CONDOR Scissor Lift 2532B 2548B Operator's Manual - PDF DOWNLOAD

c·' ,"

MODEL ZS3ZB/ZS48B AERIAL WORK PLATFORM US OPERATOR'S MANUAL

CA.LA.VAK CORPORATION 8300 IMPERIAL DRIVE WACO, TEXAS 7671Z (817) 666-4545

MANUAL 9ZZ99-001 ('. ..

JULY 1993

INTRODUCTION The primary purpose of this manual is to provide the user with a thorough understanding otthe proper operating procedures necessaryto'compty with the intended use of the CONDOR®. THIS MANUAL MUST BE RETAINED- ON THE AERIAL-WORK

PLATFORM AT ALL TIMES.'

Do not attempt to operate the CONDOR® until you ,have .read and thoroughly und.tatand all information provided In th,. manua/.~.F.m;llarlze you...." with " the functions and operations of the upper and-lowe, controls. A good underatandlng of the controls, their limitations, and capabilities, will maximize operating efficiency and satety. The various decals attached to thls'machlne are NOT for decoration. They contain vital Informatlon•••• Read the decals BEFORE operating this machine.

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

It Is also YOUR RESPONSIBIUTY to understand and obey all federal, state, and local statutes and regutations pertaining to 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 on its products without any obligation to incorporate new features into products previously sold. Our manuals are continually updated to reflect- these changes.

DO NOT ALTER OR MODIFY THIS UNIT WITHOUT PRIOR WRmEN APPROVAL FROM THE MANAGEMENT OF CAlAVAR CORPORATIONII SERVICE & MAINTENANCE Many of the parts used in the manufacture of the CONDOR® have specific properties, and Calavar Corporation recommends that replacement parts be purchased through it to ensure the original integrity of its products. Repairs and adjustments shoutd only be made by trained and qualified personnel. Please refer to the Ownerls Service Manual for information on service and maintenance of the CONDOR®.

MANUAL t:D" .eI O.......,.,• • IIAIIVAJ,

TABLE OF CONTENTS

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

TABLE OF CONTENTS ................................................. II I. PREPARAnON, INSPECTION" MAINTENANCE ·....................... . 1 A. OVI!RALL..IlACHINE CONDmON ••••••••••••••••••••••••••••••••• 1 B. LOWER CONTROL STAnON .................................. 1 c. PLATPORII "UPPI!R CONTROL STAnON •••••••••••••••••••••••••• 1 D. H'YDRAUUC 81'8 i III ••••••••••••••••••••••••••••••••••••• ••••• 2 E. BATTERIES" CHARGER •••••••••••• ·....................... . 2 II. MACHINE OPeRAnON ............................................ 2 INTRODUCTION

A.

B.

c.

RATED WORK LOAD ••••• lOWER CONTROLS ••••••••••••••• UPPER CONTROL STATION

·........ . .......

·... ...

·............ .

2 2 3

III.

OPTIONAL EQUIPM~ • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •• 3

IV.

EMERGENCY LOWERING

V.

MO~NGFROMJOBSnETOJOBSnE

A.

B.

c.

D.

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

.... ·.. ·.. ... .....·.·... .....·.

•• ·.. .. ·..... ·. ...·.·. ·. ·.

LOADING AND UNLOADING ••••• • •• RAMP M!!THOD ••••• • •• • • • FORKUFT LOADING I UNLOADING METHOD TRANSPORnNG ••••••••••••••••••••••••

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

3 4 4 4

APPENDIX: ANSI/SIA A92.6 • 1990 MANUAL OF RESPONSIBILmES

(

1IIAIfUAI, . . . . . . . .

II

OJlaA'IO"1IAIIVAL-

IMPORTANTr-A COPY OF THE ANSIISIA M2.6 • 1990 MANUAL OF"RESPONSIBIUTIES IS ATTACHED .TO THIS OPERATOR'S MANUAL. IT CONTAINS IMPORTANT OPERATING INFORMATION FOR THIS MACHINE. READ BEFORE OPERATING THIS MACHINE. I.

DECALS· ALL DECALS AND.~WARNING SIGNS ARE IN PLACE AND CLEARLY LEGI-

PREPARATION. INSPECl10N & MAINTENANCE

BLE. THE·· CONDmON OF THE UNIT IS VERY IMPORTANT AS IT DIRECTLY AFFECTS THEOPERATOR'S SAFETY AS WELL AS THE SAFETY OF-: OTHERS. THE -. OPERATOR MUST PERFORM A THOROUGH WAlJ( AROUND INSPECTION EACH DAY PRIOR TO OPERATING THE MACHINE. ANY DAMAGE OR FAULTY OPERATION SHOULD BE REPORTED IMMEDIATElY. A DO NOT OPERe ATE TAG OU1tJNING THE·· PROBlEM SHOULD BE ATTACHED" TO THE LOWER CONTROL STATION KEY SWITCH AND ANY DISCREPANCIES SHOULD BE CORRECTED BEFORE OPERATING THE CONDOR••

CAUTION: DEFECTIVE COMPONENTS,·STRUCTURALDAMAGE. MISSING PARTS OR EQUIPMENT MALFUNCTIONS JEOPARDIZE: THE SAFETY OF THE OPERATOR-AND OTHER PERSONNEL, AND 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.

KNOW THE UNIT AND ITS CAPABIUTIES. REPORTANY UNUSUAL OPERATION; ER· RATIC SWAY OR MOTION OF THE BOOM, ARMS OR PLATFORM.

CHECK THAT ALL.. FUNCTIONS .-OPERATE. PROPERLY, CONTROLS RETURN FREELYTO': NEUTRAL. CENTER, POSmON. PLATFORM & UPPER CONTROL STATION

SOME MAJOR AREAS TO CHECK DAILY ARE:

C;

A.

CHECK ElECTRICAL WIRES AND~ CABLES FOR LOOSE, BROKEN OR FRAYED WIRES.

OVERAU..MACHINE CONDmON

TIRES AND WHEELS· CHECK FOR PROPER TIRE PRESSURE; CRACKS,TEARS OR CUTS; MISSING OR LOOSE LUG NUTS·· (A RUST UNE RUNNING DOWN THE RIM FROM THE LUG NUT INDICATES A LOOSE LUG NUT).

ENTRY POINT BARS AND CHAINS ARE:FUNCTIONAL AND SECURE. CHECK THAT FOOT·· SWITCH OPERATES PROPERLY, GUARD IS IN PLACE.

MISSING, BROKEN OR DAMAGED PARTS ..

CHECK CYlINDER MOUNTING PINS, PIVOT PINS, PIN RETAINERS, WEARPADS, BOLTS AND NUTS.

RECHECK THE STRUCTURAL .CONDmON OF THE PLATFORM; PINS, RAlUNGS,

FlOOR.

CRACKED WELDS ON STRUCTURAL COMPONENTS; ARMS, PLATFORM, CHASSIS.

CHECK RED BUTION • IT DISCONNECTS POWER TO THE CONTROLS AND STOPS THE OPERATION OF ALL FUNC'nONS.

STEERING • CHECK TIE ROO ENDS AND STEERING CYUNDER FOR PROPER AND SECURE MOUNTING.

CHECK THAT ALL CONTROL lEVERS RE-_ TURN FREElY TO THEIR NEUTRAL POSI.. nON.

STRUCTURAL .. CHECK FOR DAMAGE OR

1

MAIRIAL . . . . . . . ..

ORalATO• • IlANVAL-

D.

B..· LOWER CONTROLS

HYDRAUUC SYSTEM

CHECK THE HYDRAWC TANK FWID LEVa. THE LOWER CONTROL STATION HAS A WITH THE ARMS LOWERED. MAINTAIN THE .: SB.ECTOR SWITCH, A 3-POSmON TOGGLEFWID LEVELTO A FW...l.EVEl.r. TO' THE SWITCH, ANDlWO CONTROL LEYERS. MARK ON THE SIGHT GLASS, DIPSTICK, OR WITHIN ONE lNat FROM THE TOP OF'THE TO OPERATe THE LOWER CONTROLS, TANK, DEPENDING ON THE UNIT. ADO.. TURN THe.. SB.ECTOR SWITCH TO' THE SHEU. TRillS 132 HYDRAWC OIL TO THE . LOWER posmON. SYSTEM. ENSURE .THE BREATHER CAP IS IN GOOD CLEAN CONDITION AND IN PlACE THE TWO ARTICULATING UFr-ARMS MAY ON THE.TANK. BE RAISED OR LOWERED, ElTHER"SEPA-RATELY OR TOGETHER. CHECK FOR HYDRAUUC LEAKS AT FITTINGS, VALVES AND CONTROLS. TO RAISE THE UPPER ARM, PUSH UP ON THE TOGGLE SWITCH AND UFTTHE UPPER CHECKAU.HYDRAWCHOSES AND TUBES LEVEL.. TO LOWER, PUSH DOWN ON THE FOR DAMAGE, KINKS, AND PROPER ROUT· TOGGLE SWITCH AND DOWN ON THE SAME ING TO AVOID PINCH POINTS. LEVER.

E.

BAlTERlES & CHARGER

TO RAISE THE LOWER ARM, PUSH UP THE TOGGLE. SWITCH AND UFT THE::..LOWER LEVER. TO LOWER, PUSH DOWN ON THE TOGGLE SWITCH AND DOWN ON THE-SAME LEVERS.

CHECK BATTERY B.ECTROLYrE LEVEI...

ENSURE AU... CAPS ARE PRESENT AND TIGHT ON THE BATTERIES.

TO OPERATE THE UNIT FROII THE PLAT-FORM STAnON TURN THE S. ECTOR SWITCH TO THE UPPER PosmON.

AU. BATTERY CABLE CONNECTIONS SHOULD BE TIGHT AND CLEAN.

THE BATTERY CHARGER IS IN GOOD CON· omON AND THE B.ECTRICAL PWG AND METER ARE NOT DAMAGED. II.

MACHINE OPEBAnON.

A.

RATED WORK LOAD

C.-

UPPER CONTROL STAnON

EMERGENCY POWER BUlTON • PULL.UP - THE.EMERGENCY BurroN TO HAVE POWER TO THE UPPER CONTROLS. IN AN EMERGENCY, PUSH THIS BurroN DOWN TO STOP ALLPOWERED MOVEMENT.

THE RATED WORK LOAD OF A CONDOR. MODEL 2I32B IS 750 LBS. (340 kg), 3 PER· SONS AND FOR A MODEL 2548, 1,000 LBS. (464 kg), 4 PERSONS. THIS MEANS THAT THE PLATFORM WILL SUPPORT A COM· BINED WEIGHT, EQUAL TO THE UNrrs RATED. WORK LOAD, INQ.UDING PERSON· NEl, THEIR TOOLS AND EQUIPMENT, THRC-

FOOT

swrrcH -

DEPRESS AND HOLD

DOWN THE FOOT SWITCH TO' PERFORM ANY FUNCTION FROM THE PLATFORM. TAKING YOUR FOOT OFF THE SWITCH WILL STOP AU. POWERED MOVEMENT.

DRIVE CONTROL - THE DRIVE CONTROL LEVER IS ON TOP OF THE CONSOLE.. TO DRIVE FORWARD OR REVERSE. PUSH OR .PULL. THE LEVER AND HOLD IT-IN THE INTENDED DIRECTION OF TRAVEL; Re.. ' LEASING THIS LEVER WHILE MOVING WILL

UGHOUTTHE~KlNG~OPEOFTHE

C

MACHINE.

2

MAIIUAL.........

OJIDA'I'O. . IIAIIIIAL- .

• • • • • • •

CAUSE .THELEVER TO RETURN TO THE· CENTER posmON AND THE MACHINE TO STOP. STEERING CONTROL - TO STEER LEFT OR RIGHT. MOVE THE SAME (DRIVE) lEVER IN THE I~DEO~ DIRECTION OF TRAVEL WHEN THIS lEVER IS 'RETURNED TO THE CENTERPosmON, THE S lEERING WHEaS REMAIN IN THE DIRECTED UNE OF TRAVEL AND DO NOT RETURN TO A STRAIGHT UNE OF TRAVEL UNTIL MOVED AGAIN; STEERING IS NOT SB.F CENTERING.

DECK EXTENSION STROBEUGHT 110 VOLT UNE TO PLATFORM SaF CLOSING GATEHOURMETER LOW VOLTAGE WARNING CHARGER OVERRIDE-

MANUAL BRAKE RELEASE/FREEWHEEUNG • CAUTION: WHEN USING THE FREEWHEEL OPTION THECONDORe MUST·· BE ON LEVEL GROUND. TURN THE·BRAKE VAlVE KNOB CLOCKWISE AND DRIVE THE CONDOR. ABOUT 3 FT. THIS WILL DISABLE THE BRAKE. THEN TURN THE FREE· WHEEL VALVE KNOB FULLY COUNTERCLOCKWISE. THIS WILL ALLOW THE CON· DORGD TO BE MOVED. DO NOr-exCEED 5 MPH (8.0 Km/Hr.).

PLATFORM RAISE OR LOWER - TO RAISE THE UPPER ARM, LOCATED ON THE BACK SIDE OF THE·. PLATFORM CONTROL CONSOLE.. TO LOWER THE UPPER ARM, PUSH THE LEVER DOWN. TO RAISE THE LOWER ARM, PUSH UP ON THE LOWER LEVER LOCATED ON THE BACK SIDE OF· THE·.PLATFORM CONTROL CON-· SOLE. TO LOWER THE LOWER ARM, PUSH THE LEVER DOWN.

HORN· THE MANUAl HORN PUSH BUITON IN THE UPPER CONTROL BOX IS A WARN..

ING HORN.

THE TWO ARTICULATING UFT ARMS MAY BE RAISED OR LOWERED EiTHER SEPARATELY OR TOGETHER.

THE CONDOR. IS EQUIPPED WITH EMER· GENCY LOWERING VALVE(S) LOCATED AT THE HOLDING VALVE ON THE UFTCYUN· DER(S). TO OPERATE THE EMERGENCY LOWERING VALVE(S), DEPRESS THE RED KNURLED KNOB. AND TURN IT COUNTER· CLOCKWISE UNTIL IT POPS OUTSUGHTLY (1/8 • 1/4 INCH). THE UFT/LOWER CONTROL LEVER AT THE LOWER CONTROL STATION CAN NOW BE MOVED TO THE -LOWER- PosmON AND THE PLATFORM WILLLOWER. (NO ELECTRICALACTlVATION IS NECESSARY.)

IV.

WHEN THE UPPER AND LOWER UFT ARMS ARE RAlseo-:: AND LOWERED eQUAL AMOUNTS, THE PLATFORM WILL MOVE DIRECTLY .VERnCAL. .. WHEN THE UPPER UFT ARM IS RAISED MORE THAN THE LOWER, THE PLAFORM NOT ONLY RAISES BUT ALSO MOVES HORIZONTALLY OUT OVER THE STEERING AXLE... SIMILARLY, IF THE LOWER UFT ARM IS RAISED MORE THAN THE UPPER, THE.PLATFORM MOVES HORIZONTALLY OUT OVER THE DRIVE AXLE. THIS HORIZONTAl MOVEMENT GREATLY INCREASES THE OVERALL WORK ENVE· LOPE OF THE CONDORGD. III.

EMERGENCY LOWERING

v.

MOVING FROM JOB SITE· TOJOS SITE

A.

lOADING AND UNLOADING

ALTHOUGH THE CONDOR. IS SOMEWHAT SMALL IN STATURE COMPARED TO lARGER CONSTRUCTION EQUIPMENT, IT REQUIRES THE SAME CARE AND ATTENTION IN lOADING, TRANSPORTING, AND UNLOADING, AS

OPTIONAL EQUIPMENT

THE FOll.OWlNG OPTIONS ARE AVAILABLE ON THE CONDORGD AERIAL WORK PLATFORM:

MA.NVAL . . . . . .

3

OPBBATOa.IIANV.A.I,

DOES THELARGER;: HEAVIER EQUIPMENT. AND BE POSITIONm:-AS CLOSE~TO THE (" ' AT NO ,TlME.aKlUI.DJTS SIZE,BE UNDER· " INSIDE OF THE nRES,AS POSSIBLE...ESTIMA~, Ba:oRE LCADINGIUNt.OAD THE CONDOR8, INSPECT THE UNIT FOR .; NOTE: DO NOT ATTEMPT TO UFT THESE MODB.S. FROM EITFIER END.. , ANY PHYSICALDAMAGE-OR DEFECTS.,

WHATEVER 'MEANS, IS USED TO LOAD/.

