble stator halts

1.

insert two

2.

Place stator half 1881 onto wear pia Ie

(9)

with

seal ring 141 side down, after following TorQrnOior assembly procedures 1 through 13. Be sure the seal ring is in place.

alignment

Align stator bolt holes with wear plate and housing boh holes and turn twOalignmem studs finger tight into bolt holes approximately 180 degrees apart to retain stator half and wear plate

studs

stationary. assemble rotor

3.

Assemble rotor IBAI, counterbore down if

applicable, into stator half 1881, and onto wear plate 191 with rOior splines into mesh with drive link 1101 splines.

NOTE

assemble vanes

NOTE: Use any marking you applied to rotor set components to reassemble the components in their original relationship to ensure ultimate wear life and performance.

4.

CAUTION: Excessive force used to push the rotor vanes into place could shear off the coating applied to the stator vane pockets.

CAUTION

)

Assemble six vanes IBCI. or as many vanes that will readily assemble into the stator vane pockets.

assemble full complement of vanes

5.

Grasp the output end of coupling shalt 1121 with locking pliers or other appropriate turning device and rotate coupling shaft. drive link and rotor to sea l the fOlor and the assembled vanes 18Cl into stator half 18BI. crea ling the necessary clearance to assemble the seventh or full complement of seven vanes. Assemble the seven vanes using minimum force.

assemble seal ring in stator

6.

P1ace second stator half (801 on a flat surface with seal ring groove up. Apply a small amount of grease to a new seal ring 141 and assemble it into stator half ring groove.

hall

31

assemble second stator half

7.

Assemble the second stator half 1801 over the twO alignment studs and rotor 18AI with seal ring side down OntO the first stator half I8SI aligning any timing marks applied for this purpose.

CAUTION: 11 the stator half 188) is a different height Ithicknessl than stator half 180) the stator vanes (BC) or (BE) of the same length (height) as the stator half must be reassembled in their respective stator half for the rotor set to function properly.

CAUTION

assemble vanes

B.

Assemble six vanes IBEI, or as many vanes that will readily assemble into the stator vane pockets.

assemble full complement of vanes

9.

Grasp the output end of coupling shaft 1121 with locking pliers or other appropriate turning device and rotate coupling shah, drive link and rOtor to seat the rotor and the assembled vanes 18El into stator 1801, creating the necessary clearance to assemble the seventh or full complement of seven vanes. Assemble the seven vanes using minimum force.

Go to TorqmolOr assembly procedure 115, page 26 10 continue Torqmotor assembly.

)

)

32

Final Checks

Final Checks •

Pressurize the TorqmolOr'1ot with 100 p.s.i. dry air or nitrogen and submerge in solvent 10 check for external leaks.

•

Check TOTqmolOr'M for rotation. Torque required to rotate coupling shalt should nOl be more than 50 fl. Ib,. 168 N ml

•

On MG & MF Series Torqrnotors, pressure port with "A" cast under it on housing 1181 is for clockwise coupling shah rotation as viewed from the output end of coupling shaft. Pressure port with "8" cast under it is for counter clockwise coupling shalt rOiation.

•

On MB & ME Series Torqmotors, pressure port with "8" cast under it on housing !lS) is for clockwise coupling shalt rotation as viewed from the output end of coupling shaft. Pressure port with "AU case under it is for counter clockwise coupling shaft rotation.

•

Use test stand if available, 10 check operation of the TorqmolOPOj .

Hydraulic Fluid

)

Keep the hydraulic system filled with one of the following: •

10W40 SE or SF manufacturers suggested oil.

•

Hydraulic fluid as recommended by equipment manufacturer, but the viscosity should not drop below 50 SSU or contain less than .125% zinc anti-wear additives.

CAUTION: 00 not mix oil types. Any mixture, or an unapproved oil, could deteriorate the seals, Maintain the proper fluid level in the reservoir. When changing fluid, completely drain old oil from the system. It is suggested also that you flush the system with clean oil.

Filtration Recommended filtration 20-50 micron.

Oil Temperature Maximum operating temperature. 2000F 193.3°CI.

) 33

Tips for Maintaining the Torqmotor" Hydraulic System )

•

Adjust fluid level in reservoir as necessary.

•

Encourage all operators to repon any malfunction or accident thai may have damaged the hydraulic system or component.

•

Do not attempt to weld any broken TorqmolOr'1oI component. Replace the component with original equipment only.

•

00 not cold straighten, hot straighten, or bend any TorqrnOiorHoI part.

•

Prevent dirt or other foreign matter from entering the hydraulic system. Clean the area around and the filler caps before checking oil level.

•

Investigate and correct any external leak in the hydraulic system, no matter how minor the leak.

•

Comply with manufacturer's specifications for cleaning or replacing the filter.

CAUTION: 00 not weld. braze, solder or any way alter any Torqmotor™ component.

CAUTION: Maximum operating pressure must not exceed recommended Torqmotor™ pressure capacity.

CAUTION: Always carefully inspect any system component that may have been struck or damaged during operation or in an accident. Replace any component that is damaged or that is questionable.

CAUTION: 00 not force any coupling onto the Torqmotor™ coupling shaft as this could damage the unit internally.

)

Ross Gear extends close technical cooperation and assistance. If problems occur which you cannot solve, please contact our Ross Service Department or local Ross approved Distributor.

Our phone number and telex number and address are on the back cover of this manual.

)

34

Application Data MG Series

MG frns-...

CrIItRICIUS Icklftftnllilll 1, J

(PSI)

lkglcm'l

Interm1tent l!)f1ertnuIIi 1. 3, 4 At COI11I1UOUS filed

Tlr~..