UNLOAD THE:UNIT,-SHOULDBEOF S~ CIENT STRENGTH· TO . WITHSTAND THE WEIGHT OF- ,:THE.,;~CONDOR.,·- WHICH IS, 4,480 LSS.: (2CDI-kg) FOR A 2532AND 5,600 LBS. (2540 kg) ,FOR 'A 2548. ..

B.

THE CONDOR8 SHOULD ONLY BE-RAISED TO::A HEIGHT'SUFFICIENT TO CLEAR ANY OBSTRUCTIONS.:'-

KEEP' FORKlJF'rTRAVEL WI1H. THE CON-COR8·1.QADED TO,A MINIMUM4ANO ser GENTLY DOWN TO 'GROUND lEVEL

RAMP METHOD D. '

ENSURE THAT THE~ RAMP BEING USED,IS SUFFICIENTLY STRONG ~TOHANDLE_THE WEIGHT OFTHE UNIT. THE RAMP SHOULD BE SET AT AN ANGLE, NO STEEPER THAN THE MACHINE'S RATED GRADEABIUTV OF 11- OR 21%, OR A RISE OF 25 INCHES IN 10 FEET (1 M IN 4.8M).

BEFORE DRMNG THE UNIT ON THE RAMP, LOWER THE- PL\TFORM COMPlEI'ELY SO THAT THE .CONDOR. IS IN LOW SPEED. TEST THE.DAMNG AND S lEERING CON-.TROLS AND THE. BRAKE SYSTEM. MAKE SURE THAT FREEWHEELING VALVE IS CLOSED. DRIVE UP OR DOWN THE-.RAMP SLOWLY ALLOWING FOR STEERING CORRECTIONS TO BE MADE. KEEP UNIT IN AUGNMENT WITH THE:.CARRIER AND RAMP DURING LOADING AND UNLOADING PROCEDURES.

C.'

TRANSPORTING

THE CONDOR. CAN BE EASILY AND SAFElY TRANSPORTED,.FROM THE JOB SITE IF THEFOU.OWlNG RULES AND PROCEDURES ARE FOLLOWED: BLOCK AI..L. WHEB.S TO PREVENT FORWMD AND REVERSE MOTION. TIE DOWN

THE~.CQNDOR.

WITH CHAINS

1

OR CABLES, RUNNING THEM THROUGH THE TlEOOWN BRACKETS ONLY. DO NOTCHAIN OR STRAP OVER THE PL\TFORM OR GUARD RAILS. , SEVERE DI-.MAGE' TO, THE' SCISSOR ARMS MAY RESULT FROM EXCESS PRESSURE,CUE.TO SECURING ,THE_ UNIT OVER THE~OP OF'THE PL\TFORM. ALWAYS TURN~POWIR'~ATTH~ GROUND CONTROLSTAnON.

FORKUPT LOADING I UNLOADING METHOD

ENSURE THATTHE'FORKUFT HAS SUFFICIENT C~AClTYTO HANDLE THE WEIGHT OF THE CONDOR•• (SEE PAGE 4).

THE CONDOR. SHOULD. ONLY BE UFTED FROM THE SIDE, POSmONING THE FORKS UNDERNEATH THE. CHASSIS. THE FORKS SHOULD BE:: LONG ENOUGH TO GO, ACROSS THE.FUlL..WlImf OF THE FRAME

(

4-

MAIIUAL.II •••.. OJIDA. . . . IIAIIVAL-

,

(

-.

. MODEL ZS3ZB/ZS48B AERIAL WORK PLATFORM

US

PARTS

CALAVAR CORPORATION 8~O IMPERIAL DRIVE WACO, TEXAS 76712 (817) 666-4545 MANUAL 92299-001 JULY 1993

CALAVAR CORPORATION

Self-Propelled Booms and Scissors WARRANTY Calavar Corporation ("CaIavar") warrants to the purchaser that each new aerial work platform made by Calavar is free from defects in material and workmanship arising under norrnaI use and service, in the case of major weldments (chassis, turret and booms), for a period of five (5) years after the original shipment of the aerial work platform from caJavar's plant, and in the case of all other parts. for a period of one (1) year after the aerial work platform is first placed In service or two (a) years after the original shipment of the aerial work platform from caJavar's plant. which fINer occurs first.

The obligation and liability under this Warranty Is expressly limited to repairing or, at calavar's option, replacing free of charge, at its factory in Waco, Texas or at an authorized repair facility designated by Calavar, the defective part. In no f!N8nt shall calavar or its suppliers be liable to the purchaser or any other person for transportation charges or for any Incidental, collateral, special or consequential damages, including without limitation damages for loss of profits, loss of customers, loss of goodWIll or work stoppage, claims by any party other than the purchaser, or any other similar damages or loss flNen if Calavar. its suppliers or its representatives have been advised of the possibility of such damages.

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

Any operation of the equipment beyond rated capacity. improper use or application of the equipment, substitution upon it of parts not approved by calavar or alteration or repair of the equipment by any person not authorized by CaIavar shall, at caJavar'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 CaIavar.

No agent, employee, distributor, dealer or other representative of caiavar is authorized to modify this Warrar4y in any way. Accordingly, additional statements or presentations by any such representative, whether oral or written. do not constitute warranties by CaIavar and should not be relied upon as limited warranties of calavar, and no attempt. effort or promise to repair equipment by Calavar or any such representative at any time shall modify or extend this Warranty in any way. If the purchaser has used Its own order form, no additional or different warranty terms contained in purchaser's form will be honored by calavar. This Warranty covers only new and unused aerial work platforms manufactured by Calavar.

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

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

1300 ImperiIII DrMI. P.O. Box 21447. Wet:o. Ta,. 71702-1447. (117)

eee 4545. (100' 177-5&44. Fax (117) ee&-4&44

CONTENTS DESCRIPTION FIGURE GENERAL ILLUSTRATION .................................................................................................................. 1 CHASSIS INSTALLATION .................................................................................................................... 2 STEER INSTALLATION ........................................................................................................................ 3 STEER CYLINDER ASSEMBLY ..................................................................................................... 3a DRIVE INSTALLATION ........................................................................................................................ 4 BRAKE ASSEMBLY .......................................................................................................................... 4a HYDRAULIC INSTALLATION ............................................................................................................. 5 GROUND VALVE ASSEMBLY ....................................................................................................... Sa CREEP SPEED VALVE ASSEMBLY ............................................................................................... 5b SERIES PARALLEL ., ........................................................................................................................ Sc FREEWHEEL VALVE ....................................................................................................................... 5d ELECTRIC INSTALLATION ................................................................................................................ 6 WHEEL INSTALLATION ...................................................................................................................... 7 WHEEL HUB ASSEMBLY ................................................................................................................. 7a COVER INSTALLATION ....................................................................................................................... 8 ARM INSTALLATION ........................................................................................................................... 9 UPPER & LOWER CYLINDER ....................................................................................................... 9a MANUAL BLEED DOWN INSTALLATION ................................................................................. 9b CREEP VALVE ASSEMBLY ........................................................................................................... 9d PLATFORM INSTALLATION ............................................................................................................... 10 CONTROL V ALVE ASSEMBLY .................................................................................................... lOa CONTROL BOX ASSEMBLY .......................................................................................................... lOb DECAL INSTALLATION ....................................................................................................................... 11 OVERLOAD PLATFORM ASSEMBLY (OPTION) .............................................................................. 12 ELECTRICAL SCHEMATIC ................................................................................................................... 13 HYDRAULIC SCHEMATIC .................................................................................................................... 14 ROTATING BEACON INSTALLATION (OPTION) ............................................................................. 15 BATTERY INDICATOR INSTALLATION (OPTION) .......................................................................... 16 110 VOLT LINE TO PLATFORM INSTALLATION (OPTION), .......................................................... 17 TRAVEL WARNING HORN (OPTION) ................................................................................................. 18 DESCENT WARNING HORN INSTALLATION (OPTION) ................................................................ 19 KEY SWITCH INSTALLATION (OPTION) .......................................................................................... 20 SLOPE SENSOR INSTALLATION (OPTION) ...................................................................................... 21 220 V AC CHARGER INSTALLATION (OPTION) ............................................................................... 22 SLIDE OUT EXTENSION DECK (OPTION) ..................................................................................... 23 2532 GERMAN TUEV SPECIAL (OPTION) .......................................................................................... 24 2548 GERMAN TUEV SPECIAL (OPTION) ................;......................................................................... 25 STROBE LIGHT (OPTION) .....-.;.; ......... ;.............. ".; ................................................................................ 26 JAPANESE OPTIONS .............................................................................................................................. 27 ITOCHU ELECTRICAL SCHEMATIC ................................................................................................... 28 ITOCHU LOWER CONTROL BOX ........................................................................................................ 29

FIGURE 1 GENERAL IIJ.USTRATION PART NUMBER DESCRIPnON 1 2 3 4

53094 53098 53100 53223

Q1Y

(

Cbassis Installation (See Figure 2) ••.••....•.•••.•........••••••• 1 I.jft Installation. (See Fig1lre 9) ..................................... 1 Platform Installation (See Figure 10) ...••••.••.•..••.••••••••• 1

2

1993

FIGURE 2 CHASSIS INsrAU.A1l0N

lITEM 1

2 3 4

5 6 7 -8 -9 - 10 - 11

Q1Y

PART NUMBER

DESCRIPTION

53094 .

53230 52586 53242 52587 -.

53096 53102.

52590 53104 52152A 53253 BOW36002 BOW34272

Chassi, Weldment, • 25328 .......................................... ~ Chassis Weldment - 2548B ............................................l Steering Installation - 25328 (See Figure 3) •..•••••••••_. 1

steeJ:iDg ..fDsta,IJadon - 2S488 ..........................................1 Drive fDstaUariOD (See Figure 4) ...................................l Hydraulie Installation (See Figure 5) ~ ......................_.1 FJec:tric Installation (See FiglJl1! 6) ................................1

Wheel fDstalJariOD (See Figme. 7) .................................1 Cover fDstal1ation (See Figure 8) .............................._.1 Busbing, F1aD,ged ......................................................... 4 Battery Hold Do-wn ........................................................l Bolt, Hex .2S-20UNC x .750 ........................................ 2 Nut, Hex l.ock .2S-20UNC .............................................2

. Indicates Items Not Shown

2 i

1993

,.

5(2PL)~

I

j-

6(4.pL)~

13C2PL14

I I

UPPER CONTROL VALVE

eb

I• I

~ I

!

I

~

--...,..~

,.,.

"'-... -tt

4(4PL)

FIGURE 3 STEERINSfAUATION

ITEM 1 2

3 4 5

6 7 8

9

10 11

12 13

PART NUMBER

52529 52583 53243 52688 52135 B0W36109 BOW36715 B0W36605 B0W30027 B0W36726 0244452781 52780 52592

DESCRIPTION

QTY

Kin.g Pin Weldment •..•••.••••••.•••.••..•.••••••••.••.••..•••••••••••••• 2 TIe Rod Assembly. - 25328 ........................................... 1

Tie Rod. Assem.blY - 25488 ........................................... 1 Cylind~, Steer ••.•..••••••••••..••••.•.••.••••.••••••••••••••••••.•••••.•••• 1 B'lSbing, Flang-ed. ••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4 Bolt, Hex .SQ..13UNC x 2.25 ........................................-2.

Washer, Flat .50 10 x 1.06 00 ••••••••••••••••••••••••••••••••••••• 4 . .

Nut, 1/2-13 ................................................................. 2 Bolt Hex .31-18UNC x. .75 ............................................ 2 Washer, Split l..ock .31 ID •••••••••••••••••••••••••••••••••••••••••••• 2 Elbow 90 M.JM MP06 ••••••••••••••••••••••••••••••••••••••••••••••••• 2

I..H. Yoke Weldment •••••••••••••••••••••••••••••••.•..•..••.••••••••••• 1 R.H. Yoke Weldment ....••••••..••..••••...•.•...•.•.••.......•..•••••• 1 B'UShin.g •• •••••• ••••••••• ••••••••••••• ••••••••••••••••••••••••••••••••• •••••••• 2

1993

FIGURE Sa S lEER. CYLINDER ASSEMBLY ·16

1993

[TEM

FIGURE 3a STEER CYLINDER ASSEMBLY PART NUMBER DESCRIPTION

- 1

52688

2 3 4 5 6

Assembly, Steerin.g C"Ylinder •••••••••••••••••••••••••••••••••••••••• Ref. Weldment, Tube •••••••••••••••••••••••••••••••••••••••••.•••.•.•••••••••• 1 Nut:, Piston l.oelt •••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1

Piston ....••.••..•••••••.••••••.••••••••.••••••..•.••..•••••••.•.......•.••••••• 1 Head ••••••••••••.•••••••••••••••••••••••••••••••••••••••••••••••.•••••.•.••••••• 1 Nut, Head (attaching parts) •••••••••••••••••••••••••••••••••.••••••• 1 Saew, Set (attaching parts) ••••••••••••••••••••••••••••.•.•••.••••• 1 Weldment, Shaft •••••••••••••••••••••••••••••••••••••••.••••••••.••••••••• 1

7

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

Q1Y

50230 B0W38231 14829

21 22

Pin, Clew. ........•.......•.•.••.••.......••..•.............................• 1 Pin Cotter ••••••••••••••••••••••••••••••••••••••••••••••••••••••••.••••••••••• 1 Kit, Seal (Includes Items 12-22) .................................. 1 Set, Piston Seal.................................... ..••.•...... ..... ...•..• 1 Seal, Piston •..• ••••••••••••••••••••.••.......••.•......•..•...•.•.•.•.• 2 O-Ring, Piston •••••.••.••••••.••••.•••.••••••••.• •••............ ...••• 1 O-Ring, Small ••.• ••••••••••••••••••••.••••••••••.••••••• •..... ....•.. ..•..• 1

Wash.er, Steel •••••••••••••••••••••••••••••••••.•.••••••.•..•..•......•••••• 1 O-Ring, Head ••••••••••••••••••••••••.••••.•.••.•••••••.••.. ... ..••.... .•••• 1 Ring, Lock-Head ••.•••••••••••••••••••••••••••••••••••••..•.......•••.•..• 1 Set, Sllaft Seal .••.• ••••••••••• ••••... .•••.••••....•.••.....•........ ••.. •.• 1 O-Ring, Shaft •••••••••.•••••••••••••••••••••••••••••••••. ••.•••• .••••• 1 Seal, Shaft.. ••• •••••••••• .••••• ••••.••.•.. ..•••.•••............•••• ••••• 1 Wiper, Rod ••••••• •••••••••••••••.•••••••••••..• •••••.••• •••.... ....••..• •••• 1

- Indicates Items Not Shown

J.993

FIGURE 78. WHEEL HUB ASSSEMBLY

5

6

lO-_,--"..a/

R.H. YalE WELDIDT Ref.

1993

lITEM

PART NUM8ER

1

476-00021-00 5009S 52547 52549 91029 476-00021-08 QTJ01016 B0W382S'0

2 3 4 5

6 7

8

FIGURE 7 WHEELINSTALLA110N DESCRIPTION

Q1Y

I.

Tire 400 X 8 Mo1JD.t •••• ••• ••••••••••••••• •••••••• ••••• •••• ••••••••••• •••• 3 Hub, Steering', Scissors •.••••••••••••••••••••••.•••••.••...•••••••••••• 2 Hub, Drive •••••••••••••••••••••••••••••••••••••••••••••••••••••.••••••••••••• 2 Cone Bolt •••••••••••••••••• ••••••• •••• ••••.••••.•. •••• •••• •••.. .••.••.•••. •.•• 10 Nut:, Lug 1/2" •••••••••••••••••••••• •••••••••••••••••••••••••••••••••••••••• 10

llI1! it 'Wheel Assy, Brake, ............................................ 1

Nu't, Slotted ................................................................. 2 Pin, Cotter ••••••••••••••••••••••••••••••••••••••••••••.•••.•..•••••..•.•••••• 2

1993

FIGURE 7 WHEEL INSTAU.AnON

CHASSIS WFlDIBT'

Ref.

\ 1993

I

FIGURE 6 ELECTRIC INSfALlATION

lITEM

PART NUMBER

DESCRIPTION

1 2 3 4 5 6 7 8

52627 54279 50075"

Battery', 6v ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4 ~, 24V/40A· ••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1 S'Witch, R#67760 •••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1 Guard, Toggle S'Witch. Miao •...••••••••••••••••••••••••.••••••••••• 1

-9

50089

40880

Q1Y

Ope:Eamr, Se1ect.ar ••••••••••••••••••••••••••••••••••••••••~ •••••••••••••• 1 Block., C()Dt'8,ct 2nd. ...................................................... 1

52670 52029 52138

Solenoid, 24v .............................................................. 1 Strip, TeI!IliDal ••••••••••••••••••••••••••••••••••••••••••••••••••••••••__ 1 f1lSC! Holde!" •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••. 1

34552-010

10 322-00001-00 -11 52821 12 52682 -13 52683 -14 52684 -Indicates Items Not Shown

Motor-El.ec:aic Ohio ••••••••••••••••• ~•••••••••••••••••••.•.••••••••••••• 1 Cable .AsseD1bly, Battery' .•••••••••••••••••••••••••••..•••••••••••••••• 1 Cable .AsseD1bly, Battery' ••••••••••••••••••••••••••••••.•.••••••••••••• 4 Cable .Assembly, Battery' .•.•••••••••••••••••••••••••••.•.••••••••••••• 1 Cable .Assembly, Battery' ....•••.••••••••••••••••••••••••••••.••••••••• 1

2 4 PL

6

~()

7

~s 3

1993

FIGURE Sf BRAKE VALVB

lITEM 1 2 -'"" 4

5

PART NUMBER

DESCRIPTION

00128 04601 52661 04148

Fitting, Eloow 90 MJ'06 MP04 ............................................. 1 Fittings; Straight MP04 FJ06 Swivel .................................. 1 Valve, Flow Contl'Ol •••••••••••••• 1 Fittin.g, Straigb.t FJ06 MJ'04 .••••••••••••••••••••••••••••••••..••••••••••••• 1 Fitting, Tee Mli.06 FJ06 'Mli06 .......................................... 1 Fitting" Straigb.t .M:EI06 M006 •...••••••••••••••.••••••••..•..•••••••••••• 1

6

00488 02448

7

21481

8

02662

Q'IY

<»er''"o··· •• ••••••• ••••••••••••••• e ••••••••••••

Valve, Shuttle ...................~................................................ 1 Fitting, Eloow 90 MJ'06 M006 ...••••••••_.............................. 2

/3

I

/if

6

5

1993

FIGURE Se COUNTERBALANCE

IITEM 1

2 3

Q1Y

PART NUMBER

DESCRIPTION

34062 02576 02580

Valve, Dual CoUDter~alance ................................................ 1 Tee-WOO MQ()6 M.JOO ••••••••••••••••••••••••••••••••••••••••••••••••••••••• 2 Tee WOO M.J06 M006 ••••••••••••••••••••••••••••••••••••••••••••••••••••••• 2

2 2 PL

1993

FIGURE Sd FREEWHEEL VALVE

I ITEM 1 2

Q1T

PART NUMBER

DESCRlPTION

00314 21479

Fitting, Elbow 90 W04 MP04 ....................................• 2

Valve, Needle.-l/4 NIT................................................ 1

I

2

1993

FIGURE Sc SERIES PARAU..EL

lITEM 1 2 3

PART NUMBER

315-00037-00 02448 02662 -4 B0W30010 -5 B0W30054 -6 B0W31327 -7 B0W31413 8 450-00058-00 -Includes Items Not Shown

DBSCRIP'llON

Qrr

L

Valve, Traft$m;ssi~ •••••••••••••.••••••••••••••••••••••••••.•••••••••••• 1 StJ:aigh.t.MJ'06 M006 ................................................... 5 Elbow 90 MJ'06 M006 ••.••••••••••••••••••••••••••••••.• .•.••••.•••••• 1 Bolt, Hex .2S-20tJNC x 2.50 •••••••••••••••••••••••••••••••••••••••• 1 Bolt, Hex .38-16UNC x 1.00 •••••••••••••••••••••••••••••••••••••••• 2

Washer, SpHt 1.oc:lt 3/8 [.0. •.•••••••••••••••••••••••••..••..•••••••• 2 Washer, Flat .38 1.0. x 1.000.0.......•.......................... 2 Valve, POSI Cartridge ...••••••••••••••••••••••••.••••••...•...••••••••• 1

1

1993

FIGURE Sb CREEP SPEED VALVEASSEMBLY

lITEM 1 2 3

QIT

PARTNUMBI!R

OESCRlPT[ON

315-00035-00 00344

Valve, Creep .... ••••.•..•..•..•.••.. ..... ....•.....•....•..•.•.............. 1 Tee MJQ4. fJQ4. MaiM .................................................. 2

04134

Sttaigh.t MJQ4. MOOS ..•....•...............•........................... 2

1993

FIGURE Sa GROUND VALVB ASSEMBLY

IITEM 1

2

QTY

PART NUMBER

DESCRIPTION

54231 53225

Valve, l..o:wer Cont::l;'Ol.......................................................1

Handle, I..ift.~ •••••••••~..........................................•...•...•.••••2 . .

I

mm/

/

I:

/'

/

2

..I I

/

-s:;

:,

2

I

1993

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

FIGURE 5 HYDRAUUC INsrAUATION

PART NUMBER

DESCRIPTION

45~51~0

Valve, 1/2 Ball-Shut Off••••••••••••••••••••••••••••••••••••••••••••••• 1 Tauk, Hydmulic. •••.•••••• •••• •••••••• ••••• •••••••.••• ••••••• •••••• ••••••••• 1

53090 B0W31248 B0W31325 53092 B0W3oo12 020-R0047-OO 020-A2001~0

020-A401S-OO 33430 lS2~OOO7-OO

54286-205 34062 21479 34966-415

Nut, .Hex. .•25·20UNC .................................................... 7

Washer, Split welt .25m ...••.......••••••••..••••••.••....•...•.•..• 7 Valve Assy, GI01lI1d. •••••••••••••••••••••••••••••••••••••••••••••••••••••• 1 Bolt, Hex .25-20 UNC x 3.000 ••••••••••••••••••••••••••••••••••••• 3 Assy, Creep Speed Valve •••••••••••••••••••••••••••••••••••••••••••••• 1 Assy, SIP Valve ............................................................ 1 Assy, Freewheel Valve .•••••••••••••••••••••••••••••••••••••••••••••••• 1 Fiter •••••••••••••••••••••••••••••••••••••••••••••••••••.••••.••••.••••.••••••••• 1 cap, on Fillu 703-1314 ..•••••••••••••••••••••.•.••.•.••.•...•••••.•• 1 Pump, Fixed Displ. (.205) GEAR ................................. 1 Valve, Dual CollIlteJ!!lance •.••••••••••••••••••••••••.•••••..••.•••••• 1 Valve, Brake 1/4 NPT .•.•.••••.....••............................•••.•• 1 Orifice Fig Assy 02793/.070 ........................................ 1

-[ndicates Items Not Shown

11

3 14

I

9

z

1993

FIGURE 4b BRAKE.. CYLINDER ASSEMBLY ITEM

-1 2 3 4

5 6 7 8

9 -10 11 12 13 14

15

PART NUMBER

DESCRIPTION

52613 93101 Ref. Ref. Ref.

Brake Cylindel" Ass~bly .•.•••••.••••••••••.•••••••••••••.••.•••••••• 1 Head (Wit:b. Bl,sbing) ••••••••••••••••••••••••••••••••••••••••••••••••••• 1 Bearin.g, Rod •••••••••••••••••••••• ••••••••••••• ••••• ••• •••••• ••••••• ••• ••••• 1 R,oci, Piston... •••••••••••••••••••••••••••••••• ••••• ••••••••••• .•••••. ••• ••••• 1

93103 93104 93105 Ref. 52195

Pis'ton .......................................................................... 1

QIT

8auel .•.••••••••••••••••.•••..••.•.••....•.••••••...•.•••.•..••..•........••.••. 1 Nut, Piston Rod ••••••••••••••••••••••• •••••••••••• •••••••• ••••••• ••• •••••• 1

cap .............................................................................. 1 R,oci, Tie •••••••••••••••••••••••••••.•.••.•••••••••••••••••••.•.......••..•••••• 2 Kit, Seal (Includes Items 11 thru 15) ........................... 1

Washu, Rod Seal Backup ........•.....•..•.•••••••................•• 1 Spacer, Rod Seal.............. ••••. .•. •.•• ••.•.•..•• ••• ••...•.......•.. ••• 1 Seal, Rod •••.•••••.•••••••••...•.••.•••••.••..••••.•••••••••.......••••.•••••• 1 O-Ring Seal ••..••••..•••••.••.••••.••...•.••••••••••••••..•......•.••••••••• 2 Seal, Piston •••••..•••••••••••..•••••••.•••.•••••••..•••••.••..••...•..••••••• 2

1993

FIGURE 4b BRAKE CYLINDER. ASSEMBLY

4

14·

8

1 ) ~

5 9

1993

I

FIGURE 4a WHEEL MOTOR ASSEMBLY

ITEM

PART NUMBER

DESCRIPTION

-1 2 3 4 5

50043

Assem.bly, Drive Motor •.•.•••••••••••••••••••••.•••••..••••••••••••••• Ref. Ho11S:ing ••••••••••••••• ~••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1

QTJ01011 QTJ01012 QTJOIOIO

~t,

6

QTJ01007

Key •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1

QTJ01013 QTJOI014

Shaft, Coupling ••.••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1 Bearing •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1 'fhrust, Bearing .••• ••• ••••.••••••••••••••••••••• ••• ••• •••••.•.• •••••••••••• 1 I.JDlc, Drive ••• ••••••••••••••• •••••••• ••• ••••• ••••••• ••••••.•. •••.• •••••••••••• 1

7

8 9 10

Q1Y

Bearing •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1 Bearing •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1

Nut, Hex Slotted ••••••••••••••••••••••••••••••••••••••••••••••••••••••••_ 1

11 12 13 14 15

Plate, Wear ••••••••••••.••••..•••••..••.•••••••••••••••.•.•..........•••.•••• 1 Set, Rotor .. ..••.••••••••••••••••.••••••.••.••••••••••••.. ..•.•...•.•••••••••• 1 Rotor •..••••••••••••••••••••••••••••••••.••••••••••••••••••.••••.•.••••••••••••• 1 Van.e •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 7 Assembly, Stator ........................................................... 1

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

Set, Mauif'old •••••••••••••••••••••••••••••••• ••••• ••••••• •••••••••• ......... 1 Plate, Manif'old •.•••••••••••••••••••••••••••••••••••••••••••••••.••••••••••. 1 Manif'old ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••. 1 QTJOIOOS QTJ01016

52206 QTJOI017 QTJOI021 QTJOI018 QTJOI019 QTJOI017 QTJOI004 QTJOIOlS

Set, Comm.umtor ••••••••••••••••••••••••••••••••••••••••••••.•••••••••••• 1 Commutator ....•.•••.••.••.•••••••••....••••••••••••••..••.....•.••.••••••• 1 rung, Seal •.• ••••••••••••• •.•••.•••••.• ••••• ••••••• ••••••••••.....•...•• •••••• 1 Ring, Commumtor .. .•......•...•..••••••••••.••••••...••.•........•••••• 1 Sleeve ....••••••••••..•.•..••..••......•...•.••.•..•..•....•••.................• 1 Assembly, End..Cover .....................................................1 Bolt, 5pec:ial.••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••. 7

Ki1:, Seal....................................................................... 1 Seal ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••.•••••••••••••• 1 Ring, Retaining.. •••••••••••••••••••••••••••••••••••••• •••••••••••••••••••• 1 W~, Backup ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1 W~ •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1

Seal ............................................................................. 1

Ring, Seal ••.••••••••••••••••.•••.•.••••.•• ••••••••••••••. •••••• .............. 2 Washer, TIlnlst... .•• .•••.....••.••.•• .••••• ••.••.. •.•..•...•. .•. .••••..••• 2

-lndicates Items Not Shown

1993

FIGURE4a WHEEL MOTOR AS SEMBLY

P?!?;o,

27

2 32

za

30

~,

33

31

4

5

I

/(

3

...

11

10

~,

'"

f

l

...

23

32

25

1993

6 7

I ITEM 1 2 3 4

FIGURE 4 DRIVE INSfAUATION PART NUMBER

DESCRlPTION

Q'IY

50043

Motor, Drive . ......... .......... ... ...... ...... ....... ........ ... ...... ...•.. 2 Assy, B~ Cylind.er ......................................................1 B014 Hex .SO-13UNC x 2.50 ........................................ 8 Scr, Cap, S/16-18UNC x 1 LG ...................................... 2 Bolt, Soc HD 1/4-20UNC x 1.50 .................................. 1

7 8

53150 B0W36110 B0W36029 BOW33606 B0W31348 B0W36725 00314

9 10

04149 00498

5 6

I...ockw'asher, Ex'teznal. Type .SOID ................................. 8 Was:her-, Split Lock .25ID ............................................• 2 Elbow 90 MJQ4. MPM ................................................... 2 Strai.gh.t MOIO FP06 ...................................................• 4 Elbow 90 MJ06 MP06 .... ..... .... ........... ....... ........ ..... ......... .....• 4

8

(z.PU

lITEM

FIGURE 7a STEERING HUB ASSEMBLY PART NUMBER DESCRJPTION

QTY

-1

50095

SteeringHub~bly ••••••••••••••••••••••••••••••••••Ref.

2

91022 91023 91024

Seal, Oil......................................................... 1

3 4 5 6 7

52701 91029

91100

8

BOW36720

9

BOW31289 B0W382S0 91027

10 11

Cone, Outer BeariI1g.•••••••••••••••••••••••••••••••••••••2.

ClIp, Outer Bearing.........•..........•......•............2 Stud., Whecl••••••••.•..•••...•.••......••.•.........•..•..••..5 Nut,. ~...............- ......................................s Hub, A Frame Flange••••••••••••••••••••••••••••••••.•••• 1 Washer, FlaL................................................. l Nut, Hex Castlc..............•.....•........................ l Pin, Cotter'.....................................................1 Cap, S tecring D'USt.•••••..•••..•.•..••.••.•..••..•...•.•••. l

1993

FIGURE 8 COVER INSfAIlATION

ITEM

PART NUMBER

DESCRIPTION

1 2

53089

Cover, Side ....................................................................... 2 I..a.tch, Door •••••••••••••.•••••••••••••.•.•••••••••• " .......................... 2

54048

Q"IY

o

1993

7

H1Q"l:

r

21

®

.

2.2.

I.I

~

I•

~

I

)

""

-:.

i

23

2.

CJfASSIS PIYUI'· WElDElT Ref. (P/I:5Z7II,

2.,

©

~,

FIGURE 9 ARM IN5rALLATION

ITEM 1 2 3 -4

5 6 7 8

PART NUMBER.

DESCRIPTION

53220

ArD1~Weldmenr

53219 52128 52733 53214 53216 53218 B0W34991-1

Q"lY I.

••. ;........................................................ 2 Arm., l.eYe1iDg' ••••••~.........................- ..........................-....-4 CyJiDd.ex', I..ift................................................................ 2

Valve #SVOS-20M-2P·N·24DS ......._._................._ 2. _ Pin WeJdmeDtj· Uft Cylinder Plated ............................. 4Pin Weldment, .AIm. Pla.ted .........._ .......................... a •• 2' Pin We1dmenr, Leveling Arm Platecl ............................ 4 Pm, Spiml.l/4" X 3" LG •••_ .......--......_....................... 4 HoseAssy, #04, 11.50IN, ST~~........................._ l

-9

67616-042

-10 -11 -12 -13 -14 -IS -16 -17

01159

~W06

02416 02662

-r'EIt WQ4. M.J'Q4. MJ"Q4. •••••••••••••••••••••••••••••••••••••••••••••_ 2 Elbow' 90 M.J'06 MOO6 ..............................................._ 2

04174 01160

Saaight MP04 MPM ................................................... 2, Saaight M.JM MPM .................................................._ 2 Ra'ai.cI:aI: Assy ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••_ 2.

·18 ·19

52819

52661 01159 B0W24119

20

B0W36057 53099

21

67998"()()1

22.

52S11A 23 52S12A ·24 34966-412 -Indicates Items Not Shown

M.J'06 MJ"06 ................................................. 2

Valve, flow Conttol •••••••••••••••••••••••••••••••••••••.•••••••••••••_ 2 -r'EIt MJ'06 M.J'06 MJ"06 ................................................. 1 Clamp, Hose 2ID to 2.2Sm •••••••••••••••••••••••••••••••••••••__ 1 Bolt, Hex. .38·16UNC x 1.750 ••••••••••••••••••••••••••••••••___ 1 Mid. Pivot Weldmeut ..............................................__ 1 Sc:rew', 1brd. Prmn,g .38-16 x 1.OLG ••••••••••••••••••••••••__ 10 Bteng, F1aDged. ......................................................... 6 Bl ming, P1mpcl ......................................................... 12 Odfic:e Ftg Assy MIS1/.070 ......................................_ 2

1993

FIGURE 9a UPPER. AND LOWER.CYLINDER.:

10

~ll 14

I

~

...