(In·1.kaI

!kg-ml

pressul. and flaw

MilUiTlllm Sllrtl'lO I t COrl1lllUI)IIS rlted pressur.

!.tn.m,rn S1311111\1 JI II'llermment riled prmull

)

Not es: 1. The maximum pressure at the motor inlet or outlet ports without regard to the cominuous or intermittent pressure

ratings is 2300 PSI 1161.7 kg/em'!.

2. For applications with rpm requirements in excess of the maximum rating contact your authorized Ross Gear

representative.

3. Differential pressure is the difference

between inlet and outlet port

pressures.

4. Intermittent pressure applies to a maximum of 10% of every minute.

5. Operating Temperature: Recommended -20"f to 200 "f.

6. Filtration: Recommended nominal filtration is 20 10 50 micrometers.

7. Recommended fluid: lOW40 SE or Sf API designation; 50 SUS minimum at maximum operating temperature; and .1 25% zinc antiwear bV weight.

) 35

Application Data MF Series

MF Pr....'.

IPSn Ikg/an'1

ConlWlUQ\lS [differentlall 1, 3 Irl1erlllllen1I~l!erflll.n I , J,

prmu. IItId oonnnuous T.r~_

illI·lhI Ikg","1

Mnmum SJ31110g

II

conltlUOllS "ltd pressUft

Mrimum nlllllng 11 fl1ermlttlnl filed 91esst111

FI,.

[GPM)

lIiun'!1Wl1

"C~:'::-~----------'~---c~-~-*-~----!ic--I1--i~-?f--*--Io:---ii

-

MIUTlIIII

Notes: 1. The maximum pressure at the motor

inlet or outlet pons without regard 10 the continuous or intermittent pressure

)

ratings is 2500 PSI 1175.8 kg/em'l.

2. For applications with rpm requirements

in excess of the maximum ra ting contact your authorized Ross Gear

representative.

3. Differential pressure is the difference

between inlet and ou:le1 port pressures.

4. Intermittent pressure applies 10 a maximum of 10% of every minute.

5. Operating Temperature: Recommended -20"f to 200"f.

6. Filtration: Recommended nominal filtration is 20 to 50 micrometers.

7. Recommended fluid: 10W40 SE or SF API designation; 50 SUS minimum at maximum operating tempera lUre; and .125% zinc antiwear by weight.

)

36

Application Data MB Series

MB Displ.eellltlt Pr.....

Ii 'I '

I

Cl;v!nnuoos ldiller..utll I, J

!PSI! Ikl1tm'l

Intefmlt1enl Idiflerenllill

t

Torque Itn·lbal Ikg-ml

n

rJt.o pressure Ind CDtlt()IH)IJS

Mimmum ~11111iog II COl11inuoos rated

~essurl

Mirirrum S1II1II'IO It IIlermltlent Illeo prusurl

Flow (GPMI

'Ierslnwll

ContlllUOUS

-t.'.aumum - ---------- 7C-----;::---

Notes: 1. The maximum pressure at the motOr

inlet or oUilel ports without regard to the continuous or intermittent pressure ratings is 4000 PSI 1281.2 kg/em'l.

2. For applications with rpm requirements in excess of the maximum rating contact your authorized Ross Gear

representative.

3. Differential pressure is the difference

between inlet and outlet port

pressures.

4. Intermittent pressure applies

10

a

maximum of 10% of every minute.

5. Operating Temperature: Recommended 0 10 200"1'.

6. Filtration: Recommended nominal

filtration is 20 to 50 micrometers.

7. Recommended fluid: lOW40 SE or Sf API designation; 50 SUS minimum at maximum operating temperature; and .125% zinc antiwear by weight.

) 37

Application Data ME Series

ME Oispl.tellllftl Pr.alr.

(PSD

IkgJan'l

Ii ConlDJOUS Ilkfferlltlilali I. 3

InlermlUem kj,Herlltlllall I, 3, 4 Al conunuOltl Jill~d \lleuorl IOd flow 1

n

pressure and continuous

TorqlM Un· L~aI

Ikg.ml

Mll'llmum 5lallng 81 COOtll'lUOUS rated pr8$$ur.

Millmurn S!a!tlllg 11 IOiermitlenll81ed IKmure

Flaw (GPM) lliler$/mr11

,em~':~~__________--!;~_--!!L_--!!L_~__~_-~--il--~il-_-To

-

Ma.omtfl\

Notes:

1. The maximum pressure at the motor inlet or outlet pons wilhaUi regard 10 the continuous or intermittent pressure ratings is 4000 PSI 1281.2 kg/em'l.

2. For applications with rpm requirements

)

in excess of the maximum rating

comae! your authorized Ross Gear representative.

3. Differential pressure is the difference between inlet and outlet port

pressures.

4. Intermil1ent pressure applies 10 a

maximum of 10% of every minute.

5. Operating Temperature: Recommended 0 10 200"f.

6. Filtration: Recommended nominal filtration is 20 to 50 micrometers.

7. Recommended fluid: lOW40 SE or Sf API designation; 50 SUS minimum at maximum operating temperature; and .125% zinc antiwear by weight.

)

38

(

)

MG, MF, MB, ME Series Service Procedure

.

)'

Write or call for information and added details concerning your installation and applications:

Phone: Telex: Write:

317.423.5377

219413 TRW Ross Gear Oi,i5100 BOO Heath Street Lafayeue. Indiana 47902

) MG,MF,M8,ME 101 WA/5M G.91