1993

I

~

FIGURE 9a UPPER AND LOWER CYLINDER ITEM -1

2

3 4

5 6 7 -8

QTY

PART NUMBER

DESCRIPTION

52128 SBW01004 SBW01007 SBW01008 SBW01009 SBW01005 SBW01006 52168

Assembly, Uft Cylinder - Upper and Lower ...............•. Ref.

Fitting, Grease •.••••••••••••••••.•.••••••••••..•.•...•.••••.•...•...•••••• 2 Weldment, Rod •...••.••.•••..••••.•...•.•••.....••..•.....•..•......•.••• 1 Weldment, Tube ••••.•••••.•.......•.••..•.••....•.•.......•.....•..•.•••• 1 Cap, Head •.••••••••.•.••••••.•..••..••••••••.•••.•••.•.•••..•.•....••••••••• 1 Head •••••••••••••••••••••••.•••.•••••••••••••••••••...•••.••...••.••.•••••••••• 1

Piston ...........•............•..............•.................................. 1 Kit, Seal (Includes items 9-18) .................................... 1

9

Nut, Lock •••••••.••••••••••.••••.••••.••••..••••••••••.••••••••••••.•••.••.••• 1

10

Screw Set ....•..•••.•••.•.•..•..••.•..............•.••..••..................• 1

11

Plug, Nylon..... •••••••.• ••••. .•• •••...•..••..•.........•.....•.......•....•. 1

12 13 14 15

Wiper ..••.•••••••••••••••.••.••.••••••••••••.••...•.......••.•......•......••.•• 1

16 17

U-Cup, Polypak Type B .............................................. 1

Ring, Back-Up ••••...•..••.•.....•......................................... 1 O-Ring ••••••••••••••••••••....••...•....•.•...•••...••..••.••................•. 1 O-Ring, Piston ••••••.•.•.•.•..••.•.....•.•..'................. ...... ...•..•. 1 Set, A.Q Seal .•..•.•...••..•..•.........•... ••....•......................•• 1

Ring, Wear ••...••.• ••• .••••.•.••.• ••••..••.. •••..•..•....• .•....... •••• ••.•• 1 18 -Indicates Items Not Shown

1993

FIGURE 9b MANUAL BLEED DOWN INSTALLATION

LOWER CYLINDER Ref.

1993

FIGURE 9b MANUAL BLEED DOWN INSTALLATION liTEM

PART NUMBER

-1

DESCRIPTION

4 5

52819 04174

Manual Bleed Down Installation ................................. Ref. Valve, N. C ................................................................... 2 Coil (Only) ................................................................... 2 Restridor Assembly .................................................... 2 Connector, Straight ..................................................... 2

6

52661 01160

Valve, Flow Control ..................................................... 2 Connedor, Straight ..................................................... 2

2

52733

3

7

- Indicates Items Not Shown

1993

FIGURE 10 PLATFORM IN5rALIATION

1993

FIGURE 10 PlATFORM INSTALLATION [TEM

PART NUMBER

DESCRIPTION

1

53105 53231 53101 54302 52090 51476-001 ZUA01001 50588-006 BOW2548 50286 BOW31115 245-00007-00 LBL01008 315-00035-00 53117 53235 53125 53236 52988 34552-010 34966-407 0034404134 00480 54278

Platfonn. Weldment - 25328 .... .......... ........... ••.. ....••••••• 1 Platform. Weldment - 25488 ..... •.... ..... ..... ........ ..• •..•••••• 1 Control ,Assy •••••• ~....... ••••••••• ••• •••• •••••••••••••••••••••••••••• ••• •••• 1 Deck, Plattonn..... ...... ... ...... ......... ....... ....... ......... ....••.... 1

2

3 -4 5

6 7 8 9 -10 -11 -12 13 -14

-IS -16 -17 -18 -19 -20 -21 -22

Q1Y

Plug, Protective ..•••........•. ... ........... ......•......... ....•.•••••..• 6 Pin, Quick. Release .25DIA x 1.50 ••.•••••••.••.•••••••••••••••••• 3 l.an.yard, Quick. Rel Pin. 6.00 LG ••••••••••••••••••••••••••••••••••• 3 Chain, Steel •••.••••••••.....••.•....•.••••••.•....•.....•............••••.•• 2

S-Hook ••••••••••••••••..••.••••••.•.....••••.••••••.....•....•.•.•.••••••••••• 2 Cbs] D, Snap ••• •••••••••••••••••• •••• ••••••••••••••••••••••••••••••••••• ••••• 2 Ser, FIt Slf Tap .25-20 x 1.5 LG ................................... 4

Covert - Sna.p Plated ••.•••••••••••••••.•...••••••••.•.••••.•.•••••••••••• 1 Bolt, "U" 2.000 x 1/4-20UNC ....................................... 1 Creep Speed •••.• •••••.... .•.•••.•.•.•••••.•••••• •••.•••••.••••.••.•• ••••••• 1 Toe Plate, Moveable - 2532B ....................................... 1 Toe Plate, Moveable - 2548B ....................................... 1

Rail, Guard .. 25328 ••.•••••••••.•••••.••••••••••••.••.•••••••.•.•••••••• 1 Rail, GuHd - 25488 •...•..•..•.•.••..••••••.••.........••...••.•.••••••• 1 Weldment, Moveable Guardrail •.•••..••••••••••••••••••••••••••••. 1 Smp, Tel1llinal ••••••••••.•.••••••.•••••••••••••••••••••••••••••••••••••••• 1 Ori.fice ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1 Tee, FJ04 MJ04 MV04 ••••••••••••••••••••••••••••••••••••••••••••••••• 1

.Adapter, S'Il1light MJ04 MOOS ••••••••••••••••••••••••••••••••••••• 1 Plug, MOOB ••.•••••••••••.•.••••.•••••••••.••••••••••••••••••••••••••••••••• 1 Cover ••.••.••••.••••••.•.••..•.•••••.•..••••••••••.•••••.•...•••..••.••••••••••• 1

- Indicates Items Not Shown

1993

FIGUREIOa. CONTR.OLVALVE ASSEMBI·Y

I

r=l..==3

/

10

1993

FIGURE lOa CONTROL VALVE ASSEMBLY

ITEM 1 -2 -3

-4 -5

PART NUMBER

DESCRIPTION

54230

Valve, Cont:I'Ol....... ••..• .............••••........... ........ .....•. .•.•.•. 1 Miao Switch ..••••.•.•..••....•.....•...........•............•.......•....• 3

BVDOI029 02448

00456

Sttai.gh.t MH06 M'006 •••••••••••••••••••••••••••••••••••••••••••••••••• 4 Sttai.ght MJ04 M006 ••.••••.•.•••••••.••.....•...•.•.........••.......• 2

02298

Elbow 90 MH06 FJ06 •••••••••••••••••••••••••••••••••••••••••••••••••• 2

-6 B0W31120-2 -7 BOW31341-1 -8 B0W31242 -9 53224 10 53225 11 54394 -Indicates Items Not Shown

sea., SLT, RND #04-4.() x .625 •..•..••••.••.••.••.•••••..••••••••• 6 wasW, I.oc::k-Extem.al #4 ..••••••••••••••••...•••..•••••....••.•.••• 6 Nut #4-400UNC ••••••••••••••••••••••••••••••••••••••••••••••••••.••••••••• 6

Hand.le, DrivelSteer ....•••••.•.•.•••••••••••..............•.•.••••.•••• 1 Handle, Lift Handle, Lift

................................................................. 1 ................................................................. 1

1993

FIGURE lOb PI.ATFORM CONTROL BOX ASSEMBLY

@

o

5, 6, 7

, 6, 7

1 , 11. 12

5 Pl 15

2 9

a

a

o 8

1

~17Ref.

!

I

1993

FIGURE lOb PLATFORM CONTROL BOX ASSEMBLY PART NUMBER

DESCRIPTION

1 2

52580 52594

Conttol Box Assembly .................................................. 1

3 4 5

Ref.

6

BOW31327 BOW36603 52745 52595 BOW30002

Washer, Split Lock, Grade 5, 3/8 •.••••••••...•••...•...•••.•••••• 2 Nut, Lock, Grade 12, .38-16UNC •••••••.••••••••••••.••••••..••••• 2 Guard, Control Box 38-3/4 Lg...................................... 1

BOW31373 BOW31201

Washer, Split Lock, Grade 5, 1/4 ................................. 5 Nut, Hex, Grade 5, .2S-20UNC ..................................... 5

51913

Knob, P'USh-P'Ull. .....•.•.•...••••••...•.••.••.•............................• 1

7

8 9 10 11 12 13 14 15

53093 BOW30052

-16 51914 17 36084 18 36083 19 67295-019 -Indicates Items Not Shown

Bra.cket, Control Box ....•......•.................•..................•.•. 1 Decal, Control Box (See Figure 11) .............................. 1 Valve Assembly (See Figure lOA) ................................. 1 Bolt, Hex, Grade 5, .38-16UNC X .75 ••.•....•.........••.••••.• 2

Cover, Control Box ....................................................... 1 Bolt, Hex, Grade 5, .25-20UNC X .75 ........................... 5

Block, Contact, N.C...................................................... 1

Guard, Poot Switch. ...................................................... 1 Switch, Foot ................................................................. 1 Cable, 2 Condo 16AWG Type SO •..•..•.•.•..••.•••...••••••.••••• 33 LF

1993

FIGURE 11 DECAL INsrAU.ATION

13

22

28.

26

8 80TH

SIDES BOlli

.~t""----- 20

9

SIDES

7 80TH SIDES

2

26

19

BOTH SlOES

7

2 PL

23 BOTH SlOES

8

5

14 15 16 17 18

11

9

10

10 BOlli SIDES

30

29

21

1993

FIGURE 11 DECAL IN5rALLATION

lITEM 1

2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

PART NUMBER

DESCRIPTION

50172 52567 52569 52568 54182 21882-001 54297 52635 52759 67846 58399 21850 50070 53227 34354 67793 BOW31411 BOW36725 BOW31201 58419 35656 53191 53190 54292 54299 54280 21882-002 54186 54318 54320 54319

Decal, Condor .•••.••••..•••••••••••••••..•.••..•••••..... .... ..•.. ... ••••.• 4 Decal, Chlck... ••••• •••••• .••• •••••••.••. ••••.•••••.•••..••••.......•.••••.•.• 2 Decal, 2532 ••••••••• ~ •••.•••••••••••••••••••••••••••.•••.•.••••••••••••••••• 2 Decal, 2548 •••• •••• ••• •••••• •••••....•••.•••••.•••....•..•...•..•.. ••• •••••• 2 Decal, Battery- Cl1aJ:ger Plug ••••••••••••.••••••••••...•.•••••••••.••• 1 Decal, Keep Cleu ••••••••• •••• ••••••••• ••••••• ••••••••• ••••. ••••••••••••• 2 Decal, Upper Control Oper lnstr .................................. 1 Decal, Plate Capacity 750 LBS •••••••••••••••••••••••.••••••••••••• 1 Decal, 5 tanci Cleu •• •••••••••• ••••••••• ••••••••••••••• •••.•• ••• •••• •••••• 2 Decal, Caution Tie-Do'Wll Ring ••••••••••••••••••••••••••••••••••••• 2 Decal, rae Replacement, Solid •••••••••. ..•••.•••••.• •..•.••••.••• 4 Decal, Hydraulic Fluid ••••••••••••••••••.•••••••••.••.••••••••.•••••••• 1 Decal Battery- Service .... .•••.• •••.• •••.•••.......•••..•.•.......•••. ••• 1 Decal, Upper Control Box .•.••.•••..•..••......•.•............•.••••• 1 Holder, Safety Manual - Blk Caps •.. .••..•.•••... ..•.•... ........ 1 Clamp, Cable 2·3/4 ...•••••••••••••••.•••••...••..........•..•.••••••••• 1 Washer, Flat .25 ID x .75 00 .•..•••••.•..•.••.••.........•.•••.•••• 1 Washer, Split Lock. .25 ID •.•••••••••••••.••.....••...•.....••.•••..•• 1

Q1Y

Nut, Hex .25·20UNC •..•.••..••..•••...•.•...•...•.•...........•••..••• 1 Tape, ORN/R.ED 5" •••••••••••••••••••••••••••••••••••••••••••••••••••••• 28

Ft:

Decal, Made In U.S.A. 6" ..•••.••••••••••.•..••..••.•...•....••••.•••• 1 Decal, Control Station ....••••••••••••••.•••...•..........•••.••••••••• 1 Decal, Control Box ••• ••••••.• ••••.••••.••..•.....•......•....•..•.•• ••••• 1 Decal, Em.ergen.cy Lowering ....•••••••••••••• .••..•. ......• .••••••• 1 Decal, Lower Control Oper Instr ••..•.••.•••.. .................... 1 Decal, Caution •••••••••..•.••.•••.••..••. .••.• .•...•.••..... .....•.•.••.••• 1 Decal, Danger Not Inslllated •••.•••..••••.••••••..•.•.....•••••••••• 1 Decal, Caution Guard Rail Use •.•...•......••.•..•....•...••.•••••• 1 Decal, Free 'Wh.ee1ing ••••••••••••••••••••••••••••••••••••••••••••••••••• 1 Decal, Free 'Wh.ee1 Valve ...•..•..••••.••••...•..•.........•..•.••••••• 1 Decal, Bra.ke VaJ.ve ...•• .•..• •••••.••••••••••••..•..•.....•....••.•• •••.•• 1

1993

... .a.'"'u ..., ........ .e.. v y .......'&..vnu

I.

Lon. J ...'vJ'\..lVl

rt~.;)J::.1YlDL

(OPTIOf

&

y"

, 8 9

J

'.

...,\ ---:=::'-=::.--; -r- \ {---'~:r-

I

I

I

\

._- --..:==---: '17t~ 2

-

'I

--

'-:-tr!

-I ~_ '"

Ie~ , _ -

,

I

I

-; ;l~

II

i

!!

-:1 _____ _ -jr----_

.11 I.

6 ,

I

,

I ,I

r--rr

T-- lC'i::-..

c

--i-,

r?!--l

r-.I/Q11: 1 I\M/~ ~---1::,;"-" (..')1 __ ~

!

I

,0

I

II

1'-

3.6875

--------_.....

:sHoW'" INITH 251 LBS. ON FUlLi ~XTENDED DECK

J. wL

I r-

3/ I

I

Z.

13

O.7SOO

1.5000

I I

I

'1

6.5000

------i

..J

9.8750 _ _ _ _ _ _ _ _ _ _ _ _ _

0.6550

I iI

--.

1

- t .0000 -

~

; WACO. TEXAS

JVERLOAD LAYOUT. EXTENSION

[5 ,,_ ... L091793A ..... fW.

1 OF

1

1

FIGURE 12 OVERLOAD PLATFORM ASSEMBLY (OPTION)

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

PART NUMBER

DESCRIPTION

53277 53282 51036 51038 37838-026 54399 67114-002 67123-001 67124-001 54402-001 BOW36607 BOW31418 331-00002-00

Overload Weldment, Left Hand ............................................ 1 Overload Weldment, Right Hand .......................................... 1 Limit Switch (Body Only) .................................................... 6 Head, Limit Switch ............................................................... 6 Compression Spring .............................................................. 2 Stop Switch ........................................................................... 1 Strain Relief, .50" NPT .25"/.375" ........................................ 6 Seal, Electrical Connector .50" ............................................. 6 Connector, Locknut ............................................................... 6 Bolt, Shoulder .75" -10UNC x 2.50" long ............................ 2 Nut, Hex .625" - 11 UNC ....................................................... 2 Washer, Flat .75" ID x 2.00" OD .......................................... 2 Bolt, .375" x 1.50" Elevator .................................................. 2

- Indicates Items Not Shown

QTY

~BEACON7STR08EOPTrON ~

R2-A

Jf-~ R2-B

~15

~~~---~-4-aRCU~'T------~IIIIIIIIIIIIIIII_IIIIIII lOA

~

------0

3-POS

I ..,....

I

a.tERGENCY STOP

I

(

OiARClNG UGHT

BREAKER

"'" """""

~

_-ISTCH'

~g>yBJK ~l ____

--------r

PLAlFORM RAISING

BATTERY OiARGER

.1 = GROUND

--_._--

PLAlFORM LOWERING

~ SEE NOTE 3

a.tERCENCY

HYD PUMP

--.:::::;-

_" \ J p . - - - -

--t--,---.-~*o>---..J

~ ~!~Y

NEG

-----ii --- - ----.0.--- ~

HOUR IA

1 y'~ SYttTOi

OPllONAL BATTERY CONDIllON INDICATOR

~

-,

GRN

115 VAC PLUG

....T

DESCEND WARNING

OPllONAL OIARGING CUT-OUT RELAY COIL

CREEP SPEED

SEE NOTE 5 SLOPE ALARM OPnON SLOPE SENSOR OPnON

SEE NOTE 4

~

(7)

(6)

•

LOW VOLT SENSOR

II

LOW VOLT WARNING

)-----------+;

LOW VOLT OVERRIDE

SEE NOTE 4

--<D-1

J-----------tCA)

I----------ilil SEE NOTE L---_o Q ..... o IS

....

180188-024f

l!Pl&S& 1. THIS SOiElAAllC IS STANDARD FOR MDL2532-B. MDL2548-B OiICKS. AND MDL2032 SCISSORS LFT. REfIR 10 DIAGRAM 53280.

2. SWiTOiES AcnVATED BY VAl.VE LEVERS IN PLAlFORlA. MDL2032 HAS ONLY ONE SWITCH. 3. CHICKS HAVE lWO HOLDING VAl.VES, MDL2032 ONLY ONE.

SIGNAL HORN OPnON

4. (j)THRu(1) REPRESENT

lERMINAI.S OF OPnONAI. LOW VOLTAGE WARNING/lNTERRUPT SENSOR/SWITCH. 5. UFT UulT SWITCH IS SHOWN WITH PLA lFORM ALl THE WAY DOWN. 6. PRESSURE SWITCH SENSES BRAKE RELEASE PRESSURE.

lRAVEL ALARM OPnON GROUND

L

i•

_ _._

I

.,Z!

.r.--==

r.:.==-"._'~I"," _ - __ '~~IIWA =~..Ir"""~=

o

C 1 8

8207

5110

7/21/13 RAK 07f%1/fl RAK

l

A

4027

07{1J/fl RAK

L1ft. " : : - .." : . ' : L1ft.I ........ 110.

.:-

(

(

_ _...- : : :

~~

WACO, TEXAS

11111£

SCHEMATIC, CHICK-B/2032 EL

--"::JI,,-==- B1__ "'" 54317-----·---=.

J.CANIICAL-r--'

HET

1 Of' 1

.· ;

•

UPPER c.:oNmOl.. VJ.J..V£ 54230

ORIVE M01'Oft 11.7 """ 50<>13-2 Pl

--.--::--~

:V1

I j

SHUTru:

VAL\£ 21481

C2i ~V2 L_____ J

UPl'fiR

1lWISIISSIIlH

VALVE 315-00037-0<>

1I!lUl!32-8 DlA

-....17 .070 NIlI.t54&-B .Q08 34H8-4-11 0lA.

+-----..--...

\.OW!'!!

!. I

<J

F£;E= r=£=fF

SJROt(£: 3.

,J

un en.

~

--t- $ fLOW COO'IRQ. VA!.\£ ~2ell 2 Pl

!212.8

eatt:

;:--l

4.00 ROO: 2..00 STRoKE: 13.2!

• PI.

.010

HaJ)flC

v!tJ..V£. !27JJ 2Pl

2 PI.

I

.

I

T_ 030lIO (5.0 GAl..)

RC!>. 1.00

---~ $-~jr

_'--___L __,L.L t!

5_ .1W! C'tt.. _ 2.00

LOWER CONlRa.. V,fL\o£ 54231

'

---

.... _ _ • .....----

"""""'1«Y "*,l!,l!£'ti

--.~

naIt~

:-":'~.=:fR~= Hf.

"

tw'

8

5901:

,11-.

A

57"11

09t\13/9l R.C

~

,~

'.ll

__

WACO, TEXAS

1m.£

HYDRAULIC SCHEMA TlC 2532/2548E

ltUJWfCp: (1ft . . , . . . . . . . . . . . . . . . . .

• .,..II::tJIo

CIU'':;;'' DAl£ --:: L"'- ....... 00.

~O~ '"='" ..

-

~

RUSS

-

=~~

-lIJj:.

I'I6m

BI"'~HO. 54285-'--"-"~= IREVB XN:L

ruu.

i lOIQ;T

1 Of" 1

lITEM

FIGURE 15 ROTATING BEACON [NSfALLATION (OPTION) PART NUMBER DESCRIPllON

-1

2 3 4 5

0-.

• ~ta.U1lg

4098450512 BOW31144 67295-019

Q1Y

Beacan JDSfI . n' n_& __ Baon ........................................ 1'\,C.l.

P1a.te, Beacon Motmring ............................................... 1 Beac:an, Rota..~ 24V ~ ............_••••••••••••••••••_...... 1 Screw, Round Head, Grade 5, #10-32UNF X .S ••••••••••• 3 Cable •••••••••••••••••••••••••••••••••••••••••••••••••••••• ..................... 4l...F.

. lndicates Items Not Shown

PLAiFUIII I&D&T Ref.

2

,1993

FIGtJR£l6 BATl'ERYINDlCATOR. INSTAI.t.AncN (OPTION)

z 2 Ref.

GROUltD COIITRDL

Ref.

lITEM

FIGURE 16 BA:I1E1tY' INDICATOR. INSTALLATION (OPTION) PART NUMBER. DESCRIPTION

Qrr"

52748

Kit, Battery' fndiatD:r' .....................................................R.ef.

Met:er',,' Battery' ...............................•••••........................... 1 ~ .2 Cond.. 16 AWG Type SO ......._-_..........--._.4.0LF Rela.y, Low Volta.ge ..............................~....................... 1

B0W31144

Scre'w', Ro1:lDd,..Heac::l, Gmd~ ....................................... 2-

B0W31255

Nut, KepI, Grade..S1> #10-32UNC :.···_.···......_ ......._ ...__2.

-1 2

52772 52747

3 4 5

67295-019

6

• Indicates Items Not Shown

1.993

4.

4

Ref.

RAt

I

FIGURE 17 110 VOLT UNE TO PlATFORM IN5rAUATION (OPTION) ITEM

l.

PART NUMBER.

DESCRIPTION

XS2709 52710 67703 67295-017 GAK01004

110-Volt I..\De. To PlIltform. ••••••••••••••••••••••••••••••••••••••••••• Ref. Plug, 3-Prong Male. 110 ................................................,~ TIe, Cable (Wi~ Weld Stud) .•••••••••••••••••••••••••••••••••••••.• 1 cable, 3 COND. 12,GA. ••••••••••••••••••••••••••••••••••••••••••••••• 1 CoYer', Rec:e,ptacle.......................................................... 1

7 8 9 10

80361 40956 BOW31146 BOW31362 BOW31430

Receptacle, Duplex Pemale 15 AMP / 12SV ..................1 J-aox, 110V Recepm.cle ...............................................-1' Screw R.ouDcl head, Grad.e 5 .........................................2.'<Washer, Split I.ock #10 ............................................... 2,,, Washer, Plat #10 ......................................................... 2 . .

11 12 13

6711+003 52735 67123-002

R.elief St:E1liD,. 1/2 NP'I' .371 X .50 •••••••••••••••••••••••••••••••• 1

-1

2 3 4 5

6

Q1Y

Decal, 110 Volts Power to Platform. ............................. 1

Seal, 1/2" .. .••••••••••••••.••••••••..•.••••••••.••.••.• .•.•.. ..•.•...••.••••• 1

- lndicates [tems' Not Shown

1993

FIGURE 18 TRAVEL WARNING HORN (OPTION)

t-----. ___. . r----...". _ _....

1--- •

'~IM

___

~

••

2 :11. _ _.

~

I ,.-

21

11 '

+- - '....I

'±C"-

---

JII. IIA ...,

~'"

~'S/.-

ITEM NUMBER

CAlAVAR PART NUMBER

DESCRIPTION

1 2 3 4 5

Assembly, Travel Warning Hom

1

80188-o'2.¥

. Wobulator & Speaker

QUANTITY

Ref

1

I ITEM

FIGURE 19 DESCENT WARNING HORN INSTALlATION (OPTION) PART NUMBER DESCRIPTION

Q'lY

5

51813 B0W30002 B0W31401 B0W31325

Descent Warning Hom Installation .......................•.••..• Ref. Alarm.. 12 I 24 VDe ...................................................... 1 Bolt, Hex,. Grade 5, .25·20UNC X .7S •• •••••••.•.•••.....•..••• 2 wasW, Flat .25 X .63 ................................................... 2 wasW, Split Flat .25 .•.••••••••••.•••••.•.•••••••••••••••••••....•••••• 2

6 7

B0W31201 50120

Nut:, Hex, Gmde S, .2S-20UNC •••••••••••••••••••••••••••••••••••• 2 Diode •..•••.••••••••.••••••••••••••••.•••••••••••••••••••••••••••••••.•••••••••• 2

-1 2 3 4

- fndicates items Not Shown

______ CRASS I S ,~

WELDMEKT Ref.

6

2

1993

I ITEM 1

2

FIGURE.20 KEY SWITCH IN5rAI.LATION (OPTION) PART NUMBER DESCRIPTION

54111 52029

. Q1Y

S'Witch, Key. ••••••••••••••• •••••.••••••••••.••••••. •.••••••••••... .••.••••••• 1 Block, 2. N.O.Contact ••••••••••••••••••••••••••••••••••••••••••••••••••• 1

'"

Co.

CHASSIS WElDMENT Ref.

I

1993

2 Chassis Weldment

"

lITEM -1 2 3 4 5

6

FIGURE:21 SLOPE SENSOR INSTAU..ATION (OP'IlON) DESCRIP110N PART NUMBER

32002 67701-016 B0W31401 B0W31325

Q1Y

Slope Sensor Installa:tion ••.•.•••••••••••••••••••••••.••...•.•.••••••• Ref. Seasor, Slope 2-A:I:is ........................................................1 Stud Weldment .25-20 X .S TFTC ................................ 2 Wasbeza, Fla.t .25 X .63 .................................................. 2 Wasbeza, Split l.oc:k. .2S·~.................................................2

B0W31201 67590 B0W31144 B0W31400 B0W31323

Nut, Hex, G.rade 5, .25-20UNC •••••••••••••••••••••••••••••••••••• 2 Relay ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1 Screw, Round Head, Gra.de 5 ........................................ 2

Nut, Hex, Grade S, # 10-32 •••••••••••••••••••••.•••.••...•.•••••••• 2 Alarm., 12.-24'VDC ........................................................ 1 Bolt, Hex, Grade S, .S20UNC X .7S .......................... 2

-15

BOW31288 51813 B0W30002 B0W31401 B0W31325

Washer'. Flat .25 X .63 ••••••••••••••••••••••••••••••••••••••••••••••••• 2 Wasbeza, Split Lock. .25 ••••••••••••••••••••••••••••••••••••••••••••••••• 2

-16

B0W31201

Nut, Hex, Grade S,

-7 -8

-9 -10

-11 -12 -13 -14

Wasbeza, Flat, #10 ••••••••••••••••••••••••••••••••••••••••••••••••••••••••. 2 Wasbeza, Split Lock. #10 •••••••••••••••••••••••••••••••••.••••••••••••• 2

.25~20UNC

•••••••••••••••••••••••••••••••••••• 2

- lndicates [tems Not Shown

1993

FIGURE22:22Q VAC CHAR.GmtINSTALLAllON (OmaN)

2-

,oo~

FIGURE 22 220 V AC CHARGER INSTALLATION (OPTION) lITEM

-1 2 3 4 5

QTY

PART~NUMBER

DESCRIPTION

Ref. 52817 BOW31341-1 BOW31242 67939-020

220 VAC Battery Charger Installation ................................. 1 Charger, Battery 220V, 50HZ .............................................. 1 Washer, External Lock #4 .................................................... 2 Nut, Grade 5, #4-40UNC ...................................................... 2 Fuse, 20 AMP (AGC-20) ...................................................... 1

- Indicates Items Not Shown

FIGURE 23 SLIDE OUT EXTENSION DECK (OPTION)

lITEM 1

2 3 4 5

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 -23

-24 -25

-26 -27 ·28 -29 -30 -31 -32

PART NUMBER

DESCRIPTION

53118 52939 52948 52938 52949 54203 B0W31.418

Deck, Extension (includes Items 2 thru 5) .................._1

B0W30160-375 B0W34278

Bolt, Hex, Gmde 5, .75 ••••••••••••••••••••••••••••••••••••••••••••••••• 2

Q1Y

r

Roller, Slide •.••••••••••••••••••••••••••••••••••••••••••••••.•••••••••••••••• 2 End., Slide ..................................................................... 4

PiD.................................................................................2 Bwing, InD.er .Roller ................................................... 2 RoUer, Guide, Slide Out •••••••••••••••••••••••••.•••·••••••••••••••••_2 Washer, Flat .7S-10UNC x 3.75" ••••••••••••••••••••••••••••••••••• 4

124-00028-00

50638 BOW31327 B0W36751 B0W32273 54067 B0W36751 BOW31327 B0W30055 53122 52984 51476-009 ZUA01001 54263 54265 54262 B0W30009 B0W34272 B0W34375 B0W31444

Nut, Elastic Stop 3/4 - 10 ............................................. 2 Bl,shln g 1 x 3/4 x 1 ••.•.••...•..•.•••.•..••..•....••...........•..•...••• 2

Cam,. Follower •••••••••••••••••••••••••••••••••••..••••••.••••...•.••••••••• 2 Washer, Lock 3/8 •••••••••••••••••••••••••••.••••••..••.•••••••••••••••••• 4 Washer, Flat 3/8 .••.••••••.•..••••..••.•......••.•.•..•.•....•.••.•••••••• 4 Nut, Hex 3/8 ••••••••••••••••••••••••••••••.••.••••.••...••••••.••••••••••••• 4 Washer, Flat 3/8 •••••••••••••••••••••••••••••••••••••••••••••.•••••••••••• 4 Washer, Lock 3/8 ••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4 Bolt, Grade 5, 3/816 xl 1/4 .••••••••••••••••••••••.•..•••••••••••• 4 Slide Channel Weldmenr •••••••••••••••••••••••••••••••••••••••••••••• 2 Cb,annel, Roner' Weldment ........................................... 2 Pin. Quick Release .31 x 2 •••.••••••••.••.•.••...••.•..•.•.•.••••••••• 4 Lan-yard,y Quick Release Pin 6 LG •••••••••••••••••••.•••••••••••••• 4

Pad., Slide Wear ••••••••••••••••.••.•••••.••••••••••...••.•.....•••••••••••• 2

Ronu, We...................................................................2 Pad, Button Wear ......................................................... 2 Bolt, Hex, Grade S, .25 - 20UNC x 2.25 ..................._ •• 2 Nu't, Hex I..oc:k, .25 - 20UNC ••••••••••••••••••••••••••••••••••••••••• 2 Screw, R.d HO, Slotted., .25 - 20UNC x .375 ....••••••••••••• 2 Washer, Flat:,

.25m x .630D •..••••••••••••••••••••••••••••••••••••• 2

- lndicates Items Not Shown

1993

FIGURE 23 SUCE-OUT EXTENSION DECK (OPTION)

0

oj

<>

I""

~

19 20 21

0

18

22 6

7 9 10 11

14

15 16 17 2 3 4

5

1993

Figwe 24 • 2532B German..TUEV SpcciaLOptions ITEM

1

2 3 4

5 6 7 8

9 10 11 12

13 14

15 16

PART NUMBER

DESCRIPTION

A.9:z6..2532 52671 54362 34836 52672 38051 52983 321-00013-00 321-00022-00 289-OOOO3"()1 289"()()()()7"()1 91029 476-00021-00 53150 53264 53268 126-10005-00

German TUEV Special Operator. Key Switch Hom, 24V 133DB Automotive Operator, White Pushbutton Block, Contact 2NO Coupling, Threaded Thst~Point Operator. Push 1Wist Motor-P: 114-7-HSO Motor·Brake P: 115·7-ASO Hub. Drive #1. Assy Hub, Machined Nut. Lub 1/2" TIre 400 x 8 Mount Assy, Brake Cylinder Chassis. Wldmnt 2532 Platform, Wldmnt TUEV Brake Eskridge

Q'lY

Ref 1 1 1

2 1 1 1 1 1 1

10 1 1 1 1 1

1993

Figure 2S • 2S48B German TUEV Special Optious ITEM

PARI' NUMBEll

A926-2S48

1

9

52671 54362 34836 52672 38051 52983 321-OOO1]"()o 321.()()()22..()O 28!MlOOO3'()1

10

289--00007'()1

11

91029

12 13 14 15

476-00021-00

2

3 4 5 6 7

8

53269

54366 126-1000s-OO

DESCRIPItON GcnDm TUEV Spccial2S48 Operator. Key Switch

Hom. 24V 133DB Automotive

Operator, Wbltc Pusbbutton Block, Contact 1 NO'

C"4JpIing. 1breaded 1bt-Point Operator-Push 1\vist Motor·p: 114.7-HSO Motor·Brake P: 115·7-ASO Hub, Drive #1. Assy.

Hub, Machined Nut, Lub 1fJ:' nrc 400 X 8 Mount ClIaDis Wldnuu, 2S48-B Benram Platform Wldnuu, 1UEV·2S48-B Brake Eskridge

Q1Y

Ref 1

1 1 1 1 1.

1 1 1 1

10 1 1 1

1

1993

FIGURE 26 STROBE LIGHT INSTALlATION (OPTION)

lITEM -1 2 3 4 5

Q1Y

PART NUMBER

DESCRlPTION

58Ml5 58395 BOW31144 67295-019

Strobe tight Installation .............................................. Ref Plate, Top 7" ...... ...... ....... ..... ............... ......... .......... ......... ....... 1 Light, Amber Strobe 12-72 VDe .................................. 1 Screw, Round Head, Grade 5, #10-32UNF x .5 ••••••••••• 3 Cable .. ........... ...... ... .••.. .•••••.....•..••.••••..... ........... ... ............ 4L.F ..

- Indicates Items Not Shown

PLAIFORJI WEUJMEIT

Ref-.

2

1993

FIGURE 27 JAPANESE OPTIONS

I

PART NUMBER

DESCRIPTION

1

66091

Overseas Battery Charger ..................................................... 1

2

54391

Battery Charger Stand ........................................................... 1

3 4

54374

Overload Platform Weldment ............................................... 1

53181

Overload Deck Assembly ..................................................... 1

53137

• Floating Deck Weldment ................................................... 1

53142.

• Arm, Pivot Weldment RH .................................................. 2

53143

• Arm, Pivot Weldment LH .................................................. 2

124-00028-00

• Bushing, 1.0" x .75" x 1.0" ................................................ 4

BOW31208

• Nut, Hex .75" - 10UNC ..................................................... 4

BOW36708

• Washer, Flat .75" ............................................................... 4

BOW30107 BOW31205

• Bolt, Hex .50" -13UNC x 1.75" long ................................ 12 • Nut, Hex .50" - 13UNC ..................................................... 12

BOW36769

• Washer, Flat .50" 10 x 1.375" 00 ..................................... 12

53147

• Yoke, End .43" - 20UNF ................................................... 4

BOW32284

• Nut, Jam .43" - 20UNF ...................................................... 4

53145

• Spring, Rod ........................................................................ 4

53129

• Spring, Heavy Load 100 x 4.5 FL ..................................... 4

BOW36769

• Washer, Flat .50" 10 x 1.375" 00 ..................................... 8

BOW31205

• Nut, Hex .50" - 13UNC ..................................................... 4

53146

• Tie Rod 60.5 + .125" .......................................................... 2

119-00011-00

• Rod, End Male .50" - 20 .................................................... 4

BOW36615

• Nut, Hex .50" - 20UNF ...................................................... 8

BOW36104

• Bolt, Hex .50" - 13UNC x 1.00" long ................................ 2

BOW36905

• Nut, Hex .50" - 13UNC RH Thread ................................... 2

53149

• Nut, Hex Long .50" - 13UNC ............................................ 2

54375

Overload Extension Deck Assembly .................................... 1

54405

• Slide-Out Deck Frame Weldment ...................................... 1

53277

• Overload Weldment, LH .................................................... 1

53278

• Overload Weldment, RH ................................................... 1

51036

• Limit Switch, Body Only ................................................... 6

51038

• Limit Switch, Head ............................................................ 6

37838-026 331-00002-00

• Compression Spring ........................................................... 2 • Bolt, .375" x 1.5" Elevator ................................................. 2

53276

• Switch Mount, 2.25" long .................................................. 2

67114-002

• Strain Relief, .50" NPT .25"/.375" ..................................... 6

ITEM

5

MANUAL 9Z299-003

FIGURE 27 JAPANESE OPTIONS

I

PART NUMBER

DESCRIPTION

67123-001

• Connector Seal, Electrical .50" .......................................... 6

BOW17351

• Nut, .50" Conduit Connector ............................................. 6

BOW30008

• Bolt, Hex .25" - 20UNC x 2.0" long .................................. 2

BOW31248

• Nut, Hex .25" - 20UNC ..................................................... 6

BOW31444

• Washer, Flat .25" ID x .625" OD ....................................... 4

BOW31146

• Screw, Slotted Round Head #10 - 32UNF x 1.0" long ...... 12

BOW30703

• Nut, Hex #10 - 32 .............................................................. 12

BOW31323

• Washer, Split Lock #10 ID ................................................ 12

54402-001

• Bolt, Shoulder .75" x 2.50" long ........................................ 2

BOW31418

• Washer, Flat .75" ID x 2.00" OD ....................................... 2

BOW36607

• Nut, Hex .625" - 11 UNC ................................................... 2

67295-035

• Cable, 16GN2 Conductor Type SJO ................................. 25L.F.

54406

• Slide-Out Deck Floor Weldment ....................................... 1

54402-003

• Bolt, Shoulder .50" x .75" long .......................................... 3

54399

• Stop Switch ........................................................................ 1

54398

• Slide Block ......................................................................... 4

6

51813

Alarm, 12/24V DC ................................................................ 1

7

67280

Bosch Relay .......................................................................... 4

8

54351

Weldment, Control Lever Guard .......................................... 1

9

54376

Electrical Schematic .............................................................. 1

10

54377

Wiring Diagram .................................................................... 1

11

54435

Control Box Cover ................................................................ 1

12

67295-003

Cable, 16 Conductor/16GA .................................................. 40L.F.

13

54459

Lower Control Box Mount ................................................... 1

ITEM

MANUAL 9Z299-ooJ

FIGURE 28 ITOCHU ELECTRICAL SCHEMATIC (OPTION) R4

~; 8

.---1

};-' z ~

R 5 , 8B S1ROBE/OPllON I

At

8A

.. r

'\OUTrOD 1 RIGHT Z

250 La EAat

LEFT

2 IN

~ ~

I~

ZA

.. 1

~

CIRCUIT B~

:!~,

OP1lONAl BATTERY CONDl1lON INDICATOR

6

! "'" 1IIIplllllllqllllllili ". , I

HYD PUMP

SEE NOTE 1 fOB

6

OVERlOAD SENSING

IBlK

RED

lOA

• • BAl1ERY CHARGER

750 La

z

1---------------.... OVERlOAD AlARM

2~

4--::; Tzii

6

3-POS

HOUR METER OP1lDlI 100 VAC PLUG

6

STROBE "ON"

"UP"

ffi "":,...,-,--

~

o

6

7 · , , 0 4 0 . PlAlFORIoI LOWERING

U ±mPSA ~~~:~ I cB.~

I

se

•.

040

IN PlATFORM

BIJ(

ll

WHT

GRN

2:°-:N-:::EUTR~-A-L--I 15A

HOT GROUND

r b LF

100 VAC

PWG ONatASS/S

STROBE "ON"

I

ll2D

t2

SLOPE AlARM OP1lON

G.J '2

RECEPTACLE

-. SEE NOTE 3

SEE NOTE 5

s

D

PUMP MOTOR

7 "DOWN"

EMERGENCY

s

GROUND

'="

REP (

I BLK

•• SLOPE SENSOR OP1lON

s

LOW VOLT SENSOR

1. OVERlOAD SENSING SWITCHES ARE SHOWN WITH RATED WORK LOAD OR LESS AND WITH EXTENSION DEQ( PART WAY OUT. 2. SWITCHES ARE AC1lVATED BY \.EVERS IN PLATFORM. 3. UPPER AND LOWER ARM ARE CONTROLLED BY SEPARATE VAlVE HANDLES. 4. G)THRU\DREPRESENT TERMINALS OF OP1lONAl LOW VOLTAGE WARNiNG/lNTERRUPTSENSOR/SWiTCH. 5. UFT UMIT SWITCH IS SHOWN WITH PlA1FORIoI ALL THE WAY DOWN. 6. PRESSURE SWITCH SENSES BRAKE RELEASE PRESSURE.

SEE NOTE 4

) ,s s II

,., I ,.,

'-----<>.~

SEE NOTE 6

- + LOW

CA1

VOLT WARNING

+

) - - - - - - - - - - ' - i ' LOW VOLT OVERRIDE STROBE "OfF"

'1 180188-024 ~ I -

TRAVEL AlARM OP1lON

.... GROUND

WACO, TEXAS

CHICK ITOCHU ELECTR

BGURE29 ITOCHU LOWER CONTROL BOX

NII1EIt 1. nD1115-U AND .,....7 Nt!£. NOT 1.LUS1ItA"IID.

8 9 ) 2 PL

10}

..l:

"3

z wO '" 0"''''' .go..",

"-

;t~~ >

"

I

"",i

o

t- i

-.:t::!

~'

/

"" "

/

/ / I

/

/

(

)

/

/

)

/

;i 3

/...- ....

>

\

(

I \

~a::ffi

.g~~

/

J '--

~I

w

i2u

w"'''' ~vH~

ffi~~ n.

i

~! ~! ~

(

\

~"'

'--

\ J

~

fQj ~>

COlOR

GRN;v.HT

TO O\<£RLOAD sWITCHES

2A

SLU/IIl-{T

SA T!tRY INDICA TOR

3

RCD \\HTjau< GRNjaLK BU<;v.HT REl);v.HT

SA 1.

REfER TO SCHEMA TIC 54375.

GROUND

Rfl)/BU<

17

l'lQJI;.

fUNCTION

88 10

12

0!lN

12A

ORNjaU<

13 15

BLU BLU/BtK BlK \\HT

GRN BLK/RED

UPf'ER CONmOl POWER <URN PUMP ON PLA11'00.. LOWERING

smOOt UGHT ROM OVERLOAD SWITCHES SLOPE ALARM POWER SLOPE ALARM SIGNAl LOW VOLT UGHT lOW VOLT OVERRIDE AC HOT UNE AC NEUlRAl AC GROUND SPARE

I

f

I I I :=u.."1iIE",:

~--.-----0::.'1..-:'::.. ..._ ~

I f~I'::':~:;:.IID1=-

WACO. TEXAS

WlRING, ITOCHU CHICI

-"""''''-''CI--54377

CABLE TO CHASSIS

SEE SHEET 2

~1"'(]3.-

71 } REF

WACO. n:XAS I'o1RING. ITOCHU CHICK

__._

-

ULIILUL_

-

--::JIm-=-

.-

c

54377

ATTENTION MANUAL OF RESPONSIBILITIES for Dealers, Owners, Users, Operators, Lessors and Lessees of ANSI/SIA A92.6-1990 Self-Propelled Elevating Work Platforms

WARNING F AlLURE TO COMPLY with your REQUIRED RESPONSIBILITIES in the use and operation of the Aerial Platform could result in DEATH OR SERI0U:S INJURY.

IMPORTANT You are required by ANSI/SIA A92.6-1990 to read and understand YOUR RESPONSmILITIES 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 NECESSARY SAFETY INFORMATION to users and operators. They MUST BE KEPT ON THE 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 OPERATOR AND OTHER PERSONNEL is dependent on those decisions.

FAILURE TO COMPLY with your REQUIRED RESPONSmILITIES 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 ANSI/SIA A92.6-1990 standard for Self-Propelled Elevating Work Platforms became effective January 2, 1992. This Manual incorporates sections from that standard as follows: Definitions Responsibilities of Dealers Responsibilities of Owners Responsibilities of Users Responsibilities of Operators Responsibilities of Lessors Responsibilities of Lessees Typical Examples of Equipment Covered Minimum Safe Approach Distance Published by

Scaffold Industry Association, Inc. 14039 Shennan Way, Van Nuys, California 91405-2599 Copyright 0 1992 by Scaffold Industry Association, Inc. All rights reserved.

No part of this publication may be reproduced in any form, in an electronic retrieval system or otherwise, without the prior written permission of the publisher.

Printed in the United States of America

Section Section .Section Section Section Section Section Figure Figure

3 5 6 7 8 9

10 1

3

Page Page Page Page Page Page Page Page Page

1 1 2

3 6 8 8 9

10

Single copy list price •••••••• $ 4.95

IRESPONSmILITIES MANUAL 3. Definitions aerial platform. A mobile device that has an adjustable position platform, supported from ground level by a structure. authorized personnel (authorized person). Personnel approved as assigned to perform a specific type of duty or duties at a specific location or locations at a work site. base. The relevant contact points of the aerial platform that form the stability fulcrum (e.g. wheels, casters, outriggers, stabilizers). chassis. The integral part of the aerial platform that provides mobility and support for the elevating assembly. configuration. All positions in which an aerial platform or any part thereof can be placed within its intended operating limits. dealer. A person or entity who buys from a manufacturer or distributor and who generally sells, rents, and services aerial platforms. delivery. Transfer of care, control, and custody of the aerial platform from one person or entity to another person or entity. directional controls. Controls that initiate functions that affect movement of the platform or the aerial platform. elevating assembly. The mechanisms used to position the platform relative to the aerial platform chassis. guardrail system. A vertical barrier erected to prevent personnel from falling to lower levels. hazardous location. Any location that contains, or has the potential to contain, an explosive or flammable atmosphere as defined by ANSIINFPA 505. instability. A condition of an aerial platform in which the sum of the moments that tend to overturn the unit exceeds the sum of the moments tending to resist overturning. 'insulat~d platform. A platform designed and tested to meet the specific electrical insulation ratings consistent with the manufacturer's identification plate. interlock. A control or mechanism that, under specified conditions, automatically allows or prevents the operation of another control or mechanism. manufacturer. A person or entity who makes, builds, or produces an aerial platform. maximum travel height. The maximum platform height or the most adverse configuration(s) with respect to stability in which travel is permitted by the manufacturer. modification. Modification, modifies: To make a change(s) to an aerial platform that affects the operation, stability, safety factors, rated load or safety of the aerial platform in any way. operator. A qualified person who controls the movement of tbe aerial platform. outriggers. Devices' tbat increase the stability of tbe aerial platform and tbat are capable of lifting and leveling the aerial platform.

Reprint from ANSIfSIA A92.6-1990 override. To take over aerial platform movement control functions at the upper control station by those at the lower control station. owner. A person or entity who has possession of an aerial platform by virtue of proof of purchase. passive. Automatically performed and not requiring any specific operator action to accomplish. platform. The portion of an aerial platform intended to be occupied by personnel with their necessary tools and materials. platform height. The vertical distance measured from the floor of the platform to the surface upon which the machine is being supported. powered functions. Those which control motion of the platform or the aerial platform and are caused by electromechanical, hydraulic or pneumatic forces. qualified person. A person, who by reason of knowledge, experience, or training is familiar with the operation to be performed and the hazards involved. rated work load. The designed carrying capacity of the aerial platform as specified by the manufacturer. shall. The word "shall" is to be understood as being mandatory. stability/stable. A condition of an aerial platform in which the sum of the moments that tend to overturn the unit is less than or equal to the sum of the moments tending to resist overturning. stabilizers. Devices that increase the stability of the aerial platform but are not capable of lifting or leveling the aerial platform. unintended motion or motion unintended by operator. Motion of the aerial platform or platform without activation or any control. unrestricted rated work load. The maximum designed carrying capacity of the aerial platform allowed by the manufacturer in all operating configurations. user. A person(s) or entity who has care, control and custody of tbe aerial platform. This person or entity may also be a dealer, owner, lessor, lessee, or operator.

NOTE: Operating and maintenance manuals covered 'in Section 4 of ANSIfSIA A92.6, and referred to in this document, should be obtained from the manufacturer of the aerial platform.

15. Responsibilities of Dealers 5.1 Basic 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 applied in the training of operators, in maintenance, application, safety provisions and operation

PAGE 1

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

5.2 Manuals. Dealers shall keep and maintain a copy(ies) of the operating and maintenance manual(s) required in 4.16.1. The operating manual(s) shall be provided with each rental, lease or sale delivery. The manual(s) shall be stored 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 to users and operators. In addition, parts and maintenance manuals shall be provided with each sale delivery.

5.3 Predelivery Preparation. Aerial platforms shall be inspected, serviced and adjusted to manufacturer's requirements prior to each delivery by sale, lease or rental.

5.4 Maintenance SaCety Precautions.

Before adjustments and repairs are started on an aerial platform, the following precautions shall be taken as applicable: (1) Powerplant stopped and starting means rendered inoperative (2) All controls in the "Off' position and all operating systems secured from inadvertent motion by brakes, blocks or other means (3) Elevating assembly and platform lowered down to the full down position, if possible, or otherwise secured by blocking or cribbing to prevent dropping (4) Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components (5) Safety props or latches installed where applicable as prescribed by the manufacturer 5.5 Replacement Parts. When parts or components are replaced, they shall be identical or equivalent to original aerial platform parts or components.

5.6 Training. Whenever a dealer directs or authorizes an individual to operate an aerial platform, the dealer shall ensure that the individual has been trained under the direction of a qualified person in accordance with the manufacturer's operating manual and requirements listed in Section 8 of this standard before operating the aerial platform.

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

5.7 Operation. 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 responsibilities of operators as specified in Section 8 of this standard.

S.S Assistance ~ Owners and Users. If a dealer is unable to answer an owner's or user's question(s) relating to rated capacity, intended use, maintenance, repair, inspection, or operation of the aerial platform, the dealer

Reprint from ANSI/SIA A92.6-1990 shall obtain the proper information from the manufacturer and provide that information to the owner or user.

5.9 Record Retention. Dealer(s) shall retain the following records for at least 3 years: (1) Name and address of the purchaser of each aerial platform by serial number and date of delivery (2) Records of the person(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 written permission of the manufacturer.

5.11 ManuCacturer's SaCety Bulletins. The dealer shall comply with safety-related bulletins as received 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 use and expected environment shall be applied in the performance of the responsibilities of owners with due consideration of the knowledge that the aerial platform will be carrying personnel.

6.2 Manuals. Owners 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 with each rental, lease or sale delivery and shall be stored in the weather resistant storage compartment required by 4.16.2 of this standard.

These manual(s) are considered an integral part of the aerial work platform and are 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 Maintenance. 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 use of the aerial platform. The owner shall arrange that frequent and annual inspections are performed. All malfunctions and problems identified shall be corrected before the aerial platform is returned to service.

6.4 Predelivery Preparation. Aerial platforms shall be inspected, serviced, and adjusted to manufacturer's requirements prior to each delivery by sale, lease or rental.

6.5 Frequent Inspection. The owner of an aerial platform shall cause a frequent inspection to be performed on an aerial platform: (1) That has been in service for three (3) months or 150 hours whichever comes first;

PAGE 2

J

(,

IRESPONSmILITIES MANUAL

I,.'>'\

(2) That has been out of service for a period 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 manufacturer for a frequent inspection and shall include but not be limited to the following: (3) All functions and their controls for speed(s), smoothness, and limits of motion; (4) Lower controls including the provisions for overriding of upper controls; (5) All chain and cable mechanisms for adjustment and worn or damaged parts; (6) All emergency and safety devices; (7) Lubrication of all moving parts, inspection of filter element(s), hydraulic oil, engine oil, and coolant as specified by the manufacturer; (8) Visual inspection of structural components and other critical components such as fasteners, pins, shafts and locking devices; (9) Placard, warnings and control markings; (10) 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 Annual Inspection. The owner of an aerial platform shall cause an annual inspection to be performed on the aerial platform no later than 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 of the aerial platform. The inspection sball include all items specified by the manufacturer for an annual inspection.

6.7 Maintenance Safety Precautions.

Before adjustments and repairs are started on an aerial platform, the following precautions sball be taken as applicable: (1) Powerplant stopped and starting means rendered inoperative (2) All controls in the "ofC' position and all operating systems secured from inadvertent motion by brakes, blocks, or other means (3) Elevating assembly and platform lowered to tbe full down position, if possible, or otherwise secured by blocking or cribbing to prevent dropping (4) Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing bydraulic components (5) Safety props or latches installed where applicable as prescribed by the manufacturer 6.8 Replacement Parts. When parts or components are replaced, they shall be identical or equivalent to original aerial platform parts or components.

6.9 Maintenance Training. The owners shall train their maintenance personnel in inspection and maintenance of the aerial platform in accordance with 6.3, 6.4, 6.5, 6.6, 6.7, 6.8 and 6.10 of this standard, and with the manufacturer's recommendations.

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

Manufacturer's operating instructions and required training on the proper use and operation of the aerial platform shall be provided upon each delivery by sale, lease or rental.

6.11 Operation. When an owner operates an aerial platform, the owner shall have the responsibilities of users as specified in Section 7 of this standard and his operating personnel shall have responsibilities of operators as specified in Section 8 of this standard.

6.12 As.sistance to Users and Operators. If an owner is unable to answer a user's or operator's question(s) relating to rated capacity, intended use, maintenance, repair, inspection, or operation of the aerial 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. The owner shall retain the following records for at least 3 years: (1) Name and address of the purchaser of each aerial platform by serial number and date of delivery; (2) Records of the person(s) trained upon each delivery of an aerial platform; (3) Written records of the frequent and annual inspections performed by the owner. The record sball include deficiencies found, cOlTective action and identification of the person(s) performing the inspection and repairs.

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

6.14 Modifications. Modification or alteration of an aerial platform shall be made only with prior written permission of the manufacturer.

6.15 Manufacturer's Safety Bulletins. The owner shall comply with safety-related bulletins as received from the manufacturer or dealer.

7. Responsibilities of Users 7.1 Basic Principles. TIle information in this standard must be supplemented by good job management, safety control, and the application of sound principles of safety, training, inspection, maintenance, application, and operation, consistent with all data available regarding the parameters of intended use and expected environment.

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

Decisions on the use and operation of the aerial platform must always be made with due consideration for the fact

PAGE 3

IRESPONSmILITIES MANUAL that the aerial platform will be carrying personnel whose safety is dependent on those decisions.

7.2 Manuals.

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 with each rental, lease or sale delivery and shall be stored in the weather resistant storage compartment required by 4.16.2 of this standard.

The manual is considered an integral part of the aerial platform and is vital to communicate necessary safety information to users and operators. In addition, parts and maintenance manuals shall be provided with each sale delivery.

7.3 Inspection and Maintenance. Users shall inspect and maintain the aerial platform as required to ensure proper operation. The frequency of inspection and maintenance shall be determined by the manufacturer's recommendations and be compatible with operating conditions and the severity of the operating environment.

Aerial platforms that are not in proper operating condition shall be immediately removed form service until repaired.

Repairs shall be made by a qualified person and the repairs shall be in conformance with the manufacturer's recommendations.

7.3.1 Frequent Inspection. An inspection as outlined in section 6.5 of this standard shall be conducted.

7.3.2 Annual Inspection. An inspection as outlined in section 6.6 of this standard shall be conducted.

7.3.3 Prestart Inspection. Before use each day or at the beginning of each shift, the aerial platform shall be given a visual inspection and functional test including but not limited to the following: (1) Operating and emergency controls (2) Safety devices (3) Personal protective devices (4) Air, hydraulic and fuel system leaks (5) Cables and wiring harness (6) Loose or missing parts (7) Tires and wheels (8) Placards, warnings, control markings, and operating manual(s) (9) Outriggers, stabilizers, and other structures (10) Guardrail system (11) Items specified by the manufacturer 7.3.4 Maintenance SaCety Precautions.

Before adjustments and repairs are started on an aerial platform, the following precautions shall be taken as applicable: (1) Powerplant stopped and starting means rendered inoperative (2) All controls in the "Off" position and all operating systems secured from inadvertent motion by brakes, blocks, or other means (3) Elevating assembly and platform lowered to the full down position, if possible, or otherwise secured by blocking or cribbing to prevent dropping

Reprint from ANSIISIA A92.6-1990 (4) Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components (5) Safety props or latches installed where applicable as prescribed by the manufacturer 7.4 Replacement Parts. When parts or components are replaced, they shall be identical or equivalent to the original aerial platform parts or components.

7.5 Maintenance Training. The user shall train the maintenance personnel in inspection and maintenance of the aerial platform in accordance with sections 7.3, 7.3.1, 7.3.2, 7.3.3, and 7.3.4 of this standard and with the manufacturer's recommendations.

7.6 Operator Training. Whenever a user directs or authorizes an individual to operate an aerial platform the user shall ensure that the individual has been trained in accordance with the 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. The 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 during actual work site operation. Under the direction of a qualified person, the trainee shall operate the aerial platform for a sufficient period of time to demonstrate proficiency and knowledge in the actual operation of the aerial platform. Care shall be taken to ensure the area of such operation has a minimum of obstacles and is conducive to training. Only properly trained and authorized personnel shall be permitted to operate the aerial platform.

7.6.2 Trainee Records. A record of the trainee's aerial platform instruction shall be maintained by the user for at least 3 years.

7.7 BeCore Operation. 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 that the purpose for which the aerial platform is to be used is within the scope of the intended applications defined by the manufacturer 7.8 Workplace Inspection. Before the aerial platform is used and during use, the user shall check the area in which the aerial platform is to be used for possible hazards such as, but not limited to: (1) Drop-offs or holes (2) Bumps and floor obstructions (3) Debris

PAGE 4

I

IRESPONSIBILITIES 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 of unauthorized persons (9) Other possible unsafe conditions 7.9 During Operation. The aerial platform shall be used in accordance with this standard. The user shall direct his operating personnel and supervise their operation to ensure that the following is adhered to prior to each movement of the aerial platform and each repositioning of the platform: (1) The aerial platform is operated on a surface within the limits specified by the manufacturer (2) The outriggers, stabilizers, extendable axles, or other stability enhancing means, are used as required by the manufacturer (3) The guardrails are installed and access gates or openings are closed per manufacturer's instructions (4) The load and its distribution on the platform and any platform extension are in accordance with the manufacturer's rated capacity for that specific configuration (5) There is adequate clearance from overhead obstructions (6) The minimum safe approach distances (MSAD) to energized power lines and parts, as listed in Table One of Figure 3 are maintained. See page [10] (7) The precautions defined in sections 7.3.3, 7.7, 7.8, 7.9, 7.10 and 7.11 of this standard are followed during operation of the aerial platform 7.10 Determination of Hazardous Locations. It shall be the responsibility of the user to determine the hazard classification of any particular atmosphere or location according to ANSIINFPA 505-1987.

Aerial Platforms operated in hazardous locations shall be approved in accordance with, and of the type required,

by ANSIINFPA 505-1987.

7.11 Warnings and Instructions. The user shall direct his operating personnel and supervise their work to ensure operation of the aerial platform in compliance with this standard.

7.11.1 Personnel Footing. Personnel shall maintain a fum footing on the platform floor while working thereon.

Use of planks, ladders, or any other device on the aerial platform for achieving additional height or reach shall be prohibited.

7.11.2 Other Moving Equipment.

When other moving equipment 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 limited to, flags, roped-off areas, flashing lights, and barricades shall be used.

Reprint from ANSIfSIA A92.6-1990 7.11.3 Reporting Problems or Malfunctions. TIle operator shall immediately report to the supervisor any problems or malfunctions that become evident during operation. Any problems or malfunctions that affect the safety of operations shall be repaired prior to continued use.

7.11.4 Altering Safety Devices. Altering or disabling of interlocks or other safety devices shall be prohibited.

7.11.S Entanglement. Care shall be taken to prevent rope, electric cords and hoses from becoming entangled in the aerial platform.

7.11.6 Capacity Limitations. Rated capacities shall not be exceeded when loads are transferred to the platform at any height.

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

7.11.8 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 hazards that may cause fire or explosion.

7.11.9 Battery Charging. 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 Improper Platform Stabilization. The aerial platform shall not be positioned against another object to steady the platform.

7.11.11 Misuse as a Crane. The aerial platform shall not be used as a crane.

7.11.12 Unusual Operating Support Conditions. The aerial platform shall not be operated from a position on trucks, trailers, railway cars, floating vessels, scaffolds, or similar equipment unless the application is approved in writing by the manufacturer.

7.11.13 Travel Speeds. Under all travel conditions, the operator shall limit travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel, and other factors causing hazards of collision or injury to personnel.

7.11.14 Elevated Driving Requirements. Before 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 7.11.1S Stunt Driving. Stunt driving and horseplay shall not be permitted.

7.11.16 Unauthorized Use. Means shall be used to protect against use by unauthorized person(s).

7.12 Operation of the Aerial Platform. If a user is also the operator of an aerial platform, the user shall have the responsibilities of operators specified in Section 8 of this standard as well as responsibilities of users as specified in Section 7 of this standard.

PAGE 5

IRESPONSIBILITIES MANUAL 7.13 Assistance to Operator. If a user is unable to answer an operator's question(s) relating to rated capacity, intended use, maintenance, condition, or safety of operation of the aerial platform, the user shall obtain the proper information from the dealer, owner, or manufacturer and provide that information to the operator before use of the aerial platform in the application of concern.

7.14 Shutdown of Aerial Platform. The user shall authorize and direct the operating personnel to cease operation of the aerial platform in case of any suspected malfunctions of the aerial platform, or any hazard or potentially unsafe condition that may be encountered, and to request further information as to safe operation from the owner, dealer, or manufacturer before further operation of the aerial platform.

7.1S Record Retention. The user shall retain the following records for at least 3 years: (1) Records of the operator(s) trained on each model of an aerial platform; (2) Written records of the frequent and annual inspection shall be kept by the user when performing the inspections. The records· shall include the date of inspection, any deficiencies found, the corrective action recommended and identification of the person(s) performing the inspection.

(3) Written records of all repairs accomplished on the aerial platform, including the date of any such repair, a description of the work accomplished and the identification of the person(s) performing the repair.

7.16 Modifications. Modification or alteration of an aerial platform shall be made only with prior written permission of the manufacturer.

7.17 Manufacturer's Safety Bulletins. The user shall comply with safety-related bulletins as received from the manufacturer, dealer or owner.

8. Responsibilities of Operators 8.1 Basic Principles. The information in this standard shall be supplemented by good judgment, safety control, and caution in evaluating each situation. Since the operator is in direct control of the aerial platform, conformance with good safety practices in this area is the responsibility of the operator. The operator shall make decisions on the use and operation of the aerial platform with 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 decisions.

8.2 Manuals. The operator shall ensure that the operating and safety manuals delineating the responsibilities of dealers, owners, lessors, lessees, users, and operators, are stored on the aerial platform in the weather resistant storage compartment provided. The operator shall be familiar with tbe manuals and consult

Reprint from ANSIISIA A92.6-1990 them when questions arise with respect to the aerial platform.

8.3 Prestart Inspection. Before use each day or at the beginning of each shift, the aerial platform shall be given a visual inspection and functional test including but not limited to the following: (1) Operating and emergency controls (2) Safety devices (3) Personal protective devices (4) Air, hydraulic, and fuel system leaks (5) Cables and wiring harness (6) Loose or missing parts (7) Tires and wheels (8) Placards, warnings, control markings, and operating manual(s) (9) Outriggers, stabilizers and other structures (10) Guardrail system (11) Items specified by the manufacturer 8.4 Problems or Malfunctions. Any problems or malfunctions that affect the safety of operations shall be repaired prior to the use of the aerial platform.

8.5 Training. The 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 during actual work site operation. Under the direction of a qualified person, the trainee shall operate the aerial platform for a sufficient period of time to demonstrate proficiency and knowledge in the actual operation of the aerial platform. Care shall be taken to ensure the area of such operation has a minimum of obstacles and is conducive to training. Only properly trained and authorized personnel shall be permitted to operate the aerial platform.

8.6 Before Operation. Before being authorized to operate the aerial platform, the operator shall have: (1) Been instructed by a qualified person in the intended purpose and function of each of the controls (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 by having a qualified person explain all decals, warnings, and instructions displayed on the aerial platform 8.7 Workplace Inspection. Before the aerial platform is used and during use, the operator shall check tbe area in which the aerial platform is to be used for possible hazards such as, but not limited to: (1) Drop-offs or holes (2) Bumps and floor obstructions (3) Debris (4) Overhead obstructions and bigh voltage conductors (S) Hazardous locations (6) Inadequate surface and support to withstand all load forces imposed by the aerial platform in all operating configurations

PAGE 6

IRESPONSmILITIES MANUAL (7) Wind and weather conditions (8) Other possible unsafe conditions 8.8 During Operation. The aerial platform shall be used in accordance with this standard. Before each elevation of the platform, the operator shall ensure: (1) The aerial platform is operated on a surface within the limits specified by the manufacturer (2) Outriggers, stabilizers, extendable axles, or other stability enhancing means, are used as required by the manufacturer (3) Guardrails are installed and access gates 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 for that specific configuration (5) There is adequate clearance from overhead obstructions (6) The minimum safe approach distances (MSAD) to energized power lines and parts, as listed in Table 1 of Figure 3, are maintained. See page [10] (7) All personnel on the platform are wearing safety gear as required at all times' 8.9 Determination of Hazardous Locations. It shall be the responsibility of the user to determine the hazard classification of any particular atmosphere or location according to ANSIINFPA 505.

8.9.1 Hazardous Location Operating Requirements.

Aerial platforms operated in hazardous locations shall be approved and of the type required by ANSIINFPA 505.

8.10 Operator Warnings and Instructions. The operator shall ensure the operation of the aerial platform in compliance with the following: 8.10.1 Personnel Footing. Personnel shall maintain a firm footing of the platform floor while working thereon.

Use of planks, ladders, or any other devices on the platform for achieving additional height or reach shall be prohibited.

8.10.2 Precaution for Other Moving Equipment.

When other moving equipment 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 limited to flags, roped off areas, flashing lights, and barricades shall be used.

8.10.3 Reporting Problems or Malfunctions. The operator shall immediately report to a supervisor any problems or malfunctions that become evident during operation. Any problems or malfunctions that affect the safety of operations shall be repaired prior to continued use.

8.10.4 Reporting Potentially Hazardous Locations.

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

8.10.5 Hazardous Location Operation. Operation of aerial platforms that are not approved and marked for

Reprint from ANSIISIA A92.6·1990 operation in a hazardous location shall be prohibited.

8.10.6 Entanglement. Care shall be faken to prevent rope, electric cords, and hoses, etc., from becoming entangled in the aerial platform.

8.10.7 Capacity Limitations. Rated capacities shall not be exceeded when 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 hazards that may cause fire or explosion.

8.10.10 Battery Charging. Batteries shall be charged in a well-ventilated area free of flame, sparks, or other hazards that may cause fire or explosion.

8.10.n Improper Platform Stabilization. The aerial platform shall not be positioned against another object to steady the platform.

8.10.12 Misuse as a Crane. The aerial platform shall not be used.as a crane.

8.10.13 Unusual Operating Support Conditions. The aerial platform shall not be operated from a position 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 Speeds. Under all travel conditions, the operator shall limit travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel, and other factors causing hazards of collision or injury to personnel.

8.10.1S Elevated Driving Requirements. Before 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 Driving. Stunt driving and horseplay shall not be permitted.

8.10.17 Security. The operator shall implement means provided to protect against use by unauthorized person(s).

8.10.18 Altering Safety Devices. Altering or disabling of interlocks or other safety devices shall be prohibited.

8.10.19 Driving on Slopes. The aerial platform shan not be driven on grades, side slopes or ramps exceeding those for which the aerial platform is rated by the manufacturer.

8.10.20 Snagged Platform. If the platform/basket 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 platform/basket before attempts are made to free the platform using chassis controls.

PAGE 7

IRESPONSmILITIES MANUAL 8.11 Assistance to Operator.

If an operator encounters any suspected malfunction of the aerial platform, or any hazard or potentially unsafe condition relating to capacity, intended use or safe operation of the 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.

8.12 Modifications. Modification or alteration of an aerial platform shall be made only with prior written permission of the manufacturer.

9. Responsibilities of Lessors 9.1 Basic Principles. Sound principles of safety, training, inspections, maintenance, application, and operation consistent with all data available regarding the parameters of intended use and expected environment shall be applied in the performance Of responsibilities of lessors with due consideration of the knowledge that the aerial platform will be carrying personnel.

9.2 Lessor. A lessor 'is a person(s) or entity Who leases, rents, loans, or otherwise provides an aerial platform to another 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 Lessor as an Owner. When a lessor uses the aerial platform as an owner, the lessor shall have the responsibilities of owners as specified 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 t~e responsibilities of users as specified In Section 7 of thIS standard.

9.2.4 Lessor as an Operator. When 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 ANSIISIA A92.6·1990 10. Responsibilities of Lessees 10.1 Basic Principles. Sound principles of safety, training, inspections, maintenance, application, and operation consistent with all data available regarding the parameters of intended use and expected environment shall be applied in the performance of responsibilities of lessees with due consideration of the knowledge that the aerial 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 User. When a lessee uses the aerial platform as a user, he shall have the responsibilities of users as specified in Section 7 of this standard.

10.2.4 Lessee as an Operator. When a lessee uses the aerial platform as an operator, he shall have the responsibilities of operators as specified in Section 8 of this standard.

PAGE 8

I

IRESPONSIBILITIES MANUAL

Reprint from ANSIISIA A92.6-1990

Figure 1 - Typical Examples of Equipment Covered

t' PAGE 9

IRESPONSIBILITIES MANUAL

Reprint from ANSIISIA A92.6-1990

Figure 3

BUS BARS

~

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

~

DENOTES PROHIBITED ZONE

DANGER: • DO NOT ALLOW MACHINE, PERSONNEL OR CONDUCTIVE MATERIALS INSIDE PROHIBITED ZONE .

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

• ASSUME ALL ELECTRICAL PARTS AND WIRES ARE ENERGIZED UNLESS KNOWN OTHERWISE. CA UTION: • DIAGRAMS SHOWN ARE ONLY FOR PURPOSES OF ILLUSTRATING M.S.A.D. WORK POSITIONS, NOT ALL WORK POSITIONS.

Table 1 MINIMUM SAFE APPROACH DISTANCE (M.S.A.D.) to energized (exposed or insulated) power lines and parts.

MINIMUM SAFE APPROACH DISTANCE (Feet) (Meters)

VOL TAGE RANGE (Phase to Phase)

o

AVOID CONTACT

to 300V Over 300V to SOKV Over 50KV to 200KV Over 200KV 10 3S0KV Over 350KV to SOOKV Over 500KV to 7S0KV Over 750KV 10 1000KV

10 15 20 25 35 45

PAGE 10

3.05 4.60 6.10 7.62 10.67 13.72

FIGURE 28 ITOCHU ELECTRICAL SCHEMATIC (OPTION) R4

8

R5

8A

r_P~t--_8.....;..;;..,.,J I I I I

8B

kt

2

LEFT

2

CIRCUIT BREAKER

SEE NOn: , 500 LB

tOB

IN

1

to

750 LB

SA

I

1

aLK

RED

HYD PUMP

t

OVERLOAD ALARM

1

6

3-POS

24 VDC BA1TERY

1111111111111111111' II

R1

5

OVERLOAD SENSING

1

51813

R2 2B

6

OPTIONAL BAlTERY CONDITION INDICATOR

NEG 1

lOA

11

2

1

lOA

RIGHT

OUT

2A

6 2A POS ~~------------------------------*-----------~~------.-~=-~

250 LB EACH

2

II-__'-tlll

EMERGENCY • STOP

10D

2

SlROBE/OP110N

BA1TERY CHARGER

-

GROUND

HOUR MEn:R OPllON 100 VAC PLUG

6

STROBE ·ON·

6

ffia..

1

4 LOWER

a.. ::,:)

1

7

7

6A 7

PUMP MOTOR PLAlFORM

1

7

8

3

RECEPTACLE IN PLAWORM

-

NEUTRAL GROUND

I

LF

PLUG ON CHASSIS

STROBE ·ON·

3A

NOJSS;

~'2~__~B~U~Z~~~__'~2~A__~~ SEE NOn: 5

l:~

LOWERIN(~

SEE NOn: 3

EMERGENCY

8 tSTOP

15A r--..,..-BLK----==" __HO_T___....,.--_r'b. 100 VAC D

12

~------------------~~ SEE NOn: 4

.---------------( 7

SLOPE ALARM OPTION

BLK

1

SLOPE SENSOR OPTION

1

6 t - - - - - - - - - - - - - 4 LOW VOLT SENSOR

1. OVERLOAD SENSING SWITCHES ARE SHOWN WITH RAlED WORK LOAD OR lESS AND WITH ~SlON DECK PART WAY OUT. 2. SWITCHES ARE ACTIVATED BY LEVERS IN PLAlFORM. 3. UPPER AND LOWER ARM ARE CONTROllED BY SEP ARATE VALVE HANDLES. 4. G)THRU(j)REPRESENT TERMINALS OF OPllONAL LOW VOLTAGE WARNINGI'NTERRUPT SENSOR/SWITCH. 5. UFT UMIT S'MTCH IS SHOWN WITH PLAlFORM ALL THE WAY DOWN. 6. PRESSURE SWITCH SENSES BRAKE RElEASE PRESSURE.

SEE NOn: 4

8

1

13

r-----------~Ar_------~

Q

..L

3

--------------~

SEE NOn: 4 15

1

5t------------~4 LOW VOLT OVERRIDE

14

3

14

LOW VOLT WARNING

STROBE ·OFF"

80188-024

TRAVEL ALARM OPTION

SEE NOn: 6 "='

GROUND

WACO. TEXAS

SCHEMATIC, CHICK ITOCHU ELECTR

.

.:

.

._._....

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

.....

FIGURE 29 ITOCHU LOWER CONTROL BOX

HOlm 1. I1EMS 15-22 AND 41-47 AI£ NOT lJ.IJ$lRAlED•

10;---____~--~~

• 71

REF

8721l5-OO:5

•••

LF CAlI.£. 18 QlNDUC10R 18 GA

•••

54 53 47-«11 52 5U47-o10

1'11.-e &,. i Iii

..... ..

51 50 48 41 47 41 I72U-03e

• •• • •• •••

<Ie 44 43 42 I72I6-OJ5 41 8 40

• ••

:I.

a_ .-.._~13

31 52138 JI 52872 J7 !tOW3I727 JI 8OWJM03 35 34 33 54441 3Z 8ODt533 31 34542 30 58212 28 ea251

o 9

7___ •

28 Xl

8OW31233 8OW31144 28 8OW31141 25 8OW31141 24 8ODt231 23 B0W31124 22 11712+-003 21 87123-003 20 117112 1. BOWI7350 18 117123-001 17 117117-<104 18 87117-003 15 11711+-001 14 34a52-018 13 40lI8O 12 JII8a2 11 SOCI75 10 IlOO27 82021

• • 8

52870

7

54178 801-..024 51813

5 4 3 2 1

54438 21183 87227 54440 ITEU PNU NIJIotIIa

. e

..,.

A

.,.

IlIA IWC •

...... MA . . . . . .

1.00 1.00 3.00

3.00 25.00 8.00 17.00 5.00 8.00 2.00 4.00 4.00 1.00 1.00 1.00 8.00 8.00 2.00 5.00 1.00 2.00 1.00 1.00 1.00 1.00 2.00 1.00 1.00 1.00 1.00 4.00 1.00 1.00 1.00

- .........

__

._-

..

Q1Y

WACO, TEXAS

'MRING, ITOCHU CHICK

54377 _

10f'3

c

.~. : ..~ -...;:: :,.

".

:.,'.'

....

-.

.::":'.,:':.: ...

'.;-

:.:.'.

'

,, Ii' I t-.. .I,-I

I

+

(!)

3 Q.

~I~ i

(+) SOd. I'QBI. IDIdS G

mm IDIdS to (-) tI3N t

gu

•

,..., R

:s

u Ii)

ID

u ::.: ...J

II I-

ID

ID

l)

n

I-

i ~

i

-1--<--+----4---1---_ _---4_ o

~

(]I)

...JQ.~ <::;)

>

~_l) ii~

~

~

IIJO ~Q.z

CD

o

r

.~'

'=

0::

0Ct:1IJ

'"\

~»~ u

ID

z

1-0 :::E

0

'-:"""

~r=o==~A

o~

)~

~

:::E 0

0::

-r

>-

e:

..

-

~

Z

0::

0Ct:1IJ

~~~

...Jo~ <...J

F

>

F= F=

=

,...,

.....

II)

II't

•h.

II

-

..

",

:s

.....

... .,

ID

IIJ

\.&JCt:

o

::.:~I'-

u

<III;;E

m~1II

-

Q.

n

:s

I-

i

ID

n

,..,

II II Ilf 111111 II

I-

i

n ;!:

~:::=::::---­

( \

(

\

r

~

W

,

II)

...

0

)

,I

x

~ j

.

(

\

1@/

I========f

l:I2IEi. REFER TO SCHEMAllC 54376.

) {

\

( 7

'J •

T

•

•

/ /

•

/

gp

.......

\ /

" '1

I I I I I I I

/ /

•

-

/ /

I NO. 1 2 2A 3 6A

7

J

/T

....

~--4-~--4_-+--~~

7

1.

. I

,---

" '--"" ""

..

·~

\ /

8B 10 12 12A 13 15

COLOR GRN/WHT RED/BLK BLU/WHT RED WHT/BLK GRN/BLK BLK/WHT RED/WHT ORN ORN/BLK BLU BLU/BLK BLK WHT GRN BLK/RED

CABLE TO PLA'TFORM FUNCllON GROUND TO OVERLOAD SYt1TCHES BATTERY INDICATOR UPPER CONTROL POWER TURN PUMP ON PLA'TFORM LOWERING STROBE UGHT FROM OVERLOAD SWITCHES SLOPE ALARM POWER SLOPE ALARM SIGNAL LOW VOLT UGHT LOW VOLT OVERRIDE AC HOT UNE AC NEUTRAL AC GROUND SPARE

T r"

~

i

~

h

Z

:Si ID

~

.. • R <•

('oj

~

I

o

~

I-

I-

n I ,..,~

Iii

i ~

:r t;:!::~ :J::::E~ :Jill

\.&JCt: Q.o 0 111

...Jz III IX

1--1----1---+--i ~--. ==~-= WACO, TEXAS 1--1----1--+--i ..._. _ _ • rc:L~ !:~~~~~,hIWU~~------------------~ _ _ ~-=' WIRING, ITOCHU CHICK ~-I----il--+~ - - :::I &. "':IJ"

IIGT

2 OF 3

',.: ~"~':-~'~~!-'..I..~''':' ".,.. '.~"' ..

j

~ .....:

• 0",-,'_'<.-'"'-'--__

'~~..:..';';:'·'~~'I,,-.:.-.::......:.':....:,.: ...:..

•• -.c;,;';''''''''.:'-.:.: :....:•...:,. ':..:,:''':,;...:'"'--"":"':'-0' .:',-,-''..:..''...,,;''..;.,;'::";,,~;,,,,;'-:_"~;:...:'._'...........:,;.: .• ,:.;,.

•• ....;;. ,..;;;.

••• ""' ..•• ,..........:... ............:...,; ••:',

'.'

SWITCH ON UPP::~ VALVE

IN

LOW VOLT LIGHT

2 10A

500 LB

lEFT

lOW VOLT OVERRIDE SWITCH ON lOWER VALVE

SWITCH

750 lB 10 - - - -

BAITERY INDICATOR

WHT

10A

RIGHT

OUT

GRN EMERGENCY STOP SWITCH

BU<

100

10C

AC RECEPTACLE 3 3A

12 ;38

SLOPE WARNING ALARM

.3A

12A

FOOT S'IIHCH

71

9I

REF

TO CONTACTOR SEE SHEET 2

II

51

BU< REO

BAITERY CHARGER

BU< RED ISOLATE SPARES

CABLE TO CHASSIS SEE SHEET 2

iiMiiIf'="--

REF

~~-4---+~.

:r.~

~ ~

WACO, TEXAS

IE:.-:&~=NW==~----------------~ ____ WIRING, ITOCHU CHICK

LW.I..:JO.MO.

-

...

412t

L1I!. ItAlt.MO.

--:tW&"='" .1.-.

__

_ ...

__

-

54377 ..,

C lOF3

FIGURE 12 OVERLOAD PLATFORM ASSEMBLY (OPTION)

3

Y

7

e <1

o o ----~=====---!=~-~J-------- ..·------------------------------~-~.,-1--'-------------/ r--r-

!

I

~----------------------------~ --------------;---1i -l + -

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

L~

,

- ..... ,

'~ \.

\,

--- .t--r-i--,-J.., ,_L_ oJ

-~-rJ

\

/~~ i

I

r----I i ! it ----.., i !

.

/

1.8750

---I

I

I

!!

!!

:r---·---~---·--~l

--------------------------------~--------1,--------Jl _____________________ _ l'

11 I.

,I

--~-r----

3.1128

fO

II i(.

3.6875

-!

!

I

I

!

5 5HOWN WITH 251 LBS. ON FULL Y :::XTENDED DECK

I

J

I

l ,"

1.5000

I

I

ill

(

I

J-....

-1"-;-1....- - - - - -_ __

2.

0.7500 0.6550

1.0000

6.5000 - - - - - - - - - - . . . . : 9.8750

~

WACO, TEXAS

111l..E

C VERLOAD

oI

DR~"'NQ ,,0.

SCAlL FULL

LAYOUT, EXTENSION DEC

IR(V~

L 091 79 3 A ISHEET

1

OF

1

